GFT German Fluorolined Technik GmbH
Hooghe Weg 16, 47906 Kempen, Germany
Email: sales@gft9.shop
Web: http://gft9.shop
Phone: +49 2152 9148591

Body identification:
The following are visible on the body according to DIN EN 19 and AD 2000 A4:

• Nominal size
• Rated pressure
• Body material
• Manufacturer's identification
• Melt number/Foundry identification
• Foundry date

All screws greased, tighten in diametrically opposite sequence!
The tightening torques for pipe screws and body screws mentioned must not be exceeded. For an exception, see Section 8, Flange connection valve/pipe is leaking.The following tightening torques are recommended.

This operating manual contains fundamental information which is to be observed during installation, operation and maintenance.It must be read before installation and commissioning!
This operating manual must always be available at the place of use of the valve.
For valves which are used in potentially explosive areas, see section 3.
Installation, operation and maintenance are to be performed by qualified staff.
The area of responsibility, authority and supervision of the staff must be regulated by the customer.

It is imperative to observe warnings and signs attached directly to the ball valve and they are to be kept fully legible.
Non-observance of the notes on safety may resulting the loss of any and all claims for damages.

For example, non-observance may involve the following hazards:

• Failure of important functions of the valve/plant.
• Risk to people from electric, mechanical and chemical effects.
• Risk to the environment through leaks of hazardous substances.
  

GFT9 ball valves are on/off pressure-containing components in accordance with the Pressure Equipment Directive (PED), intended for the passage and shut-off of fluids.

The Spheron9 is a two-way on/off valve. It is not intended for throttling or for operation in an intermediate position, see Section 7.2.
For the installation position, see Section 6.2.
The valves are suitable for non-boiling liquids of group 1 in acc. with the Pressure Equipment Directive (PED). Solids can lead to increased wear, damage to sealing surfaces or to a reduction in the service life of the valve.

In case of the valve is intended for operating data other than those intended, the customer must carefully examine whether the design of the valve, accessories and materials are suitable for the new application. (Please consult the manufacturer)

If a valve is used, the operator must ensure that

• hot or cold valve parts are protected by the customer against being touched
• the valve has been properly installed in the pipe system
• the usual flow rates are not exceeded in continuous operation.
• an appropriate collection system is used to contain drip leaks/leaks locally and harmlessly.

This is not the manufacturer's responsibility.

Loads caused by earthquakes were not allowed for in the design.

Fire protection to DIN EN ISO 10497 is not possible (plastic lining and plastic components).

The operational reliability of the valve supplied is only guaranteed if it is used properly in accordance with Section 2.1 of this operating manual.

The valves are intended for use in a potentially explosive area and are therefore subject to the conformity assessment procedure of the directive 2014/34/EC (ATEX).

As part of this conformity assessment, an ignition hazard analysis to EN 13463-1 to satisfy the fundamental safety and health requirements was conducted with the following result:

• The valves do not have any ignition source of their own and can be operated both manually as well as mechanically/electrically.
• The valves are not covered by the scope of application of the ATEX directive and therefore do not need to be identified accordingly.
• The valves may be used in a potentially explosive area.

Supplementary notes:

• Electric/mechanical actuators must be subjected to their own conformity assessment to ATEX.

It is imperative to observe the individual points of intended use for application in a potentially explosive are

Improper operation, even for brief periods, may result in serious damage to the valve. In connection with explosion protection, potential sources of ignition (overheating, electrostatic and induced charges, mechanical and electric sparks) may result from improper operation. Their occurrence can only be prevented by adhering to the intended use. Furthermore, reference is made to Directive 95/C332/06 (ATEX 118a), which contains the minimum regulations for improving the occupational health and safety of workers who may be at risk from an explosive atmosphere.
A distinction is made between two cases for the use of chargeable liquids (conductivity < 10⁻⁸ S/m):

Charges can occur on the lining surface, which may produce discharges inside and outside the valve.

1. Discharges inside the valve:
   These discharges cannot cause ignitions if the valve is completely filled with medium. If the valve is not completely filled, such as during evacuation and filling, the formation of an explosive atmosphere must be prevented, e.g., by superimposing a layer of nitrogen. It is recommended to wait one hour before removing the valve from the plant to allow for the elimination of static peak charges. To safely prevent ignitions, the valve must always be completely filled with medium, or an inert gas layer must be used to exclude a potentially explosive atmosphere.
2. Discharges outside the valve:
   Where the non-conductive lining protrudes on the sealing surfaces to the outside or comes into contact with the atmosphere, discharges may occur to nearby valves or attachments. To safely avoid explosion hazards and accidents, the atmosphere surrounding the valve must not be explosive.

