Emerson CP400 Instruction Manual
Contents
1. V U INI 71 TORQUE GE27401 D 10 TO 13 INCH POUNDS S U 1 1 TO 1 5 NeM GE27401 D SIDE VIEW TOP VIEW APPLY LUBRICANT L SEALANT S L ANTI SEIZE LUBRICANT S THREAD SEALANT 1 The torque range as specified is initial assembly torque Due to elastomeric compression the torque values indicated may decrease Minimum inspection torque is 35 inch pounds 4 0 Nem 2 Lubricant Sealant must be selected such that they meet the temperature requirements Figure 10 CP400 Series Pressure Loaded Pressure Reducing Regulator Assemblies aN S A TORQUE 50 TO 70 INCH POUNDS 5 6 TO 7 9 Nem A DIAPHRAGM AND STEM ASSEMBLY INTERNAL REGISTRATION EXTERNAL REGISTRATION ERAA03838_A GE27401_B APPLY ADHESIVE A APPLY LUBRICANT L L SILICON GREASE 1 Adhesive must be selected such that they meet the temperature requirements 1 Lubricant must be selected such that they meet the temperature requirements Figure 11 CP400 Series Diaphragm and Stem Assembly Figure 12 CP400 Series Registration Options 17 CP400 Series TORQUE 35 TO 45 FOOT POUNDS L1 L2 L2 47 TO 61 Nm TORQUE 35 TO 45 FOOT2. As downstream demand increases the outlet pressure registering on the underside of the main diaphragm decreases and the constant loading pressure above the main diaphragm forces the diaphragm downward This downward diaphragm motion is transferred through the lever causing the main disk to move away from the orifice seating surface to supply additional flow downstream to the required demand Decreasing Downstream Demand As downstream demand decreases the outlet pressure registering on the underside of the main diaphragm increases forcing the main diaphragm upward This upward motion is transferred through the lever causing the main disk to move toward the orifice seating surface to reduce flow to meet the required demand Zero Downstream Demand Lockup As downstream demand decreases further the outlet pressure registering under the main diaphragm together with the closing spring act to close the main disk against the orifice seating surface At this point the loading regulator will continue to supply a small amount of gas downstream that is equal to the capacity of the bleed restriction in the diaphragm assembly As downstream demand decreases to zero flow outlet pressure rises to meet the lock up pressure of the loading regulator This causes the loading regulator to lock up to stop all flow downstream Type numbers with a T for example Type CP4OOIT provide a token or low capacity relief The Token relief provides relief fr
3. 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 Type CP400 CP403 or CP404 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 3 feet 0 9 m away from any building opening 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 Downstream Control Line Installation A CP400 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 CP400 Series regulator with an EN or ET in the type number connect downstream control line tubing to the lower casing and run the tubing approximately 20 inches 0 5 m downstream For best results the outer diameter of the control
4. must test that the Integral Monitor or slam shut functions as intended The frequency of this inspection must be at intervals not exceeding 15 months but at least once each calendar year When maintenance is required on the slam shut device refer to the Type VSX4 Instruction Manual part number D103127X012 When maintenance is required on the Integral True Monitor device refer to the Type TM600 Integral Monitor Instruction Manual part number D103126X012 To Replace Main Diaphragm 1 Disconnect the tubing connector key 29 Figure 8 from the loading pressure regulator Remove closing cap key 60 Figure 8 and unscrew the nut key 47 Unthread the upper spring seat key 42 using a flat head screwdriver Remove the closing spring key 38 Unscrew and remove the cap screws key 15 and nuts key 16 and lift the spring case key 1 with attached loading regulator off the lower casing key 9 and the closing stem key 44 Note When disassembling a CP400 Series regulator lift the upper spring case key 1 and the loading pressure regulator straight up in order to avoid hitting the stem key 44 Lift the diaphragm assembly key 55 slightly so that the pusher post key 51 can release the valve lever key 10 Hold the pusher post key 51 fixed while unscrewing the closing stem key 44 from the pusher post key 51 Remove the diaphragm retainer key 43 and diaphragm head key 55 The dia
5. See Tables 7 and 8 for guidance regarding the setpoints of the regulator and associated Integral Monitor sets If the downstream pressure should rise to the setpoint of the internal monitor due to loss of pressure control by the primary regulator the Integral Monitor will assume control and regulate the flow to the downstream system See the Type TM600 Instruction Manual for additional details of operation 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 Type CP404 Slam shut Operation The Type VSX4 slam shut module on the Type CP404 regulator is a fast acting shut off device that provides overpressure OPSO or over and underpressure OPSO UPSO protection by completely shutting off the flow of gas to the downstream system See Tables 9 and 10 for guidance regarding the typical setpoints of the regulator and associated OPSO and UPSO settings The Type VSX4 s actions are independent of the Type CP404 regulator and of variations to the inlet pressure The Type VSX4 provides the option of internal or external downstream pressure registration External registration requires a downstream sensing line The Type VSX4 shut off disk is normally in the open reset position see Figure 4 If the downstream pressure below the slam shut diaphragm increases or decreases until it reaches the slam shut setpoint th
