ls ls ls ls-c06. md-006_007_012_019. lp-006_007_012_019 serie_uf. ls-009

Transcription

1 Operating Instructions - for the following couplings ls ls ls ls-c06 bf ls-k06 bf-025 lv-004 bf-050 md-006_007_012_019 hg-004 md-025_050 hp md-032 lp-003 serie_cn lp-004 serie_ct lp-006_007_012_019 serie_uf lp-019 sg-006_d.pdf lp-032_050 sp-006 ls-006 sp-009-z02 ls-009

2 Operating Instruction Revision B Datum Ersteller NH Die Betriebsanleitung unterliegt nicht dem Änderungsdienst. Self Sealing Coupling High Pressure Series n.b

3 This coupling is a quality product, in which special attention has been paid to high functionality, ease of operation, safety and reliability. As an item of technical equipment this coupling is intended for use in the commercial, industrial area and for operators, who have been trained by specialists in the handling of technical systems / tools. Customer care: As part of our individual customer care we will be happy to assist you in questions relating to use and operation and on any problems encountered. Service and maintenance: In order to maintain the high technical performance capability and reliability of your docking system over many years, we recommend regular inspection and maintenance. We can thereby offer you optimum support by our Customer Service department and the conclusion of a service and maintenance contract. Please ask for a quotation. Carl Kurt Walther GmbH & Co. KG PO Box Haan Westfalenstraße 2 Tel.: +49 (0) Fax: +49 (0) info@walther-praezision.de Internet: Contact: Application technology and service Holger R. Figge Telephone: (02129) Telefax: (02129) Handy: (0162) hfigge@walther-praezision.de Further addresses and telephone numbers of contacts can be found on the Internet on our homepage under Service / Customer service. 2

4 Operating Instruction Type List of Contents 1 List of Contents 1 LIST OF CONTENTS GENERAL SAFETY INSTRUCTION WARRANTY PRODUCT DESCRIPTION OF THE SELF SEALING COUPLING USAGE ACCORDING TO SPECIFICATION TECHNICAL DATA INSTALLATION INSTRUCTION OPERATING INSTRUCTION CONNECTION PROCESS DISCONNECTION PROCESS MAINTENANCE INSTRUCTION MAINTENANCE AND FUNCTIONAL TEST Maintenance includes following items: Functional test includes following items: LUBRICATION! STORAGE SHUT-DOWN ORDER NUMBER CODE INDEX

5 Operating Instruction Type General 2 General This manual contains all regulations for operation, commissioning and maintenance of the coupling All information and notes in this operating manual were collated while taking into consideration the valid regulations, the current engineering related status of development as well as our many years of experience and acquired knowledge. Translations of this operating manual were also produced according to the best of knowledge. However, we cannot assume liability for any translation errors. The German version provided for this operating manual is considered the authoritative version. The actual scope of delivery can deviate from the explanations and graphic representations described herein under certain circumstances, e.g. in the case of special designs, utilization of additional order options or because of state-of-the-art technical alterations. If you have any questions, please contact the manufacturer. This operating manual must be read carefully before starting work on or with the equipment, in particular before commissioning! The manufacturer assumes no liability for damage or faults arising from non-compliance with the instructions in this operating manual. The operating manual must be kept directly with the equipment and be accessible to all persons who work on or with the equipment. It is not permitted for the operating manual to be passed to third parties and if applicable this will incur damage compensation. All other rights reserved. Before commissioning the device must be checked for being not defective and its technically perfect function. The German version is the original. We reserve the right to make technical alterations to the product within the context of improving the usage properties and further development. The operating manual remains our property. Any reproduction, use by or communication to third parties incurs a penalty and will be pursued by court action (copyright law against unfair competition, BGB [German Civil Code]). All rights reserved in the case of a patent award (Paragraph 7, Section. 1 of the patent law - PG) or entry as a patented design (Paragraph 5, Section 4 of the patented design law - GMG). 4

6 Operating Instruction Type Safety Instruction 3 Safety Instruction Using these couplings does not release the customer from his obligation to comply with the pertinent work safety regulations e.g. operational safety ordinances, etc. The duty to take due care by the operator of the couplings includes planning measures to ensure proper operation and monitoring their implementation. Hazard notes If the wrong product has been selected or if there is improper use or maintenance has been omitted, then hazards arise and personal injuries and material damage can occur from: - Hazardous emission of fluid or individual particles/coupling parts - Function impairments of connected systems or tools - The metal parts of coupling and adaptor are not thermally protected. You can be burned if you touch these parts at high media temperatures. According to the ambient temperature valve lever and ring grip can also become unbearably hot. For that reason suitable, sufficiently long protective gloves should be worn. The operator must in particular make sure that - The couplings are only used according to the intended purpose. - The couplings are only operated in a perfect, functioning condition. - The operating manual is always in a legible condition and is available in its entirety to operating personnel. - The operating personnel are sufficiently acquainted with the working method and the safety notes for the coupling. - The coupling is sent to our factory for repair work. - During operation of the coupling, no safety devices are removed and/or deactivated. - Before installing or dismantling the coupling, you have made sure that the coupling has not been pressurized. After completing assembly and installation work and before commissioning the coupling, observe the following points: Check once again that all screw connections are securely fitted. Before commissioning the coupling, a function test must be carried out (see maintenance and function test). 5

7 Operating Instruction Type Warranty 4 Warranty The warranty conforms to: the regulations agreed in the purchase contract and the General Conditions for Delivery and Capacity of C.K. Walther GmbH & Co. KG of the state which was valid at the date of the purchase contract. Wearing parts are generally excluded from the warranty. Typical wearing parts of products from company C.K. Walther GmbH & Co. KG are for example: seals springs 6

8 Operating Instruction Type Product description of the coupling 5 Product description of the self sealing coupling - Coupling connection consists of: - self sealing coupling self sealing adaptor The following combination of the coupling connections is also possible: - thru type coupling thru type adaptor A one side self sealing variant is not possible. In case that both coupling halves are not connected they should be protected against external dirt and/or damages if required. - For that purpose dust cap and dust plug are available. Possible combinations : self sealing coupling or thru type coupling with dust plug self sealing adaptor or thru type adaptor with dust cap Usage according to specification - Coupling is only used as connection of two lines. - Connection and disconnection process is carried out by hand. - Coupling is especially suitable for the following media/applications: - air - hydraulic oil - and their subspecies (such as oxygen or oil with additives) - For all other possible applications, C.K. Walther should be consulted. 7

9 Operating Instruction Type Product description of the coupling 5.2 Technical Data - Working pressures of the coupling depend on materials of individual parts. - When determining working pressure of the coupling the max. permissible working pressure of the end connection is to be taken into account if standardized threads are used. Working pressure Cv flow coefficient steel (11): connected: 500 bar disconnected: adaptor side = 500 bar coupling side = 500 bar both sides self sealing = The coupling is not determined for any types of use other than those listed here. - Safe operation is not guaranteed if the coupling is used contrary to its intended use. - The operator of the coupling is responsible for all personal injuries or material damage that occur from non-intended use and disregard of the technical values; the manufacturer assumes no responsibility in these cases. 8

10 Operating Instruction Type Installation instruction 6 Installation Instruction Subject to the general accident prevention regulations coupling is to be installed into a network in such a way that: - a satisfactory operation is guaranteed according to the operating instruction. - first of all self sealing coupling is used on line side and self sealing adaptor on consumer side. - external damage of the unit as well as all moving parts are excluded. Before self sealing coupling and the self sealing adaptor are installed at a pipeline network make sure that the pipeline network is sufficiently rinsed/blown out and/or cleaned. After the assembly works are finished a functional test is to be carried out with both, without pressure and under working pressure according to operating instruction. 9

11 Operating Instruction Type Operating Instruction 7 Operating Instruction In order to avoid critical injuries of the staff and damage at the self sealing coupling during operation, coupling may be only used for the stated applications. 7.1 Connection process Before every couple cycle a visual check of coupling and adaptor is to be carried out. In case of recognizable, visible damage or deformations damaged parts are to be exchanged. Hold self sealing coupling firmly in one hand; with the other hand pull back locking sleeve. This has to be done against locking spring resistance. Push coupling (free half) with withdrawn locking sleeve axially centered onto plug part of adaptor (fixed hallf) until sensible resistance. Bring locking sleeve with support of locking spring into starting position. Self sealing coupling and self sealing adaptor are now mechanically locked. CAUTION Please take care that locking sleeve is in final position, i.e. that it is flush in front with the coupling housing as otherwise no perfect lock is guaranteed. 7.2 Disconnection process Withdraw locking sleeve against locking spring and take out coupling from self sealing adaptor. Caution! In case of an available pressure in the line connected by the coupling system a strong separation impulse - depending on the pressure - can be effective onto the coupling system during disconnection. For that reason the movable part of the coupling (free half) is to be firmly held in the hand to avoid injuries. 10

12 Operating Instruction Type Maintenance and Functional Instruction 8 Maintenance Instruction Preventive maintenance measures WALTHER self sealing couplings are to be operated in such a manner that external damages to elements and all moving parts are avoided. 8.1 Maintenance and functional test In order to always guarantee function of the self sealing coupling and hence safety of operator, a maintenance and functional testing must be made in appropriate periods of time depending on operating conditions. In order to minimize operating forces and to extend service life of the self sealing coupling we recommend to slightly grease plug surfaces (see item 9.0) Maintenance includes following items: - A visual inspection of self sealing coupling and self sealing adaptor regarding damage and contamination has to be made. - Dirt at the functional area (sealing area, operating elements) which is easily accessible from outside should be removed by simply wiping-off. If there are damaged, torn or corroded parts, coupling must be dismounted and returned to manufacturer for repair. If worn or embrittled seals are found or if there is extreme dirt, the customer can decide whether he returns coupling unit to the manufacturer's factory or whether he repairs himself Functional test includes following items: As described in the operating instruction, coupling is several times connected, pressurized and then disconnected. In doing so, the following has to be observed: - Connection and disconnection process must be absolutely smooth. - Coupling must be absolutely leak-proof in connected and disconnected state. If there are damaged, torn or corroded parts, coupling must be dismounted and returned to manufacturer for repair. If worn or embrittled seals are found or if there is extreme dirt, the customer can decide whether he returns the coupling unit to the manufacturer s factory or whether he repairs himself. 11

13 Operating Instruction Type Lubrication 9 Lubrication! In order to minimize operating forces and to extend service life of the coupling we recommend to slightly grease plug surfaces. Lubrication is to be carried out with greases which do not tend to become resin. Caution! The selection of the grease is to be suited to the sealing quality and the medium (e.g.: oxygen) in view of the compatibility. 12

14 Operating Instruction Type Storage 10 Storage The couplings must be stored in such a way that no damages can occur at the couplings. The storage conditions of the couplings must comply with the guidelines for the seals as these can change in properties due to improper storage. The following items must be kept: - The couplings must be stored dry. - To safely conserve the seals and that means also the couplings they should not be stored under the effect of daylight. For protection against oxygen the seals and also the couplings shall be stored into the packing. 13

15 Operating Instruction Type Shut-down 11 Shut-down At the end of the service life the coupling or its components have to be disposed non-polluting and according to the legal regulations. For that the local public or private disposal societies should be taken. 14

16 Operating Instruction Type Order Number Code 12 Order number code X X X - X X X X X X X X X X X - X X X X - X X X X X - X X X X X X X X X X X X X X X X - X X 1. Subject group 2. Series The information regarding the series comprises either two letters or two numbers. 3. Nomial size / Nominal bore It is rounded up or down to one. The information can be numerical as well as alphanumerical. 4. Product type or design type 5. Connection design 6. Material design: xx-x and xxxx possible 7. Material design (seal design): xx-x and xxxx possible 8. Y or Z design 9. Additional equipment 15

17 Operating Instruction Type Index 13 Index A According to intended purpose... 5 Acquired knowledge... 4 Adaptorl... 5 air... 7 Alterations... 4 Assembly... 5 B Betriebsanleitung... 1 C Commissioning... 4, 5 connection... 7, 8 Connection process coupling... 4 Coupling... 5, 8, 14 Couplings... 5 Customer care... 2 Cv flow coefficient... 8 D Damage... 4, 5 Damage compensation... 4 daylight Disconnection process Disposal societies dry dust cap... 7 dust plug... 7 E Equipment... 4 Experience... 4 external damage... 9 F Faults... 4 Fluid... 5 Function... 5 Function test... 5 Functionality... 2 G General... 4 guarantee H Hazard notes... 5 Hazardous emission... 5 High Pressure Series... 1 hydraulic oil... 7 I Implementation... 5 Improvement... 4 Index Inspection... 2 Installation Instruction... 9 L Legible condition... 5 Liability... 4 List of Contents... 3 Lubrication M Maintenance... 2, 4, 5 Maintenance and functional test Maintenance Instruction Manual... 4 Media temperatures... 5 O Operating Instruction... 1, 10 Operation... 2 Operational safety ordinances... 5 operator... 5, 11 Operator... 8 Operators... 2 Order number code original... 4 P packing particular... 5 Perfect, functioning condition... 5 Performance capability... 2 Pressurized... 5 Product description... 7 Property... 4 Protective gloves... 5 Q quality

18 Operating Instruction Type Index questions... 4 R regulations... 9 Regulations... 4 Reliability... 2 Repair work... 5 S Safety... 2 Safety devices... 5 Safety Instruction... 5 Scope of delivery... 4 Screw connections... 5 self sealing adaptor... 7, 9, 10, 11 self sealing coupling... 7, 9, 10, 11 Self sealing coupling Self Sealing Coupling... 1 service... 11, 12 Service... 2 Shut-down Special designs... 4 Specialists... 2 specification... 8 Status of development... 4 Storage subspecies... 7 Systems... 2, 5 T Technical equipment... 2 Thermally... 5 thru type adaptor... 7 thru type coupling... 7 Tools... 2, 5 Translation errors... 4 Types of use... 8 U Use... 2 V Version... 4 W Warranty... 6 Work safety regulations... 5 Working method... 5 Working pressure... 8 Wrong product selection

19 Operating instruction english Revision A Date Issuer NH This operating instruction is not subject to the updating Breath air coupling Z10-R Z07-R. optional feature: EX 1

20 This coupling is a quality product, in which special attention has been paid to high functionality, ease of operation, safety and reliability. As an item of technical equipment this tool-changer is intended for use in the commercial, industrial area and for operators, who have been trained by specialists in the handling of technical systems / tools. Customer care: As part of our individual customer care we will be happy to assist you in questions relating to use and operation and on any problems encountered. Service and maintenance: In order to maintain the high technical performance capability and reliability of your docking system over many years, we recommend regular inspection and maintenance. We can thereby offer you optimum support by our Customer Service department and the conclusion of a service and maintenance contract. Please ask for a quotation. Carl Kurt Walther GmbH & Co. KG PO Box Haan Westfalenstraße 2 Tel.: +49 (0) Fax: +49 (0) info@walther-praezision.de Internet: Contact: Application technology and service Holger R. Figge Telephone: (02129) Telefax: (02129) Handy: (0162) hfigge@walther-praezision.de Further addresses and telephone numbers of contacts can be found on the Internet on our homepage under Service / Customer service. 2

21 Operating instruction english Type List of Contents 1 List of Contents 1 LIST OF CONTENTS GENERAL WARRANTY SAFETY INSTRUCTIONS PRODUCT DESCRIPTION OF THE SELF SEALING COUPLING INTENDED USE TECHNICAL DATA OPTIONAL FEATURES EXTENDED PRODUCT DESCRIPTION FOR APPLICATION ACC. TO ATEX-GUIDE LINE 94/9/EG (SPECIAL DESIGN EX): General Extended marking INSTALLATION INSTRUCTION GENERAL EXTENDED INSTALLATION INSTRUCTION FOR APPLICATION ACC. TO ATEX-GUIDELINE 94/9/EG Details for safe operation Details for safe installation Details for a safe application area OPERATING INSTRUCTION CONNECTION PROCESS DISCONNECTION PROCESS MAINTENANCE INSTRUCTION MAINTENANCE AND FUNCTIONAL TEST Maintenance includes following items: Functional test includes following items: LUBRICATION! STORAGE SHUT-DOWN ORDER NUMBER CODE INDEX

22 Operating instruction english Type General 2 General This manual contains all regulations for operation, commissioning and maintenance of the locking coupling elementcoupling. All information and notes in this operating manual were collated while taking into consideration the valid regulations, the current engineering related status of development as well as our many years of experience and acquired knowledge. Translations of this operating manual were also produced according to the best of knowledge. However, we cannot assume liability for any translation errors. The German version provided for this operating manual is considered the authoritative version. The actual scope of delivery can deviate from the explanations and graphic representations described herein under certain circumstances, e.g. in the case of special designs, utilization of additional order options or because of state-of-the-art technical alterations. If you have any questions, please contact the manufacturer. This operating manual must be read carefully before starting work on or with the equipment, in particular before commissioning! The manufacturer assumes no liability for damage or faults arising from non-compliance with the instructions in this operating manual. The operating manual must be kept directly with the equipment and be accessible to all persons who work on or with the equipment. It is not permitted for the operating manual to be passed to third parties and if applicable this will incur damage compensation. All other rights reserved. Before commissioning the device must be checked for being not defective and its technically perfect function. The German version is the original. We reserve the right to make technical alterations to the product within the context of improving the usage properties and further development. The operating manual remains our property. Any reproduction, use by or communication to third parties incurs a penalty and will be pursued by court action (copyright law against unfair competition, BGB [German Civil Code]). All rights reserved in the case of a patent award (Paragraph 7, Section. 1 of the patent law - PG) or entry as a patented design (Paragraph 5, Section 4 of the patented design law - GMG). 4

23 Operating instruction english Type Warranty 3 Warranty The warranty conforms to: the regulations agreed in the purchase contract and the General Conditions for Delivery and Capacity of C.K. Walther GmbH & Co. KG of the state which was valid at the date of the purchase contract. Wearing parts are generally excluded from the warranty. Typical wearing parts of products from company C.K. Walther GmbH & Co. KG are for example: seals springs 5

24 Operating instruction english Type Safety instructions 4 Safety instructions Using these couplings does not release the customer from his obligation to comply with the pertinent work safety regulations e.g. operational safety regulations, etc. The duty to take due care by the operator of the couplings includes planning measures to ensure proper operation and monitoring their implementation. Hazard notes If the wrong product has been selected or if there is improper use or maintenance has been omitted, then hazards arise and personal injuries and material damage can occur from: - hazardous emission of fluid or individual particles/coupling parts. - function impairments of connected systems or tools. - the metal parts of coupling and adaptor are not thermally protected. In case of high media temperatures the contact with these parts can lead to combustion. According to the ambient temperature valve handle and ring grip can also become very hot. For that reason sufficiently long protective gloves must be worn in these cases. The operator must in particular make sure that - the couplings are only used according to the intended purpose. - the couplings are only operated in a perfect, functioning condition. - the operating manual is always in a legible condition and is available in its entirety to operating personnel. - the operating personnel are sufficiently acquainted with the working method and the safety notes for the coupling. - no safety devices must be removed and/or deactivated during operation of the couplings. - before installing or dismantling the couplings, you have made sure that the couplings have not been pressurized. After completing assembly and installation work and before commissioning the coupling, the following items have to be observed: Check once again that all screw connections are securely fitted. Before commissioning the couplings, a function test must be carried out (see maintenance and function test). 6

25 Operating instruction english Type Product description of the self sealing coupling Coupling connection consists of: - self sealing coupling Z10-R. - self sealing adaptor Z07-R. Product description of the self sealing coupling 5.1 Intended use - The coupling shall only be used to connect two lines. - When disconnected, the coupling unit blocks further media discharge by means of valves only at one side (coupling side). - The coupling- and decoupling process is manually operated. - The coupling is equipped with an automatic lock, i. e.: one-hand operation - The coupling is equipped with an automatically engaging train control. - The coupling unit is easy to operate, also with gloves by handle bolsters at the releasing sleeve. - The coupling is particularly suitable for the following use of media / applications: breath air - For all other possible applications please contact WALTHER-Präzision. 5.2 Technical data - Working pressures of coupling depend on materials of individual parts. - When determing the working with standardized threaded connections, the highest permissible working pressure of the connection must be taken into account. - When selecting a suitable connection the following static pressure is possible: operating pressure maximum: 23 bar Cv- value: 0.80 range of temperature: -40 C bis +150 C - The coupling is not determined for any types of use and technical values other than those listed here. - Safe operation is not guaranteed if the coupling is used contrary to ist intended use and technical values - The operator of the coupling is responsible for all personal injuries or material damage that occur from non-intended use and disregard of the technical values; the manufacturer assumes no responsibility in these cases. 7

26 Operating instruction english Type Product description of the self sealing coupling 5.3 Optional Features EX = ATEX version 5.4 Extended product description for application acc. to ATEX-guide line 94/9/EG (special design EX): General Only non-sparkling materials may be used. Non-sparkling materials are , or equivalent materials. Furthermore brass with different surfaces (f. ex. chrome-plated, nickel-plated). Further on it must be assured that the seal is resistant against and suitable for the flowing through media. Also the temperature resistance of the seals must be guaranteed. This must also be considered for the marking acc. to chapter Extended marking The coupling fittings are marked with As the surface temperature of the self-sealing couplings are determined by the temperature of the fluids, the temperature category or the highest surface temperature must be specified by the operator while the safe temperature distances acc. to EN must be observed and the maximum temperature resistance of the coupling materials and seals are taken into consideration. The marking of the temperature class must be effected readily visible by the operator. The determination of the temperature class must be made acc. to the following table: Max. temperature of Temperature class fluids 75 T6 90 T5 130 T4 195 T3 295 T2 445 T1 The couplings are not admitted for the temperature classes T1 and T2 and may not be marked for that by the operator. 8

27 Operating instruction english Type Installation instruction 6 Installation Instruction 6.1 General Subject to the general accident prevention regulations coupling is to be installed into a network in such a way that: - a satisfactory operation is guaranteed according to the operating instruction. - first of all self sealing coupling is used on line side and self sealing adaptor on consumer side - external damage of the unit as well as all moving parts are excluded. Before self sealing coupling and the self sealing adaptor are installed at a pipeline network make sure that the pipeline network is sufficiently rinsed/blown out and/or cleaned. After the assembly works are finished a functional test is to be carried out with both, without pressure and under working pressure of the media elements according to operating instruction. 6.2 Extended installation instruction for application acc. to ATEX-guideline 94/9/EG Details for safe operation For the use of self sealing couplings as a hose connection it must be guaranteed that in case of pressure strikes the tumbling of the self sealing coupling can be avoided by fixing at suitable constructions. In principle it must be observed that the self sealing coupling cannot strike on hard objects which could produce strike sparks when touching the housing Details for safe installation The self sealing couplings may only be connected to pipe- and hose systems which are suitable for electrostatic discharge and which are connected to the ground potential Details for a safe application area The self sealing couplings may be used according to the class of devices2 in areas susceptible to explosions where potentially explosive mixtures of gas, steam, mist and air are availble. 9

28 Operating instruction english Type Operating instruction 7 Operating Instruction In order to avoid critical injuries of the staff and damage at the self sealing coupling during operation, coupling may be only used for the stated applications. 7.1 Connection process Before each coupling process a visible check of the coupling and the adaptor has to be made. Damaged parts must be changed in case of observable, visible damages or deformations. The self-sealing coupling is equipped with an automatic lock, i. e. one-hand operation. For coupling the self-sealing coupling behind the locking sleeve or the self-sealing adaptor in the end plug area is taken up with one hand and pushed axially centred on the counter piece until the end stop. During the coupling the locking sleeve snaps in forward without the aid of the operator. Now the self-sealing coupling and the self-sealing adaptor are locked mechanically. Available valves are opened during the coupling process and thus the passage is released. CAUTION Please take care that locking sleeve is in final position, i.e. that it is flush in front with the coupling housing as otherwise no perfect lock is guaranteed. 7.2 Disconnection process For decoupling the self-sealing coupling behind the locking sleeve is taken up with one hand and first pushed forward on the self-sealing adaptor. Then the locking sleeve is pulled back and the connection is separated. During the decoupling the available valves close automatically so that no further discharge of media is possible. Caution! In case of an available pressure in the line connected by the coupling system a strong separation impulse - depending on the pressure - can be effective onto the coupling system during disconnection. For that reason the movable part of the coupling (free half) is to be firmly held in the hand to avoid injuries. 10

29 Operating instruction english Type Maintenance Instruction Maintenance and Functional instruction Preventive maintenance measures WALTHER self sealing couplings are to be operated in such a manner that external damages to elements and all moving parts are avoided. 8.1 Maintenance and functional test In order to always guarantee function of the self sealing coupling and hence safety of operator, a maintenance and functional testing must be made in appropriate periods of time depending on operating conditions. In order to minimize operating forces and to extend service life of the self sealing coupling we recommend to slightly grease plug surfaces (see item 9.0) Maintenance includes following items: - A visual inspection of self sealing coupling and self sealing adaptor regarding damage and contamination has to be made. - Dirt at the functional area (sealing area, operating elements) which is easily accessible from outside should be removed by simply wiping-off. If there are damaged, torn or corroded parts, coupling must be dismounted and returned to manufacturer for repair. If worn or embrittled seals are found or if there is extreme dirt, the customer can decide whether he returns coupling unit to the manufacturer's factory or whether he repairs himself Functional test includes following items: As described in the operating instruction, coupling is several times connected, pressurized and then disconnected. In doing so, the following has to be observed: - Connection and disconnection process must be absolutely smooth. - Coupling must be absolutely leak-proof in connected and disconnected state. If there are damaged, torn or corroded parts, coupling must be dismounted and returned to manufacturer for repair. If worn or embrittled seals are found or if there is extreme dirt, the customer can decide whether he returns the coupling unit to the manufacturer s factory or whether he repairs himself. 11

30 Operating instruction english Type Lubrication 9 Lubrication! In order to minimize operating forces and to extend service life of the coupling we recommend to slightly grease plug surfaces. Lubrication has to be done with grease, registered by NSF-H1. Caution! The selection of the grease is to be suited to the sealing quality and the medium (e.g.: oxygen) in view of the compatibility. 12

31 Operating instruction english Type Storage 10 Storage The couplings must be stored in such a way that no damages can occur at the couplings. The storage conditions of the couplings must comply with the guidelines for the seals as these can change in properties due to improper storage. The following items must be kept: - The couplings must be stored dry. - To safely conserve the seals and that means also the couplings they should not be stored under the effect of daylight. - For protection against oxygen the seals and also the couplings shall be stored into the packing. 13

32 Operating instruction english Type Shut-down 11 Shut-down At the end of the service life the coupling or its components have to be disposed non-polluting and according to the legal regulations. For that the local public or private disposal societies should be taken. 14

33 Operating instruction english Type Order number code 12 Order number code X X X - X X X X X X X X X X X - X X X X - X X X X X - X X X X X X X X X X X X X X X X - X X 1. Subject group 2. Series Series description consists of either two letters or two digits. 3. Nominal size / nominal width It is rounded up or rounded down to full units. The indication can be numerical or alphanumeric. 4. Type of product and design 5. Type of connection 6. Material: xx-x and xxxx possible 7. Material (seal version): xx-x and xxxx possible 8. Y- or Z-design 9. Optional features 15

34 Operating instruction english Type Index 13 Index A According to intended purpose... 6 Acquired knowledge... 4 Alterations... 4 Assembly... 6 B breath air... 7 C Commissioning... 4, 6 connected... 6, 11 connection... 7, 15 Connection process coupling... 4, 6 Coupling... 7, 14 Couplings... 6 Customer care... 2 D Damage... 4, 6 Damage compensation... 4 daylight disconnected Disconnection process Dismantling... 6 Disposal societies Disregard... 7 dry E Equipment... 4 Experience... 4 external damage... 9 F Faults... 4 Fluid... 6 Function... 6 Function test... 6 Functionality... 2 G General... 4 guarantee H Hazard notes... 6 Hazardous emission... 6 I Implementation... 6 Improvement... 4 Index Inspection... 2 Installation Instruction... 9 Intended use... 7 L Legible condition... 6 Liability... 4 List of Contents... 3 Lubrication M Maintenance... 2, 4, 6 Maintenance Instruction Manual... 4 O one-hand operation... 7 Operating instruction... 1 Operating Instruction Operation... 2 Operational safety regulations... 6 operator... 6 Operators... 2 Optional Features... 8 original... 4 P packing Perfect, functioning condition... 6 Performance capability... 2 Pressurized... 6 Product description... 7 Property... 4 Q quality questions... 4 R regulations... 9 Regulations... 4 Reliability... 2 responsible

35 Operating instruction english Type Index S Safety... 2 Safety devices... 6 Safety instructions... 6 Scope of delivery... 4 Screw connections... 6 seals... 5 self sealing adaptor... 7, 9, 11 self sealing coupling... 7, 9, 10, 11 service... 11, 12 Service... 2 Shut-down Special designs... 4 Specialists... 2 springs... 5 Status of development... 4 Storage Systems... 2, 6 T Technical data... 7 Technical equipment... 2 Technical values... 7 Temperaturklasse... 8 Tools... 2, 6 Translation errors... 4 Types of use... 7 U Use... 2 V Version... 4 W Warranty... 5 Work safety regulations... 6 Working method... 6 working pressure... 7 Wrong product selection

36 Operating instruction english Revision A Date Issuer NH This operating instruction is not subject to the updating Self sealing coupling optional feature: OV 1

37 This coupling is a quality product, in which special attention has been paid to high functionality, ease of operation, safety and reliability. As an item of technical equipment this tool-changer is intended for use in the commercial, industrial area and for operators, who have been trained by specialists in the handling of technical systems / tools. Customer care: As part of our individual customer care we will be happy to assist you in questions relating to use and operation and on any problems encountered. Service and maintenance: In order to maintain the high technical performance capability and reliability of your docking system over many years, we recommend regular inspection and maintenance. We can thereby offer you optimum support by our Customer Service department and the conclusion of a service and maintenance contract. Please ask for a quotation. Carl Kurt Walther GmbH & Co. KG PO Box Haan Westfalenstraße 2 Tel.: +49 (0) Fax: +49 (0) info@walther-praezision.de Internet: Contact: Application technology and service Holger R. Figge Telephone: (02129) Telefax: (02129) Handy: (0162) hfigge@walther-praezision.de Further addresses and telephone numbers of contacts can be found on the Internet on our homepage under Service / Customer service. 2

38 Operating instruction english Type List of Contents 1 List of Contents 1 LIST OF CONTENTS GENERAL WARRANTY SAFETY INSTRUCTIONS PRODUCT DESCRIPTION OF THE SELF SEALING COUPLING INTENDED USE TECHNICAL DATA OPTIONAL FEATURES INSTALLATION INSTRUCTION GENERAL OPERATING INSTRUCTION AUTOMATIC LOCK Connection process Disconnection process OPTIONAL FEATURE OV (NO ONE HAND OPERATION) Coupling process Disconnection process MAINTENANCE INSTRUCTION MAINTENANCE AND FUNCTIONAL TEST Maintenance includes following items: Functional test includes following items: LUBRICATION! STORAGE SHUT-DOWN ORDER NUMBER CODE INDEX

39 Operating instruction english Type General 2 General This manual contains all regulations for operation, commissioning and maintenance of the locking coupling elementcoupling. All information and notes in this operating manual were collated while taking into consideration the valid regulations, the current engineering related status of development as well as our many years of experience and acquired knowledge. Translations of this operating manual were also produced according to the best of knowledge. However, we cannot assume liability for any translation errors. The German version provided for this operating manual is considered the authoritative version. The actual scope of delivery can deviate from the explanations and graphic representations described herein under certain circumstances, e.g. in the case of special designs, utilization of additional order options or because of state-of-the-art technical alterations. If you have any questions, please contact the manufacturer. This operating manual must be read carefully before starting work on or with the equipment, in particular before commissioning! The manufacturer assumes no liability for damage or faults arising from non-compliance with the instructions in this operating manual. The operating manual must be kept directly with the equipment and be accessible to all persons who work on or with the equipment. It is not permitted for the operating manual to be passed to third parties and if applicable this will incur damage compensation. All other rights reserved. Before commissioning the device must be checked for being not defective and its technically perfect function. The German version is the original. We reserve the right to make technical alterations to the product within the context of improving the usage properties and further development. The operating manual remains our property. Any reproduction, use by or communication to third parties incurs a penalty and will be pursued by court action (copyright law against unfair competition, BGB [German Civil Code]). All rights reserved in the case of a patent award (Paragraph 7, Section. 1 of the patent law - PG) or entry as a patented design (Paragraph 5, Section 4 of the patented design law - GMG). 4

40 Operating instruction english Type Warranty 3 Warranty The warranty conforms to: the regulations agreed in the purchase contract and the General Conditions for Delivery and Capacity of C.K. Walther GmbH & Co. KG of the state which was valid at the date of the purchase contract. Wearing parts are generally excluded from the warranty. Typical wearing parts of products from company C.K. Walther GmbH & Co. KG are for example: seals springs 5

41 Operating instruction english Type Safety instructions 4 Safety instructions Using these couplings does not release the customer from his obligation to comply with the pertinent work safety regulations e.g. operational safety regulations, etc. The duty to take due care by the operator of the couplings includes planning measures to ensure proper operation and monitoring their implementation. Hazard notes If the wrong product has been selected or if there is improper use or maintenance has been omitted, then hazards arise and personal injuries and material damage can occur from: - hazardous emission of fluid or individual particles/coupling parts. - function impairments of connected systems or tools. - the metal parts of coupling and adaptor are not thermally protected. In case of high media temperatures the contact with these parts can lead to combustion. According to the ambient temperature valve handle and ring grip can also become very hot. For that reason sufficiently long protective gloves must be worn in these cases. The operator must in particular make sure that - the couplings are only used according to the intended purpose. - the couplings are only operated in a perfect, functioning condition. - the operating manual is always in a legible condition and is available in its entirety to operating personnel. - the operating personnel are sufficiently acquainted with the working method and the safety notes for the coupling. - no safety devices must be removed and/or deactivated during operation of the couplings. - before installing or dismantling the couplings, you have made sure that the couplings have not been pressurized. After completing assembly and installation work and before commissioning the coupling, the following items have to be observed: Check once again that all screw connections are securely fitted. Before commissioning the couplings, a function test must be carried out (see maintenance and function test). 6

42 Operating instruction english Type Product description of the self sealing coupling Coupling connection consists of: - self sealing coupling self sealing adaptor Product description of the self sealing coupling In case that both coupling halves are not connected they should be protected against external dirt and/or damages if required. For that purpose dust cap and dust plug are available. Possible comibinations : self sealing coupling with dust plug self sealing adaptor with dust cap Intended use - The coupling shall only be used to connect two lines. - The coupling- and decoupling process is manually operated. - The coupling is equipped with an automatic lock, i. e.: one-hand operation - The coupling is particularly suitable for the following use of media / applications: Mini coupling - For all other possible applications please contact WALTHER-Präzision. 5.2 Technical data - Working pressures of coupling depend on materials of individual parts. - When determing the working with standardized threaded connections, the highest permissible working pressure of the connection must be taken into account. - When selecting a suitable connection the following static pressure is possible: operating pressure maximum: 100 bar (Messing) Cv-value: The coupling is not determined for any types of use and technical values other than those listed here. - Safe operation is not guaranteed if the coupling is used contrary to ist intended use and technical values - The operator of the coupling is responsible for all personal injuries or material damage that occur from non-intended use and disregard of the technical values; the manufacturer assumes no responsibility in these cases. 5.3 Optional Features OV = without valve (no one hand operation) 7

43 Operating instruction english Type Installation instruction 6 Installation Instruction 6.1 General Subject to the general accident prevention regulations coupling is to be installed into a network in such a way that: - a satisfactory operation is guaranteed according to the operating instruction. - first of all self sealing coupling is used on line side and self sealing adaptor on consumer side - external damage of the unit as well as all moving parts are excluded. Before self sealing coupling and the self sealing adaptor are installed at a pipeline network make sure that the pipeline network is sufficiently rinsed/blown out and/or cleaned. After the assembly works are finished a functional test is to be carried out with both, without pressure and under working pressure of the media elements according to operating instruction. 8

44 Operating instruction english Type Operating instruction 7 Operating Instruction In order to avoid critical injuries of the staff and damage at the self sealing coupling during operation, coupling may be only used for the stated applications. 7.1 Automatic lock Connection process Before each coupling process a visible check of the coupling and the adaptor has to be made. Damaged parts must be changed in case of observable, visible damages or deformations. The self-sealing coupling is equipped with an automatic lock, i. e. one-hand operation. For coupling the self-sealing coupling behind the locking sleeve or the self-sealing adaptor in the end plug area is taken up with one hand and pushed axially centred on the counter piece until the end stop. During the coupling the locking sleeve snaps in forward without the aid of the operator. Now the self-sealing coupling and the self-sealing adaptor are locked mechanically. Available valves are opened during the coupling process and thus the passage is released. CAUTION Please take care that locking sleeve is in final position, i.e. that it is flush in front with the coupling housing as otherwise no perfect lock is guaranteed Disconnection process For decoupling the self sealing coupling behind the locking sleeve is taken up with one hand and the locking sleeve is pulled back with the other hand and thus the connection is separated. During the decoupling the available valves close automatically so that no further discharge of media is possible. 7.2 optional feature OV (no one hand operation) Coupling process Before every couple cycle a visual check of coupling and adaptor is to be carried out. In case of recognizable, visible damage or deformations damaged parts are to be exchanged. Hold self sealing coupling firmly in one hand; with the other hand pull back locking sleeve. This has to be done against locking spring resistance. Push free half (coupling) with withdrawn locking sleeve axially centered onto plug part of fixed half (adaptor) until sensible resistance. Bring locking sleeve with support of locking spring into starting position. Self sealing coupling and self sealing adaptor are now mechanically locked. 9

45 Operating instruction english Type Operating instruction CAUTION Es Please take care that locking sleeve is in final position, i.e. that it is flush in front with the coupling housing as otherwise no perfect lock is guaranteed Disconnection process Withdraw locking sleeve against locking spring and take out coupling from the self sealing adaptor. Caution! In case of an available pressure in the line connected by the coupling system a strong separation impulse - depending on the pressure - can be effective onto the coupling system during disconnection. For that reason the movable part of the coupling (free half) is to be firmly held in the hand to avoid injuries. 10

46 Operating instruction english Type Maintenance Instruction Maintenance and Functional instruction Preventive maintenance measures WALTHER self sealing couplings are to be operated in such a manner that external damages to elements and all moving parts are avoided. 8.1 Maintenance and functional test In order to always guarantee function of the self sealing coupling and hence safety of operator, a maintenance and functional testing must be made in appropriate periods of time depending on operating conditions. In order to minimize operating forces and to extend service life of the self sealing coupling we recommend to slightly grease plug surfaces (see item 9.0) Maintenance includes following items: - A visual inspection of self sealing coupling and self sealing adaptor regarding damage and contamination has to be made. - Dirt at the functional area (sealing area, operating elements) which is easily accessible from outside should be removed by simply wiping-off. If there are damaged, torn or corroded parts, coupling must be dismounted and returned to manufacturer for repair. If worn or embrittled seals are found or if there is extreme dirt, the customer can decide whether he returns coupling unit to the manufacturer's factory or whether he repairs himself Functional test includes following items: As described in the operating instruction, coupling is several times connected, pressurized and then disconnected. In doing so, the following has to be observed: - Connection and disconnection process must be absolutely smooth. - Coupling must be absolutely leak-proof in connected and disconnected state. If there are damaged, torn or corroded parts, coupling must be dismounted and returned to manufacturer for repair. If worn or embrittled seals are found or if there is extreme dirt, the customer can decide whether he returns the coupling unit to the manufacturer s factory or whether he repairs himself. 11

47 Operating instruction english Type Lubrication 9 Lubrication! In order to minimize operating forces and to extend service life of the coupling we recommend to slightly grease plug surfaces. Lubrication is to be carried out with greases which do not tend to become resin. Caution! The selection of the grease is to be suited to the sealing quality and the medium (e.g.: oxygen) in view of the compatibility. 12

48 Operating instruction english Type Storage 10 Storage The couplings must be stored in such a way that no damages can occur at the couplings. The storage conditions of the couplings must comply with the guidelines for the seals as these can change in properties due to improper storage. The following items must be kept: - The couplings must be stored dry. - To safely conserve the seals and that means also the couplings they should not be stored under the effect of daylight. - For protection against oxygen the seals and also the couplings shall be stored into the packing. 13

49 Operating instruction english Type Shut-down 11 Shut-down At the end of the service life the coupling or its components have to be disposed non-polluting and according to the legal regulations. For that the local public or private disposal societies should be taken. 14

50 Operating instruction english Type Order number code 12 Order number code X X X - X X X X X X X X X X X - X X X X - X X X X X - X X X X X X X X X X X X X X X X - X X 1. Subject group 2. Series Series description consists of either two letters or two digits. 3. Nominal size / nominal width It is rounded up or rounded down to full units. The indication can be numerical or alphanumeric. 4. Type of product and design 5. Type of connection 6. Material: xx-x and xxxx possible 7. Material (seal version): xx-x and xxxx possible 8. Y- or Z-design 9. Optional features 15

51 Operating instruction english Type Index 13 Index A According to intended purpose... 6 Acquired knowledge... 4 Alterations... 4 Assembly... 6 Automatic lock... 3, 9 C Commissioning... 4, 6 connected... 6, 7, 11 connection... 7, 15 Connection process... 9 coupling... 4, 6 Coupling... 7, 14 Couplings... 6 Customer care... 2 Cv-value... 7 D Damage... 4, 6 Damage compensation... 4 daylight disconnected Disconnection process... 9, 10 Dismantling... 6 Disposal societies Disregard... 7 dry dust cap... 7 dust plug... 7 E Equipment... 4 Experience... 4 external damage... 8 F Faults... 4 Fluid... 6 Function... 6 Function test... 6 Functionality... 2 G General... 4 guarantee H Hazard notes... 6 Hazardous emission... 6 I Implementation... 6 Improvement... 4 Index Inspection... 2 Installation Instruction... 8 Intended use... 7 L Legible condition... 6 Liability... 4 List of Contents... 3 Lubrication M Maintenance... 2, 4, 6 Maintenance Instruction Manual... 4 Mini coupling... 7 O one-hand operation... 7, 9 Operating instruction... 1 Operating Instruction... 9 operating pressure maximum... 7 Operation... 2 Operational safety regulations... 6 operator... 6 Operators... 2 Optional Features... 3, 7 original... 4 P packing Perfect, functioning condition... 6 Performance capability... 2 Pressurized... 6 Product description... 7 Property... 4 Q quality questions

52 Operating instruction english Type Index R regulations... 8 Regulations... 4 Reliability... 2 responsible... 7 S Safety... 2 Safety devices... 6 Safety instructions... 6 Scope of delivery... 4 Screw connections... 6 self sealing adaptor... 7, 8, 9, 10, 11 self sealing coupling... 7, 8, 9, 11 Self sealing coupling... 9 service... 11, 12 Service... 2 Shut-down Special designs... 4 Specialists... 2 Status of development... 4 Storage Systems... 2, 6 T Technical data... 7 Technical equipment... 2 Technical values... 7 Tools... 2, 6 Translation errors... 4 Types of use... 7 U Use... 2 V Version... 4 W Warranty... 3, 5 Work safety regulations... 6 Working method... 6 working pressure... 7 Wrong product selection

53 Operating instruction english Revision A Date Issuer NH This operating instruction is not subject to the updating Self sealing coupling

54 This coupling is a quality product, in which special attention has been paid to high functionality, ease of operation, safety and reliability. As an item of technical equipment this tool-changer is intended for use in the commercial, industrial area and for operators, who have been trained by specialists in the handling of technical systems / tools. Customer care: As part of our individual customer care we will be happy to assist you in questions relating to use and operation and on any problems encountered. Service and maintenance: In order to maintain the high technical performance capability and reliability of your docking system over many years, we recommend regular inspection and maintenance. We can thereby offer you optimum support by our Customer Service department and the conclusion of a service and maintenance contract. Please ask for a quotation. Carl Kurt Walther GmbH & Co. KG PO Box Haan Westfalenstraße 2 Tel.: +49 (0) Fax: +49 (0) info@walther-praezision.de Internet: Contact: Application technology and service Holger R. Figge Telephone: (02129) Telefax: (02129) Handy: (0162) hfigge@walther-praezision.de Further addresses and telephone numbers of contacts can be found on the Internet on our homepage under Service / Customer service. 2

55 Operating instruction english Type List of Contents 1 List of Contents 1 LIST OF CONTENTS GENERAL WARRANTY SAFETY INSTRUCTIONS PRODUCT DESCRIPTION OF THE SELF SEALING COUPLING INTENDED USE TECHNICAL DATA INSTALLATION INSTRUCTION GENERAL OPERATING INSTRUCTION CONNECTION PROCESS DISCONNECTION PROCESS MAINTENANCE INSTRUCTION MAINTENANCE AND FUNCTIONAL TEST Maintenance includes following items: Functional test includes following items: LUBRICATION! STORAGE SHUT-DOWN ORDER NUMBER CODE INDEX

56 Operating instruction english Type General 2 General This manual contains all regulations for operation, commissioning and maintenance of the locking coupling elementcoupling. All information and notes in this operating manual were collated while taking into consideration the valid regulations, the current engineering related status of development as well as our many years of experience and acquired knowledge. Translations of this operating manual were also produced according to the best of knowledge. However, we cannot assume liability for any translation errors. The German version provided for this operating manual is considered the authoritative version. The actual scope of delivery can deviate from the explanations and graphic representations described herein under certain circumstances, e.g. in the case of special designs, utilization of additional order options or because of state-of-the-art technical alterations. If you have any questions, please contact the manufacturer. This operating manual must be read carefully before starting work on or with the equipment, in particular before commissioning! The manufacturer assumes no liability for damage or faults arising from non-compliance with the instructions in this operating manual. The operating manual must be kept directly with the equipment and be accessible to all persons who work on or with the equipment. It is not permitted for the operating manual to be passed to third parties and if applicable this will incur damage compensation. All other rights reserved. Before commissioning the device must be checked for being not defective and its technically perfect function. The German version is the original. We reserve the right to make technical alterations to the product within the context of improving the usage properties and further development. The operating manual remains our property. Any reproduction, use by or communication to third parties incurs a penalty and will be pursued by court action (copyright law against unfair competition, BGB [German Civil Code]). All rights reserved in the case of a patent award (Paragraph 7, Section. 1 of the patent law - PG) or entry as a patented design (Paragraph 5, Section 4 of the patented design law - GMG). 4

57 Operating instruction english Type Warranty 3 Warranty The warranty conforms to: the regulations agreed in the purchase contract and the General Conditions for Delivery and Capacity of C.K. Walther GmbH & Co. KG of the state which was valid at the date of the purchase contract. Wearing parts are generally excluded from the warranty. Typical wearing parts of products from company C.K. Walther GmbH & Co. KG are for example: seals springs 5

58 Operating instruction english Type Safety instructions 4 Safety instructions Using these couplings does not release the customer from his obligation to comply with the pertinent work safety regulations e.g. operational safety regulations, etc. The duty to take due care by the operator of the couplings includes planning measures to ensure proper operation and monitoring their implementation. Hazard notes If the wrong product has been selected or if there is improper use or maintenance has been omitted, then hazards arise and personal injuries and material damage can occur from: - hazardous emission of fluid or individual particles/coupling parts. - function impairments of connected systems or tools. - the metal parts of coupling and adaptor are not thermally protected. In case of high media temperatures the contact with these parts can lead to combustion. According to the ambient temperature valve handle and ring grip can also become very hot. For that reason sufficiently long protective gloves must be worn in these cases. The operator must in particular make sure that - the couplings are only used according to the intended purpose. - the couplings are only operated in a perfect, functioning condition. - the operating manual is always in a legible condition and is available in its entirety to operating personnel. - the operating personnel are sufficiently acquainted with the working method and the safety notes for the coupling. - no safety devices must be removed and/or deactivated during operation of the couplings. - before installing or dismantling the couplings, you have made sure that the couplings have not been pressurized. After completing assembly and installation work and before commissioning the coupling, the following items have to be observed: Check once again that all screw connections are securely fitted. Before commissioning the couplings, a function test must be carried out (see maintenance and function test). 6

59 Operating instruction english Type Product description of the self sealing coupling Coupling connection consists of: - self sealing coupling self sealing adaptor Product description of the self sealing coupling In case that both coupling halves are not connected they should be protected against external dirt and/or damages if required. For that purpose dust cap and dust plug are available. Possible comibinations : self sealing coupling with dust plug self sealing adaptor with dust cap Intended use - The coupling shall only be used to connect two lines. - The coupling- and decoupling process is manually operated. - The coupling is equipped with an automatic lock, i. e.: one-hand operation - The coupling is particularly suitable for the following use of media / applications: - air - water - hydraulic oil - and their subspecies (such as oxygen or oil with additives) - For all other possible applications please contact WALTHER-Präzision. 5.2 Technical data - Working pressures of coupling depend on materials of individual parts. - When determing the working with standardized threaded connections, the highest permissible working pressure of the connection must be taken into account. - When selecting a suitable connection the following static pressure is possible: operating pressure maximum: 200 bar (Messing, stainless steel) Cv-value: The coupling is not determined for any types of use and technical values other than those listed here. - Safe operation is not guaranteed if the coupling is used contrary to ist intended use and technical values - The operator of the coupling is responsible for all personal injuries or material damage that occur from non-intended use and disregard of the technical values; the manufacturer assumes no responsibility in these cases. 7

