Emerson CS400 Instruction Manual
Contents
1. BODY MATERIAL INLET SIZE OUTLET SIZE END CONNECTION FACETO FACE DIMENSION POD YERESSURE RATING In mm psig bar 1 1 4 1 1 4 1 1 4 1 1 2 NPT 4 5 114 Gray Cast Iron 1 1 2 1 1 2 175 12 1 2 2 5 127 NPS 2 DN 50 NPS 2 DN 50 CL125 FF 10 254 1 1 4 1 1 4 45 114 1 1 2 1 1 2 NPT 4 5 114 2 2 5 127 Suei ion 1 1 4 1 1 4 4 5 114 290 20 0 1 1 2 1 1 2 Rp 4 5 114 2 2 5 127 CL125 FF CL150 FF 10 254 NPS 2 DN 50 NPS 2 DN 50 PN IGAS 0 Sn 255 m 1 1 4 1 1 4 45 114 NPT 1 1 2 1 1 2 45 114 Sipel 1 1 4 1 1 4 5 45 114 290 oun 1 1 2 1 1 2 45 114 Table 5 Outlet Pressure Ranges OUTLET PRESSURE RANGE SPRING SPRING WIRE DIAMETER SPRING FREE LENGTH TYPE PART NUMBER In w c mbar COLOR In mm In mm 3 5to5 9 to 12 GE30198X012 Red 0 098 2 49 4 18 106 4 5 to 6 5 11 to 16 GE30195X012 Purple 0 080 2 03 4 32 110 6 to 8 15 to 20 GE30188X012 Gold 0 108 2 74 4 18 106 CS400 7 5t0 11 19 to 27 GE30189X012 Blue 0 110 2 79 4 40 112 CS403 and 10 to 14 25 to 35 GE30224X012 Unpainted 0 110 2 79 4 40 112 CS404 12 to 19 30 to 47 GE30196X012 Green 0 112 2 85 4 70 119 18 in w c to 1 psig 45 to 69 GE30225X012 Orange 0 120 3 05 4 94 125 1 to 2 psig 69 to 138 GE30190X012 Black 0 140 3 56 4 66 118 2 to 5 5 psig 138 to 380 GE30197X012 Yellow 0 172 4 37 4 42 112 Table 6 Type CS403 Regulator and Integral Monitor Outlet Pressure Ranges CS400 Series2. PRIMARY REGULATOR INTEGRAL MONITOR TYPE Setpoint Spring Part Spring Setpoint Spring Part Spring Range Spring In w c mbar Number Color In w c mbar Number In w c mbar Color 4 10 GE30198X012 Red 5 12 GE30195X012 Purple 14 35 GE30189X012 12 to 21 30 to 52 Blue 7 17 GE30188X012 Gold 11 27 GE30189X012 Blue 14 35 GE30224X012 Unpainted 21 52 GE30196X012 18 to 30 45 to 75 Green CS403 18 45 GE30196X012 Green 1 psig 69 GE30225Xx012 26 to 40 65 to 99 Orange 1 psig 69 GE30225X012 Orange 1 5 psig 103 GE30190X012 1 4 to 2 9 psig 97 to 200 Black 2 psig 138 GE30190X012 Black 2 5 psig 172 GE30190X012 1 4 to 2 9 psig 97 to 200 Black 3 psig 207 GE30197X012 3 5 psig 241 GE35081X012 2 6 to 3 7 psig 179 to 255 Purple 4 psig 276 GE30197X012 Yellow 5 psig 345 GE30192X012 3 6 to 6 psig 248 to 414 Dark Blue 5 psig 345 GE30197X012 6 psig 414 GE33121X012 5 1 to 7 5 psig 352 to 517 Red 1 Integral Monitor setpoints shown represent the minimum setpoint difference between the Integral Monitor and the Primary regulator Higher monitor setpoints can be chosen e g for Primary regulator setpoint of 7 in w c 17 mbar the Integral Monitor can also be set at 14 21 in w c 1 psig 35 52 69 mbar or higher Table 7 Type CS404 Regulator and Slam shut OPSO Pressure Ranges SLAM SHUT DEVICE REGULATOR Overpressure Shutoff OPSO Setpo
3. all relief valve discharge to atmosphere without excessive backpressure and resulting excessive pressure in the regulator The Type CS403 offers an optional token relief This optional low capacity relief is located in the spring case of the Primary Regulator If necessary to vent escaping gas away install a remote vent line in the spring case tapping of the Primarily Regulator as described above Periodically check all vent openings to be sure that they are not plugged CS400 Series Outlet pressure ranges are shown in Table 5 Outlet pressure greater than 5 psi 0 34 bar above setpoint may damage internal parts such as the diaphragm head and valve disk The maximum emergency casing outlet pressure is 25 psig 1 7 bar Startup Pressure gauges should always be used to monitor downstream pressure during Startup With the downstream system depressurized use the following procedure to startup the regulator 1 Check to see that all appliances are turned off 2 Slowly open the upstream shut off valve 3 Check inlet and outlet pressure for correct values 4 Check all connections for leaks 5 Turn on utilization equipment and recheck the pressures Adjustment Note For Types that include the Integral Monitor module refer to the instruction manual for Type TM600 Integral Monitor for Adjustment and Maintenance of the Integral Monitor For Types that include the slam shut module refer to the instruction manual fo
4. VSX4 Brass O ring Nitrile NBR Type CS400 1 required Type CS403 2 required Type CS404 2 required O ring Nitrile NBR Valve Disk Aluminum Nitrile NBR Disk Clip Stainless steel Control Spring Music Wire or Stainless steel 3 5 to 5 in w c 9 to 12 mbar Red 4 5 to 6 5 in w c 11 to 16 mbar Purple 6 to 8 in w c 15 to 20 mbar Gold 7 5 to 11 in w c 19 to 27 mbar Blue 10 to 14 in w c 25 to 35 mbar Unpainted 12 to 19 in w c 30 to 47 mbar Green 18 to 28 in w c 45 to 69 mbar Orange 1 to 2 psig 69 to 138 mbar Black 2 to 5 5 psig 138 to 380 mbar Yellow R V Spring Stainless steel Spring Retainer Aluminum Spring Seat Zinc plated steel Non Relief Standard and Token Relief Valve Stem Aluminum Standard Relief Token Relief Diaphragm Screw Retainer for Non Relief Zinc plated steel Adjustable Upper Seat Token Relief Aluminum Token Restrictor Plate Zinc plated steel Pusher Post Aluminum Non Relief Standard and Token Relief Part Number T14397T0012 GE34243X012 GE32059X012 GE32060X012 GE26590X012 T1120637022 1K594906562 GE25384X012 GE25385X012 GE45216X012 GE34199X012 1E175828982 17A0960X012 71122409012 T12522T0012 GE31233X012 71122309012 71122009012 GE31234X012 T1121909012 GE30003X012 GE28684X012 10A3802X022 10A3802X022 10A3802X022 GE01439X012 GE26497X012 GE33771X012 GE30198X012 GE30195X012 GE30188X012 GE30189X012 GE30224X012 GE3019