6. Company 16 Part Number T1122409012 T12522T0012 T1122309012 T1122009012 GE31234X012 T1121909012 GE30003X012 GE28684X012 10A3802X022 GE01439X012 GE26497X012 GE33771X012 GE27211X012 GE27349X012 GE27327X012 GE27397X012 GE30042X012 ERAA00877A0 Key 53 54 55 55a 55b 55d 56 57 60 62 65 70 71 74 Description Pusher Post Pin Stainless steel Roller Pin Brass Diaphragm Assembly Steel Nitrile NBR Diaphragm Diaphragm Head Diaphragm Pad Retaining Ring Pusher Post Pin Steel Slotted Spring Pin Zinc plated steel Closing Cap Aluminum O ring Nitrile NBR Adjusting Screw Aluminum Globe Body Gray Cast Iron 1 1 4 NPT 1 1 4 X 1 1 2 NPT 1 1 2 NPT 2 NPT NPS 2 DN 50 CL125 FF Ductile Iron 1 1 4 NPT 1 1 2 NPT 2 NPT Rp 1 1 4 Rp 1 1 2 Rp2 NPS 2 DN 50 CL125 CL150 FF NPS 2 DN 50 PN 10 16 Steel 1 1 4 NPT 1 1 2 NPT Rp 1 1 4 Rp 1 1 2 Bolts Steel 2 required Blanking Plug Aluminum Part Number GE29761X012 GE27060X012 GE32574X012 GE33772X012 GE33668X012 GE29244X012 T10275X0012 GE27828X012 GE26446X012 GE44458X012 GE26448X012 GE26459X012 GE26460X012 GE26465X012 GE26466X012 GE26467X012 GE26469X012 GE26470X012 GE26471X012 GE26480X012 GE26481X012 GE26465X022 GE26466X022 GE26469X022 GE26470X022 GE32061X012 GE31255X012 CP400 Series TORQUE 63 TO 90 INCH POUNDS ll 7 TO 10 NM
7. KEY 16 TYPE 67CPR DIAPHRAGM ASSEMBLY APPLY LUBRICANT L L MULTI PURPOSE PTFE LUBRICANT 1 Lubricant must be selected such that they meet the temperature requirements 9 COO 000GA TORQUE 15 TO 30 INCH POUNDS 1 6 TO 3 4 Nem TYPE 67CP PRESSURE REDUCING REGULATOR Figure 15 67CP Series Pressure Loading Regulator Assembly 19 CP400 Series Key Description Part Number Key Description Part Number 75 O ring Nitrile NBR GF03442X012 7 Bonnet Assembly Aluminum Steel T14070T0022 76 Flange Ring Steel 10 Cartridge Polyester T80434T0012 2 required GF01942X012 11 Valve Stem Brass 77 O ring Nitrile NBR GF03443X012 Type 67CP T14053T0012 80 Screw 4 required GE38176X012 Type 67CPR GE43501X012 90 Nameplate P 12 Valve Spring Stainless steel GE27212X012 91 Warning Label 13 Valve Retainer Engineered Resin T14071T0012 93 Label 2 2 14 O ring Nitrile NBR T14063T0012 94 Overlay Label r 15 Soft Seat Nitrile NBR Type 67CP only T14055T0012 95 Grommet Nitrile NBR GE35358X012 16 Diaphragm Assembly 96 Caution Tag when specified 2 Type 67CP 100 Wire and Seal when specified Nitrile NBR Steel T14119T0022 101 Slotted Spring Pin Carbon plated steel GE32724X012 Fluorocarbon FKM Steel T14119T0042 102 Filter Se
8. MODULE 0 Without Overpressure Protection Module 3 With Integral Monitor Module 4 With Slam shut Module PRESSURE REGISTRATION E External Registration RELIEF N Non Relief I Internal Registration T Token Internal Relief Example Type number CP404IT CP400 Series regulator construction with Type VSX4 Slam shut module Internal pressure registration and Token relief 1 Refer to Instruction Manual D103126X012 for information regarding the Integral Monitor Module 2 Refer to Instruction Manual D103127X012 for information regarding the Type VSX4 Slam shut module 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 rules and regulations and Emerson Process Management Regulator Technologies Inc Regulator Technologies instructions If 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 The CP400 Series regulators are pressure loaded regulators intended for general pressure reduction for commercial and industrial applications using press
9. Overpressure Shutoff OPSO Typical Setpoint Spring Range psig bar psig bar Spring Part Number psig bar psig bar 1 69 mbar 5 0 34 1to2 Heel to 2107 3 0 14 to 0 50 GFO02172X012 2 0 14 i 5 5 0 38 3 0 21 8 5 0 59 3 2 to 11 0 22 to 0 76 GF02173X012 CP404IN CP404 IT 4 0 28 2105 0 14 to 0 34 9 5 0 66 CP404EN and CP404ET 5 0 34 10 5 0 72 6 0 41 11 5 0 79 7 0 48 5to10 0 34 to 0 69 14 0 97 5 8 to 21 0 40 to 1 4 GF04353X012 10 0 69 17 1 2 12 0 83 18 1 2 CP404IN and CP404EN 15 1 0 10to 20 0 69 to 1 4 20 1 4 20 1 4 25 1 7 13 1 to 43 5 0 90 to 3 0 GF02173X012 1 Token Relief is not available with the 10 to 20 psig 0 69 to 1 4 bar spring range Table 10 CP404 Series Regulator and Slam shut Spring Ranges Overpressure and Underpressure Shutoff OPSO and UPSO REGULATOR SLAM SHUT Typical Setpoint Spring Range Overpressure Shutoff OPSO Underpressure Shutoff UPSO TYPE Typical Setpoint Spring Range d Typical Setpoint Spring Range 2 A Spring Part Spring Part psig bar Psig n Number Number psig bar psig bar psig bar psig bar 0 36 to 0 03 to T14170T0012 2 014 014 55 oss 22 0131 Grozt7oxo12 1 59 mbar 23 0 16 3 0 21 8 5 0 59 2 0 14 CP404IN 0 14 to CP404IT 4 0 28 2105 0 34 9 5 0 66 3 0 21 use etes CP404EN 5 0 34 10 5 0 72 4 0 28 2 7 FA142869X12 and CP4
