S208~S209 Instruction Manual

Instruction Manual Form 5412

Types S208 and S209

Type S208 and S209 Gas Regulators With Safety Shutoff WARNING Fisher regulators must be installed, operated and maintained in accordance with federal, state and local codes, rules and regulations, and Fisher instructions. For LP-gas service, an approved regulator (such as one listed by U.L.) should be used. The installation, in most states, must comply with NFPA standards.

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 serviceman to service the unit. Only a qualified person must install or service the regulator.

Introduction Introduction Scope of the Manual This instruction manual provides instructions and a parts list for Types S208, S208P, S208H, S209, S209P and S209H gas service regulators with Type VSX safety shutoff module.

Description Types S208 and S209 regulators are typically installed on industrial and commercial applications. Types S208 and S209 are similar in design to the Types S201 and S202 regulators. Type S209 units contain an internal relief valve. The Types S208 and S209 include the Type VSX module. The Type VSX is a safety shutoff valve that provides overpressure or overpressure and underpressure protection by com-

Fisher, Fisher-Rosemount, and Managing The Process Better are marks owned by Fisher Controls International, Inc. or Fisher-Rosemount Systems, Inc. All other marks are the property of their respective owners.

EFisher Controls International, Inc. 1996; All Rights Reserved, 7/96

W6698 / IL

Figure 1. Typical S208 Series Gas Regulator With Type VSX Module

pletely shutting off the flow of gas to the downstream system. The safety shutoff module’s actions are independent of the Type S208 and S209 regulators and of variations to inlet pressure. The Type VSX has internal registration, on the P versions of the Type S208 or S209 a downstream sensing line is required.

Specifications Table 1 lists the specifications for the regulators. The following information is stamped on the regulator nameplate at the factory: type number, manufacture date, spring range, orifice size, Type VSX high and low trip pressures, maximum inlet pressure, maximum outlet operating pressure and outlet pressure that may damage regulator parts.

Types S208 and S209 Table 1. Specifications

Body Sizes And End Connection Styles(1) J 1-1/4 X 1-1/4-inch NPT screwed, J 1-1/2 X 1-1/2-inch NPT screwed,J 1-1/2 X 2-inch NPT screwed, J 2 X 2-inch NPT screwed, J 2-inch Class 125A flat-face flanged, J 2-inch class 250A raised-face flanged

Material Temperature Capabilities(2) With standard materials: -20 to 150_F (-29 to 66_C) With optional fluoroelastomer materials: 0 to 200_F (-18 to 93_C): upper limit due to temperature limitations of nylon flappers VSX module: -20 to 140_F (-29 to 60_C)

Maximum Inlet Pressure (Body Rating)(2) Internal Relief Performance

150 psig (10 bar) Outlet Pressure Range 2 inches wc to 10 psig (4.9 mbar to 0.69 bar) Maximum Inlet Pressure to Obtain Optimum Performance See table 2 Maximum Outlet Pressure (Casing)(2)

Internal relief valve opens at 8 inches wc to 1.1 psig (20 to 75.8 millibar) above outlet setting, depending on control spring Minimum and Maximum Trip Pressure Ranges for Type VSX See table 5 Type VSX Sensing Line Connection 1/4-inch NPT (required on the P version only)

15 Psig (1.0 Bar)

Approximate Weight

Orifice Diameters 1/4, 3/8, 1/2, 3/4, 1 and 1-3/16-inches

30 pounds (13.6 kg)

1. DIN (or other) end connections, or end connections threaded to various national or international thread standards can usually be supplied.

2. The pressure/temperature limits in this bulletin and any applicable standard or code limitation should not be exceeded.

Installation 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 on the regulator nameplate. Regulator installations 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 debris that may plug the vent or vent line. On outdoor installations, point the spring case vent downward to allow condensate to drain. This minimizes the possibility of freezing and of water or other foreign material from entering the vent and interfering with proper operation.

2

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.

If the regulator or VSX is exposed to an overpressure condition, it should be inspected for any damage that may have occurred. Operation below these limits does not preclude the possibility of damage from external sources or from debris in the pipeline.

