The Excel Master Guidebook Series - Excel Expert

GF Piping Systems
Planning Fundamentals Industry

worldwide at home
www.piping.georgfischer.com
Our sales companies and representatives ensure local customer

support in over 100 countries.
Planning For Industrial

Fundamentals Piping Systems
The technical data are not binding and not expressly warranted characteristics
of the goods. They are subject to change. Our General Conditions of Sale apply.
Australia France Malaysia Romania Taiwan

George Fischer Pty Ltd Georg Fischer SAS Georg Fischer (M) Sdn. Bhd. Georg Fischer Georg Fischer Piping Systems
Riverwood NSW 2210 Australia 95932 Roissy Charles de Gaulle Cedex 40460 Shah Alam, Selangor Piping Systems Ltd San Chung City, Taipei Hsien
Phone +61(0)2/9502 8000 Phone +33(0)1 41 84 68 84 Phone +60 (0)3-5122 5585 020257 Bucharest - Sector 2 Phone +886 2 8512 2822 Ext. 15
australia.ps@georgfischer.com fr.ps@georgfischer.com conne.kong@georgfischer.com Phone +40(0)21/230 53 80 Fax +886 2 8512 2823
www.georgefischer.com.au www.georgefischer.fr ro.ps@georgfischer.com
Mexico United Kingdom / Ireland
Austria Germany Georg Fischer S.A. de C.V. Russia George Fischer Sales Limited
Georg Fischer Georg Fischer GmbH Apodaca, Nuevo Leon Georg Fischer Piping Systems Coventry, CV2 2ST
Rohrleitungssysteme GmbH 73095 Albershausen CP66636 Mexico Moscow 125047 Phone +44(0)2476 535 535
3130 Herzogenburg Phone +49(0)7161/302-0 Phone +52 (81)1340 8586 Tel. +7 495 258 60 80 uk.ps@georgfischer.com
Phone +43(0)2782/856 43-0 info.de.ps@georgfischer.com Fax +52 (81)1522 8906 ru.ps@georgfischer.com www.georgefischer.co.uk
austria.ps@georgfischer.com www.georgfischer.de
www.georgfischer.at Middle East Singapore USA / Canada / Latin America / Caribbean
India George Fischer Piping Systems George Fischer Pte Ltd Georg Fischer LLC
Belgium / Luxembourg Georg Fischer Piping Systems Ltd Dubai, United Arab Emirates 528 872 Singapore Tustin, CA 92780-7258
Georg Fischer NV/SA 400 076 Mumbai Phone +971 4 289 41 20 Phone +65(0)67 47 06 11 Phone +1(714) 731 88 00
1070 Bruxelles/Brüssel Phone +91 224007 2001 gfdubai@emirates.net.ae sgp.ps@georgfischer.com Toll Free 800/854 40 90
Phone +32(0)2/556 40 20 in.ps@georgfischer.com www.piping.georgfischer.com www.georgefischer.com.sg us.ps@georgfischer.com
be.ps@georgfischer.com www.georgfischer.in www.us.piping.georgefischer.com
www.georgfischer.be Netherlands Spain / Portugal
Italy Georg Fischer N.V. Georg Fischer S.A. Export
Brazil Georg Fischer S.p.A. 8161 PA Epe 28046 Madrid Georg Fischer
George Fischer Ltda 20063 Cernusco S/N (MI) Phone +31(0)578/678 222 Phone +34(0)91/781 98 90 Piping Systems (Switzerland) Ltd.
04795-100 São Paulo Phone +3902/921 861 nl.ps@georgfischer.com es.ps@georgfischer.com 8201 Schaffhausen
Phone +55(0)11/5687 1311 it.ps@georgfischer.com www.georgfischer.nl www.georgfischer.es Phone +41(0)52-631 30 26
br.ps@georgfischer.com www.georgfischer.it Fax +41(0)52-631 28 93
Norway Sweden / Finland export.ps@georgfischer.com
China Japan Georg Fischer AS Georg Fischer AB www.piping.georgfischer.ch
Georg Fischer Georg Fischer Ltd 1351 Rud 12523 Älvsjö-Stockholm
Piping Systems Ltd Shanghai 556-0011 Osaka, Phone +47(0)67 18 29 00 Phone +46(0)8/506 775 00
Pudong, Shanghai 201319 Phone +81(0)6/6635 2691 no.ps@georgfischer.com info.se.ps@georgfischer.com
Phone +86(0)21/58 13 33 33 jp.ps@georgfischer.com www.georgfischer.no www.georgfischer.se
china.ps@georgfischer.com www.georgfischer.jp
www.cn.piping.georgfischer.com Poland Switzerland
Korea Georg Fischer Sp. z o.o. Georg Fischer
Denmark / Iceland Georg Fischer Piping Systems 02-226 Warszawa Rohrleitungssysteme (Schweiz) AG
Georg Fischer A/S Guro-3 dong, Guro-gu, Seoul, Korea Phone +48(0)22/313 10 50 8201 Schaffhausen
2630 Taastrup Phone +82(0)2 2081 1450 poland.ps@georgfischer.com Phone +41(0)52 631 30 26
Phone +45 (0)70 22 19 75 Fax +82(0)2 2081 1453 www.georgfischer.pl ch.ps@georgfischer.com
info.dk.ps@georgfischer.com kor.ps@georgfischer.com www.piping.georgfischer.ch
www.georgfischer.dk
GMST 5989/4 (9.06) € 50.00

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CH-8201 Schaffhausen/Switzerland, 2006
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Table of Contents
We have what you need – Introduction
Introduction to plastics
3
11
Materials used for industrial pipe work 27
Basics, terms, explanations 45
wherever you are

Market segments in industrial systems 91
Approvals and standards for industrial applications 101
Specification of GF Piping Systems products 120
Selecting your pipe material - Chemical resistance 121

A global network of distributors – your partners are our partners
Design of industrial piping systems 155
Hydraulic calculation and pressure losses 195
Processing and installations 201
GF Piping Systems Jointing technology 239
Introduction to fundamentals for valves 325

Our Mission Our values Fundamentals for ball valves, hand operated 331
We are dedicated to designing, manufacturing and We put customers first Fundamentals for ball valves, electric actuated 413
marketing piping systems for the safe and secure We act fast
Fundamentals for ball valves, pneumatic actuated 445
conveyance of liquids and gases. We do what we say
Fundamentals for diaphragm valves, hand operated 471
Fundamentals for diaphragm valves, pneumatic actuated 495
Fundamentals for butterfly valves, hand operated 523
Fundamentals for butterfly valves, electric actuated 579
Fundamentals for butterfly valves, pneumatic actuated 599
Fundamentals for angle seat valve, hand operated 617
Fundamentals for angle seat valves, pneumatic actuated 622

Pipes Fittings Jointing Technologies Valves Automation Measurement and Control Fundamentals for solenoid valves 625
Fundamentals for check valves 629
One-stop shopping at GF Piping Tailor-made solutions for any ap Competent customer support Fast delivery with our electronic Fundamentals for special valves 647
Systems with over 40 000 prod plication in which fluids or gases worldwide with our own sales inventory management system Fundamentals for actuators 743
ucts for diverse applications and are conveyed, whether in building companies and representatives. We and flexible production facilities.
specialised markets: from pipes technology, for water and gas Our logistics services are con Fundamentals for measurement and control 845
always work with the best distribu
and fittings to valves and measure utilities or for industrial sectors. tors in every country. They are our sistently improved to satisfy our Double containment 879
ment instruments and the respec key partners when it comes to the customers’ high demands.
System COOL-FIT TM 941
tive jointing technologies. fast availability of our products.
Training 952
General information 953
Index 961
Table of Contents
We have what you need – Introduction
3
11
Materials used for industrial pipe work 27
wherever you are

Selecting your pipe material - Chemical resistance 121

A global network of distributors – your partners are our partners
Design of industrial piping systems 155
Hydraulic calculation and pressure losses 195
Processing and installations 201
GF Piping Systems Jointing technology 239
Introduction to fundamentals for valves 325

Our Mission Our values Fundamentals for ball valves, hand operated 331
We are dedicated to designing, manufacturing and We put customers first Fundamentals for ball valves, electric actuated 413
marketing piping systems for the safe and secure We act fast
Fundamentals for ball valves, pneumatic actuated 445
conveyance of liquids and gases. We do what we say
Fundamentals for diaphragm valves, pneumatic actuated 495
Fundamentals for butterfly valves, hand operated 523
Fundamentals for butterfly valves, electric actuated 579
Fundamentals for butterfly valves, pneumatic actuated 599
Fundamentals for angle seat valve, hand operated 617
Fundamentals for angle seat valves, pneumatic actuated 622

Pipes Fittings Jointing Technologies Valves Automation Measurement and Control Fundamentals for solenoid valves 625
One-stop shopping at GF Piping Tailor-made solutions for any ap Competent customer support Fast delivery with our electronic Fundamentals for special valves 647
Systems with over 40 000 prod plication in which fluids or gases worldwide with our own sales inventory management system Fundamentals for actuators 743
ucts for diverse applications and are conveyed, whether in building companies and representatives. We and flexible production facilities.
specialised markets: from pipes technology, for water and gas Our logistics services are con Fundamentals for measurement and control 845
always work with the best distribu
and fittings to valves and measure utilities or for industrial sectors. tors in every country. They are our sistently improved to satisfy our Double containment 879
ment instruments and the respec key partners when it comes to the customers’ high demands.
System COOL-FIT TM 941
tive jointing technologies. fast availability of our products.
Training 952
Index 961
Content
Planning Fundamentals Industry Page
Introduction 9
Introduction to plastics 21
Materials used for pipe work 31
Selecting your pipe material - chemical resistance 110
Design of metric industrial piping systems 147
Hydraulic calculation and pressure losses of metric industrial piping systems 179
Installation of metric industrial piping systems 189
Jointing technology 233
Planning fundamentals for valves 301
Fundamentals for ball valves, hand operated 317
Fundamentals for ball valves electric actuated 377
Fundamentals for ball valves pneumatically actuated 391
Fundamentals for diaphragm valves, pneumatically actuated 423
Fundamentals for butterfly valve, hand operated 447
Fundamentals for butterfly valves electric actuated 471
Fundamentals for butterfly valves pneumatically actuated 489
Fundamentals for angle seat valve 509
Solenoid valves 513
Fundamentals for special valves 543
Special fittings 599
Fundamentals for actuators of hand valves 613
Fundamentals for Measurement and Control 703
Double containment system - CONTAIN-IT Plus 777
System COOL-FIT 833
System iJOINT 857
7
8
Introduction
Page

Disclaimer 10
Foreword 11
Overview 12
Georg Fischer 13
GF Piping Systems 14
Quality, environmental and social policies

-- Introduction 15
-- Quality assurance at all levels 15
-- Environment 15
-- Social policies 16
Training 17
Accredited test centre for components used in plastic piping systems 18
9
Introduction
Disclaimer
The technical data is not binding.They neither consti-
tute expressly warranted characteristics nor guaranteed
properties nor guarateed durability. They are subject to
modification.
Our General Terms of Sale apply.
10
Foreword
This technical handbook reflects more than 50 years of
expertise in the design and manufacture of plastic pip-
ing systems. In 1956, GF Piping Systems started with
the first production of PVC-U fittings. Since then, our
product range of pipes, fittings and valves has been
greatly expanded and many new materials have been
introduced.
With this handbook, we are proud to pass on our exten-
sive knowledge to you as our valued customer, thus as-
suring optimal safety and reliability through the correct
installation and use of GF Piping Systems products.
In general we can offer suitable products for all required
applications. This comprehensive handbook will aid you
to choose the solution best suited to your requirements.
This document of planning fundamentals has been de-
signed to be a comprehensive aid for selecting the cor-
rect product from our wide range.
The document was put together by many of our experi-
enced colleagues with utmost attention to detail, quality
and understanding.
Best regards
Michael Weyer
Schaffhausen, Switzerland
11
Overview
This technical manual will provide you with all the impor- is given in the catalogues for malleable iron fittings,
tant data for the planning, product selection, processing, Primofit and WAGA joints for non-threaded metal and
installation and commissioning of pressure pipelines in plastic pipes. For further information please contact your
industrial applications. local or national representative.
This data is based on the relevant international ISO
and EN standards, on various national standards, DVS
guidelines and additional data from piping manufactur-
ers.
Furthermore, the results of comprehensive inhouse test-
s have been included.
It is our intention to assist system planners, engineers
and installers in designing and installing the complex
system "pipeline" correctly.
This technical document comprises the following:
• Introduction to plastics
• Materials used in industrial piping work
• Basics, terms and explanations
• Market segments in industrial systems
• Approvals and standards
• Selecting your pipe material - Chemical resistance
• Design of industrial piping systems
• Hydraulic calculations and pressure loss
• Processing and installations
• Jointing technology
• Planning fundamentals for hand-operated and actuat-
ed valves
• Planning fundamentals for measurement and control
systems
• Double containment
• Training
• General information
Data on products for plastic sanitary installations and for

gas and water supply are contained in separate tech-
nical handbooks. Information on metal piping systems
12
Georg Fischer

Adding Quality to People’s

Lives
People all over the world
rely on the commitment of
Georg Fischer to satisfy
their needs today and to-
morrow.
Comfort
A reliable supply of clean water is becoming a crucial
challenge. GF Piping Systems makes the worldwide
supply of drinking water easier and enables the trans-
port of liquids for industrial purposes.

Mobility
People are increasingly mobile, and they have ever
Precision
greater demands for comfort and safety in their vehi-
cles. With its highly stress-resistant cast parts made of Series production of consumer goods and quality com-
light metal and iron, GF Automotive productsmakes it ponents requires extreme precision and demanding
possible to build passenger and commercial vehicles manufacturing technologies. The necessary moulds,
that are both lightweight and safe. tools and parts are produced with machines and sys-
tem solutions from GF AgieCharmilles.
13
GF Piping Systems
GF Piping Systems is one of the three businesses unit-
s of the Georg Fischer Corporation and a leading sup-
plier of piping systems in plastic and metal with a global
market presence.
We are dedicated to designing, manufacturing and
marketing piping systems for the safe and secure con-
veyance of liquids and gases.
One-stop shopping at GF Piping Systems with over
50000 products for diverse applications and specialised
markets: from pipes and fittings to valves and measure-
ment instruments and their respective jointing technolo-
gies. Tailor-made solutions for any application in which
fluids or gases are conveyed, whether for industrial sys-
tems, in building technology or for water and gas utili-
ties.
Sales companies in 20 countries and representatives in
another 80 countries ensure customer support round-
the-clock.
Manufacturing sites in Europe, Asia and the US are
near the customers and meet local requirements. All
components and systems comply with the applicable
standards in each market area and are tested in accred-
ited test laboratories.
Our own distribution centre together with e-commerce
and information technology ensure rapid delivery.
We are your partner for the safe and secure con-
veyance of liquids and gases
The requirements placed on piping systems are as di-
verse and demanding as the applications in which they
are implemented. Here you can find a selection of mar-
ket segments where we offer solutions. Our wide range
of systems can also be used in many other applications.
Please contact us for more information.
14
Quality, environmental and social
policies
Introduction
Quality,environment and social policies are a major con-
cern of the Georg Fischer Corporation. Approximate-
ly 90 % of the 13600 persons employed at the end of
2011 worked in corporate subsidiaries with quality man-
agement systems certified to internationally recognised
standards such as ISO 9001. We create competitive ad-
vantages for ourselves and our customers with consis-
tent quality tailored to their needs and continuous im-
provements to business processes.
Our products achieve increasingly higher ecological ef-
ficiency. This means that products are becoming more
efficient while the impact on the environment in the pro-
duction and utilisation phase remains the same or is re-
duced. Plastic piping systems from GF are lightweight
to transport, corrosion-resistant and durable. They pro-
tect drinking water, a valuable resource, all the way
from its source to individual homes.
Quality assurance at all levels

Improvement process
Your experiences with our products and services help
us to continuously improve our scope of performance
and to react quickly to your needs. Our employees are
fully behind this concept with their know-how and exper-
tise.
Customer satisfaction
This and more we offer for your benefit: Environment
• Complete systems for a wide spectrum of applications
Application know-how for a clean environment
• Reliable, high-quality products Our wealth of expertise in plastic piping systems ap-
• Comprehensive service: customer support and train- plications has always been exercised with regard to a
ing, fusion machine rentals, planning tools clean environment.
• We fulfil the various technical requirements: interna-
• ABS for the conveyance of environmentally friendly
tional standards, approvals required for specific coun-
cooling agents in refrigeration
tries and applications
• Secondary containment systems for increased safety
• Effective logistics
of persons and the environment when conveying ag-
Quality planned, manufactured and tested gressive media
You can expect consistent quality from us at all levels. • Better energy efficiency with plastics as compared to
• Dynamic research and development other pipe materials
• The most modern production technology with integrat- Value added for the customer
ed quality control in our plants We aim to understand and meet customer requirements
• Accredited test laboratory according to ISO/IEC regarding environmentally friendly products and ser-
17025 vices, and in doing so are a competent partner for envi-
ronmentally conscientious customers.
A certified management system according to ISO 9001
is essential in reaching our uppermost goal: customer We achieve this by designing products and production
satisfaction. processes which are compatible with environmental re-
quirements and also by communicating intensively with
our customers to understand what their needs are and
adjusting our performance accordingly.
Environmental management
Our environmental management system enables us to:
• handle environment-related questions professionally
• control risks
• continuously evaluate and improve processes, prod-
ucts and services
15
ISO 14001 certification is only just the beginning. We Employee satisfaction surveys
are committed to evaluating and improving our environ- Georg Fischer carries out regular employee satisfac-
mental performance on a regular basis. tion surveys. In one year, some 4000 employees were
asked to provide feedback. The responses of employ-
ees, employee representatives and management, were
then used as the basis for plans of action with clearly
defined responsibilities. These are now in implementa-
tion ideas management has also played an important
role for the improvement of work processes for many
years. Furthermore, working conditions at almost every
location have been improved by installing lifting equip-
ment, reducing noise and particle emissions, replacing
and/or reducing hazardous substances and other mea-
sures.
Social policies
Responsibility in all areas
Reporting
At the end of 2005, the Corporation for the first time sys-
tematically collected and evaluated detailed informa-
tion on the workforce, terms of employment, health and
safety in the workplace, training and continuing develop-
ment. This project is being managed by the Corporate
Sustainability Officer, who reports directly to the Head
of Corporate Planning and therefore to a member of the
Executive Committee. The results will be used as the
basis for setting targets and defining any necessary im-
provements.
Employees
Well-qualified, highly trained and dedicated employees
are a key factor for Georg Fischer’s success. Interesting
tasks, in-depth training, attractive pay and social bene-
fits are just as important as a responsible attitude to em-
ployees, even in an intensely competitive and difficult
business environment.
Employee development
Georg Fischer’s continuing personal and professional
development programmes range from apprenticeships
to further training courses for employees and managers
and seminars for senior management. By providing fo-
cused development opportunities, we keep our employ-
ees fit for the job, which in turn improves both their ca-
reer prospects and our competitiveness.
16
Training
Invest in the training of your employees
Qualified personnel is one of the key factors for the suc-
cess of a company.
Only skilled employees with the appropriate know-how
and customer focus are reliable partners.
We offer you an interesting training experience

GF Piping Systems, as a professional system and so-
lution provider, offers you training courses with a focus
on products, applications, sales arguments and different
customer requirements.
The jointing technologies, as well as measurement and
control technology are increasingly innovative. To stay
up-to-date, you need continuing education.
GF Piping Systems contributes essentially to your
know-how. No matter what your expert field may be –
utilities, building technology or industrial applications
– you can benefit from the training courses, which are
adapted to the different market segments and applica-
tions.
We offer a customised programme for salespersonnel
and occupational groups like installers, planners and
constructors. Besides the theory, we attach great im-
portance to hands-on practice. Our rooms are especial-
ly equipped for practical training. They are suitable for
simultaneous training of up to 100 persons under ideal
conditions.
For the choice of trainers, we work closely with our
sales staff. There are Basic, Advanced and Master
Courses covering the full spectrum of issues. More in-
formation about our current training program:
http://www.piping.georgfischer.com
17
Accredited test centre for compo- approvals and quality certificates etc.. Therefore, poten-
tial expenditure and time consumption is considerably
nents used in plastic piping systems reduced.
General
A testing laboratory which is an officially accredited

test centre for components used in piping systems
accredited to ISO/IEC 17025.
The Georg Fischer testing laboratory is fully equipped
to perform the most diverse tests on products used in
piping systems such as pipes, fittings, manual and au-
tomatic valves, flow meters and other pipeline compo-
nents in accordance with relevant standards as well as
own and external test specifications.
Contracts for test laboratory programmes are executed
on behalf of research and development departments,
manufacturing plants, end-users of GF Piping Systems
components as well as for authoritative organisations.
The accredited test programme also includes:
Development and product release tests are completed • Long-term internal pressure testing (EN ISO 10931,
for R & D departments (TT type testing, ITT initial type EN ISO 15493, EN ISO 15494, ISO 9393)
testing), batch release tests (BRT) and process verifica-
• Burst tests on fittings and pipes
tion tests (PVT) for our own production units as well as
other test programmes for outside companies. • Flattening tests (ISO 9853)
• Impact resistance tests (ISO 8085, ISO 13957)
The experience and competence of our personnel, the
high standard of continuous education, the technical • Decohesion test
level of our test facilities and equipment as well as the • Peeling test (ISO 13954)
well-documented recording of laboratory procedures • Tensile strength and failure mode on butt-fused test
answer all fundamental prerequisites for an ISO/IEC specimens (ISO 13953)
17025 accreditation. The accreditation through the SAS
• Pressure drop test (EN 12117)
(Schweizerische Akkreditierungsstelle) is verified by a
certificate. A reassessment for the accreditation is made • Determination of density (EN ISO 1183)
on an annual basis whilst a re-accreditation inspection • Melt flow rate (EN ISO 1133)
is implemented every 5 years. • Oxidation induction time OIT (EN 728)
A complete listing of accredited tests can be seen in

a table. This table, which is constantly updated, can
be referred to by consulting the following internet site:
www.sas.ch =>Accredited bodies =>Search =>STS
094.
The SAS, which is responsible for and has issued our

accreditation, is a member of the International Labora-
tory Accreditation Cooperation (ILAC). All laboratories
accredited by the ILAC are obliged to formally recog-
nise any test report issued by a fellow member. This
permits us, and our customers, to use all accredited test
reports originating from our laboratory to obtain product
18
Test laboratory certificate
19
20
Page

-- History 22
-- Structure of plastics 22
-- The raw material 22
-- The production of plastics 22
-- Classification of plastics 23
-- Comparison of thermoplastics, thermosets and elastomers 25
-- Relevant properties of thermoplastics 26
-- Processing of plastics 27
-- Plastics and the environment 28
21
Introduction to plastics The raw material
Raw materials for the manufacture of plastics are natu-
History ral compounds, such as cellulose, coal, petroleum and
As early as 1838 Viktor Regnault succeeded in pro- natural gas. In a refinery, petroleum is separated into
ducing polyvinylchloride in a laboratory by exposing several components by means of distillation. Grouped
vinylchloride to the sun. into evaporisation ranges, gas, benzene, petroleum,
gaseous oil, and as a residue bitumen are obtained dur-
In 1912 Fritz Klatte discovered the fundamentals for the ing distillation.
practical production of PVC.
All components consist of hydrocarbons which only dif-
During the World War I, plastics, which were still new, fer in size and form of the molecules. The most impor-
had to replace other materials falling into short supply. tant component for plastics production is crude ben-
They were then sometimes overspecified with respect zene.
to their application. Therefore, plastics needed to be im-
proved. It was necessary to scrutinise the internal struc- In a heat cracking process this crude benzene is broken
ture of these new materials closely. down into ethylene, propylene, butylene and other hy-
drocarbons and is then modified.
Only in 1938 did the production of plastics in any, sig-
nificant volume begin, when the numerous application
The production of plastics
possibilities had been recognised.
Structure of plastics
A Heating 32 %
B Traffic 41%
C Other 7 %
D Industry 10 %
E Chemicals 10 %
F incl. 6 % Plastics
Plastics are manufactured by compounding together

1 Ethylene-Monomer
large number of similar basic components (monomers)
2 Butylene-Monomer through chemical bonding.
Plastics are materials which are created by chemical The plastic industry only consumes approximately 6 %
conversion of natural products or in a synthetic manner
1)
of the petroleum products originating from refineries.
from organic compounds. The main components are
2)
the elements carbon (C) and hydrogen (H). The basis In Germany the chemical industry uses approximate-
of most plastics are carbon-hydrogen compounds, ly 10 % of the entire crude oil consumption and this in-
from which the single components of plastics, the so- cludes 6 % for plastics.
called monomers , are produced.
3)
To produce plastics three different processes are used:
1) Synthesis: production of a chemical compound from • Polymerisation
different elements or simple molecules. Synthesis is the • Polycondensation
opposite of analysis. • Polyaddition
2) Organic media are pure non-metals of natural occur-
rence, e. g. petroleum, coal, wood, natural gas. Inorgan-
ic media are compounds of metal and non-metals, e .g.
minerals, ores etc.
3) Monomers are the basic molecules, i. e. the smallest
components of which plastics are built.
22
Polymerisation Polycondensation is applied, for example, to produce
phenolic resins and polyamids.
Polyaddition
During polyaddition macromolecules are created from
chemically different molecules, however without sepa-
rating a by-product.
The procedure is used for the production of
polyurethanes and exposed resins (e. g. Araldit).
Classification of plastics
Plastics » Thermoplastics
are subdivided into three » Thermosets
main groups: » Elastomers

Thermoplastics » amorphous
are again divided into: » semi-crystalline

Thermosets » Thermoelastics
1 Monomer: Ethylene are divided into: » Resins
2 Macromolecule chain: Polyethylene
3 Polymerisation process -->Energy, Catalist, Additives
Elastomers » Synthetic caoutchouc
Polymerisation is the most frequently used procedure are divided into: (rubber)
for the synthesis of plastics. Polymerisation means the
lining up of macromolecule chains without separation
of foreign matter.
For example polyethylene, polybutene, polypropylene, Distinction of plastics
polyvinylchloride and other plastics are all produced by In the production process, the procedure and the addi-
means of polymerisation. tion of additives (stabilisers, catalists, fibres, slip addi-
tives, etc.) create macromolecules with different basic
Examples: structures.
Thermoplastics
Thermoplastics consist of long filamentary molecules
with or without branches.
Ethylene C2H4
1 Filamentary molecules without branches

Polyethylene 2 Filamentary molecules with branches
Polycondensation
During polycondensation similar and dissimilar

monomers are lined up to become macromolecule
chains, at the same time separating a by product, e. g.
water, hydrochloric acid, etc.
23
These filamentary molecules can be arranged as follows: hardness, melting temperature and a lower E modulus.
However they exhibit higher impact resistance, elonga-
amorphous, i. e. in
an inordinate struc-
tion at rupture and thermal expansion.
ture Semi-crystalline thermoplastics are more suited for fu-
or sion jointing than amorphous thermoplastics which are
semi-crystalline ideal for solvent cement jointing.
, i. e. in a partially
ordinate structure - - - - amorphous -------- semi-crystalline

Crystallisation is
increased by slow
cooling.

A crystalline
B amorphous
Semi-crystalline
thermoplastics are
polyolefines, for σ Tensile strength
example: E Strain %
Amorphous ther-
moplastics are
styrenes and vinyl
chlorides, for ex-
ample:
PE Polyethylene PVC Polyvinylchloride ε Strain

PB Polybutene PS Polystyrene T Temperature
PP Polypropylene PC Polycarbonate
Thermoplastics are plastics with simple or branched fila-

mentary molecules (macromolecules) which have an in-
ordinate or partially ordinate structure. They distort dur-
ing heating, melt and solidify again on cooling. This pro-
cess can be repeated at all times. They can be plasti-
cally deformed, distended and recovered. Due to these
properties, thermoplastics are suited for injection-mould-
ing, extrusion and fusion.
”Plastic deformation” is the processing of a material by
means of e. g. injection moulding, extrusion etc.
”Distension” is the longitudinal or longitudinal and
transversal stretching of amorphous molecule chains to
α Thermal expansion
improve the material properties.
T Temperature
The ”recovery ability” is the memory behaviour of a ma-
terial where the material is melted by heating and recov- Thermosets
er again in the original order during the cooling phrase. By means of a hardener the polymer chains of the fluid
and solid thermoset resins are cross-linked. Thermosets
Polyolefines belong to the semi-crystalline thermoplas- which have been hardened in this way cannot be melt-
tics group. Compared with amorphous thermoplastics ed, fused or deformed.
(e. g. PVC-U, PVC-C) they show less tensile strength,
24
Thermosets are normally reinforced with glass, textile or
carbon fibres and other filling materials.
PF Phenolic resin
EP Epoxy resin
UP Polyester resin
GFK Glass fibre plastic
CFK Carbon-fibre plastic Wide meshed, low cross-linked elastomer net
GF-EP Glass-fibre epoxy resin
CF-PF Carbon-fibre phenolic resin
Comparison of thermoplastics, thermosets

and elastomers
Elastomers
Elastomers are rubber-elastic plastics, also called "syn-
thetic caoutchouc”. In contrast to thermosets, the net- 1 Filamentary molecules
work has a large mesh width. By means of vulcanisation 2 Amorphous
aids the polymer chains are cross-linked. The amount of 3 Semi-crystalline
the cross-links, determines the hardness (the hardness 4 Space-net molecules, close-meshed
is indicated in Shore degrees of hardness) of the rub- 5 Space-net molecules, wide-meshed
ber. A Thermoplastic
The elastomer is very elastic, can not be melted, is not B Thermoset
fusible, can be deformed, but not reshaped. C Elastomer
Elastomers are for example
Thermoplastics
NR Natural rubber • repeated melting
EPDM Ethylene propylene rubber • fusible
• the amount of crystallites determines the density and
CR Chloroprene rubber
mechanical properties
SI Silicone rubber • under strong mechanical stress they tend to creep
FPM Fluorocarbon rubber and show lasting deformation
• the strength value decreases with increased heating
• can be transformed and deformed several times
25
Thermosets
• do not melt
• cannot be fused
• number of links is decisive for mechanical properties
• can be deformed under mechanical load, but regain
their original form after load is removed
• only behave elastically in a relatively narrow upper
temperature range, therefore more heat stable
• can only be deformed once
Elastomers
• do not melt
• cannot be fused
• number of links is decisive for the rubber hardness
• can be strongly deformed under mechanical stress
• remain elastic down to low temperatures
Relevant properties of thermoplastics

Compared to conventional materials, plastics offer the
following general advantages:
• low weight
• high elasticity
• chemical resistance
• low heat conduction
• smooth surfaces
low density = low weight Plastic 0.9 - 1.5 g/cm³

chemical resistance = no corrosion like known from met- Metals link with oxygen and rust, except for stainless and
als acids-resistant steel.
Plastics are poor heat conductors, but good insulators
low heat conductivity = small thermal loss
Thermal conductivity:
PB 0.22 W/m K
PE 0.38 W/m K
PVC 0.15 W/m K
Due to the poor thermal conductivity of plastic, less conden-

little condensation
sation occurs than with metal pipes.
high elasticity Resistant against impact and bending stresses.
abrasion resistance Approximately four times more abrasion resistant than steel
pipelines.
leakproof connections Plastics can be fused, solvent-cemented and compression
jointed.
Fusion connections and solvent-cemented joints can be
made which are absolutely leakproof without any additional
components.
smooth surface Smooth surfaces ensure low pressure losses and no encrus-
tation.
expansion Plastics react more to temperature changes than metals. The
longitudinal expansion of plastics is approx. 10 to 20 times
greater than that of steel.
behaviour in fire Most thermoplastics are combustible. Classification is made
according to the standard material fire test.
electrically nonconducting No electrolytic corrosion
sun rays Some plastics are sensitive to UV rays and have to be pro-
tected - however, resistance to weathering is good.
26
Processing of plastics
Plastics are processed differently depending on the ma-
terial and application. Some common methods are:
• Extrusion
• Compression moulding
• Injection moulding
• Foaming
Ejection of the finished part
Extrusion
In this process thermoplastic material is melted and is Compression moulding
continuously forced through a tool via a worm screw. Thermosetting material is poured into the open com-
The extruded bar is then calibrated, cools down and is pression mould in powder form. Under the impact of the
withdrawn via a take-off unit. mould pressure and heat, it then chemically reacts and
solidifies to the desired finished part.
1 Driving motor
2 Material supply
3 Extruder
4 Plasticizing worm
5 Electric heat strips
6 Die
7 Calibration device
8 Cooling tank
9 Take-off unit 1 Pressure cylinder
2 Mounting plates for both halves of the pressure mould
Injection moulding
Thermoplastic material in granular or powder form is
gradually melted in the cylinder and the mass is inject-
ed by means of the worm screw into a mould under high
pressure. The plastic then solidifies and is ejected from
the mould as a finished part.
1 Hydraulic mould closing cylinder

2 Mounting plates for both halves of the injection mould
A Fill in
3 Cylinder with injection nozzle
B Press
4 Electric cylinder heating
C Ejection
5 Material conveyor
6 Driving motor for worm screw Steam foaming
Foam machine
Injection
27
material requires an amount of energy which is given in
kilograms oil equivalent per litre material in the chart be-
low.
A Plastics, e. g. PE/PP/PB/PVC
B Steel
1 Mould closing cylinder C Copper
2 Mounting plates for both mould halves D Aluminium
3 Injector to blow in the pre-foamed material
Recycling
Granular plastic containing a blowing agent is inject- Although plastics make up only 6 % of oil consumption,
ed into the mould, expanded by means of hot steam, the conclusion is that the energy value of plastic must
cooled with water and ejected from the foam mould as be used. There are two possibilities of recycling:
an extremely light weight part. Water absorption is im-
possible as all pores are closed. • reutilisation, production of new products
Foaming mould • combustion, production of thermal energy.
In the case of reutilisation the plastic waste is brought

back to its original form in different procedures (hydroly-
sis, pyrolysis, regranulation).
At GF, production waste is regranulated and integrated
into the production process of products with lower qual-
ity and hygienic requirements than that of pipes and fit-
tings.
All thermoplastics are recyclable, e. g. PE, PP, PB,
PVC-U, PVC-C, ABS or PVDF. This is, however, not
the case for thermosetting plastics and thermoelas-
1 Mould cavity
tomers such as PE-X.
2 Injector
3 Compressed air
4 Pre-foamed granulates
5 Steam
6 Cooling water
7 Steam nozzles
8 Cooling water outlet
Plastics and the environment

Using plastics means saving energy
Plastics constitute only a small percentage of the en-
tire crude oil usage. But crude oil resources are limited.
Already today we have to fall back upon raw materials
which can be recycled and extend alternative energy
Incineration together with domestic waste (no PVDF)
sources. In this context we talk about re-usable raw ma-
does not pose any problems. In this case we talk about
terials.
energy recycling, as almost all incineration plants re-
All working processes need energy (heat, pressure, mo- cover waste heat. For example in Germany the annual
tor power). In comparison with metals, manufacturing plastic waste incinerated in this way supplies as much
plastics requires less energy. The production of 1 dm 3
energy as 500 000 t of heating oil.
28
Thermal value of different materials Ecological balance for plastic piping systems
PE/PP/PB 44000 kJ/kg Passive Active
• Raw material requirements • Applications
Heating oil 44000 kJ/kg

Coal 29000 kJ/kg • Energy requirements • Product use
- long service life
PVC/PVC-C 19000 kJ/kg • Impact on: - proven in practice
Paper 16800 kJ/kg - hygienically safe - good recycling characteris-
- air tics
Wood 16000 kJ/kg - water - high chemical resistance
Domestic waste 8000 kJ/kg - disposal properties
- simple handling
The production of corrosive combustion products is • Profit: - negligible piping losses
not possible in the case of polyolefines (PE, PP, PB) - economic - cost-effective
- technical
and ABS as halogens (e. g. chlorine) are missing in the
- ecological
molecular structure. In the case of PVC-U, PVC-C and
PVDF special scrubbing towers are installed. If one analyses the individual positions of such an eco-
Plastics as well as other materials cannot be trans- logical balance, it can be demonstrably established that
formed into nothing, so disposal in waste dumps is plastic piping systems are not only economical, but also
not the solution. This is why the use of recyclable and technically and especially ecologically profitable when
energy recyclable plastics should be promoted. compared with other material systems.
Reflections on pipeline work Following many years of research, Prof. Georg Menges
Planning and installation of piping systems is a true en- has concluded that: ”Consistent environmental protec-
gineering task, necessitating the organisation of a multi- tion would intrinsically require that crude oil be first pro-
tude of requirements and goals. For piping installations, cessed to plastic for use as commodity goods wherever
simple, critical and aggressive media in each case re- possible and only then be allowed to be burned.”
quire suitable materials. The idea is to especially cover We have inhouse a PVC-U sample pipe that was in-
the requirements of functionality, operating safety, opti- stalled in Hamburg in 1937.The PVC pipes were joined
mal service life, environmental conditions and adequate using bonding agents. The system was operated at 4 to
profitability. Included in this are overall ecological, tech- 6 bar. The material was used to supply drinking water to
nical and economic assessments. High-performance the public and was, without exception, successful. Even
plastics for piping installations, such as those, which after this long operational period, there was no evidence
you can obtain from our company, are proven and im- of incrustation or deposits.
plementable where special endurance problems in con-
nection with the media need solving. Currently PVC, besides polyethylene, is the most impor-
tant material of consideration which, because of its ver-
Environmental protection is an important responsibility satility, is not achieved by any other raw material. Pip-
affecting us all. Each one of us, businesses and indus- ing components of PVC have attained such great sig-
trial concerns alike have to meet this great challenge. nificance that not using them in many applications is no
We at Georg Fischer actively pursue these responsibili- longer imaginable. Even in the case of public criticism
ties in the development of our products as well as for in- from various sources, assertions and facts have been
vestments in our production facilities. In 1992 our com- known to deviate greatly from one another.
pany was distinguished within the scope of a competi-
tion for ecologically sound technology by the Environ- During PVC manufacture, pool concentrations of all
mental Protection Minister. dangerous intermediate products are abided by or on-
ly handled in closed systems, allowing the exclusion of
Our manufacturing plant is systematically analysed in risks to employees. During PVC processing, all effec-
accordance with strict criteria for improving environmen- tive industrial safety regulations are clearly improved
tal protection and updated accordingly. In this sector we upon and, with lowered energy requirements, the im-
have had outstanding success, which our customers pact on the environment is additionally reduced. Owing
can themselves appraise on-site. to their chemical stability, PVC products are completely
Political approaches or one-sided evaluations of indi- non-toxic in normal use, are suitable for use with food,
vidual aspects of materials, products and processes for and are used in applications involving blood conserva-
piping installations do not lead to intelligent solutions. tion and dialysis. Tin is used as a stabiliser for our PVC
Only comprehensive and objective as well as compara- materials so that risks associated with heavy metals are
tive balancing of accounts can bring us forward at any not a consideration.
one time. In this respect, ecological balance is especial- It is frequently claimed that during fires additional haz-
ly useful. ards from PVC exist for those in the immediate area.
In the following we present an ecological balance for Intensive fire testing has been carried out with PVC.
plastic piping installations: Building fires can also set fire to the difficult-to-ignite
and self-extinguishing PVC. PVC, however, does not
contribute to the spread of the fire. In cases of fire, the
fumes are always toxic, regardless of the type of materi-
al burning. The greatest danger in a fire arises from the
production of highly poisonous carbon monoxide gas.
From an insurance viewpoint, PVC is handled in the
29
same manner as other customary construction materi-
als. Dioxins/furans have been shown to be produced in
all combustion processes. PVC components have even
been shown to play a subordinate role.
If all the positions of the above ecological balance are
taken into account, then the conclusion is that current-
ly there are no acceptable substitutions for PVC piping
installations. PVC and the other high-performance plas-
tics have many positive and few critical characteristics
from an ecological viewpoint. If you would like more in-
formation about these considerations, our specialists
would be happy to be of service to you.
Recycling possibilities
30
Materials used for pipe work
Page

The material acrylonitrile-butadiene-styrene (ABS) 32
The material polyethylene (PE) 34
The material polypropylene (PP) 36
The material polyvinyl chloride unplasticized (PVC-U) 38
The material polyvinyl chloride chlorinated (PVC-C) 40
The material polyvinylidenefluoride (PVDF) 42
31
Materials used for pipe work
The material acrylonitrile-butadi-
ene-styrene (ABS)
ABS properties (reference values)
Characteristics Value *) Units Test Standard

Density ≥ 1.035 g/cm³ ISO 1183-1
Yield stress at 23 °C ≥ 40 N/mm² EN ISO 527-1
Tensile e-modulus at 23 °C ≥ 1600 N/mm² EN ISO 527-1
Charpy notched impact strength at 23 °C 42 kJ/m² EN ISO 179-1/1eA
Charpy notched impact strength at -40 °C ≥10 kJ/m² EN ISO 179-1/1eA
Ball indentation hardness (358N/30s) 87 MPa EN ISO 2039-1
Heat distortion temperature HDT A 1.82 MPa ≥ 74 °C EN ISO 75-2
Vicat-heat distortion temperature B/50N ≥ 94 °C ISO 306
Heat conductivity at 23 °C 0.17 W/m K EN 12664
Water absorption at 23 °C ≤ 0.45 % EN ISO 62
Colour similar 7001 - RAL
Limiting oxygen index (LOI) 19 % ISO 4589-1
*) Typical values measured on the material. These val- • non-toxic

ues should not be used for design purposes. • biologically inert; no support of microbial growth
• low weight
• low pressure losses due to smooth surfaces
General • good abrasion resistance
• problem-free recycling
Acrylonitrile-Butadiene-Styrene (ABS) is a versatile
standard polymer. In addition to its application in piping
systems, ABS is mainly common in automotive applica- Chemical resistance
tions and in high-quality household devices.
The wide area of application relates to the versatile
characteristic profile of ABS. It can be adapted to the ABS shows a good resistance against a broad range of
application by varying the composition of its three com- media. For more details please refer to the chemical re-
ponents: acrylonitrile, styrene and polybutadiene. sistance table. Specific questions can be addressed to
the responsible sales company.
While acrylonitrile provides strength to the material
and gives ABS an improved chemical resistance rel-
ative to polystyrene, the styrenic component provides
both strength and a quality surface finish. The chemi- Application limits
cally bound polybutadiene-rubber particles, on the oth-
er hand, give the material its toughness and impact
strength, even at very low temperatures. The application limits of the ABS material on the one
The ABS used by GF shows a good balance between hand depend on embrittlement and softening tempera-
toughness and strength, making it especially suitable for tures on the other hand on the nature and the expected
low temperature applications. Accordingly the areas of service life of the application. The p-T- diagrams gives
application are mainly refrigeration and air-conditioning details on application temperatures and pressures.
systems as well as water treatment.
The advantages of ABS include:
• high impact strength even at low temperatures Combustion behaviour
• corrosion resistance
• simple installation via solvent cement joints
ABS self-ignites at temperatures exceeding 450 °C/
• low heat conductivity 842°F. ABS burns when exposed to an open flame. Af-
• halogen free ter removing the flame, the material continues burning.
32
The oxygen index amounts to 19 %. (Materials that burn
with less than 21 % of oxygen in the air are considered
to be flammable).
According to UL-94, ABS has a HB (Horizontal Burn-
ing) flammability coefficient and falls into building mate-
rial class B2 (conventional inflammable, non-dripping)
according to DIN 4102-1. Basically, toxic substances
are released by all burning processes. Carbon monox-
ide is generally the combustion product most danger-
ous to humans. When ABS burns, primarily carbon diox-
ide, carbon monoxide and water are formed. Tests have
shown that the relative toxicity of the products of com-
bustion are similar or even lower than those of natural
products such as wood, wool and cotton. ABS combus-
tion gases are not corrosive. Nevertheless, the burn-
ing forms soot. Because of this, smoke develops during
combustion. Water, foam and carbon dioxide are suit-
able fire-fighting agents.
Electrical properties
ABS has good electrical insulation capacity. The specif-

ic volume resistance is 3.5 x 10 Ωcm and the specific
16
surface resistance is 10 Ω. These figures have to be

13
taken into account wherever there is a danger of fires or

explosion.
Physiological properties
Formulations used by GF are in general non toxic and

biologically inert. For details regarding existing ap-
provals for applications with drinking water or food stuff
please contact your sales representative.
33
The material polyethylene (PE)
PE properties (reference values)
PE 80 PE 100
Characteristics Value *) Value *) Units Test Standard
Density 0.93 0.95 g/cm³ EN ISO 1183-1
Yield stress at 23 °C 18 25 N/mm² EN ISO 527-1
Tensile e-modulus at 23 °C 700 900 N/mm² EN ISO 527-1
Charpy notched impact strength at 23 °C 110 83 kJ/ m² EN ISO 179-1/1eA
Charpy notched impact strength at -40 °C 7 13 kJ/ m² EN ISO 179-1/1eA
Ball indentation hardness (132N) 37 MPa EN ISO 2039-1
Crystallite melting point 131 130 °C DIN 51007
Heat conductivity at 23 °C 0.43 0.38 W/m K EN 12664
Water absorption at 23 °C 0.01 - 0.04 % EN ISO 62
Colour 9005 - RAL
Limiting oxygen index (LOI) 17.4 % ISO 4589-1
*) Typical values measured on the material. These val- In piping construction, PE is mostly used for buried gas
ues should not be used for design purposes. and water lines. For this range of applications, polyethy-
lene has become the dominant material in numerous
countries. But also building technology and industrial
piping installations make use of the advantages of this
General
material.
The advantages include:
Polymers which consist only of carbon and hydrogen • low weight
(hydrocarbons) are called polyolefins. • outstanding flexibility
Polyethylene (PE) belongs to this group. It is a se- • good abrasion resistance
mi-crystalline thermoplastic. Polyethylene is the best
known standard polymer. • corrosion resistance
The chemical formula is: (CH2-CH2)n. It is an environ- • high impact resistance even at very low temperatures
mentally friendly hydrocarbon product. • good chemical resistance
PE and PP belong to the non-polar materials. Because • safe and easy jointing by welding
of this, the material does not dissolve in common sol- • excellent cost-performance ratio
vents and, in addition, hardly swells. As a result, PE
pipes cannot be solvent cemented. The appropriate
jointing method for this material is welding. For piping
installations we offer three welding techniques in our Chemical resistance
product range: butt fusion, socket welding and electrofu-
sion.
The latter jointing technique is preferred for piping sys- Polyethylen shows a good resistance against a broad-
tems transporting gas, water, compressed air or oth- range of media. For more details please refer to the
er less aggressive media. Butt and socket welding are chemical resistance table. Specific questions can be ad-
preferably used on a diameter-specific basis. dressed to the responsible sales company
High molecular PE grades of medium to high density
have become state of the art for industrial piping instal-
lations. The grades are classified in accordance with Application limits
their internal pressure resistance in PE80 (MRS 8 MPa)
and PE100 (MRS 10 MPa).
In this context, we also talk about PE grades of the 3 rd The application limits of the material on the one hand
generation. PE80 grades belong, in most cases, to the 2 depend on embrittlement and softening temperatures on
nd
generation. PE grades of the 1 generation – PE63 ac-
st the other hand on the nature and the expected service
cording to current classifications— have practically no life of the application. The p-T- diagrams gives details
application anymore. on application temperatures and pressures.
34
Combustion behaviour
Polyethylene belongs to the flammable plastics. The

oxygen index amounts to 17 %. (Materials that burn with
less than 21 % of oxygen in the air are considered to be
flammable).
PE drips and continues to burn without soot after re-
moving the flame. Basically, toxic substances are re-
leased by all burning processes. Carbon monoxide is
generally the combustion product most dangerous to
humans. When PE burns, primarily carbon dioxide, car-
bon monoxide and water are formed.
The following classifications in accordance with different
combustion standards are used: According to UL94, PE
is classified as HB (Horizontal Burning) and according
to DIN 53438-1 as K2. According to DIN 4102-1 and EN
13501-1, PE is listed as B2 (normally flammable). In the
French classification of building materials, polyethylene
corresponds to M3 (of average flammability rating). Ac-
cording to ASTM D1929 the self-ignition temperature is
350 °C.
Suitable fire-fighting agents are water, foam, carbon
dioxide or powder.
Abrasion resistance
Polyethylene has excellent resistance against abrasion.

As a result, PE piping systems are used in numerous
applications for transporting solids and slurries. Expe-
rience has shown that PE offers considerable advan-
tages over metal for many such applications
The black polyethylene material types from GF are au-

thorised for use in food applications. The fittings are
odourless and tasteless as well as physiologically inert.
Usage in all related areas is thus possible. For details
regarding existing approvals for applications with drink-
ing water or food stuff please contact your sales repre-
sentative
35
The material polypropylene (PP)
PP properties (reference values)
Characteristics PP-R β PP-H Units Test Standard

Value *) Value *)
Density 0.90-0.91 0.90-0.91 g/cm³ EN ISO 1183-1
Yield stress at 23 °C 25 31 N/mm² EN ISO 527-1
Tensile e-modulus at 23 °C 900 1300 N/mm² EN ISO 527-1
Charpy notched impact strength at 23 °C 30.9 85 kJ/ m² EN ISO 179-1/1eA
Charpy notched impact strength at 0 °C 3.4 4.8 kJ/ m² EN ISO 179-1/1eA
Ball indentation hardness (132N) 49 58 MPa EN ISO 2039-1
Heat distortion temperature HDT B 0.45 MPa 75 95 °C EN ISO 75-2
Crystallite melting point 145-150 150-167 °C DIN 51007
Water absorption at 23 °C 0.1 0.1 % EN ISO 62
Colour neutral 7032 - RAL
*) Typical values measured on the material. These val- PP is one of the non-polar materials whose surface
ues should not be used for design purposes. hardly swells or dissolves. Cementing is not possible
without special surface treatment. On the other hand,
PP welds very well.
General For industrial applications GF uses beta nucleated PP-H
(PROGEF Standard, PROGEF Plus) and PP-R (PRO-
GEF natural, PROGEF Standard).
Polypropylene is a thermoplastic belonging to the poly- The internal pressure resistance is tested according to
olefin group. It is a semi-crystalline material. Its densi- ISO 1167 and calculated in compliance with ISO 9080.
ty is lower than that of other well-known thermoplastics. Under the terms of ISO 12162 our industrial grades are
Its mechanical characteristics, its chemical resistance classified as MRS 10.
and especially its relatively high heat deflection temper-
ature have made polypropylene one of the most impor-
tant materials used in piping installations today.
Chemical resistance
PP is formed by the polymerisation of propylene (C3H6)
using Ziegler-Natta catalysts.
There are three different types which are conventionally The material shows a good resistance against a broad-
supplied for piping installations: range of media. For details please refer to the chemical
resistance table by GF. Specific questions can be ad-
• Isotactic PP Homopolymeride (PP-H) dressed to the responsible sales company.
• PP block co-polymeride (PP-B)
• PP random co-polymeride (PP-R).
Because of its higher stiffness PP-H is preferred for in- Application limits
dustrial applications. The more flexible PP-R is used
predominantly in sanitary applications but also in nu-
merous industrial applications. PP-B is mainly used The application limits of the material on the one hand
for sewage piping systems because of its high impact depend on embrittlement and softening temperatures on
strength especially at low temperatures and its lower re- the other hand on the nature and the expected service
sistance to creep at elevated temperatures. life of the application. Please refer to the respective p-
Most of the grades are offered with nucleating agents T- diagrams for details on applicationtemperatures and
(crystallization seeds), because PP crystallizes at least pressures
10 times slower than PE. This way, we achieve low-
er internal stress and a finer structure. We differenti-
ate between α and β nucleation. Nucleation is realized Combustion behaviour
by merely adding ppm (parts per million) of nucleating
agents.
36
Polypropylene is a flammable plastic. The oxygen in-
dex amounts to 19%. (Materials that burn with less
than 21% of oxygen in the air are considered to be
flammable).
PP drips and continues to burn without soot after re-
moving the flame. Basically, toxic substances are re-
leased by all burning processes. Carbon monoxide is
generally the combustion product most dangerous to
humans. When PP burns, primarily carbon dioxide, car-
bon monoxide and water are formed.
The following classifications in accordance with differing
combustion standards are used:
According to UL94, PP is classified as HB (Horizon-
tal Burning) and according to DIN 53438-1 as K2. Ac-
cording to DIN 4102-1 and EN 13501-1, PP is listed as
B2 (normally flammable). In the French classification of
building materials, polypropylene corresponds to M3 (of
average flammable rating).
According to ASTM D 1929, the self-ignition tempera-
ture is 360 °C.
Suitable fire-fighting agents are water, foam or carbon
dioxide.
Since PP is a non-polar hydrocarbon polymer, it is an

outstanding insulator. These properties, however, can
be worsened considerably as a result of pollution, ef-
fects of oxidising media or weathering.
The dielectric characteristics are essentially indepen-
dent of temperature and frequency.
The specific volume resistance is >10 Ωcm; the dielec-
16
tric strength is 75 kV/mm.

Because of the possible development of electrostatic
charges, caution is recommended when using PP in ap-
plications where the danger of fires or explosion is giv-
en.
Formulations used by GF are in general non toxic and

biologically inert. For details regarding existing ap-
provals for applications with drinking water or food stuff
please contact your sales representative.
37
The material polyvinyl chloride un-
plasticized (PVC-U)
PVC-U properties (reference values)

Density 1.38 g/cm³ EN ISO 1183-1
Charpy notched impact strength at 23 °C ≥6 kJ/m² EN ISO 179-1/1eA
Vicat heat distortion temperature B/50N ≥ 76 °C ISO 306
Water absorption at 23 °C ≤ 0.1 % EN ISO 62
Colour 7011 - RAL
*) Typical values measured on the material. These val- The internal pressure resistance is tested according to
ues should not be used for design purposes. ISO 1167 and calculated in compliance with ISO 9080.
Under the terms of ISO 12162 our industrial grades are
classified as MRS 25.
General GF's PVC-U has the following characteristics:
• versatility of use
• very good chemical and corrosion resistance
Polyvinylchloride, widely known by its abbreviation PVC, • proven physiological harmlessness and therefore suit-
is one of the most important and oldest mass-produced able for contact with food
polymers. World-wide consumption of PVC is only ex-
ceeded by PE and PP, PVC was first produced in the • no influence on drinking water quality
middle of the nineteenth century. An industrial pro- • biologically inert; no support of microbial growth
duction process was, however, first patented in 1913. • high mechanical tensile strength with good impact
Nowadays, many industrial applications couldn’t be re- strength
alised without PVC. But also in the use of daily prod- • self-extinguishing
ucts, PVC has become irreplaceable.
• secure solvent cementing using Tangit cement
PVC is a polymer having approximately 56 % by weight • adhesive development designed for GF PVC-U
of chlorine. The PVC resin becomes a processable and
usable material by the use of additives only. The choice • use of tin stabilisers for fittings and valves, lead free
of the additives allows a wide variation of its characteris- system
tics and an adjustment to the planned application. • low friction loss owing to smooth surfaces
There are two classes of PVC materials. Soft PVC
(PVC-P), produced by adding plasticizers (such as, e. g.
phthalate), is not used by GF. Hard PVC, the so-called UV and weathering resistance
unplasticized PVC (PVC-U) is used for pipeline engi-
neering.
PVC-U is an amorphous thermoplastic. The character- PVC-U is very resistant to weathering. Long-term influ-
istics of PVC-U moulded parts are strongly dependent ence of direct sunlight as well as the effect of wind and
on the composition of the formula, but also on the pro- rain damage the material only superficially. Despite its
cessing. Because of our 50-year experience in PVC very good weathering resistance regarding ultraviolet
processing and the continuous advancement of our own radiation, PVC-U loses some of its impact strength. In
formulation, GF has become a benchmark in the field of extreme applications it can be advantageous to protect
PVC-U piping. The internal pressure resistance is test- the material from direct sunlight exposure. For suitable
ed according to ISO 1167 and calculated in compliance protection methods please consult your GF subsidiary.
with ISO 9080. Under the terms of ISO 12162 our indus-
trial grades are classified as MRS 25.
Application limits
38
The application limits of the material depend on the em- to odour, taste or microbiological effects is regularly
brittlement and softening temperatures and on the na- checked and monitored by neutral institutions in various
ture and the expected service life of the application. countries.
Please refer to the respective p-T- diagrams for details
GF offers PVC-U systems free from lead and cadmi-
on application temperatures and pressures.
um for your applications in the fields of drinking water
or food. The residual monomer content of vinyl chloride
lies below the detection limit of modern analytical meth-
Combustion behaviour ods.
For details regarding existing approvals for application-
swith drinking water or food stuff please contact your
The high chlorine content of PVC-U causes an advanta- sales representative.
geous combustion behaviour. Self-ignition resulting from
temperature influences occurs only at 450 °C. PVC-U
burns when exposed to an open flame, but extinguishes
immediately after removing the flame.
to be flammable).
PVC-U thus falls in the best flammability class V0 ac-
cording to UL94, and in the B1 (difficult to ignite) build-
ing material class with wall thicknesses ≤ 3.2 mm re-
spective B2 (normally flammable) with wall thickness-
es >3.2 mm according to DIN 4102-1. According to the
French test method NF P 92-501, GF PVC-U is tested
as M2.
Because the combustion of PVC produces hydrogen
chloride, which forms a corrosive acid in connection with
water, immediate cleaning of areas susceptible to corro-
sion is necessary after a fire. Danger to personnel from
HCl is minimal because its pungent odour allows early
escape from toxic combustion gases, mainly from the
odourless carbon monoxide.
There are no restrictions concerning the choice of fire-
fighting agents.
PVC-U is, as all unmodified thermoplastics, non-con-

ductive. This means that no electrochemical corrosion
takes place in PVC-U systems. On the other hand,
these non-conductive characteristics have to be taken
into account because an electrostatic charge can de-
velop in the piping. It is especially important to take this
condition into account in areas where explosive gas-
es can appear. There are various methods available to
avoid the occurrence of electrostatic charges on poly-
mer piping systems. Please contact your GF represen-
tative for more information regarding these methods.
The specific volume resistance is >10 Ωcm.
15
The PVC-U formulas were developed by GF for use

with drinking water and food. PVC-U's physiological
harmlessness regarding neutral, acidic and alcoholic
foods and the non-influence on drinking water in respect
39
The material polyvinyl chloride chlo-
rinated (PVC-C)
PVC-C properties (reference values)


Charpy notched impact strength at 23 °C ≥ 6 kJ/m² EN ISO 179-1/1eA
Ball indentation hardness (358N) ≥ 110 MPa EN ISO 2039-1
Vicat-heat distortion temperature B/50N ≥ 103 °C ISO 306
Water absorption at 23 °C 0.1 % EN ISO 62
Colour 7038 - RAL
*) Typical values measured on the material. These val- Some of the advantages of PVC-C for piping systems
ues should not be used for design purposes. are:
• very good mechanical characteristics, also at in-
creased temperatures
General • outstanding chemical resistance
• long service life, even under intensely corrosive condi-
tions
The abbreviation PVC-C stands for chlorinated polyvinyl • no support of microbial growth
chloride, a material in use since 1958. PVC-C is an • simple installation using solvent cementing, e.g. with
amorphous thermoplastic. It is made by post-chlorina- Tangit PVC-C
tion of PVC whereby chlorine is attached to the PVC
chain. Thus PVC-C is a transformed PVC-U materi- • smooth inner surface
al which, because of its chemical structure, is charac- • very low heat conductivity
terised by a higher temperature resistance than PVC-U, • exceptional fire resistance
with simultaneously higher tensile strength, good tough-
ness and an exceptional chemical resistance. Its flame
resistance is even better than that of PVC-U. These
characteristics have made PVC-C an interesting mate- UV and weathering resistance
rial for piping and fabrication of devices in the chemical
industry as well as for several other industrial applica-
tions with high requirements (e. g. the aeroplane indus- PVC-C is weathering resistant over the long term, so it
try). can be exposed to direct sunlight as well as wind and
In pressure piping systems, PVC-C is suitable for rain. Resistance to ultraviolet radiation is very good in
strongly corrosive environments, where materials such comparison to other materials, but nevertheless, PVC-
as stainless steel or even GFK demonstrate only a short C loses some of its impact strength. In extreme appli-
service life. cations it can be advantageous to protect the material
from direct sunlight exposure. For suitable protection
PVC-C is used for semi-finished products, pumps, methods please consult your GF subsidiary.
valves as well as for the entire range of accessories as-
sociated with transport of liquids.
The internal pressure resistance is tested according to Application limits
ISO 1167 and calculated in compliance with ISO 9080.
The application limits of the material depend on the em-
brittlement and softening temperatures and on the na-
ture and the expected service life of the application.
Please refer to the respective p-T- diagrams for details
on application temperatures and pressures.
40
Combustion behaviour
Due to its high chlorine content, PVC-C shows an ex-

ceptionally good combustion behaviour without the addi-
tion of flame retardants.
Under the influence of temperature, PVC-C self-ignites
only above 400°C. PVC-C burns when exposed to an
open flame, but immediately extinguishes when the
flame is removed.
to be flammable).
PVC-C thus also falls in the best flammability class
V0 according to UL94, and in the B1 (difficult to ignite)
building material class with wall thicknesses ≤ 3.2 mm
respective B2 (normally flammable) with wall thickness-
es >3.2 mm according to DIN 4102-1. Smoke develop-
ment is also low.
Since the combustion of PVC-C produces hydrogen
chloride, which forms a corrosive acid in connection with
water, immediate cleaning of areas susceptible to corro-
sion with water containing detergent is necessary after
a fire. Danger to personnel from HCl is minimal because
of its pungent odour even in very low concentrations (1-
5 ppm), allowing an early escape from toxic combus-
tion gases, mainly from the odourless carbon monox-
ide. Concerning the choice of fire-fighting agents, water,
powder-type extinguishing agents or foam are recom-
mended.
PVC-C is, like all unmodified thermoplastics, non-con-

ductive. This means that no electrochemical corrosion
takes place in PVC-C systems. On the other hand,
these non-conductive characteristics have to be taken
into account because an electrostatic charge can de-
velop in the piping. It is especially important to take this
condition into account in areas where explosive gas-
es can appear. There are various methods available to
avoid the occurrence of an electrostatic charge on poly-
mer piping systems. Please contact your GF represen-
tative if you should have applications where this needs
to be considered.
The specific volume resistance is >10 Ωcm.
15
PVC-C is an inert and toxically harmless material. Tests

have shown that there is no support of microbiological
growth in water systems from PVC-C. For details re-
garding existing approvals for applications with drinking
water or food stuff please contact your sales represen-
tative.
41
The material polyvinylidenefluoride
(PVDF)
PVDF properties (reference values)

Crystallite melting point ≥ 169 °C DIN 51007
Water absorption at 23 °C/24h ≤ 0.04 % EN ISO 62
Colour opaque - -
Limiting oxygen index (LOI) ≥ 43 % ISO 4589-1
*) Typical values measured on the material. These val- The internal pressure resistance is tested according to
ues should not be used for design purposes. ISO 1167 and calculated in compliance with ISO 9080.
General Some of the advantages of PVDF:
• outstanding mechanical properties, even at high tem-
peratures
Polyvinylidenfluoride (PVDF) is a semi-crystalline ther- • excellent chemical resistance
moplastic having outstanding mechanical, physical and • no electrochemical corrosion
chemical properties. These result from the chemical
structure of PVDF. Polyvinylidenfluoride belongs to the • long service life, even under intensely corrosive condi-
class of fluorinated polymers, whose best-known rep- tions
resentative is polytetrafluoroethylene (PTFE). PTFE is • outstanding resistance against UV and γ-radiation
characterised by a superb heat resistance and the best • very pure material by implementing without additives
chemical resistance of all polymers; a great disadvan- • no support of microbial growth
tage is that it is not melt processable - e. g. into fittings.
PVDF, on the other hand, combines various advantages • physiologically harmless
of PTFE with good workability into structural parts. The • secure jointing by high-quality welding technology
fluorine content in PVDF amounts to 59 % by weight. • smooth inner surface
PVDF from GF is characterised by a very good mechan- • very low heat conductivity
ical behaviour and high temperature resistance. Be- • excellent flame retardant properties
cause of the exceptionally wide pressure / temperature
range in which PVDF can be used, it has opened, in
connection with the specific characteristics of this mate-
rial, completely new areas of application in plastic piping Chemical resistance
fabrication. These include applications in the semi-con-
ductor, chemical and pharmaceutical industry, electro-
plating, paper and cellulose processing, the automotive The material shows a good resistance against a broad
industry and water treatment. range of media. With a few exceptions this is also valid
Pipes, fittings and valves of PVDF are uncoloured and for the welds using the suitable welding technology. For
opaque (milky, translucent). details please refer to the chemical resistance table by
GF. Specific questions can be addressed to the respon-
By avoiding the addition of any additives, the outstand- sible sales company.
ing characteristics of the material remain to the fullest
extent, especially concerning the chemical resistance
and physiological harmlessness.
Application limits
42
The application limits of the material depend on the em- This makes it the material of choice for applications
brittlement and softening temperatures and on the na- that demand a very high purity of the medium and have
ture and the expected service life of the application. stringent requirements stipulating that the materials
Please refer to the respective p-T- diagrams for details which come in contact with the medium do not leach
on application temperatures and pressures. contaminants.
The PVDF raw materials used by GF fulfil the most rigid
requirements of the semiconductor and pharmaceuti-
Combustion behaviour cal industry regarding high purity. In addition, products
made of PVDF exhibit a very smooth surface.
Leach out tests according to SEMI57 are done regularly
PVDF displays an exceptionally good combustion be- for quality control.
haviour without the addition of fire protection additives. For details regarding the properties relevant for the mar-
Material decomposition begins at 380°C. ket segments, Semicon and Life Science, please see
The oxygen index amounts to 44 %. (Materials that burn our SYGEF Plus specification:
with less than 21 % of oxygen in the air are considered www.gfps.com
to be flammable). => Support and Services/ Planning Assistance/
System Specifications
PVDF thus also falls in the best flammability class V0
according to UL94, and in the building materials class
B1 (difficult to ignite) according to DIN 4102-1. Smoke
development is also moderate.
GF PVDF products show such excellent fire safety be-
haviour that they are accepted and listed by Factory
Mutual for use in clean rooms (FM 4910).
Since the combustion of PVDF produces hydrogen flu-
oride, which forms a corrosive acid in connection with
water, immediate cleaning of areas susceptible to cor-
rosion with water containing detergent is necessary af-
ter a fire. Additional combustion products are carbon
monoxide and carbon dioxide. Concerning the choice of
fire-fighting agents, sand or powder-type extinguishing
agents are recommended.
PVDF is a good electrical insulator. Because of the pos-

sible electrostatic charges, caution is recommended
when using PVDF in applications where combustion or
explosion dangers exist.
The specific volume resistance is >10 Ωcm; the specific
14
surface resistance is 10 Ω.
14
The PVDF grades used by GF are non-toxic and biolog-

ically inert. For details regarding existing approvals for
applications with drinking water or food stuff please con-
tact your sales representative..
High purity properties
Due to the excellent stability of the PVDF molecule, it

is one of the very few materials that can be processed,
welded and used under severe conditions without the
use of additives (no pigments, thermostabilisers, pro-
cessing aids or fillers are used in the GF piping grades).
43
44
Basics, terms, explanations
Page

Basics in the physics of plastics and testing 46
Basics in general and polymer chemistry 57
Metric and inch system 73
Abbreviations 74
SI units
-- SI basic units 75
-- Internationally defined prefixes 75
-- Units 76
Conversion tables
-- Viscosities 78
-- Delivery volumes 78
-- Pressure and pressure heads 79
-- Conversion inch/mm 80
45
Basics, terms, explanations • heat radiation
• ventilation conditions
Basics in the physics of plastics and • degree of dispersal (fine-coarse)
• thickness
testing
• colour
Abrasion
Abrasion is mechanical erosion, e. g. of the inside of a • surface area
plastic pipe by solids, in the medium flowing through it. • shape
The abrasion can be reduced by using pipe materials
These factors affect the fire characteristics by influenc-
with softer particles, e. g. → Blends of → Elastomers.
ing the production of smoke (its composition and densi-
Barrier properties ty) and the flame temperature. The fire characteristics of
Barrier properties are a variety of properties concerning a substance can therefore only be assessed in the con-
a plastic's ability to resist → Permeation and → Diffu- text of a given application. Indications like "fire-resistant"
sion against gases and liquids. They are determined by etc. should no longer be used. Instead, statements such
the plastic's molecular structure and its processing. as conforms to → DIN 4102 or → UL-94 class are more
convenient.
Bursting pressure
Bursting pressure is the absolute pressure at the mo- Flammability
ment in which a test object breaks.→ Stress-rupture A plastic's flammability depends strongly on its chemical
test (creep strength). structure, fillers, additives (e.g. softening agents) and
shape. Some plastics burn very easily; others are flame
Service life retardant (as defined in → DIN 4102, B1) or stop burn-
A pipe's service life depends on the pipe material, di- ing after removal of the heat source. Fire resistance in
mensions, flow medium, temperature, etc. For the deter- equipment is often achieved by incorporating hydrated
mination of the anticipated service life of a given pipe, or alumina, antimony oxide or compounds containing halo-
the use of the intended service life in the determination gens, phosphorus, boron or nitrogen (→ Flame retar-
of other parameters, see → Stress-rupture test. dants). Numerous testing procedures using heat radi-
BgVV/BGA ators, incandescent filaments or naked flames are de-
BgVV: The German "Federal Institute for termined by the applications and produce correspond-
Health Protection of Consumers and Veterinary ingly restricted results. Investigations are carried out, as
Medicine" (Bundesinstitut für gesundheitlichen Ver- needed, on
braucherschutz und Veterinärmedizin). • how long combustion lasts
BGA: The German "Federal Health • how quickly flames spread
Office" (Bundesgesundheitsamt) • ignition temperature (ignition point)
The BgVV is one of three independent national author- • temperature of fumes produced
ities which in 1994 replaced the Federal Health Office • concentration and composition of fumes produced
(BGA). It is subdivided into eight departments and two (smoke density, toxicity) and
special units (ZEBS and ZEBET). • drops produced by burning substances.
The BGA has published in about 40 recommendations-
detailed regulations for plastics and other materials em- The results are only valid if the testing procedure and,
ployed in the manufacture of articles used with food- if necessary, the thickness of the test sample are speci-
stuffs. The recommendations complement the condi- fied. (→ DIN 4102, → UL 94)
tions given the German law (Sect. 31, Par., 1 LMBG Chromic acid test
Lebensmittel- und Bedarfsgegenständegesetz) concern-
If needed, our company performs chromic acid tests on
ing the use of articles made of high polymers, with food-
PP pipes (→ Polypropylene) to ascertain whether the
stuffs. The law has been made more specific in the Ger-
pipes are subject to internal strain.
man BGV (Bedarfsgegenstände Verordnung).
If PP pipes with an unacceptable level of internal stress
The substances used in such articles may not impair the
are immersed in 60 % chromic acid for 24 hours, clearly
foodstuffs in smell or taste. The recommendations con-
visible hairlines and cracks are produced.
sist largely of lists of → Monomers, substances used in
Our polypropylene pipes are manufactured with only
manufacturing processes, and of → Additives, i. e. sub-
slight internal stress, and pass the test without difficulty.
stances from which the articles may be made ("positive
lists"). Although the recommendations are legally noth- DIBT
ing more than the name says, in practice they are ad- German Institute for Structural Engineering (Deutsches
hered to as if they were legally binding. Institut für Bautechnik)
Fire characteristics The DIBT is a public institution with its administrative
The way a substance behaves in a fire is complicated. centre in Berlin. The institute is legally charged with en-
When assessing fire hazards, many isolated insights suring the uniform implementation of construction tech-
complement each other. Besides the flammability of the niques in public building projects. In particular, its re-
substance or of the component, the following factors are sponsibilities include:
of importance:
• position in a room
• combination with other substances
• intensity of the igniting source
46
• the technical authorisation of building commodities structures as well as through porous films. A semi-per-
in Europe, and the formulation of European guide- meable membrane (i.e. one which lets molecules up
lines for such authorisation on the basis of the build- to a certain maximum size pass through) which sepa-
ing commodity standards (89/106/EWG, 21.12.1988) rates two solutions of different concentrations, will let
molecules of the solvent diffuse through, but not out of
• the authorisation of general supervisory powers con-
the solute (→ Osmosis).
cerning building commodities and types of buildings
on the basis of the building regulations of the federal DIN 4102
states within Germany In the German standard DIN 4102, building materials
• the co-ordination of national, European and interna- are divided into combustible and incombustible cate-
tional co-operation in the formulation of technical (par- gories. The combustible materials are subdivided into
ticularly standardised) regulations those with low, normal and high combustibility. Accord-
ing to the standard, PVC-U is categorised as "B1" and
• the preparation of laws concerning technical matters
PP as "B2". The classifications are, however, also de-
for the federal states within Germany, and the publica-
pendent on the shape and the thickness of the materi-
tion of the so-called lists A, B and C of building rules
als used. The exact requirements for categorisation are
("Bauregellisten") in conformity with the building regu-
specified in the standard.
lations of those states
• the approval of bodies involved in testing, supervision Category of build- Sub-category (with official German des-
and certification ing material ignation)
• encouraging building surveys and awarding research A incom- A1
contracts, as well as advising, controlling and judging bustible
these activities A2
• commissioning experts' reports on constructional mat-
B combustible B1 flame retardant (schwerentflammbar)
ters for the parties (the German federal state and its
constituent parts) involved in settlements B2 normal combustibility (normalentflamm-
bare)
Density, measurement of
B3 high combustibility (leichtentflammbare)
The density ρ of a substance is defined as the quotient
of the mass m and its volume V. Pressure rating (PN, Nominal Pressure)
In order to choose pipes and fittings which are compat-
ible in their → Pressure stability, they are assigned to
various standardised pressure categories. The pressure
rating (PN) of these has been widely accepted. Unlike
For example the density of a substance is its mass per the → SDR or → Pipe series S, this categorisation does
unit volume. Commonly used units are g/cm³and kg/m³ not depend primarily on size or shape, but on the pipe
. One differentiates, as needed, between bulk densi- material's behaviour in the → Stress-rupture test, and
ty (taking for example, pores and enclosed air into ac- on the applicable → Safety factor. The pressure rat-
count) and the density of the pure substance. ing can be regarded as a value of the pressure (in bar)
The density of a substance is measured which the pipe can certainly withstand, at 20 °C for the
• to characterise materials duration of 50 years, with water as the flow medium.
• in quality controls PN ≙ P max (50a / 20 °C / water)
• to monitor the substance's production and processing, Pipes of a given pressure rate (like those of a given →
and Pipe series S) can withstand the same pressure - re-
gardless of their dimensions. There is, however, only an
• to calculate the weight (mass) of given quantities of approximate relationship between the pressure rating
the substances PN and the Pipe series number S, which is given by the
Densities of some materials used for pipes following formula:
S ≈ σ per(50a, 20 °C, water) / PN ≈ 0.5(d/e - 1)
Material Density (g/cm³) σper = permissible hoop stress
d = outer diameter of pipe
PVC-U 1.38
e = wall thickness of pipe
PVC-C 1.50
Pressure impulses (water hammer; surge pres-
PE 0.95 sure)
PP 0.91 Pressure impulses often occur in piping when valves
ABS 1.03
or taps are suddenly closed. If large enough, the result-
ing pressure peaks produce extra strains which can be
PVDF 1.78 detrimental after a time. Piping should therefore be in-
stalled in such a way that, wherever possible, pressure
Diffusion impulses are avoided. For example, fast-closing valves
The molecules of a gas or liquid are in motion. This in compressed-air pipelines can cause peak pressures
makes them fill the space available to them and is the which are 2½ times higher than the normal operating
underlying cause of diffusion. The amount of a sub- pressure. PVC-U pipes do not withstand such pressure
stance which diffuses in a given time through an area, impulses over a long period and are therefore not rec-
can be determined by Fick's First Law. Gases and liq- ommended in compressed-air systems. They can splin-
uids can diffuse through pits and cavities in molecular ter and be hazardous.
47
Dielectric strength Elastic modulus, tensile modulus and flexural
Break-down strength; rupture strength; disruptive dis- modulus
charge voltage The e-modulus is the constant ratio of the mechanical
The dielectric strength is the minimum potential differ- tension in a body to the corresponding deformation.
ence which has to be applied to an electrical insulator One differentiates between tensile and flexural moduli.
(most plastics are normally insulators) for it to become The moduli define a plastic's degree of stiffness. They
conductive (→ Conductivity). can be derived from the initial parts (corresponding
to the ideally elastic state) of the graphs showing ex-
DVGW tension as a function of stress. They are given in N/
German Technical and Scientific Association on Gas mm²(=MPa). The higher the numerical values, the stiffer
and Water (Deutscher Verein des Gas- und Wasser- the material is.
faches e.V.)
The association (administrative centre in Bonn) has the Explosion areas
purpose of promoting technically and scientifically as- So-called "explosion areas" are rooms and premises (e.
pects involving gas and water in particular with refer- g. factory areas) in which electrostatic discharges can
ence to safety, environmental concerns and hygiene. damage sensitive electronic systems or even lead to ex-
The aims of the association are plosions.
• setting of authorised standards Free-fall experiment/Falling ball test
• testing and certification There are two different ways of performing the free-fall
• research and development experiment:
In type A) the test specimen is dropped (either by hand
• vocational training
or with the help of a frame) from a predetermined height
• provision of information onto the floor.
• advisory services. In type B) a standardized body (such as a ball, a falling
block or dart) is dropped from a predetermined height
Plastic pipes, piping components and adhesives are onto the specimen.
controlled and tested in the DVGW's Water Technolo-
gy Centre (TZW: Technologiezentrum Wasser) in Karl- FAR
sruhe. Federal Aviation Regulations
These are globally valid regulations (from the USA)
DVS concerning the protection against fire in aircraft. FAR
The German Association for Welding Technology (DVS §25.851 defines fire protection generally. §§25.853,
= Deutscher Verein für Schweisstechnik), has published 25.855, 25.855F contain specifications for (and ways of
guidelines on various aspects of welding. grading) the materials, fittings and items of equipment in
Dynamic loading cockpit and fuselage, as well as in the compartments for
The dynamic loading of pipes (in this case by oscillation supply, luggage and freight.
in a certain range of frequencies) is a complex subject. FDA
Special care has to be taken that pipes connected to Food and Drug Administration
pumps are not under dynamic load. On occasion it may The FDA can be regarded as the USA equivalent of the
be necessary to use axial compensators in order to re- BGA in Germany. FDA authorisation is needed for many
move oscillations caused by pumps. Neglecting this can export arrangements involving pharmaceutical goods
quickly lead to breakage of the piping. and food.
Internal stress; Frozen stress Absorption of water and moisture
This stress arises by reciprocal action between parts of The absorption of water by polymers is a form of diffu-
a workpiece or test sample, e.g. in chains of molecules. sion. The amount of water taken up depends on the sur-
Essentially, it is the result of small differences in den- face area.
sity or of sterically adverse conformations. (→ Glass). The amount also depends on the sorts and quantities of
If they were cut up in an appropriate way, they would additives, fillers and strengthening agents contained in
cause deformations in the workpiece. (cf. Janson test the polymer.
with pipes made of polypropylene). Internal stress can In addition, the absorption of moisture by a polymer
arise because of is determined by its chemical composition, i. e. by the
• uneven contraction of a melted charge in cooling, presence of certain → Functional groups.
• uneven pressure during injection moulding or die- Water (chemically a highly polar compound) can have a
casting, and/or considerable influence on a plastic's mechanical prop-
• uneven cooling within the workpiece. erties, its dimensions, electrical insulation, dielectric-
loss factor and appearance. Polyamides, for instance,
Internal stress can be detrimental to the mechanical can take up large quantities of water (up to 10 % of
properties of the substance. (→ Formation of / corro- their weight), and the impact resistance can be 20 times
sion by stress-induced hairlines and cracks) higher in the saturated than in the unsaturated state.
Elasticity The precise determination of the absorption of water
Elasticity is the property of a substance to return itself and moisture has to be performed on a sample of a giv-
to its original shape or volume after deformation by ex- en shape. The graph of the sample's weight is traced as
ternal forces or torques. If the forces exceed the yield a function of time, until there is no longer any increase
point, and the material does not snap, it begins to be in weight. It is advisable to use a logarithmic scale for
deformed irreversibly, i. e. in a plastic way. Plasticity is the time axis.
the opposite of elasticity.
48
If necessary, the weight reduction experienced by the Creep
sample in yielding some of its material to the water (→ As plastics are viscoelastic, they show both an imme-
Migration) should be examined. The absorption of wa- diate (elastic) and a delayed (viscous) reaction to me-
ter is assessed in conformity with the standard EN ISO chanical loads. (The latter is due to flow processes in-
62. volving individual molecules).
In this way, thermoplastic components can change their
Flame retardants
shape. They "creep", i. e. they slowly give way to the
Flame retardants are additives which reduce the com-
load. Creep in plastics is strongly influenced by temper-
bustibility and the inflammability of plastics. They have
ature.
their effect physically (by cooling, covering or diluting) or
chemically (in the gaseous state by removing those en- Creep modulus
ergetic radicals which promote combustion; in the solid In a substance under → Creep (→ Stress-rupture test),
state by providing a protective layer of carbon or ashes). the ratio of a constant stress to its time-dependant elon-
The most important flame retardants are named under gation is called "creep modulus"
the heading → Flammability
Flame retardants are not able to prevent burning. They
only reduce the combustibility. Without flame contact,
they cause the fire to die out.
Volatiles Ec= creep modulus; σ = stress; ε(t) = elongation (tem-
A volatile or "volatile component" is the "dampness" or perature dependent)
"water content" of plastics, and is released when the KTW
plastics are dried or worked on. In most cases, other German Plastic and Drinking Water Recommendations
volatile substances (e. g. water) are also released. (Kunststoff-Trinkwasser-Empfehlungen)
FRP pipes (fibre-reinforced plastic pipes; fibre- The recommendations were published by the BGA in
glass pipes) Berlin. Every ready-made utensil made of plastic or
FRP pipes are made by wrapping glass fibres around other non-metallic materials for use in connection with
and into a sleeve made of unsaturated polyester (UP) drinking water, has to satisfy fundamental requirements
and epoxy (EP) resins. (DIN 16965, Part 1, Type A). concerning its effects on the water. These requirements
The pipes are characterised by high mechanical are tested by placing the utensil in contact with water for
strength and good heat resistance. 72 hours. The test is repeated twice.
Harmonisation of tolerances; Calibrated con- The aims of the tests are (i) to gain information about
nectors the amounts of the materials from the utensil (e. g. from
On account of our experience (gathered over decades) a PVC-U pipe for drinking water) which migrate into the
on pipes made of PVC-U and PVC-C, we know that drinking water, (ii) to ascertain that they are → physio-
such pipes have to be jointed together with particular logically harmless, and inoffensive in smell and taste,
care. The points of contact are especially at risk when (iii) to find out which quantities of these materials can
using aggressive media (→ Cementing/jointing tech- be tolerated. The DVGW's Water Technology Centre in
nology) Karlsruhe, Germany, performs such tests on pipes used
for drinking water. (→ TOC)
The parts being jointed together are affected chemi-
cally - most strongly on both sides of the gap between K-value
them. We have therefore decided to extrude (the sizes The K-value, a dimensionless parameter derived from
in question) using stricter tolerances than those pre- measurements of solution viscosity, is used for the ap-
scribed by DIN. The reduced tolerances in a pipe's out- proximate determination of the → Molecular weight of
er diameter lead to gaps which are smaller, and thus a polymer. It is extrapolated from a series of measure-
minimal chemical attack. ments of the time needed for polymer solutions, of vary-
The same effect is achieved by using normal, but sub- ing concentration, to flow through the capillary tube of
sequently calibrated connecting parts. As this method is a so-called viscometer. The conditions under which the
complex, it is no longer used. Naturally, the stricter tol- measurements are made (the temperature, the solvent
erances also have to be applied to all the fittings used, used and the structure of the polymer) are always the
i.e. there has to be a harmonisation of the tolerances. same.
The K-value obtained is close to the weight average
Vessel formula MW (→ Distribution of molecular mass) of the distri-
A pipe's → Hoop stress σ depends on the operating bution of molecular weights. The molecular weight of
pressure p, on the wall thickness e and on the diameter PVC-U is usually found by determining its K-value. Nor-
d. The so-called vessel formula gives the relationship mal values for the material qualities used in the extru-
between these quantities. sion of PVC-U pipes are between 60 and 70.
σ = (p/10)(d0 - e)/2e There are conversion tables for the coefficient of viscos-
σ = hoop stress in N/mm² ity and the K-value in EN ISO 1628-2.
p= inside pressure in bar Paint-impairment-free; Silicone-free
d0 = outer diameter Plastic pipes and moulded parts which are paint-impair-
e = wall thickness ment-free are employed in surface-coating installations
(here specifically the paint shops in the automobile in-
dustry). It is important that these parts do not contain
49
certain substances or come into contact with them when Because the FRP withstands a large pressure, the load
being processed. The substances include silicone, fats, on the inliner is small. This leads to longer life and high-
waxes and PTFE. er standards of safety. The production of liner pipes
Details are obtainable from automobile manufacturers. has to conform (inter alia) to special KRV criteria (of the
In this context silicone is particularly noteworthy. Com- Plastic Pipe Federation - ''Kunststoff-Rohr-Verband'' - in
ponents which contain silicone, or components using sil- Bonn, Germany) as well as to ISO and DIN standards.
icone-based mould-release agents during production,
Long-term regression curves
can cause unevenness in the wetting characteristics
→ Stress-rupture test (Creep strength)
of the paint, leading to severe difficulties and financial
losses. MC Test
In our company the dichloromethane test (MC test) is
Long-term characteristics
used in the production of PVC pipes as a quick check
The long-term characteristics of plastic pipes are deter-
on if the material used is homogeneous and has been
mined by many factors. There are the operating con-
treated with due care.
ditions such as flow medium, temperature, operating
In this test, sections of pipes are left in dichloromethane
pressure, and external factors, as well as the pressure
(a solvent) at 23 °C for 30 minutes. One can then as-
for which the pipes have been designed.
sess the quality of the plasticization (gelation) in the ex-
Of course, it is very important that the right piping mate-
trusion process by observing the degree and shape of
rial is chosen for the given operating conditions. In the
the swelling.
applicable lists of standards - e. g. under the heading
The plasticization was good if the surface is not at-
"permitted pressure" - one can find details of the long-
tacked. Any indication to the contrary means that the
term characteristics of pipes.
plasticization was (in various degrees) unsatisfactory,
Linear expansion, coefficient of i. e. the extrusion process was performed at a too low
Plastics and metals differ fundamentally in their atom- temperature.
ic and molecular composition and in the nature of their
Microscopy
chemical bonds. This is illustrated, for example, by ob-
Microscopy is performed to observe the condition or
serving that thermal expansion in plastics is about ten
structure of a plastic's surface. By using polarization
times greater than in metals. The coefficient of linear
techniques, the crystalline structure or states of orienta-
expansion represents a material's degree of thermal
tion can also be examined in more detail.
expansion and is measured in compliance with DIN
(→ Microtome sections, → Scanning electron micro-
53752. It denotes the extension per unit length of a
graph) Depending on its thickness, a sample can be
plastic component for 1 K (= 1 ºC) rise in temperature.
viewed using transmitted or reflected light.
The thermal expansion (or contraction) of piping can be
calculated using the formula: Microtome section
Microtome sections are thin cuts (only a few μm thick)
Δl = L ⋅ ΔT ⋅ α
used in microscopic examinations. They are particularly
Δl = thermal expansion (or contraction) in mm suitable for viewing by transmitted light.
L = length of piping in m In our company, this form of examination is used as a
ΔT= difference in K (= ºC ) between reference temper- matter of routine. Microtome sections allow assessing if
ature of piping (e. g. at installation) and temperature in a polymer has been processed in a homogeneous way.
use It is also possible to detect foreign parts (contaminants),
α = coefficient of linear expansion in mm/m K voids, cracks, etc. In addition, microtome sections facil-
(= mm m K )
-1 -1
itate the appraisal of the crystalline structure of a poly-
mer.
Coefficient of expansion of selected polymers
Example: Observation of → Spherulites in PP pipes.
Polymer α in mm/m K MRS (Minimum Required Strength)
ABS 0.1 The MRS is used as a measure of a pipe material's →
Pressure stability. The material's → Hoop stress σ (in
PA 0.1
N/mm²= MPa) for the temperature 20 ºC (water) and for
PB 0.13 the time 50 years is read from its long-term regression
PE 0.15 - 0.20 curves (→ Stress-rupture test). One obtains the MRS
by rounding down to the highest Renard number which
PP 0.16 - 0.18 is smaller than, or equal to the hoop stress.
PPS 0.15 Example: σ(50a, 20°C, water) = 10.58 N/mm², i. e. MRS10
Examples: PP-H and PE100 pipes are graded MRS10.
PVC-U 0.07 - 0.08 Some sorts of PE (PE80) and PP-copolymers (PP-R,
PVC-C 0.06 - 0.07 PP-B) are graded MRS8.
PVDF 0.12 - 0.18 Surface treatment
The surfaces of certain components are treated not only
Liner pipes to protect and improve them, but also for decorative pur-
Liner pipes are composite pipes made of a thermoplas- poses. Fine films with good physical and chemical sta-
tic (PE, PP, PVC-U, PVC-C, PVDF and PPS) inside bility can easily be formed on plastics. Metallization by
and → FRP outside. The so-called inliner (the thermo- electrolytic deposition or by other means gives plastic
plastic inner part) makes the pipe chemically resistant, the metallic appearance occasionally required. Thicker
the outer FRP composite provides mechanical strength. coatings are made by electroplating. For the most part,
the plastics PS, ABS, PMMA cellulose, polyvinyl deriva-
50
tives and thermosetting materials are metallised. In pro- some extent on the wavelength). Complex electrody-
cesses using electrolytic deposition, it is necessary (af- namical considerations show the refractive index of
ter cleaning and roughening) to provide the plastic with most polymers to be n = 1.5 ± 0.2, a value which, on
a conductive coating. Components made of ABS are account of the similar structures of all polymers (long
particularly good for metallization using electrolytic de- chains of carbon atoms), does not vary much. Large lat-
position. eral units and in particular → Functional groups do,
however, lead to deviations from the value. The refrac-
Surface properties
tive index also becomes larger with higher degrees of
When plastics are used, not only their volume-related,
crystallization.
mechanical properties (such as firmness and stiffness)
are important, but also the properties relating to the sur- Reflection of light
face topography. Included in the latter are surface hard- At the boundaries of a polymer (e. g. at its surfaces),
ness, frictional and abrasive properties, certain reac- light is reflected. An example of this phenomenon is the
tions of polymer materials to aggressive substances total internal reflection of light in fibre-optic cables. Oth-
and in particular, their tendency to develop hairlines and erwise, more light is reflected and less refracted when
cracks. the angle of incidence of the light becomes greater, and
Our company aims to produce pipes with inner surfaces when the substance has a higher refractive index.
so smooth that a Ra value of less than 1 µm is achieved. • A material's gloss (sheen) arises as a consequence
Ra (the average value of surface roughness) is the arith- of a substance's ability to reflect light. It is the ratio of
metic mean of the distances between protrusions and the reflection by a sample of the material to that (un-
a line through the middle of the surface profile. Rt (the der identical conditions of light incidence) by a stan-
maximum roughness) is the vertical distance between dardised material.
the highest and lowest points of the surface profile in
• A material's glitter originates in its gloss and arises
the section measured.
from the presence of stronger light reflections for par-
Surface resistance ticular incident angles and/or particular contrasts in
The resistance of the surfaces of raw materials and fin- colour and intensity.
ished products is an important parameter for plastic • Dependent on the refractive index, up to 95 % of per-
pipes installed in so-called → Explosion areas. The sur- pendicularly incident light (minimum reflection) can
face resistance of such pipes has to be ≤ 10 Ω. As plas-
9
enter a polymer sample. Such a degree of transparen-
tics have very good innate electrical insulation charac- cis, however, seldom reached because of additional
teristics, the pipes have to incorporate conductive fillers scattering and → Absorption, both of which weaken
such as carbon black, carbon fibres or conductive poly- the intensity of the light on its way through the poly-
mers. mer. For a given sample, the so-called transmission is
The surface resistance of pipes depends (among other the ratio of the intensity of the transmitted light to that
things) on the surrounding conditions. High humidity, for of the incident light. One differentiates between trans-
example, reduces the surface resistance slightly. parent bodies (transmission > 90 %) and translucent
bodies (transmission < 90 %). In the latter case, thin
Categories of conductivity: bodies appear transparent.
Surface resistance (R) Category
Scattering of light
R >10 Ω12
insulating The above is valid for optically homogeneous systems.
109 Ω < R ≤ 1012 Ω antistatic Inhomogeneities (such as impurities - and in emulsions)
lead to further effects in the interaction with light.
10 Ω < R ≤ 10 Ω
4 9
statically conductive
• Among these are light-scattering phenomena in which
R ≤ 10 Ω4
conductive a part of the light is dispersed in all directions. An ex-
ample of this phenomenon is the weakening of the
Optical properties of polymers light from automobile headlights in fog. In this case,
The optical properties of a material depend on its inter- light is scattered by tiny drops of water. The scatter-
action with light. "Normal", i. e. visible light consists of ing of light in crystal lattices make crystalline and part-
electromagnetic waves with wavelengths between 400 ly crystalline polymers appear to be not transparent -
nm and 800 nm. A frequency can be assigned to each as in polyethylene, polypropylene and polyphenyl sul-
wavelength. phide. Amorphous polymers, on the other hand, are
In substances which are neither magnetic nor electri- transparent (provided they contain no colouring), for
cally conductive, i. e. in nearly all polymers, the interac- example polycarbonate, polyvinyl chloride, polymethyl
tion between the material and visible light is reduced ap- methacrylate (Plexiglas) and polysulfone. The phe-
proximately to an interaction between an electromagnet- nomena can be illustrated very nicely by stretching an
ic field and the electrons in the material. As a result, we amorphous sample (e. g. of polystyrene) to reorien-
obtain a number of fundamental, physical phenomena tate its molecules ( → Stress-whitening ).
which characterise the optical properties of the material. • A body which scatters light appears to be opaque if
Refraction of light there are localised variations of the refractive index
Light incident on a transparent substance is bent, ac- and/or variations in the molecular orientation (in non-
cording to certain laws, when it enters or leaves the isotropic structures) - and if the inhomogeneous parts
substance. Examples of this phenomenon are the use are larger than the wavelength of the light used.
of a prism to break up white light into its component
colours, or a rainbow. A so-called refractive index n
of the substance has been defined (which depends to
51
OSU (Ohio State University) Rupture stress
The heat release (HR) and the heat-release rate (HRR) → Tensile test
of plastics are measured in the OSU's combustion
Chemical resistance factor fCR/Reciprocal
chamber. The respective quantities may not exceed val- chemical resistance factor
ues of 65kW/m² and 65 kW/m² per minute when applied
The chemical resistance factor can be regarded as
to the interiors of those aircraft taken into service after
a measure of the resistance to damage sustained by
July 1990. (The upper limits OSU 65/65 replaced OSU
piping used to transmit aggressive substances. In the
100/100 which had been valid up to that time).
course of time, the damage (always compared to that
Permeation/Permeability produced by water) leads to changes in the physical
The permeability of a substance is a measure of its properties of the piping, such as reduced compressive
"leakiness", i.e. its ability to let a specific medium pass strength. The factors are strongly temperature depen-
through. Example: A piping system's permeability to dent. Relevant information can be found in the → DVS
oxygen is often of critical importance. A substance's guidelines 2205, Part 1 and in the DIN standards of the
permeability depends on the sizes of its microscopic raw materials used for the piping
gaps and spaces. Pipe series S
The permeation of plastics by water vapour and gas-
The number S of a pipe series is a parameter which can
es is of interest for packaging, coverings, barrier films,
be used to calculate (ISO 4065) the wall thickness e of
gaskets and seals, pipes, containers, etc. Diffusion and
a pipe of given outer diameter d.
→ Absorption or → Desorption of substances of low
S ≈ 0.5 ⋅ (d/e - 1) i. e. e ≈ d/(2 ⋅ S + 1)
molecular weight, e. g. of the water in or from polymer-
Pipes from a given series S and of a given material
softening agents are also of importance. If a substance
quality all withstand the same pressure. However, the
of low molecular weight, the permeator, penetrates into
number S is defined purely geometrically and it is often
a polymer, its coefficient of permeation P is defined as
used as a measure of pressure resistance. [→ Nominal
the product of the coefficient of diffusion D and the coef-
Pressure (PN), → SDR = Standard Dimension Ratio]
ficient of solubility S ("solubility"), i. e.
Oxygen index (LOI, limiting oxygen index)
P = D ⋅ S
A substance's oxygen index is the minimum concentra-
For the given system and at a given temperature, the tion of O2 in a mixture of oxygen and nitrogen which just
coefficient of permeation P is an important parameter. It sustains its combustion. The higher the need of oxygen
is defined by the equation: is, the lower should the combustibility be. Use of the in-
dex in judging fire hazards is a matter of controvers.
Q = P ⋅ A ⋅ t ⋅Δp/d
Shear strength
Q is the quantity of gas or vapour, which in the time t
Shear strength is the ability of a substance to with-
(and on account of the permeator's pressure difference
stand the stress as a result of two parts of a body being
p between the front and the back of the layer), perme-
pushed or pulled in such a way that they slide relative to
ates through a polymer layer of area A and thickness d.
one another. The shear strength is of particular interest
Coefficients of permeation of different polymer materials in parts which have been cemented together. It is de-
termined by increasing the shear force applied to a sim-
Material O2 N2 (Nitro- H2 (Hy- CO2 H2O ple overlapping joint until it breaks. According to EN ISO
(Oxygen) gen) drogen) (Car- (Wa- 9311-2, the shearing strength is a quantity applicable to
bon ter
Diox- Vapour)
the entire joint.
ide) Impact resistance (impact strength)/Notched
PE 8 - 19 2-6 25 - 55 32 - 75 0.5 - impact resistance
1.5 In the impact test, the energy needed to break or de-
form a sample is measured by letting a pendulum with
PP 5 2 65 25 1.1
known kinetic energy (calculated from the correspond-
PVC 0.4 0.04 10 0.9 6.5 ing potential energy = weight x distance fallen) collide
PVDF 0.7 0.2 3 <1.0 5.2
against the sample. The impact resistance is the work
(energy) per unit area of the critical cross-section (kJ/
Positive list m²) needed to break the sample. It is determined, for
→ BGA, → FDA example, in the flexural impact test, which can be per-
formed in two different ways:
RAL colours 1.Charpy's method: The impact occurs at the centre of
Colour standards which conform to the register of the sample, which stands on two supports.
colours (colour charts) issued by the German Associa-
tion for Quality and Labelling (RAL). 2.Izod's method: The sample is held at one end while
the impact occurs at the other end.
Scanning electron micrographs
In a scanning electron microscope, electromagnetic The notch impact resistance is measured using a sam-
lenses focus the electrons reflected from the surface of ple with notches.
the specimen being viewed to produce an image of the Melt Flow Index (MFI)/Melt Flow Rate (MFR)
surface on a screen or on a photographic plate. A thermoplastic material is melted in a cylinder and then
Scanning electron micrographs are used by our compa- pressed through a die using the pressure exerted by
ny in the assessment of the inside surfaces of pipes and a piston. The MFI / MFR is the amount of material (in
of fracture surfaces. grams) pressed through a standardized die by a given
force in 10 minutes.
52
This single-point measurement characterises the flow The → Hoop stress σ read from a long-term regression
of melted thermoplastics under certain conditions of curve (→ Stress-rupture test) is taken to be a measure
pressure and temperature. It gives an approximate in- of a pipe material's maximum pressure stability under
dication of the material's processing (i. e. flow) proper- the given conditions. To ensure absolute safety in prac-
ties and thus provides information on the influence that tice, this stress is divided by a safety factor SF to give
working the material - or its thermal decomposition - can the value of the permissible stress σper.
have. In this respect, it is particularly significant for poly-
σ per (T, t, medium) = σ (T, t, water) / SF
olefins.
Apparent density A high value safety factor, value therefore inevitably
leads to a low classification of a pipe's → Pressure sta-
The apparent density is the quotient obtained by divid-
bility. Safety factors depend on a variety of circum-
ing the mass of a powder or granulated substance used
stances (according to the pipe's application), for exam-
in moulding, by its volume. It is given in g/ml (=g/cm³)
ple:
and is measured by letting the substance trickle freely
through a standardised funnel into a beaker of a given • variations in strength, possibly dependent on the raw
diameter. It is used to control the structure of powder or material or manufacturing process
granulated moulding compounds. • impact stress caused by pressure impulses or exter-
nal influences
Shrinkage
Melted thermoplastics which are cooled contract on • safety margins for the uncertainties of practical use
solidification. The contraction can be explained by the • thermal stresses due to temperature changes
plastic's crystallization. Further shrinkage may arise af- • flexural stresses produced by expansion or by ground
ter reheating polymer pipes which have been manufac- settling
tured to have anisotropically orientated molecules. (→
• flow medium
Internal stress)
One distinguishes between: More details on the relationship between chemical re-
• contraction in length sistance and safety factors can be found in the → DVS
• contraction in volume guidelines 2205, Part 1. The → Chemical resistance
• contraction due to processing factor fCR for each of the various substances is given in
the → DIBT list of media (German: Medienliste).
• delayed contraction Of course, very important safety factors (some of them
All these types of contraction are dependent on the sub- temperature dependent) are those for the various pipe
stance used in the moulding, the processes carried out, materials with water as the flow medium.
the shape of the tooling (e. g. of the dies), and on the Because of the ongoing development of pipe materials,
molecular orientation (anisotropy). Delayed contraction safety factors are subject to variations, which are partly
also depends on outside influences. due to the establishment of new and different standards.
The standards evolve under the influence of considera-
SDR (Standard Dimension Ratio) tions which are not only scientific and technical, but also
The SDR is the ratio d/e of a pipe's outer diameter d to commercial and strategic. This is well illustrated by the
its wall thickness e. Besides this, other classifications fact that for a given material, different safety factors are
are the → Pressure rating (PN) and the → Pipe series used in different countries.
S. The definitions of the SDR and the pipes series num- Please consult us if you have any questions concerning
ber S depend exclusively on pipe dimensions. This is safety factors!
not the case with the pressure rating (PN):
SDR = 2S + 1 = d/e Sieve analysis
S = (d/e - 1)/2 Sieve analysis is used to determine the distribution of
grain or particle sizes, and to determine the proportions
Shore hardness by weight of different particle size ranges. Each catego-
The Shore hardness is a way of quantifying hardness. ry is determined by two consecutive sieve-mesh sizes.
Two methods (Shore A and Shore D) are used in mea- Granulated substances used in moulding are analysed
surements - mainly on rubber-like, but also on soft and with the help of machines which contain sieves posi-
elastic-loamed plastics. The measurements are of lit- tioned above each other.
tle practical importance for the plastics used in piping. These oscillate horizontally in a circle movement. Ac-
Measurements of the Shore hardness are performed cording to DIN standards, sieve-mesh sizes are clas-
according to DIN 53505. sified by standardised numbers. The classification is
A spring presses a needle (a truncated cone for "Shore the same as that recommended by the ISO. In process-
A", a cone for "Shore D") with constant force onto ing PVC-U, sieve analysis of the pure PVC powder is a
the sample. The depth to which the needle sinks into powerful tool in maintaining the constant quality of the
the sample is a measure of the hardness. (The scale required PVC-U formula.
ranges from 0 to 100 - without units.) Methods A and D Stress crack-inducing media
are used in different ranges of hardness. These are substances which cause an inhomogeneous
Safety factor (SF) softening or a swelling of a plastic product. Hairlines
Safety factors are important, for example, in determin- and cracks in pipes have a variety of causes. They are
ing a pipe's required dimensions, its pressure rating or the physical and/or chemical effects due to the flow
its anticipated service life. medium (→ Swelling, → Solution) in combination with
internal stress. The effects are accompanied by a partial
extension, a crazing, of the hairlines and cracks. When
53
plastic articles are immersed in the substances in ques- Rigidity
tion, hairlines and cracks are produced which depend The rigidity of a pipe is determined mainly by its elastic
on internal strains and on external forces. modulus and its flexural strength. Both provide informa-
The following table shows some of the substances tion on the deformations produced by certain loads.
which are particularly likely to produce hairlines and The suitability of a part for an application in which rigidi-
cracks. The combinations of raw material and medium ty is important is generally determined using a bending
are frequently used for testing purposes, i. e. for deter- test in which the influence of its material and shape are
mining the level of internal stress in products made of examined.
the given plastics. It is important that the suitability of a The high value of ca. 3000 N/mm² for the elastic mod-
planned plastic piping system for use with various sub- ulus of PVC-U leads to high rigidity in pipes, even if
stances is discussed with the manufacturers - particular- the walls are thin. The pipes have excellent properties
ly if the piping is to transport surfactants even under the long-term effect of stresses produced
by extension, compression, bending and shearing. The
Plastic Substance modulus of elasticity should be taken into consideration
PP chromic acid when assessing the rigidity of pipes made of other ma-
terials.
PVC-U methanol
Radiation, resistance to
PSU acetone
The depth to which radiation penetrates depends on
PS petroleum/crude oil its type, its energy and on the resulting excitation →
PC carbon tetrachloride Absorption. In certain cases, ultraviolet radiation can
break chemical bonds, thereby splitting molecules. Gen-
ABS toluol, n-propanol erally, the changes which radiation causes in a poly-
mer depend on various external factors. They depend,
The presence in pressurised pipes (e. g. those made of in particular, on the radiation's energy dose. Many plas-
PVC-U, PE or PP) of substances which are surface ac- tics are hardly influenced by radiation and are finding
tive (surfactants) can reduce their durability quite con- increasing use in equipment which has to withstand
siderably and lead to premature failure. strong and energy-intensive radiation. UV radiation is
Formation of corrosion by stress-induced hair- applied commercially in the photochemical cross-linking
lines and cracks; Crazing of PE to PE-X. Pipes made of PE-X are frequently used
In a way these phenomena, which are observed in met- in sanitary installations for hot and cold water.
als and in plastics, represent physico-chemical action. Annealing
In many cases, the inducing chemical reagent is simply In the manufacture of amorphous and semi-crystalline
moisture. plastic products, the cooling process (→ Shrinkage) in-
For the phenomena to occur, stress (→ Internal stress) volved in shaping the components leads to → Internal
has to be present. It is of no consequence whether they stress (i. e. molecular stress). Annealing is a subse-
are caused by the manufacturing process, or by exter- quent heat treatment which produces the following im-
nal influences (which are somewhat under the usual provements:
limits of tensile strength). Hairlines and cracks appear a) Removal of internal stress in amorphous thermoplas-
perpendicular to the direction of tensile stress. In many tics when annealing near the → Glass transition tem-
plastics the effects are worsened by the substances perature. In the case of semi-crystalline thermoplastics,
with which they are used, particularly by surface-ac- a reduction of stress can often be achieved if the an-
tive substances. The effect of these substances may be nealing is performed at temperatures below the melting
due to impurities, or to constituents with low molecular range. By doing this, the susceptibility to → Formation
weight being dissolved out of the plastic. They could be of stress-induced hairlines can be reduced consider-
due to gradual swelling processes which enable the re- ably. Examples: PSU.
laxation of locally frozen (internal) stress, resulting in the b) Increase of the crystalline proportion in semi-crys-
formation of the observed hairlines/crazes. talline thermoplastics (post-crystallisation). This is asso-
It is certain, however, that the formation of stress-in- ciated with increased rigidity, hardness, abrasion resis-
duced hairlines and cracks is accelerated considerably tance, a better dimensional stability under heat, etc. Ex-
by raising the temperature. If damaging (surface-ac- amples: PPS
tive) substances act for longer periods of time (and pos- See → Physical ageing.
sibly with internal or external stresses), hairlines can Thermal stability
penetrate through the walls - becoming cracks which Thermal stability is a moulding compound's durability in
lead to the complete destruction of the pipe. Example: processing to thermal degradation, e.g. thermal oxida-
This effect can be seen very nicely if a piece of unan- tion. (→ Pyrolysis; → Chemical ageing)
nealed PSU piping is put into acetone. Even after a One possibility of assessing the thermal stability is to
short time, hairlines followed by strong cracking can be perform a time-trial by exposing the compound to a con-
observed. Note: The expressions 'stress-induced corro- stant, predetermined test temperature in order to age it
sion', 'stress-induced cracking' and 'crazes' are some- thermally.
times used interchangeably. 'Stress-induced corrosion' In polymers a depolymerisation or dissociation (e. g. of
is, however, usually the designation for the formation HCI from PVC-U) can occur. According to EN 728 the
of hairlines on account of the chemical attack of a flow so-called Oxidation Induction Time (OIT), the time which
medium on a pipe (i. e. it is a process involving both passes before oxidation begins, is used to characterise
the production of new and the breaking of old chemical the thermal stability of polymer compounds.
bonds).
54
Thermoanalytical measurements using DSC count. For each material, many categories are possi-
and DTA ble (depending on wall thickness). The correct categori-
The following thermoanalytical methods are used in in- sation of a material corresponds to the component's
vestigations of the structures of polymers: thinnest wall cross-section. UL 94 categories are only
• differential thermoanalysis (DTA) comparable and meaningful if the applicable wall thick-
• differential scanning calorimetry (DSC) nesses are given.
UL 94 prescribes the following groups - in which the
• thermogravimetric analysis (TGA) best category is the last:
• dynamic mechanical analysis (DMA) • UL 94 HB
• dilatometry • UL 94 V-2
Differential thermoanalysis (DTA) and differential scan- • UL 94 V-1
ning calorimetry (DSC) are based on the same principle. • UL 94 V-0
In both methods the test sample and a reference sam- • UL 94 5V
ple are heated (or cooled) simultaneously. By doing this,
• UL 94 5VB
the temperature difference between the samples (DTA)
and the difference between the specific temperatures • UL 94 5VA
(DSC) are measured.
Hoop stress (circumferential stress)
Because the DTA graphs are, ultimately, used to calcu- If every point of an elastic hoop (e. g. of an O-ring) is
late the specific heats, and because all normally obtain- pressed uniformly in an outward direction, the hoop
able, modern equipment is of the DSC type, we will on- becomes larger and its material is put under stress. In
ly discuss the DSC method. Thermograms are obtained analogy, a plastic pipe expands (at least very slightly)
which show at which temperatures the processes are when subjected to inside pressure. Its circumference
endothermic (energy absorbing) or exothermic (energy becomes enlarged, causing a so-called hoop (or cir-
releasing). The processes can, for example, be the for- cumferential) stress in the pipe material. This stress is
mation or the melting of crystals respectively. They can an important means of quantifying a pipe's state of ten-
also be → Glass transitions in which overheating or un- sion.
dercooling is observed. Further examples of the applica- The relationship between the inside pressure and the
tion of DSC to polymers are the analysis of impurities, pipe material's hoop stress is given by the → Vessel for-
the determination of the degree of cross-linkage, and mula.
the examination of thermal stability. If a semi-crystalline
sample with unknown structure is melted in a DSC ap-
Vicat softening point
paratus, the resulting thermogram gives information on In the Vicat test, measurements of a plastic's soften-
its crystalline structure and its degree of crystallinity being temperature are made. The flattened end of a round
fore treatment. needle of area 1 mm² is pressed (with predetermined
force and at steadily increasing ambient temperature)
DSC examinations of amorphous polymers enable onto the surface of a sample of the material. The soft-
an analysis of their behaviour at → Glass transition ening point (VST = Vicat Softening Temperature) is
. They also reveal equilibrium disturbances such as reached when the needle penetrates 1mm into the sam-
the quenching of amorphous thermoplastic material. ple. Practicable alternatives are:
Both DSC and DTA are very important polymer mate- • Method A with an applied force of 10N .
rial tests, which give the user a good general view of
• Method B with an applied force of 50N (ISO 306)
the polymer's structure and condition. Hence, DSC is a
valuable tool for quality assurance and for polymer re- In each case the temperature can be raised by 50 °C or
search and development. by 120 °C per hour. The test conditions are called A50,
In TGA a polymer sample's change in mass is deter- A120, B50 or B120
mined resulting from the application of a given tempera- Thermal conductivity
ture programme in a given gas atmosphere (N2, O2, air). There is a time-dependent transfer of heat (Q) between
The graph of the experimental results reveals the reduc- two points of a body which have different temperatures.
tion in weight when the temperature is raised. Considering a wall of cross-sectional area A and thick-
Using DMA, it is possible to determine both storage and ness e, the heat conducted from one side to the other is
loss moduli (E', E") of a polymer sample for a given tem- directly proportional to the (maintained) temperature dif-
perature and at a given frequency of an applied sinu- ference between the sides, to the area A and to the time
soidal vibration. The → Relaxation modes(e. g. → Glass t. It is inversely proportional to the thickness e:
transition point) of various polymers can be analysed
Q = λ ⋅ A ⋅ t ⋅ ΔT/e
using this technique.
UL94 inflammability The constant of proportionality k depends on the wall's
material and is called its coefficient of thermal conduc-
Standard 94 of the Underwriters' Laboratories (UL 94)
tivity.
has established itself as the globally accepted norm for
the classification of a plastic's fire resistance. UL 94 pre- [λ] = W / (m K) = Wm K -1 -1
scribes how a material's ability to stop burning is to be

W = watt, m = metre, K = Kelvin (= °C).
tested.
In general plastics have very low values of thermal con-
In the classification, the rate of burning, the time after
ductivity compared with other materials such as metals.
which burning stops, any drops produced, and the time
For this reason they are often used for thermal insula-
in which smouldering continues are all taken into ac-
tion.
55
Substance Coefficient of thermal conductivity a) Short-time burst-pressure tests
(Wm- 1K-1) These tests are performed by applying the highest pres-
sure possible. Failure results even after a few seconds.
Foam Plastics 0.02 - 0.05
Such tests give important information about the pres-
PVC-U 0.16 sure resistance of new products under the respective
PVC-C 0.17 conditions.
PP-H 0.22 b) Long-term stress-rupture tests

Long-term tests on pipe samples are performed (in
PE-HD 0.41 compliance with DIN 53759) to obtain the data pre-
Copper 400 sented in long-term regression curves. Each curve is a
double logarithmic plot of the time after which the pipe
Water 0.61
samples (of given material at a given temperature) fail,
Air 0.023 against the corresponding, applied → Hoop stress. Us-
ing standardised statistical algorithms, the curves can
Stress-whitening be extrapolated to predict a material's creep behaviour
Stress-whitening is a light-scattering phenomenon even for very long periods of time. (The tests on the
which can be seen in parts of a stretched plastic sam- commonly used pipe materials PE, PP and PVC-U have
ple (transparent or coloured). It is often accompanied been running for well over 30 years!) The use of hoop
by the formation of crazes (→ Formation of / corrosion stress instead of pressure makes the curves indepen-
by stress-induced hairlines and cracks; crazing), i. dent of pipe dimensions, i. e. it makes them a represen-
e. by the formation of microscopic, usually lenticular ar- tation of a property of the given pipe material. This ac-
eas, the boundaries of which are bridged by individual, counts for the extraordinary importance of the long-term
extremely strong strands of the material. Stress-whiten- regression curves.
ing is a sign of overloading.
(→ Optical properties of polymers) c) Spot tests:
Long experience has shown that stress-rupture tests
Weathering; UV stability; Atmospheric expo- can be carried out in a comparatively short time if per-
sure formed at higher temperatures than those found in prac-
These headings cover the resistance of a material to at- tical working use (principle of time-temperature super-
mospheric exposure, e. g. to temperature and tempera- position). Such tests are used, for example, in the qual-
ture fluctuations, atmospheric oxygen, ozone, humidity, ity control of batches of manufactured goods (as de-
UV radiation, environmental pollution (sulphur dioxide, manded in the applicable DIN specifications and →
nitrogen oxides) and impact by hailstones. DVGW guidelines). Examples of the hoop stress σ0 pre-
These factors can lead to a radical change in a scribed (in DIN) for such tests are given in the following
polymer's basic properties, including its colour stability. table.
Only some polymers are sufficiently resistant to degra-
dation by light and by weathering. Many products (e. g. Temperature in Material σ0 in N/mm²
PE-HD black) have to be mixed with active carbon black °C
- which still has the best stabilising effect against light 60 PVC-U 10
and weathering. Quantities of 2 % to 4 % are usual. At-
mospheric exposure can cause changes in a plastic's 80 PE 4
appearance (sheen, colour, hairlines), chemical compo- 95 PP-H 3.5
sition and handling properties. → Chemical ageing, →
Radiation, resistance to Shortened tests should only be applied if the long-term
creep behaviour of the given material is already known.
Permeability to water vapour
This a special case of general permeability and is im- Tensile test
portant for the application of plastics as packaging ma- In the tensile test, a sample (or component) is forceful-
terial and as a basic material for cable sleeving. The ly extended, in the direction of its longitudinal axis until it
permeability to water vapour depends on the material's reaks.
thickness. The unit used is grams per m² and day. The following values can be obtained from the curve of
tensile stress plotted against elongation:
Stress-rupture test
Stress-rupture tests are used to examine a polymer's • tensile strength at maximum load = greatest stress
→ Creep behaviour and are the basis on which the → sustained (N/mm²)
Pressure rating, required dimensions or anticipated → • tensile strength at break = stress at breaking point (N/
Service life of pipes (made of the polymer) can be de- mm²)
termined. • tensile strength at yield = first relative maximum (N/
In the tests, pipe samples filled with a test fluid (usually mm²) of the curve
water) and held at constant temperature in a water bath
• percentage extensions correspond to the named
or a hot-air oven, are subjected to constant inside pres-
stresses.
sure causing a three-axial stress. The pipes are tested
until they fail (i. e. break, rupture, burst). The → Vessel
formula is used to calculate the → Hoop stress result-
ing from the internally applied pressure in a pipe of giv-
en dimensions.
There are different types of stress-rupture tests:
56
Basics in general and polymer chem- dered in a large volume. The spatial arrangement of
the chains in amorphous polymers (the arrangement of
istry the elements of the chains and of their bonding angles)
Absorption leads these polymers to set in a disorderly fashion. In
Broadly speaking, absorption is a "sucking-up" or "tak- the solid state, the chains of amorphous polymers are
ing-in" process. Examples: Plastics can absorb solvents disorientated or, at best, only locally ordered. In a semi-
which cause → Swelling. Electromagnetic energy (e. crystalline polymer's solid state, the amorphous parts
g. visible light) can be absorbed by a material and be are surrounded by crystalline parts. Examples: PPS,
changed to heat, or give rise to effects such as fluores- PP, PE.
cence, splitting of molecules, and potential differences For thermodynamic reasons, a purely crystalline poly-
due to the separation of electric charges (solar cells). mer, i. e. a "polymer monocrystal", is strictly speaking
not possible.
Additives
In the context of polymer technology, 'additive' is the Inorganic/ Inorganic chemistry
collective term for auxiliary materials which are mixed Inorganic chemistry deals with all the elements and their
with a polymer to effect a change in its behaviour or compounds, except for carbon, of which only the oxides,
properties. There are two categories of additives, i. e. cyanides and carbides are covered.
those which: AOX (adsorbable organic halogen compound)
1.enable a proper processing. This is the sum parameter of the halogenated hydrocar-
Examples: stabilisers, lubricants. bons in water.
2.change the properties of the polymer to achieve long-
Aromatic compounds
term use. Examples: UV stabilisers, softening agents,
Aromatic compounds are a large category of organic
fillers, pigments, flame retardants and, sometimes,
substances. They have flat, ring-shaped structures with
other polymers (→ Blends).
a characteristic distribution of electrons, behave in a
Adhesion (= adsorption) particular way in reactions, and are chemically very sta-
This is the sticking-together of two different phases (i. ble. Benzene (benzol) is an important member of this
e. media) at their common boundary. It is due to the at- category. The name "aromatic" stems from those sub-
traction (the so-called adhesive forces) which exist be- stances which were once largely extracted from plants
tween the molecules of one medium and those of the and which had an "aromatic" smell. Examples: aromatic
other. Examples: adhesion is what causes a drop of liq- polymers include almost all plastics, e. g. PPS and PEI.
uid to wet a surface (as opposed to the surface tension
of the liquid, which tends to hold the drop together). Ad-
hesion is what causes chalk to stick to a blackboard.
The opposite of adsorption is called desorption.
Aerosol
An aerosol is a homogeneous distribution of fine liquid
droplets in a gas. Benzene
Active carbon (activated charcoal) Atom

Active carbon is a collective term for various forms of The continued division of a material leads to the small-
microcrystalline carbon. These forms differ in the size est particles which can exist alone and independent
of their pores. By using the active carbon's → Adsorp- from each other. These are the material's atoms. Nowa-
tion, substantial quantities of organic substances can days about 300 different variants (so-called nuclides)
be removed from a liquid or gas phase. Examples: are known. Each atom contains a characteristic num-
Active carbon is used in kitchen ventilator units to re- ber of electrons (carriers of negative electrical charge)
move odours and vapours (as in cooker hoods or stove and a nucleus. The electrons surround the nucleus like
vents), in the filters of gas masks, and in filters used to a shell or cloud and are found at different distances
purify water. from the nucleus. They are, therefore, not all equally
In the polymer industry, carbon black is used to stabilise easy to remove. In most chemical reactions, only the
polyolefins against UV radiation. Special grades of car- atom's electrons are involved - usually the outer ones, i.
bon black are used to make polymers electrically con- e. those electrons at the greatest distance from the nu-
ductive. cleus.
Aliphatic compounds The nucleus contains protons, each of which is near-
The molecules of this class of substances contain linear ly 2000 times as heavy as an electron, and carries as
and branched chains of carbon atoms. Aliphatic com- much positive electricity as an electron's negative ele-
pounds contain only C-C or C-H bonds and are there- mentary charge. As all atoms contain the same num-
fore relatively unpolar (→ Polarity), chemically rather in- ber of electrons as protons, they are electrically neu-
active or even inert. Examples: polyolefins like PP or PE tral. This number is characteristic of what is called an
are good examples of this class, as well as countless element. Example: the element oxygen has 8 protons
compounds of low molecular weight, such as benzine, and therefore also 8 electrons. The elements are listed
butane and paraffin. systematically in the so-called periodic table of the ele-
ments.
Amorphous/semi-crystalline
When thermoplastic polymers solidify, their molecu- Besides the protons, the nucleus of an atom contains
lar chains are more or less of an even structure. The other elementary particles, i. e. neutrons. These have
molecules of a crystalline substance are spatially or- no electrical charge, are about as heavy as protons and
57
function like a "glue", which holds the protons together. A polymer's limited -->Chemical resistance to certain
The atoms of a given element can differ in the number categories of media can lead to degradation and to no-
of neutrons, in this case we say that the element has ticeable damage. Examples: sensitivity of PP to oxidiz-
different isotopes. ing agents, such as chromic acid. PVDF is sensitive to
caustic solutions.
Atomic weight/Relative atomic mass
All substances consist of atoms. Each element has a Chemical resistance
characteristic mean "weight". Because the weights of The chemical resistance of a substance is a complex
the atoms are so minute, a scale using grams gives val- property which depends (inter alia) on its chemical com-
ues which are far too small for practical use. Instead, a position and on the way it has been processed / manu-
scale based on the unified atomic mass constant u, i. e. factured. The chemical resistance of a polymer pipe de-
1/12th of the mass of a (particular sort of) carbon atom pends predominantly on its chemical structure, on ad-
is used. The relationship 1 u = 1.6605 x 10 kg gives an
-27
ditives, on its crystalline structure and on the condition
idea of the difference between the scales. An atom's so- of its surfaces. As chemical resistance depends, ulti-
called atomic weight is its relative atomic mass, i.e. the mately, on the possibility of chemical reactions occur-
ratio of the atom's mass to the unified atomic mass con- ring (reaction kinetics), the conditions under which they
stant. take place (pressure, temperature, radiation, mechani-
An atom's gram-atomic weight (or gram-atom) is the cal loads, concentration of chemicals and the duration
mass (in grams) of one → Mole of the atoms. of contact with them, etc.) are also decisive. According
to the existing standards (DIN 16888, Parts 1 and 2),
Example: for neon gas (Ne): there are three categories for a thermoplastic pipe's be-
atomic weight = relative atomic mass = 20 haviour under chemical attack: "resistant" (+), "condi-
gram-atomic weight = gram-atom = 20 g tionally resistant" (0) and "not resistant" (-). The follow-
ing table lists synonyms and logograms:
molar mass (i.e. mass per mole) = 20 g/mole
mass of neon atom = 20 u DIN DIN Supple- Lists of ISO 4433
16888 ments to chemi-
(u = unified atomic mass constant. → Atomic weight) -1, -2 8061/8078 cal resis-
tance
Blend
In the context of this book, a blend is a homogeneous W resistant + satisfactory (S)
mixture of polymers (analogous to alloys of metals). Al- BW conditional- O limited (L)
loys are mixed to produce a given combination of prop- ly resistant
erties. Blends of polymers, however, are often high- NW nicht resistant - not satisfac-
ly complicated and unstable systems. This is due to a tory (NS)
lack of "compatibility" of certain polymers. In polymer
technology, blends are of immense importance when → Chemical stability; → Corrosion; → Swelling; →
achieving the required balance of material properties. Physically active substances; → Chemically active
BOD (Biological Oxygen Demand; Biochemical substances.
Oxygen Demand) Chlorine, chemistry of:
The BOD (German: BSB = Biologischer Sauerstoff-Be- Because of the large number of customers' questions
darf) is the mass of oxygen used by micro-organisms concerning the → Chemical resistance of GF plastic
to oxidise an organic substance in a unit volume of wa- pipes to substances containing chlorine, a summary of
ter at 20 °C. Measurements usually take 5 days to com- the most important facts is given here.
plete (BOD5). Chlorine (chemical formula CI2) is one of the most im-
Chemical active substances portant primary products of modern chemistry. In spite
In this context, chemically active substances are those of heated discussion in the last few years, it still has to
which attack or change the material of which a pipe is be regarded as a necessary and ecologically viable ba-
made. sic chemical for use in many large-scale industrial pro-
cesses (e. g. in the production of sodium hydroxide).
Example: PP can be chemically degraded by having its On a large scale it is usually manufactured by the elec-
molecules (its carbon chains) broken by strongly oxidiz- trolysis of alkali-metal chlorides. Chlorine and sodium
ing agents. hydroxide (caustic soda) are produced in an electro-
Chemical ageing chemical redox reaction from a concentrated common
Chemical ageing is the collective name for all those salt solution. One distinguishes between the diaphragm,
processes which cause a chemical degradation of or a the amalgam (mercury) and, more recently, the mem-
change in a polymer's molecules. The most important of brane processes.
these causes are: Note: Reinforced PVC-C has been used on the "chlo-
(i) Photochemical reactions: rine side", i.e. on the side of the anode, and proved it-
Radiation incident on the polymer causes chemical self to be an excellent material. In this application, our
bonds to break. (-->UV-stability, --> Radiation, resis- customers (world-wide) rely on the extraordinarily good
tance to) quality of components made of PVC-C.
(ii) Thermally induced chemical ageing: On the cathode side and for brine feed ducts,
Higher temperatures make it possible for certain degra- polypropylene pipes have proved to be the best in their
dation processes to occur. resistance to highly concentrated caustic soda. This is
(iii) Contact with flow media: an important application of PP components summary of
the most important aspects of chlorine chemistry: Chlo-
58
rine is a very versatile → Element. Via → Reduction, its polymer mixtures are compounded at our company us-
atoms each take up an electron, and a so-called "chlo- ing our own, well-established formulas for the manufac-
ride" (= CI ) is produced - such as gaseous hydrogen
-
ture of pipes.
chloride (HCI - its solution in water is called hydrochloric
Copolymer
acid) and common salt (NaCI). Chlorine can also be ox-
A copolymer results from a → Polymer synthesis using
idized, in which case each chlorine atom can lose up to
many monomers, without regard to the method used.
seven electrons from its outer shell. This unusually large
The individual monomers are combined on the basis of
number of electrons has the effect that several different
chemical criteria which can be described using so-called
chlorine compounds can result, the most important of
copolymerization parameters. Copolymers are subdivid-
which are given in the following table.
ed into:
Number of Formu- Name of Formula af- Name (i) statistical copolymers (random copolymers): the dif-
electrons la of acid ter removal of corre- ferent monomers are united unsystematically, but in
lost (+) or acid of water sponding proportion to their relative amounts. Examples: PP-
gained (-) (anhydride) salt R, Type 3, has up to 6 % of ethylene (by weight) as
(Oxidation comonomer. SAN is a copolymer made of styrene and
state) acrylonitrile.
(ii) block copolymers: these can be imagined as having
-1 HCI Hydrogen - chloride normal polymer chains (of monomer A) in which com-
chloride plete sections ("blocks") consist of chains of a second
(solution polymer (monomer B). Example: PP-B (Type 2) is a
in water is block copoIymer made of propylene and 8 % to 10 %
known as (by weight) of ethylene (PE blocks).
hydrochlo-
(iii) graft copolymers: in a chemical reaction, chains of a
ric acid)
polymer B are "grafted" as side chains onto chains of a
+1 HCIO hypochlor- CI2O hypoclorite main polymer A.
ous acid
CSB
+3 HCIO2 chlorous - chlorite → COD
acid
DAB
+5 HCIO3 chloric acid - chlorate
Abbreviation for "Deutsches Arzneibuch" ( = German
+7 HCIO4 perchloric CI2O7 perchlorate Pharmaceutical Codex)
acid
Disinfection
Important notes: Disinfection is the elimination of pathogenic (i. e. dis-
• All chlorine compounds with positive oxidation states ease-causing) micro-organisms in certain situations (e.
(oxidation numbers) are, to a greater or lesser de- g. the removal of one particular type of germ). Disinfec-
gree, strongly oxidizing agents (e. g. hypochlorites, tion, in contrast to → Sterilisation, is a partial, not an
chlorites). The use, for example, of the polyolefins absolute process.
(PP and PE) as piping for these substances must al- Disinfectant
ways be discussed carefully with our customers. At Disinfectants are a category of substances which, on
our company, we have considerable expertise in deal- account of their chemical composition, harm germs.
ing with these and similar matters. Our long, unusually Their effect can, for example, be due to damage done
comprehensive experience in the planning and instal- to the micro-organism's protein structure. (Protein is
lation of chemical plants makes us confident that we found, for example in a cell's DNS and DNA). Disin-
can solve your problems in such matters - in consulta- fection can be achieved by retarding or stopping the
tion with you. microoganism's growth, or by radically killing it off. Im-
• When chlorine is passed through water, it is partly portant factors are the concentration of the disinfectant,
changed into chlorides and hypochlorites. The latter the length of time it is used, and its temperature. It is of-
decompose slowly, releasing oxygen. This, in part, is ten possible to disinfect using heat alone (pasteuriza-
how swimming pools are disinfected. At higher tem- tion).
peratures, hypochlorites decompose into chlorides Examples of disinfectants are: acids, caustic solutions,
and chlorates. -→ Oxidizing agents, halogens (e. g. iodine, chlorine),
certain compounds of heavy metals, alcohols, aldehy-
COD (Chemical Oxygen Demand) des (e. g. formaldehyde), and ethylene oxide (for steril-
The COD (German: CSB = Chemischer Sauerstoffbe- ization at room temperature).
darf) this value quantifies the oxidizable substances In piping systems disinfectants need to be given particu-
contained in water. It indicates a volume-related mea- lar attention. They are often used with surface active so-
sure of oxygen which is equivalent to this oxidant potas- lutions (→ Surfactants), which are known to frequently
sium dichromate for the oxidative breakdown of organic trigger off stress-induced cracks in polymers.(→ Forma-
substances. tion of / corrosion by stress-induced hairlines and
Compounding cracks; crazing)
This is the concept of putting → Additives into poly- Dissociation
mers. It includes making the component parts of the The breaking up of substances, in melts or in solutions,
necessary mixtures homogeneous. Example: some into more or less freely moving → Ions is called (elec-
trolytic) dissociation.
59
Dry-blend powder mixture Fluorinated hydrocarbons
This concept arises in connection with → Compound- If fluorine is introduced into a compound, it is said to
ing and is the name of a particular quality of mixtures of be fluorinated. Important fluorinated hydrocarbons are
plastics and additives. Dry blends are so well mixed (ho- the chlorofluorocarbons (CFCs). Of these, the so-called
mogenized) that the mixture can be used directly in an Freons have properties (Iow boiling points and high
extruder or in an injection-moulding machine. chemical stability) which have made them useful as re-
frigerants in air-conditioning systems and in refrigera-
Thermosetting plastics (thermosets)
tors. They are also used as propellant gases in aerosol
The polymer chains of thermosetting plastics are so
dispensers and in the manufacture of foamed (or ex-
strongly cross-linked, that thermal deformation (below
panded) plastics. Each FreonXYZ is classified with the
the decomposition temperature) is often impossible.
help of a three-digit number:
Moulded parts and semi-finished products can only be
manufactured using the "precursor" plastic, i. e. before X number of carbon atoms per molecule minus
cross-linking takes place. The parts and products are one (For molecules with only one carbon atom,
then hardened thermally or photochemically (possibly i. e. for methane derivatives, X = 0. In this case
by adding cross-linking agents or hardeners). the first digit is omitted.)
Examples: bakelite, many dual-component adhesives, Y number of hydrogen atoms per molecule plus
PAI, curing of PPS, manufacture of polyimides, thermal one
cyclization of polyacrylonitrile (PAN) to graphite and to
Z number of fluorine atoms per molecule (All other
carbon fibres. (Cf. → Thermoplastics, → Elastomers) atoms are chlorine).
Elastomers
Elastomers consist of molecules with a relatively small Examples:
degree of cross-linking. The segments of the mesh are Fluorotrichloromethane CCI3F = Freon 11
assembled spatially in a relatively simple way, making Chlorodifluoromethane CHCIF2 = Freon 22
these parts able to move relative to each other even at When Freons are used in fire extinguishers, they are
lower temperatures. This means that the glass transition called halonsABCD (A, B, C and D being the number of
temperature TG is usually observed at negative temper- carbon, fluorine, chlorine and bromine atoms respec-
atures (e. g. for polyisobutane at TG= -70 °C). Above TG tively.)
these polymers are rubber-elastic. They are only moder- Because of their volatility and high chemical stability,
ately deformable because of counteracting forces which Freons of low molecular weight reach the upper atmo-
arise within the mesh. sphere, where they cause decomposition of the ozone
Examples: all sorts of rubber. → Thermoplastics, -→ layer. For this reason the use of Freons has been pro-
Thermosetting plastics (Thermosets). gressively reduced world-wide, or even forbidden.
Electrolytes Fluoropolymers
Electrolyte is the collective term for chemical com- Fluoropolymers are the whole range of plastics in which
pounds which, in solution or in the melted state, conduct the monomers, in some way or other, contain the el-
electricity. One distinguishes between strong and weak ement fluorine. Depending on the polymer structure
electrolytes. and the types of monomers or comonomers, one distin-
guishes between:
Enzymes (i) completely fluorinated polymers: polymers which on-
Enzymes are proteins which function as → Catalysts, i. ly contain carbon and fluorine (PTFE, FEP or PFA/TFA)
e. they facilitate chemical reactions without undergoing and
any permanent chemical change themselves. Each en- (ii) partly fluorinated polymers: polymers which contain
zyme catalyses specific biochemical reactions. fluorine, carbon and hydrogen (PVDF, PVF, ETFE).
Flame retardants Fluoropolymers have very good chemical stability.
Protection from flames can be improved by using shield- Physically, they have relatively good temperature stabili-
ing layers or by the admixture of flame retardants (as → ty as well as good mechanical and electrical properties.
Additives or in the monomer). The way in which the lat- They have particularly good sliding characteristics and
ter work is only known in a few cases. The choice of re- withstand adhesives. (This is because a fluoropolymer's
tardant is, therefore, usually empirically based. secondary structure causes a negatively charged sur-
Underlying effects: face layer of fluorine, leading to repulsive forces be-
(i) oxygen is excluded by the production of non- tween molecules.)
flammable gases, and
(ii) the flames are "poisoned" by → Radicals. Fillers
Examples: when a polycarbonate, PEEK or PEI de- Fillers are special → Additives. They are additional ma-
composes, it gives off carbon dioxide and water, which terials which increase the mass or volume of a polymer
smother flames. Flame retardants containing halogens (making it cheaper), or produce a desired change of
(bromine or chlorine) decompose in heat, producing properties.
halogen radicals. These combine with the radicals pro- Examples: added glass fibres (GF) or synthetic and car-
duced by the combustion (of the polymer) poisoning the bon fibres (CF) improve a plastic's mechanical proper-
flames (halon fire extinguishers). In a similar way, an- ties. Added chalk, quartz and mica are used, for exam-
timony (III) oxide (Sb4O6) functions as a "radical grab- ple, to increase a polymer's density and to improve its
ber" by reacting with halogen compounds. (This anti- handling properties in an extruder. Note the difference
mony oxide is the flame retardant in PP-s and in PSU between glass fibres (GF) and glass-reinforced plastics
"UDEL 1725".) Note the difference between combustion (→ FRP), between carbon fibres (CF) and carbon fibre-
inhibitors [effect (i)] and flame-retardants [effect (ii)]. reinforced plastics (CFP)!
60
Functional groups Properties: aldehydes are relatively reactive. Important
Almost all reactions in organic chemistry (→ Organic / reactions are those with alcohols and those which take
organic chemistry) depend on the presence of parts place due to the ease with which aldehydes can be ox-
of molecules with an electron density that is either rel- idised. The aldehyde group gives the molecule polar
atively low (electrophilic parts) or relatively high (nucle- properties.
ophilic parts). These "reactive centres" arise through
the insertion of functional groups, the most important of Example:
which are to be found in the following short survey. The
particular significance of the groups is that they each
have their own characteristic combination of properties.
If these properties are known, most of the properties of
a molecule (even of a macromolecule) in which a func-
tional group is present can be approximately predicted. Formaldehyde
This is very useful e. g. in assessing the → Chemical
resistance of plastic piping systems to certain media. 4) Ketones
(R = univalent group or → Radical in an organic Structure:

molecule)
1) Halides (organohalogen compounds):
Structure: R-X, where X = halogen atom (F, CI, Br or
I ). Properties: the polarity is similar to that of the aldehydes
Properties: the halogen atom is easily replaced (by oth- for equal lengths of the → Radical R. Ketones are, how-
er atoms or groups of atoms). It causes an electron ever, much less easily oxidised. Some ketones of low
deficit in the atom to which it is bonded (usually carbon). molecular weight are widely used solvents.
In many cases its presence in a molecule makes the en- Examples:
tire molecule polar.
Examples: all halogenated hydrocarbons such as chlo-
roform (CHCI3), vinyl chloride, chlorofluorocarbons
(CFC), → Polyvinyl chloride (PVC), → Fluoropoly- Acetone
mers.
Cyclohexanone
2) Alcohols:
Structure: R-OH 5) Carboxylic acids:
Properties: the properties are similar to those of the Structure:
structure element R-X. Under certain conditions the -
OH group can be replaced by a halogen. The group of-
ten functions like an acid.→ Acid / alkali (= base) Al-
cohols often react with carboxylic acids to produce es-
ters and water. Being polar, they have particular proper-
ties in relation to solvents. All alcohols of low molecular
weight (e. g. methanol, ethanol) are more soluble in wa- Properties: the combination of the -OH and -C = O
ter than in their respective hydrocarbons. Depending on groups in one functional group, the carboxyl group, low-
their structure, alcohols can be oxidised to aldehydes, ers the electron density (→ Polarity) of its carbon atom,
ketones or carboxylic acids. thereby increasing its reactivity. Carboxylic acids have
Examples: acidic properties (e. g. they form salts when added to
alkali solutions or to certain metals). In condensation
reactions with alcohols, they form esters; with amines,
they form amides. These reactions are utilized in poly-
merisation [polyesters, polyamides (e. g. nylon)]. Modi-
fications of the carboxyl group with higher reactivity are
Isopropanol to be found in the corresponding carboxylic acid anhy-
Ethanol
drides and carboxylic acid chlorides.
Examples:
Phenol
3) Aldehydes
Structure:
Benzoic acid
Oxalic acid
R=H
(formic acid)
R = CH3
(acetic acid)
With long-chained, unpolar, univalent groups R, so-

called fatty acids are formed. Example: R = CH3-(CH
2)16- yields stearic acid. The metallic salts of this acid
61
(stearates) are used widely and in different ways as → (ii) External lubricants should not have much → Affini-
Additives in polymers. Fatty acids have surface-active ty with the plastic. In processing they have to leave the
properties. Soaps are the salts of such acids. body of the polymer, moving towards the boundary sur-
faces, where they build a slippery film between the ma-
6) Esters chine and the polymer melt. However, a certain affini-
Structure: ty is indeed required so that the lubricants are not de-
posited permanently on the tools used. Examples: wax-
es and long-chained fatty acids.
Homogeneous
"Homogeneous" is synonymous with "uniform" - the op-
posite of "heterogeneous".
Properties: in the simplest case, esters are formed by
Homopolymer
the reaction of acids with alcohols. The ester group is
In contrast to a copolymer, a homopolymer is a "pure"
somewhat sensitive to acids, to alkali solutions and to
polymer, i. e. one made of a single → Monomer.
water. Esters find diverse chemical applications - as ba-
Example: PP-H, Type 1, has only propylene as a
sic, intermediate and final products.
monomer.
Examples: depending on the length of their molecules,
esters are called fats or oils. Waxes are the esters of al- Hydrolysis
cohols and carboxylic acids with longer chains. Esters There are salts which, dissolved in water, react not in
of low molecular weight are known as fruit flavouring. a neutral but in an acidic or alkaline way (→ pH Val-
Glass ue). The cause of this effect is hydrolysis, i. e. nothing
more than the effect of water splitting salts into acids
Glass is the name given to a large class of substances
and bases. Hydrolysis, the opposite of neutralisation, is
which retain their disordered molecular arrangement on
only observed with salts which are made from so-called
being cooled out of the liquid phase. There is no crys-
"weak" acids and/or "weak" bases.
tallisation and no constant temperature at which solidifi-
cation occurs. These so-called "amorphous" substances Hydrophobic
can be viewed as supercooled liquids. They have a "Hydrophobic" is the opposite of "hydrophilic". (→ Sur-
high viscosity and there is no symmetry in the way the factants) A substance, usually organic, is said to be hy-
molecules are arranged or aligned. They do not, there- drophobic if it is water repellent, if it does not dissolve in
fore, conform to the familiar "gas-liquid-solid" scheme. polar solvents (such as water) or if it does not mix with
Examples: polystyrol, PMMA and PC (polymers); amor- polar materials. The substance's hydrophobic proper-
phous silicone (semiconductors); many proteins and al- ty is usually associated with the presence of unpolar
cohols. aliphatic chains ( -[CH2]-) in its molecules. Example: one
Glass transition end of a → Surfactant molecule is hydrophobic. The
The transformation of a glass-forming substance from other end is hydrophilic.
its liquid to its glass (amorphous) state does not take Hygroscopicity
place (as with a crystal) at a definite melting point, but in Hygroscopicity is a substance's ability to take up water,
a temperature range of some (degrees) Kelvin. It proves either chemically (e. g. as with concentrated sulphuric
to be the case that the so-called glass transition tem- acid) or physically. (→ Solvation)
perature (TG) depends on the speed with which the sub-
stance is heated or cooled. If an amorphous plastic is
Ion
A positively charged ion (cation) is obtained if one
heated to its glass transition temperature, the chain seg-
or several electrons are removed from an atom or
ments of its molecules are "animated".
molecule. (→ Oxidation) Similarly, a negatively charged
Above TG its mechanical properties worsen drastical- ion (anion) is obtained when (additional) electrons are
ly on account of the molecular motion (→ Relaxation) incorporated into the atom or molecule. (→ Reduction)
which is then possible. The glass transition temperature Cations and anions are the two possible sorts of ions.
signifies an upper limit at which an amorphous materi- Example: common salt (sodium chloride, NaCI) con-
al can be worked or used. It is determined experimen- sists of the cations Na (sodium atoms, each with one
+
tally and routinely, e. g. by calorimetric measurements electron removed) and of the anions CI (chlorine atoms,
-
(→ Thermoanalytical measurements using DSC and each with one extra electron). The salt's electrical neu-
DTA) or by mechanical and dielectric relaxation spec- trality shows that both types of ions are numerically
troscopy. present in the ratio 1: 1.
Examples: PMMA, TG ≈ 90 °C; PC, TG ≈ 145 °C; rubber,
Ion exchanger
TG ≈ 70 °C.
An ion exchanger is an important device used in chem-
Lubricants ical processes such as various chromatography pro-
Lubricants are a processing aid. They are → Additives cedures and in demineralizing water. It consists of a
used to reduce a plastic melt's internal and external fric- specially prepared synthetic resin, e. g. one based on
tion. polystyrol. The resin contains → Functional groups
(i) Internal lubricants allow a polymer's chains to slide which (depending on their type) exchange either their
past one another. As with softening agents, they reduce positive or negative ions with those of a medium flowing
the melt's viscosity. They are partially soluble in poly- past.
mers. Usually compounds are used which have a low
molecular weight and → Surfactant properties, e. g.
modified esters from long chained fatty acids.
62
Catalyst Concentration
A catalyst is a substance which apparently takes no part The concentration of a component substance (in a mix-
in chemical reactions, but does accelerate them. A more ture, solution, etc.) is its quantity per unit volume or
accurate analysis of such reactions shows that the cat- mass ("weight") of the total. Common units of concen-
alyst is indeed chemically changed, but is re-formed in tration are percent by volume, percent by mass (by
the end. Its participation in the reaction is therefore not "weight"), g/l and mol/l.
evident.
Corrosion
Rubber (Caoutchouc) Corrosion can be described, quite generally, as the
Rubber is the generic term for largely → Amorphous chemical change on the surface of a solid body.
polymers, with a glass transition temperature below the Example: damage done by certain substances to the
temperature of use. Depending on the way they are pro- surfaces of plastic pipes.
duced, one distinguishes between natural and synthetic
More colloquially, corrosion is taken to be the electro-
rubbers. A rubber which has been loosely cross-linked
chemical degradation caused by the presence of an
(chemically) is called soft rubber (or simply "rubber")
electrolyte (e. g. drinking water or salt solutions) at a
and is an elastomer. A rubber which has been highly
point where two different metals come into contact.
cross-linked (chemically) is called hard rubber. Crude
rubbers (caoutchouc) are important raw materials for Crystal
elastomers. Note the difference between → elastomers Crystals are the stable structures which arise when
and → thermoplastic elastomers. atoms, ions or molecules come together in a spatial-
ly ordered way (i. e. in regularly repeated units). The
KBE (Colony-Building Unit)
crystals are held together by electrostatic or other inter-
The KBE (German: Koloniebildende Einheit) is a quanti-
molecular forces. The smallest part of a crystal which
ty used in counting bacteria, particularly in certain meth-
is repeated regularly by parallel translation is called the
ods of producing cultures.
crystal's unit cell. The various classes of external crystal
Silicic Acid symmetry are determined by the symmetry of their unit
Silicic acid is the collective name of a large number of cells. A crystal's lattice is the geometrical arrangement
silicon compounds which are obtained from the conden- of its unit cells. The crystalline structure of a substance
sation of so-called orthosilicic acid H2SiO4. Molecular can be determined by X-ray crystallography. (→ Glass,
networks are produced which can adsorb a large quan- → Amorphous/semi-crystalline)
tity of water. Further condensation leads to their becom-
Crystalline melting range
ing ever more viscous. Finally, they coagulate (gelati-
When a crystalline or semi-crystalline polymer is heat-
nous silica). If the resulting gel yields more water, it be-
ed, there might be additional phase changes other than
comes silica gel which, like → Active carbon, is a good
the → Glass transition. Between the (semi-)crystalline
adsorbing agent. Heating silica gel to incandescence
phase and the liquid (melted) phase, there can be in-
produces quartz.
termediate phases - depending on the rate of heating
Example: these substances are used to give the re-
- such as a liquid crystal phase or other crystalline al-
quired degree of viscosity in many plastic adhesives.
lotropes. The phase transitions can be examined by us-
Cohesion ing X-ray crystallography, differential calorimetry (DSC)
Cohesive forces are forces which attract between the or differential thermal analysis (DTA). (→ Thermoana-
molecules of a → Phase. In the solid state, they deter- lytical measurements using DSC and DTA)
mine the strength and mechanical stability of a material.
Legionnaire's disease
Cf. → Adhesion.
This disease is caused by a new type of very large,
Carbon rod-shaped bacteria, the most important of which is Le-
The element carbon, chemical symbol C, has the al- gionella pneumophilia - known only for some twenty
lotropes, diamond, graphite, and so-called "amorphous" years. The bacteria are 0.3 µm to 0.9 µm in diameter
forms (like soot and active carbon). Each variety of and between 2 µm and 20 µm long. The optimum tem-
these forms consists of finely crystalline graphite. Car- perature for their proliferation is between 30 °C and 45
bon atoms, unlike other atoms, are able to combine with °C.
each other in practically limitless ways to form chains
In many cases to date, infections have been traced
and rings. The resulting multitude of compounds is the
back to piping systems used for water and for ventilation
subject matter of -->Organic chemistry.
(inhalation of contaminated aerosols). Nowadays, with
Carbon atoms each have four valency electrons, i. e. pipes of quality, certain minimum requirements have
electrons which participate in chemical bonding. Ex- been specified to reduce surface roughness and there-
amples: a carbon atom can have four single bonds (as fore also the risk of bacterial infestation.
in chloroform CCI4). It can have a double bond and
Conductivity (electrical)
two single bonds (as in ethylene CH2 = CH2). It can
Conductivity is a measure of a substance's ability to
have a triple bond and one single bond (as in acetylene conduct electricity (It is the reciprocal of the substance's
HC=HC). resistivity. → Resistance, electrical). The conductivity
Hydrocarbons of solutions in water (these are of interest here) is de-
Collective term for those organic compounds which only termined by the → Dissociation of the dissolved com-
contain carbon and hydrogen. pounds. Salts in water, for example, divide into → Ions
. Similarly, acids and bases dissociate into their compo-
nent parts. Conductivity is strongly temperature depen-
dent (25 °C is the usual reference temperature).
63
A commonly used unit of conductivity is μS/cm, S being → Toxicology. It is defined in the TRG 900 (German:
the symbol for the unit "siemens" (i. e. the reciprocal 1/ Technische Regeln für Gefahrstoffe = Technical Regu-
Ω of the unit "ohm" Ω). lations for Dangerous Materials) and legally authenticat-
In practice, the conductivity is measured in order to as- ed in the GefStoffV (German: Gefahrstoffverordnung =
sess the amount of material dissolved in water. E. g. 30 Ordinance on Dangerous Materials).
μS/cm corresponds to approximately 1° total salt con-
The MAK is the highest concentration of a processed
tent. At 25 °C the intrinsic conductivity of purest wa-
substance allowed (in the form of gases, vapours or
ter (at its dissociation equilibrium) sets a lower limit of
suspended particles) in the air at a place of work - ac-
0.055 μS/cm to the conductivity of water (i. e. an upper
cording to the current state of knowledge. It takes re-
limit of 18.2 MΩcm to its resistivity).
peated and long-term exposure to the substance (nor-
Solution mally 8-hour periods) into account, so that the health of
Solutions are homogeneous mixtures. Colloquially, the those concerned is neither impaired nor endangered.
expression is usually only used for liquid solutions, al-
There are also other important parameters concern-
though alloys and gaseous mixtures also fall into the
ing safety at the workplace, for example the "Biolog-
category. A solution's major component, quantitatively,
ical Tolerances for Safety at Work" (German: BAT =
is the → Solvent. The minor component is the solute.
Biologische-Arbeitsplatz-Toleranz) and, for particular-
Important: there are degrees of solubility in all such sys-
ly dangerous materials, the "Technical Concentration
tems, i.e. one can make solutions dilute, concentrated
Standards" (German: TRK = Technische Richtkonzen-
or saturated. Solvation (Hydration): → Solvent.
trationen).
Voids
Master batch
Voids are unwanted cavities which arise during the ex-
A master batch consists of → Additives mixed with a
trusion / moulding of polymer products. Air bubbles, a
small quantity of the polymer material to be treated,
granulate which is too damp, or impurities are possible
making it a concentrated form of the additives. In prac-
causes.
tice, the additives are mixed into a polymer by inser-
Solvent tion of a calculated quantity of the master batch. The
Matter is held together by forces which have different method also makes the application of small quantities of
causes. Here, one distinguishes among other things be- additives easier.
tween (simple) electrostatic forces and interactions be-
Medium
tween dipoles. Such forces have to be overcome by the
The expression "medium" is synonymous with "chemi-
solution in order for it to be able to solvate part of the
cal", i. e. a substance which takes part in physical and
substance being dissolved. → Solvation can be envis-
chemical processes. The flow medium in a pipe is the
aged as placing a solvent covering over each particle of
substance flowing through the pipe.
the solute. Here too, there are attracting interactions be-
tween the solvent and solute. A substance's solubility in Membrane processes
a given solvent depends finally on the relative energies These are methods used on a microscopic scale in sep-
of the components of the system. For this reason the aration processes, refining and purification. Membranes
temperature always has to be taken into consideration. with different pore sizes are utilised to achieve various
According to their possible interactions, solvents can degrees of selectivity.
be divided, very roughly, into polar and unpolar groups. Important methods:
The polar solvents can be subdivided into so-called pro- • Microfiltration: this method is used to isolate micro-
tical and aprotical solvents. scopic particles with sizes between (0.06 µm (ac-
The theory of what dissolves in what has been popular- tive-carbon dust) and 100 µm (human hair)). Microfil-
ized in the slogan "same in same, like in like". tration can be regarded as the intermediate between
Examples: polar substances such as common salt, dis- conventional filtering and the following.
solve well in apolar (protical) solvents such as water.
• Ultrafiltration: This method is used to isolate particles
Unpolar substances such as fats, dissolve in unpolar
with sizes between (0.001 µm (the smallest viruses)
solvents such as dry-cleaning spirit.
and 0.05 µm (wavelength of high-energy UV radia-
The slogan is generally valid for polymers and their
tion)). Ultrafiltration, as opposed to reverse osmosis
solubility. The polymer molecules' great size and their
(see below), cannot isolate salts. It works on the so-
entanglement are, however, additional factors which
called cross-flow principle in which the substances to
should be taken into account. Here, theories of very
be separated flow tangentially over the membrane.
much greater complexity are needed, e. g. to explain
other but similar phenomena, like that of → Swelling. • Nanofiltration: this method uses membranes to filter
out particles at the lower limits of ultrafiltration and at
Macromolecules the upper limits of reverse osmosis.
Macromolecules are → Molecules consisting of a great
• Reverse osmosis (RO): this method is used to iso-
number of → Atoms. They are produced naturally (e.g.
late salts and particles with sizes between 0.0003
cellulose, enzymes and natural rubber) and synthetically
µm and 0.001 µm (approximate size of small organic
(e. g. all plastics and silicon resins).
molecules like ethylene).
MAK • Electrodialysis: this method covers the same particle
MAK is an abbreviation for the German term "Maximale sizes as the last two methods mentioned above.
Arbeitsplatzkonzentration", i. e. for the maximum per-
missible concentration of a substance in the occupation-
al environment. It signifies a concept devised to quanti-
fy occupational hazards, safety at work and matters of
64
Migration
Weight average of molecular weight:
In the context of polymers, migration is the diffusion of
additives of low molecular weight, i. e. their ability to
move around inside the polymer.
Micro-organisms (pathogenic)
Micro-organism is the collective term for a multitude of
tiny living entities and of structures like fungi, bacteria
and viruses. They differ greatly in size, structure and in
their effect on the human organism. Mi = mass of each molecule of fraction (i)
ni= number of molecules in the fraction (i)
In practice, the inside surfaces of plastic pipes used in
sanitary applications and in ventilation systems are of The distribution of molecular mass has an enormous in-
particular importance when considering the possibili- fluence on the mechanical properties of a polymer. The
ties of infestation by micro-organisms. Here, it is also of graph of the molecular weight distribution function, i.e.
significance that additives of low molecular weight can of Mi plotted against ni has a shape which can be de-
serve as a micro-organism's source of nourishment. scribed numerically by using statistical methods. For ex-
ample, the so-called "nonuniformity", i. e. the value of M
Important example: because of the presence of soften- w/Mn- 1, characterises the width of the distribution.
ing agents, soft PVC (= PVC-P) is much more suscepti- Example: Polymers used for pipes usually have higher
ble to certain microbiological infestations than hard PVC molecular weights than those used in injection mould-
(= PVC-U - contains no softening agents). ing. The distribution of mass can be determined by us-
Mole ing gel-permeation chromatography (GPC). In practice,
Mole (mol) is the globally used base unit of the amount however, worthwhile information about a polymer can
of a pure substance. It is defined as a constant number be obtained by measurements of its viscosity, or by de-
(6.022 x 10 ) of atoms, ions or molecules. One mole of
23 termination of its → Melt flow index MFI.
a substance has a mass (in g) numerically equal to its Molecule
→ Molecular weight. Two or more → Atoms joined together are called a
Molecular weight/ Relative molecular mass molecule. The strength of the bonds between the atoms
The so-called molecular weight, MW (or formula weight, of a molecule is always greater than the attracting
FW) of a molecule is its relative molecular mass, i. e. forces, the → Cohesion, between individual molecules.
the sum of its atoms' → Atomic weights (relative atomic Examples: two atoms of hydrogen and one atom of
masses). oxygen combine to form a molecule (H2O) of water.
A compound's gram-molecular weight (or gram- Two atoms of chlorine combine to create a chlorine
molecule) is the mass (in grams) of one mole of the molecule (CI2), the stable form of the element. Many -
compound. A gram-formula is the mass of one mole of often several thousand - carbon atoms combine with
formula unit. more than double the number of hydrogen atoms to
A compound's molar mass is its mass per mole. make a polyethylene → Macromolecule.
All these quantities are important characteristics of a
given compound. Example: for oxygen in its molecular Molecular chains
form (O2): → Macromolecules
molecular weight = formula weight = relative molecular Monomers
mass = 32 Monomers are the units of which → Oligomers and →
Polymers are made.
gram-molecular weight = gram-molecule = gram-formu-
la = 32 g Post-chlorinated polyvinyl chloride
PVC-C is photochemically post-chlorinated PVC-U.
molar mass = 32 g/mole In the post-chlorination reaction, there is a further ex-
mass of oxygen molecule = 32 u change of chlorine for hydrogen in the PVC chain
molecules. The exchange is more likely to occur at al-
(u = unified atomic mass constant. → Atomic weight) ready chlorinated carbon atoms of the PVC-U (-CCIH-
Distribution of molecular mass ). In this way, the chlorine content of a polymer can be
Because of the way in which a polymer is manufac- raised from 57 up to 65 % by weight. The interactions
tured, it never has molecular chains of the same length between the polymer's molecules are increased. The
and therefore of constant → Molecular weight. Instead, polymer's molecular chains then interact more strongly
it has a statistical distribution of molecular weights with each other. This leads to an increased heat resis-
(mass) which is typical of the reaction conditions under tance, some 30 K higher than in PVC-U (the glass tran-
which the polymer is made (→ Polymer synthesis). Ev- sition temperature TG being raised to about 130 °C), and
ery polymer can be characterised by the following statis- to a distinctly higher chemical resistance. The main ap-
tical formulae: plication of the moderately priced material is for chem-
ical equipment used with very aggressive substances
Number average of molecular weight: and at higher temperatures (up to T = 90 °C, e. g. in the
electrolytic production of chlorine and caustic soda).
Post-chlorination makes a material's extrusion more dif-
ficult. This is because the temperature "gap" between
plastic behaviour and the point of thermal decomposi-
65
tion is narrowed. Welding is also made more difficult. Up This results in the solution rising in the U-tube. The pro-
to OD 160 mm adhesion therefore produces the most cess ends when the hydrostatic pressure caused by the
durable joints in PVC-C pipes. transferred solvent is equal to the osmotic pressure.
Post-crystallization If one applies external pressure to the side with the con-
Many semi-crystalline polymers have a larger proportion centrated solution, the equilibrium is disturbed, and the
of amorphous material if they are cooled from their melt reverse process starts. Solvent from the solution then
in quick successive steps - even though a larger propor- flows back into the side which only contains solvent. Ex-
tion of crystalline material could be expected on the ba- amples: this effect, reverse osmosis, is often utilised
sis of the actual energy equilibrium. Because the molec- in facilities built to desalinate sea water (which can be
ular motion is "frozen", a change in crystalline order is viewed as a concentrated solution of salts in water). The
hardly attainable at ambient temperatures and in a finite same effect is used medically in dialysis equipment, i.
time span. Moderate heating (T <Tmelt) of a given poly- e. to purify blood. The production of ultrapure water (→
mer considerably accelerates the formation of crystals. Water quality) can also be based on the effect.
Example: PPS.
Oxidation
Post-crystallization in polymers can also be achieved lo-
In very many chemical reactions, electrons are trans-
cally by mechanical stretching. This can be the cause,
ferred between the reactants. Oxidation is the process
for example, of white "kinks" in small polystyrene
in which electrons are removed from an → Atom, an →
plates.
Ion, or a → Molecule. Reduction is the opposite pro-
Nucleation/ Nucleating agents cess, i.e. one in which electrons are taken up. Because
Nucleating agents are → Additives which are mixed in- the electrons (and their electric charges) do not just
to certain → Semi-crystalline polymers to act as nuclei appear or disappear, both processes are inseparably
around which crystals (possibly with modified symme- linked - in so-called redox reactions.
try) can form. They can also influence the kinetics of the
The concept of oxidation (as defined above) is wide-
production of crystals. The agents foster the growth of
ly applicable. This means that it is not necessarily de-
small-grained crystallites and prevent that of large →
pendent on the presence of oxygen. Oxidizing agents
Spherulites. They accelerate solidification and can im-
oxidize (another substance) and are thereby reduced.
prove the properties of semi-crystalline polymers con-
Reducing agents reduce (another substance) and are
siderably. Nucleation can have different causes. Impor-
thereby oxidized. Example: chromic acid (aqueous CrO
tant factors are how easily the polymer melt wets the
3 solution) is a strong oxidizing agent which also oxi-
nucleation agent or dissolves it.
dizes PP. The chrome ions of the acid are themselves
Under certain circumstances, particular properties of the reduced by taking up electrons which the PP (the reduc-
agents (e. g. their sterical structure) can be used to ening agent) gives up.
courage the development of particular crystal modifica-
pH
tions.
The pH of a substance is one of its important proper-
Example: the PP-H components are made of a specially ties, i. e. a measure of its acidity or alkalinity (→ Acid /
nucleated PP-H raw material (DAPLEN BE60). This (to- Alkali). Its name is derived from the Latin expression
gether with special processing techniques) gives them a pondus hydrogenii (= weight of hydrogen). The pH is
particularly good combination of properties. the negative common logarithm of the concentration [H +
] of hydrogen ions ( pH = -log[H ] ). Note: Acid solutions

