Spirax Sarco 58 User manual

IM-P041-03 CH Issue 5
1
Type 58
Control Valve
Installation and Maintenance Instructions
1. Safety information
2. Installation
3. Operation
4. Maintenance
5. Available Spares
IM-P041-03
CH Issue 5
0410052/5
© Copyright 2015
Printed in GB

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1. Safety information
Safe operation of this product can only be guaranteed if it is properly installed,
commissioned, used and maintained by qualied personnel (see Section 1.11) in
compliance with the operating instructions. General installation and safety
instructions for pipeline and plant construction, 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 European Pressure
Equipment Directive 97/23/EC and carry the mark when so required. The products
fall within the following Pressure Equipment Directive categories:
Product Group 2
Liquids
Bronze DN20 - DN40 SEP
TW DN50 SEP
Cast iron DN50 SEP
DN80 - DN100 SEP
i) The products have been specically designed for use on water and other non-
hazardous liquids which are in Group 2 of the above mentioned Pressure Equipment
Directive. The products’ use on other uids may be possible but, if this is
contemplated, Spirax Sarco should be contacted to conrm the suitability of the
product for the application 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 tted, or if malfunction of the product
could result in a dangerous overpressure or overtemperature 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 uid ow.
iv) Spirax Sarco products are not intended to withstand external stresses that may
be induced by any system to which they are tted. It is the responsibility of the
installer to consider these stresses and take adequate precautions to minimise
them.
v) Remove protection covers from all connections before installation.
1.2 Access
Ensure safe access and if necessary a safe working platform (suitably 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: ammable materials, substances hazardous to health,
extremes of temperature.

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1.5 Hazardous environment around the product
Consider: explosion risk areas, lack of oxygen (e.g. tanks, pits), dangerous gases,
extremes of temperature, hot surfaces, re hazard (e.g. during welding), excessive
noise, moving machinery.
1.6 The system
Consider the effect on the complete system of the work proposed. Will any proposed
action (e.g. closing isolation valves, electrical isolation) put any other part of the
system or any personnel at risk?
Dangers might include isolation of vents or protective devices or the 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 starting work ensure that you have suitable tools and/or consumables
available. Use only genuine Spirax Sarco replacement parts.
1.10 Protective clothing
Consider whether you and/or others in the vicinity require any protective clothing
to protect against the hazards of, for example, chemicals, high/low temperature,
radiation, noise, falling objects, and dangers to eyes and face.
1.11 Permits to work
All work must be carried out or be supervised by a suitably competent person.
Installation and operating personnel should be trained in the correct use of the
product 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
primary responsibility is safety.
Post 'warning notices' if necessary.
1.12 Handling
Manual handling of large and/or heavy products may present a risk of injury. Lifting,
pushing, pulling, carrying or supporting a load by bodily force can cause injury
particularly to the back. You are advised to assess the risks 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.

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1.13 Residual hazards
In normal use the external surface of the product may be very hot. If used at the
maximum permitted operating conditions the surface temperature of some products
may reach temperatures of 200°C.
Many products are not self-draining. Take due care when dismantling or removing
the product from an installation (refer to 'Maintenance instructions').
1.14 Freezing
Provision must be made to protect products which are not self-draining against frost
damage in environments where they may be exposed to temperatures below freezing
point.
1.15 Disposal
The product is recyclable. No ecological hazard is anticipated with the disposal of
this product providing due care is taken. EXCEPT;
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 landll site.
1.16 Returning products
Customers and stockists are reminded that under EC Health, Safety and Environment
Law, when returning products to Spirax Sarco they must provide information on any
hazards and the precautions 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 Safety data sheets relating to any substances identied as hazardous
or potentially hazardous.
1.17 Working safely with cast iron products on steam
Cast iron products are commonly found on steam and
condensate systems. If installed correctly using good
steam engineering practices, it is perfectly safe.
However, because of its mechanical properties, it is
less forgiving compared to other materials such as
SG iron or carbon steel. The following are the good
engineeringpracticesrequiredtopreventwaterhammer
and ensure safe working conditions on a steam system.
Cast Iron is a brittle material. If the product is dropped
during installation and there is any risk of damage the
product should not be used unless it is fully inspected and
pressure tested by the manufacturer.
Safe Handling 

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Steam
Trap set
Trap set Trap set
Steam
Gradient 1:100
Gradient 1:100
30 - 50 metre intervals
Condensate Condensate
Condensate
Prevention of water hammer
Steam trapping
on steam mains:
Steam Mains - Do's and Don'ts:
Steam 









Steam
Flow Flow

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Installing products or re-assembling after maintenance:
Thermal expansion:
Do not over tighten.
Use correct torque gures.
1
1
4 2
3
8
2
6
3
7
Flange bolts should be gradually tightened across
diameters to ensure even load and alignment.
Guides
Guides
Limit
rods
Limit rods
Fixing point
Medium
distance
Small
lateral
movement
Small
lateral
movement
Large
lateral
movement
Large
lateral
movement
Short
distance Fixing point
Axial
movement
Axial movement
Guides
Guides
5
4
Prevention of tensile stressing
Pipe misalignment:


