Emerson Csb400 Series Pressure Reducing Regulators Instruction Manual
2015-03-30
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CSB400 Series Instruction Manual Form 5836 June 2014 CSB400 Series Commercial / Industrial Pressure Reducing Regulators TYPICAL TYPE CSB400 REGULATOR P1424 TYPICAL TYPE CSB403 REGULATOR WITH INTEGRAL TRUE-MONITOR™ REGULATOR P1426 TYPICAL TYPE CSB404 REGULATOR WITH INTEGRAL TYPE VSX4 SLAM-SHUT MODULE P1425 Figure 1. Typical CSB400 Series Pressure Reducing Regulators Table of Contents Introduction Introduction .....................................................................1 Specifications .................................................................2 Principle of Operation .....................................................8 Installation and Overpressure Protection ..................... 11 Commissioning .............................................................15 Adjustment....................................................................15 Shutdown......................................................................17 Maintenance and Inspection.........................................19 Parts Ordering ..............................................................20 Parts List.......................................................................21 Scope of the Manual www.fisherregulators.com D103123X012 This Instruction Manual provides installation, maintenance and parts ordering information for the CSB400 Series regulators. Instructions and parts lists for other equipment mentioned in this instruction manual are found in separate manuals. CSB400 Series Specifications The Specifications section lists the specifications for the CSB400 Series Regulators. The following information is stamped on the nameplate of CSB400 Series: Type and Class, Maximum Outlet Pressure and Spring Range. Available Configurations See Table 1 Regulator Type: Differential Strength (DS) Accuracy Class: Up to AC5 (depending on Outlet Pressure) Lock-up Class: U p to SG10 (depending on Outlet Pressure) Failure Mode: Fail Open (FO) Body Sizes and End Connection Styles See Table 5 Integral Strength (IS) Pressure Ratings(1) See Table 3 Differential Strength (DS) Pressure Ratings and Flow and Sizing Coefficients(1) See Table 4 Operating Pressure Ranges(1) Regulator: See Table 6 Integral True-Monitor™ Module: See Table 7 Slam-Shut Module: See Table 8 Maximum Outlet Pressures(1) Emergency: 4.0 bar / 58 psig To Avoid Internal Parts Damage: Type CSB450: 1 bar / 14.5 psig above outlet pressure setting All other Types: 0.34 bar / 5 psig above outlet pressure setting Operating: 3.0 bar / 43.5 psig Spring Case Vent Connection 1 NPT Orifice Size Pressure Registration Internal, External or Dual (Internal and External) Operating Temperature (TS)(1)(2) According to PED Standards: All Types: -20 to 66°C / -4 to 150°F Non-PED with standard construction: Types CSB400/CSB404, CSB420/CSB424: -20 to 66°C / -4 to 150°F Types CSB450/CSB454(3): -30 to 66°C / -20 to 150°F Non-PED with low temperature construction: Types CSB400F/CSB404F(3), CSB420F/CB424F(3): -30 to 66°C / -20 to 150°F Approximate Weights With Threaded body Type CSB400: 4.1 kg / 9 pounds Type CSB403: 9.1 kg / 20 pounds Type CSB404: 5.0 kg / 11 pounds With Flanged Body: Add 4.1 kg / 9 pounds to threaded weights listed above PED Conformity Statement and Information The CSB400 Product Series is in conformity with the Pressure Equipment Directive PED 97/23/EC. The exceptions to this previous statement are the Types CSB403 and CSB423. Both of these types are not yet certified to conform with the PED Directive. Pressure regulator does not require any supplementary upstream safety accessory for protection against overpressure compared with its design pressure PS, when upstream reducing station is sized for a max downstream incidental MIPd <= 1.1 PS. PED Related Information See Table 2 17.5 mm / 11/16 inch 1. The pressure/temperature limits in this Instruction Manual or any applicable standard limitation should not be exceeded. 2. Standard token relief set values listed in Table 8 are based on -20 to 60°C / -4 to 140°F. 3. Product has passed Emerson Process Management Regulator Technologies, Inc. (Regulator Technologies) testing for lockup, relief start-to-discharge and reseal down to -40°. 2 CSB400 Series Table 1. Available Configurations TYPE NUMBER C S B OPTIONS 4 PRESSURE CONSTRUCTION AND UPSTREAM MONITOR APPLICATIONS 0 Low Pressure Applications (Outlet Pressure: 17 to 100 mbar / 7 to 40 inches w.c.) 1 Low Pressure, Upstream Monitoring Applications(1)(3) (Outlet Pressure: 17 to 100 mbar / 7 to 40 inches w.c.) 2 Medium Pressure Applications (Outlet Pressure: 100 to 517 mbar / 40 to 208 inches w.c.) 3 Medium Pressure, Upstream Monitoring Applications(1)(3) (Outlet Pressure: 100 to 517 mbar / 40 to 208 inches w.c.) 5 High Pressure Applications(2) (Outlet Pressure: 0.50 to 3.0 bar / 7 to 43.5 psig) OVERPRESSURE PROTECTION 0 Without Overpressure Protection Module 0F Low Temperature Capability, Without Overpressure Protection Module 3 With Integral True-Monitor™ Module(4) 3F Low Temperature Capability, With Integral True-Monitor Module(4) 4 With Type VSX4 Slam-shut Module(5) 4F Low Temperature Capability, With Type VSX4 Slam-shut Module(5) PRESSURE REGISTRATION D Dual Registration (Best solution for quick changing loads) E External Registration I Internal Registration RELIEF N No Relief T Internal Token Relief Example: Type number CSB424DT: Type CSB400 regulator constructed for medium pressure applications, with Type VSX4 slam-shut module, Dual pressure registration and Internal Token relief. 1. Not available with Integral True-Monitor option. 2. Not available with Integral True-Monitor or Token Relief option. 3. Available with External Pressure Registration only. 4. Reference Instruction Manual D103126X012 for information regarding the Type TM600 Integral True-Monitor module. 5. Reference Instruction Manual D103127X012 for information regarding the Type VSX4 Slam-Shut module. ! WARNING Failure to follow these instructions or to properly install and maintain this equipment could result in an explosion and/or fire causing property damage and personal injury or death. Fisher® regulators must be installed, operated, and maintained in accordance with federal, state, and local codes, rules and regulations and Regulator Technologies instructions. If the regulator vents gas or a leak develops in the system, service to the unit may be required. Failure to correct trouble could result in a hazardous condition. Call a gas service person to service the unit. Only a qualified person must install or service the regulator. Description CSB400 Series regulators are typically installed on industrial and commercial applications. See Table 1 for Available Configurations. Low, Medium and High outlet pressure constructions are available via Types CSB400, CSB420 and CSB450, respectively, that provide outlet setpoints ranging from 17 mbar to 3.0 bar / 7 inches w.c. to 43.5 psig. Also available are upstream monitoring configurations such as Types CSB410 and CSB430, which are installed upstream of the primary regulator to provide overpressure protection. Types that include an “F” refer to the cold temperature construction of the base Type number. For example, the Type CSB404F provides a cold temperature construction of the Type CSB404. Refer to the Operating Temperature section found on the following page for additional information regarding temperature capabilities and refer to Table 7 for inlet pressure limitations. For types that include an “F”, refer to the base type number for general information such as Principles of Operation, Maintenance instructions, Warnings and Cautionary notes. 