ASCO Valve used by Algas-SDI 2.9.98 TORQUE

ASCO Valve used by Algas-SDI 2.9.98 TORQUE
Figure 20 - ASCO Valve used by Algas-SDI 2.9.98
WARNING: TURN OFF ELECTRICAL POWER
AND DE-PRESSURIZE VALVE BEFORE MAKING
ANY REPAIRS.
TORQUE CRISSCROSS TO
110 in-Lbs [ 12.4 N-m ]
TORQUE TO
175 in-Lbs [ 19.7 N-m ]
Algas-SDI ASCO Valve Draw.wmf
SOLENOID NOISE
Solenoid valves emit a sound when operated. When energized, they emit a
clicking sound. Also, accompanying the operation of most AC valves, is AC hum.
Whether or not AC hum is objectionable actually depends on the requirements
and opinion of the user. Normal AC hum is the result of the constantly reversing
magnetic field produced by alternating current. The constantly reversing
magnetic field can cause vibrations in the solenoid parts.
1. Solenoid noise due to damage solenoid parts such as bent solenoid base
assembly, stretched return springs, loose parts, etc.
Solution:
parts.
Inspect valve internals and exterior. Replaced damaged
2. Solenoid noise due to foreign matter between the core and plug-nut. When
foreign matter is trapped between the core and plug-nut, the core assembly
will rock back and forth at 60 hertz. Eventually, the core and plug-nut face
will be distorted, at which time the noise can continue even though the
foreign material may have been flushed or removed from the valve.
Solution:
Replace damaged parts entirely, clean and reassemble.
3. Solenoid noise due to damaged coil. On rare occasions, a severe voltage
spike or over voltage can potentially short a small portion of the coil winding.
This shorting can cause solenoid noise and coil overheating. However, it
would normally lead to rapid coil burnout. The solenoid parts, however,
could be damaged enough that the noise would continue even after the coil
was replaced due to the deformation produced during the peening process.
4. Missing solenoid parts can severely weaken the magnetic circuit. This can
produce a solenoid noise condition. As discussed above, it will probably also
result in coil burn-out.
Solution: Replace damaged parts, replace lost parts, clean and reassemble.
In general, when a noise condition has been encountered, the source of the
problem should be determined and eliminated. The valve should then be
thoroughly inspected to insure that it is yet repairable. Most times, simple
installation of a spare parts kit and a solenoid base sub assembly can restore a
valve to like new condition. The restored and reinstalled solenoid valve should
be tested to insure proper operation, and a voltage check should be made at the
solenoid valve while the valve is energized. In addition, a current reading can be
obtained and compared with catalog specifications to verify normal solenoid and
coil operation.
Note: The coil may have been damaged due to excessive current draw of at
damaged shading coil within the solenoid valve. A partial rebuilding of a valve
damaged by a noise condition can prove useless as the noise condition would
continue. The entire valve should be dismantled and inspected and cleaned. All
parts supplied in a spare parts kit should be installed. Further, and additional
solenoid parts damaged by a noise condition such as a solenoid base sub
assembly, should be replaced. Examine valve seating, pistons and the valve
body to verify that they have not been damaged. Damage to major portions of
the valve may make repairing the valve uneconomical.
Should a noise condition be encountered, immediate action may prevent any
damage to the solenoid valve itself.
Installation & Maintenance Instructions
V710
2-WAY NORMALLY CLOSED GAS VALVES
GAS VALVES
3/4I, 1I, 1 1/4I, 1 1/2I, 2I, 2 1/2I OR 3I NPT Ċ FUEL GAS SERVICE
Form No.V8708R1
Provisions for Pressure and Seat Leakage Testing
WARNING
To prevent the possibility of death, serious injury or
property damage, the V710 Series Gas Valve must be
installed and serviced (tested) only by a qualified
service technician avoiding the following hazards:
S Electrical Hazard. Turn off all electrical power to
Hydramotorr Actuator. More than one circuit may
exist.
V710 Series valves are provided with four 1/4I NPT tapped
and plugged holes (pressure taps). Each side of the valve body
is provided with an upstream and downstream pressure tap for
testing. The taps closest to the valve bonnet are upstream,
while the taps closest to the bottom of the valve body are
downstream. Leakage testing frequency shall be at least
annually in accordance with NFPA-86 or original equipment
manufacturer recommendations. For instructions, refer to
section on Testing for Internal (Seat) Leakage and Figures 1 and 2.
View of valve assembly showing location
of tapped and plugged holes for pressure
and seat leakage testing
S Pressure Hazard. Depressurize valve and vent
hazardous or combustible fluid to a safe area before
inspection or removing the valve from service.
S Explosion/Fire Hazard. Extinguish all open flames
and avoid any type of sparking or ignition when
leakage testing.
Pipe plugs are 1/4I NPT
(use1/4I hex key wrench)
Identification nameplate
Service Notices
Except for actuator replacement or repair, V710 Series Gas
Valves are not repairable. When any performance problems
are detected during routine inspection, replace valve
immediately.
See separate AH Series Hydramotorr Actuator Installation
and Maintenance Instructions for information on: Actuator
Specifications, Installation, Positioning/Mounting, Wiring
and Field Service of Actuator.
DESCRIPTION
V710 Series Gas Valves are 2-way normally closed,
soft-seated poppet-type valves for safety shutoff service on
commercial or industrial gas burners. The V710 was designed
exclusively for use with AH Series Hydramotorr Push-Type
Actuators available in ON-OFF, LOW-HIGH-OFF and
proportional positioning configurations.
The valves are equipped with aluminum seats and Nitrile seals.
A quick-opening poppet is standard. Both overtravel seals
and linear trim are available as options, i.e. Quick Opening With
Overtravel Seal, Linear Opening or Linear Opening With
Overtravel Seal.
CAUTION: Use V710 Gas Valves only with natural,
mixed, manufactured or liquefied petroleum (propane)
gases.
e
MCMXCIX
Pressure tap
for downstream seat
leakage testing
Pressure tap
for upstream pressure
testing
Note: Upstream and downstream pressure
taps are on either side of valve body.
Figure 1. Provisions for pressure and seat leakage testing.
OPERATION
V710 Series is a normally closed, push-to- open valve which
opens when the valve stem is depressed by an AH Actuator.
An internal return spring closes the valve when its actuator is
de-energized or removed. The actuator is retracted by its
own internal return spring.
All Rights Reserved.
50-60 Hanover Road, Florham Park, New Jersey 07932 www.ascovalve.com
Page 1 of 3
Printed in U.S.A.
Maximum Operating Pressure Differentials:
CAUTION: To protect the valve, install a strainer or
filter, suitable for the service involved, in the inlet side as
close to the valve as possible. Clean periodically
depending on service conditions. See ASCO Series
8600, 8601, and 8602 for strainers.
S 3/4I, 1I, 1 1/4I and 1 1/2I NPT - 15 psi
S 2I, 2 1/2I and 3I NPT - 10 psi
INSTALLATION
Check nameplate for correct catalog number, pressure, and
service. Check the catalog number against Table 1 to ensure
that the valve meets the requirements of the application.
Never apply incompatible fluids or exceed pressure rating of
the valve.
Table 1. V710 Catalog System
V710 BASIC SERIES - Model D
SIZE
E = 3/4 I
F=1I
G = 1 1/4 I
H = 1 1/2 I
J=2I
K =2 1/2 I
L = 3I
BODY MATERIAL, END CONNECTION
AS = Aluminum body, NPT connections
WARNING: Explosion/Fire Hazard. To prevent the
possibility of death, serious injury or property damage
from the possible release of combustible gas to the
atmosphere, extinguish all open flames and avoid any
type of sparking or ignition.
1. Block gas flow on downstream side of valve.
2. Apply pressure to valve within nameplate rating and
energize actuator.
3. Apply a soapy solution or a commercially available leak
detecting solution to the pipe connections and check for
bubbles.
4. If leakage exists. depressurize valve and turn off
electrical power supply. Tighten connections and
retest following the above steps.
MAINTENANCE
OPTIONS
NONE =Quick opening (standard)
V15 = Linear trim
V22 = Quick opening plus overtravel seal
V25 = Linear plus overtravel seal
V710GASV15
Testing for External Leakage
Preventive Maintenance
Typical Catalog Number
Temperature Limitations
Ambient and Fluid Temperature: -40F (-40_C) to
150_F (65_C).
Positioning
Valve body may be mounted in any position.
CAUTION: Valve bonnet has a protective cap over
the stem connection, do not remove protective cap
until actuator is installed on valve body.
Piping
CAUTION: Piping must comply with applicable
local and national codes and ordinances, including
the National Fuel Gas Code ANSI Z223.1/NFPA No. 54.
Connect piping to valve according to flow arrow on valve body.
The use of a drip leg is recommended. Apply pipe compound
sparingly to male pipe threads only. If applied to valve threads,
the compound may enter the valve and cause operational
difficulty. Avoid pipe strain by properly supporting and
aligning piping. When tightening the pipe, do not use valve or
actuator as a lever. Locate wrenches applied to valve body or
piping as close as possible to connection point. Valve should
be checked for external leakage at piping connections after
installation, see Testing for External Leakage section.
CAUTION: To avoid damage to the valve body DO
NOT OVERTIGHTEN PIPE CONNECTIONS. If Teflon*
tape, paste, spray, or similar lubricant is used, use
extra care when tightening due to reduced friction.
Page 2 of 3
S Prepare and follow a routine inspection schedule based on
the media, environment, and frequency of use. This should
include periodic internal and external leakage checks.
S Keep the medium flowing through the valve as free from
dirt and foreign material as possible. Depending on
medium and service conditions, clean valve strainer, filter or
drip leg as required to keep the valve free of contamination.
In the extreme case, contamination will cause faulty valve
operation and the valve may fail to open or close.
S While in service, the valve should be operated at least once
a month to ensure proper opening and closing.
Testing for Internal (Seat) Leakage (Refer to Figures 1&2)
WARNING: Explosion/Fire Hazard. To prevent the
possibility of death, serious personal injury or property
damage from the release of combustible gas to the
atmosphere, extinguish all open flames and avoid any
type of sparking or ignition.
CAUTION: Be sure valve can be tested without
affecting other equipment.
1. Shut off both the upstream and downstream manual gas
cocks. The downstream manual gas cock should remain
closed throughout the entire test procedure.
2. Program the control system to operate the valve through
five cycles.
3. Open the upstream manual gas cock. Program the
control system to energize and maintain the valve in the
open (energized) position. Check all valve and piping
connections for external leaks with rich soap and water
solution or a commercially available leak detecting
solution.
*DuPont's Registered Trademark
Form No.V8708R1
50-60 Hanover Road, Florham Park, New Jersey 07932
www.ascovalve.com
4. Shut off the upstream manual gas cock and
de-energize valve. Remove the plug from the leak test
tap or downstream pressure tap in the valve body.
Connect leak test equipment with the test petcock in
the closed position, see Figure 2.
5. Open the upstream manual gas cock. Program the
control system to energize the valve to the full open
position, then immediately de-energize it to seat the
valve during operation.
6. Immerse the 1/4I leak test tubing vertically into the
plastic container of water to a depth of about 1/2I.
Slowly open the test petcock. Bubbles may appear in
the water as the pressure equalizes.
7. After the rate of bubbles coming through the water
stabilizes, count the number of bubbles appearing in a
10 second period. The allowable leakage in 10 seconds
for an orifice diameter of 1 inch (25.4 mm) or less is 6
bubbles (3 cc/min).
For valves with an orifice diameter over 1 inch (25.4
mm) the allowable leakage rate is 6 bubbles (3 cc/min.)
per inch (25.4 mm) of orifice diameter. If leakage
exceeds this rate, replace valve.
NOTE: The leakage rate above recognizes that some wear
and contamination from use can result in a slight amount of
leakage. The allowable leakage rate is well within the
leakage limits as recognized by applicable approval
agencies.
8. Close the upstream manual gas cock and the test
petcock. Then remove the test equipment. Apply a
small amount of Loctite Corporation's PSTr Pipe
Sealant 567 (or equivalent) to the pipe plug threads.
Reinstall pipe plug and torque to 12 ft-lbs (16.3 Nm).
9. Open the upstream manual gas cock. Program the
control system to energize and maintain the valve in
the open (energized) position. Check 1/4I NPT pipe
plug connection for external leaks with rich soap and
water solution or a commercially available leak
detecting solution.
10. De-energize the valve. Open the downstream manual
gas cock.
11. Restore the system to normal operation.
V710 Series Gas Valve with AH Series
HydramotorR Actuator
To illustrate leakage testing only.
Not for system layout.
upstream
manual
gas cock
gas
supply
leak
test tap
downstream
pressure tap
1/4I flex
tubing
1/4I aluminum
or copper
pilot tubing
external
leak
test tap
option
test
petcock
container
filled with
water
1/2I
45_ cut
FLOW
Figure 2. Testing for Internal Seat Leakage.
Form No.V8708R1
Page 3 of 3
50-60 Hanover Road, Florham Park, New Jersey 07932
downstream
manual
gas cock
www.ascovalve.com
to
burner
ransducers and TTransmitters
ransmitters
Transmitter
Current Output
Series 425
Shown with standard 1/4" NPT
with built-in snubber
4-20 mA
425 Series 4-20 mA
Pressure
Range (psi)
Features
Catalog Number
Gauge
Absolute
0-15
425H3-01
425H3-01-A
0-30
425H3-21
425H3-21-A
0-50
425H3-03
425H3-03-A
0-60
425H3-22
425H3-22-A
0-100
425H3-04
425H3-04-A
0-150
425H3-05
425H3-05-A
•
Welded Stainless
Steel Construction
•
Nema 4 Enclosure
•
EMI, ESD & RFI Protection
•
Reverse Polarity Protected
0-200
425H3-06
425H3-06-A
•
Stable, Diffused Silicon Sensor
0-300
425H3-07
425H3-07-A
•
Surface Mounted Conformal Coated Circuit
0-500
425H3-08
•
High Pressure Snubber
0-1000
425H3-10
•
0.25% Accuracy
0-2000
425H3-12
0-3000
425H3-13
0-4000
425H3-14
0-5000
425H3-15
0-6000
425H3-16
0-7500
425H3-17
0-10000
425H3-18
Qualified
Performance Characteristics*
Accuracy (LH & R)
Long Term Stability
Typical Life
Proof Pressure
Warranty
±0.25% FSO
±0.5% FSO of calibration curve
100 million cycles
2 times rated pressure or 13000 psi
max. (884 bar), whichever is less
3 years
Input
Excitation Voltage
Loop Resistance
Note: Bar pressure ranges available. Consult factory.
6 to 30 VDC (unregulated)
1500 ohms (max.)**
Temperature Shift
Zero & Span
Output
Output
Full Scale Output
Zero Output
Vibration
Shock
4 to 20 mA
16 mA ± 0.4%
4 mA ± 0.2%
Built-in Protection (with H-3 cable)
•
•
•
•
•
•
Physical
Weight
Wetted Parts
Enclosure
Pressure Connection
Electrical Connection
7.4 oz. (210 grams) to 1000 psi
9.4 oz. (266 grams) from 1000 psi
17-4 PH & 300 series stainless steel
NEMA 4, 304 stainless steel
1/4-18 NPT male
2 conductor, 22 awg, PVC jacketed,
shielded cable, 3 ft. (1m) long with
integral strain relief and ground
Conducted & Radiated RF emissions/interference to EN 55011
IEC 801-2 Level 3 ESD (6 kV contact, 8 kV air)
IEC 801-3 Level 3 Radiated RF field (80-1000 MHz at 10 V/m)
IEC 801-4 Electrical fast transient/burst (1 kV)
IEC 801-6 Level 3 conducted susceptibility 150 kHz-80 MHz -10 V rms
Pressure snubber standard on 2000 psi & above
Standard Options
S - Voltage surge protection, IEC 801-5 level 4 surge to 4 kV
T2 - 4-pin Bendix PT02A-8-4P less mating electrical connector
H4 - Subminiature DIN connection 43650 type
T4 - Hirschman ELST 412 PG9 less mating electrical connector
P1 - 7/16-20 UNF female process connector
NX4 - NEMA 4X enclosure
Environmental
Temperature Ranges
Operating
Compensated
Storage
±1.0% FSO (max.) over
compensated range
15 g’s, 10-2000 Hz, MIL-STD 202
50 g’s, 11 mS, MIL-STD 202
Method 213, Cond. G.
0 to 160oF (-18 to 71oC)
30 to 160oF (1 to 71oC)
-40 to 185oF (-40 to 85oC)
See page 13 for information on ordering standard options.
Consult factory for other options and design variations not listed.
* Definitions are in accordance with ANSI/ISA S37.1-75
** See inside cover for loop resistance curve
Barksdale, Inc. · 3211 Fruitland Avenue · Los Angeles, CA 90058 · ! 800-835-1060 · Fax (323) 589-3463 · www.barksdale.com
10
BELL & GOSSETT
INSTRUCTION MANUAL
P06451A
REVISION B
Bell & Gossett
© COPYRIGHT 1993, 1995 BY ITT CORPORATION
Morton Grove, IL, U.S.A.
2
3
4
PUMP BODY DIAGRAM
1AA, 11/4"AA, 11/2"AA and 2"AA
Discharge Gage Tapping
(on side opposite)
9
10
8
Seal Assembly
Volute Gasket
Coupler Assembly
Impeller (Enclosed)
3
Shaft Sleeve
Impeller Key
4
7
6
Pump Shaft
Impeller Lock Nut
1
5
Volute
Impeller Lock Washer
Motor Bracket Assembly
2
Face Plate
Rear Bearing
Front Bearing
Bearing Bracket Assembly
Volute Capscrews
Suction Gage Tapping
12
Companion Flange
(included)
9A Seal Housing
1AA, 11/4"AA, 11/2"AA and 2"AA
construstion details
9B Bellows
9E Seat Insert
9F Seat Gasket
9D Spring
9C Seal Ring
PUMP BODY DIAGRAM
11/2"A, 2"A, and 21/2"F
Mechanical Seal
Mechanical Seal
Discharge Gage Tapping
(on side opposite)
Seal Assembly
9
10
Coupler Assembly
Volute Gasket
Impeller (Enclosed)
3
Rear Bearing
Lip Seal
4
7
Pump Shaft
Impeller Key
6
5
Volute
Capscrews
Bearing Bracket Assembly
Impeller Lock Washer
1
Front Bearing
Motor Bracket
Impeller Lock Nut
8
Volute
Shaft Sleeve
11 Cover Plate
Suction Gage Tapping
12
Companion Flange
(included)
except 21/2F
except 2°F
11/2"A, 2"AA, and 21/2"F
construction details
5
For further information, contact ITT Bell & Gossett, 8200 N. Austin Avenue, Morton Grove, IL 60053,
Phone (847) 966-3700 – Facsimile (847) 966-9052.
Bell & Gossett
PRINTED IN U.S.A. 2-95
Morton Grove, IL, U.S.A.
BELL & GOSSETT
INSTRUCTION MANUAL
P81629
REVISION C
Bell & Gossett
© COPYRIGHT 1965, 1992 BY ITT CORPORATION
Morton Grove, IL, U.S.A.
2
3
4
Shaft
Slinger
Bracket Cover Plate
Shaft Sleeve
Seal Assembly
Impeller Washer
Impeller Key
Volute Gasket
Volute
Cap Screw
Impeller
Impeller Lock Washer
Volute
FIG. 7
Impeller Cap Screw
SERIES 80 WITH STANDARD
MECHANICAL SEAL
Shaft
Bracket
Slinger
Shaft Sleeve
Gland Bolt
Packing
Packing Gland
Flush Line
Lantern Ring
Cover Plate
Cap Screw
Drip Drain
Impeller Key
Cover Plate
Volute
Cap Screw
Volute Gasket
Impeller Washer
Impeller
Impeller Cap Screw
Impeller
Lock Washer
Volute
FIG. 8
STUFFING BOX CONSTRUCTION
5
O-RING
COVERPLATE
FOR 11/4" SEAL
113/32"
MOTOR
END
FOR 15/8" SEAL
11/4"
O-RING
SEAL LOCKING COLLAR
SEAL CAP
SEAL CAP BOLTS
MOTOR
END
O-RING
6
O-RING
7
For further information, contact ITT Bell & Gossett, 8200 N. Austin Avenue, Morton Grove, IL 60053,
Phone (847) 966-3700 – Facsimile (847) 966-9052.
Bell & Gossett
PRINTED IN U.S.A. 12-92
Morton Grove, IL, U.S.A.
BELL & GOSSETT
INSTRUCTION MANUAL
P81547
REVISION A
Bell & Gossett
© COPYRIGHT 1982, 1994 BY ITT CORPORATION
Morton Grove, IL, U.S.A.
2
3
4
7 SHAFT
SLINGER
6 SHAFT SLEEVE
8
5 SEAL ASSEMBLY
BRACKET COVER PLATE
VOLUTE CAP SCREW
4 VOLUTE GASKET
SUCTION
DISCHARGE
GAUGE TAPPING
2 IMPELLER
9 COMPANION FLANGE
1 VOLUTE
3 IMPELLER CAP SCREW
7 SHAFT
6 SHAFT SLEEVE
SLINGER
5 SEAL ASSEMBLY
8
BRACKET COVER PLATE
VOLUTE CAP SCREW
4 VOLUTE GASKET
SUCTION
DISCHARGE
GAUGE TAPPING
2
3 IMPELLER LOCK NUT
IMPELLER
1 VOLUTE
9 COMPANION FLANGE
5
For further information, contact ITT Bell & Gossett, 8200 N. Austin Avenue, Morton Grove, IL 60053,
Phone (847) 966-3700 – Facsimile (847) 966-9052.
Bell & Gossett
PRINTED IN U.S.A. 1-94
Morton Grove, IL, U.S.A.
Dual Safety Shutoff Valves
DMV-D/6, DMV-DLE/6
Two normally closed safety shutoff
valves in one housing; each with
the following approvals.
UL Recognized
• UL 429
• File # MH16727
CSA Certified
• ANSI Z21.21 • CSA 6.5
• C/I Automatic Valves
• File # 1010989
FM Approved
• Class 7411
• File # J.I.1Z6A0.AF
EU Gas Appliance Directive
• EN161
• CE-0087AU30
US, Canadian and EU Models
• DMV-D 701/6, 702/6, 703/6
• DMV-DLE 701/6, 702/6, 703/6
• 1/2 in. NPT - 2 in. NPT
• Rp1/2 - Rp2
Printed in Germany • Edition 10.02 • Nr. 226 377
DUNGS is an ISO 9001 manufacturing facility.
1…6
Description
The DUNGS Dual Modular Valve (DMV)
combines two automatic shutoff valves
in one compact housing, which can be
wired independently or in parallel.
Valve 1 (V1) of the DMV-D and DMVDLE series is fast opening and fast
closing. Valve 2 (V2) of the DMV-D is
fast opening, while V2 of the DMV-DLE
is slow-opening for smoother light-off.
Max. flow adjustment on V2 provides
variable main flow on both models.
Internal profiles and compact design
optimize flow and provide a low pressure drop. Three body styles reduce
inventory.
Directly mounting the following DUNGS
accessories creates a compact valve
train without additional piping:
- Pressure regulator
- High and low gas pressure switches
- Valve proving system
- Vent line adapter
Application
The DUNGS DMV is recommended for
industrial and commercial heating applications that require two safety shutoff valves. The DMV Dual Multi-Valve
is suitable for natural gas, propane,
butane, air and inert gases.
DMV-D…/6
Two normally closed safety shutoff valves in one housing. V1 and V2 are fast opening, fast closing.
Adjustable max flow with V2.
DMV-DLE…/6
Two normally closed safety shutoff valves in one housing. V1 fast opening, fast closing.
V2 is slow opening, fast closing. Adjustable max flow and Adjustable initial lift with V2.
Specifications
Body sizes
pipe size / thread
DMV 701
1/2” - 1” NPT or Rp
Max. operating pressure
7 PSI (500 mbar) UL, FM, CE (Class A)
Max. body pressure
15 PSI (1000 mbar)
Max. close-off pressure
7 PSI (500 mbar) UL, FM, CE (Class A)
Electrical ratings (+10% / -15%)
110 - 120 VAC/50 - 60 Hz
24 VAC/ 50 - 60 Hz
220 - 240 VAC/50 - 60 Hz
24 VDC
Power ratings
DMV 701: 45 VA
DMV 702: 65 VA
DMV 702
1” - 2” NPT or Rp
DMV 703
1” - 2” NPT or Rp
5 PSI (360 mbar) CSA
5 PSI (360 mbar) CSA
DMV 703: 90 VA
Ratings shown are total power consumption for both valves inclusive. Inrush and full load current have the same VA rating.
Enclosure rating
NEMA Type 12
Electrical connection
DIN-connector with 1/2” NPT conduit adapter
Operating time
100 % duty cycle
Closing time
<1s
Opening time (to max. flow)
DMV-D…/6
DMV-DLE…/6
V1 & V2 < 1 s
V1 < 1 s; V2 Adjustable to approx. 10 to 20 s at 70 °F
Initial lift adjustment
Adjustable on V2
DLE only; 0 to 70 % of total flow; 0 to 35% of stroke
Max. flow adjustment
Adjustable on V2
Materials in contact with gas
Housing:
Aluminium, Steel
Sealings on valve seats: NBR-based rubber
Ambient temperature rating
-40 °F to +150 °F (-40 °C to +65 °C)
Installation position
Safety valve upright vertical to horizontal
Test ports /
Pressure switch mounting ports
G 1/8 ISO 228 ports available on both sides. Each side has one port upstream V1,
one between V1 and V2, one downstream V2, and one on each flange.
Gas filter (optional)
Replaceable integral gas filter (50 micron) in inlet of DMV or
Pre-Mount Filter Block for DMV 702 and 703. (Cannot be used with FRI directly
mounted to the DMV.)
Gas strainer (standard)
Installed in the housing upstream V1 (23 mesh)
Position indication
(order separately)
CPI 400 with indication lamps and SPDT interlock switch or
Visual indicator (VI)
Valve proving system
Requires VPS 504; mounts directly to either side of DMV.
<10 to 100 % of total flow; <10 to 100% of stroke
2…6
DMV dual safety shutoff valve modular system
Optional mounting system shown,
other configurations possible
Port 1
Port 2
Port 3
Pmax. = 7 PSI
DMV dual safety shutoff
valve with upstream FRI
pressure regulator
FRI
Pressure switch can be
mounted on flange
V2
V1
DMV
Port
1
Port 3
Port
2
Position Indicator:
CPI 400 interlock switch on V1 or V2
Visual Indicator (VI) on V1 or V2,
or on both
Low gas pressure switch
Valve proving system
(VPS 504)
Port 1
Port 2
High gas
pressure switch
Port 3
Pmax. = 7 PSI
DMV dual safety shutoff
valve with downstream FRI
pressure regulator
V2
V1
DMV
Low gas pressure switch
Port
1
FRI
Port
2
Port 3
High gas
pressure switch
Position Indicator:
CPI 400 interlock switch on V1 or V2
Visual Indicator (VI) on V1 or V2, or on both
When an accessory is added
to the DMV, it may not be
possible to mount other devices.
FRI Gas pressure regulator
Mounting the FRI series gas pressure
regulator directly to the DMV dual
safety shutoff valve is possible with a
mounting kit.
The FRI pressure regulator can be installed upstream or downstream of the
DMV dual safey shutoff valve depending on application requirements.
FRI mounting kit for DMV
FRI 705 - 707/6 to DMV 701/6
Order No. 219 967
(Previously FRI 505-507/6)
Valve proving system
(VPS 504)
Additional Accessories
VPS 504
Valve proving system (approved by
some authorities having jurisdiction in
lieu of vent valve and “proof of closure”).
Integral gas filter (optional)
50 micron gas filter
Pre-Mount Filter (optional)
50 micron gas filter
GAO/GMH/GML A2 pressure switch
FRI 710-712/6 to DMV 702/6 + 703/6
Order No. 219 968
(Previously FRI 505-507/6)
3…6
Position indication
CPI 400 with indication lamps and SPDT
interlock switch, or visual indicator (VI)
DMK butterfly control valve
Mounts directly downstream of DMV to
modulate gas flow. Requires actuator.
Use DMA actuator with DMK butterfly
valve.
DMV D(LE) 7xx/6 VL (with vent line
adapter)
Factory installed vent line adapter
which integrates a vent line
connection with the DMV series.
Adapters
• 1/4” NPT adapter (D225047)
• 1/2” NPT Pilot gas adapter; Check
flow requirements. (D225043)
• G 1/8” Test nipple (D219008)
• Port 3 Pressure switch mounting
adapter (D214975)
d
Dimensions inch (mm)
Port 2
Port 1
c
Port 3
a
e
b
Type
110-120 VAC
50-60 Hz
Order No.
24 VAC
50-60 Hz
Order No.
24 VDC
Order No.
DMV-D 701/6
D224 842
D228 220
D226 990
45
DMV-D 702/6
D224 843
D228 221
D226 991
65
DMV-D 703/6
D224 844
D228 222
D226 992
90
DMV-DLE 701/6
D224 845
D228 223
D226 993
45
DMV-DLE 702/6
D224 846
D228 224
D226 994
65
DMV-DLE 703/6
D224 847
D228 225
D226 995
90
Power*
[VA]
a
Dimensions [inch]
Dimensions [mm]
b**
d
c****
e
Weight
[lbs]
[kg]
5.6
141
6.9 / 8.1
174 / 206
6.9 / 8.1
175 / 206
1.4
35
1.8
45
1.8
45
5.3
134
5.9
150
7.5
190
2.9
73
3.9
101
3.9
101
4.6
2.1
10.1
4.6
12.1
5.6
5.6
3.7
141
93
4.9 6.9 / 8.1
124 174 / 206
7.9
4.9
124 174 / 206
1.4
35
1.8
45
1.8
45
5.9
160
6.7
179
8.6
218
2.9
73
3.9
101
3.9
101
4.8
2.2
10.3
4.7
12.3
5.7
3.7
93
4.9
124
4.9
124
* Inrush current and full load current have the same VA rating.
** DMV 702/703 with 1” or 1 - 1/4” flange: 6.9” / DMV 702/703 with 1 - 1/2” or 2” flange: 8.1”
*** When using the CPI Closed Position Indicator switch add 3”. When using with the vent line adapter assembly, add 1.65”
to dimension c. (see vent line adapter information sheet)
Flange
1/2”
3/4”
1”
1”
1 1/4”
1 1/2”
2”
Valve
DMV-701/6
DMV-701/6
DMV-701/6
DMV-702/6 & 703/6
DMV-702/6 & 703/6
DMV-702/6 & 703/6
DMV-702/6 & 703/6
Pre-Mount Filter
DMV-701/6
DMV-702/6
DMV-703/6
D232 440
D226 342
D226 342
NPT
D222 371
D222 368
D221 999
D222 369
D222 370
D222 003
D221 997
Rp
D222 341
D222 342
D222 001
D222 343
D222 344
D221 884
D221 926
Pre-Mount replacement filter
DMV-701/6
D238 653
DMV-702/6
D226 997
DMV-703/6
D226 997
DIN-Connector
CPI 400
Visual indicator
D210 319
D224 253
46000-6
Please order flanges,
position indicators and
gas filters separately
Integral strainer replacement
DMV-701/6
D214 276
DMV-702/6
D214 525
DMV-703/6
D214 525
4…6
DMV-D(LE)…/6
sectional drawing
10
11
9
8
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
16
15
7
14
6
13
5
12
4
2
3
2
p1
1
V1
V2
V1
p2
V2
Strainer
Flange
Valve V1
Housing
Closing spring V1
Plunger V1
Solenoid V1
Electrical connection
Max flow adjustment
Initial lift adjustment (DMV-DLE)
Hydraulic brake (DMV-DLE)
Valve V2
Closing spring V2
Plunger V2
Solenoid V2
Solenoid housing
Visual indicator (VI)
CPI 400 interlock switch
17
CPI 400 can be used
in place of one
visual indicator
18
°
Vgas used =
°
V Natural Gas x f
f = correction factor to determine
flow through valves with other
gases.
f=
Spec. gravity of Natural Gas
Spec. gravity of gas used
sg
f
Type of gas
Density
[kg/m3]
Natural gas
0.81
0.65
1.00
Butane
2.39
1.95
0.58
Propane
1.86
1.50
0.66
Air
1.24
1.00
0.80
Flow (CFH) of natural gas, s.g. 0.65 at 60 °F with 1 in. W.C. pressure drop @ 1.25 psi inlet pressure
5…6
DMV 701
DMV 702
DMV 703
1/2 “
3/4”
1”
1-1/4”
1-1/2”
2”
345
–
–
429
–
–
457
1065
1230
–
1277
1532
–
1368
1698
–
1430
1795
Dual Safety Shutoff Valves
DMV-D/6, DMV-DLE/6
DMV 703 2”
DMV 703 1 1/2”
DMV 703 1 1/4”
DMV 703 1”
DMV 702 2”
DMV 702 1 1/2”
DMV 702 1 1/4”
DMV 702 1”
DMV 701 1”
DMV 701 3/4”
DMV 701 1/2”
Flow diagram
50
40
30
Pressure Drop (in. W.C.)
20
10
9
8
7
6
5
4
3
2
Based on 60 °F, 14.65 psia, dry
1,0
200
400
600
1,000
2,000
4,000
6,000 10,000
20,000
Flow (CFH) of natural gas s.g. 0.65 at 60 °F
20 in W.C.
We reserve the right to make any changes in the interest of technical progress.
Karl Dungs Inc.
524 Apollo Drive, Suite 10
Lino Lakes, MN 55014, U.S.A.
Phone 651 792-8912
Fax
651 792-8919
e-mail [email protected]
Internet http://www.dungs.com/usa/
Karl Dungs GmbH & Co. KG
P.O. Box 12 29
D-73602 Schorndorf, Germany
Phone +49 (0)7181-804-0
Fax
+49 (0)7181-804-166
e-mail [email protected]
Internet http://www.dungs.com
6…6
Pressure switch for
dual modular valves
GAO-A2…
GMH-A2…
GML-A2…
UL Listed
• UL 353
• File # MH 16628
CSA Certified
• CSA C22.2 No. LR 53222
• Certification # 201527
FM Approved
• Class 3510, 3530
• File # J.I. 1T7A8.AF
European models tested to EN1854
per Gas Appliance Directive 90/396/
EEC and per Pressure Equipment
Directive 97/23/EC.
Printed in Germany • Edition 10.02 • Nr. 226 359
DUNGS is an ISO 9001 manufacturing facility.
1…6
Description
The GAO-, GMH-, and GML-A2… pressure switches are compact pressure
switches for DUNGS modular valve train
components.
A2 pressure switches are suitable for
making and/or breaking a circuit when
the medium pressure changes relative
to the set point. The set point can be set
in the field by an adjustable dial with an
integrated scale.
Application
The DUNGS GAO-, GMH-, and GMLA2… pressure switches are recommended for industrial and commercial
heating applications with DUNGS DMV
dual modular valves and DUNGS FRI
modular pressure regulators. Various
mounting options allow direct mounting on the housing.
The GAO-, GMH-, and GML-A2… pressure switches are suitable for natural
gas, propane, butane, air and other inert gases.
GAO-A2… SPDT pressure switch requires no auxiliary power. The GAO-A2… is suitable for making and/or breaking a
circuit when the set point is exceeded or undershot. A tripped switch is indicated by a neon light after set point is
exceeded or undershot. Automatic reset when pressure returns below or above set point.
GMH-A2… SPDT pressure switch requires no auxiliary power. The GMH-A2… is suitable for making and/or breaking a
circuit when the set point is exceeded. A tripped switch is indicated by a neon light after set point is exceeded.
Manual reset is required to reset the switch.
GML-A2… SPDT pressure switch requires no auxiliary power. The GML-A2… is suitable for making and/or breaking a
circuit when the set point is undershot. A tripped switch is indicated by a neon light after set point is undershot.
Manual reset is required to reset the switch.
Specifications
Max. operating pressure
GAO-A2-4-2,3,5,6
GMH- and GML-A2-4-4,6
GAO-, GMH- and GML-A2-4-8
Pressure connection
O ring flange connection on underside of pressure switch
Temperature range
GAO-, GMH- and GML-A2-4
7 PSI (500mbar)
7 PSI (500mbar)
14 PSI (1000 mbar)
Ambient temperature
Medium temperature
Ambient temperature
Medium temperature
-40 °F to +140 °F
-40 °F to +140 °F
-22 °F to +140 °F
-22 °F to +140 °F
Materials
Housing
Switch
Diaphragm
Switching contact
Aluminium
Polycarbonate
NBR-based rubber
Silver or Gold
Electrical ratings
AC eff.
DC
min. 24 V max. 240 V
min. 24 V max. 48 V
Nominal current
Silver (Ag) contact ratings
AC 10A resistive @ 120 VAC
AC 8A inductive @ 120 VAC
DC min. 20 mA @ 24 VDC
DC max. 1 A @ 48 VDC
Gold (Au) contact ratings
GAO-, GMH- and GML-A2-4-8
(-40 °C to +60 °C)
(-40 °C to +60 °C)
(-30 °C to +60 °C)
(-30 °C to +60 °C)
DC max. 5m A @ 5 VDC
DC max. 20m A @ 24 VDC
Electrical connection
Screw terminals via 1/2" NPT conduit connection
Enclosure rating
NEMA Type 4
Setting tolerance
± 15% switching point deviation referred to set point. Adjusted as pressure rises
or as pressure falls, vertical diaphragm position.
GAO switching function (upper)
As pressure rises:
1 NC opens, 2 NO closes
As pressure falls:
1 NC closes, 2 NO opens
2 NO
COM
O (orange)
NE (neon)
p
N
Medium pressure
O (orange)
NE (neon)
p
N
Medium pressure
2 NO
COM
1 NC
3
1 NC
3
O
NE
GML switching function
shown in Operating state.
As pressure falls
2 NO opens, 1 NC closes
Neon light ON, tripped.
2 NO
COM
1 NC
3
GMH switching function
As pressure rises
2 NO closes, 1 NC opens
Neon light ON, tripped.
O
NE
O (orange)
NE (neon)
p
O
NE
N
Medium pressure
2…6
.8 (22)
1.7 (43,2)
Dimensions inch (mm)
GAO-, GMH-, GML-A2…
.4 (10)
Through hole
for M4 Screw
Reset button
GMH-A2…
GML-A2…
•
Slot for O ring
(10.5 x 2.25)
2.1 (53,7)
2.8 (72)
•
.07 (2)
2.1 (53,7)
2.8 (72)
Made in Germany
que 65 in. Lbs M.
torq
Adapters / replacement parts /
Accessories
Order No.
For equipment
Notes
A2 Mounting kit (included)
D226 188
GAO, GMH, GML
M4 Screws,
10.5 x 2.25 O-ring
DMV Port 3 adapter (DMV side
mount for high pressure switch)
D214 975
DMV-D(LE) 701 - 703
NPT 1/2“ - NPT 2“
Replacement conduit adapter
46000-14
GAO, GMH, GML
1/2“ NPT
Replacement cover
D228 732
GAO
Replacement cover
D233 113
GMH, GML
Replacement light
D244 156
GAO, GMH, GML
120 VAC, Red bulb
Replacement light
D244 157
GAO, GMH, GML
Gold contact versions
24 V, Red bulb
Electrical plug for A2
(For use with D210318)
D219 659
GAO
N/A
Electrical plug for A2
(For use with D210318)
D227 644
GMH, GML
N/A
DIN Connector for A2
(For use with D219 659 & D227 644)
D210 318
GAO, GMH, GML
N/A
Setpoint tolerance
Rising
Falling
Upper switching
pressure
Adjustment as
pressure rises
Pressure
at meter
Switching hysteresis ∆p
Definition of switching hysteresis ∆p
The pressure difference between the
upper and lower switching pressures
3…6
ax.
Lower switching
pressure
A2 mounting options
FRI gas pressure regulator
Pressure tap
mounting possible…
1
1
yes
p
2
yes
3
yes
max.
= 7 PSI
2
3
FRI
1
A2 mounting options
MB 053-403 GasMultiBloc
3 pa
2 pe
Pressure tap
1
4
mounting possible…
1
yes, with #D221 630
2
yes
3
yes
4
yes, with #D221 630
3 pa
2 pe
4
1
2
3
3
2
1
A2 mounting options
MB-D GasMultiBloc; MB-Z 405-412
2
Pressure tap
7
3
pe
4
pa
1
5
pBr
6
mounting possible…
1
alternativ to 7
2
no
2
7
6
3
pe
4
pa
5
pBr
4
pa
5
pBr
4
pa
5
pBr
6
1
3
yes
2
➞
4
➞
yes
2
43 5
5 34
5
yes, with #D214 975
6
yes, with #D221 630
7
yes
2
7
1
6
7
3
pe
3
pe
6
2
➞
5
➞
34
43
5
4…6
A2 mounting options
DMV 300/500 Dual modular valve
DMV 500 p
Pressure tap
= 5 PSI
4
mounting possible…
yes
2
yes
3
yes, with # D214 975
4
yes, horizontal
yes, with # D221 630
V1
4
2
1
4
3
yes, with # D214 975
= 7 PSI
4
4
yes, horizontal
yes, with #D221 630
V1
1
4
4
2
3
1
1
pmax. = 7 PSI
3
2
4
5
6
V1
Pressure tap
mounting possible…
yes
2
yes
3
yes
4
yes
5
no
6
no
1
5
3
2
1
5…6
3
4
A2 mounting options
DMV 525,5040-5125/11Dual modular
valve
1
4
V2
2
1
4
3
max.
mounting possible…
yes
2
1
DMV 700 p
2
3
2
1
3
Pressure tap
yes
2
4
A2 mounting options
DMV 701-703 Dual modular valve
1
4
V2
1
4
3
max.
DMV 300 p max.= 3 PSI
1
2
1
6
6
4
2
V2
3
4
5
3
2
1
Pressure switch for
dual modular valves
GAO-A2…
GMH-A2…
GML-A2…
Technical data
Type
Version
Order No.
Setting range
In. W.C
Switching hysteresis
∆p In. W.C (calibrated at)
GAO-A2…
pressure switch
GAO-A2-4-2
GAO-A2-4-3
GAO-A2-4-5
GAO-A2-4-6
GAO-A2-4-8
D217 085
D217 086
D217 087
D217 088
D217 089
0.16 - 1.20“
0.40 - 4.00“
2.00 - 20.00“
12.0 - 60.00“
40.00 - 200.00“
≤ 0.12“
≤ 0.20“
≤ 0.40“
≤ 1.20“
≤ 4.00“
GMH-A2…
pressure switch
GMH-A2-4-4
GMH-A2-4-6
GMH-A2-4-8
D217 323
D217 324
D217 325
1.00 - 20.00“
12.00 - 60.00“
40.00 - 200.00“
----
GML-A2…
pressure switch
GML-A2-4-4
GML-A2-4-6
GML-A2-4-8
D217 337
D217 338
D217 339
1.00 - 20.00“
12.00 - 60.00“
40.00 - 200.00“
----
All switches have 120 VAC neon lights factory installed
We reserve the right to make any changes in the interest of technical progress.
Karl Dungs Inc.
524 Apollo Drive, Suite 10
Lino Lakes, MN 55014, U.S.A.
Phone 651 792-8912
Fax
651 792-8919
e-mail [email protected]
Internet http://www.dungs.com/usa/
Karl Dungs GmbH & Co. KG
P.O. Box 12 29
D-73602 Schorndorf, Germany
Phone +49 (0)7181-804-0
Fax
+49 (0)7181-804-166
e-mail [email protected]
Internet http://www.dungs.com
6…6
Safety Shutoff Valves
MVD/6, MVDLE/6
®
Normally closed safety shutoff
valve with the following approvals.
UL Listed
• UL 429
• File # MH16727
AGA / CGA Certified
• ANSI Z21.21
• CGA 6.5
• CGA 3.9
• File # LM112901-04
FM Approved
• Class 7411
• File # J.I.0V9A8.AF
US and Canadian Models
• MVD 505/6 - MVD 530/6
• MVDLE 205/6 - MVDLE 230/6
• 1/2 in. NPT - 3 in. NPT
European models tested to EN161
per Gas Appliance Directive 90/396/
EEC.
Printed in Germany • Edition 02.00 • Nr. 226 354
DUNGS is an ISO 9001 manufacturing facility.
1 …6
Description
The DUNGS MVD and the MVDLE electrically operated normally closed, automatic safety shutoff valves for gas
burners and gas appliances.
- Closing time <1s.
- Max. operating pressure up to
7 PSI (500 mbar) on MVD
3 PSI (200 mbar) on MVDLE
- Max. close off pressure
15 PSI (1000 mbar) on all models
- MVD: fast opening/fast closing
- MVDLE: slow opening with adjustable initial lift, fast closing
- Max flow is adjustable
- 120 VAC/ 60 Hz, 24 VAC/ 60 Hz(in
some models)
- 1/2" NPT conduit connection
- Optional field installable visual indicator
(VI) or CPI 400 with indication lamps and
SPDT interlock switch for valve position.
- Reliable, quiet operation; rugged
and low maintenance.
Application
The DUNGS MVD and MVDLE are recommended for industrial and commercial heating applications that require
one safety shutoff valve or two safety
shutoff valves in series. The MVD and
MVDLE safety shutoff valves are suitable for natural gas, propane, butane,
air and other inert gases.
MVD
Normally closed automatic safety shutoff valve, fast opening, fast closing. Adjustable max. flow.
MVDLE
Normally closed automatic safety shutoff valve, slow opening, fast closing. Adjustable initial lift.
Adjustable max. flow.
Specifications
Pipe thread (NPT)
1/2"
Max. operating pressure
MVD
Max. body pressure
15 PSI (1000 mbar)
Max. close off pressure
15 PSI (1000 mbar)
Electrical ratings (-10 % to +15 %)
120 VAC, 24 VAC (available in some models) / 60 Hz; see page 3 and 4
Power ratings
Refer to type overview page 4
Enclosure rating
NEMA 1
Electrical connection
Screw terminals with 1/2" NPT conduit connection
Operating time
100 % duty cycle
Closing time
<1s
Opening time (to max. flow)
MVD < 1 s
MVDLE Adjustable to approx. 10 to 20 s at 70 °F
Initial lift adjustment
MVDLE only - 0 to 70% of total flow; 0 to 25% of stroke
Max. flow adjustment
Adjustable from <10 to 100 % of total flow; <10 to 100 % of stroke
Materials in contact with gas
Aluminium, steel, brass / Seals: NBR-based rubber
Ambient temperature rating
-20 °F to +140 °F (-30 °C to +60 °C), depending on approval. See also page 3
Installation position
Safety shut off valve from vertically upright to horizontal
Test ports
Two 1/4" NPT upstream and two 1/4" NPTdownstream ports
Gas strainer (standard)
Installed in the housing upstream (23 mesh)
Position indication (order separately)
CPI 400 with indication lamps and SPDT interlock switch or Visual indicator (VI)
Valve proving system (requires two
safety shutoff valves in system)
Type VDK 200, mounts externally using valve side ports or pipe "T"s.
3/4"
1"
1 1/4"
1 1/2"
7 PSI (500 mbar), MVDLE
2"
2 1/2"
3"
3 PSI (200 mbar), see page 3
2…6
Max. Close Off
(PSI)
-20 °F to 120 °F
-20 °F to 120 °F
-20 °F to 120 °F
-20 °F to 120 °F
7
3
7
3
7
7
7
7
120/60 (-10% +15%)
120/60 (-10% +15%)
24/60 (-10% +15%)*
24/60 (-10% +15%)*
D
DLE
-30 °F to 140 °F
-30 °F to 140 °F
7
3
15
15
120/60, 24/60 (-10% +15%)*
120/60, 24/60 (-10% +15%)*
D
DLE
-20 °F to 120 °F
-20 °F to 120 °F
5
2
5
5
120/60 (-10% +15%)
120/60 (-10% +15%)
D
DLE
-20 °F to 120 °F
-20 °F to 120 °F
7
3
7
7
120/60 (-10% +15%)
120/60 (-10% +15%)
Model
Temperature Rating
UL 429
D
DLE
D
DLE
FM 7411
®
Z21.21
3.9
6.5
* 24VAC available in some models (See page 4)
** Maximum Operating Pressure Differential
3 …6
Electrical Ratings
(Volts / Hz)
MOPD
(PSI)**
Approvals
Type
PSI
NPT
Pmax.**
[VA]
Solenoid
No.
Order
No.
46030-2
46031-2*
46030-3
46031-3*
46030-4
46031-4*
46030-5
15
approx. 10 s
25
approx. 10 s
25
approx. 10 s
60
approx. 10 s
Opening time
to max flow
a
Inrush and
Full Load
MVDLE 205/6*
3
1/2"
MVDLE 207/6*
3
3/4"
MVDLE 210/6*
3
1"
MVDLE 212/6
3
1 1/4"
100
100
200
200
200
200
300
MVDLE 215/6
3
1 1/2"
300
46030-6
60
approx. 10 s
MVDLE 220/6
3
2"
300
46030-8
60
approx. 10 s
MVDLE 225/6
3
2 1/2"
400
46030-10
80
approx. 10 s
MVDLE 230/6
3
3"
500
46030-12
90
approx. 10 s
MVD 505/6*
7
1/2"
<1s
7
3/4"
25
<1s
MVD 510/6*
7
1"
25
<1s
MVD 512/6
7
1 1/4"
46040-2
46041-2*
46040-3
46041-3*
46040-4
46041-4*
46040-5
15
MVD 507/6*
100
100
200
200
200
200
300
60
<1s
MVD 515/6
7
1 1/2"
300
46040-6
60
<1s
MVD 520/6
7
2"
400
46040-8
100
<1s
MVD 525/6
7
2 1/2"
500
46040-10
80
<1s
MVD 530/6
7
3"
550
46040-12
100
<1s
Dimensions [inch]
Dimensions [mm]
b
c
d
e
Weight
[lbs]
[kg]
1.97
50
2.76
70
2.95
75
3.74
95
3.74
95
4.53
115
5.12
130
5.91
150
2.95
75
3.94
100
4.33
110
5.91
150
5.91
150
6.69
170
9.06
230
10.43
265
5.31
135
6.50
165
6.50
165
8.07
205
8.07
205
8.07
205
11.61
295
14.21
361
2.76
70
3.15
80
3.54
90
4.57
116
4.57
116
5.12
130
6.50
165
7.87
200
6.10
155
7.48
190
7.68
195
9.65
245
9.65
245
9.84
250
13.78
350
16.97
431
2.43
1,10
5.62
2,55
6.06
2,75
9.70
4,40
12.13
5,50
13.67
6,20
25.13
11,40
38.14
17,31
1.97
50
2.36
60
2.95
75
3.74
95
3.74
95
4.53
115
5.12
130
5.91
150
2.95
75
3.94
100
4.33
110
5.91
150
5.91
150
6.69
170
9.06
230
10.43
265
3.54
90
5.31
135
5.31
135
6.89
175
6.89
175
6.89
175
8.46
215
11.22
285
2.76
70
3.15
80
3.54
90
4.57
116
4.57
116
5.12
130
6.50
165
7.87
200
4.45
113
6.30
160
6.50
165
8.27
210
8.27
210
9.25
235
10.63
270
13.94
354
2.20
1,00
5.29
2,40
5.73
2,60
11.91
5,40
11.91
5,40
19.40
8,80
31.97
14,50
55.11
25,00
* Designates model is also available in 24VAC/60 Hz. Part Number also shown.
** Inrush current and full load current have the same VA rating.
Dimensions inch (mm)
e
c
1/2” NPT conduit connection
a
NPT
1/4” NPT upstream port
2.8 (71)
1/4” NPT downstream port
b
d
4…6
Type MVDLE
sectional drawing
Type MVD
sectional drawing
9
10
8
8
7
7
120 VAC 60 Hz
120 VAC 60 Hz
6
5
4
p1
p2
3
2
NPT
p1
p2
NPT
NPT
3
2
NPT
1
1
11
12
1
2
3
4
5
6
7
8
9
10
Housing
Strainer
Valve disc
Closing spring
Plunger
Functional description
The DUNGS MVD and MVDLE valves
are automatic safety shutoff valves.
The electromagnetic drive opens against
the force of the closing spring 4.
The main flow through valve can be
limited by the maximum flow adjustment 8.
°
Vgas used =
On the MVDLE, the hydraulic brake 10
permits slow opening. Initial lift can be
adjusted 9. If power is interrupted (operating voltage), closing spring 4 closes
the valve within 1 second.
°
V Natural Gas x f
11
12
CPI 400 position
interlock switch
Visual indicator (VI)
The valve position can be visually monitored by using the field installed visual indicator (VI) 12, or it can be visually
and electronically monitored by a field
installed CPI 400 with indication lamps
and SPDT interlock switch 11.
(Order separately)
sg
f
Type of gas
Density
[kg/m3]
Natural gas
0.81
0.65
1.00
Butane
2.39
1.95
0.58
Spec. gravity of Natural Gas
Propane
1.86
1.50
0.66
Spec. gravity of gas used
Air
1.24
1.00
0.80
f = correction factor to determine
flow through valves with other
gases.
f=
5 …6
Solenoid
Electrical connection
Max flow adjustment
Initial lift adjustment MVDLE
Hydraulic brake MVDLE
Safety Shutoff Valves
MVD/6, MVDLE/6
NPT 3”
NPT 2 1/2”
NPT 2”
NPT 1 1/2”
NPT 1 1/4”
NPT 1”
NPT 3/4”
NPT 1/2”
Flow diagram
50
40
30
Recommended
operating range
Pressure Drop (in. W.C.)
20
10
8
6
5
4
3
2
Based on 60 °F,
14.65 psia, dry
1
100
200
300 400
600 800 1,000
2,000
4,000 6,000
10,000
20,000
40,000
Flow (CFH) of natural gas; s.p. 0.65 at 60 °F
We reserve the right to make any changes in the interest of technical progress.
