Emerson CS800 Instruction Manual
Contents
1. 6600886 APPLY LUBRICANT L L1 ANTI SEIZE LUBRICANT L2 EXTREME LOW TEMPERATURE BEARING GREASE 1 Lubricants must be selected such that they meet the temperature requirements Figure 15 CS800 Series Control Spring Adjustment Assemblies continued 76 i a 74 TORQUE i 4 TO 6 FT LBS 5 4 TO 8 1 Nem v6 L2 m m S1 GRAY CAST IRON BODIES GRAY CAST IRON DUCTILE IRON STEEL BODIES WITHOUT OVERPRESSURE PROTECTION WITH OVERPRESSURE PROTECTION APPLY LUBRICANT L SEALANT 5 L1 ANTI SEIZE LUBRICANT L2 EXTREME LOW TEMPERATURE BEARING GREASE S1 THREAD SEALANT WITH PTFE 1 Lubricants and sealants must be selected such that they meet the temperature requirements Figure 16 CS800 Series Body Configurations 29 CS800 Series TORQUE 25 TO 35 FT LBS 34 TO 47 Nm 25 L1 81 TYPE TM600 TRUE MONITOR ASSEMBLY FOR TYPE CS803 FINAL ASSEMBLY TORQUE L2 L2 L2 25 TO 35 FT LBS 34 TO 47 Nem 7 yl BI a N CUNY SSS N TYPE TM600 TRUE MONITOR ASSEMBLY FOR TYPE CS803 FINAL ASSEMBLY APPLY LUBRICANT L SEALANT S L2. 13 CS800 Series than the outlet pressure setting of the regulator See the 289 Series Instruction Manual D100280X012 for more information Vent Line Installation The CS800 Series regulators have a 1 or 2 1 2 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 internal relief must be large enough to vent all relief valve discharge to atmosphere without excessive backpressure and resulting excessive pressure in the regulator Ensure piping is properly supported to avoid excessive stress on the regulator spring case The CS800 Series offers optional Token Relief that provides low capacity relief which 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 CS800 Series outlet pressure ranges are shown in Table 5 Outlet pressure greater than 3 psi 0 21 bar above setpoint may damage internal parts such as the diaphragm head and valve disk The maximum emergency casing outlet pressure is 15 psig 1 0 bar Startup Pres
3. 5 345 5 5 psig 170 to 380 7 psig 483 8 5 psig 221 to 586 GF02173X012 Silver CS854 7 psig 483 5 to 10 psig 345 to 690 9 psig 621 aa 400 to 896 GF04353X012 Yellow 1 For units equipped with Token Relief if Non Factory Slam shut OPSO setpoints are specified they must be higher than the Token Relief Start to Discharge values provided in Table 6 2 If Non Factory OPSO setpoints are specified the allowable OPSO setpoint cannot exceed the maximum of 3 psig 207 mbar above the regulator setpoint in order to ensure no internal parts damage from overpressure CS800 Series Table 11 Regulator and Slam Shut Underpressure Shutoff UPSO Pressure and Overpressure Shutoff OPSO Ranges SLAM SHUT DEVICE REGULATOR Under Pressure Shut off UPSO Over Pressure Shut off OPSO SPRING RANGE FACTORY SPRING FACTORY SPRING RANGE SPRING PART FAGTORY OVER UPSO SPRING PART TYPE SETPOINT RANGE SETPOINT NUMBER AND SETPOINT SETPOINT NUMBER AND COLOR COLOR In w c mbar In w c mbar In w c mbar In w c mbar In w c mbar In w c mbar 7 17 5 5108 5 3 7 22 55 11 27 8 to 12 2010 6 15 21012 5 to 30 714166700127 25 62 17 to 28 42 to 69 ere d 30 White Brown CS804 14 35 10 to 16 p 9 22 30 75 35 0 36 to 25to T14170T0012 1 3 to 90 to GF02170X012 1psig 69 11403007 0 5psig 35 sae 160 Silver 2psig
4. All Types except Type CS850 remove the closing cap key 60 Turn the adjusting screw key 65 counterclockwise to ease spring compression Remove adjusting screw and spring key 38 See Figure 15 Type CS850 loosen hex locknut key 107 Turn adjusting screw key 65 counterclockwise to ease spring compression Unscrew bonnet key 104 and remove Remove spring key 38 See Figure 12 Remove the nuts key 16 and hex bolts key 15 Separate the upper spring case key 1 from the lower casing key 9 Note When disassembling a CS800 Series regulator lift the upper spring case straight up in order to avoid hitting the stem key 11 See Figure 12 Slide the diaphragm head assembly key 55 away from the body key 70 to unhook the pusher post key 50 from the lever key 10 Lift off the diaphragm head assembly See Figure 13 Non Relieving units unscrew the bolt key 45 The bolt threads in to the pusher post key 50 and holds the non relieving diaphragm assembly together Unscrewing the bolt will separate the diaphragm retainer key 47 the lower spring seat key 43 and diaphragm assembly key 55 and pusher post key 50 Use caution when unscrewing the relief valve stem as the relief valve spring is in compression See Figure 13 Internally Relieving units unscrew the relief valve stem key 44 The relief valve stem threads into the pusher post key 50 and holds the relieve assembly together Unscrewing the r
5. Low Flow Standard Relief High Capacity Relief Low Start to Discharge for Standard Relief High Capacity Relief Upper Spring Retainer Token Relief Low Flow Zinc plated steel Token Relief Standard Flow Zinc plated steel Standard Relief High Capacity Relief Aluminum Low Start to Discharge for Standard Relief High Capacity Relief Aluminum Recommended spare part GE01439X012 GE29773X022 GE29773X032 GE29773X042 GE29773X082 GE29773X092 GE29773X052 GE29773X062 GE33709X012 See Table 5 GE48120X012 GE48120X012 GE30347X012 GE48120X012 GE46956X012 GE46956X012 GE27059X012 GE27059X012 Key 43 44 45 46 47 48 50 52 53 54 55 55 55 56 57 60 62 65 CS800 Series Description Lower Spring Seat Aluminum Non relief Token Relief Standard Flow Token Relief Low Flow Standard Relief High Capacity Relief Low Start to Discharge for Standard Relief High Capacity Relief Relief Valve Diaphragm Stem Token Relief Low Flow Zinc plated steel Token Relief Standard Flow Zinc plated steel Standard Relief High Capacity Relief Aluminum Low Start to Discharge for Standard Relief High Capacity Relief Aluminum Hex Head Bolt Steel Types CS800 and CS820 Type CS850 Token Relief Nut Steel Token Relief Low Flow Token Relief Standard Flow Diaphragm Retainer Aluminum Types CS800 and CS820 No Relief Token Relief Standard Flow Type CS850 Retaini
6. 207 GE35081X012 2 6 to 3 7 psig 179 to 255 Purple 2 psig 138 GE30342X012 1to2 5 6910170 4 psig 276 GE30192X012 3 6to6psig 24810414 Dark Blue CS823IT A CS823IL 5 psig 345 GE30192X012 3 6to6psig 24810414 Dark Blue CS823ET d 3 psig 207 GE46922X012 1 5 to 3 5 100 to 241 Orange 6 psig 414 GE33121X012 5 1 to 7 5 psig 352 to 517 Red CS823EL 7 psig 483 GE33121X012 5 1 to 7 5 psig 352 to 517 Red 5 psig 345 GE30343X012 2 5 to 5 5 170 to 380 Yellow 7 5 psig 517 GE33121X012 5 1 to 7 5 psig 352 to 517 Red Table 10 Regulator and Slam Shut Overpressure Shutoff OPSO Pressure Ranges SLAM SHUT DEVICE REGULATOR Over Pressure Shut off OPSO Factory Setpoint Spring Range Factory Setpoint Spring Range Spring Type Part Number In w c mbar In w c mbar In w c mbar In w c mbar and Color 4 10 3 5 to 6 9 to 15 19 47 121025 30 to 60 GF02168X012 Brown 7 17 5 5 to 8 5 14 to 21 22 55 7 optional 17 optional 5 5 to 8 5 14 to 21 25 62 16 to 44 40 to 110 GF02169X012 Red CS804 11 27 8 to 12 20 to 30 14 35 10 to 16 25 to 40 30 75 24 to 78 60 to 190 GF02170X012 Orange 14 optional 35 optional 10 to 16 25 to 40 2 psig 138 14 to 44 97 to 283 GF02171X012 Pink 1 psig 69 14 to 30 35 to 75 2 psig 138 1 psig 2 138 1 to 2 5 psig 69 to 170 3 5 psig 241 1 5 to 2to 7 3 psig 13810503 GF02172X012 Green CS824 3 psig 207 3 5 psig 100 to 241 5 psig 345 2 5to 3 2 to
7. 74 188 10 to 16 25 to 40 White GE30340X012 0 18 4 6 7 4 188 14 to 30 35 to 75 Dark Green GE30341X012 0 20 5 2 7 5 191 CS820 CS823 1 to 2 5 psig 69 to 170 Dark Blue GE30342X012 0 25 6 4 7 5 191 CS824 CS825 1 5 to 3 5 psig 100 to 241 Orange GE46922X012 0 26 6 6 7 1 180 and C5826 2 5 to 5 5 psig 170 to 380 Yellow GE30343X012 0 29 7 5 6 7 170 5850 and Green with CS854 5to 10 psig 345 to 690 White Stripe GE30344X012 0 39 9 9 7 6 192 1 In order to achieve the complete spring range listed in some applications it may be required to re orient the actuator spring case to point downward to utilize the weight of the internal components Table 6 Approximate Internal Relief Valve Start to Discharge Pressure above Setpoint INTERNAL RELIEF AND HIGH CAPACITY RELIEF TOKEN RELIEF CONTROL SETPOINT SET RANGE mid phobie as SPRING Start to Discharge Pressure ption Start to Discharge Pressure Range above Setpoint Start to Discharge Pressure Range above Setpoint Range above Setpoint In w c mbar In w c mbar In w c mbar In w c mbar In w c mbar GE30337X012 4 10 3 5 to 6 9 to 15 11 to 18 27 to 42 7 to 14 17 to 35 6 to 14 15 to 35 GE30338X012 7 17 5 5 to 8 5 13to21 11 to 18 27 to 42 7 to 14 17 to 35 6 to 14 15 to 35 SEMEN x 7 17 5 5108 5 13to21 11 to 18 27 to 42 7 to 14 17 to 35 6 to 14 15 to 35 GE30339X012 11 27 8 to 12 20 to 30 11 to 18 27 to 42 7 to 14 17 to 35