3 FLUID GROUP CAT TEMP CLASS SEAT PS FLUID GROUP DN PN 0062 SERIAL NO. LOC DOM BODY CATMATL LOC SEAT TYPE PSD Pumax TYPE Wds Pumax Pmax PSD Matl Case Pmax France PED mfg: Chartres, France DN PN 0062 TS DOM Std: EN334 PS PATENT PENDING SERIAL NO. REGULATOR SLAM SHUT TEMP CLASS TS PATENT PENDING SLAM SHUT REGULATOR Std: EN334 REGULATOR REGULATOR PED mfg: Chartres, CSB400 Series BODY MATL Wds Matl Case Failure Mode Failure Mode Std: EN14382 SLAM SHUT PED mfg: Chartres, Std: EN14382 SLAM SHUTFrance REGULATOR NAMEPLATES RELAIS RELAY Pu Max Max IN PED mfg: Chartres, France MATL CASERELAIS RELAY TYPE MATL CASE Wdso OP rangeTYPE Wdso OP range SLAM-SHUT NAMEPLATE SERIAL NO. TYPE NO. P max Pu Max Max OUT Max IN P maxCLASS PSD Max OUT Wdsu PSD CLASS UP range DOM PATENT PENDING LOC MAX IN DOM PATENT PENDING MAX EMER LOC OUT Wdsu UP range MAX IN TYPE NO. RELIEF SERIAL NO. ORIFICE SPG RANGE RELIEF MAX OP ORIFICE SPG RANGE OUT MAX EMER OUT MAX OP OUT INTEGRAL TRUE-MONITOR NAMEPLATE Figure 2. CSB400 Series Regulator, Slam-shut and Integral True-Monitor™ Nameplates and Labels Table 2. PED Information TYPE DESCRIPTION PED CATEGORY FLUID GROUP CSB400, CSB400F, CSB410, CSB420, CSB420F, CSB430 and CSB450 Base regulator I CSB404, CSB404F, CSB414, CSB424, CSB424F, CSB434 and CSB454 Regulator with Slam-Shut Module IV Groups 1 and 2 according to PED 97/23/EC, 1st and 2nd family gas according to EN 437 or other gases (compressed air, nitrogen). The gas must be non-corrosive, clean (filtration on inlet side necessary) and dry. European EN Reference Standards EN 334, EN 14382 Table 3. Integral Strength (IS) Pressure Ratings MAXIMUM ALLOWABLE PRESSURE(1) / MAXIMUM EMERGENCY INLET PRESSURE TYPE MAXIMUM OPERATING INLET PRESSURE(1) PS Pumax bar psig bar psig 4.0 58 4.0 58 CSB400, CSB400F, CSB404 and CSB404F CSB420, CSB420F, CSB424 and CSB424F CSB450 and CSB454 CSB410 and CSB414 CSB403, CSB403F, CSB423 and CSB423F CSB403 and CSB423 1. For the Integral Strength (IS) version, the maximum value of PS and Pumax should be similar to the PSD used for the Differential Strength (DS) version. Table 4. Differential Strength (DS) Pressure Ratings and Flow and Sizing Coefficients TYPE SPECIFIC MAXIMUM ALLOWABLE MAXIMUM MAXIMUM PRESSURE / MAXIMUM OPERATING INLET EMERGENCY EMERGENCY OUTLET PRESSURE INLET PRESSURE(1) PRESSURE PSD bar Pumax psig ORIFICE SIZE FLOW COEFFICIENTS WIDE OPEN IEC SIZING COEFFICIENTS PS bar psig bar psig CSB400F and CSB404F 6.0 87 12.0 174 CSB403F and CSB423F 6.0 87 10.0 145 10.0 145 10.0 145 mm Inch Cg Cv C1 XT FD FL 17.5 11/16 428 11 43 1.16 0.84 0.90 CSB403 and CSB423 CSB410 and CSB414 CSB430 and CSB434 CSB400 and CSB404 CSB420F and CSB424F CSB420 and CSB424 CSB450 and CSB454 4.0 58 10.0 145 12.0 174 16.0 232 20.0 290 1. If ordered with a PN 16 flanged connection, PS rating is a maximum of 16.0 bar / 232 psig. PS rating may be lower than 16.0 bar / 232 psig as indicated by this table. 4 CSB400 Series Table 5. Body Sizes, Material, End Connections and Pressure Ratings BODY MATERIAL INLET SIZE, NPS OUTLET SIZE, NPS 1 1-1/4 1-1/2 2 1 1 1-1/4 1-1/2 2 1 1-1/4 1-1/2 2 1 1-1/4 1-1/4 1-1/2 2 DN 50 / 2 DN 50 / 2 DN 40 / 1-1/2(1) 1 1 1-1/4 1-1/2 1 1-1/4 1-1/2 DN 40 / 1-1/2(1) 2-1/4 1 1-1/4 1-1/2 1 1-1/4 1-1/2 Ductile Iron WCC Steel FACE-TO-FACE DIMENSION mm Inch 100 4 114 4.5 114 4.5 127 5 100 4 114 4.5 114 4.5 114 4.5 127 5 254 10 254 10 184 7.24 105 4.1 100 4 114 4.5 114 4.5 100 4 114 4.5 114 4.5 END CONNECTION NPT Rp CL150 FF PN 10/16 PN 16 Slip-On Rp x GAZ NPT Rp BODY PRESSURE RATING bar psig 20.0 290 16.0 232 20.0 290 1. Uses Rp 1-1/2 x 1-1/2 threaded body with PN 16 slip-on flanges. Table 6. CSB400 Series Primary Regulator Outlet Pressure Ranges OPERATING PRESSURE RANGES, Wd TYPE SPRING COLOR SPRING WIRE DIAMETER SPRING FREE LENGTH mbar Inch w.c. mm Inch mm Inch 17 to 24 6.8 to 9.6 GE30191X012 Pink 2.03 0.080 152 6.00 24 to 35 9.6 to 14 GE43955X012 Orange Stripe 2.19 0.086 110 4.35 35 to 60 14 to 24.1 GE30201X012 Dark Green 3.23 0.127 110 4.35 54 to 100 21.7 to 40 GE30202X012 Tan 2.85 0.112 127 5.00 100 to 160 1.45 to 2.3 psig GE35081X012 Purple Stripe 3.86 0.152 124 4.90 138 to 300 2.0 to 4.4 psig GE30192X012 Dark Blue 4.27 0.168 118 4.65 276 to 517 4 to 7.5 psig GE33121X012 Red 4.93 0.194 118 4.65 500 mbar to 1 bar 7.3 to 14.5 psig GE30203X012 Light Blue 5.59 0.220 102 4.00 1 to 3 bar 14.5 to 43.5 psig GE30204X012 Light Green 6.73 0.265 100 3.95 CSB400, CSB400F, CSB403, CSB403F, CSB404, CSB404F, CSB410 and CSB414 CSB420, CSB420F, CSB423, CSB423F, CSB424, CSB424F, CSB430 and CSB434 CSB450 and CSB454 PART NUMBER Table 7. Primary Regulator and Integral True-Monitor™ Outlet Pressure Ranges PRIMARY REGULATOR TYPE CSB403 and CB403F CSB423 and CB423F Factory Setpoint Set Pressure Range Color P/N Pink GE30191X012 mbar psig mbar psig 20 8 in w.c. 17 to 24 6.8 to 9.6 in w.c. 24 to 35 9.6 to 14 in w.c. Orange GE43955X012 Stripe 35 to 60 14 to 24 in w.c. Dark Green 30 50 12 in w.c. 20 in w.c. 0.78 to 1.45 69 1 54 to 100 138 2 100 to 160 1.45 to 2.3 % of REG. Set Tan GE30201X012 GE30202X012 Purple GE35081X012 Stripe 207 3 138 to 300 2.0 to 4.4 345 5 276 to 517 Red GE30192X012 GE33121X012 mbar psig No Token Relief 170% Dark Blue 4 to 7.5 INTEGRAL TRUE-MONITOR Factory Token Relief Set(1) 35 14 in w.c. No Token Relief 150% 45 18 in w.c. No Token Relief 140% 70 1 No Token Relief 130% 90 1.3 No Token Relief 130% 180 2.6 No Token Relief 125% 260 3.8 No Token Relief 125% 430 6.25 Factory Setpoint(1) Spring Range Color P/N 12 to 21 in w.c. Blue GE30189X012 45 to 75 18 to 30 in w.c. Green GE30196X012 1 65 to 99 26 to 40 in w.c. Orange GE30225X012 103 1.5 97 to 200 138 2 97 to 200 1.4 to 2.9 Black GE30190X012 172 2.5 97 to 200 241 3.5 197 to 255 2.6 to 3.7 Purple GE35081X012 276 4 345 5 248 to 414 3.6 to 6 Dark Blue GE30192X012 352 to 517 5.1 to 7.5 Red GE33121X012 mbar psig mbar psig 37 15 in w.c. 30 to 52 52 21 in w.c. 70 414 6 448 6.5 1. Recommended minimum Integral True-Monitor setpoints shown. 5 CSB400 Series Table 8. Regulator and Slam-shut OPSO and UPSO Pressure Ranges REGULATOR SLAM-SHUT MODULE Overpressure Shutoff (OPSO) TYPE CSB404, CSB404F and CSB414 CSB424, CSB424F and CSB434 CSB454(3) Set Pressure Range mbar psig 17 to 24 0.25 to 0.35 24 to 35 0.35 to 0.51 35 to 60 0.51 to 0.87 54 to 100 0.8 to 1.5 100 to 160 1.5 to 2.3 138 to 300 Standard Setpoints Token Relief Set(1)(2) mbar psig mbar psig 20 0.29 34 0.49 Available Token Relief Minimum Range Shown Required as a % of Difference Regulator between Token Setpoint Relief and OPSO Set Min(2) Max mbar psig 170% 215% 8 0.12 mbar psig 43 0.62 OPSO Set Range as a % of Regulator Setpoint Min Max 215% 270% Standard UPSO Set Values(1) Pdsu mbar psig 10 0.15 21 0.30 36 0.52 45 0.65 11 0.16 27 0.39 41 0.59 51 0.74 14 0.20 30 0.44 45 0.65 57 0.83 15 0.22 35 0.50 53 0.76 67 0.96 18 0.26 50 0.70 70 1.0 90 1.3 25 0.36 30 0.44 38 0.54 50 0.73 75 1.1 80 1.2 150% 140% 60 0.87 84 1.2 75 1.10 98 1.4 130% 100 1.5 130 1.9 150 2.2 195 2.8 130% 160% 158% 140% 140% 10 16 20 40 160 2.3 208 3.0 2.0 to 4.4 300 4.4 375 5.4 125% 140% 50 276 to 517 4.0 to 7.5 500 7.3 625 9.1 125% 140% 500 to 1000 7.3 to 14.5 1000 14.5 ---- ---- ---- 1200 17.4 ---- ---- 1500 21.6 ---- 2000 29.0 3000 43.5 1000 to 14.5 to 3000 43.5 Standard OPSO Set Values(1) Pdso Underpressure Shutoff (UPSO) 0.14 0.23 190% 180% 108 1.57 128 1.85 0.29 170% 170 2.47 248 3.59 0.58 165% 200% 200% 190% 175% UPSO Set Range as a % of Regulator Setpoint Min Max 50% 56% 50% 60% 50% 70% 50% 70% 50% 70% 264 3.83 0.73 450 6.53 150% 165% 150 2.2 50% 70% 60 0.87 700 10.2 140% 180% 250 3.6 50% 70% ---- ---- ---- 1320 19.2 112% 140% 500 7.3 50% 70% ---- ---- ---- ---- 1600 23.2 112% 133% 600 8.7 ---- ---- ---- ---- ---- 1900 27.6 112% 127% 750 10.9 50% 70% ---- ---- ---- ---- ---- ---- 2400 34.8 112% 120% 1000 14.5 ---- ---- ---- ---- ---- ---- 3400 49.3 112% 113% 1500 21.8 1. Standard factory set shown. Factory set is at the Minimum value of the range indicated. Range indicated is a percentage of Setpoint. Percentage indicated is based on the Set Pressure Range in which that setpoint resides. If non-standard sets are required, adherence must be made to constraints shown in Table 7, including Token Relief Set Range, OPSO and UPSO set range and Minimum Required difference between Token Relief and OPSO Set. 2. Minimum Token Relief values apply to -20 to 60°C / -4 to 140°F service temperatures. For service below -20°C / -4°F, add 8 mbar / 0.12 psig to the minimum Token Relief value listed. 