Emerson Process Management 99 Users Manual
99 22a2ca4a-6080-4712-b474-2c94a07aa3b3 Emerson Process Management Thermostat 99 User Guide |
2015-02-06
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Type 99 Instruction Manual Form 589 April 2008 Type 99 Pressure Reducing Regulators Introduction Scope of the Manual This manual describes and provides instructions and parts lists for Type 99 pressure reducing regulators complete with standard P590 Series integral filter. However, complete instructions and parts listing for the Type 1301F pilot supply regulator, and other Fisher® equipment, such as monitoring pilots will be found in separate instruction manuals. Description The Type 99 gas regulators provide a broad capacity for controlled pressure ranges and capacities in a wide variety of distribution, industrial, and commercial applications. A Type 99 regulator has a Type 61L (low pressure), Type 61H (high pressure), or a Type 61HP (extra high pressure) pilot integrally mounted to the actuator casing as shown in Figure 1. The Type 99 regulator can handle up to 1000 psig (69,0 bar) inlet pressures (the 1000 psig (69,0 bar) regulator requires a Type 1301F pilot supply regulator and a Type H110 pop relief valve). The pilot supply regulator reduces inlet pressure to a usable 200 psig (13,8 bar) for the extra high pressure pilot. This regulator comes standard with O-ring seals on the guide bushing and valve carrier (key 26, Figure 7) to keep main valve body outlet pressure from interfering with outlet pressure in the lower casing assembly (key 29, Figure 9). Specifications ! Warning Figure 1. Type 99 Regulator with Type 61H (high pressure) Pilot the maximum inlet pressure shown on the nameplate of either unit. When inlet pressure exceeds the pilot limitation, a pilot supply reducing regulator and/or relief valve will be required. Specifications and ratings for various Type 99 constructions are listed in the Specifications section on page 2. Some specifications for a given regulator as it originally comes from the factory are stamped on nameplates located on the pilot and actuator spring cases. A tag (key 159, Parts List) additionally may be installed on the pilot to indicate a regulator with O-ring stem seal. These regulators and their installations should be checked for compliance with applicable codes. D100260X012 Since a pilot-operated regulator is constructed of both a pilot and a main valve, care should be used not to exceed W2676 www.emersonprocess.com/regulators Type 99 Specifications Body Size and End Connection Styles 2-inch (DN 50) body with NPT; CL125, CL150, CL250, or CL300 flanged; or SWE Maximum Actuator Pressures(1) Operating: 100 psig (6,90 bar) Emergency: 110 psig (7,58 bar) Maximum Allowable Inlet Pressure(1) 160 psig (11,0 bar): When using Type 61LD pilot 400 psig (27,6 bar): When using Types 61L/ 61H pilots 600 psig (41,4 bar): Type 61HP pilot (5/8-inch (15,9 mm) orifice maximum) 1000 psig (69,0 bar): Type 61HP pilot, along with Type 1301F pilot supply regulator and Type H110 relief valve (1/2-inch (12,7 mm) orifice only) Maximum Pilot Spring Case Pressure for Pressure Loading(1, 2) Types 61L, 61LD(3), and 61LE(4): 50 psi (3,45 bar) with special steel closing cap Types 61H and 61HP: 100 psi (6,90 bar) Outlet (Control) Pressure Ranges See Table 1 Maximum Rated Travel 1/4-inch (6,35 mm) Approximate Proportional Bands See Table 2 Temperature Capabilities(1) With Nitrile (NBR) / Neoprene (CR): -20° to 180°F (-29° to 82°C) With Fluorocarbon (FKM): 0° to 300°F (-18° to 149°C) Minimum Differential Pressure Required for Full Stroke See Table 3 Maximum Allowable Pressure Drop(1) See Table 3 1. The pressure/temperature limits in this Instruction manual and any applicable standard or code limitation should not be exceeded. 2. For stability or overpressure protection, a pilot supply regulator may be installed in the pilot supply tubing between the main valve and pilot. 3. Type 61LD construction has narrower proportional band than does the standard Type 61L pilot. 4. Type 61LE construction has broader proportional band than does the standard Type 61L pilot. Table 1. Outlet Pressure Ranges Pilot type MAXIMUM PILOT SUPPLY PRESSURE, PSIG (bar) Pilot Control Spring Outlet (Control) Pressure Ranges 2 to 4-inches w.c. 3 to 12-inches w.c. 0.25 to 2 psig 1 to 5 psig 2 to 10 psig 5 to 15 psig 10 to 20 psig Part Number Color Code (5 to 10 mbar) (7 to 30 mbar) (0,02 to 0,14 bar) (0,07 to 0,34 bar) (0,14 to 0,69 bar) (0,34 to 1,03 bar) (0,69 to 1,38 bar) 1B558527052 1C680627222 1B886327022 1J857827022 1B886427022 1J857927142 1B886527022 Orange Unpainted Red Yellow Blue Brown Green Wire Diameter, Inches (cm) 0.075 0.080 0.109 0.142 0.172 0.187 0.363 (0,19) (0,20) (0,28) (0,36) (0,44) (0,47) (0,92) Free Length, Inches (cm) 4-1/8 3-1/4 2-3/4 2-3/4 2-7/8 2-7/8 3-1/8 (10,5) (8,26) (7,00) (7,00) (7,30) (7,30) (7,94) 61L 400 (27,6) 61LD(1) 160 (11,0) 61LE(2) 400 (27,6) 61H 400 (27,6) 10 to 65 psig (0,69 to 4,48 bar) 0Y0664000A2 Green stripe 0.363 (0,92) 6 (15,2) 61HP 600 (41,4) 35 to 100 psig (2,41 to 6,90 bar) 1D387227022 Blue 0.200 (0,51) 1-11/16 (4,29) 1. Type 61LD construction has narrower proportional band than does the standard Type 61L Pilot. 2. Type 61LE construction has broader proportional band than does the standard Type 61L Pilot. Table 2. Proportional Bands PILOT TYPEs 2 PILOT CONTROL SPRING Part Number Color Code Wire Diameter, Inches (cm) Free Length, Inches (cm) 61LD 1B558527052 1C680627222 Orange Unpainted 0.075 (0,19) 0.080 (0,20) 4-1/8 (10,5) 3-1/4 (8,26) PROPORTIONAL BANDS 0.1 to 0.5-inch w.c. (0,25 to 1,0 mbar) 61L 1B886327022 Red 0.109 (0,28) 2-3/4 (7,00) 1 to 2-inches w.c. (2 to 5 mbar) 61LD 1B886327022 Red 0.109 (0,28) 2-3/4 (7,00) 0.25 to 1-inch w.c. (0,62 to 2 mbar) 61LE 1B886327022 Red 0.109 (0,28) 2-3/4 (7,00) 5 to 8-inches w.c. (12 to 20 mbar) 61L, 61LD, 61LE 1B886527022 1J857927142 1B886427022 1J857827022 Green Brown Blue Yellow 0.207 0.187 0.172 0.142 3-1/8 2-7/8 2-7/8 2-3/4 61H 0Y0664000A2 Green stripe 61HP 1D387227022 Blue (0,53) (0,47) (0,44) (0,36) (7,94) (7,30) (7,30) (7,00) 0.1 to 0.3 psi (0,007 to 0,02 bar) 0.363 (0,92) 6 (15,2) 0.1 to 0.3 psi (0,007 to 0,02 bar) 0.200 (0,51) 1-11/16 (4,29) 1 to 2 psi (0,069 to 0,14 bar) Type 99 Type99 99 Type January 2008 Type 99 H d outlet pipe c b e k f inlet pressure INLET PRESSURE A6814 outlet pressure OUTLET PRESSURE INLET PRESSURE OUTLET PRESSURE loading pressure LOADING PRESSURE LOADING PRESSURE atmospheric pressure ATMOSPHERIC PRESSURE ATMOSPHERIC PRESSURE g A6469 inlet a Figure 2. Schematic of Type 99 Regulator with Type 61L (Low Pressure) Pilot Principle of Operation The key to the operation of a Type 99 regulator is the yoked double-diaphragm pilot (letter keys in this section refer to both Figures 2 and 3 unless otherwise noted). Fast response and accuracy are made possible by the amplifying effect of the pressure-balanced pilot and by the two-path control system. The function of the pilot is to sense change in the controlled pressure and amplify it into a larger change in the loading pressure. Any changes in outlet pressure act quickly on both the actuator diaphragm and the loading pilot, thus providing the precise pressure control that is characteristic of a two-path system. A typical pilot has an approximate gain of 20, which means the outlet pressure needs to droop only 1/20 as much as a self-operated regulator in order to obtain the same