07 Assembly CS - EN

LESER WORKS STANDARD LWN 322-03-EN
Torques for screw, nuts and caps H2 / lifting devices

page 1
0 Range of application
The above torque ranges are valid for material marked full shaft screws or full shaft bolts and nuts
used for the connection between body and bonnet according to AD-B7 and similar applications.
The torque ranges are valid for lubricated threads with a friction factor or 0,1 and rectangular
facings of the nuts in relation to the bore. With the above torques about 70 – 90 % of the yield
strength of the material are reached.
For higher friction factors (0,12 – 0,15) the higher valves for the torque are required. The maximum
limits must not be exceeded.
Data base: The 70 % valves (low torque valve) for friction factor 0,1 are taken from the
catalogue of „Fa. Gebr. Grohmann, 1991, Wissenswertes über Edelstahlschrauben".
1 Body and bonnet connection
Material Min. – max. Torque [Nm]

Material
equivalent Thread
DIN
ASME M10 M 12 M 16 M 20 M 24
Ck 35/ C 35 Steel 18-22
28 - 36 68 - 87 130 – 166 255 - 288
(1.1181)
A4 Class 70 B8M 25-30
45 - 58 108 - 138 204 – 261 202 - 258
(1.4401)
5.6 - 19-22 30 - 39 73 - 93 -- --
8.8 - 40-45 65 - 84 155 - 198 -- --
Screws 1.7709 B16 - 31 - 37 98 - 118 190 - 228 280 - 320
Table 1 for screws and nuts DIN 931, 933, 938 and EN 24032
Material- Min. – max. Torque [Nm] *

Material
equivalent Thread
DIN
ASME M 12 M 16
Ck 35/ C 35 (1.1181) Steel 25 – 35 40 - 50
5.6 - 25 – 35 40 - 50
Table 2 for screws and nuts for safety valves Type 447/547
*) The above mentioned torques are based on field tests. They allow a tight connection without
destroying the PTFE-material.
continues on page 2
LESER processed: Boy.cw. edition: 18.09.08
GmbH & Co. KG approved: refer to ÄM 152300 replaces edition: 22.10.07
LESER WORKS STANDARD LWN 322-03-EN
Torques for screw, nuts and caps H2 / lifting devices
page 2
2 Caps and lifting devices
Torque [Nm]** Wrench size

Size Thread
HALAR-coated
Standard gasket
0 M 24 x 1,5 60 – 75 60 - 75 SW 27
I M 33 x 1,5 80 – 100 60 - 75 SW 46
II M 42 x 1,5 100 – 125 100 - 125 SW 55
III M 60 x 1,5 140 – 175 240 - 270 SW 75
IV M 75 x 1,5 175 – 220 n.a. SW 95
Table 3: Caps and lifting devices (sealing torque)
**) To achieve manually with 200 mm extended wrench.
Sufficient for clean and lubricated threads and not damaged sealing surfaces.
n.a. Gasket not available for this size
3 Test Gag
3.1 Short locking screws

For tightening of the short locking screws (pos. 2, e.g. drawing 190.0309-XX-B01) the torque
ranges of table 4 are recommended.
Cap size Thread size Torque

Size lifting device [Nm]***
0 M12
I M12
28 - 32
II M12
III M12
IV M16
72 -76
V M16
Table 4: Test Gag: Recommended starting torque ranges for short screws
***) The used sealing rings out of vulcanised fibre may not be deformed further because they are soft
sealings.
3.2 Long locking screws

For tightening of the long locking screws (pos. 1, e.g. drawing 190.0309-XX-B01) the torque
ranges of table 5 are recommended.
Cap size Thread size Torque

Size lifting device [Nm]***
0 M12
I M12
II M12
20
III M12
IV M16
V M16
Table 5: Test Gag: Recommended starting torque ranges for long screws
End of LWN
LESER processed: PD.cw. edition: 18.11.08
GmbH & Co. KG approved: refer to ÄM 146201 replaces edition: 15.05.07
LESER Global Standard LGS_1114
Paint touch-up and painting repaired valves Page 1/4
Contents
1 Purpose ............................................................................................................... 1
2 Scope .................................................................................................................. 1
3 Disclaimer............................................................................................................ 1
4 Qualified fitting personnel .................................................................................... 1
5 General Information............................................................................................. 2
6 Paint touch-up and painting repaired valves........................................................ 2
1 Purpose
This LESER Global Standard (LGS) provides instructions on painting LESER safety
valves. The required work steps and materials are described.
2 Scope
This document must be applied when painting safety valves in agencies and
subsidiaries of LESER GmbH & Co. KG.
protected
3 Disclaimer
LESER puts in a great deal of effort into making up-to-date and correct
documentation available. Nevertheless, LESER GmbH & Co. KG gives no guarantee
that the recommended actions presented here are entirely correct and error free.
This document is to be applied exclusively to the specified type. LESER GmbH & Co.
KG declines any liability or responsibility for the correctness and completeness of the
content.
LESER GmbH & Co. KG reserves the right to change the information contained in
this document, which is for the products of LESER GmbH & Co. KG and is intended
for LESER subsidiaries, at any time and without prior announcement.
LESER GmbH & Co. KG is available to the users of this document to provide
additional information.
4 Qualified fitting personnel

The assembly of LESER safety valves may only be performed by trained or qualified
fitters. The qualifications must be obtained through the appropriate training
measures.
disclosure cat.: II proofread: OR published date: 17.11.10 effect. date: 18.11.2010

author: Niehus released by: KUW replaces: initial status: valid
resp. depart.: PP date of release: 8.11.10 revision No.: 0
doc. type: LGS change rep. No.: 00651A retention period: 10y
5 General Information
• Wear safety glasses

• Wear respirator/dust mask
6 Paint touch-up and painting repaired valves

For valves that have to be repainted, the facing and the welded-on
component/customer ID plates must be masked off correctly. Any additional plates
will only be attached after painting, if welding is not required. Open bonnets must be
sealed with protective caps. The same applies to any existing threaded holes.
Outside threads must be protected with a suitable protective cap / existing painting
socket or with masking tape.
protected
Figure 6-1: Protective cap for open bonnet Figure 6-2: Flange sticker

Figure 6-3: Component plate sticker Figure 6-4: Protective cap
protected
Figure 6-5: Component plate sticker Figure 6-6: Protective cap

Figure 6-7: Masking tape Figure 6-8: Protective cap
protected
Figure 6-9
The layer thickness of the coat of paint should be ~ 40µm for one coat of paint.

