type 546 ball valve setting a new standard in piping systemsgf+katalogi-pdf/003/foldery/+gf+... ·...

‡ Type 546 Ball Valve

Setting a new standard in piping systems

¥ ‡Piping Systems

Product Range

PVC-U, PVC-C

List of abbreviationsANSI American National Standard InstituteASTM American Society for Testing and MaterialsBS British StandardDIN Deutsche Industrie-NormenISO International Standardization OrganizationABS Acrylnitrile-Butadiene-StyrenePVC-U Polyvinyl chloride. unplasticizedPVC-C Polyvinyl chloride. post-chlorinatedPP Polypropylene. heat stabilizedPE PolyethylenePVDF Polyvinylidene fluorideEPDM Ethylene-Propylene-RubberFPM Fluororubber, e.g. Viton®

PTFE Polytetrafluoroethylene, e.g. Teflon®

FM Fusion Methodd Pipe outer diameterDN Nominal diameterPN Nominal pressure at 20 °C, waterkg Weight in kilogramsg Weight in gramsNPT Female thread, tapered, pressure tight

in the thread per ANSI B1.20.1R Male thread, tapered, pressure

tight in the thread per ISO 7/DIN 2999/1Rp Female thread, parallel,

pressure tight in the threadper ISO 7/DIN 2999/1

® Registered trademark

The technical data are notbinding. They are not war-ranted characteristics andare subject to change.Please consult our GeneralConditions of Supply.

‡ Type 546 Ball Valve

Table of Contents

Ball Valves PVC-U 6

Ball Valves PVC-C 19

Accessories 45

Valve Ends 33

Product Configurator 30

Page

Multi-functional Module 50

¥ ‡

A complete model range with manycombinationsFrom the manual valve to the electricactuated ball valve with LED display.Modular design and expandable.From DN 10 to DN 50. Up to16 barpressure.In cementable materials: PVC-U, ABS,PVC-C and in fusible materials: PP-H,PVDFConnections in all the majorstandards:• metric: DIN, EN, ISO• inch: BS, ANSI• JISThis broad range of products enablesyou to find the right solution for yourapplication.

The new ‡ type 546 ball valveconforms to the followinginternational standards

prEN ISO 16135 (pending)Industrial valves – ball valves of thermo-plastic materials (ISO/DIS 16135:2001)

ISO 9393Thermoplastic valves –pressure test methods and requirements

EN 558Flanged valve dimensions are inaccordance with EN 558

ApprovalsDIBt approval pending

Availability

April 2003PVC-U

August 2003PVC-C

1st Quarter 2004PP-H, PVDF, ABS

¥ ‡

‡ Type 546 Ball Valve.

The system at a glance.

Fixed flangeBacking flangeSolvent cement spigot Fusion spigot and socket

Manual ball valve withelectric feedback unitin the multi-functionalmodule

Threaded socketSolvent cement socket

Standard ball valve Ball valve withlockable handle

Ball valve with pneumaticactuator and manual override

Ball valve with electricactuator

Ball valve with handle extensionfor through-wall/panel mounting

«What’s the black box for?»

«Connections!»

¥ ‡

‡ Type 546 Ball Valve.

With multi-functional module.

The multi-functional module is theanswerWhat is the current status of the valvesin the system? Which ones are open,which are closed?To be able to answer these questions atall times means safety for you and youroperators.With this multi-functional module, wehave a tested and proven unit for youwhich has not been available before.The feedback concept includes aselection of 5 different limit switches,designed to fit your needs.With AS-Interface on request.

The multi-functional modulehas more to offerThanks to its robust construction andthe secure fastening on the ball valve(4 Torx screws), the multi-functionalmodule can be used as a mountingbracket. Through wall/panel mountingwas never so easy.Replace the lid and the module isequipped with a DIN EN ISO 5211mounting interface. The new GeorgeFischer actuators can be connecteddirectly.

A01 B01 C09 D01 E01 F02 G01 G43 I01 K01 L02 =

left right

Example:

Type 546 PVC-U, dimension DN 32,PTFE ball seal, EPDM seals,with threaded inserts and mounting plate,connecting part left: PVC-U cement socket metric,right: PE-100 butt fusion spigot lang SDR11 metric

That‘s all it takes to configure your ball valve.