3. Token Relief is not available for the Type CSB454. Example: If a non-standard setpoint is needed, see the following example for the proper use of Table 8. Non-standard setpoint = 140 mbar / 2 psig, using the value presented above, the factory set of the token relief will be 1.3 x 140 = 182 mbar / 2.6 psig. The factory OPSO and UPSO set pressures are 165% and 50% of the non-standard setpoint, respectively. The resulting settings are: OPSO = 231 mbar / 3.4 psig and UPSO = 70 mbar / 1 psig. 6 CSB400 Series 205 / 8.09 208 / 8.18 SPRING REMOVAL(1) SPRING REMOVAL(2) 249 / 9.81 152 / 5.97 146 / 5.77 291 / 11.46 A A B A/2 SLAM-SHUT MODULE A/2 171 / 6.72 275 / 10.81 54 / 2.13 307 / 12.08 45 / 1.79 151 / 5.95 A A A A/2 A/2 A/2 1 NPT SCREENED VENT TRUE-MONITOR™ MODULE GE34270 mm / INCH 1. MAXIMUM SPRING REMOVAL CLEARANCE FOR BOTH THE PRIMARY REGULATOR AND INTEGRAL TRUE-MONITOR IS 158 mm / 6.2 inches. 2. MAXIMUM SPRING REMOVAL CLEARANCE FOR THE SLAM SHUT IS 80 mm / 3.1 inches. Figure 3. CSB400 Series Dimensions Table 9. CSB400 Series Dimensions BODY SIZE, NPS BODY END CONNECTION STYLE FACE-TO-FACE DIAMETER (A) mm Inch 1 100 4 1-1/4 114 4.5 1-1/2 NPT or Rp 2 DN 50 / 2 CL150 FF or PN 10/16 114 4.5 127 5 254 10 PITOT TUBE (B) mm Inch 97 3.8 1 x 1-1/4 Rp 114 4.5 1 x 2-1/4 Rp x GAZ 105 4.1 20 0.8 DN 40 / 1-1/2 PN 16 Slip-On 184 7.2 97 3.8 7 CSB400 Series REGULATOR ADJUSTING SCREW REGULATOR CONTROL SPRING REGULATOR ORIFICE TOKEN RELIEF SPRING REGULATOR DISK PUSHER POST BALANCED PORT ASSEMBLY M1143 INLET PRESSURE LEVER EXTERNAL CONTROL LINE (SENSE LINE) VALVE STEM OUTLET PRESSURE ATMOSPHERIC PRESSURE Figure 4. Type CSB400DT Dual Registered Regulator Operational Schematic Additional overpressure protection options include Types CSB403 and CSB423, which offer True-Monitor™ protection provided by an integral monitor module installed on the inlet side of the valve body. This Integral True-Monitor assumes control of the pressure to the downstream system should the primary regulator fail to regulate. The Types CSB404, CSB424 and CSB454 are examples of CSB400 Series configurations that offer a slam-shut module that shuts off the flow of gas to the downstream system in the event of outlet pressure rising above or falling below the predefined levels due to a failure. Optional token relief is available, which acts as a lowcapacity internal relief valve to relieve minor overpressure situations due to nicks or other minor damage to the orifice or disk, or due to thermal expansion of the downstream system. Internal, external or dual outlet pressure registration is available. Constructions with dual or external registration require an external control line / sense line. For quick changing loads, dual sense is recommended as it provides the quickest response time. 8 Principle of Operation Type CSB400 Base Regulator Operation Refer to Figure 4. When downstream demand decreases, the pressure under the regulator diaphragm increases. This pressure overcomes the regulator setting (which is set by the regulator control spring). Through the action of the pusher post assembly, lever and valve stem, the valve disk moves closer to the orifice and reduces gas flow. If demand downstream increases, pressure under the regulator diaphragm decreases. Spring force pushes the pusher post assembly downward, the valve disk moves away from the orifice, and the gas flow increases downstream as the regulator opens in response to the decreased pressure underneath the regulator diaphragm. Type numbers with a “T”, for example, Type CSB400IT, provide a token or low-capacity relief. The Token relief provides relief from minor overpressure caused by nicks or dents on the orifice or by thermal expansion of gas in the downstream line. Token relief also provides a token or signal, in the form of odor, that an overpressure situation is occurring. CSB400 Series REGULATOR ADJUSTING SCREW MONITOR ADJUSTING SCREW REGULATOR ORIFICE REGULATOR CONTROL SPRING MONITOR CONTROL SPRING TOKEN RELIEF SPRING MONITOR DISK EXTERNAL CONTROL LINE (SENSE LINE) MONITOR LEVER MONITOR VALVE STEM REGULATOR VALVE STEM MONITOR ORIFICE MONITOR OPENING SPRING BALANCED PORT ASSEMBLY WIDE-OPEN INTEGRAL TRUE-MONITOR REGULATOR PRESSURE RETAINING PLUG (DO NOT REMOVE WHILE UNIT REGULATOR IS PRESSURIZED) LEVER REGULATOR PUSHER POST PRIMARY REGULATOR M1145 INLET PRESSURE OUTLET PRESSURE ATMOSPHERIC PRESSURE Figure 5. Type CSB403IT Internally Registered Primary Regulator with Externally Registered Integral True-Monitor™ Operational Schematic OPSO ADJUSTING SCREW OPSO SET SPRING UPSO ADJUSTING SCREW REGULATOR ADJUSTING SCREW UPSO SPRING REGULATOR CONTROL SPRING SLAM-SHUT ORIFICE VENT TOKEN RELIEF SPRING SENSE BLOCKING SCREW PROXIMITY SWITCH PLUG RESET KNOB SLAM-SHUT DISK VALVE STEM REGULATOR ORIFICE TYPE VSX4 SLAM-SHUT MODULE LEVER EXTERNAL CONTROL LINE (SENSE LINE) PRIMARY REGULATOR M1146 INLET PRESSURE OUTLET PRESSURE ATMOSPHERIC PRESSURE Figure 6. Type CSB404ET Externally Registered Regulator and Slam-shut Operational Schematic 9 CSB400 Series PROTECT VENT PIPE WITH RAIN CAP CSB400 SERIES REGULATOR NPS 2 TYPE 289H RELIEF VALVE REGULATOR VENT POINTED DOWNWARD GE27692 Figure 7. CSB400 Series Regulator Installed with the Vent Pointed Downward and with a Type 289H Relief Valve for High Capacity Relief Type CSB403 Integral True-Monitor™ Operation Type CSB403 combines the operation of a conventional two-regulator wide-open monitor set into one body, see Figure 5. The Integral True-Monitor is installed on the inlet side of the body and serves to throttle flow and maintain an acceptable downstream pressure in the case where the primary regulator ceases to regulate downstream pressure. During normal operation the Integral True-Monitor is in a wide-open state as its setpoint is set higher than the primary regulator. See Table 7 for guidance regarding the setpoints of the regulator and associated Integral True-Monitor sets. If the downstream pressure should rise to the setpoint of the Internal Monitor due to a loss of pressure control by the primary regulator, the Integral True-Monitor will assume control and regulate the flow to the downstream system. If token relief is present, it will relieve a small amount of gas to the atmosphere as an indication that the Integral True-Monitor is controlling the downstream pressure. The Type CSB403 provides the option of internal or external downstream pressure registration. External registration requires a downstream sensing line. See Figure 9 for guidance regarding installation of the downstream control line. Refer to the Type TM600 Instruction Manual for additional details of Integral True-Monitor operation. 