Operating and installation instructions

3-way control valves - STEVI® 423 / 463

Series 423 Series 463

Contents
1.0 General information on operating 7.0 Care and maintenance................................ 2-8
instructions ..................................................2-2 7.1 Replacement of stem sealings ............................ 2-8
2.0 Notes on possible dangers.........................2-2 7.1.1 Stuffing box packing design ............................ 2-8
7.1.2 Bellows seal design ........................................ 2-9
2.1 Significance of symbols ...................................... 2-2
7.1.2.1 Bellows seal and mixing plug..................... 2-9
2.2 Explanatory notes on safety information ............. 2-2 7.1.2.2 Bellows seal and diverting plug................ 2-10
3.0 Storage and transport ................................2-2 7.2 Replacement of internal parts ............................2-11
4.0 Description...................................................2-3 7.2.1 Replacement of plug and stem .....................2-11
4.1 Scope of applications .......................................... 2-3 7.2.1.1 Mixing plug design ....................................2-11
7.2.1.2 Diverting plug design ............................... 2-12
4.2 Operating principles ............................................ 2-3
7.2.2 Replacement of the seat ring........................ 2-12
4.3 Diagram............................................................... 2-4
7.3 Tightening torques............................................. 2-13
4.3.1 Mixing plug design .......................................... 2-4
7.3.1 Tightening torques for hexagon nuts ........... 2-13
4.3.2 Diverting plug design ..................................... 2-4
7.3.2 Tightening torques for seat rings ................. 2-13
4.4 Technical data ..................................................... 2-5
4.5 Marking ............................................................... 2-5
8.0 Troubleshooting ........................................ 2-13
5.0 Installation....................................................2-5 9.0 Troubleshooting table .............................. 2-14
5.1 General notes on installation............................... 2-5 10.0 Dismantling the valve or the top part ... 2-15
5.2 Requirements at the place of installation ............ 2-6 11.0 Warranty / Guarantee .............................. 2-15
5.3 Installation instructions concerning actuators ..... 2-6
6.0 Putting the valve into operation.................2-7

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 Operating and installation instructions
3-way control valves - STEVI® 423 / 463

1.0 General information on operating instructions

These operating instructions provide information on mounting and maintaining the fittings.
Please contact the supplier or the manufacturer in case of problems which cannot be
solved by reference to the operating instructions.
They are binding on the transport, storage, installation, start-up, operation, maintenance
and repair.
The notes and warnings must be observed and adhered to.
- Handling and all work must be carried out by expert personnel or all activities must be
supervised and checked.
It is the owner’s responsibility to define areas of responsibility and competence and to
monitor the personnel.
- In addition, current regional safety requirements must be applied and observed when
taking the fittings out of service as well as when maintaining and repairing them.
The manufacturer reserves the right to introduce technical modifications at any time.
These Operating Instructions comply with the requirements of EU Directives.
2.0 Notes on possible dangers
2.1 Significance of symbols
ATTENTION !
... Warning of general danger.

2.2 Explanatory notes on safety information

In these Operating and Installation Instructions dangers, risks and items of safety
information are highlighted to attract special attention.
Information marked with the above symbol and “ATTENTION ! ” describe practices, a
failure to comply with which can result in serious injury or danger of death for users or third
parties or in material damage to the system or the environment. It is vital to comply with
these practices and to monitor compliance.
All other information not specifically emphasised such as transport, installation, operating
and maintenance instructions as well as technical data (in the operating instructions,
product documentation and on the device itself) must also be complied with to the fullest
extent in order to avoid faults which in turn can cause serious injury to persons or damage
to property.

3.0 Storage and transport

ATTENTION !
- Protect against external force (like impact, vibration, etc.).
- Valve mountings such as actuators, handwheels, hoods must not be used to
take external forces, e.g. they are not designed for use as climbing aids, or as
connecting points for lifting gear.
- Suitable materials handling and lifting equipment should be used.
See catalog sheet for weights.
- At -20°C to +65°C.
- The paint is a base coat to protect against corrosion during transportation and storage. Do
not damage paint protection.

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 Operating and installation instructions
3-way control valves - STEVI® 423 / 463

4.0 Description
4.1 Scope of applications
Valves are used for „controlling the flow of liquids, gases and vapours in chemical and other
processing plants and for plant engineering“.