+
Oligomers
have pH < 7. Alkaline solutions have pH > 7. The pH of
Oligomers have short polymer chains consisting of on-
a neutral solution is 7.
ly a few (n <10) monomer units. A high proportion of
oligomers in a polymer material worsens its mechanical Phase
properties. A phase is a homogeneous, physically distinct portion of
matter present in a non-homogeneous system.
Organic chemistry
Examples: undissolved common salt (solid phase)
Organic chemistry is the chemistry of carbon com-
in contact with its saturated aqueous solution (liquid
pounds (apart from a few of the very simplest com-
phase) .
pounds which are covered in → inorganic chemistry
). The division of chemistry into organic and inorganic Physical ageing
parts has historical roots. Organic compounds always When an amorphous polymer is cooled rapidly from a
contain carbon, nearly always contain hydrogen and of- viscoelastic state to a temperature under its → Glass
ten contain oxygen, nitrogen, phosphorus or sulphur. transition temperature (and maintained at that temper-
ature), one can imagine that the molecules "freeze" in-
Osmosis
to a non-ideal conformation. The process is always as-
Osmosis, a process observed in solutions, is a physi-
sociated with strains in the material. There is a tendency
cal and chemical phenomenon of a so-called colligative
for the resulting → Glass to fall into its so-called thermo-
sort, i.e. one which depends on the number of dissolved
dynamic equilibrium by various, slow movements of its
particles and not on their exact nature.
chain segments.
Imagine the following: an U-tube is divided in the middle
This kind of ageing should not be confused with →
by a membrane. On one side the tube is filled with a sol-
Chemical ageing which is defined as a splitting of
vent, and on the other side (up to the same height) with
molecules, or as some kind of chemical change of the
a concentrated solution based on the same solvent. If
molecules themselves. In the course of time, both sorts
the membrane is only permeable to the solvent, then a
of ageing lead to changes in the properties of the mate-
so-called "osmotic pressure" causes the solvent to pass
rials involved.
through the membrane into the concentrated solution.
66
Physically active substances Polyethylene (PE)
In this context, substances are called physically active Polyethylene is a widely used plastic. It is a pure hy-
if they interact physically (i. e. without any new com- drocarbon and is used for technical piping systems in
pounds arising) with the materials of which pipes are many areas, e. g. in sanitary installations (for drinking
made. water and drainage) and in industrial applications (for
Example: the → Swelling of the inside surfaces of pipes gas pipes, for the protective sleeving of cables, and for
in contact with certain liquids. various ducts).
Physiologically harmless Important basic properties of PE are its high impact re-
In Germany, the expression "physiologically harmless" sistance (the amorphous state of PE has a glass transi-
is assigned to materials which pass certain tests. It is tion temperature TG between -120 °C and 110 °C) and,
the most stringent of the criteria to be fulfilled when us- due to its simple molecular structure, a chemical resis-
ing the materials with foodstuffs. The materials compIy tance better than other polyolefins. Crystalline PE has a
with EU requirements and with the → BgVV recommen- melting point between 115 °C and 135 °C.
dations. With a high degree of certainty, any deteriora-
tion of foodstuffs due to contact with the materials can
be excluded.
DEKAPROP PP-H-L-HP and DEKADUR-L-HP pipes
have been tested by the German Federal Institute for
Material Research and Testing (BAM), Berlin, and de- Nowadays, all sorts of PE materials can be produced
clared to be physiologically harmless. (depending on the choice of catalysts and on the pro-
(Physiology is the science which deals with the funda- cessing conditions):
mentals of life and of living matter, in particular with the • PE-HD: this abbreviation is used for a PE which is ob-
functions and activities of the human organism.) Cf. → tained by the controlled polymerization of ethylene un-
MAK → Toxicology. der very moderate processing conditions ("low-pres-
Pigment sure PE"). It is a linear polymer and has, therefore, a
Pigments are indissoluble dyes which, like soluble dyes, comparatively high density. It has a crystalline content
are particular → Additives. They are used, for exam- of up to 85 %.
ple, to colour plastics. Pigments usually have a particle • PE-MD: this medium density PE is formed at temper-
size between 0.01 µm and 1 µm. There are → Organic atures of about 160 °C and at pressures of about 50
and → Inorganic pigments. On account of their molec- bar. It has a crystalline content of up to 70 %.
ular structure, inorganic pigments do not usually colour • PE-LD: this PE is produced at temperatures of about
very intensely. However, they do have good covering 300 °C and at high pressure ("high-pressure PE").
properties, are usually very temperature-insensitive and Highly reactive, intermediate reactants cause a
colour-fast. Examples: carbon black, titanium white (= branching of the molecular chains. The material has
TiO2). a lower density than the grades mentioned above. Its
Organic pigments usually have an intense colour, but long-term stability is not as good. It has a crystalline
their covering properties are not so good. They consist content of about 50 %.
of complicated organic molecules which, understand- • PE-X: this material is a PE which has been cross-
ably enough, are not very stable at higher temperatures. linked in subsequent reactions.
Polarity
Polarity is a concept used in physical chemistry. Ulti- The properties of PE can be influenced in a controlled
mately, the polarity of a compound depends on the spa- way, by incorporating comonomers (→ Monomers) with
tial distribution of electrons (relative to the nuclei of the butene as a C4 unit. This changes the PE's crystallini-
atoms) in the compound's molecules. Whenever two → ty and density. It also improves its resistance to stress-
Atoms combine, the distribution of electrons between induced hairlines and cracks. (→ Formation of / corro-
their nuclei ceases to be symmetrical, leading to a po- sion by stress-induced hairlines and cracks; crazing
larization of the bond. The distribution of the polarized )
bonds within a molecule determines whether or not the • PE80: this is a polyethylene which, according to an
whole molecule appears to be polarized. extrapolation of the results of the long-term → Stress-
The polarity of a compound is one of its most important rupture test (DIN 8075, at 20 °C), has a → MRS
characteristics, determining almost all of its properties, (minimum required strength) of 8 MPa. There are di-
both physical and chemical. Example: the well-known verse sorts of PE in this group, depending on the pipe
solvent carbon tetrachloride (CCI4) has four polar, car- manufacturer. The name PE80 says nothing about
bon-chlorine bonds which are symmetrically so posi- the material's → Distribution of molecular mass or
tioned (tetrahedrally) that the molecule displays no ex- about the branching of its molecular chains.
ternal polarity. • PE100: this is a new PE quality, in which a → MRS
≥ 10 MPa (20 °C; 50 years) is achieved. PE100
contains both short linear and longer, branched PE
molecular chains (achieved by employing butene
comonomers). It therefore has two peaks (so-called
bimodality) in its → Distribution of molecular mass.
In spite of a branching of its long chains, a high den-
Carbon tetrachloride CCl4 sity is achieved as well as a favourable resistance to
cracks and a high degree of stiffness.
67
Polymer structure verse sorts all over the world. The pipes are routinely
This concept is used for the systematic description of butt welded instead of being cemented together. PP is
the spatial structure of the molecules of a polymer. The being increasingly favoured for applications with mate-
following categories are used: rials of the highest purity and at temperatures up to 90
• Primary structure: Which chemical configuration does °C.
the polymer have? In which sequence are the atoms Special catalytic systems have turned the production of
to be found? isotactic PP (→ Tacticity) into a standardised process.
There are two categories of PP used in piping systems
• Secondary structure: Which shape do the individual
→ Homopolymer(PP-H) and → Copolymer. The latter,
polymer chains have? Are they, for example, parts of
which contains ethylene as comonomer (typically up to
disordered bundles or are they spirally formed (as in
12 % by weight), can be obtained as a block copoIymer
PTFE)?
(PP-C) and as a statistical (= random) copolymer (PP-
• Tertiary structure: Which spatial distribution do the R).
molecular chains in the bulk of the polymer have?
What interactions are there between the chains? For this reason, PP copolymers
have slightly different mechani-
Polymer synthesis cal properties such as a higher
Polymer synthesis is the name given to those reactions impact resistance at low temper- Polypropylene
in which → Polymers are produced. Reactions to start atures. (Note: The glass transi-
the synthesis, to affect the growth of polymer chains, tion temperature of amorphous
PP is about -5 °C.) Note that the
and to terminate the chains are involved. There are the
various PP materials also differ in
following categories of polymer synthesis: their so-called → Nucleation.
1.Polymerization
Many identical or similar small molecules (or chain The crystallization characteristics of a given PP type
segments = monomers) react together to form longer can be influenced by using additives to change the nu-
molecular chains. One distinguishes between → Rad- cleation. The melting point of crystalline PP lies be-
ical and ionic (anionic or cationic) polymerization ac- tween 155 °C (β-form) and 165 °C (α-form) depending
cording to the type of the ends of the growing molec- on the nature of the nucleation (α or β).
ular chains, or the active species. Polyolefins like PP Polypropylenes are one of our main fields of research
and PE, for example, are normally polymerized by us- and development. If needed, we can send you more de-
ing highly efficient organo-metallic catalytic systems tailed information in the form of pamphlets and special-
(so-called Ziegler-Natta catalysts or, more recently, ist papers.
metalocen catalysts).
Polyvinyl chloride (PVC)
2.Condensation polymerization (polycondensation) PVC is the one of the oldest polymer materials avail-
The monomers are usually made of two different able. World-wide, it is the second most commonly used
classes of substances which have reactive groups at of all plastics. Because it consists of up to 57 % chlo-
their ends. Reactive groups at the ends of one of the rine, its production demands relatively little crude oil. It
monomers react with groups at the ends of the oth- is manufactured on an industrial scale in one of three
er. A "condensate" is produced, i. e. small molecules processes:
- mostly water molecules - which have to be removed
continuously. Examples: manufacture of all polyesters • Emulsion polymerization (PVC-E)
(PET, PC, PMMA), of phenolformaldelhyde resins, of • Suspension polymerization (PVC-S)
polyamides (all of which are sorts of nylon), or of PEI
• Bulk polymerization (PVC-M)
and PAI.
3.Addition polymerization
As with condensation polymerization, molecules from
two monomer systems, each with a reactive group
at its end, combine to form macromolecules. Un-
like condensation polymerization, there are no reac- PVC
tion products of low molecular weight. Groups at the In the polymer structure, the chlorine atoms are dis-
ends of one monomer are "added" to groups at the tributed statistically, i. e. in a tactic way. PVC is an
ends of the other monomer. Examples: production of amorphous material of 5 % crystallinity. Its glass transi-
polyurethane from di-isocyanates and alcohols. Epoxy tion temperature lies between 75 °C and 85 °C, and it
resins. has a density of 1.4 g/cm³. It can be processed without
difficulty by extrusion, calendering, blow forming, spread
Polymers
coating, dip coating and injection moulding.
Polymers are substances consisting of → Macro-
PVCs differ not only in the way they are manufactured,
molecules.
but also in the many modified forms which arise from
Polypropylene (PP) the use of different additives. For example:
Polypropylene is a thermoplastic material with a com- • PVC-U (unplasticized = hard PVC)
paratively low density. The combination of its excel- • PVC-P (plasticized = soft PVC)
lent mechanical properties, its enormous chemical re-
sistance and its heat resistance for temperatures up to
about 90 °C, make it a widely used material in industri-
al piping systems. Nowadays, PP industrial pipes are
an integral part of countless installations, of the most di-
68
PVC-U has the following characteristic properties: in many polymerization processes, and are the central
• high mechanical stability, stiffness and hardness factor in the discussion of colour retention by plastics
and dyes.
• high resistance to attack by chemicals
• intrinsic flame resistance (because of the high halo- Reduction
gen content) → Flame retardants → Oxidation
• easily cemented and welded together Relaxation
Various molecular motions are possible in a polymer
PVC-U pipes are usually extruded using the type S-PVC
material. Their analysis in so-called relaxation spec-
which has a → K-value between 65 and 68. An extrud-
troscopy, makes it possible to classify the motions,
able mixture is made by blending the initial S-PVC ma-
which are often highly complex, into certain classes -
terial with additives and other → Processing aids. A
the α, β, γ classes etc. The aim is to correlate the relax-
high K-value is needed in the manufacture of pressure
ation observed in a given polymer with certain molecular
pipes. In contrast to extrusion, injection moulding needs
motions.
a K-value below 60.
Example: a relaxation is always a motion which, in
Pipes made of PVC-U have been used for decades with
amorphous and semi-crystalline polymers, leads to the
great success in the following areas: piping and equip-
→ Glass transition. At a given temperature, a relax-
ment in the chemical industry; pipes for drinking water,
ation is always associated with a fixed frequency.
for drainage and sewage.
Acid/alkali solution (alkali = base)
ppm (parts per million), ppb (parts per billion)
In chemistry there are different interpretations of the
ppm (=10 ) and ppb (=10 ) are very common expres-
-6 -9
concepts 'acid' and 'alkaline'. We restrict ourselves to

sions used for values of concentration.
simple but narrow definitions - those based on the Ar-
Note the confusing difference in usage!
rhenius model. In an aqueous solution, an acid pro-
A US (and French) billion is 10 (German: Milliarde). A
9
duces so-called hydroniums (= H3O ), a base produces

+
German Billion is 10 . In the UK there is often the am-

12
hydroxyl (= OH ) ions.
-
biguity of whether the term billion means 10 (older us-

12
Examples:
age) or 10 .
9
(i) Acids: sulphuric acid, carboxylic acid (e. g. acetic

Pyrolysis acid), all halogen hydracids (e. g. HCI), oxalic acid, hy-
Pyrolysis is defined as the irreversible chemical decom- drocyanic acid.
position of a substance (without → Oxidization taking (ii) Bases: caustic soda (sodium hydroxide), caus-
place) brought about by the action of heat. tic potash (potassium hydroxide), ammonia solution,
Example: the unwanted pyrolysis of a polymer granulate amines.
in an extruder. Plastics consist of molecules which are organic chains.
In the case of some polymers, acids and caustic so-
Swelling
lutions can assist reactions which lead to the destruc-
Swelling is the name given to the penetration of certain
tion of the chains, or in which certain → Additives are
liquids (usually → Solvents) or gases into a polymer.
attacked. This is of particular significance when acids
The molecules of the polymer are, however, not dis-
and caustic solutions flow through plastic pipes. In these
solved out, but remain as part of the polymer structure.
cases, the pipe material has to be chosen carefully, tak-
The liquid taken up makes the polymer expand and be-
ing the conditions of use into consideration. See also →
come heavier.
pH; → Chemical resistance.
The marked swelling of a cross-linked polymer is called
gelling. For a given polymer material, swelling phenom- High-impact polymers
ena are dependent in particular on the molecular size Mixing → Rubbers and → Elastomers to polymers (usu-
and chemical structure of the solvent or gellant, on the ally brittle) increases their impact resistance. The ener-
time in which these substances act, and on the temper- gy released at impact is taken up by the elastomer com-
ature. Swelling causes a softening of the polymer ma- ponent, sustaining its molecular motion (→ Relaxation
terial, the structure of which can be permanently dam- ). Basically, there are two ways of improving the impact
aged. resistance of polymers:
For example, new cavities can be formed, i. e. the so- (i) by copolymerization of the base polymer with an
called "free volume" increases. It is possible, too, that elastomer component. Example: the block copolymer-
additives are more easily leached out after swelling. ization of styrene and butadiene to produce polystyrene
Swelling in plastic pipes is of immense importance, par- (SB).
ticularly with regard to their → Chemical resistance, or (ii) by blending the base polymer with an elastomer
when using adhesives to connect piping elements. component (→ Blend). In order to fix such a blend per-
manently as a stable, homogeneous mixture, the →
Radical
Compatibility of the two components has to be ascer-
A radical is a highly reactive, intermediate product in
tained.
a chemical reaction - particularly in organic chemistry.
Radicals arise in the uniform break-up (= homolytic fis- Example: the well-known material ABS is usually a
sion) of simple chemical bonds as schematized in A - B blend of the copolymer polyacrylonitrile polystyrene (=
→ A* + B* (in which "*" signifies an unpaired electron). SAN) with polybutadiene (PB) as its elastomer com-
The break-up can be caused by heat, by radiation or by ponent. The compatibility between SAN and PB is
chemical means. Every organic oxidation depends on achieved chemically by placing a covering of SAN over
the existence of radicals. They are of great importance the SB molecules.
69
The maintenance of a fine, homogeneous distribution of The tacticity of a material influences the ease with which
impact modifier is of decisive importance when process- discrete crystalline domains can be produced. It has an
ing the polymer. Phase separation and coagulation of enormous influence on the material's → Glass transi-
the impact modifier have to be avoided. tion temperature and on the melting points of its crystal-
lites.
Solvation (Hydration)
→ Solvent Annealing processes
The molecular strains which inevitably arise when an
Spherulite
amorphous polymer is cooled below its glass transi-
A spherulite is one possible form of a polycrystalline
tion temperature TG can be greatly reduced by storing
macrostructure to be found in semi-crystalline polymers
the material (for a "reasonable" time) at temperatures
such as PP. The spherulites in a polymer strongly af-
around TG or, depending on the polymer, slightly below
fect its morphology (i. e. the shape to which small crys-
TG. (The glass state should be regarded as a non-equi-
talline parts of the polymer join together). As a result
of three-dimensional, uniform growth, the spherulites librium state.) Example: → Annealing of pipes made, for
are spherically symmetrical. They have particular opti- example, of PSU or PE.
cal properties, which are easily recognised in → Micro- Surfactants (detergents, surface-active agents,
tome sections (illuminated by linearly polarized light) tensides)
by a characteristic Maltese cross-like interference ef- Surfactants are a whole class of organic compounds
fect. The sizes and types of the spherulites in a polymer used as washing agents, wetting agents or emulsifiers.
can be strongly influenced by the addition of special → On account of its molecular structure, a surfactant accu-
Nucleating agents, by the way in which the polymer mulates on surfaces and at the boundaries of two phas-
is processed, and by heat treatment. In PP, the sizes es making them easier to wet; i. e. it reduces the sur-
and types of spherulites have a critical influence on al- face and interfacial tension. This is the principle behind
most all the material's properties (e. g. on its impact re- washing, wetting, cleaning, emulsifying, and the effect
sistance and chemical stability). of dispersants.
A surfactant's particular properties are determined by
Stabilizers
the presence of two molecular groups:
Stabilizers are additives which, by causing certain
chemical reactions, give a polymer additional resistance • a → Hydrophobic group (usually an → Aliphatic
to heat, to radiation (e. g. UV light), to atmospheric oxy- residue)
gen and to humidity. They help the polymer to retain • a → Hydrophilic group which gives rise to the
its properties when being processed, handled or used. surfactant's solubility in water and which can contain
Usually, combinations of stabilizers are used which pro- a negative electric charge (anionic surfactant), a posi-
tect simultaneously against heat, light and oxidation. tive charge (cationic surfactant) or only certain dipolar
Important groups of stabilizers are, for example, com- groups (nonionic surfactant)
pounds of lead, and of calcium with zinc (in → Polyvinyl
The wetting properties of surfactants (→ Stress crack-
chloride, PVC), organo-zinc compounds, epoxides, UV
inducing media) are of enormous importance when
absorbers, substances which impede oxidation (→ An-
considering the → Chemical resistance of polymer pip-
tioxidants, e. g. in PP) and co-stabilizers (cf. → Radi-
ing.
cals). Example: at high temperatures, HCI is easily re-
leased from unstabilized PVC. Double (C=C) bonds Thermal decomposition
arise at those points of the PVC chains involved, mak- → Pyrolysis
ing them susceptible (by breakage) to oxidation by at-
Thermoplastics
mospheric oxygen. In this case, stabilizers stop the re-
This name has its origin in the classification of plastics
action producing HCI, or take up the HCI immediately
according to their behaviour when heated or processed,
after it has been produced.
and in their capability to be reused. Thermoplastics con-
Sterilisation sist of macromolecules which are not (or only slightly)
Sterilisation is the complete extermination of micro-or- cross-linked. It is easier for these molecules to slip past
ganisms (e. g. fungi, bacteria, spores, viruses). The each other when the thermoplastic is heated. Above the
word "sterile" is synonymous with "free of all living ma- glass transition and/or the melting temperature, a ther-
terial". Sterility is therefore an absolute condition. It can moplastic material can be re-formed - reversibly and as
be produced by heat, sophisticated filtration, oxidation often as needed. → Elastomers and → Thermosetting
and UV radiation. A medium which is sterilised is al- plastics are polymers with similar characteristics.
ways disinfected at the same time. A disinfected medi-
Thermoplastic elastomers
um does not have to be sterile. (→ Disinfection).
This is the name given to polymers which (due to forces
Tacticity of → Cohesion) are physically cross-linked at ambient
Tacticity is the spatial distribution of side groups on temperatures. At higher temperatures, the cross-linking
polymer chains (e. g. the CH3 groups in PP). is undermined by thermal motion, making the material
• syndiotactic: The side groups are arranged alternately easily processable - as with a thermoplastic.
on one and then on the other side of the chains. TOC (Total Organic Carbon)
• isotactic: All the side groups are on one side of the The TOC is a measure of the organic contamination of
polymer chains. water. When applied to ultrapure water, its value is of-
• atactic: There is no regular arrangement of the side ten identical with the DOC (Dissolved Organic Carbon).
groups. The TOC is almost always found either by oxidizing the
organic materials and by determining the total amount
70
of CO2 formed, or by measuring the increase in conduc- Water quality
tivity which is caused by the carbonic acid produced by Water can contain very many substances and has to
dissolved CO2. be processed or purified according to its proposed use.
Example: a plastic pipe's suitability for use with ultra- The results are a variety of degrees of purity which can
pure water depends (among other things) strongly on be characterised according to diverse criteria. [e. g.
the proportion of organic substances of low molecular measurements of → Conductivity (electrical); determi-
weight (e. g. → Additives, → Oligomers) which, under nation of the amount of specific types of ion.]
working conditions, are leached, or migrate, out of the
pipe. Process wa- Water with different qualitative features (its
ter suitability as → Drinking water could be in-
The TOC is an important part of the so-called "Ieach-out
cluded) for business, industrial and agricul-
values". PP-H Daplen BE60 components have extreme- tural purposes
ly low TOC values compared with other PP pipes. They
open new possibilities for the application of the material Brackish Water with medium salt content, e. g. the
water mixture of fresh and salt water which is
PP-H in the transport of ultrapure substances.
found at the mouths of rivers. The specific
Toxicology conductivity at 25 °C lies between 0.05 S/cm
Toxicology is defined as the scientific study of the harm- and 1 S/cm.
ful effects of chemicals on living organisms. Drinking wa- Water of a quality which conforms to the
Note: Because pharmacology is the study of the interac- ter TVO (Trinkwasserverordnung = German
tion between any chemicals and living organisms, it fol- Drinking Water Ordinance) regarding, for ex-
lows that toxicology is only one part of pharmacology. ample, the maximum amount of pollutants.
Drinking water has to be maintained at a
Processing aids temperature below 25 °C. Its specific con-
Processing aids are particular → Additives. ductivity at 25 °C lies between 50 µS/cm and
5000 µS/cm.
Cross-linking
Cross-linking is the process in which linear macro-
Pure water Water which has been produced using → Ion
molecules are joined together to make elastomers or exchangers, reverse osmosis or distillation,
thermosetting plastics. It can be achieved by mixing in but which still contains a residue of certain
appropriate monomers during polymerization, or (sub- ions. Purified water ("aqua purificata") pre-
sequently, in chemically suited polymers) by the addi- pared according to the → DAB (and used in
tion of hardeners (e. g. in dual-component adhesives), many pharmaceutical products) belongs to
by heating (e. g. in curing processes with PPS), or by ir- this category. Its specific conductivity at 25
radiation (e. g. photoresist). °C lies between 1 µS/cm and 50 µS/cm. Wa-
ter for injection ("aqua ad injectabilia") used
Compatibility in hypodermic syringes is categorised in the
In polymer technology this concept describes how well → DBA as a "cleaner" pure water. It is used
polymers blend. "Compatible" polymer mixtures are as a solvent and as a fluid for diluting those
those which permanently retain their homogeneous medicines which can be applied by injection
structure. "Non-compatible" mixtures separate out in the or by infusion. Sterility is a prerequisite.
course of time. Cf. → High-impact polymers. Deionized Water which is fully salt-free (deionized). It
water is produced by the use of ion exchangers
Hardness of water or by distillation. The quality of the resulting
Water's hardness is its total amount of hardening product is codified by various standards (e.
agents (alkaline-earth metals, e. g. Ca² , Mg² , Sr² ), i. e.
+ + +
g. DIN, ISO 3696). No ionogenic contents
of those substances which in the presence of carbon- (= anions and cations) may be present. The
ate and sulphate ions produce sparingly soluble precipi- specific conductivity at 25 °C lies between
tates. The total hardness has two components: the tem- 0.1 µS/cm and 1 µS/cm
porary hardness due to hydrogen carbonates and the Ultrapure Water of the very highest purity. It is made
permanent (noncarbonate) hardness due to chlorides, water from distilled water using supplementary ion-
sulphates etc. The temporary hardness can be removed exchange techniques, → Active carbon and
by boiling, which leads to the precipitation of carbon- other absorbing materials. It contains only
ates. The amount of hardness is given in "dH (Deutsche the slightest traces of organic compounds,
Härtegrade = "German degrees of hardness") or in micro-organisms and electrolytes. The spe-
cific conductivity at 25 °C is less than 0.1 µS/
mmol/l. Soft and hard water can have a hardness of 3 cm.
°dH and 22 °dH respectively.
Examples: Softening agents
a) Limescale ("fur") in water pipes arising from tempo- Softening agents are an important group of additives
rary hardness. which increase a polymer's plasticity. The effect can be
b) Precipitation of surfactants due to hardening agents. understood by imagining the softening agent to pene-
With surfactants, Mg² or Ca² form a sparingly soluble
+ +
trate into the polymer structure like a multitude of tiny
precipitate (of a calcium or magnesium "soap"). This in- "wedges". These place themselves between the poly-
creases the amount of detergents which are used. mer chains creating extra so-called "free volume". The
Ion exchangers or special compounds can remove the increased mean distance between the polymer chains
hardening agents from the water - leaving "soft" water. reduces their forces of → Cohesion and facilitates the
microscopic motion of the chains, enabling them to slide
past each other more easily. Macroscopically (i. e. on
71
a much larger scale) one observes a reduction of the
glass transition temperature. The material is more easily
formed - it is "softer".
One distinguishes between softening agents with
molecules of low molecular weight and those highly vis-
cous agents which have much larger molecules. One al-
so differentiates between primary and secondary soft-
ening agents. The latter function effectively as solvents
of the primary agents. The choice of a softening agent
is dictated by a number of factors, for example the ease
with which the agent can diffuse out of the polymer (→
Migration, → Toxicity), and its solvation.
Example: the most important use of softening agents,
particularly in piping systems, is in PVC-P. (Between 80
% and 85 % of all softening agents are used in PVC.)
Phthalate is an agent often used here. Hard PVC pipes
(PVC-U) differ from PVC-P products by containing no
softening agents at all. Note: PVC-P pipes and moulded
components are never to be used together with PVC-U
There could be a damaging → Migration of the soften-
ing agent from the PVC-P into the PVC-U.
72
Metric and inch system Imperial Sizes Metric Sizes
For those unfamiliar with the difference between met- Nominal Pipe outside Pipe outside Nominal
ric and inch sizes the following note may be helpful. In bore DN diameter d diameter d bore DN
imperial systems, the sizes of pipes, fittings and other (inch) (mm) (mm) (mm)
components such as valves are identified by reference 8 219.1 200 200
to the nominal size of the bore of the pipe expressed in
inches and fractions of an inch. 8 219.1 225 200
In metric systems, however, sizes are identified by ref- 9 244.5 250 250
erences to the outside diameter of the pipe expressed in 10 273.0 280 250
millimetres.
12 323.9 315 300
The table below shows the metric sizes which are re-
14 355.6 355 350
garded for practical purposes as being generally equiva-
lent to imperial sizes. It should, however, be understood 16 406.4 400 400
that metric sizes are not simply inch sizes which have 18 457.2 450 450
been converted into millimetres and called metric; their
actual dimensions are slightly different and they are with 20 508.0 450 500
the exception of 2½ " (75 mm) and 5" (140 mm) not in- 20 508.0 500 500
terchangeable.
22 558.2 560 600
Imperial Sizes Metric Sizes 24 609.6 630 600
Nominal Pipe outside Pipe outside Nominal 26 660.4 - -
bore DN diameter d diameter d bore DN
(inch) (mm) (mm) (mm) 28 711.2 710 700
1/8 10.2 10 6 30 762.0 - -
1/4 13.5 12 8 32 812.8 800 800
3/8 17.2 16 10 34 863.6 - -
1/2 21.3 20 15 36 914.4 900 900
3/4 26.9 25 20 40 1016.0 1000 1000
1 33.7 32 25
1 1/4 42.4 40 32
1 1/2 48.3 50 40
2 60.3 63 50
2 1/2 75.3 75 65
3 88.9 90 80
3 1/2 101.6 - -
4 114.3 110 100
- - 125 100
- - 125 1)
125
5 140.3 140 125
6 168.3 160 150
- - 180 2)
150
1) only cementing socket systems

2) only butt fusion systems
73
Abbreviations
Materials
ABS Acrylonitrile-butadiene-styrene
CR Chloroprene rubber, e. g. Neoprene
EPDM Ethylene propylene rubber
FPM Fluorocaoutchouc, e. g. Viton
Ms Brass
NBR Nitrile rubber
NR Natural rubber
PB Polybutene
PE Polyethylene
PE-X Cross-linked polyethylene
PP Polypropylene
PTFE Polytetrafluorethylene, e. g. Teflon
PVC Polyvinyl chloride
PVC-C Polyvinyl chloride, postchlorinated (increased
chlorine content)
PVC-U Polyvinyl chloride, unplasticized
PVDF Polyvinylidene fluoride
TG Malleable iron
UP-GF Unsaturated polyester resin, glassfibre rein-
forced
Dimensions and units

Dimensions are given in mm and/or inches and are to
be taken as nominal or standard dimensions.
The right to make modifications in design is reserved.
d, d1, d2, d3, Diameter
d4
DN Nominal diameter
SC Size for hex screws
AL Number of holes
s Width across flats
g Weight in gram
SP Number per standard pack
GP Number per large pack
e Wall thickness of pipe
PN Nominal pressure at 20 °C, water
Rp Cylindrical pipe - internal thread to ISO 7/1
R Conical pipe – external thread to ISO 7/1
ppm Parts per million
1 bar = 0.1 N/mm²
= 0.1 Mpa (Megapascal)
= 14.504 psi
C Design factor
S Pipe series
SDR Standard Dimension Ratio
MFR Melt Flow Rate
74
SI units
SI basic units
SI units are the seven basic units and the units de-
rived thereof coherently, i. e. with numerical factor 1.
Basic quantity SI basic unit
Name Symbol Name Symbol
Length l Metre m
Mass m Kilogram kg
Time t Second s
Electric current l Ampere A
Thermodynamic T Kelvin K
temperature
Amount of sub- n Mole mol
stance
Luminous inten- ln Candela cd
sity
Internationally defined prefixes

Prefix Factor as
Meaning Name Symbol power of ten decimal
Trillion exa E 10
18
= 1 000 000 000 000 000 000
Thousand billion peta P 10
15
= 1 000 000 000 000 000
Billion tera T 10
12
= 1 000 000 000 000
Thousand million giga G 10
9
= 1 000 000 000
Million mega M 10
6
= 1 000 000
Thousand kilo k 10
3
= 1 000
Hundred hecto h 10
2
= 100
Ten deca da 10
1
= 10
Tenth deci d 10
-1
= 0.1
Hundredth centi c 10
-2
= 0.01
Thousandth milli m 10
-3
= 0.001
Millionth micro μ 10
-6
= 0.000 001
Thousand millionth nano n 10
-9
= 0.000 000 001
Billionth pico p 10
-12
= 0.000 000 000 001
Thousand billionth femto f 10
-15
= 0.000 000 000 000 001
Trillionth atto a 10
-18
= 0.000 000 000 000 000 001
75
Units
Size Symbol SI units Permissi- Conversion into associ- No longer permissible units and conver-
ble units ated SI unit and ratios sions
other than
SI
Length I m (metre) 1” (inch = 0.0254 m)
1 nm = (nautical mile)
= 1852 m
Surface A m² 1 b (barn) = 10-28 m²
(square me- 1 a (are) = 10² m²
tre) 1 ha (hectare) = 104 m²
sq.m., sq.dm., sq.cm., etc.
(Names allowed, symbol not allowed)
Volume V m³ l (litre) 1 l = 10 m³-3

(cubic me-
tre)
Solid angle Ω sr (steradi- 1 sr = 1 m²/m² 1 ° (square degree) = 3.046 • 10-4 sr
an) 1 g (square grade) = 2.467 • 10-4 sr
Time t s (second) min (minute) 1 min = 60 s
h (hour) 1 h = 3600 s
d (day) 1 d = 86400 s
Frequency f Hz (Hertz) 1 Hz = 1/s
Rotation n s
-1
rpm 1 rpm ( 1/60) s
-1 -1

speed rpm 1 rpm = 1 (1/min)
Velocity v m/s km/h 1 km/h = (1/3.6) m/s
Accelera- g m/s² normal fall acceleration 1 gal (gal) = 10-2 m/s²
tion gn= 9.80665 m/s²
Mass m kg (kilo- t (tonne) 1 t = 10³ kg 1 q (metric hundred weight) = 100 kg
gram)
Density ρ kg/m t/m³ 1t/m³ = 1000 kg/m³
kg/l 1kg/l = 1000 kg/m³
Moment of J kg • m² 1 kp • m s² = 9.81 kg • m²
inertia
Force F N (Newton) 1 N = 1 kg • m/s² 1 dyn (dyn) = 10-5 N
1 p (pond) = 9.80665 • 10-3 N
1 kp (kilopond) = 9.80665 N
Torque M N•m 1 kpm = 9.80665 Nm
1 Nm = 0.7375 lb-ft
Pressure p Pa (Pascal) bar 1 Pa = 1 N/m² 1 atm = 1.01325 bar
1 bar = 105 Pa 1 at = 0.980665 bar
1 Torr = 1.333224 • 10-3 bar
1 m CE = 98.0665 • 10-3 bar
1 mm Hg = 1.333224 • 10-3 bar
Mechanical σ N/m² 1 N/m² = 1 Pa 1 kp/m² = 9.80665 N/m²
stress Pa 1 kp/cm² = 98.0665 10-3 N/m²
1 kp/mm² = 9.80665 • 10-6 N/m²
Dynamic Pa • s 1 Pa • s = 1 N • s/m² 1 P (Poise) = 10-1 Pa • s
viscosity
Kinematic m²/s 1 m²/s = 1 Pa • s • m³/kg 1 St (stokes) = 10-4 m²/s
viscosity
Work ener- W J (Joule) eV (elec- 1 J = 1 Nm = 1 H2O 1 cal = 4.1868 J
gy E tronvolt) W 1 W • h = 3.6 KJ 1 kpm = 9.80665 J
•h 1 erg = 10-7 J
Electric Q C 1C=1A•s
charge (Coulomb)
Electric po- U V (Volt) 1 V = 1 W/A
tential
Electric cur- I A (Ampere)
rent
76
Electric re- R Ω (Ohm) 1 Ω = 1 V/A 1 Ω abs = 1 Ω
sistance
Power P W (Watt) 1 W = 1 J/s = 1 Nm/s 1 PS = 735.498 W
1W=1V•A 1 kcal/h = 1.163 W
1 kpm/s = 10 W
Electric ca- C F (Farad) 1 F = 1 C/V
pacitance
Magnet- H A/m 1 Oe (Oersted) = 79.5775 A/m
ic field
strength
Magnetic Φ Wb (We- 1 Wb = 1 V • s 1 Mx (Maxwell) = 10-8 Wb
flux ber)
Magnetic B T (Tesla) 1 T = 1 Wb/m² 1 G (Gauss) = 10 T -4
flux density
Inductance L H (Henry) 1 H = 1 Wb/A
Electric con- G S 1 S = 1/Ω
ductance (Siemens)
Thermody- T K (Kelvin) Δ1 °C = Δ 1 K
namic tem- O °C = 273.15 K
perature
Tempera- t, ϑ °C (degree Δ 1 °C = Δ 1 K
ture (C) Celsius) O K = -273.15 °C
Thermal ca- C J/K 1 Kcl/degree = 4.1868 10-3 J/K
pacity 1 Cl (clausius) = 4.1868 J/K
77
Conversion tables
Viscosities
Kine- Abso- Engler Saybolt Red- Saybolt Ford Barbey Cup No. Absolute Kinemat-
matic lute vis- De- Universal wood 1 Seconds Cup No. Degrees 15 Sec- Viscosity ic viscosity
viscosi- cosity grees Seconds Seconds Furol 4 Sec- onds Poise Den- m²/s
ty Centi- (stan- onds sity 1,0
Centi- poise dard)
stokes
Density
1.0
1.0 1.0 1.0 31 29 -- -- -- -- 0.01 1.0x10-6
2.0 2.0 1.1 34 30 -- -- 3640 -- 0.02 2.0x10-6
3.0 3.0 1.2 35 33 -- -- 2426 -- 0.03 3.0x10-6
4.0 4.0 1.3 37 35 -- -- 1820 -- 0.04 4.0x10-6
5.0 5.0 1.39 42 38 -- -- 1300 -- 0.05 5.0x10-6
6.0 6.0 1.48 45.5 40.5 -- -- 1085 -- 0.06 6.0x10-6
7.0 7.0 1.57 48.5 43 -- -- 930 -- 0.07 7.0x10-6
8.0 8.0 1.65 53 46 -- -- 814 -- 0.08 8.0x10-6
9.0 9.0 1.74 55 48.5 -- -- 723 -- 0.09 9.0x10-6
10 10 1.84 59 52 -- -- 650 -- 0.10 1.0x10-5
20 20 2.9 97 85 15 -- 320 -- 0.2 2.0x10-5
40 40 5.3 185 163 21 -- 159 -- 0.4 4.0x10-5
60 60 7.9 280 245 30 18.7 106 5.6 0.6 6.0x10-5
80 80 10.5 370 322 38 25.9 79 6.7 0.8 8.0x10-5
100 100 13.2 472 408 47 32 65 7.4 1.0 1.0x10-4
200 200 26.4 944 816 92 60 32.5 11.2 2.0 2.0x10-4
400 400 52.8 1888 1632 184 111 15.9 18.4 4.0 4.0x10-4
600 600 79.2 2832 2448 276 162 10.6 26.9 6.0 6.0x10-4
800 800 106 3776 3264 368 217 8.1 35 8.0 8.0x10-4
1000 1000 132 7080 4080 460 415 6.6 68 10 1.0x10-3
5000 5000 660 23,600 20400 2300 1356 1.23 240 50 5.0x10-3
10,000 10,000 1,320 47,200 40,800 4,600 2713 -- 481 100 1.0x10-2
50,000 50,000 6,600 236,000 204,000 23,000 13,560 -- 2403 500 5.0x10-2
Absolute viscosity (centipoise) = kinematic viscosity

(centistokes) x density. Over 50 centistokes - conver-
sion to SSU à SSU = centistokes x 4.62
Delivery volumes
m³/h l/min l/s m³/s Imp. gal/min US gal/min cu. ft./h cu. ft./s
1.0 16.67 0.278 2.78 x 10
-4
3.667 4.404 35.311 9.81 x 10-3
0.06 1.0 0.017 1.67 x 10-5 0.220 0.264 2.119 5.89 x 10-4
3.6 60 1.0 1.00 x 10-3 13.20 15.853 127.12 3.53 x 10-2
3600 60000 1000 1.0 13200 15838 127118 35.311
0.2727 4.55 0.076 7.58 x 10
-5
1.0 1.201 9.629 2.67 x 10-3
0.2272 3.79 0.063 6.31 x 10-5 0.833 1.0 8.0238 2.23 x 10-3
0.0283 0.47 0.008 7.86 x 10-6 0.104 0.125 1.0 2.78 x 10-4
101.94 1699 28.32 2.83 x 10-2 373.77 448.8 3600 1.0
78
Pressure and pressure heads
bar kg/cm² lbf/sq. in. atm ft H2O m H2O mm Hg in. Hg kPa
1.0 1.0197 14.504 0.9869 33.455 10.197 750.06 29.530 100
0.9807 1.0 14.223 0.9878 32.808 10 735.56 28.959 98.07
0.0689 0.0703 1.0 0.0609 2.3067 0.7031 51.715 2.036 6.89
1.0133 1.0332 14.696 1.0 33.889 10.332 760.0 29.921 101.3
0.0299 0.0305 0.4335 0.0295 1.0 0.3048 22.420 0.8827 2.99
0.0981 0.10 1.422 0.0968 3.2808 1.0 73.356 2.896 9.81
13.3 x 10 -4
0.0014 0.0193 13.2 x 10-4 0.0446 0.0136 1.0 0.0394 0.133
0,0339 0.0345 0.4912 0.0334 1.1329 0.3453 25.40 1.0 3.39
1.0 x 10 -5
10.2 x 10 -6
14.5 x 10 -5
9.87 x 10 -6
3.34 x 10 -4
10.2 x 10 -5
75.0 x 10 -4
29.5 x 10 -5
1.0
atm = international standard atmosphere

kg/cm² = metric atmosphere
79
Conversion inch/mm
80
Market segments in industrial systems
Page

Cooling 82
Chemical Process Industry 83
Water Treatment 84
Micro Electronics 85
Life Science 86
Ship Building 87
Water and Gas Utilities 88
Building Services 89
81
Market segments in industrial
systems
Cooling
82
Chemical Process Industry
83
Water Treatment
84
Micro Electronics
85
Life Science
86
Ship Building
87
Water and Gas Utilities
88
Building Services
89
90
Approvals and standards for industrial applications
Page

Approvals for products 92
Approvals for materials

-- ABS 93
-- PE 93
-- Beta-PP-H and PROGEF® Natural 94
-- PVC-U 95
-- PVC-C 95
-- PVDF 95
Standards
-- Relevant standards for valves 97
-- Relevant standards for flanges 98
-- Relevant standards for threads 99
-- Relevant standards for ABS pipes and fittings 100
-- Relevant standards for PE pipes and fittings 101
-- Relevant standards for PP pipes and fittings 102
-- Relevant standards for PVC-C pipes and fittings 103
-- Relevant standards for PVC-U pipes and fittings 104
-- Relevant standards for PVDF pipes and fittings 106
-- Relevant standards for GRP pipe lines 106
91
Approvals and standards for in- ABS , PVC-U, PVC-C, PE100, PVDF and PP-H pipes,
fittings and valves
dustrial applications WRAS: Water Regulations Advisory Scheme
EPDM seals
Approvals for products ABS, PE, PVC-U and PVC-C pipes and fittings
Our products have obtained the following approvals and Please note that this list is continually subject to
testimonials: changes. Please ask your nearest GF agency for the
ABS: American Bureau of Shipping most up-to-date list.
ABS, PE100, PVC-U and PVC-C pipes, fittings and
valves
BAM: Bundesanstalt für Materialforschung und Prüfung
PVC-U pipes
BSI: British Standards Institution
PVC-U fittings, pipes, ABS fittings, PB pipes
BV: Bureau Veritas
ABS , PVC-U, PVC-C, PE100 and PP-H pipes, fittings
and valves
CCS: China Classification Society
PE100, PVC-C and PVC-U pipes, fittings and valves
CSTB: Centre Scientifique et Technique du Bâtiment
PVC-U fittings
DIBt: Deutsches Institut für Bautechnik
PVC-U, PP-H and PVDF pipes, fittings and valves,
PE fittings
DNV: Det Norske Veritas
and valves
FDA: Food and Drug Administration
EPDM, FPM, PTFE seals
PVDF-HP pipes and fittings
GL: Germanischer Lloyd
and valves
IIP: Instituto Italiano dei Plastici
PE, PVC-U fittings
KIWA: Keuringsinstituut voor Waterleidingsartikelen
PE, PVC-U fittings
KTW: Kunststoff-Trinkwasser-Empfehlungen (plastics,
drinking water-recommendations)
PE and PVC-U fittings
EPDM seals
LR: Lloyd's Register of Shipping
ABS, PE100, PVC-U, PVC-C and PP-H pipes, fittings
and valves
MAIRIE DE PARIS:
EPDM seals
NAMSA: North American Science Associates
EPDM, FPM, PTFE seals
PZH: Panstwowy Zaklad Higieny
ABS, PP-H, PVC-U fittings and valves
RINA: Registro Italiano Navale
and valves
RMROS: Russian Maritime Register of Shipping
ABS , PVC-U, PVC-C, PE100 pipes, fittings and valves
UDT:Urzad Dozoru Technicznego
92
Approvals for materials
ABS
The material is suitable for use with drinking water. The
relevant approvals are currently in preparation. Please
ask your nearest GF agency for further information.
PE
The following information is provided by the raw materials
manufacturers with regard to approvals/testimonials:
Austria ÖVGW Water supply
LHG 1975 Foodstuffs
Germany DVGW Water and gas supply
GKR Gas supply
Belgium Eandis Gas supply
Université de Water supply
Liege
Czech Republic ITC Water and gas supply
France LNE Water and gas sup-
GdF ply, industry
ACS Gas supply
Italy IIP Water and gas supply
Hungary EMI Gas supply
Netherlands KIWA Water supply
GIVEG Gas supply
Poland IGNIG Gas supply
INSTAL Water supply
Slovenia Analog DVGW Water and gas supply
Croatia Analog DVGW Water and gas supply
Sweden KP Water supply
Denmark Miljostyrelsen Water supply
Switzerland SVGW Water and gas supply
Spain Aenor Gas supply
UK DOE Water supply
British Gas Gas supply
93
Beta-PP-H and PROGEF® Natural
RA130E-PP-Natural
STATEMENT ON COMPLIANCE TO REGULATIONS
FOR DRINKING WATERPIPES
We confirm that this product fulfils the requirements on
materials used for pipes or pipe components intended to
come into contact with drinking water, as described in:
Austria Kunststoffverordnung Nr. 476/2003 und
Änderung Nr. 242/2005
Czech Re- Vyhlaska Ministerstva zdravotnictvi c. 37/2001
public Sb.
Denmark Fødevaredirektoratets Bekentgørelse nr. 802
(19.08.2005)
EU Regulation (EC) No 1935/2004 and Commis-
sion Directives 2002/72/EC, 2004/1/EC, 2004/
19/EC and 2005/79/EC
Finland KTM Asetukset 953/2002 ja 181/2005
France Repression des Fraudes (2002), No 1227, et
Arrêté du 2 janvier 2003, Arrêté du 29 mars
2005 et Arrêté du 9 aout 2005
Germany Bedarfgegenständeverordnung in der Ver-
sion vom 23.12.1997 und Änderungen vom
21. Dezember 2000, 7. April 2003 und 13. Juli
2005 sowie Leitlinie des Umweltbundesamtes
zur veränderten Durchführung der KTW
Prüfungen bis zur Gültigkeit des Europäischen
Akzeptanzsystems für Bauprodukte im Kon-
takt mit Trinkwasser (EAS), Tabelle 1 "Kunst-
stoffe", BGBl 48, 12/2005)
Italy Decreto Ministeriale 06.04.2004 N. 174
Nether- Staatstoezicht op de Volksgezondheit, Pub-
lands likatie 94-01, Deel B, 1.3. Polypropeen
Norway Sosial- og helsedepartementets forskrift 1993-
12-21-1381
Sweden Statens Livsmedelsverks kungörelse LIVSFS
2003:2, ändr. LIVSFS 2004:31 och ändr. LIVS-
FS 2005:14
Switzerland Verordnung der EDI über Bedarfsgegenstände
23.11.2005, 3. Abschnitt Bedarfsgegenstände
aus Kunststoff
USA FDA, CFR, Title 21 (2005), 177.1520 (a)(3)(i)
(c)(1), (b) and (c)3.1a Olefin polymers
USP VI conformity

Migration Monomers and additives used are not regulat-
limits ed with specific migration limits in the above
mentioned regulations.
Prepared Borealis Group Product Liability / Jürgen Emig
by
94
BE60-7032 Beta-PP • Physiologically harmless in conjunction with neutral,
STATEMENT ON COMPLIANCE TO FOOD CONTACT acid and alcoholic foods as per consumer goods order
REGULATIONS and BgW recommendations for PVC-U.
We confirm that this product fulfils the requirements on • From a microbiological view, suitable for use with
materials used for pipes or pipe components intended to drinking water as per DVGW W 270 test.
come into contact with food as described in: • Conformance with KTW (plastic materials and drink-
Austria Kunststoffverordnung Nr. 476/2003 und ing water) recommendations issued by the BGA (Fed-
Änderung Nr. 242/2005 eral Health Bulletin 1977)
Belgium Koninlijk Besluit - Arrêté Royal, du 11 mai • Conformité Sanitaire (circulaires DGS/VS4/N94/9,
1992 et 10 décembre 2002 (M.B. 20/2/2003) -155 and Arreté Interministériel of 1997)
Czech Re- Vyhlaska Ministerstva zdravotnictvi c. 38/2001 • KIWA requirements for organoleptic and microbial
public Sb. a.c. 186/2003 Sb. growth
Denmark Fødevaredirektoratets Bekentgørelse nr. 80 • NSF approval in preparation
(27.01.2005)
The following information is provided by the raw
EU Regulation (EC) No 1935/2004 and Commis- materials manufacturers with regard to approvals/
sion Directives 2002/72/EC, 2004/1/EC and testimonials:
2004/19/EC
Finland KTM Asetukset 953/2002 ja 181/2005 USA FDA 21 CFR, paragraphs 177/178
France Repression des Fraudes (2002), No 1227, et EEC Directive 90/128 EEC (as at 1990), 78/142 (1978)
Arrêté du 2 janvier 2003 et Arrêté du 29 mars 80/432 (1981), 80/766 (1980), 2002/72 EC (Contact
2005 with foodstuff)
Germany Bedarfgegenständeverordnung in der Ver- Italy: Dichiarazione di conformità alla C.M. n. 102 del
sion vom 10. April 1992, Änderungen 11. April 02.12.1978: Disciplina igienica concernente le materie
1994, 17. April 1997, 21. Dezember 2000 und plastiche e gomme per tubazioni ed accessori destinati
7. April 2003, und BfR-Empfehlungen (2005)
a venire in contatto con acqua potabile e da potabiliz-
Great Statutory Instruments, 1998 No. 1376, 2000 zare.
Britain No. 3162, 2002 No. 2364 and Polymer Specifi-
cation 5, Polypropylene
PVC-C
Italy Decreto Ministeriale 06.4.1993 N. 220, 28.10.
1994 N. 735, 24.9.1996 N.572, 6.2.1997 N.91, The following information is provided by the raw
22.7.1998 N.338, 15.6.2000 N.210, 28.3.2003 materials manufacturers with regard to approvals/
N.123 e testimonials:
Nether- Warenwet (2003), Hoofdstuk 1, Kunststoffen USA complies with National Sanitary Foundation re-
lands quirements
Norway Sosial- og helsedepartementets forskrift 1993-
12-21-1381 The material is suitable for use with drinking water.
Please ask your nearest GF agency for further informa-
Portugal Decreto-Lei n.° 4/2003 de 10 de Janeiro de tion.
2003
Spain Real Decretos 2207/1994, 442/2001, 118/
EC: Directive 2002/95/EC
2003, Orden ministerial SCO/983/2003 y
ANAIP (1982), Anexo 1, Anexo 4 PVDF
Sweden Statens Livsmedelsverks kungörelse LIVSFS The following information is provided by the raw materi-
2003:2 ochändr. LIVSFS 2004:31 als manufacturers with regard to approvals/testimonials:

Food product contact, physiological harmlessness,
Migration The product contains 3,3'-thiobis (propanoic toxicology
limits acid octadecylester), (CAS No. 693-36-7),
which is regulated with specific migration limits • Thames Water Services (UK): approval for use of
in EU pipes in SOLEF PVDF 1010 and 3410 to transport hot
Prepared Borealis Group Product Liability / Tuuli Kunnas and cold water for domestic consumption (report No.
by 2141A of 27 July 1988)
• TNO Report MRP V – 160/83: insensitivity of SOLEF
PVC-U PVDF to conventional sterilization methods
• Centre d’Enseignement et de Recherches des Indus-
Existing drinking water and food approvals: tries Alimentaires et Chimiques (CERIA-B): test report
No. 284.321 of 14 April 1974 demonstrating the ab-
sence of proliferation of mildews and bacteria on the
surface of SOLEF PVDF (comparable to glass)
• Safepharm Labs Ltd (UK): approval of SOLEF PVDF
1008 according to the tests conforming to the United
States Pharmacopoeia (USP) XXI – "Biological tests”
July 1986
95
• Hygiene-Institut des Ruhrgebietes – Gelsenkirchen
(D): test reports No. C208/92/St and C209/92/St con-
cerning the SOLEF grades 1008 and 8908/0505 for
use in transporting hot and cold water for domestic
consumption. The grades tested conform to the "Kun-
ststoff Trinkwasser Empfehlungen KTW”
• USP Class VI, Biological reactivity test, invivo
• Compliance with FDA volume 21, section 177.2510
• Compliance with European Directive 2002/72/EC
(Contact with foodstuff)
• NSF-61 Potable water, Kynar 720/740
• NSF-51 Food equipment material, Kynar 720/740
• NSF-14 Plastic piping system components, Kynar
720/740
• 3A Sanitary Standards
• Kosher Certified by the Chicago Rabbinical Council,
Kynar 720/740
96
Standards
Relevant standards for valves
ASME B 16.10 (2009-00) Face-to-face and end-to-end dimensions of valves
DIN 2429-2 (1988-01) Symbolic representation of pipework components on engineering drawings; functional rep-
resentation
DIN 3202-4 (1982-04) Face-to-face and centre-to-face dimensions of valves; Valves with female thread connec-
tion
DIN 3202-5 (1984-09) Face-to-face and centre-to-face dimensions of valves; valves for connection with compres-
sion couplings
DIN 3230-4 (1977-03) Technical conditions of delivery for valves; valves for potable water service, requirements
and testing
DIN 3230-5 (1984-08) Technical delivery conditions; valves for gas installations and gas pipelines; requirements
and testing
DIN 3230-6 (1987-09) Technical delivery conditions for valves; requirements and methods of test for valves for
use with flammable liquids
DIN 3266 (2009-05) Valves for drinking water installations on private premises - Anti-vacuum valve Types D
and E - Requirements and tests
DIN 3292-1 (1984-06) Fittings for domestic installation; nonferrous metal union nuts
DIN 3500 (1990-02) PN 10 piston type gate valves for use in drinking water supply systems
DIN 3512 (2002-10) Stop valves for domestic water supply - Two-way valves - Vertical bonnet type PN 10;
Straight pattern globe valve; Technical rule of the DVGW / Note: applies in conjunction with
DIN EN 1213
DIN 3537-1 (1990-06) Gas stop valves rated for pressures up to 4 bar; requirements and acceptance testing
DIN 3543-1 (1984-08) Metal tapping valves; requirements, testing
DIN 3543-2 (1984-05) Metallic tapping stop valves; dimensions
DIN 3543-3 (1978-07) PVC tapping valves for plastic pipes; dimensions
DIN 3543-4 (1984-08) High density polyethylene (HDPE) tapping valves for HDPE pipes; dimensions
DIN 3544-1(1985-09) High-density polyethylene (HDPE) valves; tapping valves; requirements and test
DIN 32676 (2009-05) Fittings for the food, chemical and pharmaceutical industries - Clamp connections for stain-
less steel tubes - Weld-on type
EN 593+A1 (2011-03) Industrial valves - Metallic butterfly valves
DIN EN 12266-1 (2003-06) Industrial valves - Testing of valves - Part 1: Pressure tests, test procedures and accep-
tance criteria - Mandatory requirements
DIN EN 12266-2 (2003-05) Industrial valves - Testing of valves - Part 1: Pressure tests, test procedures and accep-
tance criteria - Mandatory requirements
DIN EN 12516-2 (2004-10) Industrial valves - Shell design strength - Part 2: Calculation method for steel valve shells
DIN EN 13774 (2003-07) Valves for gas distribution systems with maximum operating pressure smaller or equal 16
bar - Performance requirements
DIN EN 14141 (2004-03) Valves for natural gas transportation in pipelines - Performance requirements and tests
EN 15389 (2008-05) Industrial valves - performance characteristics of thermoplastic valves when used as con-
struction products
DIN EN ISO 5211(2001-06) Industrial valves - Part-turn actuator attachments
EN ISO 16135 (2006-03) Industrial valves-Ball valves of thermoplastic materials
EN ISO 16136 (2006-03) Industrial valves-Butterfly valves of thermoplastic materials
EN ISO 16137 (2006-03) Industrial valves-Check valves of thermoplastic materials
EN ISO 16138 (2006-03) Industrial valves-Diaphragm valves of thermoplastic materials
EN ISO 16139 (2006-03) Industrial valves-Gate valves for thermoplastic materials
EN ISO 21787 (2006-03) Industrial valves-Globe valves of thermoplastic materials
ISO 9393-1 (2004-07) Thermoplastics valves - Pressure test methods and requirements - Part 1: General
ISO 9393-2 (2005-10) Thermoplastics valves - Pressure test methods and requirements - Part 2: Test conditions
and basic requirements
97
ISO 14617-8 (2002-09) Graphical symbols for diagrams - Part 8: Valves and dampers
JIS B 2002 (1987-02) Face-to-face and end-to-end dimensions of valves
JIS B 2003 (1994-11) General rules for inspection of valves
Relevant standards for flanges

ANSI B16.1 (2010-00) Gray Iron Pipe Flanges and Flanged Fittings: Classes 25, 125, and 250
ANSI/ASME B 16.5 (2009-00) Pipe Flanges and Flanged Fittings
ASTM D 4024 (2005-00) Standard Specification for Machine Made "Fiberglass" (Glass-Fiber-Reinforced Thermoset-
ting Resin) Flanges
ASTM D 5421 (2005-00) Standard Specification for Contact Molded "Fiberglass" (Glass-Fiber-Reinforced Ther-
mosetting Resin) Flanges
BS 10:2009 (2009-04) Specification for flanges and bolting for pipes, valves, and fittings
BS 1560-3.1:1989 (1989-06) Circular flanges for pipes, valves and fittings (class-designated). Steel, cast iron and cop-
per alloy flanges. Specification for steel flanges
BS 1560-3.2:1989 (1990-03) Circular flanges for pipes, valves and fittings (class-designated). Steel, cast iron and cop-
per alloy flanges. Specification for cast iron flanges
BS EN 1515-1:2000 (2000-02) Flanges and their joints. Bolting. Selection of bolting
BS EN 1759-1:2004 (2004-11) Flanges and their joints. Circular flanges for pipes, valves, fittings and accessories, class-
designated. Steel flanges, NPS 1/2 to 24
BS EN 1759-3:2003 (2004-03) Flanges and their joint. Circular flanges for pipes, valves, fittings and accessories, class
designated. Copper alloy flanges
resentation
DIN 16831-7 (2004-02) Pipe joints and components of polybutene (PB) for pipes under pressure; PB 125 - Part 7:
Flange adapters, flanges, sealing rings for socket welding; dimensions
DIN 16872 (1993-10) Pipe joints assemblies for pipelines of thermoplastics; glass fibre reinforced polyester resin
(UP-GF) flanges; dimensions
DIN 16966-6 (1982-07) Glass fibre reinforced polyester resin (UP-GF) pipe fittings and joint assemblies; collars,
flanges, joint rings, dimensions
DIN 16966-7 (1995-04) Pipe joints and their elements of glass fibre reinforced polyester resins - Part 7: Bushings,
flanges, flanged and butt joints; general quality requirements and test methods
DIN 28403 (1986-09) Vacuum technology; quick release couplings; clamped type couplings
DIN 28404 (1986-10) Vacuum technology; flanges; dimensions
DIN 8063-12 (1987-01) Pipe joint assemblies and fittings of unplasticized polyvinyl chloride (U-PVC) pressure
pipelines; dimensions of flanged and socket fittings
DIN 8063-4 (1983-09) Pipe joint assemblies and fittings for unplasticized polyvinyl chloride (PVC-U) pressure
pipes; bushings, flanges, seals; dimensions
DIN EN 1092-1 (2008-09) Flanges and their joints - Circular flanges for pipes, valves, fittings and accessories, PN
designated - Part 1: Steel flanges
DIN EN 1092-2 (1997-06) Flanges and their joints - Circular flanges for pipes, valves, fittings and accessories, PN
designated - Part 2: Cast iron flanges
DIN EN 1514-8 (2005-02) Flanges and their joints - Dimensions of gaskets for PN-designated flanges - Part 8: Poly-
meric O-Ring gaskets for grooved flanges
DVS 2205-4 (1988-11) suppl. Calculation of thermoplastic tanks and apparatuses - Flanged joints
DVS 2205-4 Beiblatt (1996-11) Calculation of thermoplastic tanks and apparatuses - Welded flanges, welded collars -
suppl. Constructive details
DVS 2210-1 Beiblatt 3 (2006-5)
EN 558 (2008-01) Industrial valves - Face-to-face and centre-to-face dimensions of metal valves for use in
flanged pipe systems - PN and Class designated valves
ISO 5752 (1982-06) Metal valves for use in flanged pipe systems; Face-to-face and centre-to-face dimensions
ISO 7005-1 (1992-04) Metallic flanges; part 1: steel flanges
ISO 7005-2 (1988-12) Metallic flanges; part 2: cast iron flanges
ISO 7005-3 (1988-02) Metallic flanges; part 3: copper alloy and composite flanges
98
ISO 7483 (1991-10) Dimensions of gaskets for use with flanges to ISO 7005
ISO 8483 (2003-12) Glass-reinforced thermosetting plastics (GRP) pipes and fittings - Test methods to prove
the design of bolted flange joints
ISO 9624 (1997-02) Thermoplastics pipes for fluids under pressure - Mating dimensions of flange adapters and
loose backing flanges
JIS B 2220 (2004-01) Steel pipe flanges
JIS B 2239 (2004-03) Cast iron pipe flanges
EN ISO 15493 (2003-04) Plastics piping systems for industrial applications - Acrylonitrile-butadiene-styrene (ABS),
unplasticized polyvinyl chloride (PVC-U) and chlorinated polyvinyl chloride (PVC-C) -
Specifications for components and the system; Metric series (ISO 15493:2003)
EN ISO 15494 (2003-04) Plastics piping systems for industrial applications - Polybutene (PB), polyethylene (PE) and
polypropylene (PP) - Specifications for components and the system; Metric series (ISO
15494:2003)
EN ISO 10931 (2005-12) Plastics piping systems for industrial applications - Poly(vinylidene fluoride) (PVDF) - Spec-
ifications for components and the system (ISO 10931:2005)
Relevant standards for threads

ANSI B 1.20.1 (1983-00) Pipe threads, general purpose (inch)
ASTM F 1498 (2008-00) Standard Specification for Taper Pipe Threads 60° for Thermoplastic Pipe and Fittings
BS 21:1985 (1985-09) Specification for pipe threads for tubes and fittings where pressure-tight joints are made on
the threads (metric dimensions)
DIN 103-1 (1977-04) ISO metric trapezoidal screw thread; profiles
DIN 103-2 (1977-04) ISO metric trapezoidal screw thread; general plan
DIN 103-3 (1977-04) ISO metric trapezoidal screw thread; allowances and tolerances for trapezoidal screw
threads of general purpose
DIN 103-4 (1977-04) ISO metric trapezoidal screw thread; nominal dimensions
DIN 103-5 (1972-10) ISO metric trapezoidal screw thread; limiting sizes for nut threads from 8 to 100 mm Nomi-
nal Diameter
DIN 103-6 (1972-10) ISO Metric Trapezoidal Screw Threads; Limiting Sizes for Nut Threads from 105 to 300
mm nominal diameter
DIN 103-7 (1972-10) ISO metric trapezoidal screw thread; limiting sizes for bolt threads from 8 to 100 mm nomi-
nal diameter
DIN 103-8 (1972-10) ISO metric trapezoidal screw thread; limiting sizes for bolt threads from 105 to 300 mm
nominal diameter
DIN 103-9 (1985-02) ISO metric trapezoidal screw threads; gauging of external and internal threads; gauge di-
mensions and design features
DIN 16903-1 (1974-12) Open insert nuts for plastics mouldings
DIN 16903-2 (1974-12) Closed insert nuts with disc for plastics mouldings
DIN 16903-3 (1974-12) Closed insert nuts with dead hole for plastics mouldings
resentation
DIN 3852-2 (2000-11) Stud ends, ports, for fittings, valves - Plug screw with Whitworth pipe thread - General out-
lay of types
DIN 40430 (1971-02) Steel conduit thread; dimensions
DIN 405-1 (1997-11) General purpose knuckle threads - Part 1: Profiles, nominal sizes
DIN 405-2 (1997-11) General purpose knuckle threads - Part 2: Deviations and tolerances
DIN 513-1 (1985-04) Metric buttress threads; thread profiles
DIN 513-2 (1985-04) Metric buttress threads; general plan
DIN 513-3 (1985-04) Metric buttress threads; deviations and tolerances
DIN EN 10226-1(2004-10) Pipe threads where pressure tight joints are made on the threads - Part 1: Taper external
threads and parallel internal threads - Dimensions, tolerances and designation
DIN EN 10226-3 (2005-05) Pipes threads where pressure tight joint are made on the threads - Part 3: Verification by
means of limit gauges
99
DIN ISO 1502 (1996-12) ISO general purpose metric screw threads - Gauges and gauging (ISO 1502:1996)
DIN EN ISO 228-1 (2003-05) Pipe threads where pressuretight joints are not made on the threads - Part 1: Dimensions,
tolerances and designation (ISO 228-1:2000); German version EN ISO 228-1:2003
DIN EN ISO 228-1 suppl. 1 Pipe threads where pressuretight joints are not made on the threads - Part 1: Dimensions,
(2003-05) tolerances and designation; limits of size
DIN EN ISO 228-2 (2003-05) Pipe threads where pressure-tight joints are not made on the threads - Part 2: Verification
by means of limit gauges (ISO 228-2:1987); German version EN ISO 228-2:2003
ISO 7-1 (1994-05) Pipe threads where pressure-tight joints are made on the threads - Part 1: Dimensions, tol-
erances and designation
ISO 7-2 (2000-09) Pipe threads where pressure-tight joints are made on the threads - Part 2: Verification by
means of limit gauges
ISO 68-1(1998-12) ISO general purpose screw threads - Basic profile - Part 1: Metric screw threads
JIS K 6743 (2007-03) Unplasticized polyvinyl chloride (PVC-U) pipe fittings for water supply
Relevant standards for ABS pipes and fittings

ASTM D 1527(1999-00) Standard Specification for Acrylonitrile-Butadiene-Styrene (ABS) Plastic Pipe, Schedules
40 and 80 / Note: 1. editorial change
ASTM D 3965(2005-00) Standard Specification for Rigid Acrylonitrile-Butadiene-Styrene (ABS) Materials for Pipe
and Fittings
BS 5391-1:2006 (2006-12) Acrylonitrile-butadiene-styrene (ABS) pressure pipe. Specification
BS 5392-1:2006 (2006-12) Acrylonitrile-butadiene-styrene (ABS) fittings for use with ABS pressure pipe. Specification
resentation
DVS 2210-2 (2007-10) Industrial pipework systems of thermoplastic polymers; planning and construction; above-
ground pipelines - Double Containment Systems
ISO 727-1 (2002-05) Fittings of unplasticized polyvinyl chloride (PVC-U), chlorinated polyvinyl chloride (PVC-C)
or acrylonitrile butadiene styrene (ABS) with plain sockets for pipes under pressure - Part
1: Metric series
or acrylonitrile butadiene styrene (ABS) with plain sockets for pipes under pressure - Part
2: Inch-based series
ISO 8283-4 (1992-12 Plastics pipes and fittings; dimensions of sockets and spigots for discharge systems inside
buildings; Part 4: acrylonitrile butadiene styrene (ABS)
unplasticized polyvinyl chloride (PVC-U) and chlorinated polyvinyl chloride (PVC-C) -
Specifications for components and the system; Metric series (ISO 15493:2003)
100
Relevant standards for PE pipes and fittings
ASTM D 2657 (2007-00) Standard Practice for Heat Fusion Joining of Polyolefin Pipe and Fittings
ASTM D 2737 (2003-00) Standard Specification for Polyethylene (PE) Plastic Pipe, Schedules 40 and 80, Based on
Outside Diameter
ASTM D 3261a (2010-00) Standard Specification for Butt Heat Fusion Polyethylene (PE) Plastic Fittings for Polyethy-
lene (PE) Plastic Pipe and Tubing
resentation
DIN 3543-4 (1984-08) High density polyethylene (HDPE) tapping valves for HDPE pipes; dimensions
DIN 3544-1 (1985-09) High-density polyethylene (HDPE) valves; tapping valves; requirements and test
DIN 8074 (1999-08) Polyethylene (PE) - Pipes PE 63, PE 80, PE 100, PE-HD - Dimensions
DIN 8075 (1999-08) Polyethylene (PE) pipes - PE 63, PE 80, PE 100, PE-HD - General quality requirements,
testing
DIN 8076 (2008-11) Pressure pipelines made from thermoplastics materials - Metal and plastics compression
fittings for polyethylene (PE) pipes - General quality requirements and testing
DIN 19537-3 (1990-11) Prefabricated high density polyethylene (PE-HD) manholes for use in sewerage systems;
dimensions and technical delivery conditions
DIN EN 12007-2 (2000-08) Gas supply systems - Pipelines for maximum operating pressure up to and including 16
bar - Part 2: Specific functional recommendations for polyethylene (MOP up to and includ-
ing 10 bar); German version EN 12007-2:2000
DVGW VP 302 (2006-06) Shut-off valves made of polyethylene (PE 80 und PE 100) - Requirements and tests
DVS 2205-1 Beiblatt 6 (2011-04) Design calculations for containers and apparatus made from thermoplastics - Characteris-
tic values of Polyethylene
DVS 2207-1 (2005-09) Welding of thermoplastics - Heated tool welding of pipes, pipeline, components and sheets
made from PE-HD
ground pipelines
DVS 2210-1 Beiblatt 1 (2003-04) Industrial pipework systems of thermoplastic polymers; planning and construction; above-
ground pipelines - Example for calculation
ground pipelines - Internal pressure test and leak thightness test
ground pipelines - Flanges: Requirements, Assembling
EN 1555-1 (2010-09) Plastics piping systems for the supply of gaseous fuels - Polyethylene (PE) - Part 1: Gen-
eral
EN 1555-2 (2010-09) Plastics piping systems for the supply of gaseous fuels - Polyethylene (PE) - Part 2: Pipes
EN 1555-3 (2010-09) Plastics piping systems for the supply of gaseous fuels - Polyethylene (PE) - Part 3: Fit-
tings
EN 1555-4 (2011-05) Plastics piping systems for the supply of gaseous fuels - Polyethylene (PE) - Part 4:
Valves
EN 1555-5 (2010-09) Plastics piping systems for the supply of gaseous fuels - Polyethylene (PE) - Part 5: Fit-
ness for purpose of the system
CEN/TS 1555-7 (2003-04) Plastics piping systems for the supply of gaseous fuels - Polyethylene (PE) - Part 7: Guid-
ance for the assessment of conformity
EN 12201-1 (2003-03) Plastics piping systems for water supply - Polyethylene (PE) - Part 1: General
EN 12201-2 (2003-03) Plastics piping systems for water supply - Polyethylene (PE) - Part 2: Pipes
EN 12201-3 (2003-03) Plastics piping systems for water supply - Polyethylene (PE) - Part 3: Fittings
EN 12201-4 (2001-12) Plastics piping systems for water supply - Polyethylene (PE) - Part 4: Valves
EN 12201-5 (2003-03) Plastics piping systems for water supply - Polyethylene (PE) - Part 5: Fitness for purpose
of the system
CEN/TS 12201-7 (2003-08) Plastics piping systems for water supply - Polyethylene (PE) - Part 7: Guidance for the as-
sessment of conformity
101
EN 13244-5 (2002-12) Plastics piping systems for buried and above- ground pressure systems for water of gen-
eral purposes, drainage and sewerage - Polyethylene (PE) - Part 5: Fitness for purpose of
the system
polypropylene (PP) - Specifications for components and the system; metric series (ISO
15494:2003)
ISO 12176-3 (2011-02) Plastics pipes and fittings - Equipment for fusion jointing polyethylene systems - Part 3:
Operator's badge
ISO 14236 (2000-03) Plastics pipes and fittings - Mechanical-joint compression fittings for use with polyethylene
pressure pipes in water supply systems
ISO 3458 (1976-06) Assembled joints between fittings and polyethylene (PE) pressure pipes; test of leak proof-
ness under internal pressure
ISO 3459 (1976-10) Polyethylene (PE) pressure pipes; Joints assembled with mechanical fittings; internal un-
der-pressure test method and requirement
ISO 3501 (1976-06) Assembled joints between fittings and polyethylene (PE) pressure pipes; test of resistance
to pull out
ISO 3503 (1976-06) Assembled joints between fittings and polyethylene (PE) pressure pipes; test of leakproof-
ness under internal pressure when subjected to bending
ISO 4437 (2007-06) Buried polyethylene (PE) pipes for the supply of gaseous fuels - Metric series - Specifica-
tions
ISO 9623 (1997-02) PE/metal and PP/metal adaptor fittings for pipes for fluids under pressure - Design lengths
and size of threads - Metric series
ISO/TS 10839 (2000-03) Polyethylene pipes and fittings for the supply of gaseous fuels - Code of practice for de-
sign, handling and installation
JIS K 6774 (2005-03) Polyethylene pipes for the supply of gaseous fuels
Relevant standards for PP pipes and fittings

resentation
DIN 8077 (2008-09) Polypropylene (PP) pipes - PP-H, PP-B, PP-R, PP-RCT - Dimensions
DIN 8078 (2008-08) Polypropylene (PP) pipes - PP-H, PP-B, PP-R, PP-RCT - General quality requirements
and testing
DIN 8078 Suppl. 1 (1982-02) Pipes of polypropylene (PP); chemical resistance of pipes and fittings
DVS 2207-6 (2003-12) Welding of thermoplastics - Non-contact heated tool butt welding of pipes, pipeline compo-
nents and sheets - Methods, equipment, parameters
DVS 2207-11 (2008-08) Welding of thermoplastics - Heated tool welding of pipes, components and sheets out of
PP
ground pipelines
ISO 3213 (2009-09) Polypropylene (PP) pipes - Effect of time and temperature on the expected strength
ISO 9623 (1997-02) PE/metal and PP/metal adaptor fittings for pipes for fluids under pressure - Design lengths
and size of threads - metric series
polypropylene (PP) - Specifications for components and the system; metric series (ISO
15494:2003)
102
Relevant standards for PVC-C pipes and fittings
ASTM F 437 (2009-00) Standard specification for threaded chlorinated polyvinyl chloride (CPVC) plastic pipe fit-
tings, schedule 80
ASTM F 441/F 441M (2009-00) Chlorinated polyvinyl chloride (CPVC) plastic pipe, schedules 40 and 80
ASTM F 1970 (2005-00) Standard specification for special engineered fittings, appurtenances or valves for use in
polyvinyl chloride (PVC) or hlorinated polyvinyl chloride (CPVC) systems
resentation
DIN 8079 (2009-10) Chlorinated polyvinyl chloride (PVC-C) pipes - Dimensions
DIN 8080 (2009-10) Chlorinated polyvinyl chloride (PVC-C) pipes - General quality requirements, testing
DIN 8080 Beiblatt 1 (2000-08) Chlorinated polyvinyl chloride (PVC-C) pipes, PVC-C 250 - general quality requirements
and testing; chemical resistance
DIN 16832-1 (2002-10) Pipe joints and components of chlorinated polyvinyl chloride (PVC-C) for pipes under pres-
sure - PVC-C 200 - Part 1: Dimensions
DIN 16832-2 (2002-10) Pipe joints and components of chlorinated polyvinyl chloride (PVC-C) for pipes under pres-
sure - PVC-C 200 - Part 2: General quality requirements and testing
DVS 2204-5 (2003-11)

DVS 2204-5 Beiblatt 1 (2003-12)

DVS 2204-5 Beiblatt 2 (2003-12)

ground pipelines
or acrylonitrile-butadiene-styrene (ABS) with plain sockets for pipes under pressure - part
1: Metric series
unplasticized polyvinyl chloride (PVC-U) and chlorinated polyvinyl chloride (PVC-C) - spec-
ifications for components and the system; metric series (ISO 15493:2003)
103
Relevant standards for PVC-U pipes and fittings
ASTM D 1784 (2011-00) Standard Specification for Rigid Poly(Vinyl Chloride) (PVC) Compounds and Chlorinated
Poly(Vinyl Chloride) (CPVC) Compounds
ASTM D 1785 (2006-00) Standard specification for polyvinyl chloride (PVC) plastic pipe, schedules 40, 80, and 120
ASTM D 2464 (2006-00) Standard specification for threaded polyvinyl chloride) (PVC) plastic pipe fittings, schedule
80
ASTM D 2466 (2006-00) Standard specification for polyvinyl chloride (PVC) plastic pipe fittings, schedule 40
ASTM F 1970 (2005-00) Standard specification for special engineered fittings, appurtenances or valves for use in
polyvinyl chloride (PVC) or chlorinated polyvinyl chloride (CPVC) systems
BS 3506:1969 (1969-09) Specification for unplasticized PVC pipe for industrial uses
BS 4346-1 (1969-02) Joints and fittings for use with unplasticized PVC pressure pipes. Injection moulded un-
plasticized PVC fittings for solvent welding for use with pressure pipes, including potable
water supply
resentation
DIN 8061 (2009-10) Unplasticized polyvinyl chloride pipes - general quality requirements and testing
DIN 8061 suppl. 1 (1984-02) Unplasticized polyvinylchloride pipes; chemical resistance of pipes and fittings of (PVC-U)
DIN 8062 (2009-10) Unplasticized polyvinyl chloride (PVC-U, PVC-HI) pipes; dimensions
pipelines; dimensions of socket bends
DIN 8063-10 (2002-06) Pipe joints and their elements for pipes of unplasticized polyvinylchloride (unplasticized
PVC) under pressure; wall disk, dimensions
DIN 8063-11 (1980-07) Pipe joints and pipe fittings for pipes under pressure made of unplasticized Polyvinyl Chlo-
ride (rigid PVC); sockets with primary element of copper-zinc-alloy (brass) for bonding; di-
mensions
DIN 8063-12 (1987-01) Pipe joint assemblies and fittings of unplasticized polyvinyl chloride (PVC-U) pressure
pipelines; dimensions of flanged and socket fittings
DIN 8063-2 (1980-07) Pipe joints and pipe fittings for pipes under pressure made of unplasticized polyvinyl chlo-
ride (rigid PVC); bends made by injection moulding for bonding; dimensions
DIN 8063-3 (2002-06) Pipe joints and pipe fittings for pipes under pressure made of uplasticized polyvinyl chlo-
ride (rigid PVC); screwed pipe joints; dimensions
pipes; bushings, flanges, seals; dimensions
DIN 8063-5 (1999-10) Pipe joints components of unplasticized polyvinyl chloride (PVC-U) for pipes under pres-
sure - part 5: General quality requirements, testing
ride (rigid PVC); injection moulded elbows for bonding; dimensions
DIN 8063-7 (1980-07) Pipe joints and their elements of unplasticized polyvinylchloride (unplasticized PVC) under
pressure; tees and branches of injection moulded for cold welding, dimensions
ride (rigid PVC); injection moulded sockets, caps and nipples for bonding; dimensions
DIN 8063-9 (1980-08) Pipe joints and their elements for pipes of unplasticized polyvinyl chloride (unplasticized
PVC) under pressure; sockets reducing of injection moulded for cold welding, dimensions
DVS 2204-4 (2011-12) Adhesive bonding of pipes and fittings made of thermoplastics - Polyvinyl chloride (PVC-U)
ground pipelines
DIN 16450 (1994-06) Socketfittings for pressure piping of unplasticized polyvinylchloride (PVC-U); symbols
104
DIN EN ISO 13783 (1998-07) Plastics piping systems - unplasticized polyvinyl chloride (PVC-U) end-load-bearing dou-
ble-socket joints - test method for leaktightness and strength while subjected to bending
and internal pressure (ISO 13783:1997); German version EN ISO 13783:1997
EN ISO 1452-1 (2009-12) Plastics piping systems for water supply and for buried and above-ground drainage and
sewerage under pressure - Unplasticized poly(vinyl chloride) (PVC-U) - Part 1: General
sewerage under pressure - Unplasticized poly(vinyl chloride) (PVC-U) - Part 2: Pipes
sewerage under pressure - Unplasticized poly(vinyl chloride) (PVC-U) - Part 3: Fittings
sewerage under pressure - Unplasticized poly(vinyl chloride) (PVC-U) - Part 4: Valves
sewerage under pressure - Unplasticized poly(vinyl chloride) (PVC-U) - Part 5: Fitness for
purpose of the system
EN ISO 15493 (2003-04) Plastics piping systems for industrial applications - acrylonitrile-butadiene-styrene (ABS),
unplasticized polyvinyl chloride (PVC-U) and chlorinated polyvinyl chloride (PVC-C) - spec-
ifications for components and the system; metric series (ISO 15493:2003)
ISO 15493 Technical Corrigendum Plastics piping systems for industrial applications - acrylonitrile-butadiene-styrene (ABS),
1 (2004-05) unplasticized polyvinyl chloride (PVC-U) and chlorinated polyvinyl chloride (PVC-C) - spec-
ifications for components and the system; metric series (ISO 15493:2003) Technical Corri-
gendum 1
ISO 265-1 (1988-12) Pipes and fittings of plastics materials; fittings for domestic and industrial waste pipes; ba-
sic dimensions: Metric series; part 1: Unplasticized polyvinyl chloride (PVC-U)
1: Metric series (revision of ISO 727:1985)
ISO 4132 (1979-07) Unplasticized polyvinyl chloride (PVC) and metal adaptor fittings for pipes under pressure;
laying lengths and size of threads; metric series
JIS K 6741 (2007-03) Unplasticized polyvinyl chloride (PVC-U) pipes
JIS K 6742 (2007-03) Unplasticized polyvinyl chloride (PVC-U) pipes for water supply
JIS K 6743 (2007-03) Unplasticized polyvinyl chloride (PVC-U) pipe fittings for water supply
105
Relevant standards for PVDF pipes and fittings
DVS 2205 Suppl. 4 (1996-08) Design calculations for containers and apparatus made from thermoplastics; creep rupture
curves for pipes made from PVDF
DVS 2207-6 (2003-09) Welding of thermoplastics - Non-contact heated tool butt welding of pipes, pipeline compo-
nents and sheets - Methods, equipment, parameters
DVS 2207-15 (2005-12) Welding of thermoplastics - Heated tool welding of pipes, pipeline, components and sheets
out of PVDF
ground pipelines
resentation
EN ISO 10931 (2005-12) Plastics piping systems for industrial applications - Polyvinylidene fluoride (PVDF) - Speci-
fications for components and the system (ISO 10931:2005)
ISO 10931 (2005-12) Plastics piping systems for industrial applications - Polyvinylidene fluoride (PVDF) - Speci-
fications for components and the system
ASTM D 3222 (2005-00) Standard Specification for Unmodified Poly(Vinylidene Fluoride) (PVDF) Molding Extrusion
and Coating Materials
ASTM F 1673 (2010-00) Standard Specification for Polyvinylidene Fluoride (PVDF) Corrosive Waste Drainage Sys-
tems
Relevant standards for GRP pipe lines

AD 2000-Merkblatt HP 110 Construction regulations - Piping made of glass reinforced thermosetting plastics (GRP)
R(2001-06) with and without liner - Manufacture and testing of pressure vessels
BS 7159:1989 (1989-10) Code of practice for design and construction of glass-reinforced plastics (GRP) piping sys-
tems for individual plants or sites
BS 7159 (1989-10) Code of practice for design and construction of glass-reinforced plastics (GRP) piping sys-
tems for individual plants or sites
BS 8010-2.5 (1989-08) Code of practice for pipelines. Pipelines on land: design, construction and installation.
Glass reinforced thermosetting plastics
DIN 16867 (1982-07) Glass fibre reinforced polyester resin (UP-GF) pipes, fittings and joints for use in chemical
pipelines; Technical delivery conditions
DIN 16871 (1982-02) Centrifugally cast glass fibre reinforced epoxy resin (EP-GF) pipes; Dimensions
DIN 16872 (1993-10) Pipe joints assemblies for pipelines of thermoplastics; glass fibre reinforced polyester resin
(UP-GF) flanges; dimensions
DIN 16964 (1988-11) Wound glass fibre reinforced polyester resins (UP-GF) pipes; general quality requirements
and testing
DIN 16965-1 (1982-07) Wound glass fibre reinforced polyester resin (UP-GF); pipes, Type A pipes, dimensions
DIN 16965-2 (1982-07) Wound glass fibre reinforced polyester resin (UP-GF); pipes, Type B pipes, dimensions
DIN 16965-4 (1982-07) Wound glass fibre reinforced polyester resin (UP-GF); pipes, Type D pipes, dimensions
DIN 16965-5 (1982-07) Wound glass fibre reinforced polyester resin (UP-GF); pipes, Type E pipes, dimensions
DIN 16966-1 (1988-11) Glass fibre reinforced polyester resin (UP-GF) pipe fittings and joint assemblies; fittings;
general quality requirements and testing
DIN 16966-2 (1982-07) Glass fibre reinforced polyester resin (UP-GF) pipe fittings and joints; Elbows, Dimensions
DIN 16966-4 (1982-07) Glass fibre reinforced polyester resin (UP-GF) pipe fittings an joints; Tees, Nozzles, Di-
mensions
DIN 16966-5 (1982-07) Glass fibre reinforced polyester resin (UP-GF) pipe fittings and joints; Reducers, Dimen-
sions
106
DIN 16966-6 (1982-07) Glass fibre reinforced polyester resin (UP-GF) pipe fittings and joint assemblies; collars,
flanges, joint rings, dimensions
DIN 16966-7 (1995-04) Pipe joints and their elements of glass fibre reinforced polyester resins - Part 7: Bushings,
flanges, flanged and butt joints; general quality requirements and test methods
DIN 16966-8 (1982-07) Glass fibre reinforced polyester resin (UP-GF) pipe fittings and joints; Laminated joints; Di-
mensions
DIN 16967-2 (1982-07) Glass fibre reinforced epoxy resin (EP-GF) pipe fittings and joints; Elbows, Tees, Dimen-
sions
DIN 53769-1 (1988-11) Testing of glass fibre reinforced plastics pipes; determination of the longitudinal shear
strength of type B pipe fittings
DIN 53769-2 (1986-12) Testing of glass fibre reinforced plastics pipes; long-term hydrostatic pressure test
EN 1394 (1996-09) Plastics piping systems - Glass-reinforced thermosetting plastics (GRP) pipes - Determina-
tion of the apparent initial circumferential tensile strength
EN 1447+A1 (2010-10) Plastics piping systems - Glass-reinforced thermosetting plastics (GRP) pipes - Determina-
tion of long-term resistance to internal pressure
tion of the relative flexural creep factor following exposure to a chemical environment
EN 637 (1994-04) Plastics piping systems - Glass-reinforced plastics components - Determination of the
amounts of constituents using the gravimetric method
EN 705 (1994-04) Plastics piping systems - Glass-reinforced thermosetting plastics (GRP) pipes and fittings -
Methods for regression analysis and their use
tion of the creep factor under dry conditions
ISO 10466 (1997-11) Plastics piping systems - Glass-reinforced thermosetting plastics (GRP) pipes - Test
method to prove the resistance to initial ring deflection
ISO 10471 (2003-12) Glass-reinforced thermosetting plastics (GRP) pipes - Determination of the long-term ulti-
mate bending strain and the long-term ultimate relative ring deflection under wet conditions
ISO 10928 (1997-08) Plastics piping systems - Glass-reinforced thermosetting plastics (GRP) pipes and fittings
- Methods for regression analysis and their use / Note: To be replaced by ISO/DIS 10928
(2006-03).
ISO 1172 (1996-12) Textile-glass-reinforced plastics, prepregs, moulding compounds and laminates - Determi-
nation of the textile-glass and mineral-filler content - Calcination methods
ISO 14828 (2003-12) Glass-reinforced thermosetting plastics (GRP) pipes - Determination of the long-term spe-
cific ring relaxation stiffness under wet conditions and calculation of the wet relaxation fac-
tor
ISO 15306 (2003-12) Glass-reinforced thermosetting plastics (GRP) pipes - Determination of the resistance to
cyclic internal pressure
the design of locked socket-and-spigot joints, including double-socket joints, with elas-
tomeric seals
ISO 7509 (2000-06) Plastics piping systems - Glass-reinforced thermosetting plastics (GRP) pipes - Determina-
tion of time to failure under sustained internal pressure
ISO 7511 (1999-03) Plastics piping systems - Glass-reinforced thermosetting plastics (GRP) pipes and fittings -
Test methods to prove the leaktightness of the wall under short-term internal pressure
tion of initial specific ring stiffness
the design of bolted flange joints
tion of longitudinal tensile propertiesISO 8521
tion of the apparent initial circumferential tensile strength
the design of cemented or wrapped joints
ISO 8639 (2000-03) Glass-reinforced thermosetting plastics (GRP) pipes and fittings - Test methods for leak-
tightness of flexible joints
ISO/TS 10465-1 (2007-04) Underground installation of flexible glass-reinforced pipes based on unsaturated polyester
resin (GRP-UP) - Part 1: Installation procedures
107
108
Specification of GF Piping Sys-
tems products
Tender invitation
Text for invitation of tenders is needed for pricing con-
struction work. The text has to be well-defined and clear
to every prospective supplier.
The consultant represents the end user and with the in-
vitation to tender takes over the interest of the end user.
Therefore the consultant will define the text for the invi-
tation of tenders.
The tender invitation contains specification of the prod-
ucts to be used (supply) and work to be done (manufac-
ture). With the information a prospective supplier can of-
fer appropriate products and service.
The individual products from different manufacturers are
not always interchangeable regarding quality, condition
of supply and service.
The products have to meet certain specific characteris-
tics and functions which have been specified during de-
sign.
Specifications for products and jointing technologies
from Georg Fischer can be found on our web page at:
http://www.piping.georgfischer.com.
109
Selecting your pipe material -
chemical resistance
Please see our online tool:
http://www.gfps.com/chemical-resistance
110
Design of metric industrial piping systems
Page

Planning criteria for plastic piping systems 148
Long-term behaviour of thermoplastics materials

-- MRS values 149
-- Long-term behaviour of ABS 149
-- Long-term behaviour of PE 151
-- Long-term behaviour of PP 154
-- Long-term behaviour of PVC-U 158
-- Long-term behaviour of PVC-C 160
-- Long-term behaviour of PVDF 163
Application area of pipes and fittings
-- General 165
-- Pressure/temperature diagram for ABS 165
-- Pressure/temperature diagram for PE 165
-- Pressure/temperature diagram for PP 167
-- Pressure/temperature diagram for PVC-U 167
-- Pressure/temperature diagram for PVC-C 168
-- Pressure/temperature diagram for PVDF 168
Calculation of allowable pressure/required wall thickness
-- Selecting plastic piping systems 170
-- Calculating effective design factors and permissible operating pressures 171
Water hammer 172
Plastic pipelines in highly combustible locations/transport of explosive media 174
Plastic pipelines for compressed air 175
Plastic pipelines under vacuum 176
Plastic pipelines for surface finishing and varnishing technology 177
147
Design of metric industrial pip-
ing systems
Planning criteria for plastic piping
systems
Criteria for the Choice of Material
Criteria for the Choice of Dimensions
Criteria for the Choice of Products
148
Long-term behaviour of thermoplas-
tics materials
MRS values
The following table shows the MRS values (see also the
definition in the chapter Basics) for thermoplastic ma-
terials used in industrial applications. These values are
taken from the standards:
• EN ISO 15493 (ABS, PVC-U, PVC-C)
• EN ISO 15494 (PB, PE, PP)
• EN ISO 10931 (PVDF)
Material MRS value

ABS 14 MPa
PE 80 8 MPa
PE 100 10 MPa
PP-H 10 MPa
PP-B 8 MPa
PP-R 8 MPa
PVC-U 25 MPa
PVC-C (pipe material) 25 MPa
PVC-C (fitting material) 20 MPa
PVDF 25 MPa
Long-term behaviour of ABS

Calculation (based on EN ISO 15493:2003)
The following diagram shows the long-term behaviour
of ABS. For the temperature range from 10 °C to 60 °C,
fracture lines are displayed. They are designated as
LPL curves (Lower Predictable Limit), that means, ac-
cording to the definition, 97.5 % of all fracture points are
on or above the curves.
Typically for amorphous thermoplastics like ABS the hy-
drostatic strength diagram shows no knee.
The curves are plotted in a double logarithmic scale (not
linear), please take this into account when reading out
values for stress or time.
The pressure/temperature diagram, which we indicate
for pipes and fittings made of ABS, is derived from the
hydrostatic strength diagram with the design factor in-
corporated and a lifetime of 25 years.
The hydrostatic strength diagram was determined with
the extrapolation method according to EN ISO 9080.
With the following equation (4-parameter model) stress,
temperature or time can be calculated in the tempera-
ture range of 10 °C to 60 °C.
with
t: Time to failure in hours (h)
T: Medium temperature in Kelvin
σ: Hoop stress in MPa (1 MPa = 1 N/mm²)
149
Hydrostatic strength curve ABS (based on EN ISO 15493:2003)
Y Hoop stress in megapascals (Mpa) / 1 Mpa = 1N/mm²

X Time to failure in hours (h)
a Years
150
Long-term behaviour of PE
The following diagrams show the long-term behaviour
of PE80 and PE100. For the temperature range from 10
°C to 80 °C fracture lines are displayed. They are des-
ignated as LPL curves (Lower Predictable Limit), that
means, according to the definition, 97.5 % of all fracture
points are on or above the curves.
Typically for semi-crystalline thermoplastics like PE, the
hydrostatic strength diagram shows a knee.
for pipes and fittings made of PE80 and PE100, is de-
rived from the hydrostatic strength diagram with the de-
sign factor incorporated and a lifetime of 25 years.
First branch (i. e. the left-hand portion of the curves as
shown in the following figures).
PE100:
PE80:
PE63:
with
151
Hydrostatic strength curve PE100 (EN ISO 15494:2003)
Y Hoop stress in megapascals (MPa) / 1MPa = 1N/mm²

a Years
152
Hydrostatic strength curve PE80 (EN ISO 15494:2003)
Y Hoop stress in megapascals (MPa) / 1Mpa = 1N/mm²

a Years
153
Long-term behaviour of PP mit
t: Zeit bis zum Versagen in Stunden (h)
Calculation (based on EN ISO 15494:2003) T: Medium Temperatur in Kelvin
The following diagrams show the long-term behaviour σ: Vergleichsspannung in MPa (1 MPa = 1 N/mm²)
of PP-H, PP-B and PP-R. For the temperature range
from 10 °C to 110 °C fracture lines are displayed. They
are designated as LPL curves (Lower Predictable Lim-
it), that means, according to the definition, 97.5 % of all
fracture points are on or above the curves.
Typically for semi-crystalline thermoplastics like PP, the
hydrostatic strength diagram shows a knee.
for pipes and fittings made of PP-H and PP-R, is de-
rived from the hydrostatic strength diagram with the de-
sign factor incorporated and a lifetime of 25 years.
The dotted lines of the curves apply if tests with longer
testing times are carried out at 90 °, 95 ° and 110 °C.
Attention: The 110 °C curve has been determined sep-
arately using water inside and air outside and has not
been derived from the values of the following equations.
PP-H:
PP-B:
PP-R:
Second branch (i. e. the right-hand portion of the curves

as shown in the following figures).
PP-H:
PP-B:
PP-R:
154
Hydrostatic strength curve PP-H (according EN ISO 15494:2003)
Y Hoop stress in megapascals (Mpa) / 1Mpa = 1N/mm²

a Years
155
Hydrostatic strength curve PP-B (according EN ISO 15494:2003)

a Years
156
Hydrostatic strength curve PP-R (according EN ISO 15494:2003)

a Years
157
Long-term behaviour of PVC-U
of PVC-U. For the temperature range from 20 °C to 60
°C fracture lines are displayed. They are designated as
Typically for amorphous thermoplastics like PVC-U, the
hydrostatic strength diagram shows no knee.
for pipes and fittings made of PVC-U, is derived from
the hydrostatic strength diagram with the design factor
incorporated and a life time of 25 years.
with
158
Hydrostatic strength curve PVC-U

a Years
159
Long-term behaviour of PVC-C
of PVC-C. For the temperature range from 10 °C to 95
Typically for amorphous thermoplastics like PVC-C, the
hydrostatic strength diagram shows no knee.
for pipes and fittings made of PVC-C, is derived from
the hydrostatic strength diagram with the design factor
incorporated and a lifetime of 25 years.
Pipe material in the temperature range of 10 °C to 95
°C
Fitting material in the temperature range of 10 °C to 90

°C
with
160
Hydrostatic strength curve PVC-C Pipe Material

a Years
161
Hydrostatic strength curve PVC-C Fittings Material

a Years
162
Long-term behaviour of PVDF
Calculation (EN ISO 10931)
of PVDF. For the temperature range from 10 °C to 140
for pipes and fittings made of PVDF, is derived from the
hydrostatic strength diagram with the design factor in-
corporated and a lifetime of 25 years.
Second branch (i. e. the right-hand portion of the curves

as shown in the following figures).
with
163
Hydrostatic strength curve PVDF

a Years
164
Application area of pipes and fittings Inch-based systems
General
The choice of material and the pressure rating of the
pipe components are important for both operating safety
and for attaining the specified minimum operational life
of the system.
The decisive factors are:
• operating pressure
• operating temperature
• medium transported
• duration of service.
Separate calculations are necessary if safety factors are
P Permissible pressure in bar, psi
different or the operational lifetime is modified.
T Temperature in °C, °F
The chemical resistance of the material used can be
determined from of our special list for "Chemical resis- Metric-based systems
tance of thermoplastics and elastomers for piping sys-
tems".
Pressure/temperature diagram for ABS

The following pressure/temperature diagram for ABS
pipes and fittings is valid for a lifetime of 25 years.
The design factor of 2.1 for inch-based systems and 1.8
for metric systems recommended by GF is incorporat-
ed.
It can be used for water or media resembling water, in
other words, media which have no derating factor re-
garding the chemical resistance.
Remark: Please take into account the pressure/temper- P Permissible pressure in bar, psi
ature diagrams for valves and special fittings. Because T Temperature in °C, °F
of the construction and/or sealing material used, differ-
ences are possible when compared with pipes and fit-
tings. This information can be found in the planning fun- Pressure/temperature diagram for PE
damentals of the relevant types of valves, respectively PE 100
special fittings. The following pressure/temperature diagram for PE100
The influence of the anti-freeze compound has to be pipes and fittings is valid for a lifetime of 25 years.
taken into account when calculating the allowable oper- The design factor of 1.6 (respective 1.25) recommended
ating pressure. Please contact your GF representative by GF is incorporated.
for further information.
Attention: According to the 10 °C curve in the long-term other words, media which have no derating factor re-
diagram for ABS, the permissible pressure in the tem- garding the chemical resistance.
perature range -50 ° to +10 °C can be
Remark: Please take into account the pressure/temper-
• 7.5 bar for the PN6 system.
ature diagrams for valves and special fittings. Because
• 11.8 bar for the PN10 system. of the construction and/or sealing material used, differ-
The maximum pressure for the PN16 system has been tings. This information can be found in the planning fun-
limited to 16 bar. damentals of the relevant types of valves, respectively
special fittings.
In case of long-term applications at continuous pressure
with temperatures above 40 °C, please contact your GF
representative.
165
Besides the geometric sizes such as SDR, the creep
strength/dimensioning tension and the minimum design
factor are also taken into consideration.
For plastic piping systems intended to carry water, the
nominal pressure value indicates the maximum permit-
ted operating pressure in bar, at a temperature of 20°C,
and 50 years in water, referenced to the minimum value
of the total (calculation) coefficients. It is calculated us-
ing the following equation:
[PN] = 10 • σS / [S] = 20 • σS / (SDR – 1) (σs in MPa, PN
in bar)
Minimum required strength (MRS):
1 Design Factor C = 1.25, S5, SDR11 for 20 °C water, 50 The value of σLCL at 20°C and 50 years in water, round-
years ed down to the next value in the R10 standard series of
2 Design Factor C=1.25, S8.3, SDR17.6 and S8, SDR17 for 20 numbers.
°C water, 50 years
P Permissible pressure in bar, psi σLCL is understood to mean the equivalent stress ascer-
tained for a given period and a given temperature from
the time-dependent creep diagram. LCL stands for Low-
PE 80 er Confidence Limit. The R10 standard series of num-
The following pressure/temperature diagram for PE80 bers is a Renard standard series of numbers as per ISO
pipes and fittings is valid for a lifetime of 25 years. 3 and ISO 497.
The design factor of 1.6 recommended by GF is incor- Design stress (σS):
porated. The permitted stress for a particular application or oper-
It can be used for water or media resembling water, in ating conditions stated in megapascal. It is derived by
other words, media which have no derating factor re- dividing the MRS by coefficient C and is calculated as
garding the chemical resistance. shown in the equation below:
Remark: Please take into account the pressure/temper- σS = MRS / C
ature diagrams for valves and special fittings. Because The calculated value is rounded down to the next value
of the construction and/or sealing material used, differ- in the R10 standard series of numbers.
tings. This information can be found in the planning fun- Total operating (calculation) coefficient (C):
damentals of the relevant types of valves, respectively A total coefficient having a value greater than one,
special fittings. which takes into account both the operating conditions
and also the characteristics of the pipeline component
In case of long-term applications at continuous pressure that have not yet been entered into the lower confidence
with temperatures above 40 °C please contact your GF limit σLCL.
representative.
If we use the above definition to calculate the relevant
nominal pressure for both SDR classes, the result for a
PE 100 pipe is as follows:
SDR17 SDR17.6
MRS = 10 MPa MRS = 10 MPa
C = 1.25 (minimum factor) C = 1.25 (minimum factor)
σs = 8.0 MPa σs = 8.0 MPa
PN = 10 bar PN = 9.6 bar
The above definitions thus produce a difference of 0.4

bar in PN, but in actual practice this does not matter, as
shown below:
1.) Industrial pipelines are normally designed for a ser-
vice life of 25 years. If from the time-dependent creep
P Permissible pressure in bar, psi diagrams we ascertain for ELTEX TUB 121 or CRP
T Temperature in °C, °F 100 an equivalent stress of σLCL for the operating point
of 25 years and 20°C, we obtain a tension of 10.6
Comparison of nominal pressure for SDR17 MPa (minimum value of both PE100 materials as per
and SDR17.6 manufacturer's data).
Ascertaining the nominal pressure (PN) 2.) If we use this tension to ascertain the dimensioning
According to the standard, the nominal pressure is a tension σS, and do not round it down, we obtain the val-
numeric measure of the size of a pipeline part, which ue of 8.48 MPa.
refers to the mechanical properties of that pipeline part.
3.) Thus the actual nominal pressure in practice is:
for SDR 17 =>PN = 10.6 bar and for
SDR 17.6 =>PN = 10.2 bar.
166
To summarise: Both SDR classes comply with re- Pressure/temperature diagram for PP seg-
quirements for industrial applications mentioning a ment-welded fittings
PN10 system. Segment-welded fittings have a reduction factor of
0.8 on the allowable operating pressure:
Comparison of geometric dimensions
The two SDR classes differ only slightly in wall thick-
ness, as can be seen from the diagram below. This
shows that there is an area where the wall thickness
complies with both requirements of both SDR classes.

PROGEF Natural
The following pressure/temperature diagram for PRO-
d Outside pipe diameter GEF Natural pipes and fittings is valid for a lifetime of 25
e Wall thickness years.
For butt fusion the wall thickness gap may not ex- The design factor of 2 recommended by GF is incorpo-
ceed 10 %. Looking at the differences of the wall thick- rated.
nesses of SDR17 and SDR17.6 the resulting gap is It can be used for water or media resembling water, in
much lower, that means butt fusion of both SDR's is no other words, media which have no derating factor re-
problem. garding the chemical resistance.
Pressure/temperature diagram for PP Remark: Please take into account the pressure/temper-
PROGEF Standard and Plus of the construction and/or sealing material used, differ-
The following pressure/temperature diagrams for PP ences are possible when compared with pipes and fit-
pipes and fittings are valid for a lifetime of 25 years. tings. This information can be found in the planning fun-
damentals of the relevant types of valves, respectively
The design factor of 2 recommended by GF is incorpo-
special fittings.
rated.
Remark: Using PROGEF Natural at higher tempera-
They can be used for water or media resembling water,
tures can lead to a discoloration of the material.
in other words, media which have no derating factor re-
tings. This information can be found in the planning fun-
special fittings.
Pressure/temperature diagram for PP pipes and in-
jection-moulded fittings
1) Not longer in product range
Pressure/temperature diagram for PVC-U

The following pressure/temperature diagram for PVC-U
The design factor of 2.5 recommended by GF is incor-
porated.
P Permissible pressure in bar, psi It can be used for water or media resembling water, in
T Temperature in °C, °F other words, media which have no derating factor re-
In case of applications with temperatures in the range of
the dotted lines please contact your GF representative.
167
Remark: Please take into account the pressure/temper- Remark: Please take into account the pressure/temper-
ature diagrams for valves and special fittings. Because ature diagrams for valves and special fittings. Because
of the construction and/or sealing material used, differ- of the construction and/or sealing material used, differ-
ences are possible when compared with pipes and fit- ences are possible when compared with pipes and fit-
tings. This information can be found in the planning fun- tings. This information can be found in the planning fun-
damentals of the relevant types of valves, respectively damentals of the relevant types of valves, respectively
special fittings. special fittings.
Metric-based systems Under certain conditions working temperatures up to 90
°C are possible for limited times. Please contact your lo-
cal GF representative for advice on any applications ly-
ing outside of our standard guidelines.

Inch-based systems P Permissible pressure in bar, psi

Pressure/temperature diagram for PVDF

The following pressure/temperature diagram for PVDF
The design factor of 2.0 (respectively 1.6) recommend-
ed by GF is incorporated.
T Temperature in °C, °F ences are possible when compared with pipes and fit-
tings. This information can be found in the planning fun-
Attention: PVC-U solvent cement jointing fittings
d200 to 280 from Georg Fischer are designed and testet
special fittings.
to a nominal pressure of PN10. Sizes d315 to d400 are
designed and testet to a nominal pressure of PN6. Attention: This diagram can only be used for applica-
tions with liquids!
Our experience and tests show that pipes equal or
greater than d315 can be slightly oval, which could pro- In case of long-term applications at continuous pressure
duce a heightened cementing gap. with temperatures above 100 °C, please contact your
GF representative.
Georg Fischer therefore recommends, that pipes equal
or greater than d315 should be operated at a maximum
working pressure of 6 bar. Please observe also the spe-
cial information for these dimensions in the solvent ce-
menting instruction for PVC-U.
Pressure/temperature diagram for PVC-C

The following pressure/temperature diagram for PVC-C
The design factor recommended by GF is incorporated.
It can be used for water or media resembling water, in P Permissible pressure in bar, psi
168
Application example for the material PVDF
For continuously changing conditions of temperature or
pressure the Miner's rule can be applied. The following
example, an application in the pharmaceutical industry,
shows the calculation steps necessary:
Calculation basis:
Pipe SDR21
Design factor: C = 2.0
Required operating lifetime 15 years
Main application:
Purified water (PW) at 25 °C and 5 bar pressure.
Steam Sterilisation:
Saturated steam at 135 °C and 2.2 bar pressure for 30
minutes daily.
The Miner's rule (calculation method for cumulative
damage) is used for applications with varying conditions
during their expected lifetime.
This takes into account the amount of time spent at
each of the operating conditions:
a1 a2 % of time spent at each condition

T1 T2 lifetime at the several operating conditions (pressure and
temperature constant)
Tx calculated lifetime at intermittent load
for the above example the lifetimes are given as :

T1 ≥ 50 years for the water
T2= 4471 hrs for the steam
The % of time spent at each condition is :
a1 = 97.9 %
a2 = 2.1 %
from the equation :
Tx = 214608 hrs = 24.5 years
It can be seen that this is higher than the specified oper-
ating lifetime and is therefore acceptable.
169
Calculation of allowable pressure/re- We always recommend giving the dimension and
the wall thickness, as well as the pipe series S or
quired wall thickness SDR.
Selecting plastic piping systems
The dimensioning of thermoplastic pipes subjected to
internal pressure is strictly according to strength require-
ments and is calculated according to the vessel formu-
la. All pipe dimensions listed in the standards are based
on this formula. Deviations only occur in the lower range
of diameters, since practical and manufacturing consid-
erations make it necessary to maintain certain minimum
thicknesses.
where
e wall thickness in mm
d outside pipe diameter in mm
p allowable operating pressure in bar
σzul allowable hoop stress in N/mm²
The designation "Nominal pressure" PN (also

known as pressure level) is alone not enough!
The PN classification generally used all over the world
is confusing where butt fusion is concerned.
In the case of thermoplastic pipes the established prac-
tice is to use pressure-neutral descriptions for pipes of
the same pressure capacity. This makes it easy to use
pipes in different applications or under different condi-
tions.
ISO 4065 classifies pipes into series according to pres-
sure rating, so that pipes with the same series number
have the same pressure rating as is also the case in
designation according to nominal pressure. The series
are denoted by the letter S.
The serial numbering is based on the following formula:
S is thus a dimensionless quantity.
As an example, for 110 x 10 mm PP pipe

S = 5 = (110 - 10) / (2 ⋅ 10)
SDR is also used; SDR stands for Standard Dimension
Ratio. It is the ratio of the diameter to the thickness of
the wall.
The series and the SDR are related by the formula

SDR = 2 ⋅ S + 1
In the case of the example above,
SDR = 110 / 10 = 11 = 2 ⋅ 5 + 1
All three standards, PN, S and SDR, are currently avail-
able commercially.
170
Calculating effective design factors and
permissible operating pressures
To calculate the design factor and allowable operating
pressure, it is necessary to know the long-term stress
behaviour of the material. Such a diagram allows the
long-term stress σ to be read depending on the desired
service life and working temperature. Since the wall
thickness of fittings and valves is generally greater than
that of the pipe of the equivalent pressure rating, all cal-
culations can be based on the outside diameter and wall
thickness of the pipe. The effective design factor is giv-
en by the formula:
where
C design factor
σ hoop stress in N/mm²
e wall thickness of a pipe in mm
d outside diameter of pipe in mm
p operating pressure in bar
Similarly, the permissible operating pressure is given by

rewriting the formula above as:
Example:
Intended operating life: 25 years
Max. operating temperature: 40 °C
Max. operating pressure: 3 bar
Material: PVC-U
Pressure rating: PN 16
Pipe dimensions:110 x 8.1 mm
σ from hydrostatic strength curves: 15.5 N/mm²
C = (15.5 ⋅ 20 ⋅ 8.1) / (3 ⋅ (110 - 8.1)) = 8.2 >2.5
For the sake of clarity, the calculations are carried out
using the example above, but using the usual minimum
design factor for PP-H instead of the one calculated
p = (20 ⋅ 8.1 ⋅ 15.5/2.5) / (110 - 8.1) = 9.9 bar
Attention: The calculation indicated above applies on-
ly to freely moving pipelines. Pipes which are fixed in
the axial direction (fixed installation) must be checked
for buckling. In most cases, this leads to a reduction of
maximum inner pressure as well as shorter distances
between the support brackets. Furthermore, the forces
which act on the fixed points must be taken into consid-
eration. For assistance, please contact your nearest GF
representative.
171
Water hammer vw velocity of pressure wave (m/s)
Water hammer, or surge pressure, is a term used to de- K bulk modulus of elasticity of fluid (Pa)
scribe dynamic surges caused by pressure changes in a ρ fluid density (kg/m³)
piping system. They occur whenever there is a deviation
from the steady state, i.e. when the velocity of the fluid E modulus of elasticity of pipe wall (Pa)
is increased or decreased, and may be transient or os- di pipe inner diameter (mm)
cillating. Waves of positive or negative pressure may be e pipe wall thickness (mm)
generated by any of the following:
Step 2
• opening or closing of a valve
Calculate maximum pressure change due to surging.
• pump startup or shutdown
Δp = vw · Δv · ρ · 10 –5
• change in pump or turbine speed

• wave action in a feed tank All pressure rises inducted by a flow reduction will
have a corresponding pressure drop on the other
• entrapped air
side(vacuum). If this exceeds the expected static mini-
The pressure waves travel along at speeds limited by mum operation pressure, it must be compared with the
the speed of sound in the medium, causing the pipe to pipe collapsing pressure to evaluate the safety factor in
expand and contract. The energy carried by the wave step 4.
is dissipated and the waves are progressively damped Δp maximum pressure change (bar)
(see Figure).
vw velocity of pressure wave (m/s) (see step 1)
The pressure excess to water hammer must be consid-
ered in addition to the hydrostatic load, and this total Δv change in fluid velocity (m/s) (=v1 - v2)
pressure must be sustainable by the piping system. In v1 velocity of fluid before change (m/s)
the case of oscillatory surge pressures extreme caution v2 velocity of fluid after change (m/s)
is needed as surging at the harmonic frequency of the
system could lead to catastrophic damage. ρ density of fluid (kg/m³)
Step 3
Calculate the maximum and minimum total pressures.
pmax = p + Δp
pmin = p - Δp
pmax maximum total pressure (bar)
pmin minimum total pressure (bar)
p expected operating pressure (bar)
Δp change due to surge pressure (calculated in step 2)
Damped pressure wave Step 4

l Wave length Calculate the effective safety factor for the maximum to-
p Pressure change tal pressure found in step 3.
The maximum positive or negative addition of pressure

due to surging is a function of fluid velocity, bulk mod-
ulus of elasticity of the fluid, pipe dimensions and the
modulus of elasticity of the pipe material. It can be cal-
culated using the following steps. Cmax safety factor (dimensionless)
σ circumferential stress (N/mm²)
Step 1
Determine the velocity of the pressure wave e pipe wall thickness (mm)
d outside diameter of pipe (mm)
pmax maximum total pressure (bar) (as calculated in step 3)
The value for the circumferential stress can be found

from the long-term regression curves. As most surges
last for a matter of seconds, the value for the circumfer-
In thermoplastic pipes the modulus of elasticity varies ential stress can be read from the graphs as the value
with age and temperature so service life and tempera- for a load duration of 0.1 h. The exception to this rule
ture must be known for an accurate calculation of water is when the pressure surges are oscillatory (e. g. from
hammer. a positive displacement pump). In this case the system
must be treated as if a load equal to the maximum total
pressure, pmax, exists throughout the lifetime of the pipe.
172
Step 5 Assume water velocity goes to zero after the valve is
For infrequent surges the common minimum values can closed, i. e. Δv = 1.53 m/s.
be used for safety factors. For frequent surges it should
Find pressure change
be at least 3.
Δp = 292 · (1.53) · 10³ · 10 = 4.47 bar
-5
If the safety factor found in step 4 does not meet these

criteria for safe operation, an increase in pipe diameter Step 3
size should be considered, or measures should be tak- Find maximum pressure
en to reduce surge occurrance (i. e. actuated valves,
surge tanks, slow start-up pumps). pmax= 10 + 4.47 = 14.47 bar
When using actuated valves it is common to design Δp smaller than P so no need to consider minimum
valves with closure times greater than the critical peri- pressure.
od Tc to reduce water hammer. The critical period is the Step 4
time taken by the pressure wave to complete one circuit Find the circumferential stress from PP-H long-term re-
of the pipeline. gression curve. Take the value for load duration of 0.1
h as, for non-oscillatory surges, the pipe needs to with-
stand this extra pressure for only a matter of seconds.
So
Tc critical period (s)

L pipe length (m)
vw pressure wave velocity (m/s) (see step 1)
The following example should explain the calculations:

A water pipeline from a storage tank is connected to a
master valve, which is hydraulically actuated with an
electrical remote control. The valve closing time is 1.5 s Step 5
and the water flow rate is Q= 35 m³/h. The minimum safety factor for PP-H can be set to 2.0.
Here C = 2.42 >2.0 so this piping is suitable for infre-
The pipe details are: quent surges. However it would not be suitable if fre-
quent surging occurred as we need C > 3 in this case.
material PP-H
Adjustments would need to be made to pipe dimen-
outer diameter 110 mm sions, or valve closing time, to reduce water hammer.
wall thickness 10 mm What is the critical period?
pipeline length 500 m
operating temperature 40° C
modulus of elastictity E= 800 N/mm² = 800 x 106
Pa
In this example the valve closing time is less than this
Other information: value. By increasing the closing time above this criti-
water density δ 10³ kg/m³
cal period, water hammer would be reduced. The pip-
ing would then be suitable for all situations involving fre-
bulk modulus of water K 2.05 GPa quent water surges.
Step 1
Find velocity of pressure wave
Step 2
Find velocity of fluid before change
173
Plastic pipelines in highly com- Installation in premises where explosive gas-air
mixtures can occur
bustible locations/transport of explo- • Avoid the accumulation of explosive mixtures by pro-
sive media viding for e. g. good ventilation or air extraction.
In their normal form the thermoplastics usually used for • Avoid the accumulation of electrical charge by ionising
piping systems, namely ABS, PVC-U, PVC-C, PP, PE the atmosphere.
and PVDF, are non-conductive materials. Their specific • Discharge static electricity, e. g. by coating the pipe
resistance exceeds 10 Ωcm. Thus the possibility of an
6
surface with a solvent-free paint containing metallic
electrical charge accumulating cannot be excluded. This powder or by wrapping the pipe in a conducting foil. It
must be borne in mind when designing and operating a is essential to earth the pipe.
pipe system. But by taking certain precautions detailed
• Avoid the accumulation of electrical charge by in-
below, the accumulation of electrical charge can be pre-
creasing the relative humidity of the air. A conductive
vented.
film of water on the surface of the pipe improves the
Introduction conductivity. There is hardly any accumulation of elec-
The non-conductivity of most plastics has led to their trostatic charge when the relative atmospheric humidi-
widespread application in electrical engineering and ty exceeds 65 %. Since ABS, PVC-U, PVC-C, PE, PP
electronics. But this property can be a disadvantage un- and PVDF are hydrophobic, the formation of an intact
der certain circumstances in other applications. In the film of moisture should be facilitated by treating the
case of plastic piping systems, the question of electro- surface of the pipeline with a hygroscopic soap.
static charge becomes significant when electrically non- • We advise strongly against relying solely on treating
conductive media are to be transported and when the the pipeline with an antistatic and hygroscopic soap
pipes are installed in potentially explosive premises. In to improve its conductivity because its effectiveness is
both of these cases the non-conductivity of the plastics of limited duration and accidental damage to the film
is not only a disadvantage but could constitute a defi- cannot be ruled out.
nite danger. ABS, PVC-U, PVC-C, PE, PP and PVDF
belong to the class of electrically non-conductive ma- The transport of electrically non-conductive media
terials. Electrically non-conductive materials are those • As a rule plastic pipes are not to be recommended for
whose specific resistance exceeds 10 Ωcm. The values
6
the transport of dry substances which are electrically
for the materials listed lie in the order of 10 Ωcm.
15
non-conductive due to the effects of build-up of elec-
The danger of accumulating electrostatic charge arises trostatic charge and the extensive wear on the mate-
whenever specific resistance exceeds 10 Ω. This must
9 rial. A preliminary test is recommended should plastic
be taken account of in certain operating environments. pipes be used for such applications.
• Electrically non-conductive combustible gases or flu-
For example, in the mining industry in general, and es-
ids should only be transported in closed pipeline sys-
pecially in areas exposed to the danger of firedamp,
tems.
safety dictates that plastics be used only if their specif-
ic resistance does not exceed 10 Ωcm (measured at 20
8
°C and 35 % humidity).
Similar restrictions apply to the installation of plastic
pipes wherever ignitable mixtures could occur. There is
no danger arising from the use of plastic pipes to trans-
port ignitable fluids as long as the system is a closed
one. Slower flow rates also reduce the accumulation of
electrostatic charge.
It is possible in principle to make non-conductive plas-
tics conductive by means of special measures, e. g.
adding carbon. But such additives could detrimentally
affect other desirable properties. It is therefore impera-
tive to judge each case individually on its merits to de-
cide which material offers the best solution.
Whenever plastic piping is to be installed in premis-
es where explosive gas-air mixtures could arise, and
whenever plastic pipes are used for the transportation
of electrically non-conductive media, the following points
must be observed during planning.
174
Plastic pipelines for compressed air Synthetic oils (with Polyalkylene gly- recommended
O as an cols
Introduction
Plastic pipelines have been used to transport com- additional element Poly-α-olefins recommended
pressed air for many years. Georg Fischer have carried of
out extensive tests to ensure the optimum choice of ma- molecular struc- Polyesters do not use !
terials and jointing methods. ture)
Experience has shown that oil originating from compres- Diesters do not use !
sors can be found to a greater or lesser extent in the
compressed air pipelines. This can only be avoided by Synthetic oils (with Silicon oils recommended
careful and regular servicing of the filters installed after Si, P, N
the compressors. These mineral oils vary considerably or F as an addi- Phosphoric esters do not use !
in their composition and they can also contain aromatic tional element
substances.
of molecular struc- Aromatic amines do not use !
In addition to the effect that the compressor oils may ture)
have on the plastic material, we must also take into ac- Fluorine esters do not use !
count the failure characteristics of the material.
Poly-α-olefins / do not use !
Recommended material for compressed air polyol esters
pipelines
For compressed air pipelines we recommend Please take into account the recommendations
PE (Polyethylene) or PB (Polybutylene). concerning the commissioning of compressed air
pipelines given in the chapter "Final Testing".
Both materials are lightweight, easy to install and corro-
sion-proof; they also have the advantage of high tensile Maximum allowable operating pressure for PE
strength. Therefore we recommend polyethylene up to for compressed air
a minimum temperature of -40 °C (e. g. outdoor applica- Please consider the following pressure temperature di-
tions), polybutylene up to a minimum temperature of 0 agram (PE80 and PE100) for compressed air pipelines
°C (e. g. indoor installations). Danger of explosion is ex- made of polyethylene. This diagram is based on a life-
cluded if you follow the operating instructions. time of 25 years and a design factor of 1.6. The envi-
ronment temperature has to be taken into account, for
PE and PB are generally chemically resistant to com- example for an installation under a sunny roof or in a
pressor oils. Only for a few oils, which contain esters or room with compressors running. For safety reasons
aromates, chemical resistance cannot be guaranteed. we recommend for compressed air pipelines SDR11 or
Sealing materials, such as NBR or FPM, which are reg- SDR7.4.
ularly used for compressed air networks, are also en-
dangered in such cases. In case of long term applications at continuous pressure
with temperatures above 40 °C, please contact your GF
In order to make it easier for the operator of a com- representative.
pressed air system to choose a compressor oil, we have
summarised many of the oils offered on the market
and have divided them into sections according to their
chemical structure. After consulting the oil supplier, it
is also possible to choose an oil which is not on the list
since we do not claim its entirety. The type of oil used
must be included in one of the categories deemed by us
as suitable. We also recommend that the oil selected is
approved by the compressor manufacturer as well.
You will find more information on polybutylene in the
planning fundamentals of ”Piping Systems for Building
Technology”.
Suitability of air compressor oils for compressed air
lines made of polyethylene (PE)
P Permissible pressure in bar / psi
Refined products Paraffinic oils of recommended T Environment temperature in °C / °F
of petroleum (min- aliphatic hydrocar-
eral oils) bons
Naphthenic oils of recommended
alicyclic hydrocar-
bons
Aromatic oils do not use !
175
Plastic pipelines under vacuum Valves
Ball valves are the preferred valve types in vacuum sys-
The mechanical load with absolute vacuum corresponds
tems. The permissible vacuum for valves is listed in the
to a differential partial vacuum of 1 bar, i. e. the effective
following table:
pressure on the pipe inner wall is 1 bar less than the
pressure on the outer wall under standard atmospheric Valve type DN Permissible differential par-
pressure. tial vacuum up to a maximum
temperature of 50 °C
With differential partial vacuum special attention must
be paid to the dimensional stability of the pipe. It can be Ball valve type 10 - 100 1 bar
calculated with the classical buckling formula for cylin- 546
drical pipes [1]: Diaphragm 15 - 50 0.5 bar
valve types
514-519, 314-
319
Butterfly valve 65 - 200 1 bar
type 567, 367
with
Pk: critical buckling pressure in N/mm² 250, 300 0.65 bar
(1 N/mm² = 10 bar) Ball valve type 10 - 100 0.8 bar
Ec: long term creep modulus in N/mm² 375
µ: Poisson's ratio
e: wall thickness in mm [1] Menges G. and E. Gaube: Bending and buckling of
r: mean pipe radius in mm thermoplastics from the example of hard polyethylene,
Plastics Band 58 (1968), Book 9, p. 642-648
A pipe under absolute vacuum (differential partial vac-
uum 1 bar) is adequately dimensioned against buck- [2] DVS 2205-1
ling when the critical buckling pressure Pk≥ 2 bar, i.e.
when a minimum safety factor of 2 is calculated [2]. Any
influence caused by out-of-roundness and eccentrici-
ty must be specially taken into account. With these as-
sumptions, the following maximum application tempera-
tures are obtained for the various pipe materials (taking
account of the general application temperature limits for
the specific material). Thinner walled pipe series are un-
suitable under the given conditions.
(25 year values: Poisson's ratio µ = 0.4; safety factor =
2)
Pipes: Maximum application temperatures under
vacuum (1 bar differential partial vacuum)
ABS PVC-U PVC-C
PN10, SDR17 PN10, SDR21 PN10, SDR21
up to 60 °C up to 40 °C up to 70 °C
PN16, SDR11 PN16, SDR13.6 PN16, SDR13.6
PE80 PE100 PP

PN10, SDR11 PN16, SDR11 PN10, SDR11
Pipes: Maximum application temperatures under

vacuum (1 bar differential partial vacuum) or under
0.4 bar differential partial vacuum for PVDF PN 10
system
PVDF for Δp = 0.4 PVDF for Δp = 1.0
bar bar
PN10, SDR33 PN16, SDR21
up to 20 °C up to 40 °C
Fittings
Our fittings are less critical in vacuum applications than
pipes because of their increased wall thickness.
176
Plastic pipelines for surface finishing
and varnishing technology
Silicone-free / cleaned
Growing environmental awareness, continuously in-
creasing requirements and regulations in the field of tox-
ic substances emission (TA air) have led to the develop-
ment of water-soluble paints and varnishes.
With new varnishing technologies, up to 90 % of the
emission values can be reduced. For the production,
transport and processing of water-soluble paints and
varnishes only pipeline components may be used which
are free from substances interfering with the varnish-
ing process, such as silicones, certain greases, oils and
waxes.
GF - an experienced partner
GF has worked closely from the very beginning with
manufacturers, plant constructors and operators in this
special sector of surface finishing and varnishing tech-
nology. We have successfully supplied plant construc-
tors and users of varnishing processes for years, e.
g. the automobile industry. The highest demands are
made of our products:
• silicone-free separating agents for spraying
• absolute care in cleaning, installation and packing
• uncompromising quality control
• quality assurance system certified to ISO 9001.
Fittings
The composition of the raw material (granulate) is sili-
cone-free. All moulds for standard fittings are sprayed
with silicone-free separating agents. Following injection
moulding the fittings are directly packed.
GF recommends the choice of a complete packing
unit (that means SP = Standard pack or GP as Gross
pack) when ordering fittings to exclude contamination
en route to the final consumer.
Valves and unions
The individual components of the valves and unions are
cleaned with distilled water (14 MΩ) in a special clean-
ing process. They are assembled in a special working
area with silicone-free protective gloves.
Sliding components are lubricated slightly and comply
with requirements for special lubricants for varnishing,
e. g. Syntheses PRO AA4. Each valve and union is des-
ignated with the following sticker:
Valves and unions are individually packed in a welded

bag.
Connecting seals
Connecting seals undergo the same production, clean-
ing and packing processes as hand-operated valves
and unions.
Maintenance
For safety reasons we recommend exchanging the en-
tire body when dismantling the valves.
177
178
Hydraulic calculation and pressure losses of metric indus-
trial piping systems
Page

Hydraulic calculation
-- What size should the pipe be? 180
Pressure losses
-- Pressure loss in straight pipes 185
-- Pressure loss in fittings 185
-- Pressure loss in valves 185
-- Pressure difference caused by static pressure 186
-- Sum of pressure losses 186
-- Example for pressure loss calculation 186
179
Hydraulic calculation and pres-
sure losses of metric industrial
piping systems or
Hydraulic calculation
What size should the pipe be?
v flow velocity in m/s
Formulas
The following formula can be used for a first approxima- di inside pipe diameter in mm
tion of the pipe size required for a given flow rate: Q1 flow rate in m³/h
Q2 flow rate in l/s
or 354 conversion factor for units
1275 conversion factor for units
where:
Relation ship: Outside diameter to inside diam-
v flow velocity in m/s eter
di inside pipe diameter in mm To find the outside diameter using the inside diameter
and the applicable SDR, use the following formula:
Q1 flow rate in m³/h
Q2 flow rate in l/s
18.8 conversion factor for units
35.7 conversion factor for units
Correlation outside diameter to inside diameter
The flow velocity must first be approximated according for SDR13.6, SDR21 and SDR33
to the intended use of the pipeline. Standard values for d i SDR33
the flow velocity are: (mm) (PVDF)
Liquids 85 d90
v = 0.5-1.0 m/s for suction
103 d110
v = 1.0-3.0 m/s for delivery
117 d125
Gases
v = 10-30 m/s 132 d140
The calculations of pipe diameter have not taken into 150 d160
account hydraulic losses. These require special calcu- 169 d180
lations for which we offer the following information and
recommendations. 188 d200
211 d225
Conversion table
235 d250
m³/h l/min l/s m³/s
263 d280
1.0 16.67 0.278 2.78 x 10-4
296 d315
0.06 1.0 0.017 1.67 x 10-5
333 d355
3.6 60 1.0 1.00 x 10-3
375 d400
3600 60000 1000 1.0
422 d450
The following example shows how to utilise the for-
mulas:
PP pipe SDR 11
Flow rate Q2 = 8 l/sec
Flow velocity v = 1.5 m/sec
Inside pipe diameter ? mm
In this case a DN 80 or 3" pipe can be used.

After defining the inner diameter, the real flow velocity
can be calculated with the following formula:
180
d i SDR13.6 d i SDR21 258 d315 278 d315
(mm) (PVC-U, PVC-C) (mm) (PVC-U, PVDF)
290 d355 313 d355

16 327 d400 353 d400
17 d20 d20
21 368 d450 397 d450
21 d25 d25
28 409 d500 441 d500
27 d32 d32
36 458 d560 494 d560
34 d40 d40
45 515 d630 556 d630
43 d50 d50
57 581 d710 626 d710
54 d63 d63
68 655 d800 705 d800
64 d75 d75
77 d90 81 d90 Nomogram for easy determination of diameter
94 d110 100 d110 and pressure loss
The following nomogram simplifies the determination of
107 d125 113 d125 the required diameter. In addition the pressure loss of
119 d140 127 d140 the pipes per meter pipe length can be read off.
136 d160 145 d160 Remark: The determined pressure loss from the nomo-
gram applies only to a density of the flow medium of
163 d180
1000 kg/m³, e. g. for water. Further pressure losses of
181 d200 fittings, valves, etc. have to be considered as shown in
204 d225 the following.
226 d250 Example how to use the nomogram:
Starting with a flow velocity of 1.5 m/sec draw a line
253 d280
through the required quantity of flow (e. g. 30 m³/h)
285 d315 until you cut the axis of the inside diameter di (≈ 84
362 d400
mm). Then select a diameter nearby (74 mm at SDR11)
and draw a second line back through the same quantity
Correlation outside diameter to inside diameter of flow to the axis of the pressure losses Δp (5 mbar per
for SDR11 and SDR17 meter pipe).
d i SDR11 d i SDR17

(mm) (PE, PP) (mm) SDR17.6
(ABS, PE, PP)
16 d20 16 d20
20 d25 21 d25
26 d32 28 d32
33 d40 35 d40
41 d50 44 d50
52 d63 56 d63
61 d75 66 d75
74 d90 79 d90
90 d110 97 d110
102 d125 110 d125
115 d140 124 d140
131 d160 141 d160
147 d180 159 d180
164 d200 176 d200
184 d225 199 d225
205 d250 221 d250
229 d280 247 d280
181
Nomogram for metric pipes (SDR13.6, SDR21, SDR33)
182
Nomogram for metric pipes (SDR11, SDR17)
183
Nomogram for inch pipes
184
Pressure losses Fitting type Coefficient of resistance ζ
90 ° bend bending radius R ζ-value
Pressure loss in straight pipes
1.0 * d 0.51
When calculating the pressure loss in straight pipe
lengths there is a distinction between laminar and tur- 1.5 * d 0.41
bulent flow. The important unit of measurement is the 2.0 * d 0.34
Reynold's number (Re). The changeover from laminar
4.0 * d 0.23
to turbulent flow occurs at the critical value, Reynold’s
number (Re) = 2320. 45 ° bend bending radius R ζ-value
Laminar flow occurs, in practice, particularly in the 1.0 * d 0.34
transport of viscous media, i. e. lubricating oil. In the 1.5 * d 0.27
majority of applications, including media similar to wa-
ter, a turbulent flow, having an essentially steady veloci- 2.0 * d 0.20
ty in a cross-section of pipe, occurs. 4.0 * d 0.15
The pressure loss in a straight length of pipe is inverse- 90 ° elbow 1.2
ly proportional to the pipe diameter and is calculated by
45 ° elbow 0.3
the following formula:
Tee 90 °
*)
1.3
Reduction (Contraction) 0.5
Reduction (Extension) 1.0
Connection (Flange, union, d >90 mm: 0.1
Note: In practice, when making a rough calculation (i. welding between two pipes) 20 ≤ d ≤ 90 mm:
e. smooth plastic pipe and turbulent flow) it is enough to 1.0 to 0.1:
use the value λ = 0.02 to represent the hydraulic pres-
sure loss. d20: 1.0 d50: 0.6
d25: 0.9 d63: 0.4
where: d32: 0.8 d75: 0.3
d40: 0.7 d90: 0.1
ΔpR pressure loss in a straight length of pipe in bar
λ pipe friction factor *) For a more detailed view differentiate between coa-
L length of the straight length of pipe in m lescence and separation. Values for ζ up to a maximum
of 1.3 can be found in the respective literature. Usual-
di inside diameter of pipe in mm
ly the part of a tee in the overall pressure loss is very
ρ density of transported media in kg/m³ small, therefore in most cases ζ = 1.3 can be used.
(1 g/cm³ = 1000 kg/m³)
Calculation of the pressure loss
To calculate the total pressure loss in all fittings in a
pipeline take the sum of the individual losses, i. e. the
Pressure loss in fittings sum of all the ζ-values. The pressure loss can then be
calculated according to the following formula:
Coefficient of resistance
The pressure losses depend upon the type of fitting as
well as on the flow in the fitting. The so-called ζ-value is
used for calculations.
where
ΔpFi pressure loss in all fittings in bar
Σζ sum of the individual losses
ρ density of the transported medium in kg/
m³
(1 g/cm³ = 1000 kg/m³)
Pressure loss in valves

The kv factor is a convenient means of calculating the
hydraulic flow rates for valves. It allows for all internal
resistances and for practical purposes is regarded as
reliable.
The kv factor is defined as the flow rate of water in litres
per minute with a pressure drop of 1 bar across the
valve.
185
The technical datasheets for valves supplied by GF con- 12 el-
tain the so-called kv values as well as pressure loss di- bows
agram. The latter make it possible to read off the pres- 90°
sure loss directly. But the pressure loss can also be cal- 4 el-
culated from the kv value according to the following for- bows
mula: 45°
3 tees
3 unions
2 flange
adapters
where: 1 di-
aphragm
ΔpAr pressure loss of the valve in bar valve,
Q flow rate in m³/h 30
%
ρ density of the medium transported in kg/ opened
m³
(1 g/cm³ = 1000 kg/m³)
kv valve flow characteristic in m³/h.
Height difference 2.0 m
The wall thickness of this pipeline can be calculated
with the SDR:
Pressure difference caused by static pres-
sure
Compensation for a geodetic pressure difference may
be necessary when a pipeline is vertically installed. The
pressure difference can be calculated with the following The inside diameter of the pipeline is as follows:
formula:
With the required quantity of flow of 1.5 l/sec the flow

where:
velocity is as follows:
Δpgeod geodetic pressure difference in bar
ΔHgeod difference in elevation of the pipeline in m
ρ density of media kg/m³
(1 g/cm³ = 1000 kg/m³)
Calculation of pressure losses
Pressure loss of strait pipes:
Sum of pressure losses
The sum of all the pressure losses in the pipeline is then
given by
Pressure loss of fittings and connections:
Example for pressure loss calculation

The following example shows the calculation to deter-
mine the pressure loss of a pipeline:
PVDF-pipeline d40, SDR 21 with a quantity of flow of Pressure loss of the valve, 30 % opened. With the flow
1.5 l/sec, medium stannous chloride, density 1.9 g/cm³ characteristics diagram, type 314, and 30% lift a per-
centile kv-value of 50 % can be read out, that means 50
Length of strait pipes: 15 m % of kv100 values: 0.5 * 21.2 m³/h (quantity of flow 1.5
l/sec = 5.4 m³/h):
Amount of fittings:
Pressure loss of height difference:
Total pressure loss of the pipeline:
186
ΣΔp = 0.17 bar +0.47 bar + 0.49 bar + 0.38 bar
ΣΔp = 1.51 bar
187
188
Installation of metric industrial piping systems
Page

z-dimension method 190
Handling plastic pipeline systems 194
3D, 2D CAD-Engineering 195
Change in length and flexible sections

-- Introduction 196
-- Flexible sections of ABS pipelines 199
-- Flexible sections of PE (PE80, PE100) pipelines 201
-- Flexible sections of PP pipelines 203
-- Flexible sections of PVC pipelines 207
-- Flexible sections of PVDF pipelines 211
Installation 213
Pipe bracket spacing and support of pipelines

-- General 215
-- Pipe bracket spacing for COOL-FIT ABS pipes 218
-- Pipe bracket spacing for PE pipes 219
-- Pipe bracket spacing for PP pipes 220
-- Pipe bracket spacing for PVC pipes 222
-- Pipe bracket spacing for PVDF pipes 224
-- Pipe bracket spacing plastics pipes in carriers 225
Internal pressure test and leak test
-- Introduction to pressure testing 226
-- Internal pressure test with water or a similar incompressible test fluid 226
-- Internal pressure test and leak tightness test of ABS pipelines with gas/air as test fluid (compressible medi-
um) 230
-- Internal pressure test of compressed air pipelines 231
-- Leak test with gas as test fluid (compressible medium). Maximum test pressure 0.5 bar 231
Modifications, repairs, commissioning
-- Modifications and repairs 232
-- Commissioning 232
189
Installation of metric industrial The length of pipe to be cut is given as in the following
diagram by the distance between the centre of adjoining
piping systems fittings less the sum of the z-dimension of the fittings.
Procedure for socket fusion or socket cement
z-dimension method fittings
General
The pressure of competition and high wages makes it
essential to install pipeline systems efficiently.
The GF method of assembly is highly suited to this task.
It replaces the tedious and time-consuming cutting to
size of one pipe at a time by a fast and precise way of
preparing whole groups of pipes according to plans or
jigs.
We recommend using the
chart to enter the groups of
pipes with the correspond-
ing dimensions and the cut
lengths.
The following formula is used to determine the required

pipe length:
L0 = M - z1 - z2
Please adhere to the following guidelines for drawing:

Pipes which run perpendicu-
lar to one another are drawn
like this:

Horizontal: from left to right

Vertical
Lo Length of pipe to be cut
M Distance between the centre of each fitting
Horizontal: from front to
back z z-dimension of the fitting
The following example shows how the use the z-dimen-

sion method:
Material PVC-U, d63, PN16
Centre-Centre distance M = 1000 mm
Inclined pipelines z1 (Tee 90° equal) = 33 mm
are drawn like this: z2 (Elbow 90°) = 33 mm
=>L0 = 1000 mm - 33 mm - 33 mm = 934 mm
Procedure for butt fusion fittings
Study the schedule of pipe sizes and lengths of the pipe

runs. The z-dimensions of the fittings are needed for de-
termining the actual cutting lengths of the pipes. The ta-
bles in our product ranges or in the online catalogues
contain all the relevant data for the fittings.
190
The following formula is used to determine the required
pipe length:
L0 = M - LFitt1 - LFitt2 + 2Bz + 2Xv
Lo Cut length of pipe

LFitt Length of the fitting (≙ z-dimension)
M Centre-to-centre distance of fitting
Bz Facing IR: 2 x 2 mm, BCF: 2 x 0.8 mm
Xv Overlap distance (only for IR) } material losses per fusion process
The following example shows how the use the z-dimen-

sion method:
Material PP-H, d63, SDR11, IR welded
Centre-Centre distance M = 1000 mm
LFitt1 (Tee 90° equal) = 66 mm
LFitt2 (Elbow 90°) = 66 mm
Bz = 2 x 2 mm. For each welding facing is carried out
on pipe and fitting. Because of two weldings in summery
8 mm
Xv = 1 mm for each welding. Because of two weldings in
summery 2 mm
=>L0 = 1000 mm - 66 mm - 66 mm + 8 mm + 2
mm = 878 mm
Advantage for IR and BCF: Defined facing!
The following table shows the approximate welding losses for the IR fusion process, including 1x facing:
Welding machine IR63-Plus
d PP-natural PE100 PE100 PP-H PP-H PVDF ECTFE PFA
(SDR11) (SDR17) (SDR11) (SDR17)
mm mm mm mm mm mm mm mm mm
20 5.0 5.5 - 5.0 - 4.5 - 4.5
25 5.0 5.5 - 5.0 - 4.5 - 4.5
32 5.0 5.5 - 5.0 - 4.5 - 4.5
40 5.0 6.0 - 5.0 - 4.5 - 4.5
50 5.0 6.0 - 5.0 - 4.5 - 4.5
63 5.5 6.0 - 5.0 - 4.5 - 4.5
191
Welding machine IR110-Plus
d PP-natural PE100 PE100 PP-H PP-H PVDF ECTFE PFA
(SDR11) (SDR17) (SDR11) (SDR17)
20 5.0 5.5 - 5.0 - 4.5 4.5 4.5
25 5.0 5.5 - 5.0 - 4.5 4.5 4.5
32 5.0 5.5 - 5.0 - 4.5 4.5 4.5
40 5.0 5.5 - 5.0 - 4.5 4.5 4.5
50 5.0 5.5 5.5 5.0 5.0 5.0 4.5 4.5
63 5.0 5.5 5.5 5.0 5.0 5.0 4.5 4.5
75 5.0 5.5 5.5 5.0 5.0 5.0 5.0 -
90 5.0 5.5 5.5 5.0 5.0 5.0 5.0 -
110 5.5 5.5 5.5 5.5 5.0 5.0 5.0 -
Welding machine IR225-Plus + IR315-Plus

d PP-natural PE100 PE100 PP-H PP-H PVDF
(SDR11) (SDR17) (SDR11) (SDR17)
mm mm mm mm mm mm mm
63 5.0 6.5 6.5 5.0 5.0 4.5
75 5.0 6.5 6.5 5.0 5.0 4.5
90 5.0 6.5 6.5 5.0 5.0 5.0
110 5.5 6.5 6.5 5.5 5.0 5.0
125 - 6.5 6.5 5.5 5.0 -
140 - 6.5 6.5 5.5 5.5 5.0
160 - 7.0 6.5 5.5 5.5 5.0
180 - 7.0 6.5 5.5 5.5 -
200 - 7.0 6.5 5.5 5.5 5.0
225 - 7.0 6.5 2.0 5.5 5.0
250 - - - TBA TBA 5.5
280 - - - TBA TBA 5.5
315 - - - TBA TBA 5.5
Welding machine IR-450

d PE100 PE100 PP-H PP-H PVDF
(SDR11) (SDR17) (SDR11) (SDR17)
mm mm mm mm mm mm
315 - - TBA TBA 7.0-13.0 can be selected by operator
192
Isometric paper
193
Handling plastic pipeline systems Stored pipes must not be exposed to the elements more
than absolutely necessary, i.e. they should be kept in a
Transportation covered warehouse. If stored outdoors (e.g. on a con-
Vehicles used to transport pipes must be capable of ac- struction site), they should be covered with sheeting for
commodating the full pipe length. The pipes must be protection against the weather (e.g. UV radiation).
supported to prevent them bending or deforming. The
It should also be noted that one-sided warming by sun-
area where pipes rest (including side supports) should
shine could cause deformations.
be lined with padded sheeting or corrugated cardboard
to avoid damage by protruding rivets or nails. To pre- Pipes and parts should be used in the order of manufac-
vent damage, pipes and fittings must not be slid over ture / delivery, to ensure proper warehouse turnover of
the transport vehicle’s loading area, nor should they be the plastic material.
dragged along the ground to their place of storage.
Material Permissible stacking
Due care must be taken with loading and unloading. If height
lifting gear is used, this must be fitted with special pipe
ABS 1.0 m
grips. Throwing pipes and parts down from the cargo
PE 1.0 m
surface is unacceptable. PP 1.5 m
Impacts must be avoided at all cost, especially at ambi- PVC-U 1.5 m
ent temperatures below 0°C where many plastics (e.g. PVC-C 1.5 m
PVDF 1.5 m
PVC) have significantly lower impact resistance.
Pipes and fittings must be transported and stored so
that they cannot be soiled by earth, mud, dirty water,
etc. We recommend sealing pipes with protective end-
caps to prevent the ingress of dirt.
We recommend that GF fittings and equipment are only
unpacked immediately prior to use.
Storage
The pipe storage surface must be level and free of
stones. Pipes must be layered and stacked in a way
that avoids the risk of damage or permanent deforma-
tion. Larger-diameter, thin-walled pipes must be fitted
with stiffening rings. Avoid single-point or narrow longi-
tudinal supports.
The following table gives recommended maximum
stacking heights for non-palette pipe storage. Provid-
ed pipes are stacked on palettes and protected against
sideways movement, the nominal stacking heights
specified in the table may be increased by 50%.
Pipe storage areas should be as well-protected as pos-
sible. Absorption of oil, solvents and other chemicals
must be avoided at all costs during storage.
194
3D, 2D CAD-Engineering
Product library of Georg Fischer
With this 3D-Product library Georg Fischer supports

planner and engineers at the creation of piping systems
more efficiently.
Three dimensional drawings of all the componets of the
+GF+ industrial piping systems are supplied. The user
creates two dimensional drawings on his own.
The library does work independently from the users
CAD system. A lot of systems and interfaces are sup-
ported.
More information are available in the internet with
www.piping.georgfischer.com =>Support or from your
next GF company.
195
Change in length and flexible sec- Flexible sections arise naturally at any branching or
change in direction of the pipeline. The movement LB
tions of the flexible section as a result of a change ΔL in the
length must not be restrained by fixed pipe brackets,
Introduction protrusions wall, girders or the like.
General
Thermoplastics are subject to greater thermal expan-
sion and contraction than metals. Pipes installed above
ground, against walls or in ducts, especially those ex-
posed to temperature variations, require changes in
length to be taken up in order to prevent extra strain on
the pipes. Length changes can be taken up by:
a) flexible sections
b) compensators
Flexible sections are the most common solution, being
the simplest and the most economical. The calculations
for and the positioning of flexible sections are therefore
described in detail.
Calculation of change in length

The change in length caused by temperature can be
calculated using the following formula:
with:
• ΔL = temperature-related change in length (mm)
• L = length of the pipe section (m)
• ΔT = difference of temperature (K)
• α = coefficient of linear expansion (mm / m K)
Fundamentals
The low modulus of elasticity of thermoplastics allows
changes in length to be taken up by special pipe sec-
tions, where pipe supports are positioned so that they
can take advantage of the natural flexibility of the mate-
rial. The length of such sections is determined by the di-
ameter of the pipeline and the extent of the thermal ex-
pansion to be compensated.
196
Coefficients of linear expansion of polymers: Remark: Because Ecm and σb are depending on time,
temperature and stress, the calculation of LB is very dif-
Material α in mm/m K
ficult. Therefore the following diagrams should be used
ABS 0.10 instead of the formula.
COOL-FIT ABS Plus 0.04 - 0.09* Boundary conditions for using the diagram
PA 0.10 For easy determination of the required length of flexible
section please use the following diagrams. Please take
PB 0.13 into account the given boundary conditions.
PE 0.15 - 0.20 • Assembly temperature TM = 20 °C
PP 0.16 - 0.18 • TB Operating temperature
PPS 0.15 • ΔT = TB - TM
PVC-U 0.07 - 0.08 • allowable bending stress 15 % of σv
PVC-C 0.06 - 0.07 • PN 6 .. 16
• Coefficient of friction of the pipe in the loose brackets
PVDF 0.12 - 0.18
≤ 0.5
* Exact values can be calculated using GF's online tool
(www.cool-fit.georgfischer.com) or ask your local GF Information:
representative. The following diagrams show the required flexible sec-
tions for strait pipe lengths of 10 m or 70 m. Exceeding
Tip: If the operating temperature is higher than the the maximally permissible straight pipe distance would
installation temperature, then the pipe expands. lead to buckling of the pipe due to the too large friction
If, on the other hand, the operating temperature is in the pipe clamps. Therefore the maximally possible
lower than the installation temperature, then the pipe length is to consider depending on the pipe diame-
pipe contracts in length. ter =>above the hatched range.
The installation temperature must therefore be incorpo- Example: Determining the required flexible sec-
rated into the calculations as well as the maximum and tion
minimum operating temperatures. Calculating the relevant change in length
It is preferable to use "+" to indicate expansion of the The example of an ABS process pipe serves to illustrate
pipe and "-" to indicate contraction. the procedure:
Length of piping from the fixed point to the branch point
The larger change in length is the one to be used for de-
where the change in length is to be taken up:
termining the required length of the flexible section.
• L = 8 m.
• Installation temperature: TM = 20 °C
• Max. working temperature: T1 = 35 °C
• Min. working temperature: T2 = -20 °C
Calculating of length of the flexible section

The required length of the flexible section can be calcu- Expansion of the section during heating
lated using the following formula: +ΔL1 = L ⋅ ΔT1 ⋅ α = 8 ⋅ 15 ⋅ 0.10 = 12 mm
Contraction during cooling
-ΔL2 = L ⋅ ΔT2 ⋅ α = 8 ⋅ 40 ⋅ 0.10 = 32 mm
Temperature differences
ΔT1 = T1 - TM = 15 K
with: ΔT2 = T2 - TM = - 40 K
• da = pipe outside diameter (mm)
Maximum change in temperature chosen
• ΔL = change in length (mm) ΔT = 40 K
• Ecm= average bending creep modulus for t = 25 a (N/
mm²)
• σb= permitted bending stress for t = 25a (N/mm²)
197
Determining the length of the flexible section for
ABS
The values needed to determine the necessary length
are:
• The maximum change in temperature from the 0-po-
sition (i. e. from the position in which the pipe was in-
stalled). But remember that the pipe could just as well
contract as expand.
• The pipe diameter d.
• The length of the pipe section L.
With these values the required length of the flexible sec-

tion can be read off from the diagram for ABS.
Continuing with the example introduced before and sup-
posing that an ABS pipe with d = 50 mm is installed, the
maximum change in temperature being ΔT= 40 K, the
required length of the flexible section is seen directly
from the diagram to be LB = 1300 mm.
The diagram can be used also the other way around, if

a maximum flexible section caused by the building con-
struction is given. Then the maximum straight length of
the pipe can be determined.
198
Flexible sections of ABS pipelines
L Length of the pipe section in mm

LB Required length of flexible section in mm
199
Remark: Please observe the explanations to the hatched area in the clause boundary conditions
200
Flexible sections of PE (PE80, PE100) pipelines

201
202
Flexible sections of PP pipelines

203
204
205
206
Flexible sections of PVC pipelines

207
208
209
210
Flexible sections of PVDF pipelines

211
212
Installation Installation data: L = 10m
d = 50mm
Recommendations for installation
Length changes in pipe sections should always be ac- Installation temperature: 15 °C
commodated through the arrangement of fixed brack- Max. operating temperature: 40 °C
ets. The following examples show how the changes can Material: ABS
be distributed in pipe sections by suitable positioning of
fixed brackets. a) Change in length
+ΔL = L * ΔT * αABS = 10 * 25 * 0.10 = 25 mm
b) A flexible section to take up a change in length of ΔL
= 25 mm needs to be LB = approx. 1150 mm long ac-
cording to the diagram.
c) If the flexible section is pre-stressed to ΔL/2 then
the required length of the flexible section is reduced to
about 800 mm. The variation length from the 0 position
is then ±ΔL/2 = 25/2 = 12.5 mm.
not recommended recommended Pre-stressing the flexible section makes it possible to
reduce its required length in installations where space is
restricted. Pre-stressing also reduces the bending of the
flexible section in service, improving the appearance of
the pipeline.
Expansion loops can be installed to take up changes

in length when flexible sections cannot be included at
a change in direction or branch in the pipeline or if sub-
stantial changes in the length of a straight section need
to be taken up. In such a case the compensation for
changes in length is distributed over two flexible sec-
tions.
Installing compensators
Lu ≥ 2 * ΔL The low modulus of elasticity means that the reaction
force of plastic pipes to thermal changes is low com-
pared to metal pipes. This makes normal compensators
designed for use with metal pipes unsuitable because
NOTICE of their high inherent resistance. Only freely moving
compensators may be used in plastic pipe systems, i.
e. those with a low resistance. The following compen-
Bending load at flexible sections
sators may be considered: rubber compensators, PTFE-
Caused by the bending load leakages can corrugated compensators or suitably selected metal
occur at mechanical joints. multi-disc compensators.
• Within the range of flexible sections and/or Carefully placed fixed points should be used when fitting
expansion loops no screw connections or compensators for the regulation of the pipe in order to
flange connections shall be used. ensure their unhindered operation. The installation tem-
perature provides the basis for the calculations to en-
Pre-stress sure this.
In particularly difficult situations with large changes in
one direction only, it is possible to pre-stress the flex-
ible section during installation and thereby shorten its
length, as illustrated in the next example.
213
Tip: When using compensators, additional longi- pipelines can support limited additional axial stress with-
tudinal forces are implemented into the pipeline. out becoming overloaded. In such cases the level of
These forces have to be carried by guiding the stress expected must be calculated. The same is true
pipeline. For example, threaded rods are not suit- of any section of pipe between two fixed points where
able. To estimate the lateral forces it can be as- no allowance has been made for changes in length. The
sumed that they can reach about 15 % of the ax- load at the fixed points must be calculated and consid-
ial forces. Please contact the manufactures of
ered when planning the fixed points. The distance be-
compensators for further support designing such
pipelines.
tween pipe brackets in such cases may have to be re-
duced from the normal values in order to prevent bow-
ing in the pipeline.
Care must be taken to avoid creating cavities when
plastering or concreting in the pipeline, because under
unfavourable conditions these can become areas of
stress concentration. A rich plaster mixture (1 : 3 to 1 :
4) should be used to allow the forces arising from tem-
perature variations to be transmitted away without caus-
ing the plaster to crack.
Installing valves
Valves should be secured as directly as possible, so
that the actuation forces are transmitted directly and not
via the pipeline. Valve brackets or valves from GF with
an integrated fastening device are used to securely fas-
ten plastic valves. These valve brackets are also used
to bear the loads of the valve and filling weight of the
pipeline. Any changes in length which arise can be pre-
vented with the appropriate fixed points before or after
the valve.
You will find more information under the respective
valve types.
Installing pipework under plaster or embedding
it in concrete
Padded pipework
Where pipework is installed under plaster or embedded
into concrete, the flexible sections at bends and branch-
es must be padded for the calculated distance H, as al-
so must any branches and elbows included in the affect-
ed section.
Use only flexible materials as padding, such as glass

wool, mineral wool, foam or similar.
Unpadded pipework
Unpadded pipes can also be plastered or concreted
in directly. Since the axial stress arising from internal
pressure is half as great as the circumferential stress,
214
Pipe bracket spacing and support of Arranging fixed points
pipelines What is a fixed point?
A fixed pipe bracket is a bracket which prevents the
General pipe from moving in any direction. The aim of which
is to control system stresses caused by temperature
Pipe support for plastics pipes changes.
Plastic pipe systems should be installed using supports
designed for use with plastics and should then be in-
stalled taking care not to damage or over stress the
pipe. NOTICE
Arranging Loose Brackets
What is a loose pipe bracket? Construction of fixpoint
A loose pipe bracket is a bracket which allows axial This should not be done by simply clamping
movement of the pipe, to allow stress free compensa- the bracket onto the outside of the pipe! This
tion of temperature changes and compensation of any can cause deformation and physical damage
other operating condition changes. to the pipe, damage that sometimes only lat-
er becomes visible.
• It should be done either by using pipe
brackets located between two fittings or a
double bracket must be used.(double-sided
fixed point).
• Placing a pipe bracket immediately adja-
cent to a fitting restricts movement due to
changes in length to one direction (one-sid-
ed fixed point).
one-sided fixed point

The inner diameter of the bracket should be larger than
the outside diameter of the pipe to allow free movement
of the pipe. The inner edges of the brackets should be
free from any sharp contours which could damage the
plastic. If the brackets’ inside diameter is not larger than
the pipe then the bracket should not be fully tightened, double-sided fixed point
thus allowing the pipe to move.
Information:
Another method is to use brackets with spacers which Pipe brackets must be robust and mounted firmly to be
also avoids clamping the bracket on the pipe. able to take up the forces arising from changes in length
in the pipeline. Hanging brackets or KLIP-IT pipe brack-
ets are unsuitable for use as fixed points.
KLIP-IT pipe brackets
These robust plastic pipe brackets can be used not only
under rigorous operating conditions, but also where the
pipework is subject to aggressive media or atmospheric
conditions. They may be used for all materials of pipes.
Don't use KLIP-IT pipe brackets as fixed points!
Spacer to avoid clamping
Axial movement of the pipeline must not be prevented

by fittings placed next to pipe brackets or by any other
component affecting the diameter of the pipe.
Sliding brackets and hanging brackets permit the pipe
to move in different directions. Attaching a sliding block
to the base of the pipe bracket permits free movement
of the pipe along a flat supporting surface. Sliding and
hanging brackets are needed in situations where the
pipeline changes direction and free movement of the
pipe must be allowed.
215
Pipe brackets for cold insulation (MIP)
d 16 to d32 d 40 to d 160
Open handle
Insert pipe
Close handle with quick-action clamp
d 90 to d 400
Starting from the dimension d90 the KLIP-IT brackets

must be installed standing, like shown in the assembly
examples. The support distances given in the following,
specified for the KLIP-IT tubing clamps, apply only to
this mounting method.
Assemble insulation
1. Take off foil
2. Press area of contact
Move insulation into the bracket. Attention! Make sure the insula-
tor is positioned correctly.
Tighten the screw
216
Coat areas of contact with adhesive and bond them
Using the tables for pipe bracket spacing

Plastic pipelines need to be supported at certain inter-
vals depending on several factors: the material, the av-
erage pipe wall temperature, the density of the medi-
um transported and the size and wall thickness of the
pipe. Determining the spacing between pipe brackets is
based on the permissible deflection of the pipe between
consecutive brackets.
Information:
The values given in the tables apply only to pipelines
which are freely movable in the axial direction.
Pipelines which are fastened tightly in the axial direc-
tion (fixed installations) must be checked for buckling.
In most cases, this leads to a reduction of the maximum
inner pressure and shorter distances between the sup-
port brackets. Furthermore, the forces that act on the
fixed points must also be taken into consideration. For
assistance, please contact your nearest GF representa-
tive.
217
Pipe bracket spacing for COOL-FIT ABS COOL-FIT ABS Plus pipe
pipes
Pipe diameter Pipe bracket intervals L for-
Liquids with a density of 1 g/cm³ mm COOL-FIT ABS Plus
mm (ft)
d DN Pipe bracket intervals L for pipes
mm inch PN10 / SDR17 / S8 or class C 25 1550 (5.09)
in mm at pipe wall temperature: 32 1550 (5.09)
≤ 20 °C 30 °C 40 °C 50 °C 60 °C 40 1650 (5.41)
16 3/8 700 650 600 550 450 50 1650 (5.41)
20 1/2 800 700 650 600 500
25 3/4 850 800 750 650 600 63 1750 (6.23)
32 1 1000 900 850 750 650 75 1900 (6.23)
40 1¼ 1100 1000 950 850 750
50 1½ 1150 1100 1000 900 800 90 2050 (6.73)
63 2 1300 1200 1100 1000 850
110 2200 (7.22)
75 2½ 1500 1350 1200 1100 950
90 3 1600 1450 1350 1200 1050 140 2550 (8.37)
110 4 1800 1650 1550 1350 1200
140 5 2050 1800 1700 1400 1250 160 2750 (9.02)
160 6 2200 1850 1750 1450 1300 200 3050 (10.01)
200 7 2300 2050 1850 1550 1350
225 8 2400 2200 1900 1600 1450 225 3300 (10.83)
250 9 2500 2300 2000 1650 1500 250 3300 (10.83)
280 10 2650 2400 2100 1700 1600
315 12 2800 2500 2200 1800 1650 280 3600 (11.80)
315 3800 (12.46)
For other SDR / PN values or classes multiply the val-
ues given in the table with the following factor.
SDR11 / PN16 1.08
Class B 0.90
Class D 1.05
Class E 1.09
The pipe bracket spacing given in the table may be in-
creased by 30 % in the case of vertical pipe runs, i. e.
multiply the values given by 1.3.
Fluids of a density other than 1 g/cm³
If the liquid to be transported has a density not equal
1 g/cm³, then the bracket spacings in the table above
should be multiplied by the factor given in the following
table.
Density of the flu- Type of fluid Factor for pipe
id in g/cm³ bracket spacing
1.00 Water 1.00
1.25 Other 0.96
1.50 0.92
1.75 0.88
2.00 0.84
≤ 0.01 Gaseous 1.30
218
Pipe bracket spacing for PE pipes
Liquids with a density of 1 g/cm³
d Pipe bracket intervals L for pipes SDR 11
mm in mm at pipe wall temperature:
≤20 °C 30 °C 40 °C 50 °C 60 °C
16 500 450 450 400 350
20 575 550 500 450 400
25 650 600 550 550 500
32 750 750 650 650 550
40 900 850 750 750 650
50 1050 1000 900 850 750
63 1200 1150 1050 1000 900
75 1350 1300 1200 1100 1000
90 1500 1450 1350 1250 1150
110 1650 1600 1500 1450 1300
125 1750 1700 1600 1550 1400
140 1900 1850 1750 1650 1500
160 2050 1950 1850 1750 1600
180 2150 2050 1950 1850 1750
200 2300 2200 2100 2000 1900
225 2450 2350 2250 2150 2050
250 2600 2500 2400 2300 2100
280 2750 2650 2550 2400 2200
315 2900 2800 2700 2550 2350
355 3100 3000 2900 2750 2550
400 3300 3150 3050 2900 2700
450 3550 3400 3300 3100 2900
500 3900 3650 3500 3350 3100
For other SDR multiply the values given in the table with
the following factor:
SDR 17 and SDR 17.6 with 0.91
SDR 7.4 with 1.07
1 g/cm³, then the bracket spacing in the table above
should be multiplied by the factor of the following table.
1.00 Water 1.00
1.25 Other 0.96
1.50 0.92
1.75 0.88
2.00 0.84
≤ 0.01 Gaseous 1.30 for SDR11
1.21 for SDR7.4
219
Pipe bracket spacing for PP pipes
PP-H pipes with liquids with a density of 1 g/cm³
d Pipe bracket intervals L for SDR 11 pipes
≤20 °C 30 °C 40 °C 50 °C 60 °C 70 °C 80 °C
16 650 625 600 575 550 525 500
20 700 675 650 625 600 575 550
25 800 775 750 725 700 675 650
32 950 925 900 875 850 800 750
40 1100 1075 1050 1000 950 925 875
50 1250 1225 1200 1150 1100 1050 1000
63 1450 1425 1400 1350 1300 1250 1200
75 1550 1500 1450 1400 1350 1300 1250
90 1650 1600 1550 1500 1450 1400 1350
110 1850 1800 1750 1700 1600 1500 1400
125 2000 1950 1900 1800 1700 1600 1500
140 2100 2050 2000 1900 1800 1700 1600
160 2250 2200 2100 2000 1900 1800 1700
180 2350 2300 2200 2100 2000 1900 1800
200 2500 2400 2300 2200 2100 2000 1900
225 2650 2550 2450 2350 2250 2150 2000
250 2800 2700 2600 2500 2400 2300 2150
315 3150 3050 2950 2850 2700 2600 2450
355 3350 3250 3150 3000 2850 2750 2600
400 3550 3450 3350 3200 3050 2900 2750
450 3800 3700 3600 3450 3300 3100 2950
500 4100 4000 3850 3700 3500 3350 3150
SDR17 and SDR17.6 with 0.91
PP-H pipes with fluids of a density other than 1
g/cm³
table.
1.00 Water 1.00
1.25 Other 0.96
1.50 0.92
1.75 0.88
2.00 0.84
1.47 for SDR17.6 and
SDR17
220
PP-R pipes with liquids with a density of 1 g/cm³
d Pipe bracket intervals L for SDR 11 pipes
≤20 °C 30 °C 40 °C 50 °C 60 °C 70 °C 80 °C
16 500 475 450 425 425 400 375
20 525 500 500 475 450 425 425
25 600 575 575 550 525 500 500
32 725 700 675 650 650 600 575
40 825 800 800 750 725 700 650
50 950 925 900 875 825 775 750
63 1100 1075 1050 1025 975 925 900
75 1150 1150 1100 1050 1000 975 950
90 1250 1200 1150 1150 1100 1050 1000
110 1400 1350 1300 1300 1200 1125 1050
125 1500 1450 1450 1350 1300 1200 1150
140 1600 1550 1500 1450 1350 1275 1200
160 1700 1650 1600 1500 1450 1350 1300
180 1750 1750 1650 1600 1500 1425 1350
200 1900 1800 1750 1650 1600 1500 1450
225 2000 1900 1850 1750 1700 1600 1500
250 2100 2050 1950 1900 1800 1700 1600
315 2350 2300 2200 2150 2050 1950 1850
355 2500 2425 2350 2250 2125 2050 1950
400 2650 2575 2500 2400 2275 2175 2050
450 2850 2775 2700 2575 2475 2325 2200
500 3075 3000 2875 2775 2625 2500 2350
SDR17 and SDR17.6 with 0.91
PP-R pipes with fluids of a density other than 1
g/cm³
table.
1.00 Water 1.00
1.25 Other 0.96
1.50 0.92
1.75 0.88
2.00 0.84
1.47 for SDR17.6 and
SDR17
221
Pipe bracket spacing for PVC pipes
PVC-U pipes with liquids with a density of 1 g/
cm³
d DN Pipe bracket intervals L for SDR21 / S 10 /
PN10 pipes
in mm at pipe wall temperature:
mm inch ≤20 °C 30 °C 40 °C 50 °C 60 °C
16 3/8 950 900 850 750 600
20 ½ 1100 1050 1000 900 700
25 ¾ 1200 1150 1050 950 750
32 1 1350 1300 1250 1100 900
40 1¼ 1450 1400 1350 1250 1000
50 1½ 1600 1550 1500 1400 1150
63 2 1800 1750 1700 1550 1300
75 2½ 2000 1900 1850 1700 1450
90 3 2200 2100 2000 1850 1550
110 4 2400 2300 2250 2050 1750
125 - 2550 2450 2400 2200 1850
140 5 2700 2600 2500 2300 1950
160 6 2900 2800 2700 2500 2100
180 - 3100 2950 2850 2650 2200
200 - 3250 3150 3000 2800 2350
225 8 3450 3300 3200 2950 2500
250 - 3650 3500 3350 3100 2600
280 10 3750 3700 3550 3300 2750
315 12 4100 3900 3750 3500 2950
355 14 4300 4200 4000 3700 3100
400 16 4600 4450 4250 3950 3300
For other SDR / PN multiply the values given in the ta-

ble with the following factor:
SDR51 / S25 / PN4 with 0.83
SDR34.3 / S16.7 / PN6 with 0.90
SDR13.6 / S 6.3 / PN16 with 1.08
SDR11 / S 5 / PN20 with 1.15
PVC-U pipes with fluids of a density other than
1 g/cm³
table.
1.00 Water 1.00
1.25 Other 0.96
1.50 0.92
1.75 0.88
2.00 0.84
≤ 0.01 Gaseous 1.42 for SDR21 / S8 /
PN10
1.30 for SDR13.6 /
S6.3 / PN16
1.20 for SDR11 / S5 /
PN20
222
PVC-C pipes with liquids with a density of 1 g/cm³
d mm Pipe bracket intervals L for SDR21 / S10 / PN10 pipes in mm at pipe
wall temperature:
≤20 °C 30 °C 40 °C 50 °C 60 °C 70 °C 80 °C
16 1000 950 900 850 750 675 600
20 1150 1100 1025 950 875 775 700
25 1200 1150 1100 1000 900 800 700
32 1350 1250 1200 1100 1000 900 800
40 1500 1400 1300 1250 1150 1050 900
50 1650 1600 1500 1400 1300 1200 1100
63 1850 1750 1650 1600 1500 1350 1250
75 2050 1950 1850 1750 1650 1500 1350
90 2250 2100 2000 1900 1800 1650 1500
110 2500 2350 2200 2100 1950 1800 1650
125 2650 2500 2350 2250 2100 1950 1750
140 2800 2650 2500 2350 2200 2050 1850
160 3000 2850 2700 2550 2400 2200 2000
180 3150 3000 2850 2700 2500 2300 2100
200 3350 3150 3000 2850 2650 2450 2200
225 3550 3350 3200 3000 2800 2600 2350
250 3750 3550 3350 3150 3000 2750 2500
280 3950 3750 3550 3350 3150 2900 2650
315 4200 4000 3750 3550 3350 3050 2800
350 4450 4250 4000 3800 3550 3250 2950
400 4750 4500 4250 4000 3750 3450 3150
SDR13.6 / S6.3 / PN16 with 1.08
SDR11 / S5 / PN20 with 1.12
PVC-C pipes with fluids of a density other than
1 g/cm³
table.
1.00 Water 1.00
1.25 Other 0.96
1.50 0.92
1.75 0.88
2.00 0.84
≤ 0.01 Gaseous 1.42 for SDR21 / S8 /
PN10
1.30 for SDR13.6 /
S6.3 / PN16
1.20 for SDR11 / S5 /
PN20
223
Pipe bracket spacing for PVDF pipes
Liquids with a density of 1 g/cm³
d Pipe bracket spacing L for pipes
mm PN16 / SDR21
≤20 °C 30 °C 40 °C 50 °C 60 °C 70 °C 80 °C 100 °C 120 °C 140 °C
16 725 700 650 600 575 550 500 450 400 300
20 850 800 750 750 700 650 600 500 450 400
25 950 900 850 800 750 700 675 600 500 450
32 1100 1050 1000 950 900 850 800 700 600 500
40 1200 1150 1100 1050 1000 950 900 750 650 550
50 1400 1350 1300 1200 1150 1100 1000 900 750 600
d Pipe bracket spacing L for pipes

mm PN10 / SDR33
≤20 °C 30 °C 40 °C 50 °C 60 °C 70 °C 80 °C 100 °C 120 °C 140 °C
63 1400 1350 1300 1250 1200 1150 1100 950 800 650
75 1500 1450 1400 1350 1300 1250 1200 1050 850 700
90 1600 1550 1500 1450 1400 1350 1300 1100 950 850
110 1800 1750 1700 1650 1550 1500 1450 1250 1100 950
125 1900 1850 1800 1700 1650 1600 1500 1350 1200 1000
140 2000 1950 1900 1800 1750 1700 1600 1450 1250 1050
160 2150 2100 2050 1950 1850 1800 1700 1550 1350 1150
180 2300 2200 2150 2050 1950 1900 1800 1600 1400 1200
200 2400 2350 2250 2150 2100 2000 1900 1700 1500 1300
225 2550 2500 2400 2300 2200 2100 2000 1800 1600 1400
250 2650 2600 2500 2400 2300 2200 2100 1900 1700 1500
280 2850 2750 2650 2550 2450 2350 2250 2000 1800 1600
315 3000 2950 2850 2750 2600 2500 2400 2150 1900 1650
355 3200 3100 3000 2850 2750 2650 2500 2250 2000 1750
400 3400 3300 3200 3050 2950 2800 2650 2400 2100 1800
450 3650 3550 3450 3300 3200 3000 2850 2600 2250 1900
For other PN / SDR multiply the values given in the ta-

ble (diameter ≥ d63) with the following factor:
PN16 / SDR33 with 1.08
Pipe bracket spacing for lines running vertically can be
increased by 30 % with respect to the values in the ta-
ble, i. e. table values multiplied by 1.3.
table.
Density of the Type of fluid Factor for pipe brack-
fluid in g/cm³ et spacing
1.00 Water 1.00
1.25 Other 0.96
1.50 0.92
1.75 0.88
2.00 0.84
≤ 0.01 Gaseous 1.48 for SDR33 / PN10
1.36 for SDR21 / PN16
224
Pipe bracket spacing plastics pipes in car-
riers
Continuous support may be more economical and

practicable than pipe brackets for horizontal or vertical
pipework, especially for small diameter pipes and in ar-
eas with high temperatures.
In order to avoid inadmissible loadings on the pipeline-
s ensure during assembling an overlapping of the carri-
ers in the pipe brackets.
The following table indicates the spacing distances
when using carriers. These values apply regardless of
the type of piping material or the temperature.
Spacing of supports when using carri-
d ers
mm mm
16 1600
20 1750
25 1900
32 2000
40 2150
50 2300
63 2500
75 2600
90 2750
110 2900
225
Internal pressure test and leak test
Introduction to pressure testing
Overview of the different testing methods
Testing method Internal pressure test Leak test
Medium Water Gas * Compressed air * Gas/air (oil free) Gas/air (oil free)
Art incompressible compressible compressible compressible compressible
Test pressure pp(perm) Operating pressure Operating pressure 0.5 bar (7 psi) 1.5 bar (20 psi)
(overpressure) resp. + 2 bar (29 psi) + 2 bar (29 psi)
0.85 x pp(perm)
Endangerment small high high small middle
during pressure
test
Material all plastics ABS PB, PE all plastics ABS
Informative value High: High: High: small middle
Proof of resistance Proof of resistance Proof of resistance
to pressure in- to pressure in- to pressure in-
cluding tightness cluding tightness cluding tightness
against test medi- against test medi- against test medi-
um um um
* Please consider the applicable safety precautions Remark: Gas leak tightness cannot be demonstrated by
More information is available in DVS 2210-1 Suppl. 2. a water pressure test, also not with increased test pres-
sure!
A lot of international and national standards and guide-
lines are available for leak and pressure tests. There-
fore often it is not easy to find the applicable test proce- Internal pressure test with water or a simi-
dure or for example the test pressure. lar incompressible test fluid
The purpose of a pressure test is, General
• first to ensure the resistance to pressure of the The internal pressure test is done when installation work
pipeline and has been completed and necessitates an operational
pipeline or operational test sections. The test pressure
• in addition to show the leak tightness against the test load should furnish experimental proof of operational
media. safety. The test pressure is not based on the working
pressure, but rather on the internal pressure load ca-
Usually the pressure test is done as a water pressure
pacity, derived from the pipe wall thickness.
test and only in exceptional cases (with consideration to
special safety precautions) as a gas pressure test with Supplement 2 of DVS 2210-1 forms the basis for the fol-
air or nitrogen. lowing information. This replaces the data in DVS 2210-
1 entirely. The modifications became necessary be-
The following comparison should point out the differ-
cause
ence between water and air as a test medium:
• Water is an incompressible medium, which means, • the reference value ”nominal pressure (PN)” is being
setting for example a 1m PVDF pipe d160 under used less and less to determine the test pressure (1.5
a pressure of 3 bar (44 psi) results in an energy of ca. x PN, or 1.3 x PN) and is being replaced by SDR,
1 Joule. • a short-term overload or even a reduction in the ser-
• In contrast air is a compressible medium; the same vice life can occur if in the course of the internal pres-
pipe has with 3 bar (44 psi) pressure an energy of al- sure test based on the nominal pressure the pipe wall
ready 5000 Joule. temperature TR = 20 °C (68°F) is exceeded by more
• If there were a failure during the pressure test, the wa- than 5 °C.
terfilled pipe would fly 0.02 m (¾") "high", the airfilled
pipe 110 m (361ft)! And this with a test pressure of Test pressures are therefore determined in relation to
only 3 bar (44 psi). SDR and the pipe wall temperature. The 100-h value
from the long-term behaviour diagram is used for the
Fracture behaviour of thermoplastics test clamping.
In case of failures thermoplastic materials show different Test Parameters
behaviours. PE and PB (to a lesser degree ABS) have a The following table indicates recommended methods of
ductile behaviour, that means brittle fracture cannot oc- testing the internal pressure.
cur.
Nevertheless, the following safety precautions must be
taken into consideration during the internal pressure
test. As mentioned before the pressure test is the first
loading placed on the pipeline and uncover any existing
processing faults (e.g. insufficient welding).
226
Object Pre-test Main test Filling the pipeline
Before starting with the internal pressure test, the fol-
Test pressure p p ≤ pp(perm) ≤ 0.85 pp(perm) lowing points must be checked:
(depends on the pipe
wall temperature or • Was installation done according to the available
the permissible test plans?
pressure of the built- • All pressure relief devices and flap traps mounted in
in components, see the flow direction?
clause "Determining
the test pressure") • All end valves shut?
Test duration (de- L ≤ 100 m: 3 h L ≤ 100 m: 3 h
• Valves in front of other devices are shut to protect
pends on the length of 100 m <L ≤ 500 100 m <L ≤ 500 against pressure.
the pipeline, respec- m: 6 h m: 6 h • Visual inspection of all joints, pumps, measurement
tively the sections) devices and tanks.
Checks during the At least 3 At least 2 • Has the waiting period after the last fusion / cement-
testing (test pressure checks, distribut- checks, distribut- ing been observed?
and temperature pro- ed over the test ed over the test
gression should be duration with duration without Now the pipeline can be filled from the geodetic lowest
recorded) restoring the test restoring the test point. Special attention should be given to the air vent. If
pressure pressure possible, vents should be provided at all the high points
of the pipeline and these should be open when filling the
Pre-test system. Flushing velocity should be at least 1 m/sec.
The pre-test serves to prepare the piping system for the
actual test (main test). In the course of pre-testing, a Reference values for the filling volume are given in the
tension-expansion equilibrium in relation to an increase table below.
in volume will develop in the piping system. A materi- DN V (l/sec) DN V (l/sec)
al-related drop in pressure will occur which will require
repeated pumping to restore the test pressure and al- ≤ 80 0.15 250 2.0
so frequently a re-tightening of the flange connection 100 0.3 300 3.0
screws.
150 0.7 400 6.0
The guidelines for an expansion-related pressure de-
200 1.5 500 >9.0
crease in pipes are:
Material Pressure drop Adequate time should be allowed between filling and
testing the pipeline, so that the air contained in the pip-
PVC-U 0.5 bar/h (7 psi/h) ing system can escape via the vents: ca. 6 - 12 h, de-
PVC-C 0.5 bar/h (7 psi/h) pending on the nominal diameter.
ABS 0.6 bar/h (9 psi/h) Applying the test pressure
PP 0.8 bar/h (12 psi/h) The test pressure is applied according to the diagram.
Here it is important that the pressure increase rate does
PE 1.2 bar/h (17 psi/h)
not cause any water hammer !
PB 1.4 bar/h (20 psi/h)
PVDF 0.8 bar/h (12 psi/h)
Main test
In the context of the main test, a much smaller drop in
pressure can be expected at constant pipe wall tem-
peratures so that it is not necessary to pump again.
The checks can focus primarily on leak detection at the
flange joints and any position changes of the pipe.
Observe if using compensators
If the pipeline to be tested contains compensators, this
has an influence on the expected axial forces of the
pipeline. Because the test pressure is higher than the
working pressure, the axial forces on the fixed points
become higher. This has to be taken into account when Y test pressure in %
designing the fixed points. X time for pressure increase in min
1) pressure increase rate up to DN100
Observe if using valves
2) range of pressure increase rates between DN100 - 400
When using a valve at the end of a pipeline (end or fi-
nal valve), the valve and the pipe end should be closed 3) values for pressure increase rate DN500 and greater is: 500 /
DN [bar/10 min]
by a dummy flange or cap. This prevents inadvertent
opening of the valve or any pollution of the inside of the Determining the test pressure
valve. The allowable test pressure is calculated according to
227
with
σ v(T, 100h) Long-term creep strength for the pipe wall tem-
perature TR (at t = 100 h)
Sp Minimum safety factor for long-term creep strength
AG Processing or geometrical specific factor that re-
duces the allowable test pressure
TR Pipe wall temperature: average value of test medium
temperature and pipe surface temperature
NOTICE
Diaphragm valves, types 314-319

