Iom 00

HP Valves Oldenzaal B.V.
Global Partner in Flow Solutions
Customer : Exion Asia Pte. Ltd.

Project name : Glow SPP2R Project – MOV Gates
Your P/O : PO2300085
From : HP Valves B.V.
Our order ref. : 20230083
Date : 4 May 2023
Revision : 00
Installation, Operation and

Maintenance Manuals
HP Valves | Key Valve Technologies | BVT Sweden | Members of Indutrade p. 1/5


Date : 4 May 2023
Revision : 00
Table of Contents
Chapter A Installation, Operation and Maintenance Manual Valves
Chapter B Installation, Operation and Maintenance Manual Electric Actuators
Chapter C Installation, Operation and Maintenance Manual Gearboxes


Date : 4 May 2023
Revision : 00
Chapter A
Installation, Operation and Maintenance Manual Valves

HP Valves BV
Medium & high-pressure valves in

accordance with ASME, EN, BS & API
Operation Instruction Manual

rev. 22 / 01-2023
HP Valves BV HP Valves BV Phone: +31 (0)74 - 7820000

P.O. Box 50040 Haaksbergerstraat 55 Web: www.hpvalves.com
7550 LA Hengelo (Ov) 7554 PA Hengelo (Ov) E-Mail: sales@hpvalves.com
The Netherlands The Netherlands
© 2023. This manual, its content and the copyright therein are the property of HP Valves BV. This manual is
supplied in confidence and shall not be used for any purpose other than which it is supplied for and may not
be reproduced in part or whole or passed on to others, without permission in writing from HP Valves.
Member of Indutrade AB
HP Valves BV
Medium & high pressure valves in

Contents 1 Introduction
1 Introduction 2 Once again, many thanks for showing your confidence in our
2 Safety precautions 2 products by selecting it for use in your plant.
3 Transport and Storage 3 The installation, operation and maintenance instructions in
Transport 3 this manual are intended to be used for all valves we supply
Receipt 3 from our standard product range. They may also apply to non-
Short-term storage < 3 months 3 standard products, as long as the special additional
Long-term storage > 3 months 3 instructions are followed as well; these can be made available
4 Valve Installation 4 upon request or can be found on our website
Installation 4 www.hpvalves.com Also on-line we introduce you to the
Welding 5 elementary steps on valve dis- and re-assembly by means of
Threaded valves 6 a video presentation. Watch these videos to get started
Flanges / hubs 6 www.hpvalves.com/service/youtube/
Actuator setting 6
Preservation 6
System cleaning 6 2 Safety precautions
5 Valve Operation 7
Manual 7 In terms of their hazard potential, in addition to
Electric 7 being subject to these instructions, our
Pneumatic 7 products should also be handled in accordance
General recommendations 7 with general safe handling instructions and on a
6 Start-up & Commissioning 8 par with pressure vessels. The handling and use
Packing & Gasket 8 of our valves and products should therefore only
Precautions 8 be entrusted to properly trained personnel.
Seat and obturator 8
Pressure locking 8 Proper installation, operation and maintenance are essential
Thermal binding 8 to safe and reliable operation of all products supplied by HP
7 Maintenance 9 Valves. The procedures described in this manual show
General 9 effective methods for performing the aforementioned
Lubrication 9 activities.
Cleaning 9 The installation, operation and maintenance of valves may
Disassembly & re-assembly 9 involve working in proximity to fluids at extremely high
Spare parts 9 pressures and/or high temperatures. To minimize the risk of
Torque values 10 personal injury or damage to the valve, or rendering it unsafe,
Reseating & lapping 11 it is important to follow the instructions described.
High stress areas 11 Prior to working with valves or related products, personnel
8 Troubleshooting 12 should familiarise themselves with this manual and be fully
9 Disposal 13 aware of the hazards related to these procedures.
10 Pressure-Temperature ratings 13
ASME B16.34 14 It is also important to note that "safety messages" are not
EN 12516-1 16 exhaustive. Due to the broad application of the products
supplied, HP Valves cannot possibly complete a full risk
analysis related to the installation, operation and
maintenance of its products.
The safety precautions listed here are for customer
information only. HP Valves BV waives any responsibility
related to any omissions in the precautions and instructions
for installation, operation and/or maintenance.
Should anyone decide to install, operate or maintain HP
Valves products in a way which differs from the procedures
described in this manual, they must make sure that this will
not jeopardize personal safety, nor valve reliability.
Furthermore we would like to point out that all personnel
handling our products should be trained professionals and
instructed properly prior to performing the required activity.
Member of Indutrade AB Page 2/18

HP Valves BV

If you are dissatisfied or have any questions regarding the Receipt

tools or methods described, please contact HP Valves by e-
mail or phone. Our contact details are shown on the cover Unless specified otherwise, products are packed in wooden
page. cases fitted with tarred paper on the inside and a layer of
plywood between the layers of valves (if applicable). This kind
I Valves are shipped with the packing gland nuts properly of packing allows normal requirements for transport to be
tightened, however you should ensure that the packing satisfied, guaranteeing effective resistance against humidity.
gland nuts are firmly tightened before pressurizing any All products have an adequate protection for storage in a
valve. closed environment up to a maximum period of 3~6 months.
II Do not attempt to remove the gland flange nuts while Standard protection (if not otherwise specified) includes
the valve is pressurized. treatment against rust by means of coating or phosphatising
III Do not attempt to remove the body-bonnet bolts while and caps in/on exposed openings, such as valve ends and
the valve is pressurized. cable/pneumatic entries. Damaged coating should be
IV All valves supplied by HP Valves with integral, fixed or touched-up as soon as possible in order to prevent corrosion!
screwed in backseat are in theory capable of being If protective caps are removed for inspection purposes,
repacked under pressure. However, due to the inherent ensure these are refitted in order to maintain cleanliness. If
dangers involved in working on equipment under caps are missing we suggest you tape over the openings.
pressure, HP Valves strongly recommends that the If foreign debris has got into the product, remove it
backseat is only be used to prevent the fluid from immediately. If using a cleaning agent for this purpose,
escaping through the packing chamber and not used for ensure that the proper solvent is used, especially if the valve
repacking under pressure. is installed in piping by means of welding. On receipt of our
V No alteration or modification should be made to any products, ensure the items can be properly identified and the
valve or related product, except as sanctioned and/or following documents are available for verification:
authorized in writing by HP Valves.
VI Extreme care should be taken to ensure that the arrow • Packing list
located on the valve-body of all globe and check valves, • Operation Instruction Manual
and possibly for gate valves, is pointing in the same • Material and pressure test certificates
direction as the normal flow direction of the system.
VII Never install or attempt to use any valve that cannot be Short-term storage < 3 months
properly identified as to its material and/or pressure
class. On site, products delivered must be stored properly to
protect them against mechanical damage, ingress of foreign
objects, water and/or moisture and corrosion. Storage
3 Transport and Storage indoors at ambient temperature is preferred. Should it be
unavoidable to store the products outdoors, make sure that
Transport products are supported off the ground or paving and are
protected by a watertight enclosure.
When loading or unloading our products, ensure that they are The protective packaging we provide must be left in place
handled with care and not subjected to sudden knocks. To during storage and should only be removed prior to
ensure proper functioning of our products, visually inspect all installation or commissioning. Make sure stainless steel
related products and check and rectify misaligned glands and valves are stored separately from carbon- / alloy steel valves
bonnets of valves. in order to prevent contamination.
The valves supplied should be stored in the position in which
Heavy valves and/or related products should be handled with they are delivered, this being closed for all manually and
a rope slung to the body of the valve or its designated lifting motor-operated valves and in fail-safe position for valves
eye. The use of chains is prohibited. Always make sure that with pneumatic actuator.
the product is securely fixed and the ropes are aligned in such
manner they cannot damage the product or any of its parts. Long-term storage > 3 months
If the products are to be shipped further after unloading, make The following recommendations should be followed when
sure that each individual product is properly secured against preparing our products for long-term storage. These are
damage and properly packaged, taking into account the necessary to maintain the valves and related products in a
means of shipment. proper condition prior to installation and use. It is the
purchaser's responsibility to take the necessary precautions
for the protection of products in storage.

HP Valves BV

On receipt of the products at their destination, the wooden To protect uncoated interior surfaces from corrosion, treat
cases supplied should be examined thoroughly for signs of these surfaces with a rust-prevention agent, such as:
mishandling or damage during shipment, exposure to rain Cortec VpIC377 or a similar product. If superficial corrosion
and/or ocean spray or ingress of foreign debris. is observed we advise to remove it prior to installation of the
valve. Using a Scotch pad and a solvent will suffice.
If the products are to be stored for more than 3 months,
make sure that the storage facilities are in an enclosed,
weatherproof building with a concrete floor provided with 4 Valve Installation
uniform heating, preferably at ambient temperature, or at
least 6°C (43°F), maximum temperature variations and/or Installation
relative humidity should preferably not exceed 50%.
The purchaser, contractor or end-user has overall
Long-term storage outdoors is not permitted, responsibility for the positioning, installation and operation of
unless otherwise explicitly agreed with HP the products supplied in the plant.
Valves! Planning and installation errors can affect the proper
operation of valves and related products, and may even
During long-term storage ensure to protect the products constitute a major hazard potential (e.g. incorrect positioning
against mechanical damage, ingress of rain and/or foreign of check valves or wrong direction of flow). So please take
objects and/or corrosion. Likewise, during long-term storage, notice of the following safety precautions;
the protective packaging we provide must be left in place and
only removed prior to installation or commissioning. o Before fitting the valve in position, remove
the protective caps from the flange, butt weld,
Furthermore, we recommend opening the lid of the wooden socket weld or threaded ends. The valve must be
cases slightly to allow air circulation; prevent condensation free of all foreign matter. Cleanliness is the
and corrosion (keep the cases covered to protect against cardinal rule when fitting valves. If the pipe-ends
ingress of water and foreign debris). require machining, foreign matter must be
Our products are packed with protective caps on/in all removed prior to installation of the valve.
openings; do not remove these protective caps unless o The operating limits of the valve must be at
required for inspection and installation. For storage longer least the same as, or exceed the operating limits
than one year, you could consider removing the packing and of the adjacent piping. Relevant pressure-
applying an absorber, i.e. silica gel, in the correct quantity. temperature tables should be respected – these
can be found in section 10 of this OIM and on our
Periodic inspections should be performed on products in corporate website www.hpvalves.com
long-term storage. The frequency of these inspections
should be determined on the basis of storage conditions - Direction
available. If not stored indoors all products should be
inspected at least every 4~6 months. Inspect for dirt, Check, globe and control valves are supplied with an arrow
moisture or any other type of contamination. If any of the stamped on the body, which indicates flow direction.
former are found, the product should be thoroughly cleaned When fitting these valves, be aware that the arrow located on
and dried. the valve-body points in the same direction as the normal flow
direction of the system.
When products are stored for a long period of time, it is Standard gate valves are bi-directional and therefore not
recommended they are labelled as long-term storage items. marked with a flow direction arrow. If gate valves are
When these products are ready for use, extra attention equipped with special features e.g. a bonnet equalizing
should be paid to the condition of the products. Prior to device or by-pass, the valve might be unidirectional and if so,
installing valves and/or related products, it is advisable to test this is marked with a flow direction arrow.
these products hydrostatically following visual inspection of If gate valves are equipped with an internal equalizing bore,
the packing and/or gasket and to re-torque all bolts to factory these bores are provided in the disc / wedge. If required
specifications in order to compensate for any possible bolt during hydro testing at site, the discs / wedge can be installed
relaxation. in the valve in the opposite direction to prevent leakage
through the valve during hydro testing activities. After
If high-temperature coatings (≥ 400°C / 752°F) are applied to completion of the hydro testing activities the valve should be
our products, superficial corrosion can be found exterior restored to its original lay-out.
surfaces after storage of over more than 6 months, due to the
fact these coatings require heating to obtain full curing. This
superficial corrosion does not affect the functionality of the
valve.

HP Valves BV

- Position Welding
It is recommended to install gate and globe valves with the The contractor is responsible for welding valves into the
stem in the vertical position and in horizontal lines. This piping and for any heat treatment that may be necessary. All
orientation provides enhanced packing life and simplifies welding should be performed in compliance with applicable
disassembly and re-assembly. In case of restricted space, standards, by qualified welding personnel and with the
these valves may be installed tilted at an angle (max 45°) equipment required to obtain operator safeguard and secure
between the vertical and the horizontal plane. Ensure proper material integrity. If installing a replacement valve by welding,
drainage of the bonnet area is not compromised. make sure to remove the heat affected zone (weld material)
When installed in vertical lines or with the stem tilted at an from the adjacent piping prior to refitting a new valve into the
angle over 45°, possible build-up of debris in the bonnet area piping system.
can occur and may ultimately lead to packing erosion and/or
damage to the stem. Valves must be welded when they are in their fully closed
position. When fitting the valve into the pipe, make sure that
In the case of actuated valves that are installed other than in the flow direction matches the arrow marked on the valve-
horizontal piping, external support for the actuator should be body. If there is no arrow on the valve, the valve is bi-
provided to avoid damage and unwanted strain that could directional.
cause valve or actuator malfunctioning and reduce service
life. For pneumatic actuated valves installed in any other The pipe-ends must be properly aligned so as to prevent the
position than stem vertical, please take care to rotate the air valve being subjected to unnecessary strain.
filter reducer to always be in vertical position to guarantee When welding valves with socket weld (SW) ends, make sure
proper function of the filter. Please consult HP Valves in case that the valve is installed using approximately 2.0 mm
of doubt. clearance between the bottom of the socket and the end of
the inserted pipe; this allows for expansion of the pipe-end
Check valves (swing-, piston- and ball type) are fitted in either during welding.
vertical or horizontal lines. If piston- or ball type check valves
are to be installed in vertical lines, they should be spring- When welding the valve into the pipe, the valve may remain
assisted. In case of small bore swing- and Y-type check in its fully assembled condition; the metal seated valves do
valves, ensure the flow direction is facing up. For large bore not have to be disassembled before welding.
swing type check valves it is recommended to not exceed 45°
inclined / slant position, where we recommend to limit this Prior to welding, make sure the valve is in its fully closed
position for large bore tilting disc valves to 30° maximum. position to minimize the risk of any weld spattering reaching
the seat facing. In case of motor- or pneumatically actuated
valves, the emergency handwheel can be used to close the
valves. Before welding make sure that the actuator is not
connected to the power and/or air-supply. For valves with a
fail-safe-to-open actuator without emergency handwheel,
welding of the valve in its fail-safe position is acceptable.
For control valves completed with soft seated trim,
temperatures during welding shall not exceed 240°C / 464°F.
If temperatures exceed the stated maximum value, the valve
should be dismantled prior to the welding activities. Upon
completion of the welding activities, reassembly of soft
seated control valves should always be completed with new
gaskets and seals.
Control valves should be fitted with the stem in the vertical
position and in horizontal lines.
It is prohibited to attach the welding cable (ground terminal)
to the yoke, stem, handwheel or any other part of the upper
In general stop/check valves, check valves and control valves
valve assembly. The ground terminal should be attached to
should be installed in a straight run of pipe, preferably away
an area on the valve body which is free of coating or, even
from bends or sections of pipe operated at very high velocities
better, on the adjacent pipe itself.
>8m/s (water) & >80m/s (steam). Ideally, ten (10) pipe
diameters of straight pipe should be allowed upstream and
five (5) pipe diameters of straight pipe downstream of the
valve.

HP Valves BV

- Heat treatment Preservation
Heat treatment has to be performed in compliance with the - Shot blasting

applicable standards / guidelines and with the valve in a If, for any reason valves are shot-blasted, make sure to
slightly opened position. Heating should only be applied by prevent ingress of blasting abrasive into the gland and/or
inductive means or by resistance heating pads on the welding packing chamber; afterwards it is mandatory to clean the
area to prevent damage occurring. If post-weld heat valves thoroughly. Before starting to shot blast, make sure
treatment is performed and temperatures in excess of 650°C the valves are in their fully closed positions and stems are
(1200°F) are expected at the bonnet- / packing area, properly protected. For pressure sealed valves, the bonnet
disassembly of the valve is strongly recommended prior to area should also be protected against ingress of blasting
heat treatment since packing and/or gasket material could abrasive.
deteriorate at higher temperatures. A useful tool to monitor
the temperature of this area during heat treatment is an - Painting
infrared thermometer or use a thermocouple. Make sure valves are in their fully closed position. Moving
parts, stems and identification plates should not be painted
For control valves the temperature at the valve body web and need to be protected. Before applying additional layers
should be monitored and, to prevent component damage, not of paint, check the compatibility with the coating systems
allowed to exceed 240°C / 464°F. already applied.
Threaded valves - Insulation
When fitting threaded-end valves, it is important to ensure Gland bolting and bonnet bolting should be
that both the valve- and pipe threads are clean and accessible after insulation. Make sure the
undamaged. During installation of threaded-end valves onto tightness of the stem packing can be checked
piping, make sure to use the correct sealing material for the without removing the insulation and especially
threaded connection and apply no more material than is for pressure sealed valves, accessibility of
required. It is mandatory to hold on to the valve body and bonnet bolting is mandatory.
prohibited to hold the valve in place using the handwheel or
the yoke whilst screwing in and tightening, since this may For control valves acoustic insulation could be applied to
cause damage to the valve. meet particular noise specifications. Ensure that all
supports, fittings, or other rigid connections to the
downstream pipe are thoroughly insulated as well, since
Flanges / hubs these components also can become a source of noise
radiation.
When fitting flanged end valves, it is important to ensure that
both the valve and pipe flange surfaces are clean and System cleaning
undamaged. Depending on the flange type, apply the correct
gasket between the valve and the adjacent flanges. Make - Steam blowing
sure to align the valve and the adjacent piping properly in Before steam blowing, ensure the valves are in their fully
order to eliminate stress to the installation and prevent the open position. The aforementioned does not apply in the case
creation of a possible leak path. Flange bolting should take of check valves, control valves and strainers, it is
place in compliance with the flange pressure class and its recommended the internals of these products are removed
corresponding specifications. Always apply the correct torque before steam blowing. It is permitted to use both puff and
value for flange bolting whilst installing flanged end valves. thermal cycle steam blow procedures on our products.
Actuator setting - Flushing

Before chemical treatment, ensure valves are in their fully
All valves supplied with a motor- or pneumatic actuator are open position. The aforementioned does not apply for check
factory tested. The contractor or end-user has overall valves, control valves and strainers, but it is recommended
responsibility for installation of electrical and/or pneumatic the internals of these products are removed before chemical
connections to the actuated valve. More details on actuator treatment. Failure to do this could result in welding scale,
terminal connections and setting instructions can be found in debris or other foreign matter getting trapped between the
the corresponding actuator manual. valve plug and seat/cage, causing damage to one or both
faces. Valves should be set to an almost open position in
order to facilitate thorough flushing of the valve internals after
pickling is performed.

HP Valves BV

- Cleaning / pickling design conditions. The use of spanners or pipes to increase

Applying the correct pickling process is the sole responsibility leverage can damage the valves and are therefore not
of the contractor. In case of doubt, HP Valves should be permitted. If valves do not seal using the normal operating
contacted. Before commencing the pickling process, the mechanism, often spanners will not solve the problem
valves should be in their fully open position to prevent ingress because other reasons, such as trapped foreign objects,
of pickling medium in the packing area. After pickling, the damaged sealing surfaces, misaligned glands or scoured
system should be thoroughly flushed. stems - rather than a handwheel of insufficient size - will
During flushing after pickling, the valves should be set in an prevent the valve from fully closing.
almost open position in order to facilitate thorough flushing of In the case of parallel slide gate valves, be aware that the
the valve internals. Generally, it is recommended the stopper on the valve stem is set to secure the valve is shut in
system’s non-operational time is minimized after pickling. its closed position. “Over-tightening” will only lead the stopper
Depending on the pickling medium and process applied, a becoming bent and the valve internals being damaged.
maximum of one day could be used as general
recommendation. Electric
- Hydrostatic testing Valves fitted with an electric actuator must be connected and
During hydrostatic testing of the valves and the adjacent operated in compliance with the actuator manufacturer’s
piping it is recommended to set motor operated and/or instructions (please refer to the actuator manual).
pneumatic operated globe- and/or stop/check valves in their In general, the following settings are used for motor-operated
opened position, unless specified otherwise. For manual valves:
valves it is recommended to verify that the maximum hydro Valve type Open switch Close switch
test pressure does not exceed the seating test pressure of
Globe Limit Torque
the designated pressure boundary valves, prior to performing
hydrostatic testing. Stop/check Limit Torque
Please contact the OEM to check the suitability of designated Solid wedge gate Limit Torque
boundary valves before performing the hydrotest. Flexible wedge gate Limit Limit
After completion of hydrostatic testing, all valves should be
Parallel slide gate Limit Limit
drained to prevent trapped water in the bonnet area to freeze
up under cold conditions or cause over pressurisation of the
bonnet area during first heat. The handwheel on electric actuators is for emergency
operation only; it should be disengaged during normal
5 Valve Operation operation and only engaged for manual operation when
required in an emergency situation.
• Since valves are frequently subjected to high
temperatures, protective clothing (particularly Pneumatic
gloves) should be worn during operation.
• Gate & Globe valves should only be used in Valves fitted with a pneumatic actuator must be connected
their fully open or closed position, in case and operated in compliance with the manufacturer’s
intermediate position is required a throttle type instructions (please refer to the actuator manual).
globe valve should be used instead. Make sure The handwheel (optional) on pneumatic actuators is for
minimum opening percentage remains at ≥ 20%, emergency operation only; it should be set in its neutral
as valves opened at < 20% are highly susceptible position during normal operation and only engaged after the
to seat and/or plug erosion. actuator has been fully depressurized for manual operation in
• When a main valve is equipped with a special an emergency.
safety device, such as an over pressure safety
valve or equalizing valve, these devices shall be General recommendations
kept in their (locked) open position during Medium and high-pressure vent and drain valves are often
normal operation of the main valve. placed in tandem to provide double isolation of the system,
• The valve drawings shall be checked for where the upstream valve is used as “isolator” and the
actual valve configuration and additional downstream valve as “regulator”. To prevent damage to the
instructions. disc and the seat of the upstream “isolator”, both valves need
• Valves are not grounded against static to be operated in the following sequence:
electricity.
Opening Closing
Manual st
1 Open Isolator 1st Close Regulator
Valves close when the handwheel is rotated clockwise. The
2nd Open Regulator 2nd Close Isolator
handwheel size is selected on the basis of the valve type and

HP Valves BV

rotation of the gland nut) to compress the stem packing and

Equalizing valves stop the leakage and so prevent erosion and possible blow
out of the stem packing.
In case valves are executed with an external welded on If leakage through the bonnet gasket occurs, the bonnet
equalizing valve (upstream to bonnet connection), the bolting needs to be retightened sufficiently to compress the
following instructions are applicable: To prevent over bonnet gasket and stop the leakage and so prevent erosion
pressurization of the main valve during normal operation, this of the bonnet gasket.
equalizing valve must be kept in locked open position at all The factory torque values indicate the approximate required
times. Only during (1) hydrostatic testing of the pipe section value for different valve types, sizes and pressure classes
or (2) using the valve in reverse flow this valve can be and are stipulated in the maintenance instructions in section
temporarily closed to guarantee sealing of the main valve. 7 of this manual.
After completion of (1) and/or (2) and before the main valve
is opened and returned to normal service, this equalizing Precautions
valve shall be opened immediately to safeguard the main
valve against pressure locking and/or over pressurization. During the start-up process, avoid water hammer
Please note when a valve is executed with both an external as this may damage the valves.
welded on equalizing valve (upstream to bonnet connection)
and bypass/warming valve (upstream to downstream
connection): In case of reverse flow (for example for unit Seat and obturator
isolation), the bypass/warming valve takes over the function
of the equalizing valve and vice versa. If the valves are reported to be leaking through the seat
during start-up and/or commissioning, this is usually caused
6 Start-up & Commissioning by debris and/or foreign particles. If leakage is identified, try
to flush the valves by opening and closing them with sufficient
Packing & Gasket flow. If seat leakage remains, stop operations immediately
and disassemble the valve for inspection and to clean the
On commissioning and during operating, check the stem internals. Failing to do so may lead to damaged valve
packing and bonnet gasket for leakage. If any leakage is internals. Check our disassembly & re-assembly instructions,
observed, tighten the gland- and/or bonnet bolting submitted separately, for detailed instructions.
immediately to stop this leakage and to prevent erosion of the
stem packing or bonnet gasket. If a (control) valve equipped Pressure locking
with a PTFE packing is found leaking, the packing should be
replaced rather than retightened. Pressure locking is a phenomenon that can occur to high
pressure gate valves with pressure seal bonnet. It causes
If a valve has been designated as a long-term storage item, the valve to become inoperable and occurs when the valve
extra attention should be paid to its packing and gasket. is closed and pressure in the body cavity increases or when
Deterioration of these parts may cause the valve to leak, in the pressure decreases in the line but remains in the valve
which case the gland and/or bonnet bolts should be body cavity.
retightened or the packing and/or gasket replaced. If the In order to relieve the body cavity on a valve with no
packing and/or gasket need to be replaced, check our equalizing device installed, we would advise you to loosen
disassembly & re-assembly instructions, submitted the gland bolting and bleed the overpressure through the
separately, for detailed instructions. packing.
This procedure should be performed with the utmost care
After installation, check the position of the gland; make sure and should only be entrusted to skilled personnel.
there is no contact between the gland and the stem surface. Attempting to operate the valve whilst being pressure locked
by using a handwheel lever is prohibited and can cause
During initial operations under service severe damage to the valve internals.
conditions, both after initial installation and
after re-assembly activities, all bonnet bolting on Thermal binding
pressure sealed valves should be tightened (hot-
torqued) to ensure proper sealing of the gasket Thermal binding is a phenomenon that can occur to wedge
and to prevent misalignment of the bonnet. type gate valves. It occurs when the valve is closed while
the system is hot and then allowed to cool before opening
- Retightening the stem packing / bonnet gasket
the valve. Attempting to operate the valve by using a
handwheel lever whilst it is being subjected to thermal
In the event of any leakage through the stem packing, the
binding is prohibited and can cause severe damage to the
gland bolting needs to be retightened sufficiently (½~1

HP Valves BV

valve internals. Instead, allow the valve to heat up uniformly

in order to relieve the thermal binding. Lubrication
We recommend to install a by-pass line in case the main
valve is in high temperature service and operating Thanks to the design of our hand operated valves, little to no
procedures cause thermal binding. lubrication is required for proper functioning. Depending on
the location of the valves, we recommend the following:
7 Maintenance
If lubrication is applied, make sure to clean the lubricated
General parts thoroughly before applying fresh high temperature
grease. Apply a limited amount of grease with a brush on the
Before undertaking maintenance and/or threaded part of the stem as a thin grease film. If the hand
(dis)assembly activities, please read the general operated valves are equipped with grease fittings, apply a
safety precautions and relevant safety rules of limited amount of grease using a grease gun every 6 months.
the plant.
For hand operated valves located outdoors we would advise
Our products must be serviced regularly to ensure trouble- not to use lubrication on exposed parts, since this will only
free operation. Typical maintenance includes inspection of attract sand and dust.
the gland and pressure seal construction. Furthermore, it is
recommended a functional test and visual check is performed For motor operated and gearbox operated valves, we advise
at least every 3 months. to lubricate the stem thread and drive nut once every 6
Points for inspection are: months with high temperature grease (ceramic or graphite
• Leakage of medium (bonnet or gland) based). A thin film applied with a brush on the stem thread is
• Leakage of oil or grease (MOV/gearbox only) sufficient.
• Loose bolts/nuts
• Cleanliness Actuators:
• Lubrication For lubrication instructions for actuators (electric actuators or
• Corrosion bevel gears) please refer to the actuator maintenance
• Smooth operation during functional test manual. Compressed air used for operating pneumatic
• No alarms (MOV only) actuators shall be free of oil.
Early detection of minor defects will prevent malfunctioning or
major repairs in the future. Cleaning
Before undertaking maintenance and/or The frequency and extent of cleaning depends on the location
(dis)assembly activities, make sure that the of the valve and its service conditions. It is important that the
valve is free of pressure, sufficiently cooled and stem, packing and gland are kept clean and free of foreign
the system is free of hazardous media (steam, material. Do not allow water or dirt to accumulate in body
water or acid). For pressure seal bonnet valves: cavities. Accumulation of any corrosive or extraneous
Valve shall be in a 100% open position before material may interfere with removal of valve parts during
disassembly is initiated. Risk of residual disassembly. Excessive rust should not be allowed to build
pressure build-up in the bonnet chamber due to up on valves: if any is detected it is recommended this is
bonnet construction. removed and an anti-rust agent applied.
Formal risk analysis, e.g. as per PED 97/23/EC,
does not allow repacking valves under pressure. Disassembly & re-assembly
Because of the risks for operating personnel,
this applies to valves with floating backseat Please refer to the attached disassembly & reassembly
which do not permit renewal of the packing section for valve specific instructions (for non-standard
under pressure, but also for valves with fixed or valves: available upon request) or visit our website
integral backseat. www.hpvalves.com/service/ for additional online content.
On-line we introduce you to the elementary steps on valve

dis- and re-assembly by means of a video presentation.
www.hpvalves.com/service/youtube/
Please note that the explanatory videos are meant to
support and not to replace this manual. Proper installation,
operation and maintenance are essential to safe and
reliable operation of all products supplied by HP Valves and
require compliance with the precautions and instructions in
this manual.

HP Valves BV

Spare parts Depending on the pressure class and size, we recommend

applying the following torque values for retightening of the
When, during inspection, it becomes apparent parts need to gland bolting of Gate valves after re-assembly and/or
be replaced, it is mandatory to use genuine parts to during regular inspection.
guarantee proper fit and operation of our products after re-
assembly. Recommended torque values (Nm)
Class 150 300 600 800 900 1500 2500
The use of packing cord is prohibited unless Size
specifically agreed with the valve manufacturer. ½”
- - - - 25 40 40
Only genuine packing materials should be used. DN15
¾”
When ordering spare parts, please specify the following: - - - 30 40 40 50
DN20
Type of valve, year of manufacture, nominal diameter, body 1”
markings, pressure rating, drawing number and (when - - - 30 40 40 50
DN25
possible) the purchase order number under which the
1½”
products were supplied. Spare parts must be stored in clean - - - 50 125 125 170
DN32
and dry environment. For soft spare parts the shelf time is
2”
guaranteed for 24 months. - - - 50 170 200 200
DN50
If you have any questions on this matter, please contact us at
2½”
sales@hpvalves.com 3.5 3.5 4 - 29 48 81
DN65
3”
Torque values 3.5 3.5 4 7 25 42 55
DN80
After tightening bolts by hand, follow the bolt tightening 4”

3.5 3.5 6 8 20 33 97
sequence as shown in the figure below. This sequence DN100
depends on the quantity of the bolts used. 6”
5 5 8.5 10 58 96 157
DN150
The drawing illustrates 8”
5 5 8.5 11.5 57 94 193
the logical sequence DN200
that should be followed. 10”
5 7.5 10 13.5 69 144 339
DN250
12”
7.5 7.5 13.5 17.5 146 244 448
DN300
14”
7.5 7.5 15 20 146 269 497
DN350
16”
7.5 7.5 15 - 161 298 858
DN400
18”
To maintain proper bonnet alignment, the valve 7.5 9.5 15 - 179 514 948
DN450
should be fully back-seated prior to
20”
retightening bonnet bolting. 9.5 9.5 17 - 309 568 1354
DN500
24”
11 12.5 19.5 - 341 812 1463
DN600

HP Valves BV

Depending on the pressure class and size, we recommend Depending on the bolting used, we recommend applying the
applying the following torque values for retightening of the following torque values for retightening of the bonnet bolting
gland bolting of Globe valves after re-assembly and/or in case of a pressure seal construction after re-assembly
during regular inspection. and/or during standard inspection.
These factory torques are approximate values and based on
Recommended torque values (Nm) new equipment with lubricated bolts. Specific site conditions
Class 150 300 600 800 900 1500 2500 and other factors, such as surface corrosion, may require
Size higher torques for bonnet and gland bolting.
½”
- - - - 25 40 40
DN15 - in case graphite gaskets are used, apply the following
¾” instructions;
- - - 30 40 40 50 a. If the valve is not pressurized, apply 130% of the
DN20
1” torque values below.
- - - 30 40 40 50 b. If pressurized to design pressure (operating) apply
DN25
60% of the values below.
1½”
- - - 50 125 125 170 c. For pressures between zero and design pressure, the
DN32
torque to be used is approximated by linear
2”
- - - 50 170 200 200 interpolation.
DN50
- for valve operating temperatures above 400°C (752°F)
2½”
3.5 3.5 4 - 30 51 85 apply 75% of the values below.
DN65
3”
3.5 3.5 6 7 30 51 157 See next page for bonnet bolting torque valves for ASTM
DN80
bolting.
4”
5 5 6 10 57 94 241
DN100
6”
5 6 10 15.5 146 244 448
DN150
8”
5 8.5 13 15.5 161 269 858
DN200
10”
7.5 9.5 13 20.5 - 411 662
DN250
12”
7.5 9.5 13 - - 397 1463
DN300
14”
7.5 11 22.5 - - 676 1231
DN350
16”
8 13 25.5 - 374 - 1147
DN400
18”
11 18.5 28.5 - - - -
DN450
20”
- - - - 406 - -
DN500
24”
- - - - - - -
DN600

HP Valves BV

Bonnet Torques ASTM-class bolts and nuts with standard Bonnet Torques ISO-class bolts and nuts with standard pitch
pitch [Nm] [Nm]
ASTM ISO ISO

Thread Class Class Class Thread size Class Class Class
Thread A193- A193- A193- A193- SA453- SA479- SA705- size 8.8 10.9 12.9 8.8 10.9 12.9
size B7 B8 B8M B16 660 XM19 630 M6 11 15 18 1∕ " UNC 12 17 20
4
M6 9 3 3 10 10 6 13 M8 26 36 44 5∕ " UNC 24 34 41
16
M8 21 8 8 24 24 15 32 3∕ " UNC
M10 52 72 87 8 43 61 73
M10 41 17 17 47 47 31 64 1∕ " UNC
M12 90 127 152 2 79 112 134
M12 73 29 29 83 83 54 112 M14 145 204 245 9∕ " UNC 154 217 261
16
M14 117 46 46 132 132 86 180 5∕ " UNC
M16 225 317 380 8 213 300 360
M16 181 72 72 206 206 134 280 M18 313 440 528 3∕ " UNC 380 535 642
4
M18 252 100 100 286 286 186 389 7∕ " UNC
M20 424 596 715 8 615 865 1038
M20 341 136 136 388 388 252 527
M22 606 852 1022 1" UNC 927 1304 1565
M22 487 194 194 554 554 360 752 M30 1322 1859 2231 11∕8" UNC 1325 1864 2237
M30 1064 424 424 1209 1209 785 1643
M33 2111 2969 3563 11∕4" UNC 1868 2627 3152
M33 1699 676 676 1930 1930 1254 2623 M36 2732 3843 4611 13∕8" UNC 2474 3480 4175
M36 2199 875 875 2498 2498 1622 3394 M39 3540 4978 5973 11∕2" UNC 3282 4615 5538
M39 2848 1134 1134 3235 3235 2102 4397
M42 4412 6204 7445 13∕4" UNC 5250 7383 8859
M42 3550 1413 1413 4033 4033 2619 5480 M45 5389 7578 9094 2"UNC 7959 11192 13430
M45 4337 1726 1726 4926 4926 3200 6694
M52 8657 12175 14609
M52 6967 2773 2773 7913 7913 5140 10754
M68 20024 28159 33791
M68 16113 6414 6414 18303 18303 11889 24874
1∕ "
4
UNC 9 4 4 11 11 7 15
5∕ "
16
UNC 20 8 8 22 22 14 30
3∕ "
8
UNC 35 14 14 40 40 26 54
1∕ "
2
UNC 64 25 25 73 73 47 99
9∕ "
16
UNC 124 49 49 141 141 92 192
5∕ "
8
UNC 172 68 68 195 195 127 265
3∕ "
4
UNC 306 122 122 348 348 226 472
7∕ "
8
UNC 495 197 197 562 562 365 764
1"
UNC 746 297 297 848 848 551 1152
11∕8"
UNC 1066 425 425 1211 1211 787 1646
11∕4"
UNC 1503 598 598 1708 1708 1109 2321
13∕8"
UNC 1991 793 793 2262 2262 1469 3074
11∕2"
UNC 2641 1051 1051 3000 3000 1949 4077
13∕4"
UNC 4224 1682 1682 4799 4799 3117 6521
2"UNC 6404 2549 2549 7275 7275 4726 9886

HP Valves BV

Reseating & lapping
Specially designed HP Valves reseating tools allow

refinishing of worn or damaged seats at the correct angle and
without removing the valve body from the line.
These special reseating tools can be made available for HP
Valves-manufactured globe and piston type check valves.
For enquiries, we would ask you to contact
sales@hpvalves.com
For seat repair on large bore valves, special grinding and

lapping tools can be made available. However, these should
only be handled and operated by one of our trained service
engineers.
To repair valve seats, follow our reseating instructions

included in the attached disassembly & reassembly section
of this IOM.
High stress areas
All valves supplied by HP Valves are designed for application

in severe (high temperature / high pressure) service
conditions. If valves are installed in power plants, used in high
frequency hot & cold start-up service, it is recommended the
high stress areas are checked every 10 to 15 years by LPE
(liquid penetrant examination) for signs of fatigue. High stress
areas are mainly identified by sharp edges in the valve design
and are often found around the seating area. In particular,
valves manufactured from A182-F91 (X10CrMoVNb9-1) /
A182-F92 (X10CrWMoVNb9-2) material should be checked
thoroughly because of their creep resistance properties.

HP Valves BV

8 Troubleshooting Setting of the coupling between Readjust the coupling according

the pneumatic actuator and the to the manufacturer's
Probable cause Rectification valve is incorrect and prevents instructions.
the valve from fully closing.
High operating force

Misalignment of gland flange Realign gland flange and check Valve will not completely open
causing the gland flange to stem for damage. If the stem is Foreign object(s) inside the Try to flush the foreign object(s)
contact the stem. damaged it should be replaced. valve prevent it from fully from the valve by opening it and
Overstressed gland-bolting Loosen the gland bolting to opening. providing sufficient flow. If the
reduce the packing friction. problem persists, disassemble
Make sure no leakage occurs the valve in line with
during operation. manufacturer's instructions,
remove foreign object(s) and
Foreign object(s) between stem Unscrew gland bolting and
replace damaged parts.
and gland flange remove foreign object(s). If the
stem is damaged it should be Limit switches of electric Operate the valve manually and
replaced. operated valves are readjust the limit switches
malfunctioning or are incorrectly according to the actuator
Non-genuine stem packing has Replace with genuine parts.
adjusted, preventing the valve manufacturers’ manual. If limit
been used, increasing stem
from reaching its fully opened switches malfunction these
friction.
position. should be replaced.
Torque switches of electric Reset the switches to
operated valves are manufacturer's settings, to be
Valve will not completely close / passing valves
malfunctioning or incorrectly found in the MDR of the
Foreign object(s) inside the Try to flush the foreign object(s) adjusted. supplied valve & actuator
valve prevent it from fully from the valve by opening it and combination.
closing. providing sufficient flow. If the
Setting of the coupling between Readjust the coupling according
problem persists, disassemble
the pneumatic actuator and the to the manufacturer’s
the valve in line with
valve is incorrect, preventing the instructions.
manufacturer's maintenance
valve from fully closing.
instructions as quickly as
possible in order to prevent
erosion, remove foreign Gate valve will not open
object(s) and replace damaged
Limit switches of electric Operate the valve manually and
parts.
operated valves are readjust the limit switches
Seating surfaces have been Disassemble the valve in line malfunctioning or are incorrectly according to the actuator
damaged by foreign objects. with manufacturer's adjusted, preventing the valve manual. If limit switches
maintenance instructions as from opening. malfunction, these should be
quickly as possible in order to replaced.
prevent erosion. Remove
The force required to unseat the Make sure not to apply
foreign object(s) and reseat / lap
wedge or discs has increased excessive force to open the
the valve seat(s) according to
due to pressure locking (high valve, since this will cause
the manufacturer's instructions.
pressure water captured in the damage to the internals.
Limit switches of electric Operate the valve manually and inter-disc space) or over- In the case of a pressure
operated valves are readjust the limit switches pressurization (heating up water equalizing line, make sure the
malfunctioning or are incorrectly according to the actuator captured in the inter-disc equalizing valve is opened. If a
adjusted; preventing the valve manufacturers’ manual. If limit space). pressure equalizing line is non-
from reaching its fully closed switches malfunction, these existent, carefully loosen the
position. should be replaced. gland bolting to allow water or
Torque switches of electric Reset the switches to steam passing the stem-
operated valves are manufacturer's settings, to be packing. Be careful not to cause
malfunctioning or are incorrectly found in the MDR of the packing blow-out. Consult the
adjusted. supplied valve & actuator valve manufacturer for more
combination. detailed instructions on how to
proceed as well as for

HP Valves BV

recommended accessories for Handwheel and/or stem is bent

pressure equalizing. Damaged during transportation Replace damaged parts and
The force required to unseat the Make sure not to apply or installation or excessive force prevent future damage.
wedge has increased due to excessive force to open the has been applied to the valve
thermal binding. valve since this will cause using spanners or other
damage to the internals. In the leveraging devices.
case of a bypass line, make
sure the bypass valve is
Corrosion on valve parts
opened. If a bypass line is non-
existent, try to heat up the valve This can be caused by incorrect Touch-up the damaged areas
uniformly in another manner. selection of coating systems, immediately as per
incorrect application, failure of manufacturer’s instructions. If
full curing during long-term result is insufficient contact the
Leaking stem packing storage or due to damage manufacturer.
Misaligned gland or Carefully tighten the gland during transportation and
insufficiently tightened gland bolting immediately until the installation.
bolting. leakage stops.
Valve has been a long-term Replace stem packing.
storage item at the user’s site
before being installed.
Non-genuine stem packing has Replace with genuine parts. 9 Disposal
been used, leading to leakage.
All our products are designed and manufactured for long-life
Leaking gasket service. However at the end of the product lifecycle, we would
advise our products are recycled in a proper manner. Since
Misaligned bonnet (for bolted Realign bonnet and replace
the products are free of dangerous substances, such as
bonnet valves) due to gasket if required.
asbestos, they can be disposed of without the need for
transportation or incorrect
special precautions. For the disposal of actuators and/or
maintenance.
gearboxes, the lubrication (oil / grease) should be recycled
Bonnet bolting has not been Tighten the bonnet bolting separately.
tightened immediately after the immediately. If leakage doesn't
valve first (after installation or stop, the gasket and/or valve
re-assembly) reached its body sealing area has been 10 Pressure-Temperature ratings
service conditions preventing damaged due to erosion and
the gasket to seal optimum. should be replaced/repaired as Valves supplied by HP Valves are compliant with project
per manufacturer's specifications. Depending on the applicable specifications,
recommendations. our products are selected, tested and supplied in compliance
Non-genuine gaskets have Replace with genuine parts. with e.g. ASME B16.34, EN 12516-1 or API598 regulations,
been used leading to leakage. versions are used which are valid at the moment the specific
valves were manufactured or an earlier version if required per
customer specification. Pressure class is selected
Leakage through valve body or bonnet accordingly and taking into account design pressure and
Long-term leakage across seat Replace valve. To prevent temperature together with valve wall thickness and body
has eroded through the valve future problems, repair passing material. Please reach out to sales@hpvalves.com in case of
body. valves as quickly as possible questions about suitability of our products for your specific
application. On the next pages the current valid pressure-
Imperfection in casting. If possible, weld repair the
temperature tables are available for review.
casting defect following the
correct WPS. If the casting
defect cannot be repaired by
welding, the valve should be
replaced. To prevent future
problems, review minimum NDE
specifications.

