Safe operation of these products can only be guaranteed if they are properly installed,
commissioned, used and maintained by qualified personnel (see Section 1.11) in compliance
with the operating instructions. General installation and safety instructions for pipeline and
plant constr uction, as well as the proper use of tools and safety equipment must also be
complied with.
1.1 Intended use
Referring to the Installation and Maintenance Instructions, name-plate and Technical Information
Sheet , check that the product is suitable for the intended use/application. The products listed below
comply with the requirements of the Pressure Equipment Directive (PED) and carry t he mar k
when so required. The products fall within the following Pressure Equipment Directive categories:
Product
DN15 - DN25 (PN25)SEPSEPSEPSEP
PF51G
PF6_G
i) The products have been specif ically designed for use on steam, water, compressed air, inert
indus trial gas es and cer tain oils w hich are in G roup 2 of the ab ove mentio ned Pressur e Equipmen t
Direc tive. The PF5G and PF6G (DN15 - DN25 only) can also be used on propane or methane
gases which are in Group 1 of the above Pressure Equipment Directive. The products’ use on
other f luids may be possible but, if this is contemplated, Spirax Sarco should be contac ted to
confirm the suitability of the product for the applicat ion being considered.
ii) Check material suitability, pressure and temperature and their maximum and minimum values.
If the maximum operating limits of the product are lower than those of the system in which it
is being fitted, or if malfunction of the product could result in a dangerous overpressure or
overtemper ature occurrence, ensure a safety device is included in the system to prevent such
over-limit situations.
iii) Determine the correct installation situation and direction of fluid flow.
iv) Spira x Sarco products are not intended to withstand external st resses that may be induc ed
by any system to which they are fitted. It is the responsibility of the installer to consider these
stresses and take adequate precautions to minimise them.
v) Remove p rotection c overs from all c onnection s and protective film from al l name-pl ates, where
appropriate, before installation on steam or other high temperature applications.
DN32 - DN40 (PN25)-SEPSEPSEP
DN50(PN16)-SEPSEPSEP
DN15 - DN25 (PN40)SEPSEPSEPSEP
DN32 - DN40 (PN25)1SEPSEPSEP
DN50(PN16)1SEPSEPSEP
Group 1
Gases
Group 2
Gases
Group 1
Liquids
Group 2
Liquids
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IM-P373- 05 CTLS Issue 14
1.2 Access
Ensure safe access and if necessary a safe wor king platform (suita bly guarded) before attempting
to work on the product. Arrange suitable lifting gear if required.
1.3 Lighting
Ensure adequate lighting, particularly where detailed or intricate work is required.
1.4 Hazardous liquids or gases in the pipeline
Consider what is in the pipeline or what may have been in the pipeline at some previous time.
Consider: flammable materials, substances hazardous to health, extremes of temperature.
1.5 Hazardous environment around the product
Consider: explosion r isk areas, lack of oxygen (e.g. tanks, pits), dangerous gases, extremes of
temperature, hot surfaces, fire hazard (e.g. during welding), excessive noise, moving machinery.
1.6 The system
Consider the effect on the co mplet e system of the work proposed. Will any proposed action (e.g.
closing isolation valves, electrical isolation) put any other par t of the system or any personnel at
risk?
Dangers might includ e isolation of vents or protective devices or th e rendering ineffective of
controls or alarms. Ensure isolation valves are turned on and off in a gradual way to avoid system
shocks.
1.7 Pressure systems
Ensure that any pressure is isolated and safely vented to atmospheric pressure. Consider double
isolation (double block and bleed) and the locking or labelling of closed valves. Do not assume
that the system has depressurised even when the pressure gauge indicates zero.
1.8 Temperature
Allow time for temperature to normalise after isolation to avoid danger of burns.
1.9 Tools and consumables
Before star ting work ensure that you have suitable tools and/or consumables available. Use only
genuine Spirax Sarco replacement parts.
1.10 Protective clothing
Consi der whethe r you and/or oth ers in the vic inity req uire any prote ctive clot hing to prote ct against
the hazards of, for example, chemicals, high/low temperature, radiation, noise, falling objects, and
dangers to eyes and face.
IM-P373- 05 CTLS Issue 14
3
1.11 Permits to work
All work must be carried out or be super vised by a suitably competent person.