Component Plates Page 1/10
Contents
1 Purpose ............................................................................................................... 1
2 Scope .................................................................................................................. 1
3 Disclaimer............................................................................................................ 1
6 Attaching component/customer identification plates............................................ 2
6.1 Standard plate .............................................................................................. 3
6.2 World plate (NGA) ........................................................................................ 4
6.3 Fastening to bonnets with welding spots...................................................... 8
1 Purpose
This LESER Global Standard (LGS) provides instructions on attaching the name
plates of LESER safety valves. The required work steps and materials are described.
2 Scope
protected
This LGS must be applied when attaching the name plates of safety valves in
agencies and subsidiaries of LESER GmbH & Co. KG.
3 Disclaimer
content.

The name plates of LESER safety valves must attached exclusively by trained or
qualified fitters. The relevant qualifications must be obtained through appropriate
training measures.
• Gloves must be worn for all fitting work (except for stainless steel
and painted valves).
• Wear safety glasses.
6 Attaching component/customer identification plates

If grooved pins with round heads are not required, the plate is to be welded to the
designated place with the spot welding device.
The world plate (NGA) is fastened to the bonnet. In exceptional cases, it may also be
fastened with grooved pins with round heads, in which case it may also be fastened
to the body.
protected
The standard plate is welded to the flat surface designated for that purpose.
Types 437, 438, 439 - outlet body

No fastening with grooved
pins with round heads
Types 459, 462, - bonnet
Flanged valves - on the right side as seen from the outlet side. Exception: Types
457 / 458 / 526 - on the back side using the set screw

6.1 Standard plate
Figure 6.2.1-1
The standard plate comes in two versions.
For valves that are designed according to ASME (feature N68/N70), the version is
created with the UV and NB symbols.
For valves that are designed according to TÜV, the UV and NB symbols are not
protected
included.
Attachment locations for standard component plates
Figure 6.2.1-2: Type 459 Figure 6.2.1-3: Type 462

Figure 6.2.1-4: Type 437 Figure 6.2.1-5: Type 462
protected
Figure 6.2.1-6: Standard plate on a Figure 6.2.1-7: Types 457 / 458 / 526
flanged valve
6.2 World plate (NGA)
Figure 6.2.1-1
The world plate (NGA) comes in two versions.
For valves that are designed according to ASME (feature N68/N70), the version is
created with the UV and NB symbols.

For valves that are designed according to TÜV, the UV and NB symbols are not
lasered on.
6.2.1 Pre-curving of the NGA

For bonnets with a curved cross-section, the plate must be pre-curved with a radius.
To do this, place the labelled plates in the apparatus with the lettering facing down.
Illustrations Description Aids / Tools

Pre-curving the plate Apparatus
protected
Figure 6.2.1-1
Pre-curving the plate for open bonnets Apparatus
(V20-V25)
Figure 6.2.1-2

Adjustment of plate for closed bonnets

(V20 - V32)
Figure 6.2.1-3
When opening bonnets V20-V25, the plate is bent in the longitudinal direction. To do
this, put the labelled plates into the apparatus with the lettering facing down (figure
6.2.1-2).
6.2.2 Corrosion protection

All valves that are painted must have corrosion protection under the world sign. To
do this, apply the standard primer coat (BURCHARTH'S BLUE - 60M.0120.0001) to
the respective place with a sponge.
protected
Figure 6.2.2-1

Sponge
Figure 6.2.2-2
The points where the world
plate will be welded must be
free of paint.
protected
Figure 6.2.2-3

6.3 Fastening to bonnets with welding spots
6.3.1 Quadratic cross-section
For API valves, the world plate is
fastened to the bonnet of the valve
with welding spots. For versions of
closed bonnets with a quadratic
cross-section, the world plate is
attached vertically to the front side of
the valve approx. 5 mm above the
bevelled edge.
Figure 6.3.1-1
protected
6.3.2 High Performance valves
For the High Performance series, the world plate is always attached to the bonnet.
However, the location where the plate is attached is different for individual bonnet
sizes.
a) Closed bonnets (V20 - V32)

The world plate is attached to the
bonnet (V20 - V32).
For closed bonnets, the world

plate is displaced 90° with
respect to the eyelet for the
sealing wire so that the plate is
located on the opposite side of
the outlet for a completely
assembled valve.
Figure 6.3.2-1
b) Open bonnets (V20 - V25)

The world plate is attached
to open bonnets V20 - V25.
It is attached above the cast
LESER lettering and should
be flush with the letter "L".
The plate must be mounted

so that it can be read from
the right (as shown in the
picture).
Figure 6.3.2-2
c) Open bonnet (V32)

For open bonnets V32, the world
plate is displaced 90° with respect
to the eyelet in front of the sealing
wire so that the plate is displaced
by 90° with respect to the outlet for
a completely assembled valve.
protected
The top edge of the plate should be
flush with the bevel of the bonnet.
Figure 6.3.2-3
d) Open bonnet (V40)

