Richter KNR/F series User manual

INSTALLATION AND OPERATING MANUAL
Keep for future use!
This operating manual must be strictly observed before
transport, installation, operation and maintenance
Subject to change without notice.
Reproduction is generally permitted with indication of the source.
© Richter Chemie-Technik GmbH.
9520-003-en Revision 18 Edition 05/2022
Series KNR/F, KNRP/F
KNR-D/F, KNRP-D/F
Control ball valve
with V-control ball/stem unit and Richter
ENVIPACK universal packing

Series KNR/F, KNRP/F, KNR-D/F, KNRP-D/F Page 2
9520-003-en Revision 18
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List of Contents
List of Contents.................................................2
Relevant documents.........................................2
1Technical data .............................................3
1.1 Type plate, CE and body markings .............. 3
1.2 V-control ball/stem unit................................... 4
1.3 Tightening torques .......................................... 4
1.4 Actuating torques ............................................ 5
1.5 Cavitation coefficient z for 75% duty
(Kv/Kv100=0,75).............................................. 5
1.6 Flow values Kv in %....................................... 5
1.7 Flow rates......................................................... 5
1.8 Pressure-temperature diagram..................... 6
2Notes on safety............................................6
2.1 Intended use .................................................... 6
2.2 For the customer / operator........................... 6
2.3 Improper operation.......................................... 7
3Safety notes for applications in potentially
explosive areas based on the Directive
2014/34/ EC (ATEX) .....................................7
3.1 Intended use .................................................... 7
4Safety note for valves, certified to Clean
Air Act (TA Luft)...........................................8
5Transport, storage and disposal...............8
5.1 Storage ............................................................. 8
5.2 Return consignments...................................... 8
5.3 Disposal............................................................ 8
6Installation....................................................9
6.1 Flange caps and gaskets............................... 9
6.2 Direction of flow and installation position.... 9
6.3 Grounding......................................................... 9
6.4 Test pressure................................................... 9
7Operation......................................................9
7.1 Initial commissioning....................................... 9
7.2 Improper operation and their consequences
…………………………………………………………………….9
7.3 Shutdown........................................................ 10
8Malfunctions...............................................10
9Maintenance...............................................11
9.1 Dismantling..................................................... 11
9.1.1 Ball valve with lever............................................11
9.1.2 Packing bellows..................................................11
9.1.3 Ball valve with actuator......................................11
9.2 Assembly........................................................ 11
9.2.1 Packing bellows..................................................11
9.2.2 Ball valve with lever............................................11
9.2.3 Ball valve with actuator......................................11
9.3 Conversion from lever to actuator............... 12
10 Drawings.....................................................12
10.1 Legend............................................................ 12
10.2 Sectional drawing ball valve with lever....... 13
10.3 Sectional drawing ball valve with actuator. 14
10.4 View and section ball valve with lever........ 15
10.5 Sections ball valve with actuator................. 15
10.6 Dimensional drawing ball valve with lever. 16
10.7 Dimensional drawing ball valve with gear
DN200............................................................. 17
10.8 Dimensional drawing ball valve with actuator
…………………………………………………………………..18
10.9 Flange connection dimensions.................... 19
Relevant documents
♦EG-Declaration of conformity
♦Declaration of conformity FDA & 97/48/EG
♦Manufacturer Declaration ATEX Directive
2014/34/EU
♦Manufacturer Declaration TA-Luft
♦Form for Safety Information Concerning the
Contamination QM 0912-16-2001_en
♦For KNRP/F, KNRP-D/F: Operating manual for
actuator
♦Depending on option, relevant drawing:
Double packing bonnet, Section 9520-00-3001
Dimen. 9520-00-4011
Lever elevation Section 9520-00-3011
Dimen. 9520-00-4021
Extended stem, round Section 9520-00-3010
Dimen. 9520-00-4020
Stem extension Section 9520-00-3009
DN 15-100 Dimen. 9520-00-4022
Stem extension Section 9520-00-3003
DN 150-200 Dimen. 9520-00-4013
Limit switch IFM Section 9520-00-3005
Dimen. 9520-00-4015
Spring return unit Section 9520-00-3004
Dimen. 9520-00-4014
Limit switch VDE/VDI Section 9520-00-3006
Dimen. 9520-00-4016
Turck Initiator Section 9520-00-3007
Dimen. 9520-00-4017
Locking plate 9520-00-3002
Heating jacket 9520-00-3012
Connection dimension
for actuator Dimen. 9520-00-4018