Before installing the regulator, check for damage which might have occurred in shipment. Also check for dirt or foreign matter that may have accumulated in the regulator body or in the pipeline. Apply pipe compound to the male 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 18, not shown) in order to rotate the diaphragm casing assembly.

Do not install the regulator in a location where there can be excessive water accumulation, such as directly beneath a down spout.

Types S208 and S209 Table 2. Maximum Inlet Pressure ORIFICE SIZE Inches

mm

1/4

INLET PRESSURE SETTING Optimum

Maximum

Psig

Bar

Psig

Bar

6.3

125

8.6

125

8.6

3/8

9.5

100

6.9

125

8.6

1/2

12.7

60

4.1

100

6.9

3/4

19.0

25

1.7

60

4.1

1

25.4

13

0.9

25

1.7

1-3/16

30.2

5

0.3

13

0.9

Table 3. Maximum Outlet Pressure Setting DIAPHRAGM HEAD

MAXIMUM OUTLET SETTING

Light

30-inch w.c.

Heavy

5 psig

The Type S208 and S209 regulators have 1-inch NPT screened vent openings in the spring case. If necessary to vent escaping gas away from the regulator, install a remote vent line in the spring case tapping.

Vent piping should be as short and direct as possible with a minimum number of bends and elbows. The remote vent line should have the largest practical diameter. Vent piping on regulators with internal relief (Type S209) must be large enough to vent all relief valve discharge to atmosphere without excessive back pressure and resulting excessive pressure in the regulator. The Type VSX has a 1/4-inch NPT vent opening.

Periodically check all vent openings to be sure that they are not plugged.

Maximum outlet pressure settings are shown in table 3. Outlet pressure more than 2 psi (light diaphragm head) or 3 psi (heavy diaphragm head) above the set point may damage internal parts such as the diaphragm head and valve disk. The maximum emergency (casing) outlet pressure is 15 psig.

If the downstream system is not pressurized by another regulator or manual bypass valve, use the following procedure to start up the regulator.

1. Check to see that all appliances are turned off.

2. The Type VSX is shipped in the tripped position and will need to be reset. If the VSX is a high trip only it can be reset before starting the regulator, if the VSX is a high and low trip the regulator will need to be started and the downstream system pressurized before the VSX can be reset. See the section for Type VSX reset.

3. Slowly open the upstream block valve.

4. Check all connections for leaks.

5. Light appliance pilots.

Adjustment The range of allowable pressure settings is stamped on the nameplate. If the required setting is not within this range, substitute the correct spring (as shown in table 4). If the spring is changed, be sure to change the nameplate to indicate the new pressure range. If the regulator spring is changed the Type VSX must be adjusted accordingly.

A pressure gauge should always be used to monitor downstream pressure while adjustments are being made.

1. Remove the closing cap (key 4, figure 6) 2. To increase the outlet setting, turn the adjusting screw (key 3, figure 6) clockwise. To decrease the outlet setting, turn the adjusting screw counterclockwise.

3. Replace the closing cap.

Startup Startup

Shutdown CAUTION

Pressure gauges should always be used to monitor downstream pressure during startup. Procedures used in putting this regulator into operation must be planned accordingly if the downstream system is pressurized by another regulator or by a manual bypass.

Installation arrangements may vary, but in any installation it is important that the valves be opened or closed slowly and that the outlet pressure be vented before venting inlet pressure to prevent damage caused by reverse pressurization of the regulator. The steps below apply to the typical installation as indicated.

1. Slowly close the upstream shutoff valve.

2. Slowly open vent valves up and downstream of the regulator.

3

Types S208 and S209 Table 4. Outlet Pressure Range Data CONTROL SPRING TYPE NUMBER

S208, S209

S208H, S209H

S208P1, P2, P3, S209P1, P2, P3

OUTLET PRESSURE RANGE

Part Number

Free length Inches (cm)

3.5 to 6.5 in. w.c. (9 to 16 mbar) 5 to 9 in. w.c. (13 to 23 mbar) 8.5 to 18 min. w.c. (21 to 45 mbar) 14 to 30 in. w.c. (35 to 75 mbar)