HP Valves BV

pt. 1/4 Pressure-Temperature Ratings pt. 3/4 Pressure-Temperature Ratings

ASME B16.34 - 2020 (Standard Class) ASME B16.34 - 2020 (Standard Class)
Working Pressure (barg) Working Pressure (barg)
Below w orking pressures have been calculated as per ASME B16.34-2020 nonmandatory Appendix B Below w orking pressures have been calculated as per ASME B16.34-2020 nonmandatory Appendix B
Class(1) Material inform ation Tem perature (°C) Class Material inform ation Tem perature (°C)
Forging Casting Group 38 50 100 150 200 250 300 325 350 375 400 Forging Casting Group 38 50 100 150 200 250 300 325 350 375 400
A105 WCB 1.1 19,6 19,2 17,7 15,8 13,8 12,1 10,2 9,3 8,4 7,4 6,5 A105 WCB 1.1 153,2 150,4 139,8 135,2 131,4 125,8 119,5 116,1 112,7 109,1 104,2
F11 WC6 1.9 19,8 19,5 17,7 15,8 13,8 12,1 10,2 9,3 8,4 7,4 6,5 F11 WC6 1.9 155,1 155,1 154,4 149,2 143,9 139,0 128,6 124,0 120,7 116,5 109,8
F12 - 1.17 19,8 19,5 17,7 15,8 13,8 12,1 10,2 9,3 8,4 7,4 6,5 F12 - 1.17 155,1 154,5 151,3 144,5 138,8 134,5 128,6 124,0 120,7 116,5 109,8
F22 WC9 1.10 19,8 19,5 17,7 15,8 13,8 12,1 10,2 9,3 8,4 7,4 6,5 F22 WC9 1.10 155,1 155,1 154,6 150,6 145,8 139,0 128,6 124,0 120,7 116,5 109,8
150 F91 Type 1 C12A 1.15 20,0 19,5 17,7 15,8 13,8 12,1 10,2 9,3 8,4 7,4 6,5 900 F91 Type 1 C12A 1.15 155,1 155,1 154,6 150,6 145,8 139,0 128,6 124,0 120,7 116,5 109,8
F91 Type 2 (2)

- 1.15 20,0 19,5 17,7 15,8 13,8 12,1 10,2 9,3 8,4 7,4 6,5 F91 Type 2 (2) - 1.15 155,1 155,1 154,6 150,6 145,8 139,0 128,6 124,0 120,7 116,5 109,8
F92 - 1.18 20,0 19,5 17,7 15,8 13,8 12,1 10,2 9,3 8,4 7,4 6,5 F92 - 1.18 155,1 155,1 154,6 150,6 145,8 139,0 128,6 124,0 120,7 116,5 109,8
F316 CF8M 2.2 19,0 18,4 16,2 14,8 13,7 12,1 10,2 9,3 8,4 7,4 6,5 F316 CF8M 2.2 148,9 144,3 126,6 115,5 107,0 100,1 94,9 92,7 91,0 89,6 88,3
F51 - 2.8 20,0 19,5 17,7 15,8 13,8 12,1 10,2 F51 - 2.8 155,1 155,1 152,0 137,8 128,0 121,4 116,6
A105 WCB 1.1 51,1 50,1 46,6 45,1 43,8 41,9 39,8 38,7 37,6 36,4 34,7 A105 WCB 1.1 255,3 250,6 233,0 225,4 219,0 209,7 199,1 193,6 187,8 181,8 173,6
F11 WC6 1.9 51,7 51,7 51,5 49,7 48,0 46,3 42,9 41,4 40,3 38,9 36,5 F11 WC6 1.9 258,6 258,6 257,4 248,7 239,8 231,8 214,4 206,6 201,1 194,1 183,1
F12 - 1.17 51,7 51,5 50,4 48,2 46,3 44,8 42,9 41,4 40,3 38,9 36,5 F12 - 1.17 258,6 257,5 252,2 240,9 231,3 224,1 214,4 206,6 201,1 194,1 183,1
F22 WC9 1.10 51,7 51,7 51,5 50,3 48,6 46,3 42,9 41,4 40,3 38,9 36,5 F22 WC9 1.10 258,6 258,6 257,6 250,8 243,4 231,8 214,4 206,6 201,1 194,1 183,1
300 F91 Type 1 C12A 1.15 51,7 51,7 51,5 50,3 48,6 46,3 42,9 41,4 40,3 38,9 36,5 1500 F91 Type 1 C12A 1.15 258,6 258,6 257,6 250,8 243,4 231,8 214,4 206,6 201,1 194,1 183,1
F91 Type 2 (2) - 1.15 51,7 51,7 51,5 50,3 48,6 46,3 42,9 41,4 40,3 38,9 36,5 F91 Type 2 (2) - 1.15 258,6 258,6 257,6 250,8 243,4 231,8 214,4 206,6 201,1 194,1 183,1
F92 - 1.18 51,7 51,7 51,5 50,3 48,6 46,3 42,9 41,4 40,3 38,9 36,5 F92 - 1.18 258,6 258,6 257,6 250,8 243,4 231,8 214,4 206,6 201,1 194,1 183,1
F316 CF8M 2.2 49,6 48,1 42,2 38,5 35,7 33,4 31,6 30,9 30,3 29,9 29,4 F316 CF8M 2.2 248,2 240,6 211,0 192,5 178,3 166,9 158,1 154,4 151,6 149,4 147,2
F51 - 2.8 51,7 51,7 50,7 45,9 42,7 40,5 38,9 F51 - 2.8 258,6 258,6 253,3 229,6 213,3 202,3 194,3
A105 WCB 1.1 102,1 100,2 93,2 90,2 87,6 83,9 79,6 77,4 75,1 72,7 69,4 A105 WCB 1.1 425,5 417,7 388,3 375,6 365,0 349,5 331,8 322,6 313,0 303,1 289,3
F11 WC6 1.9 103,4 103,4 103,0 99,5 95,9 92,7 85,7 82,6 80,4 77,6 73,3 F11 WC6 1.9 430,9 430,9 429,0 414,5 399,6 386,2 357,1 344,3 335,3 323,2 304,9
F12 - 1.17 103,4 103,0 100,9 96,4 92,5 89,6 85,7 82,6 80,4 77,6 73,3 F12 - 1.17 430,9 429,2 420,4 401,5 385,6 373,5 357,1 344,3 335,3 323,2 304,9
F22 WC9 1.10 103,4 103,4 103,0 100,3 97,2 92,7 85,7 82,6 80,4 77,6 73,3 F22 WC9 1.10 430,9 430,9 429,4 418,2 405,4 386,2 357,1 344,3 335,3 323,2 304,9
600 F91 Type 1 C12A 1.15 103,4 103,4 103,0 100,3 97,2 92,7 85,7 82,6 80,4 77,6 73,3 2500 F91 Type 1 C12A 1.15 430,9 430,9 429,4 418,2 405,4 386,2 357,1 344,3 335,3 323,2 304,9
(2) (2)
F91 Type 2 - 1.15 103,4 103,4 103,0 100,3 97,2 92,7 85,7 82,6 80,4 77,6 73,3 F91 Type 2 - 1.15 430,9 430,9 429,4 418,2 405,4 386,2 357,1 344,3 335,3 323,2 304,9
F92 - 1.18 103,4 103,4 103,0 100,3 97,2 92,7 85,7 82,6 80,4 77,6 73,3 F92 - 1.18 430,9 430,9 429,4 418,2 405,4 386,2 357,1 344,3 335,3 323,2 304,9
F316 CF8M 2.2 99,3 96,2 84,4 77,0 71,3 66,8 63,2 61,8 60,7 59,8 58,9 F316 CF8M 2.2 413,7 400,9 351,6 320,8 297,2 278,1 263,5 257,4 252,7 249,0 245,3
F51 - 2.8 103,4 103,4 101,3 91,9 85,3 80,9 77,7 F51 - 2.8 430,9 430,9 422,2 382,7 355,4 337,2 323,8
A105 WCB 1.1 136,2 133,7 124,3 120,2 116,8 111,8 106,2 103,2 100,2 97,0 92,6 A105 WCB 1.1 765,9 751,9 699,0 676,1 657,0 629,1 597,3 580,7 563,5 545,5 520,8
F11 WC6 1.9 137,9 137,9 137,3 132,6 127,9 123,6 114,3 110,2 107,3 103,5 97,6 F11 WC6 1.9 775,7 775,7 772,2 746,2 719,4 694,8 642,6 619,6 603,3 581,8 548,5
F12 - 1.17 137,9 137,3 134,5 128,5 123,4 119,5 114,3 110,2 107,3 103,5 97,6 F12 - 1.17 775,7 772,5 756,7 722,7 694,0 672,3 642,6 619,6 603,3 581,8 548,5
F22 WC9 1.10 137,9 137,9 137,4 133,8 129,6 123,6 114,3 110,2 107,3 103,5 97,6 F22 WC9 1.10 775,7 775,7 773,0 752,8 729,8 694,8 642,6 619,6 603,3 581,8 548,5
(3)
800 F91 Type 1 C12A 1.15 137,9 137,9 137,4 133,8 129,6 123,6 114,3 110,2 107,3 103,5 97,6 4500 F91 Type 1 C12A 1.15 775,7 775,7 773,0 752,8 729,8 694,8 642,6 619,6 603,3 581,8 548,5
F91 Type 2(2) - 1.15 137,9 137,9 137,4 133,8 129,6 123,6 114,3 110,2 107,3 103,5 97,6 F91 Type 2 (2) - 1.15 775,7 775,7 773,0 752,8 729,8 694,8 642,6 619,6 603,3 581,8 548,5
F92 - 1.18 137,9 137,9 137,4 133,8 129,6 123,6 114,3 110,2 107,3 103,5 97,6 F92 - 1.18 775,7 775,7 773,0 752,8 729,8 694,8 642,6 619,6 603,3 581,8 548,5
F316 CF8M 2.2 132,4 128,3 112,5 102,7 95,1 89,0 84,3 82,4 80,9 79,7 78,5 F316 CF8M 2.2 744,6 721,7 632,9 577,4 534,9 500,6 474,3 463,3 454,9 448,2 441,6
F51 - 2.8 137,9 137,9 135,1 122,5 113,8 107,9 103,6 F51 - 2.8 775,7 775,7 759,9 688,9 639,8 606,9 582,8
(1) (1)
Intermediate pressure ratings can be linearly interpolated in acc. with B16.34 § 2.1.1. Intermediate pressure ratings can be linearly interpolated in acc. with B16.34 § 2.1.1.
(Extrapolation is NOT permitted) (Extrapolation is NOT permitted)
(2) (2)
P-T Values follow from B16 Case 18. P-T Values follow from B16 Case 18.
(3) (3)
Pressure class 800 is linearly interpolated. Pressure class 800 is linearly interpolated.

ASME B16.34 - 2020 (Standard Class) ASME B16.34 - 2020 (Standard Class)
Class Material inform ation Tem perature (°C)

Class Material inform ation Tem perature (°C)
Forging Casting Group 425 450 475 500 538 550 575 600 625 650 Forging Casting Group 425 450 475 500 538 550 575 600 625 650
A105 WCB 1.1 5,5 4,6 3,7 2,8 1,4 A105 WCB 1.1 86,3 69,0 52,3 35,3 17,7
F11 WC6 1.9 5,5 4,6 3,7 2,8 1,4 1,4 1,4 1,4 1,4 1,1 F11 WC6 1.9 105,1 101,4 95,1 77,2 44,7 38,1 26,4 18,3 12,8 8,5
F12 - 1.17 5,5 4,6 3,7 2,8 1,4 1,4 1,4 1,4 1,4 0,9 F12 - 1.17 105,1 101,4 83,6 64,1 41,1 36,1 26,4 18,2 12,0 7,1
F22 WC9 1.10 5,5 4,6 3,7 2,8 1,4 1,4 1,4 1,4 1,4 1,4 F22 WC9 1.10 105,1 101,4 95,1 84,7 55,3 46,9 31,6 20,7 13,4 8,5
150 F91 Type 1 C12A 1.15 5,5 4,6 3,7 2,8 1,4 1,4 1,4 1,4 1,4 1,4 900 F91 Type 1 C12A 1.15 105,1 101,4 95,1 84,7 75,2 74,8 71,8 55,9 37,9 24,7
F91 Type 2 (2) - 1.15 5,5 4,6 3,7 2,8 1,4 1,4 1,4 1,4 1,4 1,4 F91 Type 2 (2) - 1.15 105,1 101,4 95,1 84,7 75,2 74,8 71,8 59,2 40,3 25,8
F92 - 1.18 5,5 4,6 3,7 2,8 1,4 1,4 1,4 1,4 1,4 1,4 F92 - 1.18 105,1 101,4 95,1 84,7 75,2 74,8 71,8 64,2 54,9 39,7
F316 CF8M 2.2 5,5 4,6 3,7 2,8 1,4 1,4 1,4 1,4 1,4 1,4 F316 CF8M 2.2 87,4 86,5 86,0 84,7 75,2 74,8 71,8 59,7 47,4 38,0
F51 - 2.8 F51 - 2.8
A105 WCB 1.1 28,8 23,0 17,4 11,8 5,9 A105 WCB 1.1 143,8 115,0 87,2 58,8 29,5
F11 WC6 1.9 35,2 33,7 31,7 25,7 14,9 12,7 8,8 6,1 4,3 2,8 F11 WC6 1.9 175,1 169,0 158,2 128,6 74,5 63,5 44,0 30,5 21,3 14,2
F12 - 1.17 35,2 33,7 27,9 21,4 13,7 12,0 8,8 6,1 4,0 2,4 F12 - 1.17 175,1 169,0 139,3 106,9 68,6 60,2 44,0 30,3 20,0 11,8
F22 WC9 1.10 35,2 33,7 31,7 28,2 18,4 15,6 10,5 6,9 4,5 2,8 F22 WC9 1.10 175,1 169,0 158,2 140,9 92,2 78,2 52,6 34,4 22,3 14,2
300 F91 Type 1 C12A 1.15 35,2 33,7 31,7 28,2 25,2 25,0 24,0 18,6 12,6 8,2 1500 F91 Type 1 C12A 1.15 175,1 169,0 158,2 140,9 125,5 124,9 119,7 93,1 63,1 41,1
F91 Type 2 (2) - 1.15 35,2 33,7 31,7 28,2 25,2 25,0 24,0 19,7 13,4 8,6 F91 Type 2 (2) - 1.15 175,1 169,0 158,2 140,9 125,5 124,9 119,7 98,7 67,2 43,0
F92 - 1.18 35,2 33,7 31,7 28,2 25,2 25,0 24,0 21,6 18,3 13,2 F92 - 1.18 175,1 169,0 158,2 140,9 125,5 124,9 119,7 107,0 91,2 66,2
F316 CF8M 2.2 29,1 28,8 28,7 28,2 25,2 25,0 24,0 19,9 15,8 12,7 F316 CF8M 2.2 145,7 144,2 143,4 140,9 125,5 124,9 119,7 99,5 79,1 63,3
F51 - 2.8 F51 - 2.8
A105 WCB 1.1 57,5 46,0 34,9 23,5 11,8 A105 WCB 1.1 239,7 191,7 145,3 97,9 49,2
F11 WC6 1.9 70,0 67,7 63,4 51,5 29,8 25,4 17,6 12,2 8,5 5,7 F11 WC6 1.9 291,6 281,8 263,9 214,4 124,1 105,9 73,4 50,9 35,5 23,6
F12 - 1.17 70,0 67,7 55,7 42,8 27,4 24,1 17,6 12,1 8,0 4,7 F12 - 1.17 291,6 281,8 232,1 178,2 114,3 100,4 73,4 50,4 33,3 19,7
F22 WC9 1.10 70,0 67,7 63,4 56,5 36,9 31,3 21,1 13,8 8,9 5,7 F22 WC9 1.10 291,6 281,8 263,9 235,0 153,7 130,3 87,7 57,4 37,2 23,6
600 F91 Type 1 C12A 1.15 70,0 67,7 63,4 56,5 50,0 49,8 47,9 37,2 25,2 16,5 2500 F91 Type 1 C12A 1.15 291,6 281,8 263,9 235,0 208,9 208,0 199,5 155,1 105,1 68,6
F91 Type 2 (2) - 1.15 70,0 67,7 63,4 56,5 50,0 49,8 47,9 39,5 26,9 17,2 F91 Type 2 (2) - 1.15 291,6 281,8 263,9 235,0 208,9 208,0 199,5 164,6 112,0 71,7
F92 - 1.18 70,0 67,7 63,4 56,5 50,0 49,8 47,9 42,9 36,6 26,5 F92 - 1.18 291,6 281,8 263,9 235,0 208,9 208,0 199,5 178,5 152,0 110,3
F316 CF8M 2.2 58,3 57,7 57,3 56,5 50,0 49,8 47,9 39,8 31,6 25,3 F316 CF8M 2.2 242,9 240,4 238,9 235,0 208,9 208,0 199,5 165,9 131,8 105,5
F51 - 2.8 F51 - 2.8
A105 WCB 1.1 76,7 61,3 46,5 31,4 15,7 A105 WCB 1.1 431,5 345,1 261,5 176,3 88,6
F11 WC6 1.9 93,4 90,2 84,5 68,6 39,7 33,9 23,5 16,3 11,4 7,6 F11 WC6 1.9 524,7 507,0 474,8 385,9 223,4 190,6 132,0 91,6 63,9 42,6
F12 - 1.17 93,4 90,2 74,3 57,0 36,5 32,1 23,5 16,2 10,7 6,3 F12 - 1.17 524,7 507,0 417,8 320,7 205,7 180,7 132,0 90,8 59,9 35,5
F22 WC9 1.10 93,4 90,2 84,5 75,3 49,2 41,7 28,1 18,4 11,9 7,6 F22 WC9 1.10 524,7 507,0 474,8 423,0 276,6 234,5 157,9 103,3 66,9 42,6
(3)
800 F91 Type 1 C12A 1.15 93,4 90,2 84,5 75,3 66,8 66,5 63,8 49,7 33,7 22,0 4500 F91 Type 1 C12A 1.15 524,7 507,0 474,8 423,0 375,8 374,2 359,1 279,3 189,3 123,4
F91 Type 2(2) - 1.15 93,4 90,2 84,5 75,3 66,8 66,5 63,8 52,6 35,8 22,9 F91 Type 2 (2) - 1.15 524,7 507,0 474,8 423,0 375,8 374,2 359,1 296,2 201,6 129,1
F92 - 1.18 93,4 90,2 84,5 75,3 66,8 66,5 63,8 57,1 48,8 35,3 F92 - 1.18 524,7 507,0 474,8 423,0 375,8 374,2 359,1 321,4 273,8 198,6
F316 CF8M 2.2 77,7 76,9 76,4 75,3 66,8 66,5 63,8 53,1 42,1 33,8 F316 CF8M 2.2 437,1 432,7 430,1 423,0 375,8 374,2 359,1 298,6 237,2 189,9
F51 - 2.8 F51 - 2.8
(1) (1)
Intermediate pressure ratings can be linearly interpolated in acc. with B16.34 § 2.1.1. Intermediate pressure ratings can be linearly interpolated in acc. with B16.34 § 2.1.1.
(2) (2)
P-T Values follow from B16 Case 18. P-T Values follow from B16 Case 18.
(3) (3)
Pressure class 800 is linearly interpolated. Pressure class 800 is linearly interpolated.

HP Valves BV


ASME B16.34 - 2020 (Special Class) ASME B16.34 - 2020 (Special Class)
Class (1) Material inform ation Tem perature (°C) Class (1) Material inform ation Tem perature (°C)
Forging Casting Group 38 50 100 150 200 250 300 325 350 375 400 Forging Casting Group 38 50 100 150 200 250 300 325 350 375 400
A105 WCB 1.1 19,8 19,8 19,8 19,6 19,4 19,4 19,4 19,2 18,7 18,1 16,6 A105 WCB 1.1 155,1 155,1 154,9 153,1 151,7 151,6 151,6 150,3 146,7 141,3 130,2
F11 WC6 1.9 19,8 19,8 19,8 19,8 19,8 19,8 19,8 19,8 19,8 19,3 19,3 F11 WC6 1.9 155,1 155,1 155,1 155,1 155,1 155,1 155,1 155,1 154,3 151,5 150,6
F12 - 1.17 19,8 19,7 19,4 19,1 19,1 19,0 18,8 18,6 18,3 18,0 18,0 F12 - 1.17 155,1 154,5 151,9 149,1 149,1 148,8 147,1 145,7 143,5 141,2 141,2
F22 WC9 1.10 19,8 19,8 19,8 19,5 19,3 19,2 19,1 19,0 18,9 18,7 18,7 F22 WC9 1.10 155,1 155,1 154,9 152,9 150,7 149,9 149,3 148,8 147,6 146,3 146,3
150 F91 Type 1 C12A 1.15 20,0 20,0 20,0 20,0 20,0 20,0 20,0 20,0 19,8 19,3 19,3 150 F91 Type 1 C12A 1.15 155,1 155,1 155,1 155,1 155,1 155,1 155,1 155,1 154,3 151,5 150,6
F91 Type 2 (2) - 1.15 20,0 20,0 20,0 20,0 20,0 20,0 20,0 20,0 19,8 19,3 19,3 F91 Type 2 (2) - 1.15 155,1 155,1 155,1 155,1 155,1 155,1 155,1 155,1 154,3 151,4 150,6
F92 - 1.18 20,0 20,0 20,0 20,0 20,0 20,0 20,0 20,0 19,8 19,3 19,3 F92 - 1.18 155,1 155,1 155,1 155,1 155,1 155,1 155,1 155,1 154,3 151,5 150,6
F316 CF8M 2.2 19,8 19,5 18,1 16,5 15,3 14,3 13,5 13,2 13,0 12,8 12,6 F316 CF8M 2.2 155,1 152,5 141,3 128,9 119,4 111,8 105,9 103,4 101,5 100,0 98,6
F51 - 2.8 20,0 20,0 20,0 19,6 18,2 17,3 16,6 16,3 16,1 16,0 15,2 F51 - 2.8 155,1 155,1 155,1 153,8 142,8 135,5 130,1 127,8 126,1 125,1 119,1
A105 WCB 1.1 51,7 51,7 51,6 51,0 50,6 50,5 50,5 50,1 48,9 47,1 43,4 A105 WCB 1.1 258,6 258,6 258,2 255,2 252,9 252,6 252,6 250,6 244,6 235,5 217,0
F11 WC6 1.9 51,7 51,7 51,7 51,7 51,7 51,7 51,7 51,7 51,5 50,6 50,3 F11 WC6 1.9 258,6 258,6 258,6 258,6 258,6 258,6 258,6 258,6 257,1 252,5 251,2
F12 - 1.17 51,7 51,5 50,6 49,7 49,7 49,6 49,0 48,6 47,8 47,1 47,1 F12 - 1.17 258,6 257,5 253,1 248,6 248,6 248,0 245,2 242,9 239,2 235,3 235,3
F22 WC9 1.10 51,7 51,7 51,6 51,0 50,2 50,0 49,8 49,6 49,2 48,8 48,8 F22 WC9 1.10 258,6 258,6 258,1 254,8 251,1 249,9 248,9 248,0 246,0 243,8 243,8
300 F91 Type 1 C12A 1.15 51,7 51,7 51,7 51,7 51,7 51,7 51,7 51,7 51,5 50,6 50,3 300 F91 Type 1 C12A 1.15 258,6 258,6 258,6 258,6 258,6 258,6 258,6 258,6 257,1 252,5 251,2
(2) (2)
F91 Type 2 - 1.15 51,7 51,7 51,7 51,7 51,7 51,7 51,7 51,7 51,5 50,6 50,3 F91 Type 2 - 1.15 258,6 258,6 258,6 258,6 258,6 258,6 258,6 258,6 257,1 252,7 251,2
F92 - 1.18 51,7 51,7 51,7 51,7 51,7 51,7 51,7 51,7 51,5 50,6 50,3 F92 - 1.18 258,6 258,6 258,6 258,6 258,6 258,6 258,6 258,6 257,1 252,5 251,2
F316 CF8M 2.2 51,7 50,8 47,1 43,0 39,8 37,3 35,3 34,5 33,8 33,3 32,9 F316 CF8M 2.2 258,6 254,1 235,5 214,8 199,0 186,3 176,4 172,3 169,2 166,7 164,3
F51 - 2.8 51,7 51,7 51,7 51,3 47,6 45,2 43,4 42,6 42,0 41,7 39,7 F51 - 2.8 258,6 258,6 258,6 256,3 238,0 225,8 216,8 213,0 210,1 208,4 198,6
A105 WCB 1.1 103,4 103,4 103,3 102,1 101,1 101,1 101,1 100,2 97,8 94,2 86,8 A105 WCB 1.1 430,9 430,9 430,3 425,3 421,4 421,1 421,1 417,6 407,6 392,5 361,7
F11 WC6 1.9 103,4 103,4 103,4 103,4 103,4 103,4 103,4 103,4 102,8 101,0 100,6 F11 WC6 1.9 430,9 430,9 430,9 430,9 430,9 430,9 430,9 430,9 428,6 420,9 418,3
F12 - 1.17 103,4 103,0 101,3 99,4 99,4 99,2 98,1 97,2 95,7 94,1 94,1 F12 - 1.17 430,9 429,2 421,9 414,3 414,3 413,3 408,6 404,8 398,7 392,1 392,1
F22 WC9 1.10 103,4 103,4 103,2 101,9 100,4 100,0 99,6 99,2 98,4 97,5 97,5 F22 WC9 1.10 430,9 430,9 430,2 424,6 418,5 416,5 414,8 413,3 410,0 406,3 406,3
600 F91 Type 1 C12A 1.15 103,4 103,4 103,4 103,4 103,4 103,4 103,4 103,4 102,8 101,0 100,6 2500 F91 Type 1 C12A 1.15 430,9 430,9 430,9 430,9 430,9 430,9 430,9 430,9 428,6 420,9 418,3
F91 Type 2 (2) - 1.15 103,4 103,4 103,4 103,4 103,4 103,4 103,4 103,4 102,8 101,0 100,6 F91 Type 2 (2) - 1.15 430,9 430,9 430,9 430,9 430,9 430,9 430,9 430,9 428,6 420,9 418,3
F92 - 1.18 103,4 103,4 103,4 103,4 103,4 103,4 103,4 103,4 102,8 101,0 100,6 F92 - 1.18 430,9 430,9 430,9 430,9 430,9 430,9 430,9 430,9 428,6 420,9 418,3
F316 CF8M 2.2 103,4 101,6 94,2 85,9 79,6 74,5 70,6 68,9 67,7 66,7 65,7 F316 CF8M 2.2 430,9 423,5 392,4 358,0 331,7 310,4 294,1 287,2 282,1 277,9 273,8
F51 - 2.8 103,4 103,4 103,4 102,5 95,2 90,3 86,7 85,2 84,0 83,4 79,4 F51 - 2.8 430,9 430,9 430,9 427,2 396,7 376,3 361,4 355,0 350,2 347,4 330,9
A105 WCB 1.1 80,4 80,4 80,4 79,4 78,6 78,7 78,7 77,9 76,1 73,3 67,5 A105 WCB 1.1 775,7 775,7 774,5 765,5 758,6 757,9 757,9 751,7 733,7 706,5 651,0
F11 WC6 1.9 80,4 80,4 80,4 80,4 80,4 80,4 80,4 80,4 79,9 78,6 78,4 F11 WC6 1.9 775,7 775,7 775,7 775,7 775,7 775,7 775,7 775,7 771,4 757,4 753,2
F12 - 1.17 80,4 80,1 78,8 77,3 77,3 77,2 76,3 75,6 74,5 73,2 73,2 F12 - 1.17 775,7 772,5 759,4 745,7 745,7 743,9 735,5 728,7 717,6 705,9 705,9
F22 WC9 1.10 80,4 80,4 80,2 79,2 78,0 77,8 77,5 77,2 76,5 75,8 75,8 F22 WC9 1.10 775,7 775,7 774,3 764,3 753,4 749,7 746,7 743,9 738,1 731,3 731,3
800 (3) F91 Type 1 C12A 1.15 80,4 80,4 80,4 80,4 80,4 80,4 80,4 80,4 79,9 78,6 78,4 4500 F91 Type 1 C12A 1.15 775,7 775,7 775,7 775,7 775,7 775,7 775,7 775,7 771,4 757,4 753,2
F91 Type 2 (2) - 1.15 80,4 80,4 80,4 80,4 80,4 80,4 80,4 80,4 79,9 78,6 78,4 F91 Type 2 (2) - 1.15 775,7 775,7 775,7 775,7 775,7 775,7 775,7 775,7 771,4 757,4 753,2
F92 - 1.18 80,4 80,4 80,4 80,4 80,4 80,4 80,4 80,4 79,9 78,6 78,4 F92 - 1.18 775,7 775,7 775,7 775,7 775,7 775,7 775,7 775,7 771,4 757,4 753,2
F316 CF8M 2.2 80,4 79,0 73,3 66,8 61,9 57,9 54,9 53,6 52,7 51,9 51,1 F316 CF8M 2.2 775,7 762,3 706,4 644,4 597,0 558,8 529,3 517,0 507,7 500,2 492,9
F51 - 2.8 80,4 80,4 80,4 79,7 74,0 70,2 67,4 66,3 65,3 64,9 61,8 F51 - 2.8 775,7 775,7 775,7 768,9 714,1 677,4 650,4 638,9 630,3 625,3 595,7
(1)
Intermediate pressure ratings can be linearly interpolated in acc. with B16.34 § 2.1.1. (1)
Intermediate pressure ratings can be linearly interpolated in acc. with B16.34 § 2.1.1.
(2)
P-T Values follow from B16 Case 18. (2)
P-T Values follow from B16 Case 18.
(3)
Pressure class 800 is linearly interpolated. (3)
Pressure class 800 is linearly interpolated.

ASME B16.34 - 2020 (Special Class) ASME B16.34 - 2020 (Special Class)
Class (1) Material inform ation Tem perature (°C)

Class (1) Material inform ation Tem perature (°C)
Forging Casting Group 425 450 475 500 538 550 575 600 625 650 Forging Casting Group 425 450 475 500 538 550 575 600 625 650
A105 WCB 1.1 13,8 11,0 8,4 5,6 2,8 A105 WCB 1.1 107,9 86,3 65,4 44,1 22,2
F11 WC6 1.9 19,0 18,1 16,4 12,3 7,1 6,1 4,2 2,9 2,0 1,4 F11 WC6 1.9 148,9 141,4 128,2 96,5 55,8 47,7 33,0 22,9 16,0 10,6
F12 - 1.17 18,0 16,5 13,3 10,2 6,6 5,8 4,2 2,9 1,9 1,1 F12 - 1.17 141,2 129,1 104,5 80,2 51,4 45,2 33,0 22,7 15,0 8,9
F22 WC9 1.10 18,7 18,1 16,4 13,7 8,8 7,5 5,0 3,3 2,1 1,4 F22 WC9 1.10 146,3 141,4 128,2 107,1 69,1 58,6 39,5 25,8 16,7 10,6
150 F91 Type 1 C12A 1.15 19,0 18,1 16,4 13,7 11,0 11,0 10,9 8,9 6,0 3,9 900 F91 Type 1 C12A 1.15 148,9 141,4 128,2 107,1 86,9 86,9 85,7 69,8 47,3 30,9
F91 Type 2 (2) - 1.15 19,0 18,1 16,4 13,7 11,0 11,0 10,9 9,5 6,4 4,1 F91 Type 2 (2) - 1.15 148,9 141,4 128,2 107,1 86,9 86,9 85,7 74,1 50,4 32,3
F92 - 1.18 19,0 18,1 16,4 13,7 11,0 11,0 10,9 10,3 8,7 6,3 F92 - 1.18 148,9 141,4 128,2 107,1 86,9 86,9 85,7 80,4 68,6 49,6
F316 CF8M 2.2 12,5 12,3 12,3 12,2 11,0 11,0 10,9 9,5 7,6 6,1 F316 CF8M 2.2 97,6 96,6 96,0 95,1 86,9 86,9 85,7 74,6 59,3 47,5
F51 - 2.8 F51 - 2.8
A105 WCB 1.1 36,0 28,8 21,8 14,7 7,4 A105 WCB 1.1 179,8 143,8 109,0 73,5 36,9
F11 WC6 1.9 49,6 47,3 42,8 32,2 18,6 15,9 11,0 7,6 5,3 3,5 F11 WC6 1.9 248,2 235,8 213,7 160,8 93,1 79,4 55,0 38,2 26,6 17,7
F12 - 1.17 47,1 43,0 34,8 26,7 17,1 15,1 11,0 7,6 5,0 3,0 F12 - 1.17 235,3 215,1 174,1 133,6 85,7 75,3 55,0 37,8 24,9 14,8
F22 WC9 1.10 48,8 47,3 42,8 35,6 23,0 19,5 13,2 8,6 5,6 3,5 F22 WC9 1.10 243,8 235,8 213,7 178,6 115,2 97,7 65,8 43,0 27,9 17,7
300 F91 Type 1 C12A 1.15 49,6 47,3 42,8 35,6 29,0 29,0 28,6 23,3 15,8 10,3 1500 F91 Type 1 C12A 1.15 248,2 235,8 213,7 178,6 145,1 145,1 143,0 116,4 78,9 51,4
F91 Type 2 (2) - 1.15 49,6 47,3 42,8 35,6 29,0 29,0 28,6 24,2 16,8 10,8 F91 Type 2 (2) - 1.15 248,2 235,8 213,7 178,6 145,1 145,1 143,0 123,9 84,0 53,8
F92 - 1.18 49,6 47,3 42,8 35,6 29,0 29,0 28,6 26,9 23,0 16,5 F92 - 1.18 248,2 235,8 213,7 178,6 145,1 145,1 143,0 134,0 114,3 82,7
F316 CF8M 2.2 32,5 32,2 32,0 31,7 29,0 29,0 28,6 24,9 19,8 15,8 F316 CF8M 2.2 162,6 161,0 160,0 158,6 145,1 145,1 143,0 124,4 98,8 79,1
F51 - 2.8 F51 - 2.8
A105 WCB 1.1 71,9 57,5 43,6 29,4 14,8 A105 WCB 1.1 299,6 239,6 181,6 122,4 61,6
F11 WC6 1.9 99,3 94,4 85,5 64,3 37,2 31,8 22,0 15,3 10,6 7,1 F11 WC6 1.9 413,7 393,1 356,3 268,0 155,1 132,4 91,7 63,6 44,4 29,5
F12 - 1.17 94,1 86,0 69,6 53,4 34,3 30,1 22,0 15,1 10,0 5,9 F12 - 1.17 392,1 358,5 290,2 222,7 142,8 125,5 91,7 63,0 41,6 24,6
F22 WC9 1.10 97,5 94,4 85,5 71,5 46,1 39,1 26,3 17,2 11,2 7,1 F22 WC9 1.10 406,3 393,1 356,3 297,5 192,1 162,8 109,7 71,7 46,5 29,5
600 F91 Type 1 C12A 1.15 99,3 94,4 85,5 71,5 57,9 57,9 57,1 46,5 31,5 20,6 2500 F91 Type 1 C12A 1.15 413,7 393,1 356,3 297,5 241,7 241,7 238,3 193,9 131,4 85,7
F91 Type 2 (2) - 1.15 99,3 94,4 85,5 71,5 57,9 57,9 57,1 49,4 33,6 21,6 F91 Type 2 (2)
- 1.15 413,7 393,1 356,3 297,5 241,7 241,7 238,3 205,7 140,0 89,6
F92 - 1.18 99,3 94,4 85,5 71,5 57,9 57,9 57,1 53,5 45,7 33,1 F92 - 1.18 413,7 393,1 356,3 297,5 241,7 241,7 238,3 223,4 190,6 137,9
F316 CF8M 2.2 65,1 64,4 64,0 63,4 57,9 57,9 57,1 49,8 39,5 31,7 F316 CF8M 2.2 271,1 268,3 266,6 264,3 241,7 241,7 238,3 207,3 164,7 131,9
F51 - 2.8 F51 - 2.8
A105 WCB 1.1 55,9 44,7 33,9 22,9 11,5 A105 WCB 1.1 539,3 431,4 326,9 220,4 110,8
F11 WC6 1.9 77,3 73,5 66,5 50,0 28,9 24,7 17,1 11,9 8,2 5,5 F11 WC6 1.9 744,6 707,6 641,3 482,4 279,2 238,3 165,1 114,5 79,9 53,2
F12 - 1.17 73,2 66,8 54,1 41,5 26,7 23,4 17,1 11,7 7,8 4,6 F12 - 1.17 705,9 645,3 522,3 400,9 257,1 225,9 165,1 113,5 74,8 44,3
F22 WC9 1.10 75,8 73,5 66,5 55,7 35,9 30,4 20,4 13,4 8,8 5,5 F22 WC9 1.10 731,3 707,6 641,3 535,4 345,7 293,1 197,4 129,1 83,7 53,2
800 (3) F91 Type 1 C12A 1.15 77,3 73,5 66,5 55,7 45,0 45,0 44,4 36,1 24,5 16,0 4500 F91 Type 1 C12A 1.15 744,6 707,6 641,3 535,4 435,1 435,1 428,8 349,1 236,6 154,3
F91 Type 2 (2) - 1.15 77,3 73,5 66,5 55,7 45,0 45,0 44,4 38,4 26,1 16,8 F91 Type 2 (2) - 1.15 744,6 707,6 641,3 535,4 435,1 435,1 428,8 370,3 252,0 161,4
F92 - 1.18 77,3 73,5 66,5 55,7 45,0 45,0 44,4 41,5 35,5 25,8 F92 - 1.18 744,6 707,6 641,3 535,4 435,1 435,1 428,8 401,9 342,8 248,2
F316 CF8M 2.2 50,7 50,1 49,8 49,3 45,0 45,0 44,4 38,8 30,7 24,7 F316 CF8M 2.2 487,9 482,9 480,0 475,7 435,1 435,1 428,8 373,2 296,5 237,4
F51 - 2.8 F51 - 2.8
(1)
Intermediate pressure ratings can be linearly interpolated in acc. with B16.34 § 2.1.1. (1)
Intermediate pressure ratings can be linearly interpolated in acc. with B16.34 § 2.1.1.
(2)
P-T Values follow from B16 Case 18. (2)
P-T Values follow from B16 Case 18.
(3)
Pressure class 800 is linearly interpolated. (3)
Pressure class 800 is linearly interpolated.

HP Valves BV


NEN-EN 12516-1:2014+A1:2018 NEN-EN 12516-1:2014+A1:2018
NEN-EN 12516-1:2014+A1:2018 - Tabulation method - Pressure in [bar(g)] NEN-EN 12516-1:2014+A1:2018 - Tabulation method - Pressure in [bar(g)]
Material information Temperature (°C) Material information Temperature (°C)
PN PN
EN/DIN Grade Type Design Group -10 20 50 100 150 200 250 300 350 375 380 400 420 425 EN/DIN Grade Type Design Group -10 20 50 100 150 200 250 300 350 375 380 400 420 425
P250GH (1) Forging 1.0460 3E0 2,5 2,5 2,5 2,3 2,2 2,1 1,9 1,7 1,6 1,6 1,5 1,5 1,4 1,3 P250GH (1)
Forging 1.0460 3E0 63,0 63,0 63,0 59,0 55,9 52,9 48,4 43,8 40,8 39,3 39,0 37,8 34,6 32,7
16Mo3 Forging 1.5415 4E0 2,5 2,5 2,5 2,5 2,4 2,3 2,1 2,0 1,9 1,8 1,8 1,8 1,7 1,7 16Mo3 Forging 1.5415 4E0 63,0 63,0 63,0 63,0 61,6 57,5 53,7 49,9 46,9 46,1 46,0 45,4 44,1 43,7
13CrMo4-5 Forging 1.7335 5E0 2,5 2,5 2,5 2,5 2,5 2,5 2,5 2,5 2,3 2,2 2,2 2,1 2,0 2,0 13CrMo4-5 Forging 1.7335 5E0 63,0 63,0 63,0 63,0 63,0 63,0 63,0 63,0 58,7 56,5 56,0 53,8 51,8 51,4
2,5 63
X10CrMoVNb9-1 Forging 1.4903 9E1 2,5 2,5 2,5 2,5 2,5 2,5 2,5 2,5 2,3 2,3 2,2 2,1 2,1 2,0 X10CrMoVNb9-1 Forging 1.4903 9E1 63,0 63,0 63,0 63,0 63,0 63,0 63,0 63,0 59,1 57,0 56,4 53,8 51,9 51,4
X2CrNiMo17-12-2 Casting 1.4404 13E0 2,5 2,5 2,5 2,5 2,2 2,0 1,8 1,6 1,5 1,5 1,5 1,5 1,4 1,4 X2CrNiMo17-12-2 Casting 1.4404 13E0 63,0 63,0 63,0 61,7 56,4 51,2 45,9 40,6 38,8 37,9 37,7 37,0 36,4 36,2
(1)
P250GH Forging 1.0460 3E0 6,0 6,0 6,0 5,6 5,3 5,0 4,6 4,1 3,9 3,7 3,7 3,6 3,3 3,1 P250GH (1) Forging 1.0460 3E0 100,0 100,0 100,0 93,6 88,8 84,0 76,8 69,6 64,8 62,4 61,9 60,0 54,9 51,9
6 100
X10CrMoVNb 9-1 Forging 1.4903 9E1 6,0 6,0 6,0 6,0 6,0 6,0 6,0 6,0 5,6 5,4 5,3 5,1 4,9 4,9 X10CrMoVNb 9-1 Forging 1.4903 9E1 100,0 100,0 100,0 100,0 100,0 100,0 100,0 100,0 93,8 90,5 89,5 85,3 82,4 81,6
P250GH (1) Forging 1.0460 3E0 10,0 10,0 10,0 9,4 8,9 8,4 7,7 7,0 6,5 6,2 6,2 6,0 5,5 5,2 P250GH (1) Forging 1.0460 3E0 160,0 160,0 160,0 149,8 142,1 134,5 122,9 111,4 103,7 99,9 99,1 96,0 87,9 83,1
10 160
(1) (1)
P250GH Forging 1.0460 3E0 16,0 16,0 16,0 15,0 14,2 13,4 12,3 11,1 10,4 10,0 9,9 9,6 8,8 8,3 P250GH Forging 1.0460 3E0 250,0 250,0 250,0 234,1 222,1 210,1 192,1 174,1 162,0 156,0 154,8 150,0 137,4 129,8
16 250
25 320
40 400
(2) (2)
Linearly Interpolated Linearly Interpolated
(1) (1)
The material group for P 250 GH is in accordance with EN 16668 Table F.3 The material group for P 250 GH is in accordance with EN 16668 Table F.3
(2) (2)
Intermediate pressure ratings and allowable working pressures may be linearly interpolated in accordance with EN 12516-1 pg. 7. Intermediate pressure ratings and allowable working pressures may be linearly interpolated in accordance with EN 12516-1 pg. 7.

NEN-EN 12516-1:2014+A1:2018 NEN-EN 12516-1:2014+A1:2018
NEN-EN 12516-1:2014+A1:2018 - Tabulation method - Pressure in [bar(g)] NEN-EN 12516-1:2014+A1:2018 - Tabulation method - Pressure in [bar(g)]
Material information Temperature (°C) Material information Temperature (°C)
PN PN
EN/DIN Grade Type Design Group 450 470 475 480 500 510 520 525 530 540 550 575 580 600 EN/DIN Grade Type Design Group 450 470 475 480 500 510 520 525 530 540 550 575 580 600
P250GH (1) Forging 1.0460 3E0 0,9 0,7 0,6 0,6 P250GH (1) Forging 1.0460 3E0 23,2 16,8 15,5 14,1
16Mo3 Forging 1.5415 4E0 1,7 1,6 1,6 1,6 1,1 1,0 0,8 0,7 0,6 16Mo3 Forging 1.5415 4E0 42,0 41,4 41,3 41,1 28,6 24,9 19,8 17,8 15,8
13CrMo4-5 Forging 1.7335 5E0 2,0 1,9 1,8 1,8 1,6 1,4 1,2 1,1 1,0 0,9 0,7 13CrMo4-5 Forging 1.7335 5E0 49,7 47,2 46,5 45,5 39,3 35,1 31,0 28,9 26,7 21,9 16,5
2,5 63
X2CrNiMo17-12-2 Casting 1.4404 13E0 1,4 1,4 1,4 1,4 1,4 1,4 1,3 1,3 1,3 1,4 1,3 X2CrNiMo17-12-2 Casting 1.4404 13E0 35,3 35,0 34,9 34,9 34,6 34,5 33,3 32,8 33,1 34,9 32,6
P250GH (1) Forging 1.0460 3E0 2,2 1,6 1,5 1,3 P250GH (1) Forging 1.0460 3E0 36,8 26,7 24,5 22,4
6 100
X2CrNiMo17-12-2 Casting 1.4404 13E0 3,3 3,3 3,3 3,3 3,3 3,3 3,2 3,1 3,1 3,3 3,1 X2CrNiMo17-12-2 Casting 1.4404 13E0 56,0 55,5 55,4 55,3 54,9 54,8 52,9 52,0 52,4 55,3 51,7
(1)
P250GH Forging 1.0460 3E0 3,7 2,7 2,5 2,2 P250GH (1) Forging 1.0460 3E0 58,9 42,7 39,3 35,9
10 160
X2CrNiMo17-12-2 Casting 1.4404 13E0 5,6 5,6 5,5 5,5 5,5 5,5 5,3 5,2 5,2 5,5 5,2
P250GH (1) Forging 1.0460 3E0 5,9 4,3 3,9 3,6
P250GH (1) Forging 1.0460 3E0 92,0 66,7 61,4 56,0
16Mo3 Forging 1.5415 4E0 10,7 10,5 10,5 10,4 7,3 6,3 5,0 4,5 4,0
16Mo3 Forging 1.5415 4E0 166,8 164,4 163,8 163,2 113,4 98,7 78,7 70,7 62,7
13CrMo4-5 Forging 1.7335 5E0 12,6 12,0 11,8 11,6 10,0 8,9 7,8 7,3 6,7 5,5 4,2
16 13CrMo4-5 Forging 1.7335 5E0 197,2 187,2 184,7 180,7 156,0 139,5 123,2 114,7 105,7 86,8 65,4
11CrMo9-10 Forging 1.7383 6E0 12,6 18,7 18,5 18,1 16,5 15,9 14,4 13,5 12,6 10,5 8,8 6,8 6,3 3,7 250
11CrMo9-10 Forging 1.7383 6E0 197,2 187,2 184,7 180,7 164,5 158,9 143,7 134,7 125,4 105,1 88,0 68,0 62,7 37,3
X10CrMoVNb 9-1 Forging 1.4903 9E1 12,6 12,0 11,8 11,6 10,5 10,2 9,8 9,6 9,5 9,4 9,3 8,9 8,8 8,0
(1)
P250GH Forging 1.0460 3E0 9,2 6,7 6,1 5,6
P250GH (1) Forging 1.0460 3E0 117,8 85,4 78,5 71,7
16Mo3 Forging 1.5415 4E0 16,7 16,4 16,4 16,3 11,3 9,9 7,9 7,1 6,3
16Mo3 Forging 1.5415 4E0 213,6 210,5 209,8 209,0 145,1 126,4 100,7 90,5 80,2
13CrMo4-5 Forging 1.7335 5E0 19,7 18,7 18,5 18,1 15,6 13,9 12,3 11,5 10,6 8,7 6,5
25 13CrMo4-5 Forging 1.7335 5E0 252,5 239,7 236,5 231,3 199,8 178,6 157,7 146,8 135,3 111,0 83,7
11CrMo9-10 Forging 1.7383 6E0 19,7 29,9 29,5 28,9 26,3 25,4 22,9 21,5 20,0 16,8 14,1 10,9 10,1 6,0 320
11CrMo9-10 Forging 1.7383 6E0 252,5 239,7 236,5 231,3 210,7 203,4 184,0 172,5 160,7 134,7 112,7 87,1 80,3 47,8
X10CrMoVNb9-1 Forging 1.4903 9E1 19,7 18,7 18,5 18,1 16,5 15,9 15,3 15,0 14,8 14,7 14,6 14,0 13,8 12,5
X10CrMoVNb9-1 Forging 1.4903 9E1 252,5 239,7 236,5 231,3 210,7 203,4 195,8 192,6 190,4 188,3 186,4 178,8 175,9 160,1
P250GH (1) Forging 1.0460 3E0 14,7 10,7 9,8 9,0
P250GH (1) Forging 1.0460 3E0 147,3 106,7 98,2 89,6
16Mo3 Forging 1.5415 4E0 26,7 26,3 26,2 26,1 18,1 15,8 12,6 11,3 10,0
16Mo3 Forging 1.5415 4E0 267,0 263,1 262,2 261,2 181,4 157,9 125,9 113,1 100,3
13CrMo4-5 Forging 1.7335 5E0 31,5 29,9 29,5 28,9 25,0 22,3 19,7 18,3 16,9 13,9 10,5
40 13CrMo4-5 Forging 1.7335 5E0 315,6 299,5 295,5 289,1 249,7 223,2 197,2 183,5 169,1 138,8 104,6
11CrMo9-10 Forging 1.7383 6E0 31,5 29,9 29,5 28,9 26,3 25,4 22,9 21,5 20,0 16,8 14,1 10,9 10,1 6,0 400
11CrMo9-10 Forging 1.7383 6E0 315,6 299,5 295,5 289,1 263,3 254,3 229,9 215,5 200,7 168,3 140,9 108,8 100,4 59,8
(2)
Linearly Interpolated (2)
(1)
Linearly Interpolated
The material group for P 250 GH is in accordance with EN 16668 Table F.3 (1)
(2) The material group for P 250 GH is in accordance with EN 16668 Table F.3
Intermediate pressure ratings and allowable working pressures may be linearly interpolated in accordance with EN 12516-1 pg. 7. (2)
Intermediate pressure ratings and allowable working pressures may be linearly interpolated in accordance with EN 12516-1 pg. 7.