ATTENTION !
- Refer to the data sheet for applications, limits on use and possibilities.
- Certain media require or preclude the use of special materials.
- The valves are designed for standard operating conditions. If conditions exceed
these requirements, e.g. aggressive or abrasive media, the operator should
state the higher requirements when ordering.
- Valves made from grey cast iron are not authorised for use in systems subject
to TRD 110.
The information complies to the Pressure Equipment Directive 2014/68/EU.
It is the responsibility of the machine planner to ensure compliance.
The special markings on the valve must be taken into account.
Refer to the catalogue sheet to see which materials are used in standard versions.
Please contact the supplier or the manufacturer if you have any questions.

4.2 Operating principles

The control valves are especially suitable for actuation by pneumatic or electrical actuators.
Depending on the mode of operation, two different execution methods are possible:
1. Execution with mixing plug
2. Execution with diverting plug
The execution with the mixing plug is the standard execution method.
This execution method is to be chosen when the valve is also employed as a mixer 
(2 entrances, 1 exit.) 
In exceptional cases, the execution with the mixing plug can also be employed as a
diverting plug (1 entrance, 2 exits). This requires, however, low differential pressures and
stable propulsion.
The execution method with the diverting plug is only to be employed with the operation of
diverting.
Explanation:
Mixing operation Diverting operation
AB A AB A

B B

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 Operating and installation instructions
3-way control valves - STEVI® 423 / 463
4.3 Diagram
4.3.1 Mixing plug design

Fig. 1: Series 423 Fig. 2: Series 463

4.3.2 Diverting plug design

Fig. 3: Series 423 Fig. 4: Series 463

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 Operating and installation instructions
3-way control valves - STEVI® 423 / 463
4.4 Technical data
for
- Principal dimensions
- Pressure-temperature-ratings, etc. refer to datasheet.
4.5 Marking
Nominal diameter Manufacturer
Type-Number CE-marking
Flow Nominal pressure
characteristic Notified body
Kvs-value

Plug Customer-specific
design information
Serial-No. Stem sealing
Material of Year of manufacture clear speech
internal parts (1. and 2. position)
Fig. 5
Address of manufacturer: refer to item 11.0 Warranty / Guarantee

5.0 Installation
5.1 General notes on installation
The following items should be taken into account besides the general principles governing
installation work:
ATTENTION !
- Remove flange covers if present.
- The interior of valve and pipeline must be free from foreign particles.
- Note installation position with reference to flow, see mark on valve.
- Steam line systems should be designed to prevent water accumulation.
- Lay pipelines so that damaging transverse, bending and torsional forces are
avoided.
- Protect valves from dirt during construction work.
- Connection flanges must mate exactly.
- Connecting bolts for pipe flanges should be mounted preferably from the
counter flange side (hexagon nuts from the valve side).
- Valve mountings such as actuators, handwheels, hoods must not be used to
take external forces, e.g. they are not designed for use as climbing aids, or as
connecting points for lifting gear.
- Suitable materials handling and lifting equipment should be used.
Refer to data sheet for weights.
- Keep the thread and shaft of the stem free from paint.
- Centre gaskets between the flanges.
- Strainers or filters should be installed before the valves.
- Planners / construction companies or operators are responsible for positioning and
installing products.
- The valves are designed for application, not influenced from weather.
- For application outside or in adverse environments like corrosion-promoting conditions
(sea water, chemical vapours, etc.), special constructions or protective measures are
recommended.

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 Operating and installation instructions
3-way control valves - STEVI® 423 / 463
5.2 Requirements at the place of installation
The place of installation should be easily accessible and provide ample space for
maintenance and removing the actuator. Stop valves should be installed before and behind
the control valve to enable maintenance working without draining the piping system. The
valve should preferably installed vertically with the actuator at the top. Inclined or horizontal
installation without supports is permissible only with light actuators.
For this installation position, the two distance columns (or joke) have to be above each
other in the vertical plane.

