MOUNTING AND
OPERATING INSTRUCTIONS
EB 01aTranslation of the original manualControl valve BR 01a • DIN and ANSI version
to combine with actuators
March 2023 edition

PFEIFFER Chemie-Armaturenbau GmbH · Hooghe Weg 41 · 47906 Kempen · Germany
Phone: +49 2152 2005-0 · Fax: +49 2152 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 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 01a_EN
March 2023 edition
Subject to technical changes

Content

Inhalt1

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

Valve type plate

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

3-3

3.4

Technical data

3-3

3.5

Assembling the valve

3-3

3.5.1

Assembling the DIN valve, DN 25 to 150

3-3

3.5.2

Assembling the DIN valve, DN 200

3-5

3.5.3

Assembling ANSI valve NPS 1 to 3 and DIN valve DN 25 to 80 [Edition 2022]

3-8

3.5.4

Assembling the ANSI valve, NPS4 to 6

3-11

3.5.5

Assembling the ANSI valve, NPS8

3-13

4

Shipment and on-site transport

4-1

4.1

Accepting delivery

4-1

4.2

Unpacking the valve

4-1

4.3

Transporting and lifting the valve

4-1

4.3.1

Transporting

4-1

4.3.2

Lifting

4-1

4.4
5

Storing the valve
Installation

4-3
5-1

5.1

Installation conditions

5-1

5.2

Preparing for assembly

5-1

5.3

Assembling the valve and actuator

5.3.1
5.4
5.4.1
5.4.2
5.5

Travel adjustment with separately supplied SAMSON actuator
Installing the valve in the pipe

5-1
5-2
5-3

General5-3Installing the valve

5-4

Checking the assembled valve

5-4

5.5.1

Functional check

5-4

5.5.2

Pressure test of the pipe section

5-4

5.5.3

Travel movement

5-4

5.5.4

Fail-safe position

5-4

EB 01a_EN
March 2023 edition
Subject to technical changes

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

8-3

9Servicing

9-1

9.1

Periodic tests

9-1

9.2

Maintenance work

9-2

9.2.1
9.3

Replacing the seat and plug
Ordering spare parts and consumables

9-2
9-2

10 Decommissioning

10-1

11 Removal

11-1

11.1

Removing the valve from the pipe

11-1

11.2

Disassembling the actuator

11-1

12 Repairs

12-1

12.1

Replacing the bellows

12-1

12.2

Replacing the bellows and the packing

12-1

12.3

Adjusting the stuffing box (option)

12-1

12.4

Replacing the seat

12-3

12.5

Replacing the plug

12-3

12.6

Additional repairs

12-3

12.7

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

Lubricant15-1

15.1.3

Tools

15-1

15.2

Spare parts

15-1

15.2.1

Spare parts for DIN-Valves, DN 25 ... 50

15-2

15.2.2

Spare parts for DIN-Valves, DN 80 ... 150

15-4

15.2.3

Spare parts for DIN-Valves, DN 200

15-6

15.2.4

Spare parts for ANSI-Valves, NPS1 ... 3 and DIN-Valves, DN 25 ... 80 [Edition 2022]

15-8

15.2.5

Spare parts for ANSI-Valves, NPS4 ... 6

15-10

15.2.6

Spare parts for ANSI-Valves, NPS8

15-12

15.3

Service

15-14

EB 01a_EN
March 2023 edition
Subject to technical changes

Safety instructions and safety measures

1

Safety instructions and safety measures

Intended use
The BR 01a valve is equipped with a manual gear or in combination with an actuator and intended for the regulation of thevolume flow, pressure and temperature of fluid, gaseous or vaporous media.
− The valve and its actuator are designed for precisely definedconditions (e.g. operating pressure, utilised medium, temperature).
Therefore the operator must make sure that the valve is onlyused when the conditions of use comply with the design criteria defined in the order.
If the operator would like to use the valve in other applications or environments, they must contact PFEIFFER.
− Manual valves are only intended for use, after installation ina pipe system, to cut off the media (mainly corrosive), let it
flow through or regulate it within the permitted pressure andtemperature limits.
− Automated valves are only intended for use, after installation
in a pipe system and after connecting the actuator to the control, to cut off the media (mainly corrosive), let it flow throughor regulate it within the permitted pressure and temperature
limits.
− The data sheet contains the permissible pressure and temperature range for these valves  TB 01a.
− 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 valves.
This manual only provides safety instructions that are to beobserved additionally for 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 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 valve.
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 valve may only be disassembled, dismantled, assembled andcommissioned by qualified specialist personnel trained in pressurised pipes who are familiar with the assembly, commissioning
and operation of this product.

EB 01a_EN
March 2023 edition
Subject to technical changes− 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 warranty and productguarantee. 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 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 SAMSON 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 thevalve.
− 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 value ensure that:− The valve is only used as intended as described in this chapter.

1-1

Safety instructions and safety measures− A actuator unit that is subsequently installed on the valve isadapted to the valve and is correctly adjusted in the end positions, and in particular in the closed position of the valve.
− The pipe system and control system are properly installed
and regularly checked. The wall thickness of the valve body ismeasured such that an additional load of the usual magnitude is taken into account for a pipe system installed properlyin 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 small 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 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 valves provided 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 “14 Certificates“.
− According to an ignition hazard assessment according to
DIN EN ISO 80079-36, PFEIFFER valves do not have any
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.
Valves with plastic lining (PFA, PTFE) through which chargeable media flows during operation, must be provided with anelectrostatically 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 PFEIFFER 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 valves!
Valves whose permissible pressure/temperature range (=”rating”) is not sufficient for the operating conditions can pose a
danger to the user and cause damage to the pipe system.
Ö Only operate valves whose permissible pressure/temperature
range (=”rating”) are sufficient for the operating conditions,see the data sheet  TB 01a)
Risk of bursting of the pressure equipment!
Valves and pipes are pressure equipment. Improper opening cancause the bursting of valve components.
Ö Observe the maximum permissible pressure the valve andplant.
Ö Before working on the valve, depressurise the concernedplant parts and the valve.
Ö Before removing the valve from the pipe, completely release
the pressure in the pipe so that the medium does not escapeuncontrolled from the line.
Ö Empty the medium from the concerned plant parts and valve.
(Wear protective equipment).

1.2 Notes regarding possible personnel injury
WARNING
Hazards due to incorrect valve use!
The incorrect use of the valve can represent a hazard for the user
and cause damage to the pipe system that are then no longer the
responsibility of PFEIFFER.
Ö The lining selected for the parts of the 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, valve components and pipes
can become very hot or very cold and cause burns upon contact.
Ö Valves must be protected against contact in the case of operating temperatures >+50°C or <-20°C together with the pipe
connections.

EB 01a_EN
March 2023 edition
Subject to technical changes

Safety instructions and safety measures

WARNING
Danger of crushing due to moving parts!
The valve contains moving parts (actuator and plug stem) thatcan lead to crushing if reaching into it.
Ö Do not reach into the yoke during operation.
Ö When working on the 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 thevalve, the actuator can be ventilated.
Ö Install the valve such that the actuator does not ventilate ateye level.
Ö Use suitable silencers and plugs.
Ö Wear eye protection and, if necessary, hearing protection
when working near the valve.
Danger of injury due to prestressed springs!
Valves that are equipped with preloaded actuator springs are under mechanical tension. These valves, in combination with thepneumatic SAMSON actuators, can be identified by the elongated screws on the bottom of the actuator.
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 valve!
When a valve must be removed from a pipe, medium can escapefrom the pipe or the valve.
Ö In the case of media that is harmful to health or hazardous,
the pipe must be completely emptied before a valve can beremoved.
Ö Pay attention to the afterflow of residuals or residuals that remain in dead spots.
Danger of injury due to the releasing of body screw connections!
If the body screw connections must be released, medium can escape from the valve.
Ö The screw connections on the connection of the body andbonnet flange may only be released or loosened after thevalve has been removed.
Ö During reassembly, tighten the screws according to Table
15-1 in Chapter “15.1.1 Tightening torques“ using a torquewrench.
Dangers 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 valve must be secured against unauthorized actuation.
Ö If a 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 01a_EN
March 2023 edition
Subject to technical changes

WARNING
Deviation of the breakaway and actuating forces due tonon-actuation of the valve!
Depending on the period of time of non-actuation, the breakway
and actuation forces can deviate considerably from the actuating
power data in the data sheet.
It is recommended to actuate the 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 valve due to contamination!
Contamination (e.g. solid particles) in the pipes can damage thevalve.
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 the valve andplant.
Damage to the valve due to unsuitable medium properties!
The valve is designed for a medium with certain properties.
Other media can damage the valve.
Ö Only use a medium that corresponds to the design criteria.
Damage to the valve and leakage due to excessively high or
low tightening torques!
The valve components must be tightened with specific torques.
Deviating torques can lead to 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”.
Damage to the valve due to unsuitable tools!
Unsuitable tools can damage the valve.
Ö Suitable tools are required to work on the valve, see Chapter“15.1.3 Tools”.

1-3Safety instructions and safety measures

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

1.4 Warning notes on the device
Warning of moving parts

Bild|1-1:

Warning of moving parts

There is a danger of crushing due to the lifting movements of theactuator and plug stem when reaching into the yoke as long as
the pneumatic power is connected to the actuator.

1-4

EB 01a_EN
March 2023 edition
Subject to technical changes

Markings on the device

2Markings on the device

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

For

1

Manufacturer

PFEIFFER

Address see Chapter “15.3 Service”

2

Valve typeBR (and number value)e.g. BR 01a = Series 01a, see the PFEIFFER catalogue

3

Body material

e.g. EN-JS 1049

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

4

Size

DN (and number value)

Number value in [mm], e.g. DN50 / number value in [inches], e.g. NPS2

5Maximum pressure

PN (and number value)

Number value in [bar], e.g. PN10 / number value in [inches], e.g. cl150 at room temperature

Max. permissible
TS (and number value)
operating temperature

6

7

Marking

RemarkMax. 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 the Pressure-Temperature Diagram on the data
sheet  TB 01a

Test pressure

PT (and number value)

The test pressure must be observed depending on the device
38

1234

/001

/001
Valve no. within the item

Manufacturer number
from 2018

Item in the ordere.g. 381234/001/001

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
2009 to 2017

Item in the ordere.g. 211234/001/001

Order
Year of manufacture (29=2009, 20=2010, 21=2011,22=2012 etc.)
207

1234

/001

/001
Valve no. within the item

Manufacturer number
until 2008

Item in the ordere.g. 2071234/001/001

Order
Year of manufacture (205=2005, 206=2006, 207=2007etc.)
9Seat diametere.g. 24 mm

10Year of manufacture

e.g. 2018

The year of manufacture is affixed on the valve

11

Plug version

e.g. V-port plug

Marking for “Parabolic plug” or “T-port plug”

12

Lininge.g. PTFE

Marking for BR 01a “PTFE”

13

Characteristic curvee.g. =%

Marking for “linear” or “equal percentage”

14

Travele.g. 30 mm

Number value in [mm]

15

Kvs

e.g. 25

Number value in [m3/h]

16

DataMatrix code
Conformity

CE

Conformity is certified separately by PFEIFFER

Code No.
Flow direction

0035
ÎAttention: see the note in Chapter “5.4 Installing the valve in the pipe”

19

Test point number

e.g. F123201-1

Specified by the customer

20

Materials

17
18

Number value in [mm]“Notified body” according to EU Directive = TÜV Rheinland Service GmbH

Materials outside of the standard in the case of parts in contact with the media

Info
Markings on the body and the type plate must be permanent so that the valve remains identifiable.
EB 01a_EN
March 2023 edition
Subject to technical changes

2-1Markings on the device

2.1 Type plates
2.1.1

Valve type plate

Figure|2-1: Marking positions of the type plate on the valve BR 01a

2.1.2

Actuator type plate

See the corresponding actuator documentation.

2.2 Material marking
The valves are marked on the body with material specification,
see Table 2-1.
Further specifications can be requested from PFEIFFER.

2-2

EB 01a_EN
March 2023 edition
Subject to technical changes

Design and principle of operation

3

Design and principle of operation− With a manual SAMSON actuator.
− With actuators from other manufacturers.

Function and principle of operation
The medium flows through the valve against the closing direction.
The position of the plug determines the cross-sectional area between the plug (13) and the seat (4).

3.1 Variants− Valve body warmed with a heating jacket.

The plug is connected via the stem (16) to the actuator stem.

− Lining with special compounds, e.g. PTFE-conductive.

The PTFE bellows (15) seal the area between the valve body (1)and the stem (16).

− For eroding media, valve plug and valve seat also made of
special material (e.g. tantalum, HC4, titanium or Al2O3).