5. head assembly key 55 away from the body key 70 to unhook the pusher post key 51 from the lever key 10 Lift off the diaphragm head assembly key 55 5 For none relieving units such as the Types CS400IN and CS400EN unscrew the screw retainer key 45 Figure 9 using a 5 8 in 16 mm wrench The screw retainer fastens the lower spring seat key 43 to the pusher post key 51 Unscrewing the screw retainer will separate the lower spring seat key 43 diaphragm head assembly key 55 and pusher post key 51 For units with internal relief such as Type CS400IR press down on the upper spring retainer key 42 Figure 10 using a 9 16 in 14 mm box end wrench and remove the E ring key 58 Slide the upper spring retainer key 42 the relief spring key 41 the lower spring seat key 43 and the diaphragm assembly key 55 off of the relief valve stem key 44 6 Reassemble in reverse order of the above steps Disassembly to Replace Valve Disk and Orifice 1 Remove the cap screws key 71 Figure 8 which hold the lower spring casing key 9 to the body key 70 Separate the lower casing key 9 from the body 2 Check the body O ring key 21 for wear and replace as necessary 3 Examine the valve disk key 36 for nicks cuts and other damage Remove the disk clip key 37 that holds the disk to the stem key 11 and replace the disk if necessary 4 Examine the seating edge of the orifice key 25 If it is ni
6. setpoint In the case of a downstream line break numerous factors can prevent the downstream pipe pressure from decreasing below the slam shut UPSO setpoint These factors include the distance of pipe to the break the diameter of the pipe size of the break and the number of restrictions such as valves elbows and bends downstream of the regulator and or slam shut device Due to these factors additional protections should be installed to stop flow in the event of a line break CS400 Series CS400 SERIES REGULATOR REGULATOR VENT POINTED DOWNWARD PROTECT VENT PIPE oot eet Naa NPS 2 DN 50 TYPE 289H RELIEF VALVE Figure 5 CS400 Series Regulator Installed with the Vent Pointed Downward and with a Type 289H Relief Valve for High Capacity Relief Installation and Overpressure Protection Personal injury or system damage may result if this regulator is installed without appropriate overpressure protection where service conditions could exceed the limits given in the Specifications section and or regulator nameplate Regulator installations should be adeguately protected from physical damage All vents should be kept open to permit free flow of gas to the atmosphere Protect openings against entrance of rain snow insects or any other foreign material that may plug the vent or vent line On outdoor installations point the spring case vent downward to allow condensate to drain see Figures 5 through 7 Th
7. steel 2 reguired Metric O ring Nitrile NBR Cap Screw Steel 4 reguired Nameplate Warning Label Information Label Overlay Label Grommet Nitrile NBR Slip Disk Stainless steel Lockwire Stainless steel Slotted Spring Pin Plated steel Part Number GE26465X022 GE26466X022 GE26469X022 GE26470X022 GE32061X012 10333528992 103335X0012 GE31255xX012 GF03442X012 GF01942X012 GF03443X012 GE38176X012 GE35358X012 GG05787X012 T14088T0012 GE32724X012 15 CS400 Series L1 TOROUE 15 TO 30 IN LBS 1 7 TO 3 4 Nem 8 8 ojn 8H 5 Hs 19 Red 6 E O ZN V N ja X SV TTA 7 EVA S EKS 37 lt Hee et AS IS FZ ENNE BEETS Swe L2 28 A SA JA Zi N KOEN KA _ lt 95 K W J SEN 7 SEN 72 j aN HUN TJ ae 6 s syi ae d TORQUE j RU I N 6 UD U J Ns N Sui aa A KU HS TORQUE YL Via 51 35 TO 45 FT LBS 7 A 47 TO 61 Nem A AG 12 1 19 0 0 900 z O Om R TOROUE 15 TO 30 IN LBS 1 7 TO 3 4 Nem S MAIN VALVE ERAA03738 APPLY LUBRICANT L SEALANT S L1 ANTI SEIZE LUBRICANT L2 SILICONE GREASE S THREAD SEALANT Lubricants and sealant must be selected such that they meet the temperature requirements Figure 8 CS400 Series Regulator Assemblies CS400 Series TOROUE 10 TO 13
8. 6X012 GE30225xX012 GE30190X012 GE30197X012 GE30194X012 GE27296X012 GE27327X012 GE28947X012 GE27297X012 GE30895X012 GE30887X012 GE33332X012 GE28948X012 ERAA00875A0 ERAA00876A0 Key 53 54 55 55a 55b 56 57 58 60 62 65 70 Description Pusher Post Pin Stainless steel Roller Pin Brass Diaphragm Head Assembly Steel Nitrile NBR Diaphragm Diaphragm Head Retaining Ring Pusher Post Pin Steel Slotted Spring Pin Zinc plated Steel E Ring Standard Relief Closing Cap Aluminum O ring Nitrile NBR Adjusting Screw Aluminum Globe Valve Body Gray Cast iron 1 1 4 NPT 1 1 4 x 1 1 2 NPT 1 1 2 NPT 2 NPT Flange NPS 2 DN 50 CL125 FF Ductile Iron 1 1 4 NPT 1 1 2 NPT 2 NPT Rp 1 1 4 Rp 1 1 2 Rp 2 NPS 2 DN 50 CL125 CL150 FF NPS 2 DN 50 PN 10 16 Recommended spare part Part Number GE29761X012 GE27060X012 GE31248X012 GE33772Xx012 GE33668X012 GE32969X012 GE29244X012 T10275X0012 GE27828X012 GE26446X012 GE44458X012 GE26448X012 GE26459X012 GE26460xX012 GE26465Xx012 GE26466X012 GE26467X012 GE26469X012 GE26470X012 GE26471X012 GE26480X012 GE26481X012 Key 70 71 72 74 75 76 77 80 90 91 93 94 95 96 100 101 CS400 Series Description Globe Valve Body continued Steel 1 1 4 NPT 1 1 2 NPT Rp 1 1 4 Rp 1 1 2 Cap Screw Steel 2 required Pipe Plug 1 4 NPT Steel Stainless steel Blanking Plug Aluminum Metric O ring Nitrile NBR Half Flange Plated
