THE XHR-300 SERIES
Contents
1. 161 13 J m me Le Se 123 2 A p71 4 S 67 g M33x1 695 5 a L i beget L Coe CD I i p gee z ALTERNATE A A 1a ae a Fe 8mm SENSOR ASSEMBLY VIEW T is ae a Ht J amp n l T 2 ewe i Ly T 4O H i i PARTS LIST ITEM PART NUMBER DESCRIPTION 3 55 3 1 PT EHR 300 001 HEATER CARTRIDGE SHEATH atl m ji 2 PT EHR 300 006 ICORTEM BOX 50 28 l 120 z 3__ PT EHR 300 007 CONNECTION FITTING 4 PT EHR 300 005 230 HEATER CARTRIDGE 230V 5 PT EHR 301 N SS 001 BODY N PORTING 1 4 NPT SOLID DISC 6 PT C 007 015 SEAT RETAINER DETAIL B 7 PT C 001 023 MAIN VALVE SOLID TYPE SCALE 31 8 PT C 205 003 PEEK SEAT 9 OR 0060 10 O RING STD 10 OR 0090 10 O RING STD 11 PT C 006 002 MAIN VALVE COMPRESSION SPRING SECTION A A 12 PT C 018 006 LOWER SPRING REST SCALE 1 5 1 13 PT C 137 12MM SENSOR HOLDER 14 PT C 138 12MM SENSOR 15 OR 0080 20 O RING STD 16 OR 0190 20 O RING STD 17 PT C 092 001 PTFE BACK UP RING 18 PT C 176 PTFE BACK UP RING 19 OR 1071 16 O RING STD 20 PT C 011 003 LOAD SPRING 21 PT C 015 BONNET 22 PT C 020 LOCKNUTS 23 PT C 062 ADJUSTING SCREW 24 PT C 017 UPPER SPRING REST 25 BALL 010 S5 316 10MM BALL BEARING 26 FIT 03 08 BSP BOND SEAL 3 8 BSP BONDED SEAL 27 PT C 105 001 8mm SENSOR HOLDER 28 PT C 106 8mm SENSOR 932 j 29 OR BS008 O RING STD2. PRESSURE TECH THE XHR 300 SERIES Operating and Service Manual Series includes all variants of XHR 300 301 310 311 Issue B September 2015 1 TABLE OF CONTENTS 1 DOSEMI PEON wicegc sieedeesinccedcasiessteaneciateaties a a E sede duanvada E EAA AEE E 3 2 Inst llation and Wiring cecseroiinenirdasnnanioaa a a E E a ai 4 2 1 Enclosure Junction BOX esssesssessssssserrrrrssssseerrrrrresseerrrrerressesrrrrernesssseerrreneeesseeerens 4 2 2 REGUL ATOM es oers a e a AEK NEES E EAEE a NAAKT 4 2 3 MOUNN E resirearini neen a E cleaved A EA 4 2 4 Wiring INSTRUCTIONS ssescaie cat ecteecaaaved a a a a aE E ES 4 3 Op ration angna yas cake sodsetcasaae ddvanecedtstesagacia secede NARAR EELE MRE EARO DEEGEN ACERA 5 3 1 Adjusting the Regulator vice sadisnscsicssinesnderine scrub inddanudcerennvasmiseiecuidunsebiniiebdertawerveentslen 5 3 2 Adjusting the TeMperature ccccsscccecssssececssssececeesseeececsenaececssseeeeceesenaeeeeseaaeeeeses 5 4 Special Conditions for Safe Use siecscssciesesladiensssicdasnssanasadeddansansetacnyaleicd ids satcniduuuslguaseaccameveaaens 6 5 Hazardous Location Usa esa jcocsictacaticsxandtaclsnanes cooceicaddsnabacadaesdaaddasaavaannidaaatistal cases ctidathenaeses 6 By AINA MUN acreana aean a EEEE aaa Eaa Aaa ESA 6 6 Servicing and Maintenance sser nossnesniitieriai siari tintan ia si iar KEREKES E EENKEER KNA ERs 7 6 1 Servicing the AHR SU0 iztsconsededieraiscssaadiuddeaseltadeagledean
3. The maximum supply pressure to the regulator should not exceed the maximum pressure indicated on the regulator label The pipe work and gauges should be sealed with the regulator using PTFE tape Note Pressure Tech do not recommend sealant compound for pipe work connections 2 3 Mounting The whole assembly should be securely fastened to a back plate or panel using the corner holes in the junction box For added support the top of the regulator can be panel mounted around the bonnet using the optional panel nut PT C 024 Note The panel nut alone should not support the regulator i e with the box left freestanding 2 4 Wiring Instructions Ensure that no electrical power is supplied during maintenance installation or servicing this product The power supply to the junction box will require a certified cable gland to be used An external earth point is located on the enclosure CAUTION Refer to accompanying documents There are three cable gland entries on the enclosure each connection is M20 x 1 5 6H Use cable and cable entry devices suitable for 77 C Feed the supply cable through the cable gland not supplied and secure the wires to the terminal block ensuring the Live and Neutral are correctly orientated ref Drawing No PT XHR 300 CIR 002 Note Wiring should be made in accordance with BS7671 Requirements for electrical installations 3 Operation 3 1 Adjusting the Regulator For the XHR 300 series of