Position of the bonnet:
The raised identifier of the product form manufacturer (foundry) is mounted in the
direction of the outlet flange.
Position of the world plate
The world plate is positioned on the free back side on the bottom edge of the bonnet.
6.3.3 Fastening with grooved pins with round heads


The plate is also curved for this
purpose.
When grooved pins with round
heads are used for fastening,
the world plate must be fastened
at the back or at the side of the
body for the API valve.
Figure 6.3.3-1
protected
Figure 6.3.3-2

LESER Global Standard LGS 4100
Assembly instructions for types 437, 438, 439, 481 Page 1/41
public
Compact Performance
TYPES 437, 438, 439, 481
disclosure cat.: I proofread: AW / TS published date: 05.2011 effect. date: 05.2011

Contents
1 Purpose ............................................................................................................... 2
2 Scope .................................................................................................................. 2
3 References .......................................................................................................... 2
4 Disclaimer............................................................................................................ 2
7 General illustration .............................................................................................. 4
8 Assembly of the Compact Performance series.................................................... 5
8.1 Assembly of the adjusting screw .................................................................. 5
8.2 Assembly of the spindle / disc assembly ...................................................... 6
8.3 Assembly of the inlet body and outlet body ................................................ 24
8.4 Adjusting the set pressure.......................................................................... 31
8.5 Testing and documenting the seat tightness. ............................................. 32
8.6 Assembly of the cap and lever ................................................................... 33
8.7 Testing the seal tightness to the outside .................................................... 39
8.8 Sealing the valve ........................................................................................ 41
public
1 Purpose
This LESER Global Standard (LGS) is assembly documentation for various assembly
scenarios for LESER safety valves of the Compact Performance series. The required
work steps and tools are described.
2 Scope
This document must be applied to the assembly of Compact Performance safety
valves in agencies and subsidiaries of LESER GmbH & Co. KG.
3 References
LWN 220.01 / LGS 0201
LWN 322-03 / LGS 3322
LWN 614-08 / LGS 3614
Note: LESER LWN standards will be replaced by LGS, latest editions apply.
4 Disclaimer
content.

fitters. The qualifications must be obtained through the appropriate training
measures.
• Gloves must be worn during the entire assembly.
public

7 General illustration
public
Figure 7-1: Type 437

8 Assembly of the Compact Performance series

8.1 Assembly of the adjusting screw
Illustration Description Tool / aid

Assemble the adjusting screw (incl.
PTFE-bushing inside) and lock nut.
Figure 8.1-1
Grease the adjusting screw on the Brush
thread and end face. Halocarbon
(OI-56 S / 60H)
public
Figure 8.1-2
Screw the adjusting screw into the
outlet body (a few turns)
Figure 8.1-3

8.2 Assembly of the spindle / disc assembly

8.2.1 Metallic seal 437
8.2.1.1 Spindle / spring plate assembly
Put the spring plate into the Assembly device,
assembly device and fasten Bench vice
in place with bench vice.
public
Figure 8.2.1.1-1
Put a very small amount of Glue
glue on the spindle thread DELO ML 5449
(1 drop on the thread).
Figure 8.2.1.1-2


Put the spindle thread in
the lower spring plate and
screw it in until it is tight to
the touch. Push the pin
punch through the spindle
hole and screw in until it is
tight to the touch.
Figure 8.2.1.1-3
Roundness check of the Indicating calliper
spindle/disc assembly device
Tolerance: max. 0.2mm
Figure 8.2.1.1-4 public

8.2.1.2 Assembly installation

Visual check: Check
sealing surface for
cleanliness and damage.
Sharpen the pin.
Figure 8.2.1.2-1
Assemble the disc body
and lifting aid (holes
public
matching each other).
Figure 8.2.1.2-2
Insert the ball.
Figure 8.2.1.2-3


Assemble the spindle with - Aligning punch,
the spring plate into the Device
preassembled parts and
place them on the
aligning punch in the
device.
Figure 8.2.1.2-4
Install the pin using a - Lever press
lever press.
public
Figure 8.2.1.2-5


Spring plate and spindle
assembled.
Figure 8.2.1.2-6
Install the spring and top Brush, Halocarbon
spring plate on the (OI-56 S / 60H)
spindle.
Only for thrust

bearings: Spring, top
spring plate, thrust
bearings, bearing washer
Grease thrust bearing.
public
Figure 8.2.1.2-7

8.2.2 Plastic sealing plate 437

8.2.2.1 Disc assembly
Visual check: Check sealing
surface of the sealing plate
(outer ring surface) for
undercut
sealing
surface
Figure 8.2.2.1-1
Visual check: Check the
evenness of the sealing plate
(front and back side, no burrs
public
permitted).
Figure 8.2.2.1-2
Screw disc body into the lifting Clamping block,
aid hand tight with fixing the Device
sealing plate inside. Clamp
parts at lifting aid in device.
Figure 8.2.2.1-3


Tighten the disc body with the
special spanner socket using 4
Nm.
Special spanner
socket
Torque wrench
Figure 8.2.2.1-4
Mark the material codes of Punch numbers,
sealing plate into the lifting aid. Hammer
public
Figure 8.2.2.1-5


Put the spring plate in the device - Bench vice
and fasten in place with bench
vice.
Figure 8.2.2.2-1
Put a very small amount of glue Glue
on the spindle thread (1 drop on DELO ML 5449
the thread).
public
Figure 8.2.2.2-2
Put the spindle thread in the Pin punch
lower spring plate and screw it in
until it is finger-tight.
Push the pin punch through the

spindle hole and screw in finger
tight.
Figure 8.2.2.2-3


Put the ball into the disc assembly
and connect to the spindle / spring
plate group.
public
Figure 8.2.2.3-1
Visual check: The pin must have Hammer
some play in the parts through- Support area for
hole of the disc body; connect with disc assembly
pin.
Figure 8.2.2.3-2


