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Emerson 1098H-EGR Instruction Manual

1. OUTLET PRESSURE RANGE PILOT TYPE psig bar SPRING COLOR SPRING PART NUMBER 3 to 20 0 21 to 1 4 Green 1B986027212 6351 5 to 35 0 35 to 2 4 Unpainted 1B788327022 35 to 100 2 4 to 6 9 Red 1K748527202 6352 14 in w c to 2 psig 35 mbar to 0 1 bar Yellow 14A9672X012 2 to 10 0 14 to 0 69 Black 14A9673X012 6353 3 to 40 0 21 to 2 8 Yellow 1E392527022 35 to 125 2 4 to 8 6 Red 1K748527202 6354L 85 to 200 5 9 to 13 8 Blue 1L346127142 6354M 175 to 220 12 1 to 15 2 Blue 1L346127142 6354H 200 to 300 13 8 to 20 7 Green 15A9258X012 7 in w c to 2 psig 17 mbar to 0 1 bar Red 1B886327022 61L 1to5 0 07 to 0 3 Yellow 15857827022 61LD 2 to 10 0 14 to 0 69 Blue 1B886427022 61LE 5 to 15 0 35 to 1 0 Brown 15857927142 10 to 20 0 69 to 1 4 Green 1B886527022 61H 10 to 65 0 69 to 4 5 Green Stripe 0Y066427022 15 to 45 1 0 to 3 1 Yellow 1E392527022 61HP 35 to 100 2 4 to 6 9 Blue 1D387227022 100 to 300 6 9 to 20 7 Red 1D465127142 4 to 8 in w c 10 to 20 mbar Red 1B653827052 7 to 16 in w c 17 to 4 mbar Unpainted 1B653927022 Y600AM 15 in w c to 1 2 psig 37 mbar to 0 08 bar Yellow 1B537027052 1 2 to 2 5 0 08 to 0 17 Green 1B537127022 2 5 to 4 5 0 17 to 0 31 Light Blue 1B537227022 4 5 to7 0 31 to 0 48 Black 1B537327052 1 Without diaphragm limiter 2 With diaphragm limiter Table 3 Actuator Sizes and Maximum Pressures OUTLET CONTROL PRESSURE EMERGENCY CASING PRESSURE ACTUATOR TYPE ACTUATOR SIZE psig bar psig bar 30 100 6 9 115 7 9 1098 40
2. 0 69 bar maximum differential pressure Supply the boiler pilot light gas with the Type 1098 EGR The pilot light gas supply line should branch off the main fuel line downstream of the Type 1098 EGR and include a separate regulator to control the final pilot light gas pressure if required see Figure 6 This allows the Type 1098 EGR to have its main valve plug just off the seat waiting for the sudden negative shock created when the boiler solenoid valve is opened to light the boiler to the high fire load This installation practice significantly increases the stroking speed of the Type 1098 EGR See Figure 6 for schematic E0711 Types 1098 EGR and 1098H EGR TYPE 1098 EGR SIZE 70 WITH QUICK OPENING CAGE 20 psi 1 4 bar MAXIMUM GAS SUPPLY SAFTEY SHUT OFF VALVE J TYPE 6352 WORKING PILOT fs TYPE Y600AM AUXILIARY PILOT Figure 5 Boiler Fuel Configuration Note Modulating solenoid load valves provide a definite time delay in moving from one position to the other effectively preventing sudden pressure changes in the system Alternately a snap acting solenoid valve can be furnished with a characterized valve plug that by allowing maximum capacity to be reached at a greater proportion of total travel slows the action slightly This action does not control shock as effectively as modulating solenoid valves Installation 1 Perform the Standard Single Pilot Regu
3. 61LD and 61LE For all except pilots with handwheel adjusting screw and pressure loaded pilots Plastic Pressure loaded trim for corrosive service Steel Standard trim with handwheel adjusting screw Brass Type 61H Capped adjusting screw Brass 6 Adjusting Screw Types 61L 61LD and 61LE For all except handwheel adjusting screw Zinc Die Casting For use with handwheel adjusting screw Brass Type 61H Steel Standard For 10 to 35 psig 0 69 to 2 4 bar range For 10 to 50 psig 0 69 to 3 5 bar range For 10 to 65 psig 0 69 to 4 5 bar range Pressure loaded capped adjusting screw Type 662 mounting Type 61HP Steel Standard 7 Control Spring Steel Type 61LD 0 to 4 in w c 0 to 10 mbar Orange 3 to 12 in w c 7 to 30 mbar Unpainted Types 61L 61LD and 61LE 0 25 to 2 psig 17 mbar to 0 14 bar Red 1 to 5 psig 69 mbar to 0 35 bar Yellow 2 to 10 psig 0 14 to 0 69 bar Blue 5 to 15 psig 0 34 to 1 0 bar Brown 10 to 20 psig 0 69 to 1 4 bar Green Type 61H 10 to 65 psig 0 69 to 4 5 bar Green Stripe Type 61HP 15 to 45 psig 1 0 to 3 1 bar Yellow 35 to 100 psig 2 4 to 6 9 bar Blue 100 to 300 psig 6 9 to 20 7 bar Red 8 Relay Orifice for 61 Series except Type 61HP 303 Stainless steel Standard applications Fast close and open open only or close only For Types 61L and 61LD only Special orifice fast open only application For Types 61L and 61LD only 9 Disk Holder Assembly for 61 Series except Type 61HP Standar
4. Key Description Part Number Key Description Part Number 27 Indicator Plug 1 Lower Casing Zinc plated steel Size 30 NPS 1 DN 25 14A6983X012 Type 1098 NPS 2 DN 50 14A9684X012 Steel 2E8007X00B2 NPS 3 DN 80 14A9684X012 Steel NACE 2E8007X0042 NPS 4 DN 100 14A9684X012 Type 1098H 316 Stainless steel NACE WCC Steel 36A8537X012 NPS 1 DN 25 14A6983X022 CF8M Stainless steel NACE 36A8537X032 NPS 2 DN 50 14A9684X032 Size 40 NPS 3 DN 80 14A9684X032 Type 1098 NPS 4 DN 100 14A9684X032 Steel 24A7155X012 NPS 6 8x6o0r12x6 Steel NACE 24A7155X072 DN 150 200 x 150 or 300 x 150 14A8178X032 304 Stainless steel NACE 24A7155X052 28 Spring Seat Size 70 Full capacity trim Type 1098 Plated steel Steel 2N1266X00B2 NPS 1 DN 25 14A6982X012 Steel NACE 2N1266X0072 NPS 2 3 or 4 DN 50 80 or 100 15A2206X012 Stainless steel NACE 2N1266X0082 NPS 6 or 8 x 6 DN 150 or 200 x 150 14A8177X012 2 Upper Casing Heat treated wrought steel NACE Size 30 NPS 1 DN 25 14A6982X022 Type 1098 NPS 2 3 or 4 DN 50 80 or 100 15A2206X022 Steel 25A7340X012 NPS 6 8x6o0r12x6 Steel NACE 25A7340X032 DN 150 200 x 150 or 300 x 150 14A8177X022 Type 1098H Restricted capacity trim WCC Steel 36A8535X012 416 Stainless steel heat treated Stainless steel NACE 36A8535X052 NPS 2 3 or 4 DN 50 80 or 100 14A9678X012 Size 40 NPS 6 DN 150 14A9688X012 Type 1098 29 Hex Nut Steel use with Stainless steel body Steel 24A5680X012 not shown Steel NACE 24A5680X062 NPS 1 DN 25
5. Maximum and Minimum Differential Pressures See Table 4 Actuator Sizes and Maximum Pressures See Table 3 Main Valve Flow Characteristic Linear standard Whisper Trim or Quick opening 1 The pressure temperature limits in this Instruction Manual or any applicable standard limita Main Valve Flow Direction In through the seat ring and out through the cage Pressure Registration External Temperature Capabilities Nitrile NBR 20 to 180 F 29 to 82 C Fluorocarbon FKM 0 to 300 F 18 to 149 C Water is limited to 0 to 200 F 18 to 93 C Ethylenepropylene EPDM 20 to 275 F 29 to 135 C Options e NACE Construction Boiler Fuel Construction e Aqueous Service Construction e Monitor Configuration e Noise Abatement Trim ion should not be exceeded he pilot according to the Installation section 2 For stability or overpressure protection a reducing regulator may be installed upstream of Table 1 Body Sizes and End Connection Styles BODY SIZE CAST IRON STEEL OR STAINLESS STEEL NPS DN 1or2 25 or 50 NPT CL125 FF or CL250 RF NPT CL150 RF CL300 RF CL600 RF BWE SWE or PN 16 25 40 3 40r6 80 100 or 150 CL125 FF or CL250 RF CL150 RF CL300 RF CL600 RF BWE or PN 16 25 40 8x6or12x6 200 x 150 or 300 x 150 CL150 RF CL300 RF CL600 RF or BWE Types 1098 EGR and 1098H EGR Table 2 Outlet Pressure Ranges
6. key 27 if necessary 9 To gain access to the Type 1806 relief valve disconnect the relief tubing at the connector fitting 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 Y600AM Pilot Body Area This procedure is for gaining access to the disk assembly orifice and body O ring All pressure must be released from the diaphragm casing and the disk assembly must be open before these steps can be performed Part key numbers are referenced in Figure 21 1 Remove the cap screws key 2 and separate the diaphragm casing key 4 from the body key 1 2 Remove and inspect the body seal O ring key 11 and the backup ring key 48 3 Inspect and replace the orifice key 5 if necessary Protect the orifice seating surface during disassembly and assembly Lubricate the threads of the replacement orifice with proper amount of anti seize lubricant and install with 29 to 38 ft lbs 39 to 52 Nem of torque 4 To replace the disk assembly key 13 remove the cotter pin key 15 If not necessary skip to step 7 5 Install the disk assembly key 13 and secure it with the cotter pin key 15 6 Place backup ring key 48 into the body key 1 Then place the body seal O ring key 11 into the body 7 Place the diaphragm casing key 4
7. on the body key 1 Secure the the diaphragm casing to the body with the cap screws key 2 using 7 to 9 ft lbs 9 5 to 12 Nem Diaphragm and Spring Case Area This procedure is for gaining access to the spring diaphragm lever assembly stem and Type Y600AM stem O ring All pressure must be released from the diaphragm casing before performing these steps 1 Remove the closing cap key 22 and turn the adjusting screw key 35 counterclockwise to remove the compression from the spring key 6 2 If the only maintenance is to change the control spring take out the control spring and replace with the desired spring Turn the adjusting screw key 35 clockwise to compress the spring to the desired outlet pressure setting according to the Installation and Startup section and restamp the nameplate if necessary Skip to step 11 3 If further maintenance to the internal diaphragm casing parts is required remove the hex nuts key 23 not shown and cap screws key 24 Remove the diaphragm key 10 plus attached parts by tilting them so that the pusher post key 8 slips off the lever assembly key 16 To separate the diaphragm from the attached parts unscrew the cap screw key 38 from the pusher post key 8 If the only maintenance needed is to replace the diaphragm parts skip to step 7 Types 1098 EGR and 1098H EGR 10 11 To replace the lever assembly key 16 remove the machine screws key 17 T
8. 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 key 16 part unscrew the seat ring key 13 from the cage key 11 and the cage from the body flange key 2 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 Trim 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 fold over 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 key 2 or gain access to the spring key 9 indicator stem key 10 stem O ring key 7 spring seat key 28 E ring key 23 or optional travel stop key 32 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
9. 0 1 The pressures shown in the table are the minimum supply pressures required by the pilot If the inlet pressure is less than shown an external pilot supply is necessary Principle of Operation The pilot operated Types 1098 EGR and 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 Type 1098 EGR regulator operation schematic is shown in Figure 2 In operation assume that outlet pressure is below the pilot control setting Control spring force on the pilot diaphragm opens the pilot valve plug providing additional loading pressure to the actuator diaphragm This loading pressure forces the actuator stem forward opening the main valve plug via a bump connection The upward motion of the plug allows gas to flow through the cage into 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 61 Series or Type Y600AM pilots or bellows Types 6352 through 6354M pilots close the pilot valve plug unbalanced in the Type 6351 or 61 Series pilots but balanced in the Types 6352 through 6354M pilots Excess loa