9. FT LBS 14 TO 18 Nem TOROUE 63 TO 90 IN LBS 7 TO 10 Nem ERAA03738 Figure 8 CS400 Series Regulator Assemblies continued TORQUE 50 TO 70 IN LBS 5 6 TO 7 9 Nem L1 TORQUE 50 TO 70 IN LBS 5 6 TO 7 9 Nem N S L ees S TORQUE A 50 TO 70 IN LBS ZA 5 6 TO 7 9 Nem A ee a NG Re 45 STANDARD RELIEF CA APPLY LUBRICANT L ADHESIVE A L1 ANTI SEIZE LUBRICANT A ADHESIVE ERAA03738 1 Lubricants and adhesive must be selected such that they meet the temperature reguirements Figure 9 CS400 Series Diaphragm and Stem Assemblies 17 CS400 Series TOROUE 15 TO 30 IN LBS 1 7 TO 3 4 Nem L2 12 VMA id OIIZLLJEZZ ERAA03738 EXTERNAL REGISTRATION INTERNAL REGISTRATION Figure 10 CS400 Series Registration Options TOROUE L2 L2 L2 35 TO 45 FT LBS 47 TO 61 Nm TORQUE L1 35 TO 45 FT LBS 47 TO 61 Nm EN xX KY T Gay N JJ jf J G pan gt N LLLP TRUE MONITOR ASSEMBLY ORIFICE AND TRUE MONITOR ASSEMBLY APPLY LUBRICANT L L1 ANTI SEIZE LUBRICANT L2 SILICONE GREASE Lubricants must be selected such that they meet the temperature requirements Figure 11 CS400 Series Slam shut and Integral Monitor Modul
10. Instruction Manual Form 5833 October 2014 CS400 Series CS400 Series Commercial Industrial Pressure Reducing Regulators ea A Ge P1190 AN TYPICAL TYPE CS400 REGULATOR P1426 TYPICAL TYPE CS403 REGULATOR WITH INTEGRAL TRUE MONITOR REGULATOR P1424 TYPICAL TYPE CS404 REGULATOR WITH INTEGRAL TYPE VSX4 SLAM SHUT MODULE Figure 1 Typical CS400 Pressure Reducing Regulators Table of Contents IRTOA WCU Oise ereseenccincatterteeccncesesaemiaaeeccrasineetanerecete nte 1 SPSCITICALIOMS iimsna isamaa saamaa EEEn i a 3 Principle of Operation uussssos sonnan ennnen 7 Installation and Overpressure Protection 8 StartUp iman N TTA NT AT te asI NEIN eA N 11 AAJUSIMONT ioiii00a ia ana a nananana mammaa namamanakamamaaukamamamanans 11 SMIUtdOWN ne 12 Maintenance and Inspection ouuuusssss nnen 13 Parts Orderimd lt siioisisaissss sian asan ansa anama saan ama aan aaasadaa 14 Parts EISt immet a aa maahan ananaaanataaahenanel a 14 www fisherregulators com Introduction Scope of the Manual This Instruction Manual provides installation maintenance and parts ordering information for the CS400 Series regulators Instructions and parts lists for other eguipment mentioned in this Instruction Manual are found in separate manuals S EMERSON D103120Xx012 CS400 Series Table 1 Available Configurations TYPE NUMBER OPTIONS OIK KMK OVERPRESSURE PROTECTI
11. ON MODULE 0 Without Overpressure Protection Module 3 With Integral Monitor Module 4 With Slam shut Module 99 PRESSURE REGISTRATION E External Registration Internal Registration RELIEF N Non Relief T Token Internal Relief R Internal Relief Example Type number CS404IT CS400 regulator constructed with Type VSX4 slam shut module with internal pressure registration and with token relief 1 Reference Instruction Manual D103126X012 for information regarding the Integral Monitor module 2 Reference Instruction Manual D103127X012 for information regarding the Type VSX4 safety shut off module 3 Available only with Non Relieving or Token Relief options not Internal Relief Table 2 Inlet Pressure Ratings and Flow and Sizing Coefficients MAXIMUM OPERATING FLOW COEFFICIENTS ORIFICE SIZE INLET PRESSURE WIDE OPEN IEC SIZING COEFFICIENTS TYPE C 3 16 4 8 125 8 6 27 0 97 27 7 0 50 0 91 1 4 6 4 125 8 6 50 1 77 28 2 0 50 0 92 CS400 5 16 7 9 100 6 9 82 2 90 28 3 0 50 0 94 CS403 and 3 8 9 5 60 4 1 113 3 72 30 4 0 58 0 89 0 89 CS404 1 2 12 40 2 8 182 5 61 32 4 0 66 0 82 5 8 16 30 21 284 7 26 39 1 0 97 0 74 3 4 19 20 1 4 356 9 83 36 2 0 83 0 72 Z WARNING Description 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 de
12. agement Regulator Technologies Inc does not assume responsibility for the selection use or maintenance of any product Responsibility for proper selection use and maintenance of any Emerson Process Management Regulator Technologies Inc product remains solely with the purchaser KS Aw EI EMERSON Emerson Process Management Regulator Technologies Inc 2008 2014 All Rights Reserved
13. ameter of the control line tubing should be 3 8 in 9 5 mm or larger CS400 Series PRIMARY REGULATOR UPSTREAM BLOCK VALVE 20 IN 508 mm DOWNSTREAM BLOCK VALVE M1062 INTEGRAL MONITOR Figure 6 Type CS403 Downstream Control Line Connection PRIMARY REGULATOR UPSTREAM BLOCK VALVE 20 IN 508 mm lt gt gt oo DOWNSTREAM BLOCK VALVE Linnalan niini M1063 I INLET PRESSURE OUTLET PRESSURE ATMOSPHERIC PRESSURE SLAM SHUT Figure 7 Type CS404 Downstream Control Line Connection 10 Downstream Control Line Installation with Integral Monitor Refer to Figure 6 When installing the Types CS403ET and CS403EN regulators connect downstream control line tubing to the lower casing of the Primary Regulator and run the tubing approximately 20 in 508 mm downstream Connect a second separate downstream control line tubing to the lower casing of the Integral Monitor and run the tubing approximately 20 in 508 mm downstream For best results the outer diameter of the control line tubing for both the Primary Regulator and the Integral Monitor should be 3 8 in 9 5 mm or larger Downstream Control Line Installation with Slam shut Refer to Figure 7 When installing the Types CS404ET and CS404EN regulators connect downstream control line tubing to the lower casin