10. 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 in the Specifications section and or 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 On outdoor installations point the spring case vent downward to allow condensate to drain see Figures 5 through 7 This minimizes the possibility of freezing and of water or other foreign materials entering the vent and interfering with proper operation For the Type CP403 with the Integral Monitor or the Type CP404 with Slam shut point the vents of both the Primary Regulator and Integral Monitor or Slam shut downward to allow condensate to drain From the factory the Integral Monitor or Slam shut will always point in the same direction as that of the Primary Regulator 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 The CP400 Series regulators have an outlet pressure rating lower than their inlet pressure rating If actual inlet pressure can exceed the outlet pressure rating
11. is 25 psig 1 7 bar Startup Pressure gauges should always be used to monitor downstream pressure during Startup Note For types that include the Integral Monitor module refer to the Instruction Manual for Type TM600 Integral Monitor for adjustment and maintenance of the Integral Monitor For the types that include the slam shut module refer to the CP400 Series instruction manual for Type VSX4 Slam shut for adjustment and maintenance of the slam shut The range of allowable pressure settings for the primary regulator 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 A pressure gauge should always be used to monitor downstream pressure while adjustments are being made Adjustment To increase the outlet pressure setting of the regulator the adjusting screw of the loading regulator key 18 Figure 15 must be turned clockwise This requires loosening the locknut key 19 To reduce the outlet pressure setting turn the adjusting screw counterclockwise Retighten the locknut A pressure gauge should always be used to monitor downstream pressure while adjustments are being made Do not remove the locknut or adjust the spring to produce an outlet pressure setting outside the range of 1 to 20 psig 69 mbar to 1 4 bar CP400 Series with Integral Monito
12. 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 m aa Ss EMERSON Emerson Process Management Regulator Technologies Inc 2009 2014 All Rights Reserved
13. outlet overpressure protection is necessary However overpressuring any portion of the regulators beyond the limits in Specifications section 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 to the CP400 Series if inlet pressure will be CP400 Series i i PROTECT VENT PIPE T WITH RAIN CAP i i i H CP400 SERIES REGULATOR TYPE 289H RELIEF VALVE e TYPE 67CP CPR VENT POINTED DOWN Figure 5 CP400 Series Regulator Installed the Vent Pointed Downward and with Type 289H Relief Valve for High Capacity Relief PRIMARY REGULATOR UPSTREAM BLOCK VALVE lt 20 INCHES 0 5 m DOWNSTREAM BLOCK VALVE M1062 EINEN INLET PRESSURE EE OUTLET PRESSURE ATMOSPHERIC PRESSURE INTEGRAL MONITOR Figure 6 Typical CP403 Downstream Control Line Connection Pressure Loading Regulator Not Shown C M1063 EHE INLET PRESSURE EE OUTLET PRESSURE ATMOSPHERIC PRESSURE P400 Series PRIMARY REGULATOR UPSTREAM BLOCK VALVE A n Ala R 20 INCHES 0 5 m e DOWNSTREAM BLOCK VALVE onilati SLAM SHUT Figure 7 Typical CP404 Downstream Cont
14. should be installed as shown in Figure 5 The outside end of the vent line should be protected with a rainproof assembly The Type 289H is typically set 10 inches w c 25 mbar higher than the outlet pressure setting of the regulator up to 30 inches w c 75 mbar outlet pressure For pressure greater than this set the Type 289H 0 75 psi 0 05 bar higher than the outlet pressure setting of the regulator Vent Line Installation The CP400 Series regulators have a 1 4 NPT screened vent opening in the spring case of the loading pressure regulator 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 For Types with optional Token relief this optional low capacity relief is located in the spring case of the Type 67CPR Loading Pressure Regulator If necessary to vent escaping gas away install a remote vent line in the spring case tapping of the Type 67CPR Loading Pressure Regulator as described above Periodically check all vent openings to be sure that they are not plugged CP400 Series Outlet pressure ranges are shown in Table 5 Outlet pressure greater than 5 psi 0 34 bar above setpoint may damage internal parts such as the diaphragm head and valve disk The maximum emergency casing outlet pressure
