Type S402
Fisher Controls
Instruction Manual
S400 Series Pressure Reducing Regulators
September 1990
Introduction
Fisher regulators must be installed, operated, and maintained in accordance with federal, state, and local codes, rules and regulations, and Fisher 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 serviceman to service the unit. Only a qualified person must install or service the regulator. 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.
Scope of Manual This instruction manual provides installation, maintenance, and parts ordering information for the S400 Series gas service regulators.
Product Description The Type S402 (figure 1) is typically used at homes to reduce intermediate gas distribution pressures down to a reduced pressure range of 4-1/2-inches w.c. to 2-1/2 psig (11.2 to 172 mbar). The Type S402 has an integral high capacity internal relief valve.
Specifications Table 1 list the specifications for S400 Ser ies constructions. The following information is stamped on the regulator at the factory: type number, orifice size, spring range, and date of manufacture.
W5485
Figure 1. Typical S400 Series Gas Regulator
D101466X012
WARNING
US Patent 4,842,013
Form 5266
Type S402 Table 1. Specifications
Body Sizes and End Connection Styles n 3/4 x 3/4, n 3/4 x 1, or n 1 x 1-in. NPT screwed
Orifice Sizes and Color Code n 1/8-inch (blue) n 3/16-inch (green) n 1/4-inch (brown)
Maximum Operating Inlet Pressure(1) 125 psig (8.6 bar)
Temperature Capabilities(1) –20° to 160°F (–29° to 71°C)
Maximum Allowable Emergency Inlet Pressure(1) 175 psig (12.1 bar)
Pressure Registration Internal
Allowable Outlet Pressure (Casing)(1) Emergency: 10 psig (0.69 bar) Maximum Operating to Avoid Internal Part Damage: 5 psig (0.34 bar)
Vent Sizes n 1-inch NPT female (standard) n 3/4-inch NPT female (option)
Outlet Pressure Range 4-1/2 inches wc to 2-1/2 psig (11.2 to 172 mbar) 1. Pressure/temperature limits in this manual, and any applicable code or standard limitations, must not be exceeded.
Approximate Weight 3.75 pounds (1.7 kg)
that could result in personal injury or property damage.
Installation WARNING Personal injury, equipment damage, or leakage due to escaping gas or bursting of pressure-containing parts may result if this regulator is overpressured or is installed where service conditions could exceed the limits given in the table or where conditions exceed any ratings of the downstream 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. All vents should be kept open to permit free flow of air into and out of the regulator. Protect openings against the entrance of rain, snow, ice formation, paint, mud, insects, or any other foreign material that could plug the vent or vent line. Natural gas may discharge to the atmosphere through the relief valve and vent. An obstructed vent which limits air or gas flow can cause abnormally low or high pressure
2
Options 3/4 or 1-inch Type Y602 angle vents
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 materials entering the vent and interfering with proper operation. 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 a safe location outdoors.
Only personnel qualified through training and experience should install, operate, and maintain a regulator. Before installing a S400 Series 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 a good grade of pipe compound to the male threads (being sure not to apply pipe compound to flow path of the pipe) of the pipeline and install the regulator so that flow is in the direction of the arrow cast on the body. Use approved piping procedures when installing the regulator. The spring case vent can be rotated to any position relative to the body.
Type S402 TO EQUIPMEMT
Install the regulator high enough above ground level (at least 18-inches) so that rain splatter cannot freeze in the vent. Whether a protective hood is used or not, do not install the regulator in a location where there can be excessive water accumulation, runoff, or ice formation, such as directly beneath a down spout, gutter, roof line of a building, or in an undrained pit. It is advisable that the downstream piping be the same size as the regulator outlet for a minimum distance of 18-inches (457 mm) or to the meter inlet. S400 Series regulators have a spring case vent which is screened to prevent insects or foreign material from entering. On indoor installations, the vent should be piped to the outside of the building, see figure 2. Remove the retaining ring and screen from the regulator vent connection and connect vent piping from that connection to the outdoors. Vent piping should be of as large a diameter as practicable, be as short as possible, and have a minimum number of bends and elbows. Install a weather and insect resistant vent assembly on the outside end of the pipe, such as Fisher Type Y602 series. The same installation precautions apply to vent assemblies as the integral regulator vents covered above.