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2. Installation
2.1 Description
The standard Type 58 temperature control is a three port mixing or diverting valve suitable
for heating or cooling applications on water or oil systems.
2.1.1 Valve option
Valves are available for use on sea water or brine applications. Please contact Spirax Sarco
for further information.
2.2 Serial numbers
All Type 58 control valves bear a serial number which is stamped on the nameplate and
should be noted in all contacts with the manufacturer.
Fig. 1
DN50 and DN80
DN100

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2.3 General arrangement
The Type 58 Control Valve should be fitted in a vertical position with the Port O at the bottom.
For ease of maintenance an isolating valve should be fitted in the line serving each port,
although for clarity these are not shown on the recommended installation layouts.
2.3.1 Recommended installation
- As a diversion valve to control the temperature of the cooling water and lubricating oil
serving a diesel engine. Figure 2 shows a typical layout.
- As a mixing valve to control the minimum return water temperature to a hot water boiler
in a low temperature hot water heating system (93°C maximum).
Figure 3 shows a typical layout for one boiler.
Where two or more boilers are used in parallel it is advisable to fit a separate Type 58 Control
Valve to each boiler as is shown in Figure 4.
Alternatively one or more Type 58 Valves may be fitted as Figure 5 to serve a range of boilers.
Fig. 3
Single boiler
application
Fig. 2 Typical installation
on diesel engine
Water Cooler
Water
Cooling
Circuit
Diesel
Engine
Type 58 Control Valve
Oil Cooler
Type 58
control
valve
Oil cooling circuit
X Z
O
X Z
O
Alternative Position for Pump
Boiler
Pump
O

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Fig. 4 Multi-boiler installation with separate Type 58 on each boiler
2.4 Pipeline stress
It is important that line stresses such as can be caused by expansion or inadequate supporting
of the pipe, are not imposed on the valve body.
Fig. 5 Multi-boiler Installation served by one Type 58 control valve
Main Duty and
Standby Pumps
3 Port
Compensating
Control
Main Duty
and Standby Pumps
Mixing
Header Boiler Boiler Boiler
Pump Pump Pump
Type 58
control
valve
Type 58
control
valve
Type 58
control
valve
Flow to system Main Duty and Standby Pumps
Boiler Boiler Boiler
Type 58
control valve
Return from System Alternative Position for Pump

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2.5 Temperature range
The sensor (18) is available in a choice of temperature settings as shown in Table 1 opposite.
Types A, B, C, D and E are the standard and type X is non-standard. In each case the
temperature at which the valve commences to move is stamped on the bottom end of each
sensor (18). In addition the type of sensor fitted to each valve is shown by the letter A, B, C,
D, E or X stamped on the nameplate fixed to the cover (3).
Fig. 6 DN50 and DN80
Z
X
18
O
3

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Table 1 - temperature settings
Type Port Z commences to open Full flow to Z
A 57°C 66°C
B 63°C 71°C
C 74°C 82°C
D 82°C 91°C
E 40°C 49°C
X
Where an X sensor is fitted the letter X on the nameplate will be followed by the
temperature setting and in all cases full movement of the valve, opening port Z
and closing port X will occur at a temperature 8/9°C higher.
18
Fig. 7 DN100
3

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Water Cooler
Water
Cooling
Circuit
Diesel
Engine
Type 58 Control Valve
Oil Cooler
Type 58
control
valve
Oil cooling circuit
X Z
O
X Z
O
2.6 Port identification
The valve ports are marked O,X,Z.
Fig. 8

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3. Operation
3.1 Adjustment
After the Type 58 Control Valve has been put into service and allowed to settle down, if it is
found that it is controlling at a slightly different temperature to that required, it may be adjusted
over a small range as follows:
Using a 16 mm A/F spanner hold the adjustment nut (1) and slacken the lock nut (2). Now
using a screw-driver in the slot provided to prevent the rod turning, the adjustment nut (1) and
lock nut (2) may be repositioned up to a maximum of ± 2 mm as shown on Figure 9.
Turning the nuts clockwise to bring the end of the rod up to a maximum of 2 mm above the
top face of the adjustment nut will raise the temperature.
Normal setting Setting for Setting for
top of rod maximum maximum
flush with top temperature temperature
of adjustment increase decrease
nut (1)
Fig. 9
+2 mm +2 mm
Fig. 11
Fig. 10
1
2
1
2Clear
space

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3.2 Fail safe device
In the event of failure of the sensor (18) allowing a substantial rise in water temperature,
a temperature sensitive fuse will come into operation at approximately 95°C mechanically
putting the piston into the position where full flow will be through port Z.
In this position the valve can be operated manually, see Section 3.3.
To replace or re-set the fail safe device see Section 4.3.
The safety fuse is provided by forming the main valve operating rod in two sections male (9)
and female (13) which are joined together by solder having a known melting point.
The melting of the solder allows the two sections to separate under the power of the overload
spring (6) which will override the piston assembly opening the valve fully to port Z.
Fig. 12 DN50 and DN80
312 6
Z
X
11
13
9
16
18
O

