‡ Type 546 Ball Valve

Setting a new standard in piping systems

Product Range

PVC-U, PVC-C

¥ ‡
Piping Systems
 List of abbreviations
ANSI American National Standard Institute FM Fusion Method
ASTM American Society for Testing and Materials d Pipe outer diameter
BS British Standard DN Nominal diameter
DIN Deutsche Industrie-Normen PN Nominal pressure at 20 °C, water
ISO International Standardization Organization kg Weight in kilograms
ABS Acrylnitrile-Butadiene-Styrene g Weight in grams
The technical data are not PVC-U Polyvinyl chloride. unplasticized NPT Female thread, tapered, pressure tight
PVC-C Polyvinyl chloride. post-chlorinated in the thread per ANSI B1.20.1
binding. They are not war-
PP Polypropylene. heat stabilized R Male thread, tapered, pressure
ranted characteristics and PE Polyethylene tight in the thread per ISO 7/DIN 2999/1
are subject to change. PVDF Polyvinylidene fluoride Rp Female thread, parallel,
Please consult our General EPDM Ethylene-Propylene-Rubber pressure tight in the thread
Conditions of Supply. FPM Fluororubber, e.g. Viton® per ISO 7/DIN 2999/1
PTFE Polytetrafluoroethylene, e.g. Teflon® ® Registered trademark
 Table of Contents
‡ Type 546 Ball Valve Page

Ball Valves PVC-U 6

Ball Valves PVC-C 19

Product Configurator 30

Valve Ends 33

Accessories 45

Multi-functional Module 50

¥ ‡
 ‡ Type 546 Ball Valve.
The system at a glance.

Standard ball valve Ball valve with Manual ball valve with Ball valve with handle extension Ball valve with electric Ball valve with pneumatic
lockable handle electric feedback unit for through-wall/panel mounting actuator actuator and manual override
in the multi-functional
module

Solvent cement socket Threaded socket Solvent cement spigot Fusion spigot and socket Backing flange Fixed flange

Availability A complete model range with many The new ‡ type 546 ball valve
combinations conforms to the following
April 2003 From the manual valve to the electric international standards
PVC-U actuated ball valve with LED display.
Modular design and expandable. prEN ISO 16135 (pending)
August 2003 From DN 10 to DN 50. Up to16 bar Industrial valves – ball valves of thermo-
PVC-C pressure. plastic materials (ISO/DIS 16135:2001)
In cementable materials: PVC-U, ABS,
1st Quarter 2004 PVC-C and in fusible materials: PP-H, ISO 9393
PP-H, PVDF, ABS PVDF Thermoplastic valves –
Connections in all the major pressure test methods and requirements
standards:
• metric: DIN, EN, ISO EN 558
• inch: BS, ANSI Flanged valve dimensions are in
• JIS accordance with EN 558
This broad range of products enables
you to find the right solution for your Approvals
application. DIBt approval pending

¥ ‡
‡ Type 546 Ball Valve.
With multi-functional module.
The multi-functional module is the
answer
What is the current status of the valves
in the system? Which ones are open,
which are closed?
To be able to answer these questions at
all times means safety for you and your
operators.
With this multi-functional module, we
have a tested and proven unit for you
which has not been available before.
The feedback concept includes a
selection of 5 different limit switches,
designed to fit your needs.
With AS-Interface on request.
¥ ‡
«What’s the
black box for?»
«Connections!»
The multi-functional module
has more to offer
Thanks to its robust construction and
the secure fastening on the ball valve
(4 Torx screws), the multi-functional
module can be used as a mounting
bracket. Through wall/panel mounting
was never so easy.
Replace the lid and the module is
equipped with a DIN EN ISO 5211
mounting interface. The new George
Fischer actuators can be connected
directly.
Find the fitting solution
with the Configurator
Ball valve Example:
A01 Ball valve 546
Type 546 PVC-U, dimension DN 32,
Material
B01 PVC-U PTFE ball seal, EPDM seals,
with threaded inserts and mounting plate,
Dimension
C05 d 16 DN 10 3/8‘‘ connecting part left: PVC-U cement socket metric,
C06 d 20 DN 15 1/2‘‘ right: PE-100 butt fusion spigot lang SDR11 metric
C07 d 25 DN 20 3/4‘‘
C08 d 32 DN 25 1‘‘ That‘s all it takes to configure your ball valve.
C09 d 40 DN 32 1 1/4‘‘
C10 d 50 DN 40 1 1/2‘‘
C11 d 63 DN 50 2‘‘

