C leaver-B rook s

Packaged Watertube Steam Boiler

Operating Instructions

Container Corporation
Santa Clara, California

Boiler Model: D L D H -118

Sales Order Number: CU9401468
Unit Numbers: W -3813
 PERFORMANCE PROVEN WORLDWIDE

PACKAGED
WATERTUBE STEAM BOILER
OPERATING INSTRUCTIONS

and

SERVICE MANUAL

for

CONTAINER CORPORATION
SANTA CLARA, CALIFORNIA

SALES ORDER NO. CU9401468

UNIT NO. W-3813

BOILER MODEL: DLDH-118 ( L.H.)

BURNER MODEL: 200-CT-27

STEAM CAPACITY: 125,000 #/Hr

PRESSURES:
PRESSURE VESSEL DESIGN: 260 psi (Steam)
OPERATING: 200 psi (Max)

FUEL INPUT TO BURNER:

#2 Oil 1,099 GPH @ 175 PSI
MAIN GAS: (Nat) 160,679 SCFH @ 15 PSIG (1000 Btu/Cu. Ft)
PILOT GAS: 500 SCFH @ 15" H20 (1000 Btu/Cu. Ft)

SAFETY VALVE SETTING: , /S fr g r -y f

FIRST VALVE: 225 0 si
SECOND VALVE: 230 psi
THIRD VALVE: 230 psi
}0~ 6)>
WATER WEIGHT: lo ~ 6 p jD 'S P
TO NORMAL WATER LEVEL: 40,737 LBS
W-3813MC
 STANDARD BURNER
MODEL: CB168F

Job Name: Container Corporation

CB Tags: W-3813
Specific Code:
G-161 -68-73/0-155-72-144/A-15-22-1000-80-325
ENGINEERING DATA SHEET PREPARED BY: J. Moore
BURNER BILL OF MATERIALS REVISION: 0

GENERAL ARRANGEMENT DRAWING: CB168F-10-2GO QUANTITY OF 1

CLEAVER BROOKS STANDARO TYPE/SIZE: CB168FGO
STANDARD DATA CODE: G-168-70-80/0-163-77-149/A-15-15-1000-80-500
GENERAL DESCRIPTION: GAS AND OIL AXIAL FLOW BURNER Note: Quantities of Hems listed below
GAS-ELECTRIC, INTERMITTENT IGNITION are on a per burner basis

! BURNER SUB-ASSEMBLY ; MANUFACTURER 2 SIZE 5 TYPE DESCRIPTION 2 QTY • LOC

i Mild Steel, type A36 2 1 • B

2 Front Plate Assembly c/w ! TODD 2 820 QED i

| Scanner Swivel Ass'y ! TODD ' i

i J TCL Swivel Mount Assembly c/w { 1 ] B
| | i i one (1) swivel base, P/N BUR-4111 2
; « i a one (1) mtg. fig., P/N BUR-3548 2
a
• ■ a one (1) bad, P/N BUR-3549 2
■ a
one (1) gasket P/N BUR-3583 2
; i a

! Sightglass Assembly ; TODD i 2 TCL Each complete with: 2 2 ; b

i
j | » a one (1) base, P/N BUR-4111 2
j ; i a one (1) pyrex, dear, P/N BUR-4058 ]
i a two (2) gaskets. P/N BUR-3583 2
! ! i a
i
} Blind Range Assembly ! TODD i J TCL Each complete with: 2 3 ; b
i
■ J i a one (1) flange. P/N BUR-3512 2
i i a one (1) gasket P/N BUR-3583 2
i ! ■ a

; Jacket Tube | TODD 2 4 in 2 TCI Mild steel, DWG 820-400 j 1 : b

i Swirler : TODD 2 450 mm 2 TCL 31 OSS. 14 ga. scalloped for eight 2 1 ; b

j j a a 2 in poker, on 19-3/4 in D.B.C.; 2
• 1 1 i for 4 in jacket tube 2
1
i a 7-7/8 in E to E, straight hub w/o stiffeners 2
! 2 a

| Gas Burner Assembly c/w | TODD | 6 in { Flanged Mild steel, fixed to gas plenum 2 1 ; b
a IGas Inlet Orientation: 9 O'Clock it
; 2 i

i Multiple Poker Pipes | TODD 2 2 in 2 TCI Mild steel 2 8 j B

J Poker Shoes ! TODD 2 2 in 2 TCI Mari is 304SS, Drill: Std2"10in14 Size: SML 2 8 | 8
; a 2 TCI 188 MMBTUH at 8.0 PSI 2
i i

| Oil Burner Assembly c/w | TODD a

2 TCL TOOD TCD Large Atomizer. Dwq 0-42262 2 1 • 8
i Dimension "A* * 90-11/32 " 2 i
a
: i a
! I a

a 2 TCD50 TCD/C50 Drilling: 350/250/200-15E 50 2

; Main Atomizer Sprayer Plate ; TODD
a i 6490 PPH at 149 PSI 2
j ! a

a a TCD Standard, for 4" JT 5 1 ; b

J Main Atomizer Coupling Block ! TODD I a
a
a
i
i 1 ; b

; Gas-Electric Ignitor Ass'y ; TODD 2 1 mmbtu 2 TCL Stabeiite ignitor 2 1 ; b

J c/w mounting bracket J a ■ Type 83 2
a i

J Ignitor Transformer J Donegan a

a
a Model A10-LA2 2 1 ; b
! a a 120V/60Hz pri/10,000V sec J
i I a

; Transformer Enclosure 2 Hammond J 10"x8"x6" { Model 1414PH16. with panel. NEMA 12 2 1 ; b

a A-36, aluminum paint DWG 820-300 1 I F
| Guide Ring Assembly 2 TODD | 820 QED a |

a
A-38, aluminum paint DWG 820-500 1 1 J F
J Throat Former 2 TODD ] 820 QED a !
; Note: 70% alum ina refractory to be supplied b y Installations contractor !

! Atomizer Tools/Aiodliaries:

i { TCI 2 W-2-1-34 t 2 1
2 Allen Wrench-2 2 TODD i
l

• 2 W-2-10-44 2 1
£

2 Open End Wrench-6 [ TODD i

i

2 Open End Wrench-7 i 2 TCI 2 W-2-10-27 • 1

2 TODD i

2 Anti-seize lubricant t { TCI I Can. P/N C-41-1-7 2 1

2 TODD i

i J Can. P/N C-41-1-6

2 Sealing Compound 2 TODD • 2 TCI 2 1

PG 1 of 1
LOC: B» Windbox mounted; R= Rack mounted; F* Shipped loose; P= control panel mounted

REVO 7/27/1995 Issued as a standard

 C le a v e r ^ B r o o k s '
PERFORMANCE PROVEN WORLDWIDE

CONTAINER CORPORATION
SANTA CLARA, CALIFORNIA

Section 1: Boiler
A. "D" Boiler Manual
B. Low Water Cut-Off (Magnetrol)
C. Feedwater Valve Actuator (Fisher 667)
D. Feedwater Valve Positioner (Fisher 3582i)
E. Feedwater Valve #2 Fuel Oil Valve Bodies (Fisher EZ)
F. Feedwater Drum Level Control (Fisher 2500R249)
G. Water Column Parts List (Clark-Reliance)
H. Sootblower (Diamond)
I. Safety Valve Calculation
J. Safety Valve (Kunkle)
K. Dimension Diagram (W-003813DD)
L. Rear View Dimension Diagram (W-003813RV)
M. Burner Arrangement w/Silencer & FGR Inlet (W-003813BA)

Section 2: Burner
A. "CT" Burner Manual
B. Engineering Data & Bill of Materials CB168F
C. Windbox/Bumer General Arrangement (60966/10-1GO)
D. Windbox/Bumer General Arrangement, CB168F (CB168F/10-2GO)
E. Chicago Blower Manual
F. FD/FGR Fan Assembly, 1900/4900, Chicago Blower (B-19-0-2091 Rev.B)
G. Program Relay (CB-100)
H. Actuator, Pneumatic (Bailey UP2331100)
I. Main Gas Flow Control Valve (Fisher 1052K-V-150)
J. Fuel Controller Inputs/Outputs
K. Master Steam Pressure Controller Inputs/Outputs
L. Combustion Air Controller Inputs/Outputs
M. Instrument and Control Systems Functional Diagram (W-003813PID)
N. Electronic Position Transmitters (Fisher 4200 Series)
O. Main Gas Valve (Maxon 5000-CP)
P. Rotary Actuators w/Mounting Adaptations (Fisher 1051 & 1052)
Q. Positioners (Fisher 3610J & 3620J Series)
R. Main Gas Pressure Regulator (Fisher 1098-EGR)
S. Main Gas Train, 6" w/4" Maxon CT Burner NFPA 8501 (W-003813MG)
T. Pilot Gas Pressure Regulator (Fisher Y600)
U. Pilot Gas Train CT Burner NFPA 8501 (W-003813PG)
 PERFORMANCE PROVEN WORLDWIDE

Section 2: Burner (Continued)

V. #2 Oil Train CT Burner NFPA 8501 (W-003813FO)
W. Steam Atomizing Train CT Burner NFPA 8501 (W-003813SA)
X. Direct-Acting Gas Regulators (Fisher 298C & 298T)
Y. Pressure Regulators (Fisher 95L & 95H)
Z. Filter Regulators (Fisher 67AF & 67AFR)
AA. Customer’s Fuel Connections 200-CT-27 Burner (W-003813FC)
BB. Piping Rack, Fuel Trains 200-CT-27 Burner (W-003813PR)
CC. Electrical Nomenclature
DD. Wiring Diagrams (W-003813WD)

Section 3: Auxiliary Equipment

A. Breeching Top Gas Outlet DLDH Boiler (719-A-1889)
B. Valve, Non-Return, 8"-250# Fig (Crane 28E)
C. Valve, Gate, 8"-250# Fig. (Crane 7-1/2)
D. Special Piping, Spool Piece, Flanged (W-003813SP)

MG95306
 PERFORMANCE PROVEN WORLDWIDE

Start-up Procedures

The following is an outline the start-up procedures which the Cleaver-Brooks Division uses when
rendering the initial start-up on all Watertube Boilers. If the installation is ready, this will permit a
smooth flow, as well as planning, of start-up.

Prior to the arrival of our Field Representative, all service connections, such as electrical, fuel, water,
pneumatic flow meters, and plant steam piping, etc., should be connected. This will avoid delay in
starting, following the internal and external inspection of the unit by our personnel.

The unit was hydrostatically tested in our shop prior to shipment. Copies of the Manufacturers’ Data
Report, signed by the inspector witnessing and evidencing the test, have been forwarded to the purchaser
of the equipment shortly after shipment from our plant.

Following an external inspection of the boiler by our personnel, a hydrostatic test of the boiler may be
conducted to determine the tightness of the pressure vessel. This is sometimes requested by the
inspection service of your local insurance carrier to assure all parties concerned that the pressure parts
are still tight following shipment from our plant to its final destination. Should a field hydrostatic test
be required, the costs involved to conduct such tests at the jobsite are the responsibility of others and
not the Cleaver-Brooks Division, unless noted in the original contract and stipulated to be the
responsibility of the Cleaver-Brooks Division.

When filling the boiler, either for the initial hydrostatic test or refilling after the unit has been drained,
the water temperature entering the boiler should be 70°F. This temperature is necessary to ensure that
there is no thermal shock induced when the boiler is filled. A means of supplying water at this
temperature is the responsibility of others.

It will be necessary to perform a boil-out of the boiler. The purpose of the boil-out is to permit the
removal of rust, grease, pipe dope and other impurities which could possibly contaminate the waterside
of the boiler and cause "foaming" or "priming" when placing a unit in plant service.

Chemicals to be used to perform the required boil-out are to be provided by and at the expense of others
and are not the responsibility of the Cleaver-Brooks Division, unless specifically called out in the
original contract. No chemical should be added to the boiler water until directed to do so by our Field
Representative supervising start-up.

- Page 1 -
 C le a v e r O B r o o k s
PERFORMANCE PROVEN WORLDWIDE

Many customers request that their feedwater consultants provide chemicals for boil-out and be present
during the boil-out period. This is certainly an acceptable method to us. In some instances, the
customer may choose to provide chemicals without consulting their chemical suppliers. If this is the
case, we could recommend which chemicals to use. Regardless of who supplies the chemicals,
provisions should be made prior to boil-out for the disposal of boil-out materials and boil-out effluent.
Providing and insuring these provisions are met, is the responsibility of others.

The field labor required to remove manhole plates, install chemicals for boil-out, install gaskets, wash­
out waterside of units, operate necessary valves and auxiliary equipment, etc., is the responsibility of
others. The Cleaver-Brooks Division will not be responsible for labor charges for this field work.

In order to provide full and complete operator training, it is requested that the operator or operators be
available throughout the entire start-up to receive the necessary instructions from our field representative.
It should be pointed out, at this time, that our representative is not a licensed operator and is on the job
in a supervisory capacity only.

Following boil-out, it is most important that it be possible to place sufficient steam demand on the unit
so all required adjustments can be made to the burner and boiler to assure all concerned that the unit
is properly adjusted throughout its entire firing range and to be sure it is developing its full-rated
capacity.

Units required to produce steam with a purity of 3 PPM, or less, will be equipped with special steam
drum internals. In the event that special boil-out and wash-out requirements prevail, Cleaver-Brooks
is not responsible for the additional manpower requirement to remove internals for wash-out or their
reinstallation following.

If venting steam to the atmosphere is required to simulate a load on the unit, it is the recommendation
of Cleaver-Brooks that a silencer be provided on the vent line for the well being of all parties concerned.
The supply and installation of the silencing equipment will be the responsibility of others.
We also wish to call to your attention that deaerated hot feedwater (generally 212°F or better) must be
available following boil-out for testing and continual usage when placing this equipment in on-line
operation.

Start-up service will be provided per our sales contract. If additional days over those specified in our
contract are required to complete start-up, an additional purchase order will be required to cover the
additional start-up time. If it should be found that time is spent by our field representative
to correct problems of our own making, the customer will not be penalized in start-up time nor will a
service charge be assessed for the time spent in corrective measures.

- Page 2 -
 •rooks*
PERFORMANCE PROVEN WORLDWIDE

Upon completion of start-up, our field representative will review the complete start-up with the
purchaser and request a signature for his Field Report indicating start-up is completed and accepted.

If for some reason, the field report is not signed as accepted, and the unit is providing beneficial use
to the end user, then our warranty is considered initiated at the date of first beneficial use as dated on
the field report.

Very truly yours,

CLEAVER-BROOKS
DIVISION OF AQUA-CHEM, INC.

SERVMAN

O - Page 3 -
 $25.00

* OPERATING IN STR UCTIO N S

CLEAVER-BROOKS PACKAGED
WATERTUBE BOILERS

M O D E L S D, DL, and D L D

CleaverO Brooks
D IV IS IO N O F A Q U A -C H E M , INC.
MILWAUKEE, WISCONSIN U.S.A.

Manual Part No. 750-302

C23-6032 Rev. 10/93
Printed in U.S.A.
 CLEAVER-BROOKS
PACKAGED
WATERTUBE BOILERS

MODELS D, DL, and DLD

Cleave rooks
©Aqua-Chem, Inc., 1993

Manual Part No. 750-302

C23-6032
10/93 Printed in U.S.A.
 -----------------------------------,-------— ----- -------- WARNING---------!------------------------------------------- ---
DO NOT OPERATE, SERVICE, OR REPAIR THIS EQUIPMENT UNLESS YOU FULLY UNDERSTAND
ALL APPLICABLE SECTIONS OF THIS MANUAL.

DO NOT ALLOW OTHERS TO OPERATE, SERVICE, OR REPAIR THIS EQUIPMENT UNLESS THEY
FULLY UNDERSTAND ALL APPLICABLE SECTIONS OF THIS MANUAL.

FAILURE TO FOLLOW ALL APPLICABLE WARNINGS AND INSTRUCTIONS MAY RESULT IN SE­
VERE PERSONAL INJURY OR DEATH.

TO: Owners, Operators and/or Maintenance Personnel

This operating manual presents information that will help to properly operate and care for the equipment. Study its contents
carefully. The unit will provide good service and continued operation if proper operating and maintenance instructions are
followed. No attempt should be made to operate the unit until the principles of operation and all of the components are
thoroughly understood. Failure to follow all applicable instructions and warning may result in severe personal injury or death.
It is the responsibility of the owner to train and advise not only his or her personnel, but the contractor's personnel who are
servicing, repairing or operating the equipment, in all safety aspects.

Cleaver-Brooks equipment is designed and engineered to give long life and excellent service on the job. The electrical and
\ mechanical devices supplied as part of the unit were chosen because of their know ability tojwiferm; however, proper operating
techniques and maintenance procedures must be followed at all times. Although thefce conqkmesnts afford a high degree of
protection and safety, operation of equipment is hot to be considered free from all daggers'and hazards inherent in handling and
firing of fuel.
Any ‘‘automatic’’ features included in the design do hot relieve the attendant of any responsibility. Such features merely free
him/her of certain repetitive chores and give him/her more time tot devote to the proper upkeep of equipment.
It is solely the operator's responsibility to properly operate and maintain the equipment. No amount of written instructions can
replace intelligent thinking and reasoning and this manual is not intended to relieve the operating personnel of the responsibility
for proper operation. On the other hand, a thorough understanding of this manual is required befbre attempting to operate,
maintain, service, or repair this equipment.

Because of state, local, or other applicable codes, there are a variety of electric controls and safety devices which vary consider­
ably from one boiler to another. This manual contains information designed to show how a basic boiler operates.

Operating controls will normally function for long periods of time and we have found that some operators become lax in their
daily or monthly tesing, assuming that normal operation will continue indefinitely. Malfunctions of controls lead to
uneconomical operation and damage and, in most cases, these conditions ca nbe traced directly to carelessness and deficiencies
in testing and maintenance.
It is recommended that a boiler room log or record be maintained. Recording of daily, weekly, nonthly and yearly maintenance
activities and recording of any unusual operation will serve as a valuable guide to any necessary investigation.

Most instances of major boiler damage are the result of operation with low water. We cannot emphasize too strongly the need
for the operator to periodically check his/her low water controls and to follow good maintenance and testing practices. Cross­
connecting piping to low water devices must be internally inspected periodically to guard against any stoppages which could
obstruct the free flow of water to the low water devices. Float bowls of these controls must be inspected frequently to check for
the presence of foreign substances that would impede float ball movement.

The waterside condition of the pressure vessel is of extreme importance. Waterside surfaces should be inspected frequently to
check for the presence of any mud, sludge, scale or corrosion.
The services of a qualified water treating company or a water consultant to recommend the proper boiler water treating practices
are essential.
The operation of this equipment by the owner and his/her operating personnel must comply with all requirements or regulations
of his/her insurance company and/or other authority having jurisdiction. In the event of any conflict or inconsistency between
such requirements and the warnings or instructions contained herein, please contact Cleaver-Brooks before proceeding.
 CONTENTS
Page
CHAPTER 1 — GENERAL DESCRIPTION..................................................................... 1-1
A. The B oiler................................................................................................. 1-1
B. The Burner and Control System ............................................................ 1-1
C. Components and Accessories .................................................................. 1-1
D. Installation................................................................................................. 1-6
E. Hydrostatic Testing and Inspection........................................................1-6
F. Boiling O u t......... ............................................................................ 1-7
G. Feedwater System and Treatm ent......................................................... 1-9

CHAPTER 2 — OPERATIONS AND PROCEDURES.....................................................2-1

A. Preparation to Initial F irin g.................................................................. 2-1
B. Filling the Boiler.............. 2-1
C. Initial Firing............................... ............................................................ 2-2
D. Routine Operation and Shutdow n......................................................... 2-2
E. Operating Procedures................ .................................. ........................... 2-3
Feed Water Regulation andControl.................................................... 2-3
Water Level Indicating System........................................................... 2-3
Water Column................................ 2-4
Blowdown.......................................................................... 2-5
Manual Blowdown.................................... 2-5
Continuous Blowdown............................................. 2-6
Soot Blowing.......................................................................................... 2-6
Superheater............................................................................................2-7

CHAPTER 3 — MAINTENANCE..................................................................................... . 3-1

A. G eneral....................................................................................................... 3-1
Waterside Inspection............................. 3-1
Fireside Inspection....... ................................... 3-2
B. Pressure Vessel Care and R epairs......................................................... 3-3
C. Tube Cleaning........................................................................................... 3.3
Mechanical Tube Cleaning.................................................................. 3-3
Chemical Cleaning....................................................*.......................... 3-5
D. Water Column........................................................................................... 3-5
Probe Installatio n ................................................................................. 3.5
Gauge Glass or Prismatic I n s e r t............................. 3-5
E. Safety Valves........................................................................ 3.5
F. Care and Protection of IdleBoilers ........... 3-7

CHAPTER 4 — PARTS ORDERING INSTRUCTIONS AND PARTS LIST...............4-1

C 2 3 -6 0 3 2 REV . 10/81
P rin te d in U .S .A .
TO: Owners, Operators or Maintenance Personnel

This operating manual presents information that will help to properly operate and care for the equipment.
Study its contents carefully. The unit will provide good service and continued operation if proper
operating and maintenance instructions are followed. No attempt should be made to operate the unit until
the principles of operation and all of the components are thoroughly understood. Only trained and
authorized personnel should be allowed to operate, adjust or repair this equipment.
Cleaver-Brooks products are designed and engineered to give long life and excellent service on the job.
The electrical and mechanical devices supplied as part of the unjt were chosen because of their
known ability to perform: however, proper operating techniques and maintenance procedures must be
followed at all times. Although these components afford a high degree of protection and safety,
operation of equipment is not to be considered free from all dangers and hazards inherent in handling and
firing of fuel.
Any “automatic” features included in the design dd not relieve the attendant of any responsibility.
Such features merely free him of certain repetitive chores and give him more time to devote to the proper
upkeep of equipment.

It is solely the operator’s responsibility to properly operate and maintain the equipment. No amount of written
instructions can replace intelligent thinking and reasoning and this manual is not intended to relieve the
operating personnel of the responsibility for proper operation.

Because of state, local or other applicable codes there are a variety of electrical controls and safety
devices which vary considerably from one installation to another. This manual contains information
designed to show how a standardly equipped burner operates.
Operating controls will normally function for long periods of time and we have found that some
operators become lax in their daily or monthly testing assuming that normal operation will continue
indefinitely. Malfunctions of controls leads to uneconomical operation and damage and in most
cases these conditions can be traced directly to carelessness and deficiencies in testing and maintenance.
It is recommended that a boiler room log or record be maintained. Recording of daily, weekly, monthly
and yearly maintenance activities and recording of any unusual operation will serve as a valuable
guide to any necessary investigation.
Most instances of major boiler damage are the result of operation with low water. We cannot emphasize
too strongly the need for the operator to periodically check his low water controls and to follow'good
maintenance and testing practices. Cross connecting piping to low water devices must be internally
ihspected periodically to guard against any stoppages which could obstruct the free flow of water to
the low water devices. Float bowls of these controls must be inspected frequently to check for the
presence of foreign substances that would impede the float ball movement.
The waterside condition of the pressure vessel is of extreme importance. Waterside surfaces should be
inspected frequently to check for the presence of any mud, sludge, scale or corrosion.
It is customary to engage the services of a qualified water treating company or a water Consultant to
recommend the proper boiler water treating practices.

The operation of this equipment by the owner and his operating personnel must comply with all requirements
or regulations of his insurance company and/or any other authority having jurisdiction. These legal
requirements take precedence over anything contained herein.

Cleaver-Brooks Service Engineers, or Cleaver-Brooks authorized service representatives, present

for start-up or service are present only in an advisory capacity. The operation of the burner or boiler is
under the scope of work to be performed by the owner’s operating personnel at the owner's risk, and under the
owner’s insurance protection. Recommendation for proper adjustments required to make the equipment
perform can ’be made by these Service Engineers.

in
 C h ap ter 1 - G eneral D escription

CHAPTER 1

GENERAL DESCRIPTION
A. THE BOILER
B. THE BURNER AND CONTROL SYSTEM
C. COMPONENTS AND ACCESSORIES
D. INSTALLATION
E. HYDROSTATIC TESTING AND INSPECTION
F. BOILING OUT
G. FEEDWATER SYSTEM AND TREATMENT

A. THE BOILER provided for the burner portion. The various

The Cleaver-Brooks Packaged Watertube Steam
Boiler is a two drum, bent-tube, “D” type Boiler.
The line consists of three Models; “D” , “DL” and
“DLD” which vary only in size, dimensions, and
capacity. All models are covered by this manual.
The Boiler has a six-wall water cooled furnace.
The inside and outside furnace walls, as well as
the floor and roof, are constructed of tangent
tubes. The front and rear walls are refractory
faced and have water cooling tubes. Figure 1-1
khows typical construction.
The entire pressure vessel is covered with a
double seal-welded insulated casing. The
pressure vessel is mounted on a heavy structural
steel skid type frame.
The steam (upper) drum has factory installed in­
ternals and baffles to control water levels, reduce
surging, and to reduce the quantity of moisture
leaving the water level before it enters the final
dryer unit. Figure 1-2 shows a cross section of
typical drum internals.
The boiler is constructed in accordance with the
ASME Power Boiler Code, and all applicable
local laws, regulations and codes having juris­
diction.
B. THE BURNER AND CONTROL
SYSTEM
The boiler is standardly equipped with a Cleaver-
Brooks Burner, or in some instances, a burner
manufactured by others. An individual manual is
safety and combustion controls are either covered
in the burner manual or by separate instructions.
All instructions and manuals applicable to the in­
stallation should be studied prior to firing the
boiler.
C. COMPONENTS AND
ACCESSORIES
This section describes some of the various com­
ponents and accessories that comprise a boiler.
Some are integral to the pressure vessel while
others are devices that are necessary for normal
and safe operation. The accessory described may
be furnished with the boiler or it may be fur­
nished separately by others. Some installations
may not require a particular component or it may
vary somewhat from the fallowing basic descrip­
tions. See Figure 1*4.
The operator must be familiar with the indi­
vidual functioning of all controls and components
in order to understand the boiler’s operation. The
following brief descriptions provide a basic un­
derstanding of the functions and relationships.
The descriptions are limited to those components
that affect the pressure vessel. The boiler and fuel
system controls, along with other special items
that might be provided, are covered elsewhere.
STEAM DRUM
The upper drum (steam drum) contains water
level control baffling to assure that all steam re­
leased from the generating tubes is released be-

1-1
C h a p te r 1 - G enera] D escription

F IG U R E 1-1 T Y PIC A L T U B E A R R A N G EM EN T

1 -2
 C h ap ter 1 - G eneral D escription

A. Dry Pan Carton D. Feedwater Pipe

B. Flow Control Baffles E. Chemical Feed Pipe
C. Dry Pan Drain F. Continuous Blowdown Pipe

FIGURE 1-2 DRUM INTERNALS AND SEPARATOR

A. Purifier and Dryer Carton D. Chemical Feed Pipe

B. Flow Control Baffles E. Continuous Blowdown Pipe
C.. Feedwater Pipe F. Steam Chest

FIGURE 1-3 DRUM INTERNALS AND STEAM PURIFIERS

1-3
Chapter 1 • Geheral Description
hind the baffles and not through the- water level.
Other drum internals include steam separators or
dryers to assure low moisture content steam.
The drum heads are fitted with 12” by 16” man­
ways on each end. The internal feed pipe, chemi­
cal feed pipe, and blowdown piping are attached
to the drum heads.
Figures 1-2 and 1-3 show typical drum internals.
LOWER WATER DRUM
The lower water drum has a blow off connection
on the underside near the rear head. Internally it
has a blow off guide baffle installed to insure ef­
fective blow off of the lower drum without distur­
bance to the water circulation of the boiler.
The drum incorporates two 12” x 16” manways
one at each end.
BLOW OFF VALVES
These are specially designed, manually operated,
valves connected to the lower drum for the pur­
pose of reducing the concentration of solids in the
boiler or for draining purposes. Two valves are
required .by the ASME Code. The valves nor­
mally furnished are of-the slow opening type.
CONTINUOUS BLOWDOWN CONNECTION
The continuous blowdown connection is normally
located in the rear head of the upper drum with
the pipe located slightly below the normal water
level. Its purpose is to remove the concentrated
boiler water from the boiler and thereby reduce
the total solids concentration. A flow control
valve, or one with a variable orifice, is used to
closely control the percent of blowdown. A stop
valve is furnished, while the blowdown valve may
be either provided with the boiler or furnished by
others.
CHEMICAL FEED CONNECTION
This connection in the upper drum is provided for
the piping from a chemical feed pump and is the
means of introducing supplementary water treat­
ment chemicals into the boiler.
SOOT BLOWER
A boiler equipped with an oil fired burner has a
soot blower installed for cleaning accumulations
of soot from the convection bank tubes. Steam is
the most commonly used cleaning medium
although compressed air is also used.
The soot blower is normally located on the rear
wall of the boiler although front wall locations
are not uncommon. Larger sizes of boilers have
two soot blowers - front and rear. Stop and drain
valves are provided. A sight cap is provided.in the
side casing to allow visual checking of soot
blower nozzle alignment.
1-4
OBSERVATION PORT
These are located in the rear wall to provide a
good clear view of the flame.
STEAM GAUGE
Indicates the internal pressure of the boiler.
FEEDWATER REGULATING VALVE AND
GENERATOR
These items comprise a system that operates
automatically to maintain a predetermined water
level in the boiler. The generator is essentially a
closed hydraulic system, connected by tubing to a
bellows on the regulating valve, that is responsive
to the boiler water level. Hydraulic pressure
created within the generator forces the valve to
open to various positions thus regulating the flow
of water to maintain a constant level.
A single element system is standardly furnished
although other systems may be used depending
upon job requirements and specifications.
FEEDWATER BYPASS VALVE
A manually operated valve provided to initially
fill the boiler or to bypass the regulating valve.
SAFETY VALVE
This is an automatic pressure relieving device
and, as the name implies, is for the purpose of
safely relieving the boiler of any excessive steam
pressure. The size and number of valves - always
two and often three - and their pressure setting
are determined by job specifications and in ac­
cordance with ASME Code requirements.
The discharge piping from the valves must also
conform to the ASME Code. See Figure 3-4. This
piping is not furnished with the boiler.
If the boiler is equipped with a super-heater, a
safety valve is also provided for the super-heater.
DRUM VENT VALVE
This manually operated valve is located on top of
the steam drum. Its sole purpose is to vent air
and entrained gases from, the drum during start­
up. It should also be opened when the boiler is
being cooled down to prevent a vacuum from
forming within the boiler.
WATER COLUMN
The water column is connected at its top to the
steam space and at its bottom to the water space
of the upper drum. A water gage, trycocks, and
water level indicating devices are attached to or
are part of the column. •
The gage glass attached to the side of the column
is used to visually indicate the boiler water level.
This glass is one of the most important guides
 C h a p te r 1 - General Description

GAGE GLASS COCKS (TRY-COCKS) STEAM DRUM .FEEDWATER REGULATOR

GENERATOR
GAGE GLASS WATER COLUMN
SHUT-OFF COCKS

WATER LEVEL GAGE GLASS

STEAM GAUGE
BLOWER
STACK OPENING MOTOR

PACKAGED
BURNER ASSEMBLY

SOOT BLOWER
ALIGNMENT PORT

FEEDWATER BY-PASS VALVE MUD DRUM

FEEDWATER INLET
FEEDWATER
REGULATING VALVE

FIGURE 1-4 TYPICAL WATERTUBE BOILER

av a ila b le to the boiler operator. It should be kept
clean and well lighted for good visibility.
T he gage glass is m ounted betw een two valves
which can be operated from floor level by m eans
of an attac h ed chain. T he valve handles are
linked together so th a t they m ay be opened or
closed sim ultaneously. The valves can be quickly
closed in th e event of glass breakage. G uard rods
are used to help protect the glass ag ain st ac­
cid en tal dam age. A fla t reflex type glass is often
used in stead of a tu b u la r glass.
T h ree trycocks are provided to check the accuracy
of the gage glass level.
T he w ater colum n is fitted w ith probes, or elec­
trodes, extending through the top flange dow n­
w ards into the steam an d w ater spaces. T hese are
wired into an electric relay system th a t will shut
the b u rn er down in the event of low w ater and
also activ ate signal lights th a t indicate norm al,
low w ater or high w ater level conditions. T he la t­
te r two are generally connected to an audible
alarm system to alert the op erato r of a condition
requiring im m ediate atten tio n . 'The operation of
the system is explained la te r in this m anual.
An auxiliary low w ater cut-off control is often in­
stalled to provide ad d itio n al protection. T his is
generally of the float operated type and is wired

1-5
Chapter 1 - General Description
to interrupt the limit circuit and to shut off the
fuel flow in the event water drops below the
master low water cut-off point.
Drain valves are provided for the water column
and for the gage glass. Piping to a safe point of
discharge must be provided by others.
D. INSTALLATION
It is not within the scope of this manual to pro­
vide installation instructions. These should
follow the design specifications of the Architect,
Engineer or Contractor. Good engineering prac­
tices must prevail.
The boiler and related equipment must be in­
stalled to conform to applicable codes. Compli­
ance with codes will do much to insure a safe and
dependable installation as the codes have been
formulated to safeguard life and property. Fail­
ure to comply with established regulations can
necessitate costly modification or reconstruction.
The proper authorities should be consulted before
installation preparation of a permanent nature is
started, particularly in regard to boiler room
structure, boiler venting, electrical service, fuel
storage and piping and all other piping such as
steam, water supply, blow-off, and drain lines.
Application should be made immediately for all
permits required by law for boiler room con­
struction and boiler installation. Although it is
customary for each Contractor involved to attend
to the permit required for his phase of the work, it
is advisable to make sure that no necessary per­
mit is 9verlooked.
The Cleaver-Brooks Boiler is constructed to con­
form with the ASME Boiler Code and other codes
known to apply. A Manufacturer’s Data Report
covering the boiler construction, test and in­
spection is provided.
When the boiler is received, it should be given a
thorough inspection by a competent person to de­
termine if any damage has occurred in transit. All
boxes and cartons should be uncrated carefully
and checked against the packing slip. In case of
damage or shortage, immediately notify the
carrier and file a claim.
The boiler should be inspected externally as well
as internally. The bracing or shoring that may be
used to protect the brick in the furnace area must
be removed. The refractory should be inspected
for evidence of loose or broken tile.
The following generalizations are intended for
assistance and do not supplant any codes or con­
struction criteria.
1-6
All piping and valves must be installed in accord­
ance with good engineering practices. Suitable
strength piping and valves are to be used. All
drains and discharge piping must be piped to a
safe point of discharge.
The discharge piping from the safety valves and
the method of connecting the piping is especially
important. The piping should be arranged so that
no "thrust from the weight or movement of the
pipe can be' imparted to the valves. Refer to
Figure 3-4 for a typical recommended method of
piping.
Electrical wiring must conform to all electrical
codes and proper size wiring used. The necessary
switches, feed boxes, circuit breakers, etc. must be
installed and operable.
All auxiliary equipment should be installed in ac­
cordance with the recommendations of the
respective manufacturers. Fan wheels, bearings,
couplings, and shaft alignment should be checked
and aligned. If the bases of auxiliary equipment
are grouted, the alignment should be checked be­
fore grouting or doweling and rechecked af­
terwards.
Aisles, ladders, and stairs should be completed
and accessible for the convenience and safety of
the operating personnel. All obstructions such as
scaffolding, refuse, tools, etc. must be removed
from ducts, breechings, and platforms. Insulation
of piping and duct work should be done in accord­
ance with accepted practices.
CAUTION
The supply piping for a gas fired burner must not
be attached to or supported from the side casing
walls.
Occasionally a unit is repainted, especially in new
construction. When this is done, care must be
taken to see that paint is not applied to any
moveable linkage, to the generator portion of the
feedwater regulator, valve steins and any other
components where paint could interfere with nor­
mal operation.
E. HYDROSTATIC TESTING
AND INSPECTION
The boiler was hydrostatically tested in our shop
and copies of the Manufacturers’ Data Report,
signed by the inspector witnessing and evidencing
the test, have been forwarded to all jurisdictional
bodies as well as to the boiler owner. To be sure
that the pressure parts are still tight following
shipment and installation, a hydrostatic test
should be conducted as soon as possible after in­
stallation. This test will generally be under the
4*

supervision and witnessed by an authorized in­
spector who may represent either the state or
municipality having jurisdiction or the insurance
company covering the installation.
At the option of this inspector, this test may be at
1 -1/2 times the design pressure of unit, or at a
pressure slightly less than the setting of the low­
est safety valve. The latter test will avoid the
necessity of blanking or gagging safety valves, re­
moving piping and plugging various pipe open­
ings, removing controls and gage glass, etc.-
Before starting a test, make sure that all foreign
material, tools, personnel, etc., are removed from
the boiler. Rinse out the boiler by playing high
pressure water into the drums, tubes, nipples and
headers. Depending upon the test pressure, be
sure to blank off any part that is not designed to
withstand the pressure to be developed. This will
include water column, gage glass, feedwater regu­
lators, pressure controls, etc. Safety valves, in this
case, must be blanked or gagged.
All connections on the boiler should be closed
with the exception of the vent, pressure gauge,
and feed line through which pressure will be ap­
plied.
When the boiler is ready for the test, it should be
filled with water of a temperature not less than
ambient and in no case less than 70°F. Care
should be taken so that all air is vented while the
boiler is being filled.
Fill the boiler until water overflows the vent.
Close the vent.
Apply pressure slowly. The recommended rate of
pressure increase is less than 50 psi per minute.
Proper control must be maintained so that
pressure does not exceed the desired setting.
When this test pressure is reached, inspection in
accordance with the test objective can begin.
Upon completion of the test, release pressure
slowly through a small drain valve. Then fully
open vents and drains. Particular care must be
given to make sure that parts not normally con­
taining water during operation, such as the super­
heater or circulating tubes above normal water
level are drained free of water.
If temporary handhole or manhole gaskets were
used for the test, they should be replaced with
regular service gaskets before readying the unit
for operation. Gaskets should never be' reused.
Chapter 1 - General Description
Replace gage glass if necessary and make sure
that gage cocks are open.
: CAUTION
Remove all blanks or gags from safety valves,
Additional inspection at ‘this time by the
authorized inspector will determine whether the
installation including piping arrangements,
valves, gauges and controls and other equipment
on the boiler meet Code and/or other juris­
dictional requirements.
F. BOILING OUT
The internal surfaces of a new boiler will invar­
iably contain deposits of oil, grease and pro­
tective coatings inherent in manufacturing pro­
cedures. It is important that these deposits be re­
moved from the heating surfaces since this con­
tamination will lower the heat transfer rate and
possibly cause overheating of pressure vessel
metal. These deposits can generally be removed
by an alkaline boil out using readily available
chemicals.
Before boil out procedures can begin, the boiler
should be ready for firing and the operator must
be familiar with the operation of the burner and
follow instructions contained in the burner
manual.
There are several boiling out procedures that
may be followed and different materials are re­
commended by different authorities. There are
specially prepared trademarked chemicals avail­
able. Some firms that manufacture and provide
these are:
Betz Laboratories, Philadelphia, Pa.
Dearborn Chemical Company, Chicago, Illinois
Dow Chemical Company, Midland, Michigan
Hall Laboratories, Pittsburgh, Pa.
Nalco Chemical Company, Chicago, Illinois
The instructions and advice provided ‘ by the
manufacturer of the chemical should be followed.
Any oils or coating that may have drained into
the drums should be wiped away with clean rags.
Also remove any debris that might be present.
One of the top manholes may be left open to aid
in filling the boiler.
If the water column if fitted with a prismatic type
gage glass, it is suggested that this be temporarily
replaced with a round glass of adequate design
pressure to avoid any damage to the prismatic
glass. •
In the event the boil out is not handled by the
feedwater consultant or water treatment com­
1-7
Chapter 1 - General Description
pany, the following procedure is effective for
cleaning a boiler.
The use of soda ash (sodium carbonate) and
caustic soda (sodium hydroxide) at the rate of 3
to 5 pounds each per 1,000 lbs. water is suggested.
A small amount of laundry detergent is often ad­
ded as a wetting agent.
The chemicals should be dissolved prior to plac­
ing them in the boiler. To make this solution,
place warm water into a suitable container.
Slowly introduce the dry chemical into the water,
stirring at all times, until the chemical is com­
pletely dissolved. Add the chemical slowly and in
small amounts to prevent excessive heat and tur­
bulence.
Use of a suitable face mask, goggles, rubber
gloves and protective garments are strongly re­
commended when handling or mixing caustic
chemicals. Do not permit the dry material or the
concentrated solution to come in contact with
skin or clothing.
Fill the boiler with ambient temperature water to
a point just below the manhole opening in the up­
per drum. Add the chemicals in the solution
through either the upper drum manhole, the up­
per drum vent valve, or the chemical feed line.
Secure the manhole if it was used for filling.
Fill the boiler with water to about 8” above nor­
mal operating level. The normal level is at the
center of the water gage glass. Exercise caution to
prevent water spilling over into the superheater,
if the boiler is equipped with one.
Open the steam drum vent valve. If the boiler is
equipped with a superheater, open the super­
heater drain and vent valves. Recheck the burner,
feedwater supply, gage glass, pressure gauge, and
the position of all valves.
Start the burner and allow the boiler to warm up
slowly. When steam vapor is noticed at the boiler
vent, close the vent valve. The superheater inlet
drain valve should also be closed, but the
superheater outlet drain valve should be left open
enough to permit continuous cooling of super­
heater tubes. Allow boiler pressure to increase at a
rate, not to exceed 100 psi per hour until pressure
has reached half of normal operating pressure but
not exceeding 150 psi. Keep the burner firing at a
low rate to maintain this pressure for approx­
imately 6 hours. During the pressure raising and
boiling out period, keep water above the bottom of
the gauge glass by adding water as required.
After completion of the boil out period, add water
slowly until the gauge glass shows full. Blow
down through the continuous blowdown line in
the steam drum until the water falls to the level
of the surface blowdown connection. From this
1-8
point, blow off with the bottom blowoff valves un­
til water level falls to within two inches of the
bottom of the gage glass. The water column and
gage glass should also be blown down.
After each blow, refill the boiler to the top of the
gage glass and allow the boiler to soak and boil for
about fifteen minutes before the next blow cycle.
Repeat this cycle of blowdown operation for a
minimum of six times or until a cool sample of the
boiler water shows no oil.
If possible, maintain the cleaning concentration
during the blowdown by using a chemical feed
pump.
Pressure should be lowered somewhat during the
blowing and refilling cycle, however, the pressure
should not be allowed to fall below 50 psi.
At the completion of the boil out, shut off the bur­
ner and allow boiler to cool. Open all vents and
drain the boiler when the water temperature has
fallen to 120°F. or less.
Inspect the drums and wipe out any sludge or
scum that may be present. Then wash out boiler
thoroughly with a high pressure hose, using water
of approximately 70°F. temperature, or ambient.
Use a hose on each individual tube including
superheater and economizer tubes. If possible,
this washing should be done from the bottom of
the tube. The fireside of the boiler should be
checked for any unusual conditions.
Upon completion of the wash down, inspect the in­
ternal surfaces and if not clean, repeat the boil out.
Replace manhole covers and install new manhole
gaskets. Replace the gage glass if necessary. Re­
install the prismatic glass if boiler is so equipped.
Refill the boiler with clean, treated water. If not
immediately being placed into service, fire the
boiler until it is heated to at least 180°F. to drive
off any dissolved gases which might otherwise
corrode the metal.
1.) SYSTEM CONTAMINATION
Steam and water piping systems connected to the
boiler may contain oil, grease or foreign matter.
In new systems, the piping usually has an ac­
cumulation of oil, grease and dirt. Old systems
have an additional hazard in that the piping and
receivers may be heavily limed and full of scale
as the result of improper water treatment.
These impurities must be prevented from enter­
ing the boiler. On a steam system the condensate
should be wasted until tests show the elimination

of undesirable impurities. During the period that
condensate is wasted, attention must be given to
the treatment of the water used as make up so
that an accumulation of unwanted materials or
corrosion of drums and tubes does not occur.
Follow the advice of your water treating com­
pany.
On a hot water system, chemical cleaning is
generally necessary and the entire system should
be drained after treatment. Consult water treat­
ment companies for recommendations, cleaning
compounds and application procedures.
If oil, dirt and scale accumulations are permitted
to get into the boiler, it may be necessary to re­
peat the boilout procedure. If this becomes
necessary, the same procedure as outlined under
boilout should be followed.
The waterside of the pressure vessel must be kept
clean from grease, sludge and foreign material.
Such deposits, if present, will not only shorten the
life of the pressure vessel and interfere with effici­
ent operation and functioning of control or safety
devices, but might quite possibly cause un­
necessary and expensive re-work, repairs and
down time.
The pressure vessel waterside should be inspected
on a periodic basis. This will reveal true internal
conditions and serve as a check against condi­
tions indicated by chemical analysis of the boiler
water. Inspection should be made three months
after initial starting and at regular 6, 9 or 12
month intervals thereafter. The frequency of fur­
ther periodic inspections will depend upon the in­
ternal conditions found.
If any unwanted conditions are observed your
water consultant or water treating company
should be contacted for recommendations.
Any sludge, mud or sediment found will have to
be flushed out. The effectiveness of the blowdown
practiced on steam boilers will be verified and
scheduling or frequency of blowdown may have to
be revised. The need for periodic draining or
washout will also be indicated.
G. FEEDWATER SYSTEM
AND TREATMENT
The subject of water supply and treatment is of
great importance and it cannot adequately be
covered in this manual. Maximum effectiveness
and long trouble-free life of the pressure vessel
are functions of properly treated water. The type
and extent of water treatment is determined by
the water supply. The services of a reliable boiler-
C h ap ter 1 - G eneral D escription
water treatment specialist or company should be
engaged to a'nalyze the water and prescribe treat­
ment. Their recommendations should be followed
rigidly to prevent the presence of unwanted solids
and corrosive gases. Failure to do so will result in
ever decreasing boiler efficiency as well as shor­
tened useful life.
Objectives of water treatment in general are:
a. Prevention of hard scale deposits or soft
sludge type deposits, which impair the rate
of heat transfer and can lead to overheated
metal and costly down time and repairs.
b. Elimination of corrosive gases, in supply or
boiler water.
c. Prevention of intercrystalline cracking or
caustic embrittlement of boiler metal.
d. Prevention of carryover and foaming.
The accomplishment of these objectives generally
require treatment before and after introduction of
water into the boiler.
The selection of pre-treatment processes depends
upon water source, chemical characteristics,
amount of make-up water needed, plant opera­
ting practices, etc. These treating methods in­
clude filtering, softening, demineralizing, de­
aerating and preheating.
After treatment involves the addition of chemi­
cals to the boiler water. This after treatment is
required to compensate for any variations in the
pre-treatment and pre-boiler system And to
assure the ultimate protection of the boiler. Be­
cause of the variables involved, no one “boiler
compound” can be considered a cure-all, nor is it
advisable to experiment with home-made treat­
ing methods. Sound recommendations and their
employment should be augmented by periodic
analysis of the raw water, boiler water and con­
densate. *
The internal or waterside surfaces of the pressure
vessel should be inspected with sufficient fre­
quency to determine the presence of any contami­
nation, accumulations of foreign matter, corro­
sion, and/or pitting. If these conditions are de­
tected, the water consultant or feedwater treat­
ment company should be consulted for advice on
corrective action.
It is advisable to have a properly sized wafter
meter installed in the raw water make-up line to
accurately determine the amount of raw water
admitted to the boiler. This will aid the water
treatment program in maintaining proper water­
side conditions.
1-9

CHAPTER 2
OPERATIONS AND PROCEDURES
A. PREPARATION TO INITIAL FIRING
B. FILLING THE BOILER
C. INITIAL FIRING
D. ROUTINE OPERATION AND SHUTDOWN
E. OPERATING PROCEDURES
A. PREPARATION TO INITIAL
FIRING
The operator must be knowledgeable of the
boiler, the burner and all controls and compo­
nents and must be competent to operate this
equipment. The operating conditions of all auxili­
ary equipment and instrumentation that serves in
the firing and feeding of the boiler should be for­
mally checked out. Be sure that auxiliary equip­
ment not supplied by Cleaver-Brooks is of ade­
quate size and pressure to insure proper
operation.
Check for proper voltage, fuses and overloads.
Check rotation of all motors by momentarily clos­
ing the motor starter or relay. Check the reset of
all starters and controls having the manual reset
feature. To the extent possible, all operating me­
chanisms, valves, and the air damper and drive
should be checked for evidence of operation and
freedom from binding. Check the settings of all
controls.
Verify fuel supply. Make certain that fuel
pressure is sufficient and that gauges are indi­
cating correctly. Properly set any adjustable limit
on interlock controls. Pretest them for proper
function at set points if feasible.
Before operating a boiler feed pump or an oil sup­
ply pump, be sure that all valves in the line are
open or properly positioned. Be certain that
pump rotation is correct. If in doubt, remove
coupling and check motor rotation. Some pumps
can be severely damaged by even a momentarily
reversed rotation. Also recheck coupling align­
ment.
Check out the burner in accordance with pro­
cedures given in the burner instruction manual.
Chapter 2 - Operations and Procedures
/
Safety valves should be inspected externally to
see that they are free to operate and that their
escape piping and drain piping are open to at­
mosphere and free to expand without imposing
strain upon the safety valve body. Make sure that
any gags used during testing are removed. Ascer­
tain that discharge piping from the safety valves
and also from all blowdown and drain valves is
piped to a SAFE point of discharge, so that
emission of hot water or steam can not possibly
cause injury to personnel or damage to property.
Prior to closing drum manholes, make certain
that all internal fittings are in place and that no
tools, gear or personnel remain inside. Make a
final check of the fireside area to make sure no
tools, construction gear, debris or personnel are
present.
For safety’s sake, make a final and complete pre­
startup inspection especially checking for any
loose or incompleted piping or wiring or any
other situation that might present a hazard.
,*•
B. FILLING THE BOILER
Check and close the manual blowoff valves, the
continuous blowdown valves, the gage cocks and
the water column and gage glass drain valves.
Open the upper drum vent valve, the water
column shutoff valves, if any, the gage glass
shutoff valves and the steam pressure gauge
valve. Open the superheater vent and drain
valves.
The boiler should be filled with properly treated
feedwater using the bypass feed line. The water
should be as close as possible to the metal tem­
perature to prevent excessive temperature
2-1
Chapter 2 - Operations and Procedures
stresses that could cause tube leakage. 70°F.
minimum water temperature is recommended
unless ambient is considerably higher or lower.
Fill to a level about two inches above the bottom
of the ^age glass. Fill slowly and vent fully to
prevent any pressure buildup from the flashing of
warm water.
Blow down the water column and gage glass
making sure that the water level returns to the
proper level promptly. The gage cocks should also
be operated to verify water level.
C. INITIAL FIRING
Start the burner following the instructions in the
burner operating manual. Make sure that com­
bustion is stable. Check and adjust the burner
and its components as outlined in the burner
manual.
The firing rate should be manually controlled
and held in the low fire position until the boiler is
properly warmed. Generally, the control circuit
has a low fire control which will prevent the bur­
ner from firing in other than the low fire position,
until the boiler is sufficiently warm. This control
is usually adjusted to cut in at approximately 50
psi.
The boiler should be brought up to temperature
and pressure at a slow and carefully controlled
rate. Conditions can vary, however, an accepted
rate of water temperature rise for a steam boiler
is approximately 80 to 100°F. per hour.
On a superheater equipped boiler, it is imperative
that the superheater vent valve be open while the
steam valve is closed. The flow of steam through
the superheater is essential for the protection of
the tubes. Refer to the superheater section in this
manual.
During this period of operation, carefully observe
that all components function properly. Be pre­
pared to shut the unit down should a lack of pro­
per operation become evident. Visually observe
combustion conditions for proof that gauges,
meters and other instrumentation are properly
reporting conditions.
Close the drum vent when steam pressure is 10 to
25 psi. Open any drain or bypass valve in the
steam piping, if provided. Refer to superheater
section for information on its vent and drain
valves.
Maintain the normal water level at all times.
This is usually 4 inches below the steam drum
center line. Maintain the water level by hand
feeding or by blowing down as necessary. Too
high a level will cause flooding and render the
2-2
separators ineffective, while too low a level will
allow possible overheating of pressure parts. If
the water level is not readily apparent, use the
gage cocks and close inspection to determine the
level. If the level is not visible, firing should be
stopped and the reason for low level determined.
The feedwater regulator should be cut in when
operating pressure is obtained and the bypass
feed line valves closed.
The operation of the safety valves should be veri­
fied. This may involve raising the boiler pressure
beyond normal operating setting to actually
determine that valves open and close within the
proper limits or it may require the hand lifting of
the valve lever. The judgment and recommenda­
tion of the authorized inspector should determine
the method used.
When boiler pressure has increased to the desired
point, the boiler can be cut into service according
to good operating practice.
D. ROUTINE OPERATION AND
SHUTDOWN
Check water level and water supply. Check set­
ting of operating controls and burner equipment.
Start burner and slowly bring boiler up to
pressure. Observe functions of all controls during
normal operations.
Maintain normal water level at all times. This is
usually 4 inches below steam drum center line.
Gage glasses should be blown down on a regu­
larly scheduled basis. Illumination of the glass
should be provided and any leakage or breakage
of glass should be promptly repaired.
Blow down the boiler at regular intervals on a
schedule based upon analysis of the water. Make
any necessary adjustments to the commuous
blowdown valve as indicated by a test analysis.
Refer to the blowdown section of this manual.
When operating with oil as the fuel, soot blowers
should be operated regularly to keep gas passages
free from soot and to maintain normal tempera­
tures and efficiency. Refer to the section on soot
blowing in this manual.
ROUTINE SHUTDOWN
Operate all soot blowers before taking the unit off
the line, if oil is the fuel being used.
Gradually reduce load and run burner to low fire
position.
With the burner in low fire position, blow down
boiler along with the water column gage glass
and the feedwater regulator. Turn the burner off

in accordance with instructions in the burner
manual. Follow instructions in regard to burner
shutdown conditions. When shutting down a gas
fired burner, it is good practice to close the
manual gas shutoff cock.
When the boiler falls below line pressure, the
non-return valve should close automatically to
isolate the unit from those remaining in service.
On a single installation or if no other boilers are
in service, the stop valve should be closed when
the boiler setting has cooled enough to insure no
pressure build up. When the drum pressure falls
below 25 psi, open the top drum vent valve. This
will prevent a vacuum that can loosen well set
gaskets and cause future leaks.
The boiler should be filled with treated hot water
in preparation for the next start up. Additional
water care may be necessary and recommended
by the feedwater consultant if the shutdown is
prolonged.
During an extended shutdown, the drain valves
under the furnace floor and the convection section
should be opened to permit any leaking water to
escape. Close valves during operation.
E. OPERATING PROCEDURES
1. FEED WATER REGULATION AND CONTROL
The boiler is standardly equipped with a thermo­
hydraulic, single element feedwater regulator
which will automatically maintain the proper
water level when used with a suitable source of
water supply.
Refer to the manufacturer’s literature, provided
separately, for specific instructions on the feed­
water regulator. The generator portion must be
properly filled with liquid - either water (pre­
ferably distilled) or with an anti-freeze solution,
if conditions require.
When placing the boiler into service, the drum
level must be maintained manually until the
boiler has reached operating pressure. Manual
control is accomplished through the manual
operation of the bypass valve or by locking the
regulator valve open with its hand jack lever and
throttling the adjacent hand valve to keep the
drum water level in the center of the gage glass.
To switch from manual to automatic operation,
release the regulator valve hand jack and open
wide the hand valve ahead of the regulator valve.
If the regulator fails to maintain proper water
level during normal operation, refer to the manu­
facturer’s instructions for corrective adjustment.
The regulator and water column are factory
piped at the proper levels and generally need no
alteration. ’ come erratic in operation or if its setting changes
Chapter 2 - Operations and Procedures
2. WATER LEVEL INDICATING SYSTEM
The water level alarm system employs electrodes
or probes mounted in a water column. These are
electrically connected to relays in the limit and
alarm circuits. The action of the relay depends on
electrode immersions to complete each circuit.
See Figure 3-1 and also refer to the wiring dia­
gram provided for the boiler.
A minimum of 4 circuits is always provided al­
though individual installations may have addi­
tional. The four circuits are comprised of two low
water cut-off circuits, a low water alarm circuit,
and a high water alarm circuit.
Electrodes numbered 1 and 4 serve as low water
cut-offs. Each of these is connected to an indivi­
dual relay. A third electrode, identified as C, is a
common electrode wired to all relays.
As long as these three are immersed, the water
level is considered suitable for operation and the
relay contacts are closed to complete the limit cir­
cuit. Should the water level lower to the point
where these are no longer immersed, the limit cir­
cuit will be interrupted and the burner will shut
down or be prevented from operating.
To assure adequate water level above the cutoff
level, a shorter electrode identified as No. 2 is
wired to a low water alarm relay. This electrode
is normally immersed. Should this electrode be
exposed by lowering water level, the alarm horn
(AH) will sound and the low water light (LWL)
will glow to alert the operator to this condition.
This protection occurs while the burner is in
operation or when the burner switch is closed in
anticipation of operation.
Normally electrode No. 3, which is connected to a
high water alarm relay, will not be immersed. If
the water level reaches the height of this elec­
trode, the relay will be energized to sound the
alarm horn and light the high water light (HWL).
An alarm test switch (ATS) is provided to simu­
late alarm conditions when depressed so that a
check may be made to determine that the alarm
signal devices are in working order without
disturbing burner operation.
The need to periodically check water level con­
trols and the waterside of the pressure vessel can­
not be overemphasized. Most instances of major
damage are the result of operating with low
water or the use of untreated (or incorrectly)
treated water.
Low water cut-off devices are generally set by the
original manufacturer and no attempt should be
made to adjust these controls to-alter the point of
low water cutoff. If a low water device should be­
2-3
C h a p te r 2 - O perations and P rocedures
from previous established levels check for reasons
and correct: repair and replace device as
required.
Figure 2.1 is a replica of the low water cut-off
plate attached to a steam boiler. The instructions
should be followed on a definite planned
schedule. These controls normally function for
long periods of time which may lead to laxity in
testing on the assumption that normal operation
will continue indefinitely.
If the boiler is equipped with a float type water
column or an auxiliary low water cut-off, the
head mechanism should be removed from the
bowl at least once a month to check and clean the
float ball, the internal moving parts, and the
bowl.
Periodically remove the pipe plugs from the tees
or crosses to make certain the cross connecting
piping is clean and free of obstructions. Controls
must be mounted in a vertical position for proper
performance. Determine that piping is vertically
aligned after shipment and installation and
throughout life of equipment.
A scheduled blowdown of the water controls
should be paintained.
W A R N IN G
SAFE OPERATION OF YOUR BOILER DEMANDS PERIODIC
INSPECTION AND MAINTENANCE OF ALL LOW WATER
C U T -O F F DEVICES. INSPECT THEM AT LEAST ONCE A
MONTH. PROPER OPERATION SHOULD BE CHECKED FRE­
QUENTLY BY CLOSING FEED WATER VALVE WITH BOILER
IN OPERATION AND ALLOWING WATER LEVEL TO DROP
AT A NORMAL RATE. IF CONTROLS UNDER TEST DO NOT
CUT OFF BURNER A T PROPER SAFE WATER LEVEL OR
ARE SEEN TO BE IN POOR PHYSICAL CONDITION, REPAIR
OR REPLACE AT ONCE. MUD AND SEDIMENT ACCUM A-
LATIONS IN THE GAGE GLASS, WATER COLUMN, AND
AUXILIARY LOW WATER CONTROLS SHOULD BE ELIM­
INATED BY PROPER BLOWDOWN PROCEDURE.
FIGURE 2-1 LOW WATER CUT-OFF PLATE
3. THE WATER COLUMN
In addition to the probes described in the pre­
vious section, the water column also contains the
equipment to provide the operator with visual
knowledge of the water level.
The gage glass attached to the side of the column
is used to visually check the boiler water level.
The trycocks can be used to check the accuracy of
the gage glass levels. The gage cocks provide a
means of isolating the gage glass in the event of
the breakage or replacement.
2-4
This visual knowledge of the water level is one of
the most important operating guides available to
the operator. The importance of frequent ob­
servation of the water level cannot be over­
emphasized.
Keep the gage glass clean and properly lighted
for good visibility. Refer to the operating and
maintenance section of this manual for blowdown
test procedures and replacement.
Operate the gage cocks regularly to insure their
being satisfactory for emergency service.
The normal water level in a Cleaver-Brooks
Watertube Boiler is 4” below the center of the
steam drum. This level is indicated at the mid
point of the gage glass.
The low water alarm probe is usually positioned
to be energized should water fall approximately
5” below normal. The alarm signal will alert the
operator of this condition.
Should water level fall to approximately to 1/2”
visibility in the gage glass, the low water cut off
probe will be exposed and will act to shut down
the burner.
The ASME Boiler and Pressure Vessel Code
requires that the lowest visible point of the water
glass shall be at least 2” above the lowest per­
missible water level. This is the point at which
there will be no danger of overheating any part of
the boiler when operation is at that level.
CAUTION: In the event the burner is firing at
any time that water is not visible in the water
gage glass, immediately turn the burner off
manually. DO NOT TURN ON THE WATER
FEED LINE. ,
DO NOT OPEN THE SAFETY VALVE. Let the
boiler cool until a drum is at hand touch tem­
perature. Then add water to a height of 1” in the
gage glass. DO NOT PUT THE BOILER BACK
INTO SERVICE UNTIL THE CONDITION
RESPONSIBLE FOR THE LOW WATER HAS
BEEN IDENTIFIED AND CORRECTED. Do
not attempt to put the boiler back into operation
if there is evidence of overheated metal, or even
suspected damage, until a thorough inspection
and/or repairs have been made.
Check the water gage on a regular basis. A
weekly frequency is suggested. The check should
be made when there is steam pressure in the
boiler. Close the lower gage glass valve, then
open the drain cock on the bottom of the valve
and blow the glass clear. Close the drain valve
and open the lower gage glass valve. Water
should return to the gage glass immediately. If

water return is sluggish, leave the lower gage
glass open and close the upper gage glass valve.
Then open the drain valve and allow water to
flow until it runs clear. Close the drain valve and
repeat the first test with the lower gage glass
valve closed.
If leaks appear around the water gage glass or fit­
tings, correct the leaks at once. Steam leaks may
result in a false water line and may also damage
fittings.
The handles on the gage glass cocks must be in­
stalled on the valve stems so that their position
indicates whether the valve is open or closed. The
operating chain on the right hand side of the
levers should be snug between levers so that both
valves will be closed tight when the chain is
pulled from below.
4. BLOWDOWN
Boiler water blowdown is the removal of some of
the concentrated water from the pressure vessel
while it is under pressure. The removed water
containing suspended solids and dissolved solids
is replaced with relatively pure feedwater so that
a lowering of the concentration occurs.
Solids are brought in with the feedwater even
though this water is treated prior to use through
external processes designed to remove the un­
wanted substances which contribute to scale and
deposit formations. Regardless of their high ef­
ficiency, none of these processes in themselves are
capable of removing all substances and a small
amount of encrusting solids will be present in the
boiler water.
The solids become less soluble in the high tem­
perature of the boiler water and as the water
boils off as relatively pure steam, the remaining
water becomes thicker with either suspended
solids or dissolved solids.
Internal chemical treatment, based on water
analysis, is used primarily to precipitate many of
the solids and to maintain them as “sludge” in a
fluid form. This sludge along with suspended
solids that may be present must be removed by
the blowdown process.
If the concentration of solids is not lowered
through blowdown but rather accumulates, foam­
ing and priming will occur along with scale and
other harmful deposits.
The scale forming salts tend to concentrate and
crystalize on the heating surfaces. Scale has a low
heat transfer value, It acts as an insulation
barrier and retards the transfer. This not only re­
sults in low operating efficiency and consequently
higher fuel consumption, but also presents the
Chapter 2 - Operations and Procedures
possibility of overheating the boiler metal. The
result can be tube failures or other pressure
vessel metal damage causing costly repairs and
downtime. Deposits of sludge on heating surfaces
will have the same detrimental effect.
There are two principal types of blowdown; in­
termittent and continuous. Intermittent, or
sludge, is done manually and is necessary for the
operation of the boiler regardless of whether or
not continuous blowdown is employed. Continu­
ous blowdown is, as the name implies, a continu­
ous and automatic removal of concentrated
water.
Manual Blowdown
The manual blowdown valve and discharge lines
are located at the bottom or low point of a boiler
so that in addition to lowering the dissolved
solids in the boiler water, a portion of sludge
which might accumulate in the lower part of a
pressure vessel can also be removed. This opening
also provides a means of draining the boiler when
it is not under pressure.
When continuous blowdown is utilized, manual
blowdown is primarily used to remove suspended
solids or sludge that may have accumulated in
the area. When continuous blowdown is not
utilized, manual blowdown is used to control the
concentration of dissolved or suspended solids in
addition to the sludge.
In practice, the valves of the bottom blowdown
are opened periodically in accordance with an
operating schedule and/or chemical control test.
The blowdown amount and schedule should be
recommended by a water treating company or a
water consultant. It is generally recommended
that a steam boiler be blown down at least once
in every eight hour period. In cases where the
feedwater is exceptionally pure, blowdown may
be employed less frequently since less sludge ac­
cumulates in the pressure vessel.
,*>
From the standpoint of control, economy, and re­
sults, frequent short blows are preferred to infre­
quent lengthy blows. This is particularly true
when the suspended solids content of the water is
high. With the use of frequent short blows, a more
uniform concentration of the pressure vessel
water is maintained. Blowing down is most ef­
fective at a time when the generation of steam is
at the lowest rate since the feedwater input then
is also low, providing a minimum dilution of the
boiler water with low concentration feedwater.
Make sure that blowoff piping, and tank if used,
are in proper operating condition, all discharge
vents clear of obstruction and that waste is piped
to point of safe discharge.
2-5
Chapter 2 - Operations and Procedures
It is recommended that the blowdown valve near­
est the boiler be opened first and closed last, with
blowing down being accomplished by the valve
furthest from the boiler. The sequence of opera­
tion once established should provide that the
valve last opened should be the first closed so
that the other valve is saved from throttling ser­
vice to insure a tight closing.
The downstream valve should be cracked slightly
to allow the discharge line to warm up, after
which this valve is opened slowly. Quickly close
the valve, and if necessary, repeat this opening
and closing.
Close the downstream valve tightly, then close
the valve next to the boiler. Slightly crack open
the downstream valve, then close it tightly. The
frequency and amount of each blow should be
determined by actual water analysis. It is advis­
able that blowdown does not exceed the necessary
amount since it involves heat losses and, if ex­
cessive, wastes treatment chemicals.
The water level should be observed during
periods of blowdown. If the glass cannot be
viewed by the party operating the valve, another
operator should watch the glass and direct the
valve operator. The blowoff valves should never
be left open and the operator should never leave
until the blowdown operation is completed and
the valves closed. Be sure the valves are shut
tight. Repair any leaking valves as soon as
possible.
Continuous Blowdown
The boiler is equipped with an internal continu­
ous blowdown pipe and an external stop valve.
The collector pipe is located several inches below
the low water level at a point where the most con­
centrated water is found.
A controlled orifice valve is used in the discharge
pipe to allow continual, yet controlled, flow of
concentrated water. This removes sediment and
oil from the surface of the water along with the
prescribed amount of dissolved solids.
In a boiler that operates continuously at full
load, there is little chance for separation of
sludge in the lower drum because of the rapid
boiler water circulation. Thus, blowoff from the
lower part of the Unit may not result in the proper
elimination of suspended solids. The use, how­
ever, of the continuous blowdown does not pre­
clude the regular use of the bottom or inter­
mittent manual blowdown.
The amount of water lost through a continuous
surface blowdown is usually considerably less
than the water lost through bottom blowoff in or­
der to remove a given amount of suspended
2-6
solids. The amount of blowdown depends upon
the rate of evaporation and the amount of sludge
forming material in the feedwater.
Periodic adjustments are made to the valve set­
ting to increase or decrease the amount of blow­
down in accordance with a test analysis.
Internal inspection, is the only true indication of
the effectiveness of water treatment and presence
of unwanted solids.
5. SOOT BLOWING
Systematic soot blowing should be included as a
regular feature in the operation of any oil burn­
ing watertube steam boiler. The frequency and
amount of cleaning will depend upon operating
conditions, grade of fuel and burner adjustment.
Experience will dictate the length of cleaning and
the interval between.
The following guidelines should be observed.
The soot blower must be operated only when the
burner is firing at a rate of 70% or higher, Place
the burner under manual operation, if necessary,
to hol'd the boiler at near maximum firing rate
despite load variations.
CAUTION
' ' ' 1
Operating at low loads should never be at­
tempted because of the possible hazards involved.
It is important to have all areas of the gas passes
thoroughly swept by utilizing maximum flue gas
flow to purge any combustible material from
pockets where it may collect. Cleaning operations
during a low firing rate may produce unfavorable
conditions that could interrupt combustion.
Prior to blowing, the drain valve in the steam line
to the soot.blower should be opened. Then open
the steam shut-off valve slowly and vent steam
for approximately five minutes to insure that no
water is present in the steam Tine and to warm
the piping. "Close the vent valve,and begin rotat­
ing the element.
Rotate with a steady pull on the chain wheel and
be sure to keep rotating whenever steam is issu­
ing from the nozzles.
The amount of cleaning, or number of times the
element is rotated, can be governed by observing
exit temperature or stack discharge.
A generally recommended practice is to operate
all soot blowers prior to taking a boiler off line.
At the conclusion of blowing, close the steam
header valve. The factory installed drain valve
has a small hole drilled in its gate to allow escape

of steam and condensate. If the drain valve was
provided by others, open it to drain the line.
The blowing pressure is adjustable and should be
set in a range of 80 to 150 psi. Refer to the manu­
facturer’s bulletin for instructions on pressure ad­
justment.
Maintenance:
Follow the manufacturer’s recommendations for
lubrication of the gears and head. Keep the pack­
ing glands just tight enough to prevent leakage,
but dp not overtighten. Also examine to the ex­
tent possible the external surfaces of the tubes
adjacent to the element nozzles for any signs of
abrasion possibly caused by movement of the ele­
ment due to distortion or shifting.
Air, taken from the blower discharge, is piped to
the head so that it and the element are suffici­
ently pressurized to prevent the backup of com­
bustion gases from the pressurized furnace.
Periodically check the condition of the airline to
make sure there are no obstructions or loose con­
nections. Also, inspect the air check valve on the
head for free operation.
6. SUPERHEATER
General
Correct operational procedures must be followed
during the starting up and shutting down of a
boiler equipped with a superheater to prevent
damage from occurring to the superheater tubes.
It is essential that definite procedures be
established and followed by all operators.
Start-up
A moderate firing rate (generally about 10% of
maximum) must be used during start-up and dur­
ing the warming up of a cold boiler and super­
heater. The addition of heat too rapidly may in­
crease the superheater metal temperature to a
point where it will oxidize or “burn” . The control
system generally includes a low fire pressure con­
trol that limits the burner to low fire operation
until the boiler pressure reaches approximately
one-third operating pressure (or approx. 50 psi).
When starting the boiler, the superheater vent
valve must be opened until the non-return valve
is opened and steam flow through the system is
established. This keeps steam flowing through the
superheater tubes. It is imperative that a positive
flow of steam be maintained whenever the super­
heater is subjected to heat. The heat absorbed by
the superheater must be carried away at the same
rate that is transmitted to the tubes.
Chapter 2 - Operations and Procedures
When boiler pressure reaches 15 to 25 psi, close
the drain valve but leave the vent valve wide
open. A tendency may exist to throttle the vent
valve in order to save steam or to raise pressure
at a faster rate. While this is not without some
advantage, it is more desirable to protect the
superheater by leaving the vent valve open until
the boiler is on the line and with a definite (not
less than 10% ) flow of steam into the system.
A steam temperature recorder or thermometer
should be installed on the upstream side of the
vent valve and as close to the outlet of the super­
heater as practical. Temperatures taken at a
more remote point may not provide true super­
heater temperature readings. Steam flow tem­
perature at this point can then be a fairly ac­
curate temperature indicator of the superheater
tube metal and the rate of firing can be con­
trolled within a safe range. The temperature
should increase gradually and should, in general,
be well below the maximum temperature for
which the superheater was designed. Tempera­
tures approaching this maximum will indicate
that the firing rate is too high. In this event, the
firing rate should be decreased or stopped alto­
gether.
An accepted rate of boiler water temperature rise
for a steam boiler is approximately 80°F. per
hour. The protection of the superheater is the pri­
mary factor controlling the time required for
placing the boiler into service.
Normal Operation
During normal operation, the superheater re­
quires no special safeguards other than the main­
tenance of the conditions for which it was
designed.
When firing on oil, use the soot blower on a regu­
larly scheduled basis to keep the superheater sur­
faces free of soot or other deposits. Periodically
check for effectiveness and also on the alignment
of the steam jets.
The superheater has a safety valve that is set to
open at a lower pressure than the boiler safety
valves. In the event of excessive steam pressure,
this valve will open first so that steam from the
boiler will continue to flow through the super­
heater tubes. If the boiler pressure is not dissi­
pated or the fire reduced, the boiler safety valves
will then open.
Shutting Down
During the shutting down operation, it is also
necessary to maintain steam flow through the
superheater. The vent valve should be opened as
the boiler is taken off the line. The drain valve
2-7
Chapter 2 - Operations and Procedures
should remain closed. An acceptable practice is to
open the vent valve fully when the boiler is first
taken off the line and then to close it in gradual
steps as furnace temperature decreases. The
amourtt -of valve opening can be based on the
temperature of the steam indicated by the
thermometer in the superheater outlet.
When the furnace is cool, the valve may be
closed. In some multiple unit installations, the
boiler may be kept on standby service with its
water kept hot through introdyction of steam
from another unit and in this event, the vent
valve should remain open.
>
2-8
If the boiler is removed from service, open all
drain valves to drain water caused by condensa­
tion. The superheater should be visually
examined during the annual inspection and, if
possible, during other down periods. Check the in­
ternal surfaces for scale, corrosion, also for
evidence of leaks or overheating. Replace the
gaskets in the header handholes. Make sure that
gasket seating surfaces are clean.
If the boiler is to be idle for any length of time,
follow the instructions in this manual pertaining
to the care and protection of idle boilers.
 Chapter 3 - Maintenance

CHAPTER 3

MAINTENANCE
A. GENERAL
WATERSIDE INSPECTION
FIRESIDE INSPECTION
B. PRESSURE VESSEL CARE AND REPAIRS
C. TUBE CLEANING
MECHANICAL TUBE CLEANING
CHEMICAL CLEANING
D. WATER COLUMN
PROBE INSTALLATION
GAUGE GLASS OR PRISMATIC INSERT
E. SAFETY VALVES
F. CARE AND PROTECTION OF IDLE BOILERS

A. GENERAL tive action that may prevent excessive repairs or

A well planned maintenance program avoids un­
necessary down time or costly repairs, promotes
safety and aids boiler code and local inspectors.
An inspection schedule listing the procedures
should be established. It is recommended that a
boiler room log or record be maintained, re­
cording the daily, weekly, monthly and yearly
maintenance activities. This provides a valuable
guide and aids in obtaining economies and length
of service from the boiler.
Even though the boiler has electrical and me­
chanical devices that make it automatic or semi­
automatic in operation, these devices require
systematic and periodic maintenance. Any “auto­
matic” features do not relieve the operator from
responsibility, but rather free him from certain
repetitive chores, providing him time to devote to
upkeep and maintenance.
Good housekeeping helps maintain a professional
appearing boiler room. Only trained and
authorized personnel should be permitted to
operate, adjust, or repair the boiler and its re­
lated equipment. The boiler room should be kept
free of all material and equipment not necessary
to the operation of the boiler or heating system.
Alertness in recognizing an unusual noise, im­
proper gauge readings, leaks, signs of over-heat­
ing, etc., can make the operator aware of a de­
veloping malfunction, permitting prompt correc­
unexpected down time. A steam, water, or fuel
leak should be repaired as soon as possible. They
are wasteful as well as hazardous.
Always be sure of the boiler water level. The
water column should be blown down at least once
each eight hour shift. Check samples of boiler
water and condensate in accordance with pro­
cedures recommended by your water consultant.
Daily maintenance should include a check of the
burner operation, including fuel pressure, atomiz­
ing air or steam pressure, visual appearance, etc.
Clean the observation ports during periods of low
fire or shutdown.
Maintain a daily schedule of soot blowing and in­
termittent blowdown. Refer to previous sections
for additional information.
WATERSIDE INSPECTION
Insurance regulations or local laws will require a
periodic inspection of the pressure vessel by an
authorized inspector. Sufficient notice is
generally given to permit removal of the boiler
from service and preparation for inspection.
Inspections of this type are usually, though not
necessarily, scheduled for periods of normal
boiler down time such as an off season. This
major inspection can often be used to accomplish
maintenance, replacements or repairs that cannot

3-1
Chapter 3 - Maintenance
easily be done at other times. This also serves as
a good basis for establishing a schedule for an­
nual, monthly or other periodic maintenance
programs.
While this inspection pertains primarily to the
waterside and fireside surfaces of the pressure
vessel, it provides the operator an excellent op­
portunity for detailed inspection and check of all
components of the boiler including piping, valves,
pumps, gaskets, refractory, etc. Comprehensive
cleaning, spot painting or re-painting and the re­
placement of expendable items should be planned
for and taken care of during this time. Any major
repairs or replacements that may be required
should also if possible be coordinated with this
period of boiler shutdown.
Replacement spare parts, if not on hand, should
be ordered sufficiently prior to shutdown.
When shutting down, the load should be reduced
gradually and the pressure vessel cooled at a rate
that avoids damaging temperature differential
that can cause harmful stresses. Vessels should
not normally be drained until all pressure is re­
lieved and water temperature is less than 120°F. -
again to prevent uneven contraction and tem­
perature differentials that can cause expanded
tubes to leak. Draining the unit too quickly may
cause the baking of deposits that may be present
on the heating surfaces. Some heat, however, may
be desirable to dry out the interior of the boiler.
If the internal inspection is being made at the re­
quest of an authorized inspector, it is well to
learn from him whether he desires to observe the
conditions prior to cleaning or flushing of water­
side surfaces.
Be certain that a supply of manhole gaskets is
available along with any other gaskets or items
needed to place the unit back into operation after
inspection.
Have available*information on the boiler design,
dimensions, generating capacity, operating
pressure or temperature, time in service, defects
found previously and any repairs or modifi­
cations. Also have available for reference records
of previous inspections.
Be prepared to perform any testing required by
the inspector including hydrostatic.
After proper cooling and draining of vessel, flush
out the waterside with a high pressure water
hose. Remove any scale or deposits from the
waterside surfaces and check for internal or ex­
ternal corrosion and leakage.
The fireside surfaces should also be thoroughly
cleaned so that metal surfaces, welds, joints, tube
3-2
ends, fittings "and any previous repairs can be
readily checked.
Be sure that steam valves, system valves, (hot
water) feedwater valves, blow-off valves, all fuel
valves, valves to expansion tanks, and electrical
switches are shut off prior to opening the drums or
the combustion area. Adequately vent the pressure
vessel prior to entry. Flashlights rather than ex­
tension cords, are recommended as a safety factor.
Cleaners should preferably work in pairs. Always
have one man standing by outside when a man is
working inside a boiler.
Clean out the low water cut-off piping, the water
level controls and cross connecting piping. Re­
place water gage glass and clean out water cocks
and tri-cocks. Also check and clean drain and
blowdown valves and piping.
Check all water and steam piping and valves for
leaks, wear, corrosion and other damage. Replace
or repair as required.
If any deposits are noted during these inspections,
they should be flushed out with a high pressure
hose. If they are not thoroughly removed by flush­
ing, this may require immediate consultation
with your water treatment representative. In a
few cases, it may be necessary to resort to acid
cleaning. Professional advice is definitely re­
commended should acid cleaning be required.
The effectiveness of treatment, water conditions
and the amount of fresh water makeup required
are all factors to be considered in establishing
frequency of future pressure vessel inspections.
The feedwater consultant or water treatment
companies service should include periodic
pressure vessel inspection and water re-analysis.
FIRESIDE INSPECTION
An internal, or fireside, inspection should be
made at least semi-annually aj»d oftener if pos­
sible. Wire brush or sweep away any deposits that
might be present in the furnace area. If excessive
soot or any signs or corrosion are evident, prompt
corrective action must be taken. Combustion ad­
justments should be made to prevent further oc­
currences. Poor combustion contributes to a dirty
boiler, adds hazards and wastes fuel.
Check the condition of all the refractory. Parti­
cularly check the expansion joints in the front
and rear walls, the seals at the corners and the
throat tile. Patch and repair as required.
Frequent wash coating of refractory surfaces is
recommended. Use high temperature bonding,
air-dry type mortar diluted with water, to the
consistency of light cream, for this purpose. This

will seal small cracks and prolong the life of the
refractory. Any large cracks should be cleaned
out and filled with mortar.
The breeching and stack should be inspected
periodically and cleaned if necessary. Also in­
spect the stack for any signs of damage.
The fireside should be thoroughly cleaned prior
to any extended lay-up of the boiler. Depending
upon circumstances a protective coating may be
required. See the section on storage.
B. PRESSURE VESSEL CARE
AND REPAIR
A well maintained and operated boiler with pro­
perly treated water will require a minimum of re­
pairs. Periodic inspection of the pressure vessel
will reveal its •condition, oftentimes permitting
corrective action designed to prevent failure of
some portion of the boiler.
Corrosion and erosion, or a combination of both,
are a chief cause of tube failure. Corrosion is a
chemical action occurring inside or outside the
tube wall. Internal corrosion appears as pitting
or a general failing of the tube wall. Pitting oc­
curs when there is free oxygen in the water where­
as general thinning indicates an acid condition in
the boiler water. External corrosion is very likely
to occur when a full boiler covered with soot lies
idle. Most soot contains some percentage of sulfur
which in the presence of moisture from condensa­
tion forms a highly corrosive acid.
Erosion takes place when considerable quantities
of fine particles are driven at high velocity
against the outside surfaces of the tubes. Erosion
may also be caused by soot blowers if nozzles are
not kept in proper alignment.
Over-heating also contributes to damage. This
usually occurs when a tube is heated to a tem­
perature which reduces its tensile strength. The
weaker walls then rupture under normal opera­
ting pressure. The chief cause of over-heating is
scale on the water side of the tubes. Scale is a
poor conductor of heat and the cooling ability of
the boiler water is lessened.'Low water is another
cause of over-heating since circulation of water is
impaired and the tube is starved of water. An oily
film also acts as an insulator permitting over­
heating. Any sign of oil in the boiler should be
considered serious and prompt action taken to
remove it. _
Over-loading a boiler to produce more steam
than intended by its design-will also shorten the
boiler life, with the tubes being first to suffer.
Chapter 3 - Maintenance
If small leaks occur, locate their source and. re­
pair them as quickly as possible. Leaking man­
holes and handholes should be corrected promp­
tly. Gasket sealing surfaces should be cleaned
thoroughly to provide a tight seal.
In the event of a serious leak or a tube failure,
shut down the burner and the supply of feed­
water. When steam pressure has dropped to zero,
continue the cooling process in the normal man­
ner. Then conduct a thorough inspection to deter­
mine the extent of damage.
No repair of any type is to be made until pressure
is removed from the boiler. Observe all safety pre­
cautions before entering the boiler for inspection
or repairs. This includes securing the burner and
positive action in insuring all valves in lines to
and from the boiler are closed and remain closed.
Minor or leaking repairs may be handled by
authorized and experienced personnel. Any re­
pairs beyond this must have the approval of an
authorized inspector. His recommendations and
advice must be followed. If welding is required,
the welder must be certified to do the work.
Boiler tubes are secured in the boiler drums by
rolling or expanding to a tight fit. In the correction
of any leak, it is imperative that rerolling of the
leaking tube be done only be experienced person­
nel. Inexperienced operators tend to overroll the
tube, thus thinning the joint and making it
difficult to tighten under any circumstances. When
seal welding is employed, a light rerolling should
be made after welding.
C. TUBE CLEANING
1. MECHANICAL TUBE CLEANING
The mechanical method of cleaning water tubes,
referred to as turbining or punching, is ac­
complished through the use of motor driven ro­
tary cutting tools and Brushes.'The necessity for
and frequency of this type of cleaning is deter­
mined by an internal inspection. The type of de­
posits will determine the need for using cutting or
scraping tools and a brush or a" brush only. Air
driven tools are most commonly used although
water driven tools are also employed. Steam
driven and electric driven tools are used infre­
quently. Cleaning tools furnished by or obtained
from Cleaver-Brooks are selected for the size of
the boiler tubes and for their ability to negotiate
the bends of the tubes.
The mecnanical cleaning of tubes and the use of
these tools should be done by experienced opera­
tors or at least under their supervision. There are
companies who specialize in cleaning and their
3-3
Chapter 3 - Maintenance
experience and equipment will quite often justify
their employment.
This work is generally done from within the up­
per drum, working the tool down through the
tubes so that debris falls into the lower drum
from where it can be collected and removed. The
baffle plates in the upper drum will have to be re­
moved for access to the tubes.
There are several general operating suggestions
that should be followed as goocl operating prac­
tices:
a) Start the cleaner rotating in the tube and
pass it slowly and uniformly through at ap­
proximately two to three feet per minute.
b) Do not allow cleaner to protrude from the
tube while under power. This can be danger­
ous to personnel and damaging to equip­
ment.
c) Care should be taken not to allow the
cleaper'to stop in any one position in the
tube.
d) Keep working tools in good condition.
e) If electrical driven tools are used, be sure
they are properly grounded.
The following specific operating instructions are
provided by Thomas C. Wilson, tnc. - Manu­
facturer of tube cleaning equipment.
OPERATING INSTRUCTIONS FOR AIR DRIVEN
CLEANER
RECOMMENDED OPERATING AIR PRESSURE
90 PSI. MAY BE OPERATED AT 60 TO 100 PSI.
HOW TO SET-UP THE TUBE CLEANER:
1. Blow out air line before attaching operating
hose in order to remove all dirt, rust, or other
foreigp matter.
2. Attach automatic lubricator (if included in
your equipment) to air outlet. Connect hose.
3. Blow out the air-line and hose again.
4. Connect the tube-cleaner air valve (if included
in your equipment) to the hose.
5. Attach motor, making sure connections are
wrench-tight — but' not jammed — to prevent
air leakage.
6. Using wrench supplied with equipment, screw
universal joint or .flexible holder to motor.
7. Attach the cleaning.or brushing tool.
HOW TO OPERATE THE TUBE CLEANER:
1. Insert the cleaning tool into the tube, then
open the air valve and feed the motor into the
tube slowly enough to properly clean the tube.
3-4
2. Don’t let the cleaning tool run out of the end
of the tube — you’ll damage it. A good prac­
tice is to mark the operating hose with tape or
other visible marking to indicate exact length
of tube.
3. Keep the motor running when pulling it back
through the tube.
4. Shut off the air and stop the motor before tak­
ing it out -of the tube.
5. If cleaning tool jams in deposit, pull motor
back gently to release it. Continue cleaning.
6. If motor functions improperly, it is probably
due to faulty lubfication or dirt in the air-line.
Take motor apart and clean all parts, includ­
ing the rotor blades, with kerosene.
LUBRICATION:
1. To lubricate the motor, use one part Wilsolube
No. 9047 oil to two parts kerosene.
2. The needle valve on the automatic lubricator
controls the feed of oil to the motor. Feed 10 to
20 drops per minute depending on the size of
cleaner. This small amount of oil will not coat
the tubes. It will be absorbed and blown out
with the debris.
3. If you do not have an automatic lubricator use
an oil can to apply a few drops of oil into the
exhaust ports of the motor. Turn the motor by
hand to distribute the oil and then blow out
motor before inserting into the tube.
4. KEEP MOTOR LUBRICATED.
HOW TO PREVENT RUST AND CORROSION IN
STORAGE:
1. Before storing your tube cleaner, clean and oil
it thoroughly with machine oil to prevent
rusting.
2. The best method of storing straight tube
motors is to keep them in oil.
3. Curved tube motors, — suspend the motor in.
oil keeping the hose piece above the level of
the oil as the hose piece will not stand pro­
longed immersion in oil.
OPERATING INSTRUCTIONS FOR
WATER DRIVEN CLEANER
The operation of the water driven cleaner is
essentially the same as the air driveh type with
the following changes or instructions:
1. The water line from the pump to the hose con­
nection should be larger than the hose fur­
nished with the water motor; If the water sup­

ply is not free of sediment, be sure to use an
adequate strainer.
2. Motors should be operated at pressures of 125
to 175 lbs. psi. Consumption will vary from 20
. to 30 gpm depending upon motor size and
operating pressure.
3. The water acts as a lubricant, therefore no
lubrication is necessary.
4. After using, it is a good policy to disassemble
motor, thoroughly clean and dry, oil and store
in a dry place.
2. CHEMICAL CLEANING
Should a waterside inspection reveal a deposit
build-up that cannot be fully removed by flushing
or mechanical means, it may be necessary to
clean with chemicals (acid). Professional advice
is recommended. There are specialist companies
equipped to provide complete chemical cleaning
service. Your feedwater consultant should be con­
tacted and be aware of the situation.
D. WATER COLUMN
1. PROBE INSTALLATION INSTRUCTIONS
Thread electrode probe into holder finger tight.
Lock in place using a wrench on lower hex and
another on the lock nut. Do not use a wrench on
the upper hex while installing the probe.
See Figure 3-1.
Clean the female threads in the water column
plate. If they require chasing, use a 3/8” SAE
DRY SEAL (PTF) tap. Do not use a standard
3/8” NPT tap. Teflon tape or a small amount of
pipe dope may be used on the male threads. Use a
13/16” deep socket wrench on upper hex to
tighten electrode holder. Take care not to crack
the insulator.
When attaching the wire lug use proper wrenches
on both lug nuts so that no torque is applied to
the electrode holder. Do not use a knurled nut or
lock washer.
2. THE GAGE GLASS OR PRISMATIC
GAGE INSERT
When a tubular glass is used, it is imperative that
the gage cocks are mounted in exact alignment. If
they are not, the glass will be strained and may
fail prematurely.
A broken or discolored glass should be replaced
at once. Periodic replacement should be a part of
the maintenance program. Always use new
gaskets when replacing a glass. Use a proper size
Chapter 3 - Maintenance
rubber packing. Do not use “loose packing
which could be forced below the glass and pos­
sibly plug the valve opening.
Close the valves when replacing the glass. Slip a
packing nut, a packing washer, and packing ring
onto each end of the glass. Insert one end of the
glass into the upper gage valve body far enough
to allow the lower end to be dropped into the
lower body. Slide the packing nuts onto each
valve and tighten. See Figure 3-2.
If the glass is replaced while the boiler is in ser­
vice, open the blowdown and slowly bring the
glass to operating temperature by cracking the
gage valves slightly. After glass is warmed up,
close the blowdown valve and open the gage
valves completely.
If the water column is equipped with a prismatic
gage insert, it should be inspected for leakage af­
ter it has been placed in service. When thoroughly
heated, expansion of the metal parts causes the
bolting pressure to ease somewhat and if leakage
is apparent, it is advisable to go over to the bolts
and tighten them lightly and evenly to prevent
further leakage. See Figure 3-3.
To clean or replace the prismatic glass, remove
the insert from the gage valves. Thoroughly clean
the gasket seat surface after the old glass and
gaskets have been removed. The surface must be
smooth and free from scratches to prevent shat­
tering the replacement glass.
The inner gasket and the glass should be placed
centrally on the insert body. Be careful that they
remain correctly located when the outer or
cushion gasket and cover plate are placed in posi­
tion. Put all the clamps, washers, and nuts
loosely on the studs. Finger tighten all of the nuts
first. Then starting from the center pair of nuts,
tighten in alternate pairs towards either end.
Tighten each nut about one sixth revolution at a
time. Go over the nuts enough times to draw them
all up to 35 to 40 fopi pounds of torque.
After mounting the insert in the valves, open the
blowdown valve and slowly bring the glass up to
operating temperature by cracking the steam
valve slightly to allow a small amount of steam
to heat the insert. When thoroughly heated, close
the blowdown valve and open both steam and
water valves.
Figures and gauge replacement information cour­
tesy of the Clark Reliance Corporation.
E. SAFETY VALVES
The safety valve is a very important safety device
on the boiler and deserves attention accordingly.
3-5
Chapter 3 - Maintenance

PLUGGED TAPPINGS FOR

COMMON OPTIONAL EQUIPMENT
LOW WATER HIGH WATER ALARM
FUEL CUTOFF 8-32
NUTS
LOW WATER LOW WATER
ALARM FUEL CUTOFF 873-96
ELECTRODE FITTING

13/16" UPPER HEX

TOP HEAD OF WATER

COLUMN BODY

3/B" LOWER HEX

1/4" - 20 NUT

1/4" DIA. ELECTRODE

Distance
Elec Wire Electrode Top of Plate to
Function Length P/N
No. Term. Tip of Electrode
1 A Low Water Fuel Cut-off 118-3/8" 67-243 20"
2 E Low Water Alarm 115-5/8" 67-242 17-1/4"
3 D High Water Alarm 5-3/8" 1 67-241 7-1/4"
4 B Low Water Fuel Cut-off 118-3/8” 1 67-243 20"
C C Common 18-3/8" 67-243 20"

FIGURE 3-1 STANDARD WATER COLUMN ASSEMBLY

TUBULAR MALLEABLE IRON

GLASS CLAMPS MALLEABLE IRON
COVER PLATE
GLASS
PACKING GLASS
WASHER PACKING NUT

PRISMATIC MACHINE
GLASS GLASS BOLTS
PACKING
GASKETS

VALVE
BODY
SEMI-STEEL BODY
CROSS SECTION
BEFORE TIGHTENING
FIGURE 3-2 FIGURE 3-3
TUBULAR GAGE GLASS PRISMATIC GAGE INSERTS

3-6

The purpose of the valve(s) is to prevent pressure
build up over the design pressure of the pressure
vessel. The size, rating and number of valves on a
boiler is determined by the ASME Boiler Code.
The installation of a valve is of primary import­
ance to its service life. A valve must be mounted
in a Vertical position so that discharge piping and
Code required drains can be properly piped to
prevent build up of back pressure and accumu­
lation of foreign material around the valve seat
area. Apply only a moderate amount of pipe com­
pound to male threads and avoid overtightening
as this can distort the seats. Use only flat jawed
wrenches on the flats provided. When installing a
flange connected valve, use a new gasket and
draw the mounting bolts down evenly.
A drip pan elbow or a flexible connection be­
tween the valve and the escape pipe is re­
commended. See Figure 3-4. The discharge piping
must be properly arranged and supported so that
its weight does not bear upon the valve.
SEE NOTES
U S
RIGIDLY
SUPPORTED
DISCHARGE
PIPE
AS POSSIBLE
NOTES: . IDLE BOILERS
1. DIMENSION BETWEEN VALVE AND DRIP PAN ELBOW SHOULD BE
AS SHORT AS POSSIBLE.
2. DISCHARGE PIPING MUST BE INDEPENDENTLY SUPPORTED SO
THAT NO STRAIN IS PLACED ON VALVE BODY.
3. ALL DRAIN LINES SHOULD BE INDEPENDENTLY SUPPORTED AND
PROPER EXPANSION PROVISIONS MADE TO ELIMINATE ALL
STRAIN ON VALVE BODY.
H. ALLOW SPACE TO COMPENSATE FOR UPWARD' EXPANSION OF
BOILER WHEN HOT.
5. PROVIDE 3 OR H EQUALLY SPACED SPACERS TO CENTER
DISCHARGE PIPE. MUST BE FREE, TO ALLOW FOR EXPANSION.
FIGURE 3-4 STEAM SAFETY VALVE
Do not paint, oil, or otherwise cover any interior
or working parts of the safety valve. A valve does
not require any lubrication or protective coating
to work properly.
Chapter 3 - Maintenance
Follow the recommendations of your Boiler^ In­
spector pertaining to valve inspection and testing.
The frequency of testing, either by the use of the
lifting lever or by raising the steam pressure,
should be based on the recommendation of your
Boiler Inspector, and/or the valve manufacturer,
and in accordance with section VII of the ASME
Boiler and Pressure Vessel Code.
Avoid excessive operation of the safety valve as
even one opening can provide a means of leakage.
Safety valves should be operated only often
enough to assure that they are in good working
order. When a pop test is required, raise the oper­
ating pressure to the set pressure of the safety
valve, allowing it to open and reseat as it would
in normal service.
Do not hand operate the valve with less than
75% of the stamped set pressure exerted on the
underside of the disc. When hand operating, be
sure and hold the valve in an open position long
enough to purge accumulated foreign material
from the seat area and then allow the valve to
snap shut.
Frequent usage of the safety valve will cause the
seat and disc to become wire drawn or steam cut.
This will cause the valve to leak and necessitate
down time of the boiler for valve repair or re­
placement. Repair of a valve must be done only
by the manufacturer or his authorized repre­
sentative.
Avoid having the operating pressure too near the
safety valve set pressure. A 10% differential is re­
commended. An even greater differential is desir­
able and will assure better seat tightness and
valve longevity.
Steam is expensive to generate and, for the sake
of economy, wastage should be avoided whenever
possible.
F. CARE AND PROTECTION OF
Many boilers used for heating or seasonal loads,
or for standby service, may have extended periods
of non-use. Special attention must be given to
these, so that neither water side nor fire side sur­
faces are allowed to deteriorate from corrosion.
Corrosion can be more serious during this down
time than when the boiler is actually in service.
Too many conditions exist to lay down definite
rules. There are two methods of storage - wet or
dry. Your water consultant or feedwater treating
company can recommend the better method, de­
pending upon circumstances in-a particular in­
stallation. Section VII of the ASME Code also
contains information relating to laying up a
boiler.
3-7
Chapter 3 - Maintenance
When shutting down, the pressure should be
reduced gradually, and the pressure vessel cooled
at a rate that avoids damaging temperature dif­
ferential that can cause harmful stresses. A vessel
should not normally be drained until all pressure
is relieved - again to prevent uneven contraction
and temperature differentials. Draining the unit
too quickly may cause the baking of deposits that
may be present on the heating surfaces. Some
heat, however, may be desirable to dry out the in­
terior of the boiler.
After proper cooling and draining, flusli out the
water side with a high pressure water hose. Re­
move any scale or deposits from the water side
surfaces and check for internal or external corro­
sion and leakage.
DRY STORAGE
Dry storage is generally employed when the boiler
will be out of service for some time or when freez­
ing temperatures may occur. In this method, the
boiler must be thoroughly dried, since any
moisture will cause corrosion. Both water side and
fire side surfaces must be clean of all scale and
deposits, soot, etc. Steps must be taken to elimi­
nate moisture by placing moisture absorbing
material, such as quick-lime or silica-gel, on trays
inside the drums and furnace. These trays should
not be completely filled with the material, so that
the corrosive liquid gathered in them does not
overflow onto the boiler surfaces. Refractories
should be brushed clean and wash-coated. Fire
side surfaces may be sprayed or coated with an
anti-corrosive material. All openings to pressure
vessel must be shut tightly. Feedwater and steam
valves should be closed. Damper and vents should
be closed to prevent air from reaching fire side sur­
face. Periodic inspection must be made and the ab­
sorption materials renewed.
Care must be taken to remove all of the moisture
absorbing material before any attempt is made to
refill the boiler. Serious damage can result other­
wise. As a precaution it is recommended that
warning signs be conspicuously posted. These
signs could be similar to the following;
3-8
IMPORTANT - MOISTURE ABSORP­
TION MATERIAL HAS BEEN PLACED
IN THE WATERSIDE AND FURNACE
AREAS OF THIS BOILER. THIS MA­
TERIAL MUST BE REMOVED BEFORE
ANY WATER IS PLACED IN BOILER
AND BEFORE BURNER IS FIRED.
INSPECT PERIODICALLY AND RE­
PLACE WITH FRESH AND/OR REGENE­
RATED MATERIALS.
WET STORAGE
Wet storage is generally used for a boiler held in
standby condition or in a case where dry storage
is not practical. The possibility of freezing tem­
peratures must be considered. Care must be taken
to protect metal surfaces. Variables preclude defi­
nite recommendations, however, it is suggested
that after the vessel is drained and cleaned that it
be refilled to overflowing with treated water. If
deaerated water is not available, the boiler
should be fired to boil the water for a short
period of time. Additional chemicals may be
suggested by the water consultant to minimize
corrosion. Internal water pressure should be
maintained at greater than atmospheric pressure.
Nitrogen is often used for this purpose. Fire side
surfaces must be thoroughly cleaned and re­
fractories should be wash-coated. It is advis­
able, if feasible, to occasionally circulate the
water to prevent stratification and to insure that
fresh inhibitor is in contact with all the surfaces.
If additional chemicals are added for this idle
period, more frequent blowdowns may be re­
quired when the boiler is returned to service to
rapidly reduce the chemical composition to nor­
mal operating levels.
During storage, steps should be taken to protect
the exterior components from the possibility of
rust or corrosion. These parts should be coated
with a rust inhibitor arid protected from moisture
and condensation. Operating controls, regulators,
valves, etc. should be drained and dried. Electri­
cal equipment should likewise be protected.
Keeping the control circuit energized may prevent
condensation from forming in the control cabinet
or on the flame safeguard control. ,
 CHAPTER 4

PARTS ORDERING INSTRUCTIONS A N D PARTS LIST

F U R N IS H C O M P L E T E IN F O R M A T IO N W H E N
O R D E R IN G P A R T S — W hen ordering p a rts for
your boiler, be sure to include on your order the
boiler serial num ber shown on the nam e plate a t­
tach ed to th e front head. Y our order should state the
C leaver-B rooks p a rt num ber and the nam e and
description of the p a rt required. S ta te the quantity
desired, an d specify m ethod of shipm ent. Indicate
d ate m a te ria l is required. If rep air p arts are required
for accessory equipm ent, such as an electric m otor,
pum p, etc., w hich m ay not be shown, be sure to give
th e com plete nam e plate d a ta from the item for
which th e p a rts are required.
W H E R E TO O R D E R PA R TS — R epair or replace­
m ent p a rts should be ordered from your Cleaver-
Brooks representative.
R E T U R N IN G P A R T S FO R R E P A IR — P a rts to be
rep aired should be directed to your C leaver-B rooks
representative. A purchase order or a letter au th o riz­
ing repairs and giving com plete details should be
m ailed to your representative. P rior to returning,
please rem ove fittings or accessories from th e com ­
ponent, properly d ra in and clean p a rt to com ply w ith
shipping regulations and include inside of the
package a packing slip identifying the p a rt w ith your
com pany’s nam e.
If you desire to re tu rn p arts for reasons other th a n
repair or exchange, please contact your rep resen ta­
tive stating reasons for the re tu rn and aw ait perm is­
sion and directions prior to retu rn in g th e m aterial.
M any controls and other com ponents can be factory-
reb u ilt (F R ) or have a trade-in value. T hese item s
are available on an exchange basis. C onsult your
C leavef-B rooks representative.
Be sure to show the serial num ber of your u n it on all
p a rts orders and correspondence.