4. 60 C 50 100 C 75 140 C 100 180 C v When the correct temperature setting is made screw back the box cover and secure grub screw 4 Special Conditions for Safe Use On non venting regulators with pressure on the outlet the hand wheel shall not be turned anti clockwise in this case pressure shall be reduced by venting downstream of the regulator and turning the hand wheel simultaneously anti clockwise The junction box should never be opened whilst there is a flammable gas atmosphere present or when there is a risk of explosion from the outside environment The user shall ensure that the equipment is appropriately connected to earth The equipment shall not be exposed to vibrations exceeding 5m sec The equipment shall be protected from mechanical impact in service by location or suitable guarding To prevent damage being caused to the regulator which may result in an ignition risk it is the user s responsibility to ensure the equipment is operated in accordance with the manufacturer s instructions and recommendations The equipment has flame paths which differ from those in IEC 60079 1 2014 The manufacturer Pressure Tech shall be contacted for guidance when maintaining the flame paths 5 Hazardous Location Usage The XHR 300 series of regulators have been certified under the ATEX directive 94 9 EC as suitable for use in Group II Category 2 gas environments where the surface temperature does not
5. 8 L T 49 BE G i PR 5 aS A ein l AN c 7 ebspead pas gE Tm r at e 1 ial agosa 2 D __ o Ma S 5 Bs 3 I S av LI ef a E il y g i TE i in a G Lawley i 1 r T T f L 23 55 23 r PARTS LIST 50 28 120 ITEM PART NUMBER DESCRIPTION 1 PT EHR 300 006 CORTEM BOX 2 PT EHR 300 005 230 HEATER CARTRIDGE 230V DETAIL c 3 PT EHR 300 N SS BODY N PORTING 1 4 NPT SCALE 3 1 4 PT C 001 013 MAIN VALVE WITH SQUARE 5 IPT C 002 011 PCTFE SEAT 6 PT C 007 002 SEAT Cv 0 06 7 PT C 006 002 MAIN VALVE COMPRESSION SPRING 8 OR 0050 10 O RING STD 9 BALL 010 SS 316 10MM BALL BEARING 10 PT C 010 002 DIAPHRAGM 11 PT C 017 UPPER SPRING REST 12 PT C 018 002 BOTTOM SPRING REST 13 PT C 019 003 ADJUSTING SCREW 14 PT C 020 LOCKNUTS 15 PT C 015 BONNET 16 FIT CAP 4343092 NAMEPLATE CAP 17 PT C 022 NAMEPLATE 18 PT C 021 SMALL HANDWHEEL E 19 PT C 016 DIAPHRAGM WASHER 5 Y 20 PT C 011 009 LOAD SPRING 21 OR 0210 10 O RING STD 22 FIT 03 08 BSP BOND SEAL 3 8 BSP BONDED SEAL a ENIN OO OES a SOB OA ONN 10 Y3 SECTION A A SCALE 1 5 1 Copyright of Pressure Tech Ltd 6 2 Servicing the XHR 311 Note fig 2 should be used as a reference for the following set of instructions 6 2 1 Accessing the Main Valve Assembly To access the Main Valve Assembly MVA vi vii viii xi xii xiii xiv Secure the regulator body 5 in a vice and using a 47mm
6. Seat Material XHR 300 XHR 310 XHR 301 XHR 311 PCTFE 210 bar 300 bar 210 bar 300 bar PEEK 300 bar 414 bar 300 bar 414 bar Regulator housings are machined from 316 SS stainless steel This ensures maximum protection against the media on which they will be used and the environment in which they will be placed The regulator can be used to regulate any gas or liquid that is compatible with the materials of construction The electronics controlling the heat input to the regulator manifold are installed within a Cortem GUB flameproof enclosure The electrical housing is of Aluminium Alloy construction with mounting lugs to provide a secure connection