Version
D01 standard, PTFE ball seal
D03 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)

Seals
E01 EPDM seals
E02 FPM seals
Threaded inserts
F01 without threaded inserts
F02 with threaded inserts
Connecting parts
G01 PVC-U Cement socket metric
G03 PVC-U Cement socket inch ASTM
G04 PVC-U Cement socket inch BS
G05 PVC-U Cement spigot metric
G06 PVC-U Threaded socket Rp
G07 PVC-U Threaded socket Rp reinforced
G09 PVC-U Threaded socket NPT
G30 PP-H Fusion socket metric
G32 PP-H Socket fusion spigot metric
G33 PP-H Threaded socket Rp
G34 PP-H Threaded socket NPT reinforced
G35 PP-H Butt fusion spigot SDR 11 metric IR-PLUS
G36 PP-H Butt fusion spigot SDR 17.6 metric (limited dimension range)
G37 PP-H Butt fusion spigot long SDR11 metric
G40 PE-100 Fusion socket metric
G41 PE-100 Butt fusion spigot SDR11 metric
G42 PE-100 Butt fusion spigot SDR17.6 metric (limited dimension range)
G43 PE-100 Butt fusion spigot lang SDR11 metric
G60 Fixed flange PVC-U serrated metric
G61 Fixed flange PVC-U flat metric
G70 Backing flange PVC-U metric
G71 Backing flange PVC-U inch ANSI
G72 Backing flange PP-steel metric
G73 Backing flange PP-steel ANSI
G80 PVC-U Valve end blank

Multi-functional module
I01 No multi-functional module
I02 Empty module
I03 Module with 2 limit switches Ag, Ni
I04 Module with 2 limit switches Au
I05 Module with 2 inductive switches Namur
I06 Module with 2 inductive switches PNP
I07 Module with 2 inductive switches NPN
Handle
K01 Standard handle red
K02 Standard handle black
K11 Multi-functional handle red
Mounting plate
L01 without mounting plate
L02 with mounting plate

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

¥ ‡
Copiable
Configurator ‡ Ball Valve Type 546 PVC-U
Ball valve You will find a large selection of different
A01 Ball valve 546
versions in our range of products. New
Material system elements also provide you with new
B01 PVC-U
opportunities for use. In order for
Dimension us to supply exactly the ball valve you need
C05 d 16 DN 10 3/8‘‘
C06 d 20 DN 15 1/2‘‘ for your application, we put together a
C07 d 25 DN 20 3/4‘‘ selection menu for you.
C08 d 32 DN 25 1‘‘
C09 d 40 DN 32 1 1/4‘‘ We supply what you put together.
C10 d 50 DN 40 1 1/2‘‘
C11 d 63 DN 50 2‘‘

Version
D01 standard, PTFE ball seal
D03 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)

Seals
E01 EPDM seals
E02 FPM seals
Threaded inserts
F01 without threaded inserts
F02 with threaded inserts
Connecting parts
G01 PVC-U Cement socket metric
G03 PVC-U Cement socket inch ASTM
G04 PVC-U Cement socket inch BS
G05 PVC-U Cement spigot metric
G06 PVC-U Threaded socket Rp
G07 PVC-U Threaded socket Rp reinforced
G09 PVC-U Threaded socket NPT
G30 PP-H Fusion socket metric
G32 PP-H Socket fusion spigot metric
G33 PP-H Threaded socket Rp
G34 PP-H Threaded socket NPT reinforced
G35 PP-H Butt fusion spigot SDR 11 metric IR-PLUS
G36 PP-H Butt fusion spigot SDR 17.6 metric (limited dimension range)
G37 PP-H Butt fusion spigot long SDR11 metric
G40 PE-100 Fusion socket metric
G41 PE-100 Butt fusion spigot SDR11 metric
G42 PE-100 Butt fusion spigot SDR17.6 metric (limited dimension range)
G43 PE-100 Butt fusion spigot lang SDR11 metric
G60 Fixed flange PVC-U serrated metric
G61 Fixed flange PVC-U flat metric
G70 Backing flange PVC-U metric
G71 Backing flange PVC-U inch ANSI
G72 Backing flange PP-steel metric
G73 Backing flange PP-steel ANSI
G80 PVC-U Valve end blank

