MOUNTING AND
OPERATING INSTRUCTIONSEB 20aTranslation of the original manualBall valve BR 20a • DIN and ANSI version
to combine with actuators
November 2023 edition

PFEIFFER Chemie-Armaturenbau GmbH · Hooghe Weg 41 · 47906 Kempen
Phone: 02152 2005-0 · Fax: 02152 1580
sales-pfeiffer-de@samsongroup.com · www.pfeiffer-armaturen.com

Note regarding this installation and operating manualThis Installation and Operating Manual (EB) provides guidance
for safe assembly and operation.
The notes and instructions in this EB are binding when handling
PFEIFFER devices. The figures and illustrations in this EB are examples and must therefore be considered as such.
Ö For safe and correct use, read this EB carefully prior to use
and keep it for later reference.
Ö In the case of questions that go beyond the scope of this EB,
please contact the After Sales Service at PFEIFFER ChemieArmaturenbau GmbH.
Ö This manual only applies to the ball valve itself, the respective
additional manual applies for the mounted actuator.

Definition of signal words
DANGER
Hazardous situations that lead to death or serious injuries

WARNING
Situations that can lead to death or serious injuries

NOTE
Property damage and malfunctions

Info
Additional information

Tip
Recommended action

EB 20a_EN
November 2023 edition
Subject to technical changes

Content

Content
1

Safety instructions and safety measures

1-1

1.1

Notes regarding possible severe personnel injury

1-2

1.2

Notes regarding possible personnel injury

1-2

1.3

Notes regarding possible property damage

1-3

1.4

Warning notes on the device

1-4

2Markings on the device

2.1

Type plates

2-1
2-2

2.1.1

Ball valve type plates

2-2

2.1.2

Actuator type plate

2-2

2.2
3

Material marking
Design and principle of operation

2-2
3-1

3.1

Variants

3-1

3.2

Additional fittings

3-1

3.3

Attachments

3-2

3.4

Technical data

3-2

3.5

Ball valve assembly

3-2

3.5.1

Assembly of the DIN ball valve, DN 15 ... 100

3-2

3.5.2

Assembly of the DIN ball valve, DN 150 ... 200

3-4

3.5.3

Assembly of the ANSI ball valve

3-6

4

Shipment and on-site transport

4-1

4.1

Accepting delivery

4-1

4.2

Unpacking the ball valve

4-1

4.3

Transporting and lifting the ball valve

4-1

4.3.1

Transporting

4-1

4.3.2

Lifting

4-1

4.3.3

Lifting points on the body

4-2

4.3.4

Lifting points on the bracket

4-2

4.4
5

Storing the ball valve
Installation

4-3
5-1

5.1

Installation conditions

5-1

5.2

Preparing for assembly

5-1

5.3

Assembling the ball valve and actuator

5-1

5.4

Installing the ball valve in the pipe

5-2

5.4.1

General

5-2

5.4.2

Installing the ball valve

5-3

5.4.3
5.5

Installation instructions for lined gate ball valves with heat pack
Checking the assembled ball valve

5-3
5-3

5.5.1

Functional test

5-3

5.5.2

Pressure test of the pipe section

5-4

5.5.3

Swivelling movement

5-4

5.5.4

Fail-safe position

5-4

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Content

6

Start up

6-1

7

Operation

7-1

8

Malfunction

8-1

8.1

Detecting and rectifying errors

8-1

8.2

Carrying out emergency measures

8-2

9Servicing

9-1

9.1

Periodic tests

9-1

9.2

Maintenance work

9-2

9.2.1

Replacing the seal rings and ball

9-2

9.3

Ordering spare parts and consumables

9-2

10 Decommissioning

10-1

11 Removal

11-1

11.1

Removing the ball valve from the pipe

11-1

11.2

Disassembling the actuator

11-1

12 Repairs

12-1

12.1

12-1

Replacing the V-ring packing in the case of a DIN ball valve

12.1.1

Ball valve in the “standard version”

12-1

12.1.2

Ball valve with “double stuffing box”

12-1

12.2

Replacing the V-ring packing in the case of a ANSI ball valve

12-3

12.3

Replacing the seat ring of the ball

12-3

12.4

Additional repairs

12-3

12.5

Sending devices to PFEIFFER

12-4

13 Disposal

13-1

14 Certificates

14-1

15 Annex

15-1

15.1

15-1

Tightening torques, lubricant and tools

15.1.1

Tightening torques

15-1

15.1.2

Lubricant15-2

15.1.3

Tools

15-2

15.2

Spare parts

15-2

15.2.1

Spare parts of the ball valve in the DIN version, DN 15 ... 100

15-3

15.2.2

Spare parts of the ball valve in the DIN version, DN 150 ... 200

15-4

15.2.3

Spare parts of the ball valve in the ANSI version

15-5

Spare parts of the ball valve with double stuffing box

15-6

15.2.415.3

Service15-7

EB 20a_EN
November 2023 edition
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Safety instructions and safety measures

1

Safety instructions and safety measures

Intended use
The PFEIFFER ball valve BR 20a is manually operated in combination with an actuator for the regulation of the volume flow,
control and regulation of fluid, gaseous or vaporous media.
− The ball valve and its actuator are designed for precisely defined conditions (e.g. operating pressure, utilised medium,
temperature).
Therefore the operator must make sure that the ball valve isonly used when the conditions of use comply with the design
criteria defined in the order, see also the pressure-temperature diagram.
If the operator would like to use the ball valve in other applications or environments, they must contact PFEIFFER.
− Manual ball valves are only intended for use, after installation in a pipe system, to cut off the media, let it flow throughor regulate it within the permitted pressure and temperature
limits.
− Automated ball valves are only intended for use, after installation in a pipe system and after connecting the drive to thecontrol, to cut off the media, let it flow through or regulate it
within the permitted pressure and temperature limits.
− The data sheet contains the permissible pressure and temperature range for these ball valves  TB 20a.
− The safety regulations that apply to the pipe system in which
the valves are installed and to the control system to which theactuator is connected also apply to the ball valves.
This manual only provides safety instructions that are to beobserved additionally for ball valves.
There may be additional safety instructions in the manuals forthe actuator assemblies.
− It is assumed that this chapter is observed when using thevalve as intended.
Reasonably foreseeable erroneous use and unintended use
The ball valve is not suited for the following areas of use:
− Use outside of the technical data and the limits defined by thedesign.
− Use outside of the limited defined by the peripheral devices
installed on the ball valve.
− Use outside any further limiting performance data on thetype plate.
Furthermore, the following activities are considered unintendeduse:− Use of third-party spare parts.
− Performance of maintenance and repair work that is not described.
Qualification of operating personnel
The ball valve may only be disassembled, dismantled, assembled
and commissioned by qualified specialist personnel trained in

EB 20a_EN
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pressurised pipes who are familiar with the assembly, commissioning and operation of this product.
− Specialist personnel in terms of this installation and operating
manual are persons who, on the basis of their vocational education, knowledge and experience and knowledge of therelevant standards, are capable of evaluating the assigned
tasks and identifying possible hazards.
Personal protective equipment
Depending on the utilized medium, PFEIFFER recommends thefollowing protective equipment:− Protective garments, protective gloves and eye protection
when using hot, cold, aggressive and/or corrosive media.
− Hearing protection when working near the valves.
− Request additional protective equipment from the plant operator.
Prohibition of modifications
Changes to the product are not permitted without consulting
PFEIFFER. Non-compliance invalidates the product guarantee.
PFEIFFER shall not be held liable for any resulting property damage or personal injury.
Protective devices
In the case of a power supply failure, the automated ball valve
automatically switches to a certain fail-safe position, see Fail-safe
positions”in Chapter “3 Design and principle of operation”.
− The fail-safe position corresponds to the effective direction
and is indicated on the type plate of PFEIFFER actuators, see
the actuator documentation.
− The valve is to be included in the equipotential bonding of theplant.
Warning of residual risks
To prevent personal injury or property damage, the operator andoperating personnel must use suitable measures to prevent thehazards that can result from the flow medium and operatingpressure as well as the signal pressure and moving parts of theball valve.
− Therefore, the operator and operating personnel must observe all the hazard information, warning information andinformation in this installation and operating manual.
Obligation of the operator to exercise diligence
The operator is responsible for proper operation as well as compliance with the safety regulations.
− The operator is responsible for providing operating personnel
with this installation and operating manual as well as the applicable documents and to provide instructions on proper operation.
− Furthermore, the operator must ensure that operating personnel and third parties are not endangered.
It is not the responsibility of PFEIFFER and therefore when using
the ball valve ensure that

1-1

Safety instructions and safety measures− The ball valve is only used as intended as described in thischapter.
− An actuator unit that is subsequently installed on the ballvalve is adapted to it and the max. torque is observed, and iscorrectly adjusted in the end positions, and in particular in
the opening position of the ball valve.
− The pipe system and control system are properly installed
and regularly checked. The wall thickness of the ball valve
body is measured such that an additional load of the usual
magnitude is taken into account for a pipe system installed
properly in this way.
− The valve is connected properly to these systems.
− The customary flow rates in continuous operation are not exceeded in this pipe system.
− PFEIFFER is contacted in the case of abnormal operating conditions, such as vibrations, hydraulic shock, cavitation andalso large amounts of solid matter in the medium, especiallyabrasive matter.
Obligation of operating personnel to exercise diligence
Operating personnel must be familiar with this installation andoperating manual and the applicable documents and comply
with the indicated hazard information, warning information andother information. Furthermore, operating personnel must be familiar with the applicable regulations concerning occupationalsafety and accident prevention and observe them.
Applicable standards and directives− The ball valves fulfil the requirements of the European Pressure Equipment Directive 2014/68/EU and the European
Machinery Directive 2006/42/EC. In the case of ball valvesprovided with a CE marking, the Declaration of Conformity
provides information about the conformity assessment procedure that was used. The corresponding declarations of conformity are available in the Annex of this EB, see chapter “14Certificates“.
− According to an ignition hazard assessment according to
DIN EN ISO 80079-36, PFEIFFER ball valves do not haveany own potential ignition sources and therefore are not subject to Directive 2014/34/EU.
CE marking based on this standard is not permitted. The inclusion of valves in the equipotential bonding of a plant applies independently of the directive for all metal parts in potentially explosive areas.
Ball valves with plastic lining (PFA, PTFE, EPDM, etc.) throughwhich chargeable media flows during operation, must be
provided with an electrostatically dissipative plastic lining
whose surface resistance does not exceed a value of 1 GΩ(109 Ω) in accordance with DIN EN ISO 80079-36.

1-2

1.1 Notes regarding possible severe personnel injury
DANGER
Hazards and ineffectiveness of the warranty!
In the case of non-compliance with the following hazard andwarning information, hazards may arise and the warranty provided by the manufacturer may become invalid.
Ö Observe the following hazards and warning information.
Ö Contact PFEIFFER in the case of questions.
Hazards and damage due to unsuitable ball valves!
Ball valves whose permissible pressure/temperature range(=”rating”) are not sufficient for the operating conditions canpose a danger to the user and cause damage to the pipe system.
Ö Only operate ball valves whose permissible pressure/temperature range (=”rating”) is sufficient for the operating conditions, see the data sheet  TB 20a.
Risk of bursting of the pressure equipment!
Ball valves and pipes are pressure equipment. Improper opening
can cause the bursting of ball valve components.
Ö Observe the maximum permissible pressure for the ball valve
and plant.
Ö Before working on the ball valve, depressurise the concernedplant parts and the ball valve.
Ö Before removing the ball valve from the pipe, completely release the pressure in the pipe so that the medium does not escape uncontrolled from the line.
Ö Remove the ball valve in the open position so the pressure isreleased from the ball.
Ö Empty the medium from the concerned plant parts and ballvalve. (Wear protective equipment)

1.2 Notes regarding possible personnel injury
WARNING
Hazards due to incorrect ball valve use!
The incorrect use of the ball valve can represent a hazard for theuser and cause damage to the pipe system that are then nolonger the responsibility of PFEIFFER.
Ö The lining selected for the parts of the ball valve that come into contact with the media must be suitable for the utilised media, pressures and temperatures.
Danger of burning due to hot or cold components and pipes!
Depending on the utilised medium, ball valve components andpipes can become very hot or very cold and cause burns upon
contact.
Ö Ball valves must be protected against contact in the case ofoperating temperatures >+50 °C or <-20 °C together withthe pipe connections.