The graphite packing (26) or PTFE V-ring packing (33) is used
for additional stem sealing.

− Bellows, stem made of special material (e.g. Hastelloy).

In conjunction with the test connection (24), they allow you tocheck the bellows (15) e.g. by connecting a suction line or inert
gas line.
The plug (13) is easy to replace thanks to the groove-spring connection with the bellows in the form of a PTFE cord (14).
The bottom flange (10) with inlay (7), PTFE washer (6) and spacer (5) house the exchangeable valve seat (4).
NOTE
Damage to the valve due to cavitation!
The valve can be damaged due to cavitation.
Ö At the onset of cavitation or with differential pressures above
3 bar and a differential pressure ratio of p2 < ∆p, PFEIFFER
recommends using a guided plug!
Ö It is also recommended to use fittings made of ceramic orresistant special metals.
Lined valves are not suitable for operation with cavitation.
Contact PFEIFFER in the case of questions.

Fail-safe positions
Depending on the mounting of the pneumatic actuator, the valve
has two fail-safe positions that are activated when the pressure isreleased as well when the supply air fails:− Valve with spring-close actuator [STAF]:
If the air supply fails, the valve is closed. The valve opens
when the signal pressure increases, acting against the forceof the springs.

− Further components made of special material.
− Designed for high-permeation media.
− Suitable for crystallising media.
− Low-temperature version for -40°C.

3.2 Additional fittings
Strainer
PFEIFFER recommends installing a strainer in front of the valve
body. A strainer prevents the solid content in the medium fromdamaging the valve.
Bypass and shut-off valves
PFEIFFER recommends installing a shut-off valve in front of thestrainer as well as behind the valve and to create a bypass. Bymeans of the bypass, the entire plant does not have to be decommissioned during maintenance and repair work on the valve.
Insulation
The valves can be insulated to reduce the passage of heat energy.
Observe the notes in Chapter “ 5 Assembly”.
Test connection
In the version with bellows sealing, a test connection (e.g. ¼"
thread) can be used on the upper flange to check the tightness ofthe bellows.

− Valve with spring-open actuator [STEF]:
If the air supply fails, the valve is opened. The valve closes
when the signal pressure increases, acting against the forceof the springs.

Grip protection

Changing the fail-safe position

Under conditions of use that require a high level of safety (e.g. if
the valve is freely accessible to untrained specialist personnel),
PFEIFFER offers a safety guard to prevent the risk of crushing due
to moving parts (actuating drive and plug stem).

The fail-safe position of the actuator can be reversed if required.
To do so, see the installation and operating manual for the respective pneumatic actuator.

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 valve in the plant.

Operating elements and functions
The BR 01a valve can be selected in the following versions:− With a pneumatic SAMSON actuating drive.

EB 01a_EN
March 2023 edition
Subject to technical changes

3-1Design and principle of operation

Figure|3-1: Cross-section of a DIN valve, DN 25 ... 150

Table|3-1: Parts list

3-2

Item

Designation

Item

Designation

1

Valve body17

Bordered flange

2

Bonnet flange

18

Washer3

O-ring

22

Bushing

4

Seat

23

Grooved pin

5Spacer

24

Locking screw

6

Washer25

Washer

7

Inlay

26

Packing10

Bottom flange

27

Stuffing box

11

Screw/ stud bolt

28

Wiper ring

12

Nut

36

Screw

13

Plug

37

Nut

14

Cord

38

Yoke (not marked)

15

Bellows

39

Groove nut (not marked)

16

Stem

40

Support bolts

EB 01a_EN
March 2023 edition
Subject to technical changes

Design and principle of operation

3.3 Attachments
The following accessories are available either individually or in
combinations:− Positioner− Limit switch− Solenoid valves− Supply air regulator/filter− Pressure gauge mounting blocks− Pneumatic volume booster
Other additional equipment is possible according to specifications on request.

NOTE
Damage to the valve due to cold welding of the screws in thebody!
PFEIFFER recommends a heavy-duty grease paste (e.g. Gleitmo
805, manufacturer Fuchs) to prevent the cold-welding of thescrews in the bodies.
Ö Do not use this product for valves with use of oxygen. A suitable lubricant must be selected for grease-free valves, especially for use with oxygen.
Damage to the parts of the stem sealing in contact with media
due to unsuitable grease.
Ö When assembling the stem, bellows, plug, bonnet flange andall other parts of the stem sealing in contact with media, only
use water-free grease (e.g. halocarbon grease).

3.4 Technical data
The type plates of the valve and actuator give information about
the valve version, see Chapter “2 Markings on the device”.
Info
Detailed information is available on the data sheet  TB 01a.

3.5 Assembling the valve
The current DIN-compliant version of the BR 01a valve has design differences in the stem sealing in comparison to the current
ANSI version, so that they cannot be documented in one construction manual.

3.5.1

Assembling the DIN valve,
DN|25|to|150

3.5.1.1 Assembling the valve bodyÖ Place the valve body (1) with the cover-side flange on aclean, soft surface at working height so that the bearing areaof the seat is easy to reach.
Ö Clean the PTFE lining of the body with detergent.
Ö Lay the PTFE O-ring (3) into the groove of the body.

− Chapter 3.5.1 describes the assembly of the DIN valve,
DN|25 to 150.

Tip
Depending on the temperature, it may be necessary to shrink the
O-ring with cold spray or by cooling it down in the refrigerator.

− Chapter 3.5.2 describes the assembly of the DIN valve,
DN|200.

Ö Insert the seat (4) into the body.

− Chapter 3.5.3 describes the assembly of the ANSI valve,
NPS 1 to 3 and the DIN valve, DN|25 to 80 [Edition 2022].
− Chapter3.5.4 describes the assembly of the ANSI valve, NPS
4 to 6.
− Chapter 3.5.5 describes the assembly of the ANSI valve,
NPS 8.
Before assembly
To assemble the valve, all parts must be prepared, e.g. the parts
are carefully cleaned and placed on a soft mat (rubber mator other). Keep in mind that plastic parts are almost always very
soft and very delicate, and in particular the sealing surfaces may
not be damaged.

Ö Press the spacer (5) into the seat (4) in the body.
NOTE
Reduction in flow rate due to improper assembly!
Ö Make sure that the passage opening in the spacer (5) aligns
with the inlet opening of the valve.
Ö The upper edge of the pressure piece must be flat with thesealing surface of the housing flange.
Ö With a 5 mm drill bit, drill diagonally approx. 10 mm deep
into the spacer (5) from the sealing surface.
Ö Secure the spacer against twisting with a piece of PTFE cord(14) inserted into this borehole.
Ö Lay the PTFE washer (6) on the spacer in the body.

Info
The position and arrangement of the individual parts shown inthe drawings must be observed during assembly.

Ö Place the elastomer inlay (7) on the PTFE washer.
Ö Carefully place the bottom flange (10) on the body.
Ö Fit the washer (6) and inlay (7) centrally in the bottom flange.
Ö Insert the screws (11) and align using the nuts (12). Tighten
the screws evenly in a criss-cross pattern.

EB 01a_EN
March 2023 edition
Subject to technical changes

3-3Design and principle of operation

NOTE
Damage to the valve due to incorrect tightening torques!
Ö The permissible torques for assembly and for retightening theconnection of the bottom flange can be found in Table 15-1
in Chapter “15.1.1 Tightening torques”.

3.5.1.3 Assembling the bonnet flange− When assembling the bonnet flange and all other parts incontact with media, only use water-free grease (e.g. halocarbon grease).
Ö Before assembly, grease the bonnet flange (2) from the inside.
Ö Lightly screw in the support bolts (40) so they do not protrude
on the inside of the cover.

3.5.1.2 Assembling the stem
− When assembling the stem, bellows, plug and all other partsof the stem sealing in contact with media, only use water-freegrease (e.g. halocarbon grease).
Ö Grease the single-section stem (16) on the bottom thread.
Info
In some versions, the stem consists of three individual parts,
whereby the guide is preassembled by a snap ring with the stem.
Ö Screw the bellows (15) with a preassembled washer andbushing onto the greased thread of the stem (16).
Tip
Due to the sliding property of the PTFE, we recommend using an
emery cloth to prevent the bellows from sliding when screwing it
onto the stem.

Assembling the stem unit DN 25 to 50
Info
To make it easy to push on the plug stem, a small notch is madein the bellows to let air escape.
Ö Push the plug (13) onto the bellows (15).
Ö Secure the connection between the plug and bellows with a
PTFE cord (14) inserted as far as possible.
Ö Grease the groove of the stem thoroughly.

Assembling the stem unit DN 80 to 150
Ö Grease the metal side of the bordered flange (17) to minimise rust.
Ö Slide the bordered flange (17) over the bellows (15) until it
stops.
Info
To make it easy to push on the plug stem, a small notch is madein the bellows to let air escape.
Ö Push the plug (13) onto the bellows (15).
Ö Secure the connection between the plug and bellows with a
PTFE cord (14) inserted as far as possible.
Ö Grease the groove of the stem thoroughly.

3-4

Info
Fit valves with a nominal size of DN 25 to 50 without support
bolts (40).
Ö For continued assembly, clamp the bonnet flange with thestem guide facing down in a vice.
NOTE
Damage to the bonnet flange due to improper handling!
Ö Do not damage the bonnet flange, especially the thread on
the stem end.
Ö Apply Loctite on the Glycodur bushings (22a and 22b).
Ö Insert the Glycodur bushing (22a) with a suitable pin as far
as possible into the stem guide.
Ö Insert the Glycodur bushings (22b) with a suitable pin so they
are flush with the inner surface of the cover.
Info
If the Glycodur bushings vary in length:First insert the shorter bushing (22a) followed by the longer bushing (22b)Ö Strike the grooved pin (23).
Ö Screw in the locking screw (24).
Ö Insert the washer (18) into the provided recess in the bonnet
flange.
Ö Insert the preassembled stem unit, see Chapter 3.5.1.2, in the
cover.

3.5.1.4 Assembling the valve
Standard stuffing box
Ö Carefully place the preassembled valve body, see Chapter
3.5.1.1, on the preassembled bonnet flange, see Chapter
3.5.1.3.
Info
Air connection (24) in the bonnet flange and type plate on thevalve body (1) point in the same direction.
Ö Insert the screws (36) and align using the nuts (37). Tighten
the screws evenly in a criss-cross pattern.

EB 01a_EN
March 2023 edition
Subject to technical changes

Design and principle of operation

NOTE
Change the position of the plug by tightening the screws!
Ö Make sure that the position of the plug remains central.
Damage to the plug, seat or guide due to clamping of the stem!
Ö Press on the stem (16) during the screwdriving process to test
its smooth movement.
Damage to the valve due to incorrect tightening torques!
Ö The permissible torques for assembly and for retightening theconnection of the bonnet flange can be found in Table 15-3
in Chapter “15.1.1 Tightening torques”.

Figure|3-2: Adjustable stuffing box

Ö Seal the stuffing box with a dot of red paint.

Ö Tighten the support bolts (40) on valves DN 80 to 150, see
Table 15-5 in Chapter “15.1.1 Tightening torques”.
Ö To continue the assembly, place the valve with the stem guidefacing up on an even work surface.
Ö Position the washer (25).
Ö Insert the packing rings (26) with a special pin into the cover.
NOTE
Improper seal due to incorrect positioning of the packing rings!
Ö Insert packing rings staggered so that the division of thepacking rings does not align.
Ö Press the wiper ring (28) into the stuffing box (27).
Ö Screw the stuffing box (27) into the cover with the wiper ring(28).
Ö Tighten the stuffing box by hand and loosen a half turnÖ Retighten the stuffing box.
NOTE
Damage to the packing due to improper assembly!
Ö Press the stuffing box packing in cleanly; the pack must notbulge through the stuffing box.

With optional adjustable stuffing box
Ö The final assembly of the valve takes place as describedabove.
Ö Do not loosen then retighten the stuffing box (27), rather unscrew it completely and remove it from the valve.
Ö Clean the removed stuffing box to ensure it is free of grease.
Ö Apply Loctite 668 onto the thread of the stuffing box (27).
Ö Screw the stuffing box (27) into the bonnet flange.
Info
Do not tighten the stuffing box, the distance between the collar of
the stuffing box and the bonnet flange must be 3 mm!