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3.3 Manual operation
If by failure of the sensor or for some other reason the fail safe device has operated releasing
the temperature sensitive fuse as described in Section 3.2, it is now possible to manually
operate the valve as follows:
Using a 16 mm A/F spanner hold the adjustment nut (1) and slacken the lock nut (2). Unscrew
and remove both these nuts completely from the rod, invert and replace them as shown in
Figure 10.
By turning the inverted adjustment nut (1) the piston can now be moved to any intermediate
position to give the required fluid temperature and if desired may be locked in position using
the lock nut (2).
To repair or replace the fail safe device see Section 4.3.
3.4 Temperature override
If it is seen that the adjustment nut (1) and lock nut (2) assembly rises with the rod clear of
the top face of the cover (3) as in Figure 11, it is an indication that the sensor is being subjected
to a temperature in the excess of normal but not sufficiently high to bring the fail safe device
into operation.
Under normal operation the expanding sensor (18) bears against the plug (16) pulling the
piston assembly down to open the cooler port 11. If the system cannot cope with the load or
if for some reason, such as dirt, the piston travel is restricted then overload of the sensor is
avoided by allowing the rod assembly to rise up against the overload spring (6).
The cause of the overload should be immediately investigated.
9 3 1 2 6
13
18
16
Fig. 13 DN100

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4. Maintenance
4.1 Inspection
At least once a year the working parts should be removed for inspection. This can be done
without uncoupling the valve body (5) from the pipework as follows but the valve should be
isolated or the system drained.
- Undo nuts (4) and remove cover (3) by levering up evenly with two screw drivers, using
the slots provided. Do not damage ‘O’ ring (7).
- The working parts are all attached to the cover (3) and may now be inspected and any
scale cleaned off.
Fig. 14 DN50 and DN80
19 32 4 8 57
Z
X
11
9
18
O

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- Check that piston (8) is seating on machined face on cover (3). If not, it is either due
to dirt, which should be cleaned off, or the safety fuse (9) is no longer ‘set’. If the latter
should be the case, repair or replace as detailed in Section 4.3.
- Without dismantling further, immerse the sensor (18) in water which is about 7°C hotter
than the temperature stamped on its end and see that the piston (8) moves.
- If there is no movement replace the sensor (18) as described in Section 4.2.
- Remove any scale adhering to the inside of the valve body, taking care not to damage
the seal (11).
- Make sure that the face on which the piston (8) seats is clean.
- If piston sealing ring (11) is worn (that is, if it is level with or below the groove into which
it fits) prise out the old one and fit a new seal, shortening it with a razor blade until there
is a gap of 1.5 mm between the two ends.
- Re-fit the cover (3) complete with working parts into the body taking care not to damage
‘O’ ring (7) or piston sealing ring (11).
- Replace and tighten nuts (4).
- Nuts (4) should not be overtightened. The joint is sealed by ‘O’ ring (7) not by
tightening nuts.
- Should water leak either from the joint between the cover (3) and the valve body or from
underneath lock nut (2) this shows that one of the ‘O’ rings (7) or (19) has been damaged
and must be replaced.
11 5 9 19 4 3 2 7 8
18
Fig. 15 DN100

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4.2 To replace sensor
If the sensor (18) has to be replaced, proceed as follows after isolating the valve and/or
draining the system:
- Undo lock nut (12) using a 42 mm A/F box spanner and unscrew sensor tube (14 a ‘C’
spanner in the slot provided if necessary.
- Remove retaining spring (17) and remove old sensor (18).
- To re-assemble drop new sensor (18) into tube (14) and replace retaining spring (17) on
top of sensor.
- Screw tube (14) back into piston (8) until it is just possible to move sensor capsule between
2 mm and 3 mm against the retaining spring (17) before it comes into contact with plug (16).
This operation should be done at ambient temperature. The sensor system is now correctly
positioned and the sensor tube (14) should be locked by tightening the lock nut (12).
- After tightening check the movement once more.
Fig. 16 DN50 and DN80
8
Z
X
17
12
14
16
18
O

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Fig. 17 DN100
12 8
14
17
18
16

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4.3 To Re-set or replace fail safe device
If safety fuse has operated for any reason it can be either re-set or replaced as follows:
- Isolate the valve and/or drain the system.
- Remove cover (3) complete with working parts as described in Section 4.1.
- Remove sensor (18) as described in Section 4.2.
- Hold hexagon plug (16) in vice and unscrew assembly from plug using 16 mm A/F spanner
on locknut (2) being careful to keep the powerful return spring (10) under compression
by pushing against cover (3).
- Then undo adjustment nut (1) and lock nut (2) and remove safety fuse assembly including
spring (6).
Fig. 18 DN50 and DN80
19 312 6
Z
X
13
15
9
10
16
18
O