Spirax Sarco PM6 User manual

IM-P373-18 CTLS Issue 5 1
1. Safety information
2. General product and
delivery information
3. Installation
4. Commissioning
5. Maintenance
6. Spare parts
7. Fault finding
© Copyright 2017
Printed in GB
IM-P373-18
CTLS Issue 5
3739350/5
PM6 Stainless Steel
Piston Actuated Modulating Control Valves
Installation and Maintenance Instructions

IM-P373-18 CTLS Issue 52
1. Safety information
marking
The positioner has been tested and approved by a Notified Body with regards to
its compliance with the EN 61326-1:2013 'Electrical equipment for measurement,
control and laboratory use. EMC requirements'.
Attention
This product complies with Electromagnetic Compatibility Directive 2004 / 108 / EC
and all its requirements.
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 product listed below complies with the requirements of the European Pressure
Equipment Directive 2014/68/EU and carries the mark when so required.
The product falls within the following Pressure Equipment Directive categories:
Product Group 1
Gases
Group 2
Gases
Group 1
Liquids
Group 2
Liquids
PM6
DN15 - DN25 (PN40) SEP SEP SEP SEP
DN32 - DN40 (PN25) 1SEP SEP SEP
DN50 (PN16) 1SEP SEP SEP
i) The products have been specifically designed for use on steam, water, compressed
air, inert industrial gases and certain oils from Group 2 of the above mentioned
Pressure Equipment Directive. The PM6 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 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 over temperature 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 and protective film from all name-
plates, where appropriate, before installation on steam or other high temperature
applications.

IM-P373-18 CTLS Issue 5 3
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.
1.5 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.

IM-P373-18 CTLS Issue 54
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 PTFE - Handling precautions
Within its working temperature range PTFE is a completely inert material, but when
heated to its 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.
Smoking should be prohibited in workshops where PTFE is handled because tobacco
contaminated with PTFE will during burning give rise to polymer fumes.
It is therefore important 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 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 180 °C (356 °F).
Many products are not self-draining. Take due care when dismantling or removing
the product from an installation (refer to 'Maintenance instructions').
1.15 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.

IM-P373-18 CTLS Issue 5 5
1.16 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. However, if the valve is fitted 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 landfill site.
1.17 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.

IM-P373-18 CTLS Issue 56
2. General product and delivery
information
2.1 Description
This document is a general installation and maintenance manual intended for the PM6
2-port pneumatically actuated modulating stainless steel control valve. The PM6 has been
designed for use on steam, water, air, oil, gases and vacuum applications. As standard it
is fitted with a PEEK plug seal for operation up to 180 °C (356 °F), and both the body and
shaped-plug have undergone a hardening treatment.
Valves are available with one of two sizes of actuator:
Type 2 (63 mm) and Type 3 (90 mm) with the following action:
-NC (Normally Closed) - Designed for flow under the seat (port 2 to 1).
Valves are available with the following fail safe options:
C - Closed The valve fails in the closed position
M - Maintained The valve fails in the last known operating position
2.2 Equipment delivery, handling and storage
Factory shipment
The product is tested, calibrated and inspected prior to shipment, to ensure reliable
operation.
Receipt of shipment
Each carton should be inspected at the time of delivery for possible external damage. Any
visible damage should be recorded immediately on the carrier’s copy of the delivery slip.
Each carton should be unpacked carefully and its contents checked for damage. If it is
found that some items have been damaged or are missing, notify Spirax Sarco immediately
and provide full details. In addition, damage must be reported to the carrier with a request
for their on-site inspection of the damaged item and its shipping carton.
Storage
If the product is to be stored for a period prior to installation, the environmental storage
conditions should be at a temperature between 0 °C and 65 °C (32 °F and 149 °F), and
between 10% and 90% relative humidity (non-condensing).
Ensure there is no condensation within the unit before installing and connecting the power.

IM-P373-18 CTLS Issue 5 7
2.3 Technical details
Leakage PEEK soft seal ASME class VI
Flow characteristic Equal percentage
Flow direction Flow under seat Port 2 to 1
Pilot media Instrument quality air 60 °C maximum
Actuator rotation 360°
Actuator
type and
size
Pilot connection Maximum pilot pressure
Type 2 = 63 mm diameter Push-in type to suit
Ø6 mm pipe 8 bar g
Type 3 = 90 mm diameter Push-in type to suit
Ø6 mm pipe 8 bar g