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1 Technical data
Manufacturer:
Richter Chemie-Technik GmbH
Otto-Schott-Str. 2
D-47906 Kempen
Telephone : [phone]
Fax: [phone]
E-Mail : [email protected]m
Internet: http://www.richter-ct.com
Designation :
Control ball valve with V-control ball/stem unit and
Richter ENVIPACK universal self-adjusting packing,
two-piece body.
Series:
KNR/F →Design with lever or
hand gear
KNRP/F →for pneumatic, hydraulic or electric
actuator to DIN EN ISO 5211
KNR-D/F →KNR/F with thick-walled (5mm) body
lining
KNRP-D/F →KNRP/F with thick-walled (5mm) body
lining
rangeability 25:1
Certified to Clean Air Act (TA Luft)
Strength and tightness (P10, P11) of the pressure-
bearing body tested to DIN EN 12266-1.
Gas-tight (P12) in the seat to DIN EN 12266-1,
leak rate A
Face to face:
DIN EN 558-1 basic series 1, ISO 5752 series 1
DN 200 to ASME B16.10, Class 150 column 8
Flange connecting dimensions: DIN EN 1092-2, type
B
(ISO 7005-2 Type B) PN 16 or flanges drilled to
ASME B16.5 Class 150
Materials :
Body material: Ductile cast iron EN-JS 1049 /
ASTM A395
Lining material: PFA/PTFE .../F
On request: antistatic …/F-L
highly permeation-resistant …/F-P
Temperature range :
see pressure-temperature diagram in Section 1.8.
Operating pressure:
DN 15 - DN 100 from vacuum to max. 16 bar (PN16)
DN 150 –200 max. 10 bar (PN 16)
optional: DN 25 –DN 80 to max. 16 bar (PN 25)
(not KNR-D/F or KNRP-D/F)
See pressure-temperature diagram in Section 1.8.
Ball valve sizes in mm:
DN 15, 20, 25, 40, 50, 80, 100, 150, 200
DN 200 with reduced bore DN150.
Weight, ball valve manually operated:
DN
15
20
25
40
50
80
ca. kg
5,6
6
6
14
16
35
DN
100
150
200/150
200
ca. kg
55
104
125
170
For weight of actuator, see actuator manufacturer's
manual.
Installation position :
Arbitrary, a direction arrow on an additional name
plate indicates the direction of flow. See Section 1.1
and 10.
Dimensions and individual parts :
See sectional drawing in Section 10
Wear parts : Seat rings
Packing components
V-control ball/stem unit
Options :
♦Richter ENVIPACK double packing
for particularly high safety requirements,
selfadjusting.
On request, monitoring and flushing connection.
♦Extended stem
for insolated pipes
♦Hand lever extension depending on requirements.
♦Limit switches
for remote monitoring of hand and remote-
activated ball valves
♦lockable hand lever
to prevent unauthorised operation
♦stainless steel heating jacket
can be retrofitted, suitable for all common heat
transfer media.
1.1 Type plate, CE and body
markings
The stainless steel name plate is undetachably riveted
to the body.
If the operator attaches his identification, it must be
ensured that the valve matches the application in
question.
No CE marking is permissible for the sizes 15, 20 and
25; the name plate therefore has no CE marking.
Example of name plate with CE marking:

