manntek.se

SBC Operating Manual1" ‑ 6"

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Foreword

This operating manual applies to the persons using the Safety Breakaway Couplings.

It is very important to read and understand this operation manual before use of this coupling. Become familiar with the unit’s operation, applications and limitations. Be particularly aware of its specific hazards. Store this manual in a clean area and always at a readily available location. Additional copies at no charge can be obtained through written requests.

IMPORTANT!!READ THE COMPLETE DOCUMENTATION

The base for this manual follows the EU-Directives:

Pressure Equipment Directive 2014/68/EU of 15 May 2014Potentially Explosion Atmosphere Directive 2014/34/EU of 29 March 2014

• Do not make modifications that are not authorized by the manufacturer.• Read and respect all warnings and instructions provided to you.• Use only original MannTek spare parts for maintenance.

SUMMARY OF REVISIONS Date of change Description2015-05-21 1. Edition2018-10-09 General review & New layout, Updated EU-Directives2018-10-31 2. Edition - devided in two sizes

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Table oF ConTenT

Foreword 2 1 Introduction 4 1.1 Intended use 4 1.2 Product specification 5 1.3 Technical data 5 1.4 Breaking pins 6 1.5 Identification plate e.g. for SBC 2½”- 2½" BSP 7 1.6 Scope of delivery 7 2 General safety rules 8 2.1 Safety instructions 8 3 Transport and storage 10 3.1 Delivery check 10 3.2 Complaints/return of goods 10 3.3 Returning used product 10 3.4 Sample of certificate of decontamination 11 3.5 Storage 11 4 Installation 12 4.1 Initial operation 12 4.2 Installation 12 5 Operation 15 5.1 General notes 15 5.2 Daily visual inspection 15 5.3 Cleaning 15 5.4 Disassembly 15 5.5 Improper use 15 5.6 Maintenance/repair 15 5.7 Miscellaneous 16 6 Maintenance and repair 17 6.1 General information 17 6.2 Maintenance and service instruction 18 6.3 Spare parts and tools 18 6.4 Assembly 19 6.5 Pressure and tightness test 22 7 Applicable documents 23 7.1 Declaration of conformity 23

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1 InTroduCTIon 1.1 InTended use

The Safety Breakaway Coupling (SBC) acts as a safety component in the supply line of mobile refuelling systems, preventing damage to the environment whenever the supply hose or pipe bursts during filling or emptying due to a change in location of the tank. The coupling valves on the tank and on the supply line immediately close whenever the housing halves Breakaway.

All MannTek products are designed for trouble free operation in a wide range of applications and operating conditions. Reliable and safe operation is dependent upon the correct installation and handling of the equipment. Regular and appropriate maintenance is essential to ensure both safety and reliability over the life of the equipment. Take care that the product is only used inside the limits of the following product specification.

There are two kinds of SBCs available. A marine type version is designed for offshore applications. The specific design requires an installation between two hoses. It is only possible to release the coupling by axial force.

The length of the hose segments should not be less than L=a/57,3 x (r+d/2).

L = min. required hose length a = max. bending angle r = min. bending radius d = outer hose diameter

Figure 1: min. required hose length depending on bending angle shown for hoses according to EN12115

The second SBC type is an industrial version. Regularly it is connected to a tank or a fix connection point inside a loading station on one side and a hose or a loading arm on the other side. This makes that the SBC can be released under a pull force angle up to 90º.

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1.2 ProduCT sPeCIFICaTIon

Product name: Safety Breakaway CouplingSizes: 1", 2", 2½", 3", 4", 5" and 6"Thread Connection: NPT-Thread ANSI B1.20.1, BSP-Thread ISO 228Flange Connection: Flange EN 1092, ANSI B16.5, DIN 28459, T.T.M.A., BS 10 Other Connection: MIL-C-10387J, DIN 11850, DIN 11864, DIN 32676, ISO 2852Material (casting): EN 10213 – 1.4408/1.4409+AT ASTM A351 – CF-3M or CF-8M EN 1982 – CC491K EN 1706 – AC-42000/42100-T6Material (machined): EN 10272 – 1.4401/1.4404+AT ASTM A479 – S31603 (316L) EN 12164 – CW614N EN 755-2 – EN AC-5083 or AC-6026/6262-T6Working pressure: 10 bar / 16 bar / 25 bar / 150 psi / 360 psi Max test pressure: 16 bar / 25 bar / 40 bar / 240 psi / 540 psiTemperature range: -20ºC to + 80ºC -Outside this range, between -54ºC and + 250ºC ask for confirmation

