Algas-SDI DFV Series Vaporizing / Mixing Systems Operations & Maintenance Manual

...Innovative liquid vaporizing and gas mixing solutions
Operations &
Maintenance Manual
1140 NW 46 Street, Seattle, Washington, USA 98107
Tel: 206-789-5410
Fax: 206-789-5414
Web: www.algas-sdi.com
FILE: MANUAL PN 52681 DFV REV 2-15-04 .DOC
WARNING
Read the OPERATION MANUAL before operating this equipment.
NOTE: Algas-SDI reserves the right to use alternate manufacturers’
components as vendor delivery applicability dictates. Literature
contained in the Operation Manual has been supplied by
vendors. Please check to be sure supplied data matches your
configuration. Contact Algas-SDI if any questions exist.
This equipment uses LPG-a flammable fuel, or NH3-a toxic gas,
(depending on the model), handled under pressure. Inherent hazards
exist and a thorough understanding of the equipment is required to
allow safe operation and maintenance.
Allow only a TRAINED and FULLY QUALIFIED PERSON to service this
equipment.
Any time a component must be replaced, use the same type, model ,
etc. DO NOT SUBSTITUTE! The consequence from such actions are
unpredictable and may lead to dire consequences. When components
are replaced with components not approved for use in our FM/UL
listed equipment, the FM/CSA listing becomes void for that unit.
DFV - Direct Fired Packaged Vaporizing / Mixing System Specifications
Sheet
Refer to Nameplate on unit for the model and voltage information then look up specific information
on the tables below.
PROPANE
70 / 30 MIX
Electrical Specification:
110V / 50-60Hz
Amps: 0.6
FUSE PN: 53096, 1-1/2 AMP
220V / 50-60Hz
Amps: 0.3
FUSE PN: 53096, 1-1/2 AMP
Mixer Specifications:
Model / LPGAir Mix
Capacity (Millions)
* Venturi Stamping Information
* Delivery
* Venturi
High Tank Low Vapor
* Motive
Pressure
Capacity
PSIG
PSIG
Pressure
PSIG
(Millions)
BTU/Hr
Kcal/Hr
DFV 2.5 - 5
Propane
70/30
2.6
2.7
0.66
0.68
7
6
22
17
2.5
2.5
25
20
4-5
3-4
DFV 2.5 - 8
Propane
70/30
2.8
2.6
0.71
0.66
11
9.5
85
86
2.5
2.5
72
73
8-9
6.5 - 7.5
DFV 7 - 5
Propane
70/30
7.0
7.2
1.76
1.81
8
8
32
24
7
7
43
35
5-6
5-6
DFV 7 - 8
Propane
70/30
7.0
7.0
1.76
1.76
11
9
66
50
7
7
70
54
8-9
6-7
DFV 14 - 5
Propane
70/30
14.0
14.2
3.53
3.58
8
7
51
46
14
14
35
30
5-6
4-5
DFV 14 - 8
Propane
70/30
14.0
14.2
3.53
3.58
11
9.5
76
60
14
14
74
58
8-9
6.5 - 7.5
Vaporizer Specifications:
DFV 2.5
1 Direct Fired 40/40 Vaporizer
DFV 7
1 Direct Fired 80/40 Vaporizer
DFV 14
2 Direct Fired 80/40 Vaporizer
Model
Capacity
(Gal/Hr)
Operating
Temperature
(internal)
40/40H
80/40H
40
80
120 - 160 deg. F
Pressure Vessel Rating
MAWP 200 PSI @ 650 F
MDMT -20F @ 200 PSI
Heat Excahnge
Surface Area
(Sq. FT.)
Relief Valve
Settting (PSIG)
3.6
7.2
250
Algas-SDI Direct Fired Vaporizer is Factory Mutual Research (FM) Approved .
Mixing capacity (BTU/Hr) is directly related to LPG motive pressure. All systems are pre-set at the factory within + 10% of rated
motive pressure. Additional field adjustment may be required due to varying operating conditions.
Warranty Registration
To Register your new equipment: Visit Algas-SDI's web site at: algas-sdi.com,
then click on the "Tech Support" button. Select online Registration or print out
the Acrobat Warranty Registration.
OR
Fill out the Warranty Registration information on the last page of this manual.
Then make a photo copy and mail to the address shown at the bottom.
Warranty, Copyrights and Approvals
WARRANTY
Algas-SDI International, LLC (ASDI) warrants that the equipment is free of
defects in materials and workmanship under normal use and service. ASDI
agrees to repair or replace, at our option, without charge f.o.b. factory, any part
which has proven defective to the satisfaction of Algas-SDI International, LLC
within one (1) year from the date of the original installation or within 18 months
from the date of shipment, whichever is earlier. Equipment, which in the opinion
of ASDI, has been damaged by improper installation or operation, or has been
abused or tampered with in any way, will not be accepted for return under
warranty.
Algas-SDI International, LLC will not accept back charges for work performed by
others upon or in conjunction with ASDI equipment, unless prior authorization is
given by means of an Algas-SDI International, LLC purchase order. Algas-SDI
International, LLC will not be liable by reason of shutdown, non-operation or
increased expense of operation of other equipment, or any other loss or damage
of any nature, whether direct or consequential, arising from any cause
whatsoever.
Algas-SDI International, LLC makes NO other warranty of any kind, whatsoever
expressed or implied; and all warranties of merchantability and fitness for a
particular purpose are hereby disclaimed by Algas-SDI International, LLC and
excluded from these terms of sale. No person has any authority to bind AlgasSDI International, LLC to any representation or warranty other than this warranty.
COPYRIGHT
Copyright 2000 by Algas-SDI International, LLC, Seattle, Washington 98107. All
rights reserved. No part of this manual may be reproduced or copied in any form
or by any means, photographic, electronic, or mechanical, without the prior
express written consent from Algas-SDI International, LLC, Seattle, Washington,
USA.
IMPORTANT WARRANTY NOTICE:
The Algas-SDI warranty period for equipment is 18 months after
shipment from our facility or 12 months after installation. See our
warranty statement at the beginning of this manual for the complete
text. A warranty registration card has been provided with this manual so
that you may register the date of installation for warranty purposes. If
you do not return the warranty registration card, the warranty term will
be 12 months after the equipment has been shipped to you, the end
user. If you do not install it immediately, your warranty may expire
earlier than necessary. The warranty registration also gives us
information to contact you if we need to send you important information
about the equipment later on.
Please register your equipment.
Symbols and Conventions
Special symbols are used to denote hazardous or important information. You
should familiarize yourself with their meaning and take special notice of the
indicated information.
Please read the following explanations thoroughly.
GENERAL WARNING OR CAUTION
Indicates hazards or unsafe practices which can result in damage to
the equipment or cause personal injury. Use care and follow the
instructions given.
FLAMMABLE GAS HAZARD
Indicates a potential hazard which can result in severe personal
injury or death. Use extreme care and follow the instructions given.
ELECTRICAL DISCONNECT REQUIRED
Indicates a potentially dangerous situation which can result in
severe personal injury or death or damage to equipment. Use great
care and follow the instruction given.
ASDI CONTACT NUMBERS
If you have questions, need help with your equipment, or want information on
other products, contact Algas-SDI at:
Telephone:
206.789.5410
Facsimile:
206.789.5414
Email:
[email protected]
Internet:
http://www.algas-sdi.com
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Table of Contents
1.
Introduction
Description/Overview
Direct Fire Vaporizer Operation
1-1
Mixer Operation
1-1
Figure 1 – DFV Vaporizer / Mixer System Typical Operation
2.
Table 1 – Minimum distance requirements from Vaporizer
4.
1-2
Installation
DFV System Installation Procedure
3.
1-1
2-3
2-3
Electrical
2-3
LPG Liquid Line
2-4
Figure 2 – Frost on the Liquid Line
2-4
Figure 3 – DFV Installation Drawing
2-5
Burner Supply Line
2-6
Safety Relief Valve
2-6
Table 2 – LPG Liquid Line Sizing Chart (minimum pipe size)
2-6
Table 3 – Equivalent Pipe Length of Various Valves and Fittings
2-6
Table 4 – Liquid Temperature VS. Tank Pressure Chart
2-7
Operation and Startup
Vaporizer Operation & Startup
3-9
Mixer Operation and Start-up
3-10
Maintenance
Table 5 – Maintenance Schedule
4-12
Adjusting Procedures for System Operating and Safety Controls
4-15
Motive Pressure (Pressure at the Venturi)
4-16
Set Pressure of the Venturi Regulator
4-16
Table 6 – Pressure Requirements & Settings
System Delivery Pressure
Venturi Pressure Control Switch (Mixed Gas / Delivery Pressure)
Table 7 – System Delivery Pressure Set points
High Tank Pressure Switch
Table 8 – High Tank Pressure Switch Set points
4-16
4-16
4-16
4-16
4-17
4-17
Low Vapor Pressure Switch
4-17
Venturi Check Valve Replacement Instruction
4-18
Figure 4 – Venturi Check Valve Detail
4-18
Figure 5 – Venturi Check Valve Assembly
4-21
Leak Check Procedure for Venturi Check Valves
4-22
BTU Adjustment Procedure
5.
4-22
Troubleshooting
Vaporizer
5-23
Pilot
5-23
Main Burner will not ignite
5-23
Drop in Vapor Pressure
5-23
Mixer
5-24
No Reaction when switch turned to ON or RESET
5-24
Vaporizer operates, but Venturi does not Open
5-24
DFV Cycles Once and Shuts Down
5-24
Troubleshooting Tree #1 Pilot will not light
5-24
Troubleshooting Tree #2 Pilot Lights but will not Hold
5-25
Troubleshooting Tree #3 Main Burner will not Light
5-25
Troubleshooting Tree #4 Vapor Service Pressure Drops
5-26
Testing Individual Components
5-27
High Tank (Mixed Gas) Pressure Safety Switch
5-27
Replacing the High Tank (Mixed Gas) Pressure Switch
5-27
Low Vapor Safety Switch
5-28
Replacing the Low Vapor Safety Switch
5-28
Venturi Pressure Control Switch (Mixed Gas/Delivery)
5-28
Replacing the Venturi Pressure Control Switch (Mixed Gas/Delivery)
5-28
Solenoid Valve Electrical Test
5-29
Figure 6 – Solenoid Valve Electrical Test
5-29
Appendix A: Component Information
Table 12 – DFV Packaged Vaporizing / Mixing System Recommended
Spare Parts And Accessories
Appendix B: Drawings & Technical Information
Equipment Drawings
DFV 2.5
DFV 7
DFV 14
Electrical Drawings
DFV 14
Warranty Registration
Refer to the nameplate on the unit to fill out the product registration. Then Photo copy and
mail to address shown. Or register on line by visiting Algas-SDI web site under "Tech
Support".
Introduction
1
The DFV Liquefied Petroleum Gas (LPG) vaporizing/mixing systems from AlgasSDI are self-contained units providing a mixture of LPG gas and air, which can
replace natural gas. An accumulator tank enables the venturi to cycle on and off
to meet the required load. Operation is quiet, reliable, and safe.
Description/Overview
The DFV compact LPG vaporizer/mixer systems are available in various propane
models providing a gas/air mix from 2.5 to 14 million BTU at pressures from 5 to
8 PSIG depending on the model selected. The gas/air provided is compatible
with natural gas systems and may be used as a direct replacement without
adjustments to your burner systems.
This combination system uses the Algas-SDI Direct Fired vaporizer to vaporize
the LPG and the Algas-SDI atmospheric venturi system. The gas is mixed with
air and stored in the accumulator tank to provide uninterrupted flow of mixed gas
from full flow to no flow, automatically.
Power requirements for the DFV are 110V/50-60Hz or 220V/50-60Hz.
A liquid pump, such as the Algas-SDI Stabilaire pump system, may be required
to provide sufficient gas pressure for the mixing process. The required pressure
for your system is indicated on the data sheet in Appendix B of this manual. If
your supply tank will not provide the required pressure under all expected
temperature conditions, a pump will be needed
Direct Fire Vaporizer Operation
The Algas-SDI Direct Fired vaporizer applies an open flame directly to the heat
exchange surface, which contacts the LPG liquid that is to be vaporized.
The outlet LPG vapor temperature of the vaporizer can be set using the
thermostat. This controls the burner(s) cycling on and off to accommodate the
load requirement. The Liquid Inlet valve and the Capacity Control valve provide
safety against liquid carry-over. Refer to the Operation section for details.
Mixer Operation
The pressure of the vaporized LPG from the vaporizer closes the low vapor
switch and activates the venturi control circuit. The venturi solenoid opens,
feeding LPG vapor through a pressure regulator and then through the venturi
nozzle. The LPG creates a pressure lower than atmospheric pressure in the
venturi housing as it exits the venturi nozzle. The air and the LPG streams are
mixed and compressed in the diffuser section and pressurize the accumulator
tank. When the pressure in the accumulator tank reaches a preset level, the
venturi solenoid valve closes. As the mixed gas is used, the pressure decreases
in the accumulator tank. Thus closing the venturi control switch and opening the
solenoid valve to refill the tank.
Algas–SDI Operations and Maintenance Manual – DFV – P/N: 52681
1-1
Introduction
Figure 1 – DFV Vaporizer / Mixer System Typical Operation
Vapor
AIR
AIR
WARNING
DISCONNECT THE SUPPLY CIRCUIT BEFORE
SERVICING TO PREVENT INJURY FROM ELECTRICAL SHOCK
P/N 50833
Liquid
Vaporizer
DFV MANUAL FIG. 1.DWG
1-2
1. OFF/0N/RESET SWITCH
10. HEAT EXCHANGER
2. LOW VAPOR PRESSURE SWITCH
11. SAFETY SOLENOID VALVE
3. HIGH TANK PRESSURE SWITCH
12. VENTURI VAPOR SOLENOID VALVE
4. VENTURI PRESSURE
CONTROL SWITCH (MIXED GAS)
13. VENTURI VAPOR PRESSURE
REGULATOR
5. INLET VALVE
14. VENTURI HOUSING ASSEMBLY
6. CAPACITY CONTROL VALVE
15. VENTURI NOZZLE
7. BURNER SUPPLY REGULATOR
16. DIFFUSER
8. THERMOSTAT
17. ACCUMULATOR TANK
9. BURNER
18. INLET STRAINER
Algas–SDI Operations and Maintenance Manual – DFV – P/N: 52681
2
Installation
DFV System Installation Procedure
The DFV systems are normally installed outside of plant buildings on a concrete
pad. Consult state, provincial, insurance carriers, and local authorities for
installation requirements. Table 1 provides information on installation distances.
Install the system on a level base and secure it through the four mounting holes.
Use 1/2“, grade 5 “J” bolts embedded in a concrete pad at least 6’ x 10’ x 8”
thick. Install a drain valve in the plugged opening at the bottom of the surge tank.
Install a manual valve after the mixed gas outlet. See Figure 3 for suggested
installation
Clean all foreign materials from all pipe lines prior to making final connections. All
joints require a pipe sealant approved for LPG. Test for leaks using an inert gas,
such as compressed carbon dioxide or nitrogen, at approximately 100 psig (7
2
kg/cm ). Check all connections using an appropriate leak detection solution or
device.
Even very small leaks are unacceptable!
Eliminate all leaks prior to operation.
Table 1 – Minimum Distance Requirements from Vaporizer
Exposure
Storage Tank
Storage tank shutoff valves
Point of transfer
Nearest important building or group of buildings or
line of adjoining property which maybe built upon
(except buildings in which vaporizer is installed).
Minimum Distance
From
Vaporizer Required
10 feet
15 feet
15 feet
25 feet
* Reference NFPA58
ELECTRICAL
The data sheet provides electrical power information and addition equipment
specifications. Install the vaporizer and circuit breaker in accordance with
applicable NFPA, NEC and local regulations. Appropriately ground the vaporizer
as specified by local regulations.
Algas–SDI Operations and Maintenance Manual – DFV – P/N: 52681
2-3
Installation
LIQUID LINE
The liquid line from the storage tank to the vaporizer should be of sufficient size
to supply the vaporizer at full capacity with a maximum pressure drop of less
than the hydrostatic head pressure (see NFPA 54). Refer to Tables 2 & 3 for line
sizing information.
An adequately sized 60 mesh strainer (provided) must be installed at the liquid
inlet to the vaporizer. Also install an isolation valve with hydrostatic relief on the
inlet liquid line before the strainer
Connect the liquid LPG line to the vaporizer inlet. Back flow of liquid from the
vaporizer toward the tank is part of the normal operation of the vaporizer. Do not
install check valves in that line.
Pressure in the LPG storage tank depends on ambient temperature. Install an
Algas-SDI Stabilaire liquid pump beneath the storage tank if the lowest ambient
temperature will not provide enough pressure from the tank to supply your
specific system. Refer to the data sheet provided in Appendix B of this manual
to determine the pressure required for your specific system. The pump should
be set up to supply LPG at a constant pressure, regardless of the flow rate.
Figure 2 – Frost on the Liquid Line
Frost.wmf
NOTE
Frost on the liquid line indicates propane is vaporizing due to a
restriction that causes a pressure drop. If the inlet pipe is too small,
the LPG vaporizes before it enters the vaporizer causing a drastic
drop in efficiency. Wrong size inlet pipes can reduce output as
much as 50%. When referring to the line sizing chart, note that the
pipe sizes recommended are minimum size. Restrictive valves or
other devices may also cause a pressure drop in the liquid line
resulting in a frosting of the line.
If pressure drop is excessive a liquid pump may be required.
2-4
Algas–SDI Operations and Maintenance Manual – DFV – P/N: 52681
Installation
WARNING
Algas–SDI Operations and Maintenance Manual – DFV – P/N: 52681
DISCONNECT THE SUPPLY CIRCUIT BEFORE
SERVICING TO PREVENT INJURY FROM ELECTRICAL SHOCK
P/N 50833
Figure 3 – DFV Installation Drawing
2-5
Installation
BURNER SUPPLY LINE
The vaporizer burners are supplied with vapor from the outlet of the vaporizer
where the least possibility of condensation will take place. However, in regions
where there is a problem with a high content of heavy ends in the LP gas, a
separate vapor supply line to the burner control on the vaporizer may be
installed. If a separate burner supply line is used, the following is recommended:
1. Disconnect the ¼” line at the burner regulator.
2. Disconnect the ¼” line at the tee on top of the heat exchanger and plug it
with ¼ NPT plug.
3. Install a first stage regulator as close to the tank vapor outlet as possible. A
manual shut-off valve should be installed ahead of the regulator.
4. Connect the supply line from the first stage regulator to the burner regulator
at the vaporizer. make sure that the supply is sized properly to handle
maximum input rating of the vaporizer burner(s).
5. Adjust the burner regulator at the vaporizer so that the vapor pressure at the
burner is 11” WC.
SAFETY RELIEF VALVE
Always install the raincap or similar device (if removed) to prevent water and
other debris from entering the relief valve discharge port. If water enters, it may
freeze and prevent the relief valve from proper discharge, creating a potentially
hazardous situation
Table 2 – LPG Liquid Line Sizing Chart (minimum pipe size)
System Size
DFV 2.5
DFV 7.0
DFV 14.0
25
¾”
¾”
1”
50
¾”
¾”
1¼”
Distance in feet from storage to vaporizer
75
100
150
200
1”
1”
1”
1¼”
1”
1”
1”
1¼”
1¼”
1¼”
1¼”
1½”
300
1¼”
1¼”
1½”
400
1¼”
1¼”
1½”
* Add equivalent length of all values and fittings to the length of pipe.
Use this value from these tables to determine minimum pipe use.