Install the spring and top
spring plate on the spindle.
public
Figure 8.2.2.3-3

8.2.3 Soft seal 438/481

8.2.3.1 Disc assembly - soft seal
Visual check: Check sealing surface for
Figure 8.2.3.1-1
public
Wet the O-Ring with soapy water.
Figure 8.2.3.1-2
Wet the lifting aid with soapy water.
Figure 8.2.3.1-3


Place the O-ring in the lifting aid.
Figure 8.2.3.1-4
Press the disc into the lifting aid.
public
Figure 8.2.3.1-5
Mark the material codes of the soft Punch numbers
seal into the lifting aid. Hammer
Figure 8.2.3.1-6


Put the spring plate in the Clamping block
assembly device and
fasten in place with
clamping block.
Figure 8.2.3.2-1
If necessary, remove
excess glue without
leaving any residue.
public
Figure 8.2.3.2-2
Put the spindle thread in Pin punch
the lower spring plate and
screw it in until it is finger-
tight.
Push the pin punch

through the spindle hole
and screw in finger tight.
Figure 8.2.3.2-3


Install the spring and top spring
plate on the spindle.
Figure 8.2.3.3-1
public

8.2.4 Vulcanised sealing surface 439

8.2.4.1 Disc assembly
Visual check: Check sealing surface for
public
Figure 8.2.4.1-1
Put disc in the inlet side of the lifting aid
and screw together hand tight with lock
nut.
Figure 8.2.4.1-2
Clamp the disc in the assembly device
and tighten with the torque wrench.
Comply with torque (4 Nm)
Special spanner
socket
Torque wrench
Vice
Figure 8.2.4.1-3


Put the spring plate into the Clamping block
assembly device and fasten in
place with clamping block.
Figure 8.2.4.2-1
Put a very small amount of glue Glue
on the spindle thread (1 drop DELO ML 5449
on the thread).
Figure 8.2.4.2-2
Put the spindle thread in the Pin punch
public
lower spring plate and screw it
in until it is finger-tight.
Push the pin punch through the

spindle hole and screw in finger
tight.
Figure 8.2.4.2-3


Put the ball in the disc
assembly and connect to the
spindle / spring plate group.
public
Figure 8.2.4.3-1
Install the pin centred. Hammer
Support area for
Visual check: The pin must disc assembly
have some play in the disc
through-hole.
Figure 8.2.4.3-2


Install the spring and top Brush
spring plate on the spindle. Halocarbon
(OI-56 S / 60H)
Only for thrust bearings:
Spring, top spring plate,
thrust bearings, bearing
washer. Grease thrust
bearings.
public
Figure 8.2.4.3-3

8.3 Assembly of the inlet body and outlet body

8.3.1 Insertion of the spindle / disc assembly

Put the spindle assembly (incl. spring and
upper spring plate) in the outlet body.
Make sure that the spindle slides smoothly
into the guide of the adjusting screw
bushing and also the lower spring plate in
the outlet body.
public
Figure 8.3.1-1
8.3.2 Securing the disc

Push the splint pin through the hole of the Pin punch
spindle.
Lift the spindle with the pin punch.
Wedge the splint pin by screwing out the

adjusting screw (for following assembly
steps).
Figure 8.3.2-1

8.3.3 Assembly of the inlet body

8.3.3.1 Assembly of inlet body for threaded connector (cylindrical thread)
Visual check of inlet body: Brush
Check sealing surface for Halocarbon
cleanliness and damage. (OI-56 S / 60H)
Grease the thread of the
inlet body.
Figure 8.3.3.1-1
The disc is in a secured
state (see 8.3.2)
Screw the inlet body into
public
the outlet body hand tight.
Figure 8.3.3.1-2
The disc is in a secured Clamping devices,
state (see 8.3.2) adapter
Clamp the inlet body on

the device (if necessary:
by using an adapter).
Figure 8.3.3.1-3


The disc is in a secured state
(see 8.3.2)
Figure 8.3.3.1-4
Tighten the inlet body with the Torque wrench
specified torque (100 Nm).
public
Figure 8.3.3.1-5

8.3.3.2 Assembly of inlet body for flanged connector (cylindrical thread)
ANSI flange ½” 150 lbs only: Halocarbon

Before gluing the inlet body to the (OI-56 S / 60H)
inlet nozzle, make sure that the
sealing surface and the sealing
strip are lightly greased with
Halocarbon.
Figure 8.3.3.2-1
ANSI flange ½” 150 lbs only:

Inlet body screwed together with
the inlet nozzle.
Figure 8.3.3.2-2
Visual check: Check sealing Brush
public
surface for cleanliness and Halocarbon
damage. (OI-56 S / 60H)
Glue
The disc is in a secured state (see DELO CA 2106
8.3.2)
Grease the inlet body and screw it

into the outlet body.
Figure 8.3.3.2-3

Tighten the inlet body with the Pin punch
specified torque (100 Nm). Torque wrench
Figure 8.3.3.2-4
public

8.3.4 Assembly of the outlet flange

8.3.4.1 Assembly of outlet adapter with cylindrical thread
Grease the sealing lip and Brush
thread of the outlet adapter. Halocarbon
Fit the outlet flange over (OI-56 S / 60H)
the outlet adapter, screw Torque wrench
the adapter into the outlet
body and tighten it.
Tighten the outlet adapter

with the specified torque
(100 Nm).
public
Figure 8.3.4.1-1

8.3.4.2 Assembly of outlet adapter with a conical thread (NPT)

Apply sealing tape to the Sealing tape
thread of the outlet flange.
public
Figure 8.3.4.2-1
Screw the outlet adapter
into the outlet body and
tighten it.
Figure 8.3.4.2-2