1.3 TeChnICal daTa

Table 1: Nominal Widths, Weight and Dimensions [mm]

Nominal width Breaking Force Connection KG (Stainless steel) D (mm) L (mm)

DN25 - 1" 3,2 kN1" Thread 1,7 74 1261" Flange 4,2 115 132

DN50 - 2" 13 kN2" Thread 2,6 114 1782" Flange 7,3 165 178

DN65 - 2½" 22 kN2½" Thread 7,4 140 2512½" Flange 13,2 191 214

DN80 - 3" 33 kN3" Thread 8,5 174 2793" Flange 15,1 210 222

DN100 - 4" 52 kN4" Thread 15,5 211 3204" Flange 20,7 254 239

DN125 - 5" 81 kN5" NPT male 32 269 3625" Victaulic 31 269 341

DN150 - 6" 92 kN6" Thread 46,8 304 4006" Flange 57,6 318 384

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Table 2: Materials

Component Material no. Standard Operating temperature

Housing Checkvalve

1.4404 EN 10270-1.4401+AT-54°C to 250° C

1.4409 EN 10213-1.4409+ATCW614N EN 12164-CW614N

-54°C to 200° CCB491K EN 1982.CB491K-GS

5083 EN 755- AW-5083-54°C to 100° C6262 EN 755- AW 6262-T6

42100 EN 1706-AC-42100-T6Spring 1.44.1 EN10270-1.4401 -54°C to 250° C

Table 3: SealsComponent Material Standard2 Operating temperature1

O-ring

NBR Perbunan TM , Buna N -38° C to 80° CEPDM Buna AP -54° C to 120° CFFKM Kalrez TM , Chemraz TM -15° C to 260° CFKM Viton TM -20° C to 200° C

1.4 breakIng PIns

Mann Teknik AB delivers breaking pins according to customer specification. Standard pins are available for different applications. The breaking force should be specified for the weakest component

Without any specification we supply our couplings with bolts according to the following table.

Table 4: Internal pressure reduces the force needed to release the coupling.Breakin Force at DN25 DN50 DN65 DN80 DN100 DN125 DN150

0 bar6 bar -0,7 kN -1,1 kN -2,6 kN -3,8 kN -5,7 kN -7,9 kN -11,1 kN

10 bar -1,1 kN -1,9 kN -4,4 kN -6,3 kN -9,5 kN -13,2 kN -18,6 kN16 bar -1,9 kN -3,1 kN -7,0 kN -10,1 kN -15,2 kN -21,2 kN -29,8 kN25 bar -2,9 kN -4,9 kN -11,0 kN -15,9 kN -23,7 kN -33,1 kN -46,5 kN

37,5 bar -4,4 kN -7,3 kN -16,5 kN -23,8 kN -35,6 kN -49,7 kN -69,8 kN40 bar -4,8 kN -7,8 kN -17,6 kN -25,4 kN -38,0 kN -53,0 kN -74,5 kN150 psi -1,2 kN -2,0 kN -4,5 kN -6,5 kN -9,8 kN -13,7 kN -19,2 kN300 psi -2,4 kN -4,0 kN -9,1 kN -13,1 kN -196 kN -27,4 kN -38,5 kN

1 For temperature stability of the seal material used must be considered separately for each individual case2 Kalrez, Viton = Registered Trademarks of DuPont; Chemraz = Registered Trademark of Green Tweed

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Our standard specification was made for LPG hoses with a minimum burst pressure at 100 bar. For other applications you can specify the breaking force depending on the burst pressure of your hose. Table 5: Recommended breaking force for different hose burst pressures:Burst pressure hose DN25 DN50 DN65 DN80 DN100 DN125 DN150