Table 3 – Equivalent Pipe Length of Various Valves and Fittings (length in feet)
Size/Description
Globe Valve
Gate Valve
Angle Valve
Elbow, 90
Elbow, 45
Elbow, 90 STR
Tee
2-6
½”
15.5
0.6
8
1.4
0.7
2.3
2.7
¾”
21
0.8
11
1.9
1
3.1
3.7
1”
27
1
14
2.4
1.2
4
4.8
1 ¼”
36
1.4
18
3.2
1.6
5.3
6.4
1 ½”
43
1.6
21
3.8
2
6.3
7.5
Algas–SDI Operations and Maintenance Manual – DFV – P/N: 52681
Installation
Table 4 – Liquid Temperature vs. Tank Pressure Chart
Propane
Tank Gauge
Pressure
Liquid Temperature
°F
°C
PSI
Kpa
-43.7
-40
-30
-41.6
-39.6
-36.8
0
1.4
3.4
0
9.6
23.6
-30
-25
-20
-15
-10
-34.1
-31.3
-28.6
-25.8
-23.1
5.6
8.1
10.7
13.6
16.7
38.9
55.6
73.7
93.5
114.9
-5
0
5
10
15
-20.3
-17.6
-14.8
-12.1
-9.3
20.0
23.6
27.5
31.7
36.2
136.1
163.1
189.9
218.9
249.9
20
25
30
35
40
-6.6
-3.8
-1.1
1.6
4.4
41.1
46.2
51.7
57.6
63.8
283.1
318.7
356.7
397.0
440.1
45
50
55
60
65
7.1
9.9
12.6
15.4
18.1
70.5
77.5
84.9
92.8
101.2
485.8
534.3
585.7
640.1
697.6
70
75
80
85
90
20.9
23.6
26.4
29.1
31.9
109.9
119.3
129.1
139.7
150.2
758.3
822.4
889.9
963.4
1035.7
95
100
105
110
115
34.6
37.4
40.1
42.9
45.6
161.6
173.6
186.1
199.2
213.0
1114.2
1196.6
1283.1
1373.7
1468.6
120
125
130
135
48.4
51.1
53.9
56.6
227.4
242.5
258.2
274.7
1567.9
1671.9
1780.5
1893.9
Algas–SDI Operations and Maintenance Manual – DFV – P/N: 52681
2-7
Installation
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2-8
Algas–SDI Operations and Maintenance Manual – DFV – P/N: 52681
Operation and Startup
3
WARNING
Do not apply power to unit if LPG fumes are present.
They may ignite!
Keep a fire extinguisher available in the immediate vicinity before
re-applying power when the control cover is removed.
CAUTION
Piping may be hot!
DFV normal operating temperature is about 500-600°F [260-315°C]
near the Direct Fire vaporizer exhaust stack. Piping may approach
this temperature under some conditions.
FOR YOUR SAFETY — IF YOU SMELL GAS:
n DO NOT TOUCH ANY ELECTRICAL
SWITCHES.
n EXTINGUISH ANY OPEN FLAME.
n SHUT OFF GAS SUPPLY IMMEDIATELY.
n SHUT OFF POWER THROUGH A REMOTE DISCO
Vaporizer Operation & Startup
Refer to Direct Fired Vaporizer Manual for Operation, Startup, Maintenance,
Troubleshooting, Spare parts and diagrams.
Algas–SDI Operations and Maintenance Manual – DFV – P/N: 52681
3-9
Operation and Startup
Mixer Operation & Start-Up
1. Complete installation and leak test.
2. Turn on the customer provided DISCONNECT for the equipment.
3. Turn the OFF/ON/RESET SWITCH to the OFF position.
4. Check for correct VOLTAGE to the system.
5. Manually close the MIXED GAS OUTLET VALVE, which is located at the
outlet of the accumulator tank.
6. Manually close VENTURI ISOLATION VALVE(S), which is located after the
outlet of the vaporizer
NOTE
Operating the unit in a “dry” condition will not damage this unit. It
is not necessary to have LPG in the unit for testing or evaluation.
7. Drain the ACCUMULATOR TANK, check that no moisture or oils are present,
re-close the valve.
8. Open all valves between the LPG storage tank and the vaporizer to allow
liquid flow to the vaporizer. If a pump is required to achieve the necessary
vapor pressure, start the pump and check the outlet pressure. Refer to the
data sheet in Appendix B for required vapor pressure.
9. Start Vaporizer. Refer to Vaporizer Operation & Start-up section in the Direct
Fired Manual for details.
10. Open the VENTURI ISOLATION VALVE(S).
11. Check the VAPOR PRESSURE GAUGE to verify the proper LPG vapor
pressure.
12. Turn the OFF/ON/RESET SWITCH to the ON position. Then turn the switch
to the RESET position to allow the venturi to start cycling.
13. The venturi will cycle, raising the pressure in the mixed gas accumulator to
the preset level. The unit is now ready to supply mixed gas and opening the
outlet shutoff valve will allow mixed gas to flow. The burner(s) and venturi(s)
will cycle automatically to match flow conditions while the accumulator tank
will insure continuous mixed gas supply.
14. Refer to BTU adjustment procedure in the maintenance section for proper
method for setting the venturi trains. The pressure has been set initially at the
factory; however, slight adjustments may be required due to altitude or
vibrations from shipping.
15. The system is now ready for operation.
16. Refer to the Troubleshooting section for any problems.
3-10
Algas–SDI Operations and Maintenance Manual – DFV – P/N :52681
Maintenance
4
The DFV packaged vaporizing/mixing system is designed for long term troublefree operation. Considering the nature of system use, with heavy prolonged
workloads, it is very important to provide scheduled maintenance.
The following maintenance schedule may be used as a guideline. This
maintenance schedule includes items that must be serviced, the type of service
to perform, and the frequency of service. However, this is only a suggested
schedule. The conditions in your area and quality of the LP gas liquid may dictate
a more stringent or more lax maintenance, but whatever your schedule,
remember that maintenance is of paramount importance for trouble free
operation.
ASDI provides a RECOMMENDED SPARE PARTS list located at the back of this
manual and the Direct Fired manual for ordering ease when replacing
components.
CAUTION
The equipment described in this manual is designed to operate with
LP gas, a flammable fuel under pressure. The nature of the
application involves inherent hazards that could result in injury.
ONLY a trained and fully qualified person should service this
equipment.
CAUTION
1. When servicing a component in the liquid or vapor line. BE
SURE that the LP-gas supply to that component is shut off
before it is removed or disassembled. The vaporizer must be
completely blown down before performing service. Be sure that
ALL sources of ignition are extinguished within 25 feet of the
work area.
2. When flaring the contents of the vaporizer, be sure that the
burners are on to prevent freezing during the flaring operation.
Algas–SDI Operations and Maintenance Manual – DFV – P/N: 52681
4-11
Maintenance
Table 5 – Maintenance Schedule
Item
1 Month
3 Months
6 Months
Annual
Inspect pilot
assembly. The
flame should
Pilot Burner Assembly
envelope 3/8” to ½”
of the thermocouple
tip.
Inspect for proper
flame. Check that
air supply openings
Main Burner Assembly are clear of debris,
dirt or trash. If
needed, clean each
burner orifice.
Safety Relief Valves
Check all relief
valves on vaporizer,
accumulator tank,
liquid, and vapor
lines for signs of
corrosion in outlet.
Check all raincaps.
Replace if damaged
or missing.
Enclosure
Check access door
and inside
enclosure for debris
and combustible
material. Check
and, if needed,
clean the inlet
louvers and vent
cap(s).
4-12
Inspect for proper flame.
Check that air supply
openings are clear of
debris, dirt or trash. If
needed, clean each
burner orifice.
Algas–SDI Operations and Maintenance Manual – DFV – P/N: 52681
Maintenance
Item
1 Month
3 Months
6 Months
Annual
Thermostat
Check the thermostat
for proper operation
(see Start-up
Procedure). If the
thermostat is not
operating properly, it
should be replaced (the
thermostat cannot be
serviced).
Thermocouple
The electrical output of
the thermocouple
should be checked with
a millivolt meter. The
thermocouple output
should be between 13
and 30 millivolts. A
lower than 13 millivolt
reading indicates the
thermocouple (P/N
46/4) should be
replaced.
Liquid Inlet Valve
Disassemble and clean
the valve. To service
valve, use kit 3-0016
Capacity Control Valve
Disassemble and clean
the valve. To service
valve, use kit 3-0017.
Use powdered graphite
as lubricant around top
of the piston with “O”
ring. Use grease as
lubricant on “O” ring.
Algas–SDI Operations and Maintenance Manual – DFV – P/N: 52681
4-13
Maintenance
Item
Liquid LPG inlet
strainer
1 Month
3 Months
6 Months
Annual
Check as conditions Check as conditions
require
require
Clean
Change the diaphragm
and operating parts if
the unit is being used
regularly or if the valve
makes unusual noises
(i.e. buzzing, etc.)
during operation. See
the enclosed
maintenance and
operation sheet for
ASCO 2-way valves
replacement procedure.
(Appendix A)
Solenoid valve
Visually inspect for
corrosion, loose wires,
Check primary
terminal lug tension heat buildup and
charring
Electric wiring and
connections
Low vapor pressure
switch set points
Verify against the
values on the data
sheet
High tank pressure
switch set points
Verify against the
values on the data
sheet
Venturi check valve
assembly
Check clevis assy.,
Check for wear and clevis pivot screw, valve
leakage
arm & valve surface for
wear. Replace if worn.
Check for leaks
Motive pressure
(pressure at the
venturi) set point
Check setting
NOTE
Before replacing thermostat, be sure thermocouple is delivering the
proper voltage to the thermostat (13 to 30 millivolts).
4-14
Algas–SDI Operations and Maintenance Manual – DFV – P/N: 52681
Maintenance
Adjustment Procedures for System Operating and
Safety Controls
All of the controls (except for the venturi regulator) are preset at the factory.
However, vibration in transportation may alter the settings or it may be desirable
to change the system delivery pressure (within the range of the installed venturi).
Thus the control settings may need to be checked or readjusted. Any replaced
controls will also require adjustment.
WARNING
Power to the control box must be turned off at a remote disconnect
before the cover is removed. Check for propane leaks before
applying power.
WARNING
DO NOT APPLY POWER IF LPG FUMES ARE PRESENT.
THEY MAY IGNITE!
WARNING
DO NOT attempt to adjust the pressure switches with the power
turned on.
WARNING
Always have a fire extinguisher handy when operating with the
control enclosure open.
Algas–SDI Operations and Maintenance Manual – DFV – P/N: 52681
4-15
Maintenance
MOTIVE PRESSURE (Pressure at the Venturi)
SET PRESSURE OF THE VENTURI REGULATOR
The initial motive pressure for the venturi is stamped on the base of the venturi
housing. This pressure is adjusted using the vapor pressure regulator on the
LPG vapor train. The adjustments should be made with the system in operation,
using a BTU METER while adjusting the motive pressure and monitoring BTU
meter to attain a 1450 BTU/cu. ft. mix.
Table 6 – Pressure Requirements & Settings
Propane Pressure Requirement Data
Mixed air/propane
*Nozzle motive
Inlet vapor pressure
delivery
pressure
psig (kg/cm2)
pressure psig (kg/cm2)
psig (kg/cm2)
5.0 (.35)
31.0-55.0 (2.18-3.87)
28.0-43.0 (1.97-3.02)
8.0 (.56)
74.0-85.0 (5.20-5.98)
70.0-74.0 (4.92-5.20)
SYSTEM DELIVERY PRESSURE
VENTURI PRESSURE CONTROL SWITCH (MIXED GAS / DELIVERY PRESSURE)
The Venturi Pressure Control Switch (Mixed Gas/Delivery) is wired normally
closed and is set to open according to the set point on the data sheet. The
Venturi Pressure Control Switch will cycle on and off as the tank pressure
changes. The system delivery pressure is adjustable within the range of the
installed venturi. The on/off and differential pressures are set by means of the
Venturi Pressure Control Switch adjustment screw and the Venturi Pressure
Control Switch differential pressure adjustment wheel.
To adjust the switch, use a 1/4“ open end wrench. Turn the main adjustment screw
counterclockwise to lower the setpoint or clockwise to raise the setpoint. Turn the
adjusting screw until the “ON” setpoint is reached, then set the differential
adjustment wheel for a deadband "OFF" of .75 to 1 psi. A typical setting is between
E and F. See Section 5: Troubleshooting for replacing the Venturi Pressure Control
Switch.
Table 7 – System Delivery Pressure Set points
Delivery
Pressure
#5
#8
4-16
System Delivery Pressure Set points
DFV 2.5 - DFV 14.0
Venturi “OFF”
Venturi “ON” (psig)
Deadband
(psig)
5
5¾-6
.75 - 1
8
8¾-9
.75 - 1
Deadband
Position
E-F
E-F
Algas–SDI Operations and Maintenance Manual – DFV – P/N: 52681
Maintenance
HIGH TANK PRESSURE SWITCH
The High Tank Pressure Switch is wired normally closed and is set to open
according to the set point on the data sheet. The high tank pressure switch is a
safety that opens due to high tank pressure. When this occurs it is an indication
that there is a component failure. See Troubleshooting Section to resolve the
problem. The pressure switch is located in the control box. To set, turn the
adjusting wheel to approximate the setting shown on the indicator scale on the
switch. The set points for the high tank pressure switch in the control box are as
follows.
Table 8 – High Tank Pressure Switch Set points
High Tank Pressure Switch Set points
Mixed air/propane delivery pressure
High tank pressure switch
5 psig
8 psig
8 psig
11 psig
LOW VAPOR PRESSURE SWITCH
The Low Vapor Pressure Switch is wired normally open and is set according to
the set point on the data sheet. The Low Vapor Pressure Switch opens when
there is in adequate pressure to operate the venturi. With the system operating,
slowly throttle the vaporizer LPG vapor outlet valve. This reduces the LPG vapor
pressure being sent to the mixer. Observe the LPG vapor pressure gauge and
note the pressure at which the low vapor pressure switch opens and disables the
venturi solenoid valve.
To set the low vapor pressure switch, turn the adjusting wheel to the approximate
setting shown on the indicator scale on the switch body. Refer to the data sheet
for set point information. Repeat the process to verify the setpoint. Note the low
vapor pressure switch only disables the venturi solenoid valve and does not shut
off the DFV.
Algas–SDI Operations and Maintenance Manual – DFV – P/N: 52681
4-17
Maintenance
Venturi Check Valve Replacement Instruction
If the venturi check valve leaks or the pivot mechanism operates poorly, the
venturi check valve assembly must be replaced. Follow the procedure below to
replace the venturi check valve and pivot arm.
NOTE
As with all components containing materials subject to
deterioration, the venturi check valves should routinely be checked
and replaced as necessary. A minimum annual inspection should
be conducted. IF REPLACEMENT VENTURI CHECK VALVE IS NOT
ASSEMBLED, follow below instructions
This instruction set is to be used for the Venturi Check Valve KitP/N - 40490.
1. After the existing check valve (A) has been removed, examine the machined
seating surface (F) on the venturi housing (D) to be sure the surface is clean
and without flaws.
2. Screw the clevis (I) into the housing, using Permatex NO. 2 or equivalent on
the threads, until 3- 3 ½ threads are exposed outside of the housing (D). Do
not use a screwdriver or other prying device to install the clevis. Clean any
excess Peratex from clevis slot.
3. Insert the check valve arm (K) into the slot of the clevis and connect the two
pieces with the clevis/arm pivot screw (L) through the aligned holes. Be sure
that the lock washer and a flat washer are inserted on the lock nut end (with
the flat washers are inserted on either side of the clevis. Tighten the lock nut
(J), allowing for free swing of the arm.
4-18
Algas–SDI Operations and Maintenance Manual – DFV – P/N: 52681
Maintenance
Check for proper clevis installation as follows:
n
With the arm (K) raised, rotate the valve (M) around the valve/arm pivot so
that the edge of the valve nearest the clevis is lowered without allowing the
valve (M) to turn around the valve/arm pivot; only the lower part of the valve
should contact the seating surface (F).
With the valve (M) rotated to the other extreme position around the valve/arm
pivot, lowering the arm (K) should cause only the upper part of the valve (M) to
contact the seating surface (F).
n Lower the arm (K) a third time, allowing free rotation of the valve (A). The
valve (M) should be able to contact the seating surface (F) uniformly all around.
Algas–SDI Operations and Maintenance Manual – DFV – P/N: 52681
4-19
Maintenance
n If the valve does not contact the seat as described above, reposition the
clevis (I) in the housing (D). At least three threads must be exposed for proper
installation of the acorn nut (G)
5. Place sealing washer (H) on to clevis (I) then tighten the acorn nut (G) onto
the clevis (I) outside the housing (D), making sure that when the nut is tight ,
the valve is centered. Do not use any tools on the clevis inside the housing,
or on the arm or valve. It may be helpful to start with the valve offset to the
side and allow it it to rotate to its centered position while tightening the acorn
nut.
6. Tighten the lock nut (J) on the clevis/arm pivot screw until the arm is tight in
the clevis. Then slowly loosen the lock nut just until the arm can swing freely.
Check that the valve is centered and clears the housing on both sides.
7. Install the venturi housing lid (B), using a new gasket (C). Apply white
Lithium grease to gasket & threads.
8. Apply pressure to the unit and check for leaks around the lid and around the
check valve. Initially a small leak may occur around the check valve, but after
a few cycles the leak should correct itself. If it persists, remove the lid and recheck the seating surfaces and the alignment.
4-20
Algas–SDI Operations and Maintenance Manual – DFV – P/N: 52681
Maintenance
Figure 5 –Venturi Check Valve Assembly
Venturi Check Valve.dxf
A. Flapper Arm Assembly
F. Seating Surface
K. Flapper Arm
B. Housing Lid
G. Acorn Nut
L. Pivot Screw
C. Housing Gasket
H. Sealing Washer
M. Flapper
D. Housing
I. Clevis
E. Diffuse/Housing “O” Ring
J. Lock Nut
Algas–SDI Operations and Maintenance Manual – DFV – P/N: 52681
4-21
Maintenance
LEAK CHECK PROCEDURE FOR VENTURI CHECK VALVES
Remove silencer from venturi.
Build up pressure in the surge tank to the system operating pressure, shut off the
system, close the inlet valve, and disconnect all power.
Use either a gas detector or a soapy solution applied to the check valve and seat
to determine if there is a leak.
If there is a slight leak from the venturi check valve, tapping the valve open
quickly with the handle of a screwdriver (DO NOT USE THE BLADE SIDE) or a
suitable tool may dislodge a small particle on the lip of the valve. Otherwise the
venturi must be disassembled to adjust the check valve pivot arm as outlined in
the previous procedure.
When assembling the silencer into the venturi housing, use an anti-seize
compound on the threads.
WARNING
LPG is heavier than air and LPG vapor either mixed with or without
air will “pool” in low areas without ventilation or wind. Check
potential pooling areas with a gas detector if gas is suspected.
BTU ADJUSTMENT PROCEDURE
The BTU adjustment procedure must be done on initial start-up to assure
proper mixed gas BTU value.
Connect your BTU analyzer to the surge tank test port.
With your system running, establish a load such that the venturi is on 50% of the
time and off 50% of the time. Adjust the venturi regulator until the venturi motive
pressure is at the pressure stamped on the venturi housing or the pressure called
out on your data sheet. This is a starting point for adjusting the BTU value of your
mixed gas.
Monitor your BTU instrument and set the venturi regulator until you have the
appropriate mix of propane/air (in most cases 1450 BTU’s per cubic foot, or
1.30 specific gravity).