8. All Materials All Connections Black GE29773X022 RCS800XBLK2 CS854 External All All Sizes All All Materials All Connections Black GE29773X022 RCS800XBLK2 1 The 3 5 to 30 in w c 9 to 75 mbar spring range indicates that all of the springs within this range are applicable 2 Repair kit includes O ring key 19 disk assembly key 36 and O ring key 62 Table 15 CS805 and CS806 Series Disk Color Selection 1 PRESSURE TYPE SORI SEF TENSE BODY END DISK REPAIR REGISTRATION In DN In w c mbar MATERIAL CONNECTION COLOR PART NUMBER 1 1 4 32 Pia GE29773X062 RCS800XYEL2 ESRUS Gray Cast Green and 1 1 2 40 3 5 to 30 9to75 y All Connections GE29773X092 RCS800XGR22 CS806 Iron White Dot Internal White 2 50 White Dot GE29773X052 RCS800XWHT2 5925 Gray Cast Yellow and All Sizes 1 to 5 5 psig 70 to 380 All Connections GE29773X062 RCS800XYEL2 CS826 Iron White Dot External All All Sizes All All Materials All Connections Black GE29773X022 RCS800XBLK2 1 The 3 5 to 30 in w c 9 to 75 mbar spring range in 2 White White Dot disk requires the open end to be directed downstream with the direction of flow 3 Repair kit includes O ring key 19 disk assembly key 36 and O ring key 62 dicates that all of the springs within this range are applicable 21 CS800 Series Parts List Key Description Regulator Repair Kit Disk Assembly Repair Kit Disk Assembl
9. GE46996X01 GE33772X012 NON GE33668X012 GE26109X01 GE26109X02 GE29750X01 2 2 N GE26108X012 GE47294X01 GE27026X01 N N 23 CS800 Series 6600886 51 1 Lubricant and sealant must be selected such that they meet the temperature requirements Key 70 71 72 74 75 72 1 15 16 TORQUE 10 TO 13 FT LBS 71 4 TO 18 Nem 17 60 L1 INSTALL TORQUE 63 TO 90 IN LBS 7 1 TO 10 Nem MINIMUM RELAXATION TORQUE 45 IN LBS 5 1 Nem PROPER TIGHTENING OF BOLTS IN CROSS PATTERN APPLY LUBRICANT L SEALANT 5 ANTI SEIZE LUBRICANT THREAD SEALANT WITH PTFE Figure 12 CS800 Series Regulator Assemblies Description Body Bolt Steel 4 required Pipe Plug Plated steel Stainless steel Blanking Plug Aluminum For Ductile Iron and Steel Bodies non Overpressure Protection service only O ring Nitrile NBR For Ductile Iron and Steel Bodies non Overpressure Protection service only Recommended spare part 24 Part Number See Table 3 GE29974X012 1C333528992 1C3335X0012 GE31255X012 GF03442X012 Key 76 77 80 81 81 Description Half Flange 2 required Steel For Ductile Iron and Steel Bodies non Overpressure Protection service only O rin
10. Schematic RELIEF VALVE STEM ADJUSTING SCREW RELIEF VALVE SPRING CONTROL SPRING DISK MIL VALVE STEM IK Zl ar DIAPHRAGM BHA PUSHER POST ASSEMBLY LEVER SEAT ORIFICE M1071 INLET PRESSURE Ez OUTLET PRESSURE ATMOSPHERIC PRESSURE Figure 3 Type CS800 Q Internally Registered Regulator with High Capacity Relief Operational Schematic CS800 Series If the slam shut device trips due to a lever disconnect failure of the main regulator it is recommended that you check downstream equipment for damage prior to re setting the slam shut Types CS805 and CS825 with Secondary Seat Protection Types CS805 and CS825 regulators do not have any means to alert when the Secondary Seat operates at lockup Therefore it is recommended that Internal relief or high capacity relief are also selected or the addition of some other method of overpressure protection be added in the downstream system as discussed in the Overpressure Protection section Refer to Figure 6 The CS805 Series provides Secondary Seat Protection As downstream demand decreases and downstream pressure rises to the regulator pressure lock up value the regulator will lock up If however damage has occurred to the primary disk or orifice s seating surface seat or debris has become lodged between the primary disk an
11. and CS806 Assemblies 31 CS800 Series 6600886 5805 SECONDARY SEAT ORIFICE ASSEMBLY DETAILED VIEW APPLY LUBRICANT L Li L2 L1 L2 SECONDARY SEAT LUBRICATION PROPERTIES AT COLD TEMPERATURES XTREME LOW TEMPERATURE BEARING GREASE OR COMPARABLE LUBRICANT THAT MAINTAINS ITS 258 ANTI SEIZE LUBRICANT EXTREME LOW TEMPERATURE BEARING GREASE 1 Lubricants must be selected such that they meet the temperature requirements Figure 18 CS800 Series Base Orifice and Secondary Seat For Types CS805 and CS806 Assemblies continued Industrial Regulators Emerson Process Management Regulator Technologies Inc USA Headquarters McKinney Texas 75070 USA Tel 1 800 558 5853 Outside U S 1 972 548 3574 Asia Pacific Shanghai 201206 China Tel 86 21 2892 9000 Europe Bologna 40013 Italy Tel 39 051 419 0611 Middle Dubai East and Africa United Arab Emirates Tel 971 4811 8100 Natural Gas Technologies Emerson Process Management Regulator Technologies Inc USA Headquarters McKinney Texas 75070 USA Tel 1 800 558 5853 Outside U S 1 972 548 3574 Asia Pacific Singapore 128461 Singapore Tel 65 6770 8337 Europe Bologna 40013 Italy Tel 39 051 419 0611 Chartres 28008 France Tel 33 2
12. factory Type number date of manufacture spring range orifice size maximum inlet pressure maximum operating outlet pressure and outlet pressure Exceeding any of these limits may damage regulator parts Available Configurations See Table 1 Body Sizes Material End Connections and Pressure Ratings See Table 3 Maximum Inlet Pressures Emergency 175 psig 12 1 bar Operating See Table 4 Maximum Outlet Pressure Emergency Regulator Casing 15 psig 1 0 bar Integral Monitor Casing 25 psig 1 7 bar Integral Slam shut Casing 87 psig 6 0 bar To avoid internal parts damage 3 psig 0 21 bar differential above outlet pressure setting Operating Pressure Ranges Regulator See Table 5 Integral True Monitor See Tables 8 and 9 Slam shut Module See Tables 10 to 11 Secondary Seat Protection Outlet Pressures See Table 7 Spring Case Vent Connection Internal Relief 1 NPT High Capacity Relief 2 1 2 NPT Internal Relief Performance See Table 6 Token Relief Performance Approximate Token Relief Start to Discharge See Table 6 Orifice Sizes Flow Coefficients and IEC Sizing Coefficients See Table 4 Pressure Registration Internal or External Temperature Capabilities 20 to 150 F 30 to 66 C According to European PED Directive that rates products to a minimum temperature of 4 F 20 C and a maximum temperature of 140 F 60 C 4 to 140 F 20 to 60 C Approximate Weight With Threaded Body
13. psig 0 17 bar 2 6 psig 0 18 bar 3 8 psig 0 26 bar 3 7 psig 0 26 bar 2 5 to 0 17 to Yellow GE30343X012 55psig 0 38 bar 5 psig 0 34 bar 0 56 bar 1 Downstream pressure buildup with Secondary Seat fixed bleed in operation and regulator relief valve relieving to atmosphere 2 Outlet pressure values listed are at maximum operating inlet pressure rating per orifice See Table 4 3 If the outlet pressure rises above setpoin exceeds 3 psig 207 mbar inspect internal parts and replace if damaged CS800 Series Table 8 Primary Regulator and Integral True Monitor Outlet Pressure Ranges without Token Relief PRIMARY REGULATOR INTEGRAL TRUE MONITOR Type CS803IN and CS803EN CS823IN and CS823EN Typical Setpoint Spring Part Spring Range Spring Setpoint Spring Part Spring Range Spring In w c mbar Number In w c mbar Color w c mbar Number In w c mbar Color 14 35 GE30189X012 12 to 21 30 to 52 Blue 4 10 6 30337 012 3 5to6 9 to 15 Red 21 52 GE30196X012 18 to 30 45 to 75 Green 1 psig 69 GE30225X012 26 to 40 65 to 99 Orange 14 35 GE30189X012 12to21 30 to 52 Blue 7 17 GE30338X012 5 5to8 5 13t021 Black 21 52 GE30196X012 181030 45 to 75 Green 1 psig 69 GE30225X012 26 to 40 65 to 99 Orange 14 35 GE30189X012 12 to 21 30 to 52 Blue 7 17
14. 1 ANTI SEIZE LUBRICANT L2 EXTREME LOW TEMPERATURE BEARING GREASE 2 MEDIUM STRENGTH THREADLOCKER SEALANT 1 Lubricants and sealants must be selected such that they meet the temperature requirements Figure 17a CS800 Series Integral True Monitor Module and Orifice Assemblies 30 L2 26 27 70 TYPE VSX8 SLAM SHUT ASSEMBLY FOR TYPE CS804 FINAL ASSEMBLY CS800 Series L2 L1 TORQUE 82 25 TO 35 FT LBS 34 TO 47 Nem INSTALL HAND TIGHT S2 APPLY LUBRICANT L SEALANT S L1 ANTI SEIZE LUBRICANT L2 EXTREME LOW TEMPERATURE BEARING GREASE 2 MEDIUM STRENGTH THREADLOCKER SEALANT 1 Lubricants and sealants must be selected such that they meet the temperature requirements O TAKE CARE NOT TO DAMAGE SENSE TUBE WHEN INSTALLING REGULATOR INTO PIPELINE Figure 17b CS800 Series Slam shut Module and Orifice Assemblies continued 36B e L2 28 L L1 25 APPLY LUBRICANT L SEALANT S L1 ANTI SEIZE LUBRICANT L2 EXTREME LOW TEMPERATURE BEARING GREASE 1 Lubricants and sealants must be selected such that they meet the temperature requirements 36 82 12 STANDARD ORIFICE AND STANDARD DISK ASSEMBLY Figure 18 CS800 Series Base Orifice and Secondary Seat For Types CS805
15. 138 5 bsig 214 Orange 1 to 69 to 0 36 to 25to T14170T0012 1 3 to 90 to GF02170X012 2psig 138 55 psig 170 P 9 99 23psiq 160 Silver 3 5 psig 241 3 4psig 214 Orange 1 5 100 to A 5824 3 psig 207 1 75 psig 121 5 psig 345 3 5 psig 241 1 5to 100 to FA142869X12 2 710 186 to GF02171X012 7 25to 1700 7 3 psig 500 Orange Stripe 5 5 psig 379 Pink 5 psig 345 5 5 psig 380 3 psig 207 7 psig 483 1 5to 345 to 1 5 to 100 to FA142869X12 2 7 to 186 to GF02171X012 5854 7psig 483 i5 psig 690 99 P99 241 73 psig 500 Orange Stripe 9PS9 621 s5psig 379 Pink 1 If Non Factory UPSO setpoints are specified a minimum differential of 4 in w c 10 mbar between UPSO setpoint and regulator setpoint must be maintained in order to ensure a secure latch of the Slam Shut 2 For units equipped with Token Relief if Non Factory Slam shut OPSO setpoints are specified they must be higher than the Token Relief Start to Discharge values provided in Table 6 3 If Non Factory OPSO setpoints are specified the allowable OPSO setpoint cannot exceed the maximum of 3 psig 207 mbar above the regulator setpoint in order to ensure no internal parts damage from overpressure During normal operation the True Monitor is in a wide open state as its setpoint is set higher than the primary regulator See Tables 8 and 9 for guidance regarding the setpoints of the regulator and ass