EB 20a_EN
November 2023 edition
Subject to technical changes

Safety instructions and safety measures

WARNING
Danger of crushing due to moving parts!
The ball valve contains moving parts (actuator and control shaft
as well as the hand lever) that can lead to crushing if reaching
into it.
Ö Do not reach into the bracket during operation.
Ö When working on the ball valve, interrupt and lock pneumatic energy and the control signal.
Danger of injury during the switching operation if performing
test runs on valves not installed in the pipe!
Ö Do not reach into the valve. This can result in serious injuries.
Danger of injury due to venting the actuator!
During operation, when regulating or opening and closing theball valve, the actuator can be ventilated.
Ö Install the ball valve such that the actuator does not ventilate
at eye level.
Ö Use suitable silencers and plugs.
Ö Wear eye protection and, if necessary, hearing protection
when working near valves.
Danger of injury due to preloaded springs!
Ball valves that are equipped with spring preloaded actuators
are under mechanical tension.
Ö Before working on the actuator, release the compression fromthe preloaded springs, see the corresponding actuator documentation.
Danger of injury due to residual medium in the ball valve!
When a ball valve must be removed from a pipe, medium canescape from the pipe or the ball valve.
Ö In the case of media that is harmful to health or hazardous,
the pipe must be completely emptied before a ball valve canbe removed.
Ö Pay attention to the afterflow of residuals or residuals that remain in dead spots of the ball valve.
Danger of injury due to the releasing of body screw connections!
If the body screw connections must be released, medium can escape from the ball valve.
Ö The screw connections on the connection of the body parts
may only be released or loosened after the ball valve has
been removed.
Ö During reassembly, tighten the screws according to Table 151 in Chapter “15-1-1 Tightening torques“ using a torquewrenchDangers due to use as an end fitting!
During normal operation, in particular with gaseous, hot and/or
hazardous media, spraying medium can cause hazards. It must
be kept in mind that the media is usually hazardous!
Ö A blind flange must be assembled on the free connecting
pieces or the ball valve must be secured against unauthorised
actuation.
Ö If a ball valve used as an end fitting in a pressurised line is
opened, this may only be done with extreme caution so thatthe escaping medium does not cause any damage.

EB 20a_EN
November 2023 edition
Subject to technical changes

WARNING
Deviation of the breakaway and actuating forces due tonon-actuation of the ball valve!
Depending on the period of time of non-actuation, the breakaway and actuation forces can deviate considerably from the actuating power data in the data sheet.
It is recommended to actuate the ball valve at regular intervals.
Ö In consideration of the design, actuation must take place during the year.
Ö Indicate the duration of non-actuation when making an enquiry, so that this condition is taken into consideration in theactuator design.
Ö In the case of retrofitted actuators by the operator, the correct
actuator design as regards the duration of non-actuation is
no longer the responsibility of PFEIFFER.

1.3 Notes regarding possible property
damageNOTE
Damage to the ball valve due to contamination!
Contamination (e.g. solid particles) in the pipes can damage theball valve.
Ö The plant operator is responsible for cleaning the pipes in theplant.
Ö Rinse the pipes prior to commissioning.
Ö Observe the maximum permissible pressure for the ball valve
and plant.
Damage to the ball valve due to unsuitable medium properties!
The ball valve is designed for a medium with certain properties.
Other media can damage the ball valve.
Ö Use the ball valve only in media that complies with the design
criteria.
Damage to the ball valve due to plant vibrations!
Ö If necessary, secure hand-operated ball valves in the case ofplant vibrations with a locking device to prevent it from moving by itself.
Damage to the ball valve and leakage due to excessively highor low tightening torques!
The ball valve components must be tightened with defined torques. Deviating torques can lead to ball valve leakage or damage.
Ö Excessively tightened components are subject to increasedwear.
Ö Insufficiently tightened components can cause leakage.
Ö Observe the tightening torques, see Table 15-1 in Chapter“15.1.1 Tightening torques”.

1-3

Safety instructions and safety measures

NOTE

Instructions for retightening the body screws

Damage to the ball valve due to an impermissible pressure increase!
The ball valve body may contain small amounts of medium in theclosed and open position.
Ö Use a ball valve with an optional relief bore if it is possiblethat the closed area of the ball filled with medium can heatup due to external heat. This prevents an impermissible pressure increase due to a change in the condition of the unit.
Damage to the ball valve due to unsuitable tools!
Unsuitable tools can damage the ball valve.
Ö Suitable tools are required to work on the ball valve, see
Chapter “15.1.3 Tools”.

Figure|1-2: Instructions for retightening the body screws

Damage to the ball valve due to unsuitable lubricants!
Unsuitable lubricants can corrode and damage the surface.
Ö The ball valve material requires suitable lubricants, see Chapter “15.1.2 Lubricants”.

1.4 Warning notes on the device
Warning of moving parts

Figure|1-1: Warning of moving parts

There is a danger of crushing due to the rotary movements of theactuator- and control shaft when reaching into the bracket as
long as the pneumatic power is connected to the actuator. At theoperator’s request, a warning note can be attached to the valve.

1-4

EB 20a_EN
November 2023 edition
Subject to technical changes

Markings on the device

2Markings on the device

Each ball valve usually has the following marking.
Table|2-1: Marking on the type plate and on the body of the ball valve
Pos.

For

1

Manufacturer

PFEIFFER

2
3

Marking

RemarkAddress see Chapter “15.3 Service”

Valve typeBR (and number value)e.g. BR 20a = Series 20a, see the PFEIFFER catalogue

Body material

e.g. EN-JS 1049

No. of the material standard according to DIN EN 1563 (previous: GGG 40.3)

Lininge.g. PTFE

Material marking of the lining “PTFE”

4

Size

DN (and number value)

Number value in [mm], e.g. DN 50/ number value in [inches], e.g. NPS2

5Maximum pressure

PN (and number value)

Number value in [bar] at room temperature, e.g. PN 10 / number value [inches], e.g. cl150

Max. permissible operating temperature

TS (and number value)

Max. permissible operating pressure

PS (and number value)

PS are TS are related values here at the max. permissible operating temperature with themax. permissible operating overpressure, see also the Pressure-Temperature Diagram PT 20a-01 and  PT 20a-02

Test pressure

PT (and number value)

The test pressure must be observed depending on the device

6

7

38

1234

/001

/001
Valve no. within the item
Item in the order

Manufacturer number
e.g. 381234/001/001
from 2018

Order
Year of manufacture (38=2018, 39=2019, 30=2020,
31=2021 etc.)
21

1234

/001

/001
Valve no. within the item

8

Manufacturer number
e.g. 211234/001/001
2009 to 2017

Item in the order
OrderYear of manufacture (29=2009, 20=2010, 21=2011,22=2012 etc.)
207

1234

/001

/001
Valve no. within the item

Manufacturer number
e.g. 2071234/001/001
until 2008

Item in the order
OrderYear of manufacture (205=2005, 206=2006, 207=2007
etc.)

9

Flow coefficiente.g. kvs 10

10

Characteristic curvee.g. %% = equal percentage, lin = linear (optional)

11

Test point number

e.g. F123201-1

Specified by the customer

Conformity

CE

Conformity is certified separately by the manufacturer

Code No.

0035“Notified body” according to EU Directive = TÜV Rheinland Service GmbH

Flow directionÎ

Attention: see the note in Chapter “5.4 Installing the ball valve in the pipe”

12
13
14

(DIN) = value, Cv (ANSI) = value (optional)

DataMatrix code

Info
Markings on the body and the type plate must be permanent so that the ball valve remains identifiable.

EB 20a_EN
November 2023 edition
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2-1Markings on the device

2.1 Type plates
2.1.1

Ball valve type plates

Figure|2-1: Type plate (82150ae) for DN 15 ... 25 and NPS½ ... 1

Figure|2-2: Type plate (82149ae) for DN 40 ... 200 and NPS1½ ... 8

2.1.2

Actuator type plate

See the corresponding actuator documentation.

2.2 Material marking
The ball valves are marked on the body with material specification, see “Table 2-1: Marking on the type plate and on the bodyof the ball valve”.
Further specifications can be requested from PFEIFFER.

2-2

EB 20a_EN
November 2023 edition
Subject to technical changes

Design and principle of operation

3

Design and principle of operation

Function and principle of operation
The media can flow in both directions through the BR 20a ballvalve with full passage.
The ball (2) with its cylindrical passage is swivel-mounted aroundthe control shaft. The ball swivel angle influences the flow throughthe area freed between the body (1) and the ball channel. Whenthe ball valve is open, the full cross section is freed.

3.1 Variants− Body made of other materials, e.g. 1.4571− Lined bottom drain valve BR 21a− Use as a control ball valve with calibrated seat ring(≤ DN 100)
− Lining with special PTFE compounds− PTFE-conductive lining− Stainless steel heat packThe ball (2), in the PTFE lined body, is sealed by replaceable seatrings (3).

− Control shaft sealing with two V-ring packings and test connection (double stuffing box).

The control shaft is sealed by PTFE V-ring packing (7). The discsprings (9) located above the packing provide the pretensioning.

− Flange with groove according to DIN EN 1092.

The control shaft that leads outside is fit up to DN 100/NPS4
with a hand lever (13). Optionally, a pneumatic rotary actuator
or a manual gear can be installed.

− FDA-compliant sealing material.

Info
The ball valve can also be used for control purposes see the data
sheet  DB 20a-kd.

− Various ball and seal ring materials.
− Customer-adapted versions.

3.2 Additional fittings
Strainer

Fail-safe position
Depending on the mounting of the pneumatic rotary actuator, theball valve has two fail-safe positions that are activated when thepressure is released as well when the supply air fails:− Ball valve with fail-close actuator [FC]:
Upon air failure, the ball valve is closed. The ball valve opens
when the signal pressure increases, acting against the forceof the springs.
− Ball valve with fail-open actuator [FO]:Upon air failure, the ball valve is opened. The ball valve closes when the signal pressure increases, acting against theforce of the springs.
Changing the fail-safe position
The fail-safe position of the actuator can be reversed if required,for this purpose see the installation and operating instructions forthe respective pneumatic actuator.
Operating elements and functions
The BR 20a ball valve can be selected in the following versions:− With a hand lever (DN 15 up to 100 or NPS1 up to 4).
− With a manual gear.
− With PFEIFFER rotary actuator BR 31a.
− With rotary actuators from other manufacturers (for details
see the respective data sheet).

EB 20a_EN
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PFEIFFER recommends installing a strainer in front of the ballvalve. A strainer prevents the solid content in the medium fromdamaging the ball valve.
Bypass and shut-off valve
PFEIFFER recommends installing a shut-off valve in front of thestrainer as well as behind the ball valve and to create a bypass.
By means of the bypass, the entire plant does not have to be decommissioned during maintenance and repair work on the ballvalve.
Insulation
The ball valves can be insulated to reduce the passage of heat
energy. If necessary, observe the notes in Chapter “5.4 Installingthe ball valve in the pipe”.
Test connection
In the version with a double stuffing box, detection is possible using the test connection (e.g. G¼“) between both packagings.
Grip protection
In the case of conditions of use that require a high level of safety(e. g. if the ball valve is freely accessible to untrained specialist
personnel), PFEIFFER offers a safety guard to prevent the risk ofcrushing due to moving parts (actuator- and control shaft).
The risk assessment of the plant by the operator will indicate if
the installation of this protective device is required for the safe
operation of the ball valve in the plant.

3-1

Design and principle of operation

3.3 Attachments
The following accessories are available for the ball valve either
individually or in combinations:Info
The position and arrangement of the individual parts shown inthe drawings must be observed during assembly.