3.5.2

Assembling the DIN valve, DN|200

3.5.2.1 Assembling the valve bodyÖ Place the valve body (1) with the cover-side flange on aclean, soft surface at working height so that the bearing areaof the seat is easy to reach.
Ö Clean the PTFE lining of the body with detergent.
Ö Lay the PTFE O-ring (3) into the groove of the body.
Tip
Depending on the temperature, it may be necessary to shrink the
O-ring with cold spray or by cooling it down in the refrigerator.
Ö Insert seat (4) into the recess of the spacer (5) and fix with PTFE cord (14).
Ö Insert spacer (5) with seat (4) into the body.
NOTE
Reduction in flow rate due to improper assembly!
Ö Make sure that the passage opening in the spacer (5) aligns
with the inlet opening of the valve.
Ö The upper edge of the spacer must be flat with the sealing
surface of the housing flange.
Ö With a 5 mm drill bit, drill diagonally approx. 10 mm deep
into the spacer (5) from the sealing surface.
Ö Secure the spacer against twisting with a piece of PTFE cord(14) inserted into this borehole.
Ö Lay the PTFE washer (6) on the spacer (5).
Ö Place the thrust washer (8) on the PTFE washer (6).
Ö Insert the spring washers (9). For the position of the spring
washers, see Fig 3-3.
Ö Carefully place the bottom flange (10) on the body.
Ö Fit the washer (6), thrust washer (8) and spring washers (9)centrally in the bottom flange.
Ö Tighten the screws (11) with the washer (43) in the valve
body. Tighten the screws evenly in a criss-cross pattern.

EB 01a_EN
March 2023 edition
Subject to technical changes

3-5Design and principle of operation

Figure|3-3: Cross-section of a DIN valve, DN 200

Table|3-2: Parts list

3-6

Item

Designation

Item

Designation

1

Valve body21

Spring washer

2

Bonnet flange

24

Locking screw

3

O-ring27

Stuffing box

4

Seat

29

Bearing bushing

5

Spacer30

O-ring6

Washer31

Guide bushing

8

Thrust washer

33

V-ring packing

9Spring washer

34

Set of spring washers

10

Bottom flange

35

O-ring

11

Screw

36

Screw

13

Plug

38

Yoke

14

Cord

39

Grooved nut

15

Bellows

41

Bearing bushing

16

Stem

42

O-ring19

O-ring43

WasherEB 01a_EN
March 2023 edition
Subject to technical changes

Design and principle of operation

NOTE
Damage to the valve due to incorrect tightening torques!
Ö The permissible torques for assembly and for retightening theconnection of the bottom flange can be found in Table 15-2
in Chapter “15.1.1 Tightening torques”.

Info
Do not screw the stuffing box (27) into the bonnet flange as far
as it will go.
Ö Push the yoke (38) onto the bonnet flange and fasten with thegrooved nut (39).
Ö Clamp the bonnet flange (2) at the yoke in a vice with theflange opening facing upwards.

3.5.2.2 Assembling the stem unit
− When assembling the stem, bellows, plug and all other partsof the stem sealing in contact with media, only use water-freegrease (e.g. halocarbon grease).
Ö The single-piece stem (16) is greased at the lower thread.
Ö Screw the bellows (15) with a preassembled washer andbushing onto the greased thread of the stem (16).
Tip
Due to the sliding property of the PTFE, we recommend using an
emery cloth to prevent the bellows from sliding when screwing it
onto the stem.

Info
To make it easy to push on the plug stem, a small notch is madein the bellows to let air escape.
Ö Push the plug (13) onto the bellows (15).
Ö Secure the connection between the plug and bellows with a
PTFE cord (14) inserted as far as possible.

3.5.2.3 Assembling the bonnet flange− When assembling the bonnet flange and all other parts incontact with media, only use water-free grease (e.g. halocarbon grease).
Ö Place the bonnet flange (2) on a clean surface at working
height so that the stem guide is easy to reach.
Ö Insert the distance bushing and V-rings and lock ring of the
V-ring packing (33). For the arrangement of the packing
rings, see Figure 3-3.
Ö Insert the set of spring washers (34) into the provided hole.
Arrangement of the spring washers, see Figure 3-3.
Ö Insert the O-ring (30) into the inner groove of the stuffing box(27).
Ö Press the upper bearing bushing (29) into the bottom part ofthe stuffing box (27).

NOTE
Damage to the bonnet flange due to improper handling!
Ö Do not damage the bonnet flange, especially the thread on
the stem end.
Ö Press the lower bearing bushing (41) into the recesses of theguide bushing (31).
Ö Insert the O-rings (35) and (42) into the corresponding recesses in the guide bushing.
Ö Grease the guide bushing (31) on the thread.
Ö Screw the guide bushing (31) into the bonnet flange (2) as
far as it will go.
NOTE
Damage to the threaded bushing due to improper assembly!
Ö The guide bushing must not be inserted at a slanted angle
when screw it into the bonnet flange.
Ö Insert the spring washer (21), thrust washer (8) and O-ring(19) in the bonnet flange (2). For the arrangement of thecomponents, see Figure 3-3.
Ö Insert the preassembled stem unit, see Chapter 3.5.2.2, in the
cover and press the flange of the bellows into the thread of
the bonnet flange.
Ö Screw in the locking screw (24).

3.5.2.4 Assembling the valve
Standard stuffing box
Ö Clamp the preassembled valve body, see Chapter 3.5.2.1, ina vice with the bonnet flange opening facing upwards.
Ö Place the preassembled bonnet flange, see Chapter 3.5.2.3,
onto the valve body carefully.

Ö Grease the stuffing box (27) on the thread.

Info
Air connection (24) in the bonnet flange and type plate on thevalve body (1) point in the same direction.

Ö Screw the stuffing box (27) into the upper thread of the bonnet flange (2), the outer groove of the stuffing box is still visible.

Ö Tighten the screws (36) with washers (43) in the valve body.
Tighten the screws evenly in a criss-cross pattern.

EB 01a_EN
March 2023 edition
Subject to technical changes

3-7Design and principle of operation

NOTE
Change the position of the plug by tightening the screws!
Ö Make sure that the position of the plug remains central.
Damage to the stem due to twisting!
Ö Before tightening the screw connection, pull the stem up as
far as it will go.
Damage to the valve due to incorrect tightening torques!
Ö The permissible torques for assembly and for retightening theconnection of the bonnet flange can be found in Table 15-4
in Chapter “15.1.1 Tightening torques”.
Ö Tighten the stuffing box (27) after adjusting the valve.

Tip
Depending on the temperature, it may be necessary to shrink the
O-ring with cold spray or by cooling it down in the refrigerator.
Ö Insert the seat (4) into the body.
Ö Press the spacer (5) into the seat (4) in the body.
NOTE
Reduction in flow rate due to improper assembly!
Ö Make sure that the passage opening in the spacer (5) aligns
with the inlet opening of the valve.
Ö The upper edge of the spacer must be flat with the sealing
surface of the housing flange.

With optional adjustable stuffing box

Ö With a 5 mm drill bit, drill diagonally approx. 10 mm deep
into the spacer (5) from the sealing surface.

Ö The final assembly of the valve takes place as described in
Chapter 3.5.2.4.

Ö Secure the spacer against twisting with a piece of PTFE cord(14) inserted into this borehole.

Ö Do not loosen then retighten the stuffing box (27), rather unscrew it completely and remove it from the valve.

Ö Lay the PTFE washer (6) on the spacer (5).

Ö Clean the removed stuffing box to ensure it is free of grease.

Ö Place the thrust washer (8) on the PTFE washer (6).

Ö Apply Loctite 668 onto the thread of the stuffing box (27).

Ö Insert the spring washers (9). For the position of the spring
washer, see Figure 3-5.

Ö Screw the stuffing box (27) into the bonnet flange.

Ö Carefully place the bottom flange (10) on the body.

Info
Do not tighten the stuffing box, the distance between the collar of
the stuffing box and the bonnet flange must be 3 mm!

Ö Fit the washer (6), thrust washer (8) and spring washers (9)centrally in the bottom flange.
Ö Screw the screws (11) into the valve body. Tighten the screws
evenly in a criss-cross pattern.
NOTE
Damage to the valve due to incorrect tightening torques!
Ö The permissible torques for assembly and for retightening theconnection of the bottom flange can be found in Table 15-2
in Chapter “15.1.1 Tightening torques”.

Figure|3-4: Adjustable stuffing box

Ö Seal the stuffing box with a dot of red paint.

3.5.3.2 Assembling the stem unit
− When assembling the stem, bellows, plug and all other partsof the stem sealing in contact with media, only use water-freegrease (e.g. halocarbon grease).

3.5.3

Assembling ANSI valve NPS|1 to|3 andDIN valve DN|25 to 80 [Edition 2022]

3.5.3.1 Assembling the valve bodyÖ Place the valve body (1) with the cover-side flange on aclean, soft surface at working height so that the bearing areaof the seat is easy to reach.

Ö The single-piece stem (16) is greased at the lower thread.
Info
In some versions, the stem consists of three individual parts,
whereby the guide is preassembled by a snap ring with the stem.
Ö Screw the bellows (15) with a preassembled washer andbushing onto the greased thread of the stem (16).

Ö Clean the PTFE lining of the body with detergent.
Ö Lay the PTFE O-ring (3) into the groove of the body.

3-8

Tip
Due to the sliding property of the PTFE, we recommend using an
emery cloth to prevent the bellows from sliding when screwing it
onto the stem.

EB 01a_EN
March 2023 edition
Subject to technical changes

Design and principle of operation

Figure|3-5: Cross-section of an ANSI valve, NPS 1 to 3

Table|3-3: Parts list
Item

Designation

Item

Designation

1

Valve body

19

O-ring2

Bonnet flange

20

Thrust washer

3O-ring23

Grooved pin

4

Seat

24

Locking screw

5

Spacer27

Stuffing box

6

Washer29

Bearing bushing

8

Thrust washer

30

O-ring9Spring washer

31

Guide bushing

10

Bottom flange

33

V-ring packing

11

Screw

34

Set of spring washers

13

Plug

35

O-ring

14

Cord

36

Screw

15

Bellows

38

Yoke

16

Stem

39

Grooved nut

EB 01a_EN
March 2023 edition
Subject to technical changes

3-9Design and principle of operationInfo
To make it easy to push on the plug stem, a small notch is madein the bellows to let air escape.

Ö Strike the grooved pin (23).
Ö Insert the preassembled stem unit, see Chapter 3.5.3.2, in thebonnet flange and press the flange of the bellows into thethread of the bonnet flange.

Ö Push the plug (13) onto the bellows (15).

Ö Screw in the locking screw (24).

Ö Secure the connection between the plug and bellows with a
PTFE cord (14) inserted as far as possible.

Bonnet flange assembly NPS3
− To assemble bonnet flange NPS3, follow the steps in “Bonnet
flange assembly NPS1 to 2”.

3.5.3.3 Assembling the bonnet flange− When assembling the bonnet flange and all other parts incontact with media, only use water-free grease (e.g. halocarbon grease).
Bonnet flange assembly NPS1 to 2
Ö Place the bonnet flange (2) on a clean surface at working
height so that the stem guide is easy to reach.
Ö Insert the distance bushing and V-rings and lock ring of the
V-ring packing (33). For the arrangement of the packing
rings, see Figure 3-5.
Ö Insert the set of spring washers (34) into the provided hole.
Arrangement of the spring washers, see Figure 3-5.
Ö Insert the O-ring (30) into the inner groove of the stuffing box(27).
Ö Press the upper bearing bushing (29) into the bottom part ofthe stuffing box (27).
Ö Grease the stuffing box (27) on the thread.
Ö Screw the stuffing box (27) into the upper thread of the bonnet flange (2), the outer groove of the stuffing box is still visible.
Info
Do not screw the stuffing box (27) into the bonnet flange as far
as it will go.
Ö Clamp the bonnet flange (2) at the yoke in a vice with theflange opening facing upwards.
Ö Press the lower bearing bushing (29) into the recesses of thethreaded bushing (31).
Ö Insert the O-ring (35) into the corresponding recess in thethreaded bushing.
Ö Grease the threaded bushing (31) on the thread.
Ö Screw the threaded bushing (31) into the bonnet flange (2)as far as it will go.

− The only difference is that the bonnet flange described here
has no integrated yoke.
Ö Push the yoke (38) onto the bonnet flange and fasten with thegrooved nut (39).

3.5.3.4 Assembling the valve
Standard stuffing box
Ö Clamp the preassembled valve body, see Chapter 3.5.3.1, ina vice with the bonnet opening facing upwards.
Ö Place the preassembled bonnet flange, see Chapter 3.5.3.3,
onto the valve body carefully.
Info
Air connection (24) in the bonnet flange and type plate on thevalve body (1) point in the same direction.
Ö Screw the screws (36) into the valve body. Tighten the screws
evenly in a criss-cross pattern.
NOTE
Change the position of the plug by tightening the screws!
Ö Make sure that the position of the plug remains central.
Damage to the stem due to twisting!
Ö Before tightening the screw connection, pull the stem up as
far as it will go.