60 Operating instruction english Type Installation instruction 6 Installation Instruction 6.1 General Subject to the general accident prevention regulations coupling is to be installed into a network in such a way that: - a satisfactory operation is guaranteed according to the operating instruction. - first of all self sealing coupling is used on line side and self sealing adaptor on consumer side - external damage of the unit as well as all moving parts are excluded. Before self sealing coupling and the self sealing adaptor are installed at a pipeline network make sure that the pipeline network is sufficiently rinsed/blown out and/or cleaned. After the assembly works are finished a functional test is to be carried out with both, without pressure and under working pressure of the media elements according to operating instruction. 8

61 Operating instruction english Type Operating instruction 7 Operating Instruction In order to avoid critical injuries of the staff and damage at the self sealing coupling during operation, coupling may be only used for the stated applications. 7.1 Connection process Before each coupling process a visible check of the coupling and the adaptor has to be made. Damaged parts must be changed in case of observable, visible damages or deformations. The self-sealing coupling is equipped with an automatic lock, i. e. one-hand operation. For coupling the self-sealing coupling behind the locking sleeve or the self-sealing adaptor in the end plug area is taken up with one hand and pushed axially centred on the counter piece until the end stop. During the coupling the locking sleeve snaps in forward without the aid of the operator. Now the self-sealing coupling and the self-sealing adaptor are locked mechanically. Available valves are opened during the coupling process and thus the passage is released. CAUTION Please take care that locking sleeve is in final position, i.e. that it is flush in front with the coupling housing as otherwise no perfect lock is guaranteed. 7.2 Disconnection process For decoupling the self-sealing coupling behind the locking sleeve is taken up with one hand, with the other hand the locking sleeve is pulled back and the connection is separated. During the decoupling the available valves close automatically so that no further discharge of media is possible. Caution! In case of an available pressure in the line connected by the coupling system a strong separation impulse - depending on the pressure - can be effective onto the coupling system during disconnection. For that reason the movable part of the coupling (free half) is to be firmly held in the hand to avoid injuries. 9

62 Operating instruction english Type Maintenance Instruction Maintenance and Functional instruction Preventive maintenance measures WALTHER self sealing couplings are to be operated in such a manner that external damages to elements and all moving parts are avoided. 8.1 Maintenance and functional test In order to always guarantee function of the self sealing coupling and hence safety of operator, a maintenance and functional testing must be made in appropriate periods of time depending on operating conditions. In order to minimize operating forces and to extend service life of the self sealing coupling we recommend to slightly grease plug surfaces (see item 9.0) Maintenance includes following items: - A visual inspection of self sealing coupling and self sealing adaptor regarding damage and contamination has to be made. - Dirt at the functional area (sealing area, operating elements) which is easily accessible from outside should be removed by simply wiping-off. If there are damaged, torn or corroded parts, coupling must be dismounted and returned to manufacturer for repair. If worn or embrittled seals are found or if there is extreme dirt, the customer can decide whether he returns coupling unit to the manufacturer's factory or whether he repairs himself Functional test includes following items: As described in the operating instruction, coupling is several times connected, pressurized and then disconnected. In doing so, the following has to be observed: - Connection and disconnection process must be absolutely smooth. - Coupling must be absolutely leak-proof in connected and disconnected state. If there are damaged, torn or corroded parts, coupling must be dismounted and returned to manufacturer for repair. If worn or embrittled seals are found or if there is extreme dirt, the customer can decide whether he returns the coupling unit to the manufacturer s factory or whether he repairs himself. 10

63 Operating instruction english Type Lubrication 9 Lubrication! In order to minimize operating forces and to extend service life of the coupling we recommend to slightly grease plug surfaces. Lubrication is to be carried out with greases which do not tend to become resin. Caution! The selection of the grease is to be suited to the sealing quality and the medium (e.g.: oxygen) in view of the compatibility. 11

64 Operating instruction english Type Storage 10 Storage The couplings must be stored in such a way that no damages can occur at the couplings. The storage conditions of the couplings must comply with the guidelines for the seals as these can change in properties due to improper storage. The following items must be kept: - The couplings must be stored dry. - To safely conserve the seals and that means also the couplings they should not be stored under the effect of daylight. - For protection against oxygen the seals and also the couplings shall be stored into the packing. 12

65 Operating instruction english Type Shut-down 11 Shut-down At the end of the service life the coupling or its components have to be disposed non-polluting and according to the legal regulations. For that the local public or private disposal societies should be taken. 13

66 Operating instruction english Type Order number code 12 Order number code X X X - X X X X X X X X X X X - X X X X - X X X X X - X X X X X X X X X X X X X X X X - X X 1. Subject group 2. Series Series description consists of either two letters or two digits. 3. Nominal size / nominal width It is rounded up or rounded down to full units. The indication can be numerical or alphanumeric. 4. Type of product and design 5. Type of connection 6. Material: xx-x and xxxx possible 7. Material (seal version): xx-x and xxxx possible 8. Y- or Z-design 9. Optional features 14

67 Operating instruction english Type Index 13 Index A According to intended purpose... 6 Acquired knowledge... 4 air... 7 Alterations... 4 Assembly... 6 C Commissioning... 4, 6 connected... 6, 7, 10 connection... 7, 14 Connection process... 9 coupling... 4, 6 Coupling... 7, 13 Couplings... 6 Customer care... 2 Cv-value... 7 D Damage... 4, 6 Damage compensation... 4 daylight disconnected Disconnection process... 9 Dismantling... 6 Disposal societies Disregard... 7 dry dust cap... 7 dust plug... 7 E Equipment... 4 Experience... 4 external damage... 8 F Faults... 4 Fluid... 6 Function... 6 Function test... 6 Functionality... 2 G General... 4 guarantee H Hazard notes... 6 Hazardous emission... 6 hydraulic oil... 7 I Implementation... 6 Improvement... 4 Index Inspection... 2 Installation Instruction... 8 Intended use... 7 L Legible condition... 6 Liability... 4 List of Contents... 3 Lubrication M Maintenance... 2, 4, 6 Maintenance Instruction Manual... 4 O one-hand operation... 7, 9 Operating instruction... 1 Operating Instruction... 9 operating pressure maximum... 7 Operation... 2 Operational safety regulations... 6 operator... 6 Operators... 2 original... 4 P packing Perfect, functioning condition... 6 Performance capability... 2 Pressurized... 6 Product description... 7 Property... 4 Q quality questions

68 Operating instruction english Type Index R regulations... 8 Regulations... 4 Reliability... 2 responsible... 7 S Safety... 2 Safety devices... 6 Safety instructions... 6 Scope of delivery... 4 Screw connections... 6 seals... 5, 10, 12 self sealing adaptor... 7, 8, 10 self sealing coupling... 7, 8, 9, 10 service... 10, 11 Service... 2 Shut-down Special designs... 4 Specialists... 2 springs... 5 Status of development... 4 Storage subspecies... 7 Systems... 2, 6 T Technical data... 7 Technical equipment... 2 Technical values... 7 Tools... 2, 6 Translation errors... 4 Types of use... 7 U Use... 2 V Version... 4 W Warranty... 3, 5 water... 7 Work safety regulations... 6 Working method... 6 working pressure... 7 Wrong product selection

69 Operating instruction english Revision A Date Issuer NH This operating instruction is not subject to the updating Ball-Face Clean-Break-Coupling 1-BF BF BF BF BF BF optional feature: EX 1

70 This coupling is a quality product, in which special attention has been paid to high functionality, ease of operation, safety and reliability. As an item of technical equipment this tool-changer is intended for use in the commercial, industrial area and for operators, who have been trained by specialists in the handling of technical systems / tools. Customer care: As part of our individual customer care we will be happy to assist you in questions relating to use and operation and on any problems encountered. Service and maintenance: In order to maintain the high technical performance capability and reliability of your docking system over many years, we recommend regular inspection and maintenance. We can thereby offer you optimum support by our Customer Service department and the conclusion of a service and maintenance contract. Please ask for a quotation. Carl Kurt Walther GmbH & Co. KG PO Box Haan Westfalenstraße 2 Tel.: +49 (0) Fax: +49 (0) info@walther-praezision.de Internet: Contact: Application technology and service Holger R. Figge Telephone: (02129) Telefax: (02129) Handy: (0162) hfigge@walther-praezision.de 2

71 Operating instruction english Type BF-005, BF-009, BF-012 List of Contents 1 List of Contents 1 LIST OF CONTENTS GENERAL WARRANTY SAFETY INSTRUCTIONS PRODUCT DESCRIPTION OF THE SELF SEALING COUPLING INTENDED USE TECHNICAL DATA OPTIONAL FEATURES EXTENDED PRODUCT DESCRIPTION FOR APPLICATION ACC. TO ATEX-GUIDE LINE 94/9/EG (SPECIAL DESIGN EX): General Extended marking INSTALLATION INSTRUCTION GENERAL EXTENDED INSTALLATION INSTRUCTION FOR APPLICATION ACC. TO ATEX-GUIDELINE 94/9/EG Details for safe operation Details for safe installation Details for a safe application area OPERATING INSTRUCTION COUPLING PROCESS (COUPLING AT THE HOSE) DISCONNECTION PROCESS (COUPLING AT THE HOSE) CONNECTION PROCESS (ADAPTOR AT THE HOSE) DISCONNECTION PROCESS (ADAPTOR AT THE HOSE) CLEANING AND MAINTENANCE MAINTENANCE INSTRUCTION MAINTENANCE AND FUNCTIONAL TEST Maintenance includes following items: Functional test includes following items: LUBRICATION! STORAGE SHUT-DOWN ORDER NUMBER CODE INDEX

72 Operating instruction english Type BF-005, BF-009, BF-012 General 2 General This manual contains all regulations for operation, commissioning and maintenance of the locking coupling elementcoupling. All information and notes in this operating manual were collated while taking into consideration the valid regulations, the current engineering related status of development as well as our many years of experience and acquired knowledge. Translations of this operating manual were also produced according to the best of knowledge. However, we cannot assume liability for any translation errors. The German version provided for this operating manual is considered the authoritative version. The actual scope of delivery can deviate from the explanations and graphic representations described herein under certain circumstances, e.g. in the case of special designs, utilization of additional order options or because of state-of-the-art technical alterations. If you have any questions, please contact the manufacturer. This operating manual must be read carefully before starting work on or with the equipment, in particular before commissioning! The manufacturer assumes no liability for damage or faults arising from non-compliance with the instructions in this operating manual. The operating manual must be kept directly with the equipment and be accessible to all persons who work on or with the equipment. It is not permitted for the operating manual to be passed to third parties and if applicable this will incur damage compensation. All other rights reserved. Before commissioning the device must be checked for being not defective and its technically perfect function. The German version is the original. We reserve the right to make technical alterations to the product within the context of improving the usage properties and further development. The operating manual remains our property. Any reproduction, use by or communication to third parties incurs a penalty and will be pursued by court action (copyright law against unfair competition, BGB [German Civil Code]). All rights reserved in the case of a patent award (Paragraph 7, Section. 1 of the patent law - PG) or entry as a patented design (Paragraph 5, Section 4 of the patented design law - GMG). 4

73 Operating instruction english Type BF-005, BF-009, BF-012 Warranty 3 Warranty The warranty conforms to: the General Conditions for Delivery and Capacity of C.K. Walther GmbH & Co. KG of the state which was valid at the date of the purchase contract and the regulations agreed in the purchase contract. Wearing parts are generally excluded from the warranty. Typical wearing parts of products from company C.K. Walther GmbH & Co. KG are for example: seals springs 5

74 Operating instruction english Type BF-005, BF-009, BF-012 Safety instructions 4 Safety instructions Using these couplings does not release the customer from his obligation to comply with the pertinent work safety regulations e.g. operational safety regulations, etc. The duty to take due care by the operator of the couplings includes planning measures to ensure proper operation and monitoring their implementation. Hazard notes If the wrong product has been selected or if there is improper use or maintenance has been omitted, then hazards arise and personal injuries and material damage can occur from: - hazardous emission of fluid or individual particles/coupling parts. - function impairments of connected systems or tools. - the metal parts of coupling and adaptor are not thermally protected. In case of high media temperatures the contact with these parts can lead to combustion. According to the ambient temperature valve handle and ring grip can also become very hot. For that reason sufficiently long protective gloves must be worn in these cases. The operator must in particular make sure that - the couplings are only used according to the intended purpose. - the couplings are only operated in a perfect, functioning condition. - the operating manual is always in a legible condition and is available in its entirety to operating personnel. - the operating personnel are sufficiently acquainted with the working method and the safety notes for the coupling. - no safety devices must be removed and/or deactivated during operation of the couplings. - before installing or dismantling the couplings, you have made sure that the couplings have not been pressurized. After completing assembly and installation work and before commissioning the coupling, the following items have to be observed: Check once again that all screw connections are securely fitted. Before commissioning the couplings, a function test must be carried out (see maintenance and function test). 6

75 Operating instruction english Type BF-005, BF-009, BF Product description of the self sealing coupling The coupling connection comprises: one clean break-coupling and one clean break adaptor one clean break-coupling and one clean break adaptor one clean break-coupling and one clean break adaptor Product description of the self sealing coupling 1-BF BF BF BF BF BF If both coupling halves are not connected both coupling halves, if necessary, should be protected against external contamination and/or damages. For this purpose dust cap and dust plug are available. Possible combinations: clean break coupling 1-BF with dust plug 1-BF self sealing adaptor 1-BF with dust cap 1-BF Intended use - The clean break coupling is used to connect two lines. - It is to be recommended to arrange the adaptor stationary and the coupling at the hose. If the adaptor must be assembled at the hose a protected parking position (hang up hose with adaptor with hanger or eye or parking in the receptacle) is to be preferred to a parking (disconnected state) on the floor. - The connection and disconnection process is carried out by hand, when connecting additionally with an automatic lock. I.e. the locking sleeve is after the disconnection always in the ready to lock position and locks automatically after the insertion of the adaptor into the coupling. The locking sleeve must not be retracted with the second hand for connection. - Squirt free connection and/or disconnection is possible in case of smallest air inclusion quantities and/or leckage quantities. - The clean break coupling was primarily developed for applications in the chemical industry. It is used for: non lubricating process liquids e.g.: demineralized water "dry" gases solvents 7

76 Operating instruction english Type BF-005, BF-009, BF-012 lubricating media e.g.: oils soap solutions. - Consult with Walther-Präzision for all other possible uses. Product description of the self sealing coupling 5.2 Technical data - The working pressures of the coupling depend on the component materials. - When determining the working pressures with standardized threaded connections, the highest permissible working pressure of the connection must be taken into consideration. - When selecting a suitable connection the following maximum static pressure is possible: Working pressure (static) stainless steel NW 5 NW 9 NW 12 connected disconnected adaptor disconnected coupling Working temperature NW 5 NW 9 NW C bis +200 C -10 C bis +200 C -10 C bis +200 C Cv flow coefficient (following the DIN IEC 534) NW 5 NW 9 NW 12 Coupling -> Adaptor Adaptor -> Coupling Discplacement volume (until beginning of the flow) NW 5 NW 9 NW 12 Nippel ca. 0,02cm 3 ca. 0,12cm 3 ca. 1.60cm 3 Kupplung ca. 0,13cm 3 ca. 0,20cm 3 ca. 1.80cm 3 Displacement volume (until beginning of the flow ) NW 5 NW 9 NW 12 ca. 0.75cm 3 ca. 6.20cm 3 ca cm 3 Connectable up to pressure increases NW 5 NW 9 NW 12 Nippelseitig auf 64 bar 12 bar 7 bar Kupplungsseitig auf 25 bar 6 bar 3 bar 8

77 Operating instruction english Type BF-005, BF-009, BF-012 Inclusion when connecting Product description of the self sealing coupling NW 5 NW 9 NW 12 ca cm 3 ca cm 3 ca cm 3 Theoretical leckage quantity when disconnecting NW 5 NW 9 NW 12 ca cm 3 ca cm 3 ca cm 3 - The coupling is not determined for any types of use and technical values other than those listed in this product description. - Safe operation is not guaranteed if the coupling is used contrary to its intended use and technical values. - The operator of the coupling is responsible for all personal injuries or material damages that occur from non-intended use and disregard of the technical values; the manufacturer assumes no responsibility in these cases. 5.3 Optional Features EX = ATEX version 9

78 Operating instruction english Type BF-005, BF-009, BF-012 Product description of the self sealing coupling 5.4 Extended product description for application acc. to ATEX-guide line 94/9/EG (special design EX): General Only non-sparkling materials may be used. Non-sparkling materials are , or equivalent materials. Furthermore brass with different surfaces (f. ex. chrome-plated, nickel-plated). Further on it must be assured that the seal is resistant against and suitable for the flowing through media. Also the temperature resistance of the seals must be guaranteed. This must also be considered for the marking acc. to chapter Extended marking The coupling fittings are marked with As the surface temperature of the self-sealing couplings are determined by the temperature of the fluids, the temperature category or the highest surface temperature must be specified by the operator while the safe temperature distances acc. to EN must be observed and the maximum temperature resistance of the coupling materials and seals are taken into consideration. The marking of the temperature class must be effected readily visible by the operator. The determination of the temperature class must be made acc. to the following table: Max. temperature of Temperature class fluids 75 T6 90 T5 130 T4 195 T3 295 T2 445 T1 The couplings are not admitted for the temperature classes T1 and T2 and may not be marked for that by the operator. 10

79 Operating instruction english Type BF-005, BF-009, BF-012 Installation instruction 6 Installation Instruction 6.1 General Subject to the general accident prevention regulations coupling is to be installed into a network in such a way that: - a satisfactory operation is guaranteed according to the operating instruction. - first of all the coupling is used on line side and the adaptor on consumer side - external damage of the unit as well as all moving parts are excluded. Before coupling and the adaptor are installed at a pipeline network make sure that the pipeline network is sufficiently rinsed/blown out and/or cleaned. After the assembly works are finished a functional test is to be carried out with both, without pressure and under working pressure of the media elements according to operating instruction. 6.2 Extended installation instruction for application acc. to ATEX-guideline 94/9/EG Details for safe operation For the use of self sealing couplings as a hose connection it must be guaranteed that in case of pressure strikes the tumbling of the self sealing coupling can be avoided by fixing at suitable constructions. In principle it must be observed that the self sealing coupling cannot strike on hard objects which could produce strike sparks when touching the housing Details for safe installation The self sealing couplings may only be connected to pipe- and hose systems which are suitable for electrostatic discharge and which are connected to the ground potential Details for a safe application area The self sealing couplings may be used according to the class of devices 2 in areas susceptible to explosions where potentially explosive mixtures of gas, steam, mist and air are availble. 11

80 Operating instruction english Type BF-005, BF-009, BF-012 Operating instruction 7 Operating Instruction In order to avoid critical injuries of the staff and damage at the self sealing coupling during operation, coupling may be only used for the stated applications. 7.1 Coupling process (Coupling at the hose) Take coupling at the hose or at the grip sleeve and slide it onto the adaptor. If the coupling axis does not align to the adaptor axis (inclined approach) the coupling can be centered with some feeling. The coupling is finally slided on until mechanical end stop. In doing so the locking sleeve jumps audibly and sensibly some mm to the front (into the direction of the adaptor) and the coupling is connected and safely locked. 7.2 Disconnection process (Coupling at the hose) Take coupling and/or hose and hold it on. Simultaneously slide back locking sleeve at the gripping shoulder. The coupling jumps from the adaptor. Then deposit hose with coupling and protect both as far as possible against dirt and damage. 12

81 Operating instruction english Type BF-005, BF-009, BF-012 Operating instruction 7.3 Connection process (Adaptor at the hose) Take the hose close to the adaptor and insert the adaptor into the coupling as described before. The locking sleeve jumps audibly and sensibly some mm to the front (in the adaptor direction) and the coupling is connected and safely locked. 7.4 Disconnection process (Adaptor at the hose) Take the hose close to the adaptor and hold it. In doing so slide back locking sleeve into the direction of the coupling. The adaptor jumps out of the coupling. Then deposit hose with adaptor and protect both as far as possible against dirt and damage. 7.5 Cleaning and maintenance Coupling and adaptor are precision parts und must therefore be protected on the sealing surfaces against damages. Greasing and oiling are not necessary for a good function. The application of resinous lubricants can lead to malfunctions and must therefore be refrained. Coupling and adaptor have smooth surfaces as far as possible and thus they are easily to be cleaned. The cleaning should be done by rinsing, blowing off and wiping. When cleaning the adaptor it is to be considered that the adaptor valve is not unintentionally pushed open in case of included dangerous media. To wipe the ball face front contour of the coupling the locking sleeve of the coupling can be brought into a pushed back cleaning position (see pictures). Locking sleeve in normal position in front (in ready to connect position) Locking sleeve pushed back (in cleaning position) To bring the locking sleeve back into the cleaning position a pressure point must be overcome. Especially with regard to higher nominal bores this happens positively through an easy blow with the flat hand onto the front surface of the coupling and/or locking sleeve. Caution For safety reasons it is not possible to connect the coupling with pushed back locking sleeve (only cleaning position). 13

82 Operating instruction english Type BF-005, BF-009, BF-012 Maintenance and Functional instruction 8 Maintenance Instruction Preventive maintenance measures WALTHER self sealing couplings are to be operated in such a manner that external damages to elements and all moving parts are avoided. 8.1 Maintenance and functional test In order to always guarantee function of the self sealing coupling and hence safety of operator, a maintenance and functional testing must be made in appropriate periods of time depending on operating conditions. In order to minimize operating forces and to extend service life of the self sealing coupling we recommend to slightly grease plug surfaces (see item 9.0) Maintenance includes following items: - A visual inspection of self sealing coupling and self sealing adaptor regarding damage and contamination has to be made. - Dirt at the functional area (sealing area, operating elements) which is easily accessible from outside should be removed by simply wiping-off. If there are damaged, torn or corroded parts, coupling must be dismounted and returned to manufacturer for repair. If worn or embrittled seals are found or if there is extreme dirt, the customer can decide whether he returns coupling unit to the manufacturer's factory or whether he repairs himself Functional test includes following items: As described in the operating instruction, coupling is several times connected, pressurized and then disconnected. In doing so, the following has to be observed: - Connection and disconnection process must be absolutely smooth. - Coupling must be absolutely leak-proof in connected and disconnected state. If there are damaged, torn or corroded parts, coupling must be dismounted and returned to manufacturer for repair. If worn or embrittled seals are found or if there is extreme dirt, the customer can decide whether he returns the coupling unit to the manufacturer s factory or whether he repairs himself. 14

83 Operating instruction english Type BF-005, BF-009, BF-012 Lubrication 9 Lubrication! See operating instruction (see point 7). 15

84 Operating instruction english Type BF-005, BF-009, BF-012 Storage 10 Storage The couplings must be stored in such a way that no damages can occur at the couplings. The storage conditions of the couplings must comply with the guidelines for the seals as these can change in properties due to improper storage. The following items must be kept: - The couplings must be stored dry. - To safely conserve the seals and that means also the couplings they should not be stored under the effect of daylight. - For protection against oxygen the seals and also the couplings shall be stored into the packing. 16

85 Operating instruction english Type BF-005, BF-009, BF-012 Shut-down 11 Shut-down At the end of the service life the coupling or its components have to be disposed non-polluting and according to the legal regulations. For that the local public or private disposal societies should be taken. 17

86 Operating instruction english Type BF-005, BF-009, BF-012 Order number code 12 Order number code X X X - X X X X X X X X X X X - X X X X - X X X X X - X X X X X X X X X X X X X X X X - X X 1. Subject group 2. Series Series description consists of either two letters or two digits. 3. Nominal size / nominal width It is rounded up or rounded down to full units. The indication can be numerical or alphanumeric. 4. Type of product and design 5. Type of connection 6. Material: xx-x and xxxx possible 7. Material (seal version): xx-x and xxxx possible 8. Y- or Z-design 9. Optional features 18

87 Operating instruction english Type BF-005, BF-009, BF-012 Index 13 Index A According to intended purpose... 6 Acquired knowledge... 4 Alterations... 4 Assembly... 6 B Ball-Face... 1 C class of devices Clean-Break-Coupling... 1 Commissioning... 4, 6 connected... 6, 14 connection Connection process coupling... 4, 6 Coupling Coupling process Couplings... 6 Customer care... 2 Cv flow coefficient... 8 D Damage... 4, 6 Damage compensation... 4 daylight disconnected Disconnection process Disconnection procss Discplacement volume... 8 Dismantling... 6 Disposal societies dry dust cap... 7 dust plug... 7 E Equipment... 4 Experience... 4 explosive mixtures Extended marking... 3, 10 external damage F Faults... 4 Fluid... 6 Function... 6 Function test... 6 Functionality... 2 G General... 4 guarantee H Hazard notes... 6 Hazardous emission... 6 I Implementation... 6 Improvement... 4 Index Inspection... 2 Installation Instruction Intended use... 3, 7 L Legible condition... 6 Liability... 4 List of Contents... 3 Lubrication M Maintenance... 2, 4, 6 Maintenance Instruction Manual... 4 O Operating instruction... 1 Operating Instruction Operation... 2 Operational safety regulations... 6 operator... 6 Operators... 2 optional feature... 1 original... 4 P packing Perfect, functioning condition... 6 Performance capability... 2 Pressurized... 6 produce strike sparks Property

88 Operating instruction english Type BF-005, BF-009, BF-012 Index Q questions... 4 R regulations Regulations... 4 Reliability... 2 S Safety... 2 Safety devices... 6 Safety instructions... 6 Scope of delivery... 4 Screw connections... 6 self sealing adaptor... 11, 14 self sealing coupling... 11, 12, 14 service Service... 2 Shut-down Special designs... 4 Specialists... 2 Status of development... 4 Storage Systems... 2, 6 T Technical data... 3, 8 Technical equipment... 2 temperature category Temperature class temperature resistance Tools... 2, 6 Translation errors... 4 U Use... 2 V Version... 4 W Warranty... 3, 5 Work safety regulations... 6 Working method... 6 Working pressure... 8 Working temperature... 8 Wrong product selection

89 Operating manual Revision A Date Created by NH This operating manual is not subject to the updating Clean-Break Safety Coupling 1-BF (Z..) 1-BF (Z..) optional feature: EX 1

90 This coupling is a quality product, in which special attention has been paid to high functionality, ease of operation, safety and reliability. As an item of technical equipment this tool-changer is intended for use in the commercial, industrial area and for operators, who have been trained by specialists in the handling of technical systems / tools. Customer care: As part of our individual customer care we will be happy to assist you in questions relating to use and operation and on any problems encountered. Service and maintenance: In order to maintain the high technical performance capability and reliability of your docking system over many years, we recommend regular inspection and maintenance. We can thereby offer you optimum support by our Customer Service department and the conclusion of a service and maintenance contract. Please ask for a quotation. Carl Kurt Walther GmbH & Co. KG PO Box Haan Westfalenstraße 2 Tel.: +49 (0) Fax: +49 (0) info@walther-praezision.de Internet: Contact: Application technology and service Holger R. Figge Telephone: (02129) Telefax: (02129) Handy: (0162) hfigge@walther-praezision.de Further addresses and telephone numbers of contacts can be found on the Internet on our homepage under Service / Customer service. 2

91 Operating manual Type BF-025 Table of Contents 1 Table of Contents 1 TABLE OF CONTENTS GENERAL SAFETY INSTRUCTIONS WARRANTY PRODUCT DESCRIPTION OF SELF SEALING COUPLING INTENDED USE TECHNICAL DATA OPTIONAL FEATURES EXTENDED PRODUCT DESCRIPTION FOR APPLICATION ACC. TO ATEX-GUIDE LINE 94/9/EG (SPECIAL DESIGN EX): General Extended marking INSTALLATION MANUAL GENERAL EXTENDED INSTALLATION INSTRUCTION FOR APPLICATION ACC. TO ATEX-GUIDELINE 94/9/EG Details for safe operation Details for safe installation Details for a safe application area OPERATING MANUAL COUPLING PROCESS Installation of the ready to couple position Mechanical connection of coupling and adaptor Opening of the valves UNCOUPLING PROCEDURE Closing of the valvese Mechanical disconnection of coupling and adaptor MAINTENANCE AND FUNCTION TEST CLEANING MAINTENANCE AND FUNCTION TEST Maintenance includes the following points: The function test contains the following points: INSTRUCTION FOR DISMANTLING AND ASSEMBLY OF THE SEALING MODULE LUBRICATION! STORAGE SHUT-DOWN ORDER NUMBERS CODE INDEX

92 Operating manual Type BF-025 General 2 General This manual contains all regulations for operation, commissioning and maintenance of the self sealing coupling BF-025. All information and notes in this operating manual were collated while taking into consideration the valid regulations, the current engineering related status of development as well as our many years of experience and acquired knowledge. Translations of this operating manual were also produced according to the best of knowledge. However, we cannot assume liability for any translation errors. The German version provided for this operating manual is considered the authoritative version. The actual scope of delivery can deviate from the explanations and graphic representations described herein under certain circumstances, e.g. in the case of special designs, utilization of additional order options or because of state-of-the-art technical alterations. If you have any questions, please contact the manufacturer. This operating manual must be read carefully before starting work on or with the equipment, in particular before commissioning! The manufacturer assumes no liability for damage or faults arising from non-compliance with the instructions in this operating manual. The operating manual must be kept directly with the equipment and be accessible to all persons who work on or with the equipment. It is not permitted for the operating manual to be passed to third parties and if applicable this will incur damage compensation. All other rights reserved. Before commissioning the device must be checked for being not defective and its technically perfect function. The German version is the original. We reserve the right to make technical alterations to the product within the context of improving the usage properties and further development. The operating manual remains our property. Any reproduction, use by or communication to third parties incurs a penalty and will be pursued by court action (copyright law against unfair competition, BGB [German Civil Code]). All rights reserved in the case of a patent award (Paragraph 7, Section. 1 of the patent law - PG) or entry as a patented design (Paragraph 5, Section 4 of the patented design law - GMG). 4

93 Operating manual Type BF-025 Safety instructions 3 Safety instructions Using these couplings does not release the customer from his obligation to comply with the pertinent work safety regulations e.g. operational safety ordinances, etc. The duty to take due care by the operator of the couplings includes planning measures to ensure proper operation and monitoring their implementation. Hazard notes If the wrong product has been selected or if there is improper use or maintenance has been omitted, then hazards arise and personal injuries and material damage can occur from: - Hazardous emission of fluid or individual particles/coupling parts - Function impairments of connected systems or tools - The metal parts of coupling and adaptor are not thermally protected. You can be burned if you touch these parts at high media temperatures. According to the ambient temperature valve lever and ring grip can also become unbearably hot. For that reason suitable, sufficiently long protective gloves should be worn. The operator must in particular make sure that - The couplings are only used according to the intended purpose. - The couplings are only operated in a perfect, functioning condition. - The operating manual is always in a legible condition and is available in its entirety to operating personnel. - The operating personnel are sufficiently acquainted with the working method and the safety notes for the coupling. - The coupling is sent to our factory for repair work. - During operation of the coupling, no safety devices are removed and/or deactivated. - Before installing or dismantling the coupling, you have made sure that the coupling has not been pressurized. After completing assembly and installation work and before commissioning the coupling, observe the following points: Check once again that all screw connections are securely fitted. Before commissioning the coupling, a function test must be carried out (see maintenance and function test). 5

94 Operating manual Type BF-025 Warranty 4 Warranty The warranty conforms to: the regulations agreed in the purchase contract and the General Conditions for Delivery and Capacity of C.K. Walther GmbH & Co. KG of the state which was valid at the date of the purchase contract. Wearing parts are generally excluded from the warranty. Typical wearing parts of products from company C.K. Walther GmbH & Co. KG are for example: seals springs 6

95 Operating manual Type BF-025 Product description of self sealing coupling 5 Product description of self sealing coupling The coupling connection comprises: self sealing coupling self sealing adaptor 1-BF BF Intended use - The self sealing coupling is used to connect two lines. - Both coupling halves can be connected and disconnected under working pressure. - The coupling is carried out with an automatic lock (one hand-operation). - The valves are separately opened and closed with a lever operated eccentric drive. - It is squirt free when coupling and uncoupling. - The self sealing coupling is used for both non-lubricating and lubricating media. - The self sealing coupling is suitable for all media/applications: However, the media resistance depends on the used materials. The self sealing coupling is especially used in the chemical industry. - Consult with C.K. Walther for all media restances which are unclear. 5.2 Technical data - The working pressures of the self sealing coupling depend on the component materials. - When determining the working pressures with standardized threaded connections, the highest permissible working pressure of the connection must be taken into consideration. Working pressure: Material : stainless steel coupled : uncoupled: max. 40 bar max. 40 bar Cv values: self sealing coupling - > self sealing adaptor = 14.7 self sealing adaptor - > self sealing coupling = 14.7 Leakage volume during uncoupling: 1 ml Working temperature: (-47) -10 C to +200 (+240) C 7

96 Operating manual Type BF-025 Product description of self sealing coupling - The safe function of the coupling requires media cleanness. Media contaminations can lead to leakages. We recommend a filter mesh of 25 µm. - Media can change rapidly or also over a longer period. That can interfere with the safe function of the coupling. The coupling is not suitable for media which show such appearances during operation of the coupling. - The permissible media temperatures depend on the permissible temperatures required for the used component materials. In critical cases, e.g. at very high temperatures or also very low temperatures the required temperature limits which are subject to the corresponding medium are to be agreed with the manufacturer. Freezing of the medium in the coupling parts stops their functionality. In addition frozen water can internally plastically deform and destroy the coupling parts. Also external water at the coupling can lead to its shut-down during freezing. - The self sealing coupling is not determined for any types of use other than those listed here. - Safe operation is not guaranteed if the self sealing coupling is used contrary to its intended use. - The operator of the self sealing coupling is responsible for all personal injuries or material damage that occur from non-intended use; the manufacturer assumes no responsibility in these cases. 5.3 Optional Features EX = ATEX version 8

97 Operating manual Type BF-025 Product description of self sealing coupling 5.4 Extended product description for application acc. to ATEX-guide line 94/9/EG (special design EX): General Only non-sparkling materials may be used. Non-sparkling materials are , or equivalent materials. Furthermore brass with different surfaces (f. ex. chrome-plated, nickel-plated). Further on it must be assured that the seal is resistant against and suitable for the flowing through media. Also the temperature resistance of the seals must be guaranteed. This must also be considered for the marking acc. to chapter Extended marking The coupling fittings are marked with As the surface temperature of the self-sealing couplings are determined by the temperature of the fluids, the temperature category or the highest surface temperature must be specified by the operator while the safe temperature distances acc. to EN must be observed and the maximum temperature resistance of the coupling materials and seals are taken into consideration. The marking of the temperature class must be effected readily visible by the operator. The determination of the temperature class must be made acc. to the following table: Max. temperature of Temperature class fluids 75 T6 90 T5 130 T4 195 T3 295 T2 445 T1 The couplings are not admitted for the temperature classes T1 and T2 and may not be marked for that by the operator. 9

98 Operating manual Type BF-025 Installation manual 6 Installation manual 6.1 General The self sealing coupling is to be integrated into the line network while taking into account the general accident prevention guidelines so that: - perfect operation is guaranteed in accordance with the operating manual (e.g. clearance of lever). - external damage to the unit and all mobile parts is excluded. Before installing the self sealing coupling and the self sealing adaptor in a pipeline network, make sure that the pipeline network has been sufficiently rinsed/blown through and/or cleaned. See point 7 for assembling and dismantling the self sealing coupling and self sealing adaptor into and out of the line system. After completing assembly work, a function test must be carried out according to the operating manual, both in depressurized state and under operating pressure. 6.2 Extended installation instruction for application acc. to ATEX-guideline 94/9/EG Details for safe operation For the use of self sealing couplings as a hose connection it must be guaranteed that in case of pressure strikes the tumbling of the self sealing coupling can be avoided by fixing at suitable constructions. In principle it must be observed that the self sealing coupling cannot strike on hard objects which could produce strike sparks when touching the housing Details for safe installation The self sealing couplings may only be connected to pipe- and hose systems which are suitable for electrostatic discharge and which are connected to the ground potential Details for a safe application area The self sealing couplings may be used according to the class of devices 2 in areas susceptible to explosions where potentially explosive mixtures of gas, steam, mist and air are availble. 10

99 Operating manual Type BF Operating manual Maintenance instructions Function test The self sealing coupling elements may only be used for the specified purposes in order to avoid critical injury to personnel and damage to the self sealing coupling elements during use. Function description of the coupling 7.1 Coupling process Installation of the ready to couple position The front adaptor component must be in non-relocatable position. This is the condition for the mechanical connection of adaptor and coupling. This ready to couple position for use is to be made if necessary as follows: The knurled ring is to be turned with its groove into the position relocatability. The now relocatable adaptor front part is to be completely moved into the direction to the coupling part. In this position the knurled ring is to be turned with its groove into the locked position. Subsequently the non-relocatable ready to couple position for use is to be checked by trying to reciprocate the adaptor front part. Knurled ring with groove Indication Locked position Indication Relocatability 11

100 Operating manual Type BF-025 Maintenance instructions Function test Mechanical connection of coupling and adaptor The coupling and/or the adaptor is to be mechanically connected by inserting into the respective counterpart. Due to the concave surface of the coupling front side it can occur that the adaptor does not immediately find its inserting position. The operator will find this position by swivelling the adaptor and/or coupling. Attention: clamp danger Jumping out of locking sleeve Shortly before reaching the finally locked position the locking sleeve jumps forward against a fixed collar. This is the feature that the coupling counterparts are mechanically locked. The sleeve is spring loaded so that there is the danger that you get your finger squashed during the coupling process. 12

101 Operating manual Type BF-025 Maintenance instructions Function test Opening of the valves To open the valves the locked position must be released by pressing the ratchet. If the locked position should be secured with a locking bolt it is to be removed before. The lever is to to be swivelled anticlockwise by 180. Thus the lever shows into the direction of the adaptor when the valves are opened. The valve opening process should be carried out continuously as it possibly results in strong flows which lead to more or less strong vibrations. Under no circumstances the coupling may be operated if the lever stands crosswise to the flow direction (i.e. after a 90 swivelling only). If the valves are completely opened attention is to be paid that the ratchet also locks in this position. This position is to be preferably secured with locking bolts so that it does not result in unintentional closing of the valves. The adaptor is secured against uncoupling by an internal locking circuit. An uncoupling is compulsorily only possible if valves are closed. Do not try to uncouple the coupling connection with force or with the aid of tools or the like. Unlocking of ratchet Locking bolt Locked position of ratchet 13

102 Operating manual Type BF-025 Maintenance instructions Function test 7.2 Uncoupling procedure Closing of the valvese Before the adaptor and the coupling can be uncoupled the valves must be compulsorily closed. For this purpose the locked position must be released by pressing again the ratchet. If the locked position was secured by a locking bolt the locking bolt is to be removed. The lever is continuously swivelled back by 180. The ratchet must snap in and if necessary it is to be secured with the locking bolt. Removal of locking bolt Unlocking of ratchet Locked position of ratchet 14

103 Operating manual Type BF-025 Maintenance instructions Function test Mechanical disconnection of coupling and adaptor Only if the valves are closed coupling and adaptor can be disconnected. The mechanical lock is opened by pressing the front bulge of the locking sleeve and the adaptorcan be taken from the coupling. 15

104 Operating manual Type BF Maintenance and Function test Maintenance instructions Function test Preventive maintenance measures WALTHER self sealing couplings are to be handled in such a way that external damage to the elements and to all mobile parts are excluded. 8.1 Cleaning The outside contours are smooth as far as possible and thus they can be easily cleaned. The front of the coupling is to be wiped with a clean, soft cloth without dirt ingress into the groove. The adaptor is to be cleaned first of all at its outside contour. Then the knurled ring with its groove is to be turned into the position relocability and the adpator front part can be pushed back. Thus the convex curved front surface is free and can be well cleaned. The detergents must be suitable for the built-in o-rings from elastomer materials. Knurled ring with groove Indication Locked position Indication Relocability 8.2 Maintenance and Function test Maintenance work and function test must be carried out at a suitable interval irrespective of the operating conditions to guarantee the function of the self sealing coupling and thereby also to protect the operator. We recommend lightly greasing the plug-in areas to minimize operating forces and to extend the service life of the self sealing coupling. 16

105 Operating manual Type BF-025 Maintenance instructions Function test Maintenance includes the following points: - An external visual inspection for damage and contamination is to be carried out for the self sealing coupling and the self sealing adaptor. - Contamination in externally accessible function areas (sealing area, operating elements) is to be removed simply by wiping. If there are damaged, torn or corroded parts the self sealing coupling and the self sealing adaptor must be dismantled and sent to the manufacturer for repair works. In the case of torn, brittle and old seals and with severe contamination the self sealing adaptormust be dismantled and sent to the manufacturer for repair works. The self sealing coupling has an easy to maintain sealing module on which all seals are placed. In the case of torn, brittle or old seals the customer must decide whether to send the self sealing coupling to the manufacturer for repair works or whether he exchanges the sealing module himself. The instruction for dismantling and assembly of the sealing module is carried out under point 8.3. The sealing module can be bought as completely mounted unit from the supplier of the self sealing coupling The function test contains the following points: As described in the operating manual, the self sealing coupling is coupled several times, pressurized and uncoupled. When doing this, pay attention to the following: - Perfect, smooth-running functioning when coupling and uncoupling. - Leak tightness of self sealing coupling in coupled and uncoupled status. If there are damaged, torn or corroded parts the self sealing coupling and self sealing adaptor must be dismantled and sent to them manufacturer for repair works. In case of torn, brittle or old seals and with severe contamination the self sealing adaptor must be dismantled and sent to the manufacturer for repair works. The self sealing coupling has an easy to maintain sealing module on which all seals are placed. In the case of torn, brittle or old seals the customer must decide whether to send the self sealing coupling to the manufacturer for repair works or whether he exchanges the sealing module himself. The instruction for dismantling and assembly of the sealing module is carried out under point 8.3. The sealing module can be bought as completely mounted unit from the supplier of the self sealing coupling. 17

106 Operating manual Type BF Instruction for dismantling and assembly of the sealing module Maintenance instructions Function test 1. Insert assembly tool BM into the coupling 2. After inserting locking sleeve jumps to the front ATTENTION: Locking sleeve is under initial load. Clamp danger for fingers 3. Assembly tool is locked Lever Position OPEN 4. The lever of the coupling is to be swivelled by 180 into position OPEN 5. Valve tappet must be loosened with a (cranked) flat spanner SW 8 BM and screwed out 18

107 Operating manual Type BF-025 Maintenance instructions Function test Lever Position CLOSED 6. Take out valve tappet 7. Swivel lever in direction CLOSED. In doing so lead tappet receptacle with the screwdriver in the female thread with the screwdriver to the back! (Avoidance of locks and surface damages) 8. Loosen assembly tool by pushing back locking sleeve ATTENTION: Counterpush assembly sleeve as it is under spring initial tension! 9. Take out assembly tool Assembly tool 10. Remove sealing module from coupling Reassembly in reverse order. (Pay attention to the guidance of the screwdriver of the tappet receptacle at point 7.) Tightening torque: 8Nm 19

108 Operating manual Type BF-025 Lubrication 9 Lubrication! We recommend lightly greasing the plug-in areas to minimize operating forces and to extend the service life of the coupling. Lubrication has to be carried out with greases which do not tend to become resin. Attention! The choice of grease with regard to compatibility must agree with the seal quality and the fluid (e.g.: oxygen). 20

109 Operating manual Type BF-025 Storage 10 Storage The couplings must be stored in such a way that no damage can occur to the couplings. The storage conditions of the couplings depend on the guidelines applicable to the gaskets, since improper storage can lead to deterioration of the gaskets. The following points must be observed: - The couplings must be stored dry. - For the preservation of the gaskets, the gaskets and couplings should not be stored where they are exposed to the effects of daylight. For protection against oxygen, the gaskets and couplings should be stored in the original packaging. 21

110 Operating manual Type BF-025 Shut-down 11 Shut-down At the end of the service life the coupling or its components have to be disposed non-polluting and according to the legal regulations. For that the local public or private disposal societies should be taken. 22

111 Operating manual Type BF-025 Order numbers code 12 Order numbers code X X X - X X X X X X X X X X X - X X X X - X X X X X - X X X X X X X X X X X X X X X X - X X z.b.: 1 B F W R Subject group 2. Series The information regarding the series comprises either two letters or two numbers. 3. Nomial size / Nominal bore It is rounded up or down to one. The information can be numerical as well as alphanumerical. 4. Product type or design type 5. Connection design 6. Material design: xx-x and xxxx possible (Order number code on request from the manufacturer) 7. Material design (seal design): xx-x and xxxx possible (Order number code on request from the manufacturer) 8. Y or Z design (Order number code on request from the manufacturer) 9. Additional equipment (Order number code on request from the manufacturer) 23

112 Operating instruction Type BF-025 Index 13 Index A According to intended purpose... 5 Acquired knowledge... 4 adaptor Adaptor... 11, 12, 13, 14, 15, 16 Adaptorl... 5 Alterations... 4 Assembling Assembly... 5 Assembly work Automatic lock... 7 C class of devices Clean Break Safety Coupling... 1 Cleaned Clearance Commissioning... 4, 5 concave surface Corroded Coupling... 5, 11, 12, 14, 15, 16, 20, 22 Coupling connection... 7 Coupling halves... 7 Coupling process Couplings... 5 Customer care... 2 Cv values... 7 D Damage... 4, 5 Damage compensation... 4 Damaged Daylight Depressurized state Detergents Dismantling Disposal societies dry E Eccentric drive... 7 Equipment... 4 Experience... 4 explosive mixtures Extended marking... 9 F Faults... 4 Fluid... 5 Function... 5 Function test...5, 10, 16, 17 Functionality... 2 G General... 4 General accident prevention guidelines H Hazard notes... 5 Hazardous emission... 5 I Implementation... 5 Improvement... 4 Index Inhaltsverzeichnis... 3 Inspection... 2 Installation manual Intended use... 7 K Knurled ring... 11, 16 L Leakage volume... 7 Legible condition... 5 Lever Liability... 4 Locked position Locking bolt... 13, 14 Locking bolts Locking circuit Lubrication M Maintenance...2, 4, 5, 16, 17 Maintenance and function test Maintenance and Function test Maintenance work Manual... 4 Media temperatures... 5 Mobile parts O One-hand operation... 7 Operating manual Operating forces... 16, 20 24

113 Operating instruction Type BF-025 Index Operating manual... 1, 10, 11 Operating pressure Operation... 2 Operational safety ordinances... 5 Operators... 2 optional feature... 1 Original... 4 Oxygen P Packaging Perfect, functioning condition... 5 Performance capability... 2 Pipeline network Pressurized... 5 produce strike sparks Product description... 7 Property... 4 Protective gloves... 5 Q Questions... 4 R Ratchet... 13, 14 Ready to couple position Regulations... 4 Reliability... 2 Relocability Relocatability Repair work... 5 Repair works S Safety... 2 Safety devices... 5 Safety instructions... 5 Scope of delivery... 4 Screw connections... 5 Seals Self sealing adaptor... 7, 10, 17 Self sealing coupling...7, 8, 10, 16, 17 Service... 2 Shut-down Smooth-running functioning Special designs... 4 Specialists... 2 Squirt free... 7 Status of development... 4 Storage Storage conditions Systems... 2, 5 T Technical data... 7 Technical equipment... 2 temperature category... 9 Temperature class... 9 temperature resistance... 9 Thermally... 5 Tools... 2, 5 Torn Translation errors... 4 Types of use... 8 U Uncoupling procedure Use... 2 V Version... 4 Vibrations W Work safety regulations... 5 Working method... 5 Working pressure... 7 Working pressures... 7 Working pressurese... 7 Working temperature... 7 Wrong product selection

114 Operating manual Revision A Date Created by NH This operating manual is not subject to the updating Clean-Break Safety Coupling 1-BF (Z..) 1-BF (Z..) optional feature : EX 1

115 This coupling is a quality product, in which special attention has been paid to high functionality, ease of operation, safety and reliability. As an item of technical equipment this tool-changer is intended for use in the commercial, industrial area and for operators, who have been trained by specialists in the handling of technical systems / tools. Customer care: As part of our individual customer care we will be happy to assist you in questions relating to use and operation and on any problems encountered. Service and maintenance: In order to maintain the high technical performance capability and reliability of your docking system over many years, we recommend regular inspection and maintenance. We can thereby offer you optimum support by our Customer Service department and the conclusion of a service and maintenance contract. Please ask for a quotation. Carl Kurt Walther GmbH & Co. KG PO Box Haan Westfalenstraße 2 Tel.: +49 (0) Fax: +49 (0) info@walther-praezision.de Internet: Contact: Application technology and service Holger R. Figge Telephone: (02129) Telefax: (02129) Handy: (0162) hfigge@walther-praezision.de Further addresses and telephone numbers of contacts can be found on the Internet on our homepage under Service / Customer service. 2

116 Operating manual Type BF-050 Table of Contents 1 Table of Contents 1 TABLE OF CONTENTS GENERAL SAFETY INSTRUCTIONS WARRANTY PRODUCT DESCRIPTION OF SELF SEALING COUPLING INTENDED USE TECHNICAL DATA OPTIONAL FEATURES EXTENDED PRODUCT DESCRIPTION FOR APPLICATION ACC. TO ATEX-GUIDE LINE 94/9/EG (SPECIAL DESIGN EX): General Extended marking INSTALLATION MANUAL GENERAL EXTENDED INSTALLATION INSTRUCTION FOR APPLICATION ACC. TO ATEX-GUIDELINE 94/9/EG Details for safe operation Details for safe installation Details for a safe application area OPERATING MANUAL COUPLING PROCESS Installation of the ready to couple position Mechanical connection of coupling and adaptor Opening of the valves UNCOUPLING PROCEDURE Closing of the valvese Mechanical disconnection of coupling and adaptor MAINTENANCE AND FUNCTION TEST CLEANING MAINTENANCE AND FUNCTION TEST Maintenance includes the following points: The function test contains the following points: INSTRUCTION FOR DISMANTLING AND ASSEMBLY OF THE SEALING MODULE LUBRICATION! STORAGE SHUT-DOWN ORDER NUMBERS CODE INDEX