HP Valves BV
Medium & high pressure valves

in accordance with ASME, EN, BS and API
Disassembly & Reassembly Instructions

Small Bore Valves – High Pressure
Rev.08
© 2019. This manual, its content and the copyright therein are the property of HP Valves BV. This manual is
supplied in confidence and shall not be used for any purpose other than which it is supplied for and may not be
reproduced in part or whole or passed on to others, without permission in writing from HP Valves.
Disassembly & Reassembly Instructions SBV-HP - Page 1

HP Valves BV

DISASSEMBLY & ASSEMBLY SWING CHECK VALVE ............................................................................... 36

INDEX PRESSURE SEAL ≤ 2” / ≤ 50mm, Fig.04.6.9 ................ 36
DISASSEMBLY & ASSEMBLY GLOBE VALVE .............................................................................................. 3
3” ~ 4” 1500 ~ 2500 LBS / 80mm ~ 100mm PN250 ~ PN 400, Fig.00.6.0 ................ 37
WITH FLOATING BACKSEAT ≤ 2” / ≤ 50mm, Fig. 01.1.0_HOV ......... 4
DISASSEMBLY & ASSEMBLY GATE VALVE.............................................................................................. 38
WITH FIXED BACKSEAT ≤ 2” / ≤ 50mm, Fig. 01.2.0_HOV ......... 5
WITH FLOATING BACKSEAT (½” ~ 1”) / (15mm ~ 25mm) , Fig. 06.6.0_MOV..... 38
WITH BAYONET YOKE AND FLOATING BACKSEAT ≤ 2” / ≤ 50mm, Fig. 01.T_HOV ............ 6
WITH BAYONET YOKE AND FLOATING BACKSEAT (½” ~ 1”) / (15mm ~ 25mm), Fig. 06.T ................. 39
LIGHT WITH FLOATING BACKSEAT ≤ 2” / ≤ 50mm, Fig. 01.5.0_HOV ......... 7
WITH BAYONET YOKE, FLOATING BACKSEAT AND E-ACT (½” ~ 1”) / (15mm ~ 25mm), Fig. 06.T.E .............. 40
WITH FLOATING BACKSEAT 3” / 80mm, Fig. 02.2.0_GOV ......... 8
WITH BAYONET YOKE, FLOATING BACKSEAT AND P-ACT (½” ~ 1”) / (15mm ~ 25mm), Fig. 06.T.P .............. 41
WITH FIXED BACKSEAT 3” / 80mm, Fig. 02.2.0_GOV ....... 10
WITH FLOATING BACKSEAT (1¼” ~ 2”) / (32mm ~ 50mm), Fig. 06.6.0_HOV ..... 42
WITH INTEGRAL BACKSEAT 4” / 100mm, Fig. 02.2.0_HOV ....... 13
PARALLEL SLIDE 2½” ~ 4” 1500-2500LBS / 65mm ~ 100mm ~ PN250-PN400, Fig. 06.6.9_HOV/MOV ... 43
DISASSEMBLY & ASSEMBLY THROTTLE GLOBE VALVE .......................................................................... 16
LIGHT WITH FLOATING BACKSEAT ≤2” / ≤ 50mm, Fig 06.5.0_HOV ..... 45
WITH FLOATING BACKSEAT ≤ 2” / ≤ 50mm, Fig. 02.1.0_HOV ...... 16
WITH FLOATING BACKSEAT AND ELECTRIC ACTUATOR (½” ~ 1”) / (15mm ~ 25mm), Fig. 06.6.2_MOV ... 46
WITH FIXED BACKSEAT ≤ 2” / ≤ 50mm, Fig. 02.2.1_HOV ...... 17
WITH FLOATING BACKSEAT AND ELECTRIC ACTUATOR (1¼” ~ 2”) / (32mm ~ 50mm) , Fig. 06.6.2_MOV ... 47
WITH BAYONET YOKE AND FLOATING BACKSEAT ≤ 2” / ≤ 50mm, Fig. 02.2(T)_HOV ..... 18
WITH FLOATING BACKSEAT AND PNEUMATIC ACTUATOR (1¼” ~ 2”) / (32mm ~ 50mm) , Fig. 06.6.9_POV .... 48
WITH FLOATING BACKSEAT AND ELECTRIC ACTUATOR ≤ 2” / ≤ 50mm, Fig. 02.2.0_MOV ...... 19
DISASSEMBLY & ASSEMBLY CONTINUOUS BLOW DOWN VALVE ......................................................... 49
WITH FIXED BACKSEAT AND ELECTRIC ACTUATOR ≤ 2” / ≤ 50mm, Fig. 02.2.1_MOV ...... 20
WITH FLOATING BACKSEAT ≤2½” / ≤65mm, Fig. 09.3.0_HOV ... 49
WITH BAYONET YOKE AND FLOATING BACKSEAT ≤ 2” / ≤ 50mm, Fig. 02.2(T)_MOV .... 22
WITH FIXED BACKSEAT ≤2½” / ≤65mm, Fig. 09.3.1_HOV ... 50
WITH FLOATING BACKSEAT AND PNEUMATIC ACTUATOR ≤ 2” / ≤ 50mm, Fig. 02.2.0_POV ....... 23
WITH FLOATING BACKSEAT AND ELECTRIC ACTUATOR ≤2½” / ≤65mm, Fig. 09.3.2_MOV . 51
WITH FLOATING BACKSEAT, BAYONET YOKE AND PNEUMATIC ACTUATOR ≤ 2” / ≤ 50mm, Fig. 02.2(T)_POV..... 24
DISASSEMBLY & ASSEMBLY Y-TYPE STRAINER ...................................................................................... 52
DISASSEMBLY & ASSEMBLY GLOBE VALVE ............................................................................................ 25
⅜” ~ 2” / 10mm ~ 50mm, Fig. 08.2.0 ........... 52
WITH PLEUMATIC ACTUATOR 4” / 100mm, Fig. 02.2.9_POV ...... 25
BAYONET CAP (⅜” ~ 2”) / (10mm ~ 50mm) , Fig. 08.Y .............. 53
DISASSEMBLY & ASSEMBLY STOP/CHECK GLOBE VALVE ...................................................................... 28
2½” ~ 4” / 65mm ~ 100mm – LOOSE STRAINER <200bar, Fig. 08.2.0 ........... 54
WITH FLOATING BACKSEAT ≤ 2” / ≤ 50mm, Fig. 03.1.0_HOV...... 28
2½” ~ 4” / 65mm ~ 100mm – FIXED STRAINER >200bar, Fig. 08.2.9 ............ 55
WITH FIXED BACKSEAT ≤ 2” / ≤ 50mm, Fig. 03.2.1_HOV...... 29
STRAINER DRAIN CONNECTION........................................................................................................................... 556
DISASSEMBLY & ASSEMBLY PISTON CHECK VALVE .............................................................................. 30
DISASSEMBLY & ASSEMBLY NEEDLE VALVE ........................................................................................ 567
PRESSURE SEAL ≤2½” / ≤ 65mm, Fig. 04.1.0............... 30
WITH FLOATING BACKSEAT ½” ~ 1” / 15mm ~ 25mm, Fig. 07.1............ 577
PRESSURE SEAL ≤2½” / ≤ 65mm, Fig. 04.T................ 31
USE OF BACKSEAT REMOVAL TOOL ...................................................................................................... 58
PRESSURE SEAL 3” 1500LBS / 80mm PN250, Fig. 04.2.0 ............... 32
RESEATING HP VALVES ......................................................................................................................... 59
PRESSURE SEAL 4” 1500 ~ 2500LBS / 100mm PN250 ~ PN400, Fig. 04.2.0 ............... 33
GLOBE VALVES ≤4” / ≤ 100mm.............................................................................................................................. 59
DISASSEMBLY & ASSEMBLY BALL TYPE CHECK VALVE........................................................................... 34
RESEATING HP VALVES ......................................................................................................................... 60
PRESSURE SEAL ≤2” / ≤ 50mm, Fig. 05.1.0 ............... 34
GLOBE VALVES WITH A BAYONET YOKE ≤4” / ≤ 100mm ....................................................................................... 60
PRESSURE SEAL AND BAYONET CAP ≤ 2” / ≤ 50mm, Fig. 05.T ................... 35

HP Valves BV

RECOMMENDED TORQUE VALUES Gland bolting torque Nm (red = Gate / blue = Globe)
Assembly hardware torque Nm Class 150 300 600 800 900 1500 2500
Maximum tightening torque Ma / Nm Thread size
Thread - - - - 25 40 40
Strength class according to ISO898/1 ½” ~ DN15
size - - - - 25 40 40
8.8 10.9 12.9 Remark - - - 30 40 40 50
¾” ~ DN20
M6 10 14 17 - - - 30 40 40 50
M8 25 35 42 - - - 30 40 40 50
1” ~ DN25
M10 50 70 85 - - 30 40 40 50
- - - 50 125 125 170
M12 87 122 147 1½” ~ DN32
Bolts clean and - - - 50 125 125 170
M16 210 299 357 - - - 50 170 200 200
lubricated 2” ~ DN50
M20 411 578 696 - - - 50 170 200 200
M30 1422 2010 2403 3½ 3½ 4 - 29 48 81
2½” ~ DN65
M36 2481 3491 4197 3½ 3½ 4 - 30 51 85
Way of tightening bolting
3½ 3½ 4 7 25 42 55
3” ~ DN80
3½ 3½ 6 7 30 51 157
3½ 3½ 6 8 20 33 97
4” ~ DN100
Bonnet bolting torque Nm 5 5 6 10 57 94 241
Thread size B7 / B16 630 / A574 B8 / B8M 660 5 5 8½ 10 58 96 157
6” ~ DN150
M8 ~ 5/16UNC 15 15 7 16 5 6 10 15½ 146 244 448
M10 ~ 3/8UNC 27 27 12 27 5 5 8½ 11½ 57 94 193
8” ~ DN200
M12 ~ 1/2UNC 68 68 27 61 5 8½ 13 15½ 161 269 858
M14 ~ 9/16UNC 95 95 39 84 5 7½ 10 13½ 69 144 339
10” ~ DN250
M16 ~ 5/8UNC 129 129 54 115 7½ 9½ 13 20½ - 411 662
M18 284 284 72 203 7½ 7½ 13½ 17½ 146 244 448
12” ~ DN300
M20 ~ 3/4UNC 400 400 95 270 7½ 9½ 13½ - - 397 1463
550 550 153 370 7½ 7½ 15 20 146 269 497
M22 ~ 7/8UNC 14” ~ DN350
7½ 11 22½ - - 676 1231
M24 ~ 1UNC 690 690 227 460
7½ 7½ 15 - 161 298 858
M27 ~ 1.1/8UNC 1030 1030 333 690 16” ~ DN400
8 13 25½ - 374 - 1147
M33 ~ 1.1/4UNC 1890 1890 468 1270
7½ 9½ 15 - 179 514 948
M36 ~ 1.3/8UNC 2400 2400 633 1620 18” ~ DN450
11 18½ 28½ - - - -
M39 ~ 1.1/2UNC 3100 3100 834 2100
9½ 9½ 17 - 309 568 1354
M42 ~ 1.3/4UNC 3900 3900 1355 2610 20” ~ DN500
- - - - 406 - -
M45 ~ 2UNC 4450 4450 2054 3270 11 12½ 19½ - 341 812 1463
24” ~ DN600
- - - - - - -

HP Valves BV

DISASSEMBLY & ASSEMBLY GLOBE VALVE, Fig. 01.1.0_HOV
1. Caution, before any attempt is made to disassemble, verify that the valve is sufficiently cooled down,
WITH FLOATING BACKSEAT ≤ 2” / ≤ 50mm
depressurised, isolated from system pressure and secured against accidental pressurisation.
2. Unscrew the nuts (09) from the gland bolts (06) and remove the gland bolts from the gland flange (07).
3. Operate the valve to the open position.
4. Loosen the yoke (12) by rotating it in a counter clockwise direction and unscrew it partly from the body
(01) :
 7 revolutions for 3/8” - 1/2” valves / (10mm - 15mm)
 10 revolutions for 3/4” - 1” valves / (20mm - 25mm)
 17 revolutions for 1 1/4” - 2” valves / (32mm - 50mm)
5. Rotate the handwheel (14) counter clockwise, past the fully open position to force the packing (05) and
the floating backseat (04) out of the stuffing box.
6. Unscrew the yoke (12) and pull it together with the remaining parts out of the valve body (01).
7. Remove the handwheel nut (21) and rotate the handwheel (14) clockwise to unscrew the stem (10) from
the yoke sleeve (50) until the handwheel disengages from the stem (10).
8. Continue unscrewing the stem (10) from the yoke (12) by hand gripping it below the yoke (12).
9. Remove the gland flange (07), the gland (08), the packing (05) and the floating backseat (04) from the
stem (10) by pressing down on the floating backseat (04) whilst holding the stem (10) upside down.
INSPECTION PRIOR TO RE-ASSEMBLY
1. Thoroughly clean all parts with solvent and a clean cloth.

2. Examine the following parts for signs of damage, i.e. pitting, erosion or scratches:
A. SEAT (02) - Sealing surface

B. STEM (10) - Packing area
C. DISC (03) - Sealing surface
IN CASE SEVERE DAMAGE IS OBSERVED, USE
D. BACKSEAT (10 & 04) - Sealing surface
REPLACEMENT PARTS INSTEAD!
3. Lubricate all threaded parts with high temperature grease, i.e. Molykote HSC.
4. Insert the stem (10) in the designated slot located in the disc (03)
5. Insert the stem/disc assembly into the valve body (01).
6. Insert the floating backseat (04) (with radius down) into the valve body (01).
7. Insert the packing (05) (markings facing down) into the valve body (01).
8. Place the gland (08) over the stem (10).
9. Put the yoke (12) together with the gland flange (07) over the stem (10).
10. Screw the yoke (12) clockwise on to the valve body (01), while rotating the stem (10) counter clockwise.
11. Fixate the gland flange (07) with the gland bolts (06) and gland nuts (09).
12. Fixate the handwheel (14) and nameplate (44) to the stem (10) with the nut (21) and washer (28).
13. Tighten the gland bolting (06/09) to compress the packing.
14. Loosen the gland nuts (09). Then carefully retighten the gland nuts (09) again.
15. Pressurise the system and check the packing (05) for signs of leakage.
16. In case leakage is observed, tighten the gland nuts (09) carefully until the leaking stops.
17. The valve is now ready for use.

HP Valves BV

DISASSEMBLY & ASSEMBLY GLOBE VALVE, Fig. 01.2.1_HOV
WITH FIXED BACKSEAT ≤ 2” / ≤ 50mm 1. Caution, before any attempt is made to disassemble, verify that the valve is sufficiently cooled down,
depressurised, isolated from system pressure and secured against accidental pressurization
2. Unscrew the nuts (09) from the gland bolts (06) and remove them from the gland flange (07).
3. Remove the handwheel nut (21) which secures the spring washer (28) and nameplate (44).
4. Loosen the yoke (12) by rotating it counter clockwise.
5. Unscrew the yoke (12) from the valve body (01) while rotating the handwheel (14) clockwise to unscrew
the stem (04) from the yoke sleeve (50) until the handwheel (14) disengages from the stem (04).
6. Remove the yoke (12) together with the gland flange (07) and gland (08) from the valve body (01).
7. Remove the packing (05) from the valve body (01).
8. Install the backseat removal tool on to the valve body (01) by screwing the adaptor to the threaded part
of the valve body (01).
9. Loosen the backseat (34) by rotating the backseat removal tool in counter clockwise direction.
10. Unscrew the backseat removal tool from the valve body (01) and remove it together with the backseat
(34), gasket (33), stem (04) and disc (03).


4. Insert the stem (04) in the designated slot located in the disc (03).
6. Insert the gasket (33) and the backseat (34) into the valve body (01).
7. Install the backseat removal tool on to the valve body (01) by screwing the adaptor to the threaded part
of the valve body (01).
8. Screw the backseat (34) into the valve body (01) and fasten it by rotating it clockwise.
9. Insert the packing (05) with markings facing down into the valve body (01).
11. Put the yoke (12) together with the gland flange (07) over the stem (04) and fixate the gland flange (07)
with the gland bolts (06).
12. Fixate the handwheel (14) and nameplate (44) to the stem (04) with the handwheel nut (21) and washer
(28).
13. Tighten the gland nuts (09) to compress the packing (05).
14. Loosen the gland nuts (09) slightly. Now carefully retighten the gland nuts (09) again.
15. Pressurise the system and check the packing (05) for leakage.
16. In case of leakage tighten the gland nuts (09 carefully until the leakage stops.

HP Valves BV

DISASSEMBLY & ASSEMBLY GLOBE VALVE, Fig. 01.1(T)_HOV 1. Caution, before any attempt is made to disassemble, verify that the valve is sufficiently cooled down,
2. Unscrew the gland bolting (09) and remove the gland bolting (09) together with the cross key (35) from
WITH BAYONET YOKE AND FLOATING BACKSEAT ≤ 2” / ≤ 50mm
the gland flange (07).
3. Operate the valve to approximately ¾ of the open position.
4. Loosen the yoke (12) by rotating it 90° in a counter clockwise direction to disconnect it from the body
(01).
5. Rotate the handwheel (14) counter clockwise, past the fully open position to force the packing (05) and
the floating backseat (04) out of the stuffing box.
6. Pull the yoke (12) together with the remaining parts out of the valve body (01).
7. Remove the handwheel nut (21), washer (28), name plate (44) and rotate the handwheel (14) clockwise
to unscrew the stem (10) from the yoke sleeve (13) until the handwheel disengages from the stem (10).
9. Remove the gland flange (07), the gland (08), the packing (05) and the floating backseat (04) from the
stem (10) by pressing down on the floating backseat (04) whilst holding the stem (10) upside down.
10. Remove the yoke cap (22) from the yoke (12) by unscrewing the yoke cap bolting (46).
11. Take out the yoke sleeve (13) from the yoke (12).


4. Insert the stem (10) in the designated slot located in the disc (03)
6. Insert the floating backseat (04) into the valve body (01).
7. Insert the NEW packing (05) (markings facing down) into the valve body (01).
10. Reconnect the yoke (12) by rotating it 90° clockwise on to the valve body (01).
11. Fixate the yoke (12) by installing the cross key (35) and insert the gland bolting (09) through the gland
flange (07), cross key (35) and valve body (01) whilst tightening it only hand tight.
12. Install the yoke sleeve (13) by rotating it counter clockwise on the stem (10).
13. Install the yoke cap (22) and tighten it with the yoke cap bolt (46).
15. Tighten the gland bolting (09) to compress the packing (05).

HP Valves BV

DISASSEMBLY & ASSEMBLY GLOBE VALVE, Fig. 01.5.0_HOV 1. Caution, before any attempt is made to disassemble, verify that the valve is sufficiently cooled down,
LIGHT WITH FLOATING BACKSEAT ≤ 2” / ≤ 50mm
4. Remove the handwheel (14) from the stem (10) by loosening the handwheel nut (21).
5. Loosen the yoke sleeve (13) by rotating it in a counter clockwise direction and unscrew it from the body
(01).
6. Remove the yoke sleeve (13) together with the stem protector (45), the spring washer (46) and the
gland flange (07A/07B).
7. Pull the stem/disc assembly from the valve body (01).
8. Remove the disc (03), gland (08), packing (05) and the floating backseat (04) from the stem (10) by
pressing down on the floating backseat (04) whilst holding the stem (10) upside down.

D. BACKSEAT (04) - Sealing surface
IN CASE SEVERE DAMAGE IS OBSERVED,
USE REPLACEMENT PARTS INSTEAD!
4. Place the floating backseat (04) (with radius down) over the stem (10).
5. Place the packing (05) on top of the floating backseat (04) (with markings down).
6. Place the gland (08) (with radius up) over the stem (10).
7. Place the disc (03) on the stem (10) and push the gland (08), packing (05) and floating backseat (04)
against the disc (03).
8. Insert the stem/disc assembly into the body/yoke (01).
9. Slide in the gland flange (07A) with radius down and groove up from the side between the yoke and add
the second gland part (07B) in the chamber.
10. Hand tighten the gland bolting (06 & 09) to secure the gland flange (07A / 07B).
11. Position the stem protection (45) on top of the gland flange (07A / 07B). Make sure the stem protection
is fitted properly in the groove on the gland flange.
12. Put the spring washer (46) over the stem (10) and screw the yoke sleeve (13) over the stem (10) and in
the body/yoke (01).
13. Make sure the valve is at least in half open position before screwing the yoke sleeve (13) in the yoke.
14. Tighten the yoke sleeve (13) applying the following torque values.
½” ~ 1”: 70Nm / (15mm - 25mm)
1½” ~ 2”: 120Nm / (40mm - 50mm)
15. Provide a notch between the yoke and yoke sleeve (13) to provide additional protection against
loosening, using a punch and hammer.
16. Fit the handwheel (14) and nameplate (44) to the stem with the nut and washer (21 & 28).
17. Close the valve rotating the handwheel (14) clockwise.
18. Tighten the nuts (09) of the gland bolts (06) to compress the packing (05).
19. Loosen the nuts (09) of the gland bolts (06).
20. Then carefully tighten the nuts (09) of the gland bolts (06) again.
22. In case of leaking, tighten the nuts (09) of the gland bolts (06) carefully until the leaking stops.

HP Valves BV

DISASSEMBLY & ASSEMBLY GLOBE VALVE, Fig. 02.2.0_GOV
WITH FLOATING BACKSEAT 3” / 80mm
FLOATING BACKSEAT 3”
FLOATING BACKSEAT 3” Fig.02
Fig.01

HP Valves BV

DISASSEMBLY & ASSEMBLY GLOBE VALVE, Fig. 02.2.0_GOV 1. Caution, before any attempt is made to disassemble, verify that the valve is sufficiently cooled down,
WITH FLOATING BACKSEAT 3” / 80mm 2. Unscrew the bolts (16) which secure the gearbox (17), rotate the gearbox clockwise to remove it from
the stem/disc (2).
3. Unscrew the gland nuts (7) from the gland bolts (9) and remove them from the gland flange (11)
4. Unscrew the hexagon socket screw (15) from the position indicator (13). Remove parallel key (12) out of
the stem/disc (2). Unscrew the hexagon socket screws (14) which secures the yoke (10) to the valve
body (1).
5. Rotate the yoke (10) 90˚ counter clockwise. Now remove the yoke (10) together with gland flange (11)
and position indicator (13) from the valve body (1).
6. Remove the gland (6), the packing (5) and loose backseat (4) out of the valve body (1) by pulling the
stem /disc (2) from the valve body (1).


4. Insert the stem/disc (2) together with loose backseat (4) into the valve body (1).
5. Insert the first packing (5) into the stuffing box (markings facing down). Insert the second packing (5)
into the stuffing box (markings facing up). Place the gland (6) over the stem (2) on top of the packing
(5).
6. Install the yoke (10) together with the gland flange (11) and position indicator (13), to the valve body
(1). Ensure the position indicator (13) gets locked up by the yoke (10), in order to prevent the stem/disc
(2) from rotating. Rotate the yoke (10) 90˚ and secure it with the hexagon socket screw (14) to the valve
body (1).
7. Place the parallel key (12) into the stem/disc (2), place the position indicator (13) over the parallel key
(12) and fixate it with the hexagon socket screw (15).
8. Install the bevel gear (17) by rotating it counter clockwise on the stem/disc (2) until the stem/disc (2) is
no longer in contact with the seat, the gearbox (17) can now be secured to the yoke (10) with the bolts
(16).
9. Fixate the gland flange (11) with the gland bolts (19), the spring washers (8) and the gland nuts (7).
11. Now loosen the gland nuts (7) slightly. Carefully retighten the gland nuts (7) again.
13. In case leakage is observed, tighten the gland nuts (7) carefully until the leakage stops.
FLOATING BACKSEAT 3”
Fig.03

HP Valves BV

WITH FIXED BACKSEAT 3” / 80mm
FIXED BACKSEAT 3”
FIXED BACKSEAT 3”
Fig.01
Fig.02

HP Valves BV

WITH FIXED BACKSEAT 3” / 80mm
FIXED BACKSEAT 3”
Fig.03
FIXED BACKSEAT 3”
Fig.04

HP Valves BV

DISASSEMBLY & ASSEMBLY GLOBE VALVE, Fig. 02.2.0_GOV INSPECTION PRIOR TO RE-ASSEMBLY
WITH FIXED BACKSEAT 3” / 80mm 2. Examine the following parts for signs of damage, i.e. pitting, erosion or scratches:

1. Caution, before any attempt is made to disassemble, verify that the valve is sufficiently cooled down, B. STEM/disc (2) - Packing area
depressurised, isolated from system pressure and secured against accidental pressurisation. C. DISC/disc (2) - Sealing surface
2. Unscrew the bolts (16) which secure the gearbox (17), rotate the gearbox clockwise to remove it from D. BACKSEAT (2 & 4) - Sealing surface
the stem/disc (2).
3. Unscrew the nuts (7) from the gland bolts (9) and remove the gland bolts. (see Fig.02)
4. Unscrew the gland nuts (7) from the gland bolts (9) and remove them from the gland flange (11)
5. Unscrew the hexagon socket screw (15) from the position indicator (13). Remove parallel key (12) out of
the stem/disc (2). Unscrew the hexagon socket screws (14) which secures the yoke (10) to the valve IN CASE SEVERE DAMAGE IS OBSERVED,
body (1). USE REPLACEMENT PARTS INSTEAD!
6. Rotate the yoke (10) 90˚ counter clockwise. Now remove the yoke (10) together with gland flange (11)
and position indicator (13) from the valve body (1).
7. Remove the gland (6) and packing (5) out of the valve body (1). Make sure to not damage the stuffing
box.
4. Insert the stem/disc (2) together with a replacement gasket (3) and the backseat (4) into the valve body
8. Place the backseat-removal tool on the valve body (1); Rotate the backseat removal tool adaptor (18)
(1).
90˚ clockwise to engage it to the valve body (1). Loosen the backseat (4) by rotating the backseat
5. Insert the backseat removal tool (18) in the valve body (1), screw the backseat (4) into the valve body
removal tool 1 turn counter clockwise. Now rotate the backseat removal tool adaptor (18) 90˚ counter
(1) rotating it clockwise. Now engage the backseat removal tool adaptor (18) by rotating it 90˚clockwise.
clockwise to disengage it from the valve body (1), the backseat (4) can now be screwed out of the valve
Fasten the backseat (4) by rotating it clockwise, be aware over tightening can cause problems for future
body (1). (see Fig.03)
disassembly.
9. Remove the backseat removal tool (18) from the valve body (1). Remove the stem/disc (2) together
6. Insert the first packing (5) into the stuffing box (markings facing down). Insert the second packing (5)
with the backseat (4) and gasket (3) by pulling the stem/disc (2) out of the valve body (1). (see Fig.04)
into the stuffing box (markings facing up). Place the gland (6) over the stem (2) on top of the packing
(5).
7. Install the yoke (10) together with the gland flange (11) and position indicator (13), to the valve body
(1). Ensure the position indicator (13) gets locked up by the yoke (10), in order to prevent the stem/disc
(2) from rotating. Rotate the yoke (10) 90˚ and secure it with the hexagon socket screw (14) to the valve
body (1).
8. Place the parallel key (12) into the stem/disc (2), place the position indicator (13) over the parallel key
(12) and fixate it with the hexagon socket screw (15).
9. Install the bevel gear (17) by rotating it counter clockwise on the stem/disc (2) until the stem/disc (2) is
no longer in contact with the seat, the gearbox (17) can now be secured to the yoke (10) with the bolts
(16).
10. Fixate the gland flange (11) with the gland bolts (19), the spring washers (8) and the gland nuts (7).
11. Tighten the gland nuts (7) to compress the packing (5). Now loosen the gland nuts (7) slightly. Carefully
retighten the gland nuts (7) again.
13. In case leakage is observed, tighten the gland nuts (7) carefully until the leakage stops.

HP Valves BV

WITH INTEGRAL BACKSEAT 4” / 100mm
INTEGRAL BACKSEAT 4”
Fig.01
Fig.02

HP Valves BV

DISASSEMBLY & ASSEMBLY GLOBE VALVE, Fig. 02.2.0_GOV 1. Caution, before any attempt is made to disassemble, verify that the valve is sufficiently cooled down,
WITH INTEGRAL BACKSEAT 4” / 100mm 2. Unscrew the bolts (20) which secure the gearbox (21) to the top flange and remove them. Rotate the gearbox
(21) clockwise to remove it from the stem/disc (2).
3. Unscrew and remove the bolt (18) which secures the position indicator (17) and remove the parallel key (16)
from the stem/disc (2).
4. Unscrew the gland nuts (11) from the gland bolts (13) and remove them together with the spring washers
(12). (see Fig.02)
5. Unscrew and remove the bolts (19) which secure the yoke (14) to the valve body (1). Rotate the yoke (14) 90˚
clockwise to disengage it from the valve body (1).
6. Remove the yoke (14) together with the position indicator (17), the gland flange (15) and gland (10) from the
valve body (1).
7. Unscrew the bolts (8) from the retaining ring (7) and remove them (see Fig.03).
8. Unscrew the retaining ring (7) from the bonnet (3), while securing the stem/disc (2) in place, in order to
prevent it from damaging. After the retaining ring (3) has been removed, lower the stem/disc (2), bonnet (3),
the packing (9), gasket (4) and ring (5) into the valve body (1).
9. Remove the segmental ring (6) from the valve body (1) by tapping a punch tool through the designated holes
(30) provided in the bonnet area of the valve body (01). Now the valve internals can be removed by pulling
the stem/disc (2) from the valve body (1).
Fig.03

HP Valves BV

DISASSEMBLY & ASSEMBLY GLOBE VALVE, Fig. 02.2.0_GOV 16. Pressurise the system and check the packing (9) and bonnet (3) for signs of leakage.
WITH INTEGRAL BACKSEAT 4” / 100mm

A. SEAT (1) - Sealing surface Important:

B. STEM/disc (2) - Packing area
C. DISC/disc (2) - Sealing surface After starting up the system, once the valve has reached its working temperature and pressure, It is
D. BACKSEAT (2 & 3) - Sealing surface recommended to tighten the bolts (8) into the retaining ring (7) to force the bonnet (3) into the gasket (4)
for optimum sealing.
17. In case of leakage of the packing (9), tighten the gland nuts (11) carefully until leakage stops.
18. In case of leaking of the bonnet (3) tighten the bolts (8) located in the retaining ring (7).
4. Apply a thin film of Molykote D321 R to the sealing surface of the gasket (4) and bonnet (3). Place gasket (4)
and gasket ring (5) over the bonnet (3), (see Fig.03) and place this assembly over the stem/disc (2).
5. Insert this completed assembly into the valve body (1).
6. Insert the segmental ring (6) into the valve body (1). Make sure the segments are located at such place, there
is a segment placed in front of each disassembly hole (30). Pull up the stem/disc (2) together with the bonnet
(3) through the segmental ring (6). Screw the retaining ring (7) to the bonnet (3) rotating it clockwise and
tighten it (hand tight).
7. Insert the bolts (8) in the retaining ring (7) and tighten them.
8. Place packing (9) (first with markings down, second with markings up) over the stem/disc (2) and into the
bonnet (3). Place the gland (10) over the stem/disc (2) on top of the packing (9).
9. Place the yoke (14) together with position indicator (17) and gland flange (15), over the stem/disc (2) and
engage the yoke (14) to the valve body. Make sure the position indicator (17) gets locked up by the yoke (14),
in order to prevent the stem/disc (2) from rotating.
10. Rotate the yoke (14) 90˚ clockwise and secure it with the hexagon socket screw (19) to the valve body (1).
11. Place the parallel key (16) into the stem/disc (2), place the position indicator (17) over the parallel key (16)
and secure it with the bolt (18).
12. Fixate the gland flange (15) with the gland bolts (13), spring washers (12) and gland nuts (11).
14. Loosen the gland nuts (11). Now carefully tighten the gland nuts (11) again.
15. Install the bevel gear (21) by rotating it counter clockwise on the stem/disc (2) until the stem/disc (2) is no
longer in contact with the seat, the gearbox (21) can now be secured to the yoke (14) with the bolts (20).

HP Valves BV

DISASSEMBLY & ASSEMBLY THROTTLE GLOBE VALVE, Fig. 02.1.0_HOV 1. Caution, before any attempt is made to disassemble, verify that the valve is sufficiently cooled down,
WITH FLOATING BACKSEAT ≤ 2” / ≤ 50mm 2. Unscrew the nuts (09) from the gland bolts (06) and remove the gland bolts from the gland flange (07).
4. Loosen the yoke (12) by rotating it in a counter clockwise direction and unscrew it partly from the body (01) :
5. Rotate the handwheel (14) counter clockwise, past the fully open position to force the packing (05) and the
floating backseat (04) out of the stuffing box.
7. Unscrew the nut (32) from the yoke sleeve (13) and remove the handwheel (14).
8. Unscrew the stem/disc (11) from the yoke sleeve (13) and remove the position indicator (15), the gland flange
(07) and parallel key (23).
9. Remove the gland flange (07), the packing (05) and the floating backseat (04) from the stem/disc (11) by
pressing down on the floating backseat (04) whilst holding the stem/disc (11) upside down.


C. DISC/disc (11) - Sealing surface
4. Insert the stem/disc (11) into the valve body (01).
6. Insert the packing (05) (with markings down) into the valve body (01).
7. Insert the parallel key (23) into the stem/disc (11) and grease it with high temperature grease, i.e. Molykote
HSC.
8. Place the yoke (12) together with the gland flange (07), position indicator (15) and yoke sleeve (13) (optional
with thrust bearing (26)) over the stem/disc (11) and screw the yoke (12) on the valve body (01) by rotating it
clockwise.
9. Align the gland flange (07) to the correct position whilst sliding the parallel key (23) in the designated slot
provided in the gland flange (07). Now fixate the gland flange (07) with the gland bolts (06).
10. Rotate the yoke sleeve (13) counter clockwise until it is in contact with the yoke (12).
11. Install the handwheel (14) to the yoke sleeve (13) and fixate it with the sleeve nut (32).
16. Adjust the position indicator (15) and fixate it with the hexagon socket screw.

HP Valves BV

DISASSEMBLY & ASSEMBLY THROTTLE GLOBE VALVE, Fig. 02.2.1_HOV 1. Caution, before any attempt is made to disassemble, verify that the valve is sufficiently cooled down,
WITH FIXED BACKSEAT ≤ 2” / ≤ 50mm
3. Remove the hexagon socket screw from the position indicator (15).
5. Unscrew the yoke (12) from the valve body (01) while rotating the handwheel (14) clockwise to unscrew the
stem/disc (11) from the yoke sleeve (13) until it disengages. Remove the yoke (12), position indicator (15) and
gland flange (07) from the valve body (01).
6. Remove the sleeve nit (32) which secures the handwheel (14) and remove the handwheel (14) and yoke
sleeve (13) from the yoke (12).
7. Remove the parallel key (23) from the stem/disc (11) and remove the packing (05) out of the valve body (01).
8. Install the backseat removal tool on to the valve body (01) by screwing the adaptor to the threaded part of
the valve body (01).
10. Unscrew the backseat removal tool from the valve body (01) and remove it together with the backseat (34),
gasket (33) and stem/disc (11).

3. Lubricate all threaded parts with high temperature grease, i.e. Molykote HSC. IN CASE SEVERE DAMAGE IS OBSERVED,
4. Insert the stem/disc (11) into the valve body (01). USE REPLACEMENT PARTS INSTEAD!
9. Place the parallel key (23) in the stem/disc (11) and lubricate it with high temperature grease, i.e. Molykote
HSC.
clockwise.
11. Align the gland flange (07) to the correct position whilst sliding the parallel key (23) in the designated slot,

HP Valves BV

DISASSEMBLY & ASSEMBLY THROTTLE GLOBE VALVE, Fig. 02.2(T)_HOV 1. Caution, before any attempt is made to disassemble, verify that the valve is sufficiently cooled down,
WITH BAYONET YOKE AND FLOATING BACKSEAT ≤ 2” / ≤ 50mm
2. Unscrew the gland bolting (09) and remove the gland bolting (09) together with the cross key (35) from the
gland flange (07).
4. Loosen the yoke (12) by rotating it 90° in a counter clockwise direction to disconnect it from the body (01).
7. Remove the handwheel nut (32), name plate (44) and remove the handwheel (14) from the yoke sleeve (13).
8. Loosen the bolting (46) and remove the yoke cap (22) from the yoke (12). Afterwards unscrew the yoke sleeve
(13) by rotating it clockwise from the stem/disc (11).
9. Remove the stem protector (15) from the yoke (12) and remove the position indicator (24) pressing it from
the stem/disc (11)
10. Now remove the stem/disc (11) from the yoke (12) by sliding it out of the gland flange (07) and gland (08).
11. Remove the packing (05) and the floating backseat (04) from the stem/disc (11) by pressing down on the
floating backseat (04) whilst holding the stem/disc (11) upside down.

3. Lubricate all threaded parts with high temperature grease, i.e. Molykote HSC. IN CASE SEVERE DAMAGE IS OBSERVED,
4. Insert the stem/disc (11) into the valve body (01). USE REPLACEMENT PARTS INSTEAD!
6. Insert the packing (05) (with markings down) into the valve body (01) and place the gland (08) on top of it.
7. Place the yoke (12) together with the gland flange (07) over the stem/disc (11) and install the yoke (12) on the
valve body (01) by rotating it 90° clockwise.
8. Insert the position indicator (24) into the stem/disc (11) and grease it with high temperature grease, i.e.
Molykote HSC.
9. Align the yoke (12) to the correct position whilst sliding the cross key (35) in the designated slot provided in
the valve body (01). Now secure the gland flange (07) and yoke (12) by fixating the gland bolts (06) hand tight.
10. Insert the stem protection (15) into the yoke (12) and align it with the position indicator (24).
11. Place the first bearing (26) on top of the stem protection (15) and install the yoke sleeve (13) on the stem/disc
(11) by rotating it counter clockwise.
12. Place the second bearing (26) on top of the yoke sleeve (13) and install the yoke cap (22) to the yoke (12) and
fixate it by screwing in the bolts (46).
13. Install the handwheel (14) to the yoke sleeve (13), place the nameplate (44) and fixate it with the sleeve nut
(32).

HP Valves BV

DISASSEMBLY & ASSEMBLY THROTTLE GLOBE VALVE, Fig. 02.2.0_MOV 1. Caution, before any attempt is made to disassemble, verify that the valve is sufficiently cooled down,
WITH FLOATING BACKSEAT AND ELECTRIC ACTUATOR ≤ 2” / ≤ 50mm
3. Remove the hexagon socket screw from the position indicator (15). Operate the valve to the open position,
using the actuator emergency handwheel rotating it counter clockwise. Now rotate it past the fully open
position to force the packing (05) and the floating backseat (04) out of the stuffing box.
4. Unscrew the bolting (47) to loosen the actuator from the yoke (12).
5. Rotate the actuator clockwise in order to unscrew it from the stem/disc (11).
6. Grind off the tack weld and unscrew the yoke (12) from the valve body (01) and remove the position indicator
(15), gland flange (07), gland (08) and parallel key (23) from the stem/disc (11).
7. Pull the stem/disc (11) together with the remaining parts out of the valve body (01).


D. BACKSEAT (04) - Sealing surface IN CASE SEVERE DAMAGE IS OBSERVED,
4. Insert the stem/disc (11) into to valve body (01).
5. Insert the floating backseat (04) (with radius down) and the packing (05) (with markings down) into the valve
body (01).
HSC.
7. Place the yoke (12) together with the gland flange (07) and position indicator (15) over the stem/disc (11) and
screw the yoke (12) on the valve body (01) by rotating it clockwise.
11. Mount the actuator on top of the connection flange (12) and tighten the bolts (47). Adjust the limit switches
of the actuator.
 3/8” - 1/2” valve 10mm travel / (10mm - 15mm)
 3/4” - 1” valve 16mm travel / (20mm - 25mm)
 1 1/2”- 2” valve 36mm travel / (40mm – 50mm)
12. Operate the actuator in manual mode, until the valve is in closed position and adjust the switch setting
according the actuator manufacturers manual. Now fixate the yoke (12) to the valve body (01) by means of a
tack weld.

HP Valves BV

DISASSEMBLY & ASSEMBLY THROTTLE GLOBE VALVE, Fig. 02.2.1_MOV 1. Caution, before any attempt is made to disassemble, verify that the valve is sufficiently cooled down,
WITH FIXED BACKSEAT AND ELECTRIC ACTUATOR ≤ 2” / ≤ 50mm
Actuator not drawn using the actuator emergency handwheel rotating it counter clockwise.
Connection flange
7. Remove the packing (05) out of the valve body (01).
11. Remove the packing (05) and the backseat (34) from the stem/disc (11) by pressing down on the backseat (34)
whilst holding the stem/disc (11) upside down.

HP Valves BV

DISASSEMBLY & ASSEMBLY THROTTLE GLOBE VALVE, Fig. 02.2.1_MOV
WITH FIXED BACKSEAT AND ELECTRIC ACTUATOR ≤ 2” / ≤ 50mm



HSC.
of the actuator.
 3/8” - 1/2” valve 10mm travel / (10mm - 15mm)
 3/4” - 1” valve 16mm travel / (20mm - 25mm)
 1 1/2”- 2” valve 36mm travel / (40mm - 50mm)
tack weld.

HP Valves BV

DISASSEMBLY & ASSEMBLY THROTTLE GLOBE VALVE, Fig. 02.2(T)_MOV 1. Caution, before any attempt is made to disassemble, verify that the valve is sufficiently cooled down,
WITH BAYONET YOKE AND FLOATING BACKSEAT ≤ 2” / ≤ 50mm 2. Unscrew the gland bolting (09) and remove the gland bolting (09) together with the cross key (35) from the gland
flange (07).
3. Operate the valve to the open position, using the actuator emergency handwheel rotating it counter clockwise.
Now rotate the handwheel (14) counter clockwise, past the fully open position to force the packing (05) and the
4. Unscrew the bolting connecting the actuator to the top flange (22) and remove the actuator from the stem/disc
(11) by rotating it clockwise until it is fully disengaged.
7. Loosen the bolting (46) and remove the top flange (22) from the yoke (12).
8. Remove the stem protector (15) from the yoke (12) and remove the position indicator (24) pressing it from the
stem/disc (11)
9. Now remove the stem/disc (11) from the yoke (12) by sliding it out of the gland flange (07) and gland (08).
10. Remove the packing (05) and the floating backseat (04) from the stem/disc (11) by pressing down on the floating
backseat (04) whilst holding the stem/disc (11) upside down.


6. Insert the packing (05) (with markings down) into the valve body (01) and place the gland (08) on top of it.
7. Place the yoke (12) together with the gland flange (07) over the stem/disc (11) and install the yoke (12) on the
valve body (01) by rotating it 90° clockwise.
8. Insert the position indicator (24) into the stem/disc (11) and grease it with high temperature grease, i.e.
Molykote HSC.
9. Align the yoke (12) to the correct position whilst sliding the cross key (35) in the designated slot provided in the
valve body (01). Now secure the gland flange (07) and yoke (12) by fixating the gland bolts (06) hand tight.
11. Install the yoke cap (22) to the yoke (12) and fixate it by screwing in the bolts (46).
12. Install the actuator by rotating it counter clockwise on the stem/disc (11) and fixate the actuator to the top
flange (22) with the provided bolting.