Karl Dungs Inc.
524 Apollo Drive Suite 10
Lino Lakes, MN 55014, U.S.A.
Phone 651 792-8912
Fax
651 792-8919
e-mail [email protected]
Internet http://www.dungs.com
Karl Dungs GmbH & Co.
P.O. Box 12 29
D-73602 Schorndorf
Phone +49 (0)7181-804-0
Fax
+49 (0)7181-804-166
e-mail [email protected]
Internet http://www.dungs.com
6…6
Instruction Manual 818
2/02
VeriFlame Single Burner
Monitoring System
Model 5600
Version 1.21
Modulation Model
No Purge Model
Purge Model
COPYRIGHT
Copyright 1997 by Eclipse Combustion, Inc. All rights reserved worldwide. This
publication is protected by federal regulation and shall not be copied,
distributed, transmitted, transcribed or translated into any human or computer
language, in any form or by any means, to any third parties, without the express
written consent of Eclipse Combustion, Inc., Rockford, Illinois, U.S.A.
DISCLAIMER NOTICE
In accordance with the manufacturer’s policy of continual product improvement,
the product presented in this brochure is subject to change without notice or
obligation.
The material in this manual is believed adequate for the intended use of the
product. If the product is used for purposes other than those specified herein,
confirmation of validity and suitability must be obtained. Eclipse Combustion,
Inc. warrants that the product itself does not infringe upon any United States
patents. No further warranty is expressed or implied.
We have made every effort to make this manual as accurate and complete as
possible. Should you find errors or omissions, please bring them to our attention
so that we may correct them. In this way we hope to improve our product
documentation for the benefit of our customers. Please send your corrections
and comments to our Marketing Communications Manager.
LIABILITY AND
WARRANTY
It must be understood that Eclipse Combustion’s liability for its products,
whether due to breach of warranty, negligence, strict liability, or otherwise, is
limited to the furnishing of burner monitoring system replacement parts and
Eclipse Combustion will not be liable for any other injury, loss, damage or
expenses, whether direct or consequential, including but not limited to loss of
use, income of, or damage to material arising in connection with the sale,
installation, use of, inability to use or the repair or replacement of Eclipse
Combustion’s products.
Eclipse Combustion, Inc., for a period of one year from shipment, warrants each
Veri-Flame burner monitoring system to the original purchaser to be free from
defects in material and workmanship under normal use as defined hereafter.
Any operation expressly prohibited in this Guide, any adjustment or assembly
procedures not recommended or authorized in these instructions, shall void
the warranty.
2
Eclipse Veri-Flame Instruction Manual 818 -2/02
About this manual
AUDIENCE
This manual has been written for the people who select and install the product
and the technicians who work on it. They are expected to have previous experience with this kind of equipment.
SCOPE
This manual contains essential information for the proper installation and operation of the Eclipse Veri-Flame Burner Monitoring System.
Following the instructions in this manual should assure trouble-free installation
and operation of the monitoring system. Read this manual carefully. Make sure
that you understand its structure and contents. Obey all the safety instructions.
Do not deviate from any instructions or application limits in this manual without written consent from Eclipse Combustion, Inc.
If you do not understand any part of the information in this manual, do not
continue. Contact your Eclipse sales office or Eclipse Combustion, Inc., Rockford, Illinois.
DOCUMENT
CONVENTIONS
There are several special symbols in this document. You must know their meaning
and importance.
The explanation of these symbols follows. Please read it thoroughly.
Danger:
Indicates hazards or unsafe practices which WILL result in severe
personal injury or even death.
Only qualified and well trained personnel are allowed to carry out
these instructions or procedures.
Act with great care and follow the instructions.
Warning:
Indicates hazards or unsafe practices which could result in severe
personal injury or damage.
Act with great care and follow the instructions.
Caution:
Indicates hazards or unsafe practices which could result in damage to the machine or
minor personal injury.
Act carefully.
Note:
Indicates an important part of the text.
Read the text thoroughly.
Eclipse Veri-Flame Instruction Manual 818 -2/02
3
HOW TO GET HELP
If you need help, you can contact your local Eclipse Combustion sales office.
You can also contact Eclipse Combustion, Inc. at:
1665 Elmwood Road
Rockford, Illinois 61103 USA
Phone: 815-877-3031
Fax: 815-877-3336
E-mail: [email protected]
http://www.eclipsenet.com
4
Eclipse Veri-Flame Instruction Manual 818 -2/02
Table of Contents
1
About this manual .....................................................................................
3
Table of contents ........................................................................................
5
Introduction ....................................................................................................
8
8
Product Description ...........................................................................................
2
Specifications ...............................................................................................
Introduction ............................................................................................................
Specifications ..........................................................................................................
Dimensions .............................................................................................................
3
DIP Switch Selection ..............................................................................
Introduction ............................................................................................................
DIP Switch Location .............................................................................................
DIP Switch Access .................................................................................................
No Purge DIP Switch Settings ...........................................................................
Modulation & Purge DIP Switch Settings ........................................................
4
Function Summary ..........................................................................................
Introduction ............................................................................................................
Standard Features ..................................................................................................
Combustion Air Flow Check .........................................................................
Main Fuel Valve Closed switch ......................................................................
Low Fire Start ...................................................................................................
High Fire/High Fire Purge Check .................................................................
Recycle Mode ....................................................................................................
Pilot Test Mode .................................................................................................
Interrupted or Intermittent Pilot .................................................................
Post Purge ..........................................................................................................
Spark, Pilot Flame & Main Flame Separation .............................................
System Error & Lockout Conditions ...........................................................
High to Low Fire Purge Modulation Capability with High to Low
Fire Position Switch Interlocks .....................................................................
9
9
9
9
12
12
12
12
12
13
14
14
14
14
14
14
14
14
14
15
15
15
15
16
Eclipse Veri-Flame Instruction Manual 818 -2/02
5
4
Optional Features .................................................................................................
Pilot Test Mode Sequence ..............................................................................
Air Switch Input Hold .....................................................................................
Remote Display & Power Supply ..................................................................
Status Lights & Push-buttons ..............................................................................
Interlocks Closed .............................................................................................
Air Failure ..........................................................................................................
System Error .....................................................................................................
Burner On ..........................................................................................................
Flame Failure .....................................................................................................
Low Fire ..............................................................................................................
High Fire .............................................................................................................
Auto .....................................................................................................................
Test/Reset ...........................................................................................................
16
16
16
16
17
17
17
17
17
17
17
17
17
17
5
System Installation ...................................................................................
18
18
18
18
18
19
19
19
19
19
20
20
21
Introduction ............................................................................................................
Interlocks and Limit Switch Input .....................................................................
Combustion Air Switch Input .............................................................................
Ignition Wiring ........................................................................................................
Low Fire Input ........................................................................................................
Main Valve Closed switch ....................................................................................
High Fire Input .......................................................................................................
Remote Reset ........................................................................................................
Remote Display & Power Supply .......................................................................
Purge and No Purge Wiring Diagram (Figure 5.1) ........................................
Modulation Wiring Diagram (Figure 5.2) ........................................................
Typical Connections for all Models (Figure 5.3) ............................................
6
Sensor Installation ....................................................................................
Introduction ............................................................................................................
Sensor Wiring .........................................................................................................
Flame Rods .............................................................................................................
Scanners ...................................................................................................................
Scanner Sighting Considerations .......................................................................
7
Test Procedures ...........................................................................................
Introduction ............................................................................................................
Flame Signal Strength ...........................................................................................
Minimum Pilot Test ................................................................................................
Pilot Flame Failure Test ........................................................................................
Main Flame Failure Test ........................................................................................
Spark Sighting Test .................................................................................................
Limits & Interlock Tests .......................................................................................
6
Eclipse Veri-Flame Instruction Manual 818 -2/02
24
24
24
25
25
25
26
26
26
26
27
27
27
27
8
Maintenance & Troubleshooting ....................................................
Introduction ............................................................................................................
Maintenance ............................................................................................................
Monthly Checklist .................................................................................................
Yearly Checklist .....................................................................................................
Troubleshooting .....................................................................................................
LED Status ..............................................................................................................
LED Status & Conditions for No Purge Models (Table 8.1) ......................
LED Status & Conditions for Purge Models (Table 8.2) ..............................
LED Status & Conditions for Modulation Models (Table 8.3) ...................
9
Remote Display Messages ...................................................................
Introduction ............................................................................................................
Veri-Flame Operating Sequence (Table 9.1) ...................................................
Remote Display Diagnostic Messages (Table 9.2) .........................................
Appendix ...........................................................................................................
Conversion Factors ..............................................................................................
Illustrated Parts List ..............................................................................................
28
28
28
28
28
29
30
30
31
32
33
33
34
38
41
41
42
Eclipse Veri-Flame Instruction Manual 818 -2/02
7
Introduction
1
PRODUCT
DESCRIPTION
The Eclipse Combustion Veri-Flame Single Burner Monitoring System controls
the start-up sequence and monitors the flame of single gas, oil, or combination
gas/oil burners. There are three different models to the Veri-Flame line: the no
purge, the purge and the modulation models. Each model features field selectable trial for ignition (TFI). Each model is also available for use with four types
of flame sensor: ultraviolet (UV), self-check UV, infrared (IR) and flame rod.
The Veri-Flame No Purge and Purge models are available in three different
series—5602, 5603 and 5605. The 5602 Series is UL listed, CSA certified, FM
approved and IRI acceptable; the 5605 Series is UL listed, FM approved and IRI
acceptable. The 5603 Series is for 240VAC applications not requiring US or
Canadian certifications.
The Veri-Flame Modulation model is available in two different series: 5602
and 5603. Both series are capable of modulation (high and low fire purging).The
5602 Series is UL listed, CSA certified, FM approved and IRI acceptable. The
5603 Series is for 240VAC applications not requiring US or Canadian certifications.
Figure 1 .1 Veri-Flame Single Burner Monitoring System (Purge Unit Shown)
8
Eclipse Veri-Flame Instruction Manual 818 -2/02
Specifications
2
INTRODUCTION
This section gives a detailed overview of Veri-Flame specifications and dimensions.
Specifications
PARAMETER
Supply
Temperature Ranges
DESCRIPTION
• Series 5602 & 5605: 120 VAC (+10%, -15%), 50/60 Hz standard.
Series 5603: 240 VAC (+10%, -15%), 50/60 Hz standard.
Internal power consumption: 12 VA (excluding external connected loads).
Unit
Model Nos.
Temperature Range
Veri-Flame
All Models
-40˚ to +60˚C (-40˚ to +140˚F)
90˚ U.V. Scanner
5600-90A
-20˚ to +60˚C
(0˚ to 140˚F)
U.V. Scanner
5600-91
-20˚ to +125˚C (0˚ to +257˚F)
NEMA4 UV Scanner
5600-91N4
-20˚ to +125˚C (0˚ to +257˚F)
I.R. Scanner
5600-92B
-40˚ to +110˚C (-40˚ to +230˚F)
UV/IR Scanner
5600-92SC
-20˚ to +80˚C (0˚ to +176˚F)
Self-Check U.V.
5602-91
-20˚ to +60˚C (0˚ to +140˚F)
Remote Display
5602DB
0˚ to 50˚C
(32˚ to 122˚F)
Remote Display
5602DBP
0˚ to 50˚C
(32˚ to 122˚F)
Flame Failure Response
3 seconds ±0.5 seconds.
Trial For Ignition (TFI)
No Purge & Purge Models:
Series 5602 & 5603: five or 10 seconds selectable.
Series 5605: ten or 15 seconds selectable.
Modulating Model: 5 or 10 seconds selectable
Pilot Interrupt (if selected)
10 seconds.
Purge Time
Selectable from 0-225 seconds in 15 second increments.
UL, CSA
Relay Contact Rating
Terminals
Inductive Load
Function
Resistive Load
Gas Valve
3, 5
175VA, 1/10 HP
10 amps
Ignition
4
375 VA
10 amps
Motor or Contactor
8
470 VA, 1/2 HP
16 amps
Output Ratings for 120 VAC
(maximum total connected
load not to exceed 15 amps)
Control Signal
Output Ratings for 240 VAC
(maximum total connected
load not to exceed 15 amps)
A, 10, 11, 12, 13
Function
Valves, Ignition
Motors or Contactor
Alarm
Control
Terminals
3, 4, 5,
8
A
10, 11, 12, 13
10 amps
175VA
Relay Contact Rating
Resistive Load
5 amps
16 amps
5 amps
5 amps
(continued onto next page)
Eclipse Veri-Flame Instruction Manual 818 -2/02
9
Specifications (continued)
PARAMETER
Approvals
(See chart below.)
DESCRIPTION
• No Purge & Purge Models:
Series 5602: UL listed, CSA certified, FM approved and IRI acceptable.
Series 5603: No approvals.
Series 5605: UL listed, FM approved and IRI acceptable.
• Modulating Models:
Series 5602: UL recognized (must be mounted in panel), CSA certified, FM
approved and IRI acceptable.
Series 5603: No approvals.
Shipping Weight
• 1.4 kilograms (3 lbs.) for all Veri-Flame models.
• 0.9 kilograms (2 lbs.) for Models 5602-10 & 5602-10-1 bases.
• 1.2 kilograms (2.6 lbs.) for Model 5602-40 base.
Approval Information
UL Listed, Guide No. MCCZ, File MH12613
UL Recognized, Guide No. MCCZ2, File MH12613
CSA Certified, Class No. 2632 01, File 37456
FM Approved, Class No. 7610, Report 1Y2A4.AF
Dimensions
Veri-Flame Unit/All Models
76mm
(3")
133mm
(5-1/4") Square
Veri-Flame Bases/Purge & No Purge Models
Model Number 5602-10
5.5mm
(7/32") Dia.
Mounting
Holes (4)
127mm
(5")
Square
38mm
(1-1/2")
10
Model Number 5602-10-1
127mm
(5")
Square
Knockouts
(10) for
13mm (1/2"
Conduit
102mm
(4") Square
13mm
(1/2")
Eclipse Veri-Flame Instruction Manual 818 -2/02
102mm
(4") Square
19mm
(3/4")
124mm
(4-7/8")
38mm
(1-1/2")
Dimensions (continued)
Veri-Flame/Modulating Model with Base Model Number 5602-40
24mm
(15/16")
171mm
(6-3/4")
25mm
(1")
1 2 3 4 5 6 7 8 A D S2 S1 10 11 12 13
40mm
(1-9/16")
5mm (3/16")
10mm (3/8")
213mm (8-3/8")
116mm
(4-9/16")
Remote Display Model Number 5602-DB
102mm
(4") Square
*
54mm
(2-1/8")
89mm
(3-1/2")
Square
Ground
Screw
Mounting
Bracket &
Screw (2)
Contrast
Adjustment
Screw
*
*
= Alternate Mounting Locations
Wiring
Terminal
15-pin Port
Terminal
24VDC Power Supply for Remote Display 5602-DB
44mm
(1-3/4")
70mm
(2-3/4")
79mm
(3-1/8")
Remote Display Model Number 5602-DBP
102mm
(4") Square
*
89mm
(3-1/2")
Square
54mm
(2-1/8")
Ground
Screw
Contrast
Adjustment
Screw
Mounting
Bracket &
Screw (2)
*
*
= Alternate Mounting Locations
Wiring
Terminals (2)
15-pin Port
Terminal
Eclipse Veri-Flame Instruction Manual 818 -2/02
11
DIP Switch Selection
3
INTRODUCTION
This section details the location, selection and description of the Veri-Flame
DIP switches, which allow for sequence and timing functions as well as system configuration.
Caution
To avoid electric shock, shut off the power supply when installing or removing any control
device. Flame monitoring systems must be installed by a qualified, licensed technician.
DIP Switch Location
All of the DIP switches are located in the back of each Veri-Flame unit (see Figure 3.1 on page 13, or the photograph on page 8).
DIP Switch Access
To gain access to the DIP switches, the Veri-Flame must be separated from the
back box (for visual reference, please refer to “Dimensions” on page 10). This
separation will expose the DIP switches on the back of the Veri-Flame unit.
No Purge
DIP Switch Settings
No Purge models of the Veri-Flame only use three of the eight DIP switches, as
shown in the labels in Figure 3.2 on page 13. They are as follows:
SW1: Recycling mode selection (On = Recycling; Off = Non-recycling)
SW2: Pilot selection (On= Intermittent, where pilot remains on during burner cycle;
Off =Interrupted, where pilot valve closes after main burner is established).
SW3: Trial-for-ignition (TFI) range selection (For 5602/5603 units: On =10
seconds; Off =5 seconds. For 5605 units: On =10 seconds; Off =15 seconds).
Modulation & Purge
DIP Switch Settings
Modulation and purge models of the Veri-Flame use all of the eight DIP switches,
as illustrated in Figure 3.2 on page 13. They are as follows:
SW1: Recycling mode selection (On = Recycling; Off = Non-recycling)
SW2: Pilot selection (On= Intermittent, where pilot remains on during burner cycle;
Off =Interrupted, where pilot valve closes after main burner is established).
SW3:Trial-for-ignition (TFI) range selection (For 5602/5603 units: On=10 seconds;
Off =5 seconds. For 5605 units: On =10 seconds; Off =15 seconds).
SW4 through 7: Purge time selection. Total purge time is the sum of each switch
selected.
SW8: Post purge selection. (On=15 second post purge).
12
Eclipse Veri-Flame Instruction Manual 818 -2/02
Figure 3.1 DIP Switch Location
Close-up of DIP switches on
back side of all Veri-Flame models.
Figure 3.2 DIP Switch Labels with Selections
No Purge Models
Purge Models
Modulation Models
Eclipse Veri-Flame Instruction Manual 818 -2/02
13
Function Summary
4
INTRODUCTION
This section describes the features of theVeri-Flame. It is broken into three categories:
Standard features, Optional features and the LED Indicator Lights on the front cover.
Refer to Figure 5.5 for sequence diagrams.
STANDARD FEATURES
The following function features are standard on the Veri-Flame models as noted:
Interlocks and Limit
Switch Input (Terminal 7)
This input is considered the normal operation control or run input to the VeriFlame system. Interlocks are generally pressure or temperature switches which,
when activated, start the burner. Limit switches are generally pressure, temperature and other switches which, when activated, stop the burner. The interlocks and
limit switches are wired in series. A break in this circuit will shut the burner down,
but will not produce an alarm.
Combustion Air
Switch Input (Terminal 6)
For purge and modulation models: This input is for monitoring the
combustion air switch separately from other interlocks and limits. The Veri-Flame
checks the air flow switch input is open before start-up, closed during operation,
and open again at burner shutdown, thus preventing operation with an air switch
that is defective, maladjusted or jumped. This input has about a 2 second delay to
filter out and ignore a momentary interruption.
The input will be proven open before start-up and after shutdown. If the input is
improperly powered before the fan output is energized, the system error light will
blink. The input must de-energize within 30 seconds or the Veri-Flame will lockout.
After the fan output has energized, the air switch input must be made within 10
seconds. If not proven, then the system will lockout, the alarm output and the air
failure light will come on. However, if the unit has the optional air switch input
hold feature, the sequence is held indefinitely without causing a lockout. When the
air switch input is made, then the sequence continues.
If the air switch opens during the main firing cycle, the system will either lockout
or recycle, depending on the DIP switch recycle selection.
Main Fuel Valve Closed
Switch (Terminal V)
Purge and No-Purge models: the Veri-Flame can be interlocked with the
main valve closed switch. This feature checks the switch position before
start-up and after shutdown to insure proper valve operation when the
jumper on the base is cut.
Low Fire Start
For modulation models: when wired, the system checks for the low fire start
position prior to light-off.
14
Eclipse Veri-Flame Instruction Manual 818 -2/02
Main Fuel Valve Closed/
High Fire Purge Check
(Terminal D)
For modulation models: This feature is enabled when the jumper on the
base is cut. The system checks that the high fire position switch and the
main valve closed switch are both made at the end of the high fire purge.
Recycle Mode
For all models: when selected, the Veri-Flame will restart the sequence after
flame or air failure. The recycle mode allows the system to re-initiate the startup sequence automatically provided the main burner has been operating for
at least 35 seconds. If the pilot flame fails to light during recycling, the system
will lock out and annunciate a pilot flame fail. If the recycle is successful and
the main burner is operational for at least 35 seconds, the system is ready for
another recycle. At no time will the system recycle in the event of pilot flame
fail.
Pilot Test Mode
For all models: this mode is entered by depressing the TEST/RESET button on
the front cover. In the pilot test mode, the Veri-Flame will hold the sequence once
the pilot flame is established (i.e., the main valve is not energized). When in the
pilot test mode, the green “Interlocks Closed” light blinks.
Test Mode
Run Mode
(Button In)
(Button Out)
To exit the pilot test mode, simply push the TEST/RESET button again and the
Veri-Flame will exit the pilot test mode (the green “Interlocks Closed” light
stops blinking but remains lit) and restart the sequence.
Interrupted or
Intermittent Pilot
For all models: pilot mode is selected using the DIP switch SW2. An interrupted pilot shuts off 10 seconds after the main valve opens. An intermittent
pilot continues during the entire main flame firing cycle.
Post Purge
For purge and modulation models: post purge is enabled by DIP switch
SW8. A post purge maintains the combustion air fan output for 15 seconds
after the interlocks and limit switch input have opened.
Spark, Pilot Flame &
Main Flame Separation
For all models: during the trial for ignition period (TFI), the pilot valve and
ignition coil remains energized. At the end of the TFI, the pilot flame remains
on and the ignition coil is de-energized. After a five second delay to prove the
pilot flame, the main gas valve is energized.
System Errors &
Lockout Conditions
A system error (illuminated by the red “System Error” LED on the front cover)
prevents gas ignition. The unit will continue its sequence after the error is cleared.
A lockout condition energizes the alarm output and de-energizes the gas valve
and ignition outputs. The unit must be reset to clear the alarm and start the
sequence. To reset, the button must be pressed twice so that the button is in
the out position.
The following system errors result in immediate lockout conditions:
1) Wiring error which puts external voltage on the output terminals (for
all models).
2) Welded internal contacts or other malfunctions in the Veri-Flame (for all
models).
3) Main fuel valve (for all models)–open after cycle shutdown or before
start-up. The system error light blinks twice and then remains on. The
fan output terminal 8 will energize.
Eclipse Veri-Flame Instruction Manual 818 -2/02
15
System Errors &
Lockout Conditions
(Continued)
4) Low fire fail (for modulating model)–low fire switch open prior to trial
for ignition.
5) High fire fail (for modulating model)–high fire switch is not closed at the
end of high fire purge.
The following situations will result in a lockout condition:
6) Air failure (for purge and modulation models) – loss of combustion air
anytime during the operational cycle. The Air Failure LED will be on for this
condition. (See “Recycle Mode”).
7) Pilot flame fail (for all models) loss of flame during the trial for pilot ignition
period. The Flame Failure LED will be on for this condition.
8) Main flame fail (for all models) loss of flame during the main burner trial for
ignition or run period (recycling not selected). The Flame Failure LED will be
on for this condition.
The following result in lockout conditions after 30 seconds, the system error
light blinks about 14 times and then remains on:
9) If a flame is detected out of sequence, which may be caused by:
a) a faulty scanner (for all models);
b) electrical interference on the sensor wiring (for all models);
c) a flame exists in the burner or in the line of sight of a scanner, due to
a gas leak, product fire or other condition (for all models).
10) Air flow switch closed before start-up (for purge and modulation models).
High to Low Fire Purge
Modulation Capability
with High to Low Fire
Position Switch Interlocks
For modulation models: the modulation feature incorporates a high fire purge
time and a low fire purge time into the purge sequence. This feature allows the
Veri-Flame to sequence internal dry contacts which can be used by the customer
requiring a high fire purge of the combustion chamber before ignition.
The high fire and low fire purge times are selectable by means of DIP switches
(see Section 3, “DIP Switch Settings” on page 12):
SW4 ................................ 15 seconds
SW5 ................................ 30 seconds
SW6 ................................ 60 seconds
SW7 ............................. 120 seconds
The selected times are additive and apply to both the high fire and low fire purge
times (that is, high and low fire times are always identical).
The modulation terminals will sequence as follows:
Sequence Step
Power Off
Power On, Limits Open
Purge To High Fire
Purge To Low Fire
Automatic Modulation
Alarm and Lockout
Internal Contact Connections
Terminal 10 (Common)
Terminal 10 (Common)
Terminal 10 (Common)
Terminal 10 (Common)
Terminal 10 (Common)
Terminal 10 (Common)
Terminal 11 (Auto)
Terminal 12 (Low Fire)
Terminal 13 (High Fire)
Terminal 12 (Low Fire)
Terminal 11 (Auto)
Terminal 12 (Low Fire)
The Automatic step occurs when the burners are operating and allows the
burner firing rate to be controlled by an automatic temperature controller.
16
Eclipse Veri-Flame Instruction Manual 818 -2/02
OPTIONAL FEATURES
The following features are available on select models, or when optional equipment
is purchased.
Air Switch Input Hold
For purge/modulation models: holds the sequence indefinitely until air switch
input is confirmed without affecting the air failure function and causing a lockout.
Remote Display &
Power Supply
Two models of remote display are available. The model 5602DB operates
on 24VDC and has no keypad. The model 5602DBP operates on
120VAC and has a keypad for reset function. The display is door panel
mounted and features a liquid crystal display in a ¼ DIN housing. The
unit connects to the Veri-Flame by a cable to the flame signal test jack,
and receives a serial communication on each sequence state change. The
display incorporates the following functions:
1) Provides status messages for the Veri-Flame sequence (see
section 9).
2) Indicates lockout conditions when they occur, as well as the
amount of time into the sequence when the lockout occurred
(see section 9).
Manual Reset on
Power Outage
3) Provides continuous monitoring of the burner’s flame signal
strength and run time during main burner operation.
This optional feature requires a reset on initial application of power or after an
interuption of power. The system error light blinks rapidly (about 4 times per
second) and a remote display will show “PUSH RESET TO START”. The reset
button must be pressed in and out to start
STATUS LIGHTS &
PUSH-BUTTON
All of the status lights and the TEST/RESET push-button are located on the front
cover of the Veri-Flame. This section describes their respective functions.
Interlocks Closed
For all models: this green LED illuminates when the operation limits are made.
These limits are wired in series to terminal 7. This input becomes energized to
begin the burner sequence. When in the test mode, this LED blinks (see “Pilot Test
Mode” on page 15).
Air Failure
For purge and modulation models: this red LED illuminates whenever combustion air is lost during the operational cycle of the Veri-Flame.
System Error
For all models: this red LED illuminates when a system error is detected (see
“System Errors & Lockout Conditions” on pages 15-16).
Flame Failure
For all models: this red LED illuminates when a pilot or main flame fails.
Low Fire
For modulation models: this yellow LED illuminates during the low fire period of the purge cycle.
High Fire
For modulation models: this red LED illuminates during the high fire period
of the purge cycle.
Auto
For modulation models: this green LED illuminates during the automatic period which occurs 20 seconds after the main valve is energized.
Test/Reset
For all models: this push-button is used to activate the pilot test mode or to
reset the Veri-Flame unit.
Flame Signal
For all models: this red LED is located behind the signal test port and illuminates when a flame signal is present.
Eclipse Veri-Flame Instruction Manual 818 -2/02
17
System Installation
5
INTRODUCTION
In this section, the necessary procedures are detailed to integrate a Veri-Flame into a
burner system; Figures 5.1 and 5.2 illustrate the various terminal strips mentioned.
Note:
Shut off the power supply before the Veri-Flame is removed or replaced from the base.
Caution:
Installation and maintenance must conform with the National Electrical Code and all
other national and local codes and authorities having jurisdiction. Flame monitoring
systems must be installed by a qualified, licensed technician.
Interlocks and
Limit Switch Input
Wire external interlock, control, and limit switches in series to this input. Guard
against induced voltage levels to wiring connected to this input. In some extreme
wiring runs, reduction of induced voltages may require a load (relay or light) connected
to terminal 7 to avoid system error lockouts. This input is the power source for the
valve and ignition output terminals. Be sure all switches wired to this input can handle
the current required by the total of all loads connected to terminals 3, 4,and 5.
Combustion Air
Switch Input
For purge and modulation models: Wire any switches and contacts in
series to this terminal for proving air flow function and relating to the air failure
light. Power must not be immediately present at terminal 6 when power is first
applied to terminals 1 or 7.
If this terminal is not used, place a jumper between the combustion blower output (terminal 8) and the air switch input (terminal 6).
If the combustion air blower is controlled outside of the Veri-Flame system, then
a three way solenoid valve must be connected between the air switch port and
the blower sensing port. The valve de-energized state should vent the switch
to ambient pressure. The energized state then connects the air switch to the
blower sensing port. Power the valve from the blower ouput terminal 8. If
accepted by local codes, the air switch could be wired between the combustion
blower output and the air switch input. Connecting the air switch in this manner will satisfy the open contact (air short) check on the switch.
18
Eclipse Veri-Flame Instruction Manual 818 -2/02
Ignition Wiring
Route ignition wiring a sufficient distance from all sensors and other low voltage wiring to avoid electrical interference, which may cause erratic operation
of the Veri-Flame system. Keep the high voltage wire run from the ignition transformer as short as possible. The best condition is to mount the ignition transformer close to the burner and keep a low impedance path from the burner
ground to the case of the transformer. Make sure the high voltage lead and
ground return paths do not create a loop antenna around the Veri-Flame and
sensor wiring.
Low Fire Input
For modulation models: it is possible to wire the system for checking low
fire start position prior to pilot ignition. To use this feature, the low fire start
switch must be connected between terminal 3 and the pilot valve (see Figure
5.2). On direct spark burners, a by-pass contact must be wired around the low
fire switch, see relay and contact CR in Figure 5.3.
Main Valve
Closed Switch
The system can be wired to check for the main valve closed switch on the main
gas valve prior to start-up and after the end of the burner cycle.
For purge and no purge models: the main valve closed switch must be connected to Terminal V and the jumper in the base must be cut (see Figure
5.4 on page 22).
For modulation models: the main valve closed switch must be wired in series between the air flow switch and the high purge damper switch (see Figure
5.1 on page 20). To use this feature, the jumper in the base must be
cut.
High Purge Input
For modulation models: the system can be wired to check for high purge
position during the high fire purge portion of the sequence. To use this feature, the red jumper in the base must be cut and the high purge position
switch must be connected from terminal 6 to D. If this feature is not used, the
jumper in the base remains intact or a jumper must be installed between terminals 1 and D. Please note that the yellow jumper on the base has no effect
whether cut or intact.
Remote Reset
This feature permits remote mounting of a switch to reset the Veri-Flame. To
use this feature, a normally closed remote reset switch must be wired so power
is interrupted to terminal 1. When it is depressed or actuated, the connection
to terminal 1 is momentarily interrupted and resets the Veri-Flame.
Remote Display &
Power Supply
Identify the model of remote display (see page 11) and wire according to figure
5.3. Mount through a ¼ DIN cutout using the two supplied brackets in either
the top and bottom or the side slots. Locate the display and wiring to minimize
electrical interference. Applying and disconnecting the display power supply
should coincide with power to terminal 1 of the Veri-Flame. Use the appropriate cable (Eclipse part #20318) to connect to the test jack and to the S2 terminal of the Veri-Flame wiring base. Do not attempt to parallel the test jack signal
to other devices when using a remote display. The LCD display contrast can be
adjusted on the back with a small blade screwdriver.
Eclipse Veri-Flame Instruction Manual 818 -2/02
19
Figure 5.1 No Purge and Purge Wiring Diagrams
Purge Models
No Purge Models
5602/5605:
120 VAC
50/60 HZ
5603:
240 VAC
50/60 HZ
5602/5605:
120 VAC
50/60 HZ
15 A On/Off
Fuse
15 A On/Off
Fuse
1
1
Interlocks & Limits
Piloted Burner
2
3
Pilot
3
Pilot
4
Ignition
4
Ignition
5
Main
5
Main
Air Flow Switch
6
A
Interlocks
& Limits
Alarm
V
7
8
Alarm
Proof of Closure
V
S1
G
S2
G
Figure 5.2 Modulation Wiring Diagram
5602/5605:
120 VAC
50/60 HZ
15 A. Fuse
5603:
240 VAC
50/60 HZ
On/Off
1
2
Low Fire Proving
Cut Red
Jumper
To Activate
Terminal D.
3
Pilot
4
Ignition
5
Main
6
7
Interlocks
& Limits
8
Fan
A
Alarm
D
Proof of
Closure
High Purge
Damper
Switch
S2
S1
10
11
12
13
Flame
Sensor
Terminals
Common
Automatic
Low Fire
High Fire
See the “High to
Low Fire Purge
Modulation
Capability” section
on page 16 for
contact connections.
G
20
Fan
A
S1
S2
Air Flow
Piloted Burner
2
7
Proof of
Closure
5603:
240 VAC
50/60 HZ
Eclipse Veri-Flame Instruction Manual 818 -2/02
Figure 5.3 Typical Connections For All Models
Model 5602 DBP
120 VAC Remote Display
Model 5602 DB
24 VDC Remote Display
12V 12V Tx
+
24V G Tx Rx G
Cable
#20318
PLUG
Flame Signal
Test Jack
To S2
120V 120V R1
L
N
Rx
R2
G
to 120 VAC
Cable
#20318
PLUG
Veri-Flame
To 1
Flame Signal
Test Jack
To S2
Veri-Flame
Power
Supply
#20317
N G
120/240VAC
U.V. / I.R.
S1
Blue (Signal)
S2 Yellow (Neutral)
Solid State U.V. / I.R.
U.V
or
I.R.
White
S1
Black
S2
G
A
B
C
D
S1
Scanner
Flame Rod
S2
Shield
Self Check U.V. 5602-91
(Requires 5602-91-7 cable)
2
1
S1
S2
Flame Rod
Blue
Direct Spark with
Low Fire Start
Direct Spark
3
4
3
MAIN
Low Fire Proving
IGNITION
5
MAIN
CR
Neutral
Note: Intermittent pilot must
be selected, DIP-SW2 = ON
4
5
IGNITION
CR
Neutral
Note: Intermittent pilot must be selected, DIP-SW2 = ON
CR is a control relay used to bypass the low fire switch after
the burner is lit.
Notes for Figures 5.1, 5.2 & 5.3:
1. Ground, shielding and conduit must not be connected to terminal S2.
2. Control circuit wires must meet 90°C (194°F) specification minimum and must
be No. 16 AWG or larger and in accordance with all applicable codes.
3. Flame sensor wires must be individually run in their own separate conduit;
flame sensor wires CANNOT be run together in a common conduit or wireway (See Section 6).
4. Flame signal should read between 4 and 10 VDC with a digital volt meter. Drop
off is approximately 4.0 VDC. Positive test jack point is on the cover marked
“Flame Signal” with negative point being the ground.
5. Purge time, TFI, intermittent/interrupted pilot, and recycle/non-recycle selections
are made with a DIP switch located on the rear plate of the control unit.
6. Neutral must be grounded.
Eclipse Veri-Flame Instruction Manual 818 -2/02
21
Figure 5.4 Purge and No Purge Bases
Model Number 5602-10
Internal Diagram
Purge & No-purge
Model Number 5602-10-1
P1
5
6
1
P1
4
P1 Fault Pilot P3
6
3
Ign P3
J1
5
Main P3
P3
3
5
6
S2
S1
7
8
3
4
V
2
1
A
3
2
1
1
Jumper
3
2
1
P1
Gnd
6
7
P3
4
P2
6
V
P1
6
Jumper
2
P2
Gnd
S1
Internal Diagram
Modulation Model
1
P1
5
6
P1
1
2
Fan
8
Red
1
J1
P3
J2
7
4
3
2
1
6
D
P1
6
4
2
Jumper
P1
4
P1 Fault Pilot P3
6
3
Ign P3
5
22K
Main P3
22K P3
3
4
P3
2
P2
Supervisor
2
Alarm
1
P2
5
Note: No purge models do not use 6 & 8.
Model Number 5602-40
1
4
Flame Signal Jack
Amplifier
P2
1
Modulating Base
6
3
Supervisor
S2
Ground Terminal
nnotNOTE:
present in plastic base.
3
2
1
A
P3
4
5 6 S2 S1 7 8 A 1 2 V 4 3
S2
S1
P2
1
Gnd
1 2 3 4 5 6 7 8 A D S2 S1 10 11 12 13
22
8
Alarm
P3
P2
P1
1
2
Fan
10
Eclipse Veri-Flame Instruction Manual 818 -2/02
J2
4
A
3
4
5
Flame Signal Jack
Amplifier
J2
Auto
2
11
J2
Low
1
12
J2
High
3
13
Ignition
5
Main Valve
7
Interlocks
V
POVC
Flame
Check
TFI
Outputs
Inputs
Terminal
Function
1
Control Power
3
Pilot Valve
4
Ignition
5
Main Valve
8
Fan
6
Air Switch
7
Interlocks
V
POVC
Prov
en
10
Sec
TFI
Outputs
Inputs
Function
1
Control Power
3
Pilot Valve
4
Ignition
5
Main Valve
8
Fan
6
Air Switch
7
Interlocks
D
High Fire & POVC
3
Low Fire Switch
Continuity 10 to 12
Between
Modulation 10 to 13
Terminals 10 to 11
35 Seconds
Main
Trial
10 Sec
Recycle
Permitted
Post
Purge
15 Sec
Firing
Cycle
Prov
en
Flame
Check
5 Sec
Pilot
Trial
Air
Star
t
Purge
Terminal
Recycle
Permitted
Firing
Cycle
Air
Star
t
Pilot
Trial
35 Seconds
Main
Trial
10 Sec
P
(Inte ilot Of
rmit f
tent
)
End
4
End
Pilot Valve
P
(Inteilot Off
rrup
ted)
Control Power
3
P
(Inte ilot Of
rmit f
tent
)
P
(Inteilot Off
rrup
ted)
Star
t
1
End
Inputs
Function
P
(Inteilot Off
rrup
ted)
Outputs
Terminal
P
(Inte ilot Of
rmit f
tent
)
Figure 5.5 Sequence Diagrams
Low Fire Purge
High Fire Purge
Automatic
10
Sec
Flame
Check
5 Sec
Pilot
Trial
TFI
High Fire
Purge
Low Fire
Purge
Main
Trial
10 Sec
Firing Cycle
Post
Recycle Purge
Permitted 15 Sec
20 Seconds
35 Seconds
Eclipse Veri-Flame Instruction Manual 818 -2/02
23
Sensor Installation
6
INTRODUCTION
This section describes the proper wiring, installation and sighting considerations for
all sensors that can be used with a Veri-Flame.
Warning
Incorrect sensor installation may cause the sensor to generate a
false flame signal, possibly resulting in the collection of unburned
fuel in the combustion chamber. This unburned fuel creates the
potential for explosions which can result in injuries, death and
property damage. Be certain that the flame sensor detects acceptable pilot and main flames only.
Sensor Wiring
Route sensor wiring a sufficient distance from ignition and other high voltage
or high current wiring to avoid electrical interference. Interference from
ground currents, nearby conductors, radio-frequency emitters (wireless divices),
and inverter drives can induce false flame signals. Shielded cables can help reduce interference with the shield connected to ground at the control end only.
The wire type and its capacitance (picofarads or microfarads) to ground may
cause low signal problems, so a grounded shield may decrease the signal due to
the cable’s internal capacitance. Multiple U.V. tube-type sensor leads run together without shielding may interfere or “cross talk”, so the shield or flexible
armor must be grounded to prevent this situation. For flame rod sensor runs
approximately 100 feet (30 meters) or greater, use Eclipse part number 21741
coax cable. To achieve the maximum wiring distance, the shield should not be
grounded (keep in mind that an ungrounded shield provides less protection
against electrical interference).
n
Flame Rods
24
Note:
Unshielded sensor wiring must not be run in common with other wires; it
must be run in separate conduit. Use #14 to #18 AWG wire suitable for
90°C (194°F) and 600 volt insulation. Multiple unshielded flame sensor
wiring must not be run together in a common conduit or wireway. Multiple
shielded flame sensor cables can be run in a common conduit.
Flame rods should be used only on gas burners. They accumulate soot on oil burners, causing nuisance shutdowns and unsafe operating conditions.
See the burner manufacturer’s literature for flame rod mounting location. When
installing flame rods, please consider the following:
Eclipse Veri-Flame Instruction Manual 818 -2/02
Figure 6.1 Flame Rod Position
WRONG
Rod Detects
Weak Pilot
CORRECT
Rod Detects
Only Strong
Pilot Flame
PILOT
1) Keep the flame rod as short as possible and at least 13 mm (1/2") away from
any refractory.
2) Position the rod into the side of both the pilot and main flames, preferably
at a descending angle to minimize drooping of the flame rod against burner
parts, as shown in Figure 6.1. Flame rod position must adequately detect
the pilot flame at all burner draft conditions. Extend the rod 13 mm (1/2")
into nonluminous flames, such as blue flames from burning an air/gas mixture. For partially luminous flames, such as atmospheric air/gas mixtures,
place the rod at the edge of the flame.
3) Provide a burner/flame grounding area that is at least four times greater than the
flame rod area contacting the flame. The flame rod/burner ground ratio and position of the rod in the flame may need adjustment to yield maximum flame signal
strength.
4) Ignition interference from the spark plug may increase or decrease the flame
signal strength. Reversing the ignition transformer primary leads may reduce
this effect. Changing the spark gap or adding grounding area between the flame
rod and spark plug may eliminate the interference.
Warning
Use only Eclipse scanner models as listed in the Illustrated Parts
List at the end of this document.
Scanners
When installing scanners, please consider the following:
1) Position the scanner within 457 mm (18") of the flame. Consult factory for
longer distances.
2) Bushing threads are 1/2 inch F.N.P.T. for all scanner models except 5602-91
which has 1 inch F.N.P.T. bushing threads.
3) The ambient temperature limits of each scanner varies; check the literature for
the specific scanner model. For higher temperatures, use Eclipse heat block
seal 23HBS for ½” N.P.T. scanners and if necessary, add cooling purge air.
4) An optional magnifying lens may also be used to increase the flame signal strength
in difficult sighting situations.
Scanner Sighting
Considerations
Figure 6.2 U.V. Scanner Sighting
MAIN
BURNER
Scanner
Sight
Line
1/3 of
Flame Length
SCANNER
Aim scanners at the third of the flame closest to the burner nozzle, as shown in
Figure 6.2 (oil flames typically have less UV radiation in the outer flame). The scanner should view the intersection of the pilot and main flames. When sighting scanners, please consider the following:
1) Sight the scanner away from the ignition spark. Sighting the spark or its reflections from burner internals can cause nuisance shutdowns during burner ignition. If necessary, use a scanner orifice to reduce spark pickup.
2) Do not allow the scanner to detect a pilot flame that is too small to ignite the
main burner.
3) Perform a minimum pilot test when installing or adjusting any pilot or main
burner system; see “Minimum Pilot Test” on page 26.
4) I.R. scanner model 5600-92B is ideal for oil flame applications. When used, aim
the I.R. scanner at the outer oil flame for flickering detection.
Eclipse Veri-Flame Instruction Manual 818 -2/02
25
Test Procedures
7
INTRODUCTION
This section describes the test procedures that must be performed after installation to insure that the Veri-Flame is operating properly; these procedures are
mandatory.
Flame Signal Strength
Insert the positive probe of a 0-15 VDC, digital volt meter into the test
point on the front cover of the Veri-Flame; connect the negative probe to
ground. A good flame signal strength will read between 6 and 11 VDC; anything below 4 VDC is inadequate. Also, the red LED inside the test point
illuminates when a flame signal is indicated.
Minimum Pilot Test
Run the following test procedures to ensure that the sensor will not detect a
pilot flame too small to reliably light the main flame:
1) Manually shut off the fuel supply to the burner, but not to the pilot.
2) Start the system normally.
3) To enter the pilot test mode, depress the test/reset button located in the
lower right corner on the front cover.
4) The control will hold the operating sequence at the pilot flame step. Measure signal strength as described above.
5) Reduce pilot fuel until the flame relay drops out. Increase pilot fuel until the
flame signal is greater than 4 VDC, and flame relay just manages to pull in.
This is the minimum pilot. If you don’t think this flame will be able to safely
light the main burner, realign the sensor so that it requires a larger pilot
flame and repeat steps 2 through 5.
6) Push the test/reset button located in the lower right corner on the front cover
to exit the test mode (reset) and begin the normal start-up sequence again.
7) When the sequence reaches the main flame trial for ignition, smoothly restore the fuel supply to the burner. If the main burner does not light within
five seconds, immediately shut off the burner supply to shut down the system. Realign the sensor so that it requires a larger pilot flame. Repeat steps
1 through 6 until the main burner lights off smoothly and reliably.
26
Eclipse Veri-Flame Instruction Manual 818 -2/02
Pilot Flame Failure Test
1) Manually shut off the fuel supply to the pilot and the main burner.
2) Place system in pilot test mode (please refer to page 15).
3) Start the system normally. The controller should lock out*; if it doesn’t,
then the controller is detecting a false flame signal (see Section 6). Find
the problem and correct it before resuming normal operation.
Main Flame Failure Test
1) Manually shut off the fuel supply to the main burner but not to the pilot.
(For Interrupted Pilot Systems)
2) Start the system normally. This should ignite the pilot and lock out* after
pilot interruption. If the system does not lock out, the controller is detecting a false flame signal (see Section 6). Find the problem and correct it before resuming normal operation.
Spark Sighting Test
1) Manually shut off the fuel supply to the pilot and the main burner.
2) Start the system normally.
3) Measure the flame signal as described in “Flame Signal Strength” in this section.
4) If a flame signal greater than 4 VDC is measured for more than three seconds during the trial for ignition, then the sensor is picking up a signal from
the spark plug; see “Sensor Wiring” on page 24.
Limits & Interlock Tests
Periodically check all interlock and limit switches by manually tripping them
during burner operation to make sure they cause the system to shut down.
Warning
Never operate a system that is improperly adjusted or has faulty interlocks or limit switches. Always replace faulty equipment with new
equipment before resuming operation. Operating a system with defective safety equipment can cause explosions, injuries, and property
damage.
* Indicated by the illuminated red “Flame Failure” LED on the Veri-Flame front cover.
Eclipse Veri-Flame Instruction Manual 818 -2/02
27
Maintenance &Troubleshooting
8
INTRODUCTION
This section is divided into two parts:
• The first part describes the maintenance procedures.
• The second part describes troubleshooting procedures, from identifying problems to interpreting the operating conditions by the lit LEDs on the front cover.
MAINTENANCE
Preventative maintenance is the key to a reliable, safe and efficient system. The
core of any preventive maintenance program is a list of periodic tasks.
In the paragraphs that follow are suggestions for a monthly list and a yearly list.
Note:
The monthly list and the yearly list are an average interval. If your environment is dirty,
then the intervals may be shorter.
Caution:
Turn off power before disconnecting or installing sensors, controls or modules.
Monthly Checklist
1. Inspect flame-sensing devices for good condition and cleanliness. Keep scanner lenses clean with a soft, damp cloth, since small amounts of dust will measurably reduce the flame signal strength. Wash the flame rod electrode and
insulator with soap and water, then rinse and dry thoroughly.
2. Test all the alarm systems for proper signals.
3. Check ignition spark electrodes and check proper gap.
4. Test interlock sequence of all safety equipment as described on page 27:
manually make each interlock fail, noting what related equipment closes or
stops as specified by the manufacturer.
Test flame safeguard by manually shutting off gas to the burner.
Yearly Checklist
1. Test (leak test) safety shut-off valves for tightness of closure.
2. Test pressure switch settings by checking switch movements against pressure setting and comparing with actual impulse pressure.
3. Visually check ignition cable and connectors.
4. Make sure that the following components are not damaged or distorted:
• the burner nozzle
• the spark plugs
• the flame sensors
• the flame tube or combustion block of the burner
28
Eclipse Veri-Flame Instruction Manual 818 -2/02
TROUBLESHOOTING
PROBLEM
Cannot initiate start sequence
POSSIBLE CAUSE
Main valve is not closed.
Air pressure switch has not made
contact.
SOLUTION
Check main valve closed switch.
No voltage on V (or D).
Check air pressure switch adjustment.
Check air filter.
Check blower rotation.
Check outlet pressure from blower.
No voltage on 6 after 8 is on.
High gas pressure switch has tripped.
Check incomming gas pressure; adjust gas
pressure if necessary.
Check pressure switch setting and
operation.
No voltage to 7.
Low gas pressure switch has tripped.
Check incomming gas pressure; adjust gas
pressure if necessary.
Check pressure switch setting and
operation.
No voltage to 7.
Malfunction of flame safeguard system
such as a shorted-out flame sensor or
electrical noise in the sensor line.
Have qualified electrician investigate and
rectify.
Purge cycle not completed.
Check switch settings.
Check air switch.
Main power is off.
Make sure power is on to control system.
No power to control unit.
Call qualified electrician to investigate.
Scrambled messages on remote display.
Electrical interference.
Check grounding in system.
Separate communication cable.
Move ignition circuit.
“UNSAFE AIR SHORT” message
appears on display.
Improperly adjusted air switch.
Air switch either shorted or wired
wrong.
Check air switch settings.
Check wiring to air switch.
Burner flame fails but no flame
failure indication occurs.
A faulty scanner.
Check scanner as explained in checklists in
“Maintenance” portion of this Section.
Improperly connected sensor wires.
Check wiring diagram on page 20 or 21 as
well as appropriate sensor information in
Section 6.
Electrical interference from other
current carrying wires.
Check Note information on page 24
regarding sensor wiring.
Improper grounding.
Check grounding of neutral at control
power transformer.
Voltage reading greater than
15VDC at “Test Point” on
Veri-Flame faceplate.
Eclipse Veri-Flame Instruction Manual 818 -2/02
29
LED STATUS
This section describes the status of operating conditions based on the LED or
combination of LEDs which are lit on the front cover of each Veri-Flame model.
Table 8.1 LED Status & Conditions for Veri-Flame No Purge Models
LED(S) LIT
POSSIBLE CAUSES
INTERLOCKS CLOSED
1) The interlocks are closed (normal operation), power on terminal 7.
SYSTEM ERROR
1)
2)
3)
4)
5)
6)
The flame detected is out of sequence, flame signal light is on.
The sensor is “runaway”, flame signal light is on.
Inductance is detected on sensor wires, flame signal light is on.
Voltage wired into terminals 3, 4 or 5.
Internal relay contacts welded.
Internal controller failure.
7) Main valve closed switch defective, no power to V.
FLAME FAILURE
1)
2)
3)
4)
5)
Pilot flame is not established in selected TFI.
Main flame is not established in selected TFI.
Main flame fails within 35 seconds of TFI.
Flame failed during operation in non-recycle mode.
Flame failed 35 seconds after TFI and was not established after try in recycle mode.
No Purge Model
30
Eclipse Veri-Flame Instruction Manual 818 -2/02
Table 8.2 LED Status & Conditions for Veri-Flame Purge Models
LED(S) LIT
POSSIBLE CAUSES
INTERLOCKS CLOSED
1) The interlocks are closed (normal operation), power on terminal 7.
SYSTEM ERROR
1)
2)
3)
4)
5)
6)
7)
8)
The flame detected is out of sequence, flame signal light is on.
The sensor is “runaway”, flame signal light is on.
Inductance is detected on sensor wires, flame signal light is on.
Voltage wired into terminals 3, 4 or 5.
Internal relay contacts welded.
Internal controller failure.
Air flow switch closed before start-up.
Main fuel valve switch opens after shutdown or before start-up, no power to V.
FLAME FAILURE
1)
2)
3)
4)
5)
Pilot flame is not established in selected TFI.
Main flame is not established in selected TFI.
Main flame fails within 35 seconds of TFI.
Flame failed during operation in non-recycle mode.
Flame failed 35 seconds after TFI and was not established after one try in recycle mode.
AIR FAILURE
1) Air flow switch not closed within ten seconds of start-up.
2) Air flow switch is open during timing cycle.
3) Air flow switch is open during firing cycle.
Purge Model
Eclipse Veri-Flame Instruction Manual 818 -2/02
31
Table 8.3 LED Status & Conditions for Veri-Flame Modulation Models
LED(S) LIT
POSSIBLE CAUSES
INTERLOCKS CLOSED
1) The interlocks are closed (normal operation), power on terminal 7.
SYSTEM ERROR
1)
2)
3)
4)
5)
6)
7)
8)
9)
The flame detected is out of sequence, flame signal light is on.
The sensor is “runaway”, flame signal light is on.
Inductance is detected on sensor wires, flame signal light is on.
Voltage wired into terminals 3, 4 or 5.
Internal relay contacts welded.
Internal controller failure.
Air flow switch closed before start-up.
High purge damper switch and/or main fuel valve switch opens during start-up.
Low fire switch not made before TFI.
FLAME FAILURE
1)
2)
3)
4)
5)
Pilot flame is not established in selected TFI.
Main flame is not established in selected TFI.
Main flame fails within 35 seconds of TFI.
Flame failed during operation in non-recycle mode.
Flame failed 35 seconds after TFI and was not established after try in recycle mode.
AIR FAILURE
1) Air flow switch not closed within ten seconds of start-up.
2) Air flow switch is open during timing cycle.
3) Air flow switch is open during firing cycle.
INTERLOCKS CLOSED and
AUTO
1) Burner in run mode, firing rate determined by automatic controller (normal operation).
INTERLOCKS CLOSED
and HIGH FIRE
1) Purge high sequence (normal operation).
INTERLOCKS CLOSED and
LOW FIRE
1) Purge low sequence (normal operation).
Modulation Model
32
Eclipse Veri-Flame Instruction Manual 818 -2/02
Remote Display Messages
9
INTRODUCTION
This section covers how the optional remote display is used with the Veri-Flame.