Installation and operating personnel should be trained in the correct use of the produc t according
to the Installation and Maintenance Instructions.
Where a formal 'permit to work' system is in force it must be complied with. Where there is no such
system, it is recommended that a responsible person should know what work is going on and,
where necessary, arrange to have an assistant whose primar y responsibility is safet y.
Post 'warning notices' if necessar y.
1.12 Handling
Manual handling of large and/or heavy produc ts may present a risk of injury. Lif ting, pushing,
pulling, carrying or supporting a load by bodily force can c ause injury particularly to the back.
You are advised to assess the r isks taking into account the task, the individual, the load and the
working environment and use the appropriate handling method depending on the circumstances
of the work being done.
1.13 PTFE - Handling precautions
Within its wor king temperature range PTFE i s a compl etely inert material, but when heated to it s
sintering temperature it gives rise to a gaseous decomposition product or fumes which can produce
unpleasant effects if inhaled. The inhalation of these fumes is easily prevented by applying local
exhaust ventilation to atmosphere as near to their source as possible.
Smoki ng should be pr ohibited i n workshops wh ere PTFE is han dled becau se tobacco c ontaminat ed
with PTFE will during burning give rise to p olymer fumes. It is therefore impor tant to avoid
contamination of clothing, especially the pockets, with PTFE and to maintain a reasonable standard
of personal cleanliness by washing hands and removing any PTFE particles lodged under the
fingernails.
1.14 Residual hazards
In normal use th e external su rface of th e product may be very hot. If used at the maximu m pe rmitted
operating conditions the surface temperature of some products
may reach temperatures of 180 °C (356 °F).
Many pro ducts are not self-draining. Take due care when dismantling or removing t he product from
an installation (refer to 'Maintenance instructions').
1.15 Freezing
Provision must be made to protect produc ts which are not self-draining against frost damage in
environments where they may be exposed to temperatures below freezing point.
4
IM-P373- 05 CTLS Issue 14
1.16 Disposal
Unles s otherwi se stated in t he Installa tion and Mai ntenance In structi ons, this pro duct is recycl able
and no ecological haz ard is anticipated with its disposal providing due care is taken. However, if
the valve is fit ted with a FKM or PTFE seat, special care must be taken to avoid potential health
hazards associated with decomposition/burning of these seats.
FKM:
Can be landfilled, when in compliance with National and Local regulations.
-
Can be incinerated, but a scrubber must be used to remove Hydrogen Fluoride, which is evolved
-
from the product and with compliance to National and Local regulations.
Is insoluable in aquatic media.
-
PTFE:
Can only be disposed of by approved methods, not incineration.
-
Keep PTFE waste in a separate container, do not mix it with other rubbish, and consign it to
-
a landf ill sit e.
1.17 Returning products
Custom ers and stockists are reminded that under EC Health, Safety and Environment Law, when
retur ning prod ucts to Spi rax Sarc o they must pr ovide info rmation o n any hazar ds and the pr ecauti ons
to be taken due to contamination residues or mechanical damage which may present a health,
safety or environmental risk. This information must be provided in writing including Health and
Safet y data sheets relating to any substances identified as hazardous or potentially haz ardous.
IM-P373- 05 CTLS Issue 14
5
2. General product information
2.1 Description
PF51G
A 2-por t pneumatically actuated on /off valve for use on water, air, oil, and gases and c an also be used on
lower specification steam applications. Note: These valves are not suitable for vacuum conditions.
PF6_G
A 2-por t pneumatically actuated on /off valve for use on steam, water, air, oil and gases.
PF51G and PF6_G operation
A pneumatic signal acts on the actuator piston (depending upon seat position top or bottom) to open or close
the valve. The valve plugs have a PTFE soft seal to provide tight shut-of f. A position indicator is included on
standard and flow regulator models.