− Locking device− Control shaft extension (100 mm standard)− Pneumatic or electric rotary actuator− Positioner (with the control ball valve option)

3.5.1− Limit switch− Solenoid valves− Filter - reducing station− Control ball valve with calibrated seat ring
Other additional equipment is possible according to specifications on request.

3.4 Technical data
The type plates of the ball valve and actuator offer information
about the valve version, see Chapter “2 Markings on the device”.
Info
Detailed information is available in the data sheet  TB 20a.

3.5.1.1

Assembly of the DIN ball valve, DN|15... 100
Assembly of the body halvesÖ Place both body halves (1a and 1b) with the flange facing
downward on an even and clean work surface, so that theinside of the ball valve is easy to reach.
Ö Insert the seat rings (3a and 3b) in the body halves (1a and
1b).
Info
The seat rings may not be installed without clearance. To achieve
the tightness of the ball valve, the seat rings must be installed intheir seat with sufficient clearance. If this is not possible, pleasecontact PFEIFFER.

Ö Place the ball (2) on the seat ring of a body half (1a or 1b).

3.5 Ball valve assembly
The BR 20a ball valves in the “DIN” version have design differences with respect to the “ANSI” version so that they cannot be
documented in one construction manual.
− The assembly of the DIN ball valve DN 15 100 is describedin chapter 3.5.1 in the “standard version” and with a “double stuffing box”.
− The assembly of the DIN ball valve DN 150 200 is describedin chapter 3.5.2.
− Chapter 3.5.3 describes the assembly of the ANSI ball valve.
Preparation of the assembly
To assemble the ball valve, all parts must be prepared, e. g. theparts are carefully cleaned and placed on a soft mat (rubber mator other).
Keep in mind that plastic parts are almost always very soft andvery delicate, and in particular the sealing surfaces may not bedamaged.
NOTE
Damage to the ball valve due to unsuitable lubricants!
Unsuitable lubricants can corrode and damage the surface. Theball valve material requires suitable lubricant. A suitable lubricant must be selected for grease-free ball valves, especially for
use with oxygen.
Ö For suitable lubricant, see Chapter “15.1.2 Lubricant”.

3-2

Ö Place the V-ring packing (7) with a slightly rotary movement
over the shaft of the ball. The number of packing rings canbe found on the drawing, see Fig. 3-1.
Ö Insert the ball shaft with the V-ring packing into the packing
space in the body.
Make sure that the ball (2) and V-ring packing (7) are clearly fitted in the body.
Ö Place the second body half onto the previously describedbody half, so that it centres itself on the ball shaft and the
V-ring packing as well as the seat ring.
Info
Make sure that the V-ring packing is not squashed at the side by
the body halves.

Ö Fasten the body halves together with screws (4), washers(28), disc springs (6) and nuts (5) so they are hand-tight. The
arrangement of the disc springs can be found on the drawing, see Fig. 3-1.
Info
− Depending on the nominal size, stud bolts with nuts or screws
can be used.
− The final screw connection of the body halves is performed during a subsequent assembly step.

EB 20a_EN
November 2023 edition
Subject to technical changes

Design and principle of operation

Fig.|3-1:

Sectional drawing of the ball valve in the DIN version, DN 15 ... 100

Table|3-1: Parts list of the ball valve in the DIN version, DN 15 ... 100
Item

Designation

Item

Designation1

Lined body18

O-ring2

Lined ball

19

Stuffing box lower section

3

Seat ring20

Distance bush4

Screw/ stud bolt

21

Disc spring set

5

Nut

22

Thrust ring

6

Disc spring

23

V-ring packing

7

V-ring packing

24

O-ring8

Thrust ring25

Stuffing box upper section

9

Disc spring set

26

Screw

10

Bearing bush27

Screw plug

11

Stuffing box flange

28

Washer12

Screw

EB 20a_EN
November 2023 edition
Subject to technical changes

3-3Design and principle of operation

The further assembly procedure depends on the respective version.
First the ball valve in a “standard version” will be described, andthen the ball valve with a “double stuffing box”.

3.5.1.2

Final assembly of the ball valve inthe “standard version”

Ö Press the thrust ring (8) over the ball stem into the corresponding position in the body.
Ö Place the disc spring set (9) over the ball stem onto the thrustring. The arrangement and quantity of the disc springs canbe found on the drawing, see Fig. 3-1.
Ö Insert the bearing bushing (10) into the stuffing box flange(11).
Ö Place the pre-assembled stuffing box flange on the body andadjust with screws (12).
Ö Tighten the screws evenly in a criss-cross pattern until a gap
between 1 - 2 mm has formed between the stuffing box
flange and the body.
Info
The final screw connection of the stuffing box is performed during a subsequent assembly step.

Ö Place the preassembled stuffing box lower section and above
the ball stem onto the provided recess in the assembled body
halves.
Ö Insert the thrust ring (8) into the stuffing box lower section sothat it lies on the V-ring packing (7).
Ö Insert the disc spring set (9), distance bushing (20) and thedisc spring set (21). The arrangement and quantity of the discsprings can be found on the drawing, see Fig. 3-1.
Ö Position the thrust ring (22).
Ö Prepare the stuffing box upper section (25) for assembly andpush in the bearing bushing (10) as well as the V-ring packing (23).
Ö Insert the o-ring (24) into the provided groove in the stuffing
box upper section.
Ö Place the preassembled stuffing box upper section onto theassembled stuffing box lower section (19).
Ö Insert the screws (26).
Info
To ensure that the stuffing box upper section can be tightenedwith screws, it must be preloaded for this assembly step.

Ö Push an assembly sleeve over the ball shaft up to the stuffing
box upper section.
Ö Screw a nut onto the ball shaft.

Ö Tighten the screws (4) on the body halves (1a and 1b).

Ö Screw a stuffing box upper section and lower section andscrews (26) into the threaded holes of the body (1).

Info
For the tightening sequence and tightening torques of the respective nominal sizes, see Figure 15.1 and Table 15.1 in Chapter“15.1.1 Tightening torques”.

Ö Tighten the screws (26) completely.
Info
The stuffing box upper section and lower section centre themselves and create a unit with the two body halves.

Ö After approx. 24 hours, retighten the screws (4) on the body
halves.
Info
For the tightening sequence and tightening torques of the respective nominal sizes, see Figure 15.1 and Table 15.1 in Chapter“15.1.1 Tightening torques”.

3.5.2

Ö To complete the assembly, tighten the screws (12) on the stuffing box (11).

Ö Drive the straight pin (29) into the body (1).

InfoMake sure to tighten the screws firmly.

3.5.1.3

Final assembly of the ball valve with“double stuffing box”

Assembly of the DIN ball valve,
DN|150 ... 200

Ö Place both body halves (1a and 1b) with the flange facing
downward on an even and clean work surface, so that theinside of the ball valve is easy to reach.
Ö Insert the seat rings (3a and 3b) in the body halves (1a and
1b).
Info
The seat rings may not be installed without clearance. To achieve
the tightness of the ball valve, the seat rings must be installed intheir seat with sufficient clearance. If this is not possible, pleasecontact the manufacturer.

Ö Insert the o-ring (18) into the stuffing box lower section (14).

3-4EB 20a_EN
November 2023 edition
Subject to technical changes

Design and principle of operation

Fig.|3-2:

Sectional drawing of the ball valve in the DIN version, DN 150 ... 200

Table|3-2: Parts list of the ball valve in the DIN version, DN 150 ... 200
Item

Designation

Item

Designation1

Lined body

11

Stuffing box flange2

Lined ball

12

Screw

3

Seat ring

14

Centring ring

4

Screw/ stud bolt

15

Bush

5

Nut

16

Disc spring

6

Disc spring

17

Bush

7

V-ring packing

28

Washer9Disc spring set

29

Straight pin

10Bearing bush

EB 20a_EN
November 2023 edition
Subject to technical changes

3-5Design and principle of operation

Ö Place the ball (2) on the seat ring of a body half (1a or 1b).
Ö Insert the control shaft into the shaft bore on the side of the
stuffing box.
Make sure that the ball and control shaft (2) are clearly fitted in
the body.
Ö Place the second body half onto the previously describedbody half, so that it centres itself on the ball stem and the seat
ring.
Info
Do not damage the PTFE-lined ball and control shaft during assembly.

Ö Fasten the body halves together with screws (4), washers(28), disc springs (6) and nuts (5) so they are hand-tight. The
arrangement of the disc springs can be found on the drawing, see Fig. 3-3.
Info
− Depending on the nominal size, stud bolts with nuts or screws
can be used.
− The final screw connection of the body halves is performed during a subsequent assembly step.

Ö Place the V-ring packing (7) in the bushing (15). The numberof packing rings can be found on the drawing, see Fig. 3-1.
Ö Push the bushing (17) carefully over the packing (7) and thebushing (15).
When this packing unit is preassembled, the bottom ring of thepacking (7) protrudes past the bushing (17).
Ö Push the preassembled packing unit with a slight rotation
movement over the ball shaft in the packing space of thebody.
Ö Place the disc springs (16) on the bushing (17). The locationand quantity of the disc springs can be found on the drawing, see Fig. 3-3.
Ö Place the centring ring (14) on the disc spring.
Ö Insert the disc spring set (9) in the centring ring until reaching
the bottom ring of the V-ring packing. The arrangement andquantity of the disc springs can be found on the drawing, seeFig. 3-3.
Ö Insert the bearing bushing (10) into the stuffing box flange(11).
Ö Place the pre-assembled stuffing box flange on the body andadjust with screws (12).
Ö Tighten the screws evenly in a criss-cross pattern until a gap
between 1 - 2 mm has formed between the stuffing box
flange and the body.
Info
The final screw connection of the stuffing box is performed during a subsequent assembly step

3-6

Ö Tighten the screws (4) on the body halves (1a and 1b).
Info
For the tightening sequence and tightening torques of the respective nominal sizes, see Figure 15.1 and Table 15.1 in Chapter“15.1.1. Tightening torques.

Ö After approx. 24 hours, retighten the screws (4) on the body
halves.
Info
For the tightening sequence and tightening torques of the respective nominal sizes, see Figure 15.1 and Table 15.1 in Chapter“15.1.1. Tightening torques.

Ö To complete the assembly, tighten the screws (12) on the stuffing box (11).
InfoMake sure to tighten the screws firmly.

3.5.3

Assembly of the ANSI ball valve

Ö Place both body halves (1a and 1b) with the flange facing
downward on an even and clean work surface, so that theinside of the ball valve is easy to reach.
Ö Drive the straight pin (29) in the case of NPS6 and NPS8 into
the body (1).
Ö Insert the seat rings (3a and 3b) in the body halves (1a and
1b).
Info
The seat rings may not be installed without clearance. To achieve
the tightness of the ball valve, the seal rings must be installed intheir seat with sufficient clearance. If this is not possible, pleasecontact the manufacturer.

Ö Place the ball (2) on the seat ring of a body half (1a or 1b).
Ö Insert the control shaft into the shaft bore on the side of the
stuffing box.
Make sure that the ball and control shaft (2) are clearly fitted in
the body.
Ö Place the second body half onto the previously describedbody half, so that it centres itself on the ball stem and the seat
ring.
Info
Do not damage the PTFE-lined ball and control shaft during assembly.

EB 20a_EN
November 2023 edition
Subject to technical changes

Design and principle of operation

Fig.|3-3:

Sectional drawing of the ball valve in the ANSI version

Table|3-3: Parts list of the ball valve in the ANSI version
Item

Designation

Item

Designation1

Lined body

11

Stuffing box flange2

Lined ball

12

Screw

3

Seat ring

14

Centring ring

4

Screw/ stud bolt

15

Bush

5

Nut

16

Disc spring

6

Disc spring

17

Bush

7

V-ring packing

28

Washer9Disc spring set

29

Straight pin

10Bearing bush

EB 20a_EN
November 2023 edition
Subject to technical changes

3-7Design and principle of operation

Ö Fasten the body halves together with screws (4), washers(28), disc springs (6) and nuts (5) so they are hand-tight. The
arrangement of the disc springs can be found on the drawing, see Fig. 3-3.
Info
− Depending on the nominal size, stud bolts with nuts or screws
can be used.
− The final screw connection of the body halves is performed during a subsequent assembly step.