NOTE
Damage to the valve due to incorrect tightening torques!
Ö The permissible torques for assembly and for retightening theconnection of the bonnet flange can be found in Table 15-4
in Chapter “15.1.1 Tightening torques”.
Ö Tighten the stuffing box (27) after adjusting the valve.

NOTE
Damage to the threaded bushing due to improper assembly!
Ö The threaded bushing must not be inserted at a slanted angle
when screw it into the bonnet flange.
Ö Insert the spring washer (21), thrust washer (20) and O-ring(19) in the bonnet flange (2). For the arrangement of thecomponents, see Figure 3-5.

3-10

With optional adjustable stuffing box
Ö The final assembly of the valve takes place as already described in Chapter 3.5.3.4.
Ö Do not loosen then retighten the stuffing box (27), rather unscrew it completely and remove it from the valve.
Ö Clean the removed stuffing box to ensure it is free of grease.

EB 01a_EN
March 2023 edition
Subject to technical changes

Design and principle of operation

Ö Apply Loctite 668 onto the thread of the stuffing box (27).
Ö Screw the stuffing box (27) into the bonnet flange.
Info
Do not tighten the stuffing box, the distance between the collar of
the stuffing box and the bonnet flange must be 3 mm!

NOTE
Damage to the valve due to incorrect tightening torques!
Ö The permissible torques for assembly and for retightening theconnection of the bottom flange can be found in Table 15-1
in Chapter “15.1.1 Tightening torques”.

3.5.4.2 Assembling the stem unit
− When assembling the stem, bellows, plug and all other partsof the stem sealing in contact with media, only use water-freegrease (e.g. halocarbon grease).
Ö Grease the single-section stem (16) on the bottom thread.
Figure|3-6: Adjustable stuffing box

Ö Seal the stuffing box with a dot of red paint.

3.5.4

Assembling the ANSI valve, NPS4|to|6

3.5.4.1 Assembling the valve bodyÖ Place the valve body (1) with the cover-side flange on aclean, soft surface at working height so that the bearing areaof the seat is easy to reach.
Ö Clean the PTFE lining of the body with detergent.
Ö Lay the PTFE O-ring (3) into the groove of the body.
Tip
Depending on the temperature, it may be necessary to shrink the
O-ring with cold spray or by cooling it down in the refrigerator.
Ö Insert the seat (4) into the body.
Ö Press the spacer (5) into the seat (4) in the body.
NOTE
Reduction in flow rate due to improper assembly!
Ö Make sure that the passage opening in the spacer (5) aligns
with the inlet opening of the valve.
Ö The upper edge of the spacer must be flat with the sealing
surface of the housing flange.
Ö With a 5 mm drill bit, drill diagonally approx. 10 mm deep
into the spacer (5) from the sealing surface.
Ö Secure the spacer against twisting with a piece of PTFE cord(14) inserted into this borehole.
Ö Lay the PTFE washer (6) on the spacer in the body.
Ö Place the elastomer inlay (7) on the PTFE washer.
Ö Carefully place the bottom flange (10) on the body.
Ö Fit the washer (6) and inlay (7) centrally in the bottom flange.

Info
In some versions, the stem consists of three individual parts,
whereby the guide is preassembled by a snap ring with the stem.
Ö Screw the bellows (15) with a preassembled washer andbushing onto the greased thread of the stem (16).
Tip
Due to the sliding property of the PTFE, we recommend using an
emery cloth to prevent the bellows from sliding when screwing it
onto the stem.
Ö Grease the metal side of the bordered flange (17) to minimise rust.
Ö Slide the bordered flange (17) over the bellows (15) until it
stops.
Info
To make it easy to push on the plug stem, a small notch is madein the bellows to let air escape.
Ö Push the plug (13) onto the bellows (15).
Ö Secure the connection between the plug and bellows with a
PTFE cord (14) inserted as far as possible.
Ö Grease the groove of the stem thoroughly.

3.5.4.3 Assembling the bonnet flange− When assembling the bonnet flange and all other parts incontact with media, only use water-free grease (e.g. halocarbon grease).
Ö Before assembly, grease the bonnet flange (2) from the inside.
Ö Lightly screw in the support bolts (40) so they do not protrude
on the inside of the cover.
Ö For continued assembly, clamp the bonnet flange with thestem guide facing down in a vice.

Ö Insert the screws (11) and align using the nuts (12). Tighten
the screws evenly in a criss-cross pattern.

EB 01a_EN
March 2023 edition
Subject to technical changes

3-11Design and principle of operation

Figure|3-7: Cross-section of an ANSI valve, NPS4 ... 6

Table|3-4: Parts list

3-12

Item

Designation

Item

Designation

1

Valve body17

Bordered flange

2

Bonnet flange

18

Washer3

O-ring

22

Bushing

4

Seat

23

Grooved pin

5Spacer

24

Locking screw

6

Washer25

Washer

7

Inlay

26

Packing10

Bottom flange

27

Stuffing box

11

Screw/ stud bolt

28

Wiper ring

12

Nut

36

Screw

13

Plug

37

Nut

14

Cord

38

Yoke (not marked)

15

Bellows

39

Groove nut (not marked)

16

Stem

40

Support bolts

EB 01a_EN
March 2023 edition
Subject to technical changes

Design and principle of operation

NOTE
Damage to the bonnet flange due to improper handling!
Ö Do not damage the bonnet flange, especially the thread on
the stem end.
Ö Apply Loctite on the Glycodur bushings (22a and 22b).
Ö Insert the Glycodur bushing (22a) with a suitable pin as far
as possible into the stem guide.
Ö Insert the Glycodur bushings (22b) with a suitable pin so they
are flush with the inner surface of the cover.
Info
If the Glycodur bushings vary in length:First insert the shorter bushing (22a) followed by the longer bushing (22b)Ö Strike the grooved pin (23).
Ö Screw in the locking screw (24).

Ö Position the washer (25).
Ö Insert the packing rings (26) with a special pin into the cover.
NOTE
Improper seal due to incorrect positioning of the packing rings!
Ö Insert packing rings staggered so that the division of thepacking rings does not align.
Ö Press the wiper ring (28) into the stuffing box (27).
Ö Grease the stuffing box (27) and screw into the cover.
Ö Tighten the stuffing box by hand and loosen a half turnÖ Retighten the stuffing box.
NOTE
Damage to the packing due to improper assembly!
Ö Press the stuffing box packing in cleanly; the pack must notbulge through the stuffing box.

Ö Insert the washer (18) into the provided recess in the bonnet
flange.
Ö Insert the preassembled stem unit, see Chapter 3.5.4.2, in the
cover.

3.5.4.4 Assembling the valve

With optional adjustable stuffing box
Ö The final assembly of the valve takes place as describedabove.
Ö Do not loosen then retighten the stuffing box (27), rather unscrew it completely and remove it from the valve.
Ö Clean the removed stuffing box to ensure it is free of grease.

Standard stuffing box

Ö Apply Loctite 668 onto the thread of the stuffing box (27).

Ö Carefully place the preassembled valve body, see Chapter
3.5.4.1, on the preassembled bonnet flange, see Chapter
3.5.4.3.

Ö Screw the stuffing (27) into the bonnet flange.

Info
Air connection (24) in the bonnet flange and type plate on thevalve body (1) point in the same direction.

Info
Do not tighten the stuffing box, the distance between the collar of
the stuffing box and the bonnet flange must be 3 mm!

Ö Insert the screws (36) and align using the nuts (37). Tighten
the screws evenly in a criss-cross pattern.
NOTE
Change the position of the plug by tightening the screws!
Ö Make sure that the position of the plug remains central.
Damage to the plug, seat or guide due to clamping of the stem!
Ö Press on the stem (16) during the screwdriving process to test
its smooth movement.
Damage to the valve due to incorrect tightening torques!
Ö The permissible torques for assembly and for retightening theconnection of the bonnet flange can be found in Table 15-3
in Chapter “15.1.1 Tightening torques”.
Ö Tighten the support bolts (40), see Table 15-5 in Chapter“15.1.1 Tightening torques”.
Ö To continue the assembly, place the valve with the stem guidefacing up on an even work surface.

EB 01a_EN
March 2023 edition
Subject to technical changes

Figure|3-8: Adjustable stuffing box

Ö Seal the stuffing box with a dot of red paint.

3.5.5

Assembling the ANSI valve, NPS8

3.5.5.1 Assembling the valve bodyÖ Place the valve body (1) with the cover-side flange on aclean, soft surface at working height so that the bearing areaof the seat is easy to reach.

3-13

Design and principle of operation

Ö Clean the PTFE lining of the body with detergent.
Ö Lay the PTFE O-ring (3) into the groove of the body.
Tip
Depending on the temperature, it may be necessary to shrink the
O-ring with cold spray or by cooling it down in the refrigerator.
Ö Insert seat (4) into the recess of the spacer (5) and fix with PTFE cord (14).
Ö Insert spacer (5) with seat (4) into the body.
NOTE
Reduction in flow rate due to improper assembly!
Ö Make sure that the passage opening in the spacer (5) aligns
with the inlet opening of the valve.
Ö The upper edge of the spacer must be flat with the sealing
surface of the housing flange.
Ö With a 5 mm drill bit, drill diagonally approx. 10 mm deep
into the spacer (5) from the sealing surface.
Ö Secure the spacer against twisting with a piece of PTFE cord(14) inserted into this borehole.
Ö Lay the PTFE washer (6) on the spacer (5).
Ö Place the thrust washer (8) on the PTFE washer (6).
Ö Insert the spring washers (9). For the position of the spring
washers, see Figure 3-9.
Ö Carefully place the bottom flange (10) on the body.
Ö Fit the washer (6), thrust washer (8) and spring washers (9)centrally in the bottom flange.
Ö Tighten the screws (11) with the washer (43) in the valve
body. Tighten the screws evenly in a criss-cross pattern.
NOTE
Damage to the valve due to incorrect tightening torques!
Ö The permissible torques for assembly and for retightening theconnection of the bottom flange can be found in Table 15-2
in Chapter “15.1.1 Tightening torques”.

Info
To make it easy to push on the plug stem, a small notch is madein the bellows to let air escape.
Ö Push the plug (13) onto the bellows (15).
Ö Secure the connection between the plug and bellows with a
PTFE cord (14) inserted as far as possible.

3.5.5.3 Assembling the bonnet flange− When assembling the bonnet flange and all other parts incontact with media, only use water-free grease (e.g. halocarbon grease).
Ö Place the bonnet flange (2) on a clean surface at working
height so that the stem guide is easy to reach.
Ö Insert the distance bushing and V-rings and lock ring of the
V-ring packing (33). For the arrangement of the packing
rings, see Figure 3-9.
Ö Insert the set of spring washers (34) into the provided hole.
Arrangement of the spring washers, see Figure 3-9.
Ö Insert the O-ring (30) into the inner groove of the stuffing box(27).
Ö Press the upper bearing bushing (29) into the bottom part ofthe stuffing box (27).
Ö Grease the stuffing box (27) on the thread.
Ö Screw the stuffing box (27) into the upper thread of the bonnet flange (2), the outer groove of the stuffing box is still visible.
Info
Do not screw the stuffing box (27) into the bonnet flange as far
as it will go.
Ö Push the yoke (38) onto the bonnet flange and fasten with thegrooved nut (39).
Ö Clamp the bonnet flange (2) at the yoke in a vice with theflange opening facing upwards.
NOTE

3.5.5.2 Assembling the stem unit
− When assembling the stem, bellows, plug and all other partsof the stem sealing in contact with media, only use water-freegrease (e.g. halocarbon grease).

Damage to the bonnet flange due to improper handling!
Ö Do not damage the bonnet flange, especially the thread on
the stem end.

Ö The single-piece stem (16) is greased at the lower thread.

Ö Press the lower bearing bushing (41) into the recesses of theguide bushing (31).

Ö Screw the bellows (15) with a preassembled washer andbushing onto the greased thread of the stem (16).

Ö Insert the O-rings (35) and (42) into the corresponding recesses in the guide bushing.
Ö Grease the guide bushing (31) on the thread.

Tip
Due to the sliding property of the PTFE, we recommend using an
emery cloth to prevent the bellows from sliding when screwing it
onto the stem.

3-14

Ö Screw the guide bushing (31) into the bonnet flange (2) as
far as it will go.