pressure differences across the main diaphragm. Advantages of a pilot operated regulator are high accuracy and high capacity. Upstream or inlet pressure is utilized as the operating medium, which is reduced through pilot operation to load the main diaphragm chamber. Tubing connects the inlet pressure to the pilot through a filter assembly. Downstream or outlet pressure registers underneath the main diaphragm (E) through the downstream control line. In operation, assume the outlet pressure is less than the setting of pilot control spring (A). The top side of pilot diaphragm assembly (F) will have a lower pressure than the setting of spring (A). Spring (A) forces the diaphragm head assembly upward, opening the relay or inlet orifice (C). Additional loading pressure is supplied to the pilot body and to the top side of main diaphragm (E). This creates a higher pressure on the top side of the main diaphragm (E) than on the bottom side, forcing the diaphragm downward. This motion is transmitted through a lever, which pulls the valve disk open, allowing more gas to flow through the valve. When the gas demand in the downstream system has been satisfied, the outlet pressure increases. The increased pressure is transmitted through the downstream control line and acts on top of the pilot diaphragm head assembly (F). This pressure exceeds the pilot spring setting and forces the head assembly down, closing orifice (C). The loading pressure acting on the main diaphragm (E) bleeds to the downstream system through a small slot between the pilot bleed valve (D) and the bleed orifice (H). Normally, excess loading pressure slowly escapes downstream around bleed valve (D) (Figure 3) or 3 Type 99 Type 99 Type 99 January 2008 downstream control line Type 99 Regulator with Type 61HP (extra high pressure) Pilot B relief valve cap E H D J K yoke cap yoke cap flange adaptor G A C relay valve A2505 yoke leg INLET PRESSURE OUTLET PRESSURE inlet pressure LOADING PRESSURE INLET PRESSURE ATMOSPHERIC PRESSURE outlet pressure OUTLET PRESSURE F inlet pressure tubing connection loading pressure LOADING PRESSURE atmospheric pressure ATMOSPHERIC PRESSURE 54A2767-a A2505 Figure 3. Schematic of Type 99 Regulator with Type 61HP (Extra High Pressure) Pilot through the relief valve body (J) (Figure 4). Since loading pressure needs to exceed outlet pressure only moderately to stroke the main valve fully open, a continued increase in loading pressure differential extends the main diaphragm (E) and the pusher post assembly (K) far enough to separate the bleed valve (D) and the bleed orifice (H). This permits quick dumping of excess loading pressure into the downstream system. With a decrease in loading pressure on top of the main diaphragm (E), the main spring (B) exerts an upward force on the diaphragm rod connected to the main diaphragm (E), pulling it upward. This moves the main valve toward its seat, decreasing flow to the downstream system. Diaphragm (G) in the pilot valve acts as a sealing member for the loading chamber and as a balancing member to diaphragm (F). These two diaphragms are connected by a yoke so any pressure change in the pilot chamber has little effect on the position of the pilot valve. Therefore, the active diaphragm in the pilot is (F) and the pressure on the top side of this diaphragm opposes the force of the pilot control spring (A). 4 Monitoring Systems Monitoring regulators serve as overpressure protection devices to limit system pressure in the event of open failure of a working regulator feeding the system. Two methods of using Type 99 regulators in monitoring systems are as follows: Working Monitor On a working monitor installation (Figure 4), the control line of the monitoring pilot is connected downstream of the working regulator. During normal operation, distribution pressure causes the monitoring pilot to stand wide open. Full pilot supply pressure enters the working monitor pilot and permits the working monitor regulator to control at its intermediate pressure setting. Open failure of the working regulator increases distribution pressure as the working regulator goes wide-open. Intermediate pressure is then ignored by the monitoring regulator, which controls downstream pressure at its own pressure setting (slightly higher than the normal control pressure). Type 99 distribution pressure control line intermediate pressure control line type 161AYW monitoring pilot (also representative of Type 627-109) working monitor pilot pilot supply line intermediate pressure loading pressure optional pilot supply regulator working regulator working monitor regulator upstream pressure optional pilot supply regulator distribution pressure pilot supply piping for working regulator when pilot is required to be supplied from upstream pressure 20A1389-A B2484 Figure 4. Working Monitor Installation The monitoring pilot should be upstream of the working monitor regulator. This enables a closer setpoint between the working regulator and the monitoring pilot. Special Types 161AYW and 627-109 monitoring pilots with quick-bleed operation have been designed to give faster response to abnormal downstream conditions. Table 4 gives the spread between normal distribution pressure and the minimum pressure at which the working monitor regulator can be set to take over if the working regulator fails open. upstream regulator (requires o-ring stem seal) 10A1388-A A2504 optional pilot supply regulator Flexible arrangement that permits wide-open monitor to be either upstream or downstream Wide-Open Monitor The control line of the upstream regulator is connected downstream of the second regulator (Figure 5), so that 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. The upstream regulator must have an O-ring seal on the valve carrier assembly. This seals off the leak path that otherwise would let line pressure ahead of the working regulator inlet try to close the wide-open monitoring regulator. upstream regulator (requires o-ring stem seal) Working regulator 10A1386-A A2503 optional pilot supply regulator Flexible arrangement that permits wide-open monitor to be either upstream or downstream Figure 5. Typical Wide-Open Monitor Installations 5 Type 99 Table 3. Maximum Allowable Drop and Minimum Differential Pressures MAXIMUM ALLOWABLE PRESSURE DROP, PSIG (bar) MAIN VALVE SPRING MINIMUM DIFFERENTIAL PRESSURE FOR FULL STROKE, PSIG (bar) Part Number SEAT MATERIAL MAXIMUM port diameter(1), INCHES (mm) 25 (1,72) 1C277127022 0.148 (0,38) 6 (15,2) 0.75 (0,05) Nitrile (NBR), Neoprene (CR), Fluorocarbon (FKM) 1-1/8 (28,6) 50 (3,45) 1N801927022 0.156 (0,40) 7-1/8 (18,1) 1.5 (0,10) Nitrile (NBR), Neoprene (CR), Fluorocarbon (FKM) 1-1/8 (28,6) 150 (10,3) 1B883327022 0.187 (0,47) 6-5/8 (16,8) 3 (0,21) Nitrile (NBR), Neoprene (CR), Fluorocarbon (FKM) 1-1/8 (28,6) 175 (12,1) 1B883327022 0.187 (0,47) 6-5/8 (16,8) 3 (0,21) Nitrile (NBR)(2), Neoprene (CR)(2), Fluorocarbon (FKM)(2) Wire Diameter, Free Length, Inches (cm) Inches (cm) 7/8 (22,2) 1B883327022 0.187 (0,47) 6-5/8 (16,8) 3 (0,21) Nitrile (NBR), Fluorocarbon (FKM) 0W019127022 0.281 (0,71) 6 (15,2) 10 (0,69) Nitrile (NBR)(3), Fluorocarbon (FKM)(3) 1-1/8 (28,6) 300 (20,7) 0W019127022 0.281 (0,71) 6 (15,2) 10 (0,69) Nylon (PA) 1-1/8 (28,6) 400 (27,6) 0W019127022 0.281 (0,71) 6 (15,2) 10 (0,69) Nylon (PA) 7/8 (22,2) 600 (41,4) 0W019127022 0.281 (0,71) 6 (15,2) 10 (0,69) Nylon (PA) 5/8 (15,9) 1000 (69,0) 0W019127022 0.281 (0,71) 6 (15,2) 10 (0,69) Nylon (PA) 1/2 (12,7)(4) 250 (17,2) 7/8 (22,2) 1. Can use all port diameters up to maximum size listed. 