CteavevfjrBrooks’
WATERTUBE BOILER
MODEL PRESSURE PSI

UNIT NO DATE
HEATING SURFACE
UNIT NO. BOILER SQ. FT. WATERWALL SQ. FT.
C LEAVER -BRO O KS DIVISION
AQ UA-CHEM , INC.
M ILW AUKEE. W ISCONSIN U.S.A.

IT IS RECOMMENDED THAT YOUR LOCAL CLEAVER-BROOKS

REPRESENTATIVE BE CONTACTED FOR PROMPT SUPPLY OF
REPLACEMENT PARTS.
CLEAVER-BROOKS

4-1
Chapter 4—Parts List

PARTS LIST
Part No. Req. Description

853-798 4 Gasket, Manway, 12” x 16”

851-213 1 Gage Glass, 3/4” x 18-1/4”
853-711 2 Gasket, 3/4” , Gage Glass •
873-96 5 Fitting, Water Column Electrode
943-259 1 Wrench, Water Column Electrode
67-241 1 Electrode, Water Column, 1/4” x 5-5/8”
67-242 1 Electrode, Water Column, 1/4” x 15-5/8” ’
67-243 3 Electrode, Water Column, 1/4” x 18-3/8” ’
67-201 1 Electrode, Water Column, 1/4” x 6-1/8”
67-247 1 Electrode, Water Column, 1/4” x 13-1/8”
825-142 1 Valve Set, Gage Glass
825-140 3 Trycock
880-100 2 Lens Kit, Blue - Observation Port
880-104 2 Lens Kit, Clear - Observation Port
880-106 2 Nut, Bakelite - Observation Port

NOTE: The above are standard replacement parts.

Refer to the Burner Manual for additional parts.

MODEL “A” BURNER Part No. 750-311

MODEL “BR” BURNER Part No. 750-305
MODEL “CN” BURNER Part No. 750-308

4-2
 B U L L E T IN : 41-610.6
E F F E C T IV E : March 1979
S U P E R S E D E S : February 1978

INSTRUCTION M ANUAL AND PARTS LIST

FOR FLANGED FLOAT CAGE MODEL
LIQ U ID LEVEL CONTROLS

DESCRIPTION OPERATING CYCLE

The flanged float cage series level controls are completely
self-contained units designed for side mounting to a vessel
or boiler with threaded or flanged pipe connections. Thir­
teen basic models are included in this series, each with a
wide range of optional features. Special models include
units constructed entirely of stainless steel (not covered
in this manual) and tandem type units with two switch
mechanisms, each operated by a separate float in a special
length float chamber.
OPERATING PRINCIPLE
Diagrams A and B illustrate the simple and foolproof
Magnetrol®operating principle. Switching action is obtained
through the use of a magnetic attracting sleeve, actuated
by a float, and a switching mechanism. These two basic
component assemblies are separated by a non-magnetic,
pressure tight enclosing tube. A switch and magnet are
assembled to a swinging arm which operates on precision
stainless steel pivot sockets.
A t "Normal Operating Level" of liquid in the chamber
(diagram "A "), the float moves the magnetic attracting
sleeve upward in the enclosing tube and into the field of the
switch mechanism magnet. As a result, the magnet is drawn
in tightly to the enclosing tube causing the switch to tilt,
"making" or "breaking" an electrical circuit. As liquid level
recedes, the float pulls the magnetic attracting sleeve down
ward until, at a pre-determined "Low Level" (diagram "B")
the switch magnet releases and is drawn outward away
from the enclosing tube by a tension spring. This in turn
tilts the switch in an opposite direction, thus reversing
switch action.
When liquid level returns to normal, the float once again
moves the magnetic attracting sleeve up the enclosing tube
causing the switch to assume its original position.
REFERENCE
B U LLETIN 41-610.6
ECN • 3032-208

CB9-48 2/83 MAGNGTROL

INTERNATIONAL, INCORPORATED
 IN S T A L L A T IO N

TYPICAL PIPING ARRANGEMENT

PIPING
Figure 2 shows a typical piping installation of a Magnetrol
flanged float cage control to a vessel or boiler. Reference
mark on float chamber should be aligned to correspond
with liquid level in vessel or boiler at which switch control
is desired (refer to dimensional drawing, if furnished).
On boiler installations, line indicated would be the low
water cut-off level.
NOTE: Refer to boiler manufacturer's specifications re­
garding control levels for piping alignment requirements.
Use pipe of sufficient strength to support the control.
If necessary, provide a stand or hanger to help support its
weight. All piping should be straight and free of "low spots"
or "pockets" so that lower liquid line will drain towards the
vessel or boiler and upper vapor line will drain toward the
control. Shut-off valves are recommended for installation
between vessel or boiler and the float chamber of the
control. If the control is to be used with a low temperature
liquid (one which will "boil" in the float chamber if outside
heat is absorbed), the chamber and piping should be in­
sulated. Such boiling in the chamber will cause false level
indications. Do NOT insulate chamber if control is to be
used with a high temperature liquid. Switch housing should
never be insulated on any application.
If the liquid to be controlled has a tendency to leave
deposits in the piping, right angle turns should be made
with cross type fittings equipped with plugs in unused
openings. Removal of plugs will permit pipe line to be
"rodded" clean. Blow-down connection on boiler instal­
lations should be piped in such a manner that the operator
will not scald himself when blowing down control.
RECOMMENDED IN S TA LLA TIO N
The lowest visible part of the water-gage glass should be
at least 2.00 inches above the lowest permissible water
level, which level should be that at which there will be no
danger of overheating any part of the boiler when in oper­
ation at that level.
Boilers of the horizontal fire-tube type should be so set that
when the water is at the lowest reading in the water-gage
glass there should be at least 3.00 inches of water over the
highest point of the tubes, flues, or crown sheet.
— continued

2 © M A G N E T R O L IN T E R N A T IO N A L 1975
 IN S T A L L A T I O N -c o n t in u e d

HUT-OFF VALVES (IF USED) 1 NOTE: See one of the followin9 bulletins furnished with
I your control for proper connections.

When shut-offs are used in the pipe connections between SW IT C H M E C H A N IS M Ref.

B U L L E T IN
a boiler and a water column or between a boiler and the (Model Suffix Number) Type
shut-off valves required for the gage glass they should 42-608 S-1
S-1 & DPS-1 Mercury Switches
be either outside-screw-and-yoke or level-lifting type gate
valves or stopcocks with levers permanently fastened J-1 Bleed Type Pneumatic Valve 42-617 J-1

thereto and marked in line with their passage, or of such J-2 Non-Bleed Type Pneumatic Valve 42-621 J-2
other through-flow construction as to prevent stoppage by
S-1 M & DPS-1 M Dry Contact Switches 42-657 S-1
deposits of sediment, and to indicate by the position of the
operating mechanism whether they are in open or closed M-1 & M-4 Anti-Vibration Dry Contact Switches 42-670 M-1
position,' and such valves or cocks should be locked or SPS-1 & SPDPS-1 Anti-Vibration Mercury Switches 42-675 S-1
sealed open. Where stop-cocks are used they should be of a
S-1 & DPS-1 High Temperature Mercury Switches 42-676 S-1
type with the plug held in place by a guard or gland.
SPS-1 & SPDPS-1 Hi-Temp, Anti-Vibration Mercury 42-677 S-1

S-1M & D PS-1M Hi-Temp, Dry Contact Switches 42-678 S-1

NOTE: On controls equipped with pneumatic switching
assemblies, consult installation bulletin on mechanism
furnished for air (or gas) piping instructions.
MOUNTING
Controls used on boiler applications should be mounted as
close to the boiler as possible. This will result in a more
responsive and accurate level change in the control. Water
in a long line will be cooler and more dense than the boiler
water causing lower level indication in the control than
actual level in the boiler.
Adjust piping as required to bring control to a vertical
position. Magnetrol controls must be mounted within three
(3°) degrees of vertical. A three degree slant is noticeable
by eye., but installation should be checked with a spirit level
on top or sides of float chamber.
3. Connect power supply to control and test switch action
by varying liquid level in float chamber. If switch
mechanism fails to function, check vertical alignment
of control and consult instruction bulletin on mechanism
furnished.
4. Replace switch housing cover and place control into
service.
NOTE: If control has been furnished with an explosion
proof (cast) or moisture proof (gasketed) switch housing,
check the following:
— After wiring connections have been completed, housings
must be sealed at the conduit outlet with a suitable
compound or "dope" to prevent entrance of air.
— Check cover to base fit to be certain gasketed joint is
tight. A positive seal is necessary to prevent infiltration
of moisture laden air or corrosive gases into switch
housing.

WIRING
Most all Magnetrol control switch housings are designed
to allow 360° positioning of the conduit outlet by loosening
the set screw(s) located under the housing base. Diagrams
of the control's internal electrical circuits (switching action
between terminals) will be found in the switch mechanism
instruction bulletin provided (see listing that follows).
On high temperature applications (above 2 5 0 ° F. in float
chamber), asbestos covered wire should be used between
control and first junction box located in a cooler area. On
non-hazardous applications, flexible conduit may be used
between control and first junction box. Conduit should
have sufficient slack to permit removal of control top
flange for cleaning and inspection.

1. To gain access to switch mechanism(s), remove switch

housing cover.
2. Pull in supply wires (conductors), wrap them around
enclosing tube under the baffle plate and connect to
proper terminals. Be certain that excess wire does not
interfere with "tilt" of switch and that adequate clear­
ance exists for replacement of switch housing cover.
3
 — P R E V E N T IV E
Periodic inspections are a necessary means to keep your Magnetrol level control in good w orking order. T h is control is, in
reality, a safety device to protect the valuable equipment it serves. Should the control fail, the resultant damage to equipment
dependent upon its performance could very well cost far in excess of the control itself. Therefore, a systematic program of
"Preventive Maintenance" should be implemented when control is placed into service. If the following sections on_"W hat to D o "
and "W hat to A v o id " are observed, your control will provide reliable protection of your capital equipment.
WHAT TO DO
1. KEEP CONTROL CLEAN
— N EVER leave switch housing cover off the control.
This cover is designed to keep dust and dirt from inter­
fering with switch mechanism operation. In addition,
it protects against damaging moisture and acts as a
safety feature by keeping bare wires and terminals from
being exposed. Should the housing cover become dam­
aged or misplaced, order a replacement immediately.
2. INSPECT SWITCH MECHANISMS, TER M IN A LS
AND CONNECTIONS M O N TH LY
— Mercury switches may be visually inspected for short
circuit damage. Check for small cracks in the glass tube
containing the mercury. Such cracks can allow entrance
of air into the tube causing the mercury to "oxidize".
This is noticeable as the mercury will appear dirty and
have a tendency to "string out" like water, instead of
breaking into clean round pools. If these conditions
exist, replace the mercury switch immediately.
— Dry contact switches should be inspected for exces­
sive wear on actuating lever or misalignment of adjust­
ment screw at point of contact between screw and lever.
Such conditions can cause false switch actuating levels.
Adjust switch mechanism to compensate (if possible)
or replace switch.
DO N O T operate your control with defective or malad­
justed switch mechanisms (refer to bulletin on switch
mechanism furnished for service instructions).
— Magnetrol controls may sometimes be exposed to ex­
cessive heat or moisture. Under such conditions, insulation
— TR O U B LE
Usually the first indication of improper operation is failure
of the controlled equipment to function — pump will not
start (or stop), signal lamps fail to light, etc. When these
symptoms occur, whether at time of installation or during
routine service thereafter, check the following potential
external causes first.
— Fuses may be blown.
— Reset button(s) may need resetting.
— Power switch may be open.
— Controlled equipment may be faulty.
— Wiring (or medium lines) leading to control may be
defective.
4
M A IN T E N A N C E
on electrical wires may become brittle, eventually breaking
or peeling away. The resulting "bare" wires can cause short
circuits. Check wiring carefully and replace at first sign of
brittle insulation.
— Vibration may sometimes cause terminal screws to work
loose. Check all terminal connections to be certain that
screws are tight. Air (or gas) operating medium lines, sub­
jected to vibration, may eventually crack or become loose
at connections causing leakage. Check lines and connections
carefully and repair or replace, if necessary.
WHAT TO A V O ID
1. NEVER leave switch housing cover off the control
longer than necessary to make routine inspections.
2. NEVER use lubricants on pivots of switch mechanisms.
A sufficient amount of lubricant has been applied at the
factory to insure a lifetime of service. Further oiling
is unnecessary and will only tend to attract dust and dirt
which can interfere with mechanism's operation.
3. NEVER place a jumper wire across terminals to "cut­
out" the control. If a "jumper" is necessary for test
purposes, be certain it is removed before placing con­
trol into service.
4. NEVER attempt to make adjustments or replace switches
without reading instructions carefully. Certain adjust­
ments provided for in Magnetrol controls should not be
attempted in the field. When in doubt, consult the
factory or your local Magnetrol representative.
S H O O T IN G —
If a thorough inspection of these possible conditions fails
to locate the trouble, proceed next to a check of the
control's switch mechanism(s).
1. Pull disconnect switch or otherwise assure that electrical
circuit(s) through the control is deactivated.
2. Remove switch housing cover.
3. Swing magnet assembly in and out by hand, checking
carefully for any sign of binding. Assembly should
require no force, however slight, to move it through
its full swing.
 TR O U B LE S H O O T IN G - continued

4. If binding exists, magnet may be rubbing enclosing tube NOTE: Control chamber, connections and pipe lines need
or pivot sockets may be overly tight. Readjust pivot not be removed from vessel or boiler.
sockets as required until a slight amount of side play is C. Remove switch housing assembly by loosening hex
evident. If magnet is rubbing, loosen magnet clamp nut located immediately below housing base.
screw and shift magnet position.
4. With switch housing assembly removed, inspect attrac­
5. If switch magnet assembly swings freely and mechanism
tion sleeve(s) and inside of enclosing tube for excessive
still fails to actuate, check.installation of control to be
corrosion or solids build-up which could restrict move­
certain it is within the specified three (3°) degrees of
ment, preventing sleeve(s) from reaching field of switch
vertical (use spirit level on side of enclosing tube in two
magnet(s).
places, 9 0 ° apart).
5. If the differential adjustment has been changed in the
6. If mechanism is equipped with a mercury switch, exa­
field by repositioning the lower jam nuts on the float
mine glass tube closely, as previously described in Pre­
stem, check for tightness and position of the jam nuts.
ventive Maintenance section. If switch is damaged, re­
place it immediately. NOTE: Differential adjustment affects a change in the
amount of level travel between "switch on" and "switch
NOTE: As a matter of good practice, spare switches should
off" actuations. Do NOT attempt adjustment without first
be kept on hand at all times.
consulting factory for assistance in computing level differ­
ential change for your control.
If switch mechanism(s) is operating satisfactorily, a test of
the complete control's performance is the next likely step. 6. Check float(s) to be certain it is bouyant in the liquid
(float chamber or vessel must have adequate liquid level).
1. Reconnect power supply and carefully actuate switch
If float is determined to be filled with liquid or collapsed,
mechanism(s) manually (using a non-conductive tool on
it must be replaced immediately. Do NOT attempt to
electrical switch mechanisms) to determine whether con­
repair a float. (See float replacement instructions on
trolled equipment will operate.
page 7.)

C A U T IO N : With electrical pow er " o n ", care should be If all the components in the control are in operating con­
taken to avoid contact w ith switch leads and connections dition, the trouble must be (and should be) located external
a t term inal block. to the control. Repeat inspection of external conditions
previously described.
2. If controlled equipment responds to manual actuation
NOTE: When in doubt about the condition or performance
test, trouble may be located in level sensing portion of
of a Magnetrol control, return it to the factory. See "Our
the control ffloat(s), stem(s) and magnetic attraction
Service Policy" on back page.
sleeve(s)].
NOTE: Check first to be certain liquid is entering float
chamber. A valve may be closed or pipe line plugged.

3. With liquid in float chamber, proceed to check level
sensing action by removing switch housing assembly.
C A U T IO N : Be certain to p u ll disconnect switch or
otherwise assure that electrical circuit(s) through co n tro l
is deactivated. Close operating medium supply valve on
controls equipped with pneum atic switch mechanisms.
A. Disconnect wiring from supply side of switch mech-
anism(s) and remove electrical conduit or operating
medium line connections to switch housing.
The instructions contained in this bulletin are general
and can be applied to most any Magnetrol flanged
float cage level control. If difficulties are encountered
which can not be identified, consult with the factory
or your local representative for assistance. A complete
description of the trouble should be provided along
with information concerning you rpiping and mounting
arrangement, and a description of you r operation se­
quence. Sketches or photographs showing the instal­
lation are also beneficial.
When communicating about your control, be cer­
tain always to specify the complete Model and
Serial numbers.

B. Perform system shut-down as required to relieve pres­

sure from float chamber of control and allow unit
to cool.
- Close shut-off valves (if so equipped) to isolate
control from vessel. Drain off liquid in chamber,
if required.
— On boiler applications or installations without shut­
off valves, relieve pressure from vessel or boiler
and drain off liquid "head” above control moun­
ting level.
 S T A N D A R D ® D I F F E R E N T IA L A D J U S T M E N T
The amount of level travel between "switch-on" and
"switch-off" actuations (differential) may be field adjusted
by repositioning the lower jam nuts on the float stem.
The standard factory setting is for a minimum amount of
play (gap) between the top jam nuts and the attraction
sleeve, as shown in diagram " A " above. This settina mav
be increased to a maximum of 0.50" as shown in diagram "B".
' NOTE: For assistance in computing level differential change
for a specific control, consult the factory giving Model and
Serial number of the control.
With level change specifications determined, proceed as
follows:
C A U T IO N : Before attem pting any work on the control,
be certain to p u ll disconnect switch o r otherwise assure
that electrical circuit(s) through co n tro l is deactivated.
Close o p e r a tin g medium supply valve on controls
equipped w ith pneum atic switch mechanisms.
1. Disconnect wiring from supply side of switch mech-
anism(s) and electrical conduit or operating medium
line connections to switch housing.
2. Perform system shut-down as required to relieve pressure
from float chamber of control and allow unit to cool.
6
NOTE: Control chamber, connections or pipe lines need
not be removed from vessel or boiler.
3. Remove switch housing assembly by loosening hex nut
located immediately below housing base (see figure 5).
4. With switch housing removed, jam nuts and attraction
sleeve are accessible. Measure position of upper jam nuts
from stem end, then loosen and remove upper jam nuts,
guidewasher and attraction sleeve.
5. Loosen and adjust lower jam nuts to desired position.
Make certain jam nuts are retightened securely.
6. Reassemble control in reverse of steps 1 thru 4 making
certain upper jam nuts are locked in original position.
NOTE: Use new gasket in assembly of switch housing to
chamber.
7. Test switch actuation by varying liquid level in float
' chamber.
© Instructions given are for standard Magnetrol controls o n l y -
not for models specifically tailored to special customer speci­
fications.
REPLACEMENT OF STANDARD®FLOAT AND STEM ASSEM BLY
(FOR REF. TYPE S-1 AND J-1 MODELS ONLY)

1. Disconnect wiring or medium lines from control and

perform system shut-down as described previously in
trouble shooting and differential adjustment instructions.

2. Remove switch housing assembly from float chamber

at head flange (not at enclosing tube hex nut as noted
in the previous instructions).

3. Remove sleeve stop strap from the underside of the head

flange and slide the float stem assembly out of the
enclosing tube.

NOTE: New float and stem assembly is supplied with

attraction sleeve components factory assembled and ad­
justed for your particular control model.

4. Check new float and stem assembly to be certain it is

the correct replacement unit:
A. Float should be of same physical size and shape.
B. Stem length should match closely.
C. Measure dimension "A " and compare on reference
chart below.

NOTE: If differential adjustment has been altered in the

field, disregard dimension "A " and re-adjust new assembly
to the previously determined level differential setting per
instructions on page 6.

5. Replace new float and stem assembly into head flange

and install new stop strap with screws included.

6. Remount head flange on float chamber using new gasket

provided. Tighten flange nuts evenly, using an alternating
pattern, typical of standard industry practice.

NOTE: Care must be taken during installation to be certain

float stem does not get bent.

7. With control assembled in place, test switch actuation

by varying liquid level in float chamber.

STANDARD LOWER JAM N UT SETTINGS

MODEL DIMENSION "A "

249 .38”
251 .48”
291 .50”
D-301 .48”
303 .50”
CO
00

601
I
• W-251 • .56”
o Instructions given are for standard Magnetrol controls only —
not for models specifically tailored to special customer speci­ W-254 .62"
fications.
W-291 .56"
W-601 .48"

7
 R E P L A C E M E N T P A R TS

IM PORTANT: Many control models are

specially tailored to meet specific cus­
tomer specifications and therefore may
contain special parts. When ordering re­
placement parts, always give Serial Num­
TYPICA L .~ 9 ber of Control. ^ t y p ic a l
MODEL MODEL
249 291
& D-301

SER IA L NUMBER TAG (Ref.)

TYPICAL
MODEL
251

TYPICA L
MODEL 303
& 601

TYPICA L
MODEL
W-251
& W-254
N O T E : Models W-291 & W-601 (not shown) are
typical of models W*251 & W -254 except for fabri­
cated float cage construction.

CAST IRON FABRICATED STEEL

FLOAT CAGE MODELS FLOAT CAGE MODELS
FIG. 5
8
 R E P L A C E M E N T P A R T S - continued
S T A N D A R D R E P L A C E M E N T A S S E M B L Y K IT S ©
u
M O DEL
D E S C R IP T IO N W-254 W-291 W-601
249 251 291 D-301 J-303 L-303 M -303 B-601 C-601 W-251
© © © ©
©
Housing Cover S E E B U L L E T IN 42-680 F O R R E F . T Y P E S-1 SW IT C H H O U S IN G R E P L A C E M E N T A S S E M B L IE S .
Housing
Kits C O N S U L T L O C A L R E P R E S E N T A T IV E O N T Y P E J-1, J-2 & M-1 H O U S IN G S .
Housing Base<«.'

Switch Mechanism S E E B U L L E T IN O N SW IT C H M E C H A N IS M F U R N IS H E D (Listed on page 3)

SO­ 89­
4 Enclosing Tube Enclosing 89­
S 0 15- 89-5909-001 89-5933-004 89-5909-001 5933­
Tube 5 9 08­ 89-5909-001
004
5 E-Tube Gasket Kits 001 001

5 E-Tube Gasket

iI 6' Head Flange

Head 89­ 89­ 89­ 89­ 89­ 89­
4206­
4203­ 4204­ 89-4205-001 89-4206-001 89-4207-001 4203
I 7 Studs / Bolts Flange 4201­ 4202-.
001 ’ 001 001
Kits 001 001 001
Hex Nuts

Flange Gasket

Studs / Bolts

Hex Nuts 89­ 89­ 89­ 89­ 89­ 89­

Float 89­ 89­
4604­ 89-4605-001 89-4606-001 4607­ 4608­ 4 6 09­ 4610­
Chamber 4601­ 4602­ 4603­
Flange Gasket 001 001 001 001
Kits 001 001 001 001
Float Chamber

24 9-BW 25 1 -BW
u Flange Gasket
89­ 89­
11 Stop Strap 3 244- 3 2 4 5 ­
D01 001 89­ 89­ 89­ 89­ 89­ 89­ 89­ 89­ 89' 89­ 89­
3 2 11­ 3212' 3 2 13­
12 Screws © © 3203­ 3 2 04­ 3 2 05­ 3206­ 3207 3208­ 3209­ 3210­
001 001 001 001 001 001 001 001 001 001 001
Float
13 Float & Stem A ss’y
& 25 1 -C
Stem 249-C
14 Jam Nuts 89­
Kits 89­
3202­
15 Guide Washer 3201­
001
001
16 Attraction Sleeve

- N O T R E Q U IR E D -
17 Stop Tube (if used)

89­ 89­ 89­

9 Flange Gasket 89­ NOT
N O T R E Q U IR E D - 4403­ 4404­
4401­ 4402­ R E Q U IR E D
Chamber Liner © 001 001
18 001 001

89­ 89­ 89­

5 E-Tube Gasket 89­
Gasket 3603­ 89-3604-001 89-3605-001 89-3601-001 3 6 02­ 3605­
89-3601-001 3602­
Flange Gasket Kits 001 001
S 001 001

NOTE:
0 All replacement assemblies listed are furnished in kit © S e e page 10 & 11 for standard tandem model replace­
form for standard base models which use ref. type S-1 ment parts.
switch mechanisms only. Consult local representative for
ordering assistance on all special model replacement parts
or accessories not included in above listing. IM PORTANT:
, | 0 Cast float cage models used on boiler service require When ordering, please specify:
brass chamber liner. See bulletin 43-618 for replacement
A. Model and Serial number of control.
instructions.
B. Replacement assembly (kit) part number.
0 Model D-301 is unit specially designed for Dowtherm
"A " service only.
9
 TA N D EM FLO A T M ODELS

DESCRIPTION
Models with tandem style floats are used on applications
where widely spaced high and low switching functions can
be accomplished with a single control. The units incor­
porate two floats which operate independently and are
arranged so that the lower float actuates the upper switch
mechanism and the upper float actuates the lower switch
mechanism. The upper float is attached to the lower attrac­
tion sleeve by means of a hollow stem. The lower float
attaches to the upper attraction sleeve with a solid stem
which extends upward through the upper float and stem
assembly.

INSTALLATIO N, PREVENTIVE M A IN TE­

NANCE AND TROUBLE SHOOTING
Installation and Maintenance of tandem float models is
accomplished in much the same manner as previously
described for standard models. Some additional consider­
ation must be given to the piping arrangement to allow
for alignment of the two switch actuating level marks on
the float chamber with the desired levels in the vessel or
boiler. When trouble-shooting the level sensing portion of
the control, additional checks may be made of the following:
1. Inspect for binding of solid (lower) float stem within
hollow (upper) float stem due to corrosion or possible
damage incurred during shipment or previous main­
tenance.
2. Make certain that retaining "snap" rings, used to locate
lower attraction sleeve, are locked in place. An extreme
shock or hammer, such as during blow-down on a water
column boiler control, may have damaged a ring causing
it to snap out of its retaining groove in the hollow
(upper) float stem.

D IFFE R E N TIA L ADJUSTMENT_______________

C A U TIO N : No d iffe re n tia l adjustment should be made
on tandem flo a t models in the field. Switch actuation
levels have been set a t the factory to m eet specific
customer specifications. Variations in actual conditions
from design conditions usually requires special co n tro l
m odifications. Consult w ith the factory o r local repre­
sentative fo r assistance.

REPLACEMENT OF FLOAT AND STEM

ASSEMBLIES
Should replacement of either upper or lower float and
stem assembly be required, instructions previously given
for standard units (page 7) may be followed with additional
considerations as follows: -
1. New float and stem assemblies are available in separate'
replacement kits, as listed on following page, with at­
traction sleeve parts furnished loose to allow for field
assembly with existing serviceable components.
2. Dimension "A " , referred to in standard instructions,
must be arrived at by direct measurement from old
assembly.
NOTE: Disregard dimension "A " figures shown in chart
on page 7. If in doubt or unable to get an accurate meas­
urement from old assembly, consult with factory or local
representative for assistance.
NOTE: ,
© All replacement assemblies listed are furnished in kit -
3. Lower attraction sleeve locks in place on hollow (upper) form for standard tandem models which use ref. type
float stem with external type snap rings. Care must be S-1 switch mechanisms only. Consult local represen­
taken to be certain rings are properly installed. Use tative for ordering assistance on all special model
correct type external snap ring pliers, if available. replacement parts or accessories not listed above.
10
 TA N D E M FLOAT MODELS -continued
REPLACEMENT PARTS
o
STANDARD REPLACEMENT ASSEMBLY KITS ©
MODEL
D E S C R IP T IO N 291- D-301- J-303- L-303- M-303- B-601- C-601- W-251- W-254- W-291- W-601
E TDM TDM TDM TDM TDM TDM TDM TDM TDM
TDM TDM
M
©

Housing Cover (Tall) S E E B U L L E T IN 42-680 F O R R E F . T Y P E S-1 SW IT C H H O U S IN G R E P L A C E M E N T A S S E M ­

Housing
Kits B L IE S . C O N S U L T L O C A L R E P R E S E N T A T IV E ON T Y P E S J-1, J-2 & M-1 H O U S IN G S .
Housing Base
S E E B U L L E T IN O N SW IT C H M E C H A N IS M S F U R N IS H E D (Listed on page 3)
Switch Mechanisms

Enclosing
89­
Enclosing Tube 5933­
89-5909-001 89-5933-004 89-5909-001
Tube
004
E-Tube Gasket Kits

E-Tube Gasket

Head Flange
89­ 89­
Head 89­ 89­
89-4205-001 89-4206-001 89-4202-001 4203­ 4206­
Studs / Bolts Flange 4203­ 4204­
001 001
Kits 001 001
Hex Nuts

Flanae Gasket

Flange Gasket

10 Stop Strap

Screws Upper
89­ 89­ 89­ 89­ 89­ 89­ 89­ 89­
Float 89­ 89­
Upper Float & Stem Ass'y. 3 2 19­ 3220­ 3221 3222­ 3 2 23­ 3 2 24­ 3225­ 3 2 17­
& 3217­ 3 2 18­
L ,4 001 001 001 001 001 001 001 001 001 001
Stem
13 Lower Attraction Sleeve Kits

14 Spacer Washer ©
Special
15 Retaining Ring Order
Item,
Flange Gasket
See
Jam Nuts Lower Order
16 89­ 89­
Float © LO W ER FLO A T A N D ST EM A SSE M B L Y Note
3 2 14­ 3 2 16
17 Upper Attraction Sleeve & IS S P E C IA L O R D E R IT E M . S E E
001
Below
Stem IM P O R T A N T O R D E R IN G N O T E BELO W . 001
18 Lower Float & Stem Ass'y. Kits

19 Safety Stop Washer

7 Studs / Bolts

© FLO AT CH AM BER A SSEM BLY 89­ 89­ 89­

8 Hex Nuts Float
IS S P E C IA L O R D E R IT E M . S E E 4607­ 4608­ 4 6 09
Chamber
Flange Gasket IM P O R T A N T O R D E R IN G N O T E B ELO W . 001 001 001
Kits

20 Float Chamber

Chamber 89­ 89­

9 Flange Gasket NOT
- N O T R E Q U IR E D - 4403­ 4404
Liner R E Q U IR E D
Chamber Liner © Kits 001 001
21
(Not Shown)_____
89­ 89­ 89­
5 E-Tube Gasket 89­
Gasket 89-3604-001 89-3605-001 89-3601-001 3602­ 3605­
3602­ 3603­
Kits 001 001
9 Flange Gasket 001 001

G “© M o d e l D-301-TDM is unit specially designed for Dow- © IM P O R T A N T :

therm "A " service only. When ordering, please specify:
© C a s t float cage models used on boiler service require A. Model and Serial number of control.
brass chamber liner. See bulletin 43-618 for replacement
B. Replacement assembly (kit) part number.
instructions.
11
 --------------------------5 - f f e a r $ r o i > u c t W a r r a n t ? — :-----------------
A ll equipm ent (except p rin te d c irc u it boards and components thereon) is warranted against defective m aterial or
workmanship fo r a p e rio d o f FIVE YEARS from the date o f shipment thereof, during which period, i f the Purchaser
notifies Magnetrol, the company w ill repair or replace the defective material, o r cause the equipment to be returned
at Purchaser s expense to Magnetrol fa cto ry fo r repair or replacement o f the p a rt o r material and returned to the
Purchaser, transportation collect. There are no other warranties expressed o r im plied, except special w ritte n warranties
covering some Magnetrol products. Magnetrol shall n o t be liable fo r tabor claims, direct o r consequential damage or
expense arising from the installation o r use o f the equipment. Printed circ u it boards carry the above w arranty fo r a
period o f tw o years from the date o f shipment. -

OUR SERVICE POLICY RETURN M A TER IA L PROCEDURE

Owners of Magnetrol controls may-request to return
a control or any part of a control for complete
rebuilding or replacement. They will be rebuilt or
replaced promptly. If, once returned, the under­
lying cause of the trouble is found to be defective
material or workmanship (within the guarantee
period), the item will be either rebuilt, or replaced
completely, without charge on an F.O.B. factory
basis. If the trouble is the result of conditions beyond
our control or is not covered by the guarantee, there
will be a charge for labor and a charge for parts
C.B>j required to rebuild or replace the item.
In some cases it may be expedient to ship new
parts or in extreme cases, a complete new control to
replace the original before it is returned. If this is
desired, inform us as to what parts are needed, the
model number and the serial number of the control
and repair part number. Credit for materials returned
in such cases will be determined on the basis of the
applicability of our guarantee.
No claims for labor or consequential damage will be
allowed.
So that we may efficiently process any materials that
are returned, it is essential that a "Return Material
Authorization" tag be obtained from the factory for
attachment to the goods. This is available through
Magnetrol's local representative or by writing directly
to the factory supplying the following information:
1. Installation Name
2. Description of Material
3. Production Number
4. Serial Number
5. Reason for Return
6. Desired Action
All shipments returned to the factory must be by
Prepaid transportation.
All replacements will be shipped F.O.B. factory.

G
 Type 667 Size 3 0 -7 6 & 87

Fisher Controls Instruction Manual

Type 667 Diaphragm

Actuator Sizes 30-76 and 87

September 1994 Form 1203

Contents

Introduction ................................................... 2
Scope of Manual ..................................... 2
Description.............................................2
Specifications ......................................... 3
Maximum Pressure Limitations ...................... 3

Installation ................................................... 3
Mounting the Actuator on the Valve ................. 4
Bench Set Spring Adjustment ....................... 5
For Direct Acting Valves (PDTC)....................6
For Reverse Acting Valves (PDTO) ................ 6
Installing the Stem Connector Assembly ............ 6
Deadband Measurement ............................ 7
Loading Connection ................................. 8

Maintenance ................................................ 8
Actuator Maintenance ................................ 8
Actuator Disassembly ............................... 9
Actuator Assembly ..................................9 W I916-r

Top-Mounted Handwheel Assembly (Adjustable

Down Travel Stop) ............................ 10
Disassembly for Top-Mounted Handwheel ...... 10
Assembly for Top-Mounted Handwheel .......... 11
Side-Mounted Handwheel Assembly for
Size 34 through 60 Actuators ................. 12
Disassembly for Side-Mounted
Handwheel (34-60) ........................... 12
Assembly for Side-Mounted
Handwheel (34-60).............................. 13
Side-Mounted Handwheel Assembly for
Size 70, 76, and 87 Actuators ................ 13
Disassembly for Side-Mounted
Handwheel (70, 76, & 87) ..................... 13
Assembly for Side-Mounted Handwheel
Figure 1. Type 667 and 667-4 Actuators Mounted
on easy-e® Valve
Parts Kits .................................................. 16
Kits for Side-Mounted Handwheels ................ 16
Kits for Top-Mounted Handwheel.................... 16
Actuator Repair Kits ................................ 16
Parts L is t .................................................... 17
Actuator Assembly...................................17
Top-Mounted Handwheel........................... 23
Side-Mounted Handwheel (30-60) ................. 24
Side-Mounted Handwheel (70, 76, & 87) ......... 29
D 10 03 1 0 X 0 1 2

Handwheel (70, 76, & 87) ..................... 14 Casing Mounted Travel Stops ...................... 29
Casing-Mounted Travel Stops ...................... 15

e a s y -e ® is a m ark owned by Fisher Controls International, Inc.

All other tradem arks are the property of their respective owners.

© Fisher Controls International, Inc. 1980, 1994; All Rights Reserved

 / V

Type 667 Size 30-76 & 87 1------------------ J

Table 1. Specifications
AC TU ATO R SIZE
SP E C IFIC A TIO N !1)
30 34 40 45 46 50 60 700) 76 87(1>
Sq Inch 46 69 69 105 156 105 156 220 156 220
N om inal E ffective A rea
Sq cm 297 445 445 667 1006 677 1006 1419 1006 1419
Inch 2-1/8 2-1/8 2-13/16 2-13/16 2-13/16 3-9/16 3-9/16 3-9/16 3-9/16 5
Yoke Boss D iam eter
mm 54 54 71 71 71 90 90 90 90 125
Inch 3/8 3/8 1/2 1/2 1/2 3/4 3/4 3/4 3/4 1
A cceptable Valve Stem D iam eter
mm 9.5 9.5 12.7 12.7 12.7 19.1 19.1 19.1 19.1 25.4
LB 2300 2300 2700 5650 7550 5650 6800 8800 6800 8800
M axim um A llow able O utput T hrust!4)
N 10,230 10,230 12,010 25,131 33,582 25,131 30,246 39,142 30,246 39,142
Inch 3/4 1-1/8 1-1/2 2 2 2 2 30) 2 3(3)
Standard
mm 19 29 38 51 51 51 51 76(3) 51 76(3)
M axim um Travel!2)
Inch ... 3/4 ... 3/4 ... ... 1-1/8 ... 1-1/8 3
Top-Loaded
mm ... 19 ... 19 --- ... 29 ... 29 76

M axim um D iaphragm Pressure to Psig 55 70 70 65 55 65 55 50 50 50

Stroke A ctuator!4) Bar 3.8 4.8 4.8 4.5 3.5 4.5 3.5 3.4 3.4 3.4

M axim um Excess Diaphragm Psig 70 45 45 30 15 30 15 15 15 15

Presssure!4) Bar 4.8 3.1 3.1 2.1 1.0 2.1 1.0 1.0 1.0 1.0

M axim um D iaphragm C asing Psig 110 90 90 65 55 65 55 55 55 55

Pressure!4'5) Bar 7.6 6.2 6.2 4.5 3.8 4.5 3.8 3.8 3.8 3.8
Pounds 34 48 50 90 121 94 122 254 190 260
A pproxim ate W eight
Kg 15 22 23 41 55 43 55 115 86 118

M aterial Nitrile E lastom ers - 4 0 to 180°F (-4 0 to 8 2°C )

Tem perature S ilicone E lastom ers - 6 5 to 3 00° F ( -5 4 to 149°C )
C apabilities F luoroelastom ers 0 to 3 0 0 °F (-1 8 to 149°C )
1. These values also apply to the Type 667-4 actuator construction.
2. Actuator travel may be less than the value listed after connected to the valve.
3. Maximum actuator travel for Type 667-4 is 4 inches (102 mm.
4. See also the Specification portion of the introduction section.
5. Maximum diaphragm casing pressure must not be exceeded and must not produce
a force on the actuator stem greater than the maximum allowable actuator output thrust
or the maximum allowable stem load. See the Maximum Pressure Limitation section.

Introduction tors. They provide automatic operation of control valves.

Scope of Manual
This instruction manual provides information on installa­
tion, adjustment, maintenance, and parts ordering for the
Type 667 actuator in sizes 30 through 76 and size 87. The
Type 667-4 actuator in sizes 70 and 87 is also covered. Re­
fer to separate instruction manuals for information about
the valve positioner and other accessories used with these
actuators.
Only personnel qualified through training or experience
should install, operate, and maintain a Type 667 actuator
(see figure 1). If you have any questions about these
instructions, contact your Fisher Controls sales or sales
representative before proceeding.
Description
The Type 667 actuator (figure 1) and the Type 667-4 actua­
tor are reverse-acting, spring-opposed diaphragm actua­
The Type 667 actuator provides 3 inches (76 mm) maxi­
mum actuator travel. The Type 667-4 actuator provides 4
inches (102 mm) maximum actuator travel. Both actuators
position the valve plug in response to varying pneumatic
loading pressure on the diaphragm. Figure 2 shows the op­
eration of these actuators.
A Type 667 or 667-4 actuator can be furnished with either a
top-mounted or a side-mounted handwheel assembly. A
top-mounted handwheel assembly is usually used as an
adjustable down travel stop. (A down travel stop limits ac­
tuator travel in the down direction. “Down” means that the
stem is traveling out of the actuator. “Up" means that the
stem is traveling into the actuator.) A side-mounted hand­
wheel assembly is usually used as an auxiliary manual ac­
tuator*. The side-mounted handwheel can also be used as
an adjustable up or down travel stop. Casing-Mounted ad­
justable up or down travel stops are also available on this
actuator.

2

Figure 2. Schematic of Type 667 and 667-4 Actuators
Figure 3. Type 667 and 667-4 Actuator Nameplate
C T C A U T IO N
If repeated or daily manual operation is ex­
pected, the actuator should be equipped
with a side-mounted handwheel rather than
a casing-mounted travel stop or top-
mounted handwheel. The side-mounted
handwheel is designed for more frequent
use as a manual operator.
Specifications
Refer to table 1 for Specifications of the Type 667 and
667-4 actuators. See the actuator nameplate (figure 3) for
specific information for your actuator.
W A R N IN G
To avoid personal injury and property dam­
age caused by bursting of parts and to
Type 667 Size 30-76 & 87
avoid parts damage, malfunction of control
valve, or loss of control of the process
caused by excessive pressure, do not ex­
ceed the Maximum Pressures listed in table
1. Refer to the Maximum Pressure Limita­
tions section selection below.
Maximum Pressure Limitations
The casing and diaphragm of Type 667 actuators are pres­
sure operated. This air pressure provides energy to com­
press the spring, to stroke the actuator, and to seat the
valve. The following explanations describe the maximum
pressure limits for an actuator. Refer to the nameplate or
table 1 for maximum values for your actuator.
• Maximum Diaphragm Pressure to Stroke the Ac­
tuator: This is the maximum pressure that can be applied
at less than full travel of the actuator. If this stroking pres­
sure is exceeded before the upper diaphragm plate con­
tacts the travel stop, damage to the stem or other parts
might result.
• Maximum Excess Diaphragm Pressure: Addition­
al pressure may be added when the actuator is at full travel.
If the Maximum Excess Diaphragm Pressure is exceeded,
damage to the diaphragm or diaphragm casing might re­
sult.
Because the actuator has traveled its specified travel, and
the diaphragm head is physically stopped from movement,
the energy from any additional air pressure is transmitted
to the diaphragm and diaphragm casings. The amount of
air pressure that can be added once the actuator has trav­
eled to the stops is limited by the resultant adverse effects
that may occur. Exceeding this limiting factor could result
in leakage or casing fatigue due to the deformation of the
upper diaphragm casing.
• Maximum Diaphragm Casing Pressure: If the
Maximum Diaphragm Casing Pressure is exceeded, dam­
age to the diaphragm, diaphragm casing, or actuator might
result. For some actuator sizes, the maximum casing pres­
sure is the sum of the maximum stroking pressure added
to the maximum excess pressure. For other actuator sizes,
the value is lower than the sum of the two pressures.
Installation
Key number locations are shown in figures 7,8, and 9, un­
less otherwise noted. Also, refer to figure 4 for location of
parts.
3
Type 667 Size 30-76 & 87 F IS H E R

VEN T NPT FEM ALE

r a WARNING C O N N E C T IO N (T O P L O A D IN G )

D IA P H R A G M C A S IN G S

To avoid personal injury or parts damage, D IA P H R A G M A N D

do not exceed any of the maximum Dia­ S T E M S H O W N IN
D O W N P O S IT IO N
phragm Pressures listed in table 1.
D IA P H R A G M
PLATE
• Valve/Actuator Assembly: If the actuator and valve
NPT FEM ALE
are shipped together as a control valve assembly, it has C O N N E C T IO N
been adjusted at the factory, and may be installed in the
pipeline. After installing the valve in the pipeline, refer to the A C T U A T O R S P R IN G

loading connection procedures.

ACTUATO R STEM

• Actuator Mounting: If the actuator is shipped sepa­ S P R IN G S E A T

rately or the actuator has been removed from the valve, it

S P R IN G A D J U S T O R
is necessary to mount the actuator on the valve before
placing the valve in the pipeline. Refer to the following ac­ STEM CONNECTO R

tuator mounting procedures before placing the valve in ser­

YOKE
vice. It is recommended that you perform the bench set
spring adjustment procedures in this section to confirm that T R A V E L IN D IC A T O R D IS K

the actuator is adjusted correctly for the valve travel.

IN D IC A T O R S C A L E

• Positioner: If a positioner is installed, or is to be

installed on the actuator, refer to the positioner instruction
manual for installation. During the adjustment procedures,
VALVE STEM
it will be necessary to provide a temporary loading pres­ M A TC H LINE
YOK E LO CK NUT
sure to the actuator diaphragm. FOR
ACTUA TOR
YOK E BO SS
D IA M ETE R
• Handwheel Cap: If the handwheel cap (key 247, fig­
ures 10, 11, or 16) is not in place, install the cap by pushing BONNET

it on by hand until it snaps in place.

Mounting the Actuator on the Valve T Y P IC A L V A LV E

(R E FE R TO
VALVE MANUAL)

CAUTION
• The Type 667 actuator spring load
pushes the stem down out of the actuator
yoke (see figure 2), and it can come in con­
tact with the valve stem during actuator
mounting.•
• If the valve stem is allowed to remain
in the up position (towards the actuator)
during actuator mounting, it can interfere
with the actuator stem during mounting. It
is possible to damage valve stem threads or
bend the valve stem. Be sure the valve stem
is pushed down (into the valve body), away
from the actuator while mounting.
It may be necessary to apply a temporary loading pressure
to the actuator to move the actuator stem away from the
valve during installation.
Figure 4. Actuator-Mounting Components for Size 30 through
70 Actuators
If it is not possible to provide a temporary loading pressure,
be very careful when lowering the actuator over the valve
stem to prevent damage to valve stem and threads.
WARNING
When moving the actuator stem with load­
ing pressure applied, exercise caution to
keep hands and tools out of the actuator
stem travel path. If the loading pressure is
accidently disconnected, personal injury
and property damage is possible if

4

something is caught between the actuator
stem and other control valve parts.
1. Provide a vise or some other method of supporting the
valve and the weight of the actuator during assembly. For
direct or reverse acting valves, push the valve stem down
away from the actuator while mounting the actuator.
2. Screw the stem locknuts all the way onto the valve
stem. With the concave side of the travel indicator disk (key
14) facing the valve, install the travel indicator disk on the
valve stem. (Note: The travel indicator disk is not used with
size 87 actuators.)
3. Lift or hoist the actuator onto the valve bonnet:
a. For size 87 actuators: Slowly lower the actuator
down on the valve while guiding the valve stem into the
opening in the end of the the actuator stem (see figure
5). Once the actuator is in place, insert the cap screws
and tighten the hex nuts, securing the actuator to the
bonnet.
b. For all other size actuators:
• Slowly lower the actuator down on the valve. As the
yoke passes over the end of the valve stem, place the yoke
locknut over the valve stem. (Note: On small size actua­
tors, it may be necessary to remove the indicator disk and
re-install it while lowering the actuator on to the valve be­
cause the disk will not go through the actuator yoke open­
ing).
Type 667 Size 30-76 & 87
NOTES:
G > THE LOWER PSIG LOADING PRESSURE (MARKED ON
NAMEPLATE) WHERE THE FIRST MOVEMENT OF ACTUATOR
STEM IS DETECTED.
[ 2 > MARK THIS POINT WITH TAPE OR A MARKER.
C D THE UPPER PSIG LOADING PRESSURE RETRACTS ACTUATOR
STEM.
H T ) MEASURE DISTANCE OF TRAVEL. IT SHOULD EQUAL THE
TRAVEL SPAN SHOWN ON THE TRAVEL INDICATOR SCALE.
<TT1 LOWER BENCH SET
LOADING PRESSURE
• Continue to lower the actuator while guiding the valve
stem into the opening in the end of the the actuator stem
until the actuator is in place (see figure 5).
• Screw the yoke locknut onto the valve bonnet and
tighten the locknut.
4. Do not connect the actuator stem to the valve stem at
this time. Whenever the actuator is installed on the valve,
it is recommended to perform the bench set spring adjust­
ment procedures below that you verify that the actuator is
still adjusted correctly.
Bench Set Spring Adjustment
The term “bench set” means that the actuator is not con­
nected to the valve, or any other loads. Ensure that the ac­
tuator diaphragm is at the bottom of its travel as shown in
figure 5. (Note: Some spring compression is required to
move the diaphragm to the bottom of its travel.)
Also, provide a certified pressure gauge that will accurately
read the diaphragm pressure from 0 through the upper
bench set pressure marked on the nameplate. Apply load­
ing pressure to the diaphragm.
Stroke the actuator a few tiraes4o ensure that the pressure
gauge is working correctly, and that the’ actuator is func­
tioning properly. It is important to be sure that the actuator
assembly is not binding or producing any friction on the ac­
tuator stem movement.
5
Type 667 Size 30-76 & 87
Key numbers are shown in figures 7, 8, and 9.
For Direct-Acting Valves (PDTC)
1. If not already accomplished, push the valve stem down
away from the actuator to the closed position.
2. Set the diaphragm loading pressure to 5 psig (0.3 bar)
over the upper bench set pressure. The upper travel stop
should be contacting the diaphragm casing.
3. Slowly decrease the pressure towards the upper bench
set pressure while checking for the first movement of the
actuator stem.
4. If movement occurs before or after the upper pressure
is reached, adjust the spring adjuster (see figure 5). Thread
the adjuster up or down on the actuator stem until the ac­
tuator stem movement is first detected at the upper bench
set pressure. (Note: You may need to lower the loading
pressure to reduce spring compression, allowing the
spring adjuster to turn.)
5. Be sure the spring adjuster is adjusted to meet the re­
quirements of step 4 above.
6. Apply the lower bench set loading pressure to the dia­
phragm. This will extend the actuator stem towards the
valve. Mark the end of the actuator stem on a nearby sur­
face using tape or some other method.
7. Slowly increase the diaphragm pressure until the upper
bench set loading pressure is applied. Again, the travel
stop should be against the diaphragm casing.
8. Measure the distance between the mark or tape to the
end of the actuator stem. This distance should match the
travel span shown on the travel indicator scale (key 18).
9. If the span of travel is correct, bench set is complete.
Proceed to the Installing the Stem Connector Assembly
subsection.
10. If the travel span is not exact, remember there are free-
length and load rate tolerances for the spring that may pro­
duce a slightly different span than specified. Or, contact
your Fisher Controls sales office or sales representative for
assistance.
For Reverse-Acting Valves (PDTO)
1. If not already accomplished, push the valve stem down
away from the actuator to the open position. Later, when
6
installing the connector, pull up the valve stem to the closed
position.
2. Set the diaphragm loading pressure to a value less than
the lower bench set pressure (near zero). The down travel
stop should be contacting the yoke.
3. Slowly increase the pressure towards the lower bench
set pressure while checking for the first movement of the
actuator stem.
4. If movement occurs before or after the lower pressure
is reached, adjust the spring adjuster (see figure 5). Thread
the adjuster up or down on the actuator stem until the ac­
tuator stem movement is first detected at the lower bench
set pressure.
5. Apply the upper bench set loading pressure to the dia­
phragm. This will retract the actuator stem away from the
valve. Mark the end of the actuator stem on a nearby sur­
face using tape or some other method.
6. Slowly decrease the diaphragm pressure until the lower
bench set loading pressure is applied. Again, the down-
stops should be against the yoke.
7. Measure the distance between the mark or tape to the
end of the actuator stem. This distance should match the
travel span shown on the travel indicator scale (key 18).
8. If the span of travel is correct, bench set is complete.
Proceed to the Installing the Stem Connector Assembly
subsection.
9. If the travel span is not exact, remember there are free-
length and load rate tolerances for the spring that may pro­
duce a slightly different span than specified. Or, contact
your Fisher Controls sales office or sales representative for
assistance.
Installing the Stem Connector Assembly
When installing the stem connector assembly (key 26), the
actuator and valve stem threads should engage the
threads of the stem connector by a distance equal to the di­
ameter of the stem.
Note
Replacement stem connectors are an as­
sembly of two stem connector halves, cap
screws, and a spacer between the connec­
tor halves. Remove the spacer and discard
it, if present, before clamping the actuator
and valve stems together.

1. If necessary, push the valve stem down so that the valve
plug is touching the seat ring on direct-acting valves. For
reverse-acting valves, pull the stem up to the closed posi­
tion. Always start with the valve plug on the seat.
2. If necessary, screw the valve stem locknuts down, away
from the connector location. For all actuators except size
87, ensure that the travel indicator disk (key 14) is on top
of the locknuts.
3. Apply the diaphragm pressure to the lower bench set
pressure. (Or, the upper bench set pressure for reverse­
acting valves.) This should be the same pressure used in
the bench set steps, and it is marked on the nameplate.
4. Place the stem connector half with the threaded holes,
approximately half way between the actuator and valve
stems. Refer to figures 7, 8, and 9 to help locate the con­
nector position.
Be sure that the actuator and valve stem threads are en­
gaging the threads of the stem connector by a distance
equal to one diameter of the stem.
C T C A U T IO N
Incomplete engagement of either the valve
stem or actuator stem in the stem connec­
tor can result in stripped threads or improp­
er operation. Be sure that the length of each
stem clamped in the stem connector is
equal to or greater than one diameter of that
stem. Damage to threads on either stem or
in the stem connector can cause the parts
to be replaced prematurely.
5. Install the other half of the stem connector and insert the
cap screws and tighten them. If installing a positioner, also
attach the feedback bracket at the same time.
6. Screw the valve stem locknuts up until the indicator disk
contacts the bottom of the stem connector, or for size 87 ac­
tuators, tighten the locknuts against the stem connector.
Do not overtighten the locknuts.
7. Slowly increase and then decrease pressure several
times, stroking the valve from the lower bench set pressure
to the upper pressure.
Be sure that the valve is in the closed position (up or down,
depending on valve action). Loosen the screws on the trav­
el scale, and align it with the travel indicator disk. Stroke the
valve full travel to ensure that the travel matches the valve
Type 667 Size 30-76 & 87
VALVE TRAVEL
NOTE:
l~T> DEADBAND IS CAUSED BY FRICTION.
A66M/G1
Figure 6. Typical Direct Acting Valve Response to Deadband
travel on the travel indicator plate. If valve travel is not cor­
rect, repeat the stem connector procedure.
Note
For push-down-to-close valves, the valve
plug seat is the limit for downward travel
and the actuator up-stop is the limit for up­
ward (away from the valve) movement. For
push-down-to-open valves, the actuator
down-stop is the limit for downward move­
ment, and the valve seat is the limit for up­
ward (away from the valve) movement. For
Type 667 actuators, a down-stop (key 77,
figure 7) is installed to limit actuator dia­
phragm downward movement when the ac­
tuator provides the limit.
Deadband Measurement
Deadband is caused by packing friction, unbalanced
forces, and other factors in the control valve assembly.
Deadband is the range a measured signal can vary without
initiating a response from the actuator (see figure 6). Each
actuator spring has a fixed spring rate (force). You have
verified that the right spring was installed in the actuator by
completing the bench set spring adjustment steps.
Deadband is one factor that affects the control valve as­
sembly operation during automatic loop control. The con­
trol loop tolerance for deadband varies widely depending
on the loop response. Some common symptoms of the
deadband being too wide are no movement, a “jump”
movement, or oscillating movements of the actuator during
automatic loop control. The following steps are provided to
7
Type 667 Size 30-76 & 87
determine the span of deadband. The percent of deadband
is helpful in troubleshooting problems with the process
control loop.
1. Start at a pressure near the lower bench set pressure,
slowly increase pressure until the valve is approximately at
mid-travel. Note this pressure reading.
2. Slowly decrease pressure until movement of the valve
stem is detected, and note this pressure.
3. The difference between these two pressures is dead­
band, in psi.
4. Calculate the percent of deadband by:
Deadband, psi
Deadband = Deadband, psi = nn %
Bench Set Span, psi
Loading Connection
Key number locations are shown in figures 7,8, and 9, un­
less otherwise noted.
The loading pressure connections are made at the factory
if the valve, actuator, and positioner come as a unit. Keep
the length of tubing or piping as short as possible to avoid
transmission lag in the control signal. If a volume booster,
valve positioner or other accessory is used, be sure that it is
properly connected to the actuator. Refer to the positioner
instruction manual or other manuals as necessary. For ac­
tuators shipped separately or whenever the actuator pres­
sure connections are installed, use the following steps:
1. Connect the loading pressure piping to the NPT female
connection in the side of the yoke (key 73).
2. For size 70 and 87 actuators, if necessary, remove the
1/4-inch NPT bushing if a 1/2-inch NPT female connection
is needed to increase connection size. The connection can
be made with either piping or tubing.
3. Cycle the actuator several times to be sure that the
valve stem travel is correct when the correct pressure
ranges are applied to the diaphragm.
4. If valve stem travel appears to be incorrect, refer to the
bench set spring adjustment procedures at the beginning
of this section. Do not place the valve in service if it is not
reacting correctly to diaphragm loading pressure changes.
8
Maintenance
Actuator parts are subject to normal wear and must be in­
spected and replaced when necessary. The frequency of
inspection and replacement depends on the severity of
service conditions. Because of the care Fisher Controls
takes in meeting all manufacturing requirements (heat
treating, dimensional tolerances, etc.), use only replace­
ment parts manufactured or furnished by Fisher Controls.
W A R N IN G
Avoid personal injury or property damage
from sudden release of process pressure or
uncontrolled movement of parts. Before
performing any maintenance operations:
• Disconnect any operating lines pro­
viding air pressure* electric power, or a con­
trol signal to the actuator. Be sure the actua­
tor cannot suddenly open or close the
valve.
• Use bypass valves or completely shut
off the process to isolate the valve from pro­
cess pressure. Relieve process pressure
from both sides of the valve. Drain the pro­
cess media from both sides of the valve.
• Vent the power actuator loading pres­
sure and relieve any actuator spring pre­
compression.
• Use lock-out procedures to be sure
that the above measures stay in effect while
you work on the equipment.
The maintenance instructions are divided into several sec­
tions: Actuator, Top-Mounted Handwheel Assembly (Ad­
justable Down Travel Stop), Side-Mounted Handwheel As­
sembly (Manual Actuator) for Size 34 through 60
Actuators, Side-Mounted Handwheel Assembly (Manual
Actuator) for Size 70, 76 and 87 Actuators, and Casing-
Mounted Travel Stops.
Actuator Maintenance
This procedure describes how the actuator can be com­
pletely disassembled and assembled. When inspection or
repairs are required, disassemble only those parts neces-

sary to accomplish the job; then, start the assembly at the
appropriate step.
Key are shown in figures 7,8, or 9, unless otherwise noted.
Figure 7 shows the size 30 through 60 actuators, figure 8
shows the size 70 actuator, and figure 9 shows the size 87
actuator.
Actuator Disassembly
Isolate the control valve from the line pressure, release
pressure from both sides of the valve body, and drain the
process media from both sides of the valve. Also shut off all
pressure lines to the power actuator, release all pressure
from the actuator. Use lock-out procedures to be sure that
the above measures stay in effect while you work on the
equipment.
1. Remove the tubing or piping from the connection in the
top of the yoke (key 73). For a top-loaded construction, also
remove the piping or tubing from the connection in the up­
per diaphragm casing (key 1).
2. Turn the spring adjuster (key 74) counterclockwise until
all spring compression is relieved.
W A R N IN G
To avoid personal injury due to the sudden
uncontrolled movement of parts, do not
loosen the stem connector cap screws
when the stem connector has spring force
applied to it.
3. If necessary, remove the actuator from the valve body
by separating the stem connector (key 31). Loosen the
stem locknuts for the size 87 actuator, and removing the
stem connector nuts. All other sizes, separate the stem
connector by loosening the stem locknuts (keys 69 and 75)
and unscrewing the two stem connector cap screws.
4. Unscrew the spring adjuster (key 74) from the actuator
stem (key 144). Also lift the spring seat and spring (Key 19
and 18) out of the yoke.
5. Remove the diaphragm casing cap screws and nuts
(keys 13 and 14), and lift off the upper diaphragm casing
(key 1).
6. Remove the following connected parts: the diaphragm
(key 3), upper diaphragm plate (key 4), spacer (key 2), cap
screw (key 12), lower diaphragm plate (key 71), and actua­
tor stem (key 144). Be careful when pulling the threads of
Type 667 Size 30-76 & 87
the actuator stem through the seal bushing (key 7) to avoid
damaging the O-rings (key 8).
7. Remove the cap screw (key 12) to separate the parts of
this assembly.
8. To remove the seal bushing, remove the snap ring (key
72), and lift out the bushing. Inspect, and if necessary, re­
place O-rings (8 and 9).
9. Remove capscrews (key 30), and take off the lower dia­
phragm casing (key 64) and the gasket (key 70, size 30
through 60 and 76) or O-ring (key 70, size 70 or 87). If nec­
essary, the down travel stops (key 77) can be removed.
Actuator Assembly
1. Coat the O-rings (key 70, sizes 70 and 87) with lubri­
cant (key 237 or equivalent). Or, coat the gasket with seal­
ant (key 238 or equivalent). Place a new gasket or O-ring
(key 70) on the yoke (key 73). Position the lower diaphragm
casing (key 64) on the yoke, align the holes, and insert and
tighten the cap screws (key 30). If down travel stops (key
77) were removed, insert and tighten them.
2. Coat the O-rings (keys 8 and 9) with lubricant (key 237
or equivalent) and place the O-rings in the seal bushing
(key 7).
3. Fill the seal bushing with lubricant (key 237 or equiva­
lent), slide the bushing into the yoke (key 73), and install
the snap ring (key 72).
4. Assemble the actuator stem (key 144), lower dia­
phragm plate (key 71), diaphragm (key 3), upper dia­
phragm plate (key 4), and the travel stop cap screw and
spacer (keys 12 and 2). Place this assembly in the actuator.
Take care when pushing the actuator stem through the seal
bushing so that the threads do not damage the O-rings.
C T C A U T IO N
Over-tightening the diaphragm cap screws
and nuts (keys 13 and 14) can damage the
diaphragm. Do not exceed 20 Ib fft (27
N ■m) torque.
5. Install the upper diaphragm casing (key 1), and Install
the cap screws and nuts (keys 13 and 14). Tighten the dia­
phragm cap screws and nuts to 20 Ibf •ft (27 N • m) torque
in a crisscross pattern. .»
6. Install the actuator spring (key 18) and spring seat (key
19). Apply lubricant (key 239 or equivalent) to the threads
of the actuator stem and to the surface of the spring adjust-
9
Type 667 Size 30-76 & 87
er (key 74) that contacts the spring seat. Thread the spring
adjuster on the actuator stem.
7. Mount the actuator on the valve in accordance with the
procedures in the Installation section.
Top-Mounted Handwheel Assembly
(Adjustable Down Travel Stop)
Actuator key numbers are shown in figures 7, 8, and 9.
And, top-mounted handwheels are shown in figures 10,11,
and 12.
Note
If repeated or daily manual operation is ex­
pected, the actuator should be equipped
with a side-mounted handwheel rather than
a casing-mounted travel stop or top-
mounted handwheel. The side-mounted
handwheel is designed for more frequent
use as a manual operator.
A top-mounted handwheel assembly (figures 10, 11, and
12) is usually used as an adjustable down travel stop to lim­
it full extension of the actuator stem. Turning the hand­
wheel counterclockwise pulls the extension rod (key 150,
figures 10,11, and 12) up, retracting the actuator stem.
Instructions are given below for complete disassembly and
assembly. Perform the disassembly only as far as neces­
sary to accomplish the required maintenance; then, begin
the assembly at the appropriate step.
Disassembly for Top-Mounted
Handwheel
1. Bypass the control valve, reduce loading pressure to at­
mospheric, and remove the tubing or piping from the con­
nection in top of the yoke (key 73, figures 7, 8, and 9).
2. Turn the handwheel (key 58) clockwise so that the
handwheel assembly is not causing any spring compres­
sion.
3. Turn the actuator spring adjuster (key 74) to relieve all
the compression from the spring (key 18).
4. If servicing just the thrust bearing, races, and hand­
wheel screw (keys 180,181, and 160) only, use the follow­
ing steps:
10
• Remove the cap and drive out the groove pin. Re­
move the castle nut, bearing retainer, thrust bearing, and
races (keys 247,167, 166, 180, and 181).
• Use the handwheel to remove the handwheel screw
(key 160) from the handwheel body (key 148).
• It necessary, remove the extension rod (key 150) at
this time. Most maintenance procedures do not require the
rod to be removed.
• Clean and inspect all parts or replace parts as neces­
sary. Upon re-assembly, lubricate handwheel threads,
bearings, and races with Never-Seez Nickel Special (key
239) or equivalent.
• Lubricate and re-install the handwheel screw into
handwheel body (key 148). Lubricate and replace the
races, bearing, and retainer (keys 181,180, and 182). Re­
place the castle nut (key 166), tighten it, and insert the
groove pin (key 167). Replace the handwheel cap (key
247).
5. For size 30 through 60 and 76 actuator
handwheels (figures 10 and 11):
• Remove the cap screws (key 161). Make sure that
the guide plate can turn between the handwheel body and
the mounting plate (keys 157, 148 and 158).
• Remove the cap (key 247) and drive out the groove
pin (key 167). Remove the castle nut (key 166) and, if nec­
essary, unscrew the extension rod (key 150). Remove the
rod, the handwheel body (key 148), and the attached parts.
• Remove the hex nuts and cap screws (keys 14 and
13, figures 7, 8, and 9) from the diaphragm casings. Lift off
the upper diaphragm casing (key 1) and the mounting plate
(key 158).
• Turn the handwheel (key 58) to remove the hand­
wheel screw (key 160) from the handwheel body (key 148).
Remove the retaining ring (key 60) if the handwheel (key
58) must be separated from the handwheel screw.
• If necessary, perform other actuator maintenance be­
fore returning to the following assembly steps.
6. For size 70 and 87 actuator handwheels (figure 12):
• Remove the cap (key 247). Drive out the groove pin
(key 167) and remove the castle nut, the bearing retainer,
and thrust bearing (keys 166,182,181, and 180). It is not
necessary to remove the extension,rod (key 150) at this
time.
• Remove the hex nuts and cap screws (keys 14 and
13, figures 7, 8, and 9) from the diaphragm casings. Lift off

the upper diaphragm casing (key 1), handwheel body (key
148) and attached parts.
• If travel stops (key 152) are used, note and record
their position relative to the cap screws (key 154) for use
in assembly. Remove the travel stops and cap screws, and
remove either the mounting plate (key 158, figure 12) orthe
handwheel body (key 148, figure 12) and attached parts.
• Turn the handwheel (key 58) to remove the hand­
wheel screw (key 160) from the handwheel body (key 148).
Remove the retaining ring (key 60) if the handwheel (key
58) must be separated from the handwheel screw.
• If necessary, perform other actuator maintenance be­
fore returning to the following assembly steps.
Assembly for Top-Mounted Handwheel
For size 30 through 60 and 76 actuator handwheels:
Refer to figures 10 and 11 for top-mounted handwheel as­
semblies.
1. If it was removed, slide the handwheel (key 58) onto the
end of the handwheel screw (key 160), and snap the retain­
ing ring (key 60) in place. Also, install the guide post (key
150) if it was removed.
2. Generously coat the threads of the handwheel screw
(key 160) with lubricant (key 239 or equivalent). Turn the
screw into the handwheel body (key 148).
3. Install the mounting plate (key 158) to the diaphragm
casing (key 1, figures 7,8, and 9) with the cap screws (key
154). Finger tighten the screws.
4. If travel stops were used, install the travel stops to their
original positions as recorded in proceeding Disassembly
steps. Tighten the screws and travel stops.
CAUTION
Over-tightening the diaphragm cap screws
and nuts (keys 13 and 14) can damage the
diaphragm. Do not exceed 20 Ibf -ft (27
N - m) torque.
5. Position the diaphragm casing (key 1, figures 7, 8, and
9), mounting plate (key 158), travel stops (key 152), if used,
and cap screws (key 154) on the diaphragm. Install the cap
screws and hex nuts (keys 13 and 14, figures 7, 8, and 9)
Type 667 Size 30-76 & 87
and finger tighten. Tighten the diaphragm cap screws and
nuts to 20 Ibf •ft (27 N • m) torque in a crisscross pattern.
6. If necessary, screw the extension rod (key 150 into the
connector (key 27). Slide the guide plate (key 157) onto the
extension rod (key 150). For size 45 through 76, place the
spacer (key 253) on top of the guide plate (key 157). If nec­
essary, replace the extension rod (key 150). Slide the
handwheel body (key 148) over the extension rod, position
the handwheel body on the spacer (key 253), align the
holes, and insert and tighten the cap screws (key 161).
7. Lubricate and install the thrust bearings (keys 181 and
180), install the bearing retainer (key 182), install the
castle nut (key 166) on the extension rod. Do not overtigh­
ten the castle nut on the bearing. Drive in the groove pin
(key 167). Replace the cap (key 247).
8. Refer to the Assembly portion of the Actuator mainte'
nance section.
For size 70 and 87 actuators handwheels (figure 12):
Refer to figurel 2 for top-mounted handwheel assemblies.
1. If removed, slide the handwheel (key 58) onto the end
of the handwheel screw (key 160), and snap the retaining
ring (key 60) in place.
2. Generously coat the threads of the handwheel screw
(key 160) with lubricant (key 239 or equivalent). Turn the
screw into the handwheel body (key 148).
3. If necessary, install the extension rod (key 150) into the
connector (key 27) and tighten it. Position the handwheel
body (key 148) on the diaphragm casing (key 1, figures 7,
8, and 9), and align the holes. Insert the cap screws (key
154). Finger tighten the screws.
4. If travel stops were used, return the travel stops to their
original positions as recorded in proceeding Disassembly
steps. Tighten the screws and travel stops.
CT CAUTION
Over-tightening the diaphragm cap screws
and nuts (keys 13 and 14) can damage the
diaphragm. Do not exceed 20 Ibf-ft (27
N ■m) torque.
5. Slide the extension rod (key 150) into the handwheel
screw (key 160), and position the diaphragm casing (key
1, figures 7, 8, and 9) with the attached parts on the dia­
phragm. Install the cap screws and hex nuts (keys 13 and
14, figures 7, 8, and 9) and finger tighten. Tighten the dia­
11
Type 667 Size 30-76 & 87
phragm cap screws and nuts to 20 Ibf-ft (27 N • m) torque
in a crisscross pattern.
6. Lubricate and install the thrust bearings (keys 180 and
181), install the bearing retainer (key 182), install the
castle nut (keys 166) on the extension rod. Do not overtigh­
ten the castle nut on the bearing. Drive in the groove pin
(key 167). Replace the cap (key 247).
7. Refer to the Assembly portion of the Actuator mainte­
nance section.
Side-Mounted Handwheel Assembly for
Size 34 through 60 Actuators
A side-mounted handwheel assembly (figures 13 and 14)
is usually used as a manual actuator. This design is fre­
quently used to drive the valve open or closed under load­
ing conditions. Turning the handwheel clockwise past the
neutral position always closes a push-down-to-close
valve. A pair of levers (key 146, figure 13) on a handwheel
assembly close the valve by moving the valve stem.
Instructions are given below for disassembly and assem­
bly. Perform the disassembly only as far as necessary to
accomplish the required maintenance; then begin the as­
sembly at the appropriate step.
Disassembly for Side-Mounted
Handwheel (34-60)
1. If desired, the handwheel assembly can be removed
from the actuator yoke. To do this, remove the nuts (keys
147 and 170) from the U-bolts (keys 166 and 143) that hold
the assembly to the yoke.
2. Remove retaining ring (key 154), and drive out the lever
pivot pin (key 153).
3. There are two screws (key 156) that hold the right- and
left-hand levers (key 146) together. Remove the screw
from the top of the levers so that the levers will drop down
out of the assembly. Disassemble further, if necessary, by
removing the other screw.
4. Remove screw (key 161) and pointer mounting bolt (key
159, not shown) located behind pointer (key 160).
5. Remove nut (key 54), lockwasher (key 150), and wash­
er (key 149), and take off the handwheel (key 51). Be care­
ful not to lose the small ball (key 55) and spring (key 56).
12
FISHER0
___________
6. Unscrew the bearing retainer (key 136) after loosening
the locking set screw (key 168, not shown).
7. Pull the screw assembly (key 145) out of the handwheel
body. The operating nut (key 132) will come out with the
screw. Also, remove the bushing (key 151) on sizes 34 and
40.
8. If required, remove the bearings (key 152), one from the
bearing retainer and the other from the handwheel body.
9. Size 34,40,45 and 76 actuator handwheels (figures
10 and 11), fasten the mounting plate (key 158) to the dia­
phragm casing (key 1, figures 7, 8, and 9):
• If travel stops were used, install the travel stops to
their original positions as recorded in proceeding disas­
sembly steps.
• Install the cap screws (key 154). Tighten the screws
and travel stops.
10. If travel stops were used, return the travel stops to their
original positions as recorded in proceeding Disassembly
steps. Tighten the screws and travel stops.
CAUTION
Over-tightening the diaphragm cap screws
and nuts (keys 13 and 14) can damage the
diaphragm. Do not exceed 20 Ibf ft (27
N - m) torque.
11. Size 60 and 76 actuator handwheels, position the di­
aphragm casing (key 1, figures 7,8, and 9), mounting plate
(key 158), travel stops (key 152), if used, and cap screws
(key 154) on the diaphragm. Install the cap screws and hex
nuts (keys 13 and 14, figures 7,8, and 9) and finger tighten.
Tighten the diaphragm cap screws and nuts to 20 Ibf •ft (27
N • m) torque in a crisscross pattern.
• Slide the guide plate (key 157) onto the extension rod
(key 150), and screw the extension rod into the connector
(key 27). For size 45 through 76, place the spacer (key 253)
on top of the guide plate (key 157). Slide the handwheel
body (key 148) over the extension rod, position the hand­
wheel body on the guide plate (key 157) or spacer (key
253), align the holes, and insert and tighten the cap screws
(key 161).
12. Size 70 or 87 actuator handwheel, slide the exten­
sion rod (key 150) into the handwheel screw (key 160), and
position the diaphragm casing (key T, figures 7, 8, and 9)
with the attached parts on the diaphragm. Insert and tight­
en the cap screws and hex nuts (keys 13 and 14, figures
7, 8, and 9).

13. Size 34 through 60, and 76 actuator handwheels,
re-lubricate the thrust bearings (key 180), install the wash­
m er and castle nut (keys 162 and 166) on the extension rod.
i Do not overtighten the bearing. Drive in the groove pin (key
167). Replace the cap (key 247).
\ 7. If the handwheel assembly was removed from the yoke,
i position the U-bolts (keys 166 and 143) on the yoke, and
• Size 70 and 87 actuators handwheels, screw the
extension rod (key 150) into the connector (key 27). Posi­
tion the handwheel body (key 148) on the diaphragm cas­
ing (key 1, figures 7, 8, and 9), and align the holes. Insert
the cap screws (key 154). Finger tighten the screws.
14. Size 70 or 87 actuator handwheels, re-lubricate the
thrust bearing (key 180), install the thrust bearing and bear­
ing retainer (keys 180 and 181) on the extension rod (key
150), and screw on the castle nut (key 166). Do not over­
tighten the bearing. Drive in the groove pin (key 167), and
replace the cap (key 247).
15. Refer to the Assembly portion of the Actuator mainte­
nance section.
Assembly for Side-Mounted Handwheel
(Sizes 34-60)
1. Pack the bearings (key 152) with lubricant (key 244 or
equivalent). Insert one bearing and the bushing (key 151)
in the handwheel body (key 142) as shown in figure 13 or
14. The bushing is not used in a handwheel assembly for
size 45 through 60 actuators.
2. Coat the screw threads with lubricant (key 244) or
equivalent, and thread the operating nut onto the screw.
Slide the second bearing (key 152) onto the screw, and in­
sert the end of the screw into either the bushing (key 151)
as shown in figure 13 or 14 or into the bearing.
3. Thread the bearing retainer (key 136) into the body (key
142). Completely tighten the bearing retainer, and then
loosen it one-quarter turn. Tighten the set screw (key 168,
not shown) to hold the bearing retainer in place.
4. Coat the groove in the handwheel body (key 142) with
lubricant (key 244 or equivalent). Insert the spring (key 56)
and ball (key 55) into the handwheel (key 51). Holding the
ball and spring in the handwheel, put the handwheel (key
51), the washer (key 149), the lockwasher (key 150), and
the hex nut (key 54) on the end of the screw (key 145).
Tighten the hex nut.
_ 5. Position the pointer mounting bolt (key 159, not shown)
and pointer (key 160) as shown in figure 13 or 14. Insert
and tighten the screw (key 161).
Type 667 Size 30-76 & 87
6. Assemble the two levers (key 146) with the cap screws
(key 156) for handwheel assemblies for size 45,50, and 60
actuators or with the machine bolts (key 156) for hand­
wheel assemblies on size 34 and 40 actuators.
tighten the nuts (keys 170 and 147) to hold the handwheel
assembly in position.
8. Position the levers (key 146) as shown in figure 13 or
14. Insert the lever pivot pin (key 153), and snap the retain­
ing ring (key 154) onto the lever pivot pin.
Side-Mounted Handwheel Assembly
(Sizes 70, 76, and 87)
A side-mounted handwheel assembly (figure 15) is usually
used as a manual actuator. Turning the handwheel clock­
wise past the neutral position always closes the valve
body. A sleeve (key 123, figure 15) on a handwheel assem­
bly for a size 70,76 or 87 actuator opens the valve body by
moving the valve stem.
Instructions are given below for complete disassembly and
assembly. Perform the disassembly only as far as neces­
sary to accomplish the required maintenance; and then be­
gin the assembly at the appropriate step.
Disassembly for Side-Mounted
Handwheel (Sizes 70, 76, & 87)
Bypass the control valve. Reduce the loading pressure to
atmospheric. Disconnect the loading pressure tubing or
piping at the yoke.
Remove cover band (key 87), and relieve spring compres­
sion by turning the spring adjuster (key 74) counterclock­
wise. .
Remove the cap screws and nuts (keys 13 and 14) and lift
off the upper diaphragm casing (key 1).
Remove the travel stop screw (key 12) and spacer (key 2),
and take off the diaphragm plate (key 4), the diaphragm
(key 3), and the lower diaphragm plate (key 71).
V
Unscrew the cap screws (key 90) and remove the following
connected parts: the lower diaphragm casing (key 64), the
O-ring (key 70), spring case adaptor (key 89), the seal
bushing, O-rings, and snap ring (keys 7, 8, 9, and 72).
Remove the snap ring (key 72), and slide the seal bushing
and O-rings (keys 7, 8, and 9) out of the spring case adap­
tor (key 89).
13
Type 667 Size 30-76 & 87
Take out the actuator spring (key 18).
Remove the stem connector (key 31) and stem connector
cap screws.
Pull the actuator stem (key 144) up and out of the yoke. The
spring seat (key 19), spring adjuster (key 74), thrust bear­
ing (key 128), and the pinned adjusting screw (key 131) will
come out with the actuator stem.
Turn the handwheel so that the lower sleeve (key 123) ex­
tends out of the bottom of the yoke.
Loosen two set screws (key 121), and unscrew the bearing
retainer flange (key 45). Take out the worm gear and two
thrust bearings (key 132), one on each side of the gear.
The worm shaft (key 51) and associated parts can be dis­
assembled, if desired, by first removing handwheel nut
(key 127) and the handwheel (key 58). Do not lose the
small ball (key 141) and spring (key 142).
Loosen the set screw (key 52) for each worm shaft retainer
(keys 48 and 49). Unscrew the two worm retainers (keys
48 and 49). The ball bearings (key 50) will come out with
the retainers.
Assembly for Side-Mounted Handwheel
(Sizes 70, 76, & 87)
1. The front and back worm retainers (keys 48 and 49)
each have a slot in their threads for a set screws (key 52).
Pack the ball bearings (key 50) with lubricant (key 239) or
equivalent, and insert one ball bearing in the back worm re­
tainer (key 49) as shown in figure 15.
2. Thread the back bearing retainer and ball bearing (keys
49 and 50) into the yoke. Align the slot in the bearing retain­
er with the set screw hole in the yoke, insert the set screw
(key 52), and tighten it.
3. Coat the worm shaft (key 51) threads with lubricant (key
239 or equivalent), and slide the shaft into the yoke so that
the end of the shaft fits snugly into the back bearing retain­
er.
4. Insert the bearing in the front bearing retainer (key 49),
and thread the retainer and ball bearing into the yoke. Align
the slot in the retainer with the hole in the yoke, insert the
set screw (key 52), and tighten it.
5. Put the spring and ball (keys 141 and 142) in the hand­
wheel (key 58). Slide the handwheel onto the worm shaft
(key 51). Thread the hex nut (key 127) onto the worm shaft.
14
F ISH E R ®
- -
6. Pack the two needle bearings (key 132) and coat the
worm gear (key 44) threads with lubricant (key 239) or
equivalent. Insert the key (key 122), the bearings, and the
worm gear in the yoke (key 73) as shown in figure 15.
7. Slots are cut in the threads of the bearing retainer flange
(key 45). Thread the flange into the yoke so that the slots
and the holes for the set screws (key 121) align. Insert the
screws, and tighten them.
8. The lower sleeve (key 123) has a milled groove in one
end. Coat the sleeve threads with lubricant (key 238 or
equivalent), slide the end of the lower sleeve with the
groove into the bearing retainer flange, turn the hand­
wheel, and feed the sleeve through the worm gear so that
the slot in the lower sleeve engages the key (key 122) in the
yoke. Continue turning the handwheel until the lower
sleeve protrudes from the yoke.
9. Pack the thrust bearing (key 128) with lubricant (key
239) or equivalent. Slide the actuator stem (key 144) and
the attached adjusting screw (key 131), pin (key 130),
thrust bearing (key 128), spring seat (key 19), and spring
adjuster (key 74) into the yoke. The lower end of the stem
slides through the lower sleeve (key 123) and the lower
sleeve slides into the adjusting screw (key 131), as shown
in figure 15.
10. Position the actuator stem (key 144) against the valve
stem. Clamp both stems between the two halves of the
stem connector (key 31), and be sure the threads are en­
gaged properly on both stems. Fasten the halves together
with the cap screws.
11. Put the actuator spring (key 18) in the yoke on the
spring seat (key 19).
12. Coat the O-rings (keys 8 and 9) with lubricant (key
237) or equivalent, and insert them in the seal bushing (key
7). Slide the seal bushing and O-rings into the spring case
adaptor (key 89).
13. Install the snap ring (key 72).
14. Slide the seal bushing and O-rings (keys 7, 8, and 9)
over the actuator stem (key 144), and position the spring
case adaptor (key 89), lower diaphragm casing (key 64),
and O-ring (key 70) on the yoke.
15. Insert and tighten the cap screws (key 90).
16. Slide the lower diaphragm plate (key 71), the dia­
phragm (key 3) with the patterned side up, the diaphragm
plate (key 4), the spacer (key 2), and the cap screw (key 12)
on the actuator stem (key 144). Tighten the cap screw.
17. Put the diaphragm casing (key 1) on the diaphragm.
Align the holes in the diaphragm (key 3) and the diaphragm
casings (keys 1 and 64).

w C A U T IO N
Over-tightening the cap screws and hex
nuts (keys 13 and 14) can damage the dia­
phragm. Do not exceed 20 Ibf •ft (27 N • m) of
torque.
18. Install the cap screws and hex nuts (keys 13 and 14)
and finger tighten. Tighten the diaphragm cap screws and
nuts to 20 Ibf •ft (27 N • m) torque in a crisscross pattern.
19. Return the actuator to service after completing the
Loading Connection procedure in the Installation section
and the procedures in the Adjustments section.
Casing-Mounted Travel Stops
Note
If repeated or daily manual operation is ex­
pected, the actuator should be equipped
with a side-mounted handwheel rather than
a casing-mounted travel stop or top-
mounted handwheel. The side-mounted
handwheel is designed for more frequent
use as manual operator.
Casing-mounted adjustable travel stops (shown in figures
16 through 20) are available to limit travel in the down direc­
tion (extending the actuator stem) or in the up direction (re­
tracting the actuator stem). The travel stop in figure 16 is a
down travel stop, the travel stop in figure 17 is an up and
down travel stop, and the travel stops in figures 18,19, and
20 are up travel stops.
Use the locknuts (key 151, figures 16 and 17), stem (key
150, figure 18), handwheel (key 58, figure 19) or cap screw
(key 177, figure 20) to set the point at which the travel stop
limits travel. Be sure to tighten the locknuts and replace the
cap (key 149, figures 16 and 18; key 247, figure 17) after
setting the travel stop.
Instructions are given below for disassembly and assem­
bly. Perform the disassembly only as far as necessary to
accomplish the required maintenance; then, begin the as­
sembly at the appropriate step.
Key numbers are shown in figures 16 through 20.
1. Remove the cap (key 149 or 247) if the travel stop uses
one. For down travel stops, loosen the locknuts (key 151,
figures 16 and 17) so that the stop is not causing any spring
compression.
Type 667 Size 30-76 & 87
2. Bypass the control valve, reduce loading pressure to at­
mospheric, and remove the tubing or piping from the con­
nection in top of the yoke (key 73, figures 7, 8, and 9).
3. For down travel stops, turn the spring adjuster (key 74,
figures 7,8, and 9) out of the yoke toward the stem connec­
tor (key 31) to relieve all the compression in the spring (key
18).
4. For style 11 travel stops (figure 17), unscrew the cap
screws (key 161), and make sure that the guide plate (key
157) can turn between the handwheel body (key 148) and
the mounting plate (key 158).
5. Use a wrench on the nuts (key 151) to unscrew the ex­
tension rod (key 150). Remove the rod, the handwheel
body (key 148), and the attached parts.
6. Unscrew the hex nuts and cap screws (keys 14 and 13,
figures 7,8, and 9) from the diaphragm casings. Lift off the
upper diaphragm casing (key 1, figures 7,8, and 9) and, for
the style 11 travel stop, the mounting plate (key 158). For
styles 10, 12 and 13, the travel stop assembly will be re­
moved with the casing.
7. Note and record the position of travel stops (key 152)
relative to the cap screws (key 154) for use in assembly.
Unscrew the travel stops and cap screws, and remove ei­
ther the mounting plate (key 158) or the handwheel body
(key 148) and attached parts.
8. Separate the stem (key 150) and screw (key 160, figure
17) from the handwheel body.
9. Before reassembling, lubricate parts indicated by key
239 in figures 16 through 20. Use lubricant (key 239 or
equivalent).
10. Reassemble parts in the reverse order of removal.
11. When replacing the cap screws (key 154) and, if used,
the travel stops (key 152), be sure to return them to their
original position as recorded in step 6.
C A U T IO N
Over-tightening the diaphragm cap screws
and nuts (keys 13 and 14), figures 7,8, and
9 can damage the diaphragm. Do not ex­
ceed 20 Ibf •ft (27 N • m) torque.
12. Install the cap screws and nuts (keys 13 and 14, fig­
ures 7,8, and 9) and finger tighten. Tighten the diaphragm
cap screws and nuts to 20 Ibf •ft (27 N • m) torque in a criss­
cross pattern.
15
Type 667 Size 30-76 & 87

13. Return the spring adjuster (key 74, figure 7, 8, and 9)
to its original position. Re-adjust the travel stop.
Parts Ordering
Kits for Top-Mounted Handwheels
R E T R O F IT KIT IN C L U D E S P A R T S T O A D D A T O P -M O U N T E D
H A N D W H EEL. KIT N U M B E R 1 IN C L U D E S T H E H A N D W H E E L
A S S E M B L Y ONLY. KIT N U M B E R 2 IN C L U D E S KIT N U M B E R 1
A N D A N E W D IA P H R A G M C A S E TH AT IS R E Q U IR E D TO
M O U N T T H E H A N D W H E E L A SSE M B L Y .