Due to the physical properties of the venturi’s, as the motive pressure increases,
the LPG flow increases accordingly. If the motive pressure is set too high, it may
overdraw the vaporizer. A general rule is, do not exceed the motive pressure
stamped on the venturi housing by more than 5 PSIG.
Increase the system load and verify the mixed gas BTU value.
Disconnect your test equipment and return the system to operation
4-22
Algas–SDI Operations and Maintenance Manual – DFV – P/N: 52681
Troubleshooting
5
VAPORIZER
There are 4 troubleshooting trees provided for the Direct Fire Vaporizer.
TREE #1 - Pilot will not light.
TREE #2 - Pilot lights but will not hold.
TREE #3 - Main Burner will not light.
TREE #4 - Vapor Pressure Drops.
PILOT
The pilot flame is adjusted at the factory to provide a non-blowing blue flame. If
the flame is not adequate or the pilot does not stay lit, check the pilot burner to
see if it is clear of any obstructions.
Flame should envelope 3/8” to ½“ of the thermocouple tip. If the burner is too
low, the thermocouple will not generate sufficient voltage to hold the main
burner’s valve open. If the pilot flame is too small, clean the pilot burner orifice, or
replace the pilot.
MAIN BURNTER WILL NOT IGNITE
Check the pilot burner as per 1 above.
Check burner regulator. Disconnect tube from outlet side of regulator and check
output pressure.
If pilot burner and burner regulator check out OK, the problem is in the
thermostat. Replace thermostat (the main burner will not come on unless the
temperature in the heat exchanger falls below 120° F).
DROP IN VAPOR PRESSURE
Check burner; check pilot as per 1 and 2 above.
If vapor pressure drops, but main burner(s) is working, vapor demand exceeds
vaporizer capacity. Cut down on vapor demand.
Check liquid excess flow valve and shut off valve; make sure they are open.
Close liquid inlet valve upstream of strainer. Bleed down system and clean
strainer filter.
AlgasSDI Operations and Maintenance Manual – DFV – P/N: 52681
5-23
Troubleshooting
MIXER
No Reaction when switch turned to ON or RESET
Be sure wiring is correct. Refer to the Wiring Schematic for proper installation.
Replace switch if defective.
Vaporizer operates, but Venturi does not Open
Hold the OFF/ON/RESET switch in the RESET position to energize the relay.
If the solenoid valves still do not open, check the continuity of the solenoid circuit.
Replace wire or solenoid valve is continuity is open. Check the wiring as well.
The pressure switches may need adjustment or replacement. Refer to the
Testing Individual Components section for details.
DFV Cycles Once and Shuts Down
Check the mixed gas pressure. Adjust the VENTURI PRESSURE CONTROL
SWITCH if the pressure is too high. Refer to the Testing Individual Components
section for details.
5-24
AlgasSDI Operations and Maintenance Manual – DFV – P/N: 52681
Troubleshooting
AlgasSDI Operations and Maintenance Manual – DFV – P/N: 52681
5-25
Troubleshooting
5-26
AlgasSDI Operations and Maintenance Manual – DFV – P/N: 52681
Troubleshooting
Testing Individual Components
NOTE
See ADJUSTMENT PROCEDURES FOR SYSTEM OPERATING AND
SAFETY CONTROLS section. Venturi Pressure Control Switch, earlier
in this manual for additional information.
HIGH TANK PRESSURE SAFETY SWITCH
Shuts off the unit when the MIXED GAS pressure is too high due to a malfunction
in the control system. See the data sheet for pressure setting. The pressure is
adjusted by turning the adjustment dial on the switch.
Accuracy of the High Tank Pressure safety switch can be checked with an
external regulator and calibrated pressure.
REPLACING THE HIGH TANK PRESSURE SAFETY SWITCH
n
Turn power off at the disconnect, bleed the system to 0 pressure.
n
Remove the wires to the switch.
n
Remove the switch with an open end wrench.
n
Install a new switch.
n
Turn power on, open isolation valve, and bring system up to operating
pressure.
n
Carefully check carefully for leaks at all connections.
n
Refer to the adjustment procedure section for setting the switch.
AlgasSDI Operations and Maintenance Manual – DFV – P/N: 52681
5-27
Troubleshooting
LOW VAPOR SAFETY SWITCH
Disables the venturi when the vapor pressure is too low to properly operate the
venturi. Once there is adequate vapor pressure the venturi will resume operation
as needed. See the data sheet for pressure setting. The pressure is adjusted by
turning the adjustment dial on the switch.
Accuracy of the low vapor safety switch can be checked with an external
regulator and calibrated pressure gauge or by removing the switch and testing it
with a known pressure.
REPLACING THE LOW VAPOR SAFETY SWITCH
n
Turn off the power at the disconnect, bleed the system to 0 pressure.
n
Remove the wires to the switch.
n
Remove the switch with an open end wrench.
n
Install a new switch.
n
Turn power on, open isolation valve and bring system up to operating
pressure.
n
Refer to the adjustment procedures section for setting the switch
VENTURI PRESSURE CONTROL SWITCH ( MIXED GAS / DELIVERY PRESSURE )
The Venturi Pressure Control Switch maintains tank pressure by cycling on and
off as required by the load.
Accuracy of the Venturi Pressure Control switch can be checked with an external
regulator and calibrated pressure.
REPLACING THE VENTURI PRESSURE CONTROL SWITCH ( MIXED GAS / DELIVERY PRESSURE )
5-28
n
Turn off the power at the disconnect, close the inlet hand valve and bleed the
system to 0 pressure.
n
Remove the wires to the switch.
n
Remove the switch with an open end wrench.
n
Install a new switch.
n
Turn power on, open isolation valve and bring system up to operating
pressure.
n
Verify operation with external pressure gauges.
n
Refer to the adjustment procedures section for setting the switch.
AlgasSDI Operations and Maintenance Manual – DFV – P/N: 52681
Troubleshooting
Solenoid Valve Electrical Test
WARNING
Shut off power at the electrical disconnect before proceeding.
Remove the cover of the conduit tee near the solenoid valves. Disconnect the
wires and measure each of the solenoid lead wires. You should measure
approximately 3 ohms on the multimeter. If the measured resistance is incorrect,
change the solenoid coil.
Figure 6 – Solenoid Valve Electrical Test.
AlgasSDI Operations and Maintenance Manual – DFV – P/N: 52681
5-29
Troubleshooting
5-30
AlgasSDI Operations and Maintenance Manual – DFV – P/N: 52681
APPENDIX A
COMPONENT INFORMATION
This page intentionally left blank.
Appendix A
Table 12 – DFV Packaged Vaporizing/Mixing System Recommended Spare Parts and Accessories
DFV Replacement Parts
Components
35539 – DFV – ALL
36081 – DFV2.5–5#
DFV––7–5#
DFV–14–5#
36082 – DFV2.5–8#
DFV––7–8#
DFV–14–8#
36118 – DFV2.5–5#
DFV––7–5#
36106 – DFV2.5–8#
DFV––7–8#
DFV–14–8#
31304
36113 - DFV – 110VAC
36112 - DFV – 220VAC
40287
50330 - DFV – 110VAC
53124 - DFV – 220VAC
51476 - DFV – 110VAC
53017 - DFV – 220VAC
37009 - DFV2.5
DFV––7
37009 - DFV–14
53096 - DFV – ALL
33950 – DFV2.5–5#
33951 – DFV––7–5#
33952 – DFV–14–5#
33953 – DFV2.5–8#
33953 – DFV––7–8#
32070 – DFV–14–8#
20122
31051
40490
36080
31016
30638
30641
52681
52642
Description
SWITCH, PRESSURE, VENTURI CONTROL (MIXED GAS), 0-20 PSI
Qty.
1
SWITCH, PRESSURE HIGH TANK (MIXED GAS), 4–12 PSI
1
SWITCH, PRESSURE HIGH TANK (MIXED GAS), 8–25 PSI
1
SWITCH, PRESSURE, LOW VAPOR, 20-50 PSI
1
SWITCH, PRESSURE, LOW VAPOR, 40–120 PSI
1
RELIEF VALVE (SURGE TANK)
VALVE, SOLENOID, ¾” (SAFETY AND VENTURI CONTROL)
VALVE, SOLENOID, ¾” (SAFETY AND VENTURI CONTROL)
REPAIR KIT, SOLENOID VALVE
LAMP, 110V
LAMP, 220V
CONTROL RELAY, 110V
CONTROL RELAY, 220V
1
2
2
2
1
1
1
1
ELECTRONIC IGNITOR 117V / 220V
1
ELECTRONIC IGNITOR 117V / 220V
FUSE, 1-1/2 AMP SLO-BLO
2
1
REGULATOR, 627
1
GASKET, VENTURI HOUSING
O-RING (DIFFUSER)
VENTURI CHECK VALVE REBUILD KIT
SILENCER
AIR INLET SCREEN
GAUGE, PRESSURE, 0-100 PSI
GAUGE, PRESSURE, 0-300 PSI
MANUAL, DFV
MANUAL, DIRECT FIRED
1
1
1
1
1
1
1
1
1
AlgasSDI Operations and Maintenance Manual – DFV – P/N: 52681
Appendix A
AlgasSDI Operations and Maintenance Manual – DFV – P/N: 52681
Installation & Maintenance Instructions
SERIES
8003G
8202G
OPEN-FRAME, GENERAL PURPOSE, WATERTIGHT/EXPLOSIONPROOF SOLENOIDS
INSTALLATION
Ċ SERVICE NOTICE Ċ
ASCO solenoid valves with design change letter G" or H" in the catalog
number (ex. 8210G 1) have an epoxy encapsulated ASCO Red Hat II
solenoid. This solenoid replaces some of the solenoids with metal enclosures
and open-frame constructions. Follow these installation and maintenance
instructions if your valve or operator uses this solenoid.
See separate instructions for basic valve.
Check nameplate for correct catalog number, service, and wattage. Check
front of solenoid for voltage and frequency.
WARNING: Electrical hazard from the accessibility
of live parts. To prevent the possibility of death,Ăserious
injury or property damage, install the open - frame
solenoid in an enclosure.
FOR BLACK ENCLOSURE TYPES 7 AND 9 ONLY
DESCRIPTION
Catalog numbers 8003G and 8202G are epoxy encapsulated pull-type
solenoids. The green solenoid with lead wires and 1/2Ăconduit connection is
designed to meet Enclosure Type 1-General Purpose, Type 2-Dripproof,
Types 3 and 3S-Raintight, and Types 4 and 4X-Watertight. The black
solenoid on catalog numbers prefixed EF" or EV" is designed to meet
Enclosure Types 3 and 3S-Raintight, Types 4 and 4X-Watertight, Types 6
and 6P-Submersible, Type 7 (A, B, C & D) Explosionproof Class I, Division
1 Groups A, B, C, & D and Type 9 (E, F, & G)-Dust-Ignitionproof Class II,
Division 1 Groups E, F & G. The Class II, Groups F & G Dust Locations
designation is not applicable for solenoids or solenoid valves used for steam
service or when a class H" solenoid is used. See Temperature Limitations
section for solenoid identification and nameplate/retainer for service. When
installed just as a solenoid and not attached to an ASCO valve, the core has
a 0.250-28 UNF-2B tapped hole, 0.38 or 0.63 minimum full thread.
NOTE: Catalog number prefix EV" denotes stainless steel construction.
Catalog numbers 8202G1, 8202G3, 8202G5 and 8202G7 are epoxy
encapsulated push-type, reverse-acting solenoids having the same
enclosure types as previously stated for Catalog numbers 8003G1 and
8003G2.
Series 8003G and 8202G solenoids are available in:
Open-Frame Construction: The green solenoid may be supplied with
1/4 spade, screw or DIN terminals. (Refer to Figure 4)
Panel Mounted Construction: These solenoids are specifically designed
to be panel mounted by the customer through a panel having a .062 to .093
maximum wall thickness. Refer to Figure 1 and section on Installation of
Panel Mounted Solenoid.
Optional Features For Type 1 - General Purpose
Construction Only
Junction Box: This junction box construction meets Enclosure Types
2,3,3S,4, and 4X. Only solenoids with 1/4 spade or screw terminals may
have a junction box. The junction box provides a 1/2 conduit connection,
grounding and spade or screw terminal connections within the junction
box (See Figure 5).
DIN Plug Connector Kit No.K236034:Ă Use this kit only for solenoids with
DIN terminals. The DIN plug connector kit provides a two pole with
grounding contact DIN Type 43650 construction (See Figure 6).
OPERATION
Series 8003G - When the solenoid is energized, the core is drawn into the
solenoid base sub-assembly. IMPORTANT: When the solenoid is
de-energized, the initial return force for the core, whether developed by
spring, pressure, or weight, must exert a minimum force to overcome
residual magnetism created by the solenoid. Minimum return force for AC
construction is 11 ounces, and 5 ounces for DC construction.
Series 8202G - When the solenoid is energized, the disc holder assembly
seats against the orifice. When the solenoid is de-energized , the disc holder
assembly returns. IMPORTANT: Initial return force for the disc or disc
holder assembly, whether developed by spring, pressure, or weight, must
exert a minimum force to overcome residual magnetism created by the
solenoid. Minimum return force is 1 pound, 5 ounces.
MM
Form No.V6584R8
All Rights Reserved.
50 Hanover Road, Florham Park, New Jersey 07932
CAUTION: To prevent fire or explosion, do not install solenoid
and/or valve where ignition temperature of hazardous atmosphere is
less than 165 C. On valves used for steam service or when a class
H" solenoid is used, do not install in hazardous atmosphere where
ignition temperature is less than 180C. See nameplate/retainer for
service.
NOTE: These solenoids have an internal non-resetable thermal fuse to
limit solenoid temperature in the event that extraordinary conditions occur
which could cause excessive temperatures. These conditions include high
input voltage, a jammed core, excessive ambient temperature or a shorted
solenoid, etc. This unique feature is a standard feature only in solenoids with
black explosionproof/dust-ignitionproof enclosures (Types 7 & 9).
CAUTION: To protect the solenoid valve or operator, install a
strainer or filter, suitable for the service involved in the inlet side as
close to the valve or operator as possible. Clean periodically
depending on service conditions. See ASCO Series 8600, 8601, and
8602 for strainers.
Temperature Limitations
For maximum valve ambient temperatures, refer to chart. The temperature
limitations listed, only indicate maximum application temperatures for field
wiring rated at 90C. Check catalog number prefix and watt rating on
nameplate to determine maximum ambient temperature. See valve
installation and maintenance instructions for maximum fluid temperature.
NOTE: For steam service, refer to Wiring section, Junction Box for
temperature rating of supply wires.
Temperature Limitations For Series 8003G or 8202G Solenoids
for use on Valves Rated at 10.1, 11.6, 17.1, or 22.6 Watts
Watt
Rating
Catalog
Number Coil Prefix
Class of
Insulation
Maximum Ambient Temp.
10.1 & 17.1
None, FB, KF, KP
SC, SD, SF, & SP,
F
125F (51.7C)
10.1 & 17.1
HB, HT, KB, KH,
SS, ST, SU,
H
140F (60C)
11.6 & 22.6
None, FB,KF, KP,
SC, SD, SF, & SP.
F
104F (40C)
11.6 & 22.6
HP, HT, KB, KH,
SS, ST, SU, & SV
H
104F (40C)
Minimum ambient temperature -40 F (-40 C).
Positioning
This solenoid is designed to perform properly when mounted in any position.
However, for optimum life and performance, the solenoid should be
mounted vertically and upright to reduce the possibility of foreign matter
accumulating in the solenoid base sub-assembly area.
Wiring
Wiring must comply with local codes and the National Electrical Code. All
solenoids supplied with lead wires are provided with a grounding wire which
is green or green with yellow stripes and a 1/2 conduit connection. To
Printed in U.S.A.
www.ascovalve.com
Page 1 of 4
facilitate wiring, the solenoid may be rotated 360. For the watertight and
explosionproof solenoid, electrical fittings must be approved for use in the
approved hazardous locations.
CAUTION: Cryogenic Applications - Solenoid lead wire
insulation should not be subjected to cryogenic temperatures.
Adequate lead wire protection and routing must be provided.
Additional Wiring Instructions For Optional Features:
Open-Frame solenoid with 1/4 spade terminals.
For solenoids supplied with screw terminal connections use #12-18 AWG
stranded copper wire rated at 90C or greater. Torque terminal block screws
to 10 ± 2 in-lbs [1,0 ± 1,2 Nm]. A tapped hole is provided in the solenoid for
grounding, use a #10-32 machine screw. Torque grounding screw to 15 - 20
in-lbs [1,7 - 2,3 Nm]. On solenoids with screw terminals, the socket head
screw holding the terminal block to the solenoid is the grounding screw.
Torque the screw to 15 - 20 in-lbs [1,7 - 2,3 Nm] with a 5/32 hex key
wrench.
Junction Box
The junction box is used with spade or screw terminal solenoids only and is
provided with a grounding screw and a 1/2 conduit connection. Connect
#12-18 AWG standard copper wire only to the screw terminals. Within the
junction box use field wire that is rated 90C or greater for connections. For
steam service use 105C rated wire up to 50 psi or use 125C rated wire above
50 psi. After electrical hookup, replace cover gasket, cover, and screws.
Tighten screws evenly in a crisscross manner.
DIN Plug Connector Kit No.K236034
1. The open-frame solenoid is provided with DIN terminals to
accommodate the plug connector kit.
2. Remove center screw from plug connector. Using a small screwdriver, pry
terminal block from connector cover.
3. Use #12-18 AWG stranded copper wire rated at 90C or greater for
connections. Strip wire leads back approximately 1/4 for installation in
socket terminals. The use of wire-end sleeves is also recommended for
these socket terminals. Maximum length of wire-end sleeves to be
approximately 1/4.ĂTinning of the ends of the lead wires is not
recommended.
4. Thread wire through gland nut, gland gasket, washer and connector cover.
NOTE: Connector housing may be rotated in 90 increments from position
shown for alternate positioning of cable entry.
5. Check DIN connector terminal block for electrical markings. Then make
electrical hookup to terminal block according to markings on it. Snap
terminal block into connector cover and install center screw.
6. Position connector gasket on solenoid and install plug connector. Torque
center screw to 5 ± 1 in-lbs [0,6 ± 1,1 Nm].
NOTE: Alternating current (AC) and direct current (DC) solenoids are built
differently. To convert from one to the other, it may be necessary to change
the complete solenoid including the core and solenoid base sub-assembly,
not just the solenoid. Consult ASCO.
Installation of Solenoid
Solenoids may be assembled as a complete unit. Tightening is accomplished
by means of a hex flange at the base of the solenoid.
Installation of Panel Mounted Solenoid (See Figure 1)
1. Disassemble solenoid following instruction under Solenoid Replacement
then proceed.
2. Install solenoid base sub-assembly through customer panel.
3. Position spring washer on opposite side of panel over solenoid base
sub-assembly.
4. Replace solenoid, nameplate/retainer and red cap.
5. Make electrical hookup, see Wiring section.
Solenoid Temperature
Standard solenoids are designed for continuous duty service. When the
solenoid is energized for a long period, the solenoid becomes hot and can be
touched by hand only for an instant. This is a safe operating temperature.
MAINTENANCE
WARNING: To prevent the possibility of death,
serious injury or property damage, turn off electrical
power, depressurize solenoid operator and/or valve,
and vent fluid to a safe area before servicing.
Cleaning
All solenoid operators and valves should be cleaned periodically. The time
between cleaning will vary depending on medium and service conditions. In
general, if the voltage to the solenoid is correct, sluggish valve operation,
excessive noise or leakage will indicate that cleaning is required. Clean
strainer or filter when cleaning the valve.
Preventive Maintenance
Keep the medium flowing through the solenoid operator or valve as free
from dirt and foreign material as possible.