Fig. 6: Pipeline vertically Fig. 7: Pipeline horizontally

Safe actuator weights for a horizontal installation position with reference to the stem,
without structural support, are as follows:
55 kg for DN 200-250
The pipes must be lagged to protect the actuators from excessive heat. Sufficient space
must be left for the maintenance of the stem packing.
To ensure that the control valves function correctly, the pipe run should be straight for at
least 2 x DN upstream and 6 x DN downstream of the valve.
5.3 Installation instructions concerning actuators
Normally, control valves are supplied complete with actuator fitted. 
It is not permitted to mantle / dismantle actuators with valves operating at service conditions
(temperature and pressure) the actuators must be assembled as describe in the operating
instructions during conversion and maintenance. 
During assembly work, the plug is not be turned on its seatring at closing pressure. 
ATTENTION !
Care must be taken with the bellow type valves when actuators are mounted or
removed. (Hold the valve-stem against turning with an open-end wrench!)
When retrofitting actuators, the maximum permissible force for valve actuation must be
taken into account:
Series 423 Series 463
59kN for DN 200-250 37kN for DN 200-250

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 Operating and installation instructions
3-way control valves - STEVI® 423 / 463

6.0 Putting the valve into operation

ATTENTION !
- Before putting the valve into operation, check material, pressure, temperature
and direction of flow.
- Regional safety instructions must be adhered to.
- Residues in piping and valves (dirt, weld beads, etc.) inevitably lead to leakage.
- Touching the valve when it is operating at high (> 50 °C) or low (< 0 °C) media
temperatures can cause injury.
Affix warning notice or protective insulation as appropriate!
Before putting a new plant into operation or restarting a plant after repairs or
modification, always make sure that:
- All works has been completed!
- The valve is in the correct position for its function.
- Safety devices have been attached.

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 Operating and installation instructions
3-way control valves - STEVI® 423 / 463

7.0 Care and maintenance

Maintenance and maintenance intervals have to be defined by the operator according to
the service conditions.

7.1 Replacement of stem sealings

7.1.1 Stuffing box packing design
Stuffing box packings (pos. 17) require maintenance.
If leaks develop, Immediately tighten hexagon nuts (pos. 22) gradually until the packing
(pos. 17) stops leaking.
The service life of stuffing box packings (pos. 17) can be increased by checking regularly
leakage.
If leaks can no longer be stopped by tightening the nuts, a new packing ring (pos. 17) must
be inserted into the gland.
Replacement of stuffing box packings:
ATTENION !
Refer to item 10.0 and 11.0 before dismantling the valve.
- Remove the actuator. (Refer to operating instructions for actuator!)
- Insert the new packing ring as shown in the Fig. 8.

Fig. 9: Split packing ring

If a split packing ring is used,
cut with a chamfer as shown
in Fig. 9.

Fig. 8: Stuffing box packing

Damaged stems must also be replaced (refer to item 7.2 for instructions), since a new
sealing will soon start leaking again if the stem is damaged.

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 Operating and installation instructions
3-way control valves - STEVI® 423 / 463
7.1.2 Bellows seal design
If the stem leaks the bellows seal (pos. 25.3) is defective. The leak can initially be stopped
by tightening the screw joint (pos. 25.17) respectively sleeve nut (pos. 25.16).
Stem and bellows seal (pos. 20.3) can only be replaced together.
Replacement of bellows seals:
ATTENION !
Refer to item 10.0 and 11.0 before dismantling the valve.
- Remove the actuator. (Refer to operating instructions for actuator!)
- Slacken screw joint (pos. 20.17) respectively sleeve nut (pos. 20.16) by about one turn.
- Loose nuts (pos. 29).
- Lift bellows housing (pos. 25.1).
- Drive pin (pos. 16) out with a drift.
7.1.2.1 Bellows seal and mixing plug
- Loose nuts (pos. 7 bottom).
- Detach the bottom flange (pos. 3).
- Unscrew plug (pos. 8) with adapter (pos. 15).
- Loose nuts (pos. 29).
- Detach bellows assembly (pos. 25).
- Loose nuts (pos. 25.8).
- Detach stuffing box housing (pos. 25.13) resp.
mounting bonnet (pos. 25.2).
- Extract stem-/bellows unit (pos. 25.3) from the
bellows housing (pos. 25.1).
(top)
- Bolt new parts together and drill them.
- Replace 2 gaskets (pos. 25.6) and 2 gaskets
(pos. 5). (top)

- Assemble in reverse order.

ATTENTION !
- Ensure that the torsion lock is
correctly positioned when inserting
new stem/bellows unit. Introduce the
grooved pin (pos. 25.9) into the
torsion lock groove. 
Make sure it runs smoothly!
- Secure with nuts (pos. 7, 25.8 and 29) and (bottom)
tighten them crosswise. 
(For tightening torques refer to point 7.3.1.)
(bottom)
- Tighten screw joint (pos. 25.17) respectively
sleeve nut (pos. 25.16) gradually up to
tightness of the stuffing box packing (pos. Fig. 10: Series 463 with mixing plug
25.10).