117 Operating manual Type BF-050 General 2 General This manual contains all regulations for operation, commissioning and maintenance of the self sealing coupling BF-050. All information and notes in this operating manual were collated while taking into consideration the valid regulations, the current engineering related status of development as well as our many years of experience and acquired knowledge. Translations of this operating manual were also produced according to the best of knowledge. However, we cannot assume liability for any translation errors. The German version provided for this operating manual is considered the authoritative version. The actual scope of delivery can deviate from the explanations and graphic representations described herein under certain circumstances, e.g. in the case of special designs, utilization of additional order options or because of state-of-the-art technical alterations. If you have any questions, please contact the manufacturer. This operating manual must be read carefully before starting work on or with the equipment, in particular before commissioning! The manufacturer assumes no liability for damage or faults arising from non-compliance with the instructions in this operating manual. The operating manual must be kept directly with the equipment and be accessible to all persons who work on or with the equipment. It is not permitted for the operating manual to be passed to third parties and if applicable this will incur damage compensation. All other rights reserved. Before commissioning the device must be checked for being not defective and its technically perfect function. The German version is the original. We reserve the right to make technical alterations to the product within the context of improving the usage properties and further development. The operating manual remains our property. Any reproduction, use by or communication to third parties incurs a penalty and will be pursued by court action (copyright law against unfair competition, BGB [German Civil Code]). All rights reserved in the case of a patent award (Paragraph 7, Section. 1 of the patent law - PG) or entry as a patented design (Paragraph 5, Section 4 of the patented design law - GMG). 4

118 Operating manual Type BF-050 Safety instructions 3 Safety instructions Using these couplings does not release the customer from his obligation to comply with the pertinent work safety regulations e.g. operational safety ordinances, etc. The duty to take due care by the operator of the couplings includes planning measures to ensure proper operation and monitoring their implementation. Hazard notes If the wrong product has been selected or if there is improper use or maintenance has been omitted, then hazards arise and personal injuries and material damage can occur from: - Hazardous emission of fluid or individual particles/coupling parts - Function impairments of connected systems or tools - The metal parts of coupling and adaptor are not thermally protected. You can be burned if you touch these parts at high media temperatures. According to the ambient temperature valve lever and ring grip can also become unbearably hot. For that reason suitable, sufficiently long protective gloves should be worn. The operator must in particular make sure that - The couplings are only used according to the intended purpose. - The couplings are only operated in a perfect, functioning condition. - The operating manual is always in a legible condition and is available in its entirety to operating personnel. - The operating personnel are sufficiently acquainted with the working method and the safety notes for the coupling. - The coupling is sent to our factory for repair work. - During operation of the coupling, no safety devices are removed and/or deactivated. - Before installing or dismantling the coupling, you have made sure that the coupling has not been pressurized. After completing assembly and installation work and before commissioning the coupling, observe the following points: Check once again that all screw connections are securely fitted. Before commissioning the coupling, a function test must be carried out (see maintenance and function test). 5

119 Operating manual Type BF-050 Warranty 4 Warranty The warranty conforms to: the regulations agreed in the purchase contract and the General Conditions for Delivery and Capacity of C.K. Walther GmbH & Co. KG of the state which was valid at the date of the purchase contract. Wearing parts are generally excluded from the warranty. Typical wearing parts of products from company C.K. Walther GmbH & Co. KG are for example: seals springs 6

120 Operating manual Type BF-050 Product description of self sealing coupling 5 Product description of self sealing coupling The coupling connection comprises: self sealing coupling self sealing adaptor 1-BF BF Intended use - The self sealing coupling is used to connect two lines. - Both coupling halves can be connected and disconnected under working pressure. - The coupling is carried out with an automatic lock (one hand-operation). - The valves are separately opened and closed with a lever operated eccentric drive. - It is squirt free when coupling and uncoupling. - The self sealing coupling is used for both non-lubricating and lubricating media. - The self sealing coupling is suitable for all media/applications: However, the media resistance depends on the used materials. The self sealing coupling is especially used in the chemical industry. - Consult with C.K. Walther for all media restances which are unclear. 5.2 Technical data - The working pressures of the self sealing coupling depend on the component materials. - When determining the working pressures with standardized threaded connections, the highest permissible working pressure of the connection must be taken into consideration. Working pressure: Material : stainless steel coupled : uncoupled: max. 16 bar max. 16 bar Cv values: self sealing coupling - > self sealing adaptor = 60 self sealing adaptor - > self sealing coupling = 60 Leakage volume during uncoupling: 2.5 ml Working temperature: -10 C bis +200 C 7

121 Operating manual Type BF-050 Product description of self sealing coupling - The safe function of the coupling requires media cleanness. Media contaminations can lead to leakages. We recommend a filter mesh of 25 µm. - Media can change rapidly or also over a longer period. That can interfere with the safe function of the coupling. The coupling is not suitable for media which show such appearances during operation of the coupling. - The permissible media temperatures depend on the permissible temperatures required for the used component materials. In critical cases, e.g. at very high temperatures or also very low temperatures the required temperature limits which are subject to the corresponding medium are to be agreed with the manufacturer. Freezing of the medium in the coupling parts stops their functionality. In addition frozen water can internally plastically deform and destroy the coupling parts. Also external water at the coupling can lead to its shut-down during freezing. - The self sealing coupling is not determined for any types of use other than those listed here. - Safe operation is not guaranteed if the self sealing coupling is used contrary to its inteded use. - The operatur of the self sealing coupling is responsible for all personal injuries or material damage that occur from non-intended use; the manufacturer assumes no responsibility in these cases. 5.3 Optional Features EX = ATEX version 8

122 Operating manual Type BF-050 Product description of self sealing coupling 5.4 Extended product description for application acc. to ATEX-guide line 94/9/EG (special design EX): General Only non-sparkling materials may be used. Non-sparkling materials are , or equivalent materials. Furthermore brass with different surfaces (f. ex. chrome-plated, nickel-plated). Further on it must be assured that the seal is resistant against and suitable for the flowing through media. Also the temperature resistance of the seals must be guaranteed. This must also be considered for the marking acc. to chapter Extended marking The coupling fittings are marked with As the surface temperature of the self-sealing couplings are determined by the temperature of the fluids, the temperature category or the highest surface temperature must be specified by the operator while the safe temperature distances acc. to EN must be observed and the maximum temperature resistance of the coupling materials and seals are taken into consideration. The marking of the temperature class must be effected readily visible by the operator. The determination of the temperature class must be made acc. to the following table: Max. temperature of Temperature class fluids 75 T6 90 T5 130 T4 195 T3 295 T2 445 T1 The couplings are not admitted for the temperature classes T1 and T2 and may not be marked for that by the operator. 9

123 Operating manual Type BF-050 Installation manual 6 Installation manual 6.1 General The self sealing coupling is to be integrated into the line network while taking into account the general accident prevention guidelines so that: - perfect operation is guaranteed in accordance with the operating manual (e.g. clearance of lever). - external damage to the unit and all mobile parts is excluded. Before installing the self sealing coupling and the self sealing adaptor in a pipeline network, make sure that the pipeline network has been sufficiently rinsed/blown through and/or cleaned. See point 8 for assembling and dismantling the self sealing coupling and self sealing adaptor into and out of the line system. After completing assembly work, a function test must be carried out according to the operating manual, both in depressurized state and under operating pressure. 6.2 Extended installation instruction for application acc. to ATEX-guideline 94/9/EG Details for safe operation For the use of self sealing couplings as a hose connection it must be guaranteed that in case of pressure strikes the tumbling of the self sealing coupling can be avoided by fixing at suitable constructions. In principle it must be observed that the self sealing coupling cannot strike on hard objects which could produce strike sparks when touching the housing Details for safe installation The self sealing couplings may only be connected to pipe- and hose systems which are suitable for electrostatic discharge and which are connected to the ground potential Details for a safe application area The self sealing couplings may be used according to the class of devices 2 in areas susceptible to explosions where potentially explosive mixtures of gas, steam, mist and air are availble. 10

124 Operating manual Type BF Operating manual Maintenance instructions Function test The self sealing coupling elements may only be used for the specified purposes in order to avoid critical injury to personnel and damage to the locking elements during use. Function description of the coupling 7.1 Coupling process Installation of the ready to couple position The front adaptor component must be in non-relocatable position. This is the condition for the mechanical connection of adaptor and coupling. This ready to couple position for use is to be made if necessary as follows: The knurled ring is to be turned with its groove into the position relocatability. The now relocatable adaptor front part is to be completely moved into the direction to the coupling part. In this position the knurled ring is to be turned with its groove into the lock position. Subsequently the non-relocatable ready to couple position for use is to be checked by trying to reciprocate the adaptor front part. Knurled ring with groove Indication Locked position Indication Relocatability 11

125 Operating manual Type BF-050 Maintenance instructions Function test Mechanical connection of coupling and adaptor The coupling and/or the adaptor is to be mechanically connected by inserting into the respective counterpart. Due to the concave surface of the coupling front side it can occur that the adaptor does not immediately find its inserting position. The operator will find this position by swivelling the adaptor and/or coupling. Attention: clamp danger Jumping out of locking sleeve Shortly before reaching the finally locked position the locking sleeve jumps forward against a fixed collar. This is the feature that the coupling counterparts are mechanically locked. The sleeve is spring loaded so that there is the danger that you get your finger squashed during the coupling process. 12

126 Operating manual Type BF-050 Maintenance instructions Function test Opening of the valves To open the valves the locked position must be released by pressing the ratchet. If the locked position should be secured with a locking bolt it is to be removed before. The lever is to to be swivelled anticlockwise by 180. Thus the lever shows into the direction of the adaptor when the valves are opened. The valve opening process should be carried out continuously as it possibly results in strong flows which lead to more or less strong vibrations. Under no circumstances the coupling may be operated if the lever stands crosswise to the flow direction (i.e. after a 90 swivelling only). If the valves are completely opened attention is to be paid that the ratchet also locks in this position. This position is to be preferably secured with locking bolts so that it does not result in unintentional closing of the valves. The adaptor is secured against uncoupling by an internal locking circuit. An uncoupling is compulsorily only possible if valves are closed. Do not try to uncouple the coupling connection with force or with the aid of tools or the like. Unlocking of ratchet Locking bolt Locked position of ratchet 13

127 Operating manual Type BF-050 Maintenance instructions Function test 7.2 Uncoupling procedure Closing of the valvese Before the adaptor and the coupling can be uncoupled the valves must be compulsorily closed. For this purpose the locked position must be released by pressing again the ratchet. If the locked position was secured by a locking bolt the locking bolt is to be removed. The lever is continuously swivelled back by 180. The ratchet must snap in and if necessary it is to be secured with the locking bolt. Removal of locking bolt Unlocking of ratchet Locked position of ratchet 14

128 Operating manual Type BF-050 Maintenance instructions Function test Mechanical disconnection of coupling and adaptor Only if the valves are closed coupling and adaptor can be disconnected. The mechanical lock is opened by pressing the front bulge of the locking sleeve and the adaptorcan be taken from the coupling. 15

129 Operating manual Type BF Maintenance and Function test Maintenance instructions Function test Preventive maintenance measures WALTHER self sealing couplings are to be handled in such a way that external damage to the elements and to all mobile parts are excluded. 8.1 Cleaning The outside contours are smooth as far as possible and thus they can be easily cleaned. The front of the coupling is to be wiped with a clean, soft cloth without dirt ingress into the groove. The adaptor is to be cleaned first of all at its outside contour. Then the knurled ring with its groove is to be turned into the position relocability and the adpator front part can be pushed back. Thus the convex curved front surface is free and can be well cleaned. The detergents must be suitable for the built-in o-rings from elastomer materials. Knurled ring with groove Indication Locked position Indication Relocability 8.2 Maintenance and Function test Maintenance work and function test must be carried out at a suitable interval irrespective of the operating conditions to guarantee the function of the self sealing coupling and thereby also to protect the operator. We recommend lightly greasing the plug-in areas to minimize operating forces and to extend the service life of the self sealing coupling. 16

130 Operating manual Type BF-050 Maintenance instructions Function test Maintenance includes the following points: - An external visual inspection for damage and contamination is to be carried out for the self sealing coupling and the self sealing adaptor. - Contamination in externally accessible function areas (sealing area, operating elements) is to be removed simply by wiping. If there are damaged, torn or corroded parts the self sealing coupling and the self sealing adaptor must be dismantled and sent to the manufacturer for repair works. In the case of torn, brittle and old seals and with severe contamination the self sealing adaptormust be dismantled and sent to the manufacturer for repair works. The self sealing coupling has an easy to maintain sealing module on which all seals are placed. In the case of torn, brittle or old seals the customer must decide whether to send the self sealing coupling to the manufacturer for repair works or whether he exchanges the sealing module himself. The instruction for dismantling and assembly of the sealing module is carried out under point 8.3. The sealing module can be bought as completely mounted unit from the supplier of the self sealing coupling The function test contains the following points: As described in the operating manual, the self sealing coupling is coupled several times, pressurized and uncoupled. When doing this, pay attention to the following: - Perfect, smooth-running functioning when coupling and uncoupling. - Leak tightness of self sealing coupling in coupled and uncoupled status. If there are damaged, torn or corroded parts the self sealing coupling and self sealing adaptor must be dismantled and sent to them manufacturer for repair works. In case of torn, brittle or old seals and with severe contamination the self sealing adaptor must be dismantled and sent to the manufacturer for repair works. The self sealing coupling has an easy to maintain sealing module on which all seals are placed. In the case of torn, brittle or old seals the customer must decide whether to send the self sealing coupling to the manufacturer for repair works or whether he exchanges the sealing module himself. The instruction for dismantling and assembly of the sealing module is carried out under point 8.3. The sealing module can be bought as completely mounted unit from the supplier of the self sealing coupling. 17

131 Operating manual Type BF Instruction for dismantling and assembly of the sealing module Maintenance instructions Function test 1. Insert assembly tool BM into the coupling 2. After inserting locking sleeve jumps to the front ATTENTION: Locking sleeve is under initial load. Clamp danger for fingers 3. Assembly tool is locked Lever Position OPEN 4. The lever of the coupling is to be swivelled by 180 into position OPEN 5. Valve tappet must be loosened with a (cranked) flat spanner SW 12 and screwed out 18

132 Operating manual Type BF-050 Maintenance instructions Function test Lever Position CLOSED 6. Take out valve tappet 7. Swivel lever in direction CLOSED. In doing so lead tappet receptacle with the screwdriver in the female thread with the screwdriver to the back! (Avoidance of locks and surface damages) 8. Loosen assembly tool by pushing back locking sleeve ATTENTION: Counterpush assembly sleeve as it is under spring initial tension! 9. Take out assembly tool Assembly tool 10. Remove sealing module from coupling Reassembly in reverse order. (Pay attention to the guidance of the screwdriver of the tappet receptacle at point 7.) Tightening torque: 20Nm 19

133 Operating manual Type BF-050 Lubrication 9 Lubrication! We recommend lightly greasing the plug-in areas to minimize operating forces and to extend the service life of the coupling. Lubrication has to be carried out with greases which do not tend to become resin. Attention! The choice of grease with regard to compatibility must agree with the seal quality and the fluid (e.g.: oxygen). 20

134 Operating manual Type BF-050 Storage 10 Storage The couplings must be stored in such a way that no damage can occur to the couplings. The storage conditions of the couplings depend on the guidelines applicable to the gaskets, since improper storage can lead to deterioration of the gaskets. The following points must be observed: - The couplings must be stored dry. - For the preservation of the gaskets, the gaskets and couplings should not be stored where they are exposed to the effects of daylight. For protection against oxygen, the gaskets and couplings should be stored in the original packaging. 21

135 Operating manual Type BF-050 Shut-down 11 Shut-down At the end of the service life the coupling or its components have to be disposed non-polluting and according to the legal regulations. For that the local public or private disposal societies should be taken. 22

136 Operating manual Type BF-050 Order numbers code 12 Order numbers code X X X - X X X X X X X X X X X - X X X X - X X X X X - X X X X X X X X X X X X X X X X - X X z.b.: 1 B F W R Subject group 2. Series The information regarding the series comprises either two letters or two numbers. 3. Nomial size / Nominal bore It is rounded up or down to one. The information can be numerical as wellas alphanumerical. 4. Product type or design type 5. Connection design 6. Material design: xx-x and xxxx possible (Order number code on request from the manufacturer) 7. Material design (seal design): xx-x and xxxx possible (Order number code on request from the manufacturer) 8. Y or Z design (Order number code on request from the manufacturer) 9. Additional equipment (Order number code on request from the manufacturer) 23

137 Operating instruction Type BF-050 Index 13 Index A According to intended purpose... 5 Acquired knowledge... 4 adaptor... 11, 12, 13 Adaptor... 12, 14, 15, 16 Adaptorl... 5 Alterations... 4 Assembling Assembly... 5 Assembly work Automatic lock... 7 C class of devices Clean Break Safety Coupling... 1 Cleaned Clearance Commissioning... 4, 5 concave surface corroded Corroded coupling... 11, 20, 22 Coupling... 5, 11, 12, 14, 15, 16 Coupling connection... 7 Coupling halves... 7 Coupling process Couplings... 5 Customer care... 2 Cv values... 7 D Damage... 4, 5 Damage compensation... 4 damaged Damaged Daylight Depressurized state Detergents Dismantling Disposal societies dry E Eccentric drive... 7 Equipment... 4 Experience... 4 explosive mixtures Extended marking... 9 F Faults... 4 Fluid... 5 Function... 5 Function test...5, 10, 16, 17 Functionality... 2 G General... 4 General accident prevention guidelines H Hazard notes... 5 Hazardous emission... 5 I Implementation... 5 Improvement... 4 Index Inhaltsverzeichnis... 3 Inspection... 2 Installation manual Intended use... 7 K Knurled ring... 11, 16 L Leakage volume... 7 Legible condition... 5 Lever Liability... 4 Lock position locking bolt Locking bolt Locking bolts Locking circuit Lubrication M Maintenance...2, 4, 5, 16, 17 Maintenance and function test Maintenance and Function test Maintenance work Manual... 4 Media temperatures... 5 Mobile parts

138 Operating instruction Type BF-050 Index O One-hand operation... 7 Operating manual operating forces Operating forces Operating manual... 1, 10, 11 Operating pressure Operation... 2 Operational safety ordinances... 5 Operators... 2 Original... 4 Oxygen P Packaging Perfect, functioning condition... 5 Performance capability... 2 Pipeline network Pressurized... 5 produce strike sparks Product description... 7 Property... 4 Protective gloves... 5 Q Questions... 4 R ratchet Ratchet ready to couple position Regulations... 4 Reliability... 2 Relocability Relocatability Repair work... 5 repair works Repair works S Safety... 2 Safety devices... 5 Safety instructions... 5 Scope of delivery... 4 Screw connections... 5 seals Seals self sealing adaptor Self sealing adaptor... 7, 10, 17 self sealing coupling... 7, 17 Self sealing coupling...7, 8, 10, 16, 17 Service... 2 Shut-down Smooth-running functioning Special designs... 4 Specialists... 2 Squirt free... 7 Status of development... 4 Storage Storage conditions Systems... 2, 5 T Technical data... 7 Technical equipment... 2 temperature category... 9 Temperature class... 9 temperature resistance... 9 Thermally... 5 Tools... 2, 5 torn Torn Translation errors... 4 Types of use... 8 U Uncoupling procedure Use... 2 V Version... 4 vibrations W Work safety regulations... 5 Working method... 5 Working pressure... 7 Working pressures... 7 Working pressurese... 7 Working temperature... 7 Wrong product selection... 5 Z Zusatzausstattung

139 Operating instruction english Revision C Date Issuer NH This operating instruction is not subject to the updating Self sealing coupling DN 4 1-HG SA514-.-Y07 1-HG NP513-.-Y05 1

140 This coupling is a quality product, in which special attention has been paid to high functionality, ease of operation, safety and reliability. As an item of technical equipment this tool-changer is intended for use in the commercial, industrial area and for operators, who have been trained by specialists in the handling of technical systems / tools. Customer care: As part of our individual customer care we will be happy to assist you in questions relating to use and operation and on any problems encountered. Service and maintenance: In order to maintain the high technical performance capability and reliability of your docking system over many years, we recommend regular inspection and maintenance. We can thereby offer you optimum support by our Customer Service department and the conclusion of a service and maintenance contract. Please ask for a quotation. Carl Kurt Walther GmbH & Co. KG PO Box Haan Westfalenstraße 2 Tel.: +49 (0) Fax: +49 (0) info@walther-praezision.de Internet: Contact: Application technology and service Holger R. Figge Telephone: (02129) Telefax: (02129) Handy: (0162) hfigge@walther-praezision.de Further addresses and telephone numbers of contacts can be found on the Internet on our homepage under Service / Customer service. 2

141 Operating instruction english Typ HG-004 List of Contents 1 List of Contents 1 LIST OF CONTENTS GENERAL WARRANTY SAFETY INSTRUCTIONS PRODUCT DESCRIPTION OF THE SELF SEALING COUPLING INTENDED USE TECHNICAL DATA GENERAL ARRANGEMENT DRAWINGS / PARTS LISTS INSTALLATION INSTRUCTION OPERATING INSTRUCTION CONNECTION PROCESS DISCONNECTION PROCESS MAINTENANCE INSTRUCTION MAINTENANCE AND FUNCTIONAL TEST Maintenance includes following items: Functional test includes following items: STORAGE SHUT-DOWN ORDER NUMBER CODE INDEX

142 Operating instruction english Typ HG-004 General 2 General This manual contains all regulations for operation, commissioning and maintenance of the locking coupling element coupling HG-004. All information and notes in this operating manual were collated while taking into consideration the valid regulations, the current engineering related status of development as well as our many years of experience and acquired knowledge. Translations of this operating manual were also produced according to the best of knowledge. However, we cannot assume liability for any translation errors. The German version provided for this operating manual is considered the authoritative version. The actual scope of delivery can deviate from the explanations and graphic representations described herein under certain circumstances, e.g. in the case of special designs, utilization of additional order options or because of state-of-the-art technical alterations. If you have any questions, please contact the manufacturer. This operating manual must be read carefully before starting work on or with the equipment, in particular before commissioning! The manufacturer assumes no liability for damage or faults arising from non-compliance with the instructions in this operating manual. The operating manual must be kept directly with the equipment and be accessible to all persons who work on or with the equipment. It is not permitted for the operating manual to be passed to third parties and if applicable this will incur damage compensation. All other rights reserved. Before commissioning the device must be checked for being not defective and its technically perfect function. The German version is the original. We reserve the right to make technical alterations to the product within the context of improving the usage properties and further development. The operating manual remains our property. Any reproduction, use by or communication to third parties incurs a penalty and will be pursued by court action (copyright law against unfair competition, BGB [German Civil Code]). All rights reserved in the case of a patent award (Paragraph 7, Section. 1 of the patent law - PG) or entry as a patented design (Paragraph 5, Section 4 of the patented design law - GMG). 4

143 Operating instruction english Typ HG-004 Warranty 3 Warranty The warranty conforms to: the General Conditions for Delivery and Capacity of C.K. Walther GmbH & Co. KG of the state which was valid at the date of the purchase contract the regulations agreed in the purchase contract and. Wearing parts are generally excluded from the warranty. Typical wearing parts of products from company C.K. Walther GmbH & Co. KG are for example: seals springs 5

144 Operating instruction english Typ HG-004 Safety instructions 4 Safety instructions Using these couplings does not release the customer from his obligation to comply with the pertinent work safety regulations e.g. operational safety regulations, etc. The duty to take due care by the operator of the couplings includes planning measures to ensure proper operation and monitoring their implementation. Hazard notes If the wrong product has been selected or if there is improper use or maintenance has been omitted, then hazards arise and personal injuries and material damage can occur from: - hazardous emission of fluid or individual particles/coupling parts. - function impairments of connected systems or tools. The operator must in particular make sure that - the couplings are only used according to the intended purpose. - the couplings are only operated in a perfect, functioning condition. - the operating manual is always in a legible condition and is available in its entirety to operating personnel. - the operating personnel are sufficiently acquainted with the working method and the safety notes for the coupling. - no safety devices must be removed and/or deactivated during operation of the couplings. - before installing or dismantling the couplings, you have made sure that the couplings have not been pressurized. - icings must be avoided as these may result in functional impairment, especially with regard to the automatic lock. After completing assembly and installation work and before commissioning the coupling, the following items have to be observed: Check once again that all screw connections are securely fitted. Before commissioning the couplings, a function test must be carried out (see maintenance and function test). 6

145 Operating instruction english Typ HG Product description of the self sealing coupling Coupling connection consists of: Product description of the self sealing coupling - self sealing coupling 1-HG NP Y05 - thru-type adaptor with check valve 1-HG SA Y Intended use - Coupling is only used as connection of two lines. - The connection/disconnection of the coupling may be only made in unpressurized state of the self sealing coupling. The refuelling receptacle can be pressurized between 0 and 875 bar during connection and disconnection process. - The connection and disconnection process is carried out by hand; the connection process is boosted by an automatic lock; i.e. after disconnection the locking sleeve is always in the position ready to be locked and locks automatically after insertion of the refuelling receptacle into the coupling. The locking sleeve must not be pulled back by hand for connection. Please observe the corresponding operating and safety instructions. - If the pressure is higher than 5 bar, disconnection is prevented by an axial safety locking device. - Coupling is especially suitable for the following media/applications: - gaseous hydrogen - For all other possible applications, Walther-Präzision should be consulted. 5.2 Technical data - Working pressures of coupling depend on materials of individual parts. - When determing the working with standardized threaded connections, the highest permissible working pressure of the connection must be taken into account. - When selecting a suitable connection the following static pressure is possible: Working pressure (static) 9-AAAL-Y07 and 0-AAAF-Y05: connected: 875 bar disconnected: adaptor side = coupling side = 875 bar 875 bar Working temperature: -40 C bis +85 C Cv flow coefficient: self sealing coupling -> thru type adaptor (both sides self sealing) =

146 Operating instruction english Typ HG-004 Product description of the self sealing coupling - The coupling is not determined for any types of use and technical values other than those listed here. - Safe operation is not guaranteed if the coupling is used contrary to its intended use and technical values - The operator of the coupling is responsible for all personal injuries or material damage that occur from non-intended use and disregard of the technical values; the manufacturer assumes no responsibility in these cases. 8

147 Operating instruction english Typ HG-004 General arrangement drawings Parts Lists 6 General Arrangement Drawings / Parts Lists 9

148 Operating instruction english Typ HG-004 General arrangement drawings Parts Lists 10

149 Operating instruction english Typ HG-004 General arrangement drawings Parts Lists 11

150 Operating instruction english Typ HG-004 General arrangement drawings Parts Lists 12

151 Operating instruction english Typ HG-004 General arrangement drawings Parts Lists 13

152 Operating instruction english Typ HG-004 Installation instruction 7 Installation Instruction Subject to the general accident prevention regulations coupling is to be installed into a network in such a way that - a satisfactory operation is guaranteed according to the operating instruction. - the self sealing coupling is primarily used at the supply side and the refuelling receptacle primarily at the consumer side. - external damage of the unit as well as all moving parts are excluded. It has to be made sure that the network is sufficiently rinsed/blown and/or cleaned prior to installation of the self sealing coupling and the refuelling receptacle at the network. The parts are to be protected against contamination and damage. After the assembly works are finished a functional test is to be carried out with both, without pressure and under working pressure of the media elements according to operating instruction. 14

153 Operating instruction english Typ HG-004 Operating instruction 8 Operating Instruction In order to avoid critical injuries of the staff and damage at the self sealing coupling during operation, coupling may be only used for the stated applications. During the connection and disconnection process, the arising side forces may not be too high: this means that not only the self sealing coupling but also the first area of the hose behind the self sealing coupling must be axially aligned to the fuel adaptor. (stiff hose! Bending radius not smaller than 1 m). Operating instructions for the safe handling of the refuelling nozzle type HG 1. The connection process is to be carried out speedy until stop. 2. The correct lock of the fitting can be seen from the position of the locking sleeve. In the disconnected state the locking sleeve is behind and the front part of the coupling housing is visible. In the connected state the locking sleeve shoots up and covers the coupling housing completely. 3. An additional safety feature is the "pressure active unlocking safety device" (white button) which is signalized by driving out of the white button. This takes place automatically from a working pressure of approx. 5 bar. This represents a secure sign for the proper lock, too. Only after this activation the working pressure is to be increased. 4. Of course, we do not want to intervene the refuelling process, however, we assume that the leakage tests are carried out at small pressures < 40 bar. In this case there is no safety risk even in the case of conscious maloperation and/or blockade. The coupling valve closes and the refuelling process cannot take place. 15

154 Operating instruction english Typ HG-004 Operating instruction 8.1 Connection process Before every coupling process, a visual inspection of the self sealing coupling and the adaptor must be made. In case of damage or deformations which can possibly cause a disturbauce of operating, the fitting has to be returned to the manufacturers factory. For connection, the unpressurized self sealing coupling is taken and held at the rear grip sleeve (hose area). Then the self sealing coupling is axially plugged onto the fuel adaptor and fully inserted. In doing so, the automatic lock is activated and the coupling locks automatically. Parallel to the insertion of the self sealing coupling onto the refuelling receptacle the valve opens on the coupling side. After the connection is pressurized now with medium and pressure, the check valve is opened on the refuelling receptacle side through the applied pressure. Thus the medium flow is released. Starting from a pressure of 5 bar, the axial safety locking device becomes active. In doing so, the button of the axial safety locking devices protrudes from the outside of the self sealing coupling. (see fig. 1) Fig. 1 16

155 Operating instruction english Typ HG-004 Operating instruction 8.2 Disconnection process Before disconnection, the connection must be depressurized. In doing so, the check valve at the thru-type adaptor s side closes and shuts off the tank. The process of de-pressurization of the connection deactivates the axial safety locking device and the button returns into the contour of the self sealing coupling. (see fig. 2). Fig. 2 The unpressurized self sealing coupling is taken and held with one hand at the rear grip sleeve (hose area). Using the second hand, the locking sleeve is pulled along the front protective sleeve to the rear in direction of the hose and the self sealing coupling is pulled from the fuel adaptor. When pulling the self sealing coupling from the fuel adaptor, the valve in the coupling closes automatically. 17

156 Operating instruction english Typ HG-004 Storage 9 Maintenance Instruction Preventive maintenance measures WALTHER self sealing couplings are to be operated in such a manner that external damages to elements and all moving parts are avoided. 9.1 Maintenance and functional test In order to always guarantee function of the self sealing coupling and hence safety of operator, a maintenance and functional testing must be made in appropriate periods of time depending on operating conditions. self sealing coupling in each case after ->15000 fuellings alternatively the maintenance is to be carried out three years after initial operation. refuelling receptacle with check valve in each case after ->15000 fuellings alternatively the maintenance is to be carried out ten years after initial operation. The coupling unit leaves the factory without being greased or oiled. Therefore, no grease or preservatives should be used for the coupling within the framework of maintenance work Maintenance includes following items: - A visual inspection of self sealing coupling and self sealing adaptor regarding damage and contamination has to be made. - Dirt at the functional area (sealing area, operating elements) which is easily accessible from outside should be removed by simply wiping-off. If there are damaged, torn or corroded parts or in case of worn, embrittled or overaged seals as well as strong pollutions the repair has to take place at the manufacturer and/or service of the manufacturer Functional test includes following items: As described in the operating instruction, coupling is several times connected, pressurized and then disconnected. In doing so, the following has to be observed: - Connection and disconnection process must be absolutely smooth. - Coupling must be absolutely leak-proof in connected and disconnected state. If there are damaged, torn or corroded parts or in case of worn, embrittled or overaged seals as well as strong pollutions the repair has to take place at the manufacturer and/or service of the manufacturer. 18

157 Operating instruction english Typ HG-004 Storage 10 Storage The couplings must be stored in such a way that no damages can occur at the couplings. The storage conditions of the couplings must comply with the guidelines for the seals as these can change in properties due to improper storage. The following items must be kept: - The couplings must be stored dry. - To safely conserve the seals and that means also the couplings they should not be stored under the effect of daylight. - For protection against oxygen the seals and also the couplings shall be stored into the packing. 19

158 Operating instruction english Typ HG-004 Shut-down 11 Shut-down At the end of the service life the coupling or its components have to be disposed non-polluting and according to the legal regulations. For that the local public or private disposal societies should be taken. 20

159 Operating instruction english Typ HG-004 Order number code 12 Order number code X X X - X X X X X X X X X X X - X X X X - X X X X X - X X X X X X X X X X X X X X X X - X X 1. Subject group 2. Series Series description consists of either two letters or two digits. 3. Nominal size / nominal width It is rounded up or rounded down to full units. The indication can be numerical or alphanumeric. 4. Type of product and design 5. Type of connection 6. Material: xx-x and xxxx possible 7. Material (seal version): xx-x and xxxx possible 8. Y- or Z-design 9. Optional features 21

160 Operating instruction english Typ HG-004 Index 13 Index A According to intended purpose... 6 Acquired knowledge... 4 adaptor side... 7 Alterations... 4 Assembly... 6 C Commissioning... 4, 6 connected... 6, 7, 18 connection... 7, 21 Connection process Corroded coupling... 4, 6 Coupling... 8, 20 coupling side... 7 Couplings... 6 Customer care... 2 Cv flow coefficient... 7 D Damage... 4, 6 Damage compensation... 4 Damaged daylight disconnected... 7, 18 Disconnection process Dismantling... 6 Disposal societies Disregard... 8 dry E Equipment... 4 Experience... 4 external damage F Faults... 4 Fluid... 6 Function... 6 Function test... 6 Functionality... 2 G General... 4 General Arrangement Drawings... 9 guarantee H Hazard notes... 6 Hazardous emission... 6 I Implementation... 6 Improvement... 4 Index Inspection... 2 Installation Instruction Intended use... 7 L Legible condition... 6 Liability... 4 List of Contents... 3 M Maintenance... 2, 4, 6 Maintenance Instruction Manual... 4 O Operating instruction... 1 Operating Instruction Operation... 2 Operational safety regulations... 6 operator... 6 Operators... 2 original... 4 P packing Parts Lists... 9 Perfect, functioning condition... 6 Performance capability... 2 Pressurized... 6 Product description... 7 Property... 4 Q questions... 4 R regulations Regulations... 4 Reliability... 2 Repair work

161 Operating instruction english Typ HG-004 Index responsible... 8 S safe handling Safety... 2 Safety devices... 6 Safety instructions... 6 Scope of delivery... 4 Screw connections... 6 self sealing adaptor... 7, 18 self sealing coupling... 7, 15, 18 Self sealing coupling... 1 Service... 2 Shut-down Special designs... 4 Specialists... 2 Status of development... 4 steel... 7 Storage Systems... 2, 6 T Technical data... 7 Technical equipment... 2 Technical values... 8 Tools... 2, 6 Torn Translation errors... 4 Types of use... 8 U Use... 2 V Version... 4 W warranty... 5 Work safety regulations... 6 Working method... 6 working pressure... 7 Working pressure... 7 Wrong product selection

162 Operating Instruction Revision C Datum Ersteller NH This operating instruction is not subject to the updating Self Sealing Coupling High Pressure Series HP-series optional features: RV OV SI GG EX 1

163 This coupling is a quality product, in which special attention has been paid to high functionality, ease of operation, safety and reliability. As an item of technical equipment this tool-changer is intended for use in the commercial, industrial area and for operators, who have been trained by specialists in the handling of technical systems / tools. Customer care: As part of our individual customer care we will be happy to assist you in questions relating to use and operation and on any problems encountered. Service and maintenance: In order to maintain the high technical performance capability and reliability of your docking system over many years, we recommend regular inspection and maintenance. We can thereby offer you optimum support by our Customer Service department and the conclusion of a service and maintenance contract. Please ask for a quotation. Carl Kurt Walther GmbH & Co. KG PO Box Haan Westfalenstraße 2 Tel.: +49 (0) Fax: +49 (0) info@walther-praezision.de Internet: Contact: Application technology and service Holger R. Figge Telephone: (02129) Telefax: (02129) Handy: (0162) hfigge@walther-praezision.de Further addresses and telephone numbers of contacts can be found on the Internet on our homepage under Service / Customer service. 2

164 Operating Instruction HP-Series List of Contents 1 List of Contents 1 LIST OF CONTENTS GENERAL WARRANTY SAFETY INSTRUCTION PRODUCT DESCRIPTION OF THE SELF SEALING COUPLING USAGE ACCORDING TO SPECIFICATION TECHNICAL DATA OPTIONAL FEATURES EXTENDED PRODUCT DESCRIPTION FOR APPLICATION ACC. TO ATEX-GUIDE LINE 94/9/EG (SPECIAL DESIGN EX): General Extended marking INSTALLATION INSTRUCTION GENERAL EXTENDED INSTALLATION INSTRUCTION FOR APPLICATION ACC. TO ATEX-GUIDELINE 94/9/EG Details for safe operation Details for safe installation Details for a safe application area OPERATING INSTRUCTION CONNECTION PROCESS DISCONNECTION PROCESS SAFETY LOCKING DEVICE SI (SUPPLEMENTARY EQUIPMENT) Coupling process Decoupling process MAINTENANCE INSTRUCTION MAINTENANCE AND FUNCTIONAL TEST Maintenance includes following items: Functional test includes following items: LUBRICATION! STORAGE SHUT-DOWN ORDER NUMBER CODE INDEX

165 Operating Instruction HP-Series General 2 General This manual contains all regulations for operation, commissioning and maintenance of the locking coupling elementcoupling. All information and notes in this operating manual were collated while taking into consideration the valid regulations, the current engineering related status of development as well as our many years of experience and acquired knowledge. Translations of this operating manual were also produced according to the best of knowledge. However, we cannot assume liability for any translation errors. The German version provided for this operating manual is considered the authoritative version. The actual scope of delivery can deviate from the explanations and graphic representations described herein under certain circumstances, e.g. in the case of special designs, utilization of additional order options or because of state-of-the-art technical alterations. If you have any questions, please contact the manufacturer. This operating manual must be read carefully before starting work on or with the equipment, in particular before commissioning! The manufacturer assumes no liability for damage or faults arising from non-compliance with the instructions in this operating manual. The operating manual must be kept directly with the equipment and be accessible to all persons who work on or with the equipment. It is not permitted for the operating manual to be passed to third parties and if applicable this will incur damage compensation. All other rights reserved. Before commissioning the device must be checked for being not defective and its technically perfect function. The German version is the original. We reserve the right to make technical alterations to the product within the context of improving the usage properties and further development. The operating manual remains our property. Any reproduction, use by or communication to third parties incurs a penalty and will be pursued by court action (copyright law against unfair competition, BGB [German Civil Code]). All rights reserved in the case of a patent award (Paragraph 7, Section. 1 of the patent law - PG) or entry as a patented design (Paragraph 5, Section 4 of the patented design law - GMG). 4

166 Operating Instruction HP-Series Warranty 3 Warranty The warranty conforms to: the regulations agreed in the purchase contract and the General Conditions for Delivery and Capacity of C.K. Walther GmbH & Co. KG of the state which was valid at the date of the purchase contract. Wearing parts are generally excluded from the warranty. Typical wearing parts of products from company C.K. Walther GmbH & Co. KG are for example: seals springs 5

167 Operating Instruction HP-Series Safety Instruction 4 Safety Instruction Using these couplings does not release the customer from his obligation to comply with the pertinent work safety regulations e.g. operational safety ordinances, etc. The duty to take due care by the operator of the couplings includes planning measures to ensure proper operation and monitoring their implementation. Hazard notes If the wrong product has been selected or if there is improper use or maintenance has been omitted, then hazards arise and personal injuries and material damage can occur from: - Hazardous emission of fluid or individual particles/coupling parts - Function impairments of connected systems or tools - The metal parts of coupling and adaptor are not thermally protected. You can be burned if you touch these parts at high media temperatures. According to the ambient temperature valve lever and ring grip can also become unbearably hot. For that reason suitable, sufficiently long protective gloves should be worn. The operator must in particular make sure that - The couplings are only used according to the intended purpose. - The couplings are only operated in a perfect, functioning condition. - The operating manual is always in a legible condition and is available in its entirety to operating personnel. - The operating personnel are sufficiently acquainted with the working method and the safety notes for the coupling. - The coupling is sent to our factory for repair work. - During operation of the coupling, no safety devices are removed and/or deactivated. - Before installing or dismantling the coupling, you have made sure that the coupling has not been pressurized. After completing assembly and installation work and before commissioning the coupling, observe the following points: Check once again that all screw connections are securely fitted. Before commissioning the coupling, a function test must be carried out (see maintenance and function test). 6

168 Operating Instruction HP-Series Product description of the coupling 5 Product description of the self sealing coupling - Coupling connection consists of: - self sealing coupling 1-HP self sealing adaptor 1-HP The following combinations of the coupling connections are also possible: - self sealing coupling 1-HP thru type adaptor 1-HP thru type coupling 1-HP thru type adaptor 1-HP- -1 In case that both coupling halves are not connected they should be protected against external dirt and/or damages if required. - For that purpose dust cap and dust plug are available. Possible combinations : self sealing coupling or thru type coupling with dust plug self sealing adaptor or thru type adaptor with dust cap 1-HP HP HP HP HP HP Usage according to specification - Coupling is only used as connection of two lines. - Connection and disconnection process is carried out by hand. - The self sealing coupling has a protection unintentional disconnection in case of vibrations. - Coupling is especially suitable for the following media/applications: - air - hydraulic oil - and their subspecies (such as oxygen or oil with additives) - For all other possible applications, C.K. Walther should be consulted. 7

169 Operating Instruction HP-Series Product description of the coupling 5.2 Technical Data - Working pressures of the coupling depend on materials of individual parts. - When determining working pressure of the coupling the max. permissible working pressure of the end connection is to be taken into account if standardized threads are used. - The coupling is not determined for any types of use other than those listed here. - Safe operation is not guaranteed if the coupling is used contrary to its intended use. - The operator of the coupling is responsible for all personal injuries or material damage that occur from non-intended use and disregard of the technical values; the manufacturer assumes no responsibility in these cases. 8

170 Operating Instruction HP-Series Product description of the coupling 5.3 Optional Features RV = with ring valve (z.b.: 1-HP RV 1-HP RV) OV = without valve (z.b.: 1-HP OV 1-HP OV) SI = with protection by safety locking device (see point 5) (z.b.: 1- HP SI) without SI with SI GG = with ring grips (aluminium cast) (z.b.: 1- HP GG) EX = ATEX version 9

171 Operating Instruction HP-Series Product description of the coupling 5.4 Extended product description for application acc. to ATEX-guide line 94/9/EG (special design EX): General Only non-sparkling materials may be used. Non-sparkling materials are , or equivalent materials. Furthermore brass with different surfaces (f. ex. chrome-plated, nickel-plated). Further on it must be assured that the seal is resistant against and suitable for the flowing through media. Also the temperature resistance of the seals must be guaranteed. This must also be considered for the marking acc. to chapter Extended marking The coupling fittings are marked with As the surface temperature of the self-sealing couplings are determined by the temperature of the fluids, the temperature category or the highest surface temperature must be specified by the operator while the safe temperature distances acc. to EN must be observed and the maximum temperature resistance of the coupling materials and seals are taken into consideration. The marking of the temperature class must be effected readily visible by the operator. The determination of the temperature class must be made acc. to the following table: Max. temperature of Temperature class fluids 75 T6 90 T5 130 T4 195 T3 295 T2 445 T1 The couplings are not admitted for the temperature classes T1 and T2 and may not be marked for that by the operator. 10

172 Operating Instruction HP-Series Installation instruction 6 Installation Instruction 6.1 General Subject to the general accident prevention regulations coupling is to be installed into a network in such a way that: - a satisfactory operation is guaranteed according to the operating instruction. - first of all self sealing coupling is used on line side and self sealing adaptor on consumer side. - external damage of the unit as well as all moving parts are excluded. Before self sealing coupling and the self sealing adaptor are installed at a pipeline network make sure that the pipeline network is sufficiently rinsed/blown out and/or cleaned. After the assembly works are finished a functional test is to be carried out with both, without pressure and under working pressure according to operating instruction. 6.2 Extended installation instruction for application acc. to ATEX-guideline 94/9/EG Details for safe operation For the use of self sealing couplings as a hose connection it must be guaranteed that in case of pressure strikes the tumbling of the self sealing coupling can be avoided by fixing at suitable constructions. In principle it must be observed that the self sealing coupling cannot strike on hard objects which could produce strike sparks when touching the housing Details for safe installation The self sealing couplings may only be connected to pipe- and hose systems which are suitable for electrostatic discharge and which are connected to the ground potential Details for a safe application area The self sealing couplings may be used according to the class of devices2 in areas susceptible to explosions where potentially explosive mixtures of gas, steam, mist and air are availble. 11

173 Operating Instruction HP-Series Operating Instruction 7 Operating Instruction In order to avoid critical injuries of the staff and damage at the self sealing coupling during operation, coupling may be only used for the stated applications. 7.1 Connection process Before every couple cycle a visual check of coupling and adaptor is to be carried out. In case of recognizable, visible damage or deformations damaged parts are to be exchanged. Hold self sealing coupling firmly in one hand; with the other hand pull back locking sleeve. This has to be done against locking spring resistance. Push coupling (free half) with withdrawn locking sleeve axially centered onto plug part of adaptor (fixed half) until sensible resistance. Bring locking sleeve with support of locking spring into starting position. Self sealing coupling and self sealing adaptor are now mechanically locked. CAUTION Please take care that locking sleeve is in final position, i.e. that it is flush in front with the coupling housing as otherwise no perfect lock is guaranteed. 7.2 Disconnection process Withdraw locking sleeve against locking spring and take out coupling from self sealing adaptor. Caution! In case of an available pressure in the line connected by the coupling system a strong separation impulse - depending on the pressure - can be effective onto the coupling system during disconnection. For that reason the movable part of the coupling (free half) is to be firmly held in the hand to avoid injuries. 12

174 Operating Instruction HP-Series Operating Instruction 7.3 Safety locking device SI (supplementary equipment) Coupling process For coupling the locking ring must be in unsecured position (picture 2). Coupling as described under 6.1. locking sleeve locking ring picture 1 picture 2 locked position unlocked position After coupling the locking ring is drawn towards the hose, turned by 90 and released. Now the locking ring snaps forward into the safety position (picture 1). Both final positions secured and unsecured are fixed by spring loaded cams. The operator can assure himself of the proper locking and saving by trying, as a control, to disconnect the coupling by drawing back the locking sleeve. This is not possible in secured position Decoupling process In coupled situation the locking ring is in secured position (picture 1). For de-blocking the locking ring is drawn towards the hose, turned by 90 and released. Now the locking ring snaps forward into the safety position (picture 1). Both final positions secured and unsecured are fixed by spring loaded cams. Decoupling as described under

175 Operating Instruction HP-Series Maintenance and Functional Instruction 8 Maintenance Instruction Preventive maintenance measures WALTHER self sealing couplings are to be operated in such a manner that external damages to elements and all moving parts are avoided. 8.1 Maintenance and functional test In order to always guarantee function of the self sealing coupling and hence safety of operator, a maintenance and functional testing must be made in appropriate periods of time depending on operating conditions. In order to minimize operating forces and to extend service life of the self sealing coupling we recommend to slightly grease plug surfaces (see item 9.0) Maintenance includes following items: - A visual inspection of self sealing coupling and self sealing adaptor regarding damage and contamination has to be made. - Dirt at the functional area (sealing area, operating elements) which is easily accessible from outside should be removed by simply wiping-off. If there are damaged, torn or corroded parts, coupling must be dismounted and returned to manufacturer for repair. If worn or embrittled seals are found or if there is extreme dirt, the customer can decide whether he returns coupling unit to the manufacturer's factory or whether he repairs himself Functional test includes following items: As described in the operating instruction, coupling is several times connected, pressurized and then disconnected. In doing so, the following has to be observed: - Connection and disconnection process must be absolutely smooth. - Coupling must be absolutely leak-proof in connected and disconnected state. If there are damaged, torn or corroded parts, coupling must be dismounted and returned to manufacturer for repair. If worn or embrittled seals are found or if there is extreme dirt, the customer can decide whether he returns the coupling unit to the manufacturer s factory or whether he repairs himself. 14

176 Operating Instruction HP-Series Lubrication 9 Lubrication! In order to minimize operating forces and to extend service life of the coupling we recommend to slightly grease plug surfaces. Lubrication is to be carried out with greases which do not tend to become resin. Caution! The selection of the grease is to be suited to the sealing quality and the medium (e.g.: oxygen) in view of the compatibility. 15

177 Operating Instruction HP-Series Storage 10 Storage The couplings must be stored in such a way that no damages can occur at the couplings. The storage conditions of the couplings must comply with the guidelines for the seals as these can change in properties due to improper storage. The following items must be kept: - The couplings must be stored dry. - To safely conserve the seals and that means also the couplings they should not be stored under the effect of daylight. For protection against oxygen the seals and also the couplings shall be stored into the packing. 16