30 bar 4 kN 7 kN 11 kN 18 kN 28 kN 40 kN40 bar 6 kN 10 kN 15 kN 24 kN 37 kN 54 kN48 bar 7 kN 12 kN 18 kN 28 kN 45 kN 65 kN60 bar 3,0 kN 9 kN 15 kN 23 kN 36 kN 56 kN 81 kN68 bar 3,2 kN 92 kN80 bar 12 kN 20 kN 30 kN 48 kN 75 kN 108 kN100bar 4,8 kN 13 kN 22 kN 33 kN 52 kN 81 kN 117 kN600 psi 6 kN 10 kN 15 kN 24 kN 39 kN 56 kN

1200 psi 3,1 kN 12 kN 21 kN 31 kN 49 kN 78 kN 112 kN

Table 6: Max. spill under disconnection at max working pressure:Nominal diameter DN25 DN50 DN65 DN80 DN100 DN125 DN150Max. spill at WP 0,05 l 0,1 l 0,2 l 0,4 l 0,6 l 1,2 l 2,0 l

1.5 IdenTIFICaTIon PlaTe e.g. For sbC 2½”- 2½" bsP

Industrial Type Marine TypeArticle no: N312D4401A* N312M4401A*Working Pressure PS: 25 bar 25 barMax Test Pressure PT: 30 bar 30 barBreaking Force BF: 22 kN 22 kNSeal: FPM (Viton) FPM (Viton)Mtrl: Stainless Steel Stainless SteelSize: DN65 – 2½“ DN65 – 2½"

*For key of article no. please ask for explanation list.

1.6 sCoPe oF delIvery

1 pcs N312D4401A Safety Breakaway Coupling

In case of flange connection gaskets and bolts to mount the coupling into the application is not part of the delivery. For NPT thread use PTFE tape for sealing (see chapter 4.2).

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2 general saFeTy rulesBefore you install any MannTek equipment it is essential to check that the material and performance specifications are acceptable for your specific application. The pressure ratings and primary materials of the construction are clearly indicated on the identification plate of each MannTek product. A drawing showing the materials of construction relating to each individual component is available upon request. The technical department at MannTeknik AB is always happy to provide guidance on material suitability. Our data is taken from published chemical resistance information as well as our own application experiences. Specification checks should always be carried out before the product is supplied, but if unsure, ask! Especially if you are using the products outside the specified temperature range, ask for confirmation regarding your application.

Do not assume that a MannTek product supplied for one specific application automatically will be suitable for other similar applications. Many variables affect the performance of materials. If you wish to use a MannTek product for a different application than the one originally specified, check with Mann Teknik AB to ensure compatibility before installation. Please remember, the application details should include all media transferred through the coupling. Not just the primary transferred media. As with all equipment, a check should be made to ensure that the installation fulfils the requirements of applicable prevailing industry, local, national and international standards. Particular attention should be paid to pressure ratings, safety factors and the position of upstream and downstream affiliated closures.

2.1 saFeTy InsTruCTIons

Proper seal and wetted metal parts material selection is critical for safe operation. To assure maximum life for the service intended, use only those materials, sealing and lubricant compatible with the fluids being handled. Please note material being supplied and make certain that it is suited for the intended service. This is important in the food processing industry.

The Safety Breakaway Coupling assembly does not eliminate possible exposure to hazardous substances. In case of an emergency release some product between both pistons will spill out. The conditions of handling and use are beyond our control, and we make no guarantee, and assume not liability for damages or injuries related to the use of this coupling assembly. It is the responsibility of the user to comply with all applicable federal, state, and local laws and regulations.

Do not handle O-ring seals if their material appears charred, gummy or sticky. Use tweezers, wear gloves and protective goggles in appropriate material, consult the material safety data sheet (MSDS) of your product. Do not touch adjacent parts with unprotected hands.

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Piping systems must always be depressurised and drained before attempting disassembly and removal of any MannTek product.

Authorized and qualified personnel must carry out all assembly and maintenance operations. The installation must be equipped with suitable controls that prevent an increase of pressure beyond the maximum allowed limit (this is the responsibility of the installer/user).

Failure to do so could result in serious personal injury, property damage, leakage or unexpected separation.

For a safe operation, read also the installation and operating instructions in this manual (see chapter 4 and 5) and ask for our service instructions.

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3 TransPorT and sTorageThe product may only be transported or stored when absolutely clean. Suitable sealing must be used for the openings to ensure no damage occurs to the surfaces/sealed areas. The seals may only be removed by trained personnel. The storage location must guarantee adequate protection from corrosion or extreme temperatures.