IM-P373-18 CTLS Issue 58
2.4 Materials
No. Part Material
1Body Stainless steel AISI 316L
2Bonnet Stainless steel AISI 316L
3Plug Stainless steel AISI 316L
4Valve plug seal PEEK
5Valve stem Stainless steel AISI 316L
6Stem seals PTFE + Carbographite
7Stem 'O' ring (Not shown) FKM
8Actuator housing 30% glass filled polyamide
9Piston Aluminium
10 Piston 'O' ring NBR
11 Gasket PTFE
12 'O' ring FKM
2.5 Kvs values
Size DN15
½"
DN20
¾"
DN25
1"
DN32
1¼"
DN40
1½"
DN50
2"
Kvs 4.5 8.7 12.7 19.8 29.7 36.3
For conversion:
Cv(UK) = Kvx 0.963
Cv(US) = Kvx 1.156

IM-P373-18 CTLS Issue 5 9
4
5
11
2
1
612 910 8
Fig. 1 PM6
3

IM-P373-18 CTLS Issue 510
Temperature °C
Pressure bar g
Steam
saturation
curve
2.6 Pressure / temperature limits
Pressure psi g
Temperature °F
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.
A - APN10 A - CPN50
A - BPN16 and ASME 150 A - D PN40
Body design
conditions
Screwed, butt weld,
socket weld
and flanged EN 1092
DN15 - DN25 (½" - 1") PN40
DN32 and DN40 (1¼" - 1½") PN25
DN50 (2") PN16
Flanged ASME DN15 - DN50 (½" - 2") Class 150
Sanitary clamp
compatible connections DN15 - DN50 PN10
Maximum design pressure Refer to the graph above
Maximum design temperature 180 °C (356 °F)
Minimum design temperature -10 °C (14 °F)
Maximum operating pressure for
saturated steam service 9 bar g @ 180 °C (130.5 psi g @ 356 °F)
Maximum operating temperature 180 °C (356 °F)
Minimum operating temperature -10 °C (14 °F)
Ambient temperature limits -10 °C to +60 °C (14 °F to 140 °F)
Maximum differential pressure (see Section 2.7)
Designed for a maximum cold hydraulic test
pressure of:
1.5 x Maximum design pressure
(PN rating)
Maximum test pressure is equal to the maximum differential pressure

IM-P373-18 CTLS Issue 5 11
2.7 PMX - Maximum differential pressures for PM6 piston
actuated valves
* Notes:
1. Maximum differential pressure for saturated steam service is 9 bar g.
2. Sanitary clamp connections are limited to PN10 pressure rating.
3. ASME flange connections are limited to ASME 150 pressure rating.
Model Valve size
Actuator
diameter
(mm)
Flow
direction
(port 2 to 1)
* Maximum
differential
pressure
(bar)
Pilot pressure
Minimum
(bar)
Maximum
(bar)
PM6_GC-2NC
and
PM6_GM-2NC
DN15 - (½") 63 under seat 16 4.5 8
DN20 - (¾") 63 under seat 16 4.5 8
PM6_GC-3NC
and
PM6_GM-3NC
DN25 - (1") 90 under seat 14 4.5 8
DN32 - (1¼") 90 under seat 12 4.5 8
DN40 - (1½") 90 under seat 84.5 8
DN50 - (2") 90 under seat 64.5 8

IM-P373-18 CTLS Issue 512
Valve size Actuator type
and size
Screwed, socket weld and butt weld
A1 B1 CD† Weight
DN15 - ½" 2(63 mm) 65 294 269.0 52.4
DN20 - ¾" 2(63 mm) 75 301 274.0 72.5
DN25 - 1" 3(90 mm) 90 316 285.0 83.3
DN32 - 1¼" 3(90 mm) 110 329 292.5 10 3.7
DN40 - 1½" 3(90 mm) 120 334 297. 5 12 3.9
DN50 - 2" 3 (90 mm) 150 352 306.5 16 4.6
2.8 Dimensions and weights (approximate) in mm and kg
B1 (Screwed, socket weld and butt weld)
C
D D
A1
(Screwed, socket weld
and butt weld)
† Dimensions Dis for socket
weld connections only.
Fig. 2
Valve size Actuator type
and size
Flanged
EN 1092
A3
ASME 150
A4
EN1092
B3
ASME 150
B4 CWeight
DN15 - ½" 2(63 mm) 130 139.7 323 321 292 3.8
DN20 - ¾" 2(63 mm) 150 152.4 330 327 297 4.2
DN25 - 1" 3(90 mm) 160 165 .1 344 343 307 5.7
DN32 - 1¼" 3(90 mm) 180 184.2 359 357 316 7.3
DN40 - 1½" 3(90 mm) 200 203.2 361 361 319 8.2
DN50 - 2" 3(90 mm) 230 228.6 384 384 330 10.4