10 Type CSB404 Slam-shut Operation The Type VSX4 slam-shut module on the Type CSB404 regulator is a fast acting shut-off device that provides overpressure (OPSO) or over and underpressure (OPSO / UPSO) protection by completely shutting off the flow of gas to the downstream system. See Table 8 for guidance regarding the typical setpoints of the regulator and associated slam-shut OPSO and also the combined OPSO and UPSO setpoints. The Type VSX4’s actions are independent of the Type CSB404 regulator and of variations to the inlet pressure. The Type VSX4 comes standard with external downstream pressure registration, with the option for internal registration only on the Rp 1 x 2-1/4 GAZ body. External registration requires a downstream sensing line. See Figure 10 for guidance regarding installation of the downstream control line. The Type VSX4 shut-off disk is normally in the open (reset) position, see Figure 6. If the downstream pressure below the slam-shut diaphragm increases (or decreases) until it reaches the slam-shut setpoint, this diaphragm moves upward (or downward) to release the trip mechanism which allows the spring force on the stem to push the disk against the seat, shutting off all gas flow. To reset the slam shut after gas has been shut off, refer to the Type VSX4 Instruction Manual for additional details. CSB400 Series In order for the Underpressure Shutoff (UPSO) of any slam shut to be triggered, the downstream pipe pressure must drop below the UPSO setpoint. In the case of a downstream line break, numerous factors can prevent the downstream pipe pressure from decreasing below the slam-shut UPSO setpoint. These factors include the distance of pipe to the break, the diameter of the pipe, size of the break and the number of restrictions, such as valves, elbows and bends, downstream of the regulator and/or slam-shut device. Due to these factors additional protections should be installed to stop flow in the event of a line break. Installation and Overpressure Protection Install in accordance with provisions of EN 12186 / EN 12279. ! WARNING Personal injury or system damage may result if this regulator is installed, without appropriate overpressure protection, where service conditions could exceed the limits given in the Specifications section and/ or regulator nameplate. Regulator and equipment installation should be adequately protected from physical damage. All vents should be kept open to permit free flow of gas to the atmosphere. Protect openings against entrance of rain, snow, insects or any other foreign material that may plug the vent or vent line. On outdoor installations, point the spring case vent downward to allow condensate to drain, see Figures 7 through 10. This minimizes the possibility of freezing and of water or other foreign materials entering the vent and interfering with proper operation. For the Type CSB403 with Integral True-Monitor™ or the Type CSB404 with Slam shut, point the vents of both the primary regulator and Integral True-Monitor or slam shut downward to allow condensate to drain. From the factory, the Integral True-Monitor or slam shut will always point in the same direction as that of the primary regulator. Under enclosed conditions or indoors, escaping gas may accumulate and be an explosion hazard. In these cases, the vent should be piped away from the regulator to the outdoors. In case of complete disassembly of the equipment (body included) from the pipeline, care must be taken not to bend, hit or otherwise damage the pitot tube (key 83 Figure 15) that protrudes beyond the body outlet. Damage to the pitot tube could result in inaccurate internal pressure registration and loss of regulation quality. CAUTION CSB400 Series regulators have an outlet pressure rating lower than their inlet pressure rating. If actual inlet pressure can exceed the outlet pressure rating, outlet overpressure protection is necessary. However, overpressuring any portion of the regulators beyond the limits in the Specifications section may cause leakage, damage to regulator parts or personal injury due to bursting of pressure-containing parts. Some type of external overpressure protection should be provided to the CSB400 Series if inlet pressure will be high enough to damage downstream equipment. Common methods of external overpressure protection include relief valves, monitoring regulators, shut-off devices, and series regulation. If the regulator is exposed to an overpressure condition, it should be inspected for any damage that may have occurred. Regulator operation below the limits specified in the Specifications section and regulator nameplate does not preclude the possibility of damage from external sources or from debris in the pipeline. 11 CSB400 Series MINIMUM OF 4 X OUTLET PIPING DIAMETER WIDE-OPEN MONITORING REGULATOR PRIMARY WORKING REGULATOR UPSTREAM BLOCK VALVE DOWNSTREAM BLOCK VALVE INLET PRESSURE INLET PRESSURE OUTLET PRESSURE OUTLET PRESSURE ATMOSPHERIC PRESSURE INTERMEDIATE PRESSURE Figure 8. Type CSB400 “Series Monitor” Regulator Downstream Control Line Installation Before installing the regulator, check for damage which might have occurred in shipment. Also check for dirt or foreign matter which may have accumulated in the regulator body or in the pipeline. Apply pipe compound to the external threads of the pipeline and install the regulator so that flow is in the direction of the arrow cast on the body. The diaphragm casing assembly can be rotated to any position relative to the body. Loosen the two cap screws (key 71, Figure 11) in order to rotate the diaphragm casing assembly. General Installation Instructions Before installing the regulator, • Check for damage, which might have occurred during shipment. • Check for and remove any dirt or foreign material, which may have accumulated in the regulator body. 12 • Blow out any debris, dirt or copper sulfate in the copper tubing and the pipeline. • Apply pipe compound to the external threads of the pipe before installing the regulator. • Make sure gas flow through the regulator is in the same direction as the arrow on the body. “Inlet” and “Outlet” connections are clearly marked. • Verify that: - Equipment limits of utilization (PS, TS) corresponds to the desired operating conditions. - The inlet is protected by an appropriate device(s) to avoid exceeding the allowable limits (PS, TS). • When designing a pressure reducing station using a CSB regulator, make an analysis if it is necessary to take into account the effects of wind, snow and temperature to avoid unnecessary load and movement to the flanges of the equipment. • If needed, a support may be used under the piping and regulator/slam-shut body to avoid excessive pressure force on the regulator/slam shut. CSB400 Series PRIMARY REGULATOR DOWNSTREAM BLOCK VALVE UPSTREAM BLOCK VALVE MINIMUM OF 4 X OUTLET PIPING DIAMETER M1062 INTEGRAL TRUE-MONITOR™ Figure 9. Type CSB403 Downstream Control Line Installation PRIMARY REGULATOR DOWNSTREAM BLOCK VALVE UPSTREAM BLOCK VALVE MINIMUM OF 4 X OUTLET PIPING DIAMETER SLAM SHUT M1063 INLET PRESSURE OUTLET PRESSURE ATMOSPHERIC PRESSURE Figure 10. Type CSB404 Downstream Control Line Installation 13 CSB400 Series Installation Location • The installed regulator should be adequately protected from vehicular traffic and damage from other external sources. • Install the regulator with the vent pointed vertically down, see Figures 7 through 10. If the vent cannot be installed in a vertically down position, the regulator must be installed under a separate protective cover. Installing the regulator with the vent down allows condensation to drain, minimizes the entry of water or other debris from entering the vent, and minimizes vent blockage from freezing precipitation. • Do not install the regulator in a location where there can be excessive water accumulation or ice formation, such as directly beneath a downspout, gutter or roof line of building. Even a protective hood may not provide adequate protection in these instances. • Install the regulator so that any gas discharge through the vent or vent assembly is over 0.91 m / 3 feet away from any building opening. Regulators Subjected to Heavy Snow Conditions Some installations, such as in areas with heavy snowfall, may require a hood or enclosure to protect the regulator from snow load and vent freeze over. Downstream Control Line Installation ! WARNING Failure to install a downstream control line could result in a hazardous condition. Install downstream control line(s) to the slam-shut device when construction uses external pressure registration. The regulator and slam-shut device will not control pressure or shutoff if a downstream control line is not installed on those constructions where external pressure registration is required. 