8.4 Adjusting the set pressure

Secure the spindle with splint Pin punch
pin against turning when Open-end
adjusting the adjusting screw. spanner
Pressure gauge
Pressurise the valve and adjust
to the set pressure with the
adjusting screw in accordance
with the specification.
Check whether the valve opens

at the set pressure. The set
pressure of the valve has been
reached when you can hear air
escaping. Full opening must be
achieved.
If the valve opens outside the

stipulated set pressure
tolerance, the adjusting screw
public
must be adjusted again.
Figure 8.4-1 Æ Turning in a clockwise

direction causes the valve to
open at higher pressure.
Æ Turning in a counter-
clockwise direction causes the
valve to open at lower
pressure.
When resetting the adjusting

screw, first of all release the
pressure.
Remark: In case of 437 with

d0=6mm, LWN 614-08 / LGS
3614 must be considered.

8.5 Testing and documenting the seat tightness.

Raise the valve to its set Kellog test
pressure 3 times. After the 3rd assembly device
opening, throttle the valve from
the set pressure to the test
pressure. Screw the test cap
on to the outlet body. Seal the
valve outlet with the test plug
thereby connecting it to the
water tank. Adjust the valve to
the given test pressure.
Check the functional seal

tightness according to the order
specifications and LWN 220.01
/ LGS 0201.
If the seal tightness is not met,

then enter the number of
bubbles that are counted in the
fields. If the seal tightness has
public
Figure 8.5-1 not been met after 3 attempts,
then initiate a fault report. If the
seal tightness has been met in
accordance with the
specifications, then document
the results in Report 1.3
"Number of Bubbles".
Unscrew test cap

8.6 Assembly of the cap and lever

8.6.1 Assembly of cap H2

Grease the thread and Brush
sealing lip of cap H2. Put Halocarbon
on the E-CTFE sealing ring (OI-56 S / 60H)
if it is shown in the parts
list.
Caution: The sealing ring

may only be used once. If it
is necessary to
disassemble the cap, the
sealing ring must be
replaced.
public
Figure 8.6.1-1
Screw the cap on and Torque wrench
tighten it with a spanner
(torque as per LWN 322-03
/ LGS 3322).
Figure 8.6.1-2

8.6.2 Assembly of lever H4

Roll the O-ring onto the spindle
cap.
Figure 8.6.2-1
Put the spindle cap onto the
spindle and connect with a
cylinder pin.
public
Figure 8.6.2-2
Grease the O-ring well (1). (1) Klübersynth
UH 14-151 / 60H
Grease the threads of the (2) Halocarbon
spindle cap (2). (OI-56 S / 60H)
Put on the E-CTFE sealing ring

if it is shown in the parts list.
Caution: The sealing ring may

only be used once. If it is
necessary to disassemble the
cap, the sealing ring must be
replaced.
Figure 8.6.2-3


Grease the thread and sealing lip of the Brush
lever cover. Halocarbon
(OI-56 S / 60H)
Figure 8.6.2-4
Screw the lever cover onto the thread of Torque wrench
the outlet body and tighten using approx.
60 - 75 Nm.
public
Figure 8.6.2-5
Fit the pin into the hole of the lever cover
and the slot of the spindle cap and secure
it with the retaining clip.
Figure 8.6.2-6


Press the spindle cap down after assembly.
Figure 8.6.2-7
Grease the threads of the lever cap and install Brush
it. Halocarbon
Attention: left-handed thread (OI-56 S / 60H)
public
Figure 8.6.2-8
Screw in cylinder pin / nut is flush when closed. Flat-tip
Set lever to "closed" / the inscription "CLOSED" screwdriver
can be read on the cap limit stop.
Check the lever after assembly to make sure

that it works (release compressed air with each
lever).
Figure 8.6.2-9


Individual parts of the assembly
Figure 8.6.3-1
Place the O-ring in the groove of the lever
cover.
public
Figure 8.6.3-2
Put the spindle cap onto the spindle and
connect with a cylinder pin.
Figure 8.6.3-3


Grease the thread and Brush
sealing lip of the lever Halocarbon
cover. (Oil 56 S / 60H)
Figure 8.6.3-4
public
Screw the lever cover Torque wrench
onto the thread of the
outlet body and tighten it
using approx. 60 - 75
Nm. Pull up the spindle
cap and install the knob
with the pin and secure
with the retaining clip.
Press the knob down
after assembly.
Figure 8.6.3-5

8.7 Testing the seal tightness to the outside

8.7.1 Testing the seal tightness to the outside (threaded valve)

Seal the valve at the Sealing cap
inlet with a sealing
cap.
public
Figure 8.7.1-1
Install a test Test connector
connector to the
outlet.
Figure 8.7.1-2


Clamp the outlet side of the valve
in the test assembly device and
apply 6 bar of pressure.
public
Figure 8.7.1-3
Pressure testing by immersion:
Check whether any bubbles can be
seen on the outside contour of the
safety valve. If the seal tightness
is good (no bubbles), document
the test result. If there are any
leaks, check the affected sealing
surfaces and seals for damage and
then test again. Dry the valve with
compressed air.
Figure 8.7.1-4