HP Valves BV

DISASSEMBLY & ASSEMBLY THROTTLE GLOBE VALVE, Fig. 02.2.0_POV 1. Caution, before any attempt is made to disassemble, verify that the valve is sufficiently cooled down,
WITH FLOATING BACKSEAT AND PNEUMATIC ACTUATOR ≤ 2” / ≤ 50mm
2. Switch the pneumatic actuator to the closed position. Unscrew bolts (18) out of the coupling (15/17) to
disconnect the upper coupling (17) from the lower coupling (15).
3. Switch the pneumatic actuator to the open position. Loosen the nut (57) of the upper coupling (17) and
unscrew the upper coupling (17) together with the position indicator (16) out of the pneumatic actuator (61).
4. Unscrew the nuts (56) from the spacer columns (14) and disconnect the air feed line together with the
electrical connections. Now remove the pneumatic actuator (61), spacer columns (14) and limit switches (63)
from the pneumatic mounting flange (12). Unscrew the gland nuts (09) from the stud bolts (06) and remove
them.
5. Pull the stem/disc (11) together with coupling (15), gland flange (07), gland (08), packing (05) and floating
backseat (04) out of the valve body (01).
6. Remove the coupling (15) and the gland flange (07) from the stem/disc (11).


D. BACKSEAT (04) - Sealing surface USE REPLACEMENT PARTS INSTEAD!
4. Insert the stem/disc (11) into the valve body (01). Insert the floating backseat (04)(with radius down) into the
valve body (01). Insert the packing (05) with markings down into the valve body (01).
5. Place the gland (08) together with the gland flange (07) over the stem/disc (11). Fixate the gland flange (07)
6. Tighten the gland bolting (06/09) to compress the packing (05).
8. Install the coupling (15) to the stem/disc (11). Lubricate stem radius with high temperature grease, i.e.
Molykote HSC. Install the upper coupling (17) and place the position indicator (16) on top of it. Secure this
assembly by screwing in the hexagon socket screws (18).
9. Place the actuator (61), spacer columns (14) and limit switches (63) on the actuator mounting flange (12).
Reconnect the air feed line and electrical connections and switch the pneumatic actuator to the open
position. Now secure the spacer columns (14) with the nuts (56) and washers (55).
10. Screw the upper coupling (17) into the pneumatic actuator until the stem contacts the loose backseat (04).
Unscrew the threaded end one revolution counter clockwise.
11. Switch pneumatic actuator to the closed position and fasten the upper coupling (17) with the nut (57).

HP Valves BV

DISASSEMBLY & ASSEMBLY THROTTLE GLOBE VALVE, Fig. 02.2.0(T)_POV 1. Caution, before any attempt is made to disassemble, verify that the valve is sufficiently cooled down,
WITH FLOATING BACKSEAT, BAYONET YOKE AND PNEUMATIC ACTUATOR ≤ 2” / ≤ 50mm 2. Switch the pneumatic actuator to the closed position. Unscrew bolts (18) out of the coupling (15/17) to
electrical connections. Now remove the pneumatic actuator (61), spacer columns (42) and limit switches from
the pneumatic mounting flange (12). Unscrew the gland nuts (09) from the stud bolts (06) and remove them.
5. Pull the stem/disc (11) together with coupling (15), gland flange (07), gland (08), packing (05) and floating
6. Remove the coupling (15) and the gland flange (07) from the stem/disc (11).


4. Insert the stem/disc (11) into the valve body (01). Insert the floating backseat (04) into the valve body (01).
Insert the packing (05) with markings down into the valve body (01).
5. Place the gland (08) together with the gland flange (07) over the stem/disc (11). Fixate the gland flange (07)
8. Install the coupling (15) to the stem/disc (11). Lubricate stem radius with high temperature grease, i.e.
Molykote HSC. Install the upper coupling (17) and place the position indicator (16) on top of it. Secure this
assembly by screwing in the hexagon socket screws (18).
9. Place the actuator (61), spacer columns (42) and limit switches on the actuator mounting flange (12).

HP Valves BV

DISASSEMBLY & ASSEMBLY GLOBE VALVE, Fig. 02.2.9_POV
WITH PLEUMATIC ACTUATOR 4” / 100mm
FIG.01 FIG.02

HP Valves BV

DISASSEMBLY & ASSEMBLY GLOBE VALVE, Fig. 02.2.9_POV 1. Caution, before any attempt is made to disassemble, verify that the valve is sufficiently cooled down,
WITH PLEUMATIC ACTUATOR 4” / 100mm 2. Switch the pneumatic actuator to the closed position. Unscrew bolts (49) (4pcs) out of the coupling (15/17) to
disconnect the upper coupling (17) from the lower coupling (15). (see Fig.02)
3. Switch the pneumatic actuator to the open position. Loosen the nut (57) of the threaded rod (14) and
unscrew the threaded rod (14) out of the pneumatic actuator (61).
4. Unscrew the nuts (48) (4pcs) which secure the pneumatic actuator (61) on the top flange (12).
5. Disconnect the air feed line from the filter/reducer (60) and disconnect the electrical connections. Now
remove the pneumatic actuator (61) together with the flange (59) from the valve top flange (12). (see Fig.02)
6. Unscrew the lower coupling (15) from the stem/disc (03) and remove it together with the spring washer (10).
7. Unscrew and remove the bolts (26) which secure the yoke (12) to the valve body (01). Rotate the yoke (12)
90˚ counter clockwise to disengage it from the valve body (01).
8. Unscrew the gland nuts (09) and remove them together with the stud bolts (06) and spring washers (27). (see
Fig.02)
10. Unscrew the bolts (29) (4pcs) from the retaining ring (18) and remove them.
11. Unscrew the retaining ring (18) from the bonnet (04); while securing the stem/disc (03) in place, in order to
prevent it from damaging. After the retaining ring (18) has been removed, lower the stem/disc (03),
bonnet (04), the packing (05), gasket (19) and ring (20) into the valve body (01).
12. Remove the segmental ring (21) from the valve body (01) by tapping a punch tool through the designated
disassembly holes provided in the bonnet area of the valve body (01). Now the valve internals can be removed
by pulling the stem/disc (03) from the valve body (01).
FIG.03

HP Valves BV

DISASSEMBLY & ASSEMBLY GLOBE VALVE, Fig. 02.2.9_POV 16. Switch the pneumatic actuator to the open position. Install the threaded rod (14) together with the coupling
(17), the position indicator (16), the nut (57) and the washer (58) to the pneumatic actuator. Fixate this
WITH PLEUMATIC ACTUATOR 4” / 100mm assembly by screwing in the hexagon socket screws (49).
17. Adjust the threaded rod (17) by screwing it into the pneumatic actuator (61) until the stem/disc (03) contacts
the backseat (04). Unscrew the threaded rod (14) one rotation counter clockwise and fixate it with the lock
nut (57).
18. Switch the pneumatic actuator to the closed position and carefully tighten the gland nuts (09) again.
2. Examine the following parts for signs of damage, i.e. pitting, erosion or scratches: 19. Pressurise the system and check the packing (05) and the bonnet (04) for signs of leakage.

Important:
After starting up the system, once the valve has reached its working temperature and pressure, It is
recommended to tighten the bolts (29) into the retaining ring (18) to force the bonnet (04) into the gasket
(19) for optimum sealing.
4. Apply a thin film of Molykote D321 R to the sealing surface of the gasket (19) and bonnet (04). Place the
gasket (19) and gasket ring (20) over the bonnet (04), (see Fig.03) and place this assembly over the stem/disc
20. In case of leakage of the packing (05), tighten the gland nuts (09) carefully until leakage stops.
(03).
21. In case of leaking of the bonnet (04) tighten the bolts (29) located in the retaining ring (18).
5. Insert this completed assembly into the valve body (01).
6. Insert the segmental ring (21) into the valve body (01). Make sure the segments are located at such place,
there is a segment placed in front of each disassembly hole. Pull up the stem/disc (03) together with the
bonnet (04) through the segmental ring (21). Screw the retaining ring (18) to the bonnet (04) rotating it
clockwise (hand tight).
7. Insert the bolts (29) in the retaining ring (18) and tighten them.
8. Insert the packing (05) (first with markings down, second with markings up) over the stem/disc (03) and into
the bonnet (04). Place the gland (08) over the stem/disc (03) on top of the packing (05).
9. Place the yoke (12) together with gland flange (07), over the stem/disc (03) and engage the yoke (12) to the
valve body (01).
10. Rotate the yoke (12) 90˚ clockwise and secure it with the hexagon socket screw (26) to the valve body (01).
11. Fixate the gland flange (15) with the gland bolts (06), spring washers (27) and gland nuts (09).
13. Loosen the gland nuts (09). Now carefully tighten the gland nuts (09) again.
14. Lubricate the stem/disc (03) with Molykote HCS or equivalent. Place the spring-washer (10) and screw the
lower coupling (15) to the stem/disc (03).
15. Install the pneumatic actuator (61) to the valve top flange (12) and secure it with the nuts (48). Now
reconnect the air feed line and reconnect al electrical connections.

HP Valves BV

DISASSEMBLY & ASSEMBLY STOP/CHECK GLOBE VALVE, Fig. 03.1.0_HOV 1. Caution, before any attempt is made to disassemble, verify that the valve is sufficiently cooled down,
WITH FLOATING BACKSEAT ≤ 2” / ≤ 50mm 2. Unscrew the nuts (09) from the gland bolts (06) and remove the gland bolts from the gland flange (07).
7. Remove the handwheel nut (21) and rotate the handwheel (14) clockwise to unscrew the stem (10) from the
yoke sleeve (50) until the handwheel disengages from the stem (10).
9. Remove the gland flange (07), the gland (08), the packing (05) and the floating backseat (04) from the stem
(10) by pressing down on the floating backseat (04) whilst holding the stem (10) upside down.


D. BACKSEAT (10 & 04) - Sealing surface IN CASE SEVERE DAMAGE IS OBSERVED,
4. Insert the disc (03) into the valve body (01) and guide it with the stem (10).
6. Insert the packing (05) markings facing down, into the valve body (01).

HP Valves BV

depressurised, isolated from system pressure and secured against accidental pressurisation
DISASSEMBLY & ASSEMBLY STOP/CHECK GLOBE VALVE, Fig. 03.2.1_HOV 2. Unscrew the nuts (09) from the gland bolts (06) and remove them from the gland flange (07).
3. Remove the handwheel nut (21) which secures the spring washer (28) and nameplate (44).
WITH FIXED BACKSEAT ≤ 2” / ≤ 50mm
stem (04) from the yoke sleeve (50) until the handwheel (14) disengages from the stem (04).
7. Remove the packing (05) from the valve body (01).
gasket (33), stem (04) and disc (03).
11. Remove the gland flange (07), the gland (08), the packing (05) and the backseat (34) from the stem (04) by
pressing down on the backseat (34) whilst holding the stem (04) upside down.


4. Insert the disc (03) into the valve body (01) and guide it with the stem (10).
10. Put the yoke (12) together with the gland flange (07) over the stem (04) and fixate the gland flange (07) with
the gland bolts (06).
11. Fixate the handwheel (14) and nameplate (44) to the stem (04) with the handwheel nut (21) and washer (28).
13. Loosen the gland nuts (09) slightly. Now carefully retighten the gland nuts (09) again.
14. Pressurise the system and check the packing (05) for leakage.
15. In case of leakage tighten the gland nuts (09 carefully until the leakage stops.

HP Valves BV

DISASSEMBLY & ASSEMBLY PISTON CHECK VALVE, Fig. 04.1.0 1. Caution, before any attempt is made to disassemble, verify that the valve is sufficiently cooled down,
PRESSURE SEAL ≤2½” / ≤ 65mm 2. Unscrew the locknut (32) approximately 12 mm from the bonnet (18), while preventing the bonnet (18) from
rotating by a spanner.
3. Unscrew the cap (20) from the valve body (01) until it contacts the locknut (32).
4. Tighten the locknut (32) to force the bonnet (18) and gasket (19) out of the valve body (01).
5. Unscrew the cap (20) together with the bonnet (18) and gasket (19) from the valve body (01).
6. Remove the spring (17) and disc (03) out of the valve body.


B. BONNET (18) - Sealing surface
4. Apply a thin film of Molykote D321 R to the sealing surface of the NEW gasket (19) and bonnet (18).
5. Insert the disc (03) and the spring (17) into the valve body (01).
6. Insert the bonnet (18) and the NEW gasket (19) into the valve body (01).
7. Screw the cap (20) on the valve body (01) and tighten it.
8. Place the washer (27) over the bonnet (18) and screw the locknut (32) on the bonnet (18).
9. Tighten the locknut (32) to force the bonnet (18) into the gasket (19).
10. Pressurise the system and again tighten the locknut (32).
Important:
recommended to tighten the locknut (32) to force the bonnet (18) into the gasket (19) for optimum sealing.

HP Valves BV

DISASSEMBLY & ASSEMBLY PISTON CHECK VALVE, Fig. 04.T 1. Caution, before any attempt is made to disassemble, verify that the valve is sufficiently cooled down,
PRESSURE SEAL AND BAYONET CAP ≤ 2½” / ≤ 65mm 2. Unscrew the locknut (32) approximately 12 mm from the bonnet (18), while preventing the bonnet (18) from
3. Unscrew and remove the hex bolt 09 and nut and remove the cross key 35.
4. Rotate the cap (20) 90° counter clockwise and pull it up until it contacts the locknut (32).
5. Now again rotate the cap (20) 90° and tighten the locknut (32) to force the bonnet (18) and gasket (19) out of
6. Remove the cap (20) together with the bonnet (18) and gasket (19) from the valve body (01).
7. Remove the spring (17) and disc (03) out of the valve body.


5. Insert the disc (03) and the spring (17) into the valve body (01).
7. Install the cap (20) on the valve body (01) and rotate it 90° clockwise.
8. Locate the cross key (35) in between the cap (20) and the valve body (01) and insert the hex bolt (09) and
tighten the nut.
Important:

HP Valves BV

2. Unscrew the locknut (9) approximately 20mm from the bonnet (4).
PRESSURE SEAL 3” 1500LBS / 80mm PN250
3. Unscrew and remove the hexagon socket screw (7).
4. Rotate the cap (6) 90° counter clockwise from the valve body (1). Pull it up against the locknut (9) and rotate
the cap (6) again 90° counter clockwise.
5. Tighten the locknut (9) to force the bonnet (4) and the gasket (5) out of the valve body (1).
6. Remove the cap (6) together with the bonnet (4) and the gasket (5) from the valve body (1).
7. Unscrew the locknut (9) completely, now remove the spring washer (8), the bonnet (4) and the gasket (5).
8. Remove the spring (3) and disc (2) out of the valve body (1).


5. Insert the piston (2) and spring (3) into the valve body (1).
6. Insert the bonnet (4) and NEW gasket (5) into the valve body (1).
7. Install the cap (6) on the valve body (1), rotate it 90˚ clockwise and fixate it with the hexagon socket screw (7)
to the valve body (1).
8. Place the spring washer (8) over the bonnet (8) and screw the locknut (9) on the bonnet (4).
Important:
3” 1500 LBS

HP Valves BV

2. Unscrew the bolts (10) from the retaining ring (9).
PRESSURE SEAL 4” 1500 ~ 2500LBS / 100mm PN250 ~ PN400
3. Remove the retaining ring (9) from the valve body (1).
4. Lower the bonnet (5) into the valve body (1) and remove the segmental ring (8), by tapping a punch tool
through the designated disassembly holes (3) provided in the bonnet area of the valve body (1).
5. Now the bonnet (5), spacer ring (7), gasket (6), spring (4) and disc (2) can be removed from the valve body (1).


5. Insert the disc (2) and spring (4) into the valve body (1).
6. Insert the bonnet (5), NEW gasket (6) and spacer ring (7) into the valve body (1).
7. Lower the bonnet (5) into the valve body (1) and install the segmental ring (8) into the valve body (1). Make
sure the segments are located at such place, there is a segment placed in front of each disassembly hole (3).
8. Insert the bolts (10) through the retaining ring (9). Place the retaining ring (9) on top of the valve body (1).
Screw the bolts (10) into the bonnet (5) and tighten them to force the bonnet (5) into the gasket (6).
9. Pressurise the system and again tighten the bolts (10).
Important:
4” 1500 ~ 2500LBS

HP Valves BV

DISASSEMBLY & ASSEMBLY BALL TYPE CHECK VALVE, Fig. 05.1.0 1. Caution, before any attempt is made to disassemble, verify that the valve is sufficiently cooled down,
PRESSURE SEAL ≤2” / ≤ 50mm 2. Unscrew the locknut (32) approximately 12 mm from the bonnet (18), while preventing the bonnet (18) from
6. Remove the spring (17) and ball (03) out of the valve body.


5. Insert the ball (03) and the spring (17) into the valve body (01).
Important:

HP Valves BV

DISASSEMBLY & ASSEMBLY BALL TYPE CHECK VALVE, Fig. 05.T
PRESSURE SEAL AND BAYONET CAP ≤ 2” / ≤ 50mm 1. Caution, before any attempt is made to disassemble, verify that the valve is sufficiently cooled down,
2. Unscrew the locknut (32) approximately 12 mm from the bonnet (18), while preventing the bonnet (18) from
3. Unscrew and remove the hex bolt (09) and nut and remove the cross key (35).
4. Rotate the cap (20) 90° counter clockwise and pull it up until it contacts the locknut (32).
5. Now again rotate the cap (20) 90° and tighten the locknut (32) to force the bonnet (18) and gasket (19) out of
6. Remove the cap (20) together with the bonnet (18) and gasket (19) from the valve body (01).
7. Remove the spring (17), ball (03) and ball holder (04) out of the valve body.


5. Insert the ball (03), ball holder (04) and the spring (17) into the valve body (01).
7. Install the cap (20) on the valve body (01) and rotate it 90° clockwise.
8. Locate the cross key (35) in between the cap (20) and the valve body (01) and insert the hex bolt (09) and
tighten the nut.
Important:

HP Valves BV

DISASSEMBLY & ASSEMBLY SWING CHECK VALVE, Fig. 04.6.9 1. Caution, before any attempt is made to disassemble, verify that the valve is sufficiently cooled down,
PRESSURE SEAL ≤ 2” / ≤ 50mm 2. Unscrew the locknut (32) approximately 12 mm from the bonnet (18), while preventing the bonnet (18) from
5. Unscrew the cap (20) together with the bonnet (18), disc (03) and gasket (19) from the valve body (01).


5. Insert the bonnet (18) together with the disc (03) and the NEW gasket (19) into the valve body (01).
Important:

HP Valves BV

DISASSEMBLY & ASSEMBLY SWING CHECK VALVE, Fig. 00.6.0 1. Caution, before any attempt is made to disassemble, verify that the valve is sufficiently cooled down,
3” ~ 4” 1500 ~ 2500 LBS / 80mm ~ 100mm PN250 ~ PN 400
2. Unscrew the nuts (28) from the retaining plate (30) and remove the spring washers (27) and the retaining
plate (30).
through the designated disassembly holes provided in the bonnet area of the valve body (01).
4. Remove the gasket ring (20), gasket (19) and the bonnet (04) from the valve body (01).
5. Unscrew the lock ring (18) from the valve body (01) using the special removal tool.
6. Remove the gasket (07) and the disc holder (16).
7. Remove the disc (03) out of the disc holder (16) by pressing out the disc pin (06).


4. Place the disc (03) into the disc holder (16) and secure it with the disc-pin (06).
5. Insert the disc assembly (16) into the valve body (01) whilst aligning both flat surfaces located at the disc
assembly (16) and valve body (01).
6. Place the gasket (07) and secure the disc assembly (16) with the lock ring (18) using the special tool.
8. Insert the bonnet (04), gasket (19) and gasket ring (20) into the valve body (01).
9. Place the segmental ring (21) into the valve body (01). Make sure the segments are located at such place,
there is a segment placed in front of each disassembly hole.
10. Insert the bolts (29) through the retaining ring (30). Place the retaining ring (30) on top of the valve body (01).
Screw the bolts (29) into the bonnet (04) and place the spring washers (27) and nuts (28). Now tighten the
nuts (28) to force the bonnet (04) into the gasket (19).
11. Pressurise the system and check the bonnet.
12. In case leakage of the bonnet (04) is observed, tighten the nuts (28).
Important:

HP Valves BV

DISASSEMBLY & ASSEMBLY GATE VALVE, Fig. 06.6.0_MOV 1. Caution, before any attempt is made to disassemble, verify that the valve is sufficiently cooled down,
WITH FLOATING BACKSEAT (½” ~ 1”) / (15mm ~ 25mm) 2. Unscrew the nuts (09) from the gland bolts (06) and remove the gland bolts from the gland flange (07).
Actuator not drawn 4. Loosen the yoke (12) by rotating it in a counter clockwise direction and unscrew it partly from the body (01) :
 7 revolutions for 3/8” - 1/2” valves (10mm – 15mm)
Connection flange
 10 revolutions for 3/4” - 1” valves (20mm – 25mm)
9. Remove the gland flange (07), the gland (08), the packing (05) and the floating backseat (04) from the stem
(10) by pressing down on the floating backseat (04) whilst holding the stem (10) upside down.


B. STEM (10) – Packing area
C. WEDGE (03) - Sealing surface
D. BACKSEAT (04) – Sealing surface
4. Insert the stem (10) in the designated slot located in the wedge (03)
5. Insert the stem/wedge assembly into the valve body (01).
½” ~ 1”

HP Valves BV

DISASSEMBLY & ASSEMBLY GATE VALVE, Fig. 06.T 1. Caution, before any attempt is made to disassemble, verify that the valve is sufficiently cooled down,
WITH BAYONET YOKE AND FLOATING BACKSEAT (½” ~ 1”) / (15mm ~ 25mm)
2. Unscrew the gland bolting (06) and remove the gland bolting (09) together with the cross key (35) from the gland
flange (07).
7. Remove the handwheel nut (32), nameplate (44) and remove the handwheel (14) from the yoke sleeve (13).
8. Loosen the bolting (46) and remove the yoke cap (22) from the yoke (12). Afterwards unscrew the yoke sleeve
(13) by rotating it clockwise from the stem (10).
9. Remove the stem protector (15) from the yoke (12) and remove the position indicator (24) pressing it from the
stem (10).
10. Now remove the stem (10) from the yoke (12) by sliding it out of the gland flange (07) and gland (08).
11. Remove the packing (05) and the floating backseat (04) from the stem (10) by pressing down on the floating
backseat (04) whilst holding the stem (10) upside down.

D. BACKSEAT (04) – Sealing surface IN CASE SEVERE DAMAGE IS OBSERVED,
3. Lubricate all threaded parts with high temperature grease, i.e. Molykote HSC. USE REPLACEMENT PARTS INSTEAD!
4. Insert the stem (10) in the designated slot located in the wedge (03) and install the stem/wedge assembly into
5. Insert the floating backseat (04) (with radius down) followed by the packing (05) (markings facing down) into the
valve body (01).
6. Place the gland (08) over the stem (10) and put the yoke (12) together with the gland flange (07) over the stem
(10).
7. Insert the position indicator (24) into the stem (10) and grease it with high temperature grease, i.e. Molykote
HSC.
10. Install the yoke sleeve (13) on the stem (10) by rotating it counter clockwise.
11. Install the yoke cap (22) to the yoke (12) and fixate it by screwing in the bolts (46).
12. Install the handwheel (14) to the yoke sleeve (13), place the nameplate (44) and fixate it with the sleeve nut (32).

HP Valves BV

DISASSEMBLY & ASSEMBLY GATE VALVE, Fig. 06.T.E 1. Caution, before any attempt is made to disassemble, verify that the valve is sufficiently cooled down,
WITH BAYONET YOKE, FLOATING BACKSEAT AND ELECTRIC ACTUATOR (½” ~ 1”) / (15mm ~ 25mm)
2. Unscrew the gland bolting (06) and remove the gland bolting (09) together with the cross key (35) from the gland
flange (07).
3. Operate the valve to the open position, using the actuator emergency handwheel rotating it counter clockwise.
Now rotate it past the fully open position to force the packing (05) and the floating backseat (04) out of the
stuffing box.
4. Unscrew the bolting to loosen the actuator from the yoke (12).
5. Rotate the actuator clockwise in order to unscrew it from the stem (10).
8. Loosen the bolting (46) and remove the yoke flange (22) from the yoke (12). Afterwards remove the stem
protector (15) from the yoke (12) and remove the position indicator (24) pressing it from the stem (10).
9. Now remove the stem (10) from the yoke (12) by sliding it out of the gland flange (07) and gland (08).

4. Insert the stem (10) in the designated slot located in the wedge (03) and install the stem/wedge assembly into
5. Insert the floating backseat (04) (with radius down) followed by the packing (05) (markings facing down) into the
valve body (01).
6. Place the gland (08) over the stem (10) and put the yoke (12) together with the gland flange (07) over the stem
(10).
7. Insert the position indicator (24) into the stem (10) and grease it with high temperature grease, i.e. Molykote
HSC.
10. Install the yoke flange (22) to the yoke (12) and fixate it by screwing in the bolts (46).
11. Mount the actuator on top of the connection flange (12) by rotating it counter clockwise and tighten the bolts.
12. Operate the actuator in manual mode, until the valve is in closed position and adjust the switch setting according
the actuator manufacturers manual.

HP Valves BV

DISASSEMBLY & ASSEMBLY GATE VALVE, Fig. 06.T.P 2. Switch the pneumatic actuator to the closed position. Unscrew bolts (18) out of the coupling (15/17) to
WITH BAYONET YOKE, FLOATING BACKSEAT AND PNEUMATIC ACTUATOR (½” ~ 1”) / (15mm ~ 25mm)
3. Switch the pneumatic actuator (61) to the open position. Loosen the nut (57) of the upper coupling (17) and
4. Unscrew the nuts (56) from the spacer columns (14) and disconnect the air feed line together with the electrical
connections. Now remove the pneumatic actuator (61), spacer columns (14) and limit switches (63) from the
pneumatic mounting flange (12). Unscrew the gland nuts (09) from the stud bolts (06) and remove them
together with the cross key (35).
5. Pull the stem (10) together with wedge (03), coupling (15), gland flange (07), gland (08), packing (05) and floating
6. Remove the coupling (15) and the gland flange (07) from the stem (10).

4. Insert the stem (10) and wedge (03) into the valve body (01). Insert the floating backseat (04)(with radius down)
into the valve body (01). Insert the packing (05) with markings down into the valve body (01).
5. Place the gland (08) together with the gland flange (07) over the stem (10). Fixate the gland flange (07) with the
cross key (35) and insert the gland bolts (06).
8. Install the coupling (15) to the stem (10). Lubricate stem radius with high temperature grease, i.e. Molykote HSC.
Install the upper coupling (17) and place the position indicator (16) on top of it. Secure this assembly by screwing
in the hexagon socket screws (18).
Reconnect the air feed line and electrical connections and switch the pneumatic actuator to the open position.
Now secure the spacer columns (14) with the nuts (56) and washers (55).

HP Valves BV

DISASSEMBLY & ASSEMBLY GATE VALVE, Fig. 06.6.0_HOV 1. Caution, before any attempt is made to disassemble, verify that the valve is sufficiently cooled down,
WITH FLOATING BACKSEAT (1¼” ~ 2”) / (32mm ~ 50mm)
 17 revolutions for 1¼” - 2” valves (31,75mm - 50mm)
6. Unscrew the yoke (12) and pull it together with the remaining parts out of the valve body (01). Special
attention should be paid to removal of the parallel key (23) located inside the valve body (01).
9. Remove the gland flange (07), the gland (08), the packing (05), the floating backseat (04) from the stem (10)
by pressing down on the floating backseat (04) whilst holding the stem (10) upside down.


5. Insert the parallel key (23) in the key way located inside the valve body (01) and place the stem/wedge
assembly into the valve body (01).
6. Insert the floating backseat (04) in the valve body (01) lining it up to the parallel key and install it into the
valve body (01).
1¼” ~ 2”

HP Valves BV

DISASSEMBLY & ASSEMBLY GATE VALVE, Fig. 06.6.9_HOV/MOV
PARALLEL SLIDE 2½” ~ 4” 1500-2500LBS / 65mm ~ 100mm ~ PN250-PN400
Fig.02
Fig.01

HP Valves BV

DISASSEMBLY & ASSEMBLY GATE VALVE, Fig. 06.6.9_HOV/MOV 3. Place the Belleville springs (06) and pin (as indicated in Fig.03) into the first disc (03). Place this disc (03) into
the disc holder (16) and rotate it 90° securing the lip in the provided groove located in the disc holder (16).
PARALLEL SLIDE 2½” ~ 4” 1500-2500LBS / 65mm ~ 100mm ~ PN250-PN400
Afterwards install the second disc (03) and rotate it 90° securing the lip in the provided groove located in the
disc holder (16) as well. Now insert the stem (10) and disc assembly inside the valve body (01).
4. Place the bonnet (04) over the stem/disc assembly. Pull up the stem/disc assembly to avoid the bonnet (04)
from dropping in the valve body (01). Install a new gasket (19) in the valve body (01), with the gasket ring (20)
2. For manual operated valves remove handwheel nut (32), handwheel (14) and parallel key (24).
on top of it.
For valves with a Gearbox or Electric Actuator, remove the actuator by unscrewing the bolts (30) from the lower
5. Place the segmental ring (21) inside the provided grove located in the valve body (01). Make sure there is no
side of the top flange (11) and remove the actuator from the stem (10) by rotating it clockwise.
split between two segments placed in front of a disassembly hole. Pull up the stem/disc assembly together
3. Unscrew the hexagon socket screws (29) from the top flange (11).
with the bonnet (04) through the segmental ring (21). Screw the retaining ring (18) on the bonnet (04) and
4. For manual operated valves screw the yoke sleeve (13) together with the needle bearing (26) from the stem (10).
tighten it. Screw the bolts (29) into the retaining ring (18) and evenly tighten them.
5. Loosen the bolts (22) from the guiding plate (15) and remove it. Unscrew the stands (12) out of the valve body
6. Place packing (05) (first with markings down, second with markings up) over the stem (10) into the bonnet
(01). Unscrew gland bolting/nuts (17-09) and remove them. Remove the gland (07) and gland-bushing (08).
(04). Place the gland bushing (08) over the stem (10) followed by the gland flange (07) and secure them with
6. Unscrew the bolts (29) from the retaining ring (18) and unscrew the retaining ring (18) from the bonnet (04),
the gland bolting (17/09). Tighten the nuts (09) to compress the packing (05). Loosen the nuts (09), then
whilst holding up the stem/disc assembly, to secure the bonnet (04) preventing it damaging the stem (10).
tighten them carefully again.
7. After the retaining ring (18) has been removed, lower the stem/disc assembly and bonnet (04). Remove the
7. Screw the stands (12) into the valve body (01) as indicated. Place the guiding plate (15) over the stem (10) on
segmental ring (21) out of the valve body (01), by pressing a punch through the provided bore holes. Now
top of stand number 2 and 5. Secure the guiding plate (15) with the hexagon socket screws (22/23) through
remove the ring (20) and gasket (19), together with the bonnet (04) and stem/disc assembly, by pulling the
the slot provided in the stem (10).
stem/disc assembly out of the valve body (01).
8. For manual operated valves screw the yoke sleeve (13) together with the needle bearing (26) on the stem
8. Dis-assemble the disc assembly by rotating the first disc (03) 90°, so that the lip will come out of the disc holder
(10).
(16). Afterwards remove the Belleville spring set (06) and pin, see fig.01 and finally remove the second disc (03)
9. Place the top flange (11) on top of the stands (12) and secure them with the hexagon socket screws (29).
by rotating it 90°.
10. For manual operated valves rotate the yoke sleeve (13) against the top flange (11), place the parallel key (24),
handwheel (14) and secure it with the handwheel nut (32).
11. Pressurise the system and check the packing (05) and gasket (19).


B. STEM (10) – Packing area Important:
C. DISC (03) - Sealing surface After starting up the system, once the valve has reached its working temperature and pressure, It is
D. BACKSEAT (04) – Sealing surface recommended to tighten the bolts (29) to force the bonnet (04) into the gasket (19) for optimum sealing.
12. In case of leakage through the packing (05) tighten the nuts (09) of the gland bolts (17) carefully until the
leaking stops.
Fig.03

HP Valves BV

DISASSEMBLY & ASSEMBLY GATE VALVE, Fig. 06.5.0_HOV 1. Caution, before any attempt is made to disassemble, verify that the valve is sufficiently cooled down,
LIGHT WITH FLOATING BACKSEAT ≤2” / ≤ 50mm
4. Remove the handwheel (14) from the stem (10) by loosening the handwheel nut (21).
5. Loosen the yoke sleeve (13) by rotating it in a counter clockwise direction and unscrew it from the body (01).
6. Remove the yoke sleeve (13) together with the stem protector (45), the spring washer (46) and the gland
flange (07A/07B).
7. Pull the stem/wedge assembly from the valve body (01).
8. Remove the wedge (03), gland (08), packing (05) and the floating backseat (04) from the stem (10) by pressing
down on the floating backseat (04) whilst holding the stem (10) upside down.
4. Place the floating backseat (04) (with radius down) over the stem (10).
5. Place the packing (05) on top of the floating backseat (04) (with markings down).
6. Place the gland (08) (with radius up) over the stem (10).
7. Place the wedge (03) on the stem (10) and push the gland (08), packing (05) and floating backseat (04) against
the wedge (03).
8. Insert the stem/disc assembly into the body/yoke (01).
9. Slide in the gland flange (07A) with radius down and groove up from the side between the yoke and add the
second gland part (07B) in the chamber.
10. Hand tighten the gland bolting (06 & 09) to secure the gland flange (07A / 07B).
11. Position the stem protection (45) on top of the gland flange (07A / 07B). Make sure the stem protection is
fitted properly in the groove on the gland flange.
12. Put the spring washer (46) over the stem (10) and screw the yoke sleeve (13) over the stem (10) and in the
body/yoke (01).
13. Make sure the valve is at least in half open position before screwing the yoke sleeve (13) in the yoke.
14. Tighten the yoke sleeve (13) applying the following torque values.
 ½” ~ 1”: 70Nm / (10mm ~ 15mm)
 1½” ~ 2”: 120Nm / (40mm ~ 50mm)
15. Provide a notch between the yoke and yoke sleeve (13) to provide additional protection against loosening,
using a punch and hammer.
16. Fit the handwheel (14) and nameplate (44) to the stem with the nut and washer (21 & 28).
17. Close the valve rotating the handwheel (14) clockwise.
18. Tighten the nuts (09) of the gland bolts (06) to compress the packing (05).
19. Loosen the nuts (09) of the gland bolts (06).
20. Then carefully tighten the nuts (09) of the gland bolts (06) again.
22. In case of leaking, tighten the nuts (09) of the gland bolts (06) carefully until the leaking stops.

HP Valves BV

WITH FLOATING BACKSEAT AND ELECTRIC ACTUATOR (½” ~ 1”) / (15mm ~ 25mm)
Actuator not drawn using the actuator emergency handwheel rotating it counter clockwise. Now rotate it past the fully open
Connection flange position to force the packing (05) and the floating backseat (04) out of the stuffing box.
(15), gland flange (07), gland (08) and parallel key (23) from the stem (10).
7. Pull the stem (10) together with the remaining parts out of the valve body (01).

5. Insert the stem/wedge assembly into to valve body (01).
body (01).
7. Place the parallel key (23) in the stem (10) and lubricate it with high temperature grease, i.e. Molykote HSC.
8. Place the yoke (12) together with the gland flange (07) and position indicator (15) over the stem (10) and
12. Mount the actuator on top of the connection flange (12) by rotating it counter clockwise and tighten the bolts
(47). Adjust the limit switches of the actuator.
 3/8” - 1/2” valve 12mm travel
 3/4” - 1” valve 22mm travel
tack weld.
½” ~ 1”

HP Valves BV

WITH FLOATING BACKSEAT AND ELECTRIC ACTUATOR (1¼” ~ 2”) / (32mm ~ 50mm)
using the actuator emergency handwheel rotating it counter clockwise. Now rotate it past the fully open
Actuator not drawn
Connection flange
(15), gland flange (07), gland (08) and parallel key (23) from the stem (10).
7. Pull the stem (10) together with the remaining parts out of the valve body (01).

5. Insert the stem/wedge assembly into to valve body (01).
body (01).
7. Place the parallel key (23) in the stem (10) and lubricate it with high temperature grease, i.e. Molykote HSC.
8. Place the yoke (12) together with the gland flange (07) and position indicator (15) over the stem (10) and
12. Mount the actuator on top of the connection flange (12) by rotating it counter clockwise and tighten the bolts
(47). Adjust the limit switches of the actuator.
 1¼” - 2” valve 42mm travel
tack weld.
1¼” ~ 2”

HP Valves BV

DISASSEMBLY & ASSEMBLY GATE VALVE, Fig. 06.6.9_POV 1. Caution, before any attempt is made to disassemble, verify that the valve is sufficiently cooled down,
WITH FLOATING BACKSEAT AND PNEUMATIC ACTUATOR (1¼” ~ 2”) / (32mm ~ 50mm)
2. Switch the pneumatic actuator to the closed position. Unscrew bolts (18) out of the coupling (15/17) to
electrical connections. Now remove the pneumatic actuator (61), spacer columns (14) and limit switches (63)
from the pneumatic mounting flange (12). Unscrew the gland nuts (09) from the stud bolts (06) and remove
them.
5. Pull the stem (10) together with wedge (03), coupling (15), gland flange (07), gland (08), packing (05) and
floating backseat (04) out of the valve body (01).
6. Remove the coupling (15) and the gland flange (07) from the stem (10).


4. Insert the stem (10) and wedge (03) into the valve body (01). Insert the floating backseat (04) (with radius
down) into the valve body (01). Insert the packing (05) with markings down into the valve body (01).
5. Place the gland (08) together with the gland flange (07) over the stem (10). Fixate the gland flange (07) with
the gland bolts (06).
8. Install the coupling (15) to the stem (10). Lubricate stem radius with high temperature grease, i.e. Molykote
HSC. Install the upper coupling (17) and place the position indicator (16) on top of it. Secure this assembly by
screwing in the hexagon socket screws (18).
1¼” ~ 2”

HP Valves BV

DISASSEMBLY & ASSEMBLY CONTINUOUS BLOW DOWN VALVE, Fig. 09.3.0_HOV depressurised, isolated from system pressure and secured against accidental pressurisation.
WITH FLOATING BACKSEAT ≤2½” / ≤65mm 3. Operate the valve to the open position.
4. Loosen the yoke (12) by rotating it in a counter clockwise direction and unscrew it partly from the body (01).
7. Unscrew the nut (32) from the yoke sleeve (13) and remove the handwheel (14).
8. Unscrew the stem/disc (11) from the yoke sleeve (13) and remove the position indicator (15), the gland flange
(07) and parallel key (23).
9. Remove the gland flange (07), the packing (05) and the floating backseat (04) from the stem/disc (11) by
pressing down on the floating backseat (04) whilst holding the stem/disc (11) upside down.


B. STEM/disc (11) – Packing area
6. Insert the packing (05) (with markings down) into the valve body (01).
7. Insert the parallel key (23) into the stem/disc (11) and grease it with high temperature grease, i.e. Molykote
HSC.
clockwise.
9. Align the gland flange (07) to the correct position whilst sliding the parallel key (23) in the designated slot

HP Valves BV

DISASSEMBLY & ASSEMBLY CONTINUOUS BLOW DOWN VALVE, Fig. 09.3.1_HOV 1. Caution, before any attempt is made to disassemble, verify that the valve is sufficiently cooled down,
WITH FIXED BACKSEAT ≤2½” / ≤65mm
3. Remove the hexagon socket screw from the position indicator (15).
stem/disc (11) from the yoke sleeve (13) until it disengages. Remove the yoke (12), position indicator (15) and
gland flange (07) from the valve body (01).
6. Remove the sleeve nit (32) which secures the handwheel (14) and remove the handwheel (14) and yoke
sleeve (13) from the yoke (12).
7. Remove the parallel key (23) from the stem/disc (11) and remove the packing (05) out of the valve body (01).
HSC.
clockwise.

HP Valves BV

DISASSEMBLY & ASSEMBLY CONTINUOUS BLOW DOWN VALVE, Fig. 09.3.2_MOV 1. Caution, before any attempt is made to disassemble, verify that the valve is sufficiently cooled down,
WITH FLOATING BACKSEAT AND ELECTRIC ACTUATOR ≤2½” / ≤65mm
Actuator not drawn using the actuator emergency handwheel rotating it counter clockwise. Now rotate it past the fully open
Connection flange 4. Unscrew the bolting (47) to loosen the actuator from the yoke (12).
7. Pull the stem/disc (11) together with the remaining parts out of the valve body (01).

4. Insert the stem/disc (11) into to valve body (01).
body.
HSC.
of the actuator.
tack weld.

HP Valves BV

DISASSEMBLY & ASSEMBLY Y-TYPE STRAINER, Fig. 08.2.0 1. Caution, before any attempt is made to disassemble, verify that the valve is sufficiently cooled down,
⅜” ~ 2” / 10mm ~ 50mm 2. Unscrew the locknut (20) approximately 12 mm from the bonnet (18), while preventing the bonnet (18) from
6. Remove the strainer (56) and the spring washer (09) out of the valve body (01).
7. Clean the strainer.

2. Examine the following parts for signs of damage and or wear:
A. GASKET (19) - Sealing surface

C. STRAINER (56) - Integrity of the mash

5. Insert the strainer (56) and the spring washer (09) into the valve body (01).
Important:

HP Valves BV

DISASSEMBLY & ASSEMBLY Y-TYPE STRAINER, Fig. 08.Y 1. Caution, before any attempt is made to disassemble, verify that the valve is sufficiently cooled down,
BAYONET CAP (⅜” ~ 2”) / (10mm ~ 50mm)
2. Unscrew the locknut (32) approximately 12 mm from the bonnet (18), while preventing the bonnet (18) from
3. Unscrew the hexagon bolt (29) by removing the nut and spring washer (54) and remove the cross key (35)
from the valve body (01).
4. Rotate the cap (20) 90° and take it together with the bonnet (18) and gasket (19) from the valve body (01).
5. Remove the strainer (56) and the spring washer (09) out of the valve body (01).



5. Insert the strainer (56) and the spring washer (09) into the valve body (01).
7. Install the cap (20) on the valve body (01) and it 90° to secure it.
8. Insert the cross key (35) between the cap (20) and the body (01) and insert the hexagon bolt (29) and tighten
it with the spring washer & nut (54)
Important:

HP Valves BV

DISASSEMBLY & ASSEMBLY Y-TYPE STRAINER, Fig. 08.2.0 1. Caution, before any attempt is made to disassemble, verify that the valve is sufficiently cooled down,
2½” ~ 4” / 65mm ~ 100mm – LOOSE STRAINER <200bar
2. Unscrew the hexagon socket screw (09) which secures the cap (06) to the valve body (01).
3. Loosen the nuts (08).
4. Rotate the cap (06) 90˚ counter clockwise from the valve body (01). Now remove the cap (06) together with
bonnet (03), gasket (04), spring washer (09) and spacer ring (05) out of the valve body (01).
5. Unscrew the nuts (08) from the bolting (07). Now remove the spacer ring (05), spring washer (09), bonnet (03)
and the gasket (04) out of the cap (06).
6. Remove the strainer (02) from the valve body (01).



5. Insert the strainer (02) into the valve body (01).
6. Insert the bonnet (03), NEW gasket (04), spring washer (09) and spacer ring (05) into the valve body (01).
7. Place the cap (09) on top of the valve body (01) and over the bolting (07) and rotate the cap (06) 90˚
clockwise.
8. Secure the cap (06) with the hexagon socket screw (09).
9. Screw the nuts (08) on the bolting (07) and tighten them.
10. Pressurise the system and again tighten the nuts (08).
Important:

HP Valves BV

DISASSEMBLY & ASSEMBLY Y-TYPE STRAINER, Fig. 08.2.9 2. Unscrew the hexagon socket screw (09) which secures the cap (06) to the valve body (01).
3. Loosen the nuts (08).
2½” ~ 4” / 65mm ~ 100mm – FIXED STRAINER >200bar
4. Rotate the cap (06) 90˚ counter clockwise from the valve body (01). Now remove the cap (06) together with
bonnet (03), gasket (04), spacer ring (05) and strainer (02) out of the valve body (01).
5. Unscrew the nuts (08) from the bolting (07). Now remove the spacer ring (05), bonnet (03), gasket (04) and
the strainer (02) out of the cap (06).
6. Unscrew the strainer (02) from the bonnet (03) and clean / replace the strainer (02).



5. Insert the strainer (02) into the bonnet (03).
6. Insert the bonnet (03), NEW gasket (04), spacer ring (05) and strainer (02) into the valve body (01).
7. Place the cap (09) on top of the valve body (01) and over the bolting (07) and rotate the cap (06) 90˚
clockwise.
8. Secure the cap (06) with the hexagon socket screw (09).
9. Screw the nuts (08) on the bolting (07) and tighten them.
10. Pressurise the system and again tighten the nuts (08).
Important:

HP Valves BV

ADDITIONAL INSTRUCTION FOR REMOVAL OF STRAINER DRAIN CONNECTION 1. Lubricate the drain connection cap (10) with some penetrating oil (i.e. PB Blaster or WD40) to ensure this part
can be unscrewed from the strainer drain (13) smoothly.
2. Unscrew the drain connection cap (10) whilst holding the bonnet (03) with a wrench to remove the actual
strainer drain (13) from the strainer.
3. Tap the drain connection cap (10) down towards the bonnet (03) until the segmental ring (11) is accessible.
4. Remove the gasket (12).
5. Pull both parts of the segmental ring (11) from the bonnet connection (03).
6. Pull up the drain connection cap (10) from the bonnet connection (03) and remove it.
7. Continue to disassemble the strainer following the instructions provided in this document. Reference is made
to pages 52 ~ 55, depending on the actual strainer.
RE-ASSEMBLY
1. Assemble the strainer following the instructions provided in this document. Reference is made to pages 52 ~
55, depending on the actual strainer.
2. Slide the drain connection cap (10) over the bonnet connection (03).
3. Place the segmental ring (11) on the bonnet connection (03) and pull down the drain connection cap (10) until
it contacts the segmental ring (11).
4. Insert a NEW gasket (12) and reconnect the strainer drain (13) by tightening the drain connection cap (10).
Important:
recommended to tighten the drain connection cap (10) to force the bonnet connection (03) into the gasket
(11) for optimum sealing.