The remote display provides LCD messages which monitor the status of the VeriFlame’s functions as well as any lockout conditions. This section is divided into two
parts or tables:
• The first table describes the start-up and shutdown monitoring sequences of the
Veri-Flame and how the progress (or halt) of the sequence can be monitored by
the messages on the remote display.
• The second table alphabetically lists and explains the diagnostic messages which
can appear on the remote display.
Eclipse Veri-Flame Instruction Manual 818 -2/02
33
Table 9.1 Veri-Flame Operating Sequence
POWER ON
Was internal safe start check successful?
NORMAL MESSAGE
YES
REMOTE DISPLAY
REVISION X.X
NO
Various lockout messages
EXTERNAL INTERLOCK CHECKS
Is flame signal present?
ERROR MESSAGE #1
YES
UNSAFE FLAME ON
Fan is energized. If signal is eliminated within 30 seconds, sequence continues. If not, then . .
NO
FOR PURGE & MODULATING Is voltage present at air flow switch?
ERROR MESSAGE #1
YES
UNSAFE AIR SHORT
ERROR MESSAGE #2 – 30 SECONDS AFTER #1
UNSAFE FLAME ON
XX:XX:XX LOCKOUT
Is main valve closed switch made?*
NO
NO
ERROR MESSAGE
MAIN VALVE FAIL
XX:XX:XX LOCKOUT
If switch is opened within 30
seconds, sequence continues. If
not, then . . .
Alarm energized.
ERROR MESSAGE #2 – 30 SECONDS AFTER #1
UNSAFE AIR SHORT
XX:XX:XX LOCKOUT
Alarm energized.
Is voltage present at interlock switch?
YES
NORMAL MESSAGE
SAFE START OK
Check_Sum = XX
NO
ERROR MESSAGE
LIMITS OPEN
TIME = XXXX:XX:XX
Holds until answer is yes.
NORMAL MESSAGE
FAN ENERGIZED
Fan output is energized; modulator is sent to low fire.
BURNER START-UP
(see next page)
* Applies to purge and no purge models only.
34
YES
Eclipse Veri-Flame Instruction Manual 818 -2/02
Table 9.1 Veri-Flame Operating Sequence (continued)
BURNER START-UP
Is voltage present at air flow switch
within ten seconds?
NO PURGE MODELS
MODULATION MODELS
Is voltage present at air switch . . .
PURGE MODELS
NORMAL MESSAGE
Is voltage present at air switch . . .
AIR PROVEN
YES
NO
ERROR MESSAGE
NORMAL MESSAGE
AIR PROVEN
YES
AIR NOT PROVEN
XX:XX:XX LOCKOUT
NO
NORMAL MESSAGE
Purge based on selected time.
PURGE TO HIGH FIRE
ERROR MESSAGE
AIR NOT PROVEN
XX:XX:XX LOCKOUT
Modulator sent to high fire for
selected purge time.
Is voltage present
at high purge switch?
NORMAL MESSAGE
PURGE TO LOW FIRE
YES
NO
Modulator sent to low fire for
selected purge time.
ERROR MESSAGE
HI DAMPER FAIL
XX:XX:XX LOCKOUT
Is low fire switch closed?
NORMAL MESSAGE
YES
PILOT TRIAL FOR
IGNITION
Spark and pilot valve energized
for selected trial for ignition.
NO
ERROR MESSAGE
LOW FIRE FAIL
XX:XX:XX LOCKOUT
Is pilot flame signal present?
NORMAL MESSAGE
PILOT FLAME ON
YES
NO
ERROR MESSAGE
PILOT FLAME FAIL
XX:XX:XX LOCKOUT
Flame signal detected
NORMAL MESSAGE
PILOT FLAME XX.XV
TIME = XXXX:XX:XX
Spark turns off at end of TFI;
sequence delayed 5 seconds.
Is main flame signal present?
NORMAL MESSAGE
MAIN FLAME ON
YES
NO
ERROR MESSAGE
MAIN FLAME FAIL
XX:XX:XX LOCKOUT
Is flame signal present?
(see next page)
Eclipse Veri-Flame Instruction Manual 818 -2/02
35
Table 9.1 Veri-Flame Operating Sequence (continued)
BURNER START-UP (continued)
Is flame signal present?
YES
ERROR MESSAGE
NO
MAIN FLAME FAIL
XX:XX:XX LOCKOUT
NORMAL MESSAGE
MAIN FLAME ON
NORMAL MESSAGE
MAIN FLAME ON
PILOT OFF
Pilot will shut off 10 seconds
after main flame is energized.
IF Interrupted Pilot is selected
IF Intermittent Pilot Is Selected
NORMAL MESSAGE
MAIN FLAME ON
NORMAL MESSAGE
MODULATION MODELS
AUTOMATIC
MODULATION
Modulator sent to automatic 20
seconds after main valve is
energized.
MODULATION MODELS
NORMAL MESSAGE
PURGE & NO PURGE MODELS
BURNER ON XX.XV
TIME = XXXX:XX:XX
Main flame of burner is proven.
Flame signal = XX.XVolts DC;
elapsed time is shown in hours:
minutes:seconds.
PURGE & NO PURGE MODELS
Is flame signal present?
YES
NO
Is air switch signal on?
YES
NO
YES
YES
NO
Was the main flame on more
than 35 seconds?
YES
ERROR MESSAGE
36
NO
ERROR MESSAGE
MAIN FLAME FAIL
RECYCLING
Unit returns to beginning
sequence.
NO
AIR FAILURE
RECYCLING
Unit returns to beginning
sequence.
NO
Was the main flame on more
than 35 seconds?
Is recycle selected?
YES
Is recycle selected?
ERROR MESSAGE
AIR FAILURE
XX:XX:XX LOCKOUT
Eclipse Veri-Flame Instruction Manual 818 -2/02
ERROR MESSAGE
MAIN FLAME FAIL
XX:XX:XX LOCKOUT
Table 9.1 Veri-Flame Operating Sequence (continued)
BURNER SHUTDOWN
Shutdown is started by opening
the operating interlock circuit.
Is voltage present at interlocks?
YES
Continued operation.
NO
Is post purge selected?
YES
NO
NORMAL MESSAGE
POST PURGE
XX
Fuel valves de-energized; fan
energized for 15 seconds.
Is main valve closed switch made?*
YES
ERROR MESSAGE
NO
MAIN VALVE FAIL
XX:XX:XX LOCKOUT
Fan energized; alarm sounds.
FOR PURGE & MODULATING
ERROR MESSAGE #1
UNSAFE AIR SHORT
If switch is opened within 30
seconds, sequence continues. If
not, then . . .
Is voltage present at air flow switch?
YES
NO
Is flame signal present?
ERROR MESSAGE #1
UNSAFE FLAME ON
Fan is energized. If signal is eliminated within 30 seconds, sequence continues. If not, then . .
ERROR MESSAGE #2 – 30 SECONDS AFTER #1
YES
NO
NORMAL MESSAGE
LIMITS OPEN
TIME = XXXX:XX:XX
UNSAFE AIR SHORT
XX:XX:XX LOCKOUT
Alarm energized.
ERROR MESSAGE #2 – 30 SECONDS AFTER #1
UNSAFE FLAME ON
XX:XX:XX LOCKOUT
Alarm energized.
* Applies to purge and no purge models only.
Eclipse Veri-Flame Instruction Manual 818 -2/02
37
Table 9.2 Remote Display Diagnostic Messages (Listed Alphabetically)
MESSAGE
38
TYPE
EXPLANATION
AIR FAILURE
XX:XX:XX LOCKOUT
Lockout
For purge & modulation models: Combustion air flow limit
switch opened for more than two seconds once initially proven.
AIR FAILURE
RECYCLING
Status
For purge & modulation models: Combustion air flow limit switch
opened; if “recycle” has been selected, the Veri-Flame will restart the
sequence after air failure (see “Recycle Mode” on page 14).
AIR NOT PROVEN
XX:XX:XX LOCKOUT
Lockout
For purge & modulation models: Combustion air flow limit
switch did not make within ten seconds of fan being energized.
AIR PROVEN
Status
For purge & modulation models: Combustion air flow limit
switch closed within ten seconds of fan being energized.
AUTOMATIC
MODULATION
Status
For modulation models only: Modulating motor is sent to automatic operation.
BURNER ON XX.XV
TIME=XXXX:XX:XX
Status
Main flame of burner is proven in the automatic modulation mode;
flame strength is XX.XV (volts DC). Elapsed time is shown in
hours:minutes:seconds.
D-INTERNAL FAIL
XX:XX:XX:XX LOCKOUT
Lockout
For modulation models only: Internal control failure; replace
controller.
FAN ENERGIZED
Status
For purge & modulation models: Blower motor is energized
at the start of pre-purge.
FLAME FAILURE
XX:XX:XX LOCKOUT
Lockout
Main flame lost during operation in the automatic modulation mode.
Burner number (X) given of failed unit.
HI DAMPER/POVC
XX:XX:XX LOCKOUT
Lockout
For modulation models only: High damper or high purge rate
switch did not make at the end of pre-purge to high fire.
K-INTERNAL FAIL
XX:XX:XX LOCKOUT
Lockout
Internal control failure; replace controller.
L-INTERNAL FAIL
XX:XX:XX LOCKOUT
Lockout
Internal control failure; replace controller.
LIMITS OPEN
TIME=XXXX:XX:XX
Status
The controller has completed its internal checks and is standing by
for the interlocks to close.
LOW FIRE FAIL
XX:XX:XX LOCKOUT
Lockout
For modulation models only: Low fire switch is open just prior
to pilot trial for ignition.
MAIN FLAME FAIL
XX:XX:XX LOCKOUT
Lockout
Main flame was not established during the main burner trial for
ignition.
MAIN FLAME FAIL
RECYCLING
Status
Main flame lost during automatic modulation; control will recycle
once if “recycle” has been selected.
Eclipse Veri-Flame Instruction Manual 818 -2/02
Table 9.2 Remote Display Diagnostic Messages (continued)
MESSAGE
TYPE
EXPLANATION
MAIN FLAME ON
Lockout
Main valve has been energized and main flame proven during trial
for ignition.
MAIN FLAME ON
PILOT OFF
Status
Pilot valve is de-energized and main flame is on.
MAIN VALVE FAIL
XX:XX:XX LOCKOUT
Lockout
For purge and no purge models: Main valve closed switch is
open before start-up or after burner shutdown.
NO PURGE SELECT
XX:XX:XX LOCKOUT
Lockout
For purge & modulation models: No purge time was selected;
lockout prior to purge to high fire.
PILOT FLAME FAIL
XX:XX:XX LOCKOUT
Lockout
Pilot flame was not established during the pilot trial for ignition.
PILOT ON
Status
Pilot flame is proven; transformer is de-energized; remaining countdown for pilot trial for ignition is.
PILOT TRIAL FOR
IGNITION
Status
Pilot valve and ignition transformer are energized; countdown for
pilot trial for ignition begins.
POST PURGE
Status
For purge & modulation models: 15 second post purge is
started on burner shutdown.
PROGM SWITCH ERR
XX:XX:XX LOCKOUT
Lockout
DIP switch improperly set or changed during cycle.
PURGE TO HIGH
FIRE
Status
For modulation models only: Modulating motor is sent to high
fire.
PURGE TO LOW
FIRE
Status
For modulation models only: Modulating motor is sent to low
fire.
RELAY FAIL
XX:XX:XX LOCKOUT
Lockout
Internal relay(s) fail initial check. Check ratings. If lockout still occurs after overload is eliminated, replace control.
SAFE START OK
Status
Control has completed internal safe-start check.
UNSAFE AIR SHORT
Status
For purge & modulation models: Combustion air switch is closed
before start-up or after shutdown; control holds start-up until switch
reopens; if interlocks close before switch opens, alarm is energized.
UNSAFE AIR SHORT
XX:XX:XX LOCKOUT
Lockout
For purge & modulation models: Same conditions as above,
except the interlocks close before the switch reopens, causing a
lockout and the alarm being energized.
Eclipse Veri-Flame Instruction Manual 818 -2/02
39
Table 9.2 Remote Display Diagnostic Messages (continued)
MESSAGE
40
TYPE
EXPLANATION
UNSAFE FLAME ON
Hold
Flame signal—actual, induced, or runaway scanner—is detected before start-up or after shutdown. The fan is energized. If the cause is
corrected within 30 seconds, as in afterburn, the control will turn
off the fan and continue the sequence.
UNSAFE FLAME ON
XX:XX:XX LOCKOUT
Lockout
Same conditions as above, except the cause has not been corrected
within 30 seconds, resulting in a lockout and the alarm being energized.
UNSAFE–FLM–PURGE
Hold
For purge & modulation models: Flame signal—actual, induced,
or runaway scanner—is detected during the selected purge time
period. The fan is energized. If the cause is corrected within 30 seconds, as in afterburn, the control will turn off the fan and continue
the sequence.
UNSAFE–FLM–PURGE
XX:XX:XX LOCKOUT
Lockout
For purge & modulation models: Same conditions as above,
except the cause has not been corrected within 30 seconds, resulting
in a lockout and the alarm being energized.
V–INTERNAL FAULT
XX:XX:XX LOCKOUT
Lockout
Internal control failure; replace controller.
WATCHDOG FAIL
XX:XX:XX LOCKOUT
Lockout
Internal control failure; replace controller.
XXXXXXX
XXXXXTESTXX
Status
In combination with other messages, shows the control is in the
minimum pilot test mode.
Eclipse Veri-Flame Instruction Manual 818 -2/02
Appendix
CONVERSION
FACTORS
Metric to English.
FROM
TO
3
MULTIPLY
3
cubic meter (m )
BY
cubic foot (ft )
35.31
cubic meter/hour (m /h)
cubic foot/hour (cfh)
35.31
degrees Celsius (°C)
degrees Fahrenheit (°F)
kilogram (kg)
pound (lb)
(°C x 1.8) + 32
2.205
kilowatt (kW)
Btu/hr
3414
meter (m)
foot (ft)
3.28
millibar (mbar)
inches water column ("wc)
0.401
millibar (mbar)
pounds/sq in (psi)
14.5 x 10-3
millimeter (mm)
inch (in)
3.94 x 10-2
FROM
TO
MULTIPLY BY
kiloPascals (kPa)
millibar (mbar)
10
meter (m)
millimeter (mm)
1000
millibar (mbar)
kiloPascals (kPa)
0.1
millimeter (mm)
meter (m)
0.001
FROM
TO
MULTIPLY BY
Btu/hr
kilowatt (kW)
0.293 x 10-3
cubic foot (ft3)
cubic meter (m3)
2.832 x 10-2
cubic foot/hour (cfh)
cubic meter/hour (m3/h)
degrees Fahrenheit (°F)
degrees Celsius (°C)
2.832 x 10-2
(°F – 32) ÷ 1.8
foot (ft)
meter (m)
0.3048
inches (in)
millimeter (mm)
25.4
inches water column ("wc)
millibar (mbar)
2.49
pound (lb)
kilogram (kg)
0.454
pounds/sq in (psi)
millibar (mbar)
68.95
3
Metric to Metric.
English to Metric.
Eclipse Veri-Flame Instruction Manual 818 -2/02
41
ILLUSTRATED PARTS
LIST
Category
Pos.
No.
1
2
3
4
5
1
Sensors
6
6
7
2
8
9
10
3
Bases
11
Test
12
4
Display
Model
Number
Part
Number
Straight U.V. scanner
NEMA 4 U.V. scanner
90˚ U.V. scanner
I.R. scanner
Self-check scanner
Solid-state U.V./I.R. scanner
10-foot cable for self-check scanner
Scanner support (max. temp. 220˚F) (1)
Scanner support (max. temp. 475˚F) (1)
Magnifying lens assembly
Lens, magnifying
Lens, non-magnifying (2)
Insulated coupling
Cable, coax, RG62A/U for flame rod
Internal terminal base, metal
Exposed terminal base, metal
Internal terminal base, plastic
Adapter Base RA890
Adapter Base R4795
Modulation base
Screw, mounting to plastic base
Screw, mounting to metal base
5600-91
5600-91N4
5600-90A
5600-92B
5602-91
5600-92SC
5602-91-7
5600-90A SS
5600-90A SSH
5600-98
49600-91
20898
49600-90
49600-92
49602-91
21349
49602-91-7
20722
20723
49600-98
49600-99
18165
49099
21741
49602-10
49602-10-1
22194
49602-12
49602-14
49602-40
22110
22385
Tester for Veri-Flame units
Relay module (3)
5602
5602-40-4
49602
49240-2
Remote display, 24V
Remote display, 120VAC with keypad
Power supply, 24VDC (4)
Cable for remote display
5602 DB
5602 DBP
20316
20896
20317
20318
Description
5600-99
5602-10
5602-10-1
5602-10-P
5602-12
5602-14
5602-40
(1) For 90º U.V. scanner (Model No. 5600-90A), I.R. scanner (5600-92B), and solid state U.V./I.R. scanner (5600-92SC)
(2) For magnifying lens assembly (Model No. 5600-98), and self-check scanner (5602-91)
(3) Used to test modulation controls on tester (Model No. 5602) above.
(4) To be used with 20316 display only (not 20896).
5
6
7
11
9
8
12
10
Instruction Manual 818 2/02
Litho in USA
Data 114-4
12/02
ThermAir
Burners
Model TA075
Version 1.10
Main Specification – TA075
BLOWER SIZE
PARAMETER
Maximum input (Btu/hr)
(To maintain 15% excess air
with standard air orifice and
standard combustion air blower)
Frequency
60 Hz
Packaged
Blower
50 Hz
Packaged
Blower
Minimum input
Natural gas
Propane
Butane
Main Gas Inlet Pressure
• Fuel pressure at gas
inlet (Tap "B")
Natural gas
Propane
Butane
High Fire Flame Length
• Measured from the outlet
end of combustor
Natural gas
Propane
Butane
Maximum Chamber Temperature
Alloy Tube
SIC Tube
Flame Detection
Fuel
3"w.c. Packaged
6"w.c. Packaged
Capacity at Chamber Pressure
Capacity at Chamber Pressure
BTU/hr
"w.c.
kW
mbar
BTU/hr
"w.c.
kW
mbar
805,000
750,000
691,000
-1.0
0.0
1.0
236
220
202
-2,5
0,0
2,5
814,000
750,000
705,000
822,000
771,000
716,000
-1.0
0.0
1.0
-1.0
0.0
1.0
238
220
206
241
226
210
-2,5
0,0
2,5
-2,5
0,0
2,5
Not Available
BTU/hr
kW
BTU/hr
kW
14,000
18,000
23,000
4,1
5,3
6,7
25,000
25,000
25,000
7,3
7,3
7,3
" w.c.
6.6
7.2
8.0
mbar
16,4
17,9
19,9
" w.c.
6.5
6.8
6.9
mbar
16
17
17
inches
39
43
43
mm
990
1092
1092
inches
30
32
32
mm
762
813
813
ºF
1500
1900
ºC
820
1038
Flame rod or UV scanner
Natural gas, Propane, or Butane.
For any other mixed gas, contact Eclipse Combustion for orifice sizing
• All information is based on laboratory testing in neutral (0.0”w.c.) chamber with standard combustor design.
Different chamber conditions and/or combustor design will affect the data.
• Maximum inputs are given for the standard combustion air blower without an air filter.
• All inputs based upon gross calorific values and standard conditions: 1 atmosphere, 70º F ( 21ºC).
• Blower motor service factors greater than 1.0 may be required when firing into negative chamber pressure
applications. For specific application questions, contact your Eclipse Combustion representative.
• Eclipse reserves the right to change the construction and/or configuration of our products at any time without
being obliged to adjust earlier supplies accordingly.
Performance Graphs
ThermAir TA075
Air Flow vs. Chamber Pressure
Control & Operation Zone
5
Typical Fixed
Air Control
1,000
100
2.0
Chamber Pressure (mbar)
Chamber Pressure (mbar)
2.5
0
-2.5
10
150
50
250
200
Burner Flame Length - 3"Blower
1000
Natural Gas
Propane
Butane
40
30
20
0
0
150
0
750
500
250
9000
220
Air Flow (Nm3 /hr)
9500
240
Burner Flame Length - 6"Blower
40
Natural Gas
Propane
Butane
30
20
10
0
Pressure Drop ("w.c.)
5
3.0
1.5
150
0
50
750
300
450
600
Input (x 1000 BTU/hr)
100
150
Input (kW)
50
100
150
Input (kW)
750
200
15
10
5
0
10
8.0
20
4.5
0
300
450
600
Input (x 1000 BTU/hr)
Fuel Orifice
Input
Fuel Orifice
∆P vs. Input
Blower
∆ P vs.- 6"
(Measuredbetween
betweenTaps
Taps B
B and D)
(Measured
D)
6.0
0.0
150
0
200
Nat. Gas (12.7 mm orifice)
Propane (10 mm orifice)
Butane (9.3 mm orifice)
7.5
0
0
Natural Gas (12.7 mm orifice)
Propane (10 mm orifice)
Butane (9.3 mm orifice)
6.0
8
6
4.0
4
2.0
2
0
750
0.0
0
150
300
450
600
Input (x 1000 BTU/hr)
200
0
50
100
150
Input (kW)
Eclipse Model TA075, v1.10, Data 114-4, 12/02
200
Pressure Drop (mbar)
10
100
150
Input (kW)
0
750
Fuel Orifice ∆P vs. Input - 3" Blower
(Measured between Taps B and D)
20
15
300
450
600
Input (x 1000 BTU/hr)
50
9.0
Pressure Drop (mbar)
8000
8500
Air Flow (scfh)
10
0
2
7500
200
Pressure Drop (mbar)
500
-1.0
Flame Length (in.)
1250
750
Flame Length (mm)
60
Flame Length (in.)
Flame Length (mm)
1500
750
100
150
Input (kW)
50
0
1000
300
450
600
Input (x 1000 BTU/hr)
0.0
-2.0
7000
-5
0
1.0
Pressure Drop (“w.c.)
% Excess Air
10,000
Performance Graphs (Continued)
ThermAir TA075
NOx Emission Data
200
Notes on emission data
Natural Gas
NOx emission data is given for:
• Ambient combustion air ~70° F (20° C)
• Minimal process air velocity
• ppm volume dry at 3% O2
• Neutral chamber pressure
Emissions are influenced by:
• Chamber conditions
• Fuel type
• Firing rate
• Combustion air temperature
Propane
150
NOx pp m
Butane
100
50
CO emission is largely influenced by chamber conditions. Contact your local Eclipse
Combustion representative for an estimate
of CO emission on your application.
0
0
150
300
450
600
Input (x 1000 BTU/hr)
50
0
Dimensions-TA075
100
150
Input (kW)
750
200
mm (in)
D
724
(28.5)
A
E
36
(1.4)
C
B
F
Tap "A"
Tap "C"
Optional Filter/Silencer
and Pressure Switch
shown in gray
Tap "D"
9
(0.35)
Tap "B"
218
(8.6)
Port Connection
14mm
Sparkplug
Flamerod or scanner 0.5" N.P.T.
0.75" N.P.T.
Peepsight
Weights
Burner, w/ blower
Burner, less blower
Filter/Silencer
lb
78
31
41
kg
35
14
19
1" N.P.T
or 1" B.S.P
G
Blower 6" w.c.
A
B
C
D
E
Hz mm in mm in mm in mm in mm in
50 484 19.0 532 20.9 N/A N/A N/A N/A 272 10.7
60 424 16.7 473 18.6 482 19.0 447 17.6 243 9.5
Blower 3" w.c.
60 338 13.3 393 15.5 N/A N/A N/A N/A 202 7.9
F
G
mm in mm in
309 12.2 291 11.5
279 11.0 291 11.5
234 9.2 192 7.6
4 x Ø 12 (0.47)
Ø 120 (4.7) OD
20 (0.8)
230 (9.1)
SiC Tube
Ø 165 (6.49)
bolt circle
190
(7.5)
114
(4.5)
79
(3.1)
Mounting
Pattern
180
330
(7.0)
(13.0)
310 Stainless Steel
Alloy Tube
Eclipse Model TA075, v1.10, Data 114-4, 12/02
3
Piping
Orientation
Upright
Piping Options
Inverted
With ratio regulator
and control BV
Right Hand Piping
Right Hand Piping
LeftHand Piping
611
(24.0)
With control BV only
Left Hand Piping
No Piping
423
(16.6)
Less ratio regulator
and control BV
No Piping
114-4 Data 12/2002
Litho in U.S.A.
Data 114-6
12/02
ThermAir
Burners
Model TA200
Version 1.10
Main Specifications - TA200
PARAMETER
Maximum input
(To maintain 15% excess air with
the standard air orifice and
standard combustion air blower.)
SPECIFICATIONS
Frequency
Btu/hr
"w.c.
kW
mbar
60 Hz
packaged
blower
2,071,000
2,000,000
1,871,000
2,235,000
2,066,000
2,028,000
-1.0
0.0
1.0
-1.0
0.0
1.0
607
586
548
655
605
594
-2,5
0,0
2,5
-2,5
0,0
2,5
50 Hz
packaged
blower
Minimum input
Natural Gas, Propane or Butane
Main gas inlet pressure
• fuel pressure at gas inlet (Tap "B")
High fire flame length
• measured from the
outlet end of combustor
Natural Gas
Propane
Butane
Natural Gas
Propane
Butane
Maximum chamber temperature
Alloy Tube
SiC Tube
Flame detection
Fuel
BTU/hr
kW
66,000
"w.c.
9.4
9.8
9.8
inches
54
54
53
˚F
1500
1900
19,4
mbar
23
24
24
mm
1370
1370
1345
˚C
815
1038
UV scanner only
Natural Gas, Propane or Butane.
(For any other mixed gas, contact Eclipse Combustion for orifice sizing.)
• All information is based on laboratory testing in neutral (0.0”w.c.) chamber with standard
combustor design. Different chamber conditions and/or combustor design will affect the
data.
• Maximum inputs are given for the standard combustion air blower without an air filter.
• All inputs based upon gross calorific values and standard conditions: 1 atmosphere, 70ºF
(21ºC).
• Blower motor service factors greater than 1.0 may be required when firing into negative
chamber pressure applications. For specific application questions, contact your Eclipse
Combustion representative.
• Eclipse reserves the right to change the construction and/or configuration of our products
at any time without being obliged to adjust earlier supplies accordingly.
Performance Graphs
ThermAir TA200
NOx Emission Data
Control & Operation Zone
100
10000
Natural Gas
Propane
% Excess Air
80
Butane
Typical Fixed
Air Control
1000
60
40
100
20
0
10
0
500
1000
1500
Input (x 1000 BTU/hr)
0
150
450
0
500
1000
1500
Input (x 1000 BTU/hr)
600
0
150
Burner Flame Length
60
1500
300
Input (kW)
2000
Flame Length (in.)
Flame Length (mm)
375
Butane
40
20
CO emission is largely influenced by chamber conditions. Contact your local Eclipse
Combustion representative for an estimate
of CO emission on your application.
0
0
0
500
1000
1500
Input (x 1000 BTU/hr)
0
150
300
Input (kW)
450
2000
600
Fuel Orifice ∆ P vs. Input
Air Flow vs. Chamber Pressure
(Measured between Taps B and D)
0
2
6.0
3.0
2.5
0
-2.5
0.0
-5
0
500
1000
1500
Input (x 1000 BTU/hr)
0
150
300
Input (kW)
450
2000
600
2.0
Chamber Pressure (“w.c.)
5
Natural Gas (20.5 mm orifice)
Propane (16 mm orif ice)
Butane (15 mm orifice)
Chamber Pressure (mbar)
10
Pressure Drop (“w.c.)
Pressure Drop (mbar)
15
5
9.0
20
600
NOx emission data is given for:
• Ambient combustion air ~70° F (20° C)
• Minimal process air velocity
• ppm volume dry at 3% O2
• Neutral chamber pressure
Emissions are influenced by:
• Chamber conditions
• Fuel type
• Firing rate
• Combustion air temperature
Propane
750
450
Notes on emission data
Natural Gas
1125
300
Input (kW)
2000
1.0
0.0
-1.0
-2.0
18,000
20,000
22,000
Air Flow (scfh)
500
550
Air Flow (Nm3 /hr)
Eclipse Model TA200, v1.10, Data 114-6, 12/02
24,000
600
Dimensions-TA200
mm (in)
D
724
(28.5)
A
E
31
(1.2)
C
B
F
Tap "A"
Tap "C"
Optional Filter/Silencer
and Pressure Switch
shown in gray
Tap "D"
Tap "B"
226
(8.9)
Port Connection
14mm
Sparkplug
Flamerod or scanner 0.5" N.P.T.
0.75" N.P.T.
Peepsight
Weights
Burner, w/ blower
Burner, less blower
Filter/Silencer
lb
99
46
41
kg
45
21
19
1.5" N.P.T
or 1.5" B.S.P
G
9
(0.35)
Blower 10" w.c.
A
B
C
D
E
F
G
Hz mm in mm in mm in mm in mm in mm in mm in
50 586 23.1 669 26.3 N/A N/A N/A N/A 322 12.7 392 15.4 290 11.4
60 503 19.8 577 22.7 608 23.9 565 22.2 283 11.1 342 13.5 298 11.7
4 x Ø 12 (0.47)
Ø 148 (5.8) OD
320 (12.6)
SiC Tube
Ø 190 (7.48)
bolt circle
220
(8.7)
141
(5.6)
81
(3.2)
Mounting
Pattern
196
330
(7.7)
(13.0)
310 Stainless Steel
Alloy Tube
Eclipse Model TA200, v1.10, Data 114-6, 12/02
3
Piping
Piping Options
Orientation
Upright
Inverted
With ratio regulator
and control BV
Right Hand Piping
Right Hand Piping
LeftHand Piping
688
(27.1)
With control BV only
Left Hand Piping
No Piping
431
(17.0)
Less ratio regulator
and control BV
No Piping
114-6 Data 12/2002
Litho in U.S.A.
Installation Guide 114
05/03
ThermAir
Burners
TA Series
version 1.10
COPYRIGHT
DISCLAIMER NOTICE
LIABILITY AND
WARRANTY
2
Copyright 1998 by Eclipse Combustion, Inc. All rights
reserved worldwide. This publication is protected by federal
regulation and shall not be copied, distributed, transmitted,
transcribed or translated into any human or computer
language, in any form or by any means, to any third parties,
without the express written consent of Eclipse Combustion,
Inc., Rockford, Illinois, U.S.A.
We reserve the right to change the construction and/or
configuration of our products at any time without being obliged
to adjust earlier supplies accordingly.
The material in this manual is believed adequate for the
intended use of the product. If the product, or its individual
modules or procedures, are used for purposes other than
those specified herein, confirmation of their validity and
suitability must be obtained. Eclipse Combustion, Inc. warrants
that the material itself does not infringe any United States
patents. No further warranty is expressed or implied.
We have made every effort to make this manual as accurate
and complete as possible. Should you find errors or omissions,
please bring them to our attention so that we may correct
them. In this way we hope to improve our product
documentation for the benefit of our customers. Please send
your corrections and comments to our Documentation
Manager.
It must be understood that Eclipse Combustion’s liability for its
products, whether due to breach of warranty, negligence, strict
liability, or otherwise, is limited to the furnishing of such
replacement parts and Eclipse Combustion will not be liable for
any other injury, loss, damage or expenses, whether direct or
consequential, including but not limited to loss of use, income
of or damage to material arising in connection with the sale,
installation, use of, inability to use or the repair or replacement
of Eclipse Combustion’s products.
Any operation expressly prohibited in this Guide, any
adjustment, or assembly procedures not recommended or
authorized in these instructions shall void the warranty.
Eclipse ThermAir T/A Series v1.10, Installation Guide No. 114, 05/03
About this manual
AUDIENCE
This manual has been written for people who are already
familiar with all aspects of a nozzle-mix burner and its add-on
components, also referred to as “the burner system.”
These aspects are:
• installation
• use
• maintenance.
The audience is expected to have had experience with this kind
of equipment.
THERMAIR
DOCUMENTS
Installation Guide No. 114
• This document
ThermAir Data Sheets, Series 114
• Available for individual TA models
• Required to complete design & selection
Design Guide No. 114
Used with Data Sheet to design burner system
ThermAir Price List No. 114
Used to order burners
RELATED DOCUMENTS
• EFE 825 (Combustion Engineering Guide)
• Eclipse Bulletins and Info Guides: 710, 732, 742, 760, 818,
832, 852, 854, 856, 610, 620, 630, 826, 820, 930, I-354.
Purpose
The purpose of this manual is to ensure the installation of a
safe, effective, and trouble-free combustion system is carried
out.
Eclipse ThermAir T/A Series v1.10, Installation Guide No. 114, 05/03
3
DOCUMENT
CONVENTIONS
There are several special symbols in this document. You
must know their meaning and importance.
The explanation of these symbols follows below. Please read
it thoroughly.
d Danger:
Indicates hazards or unsafe practices which WILL
result in severe personal injury or even death.
Only qualified and well trained personnel are
allowed to carry out these instructions or
procedures.
Act with great care and follow the instructions.
HOW TO GET HELP
4
w
Warning:
Indicates hazards or unsafe practices which
could result in severe personal injury or
damage.
Act with great care and follow the instructions.
c
Caution:
Indicates hazards or unsafe practices which could result in
damage to the machine or minor personal injury, Act carefully.
d
Note:
Indicates an important part of the text. Read thoroughly.
If you need help, contact your local Eclipse Combustion
representative. You can also contact Eclipse Combustion at any
of the addresses listed on the back of this document.
Eclipse ThermAir T/A Series v1.10, Installation Guide No. 114, 05/03
Table of contents
About this manual . . . . . . . . . . . . . . . . . . . . . . . . . .
Audience . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
ThermAir Documents . . . . . . . . . . . . . . . . . . . . . . . . .
Related Documents . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Document Conventions . . . . . . . . . . . . . . . . . . . . . . . .
How to Get Help . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3
3
3
3
4
4
Table of Contents . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
1
Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Product Description . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
2
Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Capabilities . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Operator Training . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Replacement Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . .
9
10
10
10
3
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Handling and Storage . . . . . . . . . . . . . . . . . . . . . . . . . . .
Approvals of Components . . . . . . . . . . . . . . . . . . . . . .
Electrical Wiring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Where to get standards . . . . . . . . . . . . . . . . . . . . . . . .
Pre-installation Checklist . . . . . . . . . . . . . . . . . . . . . . .
Burner . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Gas Piping . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Installing the flame sensor . . . . . . . . . . . . . . . . . . . . . . .
Check List After Installation . . . . . . . . . . . . . . . . . . . . .
Prepare for adjustment . . . . . . . . . . . . . . . . . . . . . . . . .
11
11
11
12
12
13
13
14
15
15
16
4
Adjustment, Start & Stop . . . . . . . . . . . . . . . . . . . .
Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
System 1
Burner adjustment with a ratio regulator . . . . . . . . . .
Step 1 Reset the system . . . . . . . . . . . . . . . . . . . . .
Step 2 Verify Air flow . . . . . . . . . . . . . . . . . . . . . . .
Step 3a Ignite the burner (Option 1) . . . . . . . . . . .
Step 3b Ignite the burner (Option 2) . . . . . . . . . .
Step 4 Set high fire gas . . . . . . . . . . . . . . . . . . . . . .
Step 5 Set low fire gas . . . . . . . . . . . . . . . . . . . . . .
Step 6 Verify gas settings . . . . . . . . . . . . . . . . . . . . .
17
17
Eclipse ThermAir T/A Series v1.10, Installation Guide No. 114, 05/03
17
17
18
18
19
20
21
21
5
4
5
Adjustment, Start & Stop (Cont.) . . . . . . . . . . . . .
System 2
Burner adjustment without a ratio regulator . . . . . . .
Step 1 Reset the system . . . . . . . . . . . . . . . . . . . . .
Step 2 Verify the system . . . . . . . . . . . . . . . . . . . . .
Step 3a Ignite the burner (Option 1) . . . . . . . . . . .
Step 3b Ignite the burner (Option 2) . . . . . . . . . .
Step 4 Set high fire gas . . . . . . . . . . . . . . . . . . . . . .
Step 5 Set low fire gas . . . . . . . . . . . . . . . . . . . . . .
Step 6 Verify gas settings . . . . . . . . . . . . . . . . . . . . .
21
21
22
22
22
23
24
24
24
Maintenance & Troubleshooting . . . . . . . . . . . . . .
Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Monthly Checklist . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Yearly Checklist . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Troubleshooting Procedures . . . . . . . . . . . . . . . . . . . .
25
25
25
26
27
Appendix . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
Conversion Factors . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
Key to System Schematics . . . . . . . . . . . . . . . . . . . . . . 31
Parts Drawing . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
Parts List . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
Parts List continued . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
6
Eclipse ThermAir T/A Series v1.10, Installation Guide No. 114, 05/03
Introduction
PRODUCT
DESCRIPTION
1
The ThermAir burner (TA Series) is a nozzle-mix burner with a
packaged combustion air blower that is designed to fire with
fixed combustion air over a wide gas turndown range. An
integral gas orifice is provided to ease burner setup. The
burner is designed to facilitate:
• fixed air operation
• direct spark ignition
• simple gas control
• multiple fuel capability
The burner is suitable for direct and indirect air heating for a
wide range of applications on industrial furnaces and ovens.
Figure 1.1
ThermAir Burner
Eclipse ThermAir T/A Series v1.10, Installation Guide No. 114, 05/03
7
Blank page.
8
Eclipse ThermAir T/A Series v1.10, Installation Guide No. 114, 05/03
Safety
INTRODUCTION
SAFETY
2
This section is provided as a guide for the safe operation of
the ThermAir burner system. All involved personnel should
read this section carefully before operating this system.
d
Danger:
The ThermAir burners, described herein, are
designed to mix fuel with air and burn the
resulting mixture. All fuel burning devices are
capable of producing fires and explosions if
improperly applied, installed, adjusted,
controlled, or maintained.
Do not bypass any safety feature; fire or explosion
could result.
Never try to light a burner if it shows signs of
damage or malfunction.
w
Warning:
The burner might have HOT surfaces. Always wear protective
clothing when approaching the burner.
n
Note:
This manual provides information in the use of these burners
for their specific design purpose. Do not deviate from any
instructions or application limits described herein without
written advice from Eclipse Combustion.
Read the entire manual before attempting to start this
system. If you do not understand any part of the information
contained in this manual, contact your local Eclipse
representative or Eclipse Combustion before continuing.
Eclipse ThermAir T/A Series v1.10, Installation Guide No. 114, 05/03
9
CAPABILITIES
Only qualified personnel, with good mechanical aptitude and
experience on combustion equipment, should adjust, maintain,
or troubleshoot any mechanical or electrical part of this
system.
OPERATOR TRAINING
The best safety precaution is an alert and trained operator.
Train new operators thoroughly and have them demonstrate
an adequate understanding of the equipment and its
operation. A regular retraining schedule should be
administered to ensure operators maintain a high degree of
proficiency.
REPLACEMENT PARTS
Order replacement parts from Eclipse Combustion only. All
Eclipse Combustion approved, customer supplied valves or
switches should carry UL, FM, CSA, CGA, and/or CE approval,
where applicable.
10
Eclipse ThermAir T/A Series v1.10, Installation Guide No. 114, 05/03
Installation
3
INTRODUCTION
In this section you will find important notices about safe
operation of the burner:
HANDLING AND
STORAGE
Handling:
1. Make sure that the components are clean and free of
damage.
2. Protect the components from weather, damage, dirt and
moisture.
• Transport in original shipping container
• Do not drop
3. Protect the components from excessive temperatures and
humidity.
4. Use appropriate support equipment, i.e. harnesses, straps,
chains etc. when lifting burner components.
Storage:
1. Make sure that the area is clean.
2. Store the components in a cool, clean, dry room.
3. After you have made sure everything is present and in
good condition, keep the components in the original
package as long as possible.
APPROVALS OF
COMPONENTS
Limit Controls and Safety
Equipment
All limit controls and safety equipment must comply with the
current following standards:
• NFPA Standard 86
• NFPA Standard 86C
• UL
• FM
• CGA
• EN 746-2
• all applicable local codes and/or standards.
Eclipse ThermAir T/A Series v1.10, Installation Guide No. 114, 05/03
11
Electrical wiring
All electrical wiring must comply with one of these standards:
•
•
•
•
Gas Piping
ANSI-C11981
EN 746-2
the electrical wiring must be acceptable to the local
authority having jurisdiction
All gas piping must comply with one of these standards:
•
•
•
•
Where to get standards
NFPA Standard 70
NFPA Standard 70
ANSI Z223
EN 746-2
the gas piping must be acceptable to the local authority
having jurisdiction
The NFPA Standards are available from:
National Fire Protection Agency
Batterymarch Park
Quincy, MA 02269
The ANSI Standards are available from:
American National Standard Institute
1430 Broadway
New York, NY 10018
The UL Standards are available from:
333 Pfingsten Road
Northbrook, IL 60062
The FM Standards are available from:
1151 Boston-Providence Turnpike
P.O. Box 9102
Norwood, MA 02062
Information on the EN standards, and where to get the
standards is available from:
Comité Européen de Normalisation
Strassartstraat 36
B-1050 Brussels
Phone: +32-25196811
Fax: +32-25196819
Comité Européen de Normalisation Electronique
Strassartstraat 36
B-1050 Brussels
Phone: +32-25196871
Fax: +32-25196919
12
Eclipse ThermAir T/A Series v1.10, Installation Guide No. 114, 05/03
PRE-INSTALLATION
CHECKLIST
Air Supply
Provide an opening in the burner room of at least one square
inch per 4000 BTU/hr (6 cm2 per 1 kW) to supply the
burner intake with fresh, outdoor, combustion air.
If there are corrosive fumes or materials in the surrounding
air, find an uncontaminated source to supply air to the
burner.
Exhaust
Do not allow exhaust gases to accumulate in the work area.
Provide a means for exhausting these gases from the building.
Access
Install the burner so it may be easily accessed for inspection
and maintenance.
Environment
Be sure the burner operating environment matches the
original operating specifications. Check the following items:
• voltage, frequency, and stability of electrical power
• fuel type and fuel supply pressure
• adequate fresh, clean, combustion air
• humidity, altitude, and temperature of the supply air
• presence of damaging corrosive gases in the air
• prevent direct exposure to water.
BURNER
Minimum 1/4" (6mm)
space per side
Chamber Opening
Provide an opening in the chamber wall at least ½” (12mm)
larger in diameter than the outside diameter of the combustor.
Provide an accessible pressure tap on the chamber wall to
measure the pressure inside the firing chamber. The pressure
tap should be located near the burner.
Combustor
Chamber wall
“C”
Mounting Pattern
Attach four mounting bolts to the chamber wall. Position
these bolts to match the clearance holes (C) on the burner
mounting flange. Refer to the appropriate ThermAir data
sheet.
Eclipse ThermAir T/A Series v1.10, Installation Guide No. 114, 05/03
13
Chamber Wall
Make sure the chamber wall ! is strong enough to support the
weight of the burner ". If necessary, reinforce the mounting
area.
INSTALLATION
(CONTINUED)
Burner Mounting
Mount burner to chamber wall using four (4) customer
supplied nuts and lock washers.
1
4
1. Make sure that you install the burner mounting gasket,
item #, between the burner mounting flange and the
chamber wall.
2. Make sure that the gasket does not leak.
Chamber
insulation
2
Insulate the Firing Tube
To insure that radiated heat doesn’t reach the exterior of the
chamber, insulate the combustion tube over the length
contained within the chamber wall, filling any clearance
completely. If the firing tube extends beyond the chamber
wall thickness, do not insulate the exposed end of the tube.
Burner Piping
The burner is factory assembled and shipped as ordered.
GAS PIPING
Note:
If it is necessary to redirect piping, be sure the:
• ratio regulator spring column # is pointing up.
• arrow on the ratio regulator points in the direction of
gas flow.
• integral fuel orifice and o-rings ! are re-installed.
• same straight runs of pipe $ remains between the ratio
regulator and the burner .
Supply Piping
Inlet pressure to the ratio regulator (if supplied) should be at
least 15”w.c. (37.5 mbar). It should not exceed the
maximum pressure rating of the ratio regulator.
• Locate the valve train close to the burner. The gas must
reach the burner during the fixed trial for ignition.
• Sufficiently size shut off valves in the valve train.
• Make sure piping is large enough.
• Minimize piping elbows.
Bracket
Pipe
Union
14
Pipe Connections
• Installation of a pipe union in the gas line is recommended
to simplify burner removal.
• Use of flexible pipe is optional.
Note:
Flexible pipe causes higher pressure drops than standard
pipe. Consider this when sizing your gas lines.
Eclipse ThermAir T/A Series v1.10, Installation Guide No. 114, 05/03
Piping Support
Use brackets or hangers to support the gas piping. If you
have questions, consult your local gas company.
Control Motor
Install a control motor to modulate the gas control valve if
not previously installed on the burner.
Installing the flame sensor
There are two different types of flame sensors:
U.V. scanner:
Each ThermAir burner is capable of U.V. flame monitoring.
The burner will not come equipped with a U.V. scanner. A
½” NPT connection is provided on each ThermAir burner
for the connection of a U.V. scanner.
For detailed information on how to install and connect an
Eclipse U.V. scanner, refer to:
– straight U.V. scanner; Bulletin / Info Guide 854
– 90° U.V. scanner; Bulletin / Info Guide 852
– self-check U.V. scanner; Bulletin / Info Guide 856.
Flame rod:
If the flame rod option was selected when the burner was
ordered, the burner will be delivered with the flame rod
already installed on the burner.
n
Note:
Only specific burner sizes are capable of using a flame rod.
These models are TA015, 025, 040, 075, and 100.
For detailed information on how to install and connect a
flame rod, refer to:
– Bulletin / Info Guide 832.
CHECK LIST AFTER
INSTALLATION
To verify the system was properly installed, perform the
following checks:
1. Be sure there are no leaks in the gas lines.
2. Be sure all the components contained in the flame
monitoring and control system are properly installed.
This includes verifying that:
• all the switches are installed in the correct locations.
• all wiring, pressure, and impulse lines are properly
connected.
3. Be sure all components of the spark ignition system are
installed and functioning properly.
4. Be sure the blower rotates in the proper direction. If the
rotation is incorrect, have a qualified electrician rewire the
blower to rotate in the proper direction.
5. Be sure all valves are installed in the proper location and
correctly oriented relative to the flow direction.
Eclipse ThermAir T/A Series v1.10, Installation Guide No. 114, 05/03
15
PREPARE FOR
ADJUSTMENT
After installation of the burner system components is
complete, the following steps should be followed in order to
prepare for adjustment:
1. Set the air flow switch so that it drops out at 20% below
the maximum pressure of the combustion air blower.
2. Set the low gas pressure switch at 20% below the gas
pressure measured at the inlet to the main gas valve train.
3. Set the high gas pressure switch at 20% above the gas
pressure measured at the inlet to the main gas valve train.
4. Close all manual valves feeding the burner.
5. Try to ignite the burner before the purge and other timers
have finished their cycles. Make sure that the flame
monitoring system indicates a flame failure.
6. Trip out the pressure switches and other limit interlocks.
Make sure that the main gas valve train closes.
d
Danger:
If simulated limits or simulated flame failures do
not shut down the fuel system within the
required failure response time, immediately
correct the problem before proceeding.
16
Eclipse ThermAir T/A Series v1.10, Installation Guide No. 114, 05/03
Adjustment, Start &
Stop
INTRODUCTION
4
In this chapter you will find instructions on how to start and
stop a burner. The chapter begins with general instructions
that are useful for adjustment.
Danger:
d
The ThermAir burners, described herein, are
designed to mix fuel with air and burn the
resulting mixture. All fuel burning devices are
capable of producing fires and explosions if
improperly applied, installed, adjusted,
controlled, or maintained.
Do not bypass any safety feature; fire or
explosion could result.
Never try to light a burner if it shows signs of
damage or malfunction.
Adjustment
There are two separate system adjustment procedures:
• System 1
Adjust a ThermAir burner with a ratio-regulator
• System 2
Adjust a ThermAir burner without a ratio-regulator
SYSTEM 1
BURNER ADJUSTMENT
With a Ratio-Regulator
If you are adjusting a ThermAir burner equipped with a ratioregulator for the first time, you must follow these steps:
1. Reset the system
2. Verify air flow
3. Ignite the burner
4. Set high fire gas
5. Set low fire gas
6. Verify gas settings
7. Stop Procedure
Step 1: Reset the system
1. Close these valves
- the automatic gas valves
- the manual gas cocks
2. Start the combustion air blower
Eclipse ThermAir T/A Series v1.10, Installation Guide No. 114, 05/03
17
yyy
;;;
yyy
;;;
yyy
;;;
Step 2: Verify air flow
TA 015, 025, 040, 075, 100, 200
1. Make sure that the pressure tap located on the chamber is
open.
2. Connect the manometer to the chamber pressure tap.
3. Measure the chamber air pressure.
4. Determine actual air flow from the burner specific Data
Sheet (ref.: Air flow vs. Chamber Pressure Chart) for the
burner being setup.
5. Remove the manometer.
6. Close the pressure tap.
Chamber
Wall
TA 300, 400, 500
1. Make sure that pressure taps A and C are open.
2. Connect the manometer to taps A and C.
3. Measure the air differential pressure.
4. Determine actual air flow from the burner specific Data
Sheet (ref.: Air flow vs. Air Orifice ∆P Chart) for the
burner being setup.
5. Remove the manometer.
6. Close the pressure taps
TA 015 thru TA 200
Chamber
Pressure
Tap
Tap "A"
Tap "C"
TA 300 thru TA 500
n
Note:
A pressure tap is open when the screw inside the tap is
unscrewed approximately half a turn.
n
Note:
Chamber pressure will directly influence air flow from the
blower. Air flows should be rechecked once the process
reaches its operating temperature and pressure. An oxygen
analyzer may be used to confirm air flow rates once the
system is operating.
There are two separate ignition procedures which depend
upon whether or not bypass start gas is installed on the
burner. Each procedure is unique and both are outlined
below.
Step 3a: Ignite the burner
(Option 1: Burner not
equipped with bypass
start gas)
w
Warning:
This procedure assumes that a flame monitoring
control system is installed and is serviceable. It also
assumes that normal low fire start is being used.
If low fire gas is too low to be used for ignition
consider increasing low fire or providing bypass
start gas. Refer to the section 3b on page 19.
Main Gas
Valve Train
18
Eclipse ThermAir T/A Series v1.10, Installation Guide No. 114, 05/03
1. Drive the gas control valve to low fire.
n
Note:
All ThermAir burners are limited to ignition at inputs below
40% of maximum unless the control circuit on page 15 of
Design Guide 114 is followed.
2. Make sure the combustion air blower is running.
3. Verify that the adjusting screw on the ratio-regulator is six
full (360°) turns down from the top.
4. Open all manual gas valves feeding the burner.
5. Initiate the ignition sequence through the flame
monitoring control system.
6. Verify that the burner has ignited.
If the burner does not ignite:
a) Try to ignite again to purge the air out of the gas piping.
b) If the burner does not ignite after one or two
additional ignition attempts, see the Trouble shooting
Guide contained in the Maintenance & Troubleshooting
section of this guide.
Step 3b: Ignite the burner
(Option 2: Burner equipped
with bypass start gas)
w
Warning:
This procedure assumes that a flame monitoring
control system is installed and is serviceable. It
also assumes that normal low fire start is being
used.
Main Gas
Valve Train
NC
1. Drive the gas control valve to low fire.
2. Make sure the combustion air blower is running.
3. Verify that the adjusting screw on the ratio-regulator is six
full (360°) turns down from the top.
4. Open the flow adjusting valve in the bypass gas line.
5. Open the manual gas valve in the bypass gas line.
6. Initiate the ignition sequence through the flame
monitoring control system.
7. Verify that the burner has ignited.
If the burner does not ignite:
a) Try to ignite again to purge the air out of the gas piping.
b) If the burner does not ignite after one or two
additional ignition attempts, see the Trouble shooting
Guide contained in the Maintenance & Troubleshooting
section of this guide.
Eclipse ThermAir T/A Series v1.10, Installation Guide No. 114, 05/03
19
If the burner has ignited:
a) Adjust the bypass flow adjusting valve such that the
burner is able to maintain a stable flame and an
adequate flame signal.
b) Open all remaining manual gas valves feeding the
burner.
Step 4: Set high fire gas
Tap "D"
Tap "B"
1. If the burner has and is ignited, drive the main gas control
valve to high fire (full open).
2. Verify air flow with the burner firing, repeat Step 2 “Verify
air flow”.
3. Make sure that pressure taps B and D are open.
4. Connect the manometer to taps B and D.
5. Measure the gas differential pressure.
6. Use the gas curve from the appropriate ThermAir Data
Sheet for the gas being used to find the differential gas
pressure needed at high fire.
n
Note:
Select the appropriate gas orifice differential pressure
based upon the desired amount of excess air in the burner.
7. Readjust the control valve linkage to achieve the desired
high fire gas flow.
n
Note:
The ThermAir gas orifice is sized to limit high fire gas flow
to approximately 15% excess air with a packaged burner
assembly purchased with a ratio-regulator and gas control
valve.
8. Once the chamber conditions stabilize, (i.e. pressure and
temperature), repeat items 2 through 7.
9. Check the gas pressure at the inlet to the ratio regulator.
This should be at least 15”w.c. (37.5 mbar) It should not
exceed the maximum pressure rating of the ratio
regulator.
w
20
Warning:
Insufficient gas inlet pressure may cause the
ratio regulator to remain fully open if there is a
loss of air flow to the burner. This can cause
excess fuel operation and the possible
accumulation of unburned fuel in the chamber.
In extreme cases, this may cause explosions or
fires.
Eclipse ThermAir T/A Series v1.10, Installation Guide No. 114, 05/03
10. Remove the manometer.
11. Close the pressure taps.
Step 5: Set low fire gas
1. Drive the main gas control valve to low fire.
2. Adjust the control valve linkage to provide the desired low
fire gas flow.
n
Note:
It is very difficult to measure the very low gas pressures
experienced at low fire, and it may be necessary to rely on
visual inspection of the flame. This is especially true when
gas turndowns in excess of 10 to 1 are being used. The
main intent is to provide a stable flame with good flame
signal that will not cause the chamber temperature to
overshoot.