Multi-functional module
I01 No multi-functional module
I02 Empty module
I03 Module with 2 limit switches Ag, Ni
I04 Module with 2 limit switches Au
I05 Module with 2 inductive switches Namur
I06 Module with 2 inductive switches PNP
I07 Module with 2 inductive switches NPN
Handle
K01 Standard handle red
K02 Standard handle black
K11 Multi-functional handle red
Mounting plate
L01 without mounting plate
L02 with mounting plate

A01 B01 C D E F G G I K L
left right

¥ ‡
Copiable
Configurator ‡ Ball Valve Type 546 PVC-C
Ball valve You will find a large selection of different
A01 Ball valve 546
versions in our range of products. New
Material system elements also provide you with new
B02 PVC-C
opportunities for use. In order for
Dimension us to supply exactly the ball valve you need
C05 d 16 DN 10 3/8‘‘
C06 d 20 DN 15 1/2‘‘ for your application, we put together a
C07 d 25 DN 20 3/4‘‘ selection menu for you.
C08 d 32 DN 25 1‘‘
C09 d 40 DN 32 1 1/4‘‘ We supply what you put together.
C10 d 50 DN 40 1 1/2‘‘
C11 d 63 DN 50 2‘‘

Version
D01 standard, PTFE ball seal
D03 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)

Seals
E01 EPDM seals
E02 FPM seals
Threaded inserts
F01 without threaded inserts
F02 with threaded inserts
Connecting parts
G11 PVC-C cement socket metric
G13 PVC-C cement socket inch ASTM
G14 PVC-C cement spigot metric
G15 PVC-C threaded socket Rp
G16 PVC-C threaded socket Rp reinforced
G17 PVC-C threaded socket NPT
G40 PE-100 fusion socket metric
G41 PE-100 butt fusion spigot SDR11 metric
G42 PE-100 Butt fusion spigot SDR17.6 metric (limited dimension range)
G43 PE-100 butt fusion spigot long SDR11 metric
G72 Backing flange PP-steel metric
G73 Backing flange PP-steel ANSI
G80 PVC-U Valve end blank

Multi-functional module
I01 No multi-functional module
I02 Empty module
I03 Module with 2 limit switches Ag, Ni
I04 Module with 2 limit switches Au
I05 Module with 2 inductive switches Namur
I06 Module with 2 inductive switches PNP
I07 Module with 2 inductive switches NPN
Handle
K01 Standard handle red
K02 Standard handle black
K11 Multi-functional handle red
Mounting plate
L01 without mounting plate
L02 with mounting plate

A01 B02 C D E F G G I K L
left right

¥ ‡
 T (°F)
14 32 50 68 86 104 122 140 158 176 194
17 246.5
16 232
15 PN 16 1) 217.5
14 203
13 188.5
12 174
11 PN 10 2) 159.5

P (psi)
10 145
P (bar)

9 130.5
8 116
7 101.5
6 87
5 72.5
4 PN 6 3) 58
3 43.5
2 29
1 14.5
0 0
-10 0 10 20 30 40 50 60 70 80 90
F164.4
T (°C)
1) The central part of ball valve is designed for the nominal pressure PN 16
2) According to the valve end the nominal pressure is reduced to PN 10
3) According to the valve end the nominal pressure is reduced to PN 6
T Temperature in °C / °F
p permissible pressure in bar / psi

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

9
 T (°F)
14 32 50 68 86 104 122 140 158 176 194
17 246.5
16 232
15 217.5
14 PN 16 1) 203
13 188.5
12 174
11 159.5

P (psi)
10 145
P (bar)

9 130.5
8 PN 10 2) 116
7 101.5
6 87
5 72.5
4 58
3 43.5
2 29
1 14.5
0 0
-10 0 10 20 30 40 50 60 70 80 90
F152.4
T (°C)
1) The central part of ball valve type 546 is designed for the nominal pressure PN 16
2) According to the valve end the nominal pressure is reduced to PN 10
T Temperature in °C / °F
p permissible pressure in bar / psi

X Size DN (mm)
Y Torque (Nm)

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

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

X Open angle (%)

Y Flow factor kv (%)

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

11
 The kv values for each intermediate valve position can be determined using the flow
value characteristic and the kv 100 values.