HP Valves BV

DISASSEMBLY & ASSEMBLY NEEDLE VALVE, Fig. 07.1 1. Caution, before any attempt is made to disassemble, verify that the valve is sufficiently cooled down,
WITH FLOATING BACKSEAT ½” ~ 1” / 15mm ~ 25mm 2. Unscrew the nut (13) from the handwheel (10) and remove the nameplate (11), handwheel (10) and
protection cover (09).
3. Unscrew the cap (07) from the valve-body (01), whilst preventing the threaded rod (08) against turning by
holding it with the handwheel (10).
4. Disconnect the threaded rod (08) from the stem/disc (02).
5. Unscrew the gland (06) with the special removal tool out of the valve body (01).
6. Place the cap (07) with the threaded rod (08) over the stem/disc (02), so that there will be a connection
between the threaded rod (08) and the stem/disc (02). Screw the cap (07) two rotations on the valve body
(01).
7. Pull the stem/disc (02) and remaining valve internals out of the valve body (01), by rotating the threaded rod
(08) with the handwheel (10) counter clockwise, whilst preventing the cap (07) against turning by holding it.
8. Unscrew the cap (07) from the valve-body (01). Disconnect the threaded rod (08) from the stem/disc (02).
9. Screw the threaded rod (08) out of the cap (07).


C. stem/DISC (02) – Sealing surface
4. Install the loose backseat (03) and new packing (04) with markings facing down together with the ring (05)
over the stem/disc (02).
5. Insert the complete stem/disc (02) assembly into the valve-body (01).
6. Place the gland (06) over the stem/disc (02) and screw it into the valve-body (01) using the special tool and
tighten the gland (06) to approximately 60NM.
7. Screw the threaded rod (08) into the cap (07) and attach the threaded rod (08) to the stem/disc (02).
8. Screw the cap (07) on the valve-body (01), whilst preventing the threaded rod (08) against turning by holding
it with the handwheel (10).
9. Install the protection cover (09) followed by the handwheel (10), the nameplate (11), and the spring washer
(12) on the threaded rod (08) and complete it with tightening of the nut (13).
10. Pressurise the system and check for leaks.

HP Valves BV

USE OF BACKSEAT REMOVAL TOOL

1. Disassemble the valve as described in the disassembly instructions.
2. Make sure the packing is completely removed from the valve body.
3. Insert the backseat removal tool (71) in the valve body.
4. Screw the adaptor (70) on the valve body.
5. Loosen the backseat (34) by rotating the backseat removal tool counter clockwise.
6. Unscrew the adaptor (70) from the valve body.
7. Unscrew the backseat (34) from the valve body.
8. Remove the backseat removal tool (71) from the valve body.
9. Remove the stem (11), the backseat (34) and the gasket from the valve body by pulling the stem out of the
valve body.
RE-ASSEMBLY
1. Clean all parts with solvent and a clean cloth.

2. Grease the backseat-thread with high temperature grease, i.e. Molykote HSC.
3. Insert the stem (11) into the valve body.
4. Insert the gasket together with the backseat (34) into the valve body.
5. Place the backseat removal tool (72) in the valve body and screw the backseat (34) into the valve body.
6. Screw the adaptor (70) on the valve body.
7. Now fasten the backseat (34) by rotating the backseat removal tool (72) clockwise.
8. Unscrew the adaptor (70) and remove the backseat removal tool (71) from the valve body.
9. Continue reassembly of the valve in accordance to the assembly instructions.

HP Valves BV

RESEATING HP VALVES
GLOBE VALVES ≤4” / ≤ 100mm Specially designed reseating tools allow re-cutting of worn or damaged seats without removing the valve body from
the line. Cutters of various size 3/8” - 2” straight type and 3/8” - 4” y-type assure that HP Valves manufactured
valves are cut with the correct angle. Due to the hardness, solid stellite seats require carbide cutters. These carbide
cutters should be handled with great care to prevent from chipping. Jamming these carbide cutters against the valve
seat can cause cutting-chipping, or fracturing of the hard stellite seat.
RENEWING THE SEATING SURFACE
 Disassemble the valve as described in the disassembly instructions.

 Screw the feed screw (05) out of the adaptor (04) as far as possible.
 Insert the tool assembly into the valve body (03) screwing the adaptor (04) to the threaded part located at the
valve body.
 Carefully rotate the feed screw (05) clockwise, while rotating the handle (07) clockwise until the cutter (02)
lightly contacts the valve seat (01).
 Cut the valve seat (01) by slowly rotating the handle (07) clockwise while applying a steady force with the feed
screw (05). Rotate the handle (07) as smoothly as possible (at least 3 revolutions).
 Unscrew the feed screw (05) by rotating it counter clockwise while rotating the handle (07) clockwise.
 Unscrew the adaptor (04), remove the tool assembly and clean it by removing valve seat chips.
 Inspect the seat (01) for a smooth, bright, continuous surface. Repeat the aforementioned steps if necessary,
in order to obtain a satisfactory reconditioned seat.

HP Valves BV

RESEATING HP VALVES Specially designed reseating tools allow re-cutting of worn or damaged seats without removing the valve body from
the line. Cutters of various size 3/8” - 2” straight type and 3/8” - 4” y-type assure that HP Valves manufactured
GLOBE VALVES WITH A BAYONET YOKE ≤4” / ≤ 100mm valves are cut with the correct angle. Due to the hardness, solid stellite seats require carbide cutters. These carbide
cutters should be handled with great care to prevent from chipping. Jamming these carbide cutters against the valve
seat can cause cutting-chipping, or fracturing of the hard stellite seat.
RENEWING THE SEATING SURFACE
 Disassemble the valve as described in the disassembly instructions.

 Screw the feed screw (05) out of the adaptor (04) as far as possible.
 Insert the tool assembly into the valve body (03) screwing the adaptor (04) to the threaded part located at the
valve body.
 Carefully rotate the feed screw (05) clockwise, while rotating the handle (07) clockwise until the cutter (02)
lightly contacts the valve seat (01).
 Cut the valve seat (01) by slowly rotating the handle (07) clockwise while applying a steady force with the feed
screw (05). Rotate the handle (07) as smoothly as possible (at least 3 revolutions).
 Unscrew the feed screw (05) by rotating it counter clockwise while rotating the handle (07) clockwise.
 Unscrew the adaptor (04), remove the tool assembly and clean it by removing valve seat chips.
 Inspect the seat (01) for a smooth, bright, continuous surface. Repeat the aforementioned steps if necessary,
in order to obtain a satisfactory reconditioned seat.

HP Valves BV

Disassembly & Reassembly Instructions

Large Bore Valves – High Pressure
Rev.07
© 2019. This manual, its content and the copyright therein are the property of HP Valves Oldenzaal BV. This
manual is supplied in confidence and shall not be used for any purpose other than which it is supplied for and
may not be reproduced in part or whole or passed on to others, without permission in writing from HP Valves.
Disassembly & Reassembly Instructions LBV-HP - Page 1

HP Valves BV

INDEX
DISASSEMBLY & ASSEMBLY PARALLEL SLIDE GATE VALVE, Fig. KJP .................................................................4
≤ 2” AND ≥ 1500 LBS / ≤ 50 mm AND ≥ PN 250 ................................................................................................................ 4
2½” & 3” AND ≥ 900 LBS / 65mm & 80mm AND ≥ PN100 ................................................................................................. 6
≥ 4” AND ≥ 900 LBS / ≥ 100mm AND ≥ PN100 .................................................................................................................. 8
DISASSEMBLY & ASSEMBLY SWING CHECK VALVE, Fig. KDP ..........................................................................10

≤ 6” AND ≥ 900 LBS / ≤ 150mm AND ≥ PN100 ................................................................................................................ 10
8” AND ≥ 900 LBS / ≤ 150mm AND ≥ PN100 ................................................................................................................... 11
≥10” AND ≥ 900 LBS / ≥ 250mm AND ≥ PN100 ............................................................................................................... 12
DISASSEMBLY & ASSEMBLY TILTING DISC CHECK VALVE, Fig. KDP.................................................................14

≥6” AND ≥ 900 LBS / ≥ 150mm AND ≥ PN100 ................................................................................................................. 14
DISASSEMBLY & ASSEMBLY PISTON CHECK VALVE, Fig. KDP .........................................................................15

≥6” AND ≥ 900 LBS / ≥ 150mm AND ≥ PN100 ................................................................................................................. 15
DISASSEMBLY & ASSEMBLY GLOBE AND STOP/CHECK VALVE, Fig. KGP ........................................................16
CAST STEEL ≥ 6” AND ≥ 900 LBS / ≥ 150mm AND ≥ PN100 ............................................................................................. 16
FORGED STEEL ≥ 6” AND ≥ 900 LBS / ≥ 150mm AND ≥ PN100 ........................................................................................ 18
DISASSEMBLY & ASSEMBLY DOUBLE DISC GATE VALVE, Fig. KJP ...................................................................20
≥ 6” AND ≥ 900 LBS / ≥ 150mm AND ≥ PN100 ................................................................................................................ 20
DISASSEMBLY & ASSEMBLY BALANCER ON PARALLEL SLIDE GATE VALVE .....................................................22

DISASSEMBLY & ASSEMBLY CONTROL VALVE ................................................................................................24
≥ 4” AND ≥ 300 LBS / ≥ 100mm AND ≥ PN40 .................................................................................................................. 24

HP Valves BV

RECOMMENDED TORQUE VALUES Gland bolting torque Nm (red = Gate / blue = Globe)
Assembly hardware torque Nm Class 150 300 600 800 900 1500 2500
Maximum tightening torque Ma / Nm Thread size
Thread - - - - 25 40 40
Strength class according to ISO898/1 ½” ~ DN15
size - - - - 25 40 40
8.8 10.9 12.9 Remark - - - 30 40 40 50
¾” ~ DN20
M6 10 14 17 - - - 30 40 40 50
M8 25 35 42 - - - 30 40 40 50
1” ~ DN25
M10 50 70 85 - - 30 40 40 50
- - - 50 125 125 170
M12 87 122 147 1½” ~ DN32
Bolts clean and - - - 50 125 125 170
M16 210 299 357 - - - 50 170 200 200
lubricated 2” ~ DN50
M20 411 578 696 - - - 50 170 200 200
M30 1422 2010 2403 3½ 3½ 4 - 29 48 81
2½” ~ DN65
M36 2481 3491 4197 3½ 3½ 4 - 30 51 85
Way of tightening bolting
3½ 3½ 4 7 25 42 55
3” ~ DN80
3½ 3½ 6 7 30 51 157
3½ 3½ 6 8 20 33 97
4” ~ DN100
Bonnet bolting torque Nm 5 5 6 10 57 94 241
Thread size B7 / B16 630 / A574 B8 / B8M 660 5 5 8½ 10 58 96 157
6” ~ DN150
M8 ~ 5/16UNC 15 15 7 16 5 6 10 15½ 146 244 448
M10 ~ 3/8UNC 27 27 12 27 5 5 8½ 11½ 57 94 193
8” ~ DN200
M12 ~ 1/2UNC 68 68 27 61 5 8½ 13 15½ 161 269 858
M14 ~ 9/16UNC 95 95 39 84 5 7½ 10 13½ 69 144 339
10” ~ DN250
M16 ~ 5/8UNC 129 129 54 115 7½ 9½ 13 20½ - 411 662
M18 284 284 72 203 7½ 7½ 13½ 17½ 146 244 448
12” ~ DN300
M20 ~ 3/4UNC 400 400 95 270 7½ 9½ 13½ - - 397 1463
M22 ~ 7/8UNC 550 550 153 370 7½ 7½ 15 20 146 269 497
14” ~ DN350
7½ 11 22½ - - 676 1231
M24 ~ 1UNC 690 690 227 460
7½ 7½ 15 - 161 298 858
M27 ~ 1.1/8UNC 1030 1030 333 690 16” ~ DN400
8 13 25½ - 374 - 1147
M33 ~ 1.1/4UNC 1890 1890 468 1270
7½ 9½ 15 - 179 514 948
M36 ~ 1.3/8UNC 2400 2400 633 1620 18” ~ DN450
11 18½ 28½ - - - -
M39 ~ 1.1/2UNC 3100 3100 834 2100
9½ 9½ 17 - 309 568 1354
M42 ~ 1.3/4UNC 3900 3900 1355 2610 20” ~ DN500
- - - - 406 - -
M45 ~ 2UNC 4450 4450 2054 3270 11 12½ 19½ - 341 812 1463
24” ~ DN600
- - - - - - -

HP Valves BV

DISASSEMBLY & ASSEMBLY PARALLEL SLIDE GATE VALVE, Fig. KJP
≤ 2” AND ≥ 1500 LBS / ≤ 50 mm AND ≥ PN 250

HP Valves BV

DISASSEMBLY & ASSEMBLY PARALLEL SLIDE GATE VALVE, Fig. KJP 3. Lubricate all threaded parts with high temperature grease, i.e. Molykote HSC.
4. Install the first disc (03) into the disc holder (06) and rotate the disc 90° in order to secure it, slide the conical
≤ 2” AND ≥ 1500 LBS / ≤ 50 mm AND ≥ PN 250 springs (07) over the guide pin (08) and place the pin into the corresponding socket located in the first disc (03).
Afterwards place the second disc (03) and rotate it 90° as well, now install the pin to finalise the complete disc
1. Caution, before any attempt is made to disassemble, verify that the valve is sufficiently cooled down, assembly.
depressurised, isolated from system pressure and secured against accidental pressurisation. 5. Slide the complete disc assembly (06) onto the stem (05).
2. For manual operated valves remove hand wheel nut, hand wheel (29) and parallel key. 6. Place the bonnet (02) over the stem (05). Install a NEW gasket (17) into the valve body (01), with the spacer ring
For valves fitted with a Gearbox or Electric Actuator, remove the Actuator, by unscrewing the bolts from the (18) on top of it.
lower side of the yoke flange (26). 7. Screw the lock nut (20) into the valve body (01). Pull the stem (05) towards the top of the valve and screw the
nut (21) loose onto the bonnet (02). Screw the bolts (22) into the lock nut (21) and tighten them.
3. Unscrew the bolts (28) from the yoke flange (26).
8. Place the NEW packing (12) over the stem (05) into the bonnet (02). Place the packing follower (13) over the
4. For manual operated valves screw the yoke sleeve (27) together with the needle bearings (30) from the stem
stem (05). Place the gland (14) over the stem (05) and install the gland bolting (15). Evenly tighten the nuts (16)
(05).
preventing contact between the stem (05) & packing follower (13).
5. Loosen the bolts (25) from the guiding plate (24) and remove it. Unscrew the yoke bars (23) out of the valve 9. Screw the yoke bars (23) into the valve body (01) as indicated. Place the guiding plate (24) on the designated
body (01). Unscrew gland bolting/nuts (15 & 16) and remove them. Remove the gland (14) and packing follower area located at the stem (05) . Secure the guiding plate (24) with the bolting (25).
(13). 10. For manual operated valves screw the yoke sleeve (27) together with the needle bearing(s) (30) on the stem
6. Unscrew the nut (21) from the bonnet (02) and unscrew the lock nut (20) from the body (01), while securing the (05).
stem (05) in place in order to prevent it from damaging. 11. Place the yoke flange (26) on top of the yoke bars (23) and secure them with the hexagon socket bolts (28).
7. After the lock nut (20) has been removed, lower the stem (05) and bonnet (02) down into the body (01). Now 12. For manual operated valves turn the yoke sleeve (27) against the yoke flange (26), place the parallel key and
remove the spacer ring (18) and gasket (17), together with the bonnet (02) and stem (05), by pulling the stem handwheel (29) and secure it with the handwheel nut.
(05) out of the valve body (01). 13. Pressurise the system and check the packing (12) and bonnet (02) for signs leakage.
8. Dis-assemble the “disc assembly” by removing the pin from the disc holder (06). Afterwards you can rotate the
first disc-part (03) 90°, so the lip will clear the disc holder (06).
1. Thoroughly clean all parts with solvent and a clean cloth. Important:
2. Examine the following parts for signs of damage, i.e. pitting, erosion or scratches: After starting up the system, once the valve has reached its working temperature and pressure, It is
recommended to tighten the bolts (22) into the retaining ring (21) to force the bonnet into the gasket (17)
for optimum sealing.
D. BONNET (02) - Sealing surface
14. In case leakage is observed through the packing (12), tighten the nuts (16) of the gland bolts (15) carefully until
the leaking stops. In case leakage through the bonnet (02) is observed, tighten the bolts (22) located in the lock
nut (21).


HP Valves BV

2½” & 3” AND ≥ 900 LBS / 65mm & 80mm AND ≥ PN100

HP Valves BV

DISASSEMBLY & ASSEMBLY PARALLEL SLIDE GATE VALVE, Fig. KJP 3. Lubricate all threaded parts with high temperature grease, i.e. Molykote HSC.
4. Install the first disc (105) into the disc holder (113) and mount the disc hanger (142) in the designated slot
2½” & 3” AND ≥ 900 LBS / 65mm & 80mm AND ≥ PN100 located in the disc (105) slide the conical springs (140) over the guide pin (141) and place the pin assembly into
the corresponding socket located in the first disc (105). Afterwards place the second disc (105) and lower the
disc hanger (142) in the designated slot located in the disc (105), now install the stem (109) into the disc holder
2. For manual operated valves remove hand wheel nut (133), hand wheel (170), parallel key and needle bearing (113) to finalise the complete disc assembly.
(014). 5. Place the stem (109) and disc assembly (113) in the valve body (101), make sure the seats (104) are not damaged
For valves with a Gearbox or Electric Actuator, remove the Actuator, by unscrewing the bolts from the lower side during this process.
of the yoke flange (126). 6. Place the bonnet (102) over the stem (109). Install a NEW gasket (003) into the valve body (101), with the gasket
3. Unscrew the hexagon socket screws (01C) from the top flange (126). ring (114) on top of it.
4. For manual operated valves screw the yoke sleeve (127) together with the needle bearing (014) from the stem 7. Install the segmental ring (117) in the designated area located in the valve body (101), Make sure the
(109). segments are located at such place, there is a segment placed in front of each disassembly hole.
5. Unscrew the pillars (125) from the valve body (101). Loosen the bolts (01J-02J) from the guiding plate (119) and 8. Pull the stem (109) towards the top of the valve and lower the retaining ring (118) into the valve body (101).
remove it. Unscrew gland bolting/nuts (01B-02B) and remove them. Remove the gland (123) and packing Screw the bolts (01A-02A) into the bonnet (102) and tighten them.
follower (122).
9. Place packing (004) over the stem (109) into the bonnet (102). Place the packing follower (122) over the stem
6. Unscrew the bolts (01A-02A) from the retaining ring (118) and remove the retaining ring (118) from the bonnet
(109) and install the gland flange (123) over the stem (109). Now install the gland bolting (01B-02B) and evenly
(102), while securing the stem (109) in place in order to prevent it from damaging.
tighten the nuts (02B) preventing contact between the stem (109) & packing follower (122).
7. After the retaining ring (118) is removed, lower the stem (109) and bonnet (102) down into the body (101). Now
remove the segmental ring (117) by tapping a punch tool through the designated disassembly holes provided in 10. Place the guiding plate (119) on the designated area located at the stem (109) and secure the guiding plate (119)
the bonnet area of the valve body (101), afterwards the gasket ring (114) and gasket (003), together with the with the bolting (01J-02J).
bonnet (102) and stem (109)can be removed, by pulling the stem (109) from the valve body (101). 11. Screw the yoke bars (125) into the valve body (101).
8. Dis-assemble the “disc assembly” by unscrewing the disc holder (113) from the stem (109). Afterwards remove 12. For manual operated valves screw the yoke sleeve (127) together with the needle bearing(s) (014) on the stem
the disc hanger (142) and take the discs (105) out of the disc holder (113). (109).
13. Place the yoke flange (126) on top of the yoke bars (125) and secure them with the hexagon socket bolts (01C).
INSPECTION PRIOR TO RE-ASSEMBLY 14. For manual operated valves rotate the yoke sleeve (127) against the yoke flange (126), place the needle bearing
(014), parallel key, handwheel (170) and secure it with the handwheel nut (133).
2. Examine the following parts for signs of damage, i.e. pitting, erosion or scratches: 15. Pressurise the system and check the packing (004) and bonnet (102) for signs of leakage.
A. SEATS (104) - Sealing surface

C. DISCS (105) - Sealing surface
D. BONNET (102) - Sealing surface
Important:
recommended to tighten the bolts (01A-02A) into the retaining ring (118) to force the bonnet (102) into the
gasket (003) for optimum sealing.
16. In case leakage is observed through the packing (004), tighten the nuts (01B-02B) carefully until the leaking
stops. In case leakage through the bonnet (102) is observed, tighten the bolts (01A-02A) located in retaining ring
(118).

HP Valves BV

≥ 4” AND ≥ 900 LBS / ≥ 100mm AND ≥ PN100

HP Valves BV

≥ 4” AND ≥ 900 LBS / ≥ 100mm AND ≥ PN100 3. Lubricate all threaded parts with high temperature grease, i.e. Molykote HSC.
4. Install the first disc (105) into the disc holder (113), install the disc pin(s) (140) and springs (141) and place them
1. Caution, before any attempt is made to disassemble, verify that the valve is sufficiently cooled down, into the corresponding socket located in the first disc (105). Afterwards place the second disc (105), now install
depressurised, isolated from system pressure and secured against accidental pressurisation. the disc guide (142) to finalise the complete disc assembly.
2. For gearbox / motor operated valves remove the gearbox / actuator (019), by unscrewing the bolts from the
5. Slide the complete disc assembly (113) onto the stem (109).
lower side of the adapter plate (127) and rotating the gearbox / actuator (019) clockwise to unscrew it from the
6. Place the bonnet (102) over the stem (109) and lower it into the valve body (101). Install a NEW gasket (003) into
stem (109).
3. Unscrew bolts (01C) from the yoke flange (126). the valve body (101), with the gasket ring (114) on top of it.
4. Unscrew the yoke bars (125) out of the valve body (101). Loosen the bolts (01J-02J) from the guiding plate (119) 7. Insert the retainer (117) in the designated groove. Pull the stem (109) towards the top of the valve and install the
and remove it. Unscrew gland bolting/nuts (01B-02B) and remove them. Remove the gland flange (123) and retainer ring (118) by placing it on top of the bonnet (102). Install the bolts (01D-02D) and (01A-02A) onto the
packing follower (122). body (101) and tighten them.
5. Unscrew the bolts (01A-02A) and (01D-02D from the retaining plate (118) and remove it from the body (101), 8. Place packing ring (121) and packing (004) over the stem (109) into the bonnet (102). Place the packing follower
while securing the stem (109) in place in order to prevent it from damaging. (122) over the stem (109). Place the gland flange (123) over the stem (109) and install the gland bolting (01B-
6. After the retaining plate (118) has been removed, lower the stem (109) and bonnet (102) down into the body 02B). Evenly tighten the nuts (02B) preventing contact between the stem (109) & packing follower (122).
(101). Now remove the retainer (117) by tapping a punch tool through the designated holes provided in the 9. Place the guiding plate (119) on the designated area located at the stem (109) and secure the guiding plate (119)
bonnet area of the valve body (101). with the bolting (01J-02J).
7. Remove the gasket ring (114) and the gasket (003), together with the bonnet (102) and stem (109), by pulling 10. Screw the yoke bars (125) into the valve body (101).
the stem (109) out of the valve body (101).
11. Place the yoke flange (126) on top of the yoke bars (125) and secure them with the hexagon socket bolts (01C).
8. Dis-assemble the “disc assembly” by removing the disc holder (113) from the stem (109). Afterwards remove the
12. Install the adapter plate (127) and finally install the gearbox / actuator (019) by rotating it counter clockwise.
disc guide (142) and slide both discs (105) from the disc holder (113). It is important to mark the disc position
(upstream / downstream). 13. In case of actuator operated valves, make sure to reset the limit switches.
14. Pressurise the system and check the packing (004) and bonnet gasket (003) for signs of leakage.

Important:
A. SEATS (104) - Sealing surface
C. DISCS (105) - Sealing surface
D. BONNET (102) - Sealing surface gasket (003) for optimum sealing.
15. In case leakage is observed through the packing (004), tighten the nuts (02B) of the gland bolts (01B) carefully
until the leaking stops. In case leakage through the bonnet (102) is observed, tighten the bolts (01A-02A) located
on top of the retaining plate (118).
IN CASE SEVERE DAMAGE IS OBSERVED, USE 16. The valve is now ready for use.

HP Valves BV

DISASSEMBLY & ASSEMBLY SWING CHECK VALVE, Fig. KDP 1. Caution, before any attempt is made to disassemble, verify that the valve is sufficiently cooled down,
2. Unscrew the nuts (02A) from the retaining plate (118) and remove the retaining plate (118) from the
≤ 6” AND ≥ 900 LBS / ≤ 150mm AND ≥ PN100
3. valve body (101).
6. Unscrew the bolt(s) (01R) from the seat ring (104) and remove the complete disc assembly (105) together with
the disc arm (180) and bearing block (185) from the valve body (101).
7. Remove the collar pin (193) and unscrew the disc nut (189) to remove the disc (105) from the disc arm (180).
8. Remove the dowel pin(s) (195) prior to removing the hinge pin (190) from the bearing block (185).
B. DISC (105) - Sealing surface
C. BONNET (102) - Sealing surface
D. BEARING BLOCK (192) - Bore surface
E. HINGE PIN (190) - Hinge surface
4. Place the disc arm (180) in the bearing block (185) and slide the hinge pin washer(s) (192) in place.
5. Now insert the hinge pin (190) through the bearing block (185) and disc arm (180) and secure the hinge pin by
tapping the dowel pin(s) (195) in place.
6. Place the disc (105) into the disc arm (180) and secure it with the disc nut (189), washer (186) and collar pin
(193).
7. Insert the complete disc assembly (105) into the valve body (101). Secure the bearing block (185) hand tight to
the seat ring (104) using the bolt(s) (01R), now gently tap the dowel pin(s) (195) into the seat ring (104) to align
the bearing block (185) correct against the seat ring (103) and tighten the bolt(s) (01R).
8. Insert the bonnet (102) into the valve body (101).
9. Install a NEW gasket (003) and insert the gasket ring (114) on top of it.
11. Insert the bolts (01A) in the bonnet (102). Place the retaining plate (118) on top of the valve body (101). Now
tighten the nuts (02A) to force the bonnet (102) into the gasket (003).
12. Pressurise the system and check the bonnet (102) for signs of leakage.
Important:
After starting up the system, once the valve has reached its working temperature and pressure, It is recommended to
tighten the bolts (02A) into the retaining ring (118) to force the bonnet (102) into the gasket (003) for optimum sealing.
13. In case leakage of the bonnet (102) is observed, tighten the nuts (02A).

HP Valves BV

8” AND ≥ 900 LBS / ≤ 150mm AND ≥ PN100 2. Unscrew the nuts (02A) from the retaining plate (118) and remove the retaining plate (118) from the valve body
(101).
5. Unscrew the bolt(s) (01R) from the bearing block (185) and remove the complete disc assembly (105) together
with the disc arm (180) and bearing block (185) from the valve body (101).
7. Remove the dowel pin(s) (195) prior to removing the hinge pin (190) from the bearing block (185).
D. BEARING BLOCK (185) - Bore surface
E. HINGE PIN (190) - Hinge surface
4. Place the disc arm (180) in the bearing block (185) and slide the hinge pin washer(s) (192) in place. Now insert
the hinge pin (190) through the bearing block (185) and disc arm (180) and secure the hinge pin by tapping the
dowel pin(s) (195) in place.
5. Place the disc (105) into the disc arm (180) and secure it with the disc nut (189), washer (186) and collar pin
(193).
6. Insert the complete disc assembly (105) into the valve body (101). Secure the bearing block (185) hand tight to
the seat ring (104) using the bolt(s) (01R) completed with washer(s) 03R).
7. Gently tap the dowel pins (195) into the valve body (101) to align the bearing block (185) correct against the
valve body (101) and tighten the bolt(s) (01R) in star pattern,
11. Insert the bolts (01A) through the retaining plate (118). Place the retaining plate (118) on top of the valve body
(101). Screw the bolts (01A) into the bonnet (102) and place the nuts (02A).
12. Tighten the nuts (02A) to force the bonnet (102) into the gasket (003).
Important:
tighten the bolts (02A) into the retaining ring (118) to force the bonnet into the gasket (003) for optimum sealing.

HP Valves BV

≥10” AND ≥ 900 LBS / ≥ 250mm AND ≥ PN100 2. Unscrew the nuts (02A) from the retaining plate (118) and remove the retaining plate (118) from the valve body
(101).
4. Remove the gasket ring (114), gasket (003-1) and the bonnet (102) from the valve body (101).
5. Loosen the plug nut (181) approximately 10mm and gently tap the plug bolt (183) into the valve body (101). Now
unscrew the plug bolt retainer (182) by loosening the bolting (01W-02W) and remove it together with the plug
bolt (183) and the plug bolt gasket (003-2) from the valve body (101).
6. Repeat step 5 for the opposite plug bolt (183) as well.
7. Gently tap the dowel pin (195) from the disc arm (180) in order to separate the hinge pin (190) from the disc arm
(180).
8. Now gently tap the hinge pin (190) from the valve body. Ensure the disc (105) is protected from damaging whilst
removing the hinge pin (190).
9. Remove the complete disc assembly (105) together with the disc arm (180) from the valve body (101).

HP Valves BV

DISASSEMBLY & ASSEMBLY SWING CHECK VALVE, Fig. KDP
≥10” AND ≥ 900 LBS / ≥ 250mm AND ≥ PN100

Important:
1. Thoroughly clean all parts with solvent and a clean cloth. tighten the nuts (02A) / (181) to force the bonnet (102) / plug bolts (183) into the gasket (003-1 & 003-2) for optimum
2. Examine the following parts signs of damage, i.e. pitting, erosion or scratches: sealing.

B. DISC (105) - Sealing surface 14. In case leakage of the bonnet (102) is observed, tighten the nuts (02A). In case leakage of the plug bolt(s) (183) is
C. BONNET (102) - Sealing surface observed, tighten the plug nuts (181).
D. BEARING BLOCK (185) – Bore surface 15. The valve is now ready for use.
E. HINGE PIN (190) – Hinge surface
3. Lubricate all threaded parts with high temperature grease, i.e. Molykote HCS.
4. Place the disc (105) into the disc arm (180) and secure it with the disc nut (189), washer (188) and collar pin (193).
5. Insert the complete disc assembly (105) into the valve body (101). Install the hinge pin (190) in to the valve body
(101) and through the disc arm (180).
6. Gently tap the dowel pin (195) into the disc arm (180) and through the hinge pin (190) in order to secure the hinge
pin (190) to the disc arm (180).
8. Install a NEW gasket (003-1) and insert the gasket ring (114) on top of it.
9. Place the segmental ring (117) into the valve body (101). Make sure the segments are located at such place, there
is a segment placed in front of each disassembly hole.
(101). Screw the bolts (01A) into the bonnet (102) and place the nuts (02A).
11. Tighten the nuts (02A) to force the bonnet (102) into the gasket (003-1).
12. Install both plug bolt(s) (183) in the valve body (101) and insert NEW plug gasket(s) (003-2). Now screw the plug
bolt retainer(s) (182) in place and screw the plug nut(s) (181) to the plug bolt(s) (183).
13. Pressurise the system and check both the bonnet (102) and the plug bolt(s) (183) for signs of leakage.

HP Valves BV

DISASSEMBLY & ASSEMBLY TILTING DISC CHECK VALVE, Fig. KDP 1. Caution, before any attempt is made to disassemble, verify that the valve is sufficiently cooled down,
2. Unscrew the nuts (116) from the retaining plate (107) and remove the retaining plate (107) from the valve body
≥6” AND ≥ 900 LBS / ≥ 150mm AND ≥ PN100
(101).
5. Loosen the plug nut (108) approximately 10mm and gently tap the plug bolt (111) into the valve body (101). Now
unscrew the plug bolt retainer (109) by loosening the bolting (117-118) and remove it together with the plug bolt
(111), plug bolt gasket (114), hinge pin (121) and washer (112) from the valve body (101).
6. Repeat step 5 for the opposite hinge pin (121) as well.
7. Ensure the disc (104) is protected from damaging whilst removing the hinge pin(s) (121).

D. HINGE PIN (121) - Hinge surface
3. Lubricate all threaded parts with high temperature grease, i.e. Molykote HCS. REPLACEMENT PARTS INSTEAD!
4. Insert the complete disc assembly (104) into the valve body (101).
5. Install the washer(s) (112) and gently tap the hinge pin(s) (121) into the disc (104), check the disc (104) for free
movement.
9. Insert the bolts (115) through the retaining plate (107). Place the retaining plate (107) on top of the valve body
(101). Screw the bolts (115) into the bonnet (102) and place the nuts (116).
10. Tighten the nuts (116) to force the bonnet (102) into the gasket (113).
11. Insert NEW plug gasket(s) (114) over the hinge pin(s) (121. Now screw the plug bolt retainer(s) (109) in place by
evenly tightening bolting (117-118) and screw the plug nut(s) (108) to the plug bolt(s) (111).
12. Pressurise the system and check both the bonnet (102) and the hinge pin(s) (121) for signs of leakage.
Important:
After starting up the system, once the valve has reached its working temperature and pressure, it is recommended to
tighten the nuts (116/108) to force the bonnet (102) / hinge pin(s) (121) into the gasket (113/114) for optimum sealing.
13. In case leakage of the bonnet (102) is observed, tighten the nuts (116). In case leakage of the hinge pin(s) (121) is
observed, tighten the plug nuts (108).

HP Valves BV

DISASSEMBLY & ASSEMBLY PISTON CHECK VALVE, Fig. KDP 1. Caution, before any attempt is made to disassemble, verify that the valve is sufficiently cooled down,
2. Unscrew the nuts (02A) from the retaining plate (118).
≥6” AND ≥ 900 LBS / ≥ 150mm AND ≥ PN100
3. Remove the retaining plate (118) from the valve body (101).
4. Lower the bonnet (102) into the valve body (101) and remove the segmental ring (117)), by tapping a punch tool
5. Now the bonnet (102), gasket ring (114), gasket (003) and disc (103) can be removed from the valve body (101).


C. DISC (103) - Sealing surface IN CASE SEVERE DAMAGE IS OBSERVED, USE
4. Insert the disc (103) into the valve body (101).
5. Insert the bonnet (102), NEW gasket (003) and gasket ring (114) into the valve body (101).
6. Lower the bonnet (102) into the valve body (101) and install the segmental ring (117) into the valve body (101).
Make sure the segments are located at such place, there is a segment placed in front of each disassembly hole.
(101). Screw the bolts (01A) into the bonnet (102) and tighten them evenly with the nuts (02A) in order to force
the bonnet (102) into the gasket (003).
8. Pressurise the system and again tighten the nuts (02A).
Important:
tighten the bolts (02A) to force the bonnet (102) into the gasket (003) for optimum sealing.

HP Valves BV

DISASSEMBLY & ASSEMBLY GLOBE AND STOP/CHECK VALVE, Fig. KGP 1. Caution, before any attempt is made to disassemble, verify that the valve is sufficiently cooled down,
2. Remove the gearbox / actuator (019), by unscrewing the bolts from the lower side of the yoke flange (126) and
CAST STEEL ≥ 6” AND ≥ 900 LBS / ≥ 150mm AND ≥ PN100
rotating the gearbox / actuator (019) clockwise to unscrew it from the stem (109).
3. Unscrew the hexagon bolts (01C) from the yoke flange (126).
4. Unscrew the yoke bars (125) from the valve body (101).
5. Remove the guidingplate (119) from the stem (109) by unscrewing the hexagon socket bolts (01J-02J).
6. Unscrew gland bolting/nuts (01B-02B) and remove them. Remove the gland flange (123) and packing follower
(122).
7. Unscrew the hexagon bolts (01H) from the retaining plate (116) and remove the retaining plate (116) by
unscrewing it from the bonnet (102), while securing the stem (109) in place in order to prevent it from
damaging.
8. After the retaining plate (116) has been removed, lower the stem (109) and bonnet (102) down into the body
(101). Now remove the segmental ring (117) by tapping a punch tool through the designated holes provided in
the bonnet area of the valve body (101).
9. Remove the gasket ring (114) and the gasket (003), together with the bonnet (102) and stem (109), by pulling the
stem (109) out of the valve body (101).
10. In case of a stop/check valve, the plug (106) shall be removed separately from the valve body (101).

HP Valves BV

DISASSEMBLY & ASSEMBLY GLOBE AND STOP/CHECK VALVE, Fig. KGP
CAST STEEL ≥ 6” AND ≥ 900 LBS / ≥ 150mm AND ≥ PN100
INSPECTION PRIOR TO RE-ASSEMBLY Important:

tighten the bolts (01H) into the retaining ring (116) to force the bonnet (102) into the gasket (003) for optimum sealing.
A. SEAT (101) - Sealing surface 14. In case leakage is observed through the packing (009), tighten the nuts (02B) of the gland bolts (01B) carefully
B. STEM (109) - Packing area until the leaking stops. In case leakage through the bonnet gasket (003) is observed, tighten the hexagon bolts
C. PLUG (106) - Sealing surface (01H) located on top of the retaining ring (116).
D. BONNET (102) – Sealing surface 15. The valve is now ready for use..

4. Insert the plug (106) into the valve body(101) and slide the stem (109) into the plug (106).
the valve body (101), with the gasket ring (114) on top of it.
6. Insert the segmental ring (117) in the designated groove. Make sure the segments are located at such place,
7. Pull the stem (109) towards the top of the valve and install the retaining plate (116) by mounting it to the bonnet
(102). Install the hexagon bolts (01H) into the retaining plate (116) and tighten them evenly.
8. Place the NEW packing (004) over the stem (109) into the bonnet (102). Place the packing follower (122) over
the stem (109). Place the gland flange (123) over the stem (109) and install the gland bolting (01B / 02B). Evenly
tighten the nuts (02B) preventing contact between the stem (109) & gland (122).
9. Place the guiding plate (119) on the designated area located at the stem (109) and secure the guiding plate (119)
with the bolting (01J-02J).
10. Screw the yoke bars (125) into the valve body (101) and place the yoke flange (126) on top of the yoke bars (125)
and secure them with the hexagon socket bolts (01C).
11. Install the adapter and finally install the gearbox / actuator (019) by rotating it counter clockwise.
12. In case of actuator operated valves, make sure to reset the limit switches according to the OEM manual.
13. Pressurise the system and check the packing (009) and gasket (003) for signs of leakage.

HP Valves BV

DISASSEMBLY & ASSEMBLY GLOBE AND STOP/CHECK VALVE, Fig. KYP 1. Caution, before any attempt is made to disassemble, verify that the valve is sufficiently cooled down,
FORGED STEEL ≥ 6” AND ≥ 900 LBS / ≥ 150mm AND ≥ PN100 2. Remove the gearbox / actuator (019), by unscrewing the bolts from the lower side of the yoke flange (126) and
rotating the gearbox / actuator (019) clockwise to unscrew it from the stem (109).
3. Unscrew yoke bar bolts (01C) from the yoke flange (126).
4. Unscrew the yoke bars (125) from the valve body (101).
5. Remove the guiding plate (119) from the stem by unscrewing the hexagon socket bolts (01J-02J).
6. Unscrew gland bolting/nuts (01B-02B) and remove them. Remove the gland flange (123) and packing follower
(122).
7. Unscrew the bonnet nuts (01A-02A) from the retaining plate (118) and remove the retaining plate (118) from the
body (101), while securing the stem (109) in place in order to prevent it from damaging.
8. After the retaining plate (118) is removed, lower the stem (109) and bonnet (102) down into the body (101).
Now remove the segmental ring (117) by tapping a punch tool through the designated holes provided in the
bonnet area of the valve body (101).
9. Remove the gasket ring (114) and the gasket (003), together with the bonnet (102) and stem (109), by pulling the
stem (109) out of the valve body (101).
10. In case of a stop/check valve, the plug (106) shall be removed separately from the valve body (101).

HP Valves BV

DISASSEMBLY & ASSEMBLY GLOBE AND STOP/CHECK VALVE, Fig. KYP
FORGED STEEL ≥ 6” AND ≥ 900 LBS / ≥ 150mm AND ≥ PN100

Important:
2. Examine the following parts for signs of damage, i.e. pitting, erosion or scratches: tighten the bolts (01A-02A) into the retaining ring (118) to force the bonnet (102) into the gasket (003) for optimum

B. STEM (109) - Packing area 14. In case leakage is observed through the packing (009), tighten the nuts (02B) of the gland bolts (01B) carefully
C. PLUG (106) - Sealing surface until the leaking stops. In case leakage through the bonnet gasket (003) is observed, tighten the bolts (02A)
D. BONNET (102) – Sealing surface located on top of the retaining plate (118).

4. Insert the plug (106) into the valve body(101) and slide the stem (109) into the plug (106).
the valve body (101), with the gasket ring (114) on top of it.
7. Pull the stem (109) towards the top of the valve and install the retaining plate (118) by placing it over the bonnet
(102). Install the bolts (01A-02A) into the body (101) and tighten them evenly using the nuts (02A).
8. Place the NEW packing (009) over the stem (109) into the bonnet (102). Place the packing follower (122) over
the stem (109). Place the gland flange (123) over the stem (109) and install the gland bolting (01B-02B). Evenly
tighten the nuts (02B) preventing contact between the stem (109) & packing follower (122).
9. Place the guiding plate (119) on the designated area located at the stem (109) and secure the guiding plate (119)
with the bolting (01J-02J).
10. Screw the yoke bars (125) into the valve body (101) and place the yoke flange (126) on top of the yoke bars (125)
and secure them with the hexagon socket bolts (01C).
11. Install the adapter plate (127) and finally install the gearbox / actuator (019) by rotating it counter clockwise.
12. In case of actuator operated valves, make sure to reset the limit switches according to the OEM manual.
13. Pressurise the system and check the packing (009) and gasket (003) for signs of leakage.

HP Valves BV

DISASSEMBLY & ASSEMBLY DOUBLE DISC GATE VALVE, Fig. KJP
≥ 6” AND ≥ 900 LBS / ≥ 150mm AND ≥ PN100

HP Valves BV

DISASSEMBLY & ASSEMBLY DOUBLE DISC GATE VALVE, Fig. KJP
≥ 6” AND ≥ 900 LBS / ≥ 150mm AND ≥ PN100 3. Lubricate all threaded parts with high temperature grease, i.e. Molykote HCS.
4. Place the bonnet (102) over the stem (109). Install a NEW gasket (003) into the valve body (101), with the gasket
ring (114) on top of it.
1. Caution, before any attempt is made to disassemble, verify that the valve is sufficiently cooled down, there is a segment placed in front of each disassembly hole.
depressurised, isolated from system pressure and secured against accidental pressurisation. 6. Pull the stem (109) towards the top of the valve and install the retaining ring (118) by placing it over the bonnet
2. For manual operated valves remove hand wheel nut (133), handwheel (170), parallel key and needle bearing (102). Install the bolts (01A-02A) into the body (101) and tighten them evenly using the nuts (02A).
(014). 7. Place a NEW packing (004) and packing ring (121) over the stem (109) into the bonnet (102). Place the packing
For valves with a Gearbox or Electric Actuator, remove the Actuator, by unscrewing the bolts from the lower side follower (122) over the stem (109). Place the gland flange (123) over the stem (109) and install the gland bolting
of the yoke flange (126) and rotate the Gearbox or Electric Actuator clockwise. (01A-02A). nly tighten the nuts (02A) preventing contact between the stem (109) & packing follower (122).
3. Unscrew hexagon socket screws (01C) from the yoke flange (126). 8. Screw the yoke bars (125) into the valve body (101) as indicated.
4. For manual operated valves screw the yoke sleeve (127) together with the needle bearing (014) from the stem 9. For manual operated valves screw the yoke sleeve (127) together with the needle bearing(s) (014) on the stem
(109). (109).
5. Unscrew the stands (125) out of the valve body (101). Unscrew the gland bolting/nuts (01B-02B) and remove 10. Place the yoke flange (126) on top of the yoke bars (125) and secure them with the hexagon socket bolts (01C).
them. Remove the gland flange (123) and packing follower (122) from the stem (109). 11. For manual operated valves rotate the yoke sleeve (127) against the yoke flange (126), place the needle bearing
6. Unscrew the bolts (01A-02A) from the retaining ring (118) and remove the retaining ring (118) from the bonnet (014), parallel key, handwheel (170) and secure it with the handwheel nut (133).
(102), while securing the stem (109) in place in order to prevent it from damaging. 12. Pressurise the system and check the packing (004) and gasket (003) for signs of leakage.
7. After the retaining ring (118) has been removed, lower the stem (109) and bonnet (102) down into the body
(101). Now remove the segmental ring (117) by tapping a punch tool through the designated holes provided in
the bonnet area of the valve body (101).
8. Remove the gasket ring (114) and gasket (003), together with the bonnet (102) and stem (109), by pulling the
stem (109) from the valve body (101).
Important:
1. Thoroughly clean all parts with solvent and a clean cloth. gasket (003) for optimum sealing.
A. SEAT (104) - Sealing surface 13. In case leakage is observed through the packing (004), tighten the nuts (02B) of the gland bolts (01B) carefully
B. STEM (109) - Packing area until the leaking stops. In case leakage through the bonnet (102) is observed, tighten the nuts (02A) located in
C. DISC(S) (105) - Sealing surface retaining ring (118).
D. BONNET (102) – Sealing surface 14. The valve is now ready for use.