Don't overload diaphragm valves!
• If the piping system contains diaphragm
valves the maximum allowable test pres-
sure is limited to the nominal pressure.
Material S p Minimum safety factor

ABS 1.6
PE80, PE100 1.25
PP-H 1.8
PP-R 1.4
PVC-U, PVC-C 2.5
PVDF 1.4
To make things easier, the permissible test pressures

can be taken directly from the following diagrams.
Definitions:
P = permissible test pressure in bar
T = pipe wall temperature in °C
228
Checks during testing
The following measurement values must be recorded
consistently during testing:
• Internal pressure at the absolute low point of the
pipeline
• Medium and ambient temperature
• Water volume input
• Water volume output
• Pressure drop rates
229
Internal pressure test and leak tightness components with a lower PN than the rest of the piping
test of ABS pipelines with gas/air as test systems shall be considered. The test temperature shall
fluid (compressible medium) be between 10 to 30 °C (50 to 86°F).
Introduction The pipelines must be free from any grease or paint.
Usually the pressure test is done as a water pressure Only oil free air or inert gases such as nitrogen should
test and only in exceptional cases (with consideration of be used as the test medium. No refrigerant gases, such
special safety precautions) as a gas pressure test with as R22, may be used.
air or nitrogen (please consider also the general chapter
"Introduction into pressure testing"). Once the pressure in the system has stabilised hold the
pipeline under the test pressure for at least 15 minutes.
Safety precautions If a drop in pressure is observed and inspection of the
joints is necessary this can be done using a foam-build-
ing agent. Using a soap solution which can be removed
WARNING simply with water after the test is recommended.
Compressible media like gas, air or nitro-

NOTICE
gen under internal pressure.
In case of failure danger to life during the
internal pressure testing by explosively ex- Leak detection sprays
haust of medium. Commercial leak detection sprays can cause
• The area around the pipeline under test stress cracks in plastics.
pressure is to be clearly restricted for ac- • Using these sprays remove any residues
cess only by persons assigned with the after testing.
testing.
• Necessary control equipement is to be Information:
placed at a safe distance. For valves leak tightness using a gas is not representa-
• The testing should be timed so that there tive of the valves leak tightness with a fluid. Therefore
are as few persons as possible in the im- if a GF valve shows a leakage under internal pressure
mediate area. test with a gas it is recommended to reduce the pres-
• In particular at the entrances to the endan- sure to 1.5 bar (22 psi) and re-inspect the valves.
gered area additional signs are to be set up
(Entry prohibited, Attention! Gas pressure Leak tightness test with gas/air
For checking the leak tightness shortly after installation
tests!). If necessary persons in neighbour-
a test pressure of up to 1.5 bar (22 psi) with a minimum
ing buildings are to be informed.
waiting time of 3 hours applies.
Observe if using compensators

If the pipeline to be tested contains compensators, this
has an influence on the expected axial forces of the
become higher. This has to be taken into account when-
designing the fixed points.
Observe if using valves
nal valve), the valve and the pipe end should be closed
by a dummy flange or cap. This prevents inadvertent
opening of the valve or any pollution of the inside of the
valve.
Minimum waiting times for the internal pressure test
Before carrying out the pressure test, observe the mini-
mum waiting times after the last cementing given in the
following table:
Ambient Temperature Waiting time
10 to 30 °C (50 to 86°F) min. 48 hours
Testing procedure of the internal pressure test

The test pressure shall be least 2 bar higher than the
operating pressure but with a maximum pressure of
nominal pressure PN of the installed piping system. Any
230
Internal pressure test of compressed air
pipelines Leak test with gas as test fluid (compress-
ible medium). Maximum test pressure 0.5
Introduction bar
For practical reasons this testing is done with com-
pressed air. The pressure test follows the DVGW G If it is not possible to do an internal pressure test with
469, up to length of pipelines with 500 m with the visible water (e.g. pipeline must be kept dry), a leak test can be
procedure with air A3. More details are available in the carried out with slight overpressure. For safety reasons
DVGW guideline. the test pressure must then be limited to maximum 0.5
bar overpressure.
Safety precautions
For the leak test all the joints should be sprayed with
a foam-forming medium and subsequently checked. A
WARNING soap solution, which can be removed simply with water
after the test, is best.
Compressible media like compressed

air under internal pressure. NOTICE
In case of failure danger to life during the
internal pressure testing by explosively ex-
Leak detection sprays
haust of medium.
Commercial leak detection sprays can cause
• The area around the pipeline under test stress cracks in plastics.
pressure is to be clearly restricted for ac-
cess only by persons assigned with the • Using these sprays remove any residues
testing. after testing.
• Necessary control equipement is to be
placed at a safe distance. Since the efficiency of this leak test is very restricted
• The testing should be timed so that there due to the low load, it should be used preferably for sys-
are as few persons as possible in the im- tems with working pressures under 0.5 bar.
mediate area.
• In particular at the entrances to the endan-
gered area additional signs are to be set up
(Entry prohibited, Attention! Gas pressure
tests!). If necessary persons in neighbour-
ing buildings are to be informed.
Testing procedure
The test pressure shall be least 2 bar higher than the
operating pressure . If this is not possible because of in-
sufficient power of the compressor, then the maximum
compressor pressure shall be used.
The pipelines must be free from any grease or paint.
The test pressure is applied to the installed pipeline with
an increasing of pressure of maximum 3 bar/min (Risk
of water hammer!). Holding the pipeline under the test
pressure all connection parts of the pipeline like flanges,
unions, valves, etc. are inspected on tightness using a
foam building agent. A soap solution, which can be re-
moved simply with water after the test, is best.
NOTICE
Leak detection sprays

Commercial leak detection sprays can cause
stress cracks in plastics.
• Using these sprays remove any residues
after testing.
It is recommended to reduce the test pressure to 2 bar,

and to repeat the test using a foam building agent.
231
Modifications, repairs, commission-
ing
Modifications and repairs
The following safety measures are to be observed when
modifying or repairing piping systems:
• wear protective clothing
• drain the respective pipeline section completely
• rinse the pipe section
• protect against dripping
• clean and dry the joints
An important factor for the competent repair of piping

systems is to have the work carried out by trained pro-
fessionals.
Modifications and repair work may not weaken the pip-
ing system mechanically.
To ensure the operational safety of the piping system
following a modification or a repair, an internal pressure
test should be done.
Commissioning
When putting a pipeline into operation for the first time,
besides the internal pressure test, temperature effects
are also generally examined. Thermal stress, i.e. expan-
sion, was not simulated during testing.
We recommend an initial inspection at the earliest 3
days, at the latest 7 days, after commissioning and
recording the results.
The inspection checks should include:
• critical points in the system (visual inspection)
• flange joints, unions, valves (leak-proof)
• safety and leak detection equipment (condition, func-
tion)
Continuous inspection of the piping system should be

done by operating personnel during their usual rounds
according to the operating instructions.
232
Jointing technology
Page

Mechanical joints
-- Introduction 234
-- Flange joints 235
-- Adaptor unions joining plastic piping components 242
-- Adaptor unions between plastic and metal pipes (malleable iron union end) 243
-- Adaptor unions stainless steel / plastic 243
-- Adaptor unions between plastic and non-ferrous metal pipes (brass union end) 244
-- Adaptor and threaded fittings 244
-- Adaptor fittings for connecting plastic piping systems and metal threading 245
-- Hose connections on plastic piping systems 245
-- SYGEF® Plus and PROGEF® Natural sanitary adapter for standard TriClamp connections 246
Solvent cement jointing
-- Instructions for Tangit solvent cement jointing of PVC-U dimension d6 to d400 247
-- Instructions for Tangit solvent cement jointing of PVC-C dimension d16 to d225 252
-- Instructions for Dytex solvent cement jointing of PVC-U and PVC-C dimension d12 to d140 256
-- Instructions for Tangit solvent cement jointing of ABS dimension d20 to d315 259
-- Instructions for Tangit solvent cement jointing of COOL-FIT ABS Plus dimension d25 to d225 264
-- Retrofit of adapter fittings into an existing ABS, PVC-U or PVC-C pipeline 269
-- Cementing different pipe materials 270
-- Instructions for solvent cement jointing on video 270
Fusion jointing of PE
-- IR Plus fusion jointing of PE100 piping systems 271
-- Butt fusion jointing of PE piping systems 272
-- Socket fusion jointing of PE piping systems 275
-- Electrofusion 279
Fusion jointing of PP
-- IR Plus fusion jointing of PROGEF piping systems 281
-- BCF Plus fusion jointing of PROGEF Natural piping systems 282
-- Butt fusion jointing of PP piping systems 284
-- Socket fusion jointing of PP piping systems 287
Fusion jointing of PVDF
-- IR Plus fusion jointing of PVDF piping systems 291
-- BCF Plus fusion jointing of SYGEF PVDF piping systems 292
-- Butt fusion jointing of PVDF piping systems 294
-- Socket fusion jointing of PVDF piping systems 297
233
Jointing technology Adaptor fittings
Mechanical joints
Introduction
Of the many diverse solutions offered by GF in the way Plastic fittings with Plastic fittings with Adaptor fittings
of removable joints, the following is dedicated to the rustproof re-inforce- external thread with internal or ex-
conventional methods used in industrial piping systems ment ring A2 and (nipple) ternal thread
construction: parallel or conical in-
ternal thread
Flange connections
Seal: PTFE tape, thread sealing cord , -paste, O-ring
Connection of:
• Plastic - plastic (same or different materials)
• Plastic - metal
Threaded fittings
Plastic fittings without reinforcement ring
and parallel respective conical internal
Flanges: PP-V, Flange adapters Flange adapters thread for connections
PP-steel and PVC- for cementing and for butt fusion
U socket fusion
Seals: flat gasket, O-ring, profile ring, HP-gasket
Connection of: Seal: PTFE tape, thread sealing cord , -paste
• Plastic - plastic (same or different materials) Connection of:
• Plastic - metal • Plastic - plastic (same or different materials)
Unions Hose connections

Connection of (pressure) hoses to plas-
tic piping systems
Seal: O-ring
Connection of: Connection of:
• Plastic - plastic (same or different materials) • Plastic - Hose connection
Adaptor unions Sanitary Adapter
TriClamp connection in ultrapure water

applications, e. g. in the life science sec-
tor
Seal: O-ring
Seal: PTFE
Connection of:
Connection of:
• Plastic - metal (Union end made of malleable iron)
• Plastic - plastic
• Plastic - stainless steel (Union end made of stainless
steel) • Plastic – stainless stell
• Plastic - non-ferrous metal (Union end made of
brass)
234
Type of threads
The following different types of threads are used:
Designation of the According to Typical use Description
thread standard
Rp ISO 7-1 Adaptor and threaded fittings Parallel internal pipe thread, where pressure-
tight joints are made on the threads
Rc ISO 7-1 Not used at GF Taper internal pipe thread, where pressure-
R ISO 7-1 Adaptor and threaded fittings Taper external pipe thread, where pressure-
G ISO 228-1 Unions Parallel internal or external pipe thread,
where pressure-tight joints are not made on the
threads
NPT = National ASTM F 1498 Adaptor and threaded fittings Taper internal or external pipe thread for plas-
(American Stan- tic pipes and fittings, where pressure-tight joints
dard) Pipe Taper are made on the threads
Acme thread Unions Fastening thread for ABS, PVC-U and PVC-C
unions d75, d90, d110
Buttress thread Unions Fastening thread for PE, PP and PVDF unions
d75, d90, d110
Combination G and R thread Information: Within the range of flexible sections and/
The combination of an external parallel thread G, tol- or expansion loops no flange connections shall be used,
erance class A or B in accordance with EN ISO 228-1, because the bending load can lead to leakages.
with an internal parallel thread Rp in accordance with
Ensure centrically alignment of flange adaptor, flange
ISO 7-1 needs special consideration. When it is neces-
and the seal with pipe axis.
sary to have this combination, the positive and negative
tolerance of the internal thread to ISO 7-1 must be con- When inserting a seal between the flange connections,
sidered in the relevant product standard, where exter- the dimensions of the seal should be checked to make
nal parallel threads G are used. Such a combination of sure they correspond to the outer and inner diameter
threads may not necessarily achieve a leak-tight joint. of the flange adapters. If the deviation between the in-
ner diameter of the seal and the adapter is more than
NPT
10 mm, problems may arise with the flange connection.
A combination of thread R or G with NPT is not possible
because of the different pitch. Before pre-tightening the bolts, the jointing faces must
be flush and must sit closely on the seal. Pulling the
Flange joints pipes together within the flange connection is to be
strictly avoided because of the tensile stress which re-
Creating flange joints sults thereof.
When making a flange connection, the following points
have to be taken into consideration: The length of the bolts should be selected so that the
thread at the nut does not protrude more than 2 to 3
There is a general difference between the connection of turns. A washer must be placed under the bolt head and
plastic pipes and so-called adapter joints, which repre- also under the nut.
sent the transition from a plastic pipe to a metal pipe or
a metal valve. Seals and flanges should be selected ac- To make sure that the connecting bolts can be easily re-
cordingly. moved after a lengthy period of use, the thread should
be coated with e. g. molybdenum sulphide.
Flanges with sufficient thermal and mechanical stabili-
ty should be used. GF flange types fulfil these require- Tighten the bolts diagonally and evenly first assem-
ments. ble the bolts and hand-tighten nut, so that the gasket
is perfectly in place and the flange adapters have a
Orientation of bolts outside minimum offset. Then tighten all the bolts diagonally up
main axis. to 50 % of the recommended torque, and afterwards to
Horizontal pipelines should have 100 % of the torque.
the shown orientation of the
bolts in order to avoid in case We recommend checking at a later time and, if neces-
of leakage medium drop on the sary, retightening 24 hours after assembling.
bolts.
After the pressure test, check and cinch if necessary.
For more information on flange connections, see DVS
2210-1 Suppl. 3.
235
Bolt tightening torque DVS 2210-1 Supplement 3, which are to be understood
The torque of the bolts in flange connections is of partic- as upper limit values. Of course our components of the
ular importance. We observe several different methods flange connection (adapters, flanges) are designed to
in practice: withstand these upper limit values.
As tight as possible: In time this will definitely over- Dimensions of metric (ISO) flange connections.
strain a flange connection in plastic piping systems.
Pipe di- Nominal Min. bolt Max. bolt Number
By feel: This requires a good deal of experience and ameter d diameter length length of screws
material know-how. DN (calculat- (calculat- x thread
ed) ed) diameter
Use of a torque wrench: This is the best method. We
have listed the recommended values below; however, 16 10 51 51 4 x M12
deviations can occur in practice. These can be caused 20 15 52 69 4 x M12
by the use of, for example, self-locking nuts or pipe ax-
es which are not flush. The Shore hardness of the seal 25 20 56 73 4 x M12
can also influence the necessary torque force (see also 32 25 60 75 4 x M12
the following information concerning sealing materials).
40 32 70 91 4 x M16
Bolt tightening torque guidelines for metric 50 40 72 95 4 x M16
(ISO) flange connections with PP-V, PP- steel and
PVC flanges. 63 50 78 102 4 x M16
Pipe di- Nominal Bolt tightening torque [Nm] 75 65 82 110 4 x M16

ameter d diameter 90 80 86 114 8 x M16
DN
110, 125 100 89 119 8 x M16
Flat gas- Profile O-ring up
ket up gasket to max. 140 125 101 137 8 x M16
to max. up to pressure
160, 180 150 108 145 8 x M20
pressure max. of 16 bar
of 10 bar / pressure 200, 225 200 130 167 8 x M20
40 °C of 16 bar
250, 280 250 134 177 12 x M20
16 10 10 10 10 315 300 150 185 12 x M20
20 15 10 10 10 355 350 168 192 16 x M20
25 20 10 10 10 400 400 179 207 16 x M24
32 25 15 10 10 450, 500 500 249 253 20 x M24
40 32 20 15 15 560, 630 600 291 295 20 x M27
50 40 25 15 15 The minimum and maximum bolt lengths are given on-

63 50 35 20 20 ly for orientation. They are depending from the type of
flanges and flange adaptors.
75 65 50 25 25 Exact values can be calculated from the information
90 80 30 15 15 shown in the following clause "Length of bolts".
110, 125 100 35 20 20
140 125 45 25 25
160, 180 150 60 35 30
200, 225 200 70 1)
45 35
250, 280 250 65 1)
35 30
315 300 90 1)
50 40
355 350 90 1)
50 -
400 400 100 1)
60 -
450, 500 500 190 1)
70 -
560, 630 600 220 1)
90 -
1) Up to a maximum working pressure of 6 bar

Information: Please observe the special bolt tightening
torques given for DN250 and DN300 recommended for
butterfly valves, see clause "Fundamentals for butterfly
valves, hand operated".
The indicated torques are recommended by GF; with
these torques a sufficient tightness of the flange con-
nection is ensured. They deviate from the data in the
236
Bolt tightening torque guidelines for ANSI flange • Instructions for use with pictogram:
connections with PP-V, PP- steel and PVC flanges.
Nominal Nominal Bolt tightening torque [lb-ft]
diameter- diame-
Inch ter DN

Flat gasket up Profile gas-
to max. pres- ket up to max.
sure of 10 bar / pressure of 16 Socket systems Butt fusion systems
40 °C bar
½ 15 15 10
V-groove (patented)
• To distribute the forces evenly over the flange adapter
¾ 20 15 10
• Supports a longer lasting torque for a safe joint
1 25 15 10
• Gives the name to the flange
1¼ 32 15 10
1½ 40 15 10
2 50 30 20
2½ 65 30 20
3 80 40 30
4 100 30 20
6 150 50 33
8 200 50 33
10 250 60 1)
40
12 300 75 1)
53 PP-steel flanges
The PP-steel flange is a stiff and robust flange univer-
1) Up to a maximum working pressure of 6 bar sally applicable. Its characteristics are as following:
• Corrosion-free plastic flange made out of polypropy-
PP-V flanges
lene PP-GF30 (glass-fibre reinforced) with steel inlay
The PP-V flange shows the following properties:
• High chemical resistance (esp. against hydrolysis)
• Corrosion-free backing flange made of polypropylene
PP (30 % glass-fibre reinforced) • The ambient temperature is max 80°C
• High chemical resistance (hydrolysis resistant) • UV-stabilized
• Maximum break resistance (deforms if it gets tight- PVC flanges
ened too strongly) PVC-U flanges may also be used as long as the medi-
• Suitable up to 80 °C ambient temperature. Remark: um or the ambient temperature does not exceed the
The temperature of the medium is restricted by the temperature of 45 °C.
material of the plastic piping system, i. e. ABS, PVC-
U, PVC-C, PP, PE. At higher temperatures the flanges could distort with
time.
• For PVDF up to 140 °C media temperature, the ambi- Flanges used at higher temperatures must therefore
ent temperature is limited to 40 °C have adequate thermal and mechanical stability. GF
• UV-stabilised PP-V-flanges and PP/steel-flanges satisfy these re-
quirements.
Blanking flanges
The new blanking flange set is a combination of a back-
ing flange and an end blank. The end blanks are avail-
able in PP-H and PE materials.
• Integrated fixation aids for the bolts

• Self-centering of the flanges on the flange adapters
• Symmetric design allows double-sided installation:
"wrong-side installation“ is not possible, all important
information is visible
237
The end blanks in the dimensions d63 to d315 are com- 3a. Thickness of the flat gasket
bined with the proven PP-V backing flange. The dimen-
sions d355 to d630 are combined with a backing flange DN10 to DN80 ca. 2 mm
made of PP-H with steel reinforcement. DN100 to DN600 ca. 3 mm
• With the blanking flange set, the piping system is 3b. Thickness of the profile gasket
closed off in the same material.
• If the piping system is extended, the backing flange DN10 to DN40 ca. 3 mm
can be used again, cutting down on additional costs. DN50 to DN80 ca. 4 mm
• Combined Jointing face flat and serrated, metric. DN100 to DN125 ca. 5 mm
• Suitable for pressure piping. DN150 to DN300 ca. 6 mm
• Easy mounting: The end blank is centered on the in-
DN350 to DN600 ca. 7 mm
ner diameter of the backing flange.
4. Flange thickness (Pitch circle PN10)
PP-V PP-Steel PVC-U Blank
PVC-C Flange
(PVC-U)
DN10 -- -- 10 mm --
DN15 16 mm 12 mm 11 mm 12 mm
DN20 17 mm 12 mm 12 mm 13 mm
DN25 18 mm 16 mm 14 mm 15 mm
DN32 20 mm 20 mm 15 mm 16 mm
DN40 22 mm 20 mm 16 mm 17 mm
Length of bolts
In practice it is often difficult to specify the correct bolt DN50 24 mm 20 mm 18 mm 20 mm
length for flange connections. It can be derived from the DN65 26 mm 20 mm 19 mm 21 mm
following parameter:
DN80 27 mm 20 mm 20 mm 22 mm
• Thickness of the washer (2x)
DN100 28 mm 20 mm 22 mm 24 mm
• Thickness of the nut (1x)
• Thickness of the seal (1x) DN125 30 mm 24 mm 26 mm 28 mm
• Flange thickness (2x) DN150 32 mm 24 mm 28 mm 30 mm
• Thickness of the flange adapter (2x) DN200 34 mm 27 mm 32 mm 36 mm
• Thickness of the valve, if applicable (1x) DN250 38 mm 30 mm 36 mm 36 mm
The following tables are useful in determining the nec- DN300 42 mm 34 mm 36 mm 36 mm
essary bolt length. Due to the various combinations of
DN350 46 mm 40 mm 38 mm 38 mm
the individual components, only thicknesses of the sin-
gle parts of flange connections can be given. However DN400 50 mm 40 mm 42 mm 42 mm
you simply add them together to determine the neces- DN500 -- 54 mm -- --
sary bolt length.
DN600 -- 64 mm -- --
Remark: According to DVS 2210-1 you should deter-
mine the necessary bolt length in order to ensure 2-3
screw turns.
1. Thickness of the washer
DN10 to DN25 3 mm
DN32 to DN600 4 mm
2. Thickness of the nut (= nut height)

DN10 to M 12 SW 19 1.7 mm 10.4 mm nut
DN25 (18) pitch height
DN32 to M 16 SW 24 2.0 mm 14.1 mm nut
DN125 pitch height
DN150 to M 20 SW 30 2.5 mm 16.9 mm nut
DN350 pitch height
DN400 to M 24 SW 36 3.0 mm 20.2 mm nut
DN500 pitch height
DN600 M 27 SW 41 3.0 mm 23.8 mm nut
pitch height
238
5a. Thickness of the metric flange adapter for sock- d315/DN300 35 mm -- --
et systems, flat or profile gasket
d355/DN350 -- -- --
ABS PP PVDF
PVC-C PE d400/DN400 -- -- --
PVC-U
5c. Thickness of the metric flange adapter for butt
d16/DN10 6 mm -- -- fusion systems, flat or profile gasket
d20/DN15 6 mm 7 mm 6 mm PP PP PVDF
d25/DN20 7 mm 9 mm 7 mm PE PE SDR33
SDR11 SDR17 SDR21
d32/DN25 7 mm 10 mm 7 mm
d16/DN10 -- -- --
d40/DN32 8 mm 11 mm 8 mm
d20/DN15 7 mm -- 6 mm
d50/DN40 8 mm 12 mm 8 mm
d25/DN20 9 mm -- 7 mm
d63/DN50 9 mm 14 mm 9 mm
d32/DN25 10 mm -- 7 mm
d75/DN65 10 mm 16 mm --
d40/DN32 11 mm -- 8 mm
d90/DN80 11 mm 17 mm --
d50/DN40 12 mm 12 mm 8 mm
d110/DN100 12 mm 18 mm --
d63/DN50 14 mm 14 mm 9 mm
d125/DN100 13 mm -- --
d75/DN65 16 mm 16 mm 10 mm
d140/DN125 14 mm -- --
d90/DN80 17 mm 17 mm 12 mm
d160/DN150 16 mm -- --
d110/DN100 18 mm 18 mm 13 mm
d200/DN200 24 mm -- --
d125/DN100 25 mm 25 mm 14 mm
d225/DN200 25 mm -- --
d140/DN125 25 mm 25 mm 16 mm
d250/DN250 23 mm -- --
d160/DN150 25 mm 25 mm 17 mm
d280/DN250 23 mm -- --
d180/DN150 30 mm 30 mm --
d315/DN300 27 mm -- --
d200/DN200 32 mm 32 mm 22 mm
d355/DN350 32 mm -- --
d225/DN200 32 mm 32 mm 22 mm
d400/DN400 34 mm -- --
d250/DN250 35 mm 25 mm 22 mm
5b. Thickness of the metric flange adapter for sock- d280/DN250 35 mm 25 mm 22 mm
et systems, O-ring
d315/DN300 35 mm 35 mm 24 mm
PVC-C PP PVDF
PVC-U PE d355/DN350 40 mm 30 mm 30 mm
d16/DN10 9 mm -- -- d400/DN400 46 mm 33 mm 32 mm
d20/DN15 9 mm 9 mm 9 mm d450/DN500 60 mm 60 mm --
d50/DN40 13 mm 13 mm 13 mm
d63/DN50 14 mm 14 mm 14 mm
d75/DN65 15 mm 15 mm --
d90/DN80 16 mm 16 mm --
d110/DN100 18 mm 18 mm --
d125/DN100 19 mm -- --
d140/DN125 20 mm -- --
d160/DN150 22 mm -- --
d200/DN200 30 mm -- --
d225/DN200 31 mm -- --
d250/DN250 23 mm -- --
d280/DN250 30 mm -- --
239
6. Thickness of valves installed between flange The stabilised profile flange gasket as well as O-ring
adapters gaskets have the following advantages:
Butter- Butter- Butter- Wafer • Reliable seal with little screw torque
fly valve, fly valve, fly valve, check • Can be used with higher internal pressure and internal
type 567/ type 367 type 037/ valve, vacuum
568 038 type 369
• Easy to install
DN32 -- -- -- 15 mm • Influenced less by the flange surface
DN40 -- -- -- 16 mm • Safe when connecting pipes of different materials.
DN50 45 mm -- 43 mm 18 mm
Selection of suitable seals, related to the form, can be
DN65 46 mm 46 mm 46 mm 20 mm done with the table below.
DN80 49 mm 49 mm 46 mm 20 mm
Seal form Recommended lim- Flange version
DN100 56 mm 56 mm 52 mm 23 mm its
DN125 64 mm 64 mm 56 mm 23 mm Flat gasket P = 1 to 10 bar, With sealing grooves
above DN200 only to
DN150 72 mm 70 mm 56 mm 26 mm 6 bar
DN200 73 mm 71 mm 60 mm 35 mm T to 40 °C
DN250 113 mm 76 mm 68 mm 40 mm Profile flange- P = 0 *) to 16 bar With or without seal-
gasket T= whole application ing grooves
DN300 113 mm 83 mm 78 mm 45 mm range
DN350 129 mm -- -- -- O-ring P = 0 *) to 16 bar With groove
DN400 169 mm -- -- -- T= whole application
range
DN450 179 mm -- -- --
*) 0 bar ≙ absolute vacuum
DN500 190 mm -- -- --
DN600 209 mm -- -- -- Seal material
The choice of a seal material is based on the flow me-
Selection of the seals for flange connections dia. Details on the suitability of the seal material, or
With consideration to the operating conditions and the specifically the chemical resistance, can be found in our
sealing forces, the selection of suitable flange seals in resistance tables.
thermoplastic piping systems depends on the following The use of seal materials with a high degree of hard-
factors: ness, e. g. as in steel pipes, is restricted in thermoplas-
• Form tic piping systems because the flange or the adapter
• Dimension could become deformed under the great sealing forces.
Elastomer materials, such as EPDM, CSM or FPM, with
• Material
a Shore-A-hardness up to 75 ° are preferable.
Form of the seal Dimensions of the seal
Flat gasket Gasket with profile O-ring
The dimensions of the seal are determined in the gen-
eral standards for pipe jointing components. Too big di-
vergences in the inner or outer diameter of the seal as
compared to the flange adapter can lead to increased
mechanical stress of the flange connection, to accel-
erated wear of the inner side of the seal as well as de-
In applications with low working pressures the custom-
posits inside the pipe.
ary flat gasket, which is made of 2 to 5 mm thick sheet
material (depending on the nominal diameter), is used. One gasket for everything
For flange connections with flat gaskets, flanges which GF Piping Systems makes it easy for you to find the
are sturdy enough to withstand the higher torque re- right gasket. Our new standardized gasket is ideal for
quired for fastening the bolts in such connections are both butt fusion and socket fusion systems alike. It no
necessary. All flanges from GF meet these require- longer makes any difference what SDR your piping sys-
ments. tem has. Save time in selecting the right gasket. Avoid
For increased working and testing pressures, the pro- mistakes and stock less variations. Everything has be-
file flange gaskets and O-rings have proved useful. come much easier. The new standardized gasket, avail-
Compared to the flat gasket, the profile flange gasket is able as profile flange gasket or flat gasket, always puts
made of two components. One is the crowned flat gas- you on the safe side.
ket part which is reinforced with steel, and the other is
the profiled part (O-ring, lip seal) on the seal inner side.
240
All it takes are three simple steps
• Select the gasket type
• Select the dimension
• Select the material
241
Adaptor unions joining plastic piping com-
ponents
Wherever available, unions are the preferred choice
over flange adapters for the connection of plastic pipes.
With no metal parts, there is no corrosion and the
weight is also reduced. In addition, the smaller outer di-
ameter means the distance from pipe axis to pipe axis is
smaller compared to a flange connection. Socket fusion union PVDF Standard
Unions are available in several materials:
Solvent cement connections PVC-U PRO-FIT with
solvent cement socket/spigot
General remarks for installation

To prevent unwanted stress during installation, unions
Solvent cement connections ABS, PVC-U, PVC-C with round seal rings should be used wherever possi-
with solvent cement sockets ble.
The union nut should be tightened by hand. The pipe
wrenches customarily used in steel pipe construction
are not permissible. For bigger sizes, a pipe wrench
with belt can be used.
Using unions take care of a low stress installation.
Within the range of flexible sections and/or expansion
Socket fusion union PP loops no screw connections shall be used, because the
bending load can lead to leakages.
Tip: To make installation of the union easier, wet
the union nut.
Installation tips for PP, PE, PVDF unions, d75, d90

and d110
The newest generation of plastic unions in the above
Butt fusion union PP mentioned materials and dimensions has been
equipped with a modern, plastics-oriented buttress
thread, which means you now have a product with con-
siderably increased nominal pressure and safety re-
serves. The butt fusion versions are also new. Several
points must be observed in this respect.
The thread on coupling nut and union bush in PP,
PVDF and PE have been reworked!
When using single parts, please check prior to mounting
Butt fusion union PP Natural whether the thread of the union bush and coupling nut
can be screwed together.
• Union bush with trapezoidal thread on coupling nut
with trapezoidal thread, or
• Union bush with buttress thread on coupling nut with
buttress thread
Fusion bead at unions for butt fusion

Butt fusion union PE 100 For the dimensions d90 and d110 we advise fusing the
complete union, if possible (or slide the union nut to the
collar of the union end) because after fusion the union
nut cannot be slid over the fusion bead.
Only use union bushes and union ends with the
same nominal diameter.
A butt fusion union bush d75 may not be combined with
a butt fusion union end d90 to form a reducer because
this can cause leakage, as illustrated.
Socket fusion union on request
Butt fusion union PVDF Standard
242
Adapter union with tapered external
pipe thread R
Galvanized malleable iron ↔ PVC-
U, PVC-C, ABS with solvent cement
socket
Adapter union with parallel internal
1 Union nut pipe thread Rp
2 Pipe 1 Union nut d75 Galvanized malleable iron ↔ PVC-
3 Union end 2 Insufficient seal U, PVC-C, ABS with solvent cement
3 Butt fusion union end d90 socket
4 Union bush
4 Butt fusion union bush d75 Adapter union with tapered external
pipe thread R
Unions for adapter connections with different plas- Galvanized malleable iron ↔ PP with
tics fusion socket
The component parts of the butt fusion union in PE, PP,
PVDF (d20 - d63) can be combined with each other as
well as with the PVC or ABS union. Adapter union with parallel internal
pipe thread Rp
For larger dimensions (d75-d110) this is not possible. Galvanized malleable iron ↔ PP with
The union bush and union nut must be made of the fusion socket
same material, the valve end can be taken in another
material.
Other combinations of materials available on request.
Note: To prevent electrochemical corrosion, malleable
iron connecting elements should preferably be used for
steel transitions and brass connecting elements for tran-
sitions to non-ferrous metals.
Adaptor unions stainless steel / plastic
ABS/ Stainless Steel PVC-U/ Stainless

R Steel Rp
PVC-C/ Stainless
PVC-U/ Stainless Steel R
Steel Welding end
Adaptor unions between plastic and metal
pipes (malleable iron union end) The adapter unions from stainless steel to the plastics
ABS, PVC-C and PVC-U (additional plastics can be
The GF line of fittings contains various adapter and combined from the standard single parts) can be used
threaded fittings. For the connection of plastic pip- in the following markets:
ing components to metal pipes, fittings or valves with
• Chemical industry
threaded connections, adapter unions with metal con-
nections are preferred. • Food industry
• Automobile industry
The seal in the metal thread can either be made with
hemp or a PTFE tape. • Swimming pool construction
• Metal surface finishing technology
These adapter unions with EPDM or FPM O-rings are
available for the following plastics: • Refrigeration and air-conditioning
Product features
Plastics-specific sealing of the transition is ensured by
an O-ring gasket in the materials EPDM or FPM. The
stainless steel from which the union ends are made (al-
so the cap nuts in the fusion version) is an austenitic
steel with molybdenum admixture (V4A), which provides
high resistance to pitting. This alloy is also resistant to
rust and acid and is therefore highly suitable for industri-
243
al applications and for use in aggressive environments.
The low carbon content and resulting good fusibility are
further advantages of this material. The plastic/stainless
steel union adapter is available in the three alternative
connections internal thread, external thread and fusion
end, in each case in the dimensions d16-3/8" to d63-2".
Adaptor unions between plastic and non-

ferrous metal pipes (brass union end)
To connect plastic piping components to pipes, fittings
or valves made of non-ferrous metals with threaded
connections, adapter unions with brass connectors
should preferably be used.
The seal in the brass thread can be made either with
hemp or PTFE tape.
Attention: Metal pipes may only be screwed into
These adapter unions with EPDM and FPM O-rings are transition fittings with a reinforcement ring!
available for the following plastics:
Adaptor fittings with tapered external pipe thread R
Adapter union with tapered external (nipple)
pipe thread R Adaptor fittings with tapered external pipe thread R (nip-
Brass ↔ PVC-U, PVC-C, ABS with sol- ple) with exception of double nipple make it possible to
vent cement socket connect both plastic and metal pipes as well as plastic
Adapter union with parallel internal pipe pipes with one another.
thread Rp
Brass ↔ PVC-U, PVC-C, ABS with sol-
vent cement socket
Adapter union with union end made of

red bronze for soldering ↔ ABS with
solvent cement socket
Adapter union with tapered external

pipe thread R Always mind the detailed information given for the indi-
Brass ↔ PP with fusion socket vidual products in the respective product range.
Threaded fittings (without reinforcement ring) with
parallel internal thread Rp
Adapter union with parallel internal pipe
Threaded fittings (without reinforcement ring) in the
thread Rp
materials ABS, PVC-U and PVDF with parallel internal
Brass ↔ PP with fusion socket
thread Rp make it possible to connect plastic pipes with
one another. Some examples of such threaded fittings
can be found in the following:
Other plastics on request.

Note: To prevent electrochemical corrosion, brass con-
necting elements should be used for transitions to non-
ferrous metals and malleable iron connecting elements
for steel transitions.
Adaptor and threaded fittings

Adaptor fittings with rustproof reinforcement ring
A2 and parallel internal pipe thread Rp
Adaptor fittings with rustproof reinforcement ring A2
and parallel internal pipe thread Rp make it possible to
connect both plastic and metal pipes as well as plastic
pipes with one another. A few examples of such adaptor
fittings can be found in the following:
Installation tips for adaptor and threaded fittings
It is especially important that the pipe installation is low-
stress. Adaptor or threaded fittings should be avoided at
points in the piping system which are subjected to bend-
ing stress.
244
In case of large cyclic temperature changes adaptor
unions are the preferable choice.
Attention: To avoid damages at plastics fittings
remove any flash (if present) in the area of the
metal thread.
Primarily adaptor and threaded fittings are tightening

by hand. Never use force when installing plastic fittings.
Using a suitable tool the fittings are tightening further
until 1 - 2 thread pitches are visible.
For plastic adaptor and threaded fittings, we recom-
mend using PTFE tape (e. g. Teflon) for sealing. Alter-
natively also thread sealing cord Henkel Tangit Uni-
Lock or Loctite 55 and/or thread sealing paste Loctite
5331 can be used. Please consider the appropriate in-
stallation guidelines of the manufacturer.
If other sealing materials are used, compatibility with the
plastics to be used must be checked first.
Attention: Do not use hemp! In using hemp there
is a risk of overloading the plastic fittings or dam-
aging the thread. Also, depending on the medium
used, hemp is not resistance against chemicals.
Adaptor fittings for connecting plastic pip-

ing systems and metal threading
PVC-U/ Stainless Steel R ABS/ Brass R
ABS/ Brass Rp PVC-U/ Stainless Steel Rp
The adaptor fittings for connecting plastic piping sys-

tems and metal threading offer greatest possible flexi-
bility for installation with the combined socket/spigot on
the plastic end. The metal thread can be sealed either
with hemp or PTFE-tape.
The adaptor fitting is sealed with an EPDM O-ring. It
serves also as protection against distrotion to avoid
damaging the plastic during installation. Compared to
the usual adaptor unions the special connecting tech-
nology with snap ring guarantees increased leaktight-
ness also while temperature change and during vibra-
tion.
In addition to the classic transition to metal pipes this fit-
tings can also be used for connecting pressure gauges.
Note: To avoid electrochemical corrosion in transi-
tions to non-ferrous metals, brass connections must be
used.
PVC-U pipes
Hose connections on plastic piping sys- Hose nozzle with solvent cement spigot and tapered
tems hose spigot
GF has a wide range of products for hose connections
to plastic piping systems
Information: For fixing the hose on the spigot, please
use suitable hose clips.
245
Pressure-hose nozzle with solvent cement spigot and
parallel hose spigot
Pressure-hose nozzle with tapered external pipe thread

R and parallel hose spigot
ABS and PVC-C pipes

Pressure-hose nozzle with solvent cement spigot and
parallel hose spigot.
Use of the SYGEF® Plus and PROGEF® Natural San-
itary Adapter provides an aseptic plastic/stainless steel
connection.
PE and PP pipes
Pressure-hose nozzle with socket or butt fusion spigot
and parallel hose spigot

PVDF pipes
Pressure-hose nozzle with Flare transition fitting with
BCF, IR, socket or butt fu- BCF, IR or butt fusion spig-
sion spigot and parallel ot to connect PFA (inch)
hose spigot hoses

SYGEF® Plus and PROGEF® Natural sani-

tary adapter for standard TriClamp connec-
tions
Clamp connections form part of the group of longitudinal
interference fit, detachable adapter connections and are
primarily used for pure water and production piping sys-
tems in pharmaceutical, biotechnology, food and cos-
metic industries. A special characteristic of the TriClamp
connection is the simple, rapid and low-cost installation.
This characteristic makes a connection of this kind par-
ticularly suitable for the following fields of application:
• Connection of pipelines to assemblies, machines,
equipment
• Connection of sensors
• Connection of tapping points
• Fitting of subassemblies subject to faults
246
Solvent cement jointing Our experience and tests reveal that pipes above d315
can be slightly oval, which can produce a heightened
Instructions for Tangit solvent cement cementing gap. GF therefore recommends that pipes
jointing of PVC-U dimension d6 to d400 from dimensions d315 should be operated at max. 6 bar
working pressure.
General
Solvent cement jointing calls for adequate technical Please also note the special remarks for dimensions
know-how, which can be acquired in the appropriate 250 - 400 in the following jointing instructions.
training courses. Your GF representative will gladly Tools and equipment
provide you with information about training possi-
bilities. Pipe cutter d10 - 63 790 109 001
Type KRA d50 - 110 790 109 002
d110 - 160 790 109 003
NOTICE Pipe cutter type 790 202 001
KS 355 790 109 600
230 V / 50 - 60 Hz
Pipe cutter type
Chemical resistance KS 1600
Selecting applicable solvent cement Chamfering tool d16-75 799 495 145
• Please consider the appropriate recom- d32-200 799 495 146

mendations in the chapter "Chemical Re- Cleaner 1 litre tin 799 298 010
sistance" to the use of Tangit and/or Dytex.
Tangit PVC-U sol- 0.125 kg tin 799 298 000
vent cement 0.25 kg tin 799 298 001
Dimensions and tolerances 0.50 kg tin 799 298 002
The dimensions of GF pipes, fittings and valves con- 1.0 kg tin 799 298 003
form generally to the various national standards as well
as to ISO 727-1 concerning dimensions of sockets. Our Brush sizes
fittings and valves can be used with any PVC-U pipes
Pipe outside diam- Brush
whose outside diameter tolerance conforms to ISO eter in mm
11922-1.
6-10 Round brush ø4 mm 799 299 001
According to ISO 727-1 the minimal cement lengths are
as shown in the table: 12-32 Round brush ø8 mm 799 299 002
40-63 Flat brush 1" 799 299 003
Pipe outside diameter / Socket in- Minimal cement 25 x 3 mm
side diameter length
d (mm) L (mm) 75-225 Flat brush 2" 799 299 004
50 x 5 mm
6 12.0
250-400 Flat brush 3" 799 299 005
8 12.0
75 x 6 mm
10 12.0
12 12.0 Tin lid 799 298 028
16 14.0
20 16.0 White absorbent commercially available
25 18.5 paper
32 22.0 Solvent resistant commercially available
40 26.0 protecting gloves,
50 31.0
63 37.5 Safety glasses
75 43.5
90 51.0
110 61.0
125 68.5
140 76.0
160 86.0
200 106.0
225 118.5
250 131.0
280 146.0
315 163.5
350 183.5
400 206.0
Recommendation for solvent cement jointing of

PVC-U fittings of dimensions 250 - 400 mm
PVC-U solvent cement fittings d250 to d280 from GF
are designed and tested for a nominal pressure of PN10
(10 bar). The dimensions d315 to d400 are designed Solvent cementing equipment
and tested for a nominal pressure of PN6 (6 bar).
247
PVC-U Tangit and cleaner: Amounts required Note: The quantities specified above are to be under-
stood as practice-orientated maximum values. In princi-
Pipe diameter PVC-U Tangit PVC-U Tangit ple the quantities depend on gap dimensions, tempera-
d (mm) amount per 100 number of joints
tures, working technique.
joints per tin 1 kg
(kg) Preparations
16 0.4 250
20 0.5 200
25 0.6 166
32 0.8 125
40 1.1 91
Cutting the pipe to length Chamfering the pipe
50 1.5 72
63 1.7 59
The pipe must be cut off at right angles. Remove the in-
side edges and chamfer the outside ones as illustrated
75 2.2 45 in the sketch. Only then is an optimal solvent cemented
90 4.0 25 joint possible.
110 8.0 12 Important: Well-chamfered pipe ends prevent the lay-
er of cement from being removed as the pipe is inserted
140 13.0 7
into the fitting.
160 19.0 5
200 24.0 4 Pipe outside di- b
ameter mm
225 26.0 3.5
6 - 16 mm 1 - 2 mm
250 31.0 3 20 - 50 mm 2 - 3 mm
63 - 225 mm 3 - 6 mm
280 38.0 2.5 250 - 400 mm 6 - 8 mm
315 52.0 2
355 62.0 1.6
400 75.0 1.2
Pipe diameter Tangit cleaner Tangit cleaner

joints per tin 1 litre
(litre)
16 0.2 500
20 0.3 333 Marking the jointing length
25 0.4 250 Wipe the outside of the pipe and the inside of the sock-
et with a clean cloth to remove obvious dirt. Marking
32 0.5 200
the jointing length on the pipe end makes it possible to
40 0.7 143 check afterwards whether the pipe has been inserted to
50 0.9 111 the full extent of the socket.
63 1.1 91 Note: If the outside diameter of the pipe and the inside
diameter of the socket are at opposite extremes of their
75 1.3 77 tolerances, then the pipe cannot be inserted dry into the
90 1.4 71 fitting socket. This will only become possible once the
cement has been applied.
110 1.7 59
140 2.1 48
160 2.5 40
200 3.5 29
225 4.5 22
250 5.5 18
280 6.5 15
315 10.2 10
355 14.0 7
400 18.0 5 Checking the cement
248
The Tangit PVC-U cement is supplied ready for use. Stir
thoroughly before using! Cement of the correct consis-
tency will run evenly from a wooden spatula held at a
slant. Cement which no longer runs smoothly is unus-
able. The cement must not be thinned.
For more information please consult the safety
datasheets under the following link:
www.sdb.henkel.de/index.cfm
Cement and cleaner should be stored in a cool, dry
place (5–35 °C)! Under these conditions the cement and
cleaner are durable for 24 months starting from the date
of filling (imprinted on the tin).
Cementing
Clean the outside of the pipe end and the inside of the T Temperature in °C, °F
socket thoroughly with Tangit cleaner and absorbent Y Opening time [sec]
paper. Use a fresh piece of paper for each component.
Remove any condensation which may have formed on Remark: When using Tangit Express the opening time
the parts. is shortened at 20 °C to 1 minute and at 40 °C to 30
seconds. Therefore the maximum dimension is limited
Important: Pipe end and fitting socket must be dry and
to 110 mm .
free from grease and dirt and must not be touched after
cleaning.
Cleaning the pipe and socket

Applying the cement
PVC-U pipes may have a waxy surface. To ensure
proper jointing in such a case the cleaning process must Begin by applying a normal layer of cement to the fitting
be repeated until the pipe surface becomes matt to the socket and then a thicker one to the pipe end with firm
eye. brush pressure. Work in well. The brush strokes should
always be in an axial direction.
For the range of dimensions d250 - 400, mechanical
machining of the pipe surface can be necessary in indi- To ensure that both jointing surfaces are completely
vidual cases. An indication of inadequate jointing qual- covered with a smooth, even layer of cement, the brush
ity, which could be expected, is absence of or insuffi- should be generously loaded with cement.
cient adhesion of the jointing parts following fine clean-
ing ("finger-nail check"). The jointing surfaces should Range of dimensions up to d75
then be roughened evenly with emery cloth of grain 80 Apply cement
or finer, observing the max. permitted gap. The cement joints can be produced by one person.
PVC-U pipes should be cemented at temperatures be- Jointing
tween 5 °C and 40 °C. Take the following protective After the cement has been applied, insert the pipe to
measures if the temperatures deviate from the above: the full depth of the socket immediately without twisting
At lower temperatures, condensation or frost which may and bring them into the correct alignment. Ensure that
have formed must be removed, e. g. with warm air. Ce- the outlet of the fitting is in the correct position. Hold
ment and cleaner should be stored at room tempera- them briefly in this position to allow the cement to set.
ture. Waiting time between cementing
Avoid uneven overheating (→ shorten the opening time) Wait at least 5 minutes before the next joint, extend
when cementing at higher temperatures by protecting the waiting time at temperatures under 10 °C to 15
the jointing area from direct sunlight. minutes.
The quick curing time of the cement necessitates that

the joint is made within the opening time after applica-
tion of the cement has started. The opening time of the
PVC-U cement varies with the ambient temperature and
the thickness of the cement applied:
249
Range of dimensions d90 to d225 After use, clean the brush of excess cement with dry ab-
sorbent paper and then clean thoroughly using TANGIT
Apply cement cleaner. Brushes must be dry before being re-used
The fitting socket and end of pipe should be coated (shake out).
with cement simultaneously by two persons, otherwise
the opening time of the cement cannot be observed. Replace the lid of the cement tin after use to prevent the
solvent evaporating. Using the conical lid allows leaving
Jointing the brush in the cement tin during breaks.
After the cement has been applied, insert the pipe to
the full depth of the socket immediately without twisting Both solvent cement and cleaner dissolve PVC-U. Pipes
and bring them into the correct alignment. Ensure that and fittings must therefore not be laid on or allowed to
the outlet of the fitting is in the correct position. Hold come into contact with spilled cement or paper contain-
them briefly in this position to allow the cement to set. ing cement residues.
Waiting time between cementing Do not close off cement pipelines during the drying pro-
Wait at least 5 minutes before the next joint, extend cess. This is particularly important at temperatures be-
the waiting time at temperatures under 10 °C to 15 low + 5 °C, when there is otherwise a danger of damag-
minutes. ing the material.
After the drying process (see waiting times in the follow-
Range of dimensions d250 to d400 ing table) the pipelines can be filled. To remove extant
solvent vapour, it is recommended to flush the pipeline
Apply cement
before use.
Deviating from the usual method of application, pour
For pipes that are not put into immediate use, it is rec-
the cement directly from the tin onto the middle of the
ommended, after careful cleaning, to fill them with water
cementing surface and distribute first radially and then
and flush regularly.
axially all over with a flat brush. Make sure that the ce-
Do not use compressed air for flushing.
ment layer is consistent and covers the entire surface
as appropriate for the larger tolerances. Drying period and pressure testing
Apply a thinner layer of Tangit in the fitting than on the The drying period of the cement before application of
pipe ends. The cementing of pipe work in this range the test or working pressure depends on the drying tem-
of dimensions should be carried out by at least 2 per- perature, the dimension and the fit conditions.
sons. The minimum thickness of the cement layer for
The waiting times required between completing the last
fittings is 1 mm, apply more generously on the pipe
joint and the pressure test are specified in the following
ends.
table.
Jointing
If the pipe is only subjected to the operating pressure,
After applying the cement, the pipe and fitting should
e. g. after adaptation or repair work, the following rule of
be slowly pushed together to the stop or the mark with-
thumb for the drying waiting time applies:
out twisting by 3-4 persons and aligned. Ensure that
1 hour waiting time per bar operating pressure.
the outlet end of the fitting is in the correct position.
Hold the joint in this position for 1 minute. For temperatures above 20 °C the test pressure must
be reduced according to the requirements given in the
Waiting time between cementing
chapter "Final testing and commissioning".
A waiting time of 15 minutes should be observed be-
fore further jointing; this time should be increased to 30 Remark: When using Tangit Express (only up to d110)
minutes at temperatures below 10 °C. the waiting time is shortened to 12 hours, or 1/4-hour
waiting time per bar operating pressure.
Dimension Nominal pressure Max. working pres-
(PN) of fitting 20 °C, sure 20 °C, water
water
up to d225 PN10 or PN16 10 or 16 bar
d250 PN10 10 bar
d280 PN10 10 bar
d315 PN6 6 bar
d350 PN6 6 bar
Replace the lid of the cement tin during work breaks d400 PN6 6 bar
Remove any surplus cement immediately, using ab-

sorbent paper.
A bead of excess solvent cement around the complete
external circumference of the joint and a slightly smaller
bead again around the complete internal circumference
show that the joint has been performed correctly.
250
Dimension Max. test pressure Waiting time after
20 °C, water last cementing until
test
up to d225 15 or 21 bar 15 or 24 h
d250 15 bar
d280 15 bar
d315 9 bar 24 h
d350 9 bar
d400 9 bar
Safety precautions
Tangit cement and Tangit cleaner contain highly volatile
solvents. This makes good ventilation or adequate fume
extraction essential in closed spaces. Since the solvent
fumes are heavier than air, extraction must occur at
floor level, or at least below the working level. Place pa-
per which has been used for cleaning or for the removal
of surplus cement into closed containers to minimise the
amount of solvent fumes in the air.
Cement and cleaner are inflammable. Extinguish open
fires before commencing work. Switch off unprotected
electrical apparatus, electric heaters, etc. Avoid static
charge. Do not smoke! Discontinue any welding oper-
ations. Furthermore, observe all instructions issued by
the solvent cement manufacturer (e. g. label of the tin
and any supplementary documentation).
Protect pipes and fittings from spilled solvent cement,
cleaner and absorbent paper which has been used to
wipe off cement. Do not dispose of surplus solvent ce-
ment or cleaner in drainage systems.
The use of protective gloves is recommended to avoid
contact with skin. If the cement or the cleaner get in
contact with eyes, rinse immediately with water. Consult
a doctor! Immediately change clothes that have solvent
cement on them.
Always obey the safety regulations issued by the au-
thorities responsible.
Adequate ventilation of the No open flames when cement-

workplace ing. No smoking.
251
Instructions for Tangit solvent cement Tools and equipment
jointing of PVC-C dimension d16 to d225
Pipe cutter d10 - 63 790 109 001
General Type KRA d50 - 110 790 109 002
Solvent cement jointing calls for adequate technical d110 - 160 790 109 003
know-how, which can be acquired in the appropriate Pipe cutter type 230 V / 50 - 60 Hz 790 202 001
training courses. Your GF representative will gladly KS 355
bilities.
Chamfering tool d16-75 799 495 145
d32-200 799 495 146
NOTICE Cleaner 1 litre tin 799 298 010
Tangit PVC-C sol- 0.70 kg tin 799 298 027
vent cement
Chemicale resistance
Brush sizes
Selecting applicable solvent cement
Pipe outside diam- Brush
• Please consider the appropriate recome- eter in mm
nations in the chapter "Chemicale Resis-
tance" to the use of Tangit and/or Dytex. 16-32 Round brush ø8 mm 799 299 002
40-63 Flat brush 1" 799 299 003
Dimensions and tolerances 25 x 3 mm
The dimensions of GF pipes, fittings and valves con- 75-225 Flat brush 2" 799 299 004
form generally to the various national standards as well 50 x 5 mm
as to ISO 727-1 concerning dimensions of sockets. Our Tin lid 799 298 028
fittings and valves can be used with any PVC-C pipes
whose outside diameter tolerance conforms to ISO White absorbent commercially available
paper
11922-1.
Solvent resistant commercially available
According to ISO 727-1 the following minimal cement protecting gloves,
lengths are as shown in the table:
Safety glasses
Pipe outside diameter - Minimal cement length
Socket inside diameter L (mm)
d (mm)
16 13.0
20 15.0
25 17.5
32 21.0
40 25.0
50 30.0
63 36.5
75 42.5
90 50.0
110 60.0
125 67.5
140 75.0
160 85.0
200 105.0 Solvent cementing equipment
225 117.5
The following instructions for cementing of piping com-

ponents made from PVC-C is based on the guideline
DVS 2204-5.
252
PVC-C Tangit and cleaner: Amounts required The pipe must be cut off at right angles. Remove the in-
Pipe diameter PVC-C Tangit PVC-C Tangit in the sketch. Only then is an optimal solvent cemented
joint possible.
joints per tin 1 kg
(kg) Important: Well-chamfered pipe ends prevent the lay-
16 0.4 250 er of cement from being removed as the pipe is inserted
into the fitting.
20 0.5 200
25 0.6 166 Pipe outside b
diameter mm
32 0.8 125
16 mm 1 - 2 mm
40 1.1 91 20 - 50 mm 2 - 3 mm
50 1.5 72 ≥ 63 mm 3 - 6 mm
63 1.7 59
75 2.2 45
90 4.0 25
110 8.0 12
140 13.0 7
160 19.0 5
200 24.0 4
225 26.0 3.5
Marking the jointing length
d (mm) amount per 100 number of joints Wipe the outside of the pipe and the inside of the sock-
joints per tin 1 litre et with a clean cloth to remove obvious dirt. Marking
(litre) the jointing length on the pipe end makes it possible to
16 0.2 500 check afterwards whether the pipe has been inserted to
the full extent of the socket.
20 0.3 333
Note: If the outside diameter of the pipe and the inside
25 0.4 250 diameter of the socket are at opposite extremes of their
32 0.5 200 tolerances, then the pipe cannot be inserted dry into the
fitting socket. This will only become possible once the
40 0.7 143
cement has been applied.
50 0.9 111
63 1.1 91
75 1.3 77
90 1.4 71
110 1.7 59
140 2.1 48
160 2.5 40
200 3.5 29
225 4.5 22
Note: The quantities specified above are to be under- Checking the cement
stood as practice-orientated maximum values. In princi- The Tangit PVC-C cement is supplied ready for use. Stir
ple the quantities depend on gap dimensions, tempera- thoroughly before using! Cement of the correct consis-
tures, working technique. tency will run evenly from a wooden spatula held at a
Preparations slant. Cement which no longer runs smoothly is unus-
place (5 – 35 °C)! Under these conditions the cement
Cutting the pipe to length Chamfering the pipe and cleaner are durable for 24 months starting from the
date of filling (imprinted on the tin).
253
Cementing To ensure that both jointing surfaces are completely
Clean the outside of the pipe end and the inside of the covered with a smooth, even layer of cement, the brush
socket thoroughly with Tangit cleaner and absorbent should be generously loaded with cement.
paper. Use a fresh piece of paper for each component.
The joints can be made singlehanded for pipes with di-
Remove any condensation which may have formed on
ameters up to d63 mm.
the parts.
For d75 mm and larger pipes, two people are needed
to apply the cement to the pipe end and fitting socket si-
multaneously in order to avoid exceeding the maximum
cleaning.
opening time of the cement.
The PVC-C cleaner should soften the outside of the Applying the cement
pipe. Special attention should be paid that the PVC-C
has softened ("finger-nail check"). If this is not the case, After the cement has been applied, insert the pipe to the
to aid the softening, emery cloth or medium glasspaper, full depth of the socket immediately without twisting and
grade ≥ K80, can be used to roughen the joint surface, bring them into the correct alignment. Ensure that the
repeat the cleaning process after roughening. outlet of the fitting is in the correct position. Hold them
briefly in this position to allow the cement to set. Wait at
PVC-C pipes should be cemented at temperatures be- least 10 minutes before the next joint, extend the wait-
tween +5 °C and +40 °C. Take the following protective ing time at temperatures under 10 °C to 30 minutes.
measures if the temperatures deviate from the above:
Remove any surplus cement immediately, using ab-
At lower temperatures, condensation or ice water which sorbent paper.
may have formed must be removed, e. g. with warm air.
Cement and cleaner should be stored at room tempera- A bead of excess solvent cement around the complete
ture. external circumference of the joint and a slightly smaller
bead again around the complete internal circumference
Avoid uneven overheating (→ shorten the opening time) show that the joint has been performed correctly.
when cementing at higher temperatures by protecting
the jointing area from direct sunlight. After use, clean the brush of excess cement with dry ab-
sorbent paper and then clean thoroughly using TANGIT
The quick curing time of the cement necessitates that cleaner. Brushes must be dry before being re-used
the joint is made within the opening time after applica- (shake out).
tion of the cement has started. The opening time of the
PVC-C cement varies with the ambient temperature and
the thickness of the cement applied:
Replace the lid of the cement tin during work breaks

Y Opening time [sec] Replace the lid of the cement tin after use to prevent the
solvent evaporating. Using the conical lid, allows leaving
Begin by applying a normal layer of cement to the fitting the brush in the cement tin during breaks.
socket and then a thicker one to the pipe end with firm
brush pressure. Work in well.The brush strokes should
always be in an axial direction.
254
Both solvent cement and cleaner dissolve PVC-C. Pipes
and fittings must therefore not be laid on or allowed to
come into contact with spilled cement or paper contain-
ing cement residues.
Do not close off cement pipelines during the drying pro-
cess. This is particularly important at temperatures be-
low +5 °C, when there is otherwise a danger of damag-
ing the material. Adequate ventilation of the No open flames when cement-
workplace ing. No smoking.
After the drying process (see waiting times in the follow-
ing table) the pipelines can be filled. To remove extant
solvent vapour, it is recommended to flush the pipeline
before use.
For pipes that are not put into immediate use, it is rec-
and flush regularly.
Do not use compressed air for flushing.
Drying period and pressure testing
The length of drying period before the joint may be sub-
jected to testing or operating pressure depends on the
ambient temperature and the tolerances.
Generally the waiting time after the last joint until the
pressure test at a testing pressure of 15 bar (PN10)
must be at least 15 hours, a testing pressure of 21 bar
(PN16) must be at least 24 hours. If the pipe is only
subjected to the operating pressure, e. g. after adapta-
tion or repair work, the following rule of thumb for the-
waiting time applies:
1 hour waiting time per bar operating pressure.
For temperatures above 20 °C the test pressure must
chapter "Final testing and commissioning".
Safety precautions
Tangit cement and Tangit cleaner contain highly volatile
solvents. This makes good ventilation or adequate fume
extraction essential in closed spaces. Since the solvent
fumes are heavier than air, extraction must occur at
amount of solvent fumes in the air.
Cement and cleaner are inflammable. Extinguish open
electrical apparatus, electric heaters, etc. Avoid static
cement on them.
255
Instructions for Dytex solvent cement joint- Medium % concentrations equal and above
ing of PVC-U and PVC-C dimension d12 to
Sulphuric acid ≥70 % H2SO4 concentration
d140
Chromic– sulphuric ≥70 % H2SO4 concentration
General acid mixture plus 5 % K2Cr2O7 / Na2Cr2O1
Dytex solvent cement combined with Dytex solvent /
cleaner is a special cementing system for PVC-U / PVC- Chromic acid ≥10 % CrO3 concentration
C piping systems which are exposed to the effects of Hydrochloric acid ≥25 % HCl concentration
highly aggressive chemicals, such as concentrated, in-
organic acids. For all media not mentioned below or Nitric acid ≥20 % HNO3 concentration
media in lower concentrations, Tangit solvent cement Sodium hypochlo- ≥6 % NaOCl concentration
should be used. Because Dytex is not gap-filling, a spe- rite (calcium of active chlorine
cial cement jointing procedure is required and is de- hypochlorite)
scribed in the following. Hydrogen peroxide ≥5 % H2O2 concentration
Dytex solvent cement jointing calls for adequate Hydrofluoric acid In every HF concentration
technical know-how, which can be acquired in the
appropriate training courses. Your GF representa- Tools and equipment
tive will gladly provide you with information about
training possibilities. Pipe cutter d10 - 63 790 109 001
Type KRA d50 - 110 790 109 002
The dimensions of GF pipes, fittings and valves conform d110 - 160 790 109 003
generally to the various national standards as well as
Pipe cutter type 230 V / 50 - 60 Hz 790 202 001
to ISO 727-1 concerning dimensions of sockets. Our fit- KS 355
tings and valves can be used with any PVC-U or PVC-
C pipes whose outside diameter tolerance conforms to
ISO 11922-1. Chamfering tool d16-75 799 495 145
d32-200 799 495 146
According to ISO 727-1 the following minimal cement
lengths apply: Dytex solvent and
0.5 litre tin
799 271 383
cleaner
Pipe outside diameter - Minimal cement length L
Socket inside diameter d (mm) Dytex solvent ce- 0.5 litre tin 799 271 423
(mm) ment
12 11.0 Brush sizes

16 13.0 Pipe outside diam- Brush
20 15.0 eter in mm
25 17.5
32 21.0 6-10 Round brush ø4 mm 799 299 001
40 25.0 12-32 Round brush ø8 mm 799 299 002
50 30.0
63 36.5 40-63 Flat brush 1" 799 299 003
75 42.5 25 x 3 mm
90 50.0 75-140 Flat brush 2" 799 299 004
110 60.0 50 x 5 mm
125 67.5
140 75.0 Tin lid 799 298 028
White absorbent commercially available
The use of Dytex solvent cement is recommended for paper
cement jointing PVC-U or PVC-C in connection with the
acids shown in the table.
protecting gloves,
Due to the effects of these acids on the pipe materi-
al, we recommend using pipes with a pressure rat- Safety glasses
ing PN16. For the expected lifetime and compressive
strength, please contact your GF representative.
Attention! Usually the allowable pressure must be de-
creased by one pressure rating (thus PN16 to PN10).
When using Dytex in PVC-C piping construction with the
above mentioned acids, the pressure and temperature
requirements for PVC-U must be adhered to.
Please refer to the information on the above mentioned
acids in our list of chemical resistance.
Solvent cementing equipment
256
Dytex solvent and cleaner: Amounts required Dytex solvent cement is supplied ready to use. Stir well
before using. Diluting the solvent cement is prohibited.
Pipe di- Dytex cement amount Dytex cleaner amount Cement and solvent should be stored in a dry and cool
ameter per 100 joints per 100 joints
place (5 - 35 °C)! Under these conditions the cement
d (mm) (kg) (litre)
and cleaner are durable for 24 months starting from the
date of filling (imprinted on the tin).
16 0.25 0.55
20 0.3 0.65 datasheets under the following link:
25 0.4 0.8 www.sdb.henkel.de/index.cfm
32 0.5 1.0 Cementing
Fine cleaning is done with the Dytex solvent (do not use
40 0.7 1.2
Tangit cleaner!). Soak a white, absorbent, lint-free pa-
50 0.9 1.4 per with Dytex solvent and thoroughly clean the dry sur-
63 1.1 1.8 faces which are to be cemented. Use a new sheet of
absorbent paper for each cleaning. Then brush Dytex
75 1.5 2.3 solvent onto the surfaces to be cemented (pipe ends on
90 2.1 3.1 the outside, fitting on the inside) until the surface clearly
begins to dissolve (becomes sticky).
110 2.9 4.7
Apply Dytex cement to the dissolved surfaces with a
140 4.5 7.9
brush in the axial direction and let dry for at least 30
Note: The quantities specified above are to be under- seconds. Repeat this process as indicated in the follow-
stood as practice-orientated maximum values. In princi- ing table.
ple the quantities depend on gap dimensions, tempera- Cement gap (diameter difference) of more than 0.4 mm
tures, working technique. are not permitted! Pipes / fittings from the dimension
Preparations 110 must be measured to determine the permissible
The pipe must be cut off at right angles. Remove the in- gap.
side edges and chamfer the outside ones as illustrated d up to 16 mm gap max. 2 x both
in the sketch. This is the only way to achieve an optimal = ± 0.0 mm sides
solvent cemented joint.
d 16 - 25 mm gap max. 3 x both
Important: Well-chamfered pipe ends prevent the lay- = + 0.0 mm sides
d 32 - 40 mm gap max. 4 x both
into the fitting. = + 0.1 mm sides
Pipe outside b d 50 - 63 mm gap max. 6 x
diameter mm = + 0.2 mm both sides
6 - 16 mm 1 - 2 mm d 75 - 90 mm gap max. 8 x both
20 - 50 mm 2 - 3 mm = + 0.3 mm sides
63 - 140 mm 3 - 6 mm d 110 - 140 mm gap max. 10 x both
= + 0.4 mm sides
Cement applications in relation to gap (diameter dif-

ference)
Remark: If there are smaller gaps than shown in
the table, the amount of cement applications can
be reduced.
After the final application of cement, coat both surfaces

again with the Dytex solvent until they are once again
sticky, then insert the parts immediately to the full depth
Marking the jointing length of the fitting, without twisting/tilting and hold for a few
seconds. Make sure that the fitting outlet is in the right
Wipe the outside of the pipe and the inside of the sock- position. When inserting, you must feel some resis-
et with a clean cloth to remove obvious dirt. Marking tance. The solvent cement bead that forms must be
the jointing length on the pipe end makes it possible to complete and consistent. Excess cement is wiped off
check afterwards whether the pipe has been inserted to immediately.
the full extent of the socket.
Because the solvent cement bonds quickly, the parts
Because Dytex cement is not gap-filling, the fit of the must be joined within max. 1 minute of applying the final
pipe and fitting must be checked in the dry state. If the coat of Dytex solvent. At temperatures above 25 °C this
pipe end can be inserted easily and without resistance time frame is reduced to under 1 minute.
to the stop, several applications of cement are neces-
Due to the short open assembly time of 1 minute, the
sary.
use of Dytex is limited to a pipe diameter of 140 mm.
257
The waiting time between the individual work steps The cement and the solvent are flammable. Make sure
(=next cement joint) depends on the size of the gap. there are no open flames before starting to work. Shut
off any electrical equipment that is not designed to be
Cement gap less than 0.2 Cement gap greater than explosion-proof, electric ovens, etc.Avoid static charge.
mm 0.2 to 0.4 mm Do not smoke! Stop all fusion work. Also heed the in-
Waiting time 10 - 15 minutes Waiting time 30 minutes structions of the cement manufacturer (e. g. on the tin
At temperatures under 10 °C and in the leaflets supplied).
the waiting time extends to
45 minutes Protect pipes and fittings from spilled cement, solvent
and paper that has been used to wipe the cement from
The cementing should be done at temperatures be- the parts. Do not pour cement or solvent no longer re-
tween 5 °C and 40 °C. If there are deviations, please quired into the sewer pipes.
observe the following safety measures: We recommend using protective gloves to avoid contact
At temperatures near the freezing point, any condensa- with the cement and the solvent. In case of contact with
tion or thaw must be removed, e.g. with warm air. The eyes, rinse thoroughly with water. Seek medical advice!
cement and the solvent should be kept beforehand at Replace clothing contaminated with the cement immedi-
room temperature. The finished joint must be kept at ap- ately.
prox. 25 °C for another 15-30 minutes. Observe the respective accident prevention guidelines.
At higher temperatures, protect the jointing area from
direct sunlight as the components could heat up too
much.
Up to about d63 mm, the cement joints can be manufac-
tured by one person alone. From d75 mm one person
should apply the cement to the fitting socket while an-
other coats the pipe end, otherwise it is not possible to
maintain the open assembly time of max. 1 minute.
Remove any thick cement residue on the brush with a workplace ing. No smoking.
dry absorbent paper and then rinse the brush with the
solvent. Before using the cleaned brushes again, they
must be dry to touch (shake out).
To prevent the solvent from evaporating (cement dries
up), the cement tin should be kept closed during work
breaks. A lid that allows keeping the brush in the tin can
be used.
Since Dytex cement and solvent are etching, pipes or
fittings may not be placed on spilled cement or cement
residue left on the paper or come into contact with them
in any way.
low + 5 °C, when there is otherwise a danger of damag-
ing the material.
Drying period and pressure testing
After a drying period of approx. 48 hours at room tem-
perature, the final strength of the joint is achieved. At
lower ambient temperatures, the bonding takes longer.
The pipeline may only be filled and the pressure test
may only be done at the earliest 48 hours after the last
cementing.
For temperatures above 20 °C the test pressure must
chapter "final testing and commissioning".
Safety precautions
Dytex cement and Dytex solvent contain highly volatile
solvents. Make sure there is adequate ventilation or ex-
haust fans in closed rooms. Solvent vapours are heav-
ier than air. The off-take must therefore be on the floor
or under the workbench for example. The paper used
to clean the parts and to remove the cement must be
deposited in closed containers to reduce the amount of
solvent vapours in the air.
258
Instructions for Tangit solvent cement Tools and equipment
jointing of ABS dimension d20 to d315
Pipe cutter d10 - 63 790 109 001
General Type KRA d50 - 110 790 109 002
Solvent cement jointing calls for adequate technical d110 - 160 790 109 003
know-how, which can be acquired in the appropriate Pipe cutter type 790 202 001
training courses. Your GF representative will gladly 230 V / 50 - 60 Hz
KS 355
Chamfering tool d16-75 799 495 145
bilities.
d32-200 799 495 146
The dimensions of GF pipes, fittings and valves con-
form generally to the various national standards as Cleaner 1 litre tin 799 298 010
well as to ISO 727-1 concerning dimensions of sock- Tangit ABS sol- 799 298 022
ets. Our fittings and valves can be used with any ABS 0.65 kg tin
vent cement
pipes whose outside diameter tolerance conforms to
Brush sizes
ISO 11922-1.
Pipe outside diam-
According to ISO 727-1 the following minimal cement eter in mm
Brush
lengths are as shown in the table:
20-32 Round brush ø8 mm 799 299 002
Pipe outside diameter / Minimal cement length
socket inside diameter 40-63 Flat brush 1" 799 299 003
d (mm) L (mm) 25 x 3 mm
20 15.0 75-225 Flat brush 2" 799 299 004
25 17.5 50 x 5 mm
32 21.0
40 25.0 250-315 Flat brush 3" 75 x 799 298 005
50 30.0 6 mm
63 36.5 Tin lid 799 298 028
75 42.5
90 50.0 White absorbent commercially available
110 60.0 paper
125 67.5
140 75.0
protecting gloves,
160 85.0

200 105.0
Safety glasses
225 117.5
250 130.0
280 145.0
315 162.5
Recommendation for solvent cement jointing of AB-

S fittings of dimensions 250 - 315 mm
ABS solvent cement fittings d250 to d315 from GF are
designed and tested for a nominal pressure of PN6 (6
bar).
Our experience and tests reveal that pipes above d250
can be slightly oval, which can produce a heightened
cementing gap. GF therefore recommends that pipes
from dimensions d250 should be operated at max. 6 bar
working pressure.
Please note the special remarks for dimensions 250 - Solvent cementing equipment
315 in the following jointing instructions.
259
ABS Tangit and cleaner: Amounts required Preparations
Pipe diameter ABS Tangit ABS Tangit num-
d (mm) amount per 100 ber of joints per
joints tin 0.650 kg
(kg)
20 0.35 186
25 0.40 163
Cutting the pipe to length Chamfering the pipe
32 0.45 144
The pipe must be cut off at right angles. Remove the in-
40 0.60 108
50 0.90 72 in the sketch. Only then is an optimal solvent cemented
63 1.10 59
joint possible.
75 1.25 52 Important: Well-chamfered pipe ends prevent the lay-

90 1.70 38 into the fitting.
110 2.50 26
Pipe outside di- b
140 5.00 13 ameter
160 6.50 10 20 - 50 mm 2 - 3 mm
200 10.0 6 63 - 225 mm 3 - 6 mm
250 - 315 mm 6 - 8 mm
225 12.5 5
250 16.0 4
280 19.0 3
315 26.5 2

joints per tin 1 litre
(litre)
20 0.3 333
25 0.4 250 Marking the jointing length
32 0.5 200 Wipe the outside of the pipe and the inside of the sock-
40 0.7 143 et with a clean cloth to remove obvious dirt. Marking
the jointing length on the pipe end makes it possible to
50 0.9 111
check afterwards whether the pipe has been inserted to
63 1.1 91 the full extent of the socket.
75 1.3 77 Note: If the outside diameter of the pipe and the inside
90 1.4 71 diameter of the socket are at opposite extremes of their
tolerances, then the pipe cannot be inserted dry into the
110 1.7 59 fitting socket. This will only become possible once the
140 2.1 48 cement has been applied.
160 2.5 40
200 3.5 29
225 4.5 22
250 5.5 18
280 6.5 15
315 10.2 10
Note: The quantities specified above are to be under-

stood as practice-orientated maximum values. In princi-
ple the quantities depend on gap dimensions, tempera- Checking the cement
tures, working technique.
The Tangit ABS cement is supplied ready for use. Stir
thoroughly before using! Cement of the correct consis-
tency will run evenly from a wooden spatula held at a
slant. Cement which no longer runs smoothly is unus-
260
For more information please consult the safety-
place (5–35 °C)! Under these conditions the cement and
cleaner are durable for 24 months starting from the date
of filling (imprinted on the tin).
Cementing
Clean the outside of the pipe end and the inside of the
socket thoroughly with ABS cleaner and absorbent pa-
per.
cleaning. T Temperature in °C / °F
Y Opening time [sec]
Begin by applying a normal layer of cement to the fitting

and then a thicker one to the pipe end with firm brush
pressure. Work in well. The brush strokes should al-
ways be in an axial direction.
To ensure that both jointing surfaces are completely
covered with a smooth, even layer of cement, the brush
should be generously loaded with cement.
ABS pipes should be cemented at temperatures be-

tween +5 °C and +40 °C. Take the following protective
measures if the temperatures deviate from the above:
Installation at low temperatures requires utmost care.
Since Tangit ABS cures physically by evaporation, hard-
ening may be slowed down considerably. Special instal-
lation techniques are therefore required at temperatures
below +5ºC.
Cement and cleaner should be stored at room temper- Applying the cement
ature. To remove condensation or ice water which may
have formed, pipe ends and sockets to be bonded are Range of dimension up to d63
warmed to +25 to +30ºC by means of a suitable hot-
air blower (explosion proof) and then bonding is done Apply cement
as described. The finished joint must be kept at +25 to The cement joints can be produced by one person.
+30ºC according to the waiting times mentioned in the Jointing
following before the next cementing. After the cement has been applied, insert the pipe to
Avoid uneven overheating (→ shorten the opening time) the full depth of the socket immediately without twisting
when cementing at higher temperatures by protecting and bring them into the correct alignment. Ensure that
the jointing area from direct sunlight. the outlet of the fitting is in the correct position. Hold
them briefly in this position to allow the cement to set.
The quick curing time of the cement necessitates that
the joint is made within the opening time after applica- Waiting time between cementing
tion of the cement has started. The opening time of the Wait at least 10 minutes before the next joint, ex-
ABS cement varies with the ambient temperature and tendthe waiting time at temperatures under 10 °C or
the thickness of the cement applied: above 30 °C to 15minutes.
261
Range of dimension d75 to d140
Apply cement
The fitting socket and end of pipe should be coated-
with cement simultaneously by two persons, otherwise
the opening time of the cement cannot be observed.
Jointing
After the cement has been applied, insert the pipe to
the full depth of the socket immediately without twisting
and bring them into the correct alignment. Ensure that
the outlet of the fitting is in the correct position. Hold
them briefly in this position to allow the cement to set.
Wait at least 10 minutes before the next joint, ex-
tendthe waiting time at temperatures under 10 °C or
above 30 °C to 15minutes.

Replace the lid of the cement tin during work breaks
Apply cement
The fitting socket and end of pipe should be coated Remove any surplus cement immediately, using ab-
with cement simultaneously by two persons, otherwise sorbent paper.
the opening time of the cement cannot be observed. A bead of excess solvent cement around the complete
Jointing external circumference of the joint and a slightly smaller
After the cement has been applied, insert the pipe to bead again around the complete internal circumference
the full depth of the socket immediately without twisting show that the joint has been performed correctly.
and bring them into the correct alignment. Ensure that After use, clean the brush of excess cement with dry ab-
the outlet of the fitting is in the correct position. Hold sorbent paper and then clean thoroughly using TANGIT
them briefly in this position to allow the cement to set. cleaner. Brushes must be dry before being re-used
Waiting time between cementing (shake out).
Wait at least 30 minutes before the next joint, extend Replace the lid of the cement tin after use to prevent the
the waiting time at temperatures under 10 °C or above solvent evaporating. Using the conical lid allows leaving
30 °C to 60 minutes. the brush in the cement tin during breaks.
Solvent cement dissolves ABS. Pipes and fittings must
therefore not be laid on or allowed to come into con-
Apply cement tact with spilled cement or paper containing cement
Deviating from the usual method of application, pour residues.
the cement directly from the tin onto the middle of the
cementing surface and distribute first radially and then
axially all over with a flat brush. Make sure that the ce-
low + 5 °C, when there is otherwise a danger of damag-
ment layer is consistent and covers the entire surface
ing the material.
as appropriate for the larger tolerances. Apply a thin-
ner layer of Tangit in the fitting than on the pipe ends. After the drying process (see waiting times in the follow-
The cementing of pipe work in this range of dimen- ing table) the pipelines can be filled. To remove extant
sions should be carried out by at least 2 persons. The solvent vapour, it is recommended to flush the pipeline
minimum thickness of the cement layer for fittings is 1 before use.
mm, apply more generously on the pipe ends. For pipes that are not put into immediate use, it is rec-
Jointing
and flush regularly. Do not use compressed air for flush-
After applying the cement, the pipe and fitting should
ing.
be slowly pushed together to the stop or the mark with-
out twisting by 3-4 persons and aligned. Ensure that To ensure the traceability (if necessary) of the used
the outlet end of the fitting is in the correct position. Tangit ABS batch, place the batch marking on the test
Hold the joint in this position for 1 minute. report. This batch marking is attached to each dispatch
unit. If several batches are used in one project, place
one marking from each batch on the test report.
A waiting time of 1 hours should be observed before
further jointing; this time should be increased to 2
hours at temperatures below 10 °C or above 30 °C.
262
Drying period and pressure testing Dimension d160 up to d225
The length of the drying period before the joint may be
subjected to testing or operating pressure depends on Ambient Temperature Waiting time for testing
the ambient temperature, the dimension and the toler- with fluids (non compress-
ances. The following tables shows the different waiting ible)
times. 10 ° to 30 °C (50°-86°F) 2-hour waiting time per 1 bar
operating pressure.
Remark: For temperatures above 20 °C the test pres-
sure must be reduced according to the requirements - below 10 °C (50°F) 4-hour waiting time per 1 bar
given in the chapter "Final testing and commissioning". - above 30 °C (86°F) operating pressure.
Internal pressure test or leak tightness test with

gas/air Dimension d250 up to d315
Due to the risk of a pressure test with a compressible Ambient Temperature Waiting time for testing
test medium this pressure test shall be carried out only with fluids (non compress-
in exceptional cases! Please consult also the safety pre- ible)
cautions given in the chapter "Internal pressure test of
ABS pipelines". The following diagram shows the wait- 10 ° to 30 °C (50°-86°F) 4-hour waiting time per 1 bar
operating pressure.
ing time depending on the test pressure for a ambient
temperature between 10 to 30 °C: - below 10 °C (50°F) 8-hour waiting time per 1 bar
- above 30 °C (86°F) operating pressure.
Range of dimension d20 to and including d225
Safety precautions
Ambient Temperature Waiting time
Tangit cement and cleaner contain highly volatile sol-
10 ° to 30 °C (50°-86°F) at least 24 hours vents. This makes good ventilation or adequate fume
- below 10 °C (50°F) at least 48 hours extraction essential in closed spaces. Since the solvent
- above 30 °C (86°F) fumes are heavier than air, extraction must occur at
Range of dimension d250 to and including d315
Ambient Temperature Waiting time amount of solvent fumes in the air.
10 ° to 30 °C (50°-86°F) at least 48 hours Cement and cleaner are inflammable. Extinguish open
- below 10 °C (50°F) - at least 72 hours electrical apparatus, electric heaters, etc. Avoid static
above 30 °C (86°F)
cement on them.
Ambient temperature between 10 to 30 °C (50°F-86°F)
P Test pressure in bar, psi
T Waiting time after last joint in hour
Repair works
If the pipeline is only subjected to the operating pres-
sure with fluids, e. g. after adaptation or repair works,
the following rule of thumb for the waiting time applies,
which is depending on the diameter:
Dimension d20 up to d140
Ambient Temperature Waiting time for testing workplace ing. No smoking.
with fluids (non compress-
ible)
10 ° to 30 °C (50°-86°F) 1-hour waiting time per 1 bar
operating pressure.
- below 10 °C (50°F) 2-hour waiting time per 1 bar
- above 30 °C (86°F) operating pressure.
263
Instructions for Tangit solvent cement
jointing of COOL-FIT ABS Plus dimension
d25 to d225
Instruction for pipe preparation - Calibration
only required for d200 and above
Please read the operating instructions prior to using the
Calibration Tool
3 Assemble the COOLFIT ABS Plus calibration tool using

the relevant parts for the required dimension.
Detailed instructions are delivered with the tool.
1 Cut pipe at right angles, 90°.

For COOL-FIT ABS Plus dimensions below d200 calibra-
tion of the pipe is not required, please follow cementing
instructions.
4 Always ensure that the pipe has been chamfered be-

fore inserting the calibration tool.
5 Insert the tool into the pipe to the depth indicated on

the spindle. For short lengths of pipe see instructions
packed with the tool.
2 For dimensions d200 + d225 the internal diameter of the

pipe needs to be calibrated using the COOLFIT ABS
Plus calibration tool.
264
9 The cutting knife can be rotated to cut with a fresh
edge if the knife becomes blunt or if it is damaged.
6 Windout the jaws of the tool until the tool is firmly locat-
ed.
10 Wind-in the cutting head until it butts up to the end of

the pipe.
7 Windin cutting head checking that the cutting knife and

the other 2 locating heads are assembled in the correct
location.
11 Wind-in the locating jaws until the tool is loose then

carefully retract the tool taking care not to damage the
8 Please note that the tool calibrates the pipe and there- pipe.
fore may not always remove material and may remove
different amounts of material as it cuts.
265
12 It is recommended that the installer checks the diam- Chamfer to ≈ 45° with a width according to the following
eter of the calibrated pipe using the enclosed gauge. table the internal diameter of the COOL-FIT ABS pipe.
The internal diameters required are also listed in the
COOL-FIT catalogue and in the tooling instructions. Pipe Chamfered
diameter width
mm mm
25-50 (¾"-1½") 1 (0.04")
63-90 (2"-3") 2 (0.08")
≥ 110 (≥4") 3 (0.12")
13 After the calibration process the pipe must be cham- Check the consistency of the ABS Tangit cement. The
fered again! cement should run smoothly and before jointing check
that all tools required are readily to hand.
Instruction solvent cementing COOL-FIT ABS
Plus
The jointing technique for COOL-FIT ABS Plus inter-
nal jointing follows the same tried and tested technique
as that for standard COOL-FIT ABS using exactly the
same tooling and Tangit cement.
Following is a summary of COOL-FIT ABS solvent ce-
ment jointing for COOL-FIT ABS Plus. Please refer to
the standard COOL-FIT ABS solvent cementing jointing
instructions for exact curing times, handling instructions,
health and safety advice and commissioning procedure.
266
Apply a normal layer of ABS Solvent cement to the in-
side surface of the COOL-FIT ABS Plus pipe. Apply
the cement to the depth marked, axially, smoothly in
one action, in an even layer. Use a firm pressure on the
brush when applying the cement to work the cement in-
to the pipe.
The outside surface of the COOL-FIT ABS Plus nipple

and the inner surfaces of the COOL-FIT ABS Plus pipe,
must always be cleaned using Tangit cleaner with clean
absorbent paper.
Apply a thicker layer, approximately 1 mm (0.04"), of

ABS cement to the outside of the COOL-FIT ABS Plus-
nipple, using the same technique as with the pipes.
Insert the COOL-FIT ABS Plus nipple axially into the
pipe being careful not to rotate the parts. Remove all ex-
cess cement using absorbent paper.
The installer should take note of the Tangit ABS open-
ing time and safety precautions written on the Tangit tin
and in standard ABS jointing instructions.
Instruction for insulating the gap
Please take care that the «shrink sleeve, short» has
been placed over the pipe before jointing.
Mark the inside diameter of the pipe to the minimum
socket depth required. Socket depth is always d/2 + 5
(mm), for example socket length for d90 = 50 mm (90/2
+5).
267
Place the shrink sleeve over the middle of the gap. Fit-
If it is not possible to use the shrink sleeve or the sleeve tings of the latest generation do have indicators that
is damaged GF Piping Systems has a «sealing wrap», help to position the shrink sleeve correctly. Locate the
effectively a highduty tape available on demand. It is al- sleeve by pressing it onto the double sided sticky tape.
so possible to use other heavyduty insulating tapes in-
stead of the shrink sleeve. For the lifespan and sealing
properties of these tapes please consult the individual
manufacturers.
Using an open flame apply heat to the sleeve, taking

care to keep the flame moving to avoid the sleeve melt-
ing. To avoid the sleeve distorting apply the heat to the
middle of the sleeve, not from the side. The sleeve will
now shrink to the outside diameter of the jacket pipe.
Wrap the «gap insulator» into the gap between the Note: hot air can be used to shrink the sleeve but is
COOL-FIT ABS Plus components taking care to ensure not recommended due to the high amount of energy re-
that the gap is completely filled. quired to activate shrinking.
Apply the double sided sealing tape around the com-

plete circumference of the outer pipe.
268
Retrofit of adapter fittings into an existing ABS PN6 Wall thick- Adapter dimensions
ABS, PVC-U or PVC-C pipeline ness, e
Existing situation: pipe diame- S12.5, 20 25 32 40
Occasionally there is the need to install measuring deter SDR26
vices, venting devices or similar into an existing piping 250 x 9.6 No Yes Yes No
system without using additional installation fittings.
280 x 10.7 No Yes Yes Yes
Solution: 315 x 12.1 No No Yes Yes
At the section of the piping system with greatest wall
thickness (in the middle of the joint) a hole is drilled for
PVC-U PN10 Wall thick- Adapter dimensions
the spigot of the adapter fitting. Then a suitable adapter
ness, e
fitting is solvent cemented into the hole which acts as
socket. pipe diame- S10, SDR21 20 25 32 40
ter
Installation steps in detail:
125 x 6.0 No No No No
1.The hole is drilled into a drained pipe section.
2.The hole is drilled at a right angle to the pipe axis. 140 x 6.7 Yes No No No
3.The hole diameters and tolerances given in the at- 160 x 7.7 Yes Yes No No
tached table correspond to socket dimensions accord- 180 x 8.6 Yes Yes No No
ing to ISO 727-1 and are to be observed.
200 x 9.6 Yes Yes Yes No
4.The dimension X in the attached table indicates the
distance from the entrance of the socket to the middle 225 x 10.8 Yes Yes Yes Yes
of the hole to be drilled in order to place it in the mid- 250 x 11.9 No Yes Yes Yes
dle of the joint.
280 x 13.4 No Yes Yes Yes
5.Use a suitable deburring tool to deburr the edges of
hole. 315 x 15.0 No No Yes Yes
6.Shavings should be removed from the pipe. 400 x 19.1 No No Yes Yes
7.Allowed combinations of pipe and adapter fitting are
indicated in the attached table with yes . PVC-U PN16 Wall thick- Adapter dimensions
The selection is such that the spigot of the adapter ness, e
fitting does not reach into the medium-filled pipe for pipe diame- S6.3, 20 25 32 40
more than 1 mm as well as fully covering the hole ter SDR13.6
drilled into the joint.
125 x 9.2 Yes No No No
8.The spigot is solvent cemented into the drilled hole
according to the instructions for solvent cement joint- 140 x 10.3 Yes Yes No No
ing given in our Planning Fundamentals. 160 x 11.8 Yes Yes Yes No
9.Attend to waiting times before refilling and applying
pressure to the system. Dimensions of hole to be drilled
When correctly installed the above joint is good for

PN10 at 20 °C with water as the medium.
Allowed combinations of pipe and adapter dimen-
sions
ABS PN10 Wall thick- Adapter dimensions
ness, e
pipe diame- S8, SDR17 20 25 32 40
ter
75 x 4.5 Yes Yes No No
225 x 13.4 Yes Yes Yes Yes
269
Adapter dimension Hole diameter, d b in
mm
20 20.2
25 25.2
32 32.2
40 40.2
Tolerance ± 0.1 mm
Pipe dimension Drill position X in mm

75 22
90 26
110 31
125 34
140 38
160 43
180 48
200 53
225 59
250 66
280 73
315 82
400 103
Tolerance ± 1 mm
Cementing different pipe materials

It is possible to cement the pipe materials ABS, PVC-U
and PVC-C with one another; certain conditions must,
however, be observed.
Please contact your nearest GF representative for as-
sistance.
Instructions for solvent cement jointing on

video
For the materials PVC-U, PVC-C, ABS and COOL-FIT
ABS the instructions for solvent cementing are available
also on video. Please contact your nearest GF repre-
sentative.
Medium Languages
DVD German, English
Internet: German, English
Products => Jointing Technology =>
Solvent Cementing
270
Fusion jointing of PE IR fusion jointing must only be performed by personnel
trained in the use of this method. Training is provided
IR Plus fusion jointing of PE100 piping sys- world-wide by qualified GF IR Plus welding instructors.
tems Tools required
Fusion jointing method Infrared fusion jointing requires a special jointing ma-
In infrared (IR) fusion jointing the fusion areas of the chine in addition to the tools normally used for plastic
components being joined (pipes, fittings, valves) are pipework construction (pipe cutters, etc.).
heated to fusion temperature without contact to the GF supplies several types of IR Plus fusion jointing ma-
heating element and jointed by means of mechanical chines:
pressure without using additional materials.
IR 63 Plus: for fusion joints in the size range d20 -
The principle of fusion jointing 63 mm

110 mm
1 Pipe
2 Heating element
3 Fitting
The resulting fusion joints are homogeneous and dis-

play the following characteristics:
• non-contact heating of the jointing components elimi-
nates the risk of contamination and inhomogenities;
• smaller jointing beads due to adjustment of jointing
pressure path prior to the fusion process itself, i. e.
elimination of the equalisation process;
• adjustment of the jointing pressure path also ensures
excellent reproducibility of the fusion joints;
• low-stress fusion joints due to very uniform heating by
means of IR radiator.
General requirements
The fusion procedure detailed below including the
preparation is based on DVS 2207-6 "Welding of ther-
moplastics - Non-contact heated tool butt welding of
pipes, pipeline components and sheets - Methods, IR 225 Plus: for fusion joints in the size range d63 -
equipment, parameters". 225 mm
Only same wall thicknesses in the fusion area
The basic rule is that only similar materials can be fu-
sion jointed. The components to be joined must have
the same wall thicknesses in the fusion area. Maximum
permissible wall displacement: 10 %.
General conditions
A incorrect Protect the area of the fusion joint from adverse weath-
B correct
er conditions, such as rain, snow or wind. The permitted
temperature range for IR Plus® fusion jointing between
271
+5 °C and +40 °C. Outside this range, suitable action
must be taken to ensure that these conditions are main- Butt fusion jointing of PE piping systems
tained. It must also be ensured that the components be- Butt fusion jointing method
ing joined are in this temperature range. The fusion areas of the pipes and fittings are heated to
Preparing the fusion joint and operating the IR fusion temperature and joined by means of mechanical
fusion jointing machine pressure, without using additional materials. A homo-
In principle, IR fusion jointing machines do not require geneous joint results. Butt fusion must only be carried
any special preparation, but it should be ensured that out with fusion jointing machines which allow the jointing
the components being joined are clean. pressure to be regulated.
Operation of the IR machines is defined exactly in the The principle of fusion jointing
operating instructions, but we strongly recommend at-
tending a 1-day training course to become a qualified IR
welder.
Properties and characteristics of IR fusion
joints
Non-contact heating
The components being joined are heated uniformly and
without contact to the ideal fusion temperature by in-
frared radiation.
A defined gap between the heating element and the end
faces minimises the risk of contamination of the jointing
surface. Contamination of the heating element by plastic
particles is thus also eliminated. 1 Pipe
2 Heating element
Reduced bead formation
3 Fitting
The fusion bead produced during jointing is consider-
ably reduced without any loss of quality. Bead forming General requirements
equalisation is eliminated by non-contact softening of The fusion procedure detailed below including the
the end faces. The minimal, defined bead is only formed preparation is based on DVS 2207-1 "Welding of ther-
during the jointing process. The fusion area thus has moplastics - Heated tool welding of pipes, pipeline,
improved flow dynamics, low clearance volume, and components and sheets made from PE".
greater throughput area.
Details of the requirements for machines and equipment
Reproducible jointing processes used for fusion jointing thermoplastics are contained in
The jointing path controls the jointing pressure and thus DVS 2208 Part 1.
the fusion process. The high reproducibility of the joints
is assured by the clearly defined and controlled process Join only components with similar wall thicknesses
sequence. The basic rule is that only similar materials can be fu-
sion jointed, i. e. PE with PE. This applies also for the
Clear, simple operator guidance jointing of PE80 with PE100. For best results, only com-
Clear, unambiguous operator guidance via the liquid ponents which have a melt flow index in the range from
crystal display leads the user interactively through the MFR 190/5 0.3 to 1.7 g/10 min should be fusion jointed.
fusion process in logical operating steps. This requirement is met by PE butt fusion fittings from
Welding report/traceability GF. The components to be jointed must have the same
The welding parameters for the relevant welding opera- wall thicknesses in the fusion area.
tions can be read out directly via various interfaces on
the machine. It is possible to print these out on paper
(commercially available printers), on labels or to employ
electronic data output (PCMCIA card or USB).
This automatically provides an accurate record with all
essential fusion parameters for each individual fusion
joint, as required.
A incorrect
B correct
Heated tool butt fusion jointing may only be performed

by adequately trained personnel.
272
Tools required
Butt fusion jointing requires a special jointing machine in
addition to the tools normally used for plastic piping con-
struction (pipe cutters, saw with cutting guide). The fu-
sion jointing machine must meet the following minimum
requirements:
The clamping equipment must hold the various parts se-
curely without damaging the surfaces. Possible ovali-
ty can be largely compensated by centred clamping of
the components to be joined. It must also be possible to
hold all parts firmly in alignment. Check the temperature
To test the thermostat, check temperature before com-
The machine must also be capable of face planing the mencing the fusion jointing. This is best carried out with
fusion surfaces of pipes and fittings. the help of a digital thermometer. But only thermome-
The fusion jointing machine must be sufficiently solid to ters with a sensor for measuring surface temperature
be able to absorb the pressures arising during the fu- are suitable.
sion procedure without detrimentally deforming the joint. To ensure it is being maintained at the correct level the
The heating surfaces of the heating element must fusion temperature should be checked from time to time
be flat and parallel. The temperature variation over during the jointing work. The temperature of the heating
the working area must not exceed 10 °C. The ma- element is particularly sensitive to wind.
chine should be set up and operated according to the
manufacturer's instructions.
General conditions
Protect the area of the fusion joint from adverse weath-
er conditions, such as rain, snow and wind. At tempera-
tures below +5 °C or above +45 °C, measures must be
taken to ensure that the temperature in the working area
is in the range required for satisfactory jointing and does
not hinder the necessary manual tasks.
Clean the heating element

Clean the heating element with dry, clean paper before
each fusion joint!
Protect the working surface of the heating element
from becoming soiled. Clean both faces of the heat-
ing element with dry, lint-free paper before each fusion
joint. Protect the heating element from wind, damage
and soiling during the intervals between making fusion
joints.
Planing and subsequent checking
Before machining the joining surfaces, make sure that
the tools and the work pieces are clean and grease-free
beyond the actual fusion zone; if necessary, clean with
a cleaning fluid.
Protect the fusion area
Screening the fusion area can ensure a more even tem- All the components clamped into the fusion jointing ma-
perature distribution on the entire circumference of a chine are planed simultaneously with the planer provid-
pipe subject to direct sunlight. The pipe ends at the oped. The shavings should not be thicker than ≤ 0.2 mm.
posite end of the fusion areas should be sealed when- This step is completed when there is no unmachined
ever possible to reduce to a minimum the cooling of the area left on either of the parts to be joined. This is nor-
fusion surfaces which can be caused by wind. mally the case when no more shavings come off the
machined surface.
Preparation of the fusion joint
The quality of the fusion process is governed by the Remove any shavings which may have fallen into the
care with which the preparatory work is carried out. This pipe or fitting with e. g. a brush. The fusion surfaces
part of the procedure therefore deserves special atten- should not be touched by hand under any circum-
tion. stances. Otherwise they must be cleaned with cleaning
fluid.
Heating tool
Set the temperature of the heating element to 220 °C. Once they have been machined, the parts are moved
Check the temperature. The fusion temperature should together until they touch. The gap between the two
be between 210 °C and 230 °C. parts must not exceed the values in the following table.
273
Pipe diameter Max. gap machine and the resistance of the axially mobile pipe
(mm) (mm) or fitting clamped in it. The resistance of longer pipes
should be reduced as far as possible by placing rollers
≤ 355 0.5
beneath them. The kinetic force (FB) should not exceed
400 ... <630 1.0 the jointing force (FA).
630 ... <800 1.3 Equalise and heat
800 ... <1000 1.5
≥ 1000 2.0
A Contact force
B Height of bead (see tabulated values)
A max. gap Approximate values for butt fusion of PE 1)

B max. displacement: 10 % of wall thickness
Wall thick- Equalisation at Heating time ²)
Check the wall alignment and gap ness p= 0.15 N/mm² p= 0.01 N/mm²
The alignment of the two parts should be checked at (mm) Height of bead (sec)
the same time. A possible misalignment on the outside (mm)
must not exceed 10 % of the thickness of the wall. If up to 4.5 0.5 up to 45
this limit is exceeded, a better clamping position is to be 4.5 ... 7 1.0 45 ... 70
sought, e. g. by rotating the pipe. In such a case, how-
ever, the surface must be re-planed. 7 ... 12 1.5 70 ... 120
12 ... 19 2.0 120 ... 190
Important: The fusion surfaces must be planed immedi-
ately prior to the jointing. 19 ... 26 2.5 190 ... 260
Setting the fusion pressure 26 ... 37 3.0 260 ... 370

Fusion jointing requires different pressures to be applied 37 ... 50 3.5 370 ... 500
during equalisation and jointing on the one hand and 50 ... 70 4.0 500 ... 700
during the heat soak period on the other. Please see the
following diagram.
Wall thick- Changeover Time to reach Cooling time
ness time full jointing ²)
(mm) max. (sec) under joint-
(sec) ing
p= 0.15 N/
mm²
(min)
up to 4.5 5 5 6
4.5 ... 7 5 ... 6 5 .. 6 6 ... 10
7 ... 12 6 ... 8 6 ... 8 10 ... 16
12 ... 19 8 ... 10 8 ... 11 16 ... 24
19 ... 26 10 ... 12 11 ... 14 24 ... 32
26 ... 37 12 ... 16 14 ... 19 32 ... 45
37 ... 50 16 ... 20 19 ... 25 45 ... 60
50 ... 70 20 ... 25 25 ... 35 60 ... 80
The specific jointing pressure required for equalisation 1) in accordance with DVS 2207-1
and fusion can be found in the following table with the
heating and cooling periods. The table lists the times 2) The times are affected by the pipe wall thickness, the
for various wall thicknesses. Interpolate for intermediate outside temperature and wind strength.
values. Determine the values to be set for equalisation and
The force needed for equalisation and jointing (FA) is jointing on the basis of the information above, bearing
given by the product of the fusion area and the specif- in mind the instructions from the manufacturer of the
ic jointing pressure (FA = A * p). The force (FB) required fusion jointing machine before commencing the fusion
to move the pipe must be added to this. (Ftot = FA + FB). process.
This latter force includes the intrinsic resistance of the
274
Fusion jointing procedure
Once it has attained the fusion temperature, position the Socket fusion jointing of PE piping sys-
heating element in the fusion jointing machine. Press tems
the parts to be jointed against the heating element with Socket fusion jointing method
the force required for equalisation until the entire cir- In this form of fusion jointing, which requires heating
cumference of each of the jointing faces rests complete- tools, the pipe end is inserted into the socket of the fit-
ly against it and a bead (see the table) has formed. Re- ting; no additional material is used. The pipe end and
duce the equalisation pressure almost to 0 (p ~ 0.01 N/ fitting socket are heated to fusion temperature using a
mm²). The heating time listed in the table is measured heating bush and a heating spigot, respectively, and are
from this moment. then pushed together.
The pipe end, fitting socket and heating tools corre-
spond in such a way that the necessary jointing pres-
sure is attained during jointing, resulting in a homoge-
neous joint.
Join and cool

Leave parts in the fusion jointing machine at fusion
pressure until the end of the cooling period!
Once the heating period has elapsed, remove the parts
from the heating element which should then be removed
A Fitting
without touching the jointing surfaces and push the
parts together immediately. The changeover time must B Heating spigot
not exceed the value listed in the table. Pay particular C Heating element
attention during jointing that the parts be moved togeth- D Heating bush
er swiftly until the surfaces are about to touch. E Pipe
Then they should be moved together so that they are in Heating
contact along the entire circumference. Next the pres-
sure should be increased rapidly to the present joint-
ing pressure within the period of time specified in the ta-
ble. This pressure must be maintained during the entire
cooling period. Adjustment may be necessary, especial-
ly shortly after the jointing pressure has been attained.
The jointed parts must stay in the fusion jointing ma-
chine under jointing pressure until the end of the cooling
period specified in the table.
Finished joint
Fusion check
A bead should form around the entire circumference of
the pipe. K in the diagram to the left should always be
positive. General requirements
Carrying out the pressure test preparation is based on DVS 2207-1 "Welding of ther-
All fusion joints must be allowed to cool completely be- moplastics - Heated tool welding of pipes, pipeline,
fore pressure testing, i. e. as a rule wait about 1 hour af- components and sheets made from PE".
ter the last joint has been completed.
used for fusion jointing thermoplastics are contained in
DVS 2208 Part 1.
275
The basic rule is that only similar materials can be fu- The element is heated electrically. The heating bush
sion jointed, i. e. PE with PE. This applies also for the and spigot are removable. A separate pair is required
jointing of PE80 with PE100. for each pipe size.
In socket fusion, attention must be paid to the minimum Important: The surfaces of the heating tool which come
wall thicknesses of the pipes. The melt flow index of the into contact with the pipe or the fitting must have a non-
pipes to be joined should lie within the following limits: stick coating.
0.3 to 1.7 g/10 min. MFR 190/5 (Melt flow rate at 190
°C/5 kg). Fusion jointing machine
This requirement is met by PE socket fusion fittings

from GF.
Tools required
Apart from the tools normally used in plastic piping con-
struction, such as pipe cutters or a saw with a cutting
guide, the socket fusion jointing method requires certain
special tools.
Important: The tools described here may be used for A Pipe
GF socket fusion fittings made of PP and PVDF as well B Heating element
as PE. C Fitting
Pipe peeling and chamfering tool A fusion jointing machine is recommended for fittings
with a diameter of d = 63 mm or more. It is also better to
use a machine for smaller joints if there is a large num-
ber to be made.
The machine should be set up and operated accord-
ing to its manufacturer's instructions. The procedure
detailed below (including the preparation) is for fusion
jointing with the help of a manual jointing tool.
This tool serves to calibrate the pipe end and to mark

the length of the fusion joint. At the same time it re-
moves the oxidised layer built up as a result of UV ra-
diation, which would otherwise have a detrimental ef-
fect on the fusion joint. It is of paramount importance for
high quality joints that the oxidised layer be removed.
Set the temperature of the heating tool to 260 °C. Check
Note: Further information on the fusion jointing equip- the temperature. The fusion temperature must be be-
ment hire service and training courses are available tween 250 °C and 270 °C. To test the thermostat, check
from GF. the fusion temperature from time to time on the outside
Heating element for manual fusion jointing of the heating bush, using a fast acting thermoprobe or
tempil sticks (253 °C or 274 °C). This is particularly im-
portant when working in strong wind.
Use a clean cloth or dry paper to clean the heating bush

and the heating spigot. The tools must be cleaned after
making each fusion joint.
276
Outside Peeled diameter Champfer Peeling
pipe diame- (mm) b (mm) length
ter l (mm)
d (mm)
16 15.85-15.95 2 13
20 19.85-19.95 2 14
25 24.85-24.95 2 16
32 31.85-31.95 2 18
40 39.75-39.95 2 20
50 49.75-49.95 2 23
63 62.65-62.95 3 27
75 74.65-74.95 3 31
90 89.65-89.95 3 35
Cut the pipe square using a cutter for plastic pipes and 110 109.55-109.95 3 41
deburr the inside edges with a knife.
Make sure that the tools and pipes are clean and
grease-free even beyond the fusion zone; if necessary,
clean with a cleaning fluid.
Pipe in size d16
For pipes of diameter d = 16 mm, chamfer about 2 mm
of the pipe end at an angle of 15°. Prepare about 15
mm of the pipe end with a scraper. Mark off the jointing
length of 13 mm on the pipe.
Pipes in sizes d20 to d110
In the case of SDR 11 pipes with diameter
d = 20 or 25 mm, insert a support sleeve
manually in the pipe end as far as the stop
before starting to peel, or use pipes with
smaller SDR values.
Peel the pipe end until the blades are flush with the pipe
end.
Should ovality of the pipe prevent the peeling tool from
being properly applied, the pipe must first be rounded
(e. g. in a vice or with a screw clamp).
Use a scraper to complete the peeling of any area Thoroughly clean the fitting socket with absorbent paper
where ovality impairs the effectiveness of the peeling and cleaning fluid (e. g. Tangit cleaner). Use fresh pa-
tool. per each time.
If the peeling tool can be pushed onto the pipe without
removing any material, then the dimensional accura-
cy of the pipe's outside diameter and of the peeling tool
should be checked.
Contact GF for resharpening or replacing the blades.
Should this work be carried out independently, use a
mandrel gauge to adjust the blades to the following di-
ameters.
277
Fusion jointing procedure Jointing (by hand)
Heating
Pull the fitting and pipe from the heating tools with a
"snap off" action as soon as the heating period has
Quickly push first the fitting onto the heating spigot to elapsed. Paying attention to the alignment marks, im-
the correct depth and then the pipe into the heating mediately push them together axially without twisting.
bush axially, without twisting, and hold firmly. Hold them together for the same duration as the heating
16 mm pipes should be inserted into the heating bush period
up to the mark previously made.
Pressure testing
Pipes in size d = 20 mm to 110 mm should be insert- All fusion joints must be allowed to cool completely be-
ed until the end of the peeled surface is flush with the fore pressure testing, i. e. as a rule wait about an hour
edge of the heating bush. In fusion jointing machines, after the last joint has been completed.
fixed stops regulate this. The heating times in the table
below are measured from this point on. Fusion joints
should not be used for pipes whose walls are thinner
than those listed in the table.
Heating times and minimum wall thicknesses for
socket fusion joints
Outside Heating Heating Change- Cooling Cool-
pipe di- time time over ing
ameter PN10 PN6 (Max.- fixed total
mm SDR11 SDR17 time) sec min
sec
16 5 - 4 6 2
20 5 - 4 6 2
25 7 - 4 10 2
32 8 - 6 10 4
40 12 - 6 20 4
50 18 - 6 20 4
63 24 - 8 30 6
75 30 18 8 30 6
90 40 26 8 40 6
110 50 36 10 50 8
The temperature and heating time must be strictly ob-

served.
278
Electrofusion Especially check that the electrofusion automatic ma-
chine and the fusion zone are placed under the same
General requirements climatic conditions.
preparation is based on DVS 2207-1 "Welding of ther- Storage
moplastics - Heated tool welding of pipes, pipeline, ELGEF Plus electrofusion fittings are packed separate-
components and sheets made from PE". ly in a polythene bag. If the fittings are protected from
direct sunlight in the original packing and not stored
above 50 °C, they can be stored for almost 10 years.
DVS 2208 Part 1. The storage duration commences on the date that the
fittings are produced.
Using electrofusion to join PE pipes and valves enables
a secure, systematic, economical and efficient installa- Protection of fusion area
tion of PE piping systems. The pipe and fitting surfaces to be fused should be
ELGEF Plus electrofusion products are supplied with a carefully protected from dust, grease, oil and lubricants.
magnetic card, which contains all relevant product infor- Use only cleaning agents that are suitable for PE.
mation (trace code) and fusion data. Attention: There should be no grease (such as hand
cream, oily rags, silicone etc.) in the fusion zone!
Fusion preparation
The pipe should be wiped clean, scraped and finally
cleaned with PE cleaner. Rotating scraping tools can be
used for uniform and time-saving pipe preparation.
Please comply with the assembly and operating instruc-
tions.
Processing notes
The quality of the joint depends to a considerable ex-
tent on the care with which the preparatory work is per-
formed. Electrofusion jointing should be carried out only
by trained personnel.
The melt flow range (MFR) of ELGEF Plus electrofusion
products is in the range 0.4 to 1.4 g/10 min. They can
be fused with PE pipes with a melt flow range between
0.2 and 1.4 g/10 min.
Adhere to the following scraping measurements:

d Pipe Min. chip thick- Max. chip thick-
ness ness*
20–25 mm 0.20 mm 0.20 mm
32–63 mm 0.20 mm 0.25 mm
75–225 mm 0.20 mm 0.30 mm
>225 mm 0.20 mm 0.35 mm
Tip: maximum permitted pipe ovality 1.5 %

* The data refers to the pipe inner diameter without ”+
tolerance”
Protect the fusion zone against bad weather, such as
rain, snow or wind. Admissible temperature range for Welding indicators
electrofusion is –10 °C to +45 °C. After welding, check the welding indicators. The fol-
lowing picture shows the change of the welding indica-
The national guidelines are to be observed. A more uni- tor. They only indicate that energy has reached the fu-
form temperature profile around the entire pipe circum- sion zone: they are not a guarantee for the quality of the
ference can be achieved by shielding the fusion zone welding. The height of the welding indicator depends
against direct sunlight or inclement weather. on the fitting used, the pipe material and the pipe toler-
ances.
279
Remark: For welding of ELGEF Plus fittings or for use
of the MSA electrofusion machines, please consult the
further information in the "Technical Handbook Distribu-
tion Piping Systems".
280
Fusion jointing of PP IR fusion jointing must only be performed by personnel
IR Plus fusion jointing of PROGEF piping world-wide by qualified GF IR Plus welding instructors.
systems Tools required

110 mm
1 Pipe
2 Heating element
3 Fitting

pressure path prior to the fusion process itself, i. e
means of IR radiation.
General conditions
A incorrect Protect the area of the fusion joint from adverse weath-
B correct
er conditions, such as rain, snow or wind. The permit-
ted temperature range for IR Plus® fusion jointing is be-
281
tween +5 °C and +40 °C. Outside this range, suitable Holding the melted thermoplastic under controlled pres-
action must be taken to ensure that these conditions are sure ensures ideal, homogeneous fusion of the plastic
maintained and all components being joined are in this components.
temperature range.
Fully automatic process control of the fusion jointing
Preparing the fusion joint and operating the IR process with a fusion jointing machine developed in-
fusion jointing machine house by GF permits very simple handling and repro-
In principle, IR fusion jointing machines do not require ducible fusion quality.
any special preparation, other than to ensure that all
components being joined are clean.
Operation of the IR machines is defined in the operating
instructions, but we strongly recommend attending a 1-
day training course to become a qualified IR welder.
joints
Non-contact heating
frared radiation.
1 Pipe clamping element
A defined gap between the heating element and the end
2 Fitting
faces minimises the risk of contamination of the jointing
surface. Contamination of the heating element by plastic 3 Heating element with fitting - clamping device
particles is thus also eliminated. 4 Pressurised bladder
5 Pipe
Reduced bead formation
6 Compressor for bladder
The fusion bead produced during jointing is consider-
ably reduced without any loss of quality. Bead forming 7 Cooling air blower
equalisation is eliminated by non-contact softening of 8 Control unit control panel
the end faces. The minimal, defined bead is only formed 9 Compressed air supply
during the jointing process. The fusion area thus has
improved flow dynamics, low clearance volume, and
Reproducible jointing processes
The jointing path controls the jointing pressure and thus
is assured by the clearly defined and controlled process
sequence.
Clear, simple operator guidance
Clear, unambiguous operator guidance via the liquid
crystal display leads the user interactively through the
fusion process in logical operating steps.
1 Pressurised bladder
Welding report/traceability 2 Welding zone
The welding parameters for the relevant welding opera-
3 Heating element
the machine. It is possible to print these out on paper 4 Clamping position
(commercially available printers), on labels or to employ 5 Pipe / Fitting
This automatically provides an accurate record with all PROGEF Natural fittings and pipes are suitable for
essential fusion parameters for each individual fusion working pressures up to 10 bar at 20 °C (water). PRO-
joint, as required. GEF Natural diaphragm valves are designed for a maxi-
mum working pressure of 10 bar at 20 °C (water). Refer
BCF Plus fusion jointing of PROGEF Natu- to the chapter on pressure/temperature diagrams for de-
ral piping systems tails of permissible working pressures.
Fusion jointing method Tools required
The fusion jointing process consists in transmitting pre- BCF jointing requires the GF BCF Plus jointing ma-
cisely defined thermal energy to the pipe and fitting chine in addition to the tools normally used for plastic
ends being joined by means of half-shell heating ele- pipework construction (pipe cutters, etc.).
ments.
At the same time an elastic, pressurised bladder sup-
ports the inside surface of the fusion zone in order to
prevent the formation of an internal fusion bead.
282
Preparing the fusion joint and operating the
BCF® Plus fusion jointing machine
In principle, GF BCF Plus fusion jointing machines do
not require any special preparation, other than to en-
sured that all components being jointed are clean.
Operation of the BCF Plus machines is defined exact-
ly in the operating instructions, but it is strongly recom-
mended to attend a 1-day training course to become a
qualified BCF Plus welder.
Properties and characteristics of BCF® Plus fu-
sion joints
Welding free from beads and crevices
The result of the jointing process is a surface similar
to the actual pipeline components, free from beads or
crevices. There are therefore no dead legs, the surface
roughness is in the range of the pipe components.
The high reproducibility of the joints is assured by the
clearly defined and controlled process sequence.
Welding report / traceability
electronic data output (PCMCIA card).
the essential fusion parameters for each individual fu-
sion joint.
283
Butt fusion jointing of PP piping systems The clamping equipment must hold the various parts se-
curely without damaging the surfaces. Possible ovali-
Butt fusion jointing method ty can be largely compensated by centred clamping of
The fusion areas of the pipes and fittings are heated to the components to be joined. It must also be possible to
fusion temperature and joined by means of mechanical hold all parts firmly in alignment.
pressure, without using additional materials. A homo-
geneous joint results. Butt fusion must only be carried The machine must also be capable of face planing the
out with fusion jointing machines which allow the joint- fusion surfaces of pipes and fittings.
ing pressure to be regulated. The drawing illustrates the The fusion jointing machine must be sufficiently solid to
principle of fusion jointing. be able to absorb the pressures arising during the fu-
The principle of fusion jointing sion procedure without detrimentally deforming the joint.
The heating surfaces of the heating element must
be flat and parallel. The temperature variation over
the working area must not exceed 10 °C. The ma-
General conditions
1 Pipe
2 Heating element
3 Fitting
moplastics - Heated tool welding of pipes, pipeline,
components and sheets made from PP".
DVS 2208 Part 1.
Join only components with similar wall thicknesses
sion jointed. For best results, only components which Protect the fusion area
have a melt flow index in the range from MFR 190/5 0.4 Screening the fusion area can ensure a more even tem-
to 1.0 g/10 min should be fusion jointed. This require- perature distribution on the entire circumference of a
ment is met by PP butt fusion fittings from GF. pipe subject to direct sunlight. The pipe ends at the op-
posite end of the fusion areas should be sealed when-
ever possible to reduce to a minimum the cooling of the
fusion surfaces which can be caused by wind.
The quality of the fusion process is governed by the
care with which the preparatory work is carried out. This
part of the procedure therefore deserves special atten-
tion.
Heating tool
A incorrect
Set the temperature of the heating element to 210 °C.
B correct Check the temperature. The fusion temperature should
be between 200 °C and 220 °C.
Tools required
requirements:
284
Check the temperature
Temperature of heating element 200 °C to 220 °C.
mencing the fusion jointing. This is best carried out with
the help of a digital thermometer. But only thermome-
ters with a sensor for measuring surface temperature
are suitable.
To ensure it is being maintained at the correct level, the
fusion temperature should be checked from time to time
during the jointing work. The temperature of the heating
element is particularly sensitive to wind. A max. gap
Check the wall alignment and gap

The alignment of the two parts should be checked at
the same time. A possible misalignment on the outside
must not exceed 10 % of the thickness of the wall. If
this limit is exceeded, a better clamping position is to be
ever, the surface must be re-planed.
ately prior to the jointing.
Clean the heating element with dry, clean paper before Pipe diameter Max. gap
each fusion joint! (mm) (mm)
Protect the working surface of the heating element ≤ 355 0.5

from becoming soiled. Clean both faces of the heat- 400 ... 630 1.0
joint. Protect the heating element from wind, damage Setting the fusion pressure
and soiling during the intervals between making fusion Fusion jointing requires different pressures to be applied
joints. during equalisation and jointing on the one hand and
following diagram.
Before machining the fusion surfaces, make sure that
even beyond the fusion zone; if necessary, clean with a
cleaning fluid.
All the components clamped into the fusion jointing ma-
chine are planed simultaneously with the planer provid-
ed. The shavings should not be thicker than ≤ 0.2 mm.
This step is completed when there is no unmachined
area left on either of the parts to be joined. This is nor-
mally the case when no more shavings come off the
machined surface.
Remove any shavings which may have fallen into the
pipe or fitting with e. g. a brush. The fusion surfaces
should not be touched by hand under any circum-
stances. Otherwise they must be cleaned with cleaning
fluid.
Once they have been machined, the parts are moved The specific jointing pressure required for equalisation
together until they touch. The gap between the two and fusion can be found in the following table with the
parts must not exceed the value in the following table. heating and cooling periods. The table lists the times
for various wall thicknesses. Interpolate for intermediate
values.
The force needed for equalisation and jointing (FA) is
given by the product of the fusion area and the specif-
ic jointing pressure (FA = A * p). The force (FB) required
to move the pipe must be added to this. (Ftot = FA + FB).
This latter force includes the intrinsic resistance of the
machine and the resistance of the axially mobile pipe
or fitting clamped in it. The resistance of longer pipes
285
should be reduced as far as possible by placing rollers ly against it and a bead (see the table) has formed. Re-
beneath them. The kinetic force (FB) should not exceed duce the equalisation pressure almost to 0 (p ~ 0.01 N/
the jointing force (FA). mm²). The heating time listed in the table is measured
from this moment.
Equalise and heat
A Contact force Join and cool

Approximate values for butt fusion of PP 1)
Wall thick- Equalisation at Heating time ²) Once the heating period has elapsed, remove the parts
ness p=0.10 N/mm² p=0.01 N/mm² from the heating element which should then be removed
(mm) Height of bead (sec) without touching the jointing surfaces and push the
(mm) parts together immediately. The changeover time must
up to 4.5 0.5 up to 135
not exceed the value listed in the table. Pay particular
attention during jointing that the parts be moved togeth-
4.5 ... 7 0.5 135 ... 175 er swiftly until the surfaces are about to touch.
7 ... 12 1.0 175 ... 245
Then they should be moved together so that they are in
12 ... 19 1.0 245 ... 330 contact along the entire circumference. Next the pres-
19 ... 26 1.5 330 ... 400 sure should be increased rapidly to the present joint-
ing pressure within the period of time specified in the ta-
26 ... 37 2.0 400 ... 485
ble. This pressure must be maintained during the entire
37 ... 50 2.5 485 ... 560 cooling period. Adjustment may be necessary, especial-
Wall thick- Changeover Time to reach Cooling time
The jointed parts must stay in the fusion jointing ma-
ness time max. full jointing ²)
(mm) (sec) (sec) under joint- chine under jointing pressure until the end of the cooling
ing period specified in the table.
p=0.10 N/
mm²
(min)
up to 4.5 5 6 6
4.5 ... 7 5 ... 6 6 .. 7 6 ... 12
7 ... 12 6 ... 7 7 ... 11 12 ... 20
12 ... 19 7 ... 9 11 ... 17 20 ... 30
19 ... 26 9 ... 11 17 ... 22 30 ... 40
26 ... 37 11 ... 14 22 ... 32 40 ... 55
Fusion check
37 ... 50 14 ... 17 32 ... 43 55 ... 70
1) in accordance with DVS 2207-11 the pipe. K in the diagram to the left should always be
positive.
2) The times are affected by the pipe wall thickness, the
outside temperature and wind strength. Carrying out the pressure test
All fusion joints must be allowed to cool completely be-
Determine the values to be set for equalisation and
fore pressure testing, i.e. as a rule wait about 1 hour af-
jointing on the basis of the information above, bearing
ter the last joint has been completed.
in mind the instructions from the manufacturer of the
fusion jointing machine before commencing the fusion
process.
Once it has attained the fusion temperature, position the
heating element in the fusion jointing machine. Press
the parts to be joined against the heating element with
the force required for equalisation until the entire cir-
cumference of each of the jointing faces rests complete-
286
Socket fusion jointing of PP piping sys- The basic rule is that only similar materials can be fu-
tems sion jointed, i. e. PP with PP.
Socket fusion jointing method In socket fusion, attention must be paid to the minimum
In this form of fusion jointing, which requires heating wall thicknesses of the pipes. The melt flow index of the
tools, the pipe end is inserted into the socket of the fit- pipes to be joined should lie within the following limits:
ting; no additional material is used. The pipe end and 0.4 to 0.8 g/10 min. MFR 190/5 (Melt flow rate at 190
fitting socket are heated to fusion temperature using a °C/5 kg).
heating bush and a heating spigot, respectively, and are This requirement is met by PP socket fusion fittings
then pushed together. from GF.
The pipe end, fitting socket and heating tools corre- Tools required
spond in such a way that the necessary jointing pres- Apart from the tools normally used in plastic piping con-
sure is attained during jointing, resulting in a homoge- struction, such as pipe cutters or a saw with a cutting
neous joint. guide, the socket fusion jointing method requires certain
Fusion jointing procedure special tools.
Important: The tools described here may be used for
GF socket fusion fittings made of PP and PVDF as well
as PE.
Pipe peeling and chamfering tool
A Fitting
B Heating spigot
C Heating element
D Heating bush
E Pipe
Heating the length of the fusion joint. At the same time it re-
Note: Further information on the fusion jointing equip-
ment hire service and training courses are available
from GF.
Heating element for manual fusion jointing
Finished joint
moplastics - Heated tool welding of pipes, pipeline,
components and sheets made from PP".
DVS 2208 Part 1. The element is heated electrically. The heating bush
and spigot are removable. A separate pair is required
for each pipe size.
287
Important: The surfaces of the heating tool which come
into contact with the pipe or the fitting must have a non-
stick coating.
Fusion jointing machine
A Pipe
B Heating element
C Fitting
Cut the pipe square using a cutter for plastic pipes and
A fusion jointing machine is recommended for fittings deburr the inside edges with a knife.
with a diameter of d = 63 mm or more. It is also better to Make sure that the tools and pipes are clean and
use a machine for smaller joints if there is a large num- grease-free even beyond the fusion zone; if necessary,
ber to be made. clean with a cleaning fluid.
The machine should be set up and operated accord- Pipe in size d16
ing to its manufacturer's instructions. The procedure For pipes of diameter d = 16 mm, chamfer about 2 mm
detailed below (including the preparation) is for fusion of the pipe end at an angle of 15°. Prepare about 15
jointing with the help of a manual jointing tool. mm of the pipe end with a scraper. Mark off the jointing
Preparation of the fusion joint length of 13 mm on the pipe.
Pipes in sizes d20 to d110
Set the temperature of the heating tool to 260 °C. Check

the temperature. The fusion temperature must be be-
tween 250 °C and 270 °C. To test the thermostat, check
the fusion temperature from time to time on the outside
of the heating bush, using a fast acting thermoprobe or
tempil" sticks (253 °C or 274 °C). This is particularly im-
portant when working in strong wind.
Peel the pipe end until the blades are flush with the pipe
end.
Use a scraper to complete the peeling of any area
where ovality impairs the effectiveness of the peeling
tool.
should be checked.
Use a clean cloth or dry paper to clean the heating bush Contact GF for resharpening or replacing the blades.
and the heating spigot. The tools must be cleaned after Should this work be carried out independently, use a
making each fusion joint. mandrel gauge to adjust the blades to the following di-
ameters.
288
Outside Peeled diameter Champfer Peeling Fusion jointing procedure
pipe diame- (mm) b (mm) length Heating
ter l (mm)
d (mm)
16 15.85-15.95 2 13
20 19.85-19.95 2 14
25 24.85-24.95 2 16
32 31.85-31.95 2 18
40 39.75-39.95 2 20
50 49.75-49.95 2 23
63 62.65-62.95 3 27
75 74.65-74.95 3 31
90 89.65-89.95 3 35
110 109.55-109.95 3 41
Quickly push first the fitting onto the heating spigot to

the correct depth and then the pipe into the heating
bush axially, without twisting, and hold firmly.
16 mm pipes should be inserted into the heating bush
Pipes in size 20 mm should be inserted until the end of
the peeled surface is flush with the edge of the heating
In the case of SDR 11 pipes with diameter bush. In fusion jointing machines fixed stops regulate
d = 20 or 25 mm, insert a support sleeve
manually in the pipe end as far as the stop
this. The heating times in the table below are measured
before starting to peel, or use pipes with from this point on. Fusion joints should not be used for
smaller SDR values. pipes whose walls are thinner than those listed in the ta-
ble.
Heating times and minimum wall thicknesses for socket
fusion joints
Outside Heating Heating Change Cooling Cooling
pipe time time fixed total
dia-me- PN10 PN6 (Max.- sec min
ter SDR11 SDR17 time)
mm sec
16 5 - 4 6 2
20 5 - 4 6 2
25 7 - 4 10 2
32 8 - 6 10 4
40 12 - 6 20 4
50 18 - 6 20 4
63 24 - 8 30 6
75 30 15 8 30 6
90 40 22 8 40 6
110 50 30 10 50 8
Thoroughly clean the fitting socket with absorbent paper The temperature and heating time must be strictly ob-
and cleaning fluid (e. g. Tangit cleaner). Use fresh pa- served.
per each time.
289
Jointing (by hand)
elapsed. Paying attention to the alignment marks, im-
mediately push them together axially without twisting.
Hold them together for the same duration as the heating
period.
Pressure testing
fore pressure testing, i. e. as a rule wait about an hour
after the last joint has been completed.
290
Fusion jointing of PVDF IR fusion jointing must only be performed by personnel
IR Plus fusion jointing of PVDF piping sys- world-wide by qualified GF IR Plus welding instructors.
tems Tools required

110 mm
1 Pipe
2 Heating element
3 Fitting

pressure path prior to the fusion process itself, i. e.
means of IR radiation.
A incorrect
B correct
291
IR 315 Plus: for fusion joints in the size range the end faces. The minimal, defined bead is only formed
d225-315 mm during the jointing process. The fusion area thus has
improved flow dynamics, low clearance volume, and
The jointing path controls the jointing pressure and thus
is assured by the clearly defined and controlled process
sequence.
Welding report/traceability
IR 450: for fusion joints in the size range d315-450 The welding parameters for the relevant welding opera-
mm tions can be read out directly via various interfaces on
essential fusion parameters for each individual fusion
joint, as required.
BCF Plus fusion jointing of SYGEF PVDF

piping systems
Fusion jointing method
The fusion jointing process consists in transmitting pre-
cisely defined thermal energy to the pipe and fitting
ends being joined by means of half-shell heating ele-
ments.
General conditions
Protect the area of the fusion joint from adverse weath- At the same time an elastic, pressurised bladder sup-
er conditions, such as rain, snow or wind. The permitted ports the inside surface of the fusion zone in order to
temperature range for IR Plus fusion jointing is between prevent the formation of an internal fusion bead.
+5 °C and +40 °C. Outside this range, suitable action Holding the melted thermoplastic under controlled pres-
must be taken to ensure that these conditions are main- sure ensures ideal, homogeneous fusion of the plastic
tained. It must also be ensured that the components be- components.
ing joined are in this temperature range.
Fully automatic process control of the fusion jointing
Preparing the fusion joint and operating the IR process with a fusion jointing machine developed in-
fusion jointing machine house by GF permits very simple handling and repro-
In principle, IR fusion jointing machines do not require ducible fusion quality.
any special preparation, other than to ensured that all
components being joined are clean.
Operation of the IR machines is defined exactly in the
operating instructions, but we strongly recommend to at-
tending a 1-day training course to become a qualified IR
welder.
joints
Non-contact heating
frared radiation. 1 Pipe clamping element
A defined gap between the heating element and the end 2 Fitting
faces minimises the risk of contamination of the jointing 3 Heating element with fitting - clamping device
surface. Contamination of the heating element by plastic 4 Pressurised bladder
particles is thus also eliminated. 5 Pipe
Reduced bead formation 6 Compressor for bladder
The fusion bead produced during jointing is consider- 7 Cooling air blower
ably reduced without any loss of quality. Bead forming 8 Control unit control panel
equalisation is eliminated by non-contact softening of 9 Compressed air supply
292
Welding report / traceability
electronic data output (PCMCIA card).
1 Pressurised bladder the essential fusion parameters for each individual fu-
2 Welding zone sion joint.
3 Heating element
4 Clamping position
5 Pipe / Fitting
SYGEF fittings and SYGEF pipes are suitable for work-
ing pressures up to 16 bar at 20 °C (water). SYGEF di-
aphragm valves are designed for a maximum working
pressure of 10 bar at 20 °C (water). Refer to the chapter
on pressure/temperature diagrams for details of permis-
sible working pressures.
Tools required
BCF jointing requires the SYGEF HP BCF jointing ma-
chine in addition to the tools normally used for plastic
pipework construction (pipe cutters, etc.).
Preparing the fusion joint and operating the

BCF® Plus fusion jointing machine
In principle, BCF Plus fusion jointing machines do not
require any special preparation, other than to ensure
that all components being joined are clean.
Operation of the BCF Plus machines is defined exact-
ly in the operating instructions, but we strongly recom-
mend attending a 1-day training course to become a
qualified BCF welder.
Properties and characteristics of BCF® Plus fu-
sion joints
Welding free from beads and crevices
The result of the jointing process is a surface similar
to the actual pipeline components, free from beads or
crevices. There are therefore no dead legs, the surface
roughness is in the range of the pipe components.
The high reproducibility of the joints is assured by the
clearly defined and controlled process sequence.
293
Butt fusion jointing of PVDF piping sys- The clamping equipment must hold the various parts se-
tems curely without damaging the surfaces. Possible ovali-
ty can be largely compensated by centred clamping of
Butt fusion jointing method the components to be joined. It must also be possible to
The fusion areas of the pipes and fittings are heated to hold all parts firmly in alignment.
fusion temperature and joined by means of mechanical
pressure, without using additional materials. A homo- The machine must also be capable of face planing the
geneous joint results. Butt fusion must only be carried fusion surfaces of pipes and fittings.
out with fusion jointing machines which allow the jointing The fusion jointing machine must be sufficiently solid to
pressure to be regulated. be able to absorb the pressures arising during the fu-
The principle of fusion jointing sion procedure without detrimentally deforming the joint.
The heating surfaces of the heating element must
be flat and parallel. The temperature variation over
the working area must not exceed 10 °C. The ma-
General conditions
1 Pipe
2 Heating element
3 Fitting
moplastics - Heated tool welding of pipes, piping part
and panels made of PVDF".
DVS 2208 Part 1.
Join only components with similar wall thicknesses
sion jointed. For best results, only components which Protect the fusion area
have a density between 1.70 and 1.80 g/cm³ and a melt
flow index in the range from MFR 230/5 1.0 to 25 g/10 Screening the fusion area can ensure a more even tem-
min should be fusion jointed. This requirement is met by perature distribution on the entire circumference of a
PVDF butt fusion fittings from GF. pipe subject to direct sunlight. The pipe ends at the op-
posite end of the fusion areas should be sealed when-
ever possible to reduce to a minimum the cooling of the
fusion surfaces which can be caused by wind.
The quality of the fusion process is governed by the
care with which the preparatory work is carried out. This
part of the procedure therefore deserves special atten-
tion.
Heating tool
A incorrect Set the temperature of the heating element to 240 °C.
B correct Check the temperature. The fusion temperature should
be between 232 °C and 248 °C.
Tools required
requirements:
294
Pipe diameter Max. gap
(mm) (mm)
≤ 355 0.5
400 ... 630 1.0
Check the temperature

Temperature of heating element 232 °C to 248 °C
mencing the fusion jointing. This is best carried out with
the help of a digital thermometer. But only thermome-
ters with a sensor for measuring surface temperature
are suitable. A max. gap
To ensure it is being maintained at the correct level the
fusion temperature should be checked from time to time Check the wall alignment and gap
during the jointing work. The temperature of the heating The alignment of the two parts should be checked at
element is particularly sensitive to wind. the same time. A possible misalignment on the outside
must not exceed 10 % of the thickness of the wall. If
this limit is exceeded, a better clamping position is to be
ever, the surface must be re-planed.
ately prior to the jointing.
Setting the fusion pressure
Fusion jointing requires different pressures to be applied
during equalisation and jointing on the one hand and
following diagram.
Clean the heating element with dry, clean paper before
each fusion joint!
Protect the working surface of the heating element
from becoming soiled. Clean both faces of the heat-
joint. Protect the heating element from wind, damage
and soiling during the intervals between making fusion
joints.
Before machining the fusion surfaces, make sure that
even beyond the fusion zone; if necessary, clean with a
cleaning fluid.
All the components clamped into the fusion jointing ma-
chine are planed simultaneously with the planer provid-
ed. The shavings should not be thicker than ≤ 0.2 mm.
This step is completed when there is no unmachined The specific jointing pressure required for equalisation
area left on either of the parts to be joined. This is nor- and fusion can be found in the following table with the
mally the case when no more shavings come off the heating and cooling periods. The table lists the times
machined surface. for various wall thicknesses. Interpolate for intermediate
Remove any shavings which may have fallen into the values.
pipe or fitting with e. g. a brush. The fusion surfaces The force needed for equalisation and jointing (FA) is
should not be touched by hand under any circum- given by the product of the fusion area and the specif-
stances. Otherwise they must be cleaned with cleaning ic jointing pressure (FA = A * p). The force (FB) required
fluid. to move the pipe must be added to this. (Ftot = FA + FB).
Once they have been machined, the parts are moved This latter force includes the intrinsic resistance of the
together until they touch. The gap between the two machine and the resistance of the axially mobile pipe
parts must not exceed the value in the following table. or fitting clamped in it. The resistance of longer pipes
295
should be reduced as far as possible by placing rollers duce the equalisation pressure almost to 0 (p ~ 0.01 N/
beneath them. The kinetic force (FB) should not exceed mm²). The heating time listed in the table is measured
the jointing force (FA). from this moment.
Equalise and heat
Join and cool

A Contact force
Approximate values for butt fusion of PVDF¹) Once the heating period has elapsed, remove the parts
Wall thick- Equalisation at Heating time ²) from the heating element which should then be removed
ness p=0.10 N/mm² p=0.01 N/mm² without touching the jointing surfaces and push the
(mm) Height of bead (sec) parts together immediately. The changeover time must
not exceed the value listed in the table. Pay particular
(mm) attention during jointing that the parts be moved togeth-
1.9 .. 3.5 0.5 59 .. 75 er swiftly until the surfaces are about to touch.
3.5 .. 5.5 0.5 75 .. 95 Then they should be moved together so that they are in
contact along the entire circumference. Next the pres-
5.5 .. 10.0 0.5 .. 1.0 95 .. 140
sure should be increased rapidly to the present joint-
10.0 .. 15.0 1.0 .. 1.3 140 .. 190 ing pressure within the period of time specified in the ta-
15.0 .. 20.0 1.3 .. 1.7 190 .. 240 ble. This pressure must be maintained during the entire
20.0 .. 25.0 1.7 .. 2.0 240 .. 290
cooling period. Adjustment may be necessary, especial-
Wall thick- Change-over Time to reach Cooling time The jointed parts must stay in the fusion jointing ma-
ness time max. full jointing ²) under joint- chine under jointing pressure until the end of the cooling
(mm) (sec) (sec) ing period specified in the table.
p=0.10 N/
mm²
(min)
1.9 .. 3.5 3 3 .. 4 5 .. 6
3.5 .. 5.5 3 4 .. 5 6 .. 8.5
5.5 .. 10.0 4 5 .. 7 8.5 .. 14
10.0 .. 15.0 4 7 .. 9 14 .. 19
15.0 .. 20.0 5 9 .. 11 19 .. 25
20.0 .. 25.0 5 11 .. 13 25 .. 32
Fusion check
1) in accordance with DVS 2207-15
2) The times are affected by the pipe wall thickness, the the pipe. K in the diagram to the left should always be
outside temperature and wind strength. positive.
Determine the values to be set for equalisation and Carrying out the pressure test
jointing on the basis of the information above, bearing All fusion joints must be allowed to cool completely be-
in mind the instructions from the manufacturer of the fore pressure testing, i. e. as a rule wait about 1 hour af-
fusion jointing machine before commencing the fusion ter the last joint has been completed.
process.
Once it has attained the fusion temperature, position the
heating element in the fusion jointing machine. Press
the parts to be joined against the heating element with
the force required for equalisation until the entire cir-
cumference of each of the jointing faces rests complete-
ly against it and a bead (see the table) has formed. Re-
296
Socket fusion jointing of PVDF piping sys- The basic rule is that only similar materials can be fu-
tems sion jointed. For best results, only components which
fulfill the following requirements should be fusion joint-
Socket fusion jointing method ed.
In this form of fusion jointing, which requires heating
tools, the pipe end is inserted into the socket of the fit- Characteris- Range from to
ting; no additional material is used. The pipe end and tics
fitting socket are heated to fusion temperature using a Density 1.70 g/cm³ 1.80 g/cm³
heating bush and a heating spigot, respectively, and are (= 0.0614 lb/in³) (= 0.065 lb/in³)
then pushed together.
MFR 230/5 1.0 g/10 min 25 g/10 min
The pipe end, fitting socket and heating tools corre- (= 0.0022 lb/10min) (= 0.055 lb/10min)
spond in such a way that the necessary jointing pres-
sure is attained during jointing, resulting in a homoge- This requirement is met by PVDF socket fusion fittings
neous joint. from GF.
Fusion jointing procedure Tools required
Apart from the tools normally used in plastic piping con-
struction, such as pipe cutters or a saw with a cutting
guide, the socket fusion jointing method requires certain
special tools.
Important: The tools described here may be used for
GF socket fusion fittings made of PP and PVDF as well
as PE.
Pipe peeling and chamfering tool
A Fitting
B Heating spigot
C Heating element
D Heating bush
E Pipe
Heating

the length of the fusion joint. At the same time it re-
Note: Further information on the fusion jointing equip-
Finished joint ment hire service and training courses are available
from GF.
Heating element for manual fusion jointing
moplastics - Heated tool welding of pipes, piping part
and panels made of PVDF".
DVS 2208 Part 1.
297
The element is heated electrically. The heating bush
and spigot are removable. A separate pair is required
for each pipe size.
Important: The surfaces of the heating tool which come
into contact with the pipe or the fitting must have a non-
stick coating.
Fusion jointing machine
Cut the pipe square using a cutter for plastic pipes and
A Pipe deburr the inside edges with a knife.
B Heating element
Make sure that the tools and pipes are clean and
C Fitting
grease-free even beyond the fusion zone; if necessary,
A fusion jointing machine is recommended for fittings clean with a cleaning fluid.
with a diameter of d = 63 mm or more. It is also better to Pipe in size d16
use a machine for smaller joints if there is a large num- For pipes of diameter d = 16 mm, chamfer about 2 mm
ber to be made. of the pipe end at an angle of 15°. Prepare about 15
The machine should be set up and operated accord- mm of the pipe end with a scraper. Mark off the jointing
ing to its manufacturer's instructions. The procedure length of 13 mm on the pipe.
detailed below (including the preparation) is for fusion Pipes in sizes d20 to d110
jointing with the help of a manual jointing tool.
Set the temperature of the heating tool to 260 °C / 500

°F. Check the temperature. The fusion temperature
must be between 250 °C / 482 °F and 270 °C / 518 °F.
To test the thermostat, check the fusion temperature
from time to time on the outside of the heating bush, us-
ing a fast acting thermoprobe or tempil sticks (253 °C /
253 °F or 274 °C / 525 °F). This is particularly important
when working in strong wind. Peel the pipe end until the blades are flush with the pipe
end.
Use a scraper to complete the peeling of any area
where ovality impairs the effectiveness of the peeling
tool.
should be checked.
Contact GF for resharpening or replacing the blades.
Should this work be carried out independently, use a
mandrel gauge to adjust the blades to the following di-
ameters.
Use a clean cloth or dry paper to clean the heating bush
and the heating spigot. The tools must be cleaned after
making each fusion joint.
298
Outside Peeled diameter Champfer Peeling Fusion jointing procedure
pipe diame- (mm) b (mm) length Heating
ter l (mm)
d (mm)
16 15.85-15.95 2 13
20 19.85-19.95 2 14
25 24.85-24.95 2 16
32 31.85-31.95 2 18
40 39.75-39.95 2 20
50 49.75-49.95 2 23
63 62.65-62.95 3 27
75 74.65-74.95 3 31
90 89.65-89.95 3 35
110 109.55-109.95 3 41
Quickly push first the fitting onto the heating spigot to

the correct depth and then the pipe into the heating
bush axially, without twisting, and hold firmly.
16 mm pipes should be inserted into the heating bush
Pipes in size d = 20 mm to 110 mm should be insert-
ed until the end of the peeled surface is flush with the
edge of the heating bush. In fusion jointing machines,
fixed stops regulate this. The heating times in the table
The peeling length l corresponds to the length of the
below are measured from this point on. Fusion joints
peeling blades.
should not be used for pipes whose walls are thinner
than those listed in the table.
Heating times and minimum wall thicknesses for socket
fusion joints
Pipe Mini- Heating Change Cooling Cooling
outside mum time (Max.- fixed total
diame- pipe sec time) sec min
ter wall sec
mm thick-
ness
mm
16 1.5 4 4 6 2
20 1.9 6 4 6 2
25 1.9 8 4 6 2
32 2.4 10 4 12 4
40 2.4 12 4 12 4
50 3.0 18 4 12 4
Thoroughly clean the fitting socket with absorbent paper 63 3.0 20 6 18 6
and cleaning fluid (e. g. Tangit cleaner). Use fresh pa- 75 3.0 22 6 18 6
per each time. 90 3.0 25 6 18 6
110 3.0 30 6 24 8
The temperature and heating time must be strictly ob-

served.
299
Jointing (by hand)
elapsed. Paying attention to the alignment marks, im-
mediately push them together axially without twisting.
Hold them together for the same duration as the heating
period.
Pressure testing
fore pressure testing, i. e. as a rule wait about an hour
after the last joint has been completed.
300
Planning fundamentals for valves
Page

General/Overview
-- Benefits of GF Piping Systems valves 302
-- Products and applications 303
-- General safety information 303
Application area of valves 306
Material selection
-- Pressure-temperature diagram 307
-- Chemical resistance 307
-- Other criteria for the selection of materials 307
Product selection criteria
-- Common types of valves 308
-- Nature of the medium 309
-- Functional properties 310
-- Types of connections 310
Overview actuators 313
Conceptual understanding of technical data

-- Pressure-temperature diagram for valves 315
-- Technical data 315
-- Tightening torques 315
-- Conversion factors 315
301
Planning fundamentals for
valves
General/Overview
I.) General/Overview
• Products and applications
• Benefits GF valves
• General safety information
II.) Application area of valves

• Standards
III.) Material selection

In order to make the right selection for the valve, several factors are important. The following table helps you to se-
lect the right material and valve type.

Pressure-temperature diagram Chemical resistance Other criteria for the selection of
Chapter "Material selection" Chapter "Material selection" materials
Chapter "Material selection"

Determining the material

IV.) Product selection criteria

Design of valves Chapter Nature of the medium Functional properties Types of connections
"Product selection criteria" Chapter "Product selection Chapter "Product selection Chapter "Product selection
criteria" criteria" criteria"

Selection of valve types

V.) Overview actuators

Electric actuator Pneumatic Actuator Electromagnetic actuators
Chapter "Overview actuators" Chapter "Overview actuators" Chapter "Overview actuators"

Selection of actuator types

VI.) Conceptual understanding of technical data • Good controllability

Benefits of GF Piping Systems valves • Long life time
• Wide dimensions range
• Manual valves to actuated valves available • Usable in media containing solids
• Interfaces for pneumatic or electrical actuators • Wide selection of materials and sealing materials
• Economical
• Cost-effective
• Large variety of materials for optimal chemical resis-
tance
302
Products and applications
The following table lists the different products and their
market segments.
Ship Build- Chemical Life Science Microelectron- Water Treatment Food and Energy
ing Process In- Industry ics Beverage
dustry
Ball valve + + 0 0 + 0 +
Diaphragm valve 0 + + + + 0 +
Butterfly valve + + 0 + + + +
Check valve + + 0 0 + 0 +
Wafer check valve - + 0 + + - +
Angle seat valve and 0 + 0 0 + - +
strainer
Process control valve 0 + + + + - +
Ventilating and bleed + + + + + + +
valve
Solenoid valve - + 0 0 + 0 +
Variable area flow + + + + + - +
meter
+ = suitable
0 = conditionally suitable
- = not suitable
General safety information

DANGER
The following general safety notes are an overview.
They should show compact the important instructions
and warnings of serious injuries and further damage in
Valve failure due to wrong choice of mate-
specific areas such as "Intended use", "request to the
rial
user, "transport and storage", "Installation of the valves
" and "Technical data" and information. In the following Death or serious injury can occur due to con-
chapters on the "general safety" are listed only specific tact with medium. Valve body, gaskets, di-
reference for product safety information. aphragms, backing diaphragm, housing and
mechanical parts can be damaged or im-
Intended use
paired in their function due to diffusion ef-
Valves are intended exclusively for shutting off and con-
fects, lack of chemical resistance, external in-
veying media in the allowable pressure and tempera-
ture range or for controlling flow in piping systems which fluences and worn out diaphragm.
they have been installed. • Ensure Chemical resistance of all compo-
nents: refer to the Georg Fischer Planning
Fundamentals for chemical resistance. In
DANGER case of doubt contact your Georg Fischer
representative.
Ignore the chemical resistance Requirements for user and operator responsibility
Serious injury or death caused by disregard • The valves must only be used according to the spec-
• Read the instructions on chemical resis- ifications for which they have been intended, as indi-
tance cated in the previous paragraph
• Choose the best material with help from • Piping system must be installed by professionals and
the chemical resistance list its functionality is checked regularly
• Use valves only in intended environment • Installation, operation, service and repairs must only
• Contact in borderline cases the responsible be carried out by qualified personnel
people from Georg Fischer Piping Systems • Users and operators must be instructed on a regu-
Ltd. lar basis in all aspects of work safety and environ-
mental protection especially those pertaining to pres-
sure–bearing piping systems
• The users and operators must be familiar with the per-
ating instructions and must adhere to the information.
303
Instruction Manual Installation of valves
DANGER NOTICE
Disregard instruction manual Fixation of the valve

Serious injuries or death by disregarding Due to temperature changes, longitudinal or
• Read and follow the instruction manual lateral forces may occur if thermal expansion
• Keep instruction manual is always avail- is constrained
able at the product • Absorb forces via respective fixed points
• Pass instruction manual to future users of before or after the valve
the product • Operation of a valve causes reactive forces
which could damage the valve:Mount the
The instruction manuals for all valves you can receive valve as a fixed point with the designated
from your responsible representative at Georg Fischer fastener if available or reinforce the piping
Piping Systems Ltd. or www.piping.georgfischer.com. directly before and after the valve with suit-
able supports
Transport and storage
• Superimposed loadings could damage the
• Valves should be transported and stored in its original valve: Valve and piping must be aligned
packaging
• The valve must be protected from harmful influences
such as dirt, dust, humidity and especially heat and
UV radiation NOTICE
• The connection ends should not be damaged me-
chanically or in any other way
Tightening the union nuts
• The valves should be stored in opened position
Coupling nuts are hand-tightened without-
the use of auxiliary tools. Through the use of
pliers or similar tools, the materials of screw
DANGER caps are damaged. There is also the damage
to damage the thread when exceeding the
Defective valves thightening torque.
Serious injuries or death by defective valves • Only hand-tighten
• Use valves only in a technical perfect con-
dition
DANGER
DANGER Elastomers
Serious injuries or death by damage to the
Exceeded operating pressure pipe and fittings with non-compatible use of
elastomers.
The maximum operating pressure of the en-
tire valve is determined by the maximum al- • Select the right elastomer material and
lowable operating pressure of the connect- valve material
ing part. Exceeding the maximum operating • Reed information
pressure can result in serious injury or death. • For questions, please contact your national
distributor of GF Piping Systems.
• Do not exceed maximum operating pres-
sure
• avoid pressure surges
DANGER
Medium speed
Serious injury or death due to failure to pro-
vide acceptable medium speed
• Reed information
• For questions, please contact your national
distributor of GF Piping Systems.
304
Information about normal operations
and maintenance are available at
www.piping.georgfischer.com
Spare parts
• In exchange use only the original
valves and spare parts from Georg
Fischer Piping Systems Ltd.
Technical facts
Logarithmic axis scale
• Please note the diagrams in the divi-
sion axis
kv - values
• The flow volume for any intermediate
position of the valve is determined
from the kv 100 value, multiplied by
the percentage of the kv value from
the flow characteristics diagram.
305
Application area of valves
The engineering design of valves supplied by GF is
based on the following design standards:
• EN ISO 16135: Industrial valves - Ball valves of ther-
moplastic materials
• EN ISO 16136: Industrial valves - Butterfly valves of
thermoplastic materials
• EN ISO 16137: Industrial valves - Check valves of
thermoplastic materials
• EN ISO 16138: Industrial valves - Diaphragm valves
of thermoplastic materials
• EN ISO 16139: Industrial valves - Gate valves of ther-
moplastic materials
• EN ISO 21787: Industrial valves - Valves of thermo-
plastic materials
The valves fully comply with the requirements set out in
the above standards. In many cases, they exceed the
requirements for pressure/temperature load capacity. It
should be noted that depending on the engineering de-
sign, at high temperatures, there may be a reduction in
the application limits of pipes and fittings, whether this
be in the amount of the permitted pressure or the maxi-
mum temperature.
306
Material selection • Water
• Ambient temperature
Pressure-temperature diagram • Medium temperature
In order to make the right material selection, the pres- Furthermore, the proper handling plays an important
sure-temperature diagram might help you. The pres- role to the max. life time. Regular maintenance is also
sure-temperature diagram is based on a curve showing an important factor that must be considered.
the pressure course at a certain temperature. With the
diagram, the material can be determined, because not
every material can withstand the same pressure rating.
Depending on the design of the valve their pressure-
temperature diagrams may differ from those for pipes
and fittings, e.g. limited temperature range due to a seal
or lower pressure loading at higher temperatures. This
has to be considered when dimensioning the piping sys-
tem.
Pressure-Temperature-Diagram
• Detailed information is available in
the different valve chapters.

Chemical resistance
Pipes made from plastics are used not only for drinking
water, water for general use and waste water, but also
for the conveyance of aggressive liquids and gases. It
is, however, important that the most suitable plastic ma-
terial is selected for each application. The Chemical Re-
sistance List in this section serves as a useful guide in
this respect. It contains the essential thermoplasts and
elastomers of the GF product range which can, either
through environments or through external influences,
come into direct contact with the media.
Chemical resistance
• More detailed information are avail-
able in the chapter “Material selec-
tion- Chemical resistance”.

Other criteria for the selection of materials

The following criteria must be taken into consideration
when selecting the material.
• Internal pressure
• Soil and traffic loads
• Cold
• Heat
• UV
• Chemical environment
• Fragmentation
• Gas blow
• Steam pressure
• Diffusion
• Static electricity
• Flammable substances
• Explosive environment
• Corrosion
• Air
• Humidity
307
Product selection criteria the cone also prevents jam-
ming. Malfunctions are thus
excluded.
Common types of valves

Butterfly valve
Ball valve
The butterfly valve controls
The ball valve is similar in
the flow by using a circular
concept to the plug valve but
disk or vane with its pivot axis
uses a rotating ball with a
at right angles to the direction
hole through it that allows
of flow in the pipe. The butter-
straight-through flow in the
fly valve requires a minimum
open position and shuts off
of space and is used both for
flow when the ball is rotat-
open/close and throttling ser-
ed 90º to block the flow pas-
vices.
sage. This valve is used for
open/close functions and also
for throttling services.

Diaphragm valve
The diaphragm valve has
a flexible membrane that is
moved by means of a pres-
Ventilating valve and Venti- sure pin. When the pres-
lating and Bleed valve sure pin is located in the low-
When ventilation and bleed er position, the diaphragm
valve, a novel float provides a is pushed onto a stage and
complete and reliable venting the flow is interrupted. Di-
of piping systems and tanks. aphragm valves are well suit-
At the same time, the valve ed for corrosive, abrasive and
prevents a media overflow. dirty media.
The ventilating valve is used
everywhere where a safe and
controlled air supply must Wafer check valve
be ensured. The float has If a medium flows in the flow
the contours of a spherical direction, so it opens up the
surface in the sealing zone plate of the wafer check valve
and is completely flush with and thus the flow is possible.
the sealing ring. The double If the medium pressure falls
bearing of the float addition- below a certain limit, the flap
ally prevent it from jamming, closes again.
even in very rapid closing
movements.

Process control valve
If the inlet pressure rises
above the set value, the pres-
surised valve piston is lifted
against the spring force. Con-
sequently, the valve opens
and there is a reduction of Angle seat check valve
pressure in the outlet pipe. The angle seat
The valve closes as soon as check valve has a plunger,
the inlet pressure sinks below which is arranged in the mid-
the preset spring tension. dle of the valve and press-
es on a flat stamp or seat.
By turning up the stamp, the
Cone check valve valve opens. This valve is
The unique check cone to
prevent the backflow of me-
dia forms the core of the new
generation of valves. The
optimized flow geometry re-
duces the flow resistance and
the pressure loss to a mini-
mum. Thanks to new sealing
zone and specially designed
profile seal, the valve is com-
pletely sealed, even during
very fast closing movements.
The check cone has the con-
tour of a sphere in the sealing
zone. The double bearing of
308
suitable for open/close func-
tions or for controlling media
free of foreign particles.

Variable area flow meter
A variable area flow meter
consists of a conical tube
that is passed by the medi-
um from bottom to top. In
this cone, there is a vertical-
ly moving float. If a medium
flows at a sufficient flow rate
upwards through the verti-
cally mounted taper tube,
the float is raised to the point
at which a state of equilibri-
um sets in between the lift-
ing force of the medium and
the weight of the float. Since
the mean flow rate is propor-
tional to the quantity flow-
ing through per unit of time,
this state of equilibrium corre-
sponds to the measurement
of the current flow rate.