14 CSB400 Series regulators with an “ET” or “EN” in the type number use external pressure registration. To communicate the downstream pressure to the regulator, connect a downstream control line tubing to the 3/4 NPT control line tapping in the lower diaphragm casing and connect the other end of the tubing downstream of the regulator outlet with a minimum distance of 4 times the outlet pipe diameter. For Types CSB400 and CSB404 with external control lines, use tubing with an outer diameter of 9.5 mm / 0.375 inch or larger. For Types CSB420, CSB424, CSB450 and CSB454 with external control lines, use tubing with an outer diameter of 13 mm / 0.5 inch or larger. The Types CSB410, CSB414, CSB430 and CSB434 are dedicated wide-open monitoring regulators and are installed upstream of a primary working regulator. Refer to Figure 8 for installation of the downstream control line. To communicate the downstream pressure to the wide-open monitor regulator, connect a downstream control line tubing to the 3/4 NPT control line tapping in the lower diaphragm casing of the monitor regulator and connect the other end of the tubing downstream of the regulator outlet with a minimum distance of 4 times the outlet pipe diameter. For Types CSB410 and CSB414, use tubing with an outer diameter of 9.5 mm / 0.375 inch or larger. For Types CSB430 and CSB434, use tubing with an outer diameter of 13 mm / 0.5 inch or larger. Downstream Control Line Installation with Integral True-Monitor™ Refer to Figure 9. When installing the Types CSB403 and CSB423 regulators, connect downstream control line tubing to the lower casing of the primary regulator, and run the tubing downstream of the regulator outlet with a minimum distance of 4 times the outlet pipe diameter. Connect a second, separate downstream control line tubing to the lower casing of the Integral True-Monitor, and run the tubing downstream of the regulator outlet with a minimum distance of 4 times the outlet pipe diameter. For Type CSB403 with external control lines, use tubing with an outer diameter of 9.5 mm / 0.375 inch or larger for both the primary regulator and Integral True-Monitor. CSB400 Series For Type CSB423 with external control lines, use tubing with an outer diameter of 13 mm / 0.5 inch or larger for both the primary regulator and Integral True-Monitor™. Downstream Control Line Installation with Slam shut Refer to Figure 10. When installing the Types CS404ET, CS404EN, CSB424ET, CSB424EN and CSB454EN regulators, connect downstream control line tubing to the lower casing of the regulator and run the tubing downstream of the regulator outlet with a minimum distance of 4 times the outlet pipe diameter. Connect a second, separate downstream control line tubing to the lower casing of the slam shut and run the tubing downstream of the regulator outlet a minimum distance of 4 times the outlet pipe diameter. For Type CSB404 with external control lines, use tubing with an outer diameter of 9.5 mm / 0.375 inch or larger for the primary regulator and 6.4 mm / 0.25 inch or larger for the slam shut. For Types CSB424 and CSB454 with external control lines, use tubing with an outer diameter of 13 mm / 0.5 inch or larger for the primary regulator and 6.4 mm / 0.25 inch or larger for the slam shut. Installation with External Overpressure Protection If the regulator is used in conjunction with a Type 289H relief valve, it should be installed as shown in Figure 7. The outside end of the vent line should be protected with a rainproof assembly. The Type 289H is typically set 25 mbar / 10 inches w.c. higher than the outlet pressure setting of the regulator, up to 75 mbar / 30 inches w.c. outlet pressure. For pressure greater than this, set the Type 289H 0.05 bar / 0.75 psi higher than the outlet pressure setting of the regulator. Vent Line Installation The CSB400 Series regulators have a 1 NPT screened vent opening in the spring case. If necessary to vent escaping gas away from the regulator, install a remote vent line in the spring case tapping. Vent piping should be as short and direct as possible with a minimum number of bends and elbows. The remote vent line should have the largest practical diameter. Vent piping on regulators with token relief must be large enough to vent all relief valve discharge to atmosphere without excessive backpressure and resulting excessive pressure in the regulator. For types with optional Token relief, this low capacity relief is located in the spring case of the primary regulator. If necessary to vent escaping gas away, install a remote vent line in the spring case tapping of the primary regulator as described above. Periodically check all vent openings to be sure that they are not plugged or obstructed. CSB400 Series outlet pressure ranges are shown in Table 6. Outlet pressure higher than 0.34 bar / 5 psig above the setpoint may damage internal parts such as the diaphragm head and valve disk. The maximum emergency (casing) outlet pressure is 4.0 bar / 58 psig. Commissioning CAUTION Pressure gauges must always be used to monitor downstream pressure during Startup. With the downstream system depressurized, use the following procedure to start up the regulator. 1. Check to see that all appliances are turned off. 2. Slowly open the upstream shut-off valve. 3. Check inlet and outlet pressure for correct values. 4. Check all connections for leaks. 5. Turn on utilization equipment and recheck the pressures. Adjustment Note For types that include the Integral True-Monitor module, refer to the Instruction Manual for Type TM600 Integral True-Monitor for adjustment and maintenance of the Integral True-Monitor. For the types that include the slam-shut module, refer to the Instruction Manual for Type VSX4 slam shut for adjustment and maintenance of the slam shut. 15 CSB400 Series The range of allowable pressure settings for the primary regulator is stamped on the nameplate. If the required setting is not within this range, substitute the correct spring (as shown in Table 6). If the spring is changed, re-stamp the nameplate to indicate the new pressure range. A pressure gauge must always be used to monitor downstream pressure while adjustments are being made. For Types CSB400 and CSB420 1. Remove the closing cap (key 60, Figure 16). 2. To increase the outlet setting, turn the adjusting screw (key 65) clockwise. To decrease the outlet setting, turn the adjusting screw counterclockwise. 3. Replace the closing cap. For Type CSB450 1. Loosen the hex nut (key 58, Figure 16). 2. To increase the outlet setting, turn the adjusting screw (key 65, Figure 16) clockwise. To decrease the outlet setting, turn the adjusting screw counterclockwise. 3. Tighten the hex nut. CSB400 Series with Integral True-Monitor™ When adjusting the primary regulator and Integral True-Monitor for operation, ensure that the pressure differences between the primary regulator and the integral monitor shown in Table 7 are observed. For example, if the primary regulator setpoint is set at 20 mbar / 8 inches w.c., then the Integral True-Monitor should be set at a minimum of 35 mbar / 14 inches w.c. or higher. To test the Integral True-Monitor operation, the primary regulator setpoint must be adjusted above the Integral True-Monitor’s setpoint to simulate a failure of the primary regulator. If the spring range of the primary regulator is sufficiently high, it can simply be adjusted above the Integral True-Monitor’s setpoint by following step 2 above. Otherwise, a different spring with a setpoint higher than the Integral True-Monitor’s setpoint must be installed to check the operation of the Integral True-Monitor. 