DN DN d kv 100 kv 100
mm inch mm l/min m3/h
(∆p = 1 bar) (∆p = 1 bar)
10 3/8 16 70 4.2
15 1/2 20 185 11.1
20 3/4 25 350 21
25 1 32 700 42
32 1¼ 40 1000 60
40 1½ 50 1600 96
50 2 63 3100 186

Flanged joints with flange gaskets or flat gaskets

d DN DN Total number of screws Torque Torque

mm mm inch (for 2 flanged joints) (average values) (average values)
standard nut Flange gasket2) Flat gasket
(height 0.8 x d) 1) In Nm in Nm
20 15 ½ 8 x M12 x 50 15 15
25 20 ¾ 8 x M12 x 55 15 15
32 25 1 8 x M12 x 60 15 15
40 32 1¼ 8 x M16 x 65 15 20
50 40 1½ 8 x M16 x 70 15 30
63 50 2 8 x M16 x 75 20 35

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

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

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

 a) Connecting parts for the 546 are
available as:
- Solvent cement/fusion socket (short
installation length)
- Solvent cement/fusion spigot (for
standard installation length)
- Threaded socket (on request with
stainless steel outer reinforcement
ring)
- 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. h) The backing seal effectuates
continuous readjustment of the ball seal
b) Newly designed valve nuts with and this means that under normal
buttress thread. These enable fast and working conditions maintenance-free
safe radial mounting and dismounting of operation and a constant torque can be
the valve during installation or warranted.
maintenance work, without tools.
Attention: Only hand tighten valve nuts.

c) Union bush with fine buttress thread
makes it easier to adjust the operating
torque. Attention: Please observe the
operating torque guidelines!
d) Ball with fully circular cross-section for
optimal flow characteristics. The system
with the floating ball permits a tight seal.
e) Two spigot seals with o-rings
guarantee a long service life and high
reliability.
f) The spigot features a predetermined
breaking point, which is located outside
of the housing. In case of damage, the
medium cannot therefore leak to the
outside along the spigot.
g) Sturdy ball seals made of pure PTFE
demonstrate high abrasion resistance,
good sliding properties, chemical
resistance (see the special list of
“Chemical Resistance”) and a long
working life.
The special geometry of the o-ring
chamber prevents the o-rings from being
flushed out.
i) Compact housing, designed especially
for plastics, with short installation length.
The basic model has pick-up points for
threaded inserts so that they can be
attached directly on the valve. A
multifunctional module with limit switches,
which simultaneously serves as an
interface for adding actuators, can be
mounted quickly and simply on the
housing.
k) Ergonomic polypropylene lever with
double stops and coding for clear
positioning on the spigot. Multifunctional
lever, lockable and with grid positioning
at 0° and 90°, available as an option.
l) Integrated lever clip of reinforced
polypropylene with two cams, enabling
the lever to be used as a tool for
assembly and disassembly of the union
bush (Attention: The union bush has left-
handed thread)

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

13
 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 with m) Unlocking device of reinforced

double stops and contours for clear
positioning on the spigot. The lever is
lockable and can be arrested in the 0°
and in the 90°. Included in delivery is a
stainless steel Torx screw for fastening the
lever on the spigot.
l) Integrated lever clip of reinforced
polypropylene with two cams, enabling
the lever to be used as a tool for
assembly and disassembly of the union
bush.
polypropylene, spring of stainless steel.
This mechanism can be inhibited by
adding a padlock. The bore diameter for
the padlock is 5.4 mm
n) The spacer ring works as a barrier.
After mounting a multifunctional module
on the ball valve, the multifunctional lever
can only be remounted if the spacer ring
is removed.