Nature of the medium

Type Free of foreign parti- Containing particles, Viscous Gaseous
cles crystallising
Ball valve + 0 + +
Diaphragm valve + + + 0
Butterfly valve + 0 0 0
Check valve + 0 0 +
Wafer check valve + 0 0 0
Angle seat check valve + 0 0 0
Process control valve + 0 - x
Ventilating valve and Venti- + 0 0 +
lating and Bleed valve
Solenoid valve + - 0 +
Variable area flow meter + - + +
Strainer + 0 + +
+ = recommended
- = not recommended
x = not possible / not existing
309
Functional properties
Type Adjustable Position indicator Piggable Leakproof under Triggering pres-
vacuum sure surge
Ball valve 0 * + + - 1)
Diaphragm valve + * - 0 +
Butterfly valve 0 * - 0 - 1)
Check valve x x - 0 0
Wafer check valve x x - 0 0
Angle seat check valve- x x - 0 0
and Angle seat valve
Process control valve + - - - 0
Ventilating valve and - - - 0 0
Ventilating and Bleed
valve
Solenoid valve - + - 0 0
Variable area flow me- - * - * +
ter
Strainer - - - 0 +
+ = recommended
- = not recommended
* = available for accessories
x = not possible / not existing
1) = make sure the actuation is slow (manual valve / pneumatic valve with throttle)
The following tables list the different types of connection

Types of connections with the corresponding materials. The tables are intend-
There are different types of connections for the valves. ed as an overview.
Each of these connections has several characteristics
More information is available in the product
that should be considered when selecting the connec- catalogues.
tion.
More information is available in the Chap-
ter Jointing technology.
Union
• Flexible
• Large variety of unions according to standards
• Non-permanent connection
• Uniform surface pressure on jointing face
• Variable in sealing materials
Spigot connection
• Permanent connection
• Purity of the connection
• Reasonable price
• Low component costs
Flange
• Non-permanent connection
• Many standard parts from different suppliers available
• Dismountable with standard tools
• Variable in sealing materials
• Common jointing method in CPI and Energy
310
Sockets
Picture Designation Standard Material
Solvent cement socket ASTM, BS, ISO,JIS ABS, PVC-C, PVC-U
Threaded socket ASTM, ISO, JIS/RC, Messing, ABS, PVC-C, PVC-U, PVDF,
NPT, RP PP-H, Messing
Fusion socket ISO PE-100, PP-H, PVDF
Spigot
Cement spigot ISO PVC-C, PVC-U
Threaded spigot R Brass
Socket fusion spigot ISO PP-H, PVDF
Butt fusion spigot ISO, IR-Plus, SDR11, PE-100, PP-H, PP-R, PVDF
SDR17.6
311
Flange
Fixed flange ISO, JIS PP-H, PVC-U, PVDF
Backing flange ANSI, ISO, JIS PP-St, PVC-U, PP-H, PVDF
Coupling nuts
Picture Designation Material
Union nut ABS, PROGEF Standard,
PVC-C, PVC-U, SYGEF Stan-
dard
Others
Picture Designation Material
Blind connection part PVC-U
312
Overview actuators
An actuator supports the opening and closing of valves
with the help of an electric motor or with pneumatics.
There are a number of actuators that are distinguished
in electric actuators and pneumatic actuators. Further-
more, rotary actuators and linear actuators can be dis-
tinguished.
An electric motor actuator for pipe valves is a special
type of actuator. They are used everywhere where com-
pressed air as an auxiliary energy for operation is not
available. They are preferably used in pipeline and plant
construction.
A pneumatic actuator is an actuator which is operated
by compressed air and requires no electrical energy.
Part-turn actuators are a special type of rotary actuators
and are used for the automation of quarter turn valves,
such as butterfly alves or ball valves. They have an out-
put movement of less than 360°. In general, the internal
drive gear segment is designed for a 90° movement.
The following table provides an overview of each actua-
tor and shows the special features of the different actua-
tor types. It should also help you with your decision.
Electric actuator
Advantages • Ease of installation
• Well defined performance
• No energy consumption in switching pauses
• Intermediate position possible
• Easy to maintain
• Subsequent additional elements mountable
• Robust PP-GF case with very good chemical resistance
• Flexible composition thanks to modular design, easy handling
• Additional safety due to unit and battery pack (optional)
• Long life time due to robust design and best electronics
• Suitable for universal use due to wide range power supply and standard interfaces
• Numerous monitoring and control capabilities with intelligent, self-learning accessories
Characteristics • Relatively high cost
• Low maintenance costs
• Long cycle time
• Additional equipment necessary for defined end positions
Versions • Heating element and return unit for increased safety
• Additional mechanical limit switches for feedback
• Optional adapter according to EN ISO 5211 for F04 and F05 interface
• Operating status monitoring
• Drive monitoring on an additional board: Response time monitoring, cycle counter, motor cur-
rent monitoring, cycle time extension
• Position detection and 4-20 mA position feedback
• Positioner
313
Pneumatic Actuator
Advantages • Short switching time
• Low cost
• Performance on variable pressure control
• Defined end position
• Stroke limiter (to change manually)
• Subsequent additional elements mountable
• Flow control is possible with additional elements
• Robust PP-GF housing
• Full plastic actuator
• Position indicator with integrated NAMUR interface
• Fast cycle times
• Very good price-performance ratio for all versions
• Multi functional module available with different limit switch versions
• Wide torque range, from 8 Nm up to 3840 Nm
• Construction of various limit switch versions without any problems
• Low installation height
Characteristics • Control valve necessary
• Compressed air required
• Position feedback for additional elements necessary
• Intermediate positions require more effort
Versions • Position feedback
• Digital positioner
• Opportunities for bus connection asAS-i
• Adapters for F04 and F05 interface
Electromagnetic Actuators
Advantages • Short switching time
• High switching frequency
Characteristics • Maximum operating pressure 6 bar
• Maximum operating pressure depending on DN
• Differential pressure necessary for servo-controlled solenoid valves
• Permanent demand for electricity in the open position
• Sensitive against solids when servo-controlled
• Flow control requires high effort
Versions • Direct-acting solenoid valves
• Servo-controlled solenoid valves
• Pilot valves
314
Conceptual understanding of techni- tive nominal diameter of the valves. These apply to a
completely opened valve. They are given in the follow-
cal data ing units:
Pressure-temperature diagram for valves • kv 100 value in l/min at 1 bar pressure loss
• kv 100 value in m /h at 1 bar pressure loss
3
The following conditions must be fulfilled for applications

of the pressure-temperature diagrams (p-T diagrams), • Cv 100 value in US gal/min at 1 psi pressure loss
which are given for the respective valve types: The flow volume for any intermediate position of the
valve is determined from the kv 100 value, multiplied by
the percentage of the kv value from the flow characteris-
• Low stress valve installation tics diagram.
The valve must be mounted in the piping system in-
stallation so that the piping does not cause any re-
straints on the valve, which could have a negative ef- Tightening torques
fect on valve operation. For valves with flange connections, the recommended
values for tightening the screws, and the required num-
• Appropriate fixed points before and after the valve ber and length of screws are given. These values differ
When a pipe heats up/cools off, it will expand/con- according to the type of seal. Profile gaskets and O-ring
tract. Such thermal expansion should be kept, if at seals require less tightening torque than the flat gas-
all possible, from the valve because it could have a kets.
negative effect on valve operation. We recommend
mounting fixed points before and after the valve. Conversion factors
kv - Cv
Technical data In Europe, the kv value is related to a flow rate of 1 m³/h
Operating torque at 16 °C and a pressure loss of 1 bar. In US, it is called
This diagram indicates the torque required for the open- Cv and relates to a flow rate of 1 US gal/min at a tem-
ing and closing movement. perature of 60 °F and a pressure loss of 1 psi. That
means:
These are always reference values.
For some valve types, data are also given regarding with:
how much tighter the initial breakaway torque can be
C v Cv Value in US gal/min
compared to the operating torque. This occurs when a
valve sits in the same position for a long period of time. k v kv Value in Europe in m³/h
This initial breakaway torque must be considered when 1 m³ 264.1722 US gal
selecting actuators from other suppliers. These initial
breakaway torques have been taken into consideration 1 bar 14.50377 psi
for the electric and pneumatic actuators from GF.
k v k v C v
Pressure loss
k v 1 m³/h 16.67 l/min 1.1561 US gal/min
The pressure loss, which occurs when a medium flows
through a valve, is required for the hydraulic dimension- k v 0.06 m³/h 1 l/min 0.069 US gal7min
ing of a piping system. The respective pressure loss for
C v 0.865 m³/h 14.42 l/min 1 US gal/min
the individual valve types in the completely opened po-
sition is given in the pressure loss diagrams in relation
to the desired flow volume.
Please note the logarithmic axis scale of
the flow rate and pressure loss.
Flow characteristics
The percentage flow characteristics of the individual
valve types is also given in diagram form. Based on an
aperture angle in percent (0 % = valve closed; 100 % =
valve completely open), the percentage of the kv value
can be determined from the diagram.
kv 100 values
The kv value is a characteristic value for the flow vol-
ume of a valve at a specific pressure loss in the valve.
The kv 100 values are indicated in tables for the respec-
315
316
Fundamentals for ball valves, hand operated
Page

Ball valves type 546 DN10 - DN100
-- Overview 318
-- Safety information 319
-- Graph 320
-- Instructions for use 326
-- Accessories 326
Ball valve type 543
-- Overview 337
-- Graph 339
-- Accessories 354
Ball valve type 523
-- Overview 356
-- Graph 358
Ball valve type 375
-- Overview 363
-- Graph 365
Ball valve type 322
-- Overview 368
-- Graph 369
Ball valve Coloro
-- Overview 371
-- Graph 373
317
Fundamentals for ball valves,
hand operated
Ball valves type 546 DN10 - DN100
Overview
Product description
Manual ball valves are used for shutting off or diverting
gaseous or liquid media. They are used in various appli-
cation areas. Their numerous specific product features
offer quality, flexibility, safety and, first of all, modularity. Ball valve type 546 with fixed flange serrated metric
With ball valve type 546 you obtain a well-engineered
product, which incorporates over 40 years experience of
GF Piping Systems' know how with plastic pipes. With
ball valve type 546 you get a product that is part of a
modular system. A ball valve as part of a system, which
considers your requirements for operational safety as
well as your ecological and economic requirements.
Versions
Ball valve type 546 is characterised by its versatility.
This is reflected in the different connection types and
the choice of materials. From the simple standard ver-
sion up to the actuated version, we off er you all varia-
tions with a broad range of accessories. Even the man- Ball valve type 546 with backing flange metric
ual version has interesting additional functions, such as
the integrated fixing system and a lockable lever with
catch function. With the function module, the valve posi-
tions Open/Closed of the control can be fed back in vari-
ous signal types.
Ball valve type 546 with solvent cement sockets
Product features
• From the manual valve to the automated valve with
many options - from electrical position feedback, the
lockable hand lever up to the pipe clip
• The greatest range of products (via the configurator,
all executions can be generated)
• Ergonomic hand lever (optionally lockable) with inte-
grated tool for dismounting the union bushing
Ball valve type 546 with solvent cement spigots
• Integrated fixation system with mounted threaded in-
serts
Ball valve type 546 with threaded sockets Rp
318
Overview
General Type 546
Dimension DN 10 - 100
Pressure range PN ABS / PP-H: 10
PVC / PVDF: 16
Materials used Hand lever PPGF30
Ball seal PTFE
Materials for valve body PVC-U +
PVC-C +
ABS +
PP-H +
PVDF +
Connection types Sockets +
Spigot +
Flanges +
Threaded socket +
Seal materials EPDM +
FFPM +
FPM +
Accessories Additional limit switches (multifunction module)
Standard hand lever red or black
Multifunctional hand lever
Hand lever extension
Mounting plate
Klip-IT Pipe Clips
Klip-IT Spacer
Safety information
WARNING
CAUTION
Removing the pipeline
Uncontrolled escape of the medium can
Media containing solids cause injury.
These could lead to damages/leakage due to • Before dismounting, release all pressure
abrasion. from the piping system.
• During control operation, cavitation has to • With hazardous, flammable or explosive
be avoided. media, the piping system must be com-
pletely emptied and rinsed before the valve
may be dismounted.
• Make sure that the medium is caught safe-
ly with the appropriate measures.
• Open the dismounted ball valve of type 546
halfway (45° position) and let the 546 drain
in a vertical position – catch the medium in
an appropriate vessel.
319
Graph
NOTICE Exploded view
DN10 - DN50
Installation of the ball valve
• The ball valve must always be built into the
system in the opened position.
DANGER
Selection of lubricants
Using the wrong lubricants can damage the
material of the ball valve or seals. Conse-
quences can be death or serious injuries.
• Never use petroleum-based greases or 1 Housing
Vaseline (Petrolatum). 2 Union bush
3 Valve end
• For silicon-free ball valves, please consult 4 Union nut
the special manufacturer‘s instructions. 5 Ball
• All seals should be lubricated with a sili- 6
7
Stem
Ball seal
con-based grease. 8 Backing seal
9 Body seal
10 Union seal
11 Stem seal
12 Standard hand lever
CAUTION 13 Hand lever clip

DN65 - DN100
Handling of the seals
All the seals (made of e.g. EPDM, FPM) are
organic materials which react to environmen-
tal influences. They must therefore be kept in
their original packaging, and stored cool, dry
and dark. The seals should be checked for
damages from aging, such as fissures and
hardening, before mounting.
• Do not use defective spare parts.
CAUTION 1 Housing
2 Union bush
3 Connecting part
4 Union nut
Overstraining by exceeding the maximum 5 Ball
pressure 6 Stem
7 Ball seal
The test pressure on a valve must not ex- 8 Backing seal
ceed the value 1.5 x PN, (maximum PN + 5 9 Body seal
10 Union seal
bar). The component with the lowest PN de- 11 Stem seal
termines the maximum allowable test pres- 12 Standard hand lever
sure in the piping section. 13 Hand lever clip
• Check the valves and connections on tight- Dimensions

ness during the pressure test. Document
your results. More dimensions of valves in different ma-
terials and with various connection types
are available in the ball valves product
ranges.
320
Ball valve type 546 with solvent cement sockets-
metric
d D H H1 L L1 L2 L4 L5 L6 z
mm mm mm mm mm mm mm mm mm mm mm
16 50 57 27 92 77 56 25 32 45 64
20 50 57 27 95 77 56 25 32 45 64
25 58 67 30 110 97 65 25 39 58 72
32 68 73 36 123 97 71 25 39 58 79
40 84 90 44 146 128 85 45 54 74 94
50 97 97 51 157 128 89 45 54 74 95
63 124 116 64 183 152 101 45 66 87 107
75 166 149 85 233 270 136 70 64 206 144
90 200 161 105 254 270 141 70 64 206 151
100 238 178 123 301 320 164 120 64 256 174
Ball valve type 546 with solvent cement spigots-

metric
321
d D H H1 L L1 L2 L3 L4 L5 L6
16 50 57 27 114 77 56 25 32 45
20 50 57 27 124 77 56 130 25 32 45
25 58 67 30 144 97 65 150 25 39 58
32 68 73 36 154 97 71 160 25 39 58
40 84 90 44 174 128 85 180 45 54 74
50 97 97 51 194 128 89 200 45 54 74
63 124 116 64 224 152 101 230 45 66 87
75 166 149 85 284 270 136 290 70 64 206
90 200 161 105 300 270 141 310 70 64 206
100 238 178 123 340 320 164 350 120 64 256
Ball valve type 546 with threaded socket Rp
Rp D H H1 L L1 L2 L4 L5 L6 z

inch mm mm mm mm mm mm mm mm mm mm
⅜ 50 57 27 92 77 56 25 32 45 64
½ 50 57 27 95 77 56 25 32 45 64
¾ 58 67 30 110 97 65 25 39 58 72
1 68 73 36 123 97 71 25 39 58 79
1¼ 84 90 44 146 128 85 45 54 74 94
1½ 97 97 51 157 128 89 45 54 74 95
2 124 116 64 183 152 101 45 66 87 107
2½ 166 149 85 233 270 136 70 64 206 144
3 200 161 105 254 270 141 70 64 206 151
4 238 178 123 301 320 164 120 64 256 174
322
Ball valve type 546 with fixed flange serrated metric
d D D1 D3 H H1 L L1 L2 L3 L4 L5 L6

mm mm mm mm mm mm mm mm mm mm mm mm mm
20 95 65 14 57 27 124 77 56 130 25 32 45
25 105 75 14 67 30 144 97 65 150 25 39 58
32 115 85 14 73 36 154 97 71 160 25 39 58
40 140 100 18 90 44 174 128 85 180 45 54 74
50 150 110 18 97 51 194 128 89 200 45 54 74
63 165 125 18 116 64 224 152 101 230 45 66 87
Ball valve type 546 with backing flange metric
d D H H1 H2 L L1 L2 L4 L5 L6 M

75 166 149 85 15 284 270 136 70 64 206 M8
90 200 161 105 15 300 270 141 70 64 206 M8
110 238 178 123 22 340 320 164 120 64 256 M12
Technical data
Pressure-temperature diagram
The following pressure-temperature diagrams are based
on a lifetime of 25 years and the medium water or simi-
lar media.
323
ABS PVC-C
P Permissible pressure in bar, psi 1) The central part of the ball valve is designed for the nominal
pressure PN 16
2) Depending on the valve end, the nominal pressure is reduced
PP to PN 10
PVDF
1) E. g. ball valve with PP or PE100 spigot end, SDR 17

In case of applications with temperatures in the range of 1) E. g. ball valve with threaded sockets
the dotted lines, please contact your GF representative. EPDM-sealing to max. 100 °C
PVC-U
Pressure loss
DN 10 - DN 50
1) The central part of the ball valve is designed for the nominal
pressure PN 16
to PN 10
to PN 6
X Medium: water 20 °C
Y Flow rate (l/min), (US gal./min)
Pressure loss Δp (bar), (psi)
324
DN 65 - DN 100 kv 100 values
DN DN d [mm] kv 100 Cv 100 kv 100
[mm] [inch] l/min US gal/ m³/h
(Δp = 1 min (Δp = 1
bar)) (Δp = 1 bar
psi)
10 ⅜ 16 70 4.9 4.2
15 ½ 20 185 12.9 11.1
20 ¾ 25 350 24.5 21
X Medium: water 20 °C 25 1 32 700 49.0 42
Pressure loss Δp (bar), (psi) 32 1¼ 40 1000 70.0 60
Flow characteristics 40 1½ 50 1600 112.0 96
50 2 63 3100 217.1 186
65 2½ 75 5000 350 300
80 3 90 7000 490 420
100 4 110 11000 770 660
The kv values for each intermediate valve position can

be determined by using the flow value characteristics
and the kv 100 values.
Operating torque
X Open angle (%) DN 10 - DN 50
Y kv, cv value (%)
Flow characteristics for linear ball valve type

546
For dimensions d20 DN15, d32 DN25 and d63 DN50, a
special ball with linear flow characteristics is available.
X Size DN (mm, inch)

Y Torque (Nm, Ib-ft)
DN 65 - DN 100
X Open angle (%)

Y kv, cv value (%)

Reference values for screw tightening torque

of type 546
Flanged joints with flange gaskets or flat gaskets
325
d DN DN Total number of screws (for 2 Torque Torque
mm [ mm [ inch flanged joints) standard nut (reference values) (reference values)
(height 0.8 x d) 1) Profile flange gasket 2) Flat gasket
in Nm in lb-ft in Nm in lb-ft
20 15 ½ 8 x M12 x 50 10 7.4 10 7.4
25 20 ¾ 8 x M12 x 55 10 7.4 10 7.4
32 25 1 8 x M12 x 60 10 7.4 15 11
40 32 1¼ 8 x M16 x 70 15 11 20 15
50 40 1½ 8 x M16 x 70 15 11 25 18
63 50 2 8 x M16 x 80 20 15 35 26
75 65 2½ 8 x M16 x 90 25 18 50 37
90 80 3 16 x M16 x 100 15 11 30 22
110 100 4 16 x M20 x 130 20 15 35 26
1)
For valve ends type 546 made of PP in combina- DN10 - DN50
tion with backing flanges, use half of the standard nut
height. More information about accessories are
available in the product ranges or in the
2)
Preferred gasket type (suited for plastics) online catalogue.
For more information on the use of the dif-

ferent gasket types, see Chapter: Jointing
Technology → Mechanical Joints Functions:
• Interface for mounting actuators
• Feedback unit in combination with actuators, also for
manual valve – with multifunctional hand lever
Instructions for use • Mechanical interface back wall assembly
Maintenance
Ball valves require no maintenance under normal oper-
ating conditions. However, the following measures must
be considered:
• Periodic check that no media escapes to the outside.
• We recommend a function test for ball valves which
are kept permanently in the same position 1–2 x a
year to check serviceability.
For frequent control operations – valve automation, or
due to chemical attack on the sealing material – it may
become necessary to replace parts inside the valve. For
this purpose, the valve must be removed from the piping
system.
Accessories
Multifunctional module
1 Housing
2 Housing cover
3 Stainless steel Torx screws
4 Caps
326
Assembly of multifunctional module incl. switches
1 Housing
2 Cover
3 Switching disk
4 Switch holder
5 Microswitch "OPEN"
6 Microswitch "CLOSE"
7 Connector plug 3P + E per DIN EN 175301-803 (formerly DIN
43650)
8 Seal
General technical data of multifunctional module

Protection class with DIN unit plug (7): IP 65
Protection class with cable gland: IP 67
Ambient temperature: -10 °C to +50 °C
Type of switch Contact rating Circuit diagram

Microswitch silver 250 V~ 6 A *)
Nickel (Ag Ni)
Microswitch with gold con- 4 - 30 V=
tact (Au) 1 – 100 mA
*) for ohm resistive load. For inductive loads, provide a protective circuit!
A closed
B open
C black
D blue (short cable)
E blue (long cable)
327
Type of switch Contact rating Circuit diagram
Inductive switch NPN 5 -30 V=
0.1 A
Inductive switch PNP 5 -30 V=
0.1 A
A closed
B open
C blue
D black
E black
F brown
Type of switch Nominal ratings Circuit diagram

Inductive switch Na- 8V=
mur approvals: ATEX
2032x, CSA
EMC according to
EN 60947-5-2 confor-
mance
EN 60947-5-6
A closed
B open
C blue
D brown
328
DN65 - DN100 Assembly of multifunctional module incl. switches
Coupling piece Multifunctional module with built-in limit

switches
Functions:
• Interface for mounting actuators
• Position feedback in combination with actuators
• Also for manual valve - with multifunctional hand lever
1 Housing
2 Cover
3 Switching disk
4 Microswitch "OPEN"
5 Microswitch "CLOSE"
6 Connector plug 3P + E per DIN EN 175301-803 (formerly DIN
43650)
7 Seal
General technical data of multifunctional module

Protection class with DIN unit plug (7): IP65
Protection class with cable gland: IP67
Ambient temperature -10 °C to +50 °C
Type of switch Contact rating

Microswitch silver 250 V~ 6 A *)
Nickel (Ag Ni)
Microswitch with gold contact (Au) 4 - 30 V=
1 – 100 mA
*) for ohm resistive load. For inductive loads, pro-

vide a protective circuit!
329
Circuit diagram Circuit diagram
A closed
B open
C black
D blue (short cable) A closed
E blue (long cable) B open
C blue
Type of switch Contact rating D brown
Inductive switch NPN 5 -30 V=
0.1 A
Inductive switch PNP 5 -30 V=
0.1 A
Circuit diagram
A closed
B open
C blue
D black
E black
F brown
Type of switch Nominal ratings

Inductive switch Namur approvals: 8 V=
ATEX 2032x, CSA
EMC according to
EN 60947-5-2 conformance
EN 60947-5-6
330
Standard hand lever red or black
d DN L1 L5 L6 H D
16-20 10-15 77 32 45 31 26
25 20 97 39 58 37 34
32 25 97 39 58 37 34
40 32 128 54 74 46 40
50 40 128 54 74 46 40
63 50 152 66 87 54 44
75 65 270 64 206 58 106
90 80 270 64 206 58 106
100 100 320 64 256 60 106
Multifunctional hand lever with ratchet set- DN65 - DN100

tings, lockable
DN10 - DN50
1 Multifunctional hand lever

2 Spacer
3 Fastening screw (Torx)
4 Spring
5 Hand lever clip
6 Unlocking latch 1 Hand lever clip
331
3 Spring
4 Unlocking latch
5 Mounting screw
6 Index plate
7 End stop
8 Washer
9 Nut
Dimensions
If ball valve 546 is equipped with the multi-function lever, a multifunction module is necessary in the dimensions DN65-100.
d-d DN-DN D D1 H L1 L5 L6

mm mm mm mm mm mm mm mm
16 - 20 10 - 15 26 5 53 87 42 45
- 25 - 20 34 5 59 108 50 58
- 32 - 25 34 5 59 108 50 58
- 40 - 32 40 5 69 140 66 75
- 50 - 40 40 5 69 140 66 75
- 63 - 50 44 5 80 165 78 87
- 75 - 65 115 12 105 270 64 206
- 90 - 80 115 12 105 270 64 206
110 -140 100 - 125 115 12 107 320 64 256
332
Hand lever extension
• Consisting of adapter pieces for lever connector and pin connector
• Pipe adapter of the desired length has to be procured by the customer.
d-d DN-DN H H1 H2 H3 D
16 - 20 10 - 15 41 52 29 36 26
25 - 32 20 - 25 50 62 32 39 36
40 - 50 32 - 40 65 76 34 44 40
- 63 - 50 84 87 37 48 44
333
Mounting plate
Designation d 16 - 32 d 40 - 63

DN10 - 25 DN32 - 50
mm mm
L 106 149
B 48 54
H 20 20
L1 92 134
L2 62 104
L3 31 52
L4 41 62
L5 25 45
H1 14 14
H2 4 4
D 6.5 8.5
Fastening screw M6 x 14 M8 x 18
334
Klip-IT Pipe Clips
d D D1 L1 L2 H H1 H2 H3 SC
16 6 11 14 17 27 10 6 16 M5
20 6 11 17 19 27 10 6 16 M5
25 6 11 19 22 30 10 6 16 M5
32 6 11 24 27 36 10 6 16 M5
40 7 14 34 34 44 10 7 22 M6
50 7 14 37 37 51 10 7 22 M6
63 9 17 45 45 64 10 10 25 M8
335
Klip-IT Spacer
d inch D L1 L2 H H1 H2 SC
1 ⅜ 6 14 17 20 10 16 M5
20 ½ 6 17 19 20 10 16 M5
25 ¾ 6 19 22 20 10 16 M5
32 1 6 24 27 20 10 16 M5
40 1¼ 7 34 34 20 10 22 M6
50 1½ 7 37 37 20 10 22 M6
63 2 9 45 45 20 10 25 M8
336
Ball valve type 543 Vertical/ L-port
Overview
Product description
With the new three-way ball valve type 543, GF Piping
Systems offers you a comprehensive model range with
a broad range of accessories for all versions - from the
manual valve up to the actuated version. Ball valve type
543 is the perfect valve for demanding mixing and dis-
tribution processes. It is used in various fields, such as
chemical process industry, water treatment, ship build-
ing and many more. The ball valve type 543 is available
as a horizontal and vertical version.
Versions
The new three-way ball valve type 543 appears in the
design of the ball valve type 546 and is available in
sizes DN10 to DN50. It offers quality, flexibility and se-
curity. This applies to both the horizontal and for the Product features
vertical valve. The horizontal design with an L- or T-
port in the ball is available in the materials PVC-U, PVC- • From the manual valve to the actuated ball valve with
C, ABS, PP-H and PVDF. Thus, you have the right- several options
valve for all applications. The vertical variation of the • Indicator for the position of the ball on the hand lever
ball valve type 543 is available in the materials PVC-U • Integrated fixing system with theraded inserts (hori-
and ABS. In the vertical model, the third outlet consists zontal)
of a solvent socket according to the metric standard. As • Hand lever with integrated tool for adjustment of the
an additional version of the L-port in the ball, a tripod union bushings
ball can be used in the ball valve.
• The horizontal version includes three ball seals
Horizontal/ L-port • 90° end stop included for all horizontal valves
• Clear design guaranteed due to indexed ball, stem
and hand lever
Horizontal/ T-port
337
Overview
General Type 543 horizontal 543 vertical
Dimension DN 10 - 50 10 - 50
Pressure range PN 10 10
Materials used Hand lever
Ball seal
Materials for valve body PVC-U + +
PVC-C +
ABS + +
PP-H +
PVDF +
Connection types Sockets + +
Spigot + +
Threaded socket + +
Seal materials EPDM + +
FFPM + +
FPM + +
Accessories 90 º and 180 º stop
Fixing hand lever
Safety information
NOTICE
CAUTION
Media containing solids system in the opened position.
These could lead to damages/leakage due to
abrasion.
• During control operation, cavitation has to DANGER
be avoided.
WARNING Using the wrong lubricants can damage the
Removing the pipeline • Never use petroleum-based greases or
Uncontrolled escape of the medium can Vaseline (Petrolatum).
cause injury. • For silicon-free ball valves, please consult
• Before dismounting, release all pressure the special manufacturer‘s instructions.
from the piping system. • All seals should be lubricated with a sili-
• With hazardous, flammable or explosive con-based grease.
media, the piping system must be com-
may be dismounted.
• Make sure that the medium is caught safe-
ly with the appropriate measures.
• Open the dismounted valve type 543
halfway (45° position) and let the 543 drain
in a vertical position – catch the medium in
an appropriate vessel.
338
Graph
CAUTION Exploded view type 543 horizontal

All the seals (made of e.g. EPDM, FPM) are
1 Housing
CAUTION
2 Union bush
3 Connecting part
Overstraining by exceeding the maximum 4 Union nut
pressure
5 Ball L/T
The test pressure on a valve must not ex-
6 Stem
ceed the value 1.5 x PN, (maximum PN + 5
bar). The component with the lowest PN de- 7 Ball seal
termines the maximum allowable test pres- 8 Backing seal
sure in the piping section. 9 Body seal
• Check the valves and connections on tight- 10 Union seal
11 Stem seal
your results.
Flow characteristics 13 Hand lever clip

The kv values are shown in %, i.e. to deter-
mine the absolute values, these are to be
multiplied by the respective table values.
339
Type 543 vertical
1 Housing
2 Union bush
3 Connecting part
4 Union nut
5 Ball
6 Stem
7 Ball seal
8 Backing seal
9 Body seal
10 Union seal
11 Steam seals
13 Hand lever clip
16 Spacer
Dimensions horizontal/ L-port

More dimensions of valves in different ma-
ranges.
340
Ball valve type 543 with solvent cement sockets metric
d D L L1 L2 L3 L4 L5 L6 H H1 H2 M z z1 clos-

est
mm mm mm mm mm mm mm mm mm mm mm mm mm mm inch
16 50 109 77 73 36 25 32 45 57 28 8 6 81 40 ⅜
20 50 112 77 73 36 25 32 45 57 28 8 6 81 40 ½
25 58 131 97 86 43 25 39 58 67 32 8 6 94 47 ¾
32 68 151 97 99 50 25 39 58 73 36 8 6 107 54 1
40 84 181 128 120 60 45 54 74 90 45 9 8 130 65 1¼
50 97 205 128 137 69 45 54 74 97 51 9 8 143 72 1½
63 124 261 152 179 89 45 66 87 116 65 9 8 185 92 2
341
Rp D L L1 L2 L3 L4 L5 L6 H H1 H2 M z z1

inch mm mm mm mm mm mm mm mm mm mm mm mm mm
⅜ 50 113 77 73 36 25 32 45 57 28 8 6 87 43
½ 50 117 77 73 36 25 32 45 57 28 8 6 85 42
¾ 58 135 97 86 43 25 39 58 67 32 8 6 100 50
1 68 155 97 99 50 25 39 58 73 36 8 6 113 57
1¼ 84 179 128 120 60 45 54 74 90 45 9 8 134 67
1½ 97 201 128 137 69 45 54 74 97 51 9 8 155 78
2 124 255 152 179 89 45 66 87 116 65 9 8 199 99
342
Ball valve type 543 with solvent cement spigots metric
d D L L1 L2 L3 L4 L5 L6 L7 H H1 H2 M closest

mm mm mm mm mm mm mm mm mm mm mm mm mm inch
16 50 131 77 73 36 25 32 45 137 57 28 8 6 ⅜
20 50 141 77 73 36 25 32 45 147 57 28 8 6 ½
25 58 165 97 86 43 25 39 58 171 67 32 8 6 ¾
32 68 182 97 99 50 25 39 58 188 73 36 8 6 1
40 84 209 128 120 60 45 54 74 215 90 45 9 8 1¼
50 97 242 128 137 69 45 54 74 248 97 51 9 8 1½
63 124 302 152 179 89 45 66 87 308 116 65 9 8 2
Ball valve type 543 with butt fusion spigots long
d D L L1 L2 L3 L4 L5 L6 H H1 H2 M e closest

20 50 210 77 73 36 25 32 45 57 28 8 6 2.3 ½
25 58 237 97 86 43 25 39 58 67 32 8 6 2.3 ¾
32 68 251 97 99 50 25 39 58 73 36 8 6 3.0 1
40 84 283 128 120 60 45 54 74 90 45 9 8 3.7 1¼
50 97 319 128 137 69 45 54 74 97 51 9 8 4.6 1½
63 124 399 152 179 89 45 66 87 116 65 9 8 5.8 2
343
Dimensions Horizontal/T-port
d D L L1 L2 L3 L4 L5 L6 H H1 H2 M z z1 clos-

est
mm mm mm mm mm mm mm mm mm mm mm mm mm mm inch
16 50 109 77 73 36 25 32 45 57 28 8 6 81 40 ⅜
20 50 112 77 73 36 25 32 45 57 28 8 6 81 40 ½
25 58 131 97 86 43 25 39 58 67 32 8 6 94 47 ¾
32 68 151 97 99 50 25 39 58 73 36 8 6 107 54 1
40 84 181 128 120 60 45 54 74 90 45 9 8 130 65 1¼
50 97 205 128 137 69 45 54 74 97 51 9 8 143 72 1½
63 124 261 152 179 89 45 66 87 116 65 9 8 185 92 2
344
Rp D L L1 L L3 L4 L5 L6 H H1 H2 M z z1

inch mm mm mm mm mm mm mm mm mm mm mm mm mm
⅜ 50 113 77 73 36 25 32 45 57 28 8 6 87 43
½ 50 117 77 73 36 25 32 45 57 28 8 6 85 42
¾ 58 135 97 86 43 25 39 58 67 32 8 6 100 50
1 68 155 97 99 50 25 39 58 73 36 8 6 113 57
1¼ 84 179 128 120 60 45 54 74 90 45 9 8 134 67
1½ 97 201 128 137 69 45 54 74 97 51 9 8 155 78
2 124 255 152 179 89 45 66 87 116 65 9 8 199 99
345
d D L L1 L2 L3 L4 L5 L6 L7 H H1 H2 M closest

16 50 131 77 73 36 25 32 45 137 57 28 8 6 ⅜
20 50 141 77 73 36 25 32 45 147 57 28 8 6 ½
25 58 165 97 86 43 25 39 58 171 67 32 8 6 ¾
32 68 182 97 99 50 25 39 58 188 73 36 8 6 1
40 84 209 128 120 60 45 54 74 215 90 45 9 8 1¼
50 97 242 128 137 69 45 54 74 248 97 51 9 8 1½
63 124 302 152 179 89 45 66 87 308 116 65 9 8 2
Ball valve type 543 with butt fusion sockets long
d D L L1 L2 L3 L4 L5 L6 H H1 H2 M e closest

20 50 210 77 73 36 25 32 45 57 28 8 6 2.3 ½
25 58 237 97 86 43 25 39 58 67 32 8 6 2.3 ¾
32 68 251 97 99 50 25 39 58 73 36 8 6 3.0 1
40 84 283 128 120 60 45 54 74 90 45 9 8 3.7 1¼
50 97 319 128 137 69 45 54 74 97 51 9 8 4.6 1½
63 124 399 152 179 89 45 66 87 116 65 9 8 5.8 2
346
Dimensions Vertical/L-port
d D L L1 L2 L3 L4 H H1 z closest
mm mm mm mm mm mm mm mm mm mm inch
16 50 92 77 56 32 45 57 62 64 ⅜
20 50 95 77 56 32 45 57 62 64 ½
25 58 111 97 66 39 58 67 72 74 ¾
32 68 123 97 71 39 58 73 77 79 1
40 84 146 128 85 54 74 90 87 95 1¼
50 97 157 128 89 54 74 97 97 95 1½
63 124 183 152 101 66 87 116 112 107 2
Rp D L L1 L2 L3 L4 H H1 z
inch mm mm mm mm mm mm mm mm mm
⅜ 50 96 77 56 32 45 57 62 69
½ 50 99 77 56 32 45 57 62 67
¾ 58 115 97 66 39 58 67 72 78
1 68 127 97 71 39 58 73 77 85
1¼ 84 144 128 85 54 74 90 87 100
1½ 97 153 128 89 54 74 97 97 106
2 124 177 152 101 66 87 116 112 121
347
d D L L1 L2 L3 L4 L5 H H1 closest
mm mm mm mm mm mm mm mm mm mm inch
16 50 114 77 56 32 45 120 57 62 ⅜
20 50 124 77 56 32 45 130 57 62 ½
25 58 144 97 66 39 58 150 67 72 ¾
32 68 154 97 71 39 58 160 73 77 1
40 84 174 128 85 54 74 180 90 87 1¼
50 97 194 128 89 54 74 200 97 97 1½
63 124 224 152 101 66 87 230 116 112 2
Technical data
lar media.
ABS

PVC-U

PP
the dotted lines, please contact your GF representative.

348
PVC-C Pressure loss, Version with T-port ball
Flow direction B ->A

determined in the pictured valve position
PVDF
Medium: water 20 °C
X Flow rate (l/min, US-gal/min)
Y Pressure loss Δp (bar, psi)
EPDM-sealing to max. 100 °C
Pressure loss, Version with T-port ball
Pressure loss type 543 horizontal
Pressure loss, Version with L-port ball
Flow direction B ->C

Flow direction C ->B
determined in the pictured position
X Flow rate (l/min, US-gal/min)
Medium: water 20 °C Y Pressure loss Δp (bar, psi)
X Flow rate (l/min, US gal/min)
349
Pressure loss, Version with T-port ball Flow characteristics type 543 horizontal
Ball with L-port
Flow direction C ->B and C ->A

a Open angle
kv Flow factor for kv, cv (%)
The flow characteristics is determined in the valve posi-

tions shown below:
Pressure loss type 543 vertical
Ball with T-port
X Flow rate (l/min), (US gal./min)
Y Pressure loss Δp (bar), (psi)
a Open angle
350
DN DN d kv 100 Cv 100 kv 100
mm inch mm l/min US gal./min m³/h
(Δp=1 bar) (Δp=1 psi) (Δp=1 bar)
10 ⅜ 16 50 3.5 3.0
15 ½ 20 75 5.3 4.5
20 ¾ 25 150 10.5 9.0
25 1 32 280 19.6 16.8
32 1¼ 40 480 33.6 28.8
40 1½ 50 620 43.4 37
50 2 63 1230 86.1 74
a Open angle Ball with L-port

kv kv value (%)
Flow direction B → A
The flow characteristics were determined in the valve determined in the following valve position:
positions shown below:
DN DN d kv 100 Cv 100 kv 100

mm inch mm l/min US gal./min m³/h
Flow characteristics type 543 vertical (Δp=1 bar) (Δp=1 psi) (Δp=1 bar)
Ball with L-port 10 ⅜ 16 10 0.7 0.6
15 ½ 20 15 1.1 0.9
20 ¾ 25 30 2.1 1.8
25 1 32 50 3.5 3.0
32 1¼ 40 90 6.3 5.4
40 1½ 50 110 7.7 6.6
50 2 63 220 15.4 13.2
Ball with T-port

Flow direction B → A
determined in the following valve position:
a Open angle
kv 100 values type 543 horizontal

Ball with L-port
Flow direction B → C, C → B, A → C, C → A
determined in the following valve position:
351
DN DN d kv 100 Cv 100 kv 100 DN DN d kv 100 Cv 100 kv 100
mm inch mm l/min US gal./ m³/h mm inch mm l/min US gal./ m³/h
(Δp = 1 min (Δp = 1 (Δp = 1 min (Δp = 1
bar) (Δp = 1 psi) bar) bar) (Δp = 1 psi) bar)

10 ⅜ 16 140 9.8 8.4 10 ⅜ 16 35 2.5 2.1
15 ½ 20 200 14 12.0 15 ½ 20 50 3.5 3.0
20 ¾ 25 470 32.9 28.2 20 ¾ 25 130 9.1 7.8
25 1 32 793 55.5 47.8 25 1 32 200 14 12
32 1¼ 40 1290 90.3 77.4 32 1¼ 40 380 26.6 23
40 1½ 50 1910 133.7 115 40 1½ 50 470 32.9 28
50 2 63 3100 217 186 50 2 63 890 62.3 53
Ball with T-port kv 100 values type 543 vertical

Flow direction B → C The kv values for each intermediate valve position can be
determined in the following valve position: determined by using the flow value characteristics and the kv
100 values.

DN DN d kv 100 kv 100
mm inch mm l/min m³/h
(Δp = 1 bar) (Δp = 1 bar)
10 ⅜ 16 50 3.0
15 ½ 20 80 4.8
20 ¾ 25 140 8.4
25 1 32 250 15
DN DN d kv 100 Cv 100 kv 100
mm inch mm l/min US gal./ m³/h 32 1¼ 40 430 26
(Δp = 1 min (Δp = 1 40 1½ 50 700 42
bar) (Δp = 1 psi) bar)
50 2 63 1300 78
10 ⅜ 16 40 2.8 2.4
Operating torque
15 ½ 20 70 4.9 4.2
20 ¾ 25 150 10.5 9.0
25 1 32 250 17.5 15
32 1¼ 40 470 32.9 28
40 1½ 50 600 42 36
50 2 63 1210 84.7 73
Ball with T-port

Flow direction C → B and C → A
determined in the following valve position: X Size DN (mm, inch)
Y Torque (Nm, lb-ft)
Depending on the application (e.g. operating speed, flu-

id, temperature, etc.), breakaway torques of approx. 2
times the operating torque should be taken for external
actuators.
Functions type 543 horizontal
The decision whether to use a 3-way ball valve with L-
or T-port depends on the desired functions the valve
has to perform:
L-port: Diverting function, closing (two ports closed)
352
Functions type 543 vertical
The decision whether to use a 3-way ball valve with L-
port or tripod-port depends on the desired functions the
valve has to perform:
L -port: Diverting function, closing (two ports closed)
Tripod-port: Diverting function, switching B-C open to A-
T-port: Diverting function, mixing function, branch C open with 90° turn. Attention: Mixing function in the in-
closed/passage open termediate position!
The following illustration shows the individual functions
and the corresponding position of the hand lever:
Ball with L-port
B-C open normal position
The following illustration shows the individual functions A-C open

and the corresponding position of the hand lever:
closed
Ball with L-port
A-C open Diverting function
(normal position)
Ball with tripod port
B-C open normal position
A-B-C open Mixing function
A-C open
B-C open Diverting function
Instructions for use

Maintenance
closed shutting off func- ation conditions. However, the following measures must
tion be considered:
A-B open Outlet closed/ are kept permanently in the same position 1–2 x a
Passage open year to check serviceability.
Ball with T-port

A-B-C open Mixing function
(normal position)
B-C open
Diverting function
A-B open Outlet closed/

passage opened
A-C open Diverting function
353
Accessories
Comfort and security guaranteed to you by the details of the multifunctional lever:
• Indexing with 45 ° - pitch
• Accurate, reliable positioning of the ball
• Lockable and therefore safe from unauthorized access
• Made of stable PPGF
d-d DN-DN D D1 H L1 L5 L6
16 - 20 10 - 15 26 5 53 87 42 45
- 25 - 20 34 5 59 108 50 58
- 32 - 25 34 5 59 108 50 58
- 40 - 32 40 5 69 140 66 75
- 50 - 40 40 5 69 140 66 75
DN10 - DN50 Ball with L-bore:

A-C opened / B-C
opened
A-C opened /
closed
B-C opened /
closed

2 Spacer
3 Fastening screw (Torx)
4 Spring
5 Hand lever clip
6 Unlocking latch
90° stop
The stop position enables a defined hand lever oper-
ation of 90°. It can be adjusted in two different orien-
tations to the desired stop position. The stop is conve-
niently enclosed within the hand lever and is not visible
from the outside. Place the stop in the desired control
range, before attaching the lever.
354
Ball with T-bore: Mounting plate
A-B-C opened /
B-C opened
A-B opened / A-C

opened
B-C opened / A-B

opened
A-C opened / A-
B-C opened
The basic installation steps are listed below (a-c).

Note: Observe the indexing indication marked on the
stem and hand lever!
Designation d 16 - 32 d 40 - 63
DN10 - 25 DN32 - 50
mm mm
L 106 149
B 48 54
H 20 20
a b c L1 92 134
L2 62 104
L3 31 52
L4 41 62
L5 25 45
H1 14 14
H2 4 4
D 6.5 8.5
Fastening screw M6 x 14 M8 x 18
355
Ball valve type 523
Overview
Product description
The metering ball valve type 523 (metering valve) is the
perfect valve for the precise dosing of media in your ap-
plications. The special bore profile of the ball as well as
the 180° fine scale enable an accurate adjustment of
the dosing process.
Versions
Ball valve type 523 with solvent cement spigots
Product features
• 180° scale for fine adjustment
• Special bore profile
• Radial installation and removal
• Hand lever with integrated tool for removing / adjust-
ing union bushing
356
Overview
General Type 523
Pressure range PN 10
Materials used Hand lever PPGF30
Ball seal PTFE
PP +
PVDF +
Spigot +
Threaded socket +
FPM +
Standards ISO +
BS +
ASTM +
JIS +
Safety information
CAUTION
The following safety instructions apply specifically to ball
valve type 523. They should identify the hazards and
advice that should be considered for the different use
Central part as spare part
and installation / commissioning.
Exchanging single components from the cen-
tral part can have serious consequences.
WARNING • When exchanging the ball valve type 523,
always use only the central part as a re-
placement.
Confusing fixed and loose side • When mounting / dismounting the ball
Non-observance may lead to severe injuries valve, always follow the steps of the in-
or death. struction manual.
• Housings are distinguished into a fixed and • Execute a functional test prior to commis-
a loose side. The fixed side is the side into sioning.
which the ball cannot be inserted.
• Carefully read the instruction manual dur-
ing the assembly. NOTICE
Observe changes in dimensions

CAUTION
In comparison to type 323, type 523 has dif-
ferent installation dimensions, connectors,
Overstraining by exceeding the maximum and union nuts. Using different components
pressure and installation dimensions (than required for
The test pressure on a valve must not ex- type 523) may damage the piping system.
ceed the value 1.5 x PN, (maximum PN + 5 • Compare the installation dimensions and
bar). The component with the lowest PN de- installation descriptions in the technical
termines the maximum allowable test pres- documentation with the components at
sure in the piping section. hand.
• Check the valves and connections on tight-
your results.
357
Graph
WARNING Exploded view
Risk of injury due to uncontrolled evasion

of the medium
If the pressure was not relieved complete-
ly, the medium can evade uncontrolled. De-
pending on the type of medium, risk of injury
may exist.
• Completely relieve pressure in the pipes
prior to dismounting.
• Completely empty and rinse pipe prior to
dismounting in connection with harmful,
flammable, or explosive media. Pay atten-
tion to potential residues.
• Provide for safe collection of the medium
by implementing appropriate measures 1 Housing
2 Union bush
(e.g. connection of a collection container). 3 Valve end
After dismounting, the ball valve should be 4 Union nut
stored or disassembled. 5 Ball
6 Stem
• Partially open the dismounted ball valve 7 Ball seal
(45° position) and let it drain in vertical po- 8 Backing seal
9 Body seal
sition. Thereby, collect the medium. 10 Union seal
11 Stem seal
13 Hand lever clip
14 Threaded bush
CAUTION 15 Position indicator
16 Scale disc
Risk of injury due to false mounting of the Dimensions

ball valve to the pipe More dimensions of valves in different ma-
• The ball valve must always be installed in terials and with various connection types
open position. are available in the ball valves product
ranges.
CAUTION
Pay attention to arrows on scale

Rotating the scale will impair the functionali-
ty. This can cause incorrect setting of the ball
position.
• Pay attention to the arrows on the scale.
These must always point into the direction
of the fixed side.
• The flow direction is also indicated by the
marker.
358
d DN D H H1 L L1 L2 L5 L6
mm mm mm mm mm mm mm mm mm mm
16 10 50 68 27 92 77 56 32 45
20 15 50 68 27 95 77 56 32 45
d DN D H H1 L L1 L2 L4 L6
16 10 50 68 27 114 77 56 25 32
20 15 50 68 27 124 77 56 25 32
Ball valve type 523 with solvent cement sockets JIS
inch DN D H H1 L L1 L2 L4 L5 L6
½ 15 50 68 27 95 77 56 25 32 45
359
Ball valve type 523 with solvent cement sockets inch BS
d DN D H H1 L L1 L2 L4 L5 L6
⅜ 10 50 68 27 92 77 56 25 32 45
½ 15 50 68 27 95 77 56 25 32 45
Ball valve type 523 with solvent cement sockets inch ASTM
inch DN D H H1 H2 L L1 L2 L4 L5

⅜ 10 50 68 27 12 105 77 56 25 32
½ 15 50 68 27 12 105 77 56 25 32
Ball valve type 523 with Threaded sockets Rp
Rp DN D H H1 L L1 L2 L4 L5 L6

⅜ 10 50 68 27 95 77 56 25 32 45
½ 15 50 68 27 100 77 56 25 32 45
360
Pressure loss
Technical data
lar media.
PP
X Medium: water 20 °C
Pressure loss Δp (bar), (psi)


the dotted lines, please contact your GF representative.
PVC-U
X Open angle (%)

Y Flow factor kv, cv (%)
kv 100 values
DN DN d [mm] kv 100 Cv 100 kv 100
[mm] [inch] l/min US gal/ m³/h
(Δp = 1 min (Δp = 1
bar)) (Δp = 1 bar
psi)
P Permissible pressure in bar, psi 10 ⅜ 16 11 0.8 0.7
T Temperature in °C, °F 15 ½ 20 20 1.4 1.2
PVDF The kv values for each intermediate valve position can
be determined by using the flow value characteristics
Operating torque


Reference values for tightening torque of screws
d mm DN mm DN Total number of screws (for 2 Torque (reference val- Torque
[inch] flanged joints) standard nut ues) (reference values)
(height 0.8 x d) 1) Profile flange gasket 2) Flat gasket
20 15 ½ 8 x M12 x 50 10 7.4 10 7.4
361
1)
For valve ends type 523 made of PP in combina-
tion with backing flanges, use half of the standard nut
height.
2)
Preferred gasket type (suited for plastics)
Technology → Mechanical Joints

Maintenance
ating conditions. However, the following measures must
be considered:

362
Ball valve type 375
Overview
Product description
With ball valve type 375, GF Piping Systems offers
you the ideal complement to the existing range of ball
valves. It can be used for basic applications of water
treatment as well as for simple water applications.
Versions
Ball valve type 375 with butt fusion spigots
Product features
• Available from d16DN10 up to d110DN100
• Hand lever with integrated tool for removing the union
bushing
363
Overview
General Type 375
Pressure range PN DN10 - 50: 16
DN65 - 100: 10
PVC-C +
Spigot +
Threaded socket +
FPM +
Safety information
DANGER
CAUTION
Media containing solids material of the ball valve or seals. Conse-
These could lead to damages/leakage due to quences can be death or serious injuries.
abrasion. • Never use petroleum-based greases or
• During control operation, cavitation has to Vaseline (Petrolatum).
be avoided. • For silicon-free ball valves, please consult
the special manufacturer‘s instructions.
• All seals should be lubricated with a sili-
con-based grease.
WARNING
Removing the pipeline CAUTION

Uncontrolled escape of fluid may cause in-
jury.
• Before dismounting, release all pressure
from the piping system. All the seals (made of e.g. EPDM, FPM) are
• With hazardous, flammable or explosive organic materials which react to environmen-
media, the piping system must be com- tal influences. They must therefore be kept in
pletely emptied and rinsed before the valve their original packaging, and stored cool, dry
may be dismounted. and dark. The seals should be checked for
• Make certain that the medium is caught damages from aging, such as fissures and
safely with the appropriate measures hardening, before mounting.
• Open the dismounted 375 halfway (45° po- • Do not use defective spare parts.
sition) and let the 375 drain in a vertical po-
sition – catch the medium in an appropriate
vessel.
CAUTION
NOTICE Overstraining by exceeding the maximum

pressure
Installation of the ball valve ceed the value 1.5 x PN, (maximum PN + 5
• The ball valve must always be built into the bar). The component with the lowest PN de-
system in the opened position. termines the maximum allowable test pres-
sure in the piping section.
• Check the valves and connections on tight-
your results.
364
Graph metric
Exploded view
d DN D H L L1 L2 L3 z

16 10 50 53 76 60 42 40 48
1 Union nut 20 15 50 53 80 60 42 40 48
2 Connecting part
25 20 59 60 91 65 48 45 53
3 Union brushing
32 25 68 67 102 75 54 51 58
4 Ball
40 32 80 79 120 85 62 59 68
5 Housing
50 40 94 90 140 95 72 70 78
6 Stem
63 50 115 107 169 110 86 84 93
7 Hand lever
75 65 145 129 206 130 110 103 118
A Face seal
B Body seal 90 80 168 143 242 140 128 120 140
C Backing seal 110 100 210 169 282 160 150 141 160
D Ball seal Ball valve type 375 with threaded sockets Rp

E Stem seal
Dimensions
ranges.
Rp DN D H L L1 L2 L3 z
inch mm mm mm mm mm mm mm mm
⅜ 10 50 53 76 60 42 40 48
½ 15 50 53 80 60 42 40 48
¾ 20 59 60 91 65 48 45 53
1 25 68 67 102 75 54 51 58
1¼ 32 80 79 116 85 62 59 68
1½ 40 94 90 126 95 72 70 78
2 50 115 107 149 110 86 84 93
2½ 65 145 129 184 130 110 103 118
3 80 168 143 212 140 128 120 140
4 100 210 169 244 160 150 141 160
365
Ball valve type 375 with butt fusion spigots long Pressure loss
d DN D H L L1 L2 L3 e
20 15 95 53 175 60 42 40 1.8
25 20 105 60 195 65 48 45 2.3
32 25 115 67 247 75 54 51 2.9
40 32 140 79 233 85 62 59 3.6
50 40 150 90 265 95 72 70 4.5 Medium Water, 20 °C
63 50 165 107 278 110 86 84 5.7 X Flow rate (l/min), (US gal./min)
75 65 185 129 348 130 110 103 6.8 Y Pressure loss Δp (bar), (psi)
90 80 200 143 350 140 128 120 8.2
110 100 220 169 412 160 150 141 10.0
Technical data
on a lifetime of 25 years and the medium water and sim-
ilar media.
PVC-U
X Open angle (%)

Y Flow factor kv, cv (%)
kv 100 values
DN DN d kv 100 l/ Cv 100 US kv 100 m³/
mm inch mm min (Δp = gal./min h (Δp=1
1 psi) (Δp = 1 bar)
psi)
10 ⅜ 16 70 4.9 4.2
1) For nominal dimensions of DN10 - DN50, thecentral
body of the ball valve is designed for nominal pres- 15 ½ 20 185 12.9 11.1
sure PN16
20 ¾ 25 350 24.5 21
2) For nominal dimensions of DN65 - DN100, thecentral
body of the ball valve is designed for nominal pres- 25 1 32 700 49.0 42
sure PN10 32 1¼ 40 1000 70. 60
3) Depending on the end connection, at nominaldimen- 40 1½ 50 1600 112.0 96
sions of DN10 - DN50, the nominal pressure reduces
to PN10 50 2 63 3100 217.1 186
P Permissible pressure in bar/psi 65 2½ 75 5000 350 300
T Temperature in ºC/ ºF 80 3 90 7000 490 420
100 4 110 11000 770 660
The kv values for each intermediate valve position can be
determined by using the flow value characteristics and the
kv 100 values.
366
Operating torque

Reference values at nominal pressure

actuators.
d DN DN Total number of screws (for Torque Torque
mm mm inch 2 flanged joints) standard (reference values) (reference values)
nut Profile flange gasket 1)
Flat gasket
(Height 0.8 x d)
20 15 ½ 8 x M12 x 50 10 7.4 10 7.4
25 20 ¾ 8 x M12 x 55 10 7.4 10 7.4
32 25 1 8 x M12 x 60 10 7.4 15 11
40 32 1¼ 8 x M16 x 70 15 11 20 15
50 40 1½ 8 x M16 x 70 15 11 25 18
63 50 2 8 x M16 x 80 20 15 35 26
75 65 2½ 8 x M16 x 90 25 18 50 37
90 80 3 16 x M16 x 100 15 11 30 22
110 100 4 16 x M20 x 130 20 15 35 26
1) preferred gasket type (suited for plastics)

Technology → Mechanical Joints

Maintenance
ation conditions. However, the following measures must
be considered:
system.
367
Ball valve type 322
Overview
Product description
Ball valve type 322 is the perfect valve for the use in the
laboratory. It is characterized by its compact design and
thus space saving installation.
Versions
Product features
• Compact design
• Union nut enables a one sided removal and an easy
access to the internal components
• Double hand lever indicates the position of the ball
Overview
General Type 322
Dimension DN 6-8
Materials for Ball seal PTFE +
Connection types Solvent cement socket +
FPM +
Safety information
WARNING
CAUTION
Removing the pipeline
Uncontrolled escape of fluid may cause in-
Media containing solids jury.
These could lead to damages/leakage due to • Before dismounting, release all pressure
abrasion. from the piping system.
• During control operation, cavitation has to • With hazardous, flammable or explosive
be avoided. media, the piping system must be com-
may be dismounted.
• Make certain that the medium is caught
safely with the appropriate measures
• Open the dismounted 322 halfway (45°
position) and let the 322 drain in a vertical
position – catch the medium in an appropri-
ate vessel.
368
Graph
NOTICE Exploded view

system in the opened position.
DANGER
quences can be death or serious injuries. 1 Housing
• Never use petroleum-based greases or 2 Valve end
Vaseline (Petrolatum). 3 Union nut
• For silicon-free ball valves, please consult
the special manufacturer‘s instructions. 4 Ball
• All seals should be lubricated with a sili- 5 Hand lever
con-based grease. 6 Stem
7 Ball seal
8 Stem seal
CAUTION 9 Body seal
Dimensions
All the seals (made of e.g. EPDM, FPM) are metric
CAUTION d DN D L L1 H z z1
Overstraining by exceeding the maximum 10 6 34 52 45 38 26 15
pressure
12 8 34 60 45 38 36 25
ceed the value 1.5 x PN, (maximum PN + 5
bar). The component with the lowest PN de- Technical data
termines the maximum allowable test pres- Pressure-temperature diagram
sure in the piping section. The following pressure-temperature diagrams are based
• Check the valves and connections on tight- on a lifetime of 25 years and the medium water and sim-
ness during the pressure test. Document ilar media.
your results.
369
PVC-U
P Permissible pressure in bar/psi

T Temperature in ºC/ ºF

Maintenance
be considered:
system.
Installation recommendations for type 322
The ball valve can be used as illustrated:
370
Ball valve Coloro
Overview
Product description
The ball valve type 353 - 355 is ideally suited for all ap-
plications with water. The Coloro is characterized by its
monoblock design.
Versions
Type 353 compact valve
Type 354 single union ball valve
Type 355 double union ball valve
Product features
• Space saving installation due to compact design
• Colored hand levers for a clear differentiation of pro-
cesses in your piping system
• Ideal sealing materials for water applications
Overview
General Type 353, 354, 355
Spigot +
Threaded socket +
HD-PE/ Lubricant Compound +
Safety information
CAUTION
Media containing solids

These could lead to damages/leakage due to
abrasion.
• During control operation, cavitation has to
be avoided.
371
WARNING CAUTION
Removing the pipeline Overstraining by exceeding the maximum

Uncontrolled escape of fluid may cause in- pressure
jury. The test pressure on a valve must not ex-
• Before dismounting, release all pressure ceed the value 1.5 x PN, (maximum PN + 5
from the piping system. bar). The component with the lowest PN de-
• With hazardous, flammable or explosive termines the maximum allowable test pres-
media, the piping system must be com- sure in the piping section.
pletely emptied and rinsed before the valve • Check the valves and connections on tight-
may be dismounted. ness during the pressure test. Document
• Make certain that the medium is caught your results.
safely with the appropriate measures
• Open the dismounted valve halfway (45°
position) and let it drain in a vertical posi-
tion – catch the medium in an appropriate DANGER
vessel.
Ball valve as end valve
If the ball valve, which functions as an end
DANGER valve in a piping system under pressure, is
opened, the medium can exit uncontrollably.
Consequences can be death or serious injury
Selection of lubricants from contact with the medium.
Using the wrong lubricants can damage the • The end valve in a pressure-bearing sys-
material of the ball valve or seals. Conse- tem may only be opened when the medi-
quences can be death or serious injuries. um can be caught or carried off safely and
• Never use petroleum-based greases or splashing is prevented by taking the appro-
Vaseline (Petrolatum). priate measures.
• For silicon-free ball valves, please consult
the special manufacturer‘s instructions.
con-based grease. NOTICE
Mounting of the ball valve

CAUTION Operation and temperature changes can
cause reaction forces, which lead to longitu-
dinal thermal expansion and bending forces
Handling of the seals that can damage the valve.
All the seals (made of e.g. EPDM, FPM) are • Absorb these forces by fixed points in front
organic materials which react to environmen- of or after the valve.
372
Graph
Exploded view
Rp DN z D L L1 L2 H

inch mm mm mm mm mm mm mm
½ 15 66 49 92 78 54 51
¾ 20 74 54 104 92 60 58
1 25 79 64 113 92 63 63
1¼ 32 94 78 132 116 74 77
1½ 40 109 90 147 116 79 83
1 Half of Body
2 50 127 112 175 140 91 102
2 Backing seal
3 Ball seal Ball valve type 355 with butt fusion spigots PE100
4 Stem ball
5 Stem seal
6 Socket weld
7 Hand lever
Dimensions
terials and with various connection types d DN D L L1 L2 H e clos-
are available in the ball valves product est
ranges.
mm mm mm mm mm mm mm mm inch
Ball valve type 355 with solvent cement sockets- 20 15 49 161 78 54 51 1.9 ½
metric 25 20 54 174 92 60 58 2.3 ¾
32 25 64 182 92 63 63 2.9 1
40 32 78 199 116 74 77 3.7 1¼
50 40 90 210 116 79 83 4.6 1½
63 50 112 228 140 91 102 5.8 2
d DN z D L L1 L2 H clos-
est
20 15 60 49 92 78 54 51 ½
25 20 66 54 104 92 60 58 ¾
32 25 69 64 113 92 63 63 1
40 32 80 78 132 116 74 77 1¼
50 40 85 90 147 116 79 83 1½
63 50 97 112 175 140 91 102 2
373
Ball valve type 355 with butt fusion spigots PE80 PVC-U
d DN D L L1 L2 H e clos-

est
P Permissible pressure in bar/psi
32 25 64 182 92 63 63 3 1
T Temperature in ºC/ ºF
40 32 78 199 116 74 77 3 1¼
48 40 90 210 116 79 83 3 1½
Pressure loss
50 40 90 210 116 79 83 3 1½
56 50 112 228 140 91 102 3 2
63 50 112 228 140 91 102 3 2
Ball valve type 355 with fusion sockets PE80
Medium Water, 20 °C
d DN z D L L1 L2 H clos- X Flow rate (l/min), (US gal./min)

est Y Pressure loss Δp (bar), (psi)
20 15 64 49 92 78 54 51 ½
25 20 70 54 103 92 60 58 ¾
32 25 73 64 111 92 63 63 1
40 32 84 78 128 116 74 77 1¼
50 40 89 90 141 116 79 83 1½
63 50 101 112 164 140 91 102 2
Technical data
The following pressure-temperature diagrams are based X Open angle (%)
on a lifetime of 25 years and the medium water and sim- Y Flow factor kv, cv (%)
ilar media.
374
kv 100 values
DN DN d kv 100 l/ Cv 100 US kv 100 m³/
mm inch mm min (Δp = gal./min h (Δp=1
1 psi) (Δp = 1 bar)
psi)
10 ⅜ 16 70 4.9 4.2
15 ½ 20 185 12.9 11.1
20 ¾ 25 350 24.5 21
25 1 32 700 49.0 42
32 1¼ 40 1000 70. 60
40 1½ 50 1600 112.0 96
50 2 63 3100 217.1 186
The kv values for each intermediate valve position can be
determined by using the flow value characteristics and the
kv 100 values.
Operating torque

Reference values at nominal pressure

actuators.
d DN DN Total number of screws (for Torque Torque
mm mm inch 2 flanged joints) standard (reference values) (reference values)
nut Profile flange gasket 1)
Flat gasket
(Height 0.8 x d)
20 15 ½ 8 x M12 x 50 10 89 10 89
25 20 ¾ 8 x M12 x 55 10 89 10 89
32 25 1 8 x M12 x 60 10 89 15 133
40 32 1¼ 8 x M16 x 70 15 133 20 177
50 40 1½ 8 x M16 x 70 15 133 25 222
63 50 2 8 x M16 x 80 20 177 35 310

1) preferred gasket type (suited for plastics)

ferent gasket types, see Chapter: Jointing Maintenance
Technology → Mechanical Joints Ball valves require no maintenance under normal oper-
be considered:
375
• Replace defective ball valve
376
Fundamentals for ball valves electric actuated
Page

Ball valves type 107, 130-135
-- Overview 378
-- Graph 380
-- Technical features 385
Ball valves type 185-188
-- Overview 386
-- Graph 388
377
Fundamentals for ball valves Type 130 - 135 with electrical actuator EA21, EA31
and EA42
electric actuated
Ball valves type 107, 130-135
Overview
Product description
The ball valve of type 107 is based on the Ball Valve
Type 546 (d16DN10 to d63DN50) with the electric actu-
ator EA11. Type range 107 is designed for automated
standard applications with no special demands.
Ball valves Type 130, 131, 132, 133, 134 and 135
are based on the ball valve type 546 (d16DN10 to
d110DN100) and the electric actuator EA21 (DN10-
DN50) or EA31 (DN65-DN100). Type range 130-135 is
designed as modular adjustable ball valve for applica-
tions which demand special process requirements. Product features
The ball valves type 107 and 130-135 consist of the ball
valve type 546's valve base body with the electric actua- Type 107
tors EA11, EA21, EA31 and EA42. More information about different product
The technical data concerning features are available in Chapter Actuators
• Pressure-temperature diagram type EA11
• Pressure loss
• Flow characteristics
• kv values Type 130 - 135
• Reference values for screw fastenings More information about different product
features are available in the Chapter Actu-
can be found under ball valve type 546, manual over- ators type EA21-EA42
ride. In the following, you will find all the details con-
cerning mounting, installation and commissioning of the
elkectric actuators EA11, EA21, EA31 and EA42.
Differences Type 130 - 135
Versions
Type Type Type Type Type Type
Type 107 with electrical actuator EA11 130 131 132 133 134 135
PVC-U + + + +
PVC-C + + +
ABS + +
PP-H + +
PVDF + +
ISO + + +
ASTM + + +
BS +
JIS +
378
Overview
General Type 107 130 - 135
Base type 546 546
Actuator type EA 11 EA21/EA31/EA42
Dimension DN 10 - 50 10 - 100
Pressure range PN 10 10
PVC-C + +
ABS + +
PP-H + +
PVDF + +
Spigot + +
Flanges + +
Threaded socket + +
FFPM + +
NBR + +
Standards ISO + +
BS + +
ASTM + +
JIS + +
Accessories More information about accessories are available in the
chapter actuators EA11-EA42
Safety information
CAUTION
The following safety instructions apply specifically to the
ball valve. They should identify the hazards and advice
that should be considered for the different uses and in-
Intended use of the actuators
stallation/commissioning.
When not used as prescribed injuries can oc-
cur. When mounted on a valve and connect-
DANGER ed to a system control, the purpose of this
actuator is to:
• actuate valves with 90° pivoting (ball valves
Disregarding the general safety instruc- and butterfly valves),
tions for electrical actuators • indicate the previously calibrated end posi-
Non-observance can result in serious injury tions of the valve via electrical signal to the
or death. system control (accessory), and
• Observe the general safety instructions for • provided that the actuator data corre-
electric actuators. sponds to the electrical control and the
valve and
• in case of interruption in the supply voltage,
warrant that the actuator/valve remains in
the current position. Please use the emer-
gency manual override or install the fail-
safe return unit.
379
Graph
Exploded view ball valve types 107, 130-135 (DN10 - 50)
Type 107 Type 130 - 135

Actuator type EA11 (21)

Adapter plate
with clamps

Coupling
with screws


Ball valve type 546
DN10 - 50
380
Ball valve types 130, 131, 133 - 135 (DN65 - Dimensions for type 107 solvent cement socket
DN100)
d DN D H H1 H2 H3 H5

16 10 50 200 27 64 64 137
20 15 50 200 27 64 64 137
25 20 58 209 30 73 64 137
32 25 68 209 36 73 64 137
40 32 84 220 44 84 64 137
Dimensions 50 40 97 220 51 84 64 137
Weight actuator 63 50 124 243 64 106 64 137
Information about the weight of the actu-
ators are available in the Chapter "Actua-
tors" in the planning fundamentals. L L1 L2 L4 L5 L6 L7 L8 z

92 161 56 25 77 83 122 33 64
More dimensions
More dimensions are available in the prod- 95 161 56 25 77 83 122 33 64
uct range of ball valve type 546. 110 161 65 25 77 83 122 33 72
123 161 71 25 77 83 122 33 79
146 161 85 45 77 83 122 33 94
157 161 89 45 77 83 122 33 95
183 161 101 45 77 83 122 33 107
381
Dimensions for type 107 solvent cement spig- Dimensions for type 107 threaded sockets Rp
ots
d DN D H H1 H2 H3 H5

Rp DN D H H1 H2 H3 H5
16 10 50 200 27 64 64 137
⅜ 10 50 200 27 64 64 137
20 15 50 200 27 64 64 137
½ 15 50 200 27 64 64 137
25 20 58 209 30 73 64 137
¾ 20 58 209 30 73 64 137
32 25 68 209 36 73 64 137
1 25 68 209 36 73 64 137
40 32 84 220 44 84 64 137
1¼ 32 84 220 44 84 64 137
50 40 97 220 51 84 64 137
1½ 40 97 220 51 84 64 137
63 50 124 243 64 106 64 137
2 50 124 243 64 106 64 137
L L1 L2 L3 L4 L5 L6 L7 L8
L L1 L2 L4 L5 L6 L7 L8 z
114 161 56 130 25 77 83 122 33
92 161 56 25 77 83 122 33 64
124 161 56 130 25 77 83 122 33
95 161 56 25 77 83 122 33 64
144 161 65 150 25 77 83 122 33
110 161 65 25 77 83 122 33 72
154 161 71 160 25 77 83 122 33
123 161 71 25 77 83 122 33 79
174 161 85 180 45 77 83 122 33
146 161 85 45 77 83 122 33 94
194 161 89 200 45 77 83 122 33
157 161 89 45 77 83 122 33 95
224 161 101 230 45 77 83 122 33
183 161 101 45 77 83 122 33 107
382
Dimensions for type 107 fixed flange serrated Dimensions for type 130-135 solvent cement
metric sockes metric
d DN D H H1 H2 H3 H5 H6

20 15 50 201 27 64 65 138 48
25 20 58 210 30 73 65 138 53
32 25 68 210 36 73 65 138 58 d DN D H H1 H2 H3 H5
40 32 84 221 44 84 65 138 70 mm mm mm mm mm mm mm mm
50 40 97 221 51 84 65 138 75 16 10 50 231 27 64 94 167
63 50 124 244 64 106 65 138 83 20 15 50 231 27 64 94 167
25 20 58 240 30 73 94 167
L L1 L2 L3 L4 L5 L6 L7 L8
32 25 68 240 36 73 94 167
40 32 84 251 44 84 94 167
124 160 56 130 25 77 83 122 33
50 40 97 251 51 84 94 167
144 160 65 150 25 77 83 122 33
63 50 124 273 64 106 94 167
154 160 71 160 25 77 83 122 33
75 65 166 346 85 156 94 190
174 160 85 180 45 77 83 122 33
90 80 200 358 105 168 94 190
194 160 89 200 45 77 83 122 33
110 100 238 365 123 175 94 190
224 160 101 230 45 77 83 122 33
L L1 L2 L4 L5 L6 L7 z
92 180 56 25 97 83 122 64
95 180 56 25 97 83 122 64
110 180 65 25 97 83 122 72
123 180 71 25 97 83 122 79
146 180 85 45 97 83 122 94
157 180 89 45 97 83 122 95
183 180 101 45 97 83 122 107
233 180 136 70 98 83 122 144
254 180 141 70 98 83 122 151
301 180 164 120 98 83 122 174
383
Dimensions for type 130-135 solvent cement Dimensions for type 130-135 threaded sockets
spigots metric Rp
d DN D H H1 H2 H3 H5 Rp DN D H H1 H2 H3 H5
mm mm mm mm mm mm mm mm inch mm mm mm mm mm mm mm
16 10 50 231 27 64 94 167 ⅜ 10 50 231 27 64 94 167
20 15 50 231 27 64 94 167 ½ 15 50 231 27 64 94 167
25 20 58 240 30 73 94 167 ¾ 20 58 240 30 73 94 167
32 25 68 240 36 73 94 167 1 25 68 240 36 73 94 167
40 32 84 251 44 84 94 167 1¼ 32 84 251 44 84 94 167
50 40 97 251 51 84 94 167 1½ 40 97 251 51 84 94 167
63 50 124 273 64 106 94 167 2 50 124 273 64 106 94 167
75 65 166 346 85 156 94 190 2½ 65 166 346 85 156 94 190
90 80 200 358 105 168 94 190 3 80 200 358 105 168 94 190
110 100 238 365 123 175 94 190 4 100 238 365 123 175 94 190
L L1 L2 L3 L4 L5 L6 L7 L L1 L2 L4 L5 L6 L7 z

mm mm mm mm mm mm mm mm mm mm mm mm mm mm mm mm
114 180 56 130 25 97 83 122 92 180 56 25 97 83 122 64
124 180 56 130 25 97 83 122 95 180 56 25 97 83 122 64
144 180 65 150 25 97 83 122 110 180 65 25 97 83 122 72
154 180 71 160 25 97 83 122 123 180 71 25 97 83 122 79
174 180 85 180 45 97 83 122 146 180 85 45 97 83 122 94
194 180 89 200 45 97 83 122 157 180 89 45 97 83 122 95
224 180 101 230 45 97 83 122 183 180 101 45 97 83 122 107
284 180 136 290 70 98 83 122 233 180 136 70 98 83 122 144
300 180 141 310 70 98 83 122 254 180 141 70 98 83 122 151
340 180 164 350 120 98 83 122 301 180 164 120 98 83 122 174
384
Dimensions for type 130-135 fixed flanges ser- Dimensions for type 130-135 backing flanges
rated metric PP ST metric

d DN D H H1 H2 H3 H5 H6

d DN D H H1 H2 H3 H5 H6 mm mm mm mm mm mm mm mm mm
mm mm mm mm mm mm mm mm mm 75 65 166 346 85 156 94 190 93
20 15 50 231 27 64 94 167 48 90 80 200 358 105 168 94 190 100
25 20 58 240 30 73 94 167 53 110 100 238 365 123 175 94 190 110
32 25 68 240 36 73 94 167 58
L L1 L2 L3 L4 L5 L6 L7 L8
40 32 84 251 44 84 94 167 70
50 40 97 251 51 84 94 167 75
284 180 136 290 70 98 83 122 66
63 50 124 273 64 106 94 167 83
300 180 141 310 70 98 83 122 66
L L1 L2 L3 L4 L5 L6 L7 L8 340 180 164 350 120 98 83 122 66
124 180 56 130 25 98 83 122 66 Technical features
144 180 65 150 25 97 83 122 66 More information
about the multifunctional module and
154 180 71 160 25 97 83 122 66 mounting plate are available in the Chapter
174 180 85 180 45 97 83 122 66 Ball valve type 546 hand operated in the
planning fundamentals.
194 180 89 200 45 98 83 122 66
224 180 101 230 45 97 83 122 66
385
Ball valves type 185-188
Overview
Product description
Ball valves Type 185 - 188 are based on ball valve Type
543 (d16DN10 to d63DN50) and electric actuator EA21.
Type range 185-188 is designed as modular upgrade-
able 3-way ball valve for mixing and diverting applica-
tions which demand special process requirements.
The technical data concerning
• Pressure-temperature diagram
• Pressure loss
• kv values
• Reference values for screw fastenings
can be found under ball valve type 543, manual over-
ride.
Versions
Type 185 - 188 with electrical actuator EA21
Product features
Type 185 - 188
More information about different product
features are available in the Chapter "Actu-
ators type EA21".
Difference Type 185 - 188

Type 185 Type 186 Type 187 Type 188
horizontal horizon- horizon- vertical
tal tal
PVC-U + +
PVC-C +
ABS + +
PP-H +
PVDF +
ISO + + + +
ASTM + + +
BS +
JIS + +
386
Overview
General Type 185 - 188
Base type 543
Actuator type EA 21
PVC-C +
ABS +
PP-H +
PVDF +
Spigot +
Threaded socket +
Seal materials EPDM (O-ring) +
FPM (O-ring) +
PTFE (ball) +
PVDF (ball) +
Standards ISO +
BS +
ASTM +
JIS +
Accessories More information about accessories
are available in the Chapter "Actuators
EA21".
Safety information
CAUTION
actuator is to:
valve and
safe return unit.
387
Dimensions
Graph
Weight actuator
Exploded view ball valve type 185 - 188 Information about the weight of the actu-
tors" in the planning fundamentals.
Electrical actuator EA21
(1)
More dimensions
More dimensions are available in the prod-
uct range of ball valve type 543.

adapter plate (4) Ball valve type 185
PVC-U, PVC-C, ABS with solvent cement sockets

Coupling (5)
Spacer (8)

MF housing (6)

3-way ball valve type 543
horizontal (7)
d DN D H H1 H2

mm mm mm mm mm mm
Type 185-187
16 10 50 231 28 64
20 15 50 231 28 64

Electrical actuator EA21 25 20 58 240 32 73
(1) 32 25 68 240 36 73
40 32 84 251 45 84
50 40 97 251 51 84

63 50 124 273 65 106

adapter plate (4) d DN D H3 H5 H6
mm mm mm mm mm mm
16 10 50 94 167 8
coupling (5) 20 15 50 94 167 8
Spacer (8) 25 20 58 94 167 8
32 25 68 94 167 8
MF housing (6) 40 32 84 94 167 9

50 40 97 94 167 9

63 50 124 94 167 9
3-way ball valve type 543
vertical (7)

Type 188
388
d L L1 L2 L3 L4 L5 d DN D H3 H5 H6
16 109 180 73 36 25 97 16 10 50 94 167 8
20 112 180 73 36 25 97 20 15 50 94 167 8
25 131 180 86 43 25 97 25 20 58 94 167 8
32 151 180 99 50 25 97 32 25 68 94 167 8
40 181 180 120 60 45 97 40 32 84 94 167 9
50 205 180 137 69 45 97 50 40 97 94 167 9
63 261 180 179 89 45 97 63 50 124 94 167 9
d L6 L7 L8 M z z1 d L L1 L2 L3 L4 L5

16 83 122 33 6 81 40 16 110 180 72 36 25 97
20 83 122 33 6 81 40 20 112 180 72 36 25 97
25 83 122 33 6 94 47 25 129 180 85 43 25 97
32 83 122 33 6 107 54 32 146 180 98 49 25 97
40 83 122 33 8 130 65 40 170 180 118 59 45 97
50 83 122 33 8 143 72 50 193 180 135 68 45 97
63 83 122 33 8 185 92 63 244 180 176 88 45 97
Ball valve type 186, 187 d L6 L7 L8 M z z1

PROGEF, SYGEF with fusion sockets mm mm mm mm mm mm
16 83 122 33 6 82 41
20 83 122 33 6 82 41
25 83 122 33 6 97 49
32 83 122 33 6 110 55
40 83 122 33 8 132 66
50 83 122 33 8 151 76
63 83 122 33 8 188 94
Ball valve type 188

PVC-U, ABS with solvent cement sockets
d DN D H H1 H2

mm mm mm mm mm mm
16 10 50 231 28 64
20 15 50 231 28 64
25 20 58 240 32 73
32 25 68 240 36 73
40 32 84 251 45 84
50 40 97 251 51 84
63 50 124 273 65 106
389
d DN D H H1 H2
mm mm mm mm mm mm
16 10 50 231 62 64
20 15 50 231 62 64
25 20 58 240 72 73
32 25 68 240 77 73
40 32 84 251 87 84
50 40 97 251 97 84
63 50 124 273 112 106
d DN D H3 H5 L

mm mm mm mm mm mm
16 10 50 94 167 92
20 15 50 94 167 95
25 20 58 94 167 111
32 25 68 94 167 123
40 32 84 94 167 146
50 40 97 94 167 157
63 50 124 94 167 183
d L1 L2 L5 L6 L7 L8

16 180 56 97 83 122 33
20 180 56 97 83 122 33
25 180 66 97 83 122 33
32 180 71 97 83 122 33
40 180 85 97 83 122 33
50 180 89 97 83 122 33
63 180 101 97 83 122 33
d z
mm mm
16 64
20 64
25 74
32 79
40 95
50 95
63 107
390
Fundamentals for ball valves pneumatically actuated
Page

Ball valve type 230 - 235
-- Overview 392
-- Graph 395
Universal actuator interface according to EN ISO 5211
-- Overview 404
-- Graph 406
391
Fundamentals for ball valves
pneumatically actuated
Overview
Product description
Ball valves of type 230, 231, 232, 233, 234, 235 are
based on type 546 (d16DN10 to d63DN50) and elec-
tric actuator PA11 (DN10-DN25), PA21 (DN32-DN50),
PA30-PA45 (DN65-DN100). Type range 230-235 is de-
signed as modular adjustable ball valve for applications
which demand special process requirements.
• Pressure loss
• kv values
can be found under ball valve type 546, manual over-
ride.
In the following, you will find all the details concerning
mounting, installation and commissioning of the elkec-
tric actuators PA11/PA21/30 - 45.
Versions
Type 230 - 235 with pneumatic actuator PA11 - PA 45
Product features
Type 230 - 235
More information about different product
features are available in the Chapter "Actu-
ators type PA11-45".
Difference Type 230 - 235

Type Type Type Type Type Type
230 231 232 233 234 235
PVC-U + + + +
PVC-C + + + +
ABS + + +
PP + +
PVDF + +
ISO + + +
ASTM + +
BS +
JIS +
392
Overview
Base type 546
Actuator type PA11 - PA45
PVC-C +
ABS +
PP-H +
PVDF +
Spigot +
Flanges +
Threaded socket +
Seal materials EPDM (O- ring) +
FPM (O- ring) +
PTFE (ball) +
PVDF (ball) +
Standards ISO +
BS +
ASTM +
JIS +
Accessories More information about accessories are available in the Chap-
ter Actuators PA11-PA45.
Safety information
WARNING
Dismantling of actuators
Wrong dismantling can cause serious injury
or death.
NOTICE • The dismantling of these actuators may be
executed only under guidance of a safety
expert.
Pneumatic actuators • Dismounting may only be done in safety
• Single-acting pneumatic actuators with fail- position after disconnecting the air supply.
safe positions OPEN and CLOSED (type • When working on electric auxiliary com-
additional letters in FO and FC) have pre- ponents of the pneumatic operation, the
tensioned springs for actuation under lack electrical connections of the control voltage
of pressure. must be disconnected before.
• Any necessary live-line adjustments may
only be done with specially insulated tools.
Intended use
The descriptions and instructions in the following apply
to the pneumatic actuators:
393
Type PA11 Pneumatic part-turn valve actua-
tor
NOTICE
DA/FC/FO
tor Proper function of the actuator
DA/FC/FO • The actuator can only function properly if it
has been connected professionally accord-
Type PA30-45 Pneumatic part-turn valve actua-
tor ing to the wiring diagrams for double act-
ing operation and for fail-safe OPEN or fail-
DA/FC/FO
safe CLOSE operation, respectively. OPEN
or CLOSED fachgerecht angeschlossen
wurde.
WARNING
Intended use
These actuators are intended for use after in-
stallation to GF valves and connection to a
control system of the facility. When not used
as prescribed, it can lead to serious injury or
death.
• When built into GF valves and connected
to a system control, the purpose of these
actuators is to actuate ball valves with a
control pressure of 2.8 to 7 bar and up to
driving torque of 20 Nm, and
• depending on the type of pneumatic actu-
ator, double acting (type designation DA)
or single acting with spring for fail-safe to
CLOSED (type designation FC) or single
acting for fail-safe to FO),
• control these valves to the OPEN and
CLOSED positions via a built-in solenoid
valve. The solenoid valve must be either
supplied ex GF works or already mounted
by the customer,
• indicate these positions OPEN and
CLOSED via an electric signal to the sys-
tem control, if the actuator is equipped for
this with the respective subassembly,
• enable control of these positions through
manual operation in case of failure in the
compressed air supply, if the actuator is
equipped for this with the respective sub-
assembly.
The actuator is not intended for uses other than those

stated here. Prohibited in particular are:
• control pressures above 7.5 bar,
• manual operation with forces higher than permitted
according to prEN12570 (maximum retention forces
for operation of valves),
• operating solenoid valves and position feedback units
under water.
394
Graph
Exploded view ball valve type 230-235 (DN10 - DN50)
With manual override Without manual override

Actuator type PA11/21

Coupling lever with intermediate piece on top

Control lever

Intermediate piece below

Adapter plate with clamps

Coupling piece


Ball valve type 546
395
Ball valve type 230-235 (DN65 - DN100)
Without manual override
Dimensions d DN D H H1 H2

mm mm mm mm mm mm
Weight actuator
Information about the weight of the actu- 16 10 50 229.5 26.5 61.5
20 15 50 229.5 26.5 61.5
25 20 58 238.5 30 70.5

32 25 68 238.5 35.5 70.5
More dimensions More dimensions are
available in the product range of ball valve 40 32 84 270.6 44 83.6
type 546. 50 40 97 270.6 50.5 83.6
63 50 124 293 64 106
Dimensions for types 230-235 (DN10 - DN50) d DN D H3 H4 H5

with manual override, solvent cement socket
Ball valve type 546, with solvent cement sockets, metric mm mm mm mm mm mm
with pneumatic actuator PA 11/21 with stroke limiter and 16 10 50 168 40 97
emergency manual override
20 15 50 168 40 97
25 20 58 168 40 97
32 25 68 168 40 97
40 32 84 187 51 115
50 40 97 187 51 115
63 50 124 187 51 115
396
d L* L1 L2 L4 d DN D H H1 H2
16 92 194 56 25 16 10 50 229.5 26.5 61.5
20 95 194 56 25 20 15 50 229.5 26.5 61.5
25 110 194 65 25 25 20 58 238.5 30 70.5
32 123 194 71 25 32 25 68 238.5 35.5 70.5
40 146 224 85 45 40 32 84 270.6 44 83.6
50 157 224 89 45 50 40 97 270.6 50.5 83.6
63 183 224 101 45 63 50 124 293 64 106

d DN D H3 H4 H5
* L applies to PVC-U, PVC-C and ABS; for PP and PVDF
see manual valves mm mm mm mm mm mm
16 10 50 168 40 97
d L5 L6 L7 z
20 15 50 168 40 97
mm mm mm mm mm
25 20 58 168 40 97
16 261 76 48 64
32 25 68 168 40 97
20 261 76 48 64
40 32 84 187 51 115
25 261 76 48 72
50 40 97 187 51 115
32 261 76 48 79
63 50 124 187 51 115
40 305 95 59 94
50 305 95 59 94 d L* L1 L2 L3
63 305 95 59 107 mm mm mm mm mm
16 114 194 56 -
Dimensions for types 230-235 (DN10 - DN50)
with manual override, spigots/flanges 20 124 194 56 130
Ball valve type 546, with solvent cement spigot, metric 25 144 194 65 150
with pneumatic actuator PA 11/21 with stroke limiter and
emergency manual override 32 154 194 71 160
40 174 194 85 180
50 194 194 89 200
63 224 194 101 230

see manual valves
d L4 L5 L6 L7

mm mm mm mm mm
16 25 261 76 48
20 25 261 76 48
25 25 261 76 48
32 25 261 76 48
40 45 305 95 59
50 45 305 95 59
63 45 305 95 59
Dimensions for types 230-235 (DN10 - DN50)

without manual override, solvent cement sock-
et
Ball valve type 546, with solvent cement sockets, metric
with pneumatic actuator PA 11/21 with stroke limiter
397
d L* L1 L2 L4
mm mm mm mm mm
16 92 194 56 25
20 95 194 56 25
25 110 194 65 25
32 123 194 71 25
40 146 224 85 45
50 157 224 89 45
63 183 224 101 45

see manual valves
d L5 L6 L7 z
mm mm mm mm mm
16 261 76 48 64
20 261 76 48 64
25 261 76 48 72
d DN D H H1 32 261 76 48 79

mm mm mm mm mm 40 305 95 59 94
16 10 50 166.5 26.5 50 305 95 59 95
20 15 50 166.5 26.5 63 305 95 59 107
25 20 58 175.5 30 Dimensions for types 230-235 (DN10 - DN50)
32 25 68 175.5 35.5 without manual override, spigots/flanges
Ball valve type 546, with solvent cement spigot, metric
40 32 84 209.6 44
with pneumatic actuator PA 11/21 with stroke limiter
50 40 97 209.6 50.5
63 50 124 232 64
d DN H2 H4 H5

mm mm mm mm mm
16 10 61.5 40 97
20 15 61.5 40 97
25 20 70.5 40 97
32 25 70.5 40 97
40 32 83.6 51 115
50 40 83.6 51 115
63 50 106 51 115
398
d DN D H H1
mm mm mm mm mm
16 10 50 166.5 26.5
20 15 50 166.5 26.5
25 20 58 175.5 30
32 25 68 175.5 35.5
40 32 84 209.6 44
50 40 97 209.6 50.5
63 50 124 232 64
d DN H2 H4 H5

mm mm mm mm mm
16 10 61.5 40 97
d DN D H H1 H2 H5
20 15 61.5 40 97 mm mm mm mm mm mm mm
25 20 70.5 40 97 75 65 166 262 85 156 70
32 25 70.5 40 97 90 80 200 281 105 168 78
40 32 83.6 51 115 110 100 238 292 123 175 86
50 40 83.6 51 115
63 50 106 51 115 d L* L1 L2 L4 L5 L6 z
d L* L1 L2 L3 75 233 218 136 70 276 65 144
mm mm mm mm mm 90 254 259 141 70 341 72 151
16 114 194 56 - 110 301 287 164 120 369 80 174
20 124 194 56 130
25 144 194 65 150 * L applies to PVC-U, PVC-C and ABS; for PP and PVDF
32 154 194 71 160 see manual valves
40 174 224 85 180 Dimensions for types 230-235 (DN65 - DN100)

50 194 224 89 200 without manual override, spigots/flanges
Ball valve type 546, with solvent cement spigot, metric
63 224 224 101 230 with pneumatic actuator PA 30/35/40 with stroke limiter

see manual valves
d L4 L5 L6 L7

mm mm mm mm mm
16 25 261 76 48
20 25 261 76 48
25 25 261 76 48
32 25 261 76 48
40 45 305 95 59
50 45 305 95 59
63 45 305 95 59
Dimensions for types 230-235 (DN65 - DN100) d DN D H H1 H2 H5 H6
without manual override, solvent cement sock- mm mm mm mm mm mm mm mm
et
Ball valve type 546, with solvent cement sockets, metric 75 65 166 262 85 156 70 93
with pneumatic actuator PA30/35/40 with stroke limiter 90 80 200 281 105 268 78 100
110 100 238 292 123 175 86 110
399
d L* L1 L2 L3 L4 L5 L6
75 284 218 136 290 70 276 65
90 300 259 141 310 70 341 72
110 340 287 161 350 120 369 80

see manual valves
Technical features
More information
about the multifunctional module and
mounting plate are available in the Chapter
Ball valve type 546 hand operated in the
planning fundamentals.
400
Universal actuator interface accord-
ing to EN ISO 5211
• Simple adaption of actuator with universal interface

for the ball valve Type 546
• Practical assembly set with different flange fittings
• Functional and solid through the use of rugged ma-
terials - adapter plates, flanges and couplings all an-
odised Aluminium - screws and washers all stainless
steel V2A

Configuration
Base-set (required)
Consisting of mounting flange to ball valve Type 546,
adapter plate to actuator according to EN ISO 5211 and
screws: four screws for fixation of mounting flange to
ball valve; four screws for fixation of adapter plate to
the actuator; two screws for joining of adapter-plate and
mounting flange.
401

DN Flange fitting Screw to actuator Flange fitting F03 / F05 Flange fitting F04

F03 M5x10
10/15 F04 M5x10
F05 M6x12
F03 M5x10
20/25 F04 M5x10
F05 M6x12
32/40 F04 M5x10
F05 M6x12
50 F04 M5x10
F05 M6x12
Coupling

DN Wrench size Coupling

10/15 WS9
10/15 WS11*
20/25 WS9
20/25 WS11*
32/40 WS11*
50 WS11*
Position of diagonal square is 45° distorted to
the final position.
Reducer bushing
Inner wrench size Outer wrench size Reducer bushing
WS11 WS14

402
Dimensions
WS - wrench size of coupling
TK - reference circle diameter
M - thread diameter
D - outer diameter adapter-plate and mounting-flange

Flange fitting F03 Flange fitting F04 Flange fitting F05

d DN H D TK WS H1 M TK WS H1 M TK WS H1 M
16/20 10/15 47 ø65 ø36 WS9 9 M5 ø42 WS11 11 M5 ø50 WS11 11 M6
25 20 56 ø65 ø36 WS9 9 M5 ø42 WS11 11 M5 ø50 WS11 11 M6
32 25 61 ø65 ø36 WS9 9 M5 ø42 WS11 11 M5 ø50 WS11 11 M6
40 32 73 ø75 - - - - ø42 WS11 11 M5 ø50 WS11 11 M6
50 40 79 ø75 - - - - ø42 WS11 11 M5 ø50 WS11 11 M6
63 50 96 ø75 - - - - ø42 WS11 11 M5 ø50 WS11 11 M6
Actuator details
Maximum weight of the actuator and breakaway torque
of the ball valve Type 546 with a media pressure of p =
10 bar.
d DN Breakaway
mm mm torque Nm
16/20 10/15 4
25 20 6
32 25 8
40 32 12
50 40 16
63 50 25
The actuator has to be shored up at a weight >5 kg.
403
Ball valve type 285 - 288 Differences Type 285 - 288
Overview horizon- horizon- horizontal vertical*
Product description tal tal
Ball valves Type 285 - 288 are based on ball valve PVC-U + +
Type 543 (d16DN10 to d63DN50) and electric actuator
PVC-C +
PA11 / PA21. Type range 285-288 is designed as mod-
ular upgradeable 3-way ball valve for mixing and divert- ABS +
ing applications which demand special process require- PP-H +
ments.
The technical data concerning PVDF +
• Pressure-temperature diagram ISO + + + +
• Pressure loss ASTM + + +
• Flow characteristics BS +
• kv values
JIS + +
* With special tripod ball. For further information, please con-
can be found under ball valve type 543, manual over- tact a George Fischer Piping Systems representative.
ride.
Versions
Type 285 - 288 with pneumatic actuator PA11 / PA21
Product features
Type 285 - 288
• Compact design and modular construction of the
valves
• Preloaded spring packages, standard version FC, DA;
FO on request
• Short switching time
• For FC/FO stroke limitation possible
• Pressure connector based on Namur standard
404
Overview
Base type 543
Actuator type PA11 / PA21
PVC-C +
ABS +
PP-H +
PVDF +
Spigot +
Threaded socket +
Seal materials EPDM (O- ring) +
FPM (O- ring) +
PTFE (ball) +
PVDF (ball) +
Standards ISO +
BS +
ASTM +
JIS +
Accessories More information about accessories are available in the
chapter actuators PA11/21.
Safety information
WARNING
or death.
NOTICE • The dismantling of these actuators must
only be executed according to special re-
pair instructions and under guidance of a
Pneumatic actuators safety expert.
• Single-acting pneumatic actuators with fail- • Dismounting may only be done in safety
safe positions OPEN and CLOSED (type position after disconnecting the air supply.
additional letters in FO and FC) have pre- • When working on electric auxiliary com-
tensioned springs for actuation under lack ponents of the pneumatic operation, the
of pressure. electrical connections of the control voltage
must be disconnected before.
Intended use
Type PA11 Pneumatic part-turn valve actuator
DA/FC/FO
Type PA21 Pneumatic part-turn valve actuator
DA/FC/FO
405
Graph

Intended use
Pneumatic actuator PA11/
These actuators are intended for use after in- 21 (1)
stallation to GF valves and connection to a

control system of the facility. When not used
as prescribed, it can lead to serious injury or
death. Adapter plate (4)
• When built into GF valves and connected
to a system control, the purpose of these
actuators is to actuate ball valves with a
control pressure of 2.8 to 7 bar and up to Coupling (5)
driving torque of 20 Nm, and Spacer (8)
• depending on the type of pneumatic actu-
ator, double acting (type designation DA) MF housing (6)
or single acting with spring for fail-safe to
CLOSED (type designation FC) or single
acting for fail-safe to FO),
• control these valves to the OPEN and 3-way ball valve type 543
CLOSED positions via a built-in solenoid horizontal (7)
valve. The solenoid valve must be either
supplied ex GF works or already mounted
by the customer,
Type 285-287
• indicate these positions OPEN and
CLOSED via an electric signal to the sys-

tem control, if the actuator is equipped for
this with the respective subassembly, Pneumatic actuator PA11/
• enable control of these positions through 21 (1)
manual operation in case of failure in the
compressed air supply, if the actuator is
equipped for this with the respective sub-
assembly. Adapter plate (4)

The actuator is not intended for uses other than those Coupling (5)
stated here. Prohibited in particular are: Spacer (8)
• control pressures above 7.5 bar,
• manual operation with forces higher than permitted MF housing (6)
according to prEN12570 (maximum retention forces

for operation of valves),

under water. 3-way ball valve type 543
vertical (7)

NOTICE
Type

288
Proper function of the actuator Dimensions
• The actuator can only function properly if it
has been connected professionally accord- Weight actuator
ing to the wiring diagrams for double act- ators are available in the Chapter "Actua-
ing operation and for fail-safe OPEN or fail- tors" in the planning fundamentals.
safe CLOSE operation, respectively. OPEN
or CLOSED fachgerecht angeschlossen
wurde. More dimensions
uct range of ball valve type 543.
406
Ball valve type 285 d L5 L6 L7 M z z1
PVC-U, PVC-C, ABS with solvent cement sockets mm mm mm mm mm mm
16 261 76 48 6 81 40
20 261 76 48 6 81 40
25 261 76 48 6 94 47
32 261 76 48 6 107 54
40 305 95 59 8 130 65
50 305 95 59 8 143 72
63 305 95 59 8 185 92

d DN D H H1 H2 PROGEF, SYGEF with fusion sockets
mm mm mm mm mm mm
16 10 50 159 28 62
20 15 50 159 28 62
25 20 58 168 32 71
32 25 68 168 36 71
40 32 84 203 45 84
50 40 97 203 51 84
63 50 124 225 65 106
d DN D H3 H4 H5 d DN D H H1 H2

mm mm mm mm mm mm mm mm mm mm mm mm
16 10 50 97 40 77 16 10 50 159 28 62
20 15 50 97 40 77 20 15 50 159 28 62
25 20 58 97 40 77 25 20 58 168 32 71
32 25 68 97 40 77 32 25 68 168 36 71
40 32 84 119 51 99 40 32 84 203 45 84
50 40 97 119 51 99 50 40 97 203 51 84
63 50 124 119 51 99 63 50 124 225 65 106
d H6 L L1 L2 L3 L4 d DN D H3 H4 H5

16 8 109 194 73 36 25 16 10 50 97 40 77
20 8 112 194 73 36 25 20 15 50 97 40 77
25 8 131 194 86 43 25 25 20 58 97 40 77
32 8 151 194 99 50 25 32 25 68 97 40 77
40 9 181 224 120 60 45 40 32 84 119 51 99
50 9 205 224 137 69 45 50 40 97 119 51 99
63 9 261 224 179 89 45 63 50 124 119 51 99
407
d H6 L L1 L2 L3 L4
16 8 110 194 72 36 25
20 8 112 194 72 36 25
25 8 129 194 85 43 25
32 8 146 194 98 50 25
40 9 170 224 118 60 45
50 9 193 224 135 69 45
63 9 244 224 176 89 45
d L5 L6 L7 M z z1

mm mm mm mm mm mm
16 261 76 48 6 82 41
20 261 76 48 6 82 41
25 261 76 48 6 97 49
32 261 76 48 6 110 55
40 305 95 59 8 132 66
50 305 95 59 8 151 76
63 305 95 59 8 188 94
408
Fundamentals for diaphragm valves, hand operated
Page

Diaphragm valves type 514, 515, 517, 519
-- Overview 410
-- Graph 413
-- Accessories 420
409
Fundamentals for diaphragm
valves, hand operated
Diaphragm valves type 514, 515, 517,
519
Overview
Product description
Diaphragm valves are well suited for controlling, retain-
ing and monitoring of volume flows. Their advantage
compared to other valve types is their simplicity of func-
tion and construction. They can be used for gases and
liquids and are especially well suited for soiled, aggres- Type 519
sive and abrasive media. The diaphragm valves can
be installed in any position. There will be no pressure Branched type
surges by closing a diaphragm valve. This valve is avail-
able as manual valve as well as actuated valve.
Versions
All types of diaphragm valves in sizes DN15 to DN50.
Type 514
Radial installation and removal
Indicator for diaphragm material
Type 515
Spigot ends
Friction lock on the valve body - colour shows type of di-
aphragm material:
black EPDM diaphragm
white PTFE/ EPDM diaphragm
green PTFE/ FPM diaphragm
red FPM diaphragm
blue NBR diaphragm
Product features
• No corrosion as there are no metal screws
• Increased leak-tightness during temperature changes,
Type 517 since the connection of upper part and valve body is
suited for platics
Flange version
• Double flow rate and linear characteristics due to the
innovative valve body, which significantly simplifies
the control
• Optimized diaphragm geometry for a longer lifetime
• Integrated hand wheel locking device
• At the branched valve, the sealing bar is near the pipe
wall, which leads to a valve without dead space
410
Overview
General Type 514 515 517 519
Union Spigot Flange Branched type
Dimension DN 15 - 50 15 - 50 15 - 150 15 - 15 / 100 - 50
Pressure range PN up to 16 up to 16 up to 16 up to 16
Materials used Housing nut PP GF30 for PN10 (orange)
PPS GF40 for PN16 (black)
Handwheel PP GF30
Inner body PP GF30
Indicator pin PP
Compressor PPS GF 40 / PP GF30
Diaphragm holder CuZn40Pb2
Spindle X12CrMoS17
Spindle nut PPS GF40
Materials for valve body PVC-U + + +
PVC-C + + +
ABS + +
PP-H + + + +
PP-n + +
PVDF + + +
PVDF-HP + + + +
Spigot + + +
Flanges +
Threaded socket +
Diaphragm materials EPDM + + + +
PFTE/EPDM + + + +
PFTE/FPM + + + +
FPM + + +
FFPM On request
Accessories Electrical feedback with switch design AgNi, Au
Safety information
DANGER
diaphragm valve. They should identify the hazards and
advice that should be considered in the different use
Valve failure due to wrong choice of mate-
and installation / commissioning.
rial
Death or serious injury from contact with the
medium. Valve body, gaskets, diaphragms,
diaphragm support, housing and mechani-
cal components can be damaged or impaired
in their function due to lack of chemical re-
sistance, external influences, wear of the di-
aphragm or diffusion effects.
• Ensure chemical resistance: You can find
the chemical resistance tables in the plan-
ning fundamentals. If in doubt, please con-
tact your GF Piping Systems representa-
tive.
411
DANGER NOTICE
Use of grease on the threaded connection Fastening the diaphragm valve

between housing nut and valve body Superimposed loadings could damage the di-
The use of grease, especially on amorphous aphragm valve.
plastics, can cause stress cracking on the • Diaphragm valve and piping must be
valve body. Consequences can be death or aligned.
serious injury from contact with the medium.
The functioning of the valve is not warranted
Commissioning
any longer.
• Irrespective of the valve body material, do Observe all technical information and
not use grease for threaded connection be- safety information before installing the di-
aphragm valve!
tween housing nut and valve body
Diaphragm valve pressure testing is subject to the same

DANGER regulations as the piping system, however, the test
pressure must not exceed the PN of the diaphragm
valve.
Diaphragm valve used as end valve
valve in a piping system under pressure, is NOTICE
from contact with the medium. Operating the diaphragm valve
• The diaphragm valve as an end valve may Damage of diaphragm valve is possible if the
only be opened when the medium can be actuating torque is too high.
caught or carried off safely and splashing is • Operating the valve with normal hand pow-
prevented by taking appropriate measures. er
• Use no additional tools which increase ac-
tuating torque
NOTICE
NOTICE
Fastening the diaphragm valve
Due to temperature changes, longitudinal or
lateral forces may occur through thermal ex- Control operation
pansion. Due to cavitation, the diaphragm valve could
• Absorb forces via respective fixed points in be damaged.
front or after the valve. • Use the valve only under optimal control
operation conditions.
Note
NOTICE Slight hysteresis occurs in the steady state characteris-
tics when the direction of actuation is changed.
Fastening the diaphragm valve Commissioning procedure
Operation of a valve causes reactive forces • Check that all valves are in the required open or
which could damage the valve. closed position
• Mount the diaphragm valve as a fixed point • Fill the piping system and deaerate completely
with the designated fastener or reinforce • The component with the lowest PN determines the
the piping directly before and after the di- maximum allowable test pressure in the piping section
aphragm valve with suitable supports. • The valves and connections have to be checked on a
tight seal during the pressure test
412
Graph
DANGER Exploded view
Dismounting the diaphragm valve or

opening the housing nut
The medium may exit uncontrollably or flow
out from the pipe or valve, whether under
pressure or not. The valve or pipe may con-
tain residue or remnants of an aggressive,
hazardous, flammable or explosive medium.
from contact with the medium.
• Release all pressure from the piping sys-
tem.
• Empty the piping system completely.
• Rinse the system, if aggressive, haz-
ardous, flammable or explosive media are
involved
• Empty the diaphragm valve completely
when is has been dismounted. In order to
do so, let the valve drain completely
DANGER
Dismounting the diaphragm

Position indicator will break, if spindle assem-
bly is completely turned off. Position of the
diaphragm can no longer be shown by the 1 Valve body
indicator. Position of the diaphragm can no 2 Valve end
longer be shown by the indicator. 3 Union nut
4 Diaphragm
• On opened valve: Only turn the hand wheel 5 Compressor
6 Spindle assembly incl. diaphragm holder
two times to loosen the diaphragm from the 7 Inner body
inner housing. 8 Housing nut
9 Handwheel
10 Hand wheel locking device
413
Dimensions
Dimensions
Key
L(1) Union with cemented socket, metric (Type 514)
L(2) Union with threaded socket, metric(Type 514)
L(3) Union with fusion socket (Type 514)
L(4) Union with butt fusion spigot (Type 514)
L(5) Butt fusion spigot (Type 515, 519)
L(6) Cemented spigot, metric (Type 515)
L(7) Socket fusion spigot(Type 515)
L(8) Backing flange, metric (Type 517)

Type 514
d DN D D2 D3 D3 D3 L(1) L(2) L(3) L(4) L2 H H1 H2 M z LE z for Hx
for for L(3)
PP-H PVDF/
- HP
mm mm mm mm mm mm mm mm mm mm mm mm mm mm mm mm mm mm mm
20 15 65 65 43 48 43 128 128 128 196 25 73 14 12 M6 96 90 100 7
25 20 80 65 51 58 53 152 152 150 221 25 81 18 12 M6 114 108 118 10
32 25 88 87 58 65 60 166 166 162 234 25 107 22 12 M6 122 116 126 13
40 32 101 87 72 79 74 192 192 184 260 45 115 26 15 M8 140 134 144 15
50 40 117 135 83 91 82 222 222 210 284 45 148 32 15 M8 160 154 164 19
63 50 144 135 100 111 100 266 266 248 321 45 166 39 15 M8 190 184 194 25
414
Type 515
d DN D D2 L(5) L(6) L(7) L2 H H1 H2 M Hx
20 15 65 65 124 124 124 25 73 14 12 M6 7
25 20 80 65 144 144 144 25 81 18 12 M6 10
32 25 88 87 155 154 154 25 107 22 12 M6 13
40 32 101 87 176 174 174 45 115 26 15 M8 15
50 40 117 135 193 194 194 45 148 32 15 M8 19
63 50 144 135 233 224 223 45 166 39 15 M8 25
Type 517
d DN D D2 D3 D4 D5 L(8) L2 H H1 H2 M Hx
20 15 65 65 95 65 14 130 25 73 14 12 M6 7
25 20 80 65 105 75 14 150 25 81 18 12 M6 10
32 25 88 87 115 85 14 160 25 107 22 12 M6 13
40 32 101 87 140 100 18 180 45 115 26 15 M8 15
50 40 117 135 150 110 18 200 45 148 32 15 M8 19
63 50 144 135 165 125 18 230 45 166 39 15 M8 25
Type 519
d d1 DN DN1 DN2 D D2 L(5) L1 L3 L4 H H1 Hx
mm mm mm mm mm mm mm mm mm mm mm mm mm mm
20 20 15 15 15 65 65 117 96 162 12 75 14 7
25 20 20 15 20 80 65 133 108 162 16 80 17.5 10
25 25 20 20 20 80 65 133 108 162 16 80 17.5 10
32 20 25 15 20 80 65 142 120 162 19 84 21.5 10
32 25 25 20 20 80 65 142 120 162 19 84 21.5 10
32 32 25 25 25 88 87 145 120 160 19 107 21.5 13
40 20 32 15 25 88 87 149 128 180 23 115 21.5 13
40 25 32 20 25 88 87 149 128 180 23 115 21.5 13
40 32 32 25 25 88 87 149 128 180 23 115 21.5 13
40 40 32 32 25 88 87 174 153 180 23 115 21.5 13
50 20 40 15 20 80 65 160 134 180 27 97 17.5 10
50 25 40 20 25 88 87 160 134 180 28 120 21.5 13
50 32 40 25 25 88 87 160 134 180 28 120 21.5 13
50 40 40 32 50 144 135 209 169 209 33 164 32 25
50 50 40 40 50 144 135 209 169 209 33 164 32 25
63 20 50 15 20 80 65 177 144 180 33 104 17.5 10
63 25 50 20 25 88 87 177 144 180 35 127 21.5 13
63 32 50 25 25 88 87 177 144 180 35 127 21.5 13
63 40 50 32 50 144 135 225 192 220 39 170 39 25
63 50 50 40 50 144 135 225 192 220 39 170 39 25
63 63 50 50 50 144 135 225 192 220 39 170 39 25
90 20 80 15 25 88 87 205 159 190 47 140 21.5 13
90 25 80 20 25 88 87 205 159 190 47 140 21.5 13
90 32 80 25 25 88 87 205 159 190 47 140 21.5 13
415
90 50 80 40 50 144 135 254 207 250 51 184 39 25
90 63 80 50 50 144 135 254 207 250 51 184 39 25
110 20 100 15 25 88 87 227 171 190 56 149 21.5 13
110 25 100 20 25 88 87 227 171 190 56 149 21.5 13
110 32 100 25 25 88 87 227 171 190 56 149 21.5 13
110 50 100 40 50 144 135 276 219 250 60 194 39 25
110 63 100 50 50 144 135 276 219 250 60 194 39 25
Technical data
lar media.

1) Depending on connection type and actuator, the nominal
pressure is reduced to PN6


1) PN16 only with black PPS housing nut. Depending on
connection type and actuator, the nominal pressure is re-
duced to PN10
Pressure loss
Type 514...517
x Flow rate in l/min

P Permissible pressure in bar, psi y Pressure loss Δp=1bar
1) Only with black PPS housing nut
2) Depending on connection type and actuator, the
3) nominal pressure is reduced
to PN10
Depending on connection type and actuator, the
nominal pressure is reduced
to PN6
416
Flow characteristics Type 519
Type 514...517 d d1 DN DN1 kv Cv kv 100
[mm] [mm] [mm] [mm] 100 [l/ 100 [m³/h]
min] [gal/ Δp =
Δp = min] 1bar
1bar Δp =
1psi
20 20 15 15 57 4 3
25 20 20 15 89 6 5
25 25 20 20 118 8 7
32 20 25 15 80 6 5
32 25 25 20 105 7 6
32 32 25 25 231 16 14
x Stroke in % 40 20 32 15 85 6 5
y kv, Cv value in %
40 25 32 20 119 8 7
Type 519
40 32 32 25 153 11 9
40 40 32 32 187 13 11
50 20 40 15 86 6 5
50 25 40 20 160 11 10
50 32 40 25 206 14 12
50 40 40 32 524 36 31
50 50 40 40 667 46 40
63 20 50 15 84 6 5
63 25 50 20 150 11 9
63 32 50 25 184 13 11
x Stroke in %
y kv, Cv value in % 63 40 50 32 471 32 28
63 50 50 40 610 42 37
kv 100 values
The kv values for each intermediate valve position can 63 63 50 50 747 52 45
be determined by using the flow value characteristics 90 20 80 15 82 6 5
90 25 80 20 103 7 6
Type 514 - 517
90 32 80 25 129 9 8
d [mm] DN inch kv 100 Cv 100 kv 100
90 50 80 40 623 43 37
[mm] [l/min] [gal/ [m³/h]
Δp = min] Δp = 90 63 80 50 696 48 42
1bar Δp = 1bar
1psi 110 20 100 15 78 5 4
20 15 ½ 125 9 8 110 25 100 20 103 7 6
25 20 ¾ 271 19 16 110 32 100 25 131 9 8
32 25 1 481 33 29 110 50 100 40 604 42 36
40 32 1¼ 759 52 45 110 63 100 50 661 46 40
50 40 1½ 1263 87 76 Operating torque

63 50 2 1728 119 104
y Operating torque in Nm
417
Application in vacuum Angle b for types 514 .. 517
Use of the diaphragm valve with static pressure:
Dimension Angle a for types 514... 517
• 0.5 bar
d20DN15 27
Instructions for use d25DN20 24
Installation angle for optimal draining of the d32DN25 25

valve d40DN32 23
In order to achieve optimal drainage of these diaphragm
d50DN40 24
valves, GF recommends installing them at the angles (a
and b), which correspond to the respective dimension D63DN50 22
ranges. An installation inclination of about 1 - 2° is not
taken into consideration with the stated angles. Emptying angle for type 519 is 90°, independent of
the dimension
Angle a for types 514... 517

d20DN15 2
d25DN20 2
d32DN25 3
Angle for type 519
d40DN32 4
d50DN40 5 Integrated fastening and PP-mounting plate
D63DN50 7 Integrated mounting
The diaphragm valve includes a built-in mounting. With
this, the forces that can occur when operating the valve
(e.g. breakaway torque) are absorbed. Due to the inte-
grated mounting, operation forces are not transmitted to
the piping system.
PP- mounting plate for diaphragm valves
The mounting plates are designed to allow differently
sized GF diaphragm valves to be aligned on the same
pipe centre line by equalising the different heights from
the base to the centre line of the pipe. The plates can
also be used for the PVC diaphragm valve of type 514
for equalising the union nut with the mounting surface.
• Material: PP GF 15, black
• 5 sizes, numbered from 1 to 5
• Can be plugged together to achieve the desired
height

418
Dimensions
419
Mounting Diaphragm valve Dimension [mm]
plate No.
Dimension inch H1 H L L1 L2 L3 D
1 DN15 - 25 1/2'' - 1'' 4.50 11.00 46.50 42.00 25.00 17.00 7.50
2 DN15 - 25 1/2'' - 1'' 3.50 7.00 46.50 42.00 25.00 17.00 7.50
3 DN15 - 25 1/2'' - 1'' 13.50 17.00 46.50 42.00 25.00 17.00 7.50
4 DN32 - 50 1 1/4'' - 2'' 6.75 16.75 80.00 66.50 45.00 22.00 9.50
5 DN32 - 50 1 1/4'' - 2'' 6.75 13.25 80.00 66.50 45.00 22.00 9.50
Dimensions
The length of the mounting screws is calculated by
adding the length of the thread in the valve base to the
height of the plate and the thickness of the mounting
bracket. Mounting brackets No. 1 and 4 are for plugging
directly into the valve base.
Equalising the mounting height
Quantity required x Mounting plate number
from DN... ...to DN
15 20 25 32 40 50 65

15 1x1 1x1+1x2 1x1+2x2 1x1+1x3 1x1+2x2+1x3 1x1+2x3
20 1x1 1x1+1x2 1x1+3x2 1x1+1x2+1x3 1x1+3x2+1x3
25 1x1 1x1+2x2 1x1+1x3 1x1+2x2+1x3
32 1x4 1x4+1x5 1x4+2x5
40 1x4 1x4+1x5
50 1x4
Equalising the union height for type 514 Dimension Quantity required x H [mm] H1 [mm]
[mm] plate number
15 1 x1 + 2 x 2 22.50 11.50
20 1x1+2x2 29.00 11.50
25 1x1+2x2 32.50 11.50
32 1x4+1x5 39.00 13.50
40 1x4+1x5 46.00 13.50
50 1x4+1x5 52.50 13.50
Accessories
Electrical feedback switches with Ag Ni or AU
• Accessories for Diaphragm Valve Type 514-519

• Unchanged height
• Self-adjusting
• Simple, fast and secure installation
420
• Includes plug 3P + E / Protection class: IP65
421
422
Fundamentals for diaphragm valves, pneumatically actu-
ated
Page

Diaphragm valve DIASTAR
-- Overview 424
-- Graph 428
-- Type of actuation 438
-- DIASTAR 025 DN65 - DN150 443
-- Accessories 444
423
Fundamentals for diaphragm DIASTAR TenPlus
This is our actuator for high performance applications that
valves, pneumatically actuated require high closing forces. With the DIASTAR TenPlus,
line pressures up to 10 bar on both sides are possible. The
DIASTAR TenPlus is available in all piping and diaphragm
Diaphragm valve DIASTAR materials and therefore offers maximum flexibility for your
process. Of course it has an accessory interface for easy
Overview system integration.
Product description
Diaphragm valves are well suited for controlling, retain-
ing and monitoring of volume flows. Their advantage
compared to other valve types is their simplicity of func-
tion and construction. They can be used for gases and
liquids and are especially well suited for soiled, aggres-
sive and abrasive media. The diaphragm valves can be
installed in any position. This valve is available as man-
ual valve as well as actuated valve.
The new generation of the Georg Fischer DIASTAR
series is the perfect solution for a reliable flow control
at your facility. This series features a combination of
the pneumatic actuator with a valve body of diaphragm
valve types 514 to 519. Its new design combines in-
creased safety and efficiency and easy handling.
DIASTAR Sixteen
Versions This is our strongest one. The high closing force in combi-
nation with the special housing guarantees secure control
DIASTAR Six of line pressure up to 16 bar. Are you looking for maximum
Are you looking for a cost-effective solution with a long life reliability? And do you want an integrated accessory inter-
time for elastomer diaphragms up to 6 bar? Then you are on face for simple system integration? Then DIASTAR Sixteen
the right track with DIASTAR Six. It combines high quality is your right choice.
with the basic functions of a pneumatic actuator. Its compact
design is also an advantage.
Suited valve bodies

Type 514
DIASTAR Ten
Optimally suited for all standard applications up to 10 bar re- Radial installation and removal
quiring an integration of accessories. Uncomplicated inte-
gration into the plant automation possible through the appro-
priate interface. DIASTAR Ten also offers the possibility of
using a PTFE diaphragm. The cost-performance ratio is un-
beatable.
Type 515
Spigot ends
424
Type 517
Flange version
Type 519
Branched type
Indicator for diaphragm material
Friction lock on the valve body - colour shows type of di-

aphragm material:
black EPDM diaphragm
white PTFE/ EPDM diaphragm
green PTFE/ FPM diaphragm
red FPM diaphragm
blue NBR diaphragm
Product features
• Actuators series Sixteen for 16 bar, TenPlus for 10
bar both sides, Ten for 10 bar and Six for 6 bar nomi-
nal pressure
• No corrosion as there are no metal screws
• Increased leak-tightness during temperature changes,
since the connection of upper part and valve body is
suited for platics
• Double flow rate and linear characteristics due to the
innovative valve body, which significantly simplifies
the control
• Optimized diaphragm geometry for a longer lifetime
• 90° turnable air connection for a flexible installation
• At the branched valve, the sealing bar is near the pipe
wall, which leads to a valve without dead space
425
Overview
General Title Pneumatic diaphragm valves DIASTAR
Type Six Ten TenPlus Sixteen
Dimension DN 15 - 50 15 - 50 15 - 50 15 - 50
Pressure range PN 6 10 up to 10 both up to 16
sides
Materials used Housing PP-GF30 (orange) for PN10 or PPS-GF40 (black) for PN16
Piston Metal and PP-GF30 white (Polypropylen, 30 % fiberglass-reinforced)
Position indicator / Indica- PP / SAN
tor cap
Spindle X14CrMoS17
Springs Steel, zinc coated
Seals (piston and spindle) NBR
Ambient temperature - 10 °C to 50 °C
Metal insert – valve body X6CrMoS17
Metal insert – air connec- 9 sMnPb28k
tion
Metal insert for accessory CuZn39Pb3
interface:
Functions FC (Fail safe to close) + + + +
FO (Fail-safe-to-open) +
DA (Double Acting) +
Materials for valve body PVC-U + + + +
PVC-C + + + +
ABS + + + +
PROGEF Standard + + + +
PROGEF Natural + + +
SYGEF Standard + + +
SYGEF Plus + + +
Diaphragm materials EPDM + + + +
PFTE / EPDM + + +
PFTE / FPM + + +
FPM On request + + +
NBR On request + + +
FFPM + + + +
Valves types 514 + + + +
515 + + + +
517 On request + + +
519 + + +
Connection types Union + + + +
Sockets + + + +
Spigot + + + +
Flange On request + + +
IR spigots + + + +
BCF spigots + + +
Accessories Limit switches + + +
Manual override + + +
Stroke limiter + + +
426
Positioner + + +
Bus connection +* + + +
*With appropriate pilot valve or valve island
Normal operation and maintenance

Safety information
diaphragm valve. They should identify the hazards and DANGER
advice that should be considered for the different uses
and installation/commissioning.
Diaphragm valve used as end valve
DANGER valve in a piping system under pressure, is
Reducing spring sets from contact with the medium.
Reduced spring sets lead to a reduced clos- • The end valve may only be opened when
ing force. At a rising line pressure, the valve the medium can be caught or carried off
cannot close or not close properly due to safely and splashing is prevented by taking
missing spring sets. Consequences can be appropriate measures.
death or serious injury from contact with the
medium. The process can be influenced neg-
atively.
DANGER
• Configure diaphragm valve and actuator
according to your line pressure.
Dismounting the diaphragm valve or
Commissioning opening the housing nut
The medium may exit uncontrollably or flow
out from the pipe or valve, whether under
NOTICE pressure or not. The valve or pipe may con-
Operating the diaphragm valve hazardous, flammable or explosive medium.
Use of higher control pressures or mechani- from contact with the medium.
cal aids can cause damage to the diaphragm
valve. • Release all pressure from the piping sys-
tem.
• Use the mentioned control pressures to ac- • Empty the piping system completely.
tuate the diaphragm valve. These as well • Rinse the system, if aggressive, haz-
as the corresponding control pressure dia- ardous, flammable or explosive media are
grams can be found in the Planning Funda- involved
mentals of GF Piping Systems. • Empty the diaphragm valve completely
when is has been dismounted. In order to
do so, let the valve drain completely
NOTICE
Control operation
Due to cavitation, the diaphragm valve could
be damaged.
• Use valve only in optimal control operation
427
Graph
Exploded view
1 Optical position indicator with cap

2 Piston
3 Air connections
4 All-plastic housing
5 Diaphragm holder
6 Compressor
7 Diaphragm
8 Valve body
9 Pre-loaded spring sets for FC mode
10 Spring for FO mode
Dimensions
Key
L(1) Union with cemented socket, metric
L(2) Union with threaded socket, metric
L(3) Union with fusion socket
L(4) Union with butt fusion spigot
L(5) Union with butt fusion spigot (PVDF)
L(6) Butt fusion spigot
L(7) Cemented spigot, metric
L(8) Socket fusion spigot
L(9) Backing flange, metric
428
DIASTAR Six FC (Type 514 - 517)
d DN D D1 D4 D5 L(1) L(2) L(3) L(4) L(5) L(6) L(7)
20 15 68 1/8" 65 14 128 128 128 224 196 124 124
25 20 96 1/8" 75 14 152 152 150 250 221 144 144
32 25 96 1/8" 85 14 166 166 162 262 234 154 154
40 32 120 1/8" 100 18 192 192 184 296 260 174 174
50 40 120 1/8" 110 18 222 222 210 328 284 194 194
63 50 120 1/8" 125 18 266 266 248 370 321 224 224
z for
d DN L(8) L (9) L2 H H1 H2 H3 H7 M z LE Hx
L(3)
20 15 124 130 25 101 14 12 60 43 M6 96 90 100 7
25 20 144 150 25 132 18 12 73 57 M6 114 108 118 10
32 25 154 160 25 143 22 12 84 57 M6 122 116 126 13
40 32 174 180 45 173 26 15 99 69 M8 140 134 144 14
50 40 194 200 45 193 32 15 119 69 M8 160 154 164 16
63 50 224 230 45 205 39 15 132 69 M8 190 184 194 16
DIASTAR Ten FC (Type 514 - 517)

d DN D D1 D4 D5 L(1) L(2) L(3) L(4) L(5) L(6) L(7) L(8)
20 15 68 1/8" 65 14 128 128 128 224 196 124 124 124
25 20 96 1/8" 75 14 152 152 150 250 221 144 144 144
32 25 96 1/8" 85 14 166 166 162 262 234 154 154 154
40 32 120 1/8" 100 18 192 192 184 296 260 174 174 174
50 40 150 1/4" 110 18 222 222 210 328 284 194 194 194
63 50 150 1/4" 125 18 266 266 248 370 321 224 224 224
z for
d DN L(9) L2 H H1 H2 H3 H4 H5 H7 M z LE Hx
L(3)
20 15 130 25 101 14 12 60 24 16 43 M6 96 90 100 7
25 20 150 25 132 18 12 73 25 16 57 M6 114 108 118 10
32 25 160 25 143 22 12 84 25 16 57 M6 122 116 126 13
40 32 180 45 173 26 15 99 26 26 69 M8 140 134 144 15
50 40 200 45 214 32 15 119 36 26 88 M8 160 154 164 19
63 50 230 45 226 39 15 132 36 26 88 M8 190 184 194 23
429
DIASTAR Sixteen FC (Type 514 - 517)
20 15 96 1/8" 65 14 128 128 128 224 196 124 124 124
25 20 96 1/8" 75 14 152 152 150 250 221 144 144 144
32 25 120 1/8" 85 14 166 166 162 262 234 154 154 154
40 32 150 1/4" 100 18 192 192 184 296 260 174 174 174
50 40 180 1/4" 110 18 222 222 210 328 284 194 194 194
63 50 180 1/4" 125 18 266 266 248 370 321 224 224 224
z for
d DN L(9) L2 H H1 H2 H3 H4 H5 H7 M z Hx
L(3)
20 15 130 25 127 14 12 68 25 16 57 M6 96 100 7
25 20 150 25 132 18 12 73 25 16 57 M6 114 118 10
32 25 160 25 167 22 12 93 26 26 69 M6 122 126 13
40 32 180 45 196 26 15 101 36 26 88 M8 140 144 15
50 40 200 45 239 32 15 124 37 26 103 M8 160 164 19
63 50 230 45 251 39 15 137 37 26 103 M8 190 194 23
DIASTAR TenPlus FC (Type 514 - 517)

20 15 96 1/8" 65 14 128 128 128 224 196 124 124 124
25 20 96 1/8" 75 14 152 152 150 250 221 144 144 144
32 25 120 1/8" 85 14 166 166 162 262 234 154 154 154
40 32 150 1/4" 100 18 192 192 184 296 260 174 174 174
50 40 180 1/4" 110 18 222 222 210 328 284 194 194 194
63 50 180 1/4" 125 18 266 266 248 370 321 224 224 224
z for
d DN L(9) L2 H H1 H2 H3 H4 H5 H7 M z Hx
L(3)
20 15 130 25 127 14 12 68 25 16 57 M6 96 100 7
25 20 150 25 132 18 12 73 25 16 57 M6 114 118 10
32 25 160 25 167 22 12 93 26 26 69 M6 122 126 13
40 32 180 45 196 26 15 101 36 26 88 M8 140 144 15
50 40 200 45 239 32 15 124 37 26 103 M8 160 164 19
63 50 230 45 251 39 15 137 37 26 103 M8 190 194 23
430
DIASTAR Ten FO / DA (Type 514 - 517)
20 15 68 1/8" 65 14 128 128 128 224 196 124 124 124
25 20 96 1/8" 75 14 152 152 150 250 221 144 144 144
32 25 96 1/8" 85 14 166 166 162 262 234 154 154 154
40 32 120 1/8" 100 18 192 192 184 296 260 174 174 174
50 40 150 1/4" 110 18 222 222 210 328 284 194 194 194
63 50 150 1/4" 125 18 266 266 248 370 321 224 224 224
z for
d DN L(9) L2 H H1 H2 H3 H4 H5 H7 M z LE Hx
L(3)
mm mm mm mm mm mm mm mm mm mm mm mm mm mm mm
20 15 130 25 101 14 12 60 24 16 43 M6 96 90 100 7
25 20 150 25 132 18 12 73 25 16 57 M6 114 108 118 10
32 25 160 25 143 22 12 84 25 16 57 M6 122 116 126 13
40 32 180 45 173 26 15 99 26 26 69 M8 140 134 144 15
50 40 200 45 214 32 15 119 36 26 88 M8 160 154 164 19
63 50 230 45 226 39 15 132 36 26 88 M8 190 184 194 23
DIASTAR TenPlus FC (Type 519)

d d1 DN DN1 DN2 D D1 L(6) L1 L3 L4 H H3 H4 H5 Hx
20 20 15 15 15 96 1/8" 117 96 162 12 130 71 25 16 7
25 20 20 15 20 96 1/8" 133 108 162 16 131 72 25 16 10
25 25 20 20 20 96 1/8" 133 108 162 16 131 72 25 16 10
32 20 25 15 20 96 1/8" 142 120 162 19 135 76 25 16 10
32 25 25 20 20 96 1/8" 142 120 162 19 135 76 25 16 10
32 32 25 25 25 120 1/8" 145 120 160 19 167 93 26 26 13
40 20 32 15 25 120 1/8" 149 128 180 23 175 101 26 26 13
40 25 32 20 25 120 1/8" 149 128 180 23 175 101 26 26 13
40 32 32 25 25 120 1/8" 149 128 180 23 175 101 26 26 13
40 40 32 32 25 120 1/8" 174 153 180 23 175 101 26 26 13
50 20 40 15 20 96 1/8" 160 134 180 27 148 90 25 16 10
50 25 40 20 25 120 1/8" 160 134 180 28 180 106 26 26 13
50 32 40 25 25 120 1/8" 160 134 180 28 180 106 26 26 13
50 40 40 32 50 180 1/4" 209 169 209 33 249 135 37 26 23
50 50 40 40 50 180 1/4" 209 169 209 33 249 135 37 26 23
63 20 50 15 20 96 1/8" 177 144 180 33 155 96 25 16 10
63 25 50 20 25 120 1/8" 177 144 180 35 187 113 26 26 13
63 32 50 25 25 120 1/8" 177 144 180 35 187 113 26 26 13
63 40 50 32 50 180 1/4" 225 192 220 39 255 141 37 26 23
63 50 50 40 50 180 1/4" 225 192 220 39 255 141 37 26 23
63 63 50 50 50 180 1/4" 225 192 220 39 255 141 37 26 23
90 20 80 15 25 120 1/8" 205 159 190 47 200 126 26 26 13
90 25 80 20 25 120 1/8" 205 159 190 47 200 126 26 26 13
90 32 80 25 25 120 1/8" 205 159 190 47 200 126 26 26 13
90 50 80 40 50 180 1/4" 254 207 250 51 269 155 37 26 23
431
90 63 80 50 50 180 1/4" 254 207 250 51 269 155 37 26 23
110 20 100 15 25 120 1/8" 227 171 190 56 209 135 26 26 13
110 25 100 20 25 120 1/8" 227 171 190 56 209 135 26 26 13
110 32 100 25 25 120 1/8" 227 171 190 56 209 135 26 26 13
110 50 100 40 50 180 1/4" 276 219 250 60 279 165 37 26 23
110 63 100 50 50 180 1/4" 276 219 250 60 279 165 37 26 23
DIASTAR Sixteen FC (Type 519)

20 20 15 15 15 96 1/8" 117 96 162 12 130 71 25 16 7
25 20 20 15 20 96 1/8" 133 108 162 16 131 72 25 16 10
25 25 20 20 20 96 1/8" 133 108 162 16 131 72 25 16 10
32 20 25 15 20 96 1/8" 142 120 162 19 135 76 25 16 10
32 25 25 20 20 96 1/8" 142 120 162 19 135 76 25 16 10
32 32 25 25 25 120 1/8" 145 120 160 19 167 93 26 26 13
40 20 32 15 25 120 1/8" 149 128 180 23 175 101 26 26 13
40 25 32 20 25 120 1/8" 149 128 180 23 175 101 26 26 13
40 32 32 25 25 120 1/8" 149 128 180 23 175 101 26 26 13
40 40 32 32 25 120 1/8" 174 153 180 23 175 101 26 26 13
50 20 40 15 20 96 1/8" 160 134 180 27 148 90 25 16 10
50 25 40 20 25 120 1/8" 160 134 180 28 180 106 26 26 13
50 32 40 25 25 120 1/8" 160 134 180 28 180 106 26 26 13
50 40 40 32 50 180 1/4" 209 169 209 33 249 135 37 26 23
50 50 40 40 50 180 1/4" 209 169 209 33 249 135 37 26 23
63 20 50 15 20 96 1/8" 177 144 180 33 155 96 25 16 10
63 25 50 20 25 120 1/8" 177 144 180 35 187 113 26 26 13
63 32 50 25 25 120 1/8" 177 144 180 35 187 113 26 26 13
63 40 50 32 50 180 1/4" 225 192 220 39 255 141 37 26 23
63 50 50 40 50 180 1/4" 225 192 220 39 255 141 37 26 23
63 63 50 50 50 180 1/4" 225 192 220 39 255 141 37 26 23
90 20 80 15 25 120 1/8" 205 159 190 47 200 126 26 26 13
90 25 80 20 25 120 1/8" 205 159 190 47 200 126 26 26 13
90 32 80 25 25 120 1/8" 205 159 190 47 200 126 26 26 13
90 50 80 40 50 180 1/4" 254 207 250 51 269 155 37 26 23
90 63 80 50 50 180 1/4" 254 207 250 51 269 155 37 26 23
110 20 100 15 25 120 1/8" 227 171 190 56 209 135 26 26 13
110 25 100 20 25 120 1/8" 227 171 190 56 209 135 26 26 13
110 32 100 25 25 120 1/8" 227 171 190 56 209 135 26 26 13
110 50 100 40 50 180 1/4" 276 219 250 60 279 165 37 26 23
110 63 100 50 50 180 1/4" 276 219 250 60 279 165 37 26 23
432
DIASTAR Ten FO / DA (Type 519)
20 20 15 15 15 68 1/8" 117 96 162 12 104 63 24 16 7
25 20 20 15 20 96 1/8" 133 108 162 16 131 73 25 16 10
25 25 20 20 20 96 1/8" 133 108 162 16 131 73 25 16 10
32 20 25 15 20 96 1/8" 142 120 162 19 135 76 25 16 10
32 25 25 20 20 96 1/8" 142 120 162 19 135 76 25 16 10
32 32 25 25 25 96 1/8" 145 120 160 19 143 84 25 16 13
40 20 32 15 25 96 1/8" 149 128 180 23 151 92 25 16 13
40 25 32 20 25 96 1/8" 149 128 180 23 151 92 25 16 13
40 32 32 25 25 96 1/8" 149 128 180 23 151 92 25 16 13
40 40 32 32 25 96 1/8" 174 153 180 23 151 92 25 16 13
50 20 40 15 20 96 1/8" 160 134 180 27 148 90 25 16 10
50 25 40 20 25 96 1/8" 160 134 180 28 156 97 25 16 13
50 32 40 25 25 96 1/8" 160 134 180 28 156 97 25 16 13
50 40 40 32 50 150 1/4" 209 169 209 33 224 129 36 26 23
50 50 40 40 50 150 1/4" 209 169 209 33 224 129 36 26 23
63 20 50 15 20 96 1/8" 177 144 180 33 155 96 25 16 10
63 25 50 20 25 96 1/8" 177 144 180 35 163 104 25 16 13
63 32 50 25 25 96 1/8" 177 144 180 35 163 104 25 16 13
63 40 50 32 50 150 1/4" 225 192 220 39 230 136 36 26 23
63 50 50 40 50 150 1/4" 225 192 220 39 230 136 36 26 23
63 63 50 50 50 150 1/4" 225 192 220 39 230 136 36 26 23
90 20 80 15 25 96 1/8" 205 159 190 47 176 117 25 16 13
90 25 80 20 25 96 1/8" 205 159 190 47 176 117 25 16 13
90 32 80 25 25 96 1/8" 205 159 190 47 176 117 25 16 13
90 50 80 40 50 150 1/4" 254 207 250 51 244 150 36 26 23
90 63 80 50 50 150 1/4" 254 207 250 51 244 150 36 26 23
110 20 100 15 25 96 1/8" 227 171 190 56 185 126 25 16 13
110 25 100 20 25 96 1/8" 227 171 190 56 185 126 25 16 13
110 32 100 25 25 96 1/8" 227 171 190 56 185 126 25 16 13
110 50 100 40 50 150 1/4" 276 219 250 60 254 160 36 26 23
110 63 100 50 50 150 1/4" 276 219 250 60 254 160 36 26 23
ABS
Technical data
lar media.
At operating temperatures below 0 °C,
please retighten to the prescribed tighten-
ing torque of the diaphragm after commis-
sioning, if necessary.

433
PP PVDF
P Permissible pressure in bar, psi P Permissible pressure in bar, psi

T Temperature in °C, °F T Temperature in °C, °F
1) Depending on connection type and actuator, the nominal 1) Depending on connection type and actuator, the nominal
pressure is reduced to PN6 pressure is reduced to PN10
PN16 only with black PPS housing nut

Pressure loss
PVC-U Type 514...517

1) Only with black PPS housing nut
2) Depending on connection type and actuator, the
3) nominal pressure is reduced to PN10 x Flow rate in l/min
Depending on connection type and actuator, the y Pressure loss Δp = 1bar
nominal pressure is reduced to PN6
PVC-C
Type 514...517

pressure is reduced to PN6 x Stroke in %
y kv, Cv value in %
434
Type 519 63 50 50 40 610
63 63 50 50 747
90 20 80 15 82
90 25 80 20 103
90 32 80 25 129
90 50 80 40 623
90 63 80 50 696
110 20 100 15 78
110 25 100 20 103
110 32 100 25 131
x Stroke in % 110 50 100 40 604
y kv, Cv value in %
110 63 100 50 661
kv 100 values
Control pressure diagram
The kv values for each intermediate valve position can be The following diagrams show the control pressurede-
determined by using the flow value characteristics and the kv
100 values.
pending on the nominal pressure PN.
Type 514 - 517 DIASTAR Six, FC with EPDM diaphragm
kv [l/min] Δp =
d [mm] DN [mm]
1bar
20 15 125
25 20 271
32 25 481
40 32 759
50 40 1263 (960*)
63 50 1728 (1181*)
* DIASTAR SIX
Type 519 DIASTAR Ten, FC with EPDM diaphragm

d1 [mm] kv [l/min]
d [mm] DN [mm] DN1[mm]
Δp = 1bar
20 20 15 15 57
25 20 20 15 89
25 25 20 20 118
32 20 25 15 80
32 25 25 20 105
32 32 25 25 231
40 20 32 15 85
40 25 32 20 119
40 32 32 25 153 DIASTAR Ten, FC with PTFE diaphragm
40 40 32 32 187
50 20 40 15 86
50 25 40 20 160
50 32 40 25 206
50 40 40 32 524
50 50 40 40 667
63 20 50 15 84
63 25 50 20 150
63 32 50 25 184
63 40 50 32 471
435
DIASTAR Ten, FO and DA with EPDM diaphragm DIASTAR Sixteen, FC with EPDM diaphragm
DIASTAR Ten, FO and DA with PTFE diaphragm DIASTAR Sixteen, FC with PTFE diaphragm
DIASTAR TenPlus, FC with EPDM diaphragm Application in vacuum

Use of the diaphragm valve with static pressure:
• 0.5 bar
DIASTAR TenPlus, FC with PTFE diaphragm
436
Pressure levels
Type Six FC Ten DA/FO Ten FC
Valve body ma- PVC-U, PVC-C, ABS, PP-H PVC-U, PVC-C, ABS, PVC-U, PVC-C, ABS,
terial PP-H, PVDF, PVDF-HP PP-H, PVDF, PVDF-HP
Pressure level EPDM PTFE Control pres- EPDM PTFE Control pres- EPDM PTFE Control pres-
sure sure sure
20DN15 6 bar - 6 bar 10 bar 10 bar 5 bar 10 bar 10 bar 6 bar
Working pres- -> - -> -> -> ->
sure
Type TenPlus FC Sixteen FC

Valve body ma- PVC-U, PVC-C, ABS, PVC-U, PVDF, PVDF-HP
terial PP-H, PVDF, PVDF-HP
Pressure level EPDM PTFE Control pres- EPDM PTFE Control pres-
sure sure
20DN15 10 bar 10 bar 6 bar 16 bar 16 bar 6 bar
Working pres- -><- -><- -> ->
sure
437
Type of actuation
Function FC, FO, DA
Function FC Function FO Function DA
In the non-operative state, the valve is In the non-operative state, the valve is The valve has no defined basic position.
closed by spring force. When the ac- open by spring force. When the actuator The valve is opened and closed by ap-
tuator is pressurised with the control is pressurised with the control medium plying controlpressure to the correspond-
medium (bottom connection), the valve (top connection), the valve closes. When ing connection (top connection for clos-
opens. When the control medium es- the control medium escapes, the valve is ing, bottom connection for opening).
capes, the valve is closed by the spring opened by the spring force.
force.
Selection of solenoid valve and associated connecting thread
3/2-way solenoid valves are used to con- 3/2-way solenoid valves are used to con- 4/2-way or 5/2-way solenoid valves are
trol single acting actuators (FC). They trol single acting actuators (FO). They used to control double acting actuators
are mounted either directly to the actu- are mounted either directly to the actu- DA. They can be mounted either direct-
ator via a banjo screw or via a battery ator via a banjo screw or via a battery ly to the actuator via a Namur connector
mounting plate or valve cluster, as re- mounting plate or valve cluster, as re- plate or via valve clusters.
quired. quired.
FC mode of operation with a 3/2-way FO mode with a 3/2-way solenoid valve The DA mode with a 4/2- or 5/2-way
solenoid valve for bottom connection for top connection solenoid valve. Both connections are
used.
Air connection
Six (FC) Ten (FC/ FO / DA) Ten Plus (FC) Sixteen (FC)
20DN15 1/8" 1/8" 1/8" 1/8"
25DN20 1/8" 1/8" 1/8" 1/8"
32DN25 1/8" 1/8" 1/8" 1/8"
40DN32 1/8" 1/8" 1/4" 1/4"
50DN40 1/8" 1/4" 1/4" 1/4"
63DN50 1/8" 1/4" 1/4" 1/4"
Relation between line pressure and spring sets

The closing force of the actuators were designed for the
specified PN pressure level. Operation with very low line
pressure can cause increase diaphragm wear. In order
to extend the diaphragm life span with low line pressure,
the number of spring packages can be reduced. For the
specific dimensioning, please contact your representa-
tive at Georg Fischer Piping Systems.
438
Control medium
Function FC Function FO Function DA
• 6 bar max. for FC mode; lower • 5 bar max. for the FO mode. For • 5 bar max. for the DA mode. For
control pressure possible due to DN50 and from a line pressure of DN50 and from a line pressure of
reduced spring sets 10 bar, the max control pressure is 10 bar the max. control pressure is
• Compressed air classes (ISO 6 bar. 6 bar.
8573-1) 2 or 3 for -10 °C and 3 or • When the medium pressure ex- • When the medium pressure ex-
4 for T ›0 °C ceeds 10 bar, the control pressure ceeds 10 bar, the control pressure
• Temperature of control medium, must be throttled by exhaust air must be throttled by exhaust air
max. 40 °C (adjust actuating time to approx. (adjust actuating time to approx. 3
3 s). s).
• When the medium pressure ex-
ceeds 10 bar, the control pressure • Compressed air classes (ISO • Compressed air classes (ISO
must be throttled by exhaust air 8573-1) 2 or 3 at -10 °C and 3 or 4 8573-1) 2 or 3 at -10 °C and 3 or 4
(adjust actuating time to approx. at T ›0 °C at T ›0 °C
3 s). • Temperature of control medium, • Temperature of control medium,
• The corresponding control pres- max. 40 °C max. 40 °C
sure diagrams can be found in the • Depending on the working pres- • Depending on the working pres-
Chapter "Technical data" sure PN, lower control pressures sure PN, lower control pressures
may be selected may be selected
• The corresponding control pres- • The corresponding control pres-
sure diagrams can be found in the sure diagrams can be found in the
Chapter "Technical data" Chapter "Technical data"
Control volume
Six (FC) Ten (FC) Ten (FO) Ten (DA) TenPlus (FC) Sixteen (FC)
[dm³] [dm³] [dm³] [dm³] [dm³] [dm³]
closed open
20DN15 0.07 0.07 0.07 0.07 0.07 0.20 0.20
25DN20 0.20 0.20 0.20 0.20 0.20 0.20 0.20
32DN25 0.22 0.22 0.23 0.23 0.22 0.40 0.40
40DN32 0.40 0.40 0.44 0.44 0.40 0.78 0.78
50DN40 0.44 0.77 0.86 0.86 0.77 0.85 0.85
63DN50 0.44 1.20 1.52 1.52 1.20 1.33 1.33
Angle a for types 514... 517

Installation angle for optimal draining of the
valve d20DN15 2
In order to achieve optimal drainage of these diaphragm d25DN20 2
valves, GF recommends installing them at the angles (a
and b), which correspond to the respective dimension d32DN25 3
ranges. An installation inclination of about 1 - 2° is not d40DN32 4
taken into consideration with the stated angles.
d50DN40 5
D63DN50 7
439
PP- mounting plate for diaphragm valves
The mounting plates are designed to allow differently
sized GF diaphragm valves to be aligned on the same
pipe centre line by equalising the different heights from
the base to the centre line of the pipe. The plates can
also be used for the PVC diaphragm valve of type 514
for equalising the union nut with the mounting surface.
• Material: PP GF 15, black
• 5 sizes, numbered from 1 to 5
• Can be plugged together to achieve the desired
height

Dimensions
Angle b for types 514 .. 517

d20DN15 27
d25DN20 24
d32DN25 25
d40DN32 23
d50DN40 24
D63DN50 22
Emptying angle for type 519 is 90°, independent of

the dimension
Angle for type 519
Integrated fastening and PP-mounting plate

Integrated mounting
The diaphragm valve includes a built-in mounting. With
this, the forces that can occur when operating the valve
(e.g. breakaway torque) are absorbed. Due to the inte-
grated mounting, operation forces are not transmitted to
the piping system.
440
Mounting Diaphragm valve Dimension [mm]
plate No.
Dimension inch H1 H L L1 L2 L3 D
1 DN15 - 25 1/2'' - 1'' 4.50 11.00 46.50 42.00 25.00 17.00 7.50
2 DN15 - 25 1/2'' - 1'' 3.50 7.00 46.50 42.00 25.00 17.00 7.50
3 DN15 - 25 1/2'' - 1'' 13.50 17.00 46.50 42.00 25.00 17.00 7.50
4 DN32 - 50 1 1/4'' - 2'' 6.75 16.75 80.00 66.50 45.00 22.00 9.50
5 DN32 - 50 1 1/4'' - 2'' 6.75 13.25 80.00 66.50 45.00 22.00 9.50
Dimensions
The length of the mounting screws is calculated by
adding the length of the thread in the valve base to the
height of the plate and the thickness of the mounting
bracket. Mounting brackets No. 1 and 4 are for plugging
directly into the valve base.
Equalising the mounting height
Quantity required x Mounting plate number
from DN... ...to DN
15 20 25 32 40 50 65

15 1x1 1x1+1x2 1x1+2x2 1x1+1x3 1x1+2x2+1x3 1x1+2x3
20 1x1 1x1+1x2 1x1+3x2 1x1+1x2+1x3 1x1+3x2+1x3
25 1x1 1x1+2x2 1x1+1x3 1x1+2x2+1x3
32 1x4 1x4+1x5 1x4+2x5
40 1x4 1x4+1x5
50 1x4
441
Equalising the union height for type 514
Dimension Quantity required x H [mm] H1 [mm]

[mm] plate number
15 1 x1 + 2 x 2 22.50 11.50
20 1x1+2x2 29.00 11.50
25 1x1+2x2 32.50 11.50
32 1x4+1x5 39.00 13.50
40 1x4+1x5 46.00 13.50
50 1x4+1x5 52.50 13.50
Flexible air connection

Due to the round geometry of the diaphragm valve, the
air terminals of the drive can be positioned as desired in
90 degree increments.
Maintenance intervall
We recommend regular inspection of the diaphragm
and the valve body, at the latest after:
• 100,000 operations at less than 10 bar nominal pres-
sure at 20 °C and water
• 50,000 operations at more than 10 bar nominal pres-
sure at 20 °C and water
If the flow medium should show increased tempera-
tures, chemicals, or abrasion with particles, we recom-
mend more frequent monitoring. The diaphragm can be
controlled by professionally dismounting the housing
nut.
442
DIASTAR 025 DN65 - DN150
Dimensions
d DN D D1 (G) D2 D3 D4 L L2 L3 H H1 H2 H3 H9 H10 Stroke
75 65 280 1/4 185 M8 145 290 70 - 298 148 24 46 46 15 30
90 80 280 1/4 200 M12 160 310 120 - 302 150 24 46 57 15 35
110 100 335 1/4 225 M12 180 350 120 - 409 176 24 46 69 20 40
160 150 335 1/4 285 M12 240 480 100 200 201 237 24 46 108 20 40
Pressure-temperature diagram PVDF

PP-H
1) Diastar 025 DN100 and DN150

2) Higher temperature after consultation
p Permissible pressure in bar, psi
1) Diastar 025 DN100 and DN150 T Temperature in °C, °F
p Permissible pressure in bar, psi
T Temperature in °C, °F Pressure loss
In case of applications with temperatures in the range of the
dotted lines, please contact your GF representative DIASTAR 025 DN65 - DN150 at Wasser 20 °C
PVC-U
1) Diastar 025 DN100 and DN150

p Permissible pressure in bar, psi x Flow rate in l/min
y Pressure loss Δp = 1bar
443
Control volume DIASTAR 025 DN65 - DN150

Nominal di- FC FO DA
ameter [dm³] [dm³] [dm³]
closed open
75DN65 2.20 4.40 4.40 2.20
x Stroke in %
y kv 100 value in % 90DN80 2.20 4.40 4.40 2.20
110DN100 3.80 7.60 7.60 3.80
kv 100 values
160DN150 3.80 7.60 7.60 3.80
DIASTAR 025
DIASTAR 025
Kv [l/min]
d [mm] DN [mm]
Δp = 1 bar Connections for solenoid valves
75 65 992
Nominal di-
FC FO DA
90 80 1700 ameter
110 100 2700 75DN65 G1/4"
160 150 6033 90DN80 G1/4"
110DN100 G1/4"
Control pressure diagram
160DN150 G1/4"
Control medium
Function FC with EPDM diaphragm
• 6 bar max for the function FC
• 5 bar max. for the functions FO and DA
• Control medium: oil-free compressed air or neutral
non-aggressive gases
• Temperature of control medium: max. 40 °C
• Depending on the working pressure PN, lower control
pressure may be selected Please observe the control
pressure diagrams
Control volume
Nominal di- FC FO DA
Function FC with PTFE diaphragm ameter [dm³] [dm³] [dm³]
closed open
75DN65 2.20 4.40 4.40 2.20
90DN80 2.20 4.40 4.40 2.20
110DN100 3.80 7.60 7.60 3.80
160DN150 3.80 7.60 7.60 3.80
Accessories
The DIASTAR can be made to fit your application even
better with the accessories we offer. The following
Function FO or DA with EPDM / PTFE diaphragm pages provide an overview of the accessories. More de-
tailed information can be found in the chapter "Acces-
sories for pneumatic actuators" in the Georg Fischer
Planning Fundamentals.
444
Stroke limiter / Emergency manual override MNL 532
3/2 and 5/2-way solenoid valve for activating a double acting
The stroke limiter can be used for limiting the minimum and pneumatic actuator. The mounting takes place via a NAMUR
maximum stroke as well as for the emergency manual over- connection. For the dimension range DIASTAR DN15-DN50,
ride. With the help of adapters, the stroke limiter can also be a Namur mounting plate needs to be installed between the
used together with our electrical position indicator ER52/53 actuator and the pilot valve:
• 230 V, 50-60 Hz
• 115 V, 50-60 Hz
• 48 V, 50-60 Hz
• 24 V, 50-60 Hz
• 24 VDC
Solenoid pilot valve

Type PV94
3/2-way solenoid valve for controlling single acting pneumat-
ic actuators in the dimensions DN15-DN50. Mounted with a
banjo screw directly on the actuator. For the air connection, a
G1/8", G1⁄4" and 6 mm hose coupling is available. The PV94
can be ordered for the following voltages:
• 230 V, 50-60 Hz
PV2000
• 115 V, 50-60 Hz For simultaneous controlling of several actuators, we offer
• 24 V, 50-60 Hz the PV2000 valve cluster. The cluster consists of a connect-
ing module, several pilot valves and an end module. De-
• 24 VDC
pending on the application you can choose a connecting
module for D-sub connection, AS interface or Profibus. The
modular system allows combining 3/2 and 5/2-way valves as
required by the application.
Type PV95
3/2-way solenoid valve for controlling single acting pneumat-
ic actuators in the dimensions DN65-DN150. Mounted with a
banjo screw directly on the actuator. For the air connection, a Feedback
G1/8" and G1⁄4" is available. The solenoid valve is available
in the dimensions DN1.5 and DN2 as well as with the follow- ER55
ing voltages: The ER55 has a Reed contact, which is activated via a mag-
• 230 V, 50-60 Hz net in the position indicator. The Reed contact can be set so
that either the open or closed position is indicated. To show
• 115 V, 50-60 Hz both positions, the ER55 can be retrofitted with a second
• 24 V, 50-60 Hz Reed contact.
• 24 VDC
445
ER52 and ER53 Bus communication
The ER52/53 is an electrical position indicator device with
two limit switches and can therefore indicate both, the open AS Interface
and the closed position. The limit switches are activated with Modern plants with conventional valve control require more
cams which are self-adjusting. The ER52/53 is available with and more installation and maintenance efforts. The GF AS-
the following limit switches: i controller enables state-of-the-art bus communication with
minimum effort. The controller contains all the necessary
• Silver-nickel (AG-Ni) electric and pneumatic components. Only a serial cable and
• Gold contacts (AU) the air connections is all that is to be installed, in order to be
able to independently control up to 62 valves.
• Inductive switch NPN
• Inductive switch PNP
• Inductive switch NAMUR
Positioner
DSR 500
The digital positioners of type DSR500 is the ideal prod-
uct for future control applications using our pneumatic
valves. The microprocessor controlled positioners fea-
ture a very compact and uncomplicated design that sim-
plifies installation. The positioners are supplied with or
without optical indicator.
446
Fundamentals for butterfly valve, hand operated
Page

Butterfly valve type 567/568 DN50 - DN600
-- Overview 448
-- Graph 450
-- Accessories 459
Butterfly valve type 037/038/039
-- Overview 461
-- Graph 464
447
Fundamentals for butterfly

valve, hand operated
Butterfly valve type 567/568 DN50 -
DN600
Overview
Product description
Industrial water treatment, drinking water treatment,
swimming pools, aquariums, oceanaria and wastewater
technology are typical applications of butterfly valves-
from Georg Fischer Piping Systems. In most applica- Butterfly valve with Butterfly valve with
tions of the chemical industry, chemical trade, galvaniz- fine adjustment reduction gear
ing and power plants, extremely aggressive media have
to be transported. Often, the combination of aggressive Product features
chemicals and entrained solids lead to abrasion and
corrosion problems, especially with butterfly valves. But- • 50% lower actuation torque compared to a centric but-
terfly valves type 567/568 are compact, flexible and reli- terfly valve due to the double eccentric operating prin-
able shut-off valves for wafer and lugstyle applications. ciple
Our system's modular design principle allows you to ex-
change individual system components – fast, easily and • Noticably reduced abrasion
at very little expense and effort. The butterfly valves are • Integrated electric position indicator in the mounting
available in various materials and sizes, so you will al- flange
ways find the right material for your application or medi- • Optimized gaskets
um. • All components which are in contact with the medium
Versions are made of piping material, consequently the perme-
Georg Fischer presents the new 567/568 type series of ation can be minimized
butterfly valves with a comprehensive range of products • Functional hand lever made of glass-fiber-reinforced
and a multitude of interesting combination possibilities. polypropylene (PP-GF 30) with 5° ratchet setting,
We can offer you, for example, manual valves with hand lockable
lever or reduction gear. Our system's modular design • Dimensions up to DN 600
principle allows you to exchange individual system com-
ponents – fast, easily and at very little expense and ef- • Flexibility thanks to modular design
fort. You also have a choice of materials: PVC-U, PVC- • Standard interface according to ISO 5211
C, ABS, or PP-H and PVDF. Our standard sealing ma- • For all common standards: DIN/EN/ISO, ANSI/BS, JIS
terials are EPDM, FPM and PTFE/FPM. Other materials
are available on request.
Standard Lug-type butterfly

Standard Wafer-type butter- valve/ end installation Type
fly valve Type 567 568
448
Overview
General Type 567 568
Waferstyle Lugstyle
Dimension DN 50 - 600 50 - 200
Pressure range PN Until DN300 PN10
DN350 - 400 PN6
DN450 - 600 PN4
Materials used Shaft V2A / SS304
Outside housing Type 567: PP-GF30
Type 568: GG40
Hand lever PP-GF30
PVC-C + +
ABS + +
PP-H + +
PVDF + +
Connection types Flanges + +
Diaphragm materials EPDM + +
FPM + +
PTFE / FPM + +
Accessories Integrated electric feedback in the mounting flange
Intermediate elements
Lever with fine adjustment
Safety information
DANGER
butterfly valve. They should identify the hazards and ad-
vice that should be considered for the different uses and
Butterfly valve as end valve
installation/commissioning.
When the butterfly valve is opened as end
valve with the piping system under pressure,
NOTICE the medium may escape uncontrollably! Con-
sequences can be death or serious injury.
• The end valve of a piping system under
Intended use pressure shall only be opened, when the
• Butterfly valves are not recommended for medium can be safely collected or diverted,
media containing solids. In control opera- and when splashing around can be avoid-
tions, cavitation is to be avoided. ed through corresponding measures.
• In case of degreasing or sticking media,
butterfly valves can only be used after con-
sultation with a GF Piping Systems repre-
sentative.
DANGER
• Type 568 to be used as intermediate instal-
lation valve or as end valve. Opening or closing the valve
Death or serious injury by jerky opening or
closing the valve
• Avoid pressure surges in the piping sys-
tem, especially when use the hand lever.
• For applications with high flow velocities for
manual actuation, use the manual gearbox
version.
449
DANGER CAUTION
Correct installation Pressure test and commissioning

Due to incorrect installation, injuries or death Butterfly valve pressure testing is subject to
can occur. the same regulations as the piping systems.
• Make sure that the butterfly valves to be in- • Check that all valves are in the required
stalled correspond specifically to the pres- open or closed position.
sure rating, type of connection, dimension • Fill the piping system and deaerate com-
and materials of the particular application. pletely.
• Carry out a function test: close the butterfly • Pressure must not exceed the value of 1.5
valve and open it again. x PN
• Do not install a butterfly valve which does • The valves and connections should be
not function properly. checked for a tight seal during the pressure
test.
NOTICE Graph
Exploded view butterfly valve
Handling of the seals DN50 - DN300
All sealings (material e.g. EPDM, FPM ) are
of organic materials and react to environmen-
tal influences.
• They must be stored in their original pack-
aging if possible in a cool, dry and dark
place.
• Before installing them, the sealings have to
be checked on possible ageing damages,
such as fissures and hardenings.
• Damaged sealings and spare parts must
not come into operation.
DANGER
Improper lubricants can corrode the material
of the butterfly valve or seal. Consequences 1 Wafer housing
can be death or serious injuries.
2 Inner body
• Never use mineral oil-based greases or 3 Disc
Vaseline (Petrolatum)!
• For clean silicone-free butterfly valves, ob- 4 End stop
serve the special manufacturer’s informa- 5 Bush
tion. 6 Shaft
• All seals should be lubricated with a sili- 7 Large retaining ring
con-based grease.
8 Washer
9 Small retaining ring
10 Cap
11 O-ring
12 Flange seal
13 Profile sealing
450
DN350 - DN600 Exploded view hand lever
1 Wafer housing
2 Snap ring
3 Disc
5.1 Bush
5.2 Bush 1 Hand lever clip
2 Hand lever
6 Shaft 3 Spring
4 Hand lever catch
7 Circlip 5 Screws
8 Washer 6 Index plate
7 Insert
10 Cap 8 Washer
9 Nuts
11.1 O-ring
11.2 O-ring Dimensions of type 567 with bare shaft end
12 Flange seal DN50 - DN300
13 Profile sealing
14 Feather key
15 Actuator interface
16 Mounting screw
451
d DN D D1 min D1 max DN350- DN600
mm mm mm mm mm
63 50 19 120.0 125.0
75 65 19 139.7 145.0
90 80 19 150.0 160.0
110 100 19 175.0 190.5
140 125 23 210.0 215.9
160 150 24 241.3 241.3
225 200 23 290.0 295.0
280 250 25 353.0 362.0
315 300 25 400.0 432.0
d d2 D3 D4 H
mm mm mm mm mm
d DN inch PN D1 D1 d2
63 104 70 90 222
min max
75 115 70 90 235 mm mm mm mm mm
90 131 70 90 247 d355 DN350 14" 6 445 477 535
110 161 70 90 287 d400 DN400 16" 6 510 540 595
140 187 70 90 313 d450 DN450 18" 5 565 578 635
160 215 70 90 335 d500 DN500 20" 4 620 635 700
225 267 70 90 387 d630 DN600 24" 4 725 750 813
280 329 102 125 509
315 379 102 125 553 d H1 H2 H3 H4
mm mm mm mm mm
d H1 H2 H3 H4 d355 268 410 31 100
mm mm mm mm mm d400 300 435 31 100
63 77 134 27 23 d450 320 520 35 120
75 83 140 27 23 d500 350 550 35 120
90 89 146 27 23 d630 420 610 35 120
110 104 167 16 23
140 117 181 16 23
160 130 189 19 23
225 158 210 19 23
280 205 264 40 23
315 228 285 40 23
d H5 L Q1 Q2

mm mm mm mm mm
63 11 45 40 -
75 11 46 54 35
90 11 49 67 50
110 14 56 88 74
140 14 64 113 97
160 17 72 139 123
225 17 73 178 169
280 22 113 210 207
315 22 113 256 253
452
Dimensions of type 567 with hand lever d L L1 L2 Q1 Q2
DN50 - DN300 mm mm mm mm mm mm
63 45 106 205 40 -
75 46 106 205 54 35
90 49 106 205 67 50
110 56 106 255 88 74
140 64 106 255 113 97
160 72 106 255 139 123
225 73 140 408 178 169
280 113 149 408 210 207
315 113 149 408 256 253
Dimensions of type 567 reduction gear with

handwheel
DN50 - DN300
d DN D D1 min D1 max d2

mm mm mm mm mm mm
63 50 19 120.0 125.0 104
75 65 19 139.7 145.0 115
90 80 19 150.0 160.0 131
110 100 19 175.0 190.0 161
140 125 23 210.0 215.9 187
160 150 24 241.3 241.3 215
225 200 23 290.0 295.0 267
280 250 25 353.0 362.0 329
315 300 25 400.0 432.0 379
d H H1 H2 H3

mm mm mm mm mm
d DN D D1 min D1 max
63 264 77 134 54
mm mm mm mm mm
75 277 83 140 54
63 50 19 120.0 125.0
90 289 89 146 54
75 65 19 139.7 145.0
110 325 104 167 55
90 80 19 150.0 160.0
140 352 117 181 55
110 100 19 175.0 190.5
160 373 130 189 55
140 125 23 210.0 215.9
225 435 158 210 67
160 150 24 241.3 241.3
280 554 205 264 85
225 200 23 290.0 295.0
315 598 228 285 85
280 250 25 353.0 362.0
315 300 25 400.0 432.0
453
d d2 D3 H H1 DN 350 - DN600
mm mm mm mm mm
63 104 160 278 77
75 115 160 291 83
90 131 160 303 89
110 161 160 339 104
140 187 160 365 117
160 215 160 387 130
225 267 160 436 158
280 329 160 529 205
315 379 160 573 228
d H2 H3 L L1 L2

mm mm mm mm mm mm
63 134 60 45 120 132
75 140 60 46 120 132
90 146 60 49 120 132
d DN inch PN D1 D1 d2
110 167 60 56 120 132 min max
140 181 60 64 120 132 mm mm mm mm mm mm
160 189 60 72 120 132 d355 DN350 14" 6 445 477 535
225 210 60 73 120 132 d400 DN400 16" 6 510 540 595
280 264 60 113 134 151 d450 DN450 18" 5 565 578 635
315 285 60 113 134 151 d500 DN500 20" 4 620 635 700
d630 DN600 24" 4 725 750 813
d L3 Q1 Q2
mm mm mm mm d D3 H1 H2 H3
63 236 40 - mm mm mm mm mm
75 236 54 35 d355 140 268 410 31
90 236 67 50 d400 140 300 435 31
110 236 88 74 d450 165 320 520 35
140 236 113 97 d500 165 350 550 35
160 236 139 123 d630 165 420 610 35
225 236 178 169
250 261 210 207 Technical data
315 261 256 253 Pressure-temperature diagram
lar media.
454
ABS DN50 - DN300 PVC-U DN50 - DN400
1) DN50 - DN300 1) DN50 - DN300

2) DN350 - 400
PP DN50 - DN300
PVC-C DN50 - DN300
1) DN50 - DN200
1) DN50 - DN300
2) DN250 - DN 300
PVDF and PVDF/PTFE DN50 - DN300
PP DN350 - DN600
1) DN50 - DN300
1) DN350 - 400
2) DN450
3) DN500 - 600
T Temperature in °C, °F Pressure loss
DN50 - DN300

455
DN350 - DN600 Operating torque
DN50 - DN300 for opening / closing (standard valve,
as delivered)

Flow characteristics X Size DN (mm, inch)

DN50 - DN600
Depending on the operation conditions (e.g. operat-
ing speed, fluid, temperature, etc.) the stated operating
torque can increase up to 4 times.
DN350 - DN600
X Open angle (%)

Y kv, CV value (%)
kv 100 values
DN mm DN inch d mm kv 100 Cv 100 kv 100 X Size DN (mm, inch)
l/min US gal./ m³/h Y Torque (Nm, lb-ft)
(Δp = 1 min (Δp (Δp = 1
psi) = 1 psi) bar) Reference values for tightening torque of
screws
50 2 63 1470 103 88
DN50 - DN300
65 2½ 75 2200 154 132
80 3 90 3000 210 180 AK type 567 in ISO flange connections
100 4 110 6500 455 390
d DN inch Total number of Max. closing
125 5 140 11500 805 690 screws torque
150 6 160 16600 1162 1000 in Nm in lb-ft
200 8 225 39600 2772 2380 63 50 2 4 x M16 x 140mm 20 15
250 10 280 51000 3570 3060 75 65 2½ 4 x M16 x 140mm 25 18
300 12 315 73000 5110 4380 90 80 3 8 x M16 x 150mm 15 11
350 14 335 90000 6300 5400 110 100 4 8 x M16 x 180mm 20 15
400 16 400 115000 8050 6900 140 125 5 8 x M16 x 200mm 25 18
450 18 450 155000 10850 9300 160 150 6 8 x M20 x 220mm 35 26
500 20 500 204000 14280 12240 225 200 8 8 x M20 x 220mm 45 33
600 24 630 265000 18550 15900 280 250 10 8 x M20 x 300mm 80 59
315 300 12 12 x M20 x 300mm 80 59
456
AK type 567 in ANSI flange connections
inch d DN Total number of Max. closing
screws torque
in Nm in lb-ft
2 63 50 4 x 5/8 x 3" 27 20
2½ 75 65 4 x 5/8 x 3½" 27 20
3 90 80 4 x 5/8 x 3¾" 27 20
4 110 100 8 x 5/8 x 4" 27 20
5 140 125 8 x 3/4 x 4½" 35 26
6 160 150 8 x 3/4 x 4¾" 45 33
8 225 200 8 x 7/8 x 5¼" 45 33
10 280 250 8 x 7/8 x 6" 72 53
12 315 300 12 x 7/8 x 6½" 72 53
Reference values for tightening torque of screws AK type 568 in ISO flange connections
SFA - BFA with the various flanges Max. closing torque
DN Number PP PVC-U PVDF Torque
Screws PP-V PP/ St PVC-U PP-V PP/St PP-V PP/St in Nm in lb-ft
Total Lmin Lmin Lmin Lmin Lmin Lmin Lmin
50 8 x M16 55 55 50 55 50 55 50 20 15
65 8 x M16 60 60 50 60 50 60 50 25 18
80 16 x M16 60 65 55 60 55 65 55 15 11
100 16 x M16 65 70 60 70 60 70 60 20 15
125 16 x M16 70 80 70 70 70 80 70 25 18
150 16 x M20 80 80 80 80 70 80 80 35 26
200 16 x M20 90 90 90 90 90 90 80 45 33
Reference values for tightening torque of screws AK type 568 in ANSI flange connections
SFA - BFA with the various flanges Max. closing torque
DN Number PP PVC-U PVDF Torque
Screws PP-V PP/ St PVC-U PP-V PP/St PP-V PP/St in Nm in lb-ft
Total Lmin Lmin Lmin Lmin Lmin Lmin Lmin
2 8 x 5/8 55 55 50 55 50 55 50 27 20
2½ 8 x 5/8 55 60 50 60 50 60 50 27 20
3 8 x 5/8 60 65 55 60 55 65 55 27 20
4 16 x 5/8 65 70 60 60 60 70 60 27 20
5 16 x 3/4 70 80 70 70 70 80 70 35 26
6 16 x 3/4 80 80 80 80 70 80 70 45 33
8 16 x 3/4 90 90 90 90 90 90 80 45 33
457
DN350 - DN600 internal pressure – usually between 3 and 6 bar – our
new butterfly valves are ideal for precisely this pressure
AK type 567 range. The maximum allowable nominal pressure at 20
°C is 10 bar.
inch d DN Max. closing
torque Optimised modular components
We practice quality. That’s why we look at each sealing
in Nm in lb-ft function separately, optimising each seal according to
14 355 350 80 59 its particular function.
16 400 400 100 74 We have used three separate sealing elements here:
18 450 450 100 74 • Exterior seal: double, internal shaft seal on both sides
of disc to protect against external leakage
20 500 500 100 74
• Connecting element seal: standard O-rings
24 630 600 100 74
• Disc seal: specially engineered profile seal
Technical features Reduced permeation

All the butterfly valve components that come into con-
The name GF stands for reliability and longevity and tact with the medium, such as disc, inner bodies and
has done so for over 200 years. Our products guaran- bushes, are manufactured of the corresponding pipe
tee quality, innovation and functionality. These qualities material. Your benefit: excellent corrosion and chemical
have also been incorporated in the design of our new resistance.
butterfly valves type 567/568. You will find innovative
ideas in every detail. And every detail meets your spe- New design of functional hand lever
cific needs and requirements – from a safety, technical The type 567/568 butterfly valves have been designed
and business point of view. taking every detail into consideration, even the hand
lever. The following features guarantee even more safe-
Double eccentric operating principle ty:
Making a statement is important. Especially when you • On standard versions, the indexing is in increments
do it with innovative details – like our new butterfly valve of 5 degrees. There are always six teeth engaged be-
type 567/568. tween the ratchet and the index plate. This ensures
Double eccentricity is the answer. accurate and safe positioning of the lever.
• With the fine adjustment option, the disc can be
opened at any angle between 0 ° and 90 °
• The opening angle is clearly indicated in degrees on
the index plate.
• The hand lever is lockable to prevent it from being
moved.
• The hand lever is made of high strength PP-GF
(polypropylene, fiberglass-reinforced)
Most butterfly valves are built according to a concen-
tric operating principle, ours have a double eccentric de-
sign. This means the disc doesn’t touch the seal in the
open position. Thus ensuring low torque and less wear
and tear. In addition, the double eccentric design pro-
tects our butterfly valves even better against pressure
surges. So they have a longer service life and require
less maintenance.
Integrated electrical position feedback
Now, you have a clear overview of your system at all
times. Thanks to our integrated electric position indica-
tor, you always know which valves are open and which
are closed. This contributes greatly to your and your op-
erators’ safety. The new position indicator integrated in
the mounting flange is a totally new feature for butterfly
valves.
This new integrated feedback concept includes a choice
of five different types of limit switches perfectly suited to
your needs.
Lower actuation torque
Our new butterfly valves have an actuation torque which
is up to 50 % lower than that of our previous model or
that of our competitors. They are therefore easier to op-
erate and you can use smaller, more economical actua-
tors. Since the actuation torque largely depends on the
458
or the stubs are already chamfered. If you want ti install
flanged adaptors/stubs of a different brand, then please
make sure that the inside diameter (int) of the flange
adaptor/stub is greater than the output measure (Q1) of
the disc. If necessary, the flange adaptor/stub has to be
chamfered according to the table.