16. 2 CS800 Series Regulator Assemblies continued 25 CS800 Series 558 A NOTE DIRECTION OF RETAINER RING INSTALLATION SEE DETAIL TYPE CS800 CS820 NON RELIEF TORQUE 50 TO 60 IN LBS 5 6 TO 6 8 Nem A ET ES KA i A N S NOTE DIRECTION OF S RETAINER RING INSTALLATION I TYPE CS850 NON RELIEF RETAINER RING INSTALLATION DETAIL e 6600886 APPLY ADHESIVE A 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 13 CS800 Series Diaphragm and Relief Assemblies Key Description Part Number Key Description Part Number 82 O ring Nitrile NBR GE30397X012 107 Locknut Steel Type CS850 only GE49038X012 90 Nameplate J 108 Stem Rivet Stainless steel GE45994X012 91 Warning Label 109 Retaining Ring Steel GE33772X012 93 PED EN 334 Information Label 110 Pusher Post Nut Zinc plated steel 100 Lockwire Stainless steel T12315T0022 Token Relief Low Flow only GE46959X012 103 Thrust Washer CS820 Series 111 Pusher Post Retainer Aluminum 2 5 psig to 5 5 psig 170 to 380 mbar spring only GE47292X012 Token Relief Low Flow only GE46957X012 104 Bonnet Zinc plated steel 115 Diaphragm S
17. 37 33 47 00 Middle East and Africa EXTREME LOW TEMPERATURE BEARING GREASE OR COMPARABLE LUBRICANT THAT MAINTAINS ITS LUBRICATION PROPERTIES AT COLD TEMPERATURES STANDARD ORIFICE 25 PRIMARY PRIMARY SEATING SN SEATING SURFACE N SURFACE SECONDARY SECONDARY SEATING SEATING SURFACE SURFACE SEALING NOTE RUBBER SEALING NOTE VENT SURFACE INSTALLED SURFACE DISK C BORE Pals Ej Mr a a TYPE CS806 SECONDARY SEAT ORIFICE ASSEMBLY DETAILED VIEW TESCOM Emerson Process Management Tescom Corporation USA Headquarters Elk River Minnesota 55330 2445 USA Tels 1 763 241 3238 1 800 447 1250 Europe Selmsdorf 23923 Germany Tel 49 38823 31 287 Asia Pacific Shanghai 201206 China Tel 86 21 2892 9499 The distinctive swirl pattern cast into every actuator casing uniquely identifies the regulator as part of the Fisher brand Commercial Service Regulator family Dubai United Arab Emirates Tel 971 4811 8100 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 For further information visit www emersonprocess com regulators interactive applications The Emerson logo is a trademark and service mark of Emerson Electric C
18. 6 to 14 15 to 35 GE30340X012 14 35 10to 16 25to40 11 to 18 27 to 42 7 to 14 17 to 35 6to 14 15 to 35 GE30341X012 1 psig 69 141030 351075 7 Bug to 17 to 69 554 oe 8 to 16 20 to 40 1 to 7 in w c to 7 in w c to GE30342X012 2 psig 138 70 to 170 17 to 138 17 to 69 2 5 psig 2 psig 1 psig GE46922X012 3 psig 207 1510 19915249 71 WC 10 4715438 2162 222 090 35 to 100 3 5 psig 2 psig 1 5 psig 2 5 to 7 in w c to A GE30343X012 5 psig 345 5 5 psig 170 to 380 2 5 psig 17 to 170 1 to 2 psig 69 to 138 1 Low start to discharge option is only available on the main control spring ranges up to 10 to 16 in w c 25 to 40 mbar Table 7 Secondary Seat Protection Outlet Pressures TYPES CS805 AND CS825 TYPES CS806 AND CS826 Secondary Seat Downstream Build up CONTROL SPRING SPRING RANGE SETPOINT Shut off Pressure Pressure Orifice Size In mm Orifice Size In mm 3 8 19 5 5 8116 3 8 19 5 5 8 116 Part Number In w c mbar In w c mbar In w c mbar In w c GE30338X012 5 5t108 5 131021 27 30 62 57 TEN GE49043X012 5 510 8 5 13 to 21 7 17 11 27 12 30 25 62 23 57 White GE30340X012 10to 16 25to40 14 35 19 47 20 50 36 89 33 81 c GE30341X012 141030 35to75 1 psig 69 1 2 psig 83 1 3 psig 90 2 1 psig 0 14 bar 2 psig 0 14 bar Dark 1 to 69 mbar to A Blue GE30342X012 25psig 0 17 bar 2 psig 0 14 bar 2 6
19. 6B 38 41 42 Description Housing Brass 3 8 in 9 5 mm 1 2 in 13 mm 5 8 in 16 mm 3 4 in 19 mm 7 8 in 22 mm Orifice Brass 3 8 in 9 5 mm 1 2 in 13 mm 5 8 in 16 mm 3 4 in 19 mm 7 8 in 22 mm Disk Types CS805 and CS825 without bleed Types CS806 and CS826 with bleed Internal Ring Zinc plated steel O ring Nitrile NBR 3 8 in 9 5 mm 1 2 in 13 mm 5 8 in 16 mm 3 4 in 19 mm 7 8 in 22 mm Spring Music wire or Stainless steel 3 8 in 9 5 mm 1 2 in 13 mm 5 8 in 16 mm 3 4 in 19 mm 7 8 in 22 mm Overpressure Protection Orifice Aluminum For configurations with True Monitor For configurations with Slam shut Overpressure Protection Orifice O ring Nitrile NBR Part Number GE29940X012 GE29940X012 GE29947X012 GE29947X012 GE29947X012 GE29941X012 GE29942X012 GE29948X012 GE29949X012 GE29950X012 GE29943X012 GE32017X012 GE29945X012 GE29958X012 GE29958X012 GE29756X012 GE29756X012 GE29756X012 GE29944X012 GE29944X012 GE29951X012 GE29951X012 GE29951X012 GE30327X012 GE32066X012 For configurations with True Monitor or Slum shut GE32723X012 O ring Nitrile NBR Disk Assembly See Tables 13 14 and 15 Disk Color Selection Black Blue Green Dark Gray Green White Dot White White Dot Yellow White Dot Retaining Disk Clip Stainless steel Spring Relief Valve Spring Stainless steel Token Relief Standard Flow Token Relief
20. ANT 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 Lubricant sealant and adhesive must be selected such that they meet the temperature requirements Figure 13 CS800 Series Diaphragm and Relief Assemblies continued 27 CS800 Series L2 L2 L2 LKA 2 SS KAUNE AA NN M NOTE DIRECTION OF RETAINER RING INSTALLATION GG00886_F APPLY LUBRICANT L L1 ANTI SEIZE LUBRICANT L2 EXTREME LOW TEMPERATURE BEARING GREASE 1 Lubricants must be selected such that they meet the temperature requirements SECTIONA A Figure 14 CS800 Series External Registration MAXIMUM TORQUE 9FT LBS TYPE CS800 6600886 APPLY LUBRICANT L L1 ANTI SEIZE LUBRICANT L2 EXTREME LOW TEMPERATURE BEARING GREASE 1 Lubricants must be selected such that they meet the temperature requirements Figure 15 CS800 Series Control Spring Adjustment Assemblies 28 L1 60 MAXIMUM TORQUE 9 FT LBS 12 Nem TYPE CS820 NOTE DIRECTION OF RETAINER RING INSTALLATION 100 CS800 Series L1 MAXIMUM TORQUE 9FT LBS 12 Nem
21. CS800XBLU2 5 5t08 5 13 to 21 and ron Internal 2 50 and 8 to 12 201030 Ductile Iron or Flanged Blue GE29773X032 RCS800XBLU2 WCC Steel Threaded Dark Gray GE29773X082 RCS800XGRY2 10 to 16 and 25 to 40 and 14 to 30 35 to 75 All Materials All Connections Green GE29773X042 RCS800XGRN2 CS820 and All Sizes 1 to 10 psig 69 to 690 All Materials All Connections Black GE29773X022 RCS800XBLK2 CS850 External All All Sizes All All Materials All Connections Black GE29773X022 RCS800XBLK2 1 The 3 5 to 30 in w c 9 to 75 mbar spring range indicates that all of the springs within this range are applicable 2 Repair kit includes O ring key 19 disk assembly key 36 and O ring key 62 Table 14 CS803 and CS804 Series Disk Color Selection 1 PRESSURE TYPE SETAS BODY END Disk KSSEMECI REPAIR KIT REGISTRATION In DN mbar MATERIAL CONNECTION COLOR PART NUMBER 1 1 2 40 3 5 to 30 9 to 75 All Materials All Connections Black GE29773X022 RCS800XBLK2 3 5to 6 9 to 15 All Materials All Connections Green GE29773X042 RCS800XGRN2 CS803 Ductile Iron or Flanged Blue GE29773X032 RCS800XBLU2 and 5 5to8 5 13to21and WCC Steel Threaded Dark Gray GE29773X082 RCS800XGRY2 2 50 and 8 to 12 20 to 30 S2804 Gray Cast All Connections Blue GE29773X032 RCS800XBLU2 Internal Iron 10 to 16 and 25 to 40 and A 141030 35 to 75 All Materials All Connections Green GE29773X042 RCS800XGRN2 CS823 og All Sizes 1 to 10 psig 69to 690
22. GE49043X012 5 5108 5 13to 21 TEN 21 52 GE30196X012 181030 451075 Green 1 psig 69 GE30225X012 26 to 40 65 to 99 Orange 21 52 GE30196X012 18 to 30 45 to 75 Green 11 27 GE30339X012 81012 201030 Purple 1 psig 69 GE30225X012 26 to 40 65 to 99 Orange 1 5 psig 103 GE30190X012 14 in 97 to 200 Black 2 9 psig 21 52 GE30196X012 18 to 30 45 to 75 Green 14 35 GE30340X012 101016 125040 White 1 psig 69 GE30225X012 26 to 40 65 to 99 Orange 1 5 psig 103 GE30190X012 T4 Y 97 to 200 Black 2 9 psig 4 1 5 psig 103 GE30190X012 97 to 200 Black 2 9 psig 14 to Dark 1 4 to 1 psig 69 GE30341X012 30 35 to 75 Green 2 psig 138 GE30190X012 2 9 psig 97 to 200 Black 2 6 to 179 to 3 5 psig 241 GE35081X012 3 7 psig 255 Purple 1 4 to 2 5 psig 172 GE30190X012 97 to 200 Black 2 9 psig 69 to Dark 2 6 to 179 to 2 psig 138 GE30342X012 1 to 2 5 psig 170 Blue 3 psig 207 GE35081X012 3 7 psig 255 Purple 7 3 6 to 248 to 5 psig 345 GE30192X012 6 psig 414 Dark Blue 2 6 to 179 to 3 5 241 GE35081X012 3 7 psig 255 Purple 1 5 to 100 to 3 6 to 248 to 3 psig 207 GE46922X012 3 5 psig 241 Orange 4 276 GE30192X012 6 psig 414 Dark Blue 6 414 GE33121X012 4to 7 5 Ei Red 6 414 GE33121X012 4to 7 5 aoe Red 2 5 to 170 to 276 to 5 psig 345 GE30343X012 5 5 psig 380 Yellow 7 483 GE33121X012 4to 7 5 517 Red 7 5 517 GE33121X012 4to 7 5 Red CS800 Series Tab