VENT ASSEMBLY
VENT LINE
BASEMENT S400 SUPPLY
T20897 A5427-1
Figure 2. Typical Vent Line Installation
On some installations, such as in areas of heavy snowfall or other less than ideal locations, it may be necessary to install the regulator beneath a protective hood to prevent vent freezing. If other protection is provided from the elements, the vent should be pointing or sloping down sufficiently to allow any condensate to drain.
To avoid overpressure, provide appropriate supplemental overpressure protection if needed to ensure that none of the inlet or outlet pressure limits will be exceeded. Regulators should be inspected for damage after any overpressure condition.
Regulators installed with vents in positions other than vertically down require additional vent protection from the elements. Such protection may be with separate hood, shields, or Fisher Y602 Series vents.
Startup CAUTION
Overpressure Protection
In order to avoid an overpressure condition and possible equipment damage, pressure gauges should always be used to monitor pressures during start-up.
WARNING Some type of supplemental overpressure protection in addition to the internal relief may be needed if actual inlet pressure can exceed the outlet pressure rating. Overpressuring any portion of this equipment above the limits given in tables 1 and 2 may cause damage to regulator parts, leaks in the regulator, or personal injury due to bursting of pressure-containing parts or explosion of accumulated gas.
1. Check to see that all downstream equipment is turned off. 2. Slowly open the upstream shutoff valve. 3. Slowly open the downstream shutoff valve. 4. Check all connections for leaks. 5. Light the downstream equipment pilot lights if applicable.
3
Type S402
Adjustment If set pressure adjustment is necessar y, monitor downstream pressure with a gauge during the adjustment procedure. To increase the outlet pressure, the adjusting screw (key 12) must be turned clockwise. This requires removal of the closing cap (key 11). To reduce the outlet pressure setting, turn the adjusting screw counter-clockwise. Do not adjust the spring to produce an outlet pressure setting above the limit stamped on the regulator. The range of allowable pressure settings is stamped on the regulator. If a pressure setting beyond this range is necessary, substitute the appropriate regulator control spring. When changing the spring, also change the range stamped on the regulator to indicate the actual pressure range of the spring in use. Before increasing the setting, refer to table 2. Review the pressure limits for the control spring range being used and be certain that the new pressure setting will not result in an overpressure condition. After the spring adjustment has been completed, replace the closing cap.
Shutdown Installation arrangements may vary, but in any installation it is important that the shutoff 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. Release downstream pressure and be sure the upstream pressure has been exhausted.
Principle of Operation When downstream demand is reduced, the pressure under the diaphragm increases. This pressure overcomes the regulator setting (which is set by a spring). Through the action of the cam stem 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 cam stem assembly downward and the valve disk moves away from the orifice. The shape of the cam provides an approximate 4 to 1 ratio of travel (diaphragm assembly to the cam stem) at lockup and is characterized at higher travels to provide a boost effect.
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Table 2. Outlet Pressure Range Data OUTLET PRESSURE RANGE
CONTROL SPRING CONTROL SPRING PART NUMBER COLOR CODE
Inches w.c./psig
mbar
4.5 to 6 5.5 to 8 7.5 to 9.5 9.5 to 13 13'’ wc to 1.5 psig 1.5 to 2.5 psig
11.2-15 13.7-20 18.7-23.7 23.7-32.5 32.5-103 103-172
T13539 T0012 T13527 T0012 T13563 T0012 T13529 T0012 T13564 T0012 T13536 T0012
Red Yellow Olive Green Gray Blue
The Type S402 regulators include an internal relief valve for overpressure protection. If the downstream pressure exceeds the regulator setting, depending on the relief and main springs used, the relief valve opens and excess gas escapes through the vent in the spring case.
