Operating Manual
old town hydrant DN 100 PN 16,
Model 1905/95
Pge-1
(16.03.2016)
Manufacturer:
Keulahütte GmbH
Geschwister-Scholl-Str. 15
02957 Krauschwitz
GERMANY
Production and distribution of hydrants:
Old town hydrant model 1905/95, DN 100 PN 16 with automatic drainage and water pressure
protection in single and double design according to DIN EN 14384.
Contents:
1.
Design
2.
Dimensions, masses, characteristics
3.
3.1
3.2
3.3
3.4
3.5
3.6
3.7
3.8
3.9
3.10
Constructive parameters
Hydrant housing
Predetermined breaking point
Main shut-off valve
Additional shut-off valve
Mounting set
Spindle sealing
Spindle bearing,
Functional description
Materials used
Corrosion protection
4.
4.1
4.2
Installation and operation
Mounting
Operation
5.
5.1.
5.1.1
5.1.2
5.2
5.2.1
5.2.2
5.2.3
5.2.4
5.3
Instructions for the disassembly and assembly (for repairs)
Disassembling
Hydrant and mounting set
Column upper part
Mounting
Mounting set
Mounting the column upper part
Mounting the hydrant
Commissioning
Repair instructions for the knocked-over hydrants
6.
7.
Physiological safety for non-metallic installation components
List of applicable standards for underground hydrants
8.
Assembly drawing / Materials
Pge-2
(16.03.2016)
1. Design
Design, dimensions
Flange connection
Operating key
Key A or B according to
DIN 3222
DIN 1092/2
Outflows
Above 2 B fixed couplings according to DIN 14318
Bottom 1 A fixed couplings according to DIN 14319
DN
100
100
100
100
DIN3223
Pipe cover (m)
0.75
1.00
1.25
1.50
Flange connection
8 holes
8 holes
8 holes
8 holes
2. Dimensions, masses, characteristic values
Model 1905/95 old-city design hydrant DN100 PN16
DN
Pipe cover (m)
Height (mm)
Masse(kg)
100
100
100
100
0.75
1.00
1.25
1.50
1680
1930
2180
2430
72
77
82
87
Space
requirement (m3)
0.18
0.22
0.26
0.30
- The minimum flow rate for both outflows is 210 m3/h, and for a single outflow is 120 m3/h.
- Cavitation safety in the range of 0.4 times to 1.3 times of the minimum flow rate
- Tightness of the housing, leakage rate 1 according to DIN 3230 = 0 cm3/min.
- Tightness of the main shut-off valve, leakage rate 1 according to DIN 3230 = 0 cm3/min
- Tightness of the additional shut-off, leakage rate 2 according to DIN 3230 = 0.1 cm3/min
- Tightness of the drainage, leakage rate 3 according to DIN 3230 = 1 cm3/min.
- Residual water quantity < 15ml
3. Constructive parameters
3.1 Hydrant housing
The hydrant housing consists of the stand with double shut-off valves (3), the column bottom
part (2) and the column upper part (1). The stand and the column upper part are fully coated
with epoxy resin or enameled inside and coated outside with epoxy resin.
The column upper part is fully coated with epoxy resin or enameled inside and coated outside
with epoxy resin. The column upper part has an additional polyester coating as UV protection.
The epoxy coating of the hydrant is designed with strong corrosion protection, so that the layer
thicknesses > 250 µm. Rubber seals (25,26) are arranged between the components 1-3 (Part 5
ensures, as secondary function, the sealing of the housing). As fastening elements, stainless
steel screws are used (34, 30).
Pge-3
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3.2 Predetermined breaking point
The breaking point consists of the break ring (8), the split snap ring (13) and the gasket (25).
When the hydrant is mounted, the breaking point is above the floor edge. When an inadmissible
high force is applied on the outside of the column upper part, the break ring is severed at a
defined point. When the upper part column (1) tilts, the spindle square part slides out from the
coupling (10.03). No inadmissible force is then transmitted to the column bottom part (2), the
guide bearing (6), the spindle (11) and the mounting set consisting of cone (12.03), the spacer
tube (12.02) and the spindle nut (12.01). For the preparation of the operating condition, only the
break ring (8) and the gasket (25) must be replaced.
3.3 Main shut-off
The stand (3) and the column bottom part (2) are protected by epoxy coating or inner enamel
against incrustation and corrosion. In the column bottom part (2) a rubberized steel bush (14) is
inserted by means of a special procedure and secured against rotation by means of a the pin
(33). An streamlined designed, all-sides rubberized cone (12.03) with a cast iron core performs
the the main shut-off and secures with one of the two wings the shut-off of the discharge
opening. Upon closing, the geometric shape of the cone (12:03) ensures the pressurized water
protection and the drainage of the hydrant with the drainage hole in the column bottom part and
the drain plug (17).