IM-P373-18 CTLS Issue 5 13
2.8 Dimensions and weights (approximate) in mm and kg
B2 (Sanitary clamp) and B3, B4 (Flanged)
C
A3 and A4 (Flanged)
(Sanitary clamp)
A2
E F F
Fig. 3
Valve size Actuator type
and size
Sanitary clamp (ISO 2852)
A2 B2 C E F Weight
DN15 - ½" 2(63 mm) 102 313.0 269.0 34.0 17. 2 2.5
DN20 - ¾" 2(63 mm) 114 320.5 274.0 34.0 21.3 2.7
DN25 - 1" 3(90 mm) 140 341.0 285.0 50.5 25.0 3.7
DN32 - 1¼" 3(90 mm) 159 353.5 292.5 50.5 33.7 4.1
DN40 - 1½" 3(90 mm) 159 353.5 2 97.5 64.0 40.0 4.5
DN50 - 2" 3(90 mm) 190 372.0 306.5 64.0 51.0 5.3
Valve size Actuator type
and size
Sanitary clamp (ASME BPE)
A2 B2 C E F Weight
DN15 - ½" 2(63 mm) 102 313.0 269.0 25.0 9.4 2.5
DN20 - ¾" 2(63 mm) 114 320.5 274.0 25.0 15.75 2.7
DN25 - 1" 3(90 mm) 140 341.0 285.0 50.5 2 2.1 3.7
DN32 - 1¼" 3(90 mm) - - - - - -
DN40 - 1½" 3(90 mm) 159 353.5 2 97.5 50.5 34.8 4.5
DN50 - 2" 3(90 mm) 190 372.0 306.5 64.0 47.5 5.3

IM-P373-18 CTLS Issue 514
Note: Before actioning any installation 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:
3.1 Check materials, pressure and temperature and their maximum values. Do not
exceed the performance rating of the valve. Check the limiting conditions
and the product 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 over-
pressurisation.
3.2 Determine the correct installation situation and the direction of fluid flow.
3.3 Remove protective covers from all connections and protective film from all name-
plates, where appropriate, before installation on steam or other high temperature
applications.
3.4 Caution: Butt weld and Socket weld versions must have the actuator and valve
stem removed prior to welding the body into the pipeline.
This can be carried out in one of two ways:
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.
3.5 Support pipework should be used to prevent stresses being exerted on the valve
body.
3.6 These valves can be mounted in any orientation. The actuator can also be rotated
360° in the direction indicated on the product label to facilitate easy pilot mounting
and connection.
3.7 Isolate connecting pipework. Ensure it is clean from dirt, scale etc. Any debris
entering the valve may damage the PEEK head seal preventing a tight shut-off.
3.8 Check for leaks.
3. Installation

IM-P373-18 CTLS Issue 5 15
4. Commissioning
4.1 Operating principles and description
Figure 4 illustrates the operating layout; the set-point signal coming from the control panel of
the equipment is compared with the internal signal (feedback) of the position transducer. When
the 2 values don’t match, the electronic system inside the valve operates the 2 microvalves
(which open or close the pilot air supply) to change the stroke until both signals match.
The balance between the stroke of the valve and the instantaneous ow is guaranteed by
the plug design: equal-percentage plug. When fully closed, the valve meets ASME Class VI.
24 Vdc
Control signal
(set point)
Feedback signal
Electronic board
Inlet microvalve
(instrument air)
Outlet microvalve
Position
transducer
Pneumatic
valve
Fluid flow direction
Port 2 Port 1
1
2
PU
Fig. 4
The uid ow direction for the PM6 range of valves
is always under the seat (ports 2 to 1) as illustrated

IM-P373-18 CTLS Issue 516
Fig. 5
Electronic board
Dip switches
Thread and bearing
Connectors
Caution: Care must be taken to avoid
damaging the electrical connections
when removing the top cover.
The positioner is electronic and is not programmable. The relevant parameters are pre-set
at the factory by means of 4 dip switches (see Figure 5). All calibration operations are
implemented in one easy automatic operation (see auto set-up procedure in Section 4.4.2).
PM6 valves are supplied pre-set, calibrated and tested by the manufacturer according to
the model ordered. It is possible to modify the valve set-up from its factory default setting
to better suit a particular application if required. To alter the parameters please refer to
Section 4.3.

IM-P373-18 CTLS Issue 5 17
4.2 Valve positioner disassembly
Note: Before actioning disassembly observe the ‘Safety information’ in Section 1.
Caution: Ensure that valve is both electrically and pneumatically disconnected
before disassembly.
Unscrew the two blind nuts and remove the two rubber gaskets (as shown in Figure 6). Then,
rmly hold the aluminium cylinder and then remove the top cover to access the electronic
board (see Figure 5).
Caution: Care must be taken to avoid damaging the electrical connections when
removing the top cover.
Note: A gasket for the ingress protection is assembled in the valve top cover; this o󰀨ers
some resistance when trying to lift it up.
Once the top cover has been removed, lift the electronic board very carefully to access the
dip switches (indicated in Figure 5).
Fig. 6
Positioner
Valve
Rubber gasket
M23 straight connector
Top cover
Aluminium
cylinder
Blind nuts
Rubber gasket