While in service, the solenoid operator or valve should be operated at least
once a month to insure proper opening and closing.
Depending on the medium and service conditions, periodic inspection of
internal valve parts for damage or excessive wear is recommended.
Thoroughly clean all parts. Replace any worn or damaged parts.
Causes of Improper Operation
Faulty Control Circuit: Check the electrical system by energizing the
solenoid. A metallic click signifies that the solenoid is operating. Absence
of the click indicates loss of power supply. Check for loose or blown fuses,
open-circuited or grounded solenoid, broken lead wires or splice
connections.
Burned-Out Solenoid: Check for open-circuited solenoid. Replace if
necessary. Check supply voltage; it must be the same as specified on
nameplate/retainer and marked on the solenoid. Check ambient
temperature and check that the core is not jammed.
Low Voltage: Check voltage across the solenoid leads. Voltage must be at
least 85% of rated voltage.
Solenoid Replacement
1. Disconnect conduit, coil leads, and grounding wire.
NOTE: Any optional parts attached to the old solenoid must be reinstalled
on the new solenoid. For 3-way construction, piping or tubing must be
removed from pipe adapter.
2. Disassemble solenoids with optional features as follows:
Spade or Screw Terminals
Remove terminal connections, grounding screw, grounding wire, and
terminal block (screw terminal type only).
NOTE: For screw terminals, the socket head screw holding the terminal
block serves as a grounding screw.
Junction Box
Remove conduit and socket head screw (use 5/32 hex key wrench) from
center of junction box. Disconnect junction box from solenoid.
DIN Plug Connector
Remove center screw from DIN plug connector. Disconnect DIN plug
connector from adapter. Remove socket head screw (use 5/32 hex key
wrench), DIN terminal adapter, and gasket from solenoid.
3. Snap off red cap from top of solenoid base sub-assembly. For 3-way
construction with pipe adapter (Figure 3), remove pipe adapter,
nameplate and solenoid. Omit steps 4 and 5.
4. Push down on solenoid. Then using a suitable screwdriver, insert blade
between solenoid and nameplate/retainer. Pry up slightly and push to
remove.
NOTE: Series 8202G solenoids have a spacer between the nameplate/
retainer and solenoid.
5. Remove solenoid from solenoid base sub-assembly.
6. Reassemble in reverse order of disassembly. Use exploded views for
identification and placement of parts.
7. Torque pipe adapter to 90 inch-pounds maximum [10,2 Nm maximum].
Then make up piping or tubing to pipe adapter on solenoid.
Disassembly and Reassembly of Solenoids
1. Remove solenoid, see Solenoid Replacement.
2. Remove spring washer from solenoid base sub-assembly. For 3-way
construction, remove plugnut gasket.
3. Unscrew solenoid base sub-assembly from valve body.
4. Remove internal solenoid parts for cleaning or replacement. Use
exploded views for identification and placement of parts.
5. If the solenoid is part of a valve, refer to basic valve installation and
maintenance instructions for further disassembly.
6. Torque solenoid base sub-assembly and adapter to 175±25 in-lbs
[19,8±2,8 Nm].
ORDERING INFORMATION FOR ASCO SOLENOIDS
When Ordering Solenoids for ASCO Solenoid Operators or Valves, order
the number stamped on the solenoid. Also specify voltage and frequency.
Page 2 of 4
Form No.V6584R8
50 Hanover Road, Florham Park, New Jersey 07932 www.ascovalve.com
Torque Chart
Part Name
solenoid base sub-assembly & adapter
pipe adapter
Torque Value Inch-Pounds
175 ± 25
90 maximum
Remove red cap and
push solenoid down.
Then pry here to lift
nameplate/retainer
and push to remove.
Remove red cap and
push solenoid down.
Then pry here to lift
nameplate/retainer
and push to remove.
red cap
nameplate/
retainer
grounding wire green or green with
yellow stripes
solenoid
with 1/2 NPT
finger washer
.062 to .093 maximum
thickness of panel
for mounting
core
(AC)
Torque Value Newton-Meters
19,8 ± 2,8
10,2 maximum
0.69 diameter
mounting hole
core
(DC)
Side View
finger
washer
solenoid base
sub-assembly
Tapped hole in core
0.250-28 UNF-2B
0.63 minimum full thread (AC)
0.38 minimum full thread (DC)
collar to face
valve body
0.9375-26 UNS -2A
thread
Alternate
Construction
Panel Mount
Figure 1. Series 8003G solenoids
red cap
Remove red cap and
push solenoid down.
Then pry here to lift
nameplate/retainer
and push to remove.
nameplate/
retainer
pipe adapter
spacer
plugnut gasket
grounding wire green or green with
yellow stripes
solenoid
with 1/2 NPT
spring washer
solenoid base
sub-assembly
bonnet washer
core(small end up)
solenoid base gasket
plugnut assembly
cutaway view to
show positioning
of retainer in
gasket recess
Without
Adapter
retainer gasket
retainer
adapter
gasket
stem
disc
disc holder
assembly
disc spring
disc holder
spring
Figure 2. Series 8202G solenoids
adapter
Air Only Construction
Vent to Atmosphere
With
Adapter
Figure 3. 3-Way Construction
Form No.V6584R8
50 Hanover Road, Florham Park, New Jersey 07932 www.ascovalve.com
Page 3 of 4
Torque Chart
Part Name
terminal block screws
socket head screw
center screw
Torque Value in Inch-Pounds
10 ± 2
15 - 20
5±1
Open-Frame Solenoid
with Screw Terminals.
Socket head screw is
used for grounding.
Open-Frame Solenoid
with 1/4 Spade Terminals
See
torque chart
above
Open-Frame Solenoid
with DIN Terminals
screw terminal
adapter
Indicates parts supplied
in Termination Module
Kit No. K256104
terminal
block
screw
tapped hole for
#10-32 grounding screw
(not included)
Torque Value in Newton-Meters
1,1 ± 0,2
1,7 - 2,3
0,6 ± 0,1
gasket
DIN terminal
adapter
socket head
grounding screw
(5/32 hex key wrench)
socket head screw (5/32 hex key wrench)
Figure 4. Open-frame solenoids
Junction Box Solenoid
with 1/4 Spade Terminals
or Screw Terminals
screw terminal block
(see note)
cover screw
See
torque chart
above
cover
cover gasket
grounding screw
and cup washer
junction box gasket
Note:
Junction box with screw terminals
shown. With screw terminal
block removed, remaining parts
comprise the junction box for
spade terminal construction.
junction box with
1/2 conduit connection
and grounding terminal
socket head screw
(5/32 hex key wrench)
Figure 5. Junction box (optional feature)
Open-Frame Solenoid
with DIN Terminal
Plug Conector
DIN terminal
adapter
See
torque chart
above
connector
gland nut
gasket
gland gasket
socket head screw
(5/32 hex key wrench)
Notes:
1. Connector cover may be
rotated in 90 increments from
position shown for alternate
position of cable entry.
2. Refer to markings on DIN
connector for proper
electrical connections.
Page 4 of 4
Indicates that these parts are included
in DIN plug connector Kit No. K236034
gasket
DIN connector
terminal block
(see note 2)
washer
center screw
connector cover
(see note 1)
Figure 6. DIN plug connector kit No. K236034 (optional feature)
50 Hanover Road, Florham Park, New Jersey 07932 www.ascovalve.com
Form No.V6584R8
Instruction Manual
Form 5252
627 Series
Incorporates Errata dated January 2001
07/89
627 Series Pressure Reducing Regulators
Description
Introduction
Scope of Manual
This manual provides instructions for the installation,
adjustment, maintenance, and parts ordering for the
627 Series regulators. These regulators usually are
shipped separate for line installation, although sometimes they are shipped installed on other equipment.
Refer to the instruction manual for the other equipment
for installation and operating instructions.
The 627 Series self-operated pressure reducing regulators (figure 1) are for high and low pressure systems.
These regulators can be used with natural gas, air, or a
variety of other gases. Performance characteristics
vary according to construction (see the AVAILABLE
CONFIGURATIONS specification in table 1).
Specifications
Table 1 gives some general specifications for the 627
Series regulators. The nameplates (figure 2) gives
detailed information for a particular regulator as it
comes from the factory.
NUMBER 1
10B3679-D
W4793
NUMBER 2
Figure 2. Nameplates
D101328X012
Figure 1. Typical 627 Series Self-Operated
Pressure Reducing Regulator
Regulators
www.FISHERregulators.com
627 Series
Table 1. Specifications
Available Constructions
Type 627: Self-operated pressure reducing regulator
equipped with a pitot tube for greater regulated
capacities (figure 7)
Type 627R: Type 627 with internal relief and with an
open throat (figure 8)
Type 627M: Type 627 with a stem seal between the
body outlet pressure and diaphragm case. Pressure
is measured under the diaphragm through the
1/4-inch NPT downstream control line connection
(figure 9)
Type 627MR: Type 627M with internal relief (figure 10)
Type 627H: Type 627 with a diaphragm limiter to
deliver a higher outlet pressure (figure 11)
Type 627HM: Type 627H with a stem seal between
the body outlet pressure and diaphragm case.
Pressure is measured under the diaphragm through
two 1/4-inch NPT downstream control line
connections (figure 12)
Body Sizes
3/4, 1, or 2-inch
End Connection Styles
3/4, 1, or 2-inch body sizes: NPT
1 or 2-inch body sizes: ANSI Class 300 or 600 RF
flanged
Maximum Inlet Pressure(1) (Body Rating)
2000 psig (138 bar) for NPT steel, 1480 psig
(102 bar) for RF flanged steel, or 1000 psig (69 bar)
for ductile iron
Maximum Valve Disk Inlet Pressure Rating(1)
2000 psig (138 bar) for nylon disk or 1000 psig (69
bar) for nitrile disk
Maximum Operating Inlet Pressure, Pressure
Differential, and Outlet Pressure Ranges(1)
See table 2 for pressures by port and spring range
Maximum Spring and Diaphragm Casing Pressure(1)
Maximum Body Outlet Pressure(1) (Type 627M,
627MR, and 627HM Only)
2000 psig (138 bar) for screwed steel, 1480 psig
(102 bar) for RF flanged steel, or 1000 psig (69 bar)
for ductile iron. (Type 627 and 627R are limited by
maximum diaphragm casing pressure)
Port Diameters
See table 2
Internal Relief Performance
Type 627R: See table 4
Type 627MR: Limited by field-installed control line
piping
Temperature Capabilities(1)
-20 to 180°F (-29 to 82°C)
Pressure Registration
Type 627, 627H or 627R: Internal
Type 627M, 627HM or 627MR: External through
1/4-inch NPT control line connection in the
diaphragm casing
De-Icer System
See figure 3 and Type 627M Regulator De-Icer
System Application section
Relief Indicator
For 627R and 627MR (see figures 8 and 9)
Spring Case Vent Connection
3/4-inch NPT female with removable screened vent
assembly
Control Line Connection (Type 627M, 627HM or
627MR Only)
1/4-inch NPT female
Approximate Weight
Ductile Iron or Steel Casings: 10 pounds (4,5 kg)
Aluminum Casings: 6.3 pounds (2.8 kg)
See table 3
1. The pressure/temperature limits in this instruction manual or any applicable standard limitation should not be exceeded.
2
627 Series
Table 2. Maximum Inlet Pressures, Differential Pressures, and Outlet Pressure Ranges
TYPE
NUMBER
OUTLET PRESSURE RANGE,
SPRING PART NUMBER,
AND COLOR
5(2) to 20 psig
(0,34 to 1,4 bar)
10B3076X012
Yellow
15 to 40 psig
(1,0 to 2,8 bar)
627
and
627M(3)
10B3077X012
Green
35 to 80 psig
(2,4 to 5,5 bar)
10B3078X012
Blue
70 to 150 psig
(4,8 to 10,3 bar)
10B3079X012
Red
5(2) to 20 psig
(0,34 to 1,4 bar)
10B3076X012
Yellow
15 to 40 psig
(1,0 to 2,8 bar)
627R
and
627MR
10B3077X012
Green
35 to 80 psig
(2,4 to 5,5 bar)
10B3078X012
Blue
70 to 150 psig
(4,8 to 10,3 bar)
10B3079X012
Red
140 to 250 psig
(9,7 to 17,2 bar)
627H
and
627MH(3)
10B3078X012
Blue
240 to 500 psig
(16,5 to 34,5 bar)
10B3079X012
Red
ORIFICE SIZE,
INCHES (mm)
MAXIMUM INLET
PRESSURE,
PSIG (bar)
MAXIMUM DIFFERENTIAL
PRESSURE, PSID (bar)
3/32
1/8
3/16
1/4
3/8
1/2
(2,4)
(3,2)
(4,8)
(6,4)
(9,5)
(12,7)
2000
1000
750
500
300
250
(138)(1)
(69)(1)
(51,7)
(34,5)
(20,7)
(17,2)
2000
1000
750
500
300
250
(138)(1)
(69)(1)
(51,7)
(34,5)
(20,7)
(17,2)
3/32
1/8
3/16
1/4
3/8
1/2
(2,4)
(3,2)
(4,8)
(6,4)
(9,5)
(12,7)
2000
1500
1000
750
500
300
(138)(1)
(103)(1)
(69)(1)
(51,7)
(34,5)
(20,7)
2000
1500
1000
750
500
300
(138)(1)
(103)(1)
(69)(1)
(51,7)
(34,5)
(20,7)
3/32
1/8
3/16
1/4
3/8
1/2
(2,4)
(3,2)
(4,8)
(6,4)
(9,5)
(12,7)
2000
2000
1750
1500
1000
750
(138)(1)
(138)(1)
(121)(1)
(103)(1)
(69)(1)
(51,7)
2000
2000
1750
1500
1000
750
(138)(1)
(138)(1)
(121)(1)
(103)(1)
(69)(1)
(51,7)
3/32
1/8
3/16
1/4
3/8
1/2
(2,4)
(3,2)
(4,8)
(6,4)
(9,5)
(12,7)
2000
2000
2000
1750
1250
750
(138)(1)
(138)(1)
(138)(1)
(121)(1)
(86,2)(1)
(51,7)
2000
2000
2000
1750
1250
750
(138)(1)
(138)(1)
(138)(1)
(121)(1)
(86,2)(1)
(51,7)
3/32
1/8
3/16
1/4
3/8
1/2
(2,4)
(3,2)
(4,8)
(6,4)
(9,5)
(12,7)
2000
1000
750
500
300
200
(138)(1)
(69)(1)
(51,7)
(34,5)
(20,7)
(13,8)
2000
1000
750
500
300
200
(138)(1)
(69)(1)
(51,7)
(34,5)
(20,7)
(13,8)
3/32
1/8
3/16
1/4
3/8
1/2
(2,4)
(3,2)
(4,8)
(6,4)
(9,5)
(12,7)
2000
1500
1000
750
300
200
(138)(1)
(103)(1)
(69)(1)
(51,7)
(20,7)
(13,8)
2000
1500
1000
750
300
200
(138)(1)
(103)(1)
(69)(1)
(51,7)
(20,7)
(13,8)
3/32
1/8
3/16
1/4
3/8
1/2
(2,4)
(3,2)
(4,8)
(6,4)
(9,5)
(12,7)
2000
1750
1000
750
300
200
(138)(1)
(121)(1)
(69)(1)
(51,7)
(20,7)
(13,8)
2000
1750
1000
750
300
200
(138)(1)
(121)(1)
(69)(1)
(51,7)
(20,7)
(13,8)
3/32
1/8
3/16
1/4
3/8
1/2
(2,4)
(3,2)
(4,8)
(6,4)
(9,5)
(12,7)
2000
1000
500
300
200
200
(138)(1)
(69)(1)
(34,5)
(20,7)
(13,8)
(13,8)
2000
1000
500
300
200
200
(138)(1)
(69)(1)
(34,5)
(20,7)
(13,8)
(13,8)
3/32
1/8
3/16
1/4
3/8
1/2
(2,4)
(3,2)
(4,8)
(6,4)
(9,5)
(12,7)
2000
2000
1750
1500
1000
750
(138)(1)
(138)(1)
(121)(1)
(103)(1)
(69)(1)
(51,7)
2000
2000
1750
1000
500
250
(138)(1)
(138)(1)
(121)(1)
(69)(1)
(34,5)
(17,2)
3/32
1/8
3/16
1/4
3/8
1/2
(2,4)
(3,2)
(4,8)
(6,4)
(9,5)
(12,7)
2000
2000
1750
1500
1000
750
(138)(1)
(138)(1)
(121)(1)
(103)(1)
(69)(1)
(51,7)
2000
2000
1750
1000
500
250
(138)(1)
(138)(1)
(121)(1)
(69)(1)
(34,5)
(17,2)
1. For inlet pressure in excess of 1000 psig (69 bar), refer to the maximum body and disk pressure ratings in the specification table.
2. For pressure settings under 10 psig (0,69 bar), inlet pressure should be limited to approximately 100 psig (6,9 bar) so the setpoint adjustment can be obtained.
3. The unbalance forces change from the wide-open monitor mode to an active regulator mode such that the Type 627M or 627MH should have a 3/8-inch (9,5 mm) or larger orifice
when used as a wide-open monitor.
3
627 Series
Table 3. Maximum Spring and Diaphragm Casing Pressure(1)
SPRING AND
DIAPHRAGM
CASING STYLE
TYPE 627,
PSIG (bar)
TYPE 627R,
PSIG (bar)
Maximum pressure to spring and diaphragm
casings to prevent
leak to atmosphere other than relief action
(internal par ts damage may occur)
Die cast aluminum
250 (17,2)
250 (17,2)
Die cast aluminum
250 (17,2)
250 (17,2)
250 (17,2)
Steel
250 (17,2)
250 (17,2)
250 (17,2)
Maximum pressure to spring and diaphragm
casings to prevent burst of casings during
abnormal operation (leak to atmosphere and
internal par ts damage may occur)
Die cast aluminum
375 (25,9)
375 (25,9)
MAXIMUM PRESSURE DESCRIPTION
Maximum diaphragm casing over pressure (above
setpoint) to prevent damage to internal par ts
TYPE 627M,
PSIG (bar)
TYPE
627MR,
PSIG (bar)
TYPE 627H
AND 627HM,
PSIG (bar)
Not Available Not Available Not Available
Not Available Not Available
250 (17,2)
800 (55,2)
Not Available Not Available Not Available
Ductile iron
465 (32)
465 (32)
465 (32)
465 (32)
Not Available
Steel
1500 (103)
1500 (103)
1500 (103)
1500 (103)
1500 (103)
All styles
60 (4,1)
120 (8,3)
60 (4,1)
120 (8,3)
120 (8,3)
1. If the spring case is pressurized, a metal adjusting screw cap is required. Contact your Fisher Sales Representative.
Personal injury, property damage, equipment damage, or leakage due to escaping
gas or bursting of pressure-containing
parts may result if this regulator is overpressured or is installed where service
conditions could exceed the limits given
in tables 1, 2, 3, and 4, or where conditions exceed any ratings of the adjacent
piping or piping connections.
To avoid such injury or damage, provide
pressure-relieving or pressure-limiting
devices (as required by the appropriate
code, regulation, or standard) to prevent
service conditions from exceeding those
limits. The Type 627R or 627MR regulator
with internal relief will provide downstream overpressure protection within the
limits given in tables 1, 2, 3 and 4. If these
limits are exceeded additional downstream overpressure protection must be
provided by the user.
Additionally, physical damage to the
regulator could cause personal injury or
property damage due to escaping gas. To
avoid such injury or damage, install the
regulator in a safe location.