Description Part Number

Each actuator has a serial number stamped on the name­ KIT 1

S IZ E 30 30B3940X102
plate. Always mention this number when corresponding 39B3940X022
S IZ E S 34
with the Fisher sales office or sales representative regard­ S IZ E S 40 39B3940X042
ing technical information or replacement parts. Also, refer­ S IZ E S 45 & 50 33B9224X012
S IZ E S 46, 60, A N D 76 33B9224X012
ence the complete 11 -character part number of each need­
S IZ E S 70 & 87 C V8060X0012
ed part as found in the following Parts Kits and Parts List
sections. KIT 2
S IZ E 30 30B3940X052
S IZ E S 34 30B3940X062
S IZ E S 40 30B3940X092

Parts Kits S IZ E S 45 & 50

S IZ E S 46, 60 A N D 76
33B9224X022
33B9224X032
S IZ E S 70 & 87 C V8060X0022

Kits for Side-Mounted Handwheels Actuator Repair Kits

P A R T S KIT IN C L U D E S K E Y S 8, 9, A N D 70.
Key Description Part Number O -R IN G M A T E R IA L I S NITRILE, A N D G A S K E T
M A T E R IA L IS C O M P O SIT IO N .
R E T R O F IT KIT IN C L U D E S P A R T S T O A D D A S ID E -M O U N T E D H A N D ­
Key Description Part Number
W H EEL.
S IZ E 34 P U S H -D O W N -T O -C L O S E 30A 8778X0E2
S IZ E 34 P U SH -D O W N -T O -O P E N 30A8778X0F2 S IZ E 30 R667X000302
S IZ E 40 P U S H -D O W N -T O -C L O S E 30A 8778X0G 2 S IZ E 34 & 40 R667X000402
S IZ E 40 P U SH -D O W N -T O -O P E N 30A8778X0H 2 S IZ E 45 T H R O U G H 60 R667X000502
S IZ E 45 & 46 P U S H -D O W N -T O -C L O S E 40A8779X0A 2 S IZ E 70 & 87 R667X000702
S IZ E 45 & 46 P U SH -D O W N -T O -O P E N 40A8779X0B 2 S IZ E 76 R667X000762
S IZ E 50 & 60 P U S H -D O W N -T O -C L O S E 40A8779X0C 2
S IZ E 50 & 60 P U SH -D O W N -T O -O P E N 40A8779X0D 2

16
'I

Type 667 Size 30-76 & 87

Key Description Part Number Qty

CAST IRO N
Actuator Assembly S IZ E 30 2E880419042 1
S IZ E 34 A N D 40 3 E 8 8 0 5 19042 1
Key Description Part Number Qty S IZ E 45 & 50 2E831519042 1
S IZ E 46 & 60 2E847519042 1
1 U P P E R D IA P H R A G M C A S IN G [STEEL, Z IN C P L A T E D (ZN PL)] S IZ E 70 & 87 T O 3 IN. (76 mm) T R A V E L 2N 127019042 1
S IZ E 30 2E800728992 1
S IZ E 34 & 40 2E6 81428992 1 S IZ E 70 & 87 4 IN. (102 mm) T R A V E L 10A2421X012 1
S IZ E 45 & 50 3E844628992 1 S IZ E 70 & 87 T Y P E 667-4 10A2421X012 1
S IZ E 46, 60 & 76 3E846728992 1 W CB STEEL
S IZ E 70 & 87 2 N 127828992 1 S IZ E 30 2H 510922012 1
W /TO P-M O U N TED H A N D W H E E L S IZ E 34 & 40 3H511122012 1
S IZ E 30 2E792225062 1 S IZ E 45 & 50 2H 511322012 1
W /TOP-MTD H A N D W H E E L O R S T Y L E 11 T R A V E L S T O P S IZ E 46 & 60 2H 511522012 1
S IZ E 34 & 40 2E806325062 1 S IZ E 70 & 87 2N 757522012 1
S IZ E 45 & 50 3E8 31625062 1
S IZ E 46, 60 & 76 2E847425062 1 7* BU SH IN G , S E A L
S IZ E 70 & 87 2 N 127125062 1 BRASS
W /STY LE 10 O R 13 T R A V E L S T O P S IZ E 30 1E791214012 1
S IZ E 30 2E792225062 1 S IZ E 34 & 40 1E682814012 1
W /STY LE 10 O R 12 T R A V E L S T O P S IZ E 45 T H R O U G H 60 1E845714012 1
S IZ E 34 & 40 2E806325062 1 S IZ E 70, 76 & 87 1N1316X0052 1
S IZ E 45 & 50 3E8 31625062 1 S4 16 00 [416 S T A IN L E S S S T E E L (SST)]
W /STY LE 10,12, O R 13 S T O P S IZ E 30 1E7912X0012 1
S IZ E 46, 60 & 76 2E847425062 1 S IZ E 34 & 40 1E6828X0012 1
W /STY LE 12 S T O P O R R E V E R S E VALVE S IZ E 45 T H R O U G H 60 1E8457X0012 1
S IZ E 70 & 87 2N 127125062 1 P T F E W /25% G L A S S
W /STY LE 14 T R A V E L S T O P S IZ E 70, 76 & 87 1N1316X0042 1
S IZ E 30 2F486225062 1
S IZ E 34 & 40 2F753428992 1 8* O -R IN G
S IZ E 45 & 50 3F860628992 1 N IT R ILE
S IZ E 46, 60 & 76 1K131025062 1 S IZ E 30 1E591406992 2
S IZ E 34 & 40 1D237506992 2
2 TRAVEL ST O P SP A C ER S E E F O L L O W IN G T A BLE S IZ E 45 T H R O U G H 60 1C562206992 2
S IZ E 70, 76 & 87 1E736906992 2
3* D IA P H R A G M FLU O RO ELASTO M ER
M O L D E D N ITRILE/N YLO N S IZ E 30 1E5914X0062 2
S IZ E 30 2E800002202 1 S IZ E 34 & 40 1D237506382 2
S IZ E 34 & 40 2E669902202 1 S IZ E 45 T H R O U G H 60 1N285406382 2
S IZ E 45 & 50 2E859602202 1
S IZ E 46, 60 & 76 2E859802202 1 9* O -R IN G
S IZ E 70 & 87 2 N 130902202 1 N IT RILE
FLU O RO ELASTO M ER/PO LYESTER S IZ E 30 T H R O U G H 40 1C415706992 1
S IZ E 30 1K7982X00A 2 1 S IZ E 45 T H R O U G H 87 1E845806992 1
S IZ E 34 & 40 1F3620X00A2 1 FLU O R O ELASTO M ER
S IZ E 45 & 50 1J381902402 1 S IZ E 30 T H R O U G H 40 1C4157X0032 1
S IZ E 46, 60 & 76 1R7728X00A 2 1 S IZ E 45 T H R O U G H 87 1E8458X0022 1
M O L D E D S I L IC O N E / P O L Y E ST E R
S IZ E 30 2E8000X0022 1 12 SC R E W , CAP, H E X H D
S IZ E 34 & 40 2E6699X0042 1 S T A N D A R D H A N D W H EEL, T R A V E L S T O P S T Y L E 13, ADJ.
S IZ E 45 & 50 2E8596X0012 1 U P S T O P S T Y L E 14, FOR:
S IZ E 46, 60 & 76 2E8598X0012 1 S IZ E 30
S IZ E 70 & 87 2 N 1309X0012 1 1/4, 5/16, & 11/16-INCH (6, 8, & 17 mm)
TRAVEL 1A8678X0012 1
4 U P P E R D IA P H R A G M PLATE 7/16, 5/8, & 3/4-INCH (11, 16, & 19 mm)
A L U M IN U M [200°F (93°C) M A XIM U M ] TRAVEL 1B227523052 1
S IZ E 30 31B2028X012 1 3/8, 7/16, 1/2, 9/16, & 5/8-INCH (10, 11, 13,14, & 16 mm)
S IZ E 34 & 40 31B2029X012 1 TRAVEL 1A 8678X0032 1
S IZ E 45 & 50 41B2030X012 1 11/16 & 3/4-INCH (17 & 19 mm)
S IZ E 46, 60 & 76 41B2031X012 1 TRAVEL 1B2275X0022 1

17
'Recommended spare parts
Type 667 Size 30-76 Jk 87

Figure 7. Type 667 Actuator Sizes 30 through 60

18
 Type 667 Size 30-76 & 87

S0ASS96-E

Figure 8. Type 667 Size 70 Actuator

Key Description Part Number Qty Key Description Part Number Qty
13 HEX HD C A P S C R EW (STEEL, ZN PL) 19 SEAT, LO W ER SPRING
SIZE 30 1E760324052 12 G 10300 (STEEL, ZN PL)
SIZE 34 & 40 1E760324052 16 SIZE 30 1U425623122 1
SIZE 45 & 50 1A675124052 20 SIZE 34 & 40 1R179923122 1
SIZE 46, 60 & 76 1A675124052 24 SIZE 45 TH R O U G H 60 1R180023122 1
SIZE 70 & 87 1A582824052 28 C A S T IRON
STANDARD
14 HEX N U T (STEEL, ZN PL) SIZE 70, 76 & 87 1N129619052 1
SIZE 30 1A 346524122 12 W C B STEE L
SIZE 34 & 40 1A346524122 16 STAN D AR D
SIZE 70 & 87 1N757722012 1
SIZE 45 & 50 1A 346524122 20 C A S T IRON
SIZE 46, 60 & 76 1A346524122 24 W /H A N D W H E E L
SIZE 70 & 87 1A346524122 28 SIZE 70, 76 & 87 1N887119042 1

17 V E N T AS S E M B LY 27 EX TE N SIO N RO D C O N N (STEEL, ZN P L)‘

A LL S IZES 17A5515X012 1 W /T O P -M O U N T E D H AN D W H EE L
SIZE 30 1F118824092 1
18 SPR IN G SEE FO LLO W IN G TABLE W /TO P -M TD H A N D W H E E L OR STY LE 11
SIZE 34 & 40 1F135924092 1

19
 60AM 00-E

Figure 9. Type 667 Size 87 Actuator

Key Description Part Number Qty Key Description Part Number Qty

27 E X TE N SIO N ROD C O N N (STEEL, ZN PL) (CONT.) 30 HEX HD C AP S C R E W (STEEL, ZN PL)

SIZE 45 T H R O U G H 60 & 76 1F119424092 1 SIZE 30 ‘ 1D 529824052 6
STEEL, ZN PL SIZE 34 & 40 1A368424052 6
W /T O P -M O U N T E D H AN D W H EE L SIZE 45 T H R O U G H 60 & 76 1A368424052 8
SIZE 70 & 87 T O 3 IN. (76 m m) TR AVEL 1N838331012 1 SIZE 70 & 87 1N129328992 12
SIZE 70 & 87 W /4 IN. (102 m m) TR AVE L 11A 8130X 012 1

20
 Type 667 Size 30-76 & 87

Key Description Part Number Qty Key Description Part Number Qty
31 STEM C O N N E C TO R AS SE M B LY (STEEL, ZN PL) 64 LO W ER D IAP H R AA G M C AS IN G (STEEL) (Cont.)
STAN D A R D SIZE 45 & 50 3E845325062 1
SIZE 30 & 34 18A1243X012 1 SIZE 46, 60 & 76 3E 847725062 1
SIZE 40 18A1668X012 1 SIZE 70 & 87 2 N 131025062 1
SIZE 45 & 46 18A1671X012 1 W / 1/2 N PT C O N N E C TIO N
SIZE 50 & 60 18A1672X012 1 SIZE 30 2H 3822X 00A2 1
S IZ E 70 & 76 18A1675X012 1 SIZE 34 & 40 2K506725062 1
S IZ E 87 18A1825X012 1 SIZE 45 & 50 2H 3081X 00A2 1
W /S ID E -M O U N T E D H AN D W H EE L SIZE 46 & 60 2F803325062 1
SIZE 34 1F659225142 1
SIZE 40 1F659125142 1 69 NUT, HEX, JAM (STEEL ZN PL)
SIZE 45 & 46 2F1678000A2 1 STANDARD
SIZE 50 & 60 2 F 1672000A2 1 SIZE 45 1A353724122 2
SIZE 70 3/4 TH R O U G H 3 IN. (19 TO 76 mm) SIZE 40 & 46 1A353724122 1
TRAVEL 18A1678X012 1 SIZE 50 T H R O U G H 70 & 76 1A351124122 1
SIZE 70 3/4 TH R O U G H 4 IN. (19 T O 102 mm) 1 IN. (25.4 m m) VALVE STEM
TR AVEL 2 1 A8254X012 1 SIZE 87 1C635224122 2
SIZE 76 18A1678X012 1 1-1/4 (31.8 m m) VALVE STEM
SIZE 87 1 IN. (25.4 m m) VALVE STEM 18A1825X012 1 SIZE 87 0W 073524122 2
S IZ E 87 1-1/4 (31.8 m m) VALVE STEM 18A1833X012 1
W /P M V PO SITIO NER 70* G AS KET
S IZ E 70 3/4 TO 4 IN. (19 T O 102 mm) C O M P O S ITIO N [UP TO 450°F (232°C)]
TR AVEL 11B2000X012 1 SIZE 30 TH R O U G H 40 1E801204022 1
SIZE 45 TH R O U G H 60 & 76 1E845404022 1

32 TR AVE L INDICATOR SC ALE SEE FOLLO W IN G TABLE 70* O-RING

NITRILE
33 SCR EW , SELF TAPPING SIZE 70 & 87 1D 269106992 1
STAIN LE SS STEEL
STANDARD 71 LO W ER D IAP H R AG M PLATE
SIZE 30 TH R O U G H 46 1E793238992 2 ZINC
SIZE 50 TH R O U G H 87 1E831338992 2 SIZE 30 1E791344022 1
SIZE 34 & 40 1E682744022 1
33 SC R EW , M ACH, FILL HD (STEEL, PLATED) SIZE 45 T H R O U G H 60 & 76 1E845544022 1
W /H A N D W H E E L STEE L
SIZE 45 & 46 1B992528992 2 SIZE 34 & 40 1F885824092 1
SIZE 70, 76 & 87 1A340628982 2 SIZE 45 T H R O U G H 60 1F890924092 1
STAN D A R D C O N STR U C TIO N
34 DISC, TR A V E L INDICATOR (SST) SIZE 70 & 87 T O 3-IN . (76 m m) TR AVEL 1N131524092 1
STAN D A R D STAN D A R D O R W /S ID E -M T D H AN D W H EE L
SIZE 30 & 34 1E793138992 1 SIZE 70 & 87 W /4-IN . (102 m m) TRAVEL 1V7826X0012 1
SIZE 40 T H R O U G H 46 1E807538992 1
SIZE 50 & 60 1E832838992 1 72 RING, SN AP
SIZE 70 & 76 1B971838992 1 S30200 (302 SST)
SIZE 87 10A8487X012 1 STANDARD
W /S ID E -M O U N T E D H AN D W H EE L SIZE 30 T H R O U G H 40 1E801337022 1
SIZE 34 1E793138992 1 SIZE 45 T H R O U G H 87 1E845638992 1
SIZE 40 1E807538992 1
SIZE 60 & 70 1E832838992 1 73 YOKE
SIZE 76 1B971838992 1 C A S T IRON
W /T Y P E 304 SW ITCH M O U N TIN G BOSS UNTAPPED
SIZE 30 & 34 10A0038X012 2 SIZE 30 3E 801419042 1
SIZE 40 T H R O U G H 46 1N253936012 2 SIZE 34 2E 884619042 1
SIZE 50 & 60 1N254036012 2 SIZE 40 3E 820819042 1
SIZE 45 & 46 3E 900819042 1
39 N AM EPLATE SIZE 50 & 60 3E 845919042 1
STAIN LE SS S TEE L SIZE 70 3N 130319042 1
A L L S IZES 12B6508X0A2 1 SIZE 76 42B5909X 012 1
SIZE 87 3N 664219042 1
40 SCR EW , DRIVE M O U N TIN G BO S S U N TAPPED W /H A N D W H E E L
STAIN LE SS STE E L SIZE 70 & 76 4N 890119042 1
A LL SIZES 1A368228982 4 SIZE 87 T O 3 IN. (76 mm) TR AVEL 4 N 8 8 6 6 19042 1
M O U N TIN G BO S S T APP ED ‘
64 LO W ER D IAP H R AG M C A S IN G (STEEL) SIZE 30 3L921419042 1
STANDARD SIZE 34 3L9203X 0012 1
SIZE 30 2E801125062 1 SIZE 40 3L921619042 1
SIZE 34 & 40 2E682625062 1 SIZE 45 & 46 3L894219042 1

21
'Recommended spare parts
Type 667 Size 30-76 & 87

NOTE:
THE TOP MOUNTED HANDWHEEL IS NOT DESIGNED FOR USE UNDER
HEAVY LOAD OR FREQUENT USE.
30B3S40-C

Figure 10. Top-Mounted Handwheel Assembly for Size 30 through 40 Actuators

Description Part Number Qty Key Description Part Number Qty

i'O K E (C o n t) 73 YO K E (Cont.)
3L921919042 1 SIZE 45 & 46 3L921822012 1
SIZE 50 & 60
1 SIZE 50 & 60 3L922022012 1
SIZE 70 3 N 130419042
42B6795X012 1 SIZE 70 3N 130722012 1
SIZE 76
1 SIZE 87 3N 758822012 1
SIZE 70 T Y P E 667-4 31A7392X012
SIZE 87 3N 664319042 1
SIZE 87 T Y P E 667-4 31A3813X012 1 74 SPR IN G AD JU STE R (STEEL, ZN PL)
SIZE 30 1E801724102 1
M O U N TIN G BO S S TAPPED W /H A N D W H E E L
1 SIZE 34 & 40 1E821024102 1
SIZE 70 & 76 4N 890219042
SIZE 45 TH R O U G H 60 1E 846224102 1
SIZE 70 T Y P E 667-4 4N 890119042 1
1 SIZE 70 & 87 W /H A N D W H E E L 1N886924392 1
SIZE 87 4N 889019042
SIZE 70 & 87 T Y P E 667-4 11A3811X012 1
SIZE 87 T Y P E 667-4 4N 889019042 1
SIZE 70 & 87 TYPE 667-4 W /H A N D W H E E L 1N886924392 1
W C B (STEEL)
M O U N TIN G BO S S UNTAPPED SIZE 76
3K 815622012 1 M AX SPRING A D JU S TM E N T (ADJ)
SIZE 30
1 2-IN C H (51 mm) 1N 131824102 1
SIZE 34 2H 787122012
1 2.5-IN C H (64 mm) 1N 909524502 1
SIZE 40 3H 787322012
3H 787522012 1 3.5-IN C H (89 mm) 1U1079X00A2 1
SIZE 45 & 46
3K 830322012 1 M AX S P R IN G ADJ W /S ID E -M O U N T E D H AN D W H EE L
SIZE 50 & 60
3N 130622012 1 2.25-IN C H (57 mm) 1N886924392 1
SIZE 70
3N 758722012 1 2.75-IN C H (70 mm) 1V176624092 1
SIZE 87
M O U N TIN G BO S S TAPPED
SIZE 30 3L921522012 1 NUT, HEX (STEEL, ZN PL)
SIZE 34 3L9202X 0012 1 STAN D AR D
3L921722012 1 SIZE 30 & 34 1P131224142 2
SIZE 40
SIZE 40 & 46 1A413224122 1

22
 Type 667 Size 30-76 & 87

Key Description Part Number Qty Key Description Part Number Qty
75 NUT, H EX (Cont.) 144 ACTU ATO R STEM (Cont.)
SIZE 50 T H R O U G H 76 1A375424122 1 SIZE 87 22A 1963X012 1
T Y P E 667-4 W /H A N D W H E E L
76 NUT, SP EE D , TW IN SIZE 70 23A 1793X012 1
STAIN LE SS S TEE L SIZE 87 23A 0125X012 1
STANDARD S31600 (316 SST)
SIZE 30 & 34 1E793938992 1 STANDARD
S IZ E 40 T H R O U G H 46 1E808438992 1 SIZE 30 1N429135162 1
SIZE 50 T H R O U G H 87 1E833538992 1 SIZE 34 1N429235162 1
SIZE 40 1N429335162 1
77 STOP, TR AVEL (STEEL, ZN PL) SIZE 45 1N429535072 1
(U SE FOR P U S H -D O W N -TO -O P EN ) SIZE 4 6 & 50 1N429435072 1
SIZE 30 T H R O U G H 40 1H493524092 2 SIZE 60 1N429535072 1
SIZE 45 T H R O U G H 60 1H494324092 2
227 W A SH ER ,P LAIN (STEEL, ZN PL)
78 BU SH IN G , PIPE, HEX (STEEL, P L A T E D ) W /TYPE 304 SW ITCH
SIZE 70 & 87 1C379026232 1 SIZE 40 T H R O U G H 46 1E658828982 2
C AR BO N STEE L
79 SCR EW , M ACH, FLAT HD (STEEL PLATED) W /T O P -M O U N T E D H A N D W H E E L
SIZE 87 1H736528982 2 SIZE 70 T O 3-IN. (76 m m) TRAVEL 1A521228992 1
W /TYPE 304 SW ITCH
81 SCR EW , M ACH, RD HD (C AR B O N STEEL, PLATED) SIZE 60 1A375728992 2
W /S ID E -M O U N T E D H AN D W H EE L SIZE 70 & 76 1A375728992 1
SIZE 45 & 46 1A331928982 2

82 INDICATOR, TRAVEL, AD A P TO R (BR ASS) 228 STEM DISC SPACER [S 41600 (416 SST)]
W /S ID E -M O U N TE D H A N D W H E E L , W /TYPE 304 SW ITCH
SIZE 45 & 46 1F548214012 2 SIZE 70 TO 3-IN (76 m m) TR AVEL 1N952635132 1
SIZE 76 1N952635132 1
83 W A SH ER , PLAIN
C A R B O N STEEL-PLATED 237 LUBRICANT, LU BR IPLATE MAG-1
SIZE 70, 76 & 87 W /H A N D W H E E L 1E873028992 2 OR EQUIVALENT
BRASS NO T FU R N ISH E D W ITH ACTUATO R —

SIZE 70, 76 & 87 W /H A N D W H E E L 1F565618992 2

238 SEALANT, PERM ATEX #2,
89 S P R IN G C ASE AD A P TO R (C A S T IRON) FO R M -A-G ASK ET
STANDARD NO T FU R N ISH E D W ITH ACTUATO R —

SIZE 70 & 87 T Y P E 667-4 2N 889419042 1

W /H A N D W H E E L
SIZE 70 & 87 T Y P E 667-4
90 SCR EW , C A P (STEEL, ZN PL)
SIZE 70 & 87 T Y P E 667-4
239 LUBRICANT, A N T I-S IZE LUB-3
3R 675819042 1 N E V E R -S E E Z O R EQ U IVALEN T
NO T FU R N ISH E D W ITH ACTUATO R
1N 872428992 12

102 PLUG, PIPE, H EX HD (STEEL) Top-Mounted Handwheel (Figures 10,

W / 1/2 N PT C O N N E C TIO N
SIZE 30 T H R O U G H 60 1A 767524662 1 11, And 12)
144 AC TU ATO R STEM (C H R O M IU M PLATED STEEL)
STAN D A R D
SIZE 30 2 E 8016X0022 1 58 H AN D W H EE L (C AST IRON)
SIZE 34 3E 8847X 0012 1 SIZE 30 1F119119042 1
SIZE 40 2E 8209X 0042 1 SIZE 34 & 40 1F115819042 1
SIZE 45 & 46 2J3328X 0042 1 SIZE 45 T O 60 & 76 1F119819042 1
SIZE 50 & 60 2E 8461X 0042 1 SIZE 70 & 87 2N 837919042 1
SIZE 70 & 76 2N 131724222 1 STEE L
SIZE 87 2N 664724222 1 SIZE 34 & 40 1H551922012 1
W /S ID E -M O U N T E D H AN D W H EE L SIZE 45 T O 60 & 76 1H552122012 1
SIZE 34 2E 8209X 0042 1 SIZE 70 & 87 23B 9744X012 1
SIZE 40 2F3259X0012 1
SIZE 70 3-IN. (76 m m) TRAVEL 2N 890624222 1 60 RETAINER RING (STEEL, ZN PL)
SIZE 70 TO 4-IN . (102 m m) TR AVEL 21A9816X 012 1 SIZE 34 & 40 1A911628992 1
SIZE 76 23B 7066X 012 1 Size 45 To 60 & 7 6 •
SIZE 87 3-IN. (76 m m) TRAVEL 2N 889624222 1 8-IN C H (203 m m) H AN D W H EE L 1F120028992 1
SIZE 87 TO 4-IN . (102 m m) TR AVEL 22A 1501X012 1 14-INCH (356 m m) H AN D W H EE L 1N837328992 1
T Y P E 667-4 STANDARD SIZE 70 & 87
SIZE 70 21A3812X 012 1 14-INCH (356 m m) H AN D W H EE L 1N837328992 1

23
Type 667 Size 30-76 & 87

Key Description Part Number Qty Key Description Part Number Qty

148 H A N D W H E E L BO DY 161 C AP S C R EW (Cont.)

C A S T IRON SIZE 45 TO 60 & 76 1A341824052 8
SIZE 30 T O 40 27A 9446X 012 1
SIZE 45 TO 60 & 76 27A 9444X012 1 166 C A S TLE N U T (PL STEEL)
SIZE 70 & 87 2N 837719022 1 SIZE 30 TO 40 1K193424122 1
STEE L ■ SIZE 45 TO 87 1F120224122 1
SIZE 34 & 40 27A 9636X 012 1
SIZE 45 TO 60 & 76 27A 9445X 012 1 167 G R O O V E PIN
316 SST
150 E X TE N SIO N ROD (416 SST) SIZE 30 TO 40 1H484028992 1
SIZE 30 29A9896X 012 1 STEE L
SIZE 34 & 40 29A 9897X 012 1 SIZE 45 TO 87 1F119728992 1
SIZE 45 T O 60 & 76
U N D E R 4000 LB (17,000 N • M) 23B9217X012 1 178 M AC H IN E S C R E W (PL STEEL)
4000 T O 6000 LB (17,000 TO 26,700 N M) 23B9219X012 1 SIZE 70 & 87 1B877428992 4
SIZE 45 TO 60 P-2 29A 9900X012 1
SIZE 70 & 87 179 LO C KW A SH E R (P L STEEL)
3/4 IN. (19 mm) T H R O U G H SIZE 70 & 87 1A329128982 4
3 IN. (76 m m) TR AVEL 24B0242X012 1
4 IN. (102 m m) TR AVE L 24B 0243X 012 1 180 T H R U S T BEARING (STEEL)
SIZE 30 T O 40 14A5444X012 1
152 TR AVEL STO P (STEEL, ZN PL) SE E FO LLO W IN G TABLE SIZE 45 TO 76 1N838099012 1
SIZE 70 AN D 87 13B9737X012 1
154 CAP S C R E W (PL STEEL)
SIZE 30 TO 40 1D529824052 3 181 T H R U S T RAC E (STEEL)
SIZE 45 TO 60 & 76 1A368424052 4 SIZE 30 T O 40 14A5446X012 2
SIZE 70 & 87 1N129328992 9 SIZE 45 T O 76 1N838199012 2
SIZE 70 AN D 87 13B9737X012 2
156 V E N T A S SE M B LY
SIZE 30 T O 60 & 76 27A5516X 012 1 182 BE AR IN G RETAINER (STEEL, ZN PL)
17A6572X 022 1 SIZE 30 TO 40 19A9895X012 1
SIZE 70 & 87
SIZE 45 T H R O U G H 60 & 76 19A9898X012 1
157 G U ID E PLATE (STEEL) SIZE 70 & 87 13B9741X012 1
SIZE 30 TO 40 1F116428992 1
SIZE 45 T O 60 & 76 1F119528992 1 183 PIPE NIPP LE (STEEL,GALV, ZN PL)
1N 837528982 1 SIZE 70 & 87 1K201526022 1
SIZE 70 & 87

158 M O U N TIN G PLATE 239 LUBRICANT, A N TI-S E IZE LUB-3 - --

C A S T IRON N E V E R -S E E Z O R EQUIVALENT
SIZE 30 T O 40 1F116519042 1 NO T FU R N ISH E D W ITH HAN DW HEEL
SIZE 45 T O 60 & 76 1F119319042 1
STEE L, ZN PL 247 H A N D W H E E L C AP
SIZE 34 & 40 1H552622012 1 PLASTIC
SIZE 45 TO 60 & 76 1H550922012 1 FOR C A S T IRON HAN DW HEEL
SIZE 30 27A 8621X 012 1
159 LO C K NUT SIZE 34 TO 60 & 76 2 7A 8622X 012 1
BRASS FOR S TEE L HAN DW HEEL
SIZE 30 18A1271X012 1 SIZE 34 T O 60 & 76 2 8 A 1 609X012 1
SIZE 34 & 40 18A 2302X012 1 FOR C A S T IRON O R S TEE L H AN D W H EE L
SIZE 45 TO 60 & 76 18A 2302X 012 1 SIZE 70 & 87 37A 8623X 012 1
STEEL, ZN PL
SIZE 70 & 87 1N 837824102 1 253 SPACER, H AN D JAC K
C A S T IRON
H AN D W H EEL S C R E W (BR O N ZE) SIZE 45 TO 76 23B 9218X 012 1
160
SIZE 30 27A9639X 012 1 STEE L
SIZE 34 & 40 27A9640X 012 1 SIZE 45 TO 76 23B9221X 012 1
SIZE 45 T O 60 & 76 27A9637X 012 1
SIZE 45 TO 60 P-2 27A 9638X 012 1
SIZE 70 & 87 1N 837414042 1 Side-Mounted Handwheel (30-60,
Figures 13 and 14)
161 C AP S C R E W (P L STEEL)
C A S T IRON H A N D W H E E L BO D Y
SIZE 30 T O 40 1A 344924052 6 51 H AN D W H EE L •
S TEE L H A N D W H E E L BO D Y C A S T IRON
SIZE 34 & 40 1N568232982 6 SIZE 34 & 40 2 D 3 5 8 5 19052 1
C A S T IRON & S T E E L H A N D W H E E L BO D IE S SIZE 45 TO 60 2D 405019042 1

24
 Type 667 Size 30-76 & 87

(%

25
Figure 12. Top-Mounted Handwheel Assembly for Size 70 and 87 Actuators
 Type 667 Size 30-76 & 87

Figure 13. Side Mounted Handwheel Assembly for Size 34 and 40 Actuators

Key Description Part Number Qty Key Description Part Number Qty
54 H EX JA M NUT 143 M O U N TIN G BOLTS
PL S TEE L STE E L
SIZE 34 & 40 1A352424112 1 SIZE 34 & 40 10A8522X012 2
SIZE 45 TO 60 1A352424122 1 SIZE 45 & 46 18A9147X012 2
SIZE 50 & 60 1F155624092 2
55 BALL
S TEE L 1A342732992 1 144 H EX N UT
PL STEE L
56 S P R IN G SIZE 34, 40, 50 & 60 1A375324122 4
BR O N ZE 0D 005916012 1 SIZE 45 & 46 1A 375324122 2

132 O PER ATIN G N U T (STEEL) 145 H AN D W H EE L S C R EW

LE FT-H AN D (D IR EC T-AC TIN G VALVE) BR O N ZE
SIZE 34 & 40 1F659024092 1 LEFT-HAND (D IR EC T-A C TIN G VALVE)
SIZE 45 T O 60 2F548524092 1 SIZE 34 & 40 1F6584000A2 1
R IG H T-H A N D (R EVE R SE -A C TIN G VALVE) SIZE 45 T O 60 1F548614052 1
SIZE 34 & 40 1F658924092 1 R IG HT-HAND (R E V E R S E -A C TIN G VALVE)
SIZE 45 T O 60 2F548424092 1 SIZE 34 & 40 1F6583000A2 1
SIZE 45 T O 60 1F548714052 1
136 BE AR IN G RETAINER
STE E L 146 LEVER & PIN AS SEM BLY
SIZE 45 T O 60 1D 385224092 1 STEE L
R IG H T-H A N D SIDE
142 H A N D W H E E L BO DY SIZE 34 & 40 ‘ 1F6614000A2 1
C A S T IRON SIZE 45 TO 60 1F1541000A2 1
SIZE 34 & 40 3F6572000A 2 1 LEFT-H AN D SIDE
SIZE 45 T O 60 3F1446000A2 1 SIZE 34 & 40 1F6613000A2 1
SIZE 45 TO 60 1F1539000A2 1

27
 □ APPLY LUBRICANT
40A|77t*0

, i
Figure 14. Side-Mounted Handwheel Assembly for Size 45 and 60 Actuators

Key Deecriptlon Part Number Qty Key Description Part Number Qty

147 HEX JA M N U T (P L STEEL) 155 SPACER (STEEL)

S IZ E 34 & 40 1A352224122 2 SIZE 34 & 40 1F 658224092 2
SIZE 45 T O 60 1F162524092 2
148 D O W E L PIN (STEEL, ZN PL)
SIZE 34 T O 60 1D419828992 2 156 S C R E W (P L STEEL)
SIZE 3 4 & 40 1D 980628982 2
149 W A S H E R (P L S TEEL) 1A 518925072 1 SIZE 45 TO 60 1F157624052 2

150 LO C KW A SH E R (P L S TEEL) 1A353828982 1 157 LO C KW A SH E R (P L STEE L) SIZE 34 & 40 1C225628982 2

151 BU S H IN G (P L STEEL) 158 H EX N U T (PL STEEL) SIZE 34 & 4 0 1A345724122 2

S IZ E 34 & 4 0 1F657924092 1 S IZ E 4 5 T O 60 1A341224122 4

152 B A LL BE AR IN G (STEEL) 1D361399012 2 159 PO IN TER M O U N TIN G BOLT (416 SST)

SIZE 3 4 & 4 0 • 1F657835132 1
153 LEVER PIV O T PIN (416 SST) SIZE 4 5 TO 60 1F156535132 1
SIZE 34 & 4 0 1F658135232 1
SIZE 45 T O 6 0 - 1F156235232 1 160 PO IN TER (302 SST) _ 1F157536012 1

154 RETAINING RING (P L S TEEL) 161 M A C H IN E S C R E W (P L STEEL)

SIZE 34 & 40 1F599428982 2 SIZE 3 4 & 40 1A344524052 8
SIZE 45 T O 60 1A903028992 2 SIZE 45 T O 60 1E175828982 1

28
 Type 667 Size 30-76 & 87
Key Description Part Number Qty Key Description Part Number Qty

162 INDICATO R PLATE (A LU M IN U M ) 58 H AN D W H EE L (C A S T IRON) 3H 734319052 1

SIZE 34 & 40 1F936411992 1
SIZE 45 T O 60 1D357411992 1 87 C O VE R BA N D AS S 'Y 1N8879X00A2 1

163 C AP S C R E W (PL STEEL) 89 SPRING C A S E AD A P TO R (C A S T IRON)

SIZE 34 & 40 1C403824052 2 SIZE 70 & 87 2N 889419042 1
S IZ E 45 T O 60 1A344424052 2 SIZE 76 33B8000X012 1

166 U -BO LT (STEEL) 90 C AP S C R E W (STEEL, ZN PL) 1N872428992 12

SIZE 34 & 40 1F657724092 1
SIZE 45 TO 60 1F155524092 1 121 S E T S C R EW (PL STEEL) 1A712228992 2

167 G U ID E BOLT (416 SST) 122 KEY (STEEL) 1N 888025092 1

SIZE 34 & 40 1F657535132 2
SIZE 45 T O 60 1F155235132 2 123 LOW ER S LE EVE (STEEL)
SIZE 70 & 87
168 SET S C R E W (STEEL) 3 IN. (76 mm) TRAVEL 2N 888224092 1
SIZE 34 & 40 1A344724182 1 4 IN. (102 mm) TRAVEL 21A8262X 012 1
SIZE 45 TO 60 1A341528992 1 SIZE 76 2N 888224092 1

169 G R E A S E FITTING 1H306199012 1 125 H AN D W H EE L INDICATOR (SST) 10A2446X012 1

170 H EX N U T (PL STEEL) 127 STOP N UT (STEEL, ZN PL) 1A780528992 1

SIZE 34 & 40 1A341224112 2
SIZE 45 TO 60 1A343324122 2 128 N EEDLE BE AR IN G (STEEL) 1N888599012 1

177 S P R IN G CAP (STEEL) 129 N EEDLE BE AR IN G RAC E (STEEL) 1N888699012 2

SIZE 45 TO 60 1D 385124092 1
130 R O LL PIN (STEEL) 1N 889828992 1
178 M A C H IN E S C R EW (PL STEEL)
SIZE 45 TO 60 1A331928982 2 131 SPR IN G AD JU S TIN G S C R E W (STEEL, ZN PL)
SIZE 70 & 87
244 LUBRICANT, LUBRIPLATE MAG-1 3/4 TO 3 IN (19 TO 76 m m) TR AVEL 1N889724092 1
O R EQUIVALENT 4 IN. (102 m m) TR AVEL 11A9817X012 1
N O T FU R N ISH ED W ITH H AN D W H EE L — SIZE 76 1N889724092 1

244 LUBRICANT, AN TI-S E IZE LUB-3 132 N EED LE BE AR IN G (STEEL) 1N888799012 2

N E V E R -S E E Z O R EQ U IVALEN T
N O T FU R N ISH E D W ITH H AN D W H EE L - -- 133 N EED LE BE AR IN G RACE (STEEL) 1N888899012 4

141 BA LL (STEEL) 1A342732992 1

Side-Mounted Handwheel. Size 70.76 & 142 SPR IN G (BRONZE) 0D 005916012 1
87 (Figure 15)
237 LUBRICANT, LUBRIPLATE MAG-1
O R EQUIVALENT
29 H AN D G R IP (STEEL) 0U 075624092 1 NO T FU R N ISH E D W ITH H AN D W H EE L —

38 H A N D G R IP BOLT (STEEL) 0U 077424092 1 239 LUBRICANT, AN TI-S E IZE LUB-3

N EV ER -SE EZ O R EQUIVALENT
44 W O R M G EA R (BR O N ZE) 2N 886212052 1 NO T FU R N ISH E D W ITH H A N D W H E E L - --

45 BE AR IN G RETAINER FLANGE
C A S T IRON 1N 889219042 1

48 BA C K W O R M RETAINER (STEEL, ZN PL) 1N 888324492 1 Casing-Mounted Travel Stops (Figures

49
16 Throuah 201
FR O N T W O R M RETAINER (STEEL, ZN PL) 1N888424092 1

50 BA LL BE AR IN G (STEEL) 1A339228992 2
58 H AN D W H EE L
51 W O R M S H A FT (STEEL) 2N 886331092 1 C AS T IRON ‘
STYLE 13 UP TR AVEL STOP
52 S E T S C R E W (STEEL) 1A710328992 2 SIZE 30 1F143819052 1
SIZE 34 TH R O U G H 60 1F118119042 1
57 G R E A S E FITTING 1A 926728982 2

29
 / ......\
Type 667 Size 30-76 & 87 S

□ APPLY LUBRICANT
50A6604-F

Figure 15. Size 70, 76, and 87 Actuator with Side Mounted Handwheei Assembly

30
 Type 667 Size 30-76 & 87

Figure 16. Style 10 Down Travel Stop (Casing Mounted)

Figure 17. Style 11 Up Or Down Travel Stop (Casing Mounted)

Key Description Part Number Qty

102 PLUG, PIPE

Key Description Part Number Qtv
S TY LE 12 UP TR AVEL STOP
SIZE 70 & 87 1D 754828982 1 149 TR AVEL STO P C AP (BRASS)
STYLE 10 DOW N TRAVEI STOP
127 HEX N U T (PL STEEL) SIZE 30 TH R O U G H 40 1F597814012 1
STY LE 13 UP TR AVEL STOP SIZE 45 TH R O U G H 60 1H 111114012 1
A LL S IZES 1A 353724122 1 SIZE 70 & 87 1R387614012 1
STYLE 12 UP TR AVEL STO P
148 TR A V E L STO P BO D Y (C AST IRON) SIZE 30 TH R O U G H 40 1F597814012 1
STY LE 10 DO W N TR AVEL STO P SIZE 45 T H R O U G H 60 1F839614012 1
SIZE 30 TH R O U G H 40 1K723519012 1 SIZE 70 & 87 ' 1R387614012 1
SIZE 45 TH R O U G H 60 2K723019012 1 STEE L
SIZE 70 & 87 2U 141819022 1 STYLE 12 UP TR AVEL STOP
STYLE 11 UP & DOW N TR AVE L STOP SIZE 30 T H R O U G H 40 1F597824092 1
SIZE 34 & 40 27A 9446X 012 1
SIZE 45 T H R O U G H 60 27A 9444X 012 1 150 EXTEN SIO N ROD
SIZE 70 & 87 37A 9661X 012 1 S41600 (416 SST)
S TY LE 12 U P TR AVE L STOP STYLE 11 UP & DOW N TR AVEL STOP
SIZE 30 T H R O U G H 40 37A 9437X 012 1 SIZE 34 & 40 28A 1267X022 1
SIZE 45 T H R O U G H 60 37A 9432X 012 1 STEEL, ZN PL
SIZE 70 & 87 37A 9661X 012 1 STYLE 11 UP & DO W N TR AVEL STOP
STYLE 13 UP TR AVEL STOP SIZE 45 TH R O U G H 60 28A 1266X012 1
SIZE 30 W / 1/4 N PT C O N N E C TIO N 37A9437X 012 1
SIZE 30 W / 1/2 N PT C O N N E C TIO N 37A9438X 012 1 150 TR AVEL STO P STEM
SIZE 34 & 40 W / 1/4 N PT C O N N E C TIO N 37A9439X 012 1 S30300 (303 SST)
SIZE 34 & 40 W / 1/2 N PT C O N N E C TIO N 37A9440X 012 1 STYLE 10 DOW N TR AVEL STO P '
SIZE 45 T H R O U G H 60 W / 1/4 NPT SIZE 30 1H330735032 1
C O N N E C TIO N 37A 9432X 012 1 SIZE 34 & 40 1F753635032 1
SIZE 45 TH R O U G H 60 W / 1/2 NPT SIZE 45 TH R O U G H 60 1J232735032 1
C O N N E C TIO N 37A 9434X 012 1 SIZE 70 & 87 1V 7764X00A2 1

31
Type 667 Size 30-76 & 87

Figure 19. Style 13 Up Travel Stop (Casing Mounted)

Key Description Part Number Qty

152 TR AVEL STOP

STY LE 10 A N D 11 TR AVE L STO PS SEE TABLE

153 NUT, HEX (STEEL, ZN PL)

STY LE 10 DO W N TR AVEL STOP
(TOTAL O F 2 R E Q ’D FOR SIZE 30)
Figure 18. Style 12 Up Travel Stop (Casing Mounted) SIZE 30 1A413224122 1
SIZE 30 1A346524122 1
SIZE 34 & 40 1A413224122 2
SIZE 45 TH R O U G H 87 1A 375424122 2

154 SCR EW , CAP, HEX HD (STEEL, ZN PL)

S TY LE 10 DOW N TR AVEL STOP
SIZE 30 TH R O U G H 60 1A368424052 4
Description Part Number SIZE 70 & 87 1N129328992 9
S TY LE 11 UP & DOW N TR AVEL STOP
150 TR AVEL STO P STEM (Cont.) SIZE 34 & 40 1D 529824052 3
BR O N ZE SIZE 45 TH R O U G H 60 1A368424052 4
STYLE 12 UP T R AVE L STO P S T Y LE 12 UP TR AVEL STOP
SIZE 30 T H R O U G H 40 27A9655X012 1 SIZE 30 TH R O U G H 40 1A368424052 6
SIZE 45 T H R O U G H 60 27A9656X012 1 SIZE 45 TH R O U G H 60 1A368424052 8
SIZE 70 & 87 27A9763X 012 1 SIZE 70 & 87 1N129328992 12
STYLE 13 UP T R AVE L STO P S TY LE 13 UP TRAVEL STOP
SIZE 30 27A9652X 012 1 SIZE 30 TH R O U G H 40 1A368424052 6
SIZE 34 & 40 27A 9653X012 1 SIZE 45 TH R O U G H 60 1A368424052 8
SIZE 45 T H R O U G H 60 27A9654X 012 1
155 W A SH ER , LOCK, SP LIT (STEEL)
151 HEX JA M NUT (STEEL, ZN PL) STYLE 10 DO W N TR AVEL STOP
STYLE 10 DO W N TR AVE L STO P SIZE 30 1D716228982 1
SIZE 30 T H R O U G H 40 1A353724122 1 SIZE 34 & 40 1A487828992 1
SIZE 45 T H R O U G H 87 1A351124122 1 SIZE 45 TH R O U G H 60 1A873228992 1
STYLE 11 UP & D O W N TR AVE L STOP SIZE 70 & 87 1A549328982 1
SIZE 34 & 40 1K130824122 2
SIZE 45 T H R O U G H 60 1K130424122 2 156 VENT
STY LE 13 UP TR AVEL STO P STYLE 10 & 12 TR AVE L STO P -
SIZE 30 T H R O U G H 60 18A 2300X012 1 SIZE 30 TH R O U G H 60 27A 5516X012 1
STY LE 14 UP TR AVE L STOP SIZE 70 & 87 17A 6572X022 1
SIZE 30 T H R O U G H 60 1A319224122 1 STYLE 11 UP & DOW N TR AVE L STOP
SIZE 30 TH R O U G H 60 27A 5516X012 1

32
 Type 667 Size 30-76 & 87

Key Description Part Number Qty

159 TR AVEL STOP NUT (BRASS)
STYLE 12 UP TR AVEL STOP
SIZE 45 TH R O U G H 60 18A1272X012 1

160 SCREW , H AN D W H EE L (BRONZE)

STYLE 11 UP & DO W N TR AVEL STOP
SIZE 34 & 40 27A964QX012 1
SIZE 45 TH R O U G H 60 27A 9638X012 1

161 SCREW , CAP, HEX HD (STEEL, ZN PL)

STYLE 11 UP & DOW N TR AVEL STOP
SIZE 34 & 40 1A336924052 6
SIZE 45 TH R O U G H 60 1A341824052 8

162 W A SH ER (PL STEEL)

STYLE 13 UP TR AVEL STOP
A LL SIZES 1A518925072 1

177 TR AVEL STO P SC R EW

S41600 (416 SST)
STYLE 14 UP TR AVEL STOP
SIZE 30 TH R O U G H 40 1F753735132 1
SIZE 45 TH R O U G H 60 1K131135132 1

Key Description Part Number Qty 184 NIPPLE, PIPE, N PT (STEEL Z N PL)
156 V E N T (Cont.) STYLE 10 & 12 T R AVE L STOP
STYLE 13 UP TR AVEL STOP SIZE 70 & 87 1K201526022 1
1/4 N PT C O N N E C TIO N 27A 5516X 012 1 STYLE 13 UP TR AVEL STOP
1/2 N PT C O N N E C TIO N 17A6572X022 1 W / 1/2-IN N PT C O N N E C TIO N
SIZE 30 1A 473526012 1
157 G U ID E PLATE (STEEL) SIZE 34 & 40 1C782526012 1
STYLE 11 UP & DO W N TR AVE L STOP SIZE 45 T H R O U G H 60 1H 392826012 1
SIZE 34 & 40 1F116428992 1
SIZE 45 T H R O U G H 60 1F119528992 1 237 LUBRICANT, LUBRIPLATE MAG-1
OR EQUIVALENT
158 M O U N TIN G PLATE (C A S T IRON) NO T FU R N ISH E D W ITH TR AVEL STOP
STYLE 11 UP & DOW N TR A V E L STOP
SIZE 34 & 40 1F116519042 1 239 LUBRICANT, A N TI-S E IZE LUB-3
SIZE 45 T H R O U G H 60 1F119319042 1 N EV ER -SE EZ O R EQUIVALENT
N O T FU R N ISH E D W ITH H AN D W H EE L
159 NUT, TR AVEL STOP
BRASS 247 TR AVEL STO P CAP, PLASTIC
S TY LE 11 UP & DO W N TR AVE L STOP STYLE 11
SIZE 34 & 40 SIZE 34 TH R O U G H 60 37A8623X 012 1
18A2301X012 1
SIZE 45 TH R O U G H 60 18A2302X012 1
BR O N ZE 284 M O U N TIN G PLATE (STEEL, ZN PL)
STY LE 12 UP T R AVEL STOP STYLE 11 UP & DO W N TR AVEL STOP
SIZE 30 T H R O U G H 40 SIZE 34 & 40 •* 17A9360X012 1
18A2303X012 1
STE E L SIZE 45 TH R O U G H 60 17A9361X012 1
SIZE 30 TH R O U G H 40 18A2303X 022 1

33
Type 667 Size 30-76 & 87

K e y 2. S p a ce r, S te e l, a n d K e y 12 T ra v e l S to p C a p S crew , S te e l
TRAVEL AC TU ATO R SIZE
In c h e s mm 30 34 40 45 T h ro u g h 60 76 70 & 87
— 1U 721324092 1U721324092 --- ... -"-
2
3/16 5 ... . - - —
12 1R4088X0022 1R 4088X0022 ---
2 1R737024092 1U145024092 1U145024092 1U 417824092 - -- --"
1/4 6 1R 4098X0022 —
12 1A8678X0012 1R 4088X0022 1R 4088X0022 ---
1R773024092 1U569824092 1U 569824092 __- ... --"
2
5/16 8 - - - —
12 1A8678X0012 1R 4088X0022 1R 4088X0022 -- -
— - - - ... --- ...
2 1U437224052
11/32 9 ... ... ■-----
12 1A 8678X 0012 ""- _- -
1R767724092 — ___ ... ... -- -
2
3/8 10 ... —
12 1A6857X 0032 -- - ---
2 1R 408724092 1R409324092 1R 409324092 1R 410324092 -- - ---
7/16 11 ... —
12 1A 6857X0032 1R 4088X0022 1R 4088X0022 1R4098X0022

2 1U328924092 1R782324092 1R782324092 1R411424092 --- ---

1/2 13 1R 4098X0022 —
12 1A6857X 0032 1R 4089X0042 1R4089X0042 ---
2 1J830724092 ___ - -- - -- --- "--
9/16 ... ... — —
12 1A6857X 0032 ---
2 1R408624092 1R409424092 1R 409424092 1R 410424092 - "" -- -
5/8 16 1R 4098X0022 --- —
12 1A 6857X0032 1R 4089X0042 1R 4089X0042
2 1U726324092 1U726224092 1U726224092 -- - - -- "--
11/16 17 ... —
12 1B2275X0022 1R 4089X0042 1R 4089X0042 _- -

2 1R408524092 1R409524092 1R 409524092 1R410524092 1R410524092 1R411624092

3/4 19 1R 4098X0022 1R 4098X0022 1R4110X0012
12 1B2275X0022 1R4089X0042 1R 4089X0042
... ___ 1R 927624092 17A4720X012 17A4720X012 —
2
7/8 22 ... ... 1R4099X0022 1R 4099X0022 - - -
12 1U 8659X0022
2 ... 1U866024092 1U866024092 1R411324092 1R411324092 1U803124092
1 25 ... 1R4099X0022 1R4099X0022 1R4111X0012
12 1U 8659X0022 1U8659X0022
2 ___ 1R409624092 1R 409624092 1R410824092 1R410824092 1R 411524092
1-1/8 29 ... 1R4099X0022 1R 4099X0022 1R4111X0012
12 1R 4091X0032 1R 4091X0032
___ . . _ 1U137724092 1U164824092 — —
2
1-3/16 30 ... ... 1R 4092X0022 1R 4099X0022 ... ---
12
2 _ ... 11A2680X012 1U 143224092 — —
1-1/4 32 ... ... 1R4101X0022 ... - --
12 1R 4092X0022
___ ___ 1U176124092 1U276824092 — —
2
1-3/8 35 ... ... 1R 4101X0022 ... -- -
12 1R4092X0022
2 ... ___ 1R 409724092 1R410624092 1R410624092 1R411424092
1-1/2 38 ... ... 1R4101X 0022 1R4101X0022 1R4098X0022
12 1R 4092X0022
... ... ... 1R712924092 — 1R410424092
2
1-5/8 41 ... ... ... 1R4101X0022 ... 1R4098X0022
12
2 __ _ . ... 1U 256124092 — —
1-7/8 48 ... ... ... 1R4102X0012 ... ...
12
2 ... ... — 1R 410724092 1R410724092 1R411324092
2 51 ... ... ... 1R4102X0012 1R4102X0012 1R4099X0022
12
2 _ __ ... ___ — 1R 410824092
2-1/8 54 . - - ... ... ... ... 1R 4099X0022
12
2 _ ... - - - ... — 1R 410624092
2-1/2 64 - - - ... ... ... ... 1R4101X0022
12
2 ... _ _. . — — 1R410724092<1)
3 76 ... ... ... ... ... 1R4102X0012
12
2 _ ___ ___ ... — 10A 2426X012
4 102 ... ... ... ... ' ... 1E7246X0022
12
1. For Type 667-4, part number is 17A2270X012.

34
 Type 667 Size 30-76 & 87
K e y 18. A c tu a to r S p rin g , Steel<1)
DIAPHRAGM
ACTUATOR PRESSURE TRAVEL, INCHES (mm)
SIZE RANGE 7/16 5/8 3/4 1-1/8 1-1/2 2
Psig Bar (11) (16) (19) (29) (38) (51)
1E795327082 1E795527092 1E792327092 — ...
3-15 0.2-1.0
Light Blue Brown Dark G ray
30
1E795627082 1E795427082 1E792427082 — ... ...
6-30 0.4-2.0
W hite Light G ray Light Green
1E805127082 1E804927082 1E805827082 1E805327092 ...
3-15 0.2-1.0 1 E805627092<3)
Alum inum Yellow Light G ray Dark G ray
34(2) & 40 D ark Green
1E805027082 1E804827082 1E805227082 1E805527082 ...
6-30 0.4-2.0 1E805827082<3)
Purple Light Blue Orange Dark Blue Light Gray
3-15 0.2-1.0 1E826727082 1E825527082 1E826127082 1E826627082
... 1E826927082
Purple Light G reen Dark Gray O range Dark Green
45 & 50
1E825627082 1E825527082 1E826427082 1E826227082
6-30 ... 1E826527082
0.4-2.0 Light Blue Alum inum & Light Gray Light Green Red
Red
1E825827082 1E825727082 1E826227082 1E826527082
3-15 ... 1E827027082
0.2-1.0 Yellow Brown Light G reen Red Alum inum &
46 & 60 Dark Blue
1E826027082 1E825527082 1E825727082 1E826327082
6-30 0.4-2.0 ... ... Bronze Alum inum & Brown Alum inum &
Red Dark Green
3/4(19) 1-1/8(29) 1-1/2 (38) 2(51) 3(76) 4(102)
1N127927082 1N719327082 1N128727082 1N128427082 ...
3-15 0.2-1.0 1N 128627082
Red W hite Yellow Light Green
70 & 87 Dark Gray
6-30 1N128127082 1N127927082 1N128527082 1N128727082
0.4-2.0 1 R67607082<4>
::: Brown | Red Light Blue Yellow Black
i . other spring selections are available by contacting your Fisher Controls sales office or sales representative
2.1-1/8 inch travel is available for size 34, and 1-1/2 inch travel is available for size 40 onlv
3. For size 40 only.
4. Diaphragm pressure range for this spring and travel combination is 3-30 Dsia (0 2-2 0 hart

K e y 32. T ra v e l In d ic a to r S c a le , S ta in le s s S te e l
SIZE TRAVEL, INCHES (mm)
7/16 1/2 5/8 3/4 1-1/8 1-1/2
SIZE 2 3 4
(11) (12) (16) (19) (29) (28) (51) (76) (102)
30 1E793438992 1E793538992 1E793538992 1E793638992 ... ___
34 1E793438992 1E807738982 1E807738982 1E793638992 17A9814X012
40 1E807638992 1E807738982 1E807738982 1E808138992<1) 1E808238992 1E808338992
45 1E807638992 1E807738982 1E807738982 1E808138992(2) 1E808238992 1E808338992 1R 444538982
46 1E807638992 1E807738982 1E807738982 1E808138992 1E808238992 1E808338992 1R 444538982 __. ...
50 1E833038982 1E833038982 1E833038982 1E833138992(3) 1E833238992 1E833338992 1E833438992
60 1F535238982 1E833038982 1E833138992 1E833138992 1E833238992 1E833338992 1E833428992 ...
70 ... — — 1H745738992 1H 745838992 1H 745938992 1E833438992 1H 746138992 1U 372738982
76 - - - — 1H745738992 1H745838992 1H 745938992 1E833438992 ...
87 ... - - - 13A5660X012
- " " 1 H745738992<4) 1H745838992 1H 745938992 1E833438992 1H 746138992 1J245238982
1. 1U356138982 is for 1-inch (25 mm) travel.
2. 1H147938992 is for 7/8-inch (22 mm) travel.
3 .1 U356238982 is for 1-inch (25 mm) travel.
4. 1H745838992 is for 7/8-inch (22 mm) travel.

35
Type 667 Size 30-76 & 87

K e y 152. T ra v e l S to p fo r T o p -M o u n te d H a n d w h e e ls a n d S ty le 10 a n d 11 A d ju s ta b le T ra v e l S to p s, S te e l
ACTUATOR TRAVEL INCHES (mm)
SIZE 7/16(11) 5/8(16) 3/4(19) 7/8 (22) 1(25) 1-1/8(29) 1-1/2 (38) 2(51)

30 (3 req’d) 1F393224092<1> 1E797924092<1> 1E7925240920) ... ... ... ... ...

34 & 40 1F42462409 1H 79762409 1E80672409 1E80682409 ...

1E806424092<2> 1E806524092 1E806624092
(4 req’d) 2 2 2 2
45 thru 60 &
... 1H1912X001 1H 35582409 1E83192409 1E80642409
76 1E827324092 1E831924092 1E832124092(1>
2 2 2 2
(4 req’d)
3/4(19) 7/8(22) 1 (25) 1-1/8(29) 1-1/2(38) 2(51) 3(76) 4(102) (3)
7 0 & 8 7 < 1> ... 1N12892409 1N12902409 1N12922409
1N128824092 18A0351X012 1N 12914092 11A8131X012
(3 req’d) 2 2 2
1. For top-mounted handwheels and style 10 travel stops.
2. For style 11 travel stops.
3. Type 667-4.___________________________________

While this information is presented in good faith and believed to be accurate, o r a n y o th e r m a tte r w ith re s p e c t to the products, nor as a recommendation to
Fisher Controls does not guarantee satisfactory results from reliance upon such use any product or process in conflict with any patent. Fisher Controls reserves
information. N oth in g c o n ta in e d he rein is to b e c o n stru e d as a w arranty o r g u a r- the right, without notice, to alter or improve the designs or specifications of the
antee, exp ress o r im plied, re gard ing the pe rform ance , m erchantability, fitne ss products described herein.

F o r in fo rm a tio n , c o n ta c t F is h e r C o n tro ls :
Fisher Controls M arshalltow n, Iowa 50158 U SA Sao Paulo 05424 Brazil
C ernay 68700 France S ingapore 2158

Printed in U.S.A. I^ E oyimkI O recycled paper

 Design EZ

F is h e r C o n tro ls Instruction Manual

Design EZ easy-e®
Control Valve

F IS H E R 8
April 1994 Form 5118

Contents
Introduction ................................................. 1
Scope of Manual ............................................................. 1
Description ....................................................................... 1
Specifications .................................................................... 1

Installatio n ................................................... 2

Maintenance ..................................................3
Packing L u b ricatio n ......................................................... 4
Packing M ain ten an ce................................................... . . 4
Replacing Packing .................................................. 5
Trim M aintenance............................................................. 9
Disassembly ............................................................. 9
Lapping Metal Seats .............................................. 10
A ssem bly..................................................................... 11
ENVIRO-SEAL™ Bellows Seal and B o n n e t...............14
Replacing a Plain or Extension Bonnet with an
ENVIRO-SEAL Bellows Seal (Stem/Bellows Figure 1. Design EZ Valve with Type 667
Assembly) and B o n n e t....................................... 14 Actuator and 3582 Series Positioner
Replacing an Installed ENVIRO-SEAL Bellows Seal
(Stem/Bellows Assembly) .................................15
Only personnel qualified through training or experience
Purging the ENVIRO-SEAL Bellows Seal Bonnet16
should install, operate, and maintain a Design EZ valve.
If there are any questions about these instructions,
Parts O rd erin g ............................................. 17 contact your Fisher Controls sales office or sales repre­
sentative before proceeding.
Parts Kits ..................................................... 17

Parts List ..................................................... 18 Description

The Design EZ valves (figure 1) are globe-style with
integral end connections, post guiding, and quick-
change trim. These valves are used in chemical or
Introduction hydrocarbon processing applications or in applications
that require control of nonlubricating, viscous, or other
Scope of Manual hard-to-handle fluids.
This instruction manual includes installation, mainte­
D 10 04 01 X 01 2

nance, and parts information for 1/2- through 4-inch

Design EZ valve bodies through Class 600 ratings. Specifications
Refer to separate manuals for instructions covering the Typical specifications for these valves are shown in
actuator and accessories. table 1.

e a s y -e . E N V IR O -S E A L , and H IG H -S E A L are m arks ow ned by Fisher Controls Interna­

tional, Inc.

© Fisher Controls International, Inc. 1979, 1994; All Rights Reserved

Design EZ

T a b le 1. S p e c ific a tio n s

End Connection Styles________________________ Consistent with

S c r e w e d o r S o c k e t W e ld in g :

Cast Iron Valves Class 600 per ASME/ANSI B16.34-1988

B u ttw e ld in g : Consistent with Class 600 per
F la n g e d : ANSI Class 125 flat-face or 250 raised-
face flanges per ASME/ANSI B16.1-1989 ASME/ANSI B16.34-1988
S c r e w e d : Consistent with ASME B16.4-1992
Steel and Stainless Steel Valves Shutoff Classifications per ANSI/FCI 70-2-1976
F la n g e d : ANSI Class 150, 300, and 600 raised-
(R1990)_____________ '_____________________
face or ring-type joint flanges per ASME/ANSI Metal Seats: Class IV is standard, Class V is
B16.5-1988 optional
S c r e w e d o r S o c k e t W e ld in g : Consistent with PTFE Composition Seats: Class VI
ASME B16.11-1991
B u ttw e ld in g : All available ASME B16.25-1992 Flow Characteristics_______________________
schedules that are consistent with ASME/ANSI ■ Equal percentage, ■ quick opening, and
B16.34-1988 ■ linear

Maximum Inlet Pressure*1)_____________________ Flow Direction____________________________

Cast Iron Bodies Up through the seat ring
F la n g e d : Consistent with Class 125B or 250B
per ASME/ANSI B16.1-1989 Approximate Weights______________________
S c r e w e d : Consistent with Class 250 per ASME
1/2 and 3/4-lnch Valves: 20 pounds (9.1 kg)
B16.4-1992 1-Inch Valve: 25 pounds (11 kg)
Steel and Stainless Steel Bodies
1- 1/2 Inch Valve: 40 pounds (18 kg)
F la n g e d : Consistent with Class 150, 300, or 600
2- Inch Valve: 80 pounds (36 kg)
per ASME/ANSI B16.34-1988 3- Inch Valve: 120 pounds (54 kg)
4- Inch Valve: 165 pounds (75 kg)

1. The pressure or temperature limits in this manual and any applicable code limitations
should not be exceeded.

Installation 1. Before installing the valve, inspect it and any asso­

ciated equipment for damage and any foreign material.
Make certain the body interior is clean, that pipelines are
W A R N IN G free of foreign material, and that the valve is oriented so
that pipeline flow is in the same direction as the arrow on
Personal injury or equipment damage the side of the valve.
caused by sudden release of pressure may
result if the valve assembly is installed 2. The control valve assembly may be installed in any
where service conditions could exceed the orientation unless limited by seismic criteria. However,
limits given in table 1 or on the appropriate the normal method is with the actuator vertical above
nameplates. To avoid such injury or dam­ the body. Other positions may result in uneven valve
age, provide a relief valve for overpressure plug and seat ring retainer wear, and improper opera­
protection as required by government or tion. With some valves, the actuator may also need to be
accepted industry codes and good engi­ supported when it is not vertical. For more information,
neering practices. consult the Fisher Controls sales office or sales
representative.

CAUTION 3. Use accepted piping and welding practices when

installing the valve in the line. Internal elastomeric parts
When ordered, the valve configuration and may stay in place during the welding procedure. For
construction materials were selected to flanged bodies, use a suitable gasket between the body
meet particular pressure, temperature, flange and pipeline flanges.
pressure drop, and controlled fluid condi­
tions. Since some body/trim material com­ Note
binations are limited in their pressure drop
and temperature ranges, do not apply any Depending on valve body materials used,
other conditions to the valve without first post weld heat treating may be required. If
contacting the Fisher Controls sales office so, damage to internal elastomeric and
or sales representative. plastic parts, as well as internal metal parts

2
 Design EZ

is possible. Shrunk-fit pieces and threaded

connections may also loosen. In general, if
post weld heat treating is to be performed,
all trim parts should be removed. Contact
your Fisher Controls sales office or repre­ LUBRICATOR
sentative for additional information.

4. With a leak-off bonnet construction, remove the

pipe plugs (key 14, figure 10) to hook up the leak-off
piping. If continuous operation is required during in­
spection or maintenance, install a three-valve bypass
around the control valve assembly.

5. If the actuator and valve are shipped separately,

refer to the actuator mounting procedure in the appro­
priate actuator instruction manual. Figure 2. Optional Packing Lubricator and
Lubricator/Isolating Valve

W A R N IN G
• Use bypass valves or completely shut
Personal injury could result from packing off the process to isolate the valve from
leakage. Valve packing was tightened be­ process pressure. Relieve process pres­
fore shipment; however, the packing might sure from both sides of the valve. Drain the
require some readjustment to meet specific process media from both sides of the valve.
service conditions.
• Vent the pneumatic actuator loading
Valves with ENVIRO-SEAL live-loaded packing or HIGH- pressure and relieve any actuator spring
SEAL™ Heavy-Duty live-loaded packing will not require precompression.
this initial re-adjustment. See the Fisher Controls in­
struction manuals titled E N V IR O -S E A L P a c k in g S y s te m • Use lock-out procedures to be sure that
fo r S lid in g -S te m V a lv e s or H e a v y -D u ty L iv e -L o a d e d P a c k ­ the above measures stay in effect while
in g S y s te m (as appropriate) for packing instructions. If you work on the equipment.
you wish to convert your present packing arrangement
to ENVIRO-SEAL packing, refer to the retrofit kits listed Note
in the parts kit sub-section near the end of this manual.
Whenever a gasket seal is disturbed by
removing or shifting gasketed parts, a new
Maintenance gasket should be installed upon reassem­
bly. This is necessary to ensure a good
Valve parts are subject to normal wear and must be gasket seal since the used gasket may not
inspected and replaced as necessary. Inspection and seal properly.
maintenance frequency depends on the severity of ser­
vice conditions. This section includes instructions for
packing lubrication, packing maintenance, trim mainte­ Because of the care Fisher Controls takes in meeting all
nance, and ENVIRO-SEAL bellows seal replacement. All manufacturing requirements (heat treating, dimensional
maintenance operations may be performed with the tolerances, etc.), use only replacement parts manufac­
valve in the line.
tured or furnished by Fisher Controls.

W A R N IN G Note
Avoid personal injury or property damage If the valve has ENVIRO-SEAL or HIGH-
from sudden release of process pressure SEAL live-loaded packing installed, refer to
or bursting of parts. Before performing any instruction manuals ENVIRO-SEAL Packing
maintenance operations: ■>• System for Sliding Stem Valves, Form 5306,
or HIGH-SEAL Live Loaded Packing Sys­
• Disconnect any operating lines provid­ tem, Form 5263, for packing instructions.
ing air pressure, electric power, or a control Figure 6 shows a typical HIGH-SEAL pack­
signal to the actuator. Be sure the actuator ing system. Figures 7 and 8 show typical
cannot suddenly open or close the valve. ENVIRO-SEAL systems.
High-Seal is a m ark ow ned by Fisher C ontrols International, Inc. 3
Design EZ

npv FEMALE
L -L / ADAPTOR

[T> PACKING RING

p - v MALE
U -S ADAPTOR SPACER (KEY 8)

PACKING
BOX RING (KEY 11)
r="S LOWER
WIPER

FOR 316 SST FOR MONEL PACKING

METAL PACKING BOX PARTS BOX PART MATERIALS
(T> PART OF PACKING SET
SINGLE ARRANGEMENTS
(KEY 6) (SEE PARTS LIST)

UPPER
WIPER (KEY 12)

PACKING
FOLLOWER (KEY 13)

MALE
ADAPTOR (KEY 31)

PACKING RING (KEY 7)

FEMALE
ADAPTOR (KEY 32)

m
12A8187-D
ASSEMBLY 1 ASSEMBLY 2 ASSEMBLY 3 ASSEMBLY 1 ASSEMBLY 2 LOWER
(POSITIVE (VACUUM) (POSITIVE (POSITIVE (VACUUM) WIPER
PRESSURES) PRESSURES PRESSURES) (KEY 30)
& VACUUM)
3/4-INCH
3/8-INCH (9.5 mm) STEM 1/2-INCH (12.7 mm) STEM (19.1 mm) STEM
DOUBLE ARRANGEMENTS
Figure 3. PTFE V-Ring Packing Arrangements for
Plain and Extension Bonnets

Packing Lubrication Packing Maintenance

Note
ENVIRO-SEAL or HIGH-SEAL packing does
not require lubrication.
If an optional lubricator or lubricator/isolating valve (fig­
ure 2) is provided for PTFE/composition or other pack­
ings that require lubrication, it will be installed an
optional tapped hole in the bonnet. Use a good quality
silicon-base lubricant. Packing used in oxygen service
or in processes with temperatures over 500°F (260°C)
should not be lubricated. To operate the lubricator,
simply turn the cap screw clockwise to force the lubri­
cant into the packing box. The lubricator/isolating valve
must first be opened and then closed after lubrication is
completed.
This section covers PTFE V-ring, PTFE/composition,
and graphite/ribbon packing as used in plain and exten­
sion bonnets. Unless otherwise indicated, key numbers
refer to figure 3 for PTFE V-ring packing, figure 4 for
PTFE/composition packing, and figure 5 for graphite
ribbon/filament packing.
For spring-loaded single PTFE V-ring packing, the
spring (key 8, figure 3) maintains a sealing force on the
packing. If leakage is noted around the packing follower
(key 13, figure 3), check to be sure the shoulder on the
packing follower is touching the bonnet. If the shoulder
is not touching the bonnet, tighten the packing flange
nuts (key 5, figure 10), until the shoulder is against the
bonnet. If leakage cannot be stopped in this manner,
proceed to the replacing packing procedure.

4
 Design EZ

UPPER
WIPER
(KEY 12)

1
/
PI PACKING
FOLLOWER
(KEY 13)

PACKING
RING (KEY 7)

LANTERN
RING
(KEY 8)

PACKING
BOX RING
(KEY 11)

12A7015-A

1/2-INCH
STEM STEM

PTFE/COMPOSITION PACKING
Figure 4. PTFE/Composition Packing Arrangements for
Plain and Extension Bonnets

If there is undesirable packing leakage with other than
spring-loaded packing, first try to limit the leakage and
establish a stem seal by tightening the packing flange
nuts.
If the packing is relatively new and tight on the stem, and
if tightening the packing flange nuts does not stop the
leakage, it is possible that the valve stem is worn or
nicked so that a seal cannot be made. The surface finish
of a valve stem is critical for making a good packing
seal. If the leakage comes from the outside diameter of
the packing, it is possible that the leakage is caused by
nicks or scratches around the packing box wall. If
performing any of the following procedures, inspect the
valve stem and packing box wall for nicks and
scratches.
An illustration of a HIGH-SEAL live-loaded packing sys­
tem is shown in figure 6. Illustrations of ENVIRO-SEAL
live-loaded packing systems are shown in figures 7 and
8.
Replacing Packing
This section covers replacing packing used in plain and
extension bonnets. PTFE V-ring packing is shown in
figure 3, PTFE/composition packing is shown in figure 4,
and graphite/ribbon packing is shown in figure 5.1
1. Isolate the control valve from the line pressure,
release pressure from both sides of the valve body, and
drain the process media from both sides of the valve. If
using a power actuator, also shut off all pressure lines to
the power actuator, and release all pressure from the
actuator. Use lock-out procedures to be sure that the
above measures stay in effect while you work on the
equipment. Observe the warning at the start of the
Maintenance section.
2. Disconnect the operating lines from the actuator
and any leak-off piping from the bonnet. Disconnect the
stem connector and then remove the actuator from the
valve by unscrewing the yoke locknut (key 15, figure 10).
W A R N IN G
To avoid personal injury or property dam­
age caused by uncontrolled movement of
the bonnet, loosen the bonnet by following
the instructions in the next step. Do not
remove a stuck bonnet by pulling on it with
equipment that can stretch or store energy
in any other manner. The sudden release of
stored energy can cause uncontrolled
movement of the bonnet. If the seat ring
retainer sticks to the bonnet, proceed care­
fully with bonnet removal.
Note
The following step also provides additional
assurance that the valve body fluid pres­
sure has been relieved.

5
Design EZ

PACKING
FOLLOWER (KEY 13)

GRAPHITE
RIBBON
PACKING RING (KEY 7)

GRAPHITE
FILAMENT
PACKING RING (KEY 7)

LANTERN RING (KEY 8)

PACKING BOX
RING (KEY 11)

1/2-INCH 3/4-INCH
(12.7 mm) (19.1 mm)
STEM STEM
SINGLE ARRANGEMENTS

PACKING
FOLLOWER (KEY 13)

GRAPHITE
RIBBON
PACKING RING (KEY 7)

GRAPHITE
FILAMENT
PACKING RING (KEY 7)

LANTERN RING (KEY 8)

PACKING BOX
RING (KEY 11)

3/8-INCH 1/2-INCH 3/4-INCH

(9.5 mm) (12.7 mm) (19.1 mm)
STEM STEM STEM
DOUBLE ARRANGEMENTS
NOTE:
|T> 0.004 INCH (0.102 mm) THICK SACRIFICIAL ZINC WASHERS;
USE ONLY ONE BELOW EACH GRAPHITE RIBBON RING.

Figure 5. Graphite Ribbon/Filament Packing Arrangements

for Plain and Extension Bonnets

3. Hex nuts (key 16, figure 10) attach the bonnet to the
body. Loosen these nuts or cap screws approximately
1/8 inch (3 mm). Then loosen the body-to-bonnet gas­
keted joint by either rocking the bonnet or prying be­
tween the bonnet and body. Work the prying tool around
the bonnet until the bonnet loosens.
4. Loosen the packing flange nuts (key 5, figure 10) so
that the packing is not tight on the valve stem. Remove
any travel indicator parts and stem locknuts from the
valve stem threads.
CAUTION
Avoid damaging the seating surface
caused by the valve plug and stem assem­
bly dropping from the bonnet after being
lifted part way out. When lifting the bonnet,
temporarily install a valve stem locknut on
the valve stem. This locknut will prevent the
valve plug and stem assembly from drop­
ping out of the bonnet.
5. Completely remove the cap screws (not shown) or
hex nuts (key 16, figure 11) that bolt the bonnet and body
together and carefully lift the bonnet off.
6. Remove the locknut and separate the valve plug
and stem from the bonnet. Set the parts on a protective
surface to prevent damage to gasket or seating
surfaces.
7. Remove the bonnet gasket (key 10, figure 11) and
cover the opening in the valve to protect the gasket
surface and to prevent foreign material from getting into
the body cavity.
8. Remove the packing flange nuts, packing flange,
upper wiper, and packing follower (keys 5,3,12, and 13,
figure 10). Carefully push out all the remaining packing
parts from the body side of the bonnet using a rounded
rod or other tool that will not scratch the packing box
wall. Clean the packing box and the metal packing parts.
9. Inspect the valve stem threads and the packing box
surfaces for any sharp edges which might cut the pack-

6
 Design EZ

Figure 6. Typical HIGH-SEAL™ Packing System

Figure 8. Typical ENVIRO-SEAL™ Packing

System with Graphite Packing

10. Remove the covering protecting the body cavity

and install a new bonnet gasket (key 10, figure 11),
making sure the gasket seating surfaces are clean and
smooth. Then slide the bonnet over the stem and onto
the stud bolts (key 15, figure 11), or onto the body cavity
if cap screws (not shown) are used instead.

Note

Proper performance of the tightening pro­

cedures in step 11 compresses the spiral
wound gasket (key 12, figure 11) enough to
both load and seal the seat ring gasket (key
13, figure 11). The tightening procedures
also compresses the outer edge of the bon­
net gasket (key 10, figure 11) enough to
seal the body-to-bonnet joint.

□ APPLY LUBE The prelubricated stud bolt nuts (key 16,

NOTE: figure 11) referred to in step 11 are identi­
O FOR PTFE PACKING, TIGHTEN THE PACKING BOX HEX NUTS UNTIL THE TOP fied by a black film coating on the nut
O F THE FLANGE IS EVEN W ITH TH E TO P OF THE SLEVE ON THE FOLLOWER
(SPRING PACK ASSEMBLY). threads.
A6302/Q1

Figure 7. Typical ENVIRO-SEAL™ Packing System
with PTFE Packing
ing. Scratches or burrs could cause packing box leak­
age or damage to the new packing. If the surface
condition cannot be improved by light sanding, replace
the damaged parts.
The accepted bolting procedures referred
to in step 11 include— but are-not limited
to— ensuring that bolting threads are clean,
and evenly tightening the cap screws, or
the nuts onto the studs, in a crisscross
pattern. Because of the boltup characteris­
tics of spiral wound gaskets, tightening one
cap screw or nut may loosen an adjacent

7
Design EZ

Table 2. Body-to-Bonnet Torque Guideline

VALVE SIZE, INCHES TORQUES!1)

Stud Bolt Nuts
Field-Lubricated Factory Prelubricated
Bolting w/Molykote(2)
321R Dry Film Lubricant
Design EZ Bolt Material
Bolt Material
SA193-B7 SA193-B8M(3> SA193-B7 SA193-I38M<3>

Lbf.ft N.m Lbf.ft N.m Lbf.ft N«m Lbf.ft N«m

129 47 64 75 102 37 50
1 or smaller 95
71 96 33 45 56 76 26 35
1-1/2 or 2
169 65 88 97 132 51 69
3 125
271 115 156 155 210 89 121
4 200
1. Determined from laboratory test8. 3 - SA193-B8M annealed.
2. Trademark of Dow Coming Corporation. __________________________________________________________

cap screw or nut. Repeat the crisscross Table 3. Recommended Torque for Packing Flange Nuts
(Not for Spring-Loaded Packing)
tightening pattern several times until each
cap screw or nut is tight and the body-to- VALVE GRAPHITE TYPE PTFE TYPE
PACKING PACKING
bonnet seal is made. When the operating STEM
DIA­ ANSI Maximum Minimum Maxiirium
temperature has been reached, perform Minimum
METER CLASS Torque Torque Torq ue
Torque
this torquing procedure once again.
Inches mm Lbf.in N.m Lbf.in N*m Lbf.in N.m Lbf.in N.m
125, 40 5 13 1 19 2
27 3
150
11. Lubricate the bolting (not necessary if factory pre­
3/8 9.5 250, 2 26 3
lubricated stud bolt nuts will be used) and install it, using 36 4 53 6 17
300
accepted bolting procedures during tightening so that 23 3 35 4
600 49 6 73 8
the body-to-bonnet joint can withstand test pressures
125, 31 4
and application service conditions. The bolt torques in 44 5 66 8 21 2
150
table 2 may be used as guidelines unless accepted
1/2 12.7 250, 7 88 10 28 3 42 5
bolting procedures dictate otherwise. 59
300
600 81 9 122 14 39 4 58 7
125, 149 17 47 5 70 8
99 11
150
12. Install new packing and the metal packing box
parts according to the appropriate arrangement in figure 3/4 19.1 250, 199 23 64 7 95 11
133 15
300
3, 4, or 5. If split-ring packing is being added, alternate 87 10 131 15
600 182 21 274 31
the position of the splits to avoid a leak path. Place a
smooth-edged pipe over the valve stem and gently tap
each soft packing part into the packing box, being sure
that air is not trapped between adjacent soft parts.
Note

The torque values discussed in step 14 and

Installation of graphite ribbon packing requires special
shown in table 3 are recommended guide­
care to avoid trapping air between the rings. Start with
lines only and are presented as a starting
only one ring at a time without forcing the top of the
point for this procedure. Tightening the
packing ring below the bottom of the entrance chamfer
packing flange nuts to a torque value that
of the packing box. Thus, when a ring is added, the
exceeds the table guidelines, in order to
stack should not be pushed into the cavity more than the
obstain a seal, may indicate other
thickness of the added ring.
problems.

13. Slide the packing follower, upper wiper, and pack­

ing flange (keys 13, 12, and 3, figure 10) into position.
Lubricate the packing flange studs (key 4, figure 10) and 14. For spring-loaded PTFE V-ring packing, tighten
the faces of the packing flange nuts (key 5, figure 10). the packing flange nuts until the shoulder on the packing
Install the packing flange nuts. follower (key 13, figure 11) contacts the bonnet.

For graphite packing, tighten the packing flange nuts to
the maximum recommended torque shown in table 3.
Then, loosen the packing flange nuts, and retighten
them to the recommended minimum torque shown in
table 3.
For other packing types, tighten the packing flange nuts
alternately in small equal increments until one of the
nuts reaches the minimum recommended torque shown
in table 3. Then, tighten the remaining flange nuts until
the packing flange is level and at a 90-degree angle to
the valve stem.
For ENVIRO-SEAL or HIGH-SEAL live-loaded packing,
refer to the note at the beginning of the Maintenance
section.
15. Mount the actuator on the valve body and recon­
nect the actuator and valve stem according to the proce­
dure in the appropriate actuator instruction manual.
Trim Maintenance
This procedure describes how the valve trim can be
completely disassembled. When inspection or repairs
are required, perform only those steps necessary to
accomplish the task. Observe the warning at the start of
the Maintenance section.
Disassembly
Except where indicated, key numbers referenced in the
following steps are found in figure 11.1
1. Remove the actuator and the bonnet according to
steps 1 through 6 of the Replacing Packing procedure of
the Maintenance section.
CAUTION
To avoid personal injury due to leaking flu­
ids, avoid damaging gasket sealing sealing
surfaces.
The surface finish of the valve stem (key 7)
is critical for making a good packing seal.
The inside surface of the seat ring retainer
is critical for smooth operation of the valve
plug. .,
The seating surfaces of the valve plug and
seat ring (keys 2 and 9) are critical for
proper shutoff.
Design EZ
Unless inspection reveals otherwise, as­
sume all these parts are in good condition
and protect them accordingly. Gasket se­
lection criteria is provided in Parts List
section.
2. Packing parts can be removed if desired. Replace
these parts as described in the Replacing Packing pro­
cedure.
Valves with Plain or Extension Bonnets
Perform the following steps to remove the valve trim.
1. Lift the valve plug and stem assembly [or the plug
guide, disk retainer, and disk (keys 27,28, and 29, figure
12) if used], out of the valve body and set it on a
protective surface.
Note
With some valve plug sizes and configura­
tions, the seat ring retainer and bushing
assembly (keys 3 and 26, figures 11 and 12)
will come out of the valve body with the
valve plug and stem assembly, and in other
valve plug sizes and configurations, the
valve plug or tip will slide through the seat
ring retainer and bushing assembly, leaving
the retainer and bushing assembly in the
valve body.
2. With the valve plug and stem assembly out of the
body, either slide the seat ring retainer and bushing
assembly (keys 3 and 26), and gaskets and shim (keys
10,12, and 25) up over the valve plug and stem or lift the
seat ring retainer and bushing assembly and associated
gaskets and shim out of the valve body. If the valve plug
is to be reused, protect the valve plug seating surface to
prevent scratches.
3. For valves with metal seats, drive out the groove
pin (key 8) and unscrew the valve stem (key 7) from the
valve plug (key 20).
4. For valves with 1/4 and 3/8-inch ports and compo­
sition seats, refer to figure 12. Drive out the groove pin
(key 8) and unscrew the valve stem (key 7) from the
valve plug guide (key 27). Unscrew the disk retainer (key
28) from the valve plug guide. Remove the disk (key 29)
from the valve plug tip (key 30).
For valves with 1/2 through 2-inch ports and composi­
tion seats, refer to figure 12. Drive out the groove pin
(key 8) and unscrew the valve stem (key 7) from the
valve plug guide (key 27). Drive out groove pin (key 31)
9
Design EZ
and unscrew the tip (key 30) from the valve plug guide.
Remove the disk (key 29) from the valve plug guide.
For valves with 3 and 4-inch ports and composition
seats, refer to figure 12. Drive out the groove pin (key 8)
and unscrew the valve stem from the valve plug guide
(key 27). Remove the cap screw (key 32) to remove the
tip (key 30) from the valve plug guide. Remove the disk
(key 29).
5. Remove the seat ring and seat ring gasket (keys 9
and 13).
6. Inspect parts for wear or damage that would pre­
vent proper operation of the valve. Replace or repair
trim parts according to the following Lapping Metal
Seats or Assembly procedure as appropriate.
Valves with ENVIRO-SEAL Bellows Seal Bonnets
Perform the following steps to remove the valve trim.
1. Lift the stem/bellows assembly with valve plug at­
tached [or the plug guide, disk retainer, and disk (keys
27, 28, and 29, figure 12) if used], seat ring .retainer and
gaskets out of the valve body and set them on a protec­
tive surface.
Note
With some valve plug sizes and configura­
tions, the seat ring retainer and bushing
assembly (keys 3 and 26, figures 11 and 12)
will come out of the valve body with the
stem/bellows, and in other valve plug sizes
and configurations, the valve plug or tip will
slide through the seat ring retainer and
bushing assembly, leaving the retainer and
bushing assembly in the valve body.
2. If the seat ring retainer and bushing assembly (keys
3 and 26) stayed in the valve, lift them out along with
gaskets and shim (keys 10, 12, and 25).
3. If the seat ring retainer and bushing assembly (keys
3 and 26) came out of the valve with the stem/bellows
assembly, move the seat ring retainer and bushing
assembly against the shoulder of the valve plug (key 2)
or valve plug guide (key 27, figure 12) to provide access
to the pin (key 36, figure 10).
4. Place the stem/bellows assembly and valve plug or
valve plug guide in a soft-jaw chuck or other type of vise
so that the jaws grip a portion of the valve plug or valve
plug guide that is not a seating or guiding surface. Drive
out the pin (key 36, figure 10).
10
5. Remove the stem/bellows assembly from the soft-
jaw chuck or vise. Place a wrench on the flat areas on
the valve stem just below the threads for the actuator/
stem connection to keep the stem from turning. Then,
unscrew the adaptor (key 24, figure 10), which also
includes the valve plug (key 2) or valve plug guide (key
27, figure 12), from the stem/bellows assembly (key 20,
figure 10).
6. Remove the seat ring retainer and bushing assem­
bly (keys 3 and 26) by sliding it over the adaptor. If the
valve plug is to be reused, protect the valve plug seating
surface to prevent scratches.
7. For valves with metal seats, drive out the gcoove
pin (key 8) and unscrew the adaptor (key 24, figure 10)
from the valve plug (key 2).
8. For valves with 1/4 and 3/8-inch ports and compo­
sition seats, refer to figure 12. Drive out the groove pin
(key 8) and unscrew the adaptor (key 24, figure 10) from
the valve plug guide (key 27). Unscrew the disk retainer
(key 28) from the valve plug guide. Remove the disk (key
29) from the valve plug tip (key 30).
For valves with 1/2 through 2-inch ports and composi­
tion seats, refer to figure 12. Drive out the groove pin
(key 8) and unscrew the adaptor (key 24, figure 10) from
the valve plug guide (key 27). Drive out groove pin (key
31) and unscrew the tip (key 30) from the valve plug
guide. Remove the disk (key 29) from the valve plug
guide.
For valves with 3 and 4-inch ports and composition
seats, refer to figure 12. Drive out the groove pin (key 8)
and unscrew the adaptor (key 24, figure 10) from the
valve plug guide (key 27). Remove the cap screw (key
32) to remove the tip (key 30) from-the valve plug guide.
Remove the disk (key 29).
9. Remove the seat ring and seat ring gasket (keys 9
and 13).
10. Inspect parts for wear or damage that would pre­
vent proper operation of the valve. Replace or repair
trim parts according to the following Assembly proce­
dure as appropriate.
Lapping Metal Seats on Valves with Plain
and Extension Bonnets
CAUTION
To avoid damaging the ENVIRO-SEAL Bel­
lows Seal Bonnet assembly, do not attempt
to lap the metal seating surfaces on valves
with ENVIRO-SEAL bellows seal bonnets.
The design of the bonnet assembly pre­

vents rotation of the stem and any forced
lapping rotation will damage internal com­
ponents of the ENVIRO-SEAL Bellows Seal
bonnet.
With metal-seat constructions, seating surfaces of the
valve plug and seat ring (key 2, figure 11) can be lapped
for improved shutoff. (Deep nicks should be machined
out rather than ground out.) Use a good quality lapping
compound of a mixture of 280 to 600-grit. Apply the
compound to the bottom of the valve plug.
Assemble the valve to the extent that the seat ring
retainer is in place and the bonnet is bolted to the body.
A simple handle can be made from a piece of strap iron
locked to the valve plug stem with nuts. Rotate the
handle alternately in each direction to lap the seats.
After lapping, remove the bonnet and clean the seat
surfaces. Completely assemble as described in the as­
sembly portion of the trim maintenance procedure and
test the valve for shutoff. Repeat the lapping procedure
if leakage is still excessive.
Assembly
This procedure assumes that all the trim and associated
gaskets were removed from the valve body. If these
parts were not all removed, start the assembly proce­
dure at the appropriate step. Except where indicated,
key numbers referenced in the following steps are found
in figure 11.
Valves with Plain or Extension Bonnets
Perform the following steps to assemble and install the
trim.
CAUTION
To avoid weakening the stem that may
cause failure in service, never reuse an old
stem with a new valve plug. Using an old
stem with a new plug requires drilling a new
groove pin hole in the stem,which will
weaken the stem. However, a used valve
plug may be reused with a new stem.
1. For valves with metal seats, screw the valve stem
(key 7) into the valve plug (key 2). Tighten to the torque
valve given in figure 9. Refer to figure 9 to select the
proper drill size. Drill through the stem using the hole in
the valve plug as a guide. Remove any chips or burrs
and drive in a new groove pin (key 8) to lock the
assembly.
2. For valves with 1/4 and 3/8-inch ports and compo­
sition seats, refer to figure 12. Place the disk (key 29)
on the valve plug tip (key 30). Place the disk retainer (key
28) over the disk, and then thread the disk retainer onto
the valve plug guide (key 27).
Design EZ
35A5717 C
«*'<« M IC R O -F L U TE F U L L SIZE A N D R E S T R IC T E D
Figure 9. Bolt Torque for Plug/Stem Connection and
Plug/Adaptor Connection and Groove Pin Replacement
CAUTION
To avoid failure in service for valves with 1/
2 through 1-inch ports and composition
seats, never reuse an old valve plug guide
with a new valve plug tip. Using an old valve
plug guide with a new plug tip requires
drilling a new groove pin hole in the valve
plug guide, which will weaken the guide.
However, a used valve plug tip may be
reused with a new valve plug guide.
For valves with 1/2 through 1-inch ports and composi­
tion seats, refer to figure 12. Insert the disk (key 29) in
the valve plug guide (key 27). Screw the tip (key 30) onto
the valve plug guide to clamp the disk in place. Using a
3/32-inch bit, drill through the valve plug guide using the
hole in the tip as a drilling guide. Remove any chips or
burrs and drive in a new groove pin (key 31).
CAUTION
To avoid failure in service for valves with 1-
1/2 and 2-inch ports and composition
seats, never reuse an old valve plug tip with
a new valve plug guide. Using an old valve
plug tip with a new valve plug guide re­
quires drilling a new groove pin hole in the
valve plug tip which will weaken the tip.
However, a used valve plug guide may be
reused with a new valve plug tip.
For valves with 1-1/2 and 2-inch ports and composition
seats, refer to figure 12. Insert the disk (key 29) in the
valve plug guide (key 27). Screw the tip (key 30) into the
valve plug guide to clamp the disk in place. Using a 3/32-
11
Design EZ
inch bit, drill through the valve plug tip using the hole in
the valve plug guide as a drilling guide. Remove any
chips or burrs and drive in a new groove pin (key 31).
For valves with 3 and 4-inch ports and composition
seats, refer to figure 12. Insert the disk (key 29) in the
valve plug guide (key 27). Place the tip (key 30) against
the valve plug guide to clamp the disk in place. Insert the
cap screw (key 32) through the tip and thread it into
valve plug guide to secure the tip to the valve plug guide.
CAUTION
To avoid failure in service, never reuse an
old stem with a new valve plug guide. Using
an old stem with a new valve plug guide
requires drilling a new groove pin hole in
the stem, which will weaken the stem. How­
ever, a used valve plug guide may be re­
used with a new stem except for valves with
1/2 through 1-inch ports and composition
seats (see to figure 12). For these construc­
tions, a used valve plug guide should only
be used if the tip is reused.
3. For all valves with composition seats, screw the
valve stem (key 7) into the valve plug guide (key 27,
figure 12). Tighten to the torque value given in figure 9.
Refer to figure 9 to select the proper drill size. Drill
through the stem, using the hole in the valve plug guide
as a drilling guide. Remove any chips or burrs and drive
in a new groove pin (key 8) to lock the assembly.
4. Install the seat ring gasket (key 13), and replace the
seat ring (key 9).
Note
With some valve plug sizes and configura­
tions, the valve plug or tip will slide through
the seat ring retainer and bushing assem­
bly (keys 3 and 26), and in other configura­
tions it won’t.
5. If the valve plug (key 2) or valve plug tip (key 30,
figure 12) will not slide through the seat ring retainer and
bushing assembly (keys 3 and 26), proceed as follows:
a. Place the seat ring retainer and bushing assem­
bly (keys 3 and 26) over the stem of valve plug and stem
assembly or over the stem of the valve plug guide and
stem assembly.
b. Install the seat ring retainer and bushing assem­
bly, which also includes the valve plug and stem assem­
bly or valve plug guide and stem assembly, on the top of
12
the seat ring, ensuring that the seat ring retainer slips
onto the seat ring properly. Any rotation orientation of
the seat ring retainer with respect to the body is accept­
able.
c. Place the spiral wound gasket, shim, and bonnet
gasket (keys 12, 25, and 10) on the shoulder of the seat
ring retainer.
6. If the valve plug (key 2) or the valve plug tip (key 30,
figure 12) will slide through the seat ring retainer and
bushing assembly (keys 3 and 26), proceed as follows:
a. Install the seat ring gasket (key 13), and replace
the seat ring (key 9).
b. Install the seat ring retainer and bushing assem­
bly on the top of the seat ring, ensuring that the seat ring
retainer slips onto the seat ring properly. Any rotation
orientation of the seat ring retainer with respect to the
body is acceptable.
c. Place the spiral wound gasket, shim, and bonnet
gasket (keys 12, 25, and 10) on the shoulder of the seat
ring retainer.
d. Slide the valve plug and stem assembly or the
valve plug guide and stem assembly into the seat ring
retainer and bushing assembly (keys 3 and 26).
7. Mount the bonnet on the body and complete the
assembly according to steps 10 through 15 of the Re­
placing Packing procedure, omitting steps 12 and 13 if
new packing is not being installed, and being sure to
observe the note prior to step 11.
Valves with ENVIRO-SEAL Bellows Seal Bonnets
Perform the following steps to assemble and install the
trim.
1. For valves with 1/4 and 3/8-inch ports and compo­
sition seats, refer to figure 12. Place the disk (key 29)
on the valve plug tip (key 30). Place the disk retainer (key
28) over the disk, and then thread the disk retainer onto
the valve plug guide (key 27).
CAUTION
To avoid failure in service of valves with 1/2
through 1-inch ports and composition
seats, never reuse an old valve plug guide
with a new valve plug tip. Using an old valve
plug guide with a new plug tip requires
drilling a new groove pin hole in the valve
plug guide, which will weaken the guide.
However, a used valve plug tip may be
reused with a new valve plug guide.

For valves with 1/2 through 1-inch ports and composi­
tion seats, refer to figure 12. Insert the disk (key 29) in
the valve plug guide (key 27). Screw the tip (key 30) onto
the valve plug guide to clamp the disk in place. Using a
3/32-inch bit, drill through the valve plug guide using the
hole in the tip as a drilling guide. Remove any chips or
burrs and drive in a new groove pin (key 31).
CAUTION
To avoid failure in service of valves with 1-
1/2 and 2-inch ports and composition
seats, never reuse an old valve plug tip with
a new valve plug guide. Using an old valve
plug tip with a new valve plug guide re­
quires drilling a new groove pin hole in the
valve plug tip, which will weaken the tip.
However, a used valve plug guide may be
reused with a new valve plug tip.
For valves with 1-1/2 and 2-inch ports and composition
seats, refer to figure 12. Insert the disk (key 29) in the
valve plug guide (key 27). Screw the tip (key 30) into the
valve plug guide to clamp the disk in place. Using a 3/32-
inch bit, drill through the valve plug tip using the hole in
the valve plug guide as a drilling guide. Remove any
chips or burrs and drive in a new groove pin (key 31).
For valves with 3 and 4-inch ports and composition
seats, refer to figure 12. Insert the disk (key 29) in the
valve plug guide (key 27). Place the tip (key 30) against
the valve plug guide to clamp the disk in place. Insert the
cap screw (key 32) through the tip and thread it into
valve plug guide to secure the tip to the valve plug guide.
CAUTION
To avoid weakening the adaptor that may
cause failure in service, never reuse an old
adaptor with a new valve plug or valve plug
guide. Using an old adaptor with a new
valve plug or valve plug guide requires drill­
ing a new groove pin hole in the adaptor,
which will weaken the adaptor. However, a
used valve plug or valve plug guide may be
reused with a new adaptor.
2. Thread the valve plug (key 2) or, the valve plug
guide (key 27, figure 12) if the valve has composition
seats, onto the adaptor (key 24, figure 10). Tighten to the
torque valve given in figure 9. Refer to figure 9 to select
the proper drill size. Drill through the adaptor using the
hole in the valve plug as a guide. Remove any chips or
burrs and drive in a new groove pin (key 8) to lock the
assembly.
Design EZ
Note
With some valve plug sizes and configura­
tions, the valve plug or tip will slide through
the seat ring retainer and bushing assem­
bly, and in other configurations it won’t.
3. If the valve plug (key 2) or valve plug tip (key 30,
figure 12) will not slide through the seat ring retainer and
bushing assembly (keys 3 and 26), proceed as follows:
a. Slide the seat ring retainer and bushing assembly
(keys 3 and 26) over the adaptor (key 24, figure 10) so
that the bushing rests on the shoulder of the valve plug
or valve plug guide.
b. Place the spiral wound gasket, shim, and bonnet
gasket (keys 12, 25, and 10) on the shoulder of the seat
ring retainer.
c. Place a wrench on the flat areas of the stem just
below the threads for the actuator/stem connection to
keep the stem from turning.
d. Screw the adaptor (key 24, figure 10), which also
includes the valve plug or valve plug guide and seat ring
retainer and bushing assembly and gaskets, onto the
stem/bellows assembly (key 20, figure 10). Tighten the
adaptor until it is snug. Then, turn the adaptor until the
valve stem hole lines up with the next adaptor pin hole.
Drive in a new pin (key 36) to lock the assembly.
e. Install the seat ring gasket (key 13), and replace
the seat ring (key 9).
f. Install the seat ring retainer and bushing assem­
bly, which also contains the valve plug/adaptor assem­
bly or valve plug guide/adaptor assembly, on the top of
the seat ring, ensuring that the seat ring retainer slips
onto the seat ring properly. Any rotation orientation of
the seat ring retainer with respect to the body is accept­
able.
g. Place a new gasket (key 22, figure 10) over the
stem and bellows assembly.
4. If the valve plug (key 2) or the valve plug tip (key 30,
figure 12) will slide through the seat ring retainer and
bushing assembly (keys 3 and 26), proceed as follows:
a. Place a wrench on the flat areas of the stem just
below the threads for the actuator/stem connection to
keep the stem from turning. .
b. Screw the adaptor (key 24, figure 10), which also
includes the valve plug or valve plug guide onto the
stem/bellows assembly (key 20, figure 10). Tighten the
adaptor until it is snug. Then, turn the adaptor until the
13

Design EZ
valve stem hole lines up with the next adaptor pin hole.
Drive in a new pin (key 36) to lock the assembly.
c. Install the seat ring gasket (key 13), and replace
the seat ring (key 9).
d. Install the seat ring retainer and bushing assem­
bly on the top of the seat ring, ensuring that the seat ring
retainer slips onto the seat ring properly. Any rotation
orientation of the seat ring retainer with respect to the
body is acceptable.
e. Place the spiral wound gasket, shim, and bonnet
gasket (keys 12, 25, and 10) on the shoulder of the seat
ring retainer.
f. Slide the valve plug/adaptor assembly or the
valve plug guide/adaptor assembly and the connected
stem and bellows assembly into the seat ring retainer
and bushing assembly (keys 3 and 26).
g. Place a new gasket (key 22, figure 10) over the
stem and bellows assembly.
8. Mount the bonnet on the body and complete the
assembly according to steps 10 through 15 of the re­
placing packing procedure, omitting steps 12 and 13 if
new packing is not being installed, and being sure to
observe the note prior to step 11.
ENVIRO-SEAL Bellows Seal and Bonnet
Replacing a Plain or Extension Bonnet
with an ENVIRO-SEAL Bellows Seal (Stem/
Bellows Assembly) and Bonnet
Instructions are provided for replacing a plain or exten­
sion bonnet with an ENVIRO-SEAL bellows seal bonnet
when the existing valve has a metal seat. If the valve has
a composition seat, refer to figure 12 and to composition
seat information in the Valves with ENVIRO-SEAL Bel­
lows Seal Bonnet procedure of the Trim Maintenance
section.
1. Remove the actuator and bonnet according to steps
1 through 6 of the Replacing Packing procedure of the
Maintenance section.
Note
With some valve plug sizes and configura­
tions, the valve plug will slide through the
seat ring retainer and bushing assembly,
and in other configurations it won’t. If the
valve plug will not slide through the seat
ring retainer and bushing assembly, then
14
F ISH E R ®
___________
the valve plug and stem assembly and the
seat ring retainer and bushing assembly
must be removed together.
2. Using care, remove the valve plug and stem assem­
bly, and, if necessary, the seat ring retainer andt>ushing
assembly from the valve body.
3. Remove and discard the existing bonnet gasket
(key 10, figure 11). Cover the valve body opening to
protect sealing surfaces and to prevent foreign material
from entering the valve body cavity.
Note
The ENVIRO-SEAL stem/bellows assembly
for Design E valves is available only with a
threaded and drilled plug/adaptor connec­
tion. The existing valve plug can be reused
with the new stem/bellows assembly or a
new plug can be installed.
4. Inspect the existing valve plug. If the plug is in good
condition, it can be reused with the new ENVIRO-SEAL
stem/bellows assembly. To remove the existing valve
plug from the stem, first, place the existing plug stem ''ip
assembly in a soft-jaw chuck or other type of vise so that
the jaws grip a portion of the valve plug that is not a
seating surface. Drive out or drill out the groove pin (key
8, figure 11).
5. Place a wrench on the flat areas on the existing
valve stem just below the threads for the actuator/stem
connection. Then, unscrew the stem from the valve plug
(key 2, figure 11).
CAUTION
When installing a valve plug on the EN­
VIRO-SEAL stem/bellows assembly, the
valve stem must not be rotated. Damage to
the bellows may result.
Do not grip the bellows shroud or other
parts of the stem/bellows assembly. Grip
only the flat areas on the stem where it
extends out of the top of the bellows
shroud.
Note ^
The ENVIRO-SEAL stem/bellows assembly
has a one-piece stem.

