Emerson R622 Instruction Manual
Contents
1. overpressured or installed where service conditions could exceed the limits for which the regulators were designed 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 Additionally physical damage to a regulator could cause personal injury and property damage due to escaping Type R622 gas To avoid such injury and damage install the regulator in a safe location A regulator may vent some gas to the atmosphere in hazardous or flammable gas service vented gas might 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 must be protected against condensation or clogging Before installing the 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 Apply pipe compound to the external threads of the pipeline and install the regulator so that the flow is in the direction of the arrow cast on the side of the body The diaphragm actuator assembly can be rotated to any position relative to the body in 90 incremen2. 971 4811 8100 Figure 5 Type R622 Regulator Assembly continued Natural Gas Technologies Emerson Process Management Regulator Technologies Inc USA Headquarters McKinney Texas 75069 1872 USA Tel 1 800 558 5853 Outside U S 1 972 548 3574 Asia Pacific Singapore Singapore 128461 Tel 65 6777 8211 Europe Bologna Italy 40013 Tel 39 051 4190611 Gallardon France 28320 Tel 33 0 2 37 33 47 00 For further information visit www emersonprocess com regulators TESCOM Emerson Process Management Tescom Corporation USA Headquarters Elk River Minnesota 55330 2445 USA Tel 1 763 241 3238 Europe Selmsdorf Germany 23923 Tel 49 0 38823 31 0 The Emerson logo is a trademark and service mark of Emerson Electric Co All other marks are the property of their prospective owners Fisher is a mark owned by Fisher Controls Inc a business of Emerson Process Management 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 Emerson Process Management does not assume responsibility for the selection use or maintenance of any product Responsibility for
3. proper selection use and maintenance of any Emerson Process Management product remains solely with the purchaser Emerson Process Management Regulator Technologies Inc 2004 2009 All Rights Reserved S EMERSON
4. steel 27 Lever Zinc plated steel 28 Stem Assembly 29 Pin Lever 18 8 Stainless steel 30 Machine Screw Carbon plated steel 2 required 31 Closing Cap 33 Disk Nitrile NBR 38 O Ring Nitrile NBR 41 Information Label Part Number T80567T0GY2 1D8293T0022 T21176T0BK2 T13526T0012 T14431T0012 T14436T0012 T13612T0012 T21163T0012 T40653T0012 T14396T0012 T13613T0012 See Table 1 T21186T0012 T21202T0012 T21126T0012 T40655T0022 T1121338982 T21197T0012 T14452T0012 T14397T0012 1E175828982 T21187T0012 T14437T0012 T14422T0012 Type R622 POSITION 1 VENT OVER INLET i L St on ie eg POSITION 4 It POSITION 2 ts I L AJA H oat ___J lt Ye l 11 D T EE lt lt POSITION 3 tL I VENT OVER OUTLET Figure 4 Vent Location NZ D Sy ys Ve gt gt FE Cr PEUT Ly OW Cz a NP WAYS oe 4 43 88 24 33 28 29 80 27 48 D T80577 Figure 5 Type R622 Regulator Assembly Type R622 Industrial Regulators Emerson Process Management Regulator Technologies Inc USA Headquarters McKinney Texas 75069 1872 USA Tel 1 800 558 5853 Outside U S 1 972 548 3574 Asia Pacific Shanghai China 201206 Tel 86 21 2892 9000 Europe Bologna Italy 40013 Tel 39 051 4190611 Middle East and Africa Dubai United Arab Emirates Tel
5. 622 regulators have internal relief across the diaphragm to help minimize overpressure Any outlet pressure above the start to discharge point of the nonadjustable relief valve spring moves the diaphragm off the relief valve seat allowing excess pressure to bleed out through the screened spring case vent Specifications The Specifications section lists operating conditions and other specifications of the Type R622 regulator Information specific to a regulator s construction is stamped on the nameplate Principle of Operation Refer to Figure 2 When downstream demand decreases the pressure under the diaphragm increases This pressure overcomes the regulator setting which is set by a spring Through the action of the pusher post assembly lever and valve stem the valve disk moves closer to the orifice and reduces gas flow If demand downstream increases pressure under the diaphragm decreases Spring force pushes the pusher post assembly downward and the valve disk moves away from the orifice Type R622 regulators include an internal relief valve used to help minimize overpressure Any outlet pressure above the start to discharge point of the non adjustable relief spring moves the diaphragm off of the relief seat allowing excess pressure to discharge through the vent Installation Personal injury equipment damage or leakage due to escaping gas or bursting of pressure containing parts might result if these regulators are