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

 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 the
corresponding 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 4
stainless 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 steel
Torx screws

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

15
 Assembly of multifunctional module incl. switches
1 Housing
2 Cover
3 Indexing disk
4 Switch holder
5 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 module

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

Switch type Capacity Code no. Wiring diagram

Microswitch 250 V~ 167.482.626 DN 10 - 15
Silver nickel (Ag 6 A *) 167.482.627 DN 20 - 25
Ni) 167.482.628 DN 32 - 40
167.482.629 DN 50

Microswitch 4 - 30 V= 167.482.635 DN 10 - 15
with gold contacts 1 – 100mA 167.482.636 DN 20 - 25
(Au) 167.482.637 DN 32 - 40
167.482.638 DN 50

A closed
B open
C black
D blue (short cable)
E blue (long cable)

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

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

 Switch type Capacity Code no. Wiring diagram
Inductive switch 5 -30 V= 167.482.653 DN 10 - 15
NPN 0.1 A 167.482.654 DN 20 - 25
167.482.655 DN 32 - 40
167.482.656 DN 50
Inductive switch 5 -30 V= 167.482.662 DN 10 - 15
PNP 0.1 A 167.482.663 DN 20 - 25
167.482.664 DN 32 - 40
167.482.665 DN 50

A closed
B open
C blue
D black
E black
F brown

Switch type Capacity Code no. Wiring diagram

Inductive switch 8 V= 167.482.671 DN 10 - 15
Namur 167.482.672 DN 20 - 25
167.482.673 DN 32 - 40
Approvals: 167.482.674 DN 50
ATEX 2032x, CSA
EMC per EN
60947-5-2
Norm conformity
EN 60947-5-6

A closed
B open
C blue
D brown

CE label
According to the EC Directive 98/37/EC pertaining to machines (formerly
89/392/EWG) these actuators/valves are not considered machines, but may be
installed in installations which are considered machines.

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

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

17
 As an alternative to the integrated fastening with the threaded inserts, the Ball Valve
Type 546 can also be mounted with an additional fastening plate.
Forces, which may occur under normal operation of the valve (e.g. initial breakaway
torque), are absorbed with this fastening plate. By using the fastening plate, no
operating forces are transmitted to the piping system.

In piping systems which are subject to temperature changes, longitudinal or lateral

! forces may occur if thermal expansion is hindered. So as not to impair valve
operation, these forces must be absorbed via the respective fixed points in front of or
after 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 - 63
DN 10 - 25 DN 32 - 50
L 106 149
B 48 54
H 20 20
L1 92 134
L2 62 104
L3 31 52
L4 41 62
L5 25 45
H1 14 14
H2 4 4
D 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 pipe
clamps and the corresponding spacers type 061. For more information, please see our
product range.

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

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

Imminent acute danger!

Failure to comply could result in death or extremely serious injury
Danger

Possible acute danger!

!
Failure to comply could result in serious injury.
Warning

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

Abbreviations

Type 546 Ball Valve Type 546

MF lever Lockable multifunctional lever
MF module Multifunctional module
PN Nominal pressure

The same safety guidelines apply for ball valves as for the piping system into which
they are built.
The Type 546 is intended exclusively for shutting off, conducting or controlling the flow
of allowed media within the permissible pressure and temperature ranges in the
piping system into which it has been installed. The maximum service life is 25 years.
Please note that the max. working pressure of the whole valve is determined by the
Caution maximum permissible nominal pressure of the connecting part.

Anyone involved with the mounting, dismounting, operation, handling and

maintenance (inspection, service and repair) of the valve at the plant where it has
been installed must have read and understood the complete instruction manual, and
in 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 of
such systems into which the ball valve has been built to warrant that

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

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

19
 • Only qualified and authorised personnel mounts, operates, services and repairs
the ball valve. Employees must be instructed on a regular basis in all aspects of
work safety and environmental protection as indicated by the applicable local
regulations – especially those pertaining to pressure-bearing piping systems.
• The valve is only used according to the specifications for which it has been
intended, as indicated in the section on safety
• Installation positions and locations in which manipulations can occur
unintentionally must be avoided.

Do not use ball valves for media containing solids.

!
Avoid cavitation in control operations.
Warning This could lead to damages (leakage caused by abrasion).

Removing the Type 546 from the piping system

!
Warning If the pressure has not been released completely, the medium can exit
uncontrollably.

Depending on the type of medium, injury may occur.