6. To attach the valve plug to the stem of the new
ENVIRO-SEAL stem/bellows assembly, it is necessary
to first attach the valve plug to the adaptor (key 24,
figure 10). Locate the adaptor. Notice that a hole has not
been drilled in the adaptor threads where the valve plug
screws onto the adaptor.
Secure the valve plug in a soft-jaw chuck or other type of
vise. Do not grip the plug on any seating surface.
Position the plug in the chuck or vise for easy threading
of the adaptor. Thread the adaptor into the valve plug
and tighten to the torque value given in figure 9.
7. Select the proper size of drill bit and drill through the
adaptor using the hole in the valve plug as a guide.
Remove any metal chips or burrs and drive in a new
groove pin (key 8, figure 11) to lock the valve plug/adap­
tor assembly together.
Note
For some valve plug configurations, it is
necessary to place the valve plug/adaptor
assembly inside the seat ring retainer and
bushing assembly before attaching the
adaptor to the stem extending from the
bottom of the ENVIRO-SEAL stem/bellows
assembly. If this task is necessary, then
place the spiral wound gasket, shim, and
bonnet gasket (keys 12, 25, and 10, figure
11) on the shoulder of the seat ring retainer.
Check the existing seat ring retainer and
bushing assembly for clearances. If neces­
sary, use appropriate procedures to sup­
port the seat ring retainer while screwing
the valve plug/adaptor assembly onto the
valve stem extending from the ENVIRO-
SEAL stem/bellows assembly.
8. Place a wrench on the flat areas of the valve stem
just below the threads for the actuator/stem connection
to keep the stem from turning.
9. Screw the adaptor (key 24, figure 10), which also
includes the valve plug or valve plug guide and may
include the seat ring retainer and bushing assembly and
gaskets, onto the valve stem. Tighten the adaptor until it
is snug. Then, turn the adaptor until the valve stem hole
lines up with the next adaptor pin hole. Drive in a new pin
(key 36, figure 10) to lock the assembly. Make certain
the spiral wound gasket, shim, and bonnet gasket (keys
12, 25, and 10, figure 11) are located on the shoulder of
the seat ring retainer.
10. Inspect the seat ring. Replace, if necessary.
11. Install the new stem/bellows assembly with valve
plug/adaptor by placing it into the valve body.
Design EZ
12. Place a new gasket (key 22, figure 10) over the
stem/bellows assembly. Place the new ENVIRO-SEAL
bonnet over the stem/bellows assembly.
13. Properly lubricate the bonnet stud bolts. Install
and tighten the bonnet hex nuts to the proper torque.
14. Install new packing and the metal packing box
parts according to the appropriate arrangement in figure
13 or 14.
15. Install the packing flange. Properly lubricate the
packing flange stud bolts and the faces of the packing
flange nuts.
For graphite packing, tighten the packing flange nuts to
the maximum recommended torque shown in table 3.
Then, loosen the packing flange nuts, and retighten
them to the recommended minimum torque shown in
table 3.
For other packing types, tighten the packing flange nuts
alternately in small equal increments until one of the
nuts reaches the minimum recommended torque shown
in table 3. Then, tighten the remaining flange nuts until
the packing flange is level and at a 90-degree angle to
the valve stem.
16. Install travel indicator parts, stem locknuts, and
mount the actuator on the valve body according to the
procedure in the appropriate actuator instruction man­
ual.
Replacing an Installed ENVIRO-SEAL Bel­
lows Seal (Stem/Bellows Assembly)
Instructions are provided for replacing an ENVIRO-
SEAL bellows seal (stem/bellows assembly) when the
existing valve has a metal seat. If the valve has a
composition seat, refer to figure 12 and to composition
seat information in the Valves with ENVIRO-SEAL Bel­
lows Seal Bonnet procedure of the Trim Maintenance
section.
1. Remove the actuator and bonnet according to steps
1 through 5 of the Replacing Packing procedure of the
Maintenance section.
Note
With some valve plug sizes and configura­
tions, the valve plug will slide through the
seat ring retainer and bushing assembly,
and in other configurations it won’t. If the
valve plug will not slide through the seat
ring retainer and bushing assembly, then
the valve plug and stem assembly and the
seat ring retainer and bushing assembly
must be removed together.
15
r
Design EZ
2. Using care, remove the valve plug and stem assem­
bly, and, if necessary, the seat ring retainer and bushing
assembly from the valve body. Remove and discard the
existing bonnet gasket (key 10, figure 11) and gasket
(key 22, figure 10). Cover the valve body opening to
protect sealing surfaces and to prevent foreign material
from entering the valve body cavity.
CAUTION
The ENVIRO-SEAL stem/bellows assembly
for Design E valves is available only with a
threaded and pinned adaptor/stem con­
nection. The existing valve plug can be
reused with the new stem/bellows assem­
bly or a new plug can be installed. If the
existing valve plug is reused, and the adap­
tor is in good condition, it may be reused
also. However, to avoid weakening the
adaptor that may cause failure in service,
never reuse an old adaptor with a new valve
plug. Using an old adaptor with a new plug
requires drilling a new groove pin hole in
the adaptor, which will weaken the adaptor.
However, a used valve plug may be reused
with a new adaptor.
3. Inspect the existing valve plug and adaptor. If they
are in good condition, they can be reused with the new
stem/bellows assembly, and they do not need to be
separated.
CAUTION
When removing/installing a valve plug on
the ENVIRO-SEAL stem/bellows assembly,
the valve stem must not be rotated. Dam­
age to the bellows may result.
Do not grip the bellows shroud or other
parts of the stem/bellows assembly. Grip
only the flat areas on the stem where it
extends out of the top of the bellows
shroud.
Note
The ENVIRO-SEAL stem/bellows assembly
has a one-piece stem. ' make a connection to an analyzer for leak testing.
4. If the existing valve plug and adaptor are not in
good condition and must be replaced, first, place the
16
/■
I®
Vi
existing stem/bellows assembly and valve plug and
adaptor assembly in a soft-jaw chuck or other type of
vise so that the jaws grip a portion of the valve plug that
is not a seating surface. Drive out or drill out groove pin
(keys 8, figure 11). Drive out pin (key 36, figure 10).
5. Use a wrench on the flat areas on the valve stem
just below the threads for the actuator/stem connection
in a soft-jaw chuck or vice to keep the stem from turning.
Then, unscrew the valve plug from the adaptor and the
adaptor from the stem/bellows assembly.
6. To attach either the existing valve plug or a new one
to the stem of the new ENVIRO-SEAL stem/bellows
assembly, it is necessary to first attach the valve plug to
the adaptor (key 24, figure 10), if the valve plug was
removed from the adaptor. Locate the adaptor. Notice
that a hole has not been drilled in a new adaptor threads
where the valve plug screws onto the adaptor.
If installing either a new valve plug and/or a new adap­
tor, secure the valve plug in a soft-jaw chuck or other
type of vise. Do not grip the plug on any seating surface.
Position the plug in the chuck or vise for easy threading
of the adaptor. Thread the adaptor into the valve plug
and tighten to the torque values given in figure 9.
7. Complete the installation by following steps 7
through 16 of the Replacing a Plain or Extension Bonnet
with an ENVIRO-SEAL Bellows Seal and Bonnet proce­
dure provided in the previous section.
Purging the ENVIRO-SEAL Bellows Seal
Bonnet
The ENVIRO-SEAL bellows seal bonnet has been de­
signed so that it can be purged or leak tested. Refer to
figure 10 for an illustration of an ENVIRO-SEAL bellows
seal bonnet, and perform the following steps for purging
or leak testing.
1. Remove the two diametrically opposed pipe plugs
(key 16).
2. Connect a purging fluid to one of the pipe plug
connections.
3. Install appropriate piping or tubing in the other pipe
plug connection to pipe away the purging fluid or to
4. When purging or leak testing has been completed,
remove the piping or tubing and reinstall the pipe plugs
(key 16).
 Design EZ

Parts Ordering assembly. Refer to the serial number when contacting

Each valve is assigned a serial number which can be
found on the valve body. This same number also ap­
pears on the actuator nameplate when the valve is
shipped from the factory as part of a control valve
your Fisher Controls sales office or sales representative
for technical assistance. When ordering replacement
parts, refer to the serial number and to the 11 -character
part number for each part required from the following
parts list.

Parts Kits
Gasket parts kits are in key 10 table.

Packing Kits (non-live-loaded)

Stem Diameter, Inches (mm) 3/8 (9.5) 1/2 (12.7) 3/4 (19.1)
Yoke Boss Diameter, Inches (mm) 2-1/8 (54) 2-13/16 (71) 3-9/16 (90)
PTFE (C ontains keys 6, 8, 10, 11, and 12) RPACKX00012 RPACKX00022 RPACKX00032
Double PTFE (C ontains keys 6, 8, 11, and 12) RPACKX00042(1M2) RPACKX00052(1) RPACKX00062<1>
PTFE /C om position (Contains keys 7, 8, 11, and 12) RPACKX00072 RPACKX00082 RPACKX00092
Single G raphite R ibbon/Filam ent
(C ontains keys 7 [ribbon ring], 7 [filam ent ring], 8, and 11) RPACKX00102 RPACKX00112 RPACKX00122
Double G raphite Ribbon/Filam ent
(C ontains keys 7 [ribbon ring], 7 [filam ent ring] 8, and 11) RPACKX00162 RPACKX00172 RPACKX00182
1. These parts kits contain one extra lower wiper (key 30). Discard this extra part upon 2. This parts kit contains one extra packing ring (key 7). Discard this extra part upon
assembly. assembly.

P acking K its (E N V IR O -S E A L) R epair

Stem Diameter, Inches (mm) 3/8 (9.5) 1/2 (12.7) 3/4 (19.1)
Yoke Boss Diameter, Inches (mm) 2-1/8 (54) 2-13/16 (71) 3-9/16 (90)
D ouble PTFE (c on ta in s keys 214, 215 & 218) RPAC KX 00192 RPA C KX 00202 RPAC KX 00212
S ingle G rap h ite (c on ta in s keys 207, 208, 209, 210, and 214) RPAC KX 00242 RPA C KX 00252 RPAC KX 00212

P acking K its (EN VIR O -SE AL) R e tro fit

Stem Diameter, Inches (mm) 3/8 (9.5) 1/2 (12.7) 3/4 (19.1)
Yoke Boss Diameter, Inches (mm) 2-1/8 (54) 2-13/16 (71) 3-9/16 (90)
D ouble PTFE (con ta in s keys 200, 201, 211, 212, 214, 215, 217, and 218) RPA C KX R T012 R PA C KX R T022 RPA C KX R T032
S ingle G raphite (con ta in s ke ys 200, 201, 207, 208, 209, 210, 211, 212, 214, and 217) RPA C KX R T062 R PA C KX R T072 RPA C KX R T082

17
Design EZ
FISHER*|

Key Description Part Number

Parts List
6* P acking Set, PTFE (2 re q ’d fo r d o uble packing)
3 /8 -in ch (9.5 mm) stem 1R290001012
Bonnet 1/2 -in ch (12.7 mm) stem 1 R 290201012
3 /4 -in ch (19.1 mm) stem 1R290401012
EN V IR O -S EA L B ellow s Seal P acking S et
Key Description Part Number PTFE fo r 3 /8 inch (9.5 m m) stem (1 re q ’d
fo r single packing, 2 re q ’d fo r double
1 B onnet/E N V IR O -S E A L be llo w s seal bonnet packing) 12A9016X012
If you need a bon ne t o r an EN V IR O -S EA L PTFE fo r size 2 w ith 1/2 inch (12.7 mm)
b e llo w s seal bon ne t as a replacem ent stem (2 re q ’d fo r d o uble packing) 12A9016X012
part, o rd e r by valve size and stem PTFE fo r size 3 and 4 w ith 1/2 inch
diam eter, serial num ber, and desired 12.7 m m) stem (2 re q 'd fo r double
m aterial. packing) 12A8832X012
2 B a ffle ,(fo r e x te n s io n bon ne ts only) See fo llo w in g table 6* P acking Set, PTFE/KALREZ<1>
3 P acking Flange 3 /8 -in ch (9.5 mm) stem 13B 0963X 012
2-1 /8 inch (54 m m) yoke boss 1/2 -in c h (12.7 mm) stem 13B096;4X012
PI (plated) steel (std fo r all trim s) 1E943724102 3 /4 -in ch (19.1 m m) stem 13B0965X012
S31600 (316 SST) 1E943735072 7* P acking Ring, P T F E /co m p (for
2- 13/16 inch (71 m m) yo ke boss d ouble packing)
PI steel (std fo r all trim s) 1 E944223072 3 /8 -in ch (9.5 m m) stem
S31600 1F380335072 P T F E /co m p (7 req 'd ) 1F3370X0012
3- 9 /1 6 inch (90 m m) yoke boss 1/2 -in ch (12.7 mm) stem
PI steel (std fo r all trim s) 1E944823072 P T F E /com p (10 re q ’d) 1E319001042
S31600 1F380435072 3/4 -in ch (19.1 m m) stem
3 EN V IR O -S EA L B e llo w s Seal P acking Flange P T F E /com p (8 re q ’d) 1E319101042
S31603 7* P acking Ring, g ra p h ite rib bo n ring (2 re q ’d
For 3 /8 inch (9.5 m m) stem and size 2 fo r single packing, 3 re q 'd fo r double
w / 1/2 inch (12.7 mm) stem 28A0827X012 packing)
Size 3 and 4 w / 1/2 inch (12.7 m m) stem 28A0829X 012 3 /8 -in ch (9.5 m m) stem 1V3160X0022
N 10276 1 /2 -in ch (12.7 m m) stem 1V3802X0022
For 3 /8 inch (9.5 mm) stem and size 2 3 /4 -in ch (19.1 mm) stem 1V2396X0022
w / 1/2 inch (12.7 m m) stem 28A 0827X 112 7* P acking Ring, g ra p h ite fila m e n t ring
Size 3 and 4 w / 1/2 inch (12.7 m m) stem 28A 0829X 112 3 /8 -in ch (9.5 mm) stem (2 re q 'd fo r single
4 P acking Flange S tud (2 re q ’d) packing, 4 re q ’d fo r d ouble packing) 1F3370X0322
2 -1 /8 inch (54 m m) y o ke boss 1/2 -in ch (12.7 m m) stem (3 re q ’d fo r
PI steel (std fo r all trim s) 1E944131032 single packing, 5 re q ’d fo r double
S31600 1E944135222 packing) 1E3190X0222
2- 13/16 (71 m m) y o ke boss 3 /4 -in ch (19.1 m m) stem (2 re q 'd fo r
PI steel (std fo r all trim s) 1E944431032 single packing, 4 re q ’d fo r double
S31600 1E944435222 packing) 1E3191X0282
3- 9 /1 6 inch (90 m m) yoke boss 7* EN V IR O -S E A L B ellow s Seal P acking Ring
PI steel (std fo r all trim s) 1E944931032 fo r low ch lo rid e g ra p h ite rib b o n /fila m e n t
S31600 1E944935222 packing arra n g e m e n t
4 EN V IR O -S E A L B e llo w s Seal Stud B olt R ibbon packing ring fo r 3 /8 inch (9.5 mm)
S31603 and size 2 w ith 1/2 inch (12.7 mm) stem
3 /8 inch (9.5 m m) stem 1E944135222 (4 re q ’d) 18A0908X012
S ize 2 w / 1/2 inch (12.7 m m) stem 11B6951X072 F ilam ent packing ring fo r 3 /8 inch
S ize 3 and 4 w / 1 /2 inch (12.7 m m) stem 16A1061X022 (9.5 m m ) a n d s iz e 2 w ith 1/2 inch
N 10276 (12.7 mm) stem (4 req 'd ) 1P3905X0172
3 /8 inch (9.5 mm) stem 1E944140152 R ibbon packing ring fo r size 3 and 4
Size 2 w / 1/2 inch (12.7 m m) stem 11B6951X052 w ith 1/2 inch (12.7 mm) stem (4 re q ’d) 18A0918X012
S ize 3 and 4 w / 1/2 inch (12.7 m m) stem 16A 1061X072 F ilam ent packing ring fo r size 3 and 4
5 P acking Flange N ut (2 req 'd ) w ith 1/2 inch (12.7 mm) stem (4 re q ’d) 14A 0915X042
2 -1 /8 inch (54 m m) y o ke boss 8 S pring, S31600 (fo r single PTFE packing
PI steel (std fo r all trim s) 1E944024112 only)
S31600 1E944035252 3 /8 -in ch (9.5 m m) stem 1F125437012
2- 13/16 (71 m m) yo ke boss 1/2 -in ch (12.7 mm) stem 1F125537012
PI steel (std fo r all trim s) 1 E944524112 3 /4 -in ch (19.1 m m) stem 1F125637012
S31600 1E944535252 8 Spacer, N 04400 (Monel<2>) (for
3- 9 /1 6 inch (90 mm) yo ke boss single PTFE packing only) (fo r M on e l trim
PI steel (std fo r all trim s) 1E944624112 only)
S31600 1E944635252 3 /8 -in ch (9.5 mm) stem 1F131840032
5 EN V IR O -S EA L B e llo w s Seal H ex N ut 1 /2 -in ch (12.7 mm) stem 1F131740012
S31603 3 /4 -in ch (19.1 mm) stem 1F131640032
For 3 /8 inch (9.5 m m) stem and size 2 8 Lantern Ring (fo r d o uble PTFE packing)
w / 1/2 inch (12.7 mm) stem 1E944035252 3 /8 -in ch (9.5 m m) stem
S ize 3 and 4 w / 1/2 inch (12.7 m m) stem 1A375335252 S31600 (std fo r S31600 and S41600 trim s) 1F364135072
N 10276 N 04400 (std fo r N 05500 trim ) 1F364140032
For 3 /8 inch (9.5 m m) stem and size 2 1/2 -in ch (12.7 mm) stem (2 re q ’d)
w / 1/2 inch (12.7 m m) stem 1E944040152 S31600 (std fo r S31600 and S41600 trim s) 1J962335072
Size 3 and 4 w / 1/2 inch (12.7 m m) stem 1A3753X0062 N 04400 (std fo r N 05500 trim ) 1J962340032

* Recommended spare part

1. Mark owned by E. I. & DuPont de Nemours Co., Inc.
18 2. Mark owned by INCO Alloys International.
 Design EZ

yfpV

(; 4

1 (D
1

0 ^ .
E X T E N S IO N B O N N E T E N V IR O -S E A L B E L L O W S S E A L B O N N E T

Figure 10. Typical Bonnets

19
Design EZ ✓

Key Description Pert Number Key Description Part Number

L antern R ing (fo r d o u ble PTFE packin g ) (C ont.) 11 * P acking B ox Ring (Cont.)
3 /4 -in c h (19.1 m m ) stem Double PTFE packing
S31600 (std fo r S31600 and S41600 trim s) 0N 028435072 3 /8 -in ch (9.5 m m) stem
N04400 (std fo r N 05500 trim ) 0N 028440032 S31600 (std fo r S31600 and S41600 trim s) 1J873135072
For P T F E /co m p packing G lass-filled PTFE (std fo r N 05500 trim ) 17A6872X012
3 /8 -in c h (9.5 m m) stem 1/2 -in ch (12.7 m m) stem
S31600 (std fo r S31600 and S41600 trim s) 1F364135072 S31600 (std fo r S31600 and S41600 trim s) 1J873235072
N 04400 (std fo r N 05500 trim ) 1F364140032 G lass-filled PTFE (std fo r N 05500 trim ) 17A 6873X 012
1/2 -in c h (12.7 m m) stem 3 /4 -in ch (19.1 m m) stem
S31600 (std fo r S31600 and S41600 trim s) 1J962335072 S31600 (std fo r S31600 and S41600 trim s) 1J873335072
N04400 (std fo r N 05500 trim ) 1J962340032 G lass-filled PTFE (std fo r N 05500 trim ) 17A6874X012
3 /4 -in c h (19.1 m m) s te m P T F E /co m p o sitio n packing
S31600 (std fo r S31600 and S41600 trim s) 0N 028435072 3 /8 -in ch (9.5 m m) stem
N 04400 (std fo r N 05500 trim ) 0N 028440032 S31600 (std fo r S31600 and S41600 trim s) 1J873135072
For g ra p h ite rib b o n /fila m e n t packing G lass-filled PTFE (std fo r N 05500 trim ) 17A6872X012
3 /8 -in c h (9.5 m m ) stem (2 re q 'd fo r single 1/2 -in ch (12.7 mm) stem
packing, 1 re q ’d fo r d o u ble packing) S31600 (std fo r S31600 and S41600 trim s) 1J873235072
S31600 (std fo r S31600 and S41600 trim s) 1F364135072 N 05500 (std fo r N 05500 trim ) 1J873246222
N 04400 (std fo r N 05500 trim ) 1F364140032 3 /4 -in ch (19.1 m m) stem
1/2 -in c h (12.7 m m) stem (3 re q 'd fo r S31600 (std fo r S31600 and S41600 trim s) 1J873335072
single packing, 2 re q ’d fo r d ouble G lass-filled PTFE (std fo r N 05500 trim ) 17A6874X012
packing) 12* U pper W iper, fe lt
S31600 (std fo r S31600 and S41600 trim s) 1J962335072 3 /8 -in ch (9.5 m m) stem 1J872606332
N04400 (std fo r N 05500 trim ) 1J962340032 1/2 -in ch (12.7 m m) stem 1J872706332
3 /4 -in c h (19.1 m m) stem (2 re q ’d fo r 3 /4 -in ch (19.1 m m) stem 1J872806332
single packing, 1 re q ’d fo r d o uble 12* EN V IR O -S EA L B e llo w s Seal U pper W iper
packing) For 3 /8 inch (9.5 m m) and size 2 w ith 1/2
S31600 (std fo r S31600 and S41600 trim s) 0N 028435072 inch (12.7 m m) stem 18A0868X012
N04400 (std fo r N 05500 trim ) 0N 028440032 For size 3 and 4 w ith 1/2 inch (12.7 mm)
EN V IR O -S E A L B e llo w s Seal S pring stem 18A 0870X 012
For 3 /8 inch (9.5 m m) and size 2 w ith 1/2 13 P acking F ollow er
inch (12.7 m m) stem (fo r single packing S31600 (std fo r all trim s m aterials)
1F125437012 3 /8 -in ch (9.5 m m) stem 1E943935072
only)
1/2 -in ch (12.7 m m) stem 1E944335072
EN V IR O -S E A L B e llo w s Seal S p a ce r fo r S31600
3 /4 -in ch (19.1 m m) stem 1E944735072
(316 SST) c o n s tru c tio n
For single PTFE p a ckin g size 2 N 04400 (op tio n a l fo r alloy trim s)
18A0872X012 3 /8 -in ch (9.5 m m) stem 1E943940032
w ith 1/2 inch (12.7 m m) stem
1/2 -in ch (12.7 m m) stem 1 E944340032
For d o uble PTFE, g ra p h ite rib b o n /fila m e n t
18A0872X012 3 /4 -in ch (19.1 m m) stem 1E944740032
p a ckin g 3 /8 inch (9.5 m m) stem
S ize 2 w ith 1/2 inch (12.7 m m ) stem 13* EN V IR O -S E A L B e llo w s Seal B ushing
(2 re q ’d) 18A0872X012 For 3 /8 inch (9.5 m m) stem (1 re q ’d),
S ize 3 and 4 w ith 1 /2 inch (12.7 mm) fo r size 2 w ith 1/2 inch (12.7 m m) stem
stem (2 re q ’d) 18A0874X012 (2 req 'd )
S31600/P TFE 18A0820X012
E N V IR O -S E A L B e llo w s Seal S p a ce r fo r N 10276
R 30006 18A0819X012
(H astelloy C) c o n s tru c tio n
S 3 1600/C r C t 1 1 B 1 155X012
For sin g le PTFE packing
3 /8 inch (9.5 m m) stem and size 2 For size 3 and 4 w ith 1/2 inch (12.7 mm)
w ith 1/2 inch (12.7 m m ) stem (1 re q ’d) 18A0872X032 stem (1 re q ’d)
S 31600/P TFE 18A0824X012
S ize 2 w ith 1 /2 inch s te m (12.7 m m)
1 H981540152 R30006 18A 0823X 012
stem o n ly (1 re q ’d)
S 316 0 0 /C r C t 1 1 B 1 157X012
For d o uble PTFE, g ra p h ite rib b o n /fila m e n t
p a ckin g 3 /8 inch (9.5 m m ) stem 18A0872X032 13* EN V IR O -S E A L B e llo w s Seal B u s h in g /L in e r
S ize 2 w / 1/2 inch (12.7 m m ) stem For 3 /8 inch (9.5 m m) stem (1 re q ’d),
(2 re q ’d) 18A0872X032 fo r size 2 w ith 1/2 inch (12.7 m m) stem
S ize 3 and 4 w ith 1/2 inch (12.7 mm) (2 re q ’d)
18A0874X032 N 10276 bushing, P T FE /glass liner 12B2713X012
stem (2 req 'd )
N 10276 bushing, P T F E /carbon liner 12B2713X042
10 S pecial W asher, S31600 (fo r sin g le PTFE
packing) For size 3 and 4 w ith 1/2 inch (12.7 m m)
3 /8 -in c h (9.5 m m ) stem 1F125236042 stem (1 req 'd )
1F125136042 N 10276 bushing, P T FE /glass liner 12B2715X012
1/2 -in c h (12.7 m m ) stem
1F125036042 N 10276 bushing, P T FE /carbon liner 12B 2715X042
3 /4 -in c h (19.1 m m) stem
11* P acking B o x Ring 14 Pipe Plug (not show n)
S teel bon ne t 1A767524662
S ingle PTFE packing
C F8M bo n ne t 1A767535072
3 /8 -in c h (9.5 m m ) stem
L u b rica to r 0V0873000A 2
S31600 (std fo r S 31600 and S41600 trim s) 1J873135072 14
1J873146222 14 L u b ric a to r/is o la tin g Valve ‘ A J 5428000A2
N 05500 (std fo r N 05500 trim )
1/2 -in c h (12.7 m m) stem 15 Y o ke L o ckn ut
S31600 (std fo r S31600 and S41600 trim s ) 1J873235072 2-1 /8 inch (54 m m) yo ke b o ss 1E793023062
N 05500 (std fo r N 05500 trim ) 1J873246222 2- 13/15 inch (71 m m) yo ke b o ss 1 E807423062
3- 9 /1 6 inch (90 m m) yo ke b o ss 1E832723062
3 /4 -in c h (19.1 m m) stem
S31600 (std fo r S 31600 and S41600 trim s ) 1J873335072
N 05500 (std fo r N 05500 trim ) 1J873346222

'Recommended spare part.

20
 Design EZ

Key Description Part Number Key Description Pert Number

15 EN V IR O -S E A L B e llo w s Seal Y o ke L o c k n u t 24 EN V IR O -S EA L B e llo w s Seal A d a p to r (Cont.)
2 -1 /8 inch (54 m m ) yo ke boss 1E793023062 S ize 2 M icro -F o rm w /1 /4 th ro u g h 3 /4 -in ch
2 -1 3 /1 6 inch (71 m m ) yo ke boss 1E807423062 p o rt and m etal seat, and
16 Pipe Plug (not show n) Size 2 M icro -F o rm w /3 /8 th ro u g h 3/4 -in ch
Steel 1A369224092 p o rt and co m p o sitio n seat, and
S31600 1A369235072 Size 2 restricte d p o rt w /m e ta l and
16 E N V IR O -S E A L B e llo w s Seal Pipe Plug co m p o sitio n seats 22B4256X 012
(2 re q ’d)
S ize 3 re stricte d p o rt w /m e ta l se a t 22B4257X 012
WCB 1A767524662 S ize 4 re stricte d p o rt w /m e ta l seat 22B4253X 012
C F3M (316 SST) 1A767535072 N 10276
C W 2M (H a ste lloy C) 1A767540152 S ize 1/2 th ro u g h 1-1 /2 M icro -F lo w and
C N 7M (A llo y 20) 1A767540092 M icro -F lu te w /m e ta l seat 22B 4259X022
M35-1 (M onel) 1A767540012 Size 1/2 th ro u g h 1-1/2 M icro -F lu te and
20* E N V IR O -S E A L B e llo w s Seal S te m /B e llo w s M icro -F o rm w /1 /4 th ro u g h 3 /8 inch p o rt
A sse m b ly and co m p o sitio n seats 22B 4258X022
1 Ply B ellow s S ize 1/2 th ro u g h 1-1/4 w /fu ll p o rt and
S31603 trim m at'l, N 06625 b e llo w s m a t’l co m p o sitio n seat, and
S ize 1 w / 3 /8 inch (9.5 m m) stem 32B 4224X 012 Size 1/2 th ro u g h 1-1 /2 M icro -F o rm w ith
S ize 1-1 /2 w / 3 /8 inch (9.5 m m ) stem 32B 4225X 012 1/2 th ro u g h 3 /4 inch p o rt and
S ize 2 w / 1/2 inch (12.7 m m) stem 32B 4226X 012 co m p o sitio n seat, and
S ize 3 w / 1/2 inch (12.7 m m) stem 32B 4227X 012 Size 1-1/2 w /fu ll & re stricte d p o rt and
S ize 4 w / 1/2 inch (12.7 m m) stem 3 2B 4228X 012 co m p o sitio n seat 22B 4260X022
N 06022 trim m at'l, N 06022 b e llo w s m a t’l S ize 1/2 th ro u g h 1-1/4 w /fu ll p o rt and
S ize 1 w / 3 /8 inch (9.5 m m) stem 32B 4224X 022 m etal seat, and
S ize 1-1 /2 w / 3 /8 inch (9.5 m m ) stem 32B 4225X 022 Size 1/2 th ro u g h 1-1/2 M icro -F o rm w ith
S ize 2 w / 1/2 inch (12.7 m m) stem 32B 4226X 022 m etal seat, and
S ize 3 w / 1/2 inch (12.7 m m) stem 32B 4227X 022 S ize 1-1 /2 fu ll & re stricte d p o rt w ith
S ize 4 w / 1/2 inch (12.7 m m) stem 32B 4228X 022 m etal seat 22B4249X 022
2 Ply B ellow s Size 2 M icro -F lo w w /m e ta l seat, and
S 31603 trim m at'l, N 06625 b e llo w s m a t’l Size 2 M icro -F lu te w /m e ta l and
S ize 1 w / 3 /8 inch (9.5 m m) stem 32B 4224X 032 co m p o sitio n seats, and
S ize 1-1 /2 w / 3 /8 inch (9.5 m m ) stem 32B 4225X 032 S ize 2 M icro -F o rm w /1 /4 -in c h p o rt and
S ize 2 w / 1/2 inch (12.7 m m) stem 32B 4226X 032 co m p o sitio n seat 22B 4266X 022
S ize 3 w / 1/2 inch (12.7 m m) stem 32B 4227X 032 S izes 2, 3, and 4 fu ll p o rt w /m e ta l and
S ize 4 w / 1/2 inch (12.7 m m) stem 32B 4228X 032 c o m p o sitio n seats 22B 4251X 022
N 06022 trim m a t’l, N 06022 b e llo w s m a t’l S ize 2 M icro -F o rm w /1 /4 th ro u g h 3 /4 -in ch
S ize 1 w / 3 /8 inch (9.5 m m) stem 32B 4224X 042 p o rt and m etal seat, and
S ize 1-1/2 w / 3 /8 inch (9.5 m m) stem 32B 4225X 042 Size 2 M icro -F o rm w /3 /8 th ro u g h 3/4 -in ch
S ize 2 w / 1/2 inch (12.7 m m ) stem 32B 4226X 042 p o rt and co m p o sitio n seat, and
S ize 3 w / 1/2 inch (12.7 m m) stem 32B 4227X 042 Size 2 re stricte d p o rt w /m e ta l and
S ize 4 w / 1/2 inch (12.7 m m) stem 32B 4228X 042 co m p o sitio n seats 22B 4256X022
22* E N V IR O -S E A L B e llo w s Seal B o n n e t G asket Size 3 re stricte d p o rt w /m e ta l seat 22B 4257X022
(gra p h ite lam inate) S ize 4 re stricte d p o rt w /m e ta l seat 22B 4253X 022
S ize 1/2 th ro u g h 1-1/4 12B 6316X022 27 Pipe N ipple, fo r lu b /iso la tin g valve,steel 1D239726232
S ize 1-1/2 12B 6317X022 28 EN V IR O -S EA L B e llo w s Seal N am eplate, W a rn in g l E5174X00A2
S ize 2 12B 6318X022 29 EN V IR O -S E A L B ellow s Seal D rive S crew
S ize 3 12B 6319X022 (2 req 'd ) 1A368228982
S ize 4 12B6320X022 34 Lubricant, N ever-S eez N ickel S p e c ia l®
24 EN V IR O -S E A L B e llo w s Seal A d a p to r o r equ iva le nt (not fu rn ish e d w ith valve)
S31603 36* EN V IR O -S EA L B e llo w s Seal Pin 12B3951X012
S ize 1/2 th ro u g h 1-1 /2 M ic ro -F lo w and 37 EN V IR O -S EA L B e llo w s Seal W arning Tag 22B 3975X012
M ic ro -F lu te w /m e ta l seat 22B 4259X 012 38 EN V IR O -S EA L B e llo w s Seal Tie 18A9401X012
S ize 1/2 th ro u g h 1-\1/2 M icro -F lu te and 39 ENV IR O -S EA L B e llo w s Seal T h ru s t Ring
M ic ro -F o rm w /1 /4 th ro u g h 3 /8 inch p o rt For 3 /8 inch (9.5 m m) stem
and c o m p o s itio n seats 22B 4258X 012 For use w ith S31600 trim (3 re q ’d fo r
S ize 1/2 th ro u g h 1-1 /2 w /fu ll p o rt and single PTFE packing, 1 re q 'd fo r d o uble
c o m p o s itio n seat, and PTFE and g ra p h ite /rib b o n packing) 19A9208X112
S ize 1/2 th ro u g h 1-1 /2 M icro -F o rm w ith For use w ith N 10276 trim (1 re q 'd fo r
1/2 th ro u g h 3 /4 inch p o rt and PTFE and g ra p h ite rib b o n packing) 19A9208X022
c o m p o s itio n seat 2 2B 4260X 012 For 1/2 inch (12.7 m m) stem
S ize 1/2 th ro u g h 1-1 /2 w /fu ll p o rt and -For use w ith S31600 trim (2 re q 'd fo r
m etal seat, and single PTFE packing) 19A 9208X 112
S ize 1/2 th ro u g h 1-1 /2 M ic ro -F o rm w ith 200 Stud (2 re q ’d)
m etal seat 22B 4249X 012 For EN V IR O -S EA L packing
S ize 2 M ic ro -F lo w w /m e ta l seat, and S A -193-C L 2(B 8M ), .
S ize 2 M ic ro -F lu te w /m e ta l and S train H ardened
c o m p o s itio n seats, and 3 /8 -in ch (9.5 m m) stem 1E944135222
S ize 2 M ic ro -F o rm w /1 /4 -in c h p o rt and 1/2 -in c h (12.7 m m) stem 1E944435222
c o m p o s itio n seat 22B 4266X 012 3 /4 -in ch (19.1 m m) stem 1E944935222
S izes 2, 3, and 4 fu ll p o rt w /m e ta l and
c o m p o s itio n seats 22B 4251X 012

* Recommended spare part

3. M ark owned .by Never-Seez Corp.
21
 F IS H E R *)
Design EZ

Key Description Part Number Key Description Part Number

200 Stud (2 re q 'd ) (C ont.) 210* P acking Ring (2 req'd)

For H IG H -S E A L packing For EN V IR O -S EA L and H IG H -SEA L
S31600 (316 sta in le ss steel) packing
3 /8 -in c h (9.5 m m) stem 11B6951X072 G raphite R ibbon
1/2 -in c h (12.7 m m) stem 1K7298X00A2 fo r g ra p h ite packing
3 /4 -in c h (19.1 m m) stem 1R387335222 3/8 -in ch (9.5 m m) stem 1V3160X0022
1/2 -in ch (12.7 mm) stem 1V3802X0022
201 P acking Flange
3 /4 -in ch (19.1 m m) stem 1V2396X0022
S31600
For EN V IR O -S EA L packing 211* P acking B ox Ring
3 /8 -in c h (9.5 m m) stem 12B6923)<012 For EN V IR O -S EA L packing
1 /2 -in c h (12.7 m m) stem 12B6924X012 S31600
3/4 -in ch (19.1 m m) stem 12B6925X012 For PTFE Packing
3 /8 -in ch (9.5 mm) stem 1J873135072
For H IG H -S E A L packing
3 /8 -in c h (9.5 m m) stem 21B2195X012 1/2 -in ch (12.7 mm) stem 1J873235072
1/2 -in c h (12.7 mm) stem 21B 2196X012 3 /4 -in ch (19.1 m m) stem 1J873335072
3 /4 -in c h (19.1 m m) stem 21B2197X012 For EN V IR O -S EA L and H IG H -SEA L
202 S pring, (2 req 'd ) packing
For H IG H -S E A L packing S31600
S17700 (17-7 PH SST) For G raphite packing
11B2179X022 3 /8 -in ch (9.5 m m) stem 12B5774X012
3 /8 -in c h (9.5 m m) stem
11B2182X022 1 /2 -in ch (12.7 m m) stem 12B5775X012
1/2 -in c h (12.7 m m) stem
11B 2184X022 3 /4 -in ch (19.1 mm) stem 12B5776X012
3 /4 -in c h (19.1 m m) stem
N 07718 (Inconel 718) 212 H ex N ut (2 re q ’d)
3 /8 -in c h (9.5 m m) stem 11B2179X032 For EN V IR O -S E A L and H IG H -SEA L
1/2 -in c h (12.7 m m) stem 11B2182X032 packing
3 /4 -in c h (19.1 m m) stem 11B 2184X032 SA 194 8M Strain
203 S pring guide packing fo llo w e r H ardened S31600
3 /8 -in ch (9.5 m m) stem 1E944035252
For H IG H -S E A L packing
1/2 -in ch (12.7 m m) stem 1 E944535252
S31600
21B2190X012 3 /4 -in ch (19.1 mm) stem 1E944635252
3 /8 -in c h (9.5 m m) stem
1/2 -in c h (12.7 m m) stem 21B2191X012 213 L ubricant, N ever-S eez Nickel
3 /4 -in c h (19.1 m m) stem 21B2192X012 S pecial o r equivalent
204 S crew , 18-8 SST (4 re q ’d) For EN V IR O -S E A L and H IG H -SEA L
For H IG H -S E A L packing 1B2752X0022 packing (not fu rn ish e d w ith
205 Load Scale, 18-8 SST (2 re q ’d) packing)
For H IG H -S E A L packing 214* A n ti-E xtru sio n w a sh e r (4 req 'd )
3 /8 -in c h (9.5 m m) stem 11B2168X012 For EN V IR O -S EA L packing
1/2 -in c h (12.7 m m) stem 1 1B2171X012 PTFE fille d (off-w h ite )
3 /4 -in c h (19.1 m m) stem 11B2173X012 For PTFE packing
3 /8 -in ch (9.5 m m) stem 12B6336X022
206 In d ic a to r Disk, 18-8 SST
1/2 -in ch (12.7 m m) stem 12B6335X 022
For H IG H -S E A L packing
1 1B3757X012 3 /4 -in ch (19.1 mm) stem 12B6660X012
3 /8 -in c h (9.5 m m) stem
1/2 -in c h (12.7 m m) stem 11B3787X 012 214* P acking W asher (5 re q ’d)
3 /4 -in c h (19.1 m m) stem 1 1B3788X012 For EN V IR O -S EA L packing
207* G uide B ushing, w h ite (2 req 'd ) PTFE
For EN V IR O -S E A L and H IG H -SEA L For g ra p h ite packing
3 /8 -in ch (9.5 m m) stem 12B6936X012
packing
1/2 -in ch (12.7 m m) stem 12B6937X012
C a rbo n -g ra p h ite
3 /4 -in ch (19.1 m m) stem 12B 6938X 012
fo r g ra p h ite packing
3 /8 -in c h (9.5 m m) stem 12B5780X012 215* P acking Set (2 req 'd )
1/2 -in c h (12.7 m m) stem 12B5782X012 For EN V IR O -S E A L packing
3 /4 -in c h (19.1 m m) stem 12B5784X012 P T FE -carbon/P TF E
3 /8 -in ch (9.5 m m) stem 12B 6663X 012
208* G uide B ushing, no c o lo r
1/2 -in ch (12.7 mm) stem 12B6667X012
For EN V IR O -S E A L and H IG H -SEA L
3 /4 -in ch (19.1 m m) stem 12B6671X012
packing
C arbo n -G ra p h ite 216 Lantern Ring
fo r g ra p h ite packing For EN V IR O -S EA L packing
3 /8 -in c h (9.5 m m) stem 12B5781X012 S31600
1/2 -in c h (12.7 m m) stem 12B5783X012 For PTFE packing
12B5785X012 3 /8 -in ch (9.5 m m) stem 22B6943X 012
3 /4 -in c h (19.1 m m) stem
209* P acking Ring!4) (3 re q ’d) 1 /2 -in ch (12.7 m m) stem
1 req 'd 22B 6944X 012
For EN V IR O -S EA L and H IG H -SEA L
packing 3 /4 -in ch (19.1 m m) stem
2 re q ’d 0N 028435072
G raphite C o m po site
fo r g ra p h ite packing 217 S pring Pack A ssem bly
3 /8 -in c h (9.5 mm) stem 12B5798X012 For EN V IR O -S E A L packing
1 /2 -in c h (12.7 mm) stem 12B5799X012 316 S S T /Inconel
3 /4 -in c h (19.1 m m) stem 12B5800X012 For PTFE packing
3 /8 -in ch (9.5 mm) stem 12B6921X062
1/2 -in ch (12.7 m m) stem 12B6921X072
3 /4 -in ch (19.1 m m) stem 12B6921X082

'Recommended spare part.

4. Part num ber is stamped on part.
22
 Design EZ

Key Description Part Number Key Description Part Number

217 S pring P ack A s se m b ly (Cont.) 7* Stem (C o n t’d.)
F or g ra p h ite packing 3-inch valve
3 /8 -in c h (9.5 m m) stem 12B6922X062 1/2 -in ch (12.7 mm) stem
1/2 -in c h (12.7 m m) stem 12B6922X072 S31600 1K586935162
3 /4 -in c h (19.1 m m) stem 12B6922X 082 N05500 10A8840XH 32
218* L o w e r w ip e r 3/4 -in ch (19.1 m m) stem
For E N V IR O -S E A L packing S31600 10A9265XJ62
PTFE N 05500 1 U 226550192
For PTFE packing 4-inch valve
3 /8 -in c h (9.5 mm) stem 1J872106992 R estricted ca p a city trim
1/2 -in c h (12.7 m m) stem 1J872206992 1/2 -in c h (12.7 mm) stem
3 /4 -in c h (19.1 mm) stem 1J872306992 S31600 1J320535162
N05500 1J3205X 0062
3 /4 -in ch (19.1 mm) stem
S31600 1U230835162
Body N05500 1 U 230847492
Full ca p a city trim
1/2 -in ch (12.7 mm) stem
1 V alve B ody S31600 1 K586935162
If you need a valve body as a replacem ent N05500 10A8840XH32
pa rt, o rd e r by valve size, serial num ber, 3/4 -in ch (19.1 mm) stem
and d e sire d m aterial. S31600 1U 226535162
2* V alve Plug See fo llo w in g table N05500 1U226550192
3* S eat R ing R etainer (pa rt num bers fo r th e s e a t ring 8* G roove Pin See fo llo w in g table
re ta in e r/b u s h in g assy are pro vid e d in a fo llo w in g table) 9* S eat Ring See fo llo w in g table
1/2, 3 /4 , & 1-inch valve 10* B onnet G asket See fo llo w in g table
CB7CU-1 (17-4PH SST) 25A 6683X012 12* S piral W ound G asket See fo llo w in g table
C F8M (316 SST) 25A 6683X022 13* Seat Ring G asket See fo llo w in g table
M35-1 (M onel) 25A6683X052 15 C ap S cre w o r S tud B olt See fo llo w in g table
1-1/2 inch valve 16 Nut See fo llo w in g table
CB7Cu-1 25A6685X012 17 Pipe Plug
C F8M 25A 6685X022 For use in b odies w ith d rain ta p ping only
M35-1 25A 6685X052 Steel 1A 771528992
2-inch valve S31600 1A771535072
CB7Cu-1 25A 6687X 012 18 Flow A rrow , SST
C F8M 25A6687X022 1/2, 3/4, & 1-inch bodies 1V105938982
M35-1 25A6687X052 1-1/2 th ro u g h 4-inch bodies 1V106038982
3 -inch valve 19 Drive S crew , SST (4 re q ’d) 1A368228982
CB7CU-1 25A6689X012 25* Shim See fo llo w in g table
CF8M 25A6689X022 26* Bushing See fo llo w in g table
M35-1 25A6689X052 (See add itio na l table fo r p a rt n um bers o f
4 -inch valve a ssem blies th a t include both the seat ring
CB7Cu-1 35A6691X012 and the bushing)
C F8M 35A6691X 022 27 Valve Plug G uide (for co m p o sitio n seats
M35-1 35A6691X 052 only) See fo llo w in g table
Stem 28* D isk R etainer, (co m p o sitio n seats only)
For use w ith g ro u p 1 a c tu ato rs 1/4 -in ch (6.4 mm) p o rt dia m e te r
1/2, 3 /4 , 1, & 1-1 /2 inch valve S31600 16A3441X012
3 /8 -in c h (9.5 m m) stem N05500 16A3441X042
S31600 1U 388835162 S41600 16A3441X052
N05500 10A8823XA22 3 /8 -in ch (9.5 m m) p o rt diam eter
1/2 -in c h (12.7 m m) stem S31600 16A5706X012
S31600 1U 388935162 N 05500 16A5706X042
N05500 1U 3889X0012 S41600 16A5706X052
1/2 -in c h (12.7 m m) x 3 /8 -in c h (9.5 mm) 29* Disk, PTFE (co m p o sitio n seats only)
stem 1/4 -in ch (6.4 m m) p o rt diam eter 13A1226X062
S31600 1U530935162 3 /8 -in ch (9.5 m m) p o rt diam eter 13A5125X042
N 05500 1U530946222 1/2 -in ch (12.7 mm) p o rt dia m e te r 1P696806242
2-inch valve 3/4 -in ch (19.1 m m) p o rt diam eter 1P696106242
1/2 -in c h (12.7 m m) stem 1-inch (25.4 m m) p o rt dia m e te r 1P696906242
S31600 11)388935162 1-1/2 inch (38.1 mm) p o rt diam eter 1U 279606242
N 05500 1 U 3889X0012 2-inch (50.8 m m) p o rt dia m e te r 1U 279906242
1/2 -in c h (12.7 mm) x 3 /8 -in c h 9.5 mm) * 3-inch (76.2 mm) p o rt dia m e te r 1F5653X0012
stem 4-inch (101.6 m m) p o rt diam eter 16A 3462X 012
S31600 1U530935162 30 T ip (co m p o sitio n seats only) * See fo llo w in g table
N 05500 •, 1U530946222 31* G roove Pin (co m p o sitio n seats only)
3 /4 -in c h (19.1 m m) stem 1/2 -in ch (12.7 m m) p o rt diam eter
S31600 1U 226535162 S31600 and S41600 1B599038992
N 05500 1U226550192 N 05500 1B5990X0032

'Recommended spare part. 23

Design EZ

Key Description Part Number Key Description Part Number

31* G roove Pin (c o m p o sitio n seats only) (C ont.) 32 C ap S cre w (com p o sitio n se a t only)
3 /4 -in c h (19.1 m m) p o rt dia m e te r 3- inch (76.2 mm) p o rt dia m e te r
1P730438992 S31600 15A9166X012
S31600 and S41600
1P7304X0032 N05500 15A9166X042
N 05500
1- inch (25.4 m m) and 1-1 /2 inch (38.1 mm) S41600 15A9166X052
p o rt dia m e te r 4- inch (101.6 mm) p o rt dia m e te r
1 B599335072 S31600 1A9130X0032
S31600 and S41600
1B 5993X 00B 2 S41600 1A9130X0062
N 05500
33 N am eplate, stainless steel 18A5087X0A2
2- inch (50.8 m m) p o rt dia m e te r
1 B 599538992 34 W ire, lead 1D 884799012
S31600 and S41600
N05500 1B599540032

24
 Design EZ

Figure 11. Design EZ Valve

25
 /■
I®
Design EZ V

M IC R O -FO R M V A L V E PLUG
1/4-INCH (6.4 m m ) P O R T D IA M E TE R 1/4-INCH A N D 3/8-INCH (6.4 A N D 9.5 m m )
P O R T D IA M E TE R S

M IC R O -FO R M V A L V E P LU G
1/2-INCH TH R O U G H 1-INCH 1-1/2 INCH A N D 2-IN CH
(12.7 m m TH R O U G H 25.4 m m ) (38.1 m m A N D 50.8 m m )
P O R T D IA M E TE R P O R T D IA M E TE R

E Q U A L P E R C E N TA G E V A L V E PLUG
3 -IN C H A N D 4 -IN C H P O R T D IA M E TER
(76.2 m m and 101.6 m m ) ■‘D
P O R T D IA M E TE R

Figure 12. Composition Seats for Design EZ Valve

26
 Design EZ

FEMALE ADAPTOR^

PACKING RING
• PACKING SET (KEY 6)
MALE ADAPTOR

SPACER (KEY 8)

SPACER (KEY 8)

12B4185A SHT 12B4182-A SHT 2

3/8-INCH 1/2-INCH (12.7 m m ) 3/8-INCH 1/2-INCH

(9.5 m m ) S TE M , 2 -IN C H (9.5 m m ) (12.7 m m ) S TE M ,
S TE M VALVES S TE M 2 -IN C H V A L V E S
F O R S31603 (316 S S T) PAC K IN G FO R A L L P AC K IN G B O X M A TE R IA L S
BOX P AR TS E X C E P T S31603

SINGLE ARRANGEMENTS

UPPER WIPER
BUSHING (KEY 12)
(KEY 13)

■ A
BUSHING
(KEY 13)
\
FEMALE ADAPTOR ^

PACKING RING > PACKING SET

SPACER (KEY 6)
(KEY 8) MALE ADAPTOR ^

SPACER (KEY 8)

18A0906-D

3/8-INCH 1/2-INCH 1/2-INCH

(9.5 m m ) (12.7 m m) (12.7 m m )
S TE M S TE M , 2 -IN C H S TE M , 3- AN D
A5886-1 VALVES 4-IN C H V A L V E S

DOUBLE ARRANGEMENTS
Figure 13. PTFE Packing Arrangements for
ENVIRO-SEAL Bellows Seal Bonnets

T s',

27
Design EZ

BUSHING (KEY 13)

■ GRAPHITE FILAMENT
PACKING RING (KEY 7)

- GRAPHITE RIBBON
PACKING RING (KEY 7)

SPACER (KEY 8)

3/8-INCH 1/2-INCH 1/2-INCH (12.7 m m )

(9.5 m m ) (12.7 m m ) S TE M , S TE M , FO R 3- A N D
S TE M FO R 2 -IN C H V A L V E S 4 -IN C H V A L V E S
NOTE:
PT> 0.004 INCH (0.102 mm) THICK SACRIFICIAL ZINC WASHERS;
USE ONLY ONE BELOW EACH GRAPHITE RIBBON RING.
A5887-1

Figure 14. Double Graphite Ribbon/Filament Arrangements

for ENVIRO-SEAL Bellows Seal Bonnets

Key 2 E xtension B o n n e t B affle

STEM STYLE 1 EXTENSION STYLE 2 EXTENSION

VALVE SIZE, DIAMETER Bonnet Material Bonnet Material
Inch mm Steel CF8M (316 SST) Steel CF8M
3 /8 9.5 10A2910 X012 10A2910 X032 10A2910 X012 10A2910 X032
1/2, 3 /4 , 1, & 1-1/2 10A2909 X032 10A2909 X012 10A2909 X032
1/2 12.7 10A2909 X012
— —
1-1/2 3 /4 19.1 10A2907 X012 10A2907 X032
1/2 12.7 10A2909 X012 10A2909 X032 1R 3360 24492 1R 3360 35072
2 1R 3518 24492 1R 3518 35072
3 /4 19.1 1R 3518 24492 1R 3518 35072
1/2 12.7 10A 2908 X012 10A2908 X032 1R 3360 24492 1R 3360 35072
3 1R 3518 35072 1R 3518 24492 1R 3518 35072
3 /4 19.1 1R 3518 24492
1/2 12.7 10A2908 X012 10A 2908 X032 1R 3586 24492 1R 3586 35072
4 1R 3713 24492 1R 3713 35072
3 /4 19.1 1R 3518 24492 1R 3518 35072

Key 2* M ic ro -F lo w and M ic ro -F lu te V alve Plug

PORT VALVE STEM VALVE PLUG MATERIAL

VALVE DIAMETER CONNECTION
VALVE S31600 (316 SST)
SIZE, N05500 S41600
PLUG W/R30006 (Alloy 6)
INCH Inch mm Inch mm (K-Monel) (416 SST)
Seat & Tip
M ic ro -F lo w 3 /1 6 4.8 2V9269 50332 1V1081 46222 1V1081 46172
1/2, 3 /4 , 1, 1U 8445 46222 1U 8445 46172
M icro -F lu te (1 flute) 1/4 6.4 3/8. 9.5 2U 8682 46422
1-1/2, 2 2U 8684 46422 1U 8447 46222 1U 8447 46172
M icro -F lu te (3 flu te s) 1/4 6.4

28
 Design EZ

Key 2* Equal P ercentage (Including M icro-F orm ), Linear, and Q uick-O pening V alve Plugs

PORT PLUG MATERIAL

VALVE VSC<1>
VALVE DIAMETER
SIZE, S31600 w/ S31600 w/
PLUG S31600 N05500 S41600
INCH Inch mm Inch mm CoCr-A (Alloy 6) CoCr-A Seat
(316 SST) (K-Monel) (416 SST)
Seat & Guide
1/4 6.4 15A6500 X012 15A6663 X012 15A6664 X012 15A6500 X042 15A65Q0 X052
3 /8 9.5 16A5708 X012 16A5713 X012 16A5711 X012 16A5708 X042 16A5708 X052
3 /8 q 5
1/2 12.7 15A6502 X012 15A6659 X012 15A6660 X012 15A6502 X042 15A6502 X052
3 /4 19.1 16A3335 X012 16A3337 X012 16A3339 X012 16A3335 X042 16A3335 X052
M icro -F o rm
1/4 6.4 15A6501 X012 — —
15A6501 X042 15A6501 X052
3 /8 9.5 16A5709 X012 16A5714 X012 16A5712 X012 16A5709 X042 16A5709 X052
1 12 1? 7
1/2 12.7 15A6503 X012 15A6661 X012 15A6662 X012 15A6503 X042 15A6503 X052
1/2, 3 /4 , 1, 3 /4 19.1 16A3336 X012 16A3338 X012 16A3340 X012 16A3336 X042 16A3336 X052
1-1 /2 & 2
3 /8 9.5 15A 6490 X012 15A6516 X012 15A6517 X012 15A6490 X042 15A6490 X052
Q u ick O pening 1 25.4
1/2 12.7 15A6491 X012 15A6518 X012 15A6519 X012 15A6491 X042 15A6491 X052
1 3 /8 9.5 15A6470 X012 15A6614 X012 15A6615 X012 15A6470 X042 15A6470 X052
Linear 25 4
1/2 12.7 15A6471 X012 15A6616 X012 15A6617 X012 15A6471 X042 15A6471 X052
3 /8 9.5 15A6480 X012 15A6634 X012 15A6635 X012 15A6480 X042 15A6480 X052
Equal Percentage 1 25.4
1/2 12.7 15A6481 X012 15A6636 X012 15A6637 X012 15A6481 X042 15A6481 X052
3 /8 9.5 15A6492 X012 15A 6520 X012 15A6521 X012 15A6492 X042 15A6492 X052
Q u ick O pening 1-1/2 38.1
1/2 12.7 15A6493 X012 15A6522 X012 15A6523 X012 15A6493 X042 15A6493 X052
3 /8 9.5 15A6472 X012 15A6618 X012 15A6619 X012 15A6472 X042 15A6472 X052
1-1/2 Linear 1 -1 /2 38 1
1/2 12.7 15A6473 X012 15A6620 X012 15A6621 X012 15A6473 X042 15A6473 X052
3 /8 9.5 15A6482 X012 15A6638 X012 15A6639 X012 15A6482 X042 15A6482 X052
Equal Percentage 1-1/2 38.1
1/2 12.7 15A 6483 X012 15A6640 X012 15A6641 X012 15A6483 X042 15A6483 X052
1/2 12.7 15A6494 X012 15A6524 X012 15A6525 X012 15A6494 X042 15A6494 X052
Q u ick O pening 2 50 8
3 /4 19.1 15A6495 X012 15A6526 X012 15A6527 X012 15A6495 X042 15A6495 X052
1/2 12.7 15A6474 X012 15A6622 X012 15A 6623 X012 15A6474 X042 15A6474 X052
2, 3, 4 Linear 2 50.8
3 /4 19.1 15A6475 X012 15A6624 X012 15A6625 X012 15A6475 X042 15A6475 X052
2 1/2 12.7 15A 6484 X012 15A6642 X012 15A 6643 X012 15A6484 X042 15A6484 X052
Equal Percentage 50 8
3 /4 19.1 15A6485 X012 15A6644 X012 15A6645 X012 15A6485 X042 15A6485 X052
1/2 12.7 15A 6496 X012 15A6528 X012 15A6529 X012 15A6496 X042 15A6496 X052
Q u ick O pening 3 76 2
3 /4 19.1 15A6497 X012 15A6530 X012 15A6531 X012 15A6497 X042 15A6497 X052
1/2 12.7 15A6476 X012 15A6626 X012 15A6627 X012 15A6476 X042 15A6476 X052
3 Linear 3 76.2
3 /4 19.1 15A6477 X012 15A6628 X012 15A6629 X012 15A6477 X042 15A6477 X052

3 1/2 12.7 15A 6486 X012 15A6646 X012 15A6647 X012 15A6486 X042 15A6486 X052
Equal Percentage 76 2
3 /4 19.1 15A6487 X012 15A6648 X012 15A6649 X012 15A6487 X042 15A6487 X052
1/2 12.7 15A6498 X012 15A6532 X012 15A6533 X012 15A6498 X042 15A6498 X052
Q u ick O pening 4 101.6
3 /4 19.1 15A6499 X012 15A6534 X012 15A6535 X012 15A6499 X042 15A6499 X052
4 4 1/2 12.7 15A6478 X012 15A6630 X012 15A6631 X012 15A6478 X042 15A6478 X052
Linear m i fi
3 /4 19.1 15A6479 X012 15A6632 X012 15A6633 X012 15A6479 X042 15A6479 X052
12.7 15A6488 X012 15A6650 X012 15A6651 X012 15A6488 X042
Equal P ercentage 4 101 6 V2
3 /4 19.1 15A6489 X012 15A6652 X012 15A6653 X012 15A6489 X042
15A6488 X052
15A6489 X052
1. Valve stem connection.
Design EZ

Key 2*, 7*, and 8* Valve P lug/S tem A sse m b ly fo r Plain B onnet

PORT PLUG MATERIAL

VALVE VSCd)
VALVE DIA S31600 w/ S31600 w/
SIZE, S31600 N05500 S41600
PLUG CoCr-A (Alloy 6) CoCr-A Seat
INCH Inch mm Inch mm (316 SST) (K-Monel) (416 SST)
Seat & Guide
M ic ro -F lo w 3 /1 6 4.8 2V9269 X00A2 1V1081 X0142
M ic ro -F lu te (1 flute) 1/4 6.4 3 /8 9.5 — — 2U 8682 X0032 — 1U8445 X0032
M icro -F lu te (3 flutes) 1/4 6.4 2U 8684 X0032 1U8447 X00E2
1/4 6.4 15A6500 X082 15A6663 X022 15A6664 X042 15A6500 X152 15A6500 X092
3 /8 9.5 16A5708 X092 16A5713 X032 16A5711 X022 16A5708 X182 16A5708 X112
3 /8 9.5
1/2 12.7 15A6502 X072 15A6659 X022 15A6660 X042 15A6502 X102 15A6502 X112
3 /4 19.1 16A3335 X112 16A3337 X042 16A3339 X022 16A3335 X212 16A3335 X132
M icro -F o rm
1/4 6.4 15A6664 X022 15A6500 X252
1/2, 3/4, 1, 3 /8 9.5 16A5711 X042 -------- '
16A5708 X132
1/2 x 3 /8 12.7
1-1/2 & 2 1/2 12.7 15A6502 X162 15A6659 X082 15A6660 X082 15A6502 X152
3 /4 19.1 16A3335 X142 16A3337 X032 16A3339 X092 16A3335 X182
3 /8 9.5 — 15A6516 X022 15A6490 X092
Q uick O pening 1 25.4 ::: _ _ _
1/2 x 3 /8 12.7 15A6490 X072
3 /8 9.5 15A6470 X092 — 15A6615 X022 15A6470 X052
Linear 1 25.4 _____
1/2 x 3 /8 12.7 15A6470 X072 15A6471 X052
3 /8 9.5 15A6480 X102 15A6634 X042 15A6635 X022 15A6480 X152 15A6480 X112
Equal P ercentage 1 25.4
1/2 x 3 /8 12.7 15A6480 X202 15A6634 X072 15A6635 X042 15A6480 X172
Q u ick O pening 1-1/2 38.1 3 /8 9.5 15A6492 X102 15A6520 X032 15A6521 X022 — 15A6492 X082

Linear 1-1/2 38.1 3 /8 9.5 15A6472 X132 — 15A6619 X022 — 15A6472 X072
1-1/2
Equal P ercentage 1-1/2 38.1 3 /8 9.5 15A6482 X102 15A6638 X032 15A6639 X022 — 15A6482 X112

Q u ick O pening 2 50.8 1/2 12.7 15A6494 X082 — 15A6525 X022 — 15A6494 X072
2 50.8 12.7 15A6474 X132 — 15A6623 X022 — 15A6474 X072
2 Linear 1/2
Equal P ercentage 2 50.8 1/2 12.7 15A6484 X072 15A6642 X042 15A6643 X032 15A6484 X102 15A6484 X112
1/2 12.7 — — — — 15A6494 X092
Q uick O pening 2 50.8
2 50.8 12.7 — — — — 15A6474 X152
Linear 1/2
Equal P ercentage 2 50.8 1/2 12.7 15A6484 X152 ' --------- 15A6643 X062 — 15A6484 X172
3 — —
Q uick O pening 3 76.2 1/2 12.7 15A6496 X082 15A6529 X022 15A6496 X072

76.2 12.7 15A6476 X092 — 15A6627 X022 — 15A6476 X082

Linear 3 1/2
Equal P ercentage 3 76.2 12.7 15A6486 X082 15A6646 X022 15A6647 X032 — 15A6486 X062
1/2
2 12.7 — . -------- — — 15A6484 X182
Equal P ercentage 50.8 1/2
Q u ick O pening 4 101.6 12.7 — — — — 15A6498 X072
1/2
4 —
Linear 4 101.6 12.7 15A6478 X072 — — 15A6478 X062
1/2
4 1/2 | l 2.7 — 15A6650 X022 15A6651 X022 — 15A6488 X072
Equal P ercentage 101.6
1. Valve stem connection. .

Key 3*, 26* S eat R ing R etainer and B u sh in g A sse m b ly

VALVE SEAT RING RETAINER/BUSHING MATERIAL

SIZE, CB7CU-1/S17400 CF8M/R30006 M3S-1/N05500
INCH (17-4PH SST) (316 SST/Alloy 6) (Monel/K-Monel)
1/2, 3 /4 , & 1 25A 6683 X062 25A 6683 X072 25A 6683 X172
1-1/2 25A 6685 X072 25A 6685 X082 25A 6685 X142
Full 25A 6687 X062 25A 6687 X112 25A 6687 X192
2
R estricte d 25A 6687 X092 25A 6687 X132 25A 6687 X182

3 25A 6689 X152 25A 6689 X132 25A 6689 X142

Full 35A6691 X062 35A6691 X082 35A6691 X092
4
R estricte d 35A6691 X102 — 35A6691 X112

30
 Design EZ

Key 8* G roove Pin

VALVE SIZE, VSC<1> GROOVE PIN MATERIAL

INCH VALVE PLUG STYLE
Inch mm S31600 (316 SST) N04400 (Monel)
M ic ro -F lo w & M icro -F lu te w /
m etal seats 3 /8 9.5 1B5992 35072 1B5992 40032
1/2 th ru 2
M icro -F lu te w /c o m p seats & 3 /8 9.5 1B5993 35072 1B5993 X00B2
M icro-F orm 1/2 12.7 1D5423 X00B2 1D 5423 X0012
Linear, Equal P ercentage & 3 /8 9.5 1B5993 35072 1B5993 X00B2
1/2 th ru 1-1/2
Q uick O pening 1/2 12.7 1D5423 X00B2 1D5423 X0012
Linear, Equal P ercentage & 1/2 12.7 1B5998 35072 1B 5998 40032
Q uick O pening (full cap) 3 /4 19.1 1B8136 35072
2 1B 813 6 X 0 1 0 2
Linear, Equal P ercentage & 3/8 9.5 1B5993 35072 1B 5993 X00B2
Q uick O pening (re s tric te d port) 1/2 12.7 1D5423 X00B2 1D 5423 X0012
3 All 1/2 12.7 1B5998 35072 1B5998 40032
3 /4 19.1 1B8136 35072 1B8136 X0102
1/2 12.7 1B5998 35072 1B5998 X00C2
Full C apacity
4 3 /4 19.1 1B8136 35072 1B8136 X0102
1/2 12.7 1B5998 35072 1B5998 40032
R estricted
3 /4 19.1 1B8136 35072 1B8136 X0102
1. Valve stem connection.

Key 9* S e a t Ring fo r M etal Seats

VALVE PORT DIA S31600 w/ S31600 w/

SIZE, S31600 N05S00 S41600
CoCr-A (ALLOY 6) CoCr-A SEAT
INCH Inch mm (316 SST) (K-MONEL) (416 SST)
SEAT & BORE
3 /1 6 4.8 1V1083 35072 25A 8563 X012 25A 5710 X012 1V1083 46222 1V1083 46172
1/2, 1/4 6.4 1U 2852 35072 2U 8559 46052 25A5711 X012 1U 2852 46222 1U2852 46172
3/4, 3 /8 9.5 1U 2853 35072 2U 8560 46052 1U 2853 X0012 1U 2853 46222 1U2853 46172
and 1/2 12.7 1U 2854 35072 2U8561 46052 26A0651 X012 1U 8254 46222 1U 2854 46172
1 3 /4 19.1 1U 2855 35072 2U 8562 46052 26A 3349 X012 1U 2855 X0092 1U2855 46172
1 25.4 1U 2856 35072 2U 8563 46052 26A 0652 X012 1U 2856 46222 1U2856 46172
3/16 4.8 15A6512 X012 25A 8564 X012 25A 6536 X012 15A6512 X042 15A6512 X052
1/4 6.4 15A6513 X012 15A6537 X012 25A 6539 X012 15A6513 X042 15A6513 X052
3 /8 9.5 17A6075 X012 27A 6076 X012 27A 6079 X012 17A6075 X042 17A6075 X052
1-1/2 1/2 12.7 15A6514 X012 15A6538 X012 26A 0653 X012 15A6514 X042 15A6514 X052
3 /4 19.1 16A3350 X012 26A3351 X012 26A 3352 X012 16A3350 X042 16A3350 X052
1 25.4 15A6515 X012 15A6654 X012 26A 0654 X012 15A6515 X042 15A6515 X052
1-1/2 38.1 15A6504 X012 15A6655 X012 26A 0655 X012 15A6504 X042 15A6504 X052
3 /1 6 4.8 15A6692 X012 25A 8565 X012 25A 6696 X012 15A6692 X042 15A6692 X052
1/4 6.4 15A6693 X012 25A 6698 X012 25A 6697 X012 15A6693 X042 15A6693 X052
3 /8 9.5 17A4091 X022 27A 6080 X012 27A6081 X012 17A4091 X052 17A4091 X012
2 1/2 12.7 15A6694 X012 25A 6699 X012 26A 0656 X012 15A6694 X042 15A6694 X052
3 /4 19.1 16A3353 X012 26A 3354 X012 26A 3355 X012 16A3353 X042 16A3353 X052
1 25.4 15A6695 X012 25A 1085 X012 26A 0657 X012 15A6695 X042 15A6695 X052
2 50.8 15A6505 X012 15A6656 X012 26A 0658 X012 15A6505 X042 15A6505 X052
2 50.8 25A 5713 X012 25A 5714 X012 26A 0659 X012 25A 5713 X042
3 25A 5713 X052
3 76.2 15A6506 X012 15A6657 X012 26A 0660 X012 15A6506 X042 15A6506 X052
2 50.8 25A 5715 X012 25A 5716 X012 26A0661 X012 25A 5715 X042
4 25A 5715 X052
4 101.6 15A6507 X012 15A6658 X012 26A 0662 X012 15A6507 X042 15A6507 X052

31
Design EZ Vi

Key 9* S eat R ing fo r C o m p o s itio n Seats

VALVE PORT
S31600 N05500 S41600
SIZE, DIAMETER
(316 SST) (K-MONEL) (416 SST)
INCH Inch mm
1/4 6.4 13A5872 X012 13A5872 X062 13A5872 X022
1/2, 3 /4 , & 1 13A 5873 X032
3 /8 9.5 13A 5873 X012 13A5873 X062
1/4 6.4 16A3467 X012 16A3467 X042 16A 3467 X052
1-1/2 17A 6078 X052
3 /8 9.5 17A6078 X012 17A6078 X042
1/4 6.4 16A3468 X012 16A3468 X042 16A 3468 X052
2 17A 6077 X052
3 /8 9.5 17A6077 X012 17A6077 X042

Key 10* B o n n e t G asket

Key 12* S piral W ound G asket
Key 13* S eat Ring G asket
Key 25* Shim

Valve Size, Key Gasket Gasket Gasket Gasket

Inch Number Set 1(0 Set 2<1> Set 3(0 Set<0
—
Set R G A S K E T X312 R G AS KE T X162 10A8170 X042

10 1R 2859 X0042 1R 2859 X0042 10A8163 X012 1R2859X0042

1/2 - 3 /4 & 1 12 1 R2860 99282 1R 2860 99442 10A8184 X012 1R 286099292

13 1 R2862 X0062 1R 2862 X0062 10A8177 X012 1R2862X0062

25 16A1936 X012 16A1936 X012 16A1936 X022 16A1936X022

10A8171 X032 —
Set R G A S K E T X322 R G AS KE T X172
10 1R3101 X0032 1R3101 X0032 10A8164 X012 1R 3101X0032

1-1/2 12 1R 3099 99282 1R 3099 99442 10A8185 X012 1R 309999292

13 1R 3098 X0052 1R 3098 X0052 10A8178 X012 1R3098X0052

25 16A1937 X012 16A1937 X012 16A1937 X022 16A1937X022

—
Set R G AS KE T X332 R G AS KE T X182 10A8172 X032

10 1R 3299 X0042 1R 3299 X0042 10A8165 X012 1R3299X0042

2 12 1R 3297 99282 1R 3297 99442 10A8186 X012 1R329799292

13 1R 3296 X0042 1R 3296 X0042 10A8179 X042 1R3296X0042

25 16A 1938 X012 16A1938 X012 16A1938 X022 16A1938X022

—
Set R G AS KE T X352 R G AS KE T X202 10A8174 X032

10 1R 3484 X0042 1R 3484 X0042 10A8167 X012 1R3484X0042

3 12 1R 3482 99282 1R 3482 99442 10A8188 X012 1R348299292

13 1R3481 X0052 1R3481 X0052 10A8181 X032 1R3481X0052

25 16A 1940 X012 16A1940 X012 16A1940 X022 16A1940X022

Set R G AS KE T X362 R G AS KE T X212 ------- (2)-------

10 1R 3724 X0042 1R 3724 X0042 10A8168 X012 1R3724X0042

4 12 1R 3722 99282 1R 3722 99442 10A8189 X012 1R372299292

13 1J5047 X0062 1J5047 X0062 10A8182 X032 1J5047X 0062

25 16A1941 X012 16A1941 X012 16A1941 X022 16A1941X022

1. See table below for description o f gasket sets.

2. Consult your Fisher C ontrols representative fo r gasket set part number.

32
 Design EZ

Gasket Selection Criteria

Gasket Set Seat Ring Gasket Bonnet Gasket Spiral Temperature

Shim
Wound Gasket Capabilities
316 S S T /G ra ph ite 316 S S T /G ra ph ite S31603 (316L S S T)/ S31600 - 100 to 450°F
1
fla t sheet fla t sheet co m p o sitio n (316 SST) ( - 73 to 232°C)
20)
316 S S T /g ra ph ite 1 316 S S T /g ra ph ite N 06600 (Inconel)*2)/ - 3 2 5 to 11O0°F
fla t sheet fla t sheet S31600
gra p h ite ( - 1 9 8 to 593°C)
P T FE -coated N04400 - 1 0 0 to 30Q°F
3 P T FE -coated N 04400 N 04400/P TFE N04400
(Monel)*2) ( - 7 3 to 149°C)
316 S S T /g ra ph ite 316 S S T /g ra ph ite - 1 0 0 to 450°F
4 N 0440 0/co m p o sition N04400
fla t sheet fla t sheet ( - 73 to 232°C)
1. FGM gasket set.
2. M ark owned by INCO Alloys International.

Key 15 C a p S c re w o r S tud B o lt fo r Plain and E xte n sio n B onnets

K ey 16 N u t fo r Plain and E xtension B o n n e ts

VALVE SIZE, BODY QUAN MATERIAL CAP SCREW NUT

INCH MAT’L REQ’D Cap Screw or Bolt Nut OR STUD Nonlubricated Factory Lubricated
C a st Iron 4 S teel SA E G rade 5 __ 1R2811 24052 __
Steel 4 S teel S A -193-B 7 S A -194-2H 1R 2848 X0572 1C 3306 X0712 1C 3306 X0692
1/2, 3 /4 , & 1
4 S S T S A -320-B 8 SA -194-8 1R 2848 X0012 1C 3306 X0012 __
C F8M (316 SST) 4 S S T S A -193-B 8M S A -194-8M 1R 2848 35222 1C 3306 35252 1C 3306 X0232
4 S teel S A -193-B 7 S A -194-2H 1R 2848 X0572 1C 3306 X0712 1C 3306 X0692
C a st Iron 8 S teel SAE G rade 5 __ 1A4533 24052 ___ __
Steel 8 S teel S A -193-B 7 S A -194-2H 1K2429 X0562 1A3772 X0662 1A3372 X0622
1-1 /2 & 2
8 S S T S A -320-B 8 S A -194-8 1K2429 X0022 1A3772 X0012 ___
CF8M 8 S S T S A -193-B 8M SA -194-8M 1K2429 35222 1A3772 35252 1A3372 X0232
8 S teel S A -193-B 7 SA-194-2H 1K2429 X0562 1A3772 X0662 1A3372 X0622
C a st Iron 8 S teel SA E G rade 5 __ 1A4541 24052 __ ' __
Steel 8 S teel S A -193-B 7 S A -194-2H 1A3781 X0452 1A3760 X0592 1A3760 X0572
8 S S T S A -320-B 8 S A -194-8 1A3781 X0042 1A3760 X0012 __
CF8M 8 SS T S A -193-B 8M S A -194-8M 1A3781 35222 1A3760 35252 1A3760 X0182
8 S teel S A -193-B 7 S A -194-2H 1A3781 X0452 1A3760 X0592 1A3760 X0572
C a s t Iron 8 Steel SAE G rade 5 __ 1A4402 24052 ___ __
Steel 8 Steel S A -193-B 7 SA-194-2H 1R 3690 X0422 1A3520 X0602 1A3520 X0582
8 S S T S A -320-B 8 S A -194-8 1R 3690 X0022 1A3520 X0012 _ ——
C F8M 8 S S T S A -193-B 8M S A -194-8M 1R 3690 35222 1A3520 35252 1A3520 X0162
8 S teel S A -193-B 7 S A -194-2H 1R 3690 X0422 1A3520 X0602 1A3520 X0582

33
Design EZ

Key 15 S tud B o lt fo r E N V IR O -S E A L B e llo w s Seal B onnets

Key 16 N ut fo r EN V IR O -S E A L B e llo w s Seal B onnets

V A LV E SIZE, BODY QUAN M A T E R IA L STUD NUT

INCH M AT’L REQ’ D S tu d B o lt N ut BOLT N o n lu b ric a te d F a c to ry L u b ric a te d
Steel 4 S teel S A -193-B 7 S A -194-2H 1R 2848 X0572 1C3306 X0712 1C 3306 X0692

1/2, 3/4, & 1 4 SST S A -320-B 8 SA -194-8 1R 2848 X0012 1C3306 X0012 —

C F8M (316 SST) 4 S S T S A -193-B 8M SA -194-8M 1R 2848 35222 1C 3306 35252 1C 3306 X0232
4 S teel S A -193-B 7 SA -194-2H 1R 2848 X0572 1C3306 X0712 1C 3306 X0692
Steel 8 S teel S A -193-B 7 SA -194-2H 1A3788 X0112 1A3772 X0662 1A3772 X0622

1-1/2 & 2 8 S S T S A -320-B 8 SA -194-8 1A3778 X0062 1A3772 X0012 —

C F8M 8 S S T S A -193-B 8M SA -194-8M 1A3788 35222 1A3772 35252 1A3772 X0232

8 S teel S A -193-B 7 S A -194-2H 1A3788 X0112 1A3772 X0662 1A3772 X0622
Steel 8 S teel S A -193-B 7 S A -194-2H 1P5906 X0182 1A3760 X0592 1A3760 X0572
8 SST S A -320-B 8 SA -194-8 1P5906 X0122 1A3760 X0012 —
3
CF8M 8 SST S A -193-B 8M SA -194-8M 1P5906 X0022 1A3760 35252 1A3760 X0182
8 S teel S A -193-B 7 SA -194-2H 1P5906 X0182 1A3760 X0592 1A3760 X0572
Steel 8 S teel SA -193-B 7 SA -194-2H 1B9588 X0202 1A3520 X0602 1A3520 X0582
1A3520 X0012 —
4 8 S S T S A -320-B 8 SA -194-8 1B9588 X0142
C F8M 8 S S T S A -193-B 8M SA -194-8M 1B9588 X0032 1A3520 35252 1A3520 X0162
8 S teel S A -193-B 7 S A -194-2H 1B9588 X0202 1A3520 X0602 1A3520 X0582

K ey 26* B ushing

Valve Size, Inch S17400 (17-4PH SST) R30006 (Alloy 6) N05500 (K-Monel)
1/2, 3 /4 , & 1 15A 6508 X012 15A6508 X022 15A6508 X052
1-1/2 15A7511 X012 15A7511 X022 15A7511 X052
2 (rest, po rt) 15A 6509 X012 15A6509 X022 15A6509 X052
2 (full po rt) 15A 6510 X012 15A6510 X022 15A6510 X052
3 15A7491 X012 15A7491 X022 15A7491 X052
4 (rest, po rt) 15A 5712 X012 15A5712 X022 15A5712 X052
4 (full port) 15A6511 X012 15A6511 X022 15A6511 X052

K ey 27 V alve Plug G uide (c o m p o s itio n s e a t only)

VALVE STEM
VALVE PORT DIA MATERIAL
CONNECTION
PLUG
Inch mm Inch mm S31600 (316 SST) N05500 (K-Monel) S41600 (416 SST) S31600 w/CoCr-A (Alloy 6)
M icro -F lu te 3 /8 9.5 1/4 6.4 16A3440 X012 16A3440 X042 — 19A5814 X012
1/4 6.4 16A3440 X012 16A 3440 X042 16A3440 X052 19A5814 X012
3 /8 9.5 16A5703 X012 16A 5703 X042 16A 5703 X052 19A5815 X012
3 /8 9.5
1/2 12.7 16A3445 X012 16A3445 X042 16A3445 X052 17A7250 X012
M icro -F o rm 3 /4 19.1 26A 3449 X012 26A 3449 X042 26A 3449 X052 28A8115 X012
3 /8 9.5 16A5707 X012 16A5707 X042 16A5707 X052 19A5815 X012
1/2 12.7 1/2 12.7 16A 3446 X012 16A 3446 X042 16A3446 X052 19A5817 X012
3 /4 19.1 26A 3450 X012 26A 3450 X042 26A 3450 X052 29A 5812 X012
3 /8 9.5 1 25.4 26A 3453 X012 26A 3453 X042 26A 3453 X052 29A 5806 X012
1/2 12.7 1 25.4 26A 3454 X012 26A 3454 X042 26A 3454 X052 29A 5807 X012
3 /8 9.5 1-1/2 38.1 26A 3457 X012 26A 3457 X042 26A 3457 X052 28A 1253 X012
1/2 12.7 2 50.8 26A 3460 X012 26A 3460 X042 26A 3460 X052 29A 5813 X012
Equal P ercentage
1/2 12.7 3 76.2 26A 3470 X012 26A 3470 X042 26A 3470 X052 29A5811 X012
3 /4 19.1 3 76.2 26A3471 X012 26A3471 X042 26A3471 X052 29A 5810 X012
1/2 12.7 4 102 26A 3463 X012 26A 3463 X042 26A 3463 X052 29A 5808 X012
3 /4 19.1 4 102 26A 3464 X012 26A 3464 X042 26A 3464 X052 29A 5809 X012

34
 Design EZ

K ey 30 T ip

VALVE STEM
VALVE PORT DIA MATERIAL
CONNECTION
SIZE, VALVE PLUG
INCH S31600 N05500 S41600
Inch m m Inch mm Alloy 6
(316 SST) (K-Monel) (416 SST)
M icro -F lu te (1 flute) —
13A5863 X032 13A5863 X042 __
1 /4
M icro -F lu te (3 flutes) — 13A5865 X032 13A5865 X022 —

1/4 6.4 13A6160 X022 — 13A6160 X062 13A6160 X012

3 /8 9.5 16A5704 X012 — 16A5704 X042 16A5704 X052
M O 3 /4 . 1/2 12.7 1R9537 X0022 — 1R9537 X0062 1R 9537 X0012
M icro-Form 3 /4 19.1 1R 9540 X0012 — 1R 9540 X0072 1R 9540 X0042
1, 1-1/2,
& 2 3 /8 9.5 16A5704 X012 — 16A5704 X042 16A5704 X052
1/2 12.7 1/2 12.7 1R9537 X0022 — 1R9537 X0062 1R 9537 X0012
3 /4 19.1 1R 9540 X0012 — 1R 9540 X0072 1R 9540 X0042
1 25.4 3 /8 & 1/2 9.5 & 12.7 1R 9538 35072 _______ 1R9538 X0032 1R 9538 X0012
Equal P ercentage 1-1/2 38.1 3 /8 9.5 16A3458 X012 — 16A3458 X042 16A3458 X052
2 50.8 1/2 12.7 12A3889 X012 — 12A3889 X042 12A3889 X052
3 Equal P ercentage 3 76.2 1/2 & 3 /4 12.7 & 19.1 16A3469 X012 — 16A3469 X042 16A3469 X052
4 Equal P ercentage 4 101.6 1/2 & 3 /4 12.7 & 19.1 12A3760 X022 — 12A3760 X012 12A3760 X052

G rou p 1 A c tu a to rs

2 -1 /8 , 2-1 3 /1 6 , & 3-9 /1 6 Inch

(54, 71, & 90 m m ) Yoke Boss
350-—e x c e p t 3 -9 /1 6 inch (90 m m) yo ke boss
470 S e rie s— e x c e p t 470-7 & 471-7
472 & 473
513 & 513R
585 & 585R — 3 -inch (76 m m) m ax travel
603 & 1B
608 & 618
644 & 645
655
657 & 667— 3 -inch (76 m m) m ax travel
1008— e xce p t 3 -9 /1 6 inch (90 m m) yo ke b o ss
w ith 2-inch (51 m m) travel

35
Design EZ

While this information is presented in good faith and believed to be accurate,
Fisher Controls does not guarantee satisfactory results from reliance upon such
information. N o th in g c o n t a in e d h e r e in is t o b e c o n s t r u e d a s a w a rr a n ty o r
g u a ra n te e , e x p r e s s o r im p lie d , r e g a r d in g th e p e r fo rm a n c e , m e r c h a n t a b ilit y , fitn e s s
nor as a recommendation to
o r a n y o t h e r m a tt e r w ith r e s p e c t t o th e p r o d u c t s ,
use any product or process in conflict with any patent. Fisher Controls reserves
the right, without notice, to alter or improve the designs or specifications of
the products described herein.

F o r in fo r m a tio n , c o n t a c t F is h e r C o n tr o ls :
FISHER Fisner Controls Marshalltown, Iowa 50158 USA Sao Paulo 05424 Brazil
Cernay 68700 France Singapore 0512

Printed in USA I ^ I s o y im k I recycled paper

 Type 2500

Fisher Controls Instruction Manual

2500 and 2503 Series

Level-T>ol® Controllers and
Transmitters

■
—
FISHER-
November 1994 Form 1013

Contents
Introduction ................................................................... 2
Scope of M an u al............................................................... 2
Description......................................................................... 2
Specifications ................................................................... 2

Installation ..................................................................... 2
Sensor A ssem bly............................................................. 2
U n cratin g ............................................................................2
Controller/Transmitter O rientation.................................5
Mounting Caged S e n s o r................................................. 6
Mounting Cageiess Sensor............................................. 7
Side-Mounted Sensor ........................................... 7
Top-Mounted S e n s o r............................................. 8
Special Installations......................................................... 9
Temperature-Compensated Displacer .............. 9
Piezometer R in g ..................................................... 9
Supply and Output Pressure Connection.................. 10
Supply P ressu re................................................... 10
Controller/Transmitter Output Connection . . . 12

Prestartup Checks ............................................. 12 W3121-3*

Type 2500 Controller or Type 2500T Transmitter . . 13

Type 2500S Controller................................................... 14
Type 2503 C ontroller..................................................... 15
Adjustments ....................................................................15
Controller-Transmitter Action .............................16
Level Adjustment ................................................. 16
Zero Adjustm ent................................................... 16
Proportional Band Adjustment (Except Transmit­
ters and 2503 Series Controllers)................ 16
Specific Gravity Adjustment
(Transmitters Only) ................................... 16
C alibration .............................
Precalibration Requirements ....................................... 16
Wet C alibration..................................................... 16
Dry Calibration ..................................................... 16
Figure 1. 2500 or 2503 Series Level-Trol® Controller/
Transmitter on Caged 249 Series Sensor
Controller/Transmitter and Torque Tube Arm
Disassembly ...............................................17
Determining the Amount of
Suspended W eight.................................... 17
Calibrating Procedure ...................................................18
Startup ........................................................ 19
16 Type 2500 Controller........................ ‘.........................19
Type 2500T Transmitter .............................................. 20
Type 2500S Controller.................................................. 20
Type 2503 C ontroller.................................................... 20

Level-Trol is a mark owned by Fisher Controls International, Inc.

®Fisher Controls International, Inc. 1977, 1994; All Rights Reserved


Type 2500
Principle of Operation ...............................
Type 2500 Controller or Type 2500T Transmitter .. 20
Proportional Valve ................
Type 2500S Controller..............................................22
Type 2503 Controller................................................22
M aintenance ...................................................
Troubleshooting ....................................................... 23
Removing Controller/Transmitter from Sensor ___ 23
Changing Mounting Methods...................................25
Installing Controller/Transmitter on Sensor — e . . 25
Replacing the Bourdon Tube ...................................26
Reversing Action ..................................................... 27
Relay Deadband Testing (Type 2500 Controller
or 2500T Transmitter Only)............................. 27
Replacing the Proportional Valve............................. 27
Changing Relay ...................................
Relay Assembly Maintenance ........................28
Parts Ordering ..................
Parts L is t ..........................................................
Introduction
Scope of Manual
This manual provides installation, operating, calibration,
maintenance, and parts ordering information for the 2500
and 2503 Series pneumatic controllers and transmitters
used in combination with 249 Series and Type 259B dis­
placer sensors.
Note
This manual does not include installation or
maintenance procedures for the supply
pressure regulator, sensor, or other de­
vices. For that information, refer to the ap­
propriate instruction manual for the other
device.
Only qualified personnel should install, operate, and main­
tain these controller/transmitters. If you have any ques­
tions concerning these instructions, contact your Fisher
Controls sales office or sales representative before pro­
ceeding.
Description > Unless ordered separately, the controller/transmitter is at-
These instruments control or transmit the fluid level, the
level of interface between two fluids, or the density (specif-
2
1
20 ic gravity). Each unit consists of a 249 Series or Type 259B
displacer-type fluid level sensor and a 2500 or 2503 Series
21 pneumatic controller or transmitter. Figure 1 shows a typi­
cal controller-sensor combination.
23
Specifications
Refer to table 1 for specifications.
Installation
27
The 2500 and 2503 Series controller/transmitters work in
combination with 249 Series and Type 259B displacer-type
sensors. The factory attaches the controller/transmitter to
29
the sensor, unless it is ordered separately.
29
Sensor Assembly
Table 2 shows sensors recommended for use with control­
ler/transmitters. For sensor installation and maintenance,
refer to the appropriate sensor instruction manual.
WARNING
When replacing the sensor assembly, the
displacer may retain process fluid or pres­
sure. Personal injury or property damage
may occur due to sudden release of the
pressure. Contact with hazardous fluid,
fire, or explosion can be caused by punctur­
ing, heating, or repairing a displacer retain­
ing process pressure or fluid. This danger
may not be readily apparent when disas­
sembling the sensor assembly or removing
the displacer. Before disassembling the
sensor or removing the displacer, observe
the more specific warning provided in the
sensor instruction manual.
Uncrating
_
tached to the sensor when shipped. Carefully uncrate the
assembly.

T a b le 1. S p e c ific a tio n s
Available Configurations*1)
Type 2500— Proportional-Only controller
Type 2500C—Proportional-Only controller with indica­
tor (see figure 12)
Type 2500R—Reverse acting proportional-only con­
troller
Type 2500S—Differential gap (snap acting) controller
See changing controller action procedure and figure
17.
Type 2500T—-Transmitter
Type 2503—Differential gap controller without propor­
tional valve; for applications requiring very little ad­
justment.
Input Signal*2)
Fluid Level or Fluid-to-Fluid Interface Level: From
0 to 100% of displacer length—standard lengths for
all sensors are 14 inches or 32 inches (356 mm or
812 mm). Other lengths available depending on sen­
sor construction
Fluid Density: From 0 to 100% of displacement force
change obtained with given displacer volume. Stan­
dard volume for displacers are listed in table 2.
Output Signal*2)
Type 2500 Controller and 2500T Transmitter: 3 to
15 psig (0.2 to 1 bar) or 6 to 30 psig (0.4 to 2 bar)
Type 2500S and 2503 Differential Gap Controllers:
0 psig (0 bar) when switched off and full supply [20 or
35 psig (1.4 or 2.4 bar) nominal depending on control­
ler output pressure range] when switched on
Area Ratio of Relay Diaphragms
3:1
Supply Pressure Data
See table 3*3)
Maximum Supply Pressure*3)
45 psig (3 bar) to the controller or transmitter. If con­
troller or transmitter is equipped with an integrally
mounted Type 67FR filter/regulator, typical supply
pressure to the regulator is from 35 psig (2.5 bar) to
250 psig (17 bar), maximum. For supply pressures to
the filter/regulator, refer to the appropriate regulator
instruction manual.
Steady-State Air Consumption
2500 Series Controllers and Transmitters (2500,
2500C, 2500R, 2500S, and 2500T): See Table 3
(continued)
Type 2500
Type 2503 Controller: Vents only when relay is ex­
hausting
Proportional Band*2) Adjustment (Proportional-Only
Controllers)
Full output pressure change adjustable over 10 to
100% of displacer length*5)
Differential Gap*2) Adjustment (Differential Gap Con­
trollers)
Type 2500S Controller: Full output pressure change
adjustable from 20 to 100% of displacer length*5)
Type 2503 Controller: Full output pressure change
adjustable over approximately 25 to 40% of displacer
length*5)
Span*2) Adjustment (Type 2500T Transmitter)
Full output pressure change adjustable from 20 to
100% of displacer length*5)
Set Point*2) (controllers only) or Zero*2) (transmitters
only) Adjustment
For proportional-only controllers or transmitters, level
adjustment positions the set point or zero for the fluid
level, interface level, or displacer force change (densi­
ty) within the displacer length.
For differential gap controllers, level adjustment simul­
taneously positions both ends of the gap within the
displacer length.
Performance
Independent Linearity*2) (transmitters only): 1% of
output pressure change for 100% span
Hysteresis: 0.6% of output pressure change at 100%
proportional band, differential gap, or span
Repeatability*2): 0.2% of displacer length or displace­
ment force change
Deadband*2) (except differential gap control­
lers*4)): 0.05% of proportional band or span
Typical Frequency Response*2): 4 Hz and 90 de­
gree phase shift at 100% proportional band, differen­
tial gap or span with output piped to typical instrument
bellows using 20 feet of 1/4-inch tubing
Ambient Operating Temperature Limits
For ambient temperature ranges and guidelines for
use of the optional heat insulator assembly, see figure
2. Relay temperature limits are:
Standard Construction: -40 to 180°F (-40 to 71 °C)
High-Temperature Construction:‘0 to 220° F (-18 to
104°C)
3
 1
f is h e r ]
Type 2500

T a b le 1. S p e c ific a tio n s (C o n tin u e d )

Typical Ambient Temperature Operating Influence Supply and Output Connections

Output pressure changes ±1.5% per 50° F 1/4-inch NPT female
(10°C)change in temperature at 100% proportional
band, differential gap, or span when using sensor with Maximum Working Pressure (sensors only)
standard wall M35-1 nickel alloy (alloy 400) torque
tube with 249 Series and Type 259B sensors Refer to the appropriate sensor instruction manual
1 ro n tm ite rs are field adjustable between direct or reverse action. The letter R in the type number indicates that the controller/transmitter shipped from the factory set for reverse action (see
Jhan dng ^ num ber indicates that a pointer is attached to the torque tube shaft providing visual momtonng of torque tube motion.
2. Tms term is defined in ISA Standara S51.1-1979.
3. Control and stability may be impaired if the maxim um pressures are exceeded.
i TAh » a S 1<ft% Teavn
e l change a. the maxim um proportional band dial ashing and a fluid with the specified specific
gravity. _____________________________________

Table 2. Standard Displacer Volumes

STANDARD VOLUME, STANDARD VOLUME,
SENSOR TYPE CUBIC INCHES L

249, 249B, 249BP, 249K , 249N , through

100 1.6
C lass 600, 259B
60 1.0
249C , 249C P
120 1.9
249L o v e r C lass 600
85<1> 1.40)
249V
1. w ith standard 12-inch (305 mm) flange-face-to-displacer centerline dimension only.__________________________ ____________________________________________________________

Table 3. Supply Pressure Data

NORMAL AIR CONSUMPTION AT
STANDARD SUPPLY OPERATING
AND OUTPUT NORMAL OPERATING MAXIMUM
OUTPUT SIGNAL RANGE SUPPLY SUPPLY PRESSURE SUPPLY PRESSURE
PRESSURE GAUGE PRESSURE'2)
INDICATIONS'1) Maximum*4)
Psig Bar Minimum'3)
0 to 3 0 psig 20 1.4 4.2 scfh 'b) 2 7 scfh '5)
3 to 15 psig (0.2 to 1 bar) 45 psig (3 bar)
0 to 60 psig 35 2.4 7 scfh '5) 42 scfh '5)
6 to 30 psig (0.4 to 2 bar)
1 Consult your Fisher Controls representative about gauges in other units.
2. Control and stability may be impaired if this pressure is exceeded.
3. At zero or maximum proportional band or span setting.
4. At setting in middle of proportional band or span range. ___ . „ „
5. If air consumption is desired in normal m^/hr at 0°C and 1.01325 bar, multiply scfh by 0.0258.

4
 Type 2500

AMBIENT TEMPERATURE (°C )

-1 8 - 1 0 0 10 20 30 40 50

INSULATOR (CAUTION! IF AMBIENT DEWPOINT IS

ABOVE PROCESS TEMPERATURE, ICE FORMATION MAY
CAUSE INSTRUMENT MALFUNCTION AND REDUCE
INSULATORl EFFECTIVENESS.!
I
-20 -2 9
20 40 60 80 100 120 140 160
AMBIENT TEMPERATURE (°F)
S TA N D A R D C O N T R O L L E R O R T R A N S M IT T E R
NOTE: FOR SERVICE BELOW - 2 0 ° F ( - 2 9 ° C ) CONTACT FACTORY.