EB 01a_EN
March 2023 edition
Subject to technical changes

Design and principle of operation

Figure|3-9: Cross-section of an ANSI valve, NPS8

Table|3-5: Parts list
Item

Designation

Item

Designation

1

Valve body21

Spring washer

2

Bonnet flange

24

Locking screw

3

O-ring27

Stuffing box

4

Seat

29

Bearing bushing

5

Spacer30

O-ring6

Washer31

Guide bushing

8

Thrust washer

33

V-ring packing

9Spring washer

34

Set of spring washers

10

Bottom flange

35

O-ring

11

Screw

36

Screw

13

Plug

38

Yoke

14

Cord

39

Grooved nut

15

Bellows

41

Bearing bushing

16

Stem

42

O-ring19

O-ring43

WasherEB 01a_EN
March 2023 edition
Subject to technical changes

3-15Design and principle of operation

NOTE
Damage to the guide bushing due to improper assembly!
Ö The guide bushing must not be inserted at a slanted angle
when screw it into the bonnet flange.

Info
Do not tighten the stuffing box, the distance between the collar of
the stuffing box and the bonnet flange must be 3 mm!

Ö Insert the spring washer (21), thrust washer (8) and O-ring(19) in the bonnet flange (2). For the arrangement of thecomponents, see Figure 3-9.
Ö Insert the preassembled stem unit, see Chapter 3.5.5.2, in the
cover and press the flange of the bellows into the thread of
the bonnet flange.
Ö Screw in the locking screw (24).

Figure|3-10:

Adjustable stuffing box

Ö Seal the stuffing box with a dot of red paint.

3.5.5.4 Assembling the valve
Standard stuffing box
Ö Clamp the preassembled valve body, see Chapter 3.5.5.1, ina vice with the bonnet flange opening facing upwards.
Ö Place the preassembled bonnet flange, see Chapter 3.5.5.3,
onto the valve body carefully.
Info
Air connection (24) in the bonnet flange and type plate on thevalve body (1) point in the same direction.
Ö Tighten the screws (36) with washers (43) in the valve body.
Tighten the screws evenly in a criss-cross pattern.
NOTE
Change the position of the plug by tightening the screws!
Ö Make sure that the position of the plug remains central.
Damage to the stem due to twisting!
Ö Before tightening the screw connection, pull the stem up as
far as it will go.
Damage to the valve due to incorrect tightening torques!
Ö The permissible torques for assembly and for retightening theconnection of the bonnet flange can be found in Table 15-4
in Chapter “15.1.1 Tightening torques”.
Ö Tighten the stuffing box (27) after adjusting the valve.

With optional adjustable stuffing box
Ö The final assembly of the valve takes place as described in
Chapter 3.5.5.4.
Ö Do not loosen then retighten the stuffing box (27), rather unscrew it completely and remove it from the valve.
Ö Clean the removed stuffing box to ensure it is free of grease.
Ö Apply Loctite 668 onto the thread of the stuffing box (27).
Ö Screw the stuffing box (27) into the bonnet flange.

3-16

EB 01a_EN
March 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 valve due to improper transport and storage!
Ö Valves with lining must be handled, transported and storedwith care.

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

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 thedelivery note).

4.2 Unpacking the valve
NOTE
Damage to the plastic lining!
Protect the lined valve surfaces in particular prior to/during
installation.
Ö Transport the valve in its original packaging to the installationsite and unpack it only there.
Perform the following steps before lifting and installing the valve:Ö Unpack the valve.
Ö Dispose of the packaging properly.
NOTE
Damage to the valve due to the ingress of foreign matter!
The protective caps on the valve inlet and outlet prevent foreign
matter from entering the valve and damaging it. Only remove theprotective caps prior to installation in the pipe.

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

4.3.1

Transporting

The valve can be transported using lifting equipment such as acrane or a forklift.
Ö Leave the valve on the pallet or in the transport container fortransport.
Ö Valves that weigh more than approx. 10 kg should betransported on a pallet (or supported similarly) (also to theinstallation site). The packaging should protect the scratchsensitive plastic lining of the valve against damage.
Ö Comply with the transport conditions.
Transport conditions
Ö Protect the valve against external influences, such as impacts.

4.3 Transporting and lifting the valve

Ö Do not damage the corrosion protection (paint, surface
coating). Repair damage immediately.
Ö Protect the valve against moisture and dirt.

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

4.3.2

Lifting

When installing the valve in the pipe, heavier valves can belifting using lifting equipment such as a crane or forklift.

EB 01a_EN
March 2023 edition
Subject to technical changes

4-1

Shipment and on-site transport

Figure|4-1: Schematic drawing of the lifting points on the 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 andtransport, 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.
Ö Avoid swinging and tipping the valve.

DANGER
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 andtransported safely.

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

Lifting the valve to DN|80

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

Ö 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.

Ö Also secure the valve to prevent it from tipping to the side.
Ö Make sure that in the case of valves and actuators with liftingeyes that the additional sling between the lifting eye and thesuspension element does not take on any load. This sling isused only to secure the load against turning over while lifting.
Before lifting the valve, pretension this sling so it is taut.

When doing so, ensure the safety, bearing capacity andlength of the lifting slings
Ö In the case of a actuator with a lifting eye: fasten additional
lifting slings to the lifting eye on the actuator and on thesuspension element.
Ö Lift the valve carefully. Check if the load lifting equipment
holds.

4-2

EB 01a_EN
March 2023 edition
Subject to technical changes

Shipment and on-site transport

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

Ö The valve must be stored in its protective packaging and/orwith the protective caps on the connection ends.
The packaging should protect the scratch-sensitive plastic
lining of the valve against damage.

Ö Remove the lifting slings.

Ö Valves that weigh more than approx. 10 kg should be stored
on a pallet (or supported similarly).

Lifting the valve from DN 100 upwards

Ö Valves are usually delivered in the fail-safe position. They
must be stored in the position in which they were delivered.
The actuating device must not be actuated.

Ö 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.

Ö Do not place any objects on the valve.
Ö Do not stack the valves.

Ö When doing so, ensure the safety, bearing capacity andlength of the lifting slings
Ö Secure the slings attached to the body against slipping using
a connector.
Ö In the case of a actuator with a lifting eye: fasten additional
lifting slings to the lifting eye on the actuator and on thesuspension element.
Ö Lift the valve carefully. Check if the load lifting equipment
holds.
Ö Move the valve at a constant speed to the installation site.
Ö Install the valve in the pipe, see chapter 5.4.
Ö After installation in the pipe: check that the flanges are firmly
tightened and that the valve holds in the pipe.
Ö Remove the lifting slings.

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

Info
PFEIFFER recommends checking the valve and the storage
conditions regularly during a longer storage period.
Ö In the case of storage prior to installation, the valve should
normally be stored in a closed room where it is protectedagainst harmful influences such as impacts, dirt or moisture.
PFEIFFER recommends a room temperature of 25°C ±15°C.
Ö In particular, the actuator and the ends of the valve to thepipe connection may not be damaged by mechanical or any
other influences.
Ö Prevent condensation in damp rooms. Use a desiccant orheater.

EB 01a_EN
March 2023 edition
Subject to technical changes

4-3Shipment and on-site transport

4-4

EB 01a_EN
March 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 valves. Observe
chapter “4.3 Transporting and lifting the valve” for transport to
the installation site.

5.1 Installation conditions

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).
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.

Operator level
The operator level for the valve is the front view on all operating
elements of the valve including the attachments from the 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 ofvalves in the pipe.
Install the valves such that there is low vibration and no mechanical stress. Observe the sections “Installation orientation” and“Support and mounting” in this chapter.
Install the valve so there is enough space to replace the actuatorand valve as well as to perform maintenance work.
Installation position
The valve can be installed in any installation position. PFEIFFER
recommends however to install the valve in general so that theactuator points up in a vertical position.
In the following versions the valve with the actuator must be installed pointing upwards:

5.2 Preparing for assembly
Valves with lining must be handled, transported and stored withcare, see Chapter “4 Shipment 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 valve is clean.
− The 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 typeplate, 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 valve.

− Nominal sizes from DN 100 / NPS4
− Valves with 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 installedvalve as well as the pipe.
NOTE
Damage to the valve due to improper support!
Ö Support the valve in the piping only at the body.
Ö Do not support at the end cap or bonnet flange.
Ö Support must be vibration-free.

EB 01a_EN
March 2023 edition
Subject to technical changes

5.3 Assembling the valve and actuator
PFEIFFER valves are supplied in working order. In individual cases, the actuator and 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 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 The travel torque, displacement and adjustment of the“OPEN” and “CLOSED” end stops must be adapted to thevalve.

5-1

Installation

WARNING

Table|5-1: Travel adjustment when installing SAMSON actuators(valve closed)

Danger and damage due to use of an electrical actuator!
Ö It must be made sure that the valve in the “CLOSED” position
is turned off by the signal of the torque switch.
Ö In the “OPEN” position, the valve must be turned off by thelimit switch.
Ö For further instructions, see the electrical actuator manual.

SamsonActuator

HNominal
FAIL CLOSE

HNominal
FAIL CLOSE

HNominal
FAIL OPEN

Danger and damage due to high external loads on an actuator
unit!
Actuators are not “stepladders”.
Ö Loads may not be applied to the actuators as they can damage or destroy the valve.
Danger and damage due to heavy actuator units!
Actuators that are heavier than the weight of the valve can posea danger to the user and cause damage to the pipe system.
Ö These actuators must be supported if they generate a bending stress on the valve due to their size and/or installation situation.

120

75

78

78

175v2

75

78

78

240

75

78

78

350v2

75

78

85

355v2

75

78

85

700

90

95

104

750v2

90

93

98

1400

165

169

185

2800

315

325

355

Table|5-2: Preferred combinations of the valve BR 01a with
SAMSON actuators type 3277 and 3271
Nominalsize

NOTE
Damage to the valve due to incorrect travel adjustment!
If a SAMSON actuator is retrofitted, a preadjustment of the travelis necessary:Ö For details about travel adjustment, see Chapter “5.3.1 Travel
adjustment with separately supplied SAMSON actuator”.
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.

5.3.1

Travel adjustment with separately supplied SAMSON actuator

With a separately supplied valve and SAMSON actuator, the dimension “H” from the upper edge of the coupling nut to the upper edge of the yoke must be adjusted according to the table andis checked during assembly.

SAMSONactuator

DN

15

25

40

50

80

100 150 200

NPS

½

1

1½

2

3

4

6

120 cm2•

175v2 cm2•••

240 cm2•••

350v2 cm2•••

355v2 cm2

•

•

•
•

•

•

•

•

•

•

•

700 cm2
750v2 cm2
1400 cm2•

2800 cm8••2

5.3.1.1 Actuator travel limit
In some cases, a travel limit is required for the actuator. Details
about the travel limit can be found in the corresponding actuator
documentation.
For SAMSON actuators:− Pneumatic actuator type 3271, actuator surface: 120 cm²,
see the Installation and Operating Manual  EB 8310-1,
Chapter “6.2 Setting travel limits”.
− Pneumatic actuator type 3271, actuator surface: 140060 cm², see the Installation and Operating Manual EB 8310-3, Chapter “6.2 Setting travel limits”.
− Pneumatic actuator type 3271 and type 3277, actuator surface: 355v2 cm², see the Installation and Operating Manual EB 8310-4, Chapter “6.2 Travel limits”.
− Pneumatic actuator type 3271 and type 3277, actuator surfaces: 175v2, 350v2 and 750v2 cm², see the Installation andOperating Manual  EB 8310-5, Chapter “6.2 Travel limits”.
− Pneumatic actuator type 3271 and type 3277, actuator surfaces: 240, 350 and 700 cm², see the Installation and Operating Manual  EB 8310-6, Chapter “6.2 Travel limits”.

Figure|5-1: Travel adjustment

5-2− Pneumatic actuator type 3271, actuator surface: 2800 cm²,
see the Installation and Operating Manual  EB 8310-7,
Chapter “6.1.3 Adapting the travel range”.

EB 01a_EN
March 2023 edition
Subject to technical changes

Installation

Details about the other actuators can also be found in the corresponding actuator documentation.
The dimensions provided in Table 5-3 reach a suitable pretensionthat implements the sealing between the seat and the plug.
Table|5-3: Actual travel
Travel 15 mm
Travel 30 mm

Actual travel 16 to 17 mm
Actual travel 31 to 32 mm

5.4 Installing the valve in the pipe
5.4.1

Ö The connection ends of the pipes must align with the 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 must match the control data. See the type plate(s) on the actuator unit.
Ö Prior to installation, the valve and the connected pipe must be
carefully cleaned of any contamination, in particular solid
foreign matter.
Ö The sealing surfaces on the flange connection and the utilizedflange seals must in particular be free of all contamination
during installation.
Ö An arrow is marked on the body. The direction of the arrowmust correspond to the direction of flow in the pipe.