10. 4 required 10330635252 Stainless steel NACE 24A5680X042 NPS 2 DN 50 8 required 1A377235252 Size 70 NPS 3 DN 80 8 required 1A376035252 Type 1098 NPS 4 DN 100 8 required 1A352035252 Steel 25A2607X012 NPS 6 8x6o0r12x6 Steel NACE 25A2607X032 DN 150 200 x 150 or 300 x 150 Stainless steel NACE 25A2607X042 12 required 1A440935252 3 Bonnet 31 Pipe Plug Zinc plated steel 33B0301X012 Plated steel for all sizes 1A767524662 304 Stainless steel NACE 33B0301X052 316 Stainless steel NACE 4 Cap Screw For NPS 2 3 or 4 DN 50 80 or 100 1A767535072 Sizes 30 and 40 4 required For NPS 6 8x6or12x6 Plated Steel 1D529824052 DN 150 200 x 150 or 300 x 150 1A767535072 Stainless steel NACE 1D529838992 32 Travel Stop galvanized plated steel Size 70 4 required not used with full capacity trim Plated Steel 1A368424052 NPS 2 DN 50 Stainless steel NACE 1A368435072 30 capacity 14A9677X012 5 Casing O ring 70 capacity 14A9676X012 Nitrile NBR 1F 358106992 NPS 3 DN 80 40 capacity 14A9671X012 Fluorocarbon FKM 1F3581X0022 NPS 4 DN 100 40 capacity 14A9670X012 Ethylenepropylene EPDM 1F3581X0052 NPS 6 DN 150 40 capacity 14A9682X012 6 Stem O ring 2 required 33 NACE Tag not shown NACE 19A6034X012 Nitrile NBR 10782206992 34 Tag Wire not shown NACE 1U7581X0022 Fluorocarbon FKM 1K756106382 35 Fitting Ethylenepropylene EPDM 1C07822X0052 All sizes T21104T0012 7 Diaphragm All sizes NACE T21104T0022 Type 1098 36 Backup R
11. 61L 61LD AND 61LE PILOT DETAIL OF HANDWHEEL OPTION Figure 18 Types 61L 61LD and 61LE Pilot Assemblies 33 Types 1098 EGR and 1098H EGR Types 6352 6353 6354L 6354M and 6354H Pilots Figure 17 continued Key 14 15 16 17 19 20 21 22 23 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 6 Key _ 34 Description Part Number Machine Screw 6 required Aluminum 10B6189X022 Stainless steel 1V4360X0022 Relief Valve Assembly 25 psig 1 7 bar 16A5929X052 25 psig 1 7 bar NACE 16A5929X042 25 psig 1 7 bar for Oxygen service 16A5929X032 25 psig 1 7 bar Stainless steel 16A5929X072 Bellows Assembly Stainless steel Standard for all except in Oxygen service 15A6202X032 For use in Oxygen service 15A6202X022 O ring Nitrile NBR Standard and NACE Service 1D682506992 Fluorocarbon FKM Standard and NACE Service also for Oxygen service 1D6825xX0012 Filter P590 Series standard Type P594 1 P590X1 A2 P590 Series for corrosive service Type P593 1 P590X1 A1 P590 Series for NACE service Type P593 1 P590X1 A6 Closing Cap Gasket Composition 15A6218X012 Pipe Nipple For standard and corrosive service Galvanized steel 10488226232 For NACE service Steel 1C4882X0032 For corrosive NACE service Stainless steel 10488238982 Restriction Plated Carbon Steel Standard 17A2030X012 High 17A2029X012 Diaphragm Limiter Aluminum 15A9259X012 Stainless steel 10B4407X012 NAC
12. 8x6o0r12x6 DN 150 200 x 150 or 300 x 150 WCC steel ENC heat treated NPS 1 DN 25 NPS 2 DN 50 NPS 3 DN 80 NPS 4 DN 100 NPS 6 8x6o0r12x6 DN 150 200 x 150 or 300 x 150 CF8M Stainless steel ENC NACE NPS 1 DN 25 NPS 2 DN 50 NPS 3 DN 80 NPS 4 DN 100 NPS 6 8x6o0r12x6 DN 150 200 x 150 or 300 x 150 Cap Screw plated steel use with cast iron and steel body NPS 1 DN 25 4 required NPS 2 DN 50 8 required NPS 3 DN 80 8 required NPS 4 DN 100 8 required NPS 6 8x6o0r12x6 DN 150 200 x 150 or 300 x 150 12 required 10C1212X042 10C1212X012 10C1212X022 10C1212X032 10C1212X052 10C1212X092 10C1212X062 10C1212X072 10C1212X082 10C1212X102 10C1212X142 10C1212X112 10C1212X122 10C1212X132 10C1212X152 See following table 25A3168X012 24A9034X012 25A2309X012 34A8172X012 24A6779X012 25A2254X012 25A2300X112 24A9032X012 34A7152X012 24A6779X062 25A2254X082 25A2300X012 24A9032X042 34A7152X052 1R281124052 1A453324052 1A454124052 1A485724052 1U513124052 Types 1098 EGR and 1098H EGR Key 1 Type EGR Main Valve Bodies MATERIAL END CONNECTION NPS 1 DN 25 NPS 2 DN 50 NPT 34B7611X012 38A8845xX012 Cast Iron CL125 FF 34B8630X012 38A8847X012 CL250 RF 37B5950X012 38A8846X012 NPT 37B5946X012 38A8848X012 CL150 RF 37B5947X012 38A8853X012 CL300 RF 37B5948X012 38A8849X012 CL600 RF 37B5949X012 38A8844X012 WCC Steel SWE
13. BODY SIZE Standard Steel NACE Inconel X 750 Nes an 20 psi 1 4 bar 60 psi 4 1 bar 125 psi 8 6 bar 400 psi 27 6 bar 60 psi 4 1 bar 125 psi 8 6 bar 400 psi 27 6 bar Yellow Green Blue Red Green Blue Red 1 25 ee 14A9687X012 14A9680X012 14A9679X012 11B6769X012 12B8326X012 10B1882X012 2 50 14A6768X012 14A6626X012 14A6627X012 14A6628X012 16A5501X012 16A5995X012 16A5499X012 3 80 14A6771X012 14A6629X012 14A6630X012 14A6631X012 16A5503X012 16A5996X012 16A5500X012 4 100 14A6770X012 14A6632X012 14A6633X012 14A6634X012 16A5506X012 16A5997X012 16A5998X012 pupae 150 200 x aoe 150 or 15A2253X012 14A9686X012 14A9685X012 15A2615X012 16A5510X012 16A5999X012 16A6000X012 300 x 150 Recommended spare part 1 Part included in trim package assembly can be ordered according to the parts kit trim package Inconel is a mark owned by Special Metals Corporation 24 Types 1098 EGR and 1098H EGR 36 i 4 ae a z COMPLETE CAST IRON FULL CAPACITY MAIN VALVE ASSEMBLY Figure 12 Type EGR Main Valve Construction 25 Types 1098 EGR and 1098H EGR 19 10 35 37 7 21 6 14 15 9 11 12 16 QUICK CHANGE TRIM PACKAGE ASSEMBLY 25A3170 26A3800 ill DETAIL
14. CF8M Stainless steel NACE SCH 40 BWE GE05962X022 GE05967X022 GE05971X022 GE05976X022 SCH 80 BWE GE05963X022 GE05968X022 GE05970X022 sir PN 16 GE05965xX022 GE05969X022 GE05972X022 sir CL150 RF 38A8872X062 38A8867X032 38A7115X022 GE05973X022 NACE WCC Steel CL300 RF 38A887 1X042 38A8869X022 38A8873X022 GE05974X022 CL600 RF 38A8852X032 38A8866X022 38A8874X022 GE05975xX022 23 Types 1098 EGR and 1098H EGR Type EGR Main Valve Figures 12 and 13 continued Key Description Part Number Key Description Part Number 3 Stud Bolt Stainless steel use with Stainless steel body 10 Travel Indicator Stem continued not shown 316 Stainless steel NACE NPS 1 DN 25 4 required 1R284835222 NPS 1 DN 25 714311T0022 NPS 2 DN 50 8 required 1K242935222 NPS 2 DN 50 71427570022 NPS 3 DN 80 8 required 1A378135222 NPS 3 DN 80 714312T0022 NPS 4 DN 100 8 required 1R369035222 NPS 4 DN 100 714313T0022 NPS 6 8x 6 or 12x6 NPS 6 8x6 or 12x6 DN 150 200 x 150 or 300 x 150 12 required 1A365635222 DN 150 200 x 150 or 300 x 150 714314T0022 4 0 Gasket composition Cage NPS 1 DN 25 14A6785X012 Linear CF8M Stainless steel NACE NPS 2 DN 50 14A5685X012 NPS 1 DN 25 34B4136X012 NPS 3 DN 80 14A5665X012 NPS 2 DN 50 34B5838X012 NPS 4 DN 100 14A5650X012 NPS 3 DN 80 34B5839X012 NPS6 8x60or12x6 NPS 4 DN 100 34B5840X012 DN 150 200 x 150 or 300 x 150 14A6984X012 NPS 6 8x 6 or
15. GE05951X012 GE05958xX012 SCH 40 BWE GE05953X012 GE05957X012 SCH 80 BWE GE05954X012 GE05959X012 PN 16 25 40 GE05956xX012 GE05960xX012 NPT 37B5946X032 38A8848X032 CL150 RF 37B5947X032 38A8853X072 CL300 RF 37B5948X032 38A8849X032 CF8M Stainless steel NACE CL600 RF 37B5949X032 38A8844X032 SWE GE05951X022 GE05958X022 SCH 40 BWE GE05953X022 GE05957X022 SCH 80 BWE GE05954x022 GE05959X022 PN 16 25 40 GE05956X022 GE05960X022 NT ee eee eee 38A8848X022 CL150 RF 37B5947X022 38A8853X052 NACE WCC Steel CL300 RF 37B5948X022 38A8849X022 CL600 RF 37B5949X022 38A8844X022 Key 1 Type EGR Main Valve Bodies continued MATERIAL END CONNECTION NPS 3 DN 80 NPS 4 7 DN 100 NPS 6 DN 150 NPS 8 x 6 DN 200 x 150 CL125 FF 38A8851X012 38A8865X012 38A8875X012 se Sest iron CL250 RF 38A8850X012 38A8854X012 38A7110X012 sw CL150 RF 38A8872X012 38A8867X012 38A7115X012 GE05973X012 CL300 RF 38A8871X012 38A8869X012 38A8873X012 GE05974x012 CL600 RF 38A8852X012 38A8866X012 38A8874X012 GE05975X012 AR SCH 40 BWE GE05962X012 GE05967X012 GE05971X012 se SCH 80 BWE GE05963X012 GE05968X012 GE05970X012 sr PN 16 GE05965xX012 GE05969X012 GE05972X012 se CL150 RF 38A8872X052 38A8867X042 38A7115X032 sw CL300 RF 38A887 1X052 38A8869X032 38A8873X032 se CL600 RF 38A8852X042 38A8866X032 38A8874X032 se
16. Guide 416 Stainless steel standard 410 Stainless steel NACE Adjusting Screw Type 6352 Type 6353 Type 6354 For use with Type 662 Locknut Type 6352 Type 6353 or 6354 Closing Cap Aluminum Stainless steel Body Plug Gasket O ring For Aluminum body composition For Stainless steel body Nitrile NBR For Stainless steel body Fluorocarbon FKM Vent Assembly Part Number 15A6221X012 15A6221X042 15A6207X012 15A6207X052 15A6207X042 15A6207X112 15A6216X012 15A6216X022 15A6216X092 15A6216X162 15A6216X032 15A6216X152 15A6216X552 15A6216X542 15A6216X562 15A6216X502 15A6216X572 15A6216X582 14A9672X012 14A9673X012 1E392527022 1K748527202 1L346127142 1L346127142 15A9258X012 1B798525062 1K155828982 15A6222X012 15A6222X022 10B3692X012 10B7192X012 10B6190X012 18B3500X052 1C724018992 1A946324122 23B9152X012 1H2369X0032 10495704022 1F 113906992 1N463906382 Type Y602 12 Types 1098 EGR and 1098H EGR 9 10 20 7 6 5 22 8 4 13 16 NI V a E sei N LA N l z A sam M sa Sa Raa 35A6236 DETAIL OF TYPE 6354M OR 6354H PILOT TYPE 6352 6353 OR 6354L PILOT Figure 17 Types 6352 through 6354H Pilot Assemblies 7 lt 9 yp S La i Onn 498 DETAIL OF CAPPED ADJUSTING SCREW OPTION 8 40 34 33 43 TYPES
17. OF OPTIONAL RESTRICTED CAPACITY CONSTRUCTION Figure 13 Type EGR Main Valve Internal Constructions Type EGR Main Valve Figures 12 and 13 continued Key Description Part Number 12 Port Seal Nitrile NBR standard NPS 1 DN 25 14A6788X012 NPS 2 DN 50 24A5673X012 NPS 3 DN 80 24A5658X012 NPS 4 DN 100 24A5643X012 NPS 6 8x6or12x6 DN 150 200 x 150 or 300 x 150 14A8175xX012 Fluorocarbon FKM NPS 1 DN 25 14A8186X012 NPS 2 DN 50 25A7412X012 NPS 3 DN 80 25A7375X012 NPS 4 DN 100 25A7469X012 NPS 6 8x6or12x6 DN 150 200 x 150 or 300 x 150 14A6996X012 Ethylenepropylene EPR NPS 1 DN 25 14A6788X022 NPS 2 DN 50 24A5673X062 NPS 3 DN 80 24A5658X062 NPS 4 DN 100 24A5643X052 NPS 6 8x6o0r12x6 DN 150 200 x 150 or 300 x 150 14A8175xX022 Recommended spare part 1 Part included in trim package assembly can be ordered according to the parts kit trim package 26 Key Description 13 Seat Ring 416 Stainless steel NPS 1 DN 25 1 5 16 in 33 mm port NPS 2 DN 50 2 3 8 in 60 mm port NPS 3 DN 80 3 3 8 in 86 mm port NPS 4 DN 100 4 3 8 in 111 mm port NPS 6 DN 150 7 3 16 in 183 mm port NPS 8 x 6 DN 200 x 150 7 3 16 in 183 mm port 316 Stainless steel NACE NPS 1 DN 25 1 5 16 in 33 mm port NPS 2 DN 50 2 3 8 in 60 mm port NPS 3 DN 80 3 3 8 in 86 mm port NPS 4 DN 100 4 3 8 in 111 mm port NPS 6 DN 150 7 3 16 in 183 mm port NPS 8 x 6 DN 200 x 150 7 3 16 in 183 m
18. Standard Single Pilot Regulator Installation section through step 6 2 Connect the control line of the wide open monitoring regulator Figure 8 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 Startup Repeat this procedure in turn for each regulator in the installation 1 Slowly open the pilot supply line hand valve 2 Slowly open the upstream block valve and partially open the downstream block valve for minimum flow Types 1098 EGR and 1098H EGR BODY FLANGE SEAT RING SCREWS INTO CAGE e ne FLANGE P1507 Figure 9 Trim Package Removal 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 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