23. Instruction Manual Form 5837 November 2014 CS800 Series CS800 Series Commercial Industrial Pressure Reducing Regulators TYPE CS803 REGULATOR WITH TRUE MONITOR PROTECTION P1234 P1692 TYPE CS804IT REGULATOR WITH INTEGRAL TYPE VSX8 SLAM SHUT MODULE Figure 1 Typical CS800 Series Pressure Reducing Regulators Table of Contents MEE 1 Specifications eei darte da 2 Principle of Operation 4 3 Installation and Overpressure Protection 10 Sc 14 Adjustment IIT eee edie ead 14 16 Maintenance and 16 Parts Ordering entree 20 Parts pp 22 www fisherregulators com Introduction Scope of the Manual This Instruction Manual provides instructions for the installation maintenance and parts ordering information of CS800 Series service regulators Instructions and parts list for the Type TM600 Integral True Monitor are found in Instruction Manual D103126X012 Instructions and parts list for the Type VSX8 slam shut are found in Instruction Manual D103127X012 Process Management EMERSON D103124X012 CS800 Series Specifications The Specifications section lists the specifications for the CS800 Series regulators The following information is stamped on the regulator at the
24. RIAL Gray Cast Iron END CONNECTION BODY SIZE PART NUMBER GE25859X012 GE26296X012 FACE TO FACE BODY INLET DIMENSION PRESSURE RATING psig bar GE26303X012 ERAA02437A0 NPT 20 26300 012 6 12 155 Gray Cast Iron 2 ERAA02462A0 7 5 191 2 50 26301 012 7 5 191 CL125 FF 175 NPT 1 1 4 26306 012 6 12 155 1 1 2 ERAA02453A1 6 12 155 2 ERAA02437A1 6 12 155 2 ERAA02715A1 250 17 2 Ductile Iron 2 GE48292X012 1910 CL125 FF 2 50 ERAA02711A1 10 254 5800 CS820 CL150 FF CS850 CS803 2 50 ERAA02718A1 10 5 267 CS823 CS804 2 50 GE48296X012 7 50 1919 CS824 and CS854 PN 10 16 232 16 2 50 ERAA02719A1 10 254 14 40 GE26306X022 6 12 155 NPT 1 1 2 ERAA02453A2 6 12 155 2 fobi ERAA02437A2 6 12 155 290 20 WCC Steel Rp 2 T ERAA02715A2 6 12 155 CL150 RF 2 50 ERAA02720A2 10 254 PN 10 16 2 50 ERAA02719A2 10 254 232 16 Standard on Types CS 800 CS820 and CS850 On gt receive an aluminum plug ES Not available on Types CS804 5824 and CS854 The pressure temperature limits in this Instruction Manual or any applicable s Standard on Types CS803 CS804 CS823 CS824 and CS854 If a ductile iron or steel body material is selected without an Integral True Monitor or slam shut Overpressure Protection OPP device the port located at th
25. Type CS800 CS820 25 Ibs 11 kg Type CS803 CS823 34 Ibs 16 kg Type CS804 CS824 31 Ibs 16 kg Type CS805 CS825 26 Ibs 12 kg Type CS806 CS826 26 Ibs 12 kg High Pressure Types For CS85x add 2 Ibs 1 kg to types listed above With Flanged Body Add 11 Ibs 5 kg to weights listed above PED Conformity Statement and Information Types CS800 CS804 CS820 CS824 CS850 and CS854 are in conformity with the Pressure Equipment Directive PED 97 23 EC and are classified under Category for units without a slam shut and Category IV for units with a slam shut See Table 2 For Types CS800 CS820 and CS850 equipment and pipeline situated on outlet side of the regulator are either not subject to the PED PS lt 0 5 bar or subject to PS gt 0 5 bar in which case they should come under Category maximum PED Related Information See Table 2 1 The pressure temperature limits in this Instruction Manual and any applicable standard or code limitation should not be exceeded 2 Product has passed Emerson Process Management Regulator Technologies Inc Emerson testing for lockup relief start to discharge and reseal down to 40 degrees 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
26. ally Registered Regulator with Slam Shut Module Operational Schematic 11 CS800 Series If the regulator is exposed to an overpressure condition it should be inspected for any damage that may have occurred Regulator operation below these limits does not preclude the possibility of damage from external sources or from debris in the pipeline 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 Blow out any debris dirt or copper sulfate in copper tubing and the pipeline Apply pipe compound to the external threads of the pipe before installing the regulator Note Applying pipe compound to internal threads can result in excess pipe compound collecting in the body of the regulator and potentially clog registration ports affect lockup or downstream equipment 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 When designing a pressure reducing station using a CS800 Series 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 exc
27. 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 A CS800 Series regulator with an EN or ET in the type number has a blocked throat an O ring stem seal and a 3 4 NPT control line tapping in the lower diaphragm casing A regulator with a downstream control line is used for monitoring installations or other applications where there is other equipment installed between the regulator and the pressure control point For types with an EN or ET in the type number connect downstream control line tubing to the lower casing and run the tubing a distance of approximately 6 times the outlet piping diameter as shown in Figures 9 10 and 11 For best results the outer diameter of the control line tubing should be 3 8 in 9 5 mm or larger Downstream Control Line Installation with Integral True Monitor Refer to Figure 10 When installing the Types CS803ET and CS803EN regulators connect downstream control line tubing to the lower casing of the Primary Regulator and run the tubing a distance of approximately 6 times the outlet piping diameter downstream of the regulator outlet Connect a second separate downstream control line tubing to the lower casing of the Integral Monitor and run the tubing a distance of approximately 6 times the outlet piping diameter downstream of the Integral Monitor outlet For best results the outer diame
28. ction serves only as a backup to the primary seat for lockup Refer to the sections on Overpressure Protection and Maintenance Secondary Seat Protection does not provide additional overpressure protection in the event the secondary seat or disk is damaged by debris or contamination in the pipeline or from conditions that would cause the regulator to go wide open Installation and Overpressure Protection 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 foreign material that may plug the vent or vent line For outdoor installations point the spring case vent downward to allow condensate to drain see Figure 8 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 the outdoors See Vent Line Installation section for the recommended venting practices The CS800 Series regulators have an outlet pressure rating lowe
29. d the lower spring case key 9 to the body key 70 Separate the lower spring casing from the body Check the body O ring key 19 for wear and replace as necessary Note There are multiple disk assemblies based on construction and these are identified by color See Tables 13 14 and 15 for direction in selecting appropriate disk color Product performance will be changed if the incorrect disk assembly is used Examine the disk assembly key 36 for nicks cuts and other damage To replace remove the disk retainer clip key 36B and slide the disk assembly off of the stem key 11 CS800 Series 4 See Figure 17 a Ifthe seating edge of the CS800 Series orifice key 25 is nicked or rough remove the orifice from the body using a 2 in 50 mm socket wrench b If equipped with a CS805 CS806 Series Secondary Seat orifice assembly see the following section Disassembly to Replace Valve Disk and Secondary Seat orifice assembly for maintenance instructions Note If the orifice is replaced with a different size change the nameplate to state the new size and maximum inlet pressure see Table 4 Replace O ring key 82 Apply anti seize lubricant to the external threads of the new orifice orifice assembly and reassemble into the body Install the orifice per Figure 17 and tighten the orifice or orifice subassembly into the body per Figure 12 Reassemble the regulator in reverse order of the above steps O ring
30. d seat the outlet pressure will continue to rise This additional pressure causes the disk to apply additional force to the primary seat which causes the Secondary Seat to move toward the secondary disk sealing surface If downstream demand decreases to zero then the Secondary Seat will contact the sealing surface to provide lockup Refer to Table 7 for approximate lock up values provided by the Secondary Seat Types CS806 and CS826 Secondary Seat Protection with Bleed When the Secondary Seat is providing lockup the CS806 Series provides small bleed to the downstream System as an indication that the Secondary Seat is providing lockup In the event that the primary seat and disk cannot provide lockup the Secondary Seat will move into contact with a metal disk with a small drilled hole This metal to metal interface and bleed hole will allow a small amount of gas to bleed downstream thereby increasing outlet pressure until the Internal relief valve begins to discharge gas to the atmosphere The odor of this discharged gas provides an indication that the regulator is relying on the Secondary Seat for overpressure protection See Table 7 for the Downstream Pressure Buildup of the Internal relief acting in conjunction with the Type CS806 Secondary Seat Assembly Secondary Seat Protection Limitations Overpresssure conditions can occur in the downstream piping when the Secondary Seat Protection is installed The Secondary Seat 10 Prote