3.1 delIvery CheCk

• Check for any transportation damage. If so report this immediately to the forwarder.• Check that the products and quantities are in accordance with the delivery note.

3.2 ComPlaInTs/reTurn oF goods

• If returning goods, please contact MannTeknik AB to receive a Complaint Report form.• Complete the form with as much details as possible.• Return the goods with the Complaint Report attached on the outside of the package!

3.3 reTurnIng used ProduCT

• If returning used goods, please contact MannTeknik AB to receive a Complaint Report form.• Complete the form with as much details as possible.• Rip this page out and fill in the Certificate of Decontamination.• Return the goods with the Complaint Report and the Certificate of Decontamination!

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REPAIR SERVICE

To comply with Health & Safety Regulations, all returned valves must be accompanied by a Certificate of Cleanliness and a Data Sheet for the last product carried.

CERTIFICATE OF DECONTAMINATIONWe certify that the following couplings/valves have been cleaned prior todespatch and are free of any harmful substances:

Qty:…………Part no:…………………..Serial no:…………………………..

Qty:…………Part no:………………….. Serial no:…………………………..

Qty:…………Part no:………………….. Serial no:…………………………..

Qty:…………Part no:………………….. Serial no:…………………………..

YES NO

Free al all liquid _____ _____

Air blown _____ _____

Couplings/Valve dismantled _____ _____

The last known product the coupling/valve was in contact with:……………………

Data sheet of last product attached………………….Yes/No

Company Name/Address:………………………………………………………………

Signature of Supervisor:………………………………………………………………..

Company Stamp:

3.4 samPle oF CerTIFICaTe oF deConTamInaTIon

Make a copy of this page, fill in the required information and send it back together with the goods.

3.5 sTorage

Store coupling in a dry, dust free, dark place, in ambient temperature.

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4 InsTallaTIon

4.1 InITIal oPeraTIon

The correct installation of all MannTek products is essential to ensure safe and satisfactory operation. Checks should be made to ensure that the fitting of MannTek products does not interfere with the correct operation of affiliated equipment (i.e. isolation valve, excess flow valves, etc). Before securing the flange or thread connection to mating equipment (i.e. hose, loading arm and storage tank), ensure that no foreign objects, dirt, grit, etc. are present in the coupling.

All flange and thread connections should be made without imparting excessive strain to the equipment and pressure checked according to our recommendations in chapter 6.4 table 8 prior to use. All gaskets and sealing materials used to make the permanent connection should be of suitable material and able to operate at least up to the maximum parameters of the MannTek equipment.

Each MannTek product is designed to take reasonable external loads associated with good handling practice but is not designed to accept continuous excessive load values associated with maladjustment or poor installation. Continuous excessive strain will equate to increased component wear and possibly premature failure if not corrected.

When MannTek equipment is used with hoses, attention should be paid to hose length to ensure correct handling characteristics. Hoses should be of sufficient length to ensure operation well within the stipulated hose minimum bend radius up to the maximum operation envelope. If the flow velocity exceeds 5.25 m/s additional measures are necessary due to static electricity. This could be hoses with increased conductivity, charge inhibiting additives, earth bonding.

In case of emergency release liquid will spill out between both halves, depending on pressure and size. The maximum spill is mentioned in chapter 1.5 table 6. The operator has to take care to protect the staff against spillage and provide a drain tray if necessary. Once all the above elements are satisfactory, an installation check should be carried out to prove the system.

4.2 InsTallaTIon

When installing MannTek equipment to new pipe work, tanks, etc. ensure the system is free from debris that may be transferred through the coupling. Where the hose or loading arm assembly is the primary static dissipation or earth route, the electrical continuity value of the assembly shall be checked to ensure regulatory compliance. Special attention should be paid to the balancing of loading arms. The weight of the coupling plus transfer media should be taken into account at the specification stage. It is usual for loading arm balance settings to account of weight variations due to differences in the full/empty cycle.

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The MannTek product can be installed directly in the product line and is ready for use after removing the transport protection. The installation is as follows:a. Remove the packaging and the tread/flange protectionb. Check the coupling for damages before mounting.c. To prevent damages during mounting a suitable wrench should be used for the intended bolts and nuts.

Use always a fitting wrench to mount the coupling to a hose, a pipe or a tank. Tighten the fitting using the wrench on the respective side where the connection is made.