GeneralInfo

NOTE
Damage to the lined valve surface due to improper transport
and installation!
Before and during installation, the lined surfaces can be damaged and must be specifically protected.
Ö Transport the valve in its original packaging to the installationsite and unpack it only there.
Ö Handle the valve with care and observe the instructions forthe flange connection.
Damage to the plastic lined surfaces on the body due toimproper installation!
Ö The use of PTFE flange seals is recommended.
Ö The counterflanges must have smooth sealing surfaces.
Ö Other shapes must be agreed upon with PFEIFFER.
Ö Inspect the valve and actuator for transport damage. Damaged valves or actuators may not be installed.
Ö A functional test is to be carried out at the beginning of installation only for manually-operated valves: The valve mustclose and open correctly. Detected malfunctions must be fixed
before commissioning. See also chapter 8 “Malfunction”.
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 valve may be installed whose permissible pressure/temperature range is not sufficient for the operating conditions.
Ö The max. permissible limits of use are marked on the valve,
see Chapter “2 Markings on the device”.
Ö The permissible range is defined in Chapter “1 Safety instructions and safety measures”.
Ö Make sure that only valves are installed whose pressure classes, connection type (flow rate), type of lining and connection
dimensions match the conditions of use. See the corresponding marking on the valve.

EB 01a_EN
March 2023 edition
Subject to technical changes

It may be necessary in special cases for a valve to be tightagainst the direction of flow.
For installation in these special cases, contact PFEIFFER as this
could lead to an excessive strain on the bellows, seat, plug, etc.
Ö When pushing in the valve (and the flange seals) into an already assembled pipe, the distance between the pipe ends
must be measured such that all sealing surfaces (and seals)
remain undamaged.
NOTE
Tightening the flange connections.
The flange connections must be tightened in at least three steps at
the same time and in a criss-cross pattern with the torques indicated in Table 15-7 or Table 15-8 in Chapter “15.1.1 Tightening
torques”.
Torque wrenches must be used to ensure that the torque isreached but not exceeded.
Tightening the body screws.
As the PTFE plastic sealing surfaces tend to flow, it is strongly recommended, after a long storage period of the lined valve, toretighten the body screws after installation using the tightening
torques according to Table 15-1 to Table 15-4 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.
Ö When installing peripheral devices, make sure that they canbe operated from the working area of operating personnel.

5-3Installation

5.4.2

Installing the valve

Ö Close the valve in the pipe for the duration of the installation.
Ö Remove the protective caps on the valve openings prior to installation.
Ö Lift the valve with suitable lifting equipment at the installation
site, see chapter “4.3 Transporting and lifting the valve”.
When doing so observe the flow direction of the valve. An
arrow on the valve indicates the flow direction.

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 Malfunction”

Ö Make sure that the correct flange seals are used.
Ö Screw the pipe together with the valve without tension.
Ö After installing the valve, open it slowly in the pipe.
NOTE
Damage to the valve due to a sudden pressure increase andresulting high flow speed!
Open the valve slowly in the pipe during commissioning.
Ö Check the correct function of the valve.

5.5.2

Pressure test of the pipe section

The pressure test was already performed on the valves by
PFEIFFER. Observe the following for the pressure test of a pipe
section with installed 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:–

Retract the plug in order to open the valve.

–

Valve open: The test pressure may not exceed the value
1.5 x PN (according to the type plate) or the marked test
pressure PT.

5.5 Checking the assembled valve

If a valve leaks, observe chapter “8 Malfunction”.

5.5.1

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.

Functional check

WARNING
Danger of injury due to pressurised components and escaping
medium!
− Do not loosen the test connection while the valve is pressurised.
Danger of crushing due to moving actuator stem and stem!
− Do not reach into the yoke as long as the pneumatic power isconnected to the actuator.
− Before working on the valve, interrupt and lock pneumatic energy and the control signal.
− Do not allow the jamming of objects in the yoke to hinder theoperation of the stem and actuator stem.
− If the actuator stem and stem are blocked (e.g. due to “seizure”
if not actuated for a long period of time”), release the residualenergy of the actuator (spring tension) before releasing theblockage, see the corresponding actuator documentation.
Danger of injury due to escaping exhaust air!
During operation, when regulating or when opening and closing
the valve, exhaust air can escape, for example from the actuator.
Ö Wear eye protection when working near the valve.
Ö At the end of installation, perform a functional test with thecontrol signals:

5.5.3

Travel movement

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

5.5.4

Fail-safe position

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

The valve must close and open correctly according to the control commands. Detected malfunctions must be fixed before
commissioning, see Chapter “8 Malfunction”.

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March 2023 edition
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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
Danger of burning due to hot or cold components and pipe!
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 If required, retighten the screw connection of the body parts,
see Table 15-1 to Table 15-4 in Chapter “15.1.1 Tightening
torques”.
Ö Open the valve slowly in the pipe. Opening slowly prevents a
sudden increase in pressure and a resulting high flow speed
that damages the valve.
Ö Check the correct function of the valve.

Danger of injury due to pressurised components and escaping
medium!
Ö Do not loosen the test connection while the valve is pressurised.
Danger of crushing due to moving actuator stem and stem!
Ö Do not reach into the yoke as long as the pneumatic power isconnected to the actuator.
Ö Before working on the valve, interrupt and lock pneumaticenergy and the control signal.
Ö Do not allow the jamming of objects in the yoke to hinder theoperation of the stem and actuator stem.
Ö If the actuator stem and stem are blocked (e.g. due to “seizure” if not actuated for a long period of time”), release theresidual energy of the actuator (spring tension) before releasing the blockage, see the corresponding actuator documentation.
Danger of injury due to escaping exhaust air!
During operation, when regulating or when opening and closing
the valve, exhaust air can escape, for example from the actuator.
Ö Wear eye protection when working near the valve

Ensure the following conditions prior to commissioning/recommissioning:− The valve is installed properly in the pipe, see Chapter “5 Installation”.
− The leak and function tests have been completed successfully,
see Chapter “5.5 Testing the assembled valve”.
− No residual water is present in the flow section of the valve inorder to prevent a possible reaction with the medium.
− The current conditions in the concerned plant section correspond to the design of the valve, see Intended use in Chapter“1 Safety instructions and safety measures”.
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 valve with the corresponding tightening torques, see Table 15-7 or Table 15-8
in Chapter “15.1.1 Tightening torque”.

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Start-up

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Operation

7

Operation

As soon as the commissioning/recommissioning work iscomplete, see Chapter “6 Start-up”, the valve is ready for
operation.
WARNING− Valves with a bellows generally have a test connection(e.g. ¼“) between the bellows and the outer stem sealing.
This makes it possible to check if the bellows is not damaged.
− Upon customer request, these valves can also be equippedwithout a test connection.
Ö If a valve leaks, observe chapter “8 Malfunktion”.

Danger of burning due to hot or cold components and pipe!
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 test connection while the valve ispressurised.
Danger of crushing due to moving actuator stem and stem!
Ö Do not reach into the yoke as long as the pneumatic power isconnected to the actuator.
Ö Before working on the valve, interrupt and lock pneumaticenergy and the control signal.
Ö Do not allow the jamming of objects in the yoke to hinder theoperation of the stem and actuator stem.
Ö If the actuator stem and stem 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.
Danger of injury due to escaping exhaust air!
During operation, when regulating or when opening and closing
the valve, exhaust air can escape, for example from the actuator.
Ö Wear eye protection when working near the valve.

Observe the following points during operation:Ö The PTFE plastic sealing surfaces tend to flow. After commissioning and reaching the operating temperature, tighten all
flange connections between the pipe and valve with the corresponding tightening torques, see Table 15-7 or Table 15-8
in Chapter “15.1.1 Tightening torque”.
Ö If required, retighten the screw connection of the body parts,
see Table 15-1 to Table 15-4 in Chapter “15.1.1 Tightening
torques”.
Ö The valve/actuator unit must be actuated with the control
signals.
− Valves that were delivered from the factory with an actuatorare 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.

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March 2023 edition
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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

MeasureLeaks in the pipe connection

The flange connection of thelined 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 15-7 or Table 15-8 in Chapter “15.1.1 Tightening torques”.
If necessary, increase the torque 20%.

The flange connection is still
leaky after retightening

Loosen the flange connection and remove the valve, see chapter “1Safety 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 valve together with its flange seal.
Check the flange seals. If the seals are damaged, replace them.

Leaks in the body parts

The bonnet flange connection Retighten the flange connection with the respective tightening torque,loosenedsee Table 15-1 to Table 15-4 in Chapter “15.1.1 Tightening torques”.
Body parts untight after
retightening

Increased medium flow ratewith valved closed

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

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

Repairs are necessary.
Remove the 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 stem sealing

Medium escapes from the test Repairs are necessary.
connection
Remove the valve, see chapter “1 Safety instructions and safetymeasures”.
Disassemble the valve and replace the bellows or diaphragm.
Request spare parts from PFEIFFER, see Chapter “15.2 Spare parts”.
For the required repair instructions, see Chapter “12 Repairs”.

(Additional possible causes
and measures on thefollowing page)EB 01a_EN
March 2023 edition
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With the option “adjustablestuffing box”, medium
escapes from the stuffing box

This version does not have a test connection on the bonnet. The
backup packing is leaky in the delivered state above a gas pressure of
approx. 2 bar. This is obtained with an adjustment path of 3 mm withthe red paint sealed backup packing.

8-1

Malfunction

Type of fault

Possible cause

MeasureLeaks in the stem sealing

Medium escapes from the
stuffing box

If the valve on the stuffing box is leaky, the bellows is defective.
DANGER
Danger of injury due to hazardous media!
It must be kept in mind that the media is usually hazardous.
Ö All necessary safety measures must be taken to prevent possible
accidents.
Tighten the sealed stuffing box.
WARNING
Danger due to missing primary sealing!
The valve is tight again. Sealing by the stuffing box should only takeplace for a short period, as there is no primary sealing.
Ö Repair the valve as quickly as possible.
Remove the valve, see chapter “1 Safety instructions and safetymeasures”.
Disassemble the valve and replace the bellows. Check the bonnet
flange for corrosion caused by the medium and replace if necessary.
Request spare parts from PFEIFFER, see Chapter “15.2 Spare parts”.
For the required repair instructions, see Chapter “12 Repairs”.

Malfunction.

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”.

The valve is damaged

Repairs are necessary.
Remove the 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 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 PFA lining is not
sufficiently resistant for the medium, parts must be selected
made of a suitable material.

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Malfunction

8.2 Carrying out emergency measures
In the case of a power supply failure, the 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 valve fault:− Close the valves upstream and downstream of the valve sothat no medium flows through the 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 Start-up”.

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March 2023 edition
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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 valve:− Installation and operating manual for the installed actuator,e.g  EB 8310-X for actuators type 3271 and type 3277 or
the corresponding actuator documentation of othermanufacturers.
WARNING
Danger of burning due to hot or cold components and pipe!
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 test connection while the valve is pressurised.
Danger of crushing due to moving actuator stem and stem!
Ö Do not reach into the yoke as long as the pneumatic power isconnected to the actuator.
Ö Before working on the valve, interrupt and lock pneumaticenergy and the control signal.
Ö Do not allow the jamming of objects in the yoke to hinder theoperation of the stem and actuator stem.
Ö If the actuator stem and stem 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.
Danger of injury due to escaping exhaust air!
During operation, when regulating or when opening and closing
the valve, exhaust air can escape, for example from the actuator.
Ö Wear eye protection when working near the valve.
Danger of injury due to prestressed springs!
Actuators with preloaded actuator springs are pressurised. Theseactuators can be identified by the elongated screws on the bottom of the actuator.
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 valve!
When working on the valve, residual medium can escape and,depending on the medium properties, cause injuries (e.g.
scalding, chemical burns).
Ö Wear protective garments, protective gloves and eye
protection.

EB 01a_EN
March 2023 edition
Subject to technical changes

NOTE
Damage to the valve due to excessively high or low tightening
torques!
The valve components must be tightened with specific torques.
Excessively tightened components are subject to increased wear.
Insufficiently tightened components can cause leakage.
Ö Observe the tightening torques, see Table 15-1 to Table 15-4
in Chapter “15.1.1 Tightening torques”.
Damage to the valve due to unsuitable tools!
Ö Only use tools approved by PFEIFFER, see Chapter “15.1.3
Tools”.
Damage to the valve due to unsuitable lubricants!
Ö Only use lubricants approved by PFEIFFER, see Chapter“15.1.2 Lubricants”.

Info
The valve was checked by PFEIFFER prior to delivery.
− Certain test results certified by PFEIFFER are no longer valid
when disassembling the valve. This includes the test for seatleakage 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.