3.4 Additional shut-off
The additional shut-off is designed as a ball check valve. In the "closed" position, the highstrength plastic ball (18) makes the sealing by pressing against an elastomeric gasket (5).
When opening the hydrant, the ball is compulsorily released from its seat by means of the cone
(12.03). The function of the double shut-off makes it possible to dismantle the hydrant at full
pipeline pressure all the way to the stand. The hydrant design with double shut-off valve has
several advantages.
- The sliding valve associated with the AU design can be omitted. This solution is cheaper.
- A direct mounting on the pipeline is possible. (The laterally displaced mounting with sliding
valve is not optimal in regard to the drinking water hygiene.)
The enameled stand (3) is designed with four integrated ribs and a crosspiece in the interior
area so that it can accommodate the self-floating plastic ball (18). The sealing geometry of the
sealing ring (5) is designed in such a way that the ball that is floating in the water ensures a safe
sealing both in the low-pressure and in the high-pressure range. The arrangement of the ribs
and of the cross-support in the stand is chosen so that the hydrant is also suitable for a
backwashing of the pipeline. The sealing function from the stand (3) to the column bottom part
(2) is achieved by the sealing ring (5) and an O-ring (26). The O-ring (26) ensures the
protection against penetrating of the soil moisture.
3.5 Mounting set
The mounting set consists of the wing nut (12.01), the spacer tube (12.02) and the rubberized
cone (12.03). The cone, due to its symmetrical structure, can perform the additional shut-off
with one of the two guide ribs. The cone and the wing nut are indissolubly joined by means of a
form-fitting connection through the spacer tube. The wing nut is guided in the column bottom
part in two grooves. Thereby a lifting movement is caused when it comes into contact with the
spindle thread.
Pge-4
(16.03.2016)
3.6 Spindle sealing
The sealing of the outward guided upper piece (10.1) is made by means of two O-rings (24) and
a wiper ring (27). The operating head is mounted on a sliding disc (9) made of plastic material.
The sliding disc should prevent the mechanical damaging of the corrosion protection. The
incorporation of the spindle sealing is provided by a brass bush which is fastened by means of a
KTW-approved adhesive and an additional form-fitting connection in the column upper part.
Spindle bearing, lift limitation
The spindle (11) is mounted in the guide bearing (6) by means of two sliding discs (9). This is
screwed into the wing nut (12.01). The guide bearing is set axially in the column bottom part
and fastened in a form-fitting manner against rotation by means of the inserted adjusting ring.
The lifting is limited by a metallic stop during opening and closing. In case of break of the
predetermined breaking point, these parts are not stressed by the external force.
3.8 Functional description
After removing the cover B (19), the torque is transmitted by turning the actuating head (4) to
the left using the operating key, through the cap (10.01), the spindle extension tube (10.02), the
coupling (10:03) to the spindle (11). By means of the the spindle thread and the guiding of the
wing nut, the mounting set is pressed down. The cone (12.03) is moved against the action of
the water pressure and after approx. 2 turns releases the flow of water. After 10 turns the
hydrant is full opened. The rubber cone pushes the ball (18) against the flow direction. The
hydrant closing operation is performed by turning the actuating head to the right. When the
hydrant is closed, it must be paid attention to the water drainage process. Due to the sealing
principle it is not necessary to increase the sealing pressure by "tightening".
3.9 Use of materials
The materials used are shown in the parts list that is attached The corresponding assembly
drawing shows the positioning.
3.10 Corrosion protection
The hydrant housing (individual pieces 1, 2, 3) is designed with strong corrosion protection by
means of the inner enamel and / or epoxy resin coating, thicknesses > 250 µm. All components
used that come into contact with the drinking water are made of corrosion-resistant materials or
are provided with an appropriate surface protection. All non-metallic materials and coatings are
physiologically harmless and have an appropriate approval.
Pge-5
(16.03.2016)
4. Installation and operation
4.1 Mounting
The first step is the determination of the height level. The area of the predetermined breaking
point should
be at 12cm (+/- 8 cm) above the surrounding ground. The differences that occur must be
compensated by selecting a smaller pipe cover or by means of the intermediate screws of the
FF pieces.
. The pipeline must be sufficiently cleaned before the installation. The
hydrant has a base gasket built in the flange.
