Emerson HSRL Series Second-Stage Regulator Instruction Manual
Contents
1. This Instruction Manual covers Installation and Maintenance for the R600 and HSRL Series regulators which includes first stage second stage two psig service integral two stage and integral two psig service regulators www fisherregulators com TYPE R622 TYPE R642 TYPE HSRL Figure 1 Types R622 R642 and HSRL Series Regulators used on LP Gas vapor service applications They are not to be used on liquid service Description First Stage and 2 psig 0 14 bar Service Regulators The Types R622H R622E and R652E regulators are designed for high pressure pounds per square inch vapor service These regulators have high capacity internal relief valves When used on first stage service the Type R622H regulator reduces container pressure to 10 psig 0 69 bar for a second stage regulator On final stage service the y KS gt aF EMERSON D450133T012 R600 and HSRL Series LP Gas Regulators Specifications Specifications section Tables 1 and 2 list the specifications for these regulators Contact the factory if the regulator is to be used on any service other than LP Gas natural gas or air The following information is located on the spring case Type number orifice size spring range and date of manufacture Pressure Taps Size Restriction R600 Series 1 8 NPT 54 0 055 inch 1 40 mm Drill on outlet and inlet HSRL Series None Orifice Sizes R600 Series Except R632A and R632E Series 7 32 in2. STAGE REGULATOR KR A 7 A T14445 A2 Figure 4 Basement Installation R600 and HSRL Series LP Gas Regulators GRADE GROUND DOWNWARD AND SLOPING AWAY FROM HOUSING DOME THIS PREVENTS WATER COLLECTING AND RUNNING INTO OR STANDING AROUND HOUSING DOME END OF REGULATOR VENT TUBE LOCATED AT TOP INSIDE OF HOUSING DOME COVER 2 INCHES 5 1 cm MINIMUM REGULATOR ADJUSTMENT CLOSURE CAP MUST BE TIGHT WATER MARK LEFT IN HOUSING DOME AT LEVEL ABOVE REGULATOR VENT OR END OF VENT TUBE REQUIRES REPLACEMENT OF REGULATOR INSTALL REGULATOR PROPERLY T14448 A2 Figure 5 Underground Installation Meter Installations Type R642 regulators have an angle body that makes it easy to install on to a gas meter instead of piping leading directly into a building Meter and Type R642 with Vent over Regulator Inlet Install the regulator per instructions given in the previous section Installation Location Meter and Type R642 with Vent over the Regulator Outlet and Installed over the Top of the Meter This installation orientation will put the Type R642 regulator vent in a vertical down position but very close to the top of the gas meter The regulator vent may become blocked during a freezing rain storm or heavy snows Therefore some type of protective cover should be installed over the regulator and meter or vent piping should be installed so that the vent remains open Meter and Type R642 Regulator
3. as directly beneath a down spout gutter or roof line of building Even a protective hood may not provide adequate protection in these instances e Install the regulator so that any gas discharge through the vent or vent assembly is over 3 feet 0 91 meter horizontally from any building opening below the level of discharge e Install the regulator high enough above ground level at least 18 inches 45 cm so that rain splatter cannot freeze in the vent 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 Horizontally Installed Regulators Horizontally mounted regulators such as found in single cylinder installations and ASME tanks must be installed beneath a protective cover or under the ASME tank dome refer to Figure 3 If possible slope or turn the vent down sufficiently to allow any condensation to drain out of the spring case Be careful that the slot in the tank dome or protective cover for the regulator s outlet piping does not expose the vent to the elements The first stage vent on the Types R632A and R632E should be pointed down C To Z APPLIANCE K Z 2 7 VENT UM Pe i IWA VENT LINE VENT OPENING AW MUST BE AT LEAST 5 N tM 3 FEET 0 91 meter BASEMENT 2 HORIZONTALLY FROM ANY S BUILDING OPENING Y BELOW IT SS FROM FIRST