8.7.2 Testing the seal tightness to the outside (flanged valve)

Clamp the outlet side of the valve to
the test bench. Pressurise the valve
with 6 bar.
Wet the valve with leak detector on the

interconnection points and the outlet
area. If the seal tightness is good (no
bubbles), document the test result. If
there are any leaks, check the affected
sealing surfaces and seals for damage
and then test again. Dry the valve with
Figure 8.7.2-1 compressed air.
8.8 Sealing the valve

Connect the sealing wire closely by
using the shortest path. Seal the lever,
public
or alternatively cap H2 to the outlet
body.
Figure 8.8-1

protected
Clean Service
Types 483, 484, 485, 488

Contents
1 Purpose ............................................................................................................... 2
2 Scope .................................................................................................................. 2
3 Disclaimer............................................................................................................ 2
4 Qualified assembly personnel ............................................................................. 3
6 General illustration .............................................................................................. 4
7 Assembly of the Clean Service series ................................................................. 5
7.1 Assembly of spindle/disc assembly .............................................................. 5
7.2 Assembly of the bonnet................................................................................ 9
7.3 Adjusting the set pressure.......................................................................... 14
7.4 Testing the seat tightness P12 ................................................................... 15
7.5 Testing of the seal tightness of the pressure-bearing body P11................. 15
7.6 Assembly of the cap / lever ........................................................................ 15
7.7 Sealing the valve ........................................................................................ 33
1 Purpose
This LESER Global Standard (LGS) is assembly documentation for various assembly
protected
scenarios for LESER safety valves of the Clean Service series. The required work
steps, tools and materials are described.
2 Scope
This document must be applied to the assembly of Clean Service safety valves in
agencies and subsidiaries of LESER GmbH & Co. KG.
3 Disclaimer
content.

4 Qualified assembly personnel
assembly personnel. The qualifications must be obtained through the appropriate
training measures.
• Gloves must be worn during the entire assembly operation.
protected

6 General illustration
protected
Figure 6.1-1: Cross-sectional view of type 483 HyTight

7 Assembly of the Clean Service series

7.1 Assembly of spindle/disc assembly
7.1.1 Disc assembly
Put the O-ring into the groove of the
lifting aid.
Figure 7.1.1-1
Elastomer bellows and disc body
protected
Figure 7.1.1-2
Fit the elastomer bellows onto the
other side of the lifting aid.
Figure 7.1.1-3
Put the disc body in the lifting aid.
Figure 7.1.1-4

7.1.2 Assembly of spindle assembly

Insert the ball into the disc
body.
Put the spindle in the disc and
secure with a pin.
Figure 7.1.2-1
Put the cap nut onto the Assembly aid
spindle and screw to disc body
by means of the assembly aid.
protected
Figure 7.1.2-2
Push the guide washer onto
the spindle and pull the
elastomer bellows over it.
Figure 7.1.2-3


For DN 40: Then, push the lift
stopper over the spindle.
Figure 7.1.2-4
Insert the PTFE bushing. insert the
guide washer.
protected
Figure 7.1.2-5
Insert O-ring on bottom side of the
second guide washer.
Figure 7.1.2-6
Push guide washer on the spindle. Ring spanner
Screw both guide washers finger
tight with hexagon head bolts.
Figure 7.1.2-7

7.1.3 Inserting the assembly
DN 25: Put bottom spring plate
on the spindle and secure
through the holes with pin.
Figure 7.1.3-1
DN 40: Put half-washers on the
spindle and fasten with retaining
clip.
protected
Figure 7.1.3-2
Put the assembly on the body. In
the process, carefully lower the
disc onto the seat.
Figure 7.1.3-3

7.2 Assembly of the bonnet
7.2.1 Adjusting screw assembly
Put the PTFE bushing in the
adjusting screw.
Figure 7.2.1-1
Screw lock nut onto adjusting screw. Brush
Halocarbon
protected
Figure 7.2.1-2
Grease the thread and screw into the
bonnet.
Figure 7.2.1-3

7.2.2 Bonnet without lift indicator

Put the bottom spring plate, spring and
top spring plate onto the spindle.
Figure 7.2.2-1
Put the bonnet over the spring onto the
body.
protected
Figure 7.2.2-2
Caution: Surface for BT plate always
opposite the outlet.
Figure 7.2.2-3


Firmly connect the bonnet and
body with a split ring.
Figure 7.2.2-4
Tighten it with the nut. Ring spanner
Figure 7.2.2-5 protected

7.2.3 Bonnet with lift indicator

Put control sleeve on bottom spring
plate. Then put on spring and top
spring plate.
Figure 7.2.3-1
Put the bonnet over the spring onto

the body. (Attention: Surface for BT
protected
plate always opposite to the outlet.)
Figure 7.2.3-2
Firmly connect the bonnet and body
with a split ring.
Figure 7.2.3-3


Tighten it with the nut. Ring spanner
Figure 7.2.3-4
Screw nut onto lift indicator.
Figure 7.2.3-5
protected
Screw lift indicator onto the guide sleeve
as far as it will go.
Afterwards, unscrew it one full turn.
Figure 7.2.3-6
Secure the position with the first nut and Open-end spanner
then tighten the lock nut with the open-
end spanner.
Figure 7.2.3-7

7.3 Adjusting the set pressure

Slowly pressurise the valve on the Open-end
test bench to find out whether the spanner, pin
valve opens at the set pressure. punch
The set pressure of the valve has
been reached when you can hear
air escaping. Full opening must be
achieved.
If the valve opens outside the
stipulated set pressure tolerance,
then the adjusting screw must be
adjusted again. Secure the spindle
from turning with a pin punch.
Turning the adjusting screw in a
Figure 7.3-1 clockwise direction causes the
valve to open at higher pressure.
Turning in a counter-clockwise
direction causes the valve to open
protected
at lower pressure.
Release the pressure before
readjusting the adjusting screw.
Readjust the adjusting screw and
then pressurise the valve again.
If the pressure setting has been Open-end

completed, secure the adjusting spanner
screw with a lock nut.
Afterwards, check the set
pressure once again.
Figure 7.3-2