16 CSB400 Series with Slam shut When adjusting the primary regulator and slam shut for operation, refer to Table 8 for the OPSO setpoints and also the combined OPSO and UPSO setpoints of the slam shut for a given regulator spring ranges. CAUTION Equipment installed downstream the Type VSX slam shut device can be damaged if the following procedure for resetting the Type VSX slam shut device is not followed. This equipment includes the integral Type VSX or regulator configurations. Step 1: • To properly reset the Type VSX slam shut after it has been tripped to the closed position, a flat-head screwdriver must be inserted into the position shown in Figure 8 on the backside of the reset button (refer to Type VSX4 Instruction Manual, key 30, Figure 8). Step 2: • The screwdriver should be slowly rotated to gradually pull the reset button (refer to Type VSX4 Instruction Manual, key 30) away from the Type VSX device. This slow movement allows for a slow bleed of the pressure across the Type VSX slam shut’s disk and seat area. The operator should be able to hear the pressure bleeding through the system. Step 3: • When the pressure has equalized and the air bleeding sound has dissipated, the reset button (refer to Type VSX4 Instruction Manual, key 30) should be pulled completely away from the Type VSX slam shut device by hand until the internal shut-off mechanism has been re-latched. Step 4: • Once the operator feels the click of the re-latch occurring, the reset button (refer to Type VSX4 Instruction Manual, key 30) should be pushed completely back into its original position. CSB400 Series L2 38 55 19 L2 L1 L2 L2 62 60 65 L2 100 96 TORQUE: 1.7 TO 3.4 N•m / 15 TO 30 INCH-POUNDS 4 20 5 7 19 L1 6 35 95 L1 77 L1 75 8 TORQUE: 1.7 TO 3.4 N•m / 15 TO 30 INCH-POUNDS 74 L2 51 25 TORQUE: 47 TO 61 N•m / 35 TO 45 FOOT-POUNDS L1 21 27 18 11 L1 13 L1 14 10 TORQUE: 1.7 TO 3.4 N•m / 15 TO 30 INCH-POUNDS L1 22 S1 ERAA04154 APPLY LUBRICANTS (L) / SEALANT (S)(1): L1 = DOW CORNING® 33 OR COMPARABLE EXTREME LOW TEMPERATURE LUBRICANT L2 = ANTI-SEIZE LUBRICANT S1 = MULTI-PURPOSE POLYTETRAFLUOROETHYLENE (PTFE) THREAD SEALANT 1. Lubricants and sealant must be selected such that they meet the temperature requirements. Figure 11. CSB400 Series Regulator Assembly ! WARNING In the case of a downstream line break, numerous factors affect the capability to evacuate gas from the pipeline. These factors include the distance of pipe to the break, the diameter of the pipe, size of the break and the number of restrictions, such as valves, elbows and bends, downstream of the regulator and/or slam-shut device. Due to these factors additional protections should be installed to stop flow in the event of a line break. Shutdown Installation arrangements may vary, but in any installation it is important that the valves be opened or closed slowly and that the outlet pressure be vented before venting inlet pressure to prevent damage caused by reverse pressurization of the regulator. The following steps apply to the typical installation as indicated. 1. Open valves downstream of the regulator. 2. Slowly close the upstream shut-off valve. 3. Inlet pressure should automatically be released downstream as the regulator opens in response to the lowered pressure underside of the diaphragm. 4. Close outlet shut-off valve. Dow Corning® is a mark owned by Dow Corning Corporation. 17 CSB400 Series 3 2 1 15 TORQUE: 7.1 TO 10.1 N•m / 63 TO 90 INCH-POUNDS 16 9 80 TORQUE: 14 TO 18 N•m / 10 TO 13 FOOT-POUNDS 76 S1 72 70 71 TORQUE: 14 TO 18 N•m / 10 TO 13 FOOT-POUNDS 17 ERAA04154 APPLY SEALANT (S)(1): S1 = MULTI-PURPOSE POLYTETRAFLUOROETHYLENE (PTFE) THREAD SEALANT 1. Sealant must be selected such that it meets the temperature requirements. 2. The torque range as specified is initial assembly torque. Due to elastomeric compression, the torque values indicated may decrease. Minimum inspection torque is 4 N•m / 35 inch-pounds. Figure 11. CSB400 Series Regulator Assembly (continued) 18 CSB400 Series Maintenance and Inspection ! Note For adjusting setpoints above 100 mbar / 1.5 psig, use a 13 mm / 1/2-inch hex driver, a 13 mm / 1/2-inch socket or a 27 mm / 1-1/16-inch socket to turn the adjusting screw (key 65). WARNING To avoid personal injury or equipment damage, do not attempt any maintenance or disassembly without first isolating the regulator from system pressure and relieving all internal pressure as described in “Shutdown”. Regulators that have been disassembled for repair must be tested for proper operation before being returned to service. Only parts manufactured by Regulator Technologies should be used for repairing Fisher® regulators. Restart gas utilization equipment according to normal startup procedures. Due to normal wear or damage that may occur from external sources, this regulator should be inspected and maintained periodically. The frequency of inspection and replacement depends on the severity of service conditions, test results found during the annual test, and on applicable codes and regulations. In accordance with applicable National or Industry codes, standards and regulations/recommendations, all hazards covered by specific tests after final assembly, before applying the CE marking, shall also be covered after every subsequent reassembly at installation site in order to ensure that the equipment will be safe throughout its intended life. Periodic inspection must be performed on the CSB400 Series that include the Integral True-Monitor™ or slam-shut overpressure protection modules to ensure that they protect the downstream system in the event the primary regulator losses pressure control. This inspection must test that the Integral True-Monitor or slam-shut functions as intended. Disassembly to Replace the Regulator Main Diaphragm 1. Remove the closing cap (key 60, Figure 11) or loosen hex locknut (key 58, Figure 16). Turn the adjusting screw (key 65) or nut (key 58) counterclockwise to ease spring (key 38) compression. 2. Remove the adjusting screw (key 65) and spring (key 38). 3. Remove hex nuts (key 16, Figure 11) and cap screws (key 15, Figure 11). Separate the upper spring case (key 1) from the lower casing assembly (key 9). Note When disassembling a CSB400 Series regulator, lift the upper spring case (key 1) straight up in order to avoid hitting the stem (key 44). 4. Slide the diaphragm assembly (key 55) away from the body (key 70) to unhook the pusher post (key 51) from the lever (key 10). Lift off the diaphragm assembly (key 55). 5. a. For none relieving units such as the Types CSB400IN and CSB400EN, unscrew the cap (key 45), see Figure 12, high-pressure NonRelief and low-pressure Non-Relief assemblies. The cap fastens the R.V. spring seat (key 43) to the pusher post (key 51). Unscrew the cap to separate the R.V. spring seat (key 43), diaphragm assembly (key 55) and pusher post (key 51). b. For units with internal token relief such as Type CSB400IT, refer to Figure 12, unscrew the adjusting upper seat (key 47). This will allow for removal of the relief spring (key 41), R.V. spring seat (key 43), diaphragm assembly (key 55) and pusher post (key 51). 19 CSB400 Series 6. Reassemble the spring case (key 1) unit in the reverse order of the above steps. Before tightening the cap screws (key 15) or stem (key 44) into the pusher post (key 51), place the loosely-assembled diaphragm assembly (key 55) into position in the lower casing (key 9), being sure that the pusher post (key 51) is hooked on the lever (key 10). Rotate the diaphragm (key 55A) so that the diaphragm and lower casing (key 9) holes are aligned. Tighten the stem (key 44) or diaphragm retainer (key 45) for HP and LP non-relief assemblies. Disassembly to Replace Valve Disk, Balanced Port Assembly Diaphragm and Regulator Orifice 1. Remove the bolts (key 71, Figure 11) which hold the lower spring casing (key 9) to the body (key 70). Separate the lower spring casing (key 9) from the body (key 70). 2. Check the body O-ring (key 21) for wear. 3. Remove the balanced port assembly (key 35, Figures 11 and 13) from the body, make sure to rotate the assembly toward the outlet of the body as it is being removed to clear the sense tube from the body. 4. Examine the valve disk (key 35K) for nicks, cuts and other damage. If damage is present, it is recommended to replace both the disk and also the balanced port diaphragm (key 35F) and associated diaphragm O-ring (key 35M), that comes into direct contact with the inner flange of the balanced port diaphragm. Start the process of replacing the disk by disassembling the balanced port assembly. Remove the four cap screws (key 35R) and then the cap (key 35G). 