Find the fitting solution

with the Configurator

Ball valveA01 Ball valve 546

MaterialB01 PVC-U

DimensionC05 d 16 DN 10 3/8‘‘C06 d 20 DN 15 1/2‘‘C07 d 25 DN 20 3/4‘‘C08 d 32 DN 25 1‘‘C09 d 40 DN 32 1 1/4‘‘C10 d 50 DN 40 1 1/2‘‘C11 d 63 DN 50 2‘‘

VersionD01 standard, PTFE ball sealD03 silicon-free, PTFE ball seal for inch ASTM (only with specific connecting parts)D04 silicon-free, PVDF ball seal for metric (only with specific connecting parts)

SealsE01 EPDM sealsE02 FPM seals

Threaded insertsF01 without threaded insertsF02 with threaded inserts

Connecting partsG01 PVC-U Cement socket metricG03 PVC-U Cement socket inch ASTMG04 PVC-U Cement socket inch BSG05 PVC-U Cement spigot metricG06 PVC-U Threaded socket RpG07 PVC-U Threaded socket Rp reinforcedG09 PVC-U Threaded socket NPTG30 PP-H Fusion socket metricG32 PP-H Socket fusion spigot metricG33 PP-H Threaded socket RpG34 PP-H Threaded socket NPT reinforcedG35 PP-H Butt fusion spigot SDR 11 metric IR-PLUSG36 PP-H Butt fusion spigot SDR 17.6 metric (limited dimension range)G37 PP-H Butt fusion spigot long SDR11 metricG40 PE-100 Fusion socket metricG41 PE-100 Butt fusion spigot SDR11 metricG42 PE-100 Butt fusion spigot SDR17.6 metric (limited dimension range)G43 PE-100 Butt fusion spigot lang SDR11 metricG60 Fixed flange PVC-U serrated metricG61 Fixed flange PVC-U flat metricG70 Backing flange PVC-U metricG71 Backing flange PVC-U inch ANSIG72 Backing flange PP-steel metricG73 Backing flange PP-steel ANSIG80 PVC-U Valve end blank

Multi-functional moduleI01 No multi-functional moduleI02 Empty moduleI03 Module with 2 limit switches Ag, NiI04 Module with 2 limit switches AuI05 Module with 2 inductive switches NamurI06 Module with 2 inductive switches PNPI07 Module with 2 inductive switches NPN

HandleK01 Standard handle redK02 Standard handle blackK11 Multi-functional handle red

Mounting plateL01 without mounting plateL02 with mounting plate

¥ ‡


MaterialB01 PVC-U





Connecting partsG01 PVC-U Cement socket metricG03 PVC-U Cement socket inch ASTMG04 PVC-U Cement socket inch BSG05 PVC-U Cement spigot metricG06 PVC-U Threaded socket RpG07 PVC-U Threaded socket Rp reinforcedG09 PVC-U Threaded socket NPTG30 PP-H Fusion socket metricG32 PP-H Socket fusion spigot metricG33 PP-H Threaded socket RpG34 PP-H Threaded socket NPT reinforcedG35 PP-H Butt fusion spigot SDR 11 metric IR-PLUSG36 PP-H Butt fusion spigot SDR 17.6 metric (limited dimension range)G37 PP-H Butt fusion spigot long SDR11 metricG40 PE-100 Fusion socket metricG41 PE-100 Butt fusion spigot SDR11 metricG42 PE-100 Butt fusion spigot SDR17.6 metric (limited dimension range)G43 PE-100 Butt fusion spigot lang SDR11 metricG60 Fixed flange PVC-U serrated metricG61 Fixed flange PVC-U flat metricG70 Backing flange PVC-U metricG71 Backing flange PVC-U inch ANSIG72 Backing flange PP-steel metricG73 Backing flange PP-steel ANSIG80 PVC-U Valve end blank




A01 B01 C D E F G G I K Lleft right

Copiable

Configurator ‡ Ball Valve Type 546 PVC-U

You will find a large selection of differentversions in our range of products. Newsystem elements also provide you with newopportunities for use. In order forus to supply exactly the ball valve you needfor your application, we put together aselection menu for you.We supply what you put together.

¥ ‡


MaterialB02 PVC-C





Connecting partsG11 PVC-C cement socket metricG13 PVC-C cement socket inch ASTMG14 PVC-C cement spigot metricG15 PVC-C threaded socket RpG16 PVC-C threaded socket Rp reinforcedG17 PVC-C threaded socket NPTG40 PE-100 fusion socket metricG41 PE-100 butt fusion spigot SDR11 metricG42 PE-100 Butt fusion spigot SDR17.6 metric (limited dimension range)G43 PE-100 butt fusion spigot long SDR11 metricG72 Backing flange PP-steel metricG73 Backing flange PP-steel ANSIG80 PVC-U Valve end blank




Copiable

Configurator ‡ Ball Valve Type 546 PVC-C

A01 B02 C D E F G G I K Lleft right

You will find a large selection of differentversions in our range of products. Newsystem elements also provide you with newopportunities for use. In order forus to supply exactly the ball valve you needfor your application, we put together aselection menu for you.We supply what you put together.