1D892627022 1D892727012 1D893227032 1D893327032

7-1/2 (19) 7-7/8 (20) 7-1/2 (19) 7-1/4 (18.4)

.120 (.030) .130 (.033) .156 (.039) .182 (.046)

Red Black Gray Dk. green

1 to 2 psig (70 to 140 mbar) 1-1/2 to 3-1/4 psig (105 to 225 mbar) 2 to 5 psig (140 to 345 mbar) 3.5 to 6.5 in. w.c. (9 to 16 mbar) 5 to 9 in. w.c. (13 to 23 mbar) 8.5 to 18 min. w.c. (21 to 45 mbar) 14 to 30 in. w.c. (35 to 75 mbar) 1 to 2 psig (70 to 140 mbar) 1-1/2 to 3-1/4 psig (105 to 225 mbar)

1H975827032 1H975927032 1P615427142 1D892627022 1D892727012 1D893227032 1D893327032 1H975827032 1H975927032

7-3/8 (18.7) 7-3/8 (18.7) 6-1/2 (16.5) 7-1/2 (19) 7-7/8 (20) 7-1/2 (19) 7-1/4 (18.4) 7-3/8 (18.7) 7-3/8 (18.7)

.225 (.057) .250 (.063) .283 (.072) .120 (.030) .130 (.033) .156 (.039) .182 (.046) .225 (.057) .250 (.063)

Dk. blue Orange Yellow Red Black Gray Dk. green Dk. blue Orange

Principle of Operation Refer to figure 2. When the downstream demand decreases, the pressure under the diaphragm increases.

This pressure overcomes the regulator setting (which is set by a spring). Through the action of the pusher post assembly, the valve disk moves closer to the orifice and reduces gas flow. If demand downstream increases, pressure under the diaphragm decreases.

Spring force pushes the pusher post assembly down-

Wire Diameter Inches (cm)

Color Code

ward, the valve disk moves away from the orifice, and the gas flow increases.

Type S209 regulators include a limited capacity internal relief valve for overpressure protection. If the downstream pressure exceeds the regulator setting by 8 inches wc to 2 psig (17.5 mbar to 0.14 bar), depending on the main spring used, the relief valve opens and excess gas is vented through the stabilizer vent in the upper spring case.

RELIEF VALVE SPRING VALVE DISK DIAPHRAGM

PUSHER POST VSX MODULE B2507

ORIFICE INLET PRESSURE

OUTLET PRESSURE

Figure 2. Type S209 Regulator Operational Schematic

4

Types S208 and S209 Table 5. Type VSX High and Low Trip Pressure Ranges MINIMUM TO MAXIMUM TRIP PRESSURE INCHES OF WATER COLUMN OR PSIG (mbar)

PRESSURE RANGES

High Pressure Set Point Ranges

Low Pressure Set Point Ranges

SPRING PART NUMBER

14 to 20 in. w.c. (34 to 50 mbar)

T13751T0012

20 in. w.c. to 1.3 psig (50 to 90 mbar)

T13752T0012

1.3 to 2.4 psig (90 to 165 mbar)

T13753T0012

2.2 to 3.3 psig (150 to 225 mbar)

T13754T0012

3.3 to 5.4 psig (225 to 370 mbar)

T13755T0012

4.4 to 8.0 psig (300 to 550 mbar)

T13756T0012

2 to 9 in. w.c. (6 to 23 mbar)

T13757T0012

4 to 24 in. w.c. (10 to 60 mbar)

T13760T0012

19 in. w.c. to 2.3 psig (48 to 160 mbar)

T13761T0012

24 in. w.c. to 4.6 psig (60 to 320 mbar)

T13762T0012

Type VSX The safety shutoff disk of the Type VSX is held in the open position (reset position) by a small ball holding the disk stem. In the open (or reset) position the travel indicator is visible through the clear reset button. If the pressure below the diaphragm increases (or decreases) reaching the Type VSX setpoint, the diaphragm will travel upwards (or downwards) operating a lever that in turn releases the ball.

Once the ball is released, the spring force on the stem will push the stem and disk to the closed position against the seat, shutting off all gas flow. In the closed position, the travel indicator is no longer visible through the reset button. The manual reset has an internal bypass to equalize the reset pressure on either side of the shutoff disk.