Torque forces should never be transferred via the SBCoupling.

d. Ensure that the product line is empty and all valves are closed before you connect the coupling into the line.

Flange connection

e. Table 7: Tightening torque for bolts:Metric InchSize 8.8 Size A193 B7M8 24 Nm 5/16 -18 UNC 16 lbf-ftM10 50 Nm 3/8 -16 UNC 29 lbf-ftM12 85 Nm 1/2 -13 UNC 70 lbf-ftM16 210 Nm 5/8 -11 UNC 139 lbf-ftM20 410 Nm 3/4 -10 UNC 243 lbf-ftM22 550 Nm 7/8 -9 UNC 389 lbf-ftM24 700 Nm 1 -8 UNC 582 lbf-ft

f. Bolt tightening sequence.

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NPT Thread Sealing

Sealing NPT threads can be an exasperating experience if certain techniques are not followed. The following tips will help alleviate many common problems in thread sealing: g. Always use some type of sealant (tape or paste) and apply sealant to male thread

only. If using a hydraulic sealant, allow sufficient curing time before system is pressurized.

h. When using tape sealant, wrap the threads in a clockwise motion starting at the first thread and, as layers are applied, work towards the imperfect (vanishing) thread. If the system that the connection being made to cannot tolerate foreign matter (i.e. air systems), leave the first thread exposed and apply the tape sealant as outlined above.

i. When using paste sealant, apply to threads with a brush, using the brush to work the sealant into the threads. Apply enough sealant to fill in all the threads all the way around.

j. When connecting one stainless steel part to another stainless-steel part that will require future disassembly, use a thread sealant that is designed for stainless steel. This stainless-steel thread sealant is also useful when connection aluminium to aluminium that needs to be disconnected in the future. These two materials gall easily, and if the correct sealant is not used, it can be next to impossible to disassemble.

k. When connecting parts made of dissimilar metals (i.e. steel and aluminium), standard tape or paste sealant performs satisfactorily.

l. For sizes 2” and below, tape or paste performs satisfactory. When using thread tape, four wraps (covering all necessary threads) are usually sufficient.

m. For sizes 2 1/2” and above, thread paste is recommended. If thread tape is used, eight wraps (covering all necessary threads) are usually sufficient. Apply more wraps if necessary.

n. Over-tightening threads can be just as detrimental as insufficient tightening. For sizes 2” and below, hand tighten the components and, with a wrench, tighten 3 full turns. For sizes 2 1/2” and above, hand tighten the components and, with a wrench, tighten 2 full turns.

o. For stubborn to seal threads, apply a normal coating of thread paste followed by a normal layer of thread tape.

p. For extremely stubborn to seal threads, apply a normal coating of thread paste followed by a single layer of gauze bandage followed by a single layer of gauze bandage followed by a normal layer of thread tape.

When this procedure is done, the connection becomes permanent. Extreme measures will be necessary to disconnect these components. All other measures to deal the threads should be explored prior to use of this technique.

The start-up may take place only when the MannTek product has been mounted as instructed and the necessary function tests and leak tests have been conducted by the approved authorities (see chapter 7).

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5 oPeraTIon 5.1 general noTes

Operators are obliged to provide qualified and trained personnel familiar with the handling of supply pipes, safety couplings, any fluid being pumped as well as its danger potential. Such staff must also be familiar with the applicable safety regulations and the regulations of the employer’s liability association. The pull cable must be shorter than the supply line and must always be tight and attached in such a way that the safety breakaway coupling can be safely triggered.

5.2 daIly vIsual InsPeCTIon

All couplings should be briefly inspected at the start of each day’s operation. Check for dirt, seal damage and any obvious physical damage (such as impacts, etc.).

5.3 CleanIng

Check the seal of the connections before every cleaning. In case the coupling is used for materials that harden, stick, etc., the coupling has to be cleaned of residues after every use. Before dismantling, the coupling always has to be cleaned with a suitable cleaning agent (regardless of the product carried).

5.4 dIsassembly

When the coupling should go into service there is a danger that the fluid will spurt out. Special protective measures such as personal protection equipment must therefore be adopted. Always ensure the system is cleaned in the proper manner. After cleaning, remove any residue from the cleaning agent.