HP Valves BV

DISASSEMBLY & ASSEMBLY BALANCER ON PARALLEL SLIDE GATE VALVE
Standard configuration of the Configuration of the balancer for

balancer for parallel slide gate valves parallel slide gate valves during

HP Valves BV

DISASSEMBLY & ASSEMBLY BALANCER ON PARALLEL SLIDE GATE VALVE 9. In case leakage is observed through the gaskets (104 & 105), tighten the nuts (02A) of the bolts (01A) carefully
until the leaking stops.
1. Caution, before any attempt is made to disassemble, verify that the valve is sufficiently cooled down, 10. The valve is now ready for use.
2. Unscrew the nuts (02A) from the bolts (01A) to loosen the plug flanges (103).
3. Remove both plug flanges (103) and gently push the disc (102) out of the valve body (101) using a punch.
4. Remove all gasket residue (104 & 105) from both the valve body (101) and the plug flange (103) mating surfaces. SPECIAL NOTE
When during hydrostatic testing the main parallel gate valve is considered as a pressure barrier, the balancer can be
equipped with special dummy components in order to block-off any hydrostatic test fluid.
Instalment of dummy balancer internals should be performed in the same order as aforementioned, however
without installing the disc (102). Please take notice of the orientation of dummy balancer parts and install the parts
as needed for the applicable situation during hydrostatic testing.
A. BODY (101) – Cleanliness
When reassembling the balancer in its original or hydrostatic testing configuration, it is mandatory to always install
new gaskets (104 & 105).
C. PLUG FLANGE (103) - Sealing surface
Please contact our dedicated sales team for your quotation of spare parts and/or dummy balancer internals.

4. Insert the disc (102) inside the valve body (101) whilst ensuring the disc (102) is free to move from side to side.
5. Place new gaskets (104 & 105) on the plug flanges (103).
6. Install the plug flanges (103) on the valve body (101) and locate the nuts (02A) on the bolts (01A).
7. Tighten the nuts (02A) in a star pattern applying 95Nm.
8. Pressurise the system and check the gaskets (104 & 105) for signs of leakage.
Important:
recommended to tighten the nuts (02A) on bolts (01A) for optimum sealing.

HP Valves BV

DISASSEMBLY & ASSEMBLY CONTROL VALVE
≥ 4” AND ≥ 300 LBS / ≥ 100mm AND ≥ PN40
LBV Control Valve ≥ 4” AND ≥ 300 LBS.

Fig.02
LBV Control Valve ≥ 4” AND ≥ 300 LBS.

Fig.01

HP Valves BV

DISASSEMBLY & ASSEMBLY CONTROL VALVE 1. Caution, before any attempt is made to disassemble, verify that the valve is sufficiently cooled down,
≥ 4” AND ≥ 300 LBS / ≥ 100mm AND ≥ PN40 2. For valves fitted with Pneumatic Actuator, remove the Actuator (500), by disconnecting the air supply and
disconnect all auxiliaries (i.e. solenoid valves, positioner, etc.).
3. Afterwards unscrew the bolts from the coupling (205).
4. Now unscrew the bolts from the lower side of the yoke flange (102) and carefully lift the Pneumatic Actuator
from the valve.
5. Unscrew the gland nuts (01B) and remove them. Remove the gland flange (123) and packing follower (122) from
the stem (110).
6. Unscrew all bonnet bolts/nuts (01B/02A) and remove them.
7. Carefully lift the bonnet (102) including the stem (110) and plug (108) from the valve body (101), make sure to
lift this assembly in a straight line to prevent damage from occurring to the plug (108) and cage (112).
8. Remove the stem (110) from the bonnet (102) by sliding it out towards the bottom.
9. Remove the packing (04), optional lantern ring and packing ring (121) from the bonnet (102) by tapping them
out with a drift from the bottom side of the bonnet (102).
10. Remove the bonnet gasket (03A) and the cage gasket (03C) from the valve body (101).
11. Remove the cage (112) together with the seat ring (104) and the seat ring gasket (03B) from the valve body
(101). On large control valves the cage (112) is provided with threaded holes, designated for installation of eye
bolts / lifting eyes.
1. Thoroughly clean all parts with solvent and a clean cloth and remove gasket residue from mating- and recess
surfaces.
A. SEAT RING (104) - Sealing an Gasket surface

B. CAGE (112) – Inside surface and ports.
LBV Control Valve ≥ 4” AND ≥ 300 LBS. C. PISTON RING (05) - Sealing surface
D. STEM (110) - Packing area
Fig.03 E. DISC (108) - Sealing surface
F. BONNET (102) – Sealing surface


HP Valves BV

DISASSEMBLY & ASSEMBLY CONTROL VALVE
≥ 4” AND ≥ 300 LBS / ≥ 100mm AND ≥ PN40 Valve Pressure Class Recommended Torque
< 600 LBS (PN 100) 11 +/- 3 Nm

3. Measure cage (112) clearance by performing the following measurements:
≥ 600 LBS (PN 100) 19 +/- 3 Nm
A. Assemble the trim without installing the stem (110), plug (108) and all gaskets.
B. Place a straight edge on top of the body-bonnet flange and measure the distance between the body-
bonnet flange and the top of the cage. Record this measurement.
C. Measure the height of the compression lip provided on the bonnet. Record this measurement as well. 16. After starting up the system, once the valve has reached its working temperature and pressure, It is
D. The first measurement should at least equal or exceed the second measure by 0~0.25mm. recommended to tighten the gland bolting (01B-02B).
In case measurements fail to comply the above stated, the HP Valves service coordinator should be
consulted for instructions.
4. Remove all assembled trim from the valve body (101). After removal install a new seat gasket (03B) and place NOTE: In case the valve is equipped with PTFE type packing, special installation instructions are applicable. These
the seat ring (104) on top of it whilst making sure it fits neatly in place. instructions will be provided in case required.
5. Insert the cage (112) into the valve body (101) and locate it over the raised lip provided on the seat ring (104).
Make sure to arrange the cage ports in such manner, they are not directly in line with the valve inlet connection. 17. Place the pneumatic actuator (500) on top of the yoke flange (102) and screw in the bolts from the lower side of
Afterwards install a new cage gasket (03C) on top of the cage (112). the yoke flange (102) into the pneumatic actuator (500).
6. Lubricate all threaded parts with high temperature grease, i.e. Molykote HCS. 18. Afterwards ensure the valve disc (108) is in contact with the valve seat (104) and lower the pneumatic actuator
7. Install the stem (110) and the disc (108) without the piston rings (05) by lowering it inside the cage (112). It is piston rod to install the bolts to the stem coupling (205) and tighten them applying the following torque values.
recommended to check the sealing capabilities of the disc (108) on the seat ring (104) by applying engineering
blue and check for a positive seat print. In case sealing is found to be insufficient, the disc (108) should be lapped Screw Size Recommended Torque
on the seat ring (104) surface until satisfactory seating is achieved. After lapping all parts should be thoroughly
cleaned again. M8 x 1.0 20 Nm
8. Install new piston rings (05) in the designated slots provided in the disc (108). Make sure to perform this step
with caution, since the piston rings (05) are fragile and easy to snap when handled without special care. M10 x 1.0 40 Nm
9. Install the stem (110) and the disc (108) completed with the piston rings (05) by lowering it inside the cage (112).
10. Place a new bonnet gasket (03A) on top of the valve body-bonnet flange and carefully lower the bonnet (102)
over the stem (110) until it is flush with the valve body (101) and the bonnet compression lip is located on top of
19. Reconnect all auxiliaries (i.e. solenoid valves, positioner, etc.) and perform a functional test.
the cage (112).
20. Pressurise the system and check the packing (04) and bonnet gasket (03A) for signs of leakage.
11. Lubricate all bonnet studs (01A) and hand tighten the bonnet nuts (02A).
21. In case leakage is observed through the packing (04), tighten the nuts (02B) of the gland bolts (01B) carefully
12. Operate the valve by moving the stem (110) up and down several times, in order to ensure all trim parts are
until the leaking stops. In case leakage through the bonnet (102) is observed, tighten the nuts (02A).
properly aligned.
13. Fully tighten the bonnet nuts (02A) in a “star” pattern, whilst applying the correct torque value (reference is
made to table 1). Afterwards ensure the valve body (101) is in metal-to-metal contact with the bonnet (102) all
way around.
14. Slide the new packing (04) over the stem (110) and insert it inside the stuffing box provided in the bonnet (102).
If a valve is equipped with a lantern ring, this lantern ring should be placed on top of the first 2 or 3 packing rings
and followed by the remaining 2 or 3 packing rings. During instalment of the packing rings (04) it is important to Important:
regularly compress the packing rings (04) using a tamping tool. Upon installation of all packing rings (04) a visual After starting up the system, once the valve has reached its working temperature and pressure, It is recommended to
confirmation for clear signs of contact between the packing (04) and the stem (110) is mandatory. tighten the bolts (01A-02A) to force the bonnet (102) to the bonnet gasket (03A) for optimum sealing.
15. Install the packing follower (122) and the gland flange (123) sliding it over the stem (110). Lubricate the gland
nuts (01B) and gland bolts (02B) and tighten them applying the mentioned torque values.


Date : 4 May 2023
Revision : 00
Chapter B
Installation, Operation and Maintenance Manual Electric Actuators

Multi-turn actuators
SA 07.2 – SA 16.2/SAR 07.2 – SAR 16.2
Control unit: electromechanic
with actuator controls
AUMATIC AC 01.2 Intrusive
Control
→ Parallel
Profibus DP
Modbus
Foundation Fieldbus
Operation instructions Assembly, operation, commissioning

SA 07.2 – SA 16.2/SAR 07.2 – SAR 16.2 Control unit: electromechanic
Table of contents AC 01.2 Intrusive
Read operation instructions first.

● Observe safety instructions.
● These operation instructions are part of the product.
● Preserve operation instructions during product life.
● Pass on instructions to any subsequent user or owner of the product.
Purpose of the document:

This document contains information for installation, commissioning, operation and maintenance staff. It is intended
to support device installation and commissioning.
Reference documents:
● Manual (Operation and setting) AUMATIC AC 01.2 Parallel
Reference documents can be downloaded from the Internet (www.auma.com) or ordered directly from AUMA
(refer to <Addresses>).
Table of contents Page

1. Safety instructions................................................................................................................. 5
1.1. Basic information on safety 5
1.2. Range of application 5
1.3. Applications in Ex zone 22 (option) 6
1.4. Warnings and notes 6
1.5. References and symbols 7
2. Identification........................................................................................................................... 8
2.1. Name plate 8
2.2. Short description 9
3. Transport, storage and packaging........................................................................................ 11
3.1. Transport 11
3.2. Storage 11
3.3. Packaging 11
4. Assembly................................................................................................................................ 12
4.1. Mounting position 12
4.2. Handwheel fitting 12
4.3. Multi-turn actuator: mount to valve/gearbox 12
4.3.1 Output drive types B, B1 – B4 and E 12
4.3.1.1 Multi-turn actuator (with output drive types B1 – B4 or E): mount to valve/gearbox 13
4.3.2 Output drive type A 13
4.3.2.1 Stem nut: finish machining 14
4.3.2.2 Multi-turn actuator (with output drive type A): mount to valve 15
4.4. Accessories for assembly 16
4.4.1 Stem protection tube for rising valve stem 16
4.5. Mounting positions of local controls 16
4.5.1 Mounting positions: modify 17
5. Electrical connection............................................................................................................. 18
5.1. Basic information 18
5.2. Connection with AUMA plug/socket connector 19
5.2.1 Terminal compartment: open 20
5.2.2 Cable connection 20
5.2.3 Terminal compartment: close 22
2
AC 01.2 Intrusive Table of contents
5.3. Accessories for electrical connection 22

5.3.1 Controls mounted to wall bracket 22
5.3.2 Parking frame 23
5.3.3 Protection cover 23
5.3.4 Double sealed intermediate frame 24
5.3.5 Earth connection, external 24
6. Operation................................................................................................................................ 25
6.1. Manual operation 25
6.1.1 Manual operation: engage 25
6.1.2 Manual operation: disengage 25
6.2. Motor operation 25
6.2.1 Local actuator operation 25
6.2.2 Actuator operation from remote 26
6.3. Menu navigation via push buttons (for settings and indications) 27
6.3.1 Menu layout and navigation 27
6.4. User level, password 28
6.4.1 Password entry 29
6.4.2 Password change 29
6.5. Language in the display 30
6.5.1 Change language 30
7. Indications.............................................................................................................................. 32
7.1. Indications during commissioning 32
7.2. Indications in the display 32
7.2.1 Feedback indications from actuator and valve 33
7.2.2 Status indications according to AUMA classification 36
7.2.3 Status indications according to NAMUR recommendation 37
7.3. Mechanical position indicator/running indication 38
7.4. Indication lights 39
8. Signals..................................................................................................................................... 40
8.1. Status signals via output contacts (digital outputs) 40
8.1.1 Assignment of outputs 40
8.1.2 Encoding of outputs 40
8.2. Analogue signals 40
9. Commissioning (basic settings)........................................................................................... 41
9.1. Type of seating: set 41
9.2. Switch compartment: open 42
9.3. Torque switching: set 43
9.4. Limit switching: set 43
9.4.1 End position CLOSED (black section): set 44
9.4.2 End position OPEN (white section): set 44
9.5. Intermediate positions: set 45
9.5.1 Running direction CLOSE (black section): set 45
9.5.2 Running direction OPEN (white section): set 45
9.6. Test run 46
9.6.1 Direction of rotation: check 46
9.6.2 Limit switching: check 47
9.6.3 Reference operation position feedback: perform 47
9.7. Potentiometer setting 48
9.8. Electronic position transmitter RWG: set 48
3
Table of contents AC 01.2 Intrusive
9.9. Mechanical position indicator: set 49

9.10. Switch compartment: close 50
10. Corrective action.................................................................................................................... 51
10.1. Faults during commissioning 51
10.2. Fault indications and warning indications 51
10.3. Fuses 55
10.3.1 Fuses within the actuator controls 55
10.3.2 Motor protection (thermal monitoring) 56
11. Servicing and maintenance................................................................................................... 58
11.1. Preventive measures for servicing and safe operation 58
11.2. Maintenance 58
11.3. Disposal and recycling 59
12. Technical data......................................................................................................................... 60
12.1. Features and functions of actuator 60
12.2. Features and functions of actuator controls 62
12.3. Service conditions 65
12.4. Accessories 65
12.5. Further information 65
13. Spare parts............................................................................................................................. 66
13.1. Multi-turn actuators SA 07.2 – SA 16.2/SAR 07.2 – SAR 16.2 66
13.2. Actuator controls AUMATIC AC 01.2 68
14. Certificates.............................................................................................................................. 70
14.1. Declaration of Incorporation and EC Declaration of Conformity 70
15. Index........................................................................................................................................ 71
Addresses............................................................................................................................... 73
4
AC 01.2 Intrusive Safety instructions
1. Safety instructions
1.1 Basic information on safety
Standards/directives AUMA products are designed and manufactured in compliance with recognised
standards and directives. This is certified in a Declaration of Incorporation and an
EC Declaration of Conformity.
The end user or the contractor must ensure that all legal requirements, directives,
guidelines, national regulations and recommendations with respect to assembly,
electrical connection, commissioning and operation are met at the place of installation.
Safety instructions/war- All personnel working with this device must be familiar with the safety and warning
nings instructions in this manual and observe the instructions given. Safety instructions
and warning signs on the device must be observed to avoid personal injury or property
damage.
Qualification of staff Assembly, electrical connection, commissioning, operation, and maintenance must
be carried out exclusively by suitably qualified personnel having been authorised by
the end user or contractor of the plant only.
Prior to working on this product, the staff must have thoroughly read and understood
these instructions and, furthermore, know and observe officially recognised rules
regarding occupational health and safety.
Commissioning Prior to commissioning, it is important to check that all settings meet the requirements
of the application. Incorrect settings might present a danger to the application, e.g.
cause damage to the valve or the installation. The manufacturer will not be held
liable for any consequential damage. Such risk lies entirely with the user.
Operation Prerequisites for safe and smooth operation:

● Correct transport, proper storage, mounting and installation, as well as careful
commissioning.
● Only operate the device if it is in perfect condition while observing these instruc-
tions.
● Immediately report any faults and damage and allow for corrective measures.
● Observe recognised rules for occupational health and safety.
● Observe the national regulations.
● During operation, the housing warms up and surface temperatures > 60 °C may
occur. To prevent possible burns, we recommend checking the surface tempe-
rature using an appropriate thermometer and wearing protective gloves, if re-
quired, prior to working on the device.
Protective measures The end user or the contractor are responsible for implementing required protective
measures on site, such as enclosures, barriers, or personal protective equipment
for the staff.
Maintenance To ensure safe device operation, the maintenance instructions included in this manual
must be observed.
Any device modification requires prior consent of the manufacturer.
1.2 Range of application
AUMA multi-turn actuators are designed for the operation of industrial valves, e.g.
globe valves, gate valves, butterfly valves, and ball valves.
Other applications require explicit (written) confirmation by the manufacturer.
The following applications are not permitted, e.g.:

● Industrial trucks according to EN ISO 3691
● Lifting appliances according to EN 14502
● Passenger lifts according to DIN 15306 and 15309
● Service lifts according to EN 81-1/A1
5
Safety instructions AC 01.2 Intrusive
● Escalators
● Continuous duty
● Buried service
● Permanent submersion (observe enclosure protection)
● Potentially explosive areas, with the exception of zone 22
● Radiation exposed areas in nuclear power plants
No liability can be assumed for inappropriate or unintended use.
Observance of these operation instructions is considered as part of the device's
designated use.
Information These operation instructions are only valid for the "clockwise closing" standard
version, i.e. driven shaft turns clockwise to close the valve.
1.3 Applications in Ex zone 22 (option)
Actuators of the indicated series basically meet the requirements for applications in
dust hazardous locations of ZONE 22 in compliance with the ATEX directive 94/9/EC.
The actuators are designed to meet enclosure protection IP 68 and fulfil the
requirements of EN 50281-1-1:1998 section 6 - Electrical apparatus for use in
presence of combustible dust, requirements for category 3 electrical equipment -
protected by enclosures.
To comply with all requirements of EN 50281-1-1:1998, it is imperative that the
following points are observed:
● In compliance with the ATEX directive 94/9/EC, the actuators must be equipped
with an additional identification – II3D IP6X T150 °C.
● The maximum surface temperature of the actuators, based on an ambient
temperature of +40 °C in accordance with EN 50281-1-1 section 10.4, is +150
°C. In accordance with section 10.4, an increased dust deposit on the equipment
was not considered for the determination of the maximum surface temperature.
● The correct connection of the thermoswitches or the PTC thermistors as well
as fulfilling the requirements of the duty type and the technical data are prere-
quisites for compliance with the maximum surface temperature of devices.
● The connection plug may only be plugged in or pulled out when device is dis-
connected from the mains.
● The cable glands used also have to meet the requirements of category II3 D
and must at least comply with enclosure protection IP 67.
● The actuators must be connected by means of an external ground connection
(accessory part) to the potential compensation or integrated into an earthed
piping system.
● The threaded plug (part no. 511.0) or the stem protection tube with protective
cap (part nos. 568.1 and 568.2) for sealing the hollow shaft must imperatively
be mounted to guarantee tightness and therefore the combustible dust hazard
protection.
● As a general rule, the requirements of EN 50281-1-1 must be respected in dust
hazardous locations. During commissioning, service, and maintenance, special
care as well as qualified and trained personnel are required for the safe opera-
tion of actuators.
1.4 Warnings and notes
The following warnings draw special attention to safety-relevant procedures in these

operation instructions, each marked by the appropriate signal word (DANGER,
WARNING, CAUTION, NOTICE).
Indicates an imminently hazardous situation with a high level of risk. Failure

to observe this warning could result in death or serious injury.
6
AC 01.2 Intrusive Safety instructions
Indicates a potentially hazardous situation with a medium level of risk. Failure

to observe this warning could result in death or serious injury.
Indicates a potentially hazardous situation with a low level of risk. Failure to

observe this warning may result in minor or moderate injury. May also be used
with property damage.
Potentially hazardous situation. Failure to observe this warning may result in

property damage. Is not used for personal injury.
Arrangement and typographic structure of the warnings
Type of hazard and respective source!

Potential consequence(s) in case of non-observance (option)
→ Measures to avoid the danger
→ Further measure(s)
Safety alert symbol warns of a potential personal injury hazard.

The signal word (here: DANGER) indicates the level of hazard.
1.5 References and symbols
The following references and symbols are used in these instructions:
Information The term Information preceding the text indicates important notes and information.
Symbol for CLOSED (valve closed)

Symbol for OPEN (valve open)
Important information before the next step. This symbol indicates what is required
for the next step or what has to be prepared or observed.
Via the menu to parameter
Describes the path within the menu to the parameter. By using the push buttons of
the local controls you may quickly find the desired parameter in the display.
<> Reference to other sections
Terms in brackets shown above refer to other sections of the document which provide
further information on this topic. These terms are either listed in the index, a heading
or in the table of contents and may quickly be found.
7
Identification AC 01.2 Intrusive
2. Identification
2.1 Name plate
Each device component (actuator, controls, motor) is equipped with a name plate.
Figure 1: Arrangement of name plates
[1] Actuator name plate

[2] Controls name plate
[3] Motor name plate
[4] Additional plate, e.g. KKS plate (Power Plant Classification System)
Description of actuator name plate

Figure 2: Actuator name plate (example)
[1] Name of manufacturer

[2] Address of manufacturer
[3] Type designation (see explanation below)
[4] Commission number (see explanation below)
[5] Actuator series number (see explanation below)
[6] Output speed
[7] Torque range in direction CLOSE
[8] Torque range in direction OPEN
[9] Lubricant type – [10] enclosure protection
[11] Permissible ambient temperature
[12] Can be assigned as an option upon customer request
[13] Can be assigned as an option upon customer request
8
AC 01.2 Intrusive Identification
Type designation Figure 3: Type designation (example)
1. Type and size of actuator

2. Flange size
Type and size
These instructions apply to the following devices types and sizes:
Multi-turn actuators for open-close duty: SA 07.2, 07.6, 10.2, 14.2, 14.6, 16.2
Multi-turn actuators for modulating duty: SAR 07.2, 07.6, 10.2, 14.2, 14.6, 16.2
Commission number An order-relevant commission number (order number) is assigned to each device.
This commission number can be used to directly download the wiring diagram (in
German and English language), inspection records and further information regarding
the device from the Internet: http://www.auma.com. For some details, the customer
number might be required.
Actuator series number

Table 1: Description of series number (with example)
05 12 M D 12345
1st + 2nd position: Assembly in week
05 In our example: Week 05
3rd + 4th position: Year of production
12 In our example: Year of production: 2012
All other positions
M D 12345 Internal works number for unambiguous product identification
Description of cntrols name plate

Figure 4: Controls name plate
[1] Type designation

[2] Commission number
[3] Wiring diagram
[4] Control
Type designation AC 01.2 = Actuator controls AUMATIC

Wiring diagram The 9th position in the TPA wiring diagram: Position transmitter (actuator)
Control unit: electromechanical:
0 = without position transmitter
A, B, J, K, L, N, R, T = potentiometer
C, D, E, G, H, M, P, S, U = RWG (electronic position transmitter)
Control
24 V DC = Control via parallel interface at 24 V DC control voltage
115 V AC = Control via parallel interface at 115 V AC control voltage
0/4 – 20 mA = Control via parallel interface via analogue input 0/4 – 20 mA
2.2 Short description
Multi-turn actuator Definition in compliance with EN ISO 5210:
9
Identification AC 01.2 Intrusive
A multi-turn actuator is an actuator which transmits to the valve a torque for at least
one full revolution. It is capable of withstanding thrust.
AUMA multi-turn actuators are driven by an electric motor and are capable of
withstanding thrust in combination with output drive type A. For manual operation,
a handwheel is provided. Switching off in end positions may be either by limit or
torque seating. Controls are required to operate or process the actuator signals.
Actuator controls The AUMATIC actuator controls are used to operate AUMA actuators and are supplied
ready for use. The controls may be mounted directly to the actuator or separately
on a wall bracket.
The functions of the AUMATIC controls include standard valve control in OPEN -
CLOSE duty, positioning, process control, logging of operating data right through to
diagnostic functions.
Local controls/AUMA Operation, setting, and display can be performed on site directly at the controls.
ToolSuite When set to local control, it is possible to
● operate the actuator via the local controls (push buttons and display) and perform
settings (contents of these instructions).
● read in or out data or modify and save settings via the AUMA ToolSuite software
(option), using a computer (laptop or PC). The connection between computer
and AUMATIC is wireless via Bluetooth interface (not included in these instruc-
tions).
Intrusive - Non-Intrusive ● Intrusive version (control unit: electromechanical):
Limit and torque setting is performed via switches in the actuator.
● Non-Intrusive version (control unit: electronic):
Limit and torque setting is performed via the controls, actuator and controls
housings do not have to be opened. For this purpose, the actuator is equipped
with an MWG (magnetic limit and torque transmitter), also supplying analogue
torque feedback signals/torque indication and analogue position feedback si-
gnals/position indication.
10
AC 01.2 Intrusive Transport, storage and packaging
3. Transport, storage and packaging

3.1 Transport
For transport to place of installation, use sturdy packaging.
Hovering load!
Risk of death or serious injury.
→ Do NOT stand below hovering load.
→ Attach ropes or hooks for the purpose of lifting by hoist only to housing and NOT
to handwheel.
→ Actuators mounted on valves: Attach ropes or hooks for the purpose of lifting
by hoist to valve and NOT to actuator.
→ Actuators mounted to gearboxes: Attach ropes or hooks for the purpose of lifting
by hoist only to the gearbox using eyebolts and NOT to the actuator.
→ Actuators mounted to controls: Attach ropes or hooks for the purpose of lifting
by hoist only to the actuator and NOT to the controls.
3.2 Storage
Danger of corrosion due to inappropriate storage!

→ Store in a well-ventilated, dry room.
→ Protect against floor dampness by storage on a shelf or on a wooden pallet.
→ Cover to protect against dust and dirt.
→ Apply suitable corrosion protection agent to uncoated surfaces.
Damage on display caused by temperatures below permissible level!

→ The AUMATIC actuator controls must NOT be stored below –30 °C.
Long-term storage If the device must be stored for a long period (more than 6 months) the following
points must be observed in addition:
1. Prior to storage:
Protect uncoated surfaces, in particular the output drive parts and mounting
surface, with long-term corrosion protection agent.
2. At an interval of approx. 6 months:
Check for corrosion. If first signs of corrosion show, apply new corrosion protec-
tion.
3.3 Packaging
Our products are protected by special packaging for transport when leaving the
factory. The packaging consists of environmentally friendly materials which can easily
be separated and recycled. We use the following packaging materials: wood,
cardboard, paper, and PE foil. For the disposal of the packaging material, we
recommend recycling and collection centres.
11
Assembly AC 01.2 Intrusive
4. Assembly
4.1 Mounting position
AUMA actuators and actuator controls can be operated without restriction in any
mounting position.
4.2 Handwheel fitting

Information For transport purposes, handwheels from a diameter of 400 mm are supplied sepa-
rately.
Figure 5: Handwheel
[1] Spacer
[2] Input shaft
[3] Handwheel
[4] Circlip
1. If required, fit spacer [1] onto input shaft [2].

2. Slip handwheel [3] onto input shaft.
3. Secure handwheel [3] using the circlip [4] supplied.
4.3 Multi-turn actuator: mount to valve/gearbox
Danger of corrosion due to damage to paint finish and condensation!

→ Touch up damage to paint finish after work on the device.
→ After mounting, connect the device immediately to electrical mains to ensure
that heater minimises condensation.
4.3.1 Output drive types B, B1 – B4 and E

Application ● For rotating, non-rising valve stem
● Not capable of withstanding thrust
Design Output drive bore with keyway:
● Types B1 – B4 with bore according to ISO 5210
● Types B and E with bore according to DIN 3210
● Later change from B1 to B3, B4, or E is possible.
12
AC 01.2 Intrusive Assembly
Figure 6: Output drive
[1] Output drive types B, B1 – B4, E and C

[2] Output drive sleeve/output drive plug sleve with bore and keyway
[3] Circlip
Information Spigot at flanges should be loose fit.
4.3.1.1 Multi-turn actuator (with output drive types B1 – B4 or E): mount to valve/gearbox
1. Check if mounting flanges fit together.

2. Check whether bore and keyway match the input shaft.
3. Apply a small quantity of grease to the input shaft.
4. Place multi-turn actuator.
Information: Ensure that the spigot fits uniformly in the recess and that the
mounting faces are in complete contact.
5. Fasten multi-turn actuator with screws according to table.
Information: We recommend applying liquid thread sealing material to the
screws to avoid contact corrosion.
6. Fasten screws crosswise to a torque according to table.
Table 2: Tightening torques for screws

Screws Tightening torque TA [Nm]
Threads Strength class 8.8
M8 25
M10 51
M12 87
M16 214
M20 431
4.3.2 Output drive type A

Application ● Output drive for rising, non-rotating valve stem
● Capable of withstanding thrust
Information To adapt the actuators to output drive types A available on site with flanges F10 and
F14 (year of manufacture: 2009 and earlier), an adapter is required. The adapter
can be ordered from AUMA.
13
4.3.2.1 Stem nut: finish machining
✔ This working step is only required if stem nut is supplied unbored or with pilot
bore.
Figure 7: Design of output drive type A
[1] Stem nut

[2] Bearing
[2.1] Bearing race
[2.2] Bearing rim
[3] Spigot ring
1. Remove spigot ring [3] from output drive.

2. Remove stem nut [1] together with bearings [2].
3. Remove bearing races [2.1] and bearing rims [2.2] from stem nut [1].
4. Drill and bore stem nut [1] and cut thread.
Information: When fixing in the chuck, make sure stem nut runs true!
5. Clean the machined stem nut [1].
6. Apply sufficient Lithium soap EP multi-purpose grease to bearing rims [2.2] and
bearing races [2.1], ensuring that all hollow spaces are filled with grease.
7. Place greased bearing rims [2.2] and bearing races [2.1] onto stem nut [1].
8. Re-insert stem nut [1] with bearings [2] into output drive.
Information: Ensure that dogs or splines are placed correctly in the keyway of
the hollow shaft.
9. Screw in spigot ring [3] until it is firm against the shoulder.
14
4.3.2.2 Multi-turn actuator (with output drive type A): mount to valve
Figure 8: Assembly with output drive type A
[1] Valve stem

[2] Output drive type A
[3] Screws to actuator
[4] Valve flange
[5] Screws to output drive
1. If the output drive type A is already mounted to the multi-turn actuator: Loosen
screws [3] and remove output drive type A [2].
2. Check if the flange of output drive type A matches the valve flange [4].
3. Apply a small quantity of grease to the valve stem [1].
4. Place output drive type A on valve stem and turn until it is flush on the valve
flange.
5. Turn output drive type A until alignment of the fixing holes.
6. Screw in fastening screws [5], however do not completely tighten.
7. Fit multi-turn actuator on the valve stem so that the stem nut dogs engage into
the output drive sleeve.
➥ The flanges are flush with each other if properly engaged.
8. Adjust multi-turn actuator until alignment of the fixing holes.
9. Fasten multi-turn actuator with screws [3].
10. Fasten screws [3] crosswise with a torque according to table.
Table 3: Tightening torques for screws

Screws Tightening torque TA [Nm]
Threads Strength class 8.8
M6 11
M8 25
M10 51
M12 87
M16 214
M20 431
11. Turn multi-turn actuator with handwheel in direction OPEN until valve flange
and output drive A are firmly placed together.
12. Tighten fastening screws [5] between valve and output drive type A crosswise
applying a torque according to table.
15
4.4 Accessories for assembly
4.4.1 Stem protection tube for rising valve stem

— Option —
Figure 9: Assembly of the stem protection tube
[1] Cap for stem protection tube

[2] Stem protection tube
[3] Sealing ring
1. Seal thread with hemp, Teflon tape, or thread sealing material.

2. Screw stem protection tube [2] into thread and tighten it firmly.
3. Push down the sealing ring [3] onto the housing.
4. Check whether cap for stem protection tube [1] is available and in perfect con-
dition.
4.5 Mounting positions of local controls
The mounting position of the local controls is selected according to the order. If, after
mounting the actuator to the valve or the gearbox on site, the local controls are in
an unfavourable position, the mounting position can be changed at a later date. Four
mounting positions are possible.
Figure 10: Mounting positions A and B
16
Figure 11: Mounting positions C and D
4.5.1 Mounting positions: modify
Hazardous voltage!
Risk of electric shock.
→ Disconnect device from the mains before opening.
Electrostatic discharge ESD!

Risk of damage to electronic components.
→ Earth both operators and devices.
1. Loosen screws and remove the local controls.

2. Check whether O-ring is in good condition, correctly insert O-ring.
3. Turn local controls into new position and re-place.
Cable damage due to twisting or pinching!

Risk of functional failures.
→ Turn local controls by a maximum of 180°.
→ Carefully assemble local controls to avoid pinching the cables.
4. Fasten screws evenly crosswise.
17
Electrical connection AC 01.2 Intrusive
5. Electrical connection
5.1 Basic information
Danger due to incorrect electrical connection

Failure to observe this warning can result in death, serious injury, or property damage.
→ The electrical connection must be carried out exclusively by suitably qualified
personnel.
→ Prior to connection, observe basic information contained in this chapter.
→ After connection but prior to applying the voltage, observe the <Commissioning>
and <Test run> chapters.
Wiring diagram/terminal
The pertaining wiring diagram/terminal plan (in German and English language) is
plan attached to the device in a weather-proof bag, together with these operation
instructions. It can also be obtained from AUMA (state commission no., refer to name
plate) or downloaded directly from the Internet (www.auma.com).
Permissible networks
The controls (actuators) are suitable for for use in TN and TT networks with directly
(supply networks) earthed star point and a maximum voltage of 690 V AC. Use in IT networks is
permitted while observing the respective <Protection on site> for for maiximum supply
voltages of 600 V AC.
Protection on site
For short-circuit protection and for disconnecting the actuator from the mains, fuses
and disconnect switches have to be provided by the customer.
The current values for respective sizing is derived from the current consumption of
the motor (refer to electrical data sheet) plus the current consumption of the controls.
Table 4: Current consumption controls

Mains voltage Max. current consumption
Permissible variation of the mains voltage ±10 % –30 %
100 to 120 V AC 750 mA 1,200 mA
208 to 240 V AC 400 mA 750 mA
380 to 500 V AC 250 mA 400 mA
515 to 690 V AC 200 mA 400 mA
Table 5: Maximum permissible protection

Switchgear Rated power max. protection
Reversing contactor A1 up to 1.5 kW 16 A (gL/gG)
Reversing contactor A2 up to 7.5 kW 32 A (gL/gG)
Reversing contactor A3 up to 11 kW 63 A (gL/gG)
Thyristor up to 1.5 kW 16 A (g/R) I²t<1,500A²s
Thyristor up to 3 kW 32 A (g/R) I²t<1,500A²s
Thyristor up to 5.5 kW 63 A (g/R) I²t<5,000A²s
If controls are mounted separately from actuator (controls on wall bracket): Consider
length and cross section of connecting cable when defining the protection required.
Use appropriate insulation monitors when working in power installations, for example
an insulation monitor measuring the pulse code.
Power supply for the
In case of external supply of the controls (electronics): The external power supply
controls (electronics) must have a reinforced insulation against the mains voltage in accordance with IEC
61010-1 and may only be supplied by a circuit limited to 150 VA in accordance with
IEC 61010-1.
Potential of customer All input signals (control) must be supplied with the same potential.
connections All output signals (status signals) must be supplied with the same potential.
18
AC 01.2 Intrusive Electrical connection
Safety standards All externally connected devices shall comply with the relevant safety standards.
Cable installation in ac-
Signal and bus cables are susceptible to interference.
cordance with EMC
Motor cables are interference sources.
● Lay cables being susceptible to interference or sources of interference at the
highest possible distance from each other.
● The interference immunity of signal and bus cables increases if the cables are
laid close to the earth potential.
● If possible, avoid laying long cables and make sure that they are installed in
areas being subject to low interference.
● Avoid long parallel paths with cables being either susceptible to interference or
interference sources.
● For the connection of remote position transmitters, screened cables must be
used.
Type of current, mains Type of current, mains voltage and mains frequency must match the data on the
voltage and mains fre- motor name plate.
quency
Figure 12: Motor name plate (example)
[1] Type of current

[2] Mains voltage
[3] Mains frequency (for 3-ph and 1-ph AC motors)
Connecting cables ● For device insulation, appropriate (voltage-proof) cables must be used. Specify
cables for the highest occurring rated voltage.
● Use connecting cable with appropriate minimum rated temperature.
● For connecting cables exposed to UV radiation (outdoor installation), use UV
resistant cables.
5.2 Connection with AUMA plug/socket connector
Cross sections AUMA plug/socket connector:
● Power terminals (U1, V1, W1, U2, V2, W2): max. 6 mm² flexible/10 mm² solid
●
PE connection : max. 6 mm² flexible/10 mm² solid
● Control contacts (1 to 50): max. 2.5 mm²
19
5.2.1 Terminal compartment: open
Figure 13: Connection AUMA plug/socket connector, version S
[1] Cover
[2] Screws for cover
[3] O-ring
[4] Screws for socket carrier
[5] Socket carrier
[6] Cable entry
[7] Blanking plug
[8] Cable gland (not included in delivery)
Hazardous voltage!
1. Loosen screws [2] and remove cover [1].

2. Loosen screws [4] and remove socket carrier [5] from cover [1].
3. Insert cable glands [8] suitable for connecting cables.
➥ The enclosure protection IP... stated on the name plate is only ensured if suitable
cable glands are used. Example: Name plate shows enclosure protection IP
68.
4. Seal unused cable entries [6] with suitable blanking plugs [7].
5. Insert the cables into the cable glands [8].
5.2.2 Cable connection
✔ Observe permissible cross sections.

1. Remove cable sheathing.
2. Strip wires.
3. For flexible cables: Use end sleeves according to DIN 46228.
4. Connect cables according to order-related wiring diagram.
20
In case of a fault: Hazardous voltage while protective earth conductor is NOT

connected!
→ Connect all protective earth conductors.
→ Connect PE connection to external protective earth conductor of connecting
cables.
→ Start running the device only after having connected the protective earth con-
ductor.
5. Tighten PE conductors firmly to PE connection using ring lugs (flexible cables)

or loops (rigid cables).
Figure 15: PE connection
[1] Socket carrier

[2] Screw
[3] Washer
[4] Lock washer
[5] Protective earth with ring lugs/loops
[6] PE connection, symbol:
Danger of corrosion: Damage due to condensation!

→ After mounting, commission the device immediately to ensure that heater mini-
mises condensation.
Information Some actuators are equipped with an additional motor heater. The motor heater
minimises condensation within the motor and improves the start-up behaviour for
extremely low temperatures.
21
5.2.3 Terminal compartment: close
Figure 16: Example: Version S
[1] Cover
[2] Screws for cover
[3] O-ring
[4] Screws for socket carrier
[5] Socket carrier
[6] Cable entry
[7] Blanking plug
[8] Cable gland (not included in delivery)
Short-circuit due to pinching of cables!

Risk of electric shock and functional failures.
→ Carefully fit socket carrier to avoid pinching the cables.
1. Insert the socket carrier [5] into the cover [1] and fasten with screws [4].
2. Clean sealing faces of cover [1] and housing.
3. Check whether O-ring [3] is in good condition, replace if damaged.
4. Apply a thin film of non-acidic grease (e.g. petroleum jelly) to the O-ring and
insert it correctly.
5. Fit cover [1] and fasten screws [2] evenly crosswise.
6. Fasten cable glands [8] applying the specified torque to ensure the required
enclosure protection.
5.3 Accessories for electrical connection
— Option —
5.3.1 Controls mounted to wall bracket
The wall bracket allows separate mounting of controls and actuator.
Application ● If the actuator cannot be accessed.
● If the actuator is subjected to high temperatures.
● In case of heavy vibration of the valve.
22
Design Figure 17: Design principle with wall bracket
[1] Wall bracket

[2] Connecting cables
[3] Electrical connection of wall bracket (XM)
[4] Electrical connection of actuator (XA)
[5] Electrical connection of controls (XK) – customer connector
Observe prior to ● Permissible length of connecting cables: max. 100 m.
connection ● If the actuator is equipped with a position transmitter (RWG): Connecting cables
must be available as shielded version.
● Versions with potentiometer in the actuator are not suitable.
● We recommend: AUMA cable set LSW1.
● If the AUMA cable set is not used: Use suitable flexible and screened connecting
cables.
● When using connecting cables, e.g. of the heater or switch, requiring direct wiring
from the actuator to the XK customer connector (XA-XM-XK, refer to wiring
diagram), these connecting cables must be subject to an insulation test in
compliance with EN 50178. Connecting cables of position transmitters (RWG,
IWG, potentiometer) do not belong to this group. They may not be subject to
an insulation test.
5.3.2 Parking frame
Application Parking frame for safe storage of a disconnected plug.
For protection against touching the bare contacts and against environmental
influences.
Figure 18: Parking frame
5.3.3 Protection cover

Protection cover for plug compartment when plug is removed.
23
The open terminal compartment can be closed using a protective cover (not
illustrated).
5.3.4 Double sealed intermediate frame
When removing the electrical connection or due to leaky cable glands, ingress of
dust and water into the housing may occur. This is prevented effectively by inserting
the double sealed intermediate frame [2] between the plug/socket connector [1] and
the housing of the device. The enclosure protection of the device (IP 68) will not be
affected, even if the electrical connection [1] is removed.
Figure 19: Electrical connection with double sealed intermediate frame
[1] Electrical connection

[2] Double sealed intermediate frame
5.3.5 Earth connection, external

As an option, the housing is equipped with an external earth connection (U-bracket)
to connect the device to the equipotential earth bonding.
Figure 20: Earth connection
24
AC 01.2 Intrusive Operation
6. Operation
Valve damage due to incorrect basic setting!

→ Prior to electrical operation of the actuator, the basic settings i.e. type of seating,
torque and limit switching have to be completed.
6.1 Manual operation

For purposes of setting and commissioning, in case of motor failure or power failure,
the actuator may be operated manually. Manual operation is engaged by an internal
change-over mechanism.
6.1.1 Manual operation: engage
Damage at the motor coupling due to faulty operation!

→ Engage manual operation only during motor standstill.
1. Press push button.
2. Turn handwheel in desired direction.

→ To close the valve, turn handwheel clockwise:
➥ Drive shaft (valve) turns clockwise in direction CLOSE.
6.1.2 Manual operation: disengage
Manual operation is automatically disengaged when motor is started again. The

handwheel does not rotate during motor operation.
6.2 Motor operation
✔ Perform all commissioning settings and the test run prior to motor operation.
6.2.1 Local actuator operation

Local actuator operation is performed using the push buttons of the local controls of
the AC.
25
Operation AC 01.2 Intrusive
Figure 23: Local controls
[1] Push button for operation command in direction OPEN

[2] Push button STOP
[3] Push button for operation command in direction CLOSE
[4] Push button RESET
[5] Selector switch
Hot surfaces, e.g. possibly caused by high ambient temperatures or strong

direct sunlight!
Danger of burns
→ Check surface temperature and wear protective gloves, if required.
→ Set selector switch [5] to position Local control (LOCAL).
➥ The actuator can now be operated using the push buttons [1 – 3].
- Run actuator in direction OPEN: Press push button [1] .
- Stop actuator: Press push button STOP [2].
- Run actuator in direction CLOSE: Press push button [3] .
Information OPEN - CLOSE operation commands can be given either in push-to-run or in self-
retaining operation mode. In self-retaining mode, the actuator runs to the defined
end position after pressing the button, unless another command has been received
beforehand. For further information, please refer to Manual (Operation and setting).
6.2.2 Actuator operation from remote
→ Set selector switch to position Remote control (REMOTE).
➥ Now, it is possible to operate the actuator via remote control, via operation
commands (OPEN, STOP, CLOSE) or analogue setpoints (e.g. 0 – 20 mA).
Information For actuators equipped with a positioner, it is possible to select between open-close
control (Remote OPEN-CLOSE) and setpoint control (remote SETPOINT). Selec-
tion is made via MODE input, e.g. based on a 24 V DC signal (refer to wiring diagram).
26
6.3 Menu navigation via push buttons (for settings and indications)
Menu navigation for display and setting is made via the push buttons [1 – 4] of the
local controls.
Set the selector switch [5] to position 0 (OFF) when navigating through the menu.
The bottom row of the display [6] serves as navigation support and explains which
push buttons [1 – 4] are used for menu navigation.
Figure 27:
[1–4] Push buttons or navigation support

[5] Selector switch
[6] Display
Table 6: Important push button functions for menu navigation

Push buttons Navigation sup- Functions
port on display
[1] Up ▲ Change screen/selection
Change values
Enter figures from 0 to 9
[2] Down ▼ Change screen/selection
Change values
Enter figures from 0 to 9
[3] Ok Confirm selection
Save Save
Edit Enter <Edit> menu
Details Display more details
[4] C Setup Enter Main menu
Esc Cancel process
Return to previous display
Backlight ● The display is illuminated in white during normal operation. The backlight turns
to red under fault conditions.
● The screen illumination is brighter when operating a push button. If no push
button is operated for 60 seconds, the display will become dim again.
6.3.1 Menu layout and navigation
Groups The indications on the display are divided into 3 groups:
27
Figure 28: Groups
[1] Startup menu

[2] Status menu
[3] Main menu
ID Status menu and main menu are marked with an ID.