15. the backside of the body refer to the applicable Instruction Manual for inspection and removal of the overpressure protection orifice key 26 and O ring key 27 6 Reassemble in reverse order of the above procedure Care should be taken so that the O ring key 21 is not cut Types 67CP and 67CPR Trim Maintenance Key numbers are referenced in Figure 15 1 Remove four bottom plate screws key 3 from the bottom plate key 39 and separate the bottom plate and O ring key 4 from the body key 1 2 Inspect the removed parts for damage and debris Replace any damaged parts 3 To remove the valve cartridge assembly grasp the end of cartridge key 10 and pull it straight out of body key 1 Replace with new cartridge assembly The cartridge assembly may be disassembled and parts may be cleaned or replaced If the soft seat key 15 was removed make sure it is properly snapped into place before installing the valve cartridge assembly 4 Check O ring key 14 for wear and replace if necessary Apply lubricant to the O ring and place in the body Align cartridge key to keyway in body and insert Reinstall the O ring key 4 secure the bottom plate key 39 with screws key 3 and torque to 15 to 30 inch pounds 1 9 to 3 9 Nem Regulator Reassembly As indicated by the square callouts in Figures 8 to 15 it is recommended that a good quality pipe thread sealant be applied to pressure connections and fittings and a goo
16. 04ET 5 8to 0 40t0 SF02172X012 73 0 50 6 16 14 45 0 31 5 5 0 38 8 0 55 11 6 to 0 80 to 1 5to 0 10 to 232 16 GF02173X012 9 0 62 10 9 0 75 T14171T0012 CP404IN and 15 1 0 10 to 20 0 69 to 20 1 4 10 0 69 CP404EN 9 14 xm EIS 20 1 4 25 17 161029 5 9 GF02171X012 14 0 96 SAM 2 00 FA442869X12 2 0 29 2 0 1 Token Relief is not available with the 10 to 20 psig 0 69 to 1 4 bar spring range CP400 Series TYPE 67CP PRESSURE LOADING REGULATOR ORIFICE iUnd VALVE DISK HG INLET PRESSURE m OUTLET PRESSURE ATMOSPHERIC PRESSURE LOADING PRESSURE CONTROL SPRING LOADING REGULATOR DIAPHRAGM CLOSING SPRING PUSHER POST MAIN DIAPHRAGM EXTERNAL CONTROL LINE PLUG DO NOT REMOVE IF UNIT IS PRESSURIZED VALVE STEM Figure 2 Type CP400IN with Internal Pressure Registration Operational Schematic Principle of Operation Type CP400 Base Regulator Operation The CP400 Series has spring to close construction The CP400 Series uses a 67CP Series loading pressure regulator to supply loading pressure to the top of the main diaphragm Since the loading pressure regulator controls the main regulator adjustment to the downstream pressure is made to the loading pressure regulator The load pressure supplied by the loading regulator is constant and equal to the desired downstream pressure plus the pressure required to overcome the light closing spring Increasing Downstream Demand
17. 397T0012 14 Lever Screw Zinc plated steel 2 required GE34243X012 15 Cap Screw Steel 8 required GE32059X012 16 Nut Steel 8 required GE32060X012 17 Union Ring Aluminum GE26590X012 18 Snap Ring Stainless steel T1120637022 19 O ring Nitrile NBR 1K594906562 20 Stem Guide Aluminum GE25385X012 21 O ring Nitrile NBR GE45216X012 22 Pipe Plug 3 4 NPT Carbon steel for internal registration only GE34199X012 23 Screw Steel 1E175828982 24 O ring Nitrile NBR 17A0960X012 Recommended spare part CP400 Series TORQUE 15 TO 30 INCH POUNDS 1 7 TO 3 4 Nem SS 100 L2 m L1 L1 7 8 103 5 6 4 96 62 60 47 42 38 65 19 s 29 L2 21 L1 20 E e b 37 TORQUE 44 50 TO 70 INCH POUNDS L2 28 5 6 TO 7 9 Nem 30 55 s 29 51 L1 25 27 36 12 48 11 i2 13 14 95 10 L2 104 22 L2 L2 71 TORQUE S 15 TO 30 INCH POUNDS TORQUE TORQUE 1 7 TO 3 4 Nem TORQUE 35 TO 45 FOOT POUNDS 10 TO 13 FOOT POUNDS 15 TO 30 INCH POUNDS 47 TO 61 Nem 14 TO 18 Nem 1 7 TO 3 4 Nem TORQUE 63 TO 90 INCH POUNDS 7 TO 10 Nm GE27401 D APPLY LUBRICANT L SEALANT S L1 ANTI SEIZE LUBRICANT L2 SILICON GREASE S THREAD SEALANT 1 Lubrican
18. 5 0 kg Type CP403 20 5 pounds 9 3 kg Type CP404 13 2 pounds 6 0 kg Add 8 6 pounds 3 9 kg to weights listed with flanged body 1 The pressure temperature limits in this Instruction Manual and any applicable standard or code limitation should not be exceeded 2 Product has passed Regulator Technologies testing for lockup relief start to discharge and reseal down to 40 degrees Table 2 Inlet Pressure Ratings and Flow and Sizing Coefficients ORIFICE SIZE popup or NDE OREN IEC SIZING COEFFICIENTS Inch mm psig bar C C X Fp FL 3 16 4 8 125 8 6 27 0 97 27 7 0 50 0 91 1 4 6 4 125 8 6 50 1 77 28 2 0 50 0 92 3 8 9 5 80 5 5 113 3 72 30 4 0 58 0 89 jo 1 2 13 60 4 1 182 5 61 32 4 0 66 0 82 5 8 16 50 3 4 284 7 26 39 1 0 97 0 74 3 4 19 40 2 8 356 9 83 36 2 0 83 0 72 CP400 Series Table 3 Maximum Outlet Pressures TYPE EMERGENCY OUTLET MAXIMUM OUTLET PRESSURE TO MAXIMUM OPERATING PRESSURE CASING AVOID INTERNAL PARTS DAMAGE OUTLET PRESSURE CP400 and CP404 25 psig 1 7 bar 25 psig 1 7 bar 20 psig 1 4 bar CP403 25 psig 1 7 bar 5 psi 0 34 bar over setpoint 7 5 psig 0 52 bar Table 4 Body Sizes Material End Connections and Pressure Ratings BODY END FACE TO FACE DIMENSION PRESSURE RATING TYRE MATERIAL BODY SIZE CONNECTION
19. 5 172 to 465 ranges are available with token relief 1 Outlet pressure range is controlled by 67CP Series pressure loading regulator spring Only the 1 to 2 2 to 5 and 5 to 10 psig 69 mbar to 0 14 0 14 to 0 34 and 0 34 to 0 69 bar spring Table 7 CP403 Series Spring Ranges Without Token Relief PRIMARY REGULATOR INTEGRAL MONITOR TYPE Typical Setpoint Spring Range Minimum Setpoint Spring Range Spring Color Spring Color psig bar psig bar psig bar psig bar 1 69 mbar 1 4 to 2 9 0 10 to 0 20 Black 1to2 69 mbarto 0 14 Yellow Stripe 2 0 14 2 6 to 3 7 0 18 to 0 26 Purple CP403IN and CP403EN 3 0 21 3 6 to6 0 25 to 0 41 Dark Blue 4 0 28 0 14 to 0 34 Orange Stripe E m 5 1 to 7 5 0 35 to 0 52 Red CP400 Series Table 8 CP403 Series Spring Ranges With Token Relief PRIMARY REGULATOR INTEGRAL MONITOR TYPE Typical Setpoint Spring Range Minimum Setpoint Spring Range Spring Color Spring Color psig bar psig bar psig bar psig bar 1 69 mbar 5 0 34 3 6 to 6 0 25 to 0 41 Dark Blue CEO NT dnd 1to2 69mbarto0 14 Yellow Stripe CP403ET 2 0 14 5 5 0 38 5 110 7 5 0 35 to 0 52 Red Table 9 CP404 Series Regulator and Slam shut Spring Ranges Overpressure Shutoff OPSO Only REGULATOR SLAM SHUT pe Typical Setpoint Spring Range