Air signal connection
Bonnet
Body
Fig. 1 2-port pneumatically actuated on/off valve
6
IM-P373- 05 CTLS Issue 14
2.2 Technical details
LeakagePTFE sof t sealASME Class VI
Flow characteristicFast openingOn/off
NC - Normally closedFlow over seatPort 1 to 2
Flow direction
Pilot media
Actuator rotation360°
Actuator type
and size
NO - Normally openFlow under seat Port 2 to 1
BD - Bi-directional
Instrument air or inert gases For use with other flow media contact Spirax Sarc o
Pil ot
connection
Typ e 1 = 45 mm (1¾") diameter1/8" BSP
Typ e 2 = 63 mm (2½") diameter¼" BSP
Typ e 3 = 90 mm (3½") diameter¼"BSP
Flow over seatPort 1 to 2
Flow under seat Port 2 to 1
60 °C (140 °F) maximum
Maximum pilot pressure
NC & BDNO
10 bar g
(145 psi g)
10 bar g
(145 psi g)
8 bar g
(116 psi g)
10 bar g
(145 psi g)
8 bar g
(116 psi g)
5 bar g
(73 psi g)
2.3 Kvs values
Size
K
vs
DN15
½"
PG51G4.58.015. 624.642.057.0
PF6_G4.58.015.624.642.05 7. 0
DN20
¾"
DN25
1"
DN32
1¼"
DN40
1½"
DN50
2"
For conversion:
Cv (UK) = Kv x 0.9 63
Cv (US) = Kv x 1.15 6
IM-P373- 05 CTLS Issue 14
7
2.4 Sizes, pipe connections and actuator combinations
Valve typ e and pipe connections
PF51G
PF60G
PF61G
PF62G
PF64G
PF63G
Screwed BSP or NPT
Threaded spigots to ISO 228 /1 (DN50 to ISO 338)
Screwed BSP or NPT
Butt weld to DIN 11850 pipe,ASME B 36.10/ISO 65 pipe or ISO 4200 pipe
Socket weld to ASME B 36.10/ISO 65 pipe
Flanged to EN 1092 or ASM E Class 150 (welded on flanges)
1 PTFE
PTFE
2
H
PTFE
3
HAvailable on request
PTFE
2
H
PTFE
3
HAvailable on request
2.5 Available range
Valve action
NC
Normally Closed
(flow over seat)
NO
Normally Open
(flow under seat)
BD
Bi-Directional normally closed (flo w
over or under seat)
Screwed
(BSP or NPT)
PF51G-1NC
PF61G-1NC
PF51G-2NC
PF61G-2NC
PF51G- 3NC
PF61G -3NC
PF51G-1NO
PF61G-1NO
PF51G-2NO
PF61G-2NO
PF51G- 3NO
PF61G -3NO
PF51G-1BD
PF61G-1BD
PF51G-2BD
PF61G-2BD
PF51G- 3BD
PF61G -3BD
Butt weld
PF6 2G -1NC
PF62G-2NCPF63G-2NC
PF62G-3NCPF63G-3NC
PF6 2G -1NO
PF62G-2NOPF63G-2NO
PF62G-3NOPF63G-3NO
PF6 2G -1BD
PF62G-2BDPF63G -2BD
PF62G-3BDPF63G-3BD
Flanged
(EN or ASME)
Actuator type
and
version
8
IM-P373- 05 CTLS Issue 14
DN15
½"
••
DN20
¾"
DN25
1"
PF51G only
DN32
1¼"
DN40
1½"
DN50
2"
••••••
•••
••••
•••
••••••
•••
••••
•••
Valve actionSocket weldThreaded spigots
NC
Normally Closed
(flow over seat)
NO
Normally Open
(flow under seat)
BD
Bi-Directional normally closed
(flow over or under seat)
PF6 4G -1N CPF6 0G -1N C
PF64G-2NCPF60G-2NC
PF64G-3NCPF60G-3NC
PF6 4G -1N OP F6 0G -1NO
PF64G-2NOPF60G-2NO
PF64G-3NOPF60G-3NO
PF6 4G -1B DPF60 G -1BD
PF64G-2BDPF60G -2BD
PF64G-3BDPF6 0G-3BD
Optional extras:
Travel switch (I)= PF61G-2BD-I
Flow regulator (R)= PF61G-2BD-R
Position module mechanical switch (A)= PF60G-1NC- A
Position module inductive switch (B)= P F60G -1NC- B
IM-P373- 05 CTLS Issue 14
9
2.6 Pressure/temperature limits
Pressure psi g
A - A PN10
Temperature °F
B - B PN16 and
Steam
saturation
curve
Temperature °C
Pressure bar g
The product must not be used in this region or beyond the body design conditions quoted in the
table below as damage to the internals will occur.