2. CL125 FF flanged body only. 3. O-ring seat only. 4. 1/2-inch (12,7 mm) is the only orifice available for 1000 psig (69,0 bar) maximum inlet pressure regulator. Installation ! Warning • Personal injury, equipment damage, or leakage due to escaping gas or bursting of pressure-containing parts might result if this regulator is overpressured or is installed where service conditions could exceed the limits for which the regulator was designed, or where conditions exceed any ratings of the adjacent piping or piping connections. To avoid such injury or damage, provide pressure relieving or pressure-limiting devices (as required by the appropriate code, regulation, or standard) to prevent service conditions from exceeding those limits. • A regulator may vent some gas to the atmosphere in hazardous or flammable gas service, vented gas might accumulate and cause personal injury, death or property damage due to fire or explosion. Vent a regulator in hazardous gas service to a remote, safe location away from air intakes or any hazardous location. The vent line or stack opening must be protected against condensation or clogging. 6 Like most regulators, the Type 99 regulator has a outlet pressure rating lower than its inlet pressure rating. Complete downstream overpressure protection is needed if the actual inlet pressure can exceed the regulator outlet pressure rating or the pressure ratings of any downstream equipment. Although the Type H110 relief valve provides sufficient relief capacity to protect the extra high pressure pilot of the 1000 psig (69,0 bar) maximum inlet regulator in case the Type 1301F supply regulator fails open, this protection is insufficient if the main valve body fails open. Regulator operation within ratings does not preclude the possibility of damage from external sources or from debris in the lines. A regulator should be inspected for damage periodically and after any overpressure condition. ! Warning The 1000 psig (69,0 bar) maximum inlet regulator must not be used on hazardous gas service unless the Type H110 relief valve can be vented into a safe area. If vented gas can accumulate and become a hazard in enclosed conditions such as in a pit, underground, or indoors, the relief valve must be repiped to carry the gas to a safe location. A repiped vent line or stack must be located to avoid venting gas near buildings, air intakes, or any hazardous Type 99 Table 4. Working Monitor Performance MONITORING PILOT INFORMATION Pilot Spring Construction Type 161AYW with 1/8-inch (3,18 mm) port diameter and 150 psig (10,3 bar) maximum allowable inlet pressure Type 627-109 with 1/8-inch (3,18 mm) port diameter and 150 psig (10,3 bar) maximum allowable inlet pressure for cast iron body or 750 psig (51,7 bar) maximum allowable inlet pressure for malleable iron body Spring Range MINIMUM PRESSURE AT WHICH WORKING MONITOR REGULATOR CAN BE SET Part Number Wire Diameter, Inches (cm) Free Length, Inches (cm) 5 to 15-inches w.c. (12 to 37 mbar) 11 to 28-inches w.c. (27 to 70 mbar) 1B653927022 1B537027052 0.105 (0,27) 0.114 (0,29) 3-3/4 (9,52) 4-5/16 (11,0) 3-inches w.c. (7 mbar) over normal distribution pressure 1 to 2.5 psig (0,069 to 0,17 bar) 2.25 to 4.5 psig (0,16 to 0,31 bar) 4.5 to 7 psig (0,31 to 0,48 bar) 1B537127022 1B537227022 1B537327052 0.156 (0,40) 0.187 (0,47) 0.218 (0,55) 4-1/8 (10,5) 3-15/16 (10,0) 4-1/8 (10,5) 0.5 psi (0,03 bar) over normal distribution pressure 1D892327022 1D751527022 1D665927022 1D755527142 0.168 0.187 0.218 0.500 2-15/16 2-13/16 2-15/32 9-1/4 (7,46) (7,14) (6,27) (23,5) 3.0 psi (0,21 bar) over normal distribution pressure 2-15/16 (7,46) 2-5/8 (6,67) 2-5/8 (6,67) 5.0 psi (0,34 bar) over normal distribution pressure 5 to 15 psig 10 to 25 psig 20 to 35 psig 25 to 60 psig (0,34 to 1,03 bar) (0,69 to 1,72 bar) (1,38 to 2,41 bar) (1,72 to 4,14 bar) 40 to 80 psig (2,76 to 5,52 bar) 80 to 150 psig (5,52 to 10,3 bar) 130 to 200 psig (9,00 to 13,8 bar) 1E543627142 1P901327142(1) 1P901327142(2) (0,43) (0,47) (0,55) (1,27) 0.283 (0,72) 0.240 (0,61) 0.240 (0,61) 1. With large diaphragm plate. 2. With small diaphragm plate. location. The line or stack opening must be protected against condensation, freezing, and clogging. Clean out all pipelines before installation and check to be sure the regulator has not been damaged or collected foreign material during shipping. Apply pipe compound to the male pipe threads only with a screwed body, or use suitable line gaskets and good bolting practices with a flanged body. This regulator may be installed in any position desired as long as the flow through the body is in the direction indicated by the arrow on the body. Install a three-valve bypass around the regulator if continuous operation is necessary during maintenance or inspection. Although the standard orientation of the actuator and pilot to the main valve body is as shown in Figure 1, this orientation may be changed as far as the inlet tubing (key 24, Figure 9 or 11) will permit by loosening the union nut (key 14, Figure 9), rotating the actuator lower casing (key 29, Figure 9) as desired, and tightening the union nut. To keep the pilot spring case from being plugged or the spring case from collecting moisture, corrosive chemicals, or other foreign material, the vent must be pointed down, oriented to the lowest possible point on the spring case, or otherwise protected. Vent orientation may be changed by rotating the spring case with respect to the pilot body, or on the extra high pressure pilot with optional tapped spring case by rotating the vent with respect to the spring case. To remotely vent a low pressure pilot, install the vent line in place of the pressed-in vent assembly (key 60, Figure 9). Install obstruction-free tubing or piping into the 1/4-inch (6,35 mm) vent tapping. Provide protection on a remote vent by installing a screened vent cap into the remote end of the vent pipe. To remotely vent a high pressure pilot, or an extra high pressure pilot with optional tapped spring case, remove the screwed-in vent assembly (key 72, Figure 9) from the high pressure pilot spring case or the pressed-in vent assembly from the extra high pressure pilot spring case and install obstruction-free tubing or piping into the 1/4-inch (6,35 mm) vent tapping. Provide protection on a remote vent by installing a screened vent cap into the remote end of the vent pipe. An upstream pilot supply line is not required because of the integral pilot supply tubing (key 24, Figure 9 or 11). However, as long as the 1/4-inch NPT tapping in the main valve body is plugged, this tubing may be disconnected from both the main valve and filter assembly (key 75, Figure 9) in order to install a pilot supply line from a desired remote location into the filter. If the maximum pilot inlet pressure will be exceeded by main valve pressure, install a separate reducing regulator (if not already provided) in the pilot supply line. A Type 99 regulator has two 1/2-inch threaded NPT control line pressure taps on opposite sides of the lower casing (key 29, Figure 9). The regulator normally comes from the factory with the tap closest to the regulator outlet left unplugged for the downstream control line as shown in Figure 1, and with opposite tap plugged. Attach the control line from the unplugged tap 2 to 3 feet (0,61 