20. Inch mm psig bar 1 1 4 1 1 2 NPT 45 114 CP400 Gray Cast Iron 1 1 4 x 1 1 2 175 12 1 2 5 127 NPS 2 DN 50 CL125 FF 10 254 1 1 4 1 1 2 NPT Bd na 2 5 127 1 1 4 290 20 0 Ductile Iron 1 1 2 Rp 45 Ts CP400 CP403 CL125 FF 127 d CP404 an NPS 2 DN 50 CL150 FF 40 254 NPS 2 DN 50 PN 10 16 232 16 0 s NPT 4 5 114 Steel 144 75 191 290 20 0 Rp 1 1 2 10 254 Table 5 Outlet Pressure Ranges SXBE OUTLET PRESSURE RANGE SPRING PART SPRING SPRING WIRE DIAMETER SPRING FREE LENGTH F NUMBER NUMBER COLOR psig bar Inch mm Inch mm CP400 CP4032 1to2 69 mbar to 0 14 1 GE30199X012 Yellow Stripe 0 085 2 16 1 47 37 3 and CP404 2105 0 14 to 0 34 2 GE27213X012 Orange Stripe 0 096 244 147 37 3 CP400 and 5to 10 0 34 to 0 69 3 GE39890X012 Black Stripe 0 114 2 90 1 47 37 3 CP404 10 to 20 0 69 to 1 4 4 GE30200X012 Purple Stripe 0 137 3 48 143 36 3 1 Outlet pressure range is controlled by 67CP Series pressure loading regulator spring 2 Maximum operating outlet pressure for the integral True Monitor installed on Type CP403 is 7 5 psig 0 52 bar Table 6 Token Relief Valve Start to Discharge Pressure Above Setpoint START TO DISCHARGE PRESSURE 1 SPRING RANGE SPRING COLOR SPRING PART RANGE ABOVE SETPOINT NUMBER a psig bar psig mbar 1to2 69 mbar to 0 14 Yellow Stripe GE30199X012 1 to 3 5 69 to 241 2to5 0 14 to 0 34 Orange Stripe GE27213X012 1 75 to 5 5 121 to 379 5 to 10 0 34 to 0 69 Black Stripe GE39890X012 2 5 to 6 7
21. Instruction Manual Form 5835 June 2014 CP400 Series CP400 Series Commercial Industrial Pressure Loaded Pressure Reducing Regulators P1522 TYPICAL TYPE CP403 REGULATOR WITH INTEGRAL TRUE MONITOR PROTECTION MODULE TYPICAL TYPE CP404 REGULATOR WITH INTEGRAL SLAM SHUT MODULE Figure 1 CP400 Series Pressure Loaded Pressure Reducing Regulator Table of Contents a rore 8 o To o EREMO 1 Specifications escini niii aa 3 Principle of Operation cccccceceeeeeeeeeeeeceeeeeeeeeees 6 Installation and Overpressure Protection 8 rnm cadens a N aa aeea 11 AGJUSUIM Nienna E 12 SNU OWN ete eran tte adu dpa aa aa 13 Maintenance and Inspection ssssss 13 Parts Ordering be pM er rete 14 gale REM 14 www fisherregulators com Introduction Scope of the Manual This manual provides instructions for the installation maintenance and parts ordering information for the CP400 Series pressure loaded regulators Refer to the Type TM600 Instruction Manual for additional information regarding the operation of the CP400 Series with the Integral True Monitor module Refer to the Type VSXA Instruction Manual for additional information regarding the operation of the CP400 Series with the slam shut module amp Process Management EMERSON D103122X012 CP400 Series Table 1 Available Configurations TYPE NUMBER c P 4 0 OPTIONS OVERPRESSURE PROTECTION
22. POUNDS L1 47 TO 61 Nem RENE GE27401 C TRUE MONITOR ASSEMBLY TORQUE 35 TO 45 FOOT POUNDS 47 TO 61 Nm L1 L2 L2 L1 TORQUE 35 TO 45 FOOT POUNDS 26 27 70 27 25 101 47 TO 61 Nm o CIE BENI SLAM SHUT ASSEMBLY APPLY LUBRICANT L L1 ANTI SEIZE LUBRICANT L2 SILICON GREASE 1 Lubricants must be selected such that they meet the temperature requirements Figure 13 CP400 Series Slam shut and Integral Monitor Modules 18 29 4 S 30 GE27401 D TYPE CP400 ONLY GRAY CAST IRON BODY APPLY SEALANT S S THREAD SEALANT 1 Sealant must be selected such that they meet the temperature requirements CP400 Series TYPE 67CP 67CPR PRESSURE LOADING REGULATOR 31 TE N 29 S 30 TYPES CP400 CP403 AND CP404 DUCTILE AND STEEL BODY TYPE CP400 WITH OPTIONAL INLET FILTER GRAY CAST IRON BODY Figure 14 Gray Cast Iron Ductile Iron and Steel Body Configurations VENT POSITION 2 VENT TORQUE POSITION 3 15 TO 30 INCH POUNDS 1 6 TO 3 4 NM INLET VENT POSITION 1 VENT STANDARD POSITION 4 VENT POSITION 5 GAUGE PLUG AA N LN GE38988
23. d quality lubricant be applied to all O rings except when replacing key 19 Also apply an anti seize compound to the adjusting screw threads and other areas as needed See Figures 8 through 14 for details Parts Ordering The type number orifice port size 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 If construction changes are made in the field be sure that the nameplates are also changed to reflect the most recent construction When ordering replacement parts reference the key number of each needed part as found in the following parts list Separate kit containing all recommended spare parts is available Parts List CP400 Series Pressure Loaded Regulator Main Valve and Actuator See Figures 8 through 14 Key Description Part Number Spare Parts Repair Parts Kit includes keys 12 19 21 27 36 55 and 62 Types CP400 CP403 and CP404 RCP400X0012 1 Upper Spring Case Aluminum GE24555X012 4 Stabilizer Guide Stainless steel GE27061X012 5 Stabilizer Engineered Resin GE46735X012 6 Stabilizer Spring Stainless steel GE35010X012 7 Pipe Nipple Zinc plated steel 10488226232 8 Pipe Bushing Zinc plated steel 1H1714X0032 9 Lower Casing Aluminum GE24289X012 10 Lever Steel GE27194X012 11 Stem Aluminum GE27402X012 12 O ring Nitrile NBR 1E472706992 13 Lever Pin Stainless steel T14