7.4 Testing the seat tightness P12

This test is performed for every valve after setting the pressure.
7.5 Testing of the seal tightness of the pressure-bearing body P11

This test is performed for every flanged valve without a nozzle after its assembly
P12.
7.6 Assembly of the cap / lever

7.6.1 Assembly of cap H2
Grease the thread and sealing Brush
lip.
Halocarbon
(OI-56 S / 60H)
protected
Figure 7.6.1-1
Screw the cap onto the bonnet Open-end
and tighten. spanner
Figure 7.6.1-2


Pull the O-ring over the Brush
spindle cap and grease.
Halocarbon
(OI-56 S / 60H)
Figure 7.6.2-1
Put the spindle cap onto

the spindle and secure
with a pin.
protected
Figure 7.6.2-2
Grease the sealing lip and Brush
thread of the lever cover.
Halocarbon
(OI-56 S / 60H)
Figure 7.6.2-3


Afterwards, screw the Open-end spanner
lever cover (bottom
section) onto the bonnet
and tighten slightly.
Figure 7.6.2-4
Pull the spindle cap out
entirely and secure with a
pin.
protected
Figure 7.6.2-5
Position the spindle cap in
the middle (pin is
positioned centrally in the
elongated hole)
Figure 7.6.2-6
Grease the thread of the Brush
lever cover (top section).
Halocarbon
(OI-56 S / 60H)
Figure 7.6.2-7


Grease spindle cap. Brush
Halocarbon
(OI-56 S / 60H)
Figure 7.6.2-8
Screw the cap onto the lever cover.
protected
Figure 7.6.2-9
Screw in and tighten the screw plug.
Figure 7.6.2-10
Afterwards, screw up the cap as far Flat-tip screwdriver
as it will go so that the screw plug
and cap are flush.
Figure 7.6.2-11

Testing the lever:
Pressurise the valve (approx. 90% of the set pressure).
Check the lever by manual venting.
Testing passed: Pressure drops
Testing did not pass: Pressure remains constant
protected


7.6.3.1 Lever H8 (simple piston design)

Grease the threads of Brush
the cap nut.
Halocarbon
(OI-56 S / 60H)
Figure 7.6.3.1-1
Put the cap nut on the
bonnet.
protected
Figure 7.6.3.1-2
Grease the O-ring Brush
groove of the piston
Halocarbon
guide, and insert the O-
ring avoiding twisting, (OI-56 S / 60H)
possibly with the help of
a pin punch.
Figure 7.6.3.1-3


Grease O-ring. Brush
Halocarbon
(OI-56 S / 60H)
Figure 7.6.3.1-4
Screw piston guide to bonnet C-spanner with a
and tighten with a C- nose
spanner.
protected
Figure 7.6.3.1-5
Grease the groove on the Brush
inside of the piston.
Halocarbon
(OI-56 S / 60H)
Pin punch
Figure 7.6.3.1-6


Put the O-ring in the groove Brush
of the piston and grease
Halocarbon
again.
(OI-56 S / 60H)
Figure 7.6.3.1-7
Put the piston on the piston C-spanner with a
guide. nose
protected
Figure 7.6.3.1-8
Grease the groove and Pin punch
stretch the O-ring over the
piston avoiding any twisting
of the ring, possibly with the
help of a pin punch.
Figure 7.6.3.1-9


Afterwards, grease the O-ring. Brush
Halocarbon
(OI-56 S / 60H)
Figure 7.6.3.1-10
Put the spindle cap on the
spindle and secure with a roll
pin.
Stretch the small O-ring for
securing the pin onto the spindle
cap.
protected
Figure 7.6.3.1-11
Put the spring into the piston.
Figure 7.6.3.1-12


Twist the angle-screw
with the pneumatic
valve into the cap and
tighten.
Figure 7.6.3.1-13
Grease the inside of Brush
the cap for the O-ring
Halocarbon
guide.
(OI-56 S / 60H)
protected
Figure 7.6.3.1-14
Put the cap on
(possibly some
pressure) and tighten.
Figure 7.6.3.1-15


Tightening the cap Open-end spanner
nut also tightens the
cap.
protected
Figure 7.6.3.1-16
Afterwards, secure Open-end spanner
the cap with a
second open-end
spanner.
(The angle-screw
must always be
opposite the outlet!)
Figure 7.6.3.1-17


Pressurise the
piston to 6-8 bar line
pressure via the
pneumatic valve.
During the
procedure, check
through the outlet
whether the valve
lifts.
protected
Figure 7.6.3.1-18
Spray/brush the Brush
interconnection
Leak detection
points with leak
spray
detector to check the
seal tightness.
Figure 7.6.3.1-19

7.6.3.2 Lever H8 (double piston design)

Grease the piston guide on the groove Brush
for the O-ring.
Halocarbon
(OI-56 S / 60H)
Figure 7.6.3.2-1
Insert the O-ring and grease again. Brush
Halocarbon
protected
(OI-56 S / 60H)
Figure 7.6.3.2-2
Put piston guide on valve and tighten C-spanner with a
with a C-spanner. nose
Figure 7.6.3.2-3


Insert O-ring avoiding twisting (grease Brush
before and after).
Halocarbon
(OI-56 S / 60H)
Figure 7.6.3.2-4
Insert O-ring in piston (grease before Brush
and after).
Halocarbon
protected
(OI-56 S / 60H)
Figure 7.6.3.2-5
Put piston on piston guide and put O- Brush
ring into the outer groove (grease
Halocarbon
before and after).
(OI-56 S / 60H)
Figure 7.6.3.2-6