High temperature stem seals (Option H) are required for use in this region.
PF51 Screwed - Bronze DN15 - DN25 (½" - 1")PN25
Body design conditions
Maximum design pressureRefer to the graph above
Maximum design temperature200 °C(392 °F)
Minimum design temperature-10 °C(14 °F)
Maximum operating
pressure for saturated
steam service
Maximum operating
temperature
Minimum operating temperature-10 °C(14 °F)
Note: For lower operating temperatures consult Spirax Sarco.
Ambient temperature limits-10 °C to +60 °C(14 °F to 140 °F)
Designed for a maximum cold hydraulic test pressure of: 1.5 x body design conditions
Note: Valves which are being subjected to hydraulic testing must be in the fully open position.
Screwed, butt weld, socket
weld, threaded
flanged
Flanged ASMEDN15 - DN50 (½" - 2")Class 150
Standard seals9 bar g @ 180 °C(131 psi g @ 356 °F)
High temperature seals Option H
Standard seals180 °C @ 9 bar g(356 °F @ 131 psi g)
High temperature seals Option H
spigots,
EN 109 2
DN15 - DN25 (½" - 1")PN40
DN32 and DN40 (1¼" - 1½") PN25
DN50 (2")PN16
14.5 bar g @ 200 °C(210 psi g @ 392 °F)
200 °C @ 14.5 bar g(392 °F @ 210 psi g)
ASM E 150
C - C PN25
D - D PN40
10
IM-P373- 05 CTLS Issue 14
3. Installation
Note: Before actioning any inst allation observe the 'Safety information' in Section 1.
Referring to the Installation and Maintenance Instructions, name-plate and Technical Information Sheet,
check that the product is suitable for the intended installation:
Check materials, pressure and temperature and their maximum values. Do not exce edthe
3.1
performance rating of the valve. Check the limiting conditions and the produc t label details
for pilot pressure limitations. If the maximum operating limit of the product is lower than that
of the system in which it is being fitted, ensure that a safety device is included in the system to
prevent overpressurisation.
Determine the correct installation situation and the direction of fluid f low.
3.2
WARNI NG! We recommend that a bi-directional BD type valve be selected and used to prevent
waterhammer on valve closure for liquid flow applications above 2 bar g (29 psi g).
Remove protective covers from all connections and protective film from all name -plates, where
3.3
appropriate, before installation on steam or other high temperature applications.
Caution: But t weld and Socket weld versions must have the actuator and valve stem removed
3.4
prior to welding the body into the pipeline (except for normally open version).
This can be carried out in one of two ways:
i - Undo the actuator cover to relax the spring forc e while ret aining the valve body, then remove
the actuator and valve stem.
ii - Apply air pressure at the inlet port of the actuator, which will compress the spring and remove
the downward force, then remove the actuator and valve stem.
Suppor t pipework should be used to prevent stresses being exer ted on the valve body.
3.5
These valves can be mounted in any or ientation. The actuator can also be rotated 360 ° in the direction
3.6
indicated on the product label to facilitate easy pilot mounting and connection.
Ensure adequate space is provided for the removal of the actuator from the valve body for
3.7
maintenance purposes:
- Type 1 (NC/NO/BD) = 52 mm
- Type 2 (NC/NO/BD) = 68 mm
- Type 3 (NC/NO/BD) = 92 mm
Isolate connecting pipework. Ensure it is clean from dirt, scale etc. Any debris entering the valve
3.8
may damage the PTFE head seal preventing a tight shut-of f.
A red travel indicator will appear in the actuator top cover when the valve is fully open.
3.9
Note: The red travel indicator is fitted on all models with exception to those with the optional travel
switch.
Check for leaks.
3.10
IM-P373- 05 CTLS Issue 14
11
4. Commissioning
4.1 Flow regulator
This option will regulate the maximum flow of either the normally closed (NC) or nor mally open (NO) valves.
The regulator can be used as a manual override for NO valves.
Red travel indicator
Adjustment knob
Lock-nut
Fig. 2 Flow regulator
Flow regulation - NC (normally closed) valves:
1. Isolate the primary upstream and downstream valves.
2. Undo the f low regulator lock-nut.
3. Rotate the adjustment knob clockwise until the valve is fully closed. A red travel indicator will appear
in the top of the handle.