4. Types R632A and R632E integral regulators installed on underground tanks require the use of 2 vent tubes one for the first stage vent 1 4 inch OD copper tube inverted flare connection 7 16 24 UN thread and the other for the second stage vent 3 4 NPT of the regulator Remove the vent screen and install a vent tube The vent tube must be run from the regulator vent to above the maximum water table The vent tube opening must terminate at the extreme top inside of the dome cover R600 and HSRL Series LP Gas Regulators Make sure the regulator s closing cap is on tightly and maintain drainage away from the dome at all times Adjustment Each regulator is factory set If it becomes necessary to increase the outlet pressure remove the closing cap and turn the adjustment screw clockwise Turn the adjusting screw counterclockwise to decrease the outlet pressure The first stage portion of the Types R632A and R632E integral regulators is non adjustable The outlet pressure plug may be removed using a 7 16 inch 11 mm hexagon wrench The pressure tap is restricted so the plug can be removed with pressure on the outlet of the regulator Install a pressure gauge to determine the regulator s outlet setting during adjustment Actual pressure at the second stage regulator may be less due to line loss After setting reinstall the pipe plug and replace the closing cap Check the plug for leakage Inlet pressure may be checked using the in
5. c 2 mbar pressure They have high capacity internal relief valve construction The regulators are normally painted PALM GREEN The units differ in construction and capacity rating R600 and HSRL Series LP Gas Regulators Integral Two stage Regulator The Type R6382A integral two stage regulator contains a non adjustable first stage regulator on the inlet The second stage provides 11 inches w c 27 mbar outlet pressure The second stage portion has a high capacity internal relief valve construction The first stage does not have an internal relief valve The regulators are normally painted GRAY with a BLACK CAP VENT POINTED DOWN Integral Two psig Service Regulator The Type R632E integral two psig service regulator contains a non adjustable first stage regulator on the inlet The second stage provides 2 psig 0 14 bar outlet pressure The second stage portion has a high capacity internal relief valve construction The first stage Peer does not have an internal relief valve The regulators 0 91 meter yy iy are normally painted GRAY with a WHITE CAP and ay White 2 psig STICKER T14446 A2 Figure 2 Regulator with Vent Pointed Down Installation accumulation of gas which could result in personal injury or property damage WARNING Never use a Type R622H R622E R632E or R652E pounds to pounds regulator All vents should be kept open to permit on low pressure inches of water column free f
6. 2 inch FNPT 1 2 inch FNPT R642 DFF 900 000 ene INC j Saas 1 000 000 11 inches w c 3 4 inch FNPT 27 mbar R622 CFF 1 2 inch FNPT 1 400 000 Second Stage R622 DFF 3 4 inch FNPT R622 CFGXA 1 125 000 1 2 inch FNPT 18 inches w c 3 4 inch FNPT 45 mbar HSRL BFC 3 4 inch FNPT 2 100 000 11 inches w c HSRL CFC 1 inch FNPT 1 inch FNPT 27 mbar R632A BCF 1 4 inch FNPT a 850 000 1 2 inch FNPT First Stage R632A HCF FPOL 11 inches w c Down 3 4 inch FNPT sean iieis R632A JFF 850 000 FPOL Two Stage R632A BCFXA 1 4 inch FNPT l i 850 000 1 2 inch FNPT First Stage R632A HCFXA FPOL iindeswci Opposite gauge taps R632A CFFXA 950 000 1 4 inch FNPT re 27 mbar odden Sige R632A JFFXA 850 000 FPOL Opposite gauge taps R632E BCH 850 000 1 4 inch FNPT 1 2 inch FNPT First Stage R632E HCH 900 000 FPOL Down 2 psig 0 14 bar SETTING LOCATION Over Inlet Integral 2 psig 0 14 bar Service Second Stage Over Outlet R632E CFH 1 4 inch FNPT 850 000 3 4 inch FNPT R632E JFH FPOL R622E BCH 1 250 000 1 2 inch FNPT 1 2 inch FNPT R622E DCH 1 500 000 2 psig 0 14 bar 3 4 inch FNPT 3 4 inch FNPT R652E DFH 1 400 000 R622H BGK 2 000 000 5 psig 0 35 bar 1 2 inch FNPT R622H BGJ 1 2 inch FNPT R622H HGJ 2 100 000 10 psig 0 69 bar First Stage R622H HGJKA Over Outlet FPOL R622H JGK 5 psig 0 35 bar 2 250 000 R622H JGJ 3 4 inch FNPT 10 psig 0 69 bar R622H DGJ 2 400 000 3 4 inch FNPT Capaciti