Series KNR/F, KNRP/F, KNR-D/F, KNRP-D/F Page 4
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Example: Additional name plate KNR, KNRP
Body identification :
The following are visible on the body according to DIN
EN 19 and AD 2000 A4:
♦Nominal size
♦Rated pressure
♦Body material
♦Manufacturer's identification
♦Melt number/Foundry identification
♦Foundry date
1.2 V-control ball/stem unit
The advantage of a single-piece v-control ball/stem
unit is the play-free power transmission. This applies
in particular to plastic-lined components.
The end of the stem journal or flat pivot point is
marked with:
♦flow direction
♦flow rate Kvs and Cv
♦lining material
As viewed from above, closing is in clockwise
direction.
1.3 Tightening torques
All screws greased, tighten in diametrically
opposite sequence!
The tightening torques for pipe screws and body
screws mentioned must not be exceeded. For an
exception, see Section 8, Flange connection
valve/pipe is leaking.
The following tightening torques are recommended.
Packing screws
Tighten packing gland follower 503 until spring gland
follower 502 is in contact without any gap. DN 80,
100, 150 and 200 contain 2 spring gland followers
502.
Pipe screws
Flange
nom. size
screws
Tightening
torque
[mm]
[ISO/DIN]
[Nm]
15
4 x M12
6
20
4 x M12
8
25
4 x M12
10
40
4 x M16
20
50
4 x M16
26
80
8 x M16
25
100
8 x M16
35
150
8 x M20
65
200
12 x M20
100
Pipe screws, flanges ISO/DIN
drilled to ASME Class 150
Flange nom.
size
screws
Tightening torque
[mm]
[inch]
[ASME]
[in-lbs]
[Nm]
15
½"
4 x ½“
45
5
20
¾"
4 x ½“
55
6
25
1"
4 x ½“
70
8
40
1½"
4 x ½“
135
15
50
2"
4 x ⅝“
220
25
80
3"
4 x ⅝“
400
45
100
4"
8 x ⅝“
310
35
150
6"
8 x ¾“
710
80
200
8"
8 x ¾“
1020
115
Body screws
Nominal size
screws
Tightening torque
[mm]
[inch]
[ISO/DIN]
[Nm]
[in-lbs]
15
½"
4 x M12
35
310
20
¾"
4 x M12
35
310
25
1"
4 x M12
35
310
40
1½"
4 x M16
45
398
50
2"
4 x M16
45
398
80
3"
8 x M16
50
442
100
4"
8 x M16
60
531
150
6"
8 x M20
150
1330
200/150
8“/6“
8 x M20
150
1330
200
8“
8 x M24
175
1549
Control characteristics
flow direction
Flow rate kvs and cv

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1.4 Actuating torques
Test medium: water 20 °C
Higher actuating torques may occur with other media.
DN
Δp in bar
3
6
10
16
max. adm.
[mm]
[Nm]
[Nm]
[Nm]
[Nm]
[Nm]
15
8
8
8
10
70
20
8
8
8
10
70
25
12
12
12
12
70
40
20
20
20
25
225
50
25
25
25
30
225
80
60
60
65
80
500
100
80
80
90
170
500
150
200
250
350
---
2200
200/150
200
250
350
---
2250
200
600
600
700
---
2200
The actuating torque of the actuator must be at least
as high as the actuating torque of the valve, about
20% higher being better however.
With highly viscous media and/or solids in the medium
it may be necessary to consider other safety
allowances in dimensioning the actuator. This is
particularly true for non-Newtonian fluids such as high
polymer substances, suspensions, pastes, lubricants,
resins, lacquers etc.
Admissible factors of safety lie in the range of 20 -
50% of the actuating torque.
In order to avoid damage to the valve, it is imperative
to observe the max. admissible actuating torque!
1.5 Cavitation coefficient z for
75% duty (Kv/Kv100=0,75)
There are 3-6 different V-control ball/stem units per
nominal size
DN
z1
z2
z3
z4
z5
z6
15
0.65
0.60
0.60
0.60
0.58
0.43
20
0.65
0.60
0.60
0.60
0.58
0.43
25
0.65
0.60
0.60
0.60
0.58
0.43
40
0.53
0.50
0.35
50
0.47
0.39
0.32
80
0.31
0.29
0.22
100
0.27
0.24
0.16
150
0.15
0.13
0.08
200/150
0.15
0.13
0.08
200
0.08
𝑋𝐹=∆𝑝
𝑝1− 𝑝𝑣
XF= Differential pressure ratio
Δp = Differential pressure input/outlet
p1= Absolute pressure at inlet
pv= Vapour pressure at operating temp.
XF≤z : non-critical conditions
XF≤1,4 x z : tolerable cavitation
XF> 1,4 x z: inadmissible cavitation
1.6 Flow values Kv in %
Opening
[%]
Kv
[%]
Characteristics
equal percentage
rangeability 25:1
Best control range
20-90% of angle of
opening
10
5.5
20
7.6
30
10.5
40
14.5
50
20.0
60
27.6
70
38.1
80
52.5
90
72.5
100
100.0
1.7 Flow rates
There are 3-6 different V-control ball/stem units per
nominal size
DN
Kv100 - Cv
[mm]
[m3/h]
[inch]
[USgpm]
15
½“
0.8
0.93
1.6
1.86
4
4.66
8
9.32
14
16.3
20
23.3
20
¾“
0.8
0.93
1.6
1.86
4
4.66
8
9.32
14
16.3
20
23.3
25
1"
0.8
0.93
1.6
1.86
4
4.66
8
9.32
14
16.3
20
23.3
40
1½“
16
18.64
25
29.12
40
46.6
50
2"
16
18.64
25
29.12
40
46.6
60
69.9
80
3"
40
46.6
80
93.2
120
139.8
160
186.4
100
4"
60
69.9
100
116.5
160
186.4
250
291.25
150
6"
160
186.4
250
291.25
400
466
200/150
8“/6“
160
186.4
250
291.25
400
466
200
8"
1000
1165