178 Operating Instruction HP-Series Shut-down 11 Shut-down At the end of the service life the coupling or its components have to be disposed non-polluting and according to the legal regulations. For that the local public or private disposal societies should be taken. 17

179 Operating Instruction HP-Series Order Number Code 12 Order number code X X X - X X X X X X X X X X X - X X X X - X X X X X - X X X X X X X X X X X X X X X X - X X 1. Subject group 2. Series The information regarding the series comprises either two letters or two numbers. 3. Nomial size / Nominal bore It is rounded up or down to one. The information can be numerical as well as alphanumerical. 4. Product type or design type 5. Connection design 6. Material design: xx-x and xxxx possible 7. Material design (seal design): xx-x and xxxx possible 8. Y or Z design 9. Additional equipment 18

180 Operating Instruction HP-Series Index 13 Index A According to intended purpose... 6 Acquired knowledge... 4 Adaptorl... 6 air... 7 Alterations... 4 Assembly... 6 C Commissioning... 4, 6 connection... 7, 8 Connection process coupling... 4 Coupling... 6, 8, 17 Couplings... 6 Customer care... 2 D Damage... 4, 6 Damage compensation... 4 daylight Disconnection process Disposal societies dry dust cap... 7 dust plug... 7 E Equipment... 4 Experience... 4 external damage F Faults... 4 Fluid... 6 Function... 6 Function test... 6 Functionality... 2 G General... 4 guarantee H Hazard notes... 6 Hazardous emission... 6 High Pressure Series... 1 hydraulic oil... 7 I Implementation... 6 Improvement... 4 Index Inspection... 2 Installation Instruction L Legible condition... 6 Liability... 4 List of Contents... 3 Lubrication M Maintenance... 2, 4, 6 Maintenance and functional test Maintenance Instruction Manual... 4 Media temperatures... 6 O Operating Instruction... 1, 12 Operation... 2 Operational safety ordinances... 6 operator... 6, 14 Operator... 8 Operators... 2 Order number code original... 4 P packing particular... 6 Perfect, functioning condition... 6 Performance capability... 2 Pressurized... 6 Product description... 7 Property... 4 Protective gloves... 6 Q quality questions... 4 R regulations Regulations... 4 Reliability

181 Operating Instruction HP-Series Index Repair work... 6 S Safety... 2 Safety devices... 6 Safety Instruction... 6 Scope of delivery... 4 Screw connections... 6 self sealing adaptor... 7, 11, 12, 14 self sealing coupling... 7, 11, 12, 14 Self sealing coupling Self Sealing Coupling... 1 service... 14, 15 Service... 2 Shut-down Special designs... 4 Specialists... 2 specification... 8 Status of development... 4 Storage subspecies... 7 Systems... 2, 6 T Technical equipment... 2 Temperaturklasse Thermally... 6 thru type adaptor... 7 thru type coupling... 7 Tools... 2, 6 Translation errors... 4 Types of use... 8 U Use... 2 V Version... 4 W Work safety regulations... 6 Working method... 6 Wrong product selection

182 Operating Instruction Revision A Datum Ersteller NH This operating instruction is not subject to the updating Self Sealing Coupling Low Pressure Series 1-LP LP optional features: OV, EX 1

183 This coupling is a quality product, in which special attention has been paid to high functionality, ease of operation, safety and reliability. As an item of technical equipment this tool-changer is intended for use in the commercial, industrial area and for operators, who have been trained by specialists in the handling of technical systems / tools. Customer care: As part of our individual customer care we will be happy to assist you in questions relating to use and operation and on any problems encountered. Service and maintenance: In order to maintain the high technical performance capability and reliability of your docking system over many years, we recommend regular inspection and maintenance. We can thereby offer you optimum support by our Customer Service department and the conclusion of a service and maintenance contract. Please ask for a quotation. Carl Kurt Walther GmbH & Co. KG PO Box Haan Westfalenstraße 2 Tel.: +49 (0) Fax: +49 (0) info@walther-praezision.de Internet: Contact: Application technology and service Holger R. Figge Telephone: (02129) Telefax: (02129) Handy: (0162) hfigge@walther-praezision.de Further addresses and telephone numbers of contacts can be found on the Internet on our homepage under Service / Customer service. 2

184 Operating Instruction Type LP-003 List of Contents 1 List of Contents 1 LIST OF CONTENTS GENERAL WARRANTY SAFETY INSTRUCTION PRODUCT DESCRIPTION OF THE SELF SEALING COUPLING INTENDED USE TECHNICAL DATA OPTIONAL FEATURES EXTENDED PRODUCT DESCRIPTION FOR APPLICATION ACC. TO ATEX-GUIDE LINE 94/9/EG (SPECIAL DESIGN EX): General Extended marking INSTALLATION INSTRUCTION GENERAL EXTENDED INSTALLATION INSTRUCTION FOR APPLICATION ACC. TO ATEX-GUIDELINE 94/9/EG Details for safe operation Details for safe installation Details for a safe application area OPERATING INSTRUCTION CONNECTION PROCESS DISCONNECTION PROCESS MAINTENANCE INSTRUCTION MAINTENANCE AND FUNCTIONAL TEST Maintenance includes following items: Functional test includes following items: LUBRICATION! STORAGE SHUT-DOWN ORDER NUMBER CODE INDEX

185 Operating Instruction Type LP-003 General 2 General This manual contains all regulations for operation, commissioning and maintenance of the locking coupling elementself sealing coupling elements. All information and notes in this operating manual were collated while taking into consideration the valid regulations, the current engineering related status of development as well as our many years of experience and acquired knowledge. Translations of this operating manual were also produced according to the best of knowledge. However, we cannot assume liability for any translation errors. The German version provided for this operating manual is considered the authoritative version. The actual scope of delivery can deviate from the explanations and graphic representations described herein under certain circumstances, e.g. in the case of special designs, utilization of additional order options or because of state-of-the-art technical alterations. If you have any questions, please contact the manufacturer. This operating manual must be read carefully before starting work on or with the equipment, in particular before commissioning! The manufacturer assumes no liability for damage or faults arising from non-compliance with the instructions in this operating manual. The operating manual must be kept directly with the equipment and be accessible to all persons who work on or with the equipment. It is not permitted for the operating manual to be passed to third parties and if applicable this will incur damage compensation. All other rights reserved. Before commissioning the device must be checked for being not defective and its technically perfect function. The German version is the original. We reserve the right to make technical alterations to the product within the context of improving the usage properties and further development. The operating manual remains our property. Any reproduction, use by or communication to third parties incurs a penalty and will be pursued by court action (copyright law against unfair competition, BGB [German Civil Code]). All rights reserved in the case of a patent award (Paragraph 7, Section. 1 of the patent law - PG) or entry as a patented design (Paragraph 5, Section 4 of the patented design law - GMG). 4

186 Operating Instruction Type LP-003 Warranty 3 Warranty The warranty conforms to: the General Conditions for Delivery and Capacity of C.K. Walther GmbH & Co. KG of the state which was valid at the date of the purchase contract and the regulations agreed in the purchase contract. Wearing parts are generally excluded from the warranty. Typical wearing parts of products from company C.K. Walther GmbH & Co. KG are for example: seals springs 5

187 Operating Instruction Type LP-003 Safety Instruction 4 Safety Instruction Using these couplings does not release the customer from his obligation to comply with the pertinent work safety regulations e.g. operational safety ordinances, etc. The duty to take due care by the operator of the couplings includes planning measures to ensure proper operation and monitoring their implementation. Hazard notes If the wrong product has been selected or if there is improper use or maintenance has been omitted, then hazards arise and personal injuries and material damage can occur from: - Hazardous emission of fluid or individual particles/coupling parts - Function impairments of connected systems or tools - The metal parts of coupling and adaptor are not thermally protected. You can be burned if you touch these parts at high media temperatures. According to the ambient temperature valve lever and ring grip can also become unbearably hot. For that reason suitable, sufficiently long protective gloves should be worn. The operator must in particular make sure that - The couplings are only used according to the intended purpose. - The couplings are only operated in a perfect, functioning condition. - The operating manual is always in a legible condition and is available in its entirety to operating personnel. - The operating personnel are sufficiently acquainted with the working method and the safety notes for the coupling. - The coupling is sent to our factory for repair work. - During operation of the coupling, no safety devices are removed and/or deactivated. - Before installing or dismantling the coupling, you have made sure that the coupling has not been pressurized. After completing assembly and installation work and before commissioning the coupling, observe the following points: Check once again that all screw connections are securely fitted. Before commissioning the coupling, a function test must be carried out (see maintenance and function test). 6

188 Operating Instruction Type LP-003 Product description of the coupling 5 Product description of the self sealing coupling Coupling connection consists of: - self sealing coupling 1-LP thru type adaptor 2-LP In case that both coupling halves are not connected they should be protected against external dirt and/or damages if required. For that purpose dust plug are available. Possible comibinations : self sealing coupling 1-LP- -0 with dust plug 1-LP Intended use - Coupling is only used as connection of two lines. - Connection and disconnection process is carried out by hand. - Coupling is especially suitable for the following media/applications: - air, water, hydraulic oil - and their subspecies (such as oxygen or oil with additives) - For all other possible applications, Walther-Präzision should be consulted. 5.2 Technical data - Working pressures of coupling depend on materials of individual parts. - When determing the working with standardized threaded connections, the highest permissible working pressure of the connection must be taken into account. - When selecting a suitable connection the following static pressure is possible: max. static Working pressure brass (bar) Cv-value One side Self sealing LP ,213 - The coupling is not determined for any types of use and technical values other than those listed here. - Safe operation is not guaranteed if the coupling is used contrary to ist intended use and technical values The operator of the coupling is responsible for all personal injuries or material damage that occur from non-intended use and disregard of the technical values; the manufacturer assumes no responsibility in these cases. 5.3 Optional Features OV = without valve (z.b.: 1-LP OV) EX = ATEX version 7

189 Operating Instruction Type LP-003 Product description of the coupling 5.4 Extended product description for application acc. to ATEX-guide line 94/9/EG (special design EX): General Only non-sparkling materials may be used. Non-sparkling materials are , or equivalent materials. Furthermore brass with different surfaces (f. ex. chrome-plated, nickel-plated). Further on it must be assured that the seal is resistant against and suitable for the flowing through media. Also the temperature resistance of the seals must be guaranteed. This must also be considered for the marking acc. to chapter Extended marking The coupling fittings are marked with As the surface temperature of the self-sealing couplings are determined by the temperature of the fluids, the temperature category or the highest surface temperature must be specified by the operator while the safe temperature distances acc. to EN must be observed and the maximum temperature resistance of the coupling materials and seals are taken into consideration. The marking of the temperature class must be effected readily visible by the operator. The determination of the temperature class must be made acc. to the following table: Max. temperature of Temperature class fluids 75 T6 90 T5 130 T4 195 T3 295 T2 445 T1 The couplings are not admitted for the temperature classes T1 and T2 and may not be marked for that by the operator. 8

190 Operating Instruction Type LP-003 Installation instruction 6 Installation Instruction 6.1 General Subject to the general accident prevention regulations coupling is to be installed into a network in such a way that: - a satisfactory operation is guaranteed according to the operating instruction. - first of all self sealing coupling is used on line side and thru type adaptor on consumer side. - external damage of the unit as well as all moving parts are excluded. Before self sealing coupling and the thru type adaptor are installed at a pipeline network make sure that the pipeline network is sufficiently rinsed/blown out and/or cleaned. 6.2 Extended installation instruction for application acc. to ATEX-guideline 94/9/EG Details for safe operation For the use of self sealing couplings as a hose connection it must be guaranteed that in case of pressure strikes the tumbling of the self sealing coupling can be avoided by fixing at suitable constructions. In principle it must be observed that the self sealing coupling cannot strike on hard objects which could produce strike sparks when touching the housing Details for safe installation The self sealing couplings may only be connected to pipe- and hose systems which are suitable for electrostatic discharge and which are connected to the ground potential Details for a safe application area The self sealing couplings may be used according to the class of devices2 in areas susceptible to explosions where potentially explosive mixtures of gas, steam, mist and air are availble. 9

191 Operating Instruction Type LP-003 Operating Instruction 7 Operating Instruction In order to avoid critical injuries of the staff and damage at the self sealing coupling during operation, coupling may be only used for the stated applications. 7.1 Connection process Before each coupling process a visible check of the coupling and the adaptor has to be made. Damaged parts must be changed in case of observable, visible damages or deformations. The self-sealing coupling is equipped with an automatic lock, i. e. one-hand operation. For coupling the self-sealing coupling behind the locking sleeve or the self-sealing adaptor in the end plug area is taken up with one hand and pushed axially centred on the counter piece until the end stop. During the coupling the locking sleeve snaps in forward without the aid of the operator. Now the self-sealing coupling and the self-sealing adaptor are locked mechanically. Available valves are opened during the coupling process and thus the passage is released. CAUTION Please take care that locking sleeve is in final position, i.e. that it is flush in front with the coupling housing as otherwise no perfect lock is guaranteed. 7.2 Disconnection process Withdraw locking sleeve against locking spring and take out coupling from self sealing adaptor. Caution! In case of an available pressure in the line connected by the coupling system a strong separation impulse - depending on the pressure - can be effective onto the coupling system during disconnection. For that reason the movable part of the coupling (free half) is to be firmly held in the hand to avoid injuries. 10

192 Operating Instruction Type LP-003 Maintenance and Functional Instruction 8 Maintenance Instruction Preventive maintenance measures WALTHER self sealing couplings are to be operated in such a manner that external damages to elements and all moving parts are avoided. 8.1 Maintenance and functional test In order to always guarantee function of the self sealing coupling and hence safety of operator, a maintenance and functional testing must be made in appropriate periods of time depending on operating conditions. In order to minimize operating forces and to extend service life of the self sealing coupling we recommend to slightly grease plug surfaces (see item 9.0) Maintenance includes following items: - A visual inspection of self sealing coupling and self sealing adaptor regarding damage and contamination has to be made. - Dirt at the functional area (sealing area, operating elements) which is easily accessible from outside should be removed by simply wiping-off. If there are damaged, torn or corroded parts, coupling must be dismounted and returned to manufacturer for repair. If worn or embrittled seals are found or if there is extreme dirt, the customer can decide whether he returns coupling unit to the manufacturer's factory or whether he repairs himself Functional test includes following items: As described in the operating instruction, coupling is several times connected, pressurized and then disconnected. In doing so, the following has to be observed: - Connection and disconnection process must be absolutely smooth. - Coupling must be absolutely leak-proof in connected and disconnected state. If there are damaged, torn or corroded parts, coupling must be dismounted and returned to manufacturer for repair. If worn or embrittled seals are found or if there is extreme dirt, the customer can decide whether he returns the coupling unit to the manufacturer s factory or whether he repairs himself. 11

193 Operating Instruction Type LP-003 Lubrication 9 Lubrication! In order to minimize operating forces and to extend service life of the coupling we recommend to slightly grease plug surfaces. Lubrication is to be carried out with greases which do not tend to become resin. Caution! The selection of the grease is to be suited to the sealing quality and the medium (e.g.: oxygen) in view of the compatibility. 12

194 Operating Instruction Type LP-003 Storage 10 Storage The couplings must be stored in such a way that no damages can occur at the couplings. The storage conditions of the couplings must comply with the guidelines for the seals as these can change in properties due to improper storage. The following items must be kept: - The couplings must be stored dry. - To safely conserve the seals and that means also the couplings they should not be stored under the effect of daylight. - For protection against oxygen the seals and also the couplings shall be stored into the packing. 13

195 Operating Instruction Type LP-003 Shut-down 11 Shut-down At the end of the service life the coupling or its components have to be disposed non-polluting and according to the legal regulations. For that the local public or private disposal societies should be taken. 14

196 Operating Instruction Type LP-003 Order Number Code 12 Order number code X X X - X X X X X X X X X X X - X X X X - X X X X X - X X X X X X X X X X X X X X X X - X X 1. Subject group 2. Series The information regarding the series comprises either two letters or two numbers. 3. Nomial size / Nominal bore It is rounded up or down to one. The information can be numerical as well as alphanumerical. 4. Product type or design type 5. Connection design 6. Material design: xx-x and xxxx possible 7. Material design (seal design): xx-x and xxxx possible 8. Y or Z design 9. Additional equipment 15

197 Operating Instruction Type LP-003 Index 13 Index A According to intended purpose... 6 Acquired knowledge... 4 Adaptorl... 6 air... 7 Alterations... 4 Assembly... 6 C Commissioning... 4, 6 connected... 7 connection... 7 Connection process coupling... 4 Coupling... 6, 7, 14 Couplings... 6 Customer care... 2 D Damage... 4, 6 Damage compensation... 4 daylight Disconnection process Disposal societies Disregard... 7 dry dust plug... 7 E Equipment... 4 Experience... 4 external damage... 9 F Faults... 4 Fluid... 6 Function... 6 Function test... 6 Functionality... 2 G General... 4 guarantee H Hazard notes... 6 Hazardous emission... 6 hydraulic oil... 7 I Implementation... 6 Improvement... 4 Index Inspection... 2 Installation Instruction... 9 Intended use... 7 L Legible condition... 6 Liability... 4 List of Contents... 3 Low Pressure... 1 Lubrication M Maintenance... 2, 4, 6 Maintenance and functional test Maintenance Instruction Manual... 4 Media temperatures... 6 O one-hand operation Operating Instruction... 1, 10 Operation... 2 Operational safety ordinances... 6 operator... 6, 11 Operators... 2 Order number code Original... 4 P packing particular... 6 Perfect, functioning condition... 6 Performance capability... 2 Pressurized... 6 Product description... 7 Property... 4 Protective gloves... 6 Q quality R regulations... 9 Regulations

198 Operating Instruction Type LP-003 Index Reliability... 2 Repair work... 6 responsible... 7 S Safety... 2 Safety devices... 6 Safety Instruction... 6 Scope of delivery... 4 Screw connections... 6 self sealing adaptor... 7, 9, 10, 11 self sealing coupling... 7, 9, 10, 11 Self Sealing Coupling... 1 service... 11, 12 Service... 2 Shut-down Special designs... 4 Specialists... 2 Status of development... 4 Storage subspecies... 7 Systems... 2, 6 T Technical data... 7 Technical equipment... 2 Technical values... 7 Temperaturklasse... 8 Thermally... 6 Tools... 2, 6 Translation errors... 4 Types of use... 7 U Use... 2 V Version... 4 W water... 7 Work safety regulations... 6 Working method... 6 working pressure... 7 Wrong product selection

199 Operating Instruction Revision A Datum Ersteller NH This operating instruction is not subject to the updating Self Sealing Coupling Low Pressure Series 1-LP LP optional features: OV EX 1

200 This coupling is a quality product, in which special attention has been paid to high functionality, ease of operation, safety and reliability. As an item of technical equipment this tool-changer is intended for use in the commercial, industrial area and for operators, who have been trained by specialists in the handling of technical systems / tools. Customer care: As part of our individual customer care we will be happy to assist you in questions relating to use and operation and on any problems encountered. Service and maintenance: In order to maintain the high technical performance capability and reliability of your docking system over many years, we recommend regular inspection and maintenance. We can thereby offer you optimum support by our Customer Service department and the conclusion of a service and maintenance contract. Please ask for a quotation. Carl Kurt Walther GmbH & Co. KG PO Box Haan Westfalenstraße 2 Tel.: +49 (0) Fax: +49 (0) info@walther-praezision.de Internet: Contact: Application technology and service Holger R. Figge Telephone: (02129) Telefax: (02129) Handy: (0162) hfigge@walther-praezision.de Further addresses and telephone numbers of contacts can be found on the Internet on our homepage under Service / Customer service. 2

201 Operating Instruction Type LP-004 List of Contents 1 List of Contents 1 LIST OF CONTENTS GENERAL WARRANTY SAFETY INSTRUCTION PRODUCT DESCRIPTION OF THE SELF SEALING COUPLING INTENDED USE TECHNICAL DATA OPTIONAL FEATURES EXTENDED PRODUCT DESCRIPTION FOR APPLICATION ACC. TO ATEX-GUIDE LINE 94/9/EG (SPECIAL DESIGN EX): General Extended marking INSTALLATION INSTRUCTION GENERAL EXTENDED INSTALLATION INSTRUCTION FOR APPLICATION ACC. TO ATEX-GUIDELINE 94/9/EG Details for safe operation Details for safe installation Details for a safe application area OPERATING INSTRUCTION CONNECTION PROCESS DISCONNECTION PROCESS MAINTENANCE INSTRUCTION MAINTENANCE AND FUNCTIONAL TEST Maintenance includes following items: Functional test includes following items: LUBRICATION! STORAGE SHUT-DOWN ORDER NUMBER CODE INDEX

202 Operating Instruction Type LP-004 General 2 General This manual contains all regulations for operation, commissioning and maintenance of the locking coupling elementself sealing coupling elements. All information and notes in this operating manual were collated while taking into consideration the valid regulations, the current engineering related status of development as well as our many years of experience and acquired knowledge. Translations of this operating manual were also produced according to the best of knowledge. However, we cannot assume liability for any translation errors. The German version provided for this operating manual is considered the authoritative version. The actual scope of delivery can deviate from the explanations and graphic representations described herein under certain circumstances, e.g. in the case of special designs, utilization of additional order options or because of state-of-the-art technical alterations. If you have any questions, please contact the manufacturer. This operating manual must be read carefully before starting work on or with the equipment, in particular before commissioning! The manufacturer assumes no liability for damage or faults arising from non-compliance with the instructions in this operating manual. The operating manual must be kept directly with the equipment and be accessible to all persons who work on or with the equipment. It is not permitted for the operating manual to be passed to third parties and if applicable this will incur damage compensation. All other rights reserved. Before commissioning the device must be checked for being not defective and its technically perfect function. The German version is the original. We reserve the right to make technical alterations to the product within the context of improving the usage properties and further development. The operating manual remains our property. Any reproduction, use by or communication to third parties incurs a penalty and will be pursued by court action (copyright law against unfair competition, BGB [German Civil Code]). All rights reserved in the case of a patent award (Paragraph 7, Section. 1 of the patent law - PG) or entry as a patented design (Paragraph 5, Section 4 of the patented design law - GMG). 4

203 Operating Instruction Type LP-004 Warranty 3 Warranty The warranty conforms to: the General Conditions for Delivery and Capacity of C.K. Walther GmbH & Co. KG of the state which was valid at the date of the purchase contract and the regulations agreed in the purchase contract. Wearing parts are generally excluded from the warranty. Typical wearing parts of products from company C.K. Walther GmbH & Co. KG are for example: seals springs 5

204 Operating Instruction Type LP-004 Safety Instruction 4 Safety Instruction Using these couplings does not release the customer from his obligation to comply with the pertinent work safety regulations e.g. operational safety ordinances, etc. The duty to take due care by the operator of the couplings includes planning measures to ensure proper operation and monitoring their implementation. Hazard notes If the wrong product has been selected or if there is improper use or maintenance has been omitted, then hazards arise and personal injuries and material damage can occur from: - Hazardous emission of fluid or individual particles/coupling parts - Function impairments of connected systems or tools - The metal parts of coupling and adaptor are not thermally protected. You can be burned if you touch these parts at high media temperatures. According to the ambient temperature valve lever and ring grip can also become unbearably hot. For that reason suitable, sufficiently long protective gloves should be worn. The operator must in particular make sure that - The couplings are only used according to the intended purpose. - The couplings are only operated in a perfect, functioning condition. - The operating manual is always in a legible condition and is available in its entirety to operating personnel. - The operating personnel are sufficiently acquainted with the working method and the safety notes for the coupling. - The coupling is sent to our factory for repair work. - During operation of the coupling, no safety devices are removed and/or deactivated. - Before installing or dismantling the coupling, you have made sure that the coupling has not been pressurized. After completing assembly and installation work and before commissioning the coupling, observe the following points: Check once again that all screw connections are securely fitted. Before commissioning the coupling, a function test must be carried out (see maintenance and function test). 6

205 Operating Instruction Type LP-004 Product description of the coupling 5 Product description of the self sealing coupling Coupling connection consists of: - self sealing coupling 1-LP self sealing adaptor 1-LP In case that both coupling halves are not connected they should be protected against external dirt and/or damages if required. For that purpose dust cap and dust plug are available. Possible comibinations : self sealing coupling 1-LP with dust plug 1-LP self sealing adaptor 1-LP with dust cap 1-LP Intended use - Coupling is only used as connection of two lines. - Connection and disconnection process is carried out by hand. - Coupling is especially suitable for the following media/applications: - air, water, hydraulic oil - and their subspecies (such as oxygen or oil with additives) - For all other possible applications, Walther-Präzision should be consulted. 5.2 Technical data - Working pressures of coupling depend on materials of individual parts. - When determing the working with standardized threaded connections, the highest permissible working pressure of the connection must be taken into account. - When selecting a suitable connection the following static pressure is possible: max. static Working pressure steel (bar) max. static Working pressure brass (bar) max. static Working pressure st. st. (bar) Cv-value Both sides Self sealing Cv-value One side Self sealing LP , 3 0,36 - The coupling is not determined for any types of use and technical values other than those listed here. - Safe operation is not guaranteed if the coupling is used contrary to ist intended use and technical values - The operator of the coupling is responsible for all personal injuries or material damage that occur from non-intended use and disregard of the technical values; the manufacturer assumes no responsibility in these cases. 7

206 Operating Instruction Type LP-004 Product description of the coupling 5.3 Optional Features OV = without valve (z.b.: 1-LP OV 1-LP OV) EX = ATEX version 5.4 Extended product description for application acc. to ATEX-guide line 94/9/EG (special design EX): General Only non-sparkling materials may be used. Non-sparkling materials are , or equivalent materials. Furthermore brass with different surfaces (f. ex. chrome-plated, nickel-plated). Further on it must be assured that the seal is resistant against and suitable for the flowing through media. Also the temperature resistance of the seals must be guaranteed. This must also be considered for the marking acc. to chapter Extended marking The coupling fittings are marked with As the surface temperature of the self-sealing couplings are determined by the temperature of the fluids, the temperature category or the highest surface temperature must be specified by the operator while the safe temperature distances acc. to EN must be observed and the maximum temperature resistance of the coupling materials and seals are taken into consideration. The marking of the temperature class must be effected readily visible by the operator. The determination of the temperature class must be made acc. to the following table: Max. temperature of Temperature class fluids 75 T6 90 T5 130 T4 195 T3 295 T2 445 T1 The couplings are not admitted for the temperature classes T1 and T2 and may not be marked for that by the operator. 8

207 Operating Instruction Type LP-004 Installation instruction 6 Installation Instruction 6.1 General Subject to the general accident prevention regulations coupling is to be installed into a network in such a way that: - a satisfactory operation is guaranteed according to the operating instruction. - first of all self sealing coupling is used on line side and self sealing adaptor on consumer side. - external damage of the unit as well as all moving parts are excluded. Before self sealing coupling and the self sealing adaptor are installed at a pipeline network make sure that the pipeline network is sufficiently rinsed/blown out and/or cleaned. After the assembly works are finished a functional test is to be carried out with both, without pressure and under working pressure according to operating instruction. 6.2 Extended installation instruction for application acc. to ATEX-guideline 94/9/EG Details for safe operation For the use of self sealing couplings as a hose connection it must be guaranteed that in case of pressure strikes the tumbling of the self sealing coupling can be avoided by fixing at suitable constructions. In principle it must be observed that the self sealing coupling cannot strike on hard objects which could produce strike sparks when touching the housing Details for safe installation The self sealing couplings may only be connected to pipe- and hose systems which are suitable for electrostatic discharge and which are connected to the ground potential Details for a safe application area The self sealing couplings may be used according to the class of devices2 in areas susceptible to explosions where potentially explosive mixtures of gas, steam, mist and air are availble. 9

208 Operating Instruction Type LP-004 Operating Instruction 7 Operating Instruction In order to avoid critical injuries of the staff and damage at the self sealing coupling during operation, coupling may be only used for the stated applications. 7.1 Connection process Before every couple cycle a visual check of coupling and adaptor is to be carried out. In case of recognizable, visible damage or deformations damaged parts are to be exchanged. Hold self sealing coupling firmly in one hand; with the other hand pull back locking sleeve. This has to be done against locking spring resistance. Push free half (coupling) with withdrawn locking sleeve axially centered onto plug part of fixed half (adaptor) until sensible resistance. Bring locking sleeve with support of locking spring into starting position. Self sealing coupling and self sealing adaptor are now mechanically locked. CAUTION Please take care that locking sleeve is in final position, i.e. that it is flush in front with the coupling housing as otherwise no perfect lock is guaranteed. 7.2 Disconnection process Withdraw locking sleeve against locking spring and take out coupling from self sealing adaptor. Caution! In case of an available pressure in the line connected by the coupling system a strong separation impulse - depending on the pressure - can be effective onto the coupling system during disconnection. For that reason the movable part of the coupling (free half) is to be firmly held in the hand to avoid injuries. 10

209 Operating Instruction Type LP-004 Maintenance and Functional Instruction 8 Maintenance Instruction Preventive maintenance measures WALTHER self sealing couplings are to be operated in such a manner that external damages to elements and all moving parts are avoided. 8.1 Maintenance and functional test In order to always guarantee function of the self sealing coupling and hence safety of operator, a maintenance and functional testing must be made in appropriate periods of time depending on operating conditions. In order to minimize operating forces and to extend service life of the self sealing coupling we recommend to slightly grease plug surfaces (see item 9.0) Maintenance includes following items: - A visual inspection of self sealing coupling and self sealing adaptor regarding damage and contamination has to be made. - Dirt at the functional area (sealing area, operating elements) which is easily accessible from outside should be removed by simply wiping-off. If there are damaged, torn or corroded parts, coupling must be dismounted and returned to manufacturer for repair. If worn or embrittled seals are found or if there is extreme dirt, the customer can decide whether he returns coupling unit to the manufacturer's factory or whether he repairs himself Functional test includes following items: As described in the operating instruction, coupling is several times connected, pressurized and then disconnected. In doing so, the following has to be observed: - Connection and disconnection process must be absolutely smooth. - Coupling must be absolutely leak-proof in connected and disconnected state. If there are damaged, torn or corroded parts, coupling must be dismounted and returned to manufacturer for repair. If worn or embrittled seals are found or if there is extreme dirt, the customer can decide whether he returns the coupling unit to the manufacturer s factory or whether he repairs himself. 11

210 Operating Instruction Type LP-004 Lubrication 9 Lubrication! In order to minimize operating forces and to extend service life of the coupling we recommend to slightly grease plug surfaces. Lubrication is to be carried out with greases which do not tend to become resin. Caution! The selection of the grease is to be suited to the sealing quality and the medium (e.g.: oxygen) in view of the compatibility. 12

211 Operating Instruction Type LP-004 Storage 10 Storage The couplings must be stored in such a way that no damages can occur at the couplings. The storage conditions of the couplings must comply with the guidelines for the seals as these can change in properties due to improper storage. The following items must be kept: - The couplings must be stored dry. - To safely conserve the seals and that means also the couplings they should not be stored under the effect of daylight. - For protection against oxygen the seals and also the couplings shall be stored into the packing. 13

212 Operating Instruction Type LP-004 Shut-down 11 Shut-down At the end of the service life the coupling or its components have to be disposed non-polluting and according to the legal regulations. For that the local public or private disposal societies should be taken. 14

213 Operating Instruction Type LP-004 Order Number Code 12 Order number code X X X - X X X X X X X X X X X - X X X X - X X X X X - X X X X X X X X X X X X X X X X - X X 1. Subject group 2. Series The information regarding the series comprises either two letters or two numbers. 3. Nomial size / Nominal bore It is rounded up or down to one. The information can be numerical as well as alphanumerical. 4. Product type or design type 5. Connection design 6. Material design: xx-x and xxxx possible 7. Material design (seal design): xx-x and xxxx possible 8. Y or Z design 9. Additional equipment 15

214 Operating Instruction Type LP-004 Index 13 Index A According to intended purpose... 6 Acquired knowledge... 4 Adaptorl... 6 air... 7 Alterations... 4 Assembly... 6 C Commissioning... 4, 6 connected... 7 connection... 7 Connection process coupling... 4 Coupling... 6, 7, 14 Couplings... 6 Customer care... 2 D Damage... 4, 6 Damage compensation... 4 daylight Disconnection process Disposal societies Disregard... 7 dry dust cap... 7 dust plug... 7 E Equipment... 4 Experience... 4 external damage... 9 F Faults... 4 Fluid... 6 Function... 6 Function test... 6 Functionality... 2 G General... 4 guarantee H Hazard notes... 6 Hazardous emission... 6 hydraulic oil... 7 I Implementation... 6 Improvement... 4 Index Inspection... 2 Installation Instruction... 9 Intended use... 7 L Legible condition... 6 Liability... 4 List of Contents... 3 Low Pressure... 1 Lubrication M Maintenance... 2, 4, 6 Maintenance and functional test Maintenance Instruction Manual... 4 Media temperatures... 6 O Operating Instruction... 1, 10 Operation... 2 Operational safety ordinances... 6 operator... 6, 11 Operators... 2 Order number code Original... 4 P packing particular... 6 Perfect, functioning condition... 6 Performance capability... 2 Pressurized... 6 Product description... 7 Property... 4 Protective gloves... 6 Q quality R regulations... 9 Regulations

215 Operating Instruction Type LP-004 Index Reliability... 2 Repair work... 6 responsible... 7 S Safety... 2 Safety devices... 6 Safety Instruction... 6 Scope of delivery... 4 Screw connections... 6 self sealing adaptor... 7, 9, 10, 11 self sealing coupling... 7, 9, 10, 11 Self sealing coupling Self Sealing Coupling... 1 service... 11, 12 Service... 2 Shut-down Special designs... 4 Specialists... 2 Status of development... 4 Storage subspecies... 7 Systems... 2, 6 T Technical data... 7 Technical equipment... 2 Technical values... 7 Temperaturklasse... 8 Thermally... 6 Tools... 2, 6 Translation errors... 4 Types of use... 7 U Use... 2 V Version... 4 W water... 7 Work safety regulations... 6 Working method... 6 working pressure... 7 Wrong product selection

216 Operating Instruction Revision B Datum Ersteller NH This operating instruction is not subject to the updating Self Sealing Coupling Low Pressure Series 1-LP LP LP LP LP LP LP LP optional features: OV SI GG (nur LP-019) EX VH 1

217 This coupling is a quality product, in which special attention has been paid to high functionality, ease of operation, safety and reliability. As an item of technical equipment this tool-changer is intended for use in the commercial, industrial area and for operators, who have been trained by specialists in the handling of technical systems / tools. Customer care: As part of our individual customer care we will be happy to assist you in questions relating to use and operation and on any problems encountered. Service and maintenance: In order to maintain the high technical performance capability and reliability of your docking system over many years, we recommend regular inspection and maintenance. We can thereby offer you optimum support by our Customer Service department and the conclusion of a service and maintenance contract. Please ask for a quotation. Carl Kurt Walther GmbH & Co. KG PO Box Haan Westfalenstraße 2 Tel.: +49 (0) Fax: +49 (0) info@walther-praezision.de Internet: Contact: Application technology and service Holger R. Figge Telephone: (02129) Telefax: (02129) Handy: (0162) hfigge@walther-praezision.de Further addresses and telephone numbers of contacts can be found on the Internet on our homepage under Service / Customer service. 2

218 Operating Instruction Type LP-006, LP-007, LP-012, LP-019 List of Contents 1 List of Contents 1 LIST OF CONTENTS GENERAL WARRANTY SAFETY INSTRUCTION PRODUCT DESCRIPTION OF THE SELF SEALING COUPLING INTENDED USE TECHNICAL DATA MATERIAL DEPENDENT DIFFERENCES OPTIONAL FEATURES EXTENDED PRODUCT DESCRIPTION FOR APPLICATION ACC. TO ATEX-GUIDE LINE 94/9/EG (SPECIAL DESIGN EX): General Extended marking INSTALLATION INSTRUCTION GENERAL EXTENDED INSTALLATION INSTRUCTION FOR APPLICATION ACC. TO ATEX-GUIDELINE 94/9/EG Details for safe operation Details for safe installation Details for a safe application area OPERATING INSTRUCTION CONNECTION PROCESS DISCONNECTION PROCESS SAFETY LOCKING DEVICE SI (SUPPLEMENTARY EQUIPMENT) Coupling process Decoupling process LOCKING AID (LOCKING SLEEVE) Coupling process Disconnection process MAINTENANCE INSTRUCTION MAINTENANCE AND FUNCTIONAL TEST Maintenance includes following items: Functional test includes following items: LUBRICATION! STORAGE SHUT-DOWN ORDER NUMBER CODE INDEX

219 Operating Instruction Type LP-006, LP-007, LP-012, LP-019 General 2 General This manual contains all regulations for operation, commissioning and maintenance of the locking coupling elementself sealing coupling elements. All information and notes in this operating manual were collated while taking into consideration the valid regulations, the current engineering related status of development as well as our many years of experience and acquired knowledge. Translations of this operating manual were also produced according to the best of knowledge. However, we cannot assume liability for any translation errors. The German version provided for this operating manual is considered the authoritative version. The actual scope of delivery can deviate from the explanations and graphic representations described herein under certain circumstances, e.g. in the case of special designs, utilization of additional order options or because of state-of-the-art technical alterations. If you have any questions, please contact the manufacturer. This operating manual must be read carefully before starting work on or with the equipment, in particular before commissioning! The manufacturer assumes no liability for damage or faults arising from non-compliance with the instructions in this operating manual. The operating manual must be kept directly with the equipment and be accessible to all persons who work on or with the equipment. It is not permitted for the operating manual to be passed to third parties and if applicable this will incur damage compensation. All other rights reserved. Before commissioning the device must be checked for being not defective and its technically perfect function. The German version is the original. We reserve the right to make technical alterations to the product within the context of improving the usage properties and further development. The operating manual remains our property. Any reproduction, use by or communication to third parties incurs a penalty and will be pursued by court action (copyright law against unfair competition, BGB [German Civil Code]). All rights reserved in the case of a patent award (Paragraph 7, Section. 1 of the patent law - PG) or entry as a patented design (Paragraph 5, Section 4 of the patented design law - GMG). 4

220 Operating Instruction Type LP-006, LP-007, LP-012, LP-019 Warranty 3 Warranty The warranty conforms to: the General Conditions for Delivery and Capacity of C.K. Walther GmbH & Co. KG of the state which was valid at the date of the purchase contract and the regulations agreed in the purchase contract. Wearing parts are generally excluded from the warranty. Typical wearing parts of products from company C.K. Walther GmbH & Co. KG are for example: seals springs 5

221 Operating Instruction Type LP-006, LP-007, LP-012, LP-019 Safety Instruction 4 Safety Instruction Using these couplings does not release the customer from his obligation to comply with the pertinent work safety regulations e.g. operational safety ordinances, etc. The duty to take due care by the operator of the couplings includes planning measures to ensure proper operation and monitoring their implementation. Hazard notes If the wrong product has been selected or if there is improper use or maintenance has been omitted, then hazards arise and personal injuries and material damage can occur from: - Hazardous emission of fluid or individual particles/coupling parts - Function impairments of connected systems or tools - The metal parts of coupling and adaptor are not thermally protected. You can be burned if you touch these parts at high media temperatures. According to the ambient temperature valve lever and ring grip can also become unbearably hot. For that reason suitable, sufficiently long protective gloves should be worn. The operator must in particular make sure that - The couplings are only used according to the intended purpose. - The couplings are only operated in a perfect, functioning condition. - The operating manual is always in a legible condition and is available in its entirety to operating personnel. - The operating personnel are sufficiently acquainted with the working method and the safety notes for the coupling. - The coupling is sent to our factory for repair work. - During operation of the coupling, no safety devices are removed and/or deactivated. - Before installing or dismantling the coupling, you have made sure that the coupling has not been pressurized. After completing assembly and installation work and before commissioning the coupling, observe the following points: Check once again that all screw connections are securely fitted. Before commissioning the coupling, a function test must be carried out (see maintenance and function test). 6

222 Operating Instruction Type LP-006, LP-007, LP-012, LP-019 Product description of the coupling 5 Product description of the self sealing coupling Coupling connection consists of: - self sealing coupling 1-LP self sealing adaptor 1-LP self sealing coupling 1-LP self sealing adaptor 1-LP self sealing coupling 1-LP self sealing adaptor 1-LP self sealing coupling 1-LP self sealing adaptor 1-LP In case that both coupling halves are not connected they should be protected against external dirt and/or damages if required. For that purpose dust cap and dust plug are available. Possible comibinations : self sealing coupling with dust plug self sealing adaptor with dust cap 1-LP LP LP LP Intended use - Coupling is only used as connection of two lines. - Connection and disconnection process is carried out by hand. - Coupling is especially suitable for the following media/applications: - air - water - hydraulic oil - and their subspecies (such as oxygen or oil with additives) - For all other possible applications, Walther-Präzision should be consulted. 7

223 Operating Instruction Type LP-006, LP-007, LP-012, LP-019 Product description of the coupling 5.2 Technical data - Working pressures of coupling depend on materials of individual parts. - When determing the working with standardized threaded connections, the highest permissible working pressure of the connection must be taken into account. - When selecting a suitable connection the following static pressure is possible: max. static Working pressure steel (bar) max. static Working pressure brass (bar) max. static Working pressure st. st. (bar) Cv-value Both sides Self sealing Cv-value One side Self sealing LP ,73 1,03 LP ,17 1, 5 LP ,28 4,34 LP ,4 11,6 - The coupling is not determined for any types of use and technical values other than those listed here. - Safe operation is not guaranteed if the coupling is used contrary to ist intended use and technical values - The operator of the coupling is responsible for all personal injuries or material damage that occur from non-intended use and disregard of the technical values; the manufacturer assumes no responsibility in these cases. 5.3 Material dependent Differences see different parts lists 8

224 Operating Instruction Type LP-006, LP-007, LP-012, LP-019 Product description of the coupling 5.4 Optional Features OV = without valve (z.b.: 1-LP OV 1-LP OV) SI = with protection by safety locking device (see point 5) (z.b.: 1-LP SI) without SI with SI GG = with ring grips (aluminium cast) only LP-019 (z.b.: 1-LP GG) EX = ATEX version VH = with locking aid 9

225 Operating Instruction Type LP-006, LP-007, LP-012, LP-019 Product description of the coupling 5.5 Extended product description for application acc. to ATEX-guide line 94/9/EG (special design EX): General Only non-sparkling materials may be used. Non-sparkling materials are , or equivalent materials. Furthermore brass with different surfaces (f. ex. chrome-plated, nickel-plated). Further on it must be assured that the seal is resistant against and suitable for the flowing through media. Also the temperature resistance of the seals must be guaranteed. This must also be considered for the marking acc. to chapter Extended marking The coupling fittings are marked with As the surface temperature of the self-sealing couplings are determined by the temperature of the fluids, the temperature category or the highest surface temperature must be specified by the operator while the safe temperature distances acc. to EN must be observed and the maximum temperature resistance of the coupling materials and seals are taken into consideration. The marking of the temperature class must be effected readily visible by the operator. The determination of the temperature class must be made acc. to the following table: Max. temperature of Temperature class fluids 75 T6 90 T5 130 T4 195 T3 295 T2 445 T1 The couplings are not admitted for the temperature classes T1 and T2 and may not be marked for that by the operator. 10

226 Operating Instruction Type LP-006, LP-007, LP-012, LP-019 Installation instruction 6 Installation Instruction 6.1 General Subject to the general accident prevention regulations coupling is to be installed into a network in such a way that: - a satisfactory operation is guaranteed according to the operating instruction. - first of all self sealing coupling is used on line side and self sealing adaptor on consumer side. - external damage of the unit as well as all moving parts are excluded. Before self sealing coupling and the self sealing adaptor are installed at a pipeline network make sure that the pipeline network is sufficiently rinsed/blown out and/or cleaned. After the assembly works are finished a functional test is to be carried out with both, without pressure and under working pressure according to operating instruction. 6.2 Extended installation instruction for application acc. to ATEX-guideline 94/9/EG Details for safe operation For the use of self sealing couplings as a hose connection it must be guaranteed that in case of pressure strikes the tumbling of the self sealing coupling can be avoided by fixing at suitable constructions. In principle it must be observed that the self sealing coupling cannot strike on hard objects which could produce strike sparks when touching the housing Details for safe installation The self sealing couplings may only be connected to pipe- and hose systems which are suitable for electrostatic discharge and which are connected to the ground potential Details for a safe application area The self sealing couplings may be used according to the class of devices2 in areas susceptible to explosions where potentially explosive mixtures of gas, steam, mist and air are availble. 11

227 Operating Instruction Type LP-006, LP-007, LP-012, LP-019 Operating Instruction 7 Operating Instruction In order to avoid critical injuries of the staff and damage at the self sealing coupling during operation, coupling may be only used for the stated applications. 7.1 Connection process Before every couple cycle a visual check of coupling and adaptor is to be carried out. In case of recognizable, visible damage or deformations damaged parts are to be exchanged. Hold self sealing coupling firmly in one hand; with the other hand pull back locking sleeve. This has to be done against locking spring resistance. Push free half (coupling) with withdrawn locking sleeve axially centered onto plug part of fixed half (adaptor) until sensible resistance. Bring locking sleeve with support of locking spring into starting position. Self sealing coupling and self sealing adaptor are now mechanically locked. CAUTION Please take care that locking sleeve is in final position, i.e. that it is flush in front with the coupling housing as otherwise no perfect lock is guaranteed. 7.2 Disconnection process Withdraw locking sleeve against locking spring and take out coupling from self sealing adaptor. Caution! In case of an available pressure in the line connected by the coupling system a strong separation impulse - depending on the pressure - can be effective onto the coupling system during disconnection. For that reason the movable part of the coupling (free half) is to be firmly held in the hand to avoid injuries. 12

228 Operating Instruction Type LP-006, LP-007, LP-012, LP-019 Operating Instruction 7.3 Safety locking device SI (supplementary equipment) Coupling process For coupling the locking ring must be in unsecured position (picture 2). Coupling as described under 7.1. locking sleeve locking ring picture 1 picture 2 locked position unlocked position After coupling the locking ring is drawn towards the hose, turned by 90 and released. Now the locking ring snaps forward into the safety position (picture 1). Both final positions secured and unsecured are fixed by spring loaded cams. The operator can assure himself of the proper locking and saving by trying, as a control, to disconnect the coupling by drawing back the locking sleeve. This is not possible in secured position Decoupling process In coupled situation the locking ring is in secured position (picture 1). For de-blocking the locking ring is drawn towards the hose, turned by 90 and released. Now the locking ring snaps forward into the safety position (picture 1). Both final positions secured and unsecured are fixed by spring loaded cams. Decoupling as described under

229 Operating Instruction Type LP-006, LP-007, LP-012, LP-019 Operating Instruction 7.4 Locking aid (locking sleeve) Coupling process When connecting, the locking sleeve has to be situated in its initial position. Initial position means -> arrested in a retracted position (see figure 1) figure 1 figure 2 initial position connected position If this is not the case and the locking sleeve is in the connected position (see figure 2), the locking sleeve must be brought in its initial position by retracting it to the locking. When connecting, please do not hold the coupling at the locking sleeve but at the housing or hose connection area. Slide the coupling axially centred on the connector of the adaptor as far as possible. In doing so, the locking of the locking sleeve is automatically released and brought into the locking position by the spring load. The valves are fully opened and the flow is released. Note The proper locking of the connected condition can be checked visually from the outside. In this condition, the locking sleeve is positioned in a distance of max. 1 mm from the collar of the adaptor. 1 mm Disconnection process Hold the coupling at the housing or the hose connection area, retract the locking sleeve against the spring force and pull off the coupling axially from the adaptor. This causes the valves to shut and the flow is blocked. By retracting the locking sleeve it arrests at the back stop and is again ready for connection. 14

230 Operating Instruction Type LP-006, LP-007, LP-012, LP-019 Maintenance and Functional Instruction 8 Maintenance Instruction Preventive maintenance measures WALTHER self sealing couplings are to be operated in such a manner that external damages to elements and all moving parts are avoided. 8.1 Maintenance and functional test In order to always guarantee function of the self sealing coupling and hence safety of operator, a maintenance and functional testing must be made in appropriate periods of time depending on operating conditions. In order to minimize operating forces and to extend service life of the self sealing coupling we recommend to slightly grease plug surfaces (see item 9.0) Maintenance includes following items: - A visual inspection of self sealing coupling and self sealing adaptor regarding damage and contamination has to be made. - Dirt at the functional area (sealing area, operating elements) which is easily accessible from outside should be removed by simply wiping-off. If there are damaged, torn or corroded parts, coupling must be dismounted and returned to manufacturer for repair. If worn or embrittled seals are found or if there is extreme dirt, the customer can decide whether he returns coupling unit to the manufacturer's factory or whether he repairs himself Functional test includes following items: As described in the operating instruction, coupling is several times connected, pressurized and then disconnected. In doing so, the following has to be observed: - Connection and disconnection process must be absolutely smooth. - Coupling must be absolutely leak-proof in connected and disconnected state. If there are damaged, torn or corroded parts, coupling must be dismounted and returned to manufacturer for repair. If worn or embrittled seals are found or if there is extreme dirt, the customer can decide whether he returns the coupling unit to the manufacturer s factory or whether he repairs himself. 15

231 Operating Instruction Type LP-006, LP-007, LP-012, LP-019 Lubrication 9 Lubrication! In order to minimize operating forces and to extend service life of the coupling we recommend to slightly grease plug surfaces. Lubrication is to be carried out with greases which do not tend to become resin. Caution! The selection of the grease is to be suited to the sealing quality and the medium (e.g.: oxygen) in view of the compatibility. 16