Step 6: Verify gas settings
Make sure that all settings are still the same after cycling the
system several times between high and low fire.
SYSTEM 2
BURNER ADJUSTMENT
You must provide a constant pressure to the burner to
insure proper burner operation. If you are not using a
burner equipped with a ratio-regulator, you must provide a
service pressure regulator in order to maintain a constant
inlet pressure to the burner.
Without a Ratio-Regulator
Main Gas
Valve Train
If you are adjusting a ThermAir burner equipped without a
ratio-regulator for the first time, you must follow these steps:
1. Reset the system
2. Verify air flow
3. Ignite the burner
4. Set high fire gas
5. Set low fire gas
6. Verify gas settings
Step 1: Reset the system
1. Close these valves
- the automatic gas valves
- the manual gas cocks
2. Start the combustion air
blower
Eclipse ThermAir T/A Series v1.10, Installation Guide No. 114, 05/03
21
yyy
;;;
yyy
;;;
yyy
;;;
Step 2: Verify the system
Chamber
Wall
TA 015 thru TA 200
Chamber
Pressure
Tap
TA 015, 025, 040, 075, 100, 200
1. Make sure that the pressure tap located on the chamber is
open.
2. Connect the manometer to the chamber pressure tap.
3. Measure the chamber air pressure.
4. Determine actual air flow from the burner specific Data
Sheet (ref.: Air flow vs. Chamber Pressure Chart) for the
burner being setup.
5. Remove the manometer.
6. Close the pressure tap.
TA 300, 400, 500
1. Make sure that pressure taps A and C are open.
2. Connect the manometer to taps A and C.
3. Measure the air differential pressure.
4. Determine actual air flow from the burner specific Data
Sheet (ref.: Air flow vs. Air Orifice ∆P Chart) for the
burner being setup.
5. Remove the manometer.
6. Close the pressure taps
Note:
A pressure tap is open when the screw inside the tap is
unscrewed approximately half a turn.
n
Tap "A"
Tap "C"
n
TA 300 thru TA 500
Step 3a: Ignite the burner
(Option 1: Burner not
equipped with bypass start
gas.) Ref. illustration page 21.
Note:
Chamber pressure will directly influence air flow from the
blower. Air flows should be rechecked once the process
reaches its operating temperature and pressure. An oxygen
analyzer may be used to confirm air flow rates once the
system is operating.
There are two separate ignition procedures which depend
upon whether or not bypass start gas is installed on the
burner. Each procedure is unique and both are outlined
below.
w
Warning:
This procedure assumes that a flame monitoring
control system is installed and is serviceable. It
also assumes that normal low fire start is being
used.
If low fire gas is too low to be used for ignition
consider increasing low fire or providing bypass
start gas. Refer to section 3b on page 23.
1. Drive the gas control valve to low fire.
n
22
Note:
All ThermAir burners are limited to ignition at inputs below
40% of maximum unless the control circuit on page 15 of
Design Guide 114 is followed
Eclipse ThermAir T/A Series v1.10, Installation Guide No. 114, 05/03
2. Make sure the combustion air blower is running.
3. Open all manual gas valves feeding the burner.
4. Initiate the ignition sequence through the flame
monitoring control system.
5. Verify that the burner has ignited.
If the burner does not ignite:
a) Try to ignite again to purge the air out of the gas piping.
b) If the burner does not ignite after one or two additional
ignition attempts, see the Trouble shooting Guide
contained in the Maintenance & Troubleshooting
section of this guide.
Step 3b: Ignite the burner
(Option 2: Burner equipped
with bypass start gas.)
w
Warning:
This procedure assumes that a flame monitoring
control system is installed and is serviceable. It
also assumes that normal low fire start is being
used.
Main Gas
Valve Train
1. Drive the gas control valve to low fire.
2. Make sure the combustion air blower is running.
3. Verify that the adjusting screw on the ratio-regulator is six
full (360°) turns down from the top.
4. Open the flow adjusting valve in the bypass gas line.
5. Open the manual gas valve in the bypass gas line.
6. Initiate the ignition sequence through the flame
monitoring control system.
7. Verify that the burner has ignited.
If the burner does not ignite:
a) Try to ignite again to purge the air out of the gas piping.
b) If the burner does not ignite after one or two
additional ignition attempts, see the Trouble shooting
Guide contained in the Maintenance & Troubleshooting
section of this guide.
If the burner has ignited:
a) Adjust the bypass flow adjusting valve such that the
burner is able to maintain a stable flame and an
adequate flame signal.
b) Open all remaining manual gas valves feeding the
burner.
Eclipse ThermAir T/A Series v1.10, Installation Guide No. 114, 05/03
23
Step 4: Set high fire gas
Tap "D"
Tap "B"
1. If the burner has and is ignited, set the main gas pressure
regulator for 7” w.c. outlet pressure.
2. Drive the main gas control valve to high fire (full open).
3. Verify air flow with the burner firing, repeat Step 2 “Verify
air flow”.
4. Make sure that pressure taps B and D are open.
5. Connect the manometer to taps B and D.
6. Measure the gas differential pressure.
7. Use the gas curve from the appropriate ThermAir Data
Sheet for the gas being used to find the differential gas
pressure needed at high fire.
n
Note:
Select the appropriate gas orifice differential pressure
based upon the desired amount of excess air in the burner.
8. Adjust the adjusting screw on the main gas pressure
regulator to achieve the desired gas flow.
9. Once the chamber conditions stabilize, (i.e. pressure and
temperature), repeat Steps 3 through 8.
10. Remove the manometer.
11. Close the pressure taps.
Step 5: Set low fire gas
1. Drive the main gas control valve to low fire.
2. Adjust the control valve linkage to provide the desired low
fire gas flow.
n
Note:
It is very difficult to measure the very low gas pressures
experienced at low fire, and it may be necessary to rely on
visual inspection of the flame. This is especially true when
gas turndowns in excess of 10 to 1 are being used. The
main intent is to provide a stable flame with good flame
signal that will not cause the chamber temperature to
overshoot.
Step 6: Verify gas settings
Make sure that all settings are still the same after cycling the
system several times between high and low fire.
Step 7: Stop Procedure
c
24
Eclipse ThermAir T/A Series v1.10, Installation Guide No. 114, 05/03
Caution:
Do not turn the combustion air blower off until the
chamber temperature is below 250ºF (121ºC). This will
prevent hot gases from back flowing into the burner and
blower causing damage to the burner.
1. Stop the burner through the burner control system.
2. Run the combustion air blower until the chamber
temperature drops below 250ºF (121ºC).
3. Shut off the combustion air blower.
4. Close all manual gas valves to the burner.
Maintenance &
Troubleshooting
INTRODUCTION
5
This chapter is divided into two sections:
• Maintenance procedures
• Troubleshooting guide
Preventive maintenance is the key to a reliable, safe and
efficient system. The core of any preventive maintenance
system is a list of periodic tasks.
MAINTENANCE
Note:
These are guidelines only. The customer should make the
final determination on maintenance intervals and tasks to
be performed while considering the working environment.
Monthly Checklist
1. Inspect the flame sensing devices for good condition and
cleanliness.
2. Check for proper air/gas pressures (Refer to the
ThermAir Data Sheets, Series 114).
3. Test all the system alarms for proper response signals.
4. Check and clean igniter electrodes.
5. Check valve motors and control valves for free, smooth
action and adjustment.
6. Check for the proper operation of ventilating equipment.
7. Test the interlock sequence on all safety equipment.
Manually force each interlock to intentionally fail while at
the same time noting if related equipment closes or stops
as specified by the manufacturer. Test the flame safeguard
by manually shutting off the gas to the burner.
8. Test the manual gas shut off cocks for proper operation.
9. Clean and/or replace the combustion air blower filter.
10. Inspect and clean the combustion air blower rotor.
Eclipse ThermAir T/A Series v1.10, Installation Guide No. 114, 05/03
25
Yearly Checklist
1
26
2
3
1. Leak test the safety shut-off valves for tightness of
closure.
2. Test the pressure switch settings by checking the switch
movements against pressure settings and comparing these
with the actual impulse pressure.
3. Visually check igniter cable and connectors.
4. Remove, clean, and inspect all burners.
5. Be sure the following components are not damaged or
distorted:
• the burner nozzle.
• the igniter.
• the flame sensors.
• the combustion tube.
The nozzle and combustion tube can be inspected without
removing the burner from the chamber wall or entering the
chamber. Perform the following:
a. Shut the burner off and manually close the main gas
shut off cocks.
b. Allow the chamber temperature to cool down to
250°F (121°C).
c. Disconnect the gas piping at a union or the gas inlet
flange provided on the burner.
d. Remove the four bolts 1.
e. Remove the rear cover 2 from the burner housing
3.
f. To re-assemble, follow this sequence in the reverse
order.
Eclipse ThermAir T/A Series v1.10, Installation Guide No. 114, 05/03
TROUBLESHOOTING
PROCEDURES
PROBLEM
Start-up sequence runs but
burner does not light.
POSSIBLE CAUSE
SOLUTION
No ignition:
• Attempting to ignite at inputs
greater than 40%.
Reduce start point gas flow.
Verify control circuit.
No ignition:
• Weak or non-existent spark.
Verify ignition transformer is a
6,000 - 8,000 volt transformer.
(Not half-wave)
No ignition:
• There is no power to the
ignition transformer.
No ignition:
• Open circuit between the
ignition transformer and the
igniter.
No ignition:
• The igniter needs cleaning.
No ignition:
• The igniter is not correctly
grounded to the burner.
Restore the power to the
ignition transformer.
No ignition:
• Igniter insulator is broken.
Igniter is grounding out.
Not enough gas:
• The gas flow into the burner is
too low.
Not enough gas:
• If equipped with ratio regulator,
loading line may not be attached
Not enough gas:
• The bypass valve is not open
far enough.
Inspect the igniter. Replace if
broken.
Not enough gas:
• Start gas solenoid valve does
not open.
Not enough gas:
• Gas valve does not open.
Check the solenoid valve coil
for proper operation. Replace
it if necessary.
Repair or replace the wiring to
the igniter.
Clean the igniter.
Clean the threads on the igniter
and the burner. NOTE: Do not
apply grease to the threads on
the igniter.
Check the start-up settings.
Adjust low fire gas setting if
necessary.
Reconnect loading line and
verify loading pressure.
Adjust bypass gas flow.
Check the wiring to the
automatic gas shut-off valve.
Check the output from the
flame safeguard.
Open manual gas cock.
Eclipse ThermAir T/A Series v1.10, Installation Guide No. 114, 05/03
27
PROBLEM
Start-up sequence runs but
burner does not light.
(continued)
The low fire flame is weak or
unstable.
The burner goes out when it
cycles to high fire.
POSSIBLE CAUSE
SOLUTION
No flame signal:
• Broken flamerod
• Dirty UV scanner lens
Inspect and clean sensor
Replace if necessary
No flame signal:
•
Flamerod grounding out
Verify that the flamerod is
installed correctly and is the
correct length.
Too much gas:
• Wrong or missing burner fuel
orifice.
Check ThermAir Data Sheets,
Series 114 for fuel orifice and
the given fuel.
•
Not enough gas flowing to the
burner.
Adjust the gas control valve to
increase the gas flow.
•
Not enough air.
•
Too much gas to the burner.
•
Loading line to the ratio
regulator (if installed) is leaking.
Check for proper blower
rotation.
Check air filter for blockage.
Verify gas orifice size for your
fuel (ref. Data Sheets 114).
Verify chamber pressure for
proper air flow effect.
Check the start-up settings.
Measure the gas pressures and
adjust them where necessary.
Check for valve train pressure
loss.
Repair the leak in the loading
line.
The burner is erratic and does
not respond to adjustment.
Internal damage to the burner:
• Some parts inside the burner
are loose, dirty, or burned out.
Contact your Eclipse
representative or Eclipse
Combustion for further
information.
The burner is unstable or
produces soot or smoke.
•
The air/gas ratio is out of
adjustment.
Measure all the gas pressures
and air pressures. Compare
these pressures to the
documented initial start-up
settings and adjust them where
necessary.
The burner cannot achieve full
capacity.
•
Air filter is blocked. (When
equipped with Ratio Regulator)
Clean or replace the air filter.
•
Gas pressure going into the
burner is too low.
Adjust the gas pressure.
•
Combustion chamber
pressure is too high.
Derate burner for positive
pressure installations.
28
Eclipse ThermAir T/A Series v1.10, Installation Guide No. 114, 05/03
PROBLEM
Cannot initiate a start
sequence.
POSSIBLE CAUSE
SOLUTION
•
Air pressure switch has not
made contact.
Check air pressure switch
adjustment.
Check air filter.
Check blower rotation.
Check outlet pressure from
blower.
•
High gas pressure switch has
activated.
•
Low gas pressure switch has
activated.
Check incoming gas pressure.
Adjust gas pressure if
necessary.
Check pressure switch setting
and operation.
•
•
Malfunction of the flame
safeguard system (e.g., shortedout flame sensor or electrical
noise in the sensor line).
No power to the control unit.
•
Main power is off.
Have a qualified electrician
troubleshoot and correct the
problem.
Be sure the main power to the
system is switched to the “on”
position.
Eclipse ThermAir T/A Series v1.10, Installation Guide No. 114, 05/03
29
Appendix
CONVERSION
FACTORS
Metric to English.
From
To
Multiply By
cubic meter (m3)
cubic foot (ft3)
35.31
cubic meter/hour (m3/h)
cubic foot/hour (cfh)
35.31
degrees Celsius (ºC)
degrees Fahrenheit (ºF)
(ºC x 1.8) + 32
kilogram (kg)
pound (lb)
2.205
kilowatt (kW)
BTU/hr
3414
meter (m)
foot (ft)
3.28
millibar (mbar)
inches water column (“w.c.)
0.401
millibar (mbar)
pounds/sq in (psi)
14.5 x 10-3
millimeter (mm)
inch (in)
3.94 x 10-2
MJ/m3 (normal)
BTU/ft3 (standard)
2.491 x 10-2
kiloPascals (kPa)
millibar (mbar)
10
meter (m)
millimeter (mm)
1000
millibar (mbar)
kiloPascals (kPa)
0.1
millimeter (mm)
meter (m)
0.001
From
To
Multiply By
BTU/hr
kilowatt (kW)
0.293 x 10-3
cubic foot (ft3)
cubic meter (m3)
2.832 x 10-2
degrees Fahrenheit (ºF)
degrees Celsius (ºC)
(ºF – 32) ÷ 1.8
foot (ft)
meter (m)
0.3048
inches (in)
millimeter (mm)
25.4
inches water column (“wc)
millibar (mbar)
2.49
pound (lb)
kilogram (kg)
0.454
pounds/sq in (psi)
millibar (mbar)
68.95
Metric to Metric.
English to Metric.
3
BTU/ft (standard)
30
3
MJ/m (normal)
40.14
Eclipse ThermAir T/A Series v1.10, Installation Guide No. 114, 05/03
KEY TO SYSTEM
SCHEMATICS
Symbol
Appearance
These are the symbols used in the schematics.
Name
Remarks
Bulletin/
Info Guide
ThermAir
NC
Main Gas Shutoff
Valve Train
Eclipse Combustion, Inc.
strongly endorses NFPA as a
minimum
Gas Cock
Gas cocks are used to
manually shut off the gas
supply on both sides of the
main gas shut-off valve train.
710
Solenoid Valve
(normally closed)
Solenoid valves are used to
automatically shut off the gas
supply on a bypass gas system
or on small capacity burners.
760
Adjustable Limiting
Orifice
Adjustable limiting orifices are
used for fine adjustment of
gas flow.
Pressure Regulator
Ratio Regulator
Automatic Gas
Control Valve
--------
A pressure regulator reduces
gas pressure to a stable,
usable pressure.
The ratio regulator adjusts the gas
flow in ratio with the air flow. It
contro;s the outlet pressure equal
to the impulse line pressure. The
impulse line is connected between
the top of the ratio regulator and
the blower housing.
An automatic gas control
valve adjusts gas flow to the
burner based on control
system requirements.
756
730
684
742
720
Impulse Line
Eclipse ThermAir T/A Series v1.10, Installation Guide No. 114, 05/03
31
ThermAir Parts Drawing
44
43
42
41
48
49
50
47
46
20
21
45
34
38
36
35
34
5
37
33
4
19
21
40
32
22
31
23
6
2
29
39
30
13
17
8
1
21
5
3
15
7
18
5
9 10
16
12
11
14
21
24
28
25
27
32
Eclipse ThermAir T/A Series v1.10, Installation Guide No. 114, 05/03
26
1
1
2
3
4
5
6
7
8
9
10
11
12
13
14
14
15
15
16
17
18
18
18
19
20
21
22
23
24
25
26
27
28
29
29
30
30
31
31
32
32
33
34
34
35
35
36
36
37
38
38
39
39
39
39
39
39
40
40
1
1
1
2
2
4
4
1
2
1
1
4
1
1
1
1
1
1
2
4
1
1
1
1
4
12
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
3
36
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
Pos. Qty.
Body,alloy tube
Body,SiC
Gasket,mounting
Plug,0.125"NPT
Screw,body
Tap,pressure
Insert,thread,M12xM8
Nozzle
Screw,set,nozzle
Cover,rear
Adpt,plate,rear cover
Screw,rear cover
Peepsight
Spark Plug
Flame Rod
Plug,protector,0.5"
Block,inlet,gas,NPT
Block,inlet,gas,Rc
Seal,O-ring
Screw,inlet,gas
Plate,orifice,natural gas
Plate,orifice,propane
Plate,orifice,butane
Block,inlet,blower
Screw,inlet,air
Washer,M8
Plate,orifice,air
Combustor,alloy
Block and holder
Combustor,SiC
Retaining ring,SiC
Gasket,SiC
Screw,FH
Valve,BV-A,NPT
Valve,BV-A,Rc
Nipple,NPT
Nipple,Rc
Nipple,NPT
Nipple,Rc
Ratio-Regulator,NPT
Ratio-Regulator,Rc
Bushing,Ratio-reg
Line,loading,plastic tubing
Line,Loading,S.S. hose
Ftg,TB,Load line,plastic
Ftg,load line,SS hose
Ftg,load line,elb,plastic
Ftg,load line,elb,S.S hse
Nip,ftg,load line,0.125"
Tee,ftg,0.125
Cross,ftg,0.125
Act,M7284-A-1004
Act,M7284-C-1000
Act,EMP 423-5
Act,EMP 424-5
ACT004A3B1A1AX, RH
ACT004A4B1A1AX, LH
Mtg,kit,HW
Mtg,kit,rotary,right hand
Description
7118-1
7118-2
17054
15398
16022
13445
N/A
7033-1
19969
7032-1
N/A
15886
10509
23045
17232-1
11456-1
3974-4
3974-3
14777
15887
14191-19
14191-20
14191-18
3977-3
20246
15222 (13)
14188-23
14887-6
N/A
20474
19970
19971
10001
501239
202081
20901
20903
18731
20902
11080
20900
N/A
34505 (ft.)
SC4(in)w/(2)30
14506 (2)
2484 (2)
N/A
N/A
18684
19160
N/A
12200
15273-4
22755
22735
*
*
100099
100127
TA015
7118-1
7118-2
17054
15398
16022
13445
N/A
7033-2
19969
7032-1
N/A
15886
10509
23045
17232-1
11456-1
3974-4
3974-3
14777
15887
14191-1
14191-19
14191-3
3977-3
20246
15222 (13)
14188-24
14887-6
N/A
20474
19970
19971
10001
501239
202081
20901
20903
18731
20902
11080
20900
N/A
34505 (ft.)
SC4(in)w/(2)30
14506 (2)
2484 (2)
N/A
N/A
18684
19160
N/A
12200
15273-4
22755
22735
*
*
100099
100127
TA025
TA075
TA100
TA200
TA300
TA400
7118-1
7046-1
3994
3994
7036-1
7036-1
7118-2
7046-3
3994-1
3994-1
N/A
N/A
17054
20422
14932
14932
10027
10027
15398
15398
15398
15398
15398
15398
16022
16022
16022
16022
N/A
N/A
13445
13445
13445
13445
13445
13445
N/A
N/A
N/A
N/A
N/A
N/A
7033-3
7133-2
3997-1
3997-1
7038-1
7038-1
19969
15885
15885
15885
15885
15885
7032-1
3998-1
3995
3995-1
7037-1
7037-1
N/A
N/A
N/A
N/A
N/A
N/A
15886
15886
15886
15886
15886
15886
10509
10509
10509
10509
13225
13225
23045
16927-1
16927-1
16927-1
10012
10012
17232-1
13312-6
13312-9
13312-9
N/A
N/A
11456-1
11456-1
11456-1
11456-1
11456-1
11456-1
3974-2
7001-1
7156-2
3973-3
3973-3
3973-2
3974-1
7001-3
7156-1
3973-1
3973-1
3973-10
14777
17037
14778
14778
14778
14778
15887
15893
15893
15893
15893
15893
14191-8
14934-15
14188-28
14188-26
14188-1
14188-20
14191-23
14934-3
14188-14
14188-9
14188-9
14188-1
14191-22
14934-14
14188-29
14188-27
14188-6
14188-19
3977-3
7108-4
7045-2
7045-2
N/A
N/A
20246
20270
16015
16015
15892
15892
15222 (13)
15222 (13)
15222 (13)
15222 (13)
15222
15222
14188-25
20362-4
14802-11
14802-9
10039-1
10039-4
14887-6
20400
20716-1
20716-1
100236
101279
N/A
N/A
N/A
N/A
100013
10013
20474
20463
20718
20718
N/A
N/A
19970
20464
10003
10003
N/A
N/A
19971
20465
10005
10005
N/A
N/A
10001
10001
10001
10001
10001
10001
501200
501201
501201
501203
501203
501204
101248
101249
101249
101250
101250
101251
20905
18779
18779
18808
14704
14791
20906
20891
20891
20875
20857
20823
18761
18774
18774
18806
18806
15307
20904
20884
20884
20858
20858
20814
19997
15939
15939
20312
20312
10315
19998
19999
19999
20311
20311
19990
N/A
N/A
N/A
18503
18503
20305
34505 (ft.)
34505 (ft.)
34505 (ft.)
34505 (ft.)
34505 (ft.)
34505 (ft.)
SC4(in)w/(2)30 SC4(in)w/(2)30 SC4(in)w/(2)30 SC4(in)w/(2)30 SC4(in)w/(2)30 SC4(in)w/(2)30
14506 (2)
14506
14506
14506
14506
14506
2484 (2)
2484
2484
2484
2484
2484
N/A
14689
14689
14689
14689
14689
N/A
1494
1494
1494
1494
1494
18684
18684
18684
18684
18682
18682
19160
19160
19160
19160
N/A
N/A
N/A
N/A
N/A
N/A
20668
20668
12200
12200
12200
12200
12200
12200
15273-4
15273-4
15273-4
15273-4
15273-4
15273-4
22755
22755
22755
22755
22755
22755
22735
22735
22735
22735
22735
22735
*
*
*
*
*
*
*
*
*
*
*
*
100099
100099
100099
100099
100099
100099
100127
100127
100127
100127
100127
100127
TA040
7111-1
N/A
20151
15398
N/A
13445
20304
7116-1
15885
7037-2
20150
15886
13225
10012
N/A
11456-1
3973-2
3973-10
14778
15893
14188-3
14188-1
14188-19
N/A
15892
15222 (16)
20152-3
101278
101161
N/A
N/A
N/A
10001
501204
101251
14791
20823
15307
20814
10315
19990
20305
34505 (ft.)
SC4(in)w/(2)30
14506
2484
14689
1494
18682
N/A
20668
12200
15273-4
22755
22735
*
*
100099
100127
TA500
ThermAir Parts List
Eclipse ThermAir T/A Series v1.10, Installation Guide No. 114, 05/03
33
Installation Guide 114 05/03
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
4
4
2
1
1
Mtg,kit,rotary,left hand
Air switch,AA-A2-4-5,2-20
Air switch,AA-A2-6-5,2-20
Air switch,AA-A2-6-3,.4-4
Air switch,SMDF,2-6
Air switch,JD2-P,.1-24"
Air switch,JD2-P,.1-10"
Mtg,kit,Dungs,plastic
Mtg,kit,JD2-P,plastic
Mtg,kit,SMDF,plastic
Mtg,kit,Dungs,S.S.hose
Mtg,kit,JD2-P,S.S.hose
Mtg,kit,SMDF,S.S.hose
BLOWER
Grille,inlet stdblower
Grille,inlet,3in. blower
Filter,round
Filter,square,20x20
Filter,silencer
Mtr,115-208-230/1,TEFC
Mtr,208-230/460/3,std
Mtr,208-230/460/3,3 in.
Mtr,575/3,TEFC
Mtr,115/1,TEFC
Mtr,208-230/1,TEFC
Mtr,115/1,TENV
Mtr,230/460/3, AUTO
Mtr,460/3,AUTO
Mtr,240/415/3,IEC 50Hz
Mtr,230/1,IEC 50Hz
Mtr,110/115/1,IEC 50Hz
Mtr,115-208/1, 3in.TENV
Mtr,208-230/460/3,TENV
Mtr,575/3,TENV
Screw,blower,slip fit
Washer,M6
Plug,blower
Ftg,press.,blower,0.125
Nut,M14, ftg,press,blower
Description
* ACT004A3B1A1AX
** BLOWER-PACKAGED1.1
40
41
41
41
41
41
41
42
42
42
42
42
42
43
44
44
44
44
44
45
45
45
45
45
45
45
45
45
45
45
45
45
45
45
46
47
48
49
50
Pos. Qty.
100128
20475
20440
14641-1
14494
16928-1
16928
101146
100074
100075
101182
101183
101184
**
100347-1
100346
200758
N/A
15405
N/A
N/A
N/A
N/A
21631
21727
12995
N/A
N/A
20518
20554
21057
N/A
21472
21495
15881
15625
20605
N/A
N/A
TA015
100128
20475
20440
14641-1
14494
16928-1
16928
101146
100074
100075
101182
101183
101184
**
100347-1
100346
200758
N/A
15405
N/A
N/A
N/A
N/A
21631
21727
12995
N/A
N/A
20518
20554
21057
N/A
21472
21495
15881
15625
20605
N/A
N/A
TA025
100128
20475
20440
14641-1
14494
16928-1
16928
101146
100074
100075
101182
101183
101184
**
100347-1
100346
200758
N/A
15405
N/A
N/A
N/A
N/A
21631
21727
12995
N/A
N/A
20518
20554
21057
N/A
21472
21495
15881
15625
20605
N/A
N/A
TA040
100128
20475
20440
14641-1
14494
16928-1
16928
101146
100074
100075
101182
101183
101184
**
100347-2
100346
200757
101010
20505
12033
13101
N/A
21473
N/A
N/A
N/A
20528
N/A
20520
20556
21059
21631
N/A
N/A
15881
15625
20605
N/A
N/A
TA075
100128
20475
20440
14641-1
14494
16928-1
16928
101146
100074
100075
101182
101183
101184
**
100347-2
100346
200757
101010
20505
12033
13101
25115
21473
N/A
N/A
N/A
N/A
N/A
20521
N/A
N/A
N/A
N/A
N/A
15881
15625
20605
N/A
N/A
TA100
100128
20475
20440
N/A
14494
16928-1
16928
101146
100074
100075
101182
101183
101184
**
100347-2
N/A
200757
101010
20505
N/A
14938
N/A
21475
N/A
N/A
N/A
20530
N/A
20522
N/A
N/A
N/A
N/A
N/A
15881
15625
20605
N/A
N/A
TA200
100128
20475
20440
N/A
14494
16928-1
16928
101192
100074
100075
101182
101183
101184
**
100347-2
N/A
200756
202731
15407
N/A
20547
N/A
21476
N/A
N/A
N/A
N/A
20371
20524
N/A
N/A
N/A
N/A
N/A
N/A
N/A
20605 (1)
20658
20812
TA300
100128
20475
20440
N/A
14494
16928-1
16928
101192
100074
100075
101182
101183
101184
**
100347-2
N/A
200756
202731
15407
N/A
20548
N/A
21477
N/A
N/A
N/A
N/A
20392
20524
N/A
N/A
N/A
N/A
N/A
N/A
N/A
20605 (1)
20658
20812
TA400
100128
20475
20440
N/A
14494
16928-1
16928
101192
100074
100075
101182
101183
101184
**
100347-2
N/A
200754
202731
15407
N/A
16770
N/A
21478
N/A
N/A
N/A
N/A
20360
20525
N/A
N/A
N/A
N/A
N/A
N/A
N/A
20605 (1)
20658
20812
TA500
ThermAir Parts List (Continued)
Litho in U.S.A .
R400 & R500
Fisher Controls
Low Pressure Second-Stage &
Integral 2-Stage LP-Gas Regulators
Type R400 & R500
MCK-1177
03/99
Reguladores de Baja Presión Para
Gas-LP de Segunda Etapa y Dos
Etapas Integradas Tipo R400 y R500
ADVERTENCIA
Fisher equipment must be installed, operated, and
maintained in accordance with federal, state, and
local codes and Fisher instructions. The installation
in most states must also comply with NFPA No. 54
and 58 standards.
Only personnel trained in the proper procedures,
codes, standards, and regulations of the LP-gas industry should install and service this equipment.
THINGS TO TELL THE GAS CUSTOMER:
1. Point out the regulator’s vent to the customer (or vent assembly
or vent tube), and stress that this opening must remain
unobstructed at all times. Tell the customer to be sure to check
the vent opening after a freezing rain, sleet storm, or snow to make
sure ice has not formed in the vent.
El no cumplir con estas instrucciones o no instalar
y dar mantenimiento apropiado a este equipo
puede resultar en una explosión y/o incendio,
resultando en daños, heridas, o la muerte.
Los reguladores Fisher deben instalarse, operarse
y recibir mantenimiento de acuerdo con las
regulaciones, leyes y códigos federales, estatales y
municipales, e instrucciones de Fisher. En la
mayoría de los estados, la instalación debe cumplir,
también, con los estándares NFPA 54 y 58.
Sólo personal entrenado en los procedimientos,
códigos, estándares y regulaciones apropiadas para
la industria de gas LP debe instalar y dar servicio a
este equipo.
QUE DEBE INFORMARLE AL USUARIO:
Introduction
1. Muestre al cliente la ventila del regulador (el ensamble de la ventila
o la tubería de la ventila), y haga énfasis en que esta abertura debe
estar siempre libre de obstrucciones. Indique al cliente que es
necesario que cheque la ventila después de una nevada, granizada
o tormenta de agua congelada, para asegurarse de que no se formó
hielo en la ventila.
2. Muestre al cliente el contenedor de la válvula para apagar el
regulador y adviértale que debe cerrarla de inmediato, en caso de
oler a gas, que exista falla en el encendido de los pilotos o se vean de
mayor tamaño que el normal, o si ocurre cualquier situación anormal.
3. Indique al cliente que es necesario solicitar a la compañía una
visita de servicio si el regulador registra una fuga de gas o si existe
una gotera en el sistema. Sólo una persona calificada debe
Scope of Manual
instalar o dar servicio al regulador.
This instruction manual covers installation and maintenance for the
Types R422, R522 & R552 second stage low pressure regulators,
and the Type R532 integral 2-stage unit containing a first stage
regulator on the inlet. These low pressure regulators have an integral
high capacity internal relief valve. Inlet and outlet pressure taps are
standard, making pressure testing easier.
Introducción
2. Show the customer the shutoff valve on the container. The
customer should close this valve immediately if gas is smelled,
appliance pilot lights fail to stay on or appear higher than usual, or
any other abnormal situation occurs.
3. Tell the customer to call your company to service the regulator if
the regulator vents gas or a leak develops in the system. Only a
qualified gas serviceman should install or service the regulator.
Description
These regulators are designed for low pressure (inches of water
column) vapor service and are not to be used for liquid service.
The outlet pressure setting is normally 11 inches wc. Integral 2stage (reducing container pressure to 11 inches wc) are normally
painted GRAY, while second-stage regulators (reducing first stage
pressure to 11-inches wc) are painted PALM GREEN. The units
differ in construction and capacity rating.
Alcance de este Manual
Este manual de instrucciones cubre la instalación y mantenimiento
del regulador de baja presión de segunda etapa Tipo R422, R522 y
R552 y los reguladores de 2-etapas integradas tipo 532 que incluye
un regulador de 1ra. etapa. Estos reguladores de baja presión
disponen de una válvula interna de alivío de alta capacidad. La entrada
y la salida disponen de tomas para medir la presión.
Descripción
Estos reguladores están diseñados para servicio de vapor en baja
presión (pulg. de columna de agua), y no debe usarse para líquidos.
El regulador es ajustado en fabrica a 11-pulgadas de c.a. (27.4
milibares). Los reguladores de 2-etapas integradas (reducen presión
del contenedor a 11-pulg. de c.a. (27.4 milibares) son de color GRIS,
mientras que los reguladores de segunda-etapa (que reducen de
una presión de 1ra. etapa a 11-pulgadas de c.a. son VERDE PALMA.
Los reguladores difieren en construcción y capacidades de flujo.
1
D450072T012
Failure to follow these instructions or to properly
install and maintain this equipment could result in
an explosion and/or fire causing property damage
and personal injury or death.
R400 & R500
Fisher Controls
Specifications
Especifícaciones
Table 1 lists the specifications for the regulator. Contact the factory
if the regulator is to be used on any service other than LP-gas,
natural gas, or air. Second-Stage regulators are limited to 10 psig
inlet pressure and must be used with a first-stage regulator.
La tabla 1 lista las especificaciones para este regulador. Contacte
a la fábrica si al regulador va a darse un servicio distinto a gas LP,
gas natural, o aire. Los reguladores de 2-etapas estan limitados a
10 psig (0.69 bares) de presión de entrada, por lo que deben
utilizarse con reguladores de 1ra.-etapa.
Table 1
T YPE
NU M B E R
[ M OD E L O]
T Y P E OF S E R V ICE
[ S E R V I CI O]
Tabla 1
M A X . IN L E T
PR ESSUR E
[ M A X . P R E S ION
D E E NT R AD A]
S IZ E , IN CH, F N P T
[ T A M A Ñ O, P U L GA D A S , C ON E X I ON N P T
HE M B R A ]
IN L E T C ON N E CT ION
CON E X I ON D E
E NT R AD A
OU T L E T
CON E CC T ION
CON E X I ON D E
S A L ID A
[ CA P A CI D A D D E
V A P OR E N
B T U /HR
P R OP A N O ***]
3/4"
2,025,000
1/2"
875,000
3/4"
1,375,000
1/2"
685,000
3/4"
1,100,000
3/4"
1,100,000
R422
SECOND-STAGE
[SEGUNDA ETAPA]
10 PSIG*
[0.69 Bares]
3/4"
R522
SECOND-STAGE
[SEGUNDA ETAPA]
10 PSIG*
[0.69 Bares]
1/4", 1/2", 3/4"
INTEGRAL TWO-STAGE
[INTEGRAL DE DOS ETAPAS]
250 PSIG*
[17.24 Bares]
1/4"
SECOND-STAGE
[SEGUNDA ETAPA]
10 PSIG*
[0.69 Bares]
3/4"
R532
R552
V A P OR
CA P A CI T Y ,
B T U /HR
P R OP A N E ***
* Body inlet pressure rating 250 psig
** Assumes first stage regulator failure
*** Based on 10 psig inlet pressure and 20% droop for second
and integral two-stage.
* El cuerpo soporta una presión de 250 PSIG (17.2 Bares)
** Asume falla en el regulador de 1ra. etapa.
*** Basado en una presión de entrada de 10 psig (0.69 Bar) y 20%
de caida y una unidad integrada de 2 etapas.
Installation
Instalación
ADVERTENCIA
The vent should be kept open to permit free flow of
air into and out of the regulator. Protect the vent
against the entrance of rain, snow, ice formation,
paint, mud, insects, or any other foreign material
that could plug the vent or vent line.
La ventila deberá mantenerse abierta, para permitir
que el aire fluya libremente dentro y fuera del
regulador. Proteja la ventila contra la entrada de
lluvia, nieve, hielo, pintura, mugre, insectos o
cualquier otro material ajeno que pueda obstruir la
ventila o la línea de alivío.
LP-gas may discharge to the atmosphere through
the vent. An obstructed vent which limits air or gas
flow can cause abnormally high pressure that could
result in personal injury or property damage. Failure to use a vent line on Indoor Installations can
cause a hazardous accumulation of gas which could
result in personal injury or property damage.
Gas LP puede ser descargado a la atmósfera a través
de la ventila. Una ventila obstruida limita el flujo
de aire o gas, causando sobrepresiones que puede
resultar en lesiones al personal o daño a la
propiedad.
Nunca use los reguladores de 1ra. etapa (kilos a
kilos) en servicio de baja presión (milimetros de
columna de agua), ya que pueden presentarse
lesiones al personal y/o daño a la propiedad.
Never use first stage (pounds to pounds) regulator
on low pressure (inches of water column) service
because personal injury or property damage could
occur.
Asegúrese de que el gas fluye a través del regulador en la misma
dirección que las flechas del cuerpo del regulador – las conexiones
de “entrada” y “salida” están claramente indicadas. La instalación
debe protegerse adecuadamente del tráfico vehicular y daño por
causas externas.
Make sure gas flow through the regulator is in the same direction as
the arrow on the body “Inlet” and “Outlet” connections are clearly
marked. The installation should be adequately protected from vehicular
traffic and damage from other external sources.
2
R400 & R500
Fisher Controls
Instale el regulador de tal manera que las descargas de gas a través
de la ventila o del ensamble de la ventila queden a más de 3 pies (1
metro) de cualquier abertura que tenga el edificio abajo del nivel de la
descarga. Instale el regulador a suficiente altura sobre el nivel del
piso – por lo menos 18 pulgadas (45 cm) – para que la lluvia que
salpique no llegue a congelarse en la ventila. Ya sea que use protector
o no, no instale el regulador donde exista excesiva acumulación de
agua, formación de hielo, como puede ser bajo una llave de agua,
gotera o línea de desague.
Install the regulator so that any gas discharge through the vent or
vent assembly is over 3-feet horizontally from any building opening
below the level of discharge. Install the regulator high enough above
ground level - at least 18 inches - so that rain splatter cannot freeze
in the vent. Whether a protective hood is used or not, do not install the
regulator in a location where there can be excessive water
accumulation or ice formation, such as directly beneath a down
spout, gutter, or roof line of building.
A regulator installed outdoors without a protective hood must
have its vent pointed vertically down, see figure 2, to allow
condensate to drain. This minimizes the possibility of freezing and of
water or other foreign material entering the vent and interfering with
proper operation.
Si se instala un regulador en el exterior sin “casco” protector,
deberá colocarse la ventila en forma vertical hacia abajo, ver
figura 2, para permitir que drene cualquier condensación. Así se
minimiza la posibilidad de congelamiento y de que entre a la ventila
agua o cualquier otro material ajeno, interfiriendo con la operación
adecuada del equipo. Antes de instalar el regulador, verifique que no
exista daño que pueda haber ocurrido durante el embarque. También
cheque y quite cualquier sucio o materia ajena que pueda haberse
acumulado en el cuerpo del regulador o en la tubería. Aplique
compuesto para tubería en los extremos machos de la tubería.
Before installing the regulator, check for damage which might have
occurred in shipment. Also check for and remove any dirt or foreign
material which may have accumulated in the regulator body or the
pipeline. Apply pipe compound to the male threads of the pipe.
Some installations, such as in areas with heavy snowfall, may require
a hood or enclosure to protect the regulator. Horizontally mounted
regulators, such as found in single cylinder installations, must
be installed beneath a protective cover. If possible, slope or turn
the vent down sufficiently to allow any condensation to drain out of
the spring case. Be careful that the slot in the hood or cover for the
regulator’s outlet piping does not extend too far and expose the vent
to the elments.
En algunas instalaciones, como las que se hacen en áreas con
nevadas pesadas pueden requerir de un “casco” o escudo para
proteger el regulador. Los reguladores montados en forma
horizontal, como los que se encuentran en las instalaciones
de un solo cilindro, deben instalarse bajo una cubierta
protectora. Si es posible, voltee la ventila hacia abajo lo suficiente
para permitir que cualquier condensado drene hacia fuera del
contenedor del resorte. Tenga cuidado en que el “casco” o la cubierta
de la salida del regulador no se extienda demasiado lejos y la ventila
quede expuesta a los elementos.
By code, regulators installed indoors have limited inlet pressure, and
they require a vent line to the outside of the building, see figure 3. A
vent assembly, such as Fisher Y602 series, should be used on the
end of the vent line. The same installation precautions apply to vent
assemblies as the integral regulator vents covered previously. Use a
vent line equal in size (diameter) or larger than the regulator vent.
Vent piping must not restrict the flow passage of the regulator’s internal
relief valve. To install the vent line, remove the vent screen and apply
a good grade of pipe dope to the male threads of the line.
Por código, los reguladores instalados en interiores deben tener una
presión de entrada limitada y requieren de una línea de ventilación
hacia el exterior del edificio, vea figura 3. Un ensamble de ventila,
como el Fisher serie Y602, debe usarse al final de la línea de
ventilación. Las mismas precauciones de instalación aplican a los
ensambles de las ventilas como a las ventilas integrales del regulador,
ya descritas. Use una línea de venteo del mismo diámetro o mayor
que la salida del alívio. La tuberia de venteo no debe limitar el flujo de
gas de la válvula de alívio interno del regulador. Para instalar la
ventila, remueva la malla de la ventilla, aplique compuesto de tuberia
a la rosca de la tuberia.
Underground container systems require a vent tube to prevent water
TO APPLIANCE
AL EQUIPO
SALIDA DEL
ALIVIO /
MALLA DE
PROTECCION
VENT LINE
LINEA DE ALIVIO
BASEMENT
SOTANO
FROM FIRST - STAGE REG.
DEL REGULADOR DE 1RA. ETAPA
Figure 2. Point Vent
Down on
Outdoor
Installations
Figura 2. Coloque la Ventila
hacia abajo en
Instalaciones
Exteriores
Figure 3.
Typical Indoor Installation
With Vent line and Vent
Assembly
3
VENT OPENING MUST BE AT
LEAST 3-FT HORIZONTALLY
FROM ANY BUILDING
OPENING BELOW IT.
APERTURA DEBE ESTAR A
1 METRO DE CUALQUIER
APERTURA DEBAJO DE
ELLA
Figura 3.
Instalación interior
con linea de alivio y
ensamble de alívio
R400 & R500
Fisher Controls
Los sistemas subterráneos requieren de una linea de venteo para
impedir que el agua entre al contenedor del resorte del regulador, ver
figura 4. Quite la pantalla de la ventila e instale la linea con los
mismos criterios ya mencionados. La linea de venteo debe correr
desde la ventila hasta un lugar por encima del registro máximo de
agua. La abertura de este tubo debe terminar en el extremo superior
de la tapa. Asegúrese que la tapa del regulador está firme y libre de
drenaje a todo tiempo. Para mayor información sobre instalaciones
subterráneas, pida una copia de “Instalación e Inspección de
Sistemas de Gas Subterráneos”, disponible en The National Propane Gas Association, 1600 Eisenhower Lane, Suite 100, Lisle, Il
60532, USA.
from entering the regulator spring case, see figure 4. Remove the
vent screen and install a vent tube. The vent tube must be run from
the regulator vent to above the maximum water table. The vent tube
opening must terminate at the extreme top inside of the dome cover.
Maintain drainage away from the dome at all times. For further
information on underground installations, write for a copy of
“Underground LP-Gas Systems: Suggested Installation, Inspection,”
available from The National Propane Gas Association, 1600
Eisenhower Lane, Suite 100, Lisle, IL 60532
END OF REGULATOR VENT TUBE LOCATED AT TOP INSIDE OF HOUSING
DOME COVER.
(EL FINAL DE LA LINEA DE VENTEO DEBE ESTAR POR ENCIMA DEL BORDE
DE LA CUBIERTA)
GRADE GROUND DOWNWARD AND AWAY AROUND HOUSING DOME.
THIS PREVENTS WATER COLLECTING AND RUNNING INTO OR
STANDING AROUND HOUSING DOME.
(EL TERRENO DEBE TENER INCLINACION DE TAL MANERA QUE EL
AGUA NO SE ACUMULE Y SE ALEJE DE LA CUBIERTA PROTECTORA)
MINIMUM
MINIMO (5.3 cm.)
REGULATOR ADJUSTMENT CLOSURE CAP MUST BE TIGHT
(TAPA DE AJUSTE DEL RESORTE DEBE ESTAR APRETADA FIRMEMENTE)
WATER MARK LEFT IN HOUSING DOME AT LEVEL ABOVE REGULATOR VENT, OR
END OF VENT TUBE REQUIRES REPLACEMENT OF REGULATOR, THEN CORRECT
INSTALLATION.
(SI LA LINEA DE AGUA ESTA POR ENCIMA DEL VENTEO DEL REGULADOR O DE LA
LINEA DE VENTEO, EL REGULADOR DEBERA SER CAMBIADO Y LA INSTALACION
CORREGIDA)
Figure 4. Regulators Installed on Underground
Installations Require a Vent Tube
Figura 4. Reguladores instalados En Una Instalación
Subterránea Requieren Linea de Venteo
Adjustment
Ajuste
Each regulator is indivually factory set to deliver 11 inches wc. If it
becomes necessary to increase the outlet pressure, remove the
closing cap and turn the adjustment screw clockwise. Turn the
adjusting screw counterclockwise to decrease the outlet pressure.
The outlet pressure plug may be removed using a 7/16” hexagon
wrench. The plug can be removed with pressure on the outlet of the
regulator. Install a water manometer or pressure gauge to determine
the regulator’s outlet setting during adjustment, (Actual pressure at
the appliance may be less due to line loss.) After setting, reinstall the
pipe plug and replace the closing cap. Check the plug for leakage.
Cada regulador se ajusta en forma individual en la fábrica a 11
pulgadas de columna de agua (69.6 milibares). Si es necesario
aumentar la presión de salida, quite la tapa y gire el tornillo de ajuste
en el sentido de las manecillas del reloj; Si lo que se desea es
disminuir la presión, ajuste el tornillo girándolo en sentido contrario a
las manecillas del reloj. El tapón de presión de salida puede
removerse usando una llave hexagonal de 7/16”. El tapón puede
removerse cuando existe presión en la salida del regulador. Instale
un manómetro de agua o de presión para determinar el ajuste de la
salida del regulador. (La presión real en el equipo puede ser menor
debido a pérdida en la línea). Completado el ajuste, reinstale el tapón
de prueba Asegúrese de que no hay fugas en el tapón.
Inlet pressure may be checked using the inlet pressure gauge tap
and a pressure gauge. Remove the plug using a 7/16” wrench. The
plug can be removed with pressure on the inlet of the regulator.
La presión de entrada puede verificarse usando un manómetro.
Remueva eltapón con una llave de 7/16”; puede quitarse con presión
en la entrada del regulador.
Overpressure Protection
Protección Contra SobrePresiones
Personal injury or system damage may result if these
regulators are installed without appropiate overpressure protection. Outlet pressures greater than 3 psig
above the set point may cause damage to regulator
parts, leaks in the regulator, or personal injury due
to bursting of pressure-containing parts or explosion of accumulated gas.
En caso de que estos reguladores se instalen sin
una protección por sobrepresiones apropiadas,
daños al sistema o a personas pudiera ocurrir . Una
presión de salida mayor a 3 psig (0.2 bar) por encima
del nivel de ajuste puede causar daño a partes
internas del regulador, fugas en el regulador o daño
al personal por explosión de partes presurizadas o
del gas acumulado. Si el regulador es sometido a
If the regulator is exposed to an overpressure condition, it must be inspected for damage that may
have occurred.
4
R400 & R500
Fisher Controls
Large volumes of gas may discharge through the
regulator vent during internal relief valve operation
which can result in fire or explosion from accumulated gas.
una sobrepresión, el mismo deberá inspeccionarse
para verificar que no este dañado.
Volúmenes grandes de gas pueden ser descargados
a través de la ventila del regulador si la válvula de
alivio interna opera, pudiendo resultar en incendio
o explosión del gas acumulado.
All of the regulators have an internal relief valve that opens when
downstream pressure reaches approximately 1 psig on regulators
set at 11 inches wc. When the internal relief valve opens, gas
escapes to the atmosphere through the regulator’s vent. The internal
relief valve gives overpressure protection against excessive buildup resulting from seal leakage due to worn parts or chips or foreign
material on the orifice.
Todos los reguladores cuentan con una válvula de alivio interna que
se abre cuando la presión de salida alcanza aproximadamente 1 psig
(69 milibares) en reguladores ajustados a 11 pulgadas ca (27.4
milibares). Cuando se abre, escapa el gas a la atmósfera a través de
la ventila del regulador. La válvula interna de alivio protege contra la
sobrepresión que resulte al sellar una fuga debido a partes
desgastadas, basura o material ajeno que esté en el orificio.
Some type of external overpressure protection must be provided if
inlet pressure will be high enough to damage downstream equipment.
Common methods of external overpressure protection include relief
valves, monitoring regulators, shutoff devices, and series regulation.
The internal relief valve on second-stage and integral two-stage
regulators with 1 inch vent (Type R400 series) and 3/4 inch vent
(R500 series) limits downstream pressure to 2 psig as long as inlet
pressure does not exceed the values in table 1 and the vent is
unobstructed.
Debe darse protección externa contra la sobrepresión, si la presión
interna puede ser tan alta que dañe el equipo corriente abajo. Los
métodos comunes de protección externa contra la sobrepresión
incluyen: válvulas de alivio, reguladores de monitoreo, aditamentos
para apagar el equipo y regulación en serie. La válvula de alívio
interno en los reguladores 2da. etapa e los integrados de 2-etapas
con una ventila de 1 pulgada (Serie R400) y 3/4 de pulgada (Serie
R500) limitan la presión aguas abajo del regulador a 2 psig (0.13
bares) siempre que la presión de entrada no supere los valores
indicados en la tabla 1 y la ventila no este obstruida.
Maintenance
Mantenimiento
To avoid personal injury or equipment damage, do
not attempt any maintenance or disassembly without first isolating the regulator from system pressure and relieving all internal pressure. Regulators
that have been disassembled for repair must be
tested for proper operation before being returned to
service. Only parts manufactured by Fisher should
be used for repairing Fisher regulators. Relight pilot
lights according to normal startup procedures.
ADVERTENCIA
Para evitar lesiones al personal o daño al equipo,
no intente dar mantenimiento o desensamblar el
regulador sin primero aislarlo del sistema de presión
y aliviar toda la presión interna. Los reguladores
que se han desarmado para reparación deben
probarse antes de regresarlos a servicio. Sólo deben
usarse partes de Fisher al reparar los reguladores
Fisher. Encienda nuevamente los pilotos de acuerdo
con los procedimientos estándar de arranque.
Due to normal wear or damage that may occur from
external sources, these regulators must be inspected
and maintained periodically. The frequency of inspection and replacemnet of the regulators depends
upon the severity of service conditions or the requirements of local, state, and federal regulations.
Even under ideal conditions, these regulators should
be replaced after 15 years from date of manufacture
or sooner should inspection reveal the need.
En virtud de que puede ocurrir daño ocasionado
por uso normal o por causas externas, es necesario
inspeccionar y dar mantenimiento a este regulador
en forma periódica. La frecuencia de la inspección
y substitución de partes depende de la severidad
de condiciones de operación y de los
requerimientos de leyes y regulaciones locales,
estatales y municipales. Aun en las condiciones
ideales, es necesario reemplazar estos reguladores
después de 15 años de la fecha de fabricación, o
antes, si una inspección demuestra la necesidad
de hacerlo así.
Visually inspect the regulator each time a gas delivery is made for:
1. Improper installation.
2. Plugged or frozen vent.
3. Wrong regulator or no regulator in the system.
4. Internal or external corrosion.
5. Age of the regulator.
Cada vez que se hace una entrega de gas, se debe inspeccionar
visualmente el regulador. La revisión debe incluir:
6. Any other condition that could cause the uncontrolled escape of
gas.
1. Instalación apropiada del regulador.
2. Chequeo que la ventila no este obstruida.
3. Que no se haya removido el regulador y que sea el adecuado.
Failure to do the above could result in personal injury or property
damage.
4. Que no exista corrosión interna o externa.
5. Edad del Regulador.
Make sure the regulator vent, vent assembly, or vent tube does not
become plugged by mud, insects, ice, snow, paint, etc. The vent
screen aids in keeping the vent from becoming plugged, and the
screen should be clean and properly installed.
6. Cualquier otra condición que pudiera causar el escape nocontrolado de gas.
El no llevar a cabo lo anterior puede resultar en lesiones al personal
o daño a la propiedad.
Replace any regulators that have had water in their spring case or
show evidence of external or internal corrosion. Checking for internal
5
Fisher Controls
corrosion may require complete removal of the adjusting screw
and shut down of the gas system. Closely examine regulators
directly connected to the container valve by means of a solid POL
adaptor (horizontal mounting) for signs of corrosion. Correct any
improper installations.
Older regulators are more likely to catastrophically fail because of
worn or corroded parts. Replace regulators over 15 years of age;
other service or environmental conditions may dictate replacement
of the regulator before it becomes 15 years old, refer to Fisher
Bulletin LP-32.
These regulators have an internal inlet screen to help prevent foreign
particles .003” across or larger from passing through the the
regulator and into the downsteam appliances. Such foreign material
can cause improper operation of both regulators and appliances.