19. Steel Stainless steel Machine Screw 2 required 18 8 Stainless steel Guide Insert Delrin Closing Cap Hex Nut not shown 8 required Zinc plated steel Cap Screw 8 required Zinc plated steel Closing Cap Gasket Neoprene CR Type Y602 Vent Assembly Spring case up standard Spring case down Stem O ring Nitrile NBR Throat Seal O ring Nitrile NBR Machine Screw 18 8 Stainless steel Adjusting Screw Zinc Washer Plated Carbon Steel Diaphragm Cap Screw Zinc plated steel Backup Ring 302 Stainless steel Lower Spring Seat Zinc plated steel Part Number 17B3423X012 1A866537022 1B5375X0082 19A7151X022 27B4028X012 T11069X0012 1E985324142 71070824912 1P753306992 Type Y602 11 Type Y602 1 1H292606992 1D682506992 18A0703X022 1B537944012 18B3440X012 1B290524052 18B3446X012 1B636325062 37 Types 1098 EGR and 1098H EGR 30A7022 L2 SASK Ae A wd D Bd z V Y LLM OOO APPLY ANTI SEIZE COMPOUND L2 sal cc LL a K Ng Hi X il N P PA IX bo ie SS A HH A Z a JQ L2 Figure 23 Type 95H Supply Pressure Regulator Type 95H Regulator Figure 23 Key 3 4 7 Description Parts Kit Included are keys 3 4 10 and 12 for composition Trim 3A 1 4 NPT body Body 1 4 NPT Cast iron Spring Case Cast iron Orifice 416 Stainless steel Valve Plug 416 S
20. Type 1098 EGR with Type Y600AM Mounting Parts Figure 27 Key Description 16 22 24 30 31 32 35 36 38 42 Part Number Pipe Tee Stainless steel Tubing Elbow Stainless steel Tubing Stainless steel Mounting Bracket steel Cap Screw Zinc plated steel 2 required Cap Screw Zinc plated steel 2 required Tubing Connector 4 required Stainless steel Pipe Bushing 3 required Stainless steel Pipe Nipple 316 Stainless steel Key 39 43 44 50 51 52 53 Description Part Number Pipe Nipple 3 required 316 Stainless steel Pipe Bushing 5 required 316 Stainless steel Pipe Bushing 316 Stainless steel Pipe Cross 316 Stainless steel Restrictor Fixed Restriction 316 Stainless steel Variable Restriction Optional Pipe Plug 2 required Steel 316 Stainless steel Pipe Tee 316 Stainless steel Types 1098 EGR and 1098H EGR l 45 16 37 48 SUPPLY S 21 Q O 9 0 6350 SERIES 43 TYPE Y600AM o i A ae 41 e Ho o a VIEW A A VIEW B B 9r AT fi 0 39 o fo 47 Y r E CONTROL 38 ami 47A7118 TYPE Y600AM AND SIZE 70 TYPE 1098 COMBINATION J H a S SUPPL
21. flange is aligned with the bottom scale marking Then lock both nuts against each other and install the indicator scale and protector key 19 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 15 filter body key 1 machine screw key 4 gasket key 7 two flat washers key 5 and filter element key 2 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 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 16 and mounting key numbers in Figure 24 25 26 or 28 Note The body assembly key 1 may remain on the pipe nipple key 23 Figure 24 or key 39 Figure 28 unless the entire pilot is replaced The optional bonnet key 2 for a Type 662 electric remote control drive unit may remain installed during maintenance 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 662 mounting and turn the adjusting screw key 10 counterclockwise until compression is removed from the sprin
22. grade of general purpose grease 3 Install travel indicator assembly 1001212 torque to 40 ft lbs 54 Nem 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 Replacing Trim Parts Perform this procedure when inspecting cleaning or replacing individual trim package parts Key numbers are referenced in Figures 12 and 13 Note Access to the spring key 9 flange O ring travel indicator parts or optional travel stop key 32 in step 1 can be gained without removing the body flange key 2 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 on a cast iron body or remove the hex nuts key 29 not shown on a steel body and pry the body flange key 2 loose from the valve body key 1 3 Use the valve body key 1 as a holding fixture if desired Flip the body flange key 2
23. parts together Thread the bonnet into the main valve body 6 Secure the diaphragm plate key 8 to the stem key 12 with the stem cap screw key 4 Lay the entire diaphragm key 7 diaphragm plate and stem assembly into the lower diaphragm case key 1 so the diaphragm convolution laps up over the diaphragm plate according to Figure 14 Then install the stem slowly up into the bonnet key 3 to prevent stem or O ring damage and secure the lower diaphragm case to the upper diaphragm case key 2 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 zerk fitting key 28 until excess grease emerges from 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 Ordering Each Type 1098 EGR or 1098H EGR regulator is assigned a serial number or FS number which can be found on the nameplates Refer to this number when contacting your local Sales Office 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 Parts List Note Except where indicated size
24. 0 psig 5 to 20 0 34 to 1 4 10B3076X012 10 3 bar maximum allowable pilot 15 to 40 1 0 to 2 8 10B3077X012 Pedra oe Baie inlet pressure for cast iron body 35 to 80 2 4 to 5 5 10B3078X012 P or 750 psig 51 7 bar maximum allowable pilot inlet pressure for 70 to 150 4 8 to 10 3 10B3079X012 5 0 psig 0 34 bar over malleable iron or steel body 130 to 200 9 0 to 13 8 normal distribution pressure 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 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 7 The steps followed to set the monitoring pilot may vary with each piping situation however the basic method remains the same The following sub steps 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 desire
25. 00 NPS 6 DN 150 NPS 8 x 6 DN 200 x 150 400 psi 27 6 bar spring color red Cast Iron Body Flange NPS 1 DN 25 NPS 2 DN 50 1 Part included in trim package assembly can be ordered according to the parts kit trim package 22 25A3170X012 25A3170X102 25A3170X152 25A3170X222 25A3170X272 25A3170X422 25A3170X452 25A3170X372 25A3170X482 25A3170X512 25A3170X532 25A3170X032 25A3170X082 25A3170X142 25A3170X192 25A3170X282 25A3170X432 25A3170X382 25A3170X462 25A3170X492 25A3170X342 25A3170X542 25A3170X052 25A3170X112 Key Description 3 Cast Iron Body Flange continued NPS 3 DN 80 NPS 4 DN 100 NPS 6 DN 150 Steel Body Flange NPS 1 DN 25 NPS 2 DN 50 NPS 3 DN 80 NPS 4 DN 100 NPS 6 DN 150 NPS 8 x 6 DN 200 x 150 Parts Kit Quick Change Travel Indicator Kit Part Number 25A3170X172 25A3170X242 25A3170X312 25A3170X442 25A3170X332 25A3170X472 25A3170X502 25A3170X522 25A3170X552 included are keys 10 6 35 5 8 7 and 36 2 required keys 21 18 22 23 37 19 28 and 9 60 psi 4 1 bar spring color green NPS 1 DN 25 NPS 2 DN 50 NPS 3 DN 80 NPS 4 DN 100 NPS 6 DN 150 125 psi 8 6 bar spring color blue NPS 1 DN 25 NPS 2 DN 50 NPS 3 DN 80 NPS 4 DN 100 NPS 6 DN 150 400 psi 27 6 bar spring color red NPS 1 DN 25 NPS 2 DN 50 NPS 3 DN 80 NPS 4 DN 100 NPS 6 DN 150 Valve Bodies Body Flange Cast iron ENC NPS 2 DN 50 NPS 3 DN 80 NPS 4 DN 100 NPS 6
26. 098H NACE Size 40 16 required Cap Screw Type 1098 NACE Plated steel Stainless steel 11 Hex Nut Type 1098 Size 30 12 required Plated steel NACE Size 40 16 required Plated steel 18 8 Stainless steel NACE Size 70 28 required Plated steel NACE Stainless steel NACE Type 1098H Size 30 12 required Plated steel Stainless steel NACE 12 Stem Stainless steel NPS 1 DN 25 body size NPS 1 DN 25 body size NACE NPS 2 DN 50 body size NPS 2 7 DN 50 body size NACE NPS 3 DN 80 body size NPS 3 DN 80 body size NACE NPS 4 7 DN 100 body size NPS 47 DN 100 body size NACE NPS 6 DN 150 body size NPS 6 DN 150 body size NACE NPS 8 x 6 DN 200 x 150 body size NACE Recommended spare part Inconel is a mark owned by Special Metals Corporation 30 Part Number 2E7919X0062 27B9744X032 2N1269X0042 2E791902202 2E7919X0052 2E7919X0062 15A7339X012 GE08313X012 14A5682X012 GE08466xX012 15A2606X012 19A7319X012 19A7319X022 1L545428982 1L545438992 1A582824052 1A582824052 1A5828X0122 1E760324052 1A915524052 1A219235222 1E760324052 1E7603X0072 1A346524122 1A346524122 1A3465xX0032 1A346524122 1A3465xX0102 1A340324122 1A337435252 14A6757X01 14A6757X02 14A5683X01 14A5683X02 14A5663X01 14A5663X02 14A5648X01 14A5648xX02 14A6987X01 14A6987X022 18A4217X022 2 2 2 2 2 2 2 2 N 57 Description Nameplate Vent Insert Zerk Fitting plated carbo
27. 1 2 In we 13 mm PIPE CONTROL TYPE Y600AM LINE AUXILIARY PILOT TYPE 1098 EGR SIZE 70 REGULATOR WITH QUICK OPENING CAGE AND STANDARD TYPE 6352 WORKING PILOT VENT 48A6566 A B1622 Figure 4 Typical Dual Pilot Boiler Fuel Installation Types 1098 EGR and 1098H EGR Note 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 only to the external pipe threads with a screwed body or use suitable line gaskets and good bolting practices with a flanged body With a weld end body be sure to remove the trim package including the gasket 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 buildup on all machined guiding and sealing surfaces inside the body and at the bonnet flange body joint Note Install so that flow through the main valve matches the flow arrow attached to the valve body 2 Install a three valve bypass around the regulator if continuous operation is necessar
28. 12x 6 5 Travel Indicator Fitting DN 150 200 x 150 or 300 x 150 34B5841X012 Zinc plated steel Whisper Trim NPS 1 DN 25 72111770012 416 Stainless steel NPS 1 DN 25 NACE 72111770022 NPS 1 DN 25 24A2043X012 NPS 2 3 or 4 DN 50 80 or 100 721107T0012 NPS 2 DN 50 24A5707X012 NPS 6 8x6or12x6 NPS 3 DN 80 24A5708X012 DN 150 200 x 150 or 300 x 150 NACE 721120T0012 NPS 4 DN 100 24A5709X012 316 A Stainless steel NPS 6 8 x 6 or 12 x 6 NPS 2 3 or 4 DN 50 80 or 100 NACE T21107T0022 DN 150 200 x 150 or 300 x 150 24A8174X012 6 O ring Retainer 316 Stainless steel ENC 416 Stainless steel NACE 71427670012 NPS 1 DN 25 24A2043X022 7 Travel Indicator Stem O ring NPS 2 DN 50 24A5707X022 Nitrile NBR 1E472706992 NPS 3 DN 80 24A5708X042 Fluorocarbon FKM 1N430406382 NPS 4 DN 100 24A5709X022 Ethylenepropylene EPR 1D6875X0092 NPS 6 8x6 or 12x 6 8 Travel Indicator Hex Nut plated steel 1A662228992 DN 150 200 x 150 or 300 x 150 24A8174X022 9 Spring steel standard or Inconel X 750 NACE See following table Quick Opening cast iron ENC 10 Travel Indicator Stem NPS 1 DN 25 37A7211X012 18 8 Stainless steel NPS 2 DN 50 37A7212X012 NPS 1 DN 25 T14311T0012 NPS 3 DN 80 37A7213X012 NPS 2 DN50 71427570012 NPS 4 DN 100 37A7214X012 NPS 3 DN 80 T14312T0012 NPS 6 8x 6 or 12x 6 NPS 4 DN 100 T14313T0012 DN 150 200 x 150 or 300 x 150 37A7215X022 NPS 6 8x6 or 12x6 DN 150 200 x 150 or 300 x 150 71431470012 Key 9 Spring SPRING
29. 200 x 150 or 300 x 150 Ethylenepropylene EPR NPS 1 DN 25 NPS 2 DN 50 NPS 3 DN 80 NPS 4 7 DN 100 NPS 6 8x6o0r12x6 DN 150 200 x 150 or 300 x 150 Recommended spare part 1 Part included in trim package assembly can be ordered according to the parts kit trim package Types 1098 EGR and 1098H EGR Part Number 14A6789X012 24A5674X012 24A5659X012 24A5644X012 14A8176X012 14A8187X012 25A7413X012 25A7376X012 25A7468X012 14A8185xX012 14A6789X022 24A5674X062 24A5659X062 24A5644X052 14A8176X022 14A6780X012 24A6772X012 24A9421X012 24A8182X012 24A6992X012 14A6780X022 24A6772X032 24A9421X022 24A8182X022 24A6992X022 10A7777X012 10A7779X012 14A5688X012 10A3481X012 18A2556X022 10A7778X012 10A7779X022 14A5688X022 10A3483X012 18A2556X032 10A7777X022 10A7779X052 14A5688X082 10A3481X052 18A2556X072 Key Description 18 Travel Indicator Scale plastic NPS 1 DN 25 NPS 2 DN 50 NPS 3 DN 80 NPS 4 DN 100 with 2 in 51 mm travel with 1 1 2 in 38 mm travel NPS 6 8 x 6 or 12 x 6 DN 150 200 x 150 or 300 x 150 19 Travel Indicator Protector NPS 1 or 2 DN 25 or 50 plastic NPS 3 4 6 or 8 x 6 DN 80 100 150 or 200 x 150 plated steel 20 Plug O ring Nitrile NBR standard NPS 1 DN 25 NPS 2 DN 50 NPS 3 DN 80 NPS 4 7 DN 100 NPS 6 8x6or12x6 DN 150 200 x 150 or 300 x 150 Fluorocarbon FKM NPS 1 DN 25 NPS 2 DN 50 NPS 3 DN 80 NPS 4 DN 100 NPS 6 8x6or12x6 D