Maintenance 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 �Shutdown.�

Regulators that have been disassembled for repair must be tested for proper operation before being returned to service. Only parts manufactured by Fisher should be used for repairing Fisher regulators. Relight pilot lights according to normal startup procedures.

Due to normal wear or damage that may occur from external sources, this regulator should be inspected and maintained periodically. The frequency of inspection and replacement of parts de-

pends upon the severity of service conditions or the requirements of local, state and federal rules and regulations.

The key numbers in the following sections refer to figure 6.

Disassembly to Replace Diaphragm 1. Remove the closing cap (key 4). Turn the adjusting screw (key 3) counterclockwise to remove spring compression.

2. Remove the adjusting screw (key 3) and spring (key 2).

3. Remove the hex nuts (key 15) and cap screws (key 14). Separate the upper spring case (key 1) from the lower casing assembly (key 9).

Note If disassembling a Type S209 or S209H regulator, lift the upper spring case straight up in order to avoid hitting the stem.

4. Slide the diaphragm and diaphragm head assembly (key 7) away from the body (key 21) to unhook the pusher post (key 8) from the lever (key 10). Lift off the diaphragm and diaphragm head assembly.

5. Unscrew the cap screw or stem (key 24) that fastens the lower spring seat (key 6) to the pusher post and separate the lower spring seat, diaphragm and diaphragm head assembly, and pusher post. For Type S209 regulators, the relief valve spring (key 25) and relief restriction (key 94) will also have to be removed.

6. Reassemble the spring case unit in the reverse order of the above steps. Before tightening the cap screw or stem into the pusher post, place the looselyassembled diaphragm assembly into position in the lower casing, being sure that the pusher post is hooked into the lever. Rotate the diaphragm so that the diaphragm and lower casing holes are aligned.

Tighten the screw or stem.

5

Types S208 and S209 CAUTION Before tightening the spring case cap screws (key 14) in step 6, replace the spring (key 2) and adjusting screw (key 3). Turn the adjusting screw to about mid-position. This will stretch the oversized diaphragm to ensure slack in the assembled diaphragm. The slack created by this method is necessary for good regulation. Be sure the diaphragm does not fold over at the flange when reassembling.

Disassembly to Replace Valve Disk and Orifice 1. Remove the bolts (key 18) that hold the lower spring casing (key 9) to the body (key 21). Separate the lower spring casing from the body.

2. Check the body O-ring (key 19) for wear.

Note Replace used O-rings with new O-rings.

Used or damaged O-rings can cause leaks.

3. Examine the valve disk (key 16) for nicks, cuts and other damage. Unscrew the disk holder assembly from the valve stem assembly (key 13) and replace it with a new part if necessary.

4. If the seating edge of the orifice is nicked or rough, remove the orifice from the body. Change to a new part when reassembling the regulator. If the orifice is being replaced with a different size orifice, change the nameplate to state the new size and maximum inlet pressure.

5. Reassemble the regulator in the reverse order of the above steps.

Type VSX Installation, Maintenance and Reset Installation Place new O-rings (keys 2 and 3, figure 7) on the VSX module and slide the module into the Type S208 or S209 body (key 21, figure 6) Secure the Type VSX to the Type S208 or S209 body with four set screws.

The VSX module may be oriented in any direction.

Maintenance The VSX module (key 1, figure 6) is designed to be removed as a unit from the body (key 21, figure 6) and

6

be replaced as a complete unit. The high and low pressure springs may be adjusted or replaced without removing the module from the main body.

The only replaceable parts in the Type VSX module are the O-rings (keys 2 and 3, figure 6) and the high and low pressure set point springs (keys 7 and 8, figure 6).

Reset 1. Push in reset button and rotate it slightly to open equalizing bypass.

2. Turn the button 180_ and pull out on button until it stops. The Type VSX plug is reset.

3. Push in on the button while turning it 180_ until it rests behind the tab. Release the button so it is in contact with the tab.

4. If the travel indicator is visible in the button the Type VSX is now reset.

5. The high and low pressure Type VSX can only be reset if the outlet pressure is between maximum and minimum set points.

