PFA Lined Ball Valve

GFT9
Hooghe Weg 16, 47906 Kempen, Germany
Email: sales@gft9.shop
Web: https://gft9.shop
Phone: +49 2152 9148591

Body identification:
In accordance with DIN EN 19 and AD 2000 A4, the body is marked with:

• Nominal size
• Pressure rating
• Body material
• Manufacturer's mark
• Melt number/Foundry identification
• Foundry date

Grease all screws and tighten them in diametrically opposite order!
The tightening torques stated for pipe screws and body screws must not be exceeded. An exception is described in Section 8, under 'Flange connection valve/pipe is leaking'. Recommended tightening torques are listed below.

Read this manual before installing and commissioning the valve. It contains the essential instructions for installation, operation and maintenance.
Keep the manual where the valve is in use, so that staff can refer to it at any time.
For use in potentially explosive atmospheres, also follow Section 3.
Only qualified personnel may install, operate and service the valve.
The operator must define the staff's responsibilities and authority and how the staff are supervised.

Every warning and sign on the ball valve itself must be followed and kept fully legible.
Disregarding these safety instructions can void all claims for damages.

It can also lead, for example, to the following hazards:

• Loss of essential functions of the valve or plant.
• Danger to persons from electrical, mechanical and chemical effects.
• Harm to the environment from escaping hazardous substances.
  

GFT9 ball valves are on/off valves designed to pass and shut off fluids. They are pressure-containing components as defined by the Pressure Equipment Directive (PED).

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 in the medium can increase wear, damage the sealing faces or shorten the service life of the valve.

If the operating conditions are to differ from those the valve was ordered for, the operator must carefully check that design, materials and accessories still suit the new application. (Consult the manufacturer.)

The operator is responsible for ensuring that:

• hot or cold valve parts are guarded against accidental contact
• the valve is correctly installed in the pipeline
• flow velocities in continuous service stay within the normal limits for the line.
• an appropriate collection system is used to contain drip leaks/leaks locally and harmlessly.

These points are not the manufacturer's responsibility.

The design does not take seismic loads into account.

Fire protection to DIN EN ISO 10497 cannot be provided, because the lining and other components are made of plastic.

Safe and reliable operation depends on using the valve only as described under Intended use (Section 2.1).

The valve has no electrical parts and no drive of its own (an actuator is an attachment). Its surface temperature is determined by the medium (and, on heated valves, by the heating medium). The valve carries no ATEX marking.

This manual does not give a general approval for use in potentially explosive atmospheres. Whether the valve may be used in such an area is decided for the specific application, in the operator's own assessment of the zone, the gas or dust group, the temperature class and the electrostatic behaviour of the medium.

GFT9 supports this assessment for a concrete application. On request we provide the design data needed for it — materials, lining type (standard or antistatic), earthing path, exposed non-conductive surfaces — and review the case with you. Contact: sales@gft9.shop.

Points the assessment must cover (from experience with lined valves; not a complete list):

• Earthing of the valve, e.g. tooth lock washers under the pipe screws or an earthing cable (Section 6, Grounding).
• Chargeable media (conductivity below 10⁻⁸ S/m): charge can build up on a standard lining; an antistatic lining (PFA/AS: surface resistance below 10⁹ Ω, leakage resistance below 10⁶ Ω) leads it away. With a standard lining the valve must stay completely filled or the atmosphere inside must be inerted; non-antistatic parts can limit the permitted zone and gas group.
• Exposed non-conductive surfaces, e.g. lining at the flange faces or a sight-glass window.
• Medium temperature and heating-medium temperature against the temperature class.
• Actuators, positioners, limit switches, solenoid valves, sensors and heating jackets: their own explosion-protection conformity, per their manuals.
• Abrasive media and dust deposits on the outside: inspection and cleaning intervals.
• Plastic-lined valves must not be used with carbon disulfide.
• Hand-operated as standard; an actuator is an attachment with its own conformity.

A TA Luft certificate is held for the Spheron9 ball valve. For other valves a TA Luft version is available on request. Any TA Luft certificate or manufacturer declaration is valid only if these operating instructions have been read and are followed.

• Maintain the valve at regular intervals, check that the bolted connections are tight and retighten them where necessary.

Handle the goods carefully in transit. Protect the valve from knocks and impacts while it is being transported.

Immediately on receipt, check that the consignment is complete and free of transport damage.

Take care not to damage the protective paint coat.

Valves that are not installed straight away must be stored correctly.
Store them in a dry, well-ventilated room free of vibration, at a temperature that is as constant as possible.
Keep elastomer parts out of UV light.
As a rule, the valves should not be stored for more than 10 years.