Like most regulators, 627 Series regulators have outlet
pressure ratings that are lower than their inlet pressure
ratings. A pressure relieving or pressure limiting device
must be provided by the user for the Type 627, 627H,
627M, and 627HM regulators if the inlet pressure can
exceed the outlet pressure rating, since these regulators do not have internal relief.
Type 627R regulators provide internal relief which limits
the total outlet pressure buildup over setpoint. Use table
4 to determine the total outlet pressure. This internal
relief may be adequate for the application, if not,
provide additional pressure relief or a pressure limiting
device downstream.
Note
If the regulator is shipped mounted on
another unit, install that unit according to
the appropriate instruction manual.
Perform steps 1 through 6 for all types of regulators:
1. Only personnel qualified through training and
experience should install, operate, or maintain this
regulator.
2. For a regulator that is shipped separately, make
sure that there is no damage to, or foreign material in,
the regulator.
Installation
3. Ensure that all tubing and piping have been blown
free of foreign debris.
Regulator operation within ratings does not preclude the
possibility of damage from debris in the lines or from
external sources. A regulator should be inspected for
damage periodically and after any overpressure condition. Key numbers referenced in this section are shown
in figures 7 through 12. Ensure that the operating temperature capabilities listed in table 1 are not exceeded.
4. The regulator may be installed in any position as
long as the flow through the body is in the direction
indicated by the arrow cast on the body.
4
5. If continuous operation is required during inspection
or maintenance, install a three-valve bypass around the
regulator.
627 Series
Figure 3. Schematic of De-Icer System
connected to a straight section of outlet piping 10
diameters downstream of the regulator.
A regulator may vent some gas to the
atmosphere. In hazardous or flammable
gas service, vented gasmay accumulate
and cause personal injury, death, or
property damage due to fire or explosion.
Vent a regulator in hazardousgas service
toa remote, safe location away from air
intakes or any hazardous area. The vent
line or stack opening must be protected
against condensation or clogging.
6. Position the body (key 1) and/or diaphragmspring
case (key 29) so it will not collectmoisture or debris into
the screened vent. If the regulator requires repositioning, refer to the body area maintenance procedures
and/or the diaphragm case area maintenance procedures in the Maintenance section to reposition the
screened vent for the application.
9. A hand valve should be installed in the control line.
This hand valve can be used to throttle down and
dampen outlet pulsations in control pressure which may
cause unstability or cycling of the regulator.
Remote Vent Line Installation
All 627 series regulators have a vent assembly installed
in the 3/4-inch NPT spring case vent opening. The vent
assembly can be removed to install a remote vent line if
necessary. Remote vent lines must have the largest
practical diameter. The vent line should be as short as
possible with a minimum number of bends or elbows.
Protect the remote vent opening against entrance of
rain, snow, or any other foreign material that may plug
the vent or vent line and prevent proper operation of the
regulator. Periodically check the vent opening to be sure
it is not plugged with foreign debris.
Perform steps 7 through 9 for Types 627M, 627HM,
and 627MR regulators only:
7. A Type 627M, 627HM, or 627MR regulator requires
a downstream control line. Install the control line before
putting the regulator into operation.
8. Ensure that the downstream control line piping is at
least 3/8-inch or larger outside diameter tubing and
Type 627M or 627HM Regulator DeIcer System Application
For the Type 627M or 627HM regulator de-icer system,
refer to the application shown in figure 3. With a large
pressure drop across the working regulator, ice can
5
627 Series
Table 4. Type 627R Internal Relief Performance(1)
OUTLET
MAXIMUM
OUTLET
PRESSURE
ALLOWABLE
PRESSURE
RANGE, SPRING
DOWNSTREAM
SETTING,
PART NUMBER,
SYSTEM PRESSURE,
PSIG (bar)
AND COLOR
PSIG (bar)
Orifice Size, Inches (mm)
3/8 (9,5)
1/2 (12,7)
10 (0,69)
60 (4,1)
100 (6,9)
125 (8,6)
175 (12,1)
200 (13,8)
250 (17,2)
1250
2000
2000
2000
2000
2000
(86,2)
(138)
(138)
(138)
(138)
(138)
740 (51,1)
1500 (103)
1900 (131)
2000 (138)
2000 (138)
2000 (138)
320 (22,1)
620 (42,7)
830 (57,2)
1100 (75,8)
1300 (89,6)
1600 (110)
190
390
480
670
770
960
(13,1)
(26,9)
(33,1)
(46,2)
(53,1)
(66,2)
95 (6,56)
180 (12,4)
220 (15,2)
320 (22,1)
360 (24,8)
450 (31,0)
75 (5,18)
130 (8,97)
160 (11,0)
220 (15,2)
260 (17,9)
320 (22,1)
15 (1,0)
60 (4,1)
100 (6,9)
125 (8,6)
175 (12,1)
200 (13,8)
250 (17,2)
1000
2000
2000
2000
2000
2000
(69,0)
(138)
(138)
(138)
(138)
(138)
620 (42,7)
1400 (96,5)
1900 (131)
2000 (138)
2000 (138)
2000 (138)
260 (17,9)
610 (42,1)
810 (55,8)
1100 (75,8)
1300 (89,6)
1600 (110)
170
370
480
670
770
960
(11,7)
(25,5)
(33,1)
(46,2)
(53,1)
(66,2)
90
170
220
320
360
450
70
130
160
220
260
320
20 (1,4)
60 (4,1)
100 (6,9)
125 (8,6)
175 (12,1)
200 (13,8)
250 (17,2)
850 (58,6)
2000 (138)
2000 (138)
2000 (138)
2000 (138)
2000 (138)
490 (33,8)
1300 (89,6)
1800 (124)
2000 (138)
2000 (138)
2000 (138)
210 (14,5)
600 (41,4)
800 (55,2)
1100 (75,8)
1300 (89,6)
1600 (110)
130 (9,0)
360 (24,8)
480 (33,1)
670 (46,2)
770 (53,1)
960 (66,2)
80 (5,52)
170 (11,7)
220 (15,2)
320 (22,1)
360 (24,8)
450 (31,0)
65 (4,49)
120 (8,28)
160 (11,0)
220 (15,2)
260 (17,9)
320 (22,1)
15 (1,0)
60 (4,1)
100 (6,9)
125 (8,6)
175 (12,1)
200 (13,8)
250 (17,2)
1000
2000
2000
2000
2000
2000
(69,0)
(138)
(138)
(138)
(138)
(138)
380 (26,2)
1300 (89,6)
1800 (124)
2000 (138)
2000 (138)
2000 (138)
210 (14,5)
590 (40,7)
800 (55,2)
1100 (75,8)
1300 (89,6)
1600 (66,2)
130
350
470
640
780
960
80
170
220
320
370
450
( 5,5)
(11,7)
(15,2)
(22,1)
(25,5)
(31,0)
65 (4,49)
120 (8,28)
160 (11,0)
220 (15,2)
260 (17,9)
320 (22,1)
20 (1,4)
60 (4,1)
100 (6,9)
125 (8,6)
175 (12,1)
200 (13,8)
250 (17,2)
630 (43,4)
2000 (138)
2000 (138)
2000 (138)
2000 (138)
2000 (138)
200 (13,8)
1200 (82,7)
1700 (117)
2000 (138)
2000 (138)
2000 (138)
150 (10,3)
550 (37,9)
760 (52,4)
1100 (75,8)
1300 (89,6)
1600 (66,2)
100 (6,9)
330 (22,8)
450 (31,1)
630 (43,4)
770 (53,1)
960 (66,2)
70 ( 4,83)
160 (11,0)
210 (14,5)
320 (22,1)
360 (24,8)
460 (31,7)
65 (4,49)
120 (8,28)
160 (11,0)
220 (15,2)
260 (17,9)
320 (22,1)
30 (2,1)
100 (6,9)
125 (8,6)
175 (12,1)
200 (13,8)
250 (17,2)
2000
2000
2000
2000
2000
(138)
(138)
(138)
(138)
(138)
950 (65,5)
1500 (103)
2000 (138)
2000 (138)
2000 (138)
450 (31,1)
670 (46,2)
1000 (69,0)
1200 (82,7)
1600 (110)
260
400
610
760
970
(17,9)
(27,6)
(42,1)
(52,4)
(66,9)
140
190
300
360
460
(9,66)
(13,1)
(20,7)
(24,8)
(31,7)
110
150
220
260
320
(7,59)
(10,3)
(15,2)
(17,9)
(22,1)
40 (2,8)
100 (6,9)
125 (8,6)
175 (12,1)
200 (13,8)
250 (17,2)
1500
2000
2000
2000
2000
(103)
(138)
(138)
(138)
(138)
700 (48,3)
1300 (89,6)
1800 (124)
2000 (138)
2000 (138)
330 (22,8)
560 (38,6)
1000 (69,0)
1200 (82,7)
1600 (110)
200
340
550
730
970
(13,8)
(23,4)
(37,9)
(50,3)
(66,9)
120
180
290
350
460
(8,28)
(12,4)
(20,0)
(24,1)
(31,7)
108
140
220
250
320
(7,45)
(9,66)
(15,2)
(17,2)
(22,1)
5(3) to 20 psig
(0,34 to 1,4 bar)
10B3076X012
Yellow
15 to 40 psig
(1,0 to 2,8 bar)
MAXIMUM INLET PRESSURE TO KEEP MAXIMUM ALLOWABLE DOWNSTREAM
SYSTEM PRESSURE FROM BEING EXCEEDED, PSIG (bar)(2)
10B3077X012
Green
3/32 (2,4)
form with in this regulator. The formation of ice decreases the size of the port opening, so the regulator is
unable to supply enough flow to satisfy the downstream
demand. When the downstream pressure falls below the
outlet pressure setting of the Type 627M or 627HM
regulator, the disk assembly of the Type 627Mor
627HMregulator moves off its seat ring, permitting
alcohol to flow into the main gas line. The alcohol
carried to the main regulator by the flow stream prevents additional ice from forming on the seat ring. When
normal flow resumes, and as pressure in the downstream system is restored, the Type 627M or 627HM
regulator shuts off.
6
1/8 (3,2)
3/16 (4,8)
1/4 (6,4)
(8,97)
(24,1)
(32,4)
(44,1)
(53,8)
(66,2)
(6,2)
(11,7)
(15,2)
(22,1)
(24,8)
(31,0)
(4,8)
(8,97)
(11,0)
(15,2)
(17,9)
(22,1)
Startup and Adjustment
Startup
To avoid personal injury or property damage due to explosion or damage to regulator or downstream components during
startup, release downstream pressure to
prevent an overpressure condition on the
diaphragm of the regulator.
627 Series
Table 4. Type 627R Internal Relief Performance(1) (continued)
OUTLET
PRESSURE
RANGE, SPRING
PART NUMBER,
AND COLOR
MAXIMUM
OUTLET
ALLOWABLE
PRESSURE
DOWNSTREAM
SETTING,
SYSTEM PRESSURE,
PSIG (bar)
PSIG (bar)
MAXIMUM INLET PRESSURE TO KEEP MAXIMUM ALLOWABLE DOWNSTREAM
SYSTEM PRESSURE FROM BEING EXCEEDED, PSIG (bar)(2)
Orifice Size, Inches (mm)
3/32 (2,4)
1/8 (3,2)
3/16 (4,8)
1/4 (6,4)
3/8 (9,5)
1/2 (12,7)
40 (2,8)
125 (8,6)
150 (10,3)
175 (12,1)
200 (13,8)
250 (17,2)
2000
2000
2000
2000
2000
(138)
(138)
(138)
(138)
(138)
1100
1600
2000
2000
2000
(75,8)
(110)
(138)
(138)
(138)
500 (34,5)
750 (51,7)
980 (67,6)
1200 (82,7)
1600 (110)
300
440
580
720
940
(20,7)
(30,3)
(40,0)
(49,6)
(64,8)
170
230
290
340
450
(11,7)
(15,9)
(20,0)
(23,4)
(31,0)
140
180
220
250
320
(9,66)
(12,4)
(15,2)
(17,2)
(22,1)
50 (3,4)
125 (8,6)
150 (10,3)
175 (12,1)
200 (13,8)
250 (17,2)
1400
2000
2000
2000
2000
(96,5)
(138)
(138)
(138)
(138)
820 (56,5)
1400 (96,5)
1900 (131)
2000 (138)
2000 (138)
400 (27,6)
650 (44,8)
700 (48,3)
1100 (75,8)
1500 (103)
230
370
530
670
920
(15,9)
(25,5)
(36,5)
(46,2)
(63,4)
150
210
270
330
430
(10,3)
(14,5)
(18,6)
(22,8)
(29,6)
140
170
210
240
320
(9,66)
(11,7)
(14,5)
(16,5)
(22,1)
60 (4,1)
125 (8,6)
150 (10,3)
175 (12,1)
200 (13,8)
250 (17,2)
900 (62,1)
1700 (117)
2000 (138)
2000 (138)
2000 (138)
450 (31,1)
1100 (75,8)
1700 (117)
2000 (138)
2000 (138)
270 (18,6)
540 (37,2)
780 (53,8)
1000 (69,0)
1400 (96,5)
190
300
470
610
880
(13,1)
(20,7)
(32,4)
(42,1)
(60,7)
140
190
250
310
420
(9,66)
(13,1)
(17,2)
(21,4)
(29,0)
130
160
200
230
310
(8,97)
(11,0)
(13,8)
(15,9)
(21,4)
70 (4,8)
150
175
200
250
(10,3)
(12,1)
(13,8)
(17,2)
1200
2000
2000
2000
(82,7)
(138)
(138)
(138)
850 (58,6)
1400 (96,5)
2000 (138)
2000 (138)
430 (29,6)
670 (46,2)
920 (63,4)
1300 (89,6)
250
400
550
830
(17,2)
(27,6)
(37,9)
(57,2)
170
230
280
400
(11,7)
(15,9)
(19,3)
(27,6)
160
190
230
310
(11,0)
(13,1)
(15,9)
(21,4)
80 (5,5)
150
175
200
250
(10,3)
(12,1)
(13,8)
(17,2)
800 (55,2)
1500 (103)
2000 (138)
2000 (138)
500 (34,5)
1200 (82,7)
1700 (117)
2000 (138)
300 (20,7)
550 (37,9)
800 (55,2)
1200 (82,7)
200
330
480
770
(13,8)
(22,8)
(33,1)
(53,1)
160
210
270
390
(11,0)
(14,5)
(18,6)
(26,9)
150
190
220
300
(10,3)
(13,1)
(15,2)
(20,7)
70 (4,8)
175 (12,1)
200 (13,8)
250 (17,2)
1900 (131)
2000 (138)
2000 (138)
600 (41,4)
1200 (82,7)
2000 (138)
400 (27,6)
630 (43,4)
1100 (75,8)
260 (17,9)
380 (26,2)
680 (46,9)
200 (13,8)
250 (17,2)
360 (24,8)
175 (12,1)
210 (14,5)
290 (20,0)
70 to 150 psig
(4,8 to 10,3 bar)
80 (5,5)
175 (12,1)
200 (13,8)
250 (17,2)
1400 (96,5)
2000 (138)
2000 (138)
250 (17,2)
960 (66,2)
2000 (138)
240 (16,5)
520 (35,9)
1000 (69,0)
200 (13,8)
330 (22,8)
620 (42,7)
190 (13,1)
240 (16,5)
350 (24,1)
175 (12,1)
210 (14,5)
280 (19,3)
10B3079X012
Red
100 (6,9)
200 (13,8)
250 (17,2)
1500 (103)
2000 (138)
250 (17,2)
1600 (110)
240 (16,5)
770 (53,1)
230 (15,9)
520 (35,9)
210 (14,5)
320 (22,1)
210 (14,5)
270 (18,6)
125 (8,6)
250 (17,2)
2000 (138)
1000 (69,0)
500 (34,5)
390 (26,9)
290 (20,0)
260 (17,9)
150 (10,3)
250 (17,2)
1200 (82,7)
260 (17,9)
260 (17,9)
260 (17,9)
260 (17,9)
260 (17,9)
35 to 80 psig
(2,4 to 5,5 bar)
10B3078X012
Blue
1. The internal relief performance values are obtained by removing the disk assembly.
2. For inlet pressures in excess of 1000 psig (69 bar), refer to the maximum body and disk pressure ratings in the specifications table.
3. For pressure settings under 10 psig (0,69 bar), inlet pressure should be limited to approximately 100 psig (6,9 bar) so the setpoint adjustment can be obtained.
- Shaded areas indicate maximum inlet pressures allowed during system malfunction only. Table 6 gives the maximum inlet pressure for normal regulator operation.
In order to avoid an overpressure condition and possible equipment damage,
pressure gauges should always be used
to monitor pressures during startup.
1. Slowly open the upstream shutoff valve.
2. Slowly open the downstream shutoff valve.
3. Check all connections for leaks.
4. Make final control spring adjustments according to
the adjustment procedures.
Adjustment
The range of allowable pressure settings is marked on
the nameplate (figure 2). If a pressure setting beyond
this range is necessary, substitute the appropriate
regulator control spring. Change the nameplate to
indicate the new pressure range.
Before increasing the setting, refer to tables 2, 3, or 4.
Review the pressure limits for the control spring range
being used and be certain that the new pressure setting
will not result in an overpressure condition.
7
627 Series
Table 5. Maximum Torque Values
KEY NUMBER(1)
2
3
DESCRIPTION
MAXIMUM TORQUE, FOOT-POUNDS (N•m)
Seat ring
25
(34)
Cap screw (w/ aluminum diaphragm casing)
16
(22)
Cap screw (w/ ductile iron or steel diaphragm casing)
25
(34)
7
(9)
17
(23)
18
Lever cap screw
22
Diaphragm connector nut
26
Guide retainer (for Type 627R and 627MR only)
3
(4)
Spring case cap screw (w/ aluminum or ductile iron diaphragm casing)
7
(9)
35
(47)
7
(9)
14
(19)
37
46
Spring case cap screw (w/ steel diaphragm casing)
Diaphragm cap screw (w/Type 627 or 627M)
Diaphragm cap screw (w/Type 627H or 627MH)
1. Refer to figures 7 through 10 for key number locations.
Note
Always use a pressure gauge to monitor
pressure when making adjustments.
Refer to figures 7 through 12 for key number locations.
1. Remove the adjusting screw cap (key 36).
2. Loosen the locknut (key 34).
3. Increase the outlet pressure setting by turning the
adjusting screw (key 35) clockwise. Decrease the outlet
pressure setting by turning the adjusting screw counterclockwise.
4. When the desired pressure is obtained, hold the
adjusting screw (key 35) in place and tighten the
locknut (key 34).
Shutdown
To avoid personal injury or property damage due to explosion or damage to regulator or downstream components during
shutdown, release downstream pressure to
prevent an overpressure condition on the
diaphragm of the regulator.
1. Close the nearest upstream shutoff valve.
2. Close the nearest downstream shutoff valve.
8
3. Open the vent valve between the regulator and the
downstream shutoff valve nearest to it.
4. For a Type 627, 627H, or 627R regulator, the
regulator will open to release pressure between the
upstream shutoff valve and the regulator.
5. A Type 627M, 627HM, or 627MR regulator requires
venting the control line and downstream pressure from
the regulator before maintenance. The pressure between
these shutoff valves is released through the open
regulator because the disk assembly remains open in
response to the decrease in control line pressure.
Maintenance
Unless otherwise specified, the following maintenance
procedures apply to all types of regulators. For a
summary of maximum torque values required for all
types of regulators, refer to table 5.