Ö Place the V-ring packing (7) in the bushing (15). The numberof packing rings can be found on the drawing, see Fig. 3-3.

Ö After approx. 24 hours, retighten the screws (4) on the body
halves.
Info
For the tightening sequence and tightening torques of the respective nominal sizes, see Figure 15.1 and Table 15.1 in Chapter“15.1.1. Tightening torques.

Ö To complete the assembly, tighten the screws (12) on the stuffing box (11).
InfoMake sure to tighten the screws firmly.

Ö Push the bushing (17) carefully over the packing (7) and thePTFE bushing (15).
When this packing unit is preassembled, the bottom ring of thepacking (7) protrudes past the bushing (17).
Ö Push the preassembled packing unit with a slight rotation
movement over the ball stem in the packing space of thebody.
Ö Place the disc spring(s) (16) on the bushing (17). The locationand quantity of the spring washer(s) can be found on thedrawing, see Fig. 3-3.
Ö Place the centring ring (14) on the disc spring(s).
Ö Insert the disc spring set (9) in the centring ring until reaching
the bottom ring of the V-ring packing. The arrangement andquantity of the disc springs can be found on the drawing, seeFig. 3-3.
Ö Insert the bearing bushing (10) into the stuffing box flange(11).
Ö Place the pre-assembled stuffing box flange on the body andadjust with screws (12).
Ö Tighten the screws evenly in a criss-cross pattern until a gap
between 1 - 2 mm has formed between the stuffing box
flange and the body.
Info
The final screw connection of the stuffing box is performed during a subsequent assembly step

Ö Tighten the screws (4) on the body halves (1a and 1b).
Info
For the tightening sequence and tightening torques of the respective nominal sizes, see Figure 15.1 and Table 15.1 in Chapter“15.1.1. Tightening torques.

3-8

EB 20a_EN
November 2023 edition
Subject to technical changes

Shipment and on-site transport

4

Shipment and on-site transport

The work described in this chapter may only be performed by
specialist personnel qualified to perform the corresponding task.
NOTE
Damage to the ball valve due to improper transport andstorage!
Ö Handle, transport and store ball valves with lining with particular care.
Ö Use protective caps to protect the delicate sealing surfaces inparticular.

WARNING
Overturning of the lifting equipment and damage to the load
lifting equipment by exceeding the lifting capacity!
− Only used approved lifting equipment and load lifting equipment whose lifting capacity corresponds at least to the weightof the ball valve including the actuator.
− Take the weights from the respective data sheet.
Danger of injury due to the tipping of the ball valve!
− Observe the centre of gravity of the ball valve.
− Secure the ball valve against tipping and twisting.

NOTE

4.1 Accepting delivery
Perform the following steps after receiving the goods:
Ö Check the scope of supply. Compare the delivered goods
with the delivery note.
Ö Check the supply for transport damage. Report transport
damage to PFEIFFER and the transport company (see the delivery note).

4.2 Unpacking the ball valve

Damage to the ball valve due to improper fastening of thesling!
The screwed-in lifting eyes on actuators are used only for actuator assembling and disassembling as well as for lifting the actuator without the ball valve. These lifting eyes are not intended forlifting the complete ball valve.
− When lifting the ball valve, make sure that the entire load is
carried by the sling that is fastened to the ball valve body.
− Do not fasten the load-bearing sling to the actuator, handwheel or other components.
− Do not use the control air lines, accessories or other components with safety functions for suspension or damage them.

Carry out the following steps:
Ö Unpack the ball valve directly before lifting for installation into the pipe.
Info
The packaging protects the scratch-sensitive plastic lining of theball valve against damage.

Ö Leave the ball valve on the pallet or in the transport container
for on-site transport.
Ö The protective caps on the ball valve inlet and outlet prevent
foreign matter from entering the ball valve and damaging it.
Furthermore, they are used to protect the sealing surfaces.
Only remove the protective caps prior to installation in thepipe.
Ö Dispose of the packaging properly.

4.3.1

Transporting

The ball valve can be transported using lifting equipment such asa crane or a forklift.
Ö Leave the ball valve on the pallet or in the transport container
for transport.
Ö Ball valves that weigh more than approx. 10 kg should betransported on a pallet (or supported similarly) (also to theinstallation site). The packaging protects the scratch-sensitive
lining of the ball valve against damage.
Ö Comply with the transport conditions.
Transport conditions
Ö Protect the ball valve against external influences, such as impacts.
Ö Do not damage the corrosion protection (paint, surface coating). Repair damage immediately.

4.3 Transporting and lifting the ball valve

Ö Protect the ball valve against moisture and dirt.

DANGER
Danger due to falling of suspended loads!
Do not stand under suspended loads.

EB 20a_EN
November 2023 edition
Subject to technical changes

4.3.2

Lifting

When installing the ball valve in the pipe, larger ball valves canbe lifted using lifting equipment such as a crane or forklift.

4-1

Shipment and on-site transport

Figure|4-1: Lifting points on the ball valve

Conditions for liftingÖ Use a hook with a safety clamp as the suspension element sothat the sling cannot slip off the hook during lifting and transport, see Figure 4-1.
Ö Secure the sling against shifting and slipping off.
Ö Fasten the sling such that it can be removed again after installation in the pipe.

4.3.3

Lifting points on the bodyÖ Fasten a lifting sling to each flange of the housing and on thesuspension element (e.g. hook) of the crane or forklift, see
Figure 4-1. When doing so, ensure the safety, bearing capacity and length of the lifting slings

Ö Avoid swinging and tipping the ball valve.

Ö In the case of an actuator with a lifting eye: fasten additional
lifting slings to the lifting eye on the actuator and on the suspension element.

Ö In the case of interruptions in work, do not leave the lifting
equipment suspended in the air for a long period of time.

Ö Lift the ball valve carefully. Check if the load lifting equipment
holds.

Ö Lift the ball valve aligned in the same direction in which it will
be installed in the pipe.

Ö Move the ball valve at a constant speed to the installationsite.

Ö Always lift the ball valve in the centre of gravity of the load toprevent uncontrolled tipping.

Ö Install the ball valve in the pipe, see chapter 5.4.

Ö Make sure that any slings between the lifting eyes on the rotary actuator and suspension element are not loaded. Theseslings are used only to secure the load against turning overwhile lifting. Before lifting the ball valve, pretension this sling
so it is taut.
WARNING
Danger due to incorrect lifting and transport!
The lifting points for the lifting slings shown in the schematic
drawing serve as examples for most valve variants. On site theconditions for lifting and transporting the valve can change however.
Ö The operator makes sure that the valve is lifted and transported safely.

4-2

Ö After installation in the pipe: check that the flanges are firmly
tightened and that the ball valve holds in the pipe.
Ö Remove the lifting slings.

4.3.4

Lifting points on the bracket

Ö Fasten a lifting sling to the bracket and the suspension element (e.g. hook) of the crane or forklift, see Figure 4-1.
When doing so, ensure the safety, bearing capacity andlength of the lifting slings.
Ö In the case of an actuator with a lifting eye: fasten additional
lifting slings to the lifting eye on the actuator and on the suspension element.
Ö Lift the ball valve carefully. Check if the load lifting equipment
holds.

EB 20a_EN
November 2023 edition
Subject to technical changes

Shipment and on-site transport

Ö Move the ball valve at a constant speed to the installationsite.
Ö Install the ball valve in the pipe, see chapter 5.4
Ö After installation in the pipe: check that the flanges are firmly
tightened and that the ball valve holds in the pipe.
Ö Remove the lifting slings.

4.4 Storing the ball valve
NOTE
Damage to the ball valve due to improper storage!
− Comply with the storage conditions.
− Avoid long storage periods.
− In the case of deviating storage conditions and a longer storage period, contact PFEIFFER.

Info
PFEIFFER recommends checking the ball valve and the storage
conditions regularly during a longer storage period.

Ö In the case of storage prior to installation, the ball valve
should normally be stored in a closed room where it is protected against harmful influences such as impacts, dirt ormoisture. A room temperature of 25°C ±15°C is recommended.
Ö In particular, the actuator and the plastic lined sealing surfaces of the flange ends for the pipe connection may not bedamaged by mechanical or any other influences.
Ö Do not stack the ball valves.
Ö Prevent condensation in damp rooms. Use a desiccant orheater.
Ö The ball valve must be stored in its protective packaging
and/or with the protective caps on the connection ends.
Ö Ball valves that weigh more than approx. 10 kg should be
stored on a pallet (or supported similarly).
Ö Ball valves are usually delivered in a completely open position. They must be stored in the position in which they weredelivered. The actuating device must not be actuated.
Ö Do not place any objects on the ball valve.

EB 20a_EN
November 2023 edition
Subject to technical changes

4-3Shipment and on-site transport

4-4

EB 20a_EN
November 2023 edition
Subject to technical changes

Installation

5

Installation

The work described in this chapter may only be performed by
specialist personnel qualified to perform the corresponding task.
The following instructions apply additionally for ball valves. Observe chapter “4.3 Transporting and lifting the ball valve” fortransport to the installation site.

5.1 Installation conditions
Operator level
The operator level for the ball valve is the front view on all operating elements of the ball valve including the attachments fromthe perspective of operating personnel.
The plant operator must make sure that operating personnel can
carry out all work after the device is installed safely and can access it easily from the operator level.
Pipe routing
The guidelines applicable on site apply for the installation of ballvalves in the pipe.
Install the ball valve such that there is low vibration and no mechanical stress. Observe the sections “Installation orientation”
and “Support and mounting” in this chapter.
Install the ball valve so there is enough space to replace the actuator and ball valve as well as to perform maintenance work.
Do not position the lined ball valves with the slid-on heat packdirectly in front of the pipe elbow.
Installation position
The ball valve can be installed in any installation position.
PFEIFFER recommends however to install the ball valve in general
so that the actuator points up in a vertical position.
In the following versions, the ball valve with actuator must be installed facing upwards or a corresponding support must be provided:− Nominal sizes ≥ DN 100 / NPS4
− Ball valve with a stem extension or insulating part.
Ö In the case of deviations from this installation position, contact PFEIFFER.
Support and mounting
The plant manufacturer is responsible for the selection and implementation of a suitable support or mounting for the installed ballvalve as well as the pipe.
Venting
Vents are screwed into the exhaust air connections of pneumaticand electropneumatic devices to ensure that the generated exhaust air can be released to the outside (protection against overpressure in the device). Furthermore, vents allow the intake of air(protection against underpressure in the device).

EB 20a_EN
November 2023 edition
Subject to technical changes

Ö Carry out venting on the side that faces away from the operator level.
Ö When connecting the attachments, make sure that they canbe accessed from the operator level safely and easily.

5.2 Preparing for assemblyBall valves with lining must be handled, transported and storedwith particular care, see Chapter “4 Delivery and on-site transport”.
Perform the following steps after receiving the goods:
Ö Check the scope of supply. Compare the delivered goods
with the delivery note.
Ö Check the supply for transport damage. Report transport
damage to PFEIFFER and the transport company (see the delivery note).
Ensure the following conditions prior to assembly:− The ball valve is clean.
− The ball valve data on the type plate (type, nominal size, material, nominal pressure and temperature range) matches theplant conditions (nominal size and nominal pressure of thepipe, medium temperature, etc.). For details about the marking, see Chapter “2 Markings on the device”.
− Desired or required additional fittings, see Chapter “3.2 Additional fittings”, are installed or prepared as far as necessary
before the assembly of the ball valve.