24. e P590X1 Type 67CPR Nitrile NBR Aluminum GE40272X012 103 Stabilizer Retainer Steel GE27024X012 17 Spring Stainless steel 104 Stabilizer Screw 3 required Zinc plated GE29724X012 1 to 2 psig 69 mbar to 0 14 bar Yellow Stripe GE30199X012 2 to 5 psig 0 14 to 0 34 bar Orange Stripe GE27213X012 5 to 10 psig 0 34 to 0 69 bar Black Stripe GE39890X012 67CP Series Pressure Loading Regulator 10 to 20 psig 0 69 to 1 4 bar Purple Stripe GE30200X012 18 Adjusting Screw Steel T14101T0012 See Figure 1 5 19 Lekn Sis 1A946324122 20 Upper Spring Seat Steel T14051T0012 Key Description Part Number 23 1 4 NPT Pipe Plug Alloy plated steel 1C333528992 Valve Cartridge Assembly 33 Closing Cap Plastic 23B9152X012 For Type 67CP without relief only includes 39 Bottom Plate Stainless steel NACE GE03520XRG2 keys 10 11 12 13 14 and 15 T14121T0082 45 Screen Stainless steel 0L078343062 For Type 67CPR with relief only includes 48 Relief Valve Plug Type 67CPR only Brass GE43500X012 keys 10 11 12 13 and 14 T14121T0142 4 Relief Valve Spring Type 67CPR only 1 Body Aluminum T40643TORG2 Stainless steel GE40051X012 3 Flange Screw Steel 10 required T13526T0012 4 O ring Nitrile NBR T14380T0012 Recommended spare part Industrial Regulators Emerson Process Management Regulator Technologies Inc USA McKinney Texas 75070 USA Tel 1 800 558 5853 Outside U S 1 972 548 3574 Asia Pacific Shanghai 201206 Chi
25. is 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 Refer to the Type VSXA Instruction Manual to reset the slam shut device 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 CP400 Series OPSO ADJUSTING SCREW UPSO ADJUSTING SCREW TYPE 67CP PRESSURE LOADING REGULATOR UPSO SPRING OPSO SET SPRING SLAM SHUT ORIFICE RESET KNOB TYPE VSX4 SLAM SHUT MODULE M1068 Gl INLET PRESSURE EX OUTLET PRESSURE ATMOSPHERIC PRESSURE LOADING PRESSURE SHUT OFF DISK EXTERNAL CONTROL LINE PLUG DO NOT REMOVE IF UNIT IS PRESSURIZED PRIMARY REGULATOR Figure 4 Type CP404IN Pressure Loaded Regulator with Slam shut Module and Internal Pressure Registration Operational Schematic Installation and Overpressure
26. line tubing should be 3 8 inch 9 5 mm or larger Downstream Control Line Installation with Integral Monitor Refer to Figure 6 When installing the Types CP403ET and CP403EN regulators connect downstream control line tubing to the lower casing of the Primary Regulator and run the tubing approximately 20 inches 0 5 m downstream Connect a second separate downstream control line tubing to the lower casing of the Integral Monitor and run the tubing approximately 20 inches 0 5 m downstream For best results the outer diameter of the control line tubing for both the Primary Regulator and the Integral Monitor should be 3 8 inch 9 5 mm or larger Downstream Control Line Installation with Slam shut Refer to Figure 7 When installing the Types CP404ET and CP404EN regulators connect downstream control line tubing to the lower casing of the Regulator and run the tubing approximately 20 inches 0 5 m downstream Connect a second separate downstream control line tubing to the lower casing of the slam shut and run the tubing approximately 20 inches 0 5 m downstream For best results the outer diameter of the control line tubing for the Regulator should be 3 8 inch 9 5 mm or larger The outer diameter of the control line tubing for the slam shut should be 1 4 inch 6 4 mm or larger CP400 Series Installation with External Overpressure Protection If the regulator is used in conjunction with a Type 289H relief valve it
27. m shut device Due to these factors additional protections should be installed to stop flow in the event of a line break Equipment installed downstream the Type VSX slam shut device can be damaged if the following procedure for resetting the Type VSX slam shut device is not followed This equipment includes the integral Type VSX regulator configurations Step 1 To properly reset the Type VSX slam shut after it has been tripped to the closed position a flat head screwdriver must be inserted into the position shown in Figure 8 on the backside of the reset button key 30 Figure 8 Step 2 The screwdriver should be slowly rotated to gradually pull the reset button key 30 away from the Type VSX device This slow movement allows for a slow bleed of the pressure across the Type VSX slam shut s disk and seat area The operator should be able to hear the pressure bleeding through the system Step 3 When the pressure has equalized and the air bleeding sound has dissipated the reset button key 30 should be pulled completely away from the Type VSX slam shut device by hand until the internal shut off mechanism has been re latched Step 4 Once the operator feels the click of the re latch occurring the reset button key 30 should be pushed completely back into its original position Shutdown Installation arrangements may vary but in any installation it is important that the valves be opened or closed slowl