7. 2 mbar Type R632E First Stage non adjustable Second Stage 1 to 2 2 psig 69 mbar to 0 15 bar Types R622E and R652E 1 to 2 2 psig 69 mbar to 0 15 bar Type R622H 8 to 12 psig 0 55 to 0 83 bar 4 to 6 psig 0 28 to 0 41 bar HSRL Series 9 to 13 inches w c 22 to 32 mbar Approximate Weight Type R622H with POL Inlet 1 7 pounds 771 grams Types R632A and R632E with POL inlet 2 9 pounds 1310 grams Types R632A and R632E with NPT Inlet 2 5 pounds 1125 grams All Other R600 Series 1 4 pounds 635 grams HSRL Series 4 5 pounds 2 0 kg 1 The pressure temperature limits in this Instruction Manual or any applicable standard limitation should not be exceeded 2 Product has passed Fisher testing for lockup relief start to discharge and reseal down to 40 F 40 C regulator reduces container pressure for a high pressure burner The regulator is normally painted RED The Type R622E or R652E standard outlet pressure setting is 2 psig 0 14 bar The regulator is painted PALM GREEN with a WHITE CAP It is an intermediate stage regulator that reduces 10 psig 0 69 bar first stage pressure to 2 psig 0 14 bar They are used on 2 psig 0 14 bar pressure systems The Types R622E and R652E are not suitable for first stage service Second Stage Low Pressure Regulators The Types R622 R642 R652 and HSRL Series regulators provide low pressure inches of water column delivery pressures They are normally set at 11 inches w
8. Installed Indoors Pipe the regulator vent per the section Indoor Installations Indoor Installations By code regulators installed indoors have limited inlet pressure and they require a vent line to the outside of the building see Figure 4 Avent assembly such as Fisher Y602 Series should be used on the end of the vent line The same installation precautions previously discussed throughout this manual for the regulator vent apply to the end of the vent tube assembly Vent lines must not restrict the gas flow from the regulator s internal relief valve Vent lines should be at least 3 4 inch NPT pipe or 3 4 inch NPT size Gray PVC Schedule 40 Rigid Non metallic Electrical Conduit for above Ground Service per UL 651 To install the vent line remove the vent screen and apply a good grade of pipe dope to the male threads of the line Vent lines should be as straight as possible with a minimum number of bends Underground Installations Types R632A and R632E integral regulators require 2 vent tubes one on the first stage vent and one on the second stage vent when installed on underground tanks Failure to use 2 separate vent tubes can result in early regulator failure and or over pressuring the second stage that could result in fires or personal injury Regulators installed in the dome of an underground container require a vent tube to prevent water from entering the regulator spring case see Figure 5 Note
9. Instruction Manual MCK 2141 February 2013 R600 and HSRL Series LP Gas Regulators R600 and HSRL Series Instruction Manual 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 equipment must be installed operated and maintained in accordance with federal state and local codes and Fisher instructions The installation in most states must also comply with NFPA No 54 and 58 standards Only personnel trained in the proper procedures codes standards and regulations of the LP Gas industry should install and service this equipment Things to tell the gas customer 1 Show the customer the vent or vent assembly or vent tube Stress that this opening must remain unobstructed at all times Tell the customer to check the vent opening after a freezing rain sleet storm or snow to make sure ice has not formed in the vent 2 Show the customer the shutoff valve on the container The customer should close this valve immediately if gas is smelled appliance pilot lights fail to stay on or appear higher than usual or any other abnormal situation occurs 3 Tell the customer to call your company to service the regulator if the regulator vents gas or a leak develops in the system Only a qualified gas service person should install or service the regulator Introduction Scope of the Manual
10. as escapes to the atmosphere through the regulator s vent Some type of additional external overpressure protection must be provided if the outlet pressure in an overpressure condition exceeds the inlet pressure rating of the gas system or downstream equipment Common methods of external overpressure protection include relief valves monitoring regulators shutoff devices and series regulation Maintenance 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 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 these regulators must be inspected and maintained periodically The frequency of inspection and replacement of the regulators depends upon the severity of service conditions or the requirements of local state and federal regulations Even under ideal conditions these regulators should be replaced after 20 years from date of manufacture or sooner should inspection reveal the need Visually inspect the regulator each time a gas delivery is made for e Improper installation vent not pointed vertically