to 0,91 meter) downstream of the regulator in a straight run of pipe. If impossible to comply with 7 Type 99 this recommendation due to the pipe arrangement, it may be better to make the control line tap nearer the regulator outlet rather than downstream of a block valve. Do not make the tap near any elbow, swage, or nipple which might cause turbulence. In many instances, it will be necessary to enlarge the downstream piping to keep flow velocities within good engineering practices. Expand the piping as close to the regulator outlet as possible. ! Warning Adjustment of the pilot control spring to produce an outlet pressure higher than the upper limit of the outlet pressure range for that particular spring can cause personal injury or equipment damage due to bursting of pressure-containing parts or the dangerous accumulation of gases if the maximum actuator emergency casing pressure in the Specifications section is exceeded. If the desired outlet pressure is not within the range of the pilot control spring, install a spring of the proper range according to the Maintenance section. Each regulator is factory-set for the pressure setting specified on the order. If no setting was specified, outlet pressure was factory-set at the midrange of the pilot control spring. In all cases, check the control spring setting to make sure it is correct for the application. Startup Key numbers are referenced in Figure 9 for a low or high pressure pilot and in Figure 12 for an extra high pressure pilot. With proper installation completed and downstream equipment properly adjusted, perform the following procedure while using pressure gauges to monitor pressure. 1. Very slowly open the upstream block valve. 2. Slowly open the hand valve (if used) in the control line. The unit will control downstream pressure at the pilot control spring setting. See the adjustment paragraph following these numbered steps if changes in the setting are necessary during the startup procedure. 3. Slowly open the downstream block valve. 4. Slowly close the bypass valve, if any. 5. Check all connections for leaks. 8 The only adjustment on the regulator is the reduced pressure setting affected by the pilot control spring (key 43, Figure 9 or 11). Remove the closing cap assembly (key 46, Figure 9) and turn the adjusting screw (key 45, Figure 9 or 11). Turning the adjusting screw clockwise into the spring case increases the controlled or reduced pressure setting. Turning the screw counterclockwise decreases the reduced pressure setting. Always replace the closing cap, if used, after making the adjustment. Shutdown Isolate the regulator from the system. Vent the downstream pressure first; then vent inlet pressure to release any remaining pressure in the regulator. Maintenance Regulator parts are subject to normal wear and must be inspected and replaced as necessary. The frequency of inspection and replacement of parts depends on the severity of service conditions or the requirements of local, state, and federal rules and regulations. ! Warning Avoid personal injury or damage to property from sudden release of pressure or uncontrolled gas or other process fluid. Before starting to disassemble, isolate the pilot or regulator from all pressure and cautiously release trapped pressure from the pilot or regulator. Use gauges to monitor inlet, loading, and outlet pressures while releasing these pressures. On reassembly of the regulator, it is recommended that a pipe thread sealant be applied to pressure connections and fittings as indicated in Figures 7 and 9 and lubricant be applied to sliding and bearing surfaces as indicated in Figures 7 and 9, and that an anti-seize compound be applied to adjusting screw threads and other areas indicated Figures 9 and 11. Actuator and Standard P590 Series Filter This procedure is to be performed if changing the main spring and spring seat for those of a different range, or if inspecting, cleaning, or replacing any other parts. Unless otherwise indicated, part key numbers for a Type 99 regulator with low or high pressure pilot and Type 99 disk or O-ring seat are referenced in Figure 9, part key numbers unique to the 1000 psig (69,0 bar) maximum inlet regulator are referenced in Figure 11, and part key numbers for a Type 61HP (extra high pressure) pilot is referenced in Figure 12. 1. Access to all internal actuator parts can be gained without removing the main valve body from the line. Disconnect the loading tubing from the upper casing. caution If the regulator has an indicator assembly, perform the following step carefully to avoid bending the travel indicator stem (key 103, Figure 6). Note The O-rings and gaskets (keys 111 and 108, Figure 6) in the indicator assembly are static seals and need not be disturbed, unless they are leaking. 2. Remove the four cap screws (key 58, Figure 9) and lift off the spring case (key 1, Figure 9). Remove the travel indicator stem, if any, by unscrewing the indicator stem adapter (key 101, Figure 6). 3. Remove the main spring seat (key 2, Figure 9) and main spring (key 3, Figure 9). 4. Remove the 12 cap screws (key 12, Figure 9) and hex nuts (key 13, Figure 9), and lift off the upper casing. 5. Remove the diaphragm (key 11, Figure 9) and diaphragm plate (key 10, Figure 9) by tipping it so that the lever (key 9, Figure 9) slips out of the pusher post (key 8, Figure 9). 6. Separate the diaphragm and diaphragm plate by unscrewing the diaphragm rod (key 4, Figure 9) from the pusher post. Inspect the diaphragm (key 11, Figure 9) and pusher post gasket (key 7, Figure 9). Either part must be replaced if it is damaged or no longer pliable. 7. If the unit has a stem seal O-ring (key 64, Figure 7 or 11), this O-ring may be replaced by removing the retaining ring or cotter pin (key 28, Figure 9) and disconnecting the lever from the valve carrier (key 26, Figure 9 or 11), removing the union nut (key 14, Figure 9 or 11), disconnecting the pilot supply tubing (key 24, Figure 9 or 11), and sliding the lower casing (key 29, Figure 9) away from the valve body (key 17, Figure 9), with a disk or O-ring seat, the valve carrier must be pulled out of the lower casing to gain access to the O-ring. Another O-ring, held captive by the pressed-in bushing, is part of the lower casing assembly on a stem seal unit and normally does not require replacement. 8. If clogging is suspected in the upstream regulator passages, disconnect the pilot supply tubing (key 24, Figure 9 or 11), remove the filter assembly (key 75, Figure 9), and blow through it to check for filter clogging. If necessary, to clean or replace filter parts in a standard P590 Series filter assembly, remove the following as shown in Figure 10: filter body (key 1), machine screw (key 4), spring washer (key 6), gasket (key 7), washer (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. 9. If the lower casing was removed, install a new body gasket (key 16, Figure 9) and, with a disk or O-ring seat, slide the valve carrier into the casing. Then slide the entire assembly into the valve body (disk or O-ring seat) and secure with the union nut. Secure the lever to the valve carrier with the retaining ring or cotter pin. 10. Loosely reassemble the diaphragm and diaphragm plate so that the bolt holes and loading connection hole in the diaphragm can be properly aligned with the corresponding holes in the casing when the lever is fitted properly into the pusher post. When this orientation is made, install the collar (key 6, Figure 9) and tighten the diaphragm rod into the pusher post (key 8, Figure 9). 