28. na Tel 86 21 2892 9000 Europe Bologna 40013 Italy Tel 39 051 419 0611 Headquarters USA Headquarters Tel 1 800 558 5853 Asia Pacific Tel 65 6770 8337 Europe Bologna 40013 Italy Tel 39 051 419 0611 Natural Gas Technologies Emerson Process Management Regulator Technologies Inc McKinney Texas 75070 USA Outside U S 1 972 548 3574 Singapore 128461 Singapore 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 g Chartres 28008 France Middle East and Africa Tel 33 2 37 33 47 00 1 Dubai United Arab Emirates EN Tel 011 971 4811 8100 Middle East and Africa Dubai United Arab Emirates Tel 011 971 4811 8100 The distinctive swirl pattern cast into every actuator casing uniquely identifies the regulator as part of the Fisher brand Commercial Service Regulator family 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 Co All other marks are the property
29. om minor overpressure caused by nicks or dents on the orifice or by thermal expansion CP400 Series Be TYPE 67CPR PRESSURE OREN x JEN LOADING REGULATOR S CONTROL SPRING GUIDED pomi m MONITOR STEM E aa LEVER OPENING ao SPRING MONITOR B DISK S c gt EXTERNAL CONTROL LINE PLUG DO NOT REMOVE IF UNIT IS PRESSURIZED VALVE STEM WIDE OPEN INTEGRAL MONITOR REGULATOR M1067 ENENE INLET PRESSURE EX OUTLET PRESSURE ATMOSPHERIC PRESSURE LOADING PRESSURE EXTERNAL CONTROL LINE PLUG DO NOT REMOVE IF UNIT IS PRESSURIZED PRIMARY REGULATOR Figure 3 Type CP403 T Pressure Loaded Regulator with True Monitor and Internal Pressure Registration Operational Schematic 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 Type CP403 Integral Monitor Operation Type CP403 combines the operation of a conventional two regulator wide open monitor set into one body see Figure 3 The Integral True Monitor is installed on the inlet side of the body and serves to throttle flow and maintain an acceptable downstream pressure in the case where the Primary regulator fails to regulate downstream pressure During normal operation the Integral Monitor is in a wide open state as its setpoint is set higher than the primary regulator
30. phragm can now be removed Reassemble in the reverse order of the above procedure Before tightening the cap screws key 15 or closing stem key 44 into the pusher post key 51 place the loosely assembled diaphragm assembly key 55 into position in the lower casing key 9 the arch or bow of the diaphragm should be towards the diaphragm head and lower casing see Figure 8 Ensure that the pusher post key 51 is hooked on the lever key 10 Rotate the diaphragm key 55 so that the diaphragm and lower casing key 9 holes are aligned CP400 Series To Replace Valve Disk and Orifice 1 Remove the tubing connector key 29 Figure 8 from the regulator body key 70 Figure 8 2 Remove the two cap screws key 71 which hold the union ring key 17 portion of the lower casing to the body 3 The regulator can be removed from the body exposing the disk key 36 and the orifice key 25 4 Examine the seating surface of the disk If it is nicked cut or otherwise damaged the disk should be unclipped and removed from the valve stem key 11 and replaced 5 Examine the seating edge of the orifice key 25 If it is nicked or rough it should be unscrewed from the body with a 1 1 16 inch 27 mm socket wrench and replaced with a new orifice key 25 and O ring key 27 to provide proper shutoff Apply anti seize lubricant to the male threads of the new orifice before reassembling If a slam shut or monitor is installed on
31. r When adjusting the primary regulator and Integral Monitor for operation ensure that the pressure differences between the primary regulator and the Integral Monitor shown in Tables 7 and 8 are observed For example if the primary regulator setpoint is set at 8 inches w c 20 mbar then the Integral Monitor should be set at a minimum of 14 inches 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 the adjustment procedure for the primary regulator Otherwise a different spring with a setpoint higher than the Integral Monitor s setpoint must be installed to check the operation of the Integral Monitor CP400 Series with Slam shut When adjusting the primary regulator and slam shut for operation refer to Table 9 for the OPSO setpoints and Table 10 of OPSO and UPSO setpoints of the slam shut for the given regulator spring ranges In the case of a downstream line break numerous factors affect the capability to evacuate gas from the pipeline 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 sla
32. rol Line Connection Pressure Loading Regulator Not Shown high enough to damage downstream equipment Common methods of external overpressure protection include relief valves monitoring regulators shut off devices and series regulation If the regulator is exposed to an overpressure condition it should be inspected for any damage that may have occurred Regulator operation below the limits specified in the Specifications section 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 the copper tubing and the pipeline Apply pipe compound to the male threads of the pipe before installing the regulator 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 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 Figures 5 through 7 If the vent cannot be installed in a vertically down position the regulator must be installed under a separate protective cover