5.3 Assembling the ball valve and actuator
Ball valves are supplied in working order. In individual cases, theactuator and ball valve are delivered separately and must be assembled. The tasks are listed below that are necessary for assembly and prior to the commissioning of the ball valve.
WARNING
Danger and damage due to retrofitting an actuator unit!
The subsequent fitting of an actuator unit can pose a danger tothe user and cause damage to the pipe system.
Ö Adapt the torque, rotation direction, actuation angle and adjustment of the “OPEN” and “CLOSED” end stops to the ballvalve.
Danger and damage due to use of an electrical actuator!
Ö Make sure that the actuator in the end positions is turned off
by the limit switch signal.
Ö If shut-off takes place in an intermediate position due to thesignal of the torque switch, use this signal in addition for anerror message. The fault must be remedied as soon as possible, see Chapter “8 Faults”.
Ö For further instructions, see the electrical actuator manual.

5-1

Installation

WARNING
Danger and damage due to high external loads on an actuator
unit!
Actuators and gears are not “stepladders”.
Ö Do not apply loads to the actuator units from the outside. Thiscan damage or destroy the ball valve.
Danger and damage due to heavy actuator units!
Actuators and gears that are heavier than the weight of the ballvalve can pose a danger to the user and cause damage to thepipe system.
Ö Support these actuators and gears if they generate a bending
stress on the ball valve due to their size and/or installation
situation.

NOTE
Damage to the ball valve due to the incorrect setting of the end
stops!
The actuating device is adjusted to the operating data specified
in the order.
Ö The adjustment of the “OPEN” and “CLOSED” end stops isthe responsibility of the user.

5.4 Installing the ball valve in the pipe

DANGER
Danger due to exceeding the limits of use!
Exceeding the limits of use can pose a danger to the user andcause damage to the pipe system.
Ö No ball valve may be installed whose permissible pressure/temperature range is not sufficient for the max. permissible
operating conditions.
Ö The limits of use are marked on the ball valve, see Chapter “2Markings on the device”.
Ö The permissible range is defined in Chapter “1 Safety instructions and safety measures”.

Ö The connection ends of the pipe must align with the ball valve
connections and have plane-parallel ends. Connection flanges that are not plane parallel can damage the PTFE lining
during installation.
Ö The connection data for the actuator unit match the data of
the control, see the type plate(s) on the actuator unit.
Ö Prior to installation, clean the ball valve and the connectedpipe of any contamination, in particular solid foreign matter.
Ö The sealing surfaces on the flange connection and any utilized flange seals are free of all contamination during installation.
Ö Optionally, an arrow is marked on the body. The direction of
the arrow must correspond to the direction of flow in thepipe.

Ö Transport the ball valve in its original packaging to the installation site and unpack it only there.

Ö When pushing in the ball valve and any used flange seals into an already assembled pipe, the distance between the pipe
ends is measured such that all contact surfaces of the ballvalve and seals remain undamaged.

Ö Inspect the ball valve and actuator for transport damage. Do
not install damaged ball valves or actuators.

Ö The flange connections are tightened evenly and in a crisscross pattern in at least three steps.

5.4.1

GeneralÖ A functional test is to be carried out at the beginning of installation for manually-operated ball valves: The ball valve
must close and open correctly. Detected malfunctions must be
fixed before commissioning, see Chapter “8 Faults”.
Ö Handle the ball valve with care and observe the instructions
for the flange connection.
Ö Only install ball valves whose pressure classes, connection
type (flow rate), type of lining and connection dimensions
match the conditions of use, see the corresponding marking
on the ball valve.
Ö The counterflanges must have smooth sealing surfaces. Other
flange shapes must be agreed upon with Pfeiffer.
Ö The ball valve can be used in both directions if a direction arrow is not applied.

Info
All flange connections are tightened using a torque wrench andensures that the required tightening torques are reached, but notexceeded see Table 15-2 or Table 15-3 in Chapter “15.1.1 Tightening torques”.

Ö The PTFE plastic sealing surfaces tend to flow, observe theyellow notice sign on the ball valve, see Chapter “1.4 Warning notes on the device”. After installation in the pipe, retighten the body screws according to the respective tightening torques, see Table 15-1 in Chapter “15.1.1 Tightening torques”.
Ö Vents are screwed into the exhaust air connections of pneumatic and electropneumatic devices to ensure that the generated exhaust air can be released to the outside (protection
against overpressure in the device).
Furthermore, vents allow the intake of air (protection against
underpressure in the device).
Ö Carry out venting on the side that faces away from the working area of operating personnel.

5-2

EB 20a_EN
November 2023 edition
Subject to technical changes

Installation

Ö When installing peripheral devices, make sure that they canbe operated from the working area of operating personnel.

5.4.2

Installing the ball valve

Info
The ball valve is lined with PTFE.
Ö Handle the ball valve with particular care and observe the instructions for the flange connection.
Protect the lined ball valve surfaces in particular prior to/during
installation.
Ö Transport the ball valve in its original packaging to the installation site and unpack it only there.

5.4.3

Installation instructions for lined gateball valves with heat pack

Info
When installing the lined ball valves with heat packs in the pipe,a corresponding straight outlet pipe section must be included.
Ö If the bolted joint of the body must be retightened, this outlet
section allows the heat pack to be moved away from the ballvalve.
Ö As a result, the heat line does not need to be shut off. We
recommend flexible connections for connecting the heating
jacket to the heat line.

Ö Lift the ball valve with suitable lifting equipment at the installation site, see chapter “4.3 Transporting and lifting the ballvalve”.
Ö Close the ball valve in the pipe for the duration of the installation.
Ö Remove the protective caps on the ball valve openings prior
to installation.
Ö Observe the flow direction of the ball valve. An optional arrow on the ball valve shows the flow direction, otherwise it
can be used in both directions.

Figure|5-1: Outlet section

Ö Clean the sealing surfaces on the ball valve and pipe.
Ö Use correct flange seals.

The values in the following table are intended as a guide to dimension the outlet section (L).

Info
The sealing surfaces on the ball valve body are lined with plastic.
Ö Flange seals made of PTFE are recommended.
Ö Counterflanges have smooth sealing surfaces. Other flange
shapes must be agreed upon with PFEIFFER.

Table|5-1: Outlet section

NOTE
Deformation of the pipes damages the ball valve!
Ö Prevent or fix the deformation of the pipes.

Ö Screw the pipe together with the ball valve without tension.
Ö After installing the ball valve, open it slowly in the pipe.
NOTE
Damage to the ball valve due to a sudden pressure increase
and resulting high flow speed!
Open the ball valve slowly in the pipe during commissioning.

Ö Check the correct function of the ball valve.

EB 20a_EN
November 2023 edition
Subject to technical changes

DN

15

25

40

50

80

100

L

195

240

300

345

465

525

5.5 Checking the assembled ball valve
5.5.1

Functional test

WARNING
Danger of injury due to pressurised components and escaping
medium!
Ö Do not loosen the screw of an optional test connection while
the ball valve is pressurised.
Danger of injury due to escaping exhaust air!
During operation, when regulating or when opening and closing
the ball valve, exhaust air can escape, for example from the actuator.
− Wear eye protection and, if necessary, hearing protection
when working near valves.

5-3

Installation

WARNING
Danger of crushing due to moving actuator- and control shaft!
Ö Do not reach into the bracket as long as the pneumatic power is connected to the actuator.
Ö Before working on the ball valve, interrupt and lock pneumatic energy and the control signal.
Ö Vent the actuator.
Ö Do not allow the jamming of objects in the bracket to hinder
the operation of the actuator- and control shaft.
Ö If the actuator- and control shaft are blocked (e.g. due to“seizure” if not actuated for a long period of time”), release
the residual energy of the actuator (spring tension) before releasing the blockage, see the corresponding actuator documentation.
Ö Prior to disassembly of the actuator, bring the ball valve into
the fail-safe position.

5.5.3

Swivelling movement

The rotary movement of the actuator- and control shaft must be
linear without any jerky movements.
Ö Open and close the ball valve. When doing so, observe themovement of the actuator shaft.
Ö Set the maximum and minimum control signal in succession
to check the end positions of the ball valve.
Ö Check the display on the position indicator.

5.5.4

Fail-safe position

Ö Close the signal pressure line.
Ö Check whether the ball valve moves to the fail-safe position,
see “Fail-safe positions in Chapter “3 Design and principle ofoperation”.

Ö At the end of installation, perform a functional test with thecontrol signals:
The ball valve must close and open correctly according to thecontrol commands. Detected malfunctions must be fixed before commissioning, see Chapter “8 Faults”.
WARNING
Danger due to improperly executed control commands!
Incorrectly executed control commands can cause serious injuries
or even death and cause damage to the pipe system.
Ö Check the actuator unit and control command., see chapter“8 Faults”.

5.5.2

Pressure test of the pipe section

The pressure test was already performed on the ball valves by
PFEIFFER. Observe the following for the pressure test of a pipe
section with installed ball valves:Ö First carefully rinse newly installed pipe systems in order towash out all foreign matter.
Ö Ensure the following conditions for the pressure test:–

Ball valve open: The test pressure may not exceed the value 1.5 x PN (according to the type plate).

–

Ball valve closed: The test pressure may not exceed thevalue 1.1 x PN (according to the type plate).

If a ball valve leaks, observe chapter “8 Faults”.
Info
The plant operator is responsible for performing the pressure test.
After Sales Service at PFEIFFER can provide you with support forthe planning and implementation of a pressure test specific toyour plant.

5-4

EB 20a_EN
November 2023 edition
Subject to technical changes

Start-up

6

Start up

The work described in this chapter may only be performed by
specialist personnel qualified to perform the corresponding task.
WARNING

Commissioning/recommissioningÖ The PTFE plastic sealing surfaces tend to flow. After commissioning and reaching the operating temperature, tighten all
flange connections between the pipe and ball valve with thecorresponding tightening torques, see Table 15-2 and Table
15-3 in Chapter “15.1.1 Tightening torque”.

Danger of burning due to hot or cold components and pipe!
Ball valve components and pipes can become very hot or very
cold during operation and cause burns upon contact.
Ö Let the components and pipes cool down or warm up.
Ö Wear protective garments and protective gloves.

Ö Retighten the screws of the body joint, see Table 15-1 in
Chapter “15.1.1 Tightening torques”.

Danger of injury due to pressurised components and escaping
medium!
Ö Do not loosen the screw of the optional test connection while
the ball valve is pressurised.

Ö Check the correct function of the ball valve.

Ö Open the ball valves slowly in the pipe. Opening slowly prevents a sudden increase in pressure and a resulting high flow
speed that damages the ball valve.

Danger of crushing due to moving actuator- and control shaft!
Ö Do not reach into the bracket as long as the pneumatic power is connected to the actuator.
Ö Before working on the ball valve, interrupt and lock pneumatic energy and the control signal.
Ö Vent the actuator.
Ö Do not allow the jamming of objects in the bracket to hinder
the operation of the actuator- and control shaft.
Ö If the actuator- and control shaft are blocked (e.g. due to“seizure” if not actuated for a long period of time”), release
the residual energy of the actuator (spring tension) before releasing the blockage, see the corresponding actuator documentation.
Ö Prior to disassembly of the actuator, bring the ball valve into
the fail-safe position.
Danger of injury due to escaping exhaust air!
During operation, when regulating or when opening and closing
the ball valve, exhaust air can escape, for example from the actuator.
Ö Wear eye protection and, if necessary, hearing protection
when working near valves

Ensure the following conditions prior to commissioning/recommissioning:− The ball valve is installed properly in the pipe, see Chapter“5 Assembly”.
− The leak and function tests have been completed successfully,
see Chapter “5.1 Installation conditions”.
− The current conditions in the concerned plant section correspond to the design of the ball valve, see Intended use in
Chapter “1 Safety instructions and safety measures”.