AMBIENT TEMPERATURE (°C )

-1 8 - 1 0
1100 593

400-

NO INSULATOR NECESSARY

USE INSULATOR (CAUTION! IF AMBIENT DEWPOINT IS ABOVE

PROCESS TEMPERATURE, ICE FORMATION MAY CAUSE INSTRUMENT
MALFUNCTION AND REDUCE INSULATOR EFFECTIVENESS.)
-20- ~ r
20 40 60 80 100 120 140 160 180
AMBIENT TEMPERATURE (°F)

H IG H -T E M P E R A T U R E C O N T R O L L E R O R T R A N S M IT T E R

Figure 2. Guidelines for Use o f Optional Heat Insulator Assembly

or flanged connection (see figure 3) to provide more stable

C A U T IO N operation. Be certain that the cage equalizing connections
and the damping plate are not plugged by foreign material.
Sensors used for interface or density con­
A cageless sensor comes with its displacer separated from
' trol may be so large and heavy that the
the sensor assembly. Displacers longer than 32 inches
’ torque tube cannot fully support their
(813 mm) come in a separate crate. Shorter displacers
weight in air. On the 249V, a travel stop is
come in the same crate as the sensor, but are not attached
used to prevent damage. Do not remove
to their displacer rods. Inspect the displacer to insure it is
this travel stop assembly without first re­
not dented. A dent may reduce the pressure rating of the
moving the displacer from the displacer
displacer. If a displacer is dented, replace it.
rod. Refer to the instruction manaul for
cageless 249 Series sensors.
Controller/Transmitter Orientation
Note The controller/transmitter attaches to the sensor in one of
the mounting positions shown in figure 4. Right hand
Caged sensors have rods and blocks mounting is with the controller or transmitter case to the
installed at each end of the displacers to right of the displacer when you look at the front of the case;
protect the displacers in shipping. Remove left hand mounting is with the case to the left of the displac­
these parts before you install the sensor to er. The mounting position can be changed in the field.
allow the displacer to function properly. Changing this mounting position changes the control ac­
tion from direct to reverse, or vice versa.
Caged sensors come with the displacer installed in the
cage. If a tubular gauge glass is ordered with the sensor, All caged sensors except the Type 259B have a rotatable
the gauge glass is crated separately and must be installed head. That is, the controller/transmitter may be positioned
at the site. A damping plate is installed in the lower screwed at any of eight alternate positions around the cage as indi-

5

Type 2500
Figure 3. Damping Plate Location
cated by the numbers 1 through 8 in figure 4. To rotate the
head, remove the head flange bolts and nuts and position
the head as desired.
Mounting Caged Sensor
r a CAUTION
Install the cage so that it is plumb; the dis­
placer must not touch the cage wall. If the
displacer touches the cage wall, the unit will
transmit an erroneous output signal.
Note
If the controller/transmitter is not mounted
on the sensor, refer to the Installing Con­
troller/! ransmitter on Sensor procedures in
the Maintenance section. That section also
provides instructions for adding a heat in­
sulator to a unit.
If a temperature-compensated displacer or
piezometer ring is used, refer to the Special
Installation procedures in this section be­
fore proceeding.
FISHER0
v.
RIGHT-MAND MOUNTING
AH915D-A
A2613-1
Figure 4. Cage Head Mounting Positions
Cage connections normally are either 1-1/2 or 2-Inch,
screwed or flanged. Figure 5 shows the combinations.
With flanged connections, use standard gaskets or other
flat-sheet gaskets compatible with the process fluid. Spiral-
wound gaskets without compression-controlling centering
rings cannot be used for flange connections.
As shown in figure 6, mount the cage by running equalizing
lines between the cage connections and the vessel. A
shutoff or hand valve with a 1-1/2 inch-diameter or larger
port should be installed in each of the equalizing lines. Also
install a drain between the cage and shutoff or hand valve
whenever the bottom cage line has a fluid-trapping low
point.
On fluid or interface level applications, position the sensor
so that the line marked FLOAT CENTER on the cage is as
close as possible to the center of the fluid level or interface
level range being measured. Also consider installing a
gauge glass on the vessel, or on the sensor cage (if the
cage is tapped for a gauge).
 Type 2500

STYLE 1: TOP STYLE 2: TOP

AND BOTTOM AND LOWER SIDE

SCREWED: S1 SCREWED: S2
FLANGED: F1 FLANGED: F2

STYLE 3: UPPER STYLE 4: UPPER

AND LOWER SIDE SIDE AND BOTTOM

Figure 6. Caged Sensor Mounting

trailer or transmitter sensitivity, use either

a thin-wall torque tube, an oversized dis­
placer, or both. Use an oversized displacer
SCREWED: S3 SCREWED: S4 only for those service conditions for which
A1271-2 FLANGED: F3 FLANGED: F4
it was specified.
Figure 5. Cage Connection Styles

Mounting Cageless Sensor
C A U T IO N
If a Stillwell is used, install it plumb so that
the displacer does not touch the wall of the
Stillwell. If the displacer touches the wall,
the unit will transmit an erroneous output
signal.
Since the displacer hangs inside the vessel, provide a still­
well around the displacer if the fluid is in a state of continu­
ous agitation to avoid excessive turbulence around the dis­
placer.
C A U T IO N
Displacers used in an interface level ap­
plication must be completely submerged
during operation. To obtain the desired con-
Note
If the controller/transmitter is not mounted
on the sensor, refer to the Installing Con-
troller/Transmitter on Sensor procedures in
the Maintenance section. That section also
provides instructions for adding a heat in­
sulator to a unit. If the sensor has a tempera­
ture-compensated displacer or piezometer
ring, refer to the Special Installations proce­
dures in this section before proceeding.
Attach a cageless sensor to a flanged connection on the
vessel as shown in figure 7. For interface or fluid level ap­
plications, install a gauge glass on the vessel.
Side-Mounted Sensor
If a Stillwell is required (see figure 7), attach the displacer
to the displacer rod from inside the vessel.
Connect the displacer as shown in figure 8, locking the as­
sembly with the cotter spring provided. If-a Stillwell is not re­
quired, attach the displacer rod before mounting the sensor
on the vessel. Then, you can swing the displacer out hori­
zontally for insertion into the vessel. However, once the

7

Type 2500
SIDE VIEW (SHOWING STILLWELL)
Figure 7. Cageless Sensor Mounting
sensor is installed and the displacer drops to a vertical
position, the displacer may not be capable of being with­
drawn for servicing later. Be sure there is another access
to the displacer to permit swinging it to a horizontal position
or to permit disconnecting it from the displacer rod.
if an extension is used between the displacer spud and the
displacer stem end piece, make sure the nuts are tight at
each end of the displacer stem extension. Install and tight­
en suitable bolting or cap screws in the flanged connection
to complete the installation.
Top-Mounted Sensor
Figure 7 shows an example of a top-mounted cageless
sensor. You may attach the displacer to the displacer rod
before installing the sensor on the vessel. If the displacer
diameter is small enough, you may desire to install a long
or sectionalized displacer through the sensor head access
hole afterthe sensor is installed on the vessel. Connect the
displacer as shown in figure 8, locking the assembly with
the cotter springs provided. If a stem extension is used be­
tween the displacer spud and the stem end piece, make
8
F IS H E R 9
___________
SIDE VIEW (WITHOUT STILLWELL)
sure the nuts are tight at each end of the stem. Install and
tighten suitable cap screws in the flanged connection to
complete the installation.
A special travel stop may be provided on top-mounted sen­
sors to aid in servicing of the sensor. This option prevents
dropping the displacer and stem when the displacer rod is
disconnected
CAUTION
If inserting the displacer into the vessel be­
fore attaching the displacer rod, provide a
means of supporting the displacer to pre­
vent it from dropping into the vessel and
suffering damage.
To help support a Type 249BP or 249CP displacer, install
the displacer stem and stem end piece, or a threaded rod,
into the 1/4-inch 28 UNF threaded hole in the displacer
spud or stem end piece (figure 8).
 Type 2500

DISPLACER STEM
END

DISPLACER ROD COTTER SPRING

DISPLACER COTTER SPRING

STEM DISPLACER SPUD

LOCKING NUTS

DISPLACER ROD

DISPLACER SPUD

ALL OTHER TYPES

TYPE 249V

Figure 8. Displacer and Displacer Rod Connections

Special Installations DISPLACER

SPUD

Temperature-Compensated Displacer
ACCORDION-LIKE
BELLOWS FOR
EXPANSION AND
CONTRACTION
CAUTION

The bellows style temperature compensat­

ing displacers are relatively fragile and
must be protected from all physical dam­
age.

Some sensor assemblies use a temperature-compen­

sated displacer shown in figure 9. This displacer is ap­
propriate only for density applications that rmeasure fluid
composition regardless of temperature. The displacer
must be filled completely with the fluid to be measured, or
with a fluid of equal volumetric expansion coefficient. In
PIPE
service, the displacer expands and contracts the same PLUG
A0746-1
amount as the measured fluid to nullify signal changes that
would be caused by temperature changes.
Figure 9. Temperature-Compensated Displacer
This type of displacer comes in a separate carton, but is in
the same crate as the rest of the assembly. See the ap­ locity through the cage should not exceed two feet per min­
propriate sensor manual for displacer filling instructions. ute (10 mm/second).

To install this type of sensor, connect a line to the cage inlet

Piezometer Ring
A piezometer ring, shown in figure 11, is used when mea­
suring the specific gravity of a flowing fluid in a line. The
piezometer ring reduces the velocity effects caused by fluid
passing through the displacer cage. However, the fluid ve-
and outlet piping at each end of the cage. Use hand valves
to balance the fluid flow through the cage and keep the dis­
placer cage filled. Provide a rotameter or sight flow gauge
for measuring velocity through the cage. If the flow rates
are properly balanced, the transmitter output shows little
change when flow through the cage is shut off. If the flow

9
Type 2500
FISHER®

OUTLET FLOW

WITH HEAT INSULATOR

T O P V IE W

[ T > THE TYPE 67FR FILTER/REGULAOR MOUNTED DIRECTLY

OVER THE SUPPLY CONNECTION.
10A1211-A
22A9197-B
CD1700-E
A270B-1

Figure 10. Controller/Transmitter Dimensions and Connections

rate through the cage is too high, the turbulence may cause
an erratic output pressure signal. Readjust the hand valves
to stabilize the output pressure signal.

Supply and Output Pressure Connections

W A R N IN G
To avoid personal injury or property dam­
age resulting from the sudden release of
pressure, do not install any system compo­
nent where service conditions could ex­
ceed the limits given in this manual. Use
pressure-relieving devices as required by
government or accepted industry codes
and good engineering practices.
Figure 10 shows dimensions, locations, and connections
for controller/transmitter installation. All pressure connec­
tions to the controller/transmitter are 1/4-inch NPT female.
Supply Pressure
supply medium is not clean, dry, oil-free, or
a noncorrosive gas. Industry instrument air
quality standards describe acceptable dirt,
oil, and moisture content. Due to the vari­
ability in nature of the problems these in­
fluences can have on pneumatic equip­
ment, Fisher Controls has no technical
basis to recommend the level of filtration
equipment required to prevent perfor­
mance degradation of pneumatic equip­
ment. A filter or filter regulator capable of
removing particles 40-microns in diameter
should suffice for most applications. Use of
suitable filtration equipment and the estab­
lishment of a maintenance cycle to monitor
its operation is recommended.

Supply pressure must be clean, dry air or noncorrosive gas

W A R N IN G
Personal injury or property damage may
occur from an uncontrolled process if the
that meets the requirements of ISA Standard S7.3-1975
(R1991). Use a suitable supply pressure regulator to re­
duce the supply pressure to the normal operating supply
pressure shown in table 3. As shown in figure 10, a Type

10
 Type 2500

BOURDON TUBE DETAIL OF RAISE LEVEL DIAL FOR

TYPE Z500S ON-OFF LEFT-HAND MOUNTING
CONTROLLER

LEVEL SET ARM 3-WAY VALVE

MOUNTING SCREWS
FLAPPER ALIGNMENT SCREW
LEVEL SET NOZZLE LEVEL ADJUSTMENT
ARM CLAMP NUT PROPORTIONAL

SPAN ADJUSTMENT

RIGHT-HAND MOUNTED TYPE 2503R RIGHT-HAND MOUNTED TYPE 2500

ON-OFF CONTROLLER PROPORTIONAL CONTROLLER

SPECIFIC GRAVITY OR
PROPORTIONAL BAND ADJUSTMENT

POINTER
ASSEMBLY

DETAIL OF TRANSMITTER INDICATOR ASSEMBLY WITH TRAVEL INDICATOR PLATE

ADJUSTMENTS RIGHT-HAND MOUNTING FOR LEFT-HAND MOUNTING

Figure 12. Adjustment Locations

11
Type 2500
CONTROLLER PROPORTIONAL BAND OR DIFFERENTIAL GAP SETTING
TRANSMITTER SPECIFIC GRAVITY SETTING
NOTE: EACH CURVE MARKED WITH PROPORTIONAL BAND,
DIFFERENTIAL GAP, OR 8PAN PERCENTAGE
1C9259-G
A3M1
Figure 13. Proportional Band, Differential G ap, or
S p an Setting Chart
67FR filter/regulator mounts on the back of the controller/
transmitter case and mates with the supply pressure con­
nection on the controller/transmitter case. Pipe the supply
pressure to the IN connection of the regulator. Typically, the
Type 67FR filter/regulator accepts supply pressures be­
tween 35 and 250 psig (2.5 and 17 bar). For specific regula­
tor limits, refer to the appropriate regulator instruction
manual.
If operating the controller or transmitter from a high pres­
sure source [up to 2000 psig (138 bar)], use a high pressure
regulator system, such as the Type 1367 High Pressure
Instrument Supply System. For Type 1367 system installa­
tion, adjustment, and maintenance information, see the
separate instruction manual.
Controller/Transmitter Output
Connection
As shown in figure 10, the output pressure connection is on
the back of the controller/transmitter case. After connect­
ing the output pressure line, turn on the supply pressure,
adjust the filter/regulator to the appropriate supply pres­
sure required for the controller/transmitter and check all
connections for leaks.
12
FISHER®
Prestartup Checks
Adjustments are shown in figure 12 unless otherwise indi­
cated. Open loop condition must exist when performing the
prestartup checks. To obtain open-loop conditions:
• make sure there is no process flow through the final
control element., or
• disconnect the controller/transmitter output signal
line and connect it to a pressure gauge.
During prestartup, the displacer must be positioned from its
maximum to its minimum range of operation. Provide a
means to change the process variable (the process level
or interface). If the process variable cannot be varied suffi­
ciently, use the precalibration procedures in the Calibration
section to simulate the process variable changes required
for these checks.
Make sure the RAISE LEVEL dial on the controller is
mounted with the correct side facing out. The dial is marked
on both sides with an arrow. The arrow points to the left on
one side and to the right on the other. When the sensor is
mounted to the left of the controller/transmitter, the arrow
on the raise level dial should point to the left, as shown in
figure 12. If the sensor is to the right, the arrow should point
to the right. If necessary, remove the two mounting screws,
turn the dial over so the arrow points correctly, and reinstall
the mounting screws. The level directions shown on the
dial will be correct for both direct-acting and reverse-acting
controllers. For a transmitter, use the same side of the
ZERO ADJUSTMENT dial for both right and left hand sen­
sor mountings.
On a controller or transmitter with an optional mechanical
indicator assembly, the travel indicator plate is also marked
with an arrow on both sides. If the sensor is to the left of the
controller/transmitter, the arrow on the plate should point to
the left. If the sensor is to the right, the arrow should point
to the right. If necessary, reinstall the plate so that the arrow
points in the correct direction.
Set the PROPORTIONAL BAND control on a Type 2500
or 2500S controller, or the SPECIFIC GRAVITY control on
a Type 2500T transmitter, as follows:
• Sensor with Both Standard Torque Tube and
Standard Volume Displacer— If the torque tube is stan­
dard and the displacer volume is close to that listed in table
2, use figure 13 to find the PROPORTIONAL BAND or
SPECIFIC GRAVITY setting. Identical conversion in­
formation is also provided on the instruction plate in the
controller/transmitter cover (key 18, figure 18). Locate the
specific gravity of the process fluid on fluid level applica­
tions, or the difference between minimum and maximum
specific gravity on interface level or density applications,

Table 4. R eco m m en ded Settings F o r Pre-Startup Checks
RECOMMENDED RAISE LEVEL SETTING
FOR TYPE 2500 CONTROLLER
MOUNTING ACTION For Predetermined
PROPORTIONAL BAND
Dial Setting of 10
Direct 3.0 to 3.5
R ight-hand
Reverse 6.5 to 7.0
Direct 3.0 to 3.5
Left-hand
Reverse 6.5 to 7.0
1. For proportional band dial settings between 10 and 0 or for specific
gravidy dial settings between 1.0 and 0, interpolate the value.________
on the vertical axis of the chart. From this location, trace
horizontally to the curve with the desired proportional band,
differential gap, or span percentage, and then trace verti­
cally down to determine the proper dial setting on the hori­
zontal axis.
• Sensor with Nonstandard Torque Tube and/or
Displacer with Other than Standard Volume— If the
construction has a nonstandard torque tube or a displacer
volume that deviates significantly from the volume listed in
table 2, or both, the PROPORTIONAL BAND or SPECIFIC
GRAVITY dial setting does not indicate the actual propor­
tional band, differential gap, or span of the unit. To deter­
mine the correct dial setting, solve the following equation:
Corrected
Dial Setting = (PB)(SP G R )(^)(X )
Required
where:
PB = desired proportional band or differential gap for
a controller or, the span of a transmitter in per­
cent of total input span desired to yield full out­
put signal change of controller or transmitter
SP GR = specific gravity of the process fluid (for inter­
face level control, use the difference between
the specific gravity of the two fluids; for specif­
ic gravity control, use the difference between
the upper and lower range limits of specific
gravity).
Va = actual displacer volume, cubic inches listed on
the sensor nameplate.
Vr = standard displacer volume, cubic inches, from
table 2.
X = torque tube factor (1.0 foV standard torque
tubes, 2.0 for thin-wall torque tubes, or 0.5 for
heavy-wall torque tubes).
Type 2500
RECOMMENDED ZERO ADJUSTMENT SETTING FOR
TYPE 2500T TRANSMITTER
For Predetermined For Predetermined For Predetermined
PROPORTIONAL BAND SPECIFIC GRAVITY Dial SPECIFIC GRAVITY Dial
Dial Setting of 0 Setting of 1.0 Setting of 0
4.0 to 4.5 1.5 to 2.0 to right 0.5 to 1.0 to right
0.5 to 1.0 1.5 to 2.0 to left 4.0 to 4.5 to right
4.0 to 4.5 1.5 to 2.0 to left 0.5 to 1.0 to left
0.5 to 1.0 1.5 to 2.0 to right 4.0 to 4.5 to left
Type 2500 Controller or 2500T
Transmitter
In the following steps, for a controller/transmitter with a 3
to 15 psig (0.2 to 1 bar) output pressure range, the output
pressure can go as high as 20 psig. For a controller/trans­
mitter with a 6 to 30 psig (0.4 to 2 bar) output pressure
range, the output pressure can go as high as 35 psig (2.4
bar).
1. Turn on the supply pressure and check that the supply
pressure gauge reads 20 psig (1.4 bar) for a 3 to 15 psig
(0.2 to 1 bar) or 35 psig (2.4 bar) for a 6 to 30 psig (0.4 to
2 bar) output pressure range. If the pressure is incorrect,
loosen the locknut of the Type 67FR filter/regulator (figure
10); turn the adjusting screw clockwise to increase the
pressure or, counterclockwise to decrease the pressure.
Tighten the locknut after setting the regulator pressure.
2. Set the process variable to its minimum value. (That is,
lower the fluid below the displacer on fluid level applica­
tions, place the interface at the bottom of the displacer on
interface level applications, or fill the cage with the lowest
specific gravity fluid expected.)
3. Make sure that the PROPORTIONAL BAND or SPE­
CIFIC GRAVITY control is at the setting determined earlier
in this section. Then, set the RAISE LEVEL or ZERO AD­
JUSTMENT control at an appropriate value according to
table 4. This table gives recommended settings based on
maximum and minimum possible PROPORTIONAL
BAND and SPECIFIC GRAVITY settings. If an intermedi­
ate PROPORTIONAL BAND or SPECIFIC GRAVITY set­
ting is necessary, determine an appropriate RAISE LEVEL
or ZERO ADJUSTMENT setting.
Note
The raise level dial does not reflect actual
fluid level in the tank or fluid level position
on the displacer. •
4. The OUTPUT gauge on a 3 to 15 psig (0.2 to 1 bar)
range should read 3 psig (0.2 bar) for direct or 15 psig (1
13
Type 2500
bar) for reverse action. On a 6 to 30 psig (0.4 to 2 bar) range
the OUTPUT gauge should read 6 psig (2 bar) for direct or
30 psig (2 bar) for reverse action.
5. On a controller or transmitter with a mechanical indica­
tor assembly, the pointer should be over the LOW point on
the indicator plate. If a slight adjustment is necessary, loos­
en the side hex clamp nut (key 40, figure 18), shift the point­
er, and retighten the nut.
6. Increase the process variable by an amount to produce
full output pressure change. The OUTPUT gauge on a 3 to
15 psig (0.2 to 1 bar) range should read 15 psig (1 bar) for
direct or 3 psig (0.2 bar) for reverse action. On a 6 to 30 psig
(0.4 to 2 bar) range the OUTPUT gauge should read 30
psig (2 bar) for direct or 6 psig (0.4 bar) for reverse action.
On a controller or transmitter with an indicator assembly,
the pointer should be over the HIGH point on the indicator
plate; slight plate adjustment may be necessary, as de­
scribed at the end of step 5.
7. If all prestartup checks are satisfactory, go to the start­
up procedure. If performance is unsatisfactory, proceed to
the Calibration section.
Type 2500S Controller
In the following steps, for a controller with a 0 to 20 psig (0
to 1.4 bar) output pressure range, the output pressure can
go as high as 20 psig (1.4 bar). For a controller with a 0 to
35 psig (0 to 2.4 bar) output pressure range, the output
pressure can go as high as 35 psig (2.4 bar).
1. Turn on the supply pressure and check that the SUP­
PLY pressure gauge reads 20 psig (1.4 bar) for a 0 to 20
psig (0 to 1.4 bar) output pressure range or 35 psig (2.4 bar)
for a 0 to 35 psig (0 to 2.4 bar) output pressure range. If the
pressure is incorrect, loosen the locknut of the Type 67FR
filter/regulator (figure 10); turn the adjusting screw clock­
wise to increase the pressure or counterclockwise to de­
crease pressure. Tighten the locknut after setting the pres­
sure.
2. Set the process variable to its minimum value. (That is,
lower the fluid below the displacer on fluid level applica­
tions, place the interface at the bottom of the displacer on
interface level applications, or set the specific gravity at the
minimum on density applications.)
3. On a controller with a mechanical indicator assembly,
the pointer should be over the LOW point on the indicator
plate. If a slight adjustment is necessary, loosen the hex
clamp nut (key 40, figure 18), shift the pointer and retighten
the nut.
14
FISHER
Note
Adjustment of the RAISE LEVEL control
can set the switching points anywhere with­
in the length of the displacer. Be careful not
to set the switching points so that one is off
the displacer.
4. Make sure that the PROPORTIONAL BAND control is
at the setting determined in previous procedures. Set the
RAISE LEVEL control to 0, then set it to 1.0 for a direct-act­
ing or 4.0 for a reverse-acting controller.
5. The OUTPUT gauge should read 0 psig (0 bar) for di­
rect or either 20 or 35 psig (1.4 or 2.4 bar) for reverse action
(depending on controller range).
6. Increase the process variable until the OUTPUT
gauge reads either 20 or 35 psig (1.4 or 2.4 bar) for direct
or 0 psig (0 bar) for reverse acting. On a controller with an
indicator assembly, the pointer should be over the HIGH
point on the indicator plate; slight adjustment may be nec­
essary, as described at the end of step 3.
7. Readjust the RAISE LEVEL control until the OUTPUT
gauge again reads 0 psig (0 bar) for direct or either 20 or
35 psig (1.4 or 2.4 bar) for reverse action.
8. Adjust the RAISE LEVEL control to the point where the
OUTPUT gauge reads either 20 or 35 psig (1.4 or 2.4 bar)
for direct or 0 psig (0 bar) for reverse action.
9. Decrease the process variable until the OUTPUT
gauge reads 0 psig for direct or either 20 or 35 psig for re­
verse action (depending on controller range).
10. Recheck both switching points, and adjust as neces­
sary:
a. For direct-acting controllers, the controller output
switches from zero pressure to full supply pressure
when an increasing process variable passes the upper
switching point. The output does not return to zero pres­
sure until a decreasing process variable passes the
lower switching point. Adjusting the RAISE LEVEL con­
trol moves both switching points equally in the direction
of adjustment. Adjusting the PROPORTIONAL BAND
control moves the lower switching point to widen or nar­
row the differential gap between the two switching
points.
b. For reverse-acting controllers, the controller output
switches from zero pressure to full supply pressure
when a decreasing process variable passes the lower
switching point. The output does not return to zero pres­
sure until an increasing process variable passes the up­
per switching point. Adjusting the RAISE LEVEL con­
trol moves both switching points equally in the direction

of adjustment. Adjusting the PROPORTIONAL BAND
control moves the upper switching point to widen or nar­
row the differential gap between the two switching
points.
11. If all prestartup checks are satisfactory, proceed to the
Startup section. If performance is unsatisfactory, proceed
to the Calibration section.
Type 2503 Controller
In the following steps, for a controller with a 0 to 20 psig (0
to 1.4 bar) output pressure range, the output pressure can
go as high as 20 psig (1.4 bar). For a controller with a 0 to
35 psig (0 to 2.4 bar) output pressure range, the output
pressure can go as high as 35 psig (2.4 bar).
Note
Since the Type 2503 controller has no pro­
portional valve, the differential gap between
switching points is adjusted by varying the
supply pressure. This gap can be varied
from approximately a 3.5-inch (88.9 mm)
level change at 15 psig (1 bar) to a 6.0-inch
level change at 25 psig (1.7 bar) with a stan­
dard volume displacer and a fluid with a
ff**' specific gravity of 1.0. The gap also varies
inversely according to density; a fluid with
0.8 specific gravity produces a 4.4-inch (112
mm) level change at 15 psig to a 7.5-inch
change at 25 psig (1.7 bar). Set the gap at a
pressure low enough to be compatible with
the limitations of the diaphragm control
valve or other final control element.
1. Turn on the supply pressure. If necessary, adjust the
Type 67FR regulator to produce the desired differential gap
by loosening the locknut (figure 10) and turning the adjust­
ing screw clockwise to increase or counterclockwise to de­
crease pressure. Tighten the locknut.
2. Locate the process variable at its minimum value.
(That is, lower the fluid below the displacer on fluid level ap­
plications, place the interface at the bottom of the displacer
on interface level applications, or set the specific gravity at
the minimum on density applications.)
Note
Adjustment of the RAISE LEVEL control
can set the switching points anywhere with­
in the length of the displacer. Be careful not
to set the switching points so that one is off
the displacer.
Type 2500
3. Set the RAISE LEVEL control to 0 and then reset it as
follows:
a. For direct-acting controllers, set it between 1.0 and
1.5.
b. For reverse-acting controllers, set it between 3.5
and 4.0.
4. The OUTPUT gauge should read 0 psig (0 bar) for di­
rect or full supply pressure for reverse action.
5. Increase the process variable until the OUTPUT
gauge reads full supply pressure for direct or 0 psig (0 bar)
for reverse action.
6. Readjust the RAISE LEVEL control until the OUTPUT
gauge again reads 0 psig (0 bar) for direct or full supply
pressure for reverse action. Then adjust the RAISE LEVEL
control to the point where the OUTPUT gauge reads full
supply pressure for direct or 0 psig (0 bar) for reverse ac­
tion.
7. Decrease the process variable to the desired switching
point at which the OUTPUT gauge reads 0 psig for direct
or full supply pressure for reverse action.
8. Recheck both switching points, and adjust as neces­
sary:
a. For direct-acting controllers, the controller output
switches from zero pressure to full supply pressure
when an increasing process variable passes the upper
switching point. The output does not return to zero pres­
sure until a decreasing process variable passes the
lower switching point. Adjusting the RAISE LEVEL con­
trol moves both switching points equally in the direction
of adjustment. Varying the supply pressure moves the
lower switching point to widen or narrow the differential
gap between the two switching points.
b. For reverse-acting controllers, the controller output
switches from zero pressure to full supply pressure
when a decreasing process variable passes the lower
switching point. The output does not return to zero pres­
sure until an increasing process variable passes the up­
per switching point. Adjusting the RAISE LEVEL con­
trol moves both switching points equally in the direction
of adjustment. Varying the supply pressure moves the
upper switching point to widen or narrow the differential
gap between the two switching points.
9. If all prestartup checks are satisfactory, proceed to the
Startup section. If performance is unsatisfactory, proceed
to the Calibration section.
Adjustments '
This section explains controller/transmitter action and ad­
justments. Figure 12 shows adjustment locations.
15
Type 2500
Control Action
The following is a definition of control action.
• Direct Action— Increasing fluid level, interface level,
or density, increases the output signal.
• Reverse Action—Increasing fluid level, interface
level, or density, decreases the output signal. Controller/
transmitters factory-set for reverse-acting have the suffix
letter R added to their type number.
The control action is determined by the cage head mount­
ing position and by the Bourdon tube-flapper arrangement
in the controller/transmitter. Refer to figure 4 for mounting
positions and to figure 17 for Bourdon tube-flapper ar­
rangements. To change the action, refer to the changing
action procedure in the Maintenance section.
Level Adjustment (Controllers Only)
To make a level adjustment, open the controller cover,
loosen the knurled adjustment screw, and rotate the adjust­
ment lever around the RAISE LEVEL dial. To raise the fluid
or interface level, or increase density, rotate this knob in the
direction of the arrows. To lower the level or decrease den­
sity, rotate the knob in the opposite direction. This proce­
dure is the same for either direct or reverse action. Tighten
the knurled screw.
Note
The raise level dial does not reflect actual
fluid level in the tank or fluid level position
on the displacer.
Zero Adjustment (Transmitters Only)
To make a zero adjustment, open the transmitter cover,
loosen the adjustment screw and rotate the adjustment le­
ver around the ZERO ADJUSTMENT dial. This adjustment
sets the output pressure to correspond to a specific level
on the displacer. Tighten the knurled screw.
Proportional Band Adjustment (Except
Transmitters and 2503 Series
Controllers)
The proportional band adjustment changes the amount of
displacement force required to obtain a full output pressure
change. To perform this adjustment, open the controller
cover and turn the PROPORTIONAL BAND adjustment
(see figure 12). Refer to the prestartup check procedures
to determine the proper setting.
16
Specific Gravity Adjustment
(Transmitters Only)
This adjustment also changes the amount of displacement
force required to obtain a full output pressure change. To
perform this adjustment, open the transmitter cover and
turn the SPECIFIC GRAVITY adjustment (see figure 12).
Refer to the prestartup check procedures to determine the
proper setting.
Calibration
Precalibration Requirements
Note
Calibration of a unit with a displacer de­
signed for interface or density control must
be performed with the displacer completely
submerged in a liquid of the specific gravity
for which the unit was designed.
The controller/transmitter can be calibrated in the field
mounted on the vessel containing the process fluid. It may
also be done in the shop, but other means of obtaining a
displacement force change must be provided. There are
wet and dry methods of adapting the calibrating procedure.
Wet Calibration
Remove the entire controller/transmitter and sensor as­
sembly from the vessel. For caged sensors, pour the fluid
into the cage. For cageless sensors, suspend the displacer
to an appropriate depth in a fluid having a specific gravity
equal to that of the process fluid.
If necessary, you may use water for wet calibration in the
shop. You must compensate for the difference between the
specific gravities of water and the process fluid, however.
As an example, assume the process fluid has a specific
gravity of 0.7. The specific gravity of water is 1.0. To simu­
late a process level of 50 percent of the input span, would
require a water level of 35 percent (0.7/1.0 x 50 percent =
35 percent).
Dry Calibration
Remove the controller/transmitter and torque tube arm, as
a single unit, from the cage or vessel. Then, wherever the
standard calibration procedures in this, manual require a
specific process variable input to the sensor, simulate the
process variable by suspending the proper weight (such as
a can of sand) from the end of the displacer rod. Complete

the following procedures (Controller/Transmitter and
Torque Tube Arm Disassembly) and (Determining the
Amount of Suspended Weight) before proceeding to the
Calibrating Procedure.
Controller/Transmitter and Torque Tube
Arm Disassembly
WARNING
To avoid personal injury from contact with
the process fluid, lower the vessel level be­
low the sensor torque tube arm, or shut off
the cage equalizing valves and drain the
cage before proceeding. For closed ves­
sels, release any pressure that may be in
the vessel before removing the sensor as­
sembly.
When removing the displacer from the displacer rod or re­
moving the controller/transmitter and torque tube arm from
the cage or vessel, refer to the appropriate 249 Series an/or
Type 259B instruction manual for assistance. The method
of removing the displacer or torque tube arm and attached
controller/ transmitter varies with the type of sensor.
For a caged sensor with top equalizing connection, it may
be appropriate to remove the entire cage from the vessel
before disassembling.
CAUTION
If the displacer is to be disconnected from
the displacer rod before the sensor assem­
bly is removed from the cage or vessel, pro­
vide a means of supporting the displacer to
prevent it from dropping and suffering dam­
age. The spuds or stem end pieces on all
displacers have holes suitable for inserting
rods or other supports.
Additionally, a threaded rod may be
installed into the 1/4-inch 28 UNF threaded
hole in the displacer spud or stem end piece
of top-mounted cageless and all caged sen­
sors. For some top-mounted sensors with
long displacers, the sensor may be re­
moved through the access hole in the sen­
sor head.
For Type 249BP and 249P sensors with trav­
el stop, the stem end piece pins will secure
the displacer on the travel stop as long as
Type 2500
the travel stop plate is installed and the sen­
sor head is in position.
Determining the Amount o f Suspended
Weight
CAUTION
Avoid overloading a torque tube sized for
interface or density applications. Consult
your Fisher Controls sales office or sales
representative for the maximum allowable
substitute weight, Ws, that may be used
with your particular construction.
To determine the total weight that must be suspended from
the displacer rod to simulate a certain condition of fluid lev­
el or specific gravity, solve the following equation:
ws = w^o.oseixvxsp gr)]
where:
Ws= Total suspended weight in pounds (should nev­
er be less than 0.5 pounds). For a unit with a
horizontal displacer, make sure the center of
gravity of the substitute weight is where it
would be on the actual displacer.
Note
For liquid level control only, simulate the
lower range limit of the input span by sus­
pending the displacer from the displacer
rod. For other values of input span, remove
the displacer and suspend the appropriate
weight as determined in the equation
above.
Wd = Weight of the displacer, in pounds (determine
by weighing displacer).
0.0361 = Weight of one cubic inch of water (specific
gravity = 1.0), in pounds.
V = Volume, in cubic inches, of the displacer when
submerged at the level required by the cal­
ibration procedure. Or,
V = jt/4 (displacer diameter)2 x (length of displacer
submerged)
SP GR = Specific gravity of the process fluid at operat­
ing temperature.
For interface level measurement, the equation becomes:
17
Type 2500
Table 5. Minimum and Maximum Limits for Setting Process Variables
APPLICATION MINIMUM LIMIT
Liquid Level D isplacer m ust be com pletely out of liquid
Interface D isplacer m ust be com pletely subm erged in lighter o f tw o
process liquids
Density D isplacer m ust be com pletely subm erged in liquid having
specific gravity of low est range point
Ws= Wd-[(0.0361)(V,)(SP GR,) + (0.0361 )(Vh)(SP GRh)]
where:
V| = Volume, in cubic inches, of the displacer when
submerged in the lighter of the fluids.
Or,
V= n /4(displacer diameter)2 x (length of the dis­
placer submerged)
SP GR| = Specific gravity of the lighter of the fluids at op­
erating temperature.
Vh= Volume, in cubic inches, of the displacer when
submerged in the heavier of the fluids.
Or,
V = 7i/4 (displacer diameter)2 x (length of the dis­
placer submerged)
SP GRh = Specific gravity of the heavier of the fluids at
operating temperature.
Calibrating Procedure
WARNING
The following calibration procedures re­
quire taking the controller/transmitter out
of service. To avoid personal injury and
property damage caused by an uncon­
trolled process, provide some temporary
means of control for the process before tak­
ing the controller/transmitter out of service.
Figure 12 shows adjustment locations, except as other­
wise indicated. In order to calibrate, open loop conditions
must exist. One way to obtain an open loop is to ensure that
there is no flow through the final control element. Another
way to obtain an open loop is to discohnect the controller/
transmitter output signal line and plug the output connec­
tion with a test pressure gauge.
18
MAXIMUM LIMIT
D isplacer m ust be com pletely subm erged in liquid
D isplacer m ust be com pletely subm erged in
heavier o f tw o process liquids
D isplacer m ust be com pletely subm erged in liquid having
specific gravity o f highest range point
Several steps in these calibrating procedures require set­
ting the process variable at its minimum and maximum lim­
its, according to table 5.
Note
If the process cannot be varied readily or
the Wet Calibration method cannot be used
in the following steps, be sure to use the
proper sequence of correct weights as
found in the Determining Amount of Sus­
pended Weight procedure. Whenever the
following steps require particular prestar­
tup checks, refer to the appropriate proce­
dures for: Type 2500 Controller or 2500T
Transmitter, Type 2500S Controller, or Type
2503 Controller.
1. Turn on the supply pressure and check that it is set ac­
cording to the appropriate prestartup checks procedure.
2. Make sure that the PROPORTIONAL BAND or SPE­
CIFIC GRAVITY adjustment (except on a Type 2503 con­
troller) is at the setting determined according to the ap­
propriate prestartup check procedure.
3. Locate the process variable at the minimum limit of the
input span according to the limitations given in the note
above. For constructions with an indictor assembly, make
sure that the pointer is over the LOW point.
4. Make sure that the flapper is centered over the nozzle.
If not, loosen the hex nut (key 40, figure 18) and reposition
the flapper; tighten the hex nut.
5. Use one of the following steps to adjust the alignment
screw (key 33, figure 18):
a. For a Type 2500 Controller or 2500T Transmitter,
adjust the alignment screw in or out until the flapper is
perpendicular to the nozzle tip.
b. For a Type 2500S or 2503 Controller, adjust the
alignment screw in or out to obtain a differential gap out­
put pressure of either 20 or 35 psig (1.4 to 2.4 bar) de­
pending on the output pressure range of the controller.
6. If you cannot obtain the correct initial output pressure
according to the appropriate prestartup checks procedure,

adjust the RAISE LEVEL or ZERO ADJUSTMENT control
until the output pressure reads as follows:
a. For a Type 2500 controller or Type 2500T direct-act­
ing transmitter, 3 psig (0.2 bar) for a 3 to 15 psig (0.2 to
1 bar) output pressure range or, 6 psig (0.4 bar) for a 6
to 30 psig (0.4 to 2 bar) output pressure range.
b. For Type 2500 controller or Type 2500T reverse-act­
ing transmitter, 15 psig (1 bar) for a 3 to 15 psig (0.2 to
1 bar) output pressure range, or 30 psig (2 bar) for a 6
to 30 psig (0.4 to 2 bar) output pressure range.
c. For Type 2500S or 2503 direct-acting controller, 0
psig (0 bar).
d. For Type 2500S or 2503 reverse-acting controller,
either 20 psig (1.4 bar) or 35 psig (2.4 bar), depending
on the controller output signal range.
Note
In the following step, the alignment screw
(key 33, figure 18) always must remain
screwed in far enough to provide tension on
the flapper.
7. Set the process variable at the maximum limit of the in­
put span, according to the limitations given above (refer to
the first note under the heading Calibration Procedure).
Make sure that the output pressure change is the normal
proportional span of 12 or 24 psig (0.8 bar or 1.7 bar) or dif­
ferential gap span of 20 or 35 psig (1.4 to 2.4 bar), depend­
ing on the controller output pressure range. For controller/
transmitters with indicator assemblies, the pointer should
line up with the LOW or HIGH mark on the front plate (key
54, figure 18).
8. If controller/transmitter output pressure changes and
indicator assembly agree with those given in step 7, pro­
ceed to the startup procedures. If not, proceed to step 9.
Note
Any sliding of the level set arm (key 28, fig­
ure 18) in the following step changes the
zero as well as the output pressure span.
9. To adjust the output pressure span, loosen the two lev­
el set mounting screws (see figure 18) and slide the flexure
strip base (key 27) right or left along the elongated slotted
hole as follows:•
• Slide the flexure strip base away from the torque tube
shaft to increase the output pressure span. Slide the flex­
Type 2500
ure strip base toward the torque tube shaft to decrease the
span. Retighten the screws.
10. To change the pointer span, loosen the indicator plate
screws (key 41, figure 18, detail of indicator assembly),
slide the plate until the LOW or HIGH mark is under the
pointer. Tighten the plate screws.
11. Repeat steps 1 through 10 until the required output
pressure and pointer spans are obtained.
12. Re-zero the RAISE LEVEL or ZERO ADJUSTMENT
adjustment as required. On a direct-acting Type 2500S or
2503 controller, readjust the RAISE LEVEL control until it
snaps the output pressure back to 0 psig. This ensures that
the lower switching point is near the bottom of the displac­
er.
Note
If you cannot calibrate the controller or
transmitter, look for other problems as de­
scribed in the Troubleshooting procedures,
such as a nonperpendicular flapper-nozzle,
leaky connections, or a binding displacer
rod. If none of these troubles are apparent,
the displacer or torque tube is probably
sized for a different set of service condi­
tions. Insure that the displacer is sized cor­
rectly for the application.
If the displacer information on the nameplate (key 18, fig­
ure 18) is incorrect, correct the information for the new ser­
vice and recalibrate the unit. For water service, remember
that a standard displacer and torque tube are designed to
use the full displacer length (except for a Type 2503 con­
troller). The Type 2503 controller gives full output pressure
changes over approximately 25 to 40 percent of the dis­
placer length.
Startup
Adjustment locations are shown in figure 12.
Type 2500 Controller
1. Set the PROPORTIONAL BAND control to the maxi­
mum desired setting, corrected according to the prestartup
checks section, if necessary.
2. Adjust the RAISE LEVEL control to the desired control
point.
3. Slowly open the upstream and downstream manual
control valves in the pipeline. If the pipeline has a bypass
valve, close the valve.
19
Type 2500
4. If desired, adjust the proportional band to the narrow­
est (lowest) setting that maintains stable control.
5. To confirm the optimum proportional band setting, mo­
mentarily create a load upset. If cycling occurs, broaden
(increase) the proportional band until process oscillations
diminish rapidly. In general, the narrowest proportional
band that does not produce cycling provides the best con­
trol.
Type 2500T Transmitter
1. Make sure that the SPECIFIC GRAVITY and ZERO
ADJUSTMENT controls are set according to the Type
2500 Controller or 2500T Transmitter portion of the pre­
startup checks procedures.
2. Slowly open the upstream and downstream manual
control valves in the pipeline. If the pipeline has a manual
bypass valve, close the valve.
Type 2500S Controller
1. Set the switching points according to the Type 2500S
Controller portion of the prestartup checks procedures.
2. Slowly open the upstream and downstream manual
control valves in the pipeline. If the pipeline has a manual
bypass valve, close the valve.
3. If it is necessary to change the switching points, do so
as mentioned in step 1.
Type 2503 Controller
1. Set the switching points according to the Type 2503
Controller portion of the prestartup checks procedures.
2. Slowly open the upstream and downstream manual
control valves in the pipeline. If the pipeline has a manual
bypass valve, close the valve.
3. If necessary to reposition switching points, do so by
adjusting the RAISE LEVEL control. For example, if the dif­
ferential gap is set for 4-inches (102 mm) of level change,
this 4-inches (102 mm) can be set anywhere within the
length of the displacer. Be careful to not set it so that one
end is off the displacer.
20
Principle of Operation
The controller/transmitter receives the change in fluid lev­
el, fluid-to-fluid interface level, or density from the change
in the buoyant force the fluid exerts on the sensor displacer.
The displacer, through a mechanical linkage, imparts a
rotary motion to the torque tube shaft. This rotary motion
positions the flapper according to the level position of the
displacer; the nozzle/Bourdon tube arrangement sends a
pneumatic signal to the relay valve.
All 2500 and 2503 Series controller/transmitters use the
same basic pressure-balanced relay assembly. The follow­
ing descriptions explain how the relay action produces the
output signal with the various controller/transmitter
constructions.
Type 2500 Controller or 2500T
Transmitter
Full supply pressure comes to the relay from the regulator,
as shown in figure 14. The relay has a fixed restriction
through which supply pressure bleeds before entering the
large diaphragm area and the inner Bourdon tube channel.
In a steady-state condition, the process level holds the
torque tube and attached flapper steady in relation to the
nozzle. This allows pressure to escape between the nozzle
and flapper at the same rate it bleeds into the large dia­
phragm area. The large diaphragm holds the inlet end of
the relay valve slightly open to compensate for the venting
of output pressure through the proportional valve as it
maintains a steady-state position of the final control ele­
ment. The output pressure, through the three-way propor­
tional valve, affects the Bourdon tube outer channel, hold­
ing the Bourdon tube in a steady-state position.
A process level change raises or lowers the displacer,
moving the flapper with respect to the nozzle. If the process
level change increases nozzle pressure, the large dia­
phragm moves down; this closes the exhaust end and
opens the inlet end of the relay valve (see figure 14). This
action of the relay valve increases the output pressure to
the final control element. Since the area ratio of the large
diaphragm to the small diaphragm is three-to-one, the
small diaphragm action amplifies the output pressure
change. The three-way proportional valve lets the increase
in output pressure apply to the Bourdon tube outer chan­
nel. The expansion of the Bourdon tube moves the nozzle
away from the flapper slowing the response of the pneu­
matic circuit.
If the process level change decreases the nozzle pressure,
the large diaphragm moves up. This action closes the inlet
end and opens the exhaust end of the relay valve which al­
lows output pressure to exhaust. This relay valve action re­
duces the output pressure to the final control element and
is the reverse of the previous explanation.
 Type 2500

y SUPPLY PRESSURE

E lg g j OUTPUT PRESSURE

E B It l NOZZLE PRESSURE

| PROPORTIONAL PRESSURE

| | EXHAUST
C 021I4-E
B09S8-1

Figure 14. Direct-Acting, Right-Hand-Mounted 2500-249/259B Series Controller/Transmitter

The proportional valve varies the reaction of the Bourdon
tube to changes in the output pressure. For additional in­
formation on the proportional valve action, refer to the fol­
lowing proportional valve subsection.
Proportional Valve
the Bourdon tube outer channel, providing proportional
band control (see figure 14). The Bourdon tube moves to
counteract the pressure changes in the nozzle, equaling
the relay diaphragm pressure differential. The relay valve
maintains a new output pressure according to the change
in the process variable. •

The three-way proportional valve is adjustable to allow A wide-open proportional valve (fully counterclockwise)
some or all of the output pressure change to feed back to permits feedback of the output pressure signal change and

21
Type 2500
INNER BOURDON
C 0211J-E
A1WO-1
Figure 15. Direct-Acting Left-Hand-Mounted Type 2503 Controller
produces 100 percent proportional response. A closed (ful­
ly clockwise) proportional valve produces smaller propor­
tional responses, because part of the output pressure
change vents through the proportional valve exhaust.
Type 2500S Controller
This construction has the same flapper, relay, and propor­
tional valve as the Type 2500 controller. However, the
nozzle is connected (figure 14) in such a way that output
pressure feedback (from the movement of the Bourdon
tube) moves the nozzle in the opposite direction of the flap­
per. This action completely opens the relay valve for full
output pressure or completely closes the relay valve for full
exhaust of the output pressure, allowing no in-between
throttling.
Type 2503 Controller
This construction has the same flapper and sensor ar­
rangement as the Type 2500 controller, but its Bourdon
tube has with a three way valve operated by a plunger (see
figure 15). Note that the switch point adjustment changes
the position of the moveable arm and attached Bourdon
tube assembly; this in turn changes the switch point in rela­
tionship to the process level. The differential gap of the
2503 either completely opens the relay valve for full output
22
FISH ER
pressure or completely closes the relay valve for full ex­
haust of the output pressure, allowing no in-between throt­
tling.
For a direct-acting controller, as long as the process vari­
able remains above the switch point, the flapper does not
depress the plunger of Bourdon tube valve. In this condi­
tion, the Bourdon tube valve remains closed, providing full
loading pressure to the Bourdon tube. This loading pres­
sure moves the Bourdon tube away from the flapper. Also,
in this condition, full loading pressure is on the upper dia­
phragm of the relay. The loading pressure moves the dia­
phragm down, closing the exhaust end and opening the in­
let end of the relay valve, allowing full output pressure.
When the process level sufficiently decreases, the flapper
pushes in the plunger of the Bourdon tube valve enough to
release the loading pressure and seal the inner Bourdon
valve (see figure 15). This decrease in the loading pressure
moves the Bourdon tube toward the flapper, producing the
snap action. Also, this decrease in loading pressure allows
relay spring pressure to move the large diaphragm up,
closing the inlet end and opening the-exhaust end of the
relay valve, allowing full exhaust of the output pressure.
This control action continues until a sensor level change ^
moves the flapper away from the plunger, permitting the
 Type 2500

Bourdon tube valve to close, restoring loading pressure to

if-v the pneumatic circuit. Reverse-acting controllers produce
1 the opposite effect.

Maintenance
The 2500 and 2503 Series controllers/transmitters work in
combination with 249 Series and Type 259B displacers.
Refer to figure 18 for key number locations, unless other­
wise indicated.

Due to the care Fisher Controls takes in meeting all

manufacturing requirements (heat treating, dimensional
tolerances, etc.), use only replacement parts manufac­
tured or furnished by Fisher Controls.

CT WARNING

When replacing the sensor assembly, the

displacer may retain process fluid or pres­
sure. Personal injury or property damage
may occur due to sudden release of the
pressure. Contact with hazardous fluid,
fire, or explosion can be caused by punctur­
ing, heating, or repairing a displacer that is
retaining process pressure or fluid. This
danger may not be readily apparent when
disassembling the sensor assembly or re­
moving the displacer. Before disassem­ Figure 16. Heat Insulator for 249 Series or 259B Series Sensor
bling the sensor or removing the displacer,
observe the more specific warning pro­ control device if continuous operation is re­
vided in the sensor instruction manual. quired during maintenance.

1. Disconnect the supply and output pressure tubing from

Troubleshooting
When troubleshooting, open loop conditions must exist un­
less otherwise stated. When monitoring the process
vari-able, use the most accurate level indicating device
available. The output signal measuring device should have
corresponding accuracy.
Table 6 lists some common operating faults, their probable
causes, and corrective action.
Removing Controller/Transmitter from
Sensor
WARNING
To avoid injury in the following steps, turn
off the supply pressure and carefully re­
lease any pressure trapped in the control-
fif^ ler/transmitter before breaking any pres­
sure connection. Provide a bypass for the
the controller or transmitter. For a controller/transmitter
with an indicator, remove the pointer assembly by referring
to the section entitled Replacing the Bourdon Tube.
2. Loosen the top hex clamp nut (key 40, figure 18) and
remove the flapper base (key 30, figure 18) from the torque
tube rotary shaft.
CAUTION
If the hex clamp nut has not been loosened
or the pointer removed according to step 2,
attempting to remove the controller/trans­
mitter from the sensor may bend the flapper
or rotary shaft. Be careful that the back of
the controller/transmitter case or the heat
insulator does not drop down and bend the
rotary shaft or shaft extension.‘
3. Remove any insulating tape from the joint between the
controller/transmitter case and the torque tube arm. Re

23
Type 2500
Table 6. Troubleshooting Chart for 2500 Series Controller/Transmitters
FAU LT
1. P rocess w anders o r cycles
around se t point.
2. C ontroller/transm itter
controlling off set point or
sw itching point.
3. C ontroller/transm itter cannot
attain full output range.
4. C ontroller/transm itter rem ains
a t full o r z ero o utput pressure.
24
P O S S IB LE C A U S E
1.1 Proportional band o r specific
gravity adjustm ent incorrect o r
im properly tuned control loop.
1.2 S upply pressure varying or
incorrect supply pressure setting.
1.3 S ensor not plum b a nd is in
contact w ith sidew all o r leak in
displacer.
1.4 R elay m alfunction.
2.1 S upply pressure not set
correctly.
2.2 Leak in the
controller/transm itter loop.
2.3 Leaking displacer.
2 .4 Flapper adjustm ent.
2.5 P rocess variable changed.
3.1 S upply pressure not set
correctly.
3.2 Flapper adjustm ent.
3.3 P rocess variable changed.
3.4 R elay m alfunction
3.5 Leak in the
controller/transm itter loop.
4.1 S upply o r output pressure
gauge m alfunction.
4.2 F lapper adjustm ent.
CHECK
Ensure the prestartup procedures
are com pleted correctly. Tune
control loop.
U se input pressure gauge to
m onitor stability. M ake sure
regulator IN supply pressure is
w ithin limits.
C heck cage vessel and Stillwell
installation, o r fo r leaking
displacer.
C heck fo r relay m alfunction by
using the testing relay deadband
procedure.
M ake sure regulator supply
pressure is set correctly. Make
sure regulator IN supply pressure
is w ithin limits.
Use soap and w ater to check fo r
internal and external leaks.
Ensure th e displacer is not filling
w ith process fluid.
Ensure the fla p p er is not loose on
the torque tube shaft and is
centered on the nozzle.
Ensure the process variable has
not changed from original
calibration settings, o r displacer
not designed fo r specific g ravity of
process.
M ake sure supply pressure is set
correctly. M ake sure regulator IN
supply pressure is w ithin limits.
Ensure the fla p p er is not loose on
the torque tube shaft a nd is
centered on the nozzle.
Ensure the process variable has
not changed from original
calibration settings, o r from
displacer’s designed specific
gravity.
C heck fo r relay m alfunction by
using the testing relay deadband
procedure.
Use soap and w ater to c heck for
internal and external leaks.
Ensure the pressure gauges are
registering correctly.
Ensure the fla p p er is not loose on
the torque tube shaft a nd is
centered o n the nozzle.
C O R R E C TIO N
If stable control cannot be attained
and all oth er elem ents are
functionally corre ct, exam ine other
possible causes related to the
controller/transm itter.
A pply correct s upply pressure.
Use one regulator per instrum ent.
M ake sure the displacer and
displacer rod hangs freely. M ake
sure linkage is tight. R eplace
displacer if leaking.
D epress p lunger to clean out the
fixed restriction. R eplace o r repair
relay using the procedure in the
M aintenance section.
R eset the supply regulator
pressure. If the condition occurs
again, rebuild o r replace regulator.
Provide a regulator input pressure
w ithin regulator limits.
R eplace o r repair leaking parts as
necessary.
R efer to s ensor m aintenance
procedures in the a ppropriate
sensor instruction m anual.
R eplace o rtig h te n flapper
assem bly as necessary a nd/or
cen ter fla p p er on nozzle.
C hange process variable back to
original specification or
recalibrate. If necessary, provide
replacem ent displacer of correct
size and recalibrate.
R eset th e regulator pressure. If
problem reoccurs, replace o r
rebuild the regulator. Ensure
regulator IN supply pressure is
w ithin lim its at all operating levels.
R eplace o r tighten flapper
assem bly as necessary and/or
center flapper on nozzle.
C hange process variable b ack to
original specification or
recalibrate. If necessary, provide
replacem ent displacer o f correct
size a nd recalibrate.
D epress plunger to clean out the
fixed restriction. R eplace or repair
relay using the procedure in the
M aintenance section.
R eplace o r repair leaking parts as
necessary.
R eplace p ressure gauges. Use
corrective action g iven in section 3
o f th is table.
R eplace o r tighten flapper
assem bly a s necessary and/or
cen ter flapper on nozzle.

move the four cap screws (key 39, figure 16) that hold the
controller/transmitter or heat insulator to the torque tube
arm. Pull the case straight out from the torque tube arm,
easing it over the shaft coupling (key 36, figure 16) if one
is installed.
4. If the controller/transmitter has a heat insulator, re­
move the four button head cap screws and washers (keys
40 and 53, figure 16) and remove the insulator assembly.
Changing Mounting Methods
CT WARNING
To avoid personal injury from contact with
the process fluid, lower the vessel fluid lev­
el below the torque-tube arm before pro­
ceeding. For closed vessels, release any
pressure that may be above the fluid. Also,
be careful to avoid overloading a thin-wall
torque tube with an overweight displacer.
Refer to figure 18 for key number locations.
1. Remove the controller/transmitter as described pre­
viously.
2. A controller/transmitter is attached to the sensor in one
of the mounting positions shown in figure 4. Right hand
mounting is with the controller/transmitter case (key 1) to
the right of the displacer (FLOAT), as you look at the front
of the case, left hand mounting is with with the case to the
left of the displacer. For a 249 Series or Type 259B sensor,
remove the torque tube arm from the sensor or vessel and
reinstall the torque tube arm in the opposite position ac­
cording to the appropriate instruction manual. Note that the
term FLOAT is marked on the RAISE LEVEL dial and the
indicator plate, if one is used.
3. Check the desired control action. If the control action
is no correct, refer to the changing action procedures to
change it. Mount the Bourdon tube in one of the positions
shown in figure 17.
4. The arrow on the RAISE LEVEL dial under the word
FLOAT should point toward the displacer. If not, remove
the dial from the controller, turn it over, and install it in the
correct position.
5. For a controller/transmitter with an indicator assembly,
the arrow near the word FLOAT on the indicator plate
should point toward the displacer. If it does not, remove the
two screws (key 41, see detail of indicator assembly in fig­
Type 2500
ure 18), turn the front plate (key 54) to the side with the
FLOAT arrow pointing toward the displacer, and secure the
plate with the screws.
6. Install the controller/transmitter according to the next
section.
Installing Controller/Transmitter on
Sensor
Note
If the installation is in a location that is not
readily accessible and shop calibration is
required, remove the torque tube arm from
the cage or vessel before installing the con­
troller or transmitter to the sensor. Install
the controller/transmitter on the torque
tube arm in the shop; then calibrate and re­
turn the controller/transmitter with the
torque tube arm assembly attached for
installation.
Perform step 1 only if adding a heat insula­
tor to a unit that does not have one. Key
numbers in this step are shown in figure 16.
1. To install heat insulator, secure the shaft extension
(key 37, figure 16) to the torque tube assembly rotary shaft
with the shaft coupling (key 36, figure 16). Tighten both set
screws (key 38), with the coupling centered as shown in fig­
ure 16. Then mount the insulator assembly (key 35) on the
controller/transmitter case with four button head cap
screws and washers (keys 40 and 53). Tighten the screws.
CAUTION
In the following step, avoid bending the
rotary shaft of the torque tube assembly.
Bending or side loading of this shaft could
cause erroneous readings. Additionally,
make sure the ball bearing assembly (key
12, figure 18) is removed from the case (key
1, figure 18) to provide clearance when
installing the case on the sensor.
2. Remove the bearing assembly (key 12) from the case
(key 1).
3. Carefully slide the controller/transmitter case straight
in. Secure the case on the torque arm or insulator with the
four cap screws (key 39, figure 16).
Note
If a heat insulator is used, do not insulate its
exterior.
25
Type 2500

DIRECT ACTING— RIGHT HAND MOUNTING REVERSE ACTING— RIGHT HAND MOUNTING
CONSTRUCTION REVERSE ACTING— LEFT HAND MOUNTING DIRECT ACTING— LEFT HAND MOUNTING

TYPE 2500
OR 2500T
(INCLUDING
C VERSIONS)

ACW54
ARB146
B08M-1

Figure 17. Bourdon Tube-Flapper Arrangem ents for Various Actions an d Mountings

4. Slide the bearing assembly (key 12) onto the shaft or 6. Connect the supply and output pressure tubing and
shaft extension of the insulator, and install the bearing as­ perform the calibration procedure.
sembly (key 12) into the case (key 1).

Replacing the Bourdon Tube

5. Install the flapper base (key 30) on the torque tube
rotary shaft, making sure the flapper is centered over the
nozzle or Bourdon tube valve. Secure the base with the hex
nut (key 40). For a controller/transmitter with an indicator
assembly, install the pointer assembly according to the
section entitled Replacing the Bourdon Tube.
Refer to figure 18 for key number locations.
1. Disconnect the tubing (key 10 for Type 2503 and key
11 for Type 2500) from the Bourdon tube base. For a con­
troller/transmitter with indicator assembly, loosen the side

26

hex clamp nut (key 40) and remove the pointer assembly
(key 51) from the torque tube rotary shaft.
2. Remove the mounting screws (key 45) and Bourdon
tube assembly (key 16).
3. Inspect the Bourdon tube. Replace it if necessary, us­
ing a tube with a black color code for a 3 to 15 psig or 0 to
20 psig (0.2 to 1 bar or 0 to 1.4 bar) range. Use a tube with
a red color code for a 6 to 30 psig or 0 to 35 psig (0.4 to 2
bar or 0 to 2.4 bar) range. The range is stamped at the Bour­
don tube base.
4. Mount the Bourdon tube on the level set arm (key 28).
Secure it with the mounting screws, using the proper
orientation as shown in figure 17. Connect the tubing to the
tube base, with tubing from the R connection on the relay
(key 34) going to the marked base connection. The other
tubing goes to the unmarked base connection. With an in­
dicator assembly, install the pointer assembly on the rotary
shaft and tighten the hex nut.
5. Perform the Calibrating Procedure.
Changing Action
Note
The following procedure is necessary to re­
store previous action if the mounting meth­
od has been changed. Figure 18 shows key
numbers.
1. Reposition the Bourdon tube (and indicator assembly,
if used) according to steps 1 through 4 of the section en­
titled Replacing the Bourdon Tube.
2. Loosen the hex nut (key 40) and remove the flapper
base (key 30) from the torque tube rotary shaft. Turn the
flapper base over and install it on the rotary shaft, using the
proper orientation as shown in figure 17 and making sure
the flapper is centered over the nozzle or Bourdon tube
valve.
3. Perform the calibrating procedure.
Relay Deadband Testing (Type 2500
Controller or 2500T Transmitter Only)
1. Replace the appropriate (proportional or specific grav­
ity) adjustment assembly with the 1/8-inch NPT pipe plug
according to the section entitled Replacing the Proportion­
al Valve.
Type 2500
2. Turn on the supply pressure and set it to 20 or 35 psig
(1.4 to 2.4 bar), depending on the controller/transmitter op­
erating range.
3. By changing the process variable and adjusting the
RAISE LEVEL or ZERO ADJUSTMENT control, set the
output pressure to 15 or 30 psig (1.0 or 2.0 bar). While mon­
itoring the output pressure, slowly change the process until
the output pressure just changes, and record the value of
the process variable at the detection point.
4. Change the process variable in the opposite direction
until the output pressure just changes and again record the
value of the process variable. If the difference between the
two recorded values (the deadband) is more than 0.2% of
the maximum displacer length, the relay must be replaced
or repaired according to the Changing Relay and disas­
sembling relay sections that follow.
5. Turn off the supply pressure, remove the pipe plug, and
install the appropriate adjustment assembly.
Replacing the Proportional Valve
Note
The following procedure, to convert to or
from the pipe plug or the desired adjust­
ment assembly, can be used for any type
number covered in this manual.
1. Remove the tubing (key 10) from the proportional band
valve assembly.
2. Unscrew the base of the PROPORTIONAL BAND or
SPECIFIC GRAVITY adjustment assembly (key 36 or 90,
figure 18), or the 1/8-inch NPT pipe plug (key 73, not
shown), from the relay base (key 23, figure 18).
3. Install the pipe plug or the desired adjustment assem­
bly into the relay base.
4. Replace the tubing (key 10) to the proportional band
valve assembly.
Changing Relay
The relay may be removed for cleaning, repair, or replace­
ment.
Rem oval
1. For a controller or transmitter with indicator assembly,
loosen the two lower relay screws (key 96) and slide out the
indicator base plate (key 53).
27
Type 2500
2. Disconnect the tubing (key 10 or 11) from the relay.
3. Remove both mounting screws, relay, and relay gasket
(keys 43, 34, and 22).
R e p la c e m e n t
1. Install a new gasket (key 22), the replacement relay
(key 34), and secure with two mounting screws (key 43).
On a controller or transmitter with an indicator assembly,
slide the base plate under the two lower screws of the relay
case, align the plate so the pointer will read properly, and
tighten the screws.
2. Connect the tubing (key 10 or 11) to the relay.
3. Test the relay deadband, according to the Relay Dead­
band Testing procedure in this section.
4. If the deadband is within tolerance, go to the Calibra­
tion section.
Relay Assembly Maintenance
The alignment tool shown in figure 19 is not essential for
assembly of the relay, but its use does prevent excessive
air consumption and deadband. If low air consumption and
minimum deadband are required, make or purchase the
alignment tool before disassembling the relay.
Refer to figures 20 and 21 for key number locations.
D is a s s e m b ly
1. Remove the relay according to the Changing Relay
procedure in this section.
2. Remove the orifice assembly or connector (key 88),
check to see if the orifice is plugged or damaged, and in­
spect the O-ring (key 90).
3. Remove six casing screws and washers (keys 96 and
98) and, remove the top diaphragm (key 91). For a high
temperature relay, also remove the gasket (key 100, figure
21) that covers the diaphragm.
4. Remove the spacer ring (key 84), diaphragm assembly
(key 86), and relay spring (key 92) from the relay body (key
83). On a high temperature relay, also remove the gasket
(key 99, figure 21) from underneath the diaphragm assem­
bly.
5. Remove the four screws (key 97), spring plate (key
95), spring plate gasket (key 94), spring (key 92), and inner
valve (key 87).
28
6. Inspect the valve seats for roughness due to corrosion.
One seat is in the diaphragm assembly; the other is in the
relay body (key 83). If necessary, replace the parts.
7. Inspect the diaphragms and gaskets, and replace
them if necessary. Also, replace the spring and inner valve
(keys 92 and 87) if they show signs of corrosion. The lower
diaphragm comes as part of an assembly; it must be
installed as an assembly.
8. Clean all parts thoroughly before assembly.
A s s e m b ly
1. Place the relay spring in the relay body and, for a high
temperature relay, install a bottom gasket. Install the dia­
phragm assembly, spacer ring, and top diaphragm on the
body so that all flow passage holes are in line. For a high
temperature relay, also install a gasket over the top dia­
phragm.
2. Place the casing assembly on the top diaphragm so
that the lugs on the casing and spacer ring line up and are
also in line with the body lug.
3. Install the machine screws (key 96) and, for standard
relays, the washers (key 98), but do not tighten the screws.
4. If the optional alignment tool (figure 19) is available, in­
sert the small end of the tool into the opening in the relay
body. If the tool does not engage in the hole of the dia­
phragm assembly, move the parts slightly to reposition the
diaphragm so the alignment tool does engage the hole in
the diaphragm assembly. Do not remove the alignment tool
until the machine screws (key 96) are tightened.
5. Tighten the machine screws (key 96) evenly. Remove
the alignment tool, if one is used.
6. Install the inner valve, spring, gasket, and cover plate
(keys 87, 92, 94, and 95). Secure them with the four ma­
chine screws (key 97).
7. Install the O-ring (key 90) on the orifice assembly (key
88), and install the orifice assembly into the relay casing.
8. Install the relay according to the Changing Relay pro­
cedure.
9. Install a new gasket (key 22, figure 18), the replace­
ment relay (key 34, figure 18), and secure them with two
mounting screws (key 43, figure 18).
10. Connect the tubing (key 11, figure 18) to the relay.
11. Test the relay deadband according to procedures in
this section.
 Type 2500

12. If the deadband is within tolerance, go to the Calibra­ Key Description Part Number
tion section.
10 Tubing assembly,
For all 2 500 Series except Type 2503
C opper 1C 9154 000A2
S tainless steel 1N 7983 X 0012
For Type 2503 only
Parts Ordering C opper 1 H 3 0 9 3 17052
S tainless steel 1H3093 X 0012
Whenever corresponding with the sales representative 11 R elay tubing
about this equipment, use the controller/transmitter type C opper 1H2738 000A2
number and the serial number. The serial number is found Stainless steel 1N7984 X 0012
12 Ball bearing assembly, Brass, pi
on the nameplate (key 215, figure 18). When ordering re­ 1C8983 000A2

placement parts, also state the complete 11-character part 13 R etaining ring, pi steel (2 req’d) 1A4658 28992
number of each part required as found in the following parts 14 G auge glass (2 req’d) 0T0192 06042
list. 15 G auge glass gasket, neoprene (2 req’d) 0T0191 04082
16 Bourdon tube assembly,
Brass
Type 2 500 and 2500T
3 to 15 psig 32B1231 X012
6 to 3 0 psig 32B1231 X022
Parts List Type 2500S
0 to 20 psi 32B 1233 X012
Key Description Part Number 0 to 35 psig 32B 12 3 3 X 0 2 2
Type 2503
0 to 2 0 psig 32B1234X012
0 to 35 psig 32B 1234 X022
Controller Parts Kits S tainless steel
Type 2500 C ontroller R epair Kits Type 2 500 a nd 2500T
C ontains keys 1 2 ,1 5 , 2 1 ,2 4 , 38, and the fla p p er assem bly 3 to 15 psig 32B 12 3 2 X 0 3 2
Standard tem perature R2500 X 0032 6 to 30 psig 32B 12 3 2 X 0 4 2
High tem perature R2500 X 0H 32
18 Instruction label 19A2841 X0A 2
Type 2503 C ontroller and Relay R epair Kits 19 Triple scale guage
Standard tem perature only Brass
For the controller, 0 to 30 psig/0 to 0.2 M Pa/0 to 2 bar 11B8577 X012
kit contains keys 1 2 ,2 1 ,2 2 , 24, 38, 0 to 60 psig/0 to 0.4 M Pa/0 to 4 bar 11B8577 X022
and the flapper assem bly Stainless steel
For the relay, 0 to 30 psig/0 to 0.2 M Pa/0 to 2 bar 11B8583 X012
kit contains keys 86, 90, 91, and 94 R2503 X00022 0 to 60 psig/0 to 0 .4 M Pa/0 to 4 bar 11B8583 X022
19 Dual scale guage
Relay R epair Kits Brass
C ontains keys 22, 86, 87, 9 1 ,9 2 , 83, 94, (99 and 100 high 0 to 30 psig / 0 to 2 kg/cm 2 11B8577 X042
tem perature only) and the plug and w ire assem bly 0 to 60 psig / 0 to 4 kg/cm 2 11B8577 X052
Standard tem perature R R ELAYX0L12 S tainless steel
High tem perature RRELAYX0H 12 0 to 30 psig / 0 to 2 kg/cm 2 11B8583 X032
21* C over gasket, nitrile 1C9198 06342
Relay R eplacem ent Kit
C ontains keys 22, 43, fin d the relay a ssem bly 22* R elay gasket
Standard tem perature R R ELAYX0L22 Standard tem perature, neoprene 1C 8974 03012
High tem perature RRELAYX0H 22 High tem perature, silicon 1N 8738 04142
23 Relay base 47A0950X012
24* Relay base gasket (not show n)
Common Controller/Transmitter Parts Standard tem perature, neoprene 1C 897 30 3 0 1 2
High tem perature, silicon 1N8739 04142
(figure 18) 25 Flexure strip, stainless steel, 1C 8978 36012
C ase back 57A 0953 X 012
CM CO ^

C ase cover, alum inum 50B 9454 X012 26 Flexure strip nut, pi steel (2 req’d) 1C 8975 25082
D oor handle, pi steel 1 C 8 9 7 2 25082 27 Flexure strip base, pi steel 1C 8977 25082
D oor handle shaft (not show n), brass 1 C 8 9 8 4 14012 28 Level set arm , pi steel 1C 8976 25082
29 D rivelok pin, pi steel 1C 8 9 8 9X 0 0 12
m

M achine screw, steel 1C8958 X 0022

CO N

S pring w asher, stainless steel 1C 8970 36032 30 Flapper base, brass, pi - 1C9261 14022
D oor hook, pi steel •, 1C8971 25082 31 Shaft clam p screw, SST
Stop nut, pi steel 1C 8959 X 0012 (2 req’d fo r C version only, 1 req’d fo r all others) 1B4514 35172
32 Flapper, stainless steel 1C 9262 38992
Drive-lock pin, (2 req’d) 1C8991 X 0022 33 A lignm ent screw , brass, pi 1 B 4 5 1 7 14022

29
"Recommended spare parts
Type 2500

T Y P IC A L C O N T R O L L E R

T Y P E 2503 C O N N E C T O R D E T A IL
O R IF IC E A S S E M B L Y
(SEE FIG U R E 21)

VIEW A

T Y P E 2503R C O N T R O L L E R
C O N S T R U C T IO N

10A894O-B
30A6885-C
30A6866-C
30A8869-C
00082-1 A S S E M B L Y O N C V E R S IO N S

Figure 18. 2 5 0 0 Series C o n tro ller/T ransm itter Constructions

30
 Type 2500

MACHINE SCREW (KEY 97, 4 REQUIRED)

SPRINQ PLATE (KEY 95)

F T > THESE DIAMETERS MUST BE CONCENTRIC

INCH
W ITHIN 0.001 (0.025). (mm)

Figure 19. Relay Alignment Tool

Key Description Part Number

34 Relay assem bly
(For individual parts see follow ing list and figure 21),
For all 2500 Series except Type 2503
Standard tem perature 22B 0463 X 012
High tem perature 22B 0462 X 012
C orrosive service 22B 0463 X032
Type 2 503 only
Standard tem perature 32B0464X012
High tem perature 32B0465X012
35 Level adjustm ent assem bly (controllers only) 10A 8939 X0A2
35 Zero adjustm ent assem bly (transm itters only) 10A8939 X0C2
36 Proportional band adjustm ent a ssem bly Figure 20. Relay Assembly (Standard Temeprature Only)
(except transm itters and Type 2503 controllers, see key 90)
Standard and high tem perature 10A912 2 X 0 3 2
C orrosive service 10A912 2 X 0 6 2 Key Description Part Number
51 Pointer assem bly (C versions only),
37 Type 67FR regulator Stainless steel/brass, pi 1E8735 000A2
38* F ilter gasket (not shown) 52 W asher (C versions only), steel (2 req’d) 1 E 8730X 0012
Standard tem perature, neoprene 1C 8986 03012
High tem perature, silicon 1N8740 04142 53 Base plate (C versions only), alum inum 1E8731 11992
39 C ap screw (not show n), pi steel (2 req’d) 1C 3988 X 0022 54 Front plate (C versions only), alum inum 1 E 8 7 3 2 11992
40 Hex nut, pi steel 73 Pipe plug (Type 2503 only), brass (not shown) 1 A 6 2 1 9 14012
(2 req’d fo r C versions, 1 req’d fo r all others) 1L2863 38992 90 Specific gravity a djustm ent assem bly
Standard and high tem perature 10A8870 X0A2
41 Screw, pi steel C orrosive service 10A8870 X022
(4 req’d fo r C versions, 2 req’d fo r all others) 1C 9419 X 0012
42 M achine screw, pi steel (8 req’d) 1V7435 X 0022 215 N am eplate
43 M achine screw, pi steel (2 req’d) 1A3776 X 0012
44 M achine screw, pi steel (6 req’d) 1A5733 X0012
45 M achine Screw, pi steel (2 req’d)
46 M achine Screw, pi steel (4 req’d)
1H1581 X 0012
1C 8990 X 0012
Relay (figure 20 and 21)
47 Spring (not show n), stainless steel 1J4234 37022 83 Relay body, •
48 C ap screw, pi steel (4 req’d) •. 1A3816 K0012 Standard and high-tem p., alum inum /brass 48A3776X012
C orrosive service, alum inum /stainless steel 48A 3776 X032
49 M achine screw , pi steel (13 req’d) 1B 7 8 3 9 X 0 0 1 2 84 S pacer ring, alum inum 38A 3778 X012
50 Screen, alloy 400 0L0783 43062 85 C asing assembly, alum inum /steel 12B0460 X012

31
'Recom m ended spare parts
Type 2500

22B0463-A

Figure 21. Typical Relay Assembly

Key Description Part Number Key Description Part Number

86* D iaphragm assem bly 1A 8664 X00A2

97 M achine screw, pi steel (4 req’d)
Standard tem perature, nitrile/nylon 18A2451 X012
98 W asher (standard tem perature only),
High tem perature, polyacrylate/nylon 18A2451 X092
pi steel (6 req’d) 1P8261 X0012
C orrosive service, nitrile/nylon 18A2451 X042
99* Bottom gasket (high-tem perature only), silicon 1K7001 04142
100* Top gasket (high-tem perature only), silicon 1K7002 04142
87 Inner valve, brass Lubricant, Lubriplate Mag-1 (not furnished w ith controller)
168
Standard tem perature 0 Y 0 6 1 7 14012
169 Lubricant, D ow C orning C om pound 111
C orrosive service 0Y 0617 X 0 0 2 2
(not furnished w ith controller)
88* O rifice assem bly!) (all except Type 2503), brass 12B0468 X012 _ Relay a lignm ent tool (see figure 19) 15A3519 X012
88 C onnector (Type 2503 only), brass 22B0461 X012
90* O-R ing (2 req’d)
Standard tem perature, nitrile 1D6875 06992
High tem perature, fluoroelastom er 1N 4304 06382
Heat Insulator (figure 16)
91* Top diaphragm
Standard tem perature, nitrile/nylon 1L5556 02042 35 H eat Insulator Assem bly, stainless steel 22A 0033 X 012
High tem perature, polyacrylate/nylon 1K6999 X 0012 36 S haft C oupling, stainless steel 1A5779 35032
92 Relay spring, pi steel 1C8961 27012 37 S haft extension, alloy K500 1B6815 40022
93 Valve spring, stainless steel 0 X 0 8 3 6 3 70 2 2 38 S et screw, stainless steel (2 req’d) 1E6234 X0022
94* Spring plate gasket
Standard tem perature, neoprene 1H 2696 03012 39 C ap screw, pi steel (4 req’d) 1A3816 K0012
H igh-tem perature, silicon 1K 7000 04142 40 C ap screw, pi steel (4 req’d) 1 V 2 3 9 5 28982
53 W asher, carbon steel, pi (4 req’d) 1 B 8 6 5 9 28982
95 Spring plate, pi steel 1 H 2 6 9 7 25072
96 M achine screw, pi steel (6 req’d) 1A 3294 X 0022

'Recom m ended spare parts

1. Key 88, orifice assembly, now includes the core assembly. Key 89, core assembly,
has been deleted from the parts list.

While this information is presented in good faith and believed to be accurate, o r a n y o th e r m a tte r w ith re s p e c t to the products, nor as a recommendation to
Fisher Controls does not guarantee satisfactory results from reliance upon such use any product or process in conflict with any patent. Fisher Controls reserves
information. N oth in g co n ta in e d he re in is to b e c o n stru e d a s a w arranty o r g u a r­ the right, without notice, to alter or improve the designs or specifications of the
antee, exp ress o r im plied, re g a rd in g the pe rform ance , m erchantability, fitness products described herein.

F o r in fo rm a tio n , c o n ta c t F is h e r C o n tro ls :
Fisher Controls M arshalltow n, Iowa 50158 U SA ,Sao Paulo 05424 Brazil
C ernay 68700 France S ingapore 2158

Printed in U.S.A. I ^ B otih H ^ recycled paper

 Instruction Manual

Caged 249 Series Form 1802

July 1995

Caged 249 Series Displacer Sensors

Contents
Introduction ................................................................... 1
Scope of M a n u a l................................ 1
D escription....................................................................... 1
Type Number Description ............................................. 2

Maintenance ................................................... 3
Cleaning the C a g e ...........................................................4
Removing the Displacer and Stem .............................4
Replacing the Displacer, Cotter Spring, Stem
End Piece, and Displacer S p u d ...............................5
Replacing the Displacer Rod/Driver Assembly . . . 6
Replacing the Torque T u b e ......................................... 6
Changing Cage Head P o sitio n ..................................... 7
Replacing the Torque Tube Arm and
Changing the Mounting ......................................... 8

Parts Ordering ................................................ 8

Parts Kits ........................................................ 9

Parts List 9
Figure 1. Type 249B Sensor with 2500 Series Controller

Only personnel qualified through training or experience

Introduction should install, operate, and maintain the sensor and
attached controller or transmitter. If there are any
questions concerning these instructions, contact your
Scope of Manual Fisher Controls sales office or representative before
This instruction manual includes maintenance and proceeding.
parts ordering information for the caged 249 Series
sensors.
Description
Although a Type 249 Series sensor is usually shipped
with attached controller or transmitter, this manual The 249 Series sensors are designed to measure liq­
does not include operation, installation, calibration, uid level, interface level, or density/specific gravity in­
maintenance, and parts ordering information for the side a vessel.
controller/transmitter or for the complete unit. For this A torque tube assembly (figure 2) and displacer pro­
information, refer to the appropriate controller/trans­ vide an indication of liquid level, interface level, or den­
mitter instruction manual, Note that a shipping rod and sity/specific gravity. The torque tube assembly con­
metal block must be removed from each end of the sists of a hollow torque tube with a shaft welded inside
displacer cage before installation. it at one end and protruding from it at the other end.

Fisher, Fisher-Rosem ount, and M anaging The Process Better are marks owned by Fisher
Controls International, Inc. or Fisher-Rosem ount Systems, Inc.
All other m arks a re the property of their respective owners.

“ Fisher Controls International, Inc. 1976. 1995; All Rights Resen/ed

FISHER-ROSEMOUNT Managing The Process Better
Caged 249 Series
er rod rests on the knife-edge of the driver bearing. A
keyed shaft on the bearing end of the displacer rod fits
into a socket on the outside of the welded end of the
torque tube assembly.

A change in liquid level, interface level, or density/spe-

cific gravity buoys up the displacer by a force equal to
the weight of the liquid displaced. Corresponding verti­
cal movement of the displacer results in angular move­
ment of the displacer rod around the knife edge. Since
the torque tube assembly is a torsional spring which
supports the displacer and determines the amount of
movement of the displacer rod for a given displace­
ment change, it will twist a specific amount for each
increment of buoyancy change. This rotation is
brought through the torque tube arm by the protruding
rotary shaft. A controller or transmitter attached to the
end of the rotary shaft converts the rotary motion into
varying pneumatic or electric signals.

Type Number Description

• Type 249— A N SI Class 125 or 250 cast iron cage
with screwed or flanged connections.

• Type 249B— ANSI Class 150, 300, or 600 steel

cage with screwed or flanged connections.

• Type 249BF— ANSI 150, 300, or 600 cast iron or

stainless steel cage with flanged connections only.
Available from Fisher Controls in Europe only.

• Type 249C — ANSI Class 1 5 0 ,3 0 0 , or 600 stainless

steel cage with screwed or flanged connections.

• Type 249K— ANSI Class 1500 steel cage with

flanged connections only.

• Type 249L— ANSI Class 2500 steel cage with

flanged connections only.

• Type 249N— ANSI Class 900 steel cage with

Figure 2. Typical Caged Displacer flanged connections only.

The cage head on all of the Type 249 Series construc­

The unconnected end of the tube is sealed by a gas­
ket and clamped rigidly to the torque tube arm, permit­
ting the protruding end of the shaft to twist and there­
fore transmit rotary motion. This allows the interior of
the torque tube to remain at atmospheric pressure,
thus eliminating packing and the disadvantages of
packing friction.
The displacer always exerts a downward force on one
end of the displacer rod. The other end of the displac­
tions may be rotated to any of the eight alternate posi­
tions shown in figure 6. Connection sizes are either
1-1/2 inch or 2 inch.
The Parts List section shows some Type 249 Series
sizes by construction, standard displacer lengths, and
standard materials. However, Type 249 Series parts
are available in a wide variety of materials of construc­
tion, part dimensions, and other specifications. Con­
tact your Fisher Controls sales office or representative
for assistance in selection of specific materials, dimen­
sions, and specifications.

2
 Caged 249 Series
Maintenance OUTLET FLOW

WARNING

Avoid personal injury or property dam­

age resulting from the sudden release of
pressure. Before performing any mainte­
nance procedure, relieve any process
pressure in the vessel where the Type
249 sensor is installed. Drain the pro­
cess liquid from the vessel. Shut off any
electrical or pneumatic input to the con­
troller or transmitter attached to the
Type 249 sensor and vent any pneumat­
ic supply pressure. Use caution when
loosening flange bolting (key 22) or pipe
plugs (key 17,26, or 27).
Remove the controller or transmitter
from the torque tube arm (key 3).
Before continuing with any maintenance
procedure, be sure the cage (key 1) is
also free of process pressure and/or liq­
uid. Use caution when loosening flange
bolting (key 22) or pipe plugs (key 17,
26, or 27).
Before performing any maintenance pro­
cedure requiring the handling of the dis­
placer, inspect the displacer (key 10) to
make sure process pressure or liquids
have not penetrated the displacer.
The displacer in this unit is a sealed
Figure 3. Piezometer Ring Cage Mounted in Flow Line
container. If penetrated by process pres­
sure or liquid, the displacer may hold
pressure or hazardous liquid for an ex­
tended period. A displacer that has been Note
penetrated by process pressure or liq­
uid may contain: Except for gaskets (keys 13 and 14),
trouble symptoms peculiar to specific
• pressure as a result of being in a parts are discussed in the following sec
pressurized vessel tions. Each section is specific to these
• liquid that becomes pressurized parts. Regardless of location, gasket
due to a change in temperature failure is indicated by leakage in the
gasket area. Every time a gasket is re­
• liquid that is flammable, toxic, cor­ moved, replace it with a new one upon
rosive, or reactive reassembly.
Sudden release of pressure, contact
with hazardous liquid, fire, or explosion,
which might result in personal injury or The procedures below apply to all sensor types except
property damage, can occur if a displac­ where indicated. Key numbers used are shown in the
er that is retaining pressure or process following illustrations:
liquid is punctured, subjected to heat, Type 249— Figure 7
or repaired.
Type 249B— Figure 8 *
Handle the displacer with care. Consider
the characteristics of the specific pro­ Type 249C— Figure 9
cess liquid in use. Type 249K— Figure 10

3
Caged 249 Series
Type 249L— Figure 11
Type 249N— Figure 12
Sensor parts are subject to normal wear and must be
inspected and replaced as necessary. The frequency
of inspection and replacement depends upon the se­
verity of service conditions.
Because of the care Fisher Controls takes in meeting
all manufacturing requirements (heat treating, dimen­
sional tolerances, materials of construction, and other
product characteristics specified by Fisher Controls),
use only replacement parts manufactured or furnished
by Fisher Controls.
Cleaning the Cage
Process residue buildup in the bottom of the cage (key
1) or at the connections may restrict flow in and out of
the cage or interfere with displacer motion. Remove
the cage to clean out process residue buildup.
1. Before starting any maintenance procedure, be
sure the following safety actions have been com­
pleted.
• Relieve process pressure in the vessel where the
Type 249 sensor is installed.
• Drain the process liquid from the vessel.
• Shut off any electrical or pneumatic input to the
controller or transmitter attached to the Type 249 sensor
and vent any pneumatic supply pressure. Remove the
controller or transmitter from the torque tube arm (key 3).
Take care not to damage the torque tube assembly (key
9) inside the torque tube arm.
• Be sure the cage is also free of process pressure
and/or liquid. Use caution when loosening flange bolting
(key 22) or pipe plugs (keys 17, 26, or 27).
• Be sure process pressure or liquids have not
penetrated the displacer (key 10).
2. Properly support the cage head (key 2) and the
torque tube arm. Remove the cap screws or stud bolts
(key 21) and hex nuts (key 22) that hold the cage
head to the cage.
CAUTION
When removing a sensor from a cage,
the displacer may remain attached to
the displacer rod and be lifted out with
the cage head when the cage head is
removed. If separating the displacer and
displacer rod before removing the cage
4
head, remove the cotter spring (key 11).
Be careful not to let the displacer slip
and drop into the bottom of the cage, as
displacer damage could result.
3. Carefully remove the cage head and lift out the dis­
placer.
4. A style 1 or 4 (screwed or flanged) cage must be
disconnected at the lower connection and the liquid
damper (key 29) removed. Remove the damper by
prying it out of a flanged connection or by unscrewing
it from a screwed connection with a 1/2-inch hex (Al­
len) wrench. If necessary, completely remove the style
4 cage from the vessel.
5. For complete drainage and cleaning of a cage with
style 2 or 3 (screwed or flanged) connections (figure
4), remove the pipe plug (keys 17 or 26) from the bot­
tom of the cage. Remove the liquid damper (key 29). If
necessary, completely remove the cage from the ves­
sel.
6. Use appropriate cleaning techniques, tools, and
solutions. After cleaning the cage, install the liquid
damper and reconnect the cage to the vessel. Install
the cage head and controller/transmitter. Properly cali­
brate the controller/transmitter following the proce­
dures given in the controller/transmitter instruction
manual.
Removing the Displacer and Stem
The displacer (key 10) is a sealed container. If the dis­
placer has been penetrated by process pressure or
liquid, it may hold pressure or hazardous liquid for an
extended period.
Process residue buildup on the displacer and stem
(key 24) may change displacer weight or displace­
ment. A bent stem or a dented or corroded displacer
can impair performance.
If the displacer rests against the travel stop, appears
to be overweight, or causes output drift or other output
inaccuracies, it may have been penetrated by process
pressure or liquid. Such a displacer may contain pres­
sure because it was in a pressurized vessel, may con­
tain process liquid that becomes pressurized due to a
change in temperature, and may contain process liq­
uid that is flammable, toxic, corrosive, or reactive.
Sudden release of pressure, contact with hazardous
liquid, fire, or explosion, which may result in personal
injury or property damage, can occur if a displacer that
is retaining pressure or process liquid is punctured,
subjected to heat, or repaired.
Handle the displacer with care: •
1. Before starting any maintenance procedure, be
sure the following safety actions have been com­
pleted.

STYLE 1: TOP STYLE 2: TOP
AND BOTTOM AND LOWER SIDE
SCREWED: S1 SCREWED: S2
FLANGED: F1 FLANGED: F2
A1271-2
Figure 4. Cage Connection Styles
• Relieve process pressure in the vessel where the
Type 249 sensor is installed.
• Drain the process liquid from the vessel.
• Shut off any electrical or pneumatic input to the
controller or transmitter attached to the Type 249 sensor
and vent any pneumatic supply pressure. Remove the
controller or transmitter from the torque tube arm.
• Be sure the cage is also free of process pressure
and/or liquid. Use caution when loosening flange bolting
or pipe plugs.
• Be sure process pressure or liquids have not
penetrated the displacer.
2. Properly support the cage head or sensor head
(key 2) and the torque tube arm (key 3). Remove the
cap screws or stud bolts (key 21) and hex nuts (key
22) that hold the cage head to the cage.
CAUTION
When removing the sensor from the
cage, the displacer may remain attached
to the displacer rod and be lifted out
with the cage head (key 2) when the
cage head is removed. If separating the
displacer and displacer rod/drive
assembly (key 9) before removing the
cage head, remove the cotter spring
(key 11). Be careful not to let the
displacer slip and drop into the bottom
of the cage, as displacer damage could
result. >
3. When removing the sensor from the cage, the dis­
placer may remain attached to the displacer rod and
Caged 249 Series
STYLE 3: UPPER STYLE 4: UPPER
AND LOWER SIDE SIDE AND BOTTOM
SCREWED: S3 SCREWED: S4
FLANGED: F3 FLANGED: F4
be lifted out with the cage head (key 2) when the cage
head is removed. If separating the displacer and dis­
placer rod/driver assembly (key 9) before removing the
cage head, remove the cotter spring (key 11) accord­
ing to the Replacing the Displacer, Cotter Spring,
Stem End Piece, and Displacer Spud section. Be
careful not to let the displacer slip and drop into the
bottom of the cage, as displacer damage could result.
4. Carefully remove the cage head and lift out the dis­
placer (key 10). If the displacer comes out with the
cage head, be careful not to damage the displacer or
bend the stem when setting the cage head down.
5. Follow the procedure for replacing the displacer,
displacer rod assembly, cotter spring, stem end piece,
and displacer spud as necessary.
Replacing the Displacer, Cotter Spring,
Stem End Piece, and Displacer Spud
The cotter spring (key 11), the ball on the displacer
rod/driver assembly (key 7), and the stem end piece
(key 23) or displacer spud socket may be either too
worn for a secure connection or so clogged or cor­
roded that the displacer does not pivot properly. Re­
place these parts, as necessary.
CAUTION
If the displacer is to be disconnected
from the displacer rod before being
removed from the cage, provide a
suitable means of supporting the
displacer to prevent it from dropping
into the cage and being damaged.
1. After following the proper procedure to remove the
cage head and the displacer from the cage, move the
sensor assembly to a suitable maintenance area.
5
Caged 249 Series
Properly support the assembly to avoid damage to the
displacer, displacer stem, displacer rod/driver assem­
bly, and associated parts.
2. Reach the cotter spring, displacer spud, ball end of
the displacer rod/driver assembly, stem end piece, or
displacer stem connector as follows:
• All sensors with style 1 or 2 (screwed or
flanged) connections—through the top connection.
• Type 249L sensors with style 3 or 4 (screwed or
flanged) connections— by removing the hex nuts (key
33), flange (key 30), and ring (key 31).
• All other sensors with style 3 or 4 (screwed or
flanged) connections— by removing the top pipe plug
(key 26).
3. Remove the cotter spring to free the displacer or
stem end piece from the ball end of the displacer rod/
driver assembly. Lift the displacer or stem end piece
from the ball.
4. Replace worn or damaged parts as necessary. Re­
turn the displacer or stem end piece to the displacer
rod/driver assembly. Install the cotter spring.
5. If necessary, clean the cage following the proce­
dure in this manual. Install the cage head and control­
ler/transmitter. Properly calibrate the controller/trans­
mitter following the procedures given in the
controller/transmitter instruction manual.
Replacing the Displacer Rod/Driver
Assembly
The ball on the displacer rod/driver assembly (key 7)
may be either too worn for a secure connection or so
corroded that the displacer does not pivot properly.
Replace the displacer rod/driver assembly, if neces­
sary.
C A U T IO N
If the displacer is to be disconnected
from the displacer rod/driver assembly
before being removed from the cage,
provide a suitable means of supporting
the displacer to prevent it from dropping
into the cage and being damaged.1
1. After following the proper procedure to remove the
cage head and the displacer from the cage, move the
sensor assembly to a suitable maintenance area.
Properly support the assembly to avoid damage to the
displacer, displacer stem, displacer rod assembly, and
associated parts.
6
2. Remove the controller/transmitter and displacer
(key 10). Then, remove the hex nuts (key 20) that hold
the torque tube arm (key 3) to the cage head (key 2).
Separate the torque tube arm from the cage head.
3. Using the proper tool, loosen and then remove the
upper bearing driver bolt (key 5). Lift the displacer rod/
driver assembly from the knife edge of the driver bear­
ing (key 4). Separate the displacer rod/driver assembly
from the end of the torque tube assembly (key 9).
4. If necessary, remove the bearing driver by remov­
ing the lower bearing driver bolt. Install a fresh bearing
driver and bolts.
5. If necessary, replace the displacer rod/driver as­
sembly and install it on the knife edge of the bearing
driver. Carefully fit the keyed shaft on the bearing end
of the displacer rod into a socket on the outside of the
welded end of the torque tube assembly.
6. If necessary, clean the cage following the proce­
dure in this manual. Install the cage head and control­
ler/transmitter. Properly calibrate the controller/trans­
mitter following the procedures given in the
controller/transmitter instruction manual.
Replacing the Torque Tube
Corrosion or leakage through the outer end of the
torque tube is evidence of deterioration in the torque
tube assembly (key 9) or torque tube end gasket (key
14). Erratic or nonexistent rotary shaft output may oc­
cur if the socket on the inner end Of the torque tube
assembly does not engage the bearing end of the dis­
placer rod assembly (key 7).
1. After following the proper procedure to remove the
cage head and the displacer from the cage, move the
sensor assembly to a suitable maintenance area.
Properly support the assembly to avoid damage to the
displacer, displacer stem, displacer rod assembly, and
associated parts.
2. Remove the controller/transmitter and displacer
(key 10). Then, remove the hex nuts (key 20) that hold
the torque tube arm (key 3) to the cage head (key 2).
Separate the torque tube arm from the cage head.
3. Remove the nuts (key 18) and retaining flange (key
6) holding the positioning plate (key 8) at the end of
the torque tube arm.
C A U T IO N
If the displacer is still attached to the
displacer rod at this point, be careful
not to let the torque tube assembly slip
when using the screwdriver leverage
procedure in steps 4 and 6. Sudden
release of the displacer could cause
damage.