232 Operating Instruction Type LP-006, LP-007, LP-012, LP-019 Storage 10 Storage The couplings must be stored in such a way that no damages can occur at the couplings. The storage conditions of the couplings must comply with the guidelines for the seals as these can change in properties due to improper storage. The following items must be kept: - The couplings must be stored dry. - To safely conserve the seals and that means also the couplings they should not be stored under the effect of daylight. - For protection against oxygen the seals and also the couplings shall be stored into the packing. 17

233 Operating Instruction Type LP-006, LP-007, LP-012, LP-019 Shut-down 11 Shut-down At the end of the service life the coupling or its components have to be disposed non-polluting and according to the legal regulations. For that the local public or private disposal societies should be taken. 18

234 Operating Instruction Type LP-006, LP-007, LP-012, LP-019 Order Number Code 12 Order number code X X X - X X X X X X X X X X X - X X X X - X X X X X - X X X X X X X X X X X X X X X X - X X 1. Subject group 2. Series The information regarding the series comprises either two letters or two numbers. 3. Nomial size / Nominal bore It is rounded up or down to one. The information can be numerical as well as alphanumerical. 4. Product type or design type 5. Connection design 6. Material design: xx-x and xxxx possible 7. Material design (seal design): xx-x and xxxx possible 8. Y or Z design 9. Additional equipment 19

235 Operating Instruction Type LP-006, LP-007, LP-012, LP-019 Index 13 Index A According to intended purpose... 6 Acquired knowledge... 4 Adaptorl... 6 air... 7 Alterations... 4 Assembly... 6 C Commissioning... 4, 6 connected... 7 connection... 7 Connection process coupling... 4 Coupling... 6, 8, 18 Couplings... 6 Customer care... 2 D Damage... 4, 6 Damage compensation... 4 daylight Disconnection process Disposal societies Disregard... 8 dry dust cap... 7 dust plug... 7 E Equipment... 4 Experience... 4 external damage F Faults... 4 Fluid... 6 Function... 6 Function test... 6 Functionality... 2 G General... 4 guarantee H Hazard notes... 6 Hazardous emission... 6 hydraulic oil... 7 I Implementation... 6 Improvement... 4 Index Inspection... 2 Installation Instruction Intended use... 7 L Legible condition... 6 Liability... 4 List of Contents... 3 Low Pressure... 1 Lubrication M Maintenance... 2, 4, 6 Maintenance and functional test Maintenance Instruction Manual... 4 Media temperatures... 6 O Operating Instruction... 1, 12 Operation... 2 Operational safety ordinances... 6 operator... 6, 15 Operators... 2 Order number code Original... 4 P packing particular... 6 Perfect, functioning condition... 6 Performance capability... 2 Pressurized... 6 Product description... 7 Property... 4 Protective gloves... 6 Q quality R regulations Regulations

236 Operating Instruction Type LP-006, LP-007, LP-012, LP-019 Index Reliability... 2 Repair work... 6 responsible... 8 S Safety... 2 Safety devices... 6 Safety Instruction... 6 Scope of delivery... 4 Screw connections... 6 self sealing adaptor... 7, 11, 12, 15 self sealing coupling... 7, 11, 12, 15 Self sealing coupling Self Sealing Coupling... 1 service... 15, 16 Service... 2 Shut-down Special designs... 4 Specialists... 2 Status of development... 4 Storage subspecies... 7 Systems... 2, 6 T Technical data... 8 Technical equipment... 2 Technical values... 8 Temperaturklasse Thermally... 6 Tools... 2, 6 Translation errors... 4 Types of use... 8 U Use... 2 V Version... 4 W water... 7 Work safety regulations... 6 Working method... 6 working pressure... 8 Wrong product selection

237 Operating instruction english Revision A Date Issuer NH This operating instruction is not subject to the updating Self sealing coupling Medium Pressure Series 1-LP WR LP WR optional features: GG EX 1

238 This coupling is a quality product, in which special attention has been paid to high functionality, ease of operation, safety and reliability. As an item of technical equipment this tool-changer is intended for use in the commercial, industrial area and for operators, who have been trained by specialists in the handling of technical systems / tools. Customer care: As part of our individual customer care we will be happy to assist you in questions relating to use and operation and on any problems encountered. Service and maintenance: In order to maintain the high technical performance capability and reliability of your docking system over many years, we recommend regular inspection and maintenance. We can thereby offer you optimum support by our Customer Service department and the conclusion of a service and maintenance contract. Please ask for a quotation. Carl Kurt Walther GmbH & Co. KG PO Box Haan Westfalenstraße 2 Tel.: +49 (0) Fax: +49 (0) info@walther-praezision.de Internet: Contact: Application technology and service Holger R. Figge Telephone: (02129) Telefax: (02129) Handy: (0162) hfigge@walther-praezision.de 2

239 Operating instruction english Type LP-019 List of Contents 1 List of Contents 1 LIST OF CONTENTS GENERAL WARRANTY SAFETY INSTRUCTIONS PRODUCT DESCRIPTION OF THE SELF SEALING COUPLING INTENDED USE TECHNICAL DATA OPTIONAL FEATURES EXTENDED PRODUCT DESCRIPTION FOR APPLICATION ACC. TO ATEX-GUIDE LINE 94/9/EG (SPECIAL DESIGN EX): General Extended marking INSTALLATION INSTRUCTION GENERAL EXTENDED INSTALLATION INSTRUCTION FOR APPLICATION ACC. TO ATEX-GUIDELINE 94/9/EG Details for safe operation Details for safe installation Details for a safe application area OPERATING INSTRUCTION CONNECTION PROCESS DISCONNECTION PROCESS MAINTENANCE INSTRUCTION MAINTENANCE AND FUNCTIONAL TEST Maintenance includes following items: Functional test includes following items: LUBRICATION! STORAGE SHUT-DOWN ORDER NUMBER CODE INDEX

240 Operating instruction english Type LP-019 General 2 General This manual contains all regulations for operation, commissioning and maintenance of the coupling. All information and notes in this operating manual were collated while taking into consideration the valid regulations, the current engineering related status of development as well as our many years of experience and acquired knowledge. Translations of this operating manual were also produced according to the best of knowledge. However, we cannot assume liability for any translation errors. The German version provided for this operating manual is considered the authoritative version. The actual scope of delivery can deviate from the explanations and graphic representations described herein under certain circumstances, e.g. in the case of special designs, utilization of additional order options or because of state-of-the-art technical alterations. If you have any questions, please contact the manufacturer. This operating manual must be read carefully before starting work on or with the equipment, in particular before commissioning! The manufacturer assumes no liability for damage or faults arising from non-compliance with the instructions in this operating manual. The operating manual must be kept directly with the equipment and be accessible to all persons who work on or with the equipment. It is not permitted for the operating manual to be passed to third parties and if applicable this will incur damage compensation. All other rights reserved. Before commissioning the device must be checked for being not defective and its technically perfect function. The German version is the original. We reserve the right to make technical alterations to the product within the context of improving the usage properties and further development. The operating manual remains our property. Any reproduction, use by or communication to third parties incurs a penalty and will be pursued by court action (copyright law against unfair competition, BGB [German Civil Code]). All rights reserved in the case of a patent award (Paragraph 7, Section. 1 of the patent law - PG) or entry as a patented design (Paragraph 5, Section 4 of the patented design law - GMG). 4

241 Operating instruction english Type LP-019 Warranty 3 Warranty The warranty conforms to: the regulations agreed in the purchase contract and the General Conditions for Delivery and Capacity of C.K. Walther GmbH & Co. KG of the state which was valid at the date of the purchase contract. Wearing parts are generally excluded from the warranty. Typical wearing parts of products from company C.K. Walther GmbH & Co. KG are for example: seals springs 5

242 Operating instruction english Type LP-019 Safety instructions 4 Safety instructions Using these couplings does not release the customer from his obligation to comply with the pertinent work safety regulations e.g. operational safety regulations, etc. The duty to take due care by the operator of the couplings includes planning measures to ensure proper operation and monitoring their implementation. Hazard notes If the wrong product has been selected or if there is improper use or maintenance has been omitted, then hazards arise and personal injuries and material damage can occur from: - hazardous emission of fluid or individual particles/coupling parts. - function impairments of connected systems or tools. - the metal parts of coupling and adaptor are not thermally protected. In case of high media temperatures the contact with these parts can lead to combustion. According to the ambient temperature valve handle and ring grip can also become very hot. For that reason sufficiently long protective gloves must be worn in these cases. The operator must in particular make sure that - the couplings are only used according to the intended purpose. - the couplings are only operated in a perfect, functioning condition. - the operating manual is always in a legible condition and is available in its entirety to operating personnel. - the operating personnel are sufficiently acquainted with the working method and the safety notes for the coupling. - no safety devices must be removed and/or deactivated during operation of the couplings. - before installing or dismantling the couplings, you have made sure that the couplings have not been pressurized. After completing assembly and installation work and before commissioning the coupling, the following items have to be observed: Check once again that all screw connections are securely fitted. Before commissioning the couplings, a function test must be carried out (see maintenance and function test). 6

243 5 Product description of the self sealing coupling - Coupling connection consists of: - self sealing coupling 1-LP self sealing adaptor 1-LP Operating instruction english Type LP-019 Product description of the self sealing coupling - The following combinations of the coupling connections are also possible: - self sealing coupling 1-LP thru type adaptor 1-LP thru type coupling 1-LP thru type adaptor 1-LP In case that both coupling halves are not connected they should be protected against external dirt and/or damages if required. - For that purpose dust cap and dust plug are available. Possible combinations : self sealing coupling or thru type coupling with dust plug self sealing adaptor or thru type adaptor with dust cap 1-LP LP LP LP LP LP Intended use - Coupling is only used as connection of two lines. - Connection and disconnection process is carried out by hand. - Coupling is especially suitable for the following media/applications: - air - water - hydraulic oil - and their subspecies (such as oxygen or oil with additives) - For all other possible applications, Walther-Präzision should be consulted. 5.2 Technical data - Working pressures of the coupling depend on materials of individual parts. - When determining working pressure of the coupling the max. permissible working pressure of the end connection is to be taken into account if standardized threads are used. 7

244 Operating instruction english Type LP-019 Product description of the self sealing coupling Working pressure Cv flow coefficient steel: connected: 50 bar disconnected: adaptor side = 50 bar coupling side = 50 bar brass: connected: 30 bar disconnected: adaptor side = 30 bar coupling side = 30 bar stainless steel: connected: 30 bar disconnected: adaptor side = 30 bar coupling side = 30 bar Self sealing coupling -> thru type adaptor (one side self sealing) = 11.2 self sealing adaptor -> self sealing coupling (both sides self sealing) = The coupling is not determined for any types of use other than those listed here. - Safe operation is not guaranteed if the coupling is used contrary to its intended use. - The operator of the coupling is responsible for all personal injuries or material damage that occur from non-intended use and disregard of the technical values; the manufacturer assumes no responsibility in these cases. 5.3 Optional Features GG = with ring grips (aluminium cast) EX = ATEX version 8

245 Operating instruction english Type LP-019 Product description of the self sealing coupling 5.4 Extended product description for application acc. to ATEX-guide line 94/9/EG (special design EX): General Only non-sparkling materials may be used. Non-sparkling materials are , or equivalent materials. Furthermore brass with different surfaces (f. ex. chrome-plated, nickel-plated). Further on it must be assured that the seal is resistant against and suitable for the flowing through media. Also the temperature resistance of the seals must be guaranteed. This must also be considered for the marking acc. to chapter Extended marking The coupling fittings are marked with As the surface temperature of the self-sealing couplings are determined by the temperature of the fluids, the temperature category or the highest surface temperature must be specified by the operator while the safe temperature distances acc. to EN must be observed and the maximum temperature resistance of the coupling materials and seals are taken into consideration. The marking of the temperature class must be effected readily visible by the operator. The determination of the temperature class must be made acc. to the following table: Max. temperature of Temperature class fluids 75 T6 90 T5 130 T4 195 T3 295 T2 445 T1 The couplings are not admitted for the temperature classes T1 and T2 and may not be marked for that by the operator. 9

246 Operating instruction english Type LP-019 Installation instruction 6 Installation Instruction 6.1 General Subject to the general accident prevention regulations coupling is to be installed into a network in such a way that: - a satisfactory operation is guaranteed according to the operating instruction. - first of all self sealing coupling is used on line side and self sealing adaptor on consumer side - external damage of the unit as well as all moving parts are excluded. Before self sealing coupling and the self sealing adaptor are installed at a pipeline network make sure that the pipeline network is sufficiently rinsed/blown out and/or cleaned. Assembly and disassembly of the self sealing coupling and the self sealing adaptor see item 8. After the assembly works are finished a functional test is to be carried out with both, without pressure and under working pressure of the media elements according to operating instruction. 6.2 Extended installation instruction for application acc. to ATEX-guideline 94/9/EG Details for safe operation For the use of self sealing couplings as a hose connection it must be guaranteed that in case of pressure strikes the tumbling of the self sealing coupling can be avoided by fixing at suitable constructions. In principle it must be observed that the self sealing coupling cannot strike on hard objects which could produce strike sparks when touching the housing Details for safe installation The self sealing couplings may only be connected to pipe- and hose systems which are suitable for electrostatic discharge and which are connected to the ground potential Details for a safe application area The self sealing couplings may be used according to the class of devices2 in areas susceptible to explosions where potentially explosive mixtures of gas, steam, mist and air are availble. 10

247 Operating instruction english Type LP-019 Operating instruction 7 Operating Instruction In order to avoid critical injuries of the staff and damage at the self sealing coupling during operation, coupling may be only used for the stated applications. 7.1 Connection process Before every couple cycle a visual check of coupling and adaptor is to be carried out. In case of recognizable, visible damage or deformations damaged parts are to be exchanged. Hold self sealing coupling firmly in one hand; with the other hand pull back locking sleeve. This has to be done against locking spring resistance. Push free half (coupling) with withdrawn locking sleeve axially centered onto plug part of fixed half (adaptor) until sensible resistance. Bring locking sleeve with support of locking spring into starting position. Self sealing coupling and self sealing adaptor are now mechanically locked. CAUTION Please take care that locking sleeve is in final position, i.e. that it is flush in front with the coupling housing as otherwise no perfect lock is guaranteed. 7.2 Disconnection process Withdraw locking sleeve against locking spring and take out coupling from self sealing adaptor. Caution! In case of an available pressure in the line connected by the coupling system a strong separation impulse - depending on the pressure - can be effective onto the coupling system during disconnection. For that reason the movable part of the coupling (free half) is to be firmly held in the hand to avoid injuries. 11

248 Operating instruction english Type LP-019 Maintenance and Functional instruction 8 Maintenance Instruction Preventive maintenance measures WALTHER self sealing couplings are to be operated in such a manner that external damages to elements and all moving parts are avoided. 8.1 Maintenance and functional test In order to always guarantee function of the self sealing coupling and hence safety of operator, a maintenance and functional testing must be made in appropriate periods of time depending on operating conditions. In order to minimize operating forces and to extend service life of the self sealing coupling we recommend to slightly grease plug surfaces (see item 9.0) Maintenance includes following items: - A visual inspection of self sealing coupling and self sealing adaptor regarding damage and contamination has to be made. - Dirt at the functional area (sealing area, operating elements) which is easily accessible from outside should be removed by simply wiping-off. If there are damaged, torn or corroded parts, coupling must be dismounted and returned to manufacturer for repair. If worn or embrittled seals are found or if there is extreme dirt, the customer can decide whether he returns coupling unit to the manufacturer's factory or whether he repairs himself Functional test includes following items: As described in the operating instruction, coupling is several times connected, pressurized and then disconnected. In doing so, the following has to be observed: - Connection and disconnection process must be absolutely smooth. - Coupling must be absolutely leak-proof in connected and disconnected state. If there are damaged, torn or corroded parts, coupling must be dismounted and returned to manufacturer for repair. If worn or embrittled seals are found or if there is extreme dirt, the customer can decide whether he returns the coupling unit to the manufacturer s factory or whether he repairs himself. 12

249 Operating instruction english Type LP-019 Lubrication 9 Lubrication! In order to minimize operating forces and to extend service life of the coupling we recommend to slightly grease plug surfaces. Lubrication is to be carried out with greases which do not tend to become resin. Caution! The selection of the grease is to be suited to the sealing quality and the medium (e.g.: oxygen) in view of the compatibility. 13

250 Operating instruction english Type LP-019 Storage 10 Storage The couplings must be stored in such a way that no damages can occur at the couplings. The storage conditions of the couplings must comply with the guidelines for the seals as these can change in properties due to improper storage. The following items must be kept: - The couplings must be stored dry. - To safely conserve the seals and that means also the couplings they should not be stored under the effect of daylight. - For protection against oxygen the seals and also the couplings shall be stored into the packing. 14

251 Operating instruction english Type LP-019 Shut-down 11 Shut-down At the end of the service life the coupling or its components have to be disposed non-polluting and according to the legal regulations. For that the local public or private disposal societies should be taken. 15

252 Operating instruction english Type LP-019 Order number code 12 Order number code X X X - X X X X X X X X X X X - X X X X - X X X X X - X X X X X X X X X X X X X X X X - X X 1. Subject group 2. Series Series description consists of either two letters or two digits. 3. Nominal size / nominal width It is rounded up or rounded down to full units. The indication can be numerical or alphanumeric. 4. Type of product and design 5. Type of connection 6. Material: xx-x and xxxx possible 7. Material (seal version): xx-x and xxxx possible 8. Y- or Z-design 9. Optional features 16

253 Operating instruction english Type LP-019 Index 13 Index A According to intended purpose... 6 Acquired knowledge... 4 air... 7 Alterations... 4 Assembly... 6 C Commissioning... 4, 6 connected... 6, 12 connection... 7, 16 Connection process coupling... 4, 6 Coupling... 8, 15 Couplings... 6 Customer care... 2 Cv flow coefficient... 8 D Damage... 4, 6 Damage compensation... 4 daylight disconnected Disconnection process Dismantling... 6 Disposal societies dry dust cap... 7 dust plug... 7 E elektrostatisch Equipment... 4 Experience... 4 explosionsgefährdeten Bereichen external damage F Faults... 4 Fluid... 6 Function... 6 Function test... 6 Functionality... 2 G General... 4 Gerätekategorie guarantee H Hazard notes...6 Hazardous emission...6 hydraulic oil...7 I Implementation...6 Improvement...4 Index...17 Inspection...2 Installation Instruction...10 Intended use...7 K Kennzeichnung...9 L Legible condition...6 Liability...4 List of Contents...3 Lubrication...13 M Maintenance...2, 4, 6 Maintenance Instruction...12 Manual...4 Medium Pressure Series...1 O Operating instruction...1 Operating Instruction...11 Operation...2 Operational safety regulations...6 operator...6 Operator...8 Operators...2 original...4 P packing...14 Perfect, functioning condition...6 Performance capability...2 Pressurized...6 Product description...7 Property...4 Q quality

254 Operating instruction english Type LP-019 Index questions... 4 R regulations Regulations... 4 Reliability... 2 S Safety... 2 Safety devices... 6 Safety instructions... 6 Schlagfunken Scope of delivery... 4 Screw connections... 6 self sealing adaptor... 7, 8, 10, 11, 12 self sealing coupling... 7, 8, 10, 11, 12 Self sealing coupling... 1, 8, 11 service... 12, 13 Service... 2 Shut-down Special designs... 4 Specialists... 2 specification... 8 Status of development... 4 Storage subspecies... 7 Systems...2, 6 T Technical data...7 Technical equipment...2 Temperaturbeständigkeit...9 Temperaturklasse...9 thru type adaptor...7, 8 thru type coupling...7 Tools...2, 6 Translation errors...4 Types of use...8 U Use...2 V Version...4 W water...7 Work safety regulations...6 Working method...6 Working pressure...8 Wrong product selection

255 Operating Instruction Revision A Datum Ersteller NH This operating instruction is not subject to the updating Self Sealing Coupling Low Pressure Series 1-LP LP LP LP optional features: SI GG EX 1

256 This coupling is a quality product, in which special attention has been paid to high functionality, ease of operation, safety and reliability. As an item of technical equipment this tool-changer is intended for use in the commercial, industrial area and for operators, who have been trained by specialists in the handling of technical systems / tools. Customer care: As part of our individual customer care we will be happy to assist you in questions relating to use and operation and on any problems encountered. Service and maintenance: In order to maintain the high technical performance capability and reliability of your docking system over many years, we recommend regular inspection and maintenance. We can thereby offer you optimum support by our Customer Service department and the conclusion of a service and maintenance contract. Please ask for a quotation. Carl Kurt Walther GmbH & Co. KG PO Box Haan Westfalenstraße 2 Tel.: +49 (0) Fax: +49 (0) info@walther-praezision.de Internet: Contact: Application technology and service Holger R. Figge Telephone: (02129) Telefax: (02129) Handy: (0162) hfigge@walther-praezision.de Further addresses and telephone numbers of contacts can be found on the Internet on our homepage under Service / Customer service. 2

257 Operating Instruction Type LP-050, LP-032 List of Contents 1 List of Contents 1 LIST OF CONTENTS GENERAL WARRANTY SAFETY INSTRUCTION PRODUCT DESCRIPTION OF THE SELF SEALING COUPLING INTENDED USE TECHNICAL DATA MATERIAL DEPENDENT DIFFERENCES OPTIONAL FEATURES EXTENDED PRODUCT DESCRIPTION FOR APPLICATION ACC. TO ATEX-GUIDE LINE 94/9/EG (SPECIAL DESIGN EX): General Extended marking INSTALLATION INSTRUCTION GENERAL EXTENDED INSTALLATION INSTRUCTION FOR APPLICATION ACC. TO ATEX-GUIDELINE 94/9/EG Details for safe operation Details for safe installation Details for a safe application area OPERATING INSTRUCTION CONNECTION PROCESS DISCONNECTION PROCESS SAFETY LOCKING DEVICE SI (SUPPLEMENTARY EQUIPMENT) Coupling process Decoupling process MAINTENANCE INSTRUCTION MAINTENANCE AND FUNCTIONAL TEST Maintenance includes following items: Functional test includes following items: LUBRICATION! STORAGE SHUT-DOWN ORDER NUMBER CODE INDEX

258 Operating Instruction Type LP-050, LP-032 General 2 General This manual contains all regulations for operation, commissioning and maintenance of the locking coupling elementself sealing coupling elements. All information and notes in this operating manual were collated while taking into consideration the valid regulations, the current engineering related status of development as well as our many years of experience and acquired knowledge. Translations of this operating manual were also produced according to the best of knowledge. However, we cannot assume liability for any translation errors. The German version provided for this operating manual is considered the authoritative version. The actual scope of delivery can deviate from the explanations and graphic representations described herein under certain circumstances, e.g. in the case of special designs, utilization of additional order options or because of state-of-the-art technical alterations. If you have any questions, please contact the manufacturer. This operating manual must be read carefully before starting work on or with the equipment, in particular before commissioning! The manufacturer assumes no liability for damage or faults arising from non-compliance with the instructions in this operating manual. The operating manual must be kept directly with the equipment and be accessible to all persons who work on or with the equipment. It is not permitted for the operating manual to be passed to third parties and if applicable this will incur damage compensation. All other rights reserved. Before commissioning the device must be checked for being not defective and its technically perfect function. The German version is the original. We reserve the right to make technical alterations to the product within the context of improving the usage properties and further development. The operating manual remains our property. Any reproduction, use by or communication to third parties incurs a penalty and will be pursued by court action (copyright law against unfair competition, BGB [German Civil Code]). All rights reserved in the case of a patent award (Paragraph 7, Section. 1 of the patent law - PG) or entry as a patented design (Paragraph 5, Section 4 of the patented design law - GMG). 4

259 Operating Instruction Type LP-050, LP-032 Warranty 3 Warranty The warranty conforms to: the General Conditions for Delivery and Capacity of C.K. Walther GmbH & Co. KG of the state which was valid at the date of the purchase contract and the regulations agreed in the purchase contract. Wearing parts are generally excluded from the warranty. Typical wearing parts of products from company C.K. Walther GmbH & Co. KG are for example: seals springs 5

260 Operating Instruction Type LP-050, LP-032 Safety Instruction 4 Safety Instruction Using these couplings does not release the customer from his obligation to comply with the pertinent work safety regulations e.g. operational safety ordinances, etc. The duty to take due care by the operator of the couplings includes planning measures to ensure proper operation and monitoring their implementation. Hazard notes If the wrong product has been selected or if there is improper use or maintenance has been omitted, then hazards arise and personal injuries and material damage can occur from: - Hazardous emission of fluid or individual particles/coupling parts - Function impairments of connected systems or tools - The metal parts of coupling and adaptor are not thermally protected. You can be burned if you touch these parts at high media temperatures. According to the ambient temperature valve lever and ring grip can also become unbearably hot. For that reason suitable, sufficiently long protective gloves should be worn. The operator must in particular make sure that - The couplings are only used according to the intended purpose. - The couplings are only operated in a perfect, functioning condition. - The operating manual is always in a legible condition and is available in its entirety to operating personnel. - The operating personnel are sufficiently acquainted with the working method and the safety notes for the coupling. - The coupling is sent to our factory for repair work. - During operation of the coupling, no safety devices are removed and/or deactivated. - Before installing or dismantling the coupling, you have made sure that the coupling has not been pressurized. After completing assembly and installation work and before commissioning the coupling, observe the following points: Check once again that all screw connections are securely fitted. Before commissioning the coupling, a function test must be carried out (see maintenance and function test). 6

261 Operating Instruction Type LP-050, LP-032 Product description of the coupling 5 Product description of the self sealing coupling Coupling connection consists of: - self sealing coupling 1-LP self sealing adaptor 1-LP self sealing coupling 1-LP self sealing adaptor 1-LP In case that both coupling halves are not connected they should be protected against external dirt and/or damages if required. For that purpose dust cap and dust plug are available. Possible comibinations : self sealing coupling with dust plug self sealing adaptor with dust cap 1-LP LP LP LP Intended use - Coupling is only used as connection of two lines. - Connection and disconnection process is carried out by hand. - Coupling is especially suitable for the following media/applications: - air - water - hydraulic oil - and their subspecies (such as oxygen or oil with additives) - For all other possible applications, Walther-Präzision should be consulted. 7

262 Operating Instruction Type LP-050, LP-032 Product description of the coupling 5.2 Technical data - Working pressures of coupling depend on materials of individual parts. - When determing the working with standardized threaded connections, the highest permissible working pressure of the connection must be taken into account. - When selecting a suitable connection the following static pressure is possible: max. static Working pressure steel (bar) max. static Working pressure brass (bar) max. static Working pressure st. st. (bar) Cv-value Both sides Self sealing Cv-value One side Self sealing LP LP The coupling is not determined for any types of use and technical values other than those listed here. - Safe operation is not guaranteed if the coupling is used contrary to ist intended use and technical values - The operator of the coupling is responsible for all personal injuries or material damage that occur from non-intended use and disregard of the technical values; the manufacturer assumes no responsibility in these cases. 5.3 Material dependent Differences see different parts lists 8

263 Operating Instruction Type LP-050, LP-032 Product description of the coupling 5.4 Optional Features SI = with protection by safety locking device (see point 5) (z.b.: 1-LP SI) without SI with SI GG = with ring grips (aluminium cast) (z.b.: 1-LP GG) EX = ATEX version 9

264 Operating Instruction Type LP-050, LP-032 Product description of the coupling 5.5 Extended product description for application acc. to ATEX-guide line 94/9/EG (special design EX): General Only non-sparkling materials may be used. Non-sparkling materials are , or equivalent materials. Furthermore brass with different surfaces (f. ex. chrome-plated, nickel-plated). Further on it must be assured that the seal is resistant against and suitable for the flowing through media. Also the temperature resistance of the seals must be guaranteed. This must also be considered for the marking acc. to chapter Extended marking The coupling fittings are marked with As the surface temperature of the self-sealing couplings are determined by the temperature of the fluids, the temperature category or the highest surface temperature must be specified by the operator while the safe temperature distances acc. to EN must be observed and the maximum temperature resistance of the coupling materials and seals are taken into consideration. The marking of the temperature class must be effected readily visible by the operator. The determination of the temperature class must be made acc. to the following table: Max. temperature of Temperature class fluids 75 T6 90 T5 130 T4 195 T3 295 T2 445 T1 The couplings are not admitted for the temperature classes T1 and T2 and may not be marked for that by the operator. 10

265 Operating Instruction Type LP-050, LP-032 Installation instruction 6 Installation Instruction 6.1 General Subject to the general accident prevention regulations coupling is to be installed into a network in such a way that: - a satisfactory operation is guaranteed according to the operating instruction. - first of all self sealing coupling is used on line side and self sealing adaptor on consumer side. - external damage of the unit as well as all moving parts are excluded. Before self sealing coupling and the self sealing adaptor are installed at a pipeline network make sure that the pipeline network is sufficiently rinsed/blown out and/or cleaned. Assembly and disassembly of the self sealing coupling and the self sealing adaptor into pipeline network see item 8. After the assembly works are finished a functional test is to be carried out with both, without pressure and under working pressure according to operating instruction. 6.2 Extended installation instruction for application acc. to ATEX-guideline 94/9/EG Details for safe operation For the use of self sealing couplings as a hose connection it must be guaranteed that in case of pressure strikes the tumbling of the self sealing coupling can be avoided by fixing at suitable constructions. In principle it must be observed that the self sealing coupling cannot strike on hard objects which could produce strike sparks when touching the housing Details for safe installation The self sealing couplings may only be connected to pipe- and hose systems which are suitable for electrostatic discharge and which are connected to the ground potential Details for a safe application area The self sealing couplings may be used according to the class of devices2 in areas susceptible to explosions where potentially explosive mixtures of gas, steam, mist and air are availble. 11

266 Operating Instruction Type LP-050, LP-032 Operating Instruction 7 Operating Instruction In order to avoid critical injuries of the staff and damage at the self sealing coupling during operation, coupling may be only used for the stated applications. 7.1 Connection process Before every couple cycle a visual check of coupling and adaptor is to be carried out. In case of recognizable, visible damage or deformations damaged parts are to be exchanged. Hold self sealing coupling firmly in one hand; with the other hand pull back locking sleeve. This has to be done against locking spring resistance. Push free half (coupling) with withdrawn locking sleeve axially centered onto plug part of fixed half (adaptor) until sensible resistance. Bring locking sleeve with support of locking spring into starting position. Self sealing coupling and self sealing adaptor are now mechanically locked. CAUTION Please take care that locking sleeve is in final position, i.e. that it is flush in front with the coupling housing as otherwise no perfect lock is guaranteed. 7.2 Disconnection process Withdraw locking sleeve against locking spring and take out coupling from self sealing adaptor. Caution! In case of an available pressure in the line connected by the coupling system a strong separation impulse - depending on the pressure - can be effective onto the coupling system during disconnection. For that reason the movable part of the coupling (free half) is to be firmly held in the hand to avoid injuries. 12

267 Operating Instruction Type LP-050, LP-032 Operating Instruction 7.3 Safety locking device SI (supplementary equipment) Coupling process For coupling the locking ring must be in unsecured position (picture 2). Coupling as described under 7.1. locking sleeve locking ring picture 1 picture 2 locked position unlocked position After coupling the locking ring is drawn towards the hose, turned by 90 and released. Now the locking ring snaps forward into the safety position (picture 1). Both final positions secured and unsecured are fixed by spring loaded cams. The operator can assure himself of the proper locking and saving by trying, as a control, to disconnect the coupling by drawing back the locking sleeve. This is not possible in secured position Decoupling process In coupled situation the locking ring is in secured position (picture 1). For de-blocking the locking ring is drawn towards the hose, turned by 90 and released. Now the locking ring snaps forward into the safety position (picture 1). Both final positions secured and unsecured are fixed by spring loaded cams. Decoupling as described under

268 Operating Instruction Type LP-050, LP-032 Maintenance and Functional Instruction 8 Maintenance Instruction Preventive maintenance measures WALTHER self sealing couplings are to be operated in such a manner that external damages to elements and all moving parts are avoided. 8.1 Maintenance and functional test In order to always guarantee function of the self sealing coupling and hence safety of operator, a maintenance and functional testing must be made in appropriate periods of time depending on operating conditions. In order to minimize operating forces and to extend service life of the self sealing coupling we recommend to slightly grease plug surfaces (see item 9.0) Maintenance includes following items: - A visual inspection of self sealing coupling and self sealing adaptor regarding damage and contamination has to be made. - Dirt at the functional area (sealing area, operating elements) which is easily accessible from outside should be removed by simply wiping-off. If there are damaged, torn or corroded parts, coupling must be dismounted and returned to manufacturer for repair. If worn or embrittled seals are found or if there is extreme dirt, the customer can decide whether he returns coupling unit to the manufacturer's factory or whether he repairs himself Functional test includes following items: As described in the operating instruction, coupling is several times connected, pressurized and then disconnected. In doing so, the following has to be observed: - Connection and disconnection process must be absolutely smooth. - Coupling must be absolutely leak-proof in connected and disconnected state. If there are damaged, torn or corroded parts, coupling must be dismounted and returned to manufacturer for repair. If worn or embrittled seals are found or if there is extreme dirt, the customer can decide whether he returns the coupling unit to the manufacturer s factory or whether he repairs himself. 14

269 Operating Instruction Type LP-050, LP-032 Lubrication 9 Lubrication! In order to minimize operating forces and to extend service life of the coupling we recommend to slightly grease plug surfaces. Lubrication is to be carried out with greases which do not tend to become resin. Caution! The selection of the grease is to be suited to the sealing quality and the medium (e.g.: oxygen) in view of the compatibility. 15

270 Operating Instruction Type LP-050, LP-032 Storage 10 Storage The couplings must be stored in such a way that no damages can occur at the couplings. The storage conditions of the couplings must comply with the guidelines for the seals as these can change in properties due to improper storage. The following items must be kept: - The couplings must be stored dry. - To safely conserve the seals and that means also the couplings they should not be stored under the effect of daylight. - For protection against oxygen the seals and also the couplings shall be stored into the packing. 16

271 Operating Instruction Type LP-050, LP-032 Shut-down 11 Shut-down At the end of the service life the coupling or its components have to be disposed non-polluting and according to the legal regulations. For that the local public or private disposal societies should be taken. 17

272 Operating Instruction Type LP-050, LP-032 Order Number Code 12 Order number code X X X - X X X X X X X X X X X - X X X X - X X X X X - X X X X X X X X X X X X X X X X - X X 1. Subject group 2. Series The information regarding the series comprises either two letters or two numbers. 3. Nomial size / Nominal bore It is rounded up or down to one. The information can be numerical as well as alphanumerical. 4. Product type or design type 5. Connection design 6. Material design: xx-x and xxxx possible 7. Material design (seal design): xx-x and xxxx possible 8. Y or Z design 9. Additional equipment 18

273 Operating Instruction Type LP-050, LP-032 Index 13 Index A According to intended purpose... 6 Acquired knowledge... 4 Adaptorl... 6 air... 7 Alterations... 4 Assembly... 6 C Commissioning... 4, 6 connected... 7 connection... 7 Connection process coupling... 4 Coupling... 6, 8, 17 Couplings... 6 Customer care... 2 D Damage... 4, 6 Damage compensation... 4 daylight Disconnection process Disposal societies Disregard... 8 dry dust cap... 7 dust plug... 7 E Equipment... 4 Experience... 4 external damage F Faults... 4 Fluid... 6 Function... 6 Function test... 6 Functionality... 2 G General... 4 guarantee H Hazard notes... 6 Hazardous emission... 6 hydraulic oil... 7 I Implementation... 6 Improvement... 4 Index Inspection... 2 Installation Instruction Intended use... 7 L Legible condition... 6 Liability... 4 List of Contents... 3 Low Pressure... 1 Lubrication M Maintenance... 2, 4, 6 Maintenance and functional test Maintenance Instruction Manual... 4 Media temperatures... 6 O Operating Instruction... 1, 12 Operation... 2 Operational safety ordinances... 6 operator... 6, 14 Operators... 2 Order number code Original... 4 P packing particular... 6 Perfect, functioning condition... 6 Performance capability... 2 Pressurized... 6 Product description... 7 Property... 4 Protective gloves... 6 Q quality R regulations Regulations

274 Operating Instruction Type LP-050, LP-032 Index Reliability... 2 Repair work... 6 responsible... 8 S Safety... 2 Safety devices... 6 Safety Instruction... 6 Scope of delivery... 4 Screw connections... 6 self sealing adaptor... 7, 11, 12, 14 self sealing coupling... 7, 11, 12, 14 Self sealing coupling Self Sealing Coupling... 1 service... 14, 15 Service... 2 Shut-down Special designs... 4 Specialists... 2 Status of development... 4 Storage subspecies... 7 Systems... 2, 6 T Technical data... 8 Technical equipment... 2 Technical values... 8 Temperaturklasse Thermally... 6 Tools... 2, 6 Translation errors... 4 Types of use... 8 U Use... 2 V Version... 4 W water... 7 Work safety regulations... 6 Working method... 6 working pressure... 8 Wrong product selection

275 Operation Instruction for Compressed Air Safety Coupling Type LS-006 Carl Kurt Walther GmbH & Co.KG Postfach Haan Westfalenstraße Haan Tel /567-0 Fax 02129/ LS WALPRESTA Compressed Air Safety Coupling Safety instructions Use according to its specification Installation instruction Maintenance and functional test Operation instruction The original is the German version. Revision : A Datum: Ersteller : NH Geprüft : JK 1-LS Internetversion-englisch.doc 1/4

276 Operation Instruction for Compressed Air Safety Coupling Type LS-006 Carl Kurt Walther GmbH & Co.KG Postfach Haan Westfalenstraße Haan Tel /567-0 Fax 02129/ This coupling is a high-quality product designed with particular focus on high functionality, simple handling, safety and reliability. As technical appliance, the coupling is used in the industrial field as well as by operators who have been instructed by qualified personnel in the handling of compressed air technical installations/tools. We offer an individual customer service and are ready to support you without obligation in all questions regarding the use and operation of the coupling or probably arising problems. Don't hesitate to contact our customer service, we will be pleased to assist you. Safety instructions The use of a safety coupling does not relieve the operator from the observance of the relevant industrial safety regulations, i.e. regulation concerning reliability in operation etc.. The operator has the duty of care to plan measures which guarantee an orderly operation and to control their realization. Danger references In case of wrong product selection, improper use and failure to carry out maintenance there is the danger that damages can be caused to persons and objects. This may result from: - uncontrolled with high dynamic energy whipping hose ends - dangerous spreading of compressed air or individual particles / coupling parts - impairment of function of connected installations or tools. In particular the operator must guarantee that - the coupling is always used according to specification. - the coupling is always used in a perfect, functionable way. - the operation instruction is always available to the operators in a complete and readable form. - the operating personnel is sufficiently informed about the operation and safety instructions of the coupling. - for repair, couplings are returned to our factory. - during operation of coupling, no safety devices are removed and/or set out of function. - coupling is not pressurized before mounting/dismounting of the coupling. After assembly and installation as well as before the first use of the coupling the following items have to be observed: - check again whether all screw type connections are firmly fixed. - before the first use of the coupling, a functional test must be carried out (see maintenance and functional test). Application according to specification The appropriate application is guaranteed only then if - the coupling connection consists of a self sealing coupling and one of the following thru type adaptors WALTHER thru type adaptor of Series LP made of hardened steel or thru type adaptor to DIN (Euro-adaptor), n.b. 7.2/7.8 made of hardened steel or special thru type adaptor of the company EWO, n.b. 7 made of hardened steel - medium compressed air is used - working pressures of 0 12 bar are available - temperature is between 0 C and smaller 60 C. - during selection of connections the maximum permissible working pressure of the connection is considered. Revision : A Datum: Ersteller : NH Geprüft : JK 1-LS Internetversion-englisch.doc 2/4

277 Operation Instruction for Compressed Air Safety Coupling Type LS-006 Carl Kurt Walther GmbH & Co.KG Postfach Haan Westfalenstraße Haan Tel /567-0 Fax 02129/ external working loads such as tension, bending and transverse loads on the coupling connections shall be avoided, if possible, because these can reduce the permissible working pressure. The connection and disconnection process is carried out by hand. There is no pressure switching threshold in the depressurized condition so that the adaptor can only be released in one unlocking step from the coupling. Installation instruction The coupling has to be installed into a supply network under due consideration of the accident prevention rules in such a way that - a proper operation according to the operation instruction is guaranteed - the coupling is mainly used on the supply side and the thru type adaptor is mainly used on the consumer side. - external damages of the unit as well as all movable parts are excluded. Before the coupling is installed at a pipe system it must be guaranteed that the pipe system is sufficiently rinsed/purged and/or cleaned. All components of the coupling have to be protected against dirt and damages. After finishing of the assembly works a functional test is to be carried out according to the operation instruction for both conditions the pressurized and the depressurized. Maintenance and functional test In order to always guarantee function of the coupling and protection of the operator it is necessary to carry out a maintenance and functional test at least twice a year. The coupling is not greased or oiled by the factory. In case of a maintenance no lubricants or means of preservation are supposed to be inserted into the coupling. The maintenance includes the following items: - external visual check for damages and dirt at the coupling and the used adaptors. - dirt in the external accessible functional area (sealing area, operating elements) is to be removed by simple wiping. If damaged, broken or corroded parts are available or in case of serious dirt in the functional area which is not accessible from the outside the coupling must be disassembled and sent to the manufacturer's factory for repair. This is also valid for worn out, embrittled and overaged seals. The functional test includes the following items: As described in the operation instruction the coupling is repeatedly connected and disconnected with a pressure of at least 3 bar and a hose of at least 3 m length. In this case attention is to be paid to the following: - perfect, smooth function when connecting and disconnecting. - the safety function (in this case the adaptor jumps several millimeters out of the coupling and is prevented from the complete separation of the coupling by a second locking system) must be available; thus no dangerous "back kick" must occur. - tightness of the coupling when connected and disconnected. In case of stated malfuctions or leakages the coupling is to be returned to the manufacturer's factory for repair. Revision : A Datum: Ersteller : NH Geprüft : JK 1-LS Internetversion-englisch.doc 3/4

278 Operation Instruction for Compressed Air Safety Coupling Type LS-006 Carl Kurt Walther GmbH & Co.KG Postfach Haan Westfalenstraße Haan Tel /567-0 Fax 02129/ Operation instruction Connection: Simplest connection by plugging. The one-hand operation is obtained by the well-proven automatic lock. The thru type adaptor must completely be inserted into the coupling until stop (picture 2). The locking mechanism is activated in this case and the coupling locks safely. The lock can be checked by a slight pulling at the hose. If the hose part cannot be moved out of the coupling any more, it is locked safely. Disconnection: First unlocking step and venting. At first the first unlocking step is released by means of pushing the locking sleeve into the connection piece direction (picture 3). The adaptor jumps several millimeters out of the coupling and is prevented from the complete separation of the coupling by a second locking system. The coupling valve closes in this case and the air included in the hose of the adaptor side escapes (picture 4). escaping air Second unlocking step. Only if the pressure on the adaptor side falls below the safety relevant switching threshold the second locking system can be released, too. The locking sleeve is again completely to be pushed back for that (picture 5). Now the adaptor can be separated completely and safely from the coupling (picture 6). So the dangerous "back kick" is absolutely avoided. Revision : A Datum: Ersteller : NH Geprüft : JK 1-LS Internetversion-englisch.doc 4/4

279 Oeration Instruction for Compressed Air Safety Coupling Type LS-009 Carl Kurt Walther GmbH & Co.KG Postfach Haan Westfalenstraße Haan Tel /567-0 Fax 02129/ LS WALPRESTA Compressed Air Safety Coupling Safety instruction Use according to its specification Installation instruction Maintenance and functional test Operation instruction The original is the German version. Revision : A Datum: Ersteller : NH Geprüft : JK 1-LS Internetversion-englisch.doc 1/4

280 Operation Instruction for Compressed Air Safety Coupling Type LS-009 Carl Kurt Walther GmbH & Co.KG Postfach Haan Westfalenstraße Haan Tel /567-0 Fax 02129/ This coupling is a high-quality product designed with particular focus on high functionality, simple handling, safety and reliability. As technical appliance, the coupling is used in the industrial field as well as by operators who have been instructed by qualified personnel in the handling of compressed air technical installations/tools. We offer an individual customer service and are ready to support you without obligation in all questions regarding the use and operation of the coupling or probably arising problems. Don't hesitate to contact our customer service, we will be pleased to assist you. Safety instructions The use of a safety coupling does not relieve the operator from the observance of the relevant industrial safety regulations, i.e. regulation concerning reliability in operation etc.. The operator has the duty of care to plan measures which guarantee an orderly operation and to control their realization. Danger references In case of wrong product selection, improper use and failure to carry out maintenance there is the danger that damages can be caused to persons and objects. This may result from: - uncontrolled with high dynamic energy whipping hose ends - dangerous spreading of compressed air or individual particles / coupling parts - impairment of function of connected installations or tools. In particular the operator must guarantee that - the coupling is always used according to specification. - the coupling is always used in a perfect, functionable way. - the operation instruction is always available to the operators in a complete and readable form. - the operating personnel is sufficiently informed about the operation and safety instructions of the coupling. - for repair, couplings are returned to our factory. - during operation of coupling, no safety devices are removed and/or set out of function. - coupling is not pressurized before mounting/dismounting of the coupling. After assembly and installation as well as before the first use of the coupling the following items have to be observed: - check again whether all screw type connections are firmly fixed. - before the first use of the coupling, a functional test must be carried out (see maintenance and functional test). Application according to specification The appropriate application is guaranteed only then if - the coupling connection consists of a self sealing coupling and the following thru type adaptor WALTHER thru type adaptor of Series SP made of hardened steel - medium compressed air is used - working pressures of 0 12 bar are available - temperature is between 0 C and smaller 60 C. - during selection of connections the maximum permissible working pressure of the connection is considered. - external working loads such as tension, bending and transverse loads on the coupling connections shall be avoided, if possible, because these can reduce the permissible working pressure. Revision : A Datum: Ersteller : NH Geprüft : JK 1-LS Internetversion-englisch.doc 2/4

281 Operation Instruction for Compressed Air Safety Coupling Type LS-009 Carl Kurt Walther GmbH & Co.KG Postfach Haan Westfalenstraße Haan Tel /567-0 Fax 02129/ The connection and disconnection process is carried out by hand. There is no pressure switching threshold in the depressurized condition so that the adaptor can only be released in one unlocking step from the coupling. Installation instruction The coupling has to be installed into a supply network under due consideration of the accident prevention rules in such a way that - a proper operation according to the operation instruction is guaranteed. - the coupling is mainly used on the supply side and the thru type adaptor is mainly used on the consumer side. - external damages of the unit as well as all movable parts are excluded. Before the coupling is installed at a pipe system it must be guaranteed that the pipe system is sufficiently rinsed/purged and/or cleaned. All components of the coupling have to be protected against dirt and damages. After finishing of the assembly works a functional test is to be carried out according to the operation instruction for both conditions the pressurized and the depressurized. Maintenance and functional test In order to always guarantee function of the coupling and protection of the operator it is necessary to carry out a maintenance and functional test at least twice a year. The coupling is not greased or oiled by the factory. In case of a maintenance no lubricants or means of preservation are supposed to be inserted into the coupling. The maintenance includes the following items: - external visual check for damages and dirt at the coupling and the used adaptors. - dirt in the external accessible functional area (sealing area, operating elements) is to be removed by simple wiping. If damaged, broken or corroded parts are available or in case of serious dirt in the functional area which is not accessible from the outside the coupling must be disassembled and sent to the manufacturer's factory for repair. This is also valid for worn out, embrittled and overaged seals. The functional test includes the following items: As described in the operation instruction the coupling is repeatedly connected and disconnected with a pressure of at least 3 bar and a hose of at least 3 m length. In this case attention is to be paid to the following: - perfect, smooth function when connecting and disconnecting. - the safety function (in this case the adaptor jumps several millimeters out of the coupling and is prevented from the complete separation of the coupling by a second locking system) must be available; thus no dangerous "back kick" must occur. - tightness of the coupling when connected and disconnected. In case of stated malfunctions or leakages the coupling is to be returned to the manufacturer's factory for repair. Revision : A Datum: Ersteller : NH Geprüft : JK 1-LS Internetversion-englisch.doc 3/4

282 Operation Instruction for Compressed Air Safety Coupling Type LS-009 Carl Kurt Walther GmbH & Co.KG Postfach Haan Westfalenstraße Haan Tel /567-0 Fax 02129/ Operation instruction Connection: Simplest connection by plugging. The one-hand operation is obtained by the well-proven automatic lock. The thru type adaptor must completely be inserted into the coupling until stop (picture 2). The locking mechanism is activated in this case and the coupling locks safely. The lock can be checked by a slight pulling at the hose. If the hose part cannot be moved out of the coupling any more, it is locked safely. Disconnection First unlocking step and venting. First of all only the first unlocking step is released (picture 3) by means of pushing the locking sleeve into connection piece direction. The adaptor jumps several millimeters out of the coupling and is prevented from the complete separation of the coupling by a second locking system. The coupling valve closes in this case and the air included in the hose of the adaptor side escapes (picture 4). escaping air Second unlocking step.- Only if the pressure on the adaptor side falls below the safety relevant switching threshold the second locking system can be released, too.. For this purpose the locking sleeve must completely be pushed back again (picture 5). Now the adaptor can be separated completely and safely from the coupling (picture 6). So the dangerous "back kick" is absolutely avoided. Revision : A Datum: Ersteller : NH Geprüft : JK 1-LS Internetversion-englisch.doc 4/4