¥ ‡

© Georg Fischer Rohrleitungssysteme AG, CH-8201 Schaffhausen/Schweiz (18.03.2003) 9¬ ‡

14 32 50 68 86 104 122 140 158 176 194

014.52943.55872.587101.5116130.5145159.5174188.5203217.5232246.5

T (°F)

P (

psi

)

0123456789

1011121314151617

-10 0 10 20 30 40 50 60 70 80 90

T (°C)

P (

bar

)

PN 10 2)

PN 16 1)

F164.4

PN 6 3)

1) The central part of ball valve is designed for the nominal pressure PN 162) According to the valve end the nominal pressure is reduced to PN 103) According to the valve end the nominal pressure is reduced to PN 6T Temperature in °C / °Fp permissible pressure in bar / psi

© Georg Fischer Rohrleitungssysteme AG, CH-8201 Schaffhausen/Schweiz ( 18.03.2003) ¬ ‡

014.52943.55872.587101.5116130.5145159.5174188.5203217.5232246.5

P (

psi

)

14 32 50 68 86 104 122 140 158 176 194T (°F)

0123456789

1011121314151617

-10 0 10 20 30 40 50 60 70 80 90

T (°C)

P (

bar

)

PN 10 2)

PN 16 1)

F152.4

1) The central part of ball valve type 546 is designed for the nominal pressure PN 162) According to the valve end the nominal pressure is reduced to PN 10T Temperature in °C / °Fp permissible pressure in bar / psi

X Size DN (mm)Y Torque (Nm)


Medium: water, 20 °CX Flow rate (l/min)Y Pressure loss Œp (bar)

X Open angle (%)Y Flow factor kv (%)


The kv values for each intermediate valve position can be determined using the flowvalue characteristic and the kv 100 values.

DNmm

DNinch

dmm

kv 100l/min

(∆p = 1 bar)

kv 100m3/h

(∆p = 1 bar)10152025324050

3/81/23/41

1¼1½2

16202532405063

70185350700100016003100

4.211.121426096186

Flanged joints with flange gaskets or flat gaskets

dmm

DNmm

DNinch

Total number of screws(for 2 flanged joints)

standard nut(height 0.8 x d) 1)

Torque(average values)Flange gasket2)

In Nm

Torque(average values)

Flat gasketin Nm

202532405063

152025324050

½¾1

1¼1½2

8 x M12 x 508 x M12 x 558 x M12 x 608 x M16 x 658 x M16 x 708 x M16 x 75

151515151520

151515203035

1) for connecting parts 546 in PP-H in combination with backing flanges, use halfof the standard nut height2) preferred (plastics-oriented) gasket type

Attention: For more information on the use of the different gasket types, seeChapter: Jointing Technology => Separable Connections


a) Connecting parts for the 546 areavailable as:

- Solvent cement/fusion socket (shortinstallation length)

- Solvent cement/fusion spigot (forstandard installation length)

- Threaded socket (on request withstainless steel outer reinforcementring)

- Butt fusion spigot- Spigot for electrofusion socket- Fixed flange (for standard installation

length)- Backing flange (for standard

installation length)- Solvent cement and threaded

connections for other standards.

b) Newly designed valve nuts withbuttress thread. These enable fast andsafe radial mounting and dismounting ofthe valve during installation ormaintenance work, without tools.Attention: Only hand tighten valve nuts.

h) The backing seal effectuatescontinuous readjustment of the ball sealand this means that under normalworking conditions maintenance-freeoperation and a constant torque can bewarranted.

c) Union bush with fine buttress threadmakes it easier to adjust the operatingtorque. Attention: Please observe theoperating torque guidelines!

d) Ball with fully circular cross-section foroptimal flow characteristics. The systemwith the floating ball permits a tight seal.

e) Two spigot seals with o-ringsguarantee a long service life and highreliability.

f) The spigot features a predeterminedbreaking point, which is located outsideof the housing. In case of damage, themedium cannot therefore leak to theoutside along the spigot.

g) Sturdy ball seals made of pure PTFEdemonstrate high abrasion resistance,good sliding properties, chemicalresistance (see the special list of“Chemical Resistance”) and a longworking life.

The special geometry of the o-ringchamber prevents the o-rings from beingflushed out.

i) Compact housing, designed especiallyfor plastics, with short installation length.The basic model has pick-up points forthreaded inserts so that they can beattached directly on the valve. Amultifunctional module with limit switches,which simultaneously serves as aninterface for adding actuators, can bemounted quickly and simply on thehousing.

k) Ergonomic polypropylene lever withdouble stops and coding for clearpositioning on the spigot. Multifunctionallever, lockable and with grid positioningat 0° and 90°, available as an option.

l) Integrated lever clip of reinforcedpolypropylene with two cams, enablingthe lever to be used as a tool forassembly and disassembly of the unionbush (Attention: The union bush has left-handed thread)


Functions:- lockable- can be locked at 0° (ball valve

opened)- can be locked at 90° (ball valve

closed)- for ball valves with or without

multifunctional module

k) Ergonomic lever of polypropylene withdouble stops and contours for clearpositioning on the spigot. The lever islockable and can be arrested in the 0°and in the 90°. Included in delivery is astainless steel Torx screw for fastening thelever on the spigot.

l) Integrated lever clip of reinforcedpolypropylene with two cams, enablingthe lever to be used as a tool forassembly and disassembly of the unionbush.

m) Unlocking device of reinforcedpolypropylene, spring of stainless steel.This mechanism can be inhibited byadding a padlock. The bore diameter forthe padlock is 5.4 mm

n) The spacer ring works as a barrier.After mounting a multifunctional moduleon the ball valve, the multifunctional levercan only be remounted if the spacer ringis removed.