Figure 29: Marking with ID
S ID starts with S = status menu

M ID starts with M = main menu
Group selection It is possible to select between status menu S and main menu M:
For this, set selector switch to 0 (OFF), hold down push button C for approx. 2
seconds until a screen containing the ID M... appears.
Figure 30: Select menu groups
You return to the status menu if:

● the push buttons on the local controls have not been operated within 10 minutes
● or by briefly pressing C
Direct display via ID When entering the ID within the main menu, screens can be displayed directly (without
clicking through).
Figure 31: Direct display (example)
Display indicates in the bottom row: Go to

1. Press push button Go to.
Display indicates: Go to menu M0000
2. Use push buttons Up ▲ Down ▼ to select figures 0 to 9.
3. Press push button Ok to confirm first digit.
4. Repeat steps 2 and 3 for all further digits.
5. To cancel the process: Press C Esc.
6.4 User level, password
User level The user level defines which menu items or parameters can be displayed or modified
by the active user.
There are 6 different user levels. The user level is indicated in the top row:
28
Figure 32: User level display (example)
Password A password must be entered to allow parameter modification. The display indicates:
Password 0***
A specific password is assigned to each user level and permits different actions.
Table 7: User levels and authorisations

Designation (user level) Authorisation/password
Observer (1) Verify settings
No password required
Operator (2) Change settings
Default factory password: 0000
Maintenance (3) Reserved for future extensions
Specialist (4) Change device configuration
e.g. type of seating, assignment of output
contacts
Default factory password: 0000
Service (5) Service staff
Change configuration settings
AUMA (6) AUMA administrator
6.4.1 Password entry

Display indicates: Password 0***
1. Select desired menu and hold down push button for approx. 3 seconds.
➥ Display indicates the set user level, e.g Observer (1)
2. Press Up ▲to select a higher user level and press Ok to confirm.
➥ Display shows: Password 0***
3. Use push buttons Up ▲ Down ▼ to select figures 0 to 9.
4. Confirm first digit of password via push button Ok.
5. Repeat steps 1 and 2 for all further digits.
➥ Having confirmed the last digit with Ok, access to all parameters within one
user level is possible if the password entry is correct.
6.4.2 Password change

Only the passwords of same or lower user level may be changed.
Example: The user is signed in as Specialist (4). This authorises him or her to modify
the passwords between user levels (1) to (4).
Device configuration M0053
Service functions M0222
Change passwords M0229
Menu point Service functions M0222 is only visible if user level has been set to
Specialist (4) or higher.
Select main menu 1. Set selector switch to position 0 (OFF).
2. Press push button C Setup and hold it down for approx. 3 seconds.
➥ Display goes to main menu and indicates: ▶ Display...
29
Change passwords 3. Select parameter Change passwords either:

→ click via the menu to parameter, or
→ via direct display: press and enter ID M0229
- Display indicates: ▶ Change passwords
- The user level is indicated in the top row (1 – 6), e.g.:
- For user level 1 (view only), passwords cannot be changed. To change pass-
words, you must change to a higher user level. For this, enter a password via
a parameter.
4. For a user level between 2 and 6: Press push button Ok.
➥ The display indicates the highest user level, e.g.: For user 4
5. Select user level via push buttons Up ▲ Down ▼ and confirm with Ok.
➥ Display indicates: ▶ Change passwords Password 0***
6. Enter current password (→ enter password).
➥ Display indicates: ▶ Change passwords Password (new) 0***
7. Enter new password (→ enter password).
➥ Display indicates: ▶ Change passwords For user 4 (example)
8. Select next user level via push buttons Up ▲ Down ▼ or cancel the process
via Esc.
6.5 Language in the display
The AUMATIC display is multilingual.
6.5.1 Change language
Display... M0009
Language M0049
Change language 3. Press Ok.
➥ Display indicates: ▶ Language
4. Press Ok.
➥ Display indicates the selected language, e.g.: ▶ Deutsch
5. The bottom row of the display indicates:
→ Save → continue with step 10
→ Edit → continue with step 6
6. Press Edit.
➥ Display indicates: ▶ Observer (1)
7. Select user level via Up ▲ Down ▼ resulting in the following significations:
→ black triangle: ▶ = current setting
→ white triangle: ▷ = selection (not saved yet)
8. Press Ok.
➥ Display indicates: Password 0***
30
9. Enter password (→ enter password).

➥ Display indicates: ▶ Language and Save (bottom row)
Language selection 10. Select new language via Up ▲ Down ▼ resulting in the following significati-
ons:
→ black triangle: ▶ = current setting
→ white triangle: ▷ = selection (not saved yet)
11. Confirm selection via Save.
➥ The display changes to the new language.The new language selection is saved.
31
Indications AC 01.2 Intrusive
7. Indications
7.1 Indications during commissioning
LED test When switching on the power supply, all LEDs on the local controls illuminate for
approx. 1 second. This optical feedback indicates that the voltage supply is connected
to the controls and all LEDs are operable.
Figure 36: LED test
Language selection During the self-test, the language selection can be activated so that the selected
language is immediately indicated in the display. For this, set selector switch [5] to
position 0 (OFF).
Activate language selection:
1. Display indicates in the bottom row: Language selection menu? 'Reset'
2. Press push button RESET and hold it down until the following text is displayed
in the bottom line: Language menu loading, please wait.
Figure 37: Self-test
The language selection menu follows the startup menu.

Startup menu The current firmware version is displayed during the startup procedure:
Figure 38: Startup menu with firmware version: 04.00.00–xxxx
If the language selection feature has been activated during the self-test, the menu
for selecting the display language will now be indicated. For further information on
language setting, please refer to chapter <Language in the display>.
Figure 39: Language selection
If no entry is made over a longer period of time (approx. 1 minute), the display
automatically returns to the first status indication.
7.2 Indications in the display
Status bar
The status bar (first row in the display) indicates the operation mode [1], the presence
of an error [2] and the ID number [3] of the current display indication.
32
AC 01.2 Intrusive Indications
Figure 40: Information in the status bar (top)
[1] Operation mode

[2] Error symbol (only for faults and warnings)
[3] ID number: S = Status page
Navigation support If further details or information are available with reference to the display, the following
indications Details or More appear in the navigation support (bottom display row).
Then, further information can be displayed via the push button.
Figure 41: Navigation support (bottom)
[1] shows list with detailed indications

[2] shows further available information
The navigation support (bottom row) is faded out after approx. 3 seconds. Press any
push button (selector switch in position 0 (OFF)) to fade in the navigation support.
7.2.1 Feedback indications from actuator and valve
Display indications depend on the actuator version.

Valve position (S0001)
This indication is only available if a position transmitter (potentiometer, RWG or
MWG) is installed in the actuator.
● S0001 on the display indicates the valve position in % of the travel.
● The bargraph display appears after approx. 3 seconds.
● When issuing an operation command, an arrow indicates the direction
(OPEN/CLOSE).
Figure 42: Valve position and direction of operation
Reaching the preset end positions is additionally indicated via symbols (CLOSED)
and (OPEN).
Figure 43: End position CLOSED/OPEN reached
0% Actuator is in end position CLOSED

100% Actuator is in end position OPEN
33
Torque (S0002)
The indication is only available if the actuator is equipped with an MWG (magnetic
limit and torque transmitter).
● S0002 on the display indicates the torque applied at the actuator output.
● The bargraph display appears after approx. 3 seconds.
Figure 44: Torque
Select unit The push button allows to select the unit displayed (percent %, Newton metre Nm
or pounds per foot Lbs/ft.
Figure 45: Units of torque
Display in percent 100 % indication equals the max. torque indicated on the name plate of the actuator.
Example: SA 07.5 with 20 – 60 Nm.
● 100 % corresponds to 60 Nm of nominal torque.
● 50 % corresponds to 30 Nm of nominal torque.
Operation commands (S0003)
The display S0003 indicates:
● active operation commands, like e.g.: Operation in direction CLOSE or in direc-
tion OPEN
● the actual value E2 as bargraph indication and as value between 0 and 100 %.
● for setpoint control (positioner): setpoint E1
● for stepping mode or for intermediate positions with operation profile: pivot
points and operation behaviour of pivot points
The navigation support (bottom row) is faded out after approx. 3 seconds and the
axis/axes for pivot point display are shown.
OPEN - CLOSE control Active operation commands (OPEN, CLOSE, ...) are shown above the bargraph
display. The figure below shows the operation command in direction CLOSE.
Figure 46: Display for OPEN - CLOSE control
E2 Actual position value
34
Setpoint control If the positioner is enabled and activated, the bargraph indication for E1 (position
setpoint) is displayed.
The direction of the operation command is displayed by an arrow above the bargraph
indication. The figure below shows the operation command in direction CLOSE.
Figure 47: Display for setpoint control (positioner)
E1 Position setpoint
Pivot point axis The pivot points and their operation behaviour (operation profile) are shown on the
pivot point axis by means of symbols.
The symbols are only displayed if at least one of the following functions is activated:
Operation profile M0294
Timer CLOSE M0156
Timer OPEN M0206
Figure 48: Examples: on the left pivot points (intermediate positions); on the right
stepping mode
Table 8: Symbols along the pivot point axis

Symbol Pivot point (intermediate position) Stepping mode
with operation profile
| Pivot point without reaction End of stepping mode
Stop during operation in direction Start of stepping mode in direction
CLOSE CLOSE
Stop during operation in direction Start of stepping mode in direction
OPEN OPEN
Stop during operation in directions –
OPEN and CLOSE
Pause for operation in direction CLOSE –
Pause for operation in direction OPEN –
Pause for operation in directions OPEN –
and CLOSE
Multiport valve positions (S0017)

In case of active multiport valve function, the display S0017 indicates a second
bargraph display with set positions (valve connections) above the actual position
value E2. Positions (P1, P2, ...) are displayed with a black triangle . Push buttons
are used to select positions. Both positions and the actual position value E2 are
displayed in degrees.
35
Figure 49: Status indication for multiport valve (example P4 = 180°)
P (P1, P2, ...) selected position (1, 2, ...)

(– –) no position selected
7.2.2 Status indications according to AUMA classification
These indications are available, if the parameter Diagnostic classific. M0539 is set
to AUMA.
Warnings (S0005)
If a warning has occurred, the display shows S0005:
● the number of warnings occurred
● a blinking question mark after approx. 3 seconds
Figure 50: Warnings
For further information, please also refer to <Corrective action>.

Not ready REMOTE (S0006)
The S0006 display shows indications of the Not ready REMOTE group.
If such an indication has occurred, the display shows S0006:
● the number of indications occurred
● a blinking crossbar after approx. 3 seconds
Figure 51: Not ready REMOTE indications

Fault (S0007)
If a fault has occurred, the display shows S0007:
● the number of faults occurred
● a blinking exclamation mark after approx. 3 seconds
36
Figure 52: Fault

7.2.3 Status indications according to NAMUR recommendation
These indications are available, if the parameter Diagnostic classific. M0539 is set
to NAMUR.
Out of Specification (S0008)
The S0008 indication shows out of specification indications according to NAMUR
recommendation NE 107.
● a blinking triangle with question mark after approx. 3 seconds
Figure 53: Out of specification

Function check (S0009)
The S0009 indication shows function check indications according to NAMUR
If an indication has occurred via the function check, the display shows S0009:
● a blinking triangle with a spanner after approx. 3 seconds
Figure 54: Function check

Maintenance required (S0010)
The S0010 indication shows maintenance indications according to NAMUR
● a blinking square with an oil can after approx. 3 seconds
37
Figure 55: Maintenance required

Failure (S0011)
The S0011 indication shows the causes of the failure indication according to NAMUR
● a blinking circle with a cross after approx. 3 seconds
Figure 56: Failure

7.3 Mechanical position indicator/running indication
— Option —
Mechanical position indicator:
● Continuously indicates the valve position
(For complete travel from OPEN to CLOSED or vice versa, the indicator disc
[2] rotates by approximately 180° to 230°.)
● Indicates whether the actuator is running (running indication)
● Indicates that the end positions are reached (via indicator mark [3])
Figure 57: Mechanical position indicator
[1] Cover
[2] Indicator disc
[3] Mark
[4] Symbol for position OPEN
[5] Symbol for position CLOSED
38
7.4 Indication lights

Figure 58: Arrangement and signification of indication lights
[1] Marking with symbols (standard)

[2] Marking with figures 1 – 6 (option)
1 End position CLOSED reached (blinking: for operation in direction CLOSE)
2 Tc Torque fault CLOSE
3 Motor protection tripped
4 To Torque fault OPEN
5 End position OPEN reached (blinking: for operation in direction OPEN)
6 Bluetooth connection
Modify indication light assignment (indications)
Different indications can be assigned to LEDs 1 – 5.

Local controls M0159
Indication light 1 (left) M0093
Indication light 2 M0094
Indicat. light 5 (right) M0097
Signal interm. pos. M0167
Defaut values (Europe):
Indication light 1 (left) = End p. CLOSED, blink
Indication light 2 = Torque fault CLOSE
Indication light 3 = Thermal fault
Indication light 4 = Torque fault OPEN
Indicat. light 5 (right) = End p. OPEN, blink
Signal interm. pos. = OPEN/CLOSED = Off
Further setting values:
Refer to Manual (Operation and setting).
39
Signals AC 01.2 Intrusive
8. Signals
8.1 Status signals via output contacts (digital outputs)
Characteristics Output contacts are used to send status signals (e.g. reaching the end positions,
selector switch position, faults...) as binary signals to the control room.
Status signals only have two states: active or inactive. Active means that the
conditions for the signal are fulfilled.
8.1.1 Assignment of outputs
The output contacts (outputs DOUT 1 – 12) can be assigned to various signals.
Required user level: Specialist (4) or higher.
I/O interface M0139
Digital outputs M0110
Signal DOUT 1 M0109
Default values:
Signal DOUT 1 = Fault
Signal DOUT 2 = End position CLOSED
Signal DOUT 3 = End position OPEN
Signal DOUT 4 = Selector sw. REMOTE
Signal DOUT 5 = Torque fault CLOSE
Signal DOUT 6 = Torque fault OPEN
Signal DOUT 7 = End position CLOSED
Signal DOUT 8 = End position OPEN
Signal DOUT 9 = Selector sw. REMOTE
Signal DOUT 10 = Torque fault CLOSE
Signal DOUT 11 = Torque fault OPEN
Signal DOUT 12 = Fault
8.1.2 Encoding of outputs
The output signals DOUT 1 – 12 can be set either to high active or low active.
● High active = output contact closed = signal active
● Low active = output contact open = signal active
Required user level: Specialist (4) or higher.
I/O interface M0139
Digital outputs M0110
Coding DOUT 1 M0102
Default values for DOUT 1 – 12: High active
8.2 Analogue signals
— (Option) —
If the actuator is equipped with a position transmitter (potentiometer or MWG), an
analogue feedback signal is available.
Valve position Signal: E2 = 0/4 – 20 mA (galvanically isolated)
Designation in the wiring diagram:
ANOUT1 (position)
ANOUT2 (position)
For further information on this topic, please refer to Manual (Operation and setting).
40
AC 01.2 Intrusive Commissioning (basic settings)
9. Commissioning (basic settings)

1. Set selector switch to position 0 (OFF).
Information: The selector switch is not a mains switch. When positioned to 0

(OFF), the actuator cannot be operated. The controls' power supply is
maintained.
2. Switch on the power supply.
Information: Please consider the heat-up time for ambient temperatures below
–20 °C.
3. Perform basic settings.
9.1 Type of seating: set
Valve damage due to incorrect setting!

→ The type of seating must suit the valve.
→ Only change the setting with prior consent of the valve manufacturer.
Customer settings M0041

Type of seating M0012
End position CLOSED M0086
End position OPEN M0087
Default value: Limit
Setting values:
Limit Seating in end positions via limit switching.
Torque Seating in end positions via torque switching.
Select parameter 3. Select parameter either:
→ click via the menu to parameter, or
→ via direct display: press and enter ID M0086 or M0087
➥ Display indicates: End position CLOSED
CLOSE or OPEN 4. Use Up ▲ Down ▼ to select:
→ ▶ End position CLOSED
→ ▶ End position OPEN
➥ The black triangle ▶ indicates the current selection.
5. Press Ok.
➥ Display indicates the current setting: Limit or Torque
➥ The bottom row of the display indicates either:
- Edit → continue with step 6
- Save → continue with step 10
41
Commissioning (basic settings) AC 01.2 Intrusive
6. Press Edit.
➥ Display indicates: ▶ Specialist (4)
Log on user 7. Use Up ▲ Down ▼ to select user:
Information: Required user level: Specialist (4) or higher
➥ The symbols have the following meaning:
- black triangle: ▶ = current setting
- white triangle: ▷ = selection (not saved yet)
8. Press Ok.
➥ Display indicates: Password 0***
9. Enter password (→ enter password).
➥ The screen indicates the pre-set type of seating (▶ Limit or ▶ Torque) by means
of a black triangle ▶.
Change settings 10. Select new setting Up ▲ Down ▼ resulting in the following significations:
➥ The symbols have the following meaning:
- black triangle: ▶ = current setting
- white triangle: ▷ = selection (not saved yet)
11. Confirm selection via Save.
➥ The setting for the type of seating is complete.
12. Back to step 4 (CLOSED or OPEN): Press Esc .
9.2 Switch compartment: open
The switch compartment must be opened to perform the following settings (options).
1. Loosen screws [2] and remove cover [1] from the switch compartment.
Figure 61:
42
2. If indicator disc [3] is available:

Remove indicator disc [3] using a spanner (as lever).
Information: To avoid damage to paint finish, use spanner in combination with
soft object, e.g. fabric.
Figure 62:
9.3 Torque switching: set

Once the set torque is reached, the torque switches will be tripped (overload protection
of the valve).
Information The torque switches may also trip during manual operation.
Valve damage due to excessive tripping torque limit setting!

→ The tripping torque must suit the valve.
→ Only change the setting with the consent of the valve manufacturer.
Figure 63: Torque switching heads
[1] Torque switching head black in direction CLOSE

[2] Torque switching head white in direction OPEN
[3] Lock screws
[4] Torque dials
1. Loosen both lock screws [3] at the indicator disc.

2. Turn torque dial [4] to set the required torque (1 da Nm = 10 Nm).
3. Fasten lock screws [3] again.
Information: Maximum tightening torque: 0.3 – 0.4 Nm
➥ The torque switch setting is complete.
Example: The figure above shows the following settings:
● 3.5 da Nm = 35 Nm for direction CLOSE
● 4.5 da Nm = 45 Nm for direction OPEN
9.4 Limit switching: set
The limit switching records the travel. When reaching the preset position, switches
are operated.
43
Figure 64: Setting elements for limit switching
Black section:
[1] Setting spindle: End position CLOSED
[2] Pointer: End position CLOSED
[3] Mark: End position CLOSED is set
White section:
[4] Setting spindle: End position OPEN
[5] Pointer: End position OPEN
[6] Mark: End position OPEN is set
9.4.1 End position CLOSED (black section): set
1. Engage manual operation.

2. Turn handwheel clockwise until valve is closed.
3. Turn handwheel by approximately half a turn (overrun) in the opposite direction.
4. Press down and turn setting spindle [1] with screw driver in direction of the
arrow and observe the pointer [2]: While a ratchet click is felt and heard, the
pointer [2] moves 90° every time.
5. If the pointer [2] is 90° from mark [3]: Continue turning slowly.
6. If the pointer [2] moves to mark [3]: Stop turning and release setting spindle.
➥ The end position CLOSED setting is complete.
7. If you override the tripping point inadvertently (ratchet click is heard after the
pointer has snapped): Continue turning the setting spindle in the same direction
and repeat setting process.
9.4.2 End position OPEN (white section): set
1. Engage manual operation.

2. Turn handwheel counterclockwise until valve is open.
3. Turn handwheel by approximately half a turn (overrun) in the opposite direction.
➥ The end position OPEN setting is complete.
44
9.5 Intermediate positions: set

— Option —
Actuators equipped with DUO limit switching contain two intermediate position
switches. One intermediate position may be set for each running direction.
Figure 65: Setting elements for limit switching
Black section:
[1] Setting spindle: Running direction CLOSE
[2] Pointer: Running direction CLOSE
[3] Mark: Intermediate position CLOSED is set
White section:
[4] Setting spindle: Running direction OPEN
[5] Pointer: Running direction OPEN
[6] Mark: Intermediate position OPEN is set
Information After 177 turns (control unit for 1 – 500 turns/stroke) or 1,769 turns (control unit for
1 – 5,000 turns/stroke), the intermediate switches release the contact.
9.5.1 Running direction CLOSE (black section): set
1. Move valve in direction CLOSE to desired intermediate position.

2. If you override the tripping point inadvertently: Turn valve in opposite direction
and approach intermediate position again in direction CLOSE.
Information: Always approach the intermediate position in the same direction
as in later electrical operation.
➥ The intermediate position setting in running direction CLOSE is complete.
9.5.2 Running direction OPEN (white section): set
1. Move valve in direction OPEN to desired intermediate position.

2. If you override the tripping point inadvertently: Move valve in opposite direction
and approach intermediate position again in direction OPEN (always approach
the intermediate position in the same direction as in later electrical operation).
45
➥ The intermediate position setting in running direction OPEN is complete.
9.6 Test run
Perform test run only once all settings previously described have been performed.
9.6.1 Direction of rotation: check
1. Move actuator manually to intermediate position or to sufficient distance from

end position.
2. Set selector switch to position Local control (LOCAL).
3. Switch on actuator in running direction CLOSE and observe the direction of

rotation:
with indicator disc: step 4
without indicator disc: step 5 (hollow shaft)
→ Switch off before reaching the end position.
4. With indicator disc:
→ Observe direction of rotation.
➥ The direction of rotation is correct, if actuator runs in direction
CLOSE and indicator disc turns counterclockwise.
46
5. Without the indicator disc:

→ Unscrew threaded plug [1] and seal [2] or cap for stem protection tube [4]
and observe direction of rotation at hollow shaft [3] or the stem [5].
➥ The direction of rotation is correct, if actuator runs in direction CLOSE and
hollow shaft or stem turn clockwise.
Figure 68: Hollow shaft/stem
[1] Threaded plug

[2] Seal
[3] Hollow shaft
[4] Cap for stem protection tube
[5] Stem
[6] Stem protection tube
9.6.2 Limit switching: check
1. Set selector switch to position Local control (LOCAL).
2. Operate actuator using push buttons OPEN - STOP - CLOSE.

➥ The limit switching is set correctly if (default indication):
- the yellow indication light/LED1 is illuminated in end position CLOSED
- the green indication light/LED5 is illuminated in end position OPEN
- the indication lights go out after travelling into opposite direction.
➥ The limit switching is set incorrectly if:
- the actuator comes to a standstill before reaching the end position
- one of the red indication lights/LEDs is illuminated (torque fault)
- the status indication S0007 in the display signals a fault.
3. If the end position setting is incorrect: Reset limit switching.
4. If the end position setting is correct and no options (e.g. potentiometer, position
transmitter) are available: Close switch compartment.
9.6.3 Reference operation position feedback: perform
For actuators with position feedback (RWG, potentiometer), a reference operation
has to be performed once the limit switching setting was changed to ensure that the
position feedback (0/4 – 20 mA) supplies correct values:
47
→ Operate actuator electrically (via the push buttons OPEN and CLOSE of the local
controls) once to end position OPEN and once to end position CLOSED.
9.7 Potentiometer setting

— Option —
The potentiometer as travel sensor records the valve position.
Information Due to the ratio of the reduction gearing the complete resistance range/stroke is not
always passed. Therefore, external adjustment (setting potentiometer) must be pro-
vided.
Figure 70: View of control unit
[1] Potentiometer
1. Move valve to end position CLOSED.

2. Turn potentiometer [1] clockwise to the stop.
➥ End position CLOSED corresponds to 0 %
➥ End position OPEN corresponds to 100 %
3. Turn potentiometer [1] slightly in opposite direction.
4. Perform fine-tuning of the zero point at external setting potentiometer (for remote
indication).
9.8 Electronic position transmitter RWG: set
— Option —
The electronic position transmitter RWG records the valve position. On the basis of
the actual position value measured by the potentiometer (travel sensor), it generates
a current signal between 0 – 20 mA or 4 – 20 mA.
Table 9: Technical data RWG 4020

Wiring 3- or 4-wire system
Terminal plan TPA 9th position = E or H
Output current IA 0 – 20 mA, 4 – 20 mA
Power supply UV 24 V DC, ±15 % smoothed
Max. current consump- I 24 mA at 20 mA output current
tion
Max. load RB 600 Ω
48
Figure 71: View of control unit
[1] Potentiometer (travel sensor)

[2] Potentiometer min. (0/4 mA)
[3] Potentiometer max. (20 mA)
[4] Measuring point (+) 0/4 – 20 mA
[5] Measuring point (–) 0/4 – 20 mA
1. Connect voltage to electronic position transmitter.

3. Connect ammeter for 0 – 20 mA to measuring points [4 and 5].
4. Turn potentiometer [1] clockwise to the stop.
5. Turn potentiometer [1] slightly in opposite direction.
6. Turn potentiometer [2] clockwise until output current starts to increase.
7. Turn potentiometer [2] in opposite direction until the following value is reached:
- for 0 – 20 mA approx. 0.1 mA
- for 4 – 20 mA approx. 4.1 mA
➥ This ensures that the signal remains above the dead and live zero point.
8. Move valve to end position OPEN.
9. Set potentiometer [3] to end value 20 mA.
10. Approach end position CLOSED again and check minimum value (0.1 mA or
4.1 mA). If necessary, correct the setting.
Information If the maximum value cannot be reached, the selection of the reduction gearing must
be checked. (The max. possible turns/stroke are indicated on the order-related
technical data sheet for the actuator.)
9.9 Mechanical position indicator: set

— Option —
1. Place indicator disc on shaft.

3. Turn lower indicator disc until symbol (CLOSED) is in alignment with the
mark on the cover.
4. Move actuator to end position OPEN.
49
5. Hold lower indicator disc in position and turn upper disc with symbol (OPEN)
until it is in alignment with the mark on the cover.
6. Move valve to end position CLOSED again.

7. Check settings:
If the symbol (CLOSED) is no longer in alignment with mark on the cover:
7.1 Repeat setting procedure.
7.2 Check whether the appropriate reduction gearing has been selected, if
required.
9.10 Switch compartment: close
Danger of corrosion due to damage to paint finish!

→ Touch up damage to paint finish after work on the device.
1. Clean sealing faces of housing and cover.

2. Check whether O-ring [3] is in good condition, replace if damaged.
3. Apply a thin film of non-acidic grease (e.g. petroleum jelly) to the O-ring and
insert it correctly.
4. Place cover [1] on switch compartment.

5. Fasten screws [2] evenly crosswise.
50
AC 01.2 Intrusive Corrective action
10. Corrective action
10.1 Faults during commissioning
Table 10: Faults during commissioning

Fault description Possible causes Remedy
Mechanical position indicator Reduction gearing is not suitable for Exchange reduction gearing.
cannot be set. turns/stroke of the actuator.
Fault in end position The overrun was not considered when setting Determine overrun: Overrun = travel covered
Actuator runs to end stop alt- the limit switching. from switching off until complete standstill.
hough the limit switches work The overrun is generated by the inertia of Set limit switching again considering the
properly. both the actuator and the valve and the delay overrun (turn handwheel back by the amount
time of the controls. of the overrun).
Position transmitter RWG Reduction gearing is not suitable for Exchange reduction gearing.
Measurement range 4 – 20 mA turns/stroke of the actuator.
or maximum value 20 mA cannot
be set.
Limit and/or torque switches do Switch is defective or switch setting is incor- Check setting, if required, reset end positions.
not trip. rect. → Check switches and replace them, if requi-
red.
Switch check
The red test buttons [1] and [2] are used for manual operation of the switches:
1. Turn test button [1] in direction of the TSC arrow: Torque switch CLOSED trips.
2. Turn test button [2] in direction of the TSO arrow: Torque switch OPEN trips.
If the actuator is equipped with a DUO limit switching (option), the intermediate
position switches (LSA and LSB) will be operated at the same time as the torque
switches.
1. Turn test button [1] in direction of the LSC arrow: Limit switch CLOSED trips.
2. Turn test button [2] in direction of the LSO arrow: Limit switch OPEN trips.
10.2 Fault indications and warning indications
Faults interrupt or prevent the electrical actuator operation. In the event of a fault,
the display backlight is red.
Warnings have no influence on the electrical actuator operation. They only serve
for information purposes.
Collective signals include further indications which can be displayed via the
Details push button.
51
Corrective action AC 01.2 Intrusive
Table 11: Faults and warnings via status indications in the display
Indication on display Description/cause For indicated value > 0:
Warnings S0005 Collective signal 02: Press push button Details.
Indicates the number of active warnings. For details, refer to <Warnings and Out of
specification> table.
Not ready REMOTE S0006 Collective signal 04: Press push button Details.
Indicates the number of active signals. For details, refer to <Not ready REMOTE and
Function check> table.
Fault S0007 Collective signal 03: Press push button Details to display a list
Indicates the number of active faults. of detailed indications.
The actuator cannot be operated. For details, refer to <Faults and Failure> table.
Out of specification S0008 Collective signal 07: Press push button Details.
Indication according to NAMUR recommenda- For details refer to <Warnings and Out of
tion NE 107 specification> table.
Actuator is operated outside the normal ope-
ration conditions.
Function check S0009 Collective signal 08: Press push button Details.
Indication according to NAMUR recommenda- For details, refer to <Not ready REMOTE and
tion NE 107 Function check> table.
The actuator is being worked on; output si-
gnals are temporarily invalid.
Maintenance required S0010 Collective signal 09: Press push button Details to display a list
Indication according to NAMUR recommenda- of detailed indications.
tion NE 107
Recommendation to perform maintenance.
Failure S0011 Collective signal 10: Press push button Details to display a list
Indication according to NAMUR recommenda- of detailed indications.
tion NE 107 For details, refer to <Faults and Failure> table.
Actuator function failure, output signals are
invalid
Table 12: Warnings and Out of specification

Indication on display Description/cause Remedy
Config. warning Collective signal 06: Press push button Details to display a list
Possible cause: of individual indications.
Configuration setting is incorrect. For a description of the individual signals, refer
The device can still be operated with restricti- to Manual (Operation and setting).
ons.
Internal warning Collective signal 15: Press push button Details to display a list
Device warnings of individual indications.
The device can still be operated with restricti- For a description of the individual signals, refer
ons. to Manual (Operation and setting).
24 V DC external The external 24 V DC voltage supply of the Check 24 V DC voltage supply.
controls has exceeded the power supply limits.
Wrn on time running Warning on time max. running time/h excee- ● Check modulating behaviour of actuator.
ded ● Check parameter Perm. running time/h
M0356, re-set if required.
Wrn on time starts Warning on time max. number of motor starts ● Check modulating behaviour of actuator.
(starts) exceeded ● Check parameter Permissible starts/h
M0357, re-set if required.
Failure behav. active The failure behaviour is active since all requi- Verify signals:
red setpoints and actual values are incorrect. ● Setpoint E1
● Actual value E2
● Actual process value E4
Wrn input AIN 1 Warning: Loss of signal analogue input 1 Check wiring.
Wrn input AIN 2 Warning: Loss of signal analogue input 2 Check wiring.
Wrn setpoint position Warning: Loss of signal of actuator setpoint Check setpoint signal.
position
Possible causes:
Input signal for setpoint = 0 (signal loss)
52

Op. time warning The set time (parameter Perm.op. time, manu- The warning indications are automatically
al M0570) has been exceeded. The preset cleared once a new operation command is
operating time is exceeded for a complete executed.
travel from end position OPEN to end position ● Check valve.
CLOSED. ● Check parameter Perm.op. time, manual
M0570.
Wrn controls temp. Temperature within controls housing too high Measure/reduce ambient temperature.
Wrn motor temp. Temperature within motor winding too high Check actuator sizing, correct accordingly.
Wrn gearbox temp. Temperature within actuator gear housing too Check actuator sizing, correct accordingly.
high
RTC not set Real time clock has not yet been set. Set time.
RTC button cell Voltage of the RTC button cell is too low. Replace button cell.
PVST fault Partial Valve Stroke Test (PVST) could not be Check actuator (PVST settings).
successfully completed.
PVST abort Partial Valve Stroke Test (PVST) was aborted Perform RESET or restart PVST.
or could not be started.
Wrn no reaction No actuator reaction to operation commands ● Check movement at actuator.
within the set reaction time. ● Check parameter Reaction time M0634.
Wrn FOC Optical receiving signal (channel 1) incorrect Check/repair FO cables.
(no or insufficient Rx receive level) or RS-485
format error (incorrect bit(s))
Wrn FO cable budget Warning: FO cable system reserve reached Check/repair FO cables.
(critical or permissible Rx receive level)
Wrn FOC connection Warning FO cable connection is not available. Fit FO cable connection.
Torque wrn OPEN Limit value for torque warning in direction Check parameter Wrn torque OPEN M0768,
OPEN exceeded. re-set if required.
Torque wrn CLOSE Limit value for torque warning in direction Check parameter Wrn torque CLOSE M0769,
CLOSE exceeded. re-set if required.
Table 13: Faults and Failure

Configuration error Collective signal 11: Press push button Details to display a list
Configuration error has occurred. of individual indications.
For a description of the individual signals, refer
to Manual (Operation and setting).
Config. error REMOTE Collective signal 22: Press push button Details to display a list
Configuration error has occurred. of individual indications.
Internal error Collective signal 14: AUMA service
Internal error has occurred. Press push button Details to display a list
of individual indications.
Torque fault CLOSE Torque fault in direction CLOSE Perform one of the following measures:
● Issue operation command in direction
OPEN.
● Set selector switch to position Local con-
trol (LOCAL) and reset fault indication via
push button RESET.
Torque fault OPEN Torque fault in direction OPEN Perform one of the following measures:
● Issue operation command in direction
CLOSE.
● Set selector switch to position Local con-
trol (LOCAL) and reset fault indication via
push button RESET.
53

Phase fault ● When connecting to a 3-ph AC system and Test/connect phases.
with internal 24 V DC supply of the electro-
nics: Phase 2 is missing.
● When connecting to a 3-ph or 1-ph AC
system and with external 24 V DC supply
of the electronics: One of the phases L1,
L2 or L3 is missing.
Incorrect phase seq The phase conductors L1, L2 and L3 are Correct the sequence of the phase conductors
connected in the wrong sequence. L1, L2 and L3 by exchanging two phases.
Only applicable if connected to a 3-ph AC
system.
Mains quality Due to insufficient mains quality, the controls ● Check mains voltage.
cannot detect the phase sequence (sequence ● Check parameter Tripping time M0172,
of phase conductors L1, L2 and L3) within the extend time frame if required.
pre-set time frame provided for monitoring.
Thermal fault Motor protection tripped ● Cool down, wait.
● If the fault indication display persists after
cooling down:
- Set selector switch to position Local
control (LOCAL) and reset fault indica-
tion via push button RESET.
● Check fuses.
Fault no reaction No actuator reaction to operation commands Check movement at actuator.
within the set reaction time.
Table 14: Not ready REMOTE and Function check (collective signal 04)
Wrong oper. cmd Collective signal 13: ● Check operation commands (send one
Possible causes: operation command only).
● Several operation commands (e.g. OPEN ● Set parameter Positioner to Function acti-
and CLOSE simultaneously, or OPEN and ve.
SETPOINT operation simultaneously)
● Check setpoint.
● A setpoint is present and the positioner is
not active Press push button Details to display a list
of individual indications.
● For fieldbus: Setpoint exceeds 100.0 %
Sel. sw. not REMOTE Selector switch is not in position REMOTE. Set selector switch to position REMOTE.
Service active Operation via service interface (Bluetooth) and Exit service software.
service software AUMA ToolSuite.
Disabled Actuator is in operation mode Disabled. Check setting and status of function <Local
controls enable>.
EMCY stop active The EMERGENCY stop switch has been ● Enable EMERGENCY stop switch.
operated. The motor control power supply ● Reset EMERGENCY stop state by means
(contactors or thyristors) is disconnected. of Reset command.
EMCY behav. active Operation mode EMERGENCY is active ● Detect cause for EMERGENCY signal.
(EMERGENCY signal was sent). ● Verify failure source.
0 V are applied at the EMERGENCY input.
● Apply +24 V DC at EMERGENCY input.
I/O interface The actuator is controlled via the I/O interface Check I/O interface.
(parallel).
Handwheel active Manual operation is activated. Start motor operation.
FailState fieldbus Fieldbus connection available, however no Verify master configuration
process data transmission by the master.
Local STOP A local STOP is active. Release push button STOP.
Push button STOP of local controls is opera-
ted.
Interlock An interlock is active. Check interlock signal.
Interlock by-pass By-pass function is interlocked. Check states of main and by-pass valve.
PVST active Partial Valve Stroke Test (PVST) is active. Wait until PVST function is complete.
54
10.3 Fuses
10.3.1 Fuses within the actuator controls
Fuses used
F1/F2 Primary fuses on power supply unit
G fuse F1/F2 AUMA art. no.

Size 6.3 x 32 mm
Reversing contactors 1 A T; 500 V K002.277
Power supply ≤ 500 V
Reversing contactors 2 A FF; 690 V K002.665
Power supply > 500 V
Thyristor units for motor power up to 1.5 kW 1 A T; 500 V K002.277
Thyristor units for motor power up to 3.0 kW
Thyristor units for motor power up to 5.5 kW
F3 Internal 24 V DC supply
G fuse according to IEC 60127-2/III F3 AUMA art. no.

Size 5 x 20 mm
Voltage output (power supply unit) = 24 V 2.0 A T; 250 V K006.106
F4 Internal 24 V AC supply (115 V AC) for:

● Heater, switch compartment, reversing contactors control
● PTC tripping device
● for 115 V AC also control inputs OPEN - STOP - CLOSE
G-fuse according to IEC 60127-2/III F4 AUMA art. no.

Size 5 x 20 mm
Voltage output (power supply unit) = 115 V — —
F5 Automatic reset fuse as short-circuit protection for external 24 V DC supply for

customer (see wiring diagram)
Replace fuses F1/F2
Hazardous voltage!
55
1. Loosen screws [1] and remove plug/socket connector [2].
2. Pull fuse holder [3] out of pin carrier, open fuse cover and replace old fuses by
new ones.
Fuses F3/F4: test/replace
1. Loosen screws [1] and remove cover [2] on the rear of the actuator controls.
The power supply unit has measurement points (solder pins) allowing to perform
a resistance (continuity) measurement:
Verifying Measuring points
F3 MTP5 – MTP6
F4 MTP7 – MTP8
2. To replace defective fuses:. Carefully loosen power supply unit [3] and pull out.
(The fuses are on the equipped part of the power supply board).
Cable damage due to pinching!

Risk of functional failures.
→ Carefully assemble power supply unit to avoid pinching the cables.
10.3.2 Motor protection (thermal monitoring)
In order to protect against overheating and impermissibly high surface temperatures

at the actuator, PTC thermistors or thermoswitches are embedded in the motor
winding. The thermoswitch is tripped as soon as the max. permissible winding
temperature has been reached.
The actuator is switched off and the following signals are given:
● LED 3 (thermal fault) on the local controls is illuminated.
56
● Status indication S0007 displays an error. The error Thermoswitch is displayed

when selecting Details.
The motor has to cool down before the operation can be resumed. Depending on
the parameter setting, the fault signal is either automatically reset or the fault signal
has to be reset using the push button Reset in selector switch position LOCAL.
For further information to this topic, please refer to Manual (Operation and setting).
57
Servicing and maintenance AC 01.2 Intrusive
11. Servicing and maintenance
Damage caused by inappropriate maintenance!