31. e typical installation as indicated 1 Open valves downstream of the regulator 2 Slowly close the upstream shut off valve 16 3 Inlet pressure should be released automatically downstream as the regulator opens in response to the lowered pressure on the diaphragm 4 Close outlet shut off valve Maintenance and Inspection 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 section Test the regulator that has been disassembled for repair to ensure that it is operating properly before being returned to service Only parts manufactured by Emerson 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 inspect and maintain this regulator periodically The frequency of inspection and replacement of parts depends upon the severity of service conditions or the requirement of local state and federal rules and regulations Perform periodic inspection on Wide Open Monitor regulators Integral True Monitor or Slam shut overpressure protection modules to ensure protection of the downstream system in the event of a failure to the primary regulator This inspection must test that the wide open monitor Integral True Monitor o
32. e bottom of the body will andard or code limitation should not be exceeded Table 4 Inlet Pressure Ratings and Flow and Sizing Coefficients MAXIMUM OPERATING INLET PRESSURE MAXIMUM ORIFICE SIZE TO OBTAIN OPTIMUM PERFORMANCE EMERGENCY INLET Mere IEC SIZING COEFFICIENTS psig Setpoints In w c Setpoints PRESSURE In mm psig bar psig bar psig bar C C C X F Fp 4 40 6 40 125 8 6 125 8 6 50 2 1 246 0 38 0 99 3 8 9 5 125 8 6 125 8 6 110 3 8 29 5 0 55 0 90 12 13 100 6 9 100 6 9 210 72 29 5 0 55 0 93 5 8 16 80 6 5 60 44 320 10 1 31 8 0 64 0 88 175 12 1 0 89 3 4 19 80 6 5 60 4 1 450 13 3 34 0 73 0 84 78 22 60 44 50 34 600 16 7 36 0 82 0 81 1 25 30 2 1 25 17 765 20 1 38 1 0 92 077 1 3 80 3502 15 1 0 15 1 0 1125 29 8 377 0 90 0 76 2 Not available on the Types CS803 and CS823 1 Not available on the Types CS805 CS806 CS825 and CS826 Table 5 Outlet Pressure Ranges CS800 Series OUTLET PRESSURE RANGE SPRING WIRE DIAMETER SPRING FREE LENGTH TYPE COLOR CODE PART NUMBER In w c mbar In mm In mm 3 5 to 6 9 to 15 Red GE30337X012 0 15 3 8 6 8 173 5 5 to 8 5 13 to 21 Black GE30338X012 0 17 4 3 6 8 173 5800 CS803 5519085 131021 Brown Use with Low donatio 0 16 4 1 83 211 CS804 CS805 Inlet LIN Option and CS806 8to 12 20 to 30 Purple GE30339X012 0 17 4 3
33. elief valve stem will separate the E Ring key 48 the spring retainer key 42 the relief spring key 41 the lower spring seat key 43 and the diaphragm assembly key 55 onto the pusher post key 50 See Figure 13 Token Relieving units measure and note for reassembly the distance between the top of the diaphragm stem key 44 and the top of the token relief hex nut key 46 Unscrew token relief nut with a 13 mm wrench Remove the spring seat key 42 and relief spring key 41 Unthread the second lower nut key 46 Pull the pusher post assembly key 50 through the diaphragm assembly Replace the pusher post O ring key 52 and diaphragm stem O ring key 115 Unscrew the pusher post nut key 110 which allows for separation of the lower spring seat key 43 diaphragm assembly key 55 and the pusher post retainer key 111 Reassemble in the reverse order of step five For the Token Relief Assembly ensure the distance from the top of the diaphragm stem key 44 Figure 13 to the top of the token relief hex nut key 46 is the same as before disassembly When assembling the diaphragm key 55A onto the diaphragm head key 55B apply a small amount of adhesive on the outer flat portion of the diaphragm head that contacts the diaphragm as indicated in Figure 13 Place the diaphragm head on the diaphragm and check to ensure the hole in the diaphragm head with the hole of the diaphragm are concentrically aligned Place the diap
34. er diameter opening is contacting the shelf of the orifice 6 Replace the Secondary Seat disk key 25C See Figure 18 a For Types CS805 and CS825 ensure that the rubber Nitrile NBR sealing surface is facing the Secondary Seating surface of the orifice b For Types CS806 and CS826 ensure that the hole in the center of the disk that acts as the spring seat is facing the spring 7 Press the disk inside the housing key 25A to allow the internal retaining ring to be reinserted Note If the orifice is replaced with a different size change the nameplate to state the new size and maximum inlet pressure see Table 4 8 Replace O ring key 82 Apply anti seize lubricant to the external threads of the new orifice orifice assembly and reassemble into the body Install and tighten the orifice per Figure 12 20 9 Reassemble the regulator in reverse order of the above steps O ring key 28 on end of stem key 11 should be lubricated before replacing the disk assembly The O ring is not a pressure retaining part but keeps the disk holder from rattling on the stem Note See Figure 12 always tighten bolts in a cross pattern Regulator Reassembly It is recommended that a good quality pipe thread sealant be applied to pressure connections and fittings and a good quality lubricant be applied to all O rings Also apply an anti seize compound to the adjusting screw threads and other areas as needed Reference Figures 12
35. essive pressure force on the regulator slam shut Note For Types CS805 CS825 CS806 and CS826 equipped with the white colored disk ensure that the open end of disk is oriented toward the downstream as indicated in Figure 7 If the body direction relative to the actuator is changed during installation the orientation of the white disk must also be removed turned and reinstalled to ensure the open end faces downstream 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 Figure 8 If the vent cannot be installed in 12 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 away from any building opening Regulators Subjected to Heavy Snow Conditions Some installations such
36. ever Pin Steel 14 Lever Pin Screw Plated steel 2 required 15 Hex head cap screw Steel 12 required 16 Nut Steel 10 required 17 Union Ring Aluminum 18 Snap Ring Music wire 19 O ring Nitrile NBR 25 Orifice Aluminum Standard For configurations without Secondary Seat Assembly 1 4 in 6 4 mm 3 8 in 9 5 mm 1 2 in 13 mm 5 8 in 16 mm 3 4 in 19 mm 7 8 in 22 mm 1 in 25 mm 1 3 8 in 35 mm 25 Orifice Assembly Brass Nitrile NBR For configurations with Secondary Seat Assembly For Types CS805 and CS825 without Bleed 3 8 in 9 5 mm 1 2 in 13 mm 5 8 in 16 mm 3 4 in 19 mm 7 8 in 22 mm For Types CS806 and CS826 with Bleed 3 8 in 9 5 mm 1 2 in 13 mm 5 8 in 16 mm 3 4 in 19 mm 7 8 in 22 mm Part Number GE26101X012 GE26102X012 T1121338982 GE29700X012 71120925072 GE29714X012 GE27061X012 GE27028X012 GE46735X012 GE27034X012 GE35010X012 GE29718X012 GE46526X012 GE46547X012 GE29724X012 GE26104X012 GE46833X012 GE27408X012 GE27021X012 GE29753X012 GE29701X012 GE30039X012 GE29973X012 GE30042X012 GE26416X012 GE27018X012 GE29755X012 GE29702X012 GE29703X012 GE29704X012 GE29705X012 GE29706X012 GE29707X012 GE29708X012 GE29710X012 GE29965X012 GE29968X012 GE29985X012 GE29986X012 GE29987X012 GE29970X012 GE29972X012 GE29989X012 GE29990X012 GE29991X012 25 25 25 25D 25 25 26 27 28 36 3
37. g Nitrile NBR For Ductile Iron and Steel Bodies non Overpressure Protection service only Screw 4 required Steel For Ductile Iron and Steel Bodies non Overpressure Protection service only Spring Pin Plated carbon steel For ductile iron and steel bodies not common to the Type CS804 Sense Tube For configurations with Slam Shut For configurations with True Monitor PROPER TIGHTENING OF BOLTS IN CROSS PATTERN Part Number GF01942X012 GF03443X012 GE38176X012 GE32722X012 ERAA02440A0 ERAA03562A0 CS800 Series P NOTE DIRECTION OF RETAINER RING INSTALLATION 11 12 11 8 2 do L2 38 L1 AR m O z T gt ce SA se Tu EN p N N N N N 7722222 Umm 7 M gz SN Po az 7A TN 8 8 D ee RETAINER RING L2 54 E INSTALLATION NOTE DIRECTION OF VENT SPRING INSTALLATION TORQUE 15 TO 25 IN LBS TORQUE 1 7 TO 2 8 Nem 15 TO 25 IN LBS GGO0886 F 1 7 TO 2 8 Nem 2 1 2 NPT VENT ASSEMBLY APPLY LUBRICANT L L1 ANTI SEIZE LUBRICANT L2 EXTREME LOW TEMPERATURE BEARING GREASE 1 Lubricants must be selected such that they meet the temperature requirements Figure 1
38. he Type VSX8 slam shut device is not followed This equipment includes the integral Type VSX8 or regulator configurations 1 To properly reset the Type VSX8 Slam shut after it has been tripped to the closed position insert a flat head screwdriver into the position shown in Figure 8 on the backside of the reset button refer to Type VSX8 Instruction Manual key 30 Figure 8 2 Slowly rotate the screwdriver to gradually pull the reset button refer to Type VSX8 Instruction Manual key 30 away from the Type VSX8 device This slow movement allows for a slow bleed of the pressure across the Type VSX8 Slam shut s disk and seat area The operator should be able to hear the pressure bleeding through the system 3 When the pressure has equalized and the air bleeding sound has dissipated completely pull the reset button refer to Type VSX8 Instruction Manual key 30 away from the Type VSX8 Slam shut device by hand until the internal shut off mechanism has been re latched 4 Once the operator feels the click of the re latch occurring completely push the reset button refer to Type VSX8 Instruction Manual key 30 back into its original position 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 steps below apply to th