to the panel The user must ensure that media in contact with the regulator is compatible with these materials The enclosure has three cable entries of size M20 x 1 5 through which the electrical supply can be made ref Wiring Instructions The remaining entries must be sealed with ATEX approved Blanking Plugs supplied The models are fitted with two heat exchanging sheaths each enclosing a 100W cartridge heater within The media passes over the sheath on the inlet to the regulator for pre heat and after the pressure reduction within the regulator then passes the second sheath on the outlet for secondary heat An adjustable pot within the electronics controls the amount of heat output via a burst firing controller within the circuit board Each heater cartridge ha
7. exceed 200 C based on ambient temperature conditions of 40 C to 60 C and is flameproof to EN 60079 0 and EN 60079 1 5 1 Marking The marking of the equipment shall include the following Ex II 2 G T3 Ex db IIC GB T3 Ta 40 C to 60 C 6 Servicing and Maintenance The XHR series comprises of both diaphragm and piston sensed options for pressure control Each can be fitted with one of two options of main valve assembly MVA The combinations of such result in the four models of heated regulator described in section 1 Two examples of which are used in this section with an intent of covering most options available Servicing and maintenance work on the XHR 300 series should only be performed after fully reading and understanding the Operating and Servicing Manual Due to the typical nature of the gases the regulator will be used on the operator should not endanger himself herself or others by working on this regulator without prior knowledge on the Health and Safety concerns relating to handling of technical gases Any uncertainty should be clarified with Pressure Tech before working on the regulator Repairs to the regulator should be performed in accordance with BS EN 60079 17 and BS EN 60079 19 as applicable Pressure Tech Ltd recommends the use of Krytox GPL 205 during servicing IMPORTANT Any failure within the electronics should result in the unit being returned to Pressure Tech for evaluation and repair Prior to comm
8. regulators turning the hand wheel clockwise compresses the spring which in turn opens the main valve and allows the inlet pressure to pass through the orifice until the outlet pressure is equivalent to the loading forces set by the compressed spring 3 2 Adjusting the Temperature An adjustable potentiometer on the surface of the PCB controls the amount of heat output via a burst firing controller The cartridge is fitted with a type J sensor which monitors the temperature to the unit Should this sensor fail or the wiring becomes disconnected the PCB will not apply power to the heater cartridge The adjustable pot is factory pre set to its midpoint but may need adjusting to increase or decrease the heat requirements to the regulator This adjustment must be made when there is no risk of explosion from the outside environment To adjust the setting i Loosen the M4 grub screw and open the cover of the junction box ii Change the heater output by turning the pot on the circuit board clockwise to increase and anti clockwise to decrease iii Due to the response time of heat transfer and thermal coefficients the control system will require about 5 to 10 minutes to stabilise Therefore it is recommended that the heater is switched on before allowing the media to pass through the regulator iv The following percentage turns around the potentiometer equate to an approximate temperature value for the heater cartridges 10 20 C 25