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1.8 Pressure-temperature diagram
A special material is used for the ball/stem unit for
operating limits under –10 °C to –60 °C.
2014/68/EU (PED), AD2000, DIN EN 16668
DIN EN ISO 15848-1 certificate valid from -29°C to 200 °C
When used in the minus temperature range,
the regulations applicable in the country in
question must be observed.
2 Notes on safety
This operating manual contains fundamental
information which is to be observed during installation,
operation and maintenance.
It must be read before installation and
commissioning!
For valves which are used in potentially explosive
areas, see Section 3.
Installation and operation are to be performed by
qualified staff.
The area of responsibility, authority and supervision of
the staff must be regulated by the customer.
General hazard symbol!
People may be put at risk.
Safety symbol! The ball valve and its
function may be put at risk if this safety
symbol is not observed.
It is imperative to observe warnings and signs
attached directly to the ball valve and they are to be
kept fully legible.
Non-observance of the notes on safety may result in
the loss of any and all claims for damages.
For example, non-observance may involve the
following hazards:
♦Failure of important functions of the valve/plant.
♦Risk to people from electric, mechanical and
chemical effects.
♦Risk to the environment through leaks of hazard-
ous substances.
2.1 Intended use
Richter control ball valves are pressure containing
components in accordance with the Pressure
Equipment Directive (PED) for the passage and
shutoff of fluids. The valves are suitable for vapours,
gases and non-boiling liquids of group 1 according to
the PED and have a corrosion-resistant plastic lining.
Solids can lead to increased wear, damage to sealing
surfaces or to a reduction in the service life of the
valve.
The operator must carefully examine in the event of
operating data other than those provided whether the
designs of the valve, accessories and materials are
suitable for the new application (consult the
manufacturer).
2.2 For the customer / operator
If a valve is used, the operator must ensure that
♦actuators which are retrofitted are adapted to suit
the valve
♦hot or cold valve parts are protected by the
customer against being touched
♦the valve has been properly installed in the pipe
system
♦the operating conditions stipulated in the data
sheet are not exceeded in continuous operating
mode.
This is not the manufacturer's responsibility.