6. Instruction Manual Form 5782 October 2009 Type R622 Type R622 Pressure Reducing Regulator Failure to follow these instructions or W8806 Figure 1 Type R622 Regulator If the regulator vents gas or a leak develops in the system service to the unit may be required Failure to correct trouble to properly install and maintain this equipment could result in an explosion and or fire causing property damage and personal injury or death Fisher regulators must be installed could result in a hazardous condition Call a gas service person to service the unit Only a qualified person must install or service the regulator Introduction operated and maintained in accordance with federal state and local codes rules and regulations and Emerson Process Management Regulator Technologies Inc instructions For LP Gas service an approved regulator such as one listed by UL should be used or approved by the Authority Having Jurisdiction The installation in most states must comply with NFPA 58 standard Scope of the Manual Product Description This manual provides instructions for the installation adjustment maintenance and parts ordering information for the Type R622 pressure reducing regulator Type R622 direct operated spring loaded regulators provide economical pressure reducing control in a variety of residential commercial and industrial applications These regulators can be used w
7. damage to regulator or downstream components during shutdown release downstream pressure to prevent an overpressure condition on the regulator diaphragm Installation arrangements may vary but in any installation it is important that the valves be opened or closed slowly These steps apply to the typical installation 1 Slowly close the downstream shutoff valve 2 Slowly close the upstream shutoff valve 3 Open vent valves downstream of the regulator 4 Open vent valves upstream of the regulator Maintenance Avoid personal injury or damage to property from sudden release of pressure or uncontrolled gas or other process fluid Before starting to disassemble isolate the regulator from all pressure and cautiously release trapped pressure from the regulator Use gauges to monitor inlet loading and outlet pressures while releasing these pressures These procedures are for gaining access to the diaphragm valve disk and orifice All pressure must be released from the diaphragm actuator assembly before the following steps can be performed While using the following procedures refer to Figure 5 for key number locations Diaphragm and Disk Replacement 1 Remove the closing cap key 31 and adjusting screw key 23 2 Remove the spring case machine screws key 4 out of the spring case key 25 and remove the spring case and control spring key 22 3 Lift the diaphragm assembly slightly and slide it away from the l
8. ever key 27 so that the pusher post key 18 releases the lever 4 Remove the diaphragm assembly key 17 Examine the diaphragm assembly replace if necessary 5 Reassemble in the reverse order of the above procedures Place the diaphragm assembly into position in the body key 1 being sure the pusher post is properly hooked on the lever key 27 Rotate the diaphragm so that the diaphragm and lower casing holes align Check the diaphragm for proper orientation Tighten the spring case machine screws key 4 to 15 to 30 inch pounds 2 to 4 Nem 6 To remove the disk follow steps 1 through 4 7 Remove screws key 4 Remove lever key 27 Remove stem assembly key 28 10 Remove disk key 33 from stem assembly key 28 Examine the disk If it is nicked cut or otherwise damaged the disk should be replaced 11 Put together in reverse order Inlet Screen and Orifice Replacement 1 2 Remove the regulator from line Remove machine screws key 4 Remove inlet O ring key 5 Lubricate a new inlet O ring and place on inlet fitting key 3 Remove inlet screen key 13 Clean and or replace the inlet screen if necessary Install the inlet screen key 13 and inlet fitting key 3 Then install and tighten the machine screws key 4 to 15 to 30 inch pounds force 2 to 4 Nem To replace the orifice follow steps 1 through 4 and then remove orifice key 24 from body Examine the seat