30. 22 Tube Fitting Elbow 18 Relief Tubing Brass se ee Actuator Sizes 30 and 40 Steel eee eee Copper ne eee ee Stainless steel s lt sS ee ee ee Stainless steel rrr nn nnnn 26 Pipe Bushing for size 70 actuatoronly Actuator Size 70 39 Pipe Nipple for negative shock service only Copper renee 53 Pipe Elbow for negative shock service only Stainless steel se wee eee eee 19 Tube Fitting Tee Brass eee Steel eee ee 40 Stainless steel Types 1098 EGR and 1098H EGR amp 37A0565 Figure 26 Working Monitor Assembly Auxiliary Pilot Mounting Parts Figure 26 Key Description Part Number Key Description Part Number 22 Tube Elbow gt ao aaan 34 Flared Nut 1 required for use with 24 Tubing gt a aaa Type 6352 pilot and 2 required with 30 Mounting Bracket oaan Type 61H Pilot o ann 31 Cap Screw 2 required 4 4 2 2 www wee eee ee 35 Tube Connector 1 required for use with 32 Cap Screw 2 required Type 6352 pilot and 2 required with For Type 627 109 ween ne Type 61H Pilot we wn eee For Type 161AYW ee eee eee 36 Pipe Bushing Hex 2 required 9 41 Types 1098 EGR and 1098H EGR TYPE Y600AM PILOT TYPE 95H SUPPLY PRESSURE REGULATOR 42B6644 OJO 31 38 4 140 OPTIONAL TYPE 112 RESTRICTOR Figure 27 Type 1098 EGR with Type Y600AM Mounting Parts Mounting Parts continued
31. 61 Series pilot is used Instructions and parts lists for monitoring pilots and other equipment used with this regulator are found in separate manuals Description Types 1098 EGR and 1098H EGR regulators provide economical and accurate pressure control in a wide variety of applications natural gas distribution systems fuel gas supply to industrial boilers furnaces ovens and mixers and large commercial industrial establishments such as shopping centers and schools 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 KS a we S EMERSON D100339X012 Types 1098 EGR and 1098H EGR Specifications The Specifications section lists pressure limitations and other specifications for various Types 1098 EGR and 1098H EGR constructions Specifications for a given regulator as it originally comes from the factory are stamped on nameplates located on both the actuator and main valve body while the pilot control spring range is displayed on the pilot spring case and the pilot restriction code is stamped on the pilot body S standard gain L low gain and H high gain Body Sizes and End Connection Styles See Table 1 Main Valve Maximum Inlet Pressure 400 psig 27 6 bar or body rating limit whichever is lower Maximum Pilot Supply Pressure 600 psig 41 4 bar Outlet Pressure Ranges See Table 2
32. 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 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 Management 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 2 eS EMERSON Emerson Process Management Regulator Technologies Inc 2001 2014 All Rights Reserved
33. Brass Yoke Cap for Type 61HP only 410 416 Stainless steel Lockwasher for Types 61L 61LD and 61LE Steel Machine Screw for Types 61L 61LD and 61LE only Steel Valve Spring Seat for Type 61HP only 316 Stainless steel Cap Screw 6 required for Type 61HP only Machine Screw 4 required for Type 61HP only 303 Stainless steel Cap Screw 6 required for Type 61HP only Drive Screw 2 required 18 8 Stainless steel Diaphragm Insert 2 required for Type 61HP only Standard Nitrile NBR Oxygen service Fluorocarbon FKM Lower Yoke Cap for Type 61HP only 410 416 Stainless steel Bleed Plug for Type 61HP only Brass Vent Assembly Xenoy 18 8 Stainless steel Part Number 1B989624052 1A649528982 Type Y602 1 10488226232 Type P594 1 Type P593 1 1D986735132 1H951635132 1D5604000B2 1N3798000C2 1P753306992 1B487099202 1A369224492 1D777235032 143496144012 1A351124122 1A352424122 1A352224122 13618124092 16A9812X012 10A3963X012 1D541506992 1J881624092 13A9836X012 1A352332992 16A5763X012 1L251135072 15A0690X012 1A866935032 1P327028982 1A368228982 13A9842X012 13A9842X022 13A9837X012 1V211514012 Type Y602 12 Types 1098 EGR and 1098H EGR 26 3 if 50 il 36 4 6 38 8 25 22 16 fi L2 35 14 S 24 24 18 42 1 L1 33 L1 i as L1 13 5 1 L2 47B3687 APPLY LUBRICANT
34. E Tag 18 8 Stainless steel 19A6034X012 Tag Wire 304 Stainless steel 1U7581X0022 Packing Bonnet 316 Stainless steel 1L449635072 Packing Nut Plated Steel 0P077624102 Handwheel 1L217544992 Washer Plated Carbon steel 1A329128982 Screw Plated Carbon steel 1E985428982 Packing Spring 316 Stainless steel 1F 125437012 Packing Box Gasket Plated steel 1B487099202 Packing Follower 316 Stainless steel 1K885035072 External Adaptor PTFE 1F124801012 Internal Adaptor PTFE 1F124401012 Packing Washer 316 Stainless steel 1F125236042 Packing Ring 3 required PTFE 10752601012 Adjusting Screw 410 416 Stainless steel 21B5621X012 Series Pilots Figures 18 19 and 20 Description Part Number Repair Parts Kits Nitrile NBR Includes keys 8 9 10 12 13 14 15 26 and 28 Types 61L and 61LE R61LX000012 Types 61LD R61LDX00012 Repair Parts Kits Nitrile NBR Includes keys 8 9 10 12 13 14 15 and 26 Type 61H R61HX000012 Relay Spring Case Cast Iron Types 61L 61LD and 61LE 1B983919012 Type 61H Standard adjusting screw 1B984119012 Capped adjusting screw or for Type 662 1H232619012 Type 61HP Standard adjusting screw 2P969419012 Key Description 2 Relay Valve Body Cast Iron Types 61L 61LD 61LE and 61H Type 61HP 3 Bottom Cover Types 61L 61LD 61LE and 61H Cast Iron Type 61HP Steel 4 Relay Yoke Types 61L 61LD 61LE and 61H Zinc Die Casting Type 61HP 2 required 410 416 Stainless steel 5 Closing Cap Assembly Types 61L
35. Instruction Manual Form 5084 October 2014 Types 1098 EGR and 1098H EGR Types 1098 EGR and 1098H EGR Pressure Reducing Regulators Failure to follow these instructions or to properly install and maintain this equipment could result in an explosion fire and or chemical contamination causing property damage and personal injury or death Fisher regulators must be installed operated and maintained in accordance with federal state and local codes rules and regulations and Emerson Process Management Regulator Technologies 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 Installation operation and maintenance procedures performed by unqualified personnel may result in improper adjustment and unsafe operation Either condition may result in equipment damage or personal injury Use qualified personnel when installing operating and maintaining the Types 1098 EGR and 1098H EGR pressure reducing regulator Introduction Scope of the Manual This manual describes and provides instructions and parts list for Type 1098 EGR or 1098H EGR regulator complete with a standard P590 Series filter and either a 6350 Series regulator a 61 Series pilot or a Type Y600AM pilot The Type 1806 relief www fisherregulators com W6956 Figure 1 Type 1098 EGR valve is also covered when a
36. L L1 SILICONE GREASE LUBRICANT L2 ANTI SEIZE AND LUBRICATING COMPOUND Figure 21 Type Y600AM Regulator Assembly Type Y600AM Parts List Figures 21 through 22 Key Description Parts Kit keys 10 11 12 13 15 30 31 and 33 Type Y600AM 1 Body Cast Iron 3 4 NPT Spring Case Assembly Cast iron Diaphragm Casing Cast iron Orifice Aluminum 1 4 in 6 4 mm Spring Plated steel 4 to 8 in w c 10 to 20 mbar Red OJAN 7 to 16 in w c 17 to 40 mbar Unpainted 15 in w c to 1 2 psig 37 mbar to 0 08 bar Yellow 1 2 to 2 5 psig 0 08 to 0 17 bar Green 2 5 to 4 5 psig 0 17 to 0 31 bar Light Blue 4 5 to 7 psig 0 31 to 0 52 bar Black 7 Diaphragm Head 304 Stainless steel 8 Pusher Post Aluminum 10 Diaphragm Nitrile NBR 11 Body Seal O ring Nitrile NBR 12 Insert Seal O ring Nitrile NBR 13 Disk Assembly Aluminum Disk Holder with Nitrile NBR disk Recommended spare part Delrin is a mark owned by E I du Pont de Nemours and Co Cap Screw 2 required Zinc plated steel Part Number RY600AX0012 1E987119012 10856228992 1B6365xX0342 47B2271X012 0B042009012 1B653827052 1B653927022 1B537027052 1B537127022 1B537227022 1B537327052 17B9723X032 17B9734X032 17B9726X012 1H993806992 1B885506992 104248X0212 47B3687 Figure 22 Diaphragm Casing Cap Screw Location Description Stem 303 Stainless steel Cotter Pin 302 Stainless steel Lever Assembly
37. N 150 200 x 150 or 300 x 150 Ethylenepropylene EPR NPS 1 DN 25 NPS 2 DN 50 NPS 3 DN 80 NPS 4 DN 100 NPS 6 8 x6 and 12x 6 DN 150 200 x 150 and 300 x 150 21 Travel Indicator Fitting or Indicator Plug O ring Nitrile NBR NPS 1 DN 25 NPS 2 3 or 4 DN 50 80 or 100 NPS 6 8x6or12x6 DN 150 200 x 150 or 300 x 150 Fluorocarbon FKM NPS 1 DN 25 NPS 2 3 or 4 DN 50 80 or 100 NPS 6 8x6or12x6 DN 150 200 x 150 or 300 x 150 Ethylenepropylene EPR NPS 1 DN 25 NPS 2 3 or 4 DN 50 80 or 100 NPS 6 8x6o0r12x6 DN 150 200 x 150 or 300 x 150 22 Travel Indicator Flange Nut plated steel 23 E Ring Stainless steel 1577 steel heat treated NACE 24 Drive Screw 18 8 Stainless steel 2 required 25 Flow Arrow 18 8 Stainless steel 26 Body Rating Plate Stainless steel not shown Part Number 14A6759X012 14A5678X012 14A5662X012 14A5647X012 14A5662X012 14A5647X012 24B1301X012 14A6769X012 14A6981X012 14A5686X012 1V326906562 14A5688X012 1K879306992 14A8188X012 14A5686X022 1V3269X0042 14A5688X022 1V547606382 14A6981X032 14A5686X052 1V3269X0062 14A5688X082 1K8793X0012 10A8931X012 10A3800X012 1F262906992 10A0811X012 1R727606382 1F2629X0012 10A8931X022 10A3800X042 1F2629X0032 14A5693X012 14A8181X012 14A8181X022 1A368228982 1V105938982 27 Types 1098 EGR and 1098H EGR Type EGR Main Valve Figures 12 and 13 continued Types 1098 and 1098H Actuators Figure 14
38. R and 1098H EGR Startup 1 Slowly open the pilot supply line hand valve 2 Slowly open the upstream block valve and partially open the downstream block valve for minimum flow Slowly open the hand valve in the control line 3 Adjust the pilot setting if necessary 4 Completely open the downstream block valve 5 Slowly close the bypass valve if any Dual Pilot Boiler Fuel Control Applications Boiler Fuel Pressure Control To enhance proper operation and adequate response to negative pressure shock condition in low differential pressure boiler fuel control applications use the Type 1098 EGR boiler fuel configuration e Type 1098 EGR with Type 6352 pilot e Size 70 Actuator e Quick Opening Cage e Yellow Main Spring e Type Y600AM or 627M Auxiliary Pilot mounted in parallel with the Type 6352 pilot To provide faster response two pilots mounted in parallel sense the downstream pressure The Type 6352 pilot is the primary controlling pilot and the Type Y600AM or 627M auxiliary pilot stands by until it senses a negative pressure shock condition The auxiliary pilot opens allowing additional flow into the actuator increasing the stroking speed and providing faster response See Figure 5 for schematic The quick opening cage allows maximum capacity at shorter travels to decrease stroking time in opening and closing directions The service conditions should not exceed 20 psig 1 4 bar maximum inlet pressure and 10 psi