Due to normal wear, damage from external sources, or
debris in the air or gas line, regulator parts such as the
disk assembly, seat ring, and diaphragm must be
inspected periodically and replaced as necessary to
ensure correct performance. The frequency of inspection and replacement depends upon the severity of
conditions and the requirements of state and federal
laws. Normal wear of the seat ring and disk assembly is
accelerated with high pressure drops and with large
amounts of impurities in the flow stream. Instructions
are given below for replacing the disk assembly, seat
ring, diaphragm, and O-rings. These procedures may
also be used for disassembly required for inspection
and replacement of other parts.
627 Series
Problem Indication for Type 627R and
627MR Regulators
Isolate the regulator from all pressure to
avoid personal injury and equipment
damage due to explosion or sudden
release of process pressure. Cautiously
release pressure from the regulator
before attempting disassembly.
The vent assembly is equipped with a relief indicator
(key 49, figure 4). The cap for the relief indicator snaps
over the vent assembly opening. If the relief valve
opens wide, exhaust gas pops the cap off the screen
vent assembly opening indicating a problem with the
regulator. If the cap pops off, refer to the shutdown and
to the body area maintenance procedures to inspect the
disk assembly and seat ring.
If the disk assembly and seat ring are not damaged,
refer to the diaphragm and spring case area maintenance procedures in this section.
The disk assembly and seat ring can be inspected,
removed, and replaced without removing the regulator
body from the line connections. Refer to the body area
maintenance procedures.
Body Area Maintenance Procedures
These procedures are for gaining access to the disk
assembly, seat ring, diaphragm casing O-ring and stem
assembly. All pressure must be released from the
diaphragm casing before the performing these steps.
While using the following procedures, refer to figures 7
through 12 for key number locations.
Replacing the Disk Assembly or Seat Ring
1. To inspect and replace the disk assembly (key 9) or
seat ring (key 2), remove the cap screws (key 3, figure
5), and separate the diaphragm casing (key 5) from the
body (key 1).
2. Inspect and, if necessary, remove the seat ring
(key 2). If removed, coat the threads of the replacement seat ring with lubricant (key 38) and torque to 25
foot-pounds (34 N•m).
3. Inspect the disk assembly and, if necessary,
remove the hair pin clip (key 13) that holds the disk
assembly (key 9) in place. If replacing the disk assembly is the only maintenance required, skip to step 16.
RELIEF
INDICATOR
CAP (KEY 49)
W4665*
Figure 4. Relief Indicator
Replacing the Stem Assembly
If it is necessary to perform maintenance on the stem
assembly, continue with steps 4 through 8 and 15
through 19 for Type 627, 627H, and 627R regulators, or
steps 9 through 19 for Type 627M, 627HM, and 627MR
regulators.
Perform steps 4 through 8 for Type 627, 627H, and
627R Regulators only:
4. ForType 627, 627H, and627R regulators (figure 5),
use steps 5 through 8 to remove and replace the stem
assembly.
5. Remove the boost body (key 6), stabilizer (key 7),
and stem guide (key 8) from the diaphragm casing (key
5). Unhook and remove the stem (key 10) from the
diaphragm casing (key 5).
6. Remove and inspect the diaphragm casing O-ring
(key 4, figure 7, 8, or 11) and replace it if necessary.
7. Apply lubricant (key 42) to a replacement diaphragm casing O-ring (key 4, figure 7, 8, or 11) and
install it onto the boost body (key 6). Skip to step 14.
8. For the Type 627 or 627H regulators, be sure to
insert the pitot tube (tab) into the outlet side of the body
(see figure 7 or 11). Skip to step 14.
Perform steps 9 through 19 for Type 627M, 627HM,
and 627MR Regulators only:
9. For Type 627M, 627HM, and 627MR regulators
(figure 5), use steps 10 through 14 to remove and
replace the stem assembly.
10. To remove the blocked throat (key 43), insert a
screw driver blade into the groove provided in the throat
and pry it out of the diaphragm casing (key 5). Inspect
and replace parts as necessary.
9
627 Series
LEVER
(KEY 15)
STEM BACKUP
RINGS
(KEY 12)
HAIR PIN CLIP
(KEY 13)
DIAPHRAGM CASING
O-RING (KEY 4)
STEM (KEY 10)
BODY
(KEY 1)
DISK
ASSEMBLY
(KEY 9)
STEM GUIDE
(KEY 8)
CAP SCREW
(KEY 3)
DIAPHRAGM
CASING (KEY 5)
STEM O-RING
(KEY 11)
W4792*
STABILIZER
(KEY 7)
BOOST BODY
(KEY 6)
PITOT TUBE
AND TAB FOR
TYPE 627 ONLY
SEAT RING
(KEY 2)
Type 627 and 627R
BLOCKED THROAT
BACKUP RINGS (KEY 45)
BLOCKED THROAT
(KEY 43)
BLOKED THROAT
O-RINGS (KEY 44)
W4791*
Type 627M amd 627MR
Figure 5. Stem Assemblies
11. Inspect and, if necessary, replace the blocked
throat O-rings (key 44, figure 5) and backup rings (key
45, figure 5).
12. Apply lubricant (key 42) to replacement blocked
throat O-rings (key 44) and backup rings (key 45).
19. It may be necessary to reposition the diaphragm
spring case to prevent rain, ice, and foreign debris from
entering the spring case. Refer to the diaphragm and
spring case area maintenance procedures, steps 1, 2,
and 21 through 25.
13. Apply lubricant (key 42) to the replacement stem
O-ring (key 11) and stem backup rings (key 12) and
install them on the stem (key 10).
Diaphragm and Spring Case Area Maintenance Procedures
14. For assembly, insert the stem (key 10) into the
diaphragm casing (key 5) and hook it on the lever (key
15).
These procedures are for gaining access to the control
spring, diaphragm assembly, and lever assembly. All
spring pressure must be released from the diaphragm
casing before these steps can be performed.
15. Insert parts into the diaphragm casing (key 5) that
were removed in steps 5 and 6 or step 10 (see figure 5).
16. Install the the disk assembly (key 9), line up the
hole in the disk assembly and stem (key 10) and insert
the hair pin clip (key 13).
17. Position the diaphragm casing plus attached parts
in relation to the body (key 1) so that they are correct
for the application.
18. Secure the diaphragm casing to the body with the
cap screws (key 3, figure 5). For an aluminum diaphragm casing (key 5), torque the cap screws (key 3)
to 16 foot-pounds (22 N•m). For ductile iron or steel
diaphragm casings, torque the cap screws (key 3) to 25
foot-pounds (34 N•m).
10
While using the following procedures, refer to figures 7
through 12 for key number locations.
1. Remove the adjusting screw cap (key 36), loosen
the lock nut, and turn the adjusting screw (key 35)
counterclockwise until all compression is removed from
the control spring (key 32).
2. Remove the spring case cap screws (key 37), the
nameplates, and lift off the spring case (key 29). If
changing the control spring (key 32) or repositioning the
spring case (key 29) is the only maintenance required,
install the replacement control spring or rotate the
spring case so it is correct for the application. Skip to
step 21. For diaphragm area maintenance, continue with
step 3.
627 Series
DIAPHRAGM
(KEY 23)
DIAPHRAGM
HEAD (KEY 24)
RELIEF VALVE O-RING
(KEY 28)
DIAPHRAGM CONNECTOR
NUT (KEY 22)
RELIEF VALVE
SPRING (KEY 27)
PUSTHER POST
(KEY 19)
GUIDE RETAINER
O-RING (KEY 48)
W4668*
RELIEF SEAL
RETAINER (KEY 47)
LOWER SPRING
SEAT (KEY 31)
DIAPHRAGM CONNECTOR
ASSEMBLY (KEY 21)
UPPER SPRING
SEAT (KEY 33)
GUIDE RETAINER
(KEY 26)
Type 627, 627R, 627M, or 627MR
DIAPHRAGM
(KEY 23)
PUSTHER POST
(KEY 19)
DIAPHRAGM LIMITER
O-RING (KEY 51)
DIAPHRAGM
LIMITER (KEY 50)
DIAPHRAGM
HEAD (KEY 24)
W5433-1*
PUSTHER POST
O-RING (KEY 52)
DIAPHRAGM
HEAD CAP
SCREW (KEY 46)
Type 627H amd 627HM
Figure 6. Diaphragm Assemblies
3. Remove the diaphragm limiter and O-ring (keys 50
and 51, on the Type 627H or 627HM only). Remove the
diaphragm assembly by tilting it so that the pusher post
(key 19) slips off the lever (key 15).
4. If it is necessary to replace the lever assembly,
remove the lever cap screws (key 18).
5. Install the replacement lever (key 15) into the lever
retainer (key 16) by inserting the lever pin (key 17).
Secure the lever assembly into the diaphragm casing
with the cap screws (key 18) and torque the cap screws
to 7 foot-pounds (9 N•m).
If it is necessary to perform maintenance on the
diaphragm assembly, continue with steps 6 through 11
and step 20 for Type 627, 627H, 627M, and 627HM
regulators, or steps 12 through 19 for Type 627R and
627MR regulators.
Perform steps 6 through 11 for Type 627, 627H,
627M, and 627HM Regulators only:
6. For Type 627, 627H, 627M, and 627HM regulators
(figures 5 & 6), use steps 7 through 11 to disassemble
and reassemble the diaphragm assembly.
7. Remove the diaphragm head cap screw (key 46),
lower spring seat (key 31,Type 627 or 627Monly), and
diaphragm head (key 24). On the Type 627H or 627HM,
remove the diaphragm cap screw O-rings (key 52).
Separate the diaphragm (key 23) from the pusher post
(key 19).
8. Install the diaphragm (key 23), in reverse order in
step 7, on the pusher post (key 19), insert and finger
tighten the diaphragm head cap screw (key 46).
9. Hook the pusher post on the lever (key 15), then
turn the diaphragm (key 23) to match the holes in the
diaphragm with the holes in the spring casing.
10. Unhook the pusher post from the lever and torque
the diaphragm head cap screw (key 46) to 7 footpounds (9 N•m) for the Type 627 or 627M. On the Type
627H or 627HM torque the diaphragm head cap screw
to 14 foot-pounds (18 N•m).
11. Hook the pusher post on the lever (key 15) and
check the hole alignment. If necessary, loosen the cap
screw (key 46) and reposition the diaphragm (key 23)
on the pusher post (key 19). Retorque the screw (see
step 10). Skip to step 20.
11
627 Series
Perform steps 12 through 19 for Type 627R and
627MR Regulators only:
12. For Type 627R and 627MR regulators (figure 6),
use steps 13 through 19 to disassemble and reassemble the diaphragm assembly:
24. Using a crisscross pattern, finish tightening the
spring case cap screws (key 37) to 7 foot-pounds (9
N•m) of torque.
25. If necessary, refer to the installation and/or the
startup and adjustment procedures.
13. Remove the guide retainer (key 26) and separate
the diaphragm parts. Refer to figure 6 for the sequence
of parts.
26. Install the adjusting screw cap (key 34) after
regulator adjustment.
14. To remove the diaphragm (key 23), remove the
diaphragm connector nut (key 22) and lift off the
diaphragm head (key 24) and diaphragm (key 23) from
the connector assembly (key 21). Do not attempt to
disassemble the connector assembly (key 21).
Parts Ordering
When corresponding with your Fisher sales office or
sales representative about this regulator, always
reference the type number which is found on the
nameplate (key 39, figures 7 through 12).
15. Position the replacement diaphragm (key 23) on
the connector assembly (key 21), install the diaphragm
head (key 24) and connector nut (key 22), then torque
to 17 foot-pounds (32 N•m).
When ordering replacement parts, reference the key
number of each needed part as found in the following
parts list.
16. If necessary, replace the guide retainer O-ring
(key 48) and, set the guide retainer (key 26) aside,
ready for assembly.
Parts List
Key
17. On the pusher post (key 19) install the relief seal
O-ring (key 28) and lubricate (key 42). Also, install the
relief seal retainer (key 47), diaphragm connector
assembly (key 21, with attached parts) relief spring
(key 27), upper relief spring seat (key 33), and guide
retainer (key 26). Torque the guide retainer (key 26) to 3
foot-pounds (4 N•m).
18. Hook the pusher post (with attached parts) on the
lever (key 15) to check the alignment of the holes in the
diaphragm with the holes in the spring casing. If the
holes do not line up, unhook the pusher post from the
lever, hold the pusher post, and rotate the diaphragm to
the correct position.
Type 627 Parts Kit with aluminum/nitrile trim
(includes keys 4, 9, 11, 12, and 23)
Type 627R Parts Kit with aluminum/nitrile trim
(includes keys 4, 9, 11, 12, 23, 28, and 48)
23. Screw in the adjustment screw to put slack into the
diaphragm (key 23).
1
2*
Body
Ductile iron
1000 psig (69 bar) max inlet pressure
3/4-inch NPT size
1-inch NPT size
2-inch NPT size
Steel
2000 psig (138 bar) max inlet pressure
3/4-inch NPT size
1-inch NPT size
2-inch NPT size
Steel, ANSI Class 600 RF flanged
1480 psig (102 bar) max inlet pressure
1-inch size
2-inch size
Seat ring
Aluminum
3/32-inch (2.4 mm) port diameter
1/8-inch (3.2 mm) port diameter
3/16-inch (4.8 mm) port diameter
1/4-inch (6.4 mm) port diameter
3/8-inch (9.5 mm) port diameter
1/2-inch (12.7 mm) port diameter
303 Stainless steel
3/32-inch (2.4 mm) port diameter
1/8-inch (3.2 mm) port diameter
3/16-inch (4.8 mm) port diameter
1/4-inch (6.4 mm) port diameter
3/8-inch (9.5 mm) port diameter
1/2-inch (12.7 mm) port diameter
*Recommended spare part.
12
R627X000A12
R627RX00A12
Type 627R Parts Kit with stainless steel/nitrile trim
(includes keys 4, 9, 11, 12, 23, 28, and 48)
R627RX00S12
20. Insert the diaphragm assembly into the diaphragm
casing (key 5) and hook the pusher post on the lever
(key 15).
22. Install the spring case (key 29) so that the
screened vent assembly (key 30) is in the correct
position for the application. Place the nameplates (key
39) over the screw holes, insert the spring case cap
screws (key 37), and finger tighten.
Part Number
Type 627 Parts Kit with stainless steel/nitrile trim
(includes keys 4, 9, 11, 12, and 23)
R627X000S12
19. Install the lower spring seat (key 31) over the relief
spring so it rests flat on the connector nut (key 22).
21. Install the control spring (key 32) and upper spring
seat (key 33), and apply lubricant (key 38) to the upper
spring seat (key 33).
Description
30B3046X012
30B3048X012
30B3096X012
30B3050X012
30B3051X012
30B7452X012
40B6754X012
40B6756X012
0R044109022
1A936709012
00991209012
0B042009012
0B042209012
1A928809012
0R044135032
1A936735032
00991235032
0B042035032
0B042235032
1A928835032
627 Series
Key
Description
Part Number
Key
Description
2*
Seat ring (continued)
316 Stainless steel, NACE(1) construction only
3/32-inch (2.4 mm) port diameter
0R0441X0012
1/8-inch (3.2 mm) port diameter
1A9367X0022
3/16-inch (4.8 mm) port diameter
009912X0012
1/4-inch (6.4 mm) port diameter
0B0420X0012
3/8-inch (9.5 mm) port diameter
0B0422X0012
1/2-inch (12.7 mm) port diameter
1A9288X0012
Cap Screw (not shown), (2 req’d)
Type 627 and 627R w/aluminum
diaphragm case, pl steel
18A1087X012
All Types w/ductile iron
diaphragm case, pl steel
1C403824052
or steel diaphragm case, pl steel
1C403024052
Diaphragm Case O-Ring (Type 627, 627H, or
627R only), nitrile
17A2325X022
Diaphragm Case
For Type 627 or 627R
Aluminum w/o 1/8-inch gauge tap
40B3084X012
Aluminum with 1/8-inch gauge tap
for Type 627 only
11B5380X012
Ductile iron w/o 1/8-inch gauge tap
30B3053X012
Ductile iron with 1/8-inch gauge tap
for Type 627 only
31B0641X012
Steel
30B3104X012
For Type 627M or 627MR
Ductile iron
39A5987X012
Steel
30B8734X012
For Type 627H, steel
30B3104X012
For Type 627HM, steel
30B8734X012
Boost Body (not for Type 627M, 627HM,
(2)
or 627MR), Delrin
For Type 627 or 627H
30B3056X012
For Type 627R
30B3057X012
Stabilizer (for Type 627, 627H, and 627R
only), nitrile
10B3060X012
Stem Guide (for Type 627, 627H, and 627R
only), powdered metal
20B3061X012
Disk Assembly (for all port diameters)
Aluminum holder and nitrile disk
1C4248X0212
303 Stainless steel holder and nitrile disk
1C4248X0202
Aluminum holder and nylon disk
1C4248X00A2
303 Stainless steel holder and nylon disk
1C4248X0062
NACE construction only
Aluminum holder and nitrile disk
1C4248X0212
316 Stainless steel holder and nitrile disk
1C4248X0252
Aluminum holder and nylon disk
1C4248X00A2
316 Stainless steel holder and nylon disk
1C4248X0262
Stem
303 stainless steel
10B3059X012
316 stainless steel (NACE)
10B3059X022
Stem O-Ring, nitrile
1D687506992
Stem Backup Ring, TFE (2 required)
1K786806992
Hair Pin Clip, stainless steel
10B3058X012
Drive Pin, plated steel
1A953228982
Lever, plated steel
20B3063X012
Lever Retainer, plated steel
30B3097X012
Lever Pin
Stainless steel
10B3083X012
316 stainless steel (NACE)
10B3083X022
Lever Cap Screw (2 required)
Plated steel
10B7454X012
316 stainless steel (NACE)
10B7454X022
Pusher Post, aluminum
For Type 627 or 627M
10B3098 X012
For Type 627R or 627MR
10B3098 X022
For Type 627H or 627HM,
416 stainless steel
10B3098 X032
Diaphragm Connector (for Type 627R
or 627MR only), stainless steel
10B6758X012
Diaphragm Connector Nut (for Type
627R or 627MR only), stainless steel
10B7449X012
Diaphragm, nitrile
For Type 627 or 627M w/aluminum or
ductile iron diaphragm case
10B3069X012
23*
Diaphragm, nitrile (continued)
For Type 627 or 627M w/steel
diaphragm case
For Type 627R or 627MR w/aluminum
or ductile iron diaphragm case
For Type 627R or 627MR w/steel
diaphragm case
For Type 627H or 627HM w/steel
diaphragm case (diaphragm is neoprene
with nylon fabric)
Diaphragm Head, plated steel
For Type 627 or 627M, plated steel
For Type 627R or 627MR, plated steel
For Type 627H or 627HM, 416 stainless steel
Relief Spring Seat (for Type 627R or
627MR only), steel
Guide Retainer (for Type 627R or
627MR only), stainless steel
Relief Spring (for Type 627R or 627MR
only), plated steel
Relief Seal O-Ring (for Type 627R or
627MR only), nitrile
Spring Case
For Type 627 or 627R
Aluminum
Ductile iron
Steel
For Type 627M or 627MR
Ductile iron
Steel
For Type 627H or 627HM
Steel
Screened Vent Assembly, plastic
Lower Spring Seat, plated steel
For Type 627 or 627M
For Type 627R or 627MR
Control Spring, pl steel
5 to 20 psig (0.34 to 1.4 bar), yellow
15 to 40 psig (1.0 to 2.8 bar), green
35 to 80 psig (2.4 to 5.5 bar), blue
70 to 150 psig (4.8 to 10.3 bar), red
140 to 250 psig range (9.6 to 17.2 bar),
blue, used in a Type 627H or 627HM
240 to 500 psig range (16.5 to 34.5 bar),
red, used in a Type 627H or 627HM
Upper Spring Seat, plated steel
Locknut, plated steel
Adjusting Screw, pl steel
For Type 627 or 627M
For Type 627H or 627HM
For Type 627R or 627MR
Adjusting Screw Cap, plastic
Spring Case Cap Screw, pl steel (8 required)
For aluminum or ductile iron diaphragm case
For steel diaphragm case
For Type 627H/HM, steel diaphragm case
Nameplate
Blocked Throat (for Type 627M, 627HM or
627MR only), stainless steel
Blocked Throat O-Ring (for Type 627M,
627HM, or 627MR only), nitrile (2 required)
Blocked Throat Backup Ring (for Type 627M,
627HM, or 627MR only), TFE (2 required)
Diaphragm Head Cap Screw, steel
For Type 627 or 627M
For Type 627H or 627HM
Relief Seal Retainer (for Type 627R or
627MR only), stainless steel
Guide Retainer O-Ring (for Type 627R
or 627MR only), nitrile
Relief Indicator (for Type 627R or
627MR only), rubber (not shown)
Diaphragm Limiter
Diaphragm Limiter O-Ring
Pusher Post O-Ring (2 required)
3
4*
5
6
7
8
9*
10
11*
12
13
14
15
16
17
18
19
21
22
23*
24
25
26
27
28*
29
30
31
32
33
34
35
36
37
39
43
44
45
46
47
48*
49
50
51*
52*
Part Number
10B8735X012
10B3068X012
10B8736X012
12B0178X012
1D666428982
10B3071X012
12B0175X012
10B7446X012
10B7450X012
10B6757X012
1J108506992
40B3086X012
30B3055X012
30B3102X012
30B3055X012
30B3102X012
30B3102X012
10B3093X012
1D666625072
20B3073X012
10B3076X012
10B3077X012
10B3078X012
10B3079X012
10B3078X012
10B3079X012
1D667125072
1D667728982
10B3081X012
10B3081X012
10B3080X012
20B3082X012
1A391724052
10B8737X012
1A346424052
----------10B3085X012
1E264306992
10B3106X012
1K920724052
1C379124052
10B7445X012
1D682506992
30B3100X012
22B0176X012
1K877606992
1C853806992
13
627 Series
30B3092-D
Figure 7. Type 627 Regulator Components
14
627 Series
30B3089-D
Figure 8. Type 627R Regulator Components
15
627 Series
30B6433-C
1/4-INCH NPT
CONNECTION
Figure 9. Type 627M Regulator Components
16
627 Series
1/4-INCH NPT
CONNECTION
30B6434-D
Figure 10. Type 627MR Regulator Components
17
627 Series
31B5374-B
Figure 11. Type 627H Regulator Components
18
627 Series
31B9872-B
Figure 12. Type 627HM Regulator Components
19
627 Series
January 2001
Errata Sheet
for
627 Series
Form 5252, July 1989
This errata sheet includes information covering the Type 627LB extended body regulator. This new body style
is available on all 627 Series configurations and will be an addition to key 1 in the Parts List. The pressure
ratings on the Type 627LB bodies will be identical to the existing specifications stated in the current 627
Series Instruction Manual. Each bullet on this errata sheet refers to a section of the 627 Series Instruction
Manual (form 5252) where this infornation needs to be added.