11. In order for the regulator to operate properly, the assembled collar, diaphragm, diaphragm plate, pusher post, and diaphragm rod must be mounted on the ball of the lever so that the pusher post (key 8, Figure 9) orientation is as shown in Figure 9. 12. Install the upper casing and secure it to the lower casing with the twelve cap screws torque 580 to 920 inch-pounds (65,5 to 104 N•m) and hex nuts. Put lower casing back on body and install union nut. 9 Type 99 caution To avoid part damage due to over compressing the main spring seat, always use main spring seat 1E242724092 with main spring 0W019127022. 13. Install the main spring and main spring seat, turning the main spring seat until its bottom shoulder is even with the bottom thread of the diaphragm rod. 14. Install a new spring case gasket (key 57, Figure 9), the spring case, and the four cap screws with 340 to 420 inch-pounds (38,4 to 47,5 N•m) of torque, making sure the indicator stem, O-ring, and gaskets (keys 103, 111, and 108, Figure 6) are installed If used. 15. Connect the loading tubing, then refer to the Startup section for putting the regulator into operation. Type 61L, 61LD, 61LE (Low), or 61H (High Pressure) Pilots This procedure is to be performed if changing the control spring for one of a different range, or if inspecting, cleaning or replacing any other pilot parts. Key numbers are referenced in Figure 9. 1. Remove the closing cap (key 46) if used and unscrew the adjusting screw (key 45) to relieve control spring compression. 2. Disconnect the loading tubing (key 53) and pilot supply tubing (key 24). 3. Unscrew the eight cap screws (key 47) and remove the pilot assembly from the lower casing (key 29). 4. Use the projecting prong in the relay valve body (key 39) as the restraining member and remove the diaphragm nuts (keys 13 and 51). Separate the parts and inspect the diaphragms (keys 30 and 40) and O-ring seal (key 33). Replace if worn or damaged. Note Before putting the relay spring case over the diaphragm, make certain the yoke is square with respect to the prong in the relay body. (The yoke can bind on the prong if it is not square.) 7. Use care in reassembly to be sure the edges of the diaphragms slip properly into the recess on the lower casing and relay valve body. With the pilot in place, check to see if it can be rocked. If it does not rock, it is in place and the diaphragm is free of wrinkles. With both diaphragms firmly in place, install the cap screws using torque 150 inch-pounds (16,9 N•m) of torque. Tighten using a crisscross pattern to avoid placing a strain on the unit. Set the pilot control spring (key 43) according to the adjustment information in the Startup section. 8. Reinstall the closing cap (key 46, if used). If you have a plastic closing cap, be sure that you have a vent (key 60) in place of the pipe plug installed in the low pressure pilot spring case. Type 61HP (Extra High Pressure) Pilot This procedure is to be performed if changing the control spring for one of a different range, or if inspecting, cleaning, or replacing any other pilot parts. Key numbers are referenced in Figure 12. 1. Unscrew the adjusting screw (key 45) to relieve control spring compression. 2. Disconnect the loading tubing and pilot supply tubing. 3. Remove the six cap screws (key 123) which fasten the spring case (key 44) spring seat (key 68) and control spring (key 43) to the pilot body. 4. Unscrew the diaphragm nut (key 128) and remove a diaphragm plate (key 41), diaphragm (key 40), and another diaphragm plate. 5. Unscrew the eight cap screws and remove the pilot body (key 39) and gasket. Remove six cap screws, seal washers and the flange adapter. 5. Unscrew the bleed orifice (key 52) from the yoke (key 37). Also removed with the bleed orifice are the relay disk assembly (key 48) and bleed valve (key 50). These parts can be unscrewed for inspection and replacement, if necessary. 6. Unscrew the relief valve body (key 119) and remove a diaphragm plate, diaphragm, and another diaphragm plate. Inspect the diaphragm inserts (key 150) and both diaphragms. Replace if worn or damaged. 6. When reassembling the pilot, the relay disk holder assembly and both diaphragms should be tightened on the yoke after it is placed in the body. 7. The relief valve assembly can be further disassembled for inspection by unscrewing the relief valve cap (key 118). 10 Type 99 8. Four machine screws (key 130) hold both yoke caps (keys 37 and 116) to the yoke legs (key 31). Separate these parts to expose the pilot valve. 9. Unscrew the inlet orifice (key 38) to inspect its seat, the inlet valve plug (key 117), and valve spring (key 124). Note Make certain that the yoke assembly is square with respect to the cross member of the body casting so that it will not bind on the body. 10. When reassembling, screw in the inlet orifice all the way and secure the yoke caps to the yoke legs. Replace two diaphragm plates, the diaphragms, and inserts, two more diaphragm plates, the hex nut, and the relief valve assembly. 11. Assemble the control spring and spring seat into the body and spring case, being careful that the diaphragms are free of wrinkles and properly in place, and evenly installing the cap screws in a crisscross pattern to avoid placing a strain on the unit. Install the body flange adapter with seal washers and cap screws. Install a new gasket and secure the pilot to the lower casing with eight cap screws. Set the control spring according to the adjustment information in the Startup section. Converting the Pilot Note A complete pilot assembly rather than individual parts may be ordered for the following conversion procedure. When a low pressure pilot is ordered for field conversion of a high pressure pilot or vice versa, the replacement pilot assembly comes complete with a pilot cover (key 132, Figure 9). Remove this cover before installing replacement pilot on the existing regulator. The cover can then be installed on the removed pilot to form a complete Type 61 (low or high pressure) pilot for use elsewhere. When changing one pilot construction (low pressure, high pressure, or extra high pressure) for another, all parts attached to the lower casing (key 29, Figure 9) may need to be replaced with those appropriate for the desired construction. At the very least, when changing from a low to high pressure pilot or vice versa, everything below the lower pilot diaphragm (key 40, Figure 9) except the cap screws and the hex nut (keys 47 and 13, Figure 9) will need to be replaced. Actuator and main valve parts may remain unchanged unless a change in service conditions requires a change in seat construction, main spring, or main spring seat. See the Parts List sections for obtaining the appropriate conversion parts. Main Valve Trim with Disk or O-ring Seat This procedure is to be performed if inspecting, cleaning, or replacing trim parts. Part key numbers for a Type 99 regulator with disk or O-ring seat are referenced in Figure 9, and part key numbers for the disk seat unique to the 1000 psig (69,0 bar) maximum inlet regulator are referenced in Figure 11. Note All trim maintenance may be performed with the valve body (key 17, Figure 9 or 11) in the line and with the elbow (key 23, Figure 9 or 11), pilot supply tubing (key 24, Figure 9 or 11), and pilot supply regulator (key 155, Figure 11, if used) attached to the valve body unless the valve body itself will be replaced. 