9. 8mm sensor 28 Place the Sensor 14 into the Sensor Holder 13 and position the assembly into the Regulator Body 5 Replace the O Ring 19 on the Lower Spring Rest 12 and position into the Sensor Holder 13 Place the Load Spring 20 Upper Spring Rest 24 and 10mm Ball Bearing 25 to the assembly and screw the bonnet 21 into position Finally tighten the bonnet to 90 Nm with a 47mm open ended torque wrench To ensure that the main valve assembly has been correctly and effectively installed it may be required to perform the appropriate seat leak test as per ANSI FCI 70 2 11 6 2 3 Figure 2 Sectional View of the XHR 311
10. IAS A a EN i Na l 30 PT C 104 PTFE BACK UP RING oe CY 18 15 5X5 DOE 26 Z Sy DN PI ALTERNATE PARTS Copyright of Pressure Tech Ltd 12 7 Technical Data Vibration Limits Electronics Heater Fluid Media Max Inlet Pressure Outlet Pressure Range Operating Temperature Materials Flow Capacity Cv Leakage 8 Warranty Statement Can be used where vibration limits do not exceed 5m s 115Vac or 230Vac 15 at 50Hz or 60Hz 3 Amps 1 5VA Supply Power 200W Power Load 2 x 100W Proportional type J thermocouple with automatic CJC Temp control range 0 180 C Temp control accuracy 1 Temp repeatability 0 5 All gases and liquids compatible with materials of construction XHR 300 301 300 bar PEEK or 210 bar PCTFE XHR 310 311 414 bar PEEK or 300 bar PCTFE 0 35 bar Diaphragm 0 150 bar Piston 40 C to 60 C Body and Trim 316 SS Diaphragm Inconel X750 Seat PCTFE or PEEK Enlosure Epoxy coated Aluminium 0 03 0 06 0 1 0 2 Liquid Zero drops of water at max inlet Gas Bubble tight Pressure Tech Ltd guarantee all products correspond with their specification at the time of delivery and with exception to wear and tear wilful damage negligence and abnormal working conditions will be free from defects for a period of 12 months from date of delivery 13
11. adicoehaadseiealeusdeeungdencoadacentatied 8 6 1 1 Accessing the Main Valve Assembly cccccssssececsssseeeeeeseeeeeeessnaeeeeees 8 6 1 2 Adjusting the Set Point sssnsssennnsssssseeereesrssssesrreerrssssoseeerersssssseerreenesse 9 6 1 3 Figure 1 Sectional View of the XHR 300 ssssssssssssssssrrsserrersssrrsssrsen 10 6 2 Servi ing th XHR 3L dct sine caieceaten cnn tE EEr K EE EEEN EREE tad ERRETA ORNE 11 6 2 1 Accessing the Main Valve Assembly ccccseesessececeeeeeseesesseaeeeeeesenees 11 6 2 3 Figure 2 Sectional View of the XHR 311 eee esseeceeeseeeeeeeaeeeeees 12 Je technical AU Aig cain ceeonsasnig vussicgencisanstanalaeimeansnagteavau deshensuanequisntaiteanintaee cues EEEa aa UAE Eaa 13 8 Warranty Statement sii issn eisean EE E A iat E Ea 13 1 Description The XHR 300 series comprises of the following models XHR 300 Dual heated diaphragm sensed pressure regulator standard option XHR 310 Dual heated diaphragm sensed pressure regulator disk seat option XHR 301 Dual heated piston sensed regulator standard option XHR 311 Dual heated piston sensed regulator disk seat option The maximum working pressures for each model are defined in the table below and are determined both by the model and the seat material The maximum outlet control range of the diaphragm sensed and piston sensed options are 0 35 bar and 0 150 bar respectively Model
12. e sealing face against the tip of the valve To ensure positive sealing it is recommended that a new Diaphragm 10 is placed centrally into Regulator Body 3 ensuring that the outermost convolutions are facing towards the Bonnet 15 Replace the 21x1 mm O ring 21 on the Lower Spring Rest 12 insert into the Diaphragm Washer 19 and place on top of the Diaphragm 10 Place the Load Spring 20 Upper Spring Rest 11 and 10mm Ball Bearing 9 to the assembly Screw the Bonnet 15 onto the assembly and using a torque wrench with a 47mm open ended attachment tighten to 160Nm It is recommended that