• Add the following to the Available Constructions
section of Table 1. Specifications on page 2.
• Add the following figure to the end of page 18.
Type 627LB: A 627 Series construction with an
extended NPT screwed body. Note: The pressure
ratings and capacities for a Type 627LB depend on the
627 Series construction. See the above listed constructions for ratings and specifications.
• Add the following to the Parts List on page 12.
Key
Description
1
Body
Type 627LB - Ductile iron
1000 psig (69 bar) max inlet pressure
3/4-inch NPT screwed body
1-inch NPT screwed body
2-inch NPT screwed body
Type 627LB - Steel
2000 psig (138 bar) max inlet pressure
3/4-inch NPT screwed body
1-inch NPT screwed body
2-inch NPT screwed body
Part Number
39B2450X012
39B2451X012
39B0414X012
E0650
39B0411X012
39B0412X012
39B0415X012
Figure 13. Type 627LB Regulator Body
©Fisher Controls International, Inc., 1986, 1989; All Rights Reserved
Fisher and Fisher Regulators are marks owned by Fisher Controls International, Inc. The Emerson logo is a trade mark and service mark of Emerson Electric Co.
All other marks are the property of their respective owners.
The contents of this publication are presented for informational purposes only, and while every effort has been made to ensure their accuracy, they are not to be construed as warranties or guarantees, express
or implied, regarding the products or services described herein or their use or applicability. We reserve the right to modify or improve the designs or specifications of such products at any time without notice.
For information, contact Fisher Controls:
Marshalltown, Iowa 50158 USA
28320 Gallardon, France
Sao Paulo 05424 Brazil
Singapore 128461
Printed in U.S.A.
www.FISHERregulators.com
Regulators
KUNKLE PRESSURE RELIEF VALVES
Installation and Operating Instructions
Pre-Installation Handling
This pressure relief valve is designed to protect equipment from overpressure. The valve should be handled with care,
not subjected to heavy shock loads, and protected to prevent dirt from getting inside. It should be installed correctly.
Failure to do so could result in property damage or serious injury to personnel.
Installation
1. Mount the valve in a vertical position so that the valve body is self draining. If a body drain port is provided, make
sure it is open when required by the ASME code. Do not plug any bonnet vent openings. The inlet piping should be
as short as possible, with no elbows, and equal to or greater than the size of the pressure relief valve inlet connection.
This will help to limit the inlet pressure drop to 3% or less when the valve is relieving.
2. When discharge piping is connected to valve outlet, make sure it is self draining if a body drain port is not used. The
valve should not be connected to any discharge pipe that contains pressure before the valve opens or to any pipe
where the pressure build-up is greater than 10% of the set pressure when the valve is open and relieving.
Discharge piping, other than a short tailpipe, must be supported. For steam service, a drip pan elbow or flexible
connection between the valve and the pipe should be used to prevent excessive pipe stress, due to thermal
expansion, from being imposed on the valve body.
3. For threaded valves, apply a small amount of pipe thread sealing compound to external threads only. Do not put any
sealing compound on the first thread or on any internal threads. To do so may cause the sealing compound to enter
the valve and cause seat leakage.
Use the wrench flats provided to tighten the valve to the connecting pipe. Do not use the valve body or bonnet and do
not over-tighten. To do so may cause valve leakage.
4. For flanged valves, use new gaskets and tighten the mounting studs evenly.
Operation
1. Maintain a system operating pressure at least 5 psig or 10% below the set pressure of the valve, whichever is greater.
Operating too close to the valve set pressure will cause seat leakage and will shorten the time between valve
maintenance.
2. Do not use the safety valve as a control valve to regulate system operating pressure. Excessive operation will cause
the seat to leak and will require more frequent valve maintenance.
3. ASME Section I and VIII valves equipped with lift levers are designed to be operated only when the system pressure
is 75% of set pressure or greater. ASME Section IV valves may be operated at any set pressure. When hand
operating the valve, hold it open long enough to purge any foreign matter from the seat area. If a cable or wire is
attached to the lift lever for remote actuation, make sure the direction of pull is the same as it would be if the lever
were pulled directly by hand.
Maintenance
Maintenance should be performed on a regular basis. An initial inspection interval of 12 months is recommended.
Depending on the service conditions and the condition of the e valve, the inspection interval may be decreased or
increased. Use only Kunkle parts for repair. Depending o the local jurisdictional requirements where the valve is
installed, repairs may have to be made by a repair facility holding a VR stamp
Kunkle
An Anderson, Greenwood Company
Phone: 828-669-55151281
Old US 70, Black Mountain, NC 28711
Fax: 828-669-0586
Safety Warning — LP-Gas Pressure Relief Valves
Purpose
In its continuing quest for safety, Engineered Controls International,
Inc. is publishing safety warning bulletins explaining the hazards associated with the use, misuse and aging of ECII®/ RegO® Products. LPGas dealer managers and service personnel must realize that the failure to exercise the utmost care and attention in the installation, inspection and maintenance of these products can result in personal injury
and property damage.
The National Fire Protection Association Pamphlet #58 “Storage and
Handling of Liquefied Petroleum Gases” states: “In the interests of
safety, all persons employed in handling LP-Gases shall be trained in
proper handling and operating procedures.” ECII® Warning Bulletins
are useful in training new employees and reminding older employees
of potential hazards.
This Warning Bulletin should be provided to all purchasers of ECII® /
RegO® Products and all personnel using or servicing these products.
Additional copies are available from Engineered Controls International,
Inc. and your Authorized ECII®/ RegO® Products Distributor.
What You Must Do:
• Read This Entire Warning
• Install Properly
• Inspect Regularly
• Replace In 10 Years or Less
Scope
This bulletin applies to pressure relief valves installed on stationary,
portable and cargo containers and piping systems utilized with these
containers. This bulletin is not intended to be an exhaustive treatment
of this subject and does not cover all safety practices that should be
followed in the installation and maintenance of LP-Gas systems. Each
LP-Gas employee should be provided with a copy of NPGA Safety
Pamphlet 306 “LP-Gas Regulator and Valve Inspection and
Maintenance” as well as the NPGA “LP-Gas Training Guidebooks”
relating to this subject.
Warnings should be as brief as possible. If there is a simple warning, it is:
Inspect pressure relief valves regularly. Replace unsafe or suspect valves immediately. Use common sense.
Install Properly
Consult NFPA Pamphlet #58 and/or any applicable regulations governing the application and use of pressure relief
valves. Make sure you are thoroughly trained before you
attempt any valve installation, inspection or maintenance.
adapters on ECII®/ RegO® relief valves. Adapters not designed specifically for piping away ECII®/ RegO® relief valves, such as those with
90° turns or reduced internal diameters, will decrease flow dramatically. These should never be used as they can cause the relief valve to
chatter and eventually destroy itself.
Proper installation is essential to the safe operation of pressure relief
valves. When installing ECII®/ RegO® pressure relief valves, consult
warning # 8545-500 which accompanies each valve. Check for damage and proper operation after valve installation. Check that the valve
is clean and free of foreign material.
The addition of deflectors, pipeaway adapters and piping will
restrict the flow. To properly protect any container, the total
system flow must be sufficient to relieve pressure at the pressure setting of the relief valve in accordance with all applicable
codes.
Pipeaways and deflectors may be required by local codes, laws
and regulations depending on the installation. Use only ECII®/ RegO®
®
D4
PRODUCTS
Inspect Regularly
A pressure relief valve discharges when some extraordinary circumstance causes an over pressure condition in the container. If a
pressure relief valve is known to have discharged, the relief valve,
as well as the entire system, should be immediately and thoroughly inspected to determine the reason for the discharge. In the
case of discharge due to fire, the valve should be removed from
service and replaced.
Relief valves should be inspected each time the container is
filled but no less than once a year. If there is any doubt about
the condition of the valve, it must be replaced.
Eye protection must be worn when performing inspection on relief
valves under pressure. Never look directly into a relief valve under
pressure or place any part of your body where the relief valve discharge could impact it. In some cases a flashlight and a small mirror
are suggested to assist when making visual inspections.
To Properly Inspect A Pressure Relief Valve, Check For:
1. A rain cap. Check protective cap located in valve or at end of
pipeaway for a secure fit. Protective caps help protect the relief
valve against possible malfunction caused by rain, sleet, snow, ice,
sand, dirt , pebbles, insects, other debris and contamination.
REPLACE DAMAGED OR MISSING CAPS AT ONCE AND
KEEP A CAP IN PLACE AT ALL TIMES.
4. Physical damage. Ice accumulations and improper installation
could cause mechanical damage. IF THERE ARE ANY INDICATIONS OF DAMAGE, REPLACE THE VALVE.
5. Tampering or readjustment. Pressure relief valves are factory set
to discharge at specified pressures. IF THERE ARE ANY INDICATIONS OF TAMPERING OR READJUSTMENT, REPLACE THE
VALVE.
6. Seat leakage. Check for leaks in the seating area using a noncorrosive leak detection solution. REPLACE THE VALVE IF
THERE IS ANY INDICATION OF LEAKAGE. Never force a relief
valve closed and continue to leave it in service. This could result in
damage to the valve and possible rupture of the container or piping
on which the valve is installed.
7. Corrosion and contamination. REPLACE THE VALVE IF THERE
ARE ANY SIGNS OF CORROSION OR CONTAMINATION ON
THE VALVE.
8. Moisture, foreign particles or contaminants in the valve.
Foreign material such as paint, tar or ice in relief valve parts can
impair the proper functioning of the valves. Grease placed in the
valve body may harden over time or collect contaminants, thereby
impairing the proper operation of the relief valve. DO NOT PLACE
GREASE IN THE VALVE BODY, REPLACE THE VALVE IF
THERE ARE ANY INDICATIONS OF MOISTURE OR FOREIGN
MATTER IN THE VALVE.
2. Open weep holes. Dirt, ice, paint and other foreign particles can
prevent proper drainage from the valve body. IF THE WEEP
HOLES CANNOT BE CLEARED, REPLACE THE VALVE.
9. Corrosion or leakage at container connection. Check container to valve connection with a non-corrosive leak detection solution.
REPLACE THE VALVE IF THERE IS ANY INDICATION OF CORROSION OR LEAKAGE AT THE CONNECTION BETWEEN THE
VALVE AND CONTAINER.
3. Deterioration and corrosion on relief valve spring. Exposure to
high concentrations of water, salt, industrial pollutants, chemicals
and roadway contaminants could cause metal parts to fail. IF THE
COATING ON THE RELIEF VALVE SPRING IS CRACKED OR
CHIPPED, REPLACE THE VALVE.
CAUTION: Never plug the outlet of a pressure relief valve. Any device
used to stop the flow of a properly operating pressure relief valve that is
venting an overfilled or overpressurized container - raises serious safety concerns!
Replace Pressure Relief Valves In 10 Years Or Less
The safe useful life of pressure relief valves can vary greatly depending
on the environment in which they live.
Relief valves are required to function under widely varying conditions.
Corrosion, aging of the resilient seat disc and friction all proceed at different rates depending upon the nature of the specific environment
and application. Gas impurities, product misuse and improper installations can shorten the safe life of a relief valve.
Predicting the safe useful life of a relief valve obviously is not an exact
science. The conditions to which the valve is subjected will vary widely and will determine its useful life. In matters of this kind, only basic
guidelines can be suggested. For example, the Compressed Gas
Association Pamphlet S-1.1 Pressure Relief Device Standards —
Cylinders, section 9.1.1 requires all cylinders used in industrial motor
fuel service to have the cylinder’s pressure relief valves replaced by
new or unused relief valves within twelve years of the date of manufacture of cylinder and within each ten years thereafter. The LP-Gas dealer must observe and determine the safe useful life of relief valves in his
territory. The valve manufacturer can only make recommendations for
the continuing safety of the industry.
D
WARNING: Under normal conditions, the useful safe service life
of a pressure relief valve is 10 years from the original date of
manufacture. However, the safe useful life of the valve may be
shortened and replacement required in less than 10 years
depending on the environment in which the valve lives.
Inspection and maintenance of pressure relief valves is very
important. Failure to properly inspect and maintain pressure
relief valves could result in personal injuries or property damage.
For Additional Information Read:
1. CGA Pamphlet S-1.1 Pressure Relief Standards — Cylinders,
Section 9.1.1.
2. ECII® Catalog L-500.
3. ECII® Warning # 8545-500.
4. NPGA Safety Pamphlet 306 “LP-Gas Regulator and Valve
Inspection and Maintenance” and “LP-Gas Training Guidebooks”.
5. NFPA # 58, “Storage and Handling of Liquefied Petroleum Gases”.
6. NFPA # 59, “LP-Gases at Utility Gas Plants”.
7. ANSI K61.1 Safety Requirements for Storage and Handling of
Anhydrous Ammonia.
®
PRODUCTS
D5
RegO® Pressure Relief Valves
Requirements for Pressure Relief Valves
Every container used for storing or hauling LP-Gas and anhydrous
ammonia must be protected by a pressure relief valve. These valves
must guard against the development of hazardous conditions which
might be created by any of the following:
• Hydrostatic pressures due to overfilling or the trapping of liquid
between two points.
• High pressures resulting from exposure of the container to excessive external heat.
• High pressures due to the use of incorrect fuel.
• High pressures due to improper purging of the container.
Consult NFPA Pamphlet #58 for LP-Gas and ANSI #K61.1 for
anhydrous ammonia, and/or any applicable regulations governing the application and use of pressure relief valves.
Operation of Pressure Relief Valves
Pressure relief valves are set and sealed by the manufacturer to function at a specific “start-to-discharge” pressure in accordance with
regulations. This set pressure, marked on the relief valve, depends on
the design requirement of the container to be protected by the relief
valve. If the container pressure reaches the start-to-discharge pressure, the relief valve will open a slight amount as the seat disc begins
to move slightly away from the seat. If the pressure continues to rise
despite the initial discharge through the relief valve, the seat disc will
move to a full open position with a sudden “pop”. This sharp popping
sound is from which the term “pop-action” is derived.
Whether the relief valve opens a slight amount or pops wide open, it
will start to close if the pressure in the container diminishes. After the
pressure has decreased sufficiently, the relief valve spring will force
the seat disc against the seat tightly enough to prevent any further
escape of product. The pressure at which the valve closes tightly is
referred to as the “re-seal” or “blow-down” pressure. Generally, the
re-seal pressure will be lower than the start-to-discharge
pressure.The re-seal pressure can be, and in most cases is, adversely affected by the presence of dirt, rust, scale or other foreign particles
lodging between the seat and disc. They interfere with the proper
mating of the seat and disc and the pressure in the container will usually have to decrease to a lower pressure before the spring force
embeds foreign particles into the resilient seat disc material and seals
leak-tight. The degree by which the presence of dirt decreases the
re-seal pressure, is, of course, dependent on the size of the interfering particles.
Once particles have been trapped between the disc and seat, the
start-to-discharge pressure is also affected. For example, the pressure relief valve will start-to-discharge at some pressure lower than its
original start-to-discharge pressure. Again, the pressure at which the
valve will start to discharge is dependent on the size of the foreign
particles.
In the case of a pressure relief valve that has opened very slightly due
to a pressure beyond its start-to-discharge setting, the chances of
foreign material lodging between the seat and disc is negligible
although the possibility is always present. If the relief valve continues
to leak at pressures below its start-to-discharge setting it must be
replaced.
Relief valves which have “popped” wide open must also be
checked for foreign material lodged between the seat and
disc, as well as for proper reseating of the seat and disc.
Continued leakage at pressures below the start-to-discharge
setting indicate the relief valve must be replaced.
The pressure at which a pressure relief valve will start to discharge should never be judged by the reading of the pressure
gauge normally furnished on the container.
®
D6
PRODUCTS
The reasons for this are two-fold:
• If the relief valve is called upon to open, the resulting discharge
produces an increased vaporization of the product in the container with the result that the liquid cools to a certain extent and
the vapor pressure drops. A reading taken at this time would
obviously not indicate what the pressure was when the relief valve
opened.
• The pressure gauges usually on most containers provide somewhat approximate readings and are not intended to provide an
indication of pressure sufficiently accurate to judge the setting of
the relief valve.
Repair and Testing
RegO® Pressure Relief Valves are tested and listed by Underwriters
Laboratories, Inc., in accordance with NFPA Pamphlet #58.
Construction and performance of RegO® Pressure Relief Valves are
constantly checked at the factory by U.L. inspectors. Therefore, testing of RegO® Pressure Relief Valves in the field is not necessary.