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

Medium needs to be tapped from a Type 546, which is used as an end valve
!
in a pressure-bearing piping system.
Warning
The medium can exit / splash uncontrollably.

Depending on the type of medium, injury may occur.

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

The Type 546 is to be stored or dismantled after removal from the piping
!
system.
Warning
Residual media can exit uncontrollably.

Depending on the type of medium, injury may occur.

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

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

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

 • 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 by
mechanical or thermal influences.
• The ball valve should be stored with the lever in the open position (as it was
supplied).

To begin with, the ball valve should be inspected for transport damages. Damaged
valves 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.

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

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

The installation dimensions, connections and union nuts of the type 546 have
!
been modified from the type 346.
Warning
The use of components and installation dimensions other than those prescribed for
the type 546 can cause damage to the piping system.

Compare the installation dimensions and specifications in the technical

documentation with those of the components at hand.

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

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

21
 Open the union nuts and slide them onto the pipe ends.

Join the piping components according to the material and your

connection version (fusion, cementing, screws, flange).

Place the ball valve between the connecting parts.

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

The union nuts of the Type 546 must be hand tightened – without the use of
!
additional tools.
Warning
If other tools, such as pliers, are used, the material of the union nuts may be
damaged. There is also the danger of damaging the thread if they are tightened too
strongly.

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

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

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

DN 10/15 20/25 32/40 50

Screw M6 M6 M8 M8
max. insertion depth 12 12 15 15
H (mm)

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

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

 Ball valve pressure testing is subject to the same regulations as apply to the piping
system. Detailed information can be found in the Georg Fischer Design Fundamentals
chapter 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

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

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

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

Ball valves require no maintenance under normal working conditions. Periodic

inspection to make sure that no medium is leaking is sufficient. Should leakage or
other 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 same
position 1-2x a year to check operation.

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

Exploded drawing of multifunctional lever:

13 13 Lever clip
22 Multifunctional lever
25 23 Spacer
22 24 Unlocking latch
25 Fastening screws (Torx)
24

23

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

23
 Exploded drawing of manual valve:
13

12

11 1
6

4
3
10

8 14
7
5
8 7
9
2 30
10
3
4
31

1 Housing 9 Housing seal

2 Union bush 10 Connecting part seal
3 Connecting part 11 Spigot seal
4 Union nut 12 Standard lever
5 Ball 14 Threaded insert
6 Spigot 22 Multifunctional lever
7 Ball seal 30 Fastening plate
8 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 following
these 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 be
unscrewed (Attention: left thread).

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

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

The ball can be pushed out with a rod in a soft material (plastic
or 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.

Only original Georg Fischer spare parts designed specifically for this valve may be
Caution used for replacement purposes. Orders for spare parts for the Type 546 valve should
include all the details given on the typeplate.

Selecting a lubricant
Caution
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.

Seals
Caution
All the seals (made of e.g. EPDM, FPM) are organic materials which react to
environmental influences. They must therefore be kept in their original packaging
and 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.

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

25
 To assemble the individual parts, please proceed according to the following steps:

Insert the backing seal (8) and the ball seal (7) in the groove
provided for this purpose on the inner side of the stop or the
union 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 the
union bush (2) or the fixed housing stop (1).

Insert the two lubricated (see Selection of lubricants) spigot

seals (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 stop
from the inside.

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

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

 Put the ball (5) through the outlet in the housing (1) into the
spigot 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 the

flow direction (open ball position)

Place the standard lever (12) on the spigot (6). The ball valve is
now 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 13 Lever clip
25 22 Multifunctional lever
22 23 Spacer
24 Unlocking latch
24 25 Fastening screws (Torx)

23

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

27
 To assemble the multifunctional lever, please proceed according to the following
steps:

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

Position the spigot according to the illustration. Place the lever

on the spigot.

At the bottom of the lever shaft there is a spacer (23). Make sure that it is positioned
correctly 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 rotated
90°.

The lever is locked in the respective position and may also be

secured in this position against unauthorised access by adding
a lock.

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

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

Imminent acute danger!

Failure to comply could result in death or extremely serious injury
Danger

Possible acute danger!