Adapter plate for actuators Multifunctional module Cover

Functions:• Interface to add on actuators• Feedback unit in combination with actuators• Also for manual valve – with multifunctional lever• Intermediary element for back wall installation

a) The housing is made entirely of polypropylene. It is screwed directly on the valve.The inner contour of the multifunctional module is asymmetrical and fits exactly on thecorresponding outer contour of the ball valve housing.

b) There is a choice of 5 encapsulated limit switches. To select the respective switch,please see the following table.

c) The multifunctional module is screwed directly onto the ball valve housing with 4stainless steel Torx screws.

d) The ABS indexing disk warrants a precise switching point.

e) Catch cams to lock the cover on the multifunctional module.

f) Plugs as an additional safety measure to prevent the cover from opening.

g) Connector plug 3P+E for fast and easy cable mounting – protection rating: IP65

h) Clamp to fasten the adapter plate on the multifunctional module with stainless steelTorx screws


Assembly of multifunctional module incl. switches1 Housing2 Cover3 Indexing disk4 Switch holder5 Microswitch "OPEN"6 Microswitch "CLOSE"7 Connector plug 3P + E per DIN EN 175301-803 (formerly DIN 43650)8 Seal

General technical data of multifunctional moduleProtection rating with DIN unit plug (7): IP 65Protection rating with cable gland: IP 67Ambient temperature: - 10°C to + 50°C

Switch type Capacity Code no.MicroswitchSilver nickel (AgNi)

250 V~6 A *)

167.482.626 DN 10 - 15167.482.627 DN 20 - 25167.482.628 DN 32 - 40167.482.629 DN 50

Microswitchwith gold contacts(Au)

4 - 30 V=1 – 100mA

167.482.635 DN 10 - 15167.482.636 DN 20 - 25167.482.637 DN 32 - 40167.482.638 DN 50

Wiring diagram

A closedB openC blackD blue (short cable)E blue (long cable)

*) for ohm resistive load. For inductive loads, use a protective circuit!


Switch type Capacity Code no.Inductive switchNPN

5 -30 V=0.1 A

167.482.653 DN 10 - 15167.482.654 DN 20 - 25167.482.655 DN 32 - 40167.482.656 DN 50

Inductive switchPNP

5 -30 V=0.1 A

167.482.662 DN 10 - 15167.482.663 DN 20 - 25167.482.664 DN 32 - 40167.482.665 DN 50

Wiring diagram

A closedB openC blueD blackE blackF brown

Switch type Capacity Code no.Inductive switchNamur

Approvals:ATEX 2032x, CSAEMC per EN60947-5-2Norm conformityEN 60947-5-6

8 V= 167.482.671 DN 10 - 15167.482.672 DN 20 - 25167.482.673 DN 32 - 40167.482.674 DN 50

Wiring diagram

A closedB openC blueD brown

CE labelAccording to the EC Directive 98/37/EC pertaining to machines (formerly89/392/EWG) these actuators/valves are not considered machines, but may beinstalled in installations which are considered machines.

We explicitly specify that operation is prohibited until it has been made certainthat the machine (equipment) into which this product has been built correspondsto the regulations of the EC Machine Directive 98/37/EC.


As an alternative to the integrated fastening with the threaded inserts, the Ball ValveType 546 can also be mounted with an additional fastening plate.Forces, which may occur under normal operation of the valve (e.g. initial breakawaytorque), are absorbed with this fastening plate. By using the fastening plate, nooperating forces are transmitted to the piping system.

!In piping systems which are subject to temperature changes, longitudinal or lateralforces may occur if thermal expansion is hindered. So as not to impair valveoperation, these forces must be absorbed via the respective fixed points in front of orafter the valve.

The fastening plate is available in two sizes for the dimension range DN 10 to DN 50.Included in delivery are two screws for fastening to the ball valve.

Description d 16 - 32 d 40 - 63DN 10 - 25 DN 32 - 50

L 106 149B 48 54H 20 20L1 92 134L2 62 104L3 31 52L4 41 62L5 25 45H1 14 14H2 4 4D 6.5 8.5

Fastening screw M6 x 14 M8 x 18

The fastening plate has been adapted in height to the new Georg Fischer Klip-It pipeclamps and the corresponding spacers type 061. For more information, please see ourproduct range.


Several hazard notices are used in this manual to warn you of possible injuries ordamages to property. Please read and observe these warnings at all times!