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Loads caused by earthquakes were not allowed for in
the design.
Ball valves at the end of a pipe (end valve)
must be sealed with a blind flange at the
free connection end and appropriately
secured against unauthorised activation.
Fire protection to DIN EN ISO 10497 is not possible
(plastic lining and plastic components).
2.3 Improper operation
The operational safety of the valve supplied is only
guaranteed if it is used properly in accordance with
Section 2.1 of this operating manual.
The operation limits specified on the name
plate and in the pressure-temperature
diagram must under no circumstances be
exceeded.
3 Safety notes for applications in potentially explosive areas
based on the Directive 2014/34/ EC (ATEX)
The valves are intended for use in a potentially
explosive area and are therefore subject to the
conformity assessment procedure of the directive
2014/34/EC (ATEX).
As part of this conformity assessment, an ignition
hazard analysis to EN 13463-1 to satisfy the
fundamental safety and health requirements was
conducted with the following result:
♦The valves do not have any ignition source of
their own and can be operated both manually
as well as mechanically/electrically.
♦The valves are not covered by the scope of
application of the ATEX directive and therefore
do not need to be identified accordingly.
♦The valves may be used in a potentially
explosive area.
Supplementary notes:
♦Electric/mechanical actuators must be
subjected to their own conformity assessment
to ATEX.
It is imperative to observe the individual points of
intended use for application in a potentially explosive
area.
3.1 Intended use
Improper operation, even for brief periods, may result
in serious damage to the valve.
In connection with explosion protection, potential
sources of ignition (overheating, electrostatic and
induced charges, mechanical and electric sparks) may
result from these inadmissible modes of operation;
their occurrence can only be prevented by adhering to
the intended use.
Furthermore, reference is made in this connection to
the Directive 95/C332/06 (ATEX 118a) which contains
the minimum regulations for improving the occupa-
tional health and safety of the workers who may be at
risk from an explosive atmosphere.
A difference is made between two cases for the use of
chargeable liquids (conductivity < 10-8 S/m):
1. Chargeable liquid and non-conductive lining
Charges can occur on the lining surface. As a
result, this can produce discharges inside and
outside the valve.
a) Discharges inside the valve
However, these discharges inside the valve cannot
cause ignitions if the valve is completely filled with
medium.
If the valve is not completely filled with medium,
e.g. during evacuation and filling, the formation of
an explosive atmosphere must be prevented, e.g.
by superimposing a layer of nitrogen. It is recom-
mended to wait 1 hour before removing the valve
from the plant in order to permit the elimination of
static peak charges.
This means that, to safely prevent ignitions, the
valve must be completely filled with medium at all
times or else a potentially explosive atmosphere
must be excluded by superimposing a layer of inert
gas.
b) Discharges outside the valve
At the points where the non-conductive lining e.g.
protrudes on the sealing surfaces to the outside or
gets contact with the atmosphere on the outside, it
may lead to discharges from the lining to nearby
valves or attachments.
To safely avoid explosion hazards and accidents,
therefore, the atmosphere surrounding the valve
must not be explosive.
2. Chargeable liquid and conductive lining
No hazardous charges can occur as charges are
discharged direct via the lining and shell (surface
resistance <109Ohm, leakage resistance <106
Ohm).
If non-conductive versions of individual compo-
nents are installed in the valve, it may restrict the
permitted ATEX zone and explosion subgroup
when operating the valve despite the conductive
lining of the armor plating (see “Technical rules for
hazardous substances: Avoidance of ignition
hazards due to electrostatic charges” (TRGS
727)).
In these cases, consult the manufacturer.

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Static discharges of non-conductive linings are
only produced through the interaction with a
non-conductive medium and are therefore the
responsibility of the plant operator.
Static discharges are not sources of ignition
which stem from the valves themselves!
♦The temperature of the medium must not exceed
the temperature of the corresponding temperature
class or the maximum admissible medium temper-
ature as per the operating manual.
♦If the valve is heated (e.g. heating jacket), it must
be ensured that the temperature classes pre-
scribed in the Annex are observed.
♦For safe and reliable operation, it must be ensured
with regular inspection intervals that the unit is
properly serviced and kept in a perfect technical
condition.
♦Increased wear to the valve can be expected with
the conveyance of liquids containing abrasive
constituents. The inspection intervals are to be
reduced compared with the usual times. Actuators
and electric peripherals, such as temperature,
pressure and flow sensors etc., must comply with
the valid safety requirements and explosion protec-
tion provisions.
♦The valve must be grounded.
This can be achieved in the simplest way via the
pipe screws using tooth lock washers.
Otherwise grounding must be ensured by different
measures e.g. a cable link.
♦Attachments such as actuators, position control-
lers, limit switches etc. must satisfy the relevant
safety regulations as regards explosion protection
and, if required, be designed in compliance with
ATEX.
♦Special attention must be paid to the appropriate
safety and explosion protection notes in the re-
spective operating manuals.
♦Plastic-lined valves must not be operated with
carbon disulphide.
4 Safety note for valves, certified to Clean Air Act (TA Luft)
Certificate / Manufacturer Declaration Validity is
dependent on the operating instructions being read
and observed.
♦Carry out regular maintenance intervals and check
the tightness of the screw connections and tighten
as necessary.
5 Transport, storage and disposal
For all transport work, observe generally
accepted engineering practice and the
accident prevention regulations.
The valve is supplied with flange caps. Do
not remove them until just before installation.
They protect the plastic surfaces against dirt
and mechanical damage.
Handle the goods being transported with care. During
transport protect the valve against impacts and
collisions.
Directly after receipt of the goods, check the consign-
ment for completeness and any in-transit damage.
Do not damage paint protection.
5.1 Storage
If the valve is not installed immediately after delivery,
store them properly.
It should be stored in a dry, vibration-free and well-
ventilated room at as constant a temperature as
possible.
Elastomers are to be protected against UV light.
In general, a storage period of 10 years should not be
exceeded.
5.2 Return consignments
Valves which have conveyed aggressive or
toxic media must be well rinsed and cleaned
before being returned to the manufacturer's
works.
It is imperative to enclose a safety information
sheet / general safety certificate on the field of
application with the return consignment.
Pre-printed forms are enclosed with the installation
and operating manual.
Safety precautions and decontamination methods are
to be mentioned.
5.3 Disposal
Parts of the valve may be contaminated with medium
which is detrimental to health and the environment
and therefore cleaning is not sufficient.
Risk of personal injury or damage to the
environment due to the medium!
♦Wear protective clothing when work is performed
on the valve.
♦Prior to the disposal of the valve:
▪Collect any medium, etc. which has escaped
and dispose of it in accordance with the local
regulations.
▪Neutralise any medium residues in the valve.
♦Separate valve materials (plastics, metals, etc.)
and dispose of them in accordance with the local
regulations.