1. Disconnect the pilot supply tubing and downstream control line. 2. Loosen the union nut (key 14, Figure 9) and remove the lower casing (key 29, Figure 9) with the cap screw (key 22, Figure 9) or disk and holder assembly (key 18, Figure 11) on disassembly or reassembly. A thin-walled socket may be used to remove the orifice. 3. Access to the disk or O-ring (key 19, Figure 9) can be gained by removing the cap screw and retainer (key 21, Figure 9), while on the 1000 psig (69,0 bar) maximum inlet regulator the entire disk and holder assembly is removed as a unit. If necessary, the holder (key 18, Figure 9 or 11) or adapter (key 157, Figure 11) can be removed by taking out the cotter pin (key 25, Figure 9 or 11). 4. Install a new body gasket (key 16, Figure 9) and a new disk, O-ring, or disk and holder assembly as necessary. Then slide the entire assembly into the valve body and secure with the union nut. 5. Connect the pilot supply tubing and downstream control line, then refer to the Startup section for putting the regulator into operation. 11 Type 99 20A7146-B Figure 6. Travel Indicator Assembly Parts Ordering Travel Indicator Assembly (Figure 6) A serial number is assigned to each regulator, and it is stamped on both the actuator and pilot nameplates. If the pilot is replaced, the new pilot will have its own serial number different from the main valve serial number. Always indicate one or both serial numbers when communicating with your local Sales Office. When ordering a replacement part, be sure to include the complete eleven-character part number. Key Description Parts List Key Description Part Number Repair kits include parts for regulator with composition trim only, key numbers 7, 11, 16, 19, 20, and 57. Also included are parts for pilot, key numbers 30, 33, 38, 40, 48, 49, 50, 52, 71, 117, 126, 129, 150, 153, and P590 Series filter, key numbers 2 and 7. With low pressure pilot 7/8-inch (22,2 mm) orifice R99LX000012 1-1/8-inch (28,6 mm) orifice R99LX000022 With high pressure pilot 7/8-inch (22,2 mm) orifice R99HX000012 1-1/8-inch (28,6 mm) orifice R99HX000022 With extra high pressure pilot 7/8-inch (22,2 mm) orifice R99HPX00012 1-1/8-inch (28,6 mm) orifice R99HPX00022 *Recommended Spare Parts 12 Complete Assembly (includes individual parts listed below) 1 Spring Case, Cast iron 101 Indicator Stem Adaptor, Aluminum 102 Indicator Cap, Aluminum 103 Indicator Stem, Aluminum 104 Disk Nut, Plastic 105 Machine Screw Nut, Plated steel (2 required) 106 Retainer, Aluminum 107 Indicator Window, Glass 108* Gasket, Neoprene (CR) (2 required) 109* Indicator Cover, Plastic (2 required) 110 Machine Screw, Plated steel (8 required) 111* O-ring, Nitrile (NBR) (2 required) 112 Indicator Scale, Stainless steel Part Number 20A7146X0C2 2L296219012 1R395909012 1L290809012 1L296509022 1F730506992 1A342024152 1L291009012 1L296706992 1L291103012 1L296405032 1A899028982 1E591406992 1J511638982 Actuator and Main Body Assembly (Figures 6, 7, 8, 9, 10, and 11) Key Description 1 Standard Spring Case without travel indicator, Cast iron 2 Main Spring Seat, Plated steel 250 psid (17,2 bar d) maximum allowable pressure drop, Cast iron 1000 psid (69,0 bar d) maximum allowable pressure drop Part Number 1B883119012 1B883219042 1E242724092 Type 99 26 sealant Lubricant 64 Lubricant sealant A6802 20A7148-B Figure 7. O-ring Stem Seal Key Description 3 Main Spring, Plated steel 25 psid (1,72 bar d) maximum allowable pressure drop 50 psid (3,45 bar d) maximum allowable pressure drop 250 psid (17,2 bar d) maximum allowable pressure drop 1000 psid (69,0 bar d) maximum allowable pressure drop–requires main spring seat 1E242724092 4 Diaphragm Rod, 416 Stainless steel 5 Diaphragm Rod Guide Assembly Brass with bronze insert 316 Stainless steel 6 Collar Brass 316 Stainless steel 7* Pusher Post Gasket Composition - for standard construction Fluorocarbon (FKM) - for oxygen service 8 Pusher Post Assembly Brass with bronze insert 316 Stainless steel 316 Stainless steel - for oxygen service 9 Lever, Steel 10 Diaphragm Plate, Plated steel 11* Diaphragm Nitrile (NBR) Fluorocarbon (FKM) 12 Cap Screw, Plated steel (12 required) 13 Hex Nut, Plated steel (13 required) 14 Union Nut, Iron 15 Body Snap Ring, Plated steel 16* Body Gasket Composition Graphite - for oxygen service 17 Valve Body 2-inch NPT Cast iron Steel Brass Brass - for oxygen service 2-inch (DN 50) CL125 FF flanged, Cast iron 2-inch (DN 50) CL250 RF flanged, Cast iron Figure 8. O-ring Sealed Handwheel Part Number 1C277127022 1N801927022 1B883327022 0W019127022 1B883435232 1D9712000A2 1B883535072 1B883614012 1B883635072 1B883704022 1N430306382 1D9714000A2 1B883835072 14B1320X012 2F823423072 1B989225072 1B884102052 1N378902312 1B884224052 1A340324122 0Z0176X0032 0Y095828982 1A348004032 1A3480X0022 1C254619012 2N153522012 1C254612012 1C2546X0012 2D986519012 2D986619012 Key Description 17 Valve Body (continued) 2-inch (DN 50) CL150 RF flanged Steel 2-inch (DN 50) CL300 RF flanged Steel 18 Holder for Type 99 regulator Disk seat Brass 316 Stainless steel O-ring Seat 7/8-inch (22,2 mm) orifice Brass 316 Stainless steel 1-1/8-inch (28,6 mm) orifice Brass 316 Stainless steel 18* Disk and Holder Assembly for 1000 psig (69,0 bar) maximum inlet regulator, Nylon (PA)/ 316 Stainless steel 19 Disk for Type 99 Regulator 250 psid (17,2 bar d) maximum allowable pressure drop Neoprene (CR) Nitrile (NBR) Fluorocarbon (FKM) 400 psid (27,6 bar d) maximum allowable pressure drop Nylon (PA) Polytetrafluoroethylene (PTFE) 19* O-ring 7/8-inch (22,2 mm) orifice Nitrile (NBR) Fluorocarbon (FKM) 1-1/8-inch (28,6 mm) orifice Nitrile (NBR) Fluorocarbon (FKM) 20* Orifice Disk seat for all regulators 3/8-inch (9,52 mm) orifice, 416 Stainless steel 1/2-inch (12,7 mm) orifice, 416 Stainless steel 5/8-inch (15,9 mm) orifice, 416 Stainless steel 7/8-inch x 3/8-inch (22,2 x 9,52 mm) orifice Brass 316 Stainless steel Part Number 2E275622012 2E275722012 1B884314012 1B884335072 1E603214012 1E603235072 1E342414012 1E342435072 1C1860000B2 1C997403032 1C158703332 1C9974X0012 1E480603152 1C997406242 1D237506992 1D237506382 1H8498X0012 1H8498X0032 19A7390X012 14A8410X012 19A7391X012 1N878114012 1N8781X0012 *Recommended Spare Parts 13 Type 99 AS – Apply ANti-seize compound pts – Apply pipe thread sealant LUB – Apply Lubricant AS o-ring set detail AS AS pts pts AS control line tap (other tap 180° opposite) lub pts pts pts pts 1/4-inch (6,35 mm) vent shown 90° counterclockwise from normal DJ6642 Complete Regulator showing Type 61L pilot and disk seat DJ6642_B Pilot Relay Assembly Figure 9. Type 99 Regulator with Type 61L (Low) or 61H (High Pressure) Pilot 14 Type 99 30A6800 High Pressure Pilot Parts C0289-1C Pilot Relay and cover Assembly Figure 9. Type 99 Regulator with Type 61L (Low) or 61H (High Pressure) Pilot (continued) 15 Type 99 Actuator and Main Body Assembly (Figures 6, 7, 8, 9, 10, and 11) (continued) Key Description Part Number 20* Orifice (continued) Disk seat for all regulators 7/8-inch x 1/2-inch (22,2 x 12,7 mm) orifice Brass 1C942314012 316 Stainless steel 1C942335072 7/8-inch x 5/8-inch (22,2 x 15,9 mm) orifice Brass 1C942414012 316 Stainless steel 1C9424X0012 3/4-inch (19,1 mm) orifice Brass 1C780414012 316 Stainless steel 1C780435072 7/8-inch (22,2 mm) orifice Brass 1C394714012 316 Stainless steel 1C394735072 