39. hragm assembly into position in the lower casing make sure that the pusher post is hooked on the lever Note See Figure 12 To ease in the process of inserting the diaphragm assembly into the lower case key 9 and hooking it onto the lever key 10 loosen the four body bolts key 71 This will allow the lever to be rotated upward in order to slide the diaphragm assembly key 55 onto the lever After the diaphragm assembly is hooked to the lever rotate the diaphragm so that the diaphragm and lower casing holes are aligned Reassemble the remaining parts by following steps 1 to 3 in reverse order Note See Figure 12 always tighten bolts in a cross pattern Disassembly to Replace Valve Stem O ring For externally registered Types only e g Type CS800EN See Figures 12 14 and 15 1 See Figure 12 Remove the four body bolts key 71 and remove the body key 70 2 Check the body O ring key 19 for wear and replace as necessary See Figure 15 a All types except Type CS850 remove the closing cap key 60 Turn the adjusting screw key 65 counterclockwise to ease spring compression Remove adjusting screw and spring key 38 b Type CS850 loosen hex locknut key 107 Turn adjusting screw key 65 counterclockwise to ease spring compression Unscrew bonnet key 104 and remove Remove spring key 38 See Figure 12 Remove the nuts key 16 and hex bolts key 15 Separate the upper spring case
40. int higher than the integral monitor s setpoint must be installed to check the operation of the integral monitor An alternative to using a higher set spring on the primary regulator is to attach a hand pump and gauge to the primary regulator vent to pressure load it until its setpoint exceeds that of the integral True Monitor CS800 Series PROTECT VENT PIPE WITH RAIN CAP A utm CS800 SERIES REGULATOR N 2 NPT TYPE 289H RELIEF VALVE GE00886 REGULATOR VENT POINTED DOWNWARD Figure 8 CS800 Series Regulator Installed with the Vent Pointed Downward and with a Type 289H Relief Valve for High Capacity Relief gt gt WIDE OPEN MONITORING REGULATOR PRIMARY WORKING REGULATOR UPSTREAM DOWNSTREAM BLOCK VALVE BLOCK VALVE EE INLET PRESSURE E OUTLET PRESSURE Figure 9 CS800 Series Wide open Monitor Control Line Installation 15 CS800 Series When applying pressure to the regulator spring case through the vent care must be taken not to exceed 3 psig 0 21 bar which is the maximum differential across the diaphragm Types CS804 CS824 and CS854 with Slam shut Module When adjusting the Primary Regulator and Slam shut for operation reference Tables 10 and 11 and the footnotes in each table for the OPSO and OPSO UPSO setpoints of the slam shut for the given regulator spring ranges Equipment installed downstream the Type VSX8 slam shut device can be damaged if the following procedure for resetting t
41. isk is normally in the open reset position see Figure 5 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 shutoff refer to Type VSX8 Instruction Manual D103127X012 for additional details 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 CS800 Series ADJUSTING SCREW RELIEF VALVE STEM CONTROL SPRING RELIEF VALVE SPRING DISK DIAPHRAGM VALVE STEM p PUSHER POST ASSEMBLY LEVER SEAT ORIFICE M1070 INLET PRESSURE E OUTLET PRESSURE ATMOSPHERIC PRESSURE Figure 2 Type CS800IR Internally Registered Regulator with Internal Relief Operational
42. key 1 from the lower casing key 9 When disassembling a CS800 Series regulator lift the upper spring case straight up in order to avoid hitting the stem key 11 Slide the diaphragm head assembly key 55 away from the body key 70 to unhook the pusher post key 50 from the lever key 10 Lift off the diaphragm head assembly Remove the two lever retaining screws key 14 Lift lever up slightly and then slide in the direction away from the body Once the lever pin key 13 has cleared the lower actuator the lever can be lowered and at the same time rotated upward to allow it to be removed from the slotted stem key 11 See Figure 14 Remove the disk retainer clip key 36B and then remove the disk assembly key 36 Remove the stem key 11 by sliding it in the direction away from the body Replace stem O ring key 12 making certain to apply lubricant Reassemble in the reverse order Note When placing the diaphragm assembly into position in the lower casing make sure that the pusher post is hooked on the lever After the diaphragm assembly is hooked to the lever rotate the diaphragm so that the diaphragm and lower casing holes are aligned See Figure 12 always tighten bolts in a cross pattern 10 Reassemble the remaining parts by following steps 1 to 3 in reverse order Disassembly to Replace Valve Disk and Orifice See Figure 12 and 17 1 Remove the four hex bolts key 71 which hol
43. key 28 Figure 12 on end of stem key 11 should be lubricated before replacing the disk assembly This O ring is not a pressure retaining part but keeps the disk holder from rattling on the stem Note See Figure 12 always tighten bolts in a cross pattern Disassembly to Replace Valve Disk and Secondary Seat Orifice Assembly See Figure 12 1 Remove the four hex bolts key 71 which hold the lower spring case key 9 to the body key 70 Separate the lower spring casing from the body Check the body O ring key 19 for wear and replace as necessary Note There are multiple disk assemblies based on construction and these are identified by color See Tables 13 14 and 15 for direction in selecting appropriate disk color Product performance will be changed if the incorrect disk assembly is used If the White disk is selected the open side of the disk must be directed toward the outlet of the body as indicated in Figure 7 Examine the disk assembly key 36 for nicks cuts and other damage To replace remove the disk retainer clip key 36B and slide the disk assembly off of the stem key 11 See Figure 18 Remove the orifice assembly from the body using a 2 in 50 mm socket wrench 19 CS800 Series Table 12 Adjustment Tools KEY NUMBER PART DESCRIPTION ADJUSTMENT TOOL 15 Hex Bolt 1 2 in 13 mm Socket 16 Nut 1 2 in 13 mm Socket 25 Orifice Seat 2 in 50
44. le 9 Primary Regulator and Integral True Monitor Outlet Pressure Ranges with Token Relief PRIMARY REGULATOR INTEGRAL TRUE MONITOR Spring Pressure Setpoint Spring Part Range Spring Setpoint Spring Part Spring Pressure Range Spring yp Number Color Number Color In w c mbar In w c mbar In wc mbar In w c mbar 21 52 GE30196X012 18 to 30 45 to 75 Green 4 10 GE30337X012 3 5to6 9to15 Red 1 psig 69 GE30225X012 26 to 40 65 to 99 Orange 21 52 GE30196X012 18 to 30 45 to 75 Green 7 17 GE30338X012 5 5 to 8 5 13 to 21 Black 1 psig 69 GE30225X012 26 to 40 65 to 99 Orange Brown 21 52 GE30196X012 18 to 30 45 to 75 Green CS803IT 7 17 GE49043X012 5 5 to 8 5 131021 LIN LIN 1psig 69 GE30225X012 26 to 40 651099 Orange CS803 IL CS803ET and 1psig 69 GE30225X012 264040 651099 Orange CS803EL 11 27 GE30339X012 8to 12 20to30 Purple 1 5 psig 103 GE30190X012 1 4 to 2 9 psig 97 to 200 Black 1 psig 69 GE30225X012 26 to 40 65 to 99 Orange 14 35 GE30340X012 10to 16 25to 40 White 1 5 psig 103 GE30190X012 1 4 to 2 9 psig 97 to 200 Black Dark 2 psig 138 GE30190X012 1 4 to 2 9 psig 97 to 200 Black 1 psig 69 GE30341X012 14 to 30 35 to 75 G reen 3 psig 207 GE35081X012 2 6 to3 7 psig 17910255 Purple Dark 3 psig
45. leed to indicate Secondary Seat is functioning PRESSURE REGISTRATION Internal Registration External Registration RELIEF Non Relieving Internal Relief High Capacity Relief A o nu z Token Relief Low Flow Token Relief Example Type Number CS800IR Type CS800 regulator without Overpressure Protection Module with Internal Pressure Registration and with Internal Relief 1 High pressure Construction is not available with True Monitor Protection Secondary Seat Protection or Relief 2 Available only with Internal Relief or High Capacity Relief Constructions 3 Available only with Non Relieving or Token Relief Constructions 4 Reference Instruction Manual D103126X012 for information regarding the Type TM600 Integral True Monitor or Instruction Manual D103127X012 for Type VSX8 safety slam shut module High Capacity Relief Provides an increase in relief performance over basic internal relief via a 2 1 2 NPT vent thereby offering a significant improvement in the level of overpressure protection to the downstream system in the event of an overpressure occurrence Integral True Monitor Protection Provides a monitoring regulator integrally mounted on the inlet side of the valve body that assumes control of flow to the downstream system should the primary regulator cease to regulate flow Secondary Seat Protection Provides a solution to the most common cause of regulators failing to