11. ch 5 6 mm R632A and R632E Series 0 256 inch 6 5 mm HSRL Series 3 8 inch 9 5 mm Wide open C for Relief Sizing R600 Series 38 HSRL Series 105 Maximum Allowable Inlet Pressure Types R622H R632A and R632E 250 psig 17 2 bar Types R622E and R652E 10 psig 0 69 bar Types R622 R642 R652 and HSRL Series 10 psig 0 69 bar Maximum Emergency Inlet Pressure Types R622H R632A and R632E 250 psig 17 2 bar Types R622E and R652E 15 psig 1 0 bar Types R622 R642 R652 and HSRL Series 15 psig 1 0 bar Temperature Capabilities R600 and HSRL Series 20 to 160 F 29 to 712C Pressure Registration Internal Outlet Pressure Standard Setpoint Types R622 R642 R652 and HSRL Series 11 inches w c 27 mbar Type R632A First Stage approximately 8 psig 0 55 bar at 75 psig 5 2 bar 65 SCFH 1 84 Sm h Second Stage 11 inches w c 27 mbar Outlet Pressure Standard Setpoint continued Type R632E First Stage approximately 8 psig 0 55 bar at 75 psig 5 2 bar 65 SCFH 1 84 Sm h Second Stage 2 psig 0 14 bar Types R622E and R652E 2 psig 0 14 bar Type R622H 10 psig 0 69 bar 5 psig 0 35 bar Outlet Pressure Spring Range Types R622 R642 and R652 7 5 to 9 5 inches w c 19 to 24 mbar 9 to 13 inches w c 22 to 32 mbar 13 to 20 inches w c 32 to 50 mbar 16 to 40 inches w c 40 to 99 mbar Type R632A First Stage non adjustable Second Stage 9 to 13 inches w c 22 to 3
12. down or under a cover no vent tube on underground systems e Plugged or frozen vent e Wrong regulator or no regulator in the system e Internal or external corrosion e Flooded Regulator water in spring case regulator submersed on underground tanks e Regulator age R600 and HSRL Series LP Gas Regulators e Any other condition that could cause the uncontrolled escape of gas Failure to do the above could result in personal injury or property damage Vent Opening Make sure the regulator vent vent assembly or vent tube does not become plugged by mud insects ice snow paint etc The vent screen aids in keeping the vent from becoming plugged and the screen should be clean and properly installed Water inside Regulators from Floods Weather or Water Table on Underground Systems Replace any regulator that has been flooded or has been submersed below the water table of an underground tank have had water in their spring case or show evidence of external or internal corrosion Checking for internal corrosion can be done by removing the closing cap and with the aid of a flashlight observing the condition of the relief valve spring main spring and internal spring barrel area Amore detailed examination will require shutting down of the gas system and the complete removal of the adjusting screw Closely examine regulators installed with their vent horizontal for signs of corrosion Correct any improper installations LP Gas E
13. es Based on Second Stage 10 psig 0 69 bar inlet pressure and 2 inches w c 5 mbar droop Integral Two stage 30 psig 2 1 bar and 2 inches w c 5 mbar droop Integral Two psig Service 30 psig 2 07 bar and 20 droop 2 psig 0 14 bar Service Over Inlet 2 psig 0 14 bar Service 10 psig 0 69 bar inlet pressure and 20 droop First Stage 30 psig 2 1 bar inlet pressure and 20 droop Straight globe valve body configuration Integral First Stage Vent size 7 16 24 UN thread for 1 4 inch OD copper tube inverted flare fitting e Replace old pigtails Blow out any debris dirt or copper Installation Location sulfate in the copper tubing and the pipeline Apply pipe compound to the male threads of the pipe e The installed regulator should be adequately before installing the regulator protected from vehicular traffic and damage from other external sources e Make sure gas flow through the regulator is in the same in a vertically down position the regulator must be installed under a separate protective cover Installing R600 and HSRL Series LP Gas Regulators T14447 A2 Figure 3 Tank Installation 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 e Do not install the regulator in a location where there can be excessive water accumulation or ice formation such