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 Operating and installation instructions
3-way control valves - STEVI® 423 / 463
7.1.2.2 Bellows seal and diverting plug
- Remove the cotter pin (pos. 33).
- Unscrew castle nuts (pos. 32).
- Detach V-port plug (pos. 31).
- Loose nuts (pos. 7 top).
- Detach bellows assembly (pos. 25) incl.
stuffing box housing (pos. 12).
- Loose nuts (pos. 25.8).
- Detach stuffing box housing (pos. 25.13)
resp. mounting bonnet (pos. 25.2).
- Extract stem/bellows unit (pos. 25.3) from
the bellows housing (pos. 25.1). (top)

- Bolt new parts together and drill them.

- Replace 2 gaskets (pos. 25.6) and 2
gaskets (pos. 5).
- Assemble in the reverse order.
ATTENTION !
- Ensure that the torsion lock is
correctly positioned when
inserting new stem/bellows unit.
Introduce the grooved pin (pos.
25.9) into the torsion lock groove. 
Make sure it runs smoothly!
- Secure with nuts (pos. 7, 25.8 and 29) and (bottom)

tighten them crosswise. 

(For tightening torques refer to point 7.3.1.)
- Tighten screw joint (pos. 25.17)
respectively sleeve nut (pos. 25.16)
Fig. 11: Series 463 with diverting plug
gradually up to tightness of the stuffing box
packing (pos. 25.10).

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 Operating and installation instructions
3-way control valves - STEVI® 423 / 463
7.2 Replacement of internal parts
7.2.1 Replacement of plug and stem
ATTENION !
Refer to item 10.0 and 11.0 before dismantling the valve.
- Remove the actuator. (Refer to operating instructions for actuator!)
- Slacken nuts (pos. 22) by about 2-3 turns.
7.2.1.1 Mixing plug design
Series 423
- Loose nuts (pos. 7).
- Detach bottom flange (pos. 3).
- Remove plug (pos. 8) with stem (pos. 10).
- Drive pin (pos. 9) out with a drift.
- Unscrew plug (pos. 8).
- Bolt new parts together, drill and pin them.
- Replace 2 gaskets (pos. 5).
- Assemble in reverse order.
- Secure with nuts (pos. 11) and tighten them
crosswise. 
(For tightening torques refer to point 7.3.1)
Series 463
Item 7.1.2 describes how to change mixing plug
and stem in valves with a bellows seal
(series 463).

Fig. 12: Series 423 with mixing plug

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 Operating and installation instructions
3-way control valves - STEVI® 423 / 463
7.2.1.2 Diverting plug design
Series 423
- Remove the cotter pin (pos. 33).
- Unscrew castle nuts (pos. 32).
- Unscrew V-port plug (pos. 31).
- Loose nuts (pos. 7).
- Detach stuffing box housing (pos. 12).
- Extract plug (pos. 30) and stem (pos. 10).
- Drive pin (pos. 9) out with a drift.
- Unscrew plug (pos. 30).
- Bolt new parts together, drill and pin them.
- Replace 2 gaskets (pos. 5).
- Assemble in the reverse order.
- Secure with nuts (pos. 7) and tighten them
crosswise. 
(For tightening torques refer to point 7.3.1)
Series 463
Item 7.1.2 describes how to change diverting
Fig. 13: Series 423 with diverting plug
plug and stem in valves with a bellows seal
(series 463).

7.2.2 Replacement of the seat ring

ATTENTION !
Refer to item 10.0 and 11.0 before dismantling the valve.
- Remove actuator. (Refer to operating instructions for actuator!)
- Remove plug as described in item 7.2.1.
- Unscrew seat rings (pos. 2 top and bottom) with a special wrench (can be obtained from
the manufacturer).
- Clean thread and sealing taper in body (pos. 1) respectively bottom flange (pos. 3) and
apply with suitable lubricant.
- Replace respectively recondition seat rings (pos. 2 top and bottom).
- Install seat rings (pos. 2 top and bottom). (For tightening torques refer to item 7.3.2.)
- Replace 2 gaskets (pos. 5).
- Assemble in reverse order.
- Secure with nuts (pos. 7) and tighten them crosswise. 
(For tightening torques refer to item 7.3.1.)