Maintenance WARNING To avoid personal injury or equipment damage from sudden release of pressure or uncontrolled gas, do not attempt any maintenance or disassembly without first isolating the regulator from system pressure and relieving all internal pressure as described in the shutdown procedure. Regulators that have been diassembled for repair must be tested for proper operation before being returned to service. Due to the care Fisher takes in meeting all manufacturing requirements (heat treating, dimensional tolerances, etc.), use only replacement parts manufactured or furnished by Fisher to repair 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 depends upon the severity of service conditions or the requirements of local, state, and federal rules and regulations. A program of periodic regulator inspection should be established. Visually inspect the regulator for: 1. Improper installation. 2. Plugged or frozen vent. 3. Wrong regulator in the system. 4. Internal or external corrosion. 5. Age of the regulator. 6. Any other condition that could cause the uncontrolled escape of gas.
Type S402
INTERNAL RELIEF VALVE
DIAPHRAGM
T80237-D A5428-1
INLET PRESSURE OUTLET PRESSURE
ORIFICE TUBE ASSIMBLY DISK HOLDER ASSEMBLY
DIAPHRAGM/CAM STEM ASSEMBLY
Figure 3. Type S402 Regulator Operational Schematic Failure to establish an inspection program, as outlined above, could result in personal injury or proper ty damage. Make sure the regulator vent, vent assembly, or vent pipe does not become plugged by mud, insects, ice, snow, paint, or etc. The vent screen aids in keeping the vent from becoming plugged, and the screen should be clean and properly installed. Replace any regulators that have had water in their spring case and/or show evidence of external or internal corrosion. Checking for internal corrosion may require complete removal of the adjusting screw and shut down of the gas system. Older regulators are more likely to fail because of worn, damaged or corroded par ts. Periodic repair of the diaphragm assembly, orifice tube assembly, and other parts subject to wear and/or corrosion; or a systematic replacement program should be based on the regulator’s performance, the service area’s environment, installation practices, and historical experience. The following procedures are for complete regulator disassembly and assembly. All pressure must be released from the regulator before the following steps can be performed. While using the maintenance procedures, refer to figure 4 for key number locations.
Note The regulator may remain in the pipeline during maintenance procedures unless the body (key 1) is replaced or removed for repairs.
Control Spring or Diaphragm Assembly Replacement 1. Remove the closing cap (key 11) and turn the adjusting screw (key 12) counterclockwise until all compression is removed from the control spring (key 6). 2. If changing the control spring (key 6) is the only maintenance required, remove and replace the control spring. 3. To replace or reposition the spring case, remove the spring case screws (key 13) and lift off the spring case (key 3). 4. For diaphragm maintenance, remove the diaphragm assembly (key 10a) by tilting it toward the outlet so that the cam stem (key 10b) may be pulled up and out of the orifice tube assembly (key 7).
5
Type S402
5. Reassemble in the reverse order of the above procedures. Place the diaphragm assembly into position in the lower casing (key 2), being sure the cam stem (key 10b) is properly inser ted into the orifice tube assembly (key 7). Note that the diaphragm plate is marked with “Inlet” and “Outlet”. Install the spring case assembly and using a crisscross pattern, tighten the spring case screws (key 13).
Parts List Key
Note When the actuator assembly is separated from the body, do not rotate the cam stem/ diaphragm assembly without removing the spring case screws (key 13). The assembly incorporates an anti-rotation design, any rotational movement will damage the cam stem/diaphragm assembly.
Parts Kit (included are keys 7, 8, 9, and 15) For 1/8-inch orifice tube assembly For 3/16-inch orifice tube assembly For 1/4-inch orifice tube assembly 1
2 3
4
5
6
2. Remove the actuator assembly by tilting it toward the outlet so that the cam stem (key 10b) slides up and out of the orifice tube assembly (key 7). 3. Remove the orifice tube screws (key 9) and then the orifice tube assembly (key 7).
7*
4. Reassemble in the reverse order of the above procedure. Be sure to use a new orifice tube O-ring (key 8), body O-ring (key 15), and O-ring lubricant (key 18).
8*
5. Tighten the body cap screws (key 14) to 80 inch pounds-force of torque. 6. If necessary, refer to the installation and/or the startup and adjustment procedures.