14. let pressure gauge tap and a pressure gauge Remove the plug using a 7 16 inch 11 mm wrench The pressure tap Is restricted so the plug can be removed with pressure on the inlet of the regulator Overpressure Protection Some type of overpressure protection is needed if actual inlet pressure can exceed the outlet pressure rating Overpressuring any portion of this equipment above the limits shown in the Specifications section 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 If any portion of the regulator is exposed to an overpressure condition that exceeds the limits in the Specifications section it must be inspected for damage that may have occurred Large volumes of gas may discharge through the regulator vent during internal relief valve operation which can if not controlled result in fire or explosion from accumulated gas The R600 and HSRL Series regulators except for the first stage of the Types R632A and R632E contain internal relief valves The internal relief valve in all units will give overpressure protection against excessive build up resulting from seat leakage due to worn parts or chips or foreign material on the orifice The amount of internal relief protection provided varies with the regulator type and the cause for the overpressure relief valve operation When the internal relief valve opens g
15. low of air in and out of the regulator service because personal injury or Protect vent openings against the entrance property damage could occur The of rain snow ice formation paint mud Types R622E and R652E are not suitable insects or any other foreign material that for use as a first stage regulator could plug the vent or vent line LP Gas may discharge to the atmosphere General Installation Instructions through the vent An obstructed vent which limits air or gas flow can cause Before installing the regulator abnormally high pressure that could result in personal injury or property damage Failure to use a vent line on Indoor Installations can cause a hazardous e Check for and remove any dirt or foreign material which may have accumulated in the regulator body e Check for damage which might have occurred in shipment Table 1 Relief Valve Specifications NOMINAL RELIEF VALVE MAXIMUM INLET PRESSURE TO NOT EXCEED OUTLET PRESSURE WITH DISC REMOVED TYPE TYPICAL SETPOINT START TO DISCHARGE Maximum Outlet Pressure HSRL R622 and R642 11 inches w c 27 mbar R652 R632A Not Applicable 1 For integral two stage regulators the second stage disc is removed R600 and HSRL Series LP Gas Regulators Table 2 Capacity Connection Sizes and Vent Orientation 3 4 INCH NPT REGULATOR TYPE Sera aR INLET OUTLET e E SCREENED APPLICATION NUMBER CONNECTION CONNECTION VENT STANDARD PROPANE R622 BCF 875 000 1
16. quipment Emerson Process Management Regulator Technologies Inc USA Headquarters McKinney Texas 75069 1872 USA Tel 1 800 558 5853 Outside U S 1 972 548 3574 For further information visit www fisherregulators com Regulator Replacement Older regulators are more likely to catastrophically fail because of worn or corroded parts Replace R600 and HSRL Series regulators over 20 years of age Other service or environmental conditions may dictate replacement of the regulator before it becomes 20 years old Regulators that are installed on underground systems and in areas that are subject to sea salt coastal atmospheres should be inspected annually for external and internal corrosion and may require replacement sooner Refer to Fisher Bulletin LP 32 for additional information Regulator Repair 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 to repair Fisher regulators Be sure to give the complete type number of the regulator when corresponding with the factory The type number orifice size and spring range are on a label attached to the spring barrel The date of manufacture is stamped on the regulator Always provide this information in any correspondence with your Fisher Distributor regarding replacement parts or technical assistance If construction changes are made in the field be sure that
17. the regulator marking is also changed to reflect the most recent construction 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 2001 2013 All Rights Reserved a a ey ss EMERSON
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