In most installations, the inlet screen will provide adequate filtration
capacity over the life of the regulator. However, in installations with
extreme debris contamination, it is possible for the filter screen to
become blocked and stop or restrict the flow of gas. If this should
occur, remove the four inlet fitting cap screws along with the inlet
fitting and its o-ring. Remove the filter screen and clean or replace
it. After installation of the filter screen, reinstall the inlet fitting, its oring, and the four inlet fitting cap screws. Leak test the inlet fitting
flange. NOTE: The R522 inlet screen may be accessed by
simply removing the inlet piping.
Regulator Repair
Regulators that have been disassembled for repair must be tested
for proper operation before being returned to service. Only parts
manufactured by Fisher should be used to repair Fisher regulators.
Be sure to give the complete type number of the regulator when
corresponding with the factory.
R400 & R500
Asegúrese de que la ventila del regulador, el ensamble de la ventila
o el tubo de la ventila nos encuentran obstruidos por mugre, insectos,
hielo, nieve, pintura, etc. La pantalla de la ventila es un auxiliar para
conservar la ventila limpia y bien instalada.
Substituya cualquier regulador al que le haya caído agua en el
contenedor del resorte o muestre evidencia de corrosión interna o
externa. Para hacer una inspección de corrosión interna es necesaria
la remoción total del tornillo de ajuste y apagar completamente el
sistema de gas. Examine cuidadosamente los reguladores que están
conectados directamente al contenedor de la válvula por medio de
un adaptador sólido POL (montaje horizontal), para detectar algún
signo de corrosión. Corrija cualquier instalación no adecuada.
Hay más probabilidades de que fallen los reguladores de más edad,
debido al uso o a partes desgastadas. Substituya los reguladores
de más de 15 años de edad; y a aquéllos que por el uso o las
condiciones medio ambientales deban substituirse antes de cumplir
15 años. Consulte el Boletín Fisher LP-32 para más referencias.
Estos reguladores cuentan con una pantalla interna que ayuda a
prevenir que partículas ajenas de más de .003 micras pasen al
regulador y lleguen al sistema de flujo. Estos materiales ajenos
pueden ocasionar operación inadecuada, tanto en el regulador como
en los equipos alimentados por gas.
En la mayoría de las instalaciones, la pantalla interna puede brindar
suficiente capacidad de filtración durante la vida activa del regulador.
Sin embargo, en instalaciones con demasiados desechos
contaminantes es posible que la pantalla del filtro quede obstruida y
detenga o restrinja el flujo de gas.
Si esto llega a ocurrir, desconecte la linea de alimentación, retire el
filtro y límpielo. Cambie el filtro si no se puede limpiar o si esta dañado.
Con cuidado, presione el filtro en la entrada hasta que toque el fondo.
Reinstale las tuberias y cheque si existe alguna fuga. NOTA: El
filtro de entrada del R522 puede ser removido removiendo la
tuberia de entrada.
Reparación de los reguladores
A los reguladores que se hayan desensamblado para reparación es
necesario probarlos antes de reinstalarlo para operación. Unicamente
utilize refacciones Fisher para reparar sus reguladores Fisher. Por
favor incluya el numero completo del regulador en sus
comunicaciones con la fabrica.
For further information, contact Fisher Controls International, LLC:
Para mayor información, favor comuniquese con Fisher Controls International, LLC:
P.O.Box 8004,
McKinney, Texas 75069, USA
WEB SITE: www.fisherregulators.com/lp
P.O.Box 8004
McKinney, Texas 75069, USA
DIRECCION EN EL INTERNET: www.fisherregulators.com/lp
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 guarantee, expressed or
implied, regarding the products or services herein or their use or applicability. Fisher Controls reserves the
right to modify or improve the designs or specifications of such products at any time without notice.
©Fisher Controls International, Inc., 1990,1999; All Rights Reserved. Fisher, Fisher-Rosemount,
and Managing The Process Better are marks owned by Fisher Controls International, Inc. or
Fisher-Rosemount Systems, Inc. All other marks are the property of their respective owners.
Toda la información aqui descrita es para efectos de información solamente, y se ha hecho el esfuerzo
para que sea la la más acertada, pero en ningún caso constituye una garantia, expresa o implicita,
en relación a los productos o servicios aqui descritos. Fisher Controls se reserva el derecho de alterar
o mejorar los diseños o especificaciones de los equipos aqui descritos sin previo aviso. ©Fisher
Controls International, Inc., 1990, 1999; All Rights Reserved. Fisher, Fisher-Rosemount, y Managing
The Process Better son marcas registradas y pertenecientes a Fisher Controls International, Inc. o
Fisher-Rosemount Systems, Inc.Cualquier otra marca es propiedad de su respectivo dueño.
Type R522
Fisher Controls
Installation Manual
Type R522 and R522H Pressure
Reducing Regulators
October 1992
Introduction
avoid such injury or damage, provide pressure-relieving or pressure-limiting devices
(as required by Title 49, Part 192, of the U.S.
Code of Federal Regulations, by the National Fuel Gas Code Title 54 of the National
Fire Codes of the National Fire Protection
Association, or by other applicable codes)
to prevent service conditions from exceeding those limits.
This installation manual covers the installation, startup,
and adjustment procedures for Type R522 and R522H pressure reducing regulators. The Type R522 self-operated, spring-loaded regulator provides economical
pressure-reducing control in a variety of service and
industrial applications. The regulator can be used with
a variety of gaseous fluids such as natural gas, manufactured gas, propane, or air.
The Type R522 regulators have high capacity and factory
adjustable internal relief to help minimize overpressurization of the downstream system. Any excess outlet
pressure above the start-to-discharge point of the relief
valve spring, moves the diaphragm off the relief valve
seat, allowing excess pressure to bleed out through the
screened spring case vent.
Installation
WARNING
Personal injury, equipment damage, or
leakage due to escaping accumulated 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 table 1. To
Form 5331
Additionally, physical damage to the regulator could result in personal injury or property damage due to escaping gas. To avoid
such injury and damage, install the regulator in a safe location.
1. Only personnel qualified through training and experience should install, operate, and maintain a regulator.
Before installing a Type R522 regulator, check for damage which might have occurred in shipment. Also check
for dirt or foreign matter which may have accumulated in
the regulator body or in the pipeline.
2. The Type R522 may be installed in any position (vertical or horizontal). Apply a good grade of pipe compound
to the male threads (being sure not to apply pipe compound to flow path of the pipe) of the pipe and install the
regulator so that the flow is in the direction of the arrow
cast on the body. Use approved piping procedures when
installing the regulator.
Table 1. Specifications
Body Sizes And End Connection Style
Inlet: ■ 1/4, ■ 1/2, and ■ 3/4-inch NPT screwed
Outlet: ■ 1/2 and ■ 3/4-inch NPT screwed
Maximum Allowable Inlet Pressure (1)
250 psig (17 bar)
Allowable Outlet Pressures(1)
Emergency (Casing): 20 psig (1.4 bar)
Maximum Operating to Avoid Internal Part
Damage: 3 psi (0.21 bar differential) above
outlet pressure setting
Outlet Pressure Range
4.5 inches w.c. to 15.5 psig (11.2 mbar to 1.1 bar)
Orifice Sizes and Color Code
R522: ■ 1/8-inch (gray)
R522H: ■ 13/64-inch (tan)
1. The pressure/temperature limits in this manual, and any applicable code or standard
limitations, should not be exceeded.
Material Temperature Capabilities(1)
– 40°F to 160°F ( – 40°C to 71°C)
(1)
©Fisher Controls International, Inc., 1992; All Rights Reserved
Type R522
Table 2. Outlet Pressure Ranges
Key
1
2
3
4
5
6
7
8*
9
10
11
12
13
14
15*
16
19
21
22
Regulator
Type number
Outlet Pressure Range
Control Spring
Part Number
Control Spring
Color Code
R522
4.5 to 6 inches w.c. (11.2 to 15 mbar)
5.5 to 8 inches w.c. (13.7 to 20 mbar)
7.5 to 9.5 inches w.c. (18.7 to 23.7 mbar)
9.5 to 13 inches w.c. (23.7 to 32.5 mbar)
13 to 20 inches w.c. (32.5 to 50 mbar)
20 to 28 inches w.c. (50 to 70 mbar)
T13588T0012
T13589T0012
T13590T0012
T13624T0012
T13592T0012
T13546T0012
Red
Yellow
Olive Drab
Purple
Gray
Orange
R522H
1 to 2.5 psig (70 to 172 mbar)
2.5 to 5.5 psig (172 to 379 mbar)
5.5 to 10.5 psig (379 to 724 mbar)
10.5 to 15.5 psig (724 to 1069 mbar)
T13593T0012
T13599T0012
T13600T0012
T13601T0012
Blue
Green
Red
Yellow
Description
Body
1/2-inch size
3/4-inch size
Inlet Fitting
1/4-inch size
1/2-inch size
3/4-inch size
Spring Case Assembly
Vent Screen
Retaining Ring
Control Spring
Orifice Tube Assembly
Orifice Tube O-Ring
Orifice Tube Screw
Diaphragm/Relief Valve Assembly
Closing 00061P08
Adjusting Screw
Spring Case Screw
Inlet Screw
Inlet O-Ring
Pipe Plug
Screw
Screw
Inlet Screen
*Recommeded spare part.
Figure 1. Type R522 Regulator Assembly
WARNING
A regulator may vent some gas to the atmosphere. In hazardous or flammable gas service, vented gas may accumulate, and cause
personal injury, death, or property damage
due to fire or explosion. Vent a regulator in
hazardous gas service to a remote, safe location away from air intakes or any hazardous location. The vent line or stack opening
must be protected against condensation or
clogging.
Under enclosed conditions, escaping gas
may accumulate and be an explosion hazard. In these cases the vent should be piped
away from the regulator to a safe
location outdoors.
While this information is presented in good faith and believed to be accurate,
Fisher Controls does not guarantee satisfactory results from reliance upon such
information. Nothing contained herein is to be construed as a warranty or
guarantee, express or implied, regarding the performance, merchantability, fitness
Fisher Controls
Printed in USA
3. On outdoor installations, regulators installed with vents
in positions other than vertically down require additional
vent protection from the elements. Such protection may
be with separate hood shields, or the Fisher Y602 Series
vents.
4. 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.
5. To adjust the regulator, monitor downstream pressure
with a gauge during the adjustment procedure. To increase
the outlet pressure, the adjustment screw (key 12, figure
1) must be turned clockwise. This requires removal of the
closing cap (key 11, figure 1). To reduce the outlet pressure setting, turn the adjusting screw counter-clockwise.
Do not adjust the spring to produce an outlet pressure
setting above the limit stamped on the regulator.
or any other matter with respect to the products, nor as a recommendation to
use any product or process in conflict with any patent. Fisher Controls reserves
the right, without notice, to alter or improve the designs or specifications of
the products described herein.
For information, contact Fisher Controls:
Marshalltown, Iowa 50158 USA
Cernay 68700 France
Sao Paulo 05424 Brazil
Singapore 0512
Types 1098-EGR & 1098H-EGR
Incorporates Erratas Dated 06/97, 08/99, and 07/02
Instruction Manual
Fisher Controls
Type 1098-EGR & 1098H-EGR
Pilot-Operated Regulators
R
May 1987
Form 5084
Contents
Introduction
...................................
Scope of Manual . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Product Description . . . . . . . . . . . . . . . . . . . . . . . . . . .
Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2
2
2
2
Installation and Startup
Shutdown
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Single-Pilot, Dual-Pilot Regulator or Wide-Open
Monitor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Working Monitor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Principle of Operation . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Design EGR Main Valve . . . . . . . . . . . . . . . . . . . . . .
Replacing Quick-Change Trim Package . . . . . . .
Replacing Trim Parts . . . . . . . . . . . . . . . . . . . . . . .
P590 Series Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Type 6351 Pilot . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Fisher Controls International, Inc. 1977, 1979, 1982, 1987; All Rights Reserved
14
14
14
15
16
W3115-1
TYPE 1098-EGR-6352
REGULATOR
W3417-2
TYPE 1098H-EGR-6354L
REGULATOR
Figure 1. Typical Regulator Constructions
Type 6352 Through 6354M Pilots . . . . . . . . . . . . 16
Type 61LD Pilot and Type 1806 Relief Valve . . . 16
Type 1098 or 1098H Actuator and Pilot Mounting
Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
Parts Ordering . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
Parts List . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
D100339 X012
........................ 3
Standard Single-Pilot Regulator . . . . . . . . . . . . . . . . . 3
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Prestartup Considerations . . . . . . . . . . . . . . . . . . . . 6
Pilot Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Startup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Dual-Pilot Boiler Fuel Control Regulator . . . . . . . . . . 6
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Prestartup Considerations . . . . . . . . . . . . . . . . . . . . 7
Pilot Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Startup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Working Monitor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Prestartup Considerations . . . . . . . . . . . . . . . . . . . . 8
Pilot Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Startup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Wide-Open Monitor . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Prestartup Considerations . . . . . . . . . . . . . . . . . . . 10
Pilot Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Startup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
R
Types 1098-EGR & 1098H-EGR
Introduction
Scope of Manual
This manual describes and provides instructions and parts list for
a Type 1098-EGR or 1098H-EGR regulator (figure 1) complete
with standard P590 Series filter and either a 6350 Series
regulator or a Type 61LD pilot. The Type 1806 relief valve also
is covered when a Type 61LD pilot is used. However, instructions
and parts lists for monitoring pilots and other equipment used
with this regulator are found in separate manuals.
Product Description
Type 1098-EGR and 1098H-EGR regulators provide economical, accurate pressure control in a wide variety of applications
such as gas distribution systems, heat-treating furnaces, and
boiler plants. They are also used in plant air service and in liquid
service where a slow stroking time (approximately 30 to 90
seconds) is desired on both opening and closing the main valve.
The Type 1098-EGR regulator is used with a Type 6351, 6352,
6353 or the 61 series pilot. The Type 1098H-EGR regulator is
used with a Type 6351, 6352, 6353, 6354H, 6354L, or 6354M
pilot.
Specifications
Table 1 lists specifications for various Type 1098-EGR and
1098H-EGR constructions. Specifications for a given regulator
as it originally comes from the factory are stamped on
nameplates (figure 2) located on the actuator and main valve
body, while the pilot control spring range appears on the pilot
spring case and the pilot restriction code is stamped on the pilot
body.
Table 1. Specifications
BODY SIZES AND END
CONNECTION STYLES
Body Size,
Inch
Material
Cast iron
1, 2
WCB steel
Cast iron
2, 3, 4, 6,
8x6
WCB steel
End Connection
Style
NPT screwed
OUTLET (CONTROL)
PRESSURE RANGES(4)
Type 6351 Pilot: J 3 to 20 psig
(0.21 to 1.4 bar) with green spring
J 5 to 35 psig (0.34 to 2.4 bar)
with cadmium spring or J 35 to
100 psig (2.4 to 6.9 bar) with red
spring
Type 6352 Pilot: J 2 inch wc to
2 psig (5 to 140 mbar) with yellow
spring or J 2 to 10 psig (140 to
690 mbar) with black spring
Type 6353 Pilot: J 3 to 40 psig
(0.21 to 2.8 bar) with yellow
spring or J 35 to 125 psig (2.4 to
8.6 bar) with red spring
Type 6354L Pilot: 85 to 200 psig
(5.9 to 14 bar) with blue spring
and no diaphragm limiter
Type 6354M Pilot: 175 to 220
psig (12 to 15 bar) with blue spring
and diaphragm limiter
Type 6354H Pilot: 200 to 300 psig
(14 to 21 bar) with green spring
and diaphragm limiter
Type 61LD Pilot: J 0.25 to 2
psig (0.017-0.138 bar) with red
spring
J 1 to 5 psig (0.069-0.34 bar)
with yellow spring J 2 to 10 psig
(0.138-0.69 bar) with blue spring
J 5 to 15 psig (0.34-1.02 bar)
with brown spring J 10 to 20 psig
(0.69-1.4 bar) with green spring
MAXIMUM AND
MINIMUM
DIFFERENTIAL
PRESSURES
See table 2
Rating(1)
Class 250B
NPT screwed, buttwelding, or socketwelding
Flat-face flanged
Raised-face flanged
Class 600
Class 125B
Class 250B
Class 150,
300, or 600
Class 600
Raised-face flanged
Buttwelding
MAXIMUM MAIN
VALVE INLET
PRESSURE(1)
400 psig (28 bar) or body rating
limit, whichever is lower, except
20 psig (1.4 bar) for boiler fuel
installations as shown in table 2
MAXIMUM PILOT
SUPPLY
PRESSURE(1, 2)
600 psig (41 bar)
PILOT RESTRICTION(3)
TYPE
NUMBER
6351
6352
through
6354M
2
RESTRICTION
GAIN
Used
Color Code
Letter
Code
Standard
No
None
None
Standard
Yes
Green
S
Low for liquid service
and/or broader
proportional bands
No
None
L
High for narrower
proportional bands
Yes
Red
H
Types 1098-EGR & 1098H-EGR
Table 1. Specifications (Continued)
ACTUATOR SIZES
AND MAXIMUM
ACTUATOR
PRESSURES(1)
PORT DIAMETERS
AND TRAVELS
OUTLET (CONTROL)
EMERGENCY
PRESSURE
CASING PRESSURE
Psig
Bar
Psig
Bar
ACTUATOR
SIZE
Type 1098
30
40
70
100
75
50
6.9
5.2
3.4
115
82
65
7.9
5.7
4.5
Type 1098H
30
300
21
400
28
MAIN VALVE FLOW
CHARACTERISTIC
J Linear (standard) or J quickopening
MAIN VALVE FLOW
DIRECTION
In through seat ring and out
through cage
MATERIAL
TEMPERATURE
CAPABILITIES(1)
Standard Elastomers: -20 to
150_F (-29 to 66_C)
High-Temperature Elastomers: 0
to 300_F (-18 to 149_C), except
0 to 180_F (-18 to 82_C) for
water service
1. The pressure/temperature limits in this manual, and any applicable standard
limitation should not be exceeded.
2. For stability or overpressure protection, a reducing regulator may be installed up-
Installation and Startup
WARNING
BODY SIZE
INCH
1
TRAVEL
PORT
DIAMETER
Inch
1-5/16
Standard
mm
Inch
33.3
2
2-3/8
3
3-3/8
85.7
4
4-3/8
111.1
6&8X6
7-3/16
182.6
APPROXIMATE
WEIGHTS (WITH
STANDARD SINGLEPILOT
CONSTRUCTION)
60.3
3/4
1-1/8
Restricted Capacity
Percentage of
mm
Flow Capacity
19
29
Inch mm
---
---
30
3/8
10
70
5/8
16
1-1/2
38
40
7/8
22
2
51
40
1
25
ACTUATOR
SIZE
BODY SIZE, INCH
1
2
3
4
6
Lb
Type 1098
30
55
40
65
70 140
75
85
160
115
125
200
165 350
175 360
250 435
Type 1098H
30
80
100
140
190 375
Type 1098
30
40
70
25
29
64
34
39
73
52
57
91
75 159
79 163
113 197
Type 1098H
30
36
45
64
86 170
Kg
stream of the pilot according to the installation section.
3. Restriction part numbers are given in the parts list.
4. Pilot control spring part numbers are given in the parts list.
avoid such injury and damage, install the
regulator in a safe location.
Standard Single-Pilot Regulator
Installations
Personal injury, equipment damage, or leakage due to escaping accumulated 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 and 2 and on
the appropriate nameplate, 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
Title 49, Part 192, of the U.S. Code of Federal
Regulations, by the National Fuel Gas Code
Title 54 of the National Fire Codes of the National Fire Protection Association, or by other applicable codes) to prevent service
conditions from exceeding those limits.
Additionally, physical damage to the regulator
could results in personal injury and property
damage due to escaping accumulated gas. To
A Type 1098-EGR or 1098H-EGR regulator bleeds no gas
to atmosphere, making it suitable for installation in pits and
other enclosed locations without elaborate venting
systems. This regulator also can be installed in pits subject
to flooding, by installing a special antiflood breather vent or
by venting the pilot spring case above the expected flood
level so that the pilot diaphragm can be referenced to
atmospheric pressure.
Note
On the Design EGR main valve, normal
pressure drop assists shutoff. Therefore,
leakage may result during any reverse
pressure drop condition.
1. Use qualified personnel when installing, operating, and
maintaining regulators. Before installing, inspect the main
valve, pilot, and tubing for any shipment damage or foreign
material that may have collected during crating and
shipment. Make certain the body interior is clean and the
pipelines are free of foreign material. Apply pipe compound
3
R
Types 1098-EGR & 1098H-EGR
Table 2. Maximum and Minimum Differential Pressures for Main Valve Spring Selection
Low-differential boiler
fuel installation Type
1098-EGR requiring
quick-opening cage
and limited to 20
psig (1.4 bar) max
inlet pressure
CONSTRUCTION
20 psig (1.4 bar)
60 psi (4.1 bar)
125 psi (8.6 bar)
Size 40 Actuator
Not available
2.5 psi (0.17 bar)
4 psi (0.28 bar)
400 psig (28 bar)
or body rating limit,
whichever is lower
5 psi (0.34 bar)
Size 30 Actuator
Not available
3.5 psi (0.24 bar)
5 psi (0.34 bar)
7 psi (0.48 bar)
Size 70 Actuator
1.0 psi (0.069 bar)
1 psi (0.069 bar)
1.5 psi (0.10 bar)
2.5 psi (0.17 bar)
Size 40 Actuator
Not available
3 psi (0.21 bar)
5 psi (0.34 bar)
10 psi (0.69 bar)
Size 30 Actuator
Not available
4 psi (0.28 bar)
6 psi (0.42 bar)
11 psi (0.76 bar)
Size 70 Actuator
1.0 psi (0.069 bar)
1.5 psi (0.10 bar)
2 psi (0.14 bar)
3 psi (0.21 bar)
Size 40 Actuator
Not available
4 psi (0.28 bar)
6 psi (0.41 bar)
11 psi (0.76 bar)
Size 30 Actuator
Not available
5 psi (0.34 bar)
8 psi (0.55 bar)
14 psi (0.97 bar)
Size 70 Actuator
1.0 psi (0.069 bar)
2 psi (0.14 bar)
2.5 psi (0.17 bar)
4 psi (0.28 bar)
Size 40 Actuator
Not available
5 psi (0.34 bar)
8 psi (0.55 bar)
13 psi (0.90 bar)
Size 30 Actuator
Not available
10 psi (0.69 bar)
13 psi (0.90 bar)
22 psi (1.5 bar)
Size 70 Actuator
1.3 psi (0.090 bar)
2.5 psi (0.17 bar)
3 psi (0.21 bar)
5 psi (0.34 bar)
Size 40 Actuator
Not available
9.5 psi (0.66 bar)
14 psi (0.97 bar)
19 psi (1.3 bar)
6, 8 x 6 Inch Body Size 30 Actuator
Size 70 Actuator
Not available
13 psi (0.90 bar)
19 psi (1.3 bar)
28 psi (1.9 bar)(1)
2.2 psi (0.15 bar)
4 psi (0.28 bar)
6 psi (0.42 bar)
8 psi (0.55 bar)
Yellow, except green
for 1 inch body
Green
Blue
Red
MAXIMUM ALLOWABLE
DIFFERENTIAL PRESSURE
1 Inch Body
2 Inch Body
MINIMUM
DIFFERENTIAL
PRESSURE
REQUIRED FOR
FULL STROKE
All Other Constructions
3 Inch Body
4 Inch Body
MAIN VALVE SPRING COLOR CODE (2)
1. Requires special 6350 Series pilot construction with Type 1806H relief valve.
2. Spring part numbers are given in the parts list.
13A2353-A
24A5704-B Sht 2
Figure 2. Regulator Nameplates
only to the male pipe threads with a screwed body, or use
suitable line gaskets and good bolting practices with a
flanged body.
buildup on all machined guiding and sealing surfaces inside
the body and at the bonnet flange/body joint.
Note
With a weld end body, be sure to remove the trim package,
including the gasket (key 4, figure 11), according to the
Maintenance section before welding the body into the line.
Do not install the trim package until any post-weld heat
treatment is completed. If heat treating, prevent scale
4
All Type 1098-EGR and 1098H-EGR regulators should be installed so that flow through
the main valve matches the flow arrow
attached to the valve body.
Types 1098-EGR & 1098H-EGR
48A6566-A
B1622
Figure 3. Standard Single-Pilot Installation
2. Install a three-valve bypass around the regulator if
continuous operation is necessary during maintenance or
inspection.
The standard pilot mounting position is shown in figure 1, the pilot
may be field-changed to the opposite-side mounting position by
swapping the pilot pipe nipple to the opposite bonnet tapping.
into the 1/4-inch NPT vent tapping. The Type 61LD pilot is vented
by installing the vent piping in place of the pipe plug (key 22,
figure 18). Then remove the closing cap assembly (key 5,
figure 18) in order to remove the machine screw from inside the
closing cap and tightly install it in the vent hole in the center of
the closing cap. Provide protection on a remote vent by installing
a screened vent cap into the remote end of the vent pipe.
WARNING
A regulator may vent some gas to the
atmosphere. In hazardous or flammable gas
service, vented gas may accumulate, and cause
personal injury, death, or property damage due
to fire or explosion. Vent a regulator in
hazardous gas service to a remote, safe location
away from air intakes or any hazardous
location. The vent line or stack opening must be
protected against condensation or clogging.
3. To keep the pilot spring case vent from being plugged or the
spring case from collecting moisture, corrosive chemicals, or
other foreign material, point the vent down or otherwise protect
it. Vent orientation may be changed by removing the spring case
and remounting it on the pilot body or on a standard Type 6352
through 6354M pilot, by twisting the vent (key 35, figure 13, or
key 13, figure 14) in the spring case. To remotely vent a standard
Type 6352 through 6354M pilot, remove the vent and install
obstruction-free tubing or piping
4. Run a 3/8-inch outer diameter or larger pilot supply line from
the upstream pipeline to the filter inlet as shown in figure 3,
bushing the line down to fit the 1/4-inch NPT filter connection. Do
not make the upstream pipeline connection in a turbulent area,
such as near a nipple, swage, or elbow. If the maximum pilot inlet
pressure could exceed the pilot rating, install a separate reducing
regulator in the pilot supply line. Install a hand valve in the pilot
supply line, and provide vent valves to properly isolate and
relieve the pressure from the regulator.
5. Attach a 1/2-inch NPT downstream pressure control line
downstream of the regulator in a straight run of pipe as shown
in figure 3. Connect the other end of the control line to the bonnet
connection. Do not make the tap near any elbow, swage, or
nipple that might cause turbulence. Install a hand valve in the
control line to shut off the control pressure when the bypass is
in use.
5
R
Types 1098-EGR & 1098H-EGR
6. If a quick acting solenoid is to be installed downstream
of a regulator, the regulator and solenoid should be located
as far apart as practical. This will maximize the gas piping
volume between the regulator and solenoid and improve
the regulator response to quick changing flow rates.
7. Consult the appropriate instruction manual for
installation of an optional pneumatic or electric remote
control drive unit. For optional remote pneumatic loading of
a 6350 Series or 61LD pilot, make the loading piping
connections to the 1/4-inch NPT vent connection.
Prestartup Considerations
Before beginning the startup procedures in this section,
make sure the following conditions are in effect:
D Block valves isolate the regulator.
D Vent valves are closed.
D Hand valves are closed.
CAUTION
Introduce pilot supply pressure into the regulator before introducing any downstream
pressure, or internal damage may occur due
to reverse pressurization of the pilot and
main valve components.
Pilot Adjustment
To adjust standard 6350 Series pilots: loosen the locknut
(key 11, figure 13, or key 10, figure 14), and turn the
adjusting screw (key 10, figure 13, or key 9, figure 14). Then
tighten the locknut to maintain the adjustment position. On
a standard Type 6352 through 6354M pilot, a closing cap
(key 28, figure 14) must be removed before adjustment and
replaced afterward.
WARNING
To avoid possible personal injury from a
pressure-loaded Type 61LD pilot, carefully
vent the spring case before removing the
closing cap. Otherwise, trapped loading
pressure could forcefully eject the freed
closing cap.
To adjust the Type 61LD pilot: remove the closing cap
(key 5, figure 18) and turn the adjusting screw (key 6, figure
18). Any adjustments made should set the controlled
pressure within the appropriate spring range shown in the
Specifications table.
Startup
1. Slowly open the hand valve in the pilot supply line.
2. Slowly open the upstream block valve, and partially
open the downstream block valve for minimum flow.
3. Slowly open the hand valve in the control line.
4. Adjust the pilot setting if necessary.
Always use pressure gauges to monitor
downstream pressure during startup. Procedures used in putting this regulator into
operation must be planned accordingly if
the downstream system is pressurized by
another regulator or by a manual bypass.
Note
For proper operation, pilot supply pressure
must exceed control pressure by the
minimum amount specified on the actuator
nameplate as minimum differential pressure.
The only adjustment necessary on a Type 1098-EGR or
1098H-EGR regulator is the pressure setting of the pilot
control spring. Turning the adjusting screw clockwise into
the spring case increases the spring compression and
pressure setting. Turning the adjusting screw counterclockwise decreases the spring compression and pressure
setting.
6
5. Completely open the downstream block valve.
6. Slowly close the bypass valve, if any.
Dual-Pilot Boiler Fuel Control Regulator
Installation
1. Perform the Standard Single-Pilot Regulator Installation section through step 3, making sure that the regulator
is installed in a horizontal pipeline with the actuator below
the main valve as shown in figure 4.
2. Run a 1/2-inch outer diameter or larger pilot supply line
from the upstream pipeline to the 1/2-inch NPT supply
connection in the pipe tee as shown in figure 4. Do not make
the connection in a turbulent area, such as near a nipple,
swage, or elbow. If the maximum pilot inlet pressure could
exceed the pilot rating, install a separate reducing regulator
in the pilot line. Install a hand valve in the pilot supply line,
and provide vent valves so that pressure can be properly
isolated and relieved from the regulator.
Types 1098-EGR & 1098H-EGR
48A6564-B
B1654-1
Figure 4. Typical Dual-Pilot Boiler Fuel Installation
3. Attach a 1/2-inch NPT downstream pressure control
line ten pipe diameters downstream of the regulator in a
straight run of pipe. Connect the other end of the control line
to the 1/4-inch NPT connection in the control line pipe tee
as shown in figure 4. Do not make the tap near any elbow,
swage, or nipple which might cause turbulence. Install a
hand valve in the control line to shut off the control pressure
when the bypass is in use. Also use the hand valve to
dampen out pulsations which may cause instability or
cycling of the regulator.
4. Consult the appropriate instruction manual for
installation of an optional pneumatic or electric remote
control drive unit. For optional remote pneumatic loading of
a 6350 Series or Type 61LD pilot, make the loading piping
connections to the 1/4-inch NPT vent connection.
Prestart Considerations
Before beginning the startup procedures in this section,
make sure the following conditions are in effect:
D Block valves isolate the regulator.
D Vent valves are closed.
D Hand valves are closed.
CAUTION
Introduce pilot supply pressure into the regulator before introducing any downstream
pressure, or internal damage may occur due
to reverse pressurization of the pilot and
main valve components.
Always use pressure gauges to monitor
downstream pressure during startup. Procedures used in putting this regulator into
operation must be planned accordingly if
the downstream system is pressurized by
another regulator or by a manual bypass.
Note
For proper operation, pilot supply pressure
must exceed control pressure by the
minimum amount specified on the actuator
nameplate as minimum differential pressure.
The only adjustment necessary on a Type 1098-EGR or
1098H-EGR regulator is the pressure setting of the pilot
control spring. Turning the adjusting screw clockwise into
7
R
Types 1098-EGR & 1098H-EGR
the spring case increases the spring compression and
pressure setting. Turning the adjusting screw counterclockwise decreases the spring compression and pressure
setting.
Pilot Adjustment
To adjust standard 6350 Series pilots: loosen the locknut
(key 11, figure 13, or key 10, figure 14), and turn the
adjusting screw (key 10, figure 13, or key 9, figure 14). Then
tighten the locknut to maintain the adjustment position. On
a standard Type 6352 through 6354M pilot, a closing cap
(key 28, figure 14) must be removed before adjustment and
replaced afterward.
WARNING
To avoid possible personal injury from a
pressure-loaded Type 61LD pilot, carefully
vent the spring case before removing the
closing cap. Otherwise, trapped loading
pressure could forcefully eject the freed
closing cap.
To adjust the Type 61LD pilot: remove the closing cap
(key 5, figure 18) and turn the adjusting screw (key 6, figure
18). Any adjustments made should set the controlled
pressure within the appropriate spring range shown in the
Specifications table.
Working Monitor
Installation
1. For both the working monitor regulator and the working
regulator, perform the Standard Single-Pilot Regulator
Installation section through step 6.
2. Connect another downstream pressure control line and
hand valve (figure 5) to the monitoring pilot according to the
monitoring pilot instruction manual. Attach a 1/2-inch NPT
intermediate pressure control line and hand valve from the
intermediate pressure pipeline to the working monitor
regulator. Pipe supply pressure between the monitoring
pilot and the working monitor regulator according to the
monitoring pilot manual.
For two typical monitoring pilots, table 4 gives the spread
between normal distribution pressure and the minimum
pressure at which the working monitor regulator can be set
to take over if the working regulator fails open.
Prestartup Considerations
Before beginning the startup procedures in this section,
make sure the following conditions are in effect:
D Block valves isolate the regulator.
D Vent valves are closed.
D Hand valves are closed.
Startup
1. Slowly open the hand valve in the pilot supply line.
2. Slowly open the upstream block valve, and partially
open the downstream block valve for minimum flow.
3. Slowly open the hand valve in the control line and make
sure that the standby pilot is set far enough below the
working pilot so that the standby pilot remains closed during
normal operation. For example, with final desired settings
of 11 inches wc (27 mbar) for the working pilot and 10 inches
wc (25 mbar) for the standby pilot, begin by reducing the
working pilot setting far enough below 10 inches wc (25
mbar) for the working pilot to shut off. Then set the standby
pilot for an outlet pressure of 10 inches wc (25 mbar).
Finally, set the working pilot for an outlet pressure of 11
inches wc (27 mbar).
Table 3 shows how close the standby pilot can be set to the
working pilot setting.
4. Completely open the downstream block valve.
5. Slowly close the bypass valve, if any.
8
CAUTION
Introduce pilot supply pressure into the regulator before introducing any downstream
pressure, or internal damage may occur due
to reverse pressurization of the pilot and
main valve components.
Always use pressure gauges to monitor
downstream pressure during startup. Procedures used in putting this regulator into
operation must be planned accordingly if
the downstream system is pressurized by
another regulator or by a manual bypass.
Note
For proper operation, pilot supply pressure
must exceed control pressure by the
minimum amount specified on the actuator
nameplate as minimum differential pressure.
Types 1098-EGR & 1098H-EGR
Table 3. Standby Pilots for Boiler Fuel Control Applications
STANDBY PILOT INFORMATION
Construction
Spring Range
Spring Part Number
Type Y600P with
3/8 inch (9.5 mm) port diameter
and 150 psig (10 bar)
maximum allowable pilot inlet
3 to 8 inch wc (8 to 20 mbar)(1)
5 to 15 inch wc (12 to 38 mbar)(1)
11 to 28 inch wc (27 to 68 mbar)(1)
1 to 2-1/2 psig (0.069 to 0.17 bar)(2)
2-1/4 to 4-1/2 psig (0.16 to 0.31 bar)(2)
4-1/2 to 7 psig (0.31 to 0.48 bar)(2)
1B6358 27052(1)
1B6539 27022(1)
1B5370 27052(1)
1B5371 27022(2)
1B5372 27022(2)
1B5373 27052(2)
Type 621-107 with 3/8 inch (9.5 mm)
port diameter and 150 psig (10 bar)
maximum allowable pilot inlet for cast iron body
or 750 psig (52 bar) maximum allowable pilot
inlet for malleable iron or steel body
5 to 10 psig (0.34 to 0.69 bar)
1D8923 27022
MINIMUM PRESSURE AT
WHICH STANDBY PILOT
CAN BE SET
1 inch wc (2.5 mbar)
under working pilot set point
0.2 psig (14 mbar)
under working pilot set point
0.3 psig (21 mbar)
under working pilot set point
1. With standard diaphragm plate.
2. With heavy diaphragm plate.
Table 4. Working Monitor Performance
MONITORING PILOT INFORMATION
Construction
Type Y600M with
1/8 inch (3.2 mm) port diameter
and 150 psig (10 bar)
maximum allowable pilot inlet
Type 621-109 with 1/8 inch (3.2 mm)
port diameter and 150 psig (10 bar)
maximum allowable pilot inlet for cast iron body
or 750 psig (52 bar) maximum allowable pilot
inlet for malleable iron or steel body
Spring Range
Spring Part Number
5 to 15 inch wc (12 to 38 mbar)
11 to 28 inch wc (27 to 68 mbar)
1 to 2-1/2 psig (0.069 to 0.17 bar)
2-1/4 to 4-1/2 psig (0.16 to 0.31 bar)
4-1/2 to 7 psig (0.31 to 0.48 bar)
5 to 15 psig (0.34 to 1.0 bar)
10 to 25 psig (1.0 to 1.7 bar)
20 to 35 psig (1.4 to 2.4 bar)
25 to 60 psig (1.7 to 4.1 bar)
1B6539 27022
1B5370 27052
1B5371 27022
1B5372 27022
1B5373 27052
1D8923 27022
1D7515 27022
1D6659 27022
1D7555 27142
40 to 80 psig (2.8 to 5.5 bar)
80 to 150 psig (5.5 to 10 bar)
130 to 200 psig (9.0 to 14 bar)
1E5436 27142
1P9013 27142(1)
1P9013 27142(2)
MINIMUM PRESSURE AT
WHICH WORKING MONITOR
REGULATOR CAN BE SET
3 inch wc (7 mbar)
over normal distribution pressure
0.5 psig (0.034 bar)
over normal distribution pressure
30 psig (0.21 bar)
over normal distribution pressure
5.0 psig (0.34 bar)
over normal distribution pressure
1. With large diaphragm plate.
2. With small diaphragm plate.
26A4298-A
A2118-2
Figure 5. Typical Working Monitor Installation
9
R
Types 1098-EGR & 1098H-EGR
The only adjustment necessary on a Type 1098-EGR or
1098H-EGR regulator is the pressure setting of the pilot
control spring. Turning the adjusting screw clockwise into
the spring case increases the spring compression and
pressure setting. Turning the adjusting screw counterclockwise decreases the spring compression and pressure
setting.
Pilot Adjustment
To adjust all standard 6350 Series pilots: loosen the
locknut (key 11, figure 13, or key 10, figure 14), and turn the
adjusting screw (key 10, figure 13, or key 9, figure 14). Then
tighten the locknut to maintain the adjustment position. On
a standard Type 6352 through 6354M pilot, a closing cap
(key 28, figure 14) must be removed before adjustment and
replaced afterward.
WARNING
To avoid possible personal injury from a
pressure-loaded Type 61LD pilot, carefully
vent the spring case before removing the
closing cap. Otherwise, trapped loading
pressure could forcefully eject the freed
closing cap.
To adjust the Type 61LD pilot: remove the closing cap
(key 5, figure 18) and turn the adjusting screw (key 6, figure
18). Any adjustments made should set the controlled
pressure within the appropriate spring range shown in the
Specifications table.
Startup
On a working monitor installation (figure 5), be sure that the
second-stage working regulator is set to operate at a
pressure lower than the Type 1098-EGR or 1098H-EGR
working monitor regulator. To do this, increase the setting
of the monitoring pilot until the working pilot is in control of
the intermediate pressure and the second-stage working
regulator is in control of the downstream pressure. If this is
not done, the monitoring pilot tries to take control of the
downstream pressure.
1. Slowly open the upstream block valve and the hand
valves in both pilot supply lines. This energizes both pilots
so that their setpoints can be adjusted. Partially open the
downstream block valve for minimum flow.
2. To enable intermediate pressure adjustment with the
working monitor regulator, slowly open the hand valve in the
intermediate pressure control line.
3. To enable downstream pressure adjustment with the
second-stage working regulator, slowly open the hand
valve in the control line to this regulator.
10
4. Adjust the setting of the monitoring pilot to establish the
desired emergency downstream pressure, which is to be
maintained in the event of open failure of the second-stage
working regulator. The emergency downstream pressure
should exceed the desired downstream pressure by at least
the amount listed in table 4. The steps followed to set the
monitoring pilot may vary with each piping situation;
however, the basic method remains the same. The
following substeps a and b may be used as examples for
setting the monitoring pilot:
a. Increase the outlet pressure setting of the
second-stage working regulator until the monitoring pilot
takes control of the downstream pressure. Adjust the
monitoring pilot setting until the desired emergency
downstream pressure is achieved. Then readjust the
second-stage working regulator to establish the desired
downstream pressure.
b. Install special piping (not shown in figure 5) so that
the monitoring pilot senses the intermediate pressure. The
intermediate pressure then appears to the monitoring pilot
as if it were increased downstream pressure, and the
monitoring pilot controls and reduces the intermediate
pressure. Adjust the monitoring pilot setting until the
desired emergency downstream pressure is achieved at
the intermediate pressure stage. Then slowly close the
special piping, and open up the monitoring downstream
control line for normal service.
5. Slowly open the downstream block valve.
6. Slowly close the bypass valve, if any.
Wide-Open Monitor
Installation
1. For both the wide-open monitoring regulator and the
working regulator, perform the Standard Single-Pilot
Regulator Installation section through step 6.
2. Connect the control line of a wide-open monitoring
regulator (figure 6) to downstream piping near the working
regulator control line connection. During normal operation
the wide-open monitoring regulator stands wide open with
the pressure reduction being taken across the working
regulator. Only in case of working regulator failure does the
wide-open monitoring regulator take control at its slightly
higher setting.
Prestartup Considerations
Before beginning the startup procedures in this section,
make sure the following conditions are in effect:
Types 1098-EGR & 1098H-EGR
16A4297-A
16A4296-A
Figure 6. Typical Wide-Open Monitor Installations
D Block valves isolate the regulator.
D Vent valves are closed.
D Hand valves are closed.
Pilot Adjustment
To adjust all standard 6350 Series pilots: loosen the
locknut (key 11, figure 13, or key 10, figure 14), and turn the
adjusting screw (key 10, figure 13, or key 9, figure 14). Then
tighten the locknut to maintain the adjustment position. On
a standard Type 6352 through 6354M pilot, a closing cap
(key 28, figure 14) must be removed before adjustment and
replaced afterward.
CAUTION
Introduce pilot supply pressure into the regulator before introducing any downstream
pressure, or internal damage may occur due
to reverse pressurization of the pilot and
main valve components.
Always use pressure gauges to monitor
downstream pressure during startup. Procedures used in putting this regulator into
operation must be planned accordingly if
the downstream system is pressurized by
another regulator or by a manual bypass.
WARNING
To avoid possible personal injury from a
pressure-loaded Type 61LD pilot, carefully
vent the spring case before removing the
closing cap. Otherwise, trapped loading
pressure could forcefully eject the freed
closing cap.
To adjust the Type 61LD pilot: remove the closing cap
(key 5, figure 18) and turn the adjusting screw (key 6, figure
18). Any adjustments made should set the controlled
pressure within the appropriate spring range shown in the
Specifications table.
Startup
Note
For proper operation, pilot supply pressure
must exceed control pressure by the
minimum amount specified on the actuator
nameplate as minimum differential pressure.
The only adjustment necessary on a Type 1098-EGR or
1098H-EGR regulator is the pressure setting of the pilot
control spring. Turning the adjusting screw clockwise into
the spring case increases the spring compression and
pressure setting. Turning the adjusting screw counterclockwise decreases the spring compression and pressure
setting.
Repeat this procedure in turn for each regulator in the
installation.
1. Slowly open the hand valve in the pilot supply line.
2. Slowly open the upstream block valve, and partially
open the downstream block valve for minimum flow.
3. Slowly open the hand valve in the control line and adjust
the pilot setting if necessary. Set the monitoring regulator at
a slightly higher control pressure than the working regulator.
4. Completely open the downstream block valve.
5. Slowly close the bypass valve, if any.
11
Types 1098-EGR & 1098H-EGR
Shutdown
Installation arrangements vary, but in any installation it is
important that the valves be opened or closed slowly and
that the outlet pressure be vented before venting inlet
pressure to prevent damage caused by reverse pressurization of the pilot or main valve. The following steps apply to
the typical installation as indicated.
Single-Pilot, Dual-Pilot Regulator or
Wide-Open Monitor
As well as applying to a single-pilot regulator (figure 3), the
steps in this procedure also are valid for a dual-pilot
regulator (figure 4) or a wide-open monitoring installation
(figure 6) and just need to be repeated for each regulator in
such an installation.
1. Slowly close the downstream block valve. If the control
line is downstream of the block valve, also close the hand
valve in the control line.
2. Slowly close the upstream block valve and the hand
valve in the pilot supply line.
3. Slowly open the vent valve in the downstream pipeline.
If the control line is downstream of the block valve, also
open the vent valve in the control line. Permit all pressure
to bleed out.
4. Slowly open the vent valve in the upstream pipeline.
Permit all pressure to bleed out of both the piping and the
pilot.
Working Monitor
1. Slowly close the downstream block valve and the hand
valve in the downstream pressure control line.
2. Slowly close the upstream block valve and the hand
valves in both pilot supply lines.
3. Slowly open all vent valves and permit all pressures to
bleed out of the piping and regulators.
Principle of Operation
The pilot-operated Type 1098-EGR and Type 1098H-EGR
regulators both use inlet pressure as the operating medium,
which is reduced through pilot operation to load the actuator
diaphragm. Outlet or downstream pressure opposes
loading pressure in the actuator and also opposes the pilot
control spring. The operation of each regulator is the same,
and the Type 1098-EGR regulator operation schematic is
shown in figure 7.
12
R
In operation, assume that outlet pressure is below the pilot
control setting. Control spring force on the pilot diaphragm
thus opens the pilot valve plug (Type 6351 pilot) or relay
orifice (Type 61LD pilot), providing additional loading
pressure to the actuator diaphragm. This diaphragm
loading pressure opens the main valve plug, supplying the
required gas to the downstream system.
When downstream demand has been satisfied, outlet
pressure tends to increase, acting on the pilot and actuator
diaphragms. This pressure exceeds the pilot control spring
setting, moving the pilot diaphragm away and letting the
valve plug spring (Type 6351 or Type 61LD pilots) or
bellows (Type 6352 through 6354M pilot) close the pilot
valve plug (unbalanced in the Type 6351 or Type 61LD
pilots but balanced in the Type 6352 through 6354M pilot).
Excess loading pressure on the actuator diaphragm
escapes downstream through the bleed hole (Type 6351
pilot), bleed orifice (Type 61LD pilot), or restriction (Type
6352 through 6354M pilot).
Reduced actuator loading pressure permits the main valve
to close. The combination of main valve spring force and
valve plug unbalance provides positive shutoff of the valve
plug against the port and upper seals.
To protect the Type 1098 or 1098H actuator diaphragm from
excessive differential pressure, all 6300 series and 61LD
pilots have a relief valve that allows loading pressure to
bleed downstream at approximately 25 psi (1.7 bar)
differential across the actuator diaphragm.
A dual-pilot regulator (figure 7) also operates similarly to a
single-pilot regulator. In addition, the large ports of the
standby pilot open to quickly supply additional loading
pressure to the Type 1098 diaphragm. This extra loading
pressure strokes the main valve quickly in order to satisfy
rapid load changes in the boiler system.
A working monitor system (figure 5) reduces pressure and
throttles while the working monitor regulator is in operation.
If the working regulator fails open, the working monitor
regulator takes over the entire pressure reduction function.
The working monitor concept allows observation of the
performance of the first-stage regulator at all times.
As long as the second-stage working regulator maintains
normal downstream pressure, the monitoring pilot stays
wide open. This permits inlet pressure to go straight through
to the working monitor pilot for reduction to actuator loading
pressure.
Downstream pressure is piped back to the monitoring
pilot. As long as the downstream pressure is less than
the monitoring pilot setting, the working pilot controls
the actuator to maintain intermediate pressure. If the
second-stage working regulator fails open, the
downstream pressure increases to the setting of the
monitoring pilot (slightly higher than the original downstream pressure). The monitoring pilot takes control and the
working monitor pilot throttles down the loading pressure to
Types 1098-EGR & 1098H-EGR
16A4297-A
17A9161-A
B1617
Figure 7. Principle of Operation Schematics
the working monitor regulator actuator. This actuator will
move the valve plug and control the downstream pressure
at the emergency level. Thus, downstream equipment is
protected against a major overpressure condition without
disrupting service or venting gas to the atmosphere.
Maintenance
Regulator parts are subject to normal wear and must be
inspected and replaced as necessary. The frequency of
inspection and replacement of parts depends upon the
severity of service conditions or the requirements of local,
state, and federal regulations. Due to the care Fisher takes
in meeting all manufacturing requirements (heat treating,
dimensional tolerances, etc.), use only replacement parts
manufactured or furnished by Fisher. The stem O-rings on
the Type 1098 or 1098H actuator can be lubricated
annually, using the grease fitting (key 28, figure 20). Stem
O-rings can be checked for damage during normal
operation by line pressure leakage or unexpected grease
extrusion from the actuator vent (key 27, figure 20). All
O-rings, gaskets, and seals should be lubricated with a
good grade of general-purpose grease and installed gently
rather than forced into position. Be certain that the
nameplates are updated to accurately indicate any field
changes in equipment, materials, service conditions, or
pressure settings.
WARNING
To avoid personal injury resulting from sudden release of pressure, isolate the regulator from all pressure and cautiously release
trapped pressure from the regulator before
attempting disassembly.
13
R
Types 1098-EGR & 1098H-EGR
BODY FLANGE
CAGE SCREWS INTO
BODY FLANGE
SEAT RING
SCREWS INTO CAGE
W3012-1*
Figure 8. Trim Package Removal
Design EGR Main Valve
Replacing Quick-Change Trim Package
Perform this procedure if the entire trim package (figure 8)
is replaced. Key numbers for both the complete main valve
and its trim package are referenced in figure 11. Some
replacement trim package assembly numbers are listed in
a table in the parts list.
Note
All disassembly, trim change, and reassembly steps in this section may be
performed with the regulator in the main line
and without disconnecting pilot supply or
control lines.
1. Remove the cap screws (key 3) with a cast iron body,
or remove the stud bolt nuts (key 29, not shown) with a steel
body. Pry the body flange (key 2) loose from the valve body
(key 1), and lift out the trim package.
2. Perform any required inspection, cleaning, or maintenance on the exposed surfaces of the valve body or trim
package. Replace the gasket (key 4) or cage O-ring (key
17) as necessary.
3. On a pre-built replacement trim package, check
indicator zeroing by unscrewing the indicator protector (key
19) and seeing if the flange of the indicator nut (key 22) lines
up evenly with the bottom marking on the indicator scale
(key 18). If not, remove the indicator scale and separate the
indicator nut and hex nut (key 8). Hold the indicator scale
against the indicator fitting (key 5) with the scale base
resting against the shoulder of the fitting, and turn the
indicator nut until its flange is aligned with the bottom scale
marking. Then lock both nuts against each other, and install
the indicator scale and protector.
14
W3116
Figure 9. Exploded View of Full-Capacity
Trim Package Assembly
4. Coat the cage seating surfaces of the valve body web
and the body flange seating surfaces of the valve body neck
with a good grade of general-purpose grease. Install the
trim package, and secure it evenly with the cap screws or
stud bolt nuts. No particular trim package orientation in the
body is required.
Replacing Trim Parts
Perform this procedure if inspecting, cleaning, or replacing
individual parts in a trim package. Key numbers are
referenced in figure 11. An exploded view of a standard
full-capacity trim package only is shown in figure 9.
Note
Access to the spring (key 9), flange O-ring
(key 21), travel indicator parts, or optional
travel stop (key 32) in step 1 can be gained
without removing the body flange (key 2).
Types 1098-EGR & 1098H-EGR
1. Remove the indicator fitting (key 5) and attached parts.
Proceed to step 5 if only maintenance on the fitting or
attached parts is performed.
2. Remove the cap screws (key 3) with a cast iron body,
or remove the stud bolt nuts (key 29, not shown) with a steel
body, and pry the body flange loose from the valve body
(key 1).
3. Use the valve body as a holding fixture if desired. Flip
the body flange over, and anchor it on the valve body as
shown in figure 10, removing the pipe plug (key 31) first if
necessary.
4. To gain access to the port seal (key 12), upper seal (key
15), or valve plug parts, unscrew the seat ring (key 13) from
the cage (key 11) and the cage from the body flange. For
leverage, a wrench handle or similar tool may be inserted
into the seat ring slots (figure 10) and a strap wrench may
be wrapped around a standard or a Whisper TrimR cage,
or a soft bar may be inserted through the windows of a
standard cage. To remove the piston ring (key 14) and/or
plug O-ring (key 20), remove the valve plug (key 16) from
the body flange, insert a screwdriver into the precut foldover
area of the piston ring, and unfold the piston ring. Proceed
to step 6 if no further maintenance is necessary.
5. To replace the body flange or gain access to the spring,
indicator stem (key 10), stem O-ring (key 7), spring seat
(key 28), E-ring (key 23), or optional travel stop, remove the
indicator protector (key 19) and indicator scale (key 18).
Since some compression is left in the spring, carefully
remove the flanged nut (key 22) and hex nut (key 8). A
screwdriver may be inserted through the press-fit bushing
(key 6) to remove the stem O-ring without removing the
bushing. If necessary, unscrew the travel stop (if used), and
unclip the E-ring from the indicator stem.
6. Replace and lubricate parts such as the gasket (key 4)
and cage O-ring (key 17) as necessary, making sure that if
the port and upper seals were removed they are installed in
their retaining slots with the grooved sides facing out. Also
lubricate any other surfaces as necessary for ease of
installation. No further main valve maintenance is
necessary if just the indicator fitting and attached parts were
removed.