No hazardous charges can occur because charges are discharged directly via the lining and shell (surface resistance < 10⁹ Ohm, leakage resistance < 10⁶ Ohm). However, if non-conductive versions of individual components are installed in the valve, they may restrict the permitted ATEX zone and explosion subgroup despite the conductive lining of the armor plating. In such cases, it is necessary to consult the manufacturer. According to the “Technical Rules for Hazardous Substances: Avoidance of Ignition Hazards Due to Electrostatic Charges” (TRGS 727), static discharges of non-conductive linings occur only through interaction with a non-conductive medium and are therefore the responsibility of the plant operator. Static discharges are not sources of ignition stemming from the valves themselves.
Additional safety measures include:

• The temperature of the medium must not exceed the temperature of the corresponding temperature class or the maximum permissible medium temperature as per the operating manual.
• If the valve is heated (e.g., heating jacket), the prescribed temperature classes in the Annex must be observed.
• To ensure safe and reliable operation, regular inspections must verify that the valve is properly maintained and kept in technically perfect condition.
• Increased wear to the valve can be expected when conveying liquids containing abrasive constituents, requiring shorter inspection intervals than usual.
• Actuators and electric peripherals, such as temperature, pressure, and flow sensors, must comply with valid safety requirements and explosion protection provisions.
• The valve must be grounded, which can be achieved using pipe screws with tooth lock washers. Otherwise, grounding must be ensured by other means, such as a cable link.
• Attachments such as actuators, position controllers, and limit switches must comply with relevant safety regulations concerning explosion protection and, if required, be designed in accordance with ATEX.
• Special attention must be paid to the appropriate safety and explosion protection notes in the respective operating manuals.
• Plastic-lined valves must not be operated with carbon disulfide.

The validity of the Certificate/Manufacturer Declaration depends on the operating instructions being read and observed.

• Carry out regular maintenance intervals and check the tightness of the screw connections, tightening them as necessary.

Handle the goods being transported with care. During transport protect the valve against impacts and collisions.

Directly after receipt of the goods, check the consignment for completeness and any in-transit damage.

Do not damage paint protection.

If the valve is not installed immediately after delivery, store them properly.
The valves be stored in a dry, vibration-free and well ventilated room at as constant a temperature as possible.
Protect elastomers against UV light.
In general, a storage period of 10 years should not be exceeded.

It is imperative to enclose a safety information sheet / general safety certificate on the field of application with the return consignment.
Contact the Manufacturer for more Information in that regard.
Safety precautions and decontamination measures are to be mentioned.

Parts of the valve may be contaminated with medium which is detrimental to health and the environment and therefore cleaning is not sufficient.

Wear protective clothing when work is performed on the valve.
Prior to the disposal of the valve:

• Collect any medium, etc. which has escaped and dispose of it in accordance with the local regulations.
• Neutralise any medium residues in the valve.
• Separate valve materials (plastics, metals, etc.) and dispose of them in accordance with the local regulations.
  

Examine valve for in-transit damage, damaged ball valves must not be installed.

• Before installation the valve and the connecting pipe must be carefully cleaned to remove any dirt, especially hard foreign matter.
• During installation, pay attention to the correct tightening torque, aligned pipes and tension-free assembly.
• The lever must move freely (deadman's position).

Leave protective caps on the flanges until just prior to installation.

Where there is a particularly high risk of damage to the plastic sealing surfaces, e.g. if the mating flanges are made of metal or enamel, PTFE-lined gaskets with a metal inlay should be used. Contact the Manufacturer for further discussion.

Installation is independent of the direction of flow.

Any fitting position can be chosen. Otherwise, it is marked by a direction arrow on the ball valve, in the case of cavity-free ball/stem units ore ball/stem units and Al2O3-balls with an additional relief bore.

The valve must be grounded. This can be achieved in the simplest way via the pipe screws using tooth lock washers. One pipe screw per flange is underlaid with toothed disks.

Upon customer request a set screw M6 is attached to each flange with a hex nut and washer as an additional earthing connection.

Otherwise grounding must be ensured by different measures e.g. a cable link.

The test pressure PT of a valve must not exceed the value of 1.5 x PS(PN) as per the identification of the valve.

Normally, the valves have been tested for leaks with air or water. Prior to initial operation check cover screws. For tightening torques, see Section 1.5.2!

To prevent leaks, all connection screws should be retightened after the initial loading of the valve with operating pressure and operating temperature. For tightening torques, see Section 1.5.1.