14. ath Fisher regulators must be installed operated and maintained in accordance with federal state and local codes rules and regulations and Emerson Process Management Inc Emerson instructions If the regulator vents gas or a leak develops in the system service to the unit may be required Failure to correct trouble 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 CS400 Series regulators are typically installed on industrial and commercial applications See Table 1 for available configurations Constructions with External Registration e g Type CS400EN require an external control line Optional internal relief is available as well as low capacity token relief Additional overpressure protection options include the Type CS403 that offers True Monitor Protection which is provided by an Integral Monitor installed on the inlet side of the valve body that assumes control of the pressure to the downstream system should the primary regulator cease to regulate downstream flow The Type CS404 offers a slam shut module that shuts off the flow of gas to the downstream system in the event of outlet pressure rising above or falling below the predefined levels Specifications CS400 Series The Specifications section on the following page lists the specifications for the CS400 Series regulators The following information is s
15. cked or rough remove the orifice key 25 from the body key 70 using a 1 1 16 in 27 mm socket wrench Coat the threads of the replacement orifice with a good quality lubricant and install CS400 Series Change to a new part when reassembling the regulator Coat the threads of the replacement orifice with a good guality lubricant If the orifice is being replaced with a different size update the nameplate to state the new size and maximum inlet pressure Reassemble the regulator in reverse order of the above steps Regulator Reassembly As indicated by the sguare callouts in Figures 8 through 12 it is recommended that a good quality pipe thread sealant be applied to pressure connections and fittings and a good guality lubricant be applied to O rings Also apply an anti seize compound to the adjusting screw threads and other areas as needed Parts Ordering The type number orifice size spring range and date of manufacture are stamped on the nameplate Always provide this information in any correspondence with your local Sales Office regarding replacement parts or technical assistance When ordering replacement parts reference the key number of each needed part as found in the following parts list Separate kit containing all recommended spare parts is available Parts List Key aN O 0 sf WOW N O 10 11 12 Description Spare Parts Repair Parts Kit include keys 19 21 27 36 55 and 62 T
16. e Type VSX slam shut s disk and seat area The operator should be able to hear the pressure bleeding through the system Step 3 When the pressure has egualized and the air bleeding sound has dissipated the reset button key 30 should be pulled completely away from the Type VSX slam shut device by hand until the internal shut off mechanism has been re latched Step 4 Once the operator feels the click of the re latch occurring the reset button key 30 should be pushed completely back into its original position Shutdown Installation arrangements may 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 regulator The steps in the following page apply to the typical installation as indicated 1 Open valves downstream of the regulator 2 Slowly close the upstream shut off valve 3 Inlet pressure will automatically be released downstream as the regulator opens in response to the lowered pressure on the diaphragm Maintenance and Inspection To avoid personal injury or eguipment damage do not attempt any maintenance or disassembly without first isolating the regulator from system pressure and relieving all internal pressure as described in Shutdown Regulators that have been disassembled for repair must be tested for proper operation before being retu
17. es CS400 Series TOROUE TOROUE 35 TO 45 FT LBS 35 TO 45 FT LBS L1 L2 L2 L1 47 TO 61 Nem 47 TO 61 Nem ier i g SLAM SHUT ASSEMBLY ORIFICE AND SLAM SHUT ASSEMBLY Figure 11 CS400 Series Slam shut and Integral Monitor Modules continued S TOROUE 10 TO 13 FT LBS 14 TO 18 Nem GRAY CAST IRON DUCTILE IRON OR STEEL APPLY LUBRICANT L SEALANT S L1 ANTI SEIZE LUBRICANT L2 SILICONE GREASE S THREAD SEALANT 1 Lubricants and sealant must be selected such that they meet the temperature requirements Figure 12 Gray Cast Iron Ductile Iron and Steel Body Configurations CS400 Series Industrial Regulators Emerson Process Management Regulator Technologies Inc USA Headguarters McKinney Texas 75070 USA Tel 1 800 558 5853 Outside U S 1 972 548 3574 Asia Pacific Shanghai 201206 China Tel 86 21 2892 9000 Europe Bologna 40013 Italy Tel 39 051 419 0611 Middle East and Africa Natural Gas Technologies Emerson Process Management Regulator Technologies Inc USA Headquarters McKinney Texas 75070 USA Tel 1 800 558 5853 Outside U S 1 972 548 3574 Asia Pacific Singapore 128461 Singapore Tel 65 6770 8337 Europe Bologna 40013 Italy Tel 39 051 419 0611 Chartres 28008 France Tel 33 2 37 33 47 00 TESCOM Emerson Process Management Tesco