How to disassemble:a. Wear suitable personal safety equipment.b. Make sure that the coupling is depressurised and empty.c. Clean coupling before disassembly (use cleaning agent suitable for the pumped fluid).d. Unscrew coupling always with a fitting wrench.

5.5 ImProPer use

The equipment should never be used in the case of visible damage or where there is prior knowledge of damage that may lead to malfunction.

5.6 maInTenanCe/rePaIr

Maintenance should be done regularly; at least once in the year. Maintenance and repair of the equipment may be carried out only by MannTeknik AB or by companies/technicians authorized by MannTeknik AB (see chapter 6).

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5.7 mIsCellaneous

The operator is solely responsible for the installation, operation, and maintenance of the coupling. Mann Teknik AB accepts no responsibility for damages due to faulty installation, faulty handling, as well as negligent or incorrect maintenance.

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6 maInTenanCe and rePaIr

6.1 general InFormaTIon

The SBCoupling consists of two housing halves with a check valve in each. The housings are held together by three breaking bolts during normal operation. The two check valves support each other during normal operation and keep the conduit open.

Positioning body halves

1 Body (half) 2 Coupling flange 3 Thread connection 4 Piston 5 Spring 6 Breaking bolt

In case the tank wagon rolls away or someone forgot to disconnect the supply line before the truck drives off, the SBC is activated as follows:Before the supply line is stressed by undue external forces the breaking pins become destroyed. The coupling halves are separated from each other and the spring-loaded check valves instantaneously close both ends of the line. On the industrial version one half of the coupling remains firmly connected to the tank wagon while the other half of the coupling remains connected to the supply line. The marine type is always placed between two hoses. The pull force is only working in axial direction. After releasing both halves remain at the end of each hose. This prevents the outflow of liquids or gases from both product carrying ends of the line.

Maintenance tasks, to put the released coupling back into service, may be performed only by trained personnel from an authorised professional workshop. All measures necessary for inspection, maintenance and repair must be carried out in accordance with the national regulations of the country where the system is installed.

13 2 4

5

6

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Sealing-kit 3 O-rings

An assembly drawing is following with the kit and each O-ring is marked with the respective position number.

In case of failure or Breakaway order the SBC-SEAL SET and carry out repairs according to the assembly instructions in chapter 6.4.

Breaking-bolt-kit 3 Breaking bolts.In case of failure or Breakaway order the SBC-BOLT SET and carry out repairs according to the assembly instructions. Attention: Do not forget to specify the proper size and breaking force!Tool for SBCA special tool for the piston guide of the SBC can be ordered from MannTek.

O-ring toolsSpecial tools to remove the O-rings can be ordered from MannTek.

6.2 maInTenanCe and servICe InsTruCTIon

Always depressurise the system and rinse off the parts before beginning any maintenance work. Use protective goggles. Do not handle O-ring seals if the material appears charred, gummy or sticky.

Use tweezers; wear gloves and protective goggles in appropriate material, consult the material safety data sheet (MSDS) of your product. Do not touch adjacent parts with unprotected hands. Rinse off the parts once again before starting the “daily inspection”

6.3 sPare ParTs and Tools

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6.4 assembly

1 After releaseWhen the coupling should go into service there is a danger that the fluid will spurt out. Special protective measures such as personal protection equipment must therefore be adopted. Always ensure the system is cleaned in the proper manner. After cleaning, remove any residue from the cleaning agent.

a. Wear suitable personal safety equipment.b. Make sure that the coupling is depressurised and empty.c. Clean coupling before disassembly (use cleaning agent suitable for the pumped fluid).d. Unscrew coupling with a fitting wrench.

2 Visual inspectionScrew out the destroyed parts of the breaking bolts. Check for dirt, seal damage and any obvious physical damage (such as impacts, etc.).If you have a “Non Closure” coupling continue item 10.

3 DisassembleUnscrew the three screws that lock the spindle steering.

4 DisassembleThe piston is sticking out on the other side, therefore place the coupling half on distances for easier maintenance. In newer versions the spindle steering is fixed with screws which have to be removed first. In older versions you need only to press down the steering and turn it free. Release it carefully.

Piston guide is spring loaded. Risk of injury.

Using our special tool makes work easier and therefore increases safety.