• Crystallisation must be prevented, e.g. by heating. Damage to the seat rings or the ball stem unit would be inevitable.In extreme cases a leak or blocking may occur.
• Increased wear occurs in operation with solids contents.
• The ball valve is an on/off valve and shall not be operated in an intermediate position. Damage to the seat rings or the ball/stem unit or Al2O3-ball and stem could occur.
• If the ball blocks, do not apply force as the ball/stem may break if the max.adm. torque is exceeded
• Operation during cavitation leads to increased wear.
• Non-observance of the pressure-temperature diagram can lead to damage.
• Do not transport the valve using the lever.
• Do not use a lever extension as otherwise there is a risk of damage.

The local regulations are to be observed when dismantling the valve!

After dismantling, immediately protect the valve flanges against mechanical damage by using flange caps. See also Section 6.1.
Make sure that a remote-controlled actuator cannot be switched on by accident.

1. Retighten the flange screws to a tightening torque according to Section 1.5.1. If this does not remedy the leak, the recommended torques may be exceeded by 10%.
2. If this also fails to stop the leak, dismantle and inspect the valve.

• Retighten body screws. See paragraph “Flange connection ball valve/pipe is leaking".
  

• Retighten packing nuts according to the details in Section 1.5.2.
  

1. Is the actuator supplied with power?
2. Is any directional control valve correctly connected?
3. Is there foreign matter in the valve?
   

1. Is the stem deformed?
2. Is the coupling worn?
3. With a worm gear or actuator, check whether the end stops can be re-adjusted. The operating manuals of the gear and actuator manufacturers contain accurate instructions.
4. Try to get the ball valve working again by moving the lever to and from.
5. Remove the lever stop and try to switch against the normal direction of rotation.
6. If actuation is not possible with the max. admissible actuating torque as per Section 1.7, dismantle ball valve and inspect individual components.

In General: Never apply force to the lever or use an extension.

9.1.1 Ball valve with lever

Step 1:
Remove lever.

Step 2:
Take out grounding spring washers.

Step 3:
Dismantle packing gland follower and spring gland follower.

Step 4:
The thrust ring, packing bellows and retaining washer are one unit and it is levered out using 2 screwdrivers.

Step 5:
Undo screw connection body end piece / main body. Remove body end piece

Step 6 (Only DN200):
Carefully slide the mounting sleeve (fitting aid, available from the manufacturer) up to the stop into the shaft passage of the main body. Carefully slide out the mounting sleeve.

Step 7:
Remove ball/stem unit (Pos. 6) in closed position. Make sure that you do not damage the body lining, then carefully remove seat rings.

9.1.2 Packing Bellows

Step 1:
Remove retaining washer.

Step 2:
Separate thrust ring and packing bellows by pushing them apart.

9.1.3 Ball valve with actuator

Step 1:
Remove actuator and coupling.

Step 2:
Dismantle packing gland follower and spring gland follower.

Step 3:
Remove bracket.

Further dismantling is performed as described in Section 9.1.1 and 9.1.2

Prior to assembly all parts are to be cleaned and the plastic-lined parts checked for damage.
Step 1:
Insert seat rings in the main body and body end piece.
Step 2 (Only DN200):
Carefully slide the mounting sleeve (fitting aid, available from the manufacturer) up to the stop into the shaft passage of the main body.
Step 3:
Mount ball/stem unit in closed position. Make sure that you do not damage the body lining.
NOTE: An additional bore in the ball/stem unit, e.g. to ensure it is cavity-free,must lie on the p1 side in the closed position.
Step 4 (Only DN200):
Carefully slide out the mounting sleeve.

Step 5:
Mount body end piece. Tighten the greased housing screws cross over with a tightening torque according to Section 1.5.2

9.2.1 Packing bellows

Step 1:
Press thrust ring into packing bellows. Install retaining washer (Pos. 12).
Step 2:
Press unit into main body.
Step 5:
Press in grounding spring washer.

9.2.2 Ball valve with lever

Step 1:
Mount lever stop, spring gland follower (in DN 80, 100, 150, and 200 are 2 spring gland followers (Pos. 8)) and packing gland follower. Tighten packing nuts until there is no gap between packing gland follower (Pos. 10) and spring gland follower. See Section 1.5.2 and 11.
Step 2:
Seal any tapped bores still open with plugs. Then, Mount lever.

9.2.3 Ball valve with actuator

Step 1:
Mount spring gland follower (Pos. 8) (in DN 80, 100, 150and 200 are 2 spring gland followers (Pos. 8)) and packing gland follower (Pos. 10). Tighten packing nuts until there is no gap between packing gland follower and spring gland follower.
See Section 1.5.2 and 11.
Step 2:
Mount the mounting bracket with the opening at right angles to the direction of flow. See the sectional drawing in Section 11.
Step 3:
Mount the coupling and the actuator. The actuator interface conforms to ISO 5211; the coupling and bracket must match the flange size (F05, F07, F10) of the actuator being fitted. Observe the actuator position in accordance with the actuator operating manual.O
Step 4:
Observe the ball/stem position in accordance with the position of the actuator.