Danger

Imminent acute danger!Failure to comply could result in death or extremely serious injury

!

Warning

Possible acute danger!Failure to comply could result in serious injury.

CautionDangerous situation!Failure to comply could lead to injury or damage to property.

Abbreviations

Type 546 Ball Valve Type 546MF lever Lockable multifunctional leverMF module Multifunctional modulePN Nominal pressure

The same safety guidelines apply for ball valves as for the piping system into whichthey are built.The Type 546 is intended exclusively for shutting off, conducting or controlling the flowof allowed media within the permissible pressure and temperature ranges in thepiping system into which it has been installed. The maximum service life is 25 years.

CautionPlease note that the max. working pressure of the whole valve is determined by themaximum permissible nominal pressure of the connecting part.

Anyone involved with the mounting, dismounting, operation, handling andmaintenance (inspection, service and repair) of the valve at the plant where it hasbeen installed must have read and understood the complete instruction manual, andin particular this paragraph pertaining to safety information.

We recommend having this confirmed in writing.Furthermore:

• Use only perfectly functioning valves and always observe these safety guidelines• Keep this documentation readily available in the vicinity of the valve

It is the responsibility of the piping systems engineer / installer and the operator ofsuch systems into which the ball valve has been built to warrant that

• The piping system has been installed correctly by professionals and itsfunctionality is checked periodically


• Only qualified and authorised personnel mounts, operates, services and repairsthe ball valve. Employees must be instructed on a regular basis in all aspects ofwork safety and environmental protection as indicated by the applicable localregulations – especially those pertaining to pressure-bearing piping systems.

• The valve is only used according to the specifications for which it has beenintended, as indicated in the section on safety

• Installation positions and locations in which manipulations can occurunintentionally must be avoided.

!

Warning

Do not use ball valves for media containing solids.Avoid cavitation in control operations.This could lead to damages (leakage caused by abrasion).

!

Warning

Removing the Type 546 from the piping system

If the pressure has not been released completely, the medium can exituncontrollably.

Depending on the type of medium, injury may occur.

Before dismounting, release all pressure from the piping system. Forhazardous, flammable or explosive media, the piping system must becompletely emptied and rinsed before the valve may be dismounted.(Attention: there could still be residue)

!

Warning

Medium needs to be tapped from a Type 546, which is used as an end valvein a pressure-bearing piping system.

The medium can exit / splash uncontrollably.


Make certain that the medium is caught safely with the appropriate measures(e.g. connecting a vessel to collect the exiting medium)

!

Warning

The Type 546 is to be stored or dismantled after removal from the pipingsystem.

Residual media can exit uncontrollably.


Open the dismounted valve Type 546 halfway (45° position) and let it drain ina vertical position – catch the medium in an appropriate vessel.

The Ball Valve Type 546 must be handled, transported and stored with care. Pleasenote the following:• The Type 546 should be transported and / or stored in its original, unopened

packaging.


• The ball valve must be protected from harmful physical influence such as light,dust, heat, (humidity) and UV radiation.

• The connecting ends of ball valve, in particular, must not be damaged bymechanical or thermal influences.

• The ball valve should be stored with the lever in the open position (as it wassupplied).

To begin with, the ball valve should be inspected for transport damages. Damagedvalves may not be installed.A function test – close the ball valve by hand and open it again – should be done.Ball valves which do not function properly must not be installed.

CautionThe ball valve must always be built into the system in the open position.

Only ball valves whose pressure rating, type of connection and dimensionscorrespond to the operating conditions may be installed.For fusion and cementing connections, only join identical materials with one another.

!

Warning

The installation dimensions, connections and union nuts of the type 546 havebeen modified from the type 346.

The use of components and installation dimensions other than those prescribed forthe type 546 can cause damage to the piping system.

Compare the installation dimensions and specifications in the technicaldocumentation with those of the components at hand.

We recommend only taking the ball valve out of its original packaging just beforeinstallation.The ball valve and the pipe must be aligned so that the valve is kept free ofmechanical stress.The specific jointing instructions for solvent cement, fusion, or screw connections mustbe adhered to when installing the valve into a piping system. More information canbe found in the operating instructions of the fusion machine manufacturer or thecementing instructions of the adhesive manufacturer.The tightening torque of the flange screws and other useful information can be foundin the chapter "Guidelines for fastening screws".


Open the union nuts and slide them onto the pipe ends.

Join the piping components according to the material and yourconnection version (fusion, cementing, screws, flange).

Place the ball valve between the connecting parts.

Screw the union nuts onto the connecting thread of the ballvalve and tighten by hand.

!

Warning

The union nuts of the Type 546 must be hand tightened – without the use ofadditional tools.

If other tools, such as pliers, are used, the material of the union nuts may bedamaged. There is also the danger of damaging the thread if they are tightened toostrongly.