39. With diaphragm removed check to be sure the pressure registration hole is completely open and free of all obstructions Reassemble in reverse order of the previous steps Lubricate the upper spring seat key 9 and the exposed threads of the adjusting screw key 15 Before tightening cap screws key 16 be sure to install the adjusting screw if completely removed and turn it down to obtain diaphragm slack This allows proper positioning of the diaphragm to permit full travel of the valve plug key 4 Complete reassembly procedures and temporarily install a gauge in place of the pipe plug key 52 Turn the adjusting screw to produce the desired outlet pressure values shown in Table 2 Tighten the locknut to maintain the desired setting Types 1098 EGR and 1098H EGR Types 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 14 and mounting part numbers in Figure 27 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 bearings and wiper keys 6 56 and 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
40. Y G2 VIEW A A VIEW B B TYPE 621 107 SN VS Go OW Ss L 6350 SERIES Ne O O Le 21 ones I sy AA O A 47A7119 CONTROL D TYPE 627M AND SIZE 70 TYPE 1098 COMBINATION APPLY SEALANT S ALL NPT THREAD Figure 28 Boiler Fuel Pressure Control Assembly 43 Types 1098 EGR and 1098H EGR Industrial Regulators 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 Shanghai 201206 China Tel 86 21 2892 9000 Europe Bologna 40013 Italy Tel 39 051 419 0611 Middle East and Africa Dubai United Arab Emirates Tel 971 4811 8100 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 Middle East and Africa Dubai United Arab Emirates Tel 971 4811 8100 For further information visit www emersonprocess com regulators TESCOM Emerson Process Management Tescom Corporation USA Headquarters Elk River Minnesota 55330 2445 USA Tels 1
41. auges 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 Pilot Adjustment To adjust standard 6350 Series pilots Loosen the locknut and turn the adjusting screw Then tighten the locknut to maintain the adjustment position On a standard Types 6352 through 6354M pilots closing cap must be removed before adjustment and replaced afterward To avoid possible personal injury from a pressure loaded 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 61 Series or Type Y600AM pilots Remove the closing cap and turn the adjusting screw Any adjustments made should set the controlled pressure within the appropriate spring range shown in the Table 2 1098 EG
42. ction and replacement of parts depends upon the severity of service conditions or the requirements of local state and federal regulations Due to the care Emerson takes in meeting all manufacturing requirements heat treating dimensional tolerances etc use only replacement parts manufactured or furnished by Emerson The stem O rings key 6 Figure 14 on the Type 1098 or 1098H actuator can be lubricated during regularly scheduled maintenance using the grease fitting key 28 Figure 14 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 14 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 Types 1098 EGR and 1098H EGR key 13 Figure 14 are updated to accurately indicate any field changes in equipment materials service conditions or pressure settings 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 Type EGR Main Valve Replacing Quick Change Trim Package Perform this procedure if the entire trim package is replaced Key numbers for both the complete main valve and its trim package are referenced in Figures 12 and 13 Some replace
43. ctuator Sizes 30 and 40 Copper Stainless steel NACE Actuator Size 70 Copper Stainless steel NACE Key Description Part Number 25 Tube Fitting Elbow 2 required for standard and 3 required for use with 50 psig 3 4 bar relief mounting Actuator Sizes 30 and 40 Brass Aluminum NACE Steel Stainless steel NACE Actuator Size 70 Brass Steel Stainless steel NACE 26 Pipe Bushing Steel NACE Stainless steel NACE 51 Pipe Nipple for use with 50 psig 3 4 bar relief 2 required not shown 52 Pipe Tee for use with 50 psig 3 4 bar relief not shown 39 Types 1098 EGR and 1098H EGR H FISHER gt D CD 14A5705 OT TI LL BLIZZ CONTROL LINE CONNECTION 9 A Figure 25 61 Series Pilot and Type 1806 Relief Valve Mounting Mounting Parts continued 61 Series Mounting Parts Figure 25 Key Description Part Number Key Description Part Number 14 Pipe Nipple 20 Loading Tubing For standard 61 Series mounting For standard 61 Series mounting Actuator Sizes 30 and40 s ww we ee eee Actuator Sizes 30 and 40 Actuator Size 70 0 eee ene Copper eee Negative shock service Stainless steel annn Actuator Sizes 30 and40 ssi wee eee Negative shock service sie wee eee ee ActuatorSize70 0 n 21 Tube Fitting Connector 15 Pipe Nipple Brass ee eee Actuator Sizes 30 and 40 sensnm Steel a See le Actuator Size 70 ee eee nner Stainless steel sa eeeeeeeee 16 PipeTee 22 2 2 2 2 2 2 2 o oeaan
44. d 12 emergency downstream pressure is achieved Then readjust the second stage working regulator to establish the desired downstream pressure Install special piping not shown in Figure 7 so that the monitoring pilot senses the intermediate pressure The intermediate pressure then appears to the monitoring pilot as if it was 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 Types 1098 EGR and 1098H EGR f PILOT SUPPLY REGULATOR KL A6789 m NLET PRESSURE E OUTLET PRESSURE LOADING PRESSURE EZEZ MONITOR LOADING PRESSURE E ATMOSPHERIC PRESSURE M INTERMEDIATE PRESSURE 6350 SERIES PILOT 6350 SERIES PILOT Figure 8 Typical Wide Open Monitor Installations Adjustment Recommendations for Monitor Applications Low amplitude high frequency monitor trim oscillations can occur if the monitor regulator pressure setting is adjusted too closely to the working regulator pressure setting and or if the monitor pilot supply regulator pressure setting is adjusted too closely
45. d trim Brass Nitrile NBR Trim for corrosive service 303 Stainless steel Oxygen service and pressure loaded trim for corrosive service Brass Fluorocarbon FKM Part Number 23581919012 33A9845X012 20518619012 13A9843X012 1D662544012 13A9838X012 T11069X0012 1E422724092 1R759314012 1H236514012 1B537944012 1R759414012 1A500528982 1B212028982 1A279128982 1J881524102 18B3500X072 10216032992 1B558527052 10680627222 1B886327022 1J857827022 1B886427022 1J857927142 1B886527022 0Y066427022 1E392527022 1D387227022 1D465127142 10520135032 1D373735032 1E874235132 1B8868000A2 1B8868000B2 1N3638000A2 Types 1098 EGR and 1098H EGR 32A2068 30A6330 DETAIL OF CAPPED REESE PILOT ADJUSTING SCREW OPTION APPLY SEALANT S S MULTI PURPOSE PTFE THREAD SEALANT Figure 19 Type 61H Pilot Assembly AN AV L 34A0396 Figure 20 Type 61HP Pilot Assembly 35 Types 1098 EGR and 1098H EGR 61 Series Pilots Figures 18 19 and 20 continued Key 10 11 12 13 14 15 16 16 17 18 19 Description Part Number Bleed Orifice 303 Stainless steel Types 61L 61LD 61LE and 61H Standard bleed 1B887335032 Special bleed 10831435032 Capped bleed for Types 61L and 61LD only 1D777135032 Type 61HP 1D318135032 Diaphragm Nut for 61 Series except Type 61HP Standard trim Oxygen service and pressure loaded trim for corrosive service 316 Stainles
46. ding pressure on the actuator diaphragm escapes downstream through the bleed hole Type 6351 pilot bleed orifice 61 Series pilot restriction Types 6352 through 6354M pilots or fixed restrictor Type Y600AM pilot Reduced actuator loading pressure permits the main valve to close The combination of main valve spring force and valve plug imbalance provides positive valve plug shutoff against the port and upper seals To protect the Type 1098 or 1098H actuator diaphragm from excessive differential pressure the 6300 Series pilots have a relief valve that allows loading pressure to bleed downstream at approximately 25 psig 1 7 bar differential across the actuator diaphragm An external relief valve Type 1806 is required when differential is higher than 25 psi 1 7 bar or when using the 61 Series or Y6O0AM pilots 40 psi 2 8 bar Relief Valve Amounting assembly for a 40 psi 2 8 bar differential relief valve is available for the Type 1098 EGR The standard 25 psi 1 7 bar differential relief valve construction is integrally mounted between the loading and downstream pressures in the 6351 through 6354 Series regulating pilots Both differential relief valves protect the main regulator diaphragm from damage that may occur from too high differential between the loading pressure and downstream pressure The 40 psi 2 8 bar differential relief valve construction is designed specifically for the red main valve spring selection
47. djusted Partially open the downstream block valve for minimum flow Types 1098 EGR and 1098H EGR Table 6 Auxiliary Pilot Selection Fast Stroke Dual Pilot 3 4 ORIFICE SPRING RANGE MINIMUM PRESSURE SIZE CONSTRUCTION URBES pate AT WHICH AUXILIARY In mm bar PILOT CAN BE SET 4 to 8 in w c 10 to 20 mbar 1B653827052 Red 1 in w c 2 mbar 7 to 16 in w c 17 to 40 mbar 1B653927022 Unpainted Under working 15 in w c to 1 2 psi 37 mbar to 0 08 bar 1B537027052 Yellow pilot setpoint Type Y600AM 1 4 6 4 1 2 to 2 5 0 08 to 0 17 1B537127022 Green 6 in w c 14 mbar NPT 2 5 to 4 5 0 17 to 0 31 1B537227022 Light Blue Under working 4 5to7 0 31 to 0 48 1B537327052 Black pilot setpoint 8 in w c 21 mbar Type 627M 1 2 13 5to 10 0 34 to 0 69 10B3076X012 Yellow Under working pilot setpoint Table 7 Working Monitor Performance MONITORING PILOT INFORMATION MINIMUM PRESSURE AT WHICH Spring Range WORKING MONITOR REGULATOR Construction Spring Part Number CAN BE SET psig bar 3 to 12 in w c 7 to 30 mbar 1B653927022 3 in w c 7 mbar over Type 161AYW pilot and 150 psig 11 to 25 in w c 27 to 62 mbar 1B537027052 normal distribution pressure 10 3 bar maximum allowable F pilot inlet pressure 25 in w c to 2 5 psi 62 mbar to 0 17 bar 1B537127022 f 2 5 to 4 5 psi 0 17 to 0 31 1B537227022 nat Aaa 4 5 to 7 psi 0 31 to 0 4 1B537327052 P Type 627 109 pilot and 15
48. e cage seating surface of the valve body key 1 web and the body flange key 2 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 key 3 or stud bolt nuts key 29 not shown No particular trim package orientation in the body is required Replacing Travel Indicator Assembly The Types 1098 EGR and Type 1098H EGR travel indicator assemblies now incorporate a redesigned O ring retainer key 6 Polytetrafluoroethylene PTFE backup 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 Types 1098 EGR and 1098H EGR Type EGR Main Valve Cap Screw key 3 Torque SIZE TORQUE NPS DN Ft lbs Nem 1 25 75 to 95 102 to 129 2 50 55 to 70 75 to 95 3 80 100 to 130 136 to 176 4 100 160 to 200 217 to 271 6 8x6 12x6 pes oe 275 to 300 373 to 407 1 Remove the travel indicator assembly by removing lower indicator fitting key 5 from the body flange key 2 2 Coat the threads of the lower indicator fitting key 5 with a good