A safety information sheet / general safety certificate stating the field of application must always be enclosed with any return consignment.
Contact the Manufacturer for more Information in that regard.
The safety precautions and decontamination measures must be stated.

Parts of the valve may carry medium residues that are harmful to health and the environment; cleaning alone is therefore not enough.

Wear suitable personal protective equipment for all work on the valve.
Before disposing of the valve:

• Collect any escaped medium or other substances and dispose of them according to local regulations.
• Neutralise medium remaining in the valve.
• Sort the valve materials by type (plastics, metals, etc.) and dispose of each according to local regulations.
  

Check the valve for transport damage on receipt. Do not install a damaged ball valve.

• Clean the valve and the adjoining pipework thoroughly before installation, removing all dirt and in particular hard particles.
• Install the valve free of stress between aligned pipes, and tighten the bolts to the correct torque.
• The lever must move freely (deadman's position).

Leave the flange caps on until the valve is about to be installed.

If the plastic sealing faces are at particular risk of damage, for example from metal or enamelled mating flanges, PTFE-lined gaskets with metal inserts are recommended. Contact the Manufacturer for further discussion.

The valve can be installed in any position and independent of the flow direction.

Valves with an additional relief bore (cavity-free ball/stem unit, Al₂O₃ ball) carry a flow-direction arrow: install them with the bore on the p1 side (see Sections 9.2 and 9.4).

The valve must be grounded. The simplest way is to fit tooth lock washers under the pipe screws. Fit them under one pipe screw on each flange.

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

If this is not possible, grounding must be provided another way, e.g. with an earthing cable.

The test pressure PT must not be higher than 1.5 x PS(PN), with PS(PN) as stated in the valve marking.

The valves are normally leak-tested with air or water at the factory. Check the cover screws before commissioning. For tightening torques, see Section 1.5.2!

When the valve reaches operating pressure and temperature for the first time, retighten all bolted joints to prevent leaks. For tightening torques, see Section 1.5.1.

• Prevent the medium from crystallising, for example by heating. Damage to the seat rings or the ball stem unit would be inevitable. In extreme cases a leak or blocking may occur.
• Solids in the medium increase wear.
• 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
• Operating under cavitation increases wear.
• Operating outside the pressure-temperature diagram can damage the valve.
• Do not transport the valve using the lever.
• Do not extend the lever, as this can cause damage.

Comply with the local regulations when dismantling the valve!

As soon as the valve has been removed, fit flange caps to protect the flanges from mechanical damage. See also Section 6.1.
Lock out remote-controlled actuators so that they cannot start unexpectedly.

1. Retighten the flange screws to the torque given in Section 1.5.1. If the joint still leaks, the screws may be tightened up to 10% above the recommended torque.
2. If the leak persists, dismantle the valve and inspect it.

• Retighten the body screws crosswise to the torque given in Section 1.5.2. If the leak persists, see paragraph “Flange connection ball valve/pipe is leaking".
  

• Retighten the packing nuts alternately until there is no gap between packing gland follower (Pos. 10) and spring gland follower (Pos. 8), see Section 9.2.2. Do not tighten beyond the closed gap.
• If the leak persists, dismantle and inspect the packing bellows (Pos. 3), see Section 9.3.2.

1. Is power reaching the actuator?
2. Is the solenoid valve, if fitted, connected correctly?
3. Are there foreign objects in the valve?
4. Manual valve: see “Operating torque higher than stated in Section 1.6”. Do not apply force — the ball/stem may break if the max. admissible torque is exceeded (Section 7.2).
5. Actuated valve: check the supply and the directional control valve, and check that the coupling is seated on the stem (Section 9.4.3). Check the actuator against Sections 1.6 and 1.6.1: the actuation torque rises with other media, low temperature and long standstill.

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. Check the 90° travel stop between lever and gland follower: if it is worn or damaged, the ball can turn past its end position.
6. If actuation is not possible with the max. admissible actuating torque as per Section 1.6, dismantle ball valve and inspect individual components.
7. If the ball reaches the closed position and the valve still passes, the seat rings (Pos. 4) or the ball are worn or damaged: replace the seat rings (Section 9.3.1) and inspect the lining of the ball (Pos. 6); replace the ball/stem unit if the lining is damaged.