7. Install the plug O-ring (key 20) and piston ring (key 14)
onto the valve plug. Insert the valve plug into the body
flange, install the cage plus upper seal and O-ring into the
body flange, and then install the seat ring plus port seal into
the cage. Use the valve body as a holding fixture during this
step as shown in figure 10, and insert a wrench handle or
similar tool into the seat ring slots for leverage when
tightening the seat ring and cage.
8. Remove the upside-down body flange if it was
anchored on the body. Coat the cage seating surfaces of the
valve body web and the body flange seating surfaces of the
valve body neck with a good grade of general-purpose
grease. Install the body flange on the body, and secure it
evenly with the cap screws or stud bolt nuts. Except on the
W2772-1
Figure 10. Seat Ring/Cage Removal or Installation
Using Body as Holding Fixture
1-inch body, which does not use it, the pipe plug (key 31)
must be installed in the side tapping of the flange for proper
operation.
9. Make sure that the flange and stem O-rings and the
bushings are installed in the indicator fitting. Orient the
spring seat as shown in figure 11, and attach it with the
E-ring to the slotted end of the indicator stem. Install a travel
stop (if it is used) on the spring seat, and then install the
spring.
10. Being careful not to cut the stem O-ring with the stem
threads, install the indicator fitting down over the indicator
stem until resting on the spring. Install the hex nut and then
the flanged indicator nut on the indicator stem, pushing on
the fitting if necessary to provide sufficient stem thread
exposure. To maintain clearance for indicator part
installation, draw up the spring seat by turning the hex nut
down on the stem until the threads bottom.
11. Install the indicator fitting with attached parts into the
body flange. Back the hex nut off until the spring completely
closes the valve plug against the port and upper seals, as
indicated by stem threads showing between this nut and the
fitting. Hold the indicator scale against the fitting with the
scale base resting against the shoulder of the fitting, and
turn the indicator nut until its flange is aligned with the
bottom scale marking. Then lock both nuts against each
other, and install the indicator scale and protector.
P590 Series Filter
Perform this procedure to clean or replace filter parts in a
standard Type P593-1 or P594-1 filter assembly. Remove
the following as shown in figure 12: filter body (key 1),
machine screw (key 4), gasket (key 7), two flat washers
(key 5), and filter element (key 2).
15
R
Types 1098-EGR & 1098H-EGR
Upon reassembly, one of the flat washers must go between
the filter element and filter head (key 3) and the other must
go between the filter element and gasket. Use a good grade
of pipe thread sealant on the filter head pipe threads as
shown by L.S. in figure 12.
Type 6351 Pilot
Perform this procedure if changing the control spring for one
of a different range, or if inspecting, cleaning, or replacing
any other pilot parts. Pilot key numbers are referenced in
figure 13 and mounting key numbers in figure 15, 16, or 17.
Note
The body assembly (key 1) may remain on
the pipe nipple (key 23, figure 15, or key 39,
figure 16) unless the entire pilot is replaced.
The optional spring case (key 2) for a Type
661 electric remote control drive unit may
remain installed during maintenance.
1. To gain access to the diaphragm assembly (key 7),
control spring (key 9), or spring seat (key 8), loosen the
locknut (key 11, not used with Type 661 mounting), and turn
the adjustment screw (key 10) out until compression is
removed from the spring. Remove the machine screws (key
12), and separate the body assembly from the spring case.
2. Inspect the removed parts, and replace as necessary.
Make sure the registration and bleed holes in the pilot body
are free from debris. After assembly, make sure of the
proper control spring setting according to the Startup
section, and re-mark the spring case if necessary.
3. To replace the valve plug (key 4), remove the body plug
(key 3) and body plug gasket (key 23). Be careful to keep
the valve plug spring (key 6) and valve plug spring seat (key
5) from falling out and possibly getting lost while removing
the valve plug. Inspect the removed parts, and replace as
necessary. Make sure the valve plug seating surfaces are
free from debris.
Type 6352 Through 6354M Pilots
Perform this procedure if changing the control spring for one
of a different range, or if inspecting, cleaning, or replacing
any other pilot parts. Pilot part key numbers are referenced
in figure 14. Mounting key numbers are referenced in figure
15 for single-pilot constructions and in figure 16 or 17 for
dual-pilot constructions.
16
Note
The body (key 1) may remain on the pipe
nipple (key 23, figure 15 or key 39, figure 16)
unless the entire pilot is replaced.
1. To gain access to the diaphragm assembly (key 5),
diaphragm limiter (key 23) if used, control spring (key 6),
restriction (key 22), stem guide (key 8), or spring seat (key
7), remove the closing cap (key 11), loosen the locknut (key
10), and turn the adjusting screw (key 9) counterclockwise
until compression is removed from the spring. Remove the
machine screws (key 14), and separate the body from the
spring case (key 2).
2. Inspect the removed parts, and replace as necessary.
Make sure the restriction and the registration hole in the
body are free from debris. After assembly, make sure of the
proper control spring setting according to the Startup
section, and re-mark the spring case if necessary.
3. To replace the valve plug (key 4) or bellows O-ring (key
17), remove the body plug (key 3) and body plug gasket
(key 12). Be careful to keep the bellows assembly (key 16)
from falling out and possibly getting lost while removing the
valve plug. Inspect the removed parts, and replace as
necessary. Make sure the valve plug seating surfaces are
free from debris.
Type 61LD Pilot and Type 1806 Relief
Valve
Perform this procedure if changing the control spring for one
of a different range, or if inspecting, cleaning, or replacing
relief valve or any other pilot parts. Pilot part key numbers
are referenced in figure 18 and mounting part and relief
valve key numbers in figure 19.
1. Remove the pilot from the pipe nipple (key 14) unless
just the control spring is to be changed.
2. To gain access to the control spring or other internal
parts, remove the closing cap assembly (key 5) and relieve
control spring (key 7) compression by turning the adjusting
screw (key 6) counterclockwise. Change the control spring
and install the adjusting screw and closing cap assembly if
no other maintenance will be performed. Make sure of the
proper control spring setting according to the Installation
and Startup section, and restamp the nameplate if
necessary.
3. For any other internal maintenance, relieve control
spring compression according to step 2. Then remove the
cap screw (key 20) and separate the pilot into three
sections; spring case (key 1), body (key 2), and diaphragm
case (key 3).
Types 1098-EGR & 1098H-EGR
4. To inspect the two diaphragm (keys 14 and 15)
thoroughly, remove the diaphragm nut (key 11), hex nut (key
19), and the upper and lower diaphragm plates (key 16 and
17). The projecting prong in the body may be used as the
restraining member to keep the yoke from turning while
removing the nuts. Also inspect the O-ring (key 12), and
replace any parts as necessary.
5. Take the yoke (key 4) and attached parts out of the body
to examine the disk holder assembly (key 9). Remove the
relay orifice (key 8) to check for clogging and replace if
necessary.
6. To replace the disk holder assembly, first unscrew the
bleed orifice (key 10). Remove it and the associated parts.
Then unscrew the disk holder assembly from the bleed
valve (key 26) to gain access to the relay spring (key 13).
Clean or replace any parts as necessary before
reassembling.
7. Upon reassembly, pay particular attention to the
following assembly suggestions.
a. Before replacing the diaphragm case or spring
case, be sure the yoke assembly is positioned so that it will
not bind or rub on the prong in the relay body.
b. Avoid wrinkling the diaphragms when replacing the
diaphragm case and spring case.
c. Replace the diaphragm case, carefully working the
upper diaphragm (key 14) into the recess in the diaphragm
case. If the diaphragm case rocks with respect to the pilot
body, the diaphragm is probably wrinkled.
d. Replace the spring case, using care to smooth the
lower diaphragm (key 15) evenly into the recess in the pilot
body.
e. Install the eight cap screws, tightening them down
evenly in a crisscross pattern to avoid crushing the
diaphragm. Recommended final torque on these cap
screws in 10 to 12 foot pounds (14 to 16 NSm).
8. After assembly, make sure of the proper control spring
setting according to the Installation and Startup section,
and restamp the nameplate (key 27) if necessary.
9. To gain access to the Type 1806 relief valve (key 17),
disconnect the relief tubing at the connector fitting (key 21)
and unscrew the relief valve. Make sure the spring closes
the ball, or replace the relief valve if necessary. Install the
relief valve back in the pipe tee (key 16) and reconnect the
relief tubing (key 18) and connector fitting.
Type 1098 and 1098H Actuator and Pilot
Mounting Parts
Perform this procedure if changing the actuator or
inspecting, cleaning, or replacing actuator and/or pilot
mounting parts. Actuator part key numbers are referenced
in figure 20, and mounting part key numbers in figure 15, 16,
or 17 unless otherwise indicated.
1. The actuator and pilot(s) may be removed and replaced
as a unit by disconnecting the control line and pilot supply
line.
2. Access to all internal parts except the stem O-rings (key
6) may be gained without removing the bonnet (key 3) or
upper diaphragm case (key 2) from the main valve or the
pilot(s) from the bonnet pipe nipple (key 23, figure 15, or
keys 37 and 39, figure 16). Disconnect the loading tubing
(key 24, figure 15, 16, or 17) from the actuator elbow fitting
(key 25, figure 15, or key 41, figure 16), and with a Type
61LD pilot also disconnect the relief tubing (key 18, figure
19) from the fitting tee.
3. Remove the cap screws (key 10), nuts (key 11), lower
diaphragm case (key 1), diaphragm (key 7), and diaphragm
plate (key 8). To separate the stem (key 12) from the
diaphragm plate (key 8), remove the stem cap screw (key
9).
4. To remove the Type 1098 case O-ring (key 5),
unscrew the four case cap screws (key 4), remove the
upper diaphragm case (key 2), and remove the case O-ring.
To remove the Type 1098 and Type 1098H stem O-rings
(key 6), remove the pilot(s) and pipe nipple(s) if necessary.
Unscrew either the Type 1098 bonnet (key 3) or the Type
1098H upper diaphragm case (key 2), and remove the
O-rings.
5. Lubricate both stem O-rings (key 6) with grease, and
install them in either the Type 1098 bonnet (key 3) or in the
Type 1098H upper diaphragm case (key 2).
For the Type 1098H actuator, thread the upper diaphragm
casing into the main valve body.
For the Type 1098 actuator, lubricate the case O-ring (key
5), and install it in the bonnet (key 3). Line up the holes in
the upper diaphragm casing and the bonnet; insert and
tighten the four case cap screws to secure the parts
together. Thread the bonnet into the main valve body.
6. Secure the diaphragm plate to the stem with the stem
cap screw (key 9). Lay the entire diaphragm, diaphragm
plate, and stem assembly into the lower diaphragm case so
the diaphragm convolution laps up over the diaphragm
plate according to figure 20. Then install the stem slowly up
17
R
Types 1098-EGR & 1098H-EGR
into the bonnet to prevent stem or O-ring damage, and
secure the lower diaphragm case to the upper diaphragm
case with the cap screws and nuts. Tighten the cap screws
and nuts evenly in a crisscross pattern to avoid crushing the
diaphragm.
7. Grease the stem O-rings through the grease fitting (key
28) until excess grease starts coming out the vent (key 27).
8. Install the pipe nipple(s) and pilot(s) if they were
removed during maintenance. Connect the actuator
loading tubing if it was disconnected.
Parts List
Note
Except where indicated, sizes shown are valve body
sizes.
Design EGR Main Valve (figure 11)
Key
Description
Part Number
Parts kit (included are: gasket, key 4; stem O-ring, key 7; port seal,
key 12; piston ring, key 14; upper seal, key 15; cage O-ring, key
17; plug O-ring, key 20; and indicator fitting O-ring, key 21)
2-inch
R63EG X00022
3-inch
R63EG X00032
4-inch
R63EG X00042
6-inch
R63EG X00062
Parts kit, Quick Change Trim Assembly (included are: body flange,
key 2; linear cage, key 11; spring, key 9; valve plug, key 16; seat
ring, key 13; travel indicator, key 10; and standard elastomers)
60 Psi (4.1 bar) spring color green
Cast Iron Body Flange
1-inch
25A3170 X012
2-inch
25A3170 X102
3-inch
25A3170 X152
4-inch
25A3170 X222
6-inch
25A3170 X272
Steel Body Flange
1-inch
25A3170 X422
2-inch
25A3170 X452
3-inch
25A3170 X372
4-inch
25A3170 X482
6-inch
25A3170 X512
125 Psi (8.6 bar) spring color blue
Cast Iron Body Flange
1-inch
25A3170 X032
2-inch
25A3170 X082
3-inch
25A3170 X142
4-inch
25A3170 X192
6-inch
25A3170 X282
Steel Body Flange
1-inch
25A3170 X432
2-inch
25A3170 X382
3-inch
25A3170 X462
4-inch
25A3170 X492
6-inch
25A3170 X342
400 Psi (28 bar) spring color red
Cast Iron Body Flange
1-inch
25A3170 X052
2-inch
25A3170 X112
3-inch
25A3170 X172
4-inch
25A3170 X242
6-inch
25A3170 X312
Steel Body Flange
1-inch
25A3170 X442
2-inch
25A3170 X332
3-inch
25A3170 X472
4-inch
25A3170 X502
6-inch
25A3170 X522
18
Parts Ordering
Each Type 1098-EGR or 1098H-EGR regulator is assigned
a serial number or F.S. number which can be found on the
nameplates (figure 2). Refer to this number when
contacting your Fisher sales office or sales representative
for assistance, or when ordering replacement parts.
When ordering a replacement part, be sure to include the
complete 11-character part number from the following parts
list. Some commonly used trim packages can be ordered
according to the 11-character assembly number given in the
parts kits listed in the parts list.
Key
Description
1
Valve Body
Cast Iron
NPT screwed
1 inch
2 inch
Class 125B FF
1 inch
2 inch
3 inch
4 inch
6 & 8 x 6 inch
Class 250B RF
1 inch
2 inch
3 inch
4 inch
6 & 8 x 6 inch
WCB steel, heat-treated
NPT screwed
1 inch
2 inch
2 inch (NACE)(1)
Class 150 RF
1 inch
1 inch (NACE)
2 inch
2 inch (NACE)
3 inch
3 inch (NACE)
4 inch
4 inch (NACE)
6 inch
6 inch (NACE)
8 x 6 inch
8 x 6 inch (NACE)
Class 300 RF
1 inch
2 inch
2 inch (NACE)
3 inch
3 inch (NACE)
4 inch
4 inch (NACE)
6 inch
6 inch (NACE)
8 x 6 inch
8 x 6 inch (NACE)
Class 600 RF
1 inch
2 inch
2 inch (NACE)
3 inch
3 inch (NACE)
4 inch
4 inch (NACE)
Part Number
34A6351 X012
34A6763 X012
34A6353 X012
34A5694 X012
34A5695 X012
34A5703 X012
34A6999 X012
34A6354 X012
34A5672 X012
34A5657 X012
34A5642 X012
34A7000 X012
34A6352 X012
34A6764 X012
34A6764 X022
34A6355 X012
34A6355 X042
34A6765 X012
34A6765 X022
34A6773 X012
34A6773 X032
34A6776 X012
34A6776 X032
34A6998 X012
34A6998 X032
38A4214 X012
38A4214 X022
34A6754 X012
34A6766 X012
34A6766 X032
34A6774 X012
34A6774 X022
34A6777 X012
34A6777 X032
34A6993 X012
34A6993 X022
38A5825 X012
38A5825 X032
34A6755 X012
34A6767 X012
34A6767 X032
34A6775 X012
34A6775 X022
34A6778 X012
34A6778 X022
1. National Association of Corrosion Engineers (NACE) standard MR-01-75.
Types 1098-EGR & 1098H-EGR
25A3170-C
35A3167-D
26A3800-A
Figure 11. Design EGR Main Valve
Key
Description
1
Valve Body (Continued)
Class 600 RF
6 inch
6 inch (NACE)
8 x 6 inch
8 x 6 inch (NACE)
Socket weld
1 inch
2 inch
Schedule 40 butt weld
1 inch
2 inch
3 inch
4 inch
6 & 8 x 6 inch
Schedule 80 butt weld
1 inch
2 inch
3 inch
4 inch
6 & 8 x 6 inch
Part Number
34A6997 X012
34A6997 X022
39A7068 X012
39A7068 X022
36A3941 X012
36A3945 X012
36A3942 X012
36A3944 X012
36A3947 X012
36A3949 X012
36A3952 X012
36A3943 X012
36A3946 X012
36A3948 X012
36A3950 X012
36A3951 X012
Key
Description
2
Body Flange
Cast iron, ENC(2)
1 inch
2 inch
3 inch
4 inch
6 & 8 x 6 inch
WCB steel, ENC, heat-treated
1 inch
1 inch (NACE)
2 inch
2 inch (NACE)
3 inch
3 inch (NACE)
4 inch
4 inch (NACE)
6 & 8 x 6 inch
6 & 8 x 6 inch (NACE)
Part Number
24A6761 X012
25A3168 X012
24A9034 X012
25A2309 X012
34A8172 X012
24A6779 X012
24A6779 X032
25A2254 X012
25A2254 X022
25A2300 X012
25A2300 X022
24A9032 X012
24A9032 X022
34A7152 X012
34A7152 X022
*Recommended spare part.
2. Part included in trim package assembly can be ordered according to the parts
kit trim package.
19
R
Types 1098-EGR & 1098H-EGR
Key
3
3
4*(2)
5(2)
6(2)
7*
8(2)
9(2)
10(2)
20
Description
Cap Screw, zn pl steel (use w/cast iron body)
1 inch (4 req’d)
2 inch (8 req’d)
3 inch (8 req’d)
4 inch (8 req’d)
6 & 8 x 6 inch (12 req’d)
Stud Bolt, steel (use w/steel body) (not shown)
1 inch (4 req’d)
2 inch (8 req’d)
3 inch (8 req’d)
4 inch (8 req’d)
6 & 8 x 6 inch (12 req’d)
Gasket, composition
1 inch
2 inch
3 inch
4 inch
6 & 8 x 6 inch
Indicator Fitting, pl steel
1 inch
1 inch (NACE)
2, 3, & 4 inch
2, 3, & 4 inch (NACE)
6 & 8 x 6 inch
6 & 8 x 6 inch (NACE)
Bushing
416 stainless steel
410 stainless steel (NACE)
Stem O-Ring
Nitrile(2)
Fluoroelastomer
Hex Nut, pl steel
Spring, steel
20 psi (1.4 bar) maximum drop yellow
2 inch
3 inch
4 inch
6 & 8 x 6 inch
60 psi (4.1 bar) maximum drop green
1 inch
2 inch
2 inch (NACE)
3 inch
3 inch (NACE)
4 inch
4 inch (NACE)
6 & 8 x 6 inch
6 & 8 x 6 inch (NACE)
125 psi (8.6 bar) maximum drop blue
1 inch
1 inch (NACE)
2 inch
2 inch (NACE)
3 inch
3 inch (NACE)
4 inch
4 inch (NACE)
6 & 8 x 6 inch
6 & 8 x 6 inch (NACE)
400 psi (28 bar) maximum drop red
1 inch
2 inch
2 inch (NACE)
3 inch
3 inch (NACE)
4 inch
4 inch (NACE)
6 & 8 x 6 inch
6 & 8 x 6 inch (NACE)
Indicator Stem
Stainless steel
1 inch
2 inch
3 inch
4 inch
6 & 8 x 6 inch
Part Number
1R2811 24052
1A4533 24052
1A4541 24052
1A4857 24052
1U5131 24052
1R2848 31012
1K2429 31012
1A3781 31012
1R3690 31012
1A3656 31012
14A6785 X012
14A5685 X012
14A5665 X012
14A5650 X012
14A6984 X012
14A6758 X012
14A6758 X022
14A9689 X012
14A9689 X042
24A8183 X012
24A8183 X022
14A5677 X012
14A5677 X022
1D6875 06992
1N4304 06382
1A6622 28992
14A6768 X012
14A6771 X012
14A6770 X012
15A2253 X012
14A9687 X012
14A6626 X012
16A5501 X012
14A6629 X012
16A5503 X012
14A6632 X012
16A5506 X012
14A9686 X012
16A5510 X012
14A9680 X012
10B1882 X012
14A6627 X012
16A5995 X012
14A6630 X012
16A5996 X012
14A6633 X012
16A5997 X012
14A9685 X012
16A5999 X012
14A9679 X012
14A6628 X012
16A5499 X012
14A6631 X012
16A5500 X012
14A6634 X012
16A5998 X012
15A2615 X012
16A6000 X012
14A6756 X012
14A6994 X012
14A6995 X012
14A8179 X012
14A6986 X012
Key
Description
10(2) Indicator Stem (Continued)
316 stainless steel (NACE)
1 inch (NACE)
2 inch (NACE)
3 inch (NACE)
4 inch (NACE)
6 & 8 x 6 inch (NACE)
11
Cage
Linear
Cast iron, ENC(2)
1 inch
2 inch
3 inch
4 inch
6 & 8 x 6 inch
WCB steel, ENC, heat-treated
1 inch
1 inch (NACE)
2 inch
2 inch (NACE)
3 inch
3 inch (NACE)
4 inch
4 inch (NACE)
6 inch
6 & 8 x 6 inch (NACE)
Whisper Trim
416 stainless steel
1 inch
2 inch
3 inch
4 inch
6 & 8 x 6 inch
316 stainless steel (NACE)
2 inch (NACE)
3 inch (NACE)
4 inch (NACE)
6 & 8 x 6 inch (NACE)
Quick Opening, cast iron, ENC
1 inch
2 inch
3 inch
4 inch
6 & 8 x 6 inch
12*
Port Seal
Nitrile(2) standard
1 inch
2 inch
3 inch
4 inch
6 & 8 x 6 inch
Fluoroelastomer
1 inch
2 inch
3 inch
4 inch
6 & 8 x 6 inch
Part Number
14A6756 X022
14A6994 X022
14A6995 X022
14A8179 X022
14A6986 X022
24A6783 X012
24A5669 X012
24A5654 X012
24A5639 X012
24A6990 X012
24A6783 X022
24A6783 X032
24A5669 X022
24A5669 X032
24A5654 X022
24A5654 X042
24A5639 X022
24A5639 X032
24A6990 X022
24A6990 X032
24A2043 X012
24A5707 X012
24A5708 X012
24A5709 X012
24A8174 X012
24A5707 X022
24A5708 X032
24A5709 X022
24A8174 X022
37A7211 X012
37A7212 X012
37A7213 X012
37A7214 X012
37A7215 X012
14A6788 X012
24A5673 X012
24A5658 X012
24A5643 X012
14A8175 X012
14A8186 X012
25A7412 X012
25A7375 X012
25A7469 X012
14A6996 X012
13*(2) Seat Ring
416 stainless steel
1 inch, 1-5/16 inch (33 mm) port
2 inch, 2-3/8 inch (60 mm) port
3 inch, 3-3/8 inch (86 mm) port
4 inch, 4-3/8 inch (111 mm) port
6 inch, 7-3/16 inch (183 mm) port
8 x 6 inch 7-3/16 inch (183 mm) port
316 stainless steel (NACE)
1 inch, 1-5/16 inch (33 mm) port (NACE)
2 inch, 2-3/8 inch (60 mm) port (NACE)
3 inch, 3-3/8 inch (86 mm) port (NACE)
4 inch, 4-3/8 inch (111 mm) port (NACE)
6 inch, 7-3/16 inch (183 mm) port (NACE)
8 x 6 inch 7-3/16 inch (183 mm) port (NACE)
24A6781 X022
24A5670 X022
24A5655 X022
24A5640 X022
24A6989 X022
38A4216 X022
14*(2) Piston Ring
1 inch, TFE (clear)
2 inch, TFE (clear)
3 inch, TFE (clear)
4 inch, TFE (clear)
6 & 8 x 6 inch, glass-filled TFE (yellow)
14A6786 X012
14A5675 X012
14A5660 X012
14A5645 X012
14A6985 X022
24A6781 X012
24A5670 X012
24A5655 X012
24A5640 X012
24A6989 X012
38A4216 X012
*Recommended spare part
2. Part included in trim package assembly which can be ordered according to the parts
kit trim package.
Types 1098-EGR & 1098H-EGR
Key
Description
15*
Upper Seal
Nitrile(2) (standard)
1 inch
2 inch
3 inch
4 inch
6 & 8 x 6 inch
Fluoroelastomer
1 inch
2 inch
3 inch
4 inch
6 & 8 x 6 inch
16*(2) Valve Plug, heat-treated
416 stainless steel
1 inch
2 inch
3 inch
4 inch
6 & 8 x 6 inch
316 stainless steel (NACE)
1 inch (NACE)
2 inch (NACE)
3 inch (NACE)
4 inch (NACE)
6 & 8 x 6 inch (NACE)
17*
Cage O-Ring
Nitrile(2) (standard)
1 inch
2 inch
3 inch
4 inch
6 & 8 x 6 inch
Fluoroelastomer
1 inch
2 inch
3 inch
4 inch
6 & 8 x 6 inch
18
Indicator Scale, plastic
1 inch(2)
2 inch(2)
3 inch(2)
4 inch
w/2 inch (51 mm) travel(2)
w/1-1/2 inch (38 mm) travel
6 & 8 x 6 inch(2)
19
Indicator Protector
Zn pl steel
1 & 2 inch(2)
3, 6 & 8 x 6 inch(2)
4 inch(2) w/2 inch (51 mm) travel
Pl steel
4 inch w/1-1/2 inch (38 mm) travel
20*
Plug O-Ring
Nitrile(2) (standard)
1 inch
2 inch
3 inch
4 inch
6 & 8 x 6 inch
Fluoroelastomer
1 inch
2 inch
3 inch
4 inch
6 & 8 x 6 inch
21*
Indicator Fitting O-Ring
Nitrile(2)
1 inch
2, 3, & 4 inch
6 & 8 x 6 inch
Fluoroelastomer
1 inch
2, 3, & 4 inch
6 & 8 x 6 inch
Part Number
14A6789 X012
24A5674 X012
24A5659 X012
24A5644 X012
14A8176 X012
14A8187 X012
25A7413 X012
25A7376 X012
25A7468 X012
14A8185 X012
Key
Description
Part Number
22(2)
23(2)
Flange Nut, pl steel
E-Ring
stainless steel
1577 steel, heat treated (NACE)
Drive Screw, stainless steel (4 req’d)
Flow Arrow, stainless steel
Body Rating Plate, stainless steel (not shown)
Spring Seat
Full capacity trim(2)
zinc plated steel
1 inch
2, 3, & 4 inch
6 & 8 x 6 inch
Heat-treated wrought steel (NACE)
1 inch (NACE)
2 inch, 3 inch, 4 inch (NACE)
6 & 8 x 6 inch (NACE)
Restricted capacity trim, heat-treated,
416 stainless steel
2, 3, & 4 inch
6 inch
2, 3, & 4 inch (NACE)
6 & 8 x 6 inch (NACE)
14A5693 X012
24
25
26
28
14A6780 X012
24A6772 X012
24A9421 X012
24A8182 X012
24A6992 X012
14A6780 X022
24A6772 X032
24A9421 X022
24A8182 X022
24A6992 X022
10A7777 X012
10A7779 X012
14A5688 X012
10A3481 X012
18A2556 X022
10A7778 X012
10A7779 X022
10A3441 X012
10A3483 X012
18A2556 X032
29
31(2)
32
14A6759 X012
14A5678 X012
14A5662 X012
14A5647 X012
14A5662 X012
14A5647 X012
14A8180 X012
14A6769 X012
14A6769 X012
33
34
14A8181 X012
14A8181 X022
1A3682 28982
1V1059 38982
13A2353 X012
14A6982 X012
15A2206 X012
14A8177 X012
14A6982 X022
15A2206 X022
14A8177 X022
14A9678 X012
14A9688 X012
14A9678 X012
14A9688 X012
Hex Nut Steel (use w/steel body)
(not shown)
1 inch (4 req’d)
1C3306 24072
2 inch (8 req’d)
1A3772 24072
3 inch (8 req’d)
1A3760 24072
4 inch (8 req’d)
1A3520 24072
6 & 8 x 6 inch (12 req’d)
1A4409 24072
Pipe Plug
zinc plated steel
1A7675 24662
steel (NACE)
2, 3, or 4 inch (NACE)
1A7675 24012
6 or 8 x 6 inch (NACE)
1B5731 X0012
Travel Stop, galvanized zn pl steel (not used w/full capacity trim)
2 inch
30% capacity
14A9677 X012
70% capacity
14A9676 X012
3 inch,
40% capacity
14A9671 X012
4 inch,
40% capacity
14A9670 X012
6 inch,
40% capacity
14A9682 X012
NACE Tag (not shown) (NACE)
18-8 stainless steel (NACE)
19A6034 X012
Tag Wire (not shown) (NACE)
304 stainless steel (NACE)
1U7581 X0022
14A5664 X012
14A6981 X012
14A5686 X012
1V3269 06562
14A5688 X012
1K8793 06992
14A8188 X012
14A5686 X022
1V3269 X0042
10A3441 X012
1V5476 06382
10A8931 X012
10A3800 X012
1F2629 06992
10A0811 X012
1R7276 06382
1P4877 06382
AJ5004-B
A2135-1
Figure 12. Standard P590 Series Filter Assembly
*Recommended spare part
2. Part included in trim package assembly which can be ordered according to the parts
kit trim package.
21
R
Types 1098-EGR & 1098H-EGR
34A6635-B
32A6985-A
Figure 13. Type 6351 Pilot Assembly
Key
Description
Part Number
Standard P590 Series
Filter (figure 12)
1
2*
3
4
5
7*
11
12
Filter Body
Type P594-1, brass
Type P593-1,
aluminum
aluminum (NACE)
Filter Element,
cellulose
cellulose (NACE)
Filter Head
Type P594-1, brass
Type P593-1,
aluminum
aluminum (NACE)
Machine Screw
Type P594-1, brass
Type P593-1,
aluminum
aluminum (NACE)
Washer (2 req’d)
Type P594-1, brass
Type P593-1,
aluminum
aluminum (NACE)
Gasket, composition
NACE Tag (Type P593-1 only) (NACE)
18-8 stainless steel (not shown)
Tag Wire (Type P593-1 only) (NACE)
303 stainless steel (NACE)
Type 6351 Pilot
(figure 13)
1
2
22
1E3124 14012
Key
Description
3
Body Plug
Aluminum
1B7975 09032
Brass
1B7975 14012
316 Stainless steel
1B7975 35072
Stainless steel (NACE)
1B7975 09032
Valve Plug
Nitrile w/brass stem
1D5604 000A2
Nitrile w/stainless steel stem
1D5604 000B2
Fluoroelastomer w/brass stem
1N3798 71662
Fluoroelastomer w/stainless steel stem
1N3798 000C2
Inner Valve, 304 stainless steel/nitrile (NACE)
1D5604 000B2
Valve Plug Spring Seat
Aluminum (use w/brass stem)
1E5322 11032
316 stainless steel (use w/stainless steel stem)
1L2511 35072
316 stainless steel (NACE)
1L2511 35072
Valve Plug Spring,
stainless steel
1B7979 37022
heat-treated alloy 600 (UNS N07750)
19A2860 X012
Diaphragm Assembly (includes zn pl steel diaphragm plate)
Nitrile w/aluminum pusher post
1B7980 000B2
Fluoroelastomer w/aluminum pusher post
1B7980 000C2
Nitrile w/stainless steel post
1B7980 X00A2
Nitrile diaphragm w/stainless steel pusher post &
diaphragm plate (NACE)
1B7980 X0112
4*
1E3124 09012
1E3124 09012
1E3126 06992
1E3126 06992
4
5
1E3125 14012
1E3125 09012
1E3125 09012
6
1J5002 18992
7*
1J5002 09012
1J5002 09012
1J5000 18992
1J5000 10062
1J5000 10062
1F8268 04022
8
9
19A6034 X012
1U7581 X0022
Parts kit (included are: valve plug, key 4;
valve spring, key 6; diaphragm assembly, key 7;
body plug gasket, key 23 and for the P590 Series Filter,
filter element, key 2; and gasket, key 7)
R6351 X00012
Body Assembly
Aluminum w/brass bushing
1B7971 X0092
Aluminum w/315 stainles steel bushing (NACE)
1B7971 X0232
Brass w/brass bushing
1B7971 X0112
316 stainless steel w/303 stainless steel bushing
1B7971 X0122
Spring Case, aluminum
w/untapped vent (standard)
2B7974 08012
w/1/4 inch NPT tapped vent
(for use w/Type 661 mtg)
13A0166 X012
10
11
12
22
22
23*
24
25
35
42
42
Part Number
Upper Spring Seat, zn pl steel
1B7985 25062
Control Spring, Cd pl steel
3 to 20 psig (0.21 to 1.4 bar) range, green
1B9860 27212
5 to 35 psig (0.34 to 2.4 bar) range,cadmium
1B7883 27022
35 to 100 psig (2.4 to 6.9 bar) range, red
1K7485 27202
Adjusting Screw, pl steel (not used
w/Type 661 mtg)
10A2099 X012
Locknut, zn pl steel (not used w/Type 661 mtg)
1A9463 24122
Machine Screw, pl steel (6 req’d)
1B7839 28982
Body Inlet Pipe Nipple,
galvanized zn pl steel (use w/P590 Series filter)
1C4882 26232
steel (NACE)
1C4882 X0032
Spring Case Vent Pipe Nipple,
galvanized zn pl steel (use w/Type 661 mtg)
1C6789 26232
Body Plug Gasket, composition
1C4957 04022
P590 Series Filter (parts listed under separate heading)
Type P594-1, brass & cellulose (standard)
AJ5004 000A2
Type P593-1, aluminum & cellulose
AJ5004 T0012
Sealant Loctite N. 516 (one pint can, not supplied)
1M1137 X0012
Type Y602-13 Vent Assembly, zinc
w/stainless steel screen (use w/Type 661 mtg)
17A6572 X042
Relief Valve Assembly Aluminum/stainless steel
25 psi (1.7 bar differential)
16A5929 X022
Aluminum/302 stainless steel (NACE)
25 psi (1.7 bar differential)
16A5929 X042
*Recommended spare part
Types 1098-EGR & 1098H-EGR
35A6235-A
B1403
35A8889-A
A2950
Figure 14. Type 6352 Through 6354M Pilot Assemblies
Key
Description
Key
Description
6
Control Spring
Zn pl steel
Type 6352
2 inch wc to 2 psig (5 to 140 mbar), yellow
Type 6352
2 to 10 psig (0.14 to 0.69 bar), black
2 inch wc to 2 psig (5 to 140 mbar),
yellow (NACE)
2 inch wc to 2 psig (5 to 140 mbar),
black (NACE)
Type 6353
3 to 40 psig (0.21 to 2.8 bar), yellow
35 to 125 psig (2.4 to 6.9 bar), red
Type 6354L
85 to 200 psig (5.9 to 14 bar), blue
Type 6354M
175 to 220 psig (12 to 15 bar), blue
17-4PH stainless steel
Type 6354H
200 to 300 psig (14 to 21 bar), green
Spring Seat
Zn pl steel (for Types 6352 & 6353)
Pl steel (for Type 6354L, 6354M, or 6354H)
Stem Guide
416 stainless steel, heat-treated
410 stainless steel (NACE)
Part Number
Type 6352 Through
6354M Pilot (figure 14)
1
2
3
4*
5*
Parts kit (included are: valve plug, key 4;
diaphragm assembly, key 5; body plug gasket, key 12;
bellows O-ring, key 17; closing cap gasket, key 20;
and for the P590 Series Filter, filter element, key 2;
and gasket, key 7)
Type 6352
R6352 X00012
Type 6353
R6353 X00012
Type 6354
R6354 X00012
Body
Aluminum
35A6228 X012
Brass
35A6224 X012
Steel
35A6226 X012
316 stainless steel
39A5971 X012
Aluminum (NACE)
35A6228 X012
316 stainless steel (NACE)
39A5971 X012
Spring Case
Aluminum
Use w/closing cap
25A6220 X012
Use w/o closing cap
15A1581 X012
Use w/Type 661 mtg
26A6790 X012
Brass
25A6790 X012
Steel
25A6223 X012
316 Stainless steel
28A9277 X012
Aluminum (NACE)
25A6220 X012
316 stainless steel (NACE)
28A9277 X012
Body Plug
Aluminum
15A6221 X012
Brass
15A6221 X022
Steel
15A6221 X032
316 stainless steel
15A6221 X042
Aluminum (NACE)
15A6221 X012
316 stainless steel (NACE)
15A6221 X042
Valve Plug & Stem Assembly,
nitrile disk w/stainless steel stem
15A6207 X012
316 stainless steel stem (NACE)
15A6207 X052
Diaphragm Assembly
Type 6352 w/natural rubber diaphragm
15A6216 X012
Fluoroelastomer diaphragm (NACE)
15A6216 X132
Type 6353 w/nitrile diaphragm
15A6216 X022
Type 6354L, 6354M, or 6354H w/neoprene
diaphragm
15A6216 X032
*Recommended spare part
7
8
9
10
11
12*
13
14
Part Number
14A9672 X012
14A9673 X012
14A9672 X012
14A9673 X012
1E3925 27022
1K7485 27202
1L3461 27142
1L3461 27142
15A9258 X012
1B7985 25062
1K1558 28982
15A6222 X012
15A6222 X022
Adjusting Screw
Zn pl steel (for Types 6352 & 6353)
1H3050 28982
Pl steel (for aluminum spring case w/closing cap &
Type 6354L, 6354M, or 6354H)
1B7986 28982
Locknut, zn pl steel
1A9463 24122
Closing Cap
Aluminum
1H2369 X0012
Brass
1H2369 14012
Steel
1H2369 X0022
316 stainless steel
1H2369 X0032
Body Plug Gasket
Composition
1C4957 04022
Composition (NACE)
1C4957 04022
Type Y602-12 Vent Assembly, plastic
w/stainless steel screen
Machine Screw (6 req’d)
Steel
Pl steel
For aluminum spring case w/o closing cap
For Type 661 mtg
27A5516 X012
1H4217 28992
1H2676 28982
1E9752 28982
23
R
Types 1098-EGR & 1098H-EGR
Key
Description
15
Relief Valve Assembly
Aluminum/stainless steel
25 psi (1.7 bar) differential
16A5929 X052
Aluminum/302 stainless
steel for 25 psi (1.7 bar) differential (NACE)
16A5929 X042
Bellows Assembly, stainless steel/ nickel
15A6202 X012
Bellows O-Ring, nitrile
1D6825 06992
P590 Series filter (parts listed under separate heading)
Type P594-1, brass & cellulose (standard)
AJ5004 000A2
Type 593-1, aluminum & cellulose
AJ5004 T0012
Closing Cap Gasket, composition
15A6218 X012
Pipe Nipple
Galvanized zn pl steel
1C4882 26232
Noncorrosive, NACE steel (NACE)
1C4882 X0032
Corrosive, 316 stainless steel (NACE)
1C4882 X0042
Restriction, pl steel (not used for low-gain construction)
Standard gain (indicated by S stamped on pilot body),
No. 51 drill size or 0.067 inch (1.7 mm)
diameter, green
17A2030 X012
High gain for narrower proportional bands (indicated by
H stamped on pilot body), No. 57 drill size or
0.043 inch (1.09 mm) diameter, red
17A2029 X012
Restriction, NACE construction 316 stainless steel (not used for
low-gain construction) Standard gain (indicated by S stamped on
pilot body), No. 51 drill size or 0.067 inch (1.7 mm) diameter,
green color code
17A2030 X022
High gain for narrower proportional bands (indicated by
H stamped on pilot body), No. 57 drill size or 0.043 inch
(1.09 mm) diameter, red color code
17A2029 X022
Diaphragm Limiter, aluminum (for Types 6354H or
6354M)
15A9259 X012
NACE Tag (Type 6352 only), NACE
18-8 stainless steel not shown)
19A6034 X012
Tag Wire (Type 6352 only), NACE
303 stainless steel (not shown)
1U7581 X0022
16
17*
19
20*
21
22
22
23
26
27
Part Number
Key
Description
12*
13
14*
15*
16
17
18
19
20
22
23
O-ring, nitrile
1B8855 06992
Relay Spring, 302 stainless steel
1E6436 37022
Upper Diaphragm, Nitrile
1B8852 02052
Lower Diaphragm, Nitrile
1B8860 02052
Upper Diaphragm Plate, Steel
1B9893 25072
Lower Diaphragm Plate, Steel
1B9894 25072
Spring Seat, steel, cd pl
1B8862 25072
Hex Nut, steel, cd pl
1A3403 24122
Cap Screw, steel, (8 req’d)
1B9896 24052
Pipe Plug, steel (not used with Type 661 mtg)
1A6495 28992
Vent Screen, alloy 400 (used only with
Type 661 mtg)
0L0783 43062
Pipe Nipple, steel zinc pl
1C4882 26232
P590 Series filter (parts listed under separate heading)
Type P594-1, brass & cellulose (standard)
AJ5004 000A2
Type 593-1, aluminum & cellulose
AJ5004 T0012
Bleed Valve, 416 stainless steel
1H9516 35132
Nameplate, aluminum
14A1711 X012
Gasket, neoprene
1P7533 06992
Pipe Plug, cast iron (2 req’d)
1A3619 19012
Spring Seat, steel (used only with Type 661 mtg)
1J4284 24092
Drive Screw, steel, pl (2 req’d)
1E9530 28982
24
25
26
27
28*
30
35
50
Part Number
Type 61LD Pilot
(figure 18)
1
2
3
4
5
5A
5B
5C
5D
6
7
8
9
10
11
24
Parts kit (included are: relay orifice, key 8; disk holder assembly,
key 9; bleed orifice, key 10; O-ring, key 12 relay spring, key 13;
upper relay diaphragm, key 14; lower relay diaphragm, key 15;
bleed valve, key 26; and
closing cap gasket, key 28)
R61LD X00012
Spring Case, cast iron
1B9839 19012
Body, cast iron
2J5819 19012
Diaphragm Case, Cast iron
2C5186 19012
Yoke
Zinc
1D6625 44012
Cast iron
1B9840 19012
Closing Cap Assembly (includes keys
5a, 5b, 5c and 5d)
AD5586 000A2
Screen, stainless steel (not used with
Type 661 mtg)
1B6335 38392
Snap Ring, stainless steel (not used
with Type 661 mtg)
1B6336 38992
Machine Screw, steel (not used with
Type 661 mtg)
1D5589 28992
Closing Cap, zinc (not used with
Type 661 mtg)
2D3715 44012
Adjusting Screw, zinc (not used with
Type 661 mtg)
1B5379 44012
Control Spring, steel pl
1/4-2 psig (0.017-0.138 bar) range, red spring
1B8863 27022
1-5 psig (0.069-0.34 bar) range, yellow spring
1J8578 27022
2-10 psig (0.138-0.69 bar) range, blue spring
1B8864 27022
5-15 psig (0.34-1.02 bar) range, brown spring
1J8579 27142
10-20 psig (0.69-1.4 bar) range, green spring
1B8865 27022
Relay Orifice, stainless steel
1C5201 35032
Disk Holder Assembly
Brass/nitrile (standard)
1B8868 000A2
Stainless steel/nitrile (corrosive)
1B8868 000B2
Bleed Orifice, stainless steel
1B8873 35032
Diaphragm Nut
Brass
1B9895 14012
Stainless Steel
1B9895 35072
14A5706-A
A2124-1
Figure 15. Single-Pilot Mounting Parts
Standard Single-Pilot
Mounting Parts
(figures 15 & 19)
Note
Key numbers 14 through 22 are only for mounting a Type
61LD pilot.
14
15
16
17
18
Pipe Nipple, galvanized zn pl steel
Pipe Nipple, galvanized zn pl steel
Pipe Tee, Malleable iron
Type 1806 Relief Valve, SST ball and spring
Brass body and spring seat
Aluminum body and spring seat
Stainless steel body and spring seat
Relief Tubing
Copper
Aluminum
Steel
Stainless steel
*Recommended spare part
1F7315 26012
1F7302 26012
1A4736 21992
AF5001 X00A2
AF5001 X0012
AF5001 X0022
14A9457 X012
14A9457 X032
14A9457 X022
14A9457 X042
Types 1098-EGR & 1098H-EGR
47A7118-B
47A7119-A
C0513
Figure 16. Dual-Pilot Mounting Parts for Boiler Fuel Installations
25
R
Types 1098-EGR & 1098H-EGR
37A0565-C
A2949-1
Figure 17. Dual-Mounting Parts for Working Monitor Regulator
Key
Description
19
Tee Fitting
Brass
Steel
Stainless steel
Loading Tubing
Copper
Aluminum
Steel
Stainless steel
Connector Fitting
Brass
Aluminum
Steel
Stainless steel
Elbow Fitting
Brass
Aluminum
Steel
Stainless steel
Pipe Nipple, galvanized zn pl steel
Size 30 or 40 actuator
Size 70 actuator
Pipe Nipple, NACE construction
Size 30 or 40 actuator
Aluminum
316 stainless steel
Size 70 actuator
Aluminum
316 stainless steel
Loading Tubing
Steel (standard)
Size 30 or 40 actuator
Size 70 actuator
Stainless steel
Size 30 or 40 actuator
Size 70 actuator
20
21
22
23
24
Part Number
14A9056 X012
14A9056 X032
14A9056 X042
Key
24
24A9459 X012
24A9459 X032
24A9459 X022
24A9459 X042
1H8682 18992
1J9886 11992
1J1395 28992
1L9272 38992
1L2497 18992
1K5654 11992
1J1396 28992
1N6856 38992
1C2100 26232
19A7858 X012
1C2100 X0022
1C2100 X0012
19A7858 X022
19A7858 X032
14A9458 X022
050021 2401W
14A9458 X042
050198 3807W
25
26
Part Number
Boiler Fuel Installation
Dual-Pilot Mounting
Parts (figure 16)
16
21
24
30
31
32
26
Description
Loading Tube (Continued)
Copper
Size 30 or 40 actuator
14A9458 X012
Size 70 actuator
050021 1701W
Aluminum
Size 30 or 40 actuator
14A9458 X032
Size 70 actuator
050021 1107W
NACE construction
Size 30 or 40 actuator
Aluminum
14A9458 X032
304 stainless steel
14A9458 X042
Size 70 actuator (specify main valve type number and body size)
Aluminum
050021 1107W
304 stainless steel
050198 3807W
Elbow Fitting (2 req’d)
Pl steel (standard)
15A6002 X472
Stainless steel
15A6002 X612
Brass
15A6002 X162
Aluminum
15A6002 X402
Aluminum (NACE)
15A6002 X402
316 stainless steel (NACE)
15A6002 XC72
Pipe Bushing
Malleable iron
1B2928 21992
Steel (NACE)
1B2928 X0032
Pipe Tee, galvanized malleable iron (4 req’d)
Tubing Connector, pl steel (3 req’d)
Tubing, steel
Mounting Bracket, steel (for Type 621-107)
Cap Screw, zn pl steel (2 req’d)
(for Type 621-107)
Cap Screw, zn pl steel (2 req’d)
(for Type 621-107)
1A4736 21992
15A6002 X462
050021 2401W
1H3504 X0012
1A5828 24052
1K7646 24052
Types 1098-EGR & 1098H-EGR
Key
37
38
39
41
43
44
45
47
48
49
Description
Pipe Nipple, galvanized zn pl steel
Pipe Nipple, galvanized zn pl steel
(5 req’d for Type Y600P; 4 req’d for
Type 621-107)
Pipe Nipple, galvanized zn pl steel
Tubing Elbow pl steel (3 req’d for Type
Y600P; 5 req’d for Type 621-107)
Pipe Bushing, pl steel (4 req’d)
Pipe Bushing, steel
Pipe Bushing, galvanized zn pl steel
Female Union, malleable iron
Pipe Plug, steel
Led-Plate(3) No. 250 Sealant, 5 lb (2.3 kg) can
(not furnished w/regulator)
Working Monitor DualPilot Mounting Parts
(figure 17)
22
24
30
31
32
34
35
36
Tubing Elbow, pl steel
Tubing, steel
Mounting Bracket, steel
Cap Screw, zn pl steel (2 req’d)
Cap Screw, zn pl steel (2 req’d)
Flared Nut, zn pl steel
Tubing Connector, brass
Pipe Bushing, steel (2 req’d)
Type 1098 and 1098H
Actuators (figure 20)
1
2
3
Part Number
1F7315 26012
1K2015 26022
1C5599 26232
15A6002 X472
1C3790 26232
1A3424 28992
1K2895 28992
1B5405 21992
1A3692 24492
1M5240 06992
15A6002 X472
050021 2401W
1H3504 X0012
1A5828 24052
1K7646 24052
1D6921 24272
1D6922 14012
1A3424 28992
Parts kit (included are: casing O-ring, key 5; stem O-ring,
key 6; and diaphragm, key 7)
Size 30
R1098 X00302
Size 40 (standard)
R1098 X00402
Size 70
R1098 X00702
Lower Diaphragm Case
Type 1098
Size 30, zn pl steel
2E8007 28992
Size 40, steel
24A7155 X012
Size 70, zn pl steel
2N1266 28992
Type 1098H
Size 30, WCB steel
36A8537 X012
NACE Construction
Type 1098
Size 30, heat-treated zinc plated steel (NACE)
2E8007 X0022
Size 40, NACE steel
24A7155 X032
Size 70, NACE steel
2N1266 X0022
Type 1098H (size 30 only), heat-treated
WCB steel (NACE)
36A8537 X022
Upper Diaphragm Case
Type 1098
Size 30
Steel
25A7340 X012
Wrought steel (NACE)
25A7340 X022
Size 40
zinc plated steel
24A5680 X012
Wrought steel (NACE)
24A5680 X022
Size 70
zinc plated steel
25A2607 X012
Wrought steel (NACE)
25A2607 X022
Type 1098H
Size 30
WCB steel
36A8535 X012
Heat-treated WCB steel (NACE)
36A8535 X022
Bonnet (for Type 1098 only)
Steel
24A5681 X012
Wrought steel (NACE)
24A5681 X022
*Recommended spare part
3. Trademark of Armite Laboratories.
Key
Description
4
Cap Screw (for Type 1098 only)
Zinc plated steel
B7M zinc plated steel (NACE)
Casing O-Ring
Nitrile (not req’d for Type 1098H)
Fluoroelastomer
Stem O-Ring (2 req’d)
Nitrile
Fluoroelastomer
Diaphragm, nitrile
Size 30
Size 40
Size 70
Diaphragm Plate
Cast iron
Size 30
Size 40
Size 70
Heat-treated WCB steel (NACE)
Type 1098
Size 30
Size 40
Size 70
Type 1098H (size 30 only)
Stem Cap Screw
Plated steel
Size 30 or 40
Size 70
Grade 8 black steel (NACE)
Type 1098 (NACE)
Size 30 or 40 (NACE)
Size 70 (NACE)
Type 1098H (size 30 only) (NACE)
Cap Screw, zn pl steel
Type 1098
Size 30 (12 req’d)
Size 40 (16 req’d)
Size 70 (28 req’d)
Type 1098H
Size 30 (12 req’d)
Hex Nut, zn pl steel
Type 1098
Size 30 (12 req’d)
Size 40 (16 req’d)
Size 70 (28 req’d)
Type 1098H
Size 30 (12 req’d)
Stem
17-4PH stainless steel
1 inch
2 inch
3 inch
4 inch
6 inch
8 x 6 inch
316 stainless steel (NACE)
1 inch main valve body (NACE)
2 inch main valve body (NACE)
3 inch main valve body (NACE)
4 inch main valve body (NACE)
6 inch main valve body (NACE)
8 x 6 inch main valve body (NACE)
Nameplate, stainless steel (not shown)
Size 30
Size 40
Size 70
NACE Tag, 18-8 stainless steel (not shown)
Type Y602-12 Vent Assembly
Tag Wire, 303 stainless steel
(not shown) (NACE)
Grease Fitting, steel
5*
6*
7*
8
9
10
11
12
13
26
27
27
28
Part Number
1D5287 24952
1D5298 X0012
1F9141 06992
1F9141 X0012
1C7822 06992
1K7561 06382
2E7919 02202
2E6700 02202
2N1269 02202
15A7339 X012
14A5682 X012
15A2606 X012
19A7317 X012
19A7318 X012
19A7319 X012
19A7317 X012
1L5454 28982
11B1768 X012
1L5454 X0012
11B1768 X022
1L5454 X0012
1E7603 24052
1E7603 24052
1A5828 24052
1A9155 24052
1A3465 24122
1A3465 24122
1A3465 24122
1A3403 24122
14A6757 X012
14A5683 X012
14A5663 X012
14A5648 X012
14A6987 X012
18A4217 X012
14A6757 X022
14A5683 X022
14A5663 X022
14A5648 X022
14A6987 X022
18A4217 X022
25A8373 X012
24A5704 X012
25A8374 X012
19A6034 X012
27A5516 X012
1U7581 X0022
1L8478 28992
27
R
Types 1098-EGR & 1098H-EGR
AD5586
A2131
20A6328-C
20A6326-C
Figure 18. Type 61LD Pilot Assembly
14A5705-A
Figure 19. Type 61LD Pilot and Type1806 Relief Valve
Mounting
34A5692-A
36A8540-A
Figure 20. Type 1098 and 1098H Actuator Assemblies
While this information is presented in good faith and believed to be accurate,
Fisher Controls does not guarantee satisfactory results from reliance upon such
information. Nothing contained herein is to be construed as a warranty or guarantee, express or implied, regarding the performance, merchantability, fitness
R
28
Printed in U.S.A.
Fisher Controls
or any other matter with respect to the products, nor as a recommendation to
use any product or process in conflict with any patent. Fisher Controls reserves
the right, without notice, to alter or improve the designs or specifications of the
products described herein.