1-inch (25,4 mm) orifice, Brass 13A5017X012 1-1/8-inch (28,6 mm) orifice Brass 1B884414012 316 Stainless steel 1B884435072 1/2-inch (12,7 mm) disk seat for 1000 psig (69,0 bar) maximum inlet regulator, 416 Stainless steel 14A8410X012 O-ring seat for all regulators 7/8-inch (22,2 mm) orifice Brass 1E603014012 316 Stainless steel 1E603035072 1-1/8-inch (28,6 mm) orifice Brass 1E342514012 316 Stainless steel 1E342535072 21 Retainer Disk seat 3/4-inch (19,1 mm) All except 3/4-inch (19,1 mm) or 1-1/8-inch (28,6 mm) orifice or 1000 psig (69,0 bar) maximum inlet regulator Brass 1C394814012 303 Stainless steel 1C394835032 3/4-inch (19,1 mm) orifice Brass 1C780314012 316 Stainless steel 1C7803X0012 1-1/8-inch (28,6 mm) orifice Brass 1B884514012 316 Stainless steel 1B884535072 O-ring seat for all regulators 7/8-inch (22,2 mm) orifice Brass 1E603114012 316 Stainless steel 1E603135072 1-1/8-inch (28,6 mm) orifice Brass 1E342614012 316 Stainless steel 1E342635072 22 Cap Screw, Plated steel 1A391724052 25 Cotter Pin, 316 Stainless steel 1B108438992 26 Valve Carrier Brass 1E597114072 416 Stainless steel 1E597135132 27 Lever Pin 316 Stainless steel 1B884935162 303 Stainless steel 1C911635032 28 Retaining Ring for brass trim, Plated steel (2 required) 1B8850X0012 Cotter Pin for Stainless steel trim, 316 Stainless steel (2 required) 1A866537022 *Recommended Spare Parts 1. Required with lower casing 2N379419012 2. Pilot supply regulator parts are found in Types 1301F and 1301G Instruction manual. 16 Pipe thread sealant AJ5004-A A2135/IL Figure 10. Standard P590 Series Filter Assembly Key Description Part Number 29 Lower Casing, Cast iron Standard 4B983719012 For use with optional protector, spring washer, and machine screw (keys 61, 62, and 63) 2N379419012 Lower Casing Assembly for use with O-ring stem seal, Cast iron with SST guide bushing Complete with Nitrile (NBR) O-ring 2R7230000A2 Complete with Fluorocarbon (FKM) O-ring 2R7230X0022 32 Nameplate, Aluminum ---------- 56 Upper Casing, Cast iron 3B887619012 57* Spring Case Gasket Composition 1B8877X0012 Graphite - for oxygen service 1B8877X0022 58 Cap Screw, Plated steel (4 required) 1A675124052 61(1) Lower casing protector (not shown), Brass 1N379514012 62(1) Optional Spring Washer (not shown) Plated brass (2 required) 1N339518992 63(1) Optional Machine Screw (not shown) Plated brass (2 required) 1H340518992 64* O-ring (for use only with O-ring stem seal) Nitrile (NBR) 1E220206992 Fluorocarbon (FKM) 1R620106382 73 Pipe plug, Plated steel (not shown) 1A767524662 75 Standard P590 Series Filter Assembly (parts listed under separate heading) Type P594-1, Brass FSP594-1 Type P593-1, Aluminum FSP593-1 133 Pipe Elbow, Plated steel 1B860828992 134 Pipe Nipple, Plated steel 1B218826232 152 Drive Screw, 18-8 Stainless steel (4 required for low pressure pilot and 6 required for high pressure pilot) 1A368228982 155 Type 1301F Pilot Supply Regulator(2) (for use only with extra high pressure pilot) See footnote 2 156 Type H110 Pop Relief Valve, (for use only with extra high pressure pilot) brass with Nitrile (NBR) disk and 316 Stainless steel spring Consult Factory 159 Tag (for use only with O-ring stem seal and extra high pressure pilot) alloy 1100 (not shown) 16A0957X012 Type 99 A6803 Figure 11. 1000 Psig (69,0 bar) Maximum Inlet Regulator Partial Detail Standard P590 Series Filter Assembly (Figure 10) Pilot and Tubing Parts(3) Low or High Pressure Pilot (Figure 9) Key Description Key Description 1 Filter Body Type P594-1, Brass Type P593-1, Aluminum 2* Filter Element, Cellulose 3 Filter Head Type P594-1, Brass Type P593-1, Aluminum 4 Machine Screw Type P594-1, Brass Type P593-1, Aluminum 5 Washer (2 required) Type P594-1, Brass Type P593-1, Aluminum 6 Spring Washer, Plated carbon steel 7* Gasket, Composition Part Number 1E312414012 1E3124X0022 1E312606992 1E312514012 1E3125X0022 1J500218992 1J500209012 1J500018992 1J500010062 1H885128982 1F826804022 13 Hex Nut, Plated steel (13 required) 23 Elbow (2 required) Brass 316 Stainless steel 24 Pilot Supply Tubing, disk or O-ring main valve seat Copper Copper - for oxygen service 316 Stainless steel 30* Upper Relay Diaphragm Nitrile (NBR) Fluorocarbon (FKM) 31 Upper Relay Diaphragm Plate, Plated steel For use with all low pressure pilots except LE For use with all high pressure pilots and LE low pressure pilot Part Number 1A340324122 15A6002X292 15A6002X612 1D8793000A2 0500201701W 0500213809W 1B885202052 1N162802332 1B989225072 1D558425072 *Recommended Spare Parts 3. An entire pilot assembly may be ordered from your local Sales Office. by specifying a Type 61L, a 61H, or a 61HP pilot for field conversion. 17 Type 99 Pilot and Tubing Parts(3) Low or High Pressure Pilot (Figure 9) (continued) Key Description Part Number 33* O-ring Seal Nitrile (NBR) 1B885506992 Fluorocarbon (FKM) 1B8855X0012 34 Connector Brass 1D692214012 316 Stainless steel 15A6002X602 37 Yoke Zinc 1D662544012 38* Relay Orifice, Stainless steel For use with 25 psi (1,72 bar) maximum allowable pressure drop actuator main spring 1D373735032 For use with all other main springs 1C520135032 For use with oxygen service 1N162314042 39 Relay Valve Body, Cast iron 2J581919012 40* Lower Relay Diaphragm Low pressure pilot Nitrile (NBR) 1B886002052 Fluorocarbon (FKM) 1N536102332 High pressure pilot Nitrile (NBR) 1B894202192 Fluorocarbon (FKM) 1N162702302 41 Lower Relay Diaphragm Plate, Plated steel Low pressure pilot 1B989425072 High pressure pilot 1D558325072 42 Spring Seat, Plated steel Low pressure pilot 1B886225072 High pressure pilot 1D558525072 43 Control Spring, Plated steel For use only with LD low pressure pilot 0 to 4-inches w.c. (0 to 10 mbar), Orange 1B558527052 3 to 12-inches w.c. (7 to 30 mbar), Silver 1C680627222 For use with all low pressure pilots 0.25 to 2 psig (0,02 to 0,14 bar), Red 1B886327022 1 to 5 psig (0,07 to 0,34 bar), Yellow 1J857827022 2 to 10 psig (0,14 to 0,69 bar), Blue 1B886427022 5 to 15 psig (0,34 to 1,03 bar), Brown 1J857927142 10 to 20 psig (0,69 to 1,38 bar), Green 1B886527022 For use with high pressure pilot, Green stripe 0Y066427022 44 Spring Case, Cast iron Low pressure pilot 1B983919012 High pressure pilot, Standard 1B984119012 For use with closing cap (not shown) 1H232619012 45 Adjusting Screw Low pressure pilot, Standard, Zinc 1B537944012 Handwheel-style, Plated steel 1J496428982 O-ring seated handwheel assembly 1R759414012 High pressure pilot, Standard, Plated steel 1A279128982 For use with closing cap 1H236514012 1J881524102 46 Closing Cap For use with standard low pressure pilot, Plastic T11069X0012 For use with handwheel-style low pressure pilot, Brass (not shown) 1A926114012 For use with O-ring sealed handwheel 1R759314012 For use with high pressure pilot with spring case 1H232619012, Brass (not shown) 1H236514012 47 Cap Screw, Plated steel (8 required) 1B989624052 48* Relay Disk Assembly Brass/Nitrile (NBR) 1B8868000A2 303 Stainless steel/Nitrile (NBR) 1B8868000B2 *Recommended Spare Parts 3. An entire pilot assembly may be ordered from your local Sales Office. by specifying a Type 61L, a 61H, or a 61HP pilot for field conversion. 