18. g of the Regulator and run the tubing approximately 20 in 508 mm downstream Connect a second separate downstream control line tubing to the lower casing of the slam shut and run the tubing approximately 20 in 508 mm downstream For best results the outer diameter of the control line tubing for the regulator should be 3 8 in 9 5 mm or larger The outer diameter of the control line tubing for the slam shut should be 1 4 in 6 4 mm or larger Installation with External Overpressure Protection If the regulator is used in conjunction with a Type 289H relief valve it should be installed as shown in Figure 5 The outside end of the vent line should be protected with a rainproof assembly The Type 289H should be set 10 in w c 25 mbar higher than the outlet pressure setting of the regulator up to 30 in w c 75 mbar outlet pressure For pressure greater than this set the Type 289H 0 75 psi 0 05 bar higher than the outlet pressure setting of the regulator Vent Line Installation The CS400 Series regulators have a 1 NPT screened vent opening in the spring case If necessary to vent escaping gas away from the regulator install a remote vent line in the spring case tapping Vent piping should be as short and direct as possible with a minimum number of bends and elbows The remote vent line should have the largest practical diameter Vent piping on regulators with internal relief must be large enough to vent CS400 Series
19. gulator with Internally Registered Integral Monitor Operational Schematic UPSO ADJUSTING SCREW ADJUSTING SCREW UPSO SPRING OPSO ADJUSTING CONTROL SPRING SCREW OPSO SPRING SLAM SHUT ORIFICE ORIFICE SLAM SHUT RELIEF VENT SPRING RESET KNOB SLAM SHUT DISK VALVE STEM PUSHER EXTERNAL POST CONTROL LINE DISK CONNECTION SENSE LINE TYPE VSX4 SLAM SHUT MODULE PRIMARY REGULATOR M1063 m INLET PRESSURE E OUTLET PRESSURE ATMOSPHERIC PRESSURE Figure 4 Type CS404ET Externally Registered Regulator with Slam shut Operational Schematic Principle of Operation Type CS400 Base Regulator 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 the regulator control 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 the valve disk moves away from the orifice and the gas flow increases downstream as the regulator opens in response to the decreased pressure underneath the diaphragm The Type CS400IR regulator includes an internal relief valve for overpressure protection If the downstream pressure exceeds the regulator setting by 7 to 28 in w c 17 to 69 mbar depending
20. ig mbar psig mbar psig mbar psig mbar psig mbar 0 51 0 36 to 0 51 25 to 35 0 73 to 1 9 50 to 130 GF02168X012 0 14 to 0 65 45 0 45 to 0 70 30 to 48 1 4 96 0 4 30 14 10 to 75 T14169T0012 0 72 50 1 6 112 1 4 to 3 9 97 to 270 GF02169X012 0 4 30 i 0 65 to 1 45 to 69 1 69 2 5 172 0 58 40 0 36 to 25 to 1 5 103 69 to 3 0 207 2 2to5 5 150 to 380 GF02170X012 0 73 50 T14170T0012 CS404 1to2 2 138 3 207 3 8 to 8 7 262 to 600 GF02171X012 4 276 138 to 2 to 5 5 FA142869X12 5 345 380 2 9 200 5 8 to 16 400 to 1100 GF02172X012 5 5 380 8 8 606 3 6 250 values provided in Table 4 oi the CS400 Bul 1 For Types CS404IT and CS404ET eguipped with Token etin Relief if Non Factory si lam shut OPSO setpoints are specified they musi not encroach on the Token Re ief Start to Discharge CS400 Series MONITOR MONITOR ADJUSTING CONTROL VALVE STEM ADJUSTING SCREW SPRING SCREW CONTROL SPRING GUIDED STEM MONITOR DISK RELIEF gt c OPENING VALVE lt kh SPRING SPRING amp D p amp ap Kr MONITOR LEVER VALVE DISK E EXTERNAL CONTROL EXTERNAL DO NOT REMOVE CONTROL MONITOR ORIFICE PUSHER POST ASSEMBLY a HIDE UNITS LINE PLUG ORIFICE PRESSURIZED INTEGRAL MONITOR PRIMARY REGULATOR M1061 Figure 3 Type CS403 Internally Registered Primary Re
21. int Spring Range Factory Setpoint Spring Range Spring TYPE Part Numb In w c mbar In w c mbar In w c mbar In w c mbar art Number 4 10 5105 9 to 12 18 45 5 12 4 5 to 6 5 11 to 16 19 47 12 to 25 30 to 60 GF02168X012 7 17 6 to 8 15 to 20 21 52 tu al ISSN A SE S 0 58 to 1 6 psi 40 to 110 GF02169X012 14 35 10 to 14 25 to 35 11 75 genes 0 65 psi 45 0 45 to 0 7 psi 30 to 47 1 4 psi 96 a pee ook ce 30 to 44 75 to 110 GF02170x012 i si i CS404 Pag 0 65 to 1 psig 45to69 peg 1 psig 69 2 5 psig 172 1 5 psi 103 3 0 psi 207 1 4 to 4 1 psi 95 to 280 GF02171X012 psig 1to2psig 69 to 138 psig pe BENS 2 psig 138 3 5 psig 241 3 psig 207 6 3 psig 434 4 psi 276 7 3 psi 503 psig 2to5 5psig 138 to 380 psig 3 2 to 11 psig 220 to 760 GF02173X012 5 psig 345 8 3 psig 572 5 5 psig 380 8 8 psig 606 1 For Types CS404IT and CS404ET eguipped with Token Relief if Non Factory slam shut OPSO setpoints are specified they must not encroach on the Token Relief Start to Discharge values provided in Table 4 of the CS400 Bulletin Table 8 Type CS404 Regulator and Slam shut OPSO and UPSO Pressure Ranges REGULATOR SLAM SHUT DEVICE Overpressure Shutoff OPSO Underpressure Shutoff UPSO Setpoint Spring Range Factory Factory N TYPE Setpoint Range Spring Part Setpoint Range Spring Part 3 N N Number Number psig mbar ps