9. ing edge of the orifice If it is nicked or rough it should be replaced Treat the external threads of the new orifice with lubricant before reassembling tightening to 15 to 20 inch pounds 2 to 3 Nem of torque Install the inlet screen key 13 and inlet fitting key 3 Then install and tighten the machine screws key 4 to 15 to 30 inch pounds force 2 to 4 Nem Recommended spare part Delrin is a mark owned by E I du Pont de Nemours and Co Parts Ordering Type R622 8 9 The type number orifice size spring range and date of manufacture are located on the spring case Always provide this information in any correspondence with your local Sales Office regarding replacement parts or technical assistance If construction changes are made in the field be sure that the information label is also changed to reflect the most recent construction Parts List Key Description 1 Body Aluminum 2 Pipe Plug Carbon steel 2 required 3 Inlet Fitting Aluminum 4 Machine Screw Carbon Steel 12 required 5 O Ring Nitrile NBR 13 Inlet Screen 18 8 Stainless steel 16 Relief Spring 302 Stainless steel 17 Diaphragm 18 Pusher Post Acetal 19 Lower Spring Seat Zinc plated steel 20 Relief Spring Retainer 18 8 Stainless steel 22 Spring Zinc plated steel 23 Adjusting Screw Delrin For use with inches w c springs For use with psig spring 24 Orifice Aluminum 25 Spring Case Assembly Aluminum 26 Vent Screen 18 8 Stainless
10. ith natural manufactured or liquefied petroleum gases and have the same inlet and outlet pressure capabilities wWww emersonprocess com regulators EMERSON Process Management D103093X012 Type R622 Specifications Body Size and End Connection Style 1 2 NPT Maximum Allowable Inlet Pressure Operating 125 psig 8 62 bar Emergency 125 psig 8 62 bar Except 1 8 to 2 2 inches w c 4 to 5 mbar spring range which has operating and emergency pressures of 60 psig 4 14 bar Maximum Allowable Outlet Casing Pressure Operating to Avoid Internal Part Damage 3 psid 0 21 bar d above outlet pressure setting Emergency 20 psi 1 38 bar Outlet Pressure Ranges See Table 1 Pressure Registration Internal Orifice Size 1 8 inch 3 2 mm Flow Coefficients Wide Open C for Relief Sizing 12 5 Wide Open C for Relief Sizing 0 36 C 35 IEC Sizing Coefficients X 0 78 F 0 82 F 0 89 Internal Relief Performance Start to Discharge is 8 to 22 inches w c 20 to 55 mbar for setpoints from 1 8 to 20 inches w c 4 to 50 mbar Start to Discharge is 140 to 200 over setpoint from 20 inches w c to 2 2 psig 50 to 152 mbar Spring Case Vent Connection 3 4 NPT with removable screen Maximum Temperature Capabilities 20 to 160 F 29 to 71 C Approximate Weight 2 35 pounds 1 kg 1 The pressure temperature limits in this instruction manual or any applicable standard limitation sh
11. ould not be exceeded Table 1 Outlet Pressure Ranges CONTROL SPRING OUTLET PRESSURE RANGE PART NUMBER 1 8 to 2 2 inches w c 4 to 5 mbar T14453T0012 5 to 7 inches w c 12 to 17 mbar T14398T0012 6 5 to 9 inches w c 16 to 22 mbar T14399T0012 9 to 13 inches w c 22 to 32 mbar T14400T0012 13 to 20 inches w c 32 to 48 mbar T14401T0012 16 to 35 inches w c 40 to 87 mbar T14402T0012 1 to 2 2 psig 69 to 152 mbar T14403T0012 CONTROL SPRING SPRING FREE LENGTH SPRING WIRE DIAMETER COLOR CODE INCHES mm INCHES mm Purple 3 40 86 4 0 051 1 30 Orange 3 40 86 4 0 062 1 58 Yellow 3 61 91 7 0 067 1 70 Silver 4 10 104 0 072 1 83 Gray 3 60 91 4 0 080 2 03 Pink 3 52 89 4 0 093 2 36 Light Blue 3 66 93 0 0 105 2 67 Type R622 G LO J mi j CONTROL ns O MAIN SPRING ES Er RELIEF VALVE a SPRING pe UPPER SPRING CASE Si a e O 7 __ st pi g oe e De use MSE 2 VALVE DISK H e pano CE E a7 a Bo io CE T Lee J A OT NA l q a ORIFICE EMMA ATMOSPHERIC PRESSURE ES OUTLET PRESSURE E INLET PRESSURE LEVER Figure 2 Type R622 Operational Schematic In addition Type R