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5 Detail parts after disassemblingTake out all the parts from the body

1. Spindle steering2. Spring3. Body4. Piston 5. Spring cap and PTFE-bushing

6 Piston O-ringReplace the O-ring (pos.3 ) on the piston with a new greased O-ring. Have an equal pressure around the O-ring. The O-ring must be pressed into the groove on the piston.

Use only grease which is suitable for O-ring material. For mounting the new O-ring use MannTek spare parts only. Special tools are helpful for a good fit of the O-ring.

7 Mounting pistonThe piston is bigger in diameter than the three brackets for the piston guide. Introduce the piston as shown. Put it into a relaxing position in the valve seat. Take care, the piston is sticking out on the other side.

8 Reassemble coupling halvesFit the spring with spring cap and spindle steering with PTFE-bushing. Press down the spindle steering and turn, to fix it in its position.

9 Locking the spindle steeringFit the screws into the given holes in the body and fixate the spindle steering by mounting the three locking screws. Use Loctite® 243 for locking the screws.Mount back the flat seal.

10 Outer body O-ring Replace the O-ring (pos.15 ) on the body with a new greased O-ring.

Use only grease which is suitable for O-ring material.

1 2 3 4 5

Loctite® is registered trademark of Henkel.

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11 Leakage test coupling halvesTest both coupling halves separately according to 6.5 before you continue with step 12.

Use a fitting wrench to mount the coupling halves to the test rig.

12 Breaking boltsScrew in the bolts into the intended position by hand. Do not use any tools.

The breaking bolts are sensitive elements. Any deformation will change the breaking parameters!

13 Reassemble coupling Set both halves onto each other and press them carefully together. The breaking pins should align to the bore holes in the second half.

Using a press makes work easier.

14 Fix breaking boltsScrew on the nuts by hand until stop when halves are pressed together. Fasten it a little bit with a wrench, max 45 degrees.

Screw on the second nut and lock the first one. Hold the first one with a wrench to avoid forces on the breaking bolt.

Do not use force for tightening! Risk of destroying bolts.

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6.5 Pressure and TIghTness TesT

After each service a pressure and tightness test of each coupling is mandatory. Test each half separately before you connect both halves with the breaking pins. The following test parameters are in accordance with EN12266, EN14432 and ISO5208:

Shell tightness test (water):1,5 x Working Pressure (see 1.2) stop time 1 min.

Seat tightness test (air):6 bar +/- 1bar stop time 15 s.0,1 x Working Pressure stop time 15 s.

If a pressure test should be achieved for the coupling mounted in an assembly follow the respective test instructions for the equipment but do not exceed our recommended maximum test pressure of the coupling which you will find in table 8. Always use the lower value, if break force is between two values, for correct maximum test pressure. If testing with higher pressure is necessary please ask our sales department for a special test bolt kit.

DN25 DN50 DN65 DN80 DN100 DN125 DN150kN bar kN bar kN bar kN bar kN bar kN bar kN bar

4 10 7 10 11 10 18 10 28 10 40 106 16 10 16 15 16 24 16 37 16 54 167 20 12 20 18 20 28 20 45 20 65 20

3 16 9 25 15 20 23 25 36 25 56 25 81 253,2 16 92 25

12 37,5 20 30 30 35 48 35 75 37,5 108 37,54,8 25 13 37,5 22 37,5 33 37,5 52 37,5 81 37,5 117 37,5

Do not use a higher test pressure than 1,5 x working pressure!

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7 aPPlICable doCumenTsEU Guideline 2014/68/EU PED, 2014/34/EU ATEXInternational Transport of Dangerous Goods ADR, RID, IMDGTest standards EN12266, EN14432, ISO5208Thread standards ISO 228, ANSI B1.20.1 - Flange standards EN 1092, ANSI B16.5

For use in other countries:Respective national requirements and guidelines

7.1 deClaraTIon oF ConFormITy

2014/68/EU PED 2014/34/EU ATEX

© Copyright 2017 MannTeknik AB. MannTeknik AB reserves the right to make changes at any time in prices, materials, specifications and models and to discontinue models without notice or obligations.

Mann Teknik ABStrandvägen 16, S‑54231 Mariestad, SwedenPhone +46 501 39 32 00 • Fax +46 501 39 32 09www.manntek.se • sales@manntek.se MannTeknik AB is a certified ISO9001‑company.