Parts Parts Ordering 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 Fisher representative regarding replacement parts or technical assistance. If construction changes are made in the field, be sure that the nameplate is also changed to reflect the most recent construction When ordering a replacement part, be sure to include the complete eleven-character part number from the following parts list

Parts Parts List Key 1

Description Spring Case, aluminum

2 3 4

Spring, steel Adjusting Screw, aluminum Closing Cap, aluminum

5* 6 7* 8

Closing Cap Gasket, neoprene Lower Spring Seat, aluminum Diaphragm, nitrile, steel Pusher Post, aluminum For Type S208 For Type S209

*Recommended spare parts

Part Number 4L142308032 1J718699022 see table 4 1L928608012 1L928308012 1N446206992 1L928708012

2H980608012 2H975208012

Types S208 and S209

T80386-A B2496 / IL

T80388-A B2495 / IL

Figure 4. Type P1, P2, and P3 Stem Adaptor Key 9

Description Lower Casing Assembly, aluminum

10 11

Figure 5. Relief Vent Key 24

Lever, steel Pin, 303 stainless steel

Part Number 1H9751X0012 1H9751X0022 1H974028992 1H972935032

12 13 14 15

Machine Screw, steel (2 req’d) Valve Stem Assembly Cap Screw, steel (12 req’d) Hex Nut, steel (12 req’d)

1B420428982 1H9748000A2 1B136324052 1A309324122

25

16* 18 19* 20

Disk Holder Assembly Cap Screw, not shown, steel cd pl (2 req’d) O-ring, nitrile Orifice, aluminum 1/4-inch diameter 3/8-inch diameter 1/2-inch diameter 3/4-inch diameter 1-inch diameter 1-3/16-inch diameter

1P7349000A2 1H974724052 T12587T0012

21

Body, assembly 1-1/4-inch NPT 1-1/2-inch NPT 1-1/2 X 2-inch NPT 2-inch NPT 2-inch, 125 lb. flanged 2-inch, 250 lb. flanged

*Recommended spare parts

1U981009022 1U981109022 1U981209022 1U981309022 1U981409022 1U980809022

T13746T0012 T13746T0022 T13746T0032 T13746T0042 T13746T0052 T13746T0062

32

Description Cap Screw steel, zinc pl For Type S208 For Type S208H Stem, steel, zinc pl For Type S209, S209H Relief Valve Spring, steel, cd pl For Type S209, S209H, standard Nameplate, aluminum

55 56 57 58

Flapper Stem, 302 stainless steel Lower Flapper, nylon Upper Flapper, nylon Orifice, 302 stainless steel

1H976335022 1H976406992 1H976506992 1H976636012

59 60 61 62

Self-tapping Screw, steel (3 req’d) Spring, 302 stainless steel (2 req’d) Screen, Monel Snap Ring, 302 stainless steel

1H976728982 1H976837022 1E564843122 1E564937022

63 64 65 66

Retaining Ring, O-ring O-ring Wiper Ring

1L142838992 1L142906992 1E216306992 1L143006992

67 94 101

Stem Adaptor Relief Restriction Lubricant

1L143109012 1U983936012 1M523906992

24

Part Number 1H975424272 1A667824052 1H969224272 1H976027012 ---

7

Types S208 and S209

B2508 / IL

Figure 6. Typical Type S208/S209Regulator (Type S209 is shown)

Type VSX Module Key 1

2 3 4 5 6 7 8

Description VSX Module High and low pressure shutoff High pressure shutoff only Upper O-ring Lower O-ring Set Screw, (4 req’d)

Part Number

Ball Vent Assembly Control Spring, zink plated steel High pressure Control Spring, zink plated steel Low pressure

T13767T0012 27A5516X012

T13750T0012 T13750T0022 T13769T0012 T13770T0012 1C629828992

See table 5 See table 5

T80390-A B2517 / IL

Figure 7. Type VSX Module

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.

For information, contact Fisher Controls: Marshalltown, Iowa 50158 USA Cernay 68700 France Sao Paulo 05424 Brazil Singapore 0512 8

Printed in U.S.A.