For information, contact Fisher Controls:
Marshalltown, Iowa 50158 USA
Cernay 68700 France
Sao Paulo 05424 Brazil
Singapore 0512
Types 1098-EGR & 1098H-EGR
May 1997
Errata Sheet
for
Type 1098-EGR & 1098H-EGR Pilot-Operated Regulators,
Form 5084, May 1987
This errata sheet covers updated information on the Type 1098-EGR Pilot Operated Regulators. Each bullet
on this errata sheet refers to the Type 1098 and 1098H Actuator and Pilot Mounting Parts section on page 17
and figure 20 on page 28 of the Type 1098-EGR & 1098H-EGR Pilot-Operated Regulators instruction manual
Form 5084.
The Type 1098 bonnet has been redesigned to incorporate a wiper ring, bearings and larger casing O-ring. This
redesign effects all body sizes and actuator sizes (size 30, 40, 70 and 30H) for the Type 1098.
When doing maintenance on the Type 1098 original bonnet design and the bonnet redesign, the repair kits
R1098X00302, R1098X00402 and R1098X00702 will include all the necessary parts to repair both designs.
When repairing the original design, key numbers 56 (bearings) and 57 (wiper ring) will not be needed (refer to
figure 20).
D Replace the steps in the section “Type 1098 and 1098H Actuator and Pilot Mounting Parts” on page 17 with
the following steps.
2. Access to all internal parts except the stem O-rings, bearings and wiper (keys 6, 56, 57) may be gained without
removing the bonnet (key 3) or upper diaphragm case (key 2) from the main valve or the pilot(s) from the bonnet
pipe nipple (key 23, figure 15, or keys 37 and 39, figure 16). Disconnect the loading tubing (key 24, figure 15, 16,
or 17) from the actuator elbow fitting (key 25, figure 15, or key 41, figure 16), and with a Type 61LD pilot also disconnect the relief tubing (key 18, figure 19) from the fitting tee.
Second paragraph of step 4.
the Type 1098 and Type 1098H stem O-rings (key 6), remove the pilot(s) and pipe nipple(s) if necessary. Unscrew either the Type 1098 bonnet (key 3) or the Type 1098H upper diaphragm case (key 2), and remove the wiper ring, bearings and O-rings.
To remove
5. Lubricate both stem O-rings (key 6), and wiper ring (key 57) and install them with the stem bearings (key 56) in
either the Type 1098 bonnet (key 3) or in the Type 1098H upper diaphragm case (key 2).
D Add the diagram on the following page to figure 20 on page 28 of the instruction manual.
EFisher Controls International, Inc. 1997; All Rights Reserved
Fisher, Fisher-Rosemount, and Managing The Process Better are marks owned by Fisher Controls International, Inc. or Fisher-Rosemount Systems, Inc.
T h e c o n te n ts o f th is p u b lic a tio n a re p re s e n te d fo r in fo rm a tio n a l p u rp o s e s o n ly , a n d w h ile e v e ry e ffo rt h a s b e e n m a d e to e n s u re th e ir a c c u ra c y , th e y a re n o t to b e c o n s tru e d a s w a rra n tie s o r g u a ra n te e s , e x p re s s
o r im p lie d , re g a rd in g th e p ro d u c ts o r s e rv ic e s d e s c rib e d h e re in o r th e ir u s e o r a p p lic a b ility . W e re s e rv e th e rig h t to m o d ify o r im p ro v e th e d e s ig n s o r s p e c ific a tio n s o f s u c h p ro d u c ts a t a n y tim e w ith o u t n o tic e .
For information,
contact
Fisher Controls:
Marshalltown, Iowa 50158 USA
28320 Gallardon France
Sao Paulo 05424 Brazil
Singapore 0512
Printed in U.S.A.
Types 1098-EGR & 1098H-EGR
A6968
TYPE 1098 ORIGINAL
Key
Description
3
5
6
Bonnet, Steel
Casing O-ring, Nitrile
Stem O-ring (2 req’d)
Nitrile
Fluoroelastomer
DESIGN
TYPE 1098 REDESIGN
Part Number
24A5681X012
1F914106992
Key
Description
3
5
6
Bonnet, Steel
Casing O-ring, Nitrile
Stem O-ring (2 req’d)
Nitrile
Fluoroelastomer
Bearing, Nylon (2 req’d)
Wiper Ring
1C782206992
1K756106382
56
57
Figure 20. Type 1098 and 1098H Actuator
2
Assemblies
Part Number
33B0301X012
1F358106992
1C782206992
1K756106382
17A7112X012
15A6002XN12
August 1999
Errata Sheet
for
Types 1098-EGR & 1098H-EGR Pilot-Operated Regulators
Form 5084, May 1987
The body plug on the Type 6351 pilot has been redesigned. The body plug gasket and body plug previously used
on the Type 6351 pilot have been replaced with a new body plug assembly. The body plug assembly includes the
body plug and the body plug O-ring. Replace or add the following information on the Types 1098-EGR & 1098HEGR Instruction Manual, form 5084.
.Replace
step 3 of the Type 6351 Pilot section
on page 16 with the following:
3. To replace the valve plug (key 4), remove body plug (key 3 or 3A) to let the plug spring (key 6) and plug/stem
assembly (key 4) drop freely from the body (key 1). Inspect the removed parts, replace if neccessary. Make sure
the plug seating surfaces are free from debris. Inspect body plug O-ring (key 38), replace if necessary. Type 6351
pilots manufactured before May 1999 need to have the body plug gasket (key 23) and the body plug (key 3)
replaced with a new body plug assembly (key 3), which includes the body plug (key 3A) and the body plug O-ring
(key 38). Install the body plug O-ring (key 38) over the body plug (key 3A). Stack the plug spring (key 6) and the
plug/stem assembly on the body plug assembly (key 3), and install the body plug assembly with stacked parts
into the body (key 1).
.Replace
the following
Parts List information
Type 6351 Pilot (figure
Key
3
beginning
Part Number
Parts Kit (includes keys 3, 4, 6, 7, and
P590 Series filter, key 2)
R6351XOOO12
Body Plug Assembly (includes body plug
and O-ring)
Aluminum body plug
with nitrile O-ring
with fluoroelastomer O-ring
Stainless steel body plug
with nitrile O-ring
with fluoroelastomer O-ring
the following
Parts
Key
Description
23.
Body Plug Gasket, composite
List
18B6542XO22
18B6542XO42
1886542XO52
1886542XO62
information
on page
@Fisher Contro~ International,
For
the products
information,
Marshalltown,
28320
1C495704022
Sao
Paulo
Singapore
Printed
or servK:es descrtJed herein or their use or applicability; We reserve
Iowa
05424
International,
Inc or Fisher-Rosemount
Systems,
Inc
Inc., 1999; AI Rights Reserved
contact
Gallardon,
22:
Part Number
Fisher, Fisher-Rosemount,
and Managing The Process Better are marks owned by Fisher Controls
All other marks are the property of their respective owners.
regard;!g
below:
13)
Description
.Delete
on page 21 with the information
Fisher
50158
the right to modify or improle
the designs or specif~tkms
of such products at any tine
without notK:e.
Controls:
USA
France
Brazil
128461
A
lA"".", w""
..1~lsovINKI-
in u s
"
recycled paper
FISHER.RDSEMDUNT'"
Managing
TheProcessBetter:
.Replace
theType
63511nterior
Assembly
in figure 13 on page 22 with the figure below:
NEW TYPE 67 OR 67R ASSEMBLY
DRAWING
SHOWING
NEW BODY PLUG AND BODY PLUG GASKET
OLD TYPE
SHOWING
OLD
67 OR 67R ASSEMBLY
BODY
PLUG
AND
2
BODY
DRAWING
PLUG
GASKET
Types 1098-EGR and 1098H-EGR
July 2002
Errata Sheet
for
Type 1098-EGR and 1098H-EGR Pilot-Operated Regulators
Form 5084, May 1987
This errata sheet covers the redesign of the Type 1098-EGR and 1098H-EGR travel indicator assemblies. This
redesign has been incorporated into all body sizes, regardless of actuator size. The Type 1098-EGR and 1098HEGR travel indicator assemblies now incorporate a redesigned O-ring retainer (key 6), TFE back-up rings (key 36),
and an additional indicator fitting (key 35).
When performing maintenance on the original Type 1098-EGR or 1098H-EGR body flange, travel indicator replacement is recommended. The redesigned travel indicator assembly is incorporated into all Quick-Change Trim kits
(e.g. 25A3170X012) and on the Travel Indicator Kits (see table by size). The elastomer repair kits contain the
components for the redesigned travel indicator assembly.
See the drawings below for old versus new design.
TYPE 1098 ORIGINAL DESIGN (PRIOR TO SPRING 2002)
TYPE 1098 REDESIGN (10C1212 KIT)
Type 1098-EGR and 1098H-EGR Travel Indicator Assemblies
www.FISHERregulators.com
Types 1098-EGR and 1098H-EGR
• Insert the following steps after “Replacing Quick-Change Trim Package” section on page 14.
Replacing Travel Indicator Assembly
1. Remove the travel indicator assembly by removing lower indicator fitting (key 5) from body flange (key 2).
2. Coat the threads of the lower indicator fitting (key 5) with a good grade of general-purpose grease.
3. Install travel indicator assembly (10C1212), torque to 40 inch-pounds.
4. Check indicator zeroing by unscrewing the indicator protector (key 19) and seeing if the flange of the indicator nut
(key 22) lines up evenly with the bottom marking on the indicator scale (key 18). If not, remove the indicator scale
and separate the indicator nut and hex nut (key 8). Hold the indicator scale against the indicator fitting (key 5) with
the scale base resting against the shoulder of the fitting, and turn the indicator nut until its flange is aligned with the
bottom scale marking. Then lock both nuts against each other, and install the indicator scale and protector.
• Insert the following parts kit list after “Quick Change
Trim Assembly” on page 18
Key
Description
• Insert “1098 Redesign” into figure 11, page 19.
Part Number
Parts kit, QuickChange Travel Indicator Kit
(included are: indicator stem, key 10;O-ring
retainer, key 6; indicator fitting, key 35; lower
indicator fitting, key 5; mach hex nut, key 8;
nitrile O-ring, key 7; back-up scarf ring, key 36,
2 required; nitrile o-ring, key 21; indicator cover,
key 18; flange nut, key 22; E-ring, key 23; nitrile
O-ring, key 37; adjusting screw cap, key 19;
spring seat, key 28; spring, key 9)
Note: Indicator zeroing of key 8, 12 and 18
may be needed. See Step 4 above.
60 Psi (4,1 bar) spring color green
1-inch
2-inch
3-inch
4-inch
6-inch
10C1212X042
10C1212X012
10C1212X022
10C1212X032
10C1212X052
125 Psi (8.6 bar) spring color blue
1-inch
2-inch
3-inch
4-inch
6-inch
10C1212X092
10C1212X062
10C1212X072
10C1212X082
10C1212X102
400 Psi (28 bar) spring color red
1-inch
2-inch
3-inch
4-inch
6-inch
10C1212X142
10C1212X112
10C1212X122
10C1212X132
10C1212X152
Travel Indicator Assembly
©Fisher Controls International, Inc., 2002; 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
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
L4081A,B and L6081A,C
Multiple Aquastat® Controllers
The L4081, L6081 Aquastat® Controllers provide boiler water regulation in gas- or oil-fired
hydronic heating systems.
■ An immersion type liquid-filled sensing element
actuates two snap switches.
■ Differential adjustment on low limit or circulator
switch.
■ One switch operates as a high limit control.
■ All adjustments accessible inside front cover .
■ The other switch operates as a low limit and/or
circulator control, depending on model.
■ Push-in terminals for quick connecting.
■ Single sensing element for easy installation.
■ Controller may be mounted in any position and
needs no leveling.
■ Two spst snap switches (one spst and one spdt in
L6081A,C) act independently at respective temperature settings.
■ Separate, easy-to-read calibrated dial and setpoint
adjustment for each switch.
CONTENTS
Specifications ................................................. 2
Ordering Information ..................................... 2
Installation ..................................................... 4
Wiring ............................................................. 5
Operation ....................................................... 8
Settings ........................................................... 8
Checkout ......................................................... 9
J. H. • Rev. 3-95 • ©Honeywell Inc. 1995
1
60-2105-5
60-2105—5
L4081A,B/L6081A,C
SPECIFICATIONS • ORDERING INFORMATION
Specifications
IMPORTANT: The specifications given in this publication
do not include normal manufacturing tolerances.
Therefore, this unit may not exactly match the listed
specifications. Also, this product is tested and calibrated under closely controlled conditions, and some
minor differences in performance can be expected if
those conditions are changed.
ADDITIONAL FEATURES: TRADELINE® pack with
cross reference label and special instruction sheet, well
adapter, tube of heat-conductive compound, and setting
stops.
TRADELINE® MODELS
TRADELINE® models are selected and packaged to provide
ease of stocking, ease of handling, and maximum replacement value. TRADELINE® model specifications are the
same as those of standard models except as noted below.
TRADELINE® MODEL AVAILABLE: L6081A Multiple
Aquastat Controller.
RANGES:
High Limit: 130°F (54.5°C) to 240°F (115.5°C). Stops
burner if boiler temperature exceeds setpoint.
Low Limit: 110°F (43.5°C) to 220°F (104.5°C). Controls
burner during thermostat off periods to maintain boiler
water temperature.
Circulator: 110°F (43.5°C) to 220°F (104.5°C). Permits
circulator operation only if boiler water temperature
exceeds low limit setting.
STANDARD MODELS
Refer to Table 1 for model specifications.
TABLE 1—MODEL SPECIFICATIONS.
High Temperature Side
a
b
Low Temperature Side
Model
Number
Insertion Type a
Switching
L4081A
Well
Spst
Hi Limit
Breaks
Spst
Low Limit
Breaks
L4081B
Well
Spst
Hi Limit
Breaks
Spst
Circulator
Makes
L6081A
Well
Spst
Hi Limit
Breaks
Spdt Low
Limit/Circulator
Breaks R-B
Makes R-W
L6081C b
Well
Spst
Hi Limit
Breaks
Spdt Low
Limit/Circulator
Breaks R-B
Makes R-W
Action on Temperature
Rise to Setpoint
Switching
Action on Temperature
Rise to Setpoint
Some models are shipped less well; if well is needed, refer to form 68-0040 for ordering information.
Device is less case and cover.
Ordering Information
When purchasing replacement and modernization products from your TRADELINE® wholesaler or distributor, refer to the Tradeline
Catalog or price sheets for complete ordering number, or specify—
1. Order number.
2. Accessories, if desired.
3. Order additional system components and system accessories separately.
If you have additional questions, need further information, or would like to comment on our products or services, please write or phone:
1. Your local Home and Building Control Sales Office (please check the white pages of your phone directory).
2. Home and Building Control Customer Logistics
Honeywell Inc., 1885 Douglas Drive North
Minneapolis, Minnesota 55422-4386 (612) 951-1000
In Canada—Honeywell Limited/Honeywell Limitée, 740 Ellesmere Road, Scarborough, Ontario M1P2V9. International Sales and
Service Offices in all principal cities of the world. Manufacturing in Australia, Canada, Finland, France, Germany, Japan, Mexico,
Netherlands, Spain, Taiwan, United Kingdom, U.S.A.
60-2105—5
2
L4081A,B/L6081A,C
SPECIFICATIONS
SCALE MARKINGS:
For Fahrenheit Models:
High Limit:160, 180, 200, 220°F.
Low Limit or Circulator: 120, 140, 160, 180, 200°F.
For Celsius Models:
High Limit: 55, 65, 75, 85, 95, 105°C.
Low Limit or Circulator: 45, 55, 65, 75, 85, 95°C.
DIFFERENTIALS:
High Limit: 10°F (5.5°C) nominal.
Low Limit or Circulator:
L6081A,C: 10-25°F (5.5-14°C) adjustable.
L4081A,B: 10°F (5.5°C) nominal or 10-25°F (5.514°C) adjustable.
MAXIMUM PRESSURE RATING:
Well Mounted: 200 psi (1380 kPa).
Direct Immersion: 100 psi (690 kPa).
MAXIMUM AMBIENT TEMPERATURE:
At Switches: 150°F (65.5°C).
At Sensing Element: 265°F (129.5°C).
JUMPER: The 128975 Push-in Field Addable Jumper (included) can be inserted in slot between R-R terminals to
simplify wiring. (Insert with formed legs up in slot labeled jumper. Be sure to insert fully to positive stop.)
MOUNTING DIMENSIONS: See Fig. 1 and 2.
APPROVALS:
Underwriters Laboratories Inc. Listed (L4081A,B and
L6081A): File No. MP466, Guide No. MBPR. Component Recognized (L6081C): File No. MP466, Guide
No. MBPR2.
Canadian Standards Association Component Recognized
(L4081A,B and L6081A): File No. LR1620, Guide
No. 400-E-0.
Fig. 1—L4081A,B and L6081A mounting.
INSULATION DEPTH, 1-1/2 (38)
OR 3 (76)
WELL-CLAMP
SCREW
7/8 IN. (22 MM) DIA. KNOCKOUT
FOR 1/2 IN. (12.5) CONDUIT (6)
MAXIMUM INSERTION 3-1/2
(89)
1-3/16
(30)
1-13/64 (2)
(30.5)
3-7/8
(98.5)
3/4-14 NPT OR 1/2-14 NPT
1-13/64
(2)
(30.5)
3/4 (2)
(19)
1-3/8
(2)
(35)
2-3/64 (63)
4-3/32 (125.5)
1-13/16
(4)
(46)
2-11/16 (68)
M8854
3
60-2105—5
L4081A,B/L6081A,C
SPECIFICATIONS • INSTALLATION
ELECTRICAL RATING (A): See Table 2.
Fig. 2—L6081C mounting dimensions in in.
(mm).
TABLE 2—ELECTRICAL RATINGS.
Full Load
Locked Rotor
Millivoltage
3-5/8
(92)
120 Vac
240 Vac
8.0
5.1
48.0
30.6
0.25A at 1/4 to 12 Vdc
Plus ignition transformer load of 360 VA. Maximum connected load 2000 VA.
7/8
(22)
WELL SPUD LENGTH: 1-1/2 in. (38 mm). Longer spud for
3 in. (76 mm) of insulation available.
SPUD THREAD SIZE:
3/4-14 NPT standard.
1/2-14 NPT available.
OPTIONAL SPECIFICATIONS:
Plastic coating on immersion well to minimize electrolytic deterioration (on some with well models).
Celsius scale on L4081A.
ACCESSORY: 126580 Setting Stop. Used to prevent turning setting knob beyond a predetermined point.
1/4
(6.5)
1-5/16
(33.5)
2-1/4
(57)
11/16
(17.5)
2-1/8 (54)
2-7/16 (62)
M8845
Installation
WHEN INSTALLING THIS PRODUCT...
1. Read these instructions carefully. Failure to follow
them could damage the product or cause a hazardous
condition.
2. Check the ratings given in the instructions and on
the product to make sure the product is suitable for your
application.
3. Installer must be a trained, experienced service
technician.
4. After installation is complete, check out product
operation as provided in these instructions.
Maximum permissible ambient temperature at sensing
bulb is 265°F (129.5°C); at switches, 150°F (65.5°C). The
L6081C is without enclosure or well assembly.
MOUNTING
Follow instructions provided by system manufacturer if
available. Otherwise, proceed as follows:
1. Drain the boiler if system is filled with water.
2. Place front of controller down on a horizontal surface
and gently raise the sensing bulb until it is at a right angle
with the back of the case and centered with the large hole in
the case. This requires bending the capillary tube, but be sure
to make no sharp bends and no bends near the bulb.
CAUTION
Disconnect power supply before installation to
prevent electrical shock or equipment damage.
NOTE: Some models have an adjustable tubing length to
3 in. (76 mm). In these models, extra tubing inside the
case can be pulled out, if needed. See Fig. 3
.
3. Adjust the position of the bulb so that bulb projects
4-7/8 in. (124 mm) from back of case for immersion well
designed for 1-1/2 in. (38 mm) insulation; or 6-3/8 in.
(162 mm), if designed for 3 in. (76 mm) insulation. If this
requires bending the tube inside the case, insert end of
These devices can be installed in any position. Proper
location, sizing, and threaded boiler tapping are required.
NOTE: Maximum pressure rating for these models is 200
psi (1380 kPa).
60-2105—5
4
L4081A,B/L6081A,C
INSTALLATION • WIRING
7. Loosen the wall clamp screw three or four turns; move
the screw in and out and note how it moves the well clamp.
See Fig. 4. Loosen the screw enough so that when the screw
is pushed inward, the T-shaped clamp guide is at the far end
of the slot in the case.
Fig. 3—Adjusting the capillary length.
3
1
Fig. 4—L6081A with cover removed to show
adjustments.
2
8. Mount the case on the well spud in any position that
facilitates wiring. With the case in final position, carefully
insert STRIP
the sensing
bulb into the well until the case slips over
WELL CLAMP
GAUGE
CAUTION:
EXCESSIVE HANDLING OR SHARP BENDS
CAN DAMAGE THE CAPILLARY.
SCREW
LOW LIMIT/
CIRCULATOR
DIFFERENTIAL
ADJUSTMENT
1
SENSING ELEMENT IS FACTORY FORMED FOR 1.5 INCH
INSULATION WELL ASSEMBLIES.
2
FOR 3 INCH INSULATION WELL ASSEMBLIES, PULL OUT
SUFFICENT CAPILLARY TO ASSURE THAT THE CAPSULE
BOTTOMS IN THE WELL.
3
STRAIGHTEN CAPILLARY SUFFICENTLY SO IT DOES NOT
INTERFERE WITH INSERTING THE CAPSULE INTO THE WELL.
LOW LIMIT
SETPOINT
ADJUSTMENT
M8882
index finger through the hole and carefully mold the tube
into the correct shape as you gently pull (or push) the bulb
to the correct position. The bulb must project the right
distance so that after the case is installed, the spring force
of the capillary tube holds the bulb against inner end of the
well for good thermal contact. The tube must be straight
for at least 3/8 in. (9.5 mm) inside the case so the end of
the well spud does not strike the coiled tube and pull the
bulb away from contact with the inner end of the well.
4. Remove the plug from a properly located boiler
tapping.
5. Apply pipe dope sparingly to the threads of the well;
then screw the well tightly into the boiler tapping.
6. Fill the system with water, then carefully examine
around the threads for leakage. Tighten the well if necessary
to stop any leakage.
HIGH LIMIT
SETPOINT
ADJUSTMENT
JUMPER
SLOT
M8848
the end of the well spud and fits squarely against the shoulder
of the spud.
NOTE: Open the clamp to receive the spud by pushing in the
well clamp screw.
9. While holding the case in the correct position, firmly
tighten the well clamp screw.
Wiring
CAUTION
All wiring must comply with applicable codes and ordinances. See cover insert for electrical load ratings. Refer to
Fig. 5 through 9 for typical wiring diagrams.
Use the following procedure when connecting wires to
the B tab terminals (Fig. 4):
1. Connect no. 14, 16, or 18 solid, or no. 14 or 16
unistranded wire to the tab terminals.
2. Strip insulation from the end of each wire.
3. Use the included wire nut from the bag assembly to
connect the tab terminal connector to the wire.
4. Connect the wire to the tab terminal.
• Disconnect power supply to prevent electrical
shock or equipment damage.
• Use care to avoid strain on control case when
using cable or conduit.
WARNING
CAN CAUSE PROPERTY DAMAGE,
SEVERE INJURY OR DEATH.
This Product is for use only in a system with a
pressure relief valve.
JUMPER
When using the controller field addable jumper (Fig. 4),
connect terminals R-R. When the jumper is added, make
sure that the two prongs of the jumper face the center of the
controller.
5
60-2105—5
L4081A,B/L6081A,C
WIRING
Fig. 5—L4081A used with gas burner (line
voltage limit).
Fig. 6—L4081B used to prevent circulator
operation with boiler water temperature below
low limit setting.
L1
(HOT)
L2
1
L2
2
4
3
B
R
R
L1
(HOT)
VR8300
LOW
VOLTAGE
GAS
VALVE
2
L4081B
1
24V
THERMOSTAT
B
W
R
R
BURNER
CONTROL
RA832A
SWITCHING
RELAY
T
CIRCULATOR
2
1
B
HIGH LIMIT
CIRCULATOR
LOW LIMIT
HIGH LIMIT
L4081A
CIRCULATOR
RELAY
CIRCULATOR
MOTOR
X
JUMPER
REMOVED
1R2
X
1
POWER SUPPLY. PROVIDE DISCONNECT MEANS AND OVERLOAD
PROTECTION AS REQUIRED.
2
B IS A TAB TERMINAL.
1R
T
M8787
JUMPER
REMOVED
1
POWER SUPPLY. PROVIDE DISCONNECT MEANS AND
OVERLOAD PROTECTION AS REQUIRED.
2
B TERMINALS ARE TAB TERMINALS.
M8846
Fig. 7—L4081A used with burner cycled from the water temperature.
L2
1
L1
(HOT)
PILOTSTAT®
CONTROL
L1
(HOT)
L2
1
CIRCULATOR
2
4
3
1
1R1
B
B
R
R
LOW LIMIT
24V
THERMOSTAT
HIGH LIMIT
2
L4081A
T
T
1R
GAS VALVE
RA89A SWITCHING RELAY
60-2105—5
1
POWER SUPPLY. PROVIDE DISCONNECT MEANS AND OVERLOAD
PROTECTION AS REQUIRED.
2
B TERMINALS ARE TAB TERMINALS.
6
M8788
L4081A,B/L6081A,C
WIRING
Fig. 8—L4081A used with oil burner.
L2
L1
(HOT)
L1
(HOT)
1
1
BLACK
WHITE
CIRCULATOR
1
3
1R1
24V
THERMOSTAT
B
B
R
R
LOW LIMIT
HIGH LIMIT
4
2
L2
2
JUNCTION
BOX
T
T
OIL PRIMARY
CONTROL
L4081A
X
T
1R2
T
X
1R
RA832A SWITCHING RELAY
1
POWER SUPPLY. PROVIDE DISCONNECT MEANS AND OVERLOAD
PROTECTION AS REQUIRED.
2
B TERMINALS ARE TAB TERMINALS.
M8786
Fig. 9—L6081A used with oil burner.
JUNCTION BOX
R4184D PROTECTORELAY™ CONTROL
SS
BLACK
1K2
ORANGE
1K
CAD
CELL
F
SOLID
STATE
SWITCH
BURNER MOTOR
OIL VALVE
1K1
SAFETY
SWITCH
HEATER
IGNITION
WHITE
F
L1
(HOT)
1
L2
CIRCULATOR
B
2
4
24V
THERMOSTAT
3
1
2
B
W
1R1
R
L6081A
T
1R
T
1
RA89A SWITCHING RELAY
R
JUMPER
ADDED
POWER SUPPLY. PROVIDE DISCONNECT
MEANS AND OVERLOAD PROTECTION
AS REQUIRED.
2 B TERMINALS ARE TAB TERMINALS.
7
M8855
60-2105—5
L4081A,B/L6081A,C
OPERATION • SETTINGS
Operation
HIGH LIMIT
The high limit opens and turns off the burner when the
water temperature reaches the set point. The high limit
automatically resets after the water temperature drops past
the set point and through the 10°F (5.5°C) differential.
temperature plus the difference between the differential
setting and 10°F (5.5°C).
EXAMPLES:
L4081A: Setpoint of 140°F (60°C); differential set at
25°F (14°C). On a temperature rise, the switch breaks
at 155°F (68.5°C). On a temperature fall, the switch
makes at 130°F (54.5°C).
L4081 B: Setpoint of 140°F (60°C); differential set at
25°F (14°C). On a temperature rise, the switch makes
at 155°F (68.5°C). On a temperature fall, the switch
breaks at 130°F (54.5°C).
L6081A,B: Setpoint of 140°F (60°C); differential set at
25°F (14°C). On a temperature rise, R-B breaks and RW makes at 155°F (68.5°C). On a temperature fall, RB makes and R-W breaks at 130°F (54.5°C).
LOW LIMIT AND CIRCULATOR
On a temperature rise, with the adjustable differential at
the minimum setting of 10°F (5.5°C) (also applies to fixed
10°F (5.5°C) differential models), the burner circuit (R-B)
breaks and the circulator circuit (R-W) makes at the control
setpoint. On a temperature drop of 10°F (5.5°C) below the
setpoint, the R-B circuit makes and the R-W circuit breaks.
At any differential setting greater than 10°F (5.5°C), the
R-B make temperature and R-W break temperature remains the same control setting minus 10°F (5.5°C). The
R-B break and R-W make temperature are the setpoint
Settings
SETTING STOP
Install the 126580 Setting Stop on the adjusting knob to
prevent turning the knob beyond a predetermined point.
Fig. 11 shows stops installed on knob of high limit switch
to prevent setting higher than 180°F (82°C).
Because heating systems differ, follow the boiler
manufacturer recommendations when selecting temperature settings.
Study the applicable chart in Fig. 10, which shows the
switching response to temperature changes.
With cover off, set the high limit adjustment at the
temperature desired but not higher than recommended by
the boiler manufacturer (Fig. 4).
Set the low limit and/or circulator adjustment to obtain
temperature desired but not less than 20°F (11°C) below
the high limit setting.
The differential adjustment applies to only the low-limit
and/or circulator switch(es). Minimum differential adjustment provided is 10°F (5.5°C) nominal; maximum is 25°F
(14°C) nominal. Set as desired.
60-2105—5
To install the setting stop, proceed as follows:
1. Turn knob to the setting that is to be established as the
limit.
2. Place setting stop over knob in position to arm of
setting stop (after stop is pressed into place) strikes projection A and prevents turning the knob beyond the desired limit
setting.
3. Press setting stop tightly onto knob so its inner teeth
securely engage knob.
4. Turn knob back and forth several times to make sure
stop functions properly.
5. When all settings are made, replace the cover.
8
L4081A,B/L6081A,C
SETTINGS • CHECKOUT
Fig. 10—Charts showing switching response
to temperature changes.
Fig. 11—Setting stop shown in position to limit
high limit setting to 180°F (82°C).
240°F (116°C)
KNOB SET AT 180°F (82°C)
SWITCH BREAKS ON RISE.
BURNER TURNS OFF.
HIGH LIMIT
SETTING
10°F (5.6°C)
DIFFERENTIAL
SETTING STOP
SETTING
STOP ARM
220
200
SWITCH BREAKS ON RISE.
(25°F (13.9°C) DIFFERENTIAL).
25°F (13.9°C)
DIFFERENTIAL
PROJECTION "A"
SWITCH BREAKS ON RISE.
(10°F (5.6°C) DIFFERENTIAL).
140
10°F (5.6°C)
DIFFERENTIAL
160
LOW LIMIT
SETTING
1
180
SWITCH MAKES ON FALL.
BURNER OPERATES ON
A CALL FOR HEAT.
SWITCH MAKES ON FALL.
BURNER ON.
110°F (43°C)
1
L4081A
SCALE MARKINGS IN FAHRENHEIT ONLY.
M2844
240°F (116°C)
Checkout
SWITCH BREAKS ON RISE.
BURNER TURNS OFF.
HIGH LIMIT
SETTING
10°F (5.6°C)
DIFFERENTIAL
SWITCH MAKES ON FALL.
BURNER OPERATES ON
CALL FOR HEAT.
After completing installation and controller settings,
operate the system. Carefully observe the operation of all
components through at least one complete cycle. Be sure to
include a check of the high limit switch operation. Make
any correction needed; then repeat the checkout. Repeat
until system operates properly.
SWITCH MAKES ON RISE.
(25°F (13.9°C) DIFFERENTIAL).
CIRCULATOR
SETTING
25°F (13.9°C)
DIFFERENTIAL
10°F (5.6°C)
DIFFERENTIAL
SWITCH MAKES ON RISE.
(10°F (5.6°C) DIFFERENTIAL).
SWITCH BREAKS ON FALL.
CIRCULATOR OFF.
110°F (43°C)
L4081B
240°F (116°C)
SWITCH BREAKS ON RISE.
BURNER TURNS OFF.
CIRCULATOR OPERATES
ON CALL FOR HEAT.
HIGH LIMIT
SETTING
10°F (5.6°C)
DIFFERENTIAL
LOW LIMIT AND
CIRCULATOR
SETTING
25°F (13.9°C)
DIFFERENTIAL
10°F (5.6°C)
DIFFERENTIAL
SWITCH MAKES ON FALL.
BURNER OPERATES ON
CALL FOR HEAT.
SWITCH MAKES R-W AND
BREAKS R-B ON RISE.
25°F (13.9°C) DIFFERENTIAL.
SWITCH MAKES R-W AND
BREAKS R-B ON RISE.
(10°F (5.6°C) DIFFERENTIAL)
SWITCH MAKES R-B ON
FALL,BREAKS R-W ON FALL.
BURNER ON,CIRCULATOR
OFF.
110°F (43°C)
M8847
L6081A,C
9
60-2105—5
L4081A,B/L6081A,C
MATERIAL SAFETY DATA SHEET
Material Safety Data Sheet (MSDS) for heat-conductive compound, which is included with the
TRADELINE® Aquastat Relay models.
60-2105—5
10
L4081A,B/L6081A,C
MATERIAL SAFETY DATA SHEET
Material Safety Data Sheet (MSDS) for heat-conductive compound, which is included with the
TRADELINE® Aquastat Relay models.
11
60-2105—5
Home and Building Control
Honeywell Inc.
1985 Douglas Drive North
Golden Valley, MN 55422
60-2105—5
Printed in U.S.A.
Home and Building Control
Honeywell Limited—Honeywell Limitée
740 Ellesmere Road
Scarborough, Ontario
M1P 2V9
12
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automation equipment to operate safely. Anyone who installs or uses this equipment should read this publication (and
any other relevant publications) before installing or operating the equipment.
To minimize the risk of potential safety problems, you should follow all applicable local and national codes that regulate
the installation and operation of your equipment. These codes vary from area to area and usually change with time. It is
your responsibility to determine which codes should be followed, and to verify that the equipment, installation, and
operation are in compliance with the latest revision of these codes.
At a minimum, you should follow all applicable sections of the National Fire Code, National Electrical Code, and the
codes of the National Electrical Manufacturer’s Association (NEMA). There may be local regulatory or government
offices that can also help determine which codes and standards are necessary for safe installation and operation.
Equipment damage or serious injury to personnel can result from the failure to follow all applicable codes and
standards. We do not guarantee the products described in this publication are suitable for your particular application,
nor do we assume any responsibility for your product design, installation, or operation.
Our products are not fault–tolerant and are not designed, manufactured or intended for use or resale as on–line control
equipment in hazardous environments requiring fail–safe performance, such as in the operation of nuclear facilities,
aircraft navigation or communication systems, air traffic control, direct life support machines, or weapons systems, in
which the failure of the product could lead directly to death, personal injury, or severe physical or environmental
damage (”High Risk Activities”). Automationdirect.com specifically disclaims any expressed or implied warranty of
fitness for High Risk Activities.
For additional warranty and safety information, see the Terms and Conditions section of our Desk Reference. If you
have any questions concerning the installation or operation of this equipment, or if you need additional information,
please call us at 770–844–4200.
This publication is based on information that was available at the time it was printed. At Automationdirect.com we
constantly strive to improve our products and services, so we reserve the right to make changes to the products and/or
publications at any time without notice and without any obligation. This publication may also discuss features that may
not be available in certain revisions of the product.
Trademarks
This publication may contain references to products produced and/or offered by other companies. The product and
company names may be trademarked and are the sole property of their respective owners. Automationdirect.com
disclaims any proprietary interest in the marks and names of others.
Copyright 2001, Automationdirect.com Incorporated
All Rights Reserved
No part of this manual shall be copied, reproduced, or transmitted in any way without the prior, written consent of
Automationdirect.com Incorporated. Automationdirect.com retains the exclusive rights to all information
included in this document.
2–7
Installation, Wiring, and Specifications
Environmental
Specifications
The following table lists the environmental specifications that generally apply to the
DL205 system (CPU, Bases, I/O Modules). The ranges that vary for the Handheld
Programmer are noted at the bottom of this chart. I/O module operation may
fluctuate depending on the ambient temperature and your application. Please refer
to the appropriate I/O module specifications for the temperature derating curves
applying to specific modules.
Rating
Storage temperature
–4° F to 158° F (–20° C to 70° C)
Ambient operating temperature*
32° F to 131° F (0° C to 55° C)
Ambient humidity**
30% – 95% relative humidity (non–condensing)
Vibration resistance
MIL STD 810C, Method 514.2
Shock resistance
MIL STD 810C, Method 516.2
Noise immunity
NEMA (ICS3–304)
Atmosphere
No corrosive gases
* Operating temperature for the Handheld Programmer and the DV–1000 is 32° to 122° F (0° to 50° C)
Storage temperature for the Handheld Programmer and the DV–1000 is –4° to 158° F (–20° to70° C).
**Equipment will operate below 30% humidity. However, static electricity problems occur much more
frequently at lower humidity levels. Make sure you take adequate precautions when you touch the
equipment. Consider using ground straps, anti-static floor coverings, etc. if you use the equipment in
low humidity environments.
Installation, Wiring
and Specifications
Specification
The power source must be capable of supplying voltage and current complying with
the base power supply specifications.
Power
Specification
AC Powered Bases
24 VDC Powered Bases
125 VDC Powered Bases
D2–03B–1,
D2–04B–1,
D2–06B–1,
D2–09B–1
D2–03BDC1–1,
D2–04BDC1–1,
D2–06BDC1–1,
D2–09BDC1–1
D2–06BDC2–1,
D2–09BDC2–1
Input Voltage Range
100–240 VAC
+10% –15%
10.2 – 28.8VDC (24VDC)
with less than 10% ripple
104–240 VDC
+10% –15%
Maximum Inrush Current
30 A
10A
20A
Maximum Power
80 VA
25W
30W
Voltage Withstand (dielectric)
1 minute @ 1500 VAC between primary, secondary, field ground, and run relay
Insulation Resistance
> 10 MW at 500 VDC
Auxiliary 24 VDC Output
20–28 VDC, less than 1V p-p None
300mA max.
20–28 VDC, less than 1V p-p
300mA max.
Fusing (internal to base
power supply)
non–replaceable 2A @ 250V
slow blow fuse; external fusing recommended
non–replaceable 2A @ 250V
slow blow fuse; external fusing recommended
Agency Approvals
non–replaceable 3.15A @
250V slow blow fuse; external fusing recommended
Installation and
Safety Guidelines
Part Numbers
Some applications require agency approvals. Typical agency approvals which your
application may require are:
• UL (Underwriters’ Laboratories, Inc.)
• CSA (Canadian Standards Association)
• FM (Factory Mutual Research Corporation)
S CUL (Canadian Underwriters’ Laboratories, Inc.)
DL205 User Manual, 3rd Ed., Rev. A, 06/02
2–10
Installation, Wiring, and Specifications
Installation, Wiring,
and Specifications
Using Mounting
Rails
The DL205 bases can also be secured to the cabinet by using mounting rails. You
should use rails that conform to DIN EN standard 50 022. Refer to our catalog for a
complete line of DIN rail, DINnectors and DIN rail mounted apparatus. These rails
are approximately 35mm high, with a depth of 7.5mm. If you mount the base on a rail,
you should also consider using end brackets on each end of the rail. The end
brackets help keep the base from sliding horizontally along the rail. This helps
minimize the possibility of accidentally pulling the wiring loose.
If you examine the bottom of the base, you’ll notice small retaining clips. To secure
the base to a DIN rail, place the base onto the rail and gently push up on the retaining
clips. The clips lock the base onto the rail.
To remove the base, pull down on the retaining clips, lift up on the base slightly, and
pull it away from the rail.
DIN Rail Dimensions
7.5mm
35 mm
Installation and
Safety Guidelines
Retaining Clips
DL205 User Manual, 3rd Ed. Rev. A, 08/03
2–11
Installation, Wiring, and Specifications
Installing Components in the Base
To insert components into the base: first slide the module retaining clips to the out
position and align the PC board(s) of the module with the grooves on the top and
bottom of the base. Push the module straight into the base until it is firmly seated in
the backplane connector. Once the module is inserted into the base, push in the
retaining clips to firmly secure the module to the base.
Installation, Wiring
and Specifications
CPU must be positioned in
the first slot of the base Align module PC board to
slots in base and slide in
Push the retaining
clips in to secure the module
to the DL205 base
Installation and
Safety Guidelines
WARNING: Minimize the risk of electrical shock, personal injury, or equipment
damage, always disconnect the system power before installing or removing any
system component.
DL205 User Manual, 3rd Ed., Rev. A, 06/02
2–12
Installation, Wiring, and Specifications
Base Wiring Guidelines
Installation, Wiring,
and Specifications
Base Wiring
The diagrams show the terminal
connections located on the power supply
of the DL205 bases. The base terminals
can accept up to 16 AWG. You may be
able to use larger wiring depending on
the type of wire used, but 16 AWG is the
recommended size. Do not overtighten
the connector screws; recommended
torque value is 7.81 pound-inches (0.882
N•m).
NOTE: You can connect either a 115
VAC or 220 VAC supply to the AC
terminals. Special wiring or jumpers are
not required as with some of the other
DirectLOGIC products.
12/24 VDC Base Terminal Strip
+
12 – 24 VDC
110/220 VAC Base Terminal Strip
85 – 264 VAC
G
LG
+
24 VDC OUT
0.3A
–
125 VDC Base Terminal Strip
115 – 264 VDC
–
G
G
LG
LG
+
Installation and
Safety Guidelines
24 VDC OUT
0.3A
–
WARNING: Once the power wiring is connected, install the plastic protective cover.
When the cover is removed there is a risk of electrical shock if you accidentally touch
the wiring or wiring terminals.
DL205 User Manual, 3rd Ed. Rev. A, 08/03
2–14
Installation, Wiring, and Specifications
Powering I/O
Circuits with the
Auxiliary Supply
In some cases, using the built-in auxiliary +24VDC supply can result in a cost
savings for your control system. It can power combined loads up to 300mA. Be
careful not to exceed the current rating of the supply. If you are the system designer
for your application, you may be able to select and design in field devices which can
use the +24VDC auxiliary supply.
All AC powered and 125VDC DL205 bases feature the internal auxiliary supply. If
input devices AND output loads need +24VDC power, the auxiliary supply may be
able to power both circuits as shown in the following diagram.
Installation, Wiring,
and Specifications
AC Power or 125VDC Bases
Power Input
Auxiliary
+24VDC
Supply
+
DL205 PLC
Input Module
Output Module
Inputs
Outputs Com.
Com.
–
Loads
Installation and
Safety Guidelines
12/24VDC powered DL205 bases are designed for application environments in
which low-voltage DC power is more readily available than AC. These include a wide
range of battery–powered applications, such as remotely-located control, in
vehicles, portable machines, etc. For this application type, all input devices and
output loads typically use the same DC power source. Typical wiring for
DC-powered applications is shown in the following diagram.
+
+
–
–
DC Power
DL205 PLC
Power Input
Input Module
Inputs
Com.
Output Module
Outputs Com.
Loads
DL205 User Manual, 3rd Ed. Rev. A, 08/03
2–15
Installation, Wiring, and Specifications
Powering I/O
Circuits Using
Separate Supplies
In most applications it will be necessary to power the input devices from one power
source, and to power output loads from another source. Loads often require
high-energy AC power, while input sensors use low-energy DC. If a machine
operator is likely to come in close contact with input wiring, then safety reasons also
require isolation from high-energy output circuits. It is most convenient if the loads
can use the same power source as the PLC, and the input sensors can use the
auxiliary supply, as shown to the left in the figure below.
If the loads cannot be powered from the PLC supply, then a separate supply must be
used as shown to the right in the figure below.
Power Input
Auxiliary
+24VDC
Supply
+
AC Power
Power Input
DL205 PLC
Input Module
Output Module
Inputs
Outputs Com.
Com.
–
Auxiliary
+24VDC
Supply
+
DL205 PLC
Input Module
Output Module
Inputs
Outputs Com.
Com.
Installation, Wiring
and Specifications
AC Power
–
Loads
Loads
Load
Supply
Some applications will use the PLC external power source to also power the input
circuit. This typically occurs on DC-powered PLCs, as shown in the drawing below to
the left. The inputs share the PLC power source supply, while the outputs have their
own separate supply.
+
+
–
–
DC Power
AC Power
Power Input
DL205 PLC
Power Input
Input Module
Inputs
Com.
Output Module
Auxiliary
+24VDC
Supply
Outputs Com.
+
Loads
Load
Supply
Installation and
Safety Guidelines
A worst-case scenario, from a cost and complexity view-point, is an application
which requires separate power sources for the PLC, input devices, and output loads.
The example wiring diagram below on the right shows how this can work, but also
the auxiliary supply output is an unused resource. You will want to avoid this situation
if possible.
DL205 PLC
Input Module
Output Module
Inputs
Com.
Outputs Com.
Input
Supply
Loads
–
Load
Supply
DL205 User Manual, 3rd Ed., Rev. A, 06/02
2–16
Installation, Wiring, and Specifications
Sinking / Sourcing
Concepts
Before going further in the study of wiring strategies, you must have a solid
understanding of “sinking” and “sourcing” concepts. Use of these terms occurs
frequently in input or output circuit discussions. It is the goal of this section to make
these concepts easy to understand, further ensuring your success in installation.
First the following short definitions are provided, followed by practical applications.
Installation and
Safety Guidelines
Installation, Wiring,
and Specifications
Sinking = provides a path to supply ground (–)
Sourcing = provides a path to supply source (+)
First you will notice these are only associated with DC circuits and not AC, because
of the reference to (+) and (–) polarities. Therefore, sinking and sourcing terminology
only applies to DC input and output circuits. Input and output points that are sinking
or sourcing only can conduct current in only one direction. This means it is possible
to connect the external supply and field device to the I/O point with current trying to
flow in the wrong direction, and the circuit will not operate. However, you can
successfully connect the supply and field device every time by understanding
“sourcing” and “sinking”.
For example, the figure to the right depicts
a “sinking” input. To properly connect the
external supply, you will have to connect it
so the input provides a path to ground (–).
Start at the PLC input terminal, follow
through the input sensing circuit, exit at
the common terminal, and connect the
supply (–) to the common terminal. By
adding the switch, between the supply (+)
and the input, the circuit has been
completed . Current flows in the direction
of the arrow when the switch is closed.
Input
(sinking)
+
PLC
Input
Sensing
–
Common
By applying the circuit principle above to the four possible combinations of
input/output sinking/sourcing types as shown below. The I/O module specifications
at the end of this chapter list the input or output type.
Sinking Input
Sinking Output
Input
+
–
PLC
Input
Sensing
Common
+
DL205 User Manual, 3rd Ed. Rev. A, 08/03
Load
+
–
Common
Sourcing Output
PLC
Input
Sensing
Input
Output
Output
Switch
Common
Sourcing Input
–
PLC
PLC
Common
+
Output
Switch
Output
–
Load
2–17
Installation, Wiring, and Specifications
I/O “Common”
In order for a PLC I/O circuit to operate,
Terminal Concepts current must enter at one terminal and exit
at another. Therefore, at least two
terminals are associated with every I/O
point. In the figure to the right, the Input or
Output terminal is the main path for the
current. One additional terminal must
provide the return path to the power
supply.
I/O
Circuit
+
–
Return Path
PLC
Input 1
Input
Sensing
Input 2
Input 3
Input 4
Installation, Wiring
and Specifications
If there was unlimited space and budget
for I/O terminals, every I/O point could
have two dedicated terminals as the figure
above shows. However, providing this
level of flexibility is not practical or even
necessary for most applications. So, most
Input or Output points on PLCs are in
groups which share the return path (called
commons). The figure to the right shows a
group (or bank) of 4 input points which
share a common return path. In this way,
the four inputs require only five terminals
instead of eight.
PLC
Main Path
(I/O Point)
Field
Device
+
–
Common
NOTE: In the circuit above, the current in the common path is 4 times any channel’s
input current when all inputs are energized. This is especially important in output
circuits, where heavier gauge wire is sometimes necessary on commons.
AC supply
DC supply
–
Input Switch
AC or DC supply
IN
24
VDC
A 0
4
1
5
2
6
7
B 3
D2–16ND3–2
20-28VDC
8mA
CLASS2
0
1
2
3
NC
0
1
2
3
CA
4
5
6
7
CB
4
5
6
7
Installation and
Safety Guidelines
Most DL205 input and output modules
group their I/O points into banks that share
a common return path. The best indication
of I/O common grouping is on the wiring
label, such as the one shown to the right.
The miniature schematic shows two circuit
banks with eight input points in each. The
common terminal for each is labeled “CA”
and “CB”, respectively.
In the wiring label example, the positive
terminal of a DC supply connects to the
common terminals. Some symbols you
will see on the wiring labels, and their
meanings are:
D2-16ND3-2
+
Output Load
L
DL205 User Manual, 3rd Ed., Rev. A, 06/02
2–25
Installation, Wiring, and Specifications
Special Placement In most cases, the analog modules can be placed in any slot. However, the
Considerations for placement can also depend on the type of CPU you are using and the other types of
modules installed to the left of the analog modules. If you’re using a DL230 CPU (or a
Analog Modules
DL240 CPU with firmware earlier than V1.4) you should check the DL205 Analog I/O
Manual for any possible placement restrictions related to your particular module.
You can order the DL205 Analog I/O Manual by ordering part number D2–ANLG–M.
Discrete Input
Module Status
Indicators
The discrete modules provide LED status indicators to show the status of the input
points.
Status indicators
Terminal Cover
(installed)
Installation, Wiring
and Specifications
Terminal
Wire tray area
behind terminal cover
Color Coding of I/O The DL205 family of I/O modules have a color coding scheme to help you quickly
identify if a module is either an input module, output module, or a specialty module.
Modules
This is done through a color bar indicator located on the front of each module. The
color scheme is listed below:
Module Type
Discrete/Analog Output
Discrete/Analog Input
Other
Color Code
Red
Blue
White
Installation and
Safety Guidelines
Color Bar
DL205 User Manual, 3rd Ed., Rev. A, 06/02
2–26
Installation, Wiring, and Specifications
Both types of connectors can be easily removed. If you examine the connectors
closely, you’ll notice there are squeeze tabs on the top and bottom. To remove the
terminal block, press the squeeze tabs and pull the terminal block away from the
module.
We also have DIN rail mounted terminal blocks, DINnectors (refer to our catalog for a
complete listing of all available products). ZIPLinks come with special
pre–assembled cables with the I/O connectors installed and wired.
WARNING: For some modules, field device power may still be present on the
terminal block even though the PLC system is turned off. To minimize the risk of
electrical shock, check all field device power before you remove the connector.
Installation and
Safety Guidelines
Installation, Wiring,
and Specifications
Wiring the Different There are two types of module connectors for the DL205 I/O. Some modules have
normal screw terminal connectors. Other modules have connectors with recessed
Module
screws. The recessed screws help minimize the risk of someone accidentally
Connectors
touching active wiring.
DL205 User Manual, 3rd Ed. Rev. A, 08/03
2–27
Installation, Wiring, and Specifications
I/O Wiring
Checklist
Use the following guidelines when wiring the I/O modules in your system.
1. There is a limit to the size of wire the modules can accept. The table below
lists the suggested AWG for each module type. When making terminal
connections, follow the suggested torque values.
Module type
Suggested AWG Range Suggested Torque
4 point
16* – 24 AWG
7.81 lb-inch (0.882 N•m)
8 point
16* – 24 AWG
7.81 lb-inch (0.882 N•m)
12 point
16* – 24 AWG
2.65 lb-in (0.3 N•m)
16 point
16* – 24 AWG
2.65 lb-in (0.3 N•m)
types of 16 AWG may be acceptable, but it really depends on the thickness
and stiffness of the wire insulation. If the insulation is too thick or stiff
and a majority of the module’s I/O points are used, then the plastic
terminal cover may not close properly or the connector may pull away
from the module. This applies especially for high temperature
thermoplastics such as THHN.
DINnector External Fuses
(DIN rail mounted Fuses)
Installation and
Safety Guidelines
2. Always use a continuous length of wire, do not combine wires to attain a
needed length.
3. Use the shortest possible wire length.
4. Use wire trays for routing where possible.
5. Avoid running wires near high energy wiring. Also, avoid running input
wiring close to output wiring where possible.
6. To minimize voltage drops when wires must run a long distance , consider
using multiple wires for the return line.
7. Avoid running DC wiring in close proximity to AC wiring where possible.
8. Avoid creating sharp bends in the wires.
9. To reduce the risk of having a module with a blown fuse, we suggest you
add external fuses to your I/O wiring. A fast blow fuse, with a lower current
rating than the I/O module fuse can be added to each common, or a fuse
with a rating of slightly less than the maximum current per output point can
be added to each output. Refer to our catalog for a complete line of
DINnectors, DIN rail mounted fuse blocks.
Installation, Wiring
and Specifications
*NOTE: 16 AWG Type TFFN or Type MTW is recommended. Other
NOTE: For modules which have soldered or non-replaceable fuses, we recommend
you return your module to us and let us replace your blown fuse(s) since
disassembling the module will void your warranty.