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November 2023 edition
Subject to technical changes

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Start-up

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EB 20a_EN
November 2023 edition
Subject to technical changes

Operation

7

Operation

As soon as the commissioning/recommissioning work is complete, see Chapter “6 Commissioning”, the ball valve is ready for
operation.
WARNING
Danger of burning due to hot or cold components and pipe!
Ball valve components and pipes can become very hot or very
cold during operation and cause burns upon contact.
Ö Let the components and pipes cool down or warm up.
Ö Wear protective garments and protective gloves.
Danger of injury due to pressurised components and escaping
medium!
Ö Do not loosen the screw of the optional test connection while
the ball valve is pressurised.
Danger of crushing due to moving actuator- and control shafts!
Ö Do not reach into the bracket as long as the pneumatic power is connected to the actuator.
Ö Before working on the ball valve, interrupt and lock pneumatic energy and the control signal.
Ö Vent the actuator.
Ö Do not allow the jamming of objects in the bracket to hinder
the operation of the actuator- and control shaft.
Ö If the actuator- and control shaft are blocked (e.g. due to“seizure” if not actuated for a long period of time”), release
the residual energy of the actuator (spring tension) before releasing the blockage, see the corresponding actuator documentation.
Ö Prior to disassembly of the actuator, bring the ball valve into
the fail-safe position.

Ö Ball valves that were delivered from the factory with an actuator are precisely adjusted. The user is responsible for any
changes they make.
− For the manual operation or manual override of the actuator(if present), normal manual forces are sufficient and the useof extensions to increase the actuation torque is not permitted.
− In the case of ball valves with a hand lever, the position of thehand lever indicates the location of the bore in the ball. The
hand lever moves in general parallel to the bore. Special versions are to be taken from the respective order.
–

Hand lever 90° transverse to the pipe: Ball valve closed.

–

Hand lever parallel to the pipe: Ball valve open.

Figure|7-1: Hand lever

DANGER
Danger of injury due to jerky operation of the ball valve!
The failure to observe these warnings can cause extreme danger
for persons or for the pipe system.
Ö Do not open and close the ball valve suddenly to prevent
pressure surges and/or a temperature shock in the pipe system.
− If a ball valve leaks, observe chapter “8 Faults”.

Danger of injury due to escaping exhaust air!
During operation, when regulating or when opening and closing
the ball valve, exhaust air can escape, for example from the actuator.
Ö Wear eye protection and, if necessary, hearing protection
when working near valves.

Observe the following points during operation:Ö The PTFE plastic sealing surfaces tend to flow. After commissioning and reaching the operating temperature, tighten the
body screws with the corresponding tightening torques, see
Table 15-1 in Chapter “15.1.1 Tightening torques”.
Ö Tighten all flange connections between the pipe and ballvalve, if necessary, with the corresponding tightening torques
according to Table 15-2 or Table 15-3 in Chapter “15.1.1
Tightening torques”.
Ö The ball valve/actuator unit must be actuated with the control
signals.

EB 20a_EN
November 2023 edition
Subject to technical changes

7-1Operation

7-2

EB 20a_EN
November 2023 edition
Subject to technical changes

Malfunction

8

Malfunction

When rectifying the faults, chapter “1 Safety instructions and safety measures” must be observed.

8.1 Detecting and rectifying errors
Type of fault

Possible cause

MeasuresLeaks in the pipe connection

The flange connection of thelined ball valve is leaky

Tighten the flange screws.
NOTE
An excessive tightening torque when retightening the flange screws
can damage the valve and pipe!
The permissible torque for retightening the pipe flange screws is
limited.
Retighten the flange connection with the respective tightening torque,see Table 15-2 or Table 15-3 in Chapter “15.1.1 Tightening torques”.
If necessary, increase the tightening torque to max. 20%.

The flange connection is still
leaky after retightening

Loosen the flange connection and remove the ball valve, see chapter“1 Safety instructions and safety measures“.
Check the plane parallelism of the flange connection and correct if it is
not sufficient.
Check the surfaces on all flanges. If the plastic lining is damaged,
replace the ball valve together with its flange seals, if available.
Check the flange seals. If the seals are damaged, replace them.

Leaks in the body parts

Increased medium flow ratewith the ball valve closed

The body section connectionloosened.

Retighten the body halves with the respective tightening torque, see
Table 15-1 in Chapter “15.1.1 Tightening torques”.

Body parts untight after
retightening

Replace the body sealing and/or valve, see chapter “1 Safety
instructions and safety measures“.

Leakage in the closed position Remove and inspect the ball valve, see chapter “1 Safety instructions
and safety measures”.
The ball valve is damaged

Repairs are necessary.
Remove the ball valve, see chapter “1 Safety instructions and safetymeasures”.
Request spare parts from PFEIFFER, see Chapter “15.2 Spare parts”.
For the required repair instructions, see Chapter “12 Repairs”.

Leaks in the control shaft
sealingMedium escapes

DANGER
Danger of injury due to escaping medium!
To protect operating personnel from danger, depressurise the line on
both sides of the ball valve, see Chapter “1 Safety instructions andsafety measures”.

Medium escapes from the
stuffing box

Remove the ball valve, see chapter “1 Safety instructions and safetymeasures”.
Disassemble the ball valve and replace the control shaft sealing.
Request spare parts from PFEIFFER, see Chapter “15.2 Spare parts”.
For the required repair instructions, see Chapter “12 Repairs”.

EB 20a_EN
November 2023 edition
Subject to technical changes

8-1Malfunction

Type of fault

Possible cause

MeasuresMalfunction

The actuator unit or control
does not react

Check the actuator unit and control command.

The actuator and control are
OK

Remove and inspect the valve, see chapter “1 Safety instructions andsafety measures”.
Remove the actuator unit and measure and check the ball valve
torque.

The ball valve is damaged

Repairs are necessary.
Remove the ball valve, see chapter “1 Safety instructions and safetymeasures”.
Request spare parts from PFEIFFER, see Chapter “15.2 Spare parts”.
For the required repair instructions, see Chapter “12 Repairs”.

Problems in the actuator unit

The pneumatic actuator must
be removed

Disconnect the connection to the control pressure.
Remove the actuator from the ball valve, observe the “Safety
instructions and safety measures”, see the included actuator unit
manuals.

Info− In the case of faults that are not listed in the table, contact theAfter Sales Service at PFEIFFER.
− Spare parts must be ordered indicating all the data according
to the valve marking. Only original parts from PFEIFFER Chemie-Armaturenbau GmbH may be installed.
− If it is determined after removal that the PTFE lining is not sufficiently resistant for the medium, parts must be selected made ofa suitable material.

8.2 Carrying out emergency measures
In the case of a power supply failure, the ball valve automaticallyswitches to the preset fail-safe position, see “Fail-safe positions”
in Chapter “3 Design and principle of operation”.
The system operator is responsible for emergency measures.
In case of a ball valve fault:− Close the shut-off valves upstream and downstream of theball valve so that no medium flows through the ball valve.
− Troubleshoot the error, see chapter “8.1 Detecting and rectifying errors”.
− Rectify the fault that can be fixed as indicated in the instructions provided in this installation and operating manual. For
faults that cannot be fixed, contact the After Sales Service at
PFEIFFER.
Recommissioning after faults
See Chapter “6 Commissioning”.

8-2

EB 20a_EN
November 2023 edition
Subject to technical changes

Servicing

9Servicing

The work described in this chapter may only be performed by
specialist personnel qualified to perform the corresponding task.
The following documents are required in addition for the maintenance of the ball valve:− Installation and operating manual for the installed actuator,e.g  EB 31a for BR 31a rotary actuators or the corresponding actuator documentation of other manufacturers.
WARNING
Danger of burning due to hot or cold components and pipe!
Ball valve components and pipes can become very hot or very
cold during operation and cause burns upon contact.
Ö Let the components and pipes cool down or warm up.
Ö Wear protective garments and protective gloves.
Danger of injury due to pressurised components and escaping
medium!
Ö Do not loosen the screw of the optional test connection while
the ball valve is pressurised.
Danger of crushing due to moving actuator- and control shaft!
Ö Do not reach into the bracket as long as the pneumatic power is connected to the actuator.
Ö Before working on the ball valve, interrupt and lock pneumatic energy and the control signal.
Ö Vent the actuator.
Ö Do not allow the jamming of objects in the bracket to hinder
the operation of the actuator- and control shaft.
Ö If the actuator- and control shaft are blocked (e.g. due to“seizure” if not actuated for a long period of time”), release
the residual energy of the actuator (spring tension) before releasing the blockage, see the corresponding actuator documentation.
Ö Prior to disassembly of the actuator, bring the ball valve into
the fail-safe position.
Danger of injury due to escaping exhaust air!
During operation, when regulating or when opening and closing
the ball valve, exhaust air can escape, for example from the actuator.
Ö Wear eye protection and, if necessary, hearing protection
when working near valves
Danger of injury due to preloaded springs!
Actuators with preloaded actuator springs are pressurised.
Ö Release the compression from the preloaded springs before
working on the actuator, see the corresponding actuator documentation.
Danger of injury due to residual medium in the ball valve!
When working on the ball valve, residual medium can escapeand, depending on the medium properties, cause injuries (e.g.
scalding, chemical burns).
Ö Wear protective garments, protective gloves and eye protection.
Ö Do not loosen the screw of the optional test connection while
the ball valve is pressurised.
Ö Bring the ball valve into the open position so the pressure isreleased from the ball.
EB 20a_EN
November 2023 edition
Subject to technical changes

NOTE
Damage to the ball valve due to excessively high or low tightening torques!
The ball valve components must be tightened with specific torques. Excessively tightened components are subject to increased
wear and can damage the plastic lining. Insufficiently tightenedcomponents can cause leakage.
Ö Observe the tightening torques, see Table 15-1 in Chapter“15.1.1 Tightening torques”.
Damage to the ball valve due to unsuitable tools!
Ö Only use tools approved by PFEIFFER, see Chapter “15.1.3
Tools”.
Damage to the ball valve due to unsuitable lubricants!
Ö Only use lubricants approved by PFEIFFER, see Chapter“15.1.2 Lubricants”.

Info
The ball valve was checked by PFEIFFER prior to delivery.
− Certain test results certified by PFEIFFER are no longer valid
when disassembling the ball valve. This includes the test forseat leakage and the leak test (outer tightness).
− If maintenance and repair work is performed without approval
from the After Sales Service of PFEIFFER, the product guarantee
will be voided.
− Only use original parts from PFEIFFER as spare parts that correspond to the original specification.
− Wear parts are not covered by the warranty.

9.1 Periodic tests
Ö Depending on the conditions of use, the ball valve must be
checked at defined intervals in order to take remedial measures prior to possible malfunctions. The plant operator is responsible for preparing a suitable test plan.
Ö PFEIFFER recommends the following inspections that can be
carried out during operation:
Test

Measures in the case of a negative
test result

If present, check the optional
test connection for tightness.
WARNING! Danger of injury
due to pressurised components
and escaping medium! Do notloosen the screw of the test connection while the ball valve ispressurised.

Decommission the ball valve, seechapter “10 Decommissioning”.
Contact the After Sales Service at
PFEIFFER for repairs, See chapter “12Repairs“.

Check the control shaft sealing
for tightness from the outside.

The control shaft sealing with a PTFE
V-ring packing is preloaded with adisc spring set and is therefore maintenance free.

9-1

Servicing

Test

Measures in the case of a negative
test result

Check the rotary movement of
the actuator- and control shaft
for smooth movement.

If the actuator- and control shaft areblocked, remove the blockage.
WARNING! If the actuator- and control shaft are blocked (e.g. due to“seizure” if not actuated for a long
period of time) they can release unexpectedly and move uncontrolled.
This can lead to crushing if reaching
into them.
Before trying to release a blockage ofthe actuator- and control shaft, interrupt and lock the pneumatic energy
and the control signal. Release theresidual energy of the actuator(spring tension or compressed air
reservoir) before releasing the blockage, see the corresponding actuator
documentation.

If possible, check the fail-safe
position of the ball valve bybriefly interrupting the power
supply.

Decommission the ball valve, seechapter “10 Decommissioning”. Then
determine the cause and remedy it,
see Chapter “8 Malfunctions“.

Check pipe connections andseals of the ball valve and actuator for leaks.

Regular maintenance work on theball valve is not necessary, but whenchecking the pipe section, no medium may escape from the flange andscrew connections of the body orfrom the control shaft sealing.

