Spirax Sarco HL 17 User manual

IM-P278-01-EN-ISS1 CTLS 1
1. Safety information
2. Installation
3. Start-up
4. Maintenance
5. Spare parts
© Copyright 2018
Printed in GB
1053050/2
HL17
High Limit Cut-out
Installation and Maintenance Instructions
IM-P278-01-EN-ISS1
CTLS
PREVIOUS REFERENCE NO. IM-P073-10

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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 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 Pressure Equipment Directive (PED) and carry the mark
when so required. The products fall within the following Pressure Equipment Directive categories:
Product Group 2
Gases
HL17, sizes DN15 - 40 SEP
HL17, sizes DN50 and 80 1
i) The products have been specifically designed for use on steam which is in Group 2 of the above
mentioned Pressure Equipment Directive. The products’ use on other fluids may be possible
but, if this is contemplated, Spirax Sarco should be contacted to confirm 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 fitted, 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 fluid flow.
iv) Spirax Sarco products are not intended to withstand external stresses that may be induced
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 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: flammable materials, substances hazardous to health, extremes of temperature.
1. Safety information

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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, fire 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.
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 300 °C (572 °F).
Many products are not self-draining. Take due care when dismantling or removing the product from
an installation (refer to 'Maintenance instructions').

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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
Unless otherwise stated in the Installation and Maintenance Instructions, this product is recyclable
and no ecological hazard is anticipated with its disposal providing due care is taken.
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 identified as hazardous or potentially hazardous.

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2.1 General information
The purpose of the solenoid valve is to shut-off the main valve. It can be controlled by any device capable
of interrupting the supply of current to the solenoid coil, such as a thermostat. The solenoid is arranged to
open the valve when the coil is energised to that whatever switching device is used it must be arranged to
break the current to close the main valve. In this way, the unit will always 'fail-safe', i.e. will close the main
valve in the event of a failure in electrical supply.
2.2 Electrical supply
It is important that the solenoid is connected to the correct voltage. The standard unit is suitable for 110
Vac or 230/250 Vac 50 Hz supply, but units for other ac voltages may be supplied to special order, therefore
always check on the supply details which are stamped on the solenoid valve name-plate before attempting
to connect up.
Electrical connection is by cable plug to DIN 43650. Remember that the valve is on a steam supply line and
in use will get hot. All wiring, connectors, etc. in close proximity to the valve should therefore be of heat
resisting type.
Earth
The solenoid valve should be adequately earthed.
2.3 Pipeline sizing
The piping on both sides of the valve must be sized so that velocities do not exceed 30 m/s (98 ft/s). This
means that a properly sized valve will often be smaller than the connecting pipework.
2.4 Pipeline stresses
Line stresses such as could be caused by expansion or inadequate support should not be imposed on the
valve body.
2.5 Isolating valves
These should preferably be of the fullway type.
2.6 Preventing dirt
The valve should be protected by a pipeline strainer with 100 mesh screen. The strainer should be fitted on
its side to prevent the accumulation of water.
2.7 Testing
The HL17 is an emergency safety device and as such, it is essential that it be frequently tested for satisfactory
operation. To test that the valve will close, either temporarily raise the system temperature or disconnect
the power supply to the solenoid valve. After the test has been successfully carried out, ensure that the
system temperature has returned to normal and that the power supply to the solenoid has been reconnected.
2. Installation

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In most new installations dirt collects in the steam line during construction. It is always advisable to blow
this out on initial start-up.
Remove the cap on the strainer before the steam trap, crack open the steam supply blowdown to clear dirt,
shut-off and replace cap.
It is essential that the screen in the main line strainer is not removed during this operation.
If a blowdown cock is fitted to the strainer cap it can be opened to blow out the dirt without removing the cap.
Important
Direct injection systems
This product contains a rust inhibitor to protect it against corrosion during storage. To
avoid any possible contamination of your product, after first blowing down the approach
pipework, we recommend that the valve is blown through thoroughly in order to remove
any trace of the inhibitor.
3. Start-up

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4.1 Routine maintenance
It is recommended that the valve is occasionally given a complete overhaul and ideally this should be carried
out with the valve removed from the line.
The parts that may require replacing or refurbishing are listed below:
-Main valve seat and valve head.
-Main valve screen.
-Main diaphragms.
Important - It is required to periodically check the external pipework and fittings and remove any debris
which might affect the performance of the valve.
Safety warning:
The body gasket contains a thin stainless steel support ring which may cause physical injury if
not handled and disposed of carefully.
Main valve screen
Solenoid valve shown out
of position
Main valve seat and
valve head
Main diaphragms
4. Maintenance