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 Operating and installation instructions
3-way control valves - STEVI® 423 / 463
7.3 Tightening torques
7.3.1 Tightening torques for hexagon nuts
M 12 = 35 - 50 Nm
M 16 = 80 - 120 Nm
M 20 = 150 - 200 Nm
M 24 = 340 - 410 Nm

7.3.2 Tightening torques for seat rings

DN 200 = 3300 Nm
DN 250 = 3850 Nm

Refer to operating and installation instructions for actuator

concerned for installing actuators!

8.0 Troubleshooting
In the event of malfunction or faulty operating performance check that the installation and
adjustment work has been carried out and completed in accordance with these Operating
Instructions.
ATTENTION !
- It is essential that the safety regulations are observed when identifying faults.
-

If malfunctions cannot be eliminate with the help of the following table 

“9.0 Troubleshooting table”, the supplier or manufacturer should be consulted.

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 Operating and installation instructions
3-way control valves - STEVI® 423 / 463

9.0 Troubleshooting table

ATTENTION !
- read item 10.0 and 11.0 prior to dismantling and repair work!
- read item 6.0 before restarting the plant !

Fault Possible cause Corrective measures

No flow Valve closed Open valve (using actuator)
Flange covers not removed Remove flange covers
Little flow Valve not sufficiently open Open valve (using actuator)
Dirt sieve clogged Clean / replace sieve
Piping system clogged Check piping system
Kvs value of valve unsuitable Fit valve with higher Kvs value
Stem moves in jerks Stuffing box sealing too tight (for valves Tighten packing box flange (pos. 20)
with graphite packings) resp. nuts (pos. 22) slightly; valve must
not start leaking
Valve plug slightly seized owing to solid Clean internals, smooth rough spots
dirt particles
Stem or plug cannot be Seatring and plug clogged with dirt; Clean seatring and plug with suitable
moved especially with V-port and perforated solvent
plugs
Valve plug seized in seatring or guide Replace plug and seatring; use parts
owing to deposits or dirt in medium made from different material if neces-
sary; refer to item 7.2
Stem leaking In valves with packed stuffing boxes, Tighten packing box flange (pos. 20)
tighten screw joint (pos. 22) resp. nuts (pos. 22); replace packing if
necessary; refer to item 7.1.1
Bellows defective in valves with bellow Replace bellows unit; 
seal refer to item 7.1.2
Leakage too high when Sealing surfaces of plug eroded or worn Replace plug; refer to item 7.2
valve is closed Sealing edge of seatring damages or Replace seatring; refer to item 7.2
worn
Seatring and/or plug dirty. Clean internal parts of the valve
Pneumatic actuator not completely Vent actuator air chamber completely
vented; spring force not fully effective
Actuator not powerful enough Install more powerful actuator; check
service data
Stem “hammers” flow in the closing direction Compare the plug operation (mixing- or
diverting plug) with the application and
if necessary exchange the fittings or
increase actuator force

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 Operating and installation instructions
3-way control valves - STEVI® 423 / 463

10.0 Dismantling the valve or the top part

ATTENTION !
The following points must be observed:
- Pressureless pipe system.
- Medium must be cool.
- Plant must be drained.
- Purge piping systems in case of caustic, inflammable, aggressive or toxic
media.

11.0 Warranty / Guarantee

The extent and period of warranty cover are specified in the "Standard Terms and
Conditions of Albert Richter GmbH & Co. KG“ valid at the time of delivery or, by way of
departure, in the contract of sale itself.
We guarantee freedom of faults in compliance with state-of-the-art technology and the
confirmed application.
No warranty claims can be made for any damage caused as the result of incorrect handling
or disregard of operating and installation instructions, datasheets and relavant regulations.
This warranty also does not cover any damage which occurs during operation under
conditions deviating from those laid down by specifications or other agreements.
Justified complaints will be eliminated by repair carried out by us or by a specialist
appointed by us.
No claims will be accepted beyond the scope of this warranty. The right to replacement
delivery is excluded.
The warranty shall not cover maintenance work, installation of external parts, design
modifications or natural wear.
Any damage incurred during transport should not be reported to us but rather to the
competent cargo-handling depot, the railway company or carrier company immediately or
else claims for replacements from these companies will be invalidated.

Technology for the Future.

GERMAN QUALITY VALVES
ARI-Armaturen Albert Richter GmbH & Co. KG, D-33750 Schloß Holte-Stukenbrock
Telephone (+49 5207) 994-0 Telefax (+49 5207) 994-158 or 159
Internet: http://www.ari-armaturen.com E-mail: info.vertrieb@ari-armaturen.com

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