9.2 Maintenance workÖ The ball valve must be prepared before all maintenancework, see Chapter 12 “Repairs”.
Ö After all maintenance work, the ball valve must be checkedprior to recommissioning, see Chapter “12 Repairs“.

9.2.1

Replacing the seal rings and ball

Ö Check the condition of the ball and seal rings.
Ö Remove the seal rings (3) as described in Chapter “12.2 Replacing the seal rings and ball”. Check the seal rings as well
as all plastic parts for damage and if in doubt replace them.
Ö Also remove the ball (2). Check the ball as well as all plastic
parts for damage and if in doubt replace them.

9.3 Ordering spare parts and consumables
Information about spare parts, lubricants and tools can be received from the After Sales Service at PFEIFFER.
Spare parts
Information on spare parts can be found in Chapter “15.2 Spareparts“.

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EB 20a_EN
November 2023 edition
Subject to technical changes

Decommissioning

10 Decommissioning
The work described in this chapter may only be performed by
specialist personnel qualified to perform the corresponding task.
WARNING
Danger of burning due to hot or cold components and pipe!
Ball valve components and pipes can become very hot or very
cold during operation and cause burns upon contact.
Ö Let the components and pipes cool down or warm up.
Ö Wear protective garments and protective gloves.

Observe the following points during decommissioning:
To decommission the ball valve for maintenance and repair workor for disassembly, perform the following steps:
Ö Close the valves upstream and downstream of the ball valve
so that no medium flows through the ball valve.
Ö Empty the pipe and ball valve completely.
Ö Shut off the pneumatic power and lock it, to depressurise theactuator.
Ö Let the pipe and ball valve components cool down or warmup.

Danger of injury due to pressurised components and escaping
medium!
Ö Do not loosen the screw of the optional test connection while
the ball valve is pressurised.
Danger of crushing due to moving actuator- and control shaft!
Ö Do not reach into the bracket as long as the pneumatic power is connected to the actuator.
Ö Before working on the ball valve, interrupt and lock pneumatic energy and the control signal.
Ö Vent the actuator.
Ö Do not allow the jamming of objects in the bracket to hinder
the operation of the actuator- and control shaft.
Ö If the actuator- and control shaft are blocked (e.g. due to“seizure” if not actuated for a long period of time”), release
the residual energy of the actuator (spring tension) before releasing the blockage, see the corresponding actuator documentation.
Ö Prior to disassembly of the actuator, bring the ball valve into
the fail-safe position.
Danger of injury due to escaping exhaust air!
During operation, when regulating or when opening and closing
the ball valve, exhaust air can escape, for example from the actuator.
Ö Wear eye protection and, if necessary, hearing protection
when working near valves.
Danger of injury due to residual medium in the ball valve!
When working on the ball valve, residual medium can escapeand, depending on the medium properties, cause injuries (e.g.
scalding, chemical burns).
Ö Wear protective garments, protective gloves and eye protection.
Ö Do not loosen the screw of the optional test connection while
the ball valve is pressurised.
Ö Bring the ball valve into the open position so the pressure isreleased from the ball.

EB 20a_EN
November 2023 edition
Subject to technical changes

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November 2023 edition
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Removal

11 Removal

11.1 Removing the ball valve from the pipe

The work described in this chapter may only be performed by
specialist personnel qualified to perform the corresponding task.

Ö Loosen the flange connection.
Ö Remove the ball valve from the pipe, see Chapter “4.3 Transporting and lifting the ball valve”.

WARNING
Danger of burning due to hot or cold components and pipe!
Ball valve components and pipes can become very hot or very
cold during operation and cause burns upon contact.
Ö Let the components and pipes cool down or warm up.
Ö Wear protective garments and protective gloves.
Danger of crushing due to moving actuator- and control shaft!
Ö Do not reach into the bracket as long as the pneumatic power is connected to the actuator.
Ö Before working on the ball valve, interrupt and lock pneumatic energy and the control signal.
Ö Vent the actuator.
Ö Do not allow the jamming of objects in the bracket to hinder
the operation of the actuator- and control shaft.
Ö If the actuator- and control shaft are blocked (e.g. due to“seizure” if not actuated for a long period of time”), release
the residual energy of the actuator (spring tension) before releasing the blockage, see the corresponding actuator documentation.
Ö Prior to disassembly of the actuator, bring the ball valve into
the fail-safe position.

WARNING
If a used valve is sent to the manufacturer for service:
The valves must be decontaminated properly in advance.

Ö When returning a used valve, include the safety data sheet
for the medium as well as confirmation of decontamination of
the valve. Otherwise the valve will not be accepted.
Tip− PFEIFFER recommends documenting the following contamination data in the form  FM 8.7-6 “Declaration regarding thecontamination of PFEIFFER valves and components”.
− This form is available at  www.pfeiffer-armaturen.com.

11.2 Disassembling the actuator
See the corresponding actuator documentation.

Danger of injury due to residual medium in the ball valve!
When working on the ball valve, residual medium can escapeand, depending on the medium properties, cause injuries (e.g.
scalding, chemical burns).
Ö Wear protective garments, protective gloves and eye protection.
Ö Do not loosen the screw of the optional test connection while
the ball valve is pressurised.
Ö Remove the ball valve in the open position so the pressure isreleased from the ball.
Danger of injury due to preloaded springs!
Actuators with preloaded actuator springs are pressurised.
Ö Release the compression from the preloaded springs before
working on the actuator, see the corresponding actuator documentation.

Prior to disassembly, make sure that the following conditions aremet:− The ball valve is decommissioned, see chapter “10 Decommissioning”.

EB 20a_EN
November 2023 edition
Subject to technical changes

11-1Removal

11-2

EB 20a_EN
November 2023 edition
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Repairs

12 Repairs

12.1.2 Ball valve with “double stuffing box”

If the ball valve no longer works properly or if it does not work at
all, it is defective and must be repaired or replaced.

Leak in the test connection

NOTE
Damage to the ball valve due to improper maintenance and repair!
Ö Do not perform maintenance and repair work on your own.
Ö Contact the After Sales Service at PFEIFFER for maintenanceand repair work.

If a leak is found in the test connection of the stuffing box lower
section (19), the PTFE rings of the V-ring packing (7) could be
defective.
Ö Check the condition of the V-ring packing.
Disassemble the ball valve to remove the packing. For this purpose, observe Chapter “1 Safety instructions and safety measures”.
Ö Place the ball valve on an even and clean work surface sothat the packing space is easy to reach.

In special cases, certain maintenance and repair work may be
performed.
The work described in this chapter may only be performed by
specialist personnel qualified to perform the corresponding task.
The following instructions apply additionally for ball valves. For
decommissioning and disassembly, observe Chapter “10 Decommissioning” and Chapter “11 Disassembly”.
InfoPlease note when repairing!
Influences from the process medium and residues can affect thetorque for body connections when old balls and seals are reused,
see Table 15-1 in Chapter “15.1.1 Tightening torques”.

Info
The stuffing box upper section is preloaded during assembly. To
prevent it from loosening up uncontrolled, it is secured with anassembly sleeve during disassembly.

Ö Push the assembly sleeve over the ball stem up to the stuffing
box upper section (25).
Ö Screw a nut onto the ball stem (2).
Ö Undo and remove the screws (26).
Ö Carefully undo the nut and assembly sleeve and removethem.
Ö Carefully remove the stuffing box upper section (25) with thebearing bushing (10) and the o-ring (24).
Ö Remove the V-ring packing (23).
Ö Remove the thrust ring (22).

12.1 Replacing the V-ring packing in the caseof a DIN ball valve
12.1.1 Ball valve in the “standard version”
If a leak is found in the stuffing box (11), the PTFE rings of the
V-ring packing (7) could be defective.
Ö Check the condition of the V-ring packing.
Disassemble the ball valve to remove the packing. For this purpose, observe Chapter “1 Safety instructions and safety measures”.
Ö Place the ball valve on an even and clean work surface sothat the packing space is easy to reach.
Ö Loosen the screws (12) and remove the stuffing box flange(11) with the bearing bushing (10) carefully.

Ö Remove the disc springs from the disc spring set (21), distance bushing (20) and disc springs from the set of discsprings (9).
Ö Remove the thrust ring (8).
Ö Remove the stuffing box lower section (19) with the o-ring(18).
Ö Remove the V-ring packing (7).
Ö Check the PTFE rings of both V-ring packings as well as allplastic parts for damage and, in the case of doubt, replacethem.
Ö Assemble the ball valve as described in Chapter “3.5.1 DINball valve assembly”.
Leak in the stuffing box

Ö Remove the disc springs from the disc spring set (9).

If a leak is found in the stuffing box upper section (25), the PTFE
rings of the V-ring packings (7 and 23) could be defective.

Ö Remove the thrust ring (8).

Ö Check the condition of the V-ring packings.

Ö Remove the V-ring packing (7).
Ö Check the PTFE rings of the V-ring packing as well as allplastic parts for damage and, in the case of doubt, replacethem.
Ö Assemble the ball valve as described in Chapter “3.5.1 DINball valve assembly”.

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Nobember 2023 edition
Subject to technical changes

12-1Repairs

Figure|12-1:

12-2

BR 20a ball valve

EB 20a_EN
November 2023 edition
Subject to technical changes

Repairs

Table 12-1: Parts list
Item

Designation

Item

Designation

Item

Designation1

Lined body

11

Stuffing box flange

21

Disc spring set

2

Lined ball

12

Screw

22

Thrust ring3

Seat ring

13

Hand lever

23

V-ring packing

4

Screw/ stud bolt

14

Centring ring

24

O-ring

5

Nut

15

Bush

25

Stuffing box upper section

6

Disc spring

16

Disc spring

26

Screw

7

V-ring packing

17

Bush

27

Screw plug

8

Thrust ring

18

O-ring28

Washer9Disc spring set

19

Stuffing box lower section

29

Straight pin

10Bearing bush20

Distance bush

Ö Disassemble the ball valve as described above, check the PTFE rings of both V-ring packings as well as all plastic partsfor damage and, in the case of doubt, replace them.
Ö Assemble the ball valve as described in Chapter “3.5.1 DINball valve assembly”.

12.3 Replacing the seat ring of the ball
If the ball valve leaks in the passage, the seat ring (3) and/or
the ball (2) is defective.
Ö Check the condition of the seat ring and ball.
Disassemble the ball valve to remove the seat ring and ball. For
this purpose, observe Chapter “1 Safety instructions and safetymeasures”.

12.2 Replacing the V-ring packing in the caseof a ANSI ball valve
If a leak is found in the stuffing box (11), the PTFE rings of the
V-ring packing (7) could be defective.
Ö Check the condition of the V-ring packing.
Disassemble the ball valve to remove the packing. For this purpose, observe Chapter “Safety instructions and safety measures”.
Ö Place the ball valve on an even and clean work surface sothat the packing space is easy to reach.
Ö Loosen the screws (12) and remove the stuffing box flange(11) with the bearing bushing (10) carefully.
Ö Remove the disc springs from the disc spring set (9).
Ö Remove the centring ring (14).
Ö Remove the disc spring (16) and bushing (17).
Ö Remove the V-ring packing (7) and bushing (15).
Ö Check the PTFE rings of the V-ring packing as well as allplastic parts for damage and, in the case of doubt, replacethem.
Ö Assemble the ball valve as described in Chapter “3.5.2 ANSI
ball valve assembly”.

Ö Disassemble the ball valve as described in Chapter “12.1 Replacing the V-ring packing in the case of a DIN ball valve” or
Chapter “12.2 Replacing the V-ring packing in the case of an
ANSI ball valve”.
Ö Place the ball valve with the flange on the body side (1) facing downward on an even and clean work surface, so thatthe body connection nuts (5) are easy to access.
Ö Undo the nuts (5).
Ö Carefully remove the body halves (1).
Ö Check the seat rings and ball as well as all plastic parts fordamage and, in the case of doubt, replace them.
Info
The seat rings may not be installed without clearance. To achieve
the tightness of the ball valve, the seat rings must be installed intheir seat with sufficient clearance. If this is not possible, pleasecontact PFEIFFER.