Series KNR/F, KNRP/F, KNR-D/F, KNRP-D/F Page 9
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6 Installation
♦Examine valve for in-transit damage, damaged ball
valves must not be installed.
♦Before installation the valve and the connecting
pipe must be carefully cleaned to remove any dirt,
especially hard foreign matter.
♦Observe direction of flow.
♦During installation, pay attention to the correct
tightening torque, aligned pipes and tension-free
assembly.
Ensure that a remotely actuated actuator
cannot be accidentally switched on.
6.1 Flange caps and gaskets
♦Leave protective caps on the flanges until just prior
to installation.
If plastic sealing surfaces, e.g. on mating flanges
made of metal or enamel, can be damaged, use
PTFE-lined seals with a metal inlay.
These gaskets are available as special accessories in
the Richter range.
6.2 Direction of flow and
installation position
Any fitting position can be chosen.
A direction arrow on an additional name plate for
control ball valve shows the direction of flow. See
Section 1.1.
6.3 Grounding
The valve must be grounded. This can be achieved in
the simplest way via the pipe screws using tooth lock
washers. One pipe screw per flange is underlaid with
toothed disks.
At the customer's request a setscrew M6 with a hex.
nut and washer will be provided at each flange as an
additional grounding connection.
Otherwise grounding must be ensured by different
measures e.g. a cable link.
The V-control ball/stem unit 201 is grounded using a
grounding spring washer 557.
6.4 Test pressure
The test pressure PT of a valve must not exceed the
value of 1.5 x PS(PN) as per the identification of the
valve.
7 Operation
7.1 Initial commissioning
Normally, the valves have been tested for leaks with
air or water. Prior to initial operation check cover
screws. For tightening torques, see Section 1.3.
Unless otherwise agreed there could be
residual amounts of water in the flow section
of the valve. This could result in a possible
reaction with the medium.
To prevent leaks, all connection screws should be
retightened after the initial loading of the valve with
operating pressure and operating temperature.
For tightening torques, see Section 1.3.
7.2 Improper operation and their
consequences
♦Crystallisation may result in damage to the seat
rings or V-control ball/stem unit. This can be pre-
vented by heating.
In extreme cases this may cause blocking.
♦If the ball blocks, do not apply force as the
ball/stem may break if the max. adm. torque is
exceeded.
♦Increased wear occurs in operation with solids
contents.
♦Operation during cavitation leads to increased
wear.
♦Non-observance of the pressure-temperature
diagram can lead to damage.
♦Do not subject the lever to heavy loads; the lever
or ball valve may be damaged.
♦Do not use a lever extension as otherwise there is
a risk of damage.