283 Operation Instruction for Compressed Air Safety Coupling Type LS-012 Carl Kurt Walther GmbH & Co.KG Postfach Haan Westfalenstraße Haan Tel /567-0 Fax 02129/ LS WALPRESTA Compressed Air Safety Coupling Safety instruction Use according to its specification Installation instruction Maintenance and functional test Operation instruction The original is the German version. Revision : A Datum: Ersteller : NH Geprüft : JK 1-LS Internetversion-englisch.doc 1/4

284 Operation Instruction for Compressed Air Safety Coupling Type LS-012 Carl Kurt Walther GmbH & Co.KG Postfach Haan Westfalenstraße Haan Tel /567-0 Fax 02129/ This coupling is a high-quality product designed with particular focus on high functionality, simple handling, safety and reliability. As technical appliance, the coupling is used in the industrial field as well as by operators who have been instructed by qualified personnel in the handling of compressed air technical installations/tools. We offer an individual customer service and are ready to support you without obligation in all questions regarding the use and operation of the coupling or probably arising problems. Don't hesitate to contact our customer service, we will be pleased to assist you. Safety instructions The use of a safety coupling does not relieve the operator from the observance of the relevant industrial safety regulations, i.e. regulation concerning reliability in operation etc.. The operator has the duty of care to plan measures which guarantee an orderly operation and to control their realization. Danger references In case of wrong product selection, improper use and failure to carry out maintenance there is the danger that damages can be caused to persons and objects. This may result from: - uncontrolled with high dynamic energy whipping hose ends - dangerous spreading of compressed air or individual particles / coupling parts - impairment of function of connected installations or tools. In particular the operator must guarantee that - the coupling is always used according to specification. - the coupling is always used in a perfect, functionable way. - the operation instruction is always available to the operators in a complete and readable form. - the operating personnel is sufficiently informed about the operation and safety instructions of the coupling. - for repair, couplings are returned to our factory. - during operation of coupling, no safety devices are removed and/or set out of function. - coupling is not pressurized before mounting/dismounting of the coupling. After ssembly and installation as well as before the first use of the coupling the following items have to be observed: - check again whether all screw type connections are firmly fixed. - before the first use of the coupling, a functional test must be carried out (see maintenance and functional test). Application according to specification The appropriate application is guaranteed only then if - the coupling connection consists of a self sealing coupling and the following thru type adaptor WALTHER thru type adaptor of Series LP medium compressed air is used - working pressures of 0 16 bar are available - temperature is between 0 C and smaller 60 C. - during selection of connections the maximum permissible working pressure of the connection is considered. - external working loads such as tension, bending and transverse loads on the coupling connections shall be avoided, if possible, because these can reduce the permissible working pressure. The connection and disconnection process is carried out by hand. Revision : A Datum: Ersteller : NH Geprüft : JK 1-LS Internetversion-englisch.doc 2/4

285 Operation Instruction for Compressed Air Safety Coupling Type LS-012 Carl Kurt Walther GmbH & Co.KG Postfach Haan Westfalenstraße Haan Tel /567-0 Fax 02129/ Installation instruction The coupling has to be installed into a supply network under due consideration of the accident prevention rules in such a way that - a proper operation according to the operation instruction is guaranteed. - the coupling is mainly used on the supply side and the thru type adaptor is mainly used on the consumer side. - external damages of the unit as well as all movable parts are excluded. Before the coupling is installed at a pipe system it must be guaranteed that the pipe system is sufficiently rinsed/purged and/or cleaned. All components of the coupling have to be protected against dirt and damages. After finishing of the assembly works a functional test is to be carried out according to the operation instruction for both conditions the pressurized and the depressurized. Maintenace and functional test In order to always guarantee function of the coupling and protection of the operator it is necessary to carry out a maintenance and functional test at least twice a year. The coupling is not greased or oiled by the factory. In case of a maintenance no lubricants or means of preservation are supposed to be inserted into the coupling. The maintenance includes the following items: - external visual check for damages and dirt at the coupling and the used adaptors. - dirt in the external accessible functional area (sealing area, operating elements) is to be removed by simple wiping. If damaged, broken or corroded parts are available or in case of serious dirt in the functional area which is not accessible from the outside the coupling must be disassembled and returned to the manufacturer's factory for repair. This is also valid for worn out, embrittled and overaged seals. The functional test includes the following items: As described in the operation instruction the coupling is repeatedly connected and disconnected with a pressure of at least 3 bar and a hose of at least 3 m length. In this case attention is to be paid to the following: - perfect, smooth function when connecting and disconnecting. - the safety function has to be available; thus no dangerous "back-kick" must occur. - tightness of the coupling when connected and disconnected. In case of stated malfunctions or leakages the coupling is to be returned to the manufacturer's factory for repair. Revision : A Datum: Ersteller : NH Geprüft : JK 1-LS Internetversion-englisch.doc 3/4

286 Operation Instruction for Compressed Air Safety Coupling Type LS-012 Carl Kurt Walther GmbH & Co.KG Postfach Haan Westfalenstraße Haan Tel /567-0 Fax 02129/ Operation instruction Connection: Simplest connection by plugging. The one-hand operation is obtained by the well-proven automatic lock. The thru type adaptor must completely be inserted into the coupling until stop (picture 1). The locking mechanism is activated in this case and the coupling locks safely. The lock can be checked by a slight pulling at the hose. If the hose part cannot be moved out of the coupling any more, it is locked safely. In the second step the valve is opened by turning of the hand lever by 90. Only now the medium flow is possible (picture 2). Disconnection: First unlocking step and venting. The valve is closed by a 90 turning back of the hand lever and so the media flow is interrupted (picture 3). The air included in the hose of the adaptor side escapes (picture 4). entweichende Luft Second unlocking step. Only if the pressure on the adaptor side falls below the safety relevant switching threshold the second locking system can be released, too. For this purpose the locking sleeve is to be pushed into the hand lever direction (picture 5). Now the adaptor can be separated completely and safely from the coupling (picture 6). So the dangerous "back kick" is absolutely avoided. Revision : A Datum: Ersteller : NH Geprüft : JK 1-LS Internetversion-englisch.doc 4/4

287 Operation Instruction for Compressed Air Safety Coupling Type LS-023 Carl Kurt Walther GmbH & Co.KG Postfach Haan Westfalenstraße Haan Tel /567-0 Fax 02129/ LS WALPRESTA Compressed Air Safety Coupling Safety instruction Use according to its specification Installation instruction Maintenance and functional test Operation instruction The original is the German version. Revision : A Datum: Ersteller : NH Geprüft : JK 1-LS Internetversion-englisch.doc 1/4

288 Operation Instruction for Compresse dair Safety Coupling Type LS-023 Carl Kurt Walther GmbH & Co.KG Postfach Haan Westfalenstraße Haan Tel /567-0 Fax 02129/ This coupling is a high-quality product designed with particular focus on high functionality, simple handling, safety and reliability. As technical appliance, the coupling is used in the industrial field as well as by operators who have been instructed by qualified personnel in the handling of compressed air technical installations/tools. We offer an individual customer service and are ready to support you without obligation in all questions regarding the use and operation of the coupling or probably arising problems. Don't hesitate to contact our customer service, we will be pleased to assist you. Safety instructions The use of a safety coupling does not relieve the operator from the observance of the relevant industrial safety regulations, i.e. regulation concerning reliability in operation etc.. The operator has the duty of care to plan measures which guarantee an orderly operation and to control their realization. Danger references In case of wrong product selection, improper useand failure to carry out maintenance there is the danger that damages can be caused to persons and objects. This may result from: - uncontrolled with high dynamic energy whipping hose ends - dangerous spreading of compressed air or individual particles / coupling parts - impairment of function of connected installations or tools. In particular the operator must guarantee that - the coupling is always used according to specification. - the coupling is always used in a perfect, functionable way. - the operation instruction is always available to the operators in a complete and readable form. - the operating personnel is sufficiently informed about the operation and safety instructions of the coupling. - for repair, couplings are returned to our factory. - during operation of coupling, no safety devices are removed and/or set out of function. - coupling is not pressurized before mounting/dismounting of the coupling. After assembly and installation as well as before the first use of the coupling the following items have to be observed: - check again whether all screw type connections are firmly fixed. - before the first use of the coupling, a functional test must be carried out (see maintenance and functional test). Application according to specification The appropriate application is guaranteed only then if - the coupling connection consists of a self sealing coupling and the following thru type adaptor: WALTHER thru type adaptor of Series LP-019 or LS medium compressed air is used - working pressures of 0 16 bar are available - temperature is between 0 C and smaller 60 C. - during selection of connections the maximum permissible working pressure of the connection is considered. - external working loads such as tension, bending and transverse loads on the coupling connections shall be avoided, if possible, because these can reduce the permissible working pressure. The connection and disconnection process ist carried out by hand. Revision : A Datum: Ersteller : NH Geprüft : JK 1-LS Internetversion-englisch.doc 2/4

289 Operation Instruction for Compresse dair Safety Coupling Type LS-023 Carl Kurt Walther GmbH & Co.KG Postfach Haan Westfalenstraße Haan Tel /567-0 Fax 02129/ Installation instruction The coupling has to be installed into a supply network under due consideration of the accident prevention rules in such a way that - a proper operation according to the operation instruction is guaranteed. - the coupling is mainly used on the supply side and the thru type adaptor is mainly used on the consumer side. - external damages of the unit as well as all movable parts are excluded. Before the coupling is installed at a pipe system it must be guaranteed that the pipe system is sufficiently rinsed/purged and/or cleaned. All components of the coupling have to be protected against dirt and damages. After finishing of the assembly works a functional test is to be carried out according to the operation instruction for both conditions the pressurized and the depressurized. Maintenance and functional test In order to always guarantee function of the coupling and protection of the operator it is necessary to carry out a maintenance and functional test at least twice a year. The coupling is not greased or oiled by the factory. In case of a maintenance no lubricants or means of preservation are supposed to be inserted into the coupling. The maintenance includes the following items: - external visual check for damages and dirt at the coupling and the used adaptors. - dirt in the external accessible functional area (sealing area, operating elements) is to be removed by simple wiping. If damaged, broken or corroded parts are available or in case of serious dirt in the functional area which is not accessible from the outside the coupling must be disassembled and sent to the manufacturer's factory for repair. This is also valid for worn out, embrittled and overaged seals. The functional test includes the following items: As described in the operation instruction the coupling is repeatedly connected and disconnected with a pressure of at least 3 bar and a hose of at least 3 m length. In this case attention is to be paid to the following: - perfect, smooth function when connecting and disconnecting. - the safety function has to be available; thus no dangerous "back-kick" must occur. - tightness of the coupling when connected and disconnected. In case of stated malfunctions or leakages the coupling is to be returned to the manufacturer's factory for repair. Revision : A Datum: Ersteller : NH Geprüft : JK 1-LS Internetversion-englisch.doc 3/4

290 Operation Instruction for Compresse dair Safety Coupling Type LS-023 Carl Kurt Walther GmbH & Co.KG Postfach Haan Westfalenstraße Haan Tel /567-0 Fax 02129/ Operation instruction Connection: Simplest connection by plugging. The one-hand operation is obtained by the well-proven automatic lock. The thru type adaptor must completely be inserted into the coupling until stop (picture 1). The locking mechanism is activated in this case and the coupling locks safely. The lock can be checked by a slight pulling at the hose. If the hose part cannot be moved out of the coupling any more, it is locked safely. In the second step the valve is opened by turning of the hand lever by 90. Only now the medium flow is possible (picture 2). Disconnection: First unlocking step and venting. The valve is closed by a 90 turning back of the hand lever and so the media flow is interrupted (picture 3). The air included in the hose of the adaptor side escapes (picture 4). escaping air Second unlocking step. Only if the pressure on the adaptor side falls below the safety relevant switching threshold the second locking system can be released, too. For this purpose the locking sleeve is to be pushed into the hand lever direction (picture 5). Now the adaptor can be separated completely and safely from the coupling (picture 6). So the dangerous "back kick" is absolutely avoided. Revision : A Datum: Ersteller : NH Geprüft : JK 1-LS Internetversion-englisch.doc 4/4

291 Operation Instruction for Compressed Air Safety Coupling Type LS-038 Carl Kurt Walther GmbH & Co.KG Postfach Haan Westfalenstraße Haan Tel /567-0 Fax 02129/ LS WALPRESTA Compressed Air Safety Coupling Safety instruction Use according to its specification Installation instruction Maintenance and functional test Operation instruction The original is the German version. Revision : A Datum: Ersteller : NH Geprüft : JK 1-LS Internetversion-englisch.doc 1/4

292 Operation Instruction for Compressed Air Safety Coupling Type LS-038 Carl Kurt Walther GmbH & Co.KG Postfach Haan Westfalenstraße Haan Tel /567-0 Fax 02129/ This coupling is a high-quality product designed with particular focus on high functionality, simple handling, safety and reliability. As technical appliance, the coupling is used in the industrial field as well as by operators who have been instructed by qualified personnel in the handling of compressed air technical installations/tools. We offer an individual customer service and are ready to support you without obligation in all questions regarding the use and operation of the coupling or probably arising problems. Don't hesitate to contact our customer service, we will be pleased to assist you. Safety instructions The use of a safety coupling does not relieve the operator from the observance of the relevant industrial safety regulations, i.e. regulation concerning reliability in operation etc.. The operator has the duty of care to plan measures which guarantee an orderly operation and to control their realization. Danger references In case of wrong product selection, improper use and failure to carry out maintenance there is the danger that damages can be caused to persons and objects. This may result from: - uncontrolled with high dynamic energy whipping hose ends - dangerous spreading of compressed air or individual particles / coupling parts - impairment of function of connected installations or tools. In particular the operator must guarantee that - the coupling is always used according to specification. - the coupling is always used in a perfect, functionable way. - the operation instruction is always available to the operators in a complete and readable form. - the operating personnel is sufficiently informed about the operation and safety instructions of the coupling. - for repair, couplings are returned to our factory. - during operation of coupling, no safety devices are removed and/or set out of function. - coupling is not pressurized before mounting/dismounting of the coupling. After assembly and installation as well as before the first use of the coupling the following items have to be observed: - check again whether all screw type connections are firmly fixed. - before the first use of the coupling, a functional test must be carried out (see maintenance and functional test). Application according to specification The appropriate application is guaranteed only then if - the coupling connection consists of a self sealing coupling and the following thru type adaptor: WALTHER thru type adaptor of Series LS medium compressed air is used - working pressures of 0 16 bar are available - temperature is between 0 C and smaller 60 C. - during selection of connections the maximum permissible working pressure of the connection is considered. - external working loads such as tension, bending and transverse loads on the coupling connections shall be avoided, if possible, because these can reduce the permissible working pressure. The connection and disconnection process is carried out by hand. Revision : A Datum: Ersteller : NH Geprüft : JK 1-LS Internetversion-englisch.doc 2/4

293 Operation Instruction for Compressed Air Safety Coupling Type LS-038 Carl Kurt Walther GmbH & Co.KG Postfach Haan Westfalenstraße Haan Tel /567-0 Fax 02129/ Installation instruction The coupling has to be installed into a supply network under due consideration of the accident prevention rules in such a way that - a proper operation according to the operation instruction is guaranteed. - the coupling is mainly used on the supply side and the thru type adaptor is mainly used on the consumer side. - external damages of the unit as well as all movable parts are excluded. Before the coupling is installed at a pipe system it must be guaranteed that the pipe system is sufficiently rinsed/purged and/or cleaned. All components of the coupling have to be protected against dirt and damages. After finishing of the assembly works a functional test is to be carried out according to the operation instruction for both conditions the pressurized and the depressurized. Maintenance and functional test In order to always guarantee function of the coupling and protection of the operator it is necessary to carry out a maintenance and functional test at least twice a year. The coupling is not greased or oiled by the factory. In case of a maintenance no lubricants or means of preservation are supposed to be inserted into the coupling. The maintenance includes the following items: - external visual check for damages and dirt at the coupling and the used adaptors. - dirt in the external accessible functional area (sealing area, operating elements) is to be removed by simple wiping. If damaged, broken or corroded parts are available or in case of serious dirt in the functional area which is not accessible from the outside the coupling must be disassembled and sent to the manufacturer's factory for repair. This is also valid for worn out, embrittled and overaged seals. The functional test includes the following items: As described in the operation instruction the coupling is repeatedly connected and disconnected with a pressure of at least 3 bar and a hose of at least 3 m length. In this case attention is to be paid to the following: - perfect, smooth function when connecting and disconnecting. - the safety function has to be available; thus no dangerous "back-kick" must occur. - tightness of the coupling when connected and disconnected. In case of stated malfunctions or leakages the coupling is to be returned to the manufacturer's factory for repair. Revision : A Datum: Ersteller : NH Geprüft : JK 1-LS Internetversion-englisch.doc 3/4

294 Operation Instruction for Compressed Air Safety Coupling Type LS-038 Carl Kurt Walther GmbH & Co.KG Postfach Haan Westfalenstraße Haan Tel /567-0 Fax 02129/ Operation instruction Connection: Simplest connection by plugging. The one-hand operation is obtained by the well-proven automatic lock. The thru type adaptor must completely be inserted into the coupling until stop (picture 1). The locking mechanism is activated in this case and the coupling locks safely. The lock can be checked by a slight pulling at the hose. If the hose part cannot be moved out of the couplingan any more, it is locked safely. In the second step the valve is opened by turning of the hand lever by 90. Only now the medium flow is possible (picture 2). Disconnection: First unlocking step and venting. The valve is closed by a 90 turning back of the hand lever and so the media flow is interrupted (picture 3). The air included in the hose of the adaptor side escapes (picture 4). escaping air Second unlocking step. Only if the pressure on the adaptor side falls below the safety relevant switching threshold the second locking system can be released, too. For this purpose the locking sleeve is to be pushed into the hand lever direction (picture 5). Now the adaptor can be separated completely and safely from the coupling (picture 6). So the dangerous "back kick" is absolutely avoided. Revision : A Datum: Ersteller : NH Geprüft : JK 1-LS Internetversion-englisch.doc 4/4

295 Operation Instruction for Compressed Air Safety Coupling Type LS-C.. Carl Kurt Walther GmbH & Co.KG Postfach Haan Westfalenstraße Haan Tel /567-0 Fax 02129/ LS-C LS-C LS-C WALPRESTA-Serie Compressed Air Safety Coupling Safety instruction Use according to its specification Installation instruction Maintenance and functional test Operation instruction The original is the German version. Revision : A Datum: Ersteller : NH Geprüft : JK 1-LS-C..-0-Internetversion-englisch.doc 1/4

296 . Operation Instruction for Compressed Air Safety Coupling Type LS-C.. Carl Kurt Walther GmbH & Co.KG Postfach Haan Westfalenstraße Haan Tel /567-0 Fax 02129/ This coupling is a high-quality product designed with particular focus on high functionality, simple handling, safety and reliability. As technical appliance, the coupling is used in the industrial field as well as by operators who have been instructed by qualified personnel in the handling of compressed air technical installations/tools. We offer an individual customer service and are ready to support you without obligation in all questions regarding the use and operation of the coupling or probably arising problems. Don't hesitate to contact our customer service, we will be pleased to assist you. Safety instructions The use of a safety coupling does not relieve the operator from the observance of the relevant industrial safety regulations, i.e. regulation concerning reliability in operation etc.. The operator has the duty of care to plan measures which guarantee an orderly operation and to control their realization. Danger references In case of wrong product selection, improper use and failure to carry out maintenance there is the danger that damages can be caused to persons and objects. This may result from: - uncontrolled with high dynamic energy whipping hose ends - dangerous spreading of compressed air or individual particles / coupling parts - impairment of function of connected installations or tools. In particular the operator must guarantee that - the coupling is always used according to specification. - the coupling is always used in a perfect, functionable way. - the operation instruction is always available to the operators in a complete and readable form. - the operating personnel is sufficiently informed about the operation and safety instructions of the coupling. - for repair, couplings are returned to our factory. - during operation of coupling, no safety devices are removed and/or set out of function. - coupling is not pressurized before mounting/dismounting of the coupling. After assembly and installation as well as before the first use of the coupling the following items have to be observed: - check again whether all screw type connections are firmly fixed. - before the first use of the coupling, a functional test must be carried out (see maintenance and functional test). Application according to specification The appropriate application is guaranteed only if - the coupling connection consists of a self sealing coupling and a hardened steel thru type adaptor in conformity to ISO 6150-C. - medium compressed air is used - working pressures of 0 12 bar at LS-C bar at LS-C bar at LS-C11 are available - temperature is between 0 C and smaller 60 C. - during selection of connections the maximum permissible working pressure of the connection is considered. Revision : A Datum: Ersteller : NH Geprüft : JK 1-LS-C..-0-Internetversion-englisch.doc 2/4

297 . Operation Instruction for Compressed Air Safety Coupling Type LS-C.. Carl Kurt Walther GmbH & Co.KG Postfach Haan Westfalenstraße Haan Tel /567-0 Fax 02129/ external working loads such as tension, bending and transverse loads on the coupling connections shall be avoided, if possible, because these can reduce the permissible working pressure. The connection and disconnection process is carried out by hand. Installation instruction The coupling has to be installed into a supply network under due consideration of the accident prevention rules in such a way that - a proper operation according to the operation instruction is guaranteed. - the coupling is mainly used on the supply side and the thru type adaptor is mainly used on the consumer side. - external damages of the unit as well as all movable parts are excluded. Before the coupling is installed at a pipe system it must be guaranteed that the pipe system is sufficiently rinsed/purged and/or cleaned. All components of the coupling have to be protected against dirt and damages. After finishing of the assembly works a functional test is to be carried out according to the operation instruction for both conditions the pressurized and the depressurized. Maintenance and functional test In order to always guarantee function of the coupling and protection of the operator it is necessary to carry out a maintenance and functional test at least twice a year. The coupling is not greased or oiled by the factory. In case of a maintenance no lubricants or means of preservation are supposed to be inserted into the coupling. The maintenance includes the following items: - external visual check for damages and dirt at the coupling and the used adaptors. - dirt in the external accessible functional area (sealing area, operating elements) is to be removed by simple wiping. If damaged, broken or corroded parts are available or in case of serious dirt in the functional area which is not accessible from the outside the coupling must be disassembled and sent to the manufacturer's factory for repair. This is also valid for worn out, embrittled and overaged seals. The functional test includes the following items: As described in the operation instruction the coupling is repeatedly connected and disconnected with a pressure of at least 3 bar and a hose of at least 3 m length. In this case attention is to be paid to the following: - perfect, smooth function when connecting and disconnecting. - the safety function (in this case the adaptor jumps several millimeters out of the coupling and is prevented from the complete separation of the coupling by a second locking system) must be available; thus no dangerous "back kick" must occur. - tightness of the coupling when connected and disconnected. In case of stated malfunctions or leakages the coupling is to be returned to the manufacturer's factory for repair. Revision : A Datum: Ersteller : NH Geprüft : JK 1-LS-C..-0-Internetversion-englisch.doc 3/4

298 . Operation Instruction for Compressed Air Safety Coupling Type LS-C.. Carl Kurt Walther GmbH & Co.KG Postfach Haan Westfalenstraße Haan Tel /567-0 Fax 02129/ Operation instruction Connection: Simplest connection by plugging. The one-hand operation is obtained by the well-proven automatic lock. The thru type adaptor must completely be inserted into the coupling until stop (picture 2). The locking mechanism is activated in this case und the coupling locks safely. The lock can be checked by a slight pulling at the hose. If the hose part cannot be moved out of the coupling any more, it is locked safely. Disconnection: First unlocking step and venting. First of all only the first unlocking step is released (picture 3) by pressing of the unlocking button. The adaptor jumps several millimeters out of the coupling and is prevented from the complete separation of the coupling by a second locking system. In doing so the coupling valve closes and the included air in the hose of the adaptor side escapes (picture 4). escaping air Second unlocking step. Only if the pressure on the adaptor side falls below the safety relevant switching threshold the second locking system may be released. For this purpose the thru type adaptor is to be pushed some few millimeters into the coupling (picture 5). Thus the safety locking is released and the adaptor can be pulled out without resistance (picture 6). This procedure prevents the dangerous "back kick" in case of a correct operation. Revision : A Datum: Ersteller : NH Geprüft : JK 1-LS-C..-0-Internetversion-englisch.doc 4/4

299 Operation Instruction for Compressed Air Safety Coupling Type LS-K06 Carl Kurt Walther GmbH & Co.KG Postfach Haan Westfalenstraße Haan Tel /567-0 Fax 02129/ LS-K WALPRESTA-Serie Compressed Air Safety Coupling Safety instruction Use according to its specification Installation instruction Maintenance and functional test Operation instruction The original is the German version. Revision : A Datum: Ersteller : NH Geprüft : JK 1-LS-K06-0-Internetversion-englisch.doc 1/4

300 Operation Instruction for Compressed Air Safety Coupling Type LS-K06 Carl Kurt Walther GmbH & Co.KG Postfach Haan Westfalenstraße Haan Tel /567-0 Fax 02129/ This coupling is a high-quality product designed with particular focus on high functionality, simple handling, safety and reliability. As technical appliance, the coupling is used in the industrial field as well as by operators who have been instructed by qualified personnel in the handling of compressed air technical installations/tools. We offer an individual customer service and are ready to support you without obligation in all questions regarding the use and operation of the coupling or probably arising problems. Don't hesitate to contact our customer service, we will be pleased to assist you. Safety instructions The use of a safety coupling does not relieve the operator from the observance of the relevant industrial safety regulations, i.e. regulation concerning reliability in operation etc.. The operator has the duty of care to plan measures which guarantee an orderly operation and to control their realization. Danger references In case of wrong product selection, improper use and failure to carry out maintenance there is the danger that damages can be caused to persons and objects. This may result from: - uncontrolled with high dynamic energy whipping hose ends - dangerous spreading of compressed air or individual particles / coupling parts - impairment of function of connected installations or tools. In particular the operator must guarantee that - the coupling is always used according to specification. - the coupling is always used in a perfect, functionable way. - the operation instruction is always available to the operators in a complete and readable form. - the operating personnel is sufficiently informed about the operation and safety instructions of the coupling. - for repair, couplings are returned to our factory. - during operation of coupling, no safety devices are removed and/or set out of function. - coupling is not pressurized before mounting/dismounting of the coupling. After assembly and installation as well as before the first use of the coupling the following items have to be observed: - check again whether all screw type connections are firmly fixed. - before the first use of the coupling, a functional test must be carried out (see maintenance and functional test). Application accoding to specification The appropriate application is guaranteed only if - the coupling connection consists of a self sealing coupling and the following thru type adaptor WALTHER thru type adaptor of Series LP of hardened steel - medium compressed air is used - working pressures 0 12 bar are available - temperature is between 0 C and smaller 60 C. - during selection of connections the maximum permissible working pressure of the connection is considered. - external working loads such as tension, bending and transverse loads on the coupling connections shall be avoided, if possible, because these can reduce the permissible working pressure. The connection and disconnection process is carried out by hand. Revision : A Datum: Ersteller : NH Geprüft : JK 1-LS-K06-0-Internetversion-englisch.doc 2/4

301 Operation Instruction for Compressed Air Safety Coupling Type LS-K06 Carl Kurt Walther GmbH & Co.KG Postfach Haan Westfalenstraße Haan Tel /567-0 Fax 02129/ Installation instruction The coupling has to be installed into a supply network under due consideration of the accident prevention rules in such a way that - a proper operation according to the operation instruction is guaranteed. - the coupling is mainly used on the supply side and the thru type adaptor is mainly used on the consumer side. - external damages of the unit as well as all movable parts are excluded. Before the coupling is installed at a pipe system it must be guaranteed that the pipe system is sufficiently rinsed/purged and/or cleaned. All components of the coupling have to be protected against dirt and damages. After finishing of the assembly works a functional test is to be carried out according to the operation instruction for both conditions the pressurized and the depressurized. Maintenance and functional test In order to always guarantee function of the coupling and protection of the operator it is necessary to carry out a maintenance and functional test at least twice a year. The coupling is not greased or oiled by the factory. In case of a maintenance no lubricants or means of preservation are supposed to be inserted into the coupling. The maintenance includes the following items: - external visual check for damages and dirt at the coupling and the used adaptors. - dirt in the external accessible functional area (sealing area, operating elements) is to be removed by simple wiping. If damaged, broken or corroded parts are available or in case of serious dirt in the functional area which is not accessible from the outside the coupling must be disassembled and sent to the manufacturer's factory for repair. This is also valid for worn out, embrittled and overaged seals. The functional test includes the following items: As described in the operation instruction the coupling is repeatedly connected and disconnected with a pressure of at least 3 bar and a hose of at least 3 m length. In this case attention is to be paid to the following: - perfect, smooth function when connecting and disconnecting. - the safety function (in this case the adaptor jumps several millimeters out of the coupling and is prevented from the complete separation of the coupling by a second locking system) must be available; thus no dangerous "back kick" must occur. - tightness of the coupling when connected and disconnected. In case of stated malfunctions or leakages the coupling is to be returned to the manufacturer's factory for repair. Revision : A Datum: Ersteller : NH Geprüft : JK 1-LS-K06-0-Internetversion-englisch.doc 3/4

302 Operation Instruction for Compressed Air Safety Coupling Type LS-K06 Carl Kurt Walther GmbH & Co.KG Postfach Haan Westfalenstraße Haan Tel /567-0 Fax 02129/ Operation instruction Connection: Simplest connection by plugging. The one-hand operation is obtained by the well-proven automatic lock. The thru type adaptor must completely be inserted into the coupling until stop (picture 2). The locking mechanism is activated in this case und the coupling locks safely. The lock can be checked by a slight pulling at the hose. If the hose part cannot be moved out of the coupling any more, it is locked safely. Disconnection: First unlocking step and venting. First of all only the first unlocking step is released (picture 3) by pushing of the locking sleeve into connection piece direction. The adaptor jumps several millimeters out of the coupling and is prevented from the complete separation of the coupling by a second locking system. In doing so the coupling valve closes and the included air in the hose of the adaptor side escapes (picture 4). escaping air Second unlocking step. Only if the pressure on the adaptor side falls below the safety relevant switching theshold the second locking system may be released. For this purpose the locking sleeve is to be moved into hose direction (picture 5). Now the adaptor can be separated completely and safely from the coupling (picture 6). This procedure prevents the dangerous "back kick" in case of a correct operation. Revision : A Datum: Ersteller : NH Geprüft : JK 1-LS-K06-0-Internetversion-englisch.doc 4/4

303 Operating Instruction Revision B Datum Ersteller NH This operating instruction is not subject to the updating Self Sealing Coupling Low Pressure Series 1-LV LV optional features: OV 1

304 This coupling is a quality product, in which special attention has been paid to high functionality, ease of operation, safety and reliability. As an item of technical equipment this tool-changer is intended for use in the commercial, industrial area and for operators, who have been trained by specialists in the handling of technical systems / tools. Customer care: As part of our individual customer care we will be happy to assist you in questions relating to use and operation and on any problems encountered. Service and maintenance: In order to maintain the high technical performance capability and reliability of your docking system over many years, we recommend regular inspection and maintenance. We can thereby offer you optimum support by our Customer Service department and the conclusion of a service and maintenance contract. Please ask for a quotation. Carl Kurt Walther GmbH & Co. KG PO Box Haan Westfalenstraße 2 Tel.: +49 (0) Fax: +49 (0) info@walther-praezision.de Internet: Contact: Application technology and service Holger R. Figge Telephone: (02129) Telefax: (02129) Handy: (0162) hfigge@walther-praezision.de Further addresses and telephone numbers of contacts can be found on the Internet on our homepage under Service / Customer service. 2

305 Operating Instruction Type LV-004 List of Contents 1 List of Contents 1 LIST OF CONTENTS GENERAL WARRANTY SAFETY INSTRUCTION PRODUCT DESCRIPTION OF THE SELF SEALING COUPLING INTENDED USE TECHNICAL DATA OPTIONAL FEATURES INSTALLATION INSTRUCTION GENERAL OPERATING INSTRUCTION CONNECTION PROCESS DISCONNECTION PROCESS MAINTENANCE INSTRUCTION MAINTENANCE AND FUNCTIONAL TEST Maintenance includes following items: Functional test includes following items: LUBRICATION! STORAGE SHUT-DOWN ORDER NUMBER CODE INDEX

306 Operating Instruction Type LV-004 General 2 General This manual contains all regulations for operation, commissioning and maintenance of the locking coupling elementself sealing coupling elements. All information and notes in this operating manual were collated while taking into consideration the valid regulations, the current engineering related status of development as well as our many years of experience and acquired knowledge. Translations of this operating manual were also produced according to the best of knowledge. However, we cannot assume liability for any translation errors. The German version provided for this operating manual is considered the authoritative version. The actual scope of delivery can deviate from the explanations and graphic representations described herein under certain circumstances, e.g. in the case of special designs, utilization of additional order options or because of state-of-the-art technical alterations. If you have any questions, please contact the manufacturer. This operating manual must be read carefully before starting work on or with the equipment, in particular before commissioning! The manufacturer assumes no liability for damage or faults arising from non-compliance with the instructions in this operating manual. The operating manual must be kept directly with the equipment and be accessible to all persons who work on or with the equipment. It is not permitted for the operating manual to be passed to third parties and if applicable this will incur damage compensation. All other rights reserved. Before commissioning the device must be checked for being not defective and its technically perfect function. The German version is the original. We reserve the right to make technical alterations to the product within the context of improving the usage properties and further development. The operating manual remains our property. Any reproduction, use by or communication to third parties incurs a penalty and will be pursued by court action (copyright law against unfair competition, BGB [German Civil Code]). All rights reserved in the case of a patent award (Paragraph 7, Section. 1 of the patent law - PG) or entry as a patented design (Paragraph 5, Section 4 of the patented design law - GMG). 4

307 Operating Instruction Type LV-004 Warranty 3 Warranty The warranty conforms to: the General Conditions for Delivery and Capacity of C.K. Walther GmbH & Co. KG of the state which was valid at the date of the purchase contract and the regulations agreed in the purchase contract. Wearing parts are generally excluded from the warranty. Typical wearing parts of products from company C.K. Walther GmbH & Co. KG are for example: seals springs 5

308 Operating Instruction Type LV-004 Safety Instruction 4 Safety Instruction Using these couplings does not release the customer from his obligation to comply with the pertinent work safety regulations e.g. operational safety ordinances, etc. The duty to take due care by the operator of the couplings includes planning measures to ensure proper operation and monitoring their implementation. Hazard notes If the wrong product has been selected or if there is improper use or maintenance has been omitted, then hazards arise and personal injuries and material damage can occur from: - Hazardous emission of fluid or individual particles/coupling parts - Function impairments of connected systems or tools - The metal parts of coupling and adaptor are not thermally protected. You can be burned if you touch these parts at high media temperatures. According to the ambient temperature valve lever and ring grip can also become unbearably hot. For that reason suitable, sufficiently long protective gloves should be worn. The operator must in particular make sure that - The couplings are only used according to the intended purpose. - The couplings are only operated in a perfect, functioning condition. - The operating manual is always in a legible condition and is available in its entirety to operating personnel. - The operating personnel are sufficiently acquainted with the working method and the safety notes for the coupling. - The coupling is sent to our factory for repair work. - During operation of the coupling, no safety devices are removed and/or deactivated. - Before installing or dismantling the coupling, you have made sure that the coupling has not been pressurized. After completing assembly and installation work and before commissioning the coupling, observe the following points: Check once again that all screw connections are securely fitted. Before commissioning the coupling, a function test must be carried out (see maintenance and function test). 6

309 Operating Instruction Type LV-004 Product description of the coupling 5 Product description of the self sealing coupling Coupling connection consists of: - self sealing coupling 1-LV self sealing adaptor 1-LV In case that both coupling halves are not connected they should be protected against external dirt and/or damages if required. For that purpose dust cap and dust plug are available. Possible comibinations : self sealing coupling 1-LV with dust plug 1-LP self sealing adaptor 1-LV with dust cap 1-LP Intended use - Coupling is only used as connection of two lines. - Connection and disconnection process is carried out by hand. - Coupling is especially suitable for the following media/applications: - air, water, hydraulic oil - and their subspecies (such as oxygen or oil with additives) - For all other possible applications, Walther-Präzision should be consulted. 5.2 Technical data - Working pressures of coupling depend on materials of individual parts. - When determing the working with standardized threaded connections, the highest permissible working pressure of the connection must be taken into account. - When selecting a suitable connection the following static pressure is possible: max. static Working pressure steel (bar) max. static Working pressure brass (bar) max. static Working pressure st. st. (bar) Cv-value Both sides Self sealing Cv-value One side Self sealing LV , The coupling is not determined for any types of use and technical values other than those listed here. - Safe operation is not guaranteed if the coupling is used contrary to ist intended use and technical values - The operator of the coupling is responsible for all personal injuries or material damage that occur from non-intended use and disregard of the technical values; the manufacturer assumes no responsibility in these cases. 5.3 Optional Features OV = without valve (z.b.: 1-LV OV 1-LV OV) 7

310 Operating Instruction Type LV-004 Installation instruction 6 Installation Instruction 6.1 General Subject to the general accident prevention regulations coupling is to be installed into a network in such a way that: - a satisfactory operation is guaranteed according to the operating instruction. - first of all self sealing coupling is used on line side and self sealing adaptor on consumer side. - external damage of the unit as well as all moving parts are excluded. Before self sealing coupling and the self sealing adaptor are installed at a pipeline network make sure that the pipeline network is sufficiently rinsed/blown out and/or cleaned. After the assembly works are finished a functional test is to be carried out with both, without pressure and under working pressure according to operating instruction. 8

311 Operating Instruction Type LV-004 Operating Instruction 7 Operating Instruction In order to avoid critical injuries of the staff and damage at the self sealing coupling during operation, coupling may be only used for the stated applications. 7.1 Connection process Before every couple cycle a visual check of coupling and adaptor is to be carried out. In case of recognizable, visible damage or deformations damaged parts are to be exchanged. Hold self sealing coupling firmly in one hand; with the other hand pull back locking sleeve. This has to be done against locking spring resistance. Push free half (coupling) with withdrawn locking sleeve axially centered onto plug part of fixed half (adaptor) until sensible resistance. Bring locking sleeve with support of locking spring into starting position. Self sealing coupling and self sealing adaptor are now mechanically locked. CAUTION Please take care that locking sleeve is in final position, i.e. that it is flush in front with the coupling housing as otherwise no perfect lock is guaranteed. 7.2 Disconnection process Withdraw locking sleeve against locking spring and take out coupling from self sealing adaptor. Caution! In case of an available pressure in the line connected by the coupling system a strong separation impulse - depending on the pressure - can be effective onto the coupling system during disconnection. For that reason the movable part of the coupling (free half) is to be firmly held in the hand to avoid injuries. 9

312 Operating Instruction Type LV-004 Maintenance and Functional Instruction 8 Maintenance Instruction Preventive maintenance measures WALTHER self sealing couplings are to be operated in such a manner that external damages to elements and all moving parts are avoided. 8.1 Maintenance and functional test In order to always guarantee function of the self sealing coupling and hence safety of operator, a maintenance and functional testing must be made in appropriate periods of time depending on operating conditions. In order to minimize operating forces and to extend service life of the self sealing coupling we recommend to slightly grease plug surfaces (see item 9.0) Maintenance includes following items: - A visual inspection of self sealing coupling and self sealing adaptor regarding damage and contamination has to be made. - Dirt at the functional area (sealing area, operating elements) which is easily accessible from outside should be removed by simply wiping-off. If there are damaged, torn or corroded parts, coupling must be dismounted and returned to manufacturer for repair. If worn or embrittled seals are found or if there is extreme dirt, the customer can decide whether he returns coupling unit to the manufacturer's factory or whether he repairs himself Functional test includes following items: As described in the operating instruction, coupling is several times connected, pressurized and then disconnected. In doing so, the following has to be observed: - Connection and disconnection process must be absolutely smooth. - Coupling must be absolutely leak-proof in connected and disconnected state. If there are damaged, torn or corroded parts, coupling must be dismounted and returned to manufacturer for repair. If worn or embrittled seals are found or if there is extreme dirt, the customer can decide whether he returns the coupling unit to the manufacturer s factory or whether he repairs himself. 10

313 Operating Instruction Type LV-004 Lubrication 9 Lubrication! In order to minimize operating forces and to extend service life of the coupling we recommend to slightly grease plug surfaces. Lubrication is to be carried out with greases which do not tend to become resin. Caution! The selection of the grease is to be suited to the sealing quality and the medium (e.g.: oxygen) in view of the compatibility. 11

314 Operating Instruction Type LV-004 Storage 10 Storage The couplings must be stored in such a way that no damages can occur at the couplings. The storage conditions of the couplings must comply with the guidelines for the seals as these can change in properties due to improper storage. The following items must be kept: - The couplings must be stored dry. - To safely conserve the seals and that means also the couplings they should not be stored under the effect of daylight. - For protection against oxygen the seals and also the couplings shall be stored into the packing. 12

315 Operating Instruction Type LV-004 Shut-down 11 Shut-down At the end of the service life the coupling or its components have to be disposed non-polluting and according to the legal regulations. For that the local public or private disposal societies should be taken. 13

316 Operating Instruction Type LV-004 Order Number Code 12 Order number code X X X - X X X X X X X X X X X - X X X X - X X X X X - X X X X X X X X X X X X X X X X - X X 1. Subject group 2. Series The information regarding the series comprises either two letters or two numbers. 3. Nomial size / Nominal bore It is rounded up or down to one. The information can be numerical as well as alphanumerical. 4. Product type or design type 5. Connection design 6. Material design: xx-x and xxxx possible 7. Material design (seal design): xx-x and xxxx possible 8. Y or Z design 9. Additional equipment 14

317 Operating Instruction Type LV-004 Index 13 Index A According to intended purpose... 6 Acquired knowledge... 4 Adaptorl... 6 air... 7 Alterations... 4 Assembly... 6 C Commissioning... 4, 6 connected... 7 connection... 7 Connection process... 9 coupling... 4 Coupling... 6, 7, 13 Couplings... 6 Customer care... 2 D Damage... 4, 6 Damage compensation... 4 daylight Disconnection process... 9 Disposal societies Disregard... 7 dry dust cap... 7 dust plug... 7 E Equipment... 4 Experience... 4 external damage... 8 F Faults... 4 Fluid... 6 Function... 6 Function test... 6 Functionality... 2 G General... 4 guarantee H Hazard notes... 6 Hazardous emission... 6 hydraulic oil... 7 I Implementation... 6 Improvement... 4 Index Inspection... 2 Installation Instruction... 8 Intended use... 7 L Legible condition... 6 Liability... 4 List of Contents... 3 Low Pressure... 1 Lubrication M Maintenance... 2, 4, 6 Maintenance and functional test Maintenance Instruction Manual... 4 Media temperatures... 6 O Operating Instruction... 1, 9 Operation... 2 Operational safety ordinances... 6 operator... 6, 10 Operators... 2 Order number code Original... 4 P packing particular... 6 Perfect, functioning condition... 6 Performance capability... 2 Pressurized... 6 Product description... 7 Property... 4 Protective gloves... 6 Q quality R regulations... 8 Regulations

318 Operating Instruction Type LV-004 Index Reliability... 2 Repair work... 6 responsible... 7 S Safety... 2 Safety devices... 6 Safety Instruction... 6 Scope of delivery... 4 Screw connections... 6 self sealing adaptor... 7, 8, 9, 10 self sealing coupling... 7, 8, 9, 10 Self sealing coupling... 9 Self Sealing Coupling... 1 service... 10, 11 Service... 2 Shut-down Special designs... 4 Specialists... 2 Status of development... 4 Storage subspecies... 7 Systems... 2, 6 T Technical data... 7 Technical equipment... 2 Technical values... 7 Thermally... 6 Tools... 2, 6 Translation errors... 4 Types of use... 7 U Use... 2 V Version... 4 W water... 7 Work safety regulations... 6 Working method... 6 working pressure... 7 Wrong product selection

319 Operating instruction english Revision C Date Issuer NH This operating instruction is not subject to the updating Self sealing coupling Medium Pressure Series 1-MD MD MD MD MD MD MD MD optional features: OV SI GG (nur MD-019) EX 1

320 This coupling is a quality product, in which special attention has been paid to high functionality, ease of operation, safety and reliability. As an item of technical equipment this tool-changer is intended for use in the commercial, industrial area and for operators, who have been trained by specialists in the handling of technical systems / tools. Customer care: As part of our individual customer care we will be happy to assist you in questions relating to use and operation and on any problems encountered. Service and maintenance: In order to maintain the high technical performance capability and reliability of your docking system over many years, we recommend regular inspection and maintenance. We can thereby offer you optimum support by our Customer Service department and the conclusion of a service and maintenance contract. Please ask for a quotation. Carl Kurt Walther GmbH & Co. KG PO Box Haan Westfalenstraße 2 Tel.: +49 (0) Fax: +49 (0) info@walther-praezision.de Internet: Contact: Application technology and service Holger R. Figge Telephone: (02129) Telefax: (02129) Handy: (0162) hfigge@walther-praezision.de 2

321 Operating instruction english Type MD-006, MD-007, MD-012, MD-019 standard List of Contents 1 List of Contents 1 LIST OF CONTENTS GENERAL WARRANTY SAFETY INSTRUCTIONS PRODUCT DESCRIPTION OF THE SELF SEALING COUPLING INTENDED USE TECHNICAL DATA MATERIAL DEPENDENT DIFFERENCES MD MD MD MD OPTIONAL FEATURES EXTENDED PRODUCT DESCRIPTION FOR APPLICATION ACC. TO ATEX-GUIDE LINE 94/9/EG (SPECIAL DESIGN EX): General Extended marking INSTALLATION INSTRUCTION GENERAL EXTENDED INSTALLATION INSTRUCTION FOR APPLICATION ACC. TO ATEX-GUIDELINE 94/9/EG Details for safe operation Details for safe installation Details for a safe application area OPERATING INSTRUCTION CONNECTION PROCESS DISCONNECTION PROCESS SAFETY LOCKING DEVICE SI (SUPPLEMENTARY EQUIPMENT) Coupling process Decoupling process MAINTENANCE INSTRUCTION MAINTENANCE AND FUNCTIONAL TEST Maintenance includes following items: Functional test includes following items: LUBRICATION! STORAGE SHUT-DOWN ORDER NUMBER CODE

322 Operating instruction english Type MD-006, MD-007, MD-012, MD-019 standard List of Contents 13 INDEX

323 Operating instruction english Type MD-006, MD-007, MD-012, MD-019 standard General 2 General This manual contains all regulations for operation, commissioning and maintenance of the coupling. All information and notes in this operating manual were collated while taking into consideration the valid regulations, the current engineering related status of development as well as our many years of experience and acquired knowledge. Translations of this operating manual were also produced according to the best of knowledge. However, we cannot assume liability for any translation errors. The German version provided for this operating manual is considered the authoritative version. The actual scope of delivery can deviate from the explanations and graphic representations described herein under certain circumstances, e.g. in the case of special designs, utilization of additional order options or because of state-of-the-art technical alterations. If you have any questions, please contact the manufacturer. This operating manual must be read carefully before starting work on or with the equipment, in particular before commissioning! The manufacturer assumes no liability for damage or faults arising from non-compliance with the instructions in this operating manual. The operating manual must be kept directly with the equipment and be accessible to all persons who work on or with the equipment. It is not permitted for the operating manual to be passed to third parties and if applicable this will incur damage compensation. All other rights reserved. Before commissioning the device must be checked for being not defective and its technically perfect function. The German version is the original. We reserve the right to make technical alterations to the product within the context of improving the usage properties and further development. The operating manual remains our property. Any reproduction, use by or communication to third parties incurs a penalty and will be pursued by court action (copyright law against unfair competition, BGB [German Civil Code]). All rights reserved in the case of a patent award (Paragraph 7, Section. 1 of the patent law - PG) or entry as a patented design (Paragraph 5, Section 4 of the patented design law - GMG). 5

324 Operating instruction english Type MD-006, MD-007, MD-012, MD-019 standard Warranty 3 Warranty The warranty conforms to: the regulations agreed in the purchase contract and the General Conditions for Delivery and Capacity of C.K. Walther GmbH & Co. KG of the state which was valid at the date of the purchase contract. Wearing parts are generally excluded from the warranty. Typical wearing parts of products from company C.K. Walther GmbH & Co. KG are for example: seals springs 6

325 Operating instruction english Type MD-006, MD-007, MD-012, MD-019 standard Safety instructions 4 Safety instructions Using these couplings does not release the customer from his obligation to comply with the pertinent work safety regulations e.g. operational safety regulations, etc. The duty to take due care by the operator of the couplings includes planning measures to ensure proper operation and monitoring their implementation. Hazard notes If the wrong product has been selected or if there is improper use or maintenance has been omitted, then hazards arise and personal injuries and material damage can occur from: - hazardous emission of fluid or individual particles/coupling parts. - function impairments of connected systems or tools. - the metal parts of coupling and adaptor are not thermally protected. In case of high media temperatures the contact with these parts can lead to combustion. According to the ambient temperature valve handle and ring grip can also become very hot. For that reason sufficiently long protective gloves must be worn in these cases. The operator must in particular make sure that - the couplings are only used according to the intended purpose. - the couplings are only operated in a perfect, functioning condition. - the operating manual is always in a legible condition and is available in its entirety to operating personnel. - the operating personnel are sufficiently acquainted with the working method and the safety notes for the coupling. - no safety devices must be removed and/or deactivated during operation of the couplings. - before installing or dismantling the couplings, you have made sure that the couplings have not been pressurized. After completing assembly and installation work and before commissioning the coupling, the following items have to be observed: Check once again that all screw connections are securely fitted. Before commissioning the couplings, a function test must be carried out (see maintenance and function test). 7