Ö Assemble the ball valve as described in Chapter “3.5.1 Assembly of the DIN ball valve” or “3.5.2. Assembly of the ANSI ball valve assembly”.

12.4 Additional repairs
Ö In the case of additional major damage, it is recommended
to have repairs performed by PFEIFFER.

EB 20a_EN
Nobember 2023 edition
Subject to technical changes

12-3Repairs

12.5 Sending devices to PFEIFFER
Defective ball valves can be sent to PFEIFFER for repair.
Proceed as follows to send devices:
WARNING
Danger due to a contaminated ball valve!
Ö When returning a used valve to PFEIFFER for service, decontaminate the ball valve properly in advance.
Ö When returning a used valve, include the safety data sheet
for the medium as well as confirmation of decontamination of
the valve. Otherwise the valve will not be accepted.

Tip− PFEIFFER recommends documenting the following contamination data in the form  FM 8.7-6 “Declaration regarding thecontamination of PFEIFFER valves and components”.
− This form is available at  www.pfeiffer-armaturen.com.

Ö Include the following information for returns:− Manufacturer number− Ball valve type
− Article number− Nominal size and version of the ball valve− Manual valve/automated valve− Medium (designation and consistency)− Medium pressure and temperature− Flow rate in m³/h
− Bench range of the actuator− Number of actuations (year, month, week or day)− Installation drawing if available− Completed declaration regarding contamination. This
form is available at  ww.pfeiffer-armaturen.com.

12-4

EB 20a_EN
November 2023 edition
Subject to technical changes

Disposal

13 Disposal
Ö For disposal, observe the local, national and international
regulations.
Ö Do not dispose of old components, lubricant and hazardous
materials with domestic waste.

EB 20a_EN
November 2023 edition
Subject to technical changes

13-1Disposal

13-2

EB 20a_EN
November 2023 edition
Subject to technical changes

Certificates

14 Certificates
The declaration of conformity is available on the following
pages:− Declaration of conformity according to Pressure Equipment
Directive 2014/68/EU for automated valves, see page 14-2.
− Declaration of conformity according to Pressure Equipment
Directive 2014/68/EU for manually operated valves, seepage 14-3.
− Declaration of conformity for completed machinery according to Machinery Directive 2006/42/EC for the ball valve
with actuator BR 20a, see page 14-4.
− Declaration of conformity for partly completed machinery according to Machinery Directive 2006/42/EC for ball valve
with free control shaft BR 20a, see page 14-5.
The printed certificates correspond to the status at the time ofprinting. Further optional certificates are available upon request.

EB 20a_EN
November 2023 edition
Subject to technical changes

14-1

Certificates

14-2

EB 20a_EN
November 2023 edition
Subject to technical changes

Certificates

EB 20a_EN
November 2023 edition
Subject to technical changes

14-3Certificates

14-4

EB 20a_EN
November 2023 edition
Subject to technical changes

Certificates

EB 20a_EN
November 2023 edition
Subject to technical changes

14-5

Certificates

14-6

EB 20a_EN
November 2023 edition
Subject to technical changes

Annex

Table|15-1: Tightening torques for body connections

15 Annex

Nominal size

Connection

Tightening torque15.1 Tightening torques, lubricant and tools

DN 15

1 to 425 Nm

1 to 625 Nm

15.1.1 Tightening torques

DN 25

7 to 8

35 Nm

NPS1

1 to 425 Nm

1 to 725 Nm

8 and 935 Nm

1 to 725 Nm

8 and 930 Nm

15.1.1.1 Body halves
When screwing the body sections together (1a and 1b), observe
the sequence of the screw connections and the tightening torques
for the respective nominal sizes.

DN 40 / NPS1½

DN 50 / NPS2

DN 80 / NPS3

DN 100 / NPS4

DN 150 / NPS6

DN 200 / NPS8

1 to 1335 Nm

14 and 15

40 Nm

1 to 1435 Nm

15 and 16

45 Nm

1 to 1240 Nm

13 and 14

45 Nm

1 to 1450 Nm

15 and 16

60 Nm

Info
When these instructions are followed correctly, the sealing whenthe medium flows through the control shaft as well as proper
function are ensured.
Influences such as pressure, temperature, as well as the use ofother PTFE material can lead to a change in these assembly instructions.

15.1.1.2 Flange connections
Table|15-2: Tightening torques for the DIN flange connections
DN
[mm]

25

40

50

80

100

150

200

MA
[Nm]

25

50

60

65

75

100

150

Table|15-3: Tightening torques for the ANSI flange connections

Figure|15-1:

NPS[inch]

1

1½

2

3

4

6

8

MA
[Nm]

15

30

40

65

50

80

120

Sequence of the screw connections

EB 20a_EN
November 2023 edition
Subject to technical changes

15-1Annex15.1.2 Lubricant
Table|15-4: Recommended lubricant
Use

Temperature range

LubricantScrews and nuts

-10 ... +200°C

Microgleit, GP350
Not suitable for grease-free ballvalves or for use with oxygen

Stem sealing
and parts incontact with media-10 ... +200°C

Water-free grease (e.g. halocarbon grease)

15.1.3 Tools
Suitable tools are required to work on the ball valve. Unsuitable
tools can damage the ball valve.

15.2 Spare parts
PFEIFFER recommends spare part sets for “Commissioning” andfor “2-year operation”, see Chapter:− Chapter “15.2.1 Spare parts of the ball valve in the DIN version, DN 15 ... 100” on page 15-3,− Chapter “15.2.2 Spare parts of the ball valve in the DIN version, DN 150 ... 200” on page 15-4,− Chapter “15.2.3 Spare parts of the ball valve in the ANSI
version” on page 15-5 and− Chapter “15.2.4 Spare parts of the ball valve with double
stuffing box” on page 15-6.

15-2

EB 20a_EN
November 2023 edition
Subject to technical changes

Annex15.2.1 Spare parts of the ball valve in the DIN version, DN|15 ... 100

Figure|15-2:

Exploded drawing of the ball valve in the DIN version, DN 15 ... 100

Table|15-5: Recommend spare parts for the ball valve in the DIN version, DN 15 ... 100
Pos.

Designation

Material

1

Lined body

EN-JS 1049 / PTFE

2

Lined ball

1.4313 / PTFE

3

Seat ring

PTFE

4

Screw/ stud bolt

A4-70

5

Nut

A4-70

In the spare parts set forcommissioning

In the spare parts for 2 year
operation

•
•

•

6

Disc spring

1.4310••

7

V-ring packing

PTFE / 1.4305

•

•

8

Thrust ring1.43019Disc spring set

1.8159 / DeltaTone

•

•

10

Bearing bush

PTFE with carbon

•

•

11

Stuffing box flange

1.4305

12

Screw

A4-70

28

Washer

A4

EB 20a_EN
November 2023 edition
Subject to technical changes

15-3Annex15.2.2 Spare parts of the ball valve in the DIN version, DN|150 ... 200

Figure|15-3:

Exploded drawing of the ball valve in the DIN version, DN 150 ... 200

Table|15-6: Recommend spare parts for the ball valve in the DIN version, DN 150 ... 200
Pos.

Designation

Material

1

Lined body

EN-JS 1049 / PTFE

2

Lined ball

1.4313 / PFA

3

Seat ring

PTFE

4Stud screw

A4-70

5

Nut

A4-70

In the spare parts set forcommissioning

In the spare parts for 2 year
operation

•

•

•

•

6

Disc spring

1.4310•

7

V-ring packing

PTFE / 1.4305

•

•

9

Disc spring set

1.8159 / DeltaTone

•

•

10

Bearing bush

PTFE with carbon

•

•

11

Stuffing box flange

1.4305

12

Screw

A4-70

14

Centring ring1.4301

15

Bush

PTFE

•

•

16

Disc spring

1.4310

•

•

17

Bush

1.4301

28

WasherA4

29

Straight pin

1.430115-4

EB 20a_EN
November 2023 edition
Subject to technical changes

Annex15.2.3 Spare parts of the ball valve in the ANSI version

Figure|15-4:

Exploded drawing of the ball valve in the ANSI version

Table|15-7: Recommend spare parts for the ball valve in the ANSI version
In the spare parts set forcommissioning

In the spare parts for 2 year
operation••

1.4310••V-ring packing

PTFE / 1.4305••

Disc spring set

1.8159 / DeltaTone

•

•

10

Bearing bush

PTFE with carbon

•

•

11

Stuffing box flange

1.4305

Pos.

Designation

Material

1

Lined body

EN-JS 1049 / PTFE

2

Lined ball

1.4313 / PFA

3

Seat ring

PTFE

4Stud screw

A4-70

5

Nut

A4-70

6

Disc spring

7
9

12

Screw

A4-70

14

Centring ring1.4301

•

15

Bush

PTFE

•

•

16

Disc spring

1.4310

•

•

17

Bush

1.4301

28

WasherA4

29

Straight pin

1.4301EB 20a_EN
November 2023 edition
Subject to technical changes

15-5Annex15.2.4 Spare parts of the ball valve with double stuffing box

Figure|15-5:

15-6

Exploded drawing of the ball valve with double stuffing box

EB 20a_EN
November 2023 edition
Subject to technical changes

Annex

Table|15-8: Recommended spare parts for the ball valve with double stuffing box
Pos.

Designation

Material

1

Lined body

EN-JS 1049 / PTFE

2

Lined ball

1.4313 / PTFE

3

Seat ring

PTFE

4

Screw/ stud bolt

A4-70

5

Nut

A4-70

In the spare parts set forcommissioning

In the spare parts for 2 year
operation

•
•

•

6

Disc spring

1.4310••

7

V-ring packing

PTFE / 1.4305

•

•

8

Thrust ring1.43019Disc spring set

1.8159 / DeltaTone

•

•

10

Bearing bush

PTFE with carbon

•

•

•

•

•

•

18

O-ringViton

19

Stuffing box lower section

1.430120

Distance bush1.4301

21

Set of spring washers

1.8159 / DeltaTone

22

Thrust ring1.4301

23

V-ring packing

1.4305 / PTFE

•

•

24

O-ring

Viton

•

•

25

Stuffing box upper section

1.4301

26

Screw

A2-70

27

Screw plug

1.4571••

28

Washer

A4

15.3 Service

Necessary data

For maintenance and repair work as well as malfunctions ordefects, contact the After Sales Service at PFEIFFER for support.

Provide the following information in the case of questions and fortroubleshooting:− Manufacturer number

E-mail− Ball valve type

The After Sales Service can be reached at the e-mail address sales-pfeiffer-de@samsongroup.com.

− Article number− Nominal size and version of the ball valve− Manual valve/automated valve− Medium (designation and consistency)− Medium pressure and temperature− Flow rate in m³/h
− Actuator signal pressure− Number of actuations (year, month, week or day)− Installation drawing if available− Completed declaration regarding contamination. This
form is available at  www.pfeiffer-armaturen.com.

EB 20a_EN
November 2023 edition
Subject to technical changes

15-7AnnexFurther information
The indicated data sheets and further information are available,
also in English, at the following address:

PFEIFFER Chemie-Armaturenbau GmbH
Hooghe Weg 41 • 47906 Kempen • Germany
Phone: +49 2152 2005-0 • Fax +49 2152 1580
E-Mail: sales-pfeiffer-de@samsongroup.com
Internet: www.pfeiffer-armaturen.com

15-8

EB 20a_EN
November 2023 edition
Subject to technical changes

EB 20a_EN
November 2023 edition
Subject to technical changes

PFEIFFER Chemie-Armaturenbau GmbH
Hooghe Weg 41 · 47906 Kempen · Germany
Phone: +49 2152 2005-0 · Fax: +49 2152 1580
E-Mail: sales-pfeiffer-de@samsongroup.com · Internet: www.pfeiffer-armaturen.com

EB 20a_EN
November 2023 edition
Subject to technical changes