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4.2 To clean the strainer and replace the gasket
Isolate the valve and zero the pressure.
1. Unscrew the unions and release pipework.
2. Unscrew the nuts.
3. Remove the top housing complete with the solenoid valve.
4. Remove the screen and clean (or replace if necessary).
5. Ensure the main valve return spring is still in position.
6. Fit the new gasket.
7. Replace the screen.
Assemble the top housing and tighten the nuts
to the torques shown in Table 1.
Refit the pipework and retighten the unions to
ensure a steam tight seal.
Refit the solenoid valve.
Bring the valve back into commission.
Table 1 Recommended tightening torques
Size of valve Nut size Tightening torques
½",¾" and 1"
DN15,DN20,DN25 and DN32 M10 40 N m (30 lbf ft)
DN40 and DN50 M12 45 N m (33 lbf ft)
DN80 M12 80 N m (59 lbf ft)
1
6
47
5
2
3

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4.3 To renew or clean the main diaphragms
Isolate the valve and zero the pressure.
8. Undo the long union nut and pull away.
9. Undo the M12 nuts and bolts.
10. Drop away the lower diaphragm chamber, the
two diaphragms, diaphragm plate and pushrod
assembly.
11. Thoroughly clean the lower diaphragm chamber
making sure the contact faces are clean.
12. Replace the diaphragm plate and pushrod
assembly and loosely fit the lower diaphragm
chamber on two bolts either side of the union
connection to locate spigot in recess.
13. Bring the two new diaphragms together (where
precoated sealant is applied this should
face outwards) and slide into position. If
diaphragms are not renewed, but cleaned only
care must be taken to replace diaphragms in
the original order.
14. Push the lower diaphragm chamber home to
locate in the recess and refit M12 nuts and
bolts. Progressively and evenly tighten to a
torque of 75 N m.
15. Retighten the long union nut to ensure a steam
tight seal. Bring the valve back into commission.
8
1514
11
10
9
13
12

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17
18
16
4.4 To service or renew the main valve and seat
Isolate the valve and zero the pressure.
16. Unscrew the unions and release pipework.
17. Unscrew the nuts.
18. Remove the top housing.
19. Remove the screen and clean.
20. Remove the main valve spring and the main
valve head.
21. Remove the main valve seat. Examine the faces
of the main valve head and seat. If they are only
slightly worn both the main valve head and main
seat may be lapped on a flat plate using a fine
grinding paste. If either is badly worn or unfit
for further use they will need to be replaced.
22. Refit the valve seat and tighten to the
recommended torque shown in Table 2.
Where a new part has been fitted it will be
necessary to reset the main valve pushrod
to give the correct valve lift. To do this it is
necessary to expose the main diaphragm plate
and pushrod assembly.
22
21
20
19

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23
25
24
Table 2 Recommended tightening torques for main seat
Size of valve Width across flats Tightening torque
½",½" LC, DN15 &DN15LC 30 mm (1.18 " ) (external) 110 - 120 N m (81 - 89 lbf ft)
¾" &DN20 36 mm (1.42") (external) 140 - 150 N m (103 - 111 lbf ft)
1" &DN25 19 mm (0.75") (inside) 170 - 180 N m (125 - 133 lbf ft)
DN32 24 mm (0.94") (inside) 200 - 210 N m (148 - 155 lbf ft)
DN40 30 mm (1.18 ") (inside) 230 - 240 N m (170 - 177 lbf ft)
DN50 41 mm (1.61") (inside) 270 - 280 N m (199 - 207 lbf ft)
DN80 (N/A) 600 - 700 N m (443 - 516 lbf ft)
23. Undo the long nuts and pull away.
24. Undo the M12 nuts and bolts.
25. Drop away the lower diaphragm chamber, the two diaphragms, diaphragm plate and the pushrod assembly.

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29
27
28
26
26. Refit the pushrod assembly.
27. Refit the main valve head, make sure the valve locates on seat.
28. Open the valve by pushing onto the diaphragm plate until it comes up against the stop of the body.
29. Check the valve lift (shown in Table 3) using a depth gauge.
Table 3 Valve lift
Size of
valve DN15LC DN15 DN20 DN25 DN32 DN40 DN50 DN80
Lift 3.6 mm
(0.14")
3.6 mm
(0.14")
2.9 mm
(0.11")
3.7 mm
(0.15" )
4.7 mm
(0.19 ")
5.5 mm
(0.22")
6.4 mm
(0.25")
12.5 mm
(0.49")
Adjust if necessary by screwing pushrod in or out of diaphragm plate.