It is possible with a ball valve with ball and stem to replace the seat rings and ball without dismantling the entire ball valve.
It is equally possible to remove the packing gland follower, spring gland follower and packing insert without dismantling the body.
The entire ball valve must merely be taken apart to remove the stem. For sectional drawings, see Section 11.

9.3.1 Ball and seat rings

Step 1:
Move ball (Pos. 6) into the 'closed' position.
Step 2:
Undo body nuts and bolts and remove body end piece.
Step 3:
Remove ball from the main body by swivelling it.
Step 4:
Consequently, remove seat rings from the main body and body end piece and replace.

9.3.2 Packing bellows

Step 1:
Remove lever. Then, safely dismantle packing gland follower and spring
gland follower.
Step 2:
Take out grounding spring washer.
Step 3:
The thrust ring, packing bellows and retaining washer
are one unit and it is levered out using 2 screw-drivers.
Step 4:
Remove retaining washer. Following, separate thrust ring and packing bellows by pushing them apart.

9.3.3 Ball valve with actuator

Step 1:
Remove actuator and coupling. Then, dismantle packing gland follower and spring gland follower and remove bracket.
Further dismantling is performed as described in Chapter 9.1.3.

9.3.4 Stem

Step 1:
Dismantling as described in section 9.3.1.
Step 2:
Undo screw connection body end piece / main body and remove body end piece.
Step 3:
Remove ball and stem in closed position. Make sure that you do not damage the body lining.
Step 4:
Swivel ball from stem.

Prior to assembly all parts are to be cleaned and the plastic-lined parts checked for damage!
Step 1:
Insert seat rings in the main body and body end piece. Following, insert stem from inside into the main body. In the case of DN 150 and 200 with an additional disc.
Step 3:
Move stem into the 'closed' position and swivel ball into the stem. Any pressure
relief or drain bore must lie on the p1 side in the "off" position. See also section 6.2.
Step 4:
Mount body end piece. Tighten the greased housing screws cross over with a tightening torque according to Section 1.5.2

9.4.1 Packing bellows

Step 1:
Press thrust ring into packing bellows and install retaining washer.
Step 2:
Press unit into main body and insert grounding spring washer.

9.4.2 Ball valve with lever

Step 1:
Mount lever stop, spring gland follower (in DN 80, 100, 150 and 200 are 2 spring gland followers) and packing gland follower. Tighten packing nuts until there is no gap between packing gland follower and spring gland follower. See Section 1.5.2 and 11.
Step 2:
Seal any tapped bores still open with plugs, then Mount lever.

9.4.3 Ball valve with actuator

Step 1:
Mount spring gland follower (in DN 80, 100, 150 and 200 are 2 spring gland followers) and packing gland follower. Tighten packing nuts until there is no gap between packing gland follower and spring gland follower. See Section 1.5.2 and 11.
Step 2:
Mount bracket with the opening at right angles to the direction of flow.
Step 3:
Mount coupling and actuator. Observe the actuator position in accordance with the actuator operating manual.

Step 4:
Make sure that the position of the ball valve with ball and stem, and the position of the actuator are aligned

Select the actuator in accordance with the instructions of the actuator manufacturer.
Step 1:
Remove lever, lever stop and the plug.
Step 2:
Check the fits of the coupling, bracket and actuator.
Step 3:
Mount bracket with the opening at right angles to the direction of flow.
Step 4:
Mount coupling and actuator. Observe the actuator position in accordance with the actuator operating manual. (Connecting dimensions see Section 10).

Product Ball Valve
Design 2 Piece Ball Valve
Serial number
Size DN 15 - DN 200 | NPS ½" - NPS 8"
EU-Directive 2014/68/EU
Applied Technical Specification DIN EN ISO 12100 AD 2000
Surveillance Procedure 2014/68/EU, TÜV Rheinland Industrie Service GmbH
Notified Body for Pressure ID-No. 0035
Equipment
Conformity assessment. 2014/68/EU / 2014/68/EU
Procedure
Marking 2014/68/EU¹⁾ ≥ DN 25, ≥ 1“


Advanced Fluoropolymer Devices GmbH confirms that the basic requirements of the above specified directives and standards have been fulfilled
¹⁾ For sizes not listed a marking is not permissible.

Kempen, 17.12.2024

K. Schalm