Never attempt to repair or change the setting of RegO ®
Pressure Relief Valves. Any changes in settings or repairs in the
field will void the UL® listing and may create a serious hazard.
While the functioning of a pressure relief valve appears to be relatively
simple, the assembly and test procedure used to manufacture these
RegO® products is rather complex. Highly specialized test fixtures
and specially trained personnel are necessary to attain proper relief
valve settings. These fixtures and personnel are available only at the
factory.
Any pressure relief valve which shows evidence of leakage,
other improper operation or is suspect as to its performance
must be replaced immediately using approved procedures.
Pipe-Away Adapters
Pipe-away adapters are available for most RegO® Pressure Relief
Valves, where it is required or desirable to pipe the discharge above
or away from the container. Each adapter is designed to sever if
excessive stress is applied to the vent piping – thus leaving the relief
valve fully operative.
Weep hole deflectors are available on larger relief valves. These
deflectors provide protection against flame impinging on adjacent
containers which could occur from ignition of LP-Gas escaping
through the relief valve drain hole when the valve is discharging.
Selection of RegO® Pressure Relief Valves For ASME
Containers
The rate of discharge required for a given container is determined by
the calculation of the surface area of the container as shown in
“Chart A” for LP-Gas and “Chart B” for anhydrous ammonia. See
page D9.
Setting - The set pressure of a pressure relief valve depends upon
the design pressure of the container. Refer to NFPA Pamphlet #58
for more information.
Selection of RegO® Pressure Relief Valves for DOT
Containers
To determine the proper relief valve required for a given DOT container, refer to the information shown with each pressure relief valve
in the catalog. This information will give the maximum size (pounds
water capacity) DOT container for which the relief valve has been
approved.
Setting - The standard relief valve setting for use on DOT cylinders is
375 PSIG.
Ordering RegO® Pressure Relief Valves
Part Number Explanation
Products carrying an “A” or “AA” prefix contain no brass parts and
are suitable for NH3. Hydrostatic relief valves carrying an “SS” prefix
are of stainless steel construction and are suitable for use with NH3.
The products are also suitable for use with LP-Gas service except
relief valves carrying an “AA” prefix. These are of partial aluminum
construction and are listed by U.L. for NH3 service only.
When ordering RegO® Pressure Relief Valves, be sure you are certain
that it will sufficiently protect the container as specified in the forewording information, NFPA Pamphlet #58 and any other applicable
standards or specifications.
All adapters, protective caps and deflectors must be ordered separately, unless specified otherwise.
Safety Information — Relief Valves Don’t Last Forever
Metal Seat
RegO® Relief Valve for lift truck containers
The internal spring is protected from external contamination but the other external parts must be protected with a
cap. Circular rubber seat disc ring seats on brass shoulder approximately 3⁄64" wide.
This article was prepared by the engineers of RegO® products, after
technical consultation with valve manufacturers and other industry
sources. Its purpose is to alert and remind the LP-Gas industry of the
importance of proper maintenance of pressure relief valves. It applies
most particularly to separate relief valves with emphasis on lift truck
and motor fuel containers where the hazards of contamination are
greatest.
Since the beginning of our industry, manufacturers of equipment and
distributors of LP-Gas have worked diligently to provide a safe environment for employees and consumers. The history of the industry
testifies to the success of their efforts.
But the industry is now entering its sixth decade and equipment
installed years ago is failing because of age. Every year, additional
equipment will fail unless it is replaced. Pressure relief valves are no
exception. The valve manufacturers and LP-Gas dealers are naturally concerned about this situation.
Causes of Relief Valve Failure
A relief valve is designed to have a safe useful life of many years, but
that life will vary greatly depending on the environment in which it
“lives.” To attempt to estimate the safe useful life of a relief valve
and the effect of environment on its performance, a brief discussion
of the materials used and the nature of its performance should be
helpful.
Relief valve bodies are generally made of brass or steel. Springs are
made from various spring wires which are plated or painted, or made
of stainless steel. Valve seat discs are made of synthetic rubber
compounds which will remain serviceable in an atmosphere of LPGas. Relief valve stems, guides, etc. are generally made from brass
or stainless steel.
Relief valves, over the years, may not function properly in several
ways:
• They may leak at pressures below the set pressure.
• They may open and fail to properly reseat.
• They may open at higher than the set pressure.
These failures to function properly are due primarily to four “environmental’’ conditions:
1. Corrosion of metal parts (particularly springs) which result in the
component parts failing to perform.
2. Deterioration of the synthetic rubber seat disc material.
3. Clogging or “cementing” of the movable relief valve components
so that their movement is restricted.
4. Debris on the valve seat after the relief valve opens, effectively
preventing the valve from reseating.
Corrosion is caused by water, corrosive atmospheres of salt and
industrial pollutants, chemicals, and roadway contaminants. High
concentrations can attack the metal parts vigorously. No suitable
metals are totally resistant to such corrosion.
Synthetic rubber and seat disc materials can also be attacked by
impurities in the gas and corrosive atmospheres, particularly those
with sulphur dioxide. There are no suitable rubber materials which
resist all contaminants.
“Cementing” of relief valve parts has been caused by normal industrial atmospheres containing particles of dirt, iron oxide, metal chips,
etc. combined with water, oil, or grease. Ice collecting in recessed
valves could cause relief valves to fail to open. Paint and tar in relief
valves also cause failure to function properly.
D
®
PRODUCTS
D7
Safety Information — Relief Valves Don’t Last Forever
Debris on valve seats which prevents reseating can occur whenever
the valve collects material in the relief valve opening which is not
blown out when the relief valve opens.
Use of Protective Caps
Inspection of Relief Valves
Collection of debris would be prevented. Contamination caused by
corrosive atmospheres would be reduced. Water collection in the
valves would be eliminated. Relief valves protected with caps from
the time of installation in the container would obviously have a much
longer safe useful life, but they still should be replaced at some time
because of the gradual deterioration of the rubber seat disc due to
age alone.
NFPA 58 requires that protective caps must be kept in place as a
protective cover on some relief valves. This is a mandatory requirement on several types of relief valves. The fact that use of caps may
make inspection more time consuming should not be viewed as a
reason for either not using the caps, or not making required periodic inspections.
In the event a relief valve has been used without the required cap,
the relief valve should be thoroughly inspected and the required cap
placed on the relief valve. If damage is noted to the relief valve, it
should be replaced and the replacement valve should be capped.
Relief valves with pipe-away adapters or deflectors used on lift truck
containers have been found choked with debris. Inspection of relief
valves with deflectors can only be accomplished by removing the
deflector.
Similarly, larger relief valves with vent stacks have been found
choked with debris and water. Valves have failed because springs
rusted through. The weep hole was plugged. It was obvious that the
relief valves had not been inspected in many years. These conditions
must be alleviated by periodic inspections and replacement of relief
valves as needed.
Unfortunately many of the above problems may not be easily
observed because of the compact nature of some relief valve
designs.
A casual visual inspection of a relief valve may not necessarily disclose a potential hazard. On the other hand, a visual inspection
will often disclose leakage, corrosion, damage, plugging and contamination.
If additional light is required, a flashlight should be used.
If there is any doubt about the condition of the valve, or if there is
a suspicion that the valve has not been protected by a cap for
some time, it should be replaced before refilling the container.
Eye protection must be used when examining relief valves under
pressure.
Smaller Relief Valves
The industry’s requirement for a small full-flow safety relief valve challenged design engineers some years ago:
• The valve must be leakproof before operating and must reseat
leakproof each time after each operation. The only known satisfactory seat disc materials to accomplish this have been special
synthetic rubber compounds.
• Valve discharge settings are relatively high and require high spring
loads to keep the valve closed.
• Because of the small interior diameter of the valve, the round
metal seating area is small.
All of these parameters may result in the development of a significant
indentation in the rubber seat disc after some years. The seat disc
may have a tendency to cling to the metal seat. This may result in the
relief valve not opening at the set pressure as the seat disc ages.
Test have been conducted on small LP-Gas relief valves of all the
U.S. valve manufacturers. Valves over 10 years old were removed
from service and tested to determine at what pressure the valves
discharged. In many of the valves, the pressure required to open the
valve exceeded the set pressure.
Because of the critical importance of proper functioning of relief
valves, common sense and basic safety practice dictate that
small relief valves should be replaced in about 10 years.
Some larger relief valves on bulk storage tanks can be replaced with
rebuilt valves obtained from the manufacturers. Small relief valves
cannot be rebuilt economically, thus, new valves are required. Most
LP-Gas dealers find it impractical and costly to test relief valves and
field repairing of relief valves is not sanctioned by the manufacturers,
Underwriter's Laboratories, or ASME.
®
D8
PRODUCTS
Many of the problems that cause inoperative relief valves could
be prevented if proper protective caps were kept in place at all
times.
Summary Recommendations
Predicting the safe useful life of a relief valve is obviously not an
exact science. The conditions to which the valve is subjected will
vary widely and will largely control its life. In matters of this kind, only
basic guidelines can be suggested. The LP-Gas dealer must observe
and determine the safe useful life of relief valves in his territory. The
valve manufacturers can only make recommendations for the continuing safety of the industry:
1. Make sure proper protective caps are in place at all times. Do not
release a container for service or fill a container unless it has a
protective cap in place.
2. Replace relief valves periodically, at least every 10 years. Every
relief valve has the month and year of manufacture stamped on
the valve. This is most particularly true of small separate relief
valves.
3. Carefully inspect valves each time before the container is filled.
Replace valves showing any signs of contamination, corrosion,
damage, plugging, leakage, or any other problem. Eye protection
must be used when examining relief valves under pressure.
Chart A — Minimum Required Rate of Discharge for LP-Gas Pressure Relief Valves Used on
Minimum required rate of discharge in cubic feet per minute of air at 120% of the maximum permitted start-to-discharge
ASME Containers
pressure for pressure relief valves to be used on containers other than those constructed in accordance with Interstate
From NFPA Pamphlet #58, Appendix D (1986).
Surface
Area
Sq. Ft.
20 or less
25
30
35
40
45
50
55
60
65
70
75
80
Flow
Rate
CFM
Air
626
751
872
990
1100
1220
1330
1430
1540
1640
1750
1850
1950
Surface
Area
Sq. Ft.
85
90
95
100
105
110
115
120
125
130
135
140
145
Flow
Rate
CFM
Air
2050
2150
2240
2340
2440
2530
2630
2720
2810
2900
2990
3080
3170
Commerce Commission specification.
Surface
Area
Sq. Ft.
150
155
160
165
170
175
180
185
190
195
200
210
220
Flow
Rate
CFM
Air
3260
3350
3440
3530
3620
3700
3790
3880
3960
4050
4130
4300
4470
Surface
Area
Sq. Ft.
230
240
250
260
270
280
290
300
310
320
330
340
350
Surface area =Total outside surface area of container in square feet.
When the surface area is not stamped on the name plate or when the marking is not legible, the area can be calculated by using one of the following formulas:
1. Cylindrical container with hemispherical heads. Area (in sq. ft.) = overall
length (ft.) x outside diameter (ft.) x 3.1416.
2. Cylindrical container with semi-ellipsoidal heads. Area (in sq. ft.) = [overall
length (ft.) + .3 outside diameter (ft.)] x outside diameter (ft.) x 3.1416.
3. Spherical container. Area (in sq. ft.) = outside diameter (ft.) squared x
3.1416.
Flow Rate CFM Air = Required flow capacity in cubic feet per minute of air
at standard conditions, 60ºF. and atmospheric pressure (14.7 psia).
The rate of discharge may be interpolated for intermediate values of surface
Flow
Rate
CFM
Air
4630
4800
4960
5130
5290
5450
5610
5760
5920
6080
6230
6390
6540
Surface
Area
Sq. Ft.
360
370
380
390
400
450
500
550
600
650
700
750
800
Flow
Rate
CFM
Air
6690
6840
7000
7150
7300
8040
8760
9470
10170
10860
11550
12220
12880
Surface
Area
Sq. Ft.
850
900
950
1000
1050
1100
1150
1200
1250
1300
1350
1400
1450
Flow
Rate
CFM
Air
13540
14190
14830
15470
16100
16720
17350
17960
18570
19180
19780
20380
20980
Surface
Area
Sq. Ft.
1500
1550
1600
1650
1700
1750
1800
1850
1900
1950
2000
Flow
Rate
CFM
Air
21570
22160
22740
23320
23900
24470
25050
25620
26180
26750
27310
area. For containers with total outside surface area greater than 2000 square
feet, the required flow rate can be calculated using the formula, Flow Rate in
CFM Air = 53.632 A0.82. Where A = total outside surface area of the container
in square feet.
Valves not marked “Air” have flow rate marking in cubic feet per minute of liquefied petroleum gas. These can be converted to ratings in cubic feet per
minute of air by multiplying the liquefied petroleum gas ratings by the factors
listed below. Air flow ratings can be converted to ratings in cubic feet per
minute of liquefied petroleum gas by dividing the air ratings by the factors listed below.
Air Conversion Factors
Container Type
100
125
150
175
200
Air Conversion Factor
1.162 1.142
1.113 1.078 1.010
Chart B — Minimum Required Rate of Discharge for Anhydrous Ammonia Pressure Relief Valves
Used on ASME Containers Minimum required rate of discharge in cubic feet per minute of air at 120% of the maximum permitted start-to-disFrom ANSI K61.1-1981, Appendix A (1981).
Surface
Area
Sq. Ft.
20
25
30
35
40
45
50
55
60
65
70
75
80
85
90
Flow
Rate
CFM
Air
258
310
360
408
455
501
547
591
635
678
720
762
804
845
885
Surface
Area
Sq. Ft.
95
100
105
110
115
120
125
130
135
140
145
150
155
160
165
Flow
Rate
CFM
Air
925
965
1010
1050
1090
1120
1160
1200
1240
1280
1310
1350
1390
1420
1460
charge pressure for pressure relief valves to be used on containers other than those constructed in accordance with
United States Department of Transportation cylinder specifications.
Surface
Area
Sq. Ft.
170
175
180
185
190
195
200
210
220
230
240
250
260
270
280
Flow
Rate
CFM
Air
1500
1530
1570
1600
1640
1670
1710
1780
1850
1920
1980
2050
2120
2180
2250
Surface
Area
Sq. Ft.
290
300
310
320
330
340
350
360
370
380
390
400
450
500
550
Surface area = Total outside surface area of container in square feet.
When the surface area is not stamped on the name plate or when the marking
is not legible, the area can be calculated by using one of the following formulas:
1. Cylindrical container with hemispherical heads. Area (in sq. ft.) = overall
length (ft.) x outside diameter (ft.) x 3.146.
2. Cylindrical container with other than hemispherical heads. Area (in sq. ft.) =
[overall length (ft.) + .3 outside diameter (ft.)] x outside diameter (ft.) x
3.1416.
3. Spherical container. Area (in sq. ft.) = outside diameter (ft.) squared x
3.1416.
Flow
Rate
CFM
Air
2320
2380
2450
2510
2570
2640
2700
2760
2830
2890
2950
3010
3320
3620
3910
Surface
Area
Sq. Ft.
600
650
700
750
800
850
900
950
1000
1050
1100
1150
1200
1250
1300
Flow
Rate
CFM
Air
4200
4480
4760
5040
5300
5590
5850
6120
6380
6640
6900
7160
7410
7660
7910
Surface
Area
Sq. Ft.
1350
1400
1450
1500
1550
1600
1650
1700
1750
1800
1850
1900
1950
2000
2050
Flow
Rate
CFM
Air
8160
8410
8650
8900
9140
9380
9620
9860
10090
10330
10560
10800
11030
11260
11490
Surface
Area
Sq. Ft.
2100
2150
2200
2250
2300
2350
2400
2450
2500
Flow
Rate
CFM
Air
11720
11950
12180
12400
12630
12850
13080
13300
13520
D
Flow Rate CFM Air = Required flow capacity in cubic feet per minute of air at
standard conditions, 60°F. and atmospheric pressure (14.7 psia).
The rate of discharge may be interpolated for intermediate values of surface
area. For containers with total outside surface area greater than 2,500 square
feet, the required flow rate can be calculated using the formula, Flow Rate in
CFM Air = 22.11 A0.82 where A = outside surface area of the container in
square feet.
Conversion Factor
ft2 x 0.092 903 = m2
CFM x 0.028 317 = m3/min
ft x 0.304 8
=m
®
PRODUCTS
D9
APPENDIX B
DRAWINGS & TECHNICAL
INFORMATION
Appendix B
This page intentionally left blank.
DFV2-5.wmf
WARNING
P /N 50833
D IS CO N NE CT TH E S UP PLY CI RCU IT BEFO RE
S ER VI CI N G TO PR EV EN T I NJ URY FRO M ELEC TRC
I ALS HO CK
WARNING
P /N 50833
D IS CO N NE CT TH E S UP PLY CI RCU IT BEFO RE
S ER VI CI N G TO PR EV EN T I NJ URY FRO M ELEC TRC
I ALS HO CK
Appendix B
DFV 2.5 Equipment Drawing
DFV7.wmf
WARNING
P /N 5083 3
D IS CO NN EC T TH E SU PP LY C IR CUI TB EFO RE
S ERV I CI NG TO PR EV EN TI NJU R Y FRO M E LEC TRI C AL SH OC K
WARNING
D IS CO NN EC T TH E SU PP LY C IR CUI TB EFO RE
P /N 5083 3
S ERV I CI NG TO PR EV EN TI NJU R Y FRO M E LEC TRI C AL SH OC K
Appendix B
DFV 7 Equipment Drawing
DFV14.wmf
WARNING
P/ N 50833
DI S CO NN EC T THE S UP PLY CI RCUI TBE FORE
SE RV I CI NG TO P RE VE NT I NJU RY FROM ELE CTRI CALS HOCK
WARNING
P/ N 50833
DI S CO NN EC T THE S UP PLY CI RCUI TBE FORE
SE RV I CI NG TO P RE VE NT I NJU RY FROM ELE CTRI CALS HOCK
Appendix B
DFV 14 Equipment Drawing
Appendix B
DFV Electrical Schematic
DFVelect.wmf
...Innovative liquid vaporizing and gas mixing solutions
WARRANTY REGISTRATION
Please copy the information from the data sheet supplied with your manual.
Type of Equipment:
Serial Number:
ASDI Sales Order #:
Order Date:
Purchased By:
To help us provide better service to you, please fill out this warranty registration form and retur n
it to us. Keep a copy for your records.
This will register your recent purchase and aide us in tracking the performance of your
equipment. Please help us with a small amount of information about your company and about
how you are using the equipment. Contact us via phone, fax, or email if you have a question,
problem, or concern about your equipment. Please have the type of equipment and serial
number available so we can give you accurate information.
End Customer/Company Name:
Address:
City:
Tel:
State:
Zip:
Fax:
Name of individual to contact for follow up information:
When was the equipment put in service?
Usage - Circle one:
/
/
Base Load
Standby System
Peak Shaving
Other please specify:
Application - Circle one: Agriculture:
Poultry
Livestock
Grain drying
Commercial:
Restaurant
Hospital
School
Industrial :
Construction
Automotive
Glass/ceramics
Other:
Please specify:
Note: If you have more than one piece of our equipment, fill out one warranty sheet and staple
the others to it, we’ll do the rest.
1140 NW 46 Street
Se at tle Wash ing ton 98107 USA
Tel: 206.789.5410
Fax: 206.789.5414
email: [email protected]
Internet: www.algas-sdi.com
Algas-SDI International, LLC
1140 NW 46th Street
Seattle, Washington 98107
USA
Ph.: 1.206.789.5410
Fax.: 1.206.789.5414
www.algas-sdi.com
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