49. ef Spring Case Aluminum Stainless steel Regulator Bonnet for Type 6353 Recommended spare part 32 R6352X00012 R6353X0001 R6354X00012 N 35A6228X01 17A8075X01 39A5971X01 NNN 17A8075X022 25A6220X012 28A9277X012 24B6641X022 Key 10 11 12 13 Description Body Plug Aluminum 316 Stainless steel Valve Plug and Stem Assembly Nitrile NBR disk with Stainless steel stem standard Nitrile NBR disk with 316 Stainless steel stem NACE Fluorocarbon FKM with Stainless steel stem for use in Oxygen service Fluorocarbon FKM disk with 316 Stainless steel stem NACE Diaphragm Assembly Type 6352 Nitrile NBR Type 6353 Nitrile NBR Type 6353 Fluorocarbon FKM Type 6353 Fluorocarbon FKM for use in Oxygen service Type 6354 Neoprene CR Type 6354 Fluorocarbon FKM Type 6352 Nitrile NBR NACE Type 6353 Nitrile NBR NACE Type 6353 Fluorocarbon FKM NACE Type 6354 Fluorocarbon FKM for use of Oxygen service Type 6354 Neoprene CR NACE Type 6354 Fluorocarbon FKM NACE Control Spring Type 6352 14 in w c to 2 psig 35 mbar to 0 14 bar 2 to 10 psig 0 14 to 0 69 bar Black Type 6353 3 to 40 psig 0 21 to 2 8 bar 35 to 125 psig 2 4 to 8 6 bar Type 6354L 85 to 200 psig 5 9 to 13 8 bar Type 6354M 175 to 220 psig 12 1 to 15 2 bar Type 6354H 200 to 300 psig 13 8 to 20 7 bar Spring Seat Plated steel Type 6352 or 6353 Type 6354L 6354M or 6354H Stem
50. elay Head Zinc plated steel Types 61L 61LD and 61LE 1B989425072 Type 61H 1D558325072 Spring Seat Zinc plated steel Types 61L 61LD and 61LE 1B886225072 Type 61H 1D558525072 Hex Nut Zinc plated steel Types 61L 61LD 61LE and 61H 1A340324122 Type 61HP 2 required 1A346524122 Recommended spare part 36 Key 20 23 24 25 26 27 28 30 32 33 34 35 40 41 43 44 45 46 47 48 51 52 53 54 Description Cap Screw 8 required Zinc plated steel For 61 Series except Type 61HP Pipe Plug or Vent Assembly Pipe Plug for Types 61L 61LD and 61LE Steel Vent Assembly for Type 61H Pipe Nipple Galvanized Zinc plated steel Filter Assembly Standard trim Trim for corrosive service Bleed Valve Types 61L 61LE and 61H 416 Stainless steel Type 61LD 416 Stainless steel Type 61HP Standard Trim Stainless steel Nitrile NBR Oxygen Service Stainless steel Fluorocarbon FKM Nameplate Gasket Types 61L 61LD and 61LE Neoprene CR Type 61H Steel Plated Composition Pipe Plug for 61 Series except Type 61HP Zinc plated steel Bleed Orifice Cap for Types 61L and 61LD with capped bleed only 303 Stainless steel Handwheel for Types 61L 61LD and 61LE only Zinc Die Cast Hex Nut Types 61L 61LD and 61LE Type 61H Type 61HP Spring Seat Zinc plated steel Types 61L 61LD and 61LE Type 61H Type 61HP O ring for Types 61L 61LD and 61LE only Nitrile NBR Adaptor for Type 61H only
51. electric remote control drive unit For optional remote pneumatic loading of 6350 or 61 Series pilots make the loading piping connections to the 1 4 NPT vent connection Types 1098 EGR and 1098H EGR A6788 E NLET PRESSURE OUTLET PRESSURE ATMOSPHERIC PRESSURE LOADING PRESSURE M INTERMEDIATE PRESSURE MERLOT S 6350 SERIES PILOT 6350 SERIES PILOT TYPE Y600M OR 627 109 MONITORING PILOT Figure 7 Typical Working Monitor Installation Startup 1 Slowly open the pilot supply line hand valve 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 in w c 27 mbar for the working pilot and 10 in w c 25 mbar for the standby pilot begin by reducing the working pilot setting far enough below 10 in w c 25 mbar for the working pilot to shut off Then set the standby pilot for an outlet pressure of 10 in w c 25 mbar Finally set the working pilot for an outlet pressure of 11 in w c 27 mbar Table 6 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 Working Mo
52. eplace 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 key 9 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 Types 1098 EGR and 1098H EGR a Before replacing the diaphragm case key 2 or spring case key 1 be sure the yoke assembly is positioned so that it will not bind or rub on the prong in the relay body o Avoid wrinkling the diaphragms key 14 and 15 when replacing the diaphragm case key 2 and spring case key 1 O Replace the diaphragm case key 2 carefully working the upper relay 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 key 1 using care to smooth the lower relay diaphragm key 15 evenly into the recess in the pilot body i Install the eight cap screws key 20 tightening them down evenly in a crisscross pattern to avoid crushing the diaphragm Recommended final torque on these cap screws is 10 to 12 ft lbs 14 to 16 Nem 8 After assembly make sure of the proper control spring setting according to the Installation and Startup section and restamp the nameplate
53. ess steel stem NACE Fluorocarbon FKM with Stainless steel stem Fluorocarbon FKM with Brass stem Valve Spring For Brass and Stainless steel stems 302 Stainless steel For Stainless steel stem NACE Inconel X 750 Part Number 1E312414012 1E3124X0022 1E312606992 1E312514012 1E3125X0022 1J500218992 1J500209012 1J500018992 1J500010062 1H885128982 1F826804022 19A6034X012 1U7581X0022 Part Number R6351X00012 1B7971X0092 1B7971X0342 1B7971X0122 25A6220X012 18B6542xX022 18B6542X042 18B6542X052 18B6542X062 20B9389X012 20B9389X022 20B9389X042 20B9389X032 1B797937022 19A2860X012 Types 1098 EGR and 1098H EGR E TNK 1 i A gt Figure 15 Standard P590 Series Filter Assembly NSS lam QL D Af E r ea yy Ni wee nt an mow Ki AL RK N Fag i C APPLY SEALANT S S MULTI PURPOSE PTFE THREAD SEALANT Figure 16 Type 6351 Pilot Assembly 31 Types 1098 EGR and 1098H EGR Type 6351 Pilot Figure 16 continued Key 7 24 28 35 Description Diaphragm Assembly includes plated steel diaphragm plate Nitrile NBR diaphragm and Aluminum pusher post Nitrile NBR diaphragm and Stainless steel pusher post Fluorocarbon FKM diaphragm and Aluminum pusher post Upper Spring Seat Control Spring plated steel 3 to 20 psig 0 21 to 1 4 bar range Green 5 to 35 psig 0 35 to 2 4 ba
54. g Remove the machine screws key 12 and separate the body assembly key 1 from the bonnet key 2 2 Inspect the removed parts and replace as necessary Ensure the registration and bleed holes in the pilot body are free of debris After assembly make sure of the proper control spring setting according to the Startup section and remark the spring case if necessary 3 To replace the valve plug key 4 remove the body plug key 3 to let the valve spring key 6 and inner valve assembly key 4 drop freely from the body key 1 Inspect the removed parts replace if necessary Make sure the plug seating surfaces are free from debris Inspect body plug O ring key 3 replace if necessary Type 6351 pilots Types 1098 EGR and 1098H EGR manufactured before May 1999 need to have the body plug gasket and the body plug replaced with a new body plug assembly key 3 which includes the body plug and the body plug O ring Install the body plug O ring over the body plug Stack the valve spring and the inner valve assembly on the body plug assembly key 3 and install the body plug assembly with stacked parts into the body Types 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 17 Mounting key numbers are referenced in Figure 24 for single pilot constructions and in Fig
55. gasket key 4 and cage O ring key 17 as necessary making sure that if the port key 12 and upper seals key 15 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 key 5 and attached parts were removed 7 Install the plug O ring key 20 and piston ring key 14 onto the valve plug key 16 Insert the valve plug into the body flange key 2 install the cage key 11 plus upper seal key 15 and O ring key 17 into the body flange and then install the seat ring key 13 plus port seal key 12 into the 10 11 Types 1098 EGR and 1098H EGR cage Apply a thin coating of lubricant to seals for protection during assembly Use the valve body key 1 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 Remove the upside down body flange key 2 if it was anchored on the body Coat the cage key 11 seating surfaces of the valve body key 1 web and the body flange key 2 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 key 3 screws or stud bolt nuts key 29 not shown Except on the NPS 1 DN 25 bod
56. in the NPS 6 DN 150 Type 1098 EGR 6354 with the size 30 actuator This construction uses the Type 1806H relief valve with a setting of 40 psi 2 8 bar to relieve excess loading pressure and does not interfere with the normal operation of the regulator Types 1098 EGR and 1098H EGR TYPE 1098 EGR TYPE 6352 NNOD000000000 6353 OR 6354 aaa eben neyo oan aaeeea a TYPE 1098 EGR WITH 6350 SERIES PILOT A6563 Gis INLET PRESSURE m OUTLET PRESSURE C ATMOSPHERIC PRESSURE C LOADING PRESSURE TYPE 1806 TYPE 61LD ape TYPE 1098 EGR WITH TYPE 61LD PILOT AND TYPE 1806 RELIEF VALVE E INLET PRESSURE m OUTLET PRESSURE C ATMOSPHERIC PRESSURE LOADING PRESSURE Figure 2 Operational Schematics Types 1098 EGR and 1098H EGR M1008 TYPE 1098 EGR TYPE 95H OPTIONAL TYPE 112 RESTRICTOR Ht TYPE Y600AM FIXED RESTRICTOR TYPE 1098 EGR WITH TYPE Y600AM PILOT AND TYPE 95H PRESSURE SUPPLY REGULATOR Gs INLET PRESSURE 4399 OUTLET PRESSURE C ATMOSPHERIC PRESSURE LOADING PRESSURE KW PILOT SUPPLY PRESSURE Figure 2 Operational Schematics continued Installation and Startup Additionally physical damage to the regulator may result in personal injury and property damage due to escaping N WARNING accumulated gas To avoid such injury a and damage install the regulator in a Personal injury equipment damage or safe locat
57. ing 2 Required Nitrile NBR All sizes 1K786806992 Size 30 2E791902202 37 O ring Size 40 27B9744X012 Nitrile NBR 18B3438X012 Size 70 2N126902202 Fluorocarbon FKM 1N430306382 Fluorocarbon FKM Ethylenepropylene EPR 1N4303X0012 Size 30 2E7919X0052 Size 40 27B9744X022 Size 70 2N1269X0032 Recommended spare part 1 Part included in trim package assembly can be ordered according to the parts kit trim package 28 Types 1098 EGR and 1098H EGR 6 3 8 28 66 42 57 5 27 2 Ei TYPE 1098 36A8540 TYPE 1098H Figure 14 Types 1098 and 1098H Actuator Assemblies 29 Types 1098 EGR and 1098H EGR Types 1098 and 1098H Actuators Figure 14 continued Key Description 7 Diaphragm continued Type 1098H Ethylenepropylene EPDM Size 30 Size 40 Size 70 Nitrile NBR Fluorocarbon FKM Ethylenepropylene EPDM 8 Diaphragm Plate Size 30 Cast Iron 316 Stainless steel NACE Size 40 Cast Iron 316 Stainless steel NACE Size 70 Cast Iron WCC Steel NACE 316 Stainless steel NACE 9 Cap Screw Sizes 30 and 40 Steel Stainless steel NACE Size 70 Steel Steel NACE Stainless steel NACE 10 Cap Screw Size 30 12 required Cap Screw Plated steel Type 1098 NACE Type 1098H Stud Stainless steel Type 1
58. ion leakage due to escaping accumulated gas or bursting of pressure containing parts may result if this regulator is Standard Single Pilot Regulator overpressured or is installed where service Figure 3 conditions could exceed the limits given in the Specifications section and on the Installations 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 to prevent service conditions from exceeding those limits A Type 1098 EGR or Type 1098H EGR regulator bleeds no gas to the atmosphere making it suitable for installation in pits or other enclosed locations without elaborate venting systems This regulator can also be installed in pits subject to flooding by venting the pilot spring case above the expected flood level so that the pilot diaphragm is exposed to atmospheric pressure Types 1098 EGR and 1098H EGR eT CONTROL EINE TO PILOT LIGHT IF USED FOR BOILER FUEL INSTALLATION 1 2 In 13 mm n TIF PIPE a A EN PILOT Y Ay SUPPLY ae re TN aA soy CRY lamg O ASH y T at Saud SEA ERs _ ZW 4 2 In Te rT a 13mm TTS e fs j PIPE wes TY ae if j ssa TYPE 1098 EGR OR 1098H EGR REGULATOR 4BA6566 A WITH STANDARD 6350 SERIES PILOT B1622 Figure 3 Standard Single Pilot Installation TO PILOT LIGHT a mee Ps ee 7 ome A PS 7 KA a nA A ae 5