326 5 Product description of the self sealing coupling Coupling connection consists of: - self sealing coupling 1-MD self sealing adaptor 1-MD self sealing coupling 1-MD self sealing adaptor 1-MD self sealing coupling 1-MD self sealing adaptor 1-MD self sealing coupling 1-MD self sealing adaptor 1-MD Operating instruction english Type MD-006, MD-007, MD-012, MD-019 standard Product description of the self sealing coupling In case that both coupling halves are not connected they should be protected against external dirt and/or damages if required. For that purpose dust cap and dust plug are available. Possible comibinations : self sealing coupling with dust plug self sealing adaptor with dust cap 1-MD MD MD MD Intended use - Coupling is only used as connection of two lines. - Connection and disconnection process is carried out by hand. - Coupling is especially suitable for the following media/applications: - air - water - hydraulic oil - and their subspecies (such as oxygen or oil with additives) - For all other possible applications, Walther-Präzision should be consulted. 8

327 Operating instruction english Type MD-006, MD-007, MD-012, MD-019 standard Product description of the self sealing coupling 5.2 Technical data - Working pressures of coupling depend on materials of individual parts. - When determing the working with standardized threaded connections, the highest permissible working pressure of the connection must be taken into account. - When selecting a suitable connection the following static pressure is possible: max. static Working pressure steel (bar) max. static Working pressure brass (bar) max. static Working pressure st. st. (bar) Min. burst pressure for steel (bar) Cv-value MD ,73 MD ,95 MD ,25 MD ,5 - The coupling is not determined for any types of use and technical values other than those listed here. - Safe operation is not guaranteed if the coupling is used contrary to ist intended use and technical values - The operator of the coupling is responsible for all personal injuries or material damage that occur from non-intended use and disregard of the technical values; the manufacturer assumes no responsibility in these cases. 5.3 Material dependent Differences MD-006 end plug seal material Steel: material brass and Stainless steel: valve material Steel: material brass and Stainless steel: MD-007 end plug seal material Steel: material brass and Stainless steel: valve material Steel: material brass and Stainless steel: O-Ring 1.5 und anti extrusion ring O-Ring 1.78 without anti extrusion ring MD-006 valve LP-006 valve O-Ring 1.5 und anti extrusion ring O-Ring 1.78 without anti extrusion ring MD-007 valve LP-007 valve 9

328 Operating instruction english Type MD-006, MD-007, MD-012, MD-019 standard Product description of the self sealing coupling MD-012 end plug seal material Steel: material brass and Stainless steel: valve material Steel: material brass and Stainless steel: O-Ring 1.5 und anti extrusion ring O-Ring 1.78 without anti extrusion ring MD-012 valve LP-012 valve MD-019 end plug seal material Steel: O-Ring 2.2 in PTFE material brass and Stainless steel: O-Ring 2.62 valve material Steel: material Stainless steel: material brass: MD-019 valve LP-019-Z87 valve LP-019 valve 5.4 Optional Features OV = without valve (z.b.: 1-MD OV 1-MD OV) SI = with protection by safety locking device (see point 5) (z.b.: 1-MD SI) without SI with SI GG = with ring grips (aluminium cast) only MD-019 (z.b.: 1-MD GG) EX = ATEX version 10

329 Operating instruction english Type MD-006, MD-007, MD-012, MD-019 standard Product description of the self sealing coupling 5.5 Extended product description for application acc. to ATEX-guide line 94/9/EG (special design EX): General Only non-sparkling materials may be used. Non-sparkling materials are , or equivalent materials. Furthermore brass with different surfaces (f. ex. chrome-plated, nickel-plated). Further on it must be assured that the seal is resistant against and suitable for the flowing through media. Also the temperature resistance of the seals must be guaranteed. This must also be considered for the marking acc. to chapter Extended marking The coupling fittings are marked with As the surface temperature of the self-sealing couplings are determined by the temperature of the fluids, the temperature category or the highest surface temperature must be specified by the operator while the safe temperature distances acc. to EN must be observed and the maximum temperature resistance of the coupling materials and seals are taken into consideration. The marking of the temperature class must be effected readily visible by the operator. The determination of the temperature class must be made acc. to the following table: Max. temperature of Temperature class fluids 75 T6 90 T5 130 T4 195 T3 295 T2 445 T1 The couplings are not admitted for the temperature classes T1 and T2 and may not be marked for that by the operator. 11

330 Operating instruction english Type MD-006, MD-007, MD-012, MD-019 standard Installation instruction 6 Installation Instruction 6.1 General Subject to the general accident prevention regulations coupling is to be installed into a network in such a way that: - a satisfactory operation is guaranteed according to the operating instruction. - first of all self sealing coupling is used on line side and self sealing adaptor on consumer side - external damage of the unit as well as all moving parts are excluded. Before self sealing coupling and the self sealing adaptor are installed at a pipeline network make sure that the pipeline network is sufficiently rinsed/blown out and/or cleaned. Assembly and disassembly of the self sealing coupling and the self sealing adaptor see item 8. After the assembly works are finished a functional test is to be carried out with both, without pressure and under working pressure of the media elements according to operating instruction. 6.2 Extended installation instruction for application acc. to ATEX-guideline 94/9/EG Details for safe operation For the use of self sealing couplings as a hose connection it must be guaranteed that in case of pressure strikes the tumbling of the self sealing coupling can be avoided by fixing at suitable constructions. In principle it must be observed that the self sealing coupling cannot strike on hard objects which could produce strike sparks when touching the housing Details for safe installation The self sealing couplings may only be connected to pipe- and hose systems which are suitable for electrostatic discharge and which are connected to the ground potential Details for a safe application area The self sealing couplings may be used according to the class of devices2 in areas susceptible to explosions where potentially explosive mixtures of gas, steam, mist and air are availble. 12

331 Operating instruction english Type MD-006, MD-007, MD-012, MD-019 standard Operating instruction 7 Operating Instruction In order to avoid critical injuries of the staff and damage at the self sealing coupling during operation, coupling may be only used for the stated applications. 7.1 Connection process Before every couple cycle a visual check of coupling and adaptor is to be carried out. In case of recognizable, visible damage or deformations damaged parts are to be exchanged. Hold self sealing coupling firmly in one hand; with the other hand pull back locking sleeve. This has to be done against locking spring resistance. Push free half (coupling) with withdrawn locking sleeve axially centered onto plug part of fixed half (adaptor) until sensible resistance. Bring locking sleeve with support of locking spring into starting position. Self sealing coupling and self sealing adaptor are now mechanically locked. CAUTION Please take care that locking sleeve is in final position, i.e. that it is flush in front with the coupling housing as otherwise no perfect lock is guaranteed. 7.2 Disconnection process Withdraw locking sleeve against locking spring and take out coupling from self sealing adaptor. Caution! In case of an available pressure in the line connected by the coupling system a strong separation impulse - depending on the pressure - can be effective onto the coupling system during disconnection. For that reason the movable part of the coupling (free half) is to be firmly held in the hand to avoid injuries. 13

332 Operating instruction english Type MD-006, MD-007, MD-012, MD-019 standard Operating instruction 7.3 Safety locking device SI (supplementary equipment) Coupling process For coupling the locking ring must be in unsecured position (picture 2). Coupling as described under 7.1. locking sleeve locking ring picture 1 picture 2 locked position unlocked position After coupling the locking ring is drawn towards the hose, turned by 90 and released. Now the locking ring snaps forward into the safety position (picture 1). Both final positions secured and unsecured are fixed by spring loaded cams. The operator can assure himself of the proper locking and saving by trying, as a control, to disconnect the coupling by drawing back the locking sleeve. This is not possible in secured position Decoupling process In coupled situation the locking ring is in secured position (picture 1). For de-blocking the locking ring is drawn towards the hose, turned by 90 and released. Now the locking ring snaps forward into the safety position (picture 1). Both final positions secured and unsecured are fixed by spring loaded cams. Decoupling as described under

333 Operating instruction english Type MD-006, MD-007, MD-012, MD-019 standard Maintenance and Functional instruction 8 Maintenance Instruction Preventive maintenance measures WALTHER self sealing couplings are to be operated in such a manner that external damages to elements and all moving parts are avoided. 8.1 Maintenance and functional test In order to always guarantee function of the self sealing coupling and hence safety of operator, a maintenance and functional testing must be made in appropriate periods of time depending on operating conditions. In order to minimize operating forces and to extend service life of the self sealing coupling we recommend to slightly grease plug surfaces (see item 9.0) Maintenance includes following items: - A visual inspection of self sealing coupling and self sealing adaptor regarding damage and contamination has to be made. - Dirt at the functional area (sealing area, operating elements) which is easily accessible from outside should be removed by simply wiping-off. If there are damaged, torn or corroded parts, coupling must be dismounted and returned to manufacturer for repair. If worn or embrittled seals are found or if there is extreme dirt, the customer can decide whether he returns coupling unit to the manufacturer's factory or whether he repairs himself Functional test includes following items: As described in the operating instruction, coupling is several times connected, pressurized and then disconnected. In doing so, the following has to be observed: - Connection and disconnection process must be absolutely smooth. - Coupling must be absolutely leak-proof in connected and disconnected state. If there are damaged, torn or corroded parts, coupling must be dismounted and returned to manufacturer for repair. If worn or embrittled seals are found or if there is extreme dirt, the customer can decide whether he returns the coupling unit to the manufacturer s factory or whether he repairs himself. 15

334 Operating instruction english Type MD-006, MD-007, MD-012, MD-019 standard Lubrication 9 Lubrication! In order to minimize operating forces and to extend service life of the coupling we recommend to slightly grease plug surfaces. Lubrication is to be carried out with greases which do not tend to become resin. Caution! The selection of the grease is to be suited to the sealing quality and the medium (e.g.: oxygen) in view of the compatibility. 16

335 Operating instruction english Type MD-006, MD-007, MD-012, MD-019 standard Storage 10 Storage The couplings must be stored in such a way that no damages can occur at the couplings. The storage conditions of the couplings must comply with the guidelines for the seals as these can change in properties due to improper storage. The following items must be kept: - The couplings must be stored dry. - To safely conserve the seals and that means also the couplings they should not be stored under the effect of daylight. - For protection against oxygen the seals and also the couplings shall be stored into the packing. 17

336 Operating instruction english Type MD-006, MD-007, MD-012, MD-019 standard Shut-down 11 Shut-down At the end of the service life the coupling or its components have to be disposed non-polluting and according to the legal regulations. For that the local public or private disposal societies should be taken. 18

337 Operating instruction english Type MD-006, MD-007, MD-012, MD-019 standard Order number code 12 Order number code X X X - X X X X X X X X X X X - X X X X - X X X X X - X X X X X X X X X X X X X X X X - X X 1. Subject group 2. Series Series description consists of either two letters or two digits. 3. Nominal size / nominal width It is rounded up or rounded down to full units. The indication can be numerical or alphanumeric. 4. Type of product and design 5. Type of connection 6. Material: xx-x and xxxx possible 7. Material (seal version): xx-x and xxxx possible 8. Y- or Z-design 9. Optional features 19

338 Operating instruction english Type MD-006, MD-007, MD-012, MD-019 standard Index 13 Index A According to intended purpose... 7 Acquired knowledge... 5 air... 8 Alterations... 5 Assembly... 7 C Commissioning... 5, 7 connected... 7, 8, 15 connection... 8, 19 Connection process coupling... 5, 7 Coupling... 9, 18 Couplings... 7 Customer care... 2 D Damage... 5, 7 Damage compensation... 5 daylight disconnected Disconnection process Dismantling... 7 Disposal societies Disregard... 9 dry dust cap... 8 dust plug... 8 E elektrostatisch Equipment... 5 Experience... 5 explosionsgefährdeten Bereichen external damage F Faults... 5 Fluid... 7 Function... 7 Function test... 7 Functionality... 2 G General... 5 Gerätekategorie guarantee H Hazard notes...7 Hazardous emission...7 hydraulic oil...8 I Implementation...7 Improvement...5 Index...20 Inspection...2 Installation Instruction...12 Intended use...8 K Kennzeichnung...11 L Legible condition...7 Liability...5 List of Contents...3 Lubrication...16 M Maintenance...2, 5, 7 Maintenance Instruction...15 Manual...5 Medium Pressure Series...1 O Operating instruction...1 Operating Instruction...13 Operation...2 Operational safety regulations...7 operator...7 Operators...2 original...5 P packing...17 Perfect, functioning condition...7 Performance capability...2 Pressurized...7 Product description...8 Property...5 Q quality...16 questions

339 Operating instruction english Type MD-006, MD-007, MD-012, MD-019 standard Index R regulations Regulations... 5 Reliability... 2 responsible... 9 S Safety... 2 Safety devices... 7 Safety instructions... 7 Schlagfunken Scope of delivery... 5 Screw connections... 7 self sealing adaptor... 8, 12, 13, 15 self sealing coupling... 8, 12, 13, 15 Self sealing coupling... 1, 13 service... 15, 16 Service... 2 Shut-down Special designs... 5 Specialists... 2 Status of development... 5 Storage subspecies... 8 Systems... 2, 7 T Technical data...9 Technical equipment...2 Technical values...9 Temperaturbeständigkeit...11 Temperaturklasse...11 Tools...2, 7 Translation errors...5 Types of use...9 U Use...2 V Version...5 W water...8 Work safety regulations...7 Working method...7 working pressure...9 Wrong product selection

340 Operating instruction english Revision B Date Issuer NH This operating instruction is not subject to the updating Self sealing coupling Medium Pressure Series 1-MD MD MD MD optional features: OV SI GG EX 1

341 This coupling is a quality product, in which special attention has been paid to high functionality, ease of operation, safety and reliability. As an item of technical equipment this tool-changer is intended for use in the commercial, industrial area and for operators, who have been trained by specialists in the handling of technical systems / tools. Customer care: As part of our individual customer care we will be happy to assist you in questions relating to use and operation and on any problems encountered. Service and maintenance: In order to maintain the high technical performance capability and reliability of your docking system over many years, we recommend regular inspection and maintenance. We can thereby offer you optimum support by our Customer Service department and the conclusion of a service and maintenance contract. Please ask for a quotation. Carl Kurt Walther GmbH & Co. KG PO Box Haan Westfalenstraße 2 Tel.: +49 (0) Fax: +49 (0) info@walther-praezision.de Internet: Contact: Application technology and service Holger R. Figge Telephone: (02129) Telefax: (02129) Handy: (0162) hfigge@walther-praezision.de 2

342 Operating instruction english Type MD-025_050 standard List of Contents 1 List of Contents 1 LIST OF CONTENTS GENERAL WARRANTY SAFETY INSTRUCTIONS PRODUCT DESCRIPTION OF THE SELF SEALING COUPLING INTENDED USE TECHNICAL DATA OPTIONAL FEATURES EXTENDED PRODUCT DESCRIPTION FOR APPLICATION ACC. TO ATEX-GUIDE LINE 94/9/EG (SPECIAL DESIGN EX): General Extended marking INSTALLATION INSTRUCTION GENERAL EXTENDED INSTALLATION INSTRUCTION FOR APPLICATION ACC. TO ATEX-GUIDELINE 94/9/EG Details for safe operation Details for safe installation Details for a safe application area OPERATING INSTRUCTION CONNECTION PROCESS DISCONNECTION PROCESS SAFETY LOCKING DEVICE SI (SUPPLEMENTARY EQUIPMENT) Coupling process Decoupling process MAINTENANCE INSTRUCTION MAINTENANCE AND FUNCTIONAL TEST Maintenance includes following items: Functional test includes following items: LUBRICATION! STORAGE SHUT-DOWN ORDER NUMBER CODE INDEX

343 Operating instruction english Type MD-025_050 standard General 2 General This manual contains all regulations for operation, commissioning and maintenance of the coupling. All information and notes in this operating manual were collated while taking into consideration the valid regulations, the current engineering related status of development as well as our many years of experience and acquired knowledge. Translations of this operating manual were also produced according to the best of knowledge. However, we cannot assume liability for any translation errors. The German version provided for this operating manual is considered the authoritative version. The actual scope of delivery can deviate from the explanations and graphic representations described herein under certain circumstances, e.g. in the case of special designs, utilization of additional order options or because of state-of-the-art technical alterations. If you have any questions, please contact the manufacturer. This operating manual must be read carefully before starting work on or with the equipment, in particular before commissioning! The manufacturer assumes no liability for damage or faults arising from non-compliance with the instructions in this operating manual. The operating manual must be kept directly with the equipment and be accessible to all persons who work on or with the equipment. It is not permitted for the operating manual to be passed to third parties and if applicable this will incur damage compensation. All other rights reserved. Before commissioning the device must be checked for being not defective and its technically perfect function. The German version is the original. We reserve the right to make technical alterations to the product within the context of improving the usage properties and further development. The operating manual remains our property. Any reproduction, use by or communication to third parties incurs a penalty and will be pursued by court action (copyright law against unfair competition, BGB [German Civil Code]). All rights reserved in the case of a patent award (Paragraph 7, Section. 1 of the patent law - PG) or entry as a patented design (Paragraph 5, Section 4 of the patented design law - GMG). 4

344 Operating instruction english Type MD-025_050 standard Warranty 3 Warranty The warranty conforms to: the regulations agreed in the purchase contract and the General Conditions for Delivery and Capacity of C.K. Walther GmbH & Co. KG of the state which was valid at the date of the purchase contract. Wearing parts are generally excluded from the warranty. Typical wearing parts of products from company C.K. Walther GmbH & Co. KG are for example: seals springs 5

345 Operating instruction english Type MD-025_050 standard Safety instructions 4 Safety instructions Using these couplings does not release the customer from his obligation to comply with the pertinent work safety regulations e.g. operational safety regulations, etc. The duty to take due care by the operator of the couplings includes planning measures to ensure proper operation and monitoring their implementation. Hazard notes If the wrong product has been selected or if there is improper use or maintenance has been omitted, then hazards arise and personal injuries and material damage can occur from: - hazardous emission of fluid or individual particles/coupling parts. - function impairments of connected systems or tools. - the metal parts of coupling and adaptor are not thermally protected. In case of high media temperatures the contact with these parts can lead to combustion. According to the ambient temperature valve handle and ring grip can also become very hot. For that reason sufficiently long protective gloves must be worn in these cases. The operator must in particular make sure that - the couplings are only used according to the intended purpose. - the couplings are only operated in a perfect, functioning condition. - the operating manual is always in a legible condition and is available in its entirety to operating personnel. - the operating personnel are sufficiently acquainted with the working method and the safety notes for the coupling. - no safety devices must be removed and/or deactivated during operation of the couplings. - before installing or dismantling the couplings, you have made sure that the couplings have not been pressurized. After completing assembly and installation work and before commissioning the coupling, the following items have to be observed: Check once again that all screw connections are securely fitted. Before commissioning the couplings, a function test must be carried out (see maintenance and function test). 6

346 5 Product description of the self sealing coupling Coupling connection consists of: - self sealing coupling 1-MD self sealing adaptor 1-MD self sealing coupling 1-MD self sealing adaptor 1-MD Operating instruction english Type MD-025_050 standard Product description of the self sealing coupling In case that both coupling halves are not connected they should be protected against external dirt and/or damages if required. For that purpose dust cap and dust plug are available. Possible comibinations : self sealing coupling with dust plug self sealing adaptor with dust cap 1-MD MD MD MD Intended use - Coupling is only used as connection of two lines. - Connection and disconnection process is carried out by hand. - Coupling is especially suitable for the following media/applications: - air - water - hydraulic oil - and their subspecies (such as oxygen or oil with additives) - For all other possible applications, Walther-Präzision should be consulted. 5.2 Technical data - Working pressures of coupling depend on materials of individual parts. - When determing the working with standardized threaded connections, the highest permissible working pressure of the connection must be taken into account. - When selecting a suitable connection the following static pressure is possible: max. static Working pressure steel (bar) max. static Working pressure brass (bar) max. static Working pressure st. st. (bar) Cv-value both sides self sealing Cv-value one side self sealing MD MD

347 Operating instruction english Type MD-025_050 standard Product description of the self sealing coupling - The coupling is not determined for any types of use and technical values other than those listed here. - Safe operation is not guaranteed if the coupling is used contrary to ist intended use and technical values - The operator of the coupling is responsible for all personal injuries or material damage that occur from non-intended use and disregard of the technical values; the manufacturer assumes no responsibility in these cases. 5.3 Optional Features OV = without valve (z.b.: 1-MD OV 1-MD OV) SI = with protection by safety locking device (see point 5) (z.b.: 1-MD SI) without SI with SI GG = with ring grips (aluminium cast) (z.b.: 1-MD GG) EX = ATEX version 8

348 Operating instruction english Type MD-025_050 standard Product description of the self sealing coupling 5.4 Extended product description for application acc. to ATEX-guide line 94/9/EG (special design EX): General Only non-sparkling materials may be used. Non-sparkling materials are , or equivalent materials. Furthermore brass with different surfaces (f. ex. chrome-plated, nickel-plated). Further on it must be assured that the seal is resistant against and suitable for the flowing through media. Also the temperature resistance of the seals must be guaranteed. This must also be considered for the marking acc. to chapter Extended marking The coupling fittings are marked with As the surface temperature of the self-sealing couplings are determined by the temperature of the fluids, the temperature category or the highest surface temperature must be specified by the operator while the safe temperature distances acc. to EN must be observed and the maximum temperature resistance of the coupling materials and seals are taken into consideration. The marking of the temperature class must be effected readily visible by the operator. The determination of the temperature class must be made acc. to the following table: Max. temperature of Temperature class fluids 75 T6 90 T5 130 T4 195 T3 295 T2 445 T1 The couplings are not admitted for the temperature classes T1 and T2 and may not be marked for that by the operator. 9

349 Operating instruction english Type MD-025_050 standard Installation instruction 6 Installation Instruction 6.1 General Subject to the general accident prevention regulations coupling is to be installed into a network in such a way that: - a satisfactory operation is guaranteed according to the operating instruction. - first of all self sealing coupling is used on line side and self sealing adaptor on consumer side - external damage of the unit as well as all moving parts are excluded. Before self sealing coupling and the self sealing adaptor are installed at a pipeline network make sure that the pipeline network is sufficiently rinsed/blown out and/or cleaned. Assembly and disassembly of the self sealing coupling and the self sealing adaptor see item 8. After the assembly works are finished a functional test is to be carried out with both, without pressure and under working pressure of the media elements according to operating instruction. 6.2 Extended installation instruction for application acc. to ATEX-guideline 94/9/EG Details for safe operation For the use of self sealing couplings as a hose connection it must be guaranteed that in case of pressure strikes the tumbling of the self sealing coupling can be avoided by fixing at suitable constructions. In principle it must be observed that the self sealing coupling cannot strike on hard objects which could produce strike sparks when touching the housing Details for safe installation The self sealing couplings may only be connected to pipe- and hose systems which are suitable for electrostatic discharge and which are connected to the ground potential Details for a safe application area The self sealing couplings may be used according to the class of devices2 in areas susceptible to explosions where potentially explosive mixtures of gas, steam, mist and air are availble. 10

350 Operating instruction english Type MD-025_050 standard Operating instruction 7 Operating Instruction In order to avoid critical injuries of the staff and damage at the self sealing coupling during operation, coupling may be only used for the stated applications. 7.1 Connection process Before every couple cycle a visual check of coupling and adaptor is to be carried out. In case of recognizable, visible damage or deformations damaged parts are to be exchanged. Hold self sealing coupling firmly in one hand; with the other hand pull back locking sleeve. This has to be done against locking spring resistance. If ring grips are available (optional), the self sealing coupling (free half) at the hose is taken as described in the following picture and the locking sleeve is pulled back at the front ring with the fingers. Push free half (coupling) with withdrawn locking sleeve axially centered onto plug part of fixed half (adaptor) until sensible resistance. Bring locking sleeve with support of locking spring into starting position. Self sealing coupling and self sealing adaptor are now mechanically locked. CAUTION Es Please take care that locking sleeve is in final position, i.e. that it is flush in front with the coupling housing as otherwise no perfect lock is guaranteed. 11

351 Operating instruction english Type MD-025_050 standard Operating instruction 7.2 Disconnection process Withdraw locking sleeve against locking spring and take out coupling from self sealing adaptor. Caution! In case of an available pressure in the line connected by the coupling system a strong separation impulse - depending on the pressure - can be effective onto the coupling system during disconnection. For that reason the movable part of the coupling (free half) is to be firmly held in the hand to avoid injuries. 7.3 Safety locking device SI (supplementary equipment) Coupling process For coupling the locking ring must be in unsecured position (picture 2). Coupling as described under 7.1. locking sleeve locking ring picture 1 picture 2 locked position unlocked position After coupling the locking ring is drawn towards the hose, turned by 90 and released. Now the locking ring snaps forward into the safety position (picture 1). Both final positions secured and unsecured are fixed by spring loaded cams. The operator can assure himself of the proper locking and saving by trying, as a control, to disconnect the coupling by drawing back the locking sleeve. This is not possible in secured position Decoupling process In coupled situation the locking ring is in secured position (picture 1). For de-blocking the locking ring is drawn towards the hose, turned by 90 and released. Now the locking ring snaps forward into the safety position (picture 1). Both final positions secured and unsecured are fixed by spring loaded cams. Decoupling as described under

352 Operating instruction english Type MD-025_050 standard Maintenance and Functional instruction 8 Maintenance Instruction Preventive maintenance measures WALTHER self sealing couplings are to be operated in such a manner that external damages to elements and all moving parts are avoided. 8.1 Maintenance and functional test In order to always guarantee function of the self sealing coupling and hence safety of operator, a maintenance and functional testing must be made in appropriate periods of time depending on operating conditions. In order to minimize operating forces and to extend service life of the self sealing coupling we recommend to slightly grease plug surfaces (see item 9.0) Maintenance includes following items: - A visual inspection of self sealing coupling and self sealing adaptor regarding damage and contamination has to be made. - Dirt at the functional area (sealing area, operating elements) which is easily accessible from outside should be removed by simply wiping-off. If there are damaged, torn or corroded parts, coupling must be dismounted and returned to manufacturer for repair. If worn or embrittled seals are found or if there is extreme dirt, the customer can decide whether he returns coupling unit to the manufacturer's factory or whether he repairs himself Functional test includes following items: As described in the operating instruction, coupling is several times connected, pressurized and then disconnected. In doing so, the following has to be observed: - Connection and disconnection process must be absolutely smooth. - Coupling must be absolutely leak-proof in connected and disconnected state. If there are damaged, torn or corroded parts, coupling must be dismounted and returned to manufacturer for repair. If worn or embrittled seals are found or if there is extreme dirt, the customer can decide whether he returns the coupling unit to the manufacturer s factory or whether he repairs himself. 13

353 Operating instruction english Type MD-025_050 standard Lubrication 9 Lubrication! In order to minimize operating forces and to extend service life of the coupling we recommend to slightly grease plug surfaces. Lubrication is to be carried out with greases which do not tend to become resin. Caution! The selection of the grease is to be suited to the sealing quality and the medium (e.g.: oxygen) in view of the compatibility. 14

354 Operating instruction english Type MD-025_050 standard Storage 10 Storage The couplings must be stored in such a way that no damages can occur at the couplings. The storage conditions of the couplings must comply with the guidelines for the seals as these can change in properties due to improper storage. The following items must be kept: - The couplings must be stored dry. - To safely conserve the seals and that means also the couplings they should not be stored under the effect of daylight. - For protection against oxygen the seals and also the couplings shall be stored into the packing. 15

355 Operating instruction english Type MD-025_050 standard Shut-down 11 Shut-down At the end of the service life the coupling or its components have to be disposed non-polluting and according to the legal regulations. For that the local public or private disposal societies should be taken. 16

356 Operating instruction english Type MD-025_050 standard Order number code 12 Order number code X X X - X X X X X X X X X X X - X X X X - X X X X X - X X X X X X X X X X X X X X X X - X X 1. Subject group 2. Series Series description consists of either two letters or two digits. 3. Nominal size / nominal width It is rounded up or rounded down to full units. The indication can be numerical or alphanumeric. 4. Type of product and design 5. Type of connection 6. Material: xx-x and xxxx possible 7. Material (seal version): xx-x and xxxx possible 8. Y- or Z-design 9. Optional features 17

357 Operating instruction english Type MD-025_050 standard Index 13 Index A According to intended purpose... 6 Acquired knowledge... 4 air... 7 Alterations... 4 Assembly... 6 C Commissioning... 4, 6 connected... 6, 7, 13 connection... 7, 17 Connection process coupling... 4, 6 Coupling... 8, 16 Couplings... 6 Customer care... 2 D Damage... 4, 6 Damage compensation... 4 daylight disconnected Disconnection process Dismantling... 6 Disposal societies Disregard... 8 dry dust cap... 7 dust plug... 7 E elektrostatisch Equipment... 4 Experience... 4 explosionsgefährdeten Bereichen external damage F Faults... 4 Fluid... 6 Function... 6 Function test... 6 Functionality... 2 G General... 4 Gerätekategorie guarantee H Hazard notes...6 Hazardous emission...6 hydraulic oil...7 I Implementation...6 Improvement...4 Index...18 Inspection...2 Installation Instruction...10 Intended use...7 K Kennzeichnung...9 L Legible condition...6 Liability...4 List of Contents...3 Lubrication...14 M Maintenance...2, 4, 6 Maintenance Instruction...13 Manual...4 Medium Pressure Series...1 O Operating instruction...1 Operating Instruction...11 Operation...2 Operational safety regulations...6 operator...6 Operators...2 original...4 P packing...15 Perfect, functioning condition...6 Performance capability...2 Pressurized...6 Product description...7 Property...4 Q quality...14 questions

358 Operating instruction english Type MD-025_050 standard Index R regulations Regulations... 4 Reliability... 2 responsible... 8 S Safety... 2 Safety devices... 6 Safety instructions... 6 Schlagfunken Scope of delivery... 4 Screw connections... 6 self sealing adaptor... 7, 10, 11, 12, 13 self sealing coupling... 7, 10, 11, 13 Self sealing coupling... 1, 11 service... 13, 14 Service... 2 Shut-down Special designs... 4 Specialists... 2 Status of development... 4 Storage subspecies... 7 Systems... 2, 6 T Technical data...7 Technical equipment...2 Technical values...8 Temperaturbeständigkeit...9 Temperaturklasse...9 Tools...2, 6 Translation errors...4 Types of use...8 U Use...2 V Version...4 W water...7 Work safety regulations...6 Working method...6 working pressure...7 Wrong product selection

359 Operating instruction english Revision B Date Issuer NH This operating instruction is not subject to the updating Self sealing coupling Medium Pressure Series 1-MD MD MD MD MD ZV 1-MD ZV 1-MD ZV 1-MD ZV optional features: OV SI GG EX 1

360 This coupling is a quality product, in which special attention has been paid to high functionality, ease of operation, safety and reliability. As an item of technical equipment this tool-changer is intended for use in the commercial, industrial area and for operators, who have been trained by specialists in the handling of technical systems / tools. Customer care: As part of our individual customer care we will be happy to assist you in questions relating to use and operation and on any problems encountered. Service and maintenance: In order to maintain the high technical performance capability and reliability of your docking system over many years, we recommend regular inspection and maintenance. We can thereby offer you optimum support by our Customer Service department and the conclusion of a service and maintenance contract. Please ask for a quotation. Carl Kurt Walther GmbH & Co. KG PO Box Haan Westfalenstraße 2 Tel.: +49 (0) Fax: +49 (0) info@walther-praezision.de Internet: Contact: Application technology and service Holger R. Figge Telephone: (02129) Telefax: (02129) Handy: (0162) hfigge@walther-praezision.de 2

361 Operating instruction english Type MD-032 standard List of Contents 1 List of Contents 1 LIST OF CONTENTS GENERAL WARRANTY SAFETY INSTRUCTIONS PRODUCT DESCRIPTION OF THE SELF SEALING COUPLING INTENDED USE TECHNICAL DATA MATERIAL DEPENDENT DIFFERENCES OPTIONAL FEATURES EXTENDED PRODUCT DESCRIPTION FOR APPLICATION ACC. TO ATEX-GUIDE LINE 94/9/EG (SPECIAL DESIGN EX): General Extended marking INSTALLATION INSTRUCTION GENERAL EXTENDED INSTALLATION INSTRUCTION FOR APPLICATION ACC. TO ATEX-GUIDELINE 94/9/EG Details for safe operation Details for safe installation Details for a safe application area OPERATING INSTRUCTION CONNECTION PROCESS DISCONNECTION PROCESS SAFETY LOCKING DEVICE SI (SUPPLEMENTARY EQUIPMENT) Coupling process Decoupling process MAINTENANCE INSTRUCTION MAINTENANCE AND FUNCTIONAL TEST Maintenance includes following items: Functional test includes following items: LUBRICATION! STORAGE SHUT-DOWN ORDER NUMBER CODE INDEX

362 Operating instruction english Type MD-032 standard General 2 General This manual contains all regulations for operation, commissioning and maintenance of the coupling. All information and notes in this operating manual were collated while taking into consideration the valid regulations, the current engineering related status of development as well as our many years of experience and acquired knowledge. Translations of this operating manual were also produced according to the best of knowledge. However, we cannot assume liability for any translation errors. The German version provided for this operating manual is considered the authoritative version. The actual scope of delivery can deviate from the explanations and graphic representations described herein under certain circumstances, e.g. in the case of special designs, utilization of additional order options or because of state-of-the-art technical alterations. If you have any questions, please contact the manufacturer. This operating manual must be read carefully before starting work on or with the equipment, in particular before commissioning! The manufacturer assumes no liability for damage or faults arising from non-compliance with the instructions in this operating manual. The operating manual must be kept directly with the equipment and be accessible to all persons who work on or with the equipment. It is not permitted for the operating manual to be passed to third parties and if applicable this will incur damage compensation. All other rights reserved. Before commissioning the device must be checked for being not defective and its technically perfect function. The German version is the original. We reserve the right to make technical alterations to the product within the context of improving the usage properties and further development. The operating manual remains our property. Any reproduction, use by or communication to third parties incurs a penalty and will be pursued by court action (copyright law against unfair competition, BGB [German Civil Code]). All rights reserved in the case of a patent award (Paragraph 7, Section. 1 of the patent law - PG) or entry as a patented design (Paragraph 5, Section 4 of the patented design law - GMG). 4

363 Operating instruction english Type MD-032 standard Warranty 3 Warranty The warranty conforms to: the regulations agreed in the purchase contract and the General Conditions for Delivery and Capacity of C.K. Walther GmbH & Co. KG of the state which was valid at the date of the purchase contract. Wearing parts are generally excluded from the warranty. Typical wearing parts of products from company C.K. Walther GmbH & Co. KG are for example: seals springs 5

364 Operating instruction english Type MD-032 standard Safety instructions 4 Safety instructions Using these couplings does not release the customer from his obligation to comply with the pertinent work safety regulations e.g. operational safety regulations, etc. The duty to take due care by the operator of the couplings includes planning measures to ensure proper operation and monitoring their implementation. Hazard notes If the wrong product has been selected or if there is improper use or maintenance has been omitted, then hazards arise and personal injuries and material damage can occur from: - hazardous emission of fluid or individual particles/coupling parts. - function impairments of connected systems or tools. - the metal parts of coupling and adaptor are not thermally protected. In case of high media temperatures the contact with these parts can lead to combustion. According to the ambient temperature valve handle and ring grip can also become very hot. For that reason sufficiently long protective gloves must be worn in these cases. The operator must in particular make sure that - the couplings are only used according to the intended purpose. - the couplings are only operated in a perfect, functioning condition. - the operating manual is always in a legible condition and is available in its entirety to operating personnel. - the operating personnel are sufficiently acquainted with the working method and the safety notes for the coupling. - no safety devices must be removed and/or deactivated during operation of the couplings. - before installing or dismantling the couplings, you have made sure that the couplings have not been pressurized. After completing assembly and installation work and before commissioning the coupling, the following items have to be observed: Check once again that all screw connections are securely fitted. Before commissioning the couplings, a function test must be carried out (see maintenance and function test). 6

365 5 Product description of the self sealing coupling Coupling connection consists of: - self sealing coupling 1-MD self sealing adaptor 1-MD Operating instruction english Type MD-032 standard Product description of the self sealing coupling In case that both coupling halves are not connected they should be protected against external dirt and/or damages if required. For that purpose dust cap and dust plug are available. Possible comibinations : self sealing coupling 1-MD with dust plug 1-MD self sealing adaptor 1-MD with dust cap 1-MD Intended use - Coupling is only used as connection of two lines. - Connection and disconnection process is carried out by hand. - Coupling is especially suitable for the following media/applications: - air - water - hydraulic oil - and their subspecies (such as oxygen or oil with additives) - For all other possible applications, Walther-Präzision should be consulted. 5.2 Technical data - Working pressures of coupling depend on materials of individual parts. - When determing the working with standardized threaded connections, the highest permissible working pressure of the connection must be taken into account. - When selecting a suitable connection the following static pressure is possible: max. static Working pressure steel (bar) max. static Working pressure brass (bar) max. static Working pressure st. st. (bar) Cv-value both side self sealing Cv-value one side self sealing MD ,8 29,4 - The coupling is not determined for any types of use and technical values other than those listed here. - Safe operation is not guaranteed if the coupling is used contrary to ist intended use and technical values - The operator of the coupling is responsible for all personal injuries or material damage that occur from non-intended use and disregard of the technical values; the manufacturer assumes no responsibility in these cases. 7

366 Operating instruction english Type MD-032 standard Product description of the self sealing coupling 5.3 Material dependent Differences valves material: Steel, Brass material: Stainless steel, Aluminium one part valve (1-MD ) (1-MD ) two part valve (1-MD ZV) (1-MD ZV) 5.4 Optional Features OV = without valve (z.b.: 1-MD OV 1-MD OV) SI = with protection by safety locking device (see point 5) (z.b.: 1-MD SI) without SI with SI GG = with ring grips (aluminium cast) (z.b.: 1-MD GG) EX = ATEX version 8

367 Operating instruction english Type MD-032 standard Product description of the self sealing coupling 5.5 Extended product description for application acc. to ATEX-guide line 94/9/EG (special design EX): General Only non-sparkling materials may be used. Non-sparkling materials are , or equivalent materials. Furthermore brass with different surfaces (f. ex. chrome-plated, nickel-plated). Further on it must be assured that the seal is resistant against and suitable for the flowing through media. Also the temperature resistance of the seals must be guaranteed. This must also be considered for the marking acc. to chapter Extended marking The coupling fittings are marked with As the surface temperature of the self-sealing couplings are determined by the temperature of the fluids, the temperature category or the highest surface temperature must be specified by the operator while the safe temperature distances acc. to EN must be observed and the maximum temperature resistance of the coupling materials and seals are taken into consideration. The marking of the temperature class must be effected readily visible by the operator. The determination of the temperature class must be made acc. to the following table: Max. temperature of Temperature class fluids 75 T6 90 T5 130 T4 195 T3 295 T2 445 T1 The couplings are not admitted for the temperature classes T1 and T2 and may not be marked for that by the operator. 9

368 Operating instruction english Type MD-032 standard Installation instruction 6 Installation Instruction 6.1 General Subject to the general accident prevention regulations coupling is to be installed into a network in such a way that: - a satisfactory operation is guaranteed according to the operating instruction. - first of all self sealing coupling is used on line side and self sealing adaptor on consumer side - external damage of the unit as well as all moving parts are excluded. Before self sealing coupling and the self sealing adaptor are installed at a pipeline network make sure that the pipeline network is sufficiently rinsed/blown out and/or cleaned. Assembly and disassembly of the self sealing coupling and the self sealing adaptor see item 8. After the assembly works are finished a functional test is to be carried out with both, without pressure and under working pressure of the media elements according to operating instruction. 6.2 Extended installation instruction for application acc. to ATEX-guideline 94/9/EG Details for safe operation For the use of self sealing couplings as a hose connection it must be guaranteed that in case of pressure strikes the tumbling of the self sealing coupling can be avoided by fixing at suitable constructions. In principle it must be observed that the self sealing coupling cannot strike on hard objects which could produce strike sparks when touching the housing Details for safe installation The self sealing couplings may only be connected to pipe- and hose systems which are suitable for electrostatic discharge and which are connected to the ground potential Details for a safe application area The self sealing couplings may be used according to the class of devices2 in areas susceptible to explosions where potentially explosive mixtures of gas, steam, mist and air are availble. 10

369 Operating instruction english Type MD-032 standard Operating instruction 7 Operating Instruction In order to avoid critical injuries of the staff and damage at the self sealing coupling during operation, coupling may be only used for the stated applications. 7.1 Connection process Before every couple cycle a visual check of coupling and adaptor is to be carried out. In case of recognizable, visible damage or deformations damaged parts are to be exchanged. Hold self sealing coupling firmly in one hand; with the other hand pull back locking sleeve. This has to be done against locking spring resistance. Push free half (coupling) with withdrawn locking sleeve axially centered onto plug part of fixed half (adaptor) until sensible resistance. Bring locking sleeve with support of locking spring into starting position. Self sealing coupling and self sealing adaptor are now mechanically locked. CAUTION Es Please take care that locking sleeve is in final position, i.e. that it is flush in front with the coupling housing as otherwise no perfect lock is guaranteed. 7.2 Disconnection process Withdraw locking sleeve against locking spring and take out coupling from self sealing adaptor. Caution! In case of an available pressure in the line connected by the coupling system a strong separation impulse - depending on the pressure - can be effective onto the coupling system during disconnection. For that reason the movable part of the coupling (free half) is to be firmly held in the hand to avoid injuries. 11

370 Operating instruction english Type MD-032 standard Operating instruction 7.3 Safety locking device SI (supplementary equipment) Coupling process For coupling the locking ring must be in unsecured position (picture 2). Coupling as described under 7.1. locking sleeve locking ring picture 1 picture 2 locked position unlocked position After coupling the locking ring is drawn towards the hose, turned by 90 and released. Now the locking ring snaps forward into the safety position (picture 1). Both final positions secured and unsecured are fixed by spring loaded cams. The operator can assure himself of the proper locking and saving by trying, as a control, to disconnect the coupling by drawing back the locking sleeve. This is not possible in secured position Decoupling process In coupled situation the locking ring is in secured position (picture 1). For de-blocking the locking ring is drawn towards the hose, turned by 90 and released. Now the locking ring snaps forward into the safety position (picture 1). Both final positions secured and unsecured are fixed by spring loaded cams. Decoupling as described under

371 Operating instruction english Type MD-032 standard Maintenance and Functional instruction 8 Maintenance Instruction Preventive maintenance measures WALTHER self sealing couplings are to be operated in such a manner that external damages to elements and all moving parts are avoided. 8.1 Maintenance and functional test In order to always guarantee function of the self sealing coupling and hence safety of operator, a maintenance and functional testing must be made in appropriate periods of time depending on operating conditions. In order to minimize operating forces and to extend service life of the self sealing coupling we recommend to slightly grease plug surfaces (see item 9.0) Maintenance includes following items: - A visual inspection of self sealing coupling and self sealing adaptor regarding damage and contamination has to be made. - Dirt at the functional area (sealing area, operating elements) which is easily accessible from outside should be removed by simply wiping-off. If there are damaged, torn or corroded parts, coupling must be dismounted and returned to manufacturer for repair. If worn or embrittled seals are found or if there is extreme dirt, the customer can decide whether he returns coupling unit to the manufacturer's factory or whether he repairs himself Functional test includes following items: As described in the operating instruction, coupling is several times connected, pressurized and then disconnected. In doing so, the following has to be observed: - Connection and disconnection process must be absolutely smooth. - Coupling must be absolutely leak-proof in connected and disconnected state. If there are damaged, torn or corroded parts, coupling must be dismounted and returned to manufacturer for repair. If worn or embrittled seals are found or if there is extreme dirt, the customer can decide whether he returns the coupling unit to the manufacturer s factory or whether he repairs himself. 13

372 Operating instruction english Type MD-032 standard Lubrication 9 Lubrication! In order to minimize operating forces and to extend service life of the coupling we recommend to slightly grease plug surfaces. Lubrication is to be carried out with greases which do not tend to become resin. Caution! The selection of the grease is to be suited to the sealing quality and the medium (e.g.: oxygen) in view of the compatibility. 14

373 Operating instruction english Type MD-032 standard Storage 10 Storage The couplings must be stored in such a way that no damages can occur at the couplings. The storage conditions of the couplings must comply with the guidelines for the seals as these can change in properties due to improper storage. The following items must be kept: - The couplings must be stored dry. - To safely conserve the seals and that means also the couplings they should not be stored under the effect of daylight. - For protection against oxygen the seals and also the couplings shall be stored into the packing. 15

374 Operating instruction english Type MD-032 standard Shut-down 11 Shut-down At the end of the service life the coupling or its components have to be disposed non-polluting and according to the legal regulations. For that the local public or private disposal societies should be taken. 16

375 Operating instruction english Type MD-032 standard Order number code 12 Order number code X X X - X X X X X X X X X X X - X X X X - X X X X X - X X X X X X X X X X X X X X X X - X X 1. Subject group 2. Series Series description consists of either two letters or two digits. 3. Nominal size / nominal width It is rounded up or rounded down to full units. The indication can be numerical or alphanumeric. 4. Type of product and design 5. Type of connection 6. Material: xx-x and xxxx possible 7. Material (seal version): xx-x and xxxx possible 8. Y- or Z-design 9. Optional features 17

376 Operating instruction english Type MD-032 standard Index 13 Index A According to intended purpose... 6 Acquired knowledge... 4 air... 7 Alterations... 4 Assembly... 6 C Commissioning... 4, 6 connected... 6, 7, 13 connection... 7, 17 Connection process coupling... 4, 6 Coupling... 7, 16 Couplings... 6 Customer care... 2 D Damage... 4, 6 Damage compensation... 4 daylight disconnected Disconnection process Dismantling... 6 Disposal societies Disregard... 7 dry dust cap... 7 dust plug... 7 E elektrostatisch Equipment... 4 Experience... 4 explosionsgefährdeten Bereichen external damage F Faults... 4 Fluid... 6 Function... 6 Function test... 6 Functionality... 2 G General... 4 Gerätekategorie guarantee H Hazard notes...6 Hazardous emission...6 hydraulic oil...7 I Implementation...6 Improvement...4 Index...18 Inspection...2 Installation Instruction...10 Intended use...7 K Kennzeichnung...9 L Legible condition...6 Liability...4 List of Contents...3 Lubrication...14 M Maintenance...2, 4, 6 Maintenance Instruction...13 Manual...4 Medium Pressure Series 1 O Operating instruction...1 Operating Instruction...11 Operation...2 Operational safety regulations...6 operator...6 Operators...2 original...4 P packing...15 Perfect, functioning condition...6 Performance capability...2 Pressurized...6 Product description...7 Property...4 Q quality

377 Operating instruction english Type MD-032 standard Index questions... 4 R regulations Regulations... 4 Reliability... 2 responsible... 7 S Safety... 2 Safety devices... 6 Safety instructions... 6 Schlagfunken Scope of delivery... 4 Screw connections... 6 self sealing adaptor... 7, 10, 11, 13 self sealing coupling... 7, 10, 11, 13 Self sealing coupling... 1, 11 service... 13, 14 Service... 2 Shut-down Special designs... 4 Specialists... 2 Status of development... 4 Storage subspecies... 7 Systems...2, 6 T Technical data...7 Technical equipment...2 Technical values...7 Temperaturbeständigkeit...9 Temperaturklasse...9 Tools...2, 6 Translation errors...4 Types of use...7 U Use...2 V Version...4 W water...7 Work safety regulations...6 Working method...6 working pressure...7 Wrong product selection

378 Operating manual Revision D Date Created by NH This operating instruction is not subject to the updating Clean-Break-Coupling with curved lock CN-series optional features: EX 1

379 This coupling is a quality product, in which special attention has been paid to high functionality, ease of operation, safety and reliability. As an item of technical equipment this tool-changer is intended for use in the commercial, industrial area and for operators, who have been trained by specialists in the handling of technical systems / tools. Customer care: As part of our individual customer care we will be happy to assist you in questions relating to use and operation and on any problems encountered. Service and maintenance: In order to maintain the high technical performance capability and reliability of your docking system over many years, we recommend regular inspection and maintenance. We can thereby offer you optimum support by our Customer Service department and the conclusion of a service and maintenance contract. Please ask for a quotation. Carl Kurt Walther GmbH & Co. KG PO Box Haan Westfalenstraße 2 Tel.: +49 (0) Fax: +49 (0) info@walther-praezision.de Internet: Contact: Application technology and service Holger R. Figge Telephone: (02129) Telefax: (02129) Handy: (0162) hfigge@walther-praezision.de Further addresses and telephone numbers of contacts can be found on the Internet on our homepage under Service / Customer service. 2

380 Inhalt: 1-CN A-. 1-CN A-. 1-CN A-. 1-CN A-.-GG 1-CN A-. 1-CN A-.-RG 1-CN A-. 1-CN A-.-RG 3

381 Operating manual Type CN-series Table of Contents 1 Table of Contents 1 TABLE OF CONTENTS GENERAL WARRANTY SAFETY INSTRUCTIONS PRODUCT DESCRIPTION OF THE COUPLING INTENDED USE TECHNICAL DATA OPTIONAL FEATURES EXTENDED PRODUCT DESCRIPTION FOR APPLICATION ACC. TO ATEX-GUIDE LINE 94/9/EG (SPECIAL DESIGN EX): General Extended marking INSTALLATION MANUAL GENERAL EXTENDED INSTALLATION INSTRUCTION FOR APPLICATION ACC. TO ATEX-GUIDELINE 94/9/EG Details for safe operation Details for safe installation Details for a safe application area OPERATING MANUAL COUPLING PROCESS UNCOUPLING PROCESS MAINTENANCE AND FUNCTION TEST MAINTENANCE AND FUNCTIONAL TEST Maintenance includes following items: Functional test includes following items: LUBRICATION! STORAGE SHUT-DOWN ORDERS NUMBER CODE INDEX