4. Apply sufficient pilot pressure required to overcome the maximum differential pressure condition.
5. Open the primary upstream and downstream valves.
6. Gradually open the valve until the desired maximum flowrate is achieved.
7. Tighten the flow regulator lock-nut.
8. Exhaust the pilot media pressure to check for valve tight shut- off.
9. Apply pilot pressure again to check maximum flow condition.
Flow regulation - NO (normally open) valves:
1. Ensure that the f low regulator is fully open. Undo the flow regulator lock-nut.
2. With the primar y medium f lowing gradually close the valve using the f low regulator until the desired
flowrate is achieved.
3. Tighten the flow regulator lock-nut.
4. Apply sufficient pilot media pressure to ensure the valve achieves tight shut-off.
5. Exhaust the pilot pressure to check ma ximum flow once again - adjust if necessary.
12
IM-P373- 05 CTLS Issue 14
4.2 Travel switch
The travel switch will provide an electrical
signal provided by a magnetic sensor and
non contact switch to indicate valve open
or closed position.
Relay rating:
Volt age (V) = 500 V
Current (I)= 0.5 A
Power(P) =30 W/ VA
4.4 Position module with
mechanical or inductive switch
The position modules allow the identification
of the opening or closing position through an
electrical signal. The detection is carried out by
a mechanical microswitch or inductive switch.
Mechanical switch or inductive switches can be
fitted to all standard Piston Actuated Valves.
Fig. 3 Travel switch
4.3 Wiring connections
3
4
Terminals
Valve openValve closed
3
1
4
Fig. 4 Wiring connections
2
1
3
4
Fig. 5 Position module
Technical data of mechanical switches
Number of
switches
Type of switch
Max. tension
connector
Max. current
Technical data of inductive switches
Number of
switches
Output versionNormally open contact (PN P)
1
Power supply12 - 24 Vdc
Max . load
current
Powe r
consumption
2
Change-over contacts
(NC and/or NO) – in silver
230 Vac with dirt level 2, 160
Vac with dir t level 3
6 A with resistive load
2 A with inductive load
2
50 mA per output
13 mA max. at 24 Vdc without
load
IM-P373- 05 CTLS Issue 14
13
4.5 Wiring connections for position module
Schematic illustrating the electrical connection for
Conne ct or
Fig . 6
mechanical switches
Fig. 7a
Schematic illustrating the
electrical connection for
inductive switches
Switch for op en
position
Common
No
Nc
Switch for op en
Switch for closed
position
Front view of
the connector
Common
No
Nc
Switch for closed position
position
Front view of
the connector
14
+24 Vdc
Out
0 V
+24 Vdc
Out
0 V
IM-P373- 05 CTLS Issue 14
Fig . 7b
Electrical diagram for
the inductive position
module
Out
Main circuit
Imax = 50 m A
+24 Vdc
Load
0 V
4.6 Solenoid valves (type DM - if fitted)
DM type solenoid valves should be mounted onto the piston actuator as shown below.
To fit a solenoid valve onto a normally closed valve use the pilot connection marked 'NC', for normally open
valves use the connection marked 'NO'.
Contact Spirax Sarco before using water as the pilot media - When using water as a pilot media, remove
the cap from the exhaust connection and connect a drain line.
Note: Maximum torque on the thread of the pilot fluid port is 5 Nm (3.68 lbf ft or 44. 25 lbf in).
Fi g. 11
Plug and seat seal
arrangement for the
standard version
Red travel indicator
Stem lock-nut
Washer
Piston
Stem 'O' r ing
Washer
Red travel indicator
Stem lock-nut
Piston
Spring washer
Stem 'O' r ing
Spring
Valve head seal (PTFE)
Retaining washer
Spring washer
Spring
Piston lip seal
Valve ste m
Washer
Piston lip seal
Washer
Valve ste m
Threaded nut
Fig . 12
Plug and seat seal
arrangement for the
high temperature
version - Option H
16
Valve head seal (PTFE)
Body seal
Body 'O' ring
Valve body
Retaining
cap nut
Valve ste m
Typ e PF51GTyp e PF6_G
Body seal
Valve body
IM-P373- 05 CTLS Issue 14
5.1 General information
When removing the actuator and valve stem use one of the following methods (except for normally open
version):
i - Undo the actuator cover to relax the spring force while retaining the valve body, then remove the actuator
and valve stem.
ii - Apply air pressure at the inlet port of the actuator, which will compress the spring and remove the downward
force, then remove the actuator and valve stem.