12. ssure to prevent an overpressure condition on the diaphragm of the regulator In order to avoid an overpressure condition and possible equipment damage pressure gauges should always be used to monitor pressures during startup Check to see that all appliances are turned off Slowly open the upstream shutoff valve Slowly open the downstream shutoff valve Check all connections for leaks O A N gt Make final control spring adjustments according to the adjustment procedures 6 Light the appliance pilots Adjustment To increase the outlet pressure setting of the regulator the adjusting screw key 23 Figure 5 must be turned clockwise This requires removal of the closing cap key 31 Figure 5 To reduce the outlet pressure setting turn the adjusting screw counterclockwise A pressure gauge should always be used to monitor downstream pressure while adjustments are being made Do not adjust the spring to produce an outlet pressure setting above the limit identified on the information label If the required pressure setting is not within the range of the spring being used substitute with the correct spring see Table 1 When changing the spring also change the range identified on the information label to indicate the actual pressure range of the spring in use After the spring adjustment has been completed replace the closing cap Shutdown To avoid personal injury or property damage due to explosion or
13. ts Do not install the regulator in a location where there can be excessive water accumulation such as directly beneath a downspout or in an undrained pit To obtain the maximum flow capacities or other performance characteristics the length of pipe from the regulator outlet to the meter or for the first 18 inches 457 mm whichever is closer should have no bends and should be the same size as the regulator outlet Replace the regulator if water gets into the spring case or the lower casing of the regulator Type R622 regulators have a spring case vent 3 4 NPT which is screened to prevent insects or foreign material from entering You are advised to use new vent piping because defective threads on the relief vent piping may interfere with the venting assembly if the piping obstructs the movement of the vent flapper On indoor installations the vent should be piped outside the building see Figure 3 Remove the screen from the regulator vent connection and connect vent piping from that connection to the outdoors Vent piping should be as large in diameter as practical be as short as possible and have a minimum number of bends and elbows Install a weather and insect resistant vent assembly on the outside end of the pipe such as a Type Y602 The same installation TO APPLIANCE VENT LINE gt lt VENT ASSEMBLY Figure 3 Typical Vent Line Installation precautions appl
14. y to vent assemblies as the integral regulator vents described previously A program of regular inspection of the vent opening should be established to see that it has not become plugged by foreign material On some installations such as in areas of heavy snowfall it may be necessary to install the regulator beneath a protective hood If other protection is provided from the elements the vent should be pointing or sloping down sufficiently to allow any condensate to drain Also check the regulator periodically for external or internal corrosion Overpressure Protection Some type of overpressure protection is needed if actual inlet pressure can exceed the outlet pressure rating Overpressuring any portion of this equipment above the limits given in the Specification section and table 1 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 Type R622 regulators provide internal relief that limits the total outlet pressure build up over setpoint This internal relief may be adequate for most application if not provide additional pressure relief or a pressure limiting device downstream Regulators should be inspected for damage after any overpressure condition Type R622 Startup To avoid personal injury or property damage due to explosion or damage to regulator or downstream components during startup release downstream pre
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