REMOVAL OR INSTALLATION OF POSITIONING PLATE
Figure 5, Torque Tube and Displacer Rod Assemblies
4, Remove the positioning plate (key 8) by freeing its
two lugs.
The vertical lug fits into a hole in the flange of the
torque tube arm (top of figure 5, left). The horizontal
lug (hidden behind the screwdriver at the bottom of
figure 5, left) fits into a slot in the outer tube end of the
torque tube assembly (the figure 5 exploded view
shows this lug to the right of the outer tube end).
The positioning plate may be pried away from the
torque tube arm and outer tube end if the displacer
already has been disconnected from the displacer rod.
However, if the displacer is still connected to the dis­
placer rod, place a screwdriver blade in the slots of the
positioning plate and outer tube end as shown in figure
5. Slowly turn the positioning plate to release its lug
from the torque tube arm. Then carefully turn the plate
back to allow the displacer to come to rest, and slip
the other lug of the plate from its slot in the outer tube
end.
5. Pull the torque tube assembly and tube end gasket
out of the torque tube arm.
6. Install a new tube end gasket and insert the torque
tube assembly into the torque tube arm as shown in
figure 5. Rotate the torque tube assembly until its
socket mates with the driver member on the displacer
rod assembly and so that the outer tube flange rests
against the gasket. With a thumb on the upper portion
of the positioning plate and a screwdriver in the slots
as shown in figure 5, rotate the plate and press the lug
on the plate into the hole in the torque tube arm.
7. Install the retaining flange and secure it with four
nuts (key 18), being sure to tighten all nuts evenly.
Caged 249 Series
EXPLODED VIEW OF TORQUE TUBE AND DISPLACER ROD ASSEMBLY
8. If necessary, clean the cage following the proce­
dure in this manual. Install the cage head and control­
ler/transmitter. Properly calibrate the controller/trans­
mitter following the procedures given in the
controller/transmitter instruction manual.
Changing Cage Head Position
The cage head (key 2) may be mounted so that the
torque tube arm (key 3) is in any one of eight alternate
positions around the cage as shown in figure 6. Nei­
ther the displacer nor the torque tube arm need be
removed when head position is changed.
1. Before starting any maintenance procedure, be
sure the following safety actions have been com­
pleted.
• Relieve process pressure in the vessel where the
Type 249 sensor is installed.
• Drain the process liquid from the vessel.
• Shut off any electrical or pneumatic input to the
controller or transmitter attached to the Type 249 sensor
and vent any pneumatic supply pressure. Remove the
controller or transmitter from the torque tube arm.
• Be sure the cage is also free of process pressure
and/or liquid. Use caution when loosening flange bolting
or pipe plugs.
• Be sure process pressure or liquids have not
penetrated the displacer. .
2. Remove the hex nuts (keys 20 or 22) from the bolt­
ing (key 21) and reposition the head as desired.
7
Caged 249 Series
R IG H T -H A N D M O U N T IN G
Figure 6. Cage Head Mounting Positions
Replacing the Torque Tube Arm and
Changing the Mounting
1. Looseness of the driver bearing (key 4); wear on its
knife-edged surface; or a bent, worn, or corroded dis­
placer rod assembly (key 7) may impair performance.
Be especially sure to check the ball on the displacer
rod.
2. After following the proper procedure to remove the
cage head and the displacer from the cage, move the
sensor assembly to a suitable maintenance area.
Properly support the assembly to avoid damage to the
displacer, displacer stem, displacer rod assembly, and
associated parts.
3. Remove the controller/transmitter and displacer
(key 10). Then, remove the hex nuts (key 20) that hold
8
the torque tube arm (key 3) to the cage head (key 2).
Separate the torque tube arm from the cage head.
4. Follow the proper procedure to remove the torque
tube assembly (key 9).
5. Remove the bearing bolts (key 5), displacer rod
assembly, and driver bearing.
6. Determine the new mounting orientation.
Note
Be sure that the driver bearing will be
installed so that its knife edge is point­
ing up when the torque tube arm is
mounted in the desired orientation (fig­
ure 6). Since changing the mounting
position of the torque tube arm by 180°
will change controller or transmitter ac­
tion from direct to reverse or vice versa,
the controller/transmitter action must be
reversed from what it was before the
mounting method was changed.
7. Install the driver bearing, displacer rod assembly,
and bearing bolts (key 5) into the torque tube arm.
Install a new arm gasket. Install the torque tube arm in
the desired mounting position on the cage head and
secure it with the proper bolting (keys 19 and 20).
8. Install the torque tube assembly. Install the displac­
er.
9. If necessary, clean the cage following the proce­
dure in this manual. Install the cage head and control­
ler/transmitter. Properly calibrate the controller/trans­
mitter following the procedures given in the
controller/transmitter instruction manual.
Parts Ordering
Whenever corresponding with your Fisher Controls
sales office or representative about this equipment,
always mention the sensor serial number. Each sensor
is assigned a serial number which is stamped on a
nameplate (key 54, not shown) attached to the torque
tube arm. This same number also appears on the con­
troller/transmitter nameplate when a complete control-
ler/transmitter-sensor unit is shipped from the factory.
When ordering a replacement part, be sure to include
the 11-character part number from the following parts
list.
 Caged 249 Series
Parts Kits Key
10
Description
D isplacer!1) (continued)
Part Number

Type 249K
Key Description Part Number 1-3/4 X 32 Inches (4200 PSI), S30400 15A4666 X032
SENSOR PARTS KIT 2-3/4 X 14 Inches (6000 PSI), S30400 1L7548 000A2
Kit contains keys 9 ,1 1 ,1 2 ,1 3 ,1 4 Type 249L
For Type 249 2-3/4 X 14 Inches (6000 PSI), S30400 1L7548 000A2
Kit includes 1 cage gasket (key 12) fo r Type Type 249N
249 class 125 and 1 cage gasket (key 12) for 1-29/32 X 32 Inches (3400 PSI), S30400 15A4581 X042
Type 249 C lass 250 R249X000022 2-7/8 X 14 Inches (4000 PSI), S30400 1L9152 000A2
For Type 249B R 249BX00012 11* C otter S pring!1), N 04400 (M onel) (2 req’d) 1A5179 42022
12* G age G asket!1)
Type 249, G raphite-stainless steel
(U nless otherw ise noted)

Parts List C lass 125

C lass 250
0Y 0944 X0032
0Y 0945 X 0032
Type 249B 0Y 0873 X 0082
Key Description Part Number Type 249C 1F8305 X 0062
Type 249K , com position-stainless steel 1N 9242 99152
Type 249N 0U 0365 X0032
Sensor Common Parts 12* Ring (Iron gasket)
1 Cage
Type 249L only 1N9461 21992
(If a part num ber is required, contact y o u r Fisher C ontrols sales 13* Arm G asket!1)
office o r representative.)
Type 249,249B, and 248C
2 C age Head
G raphite-stainless steel 1E5629 X 0072
(If a part num ber is required, contact y o u r Fisher C ontrols sales
Type 249K , com position-stainless steel 1N9243 99152
office or representative.)
Type 249N G raphite-stainless steel 1A1297 X0022
3 Torque T ube Arm 13* Ring (Iron gasket)
(If a part num ber is required, contact y o u r Fisher C ontrols sales Type 249L only 1A4455 21992
office or representative.) 14* Tube End G asket!1)
4 D river Bearing!1), S31600 1K5395 36042
Type 249,249B, 249C, 249K, 249L, and 249N
5 D river Bearing B olt!1), S31600 (2 req’d) 1K5394 35072
G raphite-stainless steel 0Y0876 X 0052
6 R etaining Flange 14* O uter End G asket!1)
(If a part num ber is required, contact y our Fisher controls sales Type 249L
office o r representative.)
G raphite-stainless steel 0Y0876 X 0052
7 R od/D river A ssy!1), S31600 stainless steel (SST) 15 Stud Bolt<1) (4 req’d)
Type 249 and 249B 1B5461 000A2 Type 249, Steel B7 12A 8 8 3 5 X 1 3 2
Type 249C Type 249B and 249C, Steel B7 12A8835 X132
Standard wall torque tube 1F9579 000A2 Type 249K, 249L, and 249N, Steel B7 1K6235 X 0022
H eavy w all torque tube 1J8281 X0012 16 G roove Pin, S31600 1A3618 28992
Type 249K 1C6151 000A2
Type 249L 1B 5698 000A2
Type 249N 1C6151 000A2 Note
8 Positioning Plate, Steel 1B8123 25082
9* Torque T ube Assy<1> For Key 17 see Figure 4: Two styles of vessel/cage
connections are available: screwed (S) and flanged (F).
Type 249 and 249B
Four connection configurations are available:
N 05500 (N ickel Alloy, K-M onel)
Standard w all 1K4493 X 0012 • 1, top and bottom of cage
T hin wall 1K4495 X 0012 • 2, top and lower side of cage
Heavywall 1K 44 9 7 X 0 0 1 2
Type 249C • 3, side of cage only
S31600 • 4, upper side and bottom of cage
Standard wall 1K4505 000A2
H eavy wall 1K4503 000A2
Styles 1 , 2 ,3 ,4 refer to either screwed or flanged.
Styles S1, S2, S3, S4 refer to screwed connections.
Type 249K, 249L, and 249N
Styles F1, F2, F3, F4 refer to flanged connections.
N 05500 (Nickel Alloy, K-M onel)
Standard wall 1K 44 9 9 X 0 0 1 2
Thin wall 1K4501 X0012 17 Pipe P lug!1)
10 D isplacer!1) For 249B, styles 2, 3, steel 1A7715 28992
TYPE 249 and 249B For 249C, styles 2, 3, S31600 1 A 3 6 9 2 35072
3 X 1 4 Inches (1600 PSI), S30400 15A3848 X012 For 249K, 249L, 249N, styles 2, 3, steel 1A3692 24492
2 X 32 Inches (1500 PSI), S31600 15A 4586 X022 18 H ex Nut<1) (4 req’d)
1-5/8 X 48 Inches (1800 PSI), S30400 15A5007 X022 For 249,249B, and 249C, steel-B 7 1 A 3 7 7 3 24072
1-1/2 X 60 Inches (1800 PSI), S30400 15A5017 X 0 4 2 For 249K, 249L, 249N, steel B7 1A3772 24072
1-3/8 X 72 Inches (1400 PSI), S30400 1C 1685 000A2 19 C ap S crew !1), steel B7 (4 req’d) -
Type 249C For 249
1- 1/2 X 32 Inches (1300 PSI), S31600 15A4556 X022 C lass 125 1A514 7 X 0 0 2 2
2- 3/8 X 14 Inches (1400 PSI), S31600 15A 4547 X052 C lass 250 1A 936 2 X 0 0 4 2

"Recommended spare part.

1. This part is available in a wide variety of materials of construction, part dimensions,
or other specifications. Listed here are standard or typical materials, dimensions, or
specifications. Contact your Fisher Controls sales office or representative for assis­
tance in selection of specific materials, dimensions, or specifications. 9
Caged 249 Series

DETAIL OF GLASS 250 S2, S3, OR S4 CONNECTIONS

Figure 7. Type 249 sensor construction

10
 Caged 249 Series

DETAIL OF STYLE 1 OR 2 CONNECTIONS

Figure 8. Type 249B Sensor Construction

K ey D e s c rip tio n P a rt N u m b e r K ey D e s c rip tio n P a rt N u m b e r

19 Bolt Stud<1>, steel B7 (4 req’d) 21 Bolt Stud<1), B7 (8 req’d)
F o r 2 4 9 B ,2 4 9 C 1A3544 31012 F o r 249B 1A3543 31012
F o r 249K , 249N 1A3771 31012 F o r 249C 1A8835 31012
20 Hex N ut(1), steel F or 249K 1C 7725 31012
F o r 249 F o r 2 49L 1A5010 31012
C lass 125 (12 req’d) 1A3772 24072 F o r 249N 1A3657 31012
C lass 250 (4 req’d) 1A3433 X 0042 22 Hex Nut<1>, steel
F o r 249B , 249C (8 req’d) 1 A 3 7 6 0 24072 F o r 249
F o r 249K , 249N (8 req’d) 1C17 2 7 2 4 0 8 2 C lass 250 (8 req’d) 1A3681 X 0032
F o r 2 4 9 L (4 req'd) 1A4452 24072 F o r 2 4 9 B (16 req’d) 1A3520 24072
21 C ap Screw<1), steel B7 (8 req’d) F o r 249C (8 req’d) 1A3374 24072
F o r 249 F o r 2 4 9 K (8 req’d) 1 A 4 4 0 9 24072
C lass 125 12B5478 X012 F o r 2 4 9 L (16 req’d) 1A5011 24072
C lass 2 50 1A 35 3 4 X 0 0 4 2 F o r 249N (8 req’d) 1C17 2 7 2 4 0 8 2

1. This part is available in a wide variety of materials of construction, part dimensions,

or other specifications. Listed here are standard or typical materials, dimensions, or
specifications. Contact your Fisher Controls sales office or representative for assis­
tance in selection of specific materials, dimensions, or specifications. 11
Caged 249 Series

DETAIL OF STYLE 3 OR 4 CONNECTIONS

Figure 9. Type 249C Sensor Construction

Key Description Part Number Key Description Part Number

23 D isplacer S tem End Piece(1>, S31600 1A 3933 35072 24 D isplacer Stem<1\ S 31600
Note For 249 1E7845 35072

For Key 24 see Figure 4: Two styles of vessel/cage For 249B 1 E 7 4 8 8 35072
connections are available: screwed (S) and flanged (F). For 249C 1N3635 35072
Four connection configurations are available: For 249K (styles F3, F4 only) 1L9162 35072
• 1, top and bottom of cage For 249L (styles F 1, F2 only) 1N9591 35072
For 249L (styles F3, F4 only) 1P6885 35162
• 2, top and lower side of cage
For 249N (styles F3, F4 only) 1L9162 35072
• 3, side of cage only 25 Hex Nut<1>, B8M (2 req’d) 1A3915 35252
• 4, upper side and bottom of cage
Styles 1 , 2 ,3 ,4 refer to either screwed or flanged.
Styles S1, S2, S3, S4 refer to screwed connections.
Styles F1, F2, F3, F4 refer to flanged connections.

1. This part is available in a wide variety of materials of construction, part dimensions,

or other specifications. Listed here are standard or typical materials, dimensions, or
specifications. Contact your Fisher Controls sales office or representative for assis-
12 tance in selection of specific materials, dimensions, or specifications.
 Caged 249 Series

Figure 10. Type 249K Sensor Construction

Key Description Part Number Key Description Part Number

27 Pipe Plug (2 req’d)
Note For 249, cast iron
C lass 125 1 A 3 6 1 9 19012
For Key 26 see Figure 4: Two styles of vessel/cage C lass 2 50 1 A 6 4 0 4 19012
connections are available: screwed (S) and flanged (F). For 249B, steel 1A7715 28992
Four connection configurations are available:
• 1, top and bottom of cage 29 Liquid D am pe d 1), S30400
1-1/2 inch connection 1N 2088 36022
• 2, top and lower side of cage
2 inch connection 1N 2089 36022
• 3, side of cage only 30 Blind Flange<1)
• 4, upper side and bottom of cage For 249L 1 P 4 7 5 3 23022
31* Ring!1) (Iron gasket)
styles 1 , 2 ,3 ,4 refer to either screwed or flanged, For 249L 1 P 476921042
styles S1, S2, S3, S4 refer to screwed connections,
32 Stud Bolt<1), steel B7 (4 req’d)
styles F1, F2, F3, F4 refer to flanged connections.
For 249L 1 A 3 6 5 7 31012
33 Hex Nut<1), steel (4 req’d)
26 Pipe P lug!1) For 249L 1C 1727 31012
For Type 249, m alleable cast iron 35 H eat Insulator A ss’y
1-1/2 inch N PT (styles S2, S3, S4) (2 req’d) 1A3916 21992 Use only w hen specified 22A 0033 X012
2 inch N PT (style S2, S3, & S4) 1 A 9 2 3 4 19012 36 S haft C oupling (for heat insulator a ss’y)
For 249B, steel (styles S3, S4) 1A3985 24182 Use only when specified 1 A 5 7 7 9 35032
For 249C, S31600 (styles S3, S4) 1 A 3 9 8 5 35072 37 S haft Extension (for heat insulator ass’y)
For 249K, 249N, steel (styles S3, S4) \ 1A4442 28992 Use only when specified 1B 6815 40022

•Recommended spare part.

1. This part is available in a wide variety of materials of construction, part dimensions,
or other specifications. Listed here are standard or typical materials, dimensions, or
specifications. Contact your Fisher Controls sales office or representative for assis­
tance in selection of specific materials, dimensions, or specifications. 13
Caged 249 Series

Key Description Part Number Key Description Part Number

38 S et Screw (for heat insulator a ss’y) (2 req’d) 56 NAC E N am eplate , - - -
Use only when specified 1E6234 X 0022 — S hipping Block, zinc (not shown) 1H 3059 44012
39 C ap S crew (for heat insulator a ss’y) (4 req’d) — S hipping C one, cast iron (not shown) 1J19 0 7 1 9 0 4 2
Use only w hen specified 1A3816 K0012 Indicating Gauge
40 C ap S crew (for heat insulator a ss’y) (4 req’d)
G auge* (0-100% ) (3-15 psi), steel/brass 21B9701 X012
Use o nly w hen specified 1V2995 28982
1 V bOww CiW7ufp
M ounting Bracket, steel 21 B 9 6 9 6 X 0 1 2
51 Arm Flange, For 249B (partial cage a ss’y) 1U3179 23022
H ex Nut, steel-zn-pl (2 req’d) 1E9440 24112
53 W asher (for heat insulator a ss’y) (4 req’d)
Lock Washer, steel-pl (2 req’d) 1 C 2 2 5 7 28982
Use only when specified 1 B 8 6 5 9 28982
Pipe Nipple, Steel-ZN -PL 1 C 6 7 8 9 26232
54 N am eplate
M achine Screw, steel-pl (3 req’d) 1 K 4 3 3 6 28992
55 Drive S crew “ “ "
U-bolt, steel
Use w /fabricated arm 1D7642 24092
Use w /cast arm 1N6419 24092

O s

14 'Recommended spare part.

 Caged 249 Series

Figure 12. Type 249N Sensor Construction

15
Caged 249 Series

O i

T h e co n le n lso f this publication a re p resented fo r inform ational purposes only, a nd while every e ffo rt has been m ade lo ensure the ir accuracy, they are n o t to be construed as warranties o r guarantees, express or
im plied, regarding the p roducts o r services described herein o r the ir use o r applicability. We reserve the righ t to m odify o r im prove the designs o r specifications o f such p roducts a t a n y tim e without notice.

F o r in fo rm a tio n , c o n ta c t F is h e r C o n tro ls :
M arshalltow n, Iowa 50158 U SA
C ernay 68700 France
Sao Paulo 0 5424 Brazil
S ingapore 0512

Printed in U.S.A. recycled paper

FISHER-ROSEMOUNT
 W C -1 0 5
PARTS L IS T
WATER CDLUMN F IT T IN G S
2 3 ' GAGE V A L V E CENTERS
z
<
ITM REQ PA R T-N O . S IZ E MFGR.& FIG .# DESCRIPTION
1 1 8 2 5 -0 0 1 4 1 3 / 4 ' - 2 5 0 # CLARK RELIANCE WATER GAGE V A L V E
H SET,BRONZE BODY
403RS
P
W ITH CHAIN
Z PULL HANDLES &
u
X
S-HOOKS,LESS CHAIN
H
2* 1 8 5 1 -0 0 3 0 2 3 / 4 ' - 2 5 0 # CLARK RELIANCE GAGE,WATER PRISMATIC
z 5
D
»—t5«■* C -4 4 IN S E R T,1 4 - 7 / 8 '
(/) .
V IS IB IL IT Y
>s
O z M
3 3 8 5 1 -0 0 1 4 0 3 /4 '- 4 5 0 # CLARK RELIANCE TRYCOCKS,BRONZE
COQ
GC451 W /S -H O O K S ,L E S S
□ =
OC z CHAIN PULL HANDLES
n □
cz ° LESS CHAIN
SSy
4 78 8 3 0 -0 0 0 2 8 440 AMERICAN CHAIN CHAIN,STEEL SASH
& CABLE BRIGHT ZIN C COATED
a
5* 1 8 8 1 -0 0 1 8 5 CLARK RELIANCE ILLUM. GAGE GLASS 1
>- z G L53 W /6 0 WATT LAMP
£<2 GAGE GLASS <TO BE I
u „
a. s 6* 1 8 5 1 -0 0 2 9 4 3 /4 '
°O' < X 2 0 -1 /4 ' USED FOR BO ILO UT)
o_ j
C/) p 7* 2 8 5 3 -0 0 7 1 1 3 /4 ' DIA. CLARK RELIANCE GASKET,GAGE GLASS
~ i R B G 4 0 3 R -8
a
2 H
g§
Q' C
Q>
Lj
M 13
►
—< 2* D ^U SA G E L IM IT E D TO SAFETY V A L V E SETTING DF 2 0 0 - 2 5 0 PSIG.
i 3
i- s 2 ) MAX. OPERATING PRESSURE OF 200 PSIG DURING B O IL -O U T IS

3 ) ^A X ^M U M T PRESSURE RATING IS L IM IT E D BY ITEM #1 & ITEM #2.

4 ) * = SH IPPED LODSE.

ALL MATERIAL « 7 r s ON « I OF MATERIAL ARE FOR REFERENCE ONLY.

W ITH TRYCOCKS
DRAWMQ DIMENSIONS MUST BE FOLLOWED.
TOLERANCE. UNLESS OTHERWISE SPECIFIED: FRACTIONAL ± DECIMAL t
HOLE LOCATIONS ± ANGLES t DRILLED, PUNCHED OR SLOTTED HOLES t .010 SHT 01 OF 01
O' SCALE
Z
:—j! ^
—* \s N .T .S . C le a v e r < |^ g » B r o .o k s
<A n m o i , DATE
LD Z O' 10/26/93
O a
»—« \ o > r-- — wren—
O (/> kD y u ni n R R S LIST,W A TE R C O L . F T G S . 2 0 0 - 2 5 0 l
M OJ (/) O'
> \ ► vD SIZE PSIG W /P R IS M A T IC IN S E R T J
U Oi >-< q. > n
ce.
DATE

to
EN#

O
CO
LJ □ Ul Z
-----------------
A DRVG. NO. 603 0051 1 |04 ]
 B IL L OF M A T E R IA L - P E R SET
D E S C R IP T IO N v J - .*,> A- DWG NO. F IG
ITEM PA R T NO. QUAN.
A -4 7 1 6
I B G 4 0 3 R *! 1 VALVE BO D Y -LO W E R . PA TT.N0.2I7I RED BRASS -
A -4 7 1 0 A
•M<»
2 G L A S S PA C K IN G N U T P A T T .N 0.2I58 RED BRASS S B -6 2
2 B G 4 0 3 R -2
•
S B -6 2 B
3 B G 4 0 3 R -3 2 S T E M P A C K IN G N U T P A TT.N 0.2IS 8 RED BRASS
BRASS A -4 7 1 3 A
4 B G 4 0 3 R -4 2 S T E M P A C K IN G G LA N D
" " B
6 B G 4 0 3 R -5 2 S T E M P A C K IN G W ASHER
2 STEEL m 0
6 S G 4 9 4 - I0 G LASS P A C K IN G W AS HER
3 0 3 SST A -I6 I5 4
.r BG 403RS-3B s> VALVE STEM _
B -5 3 4 4 3
R U BB ER
8 B G 403R -B 2 G L A S S P A C K IN G 1 7 /3 2 '0 .D . X ‘J f c 'l. O . X ' M
9 B G 4 0 3 R -9 6 S T E M P A C K IN G -S U P E R -S E A L * 1 - | J * 4 OlO xtf* I A X 14 B -5 3 4 4 9
A -7 2 5 5
10 B G 4 0 3 R S -I 2 SPROCKET SINTERED IRON ASTM B 202 HA
L E V E R - 1 UPPER 8 1 LOW ER MALURON A -7 2 5 4
II B G 4 0 3 R S -2 ?
2 GUARD R O D S -L E N G T H • V A L V E C E N T E R S + 1 STE E L C -6 3 4 4
12
10 FT. C H A I N - ( 2 - 5 FT. L G T H S .IB 5 S H O O K S -P L A T E D STEEL
13
BRASS A -3 0 4 7
14 B G 4 0 3 R IS 1 C H A IN F IX T U R E
8 G 4 0 3 R - I3 2 HEX HD CAP SC R E W 5 / l6 " - l8 X 5 /8 * STEEL
15
1 SET. C H A IN H AND LES ALUMINUM A - C 2 8 2
16
IT B G 4 0 3 R -1 4 2 SH AK EPR O O F LO C K W A S H E R 5 /1 6 * STEEL

B G 4 0 3 R - IA V A LV E BODY- U PPER PATT.NO. 2171 RED BR AS S S B -6 2 A -4 7 1 6

18 i

UPPER FITTING

LOWER FITTING

RELIANCE GAUGE COLUMN CO.

Cl EVELANO, OHIO
MAXIMUM W. P. — 2 5 0 LBS. PER SQ. INCH
RELIANCE STANDARD SCREWED
■ •VISIBLE GLASS*A*MINUS 4 1 /8 “ BRONZE WATER GAGE VALVE
OAOE GLASS OR OVERALL INSERT LENGTH ■ A* MINUS 2 8 /4 * CAT. N 0 . 4 0 3 R S ______
S C A L E -F U L L I D A T E - lt - l7 - 4 0 ( F IL E -
DRAWN B T - A .Z.
T R A C E !) B Y - T U T
CHECKED-^’
NQB-4882-II
 ' ■
v -i

BRONZE VALVES IN FIVE MODELS

Bronze Valves Feature

Quality Materials For
STEEL VALVES IN 18 MODELS
Extended Service Life
C la rk -R e lia n c e bro n ze w a te r g ag e v alv es a re
designed and m anufactured for heavy-duty o p era ­
Patented Gage Lever tion. Designated as high-grade valves, all models
Offers 18 Locking Positions feature bodies and packing nuts m ade from A SM E
C ode bronze. Additional design features include p er­
Positive, non-slip locking in 18 positions is assured m anent seats and quadruple stem threads for full
with this C lark-R elian ce gage lever. R egardless of open or close with only o n e-q u arter turn. R efer to
valve stem orientation w h en the valve is closed, this T a b le I for p re ss u res , c o n n e c tio n s and o th e r
lever may be adjusted to the desired angle. H ighly individual model specifications.
durable, a sintered sp ro cket slips over a flat-sid ed
stem end. Removal and adjustm en t from position A to Figure 3 Figure 4

B (note drawings) allow a q u ick and easy chan g e to

in te rm e d ia te m o u n ting a n g le s . (C la rk -R e lia n c e
P aten t No. 2,691,699)
/ V - wwhhl. _________Figure 9

M O DEL
4 0 4 RS

Figure 5

S P E C IF IC A T IO N IN F O R M A T IO N As required by She ASME Boiler

Code, chain and handles w hich indicate open or closed valve posi­
tions are provided. Lower valves have a 3/ b" pipe tap tor blowdown.
A com plete set includes upper and lower valve, pyrex tubular glass
and guard rods lit mounting centers are specified) and two h
M O DE L
iengths of chain. Valve model numbers are siamped on the top ol 5 03 8 A
upper gage valves.
SV.' Closed 6" Valve Open
NOTE: Clark-Reliance does not recommend tubular glass for use Nut Loose 5'A“ Closed
above 250 WSP. ■NutTighL—
TABLE 1 - C L A R K - R E L IA N C E B R O N Z E W A T E R G A G E V A L V E S

Figure Max.
C o n n e c tio n P r e n u re
No.
Quadruple j Quadruple
V»" M a le P ip e Thread Thread U Thread
H " Pipe Drain in PipeDrain
403R S V M a le Pipe Thread Lower Valve Only Lower Valve Only

404R S V ' M a le P ip e Thread Figure 8

F ig u re 7 ------ 6" Valve open -
502R A - 3 0 0 Lb. RF R a n g e M O D E LS 402R S , 403RS M O D E L 503RA
S C R E W E D C O N N E C T IO N FLAN GED C O N N E C T IO N
3 0 0 Lb. RF Flange 13 Lbs.
503R A
 CATALOG 500
SECTIOM AB4.1C
Clark-Reliance
GAGE COCKS (TRYCOCKS)
THREE STYLES •MAXIMUM PRESSURES 150 PSI TO 1500 PSI
BRONZE BODY, CHAIN
STAINLESS STEEL, CHAIN
OPERATED GAGE COCKS:
OPERATED GAGE COCKS:
P R E S S U R E S TO 450 PSI P R E S S U R E S TO 1500 PSI
RENEWABLE TYPE 303
TYPE 303 STAINLESS Figure 1 RENEWABLE type 303
STAINLESS STEEL Figure 4
STEEL
SEAT
STEM s«s STS S
STEEL stem
STEEL
LEVER STEEL
’ NUT LEVER
NUT

Figure 7
ASTM B61 DUCTILE
IRON TYPE 316
BRONZE
ADJUSTABLE STAINLESS
BODY
LEVER STEEL BODY
CHAIN OPERATED M O DELS
TYPE 303 FOR PRESSURES TO 1500 PSI
STAINLESS STEEL
CHAIN HOOKS 4 DISCHARGE
PULL HANDLES NOZZLE CHAIN HOOKS &
(NOT SHOWN), PULL HANDLES
CHAIN NOT (NOT SHOWN),
INCLUDED CHAIN NOT
INCLUDED

Figure 5
^V Figure 2 MODEL GC302
MODELS GC450, GC45T
Under the most severe
boiler system conditions,
Clark-Reliance Gage Clark-Reliance Gage Cock
Cock Models GC450 and Model GC302 dependably resists the
GC451 feature a stainless damaging cutting action of steam and
steel stem and seat component to water. Reliability and long service fife CHAIN/WEIGHT OPERATED M ODELS
assure positive seating and long service are the results of quality materials, FOR PRESSURES TO 250 PSI
life. Integral stem discs are precision- precision manufacturing and 150%
machined to glass smooth finishes hydrostatic testing of each unit.
•Available In Vz” NPT And 3A " NPT ■ Available In 3/4" NPT Model Only
Models •Pull Left Hand Chain To Open Rioht
•Pull Left Hand Chain To Open Right Hand To Close
Hand Chain To Close •Integral “Stop”Prevents Dead-Center
•Multiple-Thread Stem Design Provides Vertical Lever Position
Fast Response •Stainless Steel Seat Is Precision-
•Integral ‘'Slop" Prevents Dead-Center Machined In An Exclusive Clark-
Vertical Lever Position Reliance Process
•Discharge Nozzle Directs Steam/ • Seat Is Sealed Tight In The Shank With
Water Away From Operator Va Pipe Thread - Easily Renewable
•Multiple Thread Stem Opens/Closes
18-Position Lever In A Turn And Can Not Unscrew Under
Pressure
h a n d w h e e l operated m o d els
•Discharge Nozzle Directs Steam/ FOR PRESSURES TO 150 PSI AT
Water Away From Operator FLOOR LEVEL LOCATIONS

Adjustable Lever
l e v e r p o s it io n Figure 6
IS EASILY CHANGED TO ALLOW
INTERMEDIATE ADJUSTMENTS
Eighteen positive, non-slip lever "STOP"
PREVENTS DEAD-CENTER
positions offer a correct lever angle VERTICAL POSITION
regardless of the stem’s positron when
turned tight. Geared sprockets fit onto The multi-slotted operating lever allows
flat-sided stem ends. Lever gears nest a wide choice of open/closed positions.
securely into sprocket gears. Stem nut Each lever position is held in a non-slip
secures the lever. design of nesting sprocket and lever
gears, secured by a stem nut.
 CATALOG 500
SECTION AB4.2C

BRONZE BODY, CHAIN & B R A S S BODY, HAND

W EIGHT OPERATED GAGE OPERATED GAGE COCKS
COCKS FOR M A X IM U M FOR M A X IM U M P R E S S U R E S
P R E S S U R E S TO 250 PSI TO 150 PSI AT FLOOR
RENEWABLE ASTM B-51 ASTM B61 BRONZE STEM STEEL LEVEL LOCATIONS
INTEGRAL SA360 BAKELITE®
BRASS BRASS HANDWHEEL
SEAT STEM v

Figure 11

RUSTPROOF, LIGHTWEIGHT STEEL

CHAIN IS RECOMMENDED. TOTAL
CHAIN WEIGHT MUST NOT ALLOW
GAGE COCK TO OPEN.

• Twelve-Position Weight Lever Allows

■ L P 3 *
The Clark-Reliance weighted gage cock
is a high performance self-closing unit Best Location U
that provides leak-proof operation at • Weight Lug Allows For Use Of Optional MODELS GC306, GC307 Figure 13
moderate pressures, Shut-Off Chain
■Available In V2" NPT And 3A " NPT • Accepts Maximum “Open” Chain The Clark-Reliance Hand Wheel Gage
Models Length Of 25-Feet (Unless "Open" Cock is designed specifically for floor
• Pull ChainTo Open, Release ChainTo Chain Is Also Attached To ''Closed” level columns in low pressure systems.
Close Weight Lug) Time-tested design and manufacturing
• Precise Weight Distribution For Tight • Discharge Nozzle Directs Steam/ assure dependable performance. Avail­
Shut-Off Water Away From Operator able in V2" NPT and 3/V NPT models.

CLARK-RELIANCE GAGE COCKS • MODEL SELECTION GUIDE SPEC IFY GENUINE

M ODEL S IZ E N P T O P E R A T IO N M AX PRESSURE F IG U R E N O .
CLARK-RELIANCE
GC302 TV' Chain Lever 1500 PSI 4 ,5
REPLACEM EN T PARTS
GC450 y2" Chain Lever 450 PSI 1 ,2 ,7
Rely on only genuine Clark-Reliance
GC451 TV' Chain Lever 450 PSI 1 ,2 ,7 replacement parts, furnished from the
GC310 V i” Chain/W eight 250 PSI 3, 10, 11 same stocks from which your original
gage cock was factory assembled.
GC311 TV Chain/W eight 250 PSI 8, 10, 11
Replacement parts are illustrated in our
GC30S Vz" Hand Wheel 150 PSI 9, 12, 13 Instruction Manual, or contact your
9, 12,13
nearest Clark-Reliance representative
GC307 TV Hand Wheel 150 PSI
for information.

For additional information,

contact your local Clark-Reliance
M » m gg -

Clark* R e lia n c e
representative

16633 FOLTZ INDUSTRIAL PARKWAY • STRONGSVILLE, OHIO 44136 • USA

TELEPHONE: 216-572-1500 • TELEX: 985-317 • FACSIMILE: 216-238-8828

NOTE: Clark-Reliance shall not be liable for dam ages ol any kind resulting in part Irom failure lo install its products in accordance with all applicable codes and/or state and local regulations, improper application and/or maintenance.

P r in t e d
% C la rk R e lia n c e 1991
 BILL of MATERIAL
K
):
.. DWG. NO.
ITEM PART NO OUAN DESCRIPTION
1 G C 45I-I 1 BOOK. 3 /4 “ NAVY "M" BRONZE SB -61 B -7 8 3 7 -3
2 G C 4 5 0 -5 1 CONE VALVE. TYPE 4 2 0 STAINLESS STL. STNLS.STL
3 G C 4 5 0 -3 1 STEM. 3/4" DIA. BRONZE ROD BRONZE "
II
4 G C 4 5 0 -2 l PIN. 1/8*DIA. PHOSPHOR BRONZE ROD BRONZE
_ 5 _ BG403f?S-( j SPROCKET. IRON-BRONZE SAE 2 8 SPEC. IRON-BRZE, A -7 2 5 5 -1
6 G C 450 -6 1 LEVER. MALL. IRON A-8010
7 SG 454-22 1 ‘FLEXLOC' STOP 8 LOCK NUT. S46"-I8 STEEL
8 2 ‘S“ HOOK, PLATED STEEL
9 GC300-11 ( NOZZLE, 7/16*A.E HEX. BRASS BRASS A - 3159-1
10 G C 4 5 0 -4 SEAT, 9/16” DIA."R* MONEL ROD MONEL B -7 8 3 7 -3
SB-61 H •
II G C450-I BODY. 1/2" BRONZE

MAX. W.S.P. 4 5 0 LBS.

NO. G C 4 5 0 a GC45I
GAGE COCK ASSEMBLY
sa m -F U L L I 0 M t.lg -3 Q .5 4 I
Muww t . D.R.E.
TKACH) tr.
CHECKED T - JT'wt'r ho . B-7 9 0 0 -1
CATALOG 500
SECTION AB7.1A Clark* R eliance
PRISMATIC WATER GAGES
SHARP, HIGHLY VISIBLE, ACCURATE WATER LEVEL READINGS

PR ECISE, EASY-TO-READ MULTIPLE SECTIONS ALLOW

LEVEL GAGES M EET A LONGER LEVEL VIEWING AREAS
W ID E VARIETY OF INSTALL­ Large storage tanks, heater tanks and
similar applications call for Prismatic
ATION REQ U IREM EN TS Gage assemblies employing multiple
Clark-Reliance Prismatic Gages pro­ gage sections. Double, triple and
vide a well-defined, distinct image of quadruple assemblies are readily
water levels, eliminating reading errors available, and even longer
or distortions possible with less effective assemblies can be provided. .
gage types. Highly versatile, Prismatic In multiple assemblies, the
Gages are easily installed in vertical or space between gage windows
Tiltview Assemblies. In addition, Clark- is approximately 1 1/2 inches.
Reliance Prismatic Gages offer the flexi­ This gap is considered insignifi­
bility of combining multiple gage sections cant where multiple assemblies
to achieve coverage of extended viewing are normally installed.
areas.
Note the various mm
Available in two designs, “C” Types dimensions and
should be specified for pressures to 250 specifications for
PSI and “S”Types for pressures to multiple gage assem­
350 PSI. blies listed in tables
“C" TYPE
Typical Prismatic Gage applications presented elsewhere
include installation on boiler drums, on these pages.
feedwater heaters, deaerators, and
other tanks.
Quality Materials Clark-Reliance
Prismatic Gages feature quality materials
and reliable design. Gage glass is of the
highest quality borosilicate glass, IN GAGES OF THREE
tempered for improved toughness OR MORE SECTIONS,
against shattering. As an important SIDE-MOUNTED
REINFORCING
safety feature, should breakage occur, BARS CONNECT
glass fragments will in te rlo c k and ALL GAGE BODIES
remain in place. TO ASSURE PROPER
ALIGNMENT.
The unique Clark-Reliance clamping
design produces a uniform, firm, strictly
compressive load on the glass - adding
to gage reliability and prolonged service Figure 4
life. GAGE SELECTION DATA
Specific combinations of boiler water
THE P RISM A TIC PRINCIPLE pressure and boiler water pH levels
Prismatic glass is flat on the outside. suggest the installation of mica-
The inside, in contact with either water protected gages to resist gage glass
or steam, is shaped with multiple 90° deterioration and possible gage leakage.
angle prisms. .
12
Rays of light normal to glass strike the
prisms at a 45° angle.
C L A R K -R E L IA N C E
The critical angle of a ray passing from Ml C A -P R O TEC TED
glass to steam is 42°. Therefore, the 45° FI A T G L A S S G A G E S .
R E C O M M EN D ED
ray is totally reflected and causes the n. (Cat alog S ection A B7.3)
steam space to appear white (Figure 2).
C L A R K -f IE LIA N C E
The critical angle of a ray passing from PR IS M A T 1C G A G E S
8
glass to water is 62°. Therefore, with the RECOMM ENDED -
* 't" _ i r x
45° angle being less, the ray penetrates 7
STEAM APPEARS WHITE the water and reveals the gage housing 0 100 200 300 350 400

WATER APPEARS BLACK in black (Figure 3). BOILER WATER - PRESSURE (PSI) F|gura 8
 CATALOG 500
SECTION AB7.2A

PRISMATIC GAGES PRISMATIC GAGES PRISMATIC GAGES

VERTICAL ASSEMBLIES TILTVIEW® ASSEMBLIES REPLACING TUBULAR GLASS

F ig u r e 10
V e rtic a l P ris m a tic
C e n te rs W ith V e rtic a l Over*AII
N u m be r W ater Body
R e lia n c e
V e rtica l P ris m a tic V is ib ility L e n g th
C e n te rs W ith V e rtic a l O ver*A lt V a lv e s
R eliance
N u m be r W ater Body A “Ciype “S”iype C B
V is ib ility L e n g th
A “Ciype “ S"TVpe C B 15 C6 56 7% 10%
16 C7 57 8% 11% NOTE: When installing a Prismatic
14 C4 54 6% 7% 17 C8 58 10% 13 Gage to replace an existing tubular
16 C5 55 7% 9 C9 59 10% 13%
9% 10%
18 glass gage, a reduction in gage visibility
17 C6 56 19 C9 S9 10% 13%
18 C7 57 10% 11% can be avoided by installing an offset
19 C7 57 10% 11% 20 C44 S44 12% 16 assembly. The offset assembly accepts
191/z C8 58 11% 13 21 C44 S44 12% 16 a Prismatic Gage long enough to provide
20 C9 59 12% 13% 22 C55 S55 14% 18% the necessary visibility, using valves
21 C9 S9 12% 13% 23 C55 S55 14% 18%
24 C66 S66 17 20% rotated 90°. W he n o rd e rin g , p le a s e
22 C9 S9 12% 13%
25 C66 S66 17 20% s p e c ify g a g e v a lv e c e n te rs a n d C lark-
23 C44 S44 14% 16 26 C77 S77 18% 23 R e lia n c e W a te r C o lu m n a n d Valve p a r t
24 C44 S44 14% 16 27 C77 S77 18% 23 n u m b e rs .
25 C55 S55 17% 18% 28 C77 S77 18% 23
26 C55 S55 17% 18% S88 21% 26% 1"
29 C88 A-Valve C e nte rs
27 C66 S66 19% 20% 30 C99 S99 23 27%
28 C66 S66 19% 20% c P ris m a tic F la t G lass
29 C66 S66 19% 20% G age
30 C77 S77
S77
21%
21%
23
23
NOTES ON SPECIFYING No. V ls ib . M in. Max. M in. Max.

31 C77 13%
32 C77 S77 21% 23 CLARK-RELIANCE PRISMATIC 4 6% 9% 13% 9%
14%
25 26% 5 7% 10% 14% 10%
33
34
C88
C99
S88
S99 26% 27% WATER GAGES 6 9% 11% 15% 12% 16%
30% C444 S444 23 24% • When specifying Prismatic Gages, 7 10% 12% 16% 13% 17%
335/a C555 S555 26% 27% refer to the Vertical Valve Center
37% C666 S666 30% 31% dimension “A" in the tables provided. 8 11% 14% 18% 14% 18%
40% C777 S777 33% 34% Locate the “A” dimension that corres­ 12% 15% 19% 15% 19%
9
45% C888 S888 38% 39%
C999 S999 40% 41% ponds to your own gage valve centers.
47%
38% C4444 S4444 31% 32% • The over-all length of the Prismatic GAGE
Gage, including nipples, is equal to a
42%
47%
C5555
C6666
S5555
S6666
35%
40%
36%
41% Tubular Glass gage length.
ILLUMINATION
52% C7777 S7777 45 46% Gage Illuminators are a
51% 52%
• A change to Prismatic Gages reduces
57% C8888 S8888 helpful option. See our
61% C9999 S9999 54% 55% the length of visible water range 3" to
6" depending upon gage and valve Catalog Section AB8.1 for
combinations. details on Clark-Reliance
Illumination equipment. For
• Nipples are 3A " diameter. Minimum any assistance in specifying,
length of top nipple is 1 Minimum contact your nearest Clark-
length of bottom nipple is 1%" when Reliance representative.
Clark-Reliance bronze valves are used. F ig u r e 1 4

For additional information,

contact your local Clark-Reliance

Clark* R e lia n c e
representative

16633 FOLTZ INDUSTRIAL PARKWAY • STRONGSVILLE, OHIO 44136 • USA

TELEPHONE: 216-572-1500 • TELEX: 985-317 • FACSIMILE: 216-238-8828

NOTE: Clark-Reliance shall not be liable for damages o f any kind resulting in part fro m failure to install its products in accordance w ith all applicable codes and/or state and local regulations, improper application and/or maintenance.

Printed
t C la r k - R e lia n c e , 1991
n ib b l e s scbew eo m b o o t
WITH 3S0* NINE TMNEAO.

* f* W f TAB
BACK
CONNECTION
I CENTERS
F
TANNINS
ONLY IF
SNECIFIEO

BILL OF MATERIAL
ITEM PART NO NAME OF PART M ATERIAL PIECES
A P G * “ 1 BODY CAST IRON A 2 7 8 1
B F*G* — 7 GASKET I / 3 Z ' THICK ASBESTOS 2
C P G 4 - 3 T / I6 * - I4 SO. HO. BOLTS STEEL
0 PG* - 2 COVER P L A T E DUCTILE ir o n 1
c M 4 0 - 6 CLAMPS PATT. NO.4 8 9 2 OUCTILE IRON

FIG. F P G 4 - 4 HEX. N U T S -7 /W -I4 S T E E L - S E M I-F IN .

1
0 PG * -6 R E F L E X G LASS GLASS
H P 0 4 - I I NIPPLES 304 SS 2
1 M 4 0 - I0 WASHERS- 3 /4 “ X B /3 Z "X 3 /S "

MFD. IN STANDARD SIZES TO COMPLETE PART NO. ADD NUMERAL S IZ E OF INSERT ORDERED FIG. 2
NET
NO. A 8 C 0 E F DOLTS WSHTS SIZES AS USED WITH RELIANCE WATER GAGE VALVES MFD. IN STANDARD SIZES
C4 7 7 /8 8 3 /4 6 1/2 8 I I LBS TILTVIEW NET
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18 / G9 4 C7 16
C99 2 7 3 * 2 6 1 /2 2 6 3 /0 32 38
18 4 C7 4 C9 16
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20 4 C9 4 C44 20
FOR STANDARD R E LIAN C E W ATER GAGE V A L V E S
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30 4 C7T 4 C 88 29
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 Diamond Power Specialty Company

P.O. Box 4 1 5 Lancaster, Ohio 4 3 1 3 0

Instruction Manual for the....

DIAMOND® MODEL G9B SOOTBLOWER

E le c tric M o to r O p e ra te d

Diamond Power
Babcock & Wilcox*
a McDermott company

4 /8 8 IM 3 1 2 4
This manual has been prepared for use by competent and knowledgeable
personnel responsible for the operation and maintenance of the equipment.
It is imperative that such personnel thoroughly familiarize themselves with
the entire manual before attempting to install, operate, or maintain the
equipment.

It is important to note that this manual contains various warning and caution
notes which should be carefully read in order to minimize the risk of per­
sonal injury or the possibility that improper service methods will be follow­
ed which may damage the blower or render it unsafe. In this manual, "Warn­
ing" constitutes a possible personal injury situation and "Caution” consti­
tutes possible blower damage which may render it unsafe. It is also impor­
tant to understand that these warnings and cautions are not exhaustive.

T H IS IN S T R U C T IO N M A N U A L H A S B E E N F U R N IS H E D FO R U S E B Y
Y O U R O W N O R G A N IZ A T IO N O N L Y A N D FO R P U R P O S E S C O N S IS ­
T E N T W IT H T H E T R A N S A C T IO N B E T W E E N Y O U R O R G A N IZ A T IO N
A N D D IA M O N D P O W E R . N O C O P IE S O F O R D A T A FR O M T H I S
M A N U A L S H A L L B E F U R N IS H E D T O A N Y T H IR D P A R TY W I T H O U T
T H E W R IT T E N A G R E E M E N T O F D IA M O N D P O W E R , LA N C A STER .
O H IO . U . S . A .

T H IS IN S T R U C T IO N MANUAL M AY D E S C R IB E V A R IA B L E FEA T­
URES N O T A P P L IC A B L E T O YOUR S P E C IF IC U N IT : HOW EVER,
TH E P A R TS I D E N T IF IC A T IO N FO R M S A T T A C H E D T O TH E R EAR
O F T H IS M A N U A L A R E C U S T O M IZ E D FO R E A C H C O N T R A C T .

THIS EQ U IPM EN T IS COVERED BY O N E OR MORE OF

THE FOLLO W IN G U .S. PATENTS!

3 ,8 1 9 ,8 8 0 3 ,5 8 5 ,6 7 3 4 ,2 1 8 ,0 1 6 4 ,5 6 5 ,3 2 4 4 ,5 6 7 ,6 2 2
4 ,1 6 5 ,5 5 2 3 ,6 6 4 ,3 1 0 4 ,3 5 1 ,0 8 2 3 ,8 2 7 ,1 0 2 4 ,5 0 3 ,8 1 1
3 ,9 0 1 ,0 8 1 4 ,3 5 9 ,8 0 0 4 ,2 0 9 ,0 2 8 3 ,8 2 3 ,2 7 9
4 ,1 7 7 ,5 3 9 3 ,6 0 4 ,0 5 0 4 ,4 9 2 ,1 8 7 4 ,4 2 2 ,8 8 2
4 ,3 7 5 ,7 1 0 R E -3 2 ,5 17 4 ,2 2 9 ,8 5 4 4 ,3 6 0 ,9 4 5

® M A R C A R E G I S T R A D A IN V A R I O U S C O U N T R I E S
 CONTENTS

SECTION 1 GENERAL DESCRIPTION ............................................................................................... 4

1. Rotating Sootblower .......................................................................................... 4

2. Non-Rotating Sootblower .................................................................................. 4

SECTION 2 INSTALLATION INSTRUCTIONS .................................................................................. 4

1. Location of Blowers ..... 4

2. Element Bearings .................................................................................................. 4
3. Wallboxes .............................................................................................................. 5
4. Blower Mounting ................................................................................................ 5
5. Element and Swivel Tube ...................................................................... 6
6. Blower Assembly .................................................................................................. 7
7. Piping ......................................................................................................... 7
8. Valve Condensate Drain Line ............................................................................. 7
9. Scavenging Air ................................................................................... 8
10. Cam Cutting .......................................................................................................... 8
11. Adjusting Blowing Pressure ............................................................................... 9
12. Lubrication ..................... 10
13. Motor and Control ............................................................................................ 10
14. Gaskets.................................................................................................................. 10

SECTION 3 OPERATING INSTRUCTIONS ........................................................................................ 10

1. Sootblowing at Low Loads .............................................................................. 10

2. Package Boilers with Automatic Firing and Induced Draft ........................ 11
3. Package Boilers with Automatic Firing and Pressurized Furnace .............. 11
4. Blower Operation .............................................................................................. 12
5. Internal Inspections During Boiler Outages ................................................. 12
6. Cleaning Results .................................................................................................. 12
7. Tube Erosion ............... 13

SECTION 4 TROUBLESHOOTING .. ................................................ 14

SECTION 5 MAINTENANCE INSTRUCTIONS .................................................................................. 17

1. Lubrication .......................................................................................................... 17
2. Poppet Valve ...................................................................................................... 17
3. Valve Stem Packing ............................................................................................ 17
4. Swivel Tube Packing .......................................................................................... 19
5. Straightening of Elements ................................................................................ 20
6. Welding of Elements and Bearings ................................................................. 21

ILLUSTRATIONS

F ig u r e 1 M o d e i G 9 B S o o tb lo w e r , o v e r a ll v ie w ( w it h c o n tr o l b o x ) ......................................... 1
F ig u r e 1 M o d e l G 9 B S o o t b l o w e r , o v e r a l l v i e w ( w i t h N E M A 4 L i m i t S w it c h ) ....................... 2
F ig u r e 1 M o d e l G 9 B S o o tb lo w e r , o v e r a ll v ie w (H a z a r d o u s D u ty ) ...................................... 3
F ig u r e 2 M e a s u r e m e n t f o r S w iv e l T u b e C u ttin g ...................................................................... 7

IM 3124 A p r., '8 8

 ILLU ST R A T IO N S (cont'd)
u ,
F ig u r e 3 C a m C u ttin g C h a rt, s ta n d a r d b lo w in g .......................................... 9
F ig u r e 4 M a n u a l O p e r a tio n ....................................................................................................... 13
F ig u r e 5 A d j u s t a b l e P re s s u r e C o n t r o l P r o c e d u r e .................................................................. 18
F ig u r e 6 V a lv e S p r in g R e m o v a l .................................................................................................. 19
F ig u r e 7 T y p ic a l P r e p a r a t i o n f o r W e l d i n g o f B e a r in g s a n d E l e m e n t s ................................. 21

IM 3124 A p r., '8 8

Figure 1 Mo del G 9 B Soo tb lowe r, overall view (with con trol b o x )

IM 3124 1 Apr., 88
 E le ctric
M otor

S w ive l
Tube

34N17

Figure 1 M o d e l G 9 B So otb low er, ove ra ll view (with NEMA 4 Limit S w i t c h )

IM 3124 2 Apr., '88

 E le ctric
M otor

Sw ivel
Tube

G ooseneck

34 P -3

Figure 1 Mo de l G 9B Sootblower, overall view [Hazardous Duty)

IM 3124 3 Apr., '88

 SECTION 1
GENERAL DESCRIPTION
1. Rotating Sootblower
The Model G9B Rotating Sootblower is
applied to the cleaning of the surfaces of
steam g e n e ra tin g tubes. The blow er
ro ta te s and b lo w s th ro u g h a
p re d eterm in e d arc c o n tro lled by an
actuating cam. Refer to Figure 1 for an
overall view.
' The drive unit supplies motivation for the
blowing rotation. The control regulates
the number of blowing revolutions and
signals the control panel upon completion
of the blower cycle. A pre-cut cam located
at the rear of the drive gear actuates the
trigger and opens the blowing medium
valve for the desired blowing arc dictated
by the particular cleaning requirements.
The blowing medium valve is an integral
part of the blow er head and has an
adjustable pressure control feature which
reduces the supply header pressure to the
desired blow ing pressure as it passes
through the b lo w er head and m u lti-
nozzled element.
The multi-nozzled element is so positioned
with respect to the boiler tubes that each
nozzle is directed down a specific tube lane
as the elem ent is rotated through its
blowing cycle. The elements are furnished
in several different materials depending
on boiler temperature and locations. The
blower heads are furnished in several
different materials depending on pressure-
temperature applications.
In d iv id u a l c o m p o n e n ts and parts
identification of the sootblower for each
contract are illustrated on the forms
attached to the rear of these instructions.
2. Non-Rotating Sootblower
The Model G9B Non-Rotating Sootblower
is applied to installations requiring fixed
position elements such as duct blowers and
induced draft fan cleaners, or any other
IM 3124 4 A p r., '88
special boiler cleaning applications. It may
also be employed as a turn-on valve in high
pressure steam piping systems. W ith its
integral pressure control device described
above, it has a distinct advantage over
other types of turn-on valves.
For these applications the screw tube is
secured to the blower; the gear wheel,
with blowing cam, is rotated about the
swivel tube to actuate the valve trigger.
SECTION 2
INSTALLATION INSTRUCTIONS
1. Location of Blowers
Determine the proper location of the
sootblowers on the boiler as indicated on
the Diamond® installation drawings or
boiler manufacturer's standards drawing
provided with each order. Each blow er
head and e le m e n t is id e n tifie d w ith
markings similar to those specified on
these drawings.
2. Element Bearings
The blowing element is supported from
the boiler tubes by bearings attached to
the tubes. These bearings are supplied in
several different materials depending on
the gas tem perature of each location.
Check the installation draw ing fo r the
exact positioning of the bearings. Where
installations do not specify b e a rin g
location, fo llo w th e general rule of
maintaining maximum spacing of 18", 21",
and 48" for Dialoy® , calorized steel, and
plain steel elements, respectively. Care
should be taken to properly align the
bearings to ensure adequate support for
the elem en t. The d istan ce b e tw e e n
bearings must be held to prevent element
warpage.
Two types of bearings are commonly used;
one type is secured to the boiler tube with
a bolted clamp and the other is welded
directly to the tube. W hen the clamped
bearing is used, it should be hammered
lightly after installation and retightened to
ensure contact w ith th e tu b e . It is
 recommended that the bearing clamp then
be tack welded to the tube to prevent
slipping and misalignment.
When attaching welded type bearings,
refer to the welding instructions in Section
5 for th e a p p ro p ria te electrode and
procedure.
3. Wall boxes
The installation drawings give detailed
instructions and dimensions for locating
and attaching the wall boxes to the boiler
casing. The wallboxes must be mounted
squarely with the boiler casing to ensure
that the element will lay in contact with all
support bearings when it is attached to the
blower head.
NOTE: Care should be taken to align the
wallbox flange with the tapped holes in
the positions shown on the installation
drawing since these holes govern the final
position of the head.
4. Blower Mounting
Flexible Element Connection
The flexible element connection, as
illustrated on parts identification form
3448, permits relative movement up to
1-1/2" between the boiler tubes and
the boiler wall.
The swivel tube is supplied cut to
length and threaded. The fle x ib le
e le m e n t c o n n e c tio n is n o rm a lly
supplied in a single standard length,
but is occasionally fabricated in special
lengths w h e re non-standard w all
construction is involved. The element is
furnished in a finished length based on
the flexible connection length and no
further modification is required for
either part.
The tw o adjusting screws, located
b e tw ee n th e w allb o x fla n g e and
blower adapter sleeve, take up the
adjustment required to position the
element nozzles w ith respect to the
boiler tubes. When mounting a new
IM 3124
blower and adjusting nozzle position,
the element must be supported so that
the flexible connection is positioned as
shown on th e jo b in s t a lla t io n
drawings. At this point, the jets should
be located a distance off the edge of
the tube as shown on this drawing.
b. Pressurized Air Seal
The pressurized air seal, as illustrated
on parts identification form 3461, is
required w h e re furnace pressure
exceeds 16 inches H 2 O. It contains
packing to p re v e n t b o ile r gases
escaping out around the swivel tube.
The seal box has a connection for low
pressure air which surrounds the swivel
tube by means of a lantern gland. This
air also serves as an additional seal in
the event the packing becomes badly
w orn and in e ffe c tiv e . If re la tiv e
movement between the boiler tubes
and boiler wall exceeds 1/2", a flexible
element connection must be used in
conjunction w ith the pressurized air
seal.
The air seal is secured to the wallbox
flange by means of four clamps. The
clamps are o r ig in a lly in s ta lle d
fingertight. As the boiler is brought up
to operating temperature, the air seal
will orient itself to compensate for the
differential movement between boiler
casing and tubes. When the boiler is at
its operating temperature, the clamps
should be tightened to maintain this
setting.
The head is secured to the air seal by
four studs. These studs also provide the
final element positioning adjustment.
c. Floating Stuffing Box
The floating stuffing box, as illustrated
on parts identification form 3460, is
utilized on plus pressure installations
w here furnace pressure does n o t
exceed 16 inches H2 O and where the
relative movement between the boiler
tubes and boiler wall does not exceed
1/2". If relative movement does exceed
5
A p r., '8 8
 1/2", a flexible element connection
must be used in conjunction with the
floating stuffing box.
The b lo w e r e le m e n t is cut and
threaded per order, but the swivel
tube is normally supplied unthreaded
in a le n g th e x c e e d in g th e
requirements. Refer to paragraph 5 of
this section for the swivel tube cutting
procedure.
The distance stud located between the
wallbox flange and blow er bracket
provides the fin a l adjustm ent for
maintaining the element nozzles in
proper position w ith respect to the
boiler tubes.
The floating housing is fastened to the
wallbox with three spring-loaded studs
to ensure close contact at all times; the
housing is slotted to permit vertical
m ovem ent. Packing b etw een the
housing and s w iv e l tu b e helps
maintain a seal against escaping boiler
gases.
NOTE: The floating stuffing box must
always be m ounted in a vertical
position regardless of the blow er
position!
d. Floater Type
The floater mounting, as illustrated on
parts id e n tific a tio n form 3459, is
u tiliz e d on n e g a tiv e pressure
in s ta lla tio n s w h e re th e re la tiv e
movement between the boiler tubes
and boiler wall does not exceed 1/2".
The b lo w e r e le m e n t is cut and
threaded per order, but the swivel
tube is normally supplied unthreaded
in a le n g th e x c e e d in g th e
requirements. Refer to paragraph 5 of
this section for the swivel tube cutting
procedure.
The distance stud located between the
wallbox flange and blow er bracket
provides the fin a l adjustm ent for
maintaining the element nozzles in
♦ See in s id e o f fr o n t c o ve r.
IM 3124 6 A p r., '8 8
proper position w ith respect to th e
boiler tubes.
The large coiled spring between the
blo w er bracket and flo a te r body
maintains the floater body in contact
with the wallbox flange.
NOTE: The floater body must always
be mounted in a vertical p osition
regardless of the blower position.
5. Element and Swivel Tube
The element is positioned in the support
bearings with the centerline of each nozzle
usually extended 1/2" past the O.D. of the
boiler tube in each blow ing lane. The
installation drawing illustrates the exact
positioning of each element.
*CAUTION: All settings should be made
for alignment in the hot position.
Except for blowers utilizing the flexible
element mounting arrangement, package
boilers or economizers and oil heaters, the
element is supplied tw o inches longer than
required. This is done to a llo w fo r
variations in the mounting flange to tube
dimensions.
The element must be cut to length and
threaded to suit the actual installation.
Prior to cutting any element, check the
dimension from the wallbox flange to the
position of the first jet as specified on the
job installation drawing. If this dimension
is found to be correct, the element may be
cut to the specified dimension. If th e
dimension is incorrect, the cut point must
be adjusted accordingly. Figure 2 illustrates
the dimensions required.
NOTE: This final element length allows for
a nominal ± 5/8" linear adjustment.
After cutting the element to length, install
it in the bearings with the threaded end
exposed. Bring the G9B head into position
and thread the element into the coupling,
tighten, and tack weld in place. Check jet
position and adjust as necessary.
 •Y

ITHREAD
ENGAGEMENT A ' /

:lE^ entC / x £ / /
NORMALLY ;

X* DIMENSION FROM OPEN END OF

ELEMENT TO THE FIRST JET.
ELEMENT/' SWIVEL
COUPLING / TUBE A

/ /WALL B0X4^ Y* DIMENSIONS GIVEN ON INSTALLA­

C ' / / FLANGEJ TION DRAWING.
/ / / / /
/ A

BLOWER
M -1 9 0 1 -P

Figure 2 Measurement for Swivel Tube Cutting

NOTE: There is an arrow cast onto the side
of the large drive gear. This arrow should
be in alignment with the element nozzles
as it is the only visible indicator of the
rotary nozzle position after the blower is
installed.
6. Blower Assembly
W ith the blower and element connected,
push the assembly into place and secure it
a t the w allbox. M ake the final linear
elem ent adjustm ent by means o f the
wallbox distance studs.
A companion flange is furnished with the
blower for attachment to the steam supply
line. The flange should be removed before
securing the supply line to the blower.
less than th e size s p e c ifie d on th e
installation drawing. All steam piping must
have a pitch of at least 1/2 inch per foot
toward the discharge end of the drain line.
All sootblower lines are to be blown clear
of all foreign matter before connecting to
and operating units. To do this, remove the
drain valve and disconnect the blowers at
the head flanges. Separate the flanges at
the blower cleaning medium supply line
and insert a sheet metal deflector between
the flanges during the "blow ing out"
process. This is to ensure that dirt, scale, or
welding beads from the piping system do
not enter the blowers.
Piping must be designed to prevent undue
strain on the sootblower head.

A flexible sealing gasket is supplied with 8. Valve Condensate Drain Line

each blower assembly. See paragraph 14
for gasket installation instructions.
7. Piping
The emergency stop valve on the boiler
and the piping to the blowers must not be
Any steam blowing G9B sootblower w ith
its blowing medium valve installed more
than 45° off vertical centerline requires a
condensate drain line. A condensate drain
line is normally not supplied on blowers

IM 3124
A p r., '8 8
 used on small package boilers or oil
heaters.
The drain line relieves the condensate
w hich w o u ld o th e rw is e be tra p p e d
between the valve seat and the companion
fla n g e . This drain ag e elim inates the
tem perature differential created by the
presence of the condensate, maintaining a
more uniform blowing medium valve body
temperature, and preventing condensate
buildup in the valve which can contribute
to corrosion and increased condensate
carryover at the start of blowing. The drain
line enters the companion flange via a
socket weld connection. The drain line
should be covered by insulation to avoid
hazard to personnel. Refer to installation
drawing for drain line configuration.
9. Scavenging Air
Scavenging air is a means of keeping out or
scavenging the furnace gases from the
blower when it is not operating. For this
purpose, all blowers have a check valve or
whistle valve located on the gooseneck
casting in the area of the poppet valve.
On n e g a tiv e pressure in s ta lla tio n s ,
atmospheric pressure provides a sufficient
flow of room air through the check valve
and b lo w e r, b u t on plus pressure
installations, it is necessary to connect a
forced draft line to the check valve to
overcome furnace pressure. In either case,
the check valve action prevents the escape
of the blowing medium from the blower
into the room or into the forced draft line
while the blower is operating.
10. Cam Cutting
Because the cam depresses the trigger
w hich in tu rn actuates the b lo w in g
medium valve, the degree of arc to which
the cam is cut regulates the length of the
nozzle blowing arc. Likewise, the position
of the cam relative to the nozzle opening
governs the "o'clock" position of the start
and finish of the blowing arc.
The cam cutting procedure is as follows:
IM 3124 8 Apr., '88
a. Refer to in s ta lla tio n d ra w in g fo r
recommended blowing arc.
b. Refer to Figure 3 to determ ine the
required cam length to obtain the
recommended blowing arc and cut the
cam.
c. Rotate the drive gear until the nozzles
(indicated by the arrow cast on the
drive gear) are in the position required
to begin blowing.
d. Attach the cam to the drive gear with
the leading edge against the nose of
the trigger.
NOTE: Be sure to use lock washers and
tighten the nuts securely. Use at least
three bolts. '
e. Rotate the blower and check blowing
arc.
The blowing coverage is greater than the
degree of cam arc because of the length of
the trigger face and the spread of th e
nozzle je t. The m axim um co ve ra g e
possible with the standard cam is 335°. The
m inim um c o v e ra g e p o s sib le is
approximately 90°. The 90° coverage is
accomplished by om itting the cam and
substituting a short length of 1/8 inch pipe
fastened to the drive gear by a bolt or
some similar arrangement to get minimum
contact with the trigger.
For short blowing arcs requiring cut cams
less than eight inches long, it is advisable
to cut away only the trig g e r bearin g
portion of the cam. This w ill leave a
sufficient flange length to properly anchor
the cam to the gear.
Each standard blow ing s o o tb lo w e r is
equipped with a pin located in the side of
the large drive gear. This pin is intended to
pass under the lug on the trigger just after
the trigger rides off the cam. The purpose
of this pin is to pull up on the trigger and
close the valve in the event th e valve
should e v e r s tick o p e n d u e to
overtightened valve stem packing, etc. A
series of holes around the rim of the drive
 gear permit relocation of the pin when it is
necessary to reposition the cam.
11. Adjusting Blowing Pressure
The so o tb lo w er is equipped w ith an
a d ju s ta b le pressure c o n tro l on th e
downstream side of the valve seat. This is
the means for reducing the steam supply
pressure to the desired blowing pressure.
This pressure c o n tro l is o p e n e d
approximately one turn at the factory
during assembly and must be set in the
field.
Consult the installation drawing for the
recommended blowing pressures for each
blower location. Refer to Figure 5 for the
adjustable pressure control procedure.
Figure 3 Cam Cutting Chart, standard blowing
*See in s id e o f fr o n t cover.
IM 3124 9 Apr., '88
‘ CAUTION: The tapped holes in these
valve bodies are ISO metric parallel pipe
threads. When properly installed, the 1-
1/2" hex heads of the fittings w ill seat
against a gasket and the gasket against
the valve body. In no case should an N.P.T.
or other tapered thread fitting be inserted
in these valves nor should these 1-1/2" hex
head fittings be inserted into a tapered
pipe thread. The 2" diameter boss will be
an unpainted machined surface on valves
with the ISO metric parallel pipe thread.
When a steam generator is first placed into
service, the tube surfaces w ill have an
immunity to ash and slag adherence.
Consequently, it will appear at first that
the recommended blowing pressures are
 higher than required. During this period,
lasting for a few weeks, it may not be
necessary to operate the blow er very
often. Later, after the tube surfaces have
acquired a thin coating of residual slag, the
deposits of slag and ash w ill be more
difficult to clean and the recommended
blowing pressures will be required.
The following are representative blowing
pressures fo r several com m on G9B
applications:
a. Oil fired - 155 psig.
b. Pulverized coal, spreader stoker, and
coke - 80 psig.
c. Blast furnace gas -155 psig
12. Lubrication
The g e a r re d u c e r is s h ip p ed less
lubrication. Refer to Section 5 for proper
lubrication instructions before operating
the blower.
13. Motor and Control
When the blower is installed in a position
which requires the inlet flange to be to the
right side of the normal vertical position, it
is necessary to rotate the motor drive and
control unit clockwise. The motor must be
above the gear reducer to prevent oil from
the gear reducer leaking into the motor.
There is a series of threaded holes in the
d riv e s u p p o rt b ra c k e t to p e rm it
repositioning. When the position is known
in advance, the blowers w ill be shipped
with the drive unit properly positioned.
‘ CAUTION: W hen the drive motor is
m ounted in th e h o rizo n ta l position,
remove the tw o drain plugs in the housing
c en ter s e c tio n . W h en th e m o to r is
mounted in the vertical position, remove
only the drain plug in th e m ounting
flange.
The base model blower is equipped with a
single limit switch actuated by a pin in the
drive gear (see Figure 1, pages 2 & 3). The
actuator lever has been spring loaded to *
*See in s id e o f fro n t cover.
IM 3124 10
provide a manual local start feature. To
manually start the blower, grip the ring on
the actuator lever and compress the spring
until the tip of the lever clears the trip pin
and rotate the actu ato r lever to th e
opposite side of the trip pin. The blower
w ill th e n c o m p le te one b lo w in g
revolution.
‘ CAUTION: If the switch is to be removed
for maintenance, it must be held in the
actuated position. Failure to maintain the
switch in this actuated position w ill cause
the blower motor to be energized and
start the blower to operate.
The optional control box arrangement has
two limit switches actuated by pins in the
timing gear in the control box. The control
is norm ally set fo r one (1) b lo w in g
revolution, but can be changed to tw o (2)
revolutions by removing the components
illu s tra te d on th e c o n tro ls p a rts
identification form.
14. Gaskets
W hen in s ta llin g g askets b e tw e e n
sootblower flanges, all bolting should be
tightened evenly. It is not essential to use a
torque wrench since th e gaskets are
equipped with a gauging ring. Tightening
should be in several steps in a criss-cross
pattern until the flange faces contact the
gauging ring.
Care should be taken to assure that flanges
are not cocked. This w ould result in
unequal compression of the gasket and
early failure. Once gasket compression is
started in a w edge configuration, the
spiral rings may be deformed making it
impossible to obtain a satisfactory seal.
‘ CAUTION: Do not overtighten studs.
Approximate torque values when properly
tightened will be 175 foot-pounds.
Apr., '88
 SECTION 3
OPERATING INSTRUCTIONS
1. Sootblowing at Low Loads
Before operating any sootblower, the
following precautions should be observed.
On oil or pulverized fuel fired boilers,
sootblowers should be operated only while
the burners are in service at a rate of
combustion sufficiently high to ensure a
low oxygen content in the flue gases and
to prevent the fires being blown out. It is
best to have boilers operating between
half and full load when operating the
sootblowers. Operation at low load, with
its resulting colder furnace, may result in
some unburned combustibles escaping
from the furnace and depositing on tubes
or collecting in pockets. Agitation of these
combustibles during sootblowinq at low
load may result in an explosion. It is ,
therefore, important to have all of the
areas of the gas passes thoroughly swept
w ith flu e gas, th u s p u rg in g any
combustible gas from pockets w here it
may collect.
Before operating sootblowers on negative
pressure installations, the furnace draft
should be increased, without effecting an
increase in excess air, to just enough to
prevent a positive pressure in the furnace
when the units are operated. During the
sootblowing period, the air flow and fuel
should be placed on hand control to
maintain proper fuel and air relation.
3.
2. Package Boilers with Automatic Firing and
Induced Draft
*CAUTION: Operate sootblowers only
when burners are in service.
a. Put the induced draft fan damper on
manual control 100% open (th e
position corresponding to full load).
b. Set burners at 50 to 75% of boiler
rating on manual control if available.
Otherwise, have boiler operating at *
*See in s id e o f fro n t cover.
IM 3124 11
this m inimum ra te on m od u lated
control.
c. Leave flame scanner safety fuel control
in service.
d. Take vacuum operated safety fuel
control out of service (when provided).
e. Ensure that the drain valve is fully
open, then slowly open the steam
control valve.
f. Allow several minutes for the header
and branch lines to warm up.
g. When the steam leaving the drain
valve is absolutely dry, close the drain
valve.
h. Operate each sootblower one to three
re v o lu tio n s e v e ry e ig h t hours
providing the burners are in operation.
i. Rotate each sootblower at the rate of
20 seconds per revolution.
j. Keep sootblower rotating when steam
is issuing from nozzles.
k. Refer to in s ta lla tio n d ra w in g fo r
recommended blowing pressure.
L After all blowers have operated, close
the steam control valve and open the
drain valve. Leave the drain valve open
until th e next o p e ra tio n o f th e
blowers.
Package Boilers with Automatic Firing and
Pressurized Furnace
*CAUTION: Operate sootblo,wers only
when burners are in service.
a. Put forced draft fan on manual control
and increase furnace pressure by 0.10
to 0.15 inches H jO , or enough to
prevent possible blackout.
b. Set burners at 50 to 75% o f boiler
rating on manual control if available.
Otherwise, have boiler operating at
Apr., '88
 this m inim um rate on m odulated
control.
c. Leave flame scanner safety fuel control
in service.
d. Ensure that the drain valve is fully
open, then slowly open the steam
control valve.
e. Allow several minutes for the header
and branch lines to warm up.
f. When the steam leaving the drain
valve is absolutely dry, close the drain
valve.
g. Operate each sootblower one to three
re v o lu tio n s e v e ry e ig h t hours,
providing the burners are in operation.
h. Rotate each unit at a rate of 20 seconds
per revolution.
L Keep sootblower rotating when steam
is issuing from nozzles.
[. Refer to in s ta lla tio n draw ing for
recommended blowing pressure.
k. After all blowers have operated, close
the steam control valve and open the
drain valve. Leave the drain valve open
until th e next o p e ra tio n o f th e
blowers.
4. Blower Operation
a. Panel Operated Blowers
The panel must be energized to initiate
the w arm -up period of th e steam
header. The blowers w ill begin to
operate automatically and sequentially
when the warm-up timing device in
the panel system permits the blower
selector switches to energize the motor
starters.
After each blower completes its cycle, a
trip lever on the blower will actuate a
switch to de-energize the motor starter
and transfer the panel to the next unit.
IM 3124 12
b. Push-button Operated Blowers
The push-button operated blowers
must have the steam header manually
warmed up. Each blower is started by
depressing th e push b u tto n to
energize the motor starter. A fter the
blowing cycle, the trip lever on the
blower will actuate a switch to de­
energize the motor starter.
M anual w arm -u p procedure is as
follows:
(1) Ensure that the drain valve is fully
open, then slowly open the steam
control valve.
(2) Allow several minutes fo r the
header and branch lines to warm
up.
(3) When the steam leaving the drain
valve is absolutely dry, close the
drain valve.
(4) Before operating the blowers on
negative pressure installations,
th e furnace d ra ft should be
increased enough to prevent a
positive pressure in the furnace
when the units are blowing.
(5) O p e ra te th e b lo w e rs in
alphabetical or numerical order.
(6) After all blowers have operated,
close the steam control valve and
open the drain valve. Leave the
drain valve open until the next
operation of the blowers.
c. Manual Operation
In the unlikely event that it is necessary
to rotate the blower manually, it can
be accomplished by using a speed
wrench or air operated wrench (see P.l.
Form 3576) and a 7/16" socket on the
square tang at the end of the worm
shaft opposite the motor. 360 turns of
this shaft will rotate the element one
revolution. (See Figure 4.)
Apr., '88

Figure 4 Manual Operation
5. Internal Inspections During Boiler Outages
All surfaces cleaned by the sootblowers
should be checked when a boiler is out of
service long enough to perm it such an
inspection. The purpose of this inspection
is to check the cleaning results and to
check the tubes for erosion. In addition to
internal inspections during boiler outages,
observation of slag and ash deposits on the
boiler tubes should be made during
operation to determ ine if cleaning is
adequate.
6. Cleaning Results
The number of sootblowers installed and
the selection of their location were based
on th e e x p e rie n c e o f th e b o ile r
manufacturer and Diamond Power with
various fuels and firing methods. Normally,
the complement of sootblowers installed
will clean the areas required satisfactorily.
In case satisfactory cleaning results are not
obtained, one or more of the following
conditions may be a contributing factor:
IM 3124 13
a. Fuel Change
A radical change in fuel may require a
change in the blowing pressure, the
blowing schedule, and even relocation
or a d d itio n o f s o o tb lo w e rs . For
example, coal from a different source
may have more ash or the ash may
have a lower fusion temperature. Such
a change in fuel w ill change th e
amount and the nature o f th e slag
formed on the tubes.
b. Boiler Operating Change
Change in fuel preparation, air for
combustion, and the rate of boiler
operation are often responsible fo r
cleaning problems. High rates of boiler
operation and the incorrect amount of
air for combustion can cause slag
formations in areas where they are not
exp e c te d . Such fo r m a tio n s a re
som etim es beyond th e c le a n in g
capabilities of any sootblow er. The
b o ile r m a n u fa c tu re r sh o u ld be
consulted when such conditions are
encountered.
7. Tube Erosion
Boiler tube erosion in connection w ith
sootblowing is usually the result of the
following:
a. Condensate in the blowing medium.
b. Operating the blowers too often.
c. Blowing pressures set too high.
d. High gas velocity in a lane or a t a
turning point in the direction of gas
flow.
Careful attention to the application of the
recommendations in these o p e ra tin g
guides will minimize the possibility of tube
erosion and improve cleaning results from
the blowers.
Apr., '88
 SECTION 4

TROUBLESHOOTING

POSSIBLE TROUBLES PROBABLE CAUSES

Motor Fails to Start 1. No power voltage

a. No power to starter

b. Overload heater burned out

c. Open circuit between starter and

motor

2. Motor winding open or shorted

3. One power line open

a. Overload relay has o p e ra te d

without motor starting because
of single phase condition

4. Forward contactor fails to operate

a. No voltage from panel on lines A

and B

b. No signal from panel or line D

c. If o p e ra te d m a n u a lly , s ta rt
button may fail to make contact

d. Overload contacts open

e. Coil burned out

f. Loose wire in Forward coil circuit

Unit Fails to Stop 1. Limit switch not operated; trip lever

loose

2. Limit switch jammed

3. Control tim ing gear drive pinion

broken or loose from gear reducer

Motor is Overloaded 1. Element binding in bearings in boiler

2. Cam loose on drive gear, binding

trigger

3. Drive gears jammed

IM 3124 14 Apr., '88

 POSSIBLE TROUBLES PROBABLE CAUSES

4. Positive closing pin on drive gear in

wrong position, binding trigger

5. Swivel tube packing too tight

6. Valve stem fouled, binding in valve

stem guide

7. F le xib le e le m e n t c o n n e c tio n
assembly (where used) frozen, does
not flex w ith b o ile r expansion,
transmits strain to head

8. P iping in c o rre c tly s u p p o rte d ,

transmits strain to head

9. Thrust bearing rusted, fre e z in g

swivel tube

Blowing Medium Fails to Shut Off 1. Valve steam sticking in guide

2. Valve yoke broken or bent off from

valve stem

3. Valve spring broken

4. Valve disc loose from valve stem

Element Fails to Rotate Through 1. Steam not leaking out wallbox

Motor Runs (Cleaning Inadequate)
a. Set screw in drive gear loose from
swivel tube (locknut loose)

b. Element broken o ff just inside

furnace (excess moisture)

2. Steam leaking out wallbox

a. Swivel tube destroyed

b. Coupling broken inside wallbox

c. E lem e n t u n s c re w e d fro m
coupling (set screws not tight)

Tube Abrasion or Baffle Erosion Present 1. Blowing pressure too high

Upon Internal Inspection
2. N o zzle a lig n m e n t w ith tu b e s
incorrect

3. Blowing arc incorrect

IM 3124 15 Apr., '88

 POSSIBLE TROUBLES PROBABLE CAUSES

4. Excess moisture present in steam

5. Too frequent an operating cycle

observed

Frequent Breakage of Dialoy® Elements 1. Temperature zone too cool, Dialoy®

Experienced not suitable in 1000 - 1400°F zones,
crystalline fracture

2. Excess moisture in steam

a. Improper piping warm-up

b. Improper piping drainage, no

slope, connected to " b lo w
down" tank at positive pressure

c. No condensate reservoir, piping

experience high radiation loss

Nozzles on Elements Cutting Out, 1. Excess moisture in steam

"Wire Drawn"

Elements Warping to Where They 1. Improperly supported, insufficient

Bind in Bearings number of bearings used for ambient
temperature in that zone

2. Bearings im p ro p erly a lig n e d a t

erection

3. Boiler tubes misaligned carrying

bearings with them

4. Wallbox improperly set to handle

expansion in t h a t a re a (see
installation drawing)

IM 3124 16 Apr., '88

 SECTION 5
MAINTENANCE INSTRUCTIONS
* WARNING: Disconnect power source to
motor to prevent automatic operation of
blower and opening of blowing medium
valve. Even w ith valve closed, slight
leakage is possible if valve internals are
steam cut or warped; therefore, additional
c a u tio n is re c o m m e n d e d b e fo re
performing the following maintenance.
NOTE: The Lubricant Chart referred to
below is located in the Parts Identification
section.
1. Lubrication
The gear reducer is the only item requiring
lu b rica tio n . In a d d itio n to requiring
approximately 1/2 pint of oil, it has tw o
grease fittings for lubricating the worm
th ru st bearings. The e le c tric m o to r
bearings are pregreased and sealed. Some
acceptable gear reducer lubricants are
specified on the Lubricant Chart.
In special instances it may be necessary to
install the blower with the gear reducer
ab o ve th e m o to r. In these cases a
lightweight grease should be substituted
for oil to prevent leakage to the motor
when the reducer shaft seals wear.
3.
2. Poppet Valve
The valve contains an adjustable orifice
disc which provides a means of adjusting
the valve outlet pressure. To increase the
downstream pressure, remove the lock pin
containing the socket type and rotate the
fluted disc to produce a large flow area. To
reduce the pressure, simply lower the disc.
A screwdriver or similar object can be used
to insert into the fluted disc for turning.
Refer to Figure 5 for adjustable pressure
control procedure.
When the valve does not remain steam
tight when closed, it is an indication that
the seat and disc mating faces are steam
cut or warped. This condition can usually
be corrected by regrinding and lapping.*
*See inside of front cover.
IM 3124 17
Refer to th e fo rm in th e p a rts
id e n tific a tio n s e c tio n fo r la p p in g
p rocedu re. This fo rm also includes
instructions for replacing welded seats if
grinding and lapping do not correct the
damage to the seating surfaces.
It is not necessary to remove the complete
blower assembly from the w allbox for
valve maintenance. The gooseneck can be
detached from the mounting components
by the following procedure.
a. Remove the 3/8 cap screw securing the
motor drive to the support bracket and
remove drive unit.
b. Remove the two 1/2" cap screws from
lower portion of front blower bracket.
Remove slotted hex nut from the tie
bolt at the upper end of the bracket.
c. Loosen the swivel tube packing gland.
d. Remove companion flange studs.
e. Pull th e gooseneck and tr ig g e r
assembly straight back to clear swivel
tube out of the packing chamber.
f. On plus pressure boilers, plug the open
end of the swivel tube until the blower
is remounted.
Valve Stem Packing
a. Tightening
With special wrench (312227-1129) or
similar tool, turn the packing nut
located beneath the valve spring in a
clockwise direction. The packing nut is
shown on Figure 6. T ighten only
enough to prevent leakage. O ver­
tightening will shorten packing life.
b. Replacement
‘ WARNING: Refer to W arn in g a t
beginning of M aintenance section
before proceeding.
(1) Remove the trigger and replace
trigger pin as shown on Figure 6.
Apr., '88
 ‘ WARNING: Ensure that valve is closed before removing lock pin plug. Even
w ith valve closed, slight leakage is possible if valve internals are steam cut or
warped; therefore, additional caution is recommended.

‘ CAUTION: The tapped holes in these valve bodies are ISO metric parallel pipe
threads. When properly installed, the 1-1/2" hex heads of the fittings w ill seat
against a gasket and the gasket against the valve body. In no case should an
N.P.T. or other tapered thread fitting be inserted in these valves nor should
these 1-1/2" hex head fittings be inserted into a tapered pipe thread. The 2"
diameter boss will be an unpainted machined surface oh valves with the ISO
metric parallel pipe thread.

N O T E: T O IN C R E A SE PRESSURE. T U R N D ISC C O U N T E R C L O C K W ISE .

TO D E C R E A SE PRESSU RE, T U RN D ISC C L O C K W ISE.
1 R E M O V E PIPE PLUG A N D C O N N E C T G A U G E.
2. O P E R A T E B L O W E R TO O B T A IN R EA D IN G .
3. R E M O V E LO C K PIN PLUG A N D A D J U ST DISC. (SEE W A R N IN G A B O V E )
4. REPLA C E L O C K PIN PLUG A N D O P E R A T E B L O W E R F O R P R ESSU R E R E A D IN G .
5. REPEAT IF NECESSARY UNTIL DESIRED PRESSURE HAS BEEN OBTAINED.
6. IN C R E M E N T A L A D J U S T M E N T C A N BE M A D E BY IN T E R C H A N G IN G L O C K PIN
PLU G A N D A IR RELIEF V A L V E A S S E M B L Y . '
NO TE: A FT E R A D J U ST IN G PRESSU RE, BE SU R E A D J U S T IN G D ISC H A S A FLUTE
L O C A T E D S O A S T O A C C EPT LO C K PIN PLUG. M -4 4 3 2 -P

Figure 5 Adjustable Pressure Control Procedure

*See in s id e o f fr o n t cover.

IM 3124 18 Apr., '88

 TRIGGER PIN YOKE

SPRING
R ETAINER

S P R IN G

P A C K IN G
NUT

A A -887

F ig u r e 6 V a l v e S p r i n g R e m o v a l

(2) W i t h th e s p e c ia l t o o l s h o w n
(307025-1027), depress th e valve *CAUT!O N: Tighten d o w n th e packing
spring enough to p erm it removal n u t enough th a t th e spring re ta in e r is
o f th e valve stem yoke. not forced d o w n a g a in s t th e n u t by
the trig g e r w h en opening th e valve.
(3) R em o ve th e y o k e and re le a s e
spring tension. (8) O perate th e b lo w e r and tig h te n
th e packing n ut only e n o u g h to
(4) L ift o f f th e spring re ta in e r and prevent leakage. O v e rtig h te n in g
spring and rem o ve th e packing w ill bind stem and m a k e v a lv e
nut. closing difficu lt.

(5) Refer to th e parts id e n tific a tio n 4. Sw ivel Tube Packing

form for id e n tific atio n o f poppet
valve c o m p o n e n ts and re m o v e a. Tightening
the packing w asher and packing
{one ring a t a tim e ). If packing leaks and ta k e-u p distance
exists b etw een th e packing gland and
(6) R e p la c e new p a c k in g by packing cham ber fla n g e , tig h te n gland
staggering th e splits in each ring evenly and a lte rn ate ly a d v an c in g th e
180° apart. packing adjustm ent nuts. T ig h ten only
enough to prevent leakage.
(7) R ep lace a ll re m o v e d p a rts in O v e rtig h te n in g w ill sh o rte n p ackin g
reverse order. * life.

*Se e in s id e o f fr o n t cover.

IM 3124 19 Apr., '88


b. Adding a Packing Ring
When take-up distance no longer exists
b e tw e e n th e packing gland and
packing cham ber fla n g e and th e
packing appears in good condition
(not hard and dry), an extra ring of
packing may be added. This can
elim inate immediate installation of
new packing.
c. Replacing the Packing Set
‘ W ARNING: Refer to W arning at
beginning of M aintenance section
before proceeding.
(1) W ith corkscrew e x tra c to r or
s im ila r to o l, pick o u t each
individual ring of the packing set.
NOTE: These are split rings and
removed best by inserting the
extractor next to the split.
(2) Insert new packing, one ring at a
time, and stagger the splits 180°
apart.
(3) Start packing gland into packing
cham ber, ta p g e n tly to seat
p a c k in g , and a tta c h th e
a d ju stm e n t nuts. Evenly and
alternately tighten the nuts until
packing is snug. O perate the
blower to check for leaks and
retighten if necessary. Tighten
only enough to prevent leakage.
O v e rtig h te n in g w ill shorten
packing life and add unnecessary
load to blower drive components.
NOTE: If short packing life is
being experienced due to steam
temperatures over 500°F, a high
temperature packing is available
as Diam ond® p a rt n u m b e r
310578-1110.
5. Straightening of Elements
If an element becomes badly distorted, it is
usually necessary to remove it from the
‘ See in s id e o f fro n t cover.
IM 3124
boiler for repairs. If the bearings are in
proper a lig n m e n t, it is possible to
straighten the element without removing
it from the boiler by turning it to the point
where it binds in the bearings, and then
leaving it in this position for a few hours. If
this method does not s tra ig h ten th e
element so that it revolves freely, it should
then be removed from the bo iler fo r
mechanical alignment.
If the w arpage is not e xtrem e , steel
elements, including the calorized steel,
may be straightened cold by bending them
back to the proper shape.
If warpage is more severe, the elements
should be heated to a cherry red, and then
laid on a level floor or surface. Wooden
blocks should be used to tap the element
in the bent section, but not enough force
used to flatten the section in the pipe. If
the entire element cannot be heated at
one time, the sections which are warped or
distorted can be heated separately, and
then laid on the floor for straightening in
the prescribed manner. For some moderate
w a rp a g e , th e e le m e n t m ay be
straightened by heating to a cherry red,
and then quenching w ith a cold rag.
Quenching on the proper side will tend to
draw the element back in shape where the
warpage is of a very slight degree.
Dialoy® elements should first be heated to
1600°-1650°F at which tem perature the
metal will be between a bright red and
orange. The element should then be rolled
on an even surface and straightened by
using a wooden block to tap it. During
straightening, the element tem perature
should be maintained above 1300°F to
prevent cracking.
After it has been straightened, the entire
elem ent should then be quenched in
water. In case it cools considerably w hile
being straightened, it should be reheated
to 1650°F and th e n q u e n c h ed . The
quenching of Dialoy® elements tends to
soften or anneal them and prevents the
formation of an extremely hard or brittle
area which may cause a fracture upon
contact with the bearings in the furnace.
20 A p r.,'88
6. Welding of Elements and Bearings
If it becomes necessary to weld broken
Dialoy® or Calorized elements, the electric
arc process must be used. A special flux
coated rod supplied by th e Diamond
Power Specialty Company should be used
for this process. When joining elements by
electric arc welding, it is necessary to grind
a bevel surface of the prescribed degree
shown on Figure 7 to permit a functional
butt welding process. Welds should be
fused to the bottom of the joint, and the
beads built up to a weld thickness of
a p p ro xim a te ly 1-1/4 tim es pipe w all
thickness. The ends of the joint should be
spaced approximately 1/16" apart before
beginning the joining tacks. The beads
should n o t be run a ro u n d th e
c irc u m fe re n c e o f th e p ip e in one
continuous pass, rather 3 to 4 passes
should be used beginning opposite from
one another on the circumference of the
pipe and joined at the completion. Refer to
Figure 7.
It is im portant that the sections being
welded together be in correct alignment
IM 3124 21
with respect to their center axes. Nozzles
must also be held in correct alignment, and
their original center spacing held as close
as possible.
On Calorized elements, the calorizing
m aterial must be rem oved from th e
surface before w e ld in g . This is most
important as the calorized material will
show up as slag inclusions in the completed
weld if the excess material is not removed.
The recommended welding procedure is as
follows:
a. Elements
(1) Dialoy® - D ia lo v *; D ia lo v * -
Calorized: Dialov®-Plain Steel
(a) Use 1/8" d iam eter coated
Inco-Weld A Electrode (DPSC
Rod #6).
(b) Use D.C. Reverse Polarity - 75
to 100 amps.
Apr., '88
 (C) The electric arc should be as (b) Use D.C. Reverse Polarity -
short as possible. 130 to 160 amps.

(d) The m in im u m c u rre n t (c) The electric arc should be as

(within the range) that can short as possible.
be satisfactorily handled
should be used.

(2) Calorized - Calorized; Calorized -

Plain Steel

(a) Use 1/8" diameter coated (25

Cr - 20 Ni) E310-15 or 16
Electrodes (DPSC Rod #5).

(b) Use D.C. Reverse Polarity - 90

to 115 amps.

(c) The electric arc should be as

short as possible.

(3) Plain Steel - Plain Steel

(a) Use 1/8" diam eter coated

E7018 electrodes (DPSC Rod
# 2).

(b) Use D.C. Reverse Polarity -

130 to 160 amps.

(c) The electric arc should be as

short as possible.

b. Bearings

(1) Dialov*and Calorized Bearings

(a) Use 1/8" diameter coated (25

Cr - 20 Ni) E310-15 or 16
Electrodes (DPSC Rod #5).

(b) Use D.C. Reverse Polarity - 90

to 115 amps.

(c) The electric arc should be as

short as possible.

(2) Carbon Steel Bearings

(a) Use 1/8" diam eter coated

E7018 electrodes (DPSC Rod
# 2).

IM 3124 22 Apr., '88

 CLEA V E R BROOKS
D I V A Q U A C H E M INC.
P O B O X 421
MILWAUKEE, WIS 53201
U.S.A.

SAFETY VALVE CALCULATIONS

CUSTOMER: CONTAINER CORPORATION

LOCATION: SANTA CLARA, CA
U N I T NO. W-3813

B Y :M . G L O D O W S K I
D A T E :11-21-1994

DATE :

REV. NO. : 0

BOILER MODEL DLDH-118-LH

CAPACITY 125000 LB/HR

BLR HTG S 8056 X 10 = 80560 LB/HR
W.W HTG S 1253 X 16 = 20048 LB/HR

TOTAL S T E A M CAP. PER CODE = 125000 LB/HR

BLR D E S I G N P R ESSURE P S I G 260

iX S.V. S E T P R E S S (CODE) P S I G 268
OPERATING PRESSURE P S I G 200
CURATED S T E A M T E M P . D E G - F 388

MAKE OF VALVES - KUNKLE

********************************************************************************
SIZE F I G NO. ORIFICE POP @ CLOSE @ RELIEV. C-B LOCAT.
AREA PSIG PSIG LBS/HR P/N

4 xMx 4 252FMM • 3.6 225 216 40055 940-5636 UPP. DRM

4 xMx 4 252FMM 3.6 230 220 40892 9 4 0 - 5 6 3 3 U PP. DRM
4 xNx 6 252KNM 4.34 230 220 49298 9 4 0 - 5 6 3 4 UPP. DRM

TOTAL RELIEVING CAPACITY 130246 #/HR

{NOTE} - CLEAVER BROOKS DIV AND THE MANUFACTURERS RECOMMEND THAT SAFETY
V A L V E P O P P I N G P O I N T B E 25 P S I O R 1 0 % A B O V E T H E O P P R E S S , W H I C H E V E R
" IS G R E A T E R . SAFETY VALVE MANUFACTURERS WILL NOT GUARANTEE TIGHT
iJ S H U T - O F F W H E N V A L V E SETTINGS ARE BELOW T H E S E LIMITS.
 mKUNKLE Valve Division
MODEL
252
SERIES

IRON SAFETY
VALVES
FOR AIR, GAS,
o ST EA M SERVICE

^ KEYSTONE
Anderson, Greenwood & Co.
A Subsidiary of Keystone International, Inc,
mKUNKLE \felve Division
IRON SAFETY VALVES FOR
STEAM, AIR. NON-HAZARDOUS GAS SERVICE

P R E S S U R E L IM IT S
250 PS IG -406°F
MODEL
A PP LICA T IO N S
252 * S te a m B o ile rs a n d G e n e ra to rs .

SERIES * P re ssu re R e d u c in g S ta tio n s .

* A ir/G a s C o m p re s s o rs — R e c ip ro c a tin g o r R otary.
* P re ssu re V e s s e ls — In c lu d in g T an ks, R e c e iv e rs , In te rc o o le rs , Oil — G as S e p a ra to rs , lin e s .

FEATURES
H e a vy d u ty c o n s tru c tio n o f h ig h q u a lity c a s t iro n w ith b ro n z e o r s ta in le s s s te e l
s e m i-n o z z le trim . B o lte d b o n n e t d e s ig n fo r e a s y m a in te n a n c e . S e a ts la p p e d to
o p tic a l fla tn e s s . D u a l c o n tro l rin g s o ffe r e a s y a d ju s ta b ility f o r p re c is io n o p e n in g
w it h m in im u m p re o p e n o r s im m e r a n d e x a c t b lo w -d o w n c o n tro l. H e a vy d u ty lift
le v e r a sse m b ly. E ve ry v a lve 100% te s te d /in s p e c te d f o r p re s s u re s e ttin g , b lo w -d o w n
a n d le a k a g e . A ll a d ju s tm e n ts a re f a c t o r y s e a le d to p re v e n t ta m p e rin g o r d is ­
a s s e m b ly

MODEL 252 C ast Iro n . E n c lo s e d s p rin g . B ro n z e /B ra s s trim .

MODEL 253 S a m e as 252 e x c e p t S/S trim . (S e m i-n o z z le a n d d is c )

MODEL 254 S a m e as 252 e x c e p t C e rtifie d f o r A S M E C o d e S e c. IV -L o w p re s s u re

s te a m h e a tin g b o ile rs . S e t 15 p sig only. J th ru P o rific e only.

MODEL 259 V a cu u m s e rv ic e . P re ssu re t ig h t cap. C a st Iro n . B ro n z e /B ra s s trim .

M O D E L N U M B E R /O R D E R G UIDE
MODEL NO.
1 |i
3
4 5 6 7 8 9 110 11 12 13 14
15
POSITION

EXAMPLE
2 15 2 F L K 2 2 — | A S 0 0 2 0

SET PRESSURE
R ~ 5~ l4 M O D E L 252, 253
5 P SIG (0005) thru 2 50 P SIG (0250)
M O D E L 254
15 P SIG (0015)
M O D E L 259
10' HG (Inches of Mercury) (0010) thru
2 2 " HG (0022) Vacuum
CONNECTION TYPE

A — Fem ale x Fem ale

F — 25Q #FLG x Fem ale
SPRING MATERIAL
K — 2 50 #F L G x 125#FLG .
S-Steel (Pltd )

ORIFICE

J N
K P
L Q ________________________ VALVE SERVICE
M O DELS M R A-Steam A S M E S ec. I
(M odels 2 52 , 2 53 Only)
252-253 INLET SIZE________________________________________ G-Steam A S M E S ec. IV
(M odel 2 54 (15 P S IG ) Only)
254 G — VA" K-Air A S M E Sec. VIII
H — 2' M — 4 ”
(M odels 2 52 , 2 53 Only)
J — 2Vz” P — 6" L-Steam A S M E Sec. V III
K — 3” (M odels 252, 2 53 Only)
VARIATION (01 thru 9 9 )__________________ DESIGN REVISION Q-Vacuum (M odel 259 Only)

Num ber Provided Only by M anufacturer Indicates N on-lnterchangeable

to C over Specific Feature or Option. Revision. Dash (— ) if Original
Design.

IM P O R T A N T : K unkle Valve D ivision is not liable for an y da m a g e resulting from m isu se or m isapplication of its p ro d u cts (se e warranty).
 ASME Standard — N.B. Certified

D IM EN SIO N S/SP EC IF IC A T IO N S
APPROX.
W T.
M O D E L NO. IN L E T © O R IF IC E OUTLET© A 6 C L B S.

2 5 *A JG 1!4"-F.P.T. J 2 ,/2r,-F.P.T. 1 8 'A 3!4 4% 28

2 5 *F JG 114"-FLG. J 2 ,/2"-F.P.T. 18V4 3/2 4% 30
2 5 *F JH 2 "-F L G . J 2!4"-F,PT. 18 1/4 3/2 4% 33
2 5 *F JJ 2 !4 "-F L G . J 2 ,/2"-F.PT. 18V4 314 4'A 36

2 5 *A K H 2"-F.P.T. K 3 "-FP .T . m 4 4% 46
2 5 *F K H 2 "-F L G . K 3"-F.P.T. 19% 4 4% 51
2 5 *F K J 2!4”-FL G . K 3"-F.P.T. 19% 4 4% 54
2 5 *F K K 3 ”-FL G . K 3"-FP.T. 19 % 4 4% 58

2 5 *A L J 2 1/t"-F.P.T. L 4"-F.P.T. 22 4% 5% 70
2 5 *F L J 2 1/ 2"-F L G . L 4"-RP.T. 22 4% 514 76
2 5 *F L K 3 "-F L G . L 4"-FP.T. 22 4% 5% 79
2 5 *F L M 4 "-F L G . L 4"-F.P.T. 22 4% 514 81

2 5 *A M K 3"-FP.T. M 4"-F.P.T. 221/4 5% 5% 90

25+FM K 3 ”-FLG . M 4"-F.P.T. 2 2 V4 5% 5% 96
2 5 *F M M 4 "-F L G . M 4"-F.P.T. 22/4 5% 5% 100

2 5 *K N M 4 "-F L G . N 6 "-F L G . 23 VA m 150

2 5 *K P M 4 "-F L G . P 6 "-F L G . 26/4 VA 6% 176

2 5 *K Q P 6 ”-F L G . Q 8 "-F L G . 36% 9 'A 9'/« 325

2 5 *K R P 6 "-F L G . R 8 "-F L G . 42% 10 1 0 V2 375

* D a ta a p p lic a b le to M o d e ls 2 5 2 , 2 5 3 , 2 5 4 , & 2 5 9 .
© In le t F la n g e s a re A N S I B 16.1-250#.
© O u tle t F la n g e s a re A N S I B16.1-125#.