Operation of the valve causes reactive forces in the pipe to which it is connected. It istherefore necessary to mount the ball valve with its integrated / separate fastener (ifavailable) or to reinforce the corresponding piping directly before or after the ballvalve with suitable supports.

Caution

If you are using the integrated fastener in the base of the Type 546, pleasetake note of the max. insertion depth H of the screws. Failure to comply canlead to damage of the ball valve housing. The pressure load on a damagedhousing can cause breakage.

Max. insertion depth of the screws in the ball valve.

DN 10/15 20/25 32/40 50Screw M6 M6 M8 M8max. insertion depthH (mm)

12 12 15 15

!

Warning

In piping systems with temperature fluctuations, bending and longitudinal forces canoccur if thermal expansion is hindered. So as not to impair operation of the valve,these forces must be absorbed by having suitable fixed points in front of or behindthe valve.


Ball valve pressure testing is subject to the same regulations as apply to the pipingsystem. Detailed information can be found in the Georg Fischer Design Fundamentalschapter on Handling and Installation.Also applicable:• Check that all valves are in the required open or closed position• Fill the piping system and deaerate carefully

CautionThe test pressure on a valve may not exceed the value 1.5 x PN, (maximum PN+ 5 bar). The components with the lowest PN determine the maximum allowable testpressure in the piping section.

Check the valves and connections for leaks during the pressure test. Record yourresults.

When the leak test has been completed successfully, the test medium may beremoved. The system can now be used as intended.

Ball valves require no maintenance under normal working conditions. Periodicinspection to make sure that no medium is leaking is sufficient. Should leakage orother malfunctions occur, follow the instructions given under "Safety Instructions,Hazardous Situations".

We recommend a function test for ball valves which are kept permanently in the sameposition 1-2x a year to check operation.

For frequent control operations – e.g. valve automation, or due to chemical attack onthe sealing material, it may become necessary to replace parts inside the valve. Forthis purpose, the valve must be removed from the piping system, while keeping to theinstructions given under the section "Hazardous Situations".

Exploded drawing of multifunctional lever:13 Lever clip22 Multifunctional lever23 Spacer24 Unlocking latch22

13

23

24

25

25 Fastening screws (Torx)


Exploded drawing of manual valve:

11

6

13

12

30

14

43

2 9 8 75

7 8

1

10

10 34

31

1 Housing 9 Housing seal2 Union bush 10 Connecting part seal3 Connecting part 11 Spigot seal4 Union nut 12 Standard lever5 Ball 14 Threaded insert6 Spigot 22 Multifunctional lever7 Ball seal 30 Fastening plate8 Backing seal 31 Fastening screws

Once the ball valve has been removed from the pipe by loosening the union nut (4)and preparations have been made for drainage, dismantle the valve by followingthese steps:

Pull the lever off the spigot.The lever can now be used as a tool.

By using the lever clip (13) , the union bush (2) can beunscrewed (Attention: left thread).


! The mark on the spigot must now be at a right angle to theflow direction (closed ball position).

The ball can be pushed out with a rod in a soft material (plasticor wood).

Push the spigot down into the housing and take it out.

The sealing elements, as well as the ball, spigot and union bush, can be replaced.George Fischer has the respective spare parts on offer.

CautionOnly original Georg Fischer spare parts designed specifically for this valve may beused for replacement purposes. Orders for spare parts for the Type 546 valve shouldinclude all the details given on the typeplate.

CautionSelecting a lubricant

Using the wrong lubricants can damage the material of the ball valve or the seals.Never use petroleum-based greases or Vaseline (Perolatum).For silicon-free ball valves, please consult the special manufacturer’s instructions.

All the seals must be lubricated with a silicon or polyglycol based grease.

CautionSeals

All the seals (made of e.g. EPDM, FPM) are organic materials which react toenvironmental influences. They must therefore be kept in their original packagingand stored cool, dry and dark. Seals should be checked for damages from ageing,such as fissures and hardening, before mounting.

Do not use defective spare parts.


To assemble the individual parts, please proceed according to the following steps:

Insert the backing seal (8) and the ball seal (7) in the grooveprovided for this purpose on the inner side of the stop or theunion bush.

Pull the housing seal (9) onto the collar of the union bush.

Place the seal for the connecting part (10) in the groove of theunion bush (2) or the fixed housing stop (1).

Insert the two lubricated (see Selection of lubricants) spigotseals (11) in the grooves of the spigot (6).

Slide the prepared spigot (6) into the housing (1) from the inside.The spigot is correctly positioned when pushed against the stopfrom the inside.

Attention! The marks on the spigot must be at a right angle to the flow direction(closed ball position)


Put the ball (5) through the outlet in the housing (1) into thespigot guide.

Screw the assembled union bush (2) into the housing (1)(Attention: left-hand thread).The cams on the lever clip (13) can be used like a tool.

Tighten so that the ball moves snugly.