5. Grasp the spring retainer (key 35C) and slide the brazed housing (key 35A) away to expose the diaphragm (key 35F) and disk (key 35K). Still grasping the spring retainer (key 35C) insert a 5 mm Allen wrench into the disk screw (key 35E) and unscrew. Dow Corning® is a mark owned by Dow Corning Corporation. 20 6. Remove the disk (key 35K) and discard if damaged Slide the diaphragm O-ring (key 35M) off the stem (key 35B) along with the diaphragm (key 35F). Slide the new diaphragm over the stem in the same manner that it was removed, make sure that it completely contacts the surface of the inner retainer (key 35J). 7. Reassemble the Balanced Port assembly in reverse order of the above. Ensure Dow Corning® 33 or comparable extreme low temperature lubricant completely coats the O-ring (key 35M), stem (key 35B) and the center bore of the outer retainer (key 35H). 8. Examine the seating edge of the orifice (key 25). If it is nicked or rough, replace the orifice and O-ring (key 27). If a slam shut or monitor is installed on the backside of the body, refer to the applicable Instruction Manual for inspection and removal of the overpressure protection orifice (key 26) and O-ring (key 27). 9. Reassemble the regulator in reverse order of the above steps. Regulator Reassembly As indicated by the square callouts in Figures 11 to 17, it is recommended that a good quality pipe thread sealant be applied to pressure connections and fittings and a good quality extreme low temperature lubricant, such as Dow Corning® 33, be applied to O-rings. Also apply an anti-seize compound to the adjusting screw threads, orifice threads and other noted areas as needed. Parts Ordering The type number, orifice size, spring range and date of manufacture are stamped on the nameplate. Always provide this information in any correspondence with your local Sales Office regarding replacement parts or technical assistance. When ordering replacement parts, reference the key number of each needed part as found in the following parts list. Separate kit containing all recommended spare parts is available. CSB400 Series Parts List Key Description Part Number Spare Parts (Repair Parts Kit include keys 12, 19, 21, 27, 35K, 55, 62, 75 and 77) Type CSB400 RCSB400X012 Type CSB403 RCSB403X012 Type CSB404 RCSB404X012 1 Spring Case, Aluminum GE24555X012 2 Vent Screen, 18-8 Stainless steel T1121338982 3 Retaining Ring, Steel T1120925072 4 Stabilizer Guide, 304 Stainless steel GE27061X012 5 Stabilizer, Acrylonitrile Butadiene Styrene (ABS) GE27063X012 6 Stabilizer Spring, Stainless steel GE35010X012 7 Retainer Ring, Zinc-plated steel GE27024X012 8 Stabilizer Screw, Zinc-plated steel (3 required) GE29724X012 9 Lower Casing, Aluminum GE24289X012 10 Lever, Steel Types CSB400, CSB403, CSB404, CSB410 and CSB414 GE28773X012 Types CSB420, CSB423, CSB424, CSB430, CSB434, CSB450 and CSB454 GE28772X012 11 Valve Stem, Aluminum GE27812X012 12* O-ring, Nitrile (NBR) External Registration Only 1E472706992 13 Lever Pin, 18-8 Stainless steel Types CSB400, CSB403, CSB404, CSB410 and CSB414 T14397T0012 Types CSB420, CSB423, CSB424, CSB430, CSB434, CSB450 and CSB454 (2 required) T14397T0012 14 Lever Screw, Steel Types CSB400, CSB403, CSB404, CSB410 and CSB414 (2 required) GE34243X012 Types CSB420, CSB423, CSB424, CSB430, CSB434, CSB450 and CSB454 (4 required) GE34243X012 15 Cap Screw, Steel (8 required) GE32059X012 16 Nut, Steel (8 required) GE32060X012 17 Union Ring, Aluminum GE26590X012 18 Snap Ring, 302 Stainless steel T1120637022 19* O-ring, Nitrile (NBR) (2 required) 1K594906562 20 Stem Guide, Aluminum GE26027X012 21* O-ring, Nitrile (NBR) GE45216X012 22 Pipe plug, 3/4 NPT, Steel Internal Registration Only GE34199X012 23 Screw (For external registration only), Steel (2 required) 1E175828982 24* O-ring (For external registration only), Nitrile (NBR) (2 required) 17A0960X012 25 Orifice Types CSB400F and CSB404F, Aluminum GG08494X012 All other Types, Brass GE31321X012 26 OPP Orifice 18 mm / 0.69 inch With Integral True-Monitor™ Orifice, Aluminum GE30003X012 With Slam-shut Orifice, Brass GE28684X012 27* O-ring, Nitrile (NBR) Type CSB400 (1 required) 10A3802X022 Type CSB403 (2 required) 10A3802X022 Type CSB404 (2 required) 10A3802X022 35 Balanced Port Assembly for all bodies except GAZ Standard GE31196X012 Low temperature “F” version GE31196X022 35A Brazed Housing GE31261X012 35B Stem, Stainless steel GE31191X012 35C Spring Retainer, Zinc-plated steel GE31189X012 35D Spring, Stainless steel GE30193X012 35E Disk Screw, Zinc-plated steel GE31190X012 35F* Diaphragm, Nitrile (NBR) / Fabric GE30439X012 35G Cap, Brass GE31195X012 Key Description 35H Outer Retainer, Brass 35J Inner Retainer, Brass 35K* Disk Assembly, Brass / Nitrile (NBR) Standard version Low Temperature “F” version 35M O-ring, Nitrile (NBR) (2 required) 35N* O-ring, Nitrile (NBR) 35R Screw, Steel (4 required) 35S Pin, Zinc-plated steel 35 Balanced port assembly for Rp 1 x 2-1/4, GAZ Body Standard Low temperature “F” version 35A Brazed Housing 35B Stem, Stainless steel 35C Spring Retainer, Zinc-plated steel 35D Spring, Stainless steel 35E Disk Screw, Zinc-plated steel 35F* Diaphragm, Nitrile (NBR) / Fabric 35G Cap, Brass 35H Outer Retainer, Brass 35J Inner Retainer, Brass 35K* Disk Assembly, Brass / Nitrile (NBR) Standard version Low-temperature “F” version 35M O-ring, Nitrile (NBR) (2 required) 35N* O-ring, Nitrile (NBR) 35R Screw, Cap, Hex Socket, Steel (4 required) 38 Spring 17 to 24 mbar / 6.8 to 9.6 inches w.c., Pink 24 to 35 mbar / 9.6 to 14 inches w.c., Orange Stripe 35 to 60 mbar / 14 to 24 inches w.c., Dark Green 54 to 100 mbar / 0.78 to 1.5 psig, Tan 100 to 160 mbar / 1.45 to 2.3 psig, Purple Stripe 138 to 300 mbar / 2.0 to 4.4 psig, Dark Blue 276 to 517 mbar / 4 to 7.5 psig, Red 500 mbar to 1 bar / 7.3 to 14.5 psig, Light Blue 1 to 3 bar / 14.5 to 43.5 psig, Light Green 40 Upper Spring Seat, Steel High Pressure, Zinc-plated steel 41 Relief Valve Spring, 302 Stainless steel Types CSB400, CSB403 and CSB404, Token Types CSB420, CSB423 and CSB424, Token 43 Relief Valve Spring Seat, Zinc-plated steel Types CSB400 and CSB420, Non-Relief Type CSB450, Non-Relief Types CSB400 and CSB420, Token 44 Stem, Aluminum Types CSB400 and CSB420, Token 45 Diaphragm Retainer, Zinc-plated steel Types CSB400 and CSB420, Non-Relief Type CSB450, Non-Relief 47 Upper Spring Seat, Aluminum Types CSB400 and CSB420, Token 48 Restrictor Plate, Zinc-plated steel Token 51 Pusher Post, Aluminum Token Non-Relief 53 Solid Rivet, 18-8 Stainless steel 54 Roller Pin, Brass 55* Diaphragm Assembly, Steel / Nitrile (NBR) Without Diaphragm Head Limiter With Diaphragm Head Limiter 55A Diaphragm 55B Diaphragm Head Part Number GE31187X012 GE31186X012 ERSA00457A0 GE31185X012 1E472706992 1U879006562 GE25968X012 GE31232X012 GE33822X012 GE33822X022 GE32505X012 GE31191X012 GE31189X012 GE30193X012 GE31190X012 GE30439X012 GE31195X012 GE31187X012 GE31186X012 ERSA00457A0 GE31185X012 1E472706992 1U879006562 GE25968X012 GE30191X012 GE43955X012 GE30201X012 GE30202X012 GE35081X012 GE30192X012 GE33121X012 GE30203X012 GE30204X012 GE32501X012 GE30194X012 GE42225X012 GE27327X012 GE31677X012 GE28947X012 GE30895X012 GE30887X012 GE33850X012 GE33332X012 GE28948X012 ERAA00876A0 ERAA00875A0 GE29761X012 GE27060X012 GE31248X012 GE32140X012 --------------------- *Recommended spare part. 21 CSB400 Series TORQUE: 6 TO 8 N•m / 50 TO 70 INCH-POUNDS 44 47 48 41 TORQUE: 6 TO 8 N•m / 50 TO 70 INCH-POUNDS 45 43 A 55B 43 A 55B 55A NOTE DIRECTION OF RETAINER RING INSTALLATION 54 TOKEN RELIEF A 55A 55B 109 NOTE DIRECTION OF RETAINER RING INSTALLATION 53 56 108 56 51 55A 107 51 HIGH-PRESSURE NON-RELIEF 54 TORQUE: 6 TO 8 N•m / 50 TO 70 INCH-POUNDS 