382 Operating manual Type CN-series General 2 General This manual contains all regulations for operation, commissioning and maintenance of the locking coupling elementself sealing coupling elements. All information and notes in this operating manual were collated while taking into consideration the valid regulations, the current engineering related status of development as well as our many years of experience and acquired knowledge. Translations of this operating manual were also produced according to the best of knowledge. However, we cannot assume liability for any translation errors. The German version provided for this operating manual is considered the authoritative version. The actual scope of delivery can deviate from the explanations and graphic representations described herein under certain circumstances, e.g. in the case of special designs, utilization of additional order options or because of state-of-the-art technical alterations. If you have any questions, please contact the manufacturer. This operating manual must be read carefully before starting work on or with the equipment, in particular before commissioning! The manufacturer assumes no liability for damage or faults arising from non-compliance with the instructions in this operating manual. The operating manual must be kept directly with the equipment and be accessible to all persons who work on or with the equipment. It is not permitted for the operating manual to be passed to third parties and if applicable this will incur damage compensation. All other rights reserved. Before commissioning the device must be checked for being not defective and its technically perfect function. The German version is the original. We reserve the right to make technical alterations to the product within the context of improving the usage properties and further development. The operating manual remains our property. Any reproduction, use by or communication to third parties incurs a penalty and will be pursued by court action (copyright law against unfair competition, BGB [German Civil Code]). All rights reserved in the case of a patent award (Paragraph 7, Section. 1 of the patent law - PG) or entry as a patented design (Paragraph 5, Section 4 of the patented design law - GMG). 5

383 Operating manual Type CN-series Warranty 3 Warranty The warranty conforms to: the General Conditions for Delivery and Capacity of C.K. Walther GmbH & Co. KG of the state which was valid at the date of the purchase contract and the regulations agreed in the purchase contract. Wearing parts are generally excluded from the warranty. Typical wearing parts of products from company C.K. Walther GmbH & Co. KG are for example: seals springs 6

384 Operating manual Type CN-series Safety instructions 4 Safety instructions Using these couplings does not release the customer from his obligation to comply with the pertinent work safety regulations e.g. operational safety regulations, etc. The duty to take due care by the operator of the couplings includes planning measures to ensure proper operation and monitoring their implementation. Hazard notes If the wrong product has been selected or if there is improper use or maintenance has been omitted, then hazards arise and personal injuries and material damage can occur from: - hazardous emission of medium or individual particles/coupling parts. - function impairments of connected systems or tools. - the metal parts of coupling and adaptor are not thermally protected. In case of high or low media temperatures the contact with these parts can lead to combustion. According to the ambient temperature valve handle and ring grip can also become very hot and colt. For that reason sufficiently long protective gloves must be worn in these cases. The operator must in particular make sure that - the couplings are only used according to the intended purpose. - the couplings are only operated in a perfect, functioning condition. - the operating manual is always in a legible condition and is available in its entirety to operating personnel. - the operating personnel are sufficiently acquainted with the working method and the safety notes for the coupling. - no safety devices must be removed and/or deactivated during operation of the couplings. - before installing or dismantling the couplings, you have made sure that the couplings have not been pressurized. After completing assembly and installation work and before commissioning the coupling, the following items have to be observed: Check once again that all screw connections are securely fitted. Before commissioning the couplings, a function test must be carried out (see maintenance and function test). 7

385 Operating manual Type CN-series 5 Product description of the coupling The coupling connection consists of: Product description of the coupling clean-break-coupling CN- -0 usually fixed half clean-break-adaptor CN- -2 usually free half (hose side) which are connected resp. separated by a circular motion along a control curve (see point 8). If the two coupling halves are not connected, both coupling halves, if necessary, should be protected against external contaminations and/or damages. For this purpose the following dust caps and dust plugs are available. Possible combinations: clean-break-coupling with dust plug clean-break-adaptor with dust cap 1-CN CN CN CN Intended use - The coupling is only used to connect two lines. The coupling is used primarily at the supply side or receiver side (fixed half). The adaptor is used primarily at the hose side (free half). - The connection and disconnection process is carried out by hand. - The coupling is suitable especially for following media/fields of application: - chemical industry - For all other possible media Walther Präzision should be consulted. 8

386 Operating manual Type CN-series 5.2 Technical Data - The working pressures for the self sealing coupling element depend on the component materials. Product description of the coupling - When determining the working pressures with standardized threaded connections, the highest permissible working pressure of the connection must be taken into consideration. Operating pressures max.stat. (bar) Type connected coupling/ adaptor disconnected coupling disconnected adaptor connectable under max. pressure differential Cv- Wert leakage quantity per diskonnection cycle CN ,4 ml CN ,0 ml CN ,3 ml CN ,3 ml The leckage quantity per disconnectio cycle refers to the use of the media water at room temperature and a igh pressure of 1 bar in the media sector. - The self sealing coupling element is not determined for any types of use other than those listed here. - Safe operation is not guaranteed if the self sealing coupling element is used contrary to its intended use. - The operator of the self sealing coupling element is responsible for all personal injuries or material damage that occur from non-intended use and disregard of the technical values; the manufacturer assumes no responsibility in these cases. 5.3 Optional Features EX = ATEX version 9

387 Operating manual Type CN-series Product description of the coupling 5.4 Extended product description for application acc. to ATEX-guide line 94/9/EG (special design EX): General Only non-sparkling materials may be used. Non-sparkling materials are , or equivalent materials. Furthermore brass with different surfaces (f. ex. chrome-plated, nickel-plated). Further on it must be assured that the seal is resistant against and suitable for the flowing through media. Also the temperature resistance of the seals must be guaranteed. This must also be considered for the marking acc. to chapter Extended marking The coupling fittings are marked with As the surface temperature of the self-sealing couplings are determined by the temperature of the fluids, the temperature category or the highest surface temperature must be specified by the operator while the safe temperature distances acc. to EN must be observed and the maximum temperature resistance of the coupling materials and seals are taken into consideration. The marking of the temperature class must be effected readily visible by the operator. The determination of the temperature class must be made acc. to the following table: Max. temperature of Temperature class fluids 75 T6 90 T5 130 T4 195 T3 295 T2 445 T1 The couplings are not admitted for the temperature classes T1 T4 and may not be marked for that by the operator. 10

388 Operating manual Type CN-series Installation manual 6 Installation manual 6.1 General The coupling is to be integrated into the line network while taking into account the general accident prevention guidelines so that: - perfect operation is guaranteed in accordance with the operating manual. - the coupling is used primarily on the supply side or receiver side (fixed half) and the adaptor primarily at the hose side (free half) - external damage to the unit and all mobile parts is excluded. Before installing the coupling in a pipeline network, make sure that the pipeline network has been sufficiently rinsed/blown through and/or cleaned. After completing the assembly work, a function test must be carried out according to the operating manual, both in depressurized state and under working pressure. 6.2 Extended installation instruction for application acc. to ATEX-guideline 94/9/EG Details for safe operation For the use of self sealing couplings as a hose connection it must be guaranteed that in case of pressure strikes the tumbling of the self sealing coupling can be avoided by fixing at suitable constructions. In principle it must be observed that the self sealing coupling cannot strike on hard objects which could produce strike sparks when touching the housing Details for safe installation The self sealing couplings may only be connected to pipe- and hose systems which are suitable for electrostatic discharge and which are connected to the ground potential Details for a safe application area The self sealing couplings may be used according to the class of devices2 in areas susceptible to explosions where potentially explosive mixtures of gas, steam, mist and air are availble. 11

389 Operating manual Type CN-series Operating manual 7 Operating manual The self sealing coupling elements may only be used for the operating conditions specified under item 4 (product description) in order to avoid critical injury to personnel and damage to the self sealing coupling elements during operation. 7.1 Coupling process Before each coupling process a visual check of the coupling and the adaptor has to be made. In case of recognisable and visible damages or deformations, the damaged parts must be replaced. Take the clean break adaptor (free half) being at the hose as shown in the next picture. (gilt für CN-050, CN-080, CN-100) Die CN-025 wird an der Verriegelungshülse aufgenommen. Slide the free half (adaptor) axially centred onto the plug part of the fixed half (coupling) until sensible resistance. Then the free half is turned clockwise onto the coupling by hand wheel until mechanical end stop. Sequence during turn up: 1. When turning to the right, the adaptor winds onto the coupling 2. When you go on turning to the right, the dead centre of the locking is reached and crossed. 3. When you go on turning to the right, the adaptor runs back after crossing the dead centre and before reaching the groove end. 4. When you go on turning to the right, the adaptor reaches the final position. The coupling and the adaptor are now locked mechanically. 7.2 Uncoupling process Take the sealing adaptor as you do during the connection process and turn it counter clockwise. Sequence during turn off: 1. When turning to the left, the adaptor winds onto the coupling. 2. When you go on turning to the left and after crossing the dead centre, the adaptor leaves the lock and can be taken from the coupling. In doing so, the valves in the adaptor and in the coupling close in parallel. 12

390 Operating manual Type CN-series Maintenance and function test 8 Maintenance and function test Preventive maintenance measures WALTHER self sealing couplings are to be operated in such a manner that external damages to elements and all moving parts are avoided. 8.1 Maintenance and functional test In order to always guarantee function of the self sealing coupling and hence safety of operator, a maintenance and functional testing must be made in appropriate periods of time depending on operating conditions. In order to minimize operating forces and to extend service life of the self sealing coupling we recommend to slightly grease plug surfaces (see item 9.0) Maintenance includes following items: - A visual inspection of self sealing coupling and self sealing adaptor regarding damage and contamination has to be made. - Dirt at the functional area (sealing area, operating elements) which is easily accessible from outside should be removed by simply wiping-off. If there are damaged, torn or corroded parts, coupling must be dismounted and returned to manufacturer for repair. If worn or embrittled seals are found or if there is extreme dirt, the customer can decide whether he returns coupling unit to the manufacturer's factory or whether he repairs himself Functional test includes following items: As described in the operating instruction, coupling is several times connected, pressurized and then disconnected. In doing so, the following has to be observed: - Connection and disconnection process must be absolutely smooth. - Coupling must be absolutely leak-proof in connected and disconnected state. If there are damaged, torn or corroded parts, coupling must be dismounted and returned to manufacturer for repair. If worn or embrittled seals are found or if there is extreme dirt, the customer can decide whether he returns the coupling unit to the manufacturer s factory or whether he repairs himself. 13

391 Operating manual Type CN-series Lubrication 9 Lubrication! We recommend lightly greasing the plug-in areas to minimize operating forces and to extend the service life of the coupling. Do not lubricate with resinous greases. Attention! The choice of grease with regard to compatibility must agree with the seal quality and the medium (e.g.: oxygen). The bearing roll (pos. 24) and the bearing bolt (pos. 25) must be greased slightly with roller bearing grease. 14

392 Operating manual Type CN-series Storage 10 Storage The couplings must be stored in such a way that no damage can occur to the couplings. The storage conditions of the couplings depend on the guidelines applicable to the gaskets, since improper storage can lead to deterioration of the gaskets. The following points must be observed: - The couplings must be stored dry. - For the preservation of the gaskets, the gaskets and couplings should not be stored where they are exposed to the effects of daylight. For protection against oxygen, the gaskets and couplings should be stored in the original packaging. 15

393 Operating manual Type CN-series Shut down 11 Shut-down At the end of the service life the coupling or its components have to be disposed non-polluting and according to the legal regulations. For that the local public or private disposal societies should be taken. 16

394 Operating manual Type CN-series Order numbers code 12 Orders number code X X X - X X X X X X X X X X X - X X X X - X X X X X - X X X X X X X X X X X X X X X X - X X 1. Subject group 2. Series The information regarding the series comprises either two letters or two numbers. 3. Nominal size / nominal borewidth It is rounded up or down to one. The information can be numerical as well as alphanumerical. 4. Product type or design type 5. Connection design 6. Material design: xx-x and xxxx possible 7. Material design (seal design): xx-x and xxxx possible 8. Y or Z design 9. Additional equipment 17

395 Operating manual Type CN-series Index 13 Index A Accident prevention guidelines According to intended purpose... 7 Acquired knowledge... 5 Alterations... 5 Assembly... 7 Assembly work C clean-break-adaptor... 8 clean-break-coupling... 8 Clean-Break-Coupling... 1 Cleaned Commissioning... 5, 7 connected connections... 7, 9 coupling... 5 Coupling... 7, 9, 11, 12, 14, 16 Couplings... 7 curved lock... 1 Customer care... 2 D damage... 7, 15 Damage... 5, 7, 9, 11, 12 Damage compensation... 5 Daylight Depressurized Depressurized state disconnected Dismantling... 7 Disposal societies dry dust cap... 8 dust plug... 8 E elektrostatisch Equipment... 5 Experience... 5 explosionsgefährdeten Bereichen F Faults... 5 Function... 7 Function test... 7, 11 Functionality... 2 G General... 5 Gerätekategorie guarantee H Hazard notes... 7 Hazardous emission... 7 Hose side I Implementation... 7 Improvement... 5 Inspection... 2 Intended use... 8 K Kennzeichnung L Legible condition... 7 Liability... 5 M Maintenance... 2, 5, 7 Manual... 5 Medium... 7 Mobile parts O Operating manual... 1, 11 Operation... 2 Operational safety regulations... 7 Operator... 7, 9 Operators... 2 Original... 5 Oxygen P Packaging Perfect operation Perfect, functioning condition... 7 Performance capability... 2 Pipeline network Pressurized... 7 Property

396 Operating manual Type CN-series Index R Regulations... 5 Reliability... 2 S Safety... 2 Safety devices... 7 Schlagfunken Scope of delivery... 5 Screw connections... 7 self sealing adaptor self sealing coupling service Service... 2 Shut-down Special designs... 5 Specialists... 2 Status of development... 5 Storage Storage conditions Supply side Systems... 2, 7 T Table of Contents... 4 Technical Data... 9 Technical equipment... 2 Temperaturbeständigkeit Temperaturklasse Tools... 2, 7 Translation errors... 5 turn off turn up turning to the left turning to the right Types of use... 9 U Use... 2 V Version... 5 W Werkstoffkombinationen... 3 Work safety regulations... 7 Working method... 7 Working pressure... 9, 11 Working pressures... 9 Wrong product selection

397 Operating manual Revision A Date Created by NH This operating instruction is not subject to the updating Low Pressure Clean-Break-Coupling 1-CT CT CT CT CT CT CT CT CT CT optional features: EX, GG (only CT-019) 1

398 This coupling is a quality product, in which special attention has been paid to high functionality, ease of operation, safety and reliability. As an item of technical equipment this coupling is intended for use in the commercial, industrial area and for operators, who have been trained by specialists in the handling of technical systems / tools. Customer care: As part of our individual customer care we will be happy to assist you in questions relating to use and operation and on any problems encountered. Service and maintenance: In order to maintain the high technical performance capability and reliability of your coupling over many years, we recommend regular inspection and maintenance. We can thereby offer you optimum support by our Customer Service department and the conclusion of a service and maintenance contract. Please ask for a quotation. Carl Kurt Walther GmbH & Co. KG PO Box Haan Westfalenstraße 2 Tel.: +49 (0) Fax: +49 (0) info@walther-praezision.de Internet: Contact: Application technology and service Holger R. Figge Telephone: (02129) Telefax: (02129) Handy: (0162) hfigge@walther-praezision.de Further addresses and telephone numbers of contacts can be found on the Internet on our homepage under Service / Customer service.- 2

399 Operating manual Type CT-Serie Table of Contents 1 Table of Contents 1 TABLE OF CONTENTS GENERAL WARRANTY SAFETY INSTRUCTIONS PRODUCT DESCRIPTION OF THE COUPLING INTENDED USE TECHNICAL DATA OPTIONAL FEATURES EXTENDED PRODUCT DESCRIPTION FOR APPLICATION ACC. TO ATEX-GUIDE LINE 94/9/EG (SPECIAL DESIGN EX): General Extended marking INSTALLATION MANUAL GENERAL EXTENDED INSTALLATION INSTRUCTION FOR APPLICATION ACC. TO ATEX-GUIDELINE 94/9/EG Details for safe operation Details for safe installation Details for a safe application area OPERATING MANUAL COUPLING PROCESS UNCOUPLING PROCESS MAINTENANCE AND FUNCTION TEST MAINTENANCE FUNCTION TEST LUBRICATION! STORAGE SHUT-DOWN ORDER NUMBERS CODE INDEX

400 Operating manual Type CT-Serie General 2 General This manual contains all regulations for operation, commissioning and maintenance of the coupling CT-series. All information and notes in this operating manual were collated while taking into consideration the valid regulations, the current engineering related status of development as well as our many years of experience and acquired knowledge. Translations of this operating manual were also produced according to the best of knowledge. However, we cannot assume liability for any translation errors. The German version provided for this operating manual is considered the authoritative version. The actual scope of delivery can deviate from the explanations and graphic representations described herein under certain circumstances, e.g. in the case of special designs, utilization of additional order options or because of state-of-the-art technical alterations. If you have any questions, please contact the manufacturer. This operating manual must be read carefully before starting work on or with the equipment, in particular before commissioning! The manufacturer assumes no liability for damage or faults arising from non-compliance with the instructions in this operating manual. The operating manual must be kept directly with the equipment and be accessible to all persons who work on or with the equipment. It is not permitted for the operating manual to be passed to third parties and if applicable this will incur damage compensation. All other rights reserved. Before commissioning the device must be checked for being not defective and its technically perfect function. The German version is the original. We reserve the right to make technical alterations to the product within the context of improving the usage properties and further development. The operating manual remains our property. Any reproduction, use by or communication to third parties incurs a penalty and will be pursued by court action (copyright law against unfair competition, BGB [German Civil Code]). All rights reserved in the case of a patent award (Paragraph 7, Section. 1 of the patent law - PG) or entry as a patented design (Paragraph 5, Section 4 of the patented design law - GMG). 4

401 Operating manual Type CT-Serie Warranty 3 Warranty The warranty conforms to: the regulations agreed in the purchase contract and the General Conditions for Delivery and Capacity of C.K. Walther GmbH & Co. KG of the state which was valid at the date of the purchase contract. Wearing parts are generally excluded from the warranty. Typical wearing parts of products from company C.K. Walther GmbH & Co. KG are for example: seals springs 5

402 Operating manual Type CT-Serie Safety instructions 4 Safety instructions Using these couplings does not release the customer from his obligation to comply with the pertinent work safety regulations e.g. operational safety regulations, etc. The duty to take due care by the operator of the couplings includes planning measures to ensure proper operation and monitoring their implementation. Hazard notes If the wrong product has been selected or if there is improper use or maintenance has been omitted, then hazards arise and personal injuries and material damage can occur from: - hazardous emission of medium or individual particles/coupling parts. - function impairments of connected systems or tools. - the metal parts of coupling and adaptor are not thermally protected. In case of high media temperatures the contact with these parts can lead to combustion. According to the ambient temperature valve handle and ring grip can also become very hot. For that reason sufficiently long protective gloves must be worn in these cases. The operator must in particular make sure that - the couplings are only used according to the intended purpose. - the couplings are only operated in a perfect, functioning condition. - the operating manual is always in a legible condition and is available in its entirety to operating personnel. - the operating personnel are sufficiently acquainted with the working method and the safety notes for the coupling. - no safety devices must be removed and/or deactivated during operation of the couplings. - before installing or dismantling the couplings, you have made sure that the couplings have not been pressurized. After completing assembly and installation work and before commissioning the coupling, the following items have to be observed: Check once again that all screw connections are securely fitted. Before commissioning the couplings, a function test must be carried out (see maintenance and function test). 6

403 Operating manual Type CT-Serie 5 Product description of the couplingcoupling Coupling connection consists of: - self sealing coupling 1-CT self sealing adaptor 1-CT self sealing coupling 1-CT self sealing adaptor 1-CT self sealing coupling 1-CT self sealing adaptor 1-CT self sealing coupling 1-CT self sealing adaptor 1-CT self sealing coupling 1-CT self sealing adaptor 1-CT Product description of coupling In case that both coupling halves are not connected they should be protected against external dirt and/or damages if required. For that purpose dust cap and dust plug are available. Possible comibinations : self sealing coupling dust cap self sealing adaptor dust cap 1-CT with 1-SK AAAA-T015 1-CT with 1-SL AAAA-T022 self sealing coupling dust cap self sealing adaptor dust cap self sealing coupling dust cap self sealing adaptor dust cap self sealing coupling dust cap self sealing adaptor dust cap self sealing coupling dust cap self sealing adaptor dust cap 1-CT with 1-SK AAAA-T017 1-CT with 1-SL AAAA-T028 1-CT with 1-SK AAAA-T017 1-CT with 1-SL AAAA-T030 1-CT with 1-SK AAAA-T017 1-CT with 1-SL AAAA-T030 1-CT with 1-SK AAAA-T020 1-CT with 1-SL AAAA-T046 We recommend: The self sealing adaptors should be rigidly mounted and the self sealing couplings should be used as free parts which protects the sealing faces. 7

404 Operating manual Type CT-Serie Product description of coupling 5.1 Intended Use - The Clean Break couplings of the CT series are our latest generation push to connect couplings for low pressure applications (up to 64 bar). - The clean break coupling serves only to connect two lines. - Connection under residual pressures. Type CT-005 CT-007 CT-009 CT-012 CT-019 can be connected under residual pressure 25 bar 362 psi 15 bar 217 psi 15 bar 217 psi - The connection and disconnection process is carried out manually. - The coupling has an automatic lock, i.e. one-hand operation - The connection and disconnection is performed without squirting medium. - This series is suitable for all applications which demand minimal leackage, fool-proof handling and a high flow rate. - For all other possible media Walther Präzision should be consulted. 8 bar 116 psi 4 bar 58 psi 5.2 Technical data - Working pressures of coupling depend on materials of individual parts. - When determing the working with standardized threaded connections, the highest permissible working pressure of the connection must be taken into account. - When selecting a suitable connection the following static pressure is possible: Max. working pressure connected bar / psi Max. working pressure disconnected bar / psi Amount of Leakage (ml) Cv-value CT / / 435 0,1 0,8 CT / / 435 0,1 1,85 CT / / 435 0,1 2,75 CT / / 435 0,15 4,5 CT / / 435 0,3 9,8 - The coupling is not determined for any types of use and technical values other than those listed here. - Safe operation is not guaranteed if the coupling is used contrary to ist intended use and technical values - The operator of the coupling is responsible for all personal injuries or material damage that occur from non-intended use and disregard of the technical values; the manufacturer assumes no responsibility in these cases. 8

405 Operating manual Type CT-Serie 5.3 Optional Features GG = with ring grips (aluminium cast) only CT-019 (z.b.: 1-CT GG) Product description of coupling EX = ATEX version 5.4 Extended product description for application acc. to ATEX-guide line 94/9/EG (special design EX): General Only non-sparkling materials may be used. Non-sparkling materials are , or equivalent materials. Furthermore brass with different surfaces (f. ex. chrome-plated, nickel-plated). Further on it must be assured that the seal is resistant against and suitable for the flowing through media. Also the temperature resistance of the seals must be guaranteed. This must also be considered for the marking acc. to chapter Extended marking The coupling fittings are marked with As the surface temperature of the self-sealing couplings are determined by the temperature of the fluids, the temperature category or the highest surface temperature must be specified by the operator while the safe temperature distances acc. to EN must be observed and the maximum temperature resistance of the coupling materials and seals are taken into consideration. The marking of the temperature class must be effected readily visible by the operator. The determination of the temperature class must be made acc. to the following table: Max. temperature of Temperature class fluids 75 T6 90 T5 130 T4 195 T3 295 T2 445 T1 The couplings are not admitted for the temperature classes T1 and T2 and may not be marked for that by the operator. 9

406 Operating manual Type CT-Serie Installation manual 6 Installation manual 6.1 General The coupling is to be integrated into the line network while taking into account the general accident prevention guidelines so that: - perfect operation is guaranteed in accordance with the operating manual. - the coupling is primarily used by the network and the adaptor is primarily used by the consumer side. - external damage to the unit and all mobile parts is excluded. Before installing the coupling in a pipeline network, make sure that the pipeline network has been sufficiently rinsed/blown through and/or cleaned. After completing the assembly work, a function test must be carried out according to the operating manual, both in depressurized state and under working pressure. 6.2 Extended installation instruction for application acc. to ATEX-guideline 94/9/EG Details for safe operation For the use of self sealing couplings as a hose connection it must be guaranteed that in case of pressure strikes the tumbling of the self sealing coupling can be avoided by fixing at suitable constructions. In principle it must be observed that the self sealing coupling cannot strike on hard objects which could produce strike sparks when touching the housing Details for safe installation The self sealing couplings may only be connected to pipe- and hose systems which are suitable for electrostatic discharge and which are connected to the ground potential Details for a safe application area The self sealing couplings may be used according to the class of devices2 in areas susceptible to explosions where potentially explosive mixtures of gas, steam, mist and air are availble. 10

407 Operating manual Type CT-Serie Operating manual 7 Operating manual The self sealing coupling elements may only be used for the operating conditions specified under item 5 (product description) in order to avoid critical injury to personnel and damage to the self sealing coupling elements during operation. 7.1 Coupling process Before each coupling process a visible check of the coupling and the adaptor has to be made. Damaged parts must be changed in case of observable, visible damages or deformations. The self-sealing coupling is equipped with an automatic lock, i. e. one-hand operation. For coupling the self-sealing coupling behind the locking sleeve or the self-sealing adaptor in the end plug area is taken up with one hand and pushed axially centred on the counter piece until the end stop. During the coupling the locking sleeve snaps in forward without the aid of the operator. Now the self-sealing coupling and the self-sealing adaptor are locked mechanically. Available valves are opened during the coupling process and thus the passage is released. CAUTION Please take care that locking sleeve is in final position, i.e. that it is flush in front with the coupling housing as otherwise no perfect lock is guaranteed. 7.2 Uncoupling process For decoupling the self sealing coupling behind the locking sleeve is taken up with one hand and the locking sleeve is pulled back with the other hand and thus the connection is separated. After separating the connection the locking sleeve slides back to its initial position for the next coupling procedure. This position is the same in the connected and disconnected condition. During the decoupling the available valves close automatically so that no further discharge of media is possible. Caution! In case of an available pressure in the line connected by the coupling system a strong separation impulse - depending on the pressure - can be effective onto the coupling system during disconnection. For that reason the movable part of the coupling (free half) is to be firmly held in the hand to avoid injuries. 11

408 Operating manual Type CT-Serie Lubrication 8 Maintenance and function test Preventative maintenance measures WALTHER self sealing couplings are to be handled in such a way that external damage to the elements and to all movable parts is excluded. We recommend a slight greasing of the movable plug-in areas to minimize operating forces and to extend the service life of the self sealing couplings. To always guarantee the function of the coupling and hence the safety of the operator a maintenance and a functional testing must be carried out within appropriate periods of time depending on the operating conditions. 8.1 Maintenance - An external visual inspection for damage and contamination is to be carried out for the self sealing coupling and the self sealing adaptor. - Contamination in the externally accessible function areas (sealing area, operating elements) is to be removed simply by wiping. If there are damaged, torn or corroded parts, the clean break coupling must be dismantled and sent for repair to the manufacturer. In the case of torn, brittle or old seals and with severe contamination, the customer must decide whether to send the clean break coupling to the manufacturer for repair work or whether he repairs himself. 8.2 Function test As described in the operating manual, the clean break coupling is connected several times, pressurized and disconnected. When doing this, pay attention to the following: - Perfect, smooth-running functioning during connection and disconnection. - Leak tightness of the clean break coupling when connected and disconnected. If there are damaged, torn or corroded parts, the coupling must be dismantled and sent for repair to the manufacturer. In the case of torn, brittle or old seals and with severe contamination, the customer must decide whether to send the clean break coupling to the manufacturer for repair work, or whether he repairs himself. 12

409 Operating manual Type CT-Serie Lubrication 9 Lubrication! We recommend lightly greasing the plug-in areas to minimize operating forces and to extend the service life of the coupling. Lubrication has to be carried out with greases which do not tend to become resin. Do not lubricate with resinous greases. Attention! The choice of grease with regard to compatibility must agree with the seal quality and the medium (e.g.: oxygen). 13

410 Operating manual Type CT-Serie Storage 10 Storage The couplings must be stored in such a way that no damage can occur to the couplings. The storage conditions of the couplings depend on the guidelines applicable to the gaskets, since improper storage can lead to deterioration of the gaskets. The following points must be observed: - The couplings must be stored dry. - For the preservation of the gaskets, the gaskets and couplings should not be stored where they are exposed to the effects of daylight. For protection against oxygen, the gaskets and couplings should be stored in the original packaging. 14

411 Operating manual Type CT-Serie Shut down 11 Shut-down At the end of the service life the coupling or its components have to be disposed non-polluting and according to the legal regulations. For that the local public or private disposal societies should be taken. 15

412 Operating manual Type CT-Serie Order numbers code 12 Order numbers code X X X - X X X X X X X X X X X - X X X X - X X X X X - X X X X X X X X X X X X X X X X - X X 1. Subject group 2. Series The information regarding the series comprises either two letters or two numbers. 3. Nominal size / nominal borewidth It is rounded up or down to one. The information can be numerical as well as alphanumerical. 4. Product type or design type 5. Connection design 6. Material design: xx-x and xxxx possible 7. Material design (seal design): xx-x and xxxx possible 8. Y or Z design 9. Additional equipment 16

413 Operating manual Type CT-Serie Index 13 Index A Accident prevention guidelines According to intended purpose... 6 Acquired knowledge... 4 Alterations... 4 Assembling Assembly... 6 Assembly work C clean break subassembly element Cleaned Commissioning... 4, 6 connected... 7 connection... 7 Consumer side Corroded coupling... 2, 6, 12, 13 Coupling... 6, 8, 11, 12, 15 Couplings... 6 Customer care... 2 D Damage... 4, 6 Damage compensation... 4 Damaged Daylight Depressurized Depressurized state Dismantling... 6, 10 Disposal societies Disregard... 8 dry dust cap... 7 dust plug... 7 E Equipment... 4 Experience... 4 F Faults... 4 Function... 6 Function test... 6, 10, 12 Functionality... 2 G General... 4 H Hazard notes... 6 Hazardous emission... 6 I Implementation... 6 Improvement... 4 Inspection... 2 Installation manual L Legible condition... 6 Liability... 4 Lubrication M Maintenance...2, 4, 6, 12 Maintenance and function test Manual... 4 Medium... 6 Mobile parts N Network side O one-hand operation Operating manual... 1, 10 Operation... 2 Operational safety regulations... 6 Operator... 6, 12 Operators... 2 original... 4 Oxygen P Packaging Perfect operation Perfect, functioning condition... 6 Performance capability... 2 Pipeline network Pressurized... 6 Product description... 7 Property... 4 R Regulations... 4 Reliability... 2 Repair work... 12

414 Operating manual Type CT-Serie Index responsible... 8 S Safety... 2 Safety devices... 6 Scope of delivery... 4 Screw connections... 6 Seals self sealing adaptor... 7 Self sealing adaptor self sealing coupling... 7 Self sealing coupling Service... 2 Severe contamination Shut-down Smooth-running function Special designs... 4 Specialists... 2 Status of development... 4 Storage Storage conditions Systems... 2, 6 T Table of Contents... 3 Technical data... 8 Technical equipment... 2 Technical values... 8 Temperaturklasse... 9 Tools... 2, 6 Torn Translation errors... 4 Types of use... 8 U Use... 2, 10 V Version... 4 W Work safety regulations... 6 Working method... 6 working pressure... 8 Working pressure Wrong product selection... 6

415 Operating manual Revision A Date Created by NH This operating instruction is not subject to the updating Self sealing coupling Low pressure Series UF-series optional features: OV, SI, EX 1

416 This coupling is a quality product, in which special attention has been paid to high functionality, ease of operation, safety and reliability. As an item of technical equipment this tool-changer is intended for use in the commercial, industrial area and for operators, who have been trained by specialists in the handling of technical systems / tools. Customer care: As part of our individual customer care we will be happy to assist you in questions relating to use and operation and on any problems encountered. Service and maintenance: In order to maintain the high technical performance capability and reliability of your docking system over many years, we recommend regular inspection and maintenance. We can thereby offer you optimum support by our Customer Service department and the conclusion of a service and maintenance contract. Please ask for a quotation. Carl Kurt Walther GmbH & Co. KG PO Box Haan Westfalenstraße 2 Tel.: +49 (0) Fax: +49 (0) info@walther-praezision.de Internet: Contact: Application technology and service Holger R. Figge Telephone: (02129) Telefax: (02129) Handy: (0162) hfigge@walther-praezision.de Further addresses and telephone numbers of contacts can be found on the Internet on our homepage under Service / Customer service. 2

417 Operating manual Type UF-series Table of Contents 1 Table of Contents 1 TABLE OF CONTENTS GENERAL WARRANTY SAFETY INSTRUCTIONS PRODUCT DESCRIPTION OF THE COUPLING INTENDED USE TECHNICAL DATA OPTIONAL FEATURES EXTENDED PRODUCT DESCRIPTION FOR APPLICATION ACC. TO ATEX-GUIDE LINE 94/9/EG (SPECIAL DESIGN EX): General Extended marking INSTALLATION MANUAL GENERAL EXTENDED INSTALLATION INSTRUCTION FOR APPLICATION ACC. TO ATEX-GUIDELINE 94/9/EG Details for safe operation Details for safe installation Details for a safe application area OPERATING MANUAL CONNECTION PROCESS DISCONNECTION PROCESS SAFETY LOCKING DEVICE SI (SUPPLEMENTARY EQUIPMENT) Coupling process Decoupling process MAINTENANCE AND FUNCTION TEST MAINTENANCE AND FUNCTIONAL TEST Maintenance includes following items: Functional test includes following items: LUBRICATION! STORAGE SHUT-DOWN ORDERS NUMBER CODE INDEX

418 Operating manual Type UF-series General 2 General This manual contains all regulations for operation, commissioning and maintenance of the locking coupling elementself sealing coupling elements. All information and notes in this operating manual were collated while taking into consideration the valid regulations, the current engineering related status of development as well as our many years of experience and acquired knowledge. Translations of this operating manual were also produced according to the best of knowledge. However, we cannot assume liability for any translation errors. The German version provided for this operating manual is considered the authoritative version. The actual scope of delivery can deviate from the explanations and graphic representations described herein under certain circumstances, e.g. in the case of special designs, utilization of additional order options or because of state-of-the-art technical alterations. If you have any questions, please contact the manufacturer. This operating manual must be read carefully before starting work on or with the equipment, in particular before commissioning! The manufacturer assumes no liability for damage or faults arising from non-compliance with the instructions in this operating manual. The operating manual must be kept directly with the equipment and be accessible to all persons who work on or with the equipment. It is not permitted for the operating manual to be passed to third parties and if applicable this will incur damage compensation. All other rights reserved. Before commissioning the device must be checked for being not defective and its technically perfect function. The German version is the original. We reserve the right to make technical alterations to the product within the context of improving the usage properties and further development. The operating manual remains our property. Any reproduction, use by or communication to third parties incurs a penalty and will be pursued by court action (copyright law against unfair competition, BGB [German Civil Code]). All rights reserved in the case of a patent award (Paragraph 7, Section. 1 of the patent law - PG) or entry as a patented design (Paragraph 5, Section 4 of the patented design law - GMG). 4

419 Operating manual Type UF-series Warranty 3 Warranty The warranty conforms to: the General Conditions for Delivery and Capacity of C.K. Walther GmbH & Co. KG of the state which was valid at the date of the purchase contract and the regulations agreed in the purchase contract. Wearing parts are generally excluded from the warranty. Typical wearing parts of products from company C.K. Walther GmbH & Co. KG are for example: seals springs 5

420 Operating manual Type UF-series Safety instructions 4 Safety instructions Using these couplings does not release the customer from his obligation to comply with the pertinent work safety regulations e.g. operational safety regulations, etc. The duty to take due care by the operator of the couplings includes planning measures to ensure proper operation and monitoring their implementation. Hazard notes If the wrong product has been selected or if there is improper use or maintenance has been omitted, then hazards arise and personal injuries and material damage can occur from: - hazardous emission of medium or individual particles/coupling parts. - function impairments of connected systems or tools. - the metal parts of coupling and adaptor are not thermally protected. In case of high media temperatures the contact with these parts can lead to combustion. According to the ambient temperature valve handle and ring grip can also become very hot. For that reason sufficiently long protective gloves must be worn in these cases. The operator must in particular make sure that - the couplings are only used according to the intended purpose. - the couplings are only operated in a perfect, functioning condition. - the operating manual is always in a legible condition and is available in its entirety to operating personnel. - the operating personnel are sufficiently acquainted with the working method and the safety notes for the coupling. - no safety devices must be removed and/or deactivated during operation of the couplings. - before installing or dismantling the couplings, you have made sure that the couplings have not been pressurized. After completing assembly and installation work and before commissioning the coupling, the following items have to be observed: Check once again that all screw connections are securely fitted. Before commissioning the couplings, a function test must be carried out (see maintenance and function test). 6

421 Operating manual Type UF-series 5 Product description of the coupling The coupling connection consists of: Self sealing coupling Self sealing adaptor Self sealing coupling Self sealing adaptor Self sealing coupling Self sealing adaptor Self sealing coupling Self sealing adaptor Self sealing coupling Self sealing adaptor 1-UF DR/VI 1-UF DR/VI 1-UF DR/VI 1-UF DR/VI 1-UF DR/VI 1-UF DR/VI 1-UF DR/VI 1-UF DR/VI 1-UF DR/VI 1-UF DR/VI Product description of the coupling If the two coupling halves are not connected, both coupling halves, if necessary, should be protected against external contaminations and/or damages. For this purpose the following dust caps and dust plugs are available. Possible combinations: clean-break-coupling with dust plug clean-break-adaptor with dust cap 1-UF UF UF UF Intended use - The coupling is only used to connect two lines. The coupling is used primarily at the supply side or receiver side (fixed half). The adaptor is used primarily at the hose side (free half). - The connection and disconnection process is carried out by hand. - The coupling is suitable especially for following media/fields of application: - air - water - hydraulic oil - and their subspecies - (such as oxygen or oil with additives) - For all other possible media Walther Präzision should be consulted. 7

422 Operating manual Type UF-series 5.2 Technical Data - The working pressures for the self sealing coupling element depend on the component materials. Product description of the coupling - When determining the working pressures with standardized threaded connections, the highest permissible working pressure of the connection must be taken into consideration. P max.zul. (stat.) (bar) Cv- value Type brass Stainless steel both sides self sealing one side self sealing UF ,73 1,0 UF ,95 1,25 UF ,25 4,34 UF ,5 11,2 UF ,8 29,4 - The self sealing coupling element is not determined for any types of use other than those listed here. - Safe operation is not guaranteed if the self sealing coupling element is used contrary to its intended use. - The operator of the self sealing coupling element is responsible for all personal injuries or material damage that occur from non-intended use and disregard of the technical values; the manufacturer assumes no responsibility in these cases. 5.3 Optional Features OV = without valve (z.b.: 1-UF OV 1-UF OV) SI = with protection by safety locking device (see point 7) (z.b.: 1-UF SI) without SI with SI EX = ATEX version 8

423 Operating manual Type UF-series Product description of the coupling 5.4 Extended product description for application acc. to ATEX-guide line 94/9/EG (special design EX): General Only non-sparkling materials may be used. Non-sparkling materials are , or equivalent materials. Furthermore brass with different surfaces (f. ex. chrome-plated, nickel-plated). Further on it must be assured that the seal is resistant against and suitable for the flowing through media. Also the temperature resistance of the seals must be guaranteed. This must also be considered for the marking acc. to chapter Extended marking The coupling fittings are marked with As the surface temperature of the self-sealing couplings are determined by the temperature of the fluids, the temperature category or the highest surface temperature must be specified by the operator while the safe temperature distances acc. to EN must be observed and the maximum temperature resistance of the coupling materials and seals are taken into consideration. The marking of the temperature class must be effected readily visible by the operator. The determination of the temperature class must be made acc. to the following table: Max. temperature of Temperature class fluids 75 T6 90 T5 130 T4 195 T3 295 T2 445 T1 The couplings are not admitted for the temperature classes T1 and T2 and may not be marked for that by the operator. 9

424 Operating manual Type UF-series Installation manual 6 Installation manual 6.1 General The coupling is to be integrated into the line network while taking into account the general accident prevention guidelines so that: - perfect operation is guaranteed in accordance with the operating manual. - the coupling is used primarily on the supply side or receiver side (fixed half) and the adaptor primarily at the hose side (free half) - external damage to the unit and all mobile parts is excluded. Before installing the coupling in a pipeline network, make sure that the pipeline network has been sufficiently rinsed/blown through and/or cleaned. After completing the assembly work, a function test must be carried out according to the operating manual, both in depressurized state and under working pressure. 6.2 Extended installation instruction for application acc. to ATEX-guideline 94/9/EG Details for safe operation For the use of self sealing couplings as a hose connection it must be guaranteed that in case of pressure strikes the tumbling of the self sealing coupling can be avoided by fixing at suitable constructions. In principle it must be observed that the self sealing coupling cannot strike on hard objects which could produce strike sparks when touching the housing Details for safe installation The self sealing couplings may only be connected to pipe- and hose systems which are suitable for electrostatic discharge and which are connected to the ground potential Details for a safe application area The self sealing couplings may be used according to the class of devices2 in areas susceptible to explosions where potentially explosive mixtures of gas, steam, mist and air are availble. 10

425 Operating manual Type UF-series Operating manual 7 Operating manual In order to avoid critical injuries of the staff and damage at the self sealing coupling during operation, coupling may be only used for the stated applications. 7.1 Connection process Before every couple cycle a visual check of coupling and adaptor is to be carried out. In case of recognizable, visible damage or deformations damaged parts are to be exchanged. Hold self sealing coupling firmly in one hand; with the other hand pull back locking sleeve. This has to be done against locking spring resistance. Push free half (coupling) with withdrawn locking sleeve axially centered onto plug part of fixed half (adaptor) until sensible resistance. Bring locking sleeve with support of locking spring into starting position. Self sealing coupling and self sealing adaptor are now mechanically locked. CAUTION Please take care that locking sleeve is in final position, i.e. that it is flush in front with the coupling housing as otherwise no perfect lock is guaranteed. 7.2 Disconnection process Withdraw locking sleeve against locking spring and take out coupling from self sealing adaptor. Caution! In case of an available pressure in the line connected by the coupling system a strong separation impulse - depending on the pressure - can be effective onto the coupling system during disconnection. For that reason the movable part of the coupling (free half) is to be firmly held in the hand to avoid injuries. 11

426 Operating manual Type UF-series Operating manual 7.3 Safety locking device SI (supplementary equipment) Coupling process For coupling the locking ring must be in unsecured position (picture 2). Coupling as described under 7.1. locking sleeve locking ring picture 1 picture 2 locked position unlocked position After coupling the locking ring is drawn towards the hose, turned by 90 and released. Now the locking ring snaps forward into the safety position (picture 1). Both final positions secured and unsecured are fixed by spring loaded cams. The operator can assure himself of the proper locking and saving by trying, as a control, to disconnect the coupling by drawing back the locking sleeve. This is not possible in secured position Decoupling process In coupled situation the locking ring is in secured position (picture 1). For de-blocking the locking ring is drawn towards the hose, turned by 90 and released. Now the locking ring snaps forward into the safety position (picture 1). Both final positions secured and unsecured are fixed by spring loaded cams. Decoupling as described under

427 Operating manual Type UF-series Maintenance and function test 8 Maintenance and function test Preventive maintenance measures WALTHER self sealing couplings are to be operated in such a manner that external damages to elements and all moving parts are avoided. 8.1 Maintenance and functional test In order to always guarantee function of the self sealing coupling and hence safety of operator, a maintenance and functional testing must be made in appropriate periods of time depending on operating conditions. In order to minimize operating forces and to extend service life of the self sealing coupling we recommend to slightly grease plug surfaces (see item 9.0) Maintenance includes following items: - A visual inspection of self sealing coupling and self sealing adaptor regarding damage and contamination has to be made. - Dirt at the functional area (sealing area, operating elements) which is easily accessible from outside should be removed by simply wiping-off. If there are damaged, torn or corroded parts, coupling must be dismounted and returned to manufacturer for repair. If worn or embrittled seals are found or if there is extreme dirt, the customer can decide whether he returns coupling unit to the manufacturer's factory or whether he repairs himself Functional test includes following items: As described in the operating instruction, coupling is several times connected, pressurized and then disconnected. In doing so, the following has to be observed: - Connection and disconnection process must be absolutely smooth. - Coupling must be absolutely leak-proof in connected and disconnected state. If there are damaged, torn or corroded parts, coupling must be dismounted and returned to manufacturer for repair. If worn or embrittled seals are found or if there is extreme dirt, the customer can decide whether he returns the coupling unit to the manufacturer s factory or whether he repairs himself. 13

428 Operating manual Type UF-series Lubrication 9 Lubrication! We recommend lightly greasing the plug-in areas to minimize operating forces and to extend the service life of the coupling. Do not lubricate with resinous greases. Attention! The choice of grease with regard to compatibility must agree with the seal quality and the medium (e.g.: oxygen). The bearing roll (pos. 24) and the bearing bolt (pos. 25) must be greased slightly with roller bearing grease. 14

429 Operating manual Type UF-series Storage 10 Storage The couplings must be stored in such a way that no damage can occur to the couplings. The storage conditions of the couplings depend on the guidelines applicable to the gaskets, since improper storage can lead to deterioration of the gaskets. The following points must be observed: - The couplings must be stored dry. - For the preservation of the gaskets, the gaskets and couplings should not be stored where they are exposed to the effects of daylight. For protection against oxygen, the gaskets and couplings should be stored in the original packaging. 15

430 Operating manual Type UF-series Shut down 11 Shut-down At the end of the service life the coupling or its components have to be disposed non-polluting and according to the legal regulations. For that the local public or private disposal societies should be taken. 16

431 Operating manual Type UF-series Order numbers code 12 Orders number code X X X - X X X X X X X X X X X - X X X X - X X X X X - X X X X X X X X X X X X X X X X - X X 1. Subject group 2. Series The information regarding the series comprises either two letters or two numbers. 3. Nominal size / nominal borewidth It is rounded up or down to one. The information can be numerical as well as alphanumerical. 4. Product type or design type 5. Connection design 6. Material design: xx-x and xxxx possible 7. Material design (seal design): xx-x and xxxx possible 8. Y or Z design 9. Additional equipment 17

432 Operating manual Type UF-series Index 13 Index A Accident prevention guidelines According to intended purpose... 6 Acquired knowledge... 4 air... 7 Alterations... 4 Assembly... 6 Assembly work C Clean-Braek-Kupplung... 7 clean-break-adaptor... 7 clean-break-coupling... 7 Clean-Break-Nippel... 7 Cleaned Commissioning... 4, 6 connected Connection process connections... 6, 8 coupling... 4 Coupling... 6, 8, 10, 14, 16 Couplings... 6 Customer care... 2 D damage... 6, 15 Damage... 4, 6, 8, 10 Damage compensation... 4 Daylight Depressurized Depressurized state disconnected Disconnection process Dismantling... 6 Disposal societies dry dust cap... 7 dust plug... 7 E elektrostatisch Equipment... 4 Experience... 4 explosionsgefährdeten Bereichen F Faults... 4 Function... 6 Function test... 6, 10 Functionality... 2 G General... 4 Gerätekategorie guarantee H Hazard notes... 6 Hazardous emission... 6 Hose side hydraulic oil... 7 I Implementation... 6 Improvement... 4 Inspection... 2 Intended use... 7 K Kennzeichnung... 9 L Legible condition... 6 Liability... 4 M Maintenance... 2, 4, 6 Manual... 4 Medium... 6 Mobile parts O Operating manual... 1, 10 Operation... 2 Operational safety regulations... 6 Operator... 6, 8 Operators... 2 Original... 4 Oxygen P Packaging Perfect operation Perfect, functioning condition... 6 Performance capability... 2 Pipeline network Pressurized

433 Operating manual Type UF-series Index Property... 4 R Regulations... 4 Reliability... 2 S Safety... 2 Safety devices... 6 Schlagfunken Scope of delivery... 4 Screw connections... 6 self sealing adaptor... 11, 13 self sealing coupling... 11, 13 Self sealing coupling service Service... 2 Shut-down Special designs... 4 Specialists... 2 Status of development... 4 Storage Storage conditions subspecies... 7 Supply side Systems... 2, 6 T Table of Contents... 3 Technical Data... 8 Technical equipment... 2 Temperaturbeständigkeit... 9 Temperaturklasse... 9 Tools... 2, 6 Translation errors... 4 Types of use... 8 U Use... 2 V Version... 4 W water... 7 Work safety regulations... 6 Working method... 6 Working pressure... 8, 10 Working pressures... 8 Wrong product selection

434 Betriebsanleitung deutsch Revision A Datum Ersteller NH Diese Betriebsanleitung unterliegt nicht dem Änderungsdienst Verschlusskupplung Mitteldruck-Serie 1-SG SG