Parts Ordering When corresponding with your Fisher sales office or sales representative about this equipment, always reference the Type number that can be found stamped on the regulator. When ordering replacement parts, reference the key number of each needed part as found in the following parts list. Separate kits containing all recommended spare parts are available. If construction changes are made in the field, be sure that the information on the regulator is also changed to reflect the most recent construction.
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Part No.
S400 Series Regulators (figure 4)
Orifice Tube Assembly Replacement 1. Remove the body screws (key 14) which hold the lower casing (key 2) to the body (key 1).
Description
Body, cast iron 3/4-inch 3/4 x 1-inch 1-inch Lower Casing, alumimum Spring Case Assembly, aluminum/Delrin(1)/ Rynite(1) stainless steel 3/4-inch 1-inch Vent Screen, stainless steel 3/4-inch 1-inch Retaining Ring, plated steel 3/4-inch 1-inch Spring, stainless steel 4-1/2 to 6 inches-w.c. (red) 5-1/2 to 8-inches w.c. (yellow) 7-1/2 to 9-1/2-inches w.c. (olive) 9-1/2 to 13-inches w.c. (green) 13-inches w.c. to 1-1/2 psig (gray) 1-1/2 to 2-1/2 psig (blue) Orifice Assembly, Delrin/nylon/nitrile 1/8-inch (blue) 3/16-inch (green) 1/4-inch (brown) O-ring, Orifice Tube Assy., nitrile
RS400 X00012 RS400 X00022 RS400 X00032
T40457 T40454 T40453 T20890
T0012 T0012 T0012 T0012
T20893 T0022 T20393 T0012 1B6335 38392 T11213 38982
T10669 24152 T11209 25072 T13539 T13527 T13563 T13529 T13564 T13536
T0012 T0012 T0012 T0012 T0012 T0012
T13530 T13530 T13530 1K1499
T0012 T0022 T0032 06992
9
Screw, Orifice Tube Assy., plated steel (2 req’d) 10* Diaphragm/Relief Assembly, Delrin/ nitrile/stainless steel, included are: 10A - Diaphragm Assembly 10B - Cam Stem 10C - Relief Valve Spring 10D - Relief Valve Spring Seat Factory set low relief (blue spring) Factory set medium relief (green spring) Factory set high relief (brown spring) 11 Closing Cap, plastic 12 Adjusting Screw Delrin - 4-1/2 to 13-inches w.c. Zinc - 13-inches w.c. to 2-1/2 psig
T13523 T0012 1B5379 44012
13 14 15* 16
Casing Screw, plated steel (8 req’d) Body Screw, plated steel (3 req’d) O-ring, Body, nitrile Pipe Plug, steel (2 req’d)
T13526 T13531 T13541 1E8231
17
Sealant, Led-Plate(2) No 250, 5 lb. (2 kg) can (not supplied with regulator) Lubricant, Dow Corning 111(3), 14-1/2 oz. (0.4 kg) (not supplied with regulator)
1M5240 06992
18
*Recommended spare part. 1. Trademark of E.I. duPont de Nemours Co. 2. Trademark of Armite Laboratories. 3. Trademark of Dow Corning Corporation.
T13526 T0012
T20892 T0012 T20892 T0022 T20892 T0032 T13524 T0012
T0012 T0012 T0012 28982
1M5283 X0012
Type S402
T80238-D
Figure 4. Type S402 Regulator
7
Type S402
While this information is presented in good faith and believed to be accurate, Fisher Controls does not guarantee satisfactory results from reliance upon such information. Nothing contained herein is to be construed as a warranty or guarantee, express or implied, regarding the performance, merchantability, fitness
Fisher Controls
or any other matter with respect to the products, nor as a recommendation to use any product or process in conflict with any patent. Fisher Controls reserves the right, without notice, to alter or improve the designs or specifications of the products described herein. For Information, contact Fisher Controls: Marshalltown, Iowa 50158 USA Cernay 68700 France
Sao Paulo 05424 Brazil Singapore 2158