P A R T S A N D M A T ER IA L S/ M O D E L 252
NO. PART N A M E M A T E R IA L NO. PART N A M E M A T E R IA L

1 Body Iro n 15 S p r in g S te e l Pltd.

2 S e m i- N o z z le B ro n ze 16 S t e p - S p r in g S te e l Pltd.

3 W a r n R in g B ro n ze 17 S c r e w - C o m p r e s s io n B ra ss

4 W a r n R in g P in / G u id e P in B ra ss 18 L o c k N u t (Com p. S c r e w ) S te e l Pltd.

6 D is c H o ld e r B ro n ze 19 Lifting D is c S te e l

7 C o tte r P in (D is c ) S t a in l e s s S te e l 20 N u t (Lifting D is c ) S te e l

8 D is c C o p p e r A llo y 21 S te m S te e l Pltd.

9 Lift S t o p © S te e l 22 C a p A ss e m b ly Iro n

11 G u id e B ro n ze 22A L e ve r Iro n

12 S c r e w (C ap) S te e l Pltd. 22B Y o ke (Lift) Iro n

13 B o lt (B o d y ) S te e l Pltd. 22C P in s (Lever/Lift Yoke) S te e l

14 Bonnet Iro n 25 Seal L e a d & W ir e

© Lift Stop (PC. #9) Furnished in Low Pressure Valves'

Only.

IM P O R T A N T : K unkle Valve D ivision is not liable for a n y d a m a g e resulting from m is u se o r m isapplication of its p rod u cts Ise e warranty).
 ST E A M / A IR C A P A C IT IES 252 S E R IE S

To c o r r e c t c a p a c itie s fo r s u p e rh e a t o r te m p e ra tu re o th e r th a n 60°F, se e E n g in e e rin g C a ta lo g .

O r ific e j K L M N P Q R

A re a 1 .2 3 7 S q . In . 1 8 3 8 S q . In . 2 .8 5 3 S q . In . 3 .6 0 S q . In . 4 . 3 4 S q . In . 6 .3 8 S q . In . 1 1 .0 5 S q . In . 1 6 .0 S q In .

Set Lbs. Hr. Lbs. Hr. SC FM Lbs.Hr. Lbs Hr. SC FM Lbs./Hr. Lbs..'Hr. SC FM Lbs/Hr. Lbs.Hr. SC FM L ln j'H r. Lbs Hr. SC FM Lbs.'Hr. Lbs, Hr. SC FM Lbs, Hr. Lbs,Hr. SC FM Lbs.Hr. Lbs.Hr. SC FM
Press. Steam Steam Air Steam Steam Air Steam Steam Air Steam Steam Air Steam Steam Air Steam Steam Air Steam Steam Air Steam Steam Air

© © © © © © © 0
© © © © © © © © © © © © © ©
0 0

ID 1551 1692 602 2234 2392 851 3439 3712 1321 4340 4702 1674 5232 5639 2007 7691 8297 2953 13320 14420 5133 19280 20900 7441
15 1842 1998 711 2652 2824 1005 4083 4382 1550 5152 5550 1976 6211 B657 2370 9131 9795 3486 15810 17020 6059 22890 24670 8784
20 2132 2303 820 3070 3255 1159 4727 5052 1798 5965 6399 2278 7191 7675 2732 1D570 11290 4019 18300 19620 6986 26510 28450 10120
25 2423 2609 929 3489 3688 1313 5371 5721 2037 6778 7248 2580 8171 8693 3094 12010 12780 4552 20800 22220 7912 30120 32220 11470

30 2713 2914 1037 3907 4119 1466 6015 6391 2275 7590 8097 2882 9150 9711 3457 13450 14280 5086 23290 24830 8839 33730 35990 12810
35 3004 3250 1157 4325 4594 1635 6659 7128 2537 8403 9030 3214 10130 10830 3855 14890 15930 5672 25790 27690 9858 37340 40140 14290
40 3295 3586 1277 4743 5069 1804 7303 7865 2800 9215 9964 3546 11100 11950 4254 16330 17580 6258 28280 30550 10870 40950 44300 15760
45 3585 3923 1396 5162 5544 1973 7947 8602 3062 10020 10890 3879 12080 13070 4652 17770 19220 6845 30780 33420 11890 44560 48450 17240
50 3876 4259 1516 5580 6019 2143 8591 9339 3324 10840 11830 4211 13060 14180 5051 19210 20870 7431 33270 36280 12910 48180 52600 18720

55 4166 4595 1635 5998 6494 2312 9235 10070 3587 11650 12760 4543 14040 15300 5449 20650 22520 8017 35760 39140 13930 51790 56750 20200
60 4457 4931 1755 6417 5969 2481 9879 10810 3849 12460 13690 4875 15020 16420 5848 22090 24170 8604 38260 42010 14950 55400 60900 21670
65 4747 5267 1875 6835 7444 2650 10520 11550 4111 13270 14630 5208 16000 17540 6246 23530 25810 9190 40750 44870 15970 59010 65050 23150
70 5043 5603 1994 7262 7919 2819 11180 12280 4373 14100 15560 5540 1700D 18660 6645 25000 27460 9777 43300 47730 16990 62700 69200 24630
75 5343 5939 2114 7692 8394 2988 11840 13020 4636 14940 16490 5873 18010 19780 7044 25480 29110 10360 45870 50600 18010 66420 73350 26110

80 5042 6275 2233 3123 8869 3157 12500 13760 4898 15780 17430 5205 19020 20900 7442 27960 30760 10940 48440 53460 19030 70140 77500 27580
90 6240 6947 2473 8985 9819 3495 13830 15230 5423 17450 19290 6869 21040 23140 8239 30930 34050 12120 53570 59190 21060 77580 85800 30540
100 6839 7619 2712 9847 10760 3833 15160 16700 5947 19120 21160 7534 23060 25380 9036 33900 37350 13290 58710 64 91 0 23100 85020 94110 33490

110 7437 8291 2951 10700 11710 4171 16480 18180 6472 20800 23030 8199 25080 27620 9833 36860 40640 14460 63850 70640 25140 92460 102400 36450
120 8036 8963 3190 11560 12660 4509 17810 19650 6997 22470 24900 8863 27090 29860 10630 39830 43940 15640 68990 76 37 0 27180 99900 110700 39400
125 8335 9299 3310 12000 13140 4679 18470 20390 7259 23310 25830 9195 28100 30980 11020 41310 45580 15220 71560 79 23 0 28200 103600 114800 40880

130 8634 9635 3430 12430 13610 4848 19140 21130 7521 24150 26760 9528 29110 32100 11420 42800 47230 16810 74130 82090 29220 107300 119000 42360
140 9233 10300 3669 13290 14560 5186 20460 22600 8046 25820 28630 10190 31130 34340 12220 45760 50530 17980 79270 87820 31260 114700 127300 45310
160 9831 10970 3908 14150 15510 5524 21790 24070 8570 27500 30500 10850 33150 36580 13020 4B730 53820 19150 84410 93550 33290 122200 135600 48270

160 10420 11650 4147 15010 16460 5862 23120 25550 9095 29170 32360 11520 35170 38820 13810 51700 57110 20330 89540 99 27 0 35330 129600 143900 51220
170 11020 12320 4386 15870 17410 6200 24440 27020 9620 30840 34230 12180 37180 41060 14610 54670 60410 21500 94680 105000 37370 137100 152200 54180
175 11320 12650 4506 16300 17890 6369 25110 27760 9882 31680 35160 12510 38190 42180 15010 56150 62060 22090 97250 107800 38390 140800 156300 55650

180 11620 12990 4626 16730 18360 6538 25770 26500 10140 32520 36100 12850 39200 43300 15410 57630 63700 22670 99820 110700 39410 144500 160500 57130
190 12220 13660 4865 17600 19310 6876 27100 29970 10660 34190 37970 13510 41220 45540 16210 60600 67000 23840 104900 116400 41 45 0 151900 168800 60090
200 12820 14330 5104 18460 20260 7215 28420 31440 11190 35870 39830 14170 43240 47780 17000 63570 70290 25020 110100 122100 43 49 0 159400 177100 63040

210 13420 15010 5343 19320 21210 7553 29750 32920 11710 37540 41700 14840 45260 50020 17800 66530 73590 26190 115200 127900 45 52 0 166800 185400 66000
220 14020 15580 5583 20180 22160 7891 31080 34390 12240 39210 4357D 15500 47280 52260 18600 69500 76880 27360 120300 133600 47 56 0 174300 193700 68950
225 14310 16020 5702 20610 22640 8060 31740 35130 12500 40050 44500 15840 48280 53380 19000 70980 78530 27950 122900 136500 48 58 0 178000 197800 70430

230 14610 16350 5822 21040 23110 8229 32400 35860 12760 40890 45430 16170 49290 54500 19390 72470 80180 28540 125500 139300 49 60 0 181700 202000 71910
240 15210 17020 6061 21910 24060 8567 33730 37340 13290 42560 47300 16830 51310 56730 20190 75430 83470 29710 130600 145000 51640 189100 210300 74860
250 15810 17700 6300 22770 25010 8905 35060 38810 13810 44240 49170 17500 53330 58970 20990 78400 86770 30880 135700 150800 53680 196600 218600 77820

A p p r o x . 1 P S IG In c r e m e n t s

60 70 24 90 100 34 140 150 50 170 190 70 200 220 80 300 330 120 500 600 200 800 800 300
A p p r o x . 5 P S IG I n c r e m e n t s

300 340 120 430 480 170 670 740 260 840 940 330 1010 1120 400 1480 1650 590 2500 2900 1020 3700 4280 1480

2 PSIG or 3% A cc. PSIG or 10% Acc.

ASME Sec. I Steam ASME Sec. VII Air/G as/Steam Valves set under 15 PSIG are not stam ped w ith ASM E Code Symbol.

S T E A M C A P A C IT IES M O D E L 254
LBS./HOUR STEAM 3 3 V i% ACC. © ASME SEC. IV.
O r if ic e J K L M N P
15 P S I G 2016 2880 4470 5640 6800 9990

IM P O R T A N T : K unkle Valve D ivision is not liable for a n y d a m a g e resulting from m isu se or m isapplication of its p rod ucts (see warranty).

8222 B lu ffto n Road

MKUNKLE Valve Division

B o x 1740
F ort W a y n e , In d ia n a 46801-1740
219-747-1533
FAX 219-747-7958

REV. 11/93
 THIS DRAWING IS PROPERTY OF C LEAVER-BRO O KS DIVISION
IT IS SUBJECT TO CHANGE WITHOUT NOTICE, AND IS NOT TO BE COPIED OR USED IN ANY WAY DETRIMENTAL TO THE COMPANY.
SUGGESTIONS AND INFORMATION CONTAINED ON THIS DRAWING ARE NOT INTENDED TO SUPPLANT LOCAL CODES.

GJ
 2 1

CJ

UJ
>
cr
<
LlI
q:

CD

NTAINER CORP.
--- S ---
cale

NTA CLARA, CALIFORNIA

N . T . S .
C le a v e r s ^ B r o o k s “SS2?
1 2 /9 /9 4 ON, MUfc-CHEM INC. MUMJKEE.WBCONSM SIRMFORO.ONT
9401468 D&WN
D . M. DIMENSION DIAGRAM
SIZE D L D H -1 18 BOILER, L H .

SHT 01 OF 01
B drwg. NO. W -0 0 3 8 1 3RV 00
 CLIENT: Container Corp.
JOBSITE: Santa Clara, CA
PROJECT NO. CU9401468

FOREWORD

This instruction manual is provided to supply general information on the installation, operation,

and maintenance of this burner system. However, not every contingency of installation,

operation, and maintenance can be covered in any manual. Therefore, the Owner’s operating

and maintenance personnel should also be guided by Generally Accepted Industry Practice in the

installation, operation, and maintenance of this burner system.

CLEAVER BROOKS
 CLIENT: Container Corp.
JOBSITE: Santa Clara, CA
PROJECT NO. CU9401468

TABLE OF CONTENTS

SECTION CONTENTS

1 GENERAL COMBUSTION PRINCIPLES

THEORY OF COMBUSTION
PRINCIPLES OF NOx FORMATION AND CONTROL
FLAME CONSIDERATIONS FOR OIL FIRING
OIL ATOMIZATION PRINCIPLES

BURNER PRINCIPLES
GENERAL BURNER OPERATION
BURNER DESIGN CONCEPTS
BURNER ENGINEERING PRINCIPLES
SWIRLER DESIGN
THROAT DESIGN
GAS POKER DESIGN
LIQUID FUEL INJECTION DESIGN
GASEOUS FUEL INJECTION DESIGN

BURNER COMPONENTS
AIR REGISTER ASSEMBLY
FUEL CARRIAGE ASS’Y
TCD COUPLING BLOCK ASSEMBLY
TCL COUPLING BLOCK ASSEMBLY
TCD OIL ATOMIZER ASSEMBLY
TCL OIL ATOMIZER ASSEMBLY
ATOMIZER NOZZLE-DUAL FLUID "Y" JET
GAS IGNITOR ASSEMBLY-DYNALITE
GAS IGNITOR ASSEMBLY-STABELITE

4 MAINTENANCE DETAILS AND SCHEDULE

OIL ATOMIZER ASSEMBLY
COUPLING BLOCK ASSEMBLY
SWIRLER
REFRACTORY THROAT
GAS IGNITOR ASSEMBLY (DYNALITE)
GAS IGNITOR ASSEMBLY (STABELITE)
MAINTENANCE SCHEDULE

CLEAVER BROOKS
 CLIENT: Container Corp.
JOBSITE: Santa Clara, CA
PROJECT NO. CU9401468

BURNER INSTALLATION
GENERAL DISCUSSION
WINDBOX FRONT PLATE MODIFICATION
WINDBOX MODIFICATIONS
BOILER FRONT PLATE MODIFICATIONS
BURNER GUIDE RING INSTALLATION
REFRACTORY THROAT INSTALLATION
BURNER INSTALLATION
VIBRATION CONSIDERATIONS

SYSTEMS OPERATIONS
PURGING OF OIL GUNS

SAFETY MEASURES

APPLICATION-SPECIFIC CONSIDERATIONS
WINDBOX BAFFLE ARRANGEMENT

ENGINEERING DATA SHEETS

DRAWINGS - JOB SPECIFIC

CLEAVER BROOKS
 CLIENT: Container Corp.
JOBSITE: Santa Clara, CA
PROJECT NO. CU9401468

SECTION 1

GENERAL COMBUSTION PRINCIPLES

CLEAVER BROOKS
 CLIENT: Container Corp.
JOBSITE: Santa Clara, CA
PROJECT NO. CU9401468

THEORY OF COMBUSTION
Optimum performance of the burner system will be achieved by adhering to the specific
instructions included in this manual. A general understanding of the broad principles of burner
operation is also necessary. This section of the manual has been included for that purpose.

Experience obtained through actual practice in the fireroom is very important, but is complete
only when combined with a knowledge of the theory of combustion, and then applying this
theory to the operation at hand.

The ultimate objective of any fuel burning system is to obtain the maximum amount of heat
(energy) from the smallest quantity of fuel (highest thermal efficiency), while maintaining
required air emission standards. Combustion is the rapid breakdown and recombination of
combustible compounds with oxygen, and the liberation of heat as a result of this process.

The major components of fuel are carbon, hydrogen, and oxygen. Small quantities of other
components, such as sulfur, nitrogen, metals, ash, etc., may also be present. Air is composed
of a mixture of oxygen and nitrogen, with trace quantities of carbon dioxide, water vapor, and
other relatively inert gases. For practical purposes, the trace quantities of inert gases can be
ignored, and the dry air considered to be a mixture of 21% oxygen (entering as 0 2) and 79%
nitrogen (entering as N2) by volume.

Every fuel requires a specific amount of oxygen to complete the reaction of carbon to carbon
dioxide, and hydrogen to water; this amount is referred to as the "stoichiometric" oxygen
requirement. When less than this theoretical amount of oxygen is added, the reaction is said to
be proceeding under substoichiometric conditions. Substoichiometric combustion results in
unburned fuel and the formation of carbon, hydrocarbons, combustibles, and/or carbon monoxide
(CO). However, even perfectly stoichiometric combustion results in some unbumed fuel due to
the inability of any burner system to "perfectly" mix the fuel and air in the combustion process.

Consequently, it is always necessary to add more oxygen (in air) than is "stoichiometrically"
required for combustion. This additional air is called "excess air". It is important that only
enough excess air be added to ensure complete combustion, since any additional air reduces
boiler efficiency. Any gases which are not directly participating in the combustion process (that
is anything but the fuel and stoichiometric amount of oxygen), will absorb heat from the
combustion process. When these gases exit the stack at a temperature higher than the ambient
temperature, they take with them some of the useful heat generated in the combustion process.
This is known as the "dry" stack gas loss which, among other losses, is used in determining the
boiler efficiency.

The total amount of heat liberated during the burning of a fuel is referred to as the "heat of
combustion", and is the sum total of the heats of combustion of each of the component parts of
the fuel. Hydrogen, when combined with oxygen to form water in the burning process, liberates
62,000 BTU’s of heat per pound (68,317 cal/mole). Carbon liberates 14,540 BTU’s per pound
(94,052 cal/mole) when it is converted to carbon dioxide. However, when insufficient oxygen
is present to complete the reaction of carbon to carbon dioxide, carbon monoxide is produced.

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 CLIENT: Container Corp.
JOBSITE: Santa Clara, CA
PROJECT NO. CU9401468

Carbon monoxide formation liberates only 4,440 BTU’s per pound (67,636 cal/mole), ie., a net
loss of heat production of 10,100 BTU’s per pound when compared to carbon dioxide. It is
obvious, therefore, that it is essential to provide sufficient excess air to complete the combustion
process, while at the same time minimizing excess air to maximize boiler efficiency.

Controlling the quantity of excess air to insure complete combustion is, however, only a part of
the requirement. The burner system must also control the method in which the fuel is prepared
for combustion, the speed and direction of fuel injection, and how the fuel mixes with the
combustion air. These concepts form th ; basis of each manufacturer’s particular burner design.

The heating value of the fuel can be expressed either as "higher heating value" or "lower heating
value". Either value is correct and acceptable, but it is essential that the heating value be
correctly expressed. Higher heating value assumes that the water vapor formed during the
combustion process condenses and gives up this heat of condensation to the process; lower
heating value assumes no water vapor condensation. It is most common to express the heating
value as "higher heating value". When this is the case, the boiler manufacturer takes into
account the fact that the water vapor does not "actually" condense by reducing the boiler
"thermal efficiency" accordingly, which is the accepted approach to calculating thermal
efficiency. What is important, however, is that no "double dipping" occur; that is, that a lower
heating value is used, and the boiler supplier also accounts for the same loss in his thermal
efficiency calculations. When this happens, the projected fuel usage is erroneously too high,
resulting in an oversized fuel apply sy cm.

One other important consideration is that even with excess air and adequate mixing, the
combustion process can be prematurely interrupted by flame impingement on the furnace walls
or exit tubes. When this happens, the combustion reactions are slowed or stopped by the
lowering of the temperature in this region, thereby effectively "quenching" any further
combustion. This condition creates the same effects as inadequate air and must therefore be
avoided.

One final factor to be considered when designing any burner system is that any air that does not
enter the furnace through the burner system will result in a loss in efficiency and higher excess
air requirements. Air entering the furnace through overfire air ports, out-of-service burners,
hopper leakage, casing leaks on balanced draft units, penthouse air, and/or windbox leakage will
limit tli . performance of the burner. The usual result of such leakage is that the boiler must
operate at higher-than-expected excess oxygen levels to maintain CO emissions. The burner r
the only device designed to mix fuel and air for the combustion process; any air not entering
through the burner will not be properly mixed, thereby raising the minimum oxygen requireme nt.
Often these other air sources cannot be eliminated, but their quantity can be minimized.
However, the time to consider the impact of these other air sources is during the design phase,
so that their impact on performance can be evaluated.

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 CLIENT: Container Corp.
JOBSITE: Santa Clara, CA
PROJECT NO. CU9401468

PRINCIPLES OF NOx FORMATION AND CONTROL

NOx emissions are one of the primary pollutant concerns from fossil-fuel fired power plants.
The formation of NOx during the combustion of fossil fuels has been associated with two distinct
mechanisms, generally referred to as "Thermal NOx" and "Fuel NOx". An understanding of
the mechanisms involved in the formation of NOx can be used to control NOx emissions through
combustion modifications. Combustion modifications can be implemented via the design of the
combustion system and/or the selection of specific operating conditions. An understanding of
the mechanisms of Thermal and Fuel NOx formation has also been used to develop correlations
of NOx emissions for various burner types, boiler designs and different fuels. These correlations
allow projections of NOx emissions to be developed for a given combustion system.

Thermal NOx refers to the NOx generated by the high temperature reaction of atmospheric
nitrogen and oxygen present in the combustion air. The reaction rate is highly dependent on
temperature, since high energy is required to break the nitrogen molecule’s chemical bond;
thermal NOx formation is primarily controlled by temperature and by residence time of the
nitrogen in the flame zone. The formation of thermal NOx is dependent to a lesser extent on
the availability of oxygen in the flame zone. Because Thermal NOx formation is so highly
dependent on temperature, the flame environment and the furnace geometry can dramatically
affect its formation. Heat reflected back into the flame from refractory covered walls, or high
heat release rates in the boiler (BTU’s per cubic foot of furnace volume), will both tend to
increase NOx formation.

Fuel NOx is formed by the oxidation of organically bound nitrogen in the fuel during
combustion. Fuel NOx formation is less sensitive to flame temperature than Thermal NOx (since
less energy is required to free up the nitrogen atom), but is strongly influenced by oxygen
availability. Since Fuel NOx formation is directly related to the content of organically bound
nitrogen in the fuel, the higher the fuel nitrogen content, the higher the fuel NOx generated. For
combustion of fuel oil, both Fuel NOx and Thermal NOx mechanisms are important. For
natural gas firing, however, only Thermal NOx is formed in any significant quantities, since
natural gas contains negligible amounts of organic nitrogen. Some unusual gaseous fuels can
contain chemically bound nitrogen, such as ammonia, that will form Fuel NOx.

Combustion techniques that are available to reduce NOx emissions include:

(1) low excess air operation

(2) staged combustion (off-stoichiometric firing)

(3) flame temperature reduction:

a) flue gas recirculation.
b) air preheat reduction
c) recirculated flue gas temperature reduction

Low excess air operation limits the total oxygen availability in the combustion zone. It is highly

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 CLIENT: Container Corp.
JOBSITE: Santa Clara, CA
PROJECT NO. CU9401468

effective in controlling Fuel NOx formation for the reasons discussed above, and, to a lesser
extent, Thermal NOx.

Staged combustion involves creating an initial fuel-rich combustion zone, with the remaining air
added downstream to complete combustion. The interesting facet of staged combustion is that,
in the fuel rich zone, NOx is reduced by the limitation of available oxygen as well as by the
lower temperatures that result from the slower heat release. In the fuel lean zone downstream,
however, NOx formation is reduced due to the lower temperatures that result from the higher
amounts of air. Consequently, when compared to premixed, single stage ombustion, the total
NOx formation is educed significantly as the two zones combine and combustion is completed.
Staged combustion can be achieved in several ways, depending on the application. Low NOx
burners, such as the Todd burner, operate by use of near burner zone staging.

Thermal NOx can be further controlled by other means of reducing the overall flame
temperature. One effective technique is the use of flue gas recirculation (FGR). The addition
of flue gas from the boiler economizer or air heater exit to the combustion air acts to decrease
the flame temperature and lower the local oxygen concentration. FGR can have a relatively
minor impact on boiler performance if properly designed, although the increased fan power
required for the recirculation, along with the higher forced draft fan power, must be considered.
It should also be noted that use of flue gas recirculation can result in changes in the superheat
and/or reheat steam tempera ires due to the increased velocity of the flue gas past he tubes
(higher mass flew through the bo» r) and hi er furnace exit temperatures. FGR can also cause
unstable flames if used improperly. If the ilue gas is recirculated directly to the windbox to
combine with the combustion air, less recirculation is possible, due to flame instability, than if
the flue gas is added in the flame zone.

Alternative techniques to reduce flame temperature involve reduced air preheat, reduced
recirculated flue gas temperature, or use of water/steam injection. These techniques, however,
involve substantial loss in boiler thermal efficiency.

The burner supplied achieves low NOx emissions through the use of low excess air, near burner
zone staging, and (when provided) by the addition of flue gas recirculation.

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 CLIENT: Container Corp.
JOBSITE: Santa Clara, CA
PROJECT NO. CU9401468

FLAME CONSIDERATIONS FOR OIL FIRING

Optimum air velocities and proper atomization pressures are required to produce the turbulence
and droplet size necessary for correct air and oil mixing, flame shape, and stability. If
insufficient air is being used, or if the atomization pressure is insufficient, black smoke will form
and the boiler may tend to pulsate or flutter. Under these conditions, the flame will be seen to
swell and assume a dark orange to red color.

An excess of air will cause the formation of white or brown smoke, and, when the flame is
viewed, it will appear to be ragged with sparks appearing at the edges. In particularly bad cases
of high excess air, unburnt oil droplets will be tom away from the main flame and deposited on
the furnace lining and boiler surface. The white or brown smoke is normally the result of a
"chilling" of the flame by the high excess air. It may also be the result of flame impingement
on the walls of the boiler, which similarly results in "chilling" of the flame. A flame that, in
general, appears to have the proper geometry and color, but which exhibits a high level of
sparklers or oil droplets is likely the result of inadequate atomization, or, when steam is the
atomizing media, "wet steam".

When a burner is operated below the lower end of an acceptable turndown range, the flame will
also be ragged in appearance and will lose its normally well-defined shape. White smoke will
be produced as a result of the chilling of the flame by the high excess air, but black smoke may
also be present due to the poor mixing of the oil droplets and the air. Increasing the atomizing
media pressure may help in correcting this condition, but a turndown level will be reached where
no further change in operating conditions will be successful. At this level, the minimum
turndown has been reached for that particular bumer/boiler configuration. Increasing the air
flow will further chill the flame; decreasing the air flow will result in incomplete combustion.
Under such conditions, increasing the fuel flow until acceptable conditions are met may be
necessary.

A principle feature of axial flow burners is that an extremely stable primary flame is formed, and
it is practically impossible to extinguish the flame with high combustion air flow. However, the
fact that the flame does not blow out does not mean that optimum air volumes are being used.
If a continuous flame is not obtained, but rather one that is broken into several different sections
at different lengths from the burner, the air flow should be reduced to reestablish the correct
flame shape.

On first igniting an oil fire, it will generally be necessary to input fuel at a rate in excess of the
aforementioned turndown minimum. This is true because the limits of flammability for igniting
a fuel are much narrower than when the flame has already been established. Burner management
and combustion control systems must be designed to allow discrimination between these "low-fire
light off" and "minimum fire" requirements.

Under normal operating conditions when burning fuel oil there should be no difficulty in
obtaining a very good flame over a fairly wide range of atomizing media pressures. To obtain
the best combustion conditions at normal operating loads while maintaining proper flame

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 CLIENT: Container Corp.
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PROJECT NO. CU9401 8

supervision, the following steps should be performed:

1. View the flame in the furnace. It should not be touching any of the boiler walls
or tubes, and it should be symmetrical around the burner. If the flame can be
viewed appropriately, make sure that it is attached to the atomizer nozzle within
a distance corresponding to 1/2 the swirler diameter, and that it is not pulsing.

2. If all of the conditions in (1) are met, and black smoke is still present, raise the
burner atomizing media flow (i.e., increase absolute or differential pressure) until
no smoke is visible. If this is unsuccessful, raise the burner air flow until the
black smoke disappears. If white smoke is pre? nt, reduce the burner air flow
until the smoke disappears.

3. View the flame in the furnace - it should be of a bright white to orange color.

4. From minimum fire to maximum fire, the flame appearance will generally have
the following characteristics:
a) Minimum Fire to 30% Load
The fire will be a bright yellow with distinct spokes corresponding in
number to the number of atomizer nozzle orifices. The center of the fire
will be clean, and it will be possible to view the primary combustion zone
swirl. The fire will be short and of a diamete-' ^lightly larger than the
r <arl opening.

b) 30% to 60% Firing Rate

Though it will still be possible to distinguish individual atomizer jets, the
center of the fire will have dirty wisps, and the central area will lengthen
considerably. The diameter will also increase somewhat, but not as
significantly as the length. The color of the fire will tend more towards
orange, except for the central area which will appear brownish.

c) 60% to 100% Firing Rate

The outer region of the flame will bend significantly and envelop the
center region. For this reason, the brownish center will no longer be
apparent. The flame length will be only slightly longer than that viewed
in the 30-60% firing rate range. The color will remain a yellowish
orange.

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 CLIENT: Container Corp.
JOBSITE: Santa Clara, CA
PROJECT NO. CU940I468

OIL ATOMIZATION PRINCIPLES

A. VISCOSITY
To efficiently bum fuel oil, the oil must be broken down into very small droplets so that
effective intermixing with the air is possible. To accomplish this, the fuel oil must be
at the proper viscosity to permit thorough atomization. For some fuels, heating is
required to lower the viscosity to a maximum 100 ssu. Once the fuel oil is at the proper
viscosity, it must be atomized in the most effective manner.

Since it is not always possible to establish a definite oil fuel temperature/viscosity

relationship due to the varying chemical composition of the oil, it may be found that the
operator needs to vary the fuel oil temperature until the most efficient combustion is
achieved. Changes in fuel oil supply may also necessitate a variation in temperature to
determine the optimum operational point. However, all oils have a maximum
temperature above which carbonization of the oil occurs; this carbonization can result in
heat exchanger fouling, as well as line and tip pluggage of the atomizer system.

B. STEAM/AIR ATOMIZATION CONSIDERATIONS

For cold start conditions where steam is not available for atomization, dry compressed
air at approximately 80 -100 psig can be used. It is recommended that diesel oil, #1 oil,
or #2 oil be used with air atomization. Bunker C oil may also be used, but it must be
heated to approximately 225 degrees F for effective atomization.

During normal operation (and startup when possible), steam atomization is the preferred
medium. The atomizing steam must be dry. The required final steam pressure over the
entire load range must be field-determined to optimize the burner system. At maximum
load conditions, it is normally desirable to atomize at the highest possible steam pressure
to achieve the smallest droplets. At low fire conditions, however, the optimum steam
pressure is a compromise; high pressure is desirable to provide fine atomization, but it
must be low enough to maintain a stable flame. The final steam pressure is a
compromise between the high load requirements and the requirements at maximum
turndown. The burner is designed for air or steam pressures varying from a minimum
of 80 psig to a maximum of 150 psig.

C. OIL FUEL PRESSURE

The maximum oil pressure should be limited to that pressure which will allow the
maximum firing rate to be achieved. The oil flow control valve will provide the required
oil flow at lower firing rates.

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 CLIENT: Container Corp.
JOBSITE: Santa Clara, CA
PROJECT NO. CU9401468

SECTION 2

BURNER PRINCIPLES

The following section describes the general design and operating principles associated with the

burner. Additional details on each of the major assemblies comprising the burner are discussed

in a subsequent section of this manual.

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GENERAL BURNER OPERATION

Combustion air enters the air register of the burner from the windbox. To provide even
distribution of combustion air the windbox is provided with baffles, which are designed and
located, as a result of a model of the air supply system.

The air register is designed to provided axial flow, with a uniform distribution. Near the exit
of the air register, the air splits into two distinct concentric streams. The air stream passing
through the swirler is referred to as primary air. The swirler imparts a centrifugal spin to the
air, and directs it angularly outward from the burner centerline.

The air passing around the outside periphery of the swirler is defined as secondary air. It
continues a controlled expansion in the throat section of the burner where it reacts with the
unbumed fuel.

The outward spin provided to the primary air results in a low pressure region immediately in
front of the swirler. Consequently, a portion of the combustion gases are drawn from a region
several feet in front of the swirler and recirculated back into this low pressure region. This
internal recirculation of flue gases back into the area in front of the swirler provides flame
stabilization and helps to reduce NOx emissions in the primary combustion zone by reducing the
flame temperature and lowering the local oxygen concentration.

The swirler is sized with respect to the outlet divergent section of the axial flow register to
optimize recirculation and minimize burner pressure drop. The shroud around the swirler
prevents radial flow of the primary air, and also reduces turbulence between the primary and
secondary air streams.

For gas-fired applications, proprietary gas injection methods are employed to assist in further
lowering NOx emissions. The objective of the fuel injection methods is to create regions of fuel-
rich combustion, surrounded by regions of fuel-lean combustion. This patented "cross-sectional
staging" approach is discussed further in other sections of this manual.

In certain applications, a third stream of combustion air is added through a second (dual) air
register, an annular ring surrounding the main register. This air stream is defined as "tertiary
air". It provides further "staging" of the combustion process to reduce NOx, and assists in
shaping the flame.

On applications where extremely low NOx emissions are required, a portion of the boiler exhaust
flue gas may be recirculated and mixed with combustion air, to dilute its oxygen content, thereby
reducing flame temperature and local oxygen content.

Generally, pressure taps are provided for measurement of furnace and windbox pressures. By
connecting these taps, to a differential pressure transmitter or manometer, the total burner draft
loss can be established. This pressure differential is known as the "Register Draft Loss" (RDL).
It is also a measure of the total air flow, which may be essential to the control of the burner
system.

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 CLIENT: Container Corp.
JOBSITE: Santa Clara, CA
PROJECT NO. CU9401468

For gas fired applications, the gas is introduced to the burner system through the gas reservoir
on the fuel carriage assembly, where it flows into each of the several poker pipes. The gas
passes lown the poker pipes, and exits into the furnace through the poker shoes. The poker
shoes a e drilled with several injection orifices, properly sized to provide the correct velocity to
the exiting gas. In addition, the poker shoes are angled such that the gas is directed in
predetermined directions in the furnace relative to the air exit. This angling of the poker shoes
is a key element in providing the proper flame shape and minimum emissions.

For oi' red applications, the oil is introduced through a centrally located oil atomizer assembly.
Od an* atomizing steam or air are maintained as separate streams i side the , xet tube of the
assembly until they are finally mixed at the end of the assembly in the nozzle. At this point, the
steam/air and oil meet in such a way that the oil is "sheared" into small droplets, and injected
into the furnace with the air or steam in an atomized state. The oil atomizer assembly is
designed in such a way that the entire assembly can be removed from the burner for inspection
and maintenance without disconnecting the oil and steam/air lines.

The fuel is initially ignited by the ignitor assembly. This ignitor may be any of a variety of
different types. The ignitor is located near the outside edge of the swirler, and behind it at a
prescribed distance. During the ignition phase of startup, the ignitor provides a small but intense
flame directed inward toward the center of the burner. This intense flame ignites the main fuel.

This completes the discussion *f the gf d design of the burner. Flowever, this overview does

not discuss the more intimate concepts involved in the design of the burner. The next section of
this manual is devoted to these concepts.

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 CLIENT: Container Corp.
JOBSITE: Santa Clara, CA
PROJECT NO. CU9401468

BURNER DESIGN CONCEPTS

The burner is classified as an axial type design, in which the air leaving the burner flows in a
straight trajectory. The air does not swirl in the burner until the primary air contacts the fuel
for combustion. To maximize boiler efficiency while minimizing emissions, this burner operates
with reduced excess air levels and still produces minimal amounts of unbumed combustibles
(CO, hydrocarbons, and unburned carbon). To accomplish this, it is of paramount importance
that the combustion air be delivered in such a way that the air is balanced across any cross
section of the burner. This is accomplished in the following ways:

1) By assuring balanced air distribution at the entrance to the air register via
windbox baffling.

2) By accelerating the air at the air register inlet to a velocity that creates a pressure
differential that tends to further balance the air flow.

3) By designing and installing the burner elements concentrically within the air
register cross section.

4) By providing an air register design that maintains a balanced axial flow.

5) By re-accelerating the air as it is forced to pass through and around the swirler.

Key points that should be emphasized based on the above principles:

1) Swirling combustion air in the air register reduces the performance of the burner.
For this reason it is critical that air swirl at the burner inlet be minimized by
windbox baffling.

2) Although pressure drop is an effective means of assuring balanced air flow at

higher flow rates, its effect at lower air flow rates is reduced, since pressure drop
is proportional to the square of the air velocity. Thus, under high turndown
conditions it is more difficult to maintain optimum burner performance and flame
shape using pressure drop principles only.

3) Burner concentricity is established by both manufacturing/design and field

installation. Therefore, certain field installation parameters should be carefully
monitored, and the tolerances specified in the installation section of this manual
adhered to:
a) Straightness of the boiler and windbox front plates.
b) Alignment of the air register within the refractory throat.
c) Proper installation of the refractory throat, such that the throat is
concentrically located relative to the air register, and is properly shaped.

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 CLIENT: Container Corp.
JOBSITE: Santa Clara, CA
PROJECT NO. CU9401468

The design and orientation of the fuel injection system is provided to assure optimum mixing of
the fuel with the combustion air. In addition, other dimensions and tolerances are particularly
critical. Consequently, several factors must be considered:

1) The fuel injection device (poker shoe, for example) must be oriented in exact
accordance with engineering specifications. Generally this is assured during the
manufacturing stage, but if, for any reason, the device is removed, proper re­
positioning and re-orientation must be carefully monitored.

2) AX' fuel injection devices are located relative to the swirler, which i: in turn,
positioned relative to some readily referenceable and appropriate burner location,
such as the exit edge of the throat. This necessitates that the swirler be in proper
position as a stalling point. Should the burner be remove for any reason, such
as for throat replacement, it is essential that these dimensions be reestablished.

3) It is important that the extreme furnace face of the oil atomizer nozzle be located
relative to the swirler in exact accordance with design requirements. Adjustment
of this position is discussed in the Installation Section of this manual.

4) The importance of a properly installed refractory throat cannot be

overemphasized. T1 *throat must be installed in accordance with the engineering
drawings supplied ft this application, particularly with regard to the size of the
entrance and exit diameters, and the throat depth. This will assure the proper
throat expansion angle, which is a key parameter in the proper operation of the
burner. A throat former is supplied with each installation to assure these
dimensions, but care must be taken to assure that the throat former is not distorted
or moved during the refractory installation process.

With regard to the final appearance of the refractory, it is essential that the exit
edge of the throat be sharp (a rounded edge is unacceptable) and hat a smooth
contour be achieved. Generally, a high alumina plastic or castable refractory
designed for temperatures in excess of 3000 degrees F. is recommended.
However, since technological advances in refractory materials are constantly being
made, it is impractical to mandate specific types or mi ufacturers of refractory.
It should, however, be kept in mind that radiant tempt atures of the flame may
be as high as 4000 degrees F., and, although some cooling of the refractory may
take place as a result of the combustion air, the refractory must be suitable for this
environment. The burner is designed to prevent any significant direct flame
impingement on the refractory.

Regarding curing, the instructions from the refractory supplier should be

followed. As a general rule, a 24 hour cure period is desirable commencing
within a few hours of installation of the refractory (unless an air curing period is
recommended by the manufacturer.)

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 CLIENT: Container Corp.
JOBSITE: Santa Clara, CA
PROJECT NO. CU9401468

GENERAL BURNER ENGINEERING PRINCIPLES

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JOBSITE: Santa Oara, CA
PROJECT NO. C J9401468

SWIRLER DESIGN

Because the swirler is designed to both accelerate and impart spin to the air, it serves as a
restriction to the air flow. For this reason, the combustion air divides in the area behind the
swirler, with a portion passing through the swirle* (primary air), and the remainder passing
around the outside of the swirler (secondary air). The quantity of air that passes through each
area is dependent on the resistance "coefficients" of each area (for example, the degree of swirl
required, the open area within the swirler, etc.) as well as the size of the swirler in relation to
area between the swirler and burner exit. The specific split between primary and secondary air
is predetermined in the engineering phase based on the flame geometry considerations.

The primary air is imparted with a swirl, which is a function of the swirler blade angle. This
swirl gives the air a trajectory which is outward from the centerline of the burner. This outward
trajectory creates a low pressure region immediately in front of the swirler; this low pressure
region is referred to as the PCZV (Primary Combustion Zone Volume). The size and shape of
the PCZV is dependent on the swirler blade angle, the swirler diameter, the swirler pressure
drop, and the geometry of the throat.

The important feature of the PCZV is that it promotes recirculation of gases from the region
surrounding the PCZV back into the PCZV. The strength of the recirculation is a function of
the pressure drop across the swirler, which is referred to as the SDL (Swirler Draft Loss). The
size and recirculation strength of the PCZ\ are critical to the flame stability (the fire’s ability
to remain "anchored" at a location in close proximity to the fuel injection element), and to the
ability to retain the desired flame shape.

The other key flame stability factor is the fuel/air ratio (stoichiometry) in the PCZV. This is
controlled in part by the recirculation strength, but to a more significant degree by the manner
in which the fuel is directed into the PCZV. Instability can result from the following causes:

1) Inadequate PCZV size, caused, for example, by a swirler that is too small.

2) Insufficient recirculation caused by inadequate SDL. Inadequate SDL can be

caused by improper swirler sizing, improper burner sizing, or positioning of the
swirler too far forward (toward the furnace) ?i the throat.

3) Loss of recirculation into the PCZV. This can be caused by the following:

a) Too much fuel being delivered into the area in front of the swirler; this
tends to fill the PCZV with combustion gases and, as a result, discourages
recirculation from outside the PCZV.

b) Directing excessive amounts of other fluids into the PCZV, such as oil
atomizer cooling steam (when gas is being fired).

c) Improper selection or design of the oil atomizer, whereby the oil droplets

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JOBSITE: Santa Clara, CA
PROJECT NO. CU9401468

form a "screen" or full cone directed outward from the center of the
atomizer. This curtain effect, as opposed to discrete atomizer jets which
allow air to pass between the jets, effectively blocks the ability of the air
to recirculate back into the PCZV.

In general, most of the above conditions will be taken into account in the design phase of the
project, provided that proper information is available at the design phase. The concepts are
important to understand, however, because they emphasize the critical nature of proper
installation, maintenance, operation, and replacement part selection. In particular, swirler
position and concentricity relative to the throat, as well as position of the fuel injection element
relative to the swirler, are of major concern. Because of the importance of these factors in
achieving overall burner performance, extreme care should be taken whenever burner
components are removed and reinstalled, caution should be exercised if burner operating
conditions change, and off-design revisions to the system should be avoided. Finally, atomizer
cooling steam/air should be maintained at minimum levels.

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PROJECT NO. CU9401468

THROAT DESIGN

The basic function of the throat is to contain and shape the expansion of the combustion process
to an exacting degree. The following factors are carefully considered in the design phase:

A. If the throat is too short, the secondary air may expand too quickly at the throat
exit. This may adversely affect the PCZV size, recirculation energy, and fuel
trajectory, all of which will impact the flame stability and geometry.

B. If the throat is too long, normal combustion process expansion will be confined.
This will have adverse effects on the PCZV and fuel trajectories, and will also
tend to increase the burner draft loss.

C. If the throat angle is too small, the effect on performance will be similar to (B)
above, although the burner draft loss might not be adversely affected to the same
degree.

D. If the throat angle is too large, the effect on performance will be similar to (A)
above.

Gradual a,’ l controlled expansion of the combustion air from the air regisf to the ti at exit
is a keystone to achieving optimum performance. Consequently, throat integrity is or utmost
importance. Maintaining a smooth contour over the entire throat surface, providing a sharp edge
at the throat exit during refractory installation, and eliminating unacceptable refractory "steps"
from the throat exit to the furnace wall are all important.

"Tube nests" surrounding, and buried into, the throat area should be covered with at least 2
inches of refractory. To assure that the refractory is properly supported, studs should be
provided on these tube nests, and/or the proper number and type of refractory anchors should
be installed.

In summary, the design and installation of the throat is extremely critical to the operation of the
burner system. That design takes into consideration the boiler width, height, and length, as well
as the location of the burner centerline in the boiler, to achieve a flame that does not impinge
on the boiler tubes.

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 CLIENT: Container Corp.
JOBSITE: Santa Clara, CA
PROJECT NO. CU9401468

GAS POKER DESIGN

Poker gas injection is a means of delivering fuel via multiple injection elements (note: "spuds"
or "canes" are other terms used in the industry to describe the same approach). The point of
initial fuel injection into the combustion air defines the location of the gas injection, rather than
how, or by what means, the gas is conveyed to that point. The gas reservoir is on the front of
burner front plate and distributes fuel to the poker pipes.

Permanently affixed to the gas reservoir are the poker pipes. The number, size, and arrangement
of these pipes is determined based on the specific application performance requirements.
Attached to the poker pipes are the poker shoes. These shoes are removable for maintenance,
but they are fixed with set screws in a given longitudinal position and orientation relative to the
swirler.

The orientation and position of these poker shoes are critical to the successful operation of the
burner with regard to flame geometry and emissions. Whenever the poker shoes are removed,
they must be carefully reinstalled in accordance with the design requirements.

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 CLIENT: Container Corp.
JOBSITE: Santa Clara, CA
PROJECT NO. CU9401468

LIQUID FUEL INJECTION DESIGN

The key to understanding the operation and maintenance of liquid fuel combustion systems is to
recognize that the final objective of the injection process is to deliver the liquid fuel to the
combustion zone in a state that closely approximates that of a gaseous fuel. This objective can
only be approached with proper atomization of the liquid. Atomization quality is generally
defined in terms of "spray quality", which is a measure of the percentage of droplets whose
diameter is within some specified micron (millionths of an inch) range. It is important to
understand that a small difference in droplet diameter can have a significan' impact on injection
a v t combustion performance. This is true because it is the mass of the d plet, rather than its
diameter, that controls the performance of the system. For example, a ,b0 micron droplet is
only 20% larger in diameter than a 150 micron droplet. However, the mass (volume) of the 180
micron droplet is 72% greater than the 150 micron droplet, since mass is directly related to the
cube of the diameter. Consequently, 72% more droplets are injected when the mean droplet size
is 150 microns rather than 180 microns.

Atomization is accomplished by the use of an atomizing media (dual fluid) to assist the
atomization. Spray quality depends on the degree to which the liquid droplets are sheared from
the main fuel supply. Spray quality is dependent not only on the design of the atomizer, but also
on the viscosity of the liquid and the velocity of the atomizing media as it contacts the liquid
stream. No single atomizer can provide a uniform size of droplets. At an cross section of the
jet, there ill be regions f large, closely spaced droplets, along wit’- fine, well- mattered
droplets. For this reason, . is necessary to define the spray in terms of ‘ mean" or "average"
droplet characteristics.

In addition to spray quality, the performance of the burner is also affected by the velocity of the
droplets leaving the atomizer, as well as the degree to which the droplets interact with air in the
PCZV, secondary air, and tertiary air zones as the droplets pass through them.

Based upon the above factors, the following considerations apply:

A. PCZV Effects
As the fuel jets exit the atomization nozzle, some of the finer droplets recirculate to the
PCZV. This is necessary to assure that a sufficient quantity of fuel is available to
stabilize the core flame. However, excessive recirculation of the fuel wi;l produce too
much flue gas in the PCZV, and can discourage recirculation of the combustion gases
from outside the PCZV. Excessive recirculation of fuel can be caused by fuel trajectories
which are too close to the burner centerline, o: by excessive atomizatio- producing
droplets which are too fine. Recirculation of gases to the PCZV can also be inhibited if
the atomization produces a "curtain" of fuel droplets which do not allow the air to pass
through the jet streams, since it is essential that "lanes" or "channels" be present between
the jets for air to pass and react with the fuel downstream in the furnace. This "curtain"
phenomenon is known as "screening", and can be avoided with proper design of the
atomizer.

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 CLIENT: Container Corp.
JOBSITE: Santa Clara, CA
PROJECT NO. CU9401468

B. Jet Bending/Flarae Geometry Control

Proper design of the burner will minimize flame impingement on the heat transfer
surfaces, as well as provide for complete reaction of the fuel prior to its exiting the
furnace. To accomplish this, the burner must be carefully designed based upon each
specific application. For liquid fuels, the geometry of the atomization nozzle orifices is
the predominant major design consideration. In addition, the degree of atomization is
important, since this will affect the size and velocity of the droplets, the combination of
which determines how far the droplets penetrate toward the heat transfer surfaces.

C. Specific Gravity and Viscosity Considerations

Specific gravity of the liquid, which is a measure of the weight of the liquid as compared
to water, is important in terms of calculating pressure drop of the fluid in the system.
The higher the specific gravity, the higher the pressure drop through the system.
Improper consideration of specific gravity can result in inadequate or excessive flow of
liquid through the atomizer.

Viscosity of the fluid is a measure of the "thickness" or "stickiness" of the fluid, and is
measured in Sayboldt Second Universal (SSU) units. The higher the temperature of a
liquid, the lower the viscosity. The viscosity of water is about 32 SSU. Distillate fuels
(kerosene, diesel, number 1 and number 2 heating oils) do not require heating to obtain
the proper atomization viscosity. The heavy fuels (number 4, 5 and 6 and bunker C) do.
In general, it is necessary that the heavy fuels fluid delivered to the burner have a
maximum viscosity of 100 SSU to allow proper atomization and reasonable pressure drop
(higher viscosities result in higher pressure drops). For heavy fuel oils, to maintain the
viscosity, piping must be adequately insulated. In addition, a recirculation system must
be provided or heat tracing must be provided.

D. Fuel Heating Value

The design of the burner is based upon a fuel with a specified heating value (BTU/# or
BTU/gal). Significant changes in heating value will affect the quantity of fuel that is
required to be injected through the atomizer to achieve the desired boiler output. It is
recommended that a sample of the liquid fuel be taken periodically from a point in the
supply system in close proximity to the burner, and that it be analyzed for its
constituents. It is not uncommon, for example, that the steam or hot water often used
to preheat the fuel in an indirect heat exchanger will seep into the fuel due to failure of
the heat exchange system. The analysis will spot this problem. Changes in fuel quality
will also be evident if the quantity of fuel required to generate the same steam output
increases, all other factors being unchanged.

One other special precaution should be noted when determining the fuel heating value for
design purposes. The heating value of the fuel can be expressed either as "higher heating
value" or "lower heating value". Higher heating value assumes that the water vapor
formed during the combustion process condenses and gives up this heat of condensation
to the process; lower heating value assumes no water vapor condensation. It is most
common to express the heating value as "higher heating value".

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 CLIENT: Container Corp.
JOBSITE: Santa Clara, CA
PROJECT NO. C7T9401468

E. Fuel/Air Mixing
For proper combustion, it is essential that the liquid droplets intersect with the
combustion air. The angle at which this intersection takes place is important to provide
optimum mixing, turbulence, and combustion of the droplets, while still not impacting
other design requirements. Again, the design of the atomization nozzle is critical in
achieving this objective.

F. Jet Expansion Angle (JEA)

A freely expanding caseous jet always expands with a 23 degree included angle. Liquid
j- however, are not so predictable. Atomization quality and the design of the fuel
ii ction orifices have a major impact on the spray geometry. Therefore, one should be
cautious not only about atomization adjustments, but also about atomizer nozzle cleaning
procedures which could alter the injection orifice sizing or the sharp edge on the orifice
exits.

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 CLIENT: Container Corp.
JOBSITE: Santa Clara, CA
PROJECT NO. CU9401468

GASEOUS FUEL INJECTION DESIGN

The proper design of a gaseous fuel injection system requires specific information about the fuel
characteristics and site conditions to allow the designer to establish the system pressure drop and
required fuel flow. It is critical that these parameters be carefully established in the design stage
to allow the final design to operate properly.

To design any gaseous fuel delivery, metering, and injection system, there are six major
parameters that must be established to determine the total gas flow and density of the flowing
gas:
1) Gas specific gravity at standard conditions
2) Gas temperature at the burner inlet
3) Elevation at the burner inlet
4) Gas pressure at the burner inlet
5) Fuel heating value
6) Total fuel heat input
7) Fuel Analysis

Specific gravity is a ratio of the density (weight per cubic foot) of the gas at standard conditions
(normally 60 degrees F., 14.70 psia) to the density of air at standard conditions. Since the
density of air at standard conditions is .0766 #/scf, the density of any gas at standard conditions
can then be established by multiplying the specific gravity of the gas times .0766. Correction
factors can then be applied to this "standard density" to account for elevation, temperature, and
gas pressure at the inlet to the burner.

The heating value of the fuel can be expressed either as "higher heating value" or "lower heating
value". Either value is correct and acceptable, but it is essential that the heating value be
correctly expressed. Higher heating value assumes that the water vapor formed during the
combustion process condenses and gives up this heat of condensation to the process; lower
heating value assumes no water vapor condensation. It is most common to express the heating
value as "higher heating value".

Once the general design information discussed above is accurately established, the gaseous
supply, throttling, and injection system can be designed. A certain amount of the total pressure
drop will occur in the lines that supply the final injection device (poker shoe, for example).
Therefore, it is essential that the original design information be accurate, since pressure drop
increases approximately as the square of the "actual" flow. For example, if the required gas
flow is 20% higher than anticipated in the design stage, the pressure drop would increase by
44%; the injection system could be "starved" under these conditions. This would require a
proportional increase in supply pressure to achieve the required gaseous fuel flow. The
importance of proper selection of initial design parameters is apparent from the above example.

In addition to the requirement to establish the proper fuel flow to meet heat input requirements,
fuel flow also establishes the amount of air "induced" with the fuel. The burner is not designed

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 CLIENT: Container Corp.
JOBSITE: Santa Clara, C A
PROJECT NO. CU9401 8

to premix air and fuel, but rather to induce air into the moving gas stream by "jet pump" action.
The quantity of air induced at some specified distance from the point of injection into the boiler
depends on the flow rate, specific gravity, and velocity of the gas at that point. This depends
not only on the design of the injection element, but also on the correct specification of design
parameters.

Optimum mixing of the combustion air and gaseous fuel is necessary to assure complete
combustion of the fuel in the available residence time. Mixing is improved if the fuel is injected
at some angle relative to the primary and secondary air. The swirler provides this angle and
mixing for the primary air. However, the bulk of the air enters as secondary and (if supplied)
tertiary air. This air enters in a line essentially parallel to the burner centerline. Therefore, to
achieve proper mixing of fuel with air in this region, the angle of injection of the fuel relative
to these air streams is critical. In addition, the direction of fuel injection from each poker shoe
is important in creating "fuel-rich" and "fuel-lean" zones ahead of the burner to minimize NOx
formation. Thus, it is apparent that the design of the injection system, j rticularly the angle of
injection of the fuel from each of the poker shoes (which may be different for each poker shoe)
is very important in achieving proper performance and minimum emissions.

One other factor that must be considered is "jet bending". As the fuel is projected outward from
the injection device, it will tend to "bend" the combustion air stream outward. Jet bending is
a key consideration in controlling flame shape, and is particular^ important in retrofit
applications where the burner flame shape must be tailored to the boil' configuration. Under
these circumstances, t ie design of the injection system often requires a compromise between
emissions and flame shape.

In summary, the design of an optimum gas injection system requires care in the specification of
the original design parameters, careful consideration of the boiler geometry, and empirical
experience in the effects of various injection devices.

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 CLIENT: Container Corp.
JOBSITE: Santa Clara, CA
PROJECT NO. CU940I468

SECTION 3

BURNER COMPONENTS

CLEAVER BROOKS
o
 CLIENT: Container Corp.
JOBSITE: Santa Clara, CA
PROJECT NO. CU9401468

AIR REGISTER ASSEMBLY

The air register assembly is a fabricated steel assembly, and is comprised of the following major
components:
1. Front Plate
2. Radiation Flange
3. Primary/Secondary Air Register
4. Tertiary Air Register

1. FRONT PLATE
The front plate forms the structural attachment basis of the assembly. It is a steel plate
with an open central diameter to which the sprayer carriage assembly (discussed later) is
mounted. Four equi-spaced air sleeve spacer bolts are mounted around the front plate
rear face. The air register front plate mounts directly to the windbox front face via a
series of equi-spaced holes around the front plate. Gasketing material between the
register front plate and the windbox front face provides the necessary air seal to prevent
leakage from the windbox.

2. RADIATION FLANGE
A steel radiation flange is provided to shield the burner front from the thermal radiation
of the flame. The radiation flange is supported by the four spacer bolts, which pas s
through the radiation flange and are attached to the burner front plate. The radiation
flange is held in position by welding to these bolts. The dimension from the radiation
flange to the air register is a fixed dimension for any application.

3. PRIMARY/SECONDARY AIR REGISTER

The primary/secondary air register is a fabricated steel assembly.

The air register is mounted to the front plate by the four spacer bolts noted above. These
are secured to the flange of the air register by welding.

4. TERTIARY AIR REGISTER

The tertiary air register assembly is supplied as an integral part of the burner register
assembly, rather than as a separate piece. The air sleeve of the burner register provides
the internal surface of the tertiary air annulus. The outer portion of the annulus is
provided by the burner guide ring which is a rolled steel assembly.

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 CLIENT: Container Corp.
JOBSITE: Santa Clara, CA
PROJECT NO. CU9401468

FUEL CARRIAGE ASSEMBLY

The fuel carriage assembly serves two purposes. The first is to provide a support mechanism
for a number of burner components; the second is to act as a fuel distribution point for the fuel
gas pokers.

The main portion of the fuel carriage assembly is a large cylindrical gas reservoir concentrically
mounted in the center of the air register assembly. A hub located in the center of the carriage
assembly, supports and positions the oil atomizer assembly.

The fuel carriage assembly is provided with a mounting flange which is bolted to the air register
assembly front plate. A ceramic gasket placed between these two mating parts provides an air­
tight seal when they are pulled together. The fuel carriage assembly is removable for
maintenance if access to the furnace side of the burner is limited or problematic.

Six concentrically mounted sight tubes pass through the gas reservoir and surround the center
hub. These tubes are used as observation apertures and/or flame scanner ports. Generally, only
two of these ports are used for observation. Tubes not required are fitted with blank cover
plates. An additional tube, located closer to the center of the assembly, is used to support the
ignitor assembly. In addition, the assembly is also provided with swivel mounts (bolted to the
sight port) or flame scanners; for many applications, only one flame scanner is required for the
if itor. However, if multifuel firm; is required, or if it is desirable ,.o provide separate scanners
for the ignitor and main fuel, two scanner swivels are provided.

A spun air cone is welded to a spectacle plate, which is, in turn, welded to the sight tubes and/or
poker tubes. This arrangement maintains a predetermined gap between the fuel carriage
mounting flange and the entrance to the air cone to allow a fixed amount of cooling air to pass
inside the cone.

A positioning stud is welded to the outside of the gas reservoir. The jacket tube assembly is
provided with a mating positioning tab, which fits over this stud. The position of the swirler
within the air register assembly is adjusted by moving the positioning tab forward or backward
over the stud. When the swirler is properly positioned, the jacket tube assembly is locked in
place with the bolts on either side of the tab.

The gas fuel poker pipes is an integral part of the fuel carriage assembly. The poker shoes are
provided as separate assemblies which are mounted on the end of the poker pipes and held in
position on the pipes with a small bolt provided on the poker shoe assembly. A predrilled hole
is provided in the poker pipe; with the bolt threaded into the poker shoe hole, the poker shoe will
be properly positioned.

The multivane air swirler is manufactured from heat resisting stainless steel. The vanes are
designed to give the air a clockwise swirl in the direction of the airflow. The vanes are welded
between an outer shroud and a steel hub. The steel hub is bolted to the end of the jacket tube
through three equi-distant holes.

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 CLIENT: Container Corp.
JOBSITE: Santa Clara, CA
PROJECT NO. CU9401468

Four equi-spaced centralizing guides are welded to the inner hub diameter. Their purpose is to
centralize the oil gun assembly in the swirler inner hub when oil firing is in use.

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 CLIENT: Container Corp.
JOBSITE: Santa Clara, CA
PROJECT NO. CU9401468

TCL COUPLING BLOCK ASSEMBLY

The oil injection assembly is comprised of two complementary subassemblies, which, when
mated together form the complete unit. These subassemblies are the coupling block assembly
and the oil atomizer assembly.

The coupling block assembly, is threaded onto the jacket tube, which is located in the center of
the fuel carriage assembly. The coupling blo< k assembly is provided complete with ball valves,
interlock handle and mi hanism, interlock pi and an integral gas flap.

The complete coupling block assembly is located on the jacket tube assembly to provide the
correct insertion of the oil atomizer assembly. The proper method for attaching the coupling
block assembly to the jacket tube assembly is to thread the coupling block onto the jacket tube
until the oil atomizer projects through the swirler as required. Once set, the locknut on the jacket
tube should be tightened against the coupling block to secure it in place.

The final setting of the coupling block and jacket tube are determined during the initial startup,
and should not be altered in service. These two dimensions are extremely critical, since they
determine the position of the swirler and oil gun in the air sleeve and throat. If incorrectly
positioned, performance and emissions will be affected.

Where the jacket tube enters the fud carriage hub, a collar around the jacket tube ' located
against the hub by three locking hub screws equi-spaced around the collar circumference to form
a gas-tight seal.

The gas flap is an integral part of the coupling block assembly. It is attached to a shaft inside
the coupling block above the atomizer insertion hole. The shaft is extended through one wall
of the coupling block for the attachment of an external counterweight.

On inserting the oil atomizer assembly, the gas flap will rotate to a horizontal position. On
removal of the oil atomizer assembly, the counterweight will ensure that the gas flap moves
down to close the oil atomizer assembly insertion hole, thus preventing the escape of furnace
gases.

Two (2) 1" diameter safety interlock ball valves with PTFE seats and seals are fitted into the
coupling block where the oil and steam lines enter the coupling block top face. They are
connected by an operating linkage to the interlock assembly which opens and closes the valves.

The interlock assembly, is designed to ensure that the oil and steam feed lines to the oil atomizer
assembly are closed before the oil atomizer assembly can be removed. It is comprised of the
stirrup-shaped operating handle welded to the operating rod. The operating rod moves
horizontally through a bracket and sleeve on the upper face of the coupling block.

Fhe operating rod is located in the rod locating sleeve by a projecting guide pin attached to the
rod. The guide pin slides in a horizontal groove cut in the sleeve length. Also attached to tit;

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 CLIENT: Container Corp.
JOBSITE: Santa Clara, CA
PROJECT NO. CU9401468

operating rod is a yoke, which is connected by operating links to the ball valve actuating stems.

The front cover web of the operating handle is extended downward to cover the oil atomizer
assembly securing bolt, thus requiring the handle to be turned 90 degrees (into a locking
position) to remove the securing bolt.

When the operating handle is pulled out, the yoke and operating links close the ball valves. In
this position, a vertical locking groove in the locating sleeve, cut at right angles to the sleeve
length, aligns with the guide pin to allow the operating handle to be rotated through 90 degrees.
This locks the valves in the closed position. As the operating handle extension is thus rotated
and locked, the oil atomizer assembly securing bolt will be accessible for removal.

The automatic safety interlock is to prevent the interlock mechanism discussed above from being
re-selected to the "valves open" position when the oil atomizer assembly is removed.

When the oil atomizer assembly securing bolt is removed, the spring automatically moves the
safety interlock shaft through the locating sleeve and into a groove cut in the operating rod. This
locks the handle in position with the valves closed until the oil atomizer assembly securing bolt
is reinserted.

When the oil atomizer assembly securing bolt is refitted into the assembly, the interlock cone
and safety interlock shaft are pushed down by the oil atomizer assembly securing bolt bearing
against the cone and retracting it against the spring pressure. This unlocks the operating rod to
allow the handle to be rotated 90 degrees and pulled back to open the ball valves.

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 CLIENT: Container Corp.
JOBSITE: Santa Clara, CA
PROJECT NO. CU9401468

TCD ATOMIZER SAFETY COUPLING

The atomizer safety coupling (or safety shut-off device) has a two-fold purpose. It is fitted with
a clapper (internal check valve) whicn closes when the atomizer is removed. This prevents the
flow of furnace gases out into the fire room when the atomizer is removed from the air register.

The device is also fitted with two spring loaded ball checks, one for oil and one for steam. This
safety feature is designed in such a way that he ball checks seat efore the atomizer is
completely uncoupled. It also seals off both oil and steam flow before the atomizer is completely
coupled.

Atomizing steam and oil can be supplied from either side of the assembly. Making a piping a
simple matter to suit field conditions. Both oil and steam connections are standard 3/4” taper
pipe thread. The housing is designed for a 450 psi working pressure and a 600 psi hydrostatic
test.

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 CLIENT: Container Corp.
JOBSITE: Santa Clara, CA
PROJECT NO. CU9401468

TCL OIL ATOMIZER ASSEMBLY

The oil atomizer assembly is a removable assembly which directs the steam and oil to the
atomizer nozzle for atomization. When the oil atomizer assembly is assembled to the coupling
block, the steam and oil tubes are located inside the jacket tube and the atomizer projects through
the swirler inner hub. The atomizer tubes are located with spiders inside the jacket tube.

The oil atomizer block is a machined steel block. It is designed to receive the atomizer tubes,
and also to receive and direct the oil and steam flows from the coupling block to the atomizer
tubes. It has two transfer ports complete with transfer spigots and "Metaflex" sealing rings
bored into its mounting face. These ports align with the coupling block oil and steam ports. A
stirrup shaped handle is welded to the atomizer body block for removing and inserting the
assembly.

A socket headed Allen bolt secures the oil atomizer assembly to the coupling block. The bolt
is fitted through the oil atomizer body block, and held captive in the block by a retaining washer,
which is welded to the bolt on the mating face side. The collar also acts as an extractor during
atomizer assembly removal; as the Allen bolt is loosened, the collar is forced against the
atomizer assembly block, pulling it away from the coupling block.

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 CLIENT: Container Corp.
JOBSITE: Santa Clara, CA
PROJECT NO. CU9401468

TCD ATOMIZER

The atomize handle when engaged to the safety coupling, transmits fuel oil from the safety
coupling through the oil tube (inner tube) and steam throught the steam tube (atomizer barrel).

The atomizer barrel and inner tube terminate at the nozzle body. The inner tube is threaded to
the nozzle body and the atomizer handle. The atomizer barrel floats at the handle end where an
O-ring provides a seal for steam. At its o* er end the atomizer barrel is threaded to the nozzle
body. The sprayer plate is securely connected to the nozzle body by means of the mixing
nozzle.

The atomizer barrel is fitted with flats near the nozzle end which fit into the vise bracket to allow
the atomizer to be completely disassembled. A retaining ring at the floating end of the atomizer
barrel holds the barrel in the hand when the tip nut has been removed. The burner wrench is
used to tighten or loosen the nozzle body and mixing nozzle.

The atomizer handle is a bronze casting designed for a working pressure of 450 psi oil or steam,
and a hydrostatic test pressure of 600 psi.

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 CLIENT: Container Corp.
JOBSITE: Santa Clara, CA
PROJECT NO. CU9401468

DUAL FLUID "Y JET" ATOMIZER NOZZLE

The atomizer nozzle, consists of a series of drilled passages which bring together the oil and
air/steam for atomization. The air/steam enters the center of the nozzle and passes into a series
of smaller air/steam holes. The oil enters the nozzle through the outer holes. The oil holes
intersect the air/steam holes near the end of the air/steam holes, and the combined mixture leaves
the nozzle through the exit holes. As a result of the angle and velocity with which the oil and
steam intersect, the oil is sheared off and atomized by the steam at the junction point.

By varying the number of holes, the size of the exit air/steam holes, and the angle of the exit
holes in the nozzle, the correct nozzle may be sized to suit each individual installation.

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 CLIENT: Container Corp.
JOBSITE: Santa Clara, CA
PROJECT NO. CU9401468

GAS IGNITOR ASSEMBLY (DYNALITE)

The Dynalite gas ignitor is a fixed assembly which is mounted on the right hand side of the fuel
carriage front face. The ignitor passes through the fuel carriage assembly and runs through the
length of the burner register. The ignitor described below is operated using natural gas unless
otherwise specified.

The ignitor assembly is comprised of two concentric tubes which project into the air register to
a position one inch behind the air swirler. These tubes form an outer annulus through which the
gas flows, and an inner tube rough which the electrode is fitted. The final 6 inches (near the
air swirler) of the outer tube is formed into a kidney-shaped half tube with its inner diameter
hieing towards the center of the register.

Welded at right angles to the half tube, commencing with the outboard face, and spaced at one
inch intervals, are one inch diameter flame stabilizing discs. Between each pair of discs two
pairs of gas orifices are drilled on a 45 degree spacing with the centerline between the orifices
directed toward the center of the register with the ignitor properly positioned. The orifice sizes
of each pair of orifices is different to provide the proper ignitor flame pattern. In addition, one
single orifice is positioned on the centerline in the space directly in front of the electrode
position.

Where ti ; half tube commences, the end face of the full tube is fitted with a welded end plug,
to which the first stabilizing disc is attached and through which the electrode projects. Two
ground electrodes are fitted on each side of the central electrode, and are welded to the face of
this first stabilizing disc and to each pipe side to form the two spark gaps.

The high tension electrode is a stainless steel rod which is fully insulated from the inner tube by
interconnected ceramic "pink" insulating sleeves fitted inside the inner tube. The first insulator
in the series is a specially designed "white" insulator. An interconnecting insulator mates the
first "pink" and the "white" insulators. The high tension electrode runs through the central
diameter of these insulators. The electrode is threaded at the inlet end, and secured by a special
nut on which the insulated end of the high tension lead wire fits.

The ignitor outer tube is designed in two pieces. From the half tub : to the stabilizing flute end,
die outer tube is a 1" O.D. mechanical tube. From that joint to the; ignitor end body, the outer
tube is fabricated from a 1" schedule 40 seamless pipe. The stabilizing flute is provided on
natural gas ignitors to stabilize the ignitor flame by deflecting the burner combustion air away
from the ignitor flame.

The ignitor end body is fabricated from 1 1/2" hexagon bar, and is threaded at the ignitor end
to accept the 1" outer pipe. The center electrode/insulator assembly enters the block and is
insulated with an "O" ring. The electrode/insulator assembly passes through the block and is
secured in place by a locking ferrule, which grips the "white" insulator as the securing nut is
threaded into the ignitor end body. The gas inlet is an NPT connection welded on the side of
the ignitor end body.

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 CLIENT: Container Corp.
JOBSITE: Santa Clara, CA
PROJECT NO. CU9401468

The entire ignitor assembly is located in the fuel carriage assembly by the front plate mounting
flange, which is welded to the fuel carriage front plate. This mounting flange is extended
through the fuel carriage assembly to provide a guide tube for insertion of the ignitor. The
assembly is then held in place by the air seal, which screws onto the mounting flange, and is
sealed by an "O" ring. The ignitor can then be retracted by loosening the air seal collar without
removing the fuel carriage assembly.

On initial installation, after the final location of the swirler in the fuel carriage assembly has been
established, the ignitor is positioned approximately 1" behind the swirler. The concave portion
of the half tube should point inward toward the center of the burner assembly. A punch or saw
mark should be made on the ignitor to establish the correct orientation and insertion depth for
maintenance.

The burner management system controls the operation of the ignitor during a starting cycle. A
spark generated from a high tension transformer is transmitted via the high tension cable to the
ignitor electrode rod. The spark ignites a metered supply of gas emitting from the ignitor. The
voltage generated from the unit is 6,000 to 10,000 volts.

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 CLIENT: Container Corp.
JOBSITE: Santa Clara, CA
PROJECT NO. CU9401468

GAS IGNITOR ASSEMBLY - STABELITE

The Stabelite ignitor assembly contains the main gas supply line, the electrode, and the stabilizer
assembly at the firing end of the ignitor.

The ignitor assembly is inserted into the burner through the air sealing assembly, which is
mounted to a spacer plate on the fuel carriage assembly. The air sealing assembly consists of
two pieces: (a) a mounting plate that is attached to a the spacer plate using the attachment
screws, and (b) the guide ring, which is threaded onto the mounting plate and held in position
using a set screw. The ealing air line is attached to the mounting plate via a FNPT connection.
With the guide ring sci. ved onto the mounting plate, a slot will be f esent at the inr diameter.
The slot width is determined by the degree to which the guide ring is screwed into the mounting
plate; the proper adjustment must be established during installation and startup to provide
sufficient sealing air to prevent furnace gas escape. During operation, the sealing air slot
provides a positive gas seal for the ignitor assembly.

The positioning of the ignitor assembly relative to the swirler is accomplished with the
adjustment ring. With the adjustment ring loosely attached to the ignitor carrier tube, the ignitor
is first positioned 6 inches behind the swirler. Next, the adjustment ring is slid forward until it
mates with the air sealing assembly. It is attached to the air sealing assembly using Allen
screws, and the ignitor carrier tube is then firmly positioned using two set screws.

The inlet gas line is connected to the ignitor ass*. mbly through a FNPT connection on the Ignitor
block assembly. The gas passes through the ignitor block assembly, and turns l J degrees into
the inner gas pipe. Gas travels down the inner gas pipe, and then splits near the firing end of
tf e ignitor. A portion continues straight through the ignitor into the stabilizer section (discussed
b„low) of the ignitor, mixes with induced air, and is ignited by the electrode to form the main
stabilizing flame. The remainder of the gas is channelled into four gas injector pipes, which
direct the gas outside of the stabilizer assembly to the end of the ignitor. This gas, in
combination with air passing around the pipes, is ignited by the central stabilizing flame to
provide the complete ignition flame. The end of the inner gas pipe terminates in an NPT
connection, to which the stabilizer assembly is attached. The inner gas pipe is positioned inside
the ignitor carrier tube by the pipe support assemblies.

The high tension elect rica onnection is provided on the ignitor block assembly through a FNPT
ink to which the rigid or flexible electrical conduit is connected. The high tension wire is
directed through the ignitor block and emerges from the back side of the ignitor block into the
protective cap assembly. With the cap assembly disassembled, the high tension wire can be
connected to the electrode rod via the "Rajah" connector.

The electrode is directed through the ignitor block, and is contained within an isolator pipe. This
isolator pipe is welded at one end to the ignitor block, and is positioned inside the ignitor carrier
tube by the pipe support assemblies. The electrode rod is provided with insulators down its
entire length; the rod/insulator assembly slides down the inside of the isolator pipe until the end
insulator bottoms out against a collar on the end of the isolator pipe. The electrode rod extends
through the end of this last insulator, and into a slot cut longitudinally in the premix chamber,

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 CLIENT: Container Corp.
JOBSITE: Santa Clara, CA
PROJECT NO. CU9401468

with the electrode terminating at the end of the slot (and premix chamber). This slot is
positioned such that the electrode will be exactly centered in the slot, with a predetermined gap
between the electrode and each half of the slot in the premix chamber; arcing takes place
between the electrode and the slot of the premix chamber. It is, therefore, essential that the
electrode be straight. This can be determined by rotating the insulator assembly, and insuring
that the gap between the electrode and each half of the gap does not vary during rotation. The
gap should be .100 inches, plus or minus .010 inches.

With the electrode properly positioned, the electrode is now held firmly in place by threading
the packing gland nut into the back of the ignitor block. This threading compresses a split
washer inside the ignitor block onto the insulator, thereby locking the insulator (and electrode
rod) in place.

Combustion air is introduced through a FNPT connection on the ignitor carrier tube. The
combustion air passes down the inside of the ignitor carrier tube, and through openings in the
pipe support assemblies. From here, a predetermined amount of air is induced into the premix
chamber by the velocity of gas being injected into the premix chamber, and by the size of the
inlet orifice size in the premix chamber. The remainder of the air passes around the outside of
the premix chamber, and mixes with the gas from the four injector pipes for final combustion.

The stabilizer assembly is factory-installed to the end of the inner gas pipe. It consists of the
premix chamber, an inner cylinder which is attached by webs to the outer premix chamber, the
stabilizer cone, an orifice plug, and a half coupling. The half coupling contains the orifice plug.
The relative sizes of the premix chamber and inner cylinder provides the orifice for metering the
induced air flow into the premix chamber. The entire stabilizer assembly is threaded (by means
of the half coupling) onto the end of the center gas pipe at the factory, with the slot in the
premix chamber properly positioned for electrode insertion; the half coupling is then tack-welded
in place onto the inner gas pipe.

The stabilizer cone is attached by a rod end to the orifice plug located inside the half coupling.
The orifice plug is provided with predrilled orifices to provide the correct amount of gas to the
premix chamber assembly. The stabilizer cone is carefully positioned in front of the premix
chamber to provide stabilization of the inner flame.

With the ignitor assembly properly positioned relative to the swirler, the internals of the ignitor
assembly can be removed from the ignitor carrier tube. The carrier tube is flanged at its inlet
end; this flange is bolted to the ignitor block. For removal of the ignitor, the bolts are removed,
and the ignitor assembly can now be pulled out for maintenance. Should the stabilizer assembly
need to be removed from the inner gas pipe, the tack welds can be cut, and the assembly
unscrewed from the inner gas pipe.

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 CLIENT: Container Corp.
JOBSITE: Santa Clara, CA
PROJECT NO. CU9401468

SECTION 4

MAINTENANCE DETAILS AND SCHEDULE

The following maintenance section of this manual is provided to assist the Purchaser of this

burner in maintaining various components of the burner assembly. However, it is strongly

emphasized that the Purchaser’s maintenance personnel familiarize themselves with the design

and operation of this burner system by reading all other sections of this manual before any

maintenance be carried out on the equipment. In particular, the potential hazards associated with

maintenance of various components of the system should be noted, with special emphasis placed

on review of the "WARNINGS" in the SAFETY SECTION of this manual. All personnel

assigned to maintenance of the equipment should have completed a walkdown of the system,

secured proper clearances, and familiarized themselves with all safety checks and codes.

The details of the maintenance procedures refer to specific components in the major

subassemblies. For details on these components, please refer to the appropriate section of the

"Burner Components" portion of this manual.

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 CLIENT: Container Corp.
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PROJECT NO. CU9401468

OIL ATOMIZER ASSEMBLY

A. OIL ATOMIZER ASSEMBLY REMOVAL

1. Observe all relevant safety precautions in the Safety Section of this manual.

2. Shut off the steam, oil, gas, and pneumatic supply lines as applicable to the
installation.

3. Isolate the electrical supplies to the burner register.

4. Disconnect all steam, oil, and pneumatic lines connected to the coupling block
assembly at their break points, and ensure that they are clear of the assembly.

5. Remove the oil atomizer assembly through the gas flap.

6. Check that the gas flap on the coupling block is in the closed position after
removal.

B. ATOMIZER NOZZLE REMOVAL AND CLEANING

1. Two special tools are required to remove the atomizer nozzle:
a) An oil atomizer adaptor body vice bracket

b) An atomizer nozzle removal wrench

2. The oil atomizer adaptor body vice bracket is a "U" shaped clamp designed to
engage the flats on the atomizer adaptor body. It is recommended that the vice
bracket be permanently attached to a bench. This will allow the oil atomizer
assembly to be held securely during maintenance.

3. Unscrew and remove the atomizer nozzle.

4. Wash the atomizer nozzle in safety solvent, removing any deposits with a bristle
brush. If any of the passages are blocked, appropriately sized soft copper wire
may be used to clean them (hardened metal cleaning tools should not be used).

5. Clean the oil ports first, cleaning them from the rear. Clean the steam ports
second, cleaning them from the front.

6. Blow through the ports with high pressure air to remove any foreign matter.

7. Place the atomizer nozzle in front of a strong light source to ensure final
cleanliness of the atomizer.

8. Check the atomizer orifice wear limits using standard number and/or fraction
drills. The nominal limit of wear is 10%.

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 CLIENT: Container Corp.
JOBSITE: Santa Clara, CA
PROJECT NO. CU94014S8

C. OIL ATOMIZER BLOCK AND TUBE ASSEMBLY CLEANING

1. Wash out the oil and steam passages in the block and tubes with a safety solvent.

2. Blow out the passages with high pressure air to dry ana remove any foreign
matter.

D. ATOMIZER NOZZLE REFITTING

1. Fnsure that the atomizer nozzle and adaptor body mounting faces are clean and
undamaged.

2. Liberally lubricate the threads with a high temperature anti-seize compound.

Failure to use the high temperature compound may result in thread dr ge 0 lg
the next required disassembly.

3. Hand tighten the atomizer nozzle onto the adaptor body. Do not force the nozzle.
If the nozzle does not spin on freely, remove and examine the threads.

E. OIL ATOMIZER ASSEMBLY REFITTING

1. Ensure that the mating faces of the oil atomizer assembly and the coupling b f k
are clean and ser ; :ab'e

2. Open i v gas flap ad insert the oil atomizer assembly.

3. Align trie mating surfaces and tighten the securing bolt.

4. Repeat steps 2-4 in Item (A) above in reverse order to place the atomizer
assembly back in operating condition.

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 CLIENT: Container Corp.
JOBSITE: Santa Clara, CA
PROJECT NO. CU9401468

COUPLING BLOCK

After removal of the oil atomizer assembly detailed in step A of the Oil Atomizer Maintenance
Section, the coupling block assembly maintenance can be carried out.

A. COUPLING BLOCK
1. Check the oil and steam line connection for any signs of leakage.

2. Ensure that all moving parts of the interlock gas flap mechanism are clean and
well lubricated with fine oil.

3. Check to make sure that the safety interlock mechanism is functioning properly.

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 CLIENT: Container Corp.
JOBSITE: Santa Clara, CA
PROJECT NO. CU9401468

SWIRLER

A. SWIRLER MAINTENANCE
The air swirler is cleaned as follows:

1. Remove the three spigotted bolts securing the swirler to the jacket tube.

2. Remove the swirler from the jacket tube.

3. Remove any carbon deposits from the swirler, and thoroughly clean with a wire
brush. Inspect the swirler for damage, distortion, and security of the blades.
Ensure that the welded spigot bolt securing nuts are serviceable. If these
components are found to be unserviceable, they should be replaced.

4. Refit the swirler to the housing tube, ensuring that the swirler igni or orifice is in
the correct position to align with the ignitor.

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 CLIENT: Container Corp.
JOBSITE: Santa Clara, CA
PROJECT NO. CU9401468

REFRACTORY THROAT

A. REFRACTORY THROAT REPAIR PROCEDURES

With the aid of a strong light, and following proper safety precautions, visually check the
refractory throat for damage. If the damage is excessive, the throat should be repaired
as follows:
1. Only a good grade of refractory material should be used. Alumina content of the
refractory should be at least 70%.

2. If the damage is not extensive, the repair may be made with local patching
following the refractory manufacturer’s recommendations. Chip away all loose
material and undercut the firm refractory to give a key for the patch. Tamp the
new refractory into the hole, and level off smoothly after filling.

3. Pack plastic refractory as tightly as possible to give a firm smooth shape. Do not
attempt to add excess water in order to make the material more easily workable.
Normally, the correct constituency is when the material will just stick together if
clasped in the hand.

4. Combustion efficiency is affected if the throat is not formed to the correct shape
and angle. The furnace edge should be even and well defined, since irregularities
in the throat lip and its length can produce unevenness of air distribution,
turbulence, and flame shape.

5. If the damage to the refractory is too extensive to be repaired with local patching,
the following procedure should be employed:
a. Remove all of the throat refractory.
b. In order to ensure accurate shaping of the throat, use the throat formers
provided. The design and use of these throat formers is covered in the
Installation Portion of this manual in the section entitled "Refractory
Throat Installation".
c. Once the new refractory has been installed, remove the throat former and
inspect the refractory. If voids or unacceptable irregularities as defined in
(4) above exist, refer to steps (2) and (3) above.

6. After the refractory has been installed, the burner system must be reinstalled and
started up. The refractory must be cured in accordance with the refractory
manufacturer’s recommendations regarding rate of temperature increase, length
of curing time, and various other parameters.

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 CLIENT: Container Corp.
JOBSITE: Santa Clara, CA
PROJECT NO. CU9401468

GAS IGNITOR ASSEMBLY (DYNALITE)

IT IS ESSENTIAL THAT THE ELECTRIC AND GAS SUPPLIES BE

DISCONNECTED AND ISOLATED FROM THIS UNIT BEFORE ANY
MAINTENANCE
IS C A R R I E D O U T

If the ignitor fails to operate during a start cycle, the following steps should be taken before the
ignitor is removed for maintenance:
1. Ensure that the gas supply pressure is normal.

2. Verily the electric supply to the control panel.

3. Verify the electric supply to the high tension transformer and programmer (if
provided).

With all of these conditions satisfied, probable causes of failure are the following:
1. The insulated electrode is grounded to the body.

2. The electrode is worn out, and the gap exceeds 3/16".

3. The insulated electrode is oily or wet, and sparks a e jumping across to the body.

4. Gas holes on the pilot are blocked by dirt.

5. The high tension transformer is not operating satisfactorily.

6. The programmer is not operating.

7. The strainer is blocked by dirt.

The ignitor assembly may then be removed for cleaning and checking as follows:
1. Before removal, be sure a location mark exists to allow for realignment of the
ignitor at reassembly.

2. Ensure that the gas supply is turned off to the unit, and that the electric supplies
are isolated from the unit.

3. Disconnect the gas supply line.

4. Disconnect the high tension cable at the center electrode.

5. Slacken the knurled head securing nut. Note that, on natural gas ignitors, the

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 CLIENT: Container Corp.
JOBSITE: Santa Clara, CA
PROJECT NO. CU9401468

ignitor and sleeve are removed as one piece by removing the two nuts securing
the mounting sleeve.

6. Withdraw the ignitor assembly from the burner register.

With the ignitor withdrawn from the burner register, the following procedures should be
followed:
1. Clean the assembly with a wire brush, taking care not to damage the electrode.

2. Check to make sure that the gas holes are clear. If they appear blocked, use soft
copper locking wire to facilitate cleaning.

3. On completion, blow through the gas holes with an air supply connected to the
gas inlet adaptor.

4. Check the electrode gaps; they should be 1/8" on each side. The stainless steel
electrode should last for years on intermittent ignitors. However, when the gap
exceeds 3/16", the electrode gap must be adjusted. To accomplish this, the
following steps should be followed:
a. Remove the electrode assembly from the ignitor.
b. Remove the last pink insulator.
c. Remove and discard one of the 1/16" round washers.
d. Reinstall the insulator (the light bend on the electrode is used to hold the
insulators for ease of installation).
e. Reinstall the electrode assembly in the ignitor, and check that the gaps are
now 1/8".

5. Adjustment of the electrode gap can be done twice (two washers). When totally
worn out, the electrode assembly must be replaced.

6. Reassemble the ignitor into the burner register as follows:

a. Attach ignitor to burner register.
b. Check alignment using location mark.
c. Connect high tension cable. Ensure that both ends of the cable are
correctly assembled and secure. Check for signs of deterioration, damage,
and cleanliness.
d. Connect gas line.
e. Turn on gas and electric supplies.
f. Check gas supply for gas leaks at connections.

Once the ignitor is in place and ready to run, the ignitor should be energized. If problems still
exist, the following should be checked:
1. If no flame can be achieved, check the transformer output by holding the high
tension lead at 1/4" from the body. If no sparks are present when the transformer
is energized, do the following:

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 CLIENT: Container Corp.
JOBSITE: Santa Clara, CA
PROJECT NO. CU9401468

a. Ensure body continuity at other points.

b. Check the programmer to assure that the appropriate signals are being
transmitted to the valves and transformers. Check the manufacturer’s
literature, and change the programmer if necessary.
c. Change the transformer. If the problem still exists, change the high
tension lead.

2. If the ignitor lights up, but fails to continue running, the problem could be (a) the
scanner is not reading the flan or (b) the gas pressure supply is varying. These
conditions can be checked as follows:
a. Install a meter on the programmer and verify if the flame signal is within
limit. If the signal is low, slowly rotate scanner angle and check the
signal. Relocate the nipple if necessary. If the signal voltage is still low,
check the scanner with an open flame. If the scanner signal is still low,
change out the scanner.
b. Open the gauge cock and observe the gas pressure with the ignitor started.
If the pressure varies, check the gas pressure regulating valve and supply
line for integrity.

3. If the ignitor runs, but the flame is lazy and yellow, the problem can be (a) low
combustion air supply, or (b) gas pressure is too high. These condemns can be
checked as follows:
a. Ensure that the windbox combustion air pressure is sufficier .
b. Verify the gas pressure. If the pressure is too high, lower the setting of
the pressure regulating valve.

4. If the ignitor runs, but the flame dimension is (a) too long, or (b) too short, the
following can be done:
a. Lower the operating gas pressure to the required pressure switch.
b. Increase the gas pressure by adjusting the pressure regulating valve.

The ignitor sleeve should also be checked periodically for air leakage. If air leaks around the
ignitor or plug (when fitted in place), change the "O" ring as follows:
1. With the ignitor off, disconnect the ignitor system as derailed above

2. Remove the ignitor from the burner register as detailed above.

3. Remove and discard the "O" ring. Replace with a new ”0" ring.

4. Reinstall the ignitor as detailed above.

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 CLIENT: Container Corp.
JOBSITE: Santa Clara, CA
PROJECT NO. CU9401468
GAS IGNITOR ASSEMBLY - STABELITE

IT IS ESSENTIAL THAT THE ELECTRIC AND GAS SUPPLIES BE

DISCONNECTED AND ISOLATED FROM THIS UNIT BEFORE ANY
MAINTENANCE
IS CARRIED OUT

If the ignitor fails to operate during a start cycle, the following steps should be taken before the
ignitor is removed for maintenance:
1. Ensure that the gas supply pressure is normal.

2. Verify the electric supply to the control panel.

3. Verify the electric supply to the high tension transformer and programmer (if
provided).

With all of these conditions satisfied, probable causes of failure are the following:
1. The insulated electrode is grounded to the body.

2. The electrode is worn out, and the gap exceeds 3/16".

3. The insulated electrode is oily or wet, and sparks are jumping across to the body.

4. Gas holes in the orifice plug are blocked by dirt.

5. The high tension transformer is not operating satisfactorily.

6. The programmer is not operating.

7. The strainer is blocked by dirt.

The ignitor assembly may then be removed for cleaning and checking as follows:
1. Ensure that the gas supply is turned off to the unit, and that the electric supplies
are isolated from the unit.

2. Disconnect the gas supply line.

3. Remove the explosion-proof cap, and disconnect the high tension cable at the
electrode. Loosen the electrical inlet connection, and pull the high tension lead
wire through the coupling block.

4. Disconnect the coupling block from the ignitor carrier tube by removing the
securing nuts on the carrier tube flange.
5. Withdraw the ignitor assembly from the carrier tube. Reinsert a replacement
ignitor into the carrier tube, taking care that maintenance personnel are not injured

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 CLIENT: Container Corp.
JOBSITE: Santa Clara, CA
PROJECT NO. CU9401468

by hot furnace gases escaping from the open carrier tube hole during replacement.

With the ignitor withdrawn from the carrier tube, the following procedures should be followed
to repair/maintain the ignitor:
1. Clean the assembly with a wire brush, taking care not to damage the electrode.

2. Check to make sure that the gas holes in the orifice plug are clear. If they appear
blocked, use soft copper wire to facilitate cleaning.

3. On completion, blow through the gas holes with an air supply connected to the
gas inlet adaptor.

4. Check the electrode gaps. The gap should be 1/16" between the electrode and the
slot of the premix chamber on each side. The stainless steel electrode should last
for years on intermittent ignitors. When the gap exceeds 1/16", however, either
the electrode or stabilizer must b replaced. The premix chamber slot is designed
with a 5/16" dimension; the eleurode dimension is 1/8". Measurement of each
dimension will indicated which item requires replacement.

5. If the electrode gaps appear acceptable, the electrode assembly must be checked
for integrity. This is accomplished as follows:
a. .oosen the packing gland nut holding the electrode in f 7 ce on the
coupling block.

b. Remove the electrode complete with the pink insulators. These insulators
are quite tough, but gentle handling should be observed to prevent
breakage.

c. Inspect the electrode for cracked insulators, wetness, and insure that the
rod is not bent at the end.

d. To check for cracked insulators that are not readily apparent visually, a
qualified electrician should place the electrode assembly on a well-
grounded steel table, i Ltach he primary lead of a high voltage ignition
transformer test box to the tip of the electrode, and attach the ground wire
of the transformer to the table. Power can now be applied to the
transformer; any broken insulators will be apparent fron telltale sparks
between insulators jumping from the electrode to the table. Any faulty
insulators will require replacement by slipping all of the insulators off the
rod, and reinserting new insulators in their place. The assembly should
be finally checked using the above procedure once all faulty insulators
have been replaced.

e. Once the electrode has been repaired or confirmed for integrity, the
electrode assembly can be reinserted into the ignitor block assembly. The

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 CLIENT: Container Corp.
JOBSITE: Santa Clara, CA
PROJECT NO. CU9401468

spark gap should be checked by insuring that the electrode rod is centrally
located in the premix chamber slot with the electrode being rotated one
full turn in the ignitor block assembly. The gland nut can now be
tightened, and the spark rechecked as finally assembled.

6. Ignitors are reassembled into the burner as follows:

a. Insert ignitor assembly into the carrier tube.
b. Insert the high tension cable through the ignitor block, and attach to the
electrode rod. Replace the explosion-proof cap. Ensure that both ends of
the cable are correctly assembled and secure. Check for signs of
deterioration, damage, and cleanliness.
c. Connect gas line.
e. Turn on gas and electric supplies.
f. Check gas supply for gas leaks at connections.

Once the ignitor is in place and ready to run, the ignitor should be energized. If problems still
exist, the following should be checked:
1. If no flame can be achieved, check the transformer output by holding the high
tension lead at 1/4" from the body. If no sparks are present when the transformer
is energized, do the following:
a. Ensure body continuity at other points.
b. Check the programmer to assure that the appropriate signals are being
transmitted to the valves and transformers. Check the manufacturer’s
literature, and change the programmer if necessary.
c. Change the transformer. If the problem still exists, change the high
tension lead.

2. If the ignitor lights up, but fails to continue running, the problem could be (a) the
scanner is not reading the flame, or (b) the gas pressure supply is varying. These
conditions can be checked as follows:
a. Install a meter on the programmer and verify if the flame signal is within
limit. If the signal is low, slowly rotate scanner angle and check the
signal. Relocate the nipple if necessary. If the signal voltage is still low,
check the scanner with an open flame. If the scanner signal is still low,
change out the scanner.

b. Open the gauge cock and observe the gas pressure with the ignitor started.
If the pressure varies, check the gas pressure regulating valve and supply
line for integrity.

3. If the ignitor runs, but the flame is lazy and yellow, the problem can be (a) low
combustion air supply, or (b) gas pressure is too high. These conditions can be
checked as follows:
a. Ensure that the windbox combustion air pressure is sufficient.
b. Verify the gas pressure. If the pressure is too high, lower the setting of

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 CLIENT: Container Corp.
JOBSITE: Santa Clara, CA
‘ROJECT NO. CU9401468

the pressure regulating valve.

4. If the ignitor runs, but the flame dimension is (a) too long, or (b) too short, the
following can be done:
a. Lower the operating gas pressure to the required pressure and adjust the
high gas pressure switch.
b. Increase the gas pressure by adjusting the pressure regulating valve.

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 CLIENT: Container Corp.
JOBSITE: Santa Clara, CA
PROJECT NO. CU9401468
M AINTENANCE/LUBRICATION SCHEDULE

A. DAILY
1. Inspect every flame for unusual flame pattern. Also look for flame behind the
swirler, or a red swirler (indicating overheating).
B. WEEKLY
1. Check burner internals (through view port) for indications of any burner
malfunction.
C. MONTHLY
1. Empty fuel strainers of the oil, gas, and ignitor lines.
D. EVERY OUTAGE (SCHEDULED MAINTENENCE SHUTDOWN)
1. Inspect windbox internals for loose or damaged items.
2. Inspect swirler from furnace for distortion, heat damage, cracks, and damaged
welds.
3. Check burner mounting on front windbox face for tears and air leak paths.
4. Inspect poker tips for overheating.
5. Remove and clean scanner lens and view ports.
6. Empty ignitor gas strainers.
7. Check swirler concentricity from the furnace side.
E. EVERY FURNACE INSPECTION (MINIMUM OF ONCE/YEAR)
1. Inspect swirlers for distortion, overheating, loose components, and concentricity.
2. Inspect pokers for overheating, orifice cleanliness, etc.
3. Inspect refractory throat for any damage.
4. Remove and inspect the oil atomization assembly. Remove the atomizer nozzle
and inspect for cleanliness.
5. Calibrate/test safety interlocks.

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 CLIENT: Container Corp.
JOBSITE: Santa Clara, CA
PROJECT NO. CU9401468

SECTION 5

INSTALLATION PROCEDURES

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 CLIENT: Container Corp.
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GENERAL DISCUSSION

The burner assembly being provided for this application has undergone extensive design and
testing to ensure that the most precise and advantageous air flow pattern is achieved, and that
proper mixing of fuel and air is obtained to provide stable flames at the low excess air levels
demanded today. The burner and all of its associated parts are manufactured to very rigid
standards to ensure that proper combustion is attained repeatedly. Therefore, it is extremely
important that the portion of the burner which is field installed should follow the installation
guidelines detailed in this section.

* * IMPORTANT * *

REFERENCE THE CONTRACT SPECIFIC DRAWINGS SUPPLIED IN THIS MANUAL

FOR FUTHER INFORMATION IN ADDITION TO THIS SECTION OF THE
MANUAL.

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 CLIENT: Container Corp.
JOBSITE: Santa Clara, CA
PROJECT NO. CU9401468

WINDBOX FRONT PLATE MODIFICATION

In some retrofit applications, the windbox front plate may need to be modified to install the
burner inside the windbox and to provide the proper bolting pattern for the burner front plate.
These dimensions can be found on the burner general assembly drawing. It is extremely
important that the guide ring, the burner, and the refractory throat be installed concentrically.
Using the procedure described below, the windbox front plate and boiler front plate openings
need only align adequate y with some room for adjustment to insure a square and concentric
installation. Excessive warps ge of these front plates or ^alignment of the openings must be
remedied prior to installing U.e burner.

In a few installations, the new burner may require a windbox depth modification. In these cases,
the windbox must be altered by repositioning all, or a portion, of the windbox front plate to
provide the proper dimension to the front of the throat. In these instances, the dimensional
allowance for the gasket between the register flange and the windbox front plate must be taken
into consideration.

PAGE 5-2 CLEAVER BROOKS

 CLIENT: Container Corp.
JOBSITE: Santa Clara, CA
PROJECT NO. CU9401468

WINDBOX MODIFICATIONS

To ensure the burner performance, it is necessary to provide an even distribution of air to all
sides of the burner. This is achieved by installation of baffling in the windbox. This baffling
arrangement is the result of air flow model testing.

Any required modifications to the windbox, such as addition of baffles, are detailed in the Baffle
Arrangement Drawing. The modifications should be made, and equipment installed, in direct
accord with this drawing, and as shown on the General Arrangement Drawings. No additional
stiffening, webbing, etc should be added to the windbox, since they may adversely affect the
desired air flow patterns.