22. is minimizes the possibility of freezing and of water or other foreign materials entering the vent and interfering with proper operation For the Type CS403 with the Integral Monitor or the Type CS404 with slam shut point the vents of both the Primary Regulator and Integral Monitor or slam shut downward to allow condensate to drain From the factory the Integral Monitor or slam shut will always point in the same direction as that of the Primary Regulator Under enclosed conditions or indoors escaping gas may accumulate and be an explosion hazard In these cases the vent should be piped away from the regulator to the outdoors The CS400 Series regulators have an outlet pressure rating lower than their inlet pressure rating If actual inlet pressure can exceed the outlet pressure rating outlet overpressure protection is necessary However overpressuring any portion of the regulators beyond the limits in Specifications section may cause leakage damage to regulator parts or personal injury due to bursting of pressure containing parts Some type of external overpressure protection should be provided to the CS400 Series if inlet pressure will be high enough to damage downstream eguipment Common methods of external overpressure protection include relief valves monitoring regulators shut off devices and series regulation If the regulator is exposed to an overpressure condition it should be inspected for any damage that ma
23. led under a separate protective cover Installing the regulator with the vent down allows condensation to drain minimizes the entry of water or other debris from entering the vent and minimizes vent blockage from freezing precipitation Do not install the Types CS400 CS403 or CS404 in a location where there can be excessive water accumulation or ice formation such as directly beneath a downspout gutter or roof line of building Even a protective hood may not provide adequate protection in these instances e Install the Regulator so that any gas discharge through the vent or vent assembly is over 3 ft 0 91 meters away from any building opening Regulators Subjected to Heavy Snow Conditions Some installations such as in areas with heavy snowfall may require a hood or enclosure to protect the regulator from snow load and vent freeze over Downstream Control Line Installation A CS400 Series regulator with an EN or ET in the type number has a blocked throat an O ring stem seal and a 3 4 NPT control line tapping in the lower diaphragm casing A regulator with a downstream control line is used for monitoring installations or other applications where there is other equipment installed between the regulator and the pressure control point For Types CS400ET and CS400EN regulators connect downstream control line tubing to the lower casing and run the tubing approximately 20 in 508 mm downstream For best results the outer di
24. m Corporation USA Headquarters Elk River Minnesota 55330 2445 USA Tels 1 763 241 3238 1 800 447 1250 Europe Selmsdorf 23923 Germany Tel 49 38823 31 287 Asia Pacific Shanghai 201206 China Tel 86 21 2892 9499 Dubai United Arab Emirates The distinctive swirl pattern cast into every actuator Tel 971 4811 8100 Middle East and Africa casing uniquely identifies the regulator as part of the Dubai United Arab Emirates Fisher brand Commercial Service Regulator family Tel 971 4811 8100 and assures you of the highest quality engineering performance and support traditionally associated with Fisher Tartarini and Francel regulators Visit www fishercommercialservice com to For further information visit www emersonprocess com access interactive applications 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 International LLC 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 Man
25. ng with a setpoint higher than the Integral Monitor s setpoint must be installed to check the operation of the Integral Monitor CS400 Series with Slam shut Module When adjusting the primary regulator and slam shut for operation reference Tables 7 and 8 for the OPSO and UPSO setpoints of the slam shut for the given regulator spring ranges In the case of a downstream line break numerous factors affect the capability to evacuate gas from the pipeline These factors include the distance of pipe to the break the diameter of the pipe size of the break and the number of restrictions such as valves elbows and bends downstream of the regulator and or slam shut device Due to these factors additional protections should be installed to stop flow in the event of a line break Eguipment installed downstream the Type VSX slam shut device can be damaged if the following procedure for resetting the Type VSX slam shut device is not followed This eguipment includes the integral Type VSX regulator configurations Step 1 To properly reset the Type VSX slam shut after it has been tripped to the closed position a flat head screwdriver must be inserted into the position shown in Figure 8 on the backside of the reset button key 30 Figure 8 Step 2 The screwdriver should be slowly rotated to gradually pull the reset button key 30 away from the Type VSX device This slow movement allows for a slow bleed of the pressure across th