→ Servicing and maintenance must be carried out exclusively by suitably qualified
personnel having been authorised by the end user or the contractor of the plant.
Therefore, we recommend contacting our service.
→ Only perform servicing and maintenance tasks when the device is switched off.
AUMA
AUMA offer extensive service such as servicing and maintenance as well as customer
Service & Support product training. For the relevant contact addresses, please refer to <Addresses>
in this document or to the Internet (www.auma.com) .
11.1 Preventive measures for servicing and safe operation
The following measures are required to ensure safe device operation:

6 months after commissioning and then every year
● Carry out visual inspection:
Cable entries, cable glands, blanking plugs, etc. have to be checked for correct
tightness and sealing.
Respect torques according to manufacturer's details.
● Check fastening screws between actuator and gearbox/valve for tightness. If
required, fasten screws while applying the tightening torques as indicated in
chapter <Assembly>.
● When rarely operated: Perform test run.
● For devices with output drive A: Press in Lithium soap EP multi-purpose grease
on mineral oil base at the grease nipple with a grease gun.
● Lubrication of the valve stem must be done separately.
Figure 78: Output drive type A
[1] Output drive type A

[2] Grease nipple
Table 15: Grease quantities for bearing of output drive type A

Output drive A 07.2 A 10.2 A 14.2 A 16.2
Quantity [g] 1) 1.5 2 3 5
1) For grease at density r = 0.9 kg/dm³
For enclosure protection IP 68
After continuous immersion:

● Check actuator.
● In case of ingress of water, locate leaks and repair, dry device correctly and
check for proper function.
11.2 Maintenance
Lubrication ● In the factory, the gear housing is filled with grease.
58
AC 01.2 Intrusive Servicing and maintenance
● Grease change is performed during maintenance

- Generally after 4 to 6 years for modulating duty.
- Generally after 6 to 8 years if operated frequently (open-close duty).
- Generally after 10 to 12 years if operated rarely (open-close duty).
● We recommend exchanging the seals when changing the grease.
● No additional lubrication of the gear housing is required during operation.
11.3 Disposal and recycling
Our devices have a long lifetime. However, they have to be replaced at one point in
time. The devices have a modular design and may, therefore, easily be separated
and sorted according to materials used, i.e.:
● electronic scrap
● various metals
● plastics
● greases and oils
The following generally applies:
● Greases and oils are hazardous to water and must not be released into the
environment.
● Arrange for controlled waste disposal of the disassembled material or for sepa-
rate recycling according to materials.
● Observe the national regulations for waste disposal.
59
Technical data AC 01.2 Intrusive
12. Technical data

Information The following technical data includes standard and optional features. For detailed
information on the customer-specific version, refer to the order-relevant data sheet.
This data sheet can be downloaded from the Internet at http://www.auma.com in
German and English (indication of commission number required).
12.1 Features and functions of actuator
Type of duty1) Standard:

● SA: Short-time duty S2 - 15 min
● SAR: Intermittent duty S4 - 25 %
Options:
● SA: Short-time duty S2 - 30 min
● SAR: Intermittent duty S4 - 50 %
● SAR: Intermittent duty S5 – 25 %
Torque range Refer to actuator name plate
Output speed Refer to actuator name plate
Motor Standard: 3-ph AC asynchronous motor, type IM B9 according to IEC 60034
Motor voltage and frequency Refer to motor name plate
Insulation class Standard: F, tropicalized
Option: H, tropicalized
Motor protection Standard: Thermoswitches (NC)
Option: PTC thermistors (according to DIN 44082)
Self-locking Self-locking: Output speeds up to 90 rpm (50 Hz), 108 rpm (60 Hz)
NOT self-locking: Output speeds up to 125 rpm (50 Hz), 150 rpm (60 Hz)
Multi-turn actuators are self-locking, if the valve position cannot be changed from standstill
while torque acts upon the output drive.
Limit switching Counter gear mechanism for end positions CLOSED and OPEN
Turns per stroke: 2 to 500 (standard) or 2 to 5,000 (option)
Standard:
● Single switches (1 NC and 1 NO, not galvanically isolated) for each end position
Options:
● Tandem switches (2 NC and 2 NO) for each end position, switches galvanically isolated
● Triple switches (3 NC and 3 NO) for each end position, switches galvanically isolated
● Intermediate position switch (DUO limit switching), adjustable for any position
Torque switching Torque switching adjustable for directions OPEN and CLOSE
Standard:
Single switch (1 NC and 1 NO; not galvanically isolated) for each direction
Option:
Tandem switches (2 NC and 2 NO) for each direction, switches galvanically isolated
Position feedback signal, ana- Potentiometer or 0/4 – 20 mA (RWG)
logue (option)
Mechanical position indicator Continuous indication, adjustable indicator disc with symbols OPEN and CLOSED
(option)
Heater in switch compartment Standard: Resistance type heater, 5 W, 24 V DC, (internal supply)
Motor heater (option) Voltages: 110 – 120 V AC, 220 – 240 V AC or 400 V AC (externally supplied)
Power depending on the size 12.5 – 25 W
Manual operation Manual drive for setting and emergency operation, handwheel does not rotate during electrical
operation.
Option: Handwheel lockable
Connection to controls AUMA plug/socket connector with screw-type connection
60
AC 01.2 Intrusive Technical data
Valve attachment Standard: B1 according to EN ISO 5210

Options:
A, B2, B3, B4 according to EN ISO 5210
A, B, D, E according to DIN 3210
C according to DIN 3338
Special output drive types: AF, B3D, ED, DD, IB1, IB3
A prepared for stem lubrication
Sensor system
Indication for manual operation Indication whether manual operation is active/not active via switch (1 change-over contact)
(option)
1) For nominal voltage and 40 °C ambient temperature and an average load with running torque or modulating torque according to sepa-
rate technical data. The type of duty must not be exceeded.
Technical data for limit and torque switches

Mechanical lifetime 2 x 106 starts
Silver plated contacts:
U min. 30 V AC/DC
U max. 250 V AC/DC
I min. 20 mA
I max. AC current 5 A at 250 V (resistive load)
3 A at 250 V (inductive load, cos phi = 0.6)
I max. DC current 0.4 A at 250 V (resistive load)
0.03 A at 250 V (inductive load, L/R = 3 µs)
7 A at 30 V (resistive load)
5 A at 30 V (inductive load, L/R = 3 µs)
Gold plated contacts:
U min. 5V
U max. 30 V
I min. 4 mA
I max. 400 mA
Technical data for blinker transmitter

Mechanical lifetime 107 starts
U min. 10 V AC/DC
U max. 250 V AC/DC
I max. AC current 3 A at 250 V (resistive load)
2 A at 250 V (inductive load, cos phi ≈ 0.8)
I max. DC current 0.25 A at 250 V (resistive load)
Technical data for handwheel activation switches

Mechanical lifetime 106 starts
U min. 12 V DC
U max. 250 V AC
I max. AC current 3 A at 250 V (inductive load, cos phi = 0.8)
I max. DC current 3 A at 12 V (resistive load)
61
12.2 Features and functions of actuator controls
Power supply For mains voltage and mains frequency, refer to name plates at the controls and the motor
Mains frequency Permissible variation of the mains voltage: ±10 %
Permissible variation of the mains frequency: ±5 %
Option: Permissible variation of the mains voltage: ±30 %
External supply of the electro- 24 V DC +20 % / –15 %
nics (option) Current consumption: Basic version approx. 250 mA, with options up to 500 mA
The external power supply must have a reinforced insulation against the mains voltage in
accordance with IEC 61010-1 and may only be supplied by a circuit limited to 150 VA in ac-
cordance with IEC 61010-1.
Current consumption Current consumption of the controls depending on the mains voltage:
For permissible variation of mains voltage by ±10 %:
● 100 to 120 V AC = max. 740 mA
● 208 to 240 V AC = max. 400 mA
● 380 to 500 V AC = max. 250 mA
● 515 to 690 V AC = max. 200 mA
For permissible variation of mains voltage by ±30 %:
● 100 to 120 V AC = max. 1,200 mA
● 208 to 240 V AC = max. 750 mA
● 380 to 500 V AC = max. 400 mA
● 515 to 690 V AC = max. 400 mA
Motor current consumption: Refer to motor name plate
Overvoltage category Category III according to IEC 60634-4-443
Rated power The controls are designed for the rated motor power, refer to motor name plate
Switchgear1) 2) Standard:
Reversing contactors (mechanically and electrically interlocked) for motor power up to power
class A1
Options:
● Reversing contactors (mechanically and electrically interlocked) for motor power up to
power class A2
● Thyristor unit for mains voltage up to 500 V AC (recommended for modulating actuators)
for AUMA power classes B1, B2 and B3
Control Standard:
Via digital inputs OPEN, STOP, CLOSE, EMERGENCY (via opto-isolator, OPEN, STOP,
CLOSE with one common), respect minimum pulse duration for modulating actuators
Option:
Additional enable inputs for directions OPEN and CLOSE
Voltage and current values for Standard:
control inputs3) 24 V DC, current consumption: approx. 10 mA per input
Options:
48 V DC, current consumption: approx. 7 mA per input
115 V AC, current consumption: approx. 15 mA per input
62
Status signals Standard:

6 programmable output contacts:
● 5 potential-free NO contacts with one common, max. 250 V AC, 1 A (resistive load)
- Default configuration: End position CLOSED, end position OPEN, selector switch in
REMOTE, torque fault CLOSE, torque fault OPEN
● 1 potential-free change-over contact, max. 250 V AC, 5 A (resistive load)
- Default configuration: Collective fault signal (torque fault, phase failure, motor protec-
tion tripped)
Options:
● 5 change-over contacts with one common, max. 250 V AC, 5 A (resistive load)
● 1 potential-free change-over contact, max. 250 V AC, 5 A (resistive load)
12 programmable output contacts:4)
● 10 potential-free NO contacts, one common for respectively 5 contacts, max. 250 V AC,
1 A (resistive load)
● 2 potential-free change-over contacts, max. 250 V AC, 5 A (resistive load)
● 6 potential-free change-over contacts without one common, per contact max. 250 V AC,
5 A (resistive load)
10 programmable output contacts:4)
● 10 potential-free change-over contacts without one common, per contact max. 250 V
AC, 5 A (resistive load)
All output signals must be supplied with the same potential.
Position feedback signal Galvanically isolated analogue output E2 = 0/4 – 20 mA (load max. 500 Ω)
Voltage output Standard:
Auxiliary voltage 24 V DC, max. 100 mA for supply of the control inputs, galvanically isolated
from internal voltage supply
Option:
Auxiliary voltage 115 V AC, max. 30 mA to supply the control inputs5), galvanically isolated
from internal voltage supply
Local controls Standard:
● Selector switch LOCAL - OFF - REMOTE (lockable in all three positions)
● Push buttons OPEN, STOP, CLOSE, RESET
● 6 indication lights:
- End position CLOSED (yellow), torque fault CLOSE (red), motor protection tripped
(red), torque fault OPEN (red), end position and running indication OPEN (green),
Bluetooth (blue)
● Graphic LC display, illuminated
Options:
● Special colours for the 5 indication lights:
- End position CLOSED (green), torque fault CLOSE (blue), torque fault OPEN (yellow),
motor protection tripped (white), end position OPEN (red)
Bluetooth Bluetooth class II chip, version 2.0 with a range up to 10 m in industrial environments. Supports
Communication interface the SPP Bluetooth profile (Serial Port Profile).
Programming software:
AUMA ToolSuite, commissioning and diagnostic tool for windows based PCs, PDAs and
smart phones
Application functions Standard:
● Switch-off mode adjustable
- Limit or torque seating for end position OPEN and end position CLOSED
● Torque by-pass, adjustable up to 5 seconds (no torque monitoring during this time)
● Start and end of stepping mode as well as ON and OFF time (1 up to 1,800 seconds)
can be programmed individually for directions OPEN and CLOSE.
● Any 8 intermediate positions between 0 and 100 %, reaction and signal behaviour pro-
grammable
Options:
● Positioner
- Position setpoint via analogue input E1 = 0/4 – 20 mA
- Automatic adaptation of the dead band (adaptive behaviour can be selected)
- Split Range operation
- MODE input for selecting between OPEN - CLOSE duty and modulating duty
63
Failure functions Standard:

● EMERGENCY operation, behaviour programmable
- Digital input low active, reaction can be selected: Stop, move to end position CLOSED,
move to end position OPEN, move to intermediate position
- Torque monitoring can be by-passed during EMERGENCY operation.
- Thermal protection can be by-passed during EMERGENCY operation (only in combi-
nation with thermoswitch in the actuator, not with PTC thermistor).
Options:
● Enabling local controls via digital input Enable LOCAL. Thus, the actuator operation can
be enabled or disabled via push buttons on the local controls.
● Local Stop
- The actuator can be stopped via push button Stop of local controls if the selector
switch is in position REMOTE. Not activated when leaving the factory.
● EMERGENCY stop button (latching) interrupts electrical operation irrespective of the
selector switch position.
● Interlock, enabling the operation commands OPEN or CLOSE via digital inputs Interlock
OPEN or Interlock CLOSE
Monitoring functions Standard:
● Torque monitoring: Valve overload protection (adjustable), results in switching off and
generates fault indication
● Motor temperature monitoring (thermal monitoring), results in switching off and generates
fault indication
● Monitoring the heater within the actuator, generates warning signal
● Monitoring of permissible on-time and number of starts (adjustable), generates warning
signal
● Operation time monitoring (adjustable), generates warning signal
● Phase failure monitoring, results in switching off and generates fault indication
● Automatic correction of the direction of rotation upon wrong phase sequence (3-phase
AC currrent)
Diagnostic functions ● Electronic device ID with order and product data
● Logging of operating data: A resettable counter and a lifetime counter each for:
- Motor running time, number of starts, torque switch trippings in end positions CLOSED,
limit switch trippings in end position CLOSED, torque switch trippings in end position
OPEN, limit switch trippings in end position OPEN, torque faults CLOSE, torque faults
OPEN, motor protection trippings
● Time-stamped event report with setting, operation and fault history:
- Status signals in compliance with NAMUR recommendation NE 107: "Failure",
”Function check", "Out of specification", "Maintenance required"
● Torque characteristics
- 3 torque characteristics (torque-travel characteristic) for opening and closing directions,
can be saved separately. Torque characteristics stored can be shown on the display.
Electrical connection Standard:
AUMA plug/socket connector (S) with screw-type connection and M-threads
Options:
● Pg-threads, NPT-threads, G-threads, special threads
● Gold-plated control contacts (pins and sockets)
● Parking frame for wall mounting of the disconnected plug
● Protection cover for plug compartment (when plug is removed)
Wiring diagram Refer to name plate
1) The reversing contactors are designed for a lifetime of 2 million starts.
2) For the assignment of AUMA power classes, please refer to electrical data on actuator.
3) All input signals must be supplied with the same potential.
4) Not possible for low temperature versions with heating system
5) Not possible in combination with PTC tripping device
64
12.3 Service conditions
Use Indoor and outdoor use permissible

Mounting position Any position
Enclosure protection according Standard: IP 68 with AUMA 3-ph AC motor/1-ph AC motor
to EN 60529 According to AUMA definition, enclosure protection IP 68 meets the following requirements:
● Depth of water: maximum 8 m head of water
● Duration of continuous immersion in water: max. 96 hours
● Up to 10 operations during flooding.
● Modulating duty is not possible during continuous immersion.
For actual version, refer to actuator/controls name plate.
Corrosion protection Standard:
● KS: Suitable for installation in industrial units, in water or power plants with a low pollutant
concentration as well as for installation in occasionally or permanently aggressive atmo-
sphere with a moderate pollutant concentration (e.g. in wastewater treatment plants,
chemical industry)
Options:
● KX: Suitable for installation in extremely aggressive atmospheres with high humidity and
high pollutant concentration
Installation altitude Standard: ≤ 2,000 m above sea level
Option: > 2,000 m above sea level, please contact AUMA
Humidity Up to 100 % relative humidity over the entire permissible temperature range
Pollution degree Pollution degree 4 (when closed) according to 50178
Finish coating Standard: Paint based on polyurethane (powder coating)
Colour Standard: AUMA silver-grey (similar to RAL 7037)
Ambient temperature Standard:
● Open-close duty: –25 °C to +70 °C
● Modulating duty: –25 °C to +60 °C
For actual version, refer to actuator/controls name plate.
Vibration resistance according 1 g, from 10 to 200 Hz
to IEC 60068-2-6 Resistant to vibration during start-up or for failures of the plant. However, a fatigue strength
may not be derived from this. Not valid in combination with gearboxes.
Lifetime AUMA part-turn actuators meet or exceed the lifetime requirements of EN 15714-2. For further
details, please contact AUMA
Weight Refer to separate technical data
12.4 Accessories
Wall bracket1) AUMATIC mounted separately from the actuator, including plug/socket connector. Connecting
cables on request. Recommended for high ambient temperatures, difficult access, or in case
of heavy vibration during service
Programming software for PC AUMA ToolSuite
1) Cable length between actuator and AUMATIC max. 100 m. Not suitable for version with potentiometer in the actuator. Instead of the
potentiometer, an RWG has to be used.
12.5 Further information
EU Directives ● Electromagnetic Compatibility (EMC): (2004/108/EC)

● Low Voltage Directive: (2006/95/EC)
● Machinery Directive: (2006/42/EC)
65
Spare parts AC 01.2 Intrusive
13. Spare parts

13.1 Multi-turn actuators SA 07.2 – SA 16.2/SAR 07.2 – SAR 16.2
66
AC 01.2 Intrusive Spare parts
Information: Please state type and commission no. of the device (see name plate) when ordering spare parts.
Only original AUMA spare parts should be used. Failure to use original spare parts voids the warranty and exempts
AUMA from any liability. Delivered spare parts may slightly vary from the representation.
No. Designation Type No. Designation Type
001.0 Housing Sub-assembly 553.0 Mechanical position indicator Sub-assembly
002.0 Bearing flange Sub-assembly 554.0 Socket carrier with motor cable har- Sub-assembly
ness
003.0 Hollow shaft with worm wheel Sub-assembly 556.0 Potentiometer for position transmitter Sub-assembly
005.0 Drive shaft Sub-assembly 556.1 Potentiometer without slip clutch Sub-assembly
005.1 Motor coupling on output drive shaft 557.0 Heater Sub-assembly
005.3 Manual drive coupling 558.0 Blinker transmitter including pins at Sub-assembly
wires (without impulse disc and insula-
tion plate)
009.0 Planetary gear for manual drive Sub-assembly 559.0-1 Control unit with torque switching Sub-assembly
heads and switches
017.0 Torque lever Sub-assembly 559.0-2 Control unit with magnetic limit and Sub-assembly
torque transmitter (MWG) for Non-
intrusive version in combination with
AUMATIC integral controls
018.0 Gear segment 560.0-1 Switch stack for direction OPEN Sub-assembly
019.0 Crown wheel 560.0-2 Switch stack for direction CLOSE Sub-assembly
022.0 Drive pinion II for torque switching Sub-assembly 560.1 Switch for limit/torque switching Sub-assembly
023.0 Output drive wheel for limit switching Sub-assembly 560.2 Switch case
024.0 Drive wheel for limit switching Sub-assembly 566.0 Position transmitter RWG Sub-assembly
025.0 Locking plate Sub-assembly 566.1 Potentiometer for RWG without slip Sub-assembly
clutch
058.0 Wire for protective earth (pin) Sub-assembly 566.2 Electronic board RWG Sub-assembly
070.0 Motor (VD motor incl. no. 079.0) Sub-assembly 566.3 Wire harness for RWG Sub-assembly
079.0 Planetary gear for motor drive Sub-assembly 567.1 Slip clutch for potentiometer/RWG Sub-assembly
(SA/SAR 07.2 — 16.2 for VD motor)
155.0 Reduction gearing Sub-assembly 568.1 Stem protection tube (without cap)
500.0 Cover for switch compartment Sub-assembly 568.2 Cap for stem protection tube
501.0 Socket carrier (complete with sockets) Sub-assembly 568.3 V-seal
502.0 Pin carrier without pins Sub-assembly 574.1 Radial seal output drive A for ISO
flange
503.0 Socket for controls Sub-assembly 575.1 Stem nut type A
504.0 Socket for motor Sub-assembly 583.0 Motor coupling on motor shaft Sub-assembly
505.0 Pin for controls Sub-assembly 583.1 Pin for motor coupling
506.0 Pin for motor Sub-assembly 584.0 Retaining spring for motor coupling Sub-assembly
507.0 Plug cover Sub-assembly S1 Seal kit, small Set
511.0 Threaded plug Sub-assembly S2 Seal kit, large Set
514.0 Output drive form A (without stem nut) Sub-assembly
514.1 Axial needle roller bearing Sub-assembly
516.0 Output drive D Sub-assembly
535.1 Snap ring
539.0 Screw plug Sub-assembly
542.0 Handwheel with ball handle Sub-assembly
549.0 Output drive B1/B3/B4/C Sub-assembly
549.1 Output drive sleeve B1/B3/B4/C
67
Spare parts AC 01.2 Intrusive
13.2 Actuator controls AUMATIC AC 01.2
68
AC 01.2 Intrusive Spare parts
Information: Please state type and commission no. of the device (see name plate) when ordering spare parts.
Only original AUMA spare parts should be used. Failure to use original spare parts voids the warranty and exempts
AUMA from any liability. Delivered spare parts may slightly vary from the representation.
No. Designation Type
001.0 Housing Sub-assembly
002.0 Local controls Sub-assembly
002.3 Local controls board Sub-assembly
002.4 Display faceplate Sub-assembly
006.0 Power supply Sub-assembly
008.1–1 I/O board Sub-assembly
009.0 Logic board Sub-assembly
011.1 Relay board Sub-assembly
012.0 Option board Sub-assembly
500.0 Cover Sub-assembly
501.0 Socket carrier complete with sockets Sub-assembly
502.0 Pin carrier without pins Sub-assembly
503.0 Socket for controls Sub-assembly
504.0 Socket for motor Sub-assembly
505.0 Pin for controls Sub-assembly
506.0 Pin for motor Sub-assembly
507.0 Plug cover Sub-assembly
508.0 Switchgear Sub-assembly
509.1 Padlock
510.0 Fuse kit Sub-assembly
S Seal kit Set
69
Certificates AC 01.2 Intrusive
14. Certificates
14.1 Declaration of Incorporation and EC Declaration of Conformity
70
AC 01.2 Intrusive Index
H
Index Handwheel 12
8 , 32 I
Identification 8
A Indication lights 39
Accessories (electrical 22 Indications 32
connection) Indications on display 32
Accessories for assembly 16 Indicator disc 38 , 49
Actual value - indication on 34 Inspection record 9
display Intermediate frame 24
Actuator operation at the local 25 Intermediate position indicati- 39
controls on via LEDs
Actuator operation from remo- 26 Intermediate positions 45
te Intrusive 10
Ambient temperature 8 , 65
Analogue signals 40 L
Applications 5 LEDs (indication lights) 39
Assembly 12 Language in the display 30
Limit switching 43 , 47
C Local actuator operation 25
Cable set 22 Local control 25
Commission number 8, 9 Local controls 25
Commissioning 5 Local setting 27
Commissioning (indications 32 Lubrication 58
on display)
Connecting cable 22 M
Control 9, 9 Main menu 28
Corrective action 51 Mains frequency 19
Corrosion protection 11 , 65 Mains voltage 19
Cross sections 19 Maintenance 5 , 58 , 58
Current consumption 18 Maintenance required - indica- 37
tion on display
D Manual operation 25
DUO limit switching 45 Mechanical position indicator 38 , 49
Declaration of Incorporation 70 Menu navigation 27
Device type 9, 9 Motor heater 21
Digital outputs 40 Motor operation 25
Direct display via ID 28 Multiport valve - Indications 35
Direction of rotation 46 on display
Directives 5
Display (indications) 32 N
Disposal 59 Name plate 8 , 19
Double sealed 24 Network types 18
Non-Intrusive 10
E Not ready REMOTE - indicati- 36
EC Declaration of Conformity 70 on on display
EMC 19
Earth connection 24 O
Electrical connection 18 Operation 5 , 25
Electronic position transmitter 48 Operation commands - indica- 34
Enclosure protection 8 , 65 tions on display
Error - indication on display 32 Order number 8, 9
Out of specification - indicati- 37
F on on display
Failure - indication on display 38 Output contacts 40
Fault - indication on display 36 Output drive type A 13
Flange size 9 Output drive types B, B1, B2, 12
Function check - indication on 37 B3, B4, and E
display Output speed 8
71
Index AC 01.2 Intrusive
P T
Packaging 11 Technical data 60
Parking frame 23 Technical data for switches 61
Password 28 Terminal plan 18
Password change 29 Test run 46
Password entry 29 Torque - indication on display 34
Position indicator 49 Torque range 8
Position transmitter RWG 48 Torque switching 43
Positioner - indication on dis- 35 Transport 11
play Type (device type) 9, 9
Potentiometer 48 Type designation 8
Power supply 18 , 19 Type of current 19
Production, year 9 Type of lubricant 8
Protection cover 23
Protection on site 18 U
Protective measures 5 User level 28
Q V
Qualification of staff 5 Valve position - indication on 33
display
R Valve stem 16
RWG 48
Range of application 5 W
Recycling 59 Wall bracket 22
Reference operation 47 Warnings - indication on dis- 36
Remote actuator operation 26 play
Running indication 38 Wiring diagram 9 , 9 , 18
Works number 9
S
Safety instructions 5 Y
Safety instructions/warnings 5 Year of production 9
Serial number 8, 9
Service 58
Service conditions 65
Servicing 58
Setpoint - indication on dis- 35
play
Short-circuit protection 18
Signals 40
Signals (analogue) 40
Size 9, 9
Spare parts 66
Standards 5
Status menu 28
Status signals 40
Stem nut 14
Stem protection tube 16
Storage 11
Supply networks 18
Support 58
Switch check 51
72
AUMA worldwide
Europe AUMA ACTUATORS Ltd. Auma Endüstri Kontrol Sistemleri Limited

UK Clevedon, North Somerset BS21 6TH irketi
AUMA Riester GmbH & Co. KG Tel +44 1275 871141 TR 06810 Ankara
Fax +44 1275 875492 Tel+90 312 217 32 88
Plant Müllheim mail@auma.co.uk Fax+90 312 217 33 88
DE 79373 Müllheim www.auma.co.uk Servis@auma.com.tr
Tel +49 7631 809 - 0 www.megaendustri.com.tr
Fax +49 7631 809 - 1250 AUMA ITALIANA S.r.l. a socio unico
riester@auma.com IT 20023 Cerro Maggiore (MI) AUMA Technology utomations Ltd.
www.auma.com Tel +39 0331 51351 UA 02099 Kiyiv
Fax +39 0331 517606 Tel+38 044 586-53-03
Plant Ostfildern - Nellingen info@auma.it Fax+38 044 586-53-03
DE 73747 Ostfildern www.auma.it auma-tech@aumatech.com.ua
Tel +49 711 34803 - 0
Fax +49 711 34803 - 3034 AUMA BENELUX B.V. Africa
riester@wof.auma.com NL 2314 XT Leiden
Tel +31 71 581 40 40 AUMA South Africa (Pty) Ltd.
Service-Center Köln Fax +31 71 581 40 49 ZA 1560 Springs
DE 50858 Köln office@benelux.auma.com Tel +27 11 3632880
Tel +49 2234 2037 - 900 www.auma.nl Fax +27 11 8185248
Fax +49 2234 2037 - 9099 aumasa@mweb.co.za
service@sck.auma.com AUMA Polska Sp. z o.o.
PL 41-219 Sosnowiec A.T.E.C.
Service-Center Magdeburg Tel +48 32 783 52 00 EG Cairo
DE 39167 Niederndodeleben Fax +48 32 783 52 08 Tel +20 2 23599680 - 23590861
Tel +49 39204 759 - 0 biuro@auma.com.pl Fax +20 2 23586621
Fax +49 39204 759 - 9429 www.auma.com.pl atec@intouch.com
Service@scm.auma.com
OOO Priwody AUMA CMR Contrôle Maintenance Régulation
Service-Center Bayern RU 124365 Moscow a/ya 11 TN 1002 Tunis
DE 85386 Eching Tel +7 495 221 64 28 Tel +216 71 903 577
Tel +49 81 65 9017- 0 Fax +7 495 221 64 38 Fax +216 71 903 575
Fax +49 81 65 9017- 2018 aumarussia@auma.ru instrum@cmr.com.tn
Riester@scb.auma.com www.auma.ru www.cmr-tunisie.net
AUMA Armaturenantriebe GmbH ERICHS ARMATUR AB MANZ INCORPORATED LTD.

AT 2512 Tribuswinkel SE 20039 Malmö NG Port Harcourt
Tel +43 2252 82540 Tel +46 40 311550 Tel +234-84-462741
Fax +43 2252 8254050 Fax +46 40 945515 Fax +234-84-462741
office@auma.at info@erichsarmatur.se mail@manzincorporated.com
www.auma.at www.erichsarmatur.se www.manzincorporated.com
AUMA (Schweiz) AG GRØNBECH & SØNNER A/S America

CH 8965 Berikon DK 2450 København SV
Tel +41 566 400945 Tel+45 33 26 63 00 AUMA ACTUATORS INC.
Fax +41 566 400948 Fax+45 33 26 63 21 US PA 15317 Canonsburg
RettichP.ch@auma.com GS@g-s.dk Tel +1 724-743-AUMA (2862)
www.g-s.dk Fax +1 724-743-4711
AUMA Servopohony spol. s.r.o. mailbox@auma-usa.com
CZ 250 01 Brandýs n.L.-St.Boleslav IBEROPLAN S.A. www.auma-usa.com
Tel +420 326 396 993 ES 28027 Madrid
Fax +420 326 303 251 Tel+34 91 3717130 AUMA Argentina Representative Office
auma-s@auma.cz Fax+34 91 7427126 AR 1609 Boulogne
www.auma.cz iberoplan@iberoplan.com Tel/Fax +54 232 246 2283
contacto@aumaargentina.com.ar
OY AUMATOR AB D. G. Bellos & Co. O.E.
FI 02230 Espoo GR 13671 Acharnai Athens AUMA Automação do Brasil Ltda.
Tel +358 9 5840 22 Tel+30 210 2409485 BR São Paulo
Fax +358 9 5840 2300 Fax+30 210 2409486 Tel +55 11 8114-6463
auma@aumator.fi info@dgbellos.gr bitzco@uol.com.br
www.aumator.fi
SIGURD SØRUM AS AUMA Chile Representative Office
AUMA France S.A.R.L. NO 1300 Sandvika CL 9500414 Buin
FR 95157 Taverny Cedex Tel+47 67572600 Tel +56 2 821 4108
Tel +33 1 39327272 Fax+47 67572610 Fax +56 2 281 9252
Fax +33 1 39321755 post@sigum.no aumachile@adsl.tie.cl
info@auma.fr
www.auma.fr INDUSTRA TROY-ONTOR Inc.
PT 2710-297 Sintra CA L4N 8X1 Barrie Ontario
Tel+351 2 1910 95 00 Tel +1 705 721-8246
Fax+351 2 1910 95 99 Fax +1 705 721-5851
industra@talis-group.com troy-ontor@troy-ontor.ca
73
AUMA worldwide
Ferrostaal de Colombia Ltda. AUMA Actuators Middle East W.L.L.

CO Bogotá D.C. AE 15268 Salmabad 704
Tel +57 1 401 1300 Tel +973 17877377
Fax+57 1 416 5489 Fax +973 17877355
dorian.hernandez@ferrostaal.com Naveen.Shetty@auma.com
www.ferrostaal.com
PERFECT CONTROLS Ltd.
PROCONTIC Procesos y Control HK Tsuen Wan, Kowloon
Automático Tel +852 2493 7726
EC Quito Fax +852 2416 3763
Tel +593 2 292 0431 joeip@perfectcontrols.com.hk
Fax +593 2 292 2343
info@procontic.com.ec DW Controls Co., Ltd.
KR 153-702 Seoul
Corsusa International S.A.C. Tel +82 2 2624 3400
PE Miraflores - Lima Fax +82 2 2624 3401
Tel +511444-1200 / 0044 / 2321 sichoi@actuatorbank.com
Fax +511444-3664 www.actuatorbank.com
corsusa@corsusa.com
www.corsusa.com Sunny Valves and Intertrade Corp. Ltd.
TH 10120 Yannawa Bangkok
PASSCO Inc. Tel +66 2 2400656
PR 00936-4153 San Juan Fax +66 2 2401095
Tel +18 09 78 77 20 87 85 sunnyvalves@inet.co.th
Fax +18 09 78 77 31 72 77 www.sunnyvalves.co.th/
Passco@prtc.net
Top Advance Enterprises Ltd.
Suplibarca TW Jhonghe City Taipei Hsien (235)
VE Maracaibo Estado, Zulia Tel +886 2 2225 1718
Tel +58 261 7 555 667 Fax +886 2 8228 1975
Fax +58 261 7 532 259 support@auma-taiwan.com.tw
suplibarca@intercable.net.ve www.auma-taiwan.com.tw
Asia Australia
AUMA Actuators (Tianjin) Co., Ltd. BARRON GJM Pty. Ltd.
CN 300457 Tianjin AU NSW 1570 Artarmon
Tel +86 22 6625 1310 Tel +61 294361088
Fax +86 22 6625 1320 Fax +61 294393413
mailbox@auma-china.com info@barron.com.au
www.auma-china.com www.barron.com.au
AUMA INDIA PRIVATE LIMITED

IN 560 058 Bangalore
Tel +91 80 2839 4656
Fax +91 80 2839 2809
info@auma.co.in
www.auma.co.in
AUMA JAPAN Co., Ltd.

JP 211–0016 Nakaharaku, Kawasaki-shi
Kanagawa
Tel +81 44 863 8371
Fax +81 44 863 8372
mailbox@auma.co.jp
www.auma.co.jp
AUMA ACTUATORS (Singapore) Pte Ltd.

SG 569551 Singapore
Tel +65 6 4818750
Fax +65 6 4818269
sales@auma.com.sg
www.auma.com.sg
74
AUMA worldwide
75
AUMA Riester GmbH & Co. KG
P.O.Box 1362
D 79373 Muellheim
Tel +49 7631 809 - 0
Fax +49 7631 809 - 1250
riester@auma.com
www.auma.com
Y004.751/003/en/4.12
For detailed information on AUMA products refer to the Internet: www.auma.com


Date : 4 May 2023
Revision : 00
Chapter C
Installation, Operation and Maintenance Manual Gearboxes

SAMBO Bevel gears Operating Instructions
SAMBO Gear Actuators

FOR INDUSTRIAL VALVES
Since 1980 Multi-turn Bevel Gear Actuators
Operating Instructions
HTTP://www.sambo21.com
Instruction range: This operating instruction can be applied for all bevel gear models made by SAMBO
Gears.
* Standard type: Gear actuators for general type
* Single reduction type (-1S type): Horizontal input with single reduction gear attachment
* Double reduction type (-1SD type): Horizontal input with double reduction gear attachment
Table of contents page
1. Safety instructions ...................................................................................................................................2
1.1 Range of application ..............................................................................................................................2

1.2 Maintenance ..........................................................................................................................................2
1.3 Warning..................................................................................................................................................2
2. Technical data ...........................................................................................................................................3
3. Transport, storage and packing ..............................................................................................................5
3.1 Transport. ..............................................................................................................................................5

3.2 Storage ..................................................................................................................................................5
3.3 Packaging ..............................................................................................................................................5
4. Fitting the hand wheel ..............................................................................................................................5
5. Mounting to Motor actuator .....................................................................................................................6
6. Mounting to valve .....................................................................................................................................7
7. Enclosure protection IP-67, 68 ................................................................................................................9
8. Maintenance ............................................................................................................................................10
8.1 General maintenance .............................................................................................................................10

8.2 Sealing ....................................................................................................................................................10
8.3 Grease ....................................................................................................................................................10
8.4 Removal & Replacement ........................................................................................................................10
9. Exploded view standard type A.............................................................................................................11
10. Exploded view for single reduction type ..............................................................................................12
11. Exploded view for double reduction type ............................................................................................13
12. Parts List..................................................................................................................................................14
13. Warranty ..................................................................................................................................................15
14. Grease Quantity Sheet ...........................................................................................................................16
1 HTTP://www.sambo21.com
1. Safety instructions
1.1 Range of application: SAMBO Bevel gear actuators are multi-turn gear actuator intended to be
used for operating of valves (e.g. gate valves, globe valves, sluice gate valve etc.)
SAMBO bevel gear actuators are designed for not only manual operation but also motorized
operation.
If used for other applications, please ask us sambo@sambo21.com.
Only when the instructions are observed, correct operation of gear actuator can be guaranteed.
SAMBO Gears is not responsible for any damage caused by incorrect use of the gearbox.
So, the qualified personal must be fully aware of the instructions as described in this manual.
1.2 Maintenance: For operating of bevel gear actuator safely, observe maintenance instructions.
(Refer to page 10)
1.3 This pictograph means Warning!
"Warning" marks activities or procedures which, if not carried out correctly, can affect the safety of
persons or material.
2. Technical data
Features and functions
Housing Ductile Iron (FCD-450)
Base Ductile Iron (FCD-450)
Ductile Iron (FCD-450)

Drive sleeve
Supports both axial and radial loads.
A unique top Entry Replaceable stem nut.
After long years of service can be easily replaced without removing gear from valve.
Stem Nut
Material is high strength bronze (HBSC3), providing both corrosion and abrasion resistance.
The machining of stem nut can be supplied for several types such as thread, keyway, square etc.
This design incorporates dual locking nuts which provide a jam effect for positive locking.
Dual Locking Nut
No set screw or pinning is required.
Pinion gear is 4140 heat treated steel and bevel gear is 1045 steel.
Pinion & Bevel Gear Both gears are precision cut.
Keyway and key on pinion is supplied to mount hand wheel.
O-ring, gasket Units are completely O-ring sealed, suitable for temporary submergence to meet IP 67 Class.
SB-V Series Max. 42,000 N.m SB-V Series Max. 83,200 N.m
Output Torque
Max. 31,000 ft.lbf Max. 61,000 ft.lbf
SB-V Series Max. 5,450 KN SB-V Series Max. 9,400 kN
Thrust capacities
Max. 1,225,000 lbf Max. 2,113,000 lbf
Input/Output Standard: Clockwise input & Clockwise output (CW IN-CW OUT) is standard rotation type.
shaft rotation Option: Other rotation can be supplied as per customer's request.
Single reduction type
The single reduction gear is mounted on standard type to reduce input torque.
Single reduction type
This type can be supplied in various gear ratios and directions.
Mount to valve.
Standard: All machining and manufacturing is based on ISO 5211.

Mount to valve
Option: Ask us other special application.
Standard: Unbored or pilot bore stem nut.
Stem Nut
Option: Several machining type such as thread, square, key etc. can be supplied.
Mount to motor actuator
Standard: All machining and manufacturing is based on ISO 5211.

Mount to motor actuator
Option: Ask us other application as option.
Service
Enclosure protection STANDARD: IP-67

(IEC-529) Option: IP-68
STANDARD: SAMBO gears are suitable for installation on industrial units in water or power plants with a low
pollutant concentration.
Corrosion protection
Option: Suitable for installation in extremely aggressive atmosphere with high humidity and high pollutant
concentration.
STANDARD: Supplied Epoxy primer (VP184, reddish-brown colour).
Painting
Special painting can be made available upon request.
STANDARD: -20℃ to +120℃

Option: (Low temperature) -40℃ to +90℃
(Extreme low temperature) -60℃ to +90℃
Ambient temperature
(High temperature) -10℃ to +200℃
(Extreme high temperature) -10℃ to +400℃
Ask us for special temperature or use.
Accessories
Dial Indicator shows the position of the valve by 0% to 100%.

Dial indicator
Can be supplied on all bevel gear models.
Stem cover does protect valve stem from dust, rain or dirt.
Stem cover
Supplied with various lengths and several types such as pipe steel, stainless steel, acryl etc.
Locking device Input shaft can be equipped with a hand wheel locking device for manually operated units.
There are several types of hand wheel.

Hand wheel
Hand wheel for Gate valve, Round bar hand wheel for Globe valve, Adapter for Drive nut.
3. Transport, storage and packing
3.1 Transport
Transport to place of installation in sturdy packing.
If mounted together with actuator:

Attach ropes or hooks for the purpose of lifting by hoist only to the gear actuator and not to the
actuator.
3.2 Storage
SAMBO Gears should be stored in a clean, dry area in their shipping containers.
If stored for long periods of time, the actuator mounting bases should be lightly greased to
prevent corrosion.
3.3 Packaging
Our products are protected by packing for the transport ands the packing consist of
environmentally friendly materials which can easily be separated and recycled.
4. Fitting the hand wheel
For gear actuators designed for manual operation, the hand wheel is supplied separately.
Fitting is done on site according to figure 1.
Figure 1: Hand wheel
5. Mounting to Motor actuator
SAMBO Bevel gear actuators can be provided with Motor actuator input flanges to accept
standard ISO Mounting Base to meet customer's requirement.
Assembly and dismantling is as following.
Figure 2: Mounting to Motor actuator
1. Thoroughly degrease the faces of bearing flange at actuator and of input flange at bevel
gear actuator.
2. Place the flange of motor actuator on the flange of bevel gear actuator.
3. Ensure that the spigot mates uniformly in the recess and that the mounting faces are in
complete contact.
4. Fasten motor actuator with bolts and lock washers at the flange of bevel gear actuator.
5. Fasten bolts crosswise with mentioned torque according to table 1 in the next page.
6. Mounting to valve
SAMBO bevel gear actuators can be operated in any mounting position.
* Prior to mounting, the gear actuator must be checked for damage.
Damaged parts must be replaced by original spare parts.
* After mounting to valve, touch up any possible damage to paint finish.
* Check if mounting flange fits the gear actuator and spigot at flanges should be loose fit.
Stem nut to mounting valve can be replaced easily with splined bushing type.
Figure 3:
The internal thread of stem nut must match the thread of valve stem.
The square and key type thread machining as well as thread machining can be supplied.
To finish machining of stem nut, refer to the next page.
1. Check whether bore and keyway match input shaft of valve.

2. Thoroughly degrease mounting faces of gear actuator and valve.
3. Apply a small quantity of grease to input shaft of valve.
4. Place gear actuator on valve and fasten.
5. Fasten bolts evenly crosswise. (Refer to Table 1.)
Table 1: Bolt tightening torque * Refer to standard VDI 2230.
Maximum tightening torque Ma (N.m)

Thread Property class according to ISO 898/1
8,8 10,9 12,9 Remark
M8 26 36 43
M10 51 72 87
M12 89 125 150
M16 215 305 365
M20 420 590 710
M30 1450 2050 2450
M36 2530 3560 4280
Finish machining of stem nut
Stem nut to mounting valve can be replaced easily with splined bushing type.
Figure 4
1. Remove dual locking nuts of bevel gear actuator .

Use suitable locking nut tool for dismantling and
tightening.
(Ask our company for tooling of locking nuts.)
Incorrect dismantling can result to damaging of
thread.
2. Remove stem nut.
3. In case of heavy weight of stem nut for big size,

remove it by use of eye-bolt.
4. The internal thread of stem nut must be machined to

match the thread of valve stem.
Pay attention to not have any damage of stem nut .
5. Assembly is done in the reverse order of dismantling .
Use air impact tool when the stem nut does not come loose.
Incorrect tightening can result to damage.
Stem cover for rising valve stem

There are various materials and types for stem cover such as pipe steel, stainless steel, polyacryl etc.
Figure 5: Protection tube for rising valve stem
7. Enclosure protection IP-67, 68
Definition: IP 67: According to IEC 529, the conditions for meeting the requirements
of enclosure protection IP 67. IP 67.
Under the conditions for regular pressure and time, test regulation can meet to prevent
ingress of water. (15 cm ~ 1 m)
Contents: * SAMBO bevel gearboxes in enclosure protection IP 67 fulfil the following requirements
in compliance with SAMBO definitions.
IP 67: Complete enclosure protection for dust and no ingress of water during submersion.
(Standard)
IP 68: Complete enclosure protection for dust and suitable to use continuously during
submersion.
Test regulation is to be agreed between manufacturer and user. (Option)
* If submersed in other media, additional measures for corrosion protection may be necessary.
(Please consult SAMBO.)
Note: * The enclosure protection IP 67 is available to the interior of the gearbox, but does not
protect mounting flange part.
* If gearboxes are likely to be repeatedly submersed, a higher corrosion protection is

required.
(Please consult SAMBO.)
* Use suitable sealing material between valve flange and gearbox.

In case no suitable sealing is used, it cannot be prevented water enters into the coupling
of mounting flange part. This will lead to corrosion to the interior of gearbox.
To protect this type of corrosion, we recommend to select higher corrosion protection
before mounting valve.
8. Maintenance
8.1 General maintenance
* Check the external appearance on defects after receiving the gear actuator.
* Paint damage will cause corrosion or rust, so take proper action.
* In order to maintain full functionality, operate the gear actuators at least 10 times per year.
* Check below points as follows.

- 6 - 12 months after receipt of gears, check bevel gear actuators generally on
pieces of dirt & bolt fastening in mounting part.
- Have operation test each 6 months.
- Check grease leakage once per year. (Fill up grease if required)
- Make a detailed test record every 5 years.
(This will be helpful to improve better quality.)
8.2 Sealing
* The elastic sealing may be worn out.

* Life cycle of NBR sealing is about 12 years from manufacturing date.
(The life cycle is based on average 40 degree.)
* Change the worn out sealing.
8.3 Grease
* Change the grease and sealing using the following guidelines.

- In case of operating rarely: 10 to 12 years
- In case of operating normally: 6 to 8 years
- In case of operating frequently: 4 to 6 years
* Ask us for the grease specification.

* Lubricant may not be mixed with any other oil.
* For removing lubricant and cleaning inside gear actuators, observe the correct
instruction of replacement & remove.
* Our company is not responsible for any damage caused by incorrect remove and
replacement.
8.4 Removal & Replacement
* SAMBO Bevel gears have long life cycle.

But, proper replacement should be required to maintain this long life cycle.
* SAMBO Bevel gear actuators have standard design and it is made of individual
parts. It makes remove and replacement much easier.
When remove and assembly, ask our company.
* Our company is not responsible for any damage caused by incorrect remove and
assembly or replacement.
9. Exploded view standard type A
10. Exploded view for single reduction type
11. Exploded view for double reduction type
12. Parts List

MATERIAL
NO. DESCRIPTION REMARK
NAME JIS ASTM
01 Housing Ductile Iron FCD-450 A536-65-45-12 NOTE 1
02 Base Ductile Iron FCD-450 A536-65-45-12 NOTE 1
03 Bevel Gear Carbon Steel S45C A576-1045
04 Bevel Pinion Alloy Steel SCM440 A322-4140 NOTE 2
05 Drive Sleeve Ductile Iron FCD-450 A536-65-45-12 NOTE 1
06 Dual Lock Nuts Carbon Steel S45C A576-1045
07 End Cap Ductile Iron FCD-450 A536-65-45-12 NOTE 1
08 Wrench Bolt (S/W) Alloy Steel SCM440 A322-4140
10 Radial Ball Bearing Special Steel SUJ2 A295-52100
11 Radial Ball Bearing Special Steel SUJ2 A295-52100
12 Thrust Ball Bearing Special Steel SUJ2 A295-52100
13 Grease Plug Carbon Steel S20C A307 GR.B
14 O-Ring Buna N NBR NOTE 4
15 O-Ring Buna N NBR NOTE 4
16 Collar Steel Pipe STPG A53
17 Bearing Washer Carbon Steel S45C A576-1045 SNAP RING
18 Bearing Nut Carbon Steel S45C A576-1045 SNAP RING
STANDARD
19 Grease Fitting Carbon Steel S20C + Zn A307 GR.B + Zn

20 Set Screw Stainless Steel SUS340 A276-304
21 End Cap Gasket Non-Asbestos VALQUA 6500
22 Base Gasket Non-Asbestos VALQUA 6500
23 Eye Bolt Carbon Steel S20C + Zn A307 GR.B + Zn
24 Thrust Housing Ductile Iron FCD-450 A536-65-45-12
25 Thrust Gasket Non-Asbestos VALQUA 6500
27 SR. Thrust Bearing Special Steel SUJ2 A295-52100
SU-01 Support Housing Ductile Iron FCD-450 A536-65-45-12
SU-02 Helical Pinion Alloy Steel SCM440 A322-4140
SU-03 Radial Ball Bearing Special Steel SUJ2 A295-52100
SU-05 Idle Gear Alloy Steel SCM440 A322-4140
SU-07 Helical Gear Alloy Steel SCM440 A322-4140
SU-08 Key (1R) Carbon Steel S45C A576-1045
SU-09 Snap Ring Carbon Steel S45C A576-1045
SU-11 Support Cover Ductile Iron FCD-450 A536-65-45-12
SU-12 S-Cover Gasket Non-Asbestos VALQUA 6500
SU-13 Retainer Buna N NBR
OP-01 Stem Nut Bronze HBSC3 B584-C8620 NOTE 3
OP-02 Hand Wheel Steel Pipe STPG A53
OP-03 Key Carbon Steel S45C A576-1045
OP-04 Name Plate Aluminium
HANDLE PART NOTE 5
OPTION
OP-05 Washer Carbon Steel SS41 A283 GR.D

OP-06 HEX. Bolt (S/W) Alloy Steel SUS340 A276-304
OP-07 Stem Cover Steel Pipe STPG A53
OP-08 Indicate Bolt Carbon Steel S20C A307 GR.B
STEM COVER NOTE 6
OP-09 HEX. Nut Carbon Steel S20C A307 GR.B
OP-10 Indicator Plastic
1.All casings are Ductile Iron, FCD-450 (ASTM Class 65-45-12)

2.On special request, this material can be Nickel coated or replaced by high tensile stainless steel
3.On special request, this part can be provided in: ALBC3 (Aluminium Bronze), Steel (A576-1045), Austenitic Ductile Iron Casting (A439 Gr D2C).
4.O-Ring Seal & Lubricant: Standard is Buna "N", temperature range -30°C to +120°C (-22°F to +248°F)
Standard Lubricant is Shell Alvania EP2, temperature range -20°C to +120°C (-4°F to +248°F)
Option available: High temperature Viton O-Ring Grade V75, temperature range -25°C to +200°C (-13°F to +392°F)
Lubricant is Shell Darina R2, temperature range -10°C to +200°C (+14°F to + 392°F)
Low temperature Viton O-Ring Grade V115, temperature range -35°C to +160°C (-31°F to +320°F)
Lubricant is Shell S-6751, temperature range -40°C to +90°C (+40°F to + 194°F)
5.SAMBO offers a wide variety of hand wheels, chain wheels, input shaft, locking devices, etc.
6.SAMBO offers a wide variety of stem covers, stainless steel, polyacryl.
Paint: Unless specified, units are supplied with vp184 Red epoxy primer. Sambo can provide finish coating upon request.
13. Warranty
* SAMBO Industrial Co. Ltd. warrants its products (including parts) to the original purchaser
for a period of 1 year from and the date of delivery to the original customer against defects
in material and workmanship under proper and normal use and service. .
We can not be held responsible for claiming defects in case of the following.
* Case of repair or replacement of the parts and materials by user without our approval.
* Defect caused by mis-handling or improper setting.
* Defect caused by improper maintenance or non-keeping operating instruction.
* Defect caused by natural disaster such as flood, thunderbolt, earthquake etc.
MODEL WARRANTY PERIOD
SERIAL No. (12 Months)
DATE
P
CO. NAME
U
R
C
H ADDRESS
A
E
R
TELEPHONE NO.
14. GREASE QUANTITY SHEET
GENERAL -1S TYPE -1SD TYPE

MODEL BEVEL Volume MODEL 1S Volume MODEL 1SD Volume
SB-VS10 0,28 ℓ
SB-VS20 0,46 ℓ
SB-V0 0,60 ℓ SB-V0-1S 0,83 ℓ SB-V0-1SD 1,10 ℓ
SAMBO INDUSTRIAL CO., LTD

Since 1980
Adres: #561-9, GWAEBUP-DONG, SASANG-GU, BUSAN, KOREA
TEL: +82 51 316-2882 HTTP://www.sambo21.com

FAX: +82 51 316-2880 E-mail: sambo@sambo21.com

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