Maintenance
In normal operation, butterfly valves do not require
maintenance. It is enough to control periodically, if there
is no leakage. If the medium escapes at the flange con-
The new butterfly valves in the dimensions DN50 to DN300 nections, refasten these acc. to the table. In case of
have a modular design, offering you a wide range of prod- leakages or other defects, the safety instructions in the
ucts to choose from. instruction manual and in the planning fundamentals
Our attention to detail sets new standards in regard to eco- must be observed.
nomic efficiency, safety and long service life. • We recommend operating the butterfly valves which
are kept permanently in the same position 1 – 2 x a
year to check their functionality.
• Depending on the working conditions, the profile
sealings should be lubricated periodically with a (sili-
con-based) lubricant.
Accessories
The profile seal has been specially engineered for the dou-
ble eccentric operating principle. The use of standard O-rings
Integrated electrical position feedback
for sealing the pipeline makes installation easy. No displace- Functions
ment, falling out or folding over – as is often the case with
other sealing systems.
• Position feedback in combination with actuators
• Also for hand valve and for hand gear versions

General technical data of the position feedback unit
Protection class with DIN plug (2): IP 65
Protection class with cable gland: IP 67
Ambient temperature: -10 °C to +50 °C
Assignment of the position feedback to butterfly
valve type 567/568
By integrating the position indicator in the mounting flange, Shaft Dimension
the valve design was kept small and compact.
The ergonomic and practical design, compactness, and ro- 1 11 mm DN50 to DN80
bust material of the hand lever makes it very operator friend-
ly. 2 14 mm DN100 to DN125
3 17 mm DN150 to DN200

The proven concept of double, bi-directional sealing against
leakage has been implemented which provides maximum
reliability and safety. Due to the use of O-rings in standard
dimensions, an economical solution with high-quality elas-
tomers has been realised.
Chamfering of the flange adaptor/stub

When using the specified flange adaptors/stubs from
GF Piping Systems, a chamfering is not necessary, be-
cause the disc does not touch the flange adaptor/stub
459
Wiring diagram: Type of switch Contact rating Code-No.
Type of switch Contact rating Code-No. Inductive switch 5 – 30 V = 161 486 857
NPN 100 mA DN50 - 80
Microswitch 250 V ~ 161 486 859
Silver nickel 6A DN50 - 80 161 486 303
(Ag Ni) DN100 - 125
161 486 305
DN100 - 125 161 486 008
161 486 010 DN150 - 200
DN150 - 200 Inductive switch 5 – 30 V = 161 486 856
PNP 100 mA DN50 - 80
Microswitch 4 - 30 V = 161 486 858
with gold con- 1 – 100 mA DN50 - 80 161 486 302
tacts DN100 - 125
(Au) 161 486 304
DN100 - 125 161 486 007
161 486 009 DN150 - 200
DN150 - 200 Connection diagram:
Connection wiring diagram A closed
B open
A closed
C blue
B open
D black
C black
E black
D blue
F brown
E blue
Type of switch Nominal ratings Code-No.

Inductive 8 V= 161 486 855
switch DN50 - 80
Namur
161 486 301
Approvals: DN100 - 125
ATEX 2032x,
161 486 006
CSA EMV ac-
DN150 - 200
cording to
EN 60947-5-2
Standard con-
formity EN
60947-5-6
Connection diagram:
A closed
B open
C blue
D brown
460
Butterfly valve type 037/038/039 Butterfly valve type 037 with hand lever with step-
less fine adjustment
Overview
Product description
Metal butterfly valves are ideal for shutting off and con-
trolling the flow of liquid media in pipelines. They offer
high temperature and pressure resistance as well as
outstanding resistance to corrosion. Simply a high-per-
formance valve that is reliable and durable. Applications
- including the dimensions DN350 to DN1200 - can be
found in water treatment and the chemical process in-
dustry.
Versions
The metal butterfly valves type 037/038/039 can be uni-
versally used as open/close or control valve. The easy
installation of the valves between pipe flanges warrants Butterfly valve type 038 with hand lever
reliable operation and sealing. The lightweight alumini-
um valve body has special advantages in transport and
installation.
The Rilsan® coating of the valve body and the ductile
iron valve disc provide high resistance against corro-
sion. The butterfly valves are also available in a stan-
dard version with stainless steel valve disc.
The butterfly valves are available as manually operated
valves with hand lever or manual reduction gear, but al-
so with electric or pneumatic actuator. They can be eas-
ily retrofit anytime, even when the valve is mounted.
Butterfly valve type 037 with manual reduction gear Butterfly valve type 038 with manual reduction gear
Butterfly valve type 039 with manual reduction gear

Butterfly valve type 037 with hand lever
461
Butterfly valve type 039 with hand lever
Product features
• Good flow characteristics
• Rilsan®/Epoxy coating: High chemical resistance
• Easy installation
• Space-saving installation
• Large dimensions to DN1200
• Compact design
• Varied applications
• Low maintenance and high cost efficiency
• KTW / WRAS certification
Overview
General Type 037 038 039
Waferstyle Lugstyle Waferstyle
Dimension DN DN50 - DN300 DN50 - DN300 DN50 - DN1200
Nominal pressure PN 10 16 /10 16
Temperature range -10 °C to +120 °C depending on model
to +80 °C with folding plate with Rilsan ® coating
Materials used Valve housing Up to DN 300: Alu- Ductile cast iron ASTM Ductile cast iron ASTM
minum ASTM S12A, A395 M:88, Epoxy coat- A395 M:88, Epoxy coat-
Rilsan® -coated ed ed
Disc Ductile cast iron ASTM A395 M:88, Rilsan®-coated
From DN350 to DN1200: ductile cast iron ASTM A395 M:88, Epoxy coated
Optional: Stainless Steel 1.4408/ASTM A351 CF8M
Alu-Bronze on request
Collar EPDM and FPM
CSM, NBR, EPDM <High Temp>on request
Shaft Stainless Steel 1.4021/AISI 420
Stainless Steel 1.4401/AISI 316 on request
<Chevron>shaft seal Buna-N
Bush with Up to DN500 natural nylon
safety clip From DN600 to DN1200 bronze
Screw Out of stainless steel (DIN-7991), securing the bush
Actuator Up to DN 300 hand lever, manual reduction gear, pneumatic and electric ac-
tuator
From DN 350 with manual reduction gear, pneumatic and electric actuator
Hand lever Aluminium
Connection types Flanges + + +
Accessories Lever with fine adjustment
Mechanical limit switch box
462
Safety information
The following safety instructions apply specifically to the DANGER
butterfly valve. They should identify the hazards and ad-
vice that should be considered for the different uses and
installation/commissioning. Correct installation
Due to incorrect installation, injuries or death
can occur.
NOTICE
• Make sure that the butterfly valves to be in-
stalled correspond specifically to the pres-
Intended use sure rating, type of connection, dimension
and materials of the particular application.
• Butterfly valves are not recommended for • Carry out a function test: close the butterfly
media containing solids. In control opera-
valve and open it again.
tions, cavitation is to be avoided.
• Do not install a butterfly valve which does
• In case of degreasing or sticking media, not function properly.
butterfly valves can only be used after con-
sultation with a GF Piping Systems repre-
sentative.
• Type 038 to be used as intermediate instal- NOTICE
lation valve or as end valve.

All sealings (material e.g. EPDM, FPM ) are
DANGER
of organic materials and react to environmen-
tal influences.
Butterfly valve as end valve • They must be stored in their original pack-
When the butterfly valve is opened as end aging if possible in a cool, dry and dark
valve type 038 with the piping system under place.
pressure, the medium may escape uncontrol- • Before installing them, the sealings have to
lably! Consequences can be death or serious be checked on possible ageing damages,
injury. such as fissures and hardenings.
• Damaged sealings and spare parts must
• The end valve of a piping system under not come into operation.
pressure shall only be opened, when the
medium can be safely collected or diverted,
and when splashing around can be avoid-
ed through corresponding measures. DANGER
• If the valve of type 038 is used as an end
valve, the allowable operating pressure is
reduced to a maximum of 5.6 bar. Selection of lubricants
of the butterfly valve or seal. Consequences
can be death or serious injuries.
DANGER
• Never use mineral oil-based greases or
Opening or closing the valve • For clean silicone-free butterfly valves, ob-
Death or serious injury by jerky opening or serve the special manufacturer’s informa-
closing the valve tion.
• Avoid pressure surges in the piping sys- con-based grease.
tem, especially when use the hand lever.
• For applications with high flow velocities for
manual actuation, use the manual gearbox
version.
463
Dimensions
CAUTION
Pressure test and commissioning

Butterfly valve pressure testing is subject to
the same regulations as the piping systems.
• Check that all valves are in the required
open or closed position.
• Fill the piping system and deaerate com-
pletely.
• Pressure must not exceed the value of 1.5
x PN
• The valves and connections should be
checked for a tight seal during the pressure
test.
Graph
Exploded view
Butterfly valve Type 037

1
d DN inch kg (Nm) Q
mm mm mm
63 50 2" 1.1 24 32
75 65 2 ½" 1.5 30 51
90 80 3" 1.7 39 69
110 100 4" 2.6 59 89
140 125 5" 3.4 78 115
1 Valve housing 160 150 6" 4.9 98 143
2 Valve disc 225 200 8" 7.4 157 194
3 Collar 280 250 10" 15.0 209 243
4 Shaft
315 300 12" 19.0 301 293
5 Shaft sealing
6 Bush
7 Ten-position plate
8 Screw for bush
9 Hand lever
464
1 Butterfly valve type 038
d DN inch L H H 1 H 2 1
mm mm mm mm mm mm d DN inch kg (Nm) Q
63 50 2" 43 232 53 140 mm mm mm
75 65 2 ½" 46 254 63 152 63 50 2" 3.2 24 32
90 80 3" 46 269 71 159 75 65 2 ½" 4.3 30 51
110 100 4" 52 311 87 178 90 80 3" 6.0 39 69
140 125 5" 56 339 102 191 110 100 4" 8.0 59 89
160 150 6" 56 375 122 203 140 125 5" 9.8 78 115
225 200 8" 60 424 149 241 160 150 6" 11.5 98 143
280 250 10" 68 513 201 273 225 200 8" 18.3 157 194
315 300 12" 78 592 231 311 280 250 10" 31.5 209 243
315 300 12" 48.3 301 293
2
d DN inch Type d 1 d 2 d 3 H 3 1
mm mm mm mm mm mm d DN inch L H H 1 H 2
63 50 2" F-07 9 70 90 13 mm mm mm mm mm mm
75 65 2 ½" F-07 9 70 90 13 63 50 2" 43 215 63 140
90 80 3" F-07 9 70 90 13 75 65 2 ½" 46 241 73 152
110 100 4" F-07 9 70 90 16 90 80 3" 46 256 81 159
140 125 5" F-07 9 70 90 16 110 100 4" 52 295 97 178
160 150 6" F-07 9 70 90 17 140 125 5" 56 323 112 191
225 200 8" F-07 9 70 90 17 160 150 6" 56 358 122 203
280 250 10" F-10 11 102 125 17 225 200 8" 60 423 149 245
315 300 12" F-10 11 102 125 17 280 250 10" 68 521 203 275
315 300 12" 78 559 241 315
3
d DN inch H 4 d 4 ΦS 2
mm mm mm mm mm d DN inch Type d 1 d 2 d 3 H 3
63 50 2" 26 13.2 11 mm mm mm mm mm mm
75 65 2 ½" 26 13.2 11 63 50 2" F-07 9 70 90 12
90 80 3" 26 13.2 11 75 65 2 ½" F-07 9 70 90 12
110 100 4" 30 16.8 14 90 80 3" F-07 9 70 90 12
140 125 5" 30 16.8 14 110 100 4" F-07 9 70 90 14
160 150 6" 33 20.4 17 140 125 5" F-07 9 70 90 14
225 200 8" 33 20.4 17 160 150 6" F-07 9 70 90 15
280 250 10" 47 28 22 225 200 8" F-07 9 70 90 15
315 300 12" 47 28 22 280 250 10" F-10 12 102 125 17
315 300 12" F-10 12 102 125 17
1 Butterfly valve
kg = net weight
Nm = closing torque
Q = disc outlet diameter
L = mounting length
2 actuation flange
AL = number of drillings (4)
3 Shaft end
DN50 - 300: square end
DN350-1200: key way
465
3 1
d DN inch H 4 d 4 ΦS d DN inch L H H 1 H 2
63 50 2" 26 14 11 63 50 2" 43 219 53 140
75 65 2 ½" 26 14 11 75 65 2 ½" 46 241 63 152
90 80 3" 26 14 11 90 80 3" 46 256 71 159
110 100 4" 30 18 14 110 100 4" 52 295 87 178
140 125 5" 30 18 14 140 125 5" 56 323 102 191
160 150 6" 33 22 17 160 150 6" 56 358 122 203
225 200 8" 33 22 17 225 200 8" 60 423 149 241
280 250 10" 47 28 22 280 250 10" 68 521 201 273
315 300 12" 47 28 22 315 300 12" 78 559 231 311
355 350 14" 78 653 291 307
1 Butterfly valve
kg = net weight 400 400 16" 102 732 325 342
Nm = closing torque 450 450 18" 113 809 357 387
L = mounting length 500 500 20" 126 871 381 425
2 actuation flange 630 600 24" 146 1130 488 532

AL = number of drilling (4) 700 700 28" 175 1189 506 573
3 Shaft end 800 800 32" 215 1338 578 650
DN50 - 300: square end 900 900 36" 246 1460 643 707
DN350-1200: key way
1000 1000 40" 280 1594 729 755
Butterfly valve Type 039
1200 1200 48" 360 1885 855 900
1
d DN inch kg (Nm) Q 2
mm mm mm d DN inch Type d 1 d 2 d 3 H 3
63 50 2" 3.3 24 32 mm mm mm mm mm mm
75 65 2 ½" 4.0 30 51 63 50 2" F-07 9 70 90 13
90 80 3" 4.3 39 69 75 65 2 ½" F-07 9 70 90 13
110 100 4" 5.7 59 89 90 80 3" F-07 9 70 90 13
140 125 5" 7.4 78 115 110 100 4" F-07 9 70 90 16
160 150 6" 8.9 98 143 140 125 5" F-07 9 70 90 16
225 200 8" 13.5 157 194 160 150 6" F-07 9 70 90 17
280 250 10" 22.8 209 243 225 200 8" F-07 9 70 90 17
315 300 12" 31.7 301 293 280 250 10" F-10 12 102 125 17
355 350 14" 43.2 900 332 315 300 12" F-10 12 102 125 17
400 400 16" 65.2 1200 382 355 350 14" F-12 13 125 150 22
450 450 18" 84.5 1650 432 400 400 16" F-14 17 140 175 24
500 500 20" 119 2300 478 450 450 18" F-14 17 140 175 27
630 600 24" 281 4100 585 500 500 20" F-14 17 140 175 27
700 700 28" 414 5500 683 630 600 24" F-25 18 254 300 40
800 800 32" 572 8100 755 700 700 28" F-25 18 254 300 40
900 900 36" 639 10000 852 800 800 32" F-25 18 254 300 40
1000 1000 40" 918 13500 958 900 900 36" F-25 18 254 300 40
1200 1200 48" 1760 16500 1098 1000 1000 40" F-25 18 254 300 40
1200 1200 48" F-30 22 298 350 50
466
3
d DN inch H 4 d 4 ΦS
mm mm mm mm mm
63 50 2" 26 14 11
75 65 2 ½" 26 14 11
90 80 3" 26 14 11
110 100 4" 30 18 14
140 125 5" 30 18 14
160 150 6" 33 22 17
225 200 8" 33 22 17
280 250 10" 47 28 22
315 300 12" 47 28 22
355 350 14" 55 36
400 400 16" 65 42
450 450 18" 65 48
500 500 20" 65 48
630 600 24" 110 72
700 700 28" 110 72
800 800 32" 110 72
900 900 36" 110 98
1000 1000 40" 110 98
1200 1200 48" 130 120
1 Butterfly valve
kg = net weight
Nm = closing torque
L = mounting length
2 actuation flange
AL = number of drilling (4)
3 Shaft end
DN50 - 300: square end
DN350-1200: key way
467
Technical data
kv 100 values
Nominal diameter (DN) Opening angle [m³/h]
mm inch 20º 30º 40º 50º 60º 70º 80º 90º
50 2" 7 16 26 43 69 110 170 190
65 2 ½" 9 22 38 60 95 155 250 280
80 3" 14 33 57 95 150 240 370 430
100 4" 24 54 95 155 240 400 620 710
125 5" 38 86 155 240 390 640 950 1100
150 6" 52 120 220 345 550 950 1400 1600
200 8" 95 220 345 600 950 1600 2400 2800
250 10" 155 345 610 950 1600 2600 4000 4700
300 12" 220 510 860 1500 2300 3800 5900 6900
350 14" 290 660 1200 1900 2900 4800 7800 8600
400 16" 380 860 1600 2400 3900 6400 9500 11200
450 18" 490 1100 2000 3100 5000 8300 12900 15500
500 20" 610 1400 2500 4000 6200 10300 15500 19000
600 24" 860 2000 3400 5500 8600 14700 22400 25900
650 26" 980 2300 4000 6100 10400 16650 25850 31500
700 28" 1100 2600 4600 6700 12200 18600 29300 37100
750 30" 1300 3100 5200 8500 13800 22400 34500 40500
800 32" 1800 3600 6600 9700 16600 28300 43200 52300
900 36" 2200 4500 7800 12900 19800 32800 51700 60300
1000 40" 3100 5300 8700 16000 24100 42200 62100 78400
1050 42" 3400 5900 9600 17700 26600 46600 68400 86200
1100 44" 3800 6500 10600 19500 29300 51300 75100 95100
1200 48" 4500 7800 12700 23300 35200 61500 90700 114400
Operating torque
Nominal diameter(DN) Operating Operating
pressure 10 pressure 16
bar bar
mm inches (Nm) (Nm)
50 2" 15 15
65 2 ½" 20 20
80 3" 25 25
100 4" 40 40
125 5" 50 50
150 6" 60 60
200 8" 160 160
250 10" 250 250
300 12" 300 300
350 14" 900
400 16" 1200
450 18" 1650
500 20" 2300
600 24" 4100
468
Use of PVC-U flange adaptors
DIN PN-16 / PN10 Standard Required screws for type 039 Wafer Required screws for
butterfly valve type 038 Lugstyle
With PVC-U flange adaptors butterfly valve
With PVC-U flange
adapter
Butterfly Flange (DIN-2632) Studs Nuts Screws
valve
PN DN inch Hous- Flange Hole Num- Out- Length Thread Num- Thread Num- Length Thread Num-
mm ing thick- spac- ber of side-ø L M ber M ber L M ber
width ness ing holes øD Nº Nº Nº
A B øC Nº
16 50 2" 43 18 125 4 165 150 M16 4 M16 8 50 M16 4
16 65 2 ½" 46 18 145 4 185 155 M16 4 M16 8 55 M16 4
16 80 3" 46 20 160 8 200 155 M16 8 M16 16 55 M16 8
16 100 4" 52 20 180 8 220 165 M16 8 M16 16 60 M16 8
16 125 5" 56 22 210 8 250 180 M16 8 M16 16 65 M16 8
16 150 6" 56 22 240 8 285 190 M20 8 M20 16 70 M20 8
16 200 8" 60 24 295 12 340 220 M20 8 M20 16 80 M20 8
16 250 10" 68 26 355 12 405 230 M20 8 M20 16 90 M20 8
16 300 12" 78 28 410 12 460 255 M20 12 M20 16 100 M20 12
10 350 14" 78 30 470 16 520 275 M20 16 M20 32
10 400 16" 102 32 525 16 580 310 M24 16 M24 32
Use stubs PP- and PE100

DIN PN-16 / PN10 Standard Required screws for type 039 Wafer Required screws
butterfly valve for type 038 end in-
With stubs PP- and PE100 stallation of butter-
fly valve. With stubs
PP- and PE100
Butterfly Flanges (DIN-2632) Studs Nuts Screws
valve
PN DN inch Hous- Flange Hole Num- Out- Length Thread Num- Thread Num- Length Thread Num-
mm ing thick- spac- ber of side-ø L M ber M ber L M ber
width ness ing holes øD Nº Nº Nº
A B øC Nº
16 50 2" 43 18 125 4 165 160 M16 4 M16 8 55 M16 4
16 65 2 ½" 46 18 145 4 185 165 M16 4 M16 8 60 M16 4
16 80 3" 46 20 160 8 200 170 M16 8 M16 16 60 M16 8
16 100 4" 52 20 180 8 220 175 M16 8 M16 16 65 M16 8
16 125 5" 56 22 210 8 250 200 M16 8 M16 16 80 M16 8
16 150 6" 56 22 240 8 285 210 M20 8 M20 16 80 M20 8
16 200 8" 60 24 295 12 340 230 M20 8 M20 16 90 M20 8
16 250 10" 68 26 355 12 405 250 M20 8 M20 16 100 M20 8
16 300 12" 78 28 410 12 460 270 M20 12 M20 16 110 M20 12
10 350 14" 78 30 470 16 520 340 M20 16 M20 32
10 400 16" 102 32 525 16 580 380 M24 16 M24 32
10 500 20" 126 34 650 20 715 470 M24 20 M24 40
10 600 24" 146 36 770 20 840 420 M27 20 M27 40
469
Tightening torque for installing the butterfly leakages or other defects, the safety instructions in the
valve instruction manual and in the planning fundamentals
must be observed.
DN inch (Nm) lb-ft
• We recommend operating the butterfly valves which
50 2" 30 22 are kept permanently in the same position 1 – 2 x a
65 2 ½" 35 26 year to check their functionality.
80 3" 40 30
• Depending on the working conditions, the profile
sealings should be lubricated periodically with a (sili-
100 4" 45 33 con-based) lubricant.
125 5" 50 37
150 6" 60 44
200 8" 75 55
250 10" 75 55
300 12" 80 59
Technical features
Shaft sealing
is warranted due to the special profile of the collar in the
area of the shaft seal. . .
Longitudinal section of the collar
. . . and fixation of the collar with the valve housing
Cross-section of the valve housing with collar
The outer grooves of the collar seal the flange connec-

tion, so that no additional flange seals are required.

Maintenance
In normal operation, butterfly valves do not require
maintenance. It is enough to control periodically, if there
is no leakage. If the medium escapes at the flange con-
nections, refasten these acc. to the table. In case of
470
Fundamentals for butterfly valves electric actuated
Page

Butterfly valves type 140/141/142 DN50 - DN200
-- Overview 472
-- Graph 474
-- Accessories 477
Butterfly valve type 037E / 038E / 039E DN50 - DN1200
-- Overview 478
-- Graph 479
471
Product features
Fundamentals for butterfly
Type 140
valves electric actuated • Size range 2” to 24” wafer style
• 110-230 V AC auto-detecting or 24 V AD/DC
Butterfly valves type 140/141/142
• Manual override on actuator
DN50 - DN200 • Available in PVC-U, PVC-C, ABS, PP-H and PVDF
Overview • Rated for 150 PSI / 10 bar (bidirectional) EPDM or
FPM seals
Product description
The electrically actuated butterfly valve of type 140/141/ • UL certified
142 from GF Piping Systems consists of valve body, • Double eccentric, off-center shaft for reduced wear
butterfly valve type 567/568 with the electric actuator and a lower actuation torque
EA31/EA42. It is adaptable to a variety of conditions • Special O-ring design eliminates the need for flange
and enables a broad range of applications. It is avail- gaskets
able in PVC-U, PVC-C, ABS, Polypropylene, and PVDF
materials. Type 141 - 142
With the optional positioner, it goes from being a simple • Electrical position feedback 4-20 mA with
open/close valve to a precise flow control device inte- • Size range 2” to 8" lug style ISO (Type141); ANSI
grated into systems controlled by PLCs and other com- (Type142)
puterized instrumentation.
The technical data concerning • 110-230 V AC auto-detecting or 24 V AD/DC Manual
override on actuator
• Available in PVC-U, PVC-C, ABS, PP-H and PVDF
• Pressure loss
Rated for 150 PSI (bidirectional)/ 10 bar EPDM or
• Flow characteristics FPM seals
• kv values • UL certified
• Reference values for screw fastenings • Double eccentric, off-center shaft for reduced wear
can be found under butterfly valve type 567/568, manu- and a lower actuation torque
al override. • Special O-ring design eliminates the need for flange
In the following, you will find all the details concerning gaskets
mounting, installation and commissioning of the electric
actuators EA31 and EA42. Differences Type 141 - 142
Versions Type Type Type
140 141 142
Type 140 with electrical actuator EA31 and EA42
PVC-U + + +
PVC-C + + +
ABS + + +
PP-H + + +
PVDF + + +
ISO + +
ASTM + +
BS +
JIS +
Type 141/142 with electrical actuator EA31 and EA42
472
Overview
General Type 140 141 / 142
Waferstyle Lugstyle
Base type 567 568
Actuator type EA31/EA42 EA31/EA42
Dimension DN 50 - 600 50 - 200
Pressure range PN 10 / 4* 10
PVC-C + +
ABS + +
PP-H + +
PVDF + +
Connection types Flanges
FPM + +
FPM/PTFE + +
Standards ISO + +
BS + +
ASTM + +
JIS + +
Accessories Actuator EA11/EA21/EA31 100-230 V~ DN50 - 300
Actuator Valpes DN350 - 600 (VS 300, VT 600 and VT
1000)
* Depending on dimension
Safety information
CAUTION
actuator is to:
valve and
safe return unit.
473
d Actuator D L L1
Graph
mm Type mm mm mm
Dimensions
63 EA 31 19 45 122
Weight actuator
Information about the weight of the actu- 75 EA 31 19 46 122
ators are available in the Chapter "Actua- 90 EA 31 19 49 122
110 EA 31 19 56 122
140 EA 31 23 64 122
More dimensions 160 EA 31 24 72 122
uct range of butterfly valve type 567/568. 225 EA42 23 73 122
280 EA42 25 113 122
315 EA42 25 113 122
Butterfly valve type 140 without manual over-
ride
d Actuator L2 Q1 Q2
mm Type mm mm mm
63 EA 31 180 40 -
75 EA 31 180 54 35
90 EA 31 180 67 50
110 EA 31 180 88 74
140 EA 31 180 113 97
160 EA 31 180 139 123
225 EA42 180 178 169
280 EA42 180 210 207
315 EA42 180 256 253
d Actuator D D1 min D1 max D2

mm Type mm mm mm mm
63 EA 31 19 120.0 125.0 104
75 EA 31 19 139.7 145.0 115
90 EA 31 19 150.0 160.0 131
110 EA 31 19 175.0 190.5 161
140 EA 31 23 210.0 215.9 187
160 EA 31 24 241.3 241.3 215
225 EA42 23 290.0 295.0 267
280 EA42 25 353 362 329
315 EA42 25 400 432 379
d Actuator H H1 H2 H3

d DN inch PN kv-value
mm Type mm mm mm mm
mm mm (Δp=1bar)
63 EA 31 400 77 134 188
63 50 2 10 1470
75 EA 31 413 83 140 188
75 65 2.5 10 2200
90 EA 31 428 89 146 188
90 80 3 10 3000
110 EA 31 460 104 167 188
110 100 4 10 6500
140 EA 31 487 117 181 188
140 125 5 10 11500
160 EA 31 508 130 189 188
160 150 6 10 16600
225 EA42 575 158 210 208
225 200 8 10 39600
280 EA42 677 205 264 208
280 250 10 6 55200
315 EA42 721 228 285 208
315 300 12 4 80000
474
Butterfly valve type 140 with manual override d Actuator L2 L3 Q1 Q2
mm Type mm mm mm mm
63 EA 31 180 200 40 -
75 EA 31 180 200 54 35
90 EA 31 180 200 67 50
110 EA 31 180 250 88 74
140 EA 31 180 250 113 97
160 EA 31 180 250 139 123
225 EA42 180 250 178 169
d Actuator D D1 min D1 max D2

mm Type mm mm mm mm
63 EA 31 19 120.0 125.0 104
75 EA 31 19 139.7 145.0 115
90 EA 31 19 150.0 160.0 131
110 EA 31 19 175.0 190.5 161
140 EA 31 23 210.0 215.9 187
160 EA 31 24 241.3 241.3 215
225 EA42 23 290.0 295.0 267
d Actuator H H1 H2 H3 H4

mm Type mm mm mm mm mm
d DN inch PN kv-value kv-val- 63 EA 31 460 77 134 188 60
ue
75 EA 31 473 83 140 188 60
mm mm (Δp=1bar)
90 EA 31 488 89 146 188 60
63 50 2 10 1470
110 EA 31 520 104 167 188 60
75 65 2.5 10 2200
140 EA 31 547 117 181 188 60
90 80 3 10 3000
160 EA 31 568 130 189 188 60
110 100 4 10 6500
225 EA42 635 158 210 208 60
140 125 5 10 11500
160 150 6 10 16600
225 200 8 10 39600
d Actuator D L L1
mm Type mm mm mm
63 EA 31 19 45 122
75 EA 31 19 46 122
90 EA 31 19 49 122
110 EA 31 19 56 122
140 EA 31 23 64 122
160 EA 31 24 72 122
225 EA42 23 73 122
475
Butterfly valve type 141/142 without manual d D1 ANSI d2 Q1 Q2
override
mm mm mm mm mm
63 121 104 36 -
75 138 115 51 31
90 152 131 64 46
110 191 161 84 70
140 216 187 111 95
160 241 215 136 122
225 298 267 176 166
d H H1 H2 H3
mm mm mm mm mm
63 400 77 134 190
75 413 83 140 190
90 428 89 146 190
110 460 104 167 190
140 487 117 181 190
160 508 130 189 190
225 575 157 210 208
d L L1 L2 L3

mm mm mm mm mm
63 45 122 180 150
75 46 122 180 160
90 49 122 180 205
110 56 122 180 244
d DN inch PN kv-value kv-val- 140 64 122 180 272
ue
160 72 122 180 297
mm mm (Δp=1bar)
225 73 122 180 360
63 50 2 10 1470
75 65 2.5 10 2200
90 80 3 10 3000
110 100 4 10 6500
140 125 5 10 11500
160 150 6 10 16600
225 200 8 10 39600
d Actuator D metric D1 metric D ANSI

mm Type mm
63 EA 31 M16 125 UNC 5/8
75 EA 31 M16 145 UNC 5/8
90 EA 31 M16 160 UNC 5/8
110 EA 31 M16 180 UNC 5/8
140 EA 31 M16 210 UNC 3/4
160 EA 31 M20 240 UNC 3/4
225 EA42 M20 295 UNC 3/4
476
Butterfly valve type 141/142 with manual over- d D1 ANSI d2 Q1 Q2
ride
mm mm mm mm mm
63 121 104 36 -
75 138 115 51 31
90 152 131 64 46
110 191 161 84 70
140 216 187 111 95
160 241 215 136 122
225 298 267 176 166
d H H1 H2 H3 H4

mm mm mm mm mm mm
63 400 77 134 190 60
75 413 83 140 190 60
90 428 89 146 190 60
110 460 104 167 190 60
140 487 117 181 190 60
160 508 130 189 190 60
225 575 157 210 208 60
d L L1 L2 L3 L4

d DN inch PN kv-value kv-val- mm mm mm mm mm mm
ue
63 45 122 180 150 200
mm mm (Δp=1bar)
75 46 122 180 160 200
63 50 2 10 1470
90 49 122 180 205 200
75 65 2.5 10 2200
110 56 122 180 244 250
90 80 3 10 3000
140 64 122 180 272 250
110 100 4 10 6500
160 72 122 180 297 250
140 125 5 10 11500
225 73 122 180 360 250
160 150 6 10 16600
225 200 8 10 39600
Technical features
d Actuator D metric D1 met- D ANSI Flow characteristics
ric
mm Type mm
63 EA 31 M16 125 UNC 5/8
75 EA 31 M16 145 UNC 5/8
90 EA 31 M16 160 UNC 5/8
110 EA 31 M16 180 UNC 5/8
140 EA 31 M16 210 UNC 3/4
160 EA 31 M20 240 UNC 3/4
225 EA42 M20 295 UNC 3/4 X Open angle (%)
Y kv, CV value (%)
Accessories
More information about accessories are
available in the chapter actuators.
477
Butterfly valve type 037E / 038E / Product features
039E DN50 - DN1200 Type 037E / 038E / 039E
• Good flow characteristics
Overview • Rilsan®/Epoxy-coating: good chemical resistance
Product description • Easy installation
The butterfly valve type 037E / 038E / 039E consists of • Reliable automatic open/close and control valves
the basic valve body with the electric drive EA31/41/50.
• Pressure loss
• kv values
can be found under butterfly valve type 037 / 038 / 039,
manual valves.
The metal butterfly valves of type 037E/038E/039E can
be used as open/close or control valve. The easy instal-
lation of the valve between pipe flanges warrants reli-
able operation and sealing. The lightweight aluminium
valve body has special advantages in transport and in-
stallation. The Rilsan-coating of the valve body and the
ductile iron valve disc provide a high resistance against
corrosion. The butterfly valves are also available in a
standard version with stainless steel valve disc.Butterfly
valves Type 037E are available from DN50/2"-DN300/
12", Type 038E from DN50 up to DN300. Type 039E
from DN50/2" -- DN1200/48".
mounting, installation and commissioning of the electric
actuators EA31/41/50. For DN350 - DN1200 acuators
from "Auma" are installed.
Versions
Type 037E / 039E with electrical actuator EA31/40/50
Type 038E with electrical actuator EA31/40/50
478
Overview
General Type 037E 038E 039E
Base type 037 038 039
Actuator type EA31/42 EA31/42 EA31/42, Auma
Dimension DN 50 - 300 50 - 300 50 - 1200
Pressure range PN 10 16 +
Materials for valve Metal + + +
body
Connection types Flange + + +
Seal materials EPDM + + +
FPM + + +
Standards ISO + + +
BS + + +
ASTM + + +
JIS + +
Safety information
CAUTION
actuator is to:
valve and
safe return unit.
Graph
Dimensions
Weight actuator

More dimensions
uct range of butterfly valve type 037.
479
Butterfly valve type 037E with manual override
d DN inch PN kv-value (Δp=1 Cv value Q

bar) (Δp=1 psi)
mm mm l/min gal (US)/min
63 50 2 10 3140 220 32
75 65 2½ 10 4570 320 51
90 80 3 10 7140 500 69
110 100 4 10 11710 820 89
140 125 5 10 18570 1300 115
160 150 6 10 27130 1900 143
225 200 8 10 47130 3330 194
280 250 10 10 77110 5400 243
315 300 12 10 114240 8000 293
d DN inch Actuator D 3 D4 L L1 L2

mm mm Type mm mm mm mm mm
63 50 2 EA 31 96 165 43 64 181
75 65 2½ EA 31 114 185 46 28 181
90 80 3 EA 31 131 190 46 28 181
110 100 4 EA42 152 229 52 28 181
140 125 5 EA42 182 254 56 60 220
160 150 6 EA42 209 285 56 60 220
225 200 8 EA42 262 343 60 60 220
280 250 10 EA 50 323 333 68 70 220
315 300 12 EA 50 373 353 78 70 220
480
d DN inch Actuator H H1 H2 H3 H4
63 50 2 EA 31 352 53 140 159 60
75 65 2½ EA 31 374 63 152 159 60
90 80 3 EA 31 389 71 159 159 60
110 100 4 EA42 415 87 178 149 60
140 125 5 EA42 443 102 191 149 60
160 150 6 EA42 475 122 203 149 60
225 200 8 EA42 540 149 241 149 60
280* 250 10 EA 50 671 201 273 197 ---
315 300 12 EA 50 739 231 311 197 ---
* DN250 -300 H3 = H3+H4

Butterfly valve type 037E without manual over-
ride
d DN inch PN kv-value (Δp=1 Cv value Q

bar) (Δp=1 psi)
63 50 2 10 3140 220 32
75 65 2½ 10 4570 320 51
90 80 3 10 7140 500 69
110 100 4 10 11710 820 89
140 125 5 10 18570 1300 115
160 150 6 10 27130 1900 143
225 200 8 10 47130 3330 194
280 250 10 10 77110 5400 243
315 300 12 10 114240 8000 293
d DN inch Actuator D 3 D4 L L1

mm mm Type mm mm mm mm
63 50 2 EA 31 96 165 43 64
75 65 2½ EA 31 114 185 46 64
90 80 3 EA 31 131 190 46 64
110 100 4 EA42 152 229 52 64
140 125 5 EA42 182 254 56 60
160 150 6 EA42 209 285 56 60
225 200 8 EA42 262 343 60 60
280 250 10 EA 50 323 333 68 70
315 300 12 EA 50 373 353 78 70
481
d DN inch Actuator L2 H H1 H2 H3
63 50 2 EA 31 181 352 53 140 159
75 65 2½ EA 31 181 374 63 152 159
90 80 3 EA 31 181 389 71 159 159
110 100 4 EA42 181 415 87 178 149
140 125 5 EA42 220 443 102 191 149
160 150 6 EA42 220 475 122 203 149
225 200 8 EA42 220 540 149 241 149
280 250 10 EA 50 220 671 201 273 197
315 300 12 EA 50 220 739 231 311 197
Butterfly valve type 037E DN50 - DN300 without d DN Actuator L2 H H1 H2 H3
manual override
mm Type mm mm mm mm mm
63 50 EA 31 181 352 53 140 159
75 65 EA 31 181 374 63 152 159
90 80 EA 31 181 389 71 159 159
110 100 EA42 181 415 87 178 149
140 125 EA42 220 443 102 191 149
160 150 EA42 220 475 122 203 149
225 200 EA42 220 540 149 241 149
280 250 EA 50 220 671 201 273 197
315 300 EA 50 220 739 231 311 197
d DN inch PN kv-value (Δp=1 Cv value (Δp=1

bar) psi)
63 50 2 10 3140 220
75 65 2½ 10 4570 320
90 80 3 10 7140 500
110 100 4 10 11710 820
140 125 5 10 18570 1300
160 150 6 10 27130 1900
225 200 8 10 47130 3330
280 250 10 10 77110 5400
315 300 12 10 114240 8000
d DN Actuator D 3 D4 L L1

mm Type mm mm mm mm
63 50 EA 31 96.0 165.0 43 64
75 65 EA 31 114.0 185.0 46 64
90 80 EA 31 131.0 190.0 46 64
110 100 EA42 152.0 229.0 52 64
140 125 EA42 182.0 254.0 56 60
160 150 EA42 209.0 285.0 56 60
225 200 EA42 262.0 343.0 60 60
280 250 EA 50 323.0 333.0 68 70
315 300 EA 50 373.0 353.0 78 70
482
Butterfly valve type 038E
d DN inch PN kv-value (Δp=1 Cv

bar) value(Δp=1
psi)
63 50 2 10 3140 220
75 65 2½ 10 4570 320
90 80 3 10 7140 500
110 100 4 10 11710 820
140 125 5 10 18570 1300
160 150 6 10 27130 1900
225 200 8 10 47130 3330
280 250 10 6 77110 5400
315 300 12 4 114240 8000
d DN inch Actuator D 3 L L1 L2

mm mm unit type mm mm mm mm
63 50 2 EA 31 65 43 28 122
75 65 2½ EA 31 114 46 28 122
90 80 3 EA 31 131 46 28 122
110 100 4 EA 31 152 52 60 220
140 125 5 EA 31 182 56 60 220
160 150 6 EA42 209 56 60 220
225 200 8 EA42 262 60 60 220
280 250 10 EA42 331 68 70 220
315 300 12 EA42 380 78 70 220
d DN inch Actuator H H1 H2 H3

63 50 2 EA 31 393 63 140 190
75 65 2½ EA 31 415 73 152 190
90 80 3 EA 31 430 81 159 190
110 100 4 EA 31 333 97 178 58
140 125 5 EA 31 361 112 191 58
160 150 6 EA42 383 122 203 58
225 200 8 EA42 452 149 245 58
280 250 10 EA42 545 203 275 67
315 300 12 EA42 623 241 315 67
483
Butterfly valve type 039E with manual override
d DN Inch PN kv-value (Δp=1 Cv value(Δp=1 Q

bar) psi)

63 50 2 10 3140 220 32
75 65 2½ 10 4570 320 51
90 80 3 10 7140 500 69
110 100 4 10 11710 820 89
140 125 5 10 18570 1300 115
160 150 6 10 27130 1900 143
225 200 8 10 47130 3330 194
280 250 10 10 77110 5400 243
315 300 12 10 114240 8000 293
355 350 14 10 143360 --- 332
400 400 16 10 186700 --- 382
450 450 18 10 258390 --- 432
500 500 20 10 316730 --- 478
630 600 24 10 431750 --- 585
700 700 28 10 618333 --- 683
800 800 32 10 675000 --- 755
900 900 36 10 1005200 --- 852
1000 1000 40 10 1306930 --- 958
1200 1200 48 10 1907050 --- 958
484
d DN Inch Actuator D 3 D4 L L1 L2
unit
mm mm type mm mm mm mm mm
63 50 2 EA31 96 165 43 64 181
75 65 2½ EA31 114 185 46 28 181
90 80 3 EA31 131 190 46 28 181
110 100 4 EA42 152 229 52 28 181
140 125 5 EA42 182 254 56 60 220
160 150 6 EA42 209 285 56 60 220
225 200 8 EA42 262 343 60 60 220
280 250 10 EA50 323 333 68 70 220
315 300 12 EA50 373 353 78 70 220
355 350 14 GS80 442 460 78 - 130
400 400 16 GS80 493 515 102 - 154
450 450 18 GS100 544 565 113 - 182
500 500 20 GS125 601 620 126 - 182
630 600 24 GS125 695 725 146 - 286
700 700 28 GS125 798 840 175 - 286
800 800 32 GS160 908 950 215 - 286
900 900 36 GS160 1004 1050 246 - 370
1000 1000 40 GS160 1114 1160 280 - 370
1200 1200 48 GS200 1330 1380 360 - 1133
d DN Inch Actuator H H1 H2 H3 H4

unit
mm mm type mm mm mm mm mm
63 50 2 EA31 352 53 140 159 60
75 65 2½ EA31 374 63 152 159 60
90 80 3 EA31 389 71 159 159 60
110 100 4 EA42 415 87 178 149 60
140 125 5 EA42 443 102 191 149 60
160 150 6 EA42 475 122 203 149 60
225 200 8 EA42 540 149 241 149 60
280* 250 10 EA50 671 201 273 197 --
-
315 300 12 EA50 739 231 311 197 --
-
355 350 14 GS80 905 291 307 307 --
-
400 400 16 GS80 974 325 342 307 --
-
450 450 18 GS100 1065 357 387 321 ---
500 500 20 GS125 1127 381 425 321 ---
630 600 24 GS125 1350 488 532 330 --
-
700 700 28 GS125 1409 506 573 330 ---
800 800 32 GS160 1541 578 650 313 ---
900 900 36 GS160 1673 643 707 323 ---
1000 1000 40 GS160 1807 729 755 323 ---
1200 1200 48 GS200 2103 855 900 348 - - -
485
* DN250 - 1200 H3 = H3+H4
Butterfly valve type 039E without manual over-
ride
d DN Inch PN kv-value (Δp=1 Cv Q

bar) value(Δp=1
psi)
63 50 2 10 3140 220 32
75 65 2½ 10 4570 320 51
90 80 3 10 7140 500 69
110 100 4 10 11710 820 89
140 125 5 10 18570 1300 115
160 150 6 10 27130 1900 143
225 200 8 10 47130 3330 194
280 250 10 10 77110 5400 243
315 300 12 10 114240 8000 293
355 350 14 10 143360 --- 332
400 400 16 10 186700 --- 382
450 450 18 10 258390 --- 432
500 500 20 10 316730 --- 478
630 600 24 10 431750 --- 585
700 700 28 10 618333 --- 683
800 800 32 10 675000 --- 755
900 900 36 10 1005200 --- 852
1000 1000 40 10 1306930 --- 958
1200 1200 48 10 1907050 - - - 958
486
d DN Inch Actuator D 3 D4 L L1
63 50 2 EA31 96 165 43 64
75 65 2½ EA31 114 185 46 64
90 80 3 EA31 131 190 46 64
110 100 4 EA42 152 229 52 64
140 125 5 EA42 182 254 56 60
160 150 6 EA42 209 285 56 60
225 200 8 EA42 262 343 60 60
280 250 10 EA50 323 333 68 70
315 300 12 EA50 373 353 78 70
355 350 14 GS80 442 460 78 -
400 400 16 GS80 493 515 102 -
450 450 18 GS100 544 565 113 -
500 500 20 GS125 601 620 126 -
630 600 24 GS125 695 725 146 -
700 700 28 GS125 798 840 175 -
800 800 32 GS160 908 950 215 -
900 900 36 GS160 1004 1050 246 -
1000 1000 40 GS160 1114 1160 280 -
1200 1200 48 GS200 1330 1380 360 -
d DN Inch Actuator L2 H H1 H2 H3

mm mm unit type mm mm mm mm mm
63 50 2 EA31 181 352 53 140 159
75 65 2½ EA31 181 374 63 152 159
90 80 3 EA31 181 389 71 159 159
110 100 4 EA42 181 415 87 178 149
140 125 5 EA42 220 443 102 191 149
160 150 6 EA42 220 475 122 203 149
225 200 8 EA42 220 540 149 241 149
280 250 10 EA50 220 671 201 273 197
315 300 12 EA50 220 739 231 311 197
355 350 14 GS80 130 905 291 307 307
400 400 16 GS80 154 974 325 342 307
450 450 18 GS100 182 1065 357 387 321
500 500 20 GS125 182 1127 381 425 321
630 600 24 GS125 286 1350 488 532 330
700 700 28 GS125 286 1409 506 573 330
800 800 32 GS160 286 1541 578 650 313
900 900 36 GS160 370 1673 643 707 323
1000 1000 40 GS160 370 1807 729 755 323
1200 1200 48 GS200 1133 2103 855 900 348
487
Butterfly valve type 039E DN50 - DN300 without d DN Actuator L2 H H1 H2 H3
manual override
mm unit type mm mm mm mm mm
63 50 EA31 181 352 53 140 159
75 65 EA31 181 374 63 152 159
90 80 EA31 181 389 71 159 159
110 100 EA42 181 415 87 178 149
140 125 EA42 220 443 102 191 149
160 150 EA42 220 475 122 203 149
225 200 EA42 220 540 149 241 149
280 250 EA50 220 671 201 273 197
315 300 EA50 220 739 231 311 197
d DN Inch PN kv-value (Δp=1 Cv value(Δp=1
bar) psi)
63 50 2 10 3140 220
75 65 2½ 10 4570 320
90 80 3 10 7140 500
110 100 4 10 11710 820
140 125 5 10 18570 1300
160 150 6 10 27130 1900
225 200 8 10 47130 3330
280 250 10 10 77110 5400
315 300 12 10 114240 8000
d DN Actuator unit D 3 D4 L L1

mm type mm mm mm mm
63 50 EA31 96.0 165.0 43 64
75 65 EA31 114.0 185.0 46 64
90 80 EA31 131.0 190.0 46 64
110 100 EA42 152.0 229.0 52 64
140 125 EA42 182.0 254.0 56 60
160 150 EA42 209.0 285.0 56 60
225 200 EA42 262.0 343.0 60 60
280 250 EA50 323.0 333.0 68 70
315 300 EA50 373.0 353.0 78 70
488
Fundamentals for butterfly valves pneumatically actuated
Page

-- Overview 490
-- Graph 492
Butterfly valve type 037P / 038P / 039P
-- Overview 499
-- Graph 501
489
Fundamentals for butterfly Type 241/242 with pneumatic actuator PA30 - PA90
valves pneumatically actuated

Overview
Product description
The type 240/241/242 series pneumatically actuated
wafer style butterfly valve from GF Piping Systems is
the ultimate choice for the high demands of the industri-
al world. The unique double eccentric design means the
disc is not in contact with the seal in the open position.
The result is less wear and operating torques that are
half that of our previous model. Better chemical compat-
ibility is achieved because the inner body is the same
material as the pipe. The unique O-ring design insures
a superior seal with virtually any type of flange without
the need for additional gaskets. Additionally, the elec-
tro-pneumatic positioner, stroke limiter, and feed back
switches give flexibility for integration into a wide variety
of applications.
The technical data concerning Product features
Type 240/241/242
• Pressure loss
• Detachable manual override
• Limit switches
• kv values
• Electric-pneumatic positioner (4-20 mA) or 3-15 PSI
• ASI-control
can be found under butterfly valve type 567/568, manu-
al override. Differences Type 240/241/242
mounting, installation and commissioning of the electric Type Type Type
actuators PA30 - PA90. 240 241 242
PVC-U + + +
Versions
PVC-C + + +
Type 240 with pneumatic actuator PA30 - PA90
ABS + + +
PP + + +
PVDF + + +
ISO + +
ASTM + +
BS +
JIS +
490
Overview
General Type 240 241 / 242
Waferstyle Lugstyle
Base type 567 568
Actuator type PA30 - PA90 PA30 - PA90
Dimension DN 2" - 24" 2" - 8"
Pressure range PN 10 10 / 6*
PVC-C + +
ABS + +
PP-H + +
PVDF + +
Connection types Flanges + +
FPM + +
FPM/PTFE + +
Standards ISO + + Type 241
BS +
ASTM + + Type 242
JIS +
* Depending on dimensions
Safety information
WARNING
or death.
NOTICE • The dismantling of these actuators must
Pneumatic actuators safety expert.
• Single-acting pneumatic actuators with fail- • Dismounting may only be done in safety
safe positions OPEN and CLOSED (type position after disconnecting the air supply.
additional letters in FO and FC) have pre- • When working on electric auxiliary com-
tensioned springs for actuation under lack ponents of the pneumatic operation, the
of pressure. electrical connections of the control voltage
Intended use
tor
DA/FC/FO
Type PA30-45 Pneumatic part-turn valve actua-
tor
DA/FC/FO
491
d DN inch PN kv value
Graph
mm mm (Δp = 1 bar)
Dimensions
63 50 2 10 1470
Weight actuator
Information about the weight of the actu- 75 65 2½ 10 2200
ators are available in the Chapter "Actua- 90 80 3 10 3000
110 100 4 10 6500
140 125 5 10 11500
More dimensions More Dimensions are 160 150 6 10 16600
available in the product range of butterfly
valve type 567. 225 200 8 10 39600
280 250 10 8 55200
315 300 12 8 80000
Dimensions type 240 FC/FO
FC (Fail-safe-to-close)/ 355 350 14 6 90000
FO (Fail-safe-to-open) 400 400 16 6 115000
450 450 18 5 155000
Version: 500 500 20 4 204000
• Connecting dimension: ISO 7005 PN 10, EN1092
630 600 24 4 265000
PN10, DIN 2501 PN10, ANSI B 16.5 Class 150, BS
1560:1989, JIS B 2220
d Actuator D D1 min. D1 max. d2
• Overall length according to EN558-1, ISO 5752
mm Type mm mm mm mm
• Control range 90 °
63 PA-30 FC/FO 19 120.0 125.0 104
75 PA-30 FC/FO 19 139.7 145.0 115
90 PA-35 FC/FO 19 150.0 160.0 131
110 PA-40 FC/FO 19 175.0 190.5 161
140 PA-45 FC/FO 23 210.0 215.9 187
160 PA-50 FC/FO 24 241.3 241.3 215
225 PA-55 FC/FO 23 290.0 295.0 267
280 PA-65 FC 25 353.0 362.0 329
315 PA-70 FC/FO 25 400.0 432.0 379
355 29 445.0 477.0 535
400 29 510.0 540.0 595
450 32 565.0 578.0 635
500 32 620.0 635.0 700
630 35 725.0 750.0 813
492
d H H1 H2 H3 H4 H5
63 327 77 134 117 70 15
75 340 83 140 117 70 15
90 361 89 146 126 78 15
110 400 104 167 129 86
140 436 117 181 139 96
160 468 130 189 149 106
225 529 158 210 161 118
280 808 205 264 191 148
315 866 288 285 196 157
355 863 268 410 185 155 27
400 941 300 435 206 176 27
450 1046 320 520 206 176 36
500 1130 350 550 230 200 36
630 1330 420 610 300 250 36
d L L1 Q1 Q2

mm mm mm mm mm
63 45 276 36 -
75 46 276 51 31
90 49 326 64 46
mm mm (Δp=1 bar)
110 56 370 84 70
63 50 2 10 1470
140 64 411 111 95
75 65 2½ 10 2200
160 72 423 136 122
90 80 3 10 3000
225 73 452 176 166
110 100 4 10 6500
280 113 648 210 207
140 125 5 10 11500
315 113 663 256 253
160 150 6 10 16600
355 129 360 325 305
225 200 8 10 39600
400 169 380 353 350
280 250 10 8 55200
450 179 380 393 390
315 300 12 8 80000
500 190 462 444 440
355 350 14 6 90000
630 209 530 530 527
400 400 16 6 115000
Dimensions type 240 DA 450 450 18 5 155000
DA (Double Acting) 500 500 20 4 204000
630 600 24 4 265000
Version:
• Connecting dimensions according to: ISO 7005 PN
10, EN1092 PN10, DIN 2501 PN10, ANSI B 16.5
Class 150, BS 1560:1958, JIS B 2220
493
d Actuator D D1 min. D1 max. d2 d L L1 Q1 Q2
mm Type mm mm mm mm mm mm mm mm mm
63 PA-35 DA 19 120.0 125.0 104 63 45 177 36 -
75 PA-35 DA 19 139.7 145.0 115 75 46 177 51 31
90 PA-40 DA 19 150.0 160.0 131 90 49 190 64 46
110 PA-45 DA 19 175.0 190.5 161 110 56 198 84 70
140 PA-45 DA 23 210.0 215.9 187 140 64 235 111 95
160 PA-55 DA 24 241.3 241.3 215 160 72 250 136 122
225 PA-55 DA 23 290.0 295.0 267 225 73 279 176 166
280 PA-65 DA 25 353.0 362.0 329 280 113 350 210 207
315 PA-70 DA 25 400.0 432.0 379 315 113 381 256 253
355 AP 5 29 445.0 477.0 535 355 129 360 325 305
400 AP 5.5 29 510.0 540.0 595 400 169 380 353 350
450 AP 5.5 32 565.0 578.0 635 450 179 380 393 390
500 AP 6 32 620.0 635.0 700 500 190 462 444 440
630 AP 8 35 725.0 750.0 813 630 209 530 530 527
d H H1 H2 H3 H4 H5 Dimensions type 241 FC/FO

FC (Fail-safe-to-close)/
FO (Fail-safe-to-open)
63 317 77 134 107 60 15 Without manual override
75 330 83 140 107 60 15 Version:
90 348 89 146 113 66 15 • Connecting dimensions according to: ISO 7005 PN
10, EN1092 PN10, DIN 2501 PN10
110 372 104 167 102 71
140 408 117 181 111 78
160 448 130 189 129 86
225 507 158 210 139 96
280 748 205 264 161 118
315 816 228 285 173 130
355 863 268 410 185 155 27
400 941 300 435 206 176 27
450 1046 320 520 206 176 36
500 1130 350 550 230 200 36
630 1330 420 610 300 250 36
494
mm mm (Δp=1 bar)
63 50 2 10 1470
75 65 2½ 10 2200
90 80 3 10 3000
110 100 4 10 6500
140 125 5 10 11500
160 150 6 10 16600
225 200 8 10 39600
d Actuator D D1 d2

mm Type mm mm
63 PA-30 FC M16 125 104
75 PA-30 FC M16 145 115
90 PA-35 FC M16 160 131
110 PA-40 FC M16 180 161
140 PA-45 FC M16 210 187
160 PA-50 FC M20 240 215
225 PA-55 FC M20 295 267
d H H1 H2 H3 H4 H5
63 327 77 134 117 70 15
75 340 83 140 117 70 15
mm mm (Δp=1 bar)
90 361 89 146 126 78 15
63 50 2 10 1470
110 400 104 167 129 86
75 65 2½ 10 2200
140 436 117 181 139 96
90 80 3 10 3000
160 468 130 189 149 106
110 100 4 10 6500
225 529 157 210 161 118
140 125 5 10 11500
d L L1 L2 L3 Q1 Q2 160 150 6 10 16600
mm mm mm mm mm mm mm 225 200 8 10 39600
63 45 276 65 150 36 -
d Actuator D D1 d2
75 46 276 65 160 51 31
mm Type mm mm mm
90 49 326 72 205 64 46
63 PA-35 DA 19 125 104
110 56 370 80 244 84 70
75 PA-35 DA 19 145 115
140 64 411 90 272 111 95
90 PA-40 DA 19 160 131
160 72 423 100 297 136 122
110 PA-45 DA 19 180 161
225 73 452 112 360 176 166
140 PA-45 DA 23 210 187
Dimensions type 241 DA 160 PA-55 DA 24 240 215
DA (Double Acting)
Without manual override 225 PA-55 DA 23 295 267
Version:
• Connecting dimensions according to: ISO 7005 PN
10, EN1092 PN10, DIN 2501 PN10
495
d H H1 H2 H3 H4 H5
63 317 77 134 107 60 15
75 330 83 140 107 60 15
90 348 89 146 113 66 15
110 372 104 167 102 71 -
140 408 117 181 111 78 -
160 448 130 189 129 86 -
225 507 157 210 139 96 -
d L L1 L2 L3 Q1 Q2
63 45 177 55 150 36 -
75 46 177 55 160 51 31
90 49 190 60 205 64 46
110 56 198 65 224 84 70
140 64 235 72 272 111 95
160 72 250 80 297 136 122
225 73 279 90 360 176 166
Dimensions type 242 FC/FO

FC (Fail-safe-to-close)/
FO (Fail-safe-to-open)
Version: d DN inch PN kv value
• Connecting dimensions according to: ANSI B 16.5 mm mm (Δp=1 bar)
Class 150
63 50 2 10 1470
75 65 2½ 10 2200
90 80 3 10 3000
110 100 4 10 6500
140 125 5 10 11500
160 150 6 10 16600
225 200 8 10 39600
d Actuator D D1 d2

b
mm Type mm mm
63 PA-30 FC UNC 5/8 121 104
75 PA-30 FC UNC 5/8 138 115
90 PA-35 FC UNC 5/8 152 131
110 PA-40 FC UNC 5/8 191 161
140 PA-45 FC UNC 3/4 216 187
160 PA-50 FC UNC 3/4 241 215
225 PA-55 FC UNC 3/4 298 267
496
d H H1 H2 H3 H4 H5
63 327 77 134 117 70 15
75 340 83 140 117 70 15
90 361 89 146 126 78 15
110 400 104 167 129 86
140 436 117 181 139 96
160 468 130 189 149 106
225 529 157 210 161 118
d L L1 L2 L3 Q1 Q2
63 45 276 65 150 36 -
75 46 276 65 160 51 31
90 49 326 72 205 64 46
110 56 370 80 244 84 70
140 64 411 90 272 111 95
160 72 423 100 297 136 122
225 73 452 112 360 176 166
Dimensions type 242 DA

DA (Double Acting)
Version: d DN inch PN kv value
• Connecting dimensions according to: ANSI B 16.5 mm mm (Δp=1 bar)
Class 150 63 50 2 10 1470
75 65 2½ 10 2200
90 80 3 10 3000
110 100 4 10 6500
140 125 5 10 11500
160 150 6 10 16600
225 200 8 10 39600
d Actuator D D1 d2

mm Type mm mm
63 PA-35 DA UNC 5/8 121 104
75 PA-35 DA UNC 5/8 138 115
90 PA-40 DA UNC 5/8 152 131
110 PA-45 DA UNC 5/8 191 161
140 PA-45 DA UNC 3/4 216 187
160 PA-55 DA UNC 3/4 241 215
225 PA-55 DA UNC 3/4 298 267
497
d H H1 H2 H3 H4 H5
63 317 77 134 107 60 15
75 330 83 140 107 60 15
90 348 89 146 113 66 15
110 372 104 167 102 71 -
140 408 117 181 111 78 -
160 448 130 189 129 86 -
225 507 157 210 139 96 -
d L L1 L2 L3 Q1 Q2
63 45 177 55 150 36 -
75 46 177 55 160 51 31
90 49 190 60 205 64 46
110 56 198 65 224 84 70
140 64 235 72 272 111 95
160 72 250 80 297 136 122
225 73 279 90 360 176 166
498
Butterfly valve type 037P / 038P / Type 039P with pneumatic actuators
039P
Overview
Product description
The metall butterfly valves type 037P / 038P / 039P can
be used as open/close or control valve. The easy instal-
lation of the valve between pipe flanges warrants reli-
able operation and sealing. The lightweight aluminium
valve body has special advantages in transport and in-
stallation. The Rilsan-coating of the valve body and the
ductile iron valve disc provide a high resistance against
corrosion. The butterfly valves are also available in a
standard version with stainless steel valve disc. But-
terfly valves Type 037P are available from DN50/2"-
DN300/12", Type 038P from DN50 up to DN300/12",
Type 039P from DN50-DN1200/48". Product features
The technical data concerning Type 037P / 038P / 039P
• Pressure loss • Good flow characteristics
• Flow characteristics • Rilsan®/Epoxy-coating: good chemical resistance
• kv values • Easy installation
• Reference values for screw fastenings • Reliable automatic open/close and control valve
can be found under butterfly valve type 037 / 038 / 039,
manual override.
Versions
Type 037P with pneumatic actuators
Type 038P with pneumatic actuators PA30 - PA90
499
Overview
General Type 037P 038P 039P
Base type 037 038 039
Actuator type PA30 - PA90 PA30 - PA90 PA30 - PA90, Diteico
Dimension DN 50 - 300 50 - 300 50 - 1200
Pressure range PN 10 16 16
Materials for valve Matal + + +
body
Connection types Flanges + + +
FPM + + +
Standards ISO + + +
BS + +
ASTM + + +
JIS + +
Accessories Pilot valves Pilot valves Pilot valves
Intended use
Safety information This actuator is intended, after being mounted on the
The following safety instructions apply specifically to the valve, after mounting of a solenoid valve and after the
ball valve. They should identify the hazards and advice connection of this solenoid valve to a system control,
that should be considered for the different uses and in- • under the condition that a control pressure of at least
stallation/commissioning. 5.6 bar, but not more than 7.7 bar at the solenoid
valve is present permanently,
• to actuate valves with with 90° pivoting (ball valves
NOTICE and butterfly valves).
Manual pneumatic actuator PA30 - PA90

Pneumatic actuators • Actuators without spring accumulator remain in the
• Single-acting pneumatic actuators with fail- current position in case of a loss of the control pres-
safe positions OPEN and CLOSED (type sure.
additional letters in FO and FC) have pre- • Actuators with spring accumulator go into safety posi-
tensioned springs for actuation under lack tion, in case of failure or after switching off the control
of pressure. pressure, depending on the version of the actuator.
• The actuator is not intended for uses other than those
stated here. Non-observance of the instructions con-
tained in this manual will void the manufacturer's lia-
WARNING bility for the products mentioned above.
or death.
• The dismantling of these actuators must
safety expert.
• Dismounting may only be done in safety
position after disconnecting the air supply.
• When working on electric auxiliary com-
ponents of the pneumatic operation, the
electrical connections of the control voltage
500
Graph
Exploded view butterfly valve type 037P
1.Actuator PA 30 – PA 90
2.Intermediate part
3.Butterfly valve
Dimensions
Weight actuator

More dimensions
uct range of butterfly valve type 037P /
038P / 039P.
Dimensions type 037P
501
d DN inch L H1 H2 Q
mm mm mm mm mm mm
65 50 2 43 53 140 32
75 65 2½ 46 63 152 51
90 80 3 46 71 159 69
110 100 4 52 87 178 89
140 125 5 56 102 191 115
160 150 6 56 122 203 143
225 200 8 60 149 241 194
280 250 10 68 201 273 243
315 300 12 78 231 311 293
d DN inch D3 D4

mm mm mm mm
65 50 2 96 165
75 65 2 114 185
90 80 3 131 190
110 100 4 152 229
140 125 5 182 254
160 150 6 209 285
225 200 8 262 333
280 250 10 --- ---
315 300 12 373 353
Single acting FC/FO
d DN inch Type L2 L3 H H3
mm mm mm mm mm mm
65 50 2 PA30 276 65 321 128
75 65 2½ PA30 276 65 343 128
90 80 3 PA35 341 72 363 133
110 100 4 PA40 370 80 409 144
140 125 5 PA45 408 90 444 151
160 150 6 PA50 423 100 489 164
225 200 8 PA60 503 125 575 185
280 250 10 PA60 503 125 672 198
315 300 12 PA70 663 145 761 219
502
Single acting FC/FO
d DN inch Type H4 H5 H6 D2
mm mm mm mm mm mm
65 50 2 PA30 38 70 15 1/8"
75 65 2½ PA3 42 78 12 1/8"
90 80 3 PA35 46 86 15 1/8"
110 100 4 PA40 46 86 15 1/8"
140 125 5 PA45 51 96 12 1/8"
160 150 6 PA50 56 106 15 1/8"
225 200 8 PA60 68 130 12 1/8"
280 250 10 PA60 68 130 25 1/8"
315 300 12 PA70 83 153 23 ¼"
Double acting DA

d DN inch Type L1 L3 H H3
mm mm mm mm mm mm
65 50 2 PA35 176 55 311 118
75 65 2½ PA35 176 55 333 118
90 80 3 PA35 176 55 348 118
110 100 4 PA45 235 72 391 126
140 125 5 PA45 235 72 419 126
160 150 6 PA50 250 80 469 144
225 200 8 PA60 328 104 554 164
280 250 10 PA65 350 112 660 186
315 300 12 PA70 379 125 740 198
Double acting DA

d DN inch Type H4 H5 H6 D2
mm mm mm mm mm mm
65 50 2 PA35 33 60 15 1/8"
75 65 2½ PA35 33 60 15 1/8"
90 80 3 PA35 33 60 15 1/8"
110 100 4 PA45 32 68 15 1/8"
140 125 5 PA45 32 68 15 1/8"
160 150 6 PA50 46 86 15 1/8"
225 200 8 PA60 62 118 25 1/8"
280 250 10 PA65 62 118 25 1/8"
315 300 12 PA70 68 130 25 ¼"
503
d DN Inch PN kv-val- Cv-val-

ue ue
mm mm (Δp=1bar) (Δp=1psi)
65 50 2 16 3140 220
75 65 2½ 16 4570 320
90 80 3 16 7140 500
110 100 4 16 11710 820
140 125 5 16 18570 1300
160 150 6 16 27130 1900
225 200 8 16 47130 3330
280 250 10 16 77110 5400
315 300 12 16 114240 8000
d Actua- D3 L1 L2 H H1 H2 H3 H4

tor unit

mm Type mm mm mm mm mm mm
65 PA-30 95 65 240 321 63 140 15 103
75 PA-30 114 65 240 343 73 152 15 103
90 PA-35 131 72 294 365 81 159 12 113
110 PA-40 152 80 320 420 97 178 15 130
140 PA-45 182 90 357 455 112 191 12 140
160 PA-50 209 100 395 487 122 203 12 150
225 PA-60 262 124 487 580 149 245 12 174
280 PA-60 331 124 487 672 203 275 20 174
315 PA-70 380 145 551 774 241 315 20 198
504
d DN Inch L H1 H2 Q

mm mm mm mm mm mm
65 50 2 43 53 140 32
75 65 2½ 46 63 152 51
90 80 3 46 71 159 69
110 100 4 52 87 178 89
140 125 5 56 102 191 115
160 150 6 56 122 203 143
225 200 8 60 149 241 194
280 250 10 68 201 273 243
315 300 12 78 231 311 293
355 350 14 78 291 307 332
400 400 16 102 325 342 382
450 450 18 113 357 387 432
500 500 20 126 381 425 478
630 600 24 146 488 532 585
700 700 28 175 506 573 683
800 800 32 215 578 650 755
900 900 36 246 643 707 852
1000 1000 40 280 729 755 958
1200 1200 48 360 855 900 1098
505
d DN Inch D3 D4
mm mm mm mm
65 50 2 96 165
75 65 2 114 185
90 80 3 131 190
110 100 4 152 229
140 125 5 182 254
160 150 6 209 285
225 200 8 262 333
280 250 10 - - - ---
315 300 12 373 353
355 350 14 460 442
400 400 16 515 493
450 450 18 565 544
500 500 20 620 601
630 600 24 725 695
700 700 28 840 798
800 800 32 950 908
900 900 36 1050 1004
1000 1000 40 1160 1114
1200 1200 48 1380 1330
Single acting FC/FO

d DN Inch Type L2 L3 H H3
mm mm mm mm mm mm
65 50 2 PA30 276 65 321 128
75 65 2½ PA30 276 65 343 128
90 80 3 PA35 341 72 363 133
110 100 4 PA40 370 80 409 144
140 125 5 PA45 408 90 444 151
160 150 6 PA50 423 100 489 164
225 200 8 PA60 503 125 575 185
280 250 10 PA60 503 125 672 198
315 300 12 PA70 663 145 761 219
355 350 14 CH-B240 590 200 980 382
400 400 16 CH-B270 684 350 1047 380
450 450 18 CH-B270 722 281 1094 350
500 500 20 CH-B350 860 349 1238 432
630 600 24 CH-B400 918 450 1530 540
700 700 28 CH-B500 1550 640 1779 700
800 800 32 CH-B500 1550 640 1928 700
900 900 36 CH-B500 1550 640 2050 700
1000 1000 40 CH-B500 1550 640 2184 700
1200 1200 48 CH-B600 2070 850 2630 875
506
Single acting FC/FO
d DN Inch Type H4 H5 H6 D2
mm mm mm mm mm mm
65 50 2 PA30 38 70 15 1/8"
75 65 2½ PA3 42 78 12 1/8"
90 80 3 PA35 46 86 15 1/8"
110 100 4 PA40 46 86 15 1/8"
140 125 5 PA45 51 96 12 1/8"
160 150 6 PA50 56 106 15 1/8"
225 200 8 PA60 68 130 12 1/8"
280 250 10 PA60 68 130 25 1/8"
315 300 12 PA70 83 153 23 ¼"
355 350 14 CH-B240 --- --- --- ---
400 400 16 CH-B270 --- --- --- ---
450 450 18 CH-B270 --- --- --- ---
500 500 20 CH-B350 --- --- --- ---
630 630 24 CH-B400 --- --- --- ---

700 700 28 CH-B500 --- --- --- ---
800 800 32 CH-B500 --- --- --- ---
900 900 36 CH-B500 --- --- --- ---
1000 1000 40 CH-B500 --- --- - - - ---
1200 1200 48 CH-B600 --- --- --- ---
Double acting DA

d DN Inch Type L1 L3 H H3
mm mm mm mm mm mm
65 50 2 PA35 176 55 311 118
75 65 2½ PA35 176 55 333 118
90 80 3 PA35 176 55 348 118
110 100 4 PA45 235 72 391 126
140 125 5 PA45 235 72 419 126
160 150 6 PA50 250 80 469 144
225 200 8 PA60 328 104 554 164
280 250 10 PA65 350 112 660 186
315 300 12 PA70 379 125 740 198
355 350 14 CH-B200 575 220 888 290
400 400 16 CH-B240 575 220 957 290
450 450 18 CH-B240 684 350 1124 380
500 500 20 CH-B270 684 350 1186 380
630 600 24 CH-B350 860 349 1452 432
700 700 28 CH-B350 860 349 1511 432
800 800 32 CH-B400 918 450 1738 510
900 900 36 CH-B500 1550 640 2050 700
1000 1000 40 CH-B500 1550 640 2184 700
1200 1200 48 CH-B500 1550 640 2455 700
507
Double acting DA
d DN Inch Type H4 H5 H6 D2
mm mm mm mm mm mm
65 50 2 PA35 33 60 15 1/8"
75 65 2½ PA35 33 60 15 1/8"
90 80 3 PA35 33 60 15 1/8"
110 100 4 PA45 32 68 15 1/8"
140 125 5 PA45 32 68 15 1/8"
160 150 6 PA50 46 86 15 1/8"
225 200 8 PA60 62 118 25 1/8"
280 250 10 PA65 62 118 25 1/8"
315 300 12 PA70 68 130 25 ¼"
355 350 14 CH-B200 --- --- --- ---
400 400 16 CH-B240 --- --- --- ---
450 450 18 CH-B240 - - - - - - --- - - -
500 500 20 CH-B270 --- --- --- ---
630 630 24 CH-B350 --- --- --- ---
700 700 28 CH-B350 --- --- --- ---
800 800 32 CH-B400 --- --- --- ---
900 900 36 CH-B500 --- --- --- ---
1000 1000 40 CH-B500 --- --- --- ---
1200 1200 48 CH-B500 --- --- --- ---
Technical features
Setting the "Closed" position for actuators for
DN50 - 300
When the butterfly valve is in the CLOSED position, the
valve disc is not perfectly at right-angles to the axis of
the valve. The table below shows the deflection.
DN d Type 037P/
038P/039P "
b"
mm mm mm
50 63 16
65 75 16
80 90 16
100 110 18
125 140 17
150 160 17
200 225 17
250 280 15
300 315 15
508
Fundamentals for angle seat valve
Page

Angle seat valve
-- Overview 510
-- Graph 511
509
Fundamentals for angle seat
valve CAUTION
Angle seat valve Angle seat valve as end valve

Overview If the angle seat valve which functions as an
end valve in a piping system under pressure
Product description is opened, the medium can exit uncontrol-
GF Piping Systems Angle Seat Valves Type 300/301 lably! Consequences can be serious injuries.
show their strength by remarkable reliability and their
compact design. The design has evolved its strengths
• The end valve in a pressure-bearing sys-
over many years. GF Piping Systems angle seat valves tem may only be opened when the medi-
of type 300/301 do not cause pressure surges when um can be caught or carried off safely and
they are opened slowly. splashing is prevented by taking the appro-
priate measures.
Versions
Angle seat valve type 300/301
CAUTION
Dismounting the angle seat valve

The following hazardous situations
may occur when the angle seat valve is
dismounted: the medium may exit uncontrol-
lably from the pipe or the valve, whether un-
der pressure or not, the medium may flow
out of the open pipe and the valve may con-
hazardous, flammable or explosive medium.
Consequences can be serious injuries. Pri-
Product description or to opening the pipe and dismounting the
valve, it is necessary to:
• Low sensitivity to pressure surges • release all pressure from the piping sys-
• Easy maintenance without dismantling the valve tem,
• empty the piping system completely and
Overview • rinse the system, if aggressive, hazardous,
flammable or explosive media are involved.
General Type 300 / 301
Dimension DN DN10 - DN80
Pressure range 10
PN
CAUTION
Materials used Material PVC-U
Sealing PE and PTFE Pressure Test and Commissioning
Connection Cement spigot +
Angle seat valve pressure testing is subject
types to the same regulations as the piping sys-
tem. Detailed information can be found in the
Accessories Angle seat valve
«Georg Fischer Planning Fundamentals». Al-
bracket
soapplicable:
• Check that all valves are in the required
Safety information open or closed position.
The following safety instructions apply specifically to the • Fill the piping system and deaerate com-
angle seat valve. They should identify the hazards and pletely.
advice that should be considered for the different uses • The test pressure on a valve must not ex-
and installation/commissioning. ceed the value 1.5 x PN, maximum (PN +
5 bar). The component with the lowest PN
determines the maximum allowable test
pressure in the piping section.
• The valves and connections should be
checked for a tight seal during the pressure
test.
510
Dimensions
DANGER
of the butterfly valve or seal. Consequences
can be serious injuries.
• Never use mineral oilbased greases or
Vaseline!
• For angle seat valves used in varnishing
applications, please consult the special
manufacturer‘s instructions.
con-based grease.
Graph
Exploded view
d DN clos- D L L1 L2 H max.
est
mm mm inch mm mm mm mm mm
16 10 ⅜ 50 114 12 24 105
20 15 ½ 63 124 130 28 126
25 20 ¾ 63 144 150 37 140
32 25 1 80 154 160 37 166
40 32 1¼ 80 174 180 44 194
50 40 1½ 100 194 200 48 233
63 50 2 100 224 230 60 264
75 65 2½ 160 284 290 74 335
1 Housing 90 80 3 200 300 310 85 390
2 Union bush
3 Connecting part Technical data
4 Union nut Pressure-temperature diagram
5 Spindle The pressure-temperature diagram is based on a life-
time of 25 years and the medium water or similar me-
6 Threaded bush
dia.
7 Union
PVC-U
8 Handwheel
9 Wheel nut

511
Pressure loss Operating torque


X Lift (%)
Y kv, Cv value (%)
kv 100 values
d mm DN inch kv 100 l/min (Δp = 1 bar)
16 10 41
20 15 95
25 20 180
32 25 327
40 32 484
50 40 725
63 50 1130
75 65 1700
90 80 2500
512
Solenoid valves
Page

Solenoid valves
-- Overview 514
-- Graph 517
-- Coil design 518
513
Solenoid valves Type 165
Solenoid valves
Overview
Product description
A solenoid valve is a valve which is actuated by an elec-
tromagnet. Their tasks are to release, shut off, dose,
distribute or mix gases and fluids. The solenoid valves
can switch very fast, they guarantee high reliability and
a long lifetime at a low drive power. Solenoid valves
with position measuring can be operated as a servo
valve.
The range of solenoid valves is suited for a great variety
of industrial applications. Combined with other valves or
flow meters, solenoid valves from GF Piping Systems The pilot-controlled gate valve of type 165 with servo di-
offer a complete system solution, for your benefit and aphragm, is closed when currentless. A minimum dif-
profit. ferential pressure of 0.5 bar is required to fully open the
valve. Actuator and media chamber are separated by a
Versions diaphragm.
Type 157
Type 166
Type 157 is a high quality, direct-acting 2/2-way pivot-

ed armature solenoid valve, deliverable in many circuit
functions for opening, closing, dosing, mixing and dis-
tribution. The magnetic system and the media cham-
ber are separated from one another by a separating di- The solenoid valves of type 166 are direct-acting 2/2 or
aphragm system. 3/2-way valves with a clapper armature. They are used
for diverse functions, e.g. opening, shutting, dosing, dis-
Type 160/161 pensing and mixing. The solenoid system and medium
chamber are separated from one another by means of
an isolating membrane system.
The valve therefore has a long service life, even with
dry runs. Due to the use of PP and PVDF as housing
materials, type 166 is especially suitable for aggressive
media. The valve is mounted via a G 1⁄4“ union. The
valve is available as in the nominal diameters of DN3,
DN4 and DN5.
Of course, all valves are available as 24 V=, 24 V 50
Hz, 110 V 60 Hz and 230 V 50 Hz version.
Product description
Advantages
• Fast and safe switching
• Safety position
Type 160/161 is a direct-acting 2/2- or 3/2-way solenoid
valve. It can be used for diverse functions, e.g. opening, • Highly reliable
shutting, dosing, dispensing and mixing. A separating • Goof media compatibility of the used materials
diaphragm isolates the actuator from the fluid. • Low control power
The valve has a simple and robust design. The inside of
• Compact construction
the valve is free of metals. It is especially suited for ag-
gressive, abrasive and slightly soiled media. • No need for compressed air (compressor)
514
Limitations
• A maximum of 10 bar operating pressure
• Permanent electricity demand in the actuated position
• Sensitive to solids at piloted valves
• Δp mandatory for pre-controlled valves
• In direct-acting valves, the maximum fluid pressure is
inversely proportional to the diameter
Overview
Types Type 157 Type 160/161 Type 165 Type 166
Applications • Small dimensions • No compressed air • Clean liquids are • Aggressive media
are required available used (neutral or • Dosing systems
• No compressed air • Safety position re- aggressive)
• No compressed air
available quired • No compressed air available
• Safety position re- • Small medium available
• Small flow rate
quired pressure at high kv • Safety position re-
• Safety position de-
quired
sired
Material
PVC-U + + +
PP +
PVDF + +
Seal material EPDM / FPM EPDM / FPM EPDM / FPM EPDM / FPM
Dimensions DN2 - DN8 DN10 - DN20 DN15 - DN50 DN3 - DN5
Medium temperature -10 to 50°C (PVC/FPM) -10 to 50°C (PVC/FPM) -10 to 50°C (PVC/FPM) 0 to 80 °C PP with
EPDM
0 to 80 °C PP with FPM
-20 to 80 °C PVDF with
FPM
Ambient temperature 0..50°C 0..50°C 0..40°C 0..55°C
Viscosity max. 37 mm²/S max. 37 mm²/S max. 37 mm²/S
Supply voltage 24 V DC/ 230 V, 50 Hz 24 V DC/ 230 V, 50 Hz 24 V DC7 230 V, 50 24 V DC/24 V, 50 Hz/
Hz/ 110 V, 60 Hz 230 V, 50 Hz
Voltage tolerance +/- 10 % +/- 10 % +/- 10 % ± 10 %
Switching frequency approx. 100/min for AC approx. 100-150/min for approx. 1000/min
AC
approx. 10/min for UC approx. 6/min for UC
Rated duty Intermittent operation: 100% 100% Intermittent operation
10% (10min) 40 %, 30 min
Electr. connection Connector for cable Connector for cable Connector for cable Connector for cable
Connection plug ø 6-7 mm plug ø 7 mm plug ø 7 mm plug ø 7 mm
Protection class IP 65 with cable plug IP 65 with cable plug IP 65 with cable plug IP 65 with cable plug
Mode of operation A, B A, B, E, F A A, E, F
Direct-acting 3/2-way Type 160 is a direct-act- Direct-acting 3/2- Direct-acting 3/2-
solenoid valve for pipe ing 2/2-way solenoid way solenoid valve for way solenoid valve for
connections, Circuit valve for pipe connec- pipe connection, Circuit pipe connection, Circuit
function A and B tion, Circuit function A function A function A, E and F
or B
Type 161 is direct-act-
ing 3/2-way solenoid
valve for pipe connec-
tions, Circuit function E
or F
515
The manual operation is lockable after pressing, by turning clockwise
Connections Female pipe thread Solvent cement socket Solvent cement Threaded sockets G1/
sockets (PVC-U), Fu- 4"
sion sockets (PVDF)
Mounting orientation Preferably with actuator upright
Safety information
WARNING
DANGER
Risk through escaping medium
Serious injury from escaping medium.
Safety instructions • Before operating, ensure the tightness of
When ignoring the safety instructions, conse- the media connections.
• Solenoid valve to be operated only accord-
ing to the performance data.
NOTICE
WARNING Non-opening valve

• At high operating pressures, the valve will
not open electromagnetically.
Use solenoid valves only as intended.
Can cause severe injury and damage to the
product.
NOTICE
• Use solenoid valve exclusively within the
permissible limits. Another use is regarded
as not complying. Risk due to foreign substances
• The solenoid valve is not approved for use • For new installations and after repairs,
in hazardous areas. flush the piping system with valves fully
opened.
NOTICE
CAUTION
Damage to the valve body
• Solenoid valve must be installed in aligned Malfunction of the solenoid valve caused
pipes to prevent tension in the valve body. by dirty media
Solenoid valve opens or closes no longer
with control holes clogged by dirt or with
NOTICE blocked anchor.
• Clean the piping system before installing
the solenoid valve.
Damage to the valve body • Switch the solenoid valve at least once a
• Use only adhesive that is suited for the month.
valve body.
CAUTION
CAUTION
Risk of flow against the flow direction
Damage to solenoid or magnetic sleeve Damage to the solenoid valve
When using the magnetic coil as a lever, • Solenoid valve to be operated only in flow
magnetic coil and magnet sleeve can be de- direction
stroyed. • Take appropriate precautions for the back
• To refit the solenoid valve on the pipe sur- flows to be expected.
faces, use only provided key.
516
Dimensions type 165
Graph
Dimensions type 157
Housing material D B E F
mm mm mm
All versions PVC- PVDF-
Stainless steel G 1/4 89 32 76 housing housing
PVC G 3/8 91 35 65 DIN Pipe- B C F L P L P
Possible port configurations Ø
Mode of operation 1 2 3
15 20 148 62.5 40 148 16 147 16
A P - A
20 25 148 62.5 40 154 19 151 18
E P1 P2 A
25 32 147.5 85 44.5 190 22 185 20
F A B P
32 40 174.5 85 44.5 198 26 189 22
Dimensions type 160/161
40 50 212 115 44.5 254 31 245 25
50 63 212 115 44.5 268 38 253 29
Dimensions type 166

The ports are marked with 1, 2 and 3 as indicated in the
configuration table, depending on the circuit function.
DN A D (Solvent ce- D (Threaded L

ment sockets) sockets)
mm mm mm mm
10 30 Ø 16.2 G 3/8 and G 1/2 130
15 33 Ø 20.2 G 1/2 and G3/4 136
20 37 Ø25.2 G 3/4 144
517
Possible port configurations
Mode of opera- Port 1 Port 2 Port 3
tion
A A - P
E P1 A P2
F A P B That means in the de-energized state, the valve has no
connection between port P and A, therefore the valve
is closed. You could also say the valve is "normally
Coil design closed" (NC).
Coil comparison Once the valve is energized the connection goes from
Coil comparison port P to A, therefore the valve is open.
Direct current 2/2-way valve; normally closed (NC)
• Quieter Function A
• Less wear of solenoid core Gate valve; closed when de-
• High solenoid holding force energised (NC, Normally
Closed)
• Same pick-up and holding power
• No shading ring required
Alternating current Function B
Gate valve; open when de-
• Tendency to hum
energised (NO, Normally
• Risk of burn-out of solenoid coil if solenoid core is Open)
jammed
• Faster switching speed (dependent on phase angle)
Coil heating Function A
The electrical power of a coil is converted virtually 100% Pilot-operated 2/2-way valve
(Type 165); closed when de-
to thermal energy. Thus, a coil might heat up a lot in
energised
continuous operation. This means that the maximum
power rating of a coil will essentially depend on the
maximum tolerable temperature of a coil which may not
be exceeded on a sustained basis, depending on the
mode of operation (continuous operation or only short A, B: Connection to the consumer
time duty), without damaging the coil. The encapsula- P: Connection compressed air
tion materials and the largest possible coil surface area
ensure good heat dissipation and radiation from the sur-
face.
In addition to the self-heating of the coil, application-
specific factors or operating data also have a major in-
fluence on the achievable overall temperature of the
coil:
• Ambient temperature
• Medium temperature
• Medium type (fluid or gaseous)
• Heat radiation capacity (encapsulation)
• Continuous operation or reduced duty
With continuous operation and normal ambient temper-

ature (20 °C) of a solenoid valve, temperatures on the
surface of 80-90 °C or even higher may be achieved.
The maximum operating data (ambient temperature
and medium temperature, etc.) is thus specified un-
der “Technical Data” in the relevant data sheets for the
valve types.
Working principles and their symbols
Commonly, the symbols for solenoid valves are shown
for the de-energized status.
For example a valve with the function A has the symbol:
518
3/2-way solenoid valve
Function C
Gate valve; closed when de-
energised, Port A relieved

Function D
Gate valve; open when de-
energised, Port A pressurised

Function E
Mixing valve; pressurised
whende-energised, P2
connected with Port A, P1
closed.

Function F
Distribution valve; pres-
surised when de-energised,
Connection P is connected to
Port B, A closed.
A, B: Connection to the consumer

P: Connection compressed air
R: Return compressed air
519
Direct-acting solenoid valves - characteristics and applications of the solenoid actuators
Plunger Pivoted-armature
Media separation in actuator No Standard with media separation.
Wear behaviour/ service life Medium to high susceptibility to wear Low wear since there is no sliding
of the solenoid core, due to friction in friction in the armature.
the core guiding tube, depending on
application area.
Universality and possible applications Very robust solenoid coils available Very tried and tested actuation princi-
in various sizes and with various ple, only one coils size available, us-
power ratings. Can be uses for AC/ able for AC/DC/UC.
DC/ UC.
Typical media Neutral gaseous and fluid, non-abra- Neutral gaseous and fluid, media,
sive media, e.g. conditionally also aggressive and
• Water (demineralized water, abrasive, depending on use/usabili-
ty and resistance of the isolating di-
only conditional)
aphragm material, e.g.
• Air
• Water (including demineralized
• Oils water)
• Industrial gases • Oils, Acid and lyes
• Ultrapure media
Characteristics • Robust design • Very high reliability
• Good price-performance ratio • Suited for aggressive media
• Universal application area • All three fluid connections on
• AC, DC and UC versions avail- one level
able • Media separation in standard
• Without lubrication leads to fric- version
tion and to limited lifetime • Long life time
• Separation of media leads to • AC, DC and UC versions avail-
limited pressure range able
• With overstretched coil
Servo-assisted solenoid valves Limitations

At high system pressures and with large nominal diame- • Sensitive against dirt
ters, it would also be necessary to have higher magnetic • Limited lifetime when used with gaseous media
forces and electrical control power values in direct-act-
ing solenoid valves. The larger solenoid coils required • Differential pressure required
for this would increase the overall weight and overall
size. Consequently, servoassisted valves are used.
In the case of servo-assisted solenoid valves, a main
valve is controlled by a solenoid-operated pilot valve
with smaller flow cross-sections and lower electrical
control power. This control can comprise either a 2/2-
way pilot valve or a 3/2-way pilot valve. The main valve
uses a diaphragm or a piston as a moving closure ele-
ment for opening and closing the fluid path.
Depending on the design, a low pressure differential is
required to open the full cross-section. This principle is
used primarily with 2/2-way valves, both normally closed
and normally open. The valve can be operated in only
one flow direction. The back-pressure tightness is very
low.
Advantages
• Cost efficient design
• Low energy consumption
• Good damped closing
• Low pressure differential required
• Larger dimensions available
520
Technical data
Type 157
Nominal di- Mode of opera- Kv kv- Pressure range** Power consumption Power consumption Weight
ameter tion value* Pick-up (electrical) Operation (electri-
Water cal)
(mm) (l/min) AC (bar) DC (bar) AC (VA) DC (W) AC (VA/W) DC (W) (kg)
4 A 0.3 0-2 0-4 30 40 15/8 8-12 0.5
6 A 0.6 0-1 0-2 30 40 15/8 8-12 0.5
8 A 1.0 0-1 0-1 30 40 15/8 8-12 0.5
Type 160/161
Nominal di- Kv value* Pressure range** Power consumption Power consumption Weight
ameter Water Pick-up (electrical) Operation (electrical)

(mm) (m³/h) A (bar) B (bar) E (bar) F(bar) AC (VA) DC (W) AC (VA/W) DC (W) (kg)
10 2.0 0-3 0-2 0-0.6 0-1 100 1.2
15 4.5 0-1 0-1 0-0.3 0-0.5 up to 100 32/16 9 1.2
20 6.0 0-0.5 0-0.5 0-0.15 0-0.25 120 1.2
Type 165
Nominal di- Mode of opera- Kv kv-value* Water Pressure range** Power consumption Power consumption Op-
ameter tion Pick-up (electrical) eration (electrical)
(mm) (l/min) (bar) AC (VA) DC (W) AC (VA/W) DC (W)
15 A 5.0
20 A 6.0
25 A 14.0 0.5-6 20 5 11/5 5
32 A 16.0
40 A 30.0
50 A 36.0
Type 166
Nominal di- Mode of opera- Kv kv- Pressure range** Power consumption Power consumption Weight
ameter tion value* Pick-up (electrical) Operation (electrical)
Water
(mm) (l/min) AC (bar) DC (bar) AC (VA) DC (W) AC (VA/W) DC (W) (kg)
A 0-10 0-8
3 F 4.20 0-10 0-8
E 0-6 0-4
A 0-5 0-4 30 8 15/8 8 0.4
4 F 5.00 0-5 0-4
E 0-3 0-2
5 A 6.70 0-4.5 -
* Kv value (l/min) at +20°C, 1 bar Pressure at valve inlet and free outlet
** Pressure values (bar) Excess pressure to atmospheric pressure
521
Switching time
Type 157
Switching time*** Open Close

Mode of opera- (ms) (ms)
tion
A, B 15 - 20 15 - 20
Type 160/161

tion
A, B, E, F 10 - 20 40 - 60
Type 165

tion
A 100 - 800 1000 - 4000
Type 166

Mode of opera- AC DC AC DC (ms)
tion (ms) (ms) (ms)
A, E, F approx. 10 - 17 approx. 15 - 20
8 15
*** Switching time (ms) Measured at valve outlet at 6 bar and

+ 20°C
Open: Pressure build-up 0....90%, Close: Pressure build-up
100...10%
Electrical connection
Observe the voltage and type of current as given on the
type plate. Voltage tolerance ± 10%. Connection via ca-
ble plug, protection class IP 65. Cable 3 x 0.75 mm².
Flat pin terminal = Earth connection. Cable plug insert
can be rotated by 4 x 90 º. Tightening torque for cable
plug attachment 1 Nm.
522
Fundamentals for check valves
Page

Check valves type 561 and type 562
-- Overview 524
-- Graph 526
Angle seat check valves type 303/304
-- Overview 532
-- Graph 534
Wafer Check valves type 369
-- Overview 536
-- Graph 537
523
Fundamentals for check valves Safety
• The spring within the valve (type 562) guarantees
100% leakproofness when the valve is in idle mode,
Check valves type 561 and type 562 even without medium pressure and mounted horizon-
tally.
Overview
• Type 561 (no spring) is already 100% leakproof at a
Product description water column of 2m
With the new check valve from GF Piping Systems ev- • The double bearing prevents a jamming of the check
erything is under control. The new design combines in- cone.
creased safety and efficiency with easy handling. The
check valves of type 561 and 562 pave the way for a • The gasket always remains in the same position, fixed
new generation of valves, which impress with safety, by a support ring. This prevents slipping, bending or
simplicity and efficiency. They mark a milestone in vale erosion of the gasket.
technology. The two check valves of type 561 and type • Corrosion resistance
562 easily fit in all piping systems thanks to our com-
prehensive product range. Whether in water treatment, Simplicity
chemical process industry or for cooling applications, • The check valves 561 and 562 are self-closing. There
check valves from Georg Fischer can be found almost is no need for an energy source other than the exist-
everywhere, where reliable performance is required. ing medium pressure for opening or closing the valve
With their versatile choice of materials and die the high at any given time.
pressure level, the check valves of type 561 and type • Same installation length as ball valve type 546, 546
562 fulfil numerous requirements of many common ap-
plications. The self-closing function and the silent opera- Efficiency
tion of the valve underline safety and comfort. • Thanks to the aerodynamic design of the check cone,
Versions the valve permits a far higher flow rate than standard
All types are available in the dimensions from DN10 up check valves with a ball.
to DN100.
With the extensive range of options you can be sure to
Type 561 (without spring) find the check valve that perfectly suits your require-
ments:
• All jointing methods are available and leave nothing to
be desired
• Depending on your field of application, you may
choose among various types of materials for the valve
body, the cone and the spring
• The new generation of check valves are available with
ISO, BS, ASTM, ANSI and JIS connection standards
The GF Piping Systems check valve enables safe, effi-

cient and easy transport of media.
Type 562 (with spring)
Product features
With the GF Piping Systems Check Valve everything
is under control. The new design combines increased
safety and efficiency with easy handling.
524
Overview
radially re- radially re-
movable movable
Pressure range PN 16/10
Spring-assisted (V2A) +
PVC-C + +
ABS + +
PP-H + +
PVDF + +
FPM + +
Spigot + +
Flanges + +
Threaded socket + +
Standard ISO + +
ANSI + +
BS + +
JIS + +
Options Spring Nimonic 90/Hastelloy-C +
Spring Halar/ ECTFE coated +
Safety information
CAUTION
Check valves type 561 and 562 from Georg Fischer are
intended exclusively for shutting off and conducting me-
dia in the allowable pressure and temperature range in
• Check valves are not suitable for use with
piping systems into which they have been installed. The
media containing solids. When selecting
maximum operating time is 25 years.
a check valve, make surethat the densi-
ty (specific weight) of the cone isgreater
than that of the medium. (exception: bleed
valve)
• When used as a ventilating valve, the den-
sity of the cone must be less than the den-
sity of the medium.
• The flow of the fluid must be even across
the entire cross-section of the check valve
in order for it to work properly. If necessary
(after pumps, changes in direction) a tur-
bulence-free section should be allowed for.
Cavitation should be avoided.
• GF Piping Systems recommends that you
use the type check valves 561, 562 as ven-
tilation valves. Use the ventilation valves
type 595 and 591 specially developed for
this application.
525
Graph
Arrows
The arrow on the valve housing indicates the
direction of the flow. For application with ver-
tical flow, only an upward flow is permitted,
i.e. the arrow must point upward. If installed
in the opposite direction, the shut off function
is not warranted, and serious injuries might
be a consequence.
• Observe the arrow information and expla-
nation
1 Union nut
2 Connecting part
WARNING
3 O-ring
4 Screw-in ring
Connection methods
5 Sealing ring
Only identical materials may be joined to-
gether via welded or adhesive joints. Non- 6 Back-up ring
compliance can lead to serious injuries. 7 Cone
• Sections of pipework with adhesive joints 8 Spring (type 562)
should be rinsed with non-pressurized wa- 9 Housing
ter as soon as possible after completion of
the joints. Dimensions check valve type 561
• The union nuts on the valve should be
tightened “hand tight”. Check valve type 561 with solvent cement sockets-
metric
NOTICE
Opening and closing conditions

• The information in the table apply to wa-
ter or water-like media with a density of ap-
proximately 1g/cm³. If media with a higher
density are used, make sure that the cone d DN D L L2 z clos-
can float depending on the material used est
and that the closing function of the cone is mm mm mm mm mm mm inch
no longer granted. This is dependent on
16 10 50 92 56 64 ⅜
the material used.
• The values for the opening conditions ap- 20 15 50 95 56 64 ½
ply to vertical installation (->recommended 25 20 58 110 65 72 ¾
installation location). For horizontal installa-
32 25 68 123 71 79 1
tion, the valve opens at much lower differ-
ential pressures. 40 32 84 146 85 94 1¼
50 40 97 157 89 95 1½
63 50 124 183 101 107 2
75 65 166 233 136 144 2½
90 80 200 254 141 151 3
110 100 238 301 164 174 4
526
Check valve type 561 with solvent cement spigots- Check valve type 561 with fixed flange metric
metric
d DN D L L2 closest
d DN D D1 D3 L L2 L3 clos-
mm mm mm mm mm inch est
16 10 50 114 56 ⅜ mm mm mm mm mm mm mm mm inch
20 15 50 124 56 ½ 20 15 95 65 14 124 56 130 ½
25 20 58 144 65 ¾ 25 20 105 75 14 144 65 150 ¾
32 25 68 154 71 1 32 25 115 85 14 154 71 160 1
40 32 84 174 85 1¼ 40 32 140 100 18 174 85 180 1¼
50 40 97 194 89 1½ 50 40 150 110 18 194 89 200 1½
63 50 124 224 101 2 63 50 165 125 18 224 101 230 2
75 65 166 284 136 2½
Check valve type 561 with butt fusion spigots long
90 80 200 300 141 3 metric
110 100 238 340 164 4
Check valve type 561 with threaded sockets Rp
Rp DN D L L2 z
inch mm mm mm mm mm d DN D L L2 e clos-
est
⅜ 10 50 95 56 69
mm mm mm mm mm mm inch
½ 15 50 100 56 67
20 15 50 193 56 2.3 ½
¾ 20 58 114 65 78
25 20 58 216 65 2.3 ¾
1 25 68 127 71 85
32 25 68 223 71 3.0 1
1¼ 32 84 146 85 100
40 32 84 249 85 3.7 1¼
1½ 40 97 152 89 106
50 40 97 271 89 4.6 1½
2 50 124 177 101 121
63 50 124 321 101 5.8 2
2½ 65 166 233 136 144
3 80 200 254 141 151
4 100 238 301 164 174
527
Dimensions check valve type 562 Check valve type 562 with threaded sockets Rp
Check valve type 562 with solvent cement sockets-
metric
Rp DN D L L2 z
inch mm mm mm mm mm
d DN D L L2 z clos- ⅜ 10 50 95 56 69
est
½ 15 50 100 56 67
¾ 20 58 114 65 78
16 10 50 92 56 64 ⅜
1 25 68 127 71 85
20 15 50 95 56 64 ½
1¼ 32 84 146 85 100
25 20 58 110 65 72 ¾
1½ 40 97 152 89 106
32 25 68 123 71 79 1
2 50 124 177 101 121
40 32 84 146 85 94 1¼
2½ 65 166 233 136 144
50 40 97 157 89 95 1½
3 80 200 254 141 151
63 50 124 183 101 107 2
4 100 238 301 164 174
75 65 166 233 136 144 2½
90 80 200 254 141 151 3 Check valve type 562 with fixed flange metric
110 100 238 301 164 174 4
Check valve type 562 with solvent cement spigots-

metric
d DN D D1 D3 L L2 L3 clos-
est
d DN D L L2 closest
20 15 95 65 14 124 56 130 ½
mm mm mm mm mm inch 25 20 105 75 14 144 65 150 ¾
16 10 50 114 56 ⅜ 32 25 115 85 14 154 71 160 1
20 15 50 124 56 ½ 40 32 140 100 18 174 85 180 1¼
25 20 58 144 65 ¾ 50 40 150 110 18 194 89 200 1½
32 25 68 154 71 1 63 50 165 125 18 224 101 230 2
40 32 84 174 85 1¼
50 40 97 194 89 1½
63 50 124 224 101 2
75 65 166 284 136 2½
90 80 200 300 141 3
110 100 238 340 164 4
528
Check valve type 562 with butt fusion spigots long
metric

d DN D L L2 e clos-
est
20 15 50 193 56 2.3 ½
25 20 58 216 65 2.3 ¾
32 25 68 223 71 3.0 1
40 32 84 249 85 3.7 1¼ P Permissible pressure in bar, psi
50 40 97 271 89 4.6 1½ 1) e.g. check valves with PP or PE100 SDR17 spigot end
In case of applications with the temperatures in the
63 50 124 321 101 5.8 2 range of the dotted lines, please contact your
GF representative.
Technical data
lar media.

Pressure loss



529
Opening and closing conditions
DN Open (vertical installation) Closing*
Differential pressure Differential pressure Min. flow for full Min. flow rate for full Tight at Tight from
for take-off of cone for full stroke of cone stroke of cone stroke (bar) (bar) Type
(bar) (bar) (l/min) (m/sec) Type 561 562

10 0.003 0.01 8 0.7 0.2 0.1
15 0.003 0.01 9 0.7 0.2 0.1
20 0.003 0.01 13 0.7 0.2 0.1
25 0.005 0.01 18 0.8 0.2 0.1
32 0.005 0.01 35 0.8 0.2 0.1
40 0.010 0.01 70 0.8 0.2 0.1
50 0.020 0.01 100 0.8 0.2 0.1
65 0.025 0.01 120 0.9 0.2 0.1
80 0.030 0.01 170 0.9 0.2 0.1
100 0.030 0.08 250 1.0 0.2 0.1
*vertical and horizontal installation Reference values for tightening torque of

screws
Material Density
d DN inch Total num- Torque Torque
ABS 1.03 g/cm³ ber of flat gas- profile
PP-TV 20 (Cone: PP-talc-filled) 1.05 g/cm³ screws ket gasket *
PP-H 0.91 g/cm³ mm mm (Nm) (lb- (Nm) (lb-
ft.) ft.)
PVC-U 1.38 g/cm³
20 15 ½ 4 x M12 x 50 10 7.4 10 7.4
PVC-C 1.50 g/cm³
25 20 ¾ 4 x M12 x 55 10 7.4 10 7.4
PVDF 1.78 g/cm³
32 25 1 4 x M12 x 60 15 11 10 7.4
kv 100 values 40 32 1¼ 4 x M16 x 65 20 15 15 11
DN inch d kv 100 l/ Cv 100 kv 100 m³/ 50 40 1½ 4 x M16 x 70 25 18 15 11
(mm) (mm) min (Δp = US gal/ h (Δp = 1
63 50 2 4 x M16 x 75 35 26 20 15
1 bar) min (Δp = bar)
1 psi) 75 65 2½ 4 x M16 x 90 50 37 25 18
10 ⅜ 16 190 13 11 90 80 3 8 x M16 x 30 22 15 11
100
15 ½ 20 190 13 11
110 100 4 8 x M16 x 35 26 20 15
20 ¾ 25 380 26 23
130
25 1 32 460 32 28
32 1¼ 40 850 59 51
* preferable type of gasket (suited for plastics)
40 1½ 50 1080 75 65
50 2 63 1670 115 100
65 2½ 75 2950 204 177
80 3 90 3600 248 216
100 4 110 4150 286 249
530
Chemical resistance of springs
Chemical resistance at 20 °C (Applications can be very depen- Springs
dent on the concentration)
Chemicals Steel 1.4301 V2A Steel / Halar® Nimonic 90 2.4632
coated 1.4301
V2A
Acids Oxidating (HNO3, H2CrO4, etc.) o + o
Inorganic (HCl, H2SO4, etc.) - + o
Organic (formic acid, acetic acid, citric acid, - + o
etc.)
Bases Inorganic (NaOH, KOH, etc.) + + +
Salts NaCl, FeCl2, FeCl3, CaCl2, etc. o + o
Halogens Chlorine, bromine, iodine, (no fluorine) - + o
Fuels / Oils Aliphatic hydrocarbons + + +
Aromatic hydrocarbons + + +
Solvents Chlorinated hydrocarbons o o +
Ketones + + +
Alcohols + + +
Esters + + +
Aldehydes + + +
Phenols o + +
Oxidizing agents NaOCl, ozone, etc. o + +
Glycol + + +

+ good
o conditionally resistant, please consult us
- not resistant

The above list is only intended as a guideline and does not replace an indepth review of material suitability for the particular ap-
plication.
The information is based on our experience and is state of the art. These data are general indicators only.
In practice, however, other factors such as concentration, pressure and jointing technology must also be taken into considera-
tion. The technical data are binding and are not expressly warranted characteristics of the goods.
We would be glad to assist you with your selection of materials.

Minimum pressure for valve opening Type 562

DN Differential pres-
sure up to lifting of Maintenance
the cone Check valves require no maintenance under normal op-
erating conditions. It is enough to control periodically, if
(mm) (bar) there is no leakage. Should leakage or other malfunc-
10 0.028 tions occur, follow the instructions under «Safety infor-
mation».
15 0.028
We recommend a function test for check valves which
20 0.03 are kept permanently in the same position 1–2 x a year
25 0.03 to check serviceability.
32 0.035
40 0.04
50 0.05
65 0.06
80 0.06
100 0.06
531
Angle seat check valves type 303/304
Overview
Product description
GF Piping Systems Angle Seat Check Valves Type 303/
304 show their strength with remarkable reliability and
their position-independent function. The design of the
angle seat check valves has evolved its strengths over
many years.Because of its position-independent func-
tion and the simple maintenance process, the valve
grants a high degree of process reliability.
Versions
Angle seat check valves type 303 with solvent ce-
ment spigots metric
Angle seat check valve type 303 with solvent ce-

ment sockets JIS
Angle seat check valves type 303 with fixed flange-

JIS
Product features
• Self closing check valve (gravity)
• Works both horizontally and vertically
• Easy maintenance of check element without disman-
tling the valve
532
Overview
General Type 303/304
ABS +
FPM +
Connection types Solvent cement socket +
Cement spigot +
Flange +
Standard ISO +
JIS +
Safety information
DANGER
These Georg Fischer angle seat check valves of type
303/304 are intended exclusively for shutting off and
conducting media in the allowable pressure and temper-
Removal of the angle seat check valve
ature range in piping systems into which they have been
installed. The maximum operating time is 25 years. The medium may exit uncontrollably from
the pipe or the valve, whether under pres-
sure or not, the medium may flow out of
CAUTION the open pipe, and the valve may contain
residues or remnants of aggressive, haz-
ardous, flammable or explosive media. Con-
• Check valves are not suitable for use with sequences can be death or serious injuries.
media containing solids. • Remove all pressure from the piping sys-
• For the angle seat check valve to function tem
properly, the flow must be evenly distribut- • Empty the piping system completely
ed over the pipe cross-section. If neces- • Rinse the piping system, if aggressive,
sary (after pumps, changes in direction) a hazardous, flammable or explosive media
turbulence-free section should be allowed are inside the system,
for. Cavitation should be avoided.
DANGER
WARNING
Lubricants
Arrows False lubricants can corrode the material of
The arrow on the valve housing indicates the the angle seat check valve or the seal. Con-
direction of the flow. For application with ver- sequences can be death or serious injuries.
tical flow, only an upward flow is permitted, • Never use mineral oil-based greases or
i.e. the arrow must point upward. If installed Vaseline (Petrolatum)!
in the opposite direction, the shut off function • All seals should be lubricated with a sili-
is not warranted, and serious injuries might con-based grease.
be a consequence.
• Observe the arrow information and expla-
nation
533
Graph ment sockets JIS
Exploded view
inch DN z D D1 L H
inch mm mm mm mm mm mm
½ 15 162 43 53 194 65
¾ 20 170 47 53 208 75
1 25 180 56 53 224 90
1¼ 32 204 64 74 256 102
1½ 40 228 82 83 290 123
1 Housing 2 50 266 95 103 342 144
2 Flat gasket
3 Piston Angle seat check valve type 303 with fixed flange-
4 O-ring
5 Valve top JIS
6 Union
7 Circlip
Dimensions
ment spigots metric
inch DN D D1 D2 D3 L H
½ 15 95 70 48 15 130 65
¾ 20 100 75 54 15 150 75
d DN D L L1 L2 H clos- 1 25 125 90 62 19 160 90

est 1¼ 32 135 100 71 19 180 102
mm mm mm mm mm mm mm inch 1½ 40 140 105 88 19 200 123
16 10 39 114 120 24 58 ⅜ 2 50 155 120 103 19 230 144
20 15 43 124 130 28 65 ½ 2½ 65 185 140 106 19 290 186
25 20 47 144 150 37 75 ¾ 3 80 200 150 120 19 310 204
32 25 56 154 160 37 90 1
40 32 64 174 180 44 102 1¼ Technical data
50 40 82 194 200 48 123 1½ Pressure-temperature diagram
63 50 95 224 230 60 144 2 The following pressure-temperature diagrams are based
75 65 92 284 290 74 186 2½
lar media.
90 80 104 300 310 85 204 3
534
ABS kv 100 values
DN DN d kv 100 Cv 100 kv 100
mm inch mm l/min US gal./ m³/h
(Δp = 1 min (Δp = 1
bar) (Δp = 1 bar)
psi)
10 ⅜ 16 45 3.2 2.7
15 ½ 20 95 6.7 5.7
20 ¾ 25 170 11.9 10.2
25 1 32 300 21.0 18.0
P Permissible pressure in bar, psi 32 1¼ 40 440 30.8 26.4

T Temperature in °C, °F 40 1½ 50 700 49.0 42
PVC-U 50 2 63 1100 77.0 66

65 2½ 75 1700 119.0 102
80 3 90 2400 168.0 144
Technical features, pressure, ...

DN Open Closed
Differential Min. flow for Min. flow Tight
pressure for full stroke rate for full at
full stroke (l/min) stroke (bar)
(bar) (m/sec)
10 0.02 5 1.1 0.2
15 0.02 10 1.1 0.2
20 0.02 18 1.1 0.2
Pressure loss 25 0.02 28 1.1 0.2
32 0.02 50 1.2 0.2
40 0.03 95 1.4 0.2
50 0.03 200 1.5 0.2
65 0.03 280 1.8 0.2
80 0.03 420 1.8 0.2

Maintenance
Angle seat check valves require no maintenance under
normal operating conditions. It is enough to control peri-
odically, if there is no leakage. Should leakage or other
malfunctions occur, follow the instructions under «Safe-
X Flow rate (l/min, US gal/min) ty information».
We recommend a function test for angle seat check
valves which are kept permanently in the same position
1–2 x a year to check serviceability.
535
Wafer Check valves type 369 Type 369 in PVDF
Overview
Product description
GF Piping Systems Gate Check Valves Type 369 are
designed especially for large installations, demand low
service and effort and are absolutely compact. The De-
sign is optimized for installations between ISO/DIN as
well as ASTM connections. The gate check valves can
be installed both in either horizontal or vertical direction.
If a medium flows in the flow direction, it opens up the
plate of the wafer check valve and thus the flow is pos-
sible. If the medium pressure falls below a certain limit,
the flap closes again.
Versions
The wafer check valves type 369 complement the vast Product features
range of GF valves. They preventthe medium from flow- • Self closing check valve (water column/gravity/spring
ing back, they are available in PVC-U, PP and PVDF optional)
(DN32 – DN300)and also with reset springs in V4A and
• Only highly resistant materials
Hastelloy. The wafer check valves are suitablefor verti-
cal and horizontal mounting. They are robust and main- • Simple installation between standard flanges (see
tenance free and admittedfor a nominal pressure (PN) product range)
of 6 bar. • Optimized face seal (flange seal)
Type 369 in PVC-U • Robust and maintenance-free design
• Easy installation. The screws centre the check valve
via the outer diameter for ISO/DIN and ANSI flange
adaptors. The integrated supporting eye let for easy
fitting.
• Suitable for vertical or horizontal mounting.
• All parts with media contact are made in high resistant
plastics and seals material.
• Available in the dimensions from DN32 up to DN300
in PVC-U, PP-H and PVDF.
• Special EPDM or FPM gaskets are suitable for flange
adaptors with grooves.
• Disc seals are available in EPDM or FPM.
• Wafer check valves in PVC-U are suitable for ISO/
Type 369 in PP-H DIN and also ANSI flange adaptors due to their spe-
cial outer shape.
• For pulsating flow, wafer check valves with reset
spring (out of stainless steel V4A or Hastelloy C) are
available. Noises are thus reduced.
• No auxiliary energy/actuator is required to operate the
valve.
536
Overview
General Type 369
Dimension DN DN32 - DN300
Pressure range PN 6
PP-H +
PVDF +
FPM +
Spigot +
Flanges +
Threaded socket +
Standard ISO +
ANSI +
Safety information
DANGER
Wafer check valves type 369 by Georg Fischer are ex-
clusively intended for installation in a piping system me-
dia within the allowable pressure and temperature lim-
Lubricants
its to shut off or pass through. The maximum operating
time is 25 years. The use of inadequate lubricants can affect
the material of the wafer check valve or of
the sealings.Consequences can be serious
CAUTION injuries or death.
• Never use mineral oil-based greases or
• Check valves are not suitable for use with • Lubricate all gaskets with grease based on
media containing solids. During control op- silicone or polycol.
eration, cavitation has to be avoided.
• The wafer check valve is approved only for
PN6. Graph
• No direct installation on pump flange or Exploded view
bend allowed.
DANGER
Removal of the wafer check valve

The medium may exit uncontrollably from 1 Screw and washer
the pipe or the valve, whether under pres- 2 Flange
sure or not, the medium may flow out of 3 Flange adaptor/stub
4 Flange gasket
the open pipe, and the valve may contain 5 Wafer Check valve type 369
residues or remnants of aggressive, haz- 6 Nut and washer
ardous, flammable or explosive media. Con-
sequences can be death or serious injuries.
• Remove all pressure from the piping sys-
tem
• Empty the piping system completely
• Rinse the piping system, if aggressive,
hazardous, flammable or explosive media
are inside the system,
537
Dimensions Wafer check valve type 369 PP-H without spring
Wafer check valve type 369 PVC-U without spring
d DN D D1 D2 H L L1
d DN inch D D1 D2 D3 L L1 H
40 32 85 59 18 25 15 22
mm mm mm mm mm mm mm mm mm 50 40 95 72 22 28 16 27
40 32 1¼ 85 59 18 85 15 22 25 63 50 109 86 32 29 18 40
50 40 1½ 105 74 22 95 16 27 27 75 65 129 105 40 31 20 55
63 50 2 124 90 32 109 18 40 29 90 80 144 119 54 32 20 67
75 65 2½ 137 110 40 129 20 55 31 110 100 164 146 70 31 23 67
90 80 3 175 125 54 144 20 67 32 140 125 195 173 92 35 23 94
110 100 4 175 150 70 164 23 67 31 160 150 220 197 105 42 26 100
140 125 4 195 178 92 195 23 94 35 225 200 275 255 154 38 35 152
160 150 5 222 192 105 220 26 100 41 280 250 330 312 192 41 40 180
225 200 6 279 256 154 275 35 152 38 315 300 380 363 227 41 45 215
280 250 8 340 306 192 330 40 180 41
315 300 10 410 342 227 380 45 215 41
538
Wafer check valve type 369 PVDF without spring Opening pressure, tightness type 369
Diam- Opening pressure in mbar Minimum wa-
eter ter column for
sealing in m
DN Ver- Ver- Hori- Hori- PVC- PP
tical tical zontal zontal U
with- with with- with PVDF
out spring out spring
spring spring

32 10 30 1 20 2 3
40 10 30 1 20 2 3
50 10 30 1 20 2 3
65 10 30 1 20 2 3
d DN D D1 D2 L L1 H 80 10 30 1 20 2 3
mm mm mm mm mm mm mm mm 100 10 30 1 20 2 3
40 32 85 59 18 15 22 25 125 10 30 1 20 2 3
50 40 95 74 22 16 27 27 150 10 30 1 20 2 3
63 50 109 90 32 18 40 29 200 18 38 1 20 2 3
75 65 129 110 40 20 55 31 250 18 38 1 20 2 3
90 80 144 125 54 20 67 32 300 18 38 1 20 2 3
110 100 164 150 70 23 67 31
Pressure loss
140 125 195 178 92 23 94 35
PVC-U, pipe PN10
160 150 220 192 105 26 100 41
225 200 275 256 154 35 152 38
280 250 330 306 192 40 180 41
310 300 380 342 227 45 215 41
Technical data
Pressure-temperature diagram of type 369
PVC-U, PP, PVDF
The following pressure temperature diagram is based
lar media.

539
PP with outlet flange adapter PP/PE, SDR11 (PN10) kv 100 values PP with outlet flange adapter PP/
PE, SDR11 (PN10)
DN DN d kv 100 Cv 100 kv 100
mm inch mm l/min US gal./ m³/h
(Δp = 1 min (Δp = 1
bar) (Δp = 1 bar)
psi)
32 1¼ 40 280 19.6 16.8
40 1½ 50 340 23.8 20.4
50 2 63 610 42.7 36.6
65 2½ 75 1230 86.1 74
80 3 90 2610 182.7 157
100 4 110 3930 275.1 236
Medium: water 20 °C 125 5 140 7120 498.4 427

X Flow rate (l/min, US gal/min) 150 6 160 9180 642.6 551
Y Pressure loss Δp (bar, psi) 200 8 225 17600 1232 1056
PVDF, Pipe PN10 250 10 280 24400 1708 1464
300 12 315 31900 2233 1914
kv 100 values PVDF, pipe PN10

DN inch d kv 100 Cv 100 kv 100
mm mm l/min US gal/ m³/h
(Δp = 1 min (Δp = 1
bar) (Δp = 1 bar)
psi)
32 1¼ 40 280 19.6 16.8
40 1½ 50 340 23.8 20.4
50 2 63 610 42.7 36.6
65 2½ 75 1230 86.1 74
80 3 90 2610 182.7 157
X Flow rate (l/min, US gal/min) 100 4 110 3930 275.1 236
Y Pressure loss Δp (bar, psi) 125 5 140 7120 498.4 427
150 6 160 9180 642.6 551
kv 100 values PVC-U, pipe PN10
200 8 225 17600 1232 1056
DN DN d kv 100 Cv 100 kv 100
mm inch mm l/min US gal./ m³/h 250 10 280 24400 1708 1464
(Δp = 1 min (Δp = 1 300 12 315 31900 2233 1914
bar) (Δp = 1 bar)
psi)
32 1¼ 40 270 18.9 16.2
40 1½ 50 370 25.9 22.2
50 2 63 900 63.0 54
65 2½ 75 1140 79.8 68
80 3 90 1870 130.9 112
100 4 110 2870 200.9 172
125 5 140 5700 399.0 342
150 6 160 6900 483.0 414
200 8 225 18800 1316 1128
250 10 280 25000 1750 1500
300 12 315 27600 1932 1656
540
Reference values for tightening torque of
screws
Metric flange adaptor
d DN inch Total number of Torque Torque
screws Nm lb-ft
40 32 1¼ 4 x M16 x 85 15 11
50 40 1½ 4 x M16 x 85 15 11
63 50 2 4 x M16 x 95 20 15
75 65 2½ 4 x M16 x 100 25 18
90 80 3 8 x M16 x 110 25 18
110 100 4 8 x M16 x 130 30 22
140 125 5 8 x M16 x 130 35 26
160 150 6 8 x M20 x 180 40 30
225 200 8 8 x M20 x 180 50 37
280 250 10 12 x M20 x 180 55 41
315 300 12 12 x M20 x 180 60 44
ANSI flange adaptors

d DN inch Total number of Torque Torque
screws Nm lb-ft
50 40 2 4 x UNC5/8" x 3½" 20 15
63 50 2½ 4 x UNC5/8" x 4" 25 18
75 65 3 4 x UNC5/8" x 4" 25 18
90 80 4 8 x UNC5/8" x 4½" 30 22
110 100 4 8 x UNC5/8" x 4½" 30 22
160 150 6 8 x UNC3/4" x 5" 40 30
225 200 8 8 x UNC3/4" x 6" 50 37
280 250 10 12 x UNC7/8" x 6½" 55 41
315 300 12 12 x UNC7/8" x 7" 60 44

Maintenance
Normally wafer check valves do not need maintenance.
It is enough to control periodically, if there is no leak-
age. If you have a leakage in the flange connections, re-
fasten these acc. to the table "standard values for the
Screw fixing" or if it is necessary replace the flange gas-
kets.
541
542
Fundamentals for special valves
Page

Pressure reducing valve types V782, V82 and V182
-- Overview 544
-- Graph 545
Pressure retaining valve type V786 and V186 / V86
-- Overview 554
-- Graph 556
Pressure relief valve type V185/V85
-- Overview 562
-- Graph 563
Diaphragm gauge guard type Z700 / Z701
-- Overview 568
-- Graph 569
Water jet suction pump type P20
-- Overview 571
-- Graph 572
Ventilating valve type 595 and Ventilating- and bleed valve type 591
-- Overview 585
-- Graph 587
Float valves type V140
-- Overview 591
-- Graph 592
Throttle valves type V251
-- Overview 593
-- Graph 594
543
Fundamentals for special valves Pressure reducing valve V782
Pressure reducing valve types V782,

V82 and V182
Overview
Product description
The V82, V182 and V782 pressure reducing valves re-
duce the pressure within the system to a pre-set value.
By using the differential pressure, the pressure reducing
valve adjusts itself to the set working pressure.
The outlet pressure (working pressure) is not directly re-
lated to the inlet pressure. If the outlet pressure increas-
es or decreases above/below the desired value, the di-
aphragm is lifted against the spring force or pressed
down by the spring force, as the case may be, by the
outlet pressure. The pressure reducing valve begins to
close/open until a state of equilibrium is re-established;
Product description
in other words, the outlet pressure remains constant • All parts which come into contact with the medium are
irrespective of an increasing or decreasing inlet pres- made of highly resistant plastics.
sure. • The actuator is separated and hermetically sealed off
from the flow section by the control diaphragm.
The wide range of materials available for the hous-
ings (PVC-U, PP, PVDF) and the diaphragms (EPDM, • The working pressure is set with an adjusting screw
EPDM-PTFE-coated) cover many areas of applica- and locked with a locknut.
tion for technically pure, neutral and aggressive fluids • The streamlined design of the housing makes for
as well as ultrapure water applications. For more in- good flow rates.
formation, please refer to the GF Piping Systems List • The large control surface and the spiral spring keep
of Chemical Resistance. We recommend installing a standard tolerances small.
strainer upstream to avoid any breakdowns.
• No auxiliary energy is required to operate the valve.
Versions • The valve is largely maintenance-free and can be in-
Pressure reducing valve V82 stalled in any position.
• Valve can also be adjusted under working pressure.
• V82 standard version with manometer
• V182 standard version with diaphragm protected
manometer
Pressure rducing valve V182
544
Overview
General Type V82 V182 V782
Dimension DN 10 - 100 10 - 40 10 - 40
Pressure range PN DN 10 - DN50: 0.5 - 10 0.5 - 10 0.5 - 10
DN65 - DN 80: 0.5 - 6
DN100: 0.5 - 4
Materials for valve body PVC-U + + +
PP + + +
PVDF + + +
EPDM-PTFE-coated + +
FPM +
Connection types Spigot + + +
Standard DIN/ISO + + +
Working temperature PVC-U 0 to + 60 °C 0 to + 60 °C 0 to + 60 °C
PP 0 to + 80 °C 0 to + 80 °C 0 to + 80 °C
PVDF -20 to + 100 °C -20 to + 100 °C -20 to + 100 °C
Remark Belleville spring Compression Compression
spring spring
Manometer Manometer No manometer
High accuracy
Graphical representation of the functioning of the pressure reducing valve

Installation note V82, V182 and V782:

Safety information We recommend installing the valves be-
Pressure reducing valves types V82, V182 and V782 of tween two removable pipe connections.
Georg Fischer are exclusively intended for installation in
a piping system to shut off or pass through media with-
in the allowable pressure and temperature limits. The
maximum operating time is 25 years. Graph
Exploded view V82
NOTICE
Secondary pressure
If the secondary pressure is further increased
by counter pressure, the pressure reducing
valve acts as a check valve. This back pres-
sure can eventually lead to the destruction of
the valve piston.
• Do not increase the secondary pressure
# drawn without manometer / drawn offset
545
1 Valve body 1 Valve body
2 Upper valve body 2 Upper valve body
3* Diaphragm 3* Diaphragm
4* Piston 4* Piston
7 V82: Pressure plate (top) 5 V782: compressor
8 V82: Pressure plate (bottom) 6 V782: spring plate
9* Spring assembly/compression spring 9* Spring assembly / compression spring
10 Locknut 10 Locknut
11 Adjusting screw 11 Adjusting screw
12 Allen screw 12 Allen screw
13 Washer 14 Cap
14 Cap 15 Allen screw with nut and cover
15 Allen screws Valve bottom with O-ring
16 Valve bottom with O-ring 16 Lip ring
18* O-ring 17*
* Parts subject to wear or recommended spare parts Parts subject to wear or recommended spare parts
*
Exploded view V182
drawn without manometer
1 Valve body
2 Upper valve body
4* Piston
6 Spring plate
9* Compression spring
10 Locknut
11 Adjusting screw
14 Cap
15 Allen screws
16 Valve bottom with O-ring
18* O-ring
20 piston base
* Parts subject to wear or recommended spare parts
Exploded view V782
546
Dimensions V82
* special versions on request
da DN ⌀D h H L: L: L1: PVC-U, L2: PVC-U,
PVC-U ce- PVDF-HP/ PP/ PVDF PP/ PVDF
ment spig- PP Butt fu-
ots PP/ sion spig-
PVDF fu- ots BCF/
sion spig- IR
ots
16 10 70 100 130 134 - 154 140
20 15 70 100 130 134 150 154 140
25 20 100 134 180 174 190 185 180
32 25 100 134 180 174 190 185 180
40 32 130 175 230 224 240 248 230
50 40 130 175 230 224 240 252 230
63 50 150 210 285 244 260 280 250
75 65 200 250 350 300 300 - 306
90 80 250 305 425 360 360 - 370
110 100 300 345 495 420 420 - 430
Dimensions V182
547
da DN ⌀D h H L: PVC- L: PVDF-HP/ L1: PVC-U, L2: PVC-U,
U cement PP Butt fu- PP/ PVDF PP/ PVDF
spigots PP/ sion spigots
PVDF fusion BCF/ IR
spigots
16 10 70 100 130 134 - 154 140
20 15 70 100 130 134 150 154 140
25 20 100 134 180 174 190 185 180
32 25 100 134 180 174 190 185 180
40 32 130 175 230 224 240 248 230
50 40 130 175 230 224 240 252 230
Dimensions V782
Technical data
Working pressure
V82, V182 and V782

Hysteresis V82
approx. 0.1 to 0.4 bar
Hysteresis V182
Hysteresis V782
Pressure difference between inlet and outlet
min. 1 bar
da DN L: PVC- L: PVDF- I H h D
U cement HP/
Adjustment range on outlet with an inlet pressure of
spigots L: 10 barV82
PP/ L: PVDFHP/ 0.5 to 9.0 bar
PVC-U ce- PP Butt Adjustment range on outlet with an inlet pressure of
ment spig- fusion
ots PP/ spigots
10 barV182
PVDF fu- BCF/IR 0.5 to 9.0 bar
sion spig- Adjustment range on outlet with an inlet pressure of
ots 10 bar V782
mm mm mm mm mm mm mm mm 0.5 to 9.0 bar
16 10 134 - 102 138 48 83
20 15 134 172 102 138 48 83
25 20 154 190 110 205 65 112
32 25 154 190 110 205 65 112
40 32 224 262 162 248 95 165
50 40 224 262 162 248 95 165
548
Operational characteristics for a pressure re-
ducing valve (representation not full scale)
V782
x Flow rate Q (l/hr)

y Working pressure (bar)
pA set outlet pressure
pO Opening pressure
pS Closing pressure
pA -pO Hysteresis
pS -pA flow-related pressure drop in valve
pS-pmin max. pressure reduction in relation to flow rate
Example
Example 1: _ _ _ _ _ _ _ _ (see dotted line in diagram)
For a flow rate of approx. 3500 l/hr, an outlet pressure
(working pressure) of 4 bar is required. Inlet pressure
min. 5 bar or greater.
Look for the given flow rate on the x axis of the respec-
tive nominal diameter curve. When the appropriate
curve has been found, check if the valve is in the de-
sired pressure range (here 4 bar).
In this example, the hysteresis would be 0.5 bar and the
pressure drop 1 bar.
Example 2: ..................... (see dotted line in diagram)
The valve is adjusted at a desired pressure of 3 bar at 0
conveyance. If we assume a flow rate of 2500 l/hr, the
pressure drop in the valve would be approx. 0.8 bar.
* Hysteresis
** pressure drop in valve
549
Characteristics V82
550
l/h, l/min Flow volume H2O
y Outlet pressure (bar)
Characteristics are valid for a flow rate of 2 m/s.

551
Characteristics V182
l/h, l/min flow volume water

y outlet pressure
Characteristics valid for a flow rate of 2 m/s.
552

y Outlet temperature (bar)
553
Pressure retaining valve type V786 V186
and V186 / V86
Overview
Product description
The V786 and V186 / V86 pressure retaining valves
serve to keep the working or system-related pressures
constant, to balance out pressure pulsation and to re-
duce pressure peaks in chemical process systems. If
the inlet pressure rises above the set value, the pres-
surised valve piston is lifted against the spring force.
Consequently, the valve opens and there is a reduction
of pressure in the outlet pipe. The valve closes as soon
as the inlet pressure sinks below the preset spring ten-
sion.
The wide range of materials available for the hous-
ings (PVC-U, PP, PVDF) and the diaphragms (EPDM,
EPDM-PTFE-coated) cover many areas of applica-
tion for technically pure, neutral and aggressive fluids V86
as well as ultrapure water applications. For more in-
formation, please refer to the GF Piping Systems List
of Chemical Resistance. We recommend installing a
strainer upstream to avoid any breakdowns.
When used as a bypass, the pressure retention valve
V186/86 can also be used as a bleed-off valve for re-
ducing pressure peaks. Due to the dead space free de-
sign of the lower body, the valve can also be used in ul-
trapure water as well as for technically pure, neutral and
aggressive liquids. For more information, please refer to
the GF Piping Systems List of Chemical Resistance.

Versions
V786
Product description
V786
• All parts which come into contact with the medium are
made of highly resistant plastics.
• The actuator is separated and hermetically sealed off
from the flow section by the control diaphragm.
• The working pressure is set with an adjusting screw
and locked with a locknut.
• The streamlined design of the housing makes for
good flow rates.
• The large control surface and the spiral spring keep
standard tolerances small.
• No auxiliary energy is required to operate the valve.
• The valve is largely maintenance-free and can be in-
stalled in any position.
• Valve can also be adjusted under working pressure.
V186/V82
• Good control characteristics
• Low maintenance due to uncomplicated design
554
• Control unit is hermetically separated from flow
medium by serial EPDM or EPDM-PTFE-coated di-
aphragm
• Zero static lower body (V186)
• Note the direction of flow Valve mounting with thread-
ed insert on lower body
• Adjustment range: 0.5 - 9 bar
• Valve can also be adjusted under working pressure
Overview
General Type V786 V186/V86
Dimension DN 10 - 40 10 - 100
Pressure range PN DN 10 - DN25: 0.5 - 10 DN 10 - DN50: 0.5 - 10
type V186
DN32 - DN 40: 0.5 - 4 DN65 - DN 80: 1.0 - 6 type
V86
DN100: 1.0 - 4 type V86
PP + +
PVDF + +
EPDM-PTFE-coated + +
Connection types Spigot + +
Sockets +
Flange On request
Standard DIN/ISO + +
ANSI +
Working temperature PVC-U 0 to + 60 °C 0 to + 60 °C
PP 0 to + 80 °C 0 to + 80 °C
PVDF -20 to + 100 °C -20 to + 100 °C
Graphical representation of the operation of the pressure retaining valve

Safety information
Installation note:
We recommend installing the valves be-
tween two removable pipe connections.
555
1 Lower valve body
Graph 2 Upper valve body
Exploded view V786 3* Diaphragm
4* Piston
5 Compressor
6* Spring assembly
7 Locknut
8 Adjusting screw
9 Cylinder screw
10 Cap
11 Allen screws with nut and caps
Spring plate
12 Parts subject to wear or recommended spare parts
*
Exploded view V86 DN 65-100
1 Lower valve body

2 Upper valve body
3* Diaphragm
4* Piston
5 Compressor
6* Spring assembly
7 Locknut
8 Adjusting screw
9 Cylinder screw
10 Cap
11 Allen screws with nut and caps Dimensions V786
Spring plate
12 Parts subject to wear or recommended spare parts
*
Exploded view V186 DN 10-50
shown offset
556
da DN L: PVC- L: PVDF- I H h D
U ce- HP/
ment Butt
spigots fusion
PP/ spigots
PVDF BC F/IR
fusion
spigots
16 10 134 - 102 138 38 83
20 15 134 172 102 138 38 83
25 20 154 190 110 205 55 112
32 25 154 190 110 205 55 112
40 32 224 262 162 248 85 165
50 40 224 262 162 248 85 165
Metric cement and fusion spigots

Dimensions V186/V86
DN L: L: PVDF- L1 L2 ⌀D H h

PVC-U HP/PP
cement Butt fu-
spigots sion spig-
PP/ ots BC F/
PVDF fu- IR
sion spig-
ots
10 134 - 140 154 83 137 20
15/20 134 158 140 154 83 137 20
25 174 198 180 185 112 199 27
32 174 202 230 248 165 199 43
40 224 256 230 248 165 290 43
50 244 256 250 252 165 290 43
65 284 284 290 280 180 275 230
80 360 360 310 - 250 410 320
100 380 380 390 - 250 485 415
557
L1 = with flange
L2 = union
Technical data

558
Valve characteristics diagram V786
pA Air pressure
pÖ Opening pressure
pS Closing pressure
The valve characteristics diagram shows the primary or

working pressure pA in bar in relation to the flow rate Q
in l/h. The parameter is the set pressure pE at Q = 0 l/h.
The curve indicates the opening pressure progression.
The characteristics apply to water at +20 °C.
Example:
A valve XY is adjusted to 3 bar. If the flow is increased
to 900 l/hr, the input pressure increases to 4.5 bar. Ac-
cording to the characteristics, the following values ap-
ply:
Working pressure approx. 4.5 bar
Opening pressure approx. 3.1 bar
Closing pressure approx. 2.8 bar
Characteristics V86
559
l/h, l/min Flow volume water
y Outlet pressure
Characteristics are valid for a flow rate of 2 m/s

560
Installation examples for pressure retaining
valves
PA Air pressure
PP Pump pressure
PO Closing pressure
561
Pressure relief valve type V185/V85 • Note the direction of flow!
• Valve mounting with threaded insert on lower body
Overview (V185)
Product description • Adjustment range: 0.5 - 9 bar (1 - 4 bar)
The V185/V85 pressure relief valves serve to keep the
working or system-related pressures constant, to bal-
ance out pressure pulsation and to reduce pressure
peaks in chemical process systems. The third pipe spig-
ot fitted on the valve body means the valve can be in-
stalled directly in the main pipeline. If the inlet pressure
rises above the set value, the pressurised valve pis-
ton is lifted against the spring force. Consequently, the
valve opens and there is a reduction of pressure in the
outlet pipe. The valve closes as soon as the inlet pres-
sure sinks below the preset spring tension.
Versions
Pressure relief valve type V185/V85
Product description
• Good control characteristics
• Low maintenance due to uncomplicated design
• Control unit is hermetically separated from flow medi-
um by standard EPDM or EPDM-PTFE-coated di-
aphragm
• Zero static lower body (V185)
562
Overview
General Type V185/V85
Pressure range PN DN10 - DN50: 0.5 - 10 bar type V185
DN65 - 80: 1.0 - 6 bar type V85
DN100: 1.0 - 4 bar type V85
PP +
PVDF +
EPDM-PTFE-coated +
Connections Spigot +
Flanges On request
Working temperature PVC-U 0 to + 60 °C
PP 0 to + 80 °C
PVDF -20 to + 100 °C
Graphical representation of the operation of the pressure relief valve

Safety information Graph

Installation note: Exploded view V185 DN15 - DN50
We recommend installing the valves be-
tween two removable pipe connections.
shown offset
563
1 Lower part
2 Upper part
3* Diaphragm
4 Compressor
5* Compression spring/spring assembly
6 Spring plate
7* Adjusting screw with 1 locknut
8 Cap
9 Connecting screws (4 pieces)
10* Piston
* recommended spare parts
Exploded view V85 DN 65 - DN100
shown offset
1 Lower part
2 Upper part
3* Diaphragm
4 Compressor
5* Compression spring/spring assembly
7* Adjusting screw with 1 locknut
8 Cap
10* Piston
* recommended spare parts

564
Dimensions
DN L: L: L1 L2 D H h

PVC- PVDF-
U ce- HP/PP
ment Butt
spig- fusion
ots spig-
PP/ ots
PVDF BCF/IR
fusion
spig-
ots
10 134 - 140 154 83 137 20
15/20 134 158 140 154 83 137 20
25 174 198 180 185 112 199 27
32 174 202 230 248 165 199 43
40 224 256 230 248 165 290 43
50 244 256 250 252 165 290 43
65 284 284 290 280 180 275 45
80 360 300 310 - 200 400 60
100 380 380 390 - 250 475 70
L1 = with flange
L2 = union
565
Technical data
y Outlet pressure
Characteristics are valid for a flow rate of 2 m/s
566
Characteristics V85
567
Diaphragm gauge guard type Z700 /
Z701
Overview
Product description
The diaphragm-protected gauge guard is used when
measuring the pressure of neutral and corrosive me-
dia. The manometer is separated from the medium by
a PTFE-coated diaphragm and protects the pressure
gauge against corrosive influences. The pressure is
transmitted using a buffer fluid, usually Glysantin. The
large area of the diaphragm and the low compressibility
of the buffer fluid ensure an accurate display. The large
number of possible materials make for a wide range of
areas of application.
Versions
Diaphragm gauge guard type Z700/Z701
Product features
• All parts which come into the medium are made of
highly resistant plastics.
• The manometer does not come into contact with the
medium.
• The diaphragm gauge guard is low-maintenance and
can be installed in any position.
• The large area of the diaphragm ensures good accu-
racy.
568
Overview
General Type Z700/Z701
Dimension d 25 - 32
PP +
PVDF +
EPDM-PTFE-coated +
PP 0 to + 80 °C
PVDF -20 to + 100 °C
Standards ISO +
Safety information Graph

Installation note: Exploded view
We recommend installing the gauge guard
with a screw fastening and a shut-off de-
vice. This ensures that the manometer can
be moved into the required position for
reading at a later stage and can be easily
replaced in the event of a fault.
CAUTION
Leaking valve due to incorrect screw ten-

sion
• Before activating you must check the screw
tension.
• Retighten screws "crosswise" to the corre-
sponding tightening torques of 2 - 2.5 Nm.
NOTICE
Sealing
1 Flange (1 unit)
The sealing with PTFE tape or hemp can
lead to tearing off the final nozzle. 2 Upper part (1 unit)
3 Diaphragm (1 unit)
• Weld or cement the spigot.
(Parts subject to wear or recommended spare parts)
4 Manometer seal (1 unit)
5 Manometer (1 unit)
6 Hexagonal socket-head cap (12/16 units)
7 Hexagonal socket-head screw with washer and nut (6/8 units)
* required fill level
** Buffer fluid
569
Dimensions Connection spigots
• da 25 with manometer connection R ¼“
• da 32 with manometer connection R ½“
• selectable with NPT thread
Manometer ranges
Standard 0 - 10 bar, with R ¼“ Dm 63 mm, bei R ½“ Dm
100 mm, others on request
Accurancy
Standard class 2.5
Measuring range
0 - 10 bar
0 - 6 bar
Connection da d H h
mm mm mm mm
R ¼" 25 63 129 15
R ½" 32 100 210 22
Connection A ⌀D D Weight

PVC-U PP PVDF
mm mm kg kg kg
R ¼" 71 72 0.30 0.25 0.32
R ½" 90 100 0.60 0.54 0.68
Technical data
Working pressure

Allowable working pressure for connection

PN 10 bei 20°C
Manometer connections
R ¼"
R ½"
570
Water jet suction pump type P20
Overview
Product description
Water jet fluid pumps can be used where pressurised
fluid is available as a propellant. They are used for
pumping out pits, moving and mixing chemical waste,
adding acids or leaches in water treatment, etc. They
are self-priming and have no mechanically moving
parts. Because the P20 water jet suction pumps come
in various materials, they can be used wherever the ma-
terials meet the given requirements. The basic principle
of the water jet suction pump is that the propellant liq-
uid passes through a nozzle and draws in with it the liq-
uid or gaseous medium from the suction line, increas-
ing its velocity. The result of this is that the propellant
and the medium which is sucked in are mixed togeth-
er. The amount of fluid propelled is a function of the pro-
pellant pressure and the size of the nozzle. The amount
of liquid drawn in can be seen from the diagrams. The
results shown are only guidelines and depend on the
method of operation.
Versions
Designs
DN 10-20 with external thread
DN 25-50 with socket union
DN 65-80 with spigot
Product features
• Ideal for mixing, dosing and handling liquids
• No mechanically moving parts
• Self-priming
571
Overview
General Type P20
PP +
PVDF +
Connection types Spigot +
Thread +
Union +
Standard DIN/ISO +
ANSI +
PP 0 to + 80 °C
PVDF -20 to + 100 °C
Safety information
CAUTION
Installation note
Adjusting the suction volume

Do not use a diaphragm valve for adjusting
• We recommend installing the water the suction volume, since the diaphragm can
jet pump between two detachable adhere to the seat, due to the negative pres-
pipe sections. With a view to subse- sure. Consequences can be serious injuries.
quent dismantling, it is useful to pro- • Use throttle valve V251
vide shut-off devices. • Characteristics apply to suction media with
• Relaxation zone of pipe at least 5 x the density of water. Please send a re-
DN are to be provided upstream and quest, for suction media with a different
downstream of the pump. density.
• It is recommended that a flowmeter
is installed in the suction line to pro-
vide information on the suction pow- Graph
er of the pump. Exploded view
• It is useful to install manometers up-
DN 20 DN 25-50
stream and downstream of the jet
pump for reading the inlet pressure
and the back pressure.
• The suction time can be significantly
reduced by installing a check valve
in the suction line. Inlet and outlet
lines must have at least the nominal
bore of the pump.
• The propellant and suction flow can
be accurately controlled by installing
throttle valves.
Advice on faults
Faults can occur if, for example, the op-
erating water pressure fluctuates or is too
low, if the back pressure is too high or if
the nozzles are dirty or blocked.
572
1 Water jet pump (1 pc.)
2 Nozzle (1 pc.)
3 Insert (3 pcs.)
4 Union nut
5 O-ring (3 pcs.)
6 O-ring (3 pcs.)
Dimensions
up to DN20 from DN25 to DN50 from DN65
Type da DN G G1 L L1 t H h

P 20.10 - 1.5 16 10 R ¾" R ¾" - 110 40 - 35
P 20.10 - 2.0
P 20.15 - 2.0 20 15 R 1" R ¾" - 125 40 - 35
P 20.15 - 3.0
P 20.15 - 4.0
P 20.20 - 3.0 25 20 R ¼" R ¾" - 145 45 - 45
P 20.20 - 4.5
P 20.20 - 6.0
P 20.25 - 2.5 32 25 R 1½" R 1½" 245 195 - 96 71
P 20.25 - 4.0
P 20.25 - 5.0
P 20.32 - 3.0 40 32 R 2" R 2" 297 239 - 116 87
P 20.32 - 4.5
P 20.32 - 6.0
P 20.40 - 3.5 50 40 R 2¼" R 2¼" 369 301 - 139 105
P 20.40 - 5.5
P 20.40 - 7.5
P 20.50 - 5.0 63 50 R 2¾" R 2¾" 433 351 - 169 128
P 20.50 - 7.0
P 20.50 - 9.0
P 20.65 - 6.5 75 65 - - 388 - - - 115
P 20.65 - 9.0
P 20.65 - 11.5
P 20.80 - 8.0 90 80 - - 465 - - - 149
P 20.80 - 11.0
P 20.80 - 14.0
573
Technical data
Working pressure

Output diagram for water jet suction pump P 20.10
Suction medium: water Suction medium: air
Type P 20.10-1.5 Type P 20.10-1.5
Type P 20.10-2.5 Type P 20.10-2.5

574
Type P 20.15-2.0 Type P 20.15-2.0
Type P 20.15-3.0 Type P 20.15-3.0
Type P 20.15-4.0 Type P 20.15-4.0
575
Type P 20.20-3.0 Type P 20.20-3.0
Type P 20.20-4.5 Type P 20.20-4.5
Type P 20.20-6.0 Type P 20.20-6.0
576
Type P 20.25-2.5 Type P 20.25-2.5
Type P 20.25-4.0 Type P 20.25-4.0
Type P 20.25-5.0 Type P 20.25-5.0
577
Type P 20.32-3.0 Type P 20.32-3.0
Type P 20.32-4.5 Type P 20.32-4.5
Type P 20.32-6.0 Type P 20.32-6.0
578
Type P 20.40-3.5 Type P 20.40-3.5
Type P 20.40-5.5 Type P 20.40-5.5
Type P 20.40-7.5 Type P 20.40-7.5
579
Type P 20.50-5.0 Type P 20.50-5.0
Type P 20.50-7.0 Type P 20.50-7.0
Type P 20.50-9.0 Type P 20.50-9.0
580
Type P 20.65-6.5 Type P 20.65-6.5
Type P 20.65-9.0 Type P 20.65-9.0
Type P 20.65-11.5 Type P 20.65-11.5
581
Type P 20.80-8.0 Type P 20.80-8.0
Type P 20.80-11.0 Type P 20.80-11.0
Type P 20.80-14.0 Type P 20.80-14.0
Maximum possible vacuum for water jet pumps P20 DN 10-50

P 20.10 P 20.15
582
P 20.20 P 20.25
P 20.32 P 20.40
P 20.50

x vacuum (%)
y propellant pressure (bar)

The figures on the curves (e.g.

3.0) are the diameters of the noz-
zles in each case.
583
Maximum possible vacuum for water jet pumps P20 DN 65-80
P 20.65 P 20.80
x Vacuum (%)
y Propellant pressure (bar)

Design of water jet suction pump
Required specifications: Example: Data acc. to diagram:
Prop. water pressure: bar 3 bar 3 bar
Prop. water volume: l/h 1200 l/h 1180 l/h
Suction volume: l/h 550 l/h 1150 l/h
Suction medium: Water Water
Back pressure: bar 1 bar 1 bar
The suction volume must be throttled to the desired amount.
Selected type:
584
Ventilating valve type 595 and Venti- Ventilating and Bleed valve type 591 without spring
lating- and bleed valve type 591
Overview
Product description
The new Ventilating- and Bleed valves from GF Piping
Systems are now even more reliable; every detail has
been exceptionally well thought out. An innovative PP-
H float on the Ventilating- and Bleed valve type 591 has
a very low density of 0.91 g/cm³ and ensures complete
and reliable venting of the piping system. At the same
time, the valve prevents a media overflow. The Ventilat-
ing valve type 595 is used wherever safe and controlled
air inlet is a must, for example when emptying tanks.
Thanks to a comprehensive product range, the valve
type 591 and type 595 easily fit in all major plastic pip-
ing systems, worldwide.
The new valves from GF Piping Systems are a per-
fect example of this. They are easily integrated in your
normal work flow. At the same time, they ensure even
more efficiency and precision thanks to the completely
new design of the valve inner workings: the float has a
spherical surface in the sealing zone and lies absolutely
flush with the seal ring. The double bearing of the float
additionally prevent it from jamming, even in very rapid Product features
closing movements. Reasons for air in the piping system
Versions • During operation, dissolved air can be released into
the system through pumps, valves, fittings and other
Ventilating valve type 595 with spring
pipe components.
• When filling tanks and pipelines, air inclusions may
occur.
• Pressure drops or temperature increases can release
dissolved air.