59. key 23 Figure 24 or keys 37 and 39 Figure 28 Disconnect the loading tubing key 24 Figure 24 26 or 28 from the actuator elbow fitting key 25 Figure 24 or key 41 Figure 28 and with a Type 61LD pilot also disconnect the relief tubing key 18 Figure 25 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 Types 1098 and 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 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 For the Type 1098H actuator thread the upper diaphragm casing key 2 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 key 2 and the bonnet insert and tighten the four case cap screws key 4 to secure the
60. lator Installation section through step 3 making sure that the regulator is installed with the actuator below the main valve as shown in Figure 4 Runa 1 2 in 13 mm or larger pilot supply line from the upstream pipeline to the 1 2 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 TO BOILER X FAST ACTING TYPE LOAD VALVE 1098 EGR PILOT GAS SUPPLY a xX ok PILOT GAS TO PILOT LIGHT REGULATOR E0710 Figure 6 Boiler Fuel Configuration Installation Guide inlet pressure could exceed the pilot rating install a separate regulator in the pilot supply line and provide vent valves so that pressure can be properly isolated and relieved from the regulator Attach a 1 2 NPT downstream pressure control line ten pipe diameters downstream of the regulator in a straight run of pipe Do not make the tap near any elbow swage or nipple which might cause turbulence Connect the other end of the control line to the 1 4 NPT connection in the control pipe tee as shown in Figure 4 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 Consult the appropriate instruction manual for installation of an optional pneumatic or
61. m port 14 Piston Ring NPS 1 DN 25 PTFE clear NPS 2 DN 50 PTFE clear NPS 3 DN 80 PTFE clear NPS 4 DN 100 PTFE clear NPS 6 8 x 6 or 12 x 6 DN 150 200 x 150 or 300 x 150 glass filled PTFE Part Number 24A6781X012 24A5670X012 24A5655X012 24A5640X012 24A6989X012 38A4216X012 24A6781X022 24A5670X022 24A5655X022 24A5640X022 24A6989X022 38A4216X022 14A6786X012 14A5675X012 14A5660X012 14A5645X012 14A6985X022 Type EGR Main Valve Figures 12 and 13 continued Key Description 15 Upper Seal Nitrile NBR standard NPS 1 DN 25 NPS 2 DN 50 NPS 3 DN 80 NPS 4 DN 100 NPS 6 8x 6o0r12x6 DN 150 200 x 150 or 300 x 150 Fluorocarbon FKM NPS 1 DN 25 NPS 2 DN 50 NPS 3 DN 80 NPS 4 7 DN 100 NPS 6 8x6o0r12x6 DN 150 200 x 150 or 300 x 150 Ethylenepropylene EPR NPS 1 DN 25 NPS 2 DN 50 NPS 3 DN 80 NPS 4 7 DN 100 NPS 6 8x 6o0r12x6 DN 150 200 x 150 or 300 x 150 16 Valve Plug 416 Stainless steel NPS 1 DN 25 NPS 2 DN 50 NPS 3 DN 80 NPS 4 DN 100 NPS 6 8x 6o0r12x6 DN 150 200 x 150 or 300 x 150 316 Stainless steel NACE NPS 1 DN 25 NPS 2 DN 50 NPS 3 DN 80 NPS 4 DN 100 NPS 6 8x 6o0r12x6 DN 150 200 x 150 or 300 x 150 17 Cage O ring Nitrile NBR standard NPS 1 DN 25 NPS 2 DN 50 NPS 3 DN 80 NPS 4 DN 100 NPS 6 8x6o0r12x6 DN 150 200 x 150 or 300 x 150 Fluorocarbon FKM NPS 1 DN 25 NPS 2 DN 50 NPS 3 DN 80 NPS 4 DN 100 NPS 6 8x6o0r12x6 DN 150
62. ment 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 the pilot supply or control lines 1 Remove the cap screws key 3 with a cast iron body or remove the hex nuts key 29 not shown with a steel body Pry the body flange key 2 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 key 1 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 1001212 Figure 11 Types 1098 EGR and 1098H EGR Travel Indicator Assembly 4 Coat th
63. n steel NACE Tag 18 8 Stainless steel not shown Tag Wire 303 Stainless steel not shown Bearing 2 required For Nitrile NBR Diaphragm Nylon PA For Fluorocarbon FKM and Ethylenepropylene EPDM Diaphragms Nyliner Wiper Part Number Type Y602 12 1L847828992 19A6034X012 1U7581X0022 17A7112X012 17A7112X022 15A6002XN12 Standard P590 Series Filter Figure 15 Key 1 6 7 11 12 Description Filter Body Type P594 1 Brass Type P593 1 Aluminum NACE Filter Element Cellulose NACE Filter Head Type P594 1 Brass Type P593 1 Aluminum NACE Machine Screw Type P594 1 Brass Type P593 1 Aluminum NACE Washer 2 required Type P594 1 Brass Type P593 1 Aluminum NACE Spring Washer Plated carbon steel Gasket composition NACE Tag 18 8 Stainless steel not shown Tag Wire 304 Stainless steel not shown Type 6351 Pilot Figure 16 Key Description Parts Kit includes keys 3 4 6 7 23 and for the P590 Series filter keys 2 and 7 Body Assembly Aluminum with Brass bushing Aluminum with Stainless steel bushing NACE Stainless steel with Stainless steel bushing Bonnet Aluminum with closing cap Body Plug Assembly includes body plug and O ring Aluminum body plug with Nitrile NBR O ring with Fluorocarbon FKM O ring Stainless steel body plug with Nitrile NBR O ring with Fluorocarbon FKM O ring Inner Valve Assembly Nitrile NBR with Brass stem Nitrile NBR with Stainl
64. nitor Figure 7 Installation 1 For both working monitor regulator and working regulator perform the Standard Single Pilot Regulator Installation section through step 6 2 Connect another downstream pressure control line and hand valve Figure 7 to the monitoring pilot according to the monitoring pilot instruction manual Attach a 1 2 NPT 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 7 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 to open Startup On a working monitor installation Figure 7 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 a
65. o replace the stem key 14 or stem O ring key 30 also perform Body Area Maintenance procedure steps 1 and 4 and pull the stem key 14 out of the diaphragm casing key 4 Grease the replacement stem O ring key 30 with a good grade of lubricant and install it on the stem key 14 Install the stem key 14 into the diaphragm casing key 4 and perform Body Area Maintenance procedure steps 6 through 8 as necessary Install the lever assembly key 16 into the stem key 14 and secure the lever assembly with the machine screws key 17 Hold the pusher post key 8 and place diaphragm assembly parts on the pusher post in the following order diaphragm key 10 diaphragm head key 7 lower spring seat key 50 and washer key 36 and secure with diaphragm cap screw key 38 using 7 to 9 ft lbs 9 5 to 12 Nem of torque Install the pusher post key 8 and attached parts onto the lever key 16 Install the control spring key 6 and spring case key 3 on the diaphragm casing key 4 so that the vent assembly key 26 is correctly oriented and secure them with the cap screws key 24 and hex nuts key 23 to finger tightness only Turn the adjusting screw key 35 clockwise until there is enough control spring key 6 force to provide proper slack to the diaphragm key 10 Using a crisscross pattern finish tightening the cap screws key 24 and hex nuts to 5 to 6 ft lbs 6 8 to 8 1 Nem of torque Finish tu
66. r range Unpainted 35 to 100 psig 2 4 to 6 9 bar range Red Adjusting Screw Aluminum bonnet Locknut plated steel Aluminum bonnet Machine Screw Steel 6 required Hex Lock Plate Aluminum not shown Threaded Lock Plate Sluminum not shown Pipe Nipple Standard and Corrosive service Galvanized plated steel use with P590 Series Steel NACE P590 Series Filter parts listed under separate heading Type P594 1 Brass standard Type P593 1 Aluminum Closing Cap Plastic Aluminum bonnet Vent Assembly Type Y602 12 Relief Valve Assembly Aluminum 302 Stainless steel NACE All other assemblies Part Number 1B7980000B2 1B7980X00A2 1B7980000C2 1B798525062 1B986027212 1B788327022 1K748527202 10B7192X012 1A946324122 T13305T0012 10B2695xX012 10B2696X012 10488226232 104882X0032 AJ5004000A2 AJ5004T0012 23B9152X012 Y602 12 16A5929X042 16A5929X022 Types 6352 6353 6354L 6354M and 6354H Pilots Figure 17 Key Description Parts kit included are valve plug key 4 diaphragm Part Number 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 Type 6353 Type 6354 Pilot Body Aluminum with 25 psig 1 7 bar relief Aluminum with 50 psig 3 4 bar Type 1806H relief Stainless steel with 25 psig 1 7 bar relief Stainless steel with 50 psig 3 4 bar Type 1806H reli
67. rning the adjusting screw to the desired outlet pressure setting Install the closing cap key 22 Type 95H Supply Pressure Regulator This section includes instructions for disassembly and assembly of replacement parts All key numbers refer to Figure 23 20 Unscrew the valve plug guide key 5 from the body key 1 The valve plug spring key 10 and the valve plug key 4 will normally come out of the body along with the valve plug guide Inspect the seating surface of the valve plug key 4 being sure that the composition surface or polished steel surface of the valve plug is not damaged Replace if damaged Inspect the seating edge of the orifice key 3 If damaged unscrew the orifice from the body and replace it with a new part If no further maintenance is required reassemble the regulator in the reverse of the above steps When installing the valve plug guide key 5 coat the threads and sealing surface with sealant to ensure an adequate metal to metal seal To inspect the diaphragm key 12 or other internal parts loosen the locknut key 17 and turn the adjusting screw key 15 to remove all spring compression Remove the diaphragm case cap screws key 16 and lift off the spring case key 2 Remove the upper spring seat key 9 and regulator spring key 11 Remove the lower spring seat key 8 Remove the diaphragm key 12 and examine for damage Replace if damaged
68. s shown are valve body sizes 21 Types 1098 EGR and 1098H EGR Parts List continued Type EGR Main Valve Figures 12 and 13 Key Description Elastomer Trim Parts kit included are keys 4 7 12 14 15 17 20 21 36 and 37 Nitrile NBR NPS 1 DN 25 NPS 2 DN 50 NPS 3 DN 80 NPS 4 DN 100 NPS 6 DN 150 Fluorocarbon FKM NPS 1 DN 25 NPS 2 DN 50 NPS 3 DN 80 NPS 4 DN 100 NPS 6 DN 150 Ethylenepropylene EPR NPS 1 DN 25 NPS 2 DN 50 NPS 3 DN 80 NPS 4 DN 100 NPS 6 DN 150 Part Number R63EGX00112 R63EGX00122 R63EGX00132 R63EGX00142 R63EGX00162 R63EGXFK112 R63EGXFK122 R63EGXFK132 R63EGXFK142 R63EGXFK162 R63EGXEP112 R63EGXEP122 R63EGXEP132 R63EGXEP142 R63EGXEP162 Actuator Parts kit included are keys 5 6 7 56 and 57 Size 30 Nitrile NBR Fluorocarbon FKM Size 40 Nitrile NBR Fluorocarbon FKM Size 70 Nitrile NBR R1098X00302 R1098X00502 R1098X00402 R1098X00602 R1098X00702 Quick Change Trim Kit see Figure 13 for included keys 60 psi 4 1 bar spring color green Cast Iron Body Flange NPS 1 DN 25 NPS 2 DN 50 NPS 3 DN 80 NPS 4 DN 100 NPS 6 DN 150 Steel Body Flange NPS 1 DN 25 NPS 2 DN 50 NPS 3 DN 80 NPS 4 DN 100 NPS 6 DN 150 NPS 8 x 6 DN 200 x 150 125 psi 8 6 bar spring color blue Cast Iron Body Flange NPS 1 DN 25 NPS 2 DN 50 NPS 3 DN 80 NPS 4 DN 100 NPS 6 DN 150 Steel Body Flange NPS 1 DN 25 NPS 2 DN 50 NPS 3 DN 80 NPS 4 DN 1