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

1. Never apply force to the lever or use an extension; if the ball blocks, the ball/stem may break if the max. admissible torque is exceeded (Section 7.2).
2. Crystallised or solidified medium in the valve: prevent the medium from crystallising, for example by heating (Section 7.2). Flush the valve or heat it to dissolve deposits if the process allows.
3. Check the packing: the packing nuts must not be tightened beyond the point where the gap between packing gland follower (Pos. 10) and spring gland follower (Pos. 8) is closed (Section 9.2.2).
4. Actuated valves: check the fits of the coupling, bracket and actuator (Section 9.5, Step 2).
5. If the torque still exceeds the value in Section 1.6, dismantle the ball valve and inspect the seat rings (Pos. 4), see Sections 9.1 and 9.3.

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 3:
Press in grounding spring washer.

9.2.2 Ball valve with lever

Step 1:
Mount 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 11 (Pos. 8, Pos. 10). Do not tighten beyond the closed gap.
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, 150 and 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 11 (Pos. 8, Pos. 10). Do not tighten beyond the closed gap.
Step 2:
Mount the mounting bracket with the opening at right angles to the direction of flow. See the exploded view 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, F12) of the actuator being fitted. Standard bridge and coupling per nominal size: see Section 1.6.1. Observe the actuator position in accordance with the actuator operating manual.
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 the exploded view, 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 Sections 9.3.1, 9.3.2 and 9.3.4.

9.3.4 Stem

Step 1:
Dismantling as described in section 9.3.1.
Step 2:
Remove ball and stem in closed position. Make sure that you do not damage the body lining.
Step 3:
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.
Step 2:
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 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 (Pos. 10) and spring gland follower (Pos. 8). See Section 11. Do not tighten beyond the closed gap.
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 (Pos. 10) and spring gland follower (Pos. 8). See Section 11. Do not tighten beyond the closed gap.
Step 2:
Mount bracket with the opening at right angles to the direction of flow.
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, F12) of the actuator being fitted. Standard bridge and coupling per nominal size: see Section 1.6.1. 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

Applies to the conversion from lever to actuator and to fitting your own actuator on a valve delivered with bridge and coupling. Bridge, coupling and actuator flange per Section 1.6.1, drawings in Section 10.3. Everything beyond these steps — air supply or wiring, solenoid valve, limit switch box, positioner, end-stop setting — follows the actuator operating manual.
Step 1:
Lever version only: remove the lever and the plug. The 90° travel stop acts between lever and gland follower; on the actuated valve the end stops of the actuator limit the travel (Step 7).
Step 2:
Check the fits: actuator flange and drive square must match the bridge and coupling of the size (Section 1.6.1). The actuator torque must cover the actuation torque of the duty and must not exceed the max. admissible torque (Section 1.6).
Step 3:
Mount the bridge with the opening at right angles to the direction of flow and screw it to the valve top flange (EN ISO 5211), tightening the screws crosswise.
Step 4:
Slide the coupling onto the two-flat stem drive. It must go on without force and must not press on the stem.
Step 5:
Bring valve and actuator into the same position, e.g. both closed. A spring-return actuator rests in its fail position: set the valve to that position.
Step 6:
Set the actuator onto the bridge so that its drive engages the coupling square, and screw the actuator flange to the bridge crosswise.
Step 7:
Connect the actuator as described in its operating manual, set the end stops so that the ball reaches the fully open and the fully closed position, then cycle the valve several times and check the end positions and the limit switch signals.

The stem seal is spring-loaded and compensates packing set in service. After long storage the spring travel may be used up and a gap appears between the packing gland follower (Pos. 10) and the spring gland follower (Pos. 8).

Before installation, tighten the packing nuts alternately in small steps until there is no gap between packing gland follower and spring gland follower, then operate the valve once through a full stroke.

Stop once the gap is closed — further tightening raises the operating torque and wears the packing without improving tightness. See Section 9.2.2.

Manufacturer GFT German Fluorolined Technik GmbH, Hooghe Weg 16, 47906 Kempen, Germany
Product Ball Valve
Design 2-piece ball valve, PFA-lined (Spheron9)
Serial number
Size DN 15 – DN 200 | NPS ½" – NPS 8"
EU directive Pressure Equipment Directive 2014/68/EU
Applied technical specifications DIN EN ISO 12100, AD 2000
Conformity assessment procedure Module A2, certificate no. 01 202 640/Ü-18 0002.02
Notified body TÜV Rheinland Industrie Service GmbH, identification no. 0035
Marking CE 0035¹⁾ from DN 25 / NPS 1"

GFT German Fluorolined Technik GmbH declares under its sole responsibility that the product described above meets the essential requirements of the directive and standards listed above.

¹⁾ Smaller sizes must not bear this marking.

Kempen, 03.11.2026

K. Schalm