9.1 Periodic tests
Ö Depending on the conditions of use, the 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
If present, check the test connection and bellows sealing
for tightness.
WARNING! Danger of injury
due to pressurised components
and escaping medium! Do notloosen the test connection
while the valve is pressurised.

Measures in the case of a negative
test result
Decommission the valve, see chapter“10 Decommissioning”.
Contact the After Sales Service at
PFEIFFER to repair the bellows, Seechapter “12 Repairs“.

9-1Servicing

Measures in the case of a negative
test result

9.3 Ordering spare parts and consumables

Check the lifting movement of Tighten the packing correctly.
the actuator stem and stem for If the actuator stem and stem arelinear, smooth movement.
blocked, remove the blockage.
WARNING! If the actuator stem andstem are blocked (e.g. due to “seizure”
if not actuated for a long period oftime) they can release unexpectedly
and move uncontrolled. This can leadto crushing if reaching into them.
Before trying to release a blockage ofthe actuator stem and stem, interrupt
and lock the pneumatic energy and thecontrol signal. Release the residual energy of the actuator (spring tension orcompressed air reservoir) before releasing the blockage, see the corresponding actuator documentation.

Information about spare parts, lubricants and tools can be received from the After Sales Service at PFEIFFER.

Test

Spare parts
Information on spare parts can be found in Chapter “15.2 Spareparts“.

If possible, check the fail-safe Decommission the valve, see chapter
position of the valve by briefly “10 Decommissioning”. Then deterinterrupting the power supply. mine the cause and remedy it, see
Chapter “8 Malfunctions“.

9.2 Maintenance workÖ The valve must be prepared before all maintenance work, see
Chapter 12 “Repairs”.
Ö After all maintenance work, the valve must be checked prior
to recommissioning, see Chapter “5.5 Checking the mounted
valve”.

9.2.1

Replacing the seat and plug

NOTE
Damage to the sealing surfaces on the seat and plug due to incorrect maintenance!
Ö Always replace the seat and plug together.
Ö Check the condition of the plug and seat.
Ö Remove the seat (4) as described in Chapter “12.4 Replacing
the seat”. Check the seat as well as all plastic parts for damage and if in doubt replace them.
Ö Remove the plug (14) as described in Chapter “12.5 Replacing the plug”. Check the seat, plug as well as all plastic partsfor damage and if in doubt replace them.

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March 2023 edition
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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!
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 test connection while the valve ispressurised.
Danger of crushing due to moving actuator stem and stem!
Ö Do not reach into the yoke as long as the pneumatic power isconnected to the actuator.
Ö Before working on the valve, interrupt and lock pneumaticenergy and the control signal.
Ö Do not allow the jamming of objects in the yoke to hinder theoperation of the stem and actuator stem.
Ö If the actuator stem and stem 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.
Danger of injury due to escaping exhaust air!
During operation, when regulating or when opening and closing
the valve, exhaust air can escape, for example from the actuator.
Ö Wear eye protection when working near the valve.
Danger of injury due to residual medium in the valve!
When working on the valve, residual medium can escape and,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 test connection while the valve ispressurised.
To decommission the valve for maintenance and repair work or
for disassembly, perform the following steps:
Ö Close the valves upstream and downstream of the valve sothat no medium flows through the valve.
Ö Empty the pipe and valve completely.
Ö Shut off the pneumatic power and lock it, to depressurise theactuator.
Ö Let the pipe and valve components cool down or warm up.

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Removal

11 Removal

11.1 Removing the 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 valve from the pipe, see Chapter “4.3 Transporting and lifting the valve”.

WARNING
Danger of burning due to hot or cold components and pipe!
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 stem and stem!
Ö Do not reach into the yoke as long as the pneumatic power isconnected to the actuator.
Ö Before working on the valve, interrupt and lock pneumaticenergy and the control signal.
Ö Do not allow the jamming of objects in the yoke to hinder theoperation of the stem and actuator stem.
Ö If the actuator stem and stem are blocked (e.g. due to “seizure” if not actuated for a long period of time”), release theresidual energy of the actuator (spring tension) before releasing the blockage, see the corresponding actuator documentation.
Danger of injury due to residual medium in the valve!
When working on the valve, residual medium can escape and,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 test connection while the valve is pressurised.

WARNING
If a used valve is sent to PFEIFFER 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 the contamination of PFEIFFER valves and components”.

11.2 Disassembling the actuator
See the corresponding actuator documentation.

Danger of injury due to prestressed springs!
Ö SAMSON actuators with preloaded actuator springs arepressurised. These actuators can be identified by the elongated screws on the bottom of the actuator.
Ö Before working on the actuator, release the compression fromthe preloaded springs.
Prior to disassembly, make sure that the following conditions aremet:− The valve is decommissioned, see chapter “10 Decommissioning”.

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Repairs

12 Repairs
If the valve no longer works properly or if it does not work at all,it is defective and must be repaired or replaced.
WARNING
Danger due to defective lining!
Ö The lining may not be repaired!

Ö Release the stuffing box (27) and screw it out of the bonnet
flange.
Ö Remove the graphite packing (26) or the PFFE V-ring packing(33), check for damage and if in doubt replace it.
Ö Remove the bellows (15) as described in Chapter “12.1 Replacing the bellows”. Check the bellows as well as all plastic
parts for damage and if in doubt replace them also.
Ö Assemble the valve as described in Chapter 3.5.1 and Chapter 3.5.2.

NOTE
Damage to the 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.

12.3 Adjusting the stuffing box (option)
Stem unit

In special cases, certain maintenance and repair work may be
performed.

Backup packing

Packing

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 valves. For decommissioning and disassembly, observe Chapter “10 Decommissioning” and Chapter “11 Disassembly”.

Figure|12-1:

Version with adjustable backup packing

This version does not have a test connection on the bonnet.

12.1 Replacing the bellows
If a leak is found in the test connection (24), the bellows (15) is
defective.

Ö The stuffing box− is not tight in the delivered state above a gas pressure of
approx. 2 bar− is glued in place with Loctite 668

Ö Check the condition of the bellows.

− is sealed with red paint as a visual marking

Disassemble the valve for the removal of the bellows. For thispurpose, observe Chapter “1 Safety instructions and safetymeasures”.

− adjustment YES/NOÖ Clamp the assembled valve with the bonnet flange facing up
in a vice.
Ö Release the screws (36) and, depending on the design, thenuts (37).
Ö Carefully lift the bonnet flange up off the valve body andplace it on a clean, even surface.
Ö Check the bellows as well as all plastic parts for damage andif in doubt replace them.
Ö Assemble the valve as described in Chapter 3.5.1 and Chapter 3.5.2.

12.2 Replacing the bellows and the packing
If the stuffing box is not tight, the packing and the bellows can be
defective.

− can be tightened further approx. 3 mm and is then gas
tight up to 16 bar.
Ö The glued connection− is constantly stuck and afterwards can be tightened
without problems with a tool.
− is designed for a temperature range of -10 to +200°C
Ö If the valve on the stuffing box is not tight, the bellows are defective.
DANGER
Danger due to a leak in the stuffing box!
Ö All necessary safety measures must be taken to prevent possible accidents:
Ö It must be kept in mind that the media is usually hazardous

Ö Check the condition of the packing and the bellows.
Disassemble the valve for the removal of the stuffing box and thebellows. For this purpose, observe Chapter “1 Safety instructions
and safety measures”.
Ö Place the valve with the stem guide facing up on an evenwork surface.

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12-1Repairs

Figure|12-2:

12-2

Section diagram of valve BR 01a

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March 2023 edition
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Repairs

Table|12-1: Parts list
Item

Designation

Item

Designation

Item

Designation

Item

Designation

1

Valve body

12

Nut

23

Grooved pin

34

Set of spring washers

2

Bonnet flange

13

Plug

24

Screw plug

35

O-ring3

O-ring

14

Cord

25

Washer

36

Screw

4

Seat

15

Bellows

26

Packing

37

Nut

5

Spacer

16

Stem

27

Stuffing box

38

Yoke

6

Washer17

Bordered flange

28

Wiper ring

39

Grooved nut

7

Inlay

18

Washer29

Bearing bushing40

Support bolt

8

Thrust washer

19

O-ring30

O-ring41

Bearing bushing9

Spring washer

20

Thrust washer

31

Guide bushing

42

O-ring10

Bottom flange

21

Spring washer

32

Distance bushing

43

Washer11

Screw/ stud bolt

22

Bushing33

V-ring packing

Ö Tighten the stuffing box.
Info
The valve is tight again but must be repaired as soon as possible,
as there is no primary sealing and the stuffing box should besealed only for a short period.
Ö The repair must be made as described in Chapter “12.1 Replacing the bellows”.

12.5 Replacing the plug
If a leak is found in the flow, the seat and plug can be defective.
Ö Check the condition of the plug.
Disassemble the valve for the removal of the bellows. For thispurpose, observe Chapter “1 Safety instructions and safetymeasures”.
Ö Clamp the assembled valve with the bonnet flange facing up
in a vice.
Ö Release the screws (36) and, depending on the design, thenuts (37).

12.4 Replacing the seat
If a leak is found in the flow, the seat and plug can be defective.

Ö Carefully lift the bonnet flange up off the valve body andplace it on a clean, even surface.

Ö Check the condition of the seat.

Ö Check the plug, bellows as well as all plastic parts for damage and if in doubt replace them.

Disassemble the valve for the removal of the seat. For thispurpose, observe Chapter “1 Safety instructions and safetymeasures”.

Ö Assemble the valve as described in Chapter 3.5.1 andChapter 3.5.2.

Ö Clamp the valve with the stem guide facing down in a vice.
Ö Release the screws (11) and, depending on the design, thenuts (12).

12.6 Additional repairsÖ Remove the bottom flange (10).

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

Ö Remove the washer (6) and inlay (7), thrust washer (8) andspring washer (9), if applicable.
Ö Undo and remove the spacer (5).
Ö Remove the seat (4).
Ö Check the seat as well as all plastic parts for damage and if
in doubt replace them.
Ö Assemble the valve as described in Chapter 3.5.1 and Chapter 3.5.2.

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12-3Repairs

12.7 Sending devices to PFEIFFER
Defective valves can be sent to PFEIFFER for repair.
Proceed as follows to send devices:
WARNING
Danger due to a contaminated valve!
Ö When returning a used valve to the manufacturer for service,decontaminate the 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 contamination data in
the form FM 8.7-6 “Declaration regarding the contamination of
PFEIFFER valves and components”.
Ö Include the following information for returns:− Manufacturer number− Valve type
− Article number− Nominal size and version of the control valve− Manual valve / automated valve− Medium (designation and consistency)− Medium pressure and temperature− Flow rate in m³/h
− Bench range of the actuator (e.g. 0.2 to 1 bar)
− 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.

12-4

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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 01a_EN
March 2023 edition
Subject to technical changes

13-1Disposal

13-2

EB 01a_EN
March 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 valve BR 01a,
see page 14-4.
− Declaration of conformity for partly completed machinery
according to Machinery Directive 2006/42/EC for valve
BR 01a, see page 14-5.
The printed certificates correspond to the status at the time ofprinting. Further optional certificates are available upon request.

EB 01a_EN
March 2023 edition
Subject to technical changes

14-1

Certificates

14-2

EB 01a_EN
March 2023 edition
Subject to technical changes

Certificates

EB 01a_EN
March 2023 edition
Subject to technical changes

14-3Certificates

14-4

EB 01a_EN
March 2023 edition
Subject to technical changes

Certificates

EB 01a_EN
March 2023 edition
Subject to technical changes

14-5

Certificates

14-6

EB 01a_EN
March 2023 edition
Subject to technical changes

Annex

Table|15-5: Tightening values of the support bolts on the DIN
version

15 Annex
15.1 Tightening torques, lubricant and tools

DN [mm]

80

100

150

MA [Nm]

20

20

20

Table|15-6: Tightening values of the support bolts on the ANSI
version15.1.1 Tightening torques
Info− All tightening torques are indicated in Nm.
− Tightening torque tolerance: ±10%.
− After long operating times or use at temperatures above 80°C,
the breakaway torque can be considerably higher.

NPS [inch]

46

MA [Nm]20

20

15.1.1.4 Flange connections
Table|15-7: Tightening values for the DIN flange connections

15.1.1.1 Bottom flange
For the connection of the bottom flange (10) with the valve body,the screw connections are tightened in a criss-cross pattern withthe tightening torques indicated below.