45 43 51 56 53 NOTE DIRECTION OF RETAINER RING INSTALLATION 56 NOTE DIRECTION OF RETAINER RING INSTALLATION LOW-PRESSURE NON-RELIEF 54 ERAA04154 APPLY ADHESIVE (A)(1): A = ADHESIVE NOTE: APPLY ADHESIVE ON THE FLAT SURFACE OF THE DIAPHRAGM PLATE THAT CONTACTS THE DIAPHRAGM, TOWARD THE OUTER PERIMETER, AND AWAY FROM THE CENTER HOLE. 1. Adhesive must be selected such that it meets the temperature requirements. Figure 12. CSB400 Series Diaphragm and Relief Assemblies 22 53 CSB400 Series L1 L1 35F 35J 35S 35N 35H 35M 35M S2 L1 TORQUE: 2.3 TO 2.8 N•m / 20 TO 25 INCH-POUNDS 35B 35C 35E TORQUE: 2.3 TO 2.8 N•m / 20 TO 25 INCH-POUNDS 35D 35K 35R 35A TORQUE: 0.9 TO 1.4 N•m / 8 TO 12 INCH-POUNDS 35G STANDARD BALANCED PORT ASSEMBLY L1 35F 35J 35N L1 35H 35M 35B S2 35M L1 35C TORQUE: 2.3 TO 2.8 N•m / 20 TO 25 INCH-POUNDS TORQUE: 2.3 TO 2.8 N•m / 20 TO 25 INCH-POUNDS 35D 35E 35K 35R 35A TORQUE: 0.9 TO 1.4 N•m / 8 TO 12 INCH-POUNDS 35G BALANCED PORT ASSEMBLY FOR Rp 1 X 2-1/4 GAZ BODY ERAA04154 APPLY LUBRICANT (L) / SEALANT (S)(1): L1 = DOW CORNING® 33 OR COMPARABLE EXTREME LOW TEMPERATURE LUBRICANT S2 = PERMANENT THREAD SEALANT 1. Lubricant and sealant must be selected such that they meet the temperature requirements. Figure 13. Balance Trim Assemblies Dow Corning® is a mark owned by Dow Corning Corporation. 23 CSB400 Series L1 L1 L1 20 11 INTERNAL OR DUAL REGISTRATION (NO SCREWS) L1 12 L1 REF HOLES “B” L1 23 B 24 B L1 20 11 EXTERNAL REGISTRATION GE27692 APPLY LUBRICANT (L)(1): L1 = DOW CORNING® 33 OR COMPARABLE EXTREME LOW TEMPERATURE LUBRICANT 1. Lubricant must be selected such that it meets the temperature requirements. Figure 14. CSB400 Series Stem Guides Dow Corning® is a mark owned by Dow Corning Corporation. 24 L1 TORQUE: 1.7 TO 3.4 N•m / 15 TO 30 INCH-POUNDS INSTALL IN “B” HOLES (THROUGH HOLES) CSB400 Series L1 75 L1 77 80 80 TORQUE: 14 TO 18 N•m / 10 TO 13 FOOT-POUNDS TORQUE: 14 TO 18 N•m / 10 TO 13 FOOT-POUNDS 74 74 76 76 77 75 L1 L1 101 S2 70 83 82 81 ERAA04154 TORQUE: 1.7 TO 3.4 N•m / 15 TO 30 INCH-POUNDS GAZ BODY DUCTILE / STEEL BODY APPLY LUBRICANT (L) / SEALANT (S)(1): L1 = DOW CORNING® 33 OR COMPARABLE EXTREME LOW TEMPERATURE LUBRICANT S2 = PERMANENT THREAD SEALANT 1. Lubricant and sealant must be selected such that they meet the temperature requirements. Figure 15. Standard Body Assembly and Rp 1 x 2-1/4 GAZ Body Assembly L1 L2 L2 L1 65 62 38 38 60 40 62 58 L2 L2 65 61 57 100 96 CSB400 / CSB420 SERIES STANDARD CSB450 SERIES HIGH PRESSURE ERAA04154 APPLY LUBRICANT (L)(1): L1 = DOW CORNING® 33 OR COMPARABLE EXTREME LOW TEMPERATURE LUBRICANT L2 = ANTI-SEIZE LUBRICANT 1. Lubricant and sealant must be selected such that they meet the temperature requirements. Figure 16. CSB400 Series Control Spring Adjustment Assemblies Dow Corning® is a mark owned by Dow Corning Corporation. 25 CSB400 Series TORQUE: 47 TO 61 N•m / 35 TO 45 FOOT-POUNDS TORQUE: 14 TO 18 N•m / 10 TO 13 FOOT-POUNDS L2 L1 26 27 70 L1 L2 27 25 TORQUE: 47 TO 61 N•m / 35 TO 45 FOOT-POUNDS 101 L L2 26 INTEGRAL TRUE-MONITOR™ ASSEMBLY L1 L2 27 25 L1 101 L2 27 70 L1 L2 27 25 TORQUE: 47 TO 61 N•m / 35 TO 45 FOOT-POUNDS 101 26 TORQUE: 47 TO 61 N•m / 35 TO 45 FOOT-POUNDS TORQUE: 14 TO 18 N•m / 10 TO 13 FOOT-POUNDS SLAM-SHUT ASSEMBLY ERAA04154 APPLY LUBRICANTS (L)(1): L1 = DOW CORNING® 33 OR COMPARABLE EXTREME LOW TEMPERATURE LUBRICANT L2 = ANTI-SEIZE LUBRICANT 1. Lubricants must be selected such that they meet the temperature requirements. Figure 17. CSB400 Series Slam-shut and Integral True-Monitor Modules Dow Corning® is a mark owned by Dow Corning Corporation. 26 2 CSB400 Series Parts List (continued) Key Description 56 Retaining Ring, Pusher Post Pin 57 Bearing ball 58 Hex Nut, High-Pressure, (CSB450 Series only) Steel 60 Closing Cap, Low-Pressure, Aluminum 61 Bonnet, High-Pressure, (CSB450 Series only) Zinc-plated steel 62* O-ring, Nitrile (NBR) 65 Adjust Screw Low-Pressure, Aluminum High-Pressure, Steel 70 Body Ductile Cast Iron NPT: 1 1-1/4 1-1/2 2 Rp: Rp 1 Rp 1-1/4 Rp 1-1/2 Rp 1 x 1-1/4 Rp 1 x 2-1/4, GAZ Rp 2 Flange: DN 50 / NPS 2, CL150 FF DN 40 / NPS 1-1/2, PN 10/16 Slip-Flange DN 50 / NPS 2, PN 10/16 WCC Steel NPT: 1 1-1/4 1-1/2 Rp Rp 1 Rp 1-1/4 Rp 1-1/2 Part Number GE33772X012 GE33131X012 GE33132X012 GE29244X012 GE32499X012 T10275X0012 GE27828X012 GE32500X012 GE26463X012 GE26465X012 GE26466X012 GE26467X012 GE26468X012 GE26469X012 GE26470X012 GE42505X012 GE26482X012 GE26471X012 GE26480X012 GE44902X012 GE26481X012 Key Description 71 Bolt, Steel (2 required) 72 Pipe Plug, 1/4 NPT Steel 316 Stainless steel 74 Blanking Plug, Aluminum 75* O-ring, Metric, Nitrile (NBR) 76 Half Flange, Steel (2 required) 77* Metric O-ring, Nitrile (NBR) 80 Cap Screw, Steel (4 required) 81 Slotted Spring Pin 82 Tube Gasket, Nitrile (NBR) 83 Pitot Tube, Aluminum 90 Nameplate 91 Warning Label 93 Information Label 94 Overlay Label 95 Grommet, Nitrile (NBR) 96 Slip Disk, Stainless steel 100 Wire and Seal 101 Spring Pin, Steel 104 Hub, Zinc-plated steel (2 required) not shown 105 Flange Slip, Zinc-plated steel (2 required) not shown 106 O-ring, Nitrile (NBR) (2 required) not shown 107 Diaphragm Head Limiter, Zinc-plated steel 108 Diaphragm Protector, Zinc-plated steel 109 Pad, (CSB450 Series only) Part Number GE32061X012 1C333528992 1C3335X0012 GE31255X012 GF03442X012 GF01942X012 GF03443X012 GE38176X012 GE32503X012 GE32502X012 GE31988X012 ----------------------------------------GE35358X012 GG05787X012 T14088T0012 GE32724X012 GG02505X012 GG02508X012 GE41121X012 GE28761X012 GE42747X012 T13830T0012 GE26463X022 GE26465X022 GE26466X022 GE26468X022 GE26469X022 GE26470X022 27 CSB400 Series Industrial Regulators Natural Gas Technologies TESCOM Emerson Process Management Regulator Technologies, Inc. Emerson Process Management Regulator Technologies, Inc. Emerson Process Management Tescom Corporation USA - Headquarters McKinney, Texas 75070 USA Tel: +1 800 558 5853 Outside U.S. +1 972 548 3574 USA - Headquarters McKinney, Texas 75070 USA Tel: +1 800 558 5853 Outside U.S. +1 972 548 3574 USA - Headquarters Elk River, Minnesota 55330-2445, USA Tels: +1 763 241 3238 +1 800 447 1250 Asia-Pacific Shanghai 201206, China Tel: +86 21 2892 9000 Asia-Pacific Singapore 128461, Singapore Tel: +65 6770 8337 Europe Selmsdorf 23923, Germany Tel: +49 38823 31 287 Europe Bologna 40013, Italy Tel: +39 051 419 0611 Europe Bologna 40013, Italy Tel: +39 051 419 0611 Chartres 28008, France Tel: +33 2 37 33 47 00 Asia-Pacific Shanghai 201206, China Tel: +86 21 2892 9499 Middle East and Africa Dubai, United Arab Emirates Tel: +011 971 4811 8100 Middle East and Africa Dubai, United Arab Emirates Tel: +011 971 4811 8100 For further information visit www.emersonprocess.com/regulators The distinctive swirl pattern cast into every actuator casing uniquely identifies the regulator as part of the Fisher® brand Commercial Service Regulator family and assures you of the highest-quality engineering, performance, and support traditionally associated with Fisher®, Francel™ and Tartarini™ regulators. Visit www.fishercommercialservice.com to access interactive applications. The Emerson logo is a trademark and service mark of Emerson Electric Co. All other marks are the property of their prospective owners. Fisher is a mark owned by Fisher Controls International LLC, a business of Emerson Process Management. The contents of this publication are presented for informational purposes only, and while every effort has been made to ensure their accuracy, they are not to be construed as warranties or guarantees, express or implied, regarding the products or services described herein or their use or applicability. We reserve the right to modify or improve the designs or specifications of such products at any time without notice. Emerson Process 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. ©Emerson Process Management Regulator Technologies, Inc., 2009, 2014; All Rights Reserved
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