46. mm Socket 44 Relief Valve Stem 9 mm Socket or Adjustable End Wrench 45 Bolt Diaphragm Assembly 1 2 in 13 mm Socket 60 Closing Cap 2 in 50 mm Socket 7 8 in Hex Allen Wrench M 2 50 mm Socket Adjusting Screw to 2 5 psig 0 17 bar spring range TI RETIRER i Large Flat head Screw Driver Adjusting Screw 2 to 5 5 psig 0 17 to 0 38 bar spring range 1 2 in 13 mm Socket Driver Extension Adjusting Screw above 5 psig 0 35 bar spring range 15 16 in 24 mm or Adjustable End Wrench 71 Body Bolt 1 2 in 13 mm Socket 72 1 4 NPT Pipe Plug 1 4 in Hex Allen Wrench 1 Use of Adjustment tool is optional Inspect the primary seating surface as well as the secondary seating surface and sealing surface If nicks or other damage are present start to disassemble the Secondary Seat assembly by removing the internal retaining ring key 25D with retaining ring pliers Use care when removing the internal retaining ring as the spring key 25F is compressed and will exert force on the Secondary Seat disk key 25C 5 Remove the Secondary Seat disk key 25C spring key 25F and double sided orifice key 25B Finally remove the orifice O ring key 25E Lubricate O ring with extreme low temperature bearing grease or similar lubricant that maintains its lubrication properties at cold temperatures and replace O ring Insert the new double sided orifice key 25B then the spring key 25F ensuring that the larg
47. ng E Ring Copper Standard Relief High Capacity Relief Low Start to Discharge for Standard Relief High Capacity Relief Pusher Post No Relief Aluminum Token Relief Standard Flow Aluminum Token Relief Low Flow Zinc plated steel Standard Relief High Capacity Relief Aluminum Low Start to Discharge for Standard Relief High Capacity Relief Aluminum Pusher Post O ring Nitrile NBR Token Relief Low Flow only Pusher Post Pin Stainless steel Roller Pin Brass Diaphragm Assembly Types CS800 and CS820 Type CS850 Diaphragm Nitrile NBR Diaphragm Head Zinc plated steel Types CS800 and CS820 Type CS850 Pusher Post Pin Retaining Ring Steel Spring Pin Zinc plated steel Token Relief Low Flow only Closing Cap Types CS800 and CS820 only Aluminum Gray Red O ring Nitrile NBR Adjusting Screw For Types CS800 and CS820 Aluminum Spring ranges up to 2 5 psig 170 mbar For Type CS820 Brass Spring ranges above 2 5 psig 170 mbar For Type CS850 Zinc plated steel Part Number GE27025X012 GE27025X012 GE27025X012 GE26111X012 GE26111X012 ERAA00767A0 ERAA00767A GE27058X01 NO GE27058X012 GE32061X012 GE29974X01 N GE30042X01 GE30042X01 NON GE27027X01 ERAAO00916A GE47664X01 ON N GE33106X012 GE33106X012 GE44924X01 GE44947X01 GE46958X01 2 2 2 GE44947X012 GE44947X012 GE47389X012 GE29761X01 GE27060X012 N GE29775X01 GE47296X01 GE29721X012 NON GE27019X01
48. nt size Figure 3 The Types CS800IT CS800IL CS800ET and CS800EL provide a low capacity token relief 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 Types CS803 and CS823 Integral True Monitor Operation Types CS803 and CS823 combine the operation of a conventional two regulator wide open monitor set into one body see Figure 4 The Integral True Monitor is installed on the inlet side of the body and serves to control downstream pressure in the situation where the Primary regulator can no longer regulate downstream pressure CS800 Series Table 2 PED Information Groups 1 and 2 according to PED 97 23 EC 1 and 2 family gas according to EN 437 or Slam shut Module European EN Reference Standards TYPE DESCRIPTION BODY MATERIAL PED CATEGORY CS800 CS820 and CS850 Base regulator Ductile Iron and WCC Steel l CS804 CS824 and CS854 Regulator with Ductile Iron and WCC Steel IV EN 334 EN 14382 other gases compressed air nitrogen The gas must be non corrosive clean filtration on inlet side necessary and dry FLUID GROUP Table 3 Body Sizes Materials End Connections and Maximum Cold Working Pressure Ratings TYPE BODY C800 5805 5806 5820 CS825 CS826 and CS850 MATE
49. o 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 Emerson Process Management Regulator Technologies Inc 2010 2014 All Rights Reserved
50. ociated Integral Monitor sets If the downstream pressure should rise to the setpoint of the True Monitor due to loss of pressure control by the primary regulator the monitor will assume control and regulate flow to the downstream system If a Token relief is present the token relief will relieve a small amount of gas to the atmosphere as an indication that the Integral Monitor is controlling the downstream pressure Either internal or external downstream pressure registration is available External pressure registration requires a downstream sensing line See the Type TM600 Integral True Monitor Instruction Manual D103126X012 for additional details of operation Types CS804 CS824 and CS854 Slam Shut Operation The Type VSX8 Slam shut module on the CS804 Series regulators is a fast acting shutoff device that provides overpressure OPSO or overpressure and underpressure OPSO UPSO protection by completely shutting off the flow of gas to the downstream system See Tables 10 and 11 for guidance regarding the typical setpoint of the regulator and associated OPSO and UPSO sets The Type VSX8 s actions are independent of the CS804 Series regulator and of variations to the inlet pressure The Type VSX8 provides the option of internal or external downstream pressure registration External registration requires a downstream sensing line See Figure 11 for guidance regarding installation of the downstream control line The Type VSX8 shutoff d
51. r Slam shut functions as intended Maintenance on CS800 Series with Secondary Seat Protection Types CS805 and C S825 regulators do not have any means to alert when the Secondary Seat operates at lockup A lock up test can be done on the regulator to determine if the lock up pressure has elevated to or near the values in Table 7 under the heading Types CS805 and CS825 If so replace the regulator primary disk and orifice Internal relief operation on units equipped with Secondary Seat Protection is an indication that the Secondary Seat Protection on the Types CS805IR and CS805lQ may not be working and that the Types CS806IR and CS806IQ Secondary Seat may have closed Maintenance should address any potential causes for internal relief operation as well as other regulator malfunctions separate from the Secondary Seat CS800 Series M1209 Ml INLET PRESSURE OUTLET PRESSURE ATMOSPHERIC PRESSURE Figure 10 Externally Registered Types CS803 and CS823 Regulator and Integral True Monitor Downstream Control Line Installation Mi INLET PRESSURE E OUTLET PRESSURE ATMOSPHERIC PRESSURE Figure 11 Externally Registered Types CS804 CS824 and CS854 Regulator and Slam Shut Downstream Control Line Installation CS800 Series Maintenance on CS800 Series Disassembly to Replace Diaphragm See Figures 12 13 and 15 1 18 See Figure 15
52. r 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 and referenced tables 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 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 CS800 Series ADJUSTING SCREW RELIEF VALVE SPRING CONTROL SPRING DIAPHRAGM VALVE STEM PUSHER POST ASSEMBLY INTEGRAL MONITOR MODULE SEAT ORIFICE M1074 INLET PRESSURE Ez OUTLET PRESSURE ATMOSPHERIC PRESSURE Figure 4 Type CS803lIT Internally Registered Primary Regulator with Internally Registered Integral Monitor Operational Schematic ADJUSTING SCREW UPSO SPRING RELIEF VALVE SPRING CONTROL LINE OPSO SPRING CONTROL SPRING DIAPHRAGM SENSE TUBE VALVE STEM VALVE PLUG PUSHER POST ASSEMBLY LEVER SEAT ORIFICE M1075 INLET PRESSURE OUTLET PRESSURE ATMOSPHERIC PRESSURE Figure 5 Type CS804IT Intern
53. rules and regulations and Emerson 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 ina hazardous condition Call a gas service person to service the unit Only a qualified person must install or service the regulator Description CS800 Series regulators are typically installed on industrial and commercial applications See Table 1 for available configurations Constructions with External Registration e g Type CS800EN require an external control line The CS800 Series offers multiple forms of overpressure protection including Internal Relief Minimizes downstream pressure buildup by relieving gas through the diaphragm assembly and out the 1 NPT vent to atmosphere in the event of an overpressure situation CS800 Series Table 1 Available Configurations TYPE NUMBER C 5 8 OPTIONS OUTLET PRESSURE CONSTRUCTION 0 Low Pressure Applications Outlet Pressure 3 5 to 30 in w c 9 to 75 mbar 2 Medium Pressure Applications Outlet Pressure 1 to 5 5 psig 0 07 to 0 38 bar 5 High Pressure Applications Outlet Pressure 5 to 10 psig 0 34 to 0 69 bar OVERPRESSURE PROTECTION MODULE Without Overpressure Protection Module With Integral True Monitor Module With Slam shut Module With Secondary Seat Protection o oOo o o With Secondary Seat Protection with controlled b
54. shutoff by employing a secondary seating surface to provide shutoff in the event the primary orifice seating surface becomes damaged or blocked Slam Shut Protection Discontinues gas service by shutting the gas off if there is an overpressure or underpressure condition Principle of Operation Types CS800 CS820 and CS850 Base Regulators Operation Refer to Figures 2 and 3 When downstream demand decreases the pressure under the 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 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 diaphragm The Type CS800IR regulator includes an internal relief valve for overpressure protection If the downstream pressure exceeds the regulator setting by 7 in w c to 2 5 psig 17 to 172 mbar depending on the type number and main spring used the relief valve opens and excess gas is vented through the stabilizer vent in the upper spring case Units with standard internal relief valve have 1 NPT vent size Figure 2 while units with high capacity relief valve have 2 1 2 NPT ve