33. s Available Configurations See Table 1 Body Sizes End Connections Styles and Pressure Rating See Table 4 Maximum Operating Inlet Pressure See Table 2 Maximum Outlet Pressures See Table 3 Outlet Pressure Ranges See Table 5 Orifice Sizes See Table 2 Flow and IEC Sizing Coefficients See Table 2 Temperature Capabilities 20 to 150 F 29 to 66 C Control Line Connection 3 4 NPT Pressure Registration Types CP400IT CP400IN CP403IT CP403IN CP404IN and CP404 IT Internal Types CP400ET CP400EN CP403ET CP403EN CP404EN and CP404ET External Optional Internal Token Relief Performance Located in Type 67CPR Pressure Loading Regulator Token relief is a low capacity relief intended to relieve overpressure occurrences due to minor seat leakage or thermal expansion only other overpressure protection must be provided if inlet pressure can exceed the maximum pressure rating of downstream equipment or maximum outlet pressure rating of the regulator Token Relief Start to Discharge See Table 6 Factory Setpoint Inlet Pressures for Various Orifice Sizes 3 16 inch 4 8 mm 60 psig 4 1 bar 1 4 inch 6 4 mm 40 psig 2 8 bar 3 8 inch 9 5 mm 25 psig 1 7 bar 1 2 inch 13 mm 25 psig 1 7 bar 5 8 inch 16 mm 15 psig 1 0 bar 3 4 inch 19 mm 10 psig 0 69 bar Option 1 4 NPT Type P593 1 Aluminum Body Cellulose Filter Approximate Weights With threaded body Type CP400 11 pounds
34. ts Sealant must be selected such that they meet the temperature requirements Figure 8 CP400 Series Pressure Loaded Pressure Reducing Regulator Assemblies 15 CP400 Series GE27401_B TORQUE 10 TO 13 INCH POUNDS 1 1 TO 1 5 Nem GRAY CAST IRON BODY L APPLY LUBRICANT L L SILICON GREASE 1 Lubricant must be selected such that they meet the temperature requirements Key 25 26 27 28 29 30 31 36 37 38 42 43 44 47 51 DUCTILE STEEL BODY Figure 9 CP400 Series Body Assemblies Description Orifice Aluminum 3 16 inch 4 8 mm 1 4 inch 6 4 mm 3 8 inch 9 5 mm 1 2 inch 13 mm 5 8 inch 16 mm 3 4 inch 19 mm OPP Orifice With Integral Monitor Orifice 1 inch 25 mm Aluminum With Slam shut Orifice 0 75 inch 19 mm Brass O ring 1 required for Type CP400 2 required for Types CP403 and CP404 Nitrile NBR O ring Nitrile NBR Connector 2 required for Type CP400 1 required for Types CP403 and CP404 Steel Stainless steel standard Stainless steel Swagelok Pilot Supply Tubing Stainless steel Elbow Steel Stainless steel standard Stainless steel Swagelok Disk Aluminum Nitrile NBR Disk Clip Stainless steel Closing Spring Stainless steel Upper Spring Seat Aluminum Diaphragm Retainer Steel Closing Stem Aluminum Nut Steel Pusher Post Aluminum Recommended spare part Swagelok is a mark owned by Swagelok
35. ure factor measurement also referred to as fixed factor billing Overpressure protection options include the Type CP403 which offers True Monitor Protection provided by an Integral Monitor Module installed on the inlet side of the valve body This Integral Monitor assumes control of the downstream system pressure should the primary regulator no longer regulate Another Overpressure protection option is provided by the Type CP404 which offers an integral slam shut module installed on the inlet side of the valve body that shuts off the flow of gas to the downstream system in the event of outlet pressure rising above or falling below the predefined levels Optional token relief is available which acts as a low capacity internal relief valve to relieve minor overpressure situations due to nicks or other minor damage to the orifice or disk or due to thermal expansion of the downstream system The Token relief is located in the Type 67CPR pressure loading regulator Internal and external outlet pressure registration is available Constructions with external registration require an external control line sense line CP400 Series Specifications The Specifications section lists the specifications for the regulators The following information is stamped on the regulator at the factory Type date of manufacture spring range orifice size maximum inlet pressure maximum operating outlet pressure and outlet pressure which may damage part
36. y and that the outlet pressure be vented before venting inlet pressure to prevent damage caused by reverse pressurization of the regulator The steps below apply to the typical installation as indicated 1 Open valves downstream of the regulator 2 Slowly close the upstream block valve 3 Pressure releases downstream 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 Regulators that have been disassembled for repair must be tested for proper operation before being returned to service Only parts manufactured by Regulator Technologies 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 this regulator should be inspected and maintained periodically The frequency of inspection and replacement of parts depends upon the severity of service conditions or the requirements of local state and federal rules and regulations Periodic inspection must be performed on the CP400 Series that include the Integral Monitor or slam shut overpressure protection modules to ensure that they protect the downstream system in the event the primary regulator losses pressure control This inspection CP400 Series
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