all parts in the repair kits are used Any defect parts removed during the service should be disposed of Parts should be kept clean in line with media requirements Following re assembly of the regulator pressure tests should be made to both the inlet and outlet side of the regulator to ensure there is no internal or external leakage across the regulator To ensure that the main valve assembly has been correctly and effectively installed it may be required to perform the appropriate seat leak test as per ANSI FCI 70 2 Should any assistance be required during a service please do not hesitate to contact the office 8 NOTE It is not recommended or necessary to remove the Hand Wheel 18 during service as this will affect the set point of the regulator Should it be required to adjust the set point please follow the instructions b
13. elow 6 1 2 Adjusting the Set Point To adjust the set point vi vii viii xi xii xiii XIV XV xvi Remove the Nameplate 17 and Cap 16 from the Hand Wheel 18 and loosen the Lock Nut 14 such that the Hand Wheel is able to spin freely on the Adjusting Screw 13 Connect the correct fittings to the Inlet and Outlet ports of the regulator Ensure that any gauge ports are plugged or that the correct gauge is fitted With the Regulator Body 3 securely fixed to the Heater Sheaths 5 apply the Maximum Working Pressure MWP to the Inlet of the regulator Connect the Outlet port to a calibrated pressure test gauge appropriate to the required set pressure As the regulator is non venting ensure that a ball needle valve is fitted to allow pressure to be relieved downstream of the regulator Using a slotted screwdriver turn the Adjusting Screw 13 clockwise until the desired set point has been reached Ensure repeatability by allowing flow through the regulator using the ball needle valve With the outlet pressure set screw the first Lock Nut 14 to the base of the Adjusting Screw 13 against the Bonnet 15 Position the Hand Wheel 18 onto the Lock Nut 14 Ensure that the Lock Nut and Hand Wheel become engaged Fasten the second Lock Nut 14 against the Hand Wheel 18 and gently begin to tighten using a 13mm socket until it begins to secure itself At this point whilst holding the Hand Wheel 18 cont
14. encing service please ensure that The equipment has been de pressurised The load spring has been de compressed by turning the hand wheel adjusting screw fully anti clockwise Applications involving toxic flammable or corrosive media have been fully purged 6 1 Servicing the XHR 300 Note fig 1 should be used as a reference for the following set of instructions 6 1 1 Accessing the Main Valve Assembly To access the Main Valve Assembly MVA vi vii viii xi Secure the regulator body 3 in a vice and loosen the Bonnet 15 from the regulator body using a 47mm open ended torque wrench or equivalent ensuring that the Hand Wheel 3 is fully wound anti clock wise NOTE Where this is not possible it may be necessary to secure the enclosure If the lid of the enclosure is to be removed it is important to ensure that an explosive atmosphere is not present before doing so Remove the Upper Spring Rest 11 10mm Ball Bearing 9 Load Spring 20 Diaphragm Washer 19 Lower Spring Rest 12 and Diaphragm 10 from the assembly The Seat Nut 6 can then be removed using a 12mm socket Remove the Main Valve 4 5 and Main Valve Spring 7 from the assembly Visually inspect the seat nut 6 and soft seat 5 for damage under a microscope Replace the Main Valve Spring 7 and Main Valve 4 5 and place into the Regulator Body 3 Replace Seat Nut 6 fitted with new 5x1 mm O ring 8 taking care not to damage th