Attention! The marks on the spigot must now be parallel to theflow direction (open ball position)

Place the standard lever (12) on the spigot (6). The ball valve isnow ready for use.

As an alternative to the standard lever, you can use a lockable multifunctional lever(MF lever) with the Ball Valve Type 546.

Exploded drawing of the multifunctional lever

13 Lever clip22 Multifunctional lever23 Spacer24 Unlocking latch

22

13

23

24

25

25 Fastening screws (Torx)


To assemble the multifunctional lever, please proceed according to the followingsteps:

Remove the lever clip (13) with the help of a screwdriver.

Position the spigot according to the illustration. Place the leveron the spigot.

At the bottom of the lever shaft there is a spacer (23). Make sure that it is positionedcorrectly in the shaft (stop).

Attach the lever by tightening the pre-assembled screw (25)inside the lever.

Set the lever clip (13) on the lever again.

Working with the MF lever:

Press the unlocking button (24) into the lever.

Hold the button in this position. The lever can now be rotated90°.

The lever is locked in the respective position and may also besecured in this position against unauthorised access by addinga lock.


Several hazard notices are used in this manual to warn you of possible injuries ordamages to property. Please read and observe these warnings at all times!

Danger

Imminent acute danger!Failure to comply could result in death or extremely serious injury

!

Warning

Possible acute danger!Failure to comply could result in serious injury.

CautionDangerous situation!Failure to comply could lead to injury or damage to property.

Abbreviations

Type 546 Ball Valve Type 546MF lever Lockable multifunctional leverMF module Multifunctional modulePN Nominal pressure

Examine the MF module before mounting to make sure it has not been damagedduring transport. We recommend leaving the MF module in its original packaginguntil just before installation.The MF module has been equipped with the respective switches and tested ex factory!It is not necessary to dismount the cover when used with hand operated ball valves.


Assembly of the MF module with built-in switch

1 Housing2 Housing cover3 Indexing disk *3a Switching cams4 Stainless steel Torx screws

1

4

3

2

5

3a

5 Connector plug 3P + E perDIN EN 175301-803*(formerly DIN 43650)

*) for MF module version with pre-assembled microswitches

The MF module can be mounted on the Ball Valve Type 546 in the open or closed ballposition.


Attention! Spigot is asymmetrical

The position of the spigot must be identical to one of the two illustrations.

GF++

A Spigot position for closed ball valve.

GF++

B Spigot position for open ball valve.

Note the square (a), respectively, round (b) contour, as wellas the position of the asymmetrical recess (c) of the spigot.

Place the MF module on the ball valve.

Make sure the contour of themultifunctional module agrees with that ofthe ball valve!

Tighten the four pre-assembled screws.The MF module is now securely positionedon the ball valve.


close

close

Put the switching cams (3a) in therespective position.

For open ball valve

close

close

For closed ball valve

The MF module is now ready to receive the MF lever.

To mount the MF lever, follow these steps:

22

13

23

24

25

Remove the spacer (23).

Place the MF lever on the spigot.(Example: open ball position)

Remove the lever clip (13) with the help ofa screwdriver.


Attach the lever by tightening the pre-assembled screw (25) inside the lever.

Put the lever clip (13) back in the MF lever.

For general technical data and the wiring diagrams, please see the chapter"Technical Features of the Multifunctional Module".

Fi 8213/4 (12.02) © Georg Fischer Rohrleitungssysteme AG, CH-8201 Schaffhausen/Schweiz, 2002 Printed in Switzerland

¥ ‡Piping Systems

A Georg Fischer Rohrleitungssysteme GmbH, Sandgasse 16, 3130 Herzogenburg, Tel. +43(0)2782/856 43-0, Fax +43(0)2782/856 64, e-mail: [email protected] George Fischer Pty Ltd, 186–190 Kingsgrove Road, Kingsgrove NSW 2008, Tel. +61(0)2/95 54 39 77, Fax +61(0)2/95 02 25 61B/L Georg Fischer NV/SA, Digue du Canal 109-¢¢¢ — Vaartdijk 109-¢¢¢, 1070 Bruxelles/Brüssel, Tél. +32(0)2/556 40 20, Fax +32(0)2/524 34 26

e-mail: [email protected] George Fischer Ltda, Av. das Nações Unidas 21689, 04795-100 São Paulo, Brasil, Tel. +55(0)11/5687 1311, Fax +55(0)11/5687 6009CH Georg Fischer Rohrleitungssysteme (Schweiz) AG, Amsler-Laffon-Strasse ¢, Postfach, 8201 Schaffhausen, Tel. +41(0)52 631 30 26, Fax +41(0)52 631 28 97

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e-mail: [email protected] Fischer Piping Systems (Trading) Ltd Shanghai, No 516 Fute Bei Road, Waigaoqiao Free Trade Zone, 200131 Pudong, ShanghaiTel. +86(0)21/5868 0278, Fax +86(0)21/5868 0264, e-mail: [email protected]