IM-P373-18 CTLS Issue 518
4.3 Dip switces - Configuration
Altering the settings of the four dip switches gives di󰀨erent operating functions.
Contact 1 – Process temperature:
Switch 1 is factory set.
Fig. 7
Contact 2 – Fail safe position:
This parameter must be strictly defined upon order
because it needs some specic components. Therefore,
we recommend not to modify the manufacturer
configuration in order to avoid malfunctioning problems.
T h i s p a r a m e t e r a l l o w s m o d i  c at i o n o f t h e v a l v e b e h a v i o u r
in case of sudden power failure.
The two available options are:
1. CLOSED (PM6_GC) in case of power failure, the valve
closes completely.
2. MAINTAINED (PM6_GM) in case of power failure,
the valve stays in the position where it was working
before power failure.
Fig. 8
Note: Due to unavoidable leakage of air from the 2 microvalves, the valve will close slowly
after some time.
Contact 3 – Function:
This parameter allows the user to choose if the valve
has to work as 'normally closed' (Direct- acting) or
'normally open' (Reverse-acting).
See the chart below:
Fig. 9
Set-up Set-point Valve status
Direct (NC) 0 V or 4 mA Closed
10 V or 20 mA 100% Open
Reverse (NO) 0 V or 4 mA 100% Open
10 V or 20 mA Closed
Contact 4 – Set-point:
This parameter allows the user to select the type of inlet
signal (set-point) between 0-10 V (voltage) or 4-20 mA
(current). Please note that if the parameter changes, the
related electrical connection of the 12-pole connector
changes as shown in Figure 11.
Fig. 10
Once the set-up phase is finished, you can reassemble the valve.

IM-P373-18 CTLS Issue 5 19
4.4 Connections and first start-up
Caution: in order to safeguard the valve from electrostatic shocks or other electrical
problems, it is necessary to connect the valve to earth (Contact No. 9 of the connector).
4.4.1 Electrical connection
1. Unscrew and remove the
connector from the positioner.
2. Disassemble the connector
(see Figure 11).
3. Connect the wires to the
terminals in the connector (See
Table 1).
4. Reassemble the connector
ensuring that Pin 9 is in line with
the arrow on the outside and
top of the connector.
Table 1
Pin no. Function
1+24 Vdc (supply power)
20-10 V (+) set-point
34-20 mA (+) set-point
40 (common set-point)
5Alarm signal: 0 V -> the valve works properly;
24 V -> valve on alarm
6Transducer voltage (see paragraph 7).
It does not have to be connected when the valve is working properly
7NC
80 (supply power)
9Earth
10 TRX(-) pin for programming the electronic board
11 NC
12 TRX(+) pin for programming the electronic board
Fig. 11

IM-P373-18 CTLS Issue 520
4.4.2 When the valve is connected in to the pipeline proceed as follows:
1. Con nec t t he inst r ume nt q ual it y air supp ly t o th e valve by m e ans of  ex i ble p ip e s Ø 6 mm.
CAUTION: A 25 μm mesh lter must be installed on the air supply in order to protect
the micro- valves.
2. Turn on electrical supply to the valve (24 Vdc).
At this point we recommend running an auto set-up cycle.
3. Starting auto set-up cycle: The set-up is an automatic data gathering process in which
the electronics detect the stroke made by the valve. The cycle consists of 3 open-close
cycles that may last about 40 seconds:
-Once power is supplied to the valve, wait a
few seconds then press and hold the LED
push-button for 5 seconds to initiate the
set-up cycle (see Figure 12).
-The LED now ashes quickly (the cycle has
now started).
Note: the set-up procedure is always done in the
factory before shipping however we recommend
doing it again at the rst start-up of the valve and
again periodically to ensure accurate calibration.
4.5 LED push-button functionality
The LED push-button allows the user to:
1.Operate the valve according to the signals given by the inbuilt led-lit push-button:
-NORMAL – FLASHING EVERY SECOND – the valve is working properly
-AUTO SET-UP – FLASHING QUICKLY – the valve is running an auto set-up cycle.
The ashing light continues until the valve has nished the whole cycle.
-RED ALERT - FIXED LIGHT – states that the valve is on red alert.
2. Reset the valve after an alarm: generally, the valve goes to ALARM when it does not
reach the required position within an established time.
3. Identify and remove the cause of a problem. To reset the alarm, press the LED push-
button once. Two complete open and close cycles will occur.
4.6 General features
Actuator size P min (bar) P max (bar)
Ø63 4.5 8
Ø90 4.5 8
Electronic board inlet resistance for 0-10 V is 20 kΩ
Electronic board inlet resistance for 4-20 mA is 500 Ω
Fig. 12
LED push
buttons