Positioning of the valves
• Absolute and temporary high points
• After pumps
• At turning points
Safety
The new valve types 591 and 595 control the aerating
and deaerating of piping systems and tanks with high
precision and absolute dependability. They contribute
significantly to the safety and protection of your system,
for example by avoiding the unwanted buildup of a vac-
uum when emptying piping systems and tanks.
Simplicity
The valves are easy to install and practically mainte-
nance-free, thanks to the compact construction and in-
novative design details geared to maximum safety, er-
gonomics and cost efficiency.
Flexibility
The many different dimensions and optimal sizes allow
using the valves under nearly all space conditions and
in any system design. The valves are positioned at the
absolute or temporary high points in the system, after
pumps and at turning points.
585
Overview
Ventilating Ventilating-
valve and Bleed
valve
Spring-assisted (V2A/V4A) +
PVC-C + +
ABS + +
PP-H + +
PVDF + +
Float material PP-H (specific density 0.91 g/cm³) + +
PVDF (empty) + +
FPM + +
Spigot + +
Threaded sockets + +
Standard ISO + +
ASTM/ANSI + +
BS + +
Options Spring Nimonic 90 Halar® coated +
Safety information
WARNING
Ventilating valve type 595 and ventilating- and bleed
valve type 591 from Georg Fischer are exclusively in-
tended for installation in a piping system to shut off or
Connections
pass through media within the allowable pressure and
temperature limits. The maximum operating time is 25 Only identical materials may be joined to-
years. gether via welded or adhesive joints. Non-
compliance can lead to serious injuries.
• Sections of pipework with adhesive joints
WARNING should be rinsed with non-pressurized wa-
ter as soon as possible after completion of
the joints.
Installation of the valve • The union nuts on the valve should be
Incorrect installation of the valves can cause tightened “hand tight”.
serious injury
• The ventilating valve Type 595 and the
ventilating and bleed valve Type 591 must
be installed so that the arrow on the valve
housing points upwards.
586
Ventilating valve type 595 with solvent cement spig-
Graph ots metric
Exploded view
1 Union nut
2 Connecting part
3 O-ring
4 Screw-in ring d DN D L t closest
5 Sealing ring
6 Back-up ring
7 Float mm mm mm mm mm inch
8 Spring (type 595)
9 Housing 16 10 50 129 14 ⅜
10 Cap
11 Spigot 20 15 50 139 16 ½
25 20 58 160 19 ¾
Dimensions ventilating valve type 595
32 25 68 172 22 1
Ventilating valve type 595 with solvent cement sock-
ets metric 40 32 84 193 26 1¼
50 40 97 215 31 1½
63 50 124 249 38 2
75 65 166 284 44 2½
90 80 200 300 52 3
110 100 238 340 61 4
Ventilating valve type 595 with solvent cement sock-

ets Inch BS
d DN D L t closest

mm mm mm mm mm inch
16 10 50 118 14 ⅜
20 15 50 124 16 ½
25 20 58 142 19 ¾
32 25 68 157 22 1
40 32 84 179 26 1¼ inch DN D L t
50 40 97 197 31 1½ mm mm mm mm
63 50 124 229 38 2 ⅜ 10 50 118 16
75 65 166 258 45 2½ ½ 15 50 124 18
90 80 200 277 52 3 ¾ 20 58 142 21
110 100 238 320 64 4 1 25 68 157 24
1¼ 32 84 179 29
1½ 40 97 197 30
2 50 124 229 36
65 166 258 45
3 80 200 277 51
4 100 238 320 64
587
Ventilating valve type 595 with solvent cement Ventilating- and bleed valve type 591 with solvent
sockets, inch ASTM incl. 2 threaded sockets NPT cement spigots metric
NPT DN D L t
inch mm mm mm mm d DN D L t closest
⅜ 10 50 111 19 mm mm mm mm mm inch
½ 15 50 119 23 16 10 50 129 14 ⅜
¾ 20 58 137 25 20 15 50 139 16 ½
1 25 68 152 28 25 20 58 160 19 ¾
1¼ 32 84 176 31 32 25 68 172 22 1
1½ 40 97 193 35 40 32 84 193 26 1¼
2 50 124 229 38 50 40 97 215 31 1½
2½ 65 166 258 45 63 50 124 249 38 2
3 80 200 277 48 75 65 166 284 44 2½
4 100 238 320 58 90 80 200 300 52 3
110 100 238 340 61 4
Dimensions ventilating- and bleed valve type
591 Ventilating- and bleed valve type 591 with solvent
Ventilating- and bleed valve type 591 with solvent cement sockets Inch BS
cement sockets metric
inch DN D L t
d DN D L t closest mm mm mm mm

⅜ 10 50 118 16
mm mm mm mm mm inch
½ 15 50 124 18
16 10 50 118 14 ⅜
¾ 20 58 142 21
20 15 50 124 16 ½
1 25 68 157 24
25 20 58 142 19 ¾
1¼ 32 84 179 29
32 25 68 157 22 1
1½ 40 97 197 30
40 32 84 179 26 1¼
2 50 124 229 36
50 40 97 197 31 1½
65 166 258 45
63 50 124 229 38 2
3 80 200 277 51
75 65 166 258 45 2½
4 100 238 320 64
90 80 200 277 52 3
110 100 238 320 64 4
588
Ventilating- and bleed valve type 591 with solvent
cement sockets Inch ASTM incl. 2 threaded socket-
s NPT

NPT DN D L t
inch mm mm mm mm
⅜ 10 50 111 19
½ 15 50 119 23
¾ 20 58 137 25
1 25 68 152 28
1¼ 32 84 176 31
1½ 40 97 193 35 P Permissible pressure in bar, psi
2 50 124 229 38
2½ 65 166 258 45
3 80 200 277 48
4 100 238 320 58
Technical data
Pressure-temperature diagram of type 595, 591

Air volume diagram

v velocity (m/s)
V volumetric flow rate (m³/h)

589
Opening conditions of type 595
DN Differential pressure for
take-off of cone
(mm) (bar)
10 0.028
15 0.028
20 0.03
25 0.03
32 0.035
40 0.04
50 0.05
65 0.06
80 0.06
100 0.06

Maintenance
The automatic operation of the valve needs mainte-
nance to ensure problem-free functioning.
Maintenance intervall Maintenance activity

Periodical Check function
Periodical Check that valve is leak-proof
At least 1 x per year Visual inspection of functional com-
ponents, float Check for mechanical
damage and freedom of movement
590
Float valves type V140
Overview
Product description
The V140 float valves are used to automatically control
the supply to tanks and vessels. In this way, a constant
level can be maintained. The V140 float valve is fas-
tened to the vessel wall at thedesired level and connect-
ed to the supply line. Whenthe fluid level rises, the float
is lifted and closes thevalve via the lever arm. When the
fluid level sinks, thesupply line is opened and the medi-
um can enter untilthe respective level is reached again.
Versions
Float valve V140 DN10 - 80
Product features
• Optimal level control without auxiliary energy
• Robust and low-maintenance design
• Operational safety thanks to integrated seat seal
• Lever ratio
– standard 1:10
– on request 1:7 for tight installation space
Overview
General Type V140
Pressure range PN 6
Materials for valve body PVC +
PP +
Flange On request
FPM (Viton) +
Standards DIN/ISO +
Mounting orientation vertical
591
Graph
Dimensions
da DN ⌀D H a b C e A øSD SH

Lever Lever
1:10 1:7
16 10 45 120 80 36 380 305 14 270 125 130
20 15 45 120 80 36 380 305 16 270 125 130
25 20 65 160 110 50 530 430 19 340 200 170
32 25 65 165 110 50 530 430 22 345 200 170
40 32 90 210 130 65 720 575 26 440 225 210
50 40 90 215 130 65 720 575 31 445 225 210
63 50 130 255 160 86 975 775 38 595 315 290
75 65 130 260 160 86 975 775 44 600 315 290
90 80 150 290 180 101 1140 905 51 640 355 340
592
Throttle valves type V251
Overview
Product description
Throttle valves are used wherever fluids or gases need
to be throttled in pipelines. The compact design, simple
and robust construction and good control characteristics
ensure high operational safety. A spindle with cone nar-
rows down the cross section of the opening in the hous-
ing, thereby restricting the volume flow to the desired
value. The setting must be done with a tool (screwdriv-
er or flat material) which has the advantage that the set
value cannot be changed unintentionally.
Versions
Throttle valve V251
Product features
• Good chemical resistance due to highly resistant plas-
tics (PVC, PP, PVDF)
• Requires practically no maintenance and can be in-
stalled in any position
• High operational safety thanks to compact and robust
construction
• Good control characteristics from 0 to max. volume
Overview
General Type V251
PP +
PVDF +
Seal materials EPDM / FPM +
PP 0 to + 80 °C
PVDF -20 to + 100 °C
593
Graph
Exploded view
1 Housing
2 Spindle
3 Cap
4 Seal
5 Stop ring
6 O-ring
Dimensions
da DN L H h ⌀D

mm mm mm mm mm mm
16 10 47 57 45 29
20 15 55 66 51 35
25 20 66 80 62.5 40
32 25 80 96 74.5 47
40 32 100 111 86 56
50 40 120 133 101 70
63 50 146 158 118 88
594
Technical data
Performance diagram for throttle valve V251

595

To dimension the nominal diameter, we recommend
using the given values with a half opened throttle
sleeve.
Example:
Pressure upstream: 3 bar
Desired flow: 2000 l/hr
According to the diagram for DN25, the flow is 2000 l/h
when the adjusting screw is opened 2 revolutions. The
nominal diameter of DN25 is a good choice.
l/h flow volume Water

* revolutions
Flow volumes in pipelines Nom. diam. Area of 2.0 m/s

l/hr flow volume at a velocity of v = nom. diam.
Nominal diame- Area of 3.0 m/s 2.5 m/s mm inch mm² l/hr l/min
ter nom. diam. 10 1/8" 78.5 565 9.4
mm inch mm² 15 ½" 176.6 1267 21.1
10 1/8" 78.5 848 706 20 ¾" 314.0 2261 37.7
15 ½" 176.6 1901 1584 25 1" 490.6 3528 58.8
20 ¾" 314.0 3391 2826 32 1 ¼" 803.8 5782 96.4
25 1" 490.6 5292 4410 40 1 ½" 1256.0 9043 150.7
32 1 ¼" 803.8 8672 7227 50 2" 1962.5 14126 235.4
40 1 ½" 1256.0 13565 11304 65 2 ½" 3316.6 23875 397.9
50 2" 1962.5 21190 17658 80 3" 5024.0 36173 602.9
65 2 ½" 3316.6 35813 29844 100 4" 7850.0 56520 942.0
80 3" 5024.0 54259 45216 125 5" 12265.6 88308 1471.8
100 4" 7850.0 84780 70650 150 6" 17662.5 127166 2119.4
125 5" 12265.6 132462 110385
150 6" 17662.5 190750 158958
596
Nom. diam. 1.8 m/s 1.6 m/s 1.4 m/s
mm inch
10 1/8" 509 452 396
15 ½" 1140 1014 887
20 ¾" 2035 1809 1583
25 1" 3175 2822 2470
32 1 ¼" 5203 4626 4047
40 1 ½" 8139 7235 6330
50 2" 12714 11301 9888
65 2 ½" 21488 19100 16713
80 3" 32556 28938 25321
100 4" 50868 45216 39564
125 5" 79477 70646 61816
150 6" 114450 107733 89017
Nominal diame- 1.2 m/s 1.0 m/s 0.5 m/s

ter
mm inch
10 1/8" 339 283 141
15 ½" 760 634 317
20 ¾" 1357 1130 565
25 1" 2117 1764 882
32 1 ¼" 3469 2891 1445
40 1 ½" 5426 4522 2261
50 2" 8476 7063 3532
65 2 ½" 14325 11938 5969
80 3" 21704 18086 9043
100 4" 33912 28260 14130
125 5" 52985 44154 22077
150 6" 76300 63583 31792
Q = flow volume (m³/h)

F = area (of nominal diameter m²)
v = velocity (m/s)
Q = F x 3600 x v = m³/h
F = Q / (v x 3600) = m²
v = Q / (F x 3600) = m/s
The nominal diameter of our valves can be

determined on the basis of this table. We
recommend not to exceed a velocity of 2.0
m/s.
597
598
Special fittings
Page

-- Overview 600
-- Graph 602
-- Accessories 609
599
Special fittings Variable area flow meter short version

Overview
Product description
Variable area flow meters from GF Piping Systems are
radially installed dismountable meters for flow measur-
ing in industrial piping applications. A variable area flow
meter consists of a conical tube that is passed by the
medium from bottom to top. In this cone, there is a ver-
tically moving float. With the flow meters of type 355
and type 350 as well as the series SK short version and
the special versions out of PVDF, Georg Fischer offers
you radially detachable measuring devices for flow mea-
surement in industrial pipeline construction. Without any Variable area flow meter special version
energy source, these instruments provide you with re-
liable and accurate measuring values. Different instal-
lation lengths and various materials as well as the spe-
cial versions offer optimum solutions for a broad range
of applications in different types of media.
Versions
Variable area flow meter type 350
Product features
• The on-site display requires no auxiliary power
• Cost effective to measure the flow rate
• Break-proof and corrosion-resistant
• Accessories like sensor 4-20 mA and limit contacts
• Guiding rod from DN50 for stabilisation of float within
volume flow
Variable area flow meter type 335 • Low pressure loss
• Can be used for liquids and gases
• Volume and % scale as standard
600
Overview
General Type 335/350 Short version Special version
Dimension DN 25-65 10-25 25-65
Pressure range PN 10 10 10
Nominal pressure 10 10 10
Materials Measuring tube Polyamid, Polysulfone, Polysulfone, PVC-U Polysulfone, PVDF
PVDF and PVCU trans- transparent
parent
Float PTFE, PVDF PVDF PTFE, PVDF
End stops PVDF PVDF PVDF
Union PVC-U (PP, PVC-U PVDF
PVDF,ABS), other on
request
O-ring EPDM (FPM) EPDM FPM
Guiding rod V4A (316), Peek, V4A - -
(316) PVDF coated
Accessories Limit contacts GK10/ - -
GK11
4-20 mA Sensor Type - -
GK 15
Safety information
WARNING
CAUTION
Disregarding the intended use
Serious injury by ignoring the intended use
Disregarding the application area • Compliance with the stated limits for pres-
Minor injuries and material damage by violat- sure and temperature and chemical resis-
ing the permitted uses of the VAFM tance.
• Use VAFM only in prescribed areas of op-
eration.
NOTICE
• VAFM are not recommended for me-
dia containing solids.
Flow conditions
• To avoid unstable flow conditions, a damp-
ing zone is to be considered before and af-
• The allowable pressure range for ter the float type flow meter.
all allowable temperatures for every
housing material is illustrated in di- To convert the units of flow for the variable
agrams in the Georg Fischer Plan- area flow meter, please refer to the con-
ning Fundamentals (Chapter: Spe- version table "Delivery volume" in the Ap-
cial valves). This documentation also pendix of the planning fundamentals.
contains the "Chemical Resistance
List" for the different types of valve
materials.
DANGER
Pressure surges
Death or serious injury due to the occurrence
of pressure surges.
• Avoid pressure surges
• Only use appropriate media.
601
Graph
Exploded view
Pos. Item
1 Measuring tube
2 Float
3 Bottom insert
4 Top insert
5 Union nut
6 Valve end
7 O-ring
8 Flow value indicator
9* Limit contact
10** Guiding rod
* optional
** only for DN50 (1500-15000 l/h) and DN65
(all metering ranges)
602
Dimensions
Type 355
Measuring D L L1 L2 G

range
l/h mm mm mm mm inch
50 - 500 58 385 341 335 1½
100 - 1000 58 385 341 335 1½
150 - 1500 72 393 341 335 2
250 - 2500 72 393 341 335 2
200 - 2000 83 403 341 335 2¼
300 - 3000 83 403 341 335 2¼
600 - 6000 83 403 341 335 2¼
600 - 6000 101 417 341 335 2¾
1000 - 10000 101 417 341 335 2¾
1500 - 15000 101 417 341 335 2¾
2000 - 20000 135 429 341 335 3½
3000 - 30000 135 429 341 335 3½
8000 - 60000 135 429 341 335 3½
Type 350
Measuring D L L1 L2 G

range
l/h mm mm mm mm inch
50 - 500 58 400 356 350 1½
100 - 1000 58 400 356 350 1½
150 - 1500 72 408 356 350 2
250 - 2500 72 408 356 350 2
200 - 2000 83 418 356 350 2¼
300 - 3000 83 418 356 350 2¼
600 - 6000 83 418 356 350 2¼
600 - 6000 101 432 356 350 2¾
1000 - 10000 101 432 356 350 2¾
1500 - 15000 101 432 356 350 2¾
2000 - 20000 135 444 356 350 3½
3000 - 30000 135 444 356 350 3½
8000 - 60000 135 444 356 350 3½
603
Short version float in PVDF without magnet
Type D L L1 L2 Rp

mm mm mm mm inch
SK 50 35 199 171 165 ⅜
SK 51 35 199 171 165 ⅜
SK 52 35 199 171 165 ⅜
SK 60 43 223 191 185 ½
SK 61 43 223 191 185 ½
SK 62 43 223 191 185 ½
SK 70 60 250 206 200 1
SK 71 60 250 206 200 1
SK 72 60 250 206 200 1
SK 73 60 250 206 200 1
Short version float in PVDF with magnet
Type D L L1 L2 Rp
mm mm mm mm inch
SK 500 35 199 171 165 ⅜
SK 510 35 199 171 165 ⅜
SK 520 35 199 171 165 ⅜
SK 600 43 223 191 185 ½
SK 610 43 223 191 185 ½
SK 620 43 223 191 185 ½
SK 700 60 250 206 200 1
SK 710 60 250 206 200 1
SK 720 60 250 206 200 1
SK 730 60 250 206 200 1
Special version PVDF-HP float in PTFE without magnet
Type D L L2 Rp
mm mm mm inch
SK 70 60 318 200 1
SK 71 60 318 200 1
SK 73 60 318 200 1
SK 20 83 466 335 1½
SK 21 83 466 335 1½
SK 30 103 472 335 2
SK 31 103 472 335 2
SK 40 122 495 335 2½
SK 41 122 495 335 2½
604
Special version PVDF float in PVDF (red) without magnet
Type D L L (IR-SS) L1 L2 Rp

mm mm mm mm mm inch
SK 10 60 385 443 341 335 1
SK 11 60 385 443 341 335 1
SK 20 83 403 459 341 335 1½
SK 21 83 403 459 341 335 1½
SK 30 103 417 461 339 335 2
SK 31 103 417 461 339 335 2
SK 40 122 429 453 341 335 2½
SK 41 122 429 453 341 335 2½
Technical features Technical data

Mode of operation Pressure-temperature diagram
If a medium flows at a sufficient flow rate upwards Pressure loss of type 335 / 350
through the vertically mounted taper tube, the float is
raised to the point at which a state of equilibrium sets in Measuring range [l/h] Pressure loss [mbar]
between the lifting force of the medium and the weight 50 - 500 22.84
of the float. Since the mean flow rate is proportional to
the quantity flowing through per unit of time, this state of 100 - 1000 22.84
equilibrium corresponds to the measurement of the cur- 150 - 1500 22.84
rent flow rate.
250 - 2500 22.84
200 - 2000 24.99
300 - 3000 24.99
600 - 6000 24.99
1000 - 10000 24.99
1500 - 15000 28.23
2000 - 20000 45.67
3000 - 30000 45.67
8000 - 60000 47.24
Accuracy of measurement
Measuring accuracy VDE/VDI 3513 accuracy class 4, ± 1 %
of final value ± 3 % of measured value
Flow rate % Total measure- Total measure-
ment error in % ment error from fi-
nal value in %
10 13.00 1.3
20 8.00 1.6
30 6.33 1.9
40 5.50 2.2
50 5.00 2.5
Calibrated scales
60 4.67 2.9
The standard version comes with a printed on double
scale: a percentage scale and a scale giving flow rate 70 4.43 3.1
(H2O l/h). The special scales come as a sticker and 80 4.25 3.4
need to be fitted to a blank taper tube. The scales are
printed with a special hard wearing paint. 90 4.11 3.7
Standard scale: l/h 100 4.00 4.0
Special scales: m³/h, GPM
Special scales for: HCl 30-33%, NaOH 30%, NaOH Temperature range
50% and air To determine the maximum internal pressure at high
temperatures, we refer you to our material-related pres-
sure-temperature diagrams for reference values.
605
Measuring tube Union Max. temperature
at 1 bar
PVC-U PVC-U 0 to 60 °C
PA PVC-U 0 to 60 °C
PSU PVC-U 0 to 60 °C
PSU PVDF 0 to 90 °C
PVDF PVDF 0 to 100 °C
Chemical resistance
Chemical PVC-U PA PSU PVDF Peek V4A (316)
Acid Phosphoric acid H3PO4 75% + O + + + -
Sulfuric acid H2SO4 <90% + - - + - -
Nitric acid HNO3 <55% + - - + - -
Nitric acid HNO3 67% - - - + - -
Hydrofluoric acid HF <70% + - - + - -
Hydrochloric acid HCl 36% + O + + O -
Base Ammonia NH4OH 25% + + + - + +
Caustic potash KOH >50% + O + - + +
Caustic soda NaOH <50% + O + - + +
Anorganica Ferric chloride FeCl3 + + + + + -
Sodium hydrochloride NaOCl 15% + + + - + 0
Sodium bisulfite NaHSO <40% + + + + + +
3
Hydrogen peroxide H2O2 35% + - + O + +

aqueous inorganic sline solu- till saturation + + + + + 0
tions (not oxidizing)
Organica Formic acid HCOOH 85% O - O O O 0
Acetic acid CH3 85% O - O O O +
COOH
Formaldehyde H2CO <40% + - + O + +
Glycol <50% O - + + + +
Acetone undiluted - O - O + +
Ethanol, methanol undiluted O - + + + +
Aliphatic hydrocarbons undiluted O + + + + +

Valid for 40°C and 2bar X: recommended O: with limita- -: not recommended
tions

For higher or lower concentrations than mentioned in the list or entry "O", please contact gss@georgfischer.com
606
Temperature correction table for gases
Calibrating temperature (°C)
0 10 20 30 40 50 60 70 80
Operating 0 1 1.018 1.035 1.052 1.07 1.088 1.103 1.12 1.135
temperature 10 0.983 1 1.018 1.035 1.051 1.068 1.084 1.1 1.116
(°C) 20 0.965 0.983 1 1.015 1.032 1.05 1.065 1.08 1.096
30 0.948 0.966 0.983 1 1.015 1.031 1.047 1.062 1.08
40 0.933 0.95 0.967 0.984 1 1.015 1.031 1.046 1.061
50 0.92 0.936 0.953 0.968 0.984 1 1.015 1.03 1.045
60 0.905 0.922 0.938 0.953 0.968 0.985 1 1.015 1.03
70 0.892 0.907 0.924 0.94 0.955 0.97 0.985 1 1.014
80 0.88 0.895 0.912 0.927 0.943 0.965 0.971 0.987 1
Please use this chart to adjust the displayed values for

gaseous media of your flow meter, if the operating tem-
perature differs from the underlying temperature of 20°C
at calibrating time.
Example:
Calibrating temperature is 20°C and operating temper-
ature is 70°C. Take the factor 0.924 from the calibrat-
ing temperature column for 20°C and the operating tem-
perature line 70°C. The values shown by the flow me-
ter have to be multiplied by this factor, so the actual flow
volume at an operating temperature of 70°C can be cal-
culated. You get the factor with the following formula:
Tc= calibrating temperature

To= operating temperature
Note:
Operating temperature >calibrating temperature:
Factor <1
Operating temperature <calibrating temperature:
Factor >1
Density correction table for gases
Gases for calibration
Operating P
gases [kg/Nm3] Air Oxygen Nitrogen Ammonia Acetylene Chlorine
Air 1.293 1.000 1.050 0.983 0.772 0.953 1.580
Oxygen 1.429 0.953 1.000 0.935 0.735 0.906 1.500
Nitrogen 1.251 1.017 1.069 1.000 0.786 0.968 1.604
Ammonia 0.771 1.295 1.360 1.272 1.000 1.232 2.040
Acetylene 1.171 1.050 1.105 1.033 0.812 1.000 1.660
Chlorine 3.220 0.633 0.665 0.623 0.490 0.603 1.000
Hydrogen 0.089 3.810 4.010 3.750 2.940 3.630 6.020
Carbon dioxide 1.977 0.808 0.850 0.796 0.625 0.770 1.275
Sulphur dioxide 2.926 0.668 0.698 0.654 0.514 0.633 1.050
Coal gas 0.550 1.532 1.610 1.506 1.185 1.460 2.420
Propane 2.020 0.800 0.841 0.786 0.618 0.762 1.262
607
Gases for calibration
Operating P Carbon Sulphur
gases [kg/Nm ]3
Hydrogen dioxide dioxide Coal gas Propane
Air 1.293 0.262 1.238 1.495 0.652 1.250
Oxygen 1.429 0.250 1.175 1.430 0.621 1.189
Nitrogen 1.251 0.267 1.255 1.530 0.664 1.272
Ammonia 0.771 0.340 1.600 1.946 0.845 1.620
Acetylene 1.171 0.276 1.300 1.580 0.685 1.314
Chlorine 3.220 0.166 0.785 0.953 0.413 0.792
Hydrogen 0.089 1.000 4.715 5.725 2.480 4.760
Carbon dioxide 1.977 0.212 1.000 1.216 0.528 1.010
Sulphur dioxide 2.926 0.174 0.823 1.000 0.433 0.830
Coal gas 0.550 0.403 1.895 2.306 1.000 1.915
Propane 2.020 0.210 0.990 1.205 0.522 1.000
Please use this table to adjust the displayed values for gaseous media of your flow meter, if the specific media gravity dif-
fers from the underlying specific gravity of 1.293 kg/Nm3 (air)) at calibrating time.
Example:
Specific gravity at calibrating time is 1.293 kg/Nm (air). 3
The media hydrogen with its specific gravity of 0.089

kg/Nm has to be measured. From the column calibrat-
3
ing gases/air, in line seven for operating gases/hydro-

gen, you obtain the factor 3.81. The values shown by
the flow meter have to be multiplied by this factor, so
the actual flow volume at a specific gravity of 0.089 kg/
Nm can be calculated.
3
Note:
Operating gas density >calibrating gas density:
Factor <1
Operating gas density <calibrating gas density:
Factor >1
Density correction table for liquids
Density of calibrating solution (kg/l)
Float material PVDF
0.5 0.6 0.7 0.8 0.9 1 1.1 1.2
Density 0.5 1 1.105 1.2 1.29 1.38 1.464 1.545 1.63
Operating 0.6 0.903 1 1.084 1.168 1.248 1.32 1.397 1.475
liquid 0.7 0.834 0.923 1 1.078 1.15 1.22 1.29 1.36
0.8 0.775 0.856 0.928 1 1.066 1.133 1.196 1.262
0.9 0.724 0.802 0.87 0.937 1 1.06 1.12 1.18
1.0 0.683 0.755 0.818 0.883 0.94 1 1.055 1.114
1.1 0.645 0.715 0.771 0.836 0.892 0.946 1 1.055
1.2 0.613 0.678 0.735 0.793 0.845 0.896 0.947 1
1.3 0.585 0.648 0.7 0.755 0.807 0.857 0.903 0.955
1.4 0.56 0.62 0.671 0.723 0.773 0.82 0.865 0.913
1.5 0.537 0.595 0.645 0.695 0.743 0.787 0.832 0.877
1.6 0.515 0.57 0.618 0.665 0.712 0.755 0.798 0.84
1.7 0.496 0.548 0.595 0.641 0.685 0.726 0.767 0.81
1.8 0.478 0.538 0.574 0.617 0.66 0.7 0.74 0.78
1.9 0.462 0.511 0.555 0.597 0.638 0.676 0.715 0.755
2.0 0.446 0.495 0.536 0.578 0.617 0.654 0.691 0.73
608
Density of calibrating solution (kg/l)
Float material PVDF
1.3 1.4 1.5 1.6 1.7 1.8 1.9 2
Density 0.5 1.71 1.785 1.86 0.94 2.02 2.09 2.16 2.24
Operating 0.6 1.545 1.615 1.68 0.754 1.82 1.89 1.95 2.02
liquid 0.7 1.425 1.49 1.55 1.615 1.68 1.745 18 1.865
0.8 1.325 1.38 1.43 1.5 1.56 1.62 1.67 1.73
0.9 1.24 1.295 1.35 1.405 1.46 1.515 1.57 1.62
1.0 1.17 1.22 1.27 1.325 1.375 1.43 1.48 1.53
1.1 1.106 1.155 1.2 1.255 1.3 1.35 1.4 1.45
1.2 1.05 1.095 1.14 1.19 1.235 1.28 1.33 1.37
1.3 1 1.044 1.088 1.134 1.176 1.22 1.264 1.305
1.4 0.958 1 1.042 1.085 1.13 1.17 1.21 1.25
1.5 0.92 0.96 1 1.042 1.084 1.125 1.16 1.205
1.6 0.882 0.92 0.958 1 1.04 1.08 1.11 1.15
1.7 0.848 0.886 0.923 0.961 1 1.038 1.072 1.11
1.8 0.817 0.853 0.888 0.926 0.962 1 1.032 1.07
1.9 0.79 0.826 0.858 0.897 0.93 0.968 1 1.034
2.0 0.798 0.798 0.83 0.867 0.9 0.935 0.965 1
Please use this chart to adjust the displayed values for liquid media of your flow meter, if the specific media gravity
differs from the underlying specific gravity of 1.0 kg/l (water) at calibrating time.
Example:
Specific gravity at calibration 1.0 kg/l (water). The liq-
uid media with a specific gravity of 0.9 kg/l is to be mea-
sured. If you have a calibrating solution of 1.0 kg/l, you
can find the factor 1.06 in column 5 under operating liq-
uid density 0.9 kg/l. The values shown by the flow me-
ter have to be multiplied by this factor so the actual flow
volume at a specific gravity of 0.9 can be calculated.
Note:
New density is higher: factor <1
New density is lower : factor >1

Accurate reading
The top edge of the float with
the largest diameter indi-
cates the flow volume. If spe-
cial scales are applied sub-
sequently, it must be ascer-
tained that the scale marking
><is affixed congruently with
the one on the taper tube.
Accessories
Limit contacts
Variable area flow meters from GF Piping Systems are
equipped with two dovetail shafts. For external electri-
cal monitoring, these can be used for fitting magnetically
actuated limit contacts.
609
Function of the limit contact (GK)
The limit contacts serve for monitoring externally the limited flow values and
can be adjusted to any flow value on the corresponding scale. The magnet
built into the float closes or opens a reed contact in the limit contact.
When subsequently mounting limit contacts, mind that you have to replace the
standard float with a magnetic float.
The limit contacts GK10/ GK11 are only suitable for the VAFM type 335/ 350
as well as the short version of the existing range. The same contact type
cannot be used for monitoring both the min. and max. levels. (GK 10 min /
GK11 max)
Technical data of limit contacts Sensor GK15 was developed from the measurement sensor
GK05. Other than the old model, no reed-sensors are used
for the production of the GK15, but a special and new devel-
oped electronic system with microprocessor and sensors.
The sensor provides an output signal of 4 - 20 mA, accord-
ing to the level setting of the magnetic float in the flow meter.
This signal could be used by a PLC to control processes or
to show the precise flow-rate on an external display.
Since the resolution of the scales differs in

Connection: Standard plug DIN 40050 the settings, the sensor is programmed in-
Contact fitted: Reed contact dividually for each measurement range ex-
Protection class: IP 65 works. Therefore, you need to identify
Max. voltage: 230 V your required measurement range when
Max. continuous current: 0.2 A you place the order.
Peak switch-on current: 0.5 A

Technical data to sensor GK 15
For use with inductive loads, use a relay to Technical data
protect the contacts

Supply voltage: 12-24 VDC (+ - 10%)
Current consumption: <50 mA
Contact function Load resistor: Min. 0 max. 500 Ω
Position of float in relation to limit contacts: Current output: 4-20 mA (3 wire)
Top Bottom Safety class: IP65
max. contact (GK11) closed open Ambient temperature: 0 °C to +50 °C
min. contact (GK10) open closed Connection: Plug DIN 43650
Measurement accuracy: <1%
The contacts remain in these positions, even if the float

leaves the corresponding contact. When the float moves
back to the desired position, the corresponding contact Electrical connection
is deactivated.

4-20 mA Sensor Type GK 15
Pin1: Supply voltage 12-24 V
Description
Pin2: Output signal 4-20 mA
Pin3: 0V

610
Dimensions
Function elements GK 15
A: GF Flow meter M335 / M350 with

magnetic float
B: Sensor GK15
C: Cable plug
D: Guide rail
E: Clamping screws, for fastening and
sensor adjustment

611
612
Fundamentals for actuators of hand valves
Page

Specific data of actuators
-- Electric actuators 615
-- Pneumatic Actuators 617
-- Electromagnetic Actuators 618
-- Actuator - valve combinations 618
-- Operating diagram FC, FO, DA 620
-- Stroke limiter 620
-- Actuator interface per EN ISO 5211 620
-- General safety information for actuators 621
-- Troubleshooting 622
Electric Actuator EA11
-- Overview 623
-- Graph 623
-- Setting up the actuator 626
Electric Actuators EA21/31/42
-- Overview 627
-- Graph 627
-- Setting up the actuator 631
-- Accessories 633
Pneumatic Actuators PA11/21
-- Overview 634
-- Graph 634
-- Accessories 637
Pneumatic Actuators PA30 to PA90
-- Overview 638
-- Graph 638
-- Accessories 644
Pneumatic Actuator for DIASTAR 646
Accessories for electric actuators

-- Heating element 647
-- Reset unit 647
-- Additional limit switches (Ag-Ni, Au, NPN,PNP) 649
-- Limit switch kit middle position 651
-- Monitoring print with cycle time module, running time monitoring, current monitoring, cycle counter 652
-- Position signalisation 656
-- Positioner PE25 657
-- Testing adapter for RS232 interface 660
-- AS interface 663
613
Page

Accessories for pneumatic actuators
-- 3/2-way pilot solenoid valve PV 94/95 664
-- 3/2 - 5/2-way pilot solenoid valve MNL532 668
-- 4/2-way pilot solenoid valve PV5470 669
-- Namur connector plate 669
-- Pilot valve cluster PV2000 669
-- Electropneumatic positioner DSR500 674
-- Stroke limiter/Emergency manual override for DIASTAR 682
-- Electrical position indicator ER52/53 683
-- Electrical position indicator type ER 55 688
-- AS interface 689
PID controller type PE70
-- Basics 690
-- PE70-1/ -2 693
-- PE70-3/ -4 697
614
Fundamentals for actuators of
hand valves
Specific data of actuators
Electric actuators
Advantages Ease of installation
Well defined performance
No energy consumption in switching pauses
Intermediate position possible
Easy to maintain
Subsequent additional elements mountable
Characteristics Relatively high cost
Low maintenance costs
Long cycle time
Additional equipment necessary for defined end positions
EA 11 EA 21 EA 31 EA42
General Nominal torque [Mdn] 10 10 60 100
Peak torque 20 20 120 250
Duty cycle ED @ 25 40% 100% 50% 35%
°C/15 min
Tested cycles(at 20 °C 150000 250000 100000 75000
and Mdn)
Cycle time s/90° at Mdn 5 5 15 25
L/W/H [mm] 129/455/138 150/122/167 150/122/190 150/122/208
ISO 5211: F05 F05 F07 F07
WS 14/11 14/11 17 22
Protection class IP 65/67 IP 65/67
Combination Ball valve 546 (DN10- Type 107 Type 130ff. - -
DN50)
Ball valve 546 (DN65- - optional on request Type 130ff. -
DN100)
Ball valve 543 - Type 185/188 - -
Butterfly valve 567/568 - optional on request Type 140/141 Type 140/141
DN50-DN150 DN200 @ 10bar;
DN250 @ 6bar;
DN300 @ 4bar
Butterfly valve 037 - - DN50-DN80 DN100-DN200
Conditions Necessary electrical connections available (electricity,...), appropriate ambient
temperature, maximum humidity, pollution degree
Accessories Fail-safe return with +
battery
Crank (for emergency + +
manual override)
Cover screw (from + +
emergency manual
override)
Heating element + +
Heating element + fail- + +
safe return with battery
Adapter set for F05 +
(WS14/11)
Adapter WS14 for F05 +
615
Reduction sleeve +
WS11 for F05
Battery (spare part) +
Plug set +
Monitoring print +
Cycle time +
extension (Vario)
Cycle time monitoring +
Cycle counter +
Motor current monitor- +
ing
Position signalisation +
Positioner PE25 +
Positioner galvanically +
isolated
Test adapter kit for +
RS232 interface
WS14/11
Adapter WS14 for F05 +
Reduction sleeve +
WS11 for F05
Battery set +
Plug set +
Limit switch kit Ag-Ni + +
Limit switch kit Au +
Limit switch kit PNP +
Limit switch kit NPN +
Installation set for 4 lim- +
it switches
Limit switch kit middle +
position
Fail-safe return with +
battery

616
Pneumatic Actuators
Advantages Short switching time
Low cost
Performance on variable pressure control
Defined end position
Easy to maintain
Stroke limiter (to change manually)
Subsequent additional elements mountable
Flow control is possible with additional elements
Characteristics Control valve necessary
Compressed air required
Position feedback for additional elements necessary
Intermediate positions require more effort
PA 11 PA 21 PA30-90
General Nominal torque [Mdn] 5 10 4 - 1920
Peak torque 10 20 8 - 3840
Tested cycles (at 20 °C 250000 250000
and Mdn)
Cycle time s/90° at Mdn 5 5 0.5 - 4
L/W/H [mm] 194/54/74 224/58/94 177/55.5/87 - 918/180/
241
ISO 5211 F04 F05 F03 - F16
WS 11 14/11
Operating pressure 7 bar (101 psi) 7 bar (101 psi)
max.
Working principle Rack and pinion Scotch-yoke
Combination Ball valve 546 (DN10- Type 230 Type 230 -
DN50)
Ball valve 546 (DN65- - - Type 230
DN100)
Ball valve 543 Type 285 Type 285 -
Butterfly valve 567/568 - - Type 240/241-242
Conditions Compressed air available, appropriate ambient temperature, specified hu-
midity, control medium (neutral, non-aggressive gases), max. actuation
pressure
Accessories Emergency manual +
override DN10 - 25
Emergency manual +
override DN32 - 50
Namur connector plate + +
Pilot solenoid valve + +
type PV94/95 (3/2-
way)
type MNL532 (3/2 - 5/2-
way)
type MNL5470 (4/2-
way)
type PV2000 (for valve
clusters)
Digital positioner type + +
DSR201
617
Namur mounting con- + +
sole
2 additional limit switch- + +
es Ag-Ni 250 V/10 V
es NPN 10 - 30 V/0.1A
es PNP 10 - 30 V/0.1A
es Namur 5 - 24 V
es EExd 250 V/5A
es 30 V = max. 1 - 100
mA
WS11 (PA11)
WS14/11 (PA21)
Electromagnetic Actuators
Advantages Short switching time
High switching frequency
Defined end position
Easy to maintain
Characteristics Maximum operating pressure 6 bar
Maximum operating pressure / differential pressure of
pending DN
Permanent demand for electricity in the open position
Sensitive against solids when servo-controlled
Flow control requires high effort
General Duty cycle ED @ 25°C/15min 100%
Voltage tolerance +/- 10%
Supply voltage 24 V DC, 24 V / 50 Hz, 110 / 230 V / 50 Hz
Combination Diaphragm valve DIASTAR Sixteen +
Diaphragm valve DIASTAR Ten +
Diaphragm valve DIASTAR Six +
Diaphragm valve DIASTAR Ten + +
Actuator - valve combinations

The EA family of actuators is designed to fit GF valves
as well as standard valves.
The electric rotary actuator EA11/21/31/42 can be
mounted e. g. on ball valves and butterfly valves. In
case emergency manual override is needed, you have
to use a suitable adapter.
618
Actuator Type / Standards Ball valve/Butterfly valve Material
EA 11 Type 107 metric Ball valve 546 DN10 - 50 PVC-U, PVC-C, ABS, PP-H,
PVDF
EA 21 Type 130 metric Ball valve 546 DN10 - 50 PVC-U, PVC-C, ABS
Type 131 metric Ball valve 546 DN10 - 50 PP-H
Type 132 metric Ball valve 546 DN10 - 50 PVDF
Type 133 ANSI Ball valve 546 DN10 - 50 PVC-U, PVC-C, ABS, PP-H,
PVDF
Type 134 BS Ball valve 546 DN10 - 50 PVC-U, PVC-C, ABS, PP-H,
PVDF
Type 135 JIS Ball valve 546 DN10 - 50 PVC-U, PVC-C, ABS, PP-H,
PVDF
EA 31 Type 130, 131, 133 - 135 Ball valve 546 DN 65-100 PVC-U, PVC-C, ABS, PP-H
EA 21 Type 175 horizontal Ball valve 343 PVC-U, PVC-C, ABS
Type 176 horizontal Ball valve 343 PP-H
Type 177 horizontal Ball valve 343 PVDF
Type 178 vertical Ball valve 343 PVC-C
EA31/42 Type 140 wafer Butterfly valve 567 PVC-U, PVC-C, ABS, PP-H,
for DN200 PVDF
Type 141 lug Butterfly valve 568 PVC-U, PVC-C, ABS, PP-H,
PVDF
Type 142 lug ANSI Butterfly valve 568 PVC-U, PVC-C, ABS, PP-H,
PVDF
Type 143 lug JIS Butterfly valve 568 PVC-U, PVC-C, ABS, PP-H,
PVDF
The actuators are supplied ex works in the «open» po-

sition. Both end positions in the actuator have been
preset in the factory. It might be necessary to readjust
these after installation at the customer (see section
”Setting Up the Actuator”).
Actuator Type / Standards Ball valve/Butterfly valve Material
PA11 up to DN25 Type 230 metric Ball valve 546 DN10 - 50 PVC-U, PVC-C, ABS
PA21 from DN32 Type 231 metric Ball valve 546 DN10 - 50 PP-H
Type 232 metric Ball valve 546 DN10 - 50 PVDF
Type 233 ANSI Ball valve 546 DN10 - 50 PVC-U, PVC-C, ABS, PP-H,
PVDF
Type 234 BS Ball valve 546 DN10 - 50 PVC-U, PVC-C, ABS, PP-H,
PVDF
Type 235 JIS Ball valve 546 DN10 - 50 PVC-U, PVC-C, ABS, PP-H,
PVDF
PA11 up to DN25 Type 275 horizontal Ball valve 343 PVC-U, PVC-C, ABS
PA21 from DN32 Type 276 horizontal Ball valve 343 PP-H
Type 277 horizontal Ball valve 343 PVDF
PA30 - 90 Type 230, 231, 233 - 235 Ball valve 546 DN 65-100 PVC-U, PVC-C, ABS, PP-H
Type 240 wafer Butterfly valve 567 PVC-U, PVC-C, ABS, PP-H,
PVDF
Type 241 lug Butterfly valve 568 PVC-U, PVC-C, ABS, PP-H,
PVDF
Type 242 lug ANSI Butterfly valve 568 PVC-U, PVC-C, ABS, PP-H,
PVDF
Type 243 JIS Butterfly valve 568 PVC-U, PVC-C, ABS, PP-H,
PVDF
619
Operating diagram FC, FO, DA Actuator interface per EN ISO 5211
For the proper function of the actuator In case you would have to fit one of our new actuators
assembly, it is important that the posi- (EA11-21 as well as PA11/21) to a third party valve - we
tion of the actuator and valve position have the perfect solution. Our electric actuators EA31
matches. Actuator open - >valve open, and EA42 already fulfil the interface F07 (WS17/22) per
actuator closed ->valve closed. EN ISO 5211. That means it is possible without any ex-
tra adapters to fit these actuators to any other valve that
Fail-safe to follows the standard EN ISO 5211. A reduction from
close (FC)1 WS22 to WS17 is also available if needed. For our ac-
solenoid valve 3/2- tuators EA11 and PA11/21 we have adapters available
way de-energized
that allow a F04 and F05 interface per EN ISO 5211.
closed
Adapter F04 (WS11)
Fail-safe to
open (FO) 1
solenoid valve 3/2- Adapter F05 (WS14) Reduc-
way de-energized tion sleeve (WS11)
closed
Due to an octagonal in the adapter options are parallel

or diagonal square. For an overview please refer to the
Double Acting table below.
(DA) 1 solenoid
valve 5/2-way (alter- Interface overview per EN ISO 5211
native 4/2-way)
Actu- Peak torque (Nm) Interface WS
ator
Type
PA 11 10 F04 11
PA 21 20 F05 14/11
PA30- 8 - 3840 F03- F16 11-
PA90 16
EA 11 20 F05 14/11
EA 21 20 F05 14/11
EA 31 120 F07 17
EA42 250 F07 22
Stroke limiter
The stroke limiter is mounted ex works and enables lim-
iting the actuating angle up to 45° alternatively in the
closed or open direction for the FC and FO functions.
For the DA function, limitation is only possible in the
open direction.
620
General safety information for actuators
NOTICE
CAUTION
24 V devices
• 24 V devices may only be connected to
Intended use voltages which fulfill the requirements of a
When mounted on a valve and connected to safety extra low voltage circuit (SELV).
a system control and provided that the actu-
ator data correspond to the electrical control Special hazards
and the valve, the purpose of these actuators
is: When not used as prescribed, it can lead
to serious injury or death. Therefore, these DANGER
actuators are intended to:
• actuate valves with with 90° pivoting (e.g. Working at the actuator
ball valves and butterfly valves),
Under normal conditions, the actuator may
• indicate the previously calibrated end posi-
only be operated with the cover closed. If
tions of the valve via electrical signal to the
work is performed on the actuator with the
system control (accessory),
cover removed, the supply and control volt-
age must first be disconnected.
the current position (without accessories). • Adjustments, which need to be done in the
Please use the emergency manual over- energized state, should be carried out with
ride or install the fail-safe return unit. special insulated tools.
These actuators are not intended for uses other than

those listed above. Non-observance of the instructions
DANGER
contained in this manual will void the manufacturer's lia-
bility for the products mentioned above.
Operator responsibilities Instruction manual
The actuator described herein was designed and man- Non-observance of the instruction manual
ufactured with consideration to the respective har- may lead to severe injuries or death.
monised European standards. • Furthermore, the operating instructions of
It corresponds to the state of art. the manual valve must also be observed.
They are an integral component of this
manual.
WARNING
Duty of care
Failure to heed the duty of care and safety CAUTION
can lead to serious injury or death. Safety on
the job can, however, only be realised if the
operator warrants that Transport and storage
• the actuator is only used as indicated un- The actuators must be handled, transport-
der section "Intended Use", ed and stored with care. Non-observance
• he is familiar with this instruction manual might lead to injuries.Please note the follow-
and the manual of the corresponding valve ing points:
and adheres to the instructions contained • The actuators must be transported and/or
therein and stored in their unopened original packag-
• he has taken the necessary measures ing.
against electrostatic influence. • The actuators must be protected from
harmful physical influences such as dust,
heat (humidity).
• It is important that the connections are nei-
ther damaged by mechanical nor thermal
influences.
• Prior to installation, the actuators should be
inspected for transport damages. Damaged
actuators must not be installed.
621
Troubleshooting
Problem Possible causes Remedy
Motor does not No mains voltage Error on customer's
run (T 1, 2, 3) side
Internal wiring error Check wiring of ac-
tuator
Switching cams S1 See section "Set-
and S2 incorrectly ting Up the Actua-
set tor" for the corre-
sponding actuator
Motor blocked Use emergency
manual override,
check valve
Motor only runs in Limit switch defec- Replace replace
one direction tive limit switches
Overload protec- Friction torque of Clean and lubricate
tion reacts (self- valve too high valve
resetting)
Duty cycle too high Increase cycle time

Reduce ambient
temperature
Valve does not Switching cams S1 See section "Set-
close or open cor- and/or S2 not ad- ting Up the Actu-
rectly justed ator" of the corre-
sponding actuator
For service please contact the specialist at your GF

sales company.
622
Electric Actuator EA11 Graph
Overview Exploded view
The standard version of the EA 11 electrical actuator
Product description
consists of the following elements:
The EA 11 is our basic version for the open-close oper-
ation in the low torque range.Nominal torque is 10 Nm, Gear unit, direct current motor, electrical board, and
peak torque 20 Nm. Two additional limit switches can components for end position limiting.
be installed for feedback. The EA 11 can be extended
For special applications, the actuator can be equipped
by a heating element and a reset unit.
additionally with various supplementary kits (see section
Versions "Mounting and Connecting Supplementary Kits").
Type EA 11
Product features
• Robust PP-GF housing with very good chemical resis-
tance
• Flexible configuration of the actuator thanks to the 1 Limit switches S1 and S2
modular concept easy handling 2 Direct current motor
• Easy handling 3 Optical position indicator
4 Plug for accessories
• Additional safety due to fail-safe unit and battery pack 5 Terminal strip for external connections max. 1.5 mm²
(optional) 6 Electrical supply unit, without protection against accidental con-
tact
• Long life time due to robust design and best electron- 7 Shaft for emergency manual override
ics 8 Connections for DIN plug or cable gland
9 Assembly bolt for accessories
• Suitable for universal use due to wide range power
supply and standard interfaces Dimensions EA11
Safety information
NOTICE
Installation note
• If the actuator is connected directly to the
power supply, it is necessary to install a
switch-disconnector between the actuator
and the power supply (do not disconnect
the earth cable). Cross section of the feed
lines max. 1.5 mm². To avoid water perme-
ation into the actuator, make sure that the
cable entry is not directed upward
• Due to the loading of the power supply ca-
pacitor, when first time switching on the ac-
tuator current peaks can occur for a few
micro seconds. Therefore we recommend
to connect the catuator in accordance with
accompanying wiring diagram.
623
Weight
EA 11
1.857 kg
Technical data
Rated voltage 100 - 230 V, 50/60 Hz
24 V = /24 V, 50/60 Hz
± 10 %
Rated voltage tolerance
Rated output 22 VA at 24 V AC/DC
40 VA at 100 - 230 V AC
Electric impedance 230 V , 100 k
24 V, 4.7 kΩ
Altitude (UL/CSA) <2000m
Protection class IP 65 per EN 60529 3) UL/
CSA: Indoor use
Power-on time ED 40 % at 25 °C/ 15 min
Overload protection Current/time dependent (re-
setting) 1)
Connector plug 3 P+ E
Electrical connection According to DIN EN 175301-
803
additional cable entry point
for PG 11
Nominal torque Mdn 10 Nm
Peak torque 20 Nm
Cycle time 5 s/ 90 ° at Mdn
Actuating angle Max. 270 °, set to 90 °
Ambient temperature -10 ° to + +45 °C 2)
Permissible humidity Max. 80 % up to 31 °C 4)
Pollution degree 5) 2
Overload category 5)
II
Housing material PP fiberglass reinforced,
flame retardant, external
stainless steel screws
Position indicator Optical, integrated
Emergency manual override Integrated
1 Adapter SW14 for F05 198.204.057

1)
Overload protection of the motor is dimensioned so
2 Reducing sleeve SW11 for F05 198.803.145 that the motor and the power supply board are protect-
ed. As soon as the load is in the torque range, the actu-
ator runs again.
624
2)
For temperatures below –10 °C as well as condensa-
tion, the heating element no. 198 190 086 should be
built in (see section --> Accessories "Heating element”)
Protection class IP67, when used with cable glands
3)
and vertical installation.

4)
Linear decreasing to 50 % relative humidity with 40 °C.
5)
According to EN 61010-1
Technical features
Connection diagram for standard version
Position indicator
3/2-way 2/2-way
vertical
horizontal
B-C B closed
A-C C open
625
After usage, please screw back on the
Setting up the actuator screw cover (2) to avoid liquids, humidity or
dust entering the actuator!
NOTICE
Setting up the actuator

Check the following before connecting the
actuator to the mains:
• Does the mains voltage correspond to the
specifications given on the typeplate?
• Has the actuator been connected correct-
ly? (see section "Wiring Diagram for Stan-
dard Version")
Function
Push the crank down to the stop.
With nine revolutions, the ball is rotated by 90° .
Direction of rotation:
Clockwise = CW = close
Counterclockwise = CCW = open
Note the «open» and «closed» position on

the optical indicator.
Adjustment
If a complete valve is supplied by GF, no further adjust-
ments are required. Disconnect the connector plug.
After installation by the customer or after repair work, If that is not possible, pull the crank rapidly
out of the opening.
the end positions should be checked and if necessary
adjusted.
Limit switch allocation
Switch S1 (bottom) opens at «open» position
Switch S2 (top) opens at «closed» position
Procedure
Set both switching cams (1) corresponding to S1
(«open», bottom) and S2 («closed», top) so that the ro-
tating angle is less than 90 °. Let the actuator turn un-
til a limit switch is activated. By fine adjustment of the
respective switching cam, the end position can be set
since the actuator follows the cam.
Emergency manual override
Assembly and function
Assembly
Pull the crank lever (1) out of the retainer.
Remove screw cover (2) with the crank (1).
Insert the crank in the hexagon shaft under the open-
ing.
626
Electric Actuators EA21/31/42 Safety information
Overview
Product description NOTICE
The electric actuators EA21, EA31 and EA42 are not
only well equipped with a lot of extras, they also fea-
ture very high torques. This enables automating a wide Installation note
range of valves.
• If the actuator is connected directly to the
Interesting accessories: EA21 power supply, it is necessary to install a
From the EA21 model and upwards, we offer you a vari- switch-disconnector between the actuator
ety of supplementary kits to choose from. Compared to and the power supply (do not disconnect
the basic EA11 model, this actuator indicates operation the earth cable). Cross section of the feed
readiness and has a duty cycle of 100 %. Also included lines max. 1.5 mm². To avoid water per-
in the EA21 range of accessories are cycle time exten- meation into the actuator, make sure that
sion, cycle time monitoring, cycle counter, motor current the cable entry is not directed upward The
monitoring, position signalisation and a positioner. EA21/31/42 has a temperature control
High torques: EA31 and EA42 (ready-to-operate monitoring).
The EA31 and the EA42 are not only well equipped with • Due to the loading of the power supply ca-
a lot of extras, they also feature very high torques. This pacitor, when first time switching on the ac-
enables automating a wide range of valves. While the tuator current peaks can occur for a few
EA31 features a peak torque of up to 120 Nm, the EA42 micro seconds. Therefore we recommend
even goes up to 250 Nm. Both actuators are ideal for all to connect the catuator in accordance with
kinds of control tasks. accompanying wiring diagram.
Versions
Type EA21 / EA31 / EA42 Graph
Exploded view
The standard version of the EA21/31/42 electric actua-
tor consists of the following elements:
Gear unit, direct current motor, electrical board, and
components for end position limiting.
For special applications, the actuator can be equipped
additionally with various supplementary kits (see section
"Mounting and Connecting Supplementary Kits").
Product features
• Robust PP-GF housing with great chemical resis-
tance
• Flexible configuration of the actuator thanks to the
modular concept
• Easy handling
• Numerous options for controlling and monitoring with
intelligent, self-learning accessory
• Additional safety due to fail-safe unit and battery pack
(optional) 1 Limit switches S1 and S2
• Long life time due to roust concept and the choice of 2 Direct current motor
best electronic 3 Visual position indicator
• Suitable for universal use due to wide range power 4 Plug for accessories
supply and standard interfaces 5 Terminal strip for external connections max. 1.5 mm²
6 Electrical supply unit, without protection against accidental
contact
7 Shaft for emergency manual override
8 Connections for DIN plug or cable gland
9 Assembly bolt for accessories
627
Dimensions EA21/31/42
L1 L2 L3 L4 L5 L6
mm mm mm mm mm mm
EA 21 150 82.5 108 64.3 122 16
EA 31 150 82.5 108 64.3 122 16
EA42 150 82.5 108 64.3 122 16
L7 L8 L9 H1 H2 H3

mm mm mm mm mm mm
EA 21 49 33 33 167 20 188.5
EA 31 49 33 33 190 25 211.5
EA42 49 33 33 208 25 229.5 EA21/ F05
EA31/ F07
628
EA42/ F07
Weight
EA 21
2.193 kg
EA 31
3.536 kg
EA42
4.995 kg
Technical data
EA 21 EA 31 EA42
Rated voltage 100 - 230 V, 50/60 Hz 100 - 230 V, 50/60 Hz 100 - 230 V, 50/60 Hz
24 V = 24 V, 50/60 Hz 24 V = 24 V, 50/60 Hz 24 V = 24 V, 50/60 Hz
Rated voltage toler- +/-10 % +/-10 % +/-10 %
ance
Rated output 22 VA at 24 V AC/DC 32 VA at 24 V AC/DC 40 VA at 24 V AC/DC
40 VA at 100 - 230 V AC 40 VA at 100 - 230 V AC 60 VA at 100 - 230 V AC

Electric impedance 230 V , 100 k 230 V , 100 k 230 V , 100 k
24 V, 4k7 24 V, 4k7 24 V, 4k7
Altitude (UL/CSA) <2000m <2000m <2000m
Protection class IP 65 per EN 60529
3)
IP 65 per EN 60529
3)
IP 65 3) per EN 60529
UL /CSA: Indoor use UL /CSA: Indoor use UL /CSA: Indoor use
Duty cycle 100 % 5)

50 % 35 %
Overload protection Current/time dependent (re- Current/time dependent (re- Current/time dependent (re-
setting) 1), setting) 1), Temperature-de- setting) 1), Temperature-de-
Temperature-dependent pendent pendent
Electrical connection Connector plug 3 P+ E Connector plug 3 P+ E per Connector plug 3 P+ E per
per DIN EN 175301-803, DIN EN 175301-803, Cable DIN EN 175301-803, Cable
Cable gland gland gland
M20x1.5 per ISO 724 M20x1.5 per ISO 724 M20x1.5 per ISO 724
Nominal torque Mdn 10 Nm 60 Nm 100 Nm

Peak torque 20 Nm 120 Nm 250 Nm
Actuating angle Max. 180 °, set to 90 ° Max. 180 °, set to 90 ° Max. 180 °, set to 90 °
Cycle time 5 s/ 90 ° at Mdn 15 s/ 90 ° at Mdn 20 s/ 90 ° at Mdn
Ambient tempera- -10 ° to + 50 °C 2)
-10 ° to + 50 °C
2)
-10 ° to + 50 °C 2)
ture
629
Allowable humidity Max. 90 % relative humidi- Max. 90 % relative humidity, Max. 90 % relative humidity,
ty, non condensing non condensing non condensing
Pollution degree 4)
2 2 2
Overload - category II II II
4)
Housing material PP fiberglass reinforced, PP fiberglass reinforced, PP fiberglass reinforced,

flame retardant, external flame retardant, external flame retardant, external
stainless steel screws, stainless steel screws, cap- stainless steel screws, cap-
captive tive tive
Position indicator Optically integrated Optically integrated Optically integrated

Emergency manual Integrated Integrated Integrated
override
1)
Overload protection of the motor is dimensioned so
that the motor and the power supply board are protect-
ed. As soon as the load is in the torque range, the actu-
ator runs again.
2)
For temperatures below -10 °C as well as condensa-
tion, the heating element no. 198 190 086 should be in-
stalled (see section "Assembly and Wiring Supplemen-
tary Kits" and ”Heating element”)
Protection class IP67, when used with cable glands
3)
and vertical installation.

4)
According to EN 61010-1
5)
Reduced duty cycle for UL certification
630
Position indicator
Technical features
3/2-way 2/2-way
Connection diagram for standard version vertical
horizontal
B-C B closed
A-C C open
NOTICE

Check the following before connecting the
actuator to the mains:
• Does the mains voltage correspond to the
specifications given on the typeplate?
• Has the actuator been connected correct-
ly? (see section "Wiring Diagram for Stan-
dard Version")
• Fuse ≥ 6A
Adjustment
If a complete valve is supplied by GF, no further adjust-
ments are required.
After installation by the customer or after repair work,
the end positions should be checked and if necessary
adjusted.
Limit switch allocation
Switch S1 opens at «open» position
Switch S2 opens at «closed» position
631
Note the «open» and «closed» position on
the optical indicator.
Disconnect the connector plug.

If that is not possible, pull the crank rapidly
out of the opening.

Error message
If an error occurs, the red LED (8) on the base board
will light up. If the monitoring print is installed, the corre-
sponding LED on the BCD switch (10), of which the set
value has been exceeded, will also light up red.
Procedure With all occurring error messages the ready-to-operate
Set both switching cams (1) to S1 and S2 so that the ro- signal will be off (terminals 5.6 no passage).
tating angle is less than 90°. Let the actuator turn un-
Eliminating the malfunction report
til a limit switch is activated. By fine adjustment of the
Check the error cause, if necessary carry out the appro-
respective switching cam, the end position can be set
priate maintenance.
since the actuator follows the cam.
To eliminate the message, activate the reset switch
Emergency manual override (9) on the base board while the supply voltage is
Assembly and function still connected or briefly disconnect the actuator
Assembly from the mains voltage.
Pull the crank lever (1) out of the retainer. The two LEDs will go out and the actuator is ready to
Remove screw cover (2) with the crank (1). operate again.
Insert the crank in the hexagon shaft under the open-
ing.
After usage, please screw back on the
screw cover (2) to avoid liquids, humidity or
dust entering the actuator!
Function
Push the crank down to the stop.
With nine revolutions, the ball is rotated by 90° .
Direction of rotation:
Clockwise = CW = close
Counterclockwise = CCW = open
632
In case of malfunction the actua-
tor remains in its position (delivery
state).

tor moves to the OPEN position.

tor moves to the CLOSED posi-
tion.
Accessories
available in the chapter accessories for
electric actuators.
DIP switch in case of error

In case of an error the actuator can be set to the
CLOSED or the OPEN position with the help of the DIP
switch. For this, the DIP switches need to be adjusted
as follows:
DIP1 DIP2
ON Position of DIP2 effective Actuator turns to the
OPEN position
OFF Actuator remains in the Actuator turns to the
current position. (DIP2 not CLOSED position
effective)
633
Pneumatic Actuators PA11/21 • enable control of these positions through manual op-
eration in case of failure in the compressed air supply,
Overview if the actuator is equipped for this with the respective
subassembly.
Product description
Our pneumatic full plastic actuators PA11/21 can serve The actuator is not intended for uses other than those
you in many ways. They are available with or without stated here. Prohibited in particular are:
stroke limiter as well as in the different modes of op- • control pressures above 7.5 bar,
eration. Range: PA11 from d16DN10 up to d32DN25 • manual operation with forces higher than permitted
and PA21 from d40DN32 up to d63DN50. Thanks to the according to DIN EN12570 (maximum retention forces
new position indication with integrated NAMUR interface for operation of valves),
– accessory assembly to our PA11/21 is as easy as it
gets.Naturally, the flange interface also corresponds to
under water.
the NAMUR standard. Therefore, third party valves are
no problem.
Versions
NOTICE
PA11 / PA21

• The actuator can only function properly if
it has been connected professionally as
per the connection diagram for double act-
ing operation and for fail-safe OPEN or fail-
safe CLOSE operation , respectively.
Special hazards
Single acting, fail-safe OPEN and
Product features CLOSE (type description FO and FC )
• Robust PP-GF housing pneumatic actuators have pre-load-
ed springs that bring the valve into the
• Full plastic actuator
predefined position in case of com-
• Position indicator with integrated NAMUR interface pressed air loss.
• Very good price-performance ratio for all versions Dismantling these actuators is dangerous and may on-
ly be done by following special repair instructions (avail-
• Multi functional module available with different limit able from +GF+) and under the guidance of a safety ex-
switch versions pert.
Dismounting from the valve may only be done in the
Safety information safety position after cutting off the compressed air sup-
Intended use ply. Prior to any work on the electric subassemblies of
The descriptions and instructions in the following apply the pneumatic actuator, the electrical connections of the
to the pneumatic actuators: control voltage have to be disconnected. Any necessary
live-line adjustments may only be done with specially in-
Type PA11 Pneumatic part-turn valve actuator DA/FC/FO sulated tools.
Type PA21 Pneumatic part-turn valve actuator DA/FC/FO Furthermore, the operating instructions of the manual
valve must also be observed. They are an integral com-
When built into GF valves and connected to a system ponent of this manual.
control, the purpose of these actuators is
• to actuate ball valves with a control pressure of 2.8 to Graph
7 bar and up to a driving torque of 20 Nm, and
• depending on the type of pneumatic actuator, dou- Exploded view
ble acting (type designation DA) or single acting with The pneumatic actuator PA11/PA21 features the follow-
spring for fail-safe to CLOSE (type designation FC) or ing components:
single acting for fail-safe to OPEN (type designation • Housing with screwed on spring cover, position indi-
FO), cator and Namur air connection
• control these valves to the OPEN and CLOSED po- • Spring cover with mounted, preloaded spring assem-
sitions via a built-in solenoid valve. The solenoid bly
valve must be either supplied ex GF works or already
mounted by the customer, • Namur air connection with internal reversing bore for
the DA function
• indicate these positions OPEN and CLOSED via an
electric signal to the system control, if the actuator is • Piston with rack
equipped for this with the respective subassembly, • Pinion shaft
634
For special applications, actuators can be equipped with
various supplementary kits/accessories. (see "Acces-
sories").
PA11/21 connecting dimensions
1 Spring cover
2 Visual position indicator
3 Housing of PP-GF
4 Piston with rack
5 Pinion shaft
6 Preloaded spring assembly
7 Connection for control air G1/8”
Dimensions
L1 L2 L3 L4 L5 L6 L7
PA11 194 44 80 24 48 54 275
PA21 224 54.5 80 24 58.5 58 305 PA11/21 without stroke limiter
L: Length
H: Height
D: Diameter
H1 H2 H3 H4

mm mm mm mm
PA11 97 20 4 40
PA21 119 20 4 51
L: Length
H: Height
D: Diameter PA11/21 with stroke limiter
D1 D2 D3 D4 D5 D6 Weight

mm mm mm mm mm PA11 / PA21
0.75 kg - 1.445 kg
PA11 28.5 M5 61 74 G1/8" 35
PA21 28.5 M5 82 94 G1/8" 35
L: Length
H: Height
D: Diameter
635
Technical data
Actuator
Nominal torque 10 Nm (7.4 lb. ft.)
Peak torque 20 Nm (15 lb. ft.)
Cycle time 1 - 2 s, with throttle valve to 5
s
Actuating angle 90 °C
PA21 torque characteristics
Allowable ambient tempera- -10 ° to + +50 °C
ture
Permissible humidity 0 - 100 %
Technical features
Housing material PP fiberglass-reinforced Options
Position indicator Optical Stroke limiter
The stroke limiter is mounted ex works and enables lim-
Control medium Neutral, non aggressive gas- iting the actuating angle up to 45° alternatively in the
es
closed or open direction for the FC and FO functions.
(Control with fluids on re-
quest) For the DA function, limitation is only possible in the
open direction.
Compressed air class per 2 or 3 for -10 ºC
ISO 8573-1
3 or 4 for T >0 ºC
Temperature control medium Max. 40 °C
Control pressures (reference
values)
Actuator connection G1/8"
Mode of operation - Fail-safe close (FC)
- Fail-safe open (FO) - Dou- Setting the end position limits
ble acting (DA)
Stroke limiter close direction FC Version
Max. allowable control pres- 7 bar a) Make sure the springs are in the position of rest (no
sure compressed air)
b) Unscrew the transparent cap
Control vol- DN Single act- Double act- c) Drive the actuator with compressed air into the open
ume in dm³ mm ing (FC/FO) ing (DA) position
dm³ dm³ d) Turn the adjusting screw in a counterclockwise direc-
tion until the desired position is reached
PA11 10 0.15 0.18 (open)
15 0.15 (closed) e) Set the actuator in the closed position, check the set-
20 ting and if necessary repeat from step c)
25 f) Tighten the safety nut
g) Assemble the transparent cap
PA21 32 0.28 0.35 (open)
40 0.28 Stroke limiter open direction FC Version (DA)
50 (closed) a) as above
b) as above
c) Actuator in CLOSED position
d) Turn the adjusting screw in clockwise direction until
the desired position is reached
e) Drive the actuator with compressed air in the open
position, check the setting and if necessary repeat from
step c)
f) as above
g) as above
Operating diagram FC, FO, DA
Note
Please observe the following:
For the correct functioning of the actuator, the position
PA11 torque characteristics of the actuator must correspond with the position of the
valve.
Actuator open >Valve open
Actuator closed >Valve closed
636
When installing an actuator with a GF ball valve, it is im-
portant to note the position of the ball valve spigot.
Fail-safe to
close (FC)

1 Solenoid valve
3/2-way
de-energized
closed
Fail-safe to
open (FO)

1 Solenoid valve
3/2-way
de-energized
closed
Double Acting
(DA)

1 Solenoid valve
5/2-way
(alternative 4/2-
way)

5/2-way valve

4/2-way valves
Accessories
available in the Chapter Accessories for
pneumatic actuators.
637
Pneumatic Actuators PA30 to PA90 Dismounting from the valve may only be done in the
safety position after cutting off the compressed air sup-
Overview ply. Prior to any work on the electric subassemblies of
the pneumatic actuator, the electrical connections of the
Product description control voltage have to be disconnected. Any necessary
The pneumatic actuator series PA30- PA90 serves to live-line adjustments may only be done with specially in-
operate valves with a 90° positioning angle. Georg Fis- sulated tools.
cher actuators already comply with both the EN stan-
dards, as well as divers ISO standards: Actuator mount- Furthermore, the operating instructions of the manual
ing flange according to ISO 5211; Actuator connec- valve must also be observed. They are an integral com-
tion with square according to DIN 3337; Connection for ponent of this manual.
solenoid valve, positioner and limit switch according to
VDI/VDE 3845 (NAMUR); Optical position feedback. Graph
All GF Piping Systems actuators can be used as open/
Exploded view
close or control actuators. The double acting design
means that the valve is opened or closed by the actua-
tor applying compressed air. Depending on the require-
ment, the springs can open or close. The single-acting
actuators only apply compressed air on one side, while
adjustment on the other side is by spring force. This
means that if there is air failure they return automatical-
ly to a safety position. Standard interfaces enable easy
configuration of: solenoid valve, limit switch and posi-
tioner.
Versions
PA30 - PA90
1 Special lift design leads to high end torques

2 Special seals and piston guide rings guarantee a long service
life
3 Automatic bolt lubrication for long service life
4 ISO/Namur connecting shaft of stainless steel
5 End position damping
6 The cylinder bore is lapped and hard anodized
7 Outer surface is hard anodized
Product features
• Integrated NAMUR interface
• Wide torque range, from 8 Nm up to 3840 Nm
• Very good price-performance ratio for all versions
• Easy assembly with various limit switch options
• Low installation height
Safety information
Special hazards
Single acting, fail-safe OPEN and
CLOSE (type description FO and FC )
pneumatic actuators have pre-load-
ed springs that bring the valve into the
predefined position in case of com-
pressed air loss.
Dismantling these actuators is dangerous and may on-

ly be done by following special repair instructions (avail-
able from +GF+) and under the guidance of a safety ex-
pert.
638
Dimensions
Single acting (FC/FO)

Type D1 D2 D3 D4 D5 L L2 L3 L4
PA30 F03/05 36/50 30 M5/6 1/8” 10 276 11 35 70
PA35 F05/07 50/70 35 M6/8 1/8” 12 326 14 35 70
PA40 F05/07 50/70 35 M6/8 1/8” 12 370 14 35 70
PA45 F05/07 50/70 55 M6/8 1/8” 15 411 17 35 70
PA50 F05/07 50/70 55 M6/8 1/8” 15 423 17 35 70
PA55 F07/10 70/102 70 M8/10 1/8” 19 452 22 35 70
PA60 F07/10 70/102 70 M8/10 1/8” 19 503 22 35 70
PA65 F10/12 102/125 85 M10/12 1/4" - 648 27 - -
PA70 F12 125 85 M12 1/4" - 663 27 - -
PA75 F14 140 100 M16 1/4" - 824 36 - -
PA80 F14 140 100 M16 1/4" - 918 36 - -
Type L5 H H1 H2 H3 H4 H5 H6 H7 H8
PA30 - 97 70 20.5 17.9 65.5 13 20 36 -
PA35 - 104.5 77.5 20.5 17.9 72 13 20 36 -
PA40 - 129 86 25 21 80.5 13 30 36 -
PA45 - 139 96 25 21 90 16 30 36 -
PA50 - 149 106 25 26 100.5 17 30 36 -
PA55 - 161 118 25 25 112 19 30 36 -
639
PA60 - 173 130 25 32 125 19 30 36 -
PA65 32 191 148 24 34 136.5 - - - 22
PA70 32 196 153 24 38 145 - - - 24
PA75 32 229 186 24 43 166 - - - 27
PA80 32 241 198 24 44 180 - - - 32
Double Acting (DA)

Type D1 D2 D3 D4 ( G) D5 L L2 L3 L4
PA30 F03/05 36 25 M5/6 1/8 9 177 9 35 70
PA35 F03/05 42 30 M5/6 1/8 10 190 11 35 70
PA40 F03/05 42 30 M5/6 1/8 1 198 11 35 70
PA45 F05/07 50 35 M6/8 1/8 12 235 14 35 70
PA50 F05/07 50 35 M6/8 1/8 12 250 14 35 70
PA55 F05/07 70 55 M6/8 1/8 15 279 17 35 70
PA60 F05/07 70 55 M6/8 1/8 15 341 17 35 70
PA65 F07/10 102 70 M8/10 1/8 19 350 22 35 70
PA70 F07/10 102 70 M8/10 1/8 19 381 22 35 70
PA75 F10/12 125 85 M10/12 1/4 - 416 27 - -
PA80 F12 125 85 M12 1/4 - 466 27 - -
PA85 F14 140 100 M16 1/4 - 555 36 - -
PA90 F14 140 100 M16 1/4 - 581 36 - -
Type L5 H H1 H2 H3 H4 H5 H6 H7 H8
PA30 - 87 60 25 12 55.5 10 20 36 -
PA35 - 92.7 65.7 25 12.5 60 13 20 36 -
PA40 - 97 70 20.5 17.9 65.5 13 20 36 -
PA45 - 104.5 77.5 20.5 17.9 72 13 20 36 -
PA50 - 129 86 25 21 80.5 13 30 36 -
PA55 - 139 96 25 21 90 16 30 36 -
PA60 - 149 106 25 26 100.5 17 30 36 -
PA65 - 161 118 25 25 112 19 30 36 -
PA70 - 173 130 25 32 125 19 30 36 -
PA75 32 191 148 24 34 137 - - - 22
PA80 32 197 153 24 38 145 - - - 24
PA85 32 229 186 24 43 166 - - - 27
PA90 32 241 198 24 44 180 - - - 32
Weight
PA30 - PA 90
2.022 kg - 34.40 kg
640
Technical data
Actuator
Nominal torque from 4 Nm (2.9 lb. ft.) to 1920
Nm (1416 lb. ft.)
Peak torque from 8 Nm (5.9 lb. ft.) to 3840
Nm (2832 lb. ft.)
Control medium Neutral, non-aggressive gas-
es, preferably slightly oily
compressed air
Control pressures in bar Single acting Double act-
ing
min. 2.8 3
max. 7 7
Actuator connection R 1/8 with Namur plate R 1/
4"
Cycle time 0.5 - 1 s
Actuating angle 90 °
Mode of operation - Fail-safe close (FC)
- Fail-safe open (FO)
- Double acting (DA)
Permissible operating temp. -10 ° to + +80 °C
Permissible humidity 0 - 95 %
Position indicator optical
Housing material Aluminium hard anodized
Torque in relation to control pressure
Torque in Nm Double acting
Type 3 bar 4 bar 5 bar 5.6 bar* 6 bar 7 bar
PA30 DA 0° 16.1 21.4 26.8 30.0 32.1 37.5
45 ° 8.0 10.7 13.4 15.0 16.1 18.8
90 ° 12.0 16.1 20.1 22.5 24.1 28.1
PA35 DA 0° 24.0 32.1 40.2 45.0 48.3 56.4
45 ° 12.0 16.2 20.1 22.5 24.0 28.2
90 ° 18.0 24.3 30.3 34.0 36.3 42.3
PA40 DA 0° 32.1 42.9 53.6 60.0 64.3 75.0
45 ° 16.1 21.4 26.8 30.0 32.1 37.5
90 ° 24.1 32.1 40.2 45.0 48.2 56.3
PA45 DA 0° 48.0 64.2 80.4 90.0 96.6 112.8
45 ° 24.0 32.4 40.2 45.0 48.0 56.4
90 ° 36.0 48.6 60.6 68.0 72.6 84.6
PA50 DA 0° 64.3 85.7 107.1 120.0 128.6 150.0
45 ° 32.1 42.9 53.6 60.0 64.3 75.0
90 ° 48.1 64.3 80.4 90.0 96.4 112.5
PA55 DA 0° 96.0 128.4 160.8 180.0 193.2 225.6
45 ° 48.0 64.8 80.4 90.0 96.0 112.8
90 ° 72.0 97.2 121.2 135.0 145.2 169.2
PA60 DA 0° 128.1 171.4 214.3 240.0 257.1 300.0
45 ° 64.3 85.7 107.1 120.0 128.6 150.0
90 ° 96.4 128.6 160.7 180.0 192.9 225.0
PA65 DA 0° 192.0 256.8 321.6 360.0 386.4 451.2
641
45 ° 96.0 129.6 160.8 180.0 192.0 225.6
90 ° 144.0 194.4 242.4 270.0 290.4 338.4
PA70 DA 0° 257.1 342.9 428.6 480.0 514.3 600.0
45 ° 128.6 171.4 214.3 240.0 257.1 300.0
90 ° 192.9 257.1 321.4 360.0 385.7 450.0
PA75 DA 0° 384.0 513.6 643.2 720.0 772.8 902.4
45 ° 192.0 259.2 321.6 360.0 384.0 451.2
90 ° 288.0 388.8 484.8 540.0 580.8 676.8
PA80 DA 0° 514.3 685.7 857.1 960.0 1028.6 1200.0
45 ° 257.1 342.9 428.6 480.0 514.3 600.0
90 ° 385.7 514.3 642.9 720.0 771.4 900.0
PA85 DA 0° 768.0 1027.2 1286.4 1440.0 1545.6 1804.8
45 ° 384.0 518.4 643.2 720.0 768.0 902.4
90 ° 576.0 777.6 969.9 1080.0 1161.6 1353.6
PA90 DA 0° 1028.6 1371.4 1714.3 1920.0 2057.1 2400.0
45 ° 514.3 685.8 857.1 960.0 1028.6 1200.0
90 ° 771.4 1028.6 1285.7 1440.0 1542.9 1800.0
Torque in Nm Single acting

Type 2.8 bar 4.2 bar 5.6 bar*
air spring air spring air spring
PA30 FC/FO 0° 15.0 10.0 22.5 15.0 30.0 20.0
45 ° 7.5 7.5 11.3 11.3 15.0 15.0
90 ° 10.0 15.0 15.0 22.5 20.0 30.0
PA35 FC/FO 0° 22.5 15.0 33.9 22.5 45.0 30.0
45 ° 11.1 11.1 16.8 16.8 22.5 22.5
90 ° 15.0 22.5 22.5 33.9 30.0 45.0
PA40 FC/FO 0° 30.0 20.0 45.0 30.0 60.0 40.0
45 ° 15.0 15.0 22.5 22.5 30.0 30.0
90 ° 20.0 30.0 30.0 45.0 40.0 60.0
PA45 FC/FO 0° 45.0 30.0 67.5 45.0 90.0 60.0
45 ° 22.5 22.5 33.9 33.9 45.0 45.0
90 ° 30.0 45.0 45.0 67.5 60.0 90.0
PA50 FC/FO 0° 60.0 40.0 90.0 60.0 120.0 80.0
45 ° 30.0 30.0 45.0 45.0 60.0 60.0
90 ° 40.0 60.0 60.0 90.0 80.0 120.0
PA55 FC/FO 0° 90.0 60.0 135.0 90.0 180.0 120.0
45 ° 45.0 45.0 67.5 67.5 90.0 90.0
90 ° 60.0 90.0 90.0 135.0 120.0 180.0
PA60 FC/FO 0° 120.0 80.0 180.0 120.0 240.0 160.0
45 ° 60.0 60.0 90.0 90.0 120.0 120.0
90 ° 80.0 120.0 120.0 180.0 160.0 240.0
PA65 FC/FO 0° 180.0 120.0 270.0 180.0 360.0 240.0
45 ° 90.0 90.0 135.0 135.0 180.0 180.0
90 ° 120.0 180.0 180.0 270.0 240.0 360.0
PA70 FC/FO 0° 240.0 160.0 360.0 240.0 480.0 320.0
45 ° 120.0 120.0 180.0 180.0 240.0 240.0
642
90 ° 160.0 240.0 240.0 360.0 320.0 480.0
PA75 FC/FO 0° 360.0 240.0 540.0 360.0 720.0 480.0
45 ° 180.0 180.0 270.0 270.0 360.0 360.0
90 ° 240.0 360.0 360.0 540.0 480.0 720.0
PA80 FC/FO 0° 480.0 320.0 720.0 480.0 960.0 640.0
45 ° 240.0 240.0 360.0 360.0 480.0 480.0
90 ° 320.0 480.0 480.0 720.0 640.0 960.0
* Standard series; for reduced torques, special springs are available.
Note: Single acting with Namur 5/2-way valve

The torque given for FO actuators to but-
terfly valves type 240 are reduced by 15 %.
Torque Characteristics
Double acting
Single acting Single acting with Namur 3/2-way valve
Technical features
Operating diagram
Double acting with Namur 5/2-way valve
Setting the end stops
Stroke limiter «closing»

(max. 10 ° opening angle, 0 - 10 ° opening angle)
a) Make sure the springs are in the position of rest; the
groove in the shaft (part 1) should be in the same posi-
tion as in the diagram. Also check that the bore «D» is
decompressed.
b) Unscrew the special nut (part 2).
643
c) Put compressed air in the bore «D». Designation
d) With a screwdriver, turn the screws (part 3) in a
counterclockwise direction until the desired setting is Actuator PA30 FC
FO
reached.
DA
e) Release the compressed air from the bore «D».
f) Check the setting and, if necessary, repeat the proce- Actuator PA35 FC
dure from step c). FO
g) Replace the special nut (part 2) and press the O-ring DA
seals in the corresponding grooves (part 4). Actuator PA40 FC
FO
Stroke limiter «opening» DA
(max. 10 ° opening angle, 90 - 80 ° opening angle)
Actuator PA45 FC
a) Make sure the springs are in the position of rest; the FO
groove in the shaft (part 1) should be in the same posi- DA
tion as in the diagram. Also check that the bore «D» is
Actuator PA50 FC
decompressed. FO
b) Unscrew the special nut (part 2). DA
c) With a screwdriver, turn the screws (part 3) in a
clockwise direction until the desired setting is reached. Actuator PA55 FC
d) Put compressed air in the bore «D» and check that FO
DA
the pistons (part 5) hit against the screws (part 3).
e) Replace the special nut (part 2) and press the O-ring Actuator PA60 FC
seals in the corresponding grooves (part 4). FO
DA
Regulating the stroke limiter for the two
Actuator PA65 FC
pistons can only be done in one direction
FO
(close or open)!
DA
Actuator PA70 FC
FO
DA
Accessories
Actuator PA75 FC
More information about accessories are FO
available in the Chapter Accessories for DA
pneumatic actuators.
Actuator PA80 FC
FO
DA
Actuator PA85 FC
FO
DA
Actuator PA90 FC
FO
DA
Namur connector plate
Pilot solenoid valve type PV94/95
(3/2-way)
Pilot solenoid valve type MNL532
(3/2 - 5/2-way)
Pilot solenoid valve type MNL5470
(4/2-way)
Pilot solenoid valve type PV2000
(for valve clusters)
Digital positioner type DSR201
Namur mounting console
2 additional limit switches Ag-Ni 250 V/10 A
2 additional limit switches NPN 10 - 30 V/0.1 A
2 additional limit switches PNP 10 - 30 V/ 0.1 A
2 additional limit switches Namur 5 - 24 V
2 additional limit switches EExd 250 V/5 A
2 additional limit switches 30 V =
max. 1 - 100
mA
644
645
Pneumatic Actuator for DIASTAR
For further information on the DIASTAR, please refer to
the section of the planning fundamentals:
«Planning Fundamentals for diaphragm valves,
pneumatically actuated»
646
Accessories for electric actuators Assembly
Mounting the heating element (board)
Heating element
Disconnect the actuator from the supply
General voltage.
Designation Technical data
Heating element 24 V =
Remove actuator cover.
The heating element works with the EA11, EA21,
EA31 and EA42. Take the board out of its packaging and check for
The heating element is mounted on the base board and damages.
is connected electrically via a flat cable (X1). The tem- Do not touch the board itself. Electrostatic
perature is measured with a temperature sensor, which discharge can damage the components.
is mounted on this element, at approx. 0 - 5 °C the heat-
ing element is switched on.
Connection diagram Screw the three spacer bolts (1) into the assembly
EA11, EA21, EA31, EA42 bolts.
Hand-tighten.
Fasten the board (3) to the spacer bolts with the screws
(2).
Plug the flat cable into the X1 (4) connector.
Close the housing cover.
Reconnect to the power supply.
The heating element may not heat at temperatures over
+5 °C. When switched on, it heats up to 10 - 15 °C.
Heating element kit
Reset unit
General
Description Technical data
Reset unit 24 V =
The reset unit works with the EA11, EA21, EA31 and
EA42.
647
The reset unit is mounted on the base board and is con- Connection diagram
nected electrically via a flat cable. The reset unit is con-
EA11, EA21, EA31, EA42
nected to the battery via terminals and a two-core line.
In case of a failure of the supply voltage, the battery is
electronically switched on automatically after 5 s. With
DIP switches (5), the function «Move to the CLOSED or
OPEN position» can be selected.
The storage battery is charged contin-
uously. Full recharging takes approxi-
mately 15 hours.
Expected life time approx. 7 years
Possible cycles per day:
EA11/21: 10
EA31: 04
EA42: 02
Both switches ON: Actuator moves to OPEN
Both switches OFF: Actuator moves to CLOSE
Assembly
Mounting the reset unit (board)
voltage.
Take the board out of its packaging and check for damages.
Do not touch the board itself. Electrostatic
discharge can damage the components.
Screw the three spacer bolts (1) into the assembly bolts.
Hand-tighten.
Fasten the board (3) to the spacer bolts with the screws
(2).
Rechargeable battery
Connect the battery via the second plug or cable gland
to the terminals 16 and 17 (4) (we recommend 2 x 1.5
mm²).
648
Attention must be given to the polarity. Connection diagram
Charge the battery for at least 15 hours.
Mechanical limit switches: Ag-Ni, Au
In case the fail-safe return and the monitor-

ing print are installed both together, make
sure that the adjustments will not interfere
one another.
Additional limit switches (Ag-Ni, Au,

NPN,PNP)
General
Designation Technical data
Kit with 2 additional limit switches Ag-Ni 250 V ~, 6 A
*
Kit with 2 additional limit switches Au * 30 V = , 100 mA
Kit with 2 additional limit switches NPN 10 - 30 V =, 100
mA
Kit with 2 additional limit switches PNP 10 - 30 V =, 100
mA
Mounting set 4 limit switches
The additional limit switches work with the EA21,
EA31 and EA4.
The EA11 works only with the kit for the additional
limit switch Ag-Ni
* If the limit switch kit is mounted in the factory, the
switches are wired to open according to the diagram.
It is possible for the customer to convert to close by
rewiring.
Terminal (8 → 7 and terminal 10 → 9).
649
Inductive limit switches: NPN/ PNP Inductive limit Move the actuator to the two end positions and set the
switches: NPN/ PNP respective switching points.
The switching cams can be adjusted with a screwdriver
size 2.
Disconnect the device from the supply voltage.
Connect limit switches.
Close the housing cover and connect to the supply volt-
age.
Additional four limit switches

Following the mounting instructions for the two addition-
al limit switches, the EA 21/31 can be expanded to in-
clude four limit switches.
The mounting sequence for the individual parts is the
same as for the two additional limit switches.
For stability purposes, the mounting set
for four limit switches must also be used.
The fully assembled unit can be seen in
the photo below.
Assembly
Mounting the limit switches
voltage.
Remove the screws from the limit switch S2 and S1.

Mount the limit switch kit (1) on S1 and S2 as shown.
Tighten with the new, longer screws.
Mount the additional switching cams (2) as well as the
spacer rings (3).
Setting the limit switch position.
Connect the device to the supply voltage.
The switch position may only be set with
an extra-low voltage below 50 V.
650
1.Disconnect the actuator from the supply voltage.
Limit switch kit middle position
2.Remove the screws of the limit switches S1 and S2.
General
3.Connect the plug of the kit to the four-pole slot (1).
Designation Technical data Make sure that the multipoint socket connector of the
plug fits into the socket board of the four-pole plug.
Middle position
4.Attach the two switches S3 and S4 of the kit to S1 and
The middle position works with EA21, EA31, EA42 S2. When doing this, the S3 switch (assigned to PIN
1, 2) must be down and the S4 switch (PIN 3, 4) up.
The kit is mounted on the limit switches S1, S2 and (see connection diagram).
serves to move the actuator to a third position (e.g. a 3- 5.Fasten the two switches S3 and S4 with the longer
way ball valve into the middle position). screws supplied.
Connection diagram
Overview on activation
EA11, EA21, EA31, EA42
Actuator Terminal un- Activated Direction of
moves in po- der current switch(es) rotation of the
sition actuator
OPEN 1 S1 CCW*
CLOSED 2 S2 CW**
Middle 3 S3 CCW
S4 CW
* CCW - counterclockwise
** CW - clockwise
• Move actuator to position “OPEN” (CCW):
Put terminal 1 under current -->Switch S1 is activated.
• Move actuator to position “CLOSED” (CW):
Put terminal 2 under current -->Switch S2 is activated.
• Move actuator to middle position (CCW / CW):
Put terminal 3 under current -->Switch S3/S4 is acti-
vated.
Setting the end positions

• Turn switching cam 2 of switch S2 by 90 ° anti-clock-
wise (seen from above).
Assembly • Reconnect the actuator to the supply voltage.
• Move the actuator into position “CLOSED” (terminal 2
Mounting the limit middle positioning kit under current)
• Turn cam 2 until the desired position is reached (see
position of the ball)
• Replace the standard position indicator with the new
3-way position indicator
Standard position indicator
3-way position indicator
651
Setting the middle position The monitoring print is mounted on the base board and
• Move the actuator to the OPEN position (terminal 1 is connected electrically with a flat cable. The monitor-
under current) ing print enables five functions:
• Place the additional switching cams on the shaft. For 1.Cycle time extension
this, first remove the position indicator again and put it 2.Cycle time monitoring
back on again in the same position afterwards 3.Monitoring a selected maximum number of cycles
• Place cam 3 on cam 2 (cam 4 still stays on top of the 4.Monitoring a selected maximum motor current
switches)
5.Position feedback signal 4-20 mA
• Put cam 3 into the same position as cam 2 and turn it
clockwise by 90°. These monitor settings are made via the BCD switches
• Move actuator to the “middle” position (terminal 3 un- 1 to 4. They are described on the following pages. The
der current). switches must be connected for the function to be ac-
tive. The functions work independently of one another. 1
• Readjust cam 3 until the desired middle position is to 4 BCD switches can be individually connected.
reached (see position of the ball).
• Now place switching cam 4 on cam 3 in the same po-
sition. Adjust cam 4 afterwards. This should activate
switch S4 (S3 and S4 are activated, the two cams
point in opposite directions).
• Close the actuator with the housing cover. The middle
position is now set.
OPEN
MIDDLE
CLOSED
Monitoring print with cycle time module,

running time monitoring, current monitor-
ing, cycle counter
General
Monitoring print
The monitoring print works with EA21, EA31, EA42
652
Connection diagram The board has been connected correctly when:
EA11, EA21, EA31, EA42 • LED (9) above the BCD switches flashes green, and
• the green LED (6) lights up.
Assembly
Mounting the monitoring unit
voltage.
Take the board out of the packaging and check for dam-
ages.
Do not touch the board itself. Electrostatic
Screw the three spacer bolts (1) into the assembly

bolts. 1 Cycle time extension
2 Cycle time counter
Hand-tighten.
3 Cycle counter
4 Motor current monitoring
5 Position feedback
Fasten the board (3) to the spacer bolts (1) with the
screws (2).
Set the BCD switch (4) for the desired function. Secure
with the help of the nipple supplied.
Select the desired switch setting with a screwdriver.
653
Error message DIP switch in case of error
With the help of the DIP switch, the actuator can be
moved to the CLOSED or OPEN position in case of an
error. For this, the DIP switches need to be adjusted as
follows:
DIP 1 DIP 2
ON Position of DIP 2 effective Actuator moves to the
OPEN position
OFF Actuator remains in its Actuator moves to the
position (DIP 2 not effec- CLOSED position
tive)
(Please refer to the example below.)

tor remains in its position (delivery
state).

tor moves to the OPEN position.
If an error occurs, the red LED (8) on the base board

will light up. If the monitoring unit is installed, the corre-
sponding LED (10) on the BCD switch, of which the se- In case of malfunction the actua-
lected value has been exceeded will also light up red. tor moves to the CLOSED posi-
With all occurring error messages the ready-to-operate tion.
signal will be off (terminals 5, 6 no passage).
Eliminating the malfunction report
Check the error cause, if necessary carry out the appro- Settings
priate maintenance.
To delete the message, activate the reset switch (9) on 1. Cycle time extension (Vario)
the base board while the supply voltage is still connect-
ed or briefly disconnect the actuator from the mains volt- Designation
age. (Not effective with cycle counter). Cycle time extension
The two LEDs will go out and the actuator is ready to
operate again. This function allows setting the desired number of cy-
cles. To do this, the actuator is clocked in the end posi-
The ready-to-operate module can react in tions (open or closed).
the fail-safe mode as well. Resetting the For the corresponding value please refer to the table
error message does not reset the cycle
counter.
below (values are valid for 90 ° actuation). Cycle time
without BCD: 5 s for 90 ° (EA21); 15 s for 90 ° (EA31);
26 s for 90 ° (EA42)
Reset «Number of cycles»
Turn the BCD switch to the position 0 (this position cor-
responds to one cycle). Move the actuator into CLOSED
position and back to OPEN position.
The monitoring LED lights up. Press the reset button on
the base board and the cycle counter will be cleared to
0. Turn the BCD switch into delivery position.
654
Switch position Cycle
time / s
EA21 EA31 EA42
0 Delivery position 8 20 30
1 12 25 35
2 15 30 40
3 19 35 45
4 25 40 50
5 30 50 55
6 35 60 65
7 35 60 75
Switch position Number of cycles

0 1
The switch positions 8 – 9 have the function of position 1 10 000
7.
2 20 000
The extension of the cycle time is also active in case of
failure or reset operation. 3 30 000 ***
4 40 000 **
2. Cycle time monitoring
5 50 000 *
Designation
6 60 000
Cycle time monitoring
7 70 000
Cycle time monitoring monitors the duration of a preset 8 80 000
cycle time of the electric actuator.
If the cycle exceeds the preset time, a failure is report- 9 90 000
ed (see "error message"). For the corresponding value
Delivery position : *EA21 **EA31 ***EA42
please refer to the table below (values are valid for 90 °
actuation). 4. Current monitoring
Switch Cycle time monitoring / s Designation
posi-
tion Current monitoring
EA21 EA31 EA42 This function monitors the motor current. If the motor
0 7 10 15 current is greater than the preset value, a malfunction is
reported.
1 10 Delivery position 15 20
2 15 20 25 Switch position Max. motor current/mA
3 20 25 Delivery position 30 0 200
4 25 30 35 1 400
5 30 35 40 Delivery position 2 600 *
6 35 40 50 3 800
7 40 45 60 4 1 000 **
8 45 55 70 5 1 200
9 50 70 85 6 1 400 ***
7 1 600
3. Cycle monitoring
8 1 800
Designation 9 2 000
Cycle monitoring
Delivery position : *EA21 **EA31 ***EA42
This function allows setting a desired number of cycles.
When setting the BCD switch, make sure
As soon as the number of cycles exceeds the set val-
that the set functions do not block one an-
ue, an error is reported (see error message). With the other.
help of the DIP switch (8) on the monitoring print you
can preset if you wish for the actuator to keep moving in
case of an error, or if it should move to its security posi-
tion and remain there. (Refer error message.) BCD1 Cycle time level 3 = 19 s
BCD2 Cycle time monitoring level 0 = 7 s
655
Assembly
Position signalisation
Mounting the position signal
General
Designation
Position signalisation
The position signalisation works with the EA21,

EA31 and EA42.
The position signalisation enables the exact capturing
of the mechanical position of the output shaft. Output
signal is a current of 4 - 20 mA. (4 mA CLOSED, 20 mA
OPEN)
Position signal can be combined with the controller
print or the monitoring print.
The position signalisation board is mounted on the limit
switches S1, S2 and is connected electrically to the con-
troller print or the monitoring print via a system cable.
Connection diagram
EA11, EA21, EA31, EA42

voltage.
Remove the screws of the limit switches S1 and S2.

Remove the position indicator (1).
Place the position signal board in the position shown on
S1 and S2 and fasten with the longer screws.
Insert the circular magnet (3) so that the notches are on
top.
Again place the position indicator (1) on the axis in one
of the end positions..
Connect the position signal board to the controller or
monitoring print via the system cable (2).
The board has been connected correctly when the
LED (4) lights up green.
If the position signal is used together with
additional limit switches, the position sig-
nalisation has to be installed above the lim-
it switches.
Setting the position signalisation/learning run

For the position sensor (4) to recognise the OPEN and
CLOSED positions, a single learning run with 360 °
must be done. After the learning run, the OPEN and
CLOSED positions are set.
656
Further learning runs can be done between the end po-
sitions (depending on the switching cams S1 and S2).
The way in which the jumper is placed on the position
signalling determines if the learning run happens with
360 ° or if it happens between the end positions.
Jumper connects both PINs: Learning run 360 °
PINs not connected: Learning run be-
tween the end posi-
tions
When position signal is mounted at the fac-

tory, a learning run with 360 ° has been
already done. In this case the jumper is
placed on only one pin. When the position
signal is mounted by the customer, a 360
° learning run has to be done. Therefore
the two pins need to be connected by the Positioner PE25
jumper.
General
Subsequent modifications on the The positioner PE25 works with the EA21, EA31, EA42.
switching cams require a new learning
The positioner type PE25 controls a user-defined valve
run.
position proportional to a given set value. This can be 0
- 10 V or 4 - 20 mA.
The return of the valve position (actual value) is realised
Learning run 360 ° (Position signalisa-
tion kit subsequently installed)
with the position signalisation.
It is necessary to separate the actuator Power supply needs to be decoupled or
from the valve, to avoid damage to the galvanically isolated.
valve.
Before doing the learning run, set the jumper so it con-

nects the two pins. Complete the learning run. Then re-
set the jumper to its original position and remount the Signal configuration (not galvanically isolated)
actuator.
Performing a learning run Positioner type PE25 Not galvanically isolated set
Press the button (5) on the board for approx. 2 s. The value inputs
LED (6) will go out briefly. As soon as the LED lights up
again, release the button. The actuator will then do a The four DIP switches on the controller print serve for
learning run. the configuration of the signals. Signal configuration:
During this run, the LED (6) will blink. While the LED
(6) is blinking, the actuator is in the learning mode. The
learning run is finished correctly when the LED lights
continuously.
Switch assignment
Signal type S1 S2
0 - 10 V OFF OFF
If the position signalisation is combined with the 4 - 20 mA ON ON
monitoring print, the output signal 4 – 20 mA can be
processed on the terminals 18, 19 (7) on the board S3: ON: input inverted
of the monitoring print. (4 mA > "CLOSED" / 20 mA > OFF: input not inverted
"OPEN"). S4: ON: use S3L Master
If the position signalisation is connected to the po- OFF: use S3L Slave
sitioner, the latter will process the signal.
Example:
657
Signal configuration (galvanically isolated)
Connection diagram
Description Technical data EA21, EA31, EA42
Positioner type PE25 Galvanically isolated set val- Positioner 199 190 100
ue inputs
The four DIP switches on each of the three switch

blocks on the controller print serve for the configuration
of the signals. Switch combination
DIP Switch All switches
Block 1 must be set to
OFF.
DIP Switch Signal type S1 S2

Block 2
0 - 10 V OFF OFF
4 - 20 mA ON ON
S3: ON: input inverted

OFF: input not inverted
S4: ON: use S3L Master
OFF: use S3L Slave
DIP Switch S1 must be
Block 3 set to ON
S2 - S3 must
Positioner galvanically isolated 199 190 101
be set to OFF
Example:
Set signal value 4 - 20 mA, not inverted, use S3L Slave
658
For detailed terminal assignment refer to Chapter "As-
sembly " "Connecting the positioner"
Connecting the positioner
Assembly For the positioner to receive the set value signal, con-
nect the terminals of the set value inputs 20 to 23 for the
Mounting the positioner
corresponding value.
Disconnect the actuator from the supply Cable cross-section max. 1.5 mm² (see following Ta-
voltage. ble).
Terminal assignment
Positioner 199 190 100
Take the controller board out of the packaging and 20 SET value input current
check for damages. 21 SET value input voltage
Do not touch the board itself. Electrostatic 22 -
23 SET value input ground
30 Position signalisation signal
31 Position signalisation ground
Place the board vertically on the back side of the base Positioner 199 190 101
board on plug X1.
27 SET value input current/ voltage
Make sure that the board is inserted exact-
28 Output 12 V DC
ly in theguides.
29 SET value input ground
30 Position signalisation signal
31 Position signalisation ground
For setting of the position signal, see the corresponding
section of the Planning Fundamentals.
Attention: The configuration of the set val-
ue is important (see switch assignment).
Impedance at the 4...20 mA input for both

positioner versions is 150Ω.
A 4 - 20 mA current signal is available at the output of

terminals 30, 31. If necessary, this signal can be evalu-
ated (4 mA: "CLOSED";
20 mA: "OPEN").
When the set value and the position indicator have been
connected, reconnect the actuator to the supply voltage
(see connection diagram).
659
The positioner has been connected correctly, when the Performing a learning run
green LEDs (1, 2 and 4) light up green. Press the button (5) on the board for approx. 2 s. The
If the LED (3) lights red, the controller is not working. LED (6) will go out briefly. As soon as the LED lights up
(see LED arrangement) again, release the button. The actuator will then do a
Check the connections if necessary and make sure the learning run.
polarity of the set input is correct.
During this run, the LED (6) will blink. While the LED
(6) is blinking, the actuator is in the learning mode. The
Colour Green Green Red Green
learning run is finished correctly when the LED lights
LED 1 2 3 4 continuously.
After the positioner is correctly connected, do a learning

run.
Setting the position signalisation/learning run
For the position sensor (4) to recognise the OPEN and
CLOSED positions, a single learning run with 360 °
must be done. After the learning run, the OPEN and
CLOSED positions are set.
Testing adapter for RS232 interface

General
Description
Testing adapter kit for RS232 interface
The testing adapter works with the EA 21/31/42. It

Further learning runs can be done between the end po- can also be used with the EA11 for motor current
sitions (depending on the switching cams S1 and S2). measurement.
The way in which the jumper is placed on the position
signalling determines if the learning run happens with
360 ° or if it happens between the end positions. The testing adapter simplifies the testing and error de-
tection for installed accessories.
Jumper connects both PINs: Learning run 360 °
PINs not connected: Learning run be- The provided software detects automatically which ac-
tween the end posi- cessory is installed. The user interface is windows-ori-
tions ented and therefore easy to use.
When position signal is mounted at the fac- The testing adapter kit consists of the testing adapter for
tory, a learning run with 360 ° has been the RS232 interface itself, the software to install on the
already done. In this case the jumper is computer and the user's manual.
placed on only one pin. When the position
signal is mounted by the customer, a 360
° learning run has to be done. Therefore
the two pins need to be connected by the
jumper.
Subsequent modifications on the

switching cams require a new learning
run.
Learning run 360 ° (Position signalisa-

tion kit subsequently installed)
It is necessary to separate the actuator
from the valve, to avoid damage to the
valve. Installing the software
Before doing the learning run, set the jumper so it con- • Insert the CD-ROM in your CD-ROM drive.
nects the two pins. Perform the learning run. Then reset • Install the software by clicking on «Setup.exe » on the
the jumper to its original position and remount the actu- CD-ROM.
ator. • Connect the test adapter to the serial port (COM port)
of the computer.
• Connect the flat cable of the adapter to the electrical
actuator via the system-bus-connector.
660
• Start the software by double clicking on «E- • Which limit switches are activated
Valve.exe». The window «Connection Setup» will be • «ready-to-operate» state (ready/fail)
displayed.
• Setting if an error occurs (Open/Close)
• Hardware and software version
• Which additional accessory is installed
The scope function enables the graphic display of the

motor current. With «Start Log» you can store the data
in a file.
Choose the required COM port by either clicking on

«Connect To COM1» or «Connect To COM2».
If the connection works properly, the window «Basic

Print» will be displayed and additionally as many win-
dows as accessories are recognised.

Fail-safe/ Heater
The window «Fail-safe/ Heater» shows:

• Temperature of sensor 1 and 2 in °C
Functions • Setting of the DIL switches on the fail-safe unit
Basic Print • if the heating element is active
• if the battery pack is connected
• Voltage of the supply and battery pack
Monitoring print
The window «Basic Print» shows:

• Motor current in ampere (A)
The window «Monitoring print» shows:
• Internal temperature of the actuator in °C
• Which signal is applied to the actuator (Open/ Close/
Middle)
661
• BCD switch setting for cycle time extension
• BCD switch setting for cycle time monitoring
• BCD switch setting for cycle counter
• BCD switch setting for motor current monitoring
• the number of cycles since the monitoring print is in
operation
• the number of actual cycles (can be set by operator)
• the actuator position in % if the position detection is
connected to the monitoring print
(100 % matches the limit switch position OPEN and 0
% matches the limit switch position CLOSED)
Positioner/ Controller
199.190.101 Positioner with galvanic isolation
The window «Positioner/ Controller» shows:

• Setting for the set value (0 - 10 V/ 4 - 20 mA)
• Setting for the actual value (4 - 20 mA)
• Set value
• Actual value
• the actuator position in % if the position detection is
connected to the monitoring print
(100 % matches the limit switch position OPEN and 0
% matches the limit switch position CLOSED)
With a switch you can select which version of the posi-

tioner is being used. Corresponding to the selection, the
settings are displayed.
199.190.100 Positioner without galvanic isolation
Motor current measurement for EA11
With the testing adapter also you have the opportunity
to measure the motor current of the EA11.
The two outlets on the adapter give a 0 - 10 V output

signal. To convert the voltage into the corresponding
current, refer to the chart below.
Voltage Current
Volt (V) Ampere (A)
10 2
1 0.2
0.5 0.1
0.3 0.07
662
Error message • easy installation
In case the window «Basic Print» shows «No Busmem- • effective error detection and immunity
bers Found Click for new retry»,
ASi products
please check
Description
the connection from the testing adapter to the system
AS Interface connection with ASEV 2400 for EA11/ 21/ 31/
bus of the actuator or
42
check the supply voltage of the actuator.
AS interface
Introduction
AS Interface (short ASi) stands for actuator/sensor inter-
face and belongs to the standard field buses. It was de-
signed to connect actuators and sensors and therefore
is used only on the bottom level of the control system.
The goal was to replace the parallel wiring. Since 1999,
it is standardized according to the international stan-
dards: EN 50295 and IEC 62026-2.
Typical for the ASi is the yellow cable.
With AS-i, there is no restriction in the wiring structure.
The ASi is a single master system which means there is
only one master in a system. This master polls its con-
figured slaves cyclically and exchanges input and output To connect our electric actuators to an ASi network we
data. offer this module which fits exactly to our actuator inter-
face.
ASi specifications The ASEV 2400 module offers a compact solution with
There are some AS-i specifications. The most recent is the feedback already integrated.
specification 3.0 (since September 2004). The prede- For further information do not hesitate to contact your
cessors were 2.0 which can only handle 31 slaves and GF specialist.
2.1 which could already handle 62 slaves.
General system data:
• Master-slave principle
• free choice of network structure
• Energy and data via a two-wire cable
• fail-safe
• Medium unshielded wire 2 x 1.5 mm 2
• up to 8A
• four inputs/four output for each slave
• suited for IP67 control cabinet and rough industrial en-
vironment
• Penetration technology
• Cable length 100 m, with repeater up to 300 m
• electronic slave addressing
663
Accessories for pneumatic actuators
3/2-way pilot solenoid valve PV 94/95
Type PV94
3/2-way pilot solenoid valve for activating a single acting
pneumatic actuator with the dimensions DN15 -DN50.
Assembly takes place with a banjo bolt directly on the
actuator. As air connections G1/8" and 6 mm push-in
connectors are available. The PV94 can be ordered for
the following voltages:
• 230 V, 50 - 60 Hz
• 115 V, 50 - 60 Hz
• 24 V, 50 - 60 Hz
• 24 VDC
Type PV95
3/2-way pilot solenoid valve for activating a single acting
pneumatic actuator with the dimensions DN65-DN150.
Assembly takes place with a banjo bolt directly on the
actuator. As air connection a G1/8" connection is avail-
able . The solenoid valve comes in diameter DN2. Op-
tional voltages are:
• 230 V, 50 - 60 Hz
• 115 V, 50 - 60 Hz
• 24 V, 50 - 60 Hz
• 24 VDC
664
Technical data
PV 94 DN1.2 PV95 DN2
Housing material Polyamide Brass (flange housing) Aluminium anodized
(Connector housing)
Banjo bolt Nickel-plated brass Brass
Sealing material NBR FPM
Media neutral gases and fluids
Medium temperature -10...100 °C
Ambient temperature -10...55 °C
Viscosity max. 21 mm 2/S
Air connection G 1/8 G 1/8
push-in connector 6 mm
Supply voltage 24 V DC
24 V/50 Hz
110 V/50 Hz
230 V/50 Hz
Voltage tolerance +/-10 %
Rated duty Continuous duty 100 % ED
Electrical connections per DIN EN 175301-803* Form C per DIN 43650 Form A
Manual override standard
Mounting orientation user-defined, preferably actuator on top
Weight 135 g 420 g
Protection class IP 65 with socket connector
Nominal diameter [mm] DN1.2 DN2
QNn value air [l/min]* 48 120
Pressure range [bar]** 0 - 10 0 - 10
Coil output [W] 4W (AC, DC) 8 W (AC, DC)
Electrical power startup 9 VA (AC), 4W (DC) 24 VA (AC), 8W (DC)
Electrical power operation 6 VA (AC), 4W (DC) 17 VA (AC), 8W (DC)
Response time open [ms]*** 7 - 12 18
Response time close [ms]*** 7 - 12 22
* QNn value for air [l/min] at +20 °C, 6 bar valve inlet,
pressure difference 1 bar
** Pressure data [bar] gauge pressure
*** Response time [ms]: Measured at the valve outlet
at 6 bar and +20 °C open: pressure buildup 0...90 %,
close: pressure release 100...0 %
665
Dimensional drawings Type PV95
Type PV94 with hose coupling
Type PV94 with G1/8“ union
666
Valve selection guide (metric)

DN65 >DN65
Valve dimension Valve dimension

PV95
PV94

Actuator connection: Actuator connection:
G1/8" with reduction to G1/4" G1/8" with reduction to G1/4"
Air connection
6 mm hose cou- Air connection G1/4"
G1/8"
pling DN2.0 10 bar max.
24 V DC 24 V DC 24 V DC
24 V AC 24 V AC 24 V AC
110 V AC 110 V AC 110 V AC
230 V AC 230 V AC 230 V AC
667
Valve selection guide (NPT)

> DN65 > DN65

Valve dimension Valve dimension

PV95
PV94

Actuator connection: Actuator connection:
G1/8" with reduction to G1/4" G1/8" with reduction to G1/4"
Air connection Air connection NPT1/8"
NPT1/8" DN2.0 10 bar max.
- 24 V DC - 24 V DC
- 110 V AC - 110 V AC
3/2 - 5/2-way pilot solenoid valve MNL532

MNL 532
3/2 and 5/2-way solenoid valve for activating a double
acting pneumatic actuator. The mounting takes place
via a NAMUR connection. For the dimensions of the
DIASTAR series DN15 - DN50 and our pneumatic actu-
ators PA11/21 a NAMUR connector plate must be used
between the actuator and the pilot solenoid valve. Avail-
able in the following voltages:
• 230 V, 50 - 60 Hz
• 115 V, 50 - 60 Hz
• 48 V, 50 - 60 Hz
• 24 V, 50 - 60 Hz
• 24 V DC
668
Technical properties Namur connector plate for DIASTAR and PA11/21
Air connection G1/4"
Dimension 5.5 mm
Air pressure 2 - 10 bar
Temperature -10 °C ... +50 °C
Protection class IP65 per DIN40050
Voltage (VAC) / Power con- 230 V/ 5 VA 115 V/ 5 VA 48
sumption V / 5 VA 24 V/ 5 VA
Voltage (VDC)/ Power con- 24 V/ 3 W DIASTAR with NAMUR connector plate
sumption
Air flow 950 l/min
4/2-way pilot solenoid valve PV5470

Type PV5470
The 4/2-way solenoid valve is for the control of double
acting pneumatic actuators. Installation is done via a
Namur plate. For the dimension series DIASTAR DN15
- 50 a NAMUR connector plate must be mounted be-
tween the actuator and the pilot valve.
Mode of operation
4/2-way, when de-energized, pressure connection P
connected to output B, output A is vented.
Actuator
DIASTAR size 1-3 or PA11/21
DIASTAR size 4 - 5
NAMUR connector plate for PA30 - 90
Version type PV5470 (with NAMUR connector)
Actuator
PA30 - 90
230 V, AC / DC Pilot valve cluster PV2000

115 V, AC/DC The valve cluster PV 2000 is used for activating sever-
24 V, AC / DC al actuators at the same time. It consists of a connect-

ing module, several pilot solenoid valves and an end
module. Depending on the application you can choose
Namur connector plate a connecting module for D-sub connection, AS interface
or Profibus. The modular system allows a flexible com-
If you want to use a NAMUR pilot solenoid valve we bination of 3/2 and 5/2-way valves, as required.
have connector plates available. The connector plate
is mounted between the actuator and the pilot solenoid
valve.
669
Environmental conditions Mounting
Do not use valves in environments
with corrosive gases, chemicals, salt
water, water, steam, or where there is
direct contact with any of these.
Products with protection class IP65 and IP67 (according

to IEC529) are protected against dust and water. How-
ever, these products cannot be used in the water.
When using the manifold block assembly with integrated
sound absorber and protection class IP67, it has to be
ensured that the vent connection does not get in direct
contact with water or other liquids.
Any liquid entering through the vent connection of the
sound absorber can damage the valve.
Do not use the valve in an explosive environment.
Do not use in locations subject to vibration or impact.
Confirm the specifications in the technical datasheet.
Use a protective cover, etc. to shield valves from direct
sunlight. Valves are installed onto a 35-mm DIN rail.
Shield valves from radiated heat generated by nearby 1. Loosen DIN rail holding screws 1) on both ends.
heat sources. 2. Hook valve assembly on the side of pneumatic con-
Employ suitable protective measures in locations where nection to the DIN rail.
there is contact with oil or welding, spatter, etc. 3. Press valve assembly to DIN rail until it snaps in the
rail.
If solenoid valves are mounted into a switch panel or 4. Tighten DIN rail holding screws (1) .
if they are energized over a longer period, measures
for diverting the excess heat must be taken, in order to Adding solenoid valves
comply with the admissible operating temperature.
1) Loosen the screws (1) (2 pcs. on one side) that hold
Assembly the manifold base onto the DIN rail. (When removing
the manifold base from the DIN rail, loosen the hold-
ing screws at four locations.)
2) Using e. g. a flat head screwdriver, pull the lever
(b) forward on the manifold block assembly where a
station is to be added, and disconnect the manifold
block assemblies.
3) Attach the manifold block assembly to be added to
the DIN rail as shown in the figure.
4) Connect the block assemblies by pressing them to-
gether, and push the lever in firmly until it stops.
Then secure them to the DIN rail by tightening the
screws (1).
(Tightening torque: 1.4 Nm)
1 Mounting base
2 End module
3 Connection module with D-sub connector
4 Valve seal
5 Connector seal
6 Solenoid pilot valve
7 DIN rail (customer supply)
Mounting screw tightening torques

M2: 0.15 Nm
M3: 0.6 Nm
M4: 1.4 Nm
670
Technical data
Manifold type Stacking type cassette base manifold
1 (P: supply)/3, 5 (R: exhaust) Common supply, exhaust
Valve stations (max.) 18 stations
Max. number of solenoids 18
Port size 1(P)/3, 5 (R) port C8 1)
4(A)/2(B) port C6 1)
Medium Compressed air, filter 5µm or smaller recom-
mended
Internal pilot air 5/2-way monostable 1.5 to 7
Operating pressure range bar 2 x 3/2-way valve
Ambient and fluid temperature °C -10 to 50 (with no freezing)
Maximum operating frequency (Hz) 5/2-way monostable, bistable 5
2 x 3/2-way valve
Manual override non-locking type
Pilot exhaust method Main valve/Pilot valve common exhaust
Lubrication not required
Mounting orientation unrestricted
Impact/Vibration resistance (m/s²) 150/30 (8.3 to 2000 Hz)
Protection class valves/D-sub connector IP67/IP40 (acc. IEC529)
Supply voltage Power-on time 24 VDC/100 %
Allowable voltage fluctuation ± 10 % of rated voltage
Power consumption (W) 0.65
Spark suppression Zener diode
Indicator light LED
C6: One-touch fitting for O.D. 6 mm

1)
Weight
C8: One-touch fitting for O.D. 8 mm
Components Weight g
Note
5/2-way valve incl. base 105
Impact resistance: No malfunction when tested with a
drop tester in the axial direction and at a right angle to 2 x 3/2-way valve incl. base 110
the main valve and armature, one time each in ener- Connection module with D- 156
gized and de-energized states (at initial value). sub connector
Vibration resistance: No malfunction when tested with End module 102
one sweep of 8.3 to 2000 Hz in the axial direction and at
a right angle to the main valve and armature, in both en- Flow characteristics
ergized and de-energized states (at initial value).
Type Port size Flow values (Q n )
Response time
1, 5, 3 4, 2 1 -->4.2 (P - 4.2 -->5.3
Type of actuation Response time (ms) at 5 ->A, B) (A, B -->EA,
bar EB)
5/2-way monostable max. 11 (P/EA/EB) (A/ B) Flow rate (l/ Flow rate (l/
min) min)
2 x 3/2-way valve max. 15
SS5 V1-16 C8 1) C6 1) 216 226
Note: Based on JISB8375-1981 dynamic performance test
(with coil temperature of 20 °C, at rated voltage). C6: One-touch fitting for O.D. 6
1)
mm
C8: One-touch fitting for O.D. 8
mm
671
Circuit function 2 x 3/2-way valve
2 x 3/2-way valve
5/2-way valve
Pin assignment on D-sub connector
2 x 3/2-way valve 5/2-way valve
1 Valve 1A 1 Valve 1
Electrical connections 13 Common 13 Common
Applied voltage 14 Valve 1B 14 Valve 2
When electric power is connected to the
15 Valve 2B 15 Valve 4
solenoid valve, be careful to apply the
proper voltage. Improper voltage may 16 Valve 3B 16 Valve 6
cause malfunction or coil damage.
Check the connections
After completing the wiring, confirm that 18 Valve 5B 18 Valve 10
the connections are correct. 19 Valve 6B 19 Valve 12
Operating display/spark suppression 21 Valve 8B 21 Valve 16
Solenoid valves of type PV 2000 are bipolar.
5/2-way valve 25 Common 25 Common
672
Cable length
Code Length
199 190 432 1.5 m
Connector entry direction
199 190 433 3.0 m
The connector entry direction for D-sub connectors can
be changed. To change the connector‘s entry direction, 199 190 434 5.0 m
press the levers on both sides of the connector, take it
off, and change the direction as shown in the drawing. Assignment of wire colors as per DIN 47100
Since lead wire assemblies are attached to the connec-
Connection Wire color Marking
tor, excessive pulling or twisting can cause broken wires
or other problems. Also, take precautions so that lead 1 White
wires are not caught and pinched when installing the 2 Brown
connector.
3 Green
4 Yellow
5 Grey
6 Pink
7 Blue
8 Red
9 Black
10 Violet
11 Grey Pink
12 Red Blue
13 White Green
14 Brown Green
15 White Yellow
D-sub connector with connection cable PVC-U,
21x0.34 mm² 16 Yellow Brown
When a commercially available connector is required, 17 White Grey
use a 25-pin version conforming to MIL-C24308.
18 Grey Brown
19 White Pink
20 Pink Brown
21 White Blue
673
Pneumatic connections
Electropneumatic positioner DSR500
Use clean compressed air
Do not use compressed air which contains
chemicals, synthetic oils containing organic
solvents, salts or corrosive gases, etc., as
this can cause damage or malfunction.
Install air filters

Install air filters close to valves at their up-
stream side. A filtration degree of 5 µm or
less should be selected.
Install an air dryer, after-cooler or water

separator, etc.
Air that contains excessive drainage may
cause malfunction of valves and other
pneumatic equipment. Take measures by
installing an air dryer, after-cooler or water
separator, etc.
Prevent any excessive carbon powder
concentration, by installing water sepa-
rators on the valve inlet side.
If excessive carbon powder is generated
by the compressor, it may adhere to the in-
side of valves and cause malfunction.
Introduction
Pneumatically operated valves are used increasingly
not only as OPEN/ CLOSED valves, but are controlled
by external analogue command variables.
The positioner of type DSR500 can be used for pneu-
matic stroke actuators like the DIASTAR and also for
pneumatic rotary actuators like PA11/PA21 or type
PA30 - PA70 as positioner for 0° - 90°.
The positioner can be mounted on order in the plant or
1 Common exhaust retrofitted later in the field.
2 Air supply pressure
3 Valve outlet A • Electrostatic discharge caused by touching can dam-
4 Valve outlet B age certain components. Use antistatic workplace or
use appropriate connection to e.g a metal water pipe.
Manual override • Protect external cable with according insulation
Handle carefully, as connected equipment against contact.
can be actuated through manual override
operation.
Non-locking
674
Dimensions and weight
• This manual is not to be applied
Lift actuators with add-on kits without inspection
alone, but should be used in con- glass DSR100/101
junction with the instruction manual
for the valve onto which the actuator
is mounted or shall be mounted.
• Work on the actuator may only be
done by an authorised technician.
• According to the machine guide-
line 2006/42/EC (former 98/37/EC),
these actuators/valves are not con-
sidered machines, but may be built
into an installation which is consid-
ered a machine.
In such cases, please note the fol-
lowing.
We explicitly specify that operation is
prohibited until it has been made cer-
tain that the machine (equipment), into
which this product has been built, cor-
responds to the regulations of the EC
Machine Guideline 2006/42/EC (former Type Unit D H
98/37/EC)
DSR100 mm 86 139
Technical data DSR101 mm 86 167
Control signal 4 - 20 mA, Lift actuators with add-on kits inspection glass
DSR100/101
2 - 10 V
Auxiliary energy, elec- 24 VDC +/-10 %
tric
Auxiliary energy, pneu- 3 - 6 bar
matic
Stroke range type 3 - 25 mm, (DN15 - DN
100 50)
Type 101 9 - 50 mm, (DN65 - DN 150)
Type 201 Rotary actuator up to 90 °
Mounting on control Via standardised mounting kit, if re-
device quired also with optical indicator
Adjustment of stroke self-learning
and zero point
Output (at 6 bar supply 30 Nl/min.
air) 100 Nl/ min. (option)
Air consumption none
Type Unit D H H1
Allowable ambient -10 to 75 °C
temperature DSR100 mm 86 180 130
Protection class ac- IP65 DSR101 mm 86 227 160
cording to DIN 40050
Rotary actuator with add-on kit ISO DSR201
Function For single acting lift actuators (FC)
and rotary actuators (FC)
Material
Housing PA 6.6 polyamide, fibreglass
reinforced
Base plate Aluminium, black anodized
675
Type Unit D H H1 Installation and mechanical check
DSR201 mm 86 139 130 Mounting kit without inspection glass for DV
DIASTAR DN15 - DN150
Mounting the positioner on the DIASTAR pneu-
matic actuator and PA30 - PA90
Removing the position indicator
Attention: Position indicator has left-hand thread.
Mounting kit without inspection glass for DIASTAR

DN15 - DN150
Instead of the position indicator, an adapter (see below)

is used.
D
Mounting kit with inspection glass for DIASTAR DN15 -

DN150
D = outside

Mounting kit for PA30 - PA90
Outer diameter Adapter
96 mm 1
120 mm 2
150 mm 3
180 mm 4
276 - 331 mm 5
676
Turn the adapter belonging to the DV DIASTAR coun- Yu = distance required for correct installation of
terclockwise (1- 5 with an Allen wrench size SW5 / adapters
SW10), until it touches the pressure spindle.
Direct version
6 = pressure spindle
Attention: Left-hand thread DIASTAR and positioner Mechanical check
Area Yu bottom
DN15 Gr. 46.8 - 47.3
DN20 Gr. 50.4 - 51.2
DN25 Gr. 2 50.8 - 52.1
DN25 Gr. 3 54.3 - 56.3
DN32 Gr. 3 55.5 - 57.2
DN32 Gr. 4 47.5 - 48.6
DN40 Gr. 4 52.8 - 54.0
DN40 Gr. 5 52.2 - 55.1
DN50 Gr. 4 56.8 - 57.4
DN50 Gr. 5 55.8 - 58.1
DN65 71.4 - 73.4
DN80 75.8 - 76.9
DN100 75.6 - 77.4
DN150 77.0 - 77.4
All dimensions in mm
Mounting kit with inspection glass for DV DIASTAR
DN15 - DN150
1.The needle (12) is centred in the adapter (1- 5) with

the corresponding parts (remove indicator disk). (For
DN100 - 150 also place the needle protector on the
needle and then insert in adapter).
2.Place O-ring (6) on adapter (7) and screw onto DV
DIASTAR (Check the distance Yu, see below)
3.Insert DSR positioner (8) in adapter (7) and fasten
with threaded studs (9).
4.Remove the lower protective plug (FC). Connect rapid
connector (10) on actuator and positioner.
5.Connect the hose (11) between DV DIASTAR and
DSR positioner (connection A).
6.Connect air supply to Connector P.
7.Connection A (13)
8.Connection P (14)
677
1.Place the O-Ring (1) in the slot provided in the mount-
ing kit (2).
2.Screw the mounting kit onto the DV- DIASTAR (Check
the distance H, see below)
3.Mount the needle (3) on DV DIASTAR (For DN100 -
150 place the needle protector on the needle and then
insert in adapter).
4.Mount the DSR positioner (4) on the adapter of the
mounting kit (2) and fasten with threaded studs (5).
Attention: Make sure that the connector A is vertically
in line with the connections on the DV DIASTAR.
5.Remove the lower protective plug (FC) (6). Connect
rapid connector (7) on actuator and positioner. 1.The indicator (4) is fixed to the needle (5) with thread-
6.Connect hose (8) between DV DIASTAR and DSR ed stud (3) and cannot be removed. The threaded
positioner (connector A). stud (3) must be aligned parallel to the position indi-
7.Connect air supply to Connector P. cator (2). Remove the adapter (6) from the DSR posi-
tioner (1) by loosening the threaded studs (7).
8.Connection A (9)
9.Connection P (10)
1.Attach the adapter (6) on the mounting bracket

H = distance required for correct installation of adapters (10) with Allen screws (14) and washer. Fasten the
mounting bracket (10) to the pneumatic actuator (11)
DIASTAR and positioner Mechanical check through the spring washers (15), cylindrical Allen
Area H bottom screws (16) and the distance bushes (12) (not re-
DN15 Gr. 50.7 - 52.7
quired for all PAs).
2.Centre the cam (8) in the actuator axis (17). Connec-
DN20 Gr. 55.4 - 56.3
tor A must be in line with the connection of the pneu-
DN25 Gr. 2 54.2 - 57.6 matic actuator (11). Mount the DSR positioner (1) on
DN25 Gr. 3 54.7 - 56.8
the adapter via the screws with the threaded studs
(7). Fasten the cam (8) on the needle (5) by tightening
DN32 Gr. 3 56.3 - 57.7 the threaded stud (9).
DN32 Gr. 4 48.7 - 58.3 3.Connection A (20)
DN40 Gr. 4 51.9 - 54.5
DN40 Gr. 5 51.7 - 54.0
DN50 Gr. 4 56.1 - 57.9
DN50 Gr. 5 53.3 - 56.8
DN65 70.2 - 73.4
DN80 75.3 - 76.9
DN100 74.6 - 87.4
DN150 76.5 - 87.4
DSR-201 positioner incl. mounting bracket for PA30
- PA90
678
1.Connect the rapid connection (18) on the actuator and
positioner.
2.Connect the hose (19) between the actuator and DSR
positioner (Connector A).
4.Connection A (20)
5.Connection P (21)
⌀ (Copy)
Yu = distance required for correct installation of 1.Place the O-Ring (1) in the slot provided in the mount-
adapters ing kit (2).
2.Screw the mounting kit onto the DV- DIASTAR (Check
Direct version the distance H, see below)
DIASTAR and positioner Mechanical check 3.Mount the needle (3) on DV DIASTAR (For DN100 -
Area Yu bottom 150 place the needle protector on the needle and then
DN15 Gr. 46.8 - 47.3 insert in adapter).
DN20 Gr. 50.4 - 51.2 4.Mount the DSR positioner (4) on the adapter of the
mounting kit (2) and fasten with threaded studs (5).
DN25 Gr. 2 50.8 - 52.1 Attention: Make sure that the connector A is vertically
DN25 Gr. 3 54.3 - 56.3 in line with the connections on the DV DIASTAR.
DN32 Gr. 3 55.5 - 57.2 5.Remove the lower protective plug (FC) (6). Connect
rapid connector (7) on actuator and positioner.
DN32 Gr. 4 47.5 - 48.6
6.Connect hose (8) between DV DIASTAR and DSR
DN40 Gr. 4 52.8 - 54.0 positioner (connector A).
DN40 Gr. 5 52.2 - 55.1 7.Connect air supply to Connector P.
DN50 Gr. 5 55.8 - 58.1 9.Connection P (10)
DN65 71.4 - 73.4
DN80 75.8 - 76.9
DN100 75.6 - 77.4
DN150 77.0 - 77.4
Mounting kit with inspection glass for DV DIASTAR
DN15 - DN150
H = distance required for correct installation of adapters
679
DIASTAR and positioner Mechanical check through the spring washers (15), cylindrical Allen
Area H bottom screws (16) and the distance bushes (12) (not re-
quired for all PAs).
DN15 Gr. 50.7 - 52.7
2.Centre the cam (8) in the actuator axis (17). Connec-
DN20 Gr. 55.4 - 56.3 tor A must be in line with the connection of the pneu-
DN25 Gr. 2 54.2 - 57.6 matic actuator (11). Mount the DSR positioner (1) on
the adapter via the screws with the threaded studs
DN25 Gr. 3 54.7 - 56.8
(7). Fasten the cam (8) on the needle (5) by tightening
DN32 Gr. 3 56.3 - 57.7 the threaded stud (9).
DN40 Gr. 4 51.9 - 54.5
DN40 Gr. 5 51.7 - 54.0
DN50 Gr. 4 56.1 - 57.9
DN50 Gr. 5 53.3 - 56.8
DN65 70.2 - 73.4
DN80 75.3 - 76.9
DN100 74.6 - 87.4
DN150 76.5 - 87.4
DSR-201 positioner incl. mounting bracket for PA30
- PA90 1.Connect the rapid connection (18) on the actuator and
positioner.
2.Connect the hose (19) between the actuator and DSR
positioner (Connector A).
4.Connection A (20)
5.Connection P (21)
Connections
1.The indicator (4) is fixed to the needle (5) with thread-

ed stud (3) and cannot be removed. The threaded
stud (3) must be aligned parallel to the position indi-
cator (2). Remove the adapter (6) from the DSR posi-
tioner (1) by loosening the threaded studs (7).
Pneumatic
Supply air pressure
Connect the supply air with connection «P» (G1/8").
1.Attach the adapter (6) on the mounting bracket The supply air pressure has to correspond at least to
(10) with Allen screws (14) and washer. Fasten the the value that is stated on the type plate, and must not
mounting bracket (10) to the pneumatic actuator (11) exceed 6 bar. The supply air requires a filtration of at
least 5-10 μm.
680
Electrical Manual adjustment: (generally not required)
Electrical connections • Press both «IN» and «OUT» simultaneously until the
For the electrical connection of the control signal line LED blinks (after about 2–3 seconds) and then let go.
(set-point), a twisted cable is recommended. The con- • The valve does several stroke movements (open/
nection of the supply voltage should be carried out via close), the end of which is indicated by the steady
a second, separate cable, also, the system should be burning of the LED. If the LED blinks, there is an error
grounded (earth connection on the board). After remov- (e. g. not enough supply air pressure).
ing the cover on the positioner, the screw terminals for • With the «IN» button (air is pumped into the actuator)
the individual connections can be accessed (see also and «OUT» (actuator is exhausted), the valve can be
wiring diagram). moved into the opened or closed positions. If either of
Connector board the buttons is not pressed within a minute, the valve
will return to its original position.
• By alternately pressing «IN» and «OUT», the point is
reached at which the valve just begins to open (a slit
of light appears between the diaphragms). To confirm,
both «IN» and «OUT» are pressed simultaneously
within 3 seconds. (LED blinks and goes out).
• Adjustment is thus completed.
Error message output
If necessary, the failure signal (terminals K1.1 and K1.2)
can be used to analyse the valve function. The failure
signal is activated if the positioner is not able to comply
the actual value (stroke) with the set value (control sig-
nal); for example if there is no or too low supply air pres-
Connections sure. In this case, the LED on the connector board lights
+I: Control signal current \ selectively up.
–I: Control signal current Direct circuit:
+U: Control signal voltage \ selectively
–U: Control signal voltage Us = signal voltage
+24 V: Supply voltage No failure function: low sig-
0 V: Supply voltage (0 V) nal
K1.1: Failure signal connector
K1.2: Failure signal connector Failure function: 0.5 Hz im-
pulse
Other
PC: Interface cable to PC (configuration)
Max. supply voltage: UB, max
IN: Supply air valve for actuator is opened (installation)
= 24 V DC
OUT: Outgoing air valve for actuator is opened (installa-
tion) external load R: e.g. 470 Ω
LED: Light emitting diode for adjustment (installation)
Max. signal current: Is, max =
and failure signal (failure signal if malfunction)
50 mA
Adjusting the positioner
Adjusting the DSR type positioner Relay (provide recovery diode for in-
The positioner was calibrated before leaving the plant. ductive loads)
Generally, adjustments are only necessary if a replace-
ment was done, in which case you proceed as follows:
Automatic adjustment: Troubleshooting list
• Press both «IN» and «OUT» simultaneously until the
LED blinks (after about 2–3 seconds) and then let go. Problem Possible causes
• The valve does several stroke movements (open/ Controller - Connected incorrectly (electr. and pneum.)
close), the end of which is indicated by the steady fails/ does - Operating error
burning of the LED. Confirm the adjustment by press- not work - Control pressure too high
ing the IN/OUT buttons simultaneously within 3 sec- - Electronics defective
- Sensor defective
onds. The LED goes out. If the LED blinks, there is an - Transport damage
error.
681
Feedbackmodul
Design and function Stroke limiter/Emergency manual override
for DIASTAR
Technical data feedback modul
Installation and setup feedback modul The stroke limiter can be used for limiting the minimum
Failure signal feedback modul and maximum stroke as well as for the emergency man-
ual override. With the usage of adapters, the stroke lim-
Troubleshooting feedback modul iter can also be combined with our electrical position in-
Spare parts/assembly dicator (ER52/53).
Order numbers type DSR100/101/201 DN15 - DN50
Please note: For installation of DSR type positioners,
both the positioner and the corresponding mounting kit
must always be ordered.
Digital electro-pneumatic positioner
Type DSR 100/101/201
Further versions and accessories on request
No. DIASTAR DIASTAR Rotary actuators
DN15 - 50 FC DN65 -150 FC pneumatic FC
DSR100 DSR101 DSR 201
Code Code Code
1 199 190 410 199 190 411 199 190 412
Mounting kit Type DSR100 without optical position

indicator for DIASTAR DN15 - 50
No. DN Type 028-FC Type 025-FC Assembly and adjustment of the stroke limiter
• Put valve in the «open» position using control pres-
Code Code
sure (FC, DA).
3 15 - 199 190 414 • Remove indicator cap (1) and indicator pin (2) (left
3 20 199 190 414 199 190 414 thread).
• Screw threaded bush (3) with wrench into the actuator
3 25 199 190 414 199 190 415
(4) until stop.
3 32 199 190 415 199 190 415 • Screw locknut (5) on the threaded bush (3) and se-
3 40 199 190 415 199 190 415 cure with a wrench.
• Guide indicator pin (6) through the threaded bush (3),
3 50 199 190415 199 190 415
screw into spindle (7) (left thread) and secure with an
Mounting kit Type DSR100 with optical position indi- Allen wrench.
cator for DIASTAR DN15 - 50 • Screw indicator cap (8) onto locknut (5).
No. DN Type 028-FC Type 025-FC Attention: Indicator pin 2, 6 has left thread.
Code Code
2 15 - 199 190 417
2 20 199 190 417 199 190 417
2 25 199 190 417 199 190 418
2 32 199 190 418 199 190 418
2 40 199 190 418 199 190 418
2 50 199 190 418 199 190 418
Mounting kit Type DSR101 for DIASTAR DN65 - 150

No. With optical posi- Without optical position
tion indicator indicator
Code Code
2/3 199 190 419 199 190 416
Mounting kit Namur for rotary actuators pneumatic

No. Code
4 199 190 281
682
DN65 - DN150
Minimum flow adjustment

• Put valve in «open» position using the control medium
(FC, DA).
• Remove locknut (5) with a wrench and turn the
threaded bush (3) with a wrench in a counterclock-
wise direction until the desired position is reached.
The stroke limit setting can be seen by comparing the
position of the threaded bush (3) to the basic setting. 1 Visual position indicator
• Tighten locknut (5). 2 Threaded bush
3 Locknut
Maximum flow adjustment 4 Indicator pin
• Put valve in «closed» position. 5 Spindle nut
• Remove the locknut (5) with a wrench and turn the
threaded bush (3) with a wrench in a clockwise direc-
tion until the desired position is reached. The stroke Electrical position indicator ER52/53
limit setting can be seen by comparing the position of Introduction
the threaded bush (3) to the basic setting. This document contains a description and instructions
• Tighten locknut (5). for the installation and adjustment of the electrical posi-
tion indicator type ER52 and ER53.
Emergency manual override
• The position indicator must always be disconnected
• The adjustment is similar to that for the stroke limiter.
from the mains before any work is done on it.
By turning the threaded bush (3) in a clockwise direc-
tion, the valve is closed (FO, DA), by turning it in a • Only trained, authorised personnel may carry out any
counterclockwise direction, the valve is opened (FC, work on the position indicator.
DA). • According to the Machine Directive 98/37/EC (former-
• For automatic operation, the valve must be readjusted ly 89/392/EEC), these valves / actuators are not re-
according to the instructions. garded as machines; they can, however, be built into
installations which are considered machines.
• In such cases, please note the following.

Machine Guideline 98/37/EC (former 89/
392/EEC)
Description
The electrical position indicator is used to indicate the
valve position of GF diaphragm valves type DIASTAR.
The position indicator can be screwed directly onto the
diaphragm valve type DIASTAR.
Type ER 52: 20 – 63 DN15 – 50
Type ER 53: 75 –160 DN65 –150
683
Design of the position indicator 09 Connecting piece of stainless steel
10 Unit plug 3P + E / EN 43650
Type ER 52 (DN15 - 50)
Protection class IP 65 Protection class IP 65
Installation / Adjustment
Basic version of the diaphragm valve
sure (FC, DA).
• Remove indicator cap (11) and indicator pin.(Atten-
tion: indicator pin has left thread).
• Loosen the screw (1) on the electrical position indica-
tor and unscrew the transparent, protective cover.
• Pull upper cam (2) off.
• Loosen the threaded bolt (3) and pull the base with
the spindle (4) out of the housing (5).
Type ER 53 (DN65 - 150) ER52: Complete spindle with respective connecting
piece and position.
• Screw the base (4) with a wrench in the actuator.
• Screw the spindle (6) with an Allen wrench into the
spindle nut of the actuator. (Attention: left thread)
• Place housing (5) on base (4) and see that the elec-
trical connection is in the desired position; secure
threaded bolt (3).
• Put upper cam (2) on the spindle (gripper up).
• Do electrical connections according to diagrams.
01 Cover SAN
02 Microswitch ”CLOSED”
03 Microswitch ”OPEN”
04 Cams PA
05 O-rings NBR
06 Housing PP
07 Brass base
08 Spindle of stainless steel
684
Diaphragm valve with stroke limiter
sure (FC, DA).
• Remove indicator cap (11) and indicator pin and
screw the adapter (9) onto the locknut of the actuator.
• ER 53: Dismounting of indicator pin.(Attention: left-
hand thread)
• ER 53: Screw the intermediate piece (10) into the
connecting piece.
• Loosen the screw (1) on the electrical position indica- Electrical connections
tor and unscrew the transparent, protective cover. The position indicator is connected in standard version
with unit plug.
• Pull upper cam (2) off.
• Loosen the threaded bolt (3) and pull the base with Electrical position indicator type ER 52
the spindle (4) out of the housing (5). Type of switch Switching capacity
• Screw the base (4) with a wrench into the adapter (9). Type
• Screw the spindle (6) with an Allen wrench into the ER52-1 Microswitch AgNi 250 V~/6 A
spindle nut of the actuator. (Attention: left thread) ER52-2 Microswitch with gold- 4-30 V=/1 - 100 mA
• Place housing (5) on base (4) and see that the elec- plated Au
trical connection is in the desired position; secure ER52-3 Inductive switch NPN 5 - 30 V=/0.1 A
threaded bolt (3).
ER 52-4 Inductive switch PNP 5-30 V=/0.1A
• Put upper cam (2) on the spindle (gripper up).
• Do electrical connections according to diagrams. ER52-5 Inductive switch Na- 8V=
mur
Adjustment ER 52-6 Microswitch Eexd 250 V~/5 A
• Slide the upper cam (2) and the lower cam (7) flush ER52-7 Analog position sensor 15-30 V=/4 - 20 mA
against the adjustment plate (8).
• Put the valve once in the «open» position and once in Electrical position indicator type ER53
the «closed position. The cams are thereby correctly
Type of switch Switching capacity
adjusted. Type
• Screw the transparent cover back on the housing and ER53-1 Microswitch AgNi 250 V~/6 A
tighten with the screw (1).
ER53-2 Microswitch with gold- 4-30 V=/1-100 mA
plated Au
ER53-3 Inductive switch NPN 10-30 V=/0.1 A
ER 53-4 Inductive switch PNP 10-30 V=/0.1 A
ER53-5 Inductive switch Na- 8V=
mur
ER 53-6 Microswitch EExd 250 V~/5 A
ER53-7 Analog position sensor 15-30 V=/4 - 20 mA
Connection diagrams
ER 52-1, ER 52-2, ER 53-1, ER 53-2
Type
ER52-1
ER52-2
ER53-1
ER53-2
685
01 closed
02 open
03 black 01 closed
04 white 02 open
05 red 03 white
04 red
ER 52-3, ER 52-4 05 green
Type 06 black
ER52-3
ER52-5
ER 52-4
Type
ER52-5
01 closed
02 open
03 blue
04 black
05 black
06 brown
ER 53-3, ER 53-4 1 closed

2 open
Type
3 blue
ER53-3 4 brown
ER 53-4
ER53-5
Type
ER53-5
686
Type 025 - FC 025 - FO/DA
DN Actuator size Actuator size
mm
15 2 1
20 2 2
25 3 2
32 4 3
40 5 4
1 closed 50 5 4
2 open
3 black
4 white
ER 52-6, ER 53-6
Type
ER 52-6
ER 53-6
Actua- D (PP-GF) D (PA-GF ST 195-BW)

tor size mm mm
1 68 65
2 96 92
01 closed
3 120 115
02 open
03 green 4 150 142
04 brown 5 180 168
05 white
Spare parts list
ER 52-7, ER 53-7
Pos. Item Pcs. Ma- ER52-1/2 ER52-3/4/
Type teri- 5
al
ER52-7
ER53-7 Cover set, 198000217
consisting of:
For detailed information, see special data sheet. 1 Cover 1 SAN
2 O-ring 1 NBR
Actuator sizes Diastar DN 15 - 50 3 Screw 1
Type Eco - FC 028 - FC Unit plug, con- 198000214 198000216
sisting of: NBR
DN Actuator size Actuator size 4 Cable socket 1
mm Profile seal- 1
15 1 1 ing
20 2 2 5 Adapter com- -
plete *
25 2 2
Size 1, 2 199190387
32 3 3
Size 3 199190388
40 3 4
Size 4 - 5 199190389
50 3 4
*For combination ER52 / ER53 / lift limiter / manual
override
687
Pos. Item Pcs. Ma- ER53-1/2/ ER53-3/4/ type 028/ 025 and can indicate a valve position, open
teri- 7 5 or closed. The switching point can be easily set with the
al adjustable Reed contact.
Cover set, 198000213
consisting of:
1 Cover 1 SAN
2 O-ring 1 NBR
3 Screw 1
Unit plug, con- 198000214 198000216
sisting of: NBR
4 Cable socket 1
Profile seal- 1
ing
5 Adapter com- 199190310
plete * Design
*For combination ER52 / ER53 / lift limiter / manual
override
1 Unscrew indicator cap on actuator

2 Screw adapter (1) into insert (2)
Electrical position indicator type ER 55 3 Snap magnet holder (3) onto indicator pin (4)
4 Screw cap (5) onto adapter (1)
Introduction 5 Slide Reed contact (6) onto guide of cap and adjust
This document contains a description of and instruction
6 Fix screw (7)
for the installation and adjustment of the electrical posi-
tion indicator type ER55. Adjustment
• The position indicator must always be disconnected Set Reed contact to the desired switching point, add an-
from the mains before any work is done on it. other 2 mm as safety. Fix Reed contact with screw (7).
• Only trained, authorised personnel may carry out any Valve "OPEN": Contact closed
work on the position indicator. Valve "CLOSED": Contact open
• According to the machine guideline 98/37/EC (former
89/392/EEC), these actuators/valves are not consid- Drawing: Valve in open position "OPEN"
ered machines, but may be built into an installation
which is considered a machine.
• In such cases, please note the following.

Machine Guideline 98/37/EC (former 89/
392/EEC)
Description
Electric position indicators are used to signal the valve
positions. The GF position indicator type ER 55 can be Valve "OPEN": Contact open
screwed directly into the diaphragm valve series Diastar Valve "CLOSED": Contact closed
Drawing: Valve in position "CLOSED"
688
Ordering data
ER55-1: DN15 – 50:199 190 462
ER55-2: DN65 – 150:199 190 464
Spare parts:
Reed contact 198 804 875
AS interface
For our pneumatic activator we offer the following prod-
ucts to connect them to an Asi network:
Connection wiring diagram
AS interface type topmatic for DN15 - DN100
DIASTAR
Technical data
Nominal voltage: 250 V, 50 – 60 Hz max.
Max. continuous 200 mA
current:
Peak switch-on cur- 500 mA (use contact protection re-
rent: lay in case of inductive load) The Topmatic:
The Asi accessory enables a modern and easy connec-
Contact fitted: monostable Reed contact
tion to an Asi network. The controller contains all the
Electrical connec- Standard plug DIN EN 175301-803 necessary electric and pneumatic components. All you
tion: need to install is a serial cable and the air connections
Protection class: IP65 as per IEC EN 60529 to actuate up to 62 valves independently.
Dimensions (mm) Description

AS interface type ASVC 2300-11 for PA11/21 and PA30 - 90
For further information about AS interfaces please refer

to Chapter Accessories for electrical actuators, AS
interface
X: 199 190 462: 75 mm

199 190 464: 48 mm
689
PID controller type PE70 Abbreviation Meaning Heating example
x Controlled variable Actual temperature
Basics
w Set point Target temperature
(20 °C)
e System deviation Target minus actual tem-
perature
y Actuating variable Valve output from the
controller, valve position
of the heating valve
z Disturbance vari- e.g. opened window
able
Control process Space heating and room
Controller User or thermostat valve
Usually closed loops are pictured as block diagrams. In

the following a simplified block diagram of a standard
closed loop is shown.
Introduction to control engineering

Closed loop controlling is a procedure where the con-
trolled variable is recorded continuously, compared with
another variable (set point) and adapted to that value.
Control engineering is usually used, if the following vari- Feedback (degenerative feedback) – compare target
ables have to be controlled: and actual values
• Flow
Control process
• Pressure The dynamic behavior of a control process is primary
• Temperature described by its time response. With a step response,
• Fill level the behaviour of the controlled variable towards the
change of the actuating variable can be described.
• Ratio control (e.g. mixing of media)
Therefore the input signal changes abruptly by a test
The most suitable way to explain the basics of automat- signal. Depending on the attributes, control processes
ic control technique is an example: are classified in the following groups:
Heating example P control process (proportional behavior)
A user of a room heating opens the heating valve until, P processes have a proportional behaviour; this means
according to experience, 20°C ambient temperature are the controlled variable changes proportional to the
achieved. Due to the valve position, the heating output actuating variable. P processes have a proportional
and flow rate are defined. But the actually achieved am- behaviour; this means the controlled variable changes
bient temperature is affected by general conditions like proportional to the actuating variable. These control pro-
opened or closed windows. However, the changing tem- cesses are again classified in the following:
perature does not influence the heating valve position.
This target and actual temperature deviation does not • P0-behaviour
influence the heating valve and so in control technique it • PT1-behaviour
is called an open loop (open action flow). • PT2-behaviour
If the user wants to achieve the exactly room tempera-
ture, the open loop of the room heating must be com- P
pleted with a controller. The controller function can
0
be adopted by the user. If the ambient temperature
is above or below the desired 20°C, the valve can be -behaviour
opened or closed by the user. However, the controller,
the user, knows the temperature difference and at- The time factor is irrelevant in this process.
tempts to override it. Through the action of the user,
a closed process (closed loop, closed action flow) is
generated, which is characteristic for automatic con-
trol technique. New heating systems are of course con-
trolled by thermostats.
Terminology
Basic terms in control engineering according to DIN
19226 are:
T control process (control process with dead time)
T
690
o
P controllers are used in control processes which are
-behaviour easy to set. With only little complexity, a stable and dy-
namic control behaviour can be achieved.
In the control engineering, the span of time, which
passed by till a change on the input receives the out-
put of a control process, is called dead time. This is the
time, in the heating example, which the user needs to
readjust the heating valve to get the desired tempera-
ture (set point).
Advantages
• Simple design
• Easy adjustment
I control process (integral behaviour) • Very stable controlling if the right dimension is chosen
I
o
Disadvantages
-behaviour • Enduring control deviation due to disturbances can
not be compensated completely
The actuating variable in the I control process is nev- • Unsuitable for control process with dead time only
er zero. Therefore an equilibrium condition can not be
achieved. Consequently, the controlled variable con- I controller
stantly rises or falls. This is the behaviour of a control If the control deviation has to the adjusted completely,
process without equilibrium. an I controller is recommendable. The actuating variable
y rises slowly, while the actuating variable on a P con-
troller achieves its final value immediately.Thus, the I
controller responses to disturbance slowly.

Controller
Controllers affect a control process with a control sig-
nal so that controlled variable and set point values are Advantage
equal. Thus, a controller consists of a comparing and
controlling element. Generating the actuating variable • No enduring control deviation
y from the system deviation e is done by the controlling
element. D controller
Controllers differ from each other, depending on their
function to adopt actuating variables. Typically, con-
trollers are classified in continuous and non-continuous
controllers.
Continuous controller Non-continuous controller
• P controller • On/Off controller
• I controller • Two-Step controller The D controller is only used in combination with the P-
• D controller • Three-Step Controller and/or I controller. It is not responding to the control de-
• PI controller • Multi-Step Controller viation, but to its rate of change.
• PD controller • ...
Advantage
Continuous controller
• Disadvantages
P controller
The system deviation e on P controllers is always pro- Disadvantage
portional to the actuating variable y. Therefore a P con-
• Does not recognise enduring control deviation
troller can react to changes without time loss and gener-
ates an actuating variable only if a system deviation ex-
ists.
691
PI controller • No enduring control deviation
The PI controller combines the advantages of the P-
• Even faster design
and I controller. It is often used in practice, since most
of the control tasks can be solved. In case short actu- • High quality of control, if dead time is not predomi-
ating times are required, despite control path delays, a nantly in the process
PID controller should be chosen.
Disadvantage
• Complex design and adjustment compared to a P
controller
Non-continuous controller
On/Off controller
To actuate a control process, On/Off Controllers with re-
lays or solenoid valves are often used. This closed-loop
control operates without setting up control parameters
Advantages
and is cost-saving. However, it should only be used with
• No enduring control deviation low requirements regarding the quality of control.
• Useable for almost all control processes
Disadvantage
• Complex design and adjustment compared to a P
controller
PD controller
A PD controller is used, if a P controller is not suffi- Two-Step controller
cient due to its enduring control deviation, e.g. in con- This controller represents an enhancement of the On/
trol paths with long delay. This can be the case in con- Off Controller.As indicated by the name, the controller
trol processes with large delays, for instance. Because can adopt only two initial states (actuating variables).
of its D part the actuating speed is higher compared to a The difference is within the frequency of the cycle of op-
P controller and generates a bigger control dynamic. eration. A common example for Two-Step controlling is
space heating. Here, an expanding element controls the
flow in the valve.
Advantage
• PD controllers are very fast Three-Step Controller
The Three-Step Controller can adopt three different ini-
Disadvantage tial states. For example in a heating system the states
“On” and “Off” can be enhanced with the state “Cool-
• Enduring control deviation limits the field of applica- ing”. According to that, the controller inherits the func-
tion. tion of two coupled Two-Step Controllers which switch
in different states.
PID controller Valve applications often use Three-Step Controllers in
The PID controller is suitable for control processes with junction with electric actuators. With the three possible
large energy storages and thus for control processes of actuating variables an actuator can run the valve in any
higher order. The positive attributes of PD and PI con- desired position, like the states “counter-clockwise” for
troller are combined within this controller. e.g. opening, “clockwise” for e.g. closing and “off”.
Advantages
692
Design and application of a control
The controllers of +GF+ Piping Systems are mostly
used in combination with Signet products and actuat-
ed valves. These kind of valves are diaphragm valves,
butterfly valves and ball valves. In doing so, the valves
have to be equipped with additional control units. These
control units, also known as positioners, are offered by
+GF+ in following versions:
+GF+ actuators +GF+ Positioners
Electric actuator (EA) PE25
• Butterfly valves and ball
valves Continuous level control within a filtration process:
In this process the level meter transfers the measured
Pneumatic actuator (PA) DSR 201 (for rotary actua- pressure value to the transmitter. The transmitter con-
• Butterfly valves and ball tors) verts this input signal to a standardized output signal.
valves Following, this signal will be passed on to the PID con-
troller. It compares set point and actual value and ad-
Pneumatic actuator DSR 100 and 101 (for lift ac- justs it. Afterwards, the signal will be transferred to the
DIASTAR tuators) positioner, which initiates the actuation of the ball valve.
• Diaphragm valves
In control engineering, PID controllers and positioners

have different tasks:
The positioner receives a standardized signal from the
superior PID controller, e.g. 4-20 mA and implements
the signal on site by initiating the actuator. Thus, the su-
perior PID controller is free of typical disturbance vari-
ables and therefore the quality of control is better.
It is the task of the PID controller to continuously cap-
ture the control variable, to compare it with another vari-
able (set point), and to adjust it.
PE70-1/ -2
S - Sensor; T - Transmitter, C - Controller, P - Position-

er, A - Actuator, V - Valve, F - Pipes, Fittings
Fields of applications are among other things:
Ratio control:
In this example the paddlewheel flow sensor passes an
electrical impulse on to the transmitter. This transmitter
changes the electrical impulse to a standardized signal,
e.g. 4-20 mA. Afterwards this signal will be forwarded
to the PID controller. Here, the comparison between set
point and actual value, as well as the adjustment, takes
place. Following, this signal, which is standardized as
well (e.g. 4-20 mA), will be transferred to the position-
er. Now the positioner initiates the actuation of the ball
valve.
Description
The PID controller PE70-1/ -2 is a process-controller
that is suitable for standard control functions like a sin-
gle loop control, as well as for the more sophisticated
ratio control function.
693
For this, the unit provides simple 2-point (on/off) control, Process value input INP1
continuous PID control, or 3-point stepping control.The
Resolution: >14 bit
process value signal is connected via a universal
input.A supplementary analog input can be used for po- Decimal point: 0 to 3 decimal places
sition feedback mesaurement of motorized stepping Scanning cycle: 100 ms
controllers or as an external set-point input.
Measured value correction: 2-point or offset correction
Features
• Self-tuning function Current and voltage signals
• Universal version (continous and switching) for re-
Voltage: 0-10 Volt
duced stock 2.5...115 mV
• 100 ms cycle time 25...1150 mV
• 20 ms as shortest pulse length Current: 0-20 mA
• Splash water proof front (IP65) 4-20 mA
• Two individual configurable analog output Start and end of span: anywhere withing the range
• Logical combination of digital output, e.g. alarms Scaling: -1999...9999
Decimal point: adjustable
Electrical connections
Input circuit monitor: 12.5% below span start

Supplementary input INP2

Resolution: >14 bit
Scanning cycle: 100 ms

Current measurement range
Voltage: 0-10 Volt
2.5...115 mV
25...1150 mV
Input resistance: approx. 120 Ω
Span: configurable within 0...20 mA
Scaling: -1999...9999

Control Inputs di1, di2

Configurable as direct or inverse switch or push-button! Con-
nection of a potential-free contact suitable for switching „dry“
circuits.
Switched voltage: 5 V
Current: 100μA

Outputs
Inputs Output Used for
Input Used for OUT1 and Control output heating/cooling or Open/Close,
OUT2 (re- limit contacts, alarms *
INP1 As INP2 (x1default standard process value) lay)
INP2 Heating current, ext. set-point or ext. correction, OUT3, 4 as OUT1 and OUT2
position feedback Yp, process value x1, 2nd (relays or
process value x2, ext.correcting variable Y.E, logic)
input for additional limit signalling and indication
OUT3, 4 Control output, process value, measured values
di1 Operation disabled, controller off, disabled auto/ (continous) INP1/2/3, set-point, control deviation, position
di2 manual function, reset of stored alarms, switch- feedback Yp, transmitter supply 13 V / 22 mA
over to ... second set-point SP.2, external set-
point SP.E, fixed correcting variable Y2, ext. * All logic signals can be OR-linked!
correcting variable Y.E, manual operation, pa-

rameter set 2, 2nd process value X2
694
Relay Outputs OUT1...OUT4 • 3-point stepping controller with or without position
feedback
Contact type: Potential-free changeover
contact • Continuous controller with internal positioner (step-
ping controller)
Max. contact rating: 500 VA, 250 VAC, 2A at 48
...62 Hz, resistive load Two parameter sets for manual gain scheduling Self-
Min. contact rating: 6 V, 1 mA AC/DC tuning control parameters or adjustable manually via
front keys or BlueControl software.
Duty cycles electric: for I = 1A/2A: 800,000 /
500,000 (at 250 V / (resistive Behaviour with 2- and 3-point controllers
load)) • Standard behaviour:
Note: For precise matching of the required output value at
If the relays operate external contactors, these must be fit- the output signal limits, the controller changes the cy-
ted with RC snubber circuits to manufacturer specifications cle times for heating and cooling automatically and
to prevent excessive switch-off voltage peaks. continuously.
• With constant cycle times:
The length of the shortest heating and cooling pulse is
OUT3, OUT4 as universal output
adjustable >20 ms.
Galvanically isolated from the inputs. • Water cooling linear (heating=standard):
Freely scalable DA-converter limiting fre- 50 ms To ensure a sufficient cooling effect, the cooling func-
quency T90: tion starts only after reaching an adjustable tempera-
ture value. The pulse length is adjustable, >20 ms too
Limiting frequency of the complete contin- >2 Hz
uous controller:
and remains constant for all output values.
• Water cooling nonlinear (heating=standard):
Resolution: 11 bit
The general function is described above. Howev-
er, the controller additionally takes in consideration
Current output that the water cooling is usually much stronger than
the heating (thus preventing unfavourable behaviour
0/4...20 mA, configurable.
when changing from heating to cooling).
Signal range: 0...approx.22 mA
Load max.: ≤ 500 Ω Set-point functions
Load effect: none • Adjustable set-point gradient (degree) 0.01...9999 °C/
min
Resolution: ≤ 22 μA (0.1%)
• Set-point control
Accuracy: ≤ 40 μA (0.2%)
• Set-point/cascade control

• Set-point/cascade control with external correction
Voltage output
0/2...10 V, configurable. Process value correction
• Standard (xeff = INP1)
Signal range: 0...11 V
• Ratio (INP1/X2)
Load min.: ≥ 2 kΩ
• Difference (INP1-X2)
Load effect: none
• Max (INP1, X2)*
Resolution: ≤ 11 mV (0.1%)
• Min (INP1, X2)*
Accuracy: ≤ 20 mV (0.2%)
• Mean value (INP1, X2)*
• Switch-over between INP1 and X2
OUT3, OUT4 used as transmitter supply *applicable, if redundant sensors are necessary. If one
sensor fails the rest can go on.
Output: 22 mA/ ≥13 V
Behaviour with sensor break or short circuit:
OUT3 used as logic output
• Control outputs switched off
• Switch-over to a safe output value
Load ≤ 500 Ω 0/ ≤ 20 mA
• Switch-over to a mean output value
Load >500 Ω 0/ >13 V
• With process value functions min,max and mean val-
Functions ue, control iscontinued with the remaining processval-
ue.
Control behaviour
• Signaler with asymmetric adjustable switching differ- Alarms and limit signalling functions
ential (ON/OFF controller) Control loop alarm
• PID controller (2-point and continuous) Automatic detection if there is no response of the pro-
• Delta / Star / Off or 2-point controller with switch over cess to a change of output value.
from partial to full load
• 2 x PID (heating/cooling)
695
Sensor break or short circuit Universal supply 24 V UC
Depending on selected input type, the input signal is
monitored for break and short circuit. AC voltage 20.4...26.4 VAC
Frequency 48...62 Hz
Limit signalling
Max., Min. or Max./Min. monitoring with adjustable hys- DC voltage 18...31 VDC
teresis. Power consumption approx. 8 VA (W)
Signals which can be monitored:
• Process value
Behaviour in case of power failure
• Control deviation
• Control deviation with suppression during start-up or Configuration, parameters, and adjusted set-points, control
mode: Permanent storage in EEPROM
set-point changes

• Effective set-point
• Actuating variable Y
• Input values of INP1, INP2, INP3 Environmental conditions
• Difference INP1 - X2. This function allows to detect
aged thermocouples. Protection class
Front panel: IP 65
Functions Housing: IP 20
• Input signal monitoring
Terminals: IP 00
• Input signal monitoring with alarm storage (reset via

front keys or digital input)
• Rate of change monitoring (/min) Permissible temperatures
• Adjustable discriminator time of 0...9999 seconds
Operation: 0..60°C
Several limit signals or alarms can be OR-linked before Temperature effect: <100ppm/K
being output. Applications: Release of a brake with mo-
tor actuators, general alarms, etc. Operation limit: -20..65°C
Storage: -40..70°C
Maintenance manager
Display of error signals, warnings, and stored limit mes-
sages in the error list. Signals are stored, and can be re-
set manually. Possible signals in the error list: Humidity
• Sensor break, short circuit, reversed polarity 75% yearly average, no condensation
• Heating current alarm
• Control loop alarm
Self-tuning
• Fault during self-tuning For determination of optimum process parameters, self-
• stored limit messages tuning is possible.
• Re-calibration warning After starting the controller makes an adaption attempt.
• Maintenance interval of actuator Whereby the process characteristics are used to calcu-
late the parameters for fast line-out to the set-point with-
• Internal fault (RAM, EEPROM, ...) out overshoot.
Technical information Preparation
Housing material • Adjust controller measuring range as control range
Makrolon 9415, flame retardant, limits. [rnG-L] and [rnG.H ] to the limits of subsequent
Flammability class: UL94 VO, self-extinguishing control.
• Determine which parameter set shall be optimized.
(The instantaneously effective parameter set is opti-
Screw terminals for conductorcross-section from 0.5 to
mized). Activate the relevant one (1 or 2).
2.5 mm²
Auxiliary energy • Select the self-tuning method.
Depending on version:
Selectable self-tuning methods:
AC voltage
• Step attempt after start-up
Voltage 90...260 VAC • Pulse attempt after start-up
Frequency 48...62 Hz • Optimization at the set point
Power consumption approx. 8 VA
Start conditions

• A stable condition is required for the evaluation of the
control process.. Therefore, the controller waits un-
til the process has reached a stable condition after
696
self-tuning start.The rest condition is considered being
reached, when the actual value oscillation is smaller
than 0.5% of ([rnG.H] - [rnG.L]).
• For self-tuning after start-up, a 10% difference from
([SP.LO] ... [SP.Hi]) is required.
Start
Self-tuning start can be blocked via BlueControl soft-
ware.
[Strt]=0 Only manual start by pressing keys [Enter] and
[Up] simultaneously or via interface is possible.
[Strt]=1 Manual start by pressing keys [Enter] and [Up
] simultaneously via interface and automatic
start after power-on and detection of process
oscillations.
Manual self-tuning
The optimization aid can be used with units on which
control parameters shall be without self-tuning.
Adjustment aids
Parameter Control process Fault Start-up behaviour
[Pb1] higher increased damping slower line-out slower reduction of duty-cycle
smaller reduced damping faster line-out faster reduction of duty cycle
[td1] higher reduced damping faster response to distur- faster reduction of duty cycle
bances
smaller increased damping slower response to distur- slower reduction of duty cycle
bances
[ti1] higher increased damping slower line-out slower reduction of duty-cycle
For this, the unit provides simple 2-point (on/off) control,

PE70-3/ -4 continuous PID control, or 3-point stepping control.The
process value signal is connected via a universal in-
put. A supplementary analog input can be used for posi-
tion feedback mesaurement of motorized stepping con-
trollers or as an external set-point input.
Features
• Self-tuning function
• Universal version (continous and switching) for re-
duced stock
• 100 ms cycle time
• Splash water proof front (IP65)
• Two individual configurable analog output
• Freely configurable analog output
• Logical combination of digital output, e.g. alarms
Description
The PID controller PE70-3/ -4 is a process-controller
that is suitable for standard control functions like a sin-
gle loop control.

697
Electrical connections Supplementary input INP2
Resolution: >14 bit

Current measurement range
Voltage: 0-10 Volt
2.5...115 mV
25...1150 mV
Input resistance: approx. 120 Ω
Span: configurable within 0...20 mA
Scaling: -1999...9999

Control Input di1

Configurable as direct or inverse switch or push-button! Con-
nection of a potential-free contact suitable for switching „dry“
circuits.
Switched voltage: 2.5 V
Current: 50μA

Outputs
Output Used for
OUT1 and Control output heating/cooling or Open/Close,
OUT2 (re- limit contacts, alarms *
lay)
Inputs
OUT3 (re- as OUT1 and OUT2
Input Used for lays or log-
INP1 x (process value) ic)
INP2 Heating current, ext. set-point OUT3 Control output, process value, set-point, control
(continous) deviation, transmitter supply 13 V / 22 mA
di1 Operation disabled, switch-over to ... second
di2 (op- set-point SP.2, external set-point SP.E, fixed
tion) di3 output signal Y2, manual operation, controller * All logic signals can be OR-linked!
(option) off, disabled auto/manual key, reset stored
alarms, timer start
Relay Outputs OUT1, OUT2
Process value input INP1
Contact type: 2 NO contacts with common
Resolution: >14 bit connection
Decimal point: 0 to 3 decimal places Max. contact rating: 500 VA, 250 VAC, 2A at 48
...62 Hz, resistive load
Min. contact rating: 6 V, 1 mA AC/DC
Measured value correction: 2-point or offset correction
Duty cycles electric: for I = 1A/2A: 800,000 /

500,000 (at 250 V / (resistive
Current and voltage signals load))
Voltage: 0-10 Volt Note:
2.5...115 mV If the relays operate external contactors, these must be fit-
25...1150 mV ted with RC snubber circuits to manufacturer specifications
Current: 0-20 mA to prevent excessive switch-off voltage peaks.
4-20 mA
Start and end of span: anywhere withing the range
OUT3 as universal output
Scaling: -1999...9999
Decimal point: adjustable

698
Set-point functions
Galvanically isolated from the inputs.
• Adjustable set-point gradient 0.01...9999 °C/min
Freely scalable DA-converter 50 ms • Set-point control
limiting frequency T90:
• Set-point/cascade control
Limiting frequency of the >2 Hz
complete continuous con- • Program controller with 4 segments (set-point/section
troller: time)
Resolution: 11 bit Behaviour in case of sensor break or short circuit:
• Control outputs switched off
Current output • Switch-over to a safe output value
0/4...20 mA, configurable. • Switch-over to a mean output value
Signal range: 0...approx. 21.5 mA
Alarms and limit signalling functions
Load max.: ≤ 500 Ω
Control loop alarm
Load effect: 0.02% / 100 Ω
Automatic detection if there is no response of the pro-
Resolution: ≤ 22 μA (0.1%) cess to a change of output value.
Accuracy: ≤ 40 μA (0.2%) Sensor break or short circuit
Depending on selected input type, the input signal is
Voltage output monitored for break and short circuit.
0/2...10 V, configurable. Limit signalling
Signal range: 0...11 V Max., Min. or Max./Min. monitoring with adjustable hys-
teresis.
Load min.: ≥ 2 kΩ
Load effect: none
Signals which can be monitored:
• Process value
Resolution: ≤ 11 mV (0.1%)
• Control deviation
Accuracy: ≤ 20 mV (0.2%)
• Control deviation with suppression during start-up or
set-point changes
OUT3 used as transmitter supply • Effective set-point
Output: 22 mA/ ≥13 V • Actuating variable Y

Functions
OUT3 used as logic output
• Input signal monitoring
Load ≤ 500 Ω 0/ ≤ 20 mA
• Input signal monitoring with latch (reset via front key
Load >500 Ω 0/ >13 V or digital input)
OUT3 as relay output Several limit signals or alarms can be OR-linked before
being output. Applications: Release of a brake with mo-
Contact type: Potential-free changeover tor actuators, general alarms, etc.
contact
Max. contact rating: 500 VA, 250 VAC, 2A at 48 Maintenance manager
...62 HZ, resistive load Display of error signals, warnings, and stored limit mes-
sages in the error list. Signals are stored, and can be re-
Min. contact rating: 5 V, 10 mA AC/DC set manually. Possible signals in the error list:
Duty cycles electric: for I=1A/2A:1,000,000/ • Sensor break, short circuit, reversed polarity
600,000, resistive load
• Heating current alarm
Functions • Control loop alarm
Control behaviour • Fault during self-tuning
• Signaler with adjustable switching differential (ON/ • stored limit messages
OFF controller) • Re-calibration warning
• PID controller (2-point and continuous) • Maintenance interval of actuator
• Delta / Star / Off or 2-point controller with switch over • Internal fault (RAM, EEPROM, ...)
from partial to full load
• 2 x PID (heating/cooling, 3-point and continuous)
Technical information
• 3-point stepping controller Housing material
Makrolon 9415, flame retardant,
Self-tuning control parameters or adjustable manually Flammability class: UL94 VO, self-extinguishing
via front keys or BlueControl software.
Screw terminals for conductor cross-section from 0.5 to
2.5 mm²
699
Auxiliary energy Start conditions
Depending on version: • A stable condition is required for the evaluation of the
control process.. Therefore, the controller waits until
AC voltage
the process has reached a stable condition after self-
Voltage 90...260 VAC tuning start. The rest condition is considered being
Frequency 48...62 Hz reached, when the process value oscillation is smaller
than 0.5% of ([rnG.H]- [rnG.L]).
Power consumption approx. 7 VA
Start
Self-tuning start can be blocked via BlueControl Soft-
Universal supply 24 V UC ware.
The operator can start self-tuning at any time. For this,
AC voltage 20.4...26.4 VAC
keys [Enter] and [Up] must be pressed simultaneously
Frequency 48...62 Hz until the AdA LED starts blinking.
DC voltage 18...31 VDC Manual self-tuning
Power consumption approx. 7 VA (W) The optimization aid can be used with units on which
control parameters shall be without self-tuning.
Behaviour in case of power failure

Configuration, parameters, and adjusted set-points, control
mode: Non-volatile storage in EEPROM

Environmental conditions
Protection class
Front panel: IP 65
Housing: IP 20
Terminals: IP 00

Permissible temperatures
Operation: 0..60°C
Temperature effect: <100ppm/K
For operation: -20..65°C
For storage: -40..70°C

Humidity
75% yearly average, no condensation

Self-tuning
For determination of optimum process parameters, self-
tuning is possible.
After starting the controller makes an adaption attempt.
After starting the controller makes an adaption attempt,
whereby the process characteristics are used to calcu-
late the parameters for fast line-out to the set-point with-
out overshoot.
Preparation
• Adjust controller measuring range as control range
limits. [rnG-L] and [rnG.H ] to the limits of subsequent
control.
700
Adjustment aids
Parameter Control process Fault Start-up behaviour
[Pb1] higher increased damping slower line-out slower reduction of duty-cycle
[td1] higher reduced damping faster response to distur- faster reduction of duty cycle
bances
smaller increased damping slower response to distur- slower reduction of duty cycle
bances
[ti1] higher increased damping slower line-out slower reduction of duty-cycle
701
702
Fundamentals for Measurement and Control
Page

Georg Fischer Signet offers on-line information and assistance 705
Choosing Products
-- System Selection Guide 706
-- Features and Benefits 706
Systems
-- 4630 Chlorine Analyser System 711
-- 2630 Amperometric Chlorine Electrode 711
-- 2650 DryLoc® Amperometric Electronics 711
-- 8630 Chlorine Transmitter 711
-- 2750-7 pH Electronics 712
-- 4150 Turbidimeter 712
Dissolved Oxygen
-- 2610 Process Optical Dissolved Oxygen Sensor 713
Multi Parameter Instruments
-- 9900 SmartPro™ Transmitter 714
-- 8900 Multi-Parameter Controller 714
Flow
-- 515 Rotor-X Paddlewheel Flow Sensors 715
-- 525 Metalex Paddlewheel Flow Sensor 715
-- 2536 Rotor-X Paddlewheel Flow Sensors 715
-- 2537 Paddlewheel Flowmeter 715
-- 2540 Stainless Steel High Performance Paddlewheel Flow Sensor 716
-- 3519 Flow Wet-Tap Valve 716
-- 2551 Magmeter Flow Sensor 716
-- 2552 Metal Magmeter Flow Sensor 717
-- 2100 Turbine Flow Sensor 717
-- 2000 Micro Flow Rotor Sensor 717
-- 2507 Mini Flow Rotor Sensor 717
-- 5075 Totalising Flow Monitor 718
-- 5090 Sensor-Powered Flow Monitor 718
-- 5500 Flow Monitor 718
-- 5600 Batch Controller 718
-- 8150 Battery Powered Flow Totaliser 719
-- 8550 Flow Transmitters 719
pH/ORP
-- 2724-2726 DryLoc pH/ORP Electrodes 720
-- 2774-2777 DryLoc pH/ORP Electrodes 720
-- 2764-2767 Differential DryLoc pH/ORP Electrodes 720
-- 3719 pH/ORP Wet-Tap Assembly 721
-- 2750 DryLoc pH/ORP Sensor Electronics 721
-- 2760 DryLoc pH/ORP Preamplifiers and Connectors 721
-- 5700 pH/ORP Monitor 721
-- 8750 pH/ORP Transmitters 722
Conductivity/Resistivity
-- 2819-2823 Conductivity/Resistivity Electrodes 723
-- 2839-2842 Conductivity Electrodes 723
-- 2850 Conductivity/Resistivity Sensor Electronics and Integral Systems 723
-- 5800CR Conductivity/Resistivity Monitor 723
-- 5900 Salinity Monitor 724
-- 8850 Conductivity/Resistivity Transmitters 724
-- 8860 Two-Channel Conductivity/Resistivity Controllers 724
703
Page

Temperature/Pressure/Level
-- 2250 Submersible Hydrostatic Pressure Sensor 725
-- 2350 Temperature Sensor 725
-- 2450 Pressure Sensor 725
-- 8250 Level Transmitters 725
-- 8350 Temperature Transmitters 726
-- 8450 Pressure Transmitters 726
Other Products
-- 0251 PC COMM Configuration Tool 727
-- 0250 USB to Digital (S3L) Configuration/Diagnostic Tool 727
-- 6400 Intrinsic Safety Barriers 727
-- 7300 Switching Power Supplies 727
-- i-Go 8058 Signal Converter 727
-- 8059 External Relay Modules 727
Calibration Accessories
-- pH/ORP Buffer Solutions 729
-- Calibration Kits for 4150 Turbidimeter 729
-- Formazin Stock Kit for 4150 Turbidimeter 729
-- 2759 pH/ORP System Tester 729
-- Conductivity/Resistivity Tools 729
Installation
-- Installation of Turbidity 730
-- Installation of Flow Sensors 730
-- Installation of pH/ORP Electrodes 736
-- Installation of Conductivity/Resistivity Electrodes 738
-- Installation of Pressure/Level Sensors 739
-- Installation of Temperature Sensors 740
Wiring
-- Wiring Information: Turbidity 742
-- Wiring Information: Sensors & Electrodes 742
-- Wiring Information: Instruments 744
Technical Reference
-- Section: Flow 750
-- Section: pH/ORP 753
-- Section: Conductivity/Resistivity 756
-- Relay Information 758
-- Open collector output 758
-- Control Output Comparisons 760
-- RC Filter 760
-- Conversion Factors 761
-- Application Assistance Form 763
Operating Temperature & Pressure Graphs
-- Operating Temperature & Pressure Graphs: Flow Sensors 765
-- Pressure Drop Graphs: Flow Sensors 766
-- Operating Temperature & Pressure Graphs: pH/ORP Electrodes 767
-- Operating Temperature & Pressure Graphs: Conductivity Electrodes 767
-- Operating Temperature & Pressure Graphs: Temperature/Pressure Graphs 768
-- Operating Temperature & Pressure Graphs: Fittings 768
-- Backpressure Drop Graphs: Flow Sensors 769
Glossary 771
704
Fundamentals for Measurement
and Control
Georg Fischer Signet offers on-line information and assistance
Please visit our website at www.gfsignet.com for:

Product information – the “Products” link guides you
to the latest product details including data sheets and
manuals to assist in product selection, product installa-
tion, calibration and operations. Manuals are provided in
multiple languages.
The Signet Application Library – a collection of typ-
ical industry applications and processes with detailed
schematics, common measurement requirements and
Signet products to meet those needs.
Technical articles – A library of case studies, technical
product write-ups and application solutions, sorted by
technology and application
705
Choosing Products Features and Benefits
System Selection Guide Multi-Parameter Instruments
This section provides tips and suggestions on how to 9900 SmartPro™ Transmitter
choose just the right measurement system for your spe- • Multi-Parameter input selection
cific liquid application needs. For specific product infor-
• Large auto-sensing backlit display with “at a glance”
mation, refer to the individual catalog sheets.
visibility• “Dial-type” digital bar graph
Step 1: Determine Application Requirements • Intuitive and “user-friendly” interface consistent with
Defining the following variables before building your legacy Signet ProPoint® and ProcessPro® devices
system will ensure peak performance from your Signet • Optional field upgradable relays
sensors and instruments.
• Selectable error mode for current outputs, 3.6 mA or
• Measurement range
22 mA
• Installation requirements
• 4 to 20 mA input (with optional 8058 Signal Converter)
• Pipe size and material
• Warning LED indicator
• Chemical compatibility of all wetted parts to process
• Custom 13-character label capabilities for the channel
chemicals
type• Factory reset capability
• Systems specifications (such as temperature and
• Optional PC COMM configuration tool
pressure)
• Optional H COMM module for two-way communica-
• Performance requirements of sensor
tion
• Fluid particulates
• Viscosity of Fluids
• Hazardous location requirements
Step 2: Select Sensor Technology

Based on the application requirements determined in
Step 1, choose a sensor. For pH/ORP and Conductivi-
ty/Resistivity electrodes, select your preferred connec-
tion style. Keep in mind various connection types such
as cable or DryLoc systems. In addition, users may be
®
required to choose a preamplifier or sensor electronics.