DN [mm]

25

40

50

80

100

150

MA [Nm]

25

50

60

65

75

140

200

Table|15-8: Tightening values for the ANSI flange connections
NPS [inch]

1

1½

2

3

4

6

MA [Nm]

15

30

40

65

50

100

Table|15-1: Tightening values for the bottom flange screw
connections for DIN version
DN [mm]

25

40

50

80

100

150

MA [Nm]

10

15

25

30

30

40

200

Table|15-9: Recommended lubricant
Table|15-2: Tightening values for the bottom flange screw
connections for ANSI version
NPS [inch]

1

1½

2

3

4

6

MA [Nm]

50

50

50

50

30

40

15.1.2 Lubricant

815.1.1.2 Bonnet flange

Use

Temperature range

Lubricant-10 ... +200°C

Screws and nuts

Heavy-duty grease paste (e.g.
Gleitmo 805, manufacturer
Fuchs)
Not suitable for grease-freevalves or for use with oxygen!

-10 ... +200°C

Stem sealing andparts in contact
with media

Water-free grease, e.g. halocarbon TM

For the connection of the bonnet flange (2) with the valve body,the screw connections are tightened in a criss-cross pattern withthe tightening torques indicated below.

15.1.3 Tools

Table|15-3: Tightening values for the bonnet flange screw
connections for DIN version
DN [mm]

25

40

50

80

100

150

MA [Nm]

45

45

45

80

80

130

200

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

8

15.2 Spare parts

Table|15-4: Tightening values for the bonnet flange screw
connections for ANSI version
NPS [inch]

1

1½

2

3

4

6

MA [Nm]

45

45

45

80

80

130

15.1.1.3 Support bolts
To pretension the flared flange, the support bolts (40) are tightened alternately and evenly according to the following torques.

PFEIFFER recommends spare part sets for “Commissioning” andfor “2-year operation”, see Chapter:− „15.2.1 Spare parts for DIN-Valves, DN 25 ... 50“− „15.2.2 Spare parts for DIN-Valves, DN 80 ... 150“
− „15.2.3 Spare parts for DIN-Valves, DN 200“− „15.2.4 Spare parts for ANSI-Valves, NPS1 ... 3 and DINValves, DN 25 ... 80 [Edition 2022]“ and DIN-Valves, DN
25 ... 80 [Edition 2022]− „15.2.5 Spare parts for ANSI-Valves, NPS4 ... 6“− „15.2.6 Spare parts for ANSI-Valves, NPS8“

EB 01a_EN
March 2023 edition
Subject to technical change

15-1Annex15.2.1 Spare parts for DIN-Valves, DN 25 ... 50

Figure|15-1:

15-2

Exploded drawing of a DIN-Valve, DN 25 ... 50

EB 01a_EN
March 2023 edition
Subject to technical changes

Annex

Table|15-10: Recommended spare parts for a DIN-Valve, DN 25 ... 50
In the spare parts set Included in the set of In the spare parts forfor commissioningseals
2 year operation

Item

Designation

Material

1

Valve body

EN-JS 1049 / PTFE

2

Bonnet flange

EN-JS 1049

3

O-ring

PTFE

4

Seat

PTFE

5

SpacerPTFE

6

Washer

PTFE

•

•

7

Inlay

Uniseal 3400

•

•

10

Bottom flange

EN-JS 1049

11

Screw / Stud bolt

A2-70

12

Nut

A2-70

13

Plug

PTFE

14

Cord

PTFE

15

Bellows

PTFE

16

Stem

1.4571

18

WasherUniseal 3400

•

•

22

Bushing

Glycodur F

•

•

23

Grooved pin

1.4301••24

Locking screw

Steel galvanized

•

•

25

Washer

1.4571••

26

Packing

PTFE-Graphite

•

•

27

Stuffing box

1.430128

Wiper ring

Buna

•

•

36

Screw

A2-70

37

Nut

A2-70

EB 01a_EN
March 2023 edition
Subject to technical change

•

•
•

•
•

•

•
•
•

15-3

Annex15.2.2 Spare parts for DIN-Valves, DN 80 ... 150

Figure|15-2:

15-4

Exploded drawing of a DIN-Valve, DN 80 ... 150

EB 01a_EN
March 2023 edition
Subject to technical changes

Annex

Table|15-11: Recommended spare parts for a DIN-Valve, DN 80 ... 150
In the spare parts set Included in the set of In the spare parts forfor commissioningseals
2 year operation

Item

Designation

Material

1

Valve body

EN-JS 1049 / PTFE

2

Bonnet flange

EN-JS 1049

3

O-ring

PTFE

4

Seat

PTFE

5

SpacerPTFE

6

Washer

PTFE

•

•

7

Inlay

Uniseal 3400

•

•

10

Bottom flange

EN-JS 1049

11

Screw / Stud bolt

A2-70

12

Nut

A2-70

13

Plug

PTFE

14

Cord

PTFE

15

Bellows

PTFE

16

Stem

1.4571

17

Bordered flange

St 37 / PTFE

•

•

18

WasherUniseal 3400

•

•

22

Bushing

Glycodur F

•

•

23

Grooved pin

1.4301••24

Locking screw

Steel galvanized

•

•

25

Washer

1.4571••

26

Packing

PTFE-Graphit

•

•

27

Stuffing box

1.430128

Wiper ring

Buna

•

•

36

Screw

A2-70

37

Nut

A2-70

40

Screw

A2-70

EB 01a_EN
March 2023 edition
Subject to technical change

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15-5

Annex15.2.3 Spare parts for DIN-Valves, DN 200

Figure|15-3:

15-6

Exploded drawing of a DIN-Valve, DN 200

EB 01a_EN
March 2023 edition
Subject to technical changes

Annex

Table|15-12: Recommended spare parts for a DIN-Valve, DN 200
In the spare parts set Included in the set of In the spare parts forfor commissioningseals
2 year operation

Item

Designation

Material

1

Valve body

EN-JS 1049 / PTFE

2

Bonnet flange

EN-JS 1049

3

O-ring

PTFE

4

Seat

PTFE

5

SpacerPTFE

6

WasherPTFE

8

Thrust washer

1.4301

9

Spring washer

1.8159 / DeltaTone

10

Bottom flange

EN-JS 1049

11

Screw / Stud bolt

A2-70

13

Plug

PTFE

14

Cord

PTFE

15

Bellows

PTFE

16

Stem

1.4571

19

O-ring

EPDM

•

•

21

Spring washer

1.8159 / DeltaTone

•

•

24

Locking screw

Steel galvanized

•

•

27

Stuffing box

1.430129

Bearing bushing

PTFE with 25% carbon

•

•

30

O-ring

Viton

•

•

31

Guide bushing

1.430533

V-ring packing

1.4305 / PTFE

•

•

34

Set of spring washers

1.8159 / DeltaTone

•

•

35

O-ring

Viton

•

•

36

Screw

A2-70

38

Yoke

EN-JS 1049

39

Slotted nut

A2-70

41

Bearing bushing

PTFE with 25% carbon

•

•

42

O-ring

PTFE

•

•

43

WasherA2

EB 01a_EN
March 2023 edition
Subject to technical change

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15-7

Annex15.2.4 Spare parts for ANSI-Valves, NPS1 ... 3 and DIN-Valves, DN 25 ... 80 [Edition 2022]

Figure|15-4:

15-8

Exploded drawing of a ANSI-Valve, NPS1 ... 3

EB 01a_EN
March 2023 edition
Subject to technical changes

Annex

Table|15-13: Recommended spare parts for a ANSI-Valve, NPS1 ... 3
In the spare parts set Included in the set of In the spare parts forfor commissioningseals
2 year operation

Item

Designation

Material

1

Valve body

A395 / PTFE

2

Bonnet flange

A395

3

O-ring

PTFE

4

Seat

PTFE

5

SpacerPTFE

6

WasherPTFE

8

Thrust washer

1.4301

9

Spring washer

1.8159 / DeltaTone

10

Bottom flange

A105

11

Screw / Stud bolt

A193-B7

13

Plug

PTFE

14

Cord

PTFE

15

Bellows

PTFE

16

Stem

1.4571••

19

O-ring

EPDM

•

•

20

Thrust washer

1.4301

21

Spring washer

1.8159 / DeltaTone

•

•

23

Grooved pin

1.4301••24

Locking screw

Steel gavanized

•

•

27

Stuffing box

1.430129

Bearing bushing

PTFE with 25% carbon

•

•

30

O-ring

Viton

•

•

31

Guide bushing

1.430533

V-ring packing

1.4305 / PTFE

•

•

34

Set of spring washers

1.8159 / DeltaTone

•

•

35

O-ring

Viton

•

•

36

Screw

A193-B7

38

Yoke

EN-JS 1049

39

Slotted nut

A2-70

41

Bearing bushing

PTFE with 25% carbon

•

•

42

O-ringPTFE••

EB 01a_EN
March 2023 edition
Subject to technical change

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15-9

Annex15.2.5 Spare parts for ANSI-Valves, NPS4 ... 6

Figure|15-5:

15-10

Exploded drawing of a ANSI-Valve, NPS4 ... 6

EB 01a_EN
March 2023 edition
Subject to technical changes

Annex

Table|15-14: Recommended spare parts for a ANSI-Valve, NPS4 ... 6
In the spare parts set Included in the set of In the spare parts forfor commissioningseals
2 year operation

Item

Designation

Material

1

Valve body

A395 / PTFE

2

Bonnet flange

A395 1049

3

O-ring

PTFE

4

Seat

PTFE

5

SpacerPTFE

6

Washer

PTFE

•

•

7

Inlay

Uniseal 3400

•

•

10

Bottom flange

A105

11

Screw / Stud bolt

A193-B7

12

Nut

A2-70

13

Plug

PTFE

14

Cord

PTFE

15

Bellows

PTFE

16

Stem

1.4571

17

Bordered flange

St 37 / PTFE

•

•

18

WasherUniseal 3400

•

•

22

Bushing

Glycodur F

•

•

23

Grooved pin

1.4301••24

Locking screw

Steel galvanized

•

•

25

Washer

1.4571••

26

Packing

PTFE-Graphite

•

•

27

Stuffing box

1.430128

Wiper ring

Buna

•

•

36

Screw

A193-B7

37

Nut

A2-70

40

Screw

A2-70

EB 01a_EN
March 2023 edition
Subject to technical change

•

•
•

•
•

•

•
•
•

15-11

Annex15.2.6 Spare parts for ANSI-Valves, NPS8

Figure|15-6:

15-12

Exploded drawing of a ANSI-Valve, NPS8

EB 01a_EN
March 2023 edition
Subject to technical changes

Annex

Table|15-15: Recommended spare parts for a ANSI-Valve, NPS8
In the spare parts set Included in the set of In the spare parts forfor commissioningseals
2 year operation

Item

Designation

Material

1

Valve body

A395 / PTFE

2

Bonnet flange

A395 1049

3

O-ring

PTFE

4

Seat

PTFE

5

SpacerPTFE

6

WasherPTFE

8

Thrust washer

1.4301

9

Spring washer

1.8159 / DeltaTone

10

Bottom flange

A105

11

Screw / Stud bolt

A193-B7

13

Plug

PTFE

14

Cord

PTFE

15

Bellows

PTFE

16

Stem

1.4571

19

O-ring

EPDM

•

•

21

Spring washer

1.8159 / DeltaTone

•

•

24

Locking screw

Steel galvanized

•

•

27

Stuffing box

1.430129

Bearing bushing

PTFE with 25% carbon

•

•

30

O-ring

Viton

•

•

31

Guide bushing

1.430533

V-ring packing

1.4305 / PTFE

•

•

34

Set of spring washers

1.8159 / DeltaTone

•

•

35

O-ring

Viton

•

•

36

Screw

A193-B7

38

Yoke

EN-JS 1049

39

Slotted nut

A2-70

41

Bearing bushing

PTFE with 25% carbon

•

•

42

O-ring

PTFE

•

•

43

WasherA2

EB 01a_EN
March 2023 edition
Subject to technical change

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15-13

Annex15.3 Service
For maintenance and repair work as well as malfunctions or defects, contact the After Sales Service at PFEIFFER for support.

E-mailThe After Sales Service can be reached at the e-mail address“sales-pfeiffer-de@samsongroup.com”.

Necessary data
Provide the following information in the case of questions and fortroubleshooting:− Manufacturer number− Valve type
− Article number− Nominal size and version of the valve− Manual valve/automated valve− Medium (designation and consistency)− Medium pressure and temperature− Flow rate in m³/h
− Bench range of the actuator (e.g. 0.2 to 1 bar)
− Number of actuations (year, month, week or day)− Installation drawing if available− Completed declaration regarding contamination. This form isavailable at  www.pfeiffer-armaturen.com.

Further 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

15-14

EB 01a_EN
March 2023 edition
Subject to technical changes

EB 01a_EN
March 2023 edition
Subject to technical changes

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

EB 01a_EN
March 2023 edition
Subject to technical changes