After the safety cap on the flange bas been is removed, put the hydrant on the pipe
and tighten it with bolts, washers and nuts M16 arranged opposite each other with a torque of
approx. 70 to 80 Nm.
. After putting the pipeline under pressure and the functional test of the hydrant,
the filling and sealing are performed. In the area of drainage,
a water-permeable material or a water-permeable rock must be placed. During the putting of the
pipeline under pressure and the
functional test, care must be taken to ensure that this is is fully opened and is flushed
with full flow rate.
4.2 Operation
The operation takes place according to the Technical Note of the DVGW worksheet W331.
For further details see under point 3.8.
5. Instructions for the disassembly and assembly (for repairs)
5.1 Dismantling
5.1.1 Hydrant and mounting set
In case of the hydrants with double shut-off fitting, the installation of an upstream valve can be
omitted. The following disassembly steps are necessary:
- Before disassembling, make sure that the hydrant closed. The unpressurized condition of the
hydrant is checked by unscrewing a end cap.
- Unscrew the Allen screws (30) from the break ring (8) and remove the column upper part (1).
- Remove the the rubber seal (25) and the adjusting ring (7)
- Rotate the guide bearing until its wide wing will be under the broad segment area (2a) of the
column bottom part (2).
- By turning the spindle to the left, the guide bearing is raised until the wings will be on the top
edge of the segment. Thereby the broad wing of the guide bearing is guided by the broad
segment area.
- The guide bearing is turned back to the radial start position, so that the wing of the guide
bearing will be on the respective segments of the column bottom part.
- By turning the spindle (11) to the right, the mounting set (12.00) is pulled out of the sealing
seat.
- The mounting set (12.00) can be taken out by hand from the hydrant.
- The hydrant is now ready for the inspection.
- The stand (3) and the ball (18) can be dismantled only with a particular amount of work
Pge-6
(16.03.2016)
5.1.2 Column upper part
The column upper part should be dismantled as follows:
- The clamping pin (29) must be driven out of the operating head by means of the bolt. Attention
should be paid to the suitable bolt.
- Lift the operating head (4) carefully. Thereby the cylindrical pin (35) must be released from its
seat.
- After removing the operating head (4), the air valve (15) is visible.
Pull out the spindle extension (10,00) from the socket (16)
5.2 Mounting
5.2.1 Mounting set
The following mounting instructions should be observed:
- The mounting set (12,00) is offered as a complete spare part from the factory. Thereby the
dimension for the release of the drainage is always reliably ensured.
- Before the mounting, the cone (12.03) on the sealing contour and the spindle (11) must be
greased with an approved lubricant (film-like application).
- The cone (12.03) is constructively manufactured so that both sides can undertake the
additional shut-off.
- The spindle (11) with the guide bearing (6) must be screwed by turning to the right in the
spindle nut (12.01) until it stops.
- The pre-mounted set must be introduced with the cone ahead in the column bottom part in
such a way that the wings of the wing nut to be located in the corresponding grooves of the
column bottom teil. The guide bearing must be rotated so that the broad wings comes to a rest
on a broad segment area of the column bottom part.
- The mounting set should be pressed to the stop by using a suitable means. Thereafter the
guide bearing is rotated so that the broad segment of the column bottom part (2a) covers the
broad wings of the guide bearing (6).
- In this position the adjusting ring (7) can be inserted. When the mounting is appropriate, the
adjusting ring does not project beyond the support of the sealing ring (25).
5.2.2 Mounting the column upper part
The following mounting rules should be observed:
- The spindle extension (10.00) on the top part (10.01) should be greased slightly
- Insert the sealing elements (24, 27) in the socket (16)
- Carefully insert the spindle extension (10.00)
- Set the sliding disc (9)
- Set the operating head (4) and note that the cylinder pin (35) must be in the grooves of the
hood spike and of the top part.
- Grease and drive in the spring pin.
5.2.3 Mounting the the hydrant
The following mounting rules should be observed:
Pge-7
(16.03.2016)
- Clean the flange connection and insert the gasket (25).
- Pull the break ring (8) with the column part (1), thereby arrange the sinking of the fixing screws
in direction of the B-outflows.
- Put the column upper part (1) on the column lower part (2) The coupling (10.03) must be
inserted into the square of the spindle (11).
- Insert the snap ring halves (13), the break ring (8) in place and fasten with the screws (30).
- The column upper part (1) can be rotated so that the B- outflows are suitable for the location.
- Screw down the screws (30) crosswise and tighten.
5.2.4 Commissioning
Upon the commissioning is to be noted the following:
- In the unpressurized state, the hydrant is well and easy to operate.