Then, determine your signal output requirement to al-
low you to match just the right instrument (see Step 3).
If you’re not purchasing an instrument, select the sensor
electronics package that best suits your needs.
Step 3: Choose instrument
Choose an instrument. All units are available in 1/4 DIN 9900 SmartPro™ Transmitter
panel or field configuration and are available with either
digital, analog, or analog/digital display. Various retrofit
adapters and mounting accessories are also available
(see Accessories section). In cases where the sensor
feeds directly to a PLC or PC system, Signet offers a Chlorine
wide range of instruments and sensors with 4 to 20 mA Chlorine Analyser System
outputs.
• Reagent free measuring
Note: Please contact your local Georg Fischer sales • Complete panel system allows for quick and easy in-
and support office if you need assistance in choosing stallation.
any one of these products.
• Built-in flow regulator maintains constant flow and
Step 4: Determine Installation Requirements pressure to the sensors.
Signet offers a wide selection of installation fittings for • Panel includes a 100-240 VAC power supply, two 4 to
in-line pH/ORP electrodes. These fittings are specifical- 20 mA outputs and two mechanical relays.
ly designed to ensure the proper placement of the elec-
• Optional automatic pH and temperature compensa-
trode in the system to achieve optimum performance.
tion.
Other pH electrodes as well as all temperature, pres-
sure and conductivity/resistivity electrodes use standard
fittings. All submersion electrodes require conduit piping
and fixtures not supplied by Signet.
706
• Simple desiccant pouch keeps the measuring cham-
ber dry.
• Easy access for replacing desiccant.
• Standard EPA 180.1 for USA and Asia. ISO 7027 for
Europe.
• Quick and easy installation, calibration and mainte-
nance.
4150 Turbidimeter
Flow Sensors
Insertion Paddlewheel Sensors
• Four-bladed paddle design ensures optimal perfor-
mance and lower flow rates than five or six-bladed ro-
4630 Chlorine Analyser System tors that have a higher weight/bearing inertia.
Dissolved Oxygen • The open-cell design and the controlled insertion
depth work together to deliver a linear and repeatable
Process Optical Dissolved Oxygen Sensor output over a wide dynamic range, with virtually no
• Optical DO measurement no flow requirements pressure drop in the process pipe.
• Rugged construction • Choice of corrosive resistant plastics and rugged met-
• Calibration built into the measurement cap 2% of als enable use in many aggressive fluids.
range 0 to 20 mg/l • The widest choice of installation fitting materials, sizes
• One year measurement cap life and connections on the market that meet endless ap-
• No membranes or filling solutions plication needs.
• Flexibel communications, 4 to 20 mA or Modbus • Insertion design lowers installation and maintenance
(RS485) costs.
• Measurement Range: 0 to 20 mg/l • Self-powered sensors are well suited for remote loca-
tions and are FM approved which enable installation
in hazardous locations.
• Paddlewheel design has no pressure drop, making it
ideal for gravity flows.
• NIST traceable test certification with all plastic sen-
sors provides superior price-to-performance ratio.
• Hot-Tap designs are available to allow service and
maintenance without shutting-down the process;
saves costly downtime.
2610 Process Optical Dissolved Oxygen Sensor
Turbidity
Turbidimeter
• Simple to install with mounting holes pre-drilled on a
common pattern.
• Easy and fast to calibrate.
525
• Programmable analogue output signal. Metalex
Flow Sensor
• Two adjustable alarm relays.
• Easy access for wiring and maintenance.
2536
• Ultrasonic cleaning options ensures long and steady Paddlewheel
on-line measurement. Flow Sensor
707
Flow-Through Rotor Sensors • Rugged design with good chemi-cal resistance suit-
• Operating flow ranges from 110 mL/min to 12110 mL/ able for tough applications.
min (0.03 US gpm to 3.2 US gpm) in clean opaque • Analog 4 to 20 mA and frequency outputs provide sig-
or clear liquids ideal for precise low flow applications nals to remote flowmeters and data acquisition. Also
such as dosing. available with digital (S L) output for compatibility with
3
• Hall-effect devices provide excellent noise immunity multi-parameter transmitters and controllers.
output signals. • High input impedance provides low sensitivity to coat-
• Sensor body design allows easy access for cleaning, ing which makes it ideal for dirty liquids.
inspection and rotor replacement without the need for • Isolated outputs provide barrier to “ground loops”.
powering down.
• Flexibility with end connections allow flexible tubing or
rigid pipe installations.
• Four fully encapsulated magnets provide high resolu-
tion signal output.
2551 2552
Display Magmeter Metal Magmeter
Analytical Sensors and Electrodes

Standard pH and ORP Electrodes:
2507
Mini Flow Sensor • The amplified output ensures the process signal is re-
sistant to electrical noise and allows up to 120 m (400
In-line Turbine Sensors ft) before connection to the instrument.
• Small compact design for tightly-spaced installations.
• Longer reference path and larger reference volume
• Superior ceramic bearing provides long life without means extended service life.
the need for maintenance.
• Flat glass surface sensor design. Resistant to fouling
• Radio Frequency (RF) pick-up provides added advan- and abrasion in dirty applications, and prevents acci-
tage without rotor drag or contamination from ferrous dental damage to extend electrode life span.
particles.
• Unique DryLoc design enables pH and ORP connec-
®
• Detachable electronics means sensor maintenance is tions instantly.

possible without the need to cut power to unit.
• Designed to mount in standard Signet fittings or con-
• Composed of highly chemical resistant materials. nect to 3/4 in. standard fittings.
• Mounting at any angle offers total installation flexibili- • Option for blind 4 to 20 mA output or digital
ty. (S L) output for long cable runs.
3
• Wide choice of end connections in hose barb, flare or • Preamplifier does not need replacing with electrode
union ends. which significantly reduces service costs.
• Three flow ranges available for optimum measure-
ment resolution.
2100
Turbine Flow Sensor
Insertion Magnetic Sensors

• No moving parts means no fouling or reduced wear.
• Insertion design provides easier installation and re-
moval than full line magmeters.
• Model 2551 available to fit all pipe sizes ranging from
DN15 to DN900 (0.5 to 36 in.).
• Model 2552 Metal Magmeter available for pipe sizes
up to DN2550 (102 in.). Hot-Tap versions also avail-
able.
• Fluid diagnostics via LED indicators.
• Bi-directional flow and empty pipe detection.
708
2724-2726 2764-2767
pH/ORP Electrodes pH/ORP Electrode 2760
Sensor Electronics
2774-2777
pH/ORP Electrode Conductivity/Resistivity Electrodes:
• Flow-through design ensures continuous measure-
ment without air entrapment.
• Reversible threaded connections for in-line integral
mount or tank submersion.
• Standard parts offer application flexibility for the user.
• Short length electrodes available to prevent “dead-
legs”.
2750 • Blind 4 to 20 mA output or digital output for long cable
pH/ORP Sensor Electronics runs beyond 30 m (100 ft), via 2850 sensor electron-
ics.
Differential pH/ORP Electrodes: • Every sensor uses standard electrical cable. No need
• pH and reference signals are measured against third to incur additional costs for “patch” type cable connec-
electrode, a solution ground, to ensure a stable read- tions.
ing even when the smallest of unknown stray currents
• NIST calibration certificate available upon request.
are in the process liquids.
• The differential reference is designed to protect the
reference element from Br , I , CN , S and other harsh
- - - -
compounds that react with Ag . Also protects the ref-

+
erence electrolyte from Hg , Cu , Pb , ClO4 , or other

++ + + -
compounds that dilute KCl.

• Unique DryLoc design is robust and watertight, en-
®
suring rugged installation.

• Designed to mount in 1 in. standard pipe fittings for 2839-2842 Conductivity Elec-
easy installation. trodes
• The preamplified output ensures the process signal
2800
is resistant to electrical noise and allows up to 120 m Series Electrodes
(400 ft) before connection to the instrument.

• Option for blind 4 to 20 mA or digital (S L) signals for
3
long cable runs.

• Flat glass surface sensor design that is resistant to
fouling and abrasion in dirty applications.
• Large reference volume and replaceable salt bridge
allows the user to rebuild the reference and extend
the service life of the electrode.
2850
Sensor and Electronics
Temperature, Pressure and Level Sensors

Temperature Sensors:
• Unibody PVDF construction for use in either high puri-
ty or aggressive fluid conditions.
• 4 to 20 mA or digital (S L) signal for long cable runs
3
and choice of output.

• Dual threaded 3/4 in. NPT for easy installation.
709
• Options for integral mounting of instrument directly
onto sensor.
• Cable and thread permits conduit for full tank submer-
sion.
2250 Level Sensor
2350
Temperature Sensor
Pressure/Level Sensors:
• 1/2 in. male union process connection to suit installa-
tion needs.
• Three pressure ranges to meet specific requirements
and provide optimal resolution.
• 4 to 20 mA or digital (S L) signal for long cable runs
3
and choice of output.

• Unibody PVDF construction for aggressive fluid condi-
tions.
• Option for integral mounting of instrument directly on-
to sensor.
• Configure with 8350 transmitter or multi-parameter
transmitters or controllers to provide full level measur-
ing system (hydrostatic pressure).
• Cable end threads permit conduit for full tank submer-
sion.
2450 Pressure Sensor
710
Systems Signet’s patented DryLoc connector provides quick as-
®
sembly and a secure connection. Gold-plated contacts

4630 Chlorine Analyser System and an O-ring seal ensure a waterproof and reliable in-
terconnect to the Signet 2650 Amperometric Electron-
Description ics. The Signet 2630 Amperometric Chlorine Electrode
The Signet 4630 Chlorine Analyser System is an inte- has an integrated temperature element for automatic
grated all-in-one system designed to measure free chlo- temperature compensation.
rine. The 3-4630-21 chlorine panel with the optional
pH sensor is used to accurately calculate free chlorine Features
in applications that have varying pH values (±0.20 pH • Embedded memory chip accessible via the Signet
units). 8630 transmitter
In applications where the pH is stable, the pH sensor is • Quick assembly with Signet’s patented DryLoc con-®
not required and the pH value is manually entered into nector

the transmitter to calculate the chlorine levels. (-20 ver- • Integrated temperature element for automatic temper-
sion). ature compensation
The unique integrated clear flow cell combines sensors, • Separate drive electronics (Signet 2650), for easy
flow regulator, filter and variable area flow indicator in electrode replacement without running new cable
one compact unit. An integrated flow regulator with re-
movable filter accepts inlet pressures of 1 to 8 bar (15 2650 DryLoc® Amperometric Electronics
to 120 psi), while maintaining constant flow and minimal
pressure to the sensors. Description
The Signet 2650 Amperometric Electronics provide the
Water flows vertically into sensor tip eliminates bub- polarization voltage and signal conditioning required by
ble entrapment. The flow cell is designed to maintain a all Signet Amperometric Sensors. The 2760 Ampero-
minimum amount of water to ensure sensors stay sub- metric Electronics also relays important sensor informa-
merged, even when the system and flow is turned off. tion that is stored on a memory chip inside the sensor
The Signet 4630 Chlorine Analyser System allows quick and displayed on the 3-8630-3P transmitter. Information
setup and easy installation and is supplied with a 100- includes factory calibration data, service life, calibration
240 VAC power supply, two 4 to 20 mA outputs and information and more.
two dry contact mechanical relays. The flow cell accom- Signet’s patented DryLoc connector provides a quick
®
modates two sensors; one chlorine and an optional pH and secure connection to the sensor. Gold-plated con-
sensor. tacts and an O-ring seal ensure a waterproof and reli-
Features able interconnect to the sensor.
• EPA 334.0 compliant Sensor maintenance, replacement and troubleshooting
• Reagent free measuring has never been easier. The DryLoc electronics can be
• Complete panel system allows for quick and easy in- separated from the sensor, which allows the user to de-
stallation tect a faulty sensor, electronics or cable assembly.
• Built-in flow regulator maintains contant flow and pres- Features
sure to the sensors regardless of inlet pressure • Passes the data stored in sensor to the Chlorine
• Pre-wired panel includes a 100-240 VAC power sup- transmitter
ply, two 4 to 20 mA outputs and two mechanical re- • Patented DryLoc connector provides a quick and se-
®
lays. cure connection to the sensor

• Optional automatic pH and temperature compensation • Waterproof and reliable interconnect to the sensor
• Easy sensor replacement without running new cable
2630 Amperometric Chlorine Electrode • Easy sensor removal for servicing
Description
The Signet 2630 Amperometric Chlorine electrode is 8630 Chlorine Transmitter
designed to measure free chlorine in drinking water and
Description
wastewater treatment applications. The electrodes are
The Signet 3-8630-3P ProcessPro Chlorine Transmitter
available with a measurement range of 0 to 5 ppm. This
simultaneously displays free chlorine and pH levels on a
electrode requires the Signet 2650 Amperometric Elec-
bright LCD backlight display.
tronics module to communicate with the Signet 8630-3
Chlorine Transmitter. The 8630 transmitter has two 4 to 20 mA outputs that
can be programed to transmit chlorine, pH or tempera-
Utilizing smart-sensor technology, this electrode has a
ture information to a data collection device.
unique embedded memory chip and can communicate a
wide variety of information to the Signet 2650 electron- Two dry-contact mechanical relays can be used to deliv-
ics and Signet 8630-3 Transmitter. er an alarm signal or activate a chlorine dosing system.
Displayed information includes electrode type, factory Programming is simple and easy with Signet’s standard
calibration data, service time, chlorine range, high and 4 button keypad. The menu option allows the use ofan
low pH (with optional Signet pH electrode), temperature optional pH sensor to accurately calculate free chlorine
values and more. level or select “Manual pH input” and enterthe applica-
tions stable pH level to determine free chlorine levels.
711
Features The 4150 is available in two measuring ranges. The 0 to
• Displays free chlorine 0 to 5 ppm (mg/l) 100 NTU/FNU version is for low range applications such
as drinking water. The 0 to 1000 NTU/FNU range can
• Two programmable 4 to 20 mA outputs
be used for various applications including raw water and
• Two mechanical relays wastewater reclamation.
• Temperature and pH Compensation
Features
• Displays diagnostic information from sensor memory
• Simple and easy single unit installation with built-in
• Simple setup and easy customization pressure regulator
• Backlit LCD display • Versions compliant with either U.S. EPA 180.1 for
North and South America and Asia or ISO 7027 for
2750-7 pH Electronics Europe
• Time saving and efficiencies of cuvette technology
Description simplifies calibration
The Signet 2750-7 pH Electronics amplify the output
from the Signet 2724 pH Electrode and output a Digital • Spannable 4 to 20 mA output
(S L) signal to the Signet 8630 Chlorine Transmitter.
3
• Two adjustable alarm relays Bright backlit display
Signet’s patented DryLoc connector provides a quick
® • Convenient holder for In-line cuvette
and secure connection to the sensor. Gold-plated con- • Easy access for wiring and maintenance
tacts and an O-ring seal ensure a waterproof and reli- • Ultrasonic cleaning option ensures long and steady
able interconnect to the sensor. on-line measurement
Sensor maintenance, replacement and troubleshooting • Inexpensive standards allow for multiple system cali-
has never been easier. The DryLoc electronics can be brations
separated from the sensor, which allows the user to de-
tect a faulty sensor, electronics or cable assembly.
Features
• Amplifies the output from the pH electrode to the
Chlorine transmitter
• Patented DryLoc connector provides a quick and se-
®
cure connection to the sensor

• Waterproof and reliable interconnect to the sensor
• Easy sensor replacement without running new cable
• Easy sensor removal for servicing
4150 Turbidimeter
Description
The Signet 4150 Turbidimeter system provides accurate
and reliable compliant water quality monitoring for mu-
nicipal and industrial applications.
The 4150 measures turbidity via a 90 degree light which
reflects particles as they flow through a small volume,
low flow glass cuvette. Air bubbles are eliminated from
the cuvette by adjusting the backpressure valve on the
outlet tube. The cuvette islocated in a watertight dark
chamber for continuously accurate on-line measure-
ment. A replaceable desiccantpack provides a dry-sta-
ble environment to ensure reliable measurements.
Simple and fast calibration can be accomplished in un-
der five minutes by placing the In-line glass cuvettefrom
the measuring chamber into the cuvette holder while
still in service and the inlet and outlet tubing remains
connected. The inexpensive calibrationstandard allows
for dry and multiple system calibrations without mixing
chemicals. After calibration, the unit isup and running
with simple re-insertion of the glass cuvette back into
the measuring chamber.
Additional features include a message indicator when
the desiccant needs replacing and as an option, auto/
ultrasonic cleaning of the glass Inline cuvette for longer
runs between maintenance.
712
Dissolved Oxygen
2610 Process Optical Dissolved Oxygen
Sensor
Description
The Signet 2610 RDO® Pro is a rugged, reliable sensor
designed to deliver accurate dissolved oxygen (DO) da-
ta across a wide measuring range while reducing main-
tenance costs. It features the latest optical technology
for DO measurement and eliminates the replacement of
membrane and reference solutions.
The Signet 2610 optical sensor cap is calibrated at the
factory and requires no field calibration. The optical
measurement technology resists abrasion and bleach-
ing allowing for a long life in many harsh applications.
The DO sensor has a built in Modbus RS485 and 4 to
20 mA current loop outputs for ease of interface to exist-
ing control systems. Additional features include a 10 m
(32.8 ft) cable with stripped and tinned ends as well as a
titanium thermistor for improved compatibility in salt wa-
ter applications.
Features
• Optical DO measurement no flow requirements
• Rugged construction
• Calibration built into the measurement cap 2% of
range 0 to 20 mg/l
• One year measurement cap life
• No membranes of filling solutions
• Flexible communications, 4 to 20 mA or Modbus
(RS485)
• Measurement Range: 0 to 20 mg/l
713
Multi Parameter Instruments If more features are needed, analogue output and re-
lay modules are available and easily installed. Plus, the
9900 SmartPro™ Transmitter 8900 will support up to four additional relays via an ex-
ternal relay module.
Description
The Signet 9900 Transmitter provides a single channel There are other notable features that the 8900 offers.
interface for many different parameters including Flow, For instance, digital input to the 8900 enables longer
pH/ORP, Conductivity/Resistivity, Salinity, Pressure, cable runs and simplified wiring with minimal noise in-
Temperature, Level and other sensors that output a 4 to terference. Advanced relay logic allows users to select
20 mA signal. The extra large (3.90” x 3.90”) auto-sens- up to 3 measurement sources to trigger 1 relay. De-
ing backlit display features “at-a-glance” visibility that rived measurements include difference, sum, ratio, per-
can be viewed at 4-5 times the distance over tradition- cent recovery, percent rejection, percent passage and
al transmitters. The highly illuminated display and large BTU. The menu system can be programmed to display
characters reduce the risk of misreading or misinterpret- in multi-languages including English, German, French,
ing the displayed values. The display shows separate Spanish, Italian and Portuguese.
lines for units, main and secondary measurements as Features
well as a "dial-type" digital bar graph.
• Measures Flow, pH, ORP, Conductivity, Pressure,
The 9900 is offered in both panel or field mount ver- Level and Temperature
sions. Both configurations can run on 12 to 32 VDC • Multi-language display
power (24 VDC nominal). The 9900 can also be loop
• ¼ DIN enclosure
powered with compatible sensors.
• Up to 4 analogue outputs
Designed for complete flexibility, plug-in modulesal-
• Up to 8 relays
low the unit to easily adapt to meet changingcustomer
needs. Optional modules include Relay,Direct Conduc- • 12 to 24 VDC or 100 to 240 VAC ±10%, regulated
tivity/Resistivity, H COMM and a PCCOMM configura- power
tion tool. The unit can be used withdefault values for • Digital communication allows for extended cable
quick and easy programming or canbe customised with lengths and easy wiring
labelling, adjustable minimumand maximum dial set- • Accepts 3rd party 4 to 20 mA output devices when
tings, and unit and decimalmeasurement choices. used with 8058 signal converter
Features • Available with 1 to 6 channels
• Multi-Parameter input selection • Two BTU calculations
• Large auto-sensing backlit display with “at a glance”
visibility
• “Dial-type” digital bar graph
• Intuitive and “user-friendly” interface consistent with
legacy Signet ProPoint and ProcessPro devices
® ®
• Optional field upgradable relays

• Selectable error mode for current outputs,3.6 mA or
22 mA
• 4 to 20 mA input (with optional 8058 SignalConverter)
• Warning LED indicator
• Custom 13-character label capabilities for the channel
type
• Factory reset capability
• Optional PC COMM configuration tool
• Optional H COMM module for two-waycommunication
8900 Multi-Parameter Controller

Description
The Signet 8900 Multi-Parameter Controller takes the
concept of modularity to the extreme. Each 8900 is field
commissioned with the users specified combination of
inputs, outputs, and relays using simple-to-install modu-
lar boards into the base unit.
Configure the system selecting either two, four or six in-
put channels which accepts any of the Signet sensors
and/or other manufacturer's sensors via a 4 to 20 mA
signal converter (Signet Model 8058). To complete your
unit, choose a power module with universal AC line volt-
age or 12 to 24 VDC ±10%, regulated.
714
Flow • FM approved
• Operating range 0.5 to 6 m/s (1.6 to 20 ft/s)
515 Rotor-X Paddlewheel Flow Sensors
Description 2536 Rotor-X Paddlewheel Flow Sensors
Simple to install with time-honored reliable performance,
Description
Signet 515 rotor-X Paddlewheel Flow Sensors are high-
Simple to install with time-honored reliable performance,
ly repeatable, rugged sensors that offer exceptional val-
Signet 2536 Rotor-X Paddlewheel Flow Sensors are
ue with little or no maintenance. The output signal of the
highly repeatable, rugged sensors that offer exception-
Model 515 is a sinusoidal frequency capable of driving
al value with little or no maintenance. The Model 2536
a self-powered flowmeter (Model 3-5090). The wide dy-
has a process-ready open collector signal with a wide
namic flow range of 0.3 to 6 m/s (1 to 20 ft/s) allows the
dynamic flow range of 0.1 to 6 m/s (0.3 to 20 ft/s). The
sensor to measure liquid flow rates in full pipes and can
sensor measures liquid flow rates in full pipes and can
be used in low pressure systems.
be used in low pressure systems.
The Model 515 sensors are offered in a variety of ma-
The Signet 2536 sensors are offered in a variety of ma-
terials for a wide range of pipe sizes and insertion con-
terials for a wide range of pipe sizes and insertion con-
figurations. The many material choices including PP
figurations. The many material choices including PP and
and PVDF make this model highly versatile and chemi-
PVDF make this model highly versatile and chemical-
cally compatible to many liquid process solutions. Sen-
ly compatible to many liquid process solutions. Sensors
sors can be installed in up to DN900 (36 in.) pipes using
can be installed in DN15 to DN900 (½ to 36 in.) pipes
Signet's comprehensive line of custom fittings. These
using Signet’s comprehensive line of custom fittings.
custom fittings, which include tees, saddles, and weldo-
These custom fittings, which include tees, saddles, and
lets, seat the sensor to the proper insertion depth into
weldolets, seat the sensor to the proper insertion depth
the process flow. The sensors are also offered in config-
into the process flow. The sensors are also offered in
urations for wet-tap and intrinsically safe installation re-
configurations for wet-tap installation requirements.
quirements.
Features Features
• Operating range 0.3 to 6 m/s (1 to 20 ft/s)
• Wide turndown ratio of 66:1
• Wide turndown ratio of 20:1
• Open-collector output
• Highly repeatable output
• Simple, economical design
• Simple, economical design
• Highly repeatable output
• Installs into pipe sizes DN15 to DN900 (½ to 36 in.)
• Installs into pipe sizes DN15 to DN900 (½ to 36 in.)
• Self-powered/no external power required
• High resolution and noise immunity
• Test certificate included for -X0, -X1
• Test certificate included for -X0, -X1
• Chemically resistant materials
• Chemically resistant materials
525 Metalex Paddlewheel Flow Sensor
2537 Paddlewheel Flowmeter
Description
The Signet 525 Metalex Paddlewheel Flow Sensor com- Description
bines stainless steel construction with insertion paddle- The Signet 2537 Flowmeter is the next generation in
wheel technology. The result is a highly reliable sensor fluid measurement technology from the inventor of the
suitable for operation at extreme pressures and temper- original paddlewheel flowmeter. This sensor is an im-
atures. The Tungsten Carbide shaft and rulon B (Flu- provement on what’s already an industry standard. It
oroloy B/PTFE) bearing provide excellent wear resis- has the added functionality of various output options in-
tance for extended service. cluding flow switch, multi-functional pulse, digital (S L)
3
or 4 to 20 mA. Additionally, it offers low flow, low pow-

A comprehensive fitting program allows installation in er and high resolution and can be configured on-site di-
stell lines with the mini-block for small diameters, and rectly through the built-in user interface.
either the mini-tap or saddle for pipes up to DN300 (12
in.). The self-generating output signal allows use with Installation is simple because the Signet 2537 utilizes
the battery operated flow totaliser 8150. the same fittings as the popular Signet 515 and 2536
Paddlewheel Sensors and fits into pipe sizes rang-
Features ing from DN15 to DN200 (½ to 8 inches). Available in
• For up to 103 bar (1500 psi @ safety factor 1.5) pres- Polypropylene and PVDF, it is ideal for a variety of ap-
sure plications including chemical processing, water and
• For up to 149 °C (300 °F) temperatures wastewater monitoring and scrubber control.
• DN15 to DN300 (½ to 12 in.) pipe range Features
• Simple installation • Digital (S L), or 4 to 20 mA outputs or Flow Switch or
3
• Self-powered/no external power required Pulse output (multi-function)

• 316 SS body (1.4401) • Allows for up to six sensors to Signet 8900 Multi-Pa-
rameter Controller
• Tungsten Carbide or SS shaft
• Low flow capabilities down to 0.1 m/s (0.3 ft/s)
• 7.6 m (25 ft) cable include
715
• Polypropylene or PVDF sensor bodies • Rugged corrosion resistant PVC construction and
• Installs into pipe sizes DN15 to DN200 (½ to 8 in.) stainless steel hardware
• Test certificate included for -X0, -X1 • Compatible with Signet 515 or 2536 Rotor-X Wet-Tap
Flow Sensors
• Low power and high resolution
• Eliminates process downtime
2540 Stainless Steel High Performance
Paddlewheel Flow Sensor 2551 Magmeter Flow Sensor
Description Description
The Signet 2540 Paddlewheel Flow Sensor offers the The Signet 2551 Magmeter is an insertion style mag-
strength and corrosion resistance of stainless steel for netic flow sensor that features no moving parts. The
liquid applications with low velocity measurements. patented* sensor design is available in corrosion-resis-
Unique internal circuitry eliminates the need for mag- tant materials to provide long-term reliabilitywith min-
nets in the process fluid, enabling flow measurement of imal maintenance costs. Material options include PP
0.1 to 6 m/s (0.3 to 20 ft/s) while maintaining the advan- with stainless steel, PVDF with stainless steel, PVDF
tages of insertion sensor design. Rulon® B (Fluoroloy with Hastelloy-C, or PVDF with Titanium.Utilizing the
B/PTFE) bearings and Tungsten Carbide pin provide comprehensive line of Signet installation fittings, sen-
exceptional wear resistance. sor alignment and insertion depth is automatic. These
versatile, simple-to-install sensorsdeliver accurate flow
The Signet 2540 offers field replaceable electronics and measurement over a wide dynamic range in pipe sizes
transient voltage suppression (TVS) to providegreater ranging from DN15 to DN900 (½ to 36 inches), satisfy-
immunity to large voltage disturbances (i.e. lightning) ing the requirements of many diverse applications.
sometimes encountered in field wiring. Sensors can be
installed in DN40 to DN600 (1½ to 24inch) pipes using Signet 2551 Magmeters offer many output options of
the 1½ inch or ISO 7/1-R 1.5 threaded process connec- frequency/digital (S L) or 4 to 20 mA which are available
3
tion. The sensors are also offered in a hot-tap configu- on both the blind and display versions. The frequency
ration with a bleed valve service without process shut- or digital (S L) sensor output can be used with Signet’s
3
down in pipes up toDN900 (36 in.). Both styles of sen- extensive line of flow instruments while the 4 to 20 mA
sors must be used in full pipes and can be used in low output can be used for a direct input to PLCs, chart
pressure systems. recorders, etc. Both the 4 to 20 mA output and digital
(S L) sensor interface is available for long distance sig-
3
Features nal transmission. An additional benefit is the empty pipe

• Operating range 0.1 to 6 m/s (0.3 to 20 ft/s) detection which features a zero flow output when the
• Field replaceable electronics sensors are not completely wetted. Also, the frequency
output is bi-directional while the 4 to 20 mA output can
• Non-magnetic RF detection
be set for uni- or bidirectional flow using the display or
• Standard NPT or ISO process connections the 3-0250 USB to Digital (S L) Configuration/Diagnostic
3
• Hot-tap versions for installation/service without sys- setup tool which connects to PCs for programming ca-
tem shutdown pabilities.
• For pipe sizes up to DN900 (36 in.) In addition the display version of the 2551 Magmeter is
• Adjustable sensor-one size for entire pipe range available with relays and features permanent and reset-
• 7.6 m (25 ft) cable table totalizer values which can be stored andseen on
the display. Also, the display contains multi-languages
with English, Spanish, German, French, Italian and Por-
3519 Flow Wet-Tap Valve tuguese menu options.
Description Features
The Signet 3519 Flow Wet-Tap Valve serves as a • Test certificate included for -X0, -X1, -X2
unique interface between the installation fitting and the
wet-tap style Signet 515 or 2536 Rotor-X flow sensor. It • Patented Magmeter technology
provides a fast method of removing the sensor from the • No moving parts
pipe under specified operating pressures. The PVC and • Bi-directional flow
stainless steel design of the Wet-Tap makes it resistant • Empty pipe detection
to corrosion and chemical attack by acids, alkalies, salt,
and a number of other harsh chemicals. • Installs into pipe sizes DN15 to DN900 (0.5 to 36 in.)
The Signet 3519 Wet-Tap Valve mounts directly onto
standard Signet installation fittings. The 3519 Wet-Tap • Accurate measurement even in dirty liquids
consists of a flange and support plate that threadson- • Blind 4 to 20 mA, digital/frequency, relay output
to the pipe fitting insert, and a PVC ball valve through • No pressure drop corrosion resistant materials; PP or
which an extended length sensor is inserted into the PVDF with SS, Hasteloy-C or Titanium
pipe. • Multi-language display menu available
Features
• Allows sensor removal without process shutdown
• Pressure release valve for safe sensor removal
• Dual safety lanyards
716
• PVDF & ceramic wetted parts provide superior
2552 Metal Magmeter Flow Sensor chemical compatibility
Description • For use with both clear and opaque fluids
The Signet 2552 Metal Magmeter from Georg Fisch- • Small and compact design
er features all-stainless steel construction. The PVDF
• 4.6 m (15 ft) cable
nosepiece and FPM O-rings are the only other wetted
materials. The 2552 installs quickly into standard 1¼ in. • Features removable electronics that installs fron either
or 1½ in. pipe outlets, and is adjustable to fit pipes from side of the sensor
DN50 to DN2550 (2 to 102 inches). Two sensor lengths • Sensor mounts at any angle
allow maximum flexibility to accommodate a variety of
hardware configurations, including ball valves for hot-
tap installations.
2000 Micro Flow Rotor Sensor
Description
When equipped with the frequency output, the 2552
The Signet 2000 Micro Flow Rotor Sensor is construct-
is compatible with any externally powered Signet flow
ed of Polyphenylene Sulfide (PPS) which provides high
instrument, while the digital (S L) output enables mul-
3
material strength. The 2000 offers twoflow ranges start-

ti-channel compatibility with the Signet 8900 Multi-Pa-
ing at 0.11 or 1.13 lpm (0.03 or 0.3 gpm), for clean pro-
rameter Controller. Select the blind 4 to 20 mA current
cess liquids, regardless of fluid color or opacity.
output to interface directly with dataloggers, PLCs or
telemetry systems. Key features include Empty Pipe This sensor can be connected to flexible tubing or rigid
Detection, LED-assisted troubleshooting, and bi-direc- pipe, and uses standard hardware for mounting. On-
tional span capability (in 4 to 20 mA models). lyone moving part and a low pressure drop across the
sensor reduces operating costs and maintenancere-
The Signet 3-0250 USB to Digital (S L)Configuration/
3
quirements.
Diagnostic Tool is available to customize every perfor-
mance feature in the 2552 so it can be adapted to the Features
user’s application requirements. • Operating range 0.11 to 12.11 lpm (0.03 to 3.2 U.S.
Features gpm)
• Test certificate included • Simple mounting
• Award winning hot-tap magnetic flow sensor up to • ¼ in. NPT or ISO threads for simple pipe or tubing
DN2550 (102 in.) connection
• Patented Magmeter technology • Measures opaque and transparent liquids
• Operating range 0.05 to 10 m/s (0.15 to 33 ft/s) • Low pressure drop
• reliable operation in harsh environments • Standard cable 7.6 m (25 ft)
• Repeatable: ±0.5% of reading @ 25 °C
• Three output options: 4 to 20 mA, Frequency, Digial 2507 Mini Flow Rotor Sensor
(S L)
3
Description
• ISO or NPT threads The Signet 2507 Mini Flow Rotor Sensor contains a
free-running rotor that is driven by the fluid flow.Within
the given measurement range, the rotational speed of
2100 Turbine Flow Sensor
the rotor is proportional to the fluid flow rate.
Description
Magnets built into the rotor trigger an electronic switch
Engineered specifically for small pipe diameter applica-
in the top of the sensor creating a square-wave output.
tions, the Signet 2100 Turbine Flow Sensor provides ac-
Both opaque and transparent fluids can be measured
curate readings in two flow ranges: 0.3 to 3.8 lpm and 3
with kinematic viscosities between 0.2 to 20.0 centis-
to 38 lpm (0.1 to 1 gpm and 0.8 to 10 gpm).
tokes.
The injection-molded PVDF body and ceramic bearings
Features
provide excellent chemical compatibility and long ser-
vice in dosing and batching applications. Union piping • Operating range 400 to 12,000 ml/m (0.1 to 3.2
and tubing connections along with removable NEMA 4X U.S.gpm)
electronics allow for easy assembly and field replace- • Detachable signal connector for easy servicing
ability. The 2100 can be used with DN8 (¼ in.), DN10 • Simple installation with a G ¼ in. (¼ in. NPT) threaded
(3/8 in.), DN15 (½ in.) tubing, or DN15 (½ in.) piping connection
for simple installation. End connections are available in
• Standard 7.6 m (25 ft) cable
PVDF for hose barbs, fusion socket or IR/butt fusion,
and in PVC for socket or NPT thread. • PVDF construction
• Compact assembly
Features
• Operating range of 0.38 to 38 lpm (0.10 to 10 U.S.
gpm)
• Non-magnetic turbine
• Union ends for various connector types
• End connector kits for rigid or flexible tubing or DN15
(½ in.) pipe
717
Connect any one of Signet’s wide array of flow sensors,
5075 Totalising Flow Monitor then consider which output features are best for your
Description application.
The Signet 5075 Totalizing Flow Monitor features a tra- Two dry-contact relays can be configured for High or
ditional analog dial for flow rate at a glance while the Low alarm operation, or they can be set to pulse opera-
backlit LCD provides precision flow rate, total volume tion for chemical dosing applications.
and programming information.
Use the internally powered 4 to 20 mA output, pro-
Significant features of this 5075 include user selectable grammable from the front keypad, to send the flow infor-
analog dials, permanent and resettable totalizers and mation to any PLC or data logger.
pulse outputs at sensor frequency and at totalizer scale,
The 5075 is powered by virtually any 12 to 24 VDC or If you use all of these output features, you still have two
VAC ±10%, regulated power source. more output pulse terminals, one at sensor frequency,
the other triggered by the totalizer. And just for added
Connect to any of Signet’s flow sensors for a classic convenience, the resettable totalizer can be reset by a
flow meter system. remote hardwired switch, up to 30 m (100 ft), or fromthe
Features front keypad.
• Permanent and resettable totalizers Features
• Tamper proof security code • Permanent and resettable totalizers
• Non-volatile memory • Two programmable relays
• Simple push-button operation • Fully scaleable active (internally powered) 4 to 20 mA
• Pulse outputs at sensor frequency and at total volume output
• 1/4 DIN, NEMA 4X/IP65 • Tamper proof security code
• Remote totalizer reset • Non-volatile memory
• Intuitive software design
5090 Sensor-Powered Flow Monitor • Programmable pulse outputs
Description
The Signet 5090 Sensor Powered Flow Monitor is the 5600 Batch Controller
simplest and most economical instrument in the Signet Description
offering. It features a balanced-spring meter movement The Signet 5600 Batch Controller provides control capa-
that is powered by the AC output of the Signet 515 Pad- bility and process fine-tuning in a familiar package. The
dlewheel Flow Sensor. No additional power sourceis re- programming interface uses a four-button keypad and
quired. an intuitive procedure for adjusting a batching system to
This unique system is suitable for a wide range of flow the best performance possible.
rates, and is Factory Mutual (FM) approved for intrin- The standard ¼ DIN package houses an analog dis-
sic safety without the need for barriers. Packaged in a¼ play panel that features a batch status indicator with
DIN housing with a NEMA 4X/IP65 front panel, the 5090 count-up or countdown dials. The backlit LCD displays
is the first choice for simple flow monitoring, even in the flowrate and volume information and batch status, as
most demanding industrial environments. well as calibration and setup instructions. The front of
Features the unit is NEMA 4X/IP65 and is hard-coated, high-im-
pactand UV resistant polycarbonate.
• High visibility analog display
• Sensor-powered flow rate indication up to 60 m (200 The 5600 operates on 12 to 24 volts ±10%, regulated,
ft) from sensor installation either AC or DC. Removable terminal connections make
wiring the 5600 easy. Connect any Signet flow sensor
• Wide flow range: 1 to 20 ft/s in pipe sizes DN15 to
with a frequency output, then add connections to two re-
D900 (½ to 36 in.)
lays for two-stage shutdown or overrun alarm functions,
• Single-point calibration from front panel connect a remote start-stop switch anduse the end-of-
• Factory Mutual (FM) approved for intrinsic safety in batch pulse to trigger the next step in the process. A 4
Classes I, II and III, Division I to 20 mA output is also available. Advanced features in-
clude a user-set security code,an automatic calibration
option, and overrun compensation.
5500 Flow Monitor
Features
Description
The Signet 5500 Flow Monitor is an instrument that • Permanent and resettable totalizers
comes fully equipped with all of the basic tools needed • Non-volatile memory
for monitoring and controlling a flow system. The analog • Easy batch volume entry
dial enables the user to easily read instantaneous flow
• Remote start, stop & resume
rate, while the backlit LCD is useful for calibration, set-
up, and displaying totalized flow volume. The 5500 fea- • Two-stage shutdown control
tures a standard ¼ DIN package and removable wiring • Manual or automatic overrun compensation
terminals. Power the instrument with virtually any stan- • Estimates time to batch completion
dard 24-volt power supply (AC or DC).
• Overrun alarm and missing signal alarm
718
• Advanced valve control • NEMA 4X enclosure with self-healing window
• End-of-batch trigger • Output simulation for complete system testing
• Count-up or count-down to batch completion
8150 Battery Powered Flow Totaliser

Descripton
The Signet 8150 Battery Operated Flow Totaliser is
compatible with the Signet 515 and 525 flow sensors,
and will provide years of dependable operation. The
large digital display indicates flow rate and totalised flow
volume simultaneously. One of the three totalisers is re-
settable from the front panel or a remote location, while
the second resettable totaliser can only be reset by en-
tering a user-selectable security code. The third is a
permanent non-resettable totaliser.
Our intuitive software design and four-button keypad
provide for simple operation while setting screen dis-
plays and programming the system. Calibrationcan be
easily performed by entering the Auto-Cal feature and
entering a value to match an external reference. Screen
displays can be modified to suit theuser’s needs; along
with the flow rate, any of the three totalisers can be se-
lected as the displayed totaliser. Customers can quick-
ly scroll through the totaliserssimply by pressing any key
on the keypad. A display averaging feature is included
for applications where the flow in the pipe fluctuates.
For applications where flowstops and starts due to pro-
duction needs, a no-flow indicator will display the hours
of non-flow.
Features
• Three totalizers: 2 resettable and 1 permanent, user
selectable
• Long-lasting lithium batteries
• Mounting versatility
• No-flow indicator
• Large digital display with averaging
• Simple push-button operation
• User selectable access code prevents unwanted
changes
• Auto-calibration
8550 Flow Transmitters

Description
Signet 8550 Flow Transmitters are advanced instru-
ments that convert the signal from frequency and digi-
tal (S L) flow sensors into a 4 to 20 mA signal for long
3
distance transmission. Configuration flexibility is maxi-

mized with single or dual input/output, two optional re-
lays for process control, two packaging options for inte-
gral/pipe mount or panel installation, and scalability for
virtually any flow range or engineering unit. State-of-the-
art electronic design ensures long-term reliability, signal
stability, and simple user setup and operation.
Features
• 2 or 4 wire power
• Available with single or dual input/output
• 4 to 20 mA scaleable outputs
• Permanent & resettable totalizers
• Relay options available
719
pH/ORP ing ions such as Copper (CU++), Lead (Pb++), Mercury
(Hg++), and a large reference chamber that combine to
2724-2726 DryLoc pH/ORP Electrodes extend the service-life.
Description Embedded positioning of the temperature element in
The Signet 2724-2726 pH and ORP Electrodes features the pH sensing tip allows, the temperature response to
a patented reference electrode design and uses the be quick and accurate. The electrodes are offered with-
unique foul-proof patented DryLoc connector. The large
® either flat or bulb style sensing elements. The flat ver-
area PE reference junction and pathway is construct- sions allow sediment and particles to sweep past the
ed to increase the total reference effectiveness and en- measurement surface, minimizing risks of abrasion,
sures long service life. breakage and coating. The bulb versions can be used
for general-purpose applications. Due to the specially
The DryLoc® connector with corrosion resistant gold designed chambers which keep electrolyte in place,all
plated contacts readily connects the sensor to the mat- versions can be installed at any angle, even inverted.
ing 2760 preamplifier or the 2750 sensor electronics.
The robust Ryton® threaded sensor body and choice of Features
flat pH, bulb pH, or flat ORP sensing elements provides • Durable DryLoc connector with gold plated contacts
®
broad range of chemical compatibility for a wide variety • Special design allows for installation at any angle,
of applications. even inverted
There are two optional pH sensing versions available, • Quick temperature response
HF and LC. The HF version is for applications where • Easy sensor replacement using DryLoc electrode
®
traces of hydrofluoric acid (2% or less) will attack stan- connector

dard pH glass in levels of pH 6 and below. The LC ver-
• High temperature versions available
sion can be used for low conductivity fluids 20 - 100 μS/
cm nominal and below 20 μS when mounted under con- • Mounts into standard ¾ inch threads
trolled conditions. • Compatible with all pH/ORP and other suppliers’ in-
struments
The quick temperature response is available in either a
PT1000 or 3 KΩ temperature sensor and allows com-
patibility with all Signet pH/ORP instruments. The 2724- 2764-2767 Differential DryLoc pH/ORP Elec-
2726 electrodes are general-purpose sensors ideal for trodes
a wide range of applications. The sensors incorporate
¾ inch NPT or ISO 7/1-R 3/4 threads for installing into Description
standard pipetees. They can also be mounted directly The Signet 2764-2767 Differential pH & ORP electrodes
into Signet standard fittings, DN15 to System Overview are built with the DryLoc connector, a Ryton body, and
® ®
DN100 (½ to 4 inch). PTFE reference junction to handle the most extreme

and harshest of chemical applications.
Features
These differential electrodes use a fieldproven 3-elec-
• Patented DryLoc connector with gold plated contacts
®
trode differential technique: the pH and reference elec-

• Mounts in Signet standard fittings from DN15 to trodes are measured against a ground electrode, insur-
DN100 (½ to 4 in.) ing a steady and stable signal. A key feature is the ref-
• ¾” NPT or ISO 7/1-R 3/4 threaded sensors for use erence electrode, which is housed in a glass half-cell
with reducing tees DN15 to DN100 (½ to 4 in.) embedded in the reference chamber and is protected
• Special design allows for installation at any angle, from compounds that may contain sulfides (S2-) and
even inverted or horizontal metals. To ensure long service life, the reference fea-
tures a refillable electrolyte chamber and a replaceable
• Ryton (PPS) body for broad range of chemical com-
®
equitransferant salt bridge, both easily serviced in the

patibility field. The patented porous PTFE reference junction re-
• Patented reference design for exceptional perfor- sists fouling, clogging and chemical attack.
mance
Other elements of the design are the solution ground,
• Quick temperature response the pH/ORP electrodes, and the temperature element.
• HF resistant glass available for trace HF of <2% The solution ground eliminates noisy measurements by
• Optional Low conductivity sensor for liquids down to draining electrical current away from the reference elec-
20 μS/cm trode. The pH/ORP electrodes are designed with a flat
or bulb measurement surface, and a temperature de-
vice that is positioned at the tip of the measurement sur-
2774-2777 DryLoc pH/ORP Electrodes face, making the temperature response of T95% less than
Description 1 minute. Various temperature devices offered include 3
The Signet 2774 - 2777 pH and ORP Electrodes fea- KΩ, 300 Ω, or PT1000 RTD.
ture a unique foulproof DryLoc connector with goldplat-
®
The electrodes are used with the Signet 2750 Sensor

ed contacts designed specifically for use with the Signet Electronics, which provide a blind 4 to 20 mA output or
2750 and 2760 preamplifiers, sensor electronics, and use the digital (S L) output to connect the Signet 8900
3
connectors. These dependable and highly responsive Multi-Parameter Controller. The electrodes can also be
electrodes feature a PTFE double reference junction used with the Model 2760 preamplifier to connect to the
with KNO3 in the front chamber to block various poison- Signet 5700 or 8750.
720
Features The DryLoc electrode connector quickly forms a ro-
®
• Differential design for stable measurements in the bust assembly for submersible and in-line installations.
most aggressive applications NEMA 4X junction enclosures are integralparts of the
2750 in-line version and are also available as acces-
• Long service life even in severe or difficult chemical
sories for the submersible 2750.
applications
• Water-tight DryLoc connector with foulproof gold con-
® The 2750 submersible preamplifier can also be used
tacts as an In-line preamplifier when used with the 3/4” or 1”
threaded sensors including the 2724, 2774 and 2764
• Porous PTFE reference junction
series electrodes. The 2750 In-line preamplifier can be
• Rebuildable reference electrode used with Signet fittings up to DN100 (4 in.) and wet-tap
• Solution ground assemblies.
• Temperature sensor (pH) Features
• Easy sensor replacement using DryLoc electrode
®
• In-line integral mount and submersible installation ver-
connector sions
• Quick temperature response • Automatic temperature compensation
• Compatible with all Signet instruments and other sup- • Auto configuration for pH or ORP operation
pliers’ pH/ORP instruments
• Optional EasyCal calibration aid with automatic buffer
recognition
3719 pH/ORP Wet-Tap Assembly • Junction boxes for convenient wiring
Description
The Signet 3719 pH/ORP Wet-Tap allows installation 2760 DryLoc pH/ORP Preamplifiers and
and removal of pH or ORP electrodes, even under pro- Connectors
cess pressure, without the need for process shutdown
during routine electrode maintenance and calibration. Description
Automatic process isolation is achieved during elec- The Signet 2760 pH/ORP Preamplifiers features the
trode retraction with a double O-ring seal on a unique DryLoc connector, providing a robust connection to
®
and compact retraction assembly; no separate valve Signet DryLoc electrodes.

®
is required. A patented cam-activated automatic lock- The 2760 preamplifier allows any DryLoc pH/ORP elec-
®
ing mechanism, SafeLoc™, and the short stroke design trode to work with Signet ProcessPro and ProPoint pH/
® ®
help to assure operator safety. The wet-tap unit can be ORP instruments. It is also sold as a simple connector
mounted at any angle and can be used with the Signet for use with other manufacturers’ instruments that do
DryLoc Wet-Tap electrodes.
®
not require a preamplified signal.
Features The DryLoc electrode connector system quickly forms
®
• Electrode removal without process shutdown a robust assembly for submersible and in-line installa-
• Space saving 45 mm (1.75 in.) short-stroke design tions. NEMA 4X junction enclosures are to extend the
• Sealed pneumatic dampening for smooth and safe preamplifier cable to long distances.
operation The 2760 submersible preamplifier can also be used as
• SafeLoc™: Cam- activated automatic locking mecha- an In-line preamplifier when used with the ¾ in. or 1 in.
nism threaded sensors including the 2724, 2774 and 2764
• Protects electrode sensing surface from breakage series electrodes. The 2760 In-line preamplifier can be
used with Signet fittings up to DN100 (4 in.) and wet-tap
• Suitable for mounting in any orientation assemblies.
• Process threaded connection NPT or ISO
Features
• Low profile clampon saddle fittings for convenient in-
• In-line integral mount and submersible installation ver-
stallation in ASTM pipe sizes 2½ to 12 in.
sions
• Automatic temperature compensation
2750 DryLoc pH/ORP Sensor Electronics
• Auto configuration for pH or ORP operation
Description • Junction boxes for convenient wiring
The Signet 2750 pH/ORP Sensor Electronics featuring
the DryLoc connector, provides a variety of functions to
®
suit various requirements. 5700 pH/ORP Monitor

The 2750 has a preamplified signal and features two Description
different outputs: a two-wire 4 to 20 mA loop output The Signet 5700 pH/ORP Monitor is a versatile and in-
with EasyCal function or a digital (S L) output which al-
3
telligent instrument that recognizes the type of sensor
lows for longer cable lengths and is compatible with the connected, either pH or ORP, then automatically sets
Signet 8900 Multi-Parameter Controller. itself for the corresponding display and functionality.
Also, during EasyCal operation, the monitor automati-
The 2750 self-configures for pH or ORP operation via cally recognizes standard buffers/test solutions, there-
automatic recognition of the electrode type. The option- by shortening and simplifying routine calibration pro-
al EasyCal feature allows simple push-buttoncalibration cedures. Two programmable relays and one scaleable
and includes an LED indicator for visual feedback. 4 to 20 mA output are included, and the four-button
721
keypad arrangement with intuitive software design is
very user-friendly. The monitors require 12 to 24 volts ±
10%, regulated, AC or DC, and can be used with many
Signet pH/ORP electrodes and preamplifiers, or with
electrodes from other manufacturers by using the 2721
Preamplifier. Several useful accessories are available,
including the optional splashproof rear cover kit.
Features
• Displays pH/temp/mV or ORP/mV
• EasyCal simplifies routine calibration
• Simple push-button operation
• Intuitive software design
• Scaleable 4 to 20 mA output internally powered (ac-
tive)
• Two programmable relays
• Dual proportional control capability
• Non-volatile memory
• Versatile low voltage power requirement
8750 pH/ORP Transmitters

Description
The Signet 8750 pH/ORP Transmitter is designed for
broad application and ease of setup and use. The unit
autoconfigures for either pH or ORP use when connect-
ed to Signet pH or ORP electrodes. Multiple mounting
options allow for installation best suited to your partic-
ular application. The EasyCal menu features automat-
ic buffer recognition for mistake-proof pH or ORP elec-
trode calibrations. Intuitive software and the four button
keypad arrangement make it easy to access important
information such as pH or ORP, mV input, temperature,
calibration, relay setup menus and more.
Features
• Automatic temperature compensation
• Temperature display in °C or °F
• Hold and simulate functions
• Relay options available
• Output scaleability
• Optional Dual output
• NEMA 4X/IP65 enclosure with self-healing window
• EasyCal option available
722
Conductivity/Resistivity 2850 Conductivity/Resistivity Sensor Elec-
2819-2823 Conductivity/Resistivity Elec- tronics and Integral Systems
trodes Description
The Signet 2850 Conductivity/Resistivity Sensor Elec-
Description
tronics are available in various configurations for max-
Signet 2819-2823 Conductivity/Resistivity Electrodes
imum installation flexibility. The universal mount ver-
are designed to provide versatile installation and accu-
sion is for pipe, wall, or tank mounting and enables sin-
rate sensing across a very broad dynamic range. These
gle or dual (digital versions only) inputs using any stan-
electrodes are built with a controlled surface finish to
dard Signet conductivity/resistivity sensor. The threaded
ensure accuracy and repeatability. The standard elec-
j-box version can be used with these same Signet sen-
trode is constructed 316 SS or Titanium, but there are
sors for submersible sensor mounting. It is also avail-
other materials available for maximum chemical com-
able as a combined integral system configuration for in-
patibility. Reversible threads or sanitary flanges allow
line mounting and includes a conductivity electrode in a
for maximum installation versatility. Sanitary flange ver-
choice of 0.01, 0.1, 1.0, or 10.0 cm cell constants. The
-1
sions are available with an optional NIST Traceabili-

2850 is ideal for applications with a conductivity range
ty Certificate to meet USP requirements. Coupled with
of 0.055 to 400,000 μS or a resistivity range of 18.2 MΩ
Signet patented measuring circuitry, a three decade
to 10 kΩ.
measurement range is achieved without the need for
troublesome electrode platinization. A platinum RTD All 2850 units are available with a choice of two outputs,
(PT1000) located within the electrodeallows optimal digital (S L) or 4 to 20 mA. The digital (S L) output ver-
3 3
temperature sensing. sion allows for up to six sensor inputs directly into the
Signet 8900 Multi-Parameter Controller. The two-wire 4
Features
to 20 mA output version is available with eight 4 to 20
• Standard process connections mA output ranges for each electrode cell constant. Each
- ¾ in. NPT Polypro range can be inverted and are field selectable.
- Tri-clamp 1
-1½ in., 2” All 2850 units are built with NEMA 4X/IP 65 enclosures
- Opt. ½ in. NPT 316 SS which allow output wiring connections with long cable
• 316 SS or Titanium standard electrode runs of up to 1,000 feet (305 m). EasyCal is a standard
feature that automatically recognizes conductivity test
• Alternative electrode materials available solution values for simple field calibration. A certification
- Hastelloy-C tool is available for validation of the sensor electronic-
- Monel saccording to USP requirements.
• In-line or submersible mounting
Features
• NIST traceable certified cells ±1% meet USP require-
• Integral mount systems for quick and easy installation
ments
• Compact design for maximum installation flexibility
• Digital (S L) interface or two-wire 4 to 20 mA output
3
2839-2842 Conductivity Electrodes

• EasyCal with automatic test solution recognition
Description
• Dual channel unit available for low cost installation
The Signet 2839-2842 Conductivity/Resistivity Elec-
with Signet 8900 Multi-Parameter Controller
trodes are available in four cell constants from 0.01 to
10.0 cm-1, and are suitable for a wide variety of ap- • For use with ALL Signet conductivity electrodes
plications from high purity water quality monitoring to
weak acids and bases. 316 SS electrode surfacefinish- 5800CR Conductivity/Resistivity Monitor
es are controlled in a precision bead blasting operation
to ensure measurement accuracy and repeatability. The Description
PEEK™ insulator and processconnections are injec- The Signet 5800CR ProPoint® Conductivity/Resistivity
tion over-molded to minimize variance between elec- Monitor features a unique analog/digital display, making
trodes. Double threaded connections in either ¾ in. NPT it the preferred measurement instrument for applications
or ISO 7/1-R 3/4 enable quick and easy installation in requiring routine monitoring.The digital display guides
submersible or in-line configurations. Transmitter inte- the user through the simple menu system and provides
gral mounting kit and junction boxes are available as ac- precision information, while the analog dial serves as a
cessories. quick, at-a-glanceindicator of the measurement process.
Features The 5800CR offers two fully programmable dry contact
• Dual-threaded relays and a 4 to 20 mA current. The monitor requires
12 to 24 VAC or VDC ±10%, regulated and is pack-
• Compact electrode length for easy in-line installation aged in a convenient ¼ DIN, NEMA 4X/IP65 front panel.
in small pipe sizes The enclosure is hard-coated, high-impact, UV resistant
• Triple orifice flow through design reduces clogging polycarbonate.
and bubble entrapment
In addition to programmable outputs and relays, the
• 316 SS electrodes with injection molded PEEK™ pro- unit can also be set up to measure raw conductivity
cess connections and insulators values, meeting USP requirements.
• Cell constants may be traceable to NIST and certified
to within ±1% of value - meets USP requirements
723
Features front panel with a self-healing window in a convenient ¼
• Display units: μS, mS, kΩ, MΩ, PPM (TDS) DIN package for easy mounting. The 8850 can be con-
figured via a simple menu system.
• Temperature compensation
• Two programmable relays In addition to programmable outputs and relays, the unit
can also be set up to measure raw conductivity values.
• Dual proportional control capability
• Scaleable 4 to 20 mA output Features
• Simple push-button operation • Display choices of μS, mS, KΩ, MΩ, PPM (TDS)
• Intuitive software • Simulate function
• Non-volatile memory • Programmable temperature compensation
• Compatible with ALL Signet conductivity electrodes • Relay and open collector options
• 12 to 24 VAC or VDC power • Dual output option allows temperature and process
signal transmission
• NEMA 4X/IP65
• NEMA 4X/IP65 enclosure with self-healing window
• Compatible with ALL Signet conductivity electrodes
5900 Salinity Monitor
Description
8860 Two-Channel Conductivity/Resistivity
The Signet 5900 Salinity Monitor utilizes conductivity
sensors to provide direct reading, including calibration,
Controllers
of salinity in parts per thousand (PPT). Equippedwith a Description
scaleable 4 to 20 mA output and two programmable re- The Signet 8860 Two-Channel Conductivity/Resistivity
lays, the monitor requires 12 to 24 volts, ±10%, regulat- Controller is packed with a set of features and capabili-
ed, AC or DC, and is compatible with Signet 10 cm-1 or ties ideal for the real needs of water treatment applica-
20 cm-1 conductivity cells.Temperature is selectable for tions. It accommodates two separate and independent
display in either °C or °F, and compensation is automat- input sources and can be powered with AC/DC voltage.
ic. The 8860 programs via a simple and intuitive menu sys-
tem. The unit can also be programmed to measure a
Calibration is simplified with single-point salinity and
raw conductivity value by turning off the temperature
temperature entry via the wet-cal menu sequence. The
compensation mode.
four-button keypad arrangement with intuitive software
design is user-friendly, and is offered with a hard-coat- To control the process, the 8860 is equipped with four
ed, high impact, and UV resistant polycarbonate front dry contact relays and three 4 to 20 mA output loops.
face. The front panel is rated NEMA 4X/IP65 and an op- Calculated measurement include Difference, Ratio or
tional splashproof cover is available to protect the back % Rejection. Two of the relays may be converted into
of the instrument. open collector outputs with the flip of a switch. Operat-
Features ing modes for the relays and open collector outputs are
high, or low alarm, pulse, or special USP alarm mode.
• Direct reading and calibration in PPT The 8860 is offered with a NEMA 4X/IP65 front panel
• Dual proportional control capability with a self-healing window in a ¼ DIN package for easy
• Scaleable 4 to 20 mA output (active) internally pow- panel installation.
ered Features
• Two programmable relays • Meets USP requirements for measuring raw conduc-
• Tamper-proof security code tivity, USP alarm mode
• Analog and digital display • Dual sensor input
• Non-volatile memory • AC or DC powered
• Compatible with ALL Signet conductivity electrodes • Display and/or control: μS, mS, PPM or PPB (TDS),
• Versatile low voltage power requirement kΩ, MΩ, % rejection, difference, ratio,°C or °F
• NEMA 4X/IP65 • Three fully scaleable 4 to 20 mA outputs
• Two open collector outputs
8850 Conductivity/Resistivity Transmitters • Four programmable relays
• Time delay relay function
Description
The Signet 8850 Conductivity/Resistivity Transmitter is • Proportional pulse control capability
designed for multiple installation capabilities, simple set- • Compatible with ALL Signet conductivity electrodes
up and easy operation, thus satisfying a broad range of • Programmable temperature compensation
application requirements.
• NEMA 4X/IP65
Full microprocessor based electronics allow for a wide
operating range and long term signal stability in three
different instrument versions: the 8850-1 for a traditional
two-wire current loop, the 8850-2 features current loop
plus two dry contact relays, or the 8850-3 with two-wire
current loop, one sensor input signal and two current
loop outputs. The 8850 is offered with a NEMA 4X/IP65
724
Temperature/Pressure/Level nal potentiometers). Built-in temperature compensation
provides outstanding accuracy over widetemperature
2250 Submersible Hydrostatic Pressure ranges.
Sensor These sensors are available with a proprietary digital
Description output (S L), or fieldscaleable 4 to 20 mA output. Du-
3
The Signet 2250 Hydrostatic Level Sensor for level and al-threaded ends allow submersion in process ves-
depth control has a one-piece injection molded PVDF sels, or in-line installation with conduit connection. Inte-
body and ceramic diaphragm for superior compatibility gral adapters (sold separately) may be used to create
in corrosive liquids. Utilizing hydrostatic pressure, the a compact assembly with a field mount version of the
2250 disregards false level signals from steam vapors, Signet 8250 Level or 8450 Pressure Transmitter.
foam or any other debris on the liquid surface. Two Features
pressure ranges allow for optimal resolution matched to • Test certificate included
your sensing needs. Solid state circuitry eliminates drift
(no internal potentiometers). • 4 to 20 mA or digital (S L) output
3
• Standard ¾ in. NPT or ½ in. male union process con-

Built-in temperature compensation provides outstanding nection
accuracy over wide temperature ranges. These sensors
are available with a proprietary digital output (S L), or 4
3 • One-piece injection molded PVDF body
to 20 mA output. The extended cable and capillary tub- • Flush ceramic diaphragm
ing with the union connection and a customer supplied • Easy installation
conduit, allow submersion in process vessels. • Choice of three pressure ranges
Features • Pressure or level measurement
• Level and depth measurement
• 4 to 20 mA or digital (S L) output
3
8250 Level Transmitters
• Flush ceramic diaphragm
Description
• Easy submersible installation Signet 8250 Level Transmitters are compatible with
• Choice of two pressure ranges the Signet 2250 Level sensor and 2450 Pressure
• Standard union connection and extended cable and Sensor. The instrument is available in field and panel
capillary tubing (10 m) mount configurations, single or dual-channel input and
equipped with one 4 to 20 mA output, fully scaleableand
reversible for each input channel. The unit also features
2350 Temperature Sensor two relays, plus the ability to support two additional ex-
Description ternally mounted relays (for a total offour). Relay opera-
The Signet 2350 Temperature Sensor has a one piece tion is selectable for High, Low, Window or Off, and in-
injection molded PVDF body that is ideal for use in high cludes fully adjustable hysteresis and trigger time delay.
purity applications. It also outlasts metal sensors in ag- The unit also has the abilityto accept other level sen-
gressive liquids and eliminates the need for costly cus- sors with 4 to 20 mA output via the Signet 8058 Signal
tom thermowells. These sensors are available with a Converter. Automatic level-to-volume conversion allows
proprietary digital output (S L) or field-scaleable 4 to 20
3 display and control of tank volume and/or level in units
mA output. such as gallons, kilograms, feet or meters. Simply en-
ter the dimensions of yourtank or vessel, and the instru-
Dual threaded ends (¾ in. NPT) allow submersion in ment will calculate volume from the level measurement.
process vessels, or in-line installation with conduit con-
nection. An integral adapter kit (sold separately) may Features
be used to create a compact assembly with field mount • Level units for: ft, in., m, cm, %
versions of the Signet 8350 Temperature Transmitter. • Volume units for: gal., in , lbs., l, m , kg, %
3 3
Features • Available with single or dual input

• 4 to 20 mA or digital (S L) output
3
• Advanced relay control supports up to 4 relays
• Standard ¾ in. NPT process connection • Output simulation
• One-piece injection molded PVDF body • Manual (up to 10 pts.) and automatic level to- volume
• PT1000 platinum RTD in extended tip for quick re- conversion
sponse • Display level, volume or both
• Easy installation • Specific gravity entry for use with pressure sensors
• Threaded for in-line or submersible installation and mass unit conversion
• User-selectable averaging for display and output
2450 Pressure Sensor • Accepts other level sensors with 4 to 20 mA output
(via 8058 signal converter)
Description • NEMA 4X/IP65
The 2450 Pressure Sensor has a one-piece injection
molded PVDF body and ceramic diaphragm for superi-
orcompatibility in corrosive liquids. Three pressure ver-
sions allow for optimal resolution matched to your sens-
ing needs. Solid state circuitry eliminates drift (no inter-
725
• Chemical resistant enclosure and self-healing window
8350 Temperature Transmitters
Description
The Signet 8350 Temperature Transmitter offers local
or remote display with current and relay outputs. This
model offers exceptional repeatability and accuracyover
a wide operating temperature range.Configurations in-
clude open collector outputs or mechanical relays with
status indicators for process control or alarming. The
unit also has the ability to accept other temperature sen-
sors which have 4 to 20 mA output via the Signet 8058
Signal Converter. The chemical resistant NEMA 4X/
IP65 front face is found on both the highly visible field
mount or black panelmount instruments with a self-heal-
ing window and a standard 1/4 DIN cutout. Dual input
version allows difference calculation (ΔT) and offers
cost savingswith independent dual outputs. All models
offer an output simulation function for complete system
testing.
Features
• Digital (S L) input for stable & reliable reading
3
• Available with single or dual input

• Field scaleable 4 to 20 mA output
• Displays temperature and mA output
• Temperature display in degrees Celsius (°C) or
Fahrenheit (°F)
• Choice of relay or open collector output
• NEMA 4X/IP65
8450 Pressure Transmitters

Description
The Signet 8450 Pressure Transmitter is a unique in-
strument that offers local or remote display with cur-
rent and relay outputs. This model offersexceptional re-
peatability and accuracy over a wide operating pressure
range. The instrument is available in field and panel
mount configurations, single ordual channel input and is
equipped with a 4 to 20 mA output, fully scaleable and
reversible for each input channel. Configurations include
open collectoroutputs or relays with status indicators for
process control or alarming.
The unit also has the ability to accept other sensors with
4 to 20 mA output, via the Signet 8058 Signal Convert-
er. The chemical resistant NEMA 4X/IP65 frontface is
found in both the highly visible field mount or black pan-
el mount instrument, both featuring a self healing win-
dow, a standard ¼ DIN cutout and large push buttons
for easy navigation. Programming capabilities are avail-
able for single point calibration, setting of relays and
outputs, and output simulationfunction for complete sys-
tem testing. The dual input version allows difference cal-
culation (ΔP) and offers significant cost savings with in-
dependent dualoutputs.
Features
• Digital (S L) input for stable and reliable reading
3
• Available with single or dual sensor input

• Pressure can be displayed in psi, bar or kPa
• Field scaleable 4 to 20 mA output
• Choice of relay or open collector output
• NEMA 4X/IP65
726
Other Products 7300 Switching Power Supplies
0251 PC COMM Configuration Tool Description
Signet 7300 Switching Power Supplies provide regu-
0250 USB to Digital (S3L) Configuration/Di- lated output voltage in compact and lightweight plastic
agnostic Tool housings that can be DIN Rail or surface mounted. The
series includes five different outputcapacities from 300
Description mA to 4.2 A (7.5W to 100W), all of which accept univer-
The new 3-0250 USB to (S L) configuration/diagnostic
3
sal AC line voltage input and meet worldwide standards
tool interfaces with Signet’s various digital sensors to al- for performance and safety. These units meet the power
low users to select all parameters available for modifi- requirements for a single system, multiple Signet instru-
cation, monitor the sensor’s data on the PC/Laptop, or ments or other devices requiring 24 VDC operation.
log the sensor’s data to a file. Multilanguage Software in
English, German, French, Italian, Portuguese and Span- Features
ish. • Regulated 24 VDC output voltage
Features • Five output capacities: 300 mA, 600 mA, 1.3 A, 2.1 A
and 4.2 A
• User-friendly interface
• DIN rail or surface mount
• Configure blind sensors
• Universal AC input (85 to 264 VAC)
• Configure all modifiable parameters in the sensor
• DC compatible input (105 to 370 VDC)
• Monitor sensor data or log sensors data to a file
• Fused input
• Monitor mV and Temperature reading in pH/ORP sen-
sors • Auto resetting output overcurrent protection
• Graph sensor data • Unique spring-up, finger-safe terminals
• Red and Blue LED indicators for power and data • Short-circuit protection
transmission • Output voltage adjust (+/- 10%)
• 6 ft USB extension cable • Light-weight plastic housing
6400 Intrinsic Safety Barriers i-Go 8058 Signal Converter

Description Description
Georg Fischer Signet offers singlechannel intrinsic safe- The Signet i-Go™ 8058 Signal Converter accepts any
ty barriers foruse with the 515 and 525 paddlewheelflow 4 to 20 mA signal and converts it into the Signet digital
sensors. (S L) format, the serial data format used by the Signet
3
8250, 8350, 8450 and 8900 instruments. When used

Both versions use a ½ inch wide housing which snaps
with the 8900 Multi-Parameter Controller, the measure-
directly to a 35 mm DIN rail. Once mounted, an electri-
ment type and operating range are defined in the 8900
cal connection is formed between the barrier and the
setup menu. When used with level, temperature and
rail. The rail serves as the intrinsic safety ground bus
pressure transmitters, the 8058 is configured at the fac-
when connected to the designated grounding point. Two
tory to the user’s specifications.
additional ground lugs are provided andmay be used
as a redundant grounding method or for terminating The wire-mount single-channel version is easily mount-
shields. ed anywhere in the interconnecting wiring between the
sensor and the instrument. The DIN rail mounted dual-
Each barrier also contains a replaceable 160 mA fuse
channel version can convert one or two separate 4 to 20
cartridge for each channel. Safety barriers are polarity
mA inputs into a digital (S L)output.
3
sensitive devices and are available in +DC and ACvolt-

age ratings. Features
Features • Connects with level, temperature, pressure and mul-
ti-parameter Signet instruments and other manufac-
• One step, snap-on 35 mm DIN rail mounting and
turers transmitters
grounding
• Up to two 4 to 20 mA sensor inputs
• Replaceable 160 mA fuse
• Connects additional measurement parameters to
• Lowest internal resistance
Signet 8900 Multi-Parameter instrument
• Common ½ in. wide housing for single channel ver-
• Wire or DIN rail mountable
sions
• Short-circuit proof connections
• FM, UL, CSA approved
8059 External Relay Modules
• Compatible with Signet 515 and 525 flow sensors Description
Signet 8059 External Relay Modules supplement the
output capabilities of certain host instruments such as
the Signet 8900 Multi-Parameter Controller. AC-pow-
ered versions accept universal line voltage, and also
provide 24 VDC output that can be used to power the
host instrument or other device(s).
727
The host instrument controls relay operation by way of
a single digital (S L) connection. The compact plastic
3
housing is DIN rail mountable and includes LED annun-

ciators for each relay, plus one each for power-on and
data transfer or test mode.
Features
• External relays controlled by host instrument
• AC and DC powered versions
• DC power output (AC versions)
• DC power passthrough (DC versions) to simplify
wiring
• Digital (S L) passthrough to simplify sensor wiring
3
• Red LED annunciators for each relay

• Green LED indicators for power and digital (S L) data
3
transfer
• Relays may be tested locally, and also via the host in-
strument
728
Calibration Accessories Features
• Turbidity standard for most any value
pH/ORP Buffer Solutions • Three different graduated pipettes included
Description • Four glass cuvettes with light shield caps
The Signet pH buffers are ideal for many calibration re- • Easy to follow instructions
quirements. The liquid solutions are conveniently pack-
aged in one pint bottles; the powder pillows are pack-
aged in low weight, single-use containers which can 2759 pH/ORP System Tester
be mixed with water. All pH buffers are color coded for Description
easy identification; 4.01 pH is red, 7.00 pH isyellow, and The Signet 2759 pH/ORP Simulator is a battery-pow-
10.00 pH is blue. ered millivolt generator that simulates pH values of 4,
The pH buffers are traceable to NIST standards and 7 and 10, plus ORP values of ±700 mV. This device is
certificates are available upon request. They are accu- useful as a troubleshooting aid and for general verifica-
rate to within ± 0.01 pH units @ 25 °C and have long tion of system operation. It is not a substitute for period-
term stability. ic system calibration with pH buffers or testsolutions.
These solutions are temperature sensitive and are pro- Accessory adapter cables (sold separately) enable the
vided with temperature correction values for the most 2759 to connect directly to Signet 2760 preamplifiers,or
accurate calibration. For applications that requireORP 2750 pH/ORP Sensor Electronics. The adapters include
calibration, the pH 4 and pH 7 buffers can be mixed with a selector switch for pH (3K or PT1000 Temperature
quinhydrone powder for the correct measurement val- Compensation) or ORP simulation. The switch triggers
ues of +87 mV and +264 mV respectively. automatic sensorrecognition software in Signet pH/ORP
instrumentation.
Features
• NIST Traceable
Features
• Battery powered millivolt generator
• Easily identifiable color coded buffer solutions
• Simulates pH and ORP values
• Liquid or powder versions
• High impedance input simulates preamplified signal
• Temperature compensated values
• Verifies system functionality
• Kits for easy use
• Compatible with 2750 and 2760 preamplifiers
• Connects to any Signet pH/ORP instrument
Calibration Kits for 4150 Turbidimeter
• Verifies preamplifier or instrument electronics
Description
The Calibration Standard kits contain fluids in special
cuvette bottles that are used to compare the clarity of Conductivity/Resistivity Tools
the process water against the standard to calibrate the Description
turbidity instrument. The standard kits come in two pre- The Signet conductivity/resistivity tools are available for
mixed, calibrated ranges. certification or validation of electronics that are indepen-
The 0-100 version is generally used for measuring the dent of the electrode. Because there are no available
turbidity of clean, potable water applications. The 0- liquid standards for calibration in lowconductivity and re-
1,000 version is used to measure water that has atur- sistivity applications, these tools are ideal for various in-
bidity which may exceed 100, such as water in a recla- stallations. All tools are built to conform to the ASTM D
mation plant. 1125-95 Standard (StandardTest Methods for Electri-
cal Conductivity and Resistivity of Water), which is also
Features commonly used for USP 24 applications.
• Stable pre-mixed standards that are certified accurate
Signet tools simulate, within ±0.1% precision (accura-
• Sealed calibration cuvettes cy), various values: 1.0 μS, 2.5 μS, 10.0 μS, 10.0 MΩ,
• Shelf life - 1 year 18.2 MΩ. These tools also temperature compensated to
• Easy to follow instructions 25 °C and enable the user to accurately validate or cer-
• Kits for easy use tify the electronics.
Model 2830 can be used with Signet Models 5800CR,
Formazin Stock Kit for 4150 Turbidimeter 8850, and 8860 instruments. The 2850-101-X simula-
tors are used with the Model 2850 electronicsand simply
Description plugs into the same terminals as the sensor cables.
The Formazin Stock kit contains all chemicals and in-
Features
structions to dilute/ mix calibration standards between
1.0 and 1980 NTU/FNU. The Formazin Stock kit can be • Simulates five different values
used to calibrate third party turbidity instruments as well • Compatible with all Signet Conductivity/ Resistivity in-
as the Signet 4150 Turbidimeter. struments
• Verifies electronics independent of electrode
• NIST traceable units
• Temperature compensated to 25 °C
• All units ship with NIST traceable certificates
729
Installation Calibration and Operation
Please refer to the owner's manual for details.
Installation of Turbidity
Installation of Flow Sensors
4150 Turbidimeter
Paddlewheel
Turbidity Installation
An owner's manual is included with every instrument I. Piping Location
that ships. Please refer to this manual for detailed in- • The correct location of the sensor in the piping system
structions regarding installation and operation. The in- helps to ensure a proper flow profile in the pipe. It is
strument includes a mounting braket designed for the important to have sufficient straight pipe immediately
instrument to mount on a vertical surface. upstream of the sensor to create “fully developed tur-
This was made simpler by having pre-drilled mounting bulent flow.” Such a flow profile provides the stability
holes on a pattern common with instruments used for required for the paddlewheel to measure accurately.
this measurement. A pattern hole template is also in- • The diagrams below illustrate the minimum distances
cluded with the instrument when new mounting holes that are recommended to mount plastic and metal
are required. paddlewheel sensors.
Plumbing • In all scenarios, it is recommended to choose a loca-
• Use 8 mm (5/16 in.) OD, 5 mm (3/16 in.) ID flexible tion with as much straight, uninterrupted pipe length
tubing for the water supply connections. upstream of the sensor as possible
• Opaque tubing (not supplied) should be used to pre-
vent algae growth if the tubing will be exposed to sun-
light.
• The 4150 requires only 1 psi head pressure to oper-
ate.
• The flow through cuvette is rated for a flow of 100 mL/
m to 1 L/m (0.026 - 0.26 GPM).
• The integral pressure regulator is rated for a maxi-
mum pressure of 200 psi. It is factory adjusted. Do Flow Installation Tips:
not tamper with the regulator. • Use Signet fittings for proper insertion into the pro-
• Inlet water pressure should not exceed 50 psi to avoid cess flow.
damage to the tubing connection to the regulator. • Recommended up-stream distances are stated as
• Fluid temperature must not exceed 50 ºC (122 ºF). a multiplier of the I.D. (inner diameter) dimension of
• The shutoff clamp is used to interrupt the flow during the pipe. Note that these multipliers are different for
cuvette maintenance. each example and depend upon the upstream ob-
• route the sensor drain tubing to a suitable drain. struction.
Do not reintroduce the drain sample to the process • Paddlewheel sensors can be used for all water-like
stream. fluids with little or no particulates (100 micron in di-
ameter/length), and non-ferrous, non-fouling in na-
ture.
• Always use these sensors in full pipes.
• Always maximize the distance between sensors and
pump sources.
II. Mounting Angle

Paddlewheel sensors are affected by the mounting an-
gle due to the effect of gravity increasing the friction
between rotor and bearing surfaces. Air entrapment
and sediment within the pipe may also adversely affect
sensing accuracy and/or impede operation.
Paddlewheels in Vertical pipes:
• Mount the sensor in a pipe with an upward flow. This
Power position is recommended for all scenarios, as it en-
The power required is 100 - 240 volts AC at 47 - 63 Hz. sures a full pipe.
The output is a single programmable 4 to 20 mA DC in- • Vertical installations with down-ward flow are general-
strument signal that is in direct proportion to the turbid- ly not recommended.
ity. Also provided are two programmable alarm relay
outputs, one for high process alarm and the other for
low process alarm sense. Note, both alarms are used in
common to indicate an instrument malfunction, i.e. High
Humidity.
730
III. Installation Fittings
Fixed Depth
The insertion depth of a paddlewheel in a flow stream

is critical and must be achieved and maintained to en-
sure accurate flow measurements. Signet installation fit-
tings for Rotor-X and Metalex paddlewheel flow sensors
set this depth automatically and facilitate the use of con-
venient K-Factors (calibration values) published in the
sensor instruction manuals.
Paddlewheels in Horizontal pipes:
• ±45° from vertical is the recommended sensor mount-
ing angle to avoid air bubbles (pipe must be full). With
the sensor at greater angles, the drag created by the
rotor resting against the sensor body may compro-
mise performance at the lower end of the operating
range.
• Straight up installations may experience interference
from entrained air at the top of the pipe.
• Inverted installations are often subject to blockage
due to sediments in the pipe. Mounting sensors in the
bottom of the pipe is NOT recommended if sediments
are likely to be in the pipe.
The H-dimension controls the insertion depth and they

are critical for proper seating of the flow sensor into the
pipe. These dimensions can be found listed in the flow
sensor instruction manuals.
515, 2536 and 2537 Rotor-X
• This section outlines the installation fittings available
from Signet for the 515, 2536 and 2537 Rotor-X family
of flow sensors. The fitting controls the location of the
paddlewheel inside the pipe, which in turn determines
the calibration constant (K-Factor).
K-Factors • Refer to the Fittings section of this catalog for a com-
K-Factors are calibration values (pulses per unit of vol- plete listing of part numbers.
ume) used to convert flow sensor output frequencies to
flow rates. Signet publishes K-Factors for water only in
gallons (pulses per gallon) and liters (pulses per liter) for
all sensors, in all applicable pipe sizes and materials,
and/or all applicable installation fitting sizes and mate-
rials. K-Factors for fluids other than water must be de-
termined empirically, typically on-site using a secondary
standard.
Note that K-Factors are published for pipe sizes od
DN15 to DN300 (0.5 in. to 12 in.). For other pipe sizes,
statistical K-Factors may be available. Contact Techni-
cal Support for more information.
Flow Installation Tips:
• Ensure that all wetted materials are chemically com-
patible with the process liquid.
• Pressure and temperature ratings are reduced when
plastic flow sensors are mounted in metal piping sys-
tems.
• The flow sensor is designed to fit tightly into the fit-
tings. Lightly lubricate o-rings with a non-petroleum
based lubricant to ease the installation.
• Cut the cable to the desired length if too long. Do not
coil extra cable.
731
525 Metalex Consult a qualified welder to install metalex fittings.
• This section outlines the installation fittings available Use of saddle fittings reduces the pressure rating for the
from Signet for the 525 Metalex family of flow sen- 525 sensor.
sors. The fitting controls the location of the paddle- IV. Rotor placement
wheel inside the pipe, which in turn determines the Procedure for plastic paddlewheel sensors:
calibration constant (K-Factor).
• Refer to the Fittings section of this catalog for a com- 1.Hold the sensor upside down and hold the rotor still.
plete listing of part numbers. 2.Place the tip of a medium blade screwdriver between
the rotor and the sensor body.
525-1 Metalex Flow Sensor
3.Turn the screwdriver blade 90° to flex the “ear” back
just enough to angle the rotor pin out of one side.
The smallest Metalex Flow Sensor (525-1) must be in-
stalled into a specially constructed tee fitting with sock-
et-weld piping connections.
Procedure for metal paddlewheel sensors:

1. With a small pair of needle-nose pliers, firmly grip the
Use the 525-2 and one of these weld-on fittings for center of the rotor pin (shaft) and with a twisting motion,
stainless steel pipes from DN32 (1.25 inches) up to bend the rotor pin into an “S” shape. This should pull the
DN300 (12 inches) in diameter. ends of the pin out of the retainers and free the rotor as-
sembly.
The 525-3 is the longest metalex flow sensor. It requires

one of the strap-on saddles for pipes from DN50 (2 2. Remove retainer from each side by gently tapping it
inches) up to DN300 (12 inches) in diameter. inwards using a punch. Install a new retainer with its ro-
tor pin clearance hole inward. Only install one retainer
at this time.
732
3.For liquid-tight glands, tighten the compression fitting
onto the fitting sufficiently to achieve a seal around
the cable.
4.For conduit adapters, thread the cable through the
adapter and tighten the adapter into the sensor fitting.
3. Insert the new rotor assembly and bearings into the

rotor housing of the sensor and place the new rotor
pin (shaft) through the open end of the rotor housing,
through the rotor and bearings, and into the previously
installed retainer.
4. Tap the second retainer (rotor pin clearance hole in-

wards) into the hole while lining up the rotor pin with the
center of the retainer hole. This completes the rotor re-
placement procedure.
Cable Gland (Liquid Tight Connector):
V. Cable glands and conduit adapter kits

Cable Glands and Conduit adapter kits are available to
install on Models 515, 2536, 525 when used in wet en- Conduit Adapters (suitable for all plastic and metal pad-
vironments. These items protect against moisture en- dlewheel sensors):
tering the back end of the sensor. Follow these simple
instructions to prolong the life of the sensor. Conduit
adapters are included with the 2540 sensors.
1.Remove the black Nylon® bushing to expose the fe-

male threads at the back end of the flow sensor. Use
a standard medium size screwdriver to pry the bush-
ing up and out of the port. Slide it up and off the entire
length of the cable, or cut it away carefully so as not
to knick the cable jacket.
2.Thread the gland or conduit adapter over the cable Wet-Tap and Hot-Tap
and screw the 1/2 in. NPT male threads into the top of VI. Wet-Tap and Hot-Tap installation
the sensor in place of the bushing. 3519 Wet-Tap Valve
733
• The 3519 Wet-Tap consists of a flange and support In-Line Rotors and Turbines
plate that threads onto the pipe fitting insert, and a I. Piping Location
PVC ball valve through which an extended length,
• The location of the sensor in the piping system deter-
wet-tap style sensor is inserted into the pipe.
mines the flow profile that the sensor is monitoring.
• No special tools are required to install the 3519. The ideal location is to have sufficient straight pipe im-
• The Signet 3519 Wet-Tap Valve mounts directly on- mediately upstream of the sensor to create “fully de-
to standard Signet installation fittings for the 515 and veloped turbulent flow.” Such a flow profile provides
2536 flow sensors. The wet-tap sensors are identified the stability required for the paddlewheel to measure
in their part number as -P3, -P4 and -P5, depending accurately.
on the pipe size. • The diagrams below illustrate the minimum distances
• The 3519 Wet-Tap valve can only be installed in an recommended from various obstructions.
empty pipe. Once installed, the sensor can be re- • In all scenarios, it is recommended to choose a loca-
moved and re-inserted while the process is active. tion with the maximum length of straight, uninterrupt-
• Pressure must be reduced prior to insertion and reed pipe.
moval of sensor (please see individual product page • Six common installation configurations are shown
for more information). below as guidelines to help you select the best lo-
cation in your piping system for the flow sensor. Al-
ways maximize distance between sensors and pump
sources.
• Never install immediately down-stream of valves, fit-
tings, etc.
• Observe minimum Reynolds Number (see Technical
Reference section).
• The flow sensors are not for bi-di-rectional operation.
• For optimal performance of the 2507, a straight flow

2540 and 2552 Hot-Tap run of at least 100 to 150 mm (4 to 6 in.) should be al-
lowed before and after the sensor.
• The valve for Hot-Tap sensors can be installed while
the pipe is full if a hot-tap drill is used. Consult with
your piping supplier for information regarding drills.
• To install a Hot-tap sensor, you will need a hot-tap
drilling machine, a ball valve, a metal pipe nipple.
Signet Hot-Tap installation tool available (2540 only).
• Hot-Tap sensors can be installed and removed with-
out process shutdown. Care must be taken while re-
moving sensor under process conditions. The instal-
lation tool serves to hold the sensor against the line II. Mounting Angle
pressure as it is retracted or inserted into the pipe The mounting angle of the sensor may affect the perfor-
(2540 only). mance of the system.
In-line Rotors:
• The Hot-Tap installation fitting has a bleed valve to re-
lieve the pressure when retracting the sensor (2540 • Signet Models 2507 and 2000 flow sensors are de-
only). signed to be mounted on a flat surface, although the
sensors may be tilted up to ±30° if necessary.
• Installation in excess of 30° will affect the accuracy of
the sensor.
• For Model 2507, two pipe fitting adapters (included)
convert the straight threads G-1/4 in. to 1/4 in. NPT.
• These sensors should be installed securely to their
supporting surface to prevent vibrations from affecting
the performance.
Turbine Flow Sensors:
734
• All mounting angles are accept-able for these sensors
if the basic parameters are met: the pipe must be full
with no entrapped air.
• Install the sensor with the arrow pointing in the direc-
tion of the flow of liquid.
Vortex
I. Piping Location
• Install the sensor with the arrow pointing in the direc-
tion of the flow. These flow sensors are not for bi-di-
rectional operation.
• Recommended upstream distanc-es are stated as a
multiplier of the I.D. (inner diameter) of the pipe. Note
that these multipliers vary and depend upon the type
of obstruction.
• Follow these recommended distances to ensure a
good flow indication.
Magnetic
Magnetic Flow Sensors
• All mounting angles are acceptable for these sensors
if the basic parameters are met: the pipe must be full
with no entrained air.
• On horizontal pipe runs sensor may be mounted in
Vortex Installation Tips:
any position around the pipe. If air bubbles or sedi-
ments are expected; mount at a slight angle.
• Sensors must be used in full pipes.
• On vertical pipe runs sensor may be mounted in any
orientation with UPWARD flow preferred to ensure a • Sensors may be mounted at any angle.
full pipe. • Observe minimum Reynolds Number and Back
Pressure requirements.
• Never install immediately downstream of valves, fit-
tings, etc.
• For optimal performance, choose a piping location
with the maximum length of straight un-interrupted
pipe lengths upstream of the sensor.
II. Mounting Angle

Signet Vortex Flow Sensors may be mounted at any an-
gle, and either horizontal or vertical pipe runs, with up-
ward flow prefered in the case of vertical runs.
Backpressure Calculation
Minimum downstream pipe backpressure levels are re-
quired to prevent cavitation within the sensor. The mini-
mum back pressure is calculated by the following formu-
la:
(2.7 x ΔP) + (1.3 x Pv)
ΔP: Pressure drop across sensor
Pv: Liquid vapor pressure at operating temperature.
735
III. End Connector Options D) Quick release pipe clamp
Solvent socket version:
E) Tank flange
Available in PVC. Follow the PVC cement
manufacturer’s recommendations for preparation and Installation Tips:
installation. • Mount the electrode near tank outlet away from
reagent addition areas.
• Place the electrode tip in pH 4 buffer during system
maintenance or storage to avoid dehydration.
II. In-Line Installation

2724-2726
/ 2764-2767 / 2774-2777 pH/ORP Electrodes with
2750 or 2760 Preamplifier
• Models 2724-2726, 2764-2767 and 2774-2777 fea-
ture a thread close to the sensor end which allows the
Installation of pH/ORP Electrodes sensor to thread directly into a standard NPT pipe tee.
I. Submersible Installation • Electrodes must be immersed in liquid. Keep pipe full
at all times to avoid dehydration.
2724-2726
/ 2764-2767 / 2774-2777 with 27750/2760 preamplifier • Observe mounting angle requirements for models
1.The O-ring at the top of the electrode fits very tightly 2764-2767.
into the preamplifier. Use a small amount of lubricant • Any mounting angle is acceptable for Models
(non-petroleum based) to assist the assembly. 2724-2726, 2774-2777.
2.To prevent moisture from migrating into the preampli- • Models 2724-2726 are compatible with Signet installa-
fier, backfill the conduit with 3 to 4 inches of sealant. tion fittings for pipes from DN15 to DN100 (1/2 in. to 4
3.Mount electrodes in a location with ample clearance in.).
to remove them for periodic cleaning and recalibra-
tion.
4.Choose a location that keeps the electrode glass
completely submerged at all times.
III. Installation Fittings compatible with Models

2724-2726 pH/ORP Electrodes
See Fittings section for more information
Customer supplied: Installation Tips

• Use pipe adapters to install electrodes into pipe
A) 3/4 in. NPT threaded pipe sizes larger than DN100 (4 inches)
• Adapters are designed to either glue into a plain
B) Signet threaded J-box socket tee (specify socket) or thread into a 1.25 inch
threaded tee (specify threaded).
C) Flex conduit
736
IV. Mounting Angle
Sensor Mounting - Models 2764-2767

• pH electrodes must be mounted at least 15° from the Installation Tips:
horizontal to ensure proper sensing. Sensors mount- • Provide 0.6 m (20 in.) minimum clearance from the
ed at less than 15° will impede performance. top of the pipe for electrode removal.
• ORP electrodes may be mounted at any angle without • The 3719 can be mounted in any orientation, includ-
affecting the performance. ing horizontal and inverted.
Sensor Mounting - Models 2724-2726, 2774-2777 • Use caution when removing inverted sensors. Resid-
ual fluid may be present in the retraction housing.
• Keep electrode connector clean and dry at all times.
• For reliable in-line measurements of pH and ORP,
it is imperative to position the electrode tip into the
process stream.
• Because of its compact “short stroke” design, the
3719 requires low-profile fittings to assure proper
positioning in pipe sizes DN65 to DN300 (2.5 to 12
inches).
• It is strongly recommended to use the low profile PP
clamp-on saddle fittings.
3719 pH/ORP Wet-tap Installation

• Initial installation must be performed under non-pres-
surized conditions.
• Models 2724-2726 and 2774-2777 may be mounted • The 3719-11 has a 1.5 in. NPT process connection for
at any angle without affecting the performance. use with accessory saddle fittings from 2.5 to 4 inch.
• Avoid the 12 o’clock position. • The 3719-21 has a 2 in. NPT process connection for
use with accessory saddle fittings from 6 to 12 inch.
• In the presence of sediment, avoid the 6 o’clock posi-
tion. • It is possible to install the 3719 into pipe sizes below
2.5 inches by creating a “flow cell” with standard pip-
3719 Wet-tap Overview ing components.
All of these components are sold separately: • One simple solution, using a GF SCH 80 PVC tee and
reducer bushings, is illustrated below.
a) 3719 pH/ORP Wet-Tap • Avoid the entrapment of air inside the flow cell.
• Model 3719-12 has an ISO 7/1-R1.5 process connec-
b) Low Profile PP Clamp-on Saddle Fitting (ASTM sizes
tion to fit pipe sizes DN65 to DN100. Installation fit-
2.5 to12 in.)
tings are customer supplied.
c) 275X-WT and 275X-WTP DryLoc® pH or ORP Elec- • Model 3719-22 has an ISO 7/1-R2 process connec-
trode ("DryLoc" refers to the electrode connector style) tion to fit pipe sizes DN150 to DN300. Installation fit-
tings are customer supplied.
d) 2750/2760 DryLoc® pH/ORP Sensor with J-Box
e) Output signal options: digital (S³L) and 4 to 20 mA

737
4.Install the 2750 DryLoc® pH/ORP Sensor onto the
electrode connector (see individual operation manuals
for more detail).
VII. 3719 Wet-tap mounting angle
• The 3719 can be mounted in any orientation, includ-

ing horizontal and inverted.
• Avoid the 12 o’clock position.
• In the presence of sediment, avoid the 6 o’clock posi-
tion.
VI. 3719 pH Wet-tap Electrode Installation
The 3719 can be mounted in any orientation, includ-
ing horizontal and inverted (shown here with both 2720 Installation of Conductivity/Resistivity
preamplifier and 2750 Sensor). Electrodes
I. Submersible Installation
2819 to 2823/2839-1 to 2842-1 with 2850 Sensor
Electronics
• Electrode with 2850 Sensor Electronics shown below.
• All mounting brackets, electrical conduits, and pipe
extensions are customer supplied.
• Sensor Models 2819-2823 are mounted similarly,
except use a 3/4” MNPT Thread to mount to a 3/4”
FNPT pipe thread (customer supplied).
1.Slide electrode (DryLoc ) straight down into electrode

®
piston. Thread electrode into place until connector

shoulder is flush with top of electrode piston. Hand
tighten only.
2.Place the Locking Shroud over electrode; turn 1/4-turn
clockwise to unlock the piston, then press down firmly
on the locking shroud to lower the electrode piston in-
to the pipe.
3.Turn the Locking Shroud 1/4-turn counterclockwise to
lock the piston.
738
Installation Tips: Signet 2450 Pressure Sensor
• Use standard installation hardware to connect the
submersible 2850-3 or -4 directly to external equip-
ment.
• In aerated vessels install the electrode in a stilling
well to prevent air from being trapped inside the
electrode.

• Conductivity/Resistivity electrodes can be installed
into standard 3/4 inch NPT fittings or ISO 7-R3/4
threaded fittings.
• The preferred installation for in-line applications di- Signet 2250 Hydrostatic Level Sensor
rects flow straight into the electrode. This configura-
tion reduces the probability of entrapped air bubbles,
and provides the best continuous sampling of the fluid
content.
• If the electrode is mounted vertically in a tee, do not
recess the orifices inside the tee. Mounting upside
down may help prevent air entrapment.
• An oversized tee or flow cell may be helpful for inline
installations.
• At least 4 threads (ANSI B1.20.1) must be engaged to
meet pressure rating per published specifications.
Installation Tips:
• 8050-1 and 8050-2 junction boxes can be useful for
this instal-lation option.

• The 2450 can be mounted in a pipe-tee using the
threads closest to the sensing end.
• The sensor can be mounted with or without an inte-
Tri-clamp Connections gral mount kit. This kit mounts a junction box or an in-
• Models 2819-2821 are offered with 1 to 1.5 inch and 2 strument.
inch sanitary fittings. • See below for more information on instrument integral
mount and junction box/remote mount examples.
Installation Tips:
• Sensors can be mounted into any DN20 (3/4 in)
FNPT pipe tee (customer supplied)
Integral Assembly
The 3-8052 Integral Kit connects the 8450 Pressure

Transmitter and 8250 Level Transmitter directly onto the
2450 sensors.
Installation of Pressure/Level Sensors • Use the 2450 sensor with 15.2 cm (6 in.) cable and
digital (S L) output.
3
• Use the 2450 and 2250 sensors with 4.6 m (15 ft) ca- • Apply sealant or PTFE tape to the process connection
ble and 10 m (32.8 ft), respectively. threads, after inspecting threads to ensure integrity.
Do not install a sensor with damaged threads.
• Mount the sensor to an extension pipe or watertight
conduit using thread sealant. • Tighten the sensor 1.5 turns past finger tight into the
process connection.
• Use a cable gland at the top of the extension to pre-
vent moisture intrusion/accumulation inside the pipe.
• DO NOT hermetically seal (i.e. applying silicone
sealant or epoxy) the back of the sensor. To do so
may introduce measurement errors resulting from
changes in atmospheric pressure and/or temperature.
739
• The 2350 can be mounted in a pipe-tee using the
threads closest to the sensing end.
• The sensor can be mounted with or without an inte-
gral kit. This kit mounts a junction box to an instru-
ment.
• See below for more information on instrument integral
mount and junction box/remote mount examples.
Installation Tips
• Sensors can be mounted into any DN20 (3/4 in.)
FNPT pipe tee (customer supplied).
Integral Assembly
Remote Assembly
• The 3-8052 Integral Kit connects the 8350 Tempera-
• 3/4 in. NPT sensor connection ture Transmitter directly onto the 2350 sensor.
• Conduit base and cap with junction terminals • Apply sealant or PTFE tape to the process connection
• 3-9000.392-1 liquid tight connector, 0.5 in. NPT threads, after inspecting threads to ensure integrity.
• Tighten the sensor 1.5 turns past finger tight into the
process connection.
Installation of Temperature Sensors

• Use the 2350 sensor with 4.6 m (15 ft) cable. Remote Assembly
• Mount the sensor to an extension pipe or watertight
conduit using thread sealant. • The optional 3-8052-1 Integral Junction box with 3/4
• Use a cable gland at the top of the extension to pre- in. process connection offers a convenient ter-minal
vent moisture intrusion/accumulation inside the pipe. point to extend the 2350 cable over a distance.
The kit includes:
• For additional defense against possible accumulation
of condensation at the back seal area of the sensor, • 3/4 in. NPT process connection.
fill the lower 75-100 mm (3-4 inches) of conduit or ex- • Conduit base and cap with junction terminals.
tension pipe with a flexible sealant such as silicone. • 3-9000.392-1 liquid tight connector, 0.5 in. NPT.
• Apply sealant or PTFE tape to the process connection
threads, after inspecting threads to ensure integrity.
• Tighten the sensor 1.5 turns past finger tight into the
process connection.
Installation Tips
• 8050-1 and 8052-1 junction boxes can be useful for
this installation option.
740
741
Wiring Wiring Information: Sensors & Electrodes
Wiring Information: Turbidity I. Flow sensor cable details and connection to in-
strumentation
I. 4150 Turbidimeter
• Most Signet Flow sensors are supplied with a stan-
Power dard 7.6 m (25 ft) length of cable except the 2100 Tur-
• Install a circuit breaker in the AC line before the 4150 bine, which has 4.6 m (15 ft)
power connection to allow for service. • 2551 Magmeters are not supplied with cable.
• The 4150 is not supplied with a power cord. • 2552 Magmeters supplied with 7.6 m (25 ft) or sub-
• The power cable bulkhead will accept cable diameters mersible version with optional 3.9 m (13 ft) or 5.9 m
from 5.8 mm (0.230 in.) up to 10 mm (0.395 in.) (19.5 ft).
• All terminals are designed to accept wires in the range • Sensors with AC sine wave outputs (515, 525) may
of 14-28 AWG. extend cable to a maximum 60 m (200 ft)
• All wires should be stripped to a length of 6 mm (1¼ • Sensors with open collector outputs (2000, 2100,
in.). 2507, 2536, 2537, 2540, 2551, 2552) may extend ca-
ble to a maximum 300 m (1000 ft)
• A strain relief strap is provided to reduce tension on
the AC power terminal. • Maintain all cable shielding through splices or terminal
connections.
RS485 • Cable should be 2 conductor twisted pair with shield,
• The RS485 half-duplex (2 wire) digital interface oper- 18 to 22 AWG.
ates with differential levels that are not susceptible to • Signet Flow sensors use cable with Black, Red and
electrical interferences. Shield conductors. To facilitate wiring, most Signet in-
• The last device on each bus may require terminating struments have wiring terminals that are labeled with
with a 120-ohm resistor to eliminate signal reflection these same colours.
on the line.
• Do not run RS485 cables in the same conduit as pow-
er.
4 to 20 mA
• The active 4 to 20 mA outut is driven by a 15 VDC
power source and can drive external loads up to 600
ohms.
• Do not run 4 to 20 mA cables in the same conduit as
power.
I. Flow sensor wiring details for 2537 Flowmeter

Digital (S³L) Wiring:
The digital (S³L) output is compatible with Signet Multi-

Parameter Transmitters and Controllers.
742
The 2552 is a traditional 2-wire passive 4 to 20mA loop
Loop Wiring:
transmitter. Eternal loop power (24 VDC ± 10%) is re-
quired. Please refer to the Model 7300 Power Supplies.
The 4 to 20 mA output can be connected to Chart
Recorders, PLCs or any device that requires a 4 to 20 II. Wiring Connections for pH/ORP and Conductivi-
mA signal. ty/Resistivity
(S³L) pH/ORP Wiring continued
2750 In-Line version with J-Box
4 to 20mA Loop pH/ORP Wiring
On-Off/Pulse: 2750 with J-Box
Provide a single dry-contact relay output that can be

programmed as a HIGH alarm or a LOW alarm.
2750 without J-Box
Pulse/On-Off:
Provide a single solid-state relay output that represents

a volumetric pulse or pulse divided output.
2760 Preamplifier to Other Manufacturer’s Equipment
I. Flow sensor wiring details for the 2552 Magmeter

Frequency Wiring:
The 2552 offers an open collector frequency signal that
can be connected to any powered Signet flow instru-
ment. If connecting to a non-Signet instrument, 5 to 24
VDC power must be provided to the 2552.
Digital (S³L) Wiring:
The 2552 receives 5 VDC power from the 8900. No ad-
ditional power is required.
Loop Wiring: 2760 Connector to Other Manufacturer’s Equipment
743
Wiring Information: Instruments
III. Rear Terminal Views Signet Flow Instruments
Terminal 8550-1
2850 Conductivity/Resistivity Sensor Electronics
4 to 20 mA Conductivity/Resistivity Wiring Terminal 8550-2
Terminal 8550-3
Digital (S³L) Output Conductivity/Resistivity Wiring 5075
Dual Digital (S³L) Output Conductivity/Resistivity Wiring 5090
5500
744
III. Rear Terminal Views Signet pH/ORP, Conductivi-
ty/Resistivity Instruments
pH/ORP
Terminal 8750-1
5600 Terminal 8750-2
Terminal 8750-3
8150 Battery Powered Flow Totalizer
5700
Wiring Information
• The terminal blocks for the 8550 are not labeled on
the back of the unit. An adhesive label is supplied
with the instruments with terminal descriptions to
serve as a remote terminal display to aid electrical
installations.
• The 8150 Battery Powered Flow Totalizer is com-
patible only with the AC output sensors, 515, 525.
The wiring is shown here. See Operation Manual for
more information.
Conductivity
745
Terminal 8850-1
Terminal 8850-2
III. Rear Terminal Views Signet Temperature, Level

and Pressure Instruments
Terminal 8850-3 Temperature
Terminal 8350-1
5800CR Terminal 8350-2
Terminal 8350-3
5900
Level
Terminal 8250-2
Pressure
Terminal 8450-1
8860
746
Terminal 8450-2
Maximum Cable Lengths for all sensors used with

the 8900
The I/O Module (3-8900.401-x) supports frequency and

(S³L) signal types. These signal types are fundamen-
tally different from one another, and the rules govern-
ing maximum cable lengths also differ, so the two types
Terminal 8450-3 must be treated separately. Refer to the following two
sections as necessary to determine the cable length lim-
itations of any system.
Signal Type: Frequency
The maximum allowable cable length for flow sensors

with frequency output is dependent upon the output sig-
nal strength of the sensors themselves, and the degree
to which the signals are susceptible to EMI or “noise”.
This is largely a function of whether the sensors are
self-powered, or powered by an external source.
All of the sensors in the table below are compatible with

the 8900. The three models limited to 60 m (200 ft) are
self-powered sensors. The 8900 automatically provides
power to the others via the I/O Module (normal sensor
III. Rear Terminal Views Signet Instruments wiring).
8900 Multi-Parameter
These maximum recommended cable lengths apply to
individual sensors and are completely independent of
one another. Additionally, these cable lengths have no
relevance to any digital (S³L) devices that may also be
connected to the I/O Module.
Flow sensor models with Frequency output
Max. Cable Length 60 m 305 m
(200 ft) (1000ft)
515 x
525 x
2000 x
2100 x
2507 x
2536 x
2537 x
2540 x
2551 x
2552 x
V. Rear Terminal Views Signet Instruments

9900 Transmitter
747
V. Rear Terminal Views Signet Instruments
9900 Transmitter
Note: Loop Power can be used to power Signet models

515, 525, 2250, 2350, 2450, 2536 and 2540 sensors
748
749
Technical Reference al to the fluid velocity. Internal electronics then convert
this voltage into a frequency and/or a 4 to 20 mA output.
Section: Flow Signet electromagnetic flow sensors are insertion-style,
suitable for use in a wide range of pipe sizes.
Velocity-based Flow Measurement Technolo-
gies
All of the flow sensors featured in the Signet catalogue
belong to the broad category of velocity-based flow
measurement devices. This vast offering includes pad-
dlewheel, electromagnetic, in-line rotor, and turbine flow
sensors. Principles of operation vary considerably for
each type, but some very important installation consid- 2551
erations are common throughout. The following discus- Paddlewheel flow sensors are insertion devices,
sion plus the general selection guidelines at the front of mounted perpendicular to the piping system, and rely
the catalogue should help the user choose the appropri- upon the energy in the flow stream to spin a rotor (pad-
ate sensor type and obtain optimal flow measurement dlewheel) around a stationary shaft. Most paddlewheel
results. All manuals, data sheets, and additional helpful flow sensors utilise rotors with magnets embedded in
information are available at www.gfsignet.com. each blade. The magnets are typically used either in
Fully Developed Turbulent Flow conjunction with a coil internal to the sensor housing to
produce a sinusoidal output (self-generating, non-pow-
Velocity-based flow sensors depend on fully developed ered sensors), or to trigger an internal electronic switch
turbulent flow for accurate and repeatable measure- to produce a square-wave output (transistor-type, pow-
ments. Fully developed turbulent flow occurs in Newto- ered sensors). Either way, the resulting frequency is di-
nian fluids with a Reynolds Number (Re) greater than rectly proportional to the fluid velocity.
4,500. Low flow rates, viscous liquids, and large pipe
sizes make fully developed turbulent flow more diffi-
cult to achieve. The opposite is also true. That is, for a
given set of conditions, simply reducing the pipe size
to increase the local flow velocity will produce a higher
Reynolds Number.
Re : Reynolds Number 1) Sinusoidal sensors output a signal typical of self-gen-
erating, nonpowered paddlewheel sensors such as the
Re = 3,162.76 x Q x Sg/(µ x ID)
model 515, 525. The frequency and amplitude (voltage)
where: both vary directly with flow rate.
Q = Flow rate in US GPM

Sg = Specific gravity
µ = Dynamic viscosity in Centipoise (cP)
ID = Pipe inside diameter in inches

OR

Re = DN x V/ν 515
where: 525
DN = Pipe inside diameter (m)

V = Flow velocity (m/s)
ν = Kinematic viscosity (m²/s) 2) Transistor-type sensors output a signal typical of-
(ν of water = 1 x 10 - 6 m²/s) powered sensors such as the model 2536, 2540, and
all other Signet powered flow sensors with frequency-
output.
Principles of Operation
Electromagnetic
flow sensors, like Signet models 2551 and 2552 operate
on Faraday’s principle of electromagnetic induction, and
have no moving parts. As fluid (must be conductive >20
μS) moves through the magnetic field produced at the
sensor tip, a voltage occurs that is directly proportion-
750
2536
2540
2100
Flow Range Charts (GPM)

Paddlewheel and Electromagnetic Sensors
2551
2537 Signet models 515, 525, 2536, 2537, 2540, 2551, 2552
GPM flow rates for DN15 to DN450 (1/2 in. to 18 in.)
In-Line rotor flow sensors like the Signet models 2000 pipe sizes
and 2507 are similar to paddlewheel sensors, except
the rotor is positioned in a flow cell. These types of sen-
sors have a transistor-type output signal and are able to
measure lower flow rates.
2000
2507
Turbine flow sensors are full-bore devices designed for

low-flow measurements. Signet model 2100 is offered
in 6.4 mm and 12.7 mm (1/4 in. and 1/2 in.) line sizes.
Many self-aligning end connector options are available
for installation simplicity and application versatility. Sim-
ilar to paddlewheels, they rely upon the energy in the
flow stream to spin a rotor (turbine). The difference is
that the shaft is in the centre of, and parallel to, the flow
stream. The velocity of the fluid spins the turbine for de-
tection by external electronic circuitry, producing a tran-
sistor-type square wave output with a frequency directly
proportional to the flow rate.
751
Nominal Pipe Size 2551/2552 2536/8512/2537/2540 515 and 8510 525
Inch Metric Min Max Min Max Min Max Min Max
DN
(mm) 0.15 ft/s 33 ft/s 0.3 ft/s 20 ft/s 1 ft/s 20 ft/s 1.6 ft/s 20 ft/s
0.5 15 0.14 31.25 0.28 18.94 0.95 18.94 1.52 18.94
0.75 20 0.25 54.85 0.50 33.24 1.66 33.24 2.66 33.24
1 25 0.40 88.89 0.81 53.88 2.69 53.88 4.31 53.88
1.25 32 0.70 153.84 1.40 93.24 4.66 93.24 7.46 93.24
1.5 40 0.95 209.40 1.90 126.91 6.35 126.91 10.15 126.91
2 50 1.57 345.15 3.14 209.18 10.46 209.18 16.73 209.18
2.5 65 2.24 492.45 4.48 298.46 14.92 298.46 23.88 298.46
3 80 3.46 760.39 6.91 460.84 23.04 460.84 36.87 460.84
4 100 5.95 1309.40 11.90 793.57 39.68 793.57 63.49 793.57
5 125 9.35 2057.74 18.71 1247.12 62.36 1247.12 99.77 1247.12
6 150 13.51 2971.57 27.01 1800.95 90.05 1800.95 144.08 1800.95
8 200 23.39 5145.63 46.78 3118.57 155.93 3118.57 249.49 3118.57
10 250 36.87 8110.73 73.73 4915.59 245.78 4915.59 393.25 4915.59
12 300 52.33 11512.97 104.66 6977.56 348.88 6977.56 558.20 6977.56
14 350 - - 126.49 8432.82 421.64 8432.82 - -
16 400 - - 165.24 11015.97 550.80 11015.97 - -
18 450 - - 209.16 13943.74 697.19 13943.74 - -
Flow Range Charts (LPM)

Paddlewheel and electromagnetic sensors
Signet models 515, 525, 2536, 2537, 2540, 2551, 2552
LPM flow rates for DN15 to DN450 (1/2 in. to 18 in.)
pipe sizes
Nominal Pipe Size 2551/2552 2536/8512/2537/2540 515 and 8510 525
Inch Metric Min Max Min Max Min Max Min Max
DN
(mm) 0.05 ft/s 33 ft/s 0.1 ft/s 6 ft/s 1 ft/s 20 ft/s 1.6 ft/s 20 ft/s
0.5 15 0.6 117.6 1.2 70.6 3.5 70.6 5.9 70.6
0.75 20 1.0 206.4 2.1 123.9 6.2 123.6 10.3 123.9
1 25 1.7 334.5 3.3 200.7 10.0 200.7 16.7 200.7
1.25 32 2.9 579.0 5.8 347.4 17.4 347.4 28.9 347.4
1.5 40 3.9 788.1 7.9 472.8 23.6 472.8 39.4 472.8
2 50 6.5 1298.9 13.0 779.4 39.0 779.4 64.9 779.4
2.5 65 9.3 1853.3 18.5 1112.0 55.6 1112.0 92.7 1112.0
3 80 14.3 2861.7 28.6 1717.0 85.9 1717.0 143.1 1717.0
4 100 24.6 4927.8 49.3 2956.7 147.8 2956.7 246.4 2956.7
5 125 38.7 7744.2 77.4 4646.5 232.3 4646.5 387.2 4646.5
6 150 55.9 11183.3 111.8 6710.0 335.5 6710.0 559.2 6710.0
8 200 96.8 19365.3 193.7 11619.2 581.0 11619.2 968.3 11619.2
10 250 152.6 30524.2 305.2 18314.5 915.7 18314.5 1526.2 18314.5
12 300 216.6 43328.4 433.3 25997.0 1299.9 25997.0 2166.4 25997.0
14 350 - - 523.7 31419.1 1571.0 31419.1 - -
16 400 - - 684.1 41043.4 2052.2 41043.4 - -
18 450 - - 865.9 51951.7 2597.6 51951.7 - -
752
Flow Range Charts (GPM and LPM)
In-line rotor and turbine sensors
Signet models 2000, 2100, and 2507 GPM and LPM
Flow Rates
GPM LPM
Model and Size Description Min Max Min Max
3-2000-1X Micro flow - low 0.030 0.700 0.110 2.600
3-2000-2X Micro flow - high 0.300 3.200 1.130 12.110
3-2100-XL and -31 kits Turbine low - 1/2" tubing 0.100 1.000 0.380 3.800
3-2100-XL and -34 thru -38 kits Turbine low - 1/2" pipe 0.100 1.000 0.380 3.800
3-2100-XL and -40 kits Turbine low - 1/2" flare 0.100 1.000 0.380 3.800
3-2100-XH and -31 kits Turbine high - 1/2" tubing 0.800 10.000 3.000 38.000
3-2100-XH and -34 thru -38 kits Turbine high - 1/2" pipe 0.800 10.000 3.000 38.000
3-2100-X and -40 kit Turbine high - 1/2" flare 0.800 7.000 3.000 27.000
3-2507-100-2V Mini-flow - 2mm insert 0.106 0.740 0.500 2.800
Common Bases
Section: pH/ORP Egg whites: 7.5 pH
Seawater: 8.0 pH
Information in this section addresses frequently asked Sodium bicarbonate: 8.4 pH
questions regarding pH & ORP and is provided as REF- Ammonia: 11 .6 pH
ERENCE ONLY to supplement procedures and rec- Photo developer: 12.0 pH
ommendations specifically outlined in individual prod- 0.1M NaOH: 13.0 pH
uct instruction manuals. All manuals, data sheets, Lye: 14.0 pH
and additional helpful information are available at
www.gfsignet.com Definition of ORP
ORP is an abbreviation for Oxidation-Reduction Poten-
Definition of pH tial. Oxidation is a term used to denote the occurrence
pH is defined as the negative logarithm of the hydro- of a molecule losing an electron. Reduction occurs as a
gen ion concentration in aqueous solutions. The com- molecule gains an electron. The “potential” is simply an
mon pH scale ranges from 0 to 14, with 7 being neutral indication of a solution’s propensity to contribute or ac-
water (H2O). At pH 7, hydrogen ions (H ) exist in equal
+
cept electrons. ORP reactions (sometimes referred to
concentration to hydroxyl ions (OH ). A solution is con-
-
as REDOX) always take place simultaneously. There is
sidered to be acidic if the concentration of H exceeds
+
never oxidation without reduction, and ORP electrodes
that of OH , and is indicated by pH values below 7. Con-
-
are used to detect electrons exchanged by molecules
versely, a solution is considered to be basic if the con- as these reactions occur.
centration of H is less than that of OH , and is indicated
+ -
Both pH and ORP electrodes produce voltages that de-

by pH values above 7.
pend on the solutions in contact with their sensing ends.
pH Scale Most pH electrodes, including the GF Signet brand,
are designed to produce 0 mV at pH 7, positive mV be-
low pH 7 (associated with the charge of the hydrogen
ion, H ) and negative mV above pH 7 (associated with
+
(Theoretical: 59.16 mV/pH @ 25°C) the charge of the hydroxyl ion, OH ). According to the
-
Common Acids Nernst equation, the interval between each pH unit is

1M HCl: 0.0 pH approximately 59.16 mV at 25 °C. This “raw” output is
Sulfuric acid: 0.3 pH converted to a pH value by the display instrument. The
Lemon juice: 2.0 pH ORP scale is typically - 1000 mV to +1000 mV, and the
Vinegar: 3.0 pH electrodes produce these values directly.
Wine: 3.5 pH Whereas pH is a specific measure of the hydrogen ion
Beer: 4.5 pH concentration in solution, ORP only provides relative
Milk: 6.0 pH measures of chemicals and cannot discriminate one
753
from another. Although non-specific, it is a very use- ver chloride element. The reference electrolyte can be
ful and inexpensive method of monitoring and control- refreshed if it is diluted or depleted. The temperature el-
ling the activity of such compounds as chlorine, ozone, ement is embedded in the pH/ORP electrode for an ex-
bromine, cyanide, chromate, and many other chemical tremely quick response.
reactions.
It is worth noting that temperature compensation, very
important for accurate pH measurement, is NOT used
in ORP measurements. Temperature does indeed af-
fect the reactionary potential of all chemicals, some to
a greater extent than others. But even if the affects of
temperature could be precisely known in all of the many
different REDOX reactions, it would not be desirable to
remove them from the measurement. True ORP is the
direct measurement of electrons in transit during oxida-
tion-reduction reactions, regardless of temperature.
Principle of Operation
Standard pH/ORP electrodes are also commonly called
combination electrodes; a pH/ORP measuring elec-
trode and a reference measuring electrode are com-
bined in a single body. The pH/ORP sensor measures
the amount of hydrogen ions in the liquid. The pH signal
is measured against the steady reference signal. Vari-
ous chemical elements leaching through the porous ref-
erence junction can react with the reference electrolyte,
dilute the electrolyte solution, or attack the silver chlo-
ride element; in either case, it will disturb the steady ref-
Differential pH/ORP electrode: Signet offers one group
erence signal. Stray electrical currents will also affect
of differential pH/ ORP electrodes, models 2764 - 2767
the steady reference signal. A temperature element is
also built into the pH/ORP combination electrode. In- Standard versus Differential pH/ORP Elec-
struments interpret and temperature compensate the trodes
pH/ORP and reference signals into pH/ORP readings at GF Signet offers what is called combination pH/ORP
25 °C (77 °F). electrodes; that is, there is a combination of three or
four electrodes built into one common body that mea-
sures the pH or ORP of the solutions. These electrodes
are the pH/ORP sensing element, temperature sensing
element (pH only), the reference, and sometimes a so-
lution ground. An electrical path between the process
solution, reference electrode, and the pH/ORP sensing
electrode must always be present to complete the mea-
suring circuit. When the circuit is broken or interrupted,
the result is a faulty reading. There are only a few things
in a chemical process that would affect the glass-sens-
ing element. These include concentrations of HF, con-
stant high temperatures, and particles that can break
the glass.
On the other hand, there are many problems that can
occur with the reference electrode. The reference silver
chloride sensing element (wire) is exposed to the pro-
cess liquid via the primary porous reference junction,
which is in constant contact with the process and allows
Standard pH/ORP electrode: GF Signet offers three dif- liquid to pass through to the reference electrolyte. Be-
ferent groups of standard pH/ORP electrode models, cause of the direct contact with the process liquid, the
2724 - 2726, and 2774 - 2777 reference electrolyte and reference silver chloride sens-
ing element can react with chemicals in the process.
Differential pH/ORP electrodes function similar to the Many application liquids do not chemically react with the
standard (combination) electrodes, but the reference reference and therefore a standard electrode will per-
design is modified and there is a third electrode, the form well in this scenario. However, there are other pro-
solution ground. The pH and reference electrodes are
measured against the solution ground. The solution
ground drains stray currents away from the reference el-
ement, hence maintaining a steady signal at all times.
The reference salt bridge slows or stops various chem-
ical elements from leaching into the reference cham-
ber. Chemicals that leach in may dilute the electrolyte
but will not react with the glass-encased reference sil-
754
cess chemicals that will easily attack the reference and quantities of HF (<2 %), use the Signet 3-2726-HF-
therefore, a differential style electrode should be used. electrode. This electrode has a polymeric constituent
There are three advantages of the differential electrode: in the pH glass that resists attack by HF and extends
1.If the process chemicals attack the KCl electrolyte, the the service life considerably over “normal” electrodes.
reference electrolyte chamber is refillable. • In applications where process temperatures will drop
2.If the reference junction becomes clogged by chemi- below 10 °C (50 °F), use the bulb-style electrodes in
cal reactions between the KCl and the process chemi- place of the flat-style electrode. This is a function of
cals, the reference salt bridge is replaceable. the electrical impedance of the glass that increases
dramatically as temperature decreases.
3.If there are stray currents or if there are process
chemicals that attack the silver chloride wire in the • Proper electrode placement within a tank is also very
standard electrodes, it will not attack it in the differen- important. Electrodes should be mounted in well-
tial electrode because the wire is encased in a glass mixed areas, away from reagent and waste introduc-
electrode. tion. It is usually advisable to position the electrode
near the discharge outlet of the tank.
A general rule of thumb is to use a differential electrode • In-line pH control is not recommended because it is
if you have mercury, copper, lead, chlorate, bromine, io- very difficult to determine the amounts of reagent nec-
dine, cyanide, or sulfide compounds in the process liq- essary to achieve a desired reaction if both pH and
uid. Differential electrodes may also be useful in pro- flow are variables. However, in-line pH monitoring is
cesses that have oil, grease, or dirt that builds up on the very common and useful.
reference junction because it is easily replaced.
Maintenance Tips
See Model 2764-2767 Differential pH/ORP catalog
pages for more information on standard versus differen- • Cleaning pH and ORP electrodes and calibrating the
tial electrodes. systems should be done regularly. The required fre-
quency is application-dependent, but once/week for
Important Application Tips cleaning, and twice/month for calibration is recom-
• It is important that the sensing end of pH and ORP mended.
electrodes remain wet, for they may be permanently • Isopropyl alcohol may be used for removing mild
damaged if allowed to dehydrate. This is true for both grease and oils from the pH sensitive glass or from
in-line and submersible installation configurations. the metallic tips of ORP electrodes. Use 5 % HCl on
However, be careful to keep the electrical intercon- porous reference junctions clogged with hard water
nection between electrode and preamplifier dry and deposits, or other solvents/detergents as necessary.
clean at all times. Moisture in this area can also cause Always consider the electrode’s materials of construc-
permanent damage. tion when selecting a cleanser.
• Some pH and ORP electrode models should be in- • The purpose of calibration is to compensate the sys-
stalled greater than ±30 ° above the horizontal plane, tem for the continual changes occurring within the
so the internal solutions remain in contact with the electrodes. Like batteries, all pH and ORP electrodes
sensing ends. Other electrodes allow horizontal or in- eventually deplete and must be replaced. A good
verted installation. See individual sensor models for time to determine the condition of an electrode is after
more information. cleaning and during calibration. Note the mV readings
• pH control is best when performed in a tank. This is in pH buffers and replace the electrode if its actual mV
especially true in neutralisation applications since it output differs more than 50 mV from these theoretical
is very important for reagents to mix thoroughly with values: pH 7 = 0 mV, pH 4 = +177 mV, pH 10 = -177
waste fluids, and to be allowed adequate time for the mV. Replace an ORP electrode if its actual mV output
reactions to occur. Limiting adjustments to fewer than differs more than 50 mV from the theoretical values in
3 pH units per stage, and sizing tanks to provide at the table below:
least 10 minutes retention time, will increase the prob-
ability of producing safe effluents. ORP values of standard pH buffers saturated with
quinhydrone
• For bulb-style pH and ORP electrodes, significant nat-
ural self-cleaning by turbulent eddies is achieved at pH4 pH7
velocities of 1.5 m/s or more (5 ft/s). Flat surface elec-
trodes get adequate self-cleaning at velocities of 0.3 Temperature (°C) 20 25 30 20 25 30
to 0.6 m/s (1 to 2 ft/s). In all cases, exposure to veloc- ORP value (mV) 268 264 258 92 87 79
ities greater than 3 m/s (10 ft/s) can cause excessive
measurement noise and electrode wear and should • The typical shelf-life recommendation for GF Signet
be avoided. pH and ORP electrodes is 12 months at 25 °C (77 °F).
• Simply stated, the aging of pH and ORP electrodes • Refrigeration will extend this period, but do not allow
(i.e., reference depletion and decreased glass sensi- them to freeze! Expansion of internal solutions during
tivity) results from a series of chemical reactions. And freezing can cause permanent damage to the elec-
as a general rule, the rates of chemical reactions dou- trodes.
ble with every increase of 10 °C (50 °F). This means
• The risk of putting older electrodes into service is
shorter life expectancy for all pH and ORP electrodes
the possible disappointment of shorter than expect-
as application temperatures increase.
ed service life. All Signet pH and ORP electrodes are
• HF acid and strong caustics etch pH glass. High con- marked with date codes to identify the date of manu-
centrations, especially at high temperatures, destroy facture.
electrodes quickly. For applications containing trace
755
Section: Conductivity/Resistivity
Information in this section addresses frequently asked
questions regarding conductivity (resistivity) and is pro-
vided as REFERENCE ONLY to supplement proce-
dures and recommendations specifically outlined in in-
dividual product instruction manuals. All manuals, data
sheets, and additional helpful information are available
at www.gfsignet.com.
Definition of Conductivity and Resistivity Principle of Operation
Conductivity is a measure of the ability of a material to Most conductivity electrodes consist of two measuring
convey an electric current. The proper term for this abil- half-cells. The geometry of the half-cells can be tailored
ity of a solution is electrolytic conductivity since only to provide highly accurate measurements over a spe-
ions conduct electric current in solution. When dissolved cific conductivity range. Cell constants help to describe
in solution, many substances such as salts, acids and electrode geometry for the purpose of selecting the ap-
bases dissociate into ions. Electrolytic conductivity (or propriate electrode for a given application. A cell con-
simply conductivity) is therefore an indirect measure of stant is defined as the length between the two half-cells
the ionic concentration of a solution. Generally, conduc- divided by the area of the cells.
tivity increases and decreases with the concentration of
ions. Conductivity cell constant = Length/CSA = z/xy
As an example, When x = y = z = 1cm the cell constant
Unlike pH, which is a specific measure of hydrogen ion becomes 1cm/1cm² = 1cm-1
concentration, conductivity is a non-selective measure-
ment of all the dissolved ionic species in a solution. As *CSA is cross-sectional area.
such, it is a highly utilised parameter in water, waste
water and industrial process analyses. For example,
conductivity is used to monitor the salt load of waters
entering treatment facilities, to monitor and control the
quality of drinking water and ultra pure water, and to
otherwise detect contaminants in industrial processes.
According to the International Standards Organization
(ISO) the unit of conductance is the Siemens (S), after
Werner von Siemens (1816-1892). However, the follow-
ing three separate units of measure are commonly used
to express conductivity: Siemens/cm (S/cm), mhos/ cm,
and µS/cm. For any given measurement Siemens/cm
and mhos/cm are exactly equal; they are merely dif-
ferent labels for the same value. The denominator in
these units (cm) is sometimes truncated but is always
assumed to be present.
Ohm·cm is a unit of resistivity (the inverse of conductivi-
ty) and is frequently replaced by “Ω” the symbol for elec-
trical resistance. Units of resistivity are most common- Solutions of very low conductivity (high resistivity) such
ly associated with ultra pure water measurements in the as ultra pure water are best measured with half-cells
millions of ohm·cm, or MΩ (megohms). that are very close together (i. e., cell constant = 0.01
cm ). Highly conductive solutions should be measured
-1
Some users will also find it desirable to express conduc- with half-cells that are farther apart and that have rela-
tivity in terms of parts per million (PPM) or parts per bil- tively little cross-sectional area between them (i. e., cell
lion (PPB) of total dissolved solids (TDS). GF Signet in- constant = 20.0 cm ).
-1
struments accommodate this by allowing the entry of

a TDS factor to convert from standard units of conduc- Temperature Compensation
tivity. (See the instruction manual of any current GF The conductivity of a solution is highly dependent upon
Signet conductivity instrument for details.) temperature. Therefore, conductivity measurements are
Conductivity is a measurement parameter with a very almost always converted to an equivalent conductivity
wide range. For example, ultra pure water has a theo- at the common reference temperature of 25 °C (77 °F).
retical maximum resistivity of approximately 18.3 MΩ, This is accomplished by means of temperature com-
approximately 0.055 µS (microsiemens), whereas con- pensation algorithms in the instruments, which require
centrated acids and bases can exceed 400,000 µS. De- temperature as well as conductivity measurement input.
spite the wide-ranging possibilities most applications To simplify and facilitate this requirement all GF Signet
for conductivity measurement are much narrower. Tap conductivity electrodes contain high-quality temperature
water, for instance, typically measures between 50 and sensing elements intelligently positioned for quick and
1,000 µS. accurate response.
Temperature effects on conductivity are more or less
linear for normal water-based solutions, hovering
around 2 % per °C. However, the actual linear relation-
756
ship varies considerably with the ionic composition of conditions for reliable continuous conductivity measure-
the solution and can range from less than 1 % to more ments. If the application is such that sediment is likely to
than 3 % per °C. This is true of regional ground water accumulate on the bottom of the tank, then position the
sources as well as for other solutions such as brack- electrode to avoid it being smothered by debris.
ish water, acids and bases. Signet instruments allow
the entry of custom linear compensation coefficients
for these applications. See the instruction manual of
any GF Signet conductivity instrument for details. The
conductivity or resistivity of pure water is not a linear
function with respect to temperature. In fact, the latest-
GF Signet conductivity instruments utilise a sophisticat-
ed polynomial to compensate for the peculiar effects.
For seamless measurement accuracy all current GF
Signet conductivity instruments switch automatically be-
tween linear and pure water compensation as certain
measurement thresholds are crossed.
Temperature Compensation Exception
One exception to the requirement for temperature com-
pensation has been established by USP (United States
Pharmacopeia), which prescribes limits of acceptabili-
ty for ultrapure water quality based upon non-compen-
sated measurements. This methodology is used to elim-
inate measurement variances that may result from dif-
ferences in the pure water temperature compensation
algorithms used by different manufacturers of conduc-
tivity measurement equipment. A more thorough treat-
Mounting a submersed sensor on the side of the baffle
ment of the USP standard and instrument functionality
that is free of air bubbles is preferred.
can be found in the instruction manuals of the following-
GF Signet conductivity instruments: Model 8900 Multi- Most GF Signet conductivity electrodes are supplied
Parameter Controller, Model 8860 Dual Channel Con- with a standard 4.6 m (15 ft) of cable. Generally, this
ductivity/Resistivity Controller. can be extended up to a maximum of 30 m (100 ft). If
splicing in the field, then use good quality 3-conduc-
Important Application Tips tor shielded 22 AWG cable and be sure to maintain the
The two basic installation configurations for conductivi-
shield through the splice. Electrode cable should be
ty electrodes are in-line and submersible. In-line config-
routed separately from power wiring. The maximum al-
uration refers to installation into a piping system as op-
lowable cable length for resistivity measurements above
posed to submersion in a tank. In either case the prima-
10 MΩ (below 0.1 µS) is 7.6 m (25 ft), except for the
ry considerations are to minimise the propensity for air
model 2850 conductivity sensor which allows cable
entrapment inside and/or around the electrode and to
lengths of almost 915 m (3,000 ft) for all measurements.
position the electrode for representative exposure to the
process. The primary purpose of calibration is to compensate the
system for possible changes occurring to the electrode’s
In-Line Installation
cell constant. Since the cell constant accuracy of all GF
For in-line configurations it is best to install the electrode
Signet conductivity electrodes is tightly controlled, and
in the “dead leg” of a tee fitting. That is, use a tee fitting
since brand new electrodes should be allowed to “soak”
in place of an elbow and install the electrode in the hor-
overnight prior to calibration, “out-of-the-box” calibration
izontal plane. Best results will be obtained if fluid flows
of conductivity systems is not recommended.
into and around, then up and away from the electrode.
Be sure that at least one of the holes in a flow-through Maintenance Tips
electrode is facing upward to allow air bubbles to es- Conductivity electrodes are not inherently perishable
cape. as pH and ORP electrodes. This means system calibra-
tions and electrode replacements are typically not re-
quired as frequently. However, depending upon the ap-
plication, conductivity electrodes may require periodic
cleaning to remove coatings, algae growth, scale build-
up, etc. Use isopropyl alcohol for removing mild grease
and oils, and/or other cleansing agents as necessary.
Always consider the electrode’s materials of construc-
tion when selecting a cleanser.
Upward flow is the preferred installation when mounting The shelf-life of GF Signet conductivity electrodes is lim-
the sensor in a tee. itless. However, oxidation can cause cell constants to
drift over time. If there is any doubt about an electrode’s
For submersible installation when conductivity elec- condition, then clean it thoroughly before placing it into
trodes are submerged in tanks beware of mechanical service.
mixers, sparges and inlets as potential sources of air
bubbles. Baffles may be used to create more favourable
757
When installing new electrodes, it is recommended to and improve precision. Establishing a proportional con-
“soak” the electrode into the process solution for several trol scenario requires the selection of setpoint(s), devi-
days before the first use. This will condition the surfaces ation range(s) and maximum pulse rates. The example
of the electrode. shown here illustrates how two relays in ”pulse mode”
can be used to proportionally control pH within a desired
Relay Information range, or to a single setpoint. This is called “Dual Pro-
portional Control”. Of course, a single relay in propor-
The two most common methods of controlling a process tional pulse mode can be used to establish a high or low
are “on/off” and “proportional” control. In on/off control, limit and will also reduce overshoot.
relay setpoints are defined as either high or low limits
on the process variable. When the measurement val- Metering pumps are idle at and between setpoints.
ue reaches a limit the relay is energized, typically for When a setpoint is exceeded, the pump begins deliver-
the purpose of opening a valve or starting a pump to in- ing reagent at a rate proportional to the difference be-
troduce a chemical reagent to the process. This should tween the measurement value and the setpoint. The
cause the measurement value to change in the direc- larger the difference, the faster the delivery. The pro-
tion of the setpoint as shown in these on/off control dia- grammed deviation value defines how quickly the max-
grams: imum pulse rate is reached. Depending on the input re-
quirements of the metering pump, proportional control
High limit on/off relay control can also be accomplished with scaleable 4 to 20 mA
outputs instead of pulsing relays or open collectors.
Dual proportional pulse relay control
Low limit on/off control
Open collector output

Many GF Signet instruments and sensors feature “Open
Collector Outputs” for purposes of signal transmission,
alarming, control signal output, etc. Although such out-
puts allow for a lot of wiring flexibility, care must be
Notice the relay will not de-energize until the setpoint taken not to destroy the circuits via incorrect polarity,
is exceeded by the hysteresis value. This is a pro- over-voltage, transients or current overload. Below is
grammable value and is primarily used to prevent ”relay an explanation of proper wiring and dimensioning of re-
chatter”, which occurs if a relay is set to energize and lated circuit components. Please note that the follow-
de-energize at the same value. Because of hysteresis, ing recommendations may or may not apply to other
and because reagent delivery is fairly constant while the manufacturer’s equipment.
relay is energized, a condition known as “overshoot” is
inherent to the on/off control method. Overshoot refers 1. Function
to the introduction of more chemical reagent than is ab- Open Collector (“OC”) outputs are low-powered, sol-
solutely necessary for achieving a desired adjustment to id state switches. Although the term “Open Collector”
the process value, and can be expensive over time. stipulates the use of bipolar transistors (NPN-type or
PNP-type) as a switch, nowadays Field Effect Transis-
Proportional control is a popular alternative to the on/ tors (FET or MOSFET) are used. Unlike electromechan-
off control method. This method typically makes use ical switches (e. g. pushbuttons or dry contact relays)
of variable rate metering pumps to reduce overshoot these OC switches are very fast, use little power, are
758
inexpensive, do not bounce and do not wear. Howev-
er, OC’s are also more limited in terms of voltage and
current rating as well as being polarized (i. e. they have
a “plus” and “minus” terminal and thus DC only switch-
ing capability). They are less tolerant to overload abuse
than electromechanical devices. Usually these switches
have higher resistance and voltage drop.
2. Sensor Wiring
A typical example of the need for high speed switching
capability is the OC frequency output of GF Signet flow
sensors like 3-2536 or 3-2540. Signal frequencies can Alarm circuit or alarm lamp wiring to a single Signet
reach several hundred pulses per second while voltage instrument
and current requirements are small enough, allowing
the use of a transistor switch. For each output pulse this
switch connects the signal output to the negative sup-
ply or ground terminal of the sensor and is therefore an
“NPN” style output. GF Signet does not produce sen-
sors with PNP style outputs (which connect the signal
output internally to the positive supply terminal). Most
indicating instruments or control system inputs require
a signal voltage of 0 to 5 V (TTL or CMOS logic lev-
els) or 0 to 24 V. Therefore, Open Collector output cir-
cuits must be complemented with a “Pull-Up-Resistor” Alarm circuit or alarm lamp wiring to serve multiple
to function properly. Please see the following example Signet instruments
diagram for wiring with a PLC input: (Triggers the alarm if any one of the instruments open
collector outputs are on)
Do not exceed the absolute maximum voltage rating of

the OC output as listed in the sensor specifications, nor- 4. Voltage and Current Limitation
mally 27 or 30 Volt, DC only. This includes changes to As mentioned before, the supply voltage in the OC out-
power line fluctuations, transients or power supply insta- put circuit MUST be limited to the specified maximum
bility, otherwise damage to the OC will occur. OC voltage (see operating manual for specific instru-
ment). The use of a quality regulated 5 V, 12 V or 24 V
Please note that the voltage connected to the positive (depending on the application) power supply is recom-
sensor supply (V+) must correspond to the required mended.
high-level PLC input voltage (i.e. if the high-input volt-
age of the PLC is 24 V, then the pull-up must be sup- Depending on the stability of the main power line and
plied with 24 V). If the input is “TTL-Level” or “CMOS- the location, it may be necessary to use additional over-
Level”, that means 5V for high level, then the pull-up voltage protection components or lightning arrestors.
should not be connected with a supply higher than 5 V. Similarly, the current through the open collector switch
must be limited. Typical OC outputs allow only for 10 to
3. Instrument Output Wiring 50 mA switch current (please consult manual). Exceed-
Open collector control and alarm outputs on Signet in- ing this current limit can burn out the OC output compo-
struments (i. e. ProcessPro or ProPoint series) are elec- nents immediately. Please see the following section on
trically isolated from the instrument’s power supply. how to dimension the loads.
That means these can be used in the above mentioned
NPN configuration as well as in PNP configuration, if re- 5. Load and Pull-Up/Down Resistor Considera-
quired. Below are a few sample circuits: tions
By utilising basic arithmetic and Ohm’s law, one can de-
PLC wiring “NPN” style termine the safe limits of load resistance. When the OC
switch is closed, almost the entire supply voltage is ap-
plied to the load, (i. e. the pull-up or pull-down resistor,
the alarm horn input, a potential power relay coil or an-
nunciator lamp). The resulting current through the load
and through the OC switch, as well, can be calculated
as:
(Current) = (Supply Voltage)/(Load Resistance)
• Example 1:
759
The supply voltage is 24 V and a pull-up resistor of Many Signet products offer control outputs that can be
10kΩ is used. Current is 24/10,000 = 2.4 mA (If the categorized into three categories: Mechanical Relay,
OC current rating is 10 mA, then in this example, it Solid-State Relay and Open Collector. Each control out-
would be considered safe). put offers benefits and limitations based on the applica-
• Example 2: tion requirements. See below for comparisons.
The supply voltage is 12 V and a horn with a resis- Open Collector
tance of 100Ω is used. Current is 12/100 = 120 mA
(Even if the OC current rating is 50 mA, this load will Benefits:
damage the instrument). • Longer life than a Mechanical Relay
• No moving parts
6. Transient Protection
There are several “difficult” load cases that must be • Can switch DC voltage only (typically ≤ 30VDC)
considered: • Faster ON/OFF switching capabilities than Mechani-
• Inductive loads: These can be power relay or oth- cal Relays
er solenoids, motors, alarm horn coils, etc. Such Considerations:
loads generate very high voltage spikes when the OC
• Can only be used with DC voltage
switch is turned off. If such a load is unavoidable, the
use of transient suppression components or RC filters • Polarity very important when wiring
(or snubbers) wired parallel to the load is required. • Not recommended for use with inductive loads
This is critical, as a single transient pulse may destroy • Lower voltage and current ratings than Mechanical
the output. Relays
• Capacitive loads: This type of load should be rare • Typically should not apply current >25mA
but can occur if the load contains an internal power
supply/regulator that is fed from the OC output circuit. Solid-State Relays
In such a case, it must be assured that the in-rush
current does not exceed the OC current rating. Benefits:
• Has isolated outputs (optically)
• Incandescent lamps: Such lamps have a very high
start-up current until the filament glows and the cur- • Can switch DC voltage (typically ≥ 40VDC)
rent settles to the specified value. The use of incan- • Can switch AC voltage (typically ≥ 33VAC)
descent lamps on an OC output is not recommended. • Longer life than a Mechanical Relay
An LED type annunciator should be used instead.
• No moving parts
7. "Active High" and "Active Low" Setting • Faster ON/OFF switching capabilities (Equal rise/fall
Depending on the desired function of the circuit at- times)
tached to the OC output, it may be necessary to have
Considerations:
the OC output switch turned “on” or “off” when the crite-
ria for the activation of this output are met. • Not recommended for use with:
Inductive loads (ex. Solenoid, Pumps)
By default, GF Signet instruments are set to operate in If using inductive loads, snubbers (RC Filter) can pre-
“active low” mode. This means when the user-defined vent IC damage
condition for the activation is met (e. g. exceeding of
• Lower voltage and current ratings than Mechanical
an alarm limit) the OC switch is turned “on”. If wired as
Relays
standard “NPN-style” output (see previous page) the
logic level of the attached control system or PLC input Mechanical Relays
consequently becomes “low” logic level.
Benefits:
If a high input logic level is required for activation, it can
• Can switch line voltage (typically ≥ 120 to 240 VAC)
be accomplished in two ways:
• Can switch DC voltage (typically ≥ 30VDC @ 5A)
• wire the OC output “PNP” style as described on the
previous page • Has a large current rating (typically 5A to 10A)
• change the OC output function to “active high” in the • Larger voltage and current ratings than Solid-State
menu system of the instrument. Most Signet instru- Relay and Open Collector Outputs
ments allow for this option. Considerations:
8. Fail-Safe Behaviour • Slower ON/OFF switching capabilities than Sol-
No matter what the setting, all OC outputs of GF Signet id-State Relay and Open Collector Outputs
instruments turn off when the instrument loses pow- • Mechanical contacts can burn/wear over time
er. This must be taken into account when evaluating • Snubbers (RC Filter), Signet 3-8050.396, can prolong
system failure consequences. If the system layout re- contact life
quires a “closed” or “on” condition for the output in case
of power loss, a mechanical dry contact relay (NC con-
tacts) must be used instead of the OC output. RC Filter
RC Filter kits are recommended when using a Signet
Control Output Comparisons transmitter or controller with mechanical relays, and/or
the external relay module 3-8059 to switch on and off
Control Outputs
inductive loads. Signet RC filter kits provide protection
and extend the life of the relay by preventing premature
760
wearing of of the relay contacts, usually caused by volt-
age/current arching and line noises generated by the Conversion Factors
activation and deactivation of mechanical relays.
Volume
RC filter kit (3-8050.396) comes with two RC filter as- To Convert Into Multiply by
semblies.
Gallons (U.S.) fl. oz. (U.S.) 128
Gallons (U.S.) cubic in. (in3) 231
Gallons (U.S.) cubic ft. (ft3) 0.1336
Gallons (U.S.) liters 3.785
Gallons (U.S.) cubic meters (m3) 0.00379
Gallons (U.S.) pounds 8.33
Gallons (U.S.) cubic centimeter (cm3 3785.41
or cc)
Gallons (U.S.) Gallon (UK) 0.833
Gallons (U.S.) milliliter (mL) 3785.41
During the activation and deactivation of a relay, a spark Cubic ft. (ft3) liters 28.32
can be generated on the surface of the relay contacts. Cubic ft. (ft3) cubic meter (m3) 0.028317
This spark, over a period of time, melts the surface of
Liters ft. oz. (U.S.) 33.81
the contacts which will prevent the contacts from mak-
ing a physical connection. Liters cubic in. (in3) 61.02
Figure A is suitable for AC and DC applications Liters cubic ft. (ft3) 0.0353
Liters Gallons (U.S.) 3785.41
Cubic meter (m3) cubic ft. (ft3) 35.31
Cubic meter (m3) Gallon (UK) 219.97
Cubic meter (m3) Gallons (U.S.) 264.17
1 Acre foot Gallons (U.S.) 325.853
Cubic ft. (ft3) Gallons (UK) 6.23
Cubic ft. (ft3) Gallons (U.S.) 7.48
Pressure
Figure B is also suitable for AC and DC applications. To Convert Into Multiply by
However, if this configuration is used with an AC pow-
er source, verify that the impedance of the load is less psi bar 0.069
than the impedance of the RC filter; current leak through psi kPa 6.89
the filter may occur and cause the device to be con- psi atmosphere 0.068
stantly on.
• R = 47 Ω psi mm of Hg 51.71
• C = 0.01 μF atmosphere bar 1.013

atmosphere psi 14.696
atmosphere kPa 101.325
atmosphere mm of Hg 760
bar psi 14.5
bar kPa 100
bar atmosphere 0.987
bar mm of Hg 750.06
kPa bar 0.01
kPa psi 0.145
kPa atmosphere 0.00987
kPa mm of Hg 7.5
761
Temperature Area
To Convert Into Multiply by To Convert Into Multiply by
Deg F Deg C (F-32)*0.5555 Acre Hectare 0.4047
Deg C Deg F C*1.8+32 Acre square ft. (ft2) 43559.66
Acre square meter (m2) 4046.82
Length
Acre square kilometer 0.004047
To Convert Into Multiply by (km2)
inch meter (m) 0.0254 square meter Hectare 0.0001
inch millimeter (mm) 25.4 (m2)
inch centimeter (cm) 2.54 square meter square ft. (ft2) 10.764
(m2)
foot meter (m) 0.3048
square centime- square ft. (ft2) 0.00108
foot millimeter (mm) 304.8 ter (cm2)
foot centimeter (cm) 30.48 square inch (in2) square centimeter 0.155
(cm2)
cm foot (ft.) 0.0328
cm inch (in.) 0.3938 Equations:
m foot (ft.) 3.28 Flow:
m inch (in.) 39.37 • To convert fluid velocity into a volumetric flow rate.
GPM = (ID2 x Feet/sec)/0.4084967
Flow rate LPM = 0.0471189 x ID2 x m/s
• To conver volumetric flow rate into fluid velocity.
To Convert Into Multiply by
Feet/sec = (GPM x 0.4084967)/ID2
gallon (US)/min m3/h 0.227 m/s = (LPM x 21.22291)/ID2
gallon (US)/min l/s 0.063
Conductivity
gallon (US)/min ft3/min 0.134
Conductivity = 1/Resistivity
ft3/min m3/h 1.699
1/Ohm = 1 Siemen = 1 mho
ft3/min l/s 0.472
Measured conductivity = ((solution conductivity)
ft3/min gallon (US)/min 7.48 x (electrode sectional
m3/h l/s 0.2278 area)) / electrode separa-
tion
m3/h ft3/min 0.589
Measured conductivity = Siemen/cm
m3/h gallon (US)/min 4.4
Nominal Pipe Sizes
l/s m3/h 3.6
Below are the NPS (Nominal Pipe Sizes) inch names
l/s ft3/min 2.12
and their metric equivalents called DN or diamtre
l/s gallon (US)/min 15.85 nominel. The metric designations conform to Interna-
tional Standards Organization (ISO).
Weight
To Convert Into Multiply by
ounce (Av.) grams (g) 28.35
pound (Av.) grams (g) 453.59
pound (Av.) ounce (Av.) 16
grams (g) ounce (Av.) 0.035274
grams (g) pound (Av.) 0.0022046
762
Metric NPS (inch) Metric NPS (inch)
DN (mm) DN (mm)
6 1/8 450 18
8 ¼ 500 20
10 ⅜ 550 22
15 ½ 600 24
20 ¾ 650 26
25 1 700 28
32 1.25 750 30
40 1.5 800 32
50 2 900 36
65 2.5 1000 40
80 3 1100 42
100 4 1200 48
125 5 1400 54
150 6 1500 60
200 8 1600 64
250 10 1800 72
300 12 2000 80
350 14 2200 88
400 16
Application Assistance Form

Please provide as much detail as possible for prompt assistance. Fax the completed form to Technical Support at your local FG
sales office.
Date:
Company:
Contact:
Address:
City: State/Province: Zip/Postal Code:
Country:
Phone: Ext: Fax:
Name of project:
GF Distributor: Contact: Tel:
Description of application(use seperate sheet if necessary):

Piping system: (if flow sensor, on separate sheet sketch piping system - see Installation section for upstream and downstream
requirements)
Piping material: Size: Schedule: Angle: Vertical or Horizontal
Fluid temp. range: min: max: nominal: Control range:
Line press. range: min: max: nominal: Control range:
Process pH range: min: max: nominal: Control range:
Cond/Resist range: min: max: nominal: Control range:
Turbidity range: min: max: nominal: Control range:
763
Sensor mounted: Indoor or Outdoor Indicator mounted: Indoor or Outdoor
Sensor mounted: In-line or Submersible
If submersible, tank size and shape:
Fluid to be measured: Chemistry:
Fluid viscosity: Specific gravity:
Percent solids: Description: Size of solids:
Flow rate: min: max: nominal:
Back pressure after sensor: psig/bar
Required accuracy: Unit of measurement:
Cable run from sensor to indicator: ft./m
Available power: Amperage:
Required outputs &
Qty:
764
Operating Temperature & Pressure
Graphs
Operating Temperature & Pressure Graphs:
Flow Sensors
Model 515
Model 525
Model 2536 and 2537*
Model 2540
*2537 only:
Graph applies to wetted materials (sensor) only. Maxi- Model 2551
mum ambient temperature is 65ºC.
Model 3519 WetTap
765
Pressure Drop Graphs: Flow Sensors
Model 2000
Model 2552
Model 2100
Model 2100
Model 2507
Model 2507
766
Model 3719

pH/ORP Electrodes
Models 2724-2726

Conductivity Electrodes
Model 2819, 2820, 2821
Models 2764-2767
Models 2774-2777
Model 2822
767
Model 2823 Model 2450
Models 2839-2842

Fittings
Note: The pressure/temperature graphs are specifical-
ly for the Signet sensor. During system design the spec-
ifications of all components must be considered. In the
Operating Temperature & Pressure Graphs: case of a metal piping system, a plastic sensor will re-
Temperature/Pressure Graphs duce the system specification. When using a PVDF sen-
sor in a PVC piping system, the fitting will reduce the
Model 2250 system specification.
PVC-U and PVC-C Tees
Model 2350
Fiberglass Tees

768
Metal Tees
PP and PDVF Tees

Backpressure Drop Graphs: Flow Sensors
Backpressure Calculation:
Minimum downstream pipe backpressure levels (full pipes)
are required to prevent cavitation within the sensor. The min-
imum back pressure is calculated by the following formula:

2.7 x ΔP + 1.3 x Pv

ΔP = Pressure drop across sensor
Pv = Liquid vapor pressure at operating temperature
Model 7000-7001
Metal Weldolets and Saddle Fittings
769
770
Glossary Boolean: A logic system treating variables through the
operators AND, OR, NOT, and XOR, where each opera-
4 to 20 mA: A standard analogue (also analog) signal
tor can have one of two values, true or false.
used for the proportional representation of a measure-
ment variable or process condition. Buffer: Typically a solution used as a calibration stan-
dard due to its ability to maintain a stable pH value.
Absorb: To take up or receive by chemical or molecular
action. Calibration: Systematic adjustment of the display and/
or output of a measuring instrument for the purpose of
AC(Alternating Current): An electric current in which the
conforming to a standard or actual value.
flow reverses periodically. Compare direct current (DC).
Caustic: Any strongly corrosive chemical substance,
Accumulator: See Totalizer
especially one that attacks organic matter. A caustic al-
Accuracy: The ability of a measurement to match the kali is a metal hydroxide, especially that of an alkali met-
actual value of the quantity being measured. al; caustic soda is sodium hydroxide, and caustic potash
is potassium hydroxide. Most inorganic acids, e. g., sul-
Acid: A corrosive liquid (usually in a solution) that dis-
phuric acid, are caustic, especially when concentrated.
solves metals and other materials. Technically, acidic
material produces positive ions in solution. An acid is Cavitation: The formation and collapse of a gas pocket
the opposite of a base and has a pH between 0 to 7. or bubble due to mechanical shearing of a fluid.
A given amount of an acid added to the same amount
CE: Conformité Européene. A mark that is affixed to a
of a base neutralises the base, producing water and a
product to designate that it is in full compliance with all
salt. Common vinegar, for example, is a weak solution
applicable European Union legal requirements.
of acetic acid.
Cell Constant: 1) The distance between the two elec-
Active Outputs: These outputs throttle current in loops
trodes of a conductivity cell divided by their cross-sec-
powered by the 8900; no external power source is re-
tional area. 2) A value associated with an effective mea-
quired.
surement range used in the proper selection of conduc-
Adsorption:The clinging of molecules to the surface tivity cells for specific applications.
of particles; the process by which activated carbon re-
Chlorine: A halogen element, a heavy, greenish-yel-
moves contaminants from water.
low, incombustible, water-soluble, poisonous gas, ob-
Alkali: A bitter, caustic mineral often found in large beds tained chiefly by electrolysis of sodium chloride brine:
in the desert. Alkalis are bases; two common examples used for water purification in the making of bleaching
are lye and ammonia. powder, and in the manufacture both of chemicals that
do no contain chlorine and those that do.
Analogue (also analog):A type of signal in which da-
ta is represented by continuously variable, measurable, Condensation: The transformation of water vapour to
physical quantities, such as current or voltage. 4 to 20 liquid. Also, a chemical reaction in which two or more
mA is a common analogue signal. As opposed to Digi- molecules combine, usually with the expulsion of water
tal. or some other substance.
Base: A bitter, caustic liquid. Technically, a basic ma- Conductivity: The measure of the ability of a fluid to
terial produces negative ions in solution. A base is the conduct an electrical current. In water, this ability is due
opposite of an acid and has a pH of 7 to 14. A given to the presence of ionized substances in solution. Con-
amount of a base added to the same amount of an acid ductivity measurements usually include temperature
neutralises the acid; water and a salt are produced. Al- compensation.
kalis are bases; ammonia is a common base.
Corrosion: Material deterioration due to chemical at-
Batch Control: The process of dispensing a precise tack.
volume of fluid repetitively or in conjunction with another
Current (loop) Output: See 4 to 20 mA
process.
DC (Direct Current): Electric current in which electrons
BCF: Bead and Crevice Free; a welding technique for
flow in one direction only. Compare alternating current
plastic pipes that yields a weld surface suitable for high
(AC).
purity application requirements.
Dead Band: The limits between which the input to an
Bi-Directional Flow: (1) All Signet flow sensors with a
instrument can vary without causing a change to the in-
frequency output are bi-directional; the sensor will all-
strument output.
ways have an output of "positive" flow no matter which
In relay operation: the difference between the increas-
direction the fluid is flowing in the pipe. (2) Flow sensors
ing and decreasing readings when the switch is operat-
with 4 to 20 mA output can be set for uni- or bi-direc-
ed between setpoint and reset point.
tional flow. Uni-directional flow indicates one direction
See also Hysteresis.
of flow only, typically set as 4 mA equal to zero flow and
20 mA equal to the maximum flow rate required. Bi-di- DIN: Deutsches Institut für Normung e.V. DIN is a non-
rectional flow can be set-up by making the 20 mA output governmental organisation established to promote the
equal to a positive number (for instance, +5 m/s). development of standardisation and related activities in
Germany and related markets with the goal of facilitat-
Blind Transmitter: Any device having 4 to 20 mA out-
ing the international exchange of goods and services,
put without also having a local/permanent display.
and to developing co-operation in the spheres of intel-
lectual, scientific, technological and economic activity.
Through the European standards organisations CEN
771
and CENELEC, DIN also presents the German view in EP, EPDM, EPM, EPR: Copolymer of Ethylene and
the development of the European standards that are Propolene or terpolymer with butadiene. Typically fea-
critical to completion of the single European market. tures good weather and chemical resistance Typically
used with diluted acids and alkalis, detergents, alcohols,
DN: Diametre Nominal; Term used by DIN standards for
steam and silicone oils.
the inside diameter of pipes.
FFPM: Also know as FFKM, trade names include or
Deionization: A purification process by which ionized
Kalrez (trademark) or Chemraz (registered trademark).
particles are removed from water.
Typical applications for this material include highly ag-
Desalination: Processes that remove salt from water, gressive chemical processing, semiconductor wafer
such as reverse osmosis, ion exchange, distillation and processing, pharmaceutical, oil and gas recovery, ae-
evaporation. orspace and petroleum.
Desiccant: A granular, porous, silica based materi- FM: Factory Mutual; An organisation that sets various
al that has the ability to absorb moisture. Desiccant is product standards, especially related to intrinsic safety
used to control humidity in a closed environment. and explosion proof. Insurance companies look to see if
items such as cooling towers have earned Factory Mu-
Desiccant Silica Gel: Is a granular, porous form of sili-
tual Approval and typically offer reduced rates for equip-
ca made synthetically from sodium silicate. Despite the
ment that has been demonstrated as unlikely to burn in
name, silica gel is a solid. Silica gel is most commonly
a fire.
encountered in everyday life as beads packed in a se-
mi-permeable. In this form, it is used as a desiccant to Formazin: A very stable suspended solid that remain
control local hunidity and is used in industry for many suspended in solution with water indefinitely. The su-
purposes. pended solid in Formazin can be hydrazine sulphate,
(NH2)2(H2SO4) or hexa-methylene-tetramine in wateror
Diffusion: An intermingling of the molecules of liquids
or gases. FPM: FPM is an elastomer, better known as Viton. See
Viton entry.
Digital: A type of signal in which data is represented in
numerical form. Opposite of analog. Frequency: The number of repetitions that occur in one
second. Frequency can be used to describe electrical
Dry Contact Closure: Relay. The contacts of a me-
quantities, sound waves, mechanical vibrations, etc.
chanical switch.
Frequency is measured in units of Hertz (Hz). In GF
Dry Contact Relay: (DCR): An electromechanical de- Signet flow sensors, the output is defined in terms of
vice used to switch external power. frequency and used to calculate flow rate.
DryLoc: Georg Fischer Signet LLC trade name and Formazin Nephelometric Unit (FNU): A unit of turbidi-
patented design for a versatile and robust connector ty based upon a comparison of scattered light intensity
scheme between sensor electronics and electrodes. by a sample under defined conditions with the intensity
of light scattered by a standard reference Formazin sus-
Dual Proportional Control: See relay control discus-
pension. The higher the intensity of scattered light, the
sion on page ___ (also applies to transistor-type out-
greater is the turbidity. The design of the nephelome-
puts).
ter is specified in the method. A standard suspension of
EasyCal: The calibration routine in Signet pH and ORP Formazin is used for calibration.
systems in which standard buffers or test solutions are
Hot-Tap: A mechanical assembly that allows the inser-
automatically recognised by the instrument.
tion and removal of a sensor or electrode without the
Efficiency: For pH and ORP electrodes, the percent of need for system shutdown, and initial installation may
theoretical slope. be performed under pressurised conditions. Similar to
Wet-Tap.
Effluent: Liquid flowing out of a system, such as a dis-
charge of liquid waste from a factory or water leaving a Hysteresis: In relay Setpoint programming, the differ-
sewage treatment plant. ence between the activation point and the release point.
See also Deadband.
Electrode: 1) Primary detection device, typically analyt-
ical, requiring or benefiting from some secondary condi- Impedance: A measure of the apparent resistance
tioning circuitry (e.g., pH and ORP electrodes). 2) Sen- posed by an electrical circuit to an alternating current
sor. (AC).
Emissions: The potentially disruptive electromagnet- Immunity: Ability of a device to function without disrup-
ic frequencies generated by an electronic device. Var- tion in the presence of electromagnetic interference.
ious standards defining allowable limits have been es-
Insertion Flow Sensor: A type of flow sensor that in-
tablished.
stalls through a hole in the wall of a pipe and converts
Empty Pipe Detection: The empty pipe detection in a local velocity measurement into a calculation of the
Signet products features a zero flow output when the flow rate in the pipe. Usually used in comparison to “full
sensors are not compltetely wetted. This does not in- bore” or “full line” flow sensor.
dicate an empty pipe, but rather a pipe that is not com-
Intrinsically Safe: Term used to identify any device, in-
pletely full.
strument or component that will not produce any spark
or thermal effects under any conditions that are nor-
mal or abnormal that will ignite a specified gas mixture.
772
Electrical and thermal energy limits are at levels inca- marily to provide a degree of protection against wind-
pable of causing ignition. It is common practice to use blown dust and rain, splashing water, and hose-directed
external barriers with intrinsically safe installations. water.
Ion: An electrically charged atom or group of atoms. NEMA 4X: Same as NEMA 4, with added protection
from corrosion.
IP65: A European standard for the degree of protection
provided by enclosures for splash proof and dust-proof NEMA 6: A standard for enclosures maintained by the
rating. National Electrical Manufacturers Association; NEMA 6
enclosures are intended for indoor or outdoor use pri-
IP68: The European standard for degree of protection
marily to provide a degree of protection in submersible
provided by enclosures for submersible and dust-proof
applications.
rating.
NIST: National Institute of Standards and Technology.
IR: Infrared, refers to a welding technique offered within
the range of SYGEF® HP products. Non-isolated: Two or more electrical circuits sharing a
common ground. When separated by distance or con-
IR - Infrared Light: Light whose wave length is just be-
nected to additional circuitry there is increased probabil-
low the light sensitivity of the human eye.
ity for measurement errors due to ground loops.
ISO: International Organisation for Standardisation: A
Nephelometric Turbidity Unit (NTU): A unit of meaure
voluntary organisation that creates international stan-
used when comparing the light scattered by a liquid me-
dards, including the standards for computers and com-
dia to the light scattered by a known concentration For-
munications. The American National Standards Insti-
mazin Polymer. This unit of measure is recognised as
tute, ANSI is a member of ISO.
a measure of the optical clarity of an aqueous sample.
ISO 14001: International Organisation for Standardisa- NTU is the accepted unit of measurement of turbidity.
tion environmental standard.
Ohm: The unit of measure for electrical resistance. A
ISO 9001: International Organisation for Standardisation resistance of 1 ohm will pass 1 ampere of current when
quality standard. a voltage of 1 volt is applied.
Isolated/Isolation: Electrical separation between two or OHSAS 18001: Occupational Health and Safety As-
more circuits used to prevent measuring errors, ground sessment Series - Published by BSI, the National Stan-
loops, or a shock hazard. dards Body of the UK, this is an international group of
standards and guidelines dedicated to occupational
K-Factor: In Signet Flow sensors, the number of puls-
health and safety.
es generated by the sensor for each unit of volume that
passes by the sensor. Usually published in pulses per Open Collector Output: An NPN transistor or FET out-
gallon and pulses per litre. put generally used to pull a signal from high to low. De-
vice used for frequency, pulse, and alarm outputs.
Linearity: The extent to which an output (response) is
strictly proportional to an input (stimulus). Operating Pressure: Maximum vapor pressure from
process.
Loop: In electricity, a complete circuit. Usually used in
reference to a 4 to 20 mA loop, an output signal used to Operating Temperature: The temperature at which a
control valves, actuators etc. product is capable of operating; usually a minimum and
maximum value.
Loop Impedance: The maximum allowable total electri-
cal resistance of all devices, including wiring, connected ORP (Oxidation Reduction Potential): A method of
to any electrical loop; expressed in ohms at a specified measuring the degree of completion of a chemical reac-
voltage level, i. e.; 600Ω at 12 VDC. tion by detecting the ratio of ions in the reduced form to
those in the oxidised form as a variation in electrical po-
Loop Output: An analog output signal, usually 4 to 20
tential measured by an ORP electrode.
mA.
Paddlewheel: A type of insertion flow sensor (pio-
Loop Powered: In Signet products, any instrument that
neered by Georg Fischer Signet LLC) that utilises a
derives operating power from a 4 to 20 mA loop.
bladed rotor to engage the fluid flowing in a pipe. The
Magmeter: Electromagnetic flow meter. spinning rotor produces a frequency output directly pro-
portional to the fluid velocity.
Metalex: Product name of fixed insertion metal pad-
dlewheel flow sensors manufactured by Georg Fischer Passive Outputs: These outputs throttle current in
Signet LLC loops powered by a supply external to the 8900.
Mho: The unit of conductance such that a constant volt- PBT: PolyButylene Terephthalate: A semi-crystalline
age of one volt between its ends produces a current of polymer, combining good strength and stiffness with low
one ampere in the conductor. moisture absorption, exceptional thermal stability, excel-
lent electrical insulation properties, outstanding dimen-
Mini-Tap: Stainless steel installation fittings for use with
sional stability and resistance to the effects of a wide
Metalex flow sensors.
range of chemicals, solvents, and oils.
NEMA 4: A standard for enclosures maintained by the
PEEK: PolyEtherEtherKetone; an engineering thermo-
National Electrical Manufacturers Association; NEMA 4
plastic with excellent chemical and water resistance.
enclosures are intended for indoor or outdoor use pri-
In Signet products, the yellow housing in ProcessPro®
field-mount instruments.
773
Percent Rejection: An indicator of RO system efficien- Resistivity: The inverse of conductivity (1/conductivi-
cy and membrane condition. Defined as one minus the ty).
ratio of the conductivity of RO product water to feed wa-
Reverse Osmosis: a process that allows the removal
ter, expressed as a percentage, and representing the
of particles as small as ions from a solution. The most
extent to which incoming contaminants were rejected by
common use for reverse osmosis is in purifying water. It
the system.
is used to produce water that meets the most demand-
pH: A measure of the acidity or alkalinity of a solution, ing specifications that are currently in place.
numerically equal to 7 for neutral solutions, increasing
Reynolds number: A dimensionless quantity associat-
with increasing alkalinity and decreasing with increasing
ed with the smoothness of flow of a fluid. At low veloci-
acidity. The pH scale commonly in use ranges from 0 to
ties fluid flow is smooth, or laminar, and the fluid can be
14.
pictured as a series of parallel layers, or lamina, moving
Polypropylene (PP): PP is a polymer of ethylene with at different velocities. The fluid friction between these
an isotactic arrangement of methyl groups. layers gives rise to viscosity. As the fluid flows more
rapidly, it reaches a velocity, known as the critical ve-
Preamplifier: A device used typically to protect the rel-
locity, at which the motion changes from laminar to tur-
atively weak output signals of pH and ORP electrodes
bulent, with the formation of eddy currents and vortices
from the wide variety of electromagnetic interference
that disturb the flow. The formula can be stated as: R =
common in most industrial environments.
dv/ μ where d is inside diameter, v is velocity and μ is
ProcessPro: Signet product name for a group of viscosity. In general
instruments characterised by a basic 4 to 20 mA • R « 2000 = Laminar flow
loop output, for the measurement of Flow, pH/ORP,
• R » 2000 « 4500 = Transitional (indeterminate)
Conductivity, Pressure and Temperature.
• R » 4500 = Fully developed and turbulent (most flow
Proof Pressure: Maximum water or hydraulic pressure. sensors operate best in turbulent flow)
ProPoint: Signet product name for a group of panel
Rotor-X: Family trade name of the original Signet plas-
mount instruments for the measurement of Flow, Batch,
tic paddlewheel flow sensors.
pH/ORP, Conductivity/Resistivity, Salinity and others.
Characterised by a unique analogue and digital display. Ryton : Trade name for Polyphenylene Sulfide or PPS.
Other trade names include Forton®, Tedar®, Supec®,
Proportional Pulse: In Signet products, an operating
and Tedur® (all registered trademarks).
mode for relays and open-collector outputs that varies
the frequency of the pulse in direct proportion to input S³L: Acronym for Signet Sensor Serial Link; a digital
variations. communication method between Signet sensors and
host instruments.
PTFE: Polytetrafluoroethylene, also known as TFE.
Trade names include Teflon®, Halon®, Floun® (all reg- SafeLoc: Name coined by Georg Fischer Signet LLC to
istered trademarks). define the unique locking mechanism used in the Signet
3719 pH Wet-Tap assembly.
Pull-up resistor: A resistor needed to obtain the high-
level voltage signal in a transistor- type output circuit. Salinity: A measurement of dissolved salt concentra-
tion, as in seawater, typically expressed in parts per
PWM: Pulse Width Modulation; In Signet products, an
thousand (ppt).
operating mode for relays and open-collector outputs
characterised by varying the time that a pulse is “on” Sensor: 1) A primary detection device typically provid-
versus the time it is “off”. Also, a method of digitally ening direct input to a measurement instrument (i.e., pad-
coding analogue signal levels. dlewheel flow sensor). 2) The combination of an elec-
trode and some secondary conditioning circuitry (i.e.,
Quinhydrone: A crystalline powder typically added to
pH electrode and preamplifier). 3) Electrode.
pH 4 and 7 buffers for the purpose of producing stan-
dard solutions used in the calibration of ORP measuring Signet: Model name of fluid measurement sensors and
systems. instruments marketed under the Georg Fischer Piping
Systems brand.
RC Filter: A resistive-capacitive device, often referred
to as a “snubber”, designed to protect instrumentation Sleeved Rotor: An accessory rotor featuring a self-lu-
and relay contacts by capturing the voltage spikes re- bricating mechanical sleeve that replaces the standard
sulting from the switching of large inductive loads such liquid bearing of Rotor-X paddlewheel flow sensors.
as solenoids and motor starters, etc. Sleeved rotors will extend the maintenance interval in
applications known to produce premature rotor wear,
REDOX: Reduction/Oxidation; Same as ORP.
such as those involving abrasive liquids.
Relative Humidity: The amount of moisture in the air
Specific gravity: Ratio of the mass of a body to the
as compared with the maximum amount that the air
mass of an equal body of volume of water at 4 °C, or
could contain at the same temperature, expressed as a
some other specified temperature.
percentage.
Suspended Solids: Particulate suspended (as opposed
Relay: An electromechanical switch.
to being dissolved) and typically creating turbid, cloudy
Repeatability: The extent to which an output (re- conditions in liquid.
sponse) repeatedly corresponds to identical input (stim-
SSR: Solid-state relay
ulus) during dynamic conditions.
TDS: Total dissolved solids.
774
Totalizer: In flow instrumentation, a permanent or reset-
table counter for volume such as gallons or tens of gal-
lons, etc.
Transmitter (two-wire): A device that converts an elec-
trode or sensor input to a 4 to 20 mA output using the
same two wires for signal transmission as for system
power.
Turbidity: The reduction of transparency of a liquid
caused by the presence of undissolved matter (ISO
7027 Definition of Turbidity)
Turndown Ratio: Dynamic response characteristic. The
ratio of a sensor’s maximum measurement range to its
minimum measurement range.
UHMW Polyethylene: Ultra High Molecular Weight
polyehtylene. Very good chemical resistance of corro-
sives; very good stress cracking resistance (with the ex-
eption of strong oxidizing acids at elevated tempera-
tures).
Viscosity: The internal friction of a fluid, caused by
molecular interaction, which makes it resist a tendency
to flow.
Viton: Viton® fluoroelastomer is well known for its ex-
cellent heat resistance. It offers excellent resistance to
aggressive chemicals.
Voltage (output): A standard analogue signal (0 to 5 or
0 to 10 VDC for Signet products) used for the propor-
tional representation of a measurement variable or pro-
cess condition.
Weldolet: A weld-on branch connection for metal pipe
typically used as an installation fitting for insertion-style
sensors or electrodes.
Wet-Tap: A mechanical assembly that, after initial in-
stallation into a non-pressurised system, allows the in-
sertion and removal of a sensor or electrode without the
need for system shutdown. Similar to Hot-Tap.
White Light: The combined light whose wave lengths
are all within the range of sensitivity of the human eye.
Window (Relay Module): An out-of-range alarm sce-
nario that allows a single relay to be triggered by either
a high or a low process condition. For example, a re-
lay in window mode can be programmed to trigger if a
pH value in a final effluent tank drops below 6.0 or rises
above 8.5.
775
776
Double containment system - CONTAIN-IT Plus
Page