69. s steel 1B989514012 Trim for corrosive service 18 8 Stainless steel 1B989535072 O ring Seal for 61 Series except Type 61HP Standard and trim for corrosive service Nitrile NBR 1B885506992 Oxygen service and pressure loaded trim for corrosive service Fluorocarbon FKM 1B8855x0012 Relay Spring 302 Stainless steel Types 61L and 61LE 10911537022 Type 61LD 1E643637022 Type 61H Up to 300 psig 20 7 bar inlet pressure 10911537022 300 to 400 psig 20 7 to 27 6 bar inlet pressure 1N859137022 Type 61HP 1B797937022 Upper Relay Diaphragm Types 61L 61LD 61LE and 61H Standard and trim for corrosive service Nitrile NBR 1B885202052 Oxygen service and pressure loaded trim for corrosive service Fluorocarbom FKM 1N162802332 Type 61HP Standard Neoprene CR 13A9841X022 Oxygen service Fluorocarbon FKM 13A9841X012 Lower Relay Diaphragm Types 61L 61LD and 61LE Standard and trim for corrosive service Nitrile NBR 1B886002052 Oxygen service and pressure loaded trim for corrosive service Fluorocarbon FKM 1N536102332 Type 61H Standard and trim for corrosive service Neoprene CR 1B894202192 Oxygen service Fluorocarbon FKM 2 required 1N162702302 Type 61HP Standard Neoprene CR 13A9840X012 Oxygen service Fluorocarbon FKM 13A9840X022 Upper Relay Head Zinc plated steel Types 61L and 61LD 1B989325072 Type 61LE 1D558425072 Type 61H 1D558425072 Diaphragm Plate 410 416 Stainless steel Type 61HP 4 required 13A9839X012 Lower R
70. standard 75 52 82 5 6 70 50 3 4 65 4 5 1098H 30 350 24 1 400 27 6 Table 4 Maximum and Minimum Differential Pressures for Main Valve Selection MINIMUM DIFFERENTIAL PRESSURE BODY SIZE SPRING PART SPRING EEEN EREE REQUIRED FOR FULL STROKE NUMBER COLOR Size 30 Actuator Size 40 Actuator Size 70 Actuator NPS DN psig bar psig bar psig bar psig bar 4A9687X012 Green 60 4 1 3 5 0 24 2 5 0 17 1 0 07 1 25 4A9680X012 Blue 125 8 6 5 0 34 3 0 21 1 5 0 10 4A9679X012 Red 400 27 6 7 0 48 5 0 34 2 5 0 17 4A6768X012 Yellow 20 1 4 1 0 07 4A6626X012 Green 60 41 4 0 28 3 0 21 1 5 0 10 A 3 4A6627X012 Blue 125 8 6 6 0 41 5 0 34 2 0 14 4A6628X012 Red 400 27 6 11 0 76 10 0 69 3 0 21 4A6771X012 Yellow 20 1 4 1 0 07 4A6629X012 Green 60 41 5 0 34 4 0 28 2 0 14 3 20 4A6630X012 Blue 125 8 6 8 0 55 6 0 41 2 5 0 17 4A6631X012 Red 400 27 6 14 0 97 11 0 76 4 0 28 4A6770X012 Yellow 20 1 4 1 3 0 09 4A6632X012 Green 60 4 1 10 0 69 5 0 34 2 5 0 17 ne 4A6633X012 Blue 125 8 6 13 0 90 8 0 55 3 0 21 4A6634X012 Red 400 27 6 22 1 5 13 0 90 5 0 34 5A2253X012 Yellow 20 1 4 2 2 0 15 6 8x6 150 200 x 150 4A9686X012 Green 60 4 1 13 0 90 9 5 0 66 4 0 28 or 12x6 or 300 x 150 4A9685X012 Blue 125 8 6 19 1 3 14 0 97 6 0 41 5A2615X012 Red 400 27 6 282 1 92 19 1 3 8 0 55 1 Maxim
71. t part key numbers are referenced in Figures 18 and 19 and mounting part and relief valve key numbers in Figure 25 1 Remove the pilot from the pipe nipple key 24 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 bottom cover key 3 4 To inspect the two diaphragms keys 14 and 15 thoroughly remove the diaphragm nut key 11 hex nut key 19 and the upper and lower relay heads keys 16 and 17 The projecting prong in the body may be used as the restraining member to keep the yoke key 4 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 r
72. tainless steel Nitrile NBR Valve Plug Guide 416 Stainless steel Stem Assembly 416 Stainless steel Stem Guide Bushing 416 Stainless steel Recommended spare part 38 Part Number R95HX000102 1E391019012 2E391219012 1E393235132 1E3933000E2 1E391835132 1F2113000A2 1E392235132 Key 8 9 10 11 12 13 15 16 17 Description Lower Spring Seat Aluminum standard Upper Spring Seat Zinc plated steel Valve Plug Spring 302 Stainless steel Spring Zinc plated steel Yellow Diaphragm Neoprene CR Nameplate Adjusting Screw Plated Carbon steel Cap Screw 6 required Zinc plated steel Locknut Zinc plated steel Part Number 1E392309012 1B798525062 1E392437022 1E392527022 1E393502112 1E639928992 1A407824052 1A352224122 Types 1098 EGR and 1098H EGR BOTTOM VIEW OF PILOT SHOWN ROTATED 90 FROM NORMAL 14A5706 A CONTROL LINE CONNECTION a ay 2 NCZ Df SN oe Cinta 4k Figure 24 Single Pilot Mounting Assembly Mounting Parts 6350 Series Mounting Parts Figure 24 Part Number Key Description 16 Pipe Tee for use with 50 psig 3 4 bar relief 21 Tube Fitting Connector for use with 50 psig 3 4 bar relief steel 23 Pipe Nipple Type 1098 Actuator Sizes 30 and 40 Plated steel Stainless steel NACE For use with 50 psig 3 4 bar relief Actuator Size 70 Plated steel Stainless steel NACE Type 1098H Steel Stainless steel 24 Tubing A
73. to the monitor regulator pressure setting The monitor pressure setting should be adjusted so it is at minimum two times the pilot proportional band pressure above the working regulator pressure setting The monitor pilot supply pressure setting should be adjusted so it is at minimum 5 psig 0 34 bar plus the monitor minimum differential pressure above the working regulator pressure setting These adjustments must be made such that other governing pressure limits such as casing ratings pilot maximum differential pressures or regulatory limits are not exceeded Wide Open Monitor Figure 8 Either the upstream or downstream regulator can be the monitor regulator During normal operation the monitoring regulator is standing wide open with the reduction to distribution pressure being taken across the working regulator Only in case of open failure of the working regulator does the wide open monitoring regulator take control at its slightly higher setting Regardless of which regulator is used as the monitor it should be equipped with a pilot supply regulator set to limit the pilot supply pressure to 10 to 15 psig 0 69 to 1 0 bar above control pressure Since the pilot on the monitoring regulator is wide open during normal operation the pilot supply regulator prevents differential relief valve chatter on the monitoring regulator pilot Installation 1 For both the wide open monitoring regulator and the working regulator perform the
74. 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 are also valid for a dual pilot regulator Figure 4 or a wide open monitoring installation Figure 8 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 CAGE SCREWS INTO P1508 Figure 10 Seat Ring Cage Removal or Installation Using Body as Holding Fixture 4 Slowly open the upstream pipeline vent valve Allow 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 Maintenance Regulator parts are subject to normal wear and must be inspected and replaced as necessary The frequency of inspe
75. um inlet pressure is equal to set pressure plus maximum differential 2 Requires special 6300 Series pilot construction without integral relief valve and with external Type 1806 40 psid 2 8 bar d relief valve 3 Should not exceed the body rating limit Use this pressure value or the body rating limit whichever is lower Types 1098 EGR and 1098H EGR Table 5 Supply Pressure Settings Required for the Type 95H Regulator SUPPLY PRESSURE BODY SIZE TYPE EGR Type Y600AM Spring Color SPRING COLOR Red Unpainted Yellow Green Light Blue Black NPS DN psig bar psig bar psig bar psig bar psig bar psig bar Green 6 0 41 6 0 41 7 0 48 8 0 55 11 0 76 13 0 90 1 25 Blue 7 0 48 7 0 48 8 0 55 10 0 69 13 0 90 14 0 97 Red 8 0 55 8 0 55 9 0 62 11 0 76 14 0 97 15 1 0 Green 6 0 41 6 0 41 7 0 48 9 0 62 12 0 83 13 0 90 2 50 Blue 8 0 55 8 0 55 9 0 62 11 0 76 14 0 97 15 1 0 Red 13 0 90 13 0 90 14 0 97 16 1 1 19 1 3 20 1 4 Green 7 0 48 7 0 48 8 0 55 10 0 69 13 0 90 14 0 97 3 80 Blue 9 0 62 9 0 62 10 0 69 12 0 83 15 1 0 16 1 1 Red 14 0 97 14 0 97 15 1 0 17 1 2 20 1 4 21 1 5 Green 8 0 55 8 0 55 9 0 62 11 0 76 14 0 97 15 1 0 4 100 Blue 11 0 76 11 0 76 12 0 83 14 0 97 17 1 2 18 1 2 Red 16 1 1 16 1 1 17 1 2 19 1 3 22 1 5 23 1 6 150 Green 13 0 90 13 0 90 14 0 97 15 1 0 18 1 2 20 1 4 6or8x6 200 oe Blue 17 1 2 17 1 2 18 1 2 20 1 4 23 1 6 24 1 7 Red 22 1 5 22 1 5 23 1 6 25 1 7 28 1 9 29 2
76. ures 26 and 28 for dual pilot constructions Note The body key 1 may remain on the pipe nipple key 23 Figure 24 or key 39 Figure 28 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 remark 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 61 Series 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 Pilo
77. y which does not use it the pipe plug key 31 must be installed in the side tapping of the flange for proper operation Make sure that the flange key 2 and stem O rings key 7 and the bushings are installed in the indicator fitting key 5 Orient the spring seat key 28 as shown in Figure 12 and attach it with the E ring key 23 to the slotted end of the indicator stem key 10 Install the travel stop key 32 if used on the spring seat and then install the spring key 9 Being careful not to cut the stem O ring key 7 with the stem threads install the indicator fitting key 5 down over the indicator stem key 10 until resting on the spring key 9 Install the hex nut key 8 and then the flanged indicator nut key 22 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 key 28 by turning the hex nut down on the stem until the threads bottom Install the indicator fitting key 5 with attached parts into the body flange key 2 Back the hex nut off until the spring completely closes the valve plug key 16 against the port key 12 and upper seals key 15 as indicated by stem threads showing between this nut and the fitting Hold the indicator scale key 18 against the fitting with the scale base resting against the shoulder of the fitting and turn the indicator nut key 22 until its
78. y during maintenance or inspection The pilot may be field changed to the opposite side mounting position by swapping the pilot pipe nipple to the opposite bonnet tapping 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 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 To remotely vent the standard pilot remove the vent and install obstruction free tubing or piping into the 1 4 NPT vent tapping Provide protection on a remote vent by installing a screened vent cap into the remote end of the vent pipe Run a 3 8 in 9 5 mm outer diameter or larger pilot supply line from the upstream pipeline to the filter inlet as shown in Figure 3 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 Attach a 1 2 NPT downstream pressure control line downstream of the regulator in a straight run of pipe as shown in Figure 3 Do not make the tap near an
79. y elbow swage or nipple that might cause turbulence Connect the other end of the control line to the bonnet connection Install a hand valve in the control line to shut off the control pressure when the bypass is in use 6 If a quick acting solenoid is to be installed downstream of the regulator the regulator and solenoid should be located as far apart as practical This maximizes the gas piping volume between the regulator and solenoid and improves the regulator response to quick changing flow rates Consult the appropriate instruction manual for installation of an optional Type 662 pneumatic or electric remote control drive unit For optional remote pneumatic loading of a 6350 or 61 Series pilot make the loading piping connections to the 1 4 NPT vent connection explosion Vent a regulator in hazardous Pre startup Considerations 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 Before beginning the startup procedures in this section make sure the following conditions are in effect e Block valves isolate the regulator e Vent valves are closed e Hand valves are closed Types 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 g

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