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7.3 Shutdown
The local regulations are to be observed when
dismantling the valve.
Prior to undoing the flange connection ensure, that the
plant is depressurised and emptied.
Move V-control ball/stem unit into the "half-open
position".
Prior to starting any repair work, the valve is
to be thoroughly cleaned. Medium residue
may be in the valve even if it has been
properly drained and flushed.
After dismantling, immediately protect the valve
flanges against mechanical damage by using flange
caps. See also Section 6.1.
Make sure that a remote-controlled actuator
cannot be switched on by accident.
8 Malfunctions
♦Flange connection ball valve/pipe is leaking
Retighten the flange screws to a tightening torque
according to Section 1.3. If this does not remedy
the leak, the recommended torques may be
exceeded by 10%.
If this also fails to stop the leak, dismantle and
inspect the valve.
♦Flange connection main body/body end piece is
leaking
Retighten body screws. See paragraph "Flange
connection ball valve/pipe is leaking".
♦Packing is leaking
Retighten packing nuts according to the details in
section 1.3 .
♦Ball valve does not operate
Is the actuator supplied with power?
Is any directional control valve correctly connect-
ed?
Is there foreign matter in the valve?
♦The ball no longer closes completely
Is the stem deformed?
Is the coupling worn?
Are the sleeve nuts 512 and setscrew 904/4 tight-
ened?
The V-control ball/stem unit has too much
play/hysteresis.
With a worm gear or actuator, check whether the
end stops can be re-adjusted. The operating
manuals of the gear and actuator manufacturers
contain accurate instructions.
Never apply force to the lever or use an
extension.
1. Try to get the ball valve working again by mov-
ing the lever to and from.
2. Remove the lever stop and try to switch against
the normal direction of rotation.
3. If actuation is not possible with the max. admis-
sible actuating torque as per section 1.4, dis-
mantle ball valve and inspect individual compo-
nents.

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9 Maintenance
♦All repair work is to be performed by qualified
personnel using the appropriate tools.
♦For the arrangement, designation and item
numbers of all parts of the valve, see Section 10.
♦Spare parts are to be ordered with all the details
in acc. with the valve identification.
♦Only original spare parts may be installed.
♦To prevent leaks, a regular check of the connec-
tion screws should be made in line with the oper-
ating requirements.
For tightening torques, see Section 1.3.
9.1 Dismantling
9.1.1 Ball valve with lever
♦Remove lever 203.
♦Take out grounding spring washer 557.
♦Dismantle packing gland follower 503 and spring
gland follower 502.
♦The thrust ring 405/1, packing bellows 403 and
retaining washer 526 (not in DN 150 and DN 200)
are one unit and it is levered out using 2 screw-
drivers.
♦Undo screw connection body end piece 102 /
main body 100.
♦Remove body end piece 102.
♦Remove V-control ball/stem unit 201. Make sure
that you do not damage the body lining.
♦Remove seat rings 401.
9.1.2 Packing bellows
♦Remove retaining washer 526.
♦Separate thrust ring 405/1 and packing bellows
403 by pushing them apart.
9.1.3 Ball valve with actuator
♦Undo setscrew 904/4 in the coupling 804 by one
turn.
♦Undo sleeve nut 512 on the coupling by about 2
turns. Left-hand thread. Observe drawing in
Sections 10.3 and 10.5.
♦Remove actuator 850 and coupling 804.
♦Dismantle packing gland follower 503 and spring
gland follower 502.
♦Remove bracket 510.
♦Further dismantling is performed as described in
Section 9.1.1.
9.2 Assembly
♦Prior to assembly all parts are to be cleaned and
the plastic-lined parts checked for damage.
♦Insert seat rings 401 in the main body 101 and
body end piece 102.
♦Mount and adjust V-control ball/stem unit 201.
Make sure that you do not damage the body lining.
♦Observe direction of flow. See sectional drawing in
Section 10.
♦Mount body end piece 102. Tighten the greased
housing screws cross over with a tightening torque
according to section 1.3.
9.2.1 Packing bellows
♦Press thrust ring 405/1 into packing bellows 403.
♦Install retaining washer 526 (not in DN 150 and
DN 200).
♦Press unit into main body 101.
♦Press in grounding spring washer 557.
9.2.2 Ball valve with lever
♦Mount lever stop 577, spring gland follower 502 (in
DN 80, 100, 150 and 200 are 2 spring gland
followers 502) and packing gland follower 503.
Tighten packing nuts until there is no gap between
packing gland follower and spring gland follower.
See Section 1.3 and 10.4.
♦Notice direction of rotation of V-control ball/stem
unit.
♦Seal any tapped bores still open with plugs.
♦Mount lever 203.
9.2.3 Ball valve with actuator
♦Mount spring gland follower 502 (in DN 80, 100,
150 and 200 are 2 spring gland followers 502) and
packing gland follower 503. Tighten packing nuts
until there is no gap between packing gland fol-
lower and spring gland follower. See Section 1.3
and 10.5.
♦Mount bracket 510 with the opening at right angles
to the direction of flow.
♦Mount coupling 804 and actuator 850. Notice
direction of rotation of V-control ball/stem unit.