18 Key Description Part Number 48* Relay Disk Assembly (continued) Brass/Fluorocarbon (FKM) 303 Stainless steel/Fluorocarbon (FKM) 49* Bleed Valve Spring, Stainless steel For use with low pressure pilot with relay orifice 1D373735032 or bleed valve 1H951635132 For use with all low and high pressure pilots Inlet pressure up to 250 psig (17,2 bar) Inlet pressure over 250 psig (17,2 bar) 50* Bleed Valve, Stainless steel For use with LD low pressure pilot with bleed valve spring 1E643637022 For use with all low and high pressure pilots 51 Diaphragm Nut Brass 316 Stainless steel 52* Bleed Orifice, 316 Stainless steel 53 Loading Tubing Copper 316 Stainless steel 54 Connector Brass 316 Stainless steel 55 Pipe Nipple Plated steel (1 required with copper tubing and 2 required with aluminum tubing) 316 Stainless steel 59 Pipe plug, Steel (not shown) 60 Type Y602-1 Vent Assembly 68 Spring Seat Handwheel-style low pressure pilot, Steel, (not shown) High pressure pilot, Zinc 71* Closing Cap Gasket (for use only with low pressure pilot), Neoprene (CR) 72 Type Y602-1 Vent Assembly (for use only with standard high pressure pilot spring case), Zinc/18-8 Stainless steel 78 Handwheel (for use only with handwheel-style low pressure pilot), Zinc 79 Machine Screw (for use only with handwheel-style low pressure pilot), Plated steel 80 Lockwasher (for use only with handwheel-style low pressure pilot), Steel 81 O-ring (for use only with O-ring sealed handwheel assembly) 82 Hex nut For use only with O-ring sealed handwheel assembly For use with high pressure pilot, Plated steel 114* Gasket (for use only with high pressure pilot with spring case 1H232619012), Steel/ Composition (not shown) 115 Adaptor (for use only with high pressure pilot with spring case 1H232619012), Steel (not shown) 132 Pilot Cover (used only with complete replacement pilot assembly for field conversion), Cast iron 152 Drive Screw, 18-8 Stainless steel (4 required for low pressure pilot and 6 required for high pressure pilot) 154 Drive Screw (for use only with low pressure pilot), 18-8 Stainless steel (2 required) 1B8868X0012 1B8868X0022 1E643637022 1C911537022 1N859137022 1H951635132 1D986735132 1B989514012 1B989535072 1B887335032 1J4928000A2 0500213809W 1H628114012 15A6002X992 1C488226232 1C488238982 1A369224492 27A5516X012 1J618124092 16A9812X012 1P753306992 17A6570X012 1J496144012 16A5763X012 1A352332992 1D541506992 1A351124122 1A352224122 1B487099202 1J881624092 2C518619012 1A368228982 1A368228982 Type 99 A.S. – Apply ANti-seize compound A6804 Figure 12. Type 61HP (Extra High Pilot) Pilot Type 61HP (Extra High Pressure) Pilot (Figure 12) Key Description Part Number 23 Elbow For use with all standard regulators Brass 15A6002X292 316 Stainless steel 15A6002X202 For use with 1000 psig (69,0 bar) maximum inlet regulator, Steel 1J139628982 24 Pilot Supply Tubing For use with all standard regulators Copper 1D7703000A2 316 Stainless steel 0500213809W For use with 1000 psig (69,0 bar) maximum inlet regulator, Steel 0500213809W 30* Diaphragm Neoprene (CR) 13A9840X012 Fluorocarbon (FKM)/Dacron® 13A9840X022 31 Yoke Leg, 416 Stainless steel (2 required) 13A9838X012 Key Description 34 Connector (3 required) For use with all standard regulators Brass 316 Stainless steel For use with 1000 psig (69,0 bar) maximum inlet regulator, Steel 35 Cap Screw, Plated steel (6 required) 36 Elbow, Plated steel 37 Yoke Cap, 416 Stainless steel 38 Inlet Orifice 303 Stainless steel 39 Pilot Body, Cast iron 40* Diaphragm Neoprene (CR) Fluorocarbon (FKM)/Dacron(4) 41 Diaphragm Plate, 416 Stainless steel (4 required) 43 Control Spring, Plated steel (blue) 44 Spring Case, Cast iron Standard Part Number 1D692214012 15A6002X602 15A6002XW22 1A930424052 1B860828992 13A9837X012 1D318135032 33A9845X012 13A9841X022 13A9841X012 13A9839X012 1D387227022 2P969419012 *Recommended Spare Parts 4. Dacron® is a mark owned by E.I. du Pont de Nemours and Co. 19 Type 99 Type 61HP (Extra High Pressure) Pilot (Figure 12) (continued) Key Description 45 Adjusting Screw, Plated carbon steel Standard 47 Cap Screw, Plated steel (8 required) 49 Relief Valve Spring, 316 Stainless steel 50 Relief Valve Plug, 316 Stainless steel 52 Bleed Orifice Brass 53 Loading Tubing For use with all standard regulators Copper 317 Stainless steel For use with 1000 psig (69,0 bar) maximum inlet regulator, Steel 55 Pipe Nipple, Plated steel (2 required) 60 Pipe plug, Steel (not shown) 68 Spring Seat, Plated steel 72 Type Y602-12 Vent Assembly (for use only with tapped spring case 20A4735X012), Zinc with 18-8 Stainless steel screen 82 Locknut, Plated steel 116 Yoke Cap, 416 Stainless steel 117* Inlet Valve Plug 304 Stainless steel/Nitrile (NBR) 304 Stainless steel/Fluorocarbon (FKM) Part Number 1C216032992 1B787724052 1C374037022 1K377535162 1B329014012 1D7702000A2 0500213809W 1K5466X0042 1C488226232 1A649528982 10A3963X012 27A5516X012 1A352224122 13A9836X012 1D5604000B2 1N3798000C2 Key Description Part Number 118 Relief Valve Cap Brass 303 Stainless steel 119 Relief Valve Body Brass 316 Stainless steel 120 Spring Seat Brass 316 Stainless steel 121 Spring Seat Washer Brass 316 Stainless steel 122 Pipe Bushing, Carbon-plated steel 123 Cap Screw, Plated steel (6 required) 124 Valve Spring, 316 Stainless steel 125 Flange Adaptor, Steel 126* Gasket, Composition 128 Diaphragm Nut, Plated steel 129* Valve Spring Seat, Aluminum 130 Machine Screw, 303 Stainless steel (4 required) 131 Pipe plug, Steel (not shown) 150 Diaphragm Insert (2 required) Nitrile (NBR) Fluorocarbon (FKM) 152 Drive Screw, 18-8 Stainless steel (2 required) 153 Seal Washer, Nitrile (NBR)/Plated steel (6 required) 1D904914012 1D904935072 1D904814012 1D904835072 1K377718992 1K377735072 1B495118992 1K377835072 1C379026232 1P327028982 1B797937022 23A9846X012 0U0365X0032 1A346524122 1L251135072 1A866935032 1A369224492 13A9842X012 13A9842X022 1A368228982 13A9849X012 *Recommended Spare Parts Industrial Regulators Regulator Division Emerson Process Management Natural Gas Technologies Regulator Division Emerson Process Management TESCOM Regulator Division Emerson Process Management USA - Headquarters McKinney, Texas 75070 USA Tel: 1-800-558-5853 Outside U.S. 1-972-548-3574 USA - Headquarters McKinney, Texas 75070 Tel: 1-800-558-5853 Outside U.S. 1-972-548-3574 USA - Headquarters Elk River, Minnesota 55330 USA Tel: 1-763-241-3238 Asia-Pacific Shanghai, China 201206 Tel: +86 21 2892 9000 Asia-Pacific Singapore, Singapore 128461 Tel: +65 6777 8211 Europe Bologna, Italy 40013 Tel: +39 051 4190611 Europe Bologna, Italy 40013 Tel: +39 051 4190611 Gallardon, France 28320 Tel: +33 (0)2 37 33 47 00 Europe Selmsdorf, Germany 23923 Tel: +49 (0) 38823 31 0 For further information visit www.emersonprocess.com/regulators The Emerson logo is a trademark and service mark of Emerson Electric Co. All other marks are the property of their prospective owners. Fisher is a mark owned by Fisher Controls, Inc., a business of Emerson Process Management. The contents of this publication are presented for informational purposes only, and while every effort has been made to ensure their accuracy, they are not to be construed as warranties or guarantees, express or implied, regarding the products or services described herein or their use or applicability. We reserve the right to modify or improve the designs or specifications of such products at any time without notice. Emerson Process Management does not assume responsibility for the selection, use or maintenance of any product. Responsibility for proper selection, use and maintenance of any Emerson Process Management product remains solely with the purchaser. ©Fisher Controls International, Inc., 1979, 2008; All Rights Reserved
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