!
Failure to comply could result in serious injury.
Warning

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

Abbreviations

Type 546 Ball Valve Type 546

MF lever Lockable multifunctional lever
MF module Multifunctional module
PN Nominal pressure

Examine the MF module before mounting to make sure it has not been damaged
during transport. We recommend leaving the MF module in its original packaging
until 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.

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

29
 Assembly of the MF module with built-in switch

1 Housing
2 2 Housing cover
3 Indexing disk *
3a Switching cams
4 Stainless steel Torx screws
3
5 Connector plug 3P + E per
3a DIN EN 175301-803*
(formerly DIN 43650)
4
5

*) 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 ball
position.

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

 Attention! Spigot is asymmetrical

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

A Spigot position for closed ball valve.

+
+ GF

B Spigot position for open ball valve.

+
+ GF

Note the square (a), respectively, round (b) contour, as well

as the position of the asymmetrical recess (c) of the spigot.

Place the MF module on the ball valve.

Make sure the contour of the

multifunctional module agrees with that of
the ball valve!

Tighten the four pre-assembled screws.

The MF module is now securely positioned
on the ball valve.

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

31
 close

Put the switching cams (3a) in the

respective position.
close

For open ball valve

close

For closed ball valve

close

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

To mount the MF lever, follow these steps:

13
25
22 Remove the spacer (23).
24

23

Place the MF lever on the spigot.

(Example: open ball position)

Remove the lever clip (13) with the help of

a screwdriver.

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

 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".

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

33
¥ ‡
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: office@georgfischer.at
AUS 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 61
B/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: info.be@be.piping.georgfischer.com
BR George Fischer Ltda, Av. das Nações Unidas 21689, 04795-100 São Paulo, Brasil, Tel. +55(0)11/5687 1311, Fax +55(0)11/5687 6009
CH 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
e-mail: info@rohrleitungssysteme.georgfischer.ch
CHINA Georg Fischer Piping Systems Ltd Shanghai, No. 2Ý8 Kang Qiao Dong Rd., Shanghai 201319, Tel. +86(0)2¢/58 13 33 33, Fax +86(0)2¢/58 13 33 66
e-mail: gfsro@public.shanghai.cngb.com
Georg Fischer Piping Systems (Trading) Ltd Shanghai, No 516 Fute Bei Road, Waigaoqiao Free Trade Zone, 200131 Pudong, Shanghai
Tel. +86(0)21/5868 0278, Fax +86(0)21/5868 0264, e-mail: gftrade@sh.cngb.com
D Georg Fischer GmbH, Daimlerstraße 6, 73095 Albershausen, Tel. +49(0)7161/302-0, Fax +49(0)7161/30 2 111
e-mail: info@georgfischer.de, Internet: http://www.rls.georgfischer.de
Georg Fischer DEKA GmbH, Kreuzstrasse 22, 35232 Dautphetal-Mornshausen, Tel. +49(0)6468/915-0, Fax +49(0)6468/915 221/222
e-mail: info@dekapipe.de, 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 76
e-mail: info@dk.piping.georgfischer.com, 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 23
e-mail: info@georgfischer.es
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: info@georgefischer.fr
GB George Fischer Sales Limited, Paradise Way, Coventry, CV2 2ST, Tel. +44(0)2476/535 535, Fax +44(0)2476/530 450
e-mail: info@georgefischer.co.uk, Internet: http://www.georgefischer.co.uk
GR 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: dderv_piping_gf@oneway.gr
I 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: office@piping.georgfischer.it
ID 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 63
IND 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: branchoffice@georgefischer.net
J 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: info@georgfischer.jp
N 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.no
NL Georg Fischer N.V., Postbus 35-8160, 8161 PA Epe, Tel. +31(0)578/678222, Fax +31(0)578/621768
e-mail: info.vgnl@nl.piping.georgfischer.com, Internet: http://www.georgfischer.nl
PL 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 94
RO 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: office@georgfischer.ro
RU 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: lazer@orc.ru
S/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: info@georgfischer.se, Internet: http://www.georgfischer.se
SGP 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: info@georgfischer.com.sg
USA 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) 7 3¢ 62 01
e-mail: info@us.piping.georgefischer.com, Internet: http://www.us.piping.georgefischer.com
Export 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: export@piping.georgfischer.com, Internet: http://www.piping.georgfischer.com

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