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♦Observe the actuator position in accordance with
the actuator operating manual.
♦Tighten setscrew 904/4 in the coupling 804.
♦Tighten sleeve nut 512 on the coupling tight.
Attention: Left-hand thread.
♦Observe drawing in Section 10.3 and 10.5.
9.3 Conversion from lever to
actuator
♦Select the actuator in accordance with the
instructions of the actuator manufacturer.
♦Remove lever 203.
♦Remove lever stop 577 and plug.
♦Check the fits of the coupling 804, bracket 510
and actuator 850.
♦Mount bracket 510 with the opening at right angles
to the direction of flow.
♦Mount coupling 804 and actuator 850. Notice
direction of rotation of V-control ball/stem unit.
♦Observe the actuator position in accordance with
the actuator operating manual.
♦Tighten setscrew 904/4 in the coupling 804.
♦Tighten sleeve nut 512 on the coupling tight.
Attention: Left-hand thread.
♦Observe drawing in Sections 10.3 and 10.5.
10 Drawings
10.1 Legend
101 main body
102 body end piece
201 ball/stem unit
203 lever
401 seat ring
403 stuffing box bellows
405/1 Thrust ring
502 spring gland follower
503 Spring gland follower
510 bracket
526 retaining washer
(DN 15,20,25,40,50,80,100)
554/1 Washer
554/4 Washer
(DN 25)
554/5 Washer
557 grounding spring washer
577 lever stop
804 Coupling
includes:
512 sleeve nut
904/4 setscrew
980/1 round head grooved pin
850 actuator
901/1 Hex. screw
(DN 25,40,50)
901/2 Hex. screw
901/3 Hex. screw
901/4 Hex. screw
902/1 Stud screw
(DN 15,20,80,100,150,150/200)
904/1 Setscrew
914/2 hex socket screw (F07)
918/1 threaded rod
(DN 150, 150/200)
920/x Hex. nut
936/x Tooth lock washer

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10.2 Sectional drawing ball valve with lever
Holes of the flange- and housing screws view displaced by 45°.

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10.3 Sectional drawing ball valve with actuator
Holes of the flange- and housing screws view displaced by 45°.

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10.4 View and section ball valve with lever
10.5 Sections ball valve with actuator

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10.6 Dimensional drawing ball valve with lever
DN
15
20
25
40
50
80
100
150
200/150 *
200
L
130
150
160
200
230
310
350
480
457
457
H
130
130
130
155
155
180
195
265
265
-
HL
179
179
179
259
259
410
410
513
513
-
* DN 200 with reduced bore DN150.
all dimensions in mm
Flange connecting dimensions:
DIN EN 1092-2, type B (ISO 7005-2, type B) PN 16 or flanges drilled to ASME 16.5 Class 150

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10.7 Dimensional drawing ball valve with gear DN200

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10.8 Dimensional drawing ball valve with actuator
DN
H1
H2
Connecting
dimen. acc. to
ISO 5211
H3
H4
L
L1
L2
L3
15
50
60
F05
130
20
150
25
160
40
77
60 **
F07
200
50
80
230
80
118
80
F10
310
100
134
350
150
184
80
F12
480
200/150 *
457
200
457
* DN 200 with reduced bore DN 150
** H2 = 3.15” (80mm) if F10 or F12 on the actuator side
Dimensions L1, L2, L3, H3 and H4 vary depending on the actuator manufacturer.
all dimensions in mm

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10.9 Flange connection dimensions
1) DN 200/150 with reduced bore DN 150
all dimensions in mm
DN
DIN EN 1092-2, Form B (ISO 7005-2, Form B)
PN 16
Flansche gebohrt nach
ASME B16.5 Class 150
ØD
Øk
n x d1
Øk
n x d1
mm
inch
mm
mm
mm
mm
mm
15
½
95
65
4x14
60.5
4x16
20
¾
105
75
4x14
70
4x16
25
1
115
85
4x14
79.5
4x16
40
1½
150
110
4x19
98,5
4x16
50
2
165
125
4x19
120.5
4x19
80
3
200
160
8x19
152.5
4x19
100
4
220
180
8x19
190.5
8x19
150
6
285
240
8x23
241.5
8x23
200/1501)
6/8
340
295
8x23
298,5
8x23
200
8
343
295
12x23
298.5
8x23