Introduction 779
Double containment
-- CONTAIN-IT Plus pressure-tight outer pipe 782
-- CONTAIN-IT Plus splash guard 782
-- Authorisation of installation personnel 782
-- CONTAIN-IT Plus product range 783
Planning criteria
-- Material selection for the medium-conveying inner pipes 785
-- Material selection for the outer pipes 785
-- Questionnaire for static evidence 785
-- Layout 785
-- Leak detection 785
-- Isometric drawing 785
-- Sizing 785
Installation instructions
-- Jointing double containment pipes 786
-- Jointing the outer pipe 786
-- Jointing the outer pipe using the EPDM rubber sleeve with stainless steel coupler 788
Fittings for solvent cementing / fusion and installation
-- Introduction 790
-- Various connection examples 792
-- Dimensions for calculating the cutting lengths 797
-- Connection sizes for double containment fittings 801
Fittings for butt and IR fusion and installation
-- Various connection examples 803
-- Dimensions for calculating the cutting lengths 806
Leak detection and leak locating systems
-- Differential pressure 811
-- Optical monitoring 811
-- Optoelectronic monitoring 811
-- Sensor cable 812
-- Tools for locating leaks in all systems: Termination fittings 812
Operating and maintenance instructions 813
Pressure testing the inner and outer pipes

-- Inner pipe 814
-- Outer pipe 816
Static evidence
-- CONTAIN-IT Plus loadings 818
-- CONTAIN-IT Plus system 818
-- Questionnaire for static evidence 819
-- Static evidence - Calculation by GF Piping Systems 820
Welding machines for butt and socket fusion 821
Safety measures - extensions and repairs

-- Separating for retrofit installation of a T-90° 823
-- CONTAIN-IT Plus - mechanical joint 823
-- Double containment - flanged connection to a tank 823
Double containment valves
-- Versions 824
777
Page

-- CONTAIN-IT Plus ball valve 824
-- Installation example of double containment valves 829
Customized parts
-- T-piece with 45 ° tapping point for socket fusion and cementing or butt fusion 830
-- 90 ° elbow including termination fitting 830
-- Double containment reducing 90 ° T-piece with elbow 831
778
Double containment system -
CONTAIN-IT Plus
Introduction
Application range
• Recommended for gaseous or liquid media, where
any leakage of the piping system would endanger the
personnel, the operations or the environment.
• For strong diffusing media (HF, HCL, HNO3)
• Recommended for application conveying critical liq-
uids.
• For piping systems which must be maintained in op- Drainage system für HCl, HF and hydrocarbons in the semicon-
eration under all circumstances, in order to guarantee ductor industry
process reliability, even in the case of a leak.
Sulphuric acid pipe system for water conditioning for pigment pro-

duction
Hydrochloric acid and caustic soda solution for water treatment Market segments
• Water treatment (waste water treatment)
• Chemical process industry (distribution pipe systems,
galvanization plant for metal treatment)
• Micro electronics industry (chemical waste, photo-
voltaics)
• Life science (breweries and food industry)
Nitric acid pipe system under construction for metal finishing in

the automotive industry
Personnel protection in solar cell production
779
standard thermoplastic piping connections. Therefore
the double containment piping system from +GF+ al-
lows a pressure testing of the inner pipe before the out-
side pipe is welded. This unique and patented technique
gives the operational safety that the inner pipe really is
leak-tight.
The design benefit
To ensure operational safety, reliability and long life, the
choice of the material and welding technology is of key
importance.
GF helps you to find the ideal material for your applica-
tion from a large product range in six different thermo-
plastics materials.
The planning benefit
Electroplating plant in the chemical-process industry
A large number of well known international companies

choose a complete system from a single source suppli-
er. Reliable calculation can be made only with a ded-
icated system. An optimal piping design can only be
achieved with perfectly harmonised piping components
Life science system in a brewery under defined process conditions. We offer the possibil-
ity to calculate the longitudinal expansion stresses and
temperature differences between the inside and out-
side pipe. This will confirm the mechanical stability of
the whole piping system.
The environmental benefit
Environmental risks are systematically analysed in the
scope of ISO 14001, and appropriate measures are
then taken to minimise these risks. Double containment
systems help you to minimise the risks of incidents, giv-
ing you the opportunity to reduce insurance premium-
s and maintain your company image.
Enviroment
Environmental awareness and increased safety stan-
dards are becoming ever more important in today's so-
Precipitant, ferric chloride in a sewage works ciety.
Characteristics Personal injury, property damage and environmental
pollution, caused by leakages, are key concerns that
The connection benefit have led us, as a piping system supplier, to design
a suitable system to reduce potential hazards.
To ensure plant safety in the conveyance of hazardous
liquids jeopardizing personnel, process and environ-
ment, piping systems are needed which offer the opti-
mal chemical resistance and which signal and collect
any leakage which may occur.
Customer-friendly installation and approved connection
techniques are important requirements for the design of
such double containment system.
The patented double containment jointing technique al-
lows fitting of the double containment pipe to the single
pipe according to the same directives and guidelines
from the DVS (German association for jointing) as for
780
Legal provisions Switzerland
The regulation concerning the protection of distur-
bances (§ 3, General Safety Measures) stating that
companies are subject to take all measures in order to
minimize risks. By definition, these measures are the
decrease of the risk potential, the avoidance of distur-
bances and limitation of interferences in the nature.
The federal law about the prevention of water pollution
(§ 22, General Requirements) states that owners of in-
stallations conveying liquids hazardous to waters have
to make sure that all measures are taken to protect wa-
ters. These Measures define that installations must be
designed, installed, maintained and operated to guaran-
tee that no natural water supplies can be polluted. Fur-
thermore, for storage facilities and reloading points, any
kind of loss of liquids must be avoided and any leakage
of liquids must be prevented.
Legal provisions Germany
The German Water Management Act (§ 19 g WHG) ap-
plies the "duty of care" principle for the storage, filling,
manufacturing and treatment of substances which are
hazardous to water and to internal piping systems in the
industry. This defines that installations which handle liq-
uids that endanger the water quality must be designed,
installed, maintained and operated to guarantee that no
natural water supplies can be polluted.
In accordance with a ruling of the German Federal Ad-
ministrative Court, the "duty of care" principle requires
the elimination of even the likelihood of water pollution
occurring.
Requirement of German regulations on installations
handling substances which are hazardous to water
(§3 VAwS)
Installations must be designed and operated in such a
way that no substances which are hazardous to water
can leak. They must be leak-proof, stable and sufficient-
ly resistant against the expected thermal, mechanical
and chemical influences.
Leakage of any part of an installation conveying media
which endanger the water quality, needs to be recog-
nised in a fast and reliable way.
The above mentioned requirements for piping sys-
tems can be fulfilled through the existing retention
space between the inner and outside pipe in our
double containment system.
781
Double containment
CONTAIN-IT Plus pressure-tight outer pipe
The CONTAIN-IT Plus pressure-tight double contain-
ment system comprises an outer protective pipe, made
from PE100, which is welded pressure-tight,
using ELGEF Plus electrofusion coupler.
®
The following criteria are significant for safe opera-

tion:
1.For safety reasons, the components of the media-con-
veying inner pipe should not be altered from their
standard version. This, in order to guarantee the con-
The protective pipe serves as a leak monitoring space, sistent, tested quality of our DIBt-approved (German
where spills which, under certain circumstances could Institute for Building Technology) individual compo-
leak from the inner pipe, are contained until the leak has nents of the fittings for the following materials:
been discovered and repaired. Also it is to convey flu- PVC-U Z-40.23-2;
ids for the purpose of stabilising the temperature of the PE–80 / PE–100 Z-40.23-282 ;
medium in the inner pipe. PP-H Z-40.23-264; PVDF Z-40.23-262.
Please ensure that the pipes are also DIBt-ap-
Both the inner and the outer protective pipes are reli- proved!
able, quality-controlled pressure piping systems, which
2.The DVS (German Association for Fusion Technolo-
are implemented unmodified. The jointing techniques
gy) fusion guidelines and KRV (Plastic Pipe Associ-
correspond without exception to the relevant guidelines
ation) solvent cementing instructions are applicable
for pressure piping system construction. There are no
without exception, especially to double containment
limits to the choice of pipe materials, ensuring that the
piping systems. Particularly important quality factors
material can be ideally matched to the chemical resis-
are the monitoring and the visual inspection during the
tance required by the particular application.
building-up of the weld bead on the internal pipe dur-
ing the welding process.
CONTAIN-IT Plus splash guard
3.The pressure test on the inner pipe must be carried
The CONTAIN-IT Plus spray protection system dif- out before the outer pipe is sealed. Particularly in the
fers from the pressure-tight system in that the measure case of double containment systems, where the em-
makes use of an EPDM rubber sleeve with a stainless phasis is on safety, no "dry joints" can be tolerated.
steel coupler for connection of the outer pipe. 4.Fixed-point installation with structural certificate: the
minimum dimensional difference between the inner
and outer pipes prevents any possible longitudinal
expansion. The entire system must be finished as a
fixed-point installation. A structural certificate is rec-
ommended for the pipe system (cf. Questionnaire
for the structural certificate, Section: Structural certifi-
cate).
5.The product range includes radial dismountable me-
chanical couplings for maintenance or repair of the
piping system, or to carry out subsequent extensions.
6.Connections for commercial leak detection devices
must be provided.
The EPDM rubber sleeve is pressure-tight up to 1 bar
. The rubber sleeve allows different outer pipe materi- Authorisation of installation personnel
als to be quickly connected together, without the use of
tools or any machining of the pipe. The connection of th- Easy-to-learn technology, strict adherence to norms and
e fittings (elbow, T-piece and termination fitting) is the regulations as well as many years of experience in plas-
same as on the pressure-tight system. The preferred tic piping system construction are the marks of distinc-
material for the outer pipe is transparent PVC-U. tion of the GF double containment piping system.
Added to these essential prerequisites is the careful
training of the installation personnel, in the interest of
safety.
782
For this reason: Seals
Double containment systems must be installed only When laying the inner pipe, sealing material should be
by persons who have been specifically trained and selected that is suitable for the prevailing operating con-
authorised by GF. ditions. Available choices are EPDM, FPM and, for ball
valves, also FFPM. The sealing material used for the
CONTAIN-IT Plus product range protective pipe is EPDM.
Inner pipe Fittings for inner and outer pipes
The choice of different types of plastic for the inner The individual fittings for the inner and outer pipes are
pipe allows the pipe material to be optimally matched injection moulded using the latest quality assured pro-
to the physical and chemical requirements: PVC- cedures. The inner fittings are available in all GF plastic
U (unplasticized polyvinyl chloride), PVC-C (post-chlo- materials. Fittings are factory made and supplied ready
rinated PVC-U), PP-H (polypropylene), PE (polyethy- to install.
lene), PVDF (polyvinylidene fluoride). In the CONTAIN-IT Plus double containment system,
"Click system" spacers are clamped to the inner pipe, the outer fitting – always made from PE-100 polyethy-
which is then pushed into the outer pipe – pipes are not lene – is already attached to the inner fitting. The in-
supplied ex-works as double pipes. The pipes can also ner and outer fittings are connected together using stur-
be used as single pipes. dy support rings, which act as fixed points for the in-
ner pipe. This prevents expansion of the inner pipe in
the outer pipe. The entire system must be finished as a
fixed-point installation with a structural certificate.
On solvent cementable plastics (PVC-U, PVC-C), a ce-
mented socket joint is used to connect the inner pipes.
A number of different fusion processes are available for
connecting weldable plastics (PE, PP-H, PVDF). Socket
fusion can be used for PP-H / PE (d 20/50 to d 110/160)
and PVDF (d 20/50 to d 63/110). For the size range d
20/50 to d 225/315, butt fusion techniques can be used.
Infrared fusion techniques can also be used in certain
cases (refer to Overview of product range). Wherever
possible, factory-finished joints are made by infrared fu-
sion.
The PE outer fittings have integrated joint spigots –
which also act as the support rings for the inner pipes –
for connection by means of push-on ELGEF® Plus elec-
trofusion coupler or EPDM rubber sleeves.
The push-on ELGEF® Plus electrofusion coupler or rub-

ber sleeve can be pushed over the end of the pipe be-
ing connected, or the long end of the fitting, before the
inner pipe is connected. The electrofusion coupler will fit
along only half the length of the short end of the fitting.
PE 100 outer pipe

The outer protective pipe, which surrounds the medium-
conveying inner pipe, is made of PE100 polyethylene.
The key features of this material are its good chemi-
cal resistance to acids, alkalis and salts as well as a
number of organic and inorganic solvents. The high
resistance of this black (stabilised with carbon black)
polyethylene to UV effects, its insusceptibility to notch-
ing, flexibility and impact resistance, even at low tem-
peratures down to -50 °C, make this protective pipe ma-
terial ideal for pipes laid indoors, outdoors and in the
ground.
Transparent PVC-U splash outer pipe
The pressure level of the outer pipe is restricted to 1 bar
by the use of an EPDM rubber sleeve.
The code numbers and wall thicknesses of the protec- Termination fittings
tive pipes (PE100 or PVC-U) are listed in the double Specially designed and patented termination fittings,
containment product catalogue. with an Rp ½" connection to the monitoring space, are
installed at the start and end of the double containment
783
system. These fittings are also suitable for subdividing
the outer pipe, i. e. to divide the pipe system into leak
detection zones, thereby enabling easier location of
leaks.
Branch saddles
Branch saddles, for fitting to the protective pipe after
connection, are used for the installation of a leakage
locating system, for flushing the space between the
pipes or as unions for carrying out a pressure test in the
space between the pipes.
Valves
Specially designed manual and actuated double con-
tainment valves can be integrated in the system. In the
same way as the fittings they are easy to install in the
pipe system. Double containment valves are factory
made and supplied as a system unit. They can be exter-
nally operated and opened for maintenance purposes
and to carry out a pressure test on the inner pipe.
Overview of product range
Outer Pipe PE-100
Dimension Inner Pipe
d*D Socket Cementing Socket Fusion Butt Fusion
inner x out- PVC-U PVC-U PVC-C PVC-C PP-H PE-80 PVDF PP-H PE-100 PVDF PVDF
er Tangit Dytex Tangit Dytex SDR11 SDR11 PN16 PN10
20*50 X X X X X X X ° ° °
25*50 X X X X X X X ° ° °
32*63 X X X X X X X ° ° °
40*75 X X X X X X X X X X
50*90 X X X X X X X X X X
63*110 X X X X X X X ° ° °
75*125 X X X X X X ° ° °
90*140 X X X X X X ° ° °
110*160 X X X X X X ° ° °
125*180 X X X X
140*200 X X X X
160*225 X X X X
200*280 X X X X
225*315 X X X X
° = Butt-welding and infrared-compatible (IR-Plus)

Other combinations e. g. PVDF BCF (beat and crevice
free welded) on request.
784
Planning criteria The calculation also indicates the distances between
spacers for the inner pipe and the distances between
Material selection for the medium-convey- pipe brackets for the outer pipe, as well as the forces on
ing inner pipes fixed points.
To ensure operational safety and achieve the minimum Expansion in the pipeline need not be taken into consid-
designed service life, the selection of the material and eration; no additional expansion loops or compensators
the pressure classification of the pipe system compo- are required.
nents are extremely important. The key influential fac-
tors are: operating pressure, operating temperature, the Layout
medium being transported and the duration of stress-
The pipe layout should be planned so that the pipes are
ing.
protected from mechanical and thermal effects.
The chemical resistance list and the material-related
The necessary minimum distance from walls and ceil-
pressure and temperature charts can be used to pre-
ings as well as the required axis dimensions can be
select the material. These aids can be found in our
found in the tables for calculation of cutting lengths.
technical manual, on the CD and on our website at
www.piping.georgfischer.com, Support, Planning Fun- For great fixed-point forces, the anchoring method on
damentals. the building material should be checked. If building ma-
terial cannot absorb any fixed-point forces (e.g. trape-
We will naturally provide any assistance you need in se-
zoidal corrugated roofs), the forces must be absorbed
lecting the right material.
via sturdy travelling rails.
General chemical resistance of thermoplastics
Leak detection
PVC-U / PP / PE PVDF
PVC-C Leak detection is an important element of the double
containment piping system and must be taken into con-
Resistant Acids and alka- Acids, alka- Acids, oxi-
sideration. Please see the section on leak detection and
to lis lis and weak dizing me-
solvents dia, sol- location.
vents, halo-
gens Isometric drawing
Not resis- Aromatic sol- Oxidizing Amines, al- The 30° isometric diagram (see example of cutting
tant to vents, tensides acids, halo- kalis length calculation) provides an accurate view of the pip-
gens ing layout. When the axis dimensions are entered, the
cutting lengths can be calculated and the installation di-
Material selection for the outer pipes rection of the fittings determined.
The pressure rating of the outer pipe must correspond This can be used to represent the ventilation, rinsing
to the service pressure of the inner pipe until the dam- and shut-off requirements, as well as the installation po-
age is repaired. In case of leakage, the pressure-resis- sition of the end and sectional fittings.
tant and chemical-resistant PE100 outer pipe must be
able to contain the spill. In the event of a leak, exposure Sizing
to the medium normally does not require an immediate
The pipe diameter is determined by calculating the pres-
shutdown of the operation. It may be possible to com-
sure loss within the pipe. This depends not only on the
plete ongoing production runs before shutting down.
diameter, length, and pipe material but also on the flow
When using the splash guard outer pipe system with a medium and the flow volume.
transparent PVC-U outer pipe, the restricted pressure
For project planning, construction and installation of
loading of 1 bar must be taken into account. There must
double containment systems, please refer to DVS 2210-
be no possibility of higher pressure developing in the
2.
protective pipe in the event of a leak.
Questionnaire for static evidence

The questionnaire for static evidence (Section: Stat-
ic Evidence) is used by GF to determine if the select-
ed pipeline is resistant under the given operating condi-
tions.
For fixed-point installation (restricted longitudinal ex-
pansion), it is necessary to calculate the stresses and
forces on the outer pipe fittings, which the fixed-point
pipe brackets are required to absorb.
The fixed point for the inner pipe is already built into
each fitting by means of a support ring. If the calculated
stress on the pipe is too great, the operating conditions
or the material must be changed.
785
Installation instructions Butt fusion heater element (PP, PE and SYGEF
PVDF)
Jointing double containment pipes
Patented double containment jointing technology
The principle of the GF double containment jointing
technology is based on the fact that the inner pipe is
joined first using the techniques described below. This
means that a double containment pipeline is joined in
the same manner as a single pipeline. The so-called
"last joints", which occur with every change of direc-
tion in other systems and which are then usually done
"blind", are therefore not applicable. When the clamp-
s are removed, there is a gap of 30 mm between the
ends of the outer pipe. This serves to check the joint of
the inner pipe according to the DVS guidelines. When
the pressure test on the inner pipe has been completed,
this gap is closed with a snap ring.
Inner pipe In pressurised pipe systems, all butt fusion joints must
The inner pipes are connected using standard, tried be produced in a butt fusion machine, and not by hand!
and tested jointing methods. Depending on the materi-
al and sizes, the available options are: solvent cement- IR infrared fusion (PP, SYGEF PVDF)
ing, socket fusion, butt fusion and infrared fusion. The
choice of method is also determined by suitability for
the operating conditions. PVDF BCF (beat and crevice
free welded) on request.
Solvent cement joints (PVC-U, PVC-C)
A quick jointing method, carried out without extensive
use of tools or machinery.
Socket fusion heater element (PP, PE and SYGEF
PVDF)
In IR fusion, the parts to be connected (pipe and fitting)

are heated to fusion temperature in the fusion zone and
fused in a contact-free process. This low-stress fusion
method allows smaller fusion beads to be created.
Jointing the outer pipe

Socket fusion in a fusion machine After the inner pipe has been pressure-tested, the out-
er pipe is sealed. A pressure-resistant version with an
Socket fusion is particularly suited for use with smaller electrofusion coupler and the splash guard version (PN
sizes. Up to and including 50 mm diameter inner pipes, 1) with an EPDM rubber sleeves are available for this
these joints can be easily made in the pipeline route, us- purpose. The activities described next, to prepare for
ing hand fusion equipment. making the joint, must be carried out at the same time
as the installation of the inner pipe.
Jointing the outer pipe with ELGEF® Plus elec-
trofusion coupler
• Cut the pipe to size, square, in accordance with the
calculation sheet (it is advisable to number the cut
lengths of pipe)
• Clean any coarse dirt from the pipe
• Machine the pipe ends with a rotary scraper
786
• Depending on the recess type of the electrofusion Permissible minimum pipe outside diameter:
coupler, the length of the pipe to be scraped is either
½ or full length of the coupler Pipe diameter Min. Permissible minimum
(mm) chip thick-
• New double containment fittings, removed from the ness (mm) pipe outside diame-
packaging shortly before processing, do not need to ter
be scraped! (mm)
• Please refer to the separate installation instructions 50 0.20 49.5
for electrofusion fittings and the dimensional toler-
ances when scraping the PE pipes 63 0.20 62.5
• Clean/degrease pipe end with Tangit KS cleaner and 75 0.20 74.4

clean absorbent paper. 90 0.20 89.4
110 0.20 109.4
125 0.20 124.4
140 0.20 139.4
160 0.20 159.4
180 0.20 179.4
200 0.20 199.4
225 0.20 224.4
250 0.20 249.3
280 0.20 279.3
315 0.20 314.3
Push on electrofusion coupler

• Insertion depth: mark ½ coupler length minus 15 mm
(snap ring width 30 mm divided by 2 = 15 mm)
• Immediately prior to use, remove
ELGEF Plus electrofusion coupler from the bag, with-
®
out dirtying it, remove the middle stop and push com-

pletely over the stripped end of the pipe. Seal/secure
with the PE stretch film to protect from contamination
and moisture. Check for proper functioning.
Important:
The ELGEF Plus coupler must be on the pipe before
®
the inner pipes are jointed.

• Remove the stretch film immediately before fusing the
outer pipe
• Apply the snap ring: if the electrofusion coupler is
pushed on without a snap ring, the outer pipe can
shift, so that a reliable weld can no longer be guaran-
teed.
The snap ring must sit centrally on the
ELGEF Plus electrofusion coupler (cold zone). The
®
ends of the outer pipes must butt up to the snap ring

with no gap.
787
• Clean the fusion zone MSA 400 fusion machine for
ELGEF Plus coupler
®
• Refer to instructions, wherever possible, use clamps-

for electrofusion of couplers and branch saddles. D SDR L 1/2 L - 15
• Fuse
50 11 88 29
63 11 96 33
75 11 110 40
90 11 125 47.5
110 11 145 57.5
125 11 158 64
140 11 168 69
160 11 180 75
180 11 194 82
200 11 208 89
225 11 224 97
280 11 252 111
315 17 268 119
L = Length of ELGEF® Plus coupler
Jointing the outer pipe using the EPDM

rubber sleeve with stainless steel coupler
Snap ring 30 mm When carrying out installation using the rubber sleeve,
it is essential to ensure that the outer pipe is secure-
ly clamped to prevent axial movement (clamping force
details in structural certificate) and that no pipe expan-
sion occurs. The rubber sleeve has no tensile strength.
Clean the square-cut pipe with a clean cloth, push the
rubber sleeve onto the outer pipe. The snap ring must
sit centrally on the rubber sleeve. The ends of the out-
er pipes must butt up to the snap ring without gap. On
long lengths of pipe, the snap ring can be dispensed
with transparent PVC-U pipes / pipe joints. Advantage:
Achieving greater tensile strength by jointing Pipe /
Pipe.
788
Insertion depth: mark ½
socket length minus 15 mm
(snap ring width 30 mm di-
vided by 2 = 15 mm)
Important: The rubber
sleeve must be on the pipe
before the inner pipes are
jointed.
L = Length of the rubber
sleeve
D Number of pipe clips L ½ L - 15

50 2 85 27.5
63 2 85 27.5
75 2 85 27.5
90 2 85 27.5
110 4 125 47.5
V2A metal pipe clip
125 4 125 47.5
140 4 125 47.5
160 4 125 47.5
180 4 125 47.5
200 4 125 47.5
225 4 125 47.5
280 4 150 60
315 4 150 60
Snap ring
789
Fittings for solvent cementing / fu-
sion and installation
Introduction
As the axis sizes of 90 ° and 45 ° elbows and the T-
piece are the same, only the 90 ° elbow is shown.
The coupler is always on the long side of the fitting.
Possible connections:
• fitting to fitting direct
• fitting to intermediate pipe section
• fitting to termination fitting
From the central axis to the front edge, all types of fit-
tings have the same Z dimension (i. e. same axis size).
Note: This applies only to fittings made from the same
material and for use with the same jointing method!
The lengths of the outer pipe (black, scraped and

cleaned fusion surfaces) and inner pipe (grey with
clipped-on spacers) are different .
1 Spigot for coupler cementing / fusion
2 Space for ½ ELGEF Plus coupler
®
3 Socket on double containment fitting for coupler cementing /

fusion
4 Space for complete ELGEF Plus coupler or EPDM sleeve
®
790
2. Standard heating element for coupler fusion.
The pipe and fitting are heated simultaneously.
The inner pipe is pushed into the outer pipe and the fu-
sion coupler are positioned on the outer pipe.
3. Heating element for coupler fusion.
The fitting is first of all jointed (fused or cemented) to the

inner pipe with the prepared double containment pipe
piece. The inner pipe is now pressure tested. Following
the successful pressure test, a pressure-tight joint of the
outer pipe with inserted snap ring is produced, using an
electrofusion coupler.
4. Visual inspection.
Check the joint, then pressure test the inner pipe.
1. Special clamps hold the inner pipe and the inner fitting.
791
Legend:
The following symbols are used to demonstrate the various
connection examples.
Abbreviation: Example 90 ° elbow:
S = Short end of
fitting with internal
spigot

5. Place the snap ring between the ends of the outer pipe.
L = Long end of fit-
ting with internal
socket

E = Endfitting

6. A pressure-tight seal of the outer pipe is produced by the

ELGEF® Plus electrofusion coupler, or the EPDM sleeve is
used as splash guard.
Various connection examples

CONTAIN-IT Plus: socket cementing / fusion
• Short end of fitting with internal spigot (S)
(90 ° elbow, 45 ° elbow, equal-sided 90 ° T-piece)
• Long end of fitting with internal socket (L)
(90 ° elbow, 45 ° elbow, equal-sided 90 ° T-piece)
• Termination fitting (E) - long end of fitting with internal
socket
• Pipe (P)
792
Example Symbol Combination
a) S - P - S Fitting end with spigot -
Pipe with 2 equal sock-
ets -
Fitting end with spigot
b) Fitting end with spigot

S - L -
direct -
Fitting end with socket
c) Fitting end with spigot -

S - P - L Pipe with 1 socket -
d) Fitting end with socket

L - P - L -
Pipe -
e) Fitting end with spigot

S-E -
direct -
Termination fitting with
socket
f) Fitting end with spigot
S - P - E -
Pipe with 1 socket -
socket
g) Fitting end with socket
L - P - E -
Pipe -
socket
Example calculation to find cutting lengths for

inner and outer pipes
In the double containment system, the inner and outer
pipes are always cut to different lengths.
The deduction sizes./. M min and allowance
sizes + Yi min for the inner pipe and + YO min for the outer
pipe are dependent on a combination of the installation
length of the fittings, and can be found in the following
tables.
Since the axis sizes for the 90 ° elbow, 45 ° elbow
and T-piece are the same, only the 90 ° elbows are
shown and discussed here.
793
Pipeline section: 1 M 1250 Pipeline section: 5 M 3654
Case S - P - E ./. M min 510 Case: S - P - L ./. M min 475
= Difference 740 = Difference 740 = Difference 3179 = Difference 3179
+ Y i min 145 + Y O min 75 + Y i min 128 + Y O min 105
= Y i inner pipe 885 = Y O outer pipe 815 = Y i inner pipe 3307 = Y O outer pipe 3284
Pipeline section: 2 M 340 Pipeline section: 6 M 4270

Case: b) S - L direct ./. M min - Case: a) S - P - S ./. M min 505
= Difference 0 = Difference - = Difference 3765 = Difference 3765
+ Y i min - + Y O min - + Y i min 185 + Y O min 230
= Y i inner pipe no pipe re- = Y O outer pipe no pipe re- = Y i inner pipe 3950 = Y O outer pipe 3995
quired quired
Pipeline section: 7 M 2154
Case: L - P - E ./. M min 510
Case: a) S - P - S ./. M min 505
= Difference 1644 = Difference 1644
+ Y i min 145 + Y O min 75
+ Y i min 185 + Y O min 230
= Y i inner pipe 1789 = Y O outer pipe 1719
Calculation of examples on previous pages
Pipeline section: 4 M 2400 The shortest connection between 2 double containment
fittings is the direct connection. The M dimension be-
Case: L - P - L ./. M min 515
tween axes is preset.
+ Y i min 141 + Y O min 75
794
Pipeline section*: 2 M 340
Case: b) S - L direct ./. M min -
= Difference - = Difference -
+ Y i min - + Y O min -
= Y i inner pipe no pipe = Y O outer pipe no pipe
required required
*given axes distance
If a pipe is required between the fittings, the minimum

dimension M min between axes must be observed.
Case: a) S- P- S ./. M min 505 * 1
+ Y i min 185 + Y O min 230 * 2
* minimum distance between axes
1
* 2minimum length of inner or outer pipe
All longer dimensions are calculated as follows:

Pipeline section: 6 M 4270 *
Case: a) S - P - S ./. M min 505
+ Y i min 185 + Y O min 230
distance between axes
Material checklist
Required Socket Snap ELGEF EPDM
quantity per equal ring ® Plus rubber
electro- sleeve
fusion
coupler
90 ° elbow 1 2 2 2
45 ° elbow 1 2 2 2
T-90 ° equal 2 3 3 3
Termination fit- 0 (1**) 1 (2**) 1 (2**) 1 (2**)
ting
Butt fusion
90 ° elbow 0 2 2 2
45 ° elbow 0 2 2 2
T-90 ° equal 0 3 3 3
Termination fit- 0 1 1 1
ting
Inner pipeline * 0 0 0
Outer pipeline 0 * * *
* 1 x per pipe length
** For segmentation of the pipeline into leak detection sec-
tions
795
796
Dimensions for calculating the cutting lengths
CONTAIN-IT Plus: socket cementing / fusion
Attention: The ”last joint” should always be made on the double containment fitting. Loose sockets should first be
connected with the intermediate pipe.
Example a) S - P - S
Pipeline 3 + 6
1 Spigots (S)
d*D Direct M M min. Inner pipe: Y i min / Material Outer pipe
Y A min
S - P - S PVC-U PVC-C PP-H, PE80 PVDF

20*50 - 460 182 182 178 178 190
25*50 - 460 176 176 174 174 190
32*63 - 505 185 185 185 185 230
40*75 - 580 202 202 204 204 230
50*90 - 660 222 222 228 228 260
63*110 - 780 248 248 264 260 300
75*125 - 840 264 264 286 - 330
90*140 - 905 263 263 284 - 345
110*160 - 950 266 261 290 - 370
125*180 - 1020 278 - - - 400
140*200 - 1060 294 - - - 430
160*225 - 1190 302 - - - 460
200*280 - 1315 313 - - - 515
225*315 - 1310 322 - - - 550
797
Example b) S - L Example c-) S - P - L
Pipeline 2
1 Spigot (S)
2 Coupler (L)
1 Spigot (S)
2 Coupler (L)
d*D Direct M M min. Inner pipe: Y i min /Material Outer pipe
Y A min
S - L S - P - L PVC-U PVC-C PP-H, PE80 PVDF

20*50 310 435 122 122 118 118 95
25*50 310 435 122 122 118 118 95
32*63 340 475 132 132 128 128 105
40*75 400 545 142 142 137 137 115
50*90 460 620 157 157 152 152 130
63*110 550 730 177 177 176 172 150
75*125 585 780 191 191 191 - 165
90*140 640 845 200 200 194.5 - 175
110*160 665 880 209 209 201 - 185
125*180 710 940 223 - - - 200
140*200 720 965 238 - - - 215
160*225 825 1085 252 - - - 230
200*280 900 1190 280 - - - 260
225*315 880 1185 295 - - - 275
Example d) L - P - L
798
1 Coupler (L)
Y A min
L - P - L PVC-U PVC-C PP-H, PE80 PVDF

20*50 - 475 127 127 123 123 65
25*50 - 475 133 133 127 127 65
32*63 - 515 149 149 141 141 75
40*75 - 595 167 167 155 155 85
50*90 - 680 192 192 176 176 100
63*110 - 800 226 226 208 204 120
75*125 - 855 253 253 231 - 135
90*140 - 925 277 277 245 - 145
110*160 - 965 307 312 267 - 155
125*180 - 1030 338 - - - 170
140*200 - 1055 367 - - - 185
160*225 - 1180 402 - - - 200
200*280 - 1290 472 - - - 230
225*315 - 1305 513 - - - 245
799
Example e) S - E Example f) S - P - E
1 Spigots (S)
2 Socket (E)
Y A min
S - E S - P - E PVC-U PVC-C PP-H, PE80 PVDF

20*50 310 428 115 115 113 113 88
25*50 310 428 115 115 114 114 88
32*63 340 466 128 128 128 128 101
40*75 400 540 157 157 158 158 130
50*90 460 615 162 162 165 165 135
63*110 550 725 212 212 220 218 185
75*125 585 773 224 224 235 - 198
90*140 640 838 243 243 253.5 - 218
110*160 665 875 249 246.5 261 - 225
125*180 710 934 272 - - - 249
140*200 720 958 276 - - - 253
160*225 825 1079 316 - - - 294
200*280 900 1182 397 - - - 377
225*315 880 1178 358 - - - 338
800
Example g) L - P - E
1 Coupler (L)
2 Coupler (E)
Y A min
L - P - E PVC-U PVC-C PP-H, PE80 PVDF

20*50 - 475 127 127 125 125 65
25*50 - 475 133 133 130 130 65
32*63 - 510 149 149 145 145 75
40*75 - 575 167 167 161 161 85
50*90 - 670 192 192 184 184 100
63*110 - 760 226 226 217 215 120
75*125 - 815 253 253 242 - 135
90*140 - 875 277 277 261 - 145
110*160 - 920 307 309.5 287 - 155
125*180 - 975 338 - - - 170
140*200 - 1010 367 - - - 185
160*225 - 1110 402 - - - 200
200*280 - 1165 472 - - - 230
225*315 - 1235 513 - - - 245
Connection sizes for double containment

fittings
If the cutting sizes on long pipes are not calculated from
tables, the inner and outer pipes can be finished to di-
mension “f” for connection to fitting end S, and to dimen-
sion “g” for connection to fitting end L.
Note:
Last connection always on the double containment fit-
ting!
First, fit equal socket to the pipe section to be connect-
ed.
f insertion depth of socket: "L" + z-dimension of equal socket
"z" - 15 mm
g insertion depth of socket: "L" + 15 mm
30 width of snap ring
L insertion depth of pipe in socket
z z-dimension of socket
0 type 0
1 type 1
801
Diameter Connection to DC Connection to DC
d fitting, spigot end. fitting, coupler end.
Shorter length com- Longer length com-
pared with outer pipe: pared with outer
"f" pipe: "g"

Inner PVC-U, PP, PE, PVC-U PP, PE,
pipes PVC-C PVDF PVDF
20 4.0 6.0 31.0 29.0
25 7.0 8.0 34.0 31.0
32 10.0 10.0 37.0 33.0
40 14.0 13.0 41.0 35.0
50 19.0 16.0 46.0 38.0
63 26.0 20.0 53.0 42.0
75 33.0 24.0 59.0 46.0
90 41.0 30.5 66.0 50.0
110 52.0 40.0 76.0 56.0
125 61.0 - 84.0 -
140 68.0 - 91.0 -
160 79.0 - 101.0 -
200 100.0 - 121.0 -
225 114.0 - 134.0 -
802
Fittings for butt and IR fusion and in- Patented GF double containment pipe jointing
method for butt fusion in 6 steps
stallation
Butt fusion
Possible connections:
• fitting to fitting direct
• fitting to intermediate pipe section
• fitting to termination fitting
1. Clamps hold the inner pipe and/or fitting.
2. Standard heating element for butt fusion. The pipe and fitting
are heated simultaneously.
1 Spigot for butt fusion

2 Space for full ELGEF® Plus electrofusion coupler or EPDM
rubber sleeve
3 Space for ½ ELGEF® Plus electrofusion coupler or EPDM
rubber sleeve
3. Heating element for butt fusion.
803
Legend:
The following symbols are used to demonstrate the various
connection examples.
Abbreviation, Sym- Example 90 ° elbow:
bol:
S = Short end of
fitting with internal
spigot.
4. Carry out a visual inspection of the joint, then pressure test

the inner pipe.
L = Long end of fit-

ting with internal
spigot.
E = Endfitting
5. A snap ring is fitted between the ends of the outer pipes to

close the inspection gap.
6. An ELGEF Plus coupler or EPDM rubber sleeve is used to

®
seal the outer pipe.

CONTAIN-IT Plus: butt fusion
• Short end of fitting (S) with space for (½ - 15 mm)
ELGEF Plus coupler
®
• Long end of fitting (L) for full ELGEF Plus coupler

®
• Termination fitting (E)

• Pipe (P)
804
Example Symbol Combination
m) Short end of fitting -
S - P - S Pipe -
Short end of fitting
n) S - L Short end of fitting -

Direct -
Long end of fitting
o) S - P - L Short end of fitting -

Pipe -
Long end of fitting
p) L - P - L Long end of fitting -

Pipe -
Long end of fitting
q) S - E Short end of fitting -

Direct -
Termination fitting (long)
r) S - P - E Short end of fitting -

Pipe -
Termination fitting (long)
s) L - P - E Long end of fitting -

Pipe -
Termination fitting
(long)
805
Dimensions for calculating the cutting lengths
CONTAIN-IT Plus: butt fusion
Attention: Dimensional allowances, for planning (preparation for welding) and the weld bead (fusion process), need to be
added when calculating the cut size!
Example m) S - P - S
d*D Direct M M min. Inner pipe: Y i min / Material Outer pipe Y A min
S - P - S PP PE PVDF
20*50 - 455 215 215 215 185
25*50 - 455 215 215 215 185
32*63 - 500 230 230 230 200
40*75 - 575 255 255 255 225
50*90 - 655 285 285 285 255
63*110 - 775 325 325 325 295
75*125 - 835 355 355 355 325
90*140 - 905 375 375 375 345
110*160 - 945 395 395 395 365
125*180 - 1015 425 425 425 395
140*200 - 1055 455 455 455 425
160*225 - 1185 485 485 485 455
200*280 - 1310 540 540 540 510
225*315 - 1305 575 575 575 545
806
Example n) S - L Example o) S - P - L
S - L S - P - L PP PE PVDF
20*50 310 435 125 125 125 95
25*50 310 435 125 125 125 95
32*63 340 475 135 135 135 105
40*75 400 545 145 145 145 115
50*90 460 620 160 160 160 130
63*110 550 730 180 180 180 150
75*125 585 780 195 195 195 165
90*140 640 845 205 205 205 175
110*160 665 880 215 215 215 185
125*180 710 940 230 230 230 200
140*200 720 965 245 245 245 215
160*225 825 1085 260 260 260 230
200*280 900 1190 290 290 290 260
225*315 880 1185 305 305 305 275
807
Example p) L - P - L
L - P - L PP PE PVDF
20*50 380 480 100 100 100 70
25*50 380 480 100 100 100 70
32*63 410 515 105 105 105 75
40*75 480 595 115 115 115 85
50*90 550 680 130 130 130 100
63*110 650 800 150 150 150 120
75*125 690 855 165 165 165 135
90*140 750 925 175 175 175 145
110*160 780 965 185 185 185 155
125*180 830 1030 200 200 200 170
140*200 840 1055 215 215 215 185
160*225 950 1180 230 230 230 200
200*280 1030 1290 260 260 260 230
225*315 1030 1305 275 275 275 245
808
Example q) S - E Example r) S - P - E
d*D Direct M M min. Inner pipe: Y i min / Material Aussenrohr Y A min
S - E S - P - E PP PE PVDF
20*50 310 435 125 125 125 95
25*50 313 435 125 125 125 95
32*63 335 475 140 140 140 110
40*75 380 545 165 165 165 135
50*90 450 620 170 170 170 140
63*110 510 730 220 220 220 190
75*125 545 780 235 235 235 205
90*140 590 845 255 255 255 225
110*160 620 880 260 260 260 230
125*180 655 940 285 285 285 255
140*200 675 965 290 290 290 260
160*225 755 1085 330 330 330 300
200*280 775 1190 415 415 415 385
225*315 810 1185 375 375 375 345
809
Example s) L - P - E
L - P - E PP PE PVDF
20*50 380 480 100 100 100 70
25*50 380 480 100 100 100 70
32*63 405 510 105 105 105 75
40*75 460 575 115 115 115 85
50*90 540 670 130 130 130 100
63*110 610 760 150 150 150 120
75*125 650 815 165 165 165 135
90*140 700 875 175 175 175 145
110*160 735 920 185 185 185 155
125*180 775 975 200 200 200 170
140*200 795 1010 215 215 215 185
160*225 880 1110 230 230 230 200
200*280 905 1165 260 260 260 230
225*315 960 1235 275 275 275 245
810
Leak detection and leak locating sys- vided into leakage sections, each with its own vacuum
pump (Divisions with termination fittings, refer to Sec-
tems tion: Tools for locating leaks in all systems).
To make certain that a leak in the inner pipe of a double
containment system does not go unnoticed (rendering Leak location:
the system no better than a regular single pipe), it is es- • Outer pipe direct
sential that leaks are being detected. There are sever- • Inner pipe through special holes in the outer pipe
al different systems available on the market for the pur-
pose of monitoring pipes. Suppliers of differential pressure monitoring sys-
tems:
Differential pressure SGB Sicherungsgerätebau GmbH
We distinguish between over and underpressure monitoring: Hofstrasse 10
57076 Siegen, Germany
Tel: +49 271 48964 0
Overpressure monitoring Fax: + 49 271 48964 6
sgb@sgb.de
In differential pressure monitoring with overpressure, ni-
www.sgb.de
trogen is pumped at a specific pressure into the space
between the inner and outer pipes. If there is a pressure
loss in this space, an alarm will indicate the leak. Optical monitoring
Advantages: For optical leak detection, a 20-mm diameter ball valve
• The inner and outer pipes are monitored for leak-tight- with a transparent PVC-U monitoring pipe is mounted
ness on the Rp ½" branch of the termination fitting or on the
• Retrofit installation is possible branch saddle.
• TÜV test certificate Advantages:
• Automatic alarm • Cost-efficient
Disadvantage: • Retrofit on the branch saddle is possible
• The nitrogen, which is pumped in, must be at a high- Disadvantages:
er pressure than the medium-conveying inner pipe. It
is therefore essential to check that the inner pipe will • No automatic alarm
not collapse, taking account of the operating condi- • Outer pipe is not monitored
tions (please refer to the questionnaire for the struc-
tural certificate). • Can be installed only at the lowest point
Locating leaks:
• Outer pipe direct
• Inner pipe through special holes in the outer pipe
Vacuum monitoring (underpressure monitoring)

In differential pressure monitoring in a vacuum, a pump
is used to create a vacuum in the range of 600 – 700
mbar in the space between the inner and outer pipes.
If there is a pressure loss in this space, a vacuum
switch (VS) switches on a vacuum pump. At the same
time, a warning light and buzzer provide visual and a-
coustic warnings.
Advantages:
• No pressure loading on the inner pipe
• The inner and outer pipes are monitored for leak-tight-
ness
Branch saddle with leak monitoring
• Retrofit installation is possible
• Automatic alarm
Optoelectronic monitoring
• TÜV test certificate
For optoelectronic leak detection, a fluid sensor and a
Disadvantages: 20-mm diameter ball valve with a transparent PVC-U
• Pumping volume of the vacuum pump must be at monitoring pipe is mounted on the ½" branch of the ter-
least 750 mbar with clear intake. mination fitting or on the branch saddle.
• Where there is a large volume of space between the Advantages:
inner and outer pipes, the vacuum pump will need to
be powerful enough, or the pipeline will need to be di- • Relatively cost-efficient
• Retrofit on the branch saddle is possible
• Automatic alarm
811
Disadvantages: Note:
Due to the minimal difference in dimensions between
• Outer pipe is not monitored the inner and outer pipes in the CONTAIN-IT Plus dou-
• Can be installed only at the lowest point ble containment system, sensor cables are not feasible.
If this option is required, please contact our local sales
representative.
Tools for locating leaks in all systems: Ter-

mination fittings
By separating the outer pipe into leak detection sections
with termination fittings, the spill and the leak can be
easily localised in the section between the built-in termi-
nation fittings.

Advantages:
• Fast and safe leak detection
• Only the respective section of the outer pipe needs to
be rinsed and cleaned
Suppliers of optoelectronic leak detection systems:
Fa. CARLO CAVAZZI AG • Length of leakage sections freely selectable
Verkauf Schweiz/Vente
Sumpfstrasse 32
CH-6312 Steinhausen
Tel. +41 41 747 45 25
Fax +41 41 740 45 60
verkauf_vente@carlovagazzi.ch
www.carlogavazzi.ch,
www.gavazzi-automation.com
Fa. BAMO-IER GmbH
Innstrasse 2
D-68199 Mannheim
Tel: +49 621 842240
Fax +49 621-8422490
info@ier
www.ier.de
Fa. VEGA Grieshaber KG
Am Hohenstein 113
D-77761 Schiltach
Tel: +49 7836 50-0
Fax +49 7836 50-201
info@de.vega.com
www.vega.com
Sensor cable
In the space between the inner and outer pipes a cable
is laid which reacts either to conductive fluids or chemi-
cals and emits an alarm.
Advantages:
• Leak point is indicated precisely to within 1 m
• Automatic alarm
Disadvantages:
• Outer pipe is not monitored
• Relatively expensive
• Retrofit is not possible
• Depending on the system, larger outer diameter of
outer pipe will be required
• Susceptibility to condensates
812
Operating and maintenance instruc-
tions
Important:
Installation or repair of double containment systems
must be made only by personnel trained for the purpose
and authorised by GF.
Maintenance
• If the leakage warning system signals an incident, the
safety procedures – defined in advance by the oper-
ator of the double containment – system, must be fol-
lowed.
• If the installation includes more than one double con-
tainment line or section, a leak detection system must
be installed in each individual sector. If this is not
done, and the space between the pipes becomes
filled with the medium being carried, the double con-
tainment system effectively becomes a single pipe
system. The leak detection system must be capable
of detecting and indicating a leak within 72 hours.
• Double containment systems must be protected from
uncontrolled thermal and mechanical influences.
Pressure test
Refer to section: "Pressure testing the inner und outer
pipes".
Carrying out repairs
• Prior to beginning with a repair, it is essential to take
appropriate precautions, including completely empty-
ing and flushing the inner and outer pipes, preventing
any dripping, etc.
If a leak cannot be precisely located, it is useful to
proceed section by section.
Caution: Only use water to search for the leak.
• Our mechanically fastened drill-in saddle, with a ½"
tapping point, allows test drillings to be carefully made
on the underside of the protective pipe to section off
the leak. The saddle is later resealed with a PVC plug.
• We recommend the use of termination fittings when
the pipe system is being installed, to divide it up into
leakage detection zones.
• The pipe must be replaced in accordance with our
pipe installation instructions.
Extension of the installation and retrofit installation

of a T-piece
Before starting work, it is essential to take appropriate
precautions, including completely emptying and flushing
the inner and outer pipes, preventing any dripping, etc.
Safety and fire prevention measures
We refer to the relevant safety datasheets of the plastic
materials used.
Laying pipes in the ground
When laying pipes in the ground, care must be taken to
ensure compliance with the relevant regulations and di-
rectives of professional organisations and public author-
ities and agencies, relating to trenching, embedding the
double containment system and backfilling.
813
Pressure testing the inner and outer Material Pressure drop
pipes PVC-U 0.5 bar/h
PVC-C 0.5 bar/h
Inner pipe
ABS 0.6 bar/h
General
PP 0.8 bar/h
The internal pressure test is done when installation work
has been completed and necessitates an operational PE 1.2 bar/h
pipeline or operational test sections. The test pressure PB 1.4 bar/h
load should furnish experimental proof of operational
PVDF 0.8 bar/h
safety. The test pressure is not based on the working
pressure, but rather on the internal pressure load ca- Main test
pacity, derived from the pipe wall thickness. In the context of the main test, a much smaller drop in
Supplement 2 of DVS 2210-1 forms the basis for the fol- pressure can be expected at constant pipe wall tem-
lowing information. This replaces the data in DVS 2210- peratures so that it is not necessary to pump again.
1 entirely. The modifications became necessary be- The checks can focus primarily on leak detection at the
cause flange joints and any position changes of the pipe.
• the reference value ”nominal pressure (PN)” is being Observe if using compensators
used less and less to determine the test pressure (1.5 If the pipeline to be tested contains compensators, this
x PN, or 1.3 x PN) and is being replaced by SDR, has an influence on the expected axial forces of the
• a short-term overload or even a reduction in the ser-
vice life can occur if in the course of the internal pres-
become higher. This has to be taken into account when
sure test based on the nominal pressure the pipe wall
designing the fixed points.
temperature TR = 20 °C is exceeded by more than 5
°C. Observe if using valves
Test pressures are therefore determined in relation to nal valve), the valve and the pipe end should be closed
SDR and the pipe wall temperature. The 100-h value by a dummy flange or cap. This prevents inadvertent
from the long-term behaviour diagram is used for the opening of the valve or any pollution of the inside of the
test clamping. valve.
Test Parameters Filling the pipeline
The following table indicates recommended methods of Before starting with the internal pressure test, the fol-
testing the internal pressure. lowing points must be checked:
Object Pre-test Main test • Was installation done according to the available
plans?
Test pressure p p ≤ pp(perm) ≤0.85 pp(perm)
(depends on the pipe
• All pressure relief devices and flap traps mounted in
wall temperature or the flow direction?
the permissible test • All end valves shut?
pressure of the built- • Valves in front of other devices are shut to protect
in components, see
clause "Determining
against pressure.
the test pressure") • Visual inspection of all joints, pumps, measurement
devices and tanks.
Test duration (de- L ≤ 100 m: 3 h L ≤ 100 m: 3 h
pends on the length of 100 m <L ≤ 500 100 m <L ≤ 500 • Has the waiting period after the last fusion / cement-
the pipeline, respec- m: 6 h m: 6 h ing been observed?
tively the sections)
Now the pipeline can be filled from the geodetic lowest
Checks during the At least 3 At least 2 point. Special attention should be given to the air vent. If
testing (test pressure checks, distribut- checks, distribut- possible, vents should be provided at all the high points
and temperature pro- ed over the test ed over the test of the pipeline and these should be open when filling the
gression should be duration with duration without
recorded) restoring the test restoring the test
system. Flushing velocity should be at least 1 m/sec.
pressure pressure Reference values for the filling volume are given in the
table below.
Pre-test
The pre-test serves to prepare the piping system for the DN V (l/sec) DN V (l/sec)
actual test (main test). In the course of pre-testing, a
≤ 80 0.15 250 2.0
tension-expansion equilibrium in relation to an increase
in volume will develop in the piping system. A materi- 100 0.3 300 3.0
al-related drop in pressure will occur which will require 150 0.7 400 6.0
repeated pumping to restore the test pressure and al-
so frequently a re-tightening of the flange connection 200 1.5 500 >9.0
screws.
The guidelines for an expansion-related pressure de-
crease in pipes are:
814
Adequate time should be allowed between filling and
testing the pipeline, so that the air contained in the pip-
ing system can escape via the vents: ca. 6 - 12 h, de-
pending on the nominal diameter.
Applying the test pressure
The test pressure is applied according to the diagram.

Here it is important that the pressure increase rate does
not cause any water hammer !
Definitions
Y = test pressure in %
X = time for pressure increase in min
1) = pressure increase rate up to DN 100
2) = range of pressure increase rates >DN 100 - 400
3) = reference values for pressure increase rate DN 500
and greater is: 500 / DN [bar/10 min]
Determining the test pressure
The allowable test pressure is calculated according to
with
σ v(T, 100h) Long-term creep strength for the pipe wall tem-
perature TR (at t = 100 h)
Sp Minimum safety factor for long-term creep strength
AG Processing or geometrical specific factor that re-
duces the allowable test pressure
TR Pipe wall temperature: average value of test medium
temperature and pipe surface temperature
Attention: If the piping system contains di-
aphragm valves the maximum allowable test
pressure is limited to the nominal pressure.
To make things easier, the permissible test pressures

can be taken directly from the following diagrams.
Definitions:
P = permissible test pressure in bar
T = pipe wall temperature in °C
815
After the installation of the double containment system
has been completed, the pressure connection (pressure
union) for the leakage indicator, or a test union to mon-
itor the proper operation of the leakage indicator, is in-
stalled as near as possible to (no further than 1 m from)
or directly inside the termination fitting and at the end
of each length of piping. The leak-tightness test of the
space between the pipes is carried out at room temper-
ature (20 °C).
Caution:
Thin-walled inner pipes in particular can collapse un-
der excess pressure in the space between the pipes.
The maximum permissible test and / or overpressure in
the space between the pipes depends on the load ca-
pacity of the medium-conveying inner pipe. Care should
be taken here to ensure that the internal pressure load
on the pipe (PN stage) is not the same as the external
pressure load.
Water is the preferred test medium. However, complete
drainage must be ensured. In many cases, air or inert
gas are also suitable test media. The following points
should be noted:
• Compressor oils can contain damaging elements for
the pipe.
• Depending on the temperature, some materials tend
to chip and break under mechanical influence and in-
ner pressure of compressed media.
• The appropriate safety precautions should be taken in
Checks during testing the event of a crack in the outer pipe, especially trans-
The following measurement values must be recorded parent PVC-U.
consistently during testing:
• The maximum gas pressure depends on the material
• Internal pressure at the absolute low point of the and should not exceed the following values:
pipeline
Test Parameter CONTAIN-IT Plus
• Medium and ambient temperature
• Water volume input Pipelines PE100 outer pipe, PVC-U outer pipe,
• Water volume output pressure-resis- spray protection
tant fused with with EPDM rubber
• Pressure drop rates ELGEF® Plus sleeve
coupler
Leak-tightness test
If it is not possible to use water to carry out an internal SDR11
SDR17 or
pressure test (e.g. piping systems need to be kept dry),
SDR17.6
a leak-tightness test can be carried out at low pressure.
For safety reasons, the test pressure must be restricted Pre-test Main Pre-test Main
to 0.5 bar (overpressure). test test
During the leak-tightness test, all joints are sprayed with Water ≤ pp (zul) ≤ 0.85 * 1 bar 1 bar
a foaming agent and checked. Since the efficiency of pp (zul)
the leak-tightness test is considerably restricted, due to
Inert gas 0.5 bar 0.5 bar 0.3 bar 0.3 bar
the low loading, this should preferably be used only on
systems with operating pressures below 0.5 bar. Testing time
Holding the pipeline under the test pressure all connec-
Outer pipe tion parts of the pipeline like flanges, unions, valves,
General etc. are inspected on tightness using a foam building
Once the test of the inner pipe is complete, the outer agent. A soap solution, which can be removed simply
pipe is tested with a fully filled inner pipe under internal with water after the test, is best.
pressure (the internal pressure of the inner pipe must be Attention: Commercial leak detection sprays
at least equal to or greater than the internal pressure of can cause stress cracks in plastics. Using these
the outer pipe) to avoid loading the inner pipe as a re- sprays remove any residues after testing.
sult of external pressure. To carry out the pressure test,
suitable filling and ventilation facilities must be provided No overloading of the components
on the outer pipe. Please consider that the test pressure has to be adapt-
ed to the installed components: for example where fit-
tings or valves are installed a maximum test pressure
of 6 bar is admissible for the protective pipe!
816
Double contain- PE100 outer pipe, PVC-U outer pipe,
ment valves pressure-resis- spray protection
tant fused with with EPDM rubber
ELGEF® Plus sleeve
coupler
SDR11
SDR17 or
SDR17.6
Pre-test Main Pre-test Main
test test
Water 6 bar 6 bar 1 bar 1 bar
Inert gas 0.5 bar 0.5 bar 0.3 bar 0.3 bar
817
Static evidence CONTAIN-IT Plus system
The questionnaire for static evidence is used by GF to
determine if the selected pipeline is resistant under the
given operating conditions. For fixed-point installation
(inhibited longitudinal expansion), it is necessary to cal-
culate the stresses and forces on the outer pipe fittings,
which the fixed-point pipe brackets are required to ab-
sorb.
The fixed point for the inner pipe is already built into
each fitting by means of a support ring. If the calculat-
ed stress on the pipe is too great, the operating condi-
tions or the material must be changed. The calculation
also indicates the distances between spacers for the in-
ner pipe and the distances between pipe brackets for
the outer pipe as well as the forces on fixed points. Ex- 1 Monitoring space
pansion in the pipeline need not be taken into consider- 2 Outer pipe
ation; no additional expansion loops or compensators 3 Inner pipe
are required. To prevent the pipe sagging because of 4 Pipe bracket
bending or not exactly aligned installation, it is advis-
5 Spacer
able to install guide supports between the fixed points,
designed for lateral forces of around 15 % of the axial-
forces, acting on the fixed points.
1 Fixed point
2 Guide supports
Double containment system fixed point
CONTAIN-IT Plus loadings

• Medium, pressure, temperature, time
• Stresses resulting from impeded thermal expansion
• Kink resistance
• External pressure stability
• Intermittent stressing
• Special case of EPDM sleeve
818
Questionnaire for static evidence
819
Static evidence - Calculation by GF Piping
Systems
On the basis of the customer data entered in the ques-
tionnaire (cf. Questionnaire for static evidence, Section:
Static evidence) the calculation programme produces a
static evidence, as shown in the following illustrations.
The static evidence is sent to the customer.
820
Welding machines for butt and sock-
et fusion
SG 160 welding machine

• for butt fusion joints from d20/50 to d110/160
• for larger sizes, use SG 315 welding machine
Welding machine IR110:
SG160
• for socket fusion joints from d20/50 to d110/160
Welding machine for IR-fusion

• For IR-fusion joints up to Dimension d50/90

• No special half shells

• Please use the special half shell for the double con-
tainment system.
821
• Please use the special half shell for the double con-
tainment system.
822
Safety measures - extensions and re-
pairs
• Completely drain the inner and outer pipes
• If necessary, wash out
• Take precautions to ensure no dripping of medium
• Caution when separating the pipes – protect person-
nel and equipment from leaking medium Further information available on request.
• Use water to search for leak (must be compatible with
product) Double containment - flanged connection
to a tank
Separating for retrofit installation of a T-90°
1 Separation inner and outer

2, 3, 4 Separation outer
5, 6 Separation inner
7 Branch axis for 90 ° T-piece
X = 30 mm snap ring width
Z-dimensions can be taken from the double contain-

ment product catalogue.
Branch axis for 90 ° T-piece The piping must be capable
of being moved axially.
CONTAIN-IT Plus - mechanical joint

Radially removable stainless steel collar for the out-
er pipe
For retrofit extension or repair
• Inner pipe with screwed union
• Flanged inner pipe
823
Double containment valves
Versions
• Pneumatic actuator
• Electric actuator
• Hand operated
• PVC-U PN 6 protective case
• Internal ball valve: can be radially installed and re-
moved
CONTAIN-IT Plus ball valve

Operating instructions
1 Introduction
2 Design of a double containment valve
Double containment valves from GF Piping Systems are
supplied as a ready-to-install system unit and the joint-
ing technology used is similar to that for a double con-
tainment fitting. The concept is that the inner pipe is first
joined according to the jointing technology which you
have selected. The following jointing methods and ma-
terials can be chosen from:
Jointing methods for inner pipe Material
Butt fusion PE100, PP-H, PVDF
IR fusion PE100, PP-H, PVDF
Socket fusion PE80, PP-H, PVDF
Socket cementing PVC-C, PVC-U
1 Protective housing
• installation and pressure testing of a double contain-
ment ball valve 2 Stem
3 Union end
• removing and reinstalling, e.g. in case of a leak
4 Union bush
• retrofitting the valve for actuation
5 Union nut of protective housing
Please note that the installation conditions and 6 Hand lever
safety instructions contained in the enclosed 7 Nuts and screws to fix the hand lever
installation and operation instruction manual 8 Support pieces PE
for the 2-way ball valve type 546, manual op-
eration, must be complied with each time the 9 Ball valve type 546 (central part)
double containment valve is built in or disman- 10 Union nut ball valve type 546
tled! 11 Connection for 1/2 inch leak detection or PVC-U 1/2 inch
plug
12 Spacer
13 Borehole for leak detection of inner pipe
14 O-ring for PE connection adaptor
15 O-rings for stem
16 O-rings for union bush / union end
3. Installation
Before putting the double containment valve into op-
eration, the following 4 steps are required to install the
CONTAIN-IT Plus ball valve:
824
Step 1: Valve mounting
NOTICE
Installation of the valve

Incorrect installation may cause problems
with tolerances.
• Make sure to join up the pipe ends with the
other pipe sections only after the valve has 3 Loosen the union nuts of the protective housing and move
been assembled them aside.
NOTICE
Fixing of the valve

Tension within the assembly reduced the life
expectancy and functionality of the valve.
• Fix the valve at both ends with fixing points
in order to minimise any tension within the
assembly
4 Unscrew the union bush (left-hand thread!) and move it aside.
Note: The use of a pin wrench is recommended (00 23 90).
Step 2: Preparing for pressure testing
CAUTION
Removing the hand lever

A build-up of internal pressure may cause the
valve pinion to pop out, leading to injury and /
or damage.
• Before removing the hand lever, any inter-
nal operating or test pressures must be re-
leased
Procedure: 5 Remove the stem from the protective housing. A groove on

the stem allows the use of a screw driver.
1 Make sure that the red hand lever is in parallel position to the
pipe system.
6 Move the protective housing aside. The ball valve is now ac-
cessible.
2 Loosen the nuts and remove the hand lever.
825
Step 3: Pressure testing the inner pipe
WARNING
Pressure Testing
Using hazardous media for pressure test-
ing may put the installation at risk and cause
physical damage or bodily harm in case of
leakage.
• The pressure test must be performed using 2 Plug the stem through the hole in the protective housing on-
non-hazardous media (e.g. water) and with to the ball valve. Note: Please make sure that the stem is in
due care and attention in handling. the right position. Therefore please consider the outline of the
stem and of the ball valve.
• Please pay attention to the instructions in
the user manual included for ball valve type
546 (valves only)
Procedure:
1. Check to make sure the protective housing is open
(cover removed) to determine if there is leakage during
the pressure testing.
2. The pressure test must be performed with water or
another non-hazardous medium. See DVS 2210-2 with
reference to DVS 2210-1, Suppl. 2, as well as the in-
structions contained in the above mentioned Instal-
lation and Operating Instructions for Ball Valve Type
546.
When the pressure test has been successfully complet- 3 Check if the stem is flush with the bottom of the connecting el-
ement.
ed, proceed to Step 4.
Step 4: Assembling the CONTAIN-IT Plus Ball Valve
Type 546
4 Screw the union bush (left-hand thread!) into the protective

housing and tighten it. Note: The use of a pin wrench is rec-
ommended (00 23 90).
1 Move the protective housing over the ball valve.
5 Reposition the union end and tighten the union nuts on both
sides with an adequate wrench.
826
5 Upgrade the CONTAIN-IT Plus Ball Valve Type 546
with an actuator
The CONTAIN-IT Plus Ball Valve can be upgraded with
the EA11, EA21 and PA21 actuators according to the
following description.
To upgrade the CONTAIN-IT Plus Ball Valve you will
need the Adaptor Set 700 238 796. This Adaptor Set in-
cludes the following items:
• 1 x Adaptor Code 198 204 007
• 1 x Interface adaptor Code 198 803 156
• 2 x Reducing bush Code 198 803 145
6 Mount the hand lever onto the connecting element.
4 Installing and removing the double containment

Ball Valve Type 546 Upgrades with other actuators on request.
WARNING 5.1: Procedure:

The upgrade of the actuators EA11, EA21 and PA21 fol-
lows the same steps.
Opening of protective housing and ball
valve
Uncontrolled leakage of medium may oc- CAUTION
cur from the pipeline or the valve both with
and without pressure. Contact with any re-
Removing the hand lever
maining quantities of hazardous, aggres-
sive, flammable or explosive media within the A build-up of internal pressure may cause the
pipeline or the valve may cause death or se- valve pinion to pop out, leading to injury and /
rious injury. or damage.
• Release the control and operating pres- • Before removing the hand lever, any inter-
sures nal operating or test pressures must be re-
• Completely drain the medium from protec- leased
tive housing (the medium-conducting inner
pipe as well as the outer pipe)
• Rinse the inner and outer pipes
• Protect against dripping
4.1: Opening the protective housing

Procedure see chapter 3 - step 2
4.2: Removing the ball valve type 546
Procedure:
1.Loosen the union nuts of the ball valve 1 Make sure that the red hand lever is in parallel position to the
2.Take the ball valve out of the inner pipe pipe system.
3.Perform revision work according to the instruction

manual of the ball valve type 546
4.3: Re-installing the ball valve type 546

Procedure:
1.Check O-rings on ball valve and grease with a ten-
side-free, silicone or polyglycol-based lubricant (we
recommend using new gaskets when re-installing the
ball valve).
2.Fit the ball valve 546 in the inner pipe, making sure
the ball valve is in the "open" position.
3.Re-tighten the adjustment bush and union nut in the 2 Loosen the nuts and remove the hand lever.
counter-clockwise direction (Fig. 4)
4.Perform pressure test and assembly according to
steps 3 and 4 described in paragraph 3.
827
3 Plug the adaptor into the actuator.
6 Mount the actuator with the adaptor interface on the connect-

ing element.
4 Mount the adaptor interface with four allen screws onto the ac-
tuator.
5 Put the reducing bush onto the stem.
7 The CONTAIN-IT Plus Ball Valve and the actuator are now
ready to use.
828
6 Spare part seals for the CONTAIN-IT Plus Ball
Valve Type 546 Installation example of double containment
valves
6.1 Stem
Dimension Code Qty. Dimension O-ring
Ball Valve mm
d20/50-d32/50 748410103 2 3.54 x 29.75 EPDM
749410103 2 3.54 x 29.75 FPM
d40/75-d63/110 748410027 2 3.54 x 37.69 EPDM
749410027 2 3.54 x 37.69 FPM
6.2 PE-connecting adaptor

d20/50–d25/50 748410119 2 5.34 x 71.39 EPDM
749410119 2 5.34 x 71.39 FPM
d32/63 748410023 2 5.34 x 91.44 EPDM
749410023 2 5.34 x 91.44 FPM
d40/75-d63/110 748410254 2 7.0 x 108.0 EPDM
Installation example
749410254 2 7.0 x 108.0 FPM
6.3 Union end / union bush

d20/50–d25/50 748410111 2 5.34 x104.37 EPDM
749410111 2 5.34 x104.37 FPM
d32/63 748410249 2 5.34 x123.19 EPDM
749410249 2 5.34 x123.19 FPM
d40/75–d63/110 748410258 3 5.34 x146.1 EPDM
749410258 (d63=4) 5.34 x146.1 FPM
6.4 Ball Valve Type 546 (Central Part)

Seal sets consist of:
2 backing seals, 1 body seal, 2 face seals, 2 stern seals
EPDM sealing set:
Dimension Code
d20/50 161486400
d25/50 161486401
d32/63 161486402
d40/75 161486403
d50/90 161486404
d63/110 161486405

FPM sealing set:
Dimension Code
d20/50 161486410
d25/50 161486411
d32/63 161486412
d40/75 161486413
d50/90 161486414
d63/110 161486415
829
Customized parts
A large number of components in the double contain-
ment range are manufactured to customer require-
ments. Prefabricated tapping pieces, reducing T-pieces,
termination fittings integrated into the preform or the
prefabrication of entire sub-assemblies offer simplified
installation on the construction site.
T-piece with 45 ° tapping point for socket

fusion and cementing or butt fusion
90 ° elbow including termination fitting
830
Double containment reducing 90 ° T-piece with elbow
831
832
System COOL-FIT
Page

COOL-FIT Top quality 835
System advantages: Your benefit 837
System Specification
-- COOL-FIT ABS 838
-- COOL-FIT ABS Plus 838
COOL-FIT ABS Plus technical details
-- COOL-FIT ABS Plus pipes 839
-- COOL-FIT ABS Plus Fittings 839
-- Reducing diameters 840
-- Accessory Equipment 840
Technical Data
-- General comments to plastics orientated pipeline design and installation 844
-- COOL-FIT ABS Plus pressure-temperature diagram 844
-- COOL-FIT On-Line calculation tool 845
Installation
-- COOL-FIT ABS Plus fixed point 847
-- Plastic to Metal Connections 847
-- Measuring Equipment in an COOL-FIT ABS Plus System 848
-- Other installation topics 849
-- Determining of COOL-FIT ABS Plus changes in length 852
-- Flexible length for COOL-FIT ABS Plus 852
-- Comparision pipe diameter 854
COOL-FIT Product Range
-- Background Information to the COOL-FIT Product Range from GF Piping Systems 855
833
System COOL-FIT Note:
COOL-FIT is not for use with primary gases such as:
• Ammonia, Propane, R407, R22 and also not for use
General information for compressed air systems
COOL-FIT is a complete plastic pipe system for sec-
ondary cooling and refrigeration systems operated with Application Areas:
brine or water diluted glycols. The system is based on • Dairies
proven and cold-shock resistant ABS pipes and fittings.
• Slaughter houses
COOL-FIT is ideal for use in cold storage, in food and
beverage production (e.g. breweries, dairies, slaughter- • Meat processing
houses), in supermarkets as well as for process cooling • Industrial cooling water
in industrial cooling water systems or in data centers. • Breweries
• Food production
• Fish industry
• Air conditioning
COOL-FIT technical information and installation details
are available separately on request.
GF offers technical support during the planning phase
and on-site training for jointing and handling. Please
contact GF for details.
The COOL-FIT system is available in three different ver-

sions:
• COOL-FIT ABS: standard ABS (not insulated), post-
insulation on-site possible
• COOL-FIT ABS Lite: pre-insulated ABS with Armacell
insulation: fire classification: BL-s3,d0
• COOL-FIT ABS Plus: pre-insulated ABS with UV re-
sistant and vapor tight jacket
Both pipes and fittings are delivered ready to install.

Typical working conditions
Working temperature range from:
• -50 °C (-58°F) to +60°C (140°F) COOL-FIT ABS
• -50 °C (-58°F) to +60°C (140°F) COOL-FIT ABS Lite
• -50 °C (-58°F) to +40°C (104°F) COOL-FIT ABS Plus
Typical mediums
COOL-FIT can be used for example with the following
mediums:
• chilled water and general water
• Salt solutions
• Antifrogen KF
• Hycool
• Temper
• Freezium
• Zitrec
Glycol solutions
• Antifrogen L
• Antifrogen N
• Dowfrost
• Tyfocor
Alcohol solutions
For compatibility of COOL-FIT to non-water mediums
please consult GF Piping Systems.
834
COOL-FIT Top quality
Minimum on site time
835
836
System advantages: Your benefit
Hygienic and aesthetic

Speed Top quality in performance and looks. Smooth outer
Fittings and pipes are delivered direct to the site ready surfaces for hygienic environments. No detrimental ef-
to install. Simple installation technique using speedy fects under high pressure cleaning.
solvent cementing with no need to remove the PUR us-
ing internal diameter jointing fittings. Time and cost sav- Full technical design support
ing handling due to the low weight of plastics. www.cool-fit.georgfischer.com for online calculations of
energy losses, temperature differences and more. CAD
Zero corrosion libraries for accurate and quicker drawing. Specialist
No maintenance, reduced downtime, constant long-term guidelines for design and installation and design of vent-
efficiency. ing equipment, measuring equipment, transitions.
Reduce costs for your hanging system Full technical support during installation
Simplified pipe supports on outer jacket, no need for On-site advice and jointing technique training. Training
special refrigeration pipe hangers. Preinsulated pipe re- video for ABS jointing technique.
quires about 30 % less hangers than standard plastic
pipe. Lower weight compared to metals means lower Sustainability
structural costs. Reduce the carbon footprint of your plant and factory
with recyclable plastics. Lower ODP and GWP values
Top efficiency compared to traditional metal systems.
Save energy, thermal conductivity 0.026 W/m K. PUR
density ≥ 55 kg/m³ with standard thickness of 35 mm
for excellent insulating properties. Smooth pipes: no en-
crustation, low pressure drops, no energy bridges due
to support on outer jacket.
Reliability
Quality: GF Piping Systems products is the number 1
Plastics Industrial Piping system manufacturer in the
world. Tried and Tested jointing technique with gap fill-
ing solvent cement TANGIT ABS.
Innovative and clever
Developed for your needs. Internal pipe connections
means no need to remove the PUR insulation from the
pipe or fitting.
Outdoor and indoor systems:
Vapour sealed black shrink sleeve for 100 % vapour
sealing, 100 % water tight system.
837
System Specification 1.1 Carrier Pipe
Pipes and Fittings from GF Piping Systems are manu-
COOL-FIT ABS factures from acrylonitrile butadiene styrene. The mate-
rial is designed for use with pressure bearing piping sys-
tems with long term properties in accordance with EN
ISO 15493.
1.2 Insulation
The insulation material is a hard polyurethane foam
(PUR) with a thermal conductivity of <0.023 W/mK and
a density of ≥55kg/m3. The greenhouse warming poten-
tial (GWP) and the ozone depletion potential is zero.
1.3 Outer jacket
The outer jacket is a high density polyethylene in black.
The jacket is UV resistant according to EN ISO 16871.
It offers extremely good impact resistance and a good
resistance to oil splashes and grease or other external
contamination.
All the components are bonded together and guarantee
one thermal coefficient .
1 Material
2 Jointing
1.1 Acrylonitrile Butadiene Styrene Material All components will be jointed with solvent cement ac-
GF Piping Systems COOL-FIT ABS pipes and fittings cording the GF Piping Systems Guideline
shall be manufactured from acrylonitrile butadiene
styrene, ABS. The raw material used shall be material Technical Data
designed for use with pressure bearing piping systems Thermal conductivity at 20°C: ≤ 0.026 W/m K
with long term hydrostatic properties in accordance with
EN ISO 15493, as supplied by GF Piping Systems. Axial shear strength: ≥ 0.12 N/mm²
Tensile strength: ≥ 0.2 N/mm²
All COOL-FIT ABS pipes are metric sizes manufactured
in accordance with the requirements of EN ISO 15493, Compressive strength: ≥ 0.3 N/mm²
supplied by GF Piping Systems. Foam density: ≥ 55 kg/m³
All COOL-FIT ABS fittings are metric sizes manufac- Average cell sizes: max. 0.5 mm
tured by GF Piping Systems or equal, with dimensions Expansion coefficient: indoor: 0.04 mm/mK
and tolerances in accordance with ISO 727 and EN ISO
15493. All threaded connections shall have pipe threads outdoor: 0.09 mm/mK
in accordance with the requirements of ISO 7.
All COOL-FIT ABS valves are metric sizes manufac-
tured by GF Piping Systems or equal in accordance with
EN ISO 16135 to 16138.
Should be in accordance with GF Piping Systems Guide
to the Installation and Use of Plastic Pipelines.
COOL-FIT ABS Plus
1 Material
COOL-FIT ABS Plus consists of the following materials:
838
COOL-FIT ABS Plus technical details
COOL-FIT ABS Plus pipes
COOL-FIT ABS Plus pipe is produced with high grade ABS pressure piping
raw material, in use for over 20 years together with a high grade low tem-
perature PUR produced in high density to offer optimal insulating properties.
The high density PE jacket pipe guarantees a vapor tight an UV resistant so-
lution.
Connection
COOL-FIT ABS Plus pipe to pipe connections are achieved using the di-di COOL-FIT ABS Plus nipple. di is the
designation for a joint which takes place in the internal diameter of the pipe. di25 for instance refers to the inter-
nal diameter of a d25 pipe.
1 COOL-FIT ABS Plus pipe

2 COOL-FIT ABS Plus nippel di-di

Note: Dimensions from d200 (incl.) must be calibrated using the COOL-FIT
ABS Plus calibration tool.
Carrier pipe Carrier pipe Jacket pipe Weight (PE + Volume Pipe support Heat transfer co-
COOL-FIT COOL-FIT PE ABS + PUR) l/m Distance efficient [U]
ABS ABS D x e1 kg/m (lb/ft) m (ft) W/m K
d x e d i
25 x 2.3 20.4 90 x 3.0 1.3 (0.83) 0.36 1.55 (5.09) 0.13
32 x 1.9 28.2 90 x 3.0 1.5 (0.87) 0.61 1.55 (5.09) 0.16
40 x 2.4 35.2 110 x 3.0 1.9 (1.18) 0.95 1.65 (5.41) 0.17
50 x 3.0 44.0 110 x 3.0 2.1 (1.27) 1.49 1.65 (5.41) 0.21
63 x 3.8 55.4 125 x 3.0 2.7 (1.67) 2.34 1.75 (5.74) 0.25
75 x 4.5 66.0 140 x 3.0 3.5 (2.13) 3.36 1.90 (6.23) 0.27
90 x 5.4 79.2 160 x 3.0 4.4 (2.76) 4.80 2.05 (6.73) 0.29
110 x 6.6 96.8 180 x 3.0 5.5 (3.51) 7.21 2.20 (7.22) 0.34
140 x 8.3 123.4 225 x 3.4 8.5 (5.48) 11.69 2.55 (8.37) 0.35
160 x 9.5 141.0 250 x 3.6 10.5 (6.34) 15.22 2.75 (9.02) 0.37
200 x 12.3 175.4 280 x 3.9 13.5 (9.02) 24.50 3.05 (10.01) 0.50
225 x 13.9 197.2 315 x 4.1 18.5 (9.16) 30.05 3.30 (10.83) 0.50
250 x 9.6 230.8 355 x 5.6 14.9 (9.99) 41.84 3.3 (10.83) 0.49
280 x 10.7 258.6 400 x 4.8 18.7 (12.54) 52.50 3.6 (11.80) 0.48
315 x 12.1 290.8 450 x 5.2 23.7 (15.90) 66.42 3.8 (11.80) 0.48
• COOL-FIT ABS Plus support distances are the same

from –50°C to +40 °C (-58°F to +104°F)
COOL-FIT ABS Plus Fittings
• d: nominal outside diameter of COOL-FIT ABS carrier COOL-FIT ABS Plus Fittings are manufactured using
pipe the same raw materials as the pipe and are thus com-
pletely compatible with COOL-FIT ABS Plus pipes in
• di: nominal inside diameter of COOL-FIT ABS carrier
terms of insulating properties and also jointing tech-
pipe
nique.
• D: nominal outside of PE jacket pipe
• e and e1: nominal wall thicknesses
839
1 COOL-FIT ABS Plus nipple di-d red.; di90-d75
Connections
2 COOL-FIT ABS Plus pipe d90/D160
Pipe to Fitting 3 COOL-FIT ABS short reducer d75-d50
COOL-FIT ABS Plus pipe to fitting connections are 4 COOL-FIT ABS Plus nipple d-di; d50-di50
achieved using the d-di COOL-FIT ABS Plus nipple. d
is the designation for a normal socket solvent cement-
ed joint as per the standard GF Piping Systems ABS
range. di is the designation for a joint which takes place Reducing with a COOL-FIT ABS Plus Fitting to
in the internal diameter of the pipe. COOL-FIT ABS Plus pipe
The d type of fittings have a standard COOL-FIT ABS d
joint as the fitting connection and therefore the standard
COOL-FIT ABS short reducers can be used to reduce
the diameter and then the d-di COOL-FIT ABS Plus nip-
ples for the connection to the COOL-FIT ABS Plus pipe.

2 COOL-FIT ABS Plus nipple d-di
3 COOL-FIT ABS Plus fitting
Fitting to Fitting
COOL-FIT ABS plus fitting to fitting connections are
achieved using a d-d+10 COOL-FIT ABS Plus nipple.
1 COOL-FIT ABS Plus tee 90° equal, d75

2 COOL-FIT ABS short reducer d75-d50
3 COOL-FIT ABS Plus nipple d-di, d50-di50
Accessory Equipment
The jointing material and technique for all variants are COOL-FIT ABS Plus Nipples
always the same, with the same cement and the same These nipples are necessary to connect the COOL-FIT
tooling. ABS Plus System
Reducing diameters di-di

Reducing with a COOL-FIT ABS Plus pipe
The example below shows how the carrier pipe dimen- di-di for pipe to pipe and pipe to fitting connections, us-
sion is reduced from COOL-FIT ABS Plus d90/D160 (3”/ ing the internal diameter of the pipes.
6”) to d50/D110 (1 1/2”/4”)
Note: the configurator below results in a gap twice as
wide usual app. 20mm (0.8”) and therefore twice the d-di
amount of gap filler is required.
d-di for pipe to fitting connections
840
Accessory for gap closing
d-d COOL-FIT Plus Gap Insulator
d-d +10 for fitting to fitting connections
d red-di
d red – di to reduce diameter of the carrier pipe

(Note: for dimensions d200 and above the COOL-FIT
ABS Plus calibration is required before joining the inter-
nal diameters of the pipe)
COOL-FIT ABS Plus calibration tool Width 13 mm and a lamda / heat conductivity of 0.04 W/
m K, use of this insulation ensures nearly the same in-
sulating properties in the gap as the pipe.
COOL-FIT Plus sealing tape
A roll of 40mm wide, butylene rubber-
based band. For a water- and steam-tight
sealing of inspection gaps in combination
with shrink sleeves or shrink sockets.
It is necessary to calibrate pipe in dimension d200 +

d225 to allow joining using the COOL-FIT ABS Plus nip-
ple. This tool calibrates the inside diameter of the pipe COOL-FIT Plus shrink sleeve, short
to an exact dimension to allow internal joining.
Accessory equipment for solvent cement jointing
Used to vapour seal the control gap on the outer jack-

et between pipe and pipe or pipe and fitting. The sleeve
is 100mm wide and can only seal equal dimensioned
jackets. To ensure the proper functionality of the sys-
tem, the shrink sleeve must be used in conjunction
with the gap insulator and the butylene-rubber sealing
tape. It can be shrunk with an open burner (soft, yellow
flame) or alternatively with a powerful hot-air gun. For a
long lasting quality seal GF recommends the use of the
The solvent cementing equipment is exactly the same shrink sleeve.
for internal di jointing as for standard d jointing.. COOL-FIT Plus shrink socket
Used to vapour seal the control gap on the outer jack-

et between pipe and pipe or pipe and fitting. The sock-
et is 100mm wide and can therefore only seal equal di-
mensioned jackets. To ensure the proper functionality
of the system, the shrink socket must be used in con-
junction with the gap insulator and the butylene-rubber
sealing tape. This heavy duty version provides addition-
841
al mechanical strength with regards to bending forces. 90 110 125 140 160 180 225 250 280 315
It shrinks uniformly, resulting in a good visual appear-
ance. It can be shrunk with an open burner (soft, yel- 738.011.167
low flame). For a long lasting quality seal combined with 738.
high mechanical strength and good appearance, GF 011.170
recommends the use of the shrink socket. 738.011.173
COOL-FIT Plus cold and hot shrink sleeve
COOL-FIT Plus shrink cap
The shrink cap is only to be used to seal PE to PE, not

Used to vapor seal the control gap on the outer PE jack- to be used on ABS pipe. The flame used to shrink the
et. For indoor use only. The cold shrink sleeve shrinks sleeve may damage the ABS pipe. Ideal for use with
without the application of heat and the hot shrink sleeve T90° reducers. For dimensions please refer to the prod-
with the application of an open burner. The tape is 100 uct range. No separate sealing tape is required, the
mm wide and can therefore only seal equal dimen- sealant is integrated into the cap. If the length of the cap
sioned PE jackets. It is applied firmly with an overlap of is longer than the surface to be sealed then the cap can
app. 10cm (4”). To ensure the proper functionality of the be cut back but without removing any sealant.
system, the tape must be used in conjunction with the
gap insulator. End cap
COOL-FIT Plus shrink tape for underground applica- End caps are to be used for sealing the
tions PUR against water ingress at the tran-
sition to COOL-FIT ABS.
This tape is specially made for underground applica-

tions. The integrated butyl surface guarantees a vapor- 1 COOL-FIT ABS Plus nipple
and watertight sealing. 2 Sealing mass
COOL-FIT Plus shrink sleeve, long 3 End caps
Sealing the PUR should be achieved using a chemically

compatible sealing mass to COOL-FIT ABS. GF Piping
Systems offers a sealing mass. If silicon products are
prohibited then nonsolvent based glues can be used.
Chemical compatability can also be checked by GF Pip-
ing Systems.
This shrink sleeve is 285mm long and can be used to

seal connections with different diameter on the outer
jacket. The table below shows which dimension can be
sealed using which long shrink sleeve. NOTE: the seal-
ing tape should be applied to both outer diameters of
the PE jacket pipe.
842
Valve insulation
GF Piping System offers tailor made insulation sets for

the ball valves type 546. The sets consist of UV resis-
tant PE foam with a shrink tape jacket and are available
from d25 up to d110mm.
843
Technical Data Pressure-temperature diagram for COOL-FIT ABS
Plus pipes and fittings 25-years-values incorporat-
ing the safety factor (with water as medium).
General comments to plastics orientated
pipeline design and installation
The design and installation of thermoplastic pipe sys-
tems requires designers and installers alike to take in-
to account the fact that plastics have different physi-
cal characteristics to metal. Although CF is a very ro-
bust systems, nevertheless, care should be taken dur-
ing handling and transport to avoid damage. Also ther-
moplastics have certain physical characteristics, such
as a high expansion coefficient, which need to be taken
into account in the design phase.
GF Piping Systems has been successfully developing
and selling plastic pipe systems into a spectrum of high
performance installations, such as highly concentrat-
ed chemicals, for over 50 years, and experience has P Permissible pressure in bar, psi
shown that when engineers and installers take into ac- T Temperature in °C, °F
count the advice given in our technical literature plastics
are an economical and reliable alternative to metals. Chemical resistance
COOL-FIT is generally resistant to most diluted inorgan-
As a general rule for designing and installing plastics ic acids, bases and salts and to most animal oils and
one of the major differences is that plastics can and fats. It is not resistant to organic solvents, pure alcohol,
should be allowed to move after commissioning i.e. petrol, acetic acid and vegetable oils.
move under the influence of temperature fluctuation and
pressure changes. For instance using pipe brackets that For working temperature below 0°C/32°F, an antifreeze
allow horizontal movement and not clamping the system has to be used in the water to prevent freezing. The
in place is a must for plastic piping installations. above pressure temperature curve applies only when
the medium is water, therefore for non-pure water medi-
The following technical information covers the funda- ums a derating factor has to be applied to the above
mental information required to ensure an economi- curve. This is standard procedure for all plastic piping
cal and trouble free installation: Not all details how- systems.
ever are published in this document, for more de-
tailed information or if you have a specific question Derating factors
please ask your local GF Piping Systems company, Inorganic salt solutions: F=1
consult www.coolfit.georgfischer.com or email us at Organic salt solutions: F=1.25
info@coolfit.georgfischer.com for advice if you have any Diluted Glycols (max 50%): F=1.7
questions. diluted alcohol (max 50%): F=1.7
For more details regarding these derating values for
COOL-FIT ABS Plus pressure-temperature chemical solutions please consult GF Piping Systems.
diagram Ice Slurry
Pressure ratings for thermoplastic pipe are always quot- Ice slurry is a mixture of ice particles (0.01-0.03 mm
ed for water at 20 °C/68°F. It can be used at higher tem- width), water and antifreeze agent, usually an alcohol,
peratures but it is a fundamental principle in thermoplas- salt or glycol. GF Piping Systems has undertaken exten-
tic pipework that if the working temperature is increased sive testing of ice slurry with CF and give recommenda-
then the working pressure must be reduced. tions regarding for example pipeline layout, flow rates
and pressure drops. Please ask your local GF Piping
The diagram shows for COOL-FIT ABS Plus pipes and
Systems representative for details.
fittings the maximum permissible pressures at various
temperatures up to the maximum allowable working Glycol Solutions
temperature of +40 °C/104°F. The diagram is based on COOL-FIT can be used with diluted glycol solutions
an ambient temperature of 20 °C/68°F with water as the (max. 50%), however a derating factor of 1.7applies to
medium. A safety factor of 1.8 is incorporated into all the standard water based pressure-temperature curve.
calculations with a minimum life time of 25 years. The following coolants can be used with the COOL-FIT
system regarding chemical resistance: ANTIFROGEN
L,N, TYFOCOR, DOWFROST.
Example: water diluted glycol
For example if the medium is a waterdiluted glycol solu-
tions ≤50% (max. concentration allowable for COOL-FIT
ABS) then a derating factor of 0.6 applies to the stan-
dard pressure temperature curve. So at -10° C/150°F
for a minimum lifespan of 25 years the maximum allow-
able working pressure is 0.6 x 11.8bar = 7.1bar
844
Pressure-temperature diagram for pre-insulated to metal pipe (copper, stainless steel or steel). The sur-
ABS pipes and fittings 25-years-values incorporat- face roughness of the metal system can be entered in-
ing the safety factor (with waterdiluted glycol as dividually, for example if the user would like to compen-
medium). sate for future encrustation and corrosion of the metal
pipe.
Many other calculation options exist, including for ex-
ample energy gain comparison calculation along a pip-
ing system, pipe dimensioning, temperature loss along
a given piece of pipe etc. All available via the internet
page.

Organic Salt Solutions

These mediums are usually potassium formate or ac-
etate water based solutions, with low viscosities at low
temperatures. Trade name examples: HYCOOL, TEM-
PER, ANTIFROGEN KF, FREEZIUM, ZITREC. COOL-
FIT can be used with these types of mediums; however,
a derating factor of 1.25 applies to the standard water
based pressure/temperature curve. Please consult GF
Piping Systems for details. It is important that the com-
plete pipe, irrespective of pipe system material is prop-
erly devented both during filling and commissioning. It is
very important to follow the manufacturer’s instructions
for pipeline design and handling of these mediums.
COOL-FIT On-Line calculation tool

For further more detailed technical information as well
as references and product range documentation please
consult the COOL-FIT homepage or the GF Piping Sys-
tems homepage:
www.cool-fit.georgfischer.com
www.georgfischer.com
The COOL-FIT homepage offers a free of charge, real-
time on-line calculation tool to calculate all the important
characteristics of a piping system. Available in 9 differ-
ent languages all the standard fluids and concentrations
thereof on the market are available as options.
The planning engineer or consultant can thus calculate
his core system parameters using this tool for COOL-
FIT ensuring optimal dimensioning and design of the
system.
Core functions which can be calculated are shown at
the top of the menu, once chosen then the various sub-
functions appear below in a drop-down menu. The core
functions are: pressure drop, condensation, heat loss,
pipe dimensioning, pipe support distances, contraction
and temperature.
For example under the Pressure Drop function the us-
er has 5 options. He can calculate individual products in
all dimensions, for example pipe, fittings or valves. The
network option allows the user to calculate the pressure
drop in complete pipeline consisting of different dimen-
sions and products. The last option, comparison, allows
the pressure drop along COOL-FIT pipe to be compared
845
846
Installation
COOL-FIT ABS Plus fixed point
Fixed points are created using the special COOL-FIT
ABS Plus fix point. The product consists of two com-
ponents namely a welding band and a pipe bracket.
Electro-fusion welded band as permanent connection
to transmit the forces that occur in the pipe to the fixed
point. The delivered pipe brackets are needed to deliv-
er welding pressure during installation and give stabili-
ty during operation. For welding, use an MSA 250, 300,
350, 400 or commercially availabe 220 V fusion ma-
chines. If you use an MSA fusion machine from GF Pip-
ing Systems, use the 799 350 339 adapter. Please take
note of the maximum allowed forces for this version in
the table below.
Outside diameter Maximum force
D (mm) F (kN)
90 1.5
110 2.0
125 3.5
140 5.5
160 9.0
180 10.0
225 10.0
250 10.0
280 10.0 Plastic to Metal Connections
315 10.0 Fundamentally three options are available for plastic to
metal connections, namely; threads, flanged connection
355 10.0
and unions.
GF Piping Systems recommends that wherever possible
Remark: Fixed point brackets and cross braces have to
mechanical connections are used (unions and flanges)
be calculated and obtained by the installer. They are not
together with a located gasket such as O-Ring.
included in the fixed point set from GF.
Adaptor fittings
The adaptor fittings for connecting plastic piping sys-

tems and metal threading offer greatest possible flex-
ibility for installation with the combined socket/spig-
No need for pipe brackets for cold insulation
ot on the plastic end. The metal thread can be sealed
Due to the excellent characteristics of the COOL-FIT
either with hemp or PTFE-tape. The adaptor fitting is
ABS Plus pipes no special pipe brackets for cold insula-
sealed with an EPDM O-ring. It serves also as protec-
tion are needed.
tion against distrotion to avoid damaging the plastic dur-
ing installation. Compared to the usual adaptor unions
the special connecting technology with snap ring guar-
antees increased leaktightness also while temperature
change and during vibration. In addition to the classic
transition to metal pipes this fittings can also be used for
connecting pressure gauges.
Note: To avoid electrochemical corrosion in transitions
to non-ferrous metals, brass connections must be used.
847
Union Connections
This is the most reliable and cost effective method to Measuring Equipment in an COOL-FIT ABS
connect metal to plastic. Plus System
GF Piping Systems has a whole range of transition Measuring Equipment in an COOL-FIT ABS Plus
unions with O-Rings specially designed to compensate Piping Systems
for the changes in length which can occur due to tem- Special installation fittings are developed to connect dif-
perature fluctuations. See COOL-FIT product range for ferent types of sensores. The branch with a ½" Rp fe-
details of the copper, brass, stainless steel and mal- male thread can be used for pressure and temperature
leable iron transition unions available. sensors.
ABS Located Copper

De-Venting or De-aeration
O-ring It is always important to remove air from any piping sys-
tem, for salt solutions this is particularly important due to
Flange connections their corrosive nature. Summary of Deaeration process,
Flange connections up to DN300 are also possible. For • always fill the system slowly from the bottom up
bolt torques, tightening sequences etc please refer to • induce a vacuum in the system before filling
standard the GF Piping Systems Plastics Technical
• install manual and/or automatic deaerators at the
Handbook.
highest points in the system
GF Piping Systems’s new revolutionary PN16 PP- V
flange is light weight, with location stubs to aid installa- • long horizontal runs should be installed at a slight gra-
tion and is designed to avoid high stresses during tight- dient
ening. GF Piping Systems recommends this type of • avoid low points i.e. Uconfigurations where air can be
flange for use with plastic flange connections. trapped
All mechanical connections including flanges should be • install deaerators with a buffer zone of fluid below
retightened after commissioning if the working tempera- them, see sketch below
ture is lower than the temperature during installation.
• always observe the medium manufacturers specific
Threaded Connections recommendation for filling, mixing etc as secondary
GF Piping Systems recommends avoiding thread- fluids differ in their composition
ed connections for plastic wherever possible, sol-
vent cementing is a very reliable and speedy method
of jointing and should be preferred to threaded
connections.Mechanical wrenches should not be used
to tighten the joint. Namely strap type wrenches prevent
damage to the plastic components.
For sealing threaded joints the mating parts should al-
ways be parallel to tapered. In the COOL-FIT range on-
ly the plastic female thread with reinforced ring should
be used for connection to metal threads. For sealing
we recommend PTFE tape. 2 layers of tape applied in
a clockwise direction, the components should then be
joined carefully to avoid damage to the plastic thread.
Alternatively also thread sealing cord Henkel Tangit Uni-
Lock or Loctite 55 and/or thread sealing paste Loctite
5331 can be used. Please consider the appropriate in-
stallation guidelines of the manufacturer. If other sealing
materials are used, compatibility with the plastics to be
used must be checked first.
1 Air release valve
2 ABS reduced
3 ABS tee 90°
848
SIGNET Flow Measuring Equipment Insulation to avoid Dew on COOL-FIT
GF Piping Systems Signet offer paddle wheel flow mea- To calculate the necessary thickness of insulation re-
suring equipment which can be used to very cost effec- quired on COOL-FIT ABS to avoid Dew or Condensa-
tively measure the flow of your medium, with digital and tion can be done via GF Piping Systems’s online cooling
analogue display devices including cabinet housings for calculation program, see www.coolfit.georgfischer.com
installation in display units. Under the button «condensation» you will be asked to
input the system parameters and type of insulation. The
These SIGNET flow sensors can be installed using spe-
results are guideline values based on tradename pub-
cially designed installation fittings, ask GF Piping Sys-
lished data and general physical data regarding types of
tems for installation fittings details.
insulation. We recommend the user consults the insula-
tion manufacturer for detailed specific advice regarding
the insulation when not using COOLFIT ABS Plus.
COOL-FIT ABS Plus: Condensation, Yes or No?
COOLFIT ABS Plus has set thicknesses of insulation,
once again via www.COOL-FIT.georgfischer.com the
user can input his system parameters and the program
will identify whether using COOLFIT ABS Plus dew will
appear on the outside of the pipe or not.
PUR has a thermal conductivity of 0.026 W/m.K and the
thickness is +/–35mm/1.38" for all dimensions so the
system parameters need to be extreme for dew to ap-
Other installation topics pear on the outside of COOLFIT ABS Plus.
Foaming ABS with PUR On-Site
There are various types of PUR on the market using For example:
different types of activators to initiate the foaming pro- Medium temperature: –50 °C/-58°F
cess. All are however an exothermic reaction, i.e. gen- Temperature of the surrounding +20 °C/68°F
erate heat, usually reaching temperatures of about 120
°C/248°F, which can be dangerous for thermoplastics. Relative atmospheric humidity 75%
COOL-FIT ABS has a vicat point, softening point of 98 Wind velocity: 1 m/s
°C/208°F, this means that any temperatures reached
above this have a detrimental effect on the COOL-FIT Under the above circumstance there will be no conden-
ABS. Also usually the foaming onsite takes place in an sation on the pipes.
enclosed volume which then causes external pressures De-Frosting
on the component. Many secondary refrigeration loops are not only used
For these reasons we recommend that COOL- for normal and low temperature cooling but are also
FIT ABS fittings and pipe are not insulated us- used for defrosting. GF Piping Systems has many years
ing PUR foaming onsite. of good experience with the use of COOL-FIT in such
dual defrost / cooling systems without any detrimental
COOLFIT ABS Plus is foamed under controlled condi- effects to the system.
tions ensuring that the quality of the ABS is not affected
by the PUR foaming process.
Insulating ABS
ABS is not chemically resistant to solvents. Solvents
are used in the jointing process to soften and swell the
COOL-FIT ABS to create a weld. This use of solvent
takes place under controlled conditions and uses double
wall thickness by inserting pipe in fitting.
Any other contact of solvents with COOL-FIT ABS
should be avoided. Some insulation materials on the
market use solvent based glues to position the insula-
tion, as per manufacturers’ instructions only the insula-
tion itself should be glued together.
Any excess glue which may come into contact direct-
ly with the COOL-FIT ABS should be removed with a
cloth.
If insulation has been glued directly to the pipe this does
not mean that the system is now dangerous. It can how-
ever only be determined on a case to case basis if the
situation will have a detrimental effect on the perfor-
mance of the pipe. Contact GF Piping Systems if you
require more information on this subject.
849
Heat transfer coefficient of pipes: COOL-FIT ABS to avoid damage to the outside surface of the pipe, for
Plus instance no dragging along the ground. Avoid pipe over-
hangs when stored as this will cause the pipe to bend.
Pipe diameter U-Value R-Value
mm COOL-FIT ABS COOL-FIT ABS UV Resistance
Plus Plus Most plastics suffer some loss of physical properties
W/m K m K/W when exposed to UV light, only PE Black, used also for
25 0.13 7.7 the outer jacket of the COOL-FIT ABS Plus black, is UV
resistant.
32 0.16 6.3
40 0.17 5.9 COOL-FIT ABS Plus underground installation.
COOL-FIT ABS Plus can be used underground. We rec-
50 0.21 4.8 ommend for closing the gap our shrink tape for under-
63 0.25 4.0 ground applications. Standard guidelines for installa-
tion of plastic pipe systems should be followed. Please
75 0.27 3.7
pay attention to local regulations. In general, trenches
90 0.29 3.4 should not be less than 1 meter deeper.
110 0.34 2.9 The pipe should be laid in a sand bed, all large pieces
140 0.35 2.9 of rock and sharp objects must be removed. Com-
pressed sand should be used to pack the pipe.
160 0.37 2.7
200 0.50 2.0
225 0.50 2.0
250 0.49 2.1
280 0.48 2.1
315 0.48 2.1
Handling
How to carry pipes after connection with COOL-FIT
ABS Plus nipples:
The pipe zone has to be designed according to plan-

ning fundamentals and static calculation. The area be-
tween trench sole and side fill is referred to as bedding.
By exchanging ground a load carrying bedding has to
be created. Usually, the minimum bedding is according
to EN1610 a = 100mm, in case of bedrock or compact-
Pipes must be kept straight!
ed underground a= 150mm. Further, there are demands
concerning the filling material. Materials with elements
bigger than:
• 22 mm at DN ≤ 200
• 40 mm at DN >200 until DN ≤ 600
should not be used
The upper bedding layer b is assessed from static cal-
culations. It is important to assure no cavities below the
pipe. The bedding dissipates all loads from the pipe
evenly into the ground. For this reason the COOL-FIT
ABS Plus pipe has to lay evenly on the bedding over its
complete length. The upper end of the pipe zone is de-
fined according to EN 1610 as 150mm above the pipe
apex respectively 100mm above the pipe connection.
When filling and compacting the cover depth and the
main backfill one has to make sure not to damage the
pipe.
COOL-FIT ABS Plus pipes have a higher stiffness and
weight than COOL-FI ABS. It is therefore recommended
Storage to perform joining in the trench itself wherever possible
All plastic pipes including preinsulated plastic pipes, i.e. to avoid unnecessary stressing of the joints. It should
COOL-FIT ABS Plus should be stacked on a flat surface not be necessary to use any mechanical expansion el-
free from sharp edges, such as stones or building de- bows in the system design underground. Please consult
bris for instance. During handling care should be taken GF for technical advice.
850
The Environment flammable rating). The self ignition temperature is 350
COOL-FIT is halogen free. The materials used in °C/662°F. Suitable firefighting agents are water, foam,
COOL-FIT ABS Plus namely ABS, PE and PUR are carbon dioxide or powder.
all recyclable materials. GF Piping Systems as a com-
pany aims to understand and meet customer require- PUR Flammability
ments regarding the environment. We design products Rigid polyurethanebased foams are effective insulation
and develop our processes taking into account the en- materials commonly used in the construction industry.
vironment and its needs. TEWI, ODP and GWP values Polyurethane foam will burn if exposed to flames. The
and reports exist for COOL-FIT ABS Plus, please see combustibility characteristics vary with chemical compo-
www.coolfit.georgfischer.com sition. Unlike expanded polystyrene (eps), polyurethane
does not melt. It flashes into flames between 427°C/
800 °F and 454°C/850 °F, and only chars rather than
melts at temperatures below that range. The charring
may in fact help protect the adjacent foam. Some stud-
ies have indicated that Douglas Fir was more toxic than
polyurethane foam. In a paper presented at the 1985
Society of the Plastics Industry, annual meeting on
polyurethane foam. Please consult GF Piping Systems
for further details.
Fire Wall Penetrations
To seal a combustible pipe penetrating a fire wall it is

necessary to use locally approved sealing systems to
preserve the integrity of the fire wall. There are various
international and local companies offering solutions for
plain combustible pipe (e.g. plastic pipe). The company
Kuhn have tested their product series ROKU® R AWM
II to the EN1366-3 (European Standard for “Fire resis-
tance tests for service installations – Part 3 Penetration
seals). Test data is available from the company Kuhn
which can be extrapolated by local test authorities to
show the integrity of the solution.
For product information see www.kuhn-
brandschutz.com KUHN Brandschutz Systems Solu-
Flammability
tions for building services
According to UL94, ABS has an HB (Horizontal Burn-
ing) flammability coefficient and falls into building ma-
terial class B2 (conventional inflammable, nondripping)
according to DIN 41021. Fundamently, toxic substance
are released by all burning process. Carbon monoxide
is generally the most important. When ABS burns, pri-
marily carbon dioxide, carbon monoxide and water are
formed. Tests have shown that the relative toxicity of
the products of combustion are similar or even lower
than those of natural products such as wood, wool and
cotton. ABS combustion gases are not corrosive. That
the burning nevertheless forms soot, smoke develops
during combustion. Suitable firefighting agents are wa-
ter, foam and carbon dioxide.
PE Flammability
The following classifications in accordance with differ-
ing combustion standards: According to UL94, PE is
classified as HB (Horizontal Burning) and according
to DIN 534381 as K2. According to DIN 4102 part 1
and ÖNORM B3800 part 1, PE is listed as B2 (normal-
ly flammable). In the French classification of building
materials, polyethylene corresponds to M3 (of average
851
Determining of COOL-FIT ABS Plus changes in length
Table outside applications
α= L = 25m L = 50m L = 100m L = 150m L = 200m
0.09mm/mK

ΔT [K] ΔL [mm] ΔL [mm] ΔL [mm] ΔL [mm] ΔL [mm]
5 11 23 45 68 90
10 23 45 90 135 180
15 34 68 135 203 270
20 45 90 180 270 360
25 56 113 225 338 450
30 68 135 270 405 540
35 79 158 315 473 630
40 90 180 360 540 720
45 101 203 405 608 810
50 113 225 450 675 900
It is a recommended value. Exact values can be calculated using GF’s online tool (www.cool-
fit.georgfischer.com) or ask your local GF representative.
Table inside applications

α= L = 25m L = 50m L = 100m L = 150m L = 200m
0.07mm/mK

ΔT [K] ΔL [mm] ΔL [mm] ΔL [mm] ΔL [mm] ΔL [mm]
5 9 18 35 53 70
10 18 35 70 105 140
15 26 53 105 158 210
20 35 70 140 210 280
25 44 88 175 263 350
30 53 105 210 315 420
35 61 123 245 368 490
40 70 140 280 420 560
45 79 158 315 473 630
50 88 175 350 525 700
It is a recommended value. Exact values can be calculated using GF’s online tool (www.cool-
fit.georgfischer.com) or ask your local GF representative.
The LB value for a given ΔL and dimension can be read

Flexible length for COOL-FIT ABS Plus from the table below, ΔL and LB values are in mm.
For calculation the change in length ΔL of COOL-FIT
ABS Plus pipes the following temperatures are needed:
• Installation temperature
• Minimum media temperature
• Maximum media temperature
• Minimum ambient temperature
• Maximum ambient temperature
Please use our online-tool to calculate the applicable
change in length out of these temperatures:
www.cool-fit.georgfischer.com
852
COOL-FIT ΔL COOL-FIT ΔL
ABS Plus ABS Plus
d/D 10 20 30 40 50 d/D 100 150 200 300
25/90 800 1100 1350 1550 1750 25/90 2450 3000 3500 4250
32/90 800 1100 1350 1550 1750 32/90 2450 3000 3500 4250
40/110 850 1200 1500 1700 1950 40/110 2750 3350 3850 4700
50/110 850 1200 1500 1700 1950 50/110 2750 3350 3850 4700
63/125 900 1300 1600 1850 2050 63/125 2900 3550 4100 5050
75/140 950 1400 1700 1950 2200 75/140 3100 3750 4350 5350
90/160 1050 1450 1800 2100 2350 90/160 3300 4050 4650 5700
110/180 1100 1550 1900 2200 2450 110/180 3500 4250 4950 6050
140/225 1250 1750 2150 2450 2750 140/225 3900 4800 5500 6750
160/250 1300 1850 2250 2600 2900 160/250 4150 5050 5850 7150
200/280 1450 2050 2550 2900 3250 200/280 4600 5650 6550 8000
225/315 1550 2200 2700 3100 3450 225/315 4900 6000 6950 8500
250/355 1650 2300 2850 3250 3650 250/355 5150 6350 7300 8950
280/400 1750 2450 3000 3450 3850 280/400 5450 6700 7750 9500
315/450 1850 2600 3200 3650 4100 315/450 5800 7100 8200 10050
COOL-FIT ΔL
ABS Plus
d/D 60 70 80 90
25/90 1900 2050 2200 2340
32/90 1900 2050 2200 2340
40/110 2100 2300 2450 2600
50/110 2100 2300 2450 2600
63/125 2250 2450 2600 2750
75/140 2400 2500 2750 2900
90/160 2550 2750 2950 3100
110/180 2700 2900 3100 3300
140/225 3000 3250 3500 3700
160/250 3200 3450 3700 3900
200/280 3600 3850 4150 4400
225/315 3800 4100 4400 4650
250/355 4000 4300 4600 4900
280/400 4250 4600 4900 5200
315/450 4500 4850 5200 5500
853
Comparision pipe diameter
DN, plastics/metal, mm/inch
Plastics Metal Chrome
steel CN
da mm di COOL-FIT di PE100, di PB mm DN Inch da mm da mm
mm SDR11 mm
10 - - - 6 1/8" 10.2 -
12 - - - 8 1/4" 13.5 -
16 12.4 - 11.6 10 3/8" 17.2 15
20 15.4 16.0 14.4 15 1/2" 21.3 18
25 20.4 20.4 20.4 20 3/4" 26.9 22
32 28.2 26.2 26.2 25 1" 33.7 28
40 35.2 32.6 32.6 32 1 1/4" 42.4 35
50 44.0 40.8 40.8 40 1 1/2" 48.3 42
63 55.4 51.4 51.4 50 2" 60.3 54
75 65.8 61.4 61.4 65 2 1/2" 75.3 76.1
90 79.2 73.6 73.6 80 3" 88.9 88.9
110 96.8 90.0 90.0 100 4" 114.3 108
125 - 102.2 - 100 - - -
140 121.6 114.6 - 125 5" 140.3 -
160 139.0 130.8 - 150 6" 168.3 -
180 - 147.2 - 150 - - -
200 173.8 163.6 - 200 7" 193.7 -
225 195.4 184.0 - 200 8" 219.1 -
250 230.8 204.6 - 250 9" 244.5 -
280 258.6 229.2 - 250 10" 273.0 -
315 290.8 257.8 - 300 12" 323.9 -
854
COOL-FIT Product Range
Background Information to the COOL-FIT Product Range from GF Piping Systems
COOL-FIT has been developed closely with the market

to fulfil all the essential requirements of a secondary re-
frigeration piping system, namely:
• complete reliability
• lowest possible energy gains
• low maintenance long life-span
• simple cost effective installation
COOL-FIT ABS Plus combines pre-insulated pipe and

fittings with normal standard plastic piping with a com-
plete range of the necessary valves for manual or au-
tomatic actuation. The complete system is designed to
optimise the efficiency, installation costs and life-span of
the secondary piping system.
Examples of application areas are in commercial as well
as industrial refrigeration, air-conditioning and industrial
cooling water.
Examples of end-user markets are: supermarkets,
breweries, cold stores and numerous types of food
manufacturing plants, as well as hospitals and pharma-
ceutical plants.
855
856
System iJOINT
Page

General Information
-- Benefits of compression fittings 858
-- Application 858
-- Features 858
System specification
-- Range, materials, standards 860
Technical data
-- General comments to plastics oriented pipeline design 861
-- Pressure-temperature diagram 861
-- Flange connections 861
-- Adaptors and threaded fittings 861
Hydraulic calculation and pressure loss
-- Hydraulic calculation 863
-- Pressure loss in straight pipes 863
-- Pressure loss in fittings 863
Installation instructions
-- General 864
-- Coupling d 20 - 63 mm 864
-- Coupling d 75 - 110 mm 865
-- Repair coupling d 20 - 110 mm 865
857
System iJOINT Application
The iJOINT system is designed for new installations as
General Information well as renovations or extensions of existing water lines.
iJOINT is also suited for use as house connections and
Benefits of compression fittings
service lines. In addition, iJOINT is used for bypass sys-
iJOINT polypropylene compression fittings combine the tems, where temporarily laid lines need to be disassem-
two main advantages of the mechanical connection sys- bled in a quick and easy way, leaving the coupler intact
tems, push-fit and compression: easy installation as by simply unscrewing and sliding the joint back from the
a push-fit and safe as a traditional compression fitting pipe.
(mechanical compensation). iJOINT is used in water ap-
plications.
The iJOINT range contains straight and reducing join-

ers, tees, elbows, threaded connectors and end caps, 1
ranging from d20 to d110 mm and threads from 1/2" to • Water Distribution Lines
4".
• House Connections and Service Lines
• Pressure Sewage
Fast and easy installation
2
The clamp ring made of polyacetal does not come in-
• Industrial Applications
to contact with the pipe during insertion of the pipe and
there is no need to disassemble the iJOINT fitting be- • Mining Industry
fore installation. This combined with a defined stop po-
sition for the nut and that the nut can be fixed with less 3
than one turn makes installation easy. • Leisure Parks
• Golf Courses
High resistance and no corrosion • Camping Grounds
The special coated NBR gasket – which is approved 4

for potable water – in combination with the unique body • Farming
design ensure high performance in terms of pressure • Greenhouses
and pull-out resistance, vacuum as well as suction. The • High-end Irrigation
body made of polypropylene is completely corrosion-
free and guarantees top performance as well as high re-
sistance to stress in long lifetimes. The fittings are suit- Features
able for applications under and above ground thanks to iJOINT compression fittings have been developed for
very high resistance to UV rays. use in water and drinking water systems, assuring a
quicker and easier installation compared to a traditional
Safe design compression fitting.
The coated sealing system makes this product both
The special design allows perfect resistance to water unique and long-lasting. iJOINT comprises the benefits
hammer and pull-out forces without having a negative of plastics: no rust and no incrustation, lightweight con-
impact on the connection lifetime. The stop ring for the struction, high pressure resistance, excellent cost-bene-
nut works as a helpful indicator of a proper nut closing fit ratio with a life cycle of at least 50 years.
position and the nut does not loosen by itself due to an
anti-rotation nut locking system. The clamp ring and
all other components are contained in the body so that
they cannot be lost even when disassembling the fitting
or during transportation.
858
1 Nut
Ready for pipe insertion, tightened with approx. one turn
2 Gasket
Coated sealing system for more safety
3 Clamp ring
No interference during pipe insertion and removal
4 Stop ring
Defines sealing-locking position for the nut
5 Nut locking
When tightened, two protrusions prevent accidental un-
screwing of the nut over time
6 Transport fixation
Avoids accidental disassembling of the fitting during
transportation.
859
System specification
Range, materials, standards
iJOINT compression fittings are suitable with the follow-
ing types of polyethylene pipes:
PE HD, PE 80, PE 100 and PEX-a in SDR 11 and 17.
The fitting is ready to be installed out of the box without
any preparation. The pipe can be inserted directly with-
out loosening the nut or disassembling the fitting.
Pressure range
16 bar resistance for the complete range of iJOINT fit-
tings d20 to d110 mm (3" and 4" female threads = 10
bar).
Temperature range
-10 °C to +45 °C
Materials
Body (and thrust ring from d75 to d110 mm):
UV stabilized polypropylene (PP)
Nut:
UV stabilized blue polypropylene (PP)
Clamp ring:
Acetalic resin (POM)
Gasket:
Black food-safe rubber NBR suitable for potable water;
70 sh. PTFE coated
Reinforcement ring (for female threads):
Stainless steel AISI 430
Regulations for drinking water
• W270 and KTW (Germany)
• ATA (Netherlands)
• DM 174-06/04/2004 (Italy)
• Global Mark (Australia)
• ACS (France)
Approvals
• DVGW (Germany)
• IIP (Italy)
• SVGW (Switzerland)
• KIWA (Netherlands)
• ACS (France)
• Global Mark (Australia)
• SITAC (Sweden)
• STF (Finland)
• ETA (Denmark)
• BIGGFORSK (Norway)
Standards
For PE pipes:
EN 12201; ISO 11922-1; DIN 8074; AS/NZS 4130; ISO
4427; UNI 7990; ISO 12162
Threads
EN 10226 (ISO 7-1); BS 21; AS 1722.1
Flanges
EN1092-1
Test standards
ISO 14236; DIN 8076-3; AS/NZS 4129; BRL K534/03 –
UNI; ISO 3501; ISO 3503; ISO 3458; ISO 3459; VP609
860
Technical data Pressure-temperature diagram for system
iJOINT (with water as medium).
General comments to plastics oriented
pipeline design
The design and installation of thermoplastic pipe sys-
tems requires designers and installers alike to take in-
to account the fact that plastics have different physical
characteristics to metal. Although GF Piping System-
s offers very robust systems, nevertheless, care should
be taken during handling and transport to avoid dam-
age. Also thermoplastics have certain physical charac-
teristics, such as a high expansion coefficient, which
need to be taken into account in the design phase.
GF Piping Systems has been successfully developing
and providing plastic pipe systems into a spectrum of
high performance installations for over 50 years, and
experience has shown that when engineers and in- P Permissible pressure in bar, psi
stallers take into account the advice given in our techni- T Temperature in °C, °F
cal literature plastics are an economical and reliable al-
For working temperatures below 0 °C an antifreeze
ternative to metals. As a general rule for designing and
has to be used in the water to prevent freezing. The
installing plastics one of the major differences is that
above pressure temperature curve applies only when
plastics can and should be allowed to move after com-
the medium is water, therefore for non pure water medi-
missioning i.e. move under the influence of temperature
ums a derating factor has to be applied to the above
fluctuation and pressure changes. For instance using
curve. This is standard procedure for all plastic piping
pipe brackets that allow horizontal movement and not
systems.
clamping the system in place is a must for plastic piping
installations.
The following technical information covers the fun- Flange connections
damental information required to ensure an eco- Flanged joint with metal flange
nomical and trouble free installation: Not all details Material: steel ST37-2
however are published in this document, for more (1.0038 or S235JR)
detailed information or if you have a specific ques- The flange can be connected to the PE or PEX-a pipe
tion please ask your local GF Piping Systems com- without disassembling. The gasket is PTFE coated
pany, consult www.georgfischer.com or email us at NBR, and has drinking water quality.
info@georgfischer.com.
Dimensions
ø
Pressure ratings for thermoplastic pipe are always quot-
ed for water at 20 °C. It can be used at higher temper- [inch] internal external hole circle
atures but it is a fundamental principle in thermoplastic 1 1/2 80 150 110
pipework that if the working temperature is increased
2 99.6 160 125
then the working pressure must be reduced.
The diagram shows for PE pipes and PP fittings the 2 1/2 119 186.5 145.5
maximum permissible pressures at various tempera- 3 134.8 204.5 160
tures up to the maximum allowable working temperature
of +45 °C. The diagram is based on an ambient temper- 4 156.3 220 180
ature of 20 °C with water as the medium. A safety factor
is incorporated into all calculations with a minimum life
time of 50 years. For more detailed information, please refer to our Tech-
nical Handbook for Industrial applications.
Adaptors and threaded fittings

verlinken auf IS
Übergangsfittings mit rostfreiem Verstärkungsring
A2 und zylindrischem Rohr-Innengewinde Rp
Übergangsfittings mit rostfreiem Verstärkungsring A2
und zylindrischem Rohr-Innengewinde Rp ermöglichen
sowohl die Herstellung von Verbindungen zwischen
Kunststoff- und Metallrohrleitungen als auch zwischen
Kunststoffrohrleitungen untereinander. Im Folgen-
den sind einige Beispiele für solche Übergangsfittings
aufgezeigt:
861
Hinweise zur Montage von Übergangs- und Gewind-
efittings
Bei der Montage ist auf eine besonders spannungsarme
Verlegung der Rohrleitung zu achten. An biege-
beanspruchten Stellen der Rohrleitung ist die Verwen-
dung von Übergangsfittings zu vermeiden. Unterliegen-
Rohrleitungen grossen Temperaturwechseln, sind
Übergangsverschraubungen zu bevorzugen.
Achtung: Ein evtl. vorhandener Grat im Gewinde-
bereich von Metallfittings muss vorher entfer-
nt werden, damit die Kunststofffittings nicht
beschädigt werden.
Übergangs- und Gewindefittings aus Kunststoff wer-

den zunächst von Hand eingeschraubt. Gewalt darf
dabei keinesfalls angewendet werden. Unter Verwen-
dung eines geeigneten Werkzeuges werden die Fit-
tings anschliessend weiter eingeschraubt, bis ca. 1 - 2
Merke: Metallrohrleitungen dürfen nur in
Übergangsfittings mit Verstärkungsring
Gewindegänge noch sichtbar sind.
eingeschraubt werden! Bei Übergangs- und Gewindefittings aus Kunststoff
empfehlen wir, zum Dichten PTFE-Band (z. B. Teflon)
Übergangsfittings mit konischem Aussengewinde R zu verwenden. Alternativ können auch Gewindedicht-
(Nippel)
faden Henkel Tangit Uni-Lock oder Loctite 55 bzw.
Die Übergangsverbindungen mit konischem Rohr-Aus-
Gewindedichtpaste Loctite 5331 eingesetzt werden.
sengewinde R (Nippel) sind mit Ausnahme des Doppel-
Bitte beachten Sie dazu die entsprechenden Verar-
nippels sowohl für die Verbindung Kunststoff-Kunststoff
beitungsrichtlinien des Herstellers.
als auch Kunststoff-Metall geeignet.
Bei Verwendung anderer Dichtmittel ist unbedingt
die Verträglichkeit mit dem vorgesehenen Kunststoff
abzuklären.
Achtung: Keinen Hanf verwenden! Mit Hanf
besteht die Gefahr, dass die Kunststofffittings
beim Montieren überlastet werden bzw. das
Kunststoffgewinde beschädigt wird. Ausserdem
ist Hanf je nach verwendetem Medium nicht
chemikalienbeständig.
Bitte beachten Sie die detaillierten Angaben zu den

einzelnen Produkten im jeweiligen Lieferprogramm.
Gewindefittings (ohne Verstärkungsring) mit zylin-
drischem Rohr-Innengewinde Rp
Gewindefittings (ohne Verstärkungsring) aus den Werk-
stoffen ABS, PVC-U und PVDF mit zylindrischem Rohr-
Innengewinde Rp ermöglichen die Herstellung von
Verbindungen zwischen Kunststoffrohrleitungen untere-
inander. Im Folgenden sind einige Beispiele für solche
Übergangsfittings aufgezeigt:
862
Hydraulic calculation and pressure Formstück Typ Widerstandsbeiwert ζ
loss 90 ° Bogen Biegeradius R ζ-Wert
Hydraulic calculation 1.0 * d 0.51

1.5 * d 0.41
Pressure loss in straight pipes 2.0 * d 0.34
verlinken auf IS 4.0 * d 0.23
Bei der Ermittlung der Druckverluste in geraden
Rohrstrecken unterscheidet man zwischen laminaren 45 ° Bogen Biegeradius R ζ-Wert
und turbulenten Strömungen. Massgebend ist dabei die 1.0 * d 0.34
sogenannte Reynoldszahl (Re). Der Wechsel von lami-
nar zu turbulent erfolgt bei der kritischen Reynoldszahl 1.5 * d 0.27
Rekrit = 2320. 2.0 * d 0.20
Laminare Strömung tritt in der Praxis insbesondere 4.0 * d 0.15
beim Transport von viskosen Medien auf, wie z. B.
Schmieröle. In den meisten Anwendungsfällen, so 90 ° Winkel 1.2
auch bei wässerigen Durchflussstoffen, handelt es 45 ° Winkel 0.3
sich um turbulente Strömungen mit einer wesentlich
T-Stück
*)
1.3
gleichmässigeren Geschwindigkeitsverteilung über dem
Rohrquerschnitt als bei der laminaren Strömung. Reduktion (Kontraktion) 0.5
Der Druckverlust in einer geraden Rohrstrecke ist Reduktion (Erweiterung) 1.0
umgekehrt proportional zum Rohrdurchmesser und er- Verbindungen (Flansche, d >90 mm: 0.1
mittelt sich wie folgt: Verschraubungen, Schweis- 20 ≤ d ≤ 90 mm: 1.0 bis 0.1:
sung zwischen zwei Rohren
d20: 1.0 d50: 0.6
d25: 0.9 d63: 0.4
d32: 0.8 d75: 0.3
d40: 0.7 d90: 0.1
Hinweis: Für praxisbezogene Überschlagsrechnungen
(d. h. glatte Kunststoffrohre und turbulente Strömung) *) Für eine detailliertere Betrachtung muss bei einem
genügt es, die hydraulischen Verluste von geraden T-Stück zwischen Stromvereinigung und Stromtren-
Rohrleitungsstrecken mit λ = 0.02 zu ermitteln. nung unterschieden werden. Die Literatur nennt dazu
Werte für ζ bis zu einem Maximalwert von 1.3. Da in der
wobei: Regel der Anteil des T-Stückes am gesamten Druck-
ΔpR Druckverlust in der geraden Rohrstrecke in bar verlust einer Rohrleitung sehr klein ist, genügt es in den
meisten Fällen mit ζ = 1.3 zu rechnen.
λ Rohrreibungszahl
Berechnung des Druckverlustes
L Länge der geraden Rohrstrecke in m
Für die Berechnung des Druckverlustes aller Fittinge
di Innendurchmesser der Rohrleitung in mm einer Rohrleitung ist die Summe aller Einzelverluste,
ρ Dichte des Durchflussstoffes in kg/m³ d. h., die Summe aller ζ-Werte zu ermitteln. Der Druck-
(1 g/cm³ = 1000 kg/m³) verlust kann dann unmittelbar mit der folgenden Formel
v Durchflussgeschwindigkeit in m/s berechnet werden:
Pressure loss in fittings

verlinken auf IS
Hierbei bedeuten:
Widerstandsbeiwerte
Die Druckverluste sind vom Fittingstyp sowie ΔpFi Druckverlust aller Fittings in bar
vom Strömungsverlauf im Fitting abhängig. Als
Σζ Summe aller Einzelverluste
Berechnungsgrösse dient der sogenannte ζ-Wert.
v Fliessgeschwindigkeit in m/s
ρ Dichte des Fördermediums in kg/m³
(1 g/cm³ = 1000 kg/m³)
863
Installation instructions Cut the pipe square and deburr it. Mark the insertion
depth on the pipe (see below table: insert depth).
General
The installation manual is part of the product and an im- Attention! Do not disassemble the fitting!
portant module of the safety concept. Non-observance
could result in serious injury or death.
Read and observe the installation manual. The installa-
tion manual must be available with the product. Pass in-
stallation manual to further users of the product .
The iJOINT fittings should be transported and stored
in the original packaging. The iJOINT fittings must be
protected from harmful influences such as dirt and es-
pecially heat and UV radiation. The technical data are
not binding. They neither constitute expressly warrant-
ed characteristics, nor guaranteed properties nor guar- 3
anteed durability. They are subject to modification.
NOTICE
Requirements for user and operator re-

sponsibility
For safety use and to guarantee the opera-
tion please note:
• The iJOINT fittings must only be used ac-
cording to the specifications. Push the pipe into the fitting through the clamp ring un-
• Assembly and installation must be carried til the first stop, meaning you have reached the gasket.
out by qualified personnel. Lubrication and chamfering of pipe ends makes pipe in-
• Piping system must be installed by profes- sertion easier.
sionals, its functionality checked regularly.
Users and operators must be instructed on 4
a regular basis in all aspects of work safe-
ty and environmental protection especially
those pertaining to pressure-bearing piping
systems.
• Users and operators must be familiar with
the operating instructions and must adhere
to the information contained therein.
Intended use
The iJOINT fittings are intended exclusively for convey-
ing media in the allowable pressure and temperature
range or for controlling flow in piping systems into which Push the pipe through the gasket until you reach the
they have been installed. Application: Water pipe stop of the fitting. Check the mark of the insertion
Before proceeding with the assembly, check the pres- depth on the pipe for correct assembly.
ence of all components (clamp ring, gasket).
5
Coupling d 20 - 63 mm
1-2
Tighten the nut up to the stop ring using the Georg Fis-
cher tool or a wrench for fittings.
864
Insert depth Tighten the nut until the stop ring using the Georg Fis-
Fittings
ø mm Repair coupling d 20 - 110 mm
20 51 1
25 56
32 63
40 73
50 84
63 99
Flanged fittings
ø mm Cut the pipe close to the damage.
50 102 2
63 118
Coupling d 75 - 110 mm
1
The maximum pipe gap (Z) is marked on the fitting body

and corresponds to the fitting diameter (see also table
A for minimum gap).Chamfer the pipes and grease the
seal if necessary.
3
Cut the pipe square and deburr it. Do not chamfer.

2
Mark the pipe as indicated above.

4
Push the pipe into the fitting until you have reached the
pipe stop.
Attention: for re-installations consider a minimum Insert the fitting on one side of the pipe.
gap of 10 mm between pipe end and pipe stop. 5
3
Align the two pipes and slide the fitting till the marks on
the pipes.
865
6
Tighten the nuts until the stop ring using the Georg Fis-
Table A
ø Z [mm]

[mm] min. max.
20 5 20
25 5 25
32 5 32
40 5 40
50 5 50
63 5 63
75 20 75
90 20 90
110 20 110

866
Index
Page Page
3/2 - 5/2-way pilot solenoid valve 669 Air volume diagram ventilating and venti- 589
MNL532 lating- and bleed valve
3/2-way pilot solenoid valve PV 94/95 664 Amorphous 23
3D CAD-Engineering 195 Amount of solvent cement 248, 253, 257, 260
4-20 mA Sensor Type GK 15 variable 610 Amperometric Chlorine Electrode 711

area flow meter
Amperometric Electronics 711
4/2-way pilot solenoid valve PV5470 669
Analytical Sensors and Electrodes 708
90° stop 354
Angle seat check valve type 303/304 532
Abbreviations 74
Angle seat valve type 300/301 510
ABS cementing 259
Application area of valves 306
ABS flexible section 200
Application in vacuum 418, 436
ABS long-term behaviour 149
Application limits 34, 36, 39, 40, 43
ABS material properties 32
Approvals for materials 93, 94, 95, 96
ABS pipe bracket spacing 218
Approvals for products 92
ABS pressure test 230
AS interface 663, 689
ABS pressure/temperature diagram 165
ASi 663, 689
ABS standards 100
Ball valve Coloro 371
Accessories ball valve type 546 326
Ball valve for double containment sys- 824
Accessories butterfly valve type 477 tems
140/141/142
Ball valve type 107 378
Accessories diaphragm valve 444
Ball valve type 130-135 378
Accessories DIASTAR 444, 664, 674, 682,
689 Ball valve type 185-188 386
Accessories EA11 647 Ball valve type 230-235 392
Accessories EA21/ EA31/ EA42 647 Ball valve type 285-288 404
Accessories EA21/31/42 633 Ball valve type 322 368
Accessories of diaphragm valve hand 421 Ball valve type 375 363
operated
Accessories PA11/ PA21 664, 674, 689
Accessories PA11/21 637
Accessories PA30 - PA90 645, 664, 674, 689
Basics 46
Accessories variable area flow meter 609, 610
Batch Controllers 718
Accredited testing laboratory 18
BCF Plus fusion jointing 282, 292
Accuracy of measurement of variable 605
area flow meter Benefits GF valves 302
Accurate reading of variable area flow 609 Blanking flanges 237
meter
Bolts 238
Actuator interface per EN ISO 5211 620
Bracket spacing 218, 219, 220, 221,
Actuators 619 222, 223, 224
Adapter unions 243, 244 Brandverhalten 33
Adaptor fittings 245 Buffer Solutions 729
Advice 17
867
Index
Page Page
Building Services 89 Commissioning 232
Bus communication 446 Compensator 213
Butt fusion jointing 272, 284, 294 Compressed air 175
Butterfly valve type 037/038/039 461 Compressed air pipelines: Pressure test 231
Butterfly valve type 037E/038E 478 Concrete 214
Butterfly valve type 037P/038P 499 Conductivity/Resistivity 723, 724, 739, 756
Butterfly valve type 140/141/142 472 Conductivity/Resistivity Tools 729
Butterfly valve type 240/241/242 490 Configuration/Diagnostic Tools 727
Butterfly valve type 567/568 448 Connection diagram EA11 625
CAD 195 Connection diagram EA21/31/42 631
Calculation 170 Control pressure diagram diaphragm 435

valve pneumatically actuated
Calibrated scales for variable area flow 605
meter Control pressure diagrams DIASTAR 444
025
Calibration 264
Controllers 714, 724
Calibration Kits 729
Conversion factor 315
Carriers: Pipe bracket spacing 225
Conversion tables 78
Cementing ABS 259
COOL-FIT 834
Cementing COOL-FIT 266
COOL-FIT ABS pipe bracket spacing 218
Cementing different pipe materials 270
COOL-FIT Calibration 264
Cementing PVC-C 252
COOL-FIT cementing 266
Cementing PVC-U 247
COOL-FIT fixed point 847
Change in length 196
COOL-FIT Insulation gap 267
Characteristics pressure reducing valve 550, 552, 553
Cooling 82
Characteristics pressure relief valve 566, 567
Correction tables for variable area flow 607, 608
Characteristics pressure retaining valve 558, 559, 560 meter
Check valve type 561/562 524 current monitoring 652
Chemical Process Industry 83 Cutting length butt fusion systems 806
Chemical resistance 110, 307 Cutting length socket systems 797
Chemical resistance of springs of check 531 Cv-kv 315

valve type 561/562
cycle counter 652
Chemical resistance of variable area flow 606
meter d outside diameter 73
Chlorine 706, 711, 712 Delivery volumes 78
Choice of material 110 Design factor 171
Clamp 246 Design water jet suction pump 584
Coil design 518 Diaphragm gauge guard 568
Coil heating 518 Diaphragm valve 410
Combustible location 174 diaphragm valve 418
Combustion Behaviour 35, 37, 39, 41, 43 Diaphragm valve DIASTAR 424
868
Index
Page Page
Diaphragm valve pneumatically actuated 424 Dimensions diaphragm valve type 515 414
diaphragm valve pneumatically actuated 436, 437 Dimensions diaphragm valve type 517 414
DIASTAR 025 444 Dimensions diaphragm valve type 519 414
DIASTAR Six 424 Dimensions DIASTAR 025 443
DIASTAR Sixteen 424 Dimensions DIASTAR Six 428
DIASTAR Ten 424 Dimensions DIASTAR Sixteen 428
DIASTAR TenPlus 424 Dimensions DIASTAR Ten 428
Differential pH/ORP Electrodes 720 Dimensions DIASTAR TenPlus 428
Digital positioner DSR500 674 Dimensions EA11 623
Dimensions angle seat check valve type 534 Dimensions EA21/31/42 628
303/304
Dimensions float valve 592
Dimensions angle seat valve type 511
300/301 Dimensions of butterfly valve type 479
037E/038E
Dimensions ball valve Coloro 373
Dimensions of diaphragm valve hand op- 414
Dimensions ball valve type 107 381, 382, 383 erated
Dimensions ball valve type 130-135 381 Dimensions of variable area flow meter 603
Dimensions ball valve type 185-188 388, 389 Dimensions PA11/21 635
Dimensions ball valve type 230-235 396 Dimensions PA30-90 639, 640
Dimensions ball valve type 285-288 406 Dimensions pressure reducing valve 547, 548
Dimensions ball valve type 322 369 Dimensions pressure relief valve 565
Dimensions ball valve type 375 365 Dimensions pressure retaining valve 556, 557
Dimensions ball valve type 523 358 Dimensions solenoid valve 517
Dimensions ball valve type 543 340, 344, 347 Dimensions throttle valve 594
Dimensions ball valve type 546 320 Dimensions ventilating and ventilating- 587, 588
and bleed valve
Dimensions butterfly valve type 464
037/038/039 Dimensions wafer check valve type 369 538
Dimensions butterfly valve type 480, 481, 482, 483 Dimensions water jet suction pump 573
037E/038E
Dimesions ball valve type 130-135 383, 384, 385
Dimensions butterfly valve type 501, 504
037P/038P Dimesions ball valve type 230-235 396, 397, 398, 399
Dimensions butterfly valve type 039E 484, 486, 488 Dimesions ball valve type 285-288 407
Dimensions butterfly valve type 039P 505 Direct-acting solenoid valves 520
Dimensions butterfly valve type 474, 475, 476, 477 DN 73

140/141/142
Double containment 779
Dimensions butterfly valve type 492, 493, 494, 495,
240/241/242 496, 497 Double containment jointing 786
Dimensions butterfly valve type 567/568 451, 453 Dytex cementing PVC-U/PVC-C 256
Dimensions check valve type 561/562 526, 528 Einsatzgrenzen 32
Dimensions diaphragm gauge guard 570 Elastomers 25
Dimensions diaphragm valve pneumati- 428 Electric actuator 616
cally actuated
Electric Actuator EA11 623
Dimensions diaphragm valve type 514 414
869
Index
Page Page
Electric Actuator EA21/31/42 627 Exploded view EA21/31/42 627
Electrical feedback 421 Exploded view hand lever 451
Electrical position indicator ER52/53 683 Exploded view of ball valve type 546 320
Electrical position indicator type ER 55 688 Exploded view PA11/21 634
Electrical Properties 33, 35, 37, 39, 41, 43 Exploded view PA30 - PA90 638
Electrodes 723 Exploded view pressure reducing valve 545, 546
Electrofusion 279 Exploded view pressure relief valve 563, 564
Electromagnetic actuators 618 Exploded view pressure retaining valve 556
Emergency manual override 626, 632 Exploded view throttle valve 594
Environment 16 Exploded view variable area flow meter 602
Error message 654, 663, 681 Exploded view ventilating valve and ven- 587
tilating- and bleed valve
Error message EA21/31/42 632
Exploded view wafer check valve type 537
Expansion coefficient 50, 196 369
Exploded view angle seat check valve 534 Exploded view water jet suction pump 572
type 303/304
Explosive media 174
Exploded view angle seat valve type 511
300/301 External Relay Modules 727
Exploded view ball valve Coloro 373 Facing 190
Exploded view ball valve type 107 380 Feedback 445
Exploded view ball valve type 130-135 380, 381 fieldbus 663
Exploded view ball valve type 185 - 188 388 Fieldbus 689
Exploded view ball valve type 230-235 395, 396 Fixed point 215, 847
Exploded view ball valve type 285-288 406 Flammability 851
Exploded view ball valve type 322 369 Flange standards 99
Exploded view ball valve type 375 365 Flanges 235, 237
Exploded view ball valve type 523 358 Flat gasket 240
Exploded view ball valve type 543 hori- 339 Flexible air connection diaphragm valve 442
zontal pneumatically actuated
Exploded view ball valve type 543 verti- 340 Flexible section 196, 197, 200, 202,
cal 204, 206, 208, 210,
212
Exploded view butterfly valve type 464
037/038/039 Float valve 591
Exploded view butterfly valve type 501 Flow 707, 715, 716, 717,

037P/038P 718, 719, 730
Exploded view butterfly valve type 450 flow characteristics 315

567/568
Flow characteristics angle seat valve 512
Exploded view check valve type 561/562 526 type 300/301
Exploded view diaphragm gauge guard 569 Flow characteristics ball valve Coloro 374
Exploded view diaphragm valve 413 Flow characteristics butterfly valve type 456
567/568
Exploded view diaphragm valve pneu- 428
matically actuated Flow characteristics diaphragm valve 417
Exploded view EA11 623 Flow characteristics diaphragm valve 434

870
Index
Page Page
Flow characteristics DIASTAR 025 444 In-Line Rotors 717, 734
Flow characteristics for linear ball valve 325 Inch system 73

type 546
Indicator for diaphragm material 410, 425
Flow characteristics of ball valve type 366
375 Inside diameter 180
Flow characteristics of ball valve type 361 Installation angle of diaphragm valve 418, 439
523
Installation examples pressure retaining 561
Flow characteristics of ball valve type 350, 351 valve
543
Installation recommendations for ball 370
Flow characteristics of ball valve type 325 valve type 322
546
Installation recommendations pipelines 213
Flow Monitors 718
Installationshinweise iJOINT 864
Flow Sensors 735
Insulating ABS 849
Flow volumes in pipelines throttle valve 596
Insulation gap 267
Flowmeter 715
Integrated electrical position feedback 459
Foaming ABS with PUR On-Site 849
Integrated fastening 418
Formazin Stock Kit 729
Integrated fastening of diaphragm valve 440
Function DA 438
Intrinsic Safety Barriers 727
Function FC 438
IR Plus fusion jointing 271, 281, 291
Function FO 438
ISO 14001 16
Functional properties 310
ISO 9001 15
Functions ball valve type 543 352, 353
Isometric paper 190, 193
Gaskets 240
KLIP-IT pipe brackets 215
Geodetical pressure difference 186
Klip-IT Pipe Clips 335
Georg Fischer 13
Klip-IT Spacer 336
GF Piping Systems 14
kv 100 values angle seat check valve 535
Glossary Measurement and Instrumenta- 775 type 303/304
tion
kv 100 values ball valve Coloro 375
GRP standards 108
kv 100 values ball valve type 375 366
Hand lever extension 333
kv 100 values ball valve type 523 361
hand operated 410, 413, 416, 417,
418 kv 100 values ball valve type 543 351, 352
Handling 194 kv 100 values ball valve type 546 325
Heating element 647 kv 100 values butterfly valve type 468
037/038/039
Hemp 243, 244, 245, 861
kv 100 values butterfly valve type 456
High Purity 43 567/568
Hose connections 246 kv 100 values check valve type 561/562 530
Hot-Tap 733 kv 100 values diaphragm valve 417
Hydraulic calculation 180 kv 100 values diaphragm valve pneumat- 435

ically actuated
Hydrostatic Level Sensor 740
kv 100 values DIASTAR 025 444
Hydrostatic Pressure Sensor 725
kv 100 values of angle seat valve type 512
iJOINT 858 300/301
871
Index
Page Page
kv 100 values technical data of valves 315 Micro Electronics 85
kv 100 values wafer check valve type 540 Micro Flow Rotor Sensor 717
369
Miners Rule 169
kv-Cv 315
Mini Flow Rotor Sensor 717
Leak detection 785, 811
Minimum pressure for valve opening 531
Leak locating 811 check valve type 562
Leak Test with gas 231 Mode of operation variable area flow me- 605
ter
Length of bolts 238
Modification 232
Level 709, 725
Monitoring print with cycle time module 652
Life Science 86
Monitors 721, 723, 724
Limit contacts of variable area flow meter 609
Mounting plate 334, 355
Limit switches 649, 651, 683, 688
MRS-values 149
lockable 331
Multi-Parameter 706, 714
Long-term behaviour 149, 151, 154, 158,
160, 163 Multifunctional hand lever 354
Loose Brackets 215 Multifunctional hand lever with ratchet 331

settings
Magmeters 716, 717, 735
Multifunctional module 326, 329
Maintenance angle seat check valve 535
type 303/304 Namur connector plate 669
Maintenance ball valve Coloro 375 Nature of the medium 309
Maintenance butterfly valve type 567/568 459 Nomogram 182, 183, 184
Maintenance check valve type 561/562 531 O-ring 240
Maintenance interval of diaphragm valve 442 Open collector output 758
Maintenance of ball valve type 322 370 Opening and closing conditions check 530
valve type 561/562
Maintenance of ball valve type 375 367
Opening conditions of ventilating valve 590
Maintenance of ball valve type 523 362
Opening pressure wafer check valve 539
Maintenance of ball valve type 543 353 type 369
Maintenance of ball valve type 546 326 Operating diagram DA 620, 636
Maintenance of butterfly valve type 470 Operating diagram FC 620, 636

037/038/039
Operating diagram FO 620, 636
Maintenance ventilating valve and venti- 590
lating- and bleed valve Operating diagram PA30-90 643
Maintenance wafer check valve type 369 541 Operating pressure 170
Market segments 83 Operating torque 315
Material selection 110 Operating torque angle seat valve type 512
300/301
Maximum possible vacuum water jet 582, 584
pump Operating torque ball valve Coloro 375
Mechanical joints 234 Operating torque ball valve type 375 367
Metal Magmeters 717 Operating torque ball valve type 523 361
Metalex 715 Operating torque ball valve type 543 352
Metric system 73 Operating torque ball valve type 546 325
872
Index
Page Page
Operating torque butterfly valve type 468 Overview DIASTAR Six 426
037/038/039
Overview DIASTAR Sixteen 426
Operating torque butterfly valve type 456
567/568 Overview DIASTAR Ten 426
Operating torque diaphragm valve 417 Overview DIASTAR TenPlus 426
Operational characteristics pressure re- 549 Overview float valve 591

ducing valve
Overview planning fundamentals 12
Other criteria for the selection of materi- 307
als Overview pressure reducing valve 545
Output diagram water jet suction pump 574, 575, 576, 577, Overview pressure relief valve 563
578, 579, 580, 581,
582 Overview pressure retaining valve 555
Outside diameter 180 Overview solenoid valve 515
Overlap distance 190 Overview throttle valve 593
Overview actuators 314 Overview type 514 411
Overview angle seat check valve type 533 Overview type 515 411
303/304
Overview type 517 411
Overview angle seat valve type 300/301 510
Overview type 519 411
Overview ball valve Coloro 371
Overview variable area flow meter 601
Overview ball valve type 107 379
Overview ventilating valve and ventilat- 586
Overview ball valve type 130-135 379 ing- and bleed valve
Overview ball valve type 185-188 387 Overview wafer check valve type 369 537
Overview ball valve type 230-235 393 Overview water jet suction pump 572
Overview ball valve type 285-288 405 Paddlewheel 715, 730
Overview ball valve type 322 368 Paddlewheel Flow Sensors 715, 716
Overview ball valve type 375 364 PE flexible section 202
Overview ball valve type 523 357 PE long-term behaviour 151
Overview ball valve type 543 338 PE material properties 34
Overview ball valve type 546 319 PE pipe bracket spacing 219
Overview butterfly valve type 462 PE pressure/temperature diagram 165
037/038/039
PE standards 102
Overview butterfly valve type 037E/038E 479
PE Welding 271, 272, 275, 279
Overview butterfly valve type 037P/038P 500
Performance diagram throttle valve 595
Overview butterfly valve type 473
140/141/142 pH Electronics 712
Overview butterfly valve type 491 pH/ORP 720, 721, 722, 729,
240/241/242 738, 753
Overview butterfly valve type 567/568 449 pH/ORP Electrodes 720
Overview check valve type 561/562 525 pH/ORP Preamplifiers and Connectors 721
Overview diaphragm gauge guard 569 pH/ORP Sensor Electronics 721
Overview diaphragm valve hand operat- 411 pH/ORP System Tester 729
ed
PID controller type PE70 690
Overview diaphragm valve pneumatically 426
actuated Pilot solenoid valve 664, 669
873
Index
Page Page
Pilot valve cluster PV 2000 669 Pressure loss angle seat valve type 512
300/301
Pipe bracket spacing 218, 219, 220, 221,
222, 223, 224 Pressure loss ball valve Coloro 374
Pipe brackets for cold isolating 216 Pressure loss ball valve type 375 366
Pipe preparation 264 Pressure loss ball valve type 523 361
Pipe support 215 Pressure loss ball valve type 543 349, 350
Plaster 214 Pressure loss ball valve type 546 324
Plastic screw connections 243 Pressure loss butterfly valve type 455
567/568
Pneumatic Actuator 618
Pressure loss calculation 185, 186, 863
Pneumatic Actuator DIASTAR 646
Pressure loss check valve type 561/562 529
Pneumatic Actuator PA11/ PA21 634
Pressure loss diaphragm valve 416
Pneumatic Actuators PA30 - PA90 638
Pressure loss diaphragm valve pneumat- 434
pneumatically actuated 442, 444 ically actuated
Polyaddition 23 Pressure loss DIASTAR 025 443
Polycondensation 23 Pressure loss example 187
Polymerisation 23 Pressure loss of variable area flow meter 605
Position signalisation 656 Pressure loss wafer check valve type 539
369
Positioner 446
Pressure reducing valve 544
Positioner PE25 657
Pressure relief valve 562
PP flexible section 204, 206
Pressure retaining valve 554
PP long-term behaviour 154
Pressure Sensor 725, 740
PP material properties 36
Pressure test ABS 230
PP pipe bracket spacing 220, 221
Pressure testing 226
PP pressure/temperature diagram 167
Pressure testing Double containment 814
PP Schweissen 284
Pressure-temperature diagram 307
PP standards 102
Pressure-temperature diagram COOL- 845
PP Welding 281, 282, 287 FIT ABS
PP-mounting plate diaphragm valve 418 Pressure-temperature diagram di- 416

aphragm valve
PP-mounting plate of diaphragm valve 440
Pressure-temperature diagram di- 433
PP-steel-flange 237 aphragm valve pneumatically actuated
PP-V flange 237 Pressure-temperature diagram DIASTAR 443

025
Pre-stress 213
Pressure-temperature diagram for valves 315
Prefixes 75
Pressure-temperature diagram iJOINT 861
Pressure 709, 726
Pressure-temperature diagram of angle 534
Pressure increase rate 227, 815 seat check valve type 303/304
Pressure levels 437 Pressure-temperature diagram of angle 511

seat valve type 300/301
pressure loss 315
Pressure-temperature diagram of ball 374
Pressure loss angle seat check valve 535 valve Coloro
type 303/304
874
Index
Page Page
Pressure-temperature diagram of ball 369 Product features of ball valve type 375 363
valve type 322
Product features of ball valve type 523 356
Pressure-temperature diagram of ball 366
valve type 375 Product features of ball valve type 543 337
Pressure-temperature diagram of ball 361 Product features of ball valve type 546 318
valve type 523
Product features of butterfly valve type 462
Pressure-temperature diagram of ball 348 037/038/039
valve type 543
Pressure-temperature diagram of ball 323 140/141/142
valve type 546
Pressure-temperature diagram of butter- 454 240/241/242
fly valve type 567/568
Product features of check valve type 524
Pressure-temperature diagram of check 529 561/562
valve type 561/562
Product features of diaphragm valve 410
Pressure-temperature diagram of vari- 605
able area flow meter Product features of float valve 591
Pressure-temperature diagram of venti- 589 Product features of pressure retaining 554
lating and ventilating- and bleed valve valve
Pressure-temperature diagram of wafer 539 Product features of solenoid valve 514
check valve type 369
Product features of throttle valve 593
Pressure/temperature diagrams pipes 165, 167, 168
and fittings Product Features of variable area flow 600
meter
Product features ball valve Coloro 371
Product features of ventilating valve and 585
Product Features ball valve type 230-235 392 ventilating- and bleed valve
Product Features butterfly valve type 478 Product features PA11/21 634
037E/038E
Product Features PA30-90 638
Product Features butterfly valve type 499
037P/038P Product Features pressure reducing 544
valve
Product Features butterfly valve type 448
567/568 Product Features pressure relief valve 562
Product Features diaphragm gauge 568 Product Features wafer check valve type 536
guard 369
Product features diaphragm valve pneu- 425 Product Features water jet suction pump 571
matically actuated
Product library 195
Product features DIASTAR 425
Products and applications of valves 303
Product Features EA11 623
Profiled gasket 240
Product Features EA21/31/42 627
PROGEF 167, 282
Product features of angle seat check 532
valve type 303/304 PTFE tape 243, 244, 245, 861
Product features of angle seat valve type 510 PVC flanges 237
300/301
PVC-C cementing 252
Product features of ball valve type 107 378
PVC-C flexible section 210
Product features of ball valve type 378
130-135 PVC-C long-term behaviour 160
Product features of ball valve type 386 PVC-C material properties 40
185-188
PVC-C pipe bracket spacing 223
Product features of ball valve type 404
285-288 PVC-C pressure/temperature diagram 168
Product features of ball valve type 322 368 PVC-C standards 103
875
Index
Page Page
PVC-U cementing 247 Safety information ball valve type 406
285-288
PVC-U flexible section 208
Safety information butterfly valve type 464
PVC-U long-term behaviour 158 037/038/039
PVC-U material properties 38 Safety information butterfly valve type 479

037E/038E
PVC-U pipe bracket spacing 222
PVC-U pressure/temperature diagram 168 037P/038P
PVC-U standards 105 Safety information butterfly valve type 473

140/141/142
PVC-U/PVC-C Dytex cementing 256
PVDF flexible section 212 240/241/242
PVDF long-term behaviour 163 Safety information butterfly valve type 450
567/568
PVDF material properties 42
Safety information diaphragm gauge 569
PVDF pipe bracket spacing 224 guard
PVDF pressure/temperature diagram 168 Safety information diaphragm valve 427

PVDF standards 106
Safety information EA11 623
PVDF Welding 291, 292, 294, 297
Safety information EA21/31/42 627
Quality 15
Safety information for ball valve type 322 369
Reference values for tightening torque of 367
ball valve type 375 Safety information for ball valve type 375 365
Reference values for tightening torque of 361 Safety information for ball valve type 523 358
ball valve type 523
Safety information for ball valve type 543 339
Reference values for tightening torque of 325
ball valve type 546 Safety information for ball valve type 546 320
Relay 758 Safety information for diaphragm valve 413
Repair 232 Safety information for variable area flow 601

meter
Reset unit 647
Safety information PA11/21 634
running time monitoring 652
Safety information PA30-90 638
S 170
Safety information pressure reducing 545
Safety factor 171 valve
Safety information actuators 621 Safety information pressure relief valve 563
Safety information angle seat check 533 Safety information pressure retaining 555
valve type 303/304 valve
Safety information angle seat check 526 Safety information solenoid valve 516
valve type 561/562
Safety information valves 305
Safety information angle seat valve type 511
300/301 Safety information ventilating valve and 586
ventilating- and bleed valve
Safety information ball valve Coloro 372
Safety information wafer check valve 537
Safety information ball valve type 107 379 type 369
Safety information ball valve type 379 Safety information water jet pump 572
130-135
Salinity 724
Safety information ball valve type 387
185-188 Sanitary adapter 246
Safety information ball valve type 394 Screw connections plastic 243
230-235
876
Index
Page Page
SDR 170, 180 Technical characteristics ball valve type 385
130-135
SDR17 - SDR17.6 166
Technical characteristics ball valve type 400
Seals 240 230-235
Selecting material 110 Technical characteristics butterfly valve 508

type 037P/038P
Semi-crystalline 23
Technical characteristics butterfly valve 477
Sensor Electronics 723 type 140/141/142
Servo-assisted solenoid valves 520 Technical characteristics solenoid valve 518, 519, 520
Setting the end stops PA30-90 643 Technical data EA11 625
Setting up the actuator EA11 626 Technical data EA21/31/42 630
Setting up the actuator EA21/31/42 632 Technical data iJOINT 861
Ship Building 87 Technical data PA11/21 636
SI 75 Technical data solenoid valve 521, 522
Signal Converter 727 Technical facts PA30-90 641
Signet 705 Technical features butterfly valve type 459

567/568
Silicone-free 177
Technical features of angle seat check 535
Snap ring 786 valve type 303/304
Social policies 16 Technical features of butterfly valve type 470

037/038/039
Socket fusion jointing 275, 287, 297
Technical Reference 750, 751, 752, 753
Solenoid pilot valve 445
Temperature 709, 726
Solenoid valve 514
Temperature range of variable area flow 605
Spacer 783 meter
Specification 109 Temperature Sensor 725, 741
Standard hand lever red or black 331 Tender invitation 109
Standards 98, 108, 306 Test pressure 226, 814
Static evidence 785, 818 Testing adapter for RS232 interface 660
Storage 194 Testing laboratory 18
Stroke limiter 620, 636 Thermal expansion coefficient 50, 196
Stroke limiter / Emergency manual over- 445 Thermoplastics 23

ride
Thermosets 24
Stroke limiter/Emergency manual over- 682
ride for DIASTAR Threaded fittings 245, 861
Suited valves bodies diaphragm valve 424 Threads standards 100
Surface finishing 177 Threads: Types 235
Switching Power Supplies 727 Throttle valve 593
SYGEF 43, 293 Tightening torque ball valve Coloro 375
Tangit Express 249 Tightening torque butterfly valve type 469

037/038/039
Tangit solvent cementing 247, 252, 259, 266
Tightening torque butterfly valve type 456
Technical characteristics ball valve type 385 567/568
107
Tightening torque flanges 235
877
Index
Page Page
Tightening torque for installing the butter- 470 Type 2100 717
fly valve type 037/038/039
Type 2250 725
Tightening torque wafer check valve type 541
369 Type 230-235 392
Tightening torques 315 Type 2350 725
Tightening torques values check valve 530 Type 240 490

type 561/562
Type 241 490
Tools Cementing 247, 252, 259
Type 242 490
Torque Characteristics PA30-90 643
Type 2450 725
Torque in relation to control pressure 641
PA30-90 Type 2507 717
Totaliser 719 Type 2536 715
Training 17 Type 2537 715
Transition fittings 245, 861 Type 2540 716
Transmitters 714, 719, 722, 724, Type 2551 716
725, 726
Type 2552 717
Transportation 194
Type 2630 711
TriClamp 246
Type 2650 711
Troubleshooting 622, 632, 654, 681
Type 2724-2726 720
Turbidity 707, 712, 729, 730,
742 Type 2750 721
Turbines 717, 734 Type 2750-7 712
Type 0250 727 Type 2759 729
Type 037 461 Type 2760 721
Type 037E 478 Type 2764-2767 720
Type 037P 499 Type 2774-2777 720
Type 038 461 Type 2819-2823 723
Type 038E 478 Type 2839-2842 723
Type 038P 499 Type 285-288 404
Type 039 461 Type 2850 723
Type 107 378 Type 300 510
Type 130-135 378 Type 301 510
Type 140 472 Type 303 532
Type 141 472 Type 304 532
Type 142 472 Type 322 368
Type 157 514 Type 335 600
Type 160/161 514 Type 350 600
Type 165 514 Type 3519 716
Type 166 514 Type 353 371
Type 185-188 386 Type 354 371
Type 2000 717 Type 355 371
878
Index
Page Page
Type 369 536 Type 8860 724
Type 3719 721 Type 8900 714
Type 375 363 Type 9900 706, 714
Type 4150 707, 712, 730, 742 type DSR500 674
Type 4630 706, 711 Type EA11 619, 623
Type 5075 718 Type EA21 627
Type 5090 718 Type EA21/ EA31/ EA42 619
Type 514 410 Type EA31 627
Type 515 410, 715 Type EA42 627
Type 517 410 Type ER52 683
Type 519 410 Type ER53 683
Type 523 356 Type ER55 688
Type 525 715 Type MNL532 669
Type 543 337 Type P20 571
Type 546 318 Type PA11 634
Type 5500 718 Type PA11/ PA21 619
Type 5600 718 Type PA21 634
Type 561 524 Type PA30 - PA90 619, 638
Type 562 524 Type PE70 690
Type 567 448 type PV2000 669
Type 568 448 Type PV5470 669
Type 5700 721 Type PV94 664
Type 5800CR 723 Type PV95 664
Type 5900 724 Type Short version 600
type 591 585 Type Special version 600
type 595 585 type V140 591
Type 6400 727 Type V182 544
Type 7300 727 Type V185 562
Type 8058 727 Type V186 554
Type 8059 727 Type V251 593
Type 8150 719 type V251 593
Type 8250 725 Type V782 544
Type 8350 726 Type V786 554
Type 8450 726 Type V82 544
Type 8550 719 Type V85 562
Type 8630 711 Type V86 554
Type 8750 722 Type Z700 568
Type 8850 724 Type Z701 568
879
Index
Page Page
Types of connections 310, 312 Working Pressure water jet suction pump 574
Unions 243 Working principles and their symbols 518, 519
Units 75 z-dimension method 190
Universal actuator interface according to 401

EN ISO 5211
UV resistance 36
Vacuum 176
Valve designs 309
Valves 302
Valves standards 98
Variable area flow meter 600
Varnishing technology 177
Ventilating Valve and Ventilating- and 585

bleed valve
Vessel formula 170
Video Cementing 270
Viscosities 78
Wafer check valve type 369 536
Wall thickness 170
Water & Gas Utilities 88
Water hammer 173
Water jet suction pump 571
Water Treatment 84
Weight EA11 381, 624
Weight EA21 388
Weight EA21/31/42 381, 474
weight EA21/31/42 479
Weight EA21/31/42 629
Weight PA11/21 396, 406, 635
Weight PA30-90 396, 492, 501, 640
Wet-Tap 733
Wet-Tap Assembly 721
Wet-Tap Valve 716
Wiring 742, 744, 749
Wiring diagrams 647, 648, 649, 651,

653, 656, 658, 685,
689
Working Pressure diaphragm gauge 570

guard
Working pressure of pressure reducing 548

valve
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GF Piping Systems – worldwide at home
Our sales companies and representatives
ensure local customer support in over 100 countries. www.gfps.com
The technical data are not binding. They neither constitute expressly
warranted characteristics nor guaranteed properties nor a guaranteed durability.
They are subject to modification. Our General Terms of Sale apply. Adding Quality to People’s Lives
Argentina / Southern South America China Japan Norway Switzerland
Georg Fischer Central Plastics Georg Fischer P iping Systems Ltd. Georg Fischer Ltd. Georg Fischer AS Georg Fischer
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GF Piping Systems

Planning Fundamentals Industry

Our sales companies and representatives ensure local customer

Planning For Industrial

Australia France Malaysia Romania Taiwan

GMST 5989/4 (9.06) € 50.00

Materials used for industrial pipe work 27

Basics, terms, explanations 45

wherever you are

Approvals and standards for industrial applications 101

Specification of GF Piping Systems products 120

Selecting your pipe material - Chemical resistance 121

Hydraulic calculation and pressure losses 195

Processing and installations 201

GF Piping Systems Jointing technology 239

Introduction to fundamentals for valves 325

Fundamentals for diaphragm valves, pneumatic actuated 495

Fundamentals for butterfly valves, hand operated 523

Fundamentals for butterfly valves, electric actuated 579

Fundamentals for butterfly valves, pneumatic actuated 599

Fundamentals for angle seat valve, hand operated 617

Fundamentals for angle seat valves, pneumatic actuated 622

Fundamentals for check valves 629

General information 953

Materials used for industrial pipe work 27

Basics, terms, explanations 45

wherever you are

Approvals and standards for industrial applications 101

Specification of GF Piping Systems products 120

Selecting your pipe material - Chemical resistance 121

Hydraulic calculation and pressure losses 195

Processing and installations 201

GF Piping Systems Jointing technology 239

Introduction to fundamentals for valves 325

Fundamentals for diaphragm valves, pneumatic actuated 495

Fundamentals for butterfly valves, hand operated 523

Fundamentals for butterfly valves, electric actuated 579

Fundamentals for butterfly valves, pneumatic actuated 599

Fundamentals for angle seat valve, hand operated 617

Fundamentals for angle seat valves, pneumatic actuated 622

Fundamentals for check valves 629

General information 953

Quality, environmental and social policies

Accredited test centre for components used in plastic piping systems 18

Data on products for plastic sanitary installations and for

Adding Quality to People’s

Quality assurance at all levels

We offer you an interesting training experience

A testing laboratory which is an officially accredited

A complete listing of accredited tests can be seen in

The SAS, which is responsible for and has issued our

Plastics are manufactured by compounding together

1 Filamentary molecules without branches

During polycondensation similar and dissimilar

PE Polyethylene PVC Polyvinylchloride ε Strain

Thermoplastics are plastics with simple or branched fila-

Comparison of thermoplastics, thermosets

Relevant properties of thermoplastics

low density = low weight Plastic 0.9 - 1.5 g/cm³

Due to the poor thermal conductivity of plastic, less conden-

1 Hydraulic mould closing cylinder

In the case of reutilisation the plastic waste is brought

Plastics and the environment

The material polyethylene (PE) 34