5.2 How to fit a new seal kit:
A spare seal kit is available comprising: valve head seal (PTFE), stem 'O' ring, piston lip seal, body seal (and
body 'O' ring for the type PF6 _G). To replace t hese items proceed as follows:
Isolate the upstream and downstream valves.
-
Vent the pilot pressure from the actuator and disconnect the pilot pipework/solenoid valve.
-
Remove the piston actuated valve from the pipeline.
-
Remove the valve body and inspect the valve head seal. Replace if necessary. Caut ion: Before removing
-
the valve body on normally closed valves (type NC and BD), the spring pressure acting down onto the
valve head seal should be relaxed to prevent damage. This can be carried out in one of two ways, see
Section 5.1.
If a replac ement valve head seal is required, remove the retaining cap nut whilst holding the valve head
firmly (two flats are provided on the valve head for this purpose). Fit a new (PTFE) valve head seal and
refit the retaining cap (paying attention to keep the dented prof ile in contact with the PTFE seal) nut
applying Loctite 620 to the threaded portion of the stem. Tighten the c ap nut to 13 N m (9.5 lbf f t). Replace
the valve body and tighten the bonnet to the recommended torque as specified in Table 1.
To inspect or replace the stem 'O' ring or piston lip seal, remove the actuator housing cover whilst holding
-
the valve body firmly. Warning: The internal spring is under compression. Remove the valve body
as previously described in Section 5.1.
Whilst holding the valve head, unscrew the red travel indicator and stem lock-nut and remove together
-
with the t wo washer s.
Remove the piston, stem 'O' ring and washer. Inspect the piston lip seal and 'O' ring and replac e if required.
-
Clean out any dirt or waste deposits from inside the piston housing area and carefully apply Viton
-
compatible iner t grease to the 'O' ring and piston lip seal.
Reassemble in reverse order referring to the drawings showing correc t location of components. Whilst
-
holding the valve head, tighten the stem lock-nut. Replace the red travel indic ator and finger tighten.
-
Refit the actuator c over and
tighten to the following tightening
torques:
Refit the valve body replacing the body seal (and body 'O' ring type PF61G) and tighten the bonnet to
-
the recommended torque as specified in Table 1.
Type 1 NC= 18 to 22 N m(13.3 to 16.2 lbf ft)
Type 1 NO= 10 N m(7.37 lbf ft)
Type 2 and Type 3= 56 to 60 N m(41.3 to 44.2 lbf f t)
Table 1 Body/ bonnet recommended tight ening torque - N m (lbf ft)
Valve sizeTorqu eValve sizeTorqu eValve sizeTorqu e
DN15½"55 (40)DN25 1"80 (59)DN40 1½"110 ( 81)
DN20 ¾"55 (40)DN32 1¼"80 (59)DN50 2"110 (8 1)
IM-P373- 05 CTLS Issue 14
17
6. Spare parts
Available spares
A main spare seal kit is available comprising: valve head seal (PTFE), stem 'O' ring, bonnet /actuator 'O' ring,
piston lip seal, body seal (and body 'O' ring for the type PF6_G).
See Figures 10 and 11 for clarity
Exploded view
showing the stem chevron seal kit
Please note that the stem chevron seal
kit is not included in the main seal kit, and
must be ordered separetely.
Stem chevron seal kit
Valve head seal
Body 'O' ring
Body seal
Piston lip seal
Steam 'O' ring
Bonnet /actuator 'O' ring
Fig. 13 Available spares
How to order a spare seal kits
Always order spares by specif ying the valve size, type and date code (month and year) given on the actuator
label i.e.: 04/14 (April 2014).
Example: 1 - Seal kit for a 1" PF51G-2NO, date code 04/14
Please note that the stem seal kit for the high temperature version is different from the standard one.
18
17103 7UE0
IM-P373- 05 CTLS Issue 14
IM-P373- 05 CTLS Issue 14
19
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IM-P373- 05 CTLS Issue 14
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