- In the unpressurized state, the hydrant should be operated with an actuating key by approx. 60
Nm.
- The opening takes place by turning to the left, the closing by turning to the right.
- After the spindle is at the end of the opening or closing position, it must be moved back by a
quarter turn.
-The drainage must be checked after the closing
5.3 Repair instructions for the knocked-over hydrants
The knocked-over hydrants should be repaired as follows:
- Unscrew the 6 Allen screws (30).
- Take the column upper part (1) from the column bottom part (2).
- Remove the fragments of the broken ring
- Remove the split spring ring (13)
- Take up the rubber gasket (25).
- Slide the new break ring over the part 1.
- Insert the new gasket (25).
- Put the column upper part (1) on the column bottom part (2)
- Lift the break ring (8), insert both snap ring halves (13).
- Slide the ring (8), compare the bores and tighten the screws (30).
- The column upper part is in this state is free to rotate and can be adjusted to the location.
- Tighten the screws (30).
6. Physiological safety for non-metallic
installation components
The declarations of harmlessness for the non-metallic parts used are available:
- rubber seals, O-rings, wiper ring
- cone, rubberized,
- socket, rubberized,
- sealing ring, rubberized,
- coated with epoxy synthetic resin (ESR)
- enamels
- lubricants
- sliding discs
- plastic ball
Pge-8
(16.03.2016)
- ball
7. List of applicable standards for above-ground hydrants
DIN EN 14384
Above-ground hydrants
DIN EN 14318
B fixed couplings
DIN EN 1074-1
Valves for water supply
Part 1 - General Requirements
DIN EN 1074-2
Valves for water supply
Part 2 - Shut-off valves
DIN EN 1074-3
Valves for water supply
Part 3 - Backflow prevention products
DIN EN 1074-6
Valves for water supply
Part 6 - Hydrants
DIN EN 1092-2
Flanges and their joints
Part 2 - Cast iron flanges
DIN EN 1503-3
Valves
Part 3 - Cast iron, that is specified in the European standards
DIN EN 681-1
Elastomeric seals
Part 1 - Vulcanized rubber
DIN EN ISO 9001
Quality Management Systems
DIN 3223
Actuating keys
Pge-9
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8. Assembly drawing / Materials
Pos.
For DN 100 a
lower outlet
41
Designation
upper part of pillar, old-city
1
design
1.01 Hood, old-city design
2
Lower part of pillar, all pc.
2.01 Socket
3
Stand AU/AUD
4
Hood spike
5
Sealing ring, rubberized,
6
Guide bearing
7
Adjusting ring
8
Break ring
9
Sliding disc
10
Spindle extension, cpl.
10.01 Top part
10.02 Spindle extension tube
10.03 Coupling
11
Spindle
12
Mounting set, cpl.
12.01 Wing nut
12.02 Spacer tube
12.03 Rubberized cone
13
Divided break ring
14
In case of single shut-off hydrants (A1), the positions 5, 18 are
omitted.
EN-GJS
EN-GJS
EN-GJS
EN-GJS
EN-GJS
AL
EN-GJS/EPDM
EN-GJS
EN-GJS.
EN-GJL
Grivory GV-4H
Stainless steel
Stainless steel
Brass
Stainless steel
Brass
Stainless steel
EN-GJS/EPDM
Stainless steel
Stainless steel /
EPDM
15
Air valve cpl.
15.01 Air valve,
15.02 Ball
15.03 Cylinder notch pin
16
Socket
Brass
EPDM
Stainless steel
Brass
17
18
19
20
21
22
23
24
25
26
27
28
29
Polyamide
Hostalen
Al
AL
EPDM
EPDM
Stainless steel
EPDM
EPDM
EPDM
EPDM
Stainless steel
Stainless steel
30
40
Socket, rubberized,
Material
31
32
33
34
35
36
37
38
39
41
40
Drain plug
Hollow ball 125
Cover B
Fixed coupling B
Gasket 78x64x4
Gasket 90x76x4
Chain B
O-ring 25x3
Gasket 141x131x3
O-ring 145x3
Wiper ring
Clamping pin 6x40
Clamping pin 5x40
Cylinder Screw with l.-hex
M12x25
Adjusting ring B
Disc
Notch pin 4x8
Hex screw M16x50
Cylinder pin 6x24
Cover A
Fixed coupling A
Gasket 119x100x4
O-ring 130x114x4
Sealing ring
Chain A
Stainless steel
Stainless steel
Stainless steel
Stainless steel
Stainless steel
Stainless steel
AL
AL
EPDM
EPDM
EPDM
Stainless steel
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Pge-11
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