Put on the spindle cap and secure with
a pin and retaining clip.
Figure 7.6.3.2-7
Put on the spring.
protected
Figure 7.6.3.2-8
Put on the cylinder. In the process,
make sure the pneumatic valve is
opposite the outlet.
Figure 7.6.3.2-9


Fasten cylinder with split ring.
Figure 7.6.3.2-10
Pull on O-ring.
protected
Figure 7.6.3.2-11
Insert O-ring in second piston.
Figure 7.6.3.2-12


Grease all O-rings before and after! Brush
Put piston on and insert O-ring.
Halocarbon
(OI-56 S / 60H)
Figure 7.6.3.2-13
Put on the spindle cap and secure
with a pin and retaining clip.
protected
Figure 7.6.3.2-14
Put the spring onto the piston.
Figure 7.6.3.2-15


Put on the cap. In the process, make
sure the angle-screw is opposite the
outlet.
Figure 7.6.3.2-16
Connect cap with split ring and tighten Ring spanner
the nut.
protected
Figure 7.6.3.2-17
Pressurise the piston to 6-8 bar line
pressure via the pneumatic valve.
During the procedure, check through
the outlet whether the valve lifts.
Afterwards, test the seat tightness P12
and seal tightness of the pressure-
bearing body P11.
Apply leak detector to the
interconnection points and look for
bubbles.
Figure 7.6.3.2-18

7.7 Sealing the valve
Weld on sealing lug if Sealing wire
necessary.
Sealing block
Closely connect the sealing
Wire twisting pliers
hole or lug from the cap/lever
and bonnet in a clockwise
direction. Interlace the wire.
Seal the lever/cap to the
outlet body.
Figure 7.7-1
Sealed cap H2
protected
Figure 7.7-1Fehler! Es wurde keine Folge
festgelegt.
Sealed cap H4

festgelegt.
Sealed cap H8 (simple piston
design)

festgelegt.


07 Assembly CS - EN

Uploaded by

Copyright:

Available Formats

07 Assembly CS - EN

Uploaded by

Document Information

Original Title

Copyright

Available Formats

Share this document

Share or Embed Document

Sharing Options

Did you find this document useful?

Is this content inappropriate?

Copyright:

Available Formats

07 Assembly CS - EN

Uploaded by

Copyright:

Available Formats

LESER WORKS STANDARD LWN 322-03-EN

Torques for screw, nuts and caps H2 / lifting devices

1 Body and bonnet connection

Material Min. – max. Torque [Nm]

Material- Min. – max. Torque [Nm] *

2 Caps and lifting devices

Torque [Nm]** Wrench size

3.1 Short locking screws

Cap size Thread size Torque

3.2 Long locking screws

Cap size Thread size Torque

4 Qualified fitting personnel

disclosure cat.: II proofread: OR published date: 17.11.10 effect. date: 18.11.2010

• Wear safety glasses

6 Paint touch-up and painting repaired valves

disclosure cat.: II proofread: OR published date: 17.11.10 effect. date: 18.11.2010

Figure 6-3: Component plate sticker Figure 6-4: Protective cap

disclosure cat.: II proofread: OR published date: 17.11.10 effect. date: 18.11.2010

Figure 6-7: Masking tape Figure 6-8: Protective cap

disclosure cat.: II proofread: OR published date: 17.11.10 effect. date: 18.11.2010

disclosure cat.: II proofread: OR published date: 17.11.10 effect. date: 18.11.2010

6 Attaching component/customer identification plates

Types 437, 438, 439 - outlet body

disclosure cat.: II proofread: OR published date: 17.11.10 effect. date: 18.11.2010

The standard plate comes in two versions.

Attachment locations for standard component plates

Figure 6.2.1-2: Type 459 Figure 6.2.1-3: Type 462

disclosure cat.: II proofread: OR published date: 17.11.10 effect. date: 18.11.2010

Figure 6.2.1-4: Type 437 Figure 6.2.1-5: Type 462

6.2 World plate (NGA)

The world plate (NGA) comes in two versions.

disclosure cat.: II proofread: OR published date: 17.11.10 effect. date: 18.11.2010

6.2.1 Pre-curving of the NGA

Illustrations Description Aids / Tools

Illustrations Description Aids / Tools

disclosure cat.: II proofread: OR published date: 17.11.10 effect. date: 18.11.2010

Adjustment of plate for closed bonnets

6.2.2 Corrosion protection

Illustrations Description Aids / Tools

disclosure cat.: II proofread: OR published date: 17.11.10 effect. date: 18.11.2010

disclosure cat.: II proofread: OR published date: 17.11.10 effect. date: 18.11.2010

a) Closed bonnets (V20 - V32)

For closed bonnets, the world

b) Open bonnets (V20 - V25)

The plate must be mounted

c) Open bonnet (V32)

d) Open bonnet (V40)

Position of the world plate

6.3.3 Fastening with grooved pins with round heads

disclosure cat.: II proofread: OR published date: 17.11.10 effect. date: 18.11.2010

disclosure cat.: II proofread: OR published date: 17.11.10 effect. date: 18.11.2010

disclosure cat.: I proofread: AW / TS published date: 05.2011 effect. date: 05.2011

5 Qualified fitting personnel

• Gloves must be worn during the entire assembly.

disclosure cat.: I proofread: AW / TS published date: 05.2011 effect. date: 05.2011

Figure 7-1: Type 437

8 Assembly of the Compact Performance series

Illustration Description Tool / aid

disclosure cat.: I proofread: AW / TS published date: 05.2011 effect. date: 05.2011