26. on the main spring used the relief valve opens and excess gas is vented through the stabilizer vent in the upper spring case The Types CS400IT and CS400ET provide a low capacity token relief Token relief provides relief from minor overpressure caused by nicks or dents on the orifice or by thermal expansion of gas in the downstream line Token relief also provides a token or signal in the form of odor that an overpressure situation is occurring Type CS403 Integral Monitor Operation Type CS403 combines the operation of a conventional two regulator wide open monitor set into one body see Figure 3 The Integral True Monitor is installed on the inlet side of the body and serves to throttle flow and maintain an acceptable downstream pressure in the case where the Primary regulator fails to regulate downstream pressure During normal operation the Integral Monitor is in a wide open state as its setpoint is set higher than the primary regulator See Table 6 for guidance regarding the setpoints of the regulator and associated integral monitor sets If the downstream pressure should rise to the setpoint of the internal monitor due to loss of pressure CS400 Series control by the primary regulator the integral monitor will assume control and regulate the flow to the downstream system See the Type TM600 Instruction Manual for additional details of operation If token relief is present it will relieve a small amount of gas to the atm
27. osphere as an indication that the Integral monitor is controlling the downstream pressure Type CS404 Slam shut Operation The Type VSX4 slam shut module on the Type CS404 regulator is a fast acting shut off device that provides overpressure OPSO or over and underpressure OPSO UPSO protection by completely shutting off the flow of gas to the downstream system See Tables 7 and 8 for guidance regarding the typical setpoints of the regulator and associated OPSO and UPSO setpoints The Type VSX4 s actions are independent of the Type CS404 regulator and of variations to the inlet pressure The Type VSX4 provides the option of internal or external downstream pressure registration External registration reguires a downstream sensing line See Figure 7 for guidance regarding installation of the downstream control line The Type VSX4 shut off disk is normally in the open reset position see Figure 4 If the downstream pressure below the slam shut diaphragm increases or decreases until it reaches the slam shut setpoint this diaphragm moves upward or downward to release the trip mechanism which allows the spring force on the stem to push the disk against the seat shutting off all gas flow To reset the slam shut after gas has been shutoff refer to Type VSX4 Instruction Manual for additional details In order for the Underpressure Shutoff UPSO of any slam shut to be triggered the downstream pipe pressure must drop below the UPSO
28. r Type VSX4 slam shut for Adjustment and Maintenance of the slam shut CS400 Series The range of allowable pressure settings is stamped on the nameplate If the reguired setting is not within this range substitute the correct spring as shown in Table 5 If the spring is changed change the nameplate to indicate the new pressure range A pressure gauge should always be used to monitor downstream pressure while adjustments are being made 1 Remove the closing cap key 60 Figure 8 2 Toincrease the outlet setting turn the adjusting screw key 65 Figure 8 clockwise To decrease the outlet setting turn the adjusting screw counterclockwise 3 Replace the closing cap CS400 Series with Integral Monitor Module When adjusting the Primary Regulator and Integral Monitor for operation ensure that the pressure differences between the Primary Regulator and the integral monitor shown in Table 6 are observed For example if the Primary Regulator setpoint is set at 7 in w c 17 mbar than the Integral Monitor should be set at a minimum of 14 in w c 35 mbar or higher To test the Integral Monitor operation the Primary regulator setpoint must be adjusted above the Integral Monitor s setpoint to simulate a failure of the primary regulator If the spring range of the Primary Regulator is sufficiently high it can simply be adjusted above the Integral Monitor s setpoint by following step 2 above Otherwise a different spri
29. rned to service Only parts manufactured by Emerson should be used for repairing Fisher regulators Relight pilot lights according to normal startup procedures Due to normal wear or damage that may occur from external sources this regulator should be inspected and maintained periodically The freguency of inspection and replacement of parts depends upon the severity of service conditions or the reguirement of local state and federal rules and regulations Periodic inspection must be performed on the Types CS403 and CS404 to ensure that the integral monitor or slam shut overpressure protection modules respectively protect the downsteam system in the event of a failure to the primary regulator This inspection must test that the integral monitor or slam shut functions as intended The freguency of this inspection must be at intervals not exceeding 15 months but at least once each calendar year Disassembly to Replace Diaphragm 1 Remove the closing cap key 60 Figure 8 Turn the adjusting screw key 65 counterclockwise to ease spring compression 2 Remove the adjusting screw key 65 and control spring key 38 CS400 Series 3 Remove hex nuts key 16 and cap screws key 15 Separate the upper spring case key 1 from the lower casing assembly key 9 Note If disassembling a CS400 Series regulator lift the upper spring case straight up in order to avoid hitting the stem key 44 4 Slide the diaphragm