55. size 7 8 in 22 mm orifice size Types CS806 and CS826 Secondary Seat with Bleed Disk or Backplate Repair Parts Kit For use with 3 8 and 1 2 in 9 5 and 13 mm orifice sizes For use with 5 8 3 4 and 7 8 in 16 19 and 22 mm orifice sizes Orifice Assembly Repair Parts Kit 3 8 in 9 5 mm orifice size 1 2 in 13 mm orifice size 5 8 in 16 mm orifice size 3 4 in 19 mm orifice size 7 8 in 22 mm orifice size Slam shut Repair Kit RCS805X0022 RCS805X0032 RCS805RFC38 RCS805RFC12 RCS805RFC58 RCS805RFC34 RCS805RFC78 RCS806X0022 RCS806X0032 RCS806RFC38 RCS806RFC12 RCS806RFC58 RCS806RFC34 RCS806RFC78 See Type VSX8 Instruction Manual Recommended spare part 22 D103127X012 Key Description 1 Upper Spring Case Aluminum 1 NPT vent size 2 1 2 NPT vent size 2 Vent Screen Stainless steel 1 NPT vent size 2 1 2 NPT vent size 3 Retaining Ring 1 NPT vent size Zinc plated steel 2 1 2 NPT vent size Stainless steel 4 Stabilizer Guide Stainless steel 1 NPT vent size 2 1 2 NPT vent size 5 Stabilizer 1 NPT vent size 2 1 2 NPT vent size 6 Stabilizer Spring Stainless steel 1 NPT vent size 2 1 2 NPT vent size 7 Stabilizer Retainer Ring Steel Nitrile NBR 1 NPT vent size 2 1 2 NPT vent size 8 Stabilizer screw 3 required Zinc plated steel 9 Lower Spring Case Aluminum Internal Sensing External Sensing 10 Lever Steel 11 Stem Stainless steel 12 O ring Nitrile NBR external sensing only 13 L
56. sure gauges should always be used to monitor downstream pressure during Startup With the downstream system depressurized perform the following procedure to startup the regulator 1 Check to see that all appliances are turned off Slowly open the upstream shut off valve Check inlet and outlet pressure for correct values Check all connections for leaks 9r 25 697 qw Turn on utilization equipment and recheck the pressures Adjustment Note The range of allowable pressure setting is stamped on the nameplate If the required setting is not within this range substitute the correct spring as shown in Table 5 If the spring is changed change the nameplate to indicate the new pressure range 14 Because of the weight of internal regulator parts the Red spring 3 5 to 6 in w c 9 to 15 mbar spring range nominal 4 in w c 10 mbar setting gives the best pressure control when the regulator spring barrel is pointed down Spring barrel down orientation may require that vent piping or vent adaptors are installed to keep the vent pointed down For types that include the Integral Monitor module refer to the Instruction Manual for Type TM600 Integral Monitor document D103126X012 for Adjustment and Maintenance of the Integral Monitor For types that include the Slam shut module refer to the Instruction Manual for Type VSX8 Slam shut document D103127X012 for Adjustment and Maintenance of the Slam shut A pressure ga
57. tem O ring Nitrile NBR Type CS850 only GE26812X012 Token Relief Low Flow only GE49041X012 105 Upper Spring Seat Zinc plated carbon steel Type CS850 only GE26809X012 106 Ball Bearing Stainless steel Type CS850 only GE33131X012 26 CS800 Series TORQUE 50 TO 60 IN LBS 48 5 6 TO 6 8 Nem 42 44 2 41 BEC 55B A Pd ES 43 d ES 99A MEASURE THIS DISTANCE AND NOTE FOR REASSEMBLY i i 53 50 y NOTE DIRECTION OF E 56 RETAINER RING INSTALLATION SEE DETAIL TYPE CS800 CS820 STANDARD HIGH CAPACITY RELIEF TORQUE 50 TO 60 IN LBS 5 6 TO 6 8 Nem L2 n5 42 TORQUE 50 TO 60 IN LBS 110 5 6 TO 6 8 Nem DO NOT 558 A LUBRICATE 95A D RE di N 4 S2 X MEASURE THIS DISTANCE AND NOTE FOR REASSEMBLY 56 12 NOTE DIRECTION OF ae RETAINER RING INSTALLATION SS TORQUE SEE DETAIL 50 TO 60 IN LBS 5 6 TO 6 8 Nem TYPE CS800 CS820 TOKEN RELIEF LOW FLOW DO NOT y LUBRICATE i NOTE DIRECTION OF RETAINER RING INSTALLATION RETAINER RING INSTALLATION DETAIL NOTE DIRECTION OF RETAINER RING INSTALLATION SEE DETAIL TYPE CS800 CS820 STANDARD FLOW TOKEN RELIEF 6600886 APPLY LUBRICANT L SEALANT S ADHESIVE A L2 EXTREME LOW TEMPERATURE BEARING GREASE 52 MEDIUM STRENGTH THREADLOCKER SEAL
58. ter of the control line tubing for both the Primary Regulator and the Integral Monitor should be 3 8 in 9 5 mm or larger 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 8 The outside end of the vent line should be protected with a rainproof assembly The Type 289H should be set 10 in w c 25 mbar higher than the outlet pressure setting of the regulator up to 30 in w c 75 mbar outlet pressure For pressure greater than this set the Type 289H 0 75 psi 52 mbar higher CS800 Series PRIMARY ORIFICE ELASTOMERIC SECONDARY METALLIC SECONDARY PRIMARY DISK SEATING SURFACE SEATING SURFACE ORIFICE SEATING SURFACE NORMAL OPERATION NORMAL LOCKUP DEBRIS OBSTRUCTING SECONDARY SEAT TYPE CS806 LOCKUP LOCKUP SECONDARY SEAT WITH SECONDARY SEATING CONTROLLED BLEED SURFACE SECONDARY SEAT DETAILED VIEW RELIEF VALVE STEM CONTROL SPRING RELIEF VALVE SPRING VALVE STEM SECONDARY SEAT DETAIL RELIEF SEAT M1072 INLET PRESSURE Ez OUTLET PRESSURE ATMOSPHERIC PRESSURE Figure 6 Type CS805IR with Secondary Seat Protection IF ACTUATOR ORIENTATION IS CHANGED THE WHITE DISK MUST BE REMOVED TURNED AND INSTALLED WITH THE DISK OPENING DOWNSTREAM Downstream DOWNSTREAM P1423 6600886 Figure 7 White Disk Orientation for use with Secondary Seat Protection
59. through 18 to determine the recommended lubricant sealant adhesive for these parts All lubricants sealants adhesives must be selected such that they meet the temperature requirements When reassembling torque bolts and fasteners per torque values are indicated on Figures 12 through 18 Some relaxation from initial torque values may occur Always tighten bolts in a cross pattern 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 and the 11 digit Part Number of each needed part as found in the following parts list Separate repair part kits containing all recommended elastomer spare parts are available Table 13 CS800 Series Disk Color Selection CS800 Series 1 PRESSURE TYPE OE SPANG RANGE BODY END DISK ABSEMEL REPAIR KIT REGISTRATION In DN In w c mbar MATERIAL CONNECTION COLOR PART NUMBER 1 1 4 32 and and 3 5 to 30 9 to 75 All Materials All Connections Black GE29773X022 RCS800XBLK2 1 1 2 40 3 5to 6 9 to 15 All Materials All Connections Green GE29773X042 RCS800XGRN2 CS800 us Cast All Connections Blue GE29773X032 R
60. uge should always be used to monitor downstream pressure while adjustments are being made 1 Remove the closing cap key 60 Figure 12 During setpoint adjustment do not mistake the Token Relief Spring Nut key 46 for the main spring adjusting screw Turning the Token Relief Spring Nut will change the token relief setting and if rotated counterclockwise could result in gas discharge and possible personal injury 2 To increase the outlet setting turn the adjusting screw key 65 Figure 12 clockwise To decrease the outlet setting turn the adjusting screw counterclockwise 3 Replace the closing cap or tighten the hex locknut Types CS803 and CS823 with Integral True Monitor Module When adjusting the primary regulator and integral True Monitor for operation ensure that the pressure differences between the primary regulator and the integral True Monitor shown in Tables 8 and 9 are observed For example if the primary regulator setpoint is set at 7 in w c 17 mbar then the integral monitor should be set at a minimum of 14 in w c 35 mbar or higher To test the integral monitor operation the primary regulator setpoint must be adjusted above the integral 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 monitor s setpoint by following step 2 above Otherwise a different spring with a setpo
61. y Repair Parts kit includes O ring key 19 disk assembly key 36 and O ring key 62 Orifice Repair Kit Part Number See Table 13 14 and 15 Orifice Repair Parts kit includes keys 25 Orifice and 82 O ring 1 4 in 6 4 mm orifice size 3 8 in 9 5 mm orifice size 1 2 in 13 mm orifice size 5 8 in 16 mm orifice size 3 4 in 19 mm orifice size 7 8 in 22 mm orifice size 1 in 25 mm orifice size 1 3 8 in 35 mm orifice size True Monitor Repair Kit When ordering repair kits for Types CS803 and CS823 it is necessary to order both a Primary GE31286X012 GE31287X012 GE31288X012 GE31289X012 GE31290X012 GE31291X012 GE31292X012 GE31294X012 Regulator Repair Kit found on Tables 13 14 and 15 and a True Monitor Repair Kit See the Type TM600 Instruction Manual for details on which parts are included Secondary Seat Repair Kit Disk or Backplate Repair Parts kit includes RTM600X0012 disk or backplate key 25C O ring key 25E and O ring key 82 Orifice Assembly Repair Parts kit includes orifice assembly key 25 and O ring key 82 Types CS805 and CS825 Secondary Seat without Bleed Disk or Backplate Repair Parts Kit For use with 3 8 and 1 2 in 9 5 and 13 mm orifice sizes For use with 5 8 3 4 and 7 8 in 16 19 and 22 mm orifice sizes Orifice Assembly Repair Parts Kit 3 8 in 9 5 mm orifice size 1 2 in 13 mm orifice size 5 8 in 16 mm orifice size 3 4 in 19 mm orifice
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