15. inue to tighten whilst simultaneously turning slightly anti clockwise to prevent it from locking against the Bonnet 15 Ensure that the Lock Nut 14 is sufficiently tightened taking care not to adjust the set point Turning of the Hand Wheel 18 should now also turn the Adjusting Screw 13 which will control the pressure Turn the Hand Wheel 18 clockwise until it reaches its set point and check to make sure that the desired outlet pressure is correct If the set point is not correct repeat steps v to xiii Reduce the pressure downstream by venting the pressure through ball needle valve and then turning the Hand Wheel 18 anti clockwise until the regulator closes The Cap 16 and Nameplate 17 can now be placed into the Hand Wheel 18 Ensure that the information stated on the Nameplate 17 is in accordance with the set pressure of the regulator 10 6 1 3 Figure 1 Sectional View of the XHR 300 7 172 6 m j r 4 i 111 1 _ L sit 65 T M33x1 697 z
16. open ended torque wrench or equivalent loosen and remove the Bonnet 21 from the Regulator Body Where this is not possible it may be necessary to secure the enclosure If the lid of the enclosure is to be removed it is important to ensure that an explosive atmosphere is not present before doing so Remove the Upper Spring Rest 24 10mm Ball Bearing 25 and Load Spring 20 from the assembly Lift the Lower Spring Rest 11 out of the assembly and then remove the sensor assembly comprising of Sensor 14 and Sensor Holder 13 from the Body 5 Using a 12mm socket remove the Seat Retainer 6 and O Ring 10 from the Regulator Body 5 Grip the main valve 7 needle nose pliers may be useful and lift out of the Body 5 which will in turn bring out the Soft Seat Disk 8 and O Ring 9 The Main Valve Spring 11 can then be removed and replaced if required Place new Main Valve 7 on to the Main valve Spring 11 The Soft Seat Disk 8 can then be positioned into the Body 5 ensuring that the O Ring groove is facing outwards then carefully position the O Ring 9 into place care should be taken when positioning the seat disk over the main valve Replace the O Ring 10 on the Seat Retainer 6 and screw the Seat Retainer into the Body 5 and tighten with a 12mm socket Replace the O Ring 16 and Back Up ring 18 on the Sensor Holder 137 and replace the O Ring 15 and Back Up Rings 17 on the Sensor 19 29 and 30 for smaller
17. s an independent switch which can be used to isolate the power to either channel The cartridges are wired independently and fitted with type J sensors which monitor the temperature to each unit separately and keep the regulator within its T3 temperature class The XHR 300 series should not be exposed to any vibrations or impacts and should be securely fastened in accordance to the Installation Instructions below and should be limited to the vibration limits stated in the Section 7 Technical Data Any pressure gauges used on the regulator must be designed as Full Safety Pattern to BS1780 ANSI B40 1 and EN837 1 2 Installation and Wiring Before installation check the nameplate where applicable model number reference and regulator label affixed to the enclosure and ensure that the voltage type and pressure range complies with the installation requirements Note Installation of the XHR 300 series of heated regulators should be in accordance with EN 60079 14 2 1 Enclosure Junction Box The enclosure is of series GUB manufactured by Cortem The enclosure is marked Ex Il 2 Gb Ex d IIC Gb equipment group II cat 2 in accordance with certificate CESI 01 ATEX 034U and IECEx CES 14 0012U The enclosure has an ingress protection level IP 66 2 2 Regulator The pressure regulator is supplied with 1 4 NPT connections for both the inlet and outlet ports Connections for gauges are available and will be 1 4 NPT as standard
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