30. sure regulator does not require any supplementary upstream safety accessory for protection against overpressure compared with its design pressure PS when upstream reducing station is sized for a max downstream incidental MIPd lt 1 1 PS 1 The pressure temperature limits in this Instruction Manual and any applicable standard or code limitation should not be exceeded 2 Product has passed Emerson testing for lockup relief start to discharge and reseal down to 40 degrees Table 3 PED Information TYPE DESCRIPTION PED CATEGORY CS400 Base regulator CS404 Regulator with Slam Shut Module IV European EN Reference Standards EN 334 EN 14382 FLUID GROUP Groups 1 and 2 according to PED 97 23 EC 1st and 2nd family gas according to EN 437 or other gases compressed air nitrogen The gas must be non corrosive clean filtration on inlet side necessary and dry CS400 Series M1060 EG INLET PRESSURE E OUTLET PRESSURE ATMOSPHERIC PRESSURE RELIEF VALVE STEM RELIEF SPRING RELIEF VALVE SPRING RELIEF SEAT PRESSURE RETAINING PLUG DO NOT REMOVE WHILE UNIT IS PRESSURIZED Figure 2 Type CS400IR Internally Registered Regulator with Internal Relief Operational Schematic Table 4 Body Sizes Material End Connections and Pressure Ratings
31. tamped on the regulator at the factory type number date of manufacture spring range orifice size maximum inlet pressure maximum operating outlet pressure and outlet pressure which may damage regulator parts Available Configurations See Table 1 Body Sizes End Connection Styles and Pressure Rating See Table 4 Maximum Inlet Pressures Emergency 175 psig 12 1 bar Operating See Table 2 Operating Pressure Ranges Regulator See Table 5 Integral Monitor Module See Table 6 Slam shut Module See Tables 7 and 8 Maximum Outlet Pressures Emergency Casing 25 psig 1 7 bar To Avoid Internal Parts Damage 5 psig 0 34 bar over set pressure Operating 5 5 psig 0 38 bar Flow Coefficients and Orifice Sizes See Table 2 IEC Sizing Coefficients See Table 2 Spring Case Vent Connection 1 NPT Operating Temperature TS According to PED Standards All Types 4 to 150 F 20 to 66 C Non PED All Types 20 to 150 F 29 to 66 C Pressure Registration Internal or External Approximate Weights With Threaded Body Type CS400 9 Ibs 4 kg Type CS403 18 5 lbs 8 kg Type CS404 11 2 lbs 5 kg With Flanged Body Add 8 6 lbs 4 kg to weights listed PED Conformity Statement and Information The CS400 Product Series is in conformity with the Pressure Equipment Directive PED 97 23 EC The exception to this previous statement is the Type CS403 which is not yet certified to conform with the PED Directive Pres
32. y have occurred Regulator operation below these limits does not preclude the possibility of damage from external sources or from debris in the pipeline General Installation Instructions Before installing the regulator e Check for damage which might have occurred during shipment e Check for and remove any dirt or foreign material which may have accumulated in the regulator body Blow out any debris dirt or copper sulfate in the copper tubing and the pipeline Apply pipe compound to the male threads of the pipe before installing the regulator e 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 e When designing a pressure reducing station using a CS400 Series regulator make an analysis if it is necessary to take into account the effects of wind snow and temperature to avoid unnecessary load and movement to the flanges of the equipment CS400 Series f needed a support may be used under the piping and regulator slam shut body to avoid excessive pressure force on the regulator slam shut Installation Location The installed regulator should be adequately protected from vehicular traffic and damage from other external sources e Install the regulator with the vent pointed vertically down see Figures 5 through 7 If the vent cannot be installed in a vertically down position the regulator must be instal
33. ype CS400 Type CS403 Type CS404 Spring Case Aluminum Vent Screen Stainless steel Retaining Ring Zinc plated steel Stabilizer Guide Stainless steel Stabilizer Stabilizer Spring Stainless steel Stabilizer Retaining Ring Zinc plated steel Stabilizer Screw 3 reguired Zinc plated Lower Casing Aluminum Lever Steel Stem Aluminum O ring External Registration Nitrile NBR Recommended spare part 14 Part Number RCS400X0012 RCS403X0012 RCS404Xx0012 GE24555X012 T1121338982 T1120925072 GE27061X012 GE27063X012 GE35010X012 GE27024X012 GE29724X012 GE24289X012 GE27194X012 GE27402x012 1E472706992 Key 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 36 37 38 41 42 43 44 45 47 48 51 Description Lever Pin Stainless steel Lever Screw 2 reguired Zinc plated steel Cap Screw 8 reguired Steel Nut 8 reguired Steel Union Ring Aluminum Snap Ring Stainless steel O ring Nitrile NBR Stem Guide Aluminum Internal Registration Open Throat External Registration Closed Throat O ring Nitrile NBR Pipe Plug 3 4 NPT Steel Internal Registration Screw External Registration Zinc plated steel O ring External Registration Nitrile NBR Orifice Aluminum 3 16 in 4 8 mm 1 4 in 6 4 mm 5 16 in 7 9 mm 3 8 in 9 5 mm 1 2 in 13 mm 5 8 in 16 mm 3 4 in 19 mm OPP Orifice 3 4 in 4 8 mm True Monitor Aluminum Type
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