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30. Thoroughly clean the lower diaphragm chamber making sure the contact faces are clean.
31. Replace diaphragm plate and pushrod assembly and loosely fit the lower diaphragm chamber on two bolts
either side of the union connection to locate the spigot in the recess.
32. Refit the diaphragms in exactly the same way as when dismantled.
33. Push the lower diaphragm chamber home to locate in the recess and refit the M12 nuts and bolts.
Progressively and evenly tighten to a torque of 80 - 100 N m (59 - 74 lbf ft).
34. Retighten the long union nut to ensure a steam tight seal.
34
33
30
31
32
31

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35. Ensure the gasket faces are clean.
36. Refit the main valve head.
37. Replace the main valve return spring.
38. Fit a new gasket.
39. Replace the screen.
40. Assemble the top housing complete with the spring housing assembly and tighten the nuts to the
recommended torques shown in Table 1, page 8.
41. Refit the pipework and retighten the unions to ensure a tight seal. Bring the valve back into commission.
36
3538
37
41
39
40

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4.5 To service or renew solenoid valve
42. Remove the retaining nut, washer and seal and slip the entire solenoid enclosure off the solenoid base
and sub-assembly or plugnut/core tube sub-assembly.
43. Unscrew the bonnet or solenoid base sub-assembly and remove the core spring, core assembly and
body gasket. All parts are now accessible for cleaning replacement. Replace worn or damaged parts
with a complete Spare parts kit (item W, Section 5) for best results.
44. Reassemble in reverse order paying careful attention to the exploded views provided.
44
42
43
45
46
4.6 Coil replacement
Switch off electrical power supply and disconnect coil lead wires.
45. Undo retaining nut.
46. Slip washer, insulating washers and coil off solenoid base
sub-assembly. Reassemble in reverse order.
CAUTION
Solenoid must be fully reassembled as the housing is part of,
and completes the magnetic circuit.

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Available spares
Spare parts are available as indicated. No other parts are supplied as spares.
Maintenance kit
A stand-by set of spares for general maintenance purposes which covers all spares marked *
Main diaphragm * (2 off) A
Main valve assembly K, L
Internal strainer * M
Main valve return spring * N
Control pipe assembly * P
Gasket set * (3 off) R
Set of top securing stud and nuts (set of 4) S
Set of main body studs and nuts (set of 4) T
Set of diaphragm securing bolts and nuts
DN15 - DN32 (set of 10)
VValve sizes DN40 and DN50 (set of 12)
DN80 (set of 20)
Solenoid valve complete W
Replacement coil X1
Valve seat and core assembly X2
How to order spares
Always order spares by using the description given in the column headed 'Available spares' and state the
size and type of valve and whether it is screwed or flanged.
Example: 1 - Main valve assembly for a Spirax Sarco DN25 HL17 High limit cut-out valve.
Note: To provide a stand-by set of spares for general maintenance purposes, an order for 1 maintenance
kit will cover all spares marked*.
5. Spare parts

IM-P278-01-EN-ISS1 CTLS 17
T
M
L
K
N
Main valve assembly
V
A
V
T
S
R
Solenoid valve assembly
W
P
X2
X1

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Interchangeability of spares
The following table shows how in certain sizes some parts are interchangeable. For example in the line
headed 'Main diaphragm' the diaphragm used in the screwed valves ½" and ¾" is common to these sizes by
the letter 'a', the letter 'c' indicates that one diaphragm is common to the DN40 and DN50 valves. All spares
marked †are interchangeable with the DP17 pressure reducing valve.
Size DN
Screwed Flanged
½" ¾" 1" 15 20 25 32 40 50 80
Maintenance kit a a b f a b c d e g
Main diaphragm †aabaabbccd
Main valve assembly †b c d b c d e f g h
Internal strainer †a a b f a b c d e g
Main valve return spring †aaaaaaaccb
Control pipe assembly †a a b f a b c d e g
Gasket set †aaaaaaabbc
Set of top housing
securing studs and nuts aaaaaaabbc
Set of main body studs
and nuts
†aaaaaaabbc
Set of diaphragm
securing bolts and nuts
†aaaaaaabbc

IM-P278-01-EN-ISS1 CTLS 19
T
M
L
K
N
Main valve assembly
V
A
V
T
S
R
Solenoid valve assembly
W
P
X2
X1

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