D Georg Fischer GmbH, Daimlerstraße 6, 73095 Albershausen, Tel. +49(0)7161/302-0, Fax +49(0)7161/302 111e-mail: [email protected], Internet: http://www.rls.georgfischer.deGeorg Fischer DEKA GmbH, Kreuzstrasse 22, 35232 Dautphetal-Mornshausen, Tel. +49(0)6468/915-0, Fax +49(0)6468/915 221/222e-mail: [email protected], Internet: http://www.dekapipe.de

DK/IS Georg Fischer A/S, Rugvænget 30, 2630 Taastrup, Tel. +45 70 22 19 75, Fax +45 70 22 19 76e-mail: [email protected], Internet: http://www.georgfischer.dk

E Georg Fischer S.A., Alcalá, 85, 2a, 28009 Madrid, Tel. +34(0)9¢/781 98 90, Fax +34(0)9¢/426 08 23e-mail: [email protected]

F George Fischer S.A., 105–1¢3, rue Charles Michels, 93208 Saint-Denis Cedex 1, Tél. +33(0)1/49 22 ¢3 4¢, Fax +33(0)¢/49 22 ¢3 10, e-mail: [email protected] George Fischer Sales Limited, Paradise Way, Coventry, CV2 2ST, Tel. +44(0)2476/535 535, Fax +44(0)2476/530 450

e-mail: [email protected], Internet: http://www.georgefischer.co.ukGR Georg Fischer S.p.A., Athens Branch, 101, 3rd September Str., 10434 Athen, Tel. +30(0)1/882 0491, Fax +30(0)1/881 0291, e-mail: [email protected] Georg Fischer S.p.A., Via Sondrio 1, 20063 Cernusco S/N (MI), Tel. +3902/921 86 20 1, Fax +3902/921 86 24 7, e-mail: [email protected] George Fischer Representative Office, c/o Wisma Aria, 3rd Floor, Jl. H.O.S. Cokroaminoto 81, Jakarta 10310, Indonesia, Tel. +62(0)21/391 48 62, Fax +62(0)21/391 48 63IND George Fischer Piping Systems Ltd, India Branch Office, Solitaire Corporate Park, 532, Building No. 5, 3rd Floor, Chakala, Ghatkopar Link Road, Andheri (E)

400 093 Mumbai, Tel. +91(0)22/820 2362, Fax +91(0)22/820 2462, e-mail: [email protected] Georg Fischer Ltd, 2–47, Shikitsuhigashi 1-chome, Naniwa-ku, 556-8601 Osaka, Tel. +81(0)6/664 82 59 4, Fax +81(0)6-664 82 56 5, e-mail: [email protected] Georg Fischer AS, Rudsletta 97, ¢35¢ Rud, Tel. +47(0)67 18 29 00, Fax +47(0)67 13 92 92, Internet: http://www.georgfischer.noNL Georg Fischer N.V., Postbus 35-8160, 8161 PA Epe, Tel. +31(0)578/678222, Fax +31(0)578/621768

e-mail: [email protected], Internet: http://www.georgfischer.nlPL Georg Fischer Sp. z o.o., ul. Radiowa 1A, 01-485 Warszawa, Tel. +48(0)22/638 91 39, Fax +48(0)22/638 00 94RO Georg Fischer Rohrleitungssysteme AG, Rep. Office Romania, 11 Barbu Delavrancea, 70000 Bucharest - Sector 1, Tel. +40(0)1/222 91 36, Fax +40(0)1/222 91 77

e-mail: [email protected] Georg Fischer Piping Systems Ltd, Moscow Representative Office, Sheremetievskaya ul., 47, 127521 Moscow, Tel. +7 095/219 9604, Fax +7 095/232 3625

e-mail: [email protected]/FIN Georg Fischer AB, Box 113, 12523 Älvsjö-Stockholm, Tel. +46(0)8/506 77 500, Fax +46(0)8/749 23 70, e-mail: [email protected], Internet: http://www.georgfischer.seSGP George Fischer Pte Ltd, ¢5 Kaki Bukit Road 2, KB Warehouse Complex, 4¢7 845 Singapore, Tel. +65(0)7/47 06 ¢¢, Fax +65(0)7/47 05 77, e-mail: [email protected] George Fischer Inc., 2882 Dow Avenue, Tustin, CA 92780-7258, Tel. +1(714) 731 88 00, Toll Free 800/854 40 90, Fax +1(714) 73¢ 62 01

e-mail: [email protected], Internet: http://www.us.piping.georgefischer.comExport Georg Fischer Rohrleitungssysteme AG, Ebnatstrasse ¢¢¢, Postfach, CH-820¢ Schaffhausen, Tel. +41(0)52 63¢ ¢¢ ¢¢, Fax +41(0)52 63¢ 28 93/631 28 58

e-mail: [email protected], Internet: http://www.piping.georgfischer.com

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