DL205 User Manual, 3rd Ed., Rev. A, 06/02
2–33
Installation, Wiring, and Specifications
D2–08NA-1 AC Input
D2–08NA–2 AC Input
8
Inputs per module
8
Commons per module
1 (2 I/O terminal points)
Commons per module
2 (internally connected)
Input voltage range
80–132 VAC
Input voltage range
170–265 VAC
Peak voltage
132 VAC
Peak voltage
265 VAC
AC frequency
47–63 Hz
AC frequency
47–63 Hz
ON voltage level
75 VAC minimum
ON voltage level
150 VAC minimum
OFF voltage level
20 VAC maximum
OFF voltage level
40 VAC maximum
Input impedance
12K @ 60 Hz
Input impedance
18K @ 60 Hz
Input current
13mA @ 100VAC, 60Hz
11mA @ 100VAC, 50Hz
Input current
Minimum ON current
5 mA
9mA @ 220VAC, 50Hz
11mA @ 265VAC, 60Hz
10mA @ 220VAC, 60Hz
12mA @ 265VAC, 60Hz
Maximum OFF current
2 mA
Minimum ON current
10 mA
Base power required
50 mA Max
Maximum OFF current
2 mA
OFF to ON response
5 to 30 ms
Base power required
100 mA Max
ON to OFF response
10 to 50 ms
OFF to ON response
5 to 30 ms
Terminal type
Removable
ON to OFF response
10 to 50 ms
Status indicator
Logic side
Terminal type
Removable
Weight
2.5 oz. (70 g)
Status indicator
Logic side
Weight
2.5 oz. (70 g)
Installation, Wiring
and Specifications
Inputs per module
Derating Chart
Points
Derating Chart
Points
8
8
6
6
4
IN
2
0
10
20
30
40
50 55 °C
50
68
86
104
122 131 °F
Ambient Temperature (°C/°F)
0
32
Internally
connected
C
C
4
IN
2
0
10
20
30
40
50 55 °C
50
68
86
104
122 131 °F
Ambient Temperature (°C/°F)
0
32
220 VAC
80Ć132VAC
10Ć20mA
50/60Hz
C
0
C
4
5
4
6
5
0
C
4
6
5
7
C
2
1
3
4
1
0
2
220VAC
10Ć20mA
50/60Hz
0
C
1
Internally
connected
C
0
1
2
3
D2–08NA–2
1
3
2
5
7
6
2
7
3
6
3
Internal module circuitry
V+
220
VAC
4
5
6
7
Installation and
Safety Guidelines
110 VAC
0
1
2
3
D2–08NA–1
110
VAC
4
5
6
7
Internal module circuitry
V+
7
D2–08NA-1
INPUT
D2–08NA-2
INPUT
To LED
To LED
COM
Line
Optical
Isolator
COM
110 VAC
COM
Line
Optical
Isolator
220 VAC
COM
DL205 User Manual, 3rd Ed., Rev. A, 08/03
2–34
Installation, Wiring, and Specifications
Installation, Wiring,
and Specifications
D2–16NA AC Input
F2–08SIM Input Simulator
Inputs per module
16
Inputs per module
8
Commons per module
2 (isolated)
Base power required
50 mA Max
Input voltage range
80–132 VAC
Terminal type
None
Peak voltage
132 VAC
Status indicator
Switch side
AC frequency
47–63 Hz
Weight
2.65 oz. (75 g)
ON voltage level
70 VAC minimum
OFF voltage level
20 VAC maximum
Input impedance
12K @ 60 Hz
Input current
11mA @ 100VAC, 50Hz
13mA @ 100VAC, 60Hz
15mA @ 132VAC, 60Hz
Minimum ON current
5 mA
Maximum OFF current
2 mA
Base power required
100 mA Max
OFF to ON response
5 to 30 ms
ON to OFF response
10 to 50 ms
Terminal type
Removable
Status indicator
Logic side
Weight
2.4 oz. (68 g)
SIM
0
1
2
3
F2–08SIM
0
1
2
3
Derating Chart
Points
IN
16
4
12
5
8
IN
4
0
0
32
10
20
30
40
50 55 °C
50
68
86
104
122 131 °F
Ambient Temperature (°C/°F)
Installation and
Safety Guidelines
110 VAC
A 0
1
2
B 3
D2–16NA
110
VAC
4
5
6
7
CA
0
80-132VAC
10-20mA
50/60Hz
4
1
5
2
0
6
3
1
7
110 VAC
2
NC
CB
3
0
4
NC
1
5
0
2
6
1
7
2
3
3
CA
4
5
6
7
CB
4
5
6
7
Internal module circuitry
V+
D2–16NA
INPUT
To LED
COM
Line
110 VAC
Optical
Isolator
When the AB switch is in the A position,
the LEDs display the input status of the
module’s first 8 input points. Positon B
displays the input status of the module’s
second group of 8 input points.
DL205 User Manual, 3rd Ed., Rev. A, 08/03
6
7
4
5
6
7
' ON
2–40
Installation, Wiring, and Specifications
Installation, Wiring,
and Specifications
D2–12TA AC Output
Outputs per module
12
Max leakage current
2mA (132VAC, 60Hz)
Output Points Consumed
16 (4 unused, see chart below)
Max inrush current
10A for 10 ms
Commons per module
2 (isolated)
Minimum load
10 mA
Operating voltage
15–132 VAC
Base power required
350 mA Max
Output type
SSR (Triac)
OFF to ON response
1 ms
Peak voltage
132 VAC
ON to OFF response
1 ms +1/2 cycle
AC frequency
47 to 63 Hz
Terminal type
Removable
ON voltage drop
< l.5 VAC (> 50mA)
< 4.0 VAC (< 50mA)
Status indicators
Logic Side
Weight
3.8 oz. (110 g)
Max load current
0.3A / point,
1.8A / common
Fuses
(2) 1 per common
3 15A slow blow
3.15A
blow, replaceable
Order D2–FUSE–1 (5 per pack)
Derating Chart
250mA / Pt.
Points
Points
12
OUT
6
3
0
0
32
10
20
30
40
50 55 °C
50
68
86
104
122 131 °F
Ambient Temperature (°C/°F)
15–132 VAC
L
CA
0
L
L
15–132 VAC
L
5
2
NC
3
NC
L
L
L
1
2
0
0
4
1
5
2
NC
Yes
Yes
Yes
Yes
Yes
Yes
No
No
4
5
Internal module circuitry
OUTPUT
1
2
Used?
CA
Optical
Isolator
L
CB
Yn+10
Yn+11
Yn+12
Yn+13
Yn+14
Yn+15
Yn+16
Yn+17
n is the starting address
CB
4
5
COM
3
Line
3
L
Yes
Yes
Yes
Yes
Yes
Yes
No
No
3
NC
L
15-110
VAC
4
5
15-132VAC
10mA-0.3A
50/60 Hz
0
1
L
L
A 0
1
2
B 3
D2–12TA
4
L
Installation and
Safety Guidelines
Yn+0
Yn+1
Yn+2
Yn+3
Yn+4
Yn+5
Yn+6
Yn+7
300mA / Pt.
9
Addresses Used
Used?
Points
15–132
VAC
NC
D2–12TA
When the AB switch is in the A position,
the LEDs display the output status of the
module’s first 6 output points. Positon B
displays the output status of the module’s second group of 6 output points.
DL205 User Manual, 3rd Ed., Rev. A, 08/03
3.15A
To LED
3–2
CPU Specifications and Operation
Overview
CPU Specifications
and Operation
The CPU is the heart of the control
system. Almost all system operations are
controlled by the CPU, so it is important
that it is set-up and installed correctly.
This chapter provides the information
needed to understand:
S the differences between the
different models of CPUs
S the steps required to setup and
install the CPU
General CPU
Features
The DL230, DL240, DL250–1 and D2–260 are modular CPUs which can be installed
in 3, 4, 6, or 9 slot bases. All I/O modules in the DL205 family will work with any of the
CPUs. The DL205 CPUs offer a wide range of processing power and program
instructions. All offer RLL and Stage program instructions (See Chapter 5). They
also provide extensive internal diagnostics that can be monitored from the
application program or from an operator interface.
DL230 CPU
Features
The DL230 has 2.4K words of memory comprised of 2.0K of ladder memory and
approximately 400 words of V-memory (data registers). It has 90 different
instructions available for programming, and supports a maximum of 256 I/O points.
Program storage is in the EEPROM which is installed at the factory. In addition to the
EEPROM there is also RAM on the CPU which will store system parameters,
V-memory, and other data which is not in the application program.
The DL230 provides one built-in RS232C communication port, so you can easily
connect a handheld programmer or a personal computer without needing any
additional hardware.
DL240 CPU
Features
The DL240 has a maximum of 3.8K of memory comprised of 2.5K of ladder memory
and approximately 1.3K of V-memory (data registers). There are129 instructions
available for program development and a maximum of 256 points local I/O and 896
points with remote I/O are supported.
Program storage is in the EEPROM which is installed at the factory. In addition to the
EEPROM there is also RAM on the CPU which will store system parameters,
V-memory and other data which is not in the application program.
The DL240 has two communication ports. The top port is the same port configuration
as the DL230. The bottom port also supports the DirectNET protocol, so you can
use the DL240 in a DirectNET network. Since the port is RS232C, you must use an
RS232C/RS422 converter for multi-drop connections.
DL205 User Manual, 3rd Ed., Rev. A, 08/03
CPU Specifications and Operation
3–3
The DL250–1 replaces the DL250 CPU. It offers all the DL240 features, plus more
program instructions, a built–in Remote I/O Master port. It offers all the features of
the DL250 CPU with the addition of supporting Local expansion I/O. It has a
maximum of 14.8K of program memory comprised of 7.6K of ladder memory and
7.2K of V-memory (data registers). It supports a maximum of 256 points of local I/O
and a maximum of 768 I/O points (max. of two local expansion bases). In addition,
port 2 supports up to 2048 points if you use the DL250–1 as a Remote master. It
includes an internal RISC–based microprocessor for greater processing power. The
DL250–1 has 174 instructions. The additional instructions to the DL240 instruction
set include drum timers, a print function, floating point math, and PID loop control for
4 loops.
The DL250–1 has a total of two built–in communications ports. The top port is
identical to the top port of the DL240/DL250 with the exception of DirectNet slave
feature. The bottom port is a 15–pin RS232C/RS422 port. It will interface with
DirectSOFT32, and operator interfaces, and provides DirectNet and MODBUS
RTU Master/Slave connections.
DL260 CPU
Features
The DL260 offers all the DL250–1 features, plus ASCII IN/OUT and expanded
MODBUS instructions. It also supports up to 1280 local I/O points by using up to four
local expansion bases. It has a maximum of 30.4K of program memory comprised of
15.8K of ladder memory and 14.6K of V-memory (data registers). It also includes an
internal RISC–based microprocessor for greater processing power. The DL260 has
231 instructions. The additional instructions to the DL250–1 instruction set includes
table instructions, trigonometric instructions and support for 16 PID loops.
The DL260 has a total of two built–in communications ports. The top port is identical
to the top port of the DL250–1. The bottom port is a 15–pin RS232C/RS422/RS485
port. It will interface with DirectSOFT32 (version 4.0 or later), operator interfaces,
and provides DirectNet, MODBUS RTU Master/Slave connections. Port 2 is also
support ASCII IN/OUT instructions.
CPU Specifications
and Operation
DL250–1 CPU
Features
DL205 User Manual, 3rd Ed., Rev. A, 08/03
3–6
CPU Specifications and Operation
CPU Hardware Features
Status Indicators
DL260
DL250-1
Mode Switch
Port 1
Port 2
CPU Specifications
and Operation
Battery Slot
Status Indicators
PWR
BATT
PWR
BATT
RUN
CPU
DL240
Port 1
DL230
RUN
CPU
CPU
CPU
Mode Switch
RUN
TERM
CH1
CH2
CH3
CH4
Analog
Adjustments
PORT 1
PORT 1
Port 2
PORT2
DL205 User Manual, 3rd Ed., Rev. A, 08/03
CPU Specifications and Operation
Mode Switch
Functions
3–7
The mode switch on the DL240, DL250–1 and DL260 CPUs provide positions for
enabling and disabling program changes in the CPU. Unless the mode switch is in
the TERM position, RUN and STOP mode changes will not be allowed by any
interface device, (handheld programmer, DirectSOFT32 programing package or
operator interface). Programs may be viewed or monitored but no changes may be
made. If the switch is in the TERM position and no program password is in effect, all
operating modes as well as program access will be allowed through the connected
programming or monitoring device.
Modeswitch Position CPU Action
RUN
(Run Program)
CPU is forced into the RUN mode if no errors are encountered. No
changes are allowed by the attached programming/monitoring device.
TERM (Terminal)
RUN, PROGRAM and the TEST modes are available. Mode and
program changes are allowed by the programming/monitoring device.
STOP (DL250–1 and
DL260 only Stop Program)
CPU is forced into the STOP mode. No changes are allowed by the
programming/monitoring device.
There are two ways to change the CPU mode.
NOTE: If the CPU is switched to the RUN Mode without a program in the PLC, the
PLC will produce a FATAL ERROR which can be cleared by cycling the power to the
PLC.
Status Indicators
CPU Specifications
and Operation
1. Use the CPU mode switch to select the operating mode.
2. Place the CPU mode switch in the TERM position and use a programming
device to change operating modes. In this position, you can change
between Run and Program modes.
The status indicator LEDs on the CPU front panels have specific functions which can
help in programming and troubleshooting.
Indicator
Status
Meaning
PWR
ON
Power good
OFF
Power failure
ON
CPU is in Run Mode
OFF
CPU is in Stop or program Mode
ON
CPU self diagnostics error
OFF
CPU self diagnostics good
ON
CPU battery voltage is low
OFF
CPU battery voltage is good or disabled
RUN
CPU
BATT
DL205 User Manual, 3rd Ed., Rev. A, 08/03
3–8
CPU Specifications and Operation
Adjusting the
Analog
Potentiometers
230
240 250–1 260
There are 4 analog potentiometers (pots)
on the face plate of the DL240 CPU.
These pots can be used to change timer
constants, frequency of pulse train
output, etc. Each analog channel has
corresponding V-memory locations for
setting lower and upper limits for each
analog channel. The setup procedures
are covered later in this chapter.
To increase the value associated with the
analog pot, turn the pot clockwise. To
decrease the value, turn the pot counter
clockwise.
PWR
BATT
DL240
CPU
RUN
TERM
CH1
CH2
Analog Pots
CH3
CH4
PORT 1
PORT2
0
Turn clockwise to increase value
RUN
CPU
Max
CH1
CH2
CPU Specifications
and Operation
Communication
Ports
The DL240, DL250–1 and DL260 CPUs have two ports while the DL230 has only
one.
Port 1
DL250–1 and DL260
6P6C Phone Jack
RS232C, 9600 baud
Communication Port
–K-sequence
–DirectNET slave
–MODBUS RTU slave
–easily connect
DirectSOFT32,
handhelds, operator
interfaces, any DirectNet
master
PWR
BATT
DL260
Port 2
DL250–1 and DL260
15-pin SVGA Connector
RS232C/RS422, up to 38.4K baud
Communication Port
–K-sequence
–DirectNET Master/Slave
–MODBUS RTU Master/Slave
–easily connect
DirectSOFT32,
handhelds, operator
interfaces, any DirectNet
or MODBUS master or slave
RUN
CPU
DL230
CPU
Port 1
6P6C Phone Jack
RS232C, 9600 baud
Communication Port
–K-sequence
–easily connect
DirectSOFT, handhelds,
operator interfaces, etc.
Port 2
PORT 1
6P6C Phone Jack
RS232C, up to 19.2K baud
Communication Port
–K-sequence
–DirectNET Slave
–easily connect
DirectSOFT, handhelds,
operator interfaces, or any
DirectNet master
DL205 User Manual, 3rd Ed., Rev. A, 08/03
Port 2
Additional DL260 Features
–ASCII IN/OUT Instructions
–Extended MODBUS Instructions
–RS485 support
PWR
BATT
RUN
CPU
DL240
CPU
RUN
TERM
CH1
CH2
CH3
CH4
PORT 1
PORT2
CPU Specifications and Operation
Port 1
Specifications
230
240 250–1 260
The operating parameters for Port 1 on the DL230 and DL240 CPUs are fixed.
S 6 Pin female modular (RJ12 phone jack) type connector
S K–sequence protocol (slave only)
S RS232C, 9600 baud
S Connect to DirectSOFT32, D2–HPP, DV–1000, OI panels
S Fixed station address of 1
S 8 data bits, one stop
S Asynchronous, Half–duplex, DTE
S Odd parity
1
6
6-pin Female
Modular Connector
230
240 250–1 260
Port 1 Pin Descriptions (DL230 and DL240)
1
2
3
4
5
6
0V
5V
RXD
TXD
5V
0V
Power (–) connection (GND)
Power (+) connection
Receive Data (RS232C)
Transmit Data (RS232C
Power (+) connection
Power (–) connection (GND)
The operating parameters for Port 1 on the DL250–1 and DL260 CPU are fixed. This
applies to the DL250 as well.
S 6 Pin female modular (RJ12 phone jack) type connector
S K–sequence protocol (slave only)
S DirectNet (slave only)
S MODBUS RTU (slave only)
S RS232C, 9600 baud
S Connect to DirectSOFT32, D2–HPP, DV1000 or DirectNet master
S 8 data bits, one start, one stop
S Asynchronous, Half–duplex, DTE
S Odd parity
1
6
6-pin Female
Modular Connector
CPU Specifications
and Operation
Port 1
Specifications
3–9
Port 1 Pin Descriptions (DL250–1 and DL260)
1
2
3
4
5
6
0V
5V
RXD
TXD
5V
0V
Power (–) connection (GND)
Power (+) connection
Receive Data (RS232C)
Transmit Data (RS232C
Power (+) connection
Power (–) connection (GND)
NOTE: The 5V pins are rated at 200mA maximum, primarilly for use with some
operator interface units.
DL205 User Manual, 3rd Ed., Rev. A, 08/03
3–10
CPU Specifications and Operation
The operating parameters for Port 2 on the DL240 CPU is configurable using Aux
functions on a programming device.
S 6 Pin female modular (RJ12 phone jack) type connector
S K–sequence protocol, DirectNet (slave),
S RS232C, Up to 19.2K baud
S Address selectable (1–90)
S Connect to Direct SOFT32, D2–HPP, DV1000, MMI, or DirectNet
master
S 8 data bits, one start, one stop
S Asynchronous, Half–duplex, DTE
S Odd or no parity
Port 2
Specifications
230
240 250–1 260
Port 2 Pin Descriptions (DL240 only)
1
1
2
3
4
5
6
6
CPU Specifications
and Operation
6-pin Female
Modular Connector
230
Power (–) connection (GND)
Power (+) connection (200mA max.)
Receive Data (RS232C)
Transmit Data (RS232C
Request to Send
Power (–) connection (GND)
Port 2 on the DL250 and DL260 CPUs is located on the 15 pin D-shell connector. It is
configurable using AUX functions on a programming device. This applies to the
DL250 as well
S 15 Pin female D type connector
S Protocol: K sequence, DirectNet Master/Slave, MODBUS RTU
Master/Slave, Remote I/O, (ASCII IN/OUT DL260 only)
S RS232C, non-isolated, distance within 15 m (approx. 50 feet)
S RS422, non-isolated, distance within 1000 m
S RS485, non–isolated, distance within 1000m (DL260 only)
S Up to 38.4K baud
S Address selectable (1–90)
S Connects to DirectSOFT32, D2–HPP, operator interfaces, any
DirectNet or MODBUS master/slave, (ASCII devices DL260 only)
S 8 data bits, one start, one stop
S Asynchronous, Half–duplex, DTE Remote I/O
S Odd/even/none parity
Port 2
Specifications
0V
5V
RXD
TXD
RTS
0V
240 250–1 260
Port 2 Pin Descriptions (DL250–1 / DL260)
6
11
1
10
5
15
15-pin Female
D Connector
DL205 User Manual, 3rd Ed., Rev. A, 08/03
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
5V
TXD2
RXD2
RTS2
CTS2
RXD2–
0V
0V
TXD2+
TXD2 –
RTS2 +
RTS2 –
RXD2 +
CTS2 +
CTS2 –
5 VDC
Transmit Data (RS232C)
Receive Data (RS232C)
Ready to Send (RS–232C)
Clear to Send (RS–232C)
Receive Data – (RS–422) (RS–485 DL260)
Logic Ground
Logic Ground
Transmit Data + (RS–422) (RS–485 DL260)
Transmit Data – (RS–422) (RS–485 DL260)
Request to Send + (RS–422) (RS–485 DL260)
Request to Send – (RS–422)(RS–485 DL260)
Receive Data + (RS–422) (RS–485 DL260)
Clear to Send + (RS422) (RS–485 DL260)
Clear to Send – (RS–422) (RS–485 DL260)
CPU Specifications and Operation
3–11
Using Battery Backup
An optional lithium battery is available to maintain the system RAM retentive
memory when the DL205 system is without external power. Typical CPU battery life
is five years, which includes PLC runtime and normal shutdown periods. However,
consider installing a fresh battery if your battery has not been changed recently and
the system will be shutdown for a period of more than ten days.
NOTE: Before installing or replacing your CPU battery, back-up your V-memory and
system parameters. You can do this by using DirectSOFT32 to save the program,
V-memory, and system parameters to hard/floppy disk on a personal computer.
DL230 and DL240
DL250–1 and DL260
To install the D2–BAT–1 CPU battery in the
DL250–1 / DL260 CPUs: (#CR2354)
1. Press the retaining clip on the battery door
down and swing the battery door open.
2. Place the battery into the coin–type slot
with the (+) side outward.
3. Close the battery door making sure that it
locks securely in place.
4. Make a note of the date the battery was
installed.
CPU Specifications
and Operation
To install the D2–BAT CPU battery in
DL230 or DL240 CPUs:
1. Gently push the battery connector
onto the circuit board connector.
2. Push the battery into the retaining
clip. Don’t use excessive force. You
may break the retaining clip.
3. Make a note of the date the battery
was installed.
WARNING: Do not attempt to recharge the battery or dispose of an old battery by
fire. The battery may explode or release hazardous materials.
Enabling the
Battery Backup
In the DL205 CPUs, the battery can be enabled by setting bit 12 in V7633 On. In this
mode the battery Low LED will come on when the battery voltage is less than
2.5VDC (SP43) and error E41 will occur. In this mode the CPU will maintain the data
in C,S,T,CT, and V memory when power is removed from the CPU, provided the
battery is good. The use of a battery can also determine which operating mode is
entered when the system power is connected. See CPU Setup, which is discussed
later in this chapter.
Even if you have installed a battery, the battery circuit can be disabled by turning off
bit 12 in V7633. However, if you have a battery installed and select “No Battery”
operation, the battery LED will not turn on if the battery voltage is low.
DL205 User Manual, 3rd Ed., Rev. A, 08/03
3–12
CPU Specifications and Operation
Selecting the Program Storage Media
Built-in EEPROM
230
240 250–1 260
The DL230 and DL240 CPUs provide built-in EEPROM storage. This type of
memory is non-volatile and is not dependent on battery backup to retain the
program. The EEPROM can be electrically reprogrammed without being removed
from the CPU. You can also set Jumper 3, which will write protect the EEPROM. The
jumper is set at the factory to allow changes to EEPROM. If you select write
protection by changing the jumper position, you cannot make changes to the
program.
WARNING: Do NOT change Jumper 2. This is for factory test operations. If you
change Jumper 2, the CPU will not operate properly.
CPU Specifications
and Operation
Jumper in position
shown selects write
protect for EEPROM
EEPROM
EEPROM Sizes
The DL230 and DL240 CPUs use different sizes of EEPROMs. The CPUs come
from the factory with EEPROMs already installed. However, if you need extra
EEPROMs, select one that is compatible with the following part numbers.
CPU Type
EEPROM
Operations
EEPROM Part Number
Capacity
DL230
Hitachi HN58C65P–25
8K byte (2Kw)
DL240
Hitachi HN58C256P–20
32K byte (3Kw)
There are many AUX functions specifically for use with an EEPROM in the Handheld
Programmer. This enables you to quickly and easily copy programs between a
program developed offline in the Handheld and the CPU. Also, you can erase
EEPROMs, compare them, etc. See the DL205 Handheld Programmer Manual for
details on using these AUX functions with the Handheld Programmer.
NOTE: If the instructions are supported in both CPUs and the program size is within
the limits of the DL230, you can move a program between the two CPUs. However,
the EEPROM installed in the Handheld Programmer must be the same size (or
larger) than the CPU being used. For example, you could not install a DL240
EEPROM in the Handheld Programmer and download the program to a DL230.
Instead, if the program is within the size limits of the DL230, use a DL230 chip in the
Handheld when you obtain the program from the DL240.
DL205 User Manual, 3rd Ed., Rev. A, 08/03
3–16
CPU Specifications and Operation
Setting the CPU
Network Address
230
240 250–1 260
The DL240, DL250–1 and DL260 CPUs have built in DirectNet ports. You can use
the Handheld Programmer to set the network address for the port and the port
communication parameters. The default settings are:
S Station Address 1
S Hex Mode
S Odd Parity
S 9600 Baud
The DirectNet Manual provides additional information about choosing the
communication settings for network operation.
The DL205 CPUs provide certain ranges of retentive memory by default. The default
ranges are suitable for many applications, but you can change them if your
application requires additional retentive ranges or no retentive ranges at all. The
default settings are:
Setting Retentive
Memory Ranges
DL230
CPU Specifications
and Operation
Memory Area
Default Range
Avail. Range
DL240
Default Range
Avail. Range
DL250–1
Default Range
Avail. Range
DL260
Default Range
Avail. Range
Control Relays
C300 – C377
C0 – C377
C300 – C377
C0 – C377
C1000 – C1777
C0 – C1777
C1000 – C1777
C0 – C3777
V Memory
V2000 – V7777
V0 – V7777
V2000 – V7777
V0 – V7777
V1400 – V3777
V0 – V17777
V1400 – V3777
V0 – V37777
Timers
None by default
T0 – T77
None by default
T0 – T177
None by default
T0 – T377
None by default
T0 – T377
Counters
CT0 – CT77
CT0 – CT77
CT0 – CT177
CT0 – CT177
CT0 – CT177
CT0 – CT177
CT0 – CT377
CT0 – CT377
Stages
None by default
S0 – S377
None by default
S0 – S777
None by default
S0 – S1777
None by default
S0 – S1777
You can use AUX 57 to set the retentive ranges. You can also use DirectSOFT32
menus to select the retentive ranges.
WARNING: The DL205 CPUs do not come with a battery. The super capacitor will
retain the values in the event of a power loss, but only for a short period of time,
depending on conditions. If the retentive ranges are important for your application,
make sure you obtain the optional battery.
Password
Protection
The DL205 CPUs allow you to use a password to help minimize the risk of
unauthorized program and/or data changes. The DL240, DL250–1 and DL260 offer
multi–level passwords for even more security. Once you enter a password you can
“lock” the CPU against access. Once the CPU is locked you must enter the
password before you can use a programming device to change any system
parameters.
You can select an 8-digit numeric password. The CPUs are shipped from the factory
with a password of 00000000. All zeros removes the password protection. If a
password has been entered into the CPU you cannot enter all zeros to remove it.
Once you enter the correct password, you can change the password to all zeros to
remove the password protection.
For more information on passwords, see the appropriate appendix on auxiliary
functions.
WARNING: Make sure you remember your password. If you forget your password
you will not be able to access the CPU. The CPU must be returned to the factory to
have the password removed.
DL205 User Manual, 3rd Ed., Rev. A, 08/03
4–23
System Design and Configuration
Network Connections to MODBUSR and DirectNet
Configuring Port 2 This section describes how to configure the CPU’s built-in networking ports for either
MODBUS or DirectNET. This will allow you to connect the DL205 PLC system
For DirectNet
directly to MODBUS networks using the RTU protocol, or to other devices on a
5 4 4 4
DirectNET network. MODBUS hosts system on the network must be capable of
230 240 250–1 260
issuing the MODBUS commands to read or write the appropriate data. For details on
For MODBUS RTU the MODBUS protocol, please refer to the Gould MODBUS Protocol reference
Guide (P1–MBUS–300 Rev. J). In the event a more recent version is available,
5 5 4 4
check with your MODBUS supplier before ordering the documentation. For more
230 240 250–1 260
details on DirectNET, order our DirectNET manual, part number DA–DNET–M.
You will need to determine whether the network connection is a 3-wire RS–232 type,
or a 5-wire RS–422 type. Normally, the RS–232 signals are used for shorter
distances (15 meters max), for communications between two devices. RS–422
signals are for longer distances (1000 meters max.), and for multi-drop networks
(from 2 to 247 devices). Use termination resistors at both ends of RS–422 network
wiring, matching the impedance rating of the cable (between 100 and 500 ohms).
RXD+
RXD–
TXD+
TXD–
Signal GND
RS–422
Multi–drop
Network
PC/PLC Master
9 TXD+
10 TXD–
13 RXD+
6 RXD–
11 RTS+
12 RTS–
14 CTS+
15 CTS–
7 0V
PORT 1: DL250–1, DL260 (slave only)
PORT 2: DL240 (slave only)
1 0V
3 RXD
4
TXD
RS–232C
Point-to-point
DTE Device
Signal GND
RXD
RS–232
Master
TXD
Port 1 Pinouts (DL250–1 / DL260)
0V
5V
RXD
TXD
5V
0V
Power (–) connection (GND)
Power (+) conection
Receive Data (RS232C)
Transmit Data (RS232C
Power (+) conection
Power (–) connection (GND)
PORT 2
(DL250–1, DL260)
RS–422 Slave
Port 2 Pin Descriptions (DL240 only)
1
2
3
4
5
6
0V
5V
RXD
TXD
RTS
0V
Power (–) connection (GND)
Power (+) conection
Receive Data (RS232C)
Transmit Data (RS232C
Request to Send
Power (–) connection (GND)
Port 2 Pin Descriptions (DL250–1 / DL260)
6
11
1
10
5
15-pin Female
D Connector
15
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
5V
TXD2
RXD2
RTS2
CTS2
RXD2–
0V
0V
TXD2+
TXD2 –
RTS2 +
RTS2 –
RXD2 +
CTS2 +
CTS2 –
5 VDC
Transmit Data (RS232C)
Receive Data (RS232C)
Ready to Send (RS–232C)
Clear to Send (RS–232C)
Receive Data – (RS–422) (RS–485 DL260)
Logic Ground
Logic Ground
Transmit Data + (RS–422) (RS–485 DL260)
Transmit Data – (RS–422) (RS–485 DL260)
Request to Send + (RS–422) (RS–485 DL260)
Request to Send – (RS–422)(RS–485 DL260)
Receive Data + (RS–422) (RS–485 DL260)
Clear to Send + (RS422) (RS–485 DL260)
Clear to Send – (RS–422) (RS–485 DL260)
The recommended cable
for RS422 is Belden
9729 or equivalent.
System Design
and Configuration
6-pin Female
Modular Connector
1
2
3
4
5
6
Termination
Resistor on
last slave only
Note: The DL260 supports
RS–485 multi–drop networking. See the Network
Master Operation (DL260
0nly) section later in this
chapter for details.
DL205 User Manual, 3rd Ed., Rev. A, 08/03
9–2
Maintenance and Troubleshooting
Hardware Maintenance
Standard
Maintenance
Maintenance
and Troubleshooting
Air Quality
Maintenance
Low Battery
Indicator
CPU Battery
Replacement
The DL205 is a low maintenance system requiring only a few periodic checks to help
reduce the risks of problems. Routine maintenance checks should be made
regarding two key items.
S Air quality (cabinet temperature, airflow, etc.)
S CPU battery
The quality of the air your system is exposed to can affect system performance. If
you have placed your system in an enclosure, check to see that the ambient
temperature is not exceeding the operating specifications. If there are filters in the
enclosure, clean or replace them as necessary to ensure adequate airflow. A good
rule of thumb is to check your system environment every one to two months. Make
sure the DL205 is operating within the system operating specifications.
The CPU has a battery LED that indicates the battery voltage is low. You should
check this indicator periodically to determine if the battery needs replacing. You can
also detect low battery voltage from within the CPU program. SP43 is a special relay
that comes on when the battery needs to be replaced. If you are using a DL240 CPU,
you can also use a programming device or operator interface to determine the
battery voltage. V7746 contains the battery voltage. For example, a value of 32 in
V7746 would indicate a battery voltage of 3.2V.
The CPU battery is used to retain program V memory and the system parameters.
The life expectancy of this battery is five years.
Maintenance
and Troubleshooting
NOTE: Before installing or replacing your CPU battery, back-up your V-memory and
system parameters. You can do this by using DirectSOFT32 to save the program,
V-memory, and system parameters to hard/floppy disk on a personal computer.
To install the D2–BAT CPU battery in
DL230 or DL240 CPUs:
1. Gently push the battery connector
onto the circuit board connector.
DL230
2. Push the battery into the retaining and
clip. Don’t use excessive force. You DL240
may break the retaining clip.
3. Make a note of the date the battery
was installed.
To install the D2–BAT–1 CPU battery in the
DL250–1 and DL260 CPUs: (#CR2354)
DL250–1
1. Press the retaining clip on the battery door
DL260
down and swing the battery door open.
2. Remove old battery and insert the new
battery into the coin–type slot with the
larger (+) side outwards.
3. Close the battery door making sure that it
locks securely in place.
4. Make a note of the date the battery was
installed.
WARNING: Do not attempt to recharge the battery or dispose of an old battery by
fire. The battery may explode or release hazardous materials.
DL205 User Manual, 3rd Ed., Rev. A, 08/03
9–10
Maintenance and Troubleshooting
CPU Indicators
Maintenance
and Troubleshooting
The DL205 CPUs have indicators on the front to help you diagnose problems with
the system. The table below gives a quick reference of potential problems
associated with each status indicator. Following the table will be a detailed analysis
of each of these indicator problems.
Indicator Status
Potential Problems
PWR (off)
1. System voltage incorrect.
2. Power supply/CPU is faulty
3. Other component such an I/O module has power
supply shorted
4. Power budget exceeded for the base being used
RUN
(will not come on)
1. CPU programming error
2. Switch in TERM position
3. Switch in STOP position (DL250–1, DL260 only)
CPU (on)
1. Electrical noise interference
2. CPU defective
BATT (on)
1. CPU battery low
2. CPU battery missing, or disconnected
Status Indicators
DL260
DL250-1
Mode Switch
Maintenance
and Troubleshooting
Port 1
Port 2
Battery Slot
Status Indicators
PWR
BATT
PWR
BATT
RUN
CPU
RUN
CPU
DL240
DL230
CPU
CPU
Port 1
RUN
TERM
CH1
CH2
CH3
CH4
PORT 1
Port 2
PORT 1
PORT2
DL205 User Manual, 3rd Ed., Rev. A, 08/03
Mode Switch
9–11
Maintenance and Troubleshooting
PWR Indicator
There are four general reasons for the CPU power status LED (PWR) to be OFF:
1. Power to the base is incorrect or is not applied.
2. Base power supply is faulty.
3. Other component(s) have the power supply shut down.
4. Power budget for the base has been exceeded.
If the voltage to the power supply is not correct, the CPU and/or base may not
operate properly or may not operate at all. Use the following guidelines to correct the
problem.
WARNING: To minimize the risk of electrical shock, always disconnect the system
power before inspecting the physical wiring.
Faulty CPU
Maintenance
and Troubleshooting
1. First, disconnect the system power and check all incoming wiring for loose
connections.
2. If you are using a separate termination panel, check those connections to
make sure the wiring is connected to the proper location.
3. If the connections are acceptable, reconnect the system power and
measure the voltage at the base terminal strip to insure it is within
specification. If the voltage is not correct shut down the system and correct
the problem.
4. If all wiring is connected correctly and the incoming power is within the
specifications required, the base power supply should be returned for
repair.
There is not a good check to test for a faulty CPU other than substituting a known
good one to see if this corrects the problem. If you have experienced major power
surges, it is possible the CPU and power supply have been damaged. If you suspect
this is the cause of the power supply damage, a line conditioner which removes
damaging voltage spikes should be used in the future.
Maintenance
and Troubleshooting
Incorrect Base
Power
DL205 User Manual, 3rd Ed., Rev. A, 08/03
9–12
Maintenance and Troubleshooting
Device or Module
It is possible a faulty module or external device using the system 5V can shut down
causing the Power the power supply. This 5V can be coming from the base or from the CPU
communication ports.
Supply to
Shutdown
To test for a device causing this problem:
1. Turn off power to the CPU.
2. Disconnect all external devices (i.e., communication cables) from the CPU.
3. Reapply power to the system.
Maintenance
and Troubleshooting
If the power supply operates normally you may have either a shorted device or a
shorted cable. If the power supply does not operate normally then test for a module
causing the problem by following the steps below:
If the PWR LED operates normally the problem could be in one of the modules. To
isolate which module is causing the problem, disconnect the system power and
remove one module at a time until the PWR LED operates normally.
Follow the procedure below:
S Turn off power to the base.
S Remove a module from the base.
S Reapply power to the base.
Bent base connector pins on the module can cause this problem. Check to see the
connector is not the problem.
Maintenance
and Troubleshooting
Power Budget
Exceeded
If the machine had been operating correctly for a considerable amount of time prior
to the indicator going off, the power budget is not likely to be the problem. Power
budgeting problems usually occur during system start-up when the PLC is under
operation and the inputs/outputs are requiring more current than the base power
supply can provide.
WARNING: The PLC may reset if the power budget is exceeded. If there is any doubt
about the system power budget please check it at this time. Exceeding the power
budget can cause unpredictable results which can cause damage and injury. Verify
the modules in the base operate within the power budget for the chosen base. You
can find these tables in Chapter 4, Bases and I/O Configuration.
DL205 User Manual, 3rd Ed., Rev. A, 08/03
9–13
Maintenance and Troubleshooting
RUN Indicator
CPU Indicator
If the CPU indicator is on, a fatal error has occurred in the CPU. Generally, this is not
a programming problem but an actual hardware failure. You can power cycle the
system to clear the error. If the error clears, you should monitor the system and
determine what caused the problem. You will find this problem is sometimes caused
by high frequency electrical noise introduced into the CPU from an outside source.
Check your system grounding and install electrical noise filters if the grounding is
suspected. If power cycling the system does not reset the error, or if the problem
returns, you should replace the CPU.
Maintenance
and Troubleshooting
If the CPU will not enter the Run mode (the RUN indicator is off), the problem is
usually in the application program, unless the CPU has a fatal error. If a fatal error
has occurred, the CPU LED should be on. (You can use a programming device to
determine the cause of the error.)
If you are using a DL240, DL250–1 or DL260 and you are trying to change the modes
with a programming device, make sure the mode switch is in the TERM position.
Both of the programming devices, Handheld Programmer and DirectSOFT32, will
return a error message describing the problem. Depending on the error, there may
also be an AUX function you can use to help diagnose the problem. The most
common programming error is “Missing END Statement”. All application programs
require an END statement for proper termination. A complete list of error codes can
be found in Appendix B.
BATT Indicator
Communications Problems
If you cannot establish communications with the CPU, check these items.
S The cable is disconnected.
S The cable has a broken wire or has been wired incorrectly.
S The cable is improperly terminated or grounded.
S The device connected is not operating at the correct baud rate (9600
baud for the top port. Use AUX 56 to select the baud rate for the bottom
port on a DL240, DL250–1 and DL260).
S The device connected to the port is sending data incorrectly.
S A grounding difference exists between the two devices.
S Electrical noise is causing intermittent errors.
S The CPU has a bad communication port and the CPU should be
replaced.
If an error occurs the indicator will come on and stay on until a successful
communication has been completed.
Maintenance
and Troubleshooting
If the BATT indicator is on, the CPU battery is either disconnected or needs
replacing. The battery voltage is continuously monitored while the system voltage is
being supplied.
DL205 User Manual, 3rd Ed., Rev. A, 08/03
9–17
Maintenance and Troubleshooting
Noise Troubleshooting
Reducing
Electrical Noise
While electrical noise cannot be eliminated it can be reduced to a level that will not
affect the system.
S Most noise problems result from improper grounding of the system. A
good earth ground can be the single most effective way to correct noise
problems. If a ground is not available, install a ground rod as close to
the system as possible. Insure all ground wires are single point grounds
and are not daisy chained from one device to another. Ground metal
enclosures around the system. A loose wire is no more than a large
antenna waiting to introduce noise into the system; therefore, you
should tighten all connections in your system. Loose ground wires are
more susceptible to noise than the other wires in your system. Review
Chapter 2 Installation, Wiring, and Specifications if you have questions
regarding how to ground your system.
S Electrical noise can enter the system through the power source for the
CPU and I/O. Installing a isolation transformer for all AC sources can
correct this problem. DC sources should be well grounded good quality
supplies. Switching DC power supplies commonly generate more noise
than linear supplies.
S Separate input wiring from output wiring. Never run I/O wiring close to
high voltage wiring.
Maintenance
and Troubleshooting
Noise is one of the most difficult problems to diagnose. Electrical noise can enter a
system in many different ways and falls into one of two categories, conducted or
radiated. It may be difficult to determine how the noise is entering the system but the
corrective actions for either of the types of noise problems are similar.
S Conducted noise is when the electrical interference is introduced into
the system by way of an attached wire, panel connection ,etc. It may
enter through an I/O module, a power supply connection, the
communication ground connection, or the chassis ground connection.
S Radiated noise is when the electrical interference is introduced into the
system without a direct electrical connection, much in the same manner
as radio waves.
Maintenance
and Troubleshooting
Electrical Noise
Problems
DL205 User Manual, 3rd Ed., Rev. A, 08/03
BULLETIN MI2030-11/00
SAFETY WARNING INSTRUCTIONS
FOR MAXITROL GAS PRESSURE REGULATORS
INSTRUCCIONES PARA PRECAUCIONES DE
SEGURIDAD
NOTE
NOTE: GAS PRESSURE REGULATORS WILL NOT
TURN OFF THE FLOW OF GAS.
PARA REGULADORES DE PRESION DE GAS
MAXITROL
SPECIAL WARNINGS
IF YOU DO NOT FOLLOW THESE INSTRUCTIONS EXACTLY, A
FIRE OR EXPLOSION MAY RESULT CAUSING PROPERTY
DAMAGE, PERSONAL INJURY OR LOSS OF LIFE.
NO UNTRAINED PERSON SHOULD ATTEMPT TO INSTALL,
MAINTAIN OR SERVICE GAS PRESSURE REGULATORS.
To minimize the possibility of FIRE, EXPLOSION, and OTHER HAZARDS:
1. All products, including gas pressure regulators, used with combustible
gas must be installed and used strictly in accordance with the instructions
of the manufacturer, with government codes and regulations, and plumbing
codes and practices.
2. Do not use a gas pressure regulator if it appears to have been subjected
to high temperatures, damaged in any way, or to have been taken apart or
tampered with. Any of these may be signs of possible leakage or other
damage that may affect proper operation and cause potentially dangerous
combustion problems
3.
a. Install the regulator properly with gas flowing as indicated by the arrow
on the casting.
b. Use pipe compound or thread sealant, properly threaded pipes and
careful assembly procedure so that there is no cross threading, etc.,
which might cause damage or leakage.
c. Apply wrench or vise pressure only to the flat areas around the
pipe tappings at the end being threaded to the pipe to avoid possible
fracture of the regulator body which could result in leakage
d. Make sure markings or wording on regulator are not painted over or
obliterated.
4. Check carefully for gas leaks immediately after the regulator has been
installed and the gas turned on. Do this before attempting to operate the
appliance or other gas burning device. Use a rich soap solution (or other
accepted leak tester) around the diaphragm flanges, bottom plate, vent
opening, seal cap, pipe connections, and all other joints. Wipe clean with a
damp rag. It is a good practice to periodically check for leakage during use
of the appliance. Absolutely no leakage should occur, otherwise there
is a danger of fire or explosion depending upon conditions. Never use
if leakage is detected.
CAUTION
NEVER CONNECT REGULATOR DIRECTLY TO THE PROPANE
SUPPLY SOURCE. MAXITROL REGULATORS REQUIRE AN
EXTERNAL REGULATOR (NOT SUPPLIED). INSTALL THE
EXTERNAL REGULATOR BETWEEN THE PROPANE SUPPLY
SOURCE AND MAXITROL REGULATOR.
5. Very high pressure surges in the gas supply line (or as a result of exposing
the system to high pressure) may result in serious internal damage and
cause leakage or affect regulator operation. If you suspect that a Maxitrol
regulator has been exposed to more than twice the maximum operating
inlet pressure, as shown in the following chart, turn off the gas and have
the system checked by an expert.
(over)
NOTA
NOTA: LOS REGULADORES DE PRESION DE GAS
NO CORTAN EL FLUJO DE GAS
¡PRECAUCIONES ESPECIALES!
SI USTED NO SIGUE ESTAS INSTRUCCIONES EXACTAMENTE,
PUEDE OCURRIR UN INCENDIO O UNA EXPLOSION, CAUSANDO
DAÑOS A LA PROPIEDAD, LESIONES PERSONALES O PERDIDA
DE VIDAS. NADIE QUE NO HAYA SIDO ENTRENADO DEBERA DE
TRATAR DE INSTALAR, DAR SERVICIO O DAR MANTENIMIENTO A
LOS REGULADORES DE PRESION DE GAS
Para reducir la posibilidad de INCENDIO, EXPLOSION Y OTROS RIESGOS:
1. Todos los productos, incluyendo los reguladores de presión de gas, que se
usan con gases combustibles deberán instalarse y usarse estrictamente de
acuerdo con las instrucciones del fabricante, usando los códigos y reglamentos
gubernamentales así como los códigos y prácticas de plomería.
2. No usar un regulador de presión de gas si parece haber estado expuesto a
altas temperaturas, dañado en alguna forma o que se haya desmantelado o
maltratado. Cualquiera de éstas pueden ser señales de posibles fugas u otros
daños que pueden afectar el funcionamiento correcto y causar problemas de
combustión potencialmente peligrosos.
3.
a.
b.
c.
d.
Instalar el regulador correctamente con el gas fluyendo como se indica en la
flecha en la carcasa de fundición.
Usar un compuesto sellador de tubería o hilo sellador de rosca, tuberías
correctamente roscadas y procedimientos de ensamble cuidadoso,
asegurándose de que no haya trasroscados, lo cual podría causar daños o fugas.
Aplicar únicamente la presión de una llave o tornillo de banco en las áreas planas
alrededor de las roscas de la tubería del extremo a enroscar para evitar la posible
rotura del cuerpo del regulador que podría resultar en fugas.
Asegurarse de que no se pinten o tachen las marcas o escritura en el regulador.
4. Verificar inmediatamente que no haya fugas de gas después de que el regulador
haya sido instalado y se haya abierto el paso del gas. Esto deberá hacerse antes de
tratar de operar el aparato electrodoméstico o cualquier otro dispositivo
quemador de gas.
gas. Usar una solución espesa de jabón (u otro probador de fugas
aceptado) alrededor de las bridas del diafragma, el fondo del plato, la apertura de
ventilación, la tapa selladora y las conexiones de la tubería y todas las demás juntas.
Limpiar con un trapo húmedo. Es una buena práctica verificar periódicamente que no
haya fugas durante el uso del aparato electrodoméstico. Absolutamente no deberá
haber ninguna fuga. De otra forma hay peligro de incendio o explosión
dependiendo de las condiciones. Nunca deberá usarse si se detectan fugas.
¡PRECAUCION!
NUNCA CONECTAR EL REGULADOR DIRECTAMENTE AL
SUMINISTRO DE PROPANO. LOS REGULADORES MAXITROL
REQUIEREN UN REGULADOR EXTERNO (NO PROVISTO).
INSTALAR EL REGULADOR EXTERNO ENTRE EL SUMINISTRO DE
PROPANO Y EL REGULADOR MAXITROL
5. Aumentos grandes de presión en la línea de suministro de gas (o como resultado de
exponer el sistema a alta presión) pueden resultar en daños internos y causar fugas o
afectar el funcionamiento del regulador. Si usted sospecha que un regulador Maxitrol ha
sido expuesto a más del doble de la presión máxima de entrada, como se muestra en
la tabla siguiente, cierre el paso del gas y haga que el sistema sea verificado por un
experto.
(a la vuelta)
A copyrighted publication of
www.maxitrol.com
Maxitrol Company
23555 Telegraph Rd., P.O. Box 2230
Southfield, MI 48037-2230 U.S.A.
248.356.1400 • Fax 248.356.0829
6. Venting must be controlled in accordance with government and plumbing
codes and regulations to avoid the danger of escaping gas should there be
internal leakage. Vent pipes must be open and the open end protected against
entry of foreign matter, including water.
6. La ventilación deberá estar controlada de acuerdo con los códigos y reglamentos
gubernamentales de plomería para evitar el peligro de que se escape el gas en caso
de una fuga interna. Los tubos de ventilación deberán estar abiertos y el extremo
abierto deberá estar protegido contra cualquier materia extraña, incluyendo el agua.
7. La presión de salida del regulador deberá medirse para asegurarse que está de
7. The outlet pressure of the regulator must be measured to make sure it is in acuerdo para el uso que se pretende. Si se necesita cambiar un resorte para
accordance with intended usage. If a spring change is required to develop desarrollar la presión de salida requerida, el resorte deberá ser especificado por
the required outlet pressure, the spring must be one specified by MAXITROL MAXITROL y la nueva presión de salida deberá anotarse en el regulador.
8. Caution should be used to guarantee that there is sufficient inlet pressure
to achieve the desired outlet pressure and no readjustment of the outlet
pressure setting should be made unless the inlet pressure is within the proper
limits for the regulator. Failure to follow this may result in overfiring of the
appliance or other gas burning device. The MAXITROL bulletin for the
regulator should be consulted for specific inlet and outlet pressure
relationships.
8. Deberá usarse precaución para garantizar que hay suficiente presión interna para
alcanzar la presión de salida deseada y no deberá hacerse ningún reajuste en la
presión de salida a menos que la presión interna esté dentro de los límites correctos
para el regulador. Si esto no se lleva a cabo podría resultar en una llama excesiva del
aparato electrodoméstico u otro dispositivo quemador de gas. Deberá consultarse el
boletín MAXITROL para el
el regulador
regulador para ver la relación específica entre la presión
de entrada y la de salida.
usarse dentro del rango de temperatura y no
9. Un regulador MAXITROL deberá usarse
deberá excederse la presión máxima de entrada que se muestra en la tabla siguiente
9. A MAXITROL regulator must be used within the temperature range and y deberá estar en la posición indicada de montaje. Los reguladores MAXITROL
not in excess of the maximum inlet pressure shown in the following table and pueden usarse con todo tipo de gases combustibles.
should be in the mounting position indicated. Maxitrol regulators can be used
10. En caso de dudas, favor de comunicarse con el Service Manager (Gerente de
with all fuel gases.
Servicio), Maxitrol Company, Southfield, MI USA. Teléfono: 248-356-1400.
10. In case of any doubt, please contact the Service Manager, Maxitrol
Company, Southfield, MI USA. Phone: 248/356-1400.
Maximum Operating
Inlet Pressure
(Presión Máxima de
Entrada para
Operación)
Ambient Temperature Range
(Rango de Temperatura
Ambiente)
Mounting Position
[see below]
(Posiciónde Montaje)
[ver abajo]
RV12LT, RV20LT
1/2 psi (34 mbar)
-40° to 275° F (-40° to 135° C)
A, B, C, D
RV20L
2 psi (138 mbar)
-40° to 225° F (-40° to 107° C)
A, B, C, D
RV47, RV48 (*1)
1/2 psi (34 mbar)
32° to 225° F (0° to 107° C)
A, B, C, D, (*1)
RV48T (*1)
1/2 psi (34 mbar)
32° to 275° F (0° to 135° C)
A, B, C, D, (*1)
RV52, RV53, (*1)
1/2 psi (34 mbar)
-40° to 205° F (-40° to 96° C)
A, B, C, D, (*1)
RV61, (*1)
1 psi (69 mbar)
-40° to 205° F (-40° to 96° C)
A, B, C, D, (*1)
RV81, RV91
1 psi (69 mbar)
-40° to 205° F (-40° to 96° C)
A only (únicamente)
RV111
1 psi (69 mbar)
-40° to 205° F (-40° to 96° C)
A only (únicamente)
RV131
2 psi (138 mbar)
-40° to 125° F (-40° to 52° C)
A only (únicamente)
R400, R500, R600, (*1)
1 psi (69 mbar)
-40° to 205° F (-40° to 96° C)
A, B, C, D, (*1)
R400S, R500S, R600S, (*1)
5 psi (345 mbar)
-40° to 205° F (-40° to 96° C)
A, B, C, D, (*1)
1psi (69 mbar)
-40° to 205° F (-40° to 96° C)
A, B, C, D, (*1)
210D, E, G, J
10 psi (690 mbar)
-40° to 205° F (-40° to 96° C)
A only (únicamente)
210DZ, EZ, GZ, JZ
5 psi (345 mbar)
-40° to 205° F (-40° to 96° C)
A only (únicamente)
220D, E, G, J
10 psi (690 mbar)
-40° to 205° F (-40° to 96° C)
A only (únicamente)
10 psi (690 mbar) (*1)
-40° to 205° F (-40° to 96° C)
A, B, C, D, (*1)
Model Number
(Número de Modelo)
R400Z, R500Z, R600Z
325-3 (*1), 325-5A (*1), 325-7
(*1) When equipped with a ball-check type automatic
vent limiting device (12A04, 12A09, 12A39), regulators
must be in upright position (A) with non-integral vent
limiter installed directly into vent threads. Any other
mounting position may interfere with lockup or
cause pilot outage, where applicable. Maximum inlet
pressure for regulators with 12A09 or 12A39 is 2 psi
(LP) or 5 psi (natural). Inlet pressures exceeding 2 psi
(LP) or 5 psi (natural) require a vent line.
(*1) Para estar seguro que el regulador responde con rapidez cuando
está equipado con un dispositivo limitador de ventilación automático
tipo bola (12A04, 12A09,12A39), los reguladores deberán estar en
posición vertical (A) con el limitador de ventilación instalado directamente
a las roscas del tubo de ventilación. Si se usa cualquier otra posición
durante su instalación, esto podrá interferir con el cierre o causar
que el piloto se apague.
apague. La presión máxima de admisión para
reguladores con los dispositivos 12A09 o 12A39 es de 2 psi (gas licuado)
o 5 psi (gas natural). Las presiones de admisión que excedan 2 psi
(gas licuado) o 5 psi (gas natural) requerirán una línea de ventilación.
Mounting Position (Posición de Montaje)
A
D
Vertical
Flow
(Flujo
Vertical)
B
B
C
Horizontal
Flow
(Flujo
Horizontal)
LITHO IN U.S.A. 110MMP
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
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