PAGE 5-3 CLEAVER BROOKS

 CLIENT: Container Corp.
JOBSITE: Santa Clara, CA
PROJECT NO. CU9401468

BOILER FRONT PLATE MODIFICATION

Due to the need for precise air flow shaping, the burner is designed with an axial flow shape
which requires a longer overall burner than older designs. Conversely, the refractory throat
depth required by the burner is normally much less than burners of older design. Together, these
two circumstances often require that the boiler front plate be recessed into the boiler refractory
wall in order to provide the required refractory throat depth and to allow the burner to fit into
th windbox. In 'ther applications, no recess is the boiler front plate is required. The specific
re drements for his application are shown on the General Arrangement Drawings.

PAGE 5-4 CLEAVER BROOKS

 CLIENT: Container Corp.
JOBSITE: Santa Clara, CA
PROJECT NO. CU9401468

"BURNER GUIDE RING" INSTALLATION

The ideal method for installing the burner guide ring assembly is to weld it to the front wall with
the burner register in place. (The only time this may not be possible is when the burner guide
ring must be installed prior to delivery of the burner to allow completion of brickwork or
refractory.) The burner guide ring assembly is first loosely fitted onto the front end of the
burner register, and inserted into the windbox as the burner is installed. With the burner guide
ring loose, the burner register is now tightly bolted to the windbox front plate using gasket
material. The burner will now be properly positioned in the boiler to allow exact positioning of
the burner guide ring, assuming that the windbox and boiler front wall openings align adequately
for the insertion. Should this not be the case, these openings must be modified at this time to
allow for the installation of the burner guide ring.

The general positioning of the burner guide ring assembly on the burner front plate is first slid
forward on the burner until it mates with the boiler front plate. A reinforcement guide ring is
provided on the end of the burner venturi; this guide ring fits within the guide cylinder of the
burner guide ring. It is essential that the guide cylinder be concentrically located around the
guide ring, ie., that the gap between these two components be equal all around the burner. If
the gap is not equal, shims should be inserted in the gap at appropriate locations to equalize the
gap. The burner guide ring is now properly positioned for welding to the boiler front plate, and
can be seal welded to the boiler front plate from either the boiler side or the windbox side.

The next step is to horizontally position the guide cylinder of the burner guide ring relative to
the guide ring on the venturi. When properly installed, a 1/2" gapshould exist between the
furnace edge of the guide ring and the inside edge of the guide cylinder stop ring. The guide
cylinder is normally shipped to the site lightly tack welded to the burner guide ring outer ring.
These tacks must be removed and the guide cylinder positioned as noted above. To assure the
1/2" gap all around the cylinder, it may be necessary to tack the cylinder to the burner guide ring
outer ring at one location (maintaining the 1/2" gap), and then repeat this operation at two other
locations around the cylinder periphery. With the cylinder now properly located by the three
tack welds, it can be tack welded finally using 1" welds on 3" centers. Welding can be on either
side of the boiler front plate.

It should also be noted that, when a tertiary air register assembly is provided with the
installation, the burner guide ring assembly is replaced by the tertiary air assembly. However,
the mounting and location of the tertiary air register are similar to the mounting of the burner
guide ring.

As noted above, it may be occasionally necessary to install the burner guide ring prior to receipt
of the burner. When this is required, the burner guide ring must be carefully positioned relative
to the center of the windbox bolt hole pattern. However, it is possible that the guide ring of the
burner, when installed, will not be exactly centered within the burner guide ring cylinder.
Consequently, the burner guide ring should only be tack welded to the boiler front plate, with
final adjustment made after the burner installation.

PAGE 5-5 CLEAVER BROOKS

 CLIENT: Container Corp.
JOBSITE: Santa Clara, CA
PROJECT NO. CU9401463

The proper dimensions for installation of the specific burner guide ring required for this job are
detailed on the burner general assembly drawing. The tolerances defined on these drawings are
extremely important to a successful job, and should be carefully maintained.

PAGE 5-6 CLEAVER BROOKS

 CLIENT: Container Corp.
JOBSITE: Santa Clara, CA
PROJECT NO. CU9401468

REFRACTORY THROAT INSTALLATION

The refractory throat is an extension of the venturi shape of the burner. Consequently, it is an
extremely important component in obtaining the proper air flow patterns required for optimum
combustion and flame shaping. The refractory throat depth, from the burner guide ring (or
burner guide ring) to the flat vertical face of the furnace front refractory wall, is fixed for each
register size. This dimension is shown on the burner general assembly drawing for this job.

The general design and installation of a typical throat former is established in the design phase
of the project. To establish this precise shape, and to locate the throat properly relative to the
burner, a throat former is provided with each installation. As discussed before, the furnace
refractory wall depth may need to be modified to match the required throat depth. It should also
be noted that, when the installation is complete, the furnace front wall that extends outside of
the new throat refractory should be flush with the new throat refractory. No steps should
remain, as these could cause air flow anomalies.

When the windbox front plate and boiler front plate modifications have been completed, the
throat former should be inserted through the openings for later use. Once the burner guide ring
assembly is properly located, and with the burner in place (see next section of this manual), the
throat former can be installed. The throat former is designed to fit concentrically within the
burner guide ring assembly, and to be drawn tight up against the burner guide ring using angle
bracing. The front retaining angle is located on the boiler side of the throat former, and the back
retaining angle is located outside the burner against the back side of either the coupling block,
fuel carriage assembly, or register front plate, as appropriate. A threaded rod extends through
the center of the burner, and through the two retaining angles, with a nut on each end of the rod.
As the nut(s) are tightened, the throat former is drawn into the burner guide ring until the cone
of the throat former is tightly in place against the front end of the burner guide ring assembly.
When firmly in place, the furnace side of the throat former, by design, should be properly
located relative to the furnace front wall refractory.

If the burner register has not been installed, the above procedures should be followed with the
exception that the rear bracing angle will be located at the windbox end of the burner guide ring
assembly, rather than against the coupling block assembly.

Coating the throat former with grease prior to installation of the refractory will facilitate removal
later. Check that the throat former itself is not out of round more than 1/8", and that the throat
former is not tilted with respect to the burner guide ring assembly. The front face of the former
should be parallel with the boiler front face refractory.

Using plastic refractory suitable for at least 3000 degrees F., fill in the space around the throat
former using a ramming method. When the refractory has dried properly, dismantle and remove
the throat former. Check the surface of the throat throat for smoothness, and the face of the
throat for flushness with the existing refractory. Also, make one final check for exit diameter
location relative to the critical dimensions noted above. Any irregularities must be corrected

PAGE 5-7 CLEAVER BROOKS

 CLIENT: Container Corp.
JOBSITE: Santa Clara, CA
PROJECT NO. CU9401468

prior to the final burner startup to ensure proper operation in accordance with contract design
requirements. Retain the throat former for future use in the event that extensive damage of the
throat requires reuse of the throat former. The throat former, which is usually supplied as a two-
piece assembly, can be either be removed through the throat opening or through the furnace wall
opening (which must be available if the throat refractory is installed with the burner in place).

PAGE 5-8 CLEAVER BROOKS

 CLIENT: Container Corp.
JOBSITE: Santa Clara, CA
PROJECT NO. CU9401468

BURNER INSTALLATION

Prior to installing the burner into the windbox, check to be sure the windbox is free of all
obstructions, and that the mounting bolts are installed correctly. Make sure that the burner is
properly oriented relative to the ignitor, guide rods (if provided), etc. Make one final check of
the burner front for damage or loose fittings.

Place the windbox front plate gasket material near the outside edge of the register front plate
using appropriate adhesive. Installation of the burner into the windbox can occasionally be
performed using a lift truck with a pipe assembly inserted through the center of the burner
(through the coupling block and center tube). This allows insertion of the burner in a horizontal
position. Typically, however, sufficient space is not available in front of the boiler for a lift
truck. Under these circumstances, the most common method of installation involves lifting the
burner near its center of gravity using a fabric sling around the poker pipes. Because the burner
register must be slid forward into the windbox, the hoists outside the windbox must be movable,
either on floor rollers, or on a rail located a few feet above the windbox and parallel to the
burner centerline. For safety during this initial sling hoisting, a second hoist is usually also
attached to the lifting lug on the register front face. Note that the fuel carriage assembly is
typically removed to facilitate installation by reducing the weight of the assembly.

With the burner register slung as noted, it is carefully lifted, and slowly inserted through the
opening in the windbox front wall as far as possible. At this point, a small hoist or come-along
is attached to an eye bolt (supplied by the customer) at the top of the windbox near the boiler
front wall, and attached to the front end of the burner register using another fabric sling. The
cable attached to the register front plate lifting lug is now tightened using its hoist, and the center
sling removed. The outside hoist should now be moved forward, with the internal hoist or come-
along being tightened accordingly to maintain the burner register in a horizontal position. The
burner register front plate can now be carefully installed over the bolts on the windbox front
plate, and secured to the windbox front face firmly with the proper bolts and nuts.

Following installation of the register, the fuel carriage assembly should be reinstalled. With the
entire burner now in place, the following dimensions applying to this particular job (as noted on
the general arrangement drawings) should be checked:
1. The dimension from the front face of the swirler to the end of the venturi should
be as shown on the General Arrangement Drawings. If adjustment is required,
loosen the two locknuts on the tab under the housing tube and adjust with the
locknuts as required.

2. The position of the tip of the oil atomizer nozzle (if supplied) relative to the front
of the swirler, as noted on the General Arrangement Drawings, is critical. If
adjustment is required, the coupling block must be screwed onto or off of the
jacket tube as required, and then secured back in place using the lockscrew. If
piping has already been connected, the jacket tube must be turned instead of the
coupling block. If this is done, then the adjustment detailed in item (1) above

PAGE 5-9 CLEAVER BROOKS

 CLIENT: Container Corp.
JOBSITE: Santa Clara, C i
PROJECT NO. CU9401468

must be redone. Be sure to pull clear any ignitors prior to turning the jacket tube.

3. The concentricity of the swirler in relation to the venturi must be maintained to

the tolerances shown on the General Arrangement Drawings. If adjustments are
required, the proper method is to adjust the position of the venturi within the
burner guide ring (or tertiary air assembly) until the swirler is concentr ic within
the venturi. The annular gap between the venturi guide ring and the burner guide
ring guide cylinder should be sufficient to allow the required adjustment. The
particular method to be used f< adjusting the venturi posit m is indicated on the
General Am igement Drawing".

4. If gas pokers are provided, the toe of the poker shoes should be positioned
relative to the downstream (furnace) side of the swirler to the dimensions shown
on the General Arrangement Drawings. The poker faces must also be set relative
to one another as shown in the Poker Orientation General Arrangement Drawings.

The above dimensions should be recorded for checkout by the Todd startup engineer.

PAGE 5 10 CLEAVER BROOKS

 CLIENT: Container Corp.
JOBSITE: Santa Clara, CA
PROJECT NO. CU9401468

VIBRATION CONSIDERATIONS

In the complete burner installation, there are a number of components that are mechanically
fastened. During normal boiler operation (or for burners supplied for portable or rental use)
vibration is not an unusual occurrence, and it can cause nuts to loosen. Consequently, it is
recommended that all fastened components be secured with lock washers. For the components
supplied as an integral part of the burner system, provisions have been made in the design and
supply of these components to assure that bolts and/or set screws will not loosen. However, the
attachment of certain portions of the burner system, such as register front plate attachments and
windbox baffles, are not within the manufacturer’s control. For these attachments, the use of
locknuts, locking chemicals such as Locktite, castellated nuts, etc. are strongly recommended to
prevent such loosening. If vibration is considered to be a significant factor, or if absolute
assurance of tightness is desired, the customer may want to consider tack welding of some of
these bolts.

PAGE 5-11 CLEAVER BROOKS

 CLIENT: Container Corp.
JOBSITE: Santa Clara, CA
PROJECT NO. CU9401468

SECTION 6

SYSTEMS OPERATIONS

CLEAVER BROOKS
 CLIENT: Container Corp.
JOBSITE: Santa Clara, CA
PROJECT NO. CU9401468

PURGING OF OIL GUNS

This recommendation is in accordance with the National Fire Protection Association’s Code
#85A "Prevention of Furnace Explosions in a Fuel Oil and Natural Gas Fired Single Burner
Boiler Furnace".

Section 4-4.2.6 - Any procedure for cleaning the atomizer and piping into the furnace prior to
shutdown shall be accomplished while the fan is operating and the ignitor is re-established, or
the main flame is continuously proven during this operation.

Section 4-4.2.7 - Cleaning of the oil passages of the atomizer into the furnace immediately after
a safety shutdown shall be prohibited.

The intent of this recommendation is to provide the operator with a safe means of purging the
oil gun when an automatic purge system has not been installed. It is assumed that the proper
crossover piping, valves, and check valves have been installed in an acceptable manner to prevent
the backflow of oil into the steam system, or high pressure steam into the oil system. This
recommendation is not intended to relieve the operating personnel of the responsibility for proper
operation of the equipment.

In accordance with the above NFPA recommendations, the procedure for purging the oil guns
is as follows:
1) Restart the boiler and allow for a complete purge of the furnace.

2) During the purge, close the manual oil valve between the automatic shutoff valve
and the atomizing medium crossover piping.

3) After the air purge, begin the trial for ignition. The trial for ignition requires a
10 second interval, and is followed by a 15 second trial for main flame. Note
that the oil shutoff valves will be energized during the trial for main flame, but,
with the manual valve closed, no oil will flow to the gun.

4) As soon as the trial for ignition has been initiated and a flame has been
established, slowly open the crossover valve to allow the atomizing medium to
flush the gun of any remaining oil. The oil will safely ignite and burn in the
furnace.

5) The main flame will continue to burn until all of the oil has been flushed through
the atomizer. At this point the scanner will recognize loss of flame, and the unit
will be shutdown.

6) Secure all valves and electrical disconnects in accordance with the normal
shutdown procedure established for safe operation.

PAGE 6-1 CLEAVER BROOKS

 t

CLIENT: Container Corp.

JOBSITE: Santa Clara, CA
PROJECT NO. CU9401468

1
\
SECTION 7

SAFETY MEASURES

CLEAVER BROOKS
 CLIENT: Container Corp.
JOBSITE: Santa Clara, CA
PROJECT NO. CU9401468

GENERAL

The safety measures listed below are tabulated for ease of reference - not in their order of
importance.

1. No modifications to equipment described in this manual may be made without prior

consultation with Cleaver Brooks.

2. In order to ensure plant and operation safety, it is important that the installation,
operation, and maintenance of this equipment is carried out by suitably trained personnel.

3. Before working on or operating the equipment, all relevant sections of this manual should
be read and the requirements of associated equipment considered.

4. During maintenance procedures, the equipment should be isolated from the main
electrical, fuel oil, steam, gas and high pressure air supplies (as applicable) for the system
being maintained.

5. Always ensure that all pressure has been dissipated, and that fluid temperatures are down
to safe working limits before dismantling system pipelines and components.

6. Prior to carrying out hydraulic tests on systems, the normal system pressure gauges and
pressure switches must be removed or isolated to prevent damage. Suitable hydraulic
gauges should be fitted to monitor test pressures employed.

7. Recommended procedures must be carried out when called for by the manufacturers of
the equipment or as part of the operator’s standing safety regulations (either during the
normal operating procedure or when required prior to maintenance).

8. All systems are provided with a number of interlocks; these must not be by-passed.
Refer also to PRECAUTIONS page - "Safety Interlocks - Routine Checks."

9. When combined fuel firing is employed (e.g. gas/oil) specific instructions should be given
to operators on the correct changeover procedure if there is a requirement to change over
on load.

10. Attention is drawn to the hazard associated with oil being sprayed onto hot refractory.
If this is allowed to happen, the oil will vaporize and form an explosive concentration.
An oil gun should never be purged into a hot furnace unless the fan is running to first
purge the furnace. The burner ignitor is then initiated and the flame established to burn
the oil off, followed by the oil gun purge initiation. Refer also to WARNING page
"EXPLOSIONS".

11. Attention is drawn to the hazard of allowing casual oil to accumulate around the boiler,

PAGE 7-1 CLEAVER BROOKS

 CLIENT: Container Corp.
JOBSITE: Santa Clara, CA
PROJECT NO. CU9401468
particularly if the oil is of low viscosity. For example, gas oil and some types of crude
oil are extremely dangerous. Refer also to WARNING page "EXPLOSIONS".

12. All moving machinery supplied with guards must have the prime mover effectively
isolated before removal of the guards is undertaken for maintenance purposes. The
guards must be correctly refitted before the machinery is brought back into operation.

13. During maintenance, the following procedures should be followed:

i. 'team Lin s
Steam lines should be isolated, and whenever possible there should be two valves
providing shut-off. Valves should be either locked or lashed and an appropriate
notice attached to the valve.

ii. Oil Lines

Oil lines should be isolated as stated above. Because hot oil can cause severe
bums, it is recommended that drainage by breaking joints not be undertaken.
Should this not be possible, the oil must first be allowed to cool to below (100°F).

iii. Gas Lines

Gas lines should be isolated as stated above. The gas lines should be vented
outside the boiler house atmosphere, and purged with nitrogen. The gas should
not be ah ;w ■to escape via block valves into ft boiler or the boiler /use.

iv. Normal safety precautions must be taken to avoid the possibility of electrical
shock.

14. In addition to the general safety measures stated above, the operators’s current safety
regulations must be complied with at all times.

PAGE 7-2 CLEAVER BROOKS

 CLIENT: Container Corp.
JOBSITE: Santa Clara, CA
PROJECT NO. CU9401468

ALL MEASURES AFFECTING OPERATOR SAFETY ARE OF EQUAL

IMPORTANCE AT ALL TIMES

Attention is drawn to the specific WARNING OR PRECAUTION pages which follow:

TITLE PURPOSE
Explosions WARNING
Boiler Purge WARNING
Hazards of Sub-StoichiometricCombustion WARNING
Danger of Visual Sighting to CorrectAir/Fuel Ratio WARNING
Gas Ignitor WARNING

PAGE 7-3 CLEAVER BROOKS

 CLIENT: Container Corp.
JOBSITE: Santa Clara, CA
PROJECT NO. C119401468

WARNING
EXPLOSIONS

1. Before an explosion can occur, there must be a means of ignition, and an explosive
mixture; if one of these can be eliminated an explosion cannot occur. As it is not
possible to eliminate all causes of ignition, (for example, hot refractory), measures must
be directed toward the prevention of explosive concentrations.

2. Most explosions can b traced to the unintentional ere y of fuel oil or gas into combustion
chambers. In this connection, gases and vapors, which readily mix with ;.ir, constitute
a hazard. It should therefore be remembered that heavy grades of fue? oil in contact with
hot surfaces produce sufficient vapor to provide an explosive concentration.

3. If a furnace is being purged with air it is unlikely that an explosive concentration will
develop. If, however, a large quantity of fuel is leaking into the furnace, it is possible
to generate an explosive concentration. Under these circumstances, the volume of the
explosive mixture could be substantial.

4. Fuel lines to main burners and ignitors are provided with shut-off valves, and under no
circumstances should the function of these valves be interfered with. The valves should
be included in a preventative mai'-fcnance program in order to gut ntee their reliability.
Attention is again drawn to the need for regular maintenance of all safety interlocks (and
this includes devices such as flame monitoring equipment) which are provided to prevent
the unintentional entry of fuel into a furnace.

5. If a plant is manually operated, it is important to follow all of the instructions, but

particular attention should be given to the lightoff procedure, furnace purging, and the
purging of oil atomizers.

6. From the above it may be seem that one of the major considerations, when designing the
system and when developing the operating and maintenance procedures, is to prevent a
combination of an explosive concentration and a source of ignition occurring together.
All opf u should be aware of this basic concept in order to appreciate the dangers
involve in uie use or incorrect operating procedures and lax maint ance routines.

PAGE 7-4 CLEAVER BROOKS

 CLIENT: Container Corp.
JOBSITE: Santa Clara, CA
PROJECT NO. CU9401468

WARNING

BOILER PURGE

1. A PURGE CYCLE SHALL ALWAYS BE CARRIED OUT BEFORE LIGHTING UP

THE BURNER. This will ensure that any explosive gases which may have formed as
a result of the previous operation are dispersed.

2. If difficulty is experienced when attempting to ignite the burner, unburnt oil or gas may
be introduced into the furnace, with the danger of forming an explosive mixture.
CONSEQUENTLY. EACH FURTHER ATTEMPTED LIGHT-OFF SHALL BE
PRECEDED BY ANOTHER COMPLETE PURGE CYCLE.

3. When purging a furnace, it is necessary to continue the purge for a sufficient time in
order to give seven complete furnace volume changes of air.

4. With larger furnaces equipped with multiple burners, it is necessary to purge through
more than one bumer/register in order to enable the purge to be completed within a
reasonably short period of time. This multiple burner purge procedure also ensures that
the purge air sweeps the entire furnace and does not leave pockets of gas. For example,
in the case of a horizontally fired furnace with the gas exit at the top, the bottom burner
register should always be opened during the purge to ensure that the furnace does not
retain gases in the lower portion of the furnace (in some cases this gas may be heavier
than air).

5. In some installations it may be necessary to make special arrangements to purge pockets

of gas in the furnace which are out of the main purge stream and cannot be adequately
purged with the burner register alone.

PAGE 7-5 CLEAVER BROOKS

 CLIENT: Container Corp.
JOBSITE: Santa Clara, CA
PROJECT NO. CU9401468

WARNING
HAZARDS OF SUB STOICHIOMETRIC FIRING OF GAS

1. Attention is drawn to the hazard which exists when a sub-stoichiometric state (less air
supplied than is needed for complete combustion) occurs in the boiler when firing on gas.

2. IN THE EVENT THAT A SUB-STOICHIOMETRIC STATE EXISTS. THE RAPID

INTBODUCTION OF AI J IS DANGEROUS. THE CO R -ECT PRO IEDURE IS TO
REDUCE THE GAS ( ANTITY I Q BRjNG Hi PLANT rp NORMAL
CONDITIONS.

3. One of the most likely causes of sub-stoichiometric firing is when the boiler is under
manual control with independent control of air and fuel.

4. Visual examination of a gas flame does not give a good indication of the air/fuel ratio.

5. O2 meters cannot measure sub-stoichiometric conditions. As the air is continuously

reduced, the meter will show the change in 02 value only until it reaches the zero point
of the meter. The 0 2 meter cannot, therefore, indicate that a sub-stoichiometric state is
existing.

6. Because of the above factors, suitable instrumentation must be used to indicate and record
conditions in the furnace at any given time.
To indicate:
1. Stoichiometric and above - use 0 2 and C 02 meters.
2. Sub-stoichiometric conditions - use CO meters.

PAGE 7-6 CLEAVER BROOKS

 CLIENT: Container Corp.
JOBSITE: Santa Clara, CA
PROJECT NO. CU9401468

WARNING
THE DANGER OF VISUAL SIGHTING FOR CORRECT AIR/FUEL
RATIO WHEN FIRING ON GAS OR GAS/OIL COMBINATIONS

1. When gas-only burners, or dual oil/gas burners, are employed, visual examination of the
flame does not give an accurate indication of the air/fuel ratio.

2. Because of the above factor, suitable instrumentation must be used to indicate conditions
in the furnace when firing on gas or a combination of gas and oil.
To indicate:
1. Stoichiometric conditions and above - use 02 and C 02 meters.
2. Sub-stoichiometric conditions - use CO meters.

Attention is also drawn to the WARNING - "HAZARDS OF SUB-STOICHIOMETRIC

FIRING ON GAS"

PAGE 7-7 CLEAVER BROOKS

 CLIENT: Container Corp.
JOBSITE: Santa Clara, CA
PROJECT NO. CU9401468

WARNING
GAS IGNITOR

It is essential that the ELECTRICAL AND GAS SUPPLIES shall be disconnected and isolated
from this unit before any maintenance is carried out.

PAGE 7-8 CLEAVER BROOKS

 CLIENT: Container Corp.
JOBSITE: Santa Clara, CA
PROJECT NO. CU9401468

SECTION 8

APPLICATION-SPECIFIC CONSIDERATIONS

CLEAVER BROOKS
 CLIENT: Container Corp.
JOBSITE: Santa Clara, CA
PROJECT NO. CU9401468
WINDBOX BAFFLE ARRANGEMENT

The windbox of this burner requires internal baffles to direct the air properly into the burner.
The scope of supply for this project indicates whether these baffles are to be supplied by the
customer, or whether they are supplied as a part of this contract.

The purpose of windbox baffles is discussed in detail below. Considering that air in the
combustion process accounts for approximately 94% of the total mass flow in the burner,
numerous observations of burner performance have shown that the correct air distribution and
peripheral entry condition are key factors in the achievement of high burner performance.
Particularly, when low NOx, low excess air, and/or low CO are critical, windbox baffling is
important.

The specific objectives of windbox baffling are as follows:

1) To ensure that the air enters the burners with minimal swirl
The creation of swirling air is a fundamental requirement of all burners. Louvered
burners create this swirl by swirling the entire air mass. Unfortunately, this creates a
problem at high turndown rates. At these low loads (10%, for example), excess air is
typically 11-13%. By swirling the entire air mass, the fuel is diluted to the point where
flame stability becomes questionable.

The Todd burner operates on the principle of providing axial air flow through the burner,
and developing a controlled limited vortex (swirl) of primary air at the face of the smaller
centrally-located swirler. This concept maintains a stable flame at the core of the burner
by limiting the dilution factor at high turndown rates. The secondary air that passes
outside of the swirler, however, is most effective if it is not swirling (which is the
concept behind "axial flow" burners). Swirling secondary air could add to the dilution
phenomenon discussed above. In addition, if this swirling occurs in the absence of
louvers, it indicates uneven air distribution, which is discussed below.

2) To provide uniform peripheral air velocity distribution around the entrance of the
burner
The equalization of the peripheral air velocity at the burner inlet will result in equal mass
flow of primary air around the periphery of the swirler. The venturi throat will tend to
equalize any remaining flow deviations because of the high velocity developed in the
throat. The result of this equal air mass flow distribution through the swirler will be a
fully developed and balanced air vortex forming at the outlet of the swirler. Flame
stability and turndown of the burner depend on the condition of this vortex; unequal air
distribution results in an asymmetric vortex. An asymmetrical vortex leads to a flame
that is more sensitive to operating conditions, ie., turndown may be limited, flue gas
recirculation may cause flame instability at lower loads, light-off by the ignitor may be
• more difficult, and flame scanning may show increased sensitivity.

Thus, the importance of proper windbox baffling is apparent. The baffling arrangement provided
in this manual is intended to eliminate this potential source of burner malperformance.

PAGE 8-1 CLEAVER BROOKS

 CLIENT: Container Corp.
JOBSITE: Santa Clara, CA
PROJECT NO. CU9401468

SECTION 9

ENGINEERING DATA SHEETS

CLEAVER BROOKS
 STANDARD BURNER
MODEL: CB168F

Job Name: Container Corporation

CB Tags: W-3813
Specific Code:
G-161 -68-73/0-155-72-144/A-15-22-1000-80-325
ENGINEERING DATA SHEET PREPARED BY: J. Moore
BURNER BILL OF MATERIALS REVISION: 0

GENERAL ARRANGEMENT DRAWING: CB168F-10-2GO QUANTITY OF 1

CLEAVER BROOKS STANDARO TYPE/SIZE: CB168FGO
STANDARD DATA CODE: G-168-70-80/0-163-77-149/A-15-15-1000-80-500
GENERAL DESCRIPTION: GAS AND OIL AXIAL FLOW BURNER Note: Quantities of Hems listed below
GAS-ELECTRIC, INTERMITTENT IGNITION are on a per burner basis

! BURNER SUB-ASSEMBLY ; MANUFACTURER 2 SIZE 5 TYPE DESCRIPTION 2 QTY J LOC

2 Front Plate Assembly c/w ! TODD 2 820 QED ii Mild Steel, type A36 2 1 • B

| Scanner Swivel Ass'y ! TODD ' ii J TCL Swivel Mount Assembly c/w { 1 ] B
| | i i one (1) swivel base, P/N BUR-4111 2
; « i a
a one (1) mtg. fig., P/N BUR-3548 2
• ■ a one (1) bad, P/N BUR-3549 2
■ a
a one (1) gasket P/N BUR-3583 2
; i

! Sightglass Assembly ; TODD i 2 TCL Each complete with: 2 2 ; b

i
j | » a one (1) base, P/N BUR-4111 2
j ; i a one (1) pyrex, dear, P/N BUR-4058 ]
ii a
a two (2) gaskets. P/N BUR-3583 2
! !
i
} Blind Range Assembly ! TODD i J TCL Each complete with: 2 3 ; b
i
■ J i a one (1) flange. P/N BUR-3512 2
ii i■ a
a one (1) gasket P/N BUR-3583 2
!

; Jacket Tube | TODD 2 4 in 2 TCI Mild steel, DWG 820-400 j 1 : b

i Swirler : TODD 2 450 mm 2 TCL 31 OSS. 14 ga. scalloped for eight 2 1 ; b

j j a a 2 in poker, on 19-3/4 in D.B.C.; 2
• 1 1 i for 4 in jacket tube 2
1
2
i a
a 7-7/8 in E to E, straight hub w/o stiffeners 2
!
| Gas Burner Assembly c/w | TODD | 6 in { Flanged Mild steel, fixed to gas plenum 2 1 ; b
2 a
i IGas Inlet Orientation: 9 O'Clock it
;

i Multiple Poker Pipes | TODD 2 2 in 2 TCI Mild steel 2 8 j B

J Poker Shoes ! TODD 2 2 in 2 TCI Mat'l is 304SS, Drill: Std 2" 10in14 Size: SML 2 8 | 8
; a
i 2 TCI 188 MMBTUH at 8.0 PSI 2
i

| Oil Burner Assembly c/w | TODD a 2 TCL TOOD TCD Large Atomizer. Dwq 0-42262 2 1 • 8
ia Dimension "A* * 90-11/32 " 2 i
: i a
! I a

; Main Atomizer Sprayer Plate ; TODD a 2 TCD50 TCD/C50 Drilling: 350/250/200-15E 50 2

j ! a ia 6490 PPH at 149 PSI 2

J Main Atomizer Coupling Block ! TODD a

I
a
a TCD Standard, for 4" JT 5 1 ; b
a ii 1 ; b
a

; Gas-Electric Ignitor Ass'y ; TODD 2 1 mmbtu 2 TCL Stabelite ignitor 2 1 ; b

J c/w mounting bracket J a
a
■
i Type 83 2

J Ignitor Transformer J Donegan a

a a Model A10-LA2 2 1 ; b
! a
I
a
a 120V/60Hz pri/10,000V sec J
i

; Transformer Enclosure 2 Hammond J 10"x8"x6" { Model 1414PH16. with panel. NEMA 12 2 1 ; b

| Guide Ring Assembly 2 TODD | 820 QED a

a A-36, aluminum paint DWG 820-300 | 1 I F

J Throat Former 2 TODD ] 820 QED a

A-38, aluminum paint DWG 820-500
a 1 ! 1 J F
; Note: 70% alumina refractory to be supplied by Installations contractor !

! Atomizer Tools/Aiodliaries:

2 Allen Wrench-2 2 TODD i { TCI 2 W-2-1-34 t 2 1

i
l

• 2 W-2-10-44 2 1
£

2 Open End Wrench-6 [ TODD i

i

2 Open End Wrench-7 2 TODD i 2 TCI 2 W-2-10-27 • 1

i

2 Anti-seize lubricant 2 TODD t { TCI I Can. P/N C-41-1-7 2 1

i

2 Sealing Compound 2 TODD i 2 TCI J Can. P/N C-41-1-6 2 1

•

PG 1 of 1
LOC: B» Windbox mounted; R= Rack mounted; F* Shipped loose; P= control panel mounted

REVO 7/27/1995 Issued as a standard

 Job Name: STANDARD WINDBOX
CB Tags: 7x7x6
Windbox Orientation:
ENGINEERING OATA SHEET
Right Hand w/ Special Air Inlet
o WINDBOX SPECIFICATIONS
PREPARED BY:
REVISION:
TODD GENERAL ARRANGEMENT DRAWING- 60966-10-1
OVERALL DIMENSIONS: ' t
! SPECIAL REQUIF
| HEIGHT: 7 FT - 0 IN 1 Prime only, standard Cleaver Brooks primer
1
| WIDTH: 7 FT - 0 IN 1
1 DEPTH: 6 F T - 0 IN
I ! QTY REQUIRED
PLATE DESIGN:
MATERIAL J THICK, IN ! COMMENTS:
TOP PLATE ASTMA-36 J 1/4 1
FRONT PLATE ASTMA-36 | 1/4 t
- LEFT SIDE PLATE ASTMA-36 j 1/4 1
RIGHT SIDE PLATE ASTMA-36 j 1
1/4
BOTTOM PLATE ASTMA-36 | 1/4 1
BACK PLATE N/A j N/A 1 '
1
INSULATION/CLADDING MATERIAL | THICK, IN
INSULATION ! COMMENTS:
N/A 1 N/A 1
CLADDING N/A j 1
N/A 1
WINDBOX NOZZLES 1
: s iz e ;
LOCATION QUANTITY ! CONN, IN.
COMBUSTION AIR INLE 9:00 ' COMMENTS
1 ! 2'9-1/16"x47-3/4"
FGR INLET N/A 1 1
N/A 1
ACCESS DOOR j Bttm RHS |! 2 ! 18 x18
PRESSURE TAP TBD | STUD WALL FOR 22 IN X 22 IN BOLTED DOOR
2 ! 1/2
DRAIN Bttm ( WITH PLUG
1 I N/A
BAFFLES & VANES
MATERIAL J THICK, IN 1
AS REQUIRED USING: ASTM A-36 ! 1
1/4
I STANDARD ARRANGEMENT (FOR AIR FLCOW ENTRY)
-
PREPARATION/FINISHING:
SANDBLAST TO REMOVE RUST

G
PAGE 1 OF 1

REVO
7/27/1995 Issued as a standard

G
 CLIENT: Container Corp.
JOBSITE: Santa Clara, CA
PROJECT NO. CU9401468

SECTION 10

DRAWINGS - JOB SPECIFIC

DB95206

CLEAVER BROOKS
 Safety
Installation
Operation
Maintenance
SERVICE MANUAL
FOR HEAVY D U TY FANS

'H IC A B B B L O W E R C O R P O R A T / O At
1675 Glen Ellyn Road • Glendale Heights, IL 60139 • Phone 708/858-2600
 CONTENTS

INTRODUCTION.................................................................................................1
INSTALLATION.................................................................................................... 2
Unloading and Handling..................................................................................... 2
Foundations.......................................................................................................... 2
Duct Location and Design................................................................................... 2
Fan Erection..........................................................................................................4
Housing Alignment................................................................................................4
Pedestal Alignment..............................................................................................5
Rotor Assembly....................................................................................................5
Inlet Cone/lnlet Volume Control..........................................................................5
Bearing Assembly & Alignment............................................................................6
Flexible Couplings................................................................................................7
V-Belt Fan Drive....................................................................................................9
Accessory Installation........................................................................................10
OPERATION........................................................................................................ 11
Vibration Limits................................................................................................... 12
MAINTENANCE...................................................................................................13
TROUBLE-SHOOTING GUIDE..........................................................................14
BEARING DETAIL.............................................................................................. 16
Dodge Sleevoil Bearings....................................................................................16
Dodge Sleevoil RT20 Bearings..........................................................................19
Link Belt Solid Pillow Block-Bearings............................................................... 20
Link Belt Split Pillow Block-Bearings............................................................... 22
Record of Fan Installation..................................................................................25
Warranty.............................................................................................................. 25

a m c a
y ......... |i

Air Movement and Control Association

i i .......i l II
30 West University Drive
HDM-2153 Rev. 1988 Arlington Heights, III 60004
INTRODUCTION
GENERAL INFORMATION
This manual is intended to aid in proper installation and opera­
tion of Heavy Duty fans manufactured by Chicago Blower Cor­
poration (CBC). Due to the wide variety of arrangements and
types of Heavy Duty fans, it is not intended to cover detailed
installation procedures. Each purchaser of a Chicago Blower
Heavy Duty fan is furnished with a detailed assembly drawing
showing working conditions and a bill of material which is your
Parts List. Any special features or installation requirements are
described on this drawing to aid in proper installation and star­
tup. A bulletin covering this fan in more detail, and operating
performance curves, are available through the CBC sales of­
fice which sold this equipment. A convenient Record of Fan In­
stallation is located on the inside back cover of this manual.
It is the responsibility of the purchaser to insure that installation
and operation is handled by qualified personnel experienced in
this type of equipment. Omission in this manual or on CBC
assembly drawings of details or operation methods commonly
considered good practice by competent erection personnel are
not the responsibility of Chicago Blower Corporation.
A staff of trained field service and erection personnel is available
from CBC to supervise installation or check alignment and
balance at startup. Contact your local CBC representative to ar­
range for this service.
SAFETY PRECAUTIONS
The fan you have purchased is a rotating piece of equipment
that can become a source of danger to life, and can cause in­
jury if not properly applied. Maximum operating temperature
and speed for which this fan is designed must not be ex­
ceeded. These limits are given in our catalog, or in the order
acknowledgement, or on Chicago Blower Corporation drawings.
Personnel who will operate this fan, or those who will perform
maintenance thereon, must be given a copy of this manual to
read and warned of the potential hazards of this equipment.
This manual contains general recommendations, but attention
must also be paid to the specific safety requirements which apply
to the individual installation. Such requirements are outlined in
federal, state and local safety codes. Strict compliance with these
codes, as well as strict adherence to installation instructions,
are the responsibility of the user and are necessary to the safe
operation of this fan.
The elements which connect the driving mechanism to the
fan (V-belt drives or couplings) create potential DANGER to
personnel and suitable guards must be provided.
Bearing assemblies and drive couplings must be covered
so that no rotating element can snag clothing or skin. Shaft
cooling wheels or any other rotating part must be covered. Any
open sheave, pulley, sprocket, belt, chain, and other similar
transmission device must be enclosed by guards.
1
Another potential hazard is the ability of the fan to convey loose
material which can be a projectile. Ducts must be protected
to prevent objects from entering the air stream. Place
suitable guards over inlets and outlets of fans to prevent the
entrance of clothing or flesh into the rotating parts.
Vibration limiting switches should be provided to detect sudden
changes in the operation of the fan, especially when operating
a fan under high temperature or in an extremely corrosive
atmosphere.
Any access door in the housing must not be opened when
the fan is in operation. Those on the discharge side of the fan
can explode when unbolted.
Proper protection from electrical start of the fan during
maintenance is required. A disconnect switch provided with
a padlock to prevent operation of the fan switch is required.
In addition, a disconnect switch should be located at the fan for
use by personnel working on the fan.
RECEIVING and INSPECTION
All shipments are thoroughly inspected prior to shipment F.O.B.
Glendale Heights, Illinois. All shipments must be carefully in­
spected by the Receiving Agent for damage. Any damage must
be noted on the carrier’s Bill of Lading and a claim filed im­
mediately with the freight company by the receiver. Partial
shipments are common on equipment of this type. Make a
careful check that all parts shown on the Bill of Lading have been
received.
STORAGE PRECAUTIONS
If storage of equipment is necessary prior to erection, precau­
tions must be taken to prevent damage. The rust preventative
paint applied to the fan housing is sufficient in most environments
to protect it from damage for a short time outside. The rust
preventative compound applied to machined surfaces at CBC,
such as shafting, bearing pedestals and sole plates, is intend­
ed for in-transit protection only. If prolonged outside storage is
necessary, additional applications of rust preventative com­
pound, waterproof paper, tarpaulin or plastic covers are the
responsiblity of the purchaser. Covered equipment must be pro­
vided with moisture absorption material. Motors, pedestals,
dampers, shafts and bearings should be stored in a temperature
controlled building to prevent deterioration prior to erection. Bear­
ings should be tightly sealed to prevent corrosion or buildup of
foreign material during storage. In most cases, standard prepara­
tion for shipment by bearing, coupling and motor manufacturers
is not sufficient for prolonged outdoor storage.
If a wheel and shaft is received as a separate assembly, block
each end of the shaft to prevent sagging. When a wheel is
located in a fan housing, the wheel should be rotated 180° ap­
proximately once every two weeks.
INSTALLATION
UNLOADING and HANDLING
Rotor Assembly:
Many CBC Heavy Duty wheels are furnished as a rotor assembly
complete with a shaft and often with a shrink fit between wheel
and shaft. This rotor assembly may be shipped on a fabricated
steel wheel cradle for ease of handling in shipment and
unloading. Remove the rotor assembly from the cradle by plac­
ing slings around the shaft as close as possible to either side
of the wheel. A spreader bar on the hoisting cables must be us­
ed to eliminate damage to the wheel during lifting. (See figure
1). Do not use any part of the wheel rim for lifting purposes. Do
not put the sling on that portion of the shaft where the bearings
will later be mounted. Rotors must never be lifted by the wheel,
blades or sideplates, or allowed to rest on the ground without
blocking the shaft ends. Wheels should never be rolled when
lifting equipment is available. If rolling becomes necessary, ex­
treme caution must be exercised to prevent damage. A wheel
that has been knocked out of round must be rebalanced.
If the fan wheel is separate from the shaft, a wrapped sling or
timber may be passed through the hub for lifting. Extreme care
must be taken not to damage the finished bore of the hub, or
the bearing and hub surfaces of the shaft.
Housing:
In unloading and handling large housing sections, an attempt
should be made to lift from as many points as possible. Spreader
bars must be used to prevent concentrated stresses that can
collapse the housing and cause permanent distortion. Inlet box
and outlet dampers must be handled with care as distortion could
cause binding during operation.
Fans covered with special coating or paint must be protected
in handling to prevent damage. Avoid nicks or cuts in the
coating which may be difficult and expensive to repair.
FOUNDATIONS
A rigid, level foundation is a must for every fan. It assures
permanent alignment of fan and driving equipment, reduces ex­
cess vibration, and minimizes maintenance costs. The sub foun­
dation (soil, stone, rock, et cetera) should be firm enough to pre­
vent uneven settlement of the structure. Foundation bolt loca­
tions are found on the assembly drawings.
Poured Concrete: ..
Reinforced poured concrete is the preferred foundation for Heavy
Duty fans. The minimum design weight of a concrete founda­
tion should be three times the total assembly weight of the fan
and driver. This mass acts as an inertia block and will absorb
any normal vibration that might develop as well as hold driver
and fan in perfect alignment. It is preferred that the bottom of
2
the base be larger than the top with the degree of taper to the
footing course dependent on the available sub-foundation. The
edges of the foundation should be beveled to prevent chipping
and should extend at least 6" beyond the fan structure. A
minimum allowance of 1" should be made for shimming and
grouting when the top level of the foundation is determined (See
figure 3).
Sole plates under the fan pedestals and motor base plate,(figure
7), are recommended for use on concrete foundations. Parts can
then be removed without disturbing the cement, grout and
realignment is easier.
“ L” shaped hold down bolts should be used in the concrete,
(See figure 2). They should be placed in a metal sleeve or pipe
having a diameter 2 1/2 times the hold-down bolt diameter to allow
minor adjustment after the concrete has cured. When determin­
ing the length of anchor bolts, allow 1" extra length for leveling
and grout, flange thickness of the fan foundation, nut, washer,
and extra threads for drawdown. “ L” bolts must be positioned
so the bottom does not break out of the concrete.
B. Structural Steel Foundations:
If the fan is mounted on equipment having parts which cause
vibration, it is very important that the fan support be rigid
enough to prevent such vibration from being carried to the
fan. The reasonance frequency of this support must be a
minimum of 25% above the maximum fan speed.
When a structural steel foundation is necessary, it must be suf­
ficiently rigid enough to assure permanent alignment. It must
be designed to carry, with minimum deflection, the weight of
the equipment plus the loads imposed by centrifugal forces set
up by the rotating element. In such cases, the design of the struc­
ture must permit field revisions (such as knee braces) if initial
operation indicates a need for increased stiffness.
DUCT LOCATION and DESIGN
When locating the foundation, carefully plan the ducting or
breaching to the fan to avoid possible air performance problems.
To deliver stable rated performance, fans require smooth,
straight distributed flow into the inlet and straight flow out of the
outlet for a distance of at least three duct diameters. Where duct
turns or abrupt change in duct dimensions are necessary within
three duct diameters of fan inlet, flow distributing devices (turn­
ing vanes) must be installed (See figures 4 and 5). Where these
means are impractical, such as close to" the fan outlet, the
amount of fan performance loss can be found from AMCA
Publication 201 (see front cover for address). Care must be taken
to prevent spiral or vortex flow into fan inlet since these flow con­
ditions frequently cause pulsation or unstable delivery. Contact
your local Chicago Blower sales office for further information.
See Back Cover.
Duct Connections OUTLET CONNECTIONS
Flexible connections and or expansion joints must be pro­
vided at fan inlet and outlet to isolate the fan from duct static
loads, duct temperature expansion loads and from vibration 3 p
loads. Flexible connections may be multiple bellows expansion
joints, banded slip joints or fabric or sheet plastic flexible joints.
Flexible connections may require acoustic treatment to reduce RIGHT
noise radiation. Ducts must be separately anchored near the fan.

Shim Placement Detail

1< l < TT RIGHT WRONG
I j
i i >*
w i i
J Lt t
Steel shims must be
placed at all anchor
bolts, all four
corners, and at inter­
] mediate points, if [ TURNING
.0- - / any deflection is r .0 . VANES
' determined visually. ■­ RIGHT

Notch shims for

corner anchor bolts
n r V if required. r
\° i u
S° t
i i •1 1
l ii *|
-LJ.
Plan View
Shims must
Elevation View extend beyond
base angles.
3
3 £ o
FIGURE 3
H

RIGHT WRONG

INLET CONNECTIONS

RIGHT WRONG
RIGHT RIGHT
TURNING
VANES

RIGHT WRONG

RIGHT RIGHT WRONG

R IG H T W RONG

im C

I-

FIGURE 4 RIGHT WRONG RIGHT WRONG

FIGURE 5

3
 FAN ERECTION
Erection as covered in this section specifically covers Arrange­
ment 3-SISW and 3-DIDW fans with 'independent pedestals.
Although the procedure for installing A/1 or A/8 fans differ slight­
ly, they are generally less complicated to install and incorporate
simple modifications of some of the steps outlined. See figure 6.
For arrangement 1 and 8 fans, (fan wheel overhung, bearings
on one pedestal), level shaft between bearings, using a spirit
level. Shim under pedestal to attain level. Tighten foundation
hold down bolts.
For fans with independent pedestals proceed as follows:
Set and Align Housing on Foundation:
If the housing was shipped knocked down, the bottom half must
be lifted onto the foundation first.
Place wooden blocks beside the anchor bolts to prevent damage
to them while the housing is being moved into proper position.
The housing should be lifted from as many points as possible.
The use of spreader bars will help minimize distortion. When
the housing is properly aligned over the anchor bolts, it should
be lifted up one side at a time, the block removed, and the hous­
ing lowered carefully onto the foundation. Temporary shims ap­
proximately the same thickness as the grout should be placed
on either side of each anchor bolt. The shims should be flush
with the edge of the base angle and should be approximately
4" wide. These shims will give the housing good support and
prevent it from slipping when the anchor bolts are drawn down.
See figure 3.

DRIVE ARRANGEMENTS FOR CENTRIFUGAL FANS

SW - Single Width DW - Double Width
SI - Single Inlet Dl - Double Inlet

A R R . 1 S IS W W IT H IN L E T B O X F o r b e lt
d riv e o r d ire c t c o n n e c tio n . Im p e lle r o ve rh u n g ,
tw o b e a rin g s o n b a se . In le t b o x m a y b e s e lf­
s u p p o rtin g .
A R R . 3 S IS W W IT H IN D E P E N D E N T
P E D E S T A L F o r b e lt d riv e o r d ire c t, c o n n e c ­
tio n fa n . H o u s in g is s e lf-s u p p o rtin g . O n e
b e a rin g o n e a c h s id e s u p p o rte d b y in d e p e n ­
d e n t p e d e s ta ls .
A R R . 3 S IS W W IT H IN L E T B O X A N D IN ­
D E P E N D E N T P E D E S T A L S F o r b e lt d riv e o r
d ire c t c o n n e c tio n fa n . H o u s in g is s e lf­
s u p p o rtin g . O n e b e a rin g o n e a c h s id e s u p ­
p o rte d b y in d e p e n d e n t p e d e s ta ls w ith s h a ft
e x te n d in g th ro u g h in le t b o x.

A R R . 3 D ID W W IT H IN D E P E N D E N T A R R . 3 D ID W W IT H IN L E T B O X A N D IN ­ A R R . 4 S IS W F o r d ire c t d riv e . Im p e lle r

P E D E S T A L F o r b e lt d riv e o r d ire c t c o n n e c ­
tio n fa n . H o u s in g is s e lf-s u p p o rtin g . O n e
b e a rin g o n e a c h s id e s u p p o rte d b y in d e p e n ­
d e n t p e d e s ta ls .
D E P E N D E N T P E D E S T A L S F o r b e lt d riv e o r
d ire c t c o n n e c tio n fa n . H o u s in g is s e lf­
s u p p o rtin g . O n e b e a rin g o n e a c h s id e s u p ­
p o rte d b y in d e p e n d e n t p e d e s ta ls w ith s h a ft
e x te n d in g th ro u g h in le t b o x.
o ve rh u n g on p rim e m o v e r sh a ft. N o b e a rin g s
o n fa n . P rim e m o v e r b a s e m o u n te d o r in ­
te g ra lly d ire c tly c o n n e c te d .

A R R . 7 D ID W F o r b e lt d riv e o r d ire c t c o n - A R R . 8 S IS W W IT H IN L E T B O X F o r b e lt A R R . 9 S IS W F o r b e lt d riv e . Im p e lle r

n e c tio n . A rra n g e m e n t 3 p lu s b a s e fo r p rim e d riv e o r d ire c t co n n ectio n , im p e lle r o ve rh u n g , o v e rh u n g , tw o b e a rin g s , w ith p rim e m o v e r
m o v e r. tw o b e a rin g s o n b a se p lu s e xte n d e d b a se fo r o u ts id e b a se .
p rim e m o v e r. In le t b o x m a y b e s e lf­
FIGURE 6 s u p p o rtin g .

4
Set and Align Bearing Pedestals:
The bearing pedestals should be put in place, using shims, to
approximate the proper bearing centerline height. The fixed, or
drive side, bearing must be leveled at this time using flat shims
under the sole plate. Approximately 1/8" should be allowed for
shimming between pedestal top and bearing for possible future
alignment problems caused by settling of the foundation. In level­
ing the sole plate, adjusting bolts on the “ L” bolts are helpful
but after final alignment hard shims must be placed next to each
“ L” bolt and under the center of the sole plate before grouting.
See figure 7. Note that pedestal can be removed from the side
without disturbing foundation bolts.
On top of the pedestal, shims running the full length and half
the width of the bearing foot, slotted to fit around the mounting
bolts, provide the most solid mounting arrangement for later
mounting the bearings. Temporarily bolt down bearing pedestals.
CLEARANCE FOR
FOUNDATION BOLT W HEN
REMOVING PEDESTAL
SOLE PLATE
L-BOLT
Section view showing pedestal, sole plate and grouting.
Prepare Rotor Assembly:
All Chicago Blower Corporation Heavy Duty wheels are ship­
ped with a shrink or slip fit to the shaft. Check the proper wheel
rotation with the rotation arrow on the drawings on the fan, or
the diagrams in figure 8.
ROTATION ROTATION ROTATION
Design 4800, 4806, Design 2000 Design 1900 Design 1910
4900 and 1807 and 2300 and 1910
FIGURE 8 Direction of Rotation for Various Blade Shapes
(shown for counterclockwise from drive side)
Carefully place the wheel on the floor and brace in position.
Remove any protective coating from the shaft and hub. Check
for rust, corrosion and nicks. If cleanup is necessary, DO NOT
USE EMERY CLOTH on any bearing surface. Crocus cloth may
be used if necessary. Clean and oil the shaft portion which fits
into the wheel, as well as the wheel bore itself. Remove all keys
and loosen set screws. Check fan assembly drawing for loca­
tion of wheel on the shaft. Rotation is as viewed from the drive
side. On dual drive units, it is generally from the “fixed”
bearing end. Refer to general assembly drawing.
Lift shaft, using padded slings; carefully slide end into wheel
hub and push through until wheel is properly located on shaft
as shown on the assembly drawing. Extreme care must be taken
not to damage wheel bore or shaft seat. Set keys in position,
tighten set screws just enough to hold wheel on shaft during
handling. Tighten fully when clearances have been set.
See page 6.
On a rotor with a factory shrink fit, the preparation of the rotor
assembly is limited to cleaning up the shaft for installation.
g^ °
c p to o *
' ROTATION
FIGURE 7
PEDESTAL
Set Inlet Cone, Ring, or Inlet Volume Control
At this time, the inlet Cone and retaining rings (or inlet Volume
Controls, if furnished) are placed over the shaft end for moun­
ting the rotor assembly in the housing. See figure 9. If inlet
volume controls are provided, check for proper rotation. See
figure 10. Inlet vanes in the half closed position must pre-spin
the air in direction of wheel rotation. On a DIDW fan one inlet
vane control is clockwise and the other counter-clockwise. Do
not install them reversed. Secure inlet vane controls to wheel
ROTATION for lifting purposes. Do not allow vane center mechanism to rest
on shaft as damage will result.
Type B
Prepare Bearings, Set Rotor Assembly:
1. For Sleeve Bearings:
Remove bearing caps and clean bearings with solvent. Coat with
clean oil and cover to avoid contamination. Clean oil rings and
shaft seals. Do not mix parts between the bearings as they
are not interchangeable. Bolt the lower half of the bearing
loosely in place. Again cover to prevent contamination. Sling
the rotor assembly as previously described. To prevent damage
to the liner in the fixed bearing (having the thrust collars) when
putting large rotor assemblies in place follow this procedure: The
rotor assembly is to be positioned above the bearing journals
and the liner for the fixed bearing is then fastened to the shaft
and lowered into the bearing housing with the rotor assembly.
For further information refer to Sleeve Bearing Detail Sec­
tion, pg. 16.
5
 2. For Anti-friction Bearings— Solid Pillow Blocks:
Non-split pillow blocks are slipped over the shaft ends prior to
putting the rotor in place. Check to insure that the floating bear­
ing (unless specified on the assembly drawing) is on the side
opposite the driver. See figure 12. Bolt bearings loosely on
pedestals. For further information, see page 20.
3. For Anti-friction (roller) Bearings— Adapter mount, Split
Pillow Block:
Cleaning of internal parts should not be required as the corro­
sion preventative compound applied by the manufacturer is com­
patible with recommended lubricants. Careful inspection of all
internal parts is good practice, as any corrosion present is like­
ly to cause problems at a later date. Do not mix parts between
bearings as they may not be interchangeable.
The bottom half of the pillow blocks is loosely bolted in place
on the pedestals. Open pillow blocks and bearing parts expos­
ed to atmosphere must be covered with a clean cloth to pre­
vent contamination.
The internal parts of the bearing are placed on the shaft ends
in the same order that they were removed from the pillow block.
See figure 13. Sling the rotor assembly as described previously
and lift into place. Put bearing caps in place to prevent con­
tamination prior to final alignment.
Align Rotor and Housing
As a first step to proper alignment, level the drive side bearing
first. The floating bearing will later be shimmed to account for
the shaft deflection. See figure 11 A. In leveling the bearing, see
that the shaft centerline is the proper height for connection to
the driver. After shimming of the drive bearing is complete, it
should be drawn down. The floating bearing should be shimm­
ed to take up the shaft deflection and should be drawn down
in conjunction with the alignment of the inlet cone or inlet volume
control.
Wheel to cone alignment details are included on the assembly
drawing provided with each fan. The drawing gives a dimension
for the inlet cone to wheel backplate distance. Check this align­
ment before final tightening of pedestals, bearing bolts and bear­
ing locking devices. See figure 11B.
„„„„„ FIXED FLOAT H \
DRIVER CPLG BRG W HEEL BRG
FIGURE 11A LEVEL FIGURE 11B
_________
UNIFORM ALL
EXCEPTION
HIGH TEMP. FANS
AROUND -
Adjustments for Expansion
Induced Draft fans, or other high temperature applications,
require wheel and cone adjustments for expansion due to
temperature. This is because the housing expands up from the
foundation while the rotor expands concentrically from the shaft
centerline as well as axially from the fixed bearing. The follow­
ing rules of thumb should be used on applications in excess of
300° F:
1. Axial overlap on double width fans should be approximately
twice as much on the drive side as on the floating side.
2. Radial clearance between the wheel and inlet cones should
be twice as much at the top as at the bottom.
For forced draft fans or other low temperature applications
under 300°F., care should be taken to duplicate exactly the
6
wheel to cone clearances recommended on the assembly
drawing. Cold settings are shown on the assembly drawing.
FIXED
BEARING
V. FLOAT
BEARING
I— I DIRECTION OF
DRIVER
p zp e x p a n s io n ^
"O '
'C O U P LIN G
a r> t DIRECTION OF
FIGURE 12 | EXPANSION
Set and Align Bearings
The setting of the drive side bearing level with the driver and
aligning the outboard bearing have been mentioned previous­
ly. It is preferable that the drive bearing be set level to facilitate
alignment of the driver which is also set level. Any shaft deflec­
tion caused by suspension of the rotor weight between the bear­
ings must be accounted for in the outboard bearing by placing
shims under it. See figure 11A. Shaft level is placed on the shaft
at the journals and compared to the machined surface of the
bearing housing until an equal slope is achieved. This equal
alignment of the bearings to the shaft can also be checked by
measuring the bearing seal as being equal distance from the
shaft all around.
Align Inlet Cones or Inlet Volume Controls
After the alignment of the rotor assembly, coupling and drives
is complete, the inlet cones or IVC’s should be repositioned
to give proper clearance. Center the cones on the inlet eye
of the wheel. At this time, the IVC linkage should be assembled
as required. Details of linkage arrangement are supplied on the
fan assembly drawing. Install gasketing in housing split, install
split portion of housing. Allowance must be made for expansion
when operation is to be at elevated temperature. (Refer to the
assembly drawing). Tighten all fasteners in foundation,
pedestals, etc. that were previously left loose. Install shaft seals
if supplied. Turn rotor by hand to make sure it runs freely.
1. Dodge Sleeve Bearings
The elliptical shape of sleeve bearing liners makes lining up the
bearings square with the shaft relatively simple. When the shaft
rests in the liners, there is clearance on both sides the full length
of the liners. In squaring up the bearings, a .0015 or .002 shim
should be able to run the entire length of the liner at a fixed
depth.
After alignment, install oil rings. Sizes up to 3-7/16" have a single
ring; 3-15/16" and up, double rings. Tighten set screws on the
rings and be sure that rings rotate freely on shaft. Run dust seal
into its groove in the housing and fasten ends together. Next,
put a coating of oil on the upper portion of the liner and put in
place. Place cap on bearing and tighten stud nuts. The plunger
screw must be loose before the stud nuts are tightened.
Detail instructions on sleeve bearing assembly can be found in
the Bearing Detail Section, page 16.
2. Split Pillow Blocks Spherical Roller Bearings
The lower half of the pillow block should be bolted loosely to
the pedestal. After assembling bearing parts on the shaft in the
same order as figure 13, hand tighten the adapter assembly.
Be sure that the bearing is properly positioned on the shaft before
tightening to the proper clearances. The space in the expan­
sion or floating bearing should always be on the outboard side
or side away from the drive (coupling) bearing. See the bearing
assembly instructions in Bearing Detail section, page 22.
3. Solid Pillow Block Spherical Roller Bearings
Slide, tap or press bearings on shaft. Establish final shaft posi­
tion and tighten bearing to support using SAE Grade 5 moun­
ting bolts. Position locking collar and tighten setscrews to the
torque shown in table VIII on page 20. For further details see
page 20.

Flexible Coupling Installation and Alignm ent
These instructions cover, in general, the installation of flexible
couplings of the pin, gear, or grid types.
1. Before mounting coupling(s), be sure ail bearing(s),inlet
vane(s), etc., have been installed.
2. Install each coupling half cover with“0” ring on its shaft.
3. Determine which direction, long or short shank of coupling
hub should be located; see manufacturer’s manual.
4. Heat coupling hub to approximately 300°F by means of hot
oil bath or oven. Do not apply flam e to hub teeth.
5. Install coupling hub(s) on shaft. Hub and shaft face should
be flush.
6. Key the couplings to the shafts while the hub(s) are still hot.
7. Adjust the clearance between the coupling faces. The pro­
per clearance dimension is listed on the assembly drawings and
included in manufacturer’s information. This dimension may also
be stamped on the coupling hubs.
8. When a sleeve bearing motor is used, locate it so that when
the motor rotor is closest to the fan, the motor shaft will not touch
the fan shaft. If the motor shaft has its magnetic center mark­
ed, align it in this position; otherwise equally divide the max­
imum play to obtain the mechanical center. Align in this position.
9. With tapered wedge, feeler gauges, or dial indicator, observe
that the faces of the fan and driver couplings are parallel.
10. Align the shafts until a straightedge appears to be parallel
to the shafts. Repeat at three additional points at 90° from each
other. Recheck angular alignment and hub separation. (See
Figure 14.)
11. For more accurate alignment, use a dial indicator clamped
on one hub, with the dial indicator button resting on the other
hub. Rotate the hub on which the indicator is clamped, and
observe the indicator reading. Take readings at four locations,
90° apart. With correct alignment, the faces of the couplings
should be parallel within .001 per inch of shaft diameter, in both
parallel and angular planes. (See Figure 15.)
FIGURE 15
12. Where large turbines or motors are used as drivers, the driver
side of the coupling should be set low by a few thousandths to
allow for the driver to heat up during operation when it will ex­
pand and bring the coupling into alignment.
A rule of the thumb for initial alignment of a large motor is: Set
driver low .001" for each 1* of shaft diameter; i.e. 1" shaft motor
low by .001", 2" shaft motor low by .002”. Set turbines low by
,001" per inch of turbine height from mounting feet to center
line of shaft. After unit has operated and thermal expansion is
complete, coupling alignment should be checked and corrected
if necessary.
13. After completing the coupling alignment, clean both sides
of the coupling thoroughly, and inspect the gasket for tears,
cracks or other damage.
14. Install the gasket between the coupling halves. Draw together
the coupling flanges keeping gasket holes in line with bolt holes.
Insert and tighten bolts, lockwashers and nuts.
15. Lubricate in accordance with type of operating condition.
See Table I, Page 8.
SPECIAL NOTE ON ALIGNMENT:
On any completely assembled fan, where CBC has mounted the
motor and coupling, it is required that the alignment be recheck­
ed after the fan is set on its permanent foundation. It is not possi­
ble to hold alignment during shipment or when set on a different
foundation. Alignment must be redone, if necessary, and the
coupling lubricated. A tag is on the coupling. See below.
NOTICE
This coupling was carefully aligned at the factory
before shipment. Due to variations in foundations
THIS COUPLING MUST BE REALIGNED after fan
is finally “set” . See Coupling Mounting Instructions
which are enclosed in Packing List Envelope.
7
The lubricants listed below are recommended by the lubricant
manufacturers for the indicated conditions. This list is solely for
our customers’ convenience and does not constitute an endorse­
ment. The listing is not intended to be complete nor necessari­
ly current due to continuous research and improvement by the
various manufacturers.

TABLE I
COUPLING LUBRICANTS
L U B R IC A N T
M ANUFACTURER GENERAL M O IS T O R W E T H IG H T O R Q U E 1 5 0 °-3 0 0 °F C L A S S III

A m e ric a n L u b ric a n ts C o. A lu b c o B is o n 1650 (sam e) (sam e ) (sam e ) (sam e )

A tla n tic R ic h fie ld C o. A rc o M P A rc o M P A rc o E P o r M o ly D D o m in io n H 2 D o m in io n H 3
A m oco A m o lith # 2 A m o lith # 2 A m o lith #2 R y k o n E P -2 A m o c o C P L G G re a s e
C h e v ro n U S A ,In c . D u ra lith E P -2 D u ra lith E P -2 D u ra lith E P -2 D u ra lith E P -2 N L G ear C om pound 460

C itie s S e rv ic e O il C o. C itg o A P o r H E P -2 A P o r H E P -2 A P o r H E P -2 A P o r H E P -2 C itg o A P o r E P C o m ­

p o u n d 130
C o n tin e n ta l O il C o. S u p e r S ta G re a s e H D C a lc iu m G re a s e H D C a lc iu m H D C a lc iu m H D C a lc iu m , T ra n s m is ­
s io n O il N o . 140
F a r B e st M o ly v is S T -20 0 (sam e ) (sam e ) (sam e ) —

F is k e B ro s. R e fin in g C o. L u b rip la te 6 3 0 -A A L u b rip la te 6 3 0 -A A L u b rip la te 6 3 0 -A A L u b rip la te 1200-2 L u b rip la te N o . 8

G u lf O il C o. G u lfc ro w n E P # 2 G u lfc ro w n E P # 2 G u lfc ro w n E P # 2 H i-T e m p G re a se P re c is io n N o . 3

E x x o n C o. P e n -O -L e a d E P 3 5 0 R o lu b ric a n t E P -3 0 0 R o lu b ric a n t E P -3 5 0 U n ire x N 2 U n ire x N 2 o r N u to N o.

K e n d a ll R e fin in g C o. K e n lu b e L-421 o r
W a v e rly T o rq u e
Lube A
M o b il O il C o. M o b ilu x E P -0
146
L-421 o r T o rq u e L-421 o r T o rq u e L-421 o r T o rq u e L-427
Lube A Lube A Lube A
M o b ilu x E P -0 M o b il T e m p 7 8 M o b il T e m p 78 M o b il N o . 28

P e n n z o il C o. P e n n lith 711 o r 712 P e n n lith 711 o r 7 1 2 P e n n lith 711 o r 712 P e n n lith 7 1 2 o r H i S p e e d P e n n lith 7 1 2
B e a rin g L u b e 7 0 6 o r B e a rin g L u b e 7 0 6

S u n te c h , Inc. S u n a p le x 991 E P o r
P re s tig e 741 E P (sam e ) (sam e) (sam e ) _
S yn -T e c h 3913-G 1 (sam e ) (sam e) (sam e ) (sam e)

T e n n e c o C h e m ic a ls , Inc. A n d e ro l 786 (sam e) (sam e) (sam e ) (sam e )

T e x a c o , Inc. M u ltifa k E P -2 M u ltifa k E P -2 M u ltifa k EP -2 T h e rm a te x E P -2 T h e rm a te x E P -2

U n io n O il C o . o f C a lif. U N O B A E P -2 U N O B A E P -2 U N O B A E P -2 U N O B A E P -2 M P G e a r L u b e 140
F o r lo w te m p . (-6 5 °), A e ro s h e ll # 2 2 b y S h e ll O il C o ., A n d e ro l 7 9 3 b y T e n n e c o C h e m ic a ls , In c. & M o b il G re a s e # 2 8 b y M o b il O il C o.

8
V-BELT FAN DRIVE ALIGNMENT
Proper alignment, adjustment and balance of the V-Belt drive
is essential to smooth fan operation and life. The following should
be checked:
1. Fan and motor shafts must be parallel; adjust and shim motor
as required. See Figure 16.
2. Fan and motor sheaves must be aligned axially. See Figure
16.
3. Adjustable motor sheave grooves must have no noticeable
eccentricity.
4. Fan and motor sheave balance should be checked when there
is any vibration.
5. Belts must have proper tension; follow drive manufacturer’s
instructions.
6. Belts either too loose or too tight cause vibration and excessive
wear. See Figure 17.

Belt Tension Adjustment

Step 1: With all belts in their proper grooves, adjust the centers
to take up all slack and until the belts are fairly taut.
Step 2. Start the drive and continue to adjust until the belts have
only a slight bow on the slack side of the drive while operating
under load. See sketch above.
Step 3. After a few days operation the belts will seat themselves
in the sheave grooves and it may become necessary to read­
just so that the drive again shows a slight “ bow”in the slack side.
The drive is now properly tensioned and should operate satisfac­
torily with only an occasional readjustment to compensate for
belt and groove wear.

Grouting Unit
After completion of all installation and alignment it is recom­
mended that a Chicago Blower Corporation Service Engineer
check the installation prior to grouting. This service is available
on a daily fee plus expenses basis through your CBC local sales
office. After verification of alignment, grouting can be completed.
There are a number of commercial non-shrinking grouts
available such as 5 star grout having aluminum chips or Em-
baco with steel chips. Allow 72 hours after grouting before
startup.

9
 ACCESSORY INSTALLATION
Shaft Coolers— have split cast aluminum radial bladed wheels,
designed to dissipate heat conducting down the shaft toward
the bearings. The two halves are bolted together around the fan
shaft with the backplate toward the fan housing and the cooling
fins drawing air over the bearing. Consult the assembly draw­
ing for proper location. An expanded metal guard must be in­
stalled over this cooling wheel.
Shaft seals are compressed fiberous material, split type furnish­
ed as a standard on most fans, both on the inlet box and drive
sides of the fan.
Inlet Volum e Controls (IVC) are inlet cones with variable inlet
vanes mounted in them for regulation of fan volume and power.
On double inlet units, interconnecting linkage assures
simultaneous operation. See page 5 on how to check that the
vanes are spinning the inlet air in the direction of wheel rotation.
INLET VANE CONTROL
Linkage assembly details are provided on the fan assembly
drawing. IVC’s are furnished for manual operation with a lock­
ing quadrant or for automatic operation using an electric or
pneumatic operator furnished by others.
10
Inlet Box Dampers are provided for volume control and power
savings similar to that achieved with the IVC. The damper comes
in a separate channel iron frame with damper axles running
parallel to the fan shaft. When partially closed, the blades prespin
the air in the direction of wheel rotation. Units operating in ex­
cess of 300°F. are provided with flanged ball bearings mounted
on stand-off channels, and cast stuffing boxes containing braided
fiberous packing to prevent leakage. For units shipped knock­
ed down, or DIDW units, detailed linkage mounting information
is on the fan assembly drawings. At installation make sure they
prespin the air in direction of wheel rotation.
Outlet Dampers are mounted in a separate channel frame and
bolt to the discharge outlet of the fan for volume control. The
damper blades are double surface and are opposed blade.
Dampers operating in excess of 300° F. are provided with flanged
ball bearings mounted on remount channel and cast stuffing
boxes with braided fiberous packing to prevent leakage.
Note: On high tem perature dampers (above 300°F.) the set
screws should not be tightened in the damper axle bearings
on the side opposite the operating linkage. This allows the
damper shaft to expand away from the locked bearings on the
linkage side.
INLET DAMPER OUTLET DAMPER
Damper Inspection
Whether damper is received installed on the fan or shipped
separately, check all the levers, linkage and blade hardware to
see that they are secure. Operate the control handle manually
to check that all the blades are operating freely, open fully and
close tightly.
Damper Installation
When installing dampers in the field, refer to the assembly draw­
ing to assure that damper linkage is in the proper position and
the blades rotate from closed to open position in the correct rota­
tion. Desired fan perform ance may not be obtained if pro­
per damper blade rotation shown on drawing is not
observed.
Double width fans using two dampers operate with a single con­
trol arm and a shaft connecting the two dampers. Blades in both
dampers must fully open and close together. The connec­
ting shaft often is in two pieces and although a set screw is pro­
vided in the coupling as an aid for assembly, this section should
be field welded to the shaft after the damper blades are syn­
chronized. Fans operating at higher temperatures have shaft
coupling arrangement to provide for expansion, do not weld both
ends to the shaft.
Do not insulate dampers with ball bearings If above 180°F
or enclose exposed shaft and bearings in a manner that
would restrict natural cooling by ambient air.
OPERATION
INITIAL STARTUP
In the event that startup service and a vibration survey is not
purchased from CBC the following general check lists should
act as an aid. It is not intended to cover all contingencies and
it is assumed that the installing contractor is experienced in in­
stalling this type of equipment, and will follow all good initial start­
up procedures.
OPERATION OF FAN
Assuming that the equipment has been installed in accordance
with these instructions and those of the manufacturers of com­
ponents, and that a check has been made for tightness of all
hardware and mounting bolts, the fan will be ready to operate
after some final safety checks to prevent injury to personnel or
damage to the equipment.
1. Lock out power source.
2. Check bearings for alignment, proper lubrication, tolerance,
locking collars tight, cleanliness, burrs, or corrosion, and water
connections for cooling, if required.
3. Check keys and wheel set screws for tightness. Check foun­
dation bolts for tightness.
4. Check in housing and duct work for extraneous matter and
debris. Secure all access doors.
5. Check wheel position for proper clearance at inlet.
6. Turn wheel over by hand, if possible, to see that it rotates
freely.
7. Close inlet Volume Control and/or dampers to lessen start­
ing load on driver.
Warning
Do not operate this fan in the stall/surge region. Operation
of this equipment in the stall/surge region is extremely
dangerous and may result in damage to the equipment as
well as nearby personnel or other equipment. Operate this
fan only in accordance with the installation, operation and
maintenance manual.
AERODYNAMIC PULSATIONS
Under certain conditions, a fan may experience damaging pulsa­
tions. This is not always obvious. It is characterized by a rumbling
sound and vibration in the fan and ducts. There are two main
causes, and the method of detection is different for each. Detec­
tion is important, for such pulsations can cause bearing failures
or weld failures in the fan or ductwork.
First, the system resistance may be too high. The fan could go
into stall if restricted beyond the design range of operation. This
can happen if the actual resistance exceeds that which was
specified. This condition may be detected by somehow reduc­
ing the system resistance in a controlled manner and listening
for a change to smooth flow.
Second, the air controller may be the cause. This would be either
a prespin inlet damper or an inlet vane control. At moderate
openings, say 20 to 60 percent open, a significantly higher rumbl­
ing sound can occur. This can be detected by listening and feel­
ing as the air controller is closed from the wide open position.
If the rumbling is present and long term operation is desired at
this capacity setting, it is recommended that the inlet air con­
troller be opened to the point where smooth flow is obtained,
then use an outlet damper to return to the desired capacity. This
combination of control will greatly reduce the amplitude of the
pulsations. ..
8. Supply water to water cooled bearings according to
instructions.
9. Start fan with driver, check for rotation in proper direction.
10. Start equipment in accord with recommendations of
manufacturers of starting equipment and driver unit.
11
11. Allow unit to reach full speed, then shut down. During this
short period check for vibration or any unusual noise. If any are
observed,locate the cause and correct.
12. Lock the power source in “ O FF” position.
13. Recheck for tightness of hold down bolts, all set screws and
keys, and tighten if necessary. Initial start up has tendency to
relieve the tightness of nuts, bolts and set screws.
Assuming unit operates satisfactorily, the run in period must be
at least eight hours. Observe bearings a minimum of once each
hour during the first eight hours of operation. Over greasing
may cause bearings to heat up. There need be no concern
if the bare hand can be held on the bearing for one second. A
bearing full of grease will heat up and then gradually cool down
to 140°-160°F.
Oil rings of sleeve bearings should rotate freely and carry oil.
This can be checked by removing the inspection caps and the
use of a flash light to illuminate the rings. Check the equipment
for vibration. If vibration is excessive, stop fan and determine
the cause of vibration. Do not operate until cause has been
corrected. See Pages 14-15.
DOWELING OF BEARINGS
Bearings must not be doweled before the equipment has run
30 days. This allows for foundation settle or shift. Alignment of
all components must be carefully checked and location of bear­
ings fixed. Holes are drilled through the base of the bearings
and pedestals, then reamed to size to fit suitable dowel pins.
Dowel pins are then driven into place. Threaded pins may be
used if so desired.
WARNING
Never allow the fan rotating assembly to sit idle in
temperature above 200°F.
Fan Balance
Heavy rotors and high speeds make static and dynamic balan­
cing a necessity. This balancing is carefully done at our plant
by experienced personnel. Occasionally, mishaps in transpor­
tation, handling, operation, or wear, will necessitate rebalanc­
ing in the field. The impeller must be rebalanced when mounted
on a soft foundation and coupled to its own driver to suit the
foundation peculiarities. However, fan rotors can not be
balanced or operated on inadequately supported or weak
foundations.
Balancing impellers is a delicate operation and requires
specialized knowledge, experience and careful procedure. A
balance weight of a few ounces incorrectly placed may cause
serious damage. For these reasons we strongly recommend
that an experienced, Chicago Blower factory representative, be
contacted.
Running fan(s) with high vibration (see “Bearing Vibration
Limits”, Table II) could result in personal injury or property
damage.
Bearing Vibration Limits (See Table II on page 12)
Vibration amplitudes shown in mils (1 mil = 0.001") are
measured in any of three planes on either bearing housing, ver­
tical, horizontal and axial.
Alarm values are a warning that vibration must be corrected at
the earliest possible moment (short term hours). Long term
operation, at or exceeding ALARM values greatly reduces
rotor and bearing life-hours and voids the Chicago Blower
warranty. .
SHUT-DOWN limit signals hazardous operation and requires
immediate repair. Operation at this limit voids the Chicago
Blower warranty and could result in personal injury or pro­
perty damage.
Causes of Vibration
Refer to Trouble-Shooting Guide, page 14.
TABLE II
VIBRATION SEVERITY CHART

Vibration in Mils (Peak to Peak)

Maximum or 2865 4200 Shut- 9550

Design RPM Norm3 ' = R P M * RPM* Down - RPM*

400 7.1 10.5 23.9

600 4.8 7.0 15.9

800 3.6 5.3 11.9

1000 2.9 4.2 9.6

1200 2.4 3.5 7.8

1400 2.0 3.0 6.8

1600 1.8 2.6 6.0

1800 1.6 2.3 5.3

2000 1.4 2.1 4.8

2200 1.3 1.9 4.3

2400 1.2 1.8 4.0

2600 1.1 1.6 3.7

2800 1.0 1.5 3.4

3000 .9 1.4 3.2

3200 .9 1.3 3.0

3400 .8 1.2 2.8

3600 .8 1.2 2.7

3800 .7 1.1 2.5

4000 .7 1.1 2.4

Approx. Velocity
.15 .22 .5
(In.) Sec.

*Not to exceed given maximum or designed RPM.

12
MAINTENANCE

To insure long life and trouble free service, a frequent and regular
check of all lubricants in bearings and couplings should be made.
Sleeve bearings should be drained, flushed and refilled with
clean oil after the first month, and each six months thereafter.
Other types of bearings should be maintained in accordance with
manufacturer’s recommendations.
A preventive maintenance schedule is a necessity for extend­
ed fan life. Establish a lubrication schedule based on time
periods suggested in lubrication instructions and by motor
manufacturer.
After approximately after one (1) month of operation, all base,
hub, bearing, pedestal, etc. bolts should be re-tightened.
Potentially damaging conditions are often signalled in advance
by change in vibration and sound. A simple, regular audio-visual
inspection of fan operation leads to correction of the condition
before expensive damage occurs. Vibration levels should be
checked by an approved technician using electronic balancing
equipment.
Mechanical integrity
Certain operating conditions reduce the built-in strength of the
fan impeller and may cause unsafe operation. It is the users
responsibility to inspect for these conditions as frequently as
necessary and to make correction as required. Failure to com­
ply with the following limits voids Chicago Blower Corporation
warrantee.
Temperature Changes
Temperature change rate exceeding 5 °F per minute and
temperature fluctuations exceeding 100°F must not be applied
to fan inlet air.
Maximum Safe Speed and Temperature
Operation exceeding maximum safe R.P.M. and temperature
even for a short time causes overstressing or fatigue cracking
of the impeller resulting in unsafe condition. Maximum safe
speed and maximum safe temperature are shown on fan
assembly drawings, catalogs or order acknowledgement.

Where air handled by the fan contains corrosive, erosive or sticky

materials, fan should be shut down regularly for inspection,
cleaning and reconditioning of interior parts.

REPLACEMENT PARTS NOTE

Renewal, repair or replace­
When ordering parts the following information is necessary:
ment parts are not
necessarily stocked by
Chicago Blower. If your fan
From Nameplate on Fan FAN TYPE, SIZE, AND SERIAL NUMBER
is important to plant opera­
tion please order spare
or
parts. Contact your local
Chicago Blower sales office.
From Original Purchaser FAN TYPE, SIZE, PURCHASE ORDER NUMBER
AND CUSTOMER DRAWING
NUMBER OF THE FAN

Replacing Motor FRAME NUMBER, MAKE, HP, RPM AND

ELECTRICAL CHARACTERISTICS.

Replacing Coupling MAKE, BORE FOR DRIVE HUB, BORE FOR

DRIVEN HUB AND SIZE MUST REFER TO FAN
DRAWING FOR SHRINK FIT.

Replacing V-Drives ORDER FROM NEAREST DRIVE SUPPLIER. GIVE

NUMBERS FROM SHEAVES ANP BELTS.

NOTE: Repairs for motors should be ordered from the nearest authorized motor service station for the make of
motor furnished. Check the yellow pages of your telephone directory.

13
TROUBLE-SHOOTING GUIDE

PROBLEM CAUSE REMEDY

VIBRATION The most common cause Check the wheel for any dirt or foreign material, especially hard-to-see places
of vibration problems is like the backside of the wheel and the underside of the blades.
an out of balance fan Airfoil blades are usually hollow. When exposed to rain or excessive moisture
wheel or rotor. they can get water inside of them. Drilling one 3/16" drain hole in the upper
surface of each blade near the trailing edge should cure the problem. Rebalanc­
ing is usually not necessary.
Inspect the wheel for erosion or corrosion. Usually wheel erosion will occur at
the leading edge of the blade. On a paddle wheel type fan the outer blade tip
may also be worn. An airfoil wheel exposed to sand or abrasive dust can actual­
ly develop pin holes in the leading edge of the blades. Do all you can to
eliminate these damaging conditions and then rebalance the wheel. If the wheel
is seriously damaged it will have to be replaced.

Improper or loose Foundation bolts and bearing mounting bolts can loosen themselves. Make sure
mounting they are tight.

Loose set screws that Again tighten the screws, but first be certain the wheel hasn’t shifted on the
hold the wheel to shaft or is rubbing on the inlet cone or drive side of the housing.
the shaft

Bent fan shaft. First, check the shaft with a dial indicator. If bent, it should be replaced as soon
as possible to avoid replacing the entire fan.

Misaligned V-belt drive Realign assembly so fan and motor shaft are parallel and faces of sheaves
(pulleys) are flush to a straight edge. W e ’ve found that a taut string will work
fine. Refer to Page 9

Fan wheel turbulence Since blade angles and shapes vary greatly, it is easy to misread rotor direction.
due to the rotor running Check for correct wheel rotation, clockwise or counter clockwise, as seen from
backwards the drive side. Refer to Page 5.

Air pulsation. Fan may be operating in the stall area of its performance curve. That means it
is oversized for your particular sytem or the system resistance is higher than in­
tended. You can lower the system resistance by cleaning the filters or opening
the dampers.

NOISE Foreign material in the This could be anything from a loosened bolt to somebody’s lunch bag. Inspect
fan housing. the wheel and inside of fan housing and clean thoroughly.

Squealing V-belts. The belts are either loose or misaligned. If belts show wear, you are better off to
replace them now and avoid a future breakdown.

Worn ball or roller Change the bearings immediately before they cause additional damage. Failing
bearings (Howling, bearings tend to wear the shaft, so you want to be absolutely certain the shaft
screeching or clicking). is full size before installing those new bearings. “ Mike” the shaft both under the
bearing and next to it and compare the two readings. If they don’t match
replace the shaft. New bearings installed on a worn shaft will not last long.

Bearing seal misaligned. Realign the face of the bearing so that it is perpendicular to the shaft.
(High pitch squeal).

If the fan housing has a Loosen seal plate bolts, recenter the seal on the fan shaft and tighten the bolts.
metal shaft seal it could If the seal is fiberglass, cork or rubber, be sure the metal backing plate does
be misaligned and not touch the shaft.
rubbing on the shaft.

14
 PROBLEM CAUSE
OVERHEATED Bearings may be worn
BEARINGS and failing.
(See Note Below)
Improper grease.
Overgreasing.
Bearing exposed to
“ heat soak” from an
oven or dryer after shut
down.
Loose V-belts may
cause belt slippage and
friction heating resulting
in hot bearings, shafts
or sheaves.
Excessive V-belt
tension.
POOR AIR Fan rotation incorrect
PERFORMANCE
Abrupt turn in the duct
close to the fan dis­
charge or air pre-spin
caused by ductwork
elbows at the inlet.
If fan has an Inlet
Volume Control is it
improperly installed?
Off-center wheel.
Fan horsepower
unexpectedly low.
Fan horsepower
unexpectedly high.
NOTE: Ball or roller bearings tend to heat up when they have been overgreased and will cool down
to their normal running level when the excess grease oozes out. The normal operating temperature
of a bearing may be well above the 140° which is “ hot" to touch. Temperatures over this have to
be read with instruments and anything over 180° should be questioned. If you put a drop of water
on the bearing and it sizzles, the bearing is in distress and should be changed before it seizes and
ruins the shaft.
REMEDY
Replace the bearings. Remember to also check the shaft (refer back to the
NOISE section).
Use a lithium base, high speed, channeling type grease. Do not use high
temperature or general purpose grease.
If you allow the bearing to run for a few hours it will normally purge itself
of the extra grease. You can simply remove excess grease from split roller
bearings by lifting the top half of the block for access.
“ Heat soak” occurs when a fan is idle and it’s shaft cooling wheel
can no longer cool the inboard bearing. Heat from inside the fan can
then actually cook the grease. A 15 minute fan run after the oven
heat is turned off will cool the fan shaft and protect the bearing.
Tighten belt to the proper tension. A good rule of thumb—-you
should be able to depress the belt the same distance as the
the thickness of the belt
Belts may be too tight. Adjust to the correct tension.
Refer to the Vibration section. An easy way to change rotation
on most 3-phase motors is to reverse any two motor leads.
Install turning vanes or elbow splitters in the duct. If air performance
is still inadequate, the discharge position may have to be changed.
Refer to Page 3.
Be sure the IVC is installed with pre-spin of the air in direction
of wheel rotation when the IVC is partially closed. Refer to Page 5.
This can occur on double width, double inlet fans. Center the fan
between the inlet cones to avoid overloading one side of the wheel while
starving the other.
Correct one or more of the following conditions.
• Air pre-spin into the fan inlet.
• Fan drive sheaves set for too low a fan speed.
• Resistance to airflow, such as caused by a closed damper, much
higher than calculated.
Be sure fan speed is not too high. Fan may be operating without
ductwork at low resistance so that too much air is flowing.
The fan may be handling ambient air when it was originally intended for hot,
less dense air. .
Fan may be running backwards.
15
Dodge Sleevoil Pillow Block Bearings
(Sizes 3 15/16" thru 8" XC and Plain).
INSTALLATION
The design of this pillow block is unique
in that it allows the use of either a plain or
XC (externally cooled) liner in the same
housing. This is accomplished by using a
“ universal" grommet for the application.
Complete basic pillow block assemblies
are shipped in two packages, the housing
and its associated parts are in one package
and the liner in the other. Any optional ac­
cessories are packaged separately.
Before mounting the pillow block read all
instructions in this manual to become
familiar with the mounting procedure and
pillow block parts nomenclature.
1. Check mounting structure making sure
it is rigid, level and well supported. Inspect
shaft to insure It is smooth (32 micro-inch
finish or better), within commercial
tolerances and free of burrs or rough spots.
2. Disassemble and thoroughly clean all
parts of the pillow block. Housing caps and
liner caps are matched to their bases and-
should not be interchanged. Housing and
liners should be in terchan g ed as
assemblies only.
3. Position housing base on pedestal so
that oil gage is in the position specified on
the construction drawing. Do not tighten
housing base to pedestal. Apply oil to the
spherical seats in the housing base.
4. Note location of thermocouple holes in
liner base. Set liner base in housing base
so that thermocouple holes in housing align
with holes in liner. Thermocouple holes in
housing base are on side opposite oil gage
holes (oil gage side of housing base is
marked “X ”). Apply oil to liner bearing
surface.
5. Apply oil to shaft in the bearing area and
set shaft in place.
6. Check alignment of pillow block by
noting clearance between housing and
shaft at each end of the housing —
clearance should be uniform with 1/32".
Use shims under base as required. Align­
ment of pillow block should be as accurate
as possible. The self-alignment feature of
the unit is to compensate for normal shaft
deflection and possible settling of the
supports.
7. Place oil rings around outside of lower
liner and over shaft. Peen screws to insure
that they are secure. Make sure rings rotate
freely on shaft.
8. Remove clamp screws from thrust col­
lars and make sure cracked joint is clean.
Place one collar half on shaft so that finger
groove is next to liner base in the non­
expansion (fixed) bearing. Rotate collar half
around shaft and place other half in posi­
tion. Bring halves together at joint, making
sure match at joint is perfect and insert
clamp screws. There should be no offset
at collar face. Tap half together and tighten
clamp screws. Repeat above operation for
opposite end of bearing. Assemble tw o
collars on one bearing only. Tap collar
up to face of lower liner allowing a total of
.010" to .015" running clearance and
tighten set screws. Collar should run
parallel to end face of liner within 002". See
Axial Clearance Table IV, Page 18.
9. Apply oil to bearing surface of liner cap.
Locate cap in place on lower liner making
sure oil rings are in their cavities and are
free to rotate. Install and tighten cap
screws.
10. Tighten housing base to pedestal.
11. Thread dust seal and seal retainer in­
to groove at end of housing base and
around shaft. Slide free end of seal retainer
thru clasp and pull tightly. Hold clasp with
16
long nose pliers and pull free end of re­
tainer as tightly as possible with another
pair of pliers. Cut off excess material and
press down clasp lip. Seal retainer may be
disengaged by inserting a straightened
paper clip between the bands at the clasp
and pulling the free end of the retainer out
of the clasp.
12. Position gasket on housing base.
Loosen plunger screw and locate hous­
ing cap on base taking care not to damage
dust seals or housing gasket. Tighten
housing bolts then turn plunger screw
down snugly. The plunger screw must be
loose until the housing bolts have been
tightened.
Base Loaded Bearings: Tighten plunger
screw locknut. Torque Table III, Page 18.
Cap Loaded Bearings: If shaft must be
held down to install cap, tighten plunger
screws tightly with shaft held down. Mark
position of plunger screw. Loosen plunger
screw one complete turn and loosen shaft
hold-down. Then tighten plunger screw
while tightening shaft hold-down until
plunger screw is tightened to the mark. Do
not over-tighten shaft hold-down as this can
misalign the bearing. Remove shaft hold­
down and tighten plunger screw locknut.
Note: Do not tighten plunger screw on
accompanying base loaded bearing un­
til cap loaded bearing has been install­
ed and hold-down rem oved.
13. Plain Liner: When using a Plain Liner
(without coolant pipes), install grommet and
grommet plate over openings in the sides
of the housing.
Externally Cooled Liner: For XC or Water
Cooled Liners (with coolant pipes), cut out
2 holes in each neoprene grommet to
match coolant pipes in liner. Note that pipe
sizes are shown on the grommet. Use a
sharp knife or small hand held grinder and
be sure to remove all burrs. Install grom­
met and grommet plate over pipes and
tighten screws.
14. The oil level gage may be located any
distance from the pillow block by the use
of a coupling and pipe of the desired
length. The extended pipe must be sup­
ported so that it remains straight and
perfectly level. Use a spirit level — Do not
guess. Use pipe sealer on all connections.
15. Remove all pipe plugs and reinstall us­
ing pipe sealer. Tighten securely.
16. Make pipe connections required for
coolant, making sure that all pipe lengths
are correct and unions are well aligned.
Careless fitting will result in serious
preloading of bearing. Lengths of flexible
hose between pillow block and rigid piping
are recommended to avoid preloading of
bearing. A regulating valve should be plac­
ed ahead of the inlet and a slight drain at
the outlet for liquid coolants. The recom­
mended method of pipe connection for li­
quid coolants is to connect the inlet to one
pipe and the outlet to the other pipe on the
same side of the bearing. A return is then
used to connect the two pipes on the other
side of the bearings. (See Figure 20). Ad­
XC PILLOW BLOCKS - 3 ' * . ' AND LARGER
just coolant flow rate specified on construc­
tion drawing or to suit conditions (See table
V on page 18). When using air as the cool­
ing medium, connect an inlet to each pipe
on one side of the bearing and an outlet
to the pipes on the other side.
Warning: W ater cooled sleeve bearings
must be protected from freezing. If they
are to remain idle in freezing tem p., the
liner water chambers must be blown
clear with compressed air.
LUBRICATION and OPERATION
Since the satisfactory operation of the
pillow block depends almost entirely on the
oil film being maintained between the shaft
and liner bearing surface, it is recom ­
mended that a high grade straight
m ineral oil with rust and oxidation (R &
O) inhibitors and antifoam agents be us­
ed. Information regarding qualities and pro­
perties of specific oils should be referred
to the lubricant manufacturers. See Table
VI and VII Page 18 for further information.
Fill the pillow block with oil to the top of
the center circle in the oil gage. After plac­
ing into operation, remove inspection
covers and check to make sure oii rings are
bringing up oil. Operation should be check­
PLUNGER SCREW ASSEMBLY
17
ed frequently during the first few days. If
noise develops, check alignment of hous­
ing, collar runout, plunger screw and all
operating parts. Check all points and make
sure all screws and nuts are tightened after
several days operation. Drain, flush and
refill with oil after 2 to 3 weeks of opera­
tion and every 3 months thereafter for con­
tinuous service and every 6 months for 8
hours a day service. Visually check the oil
for contamination periodically between oil
changes. Maintain oil level above bottom
of center circle at all times while unit is
in operation.
The water flow rate is a general starting
point for proper cooling. See Table V Page
18. Lower water inlet temperature and (or)
lower ambient temperature require less
flow. The water inlet temperature should
never exceed 90°F. The interior pressure
of the liner should never exceed 80 psi.
Anti-freeze type additives may be used with
the water in cold operating environments,
otherwise purge all coolant from the liner
by blowing out with compressed air or
steam anytime bearing coolant is subject
to freezing.
Any questions on installation,
maintenance or operation should be refer­
red to the equipment manufacturer.
XC LINER ASSEMBLY
 T A B L E III T A B L E VI
STANDARD SLEEVOIL BEARING REQUIRED OIL VISCOSITY
COLLAR & PLUNGER SCREW TORQUE VALUES ___________ If n o t s p e c ifie d b y e q u ip m e n t m a n u fa c tu r e r .
Room Tem p.
Collar F a h r. D u r in g S ta r t
Clamp Screw Set Screw Plunger Screw Up Speed O il re q u ir e d
Standard Screw Wrench Screw Wrench Wrench Wrench
Sleevoil Size Torque Size Torque Size Torque
Size (Allen) (In-Lbs) (Allen) (In-Lbs) (Allen) (In-lbs) B e lo w — 1 0 ° A ll C o n s u lt E q u ip m e n t M a n u fa c tu re r
2 7/16 3/8-16NC 580 1/2-13NC 515 — —

2 11/16 3/8-16NC 580 5/8-11NC 1200 — — — 1 0 ° to 3 2 ° A ll S A E 10

2 15/16 3/8-16NC 580 5/8-11NC 1200 — —

3 7/16 1/2-13NC 1425 5/8-11NC 1200 — —

3 2 ° to 7 0 ° Low S A E 20
3 15/16 1/2-13NC 1425 3/4-10NC 1750 7/32 425
4 7/16 1/2-13NC 1425 3/4-10NC 1750 1/4 630 H ig h S A E 10
4 15/16 1/2-13NC 1425 3/4-10NC 1750 1/4 630
5 7/16 1/2-13NC 1425 3/4-10NC 1750 1/4 630 Above 70° Low SA E 30
6 5/8-11NC 2800 7/8-9NC 3500 5/16 1250
H ig h S A E 10 fo r L ig h t L o a d s
7 5/8-11NC 2800 7/8-9NC 4100 5/16 1250
8 3/4-10NC 5000 1-8NC 5600 5/16 1250 S A E 2 0 fo r H e a v y L o a d s
9 PL. 7/8-9NC 8100 1-8NC 5600 5/16 1250
9 W.C. 7/8-9NC 8100 1-8NC 5600 3/8 2150 O il film te m p e ra tu re in lin e r d u rin g o p e ra tio n s h o u ld n o t e x c e e d 18 0 °F .
10 PL. 1/2-13NC 1425 3/4-10NC 1750 5/16 1250
If in d o u b t c o n s u lt e q u ip m e n t m a n u fa c tu re r.
10 W.C. 7/8-9NC 8100 1-8NC 5600 3/8 2150
12 PL. 1/2-13NC 1425 7/8-9NC 4100 3/8 2150 U se h ig h g ra d e , h ig h q u a lity , w e ll re fin e d p e tro le u m o ils o f th e s tra ig h t
12 W.C. 1-8NC 12100 1-8NC 5600 3/8 2150 m in e ra l ty p e , w ith ru s t a n d o x id a tio n in h ib ito r a n d a n ti-fo a m a g e n t o n ly.
14 PL. 1/2-13NC 1425 7/8-9NC 4100 3/8 2150 Approximate Viscosity:
S A E 10 — 183 S U S a t 1 0 0 °F ; 4 6 S U S a t 2 1 0 ° F
SAE 20 — 3 4 8 S U S a t 1 0 0 °F ; 5 7 S U S a t 2 1 0 ° F
SAE 30 — 4 8 9 S U S a t 1 0 0 °F ; 6 5 S U S a t 2 1 0 ° F
T A B L E IV
SLEEVE BEARINGS AXIAL CLEARANCES
BETWEEN LINER AND COLLARS
B E A R IN G S IZ E T O T A L C LEAR AN C E T A B L E V II
(In c h e s ) M in im u m M a x im u m R E C O M M E N D E D T U R B IN E G R A D E O IL S -A S T M D -9 4 3 (1 8 0 0 H rs .)
1-7/16 .005 .009 T e x a c o D e s ig n a tio n
1 -11/16 .005 .009 B e a r in g T e m p . S A E V is c o s ity ( o r E q u iv .)
1 -1 5 /1 6 .006 .010 1 0 0 ° - 1 6 0 °F 20 R e g a l R & O - 68
2 -3 /1 6 .006 .010 1 6 0 ° - 1 7 0 °F 30 R e g a l R & 0 -1 0 0
2 -7 /1 6 .008 .012 1 7 0 ° - 1 8 0 °F 40 R e g a l R & 0 -1 5 0
2 -1 1 /1 6 .008 .012
2 -1 5 /1 6 .008 .012
3 -7 /1 6 .009 .013 R E C O M M E N D E D S Y N T H E T IC O IL
3 -1 5 /1 6 .009 .013
4 -7 /1 6 .009 .013 Tem p. M o b il 6 3 2 M o b il 6 3 4
4 -1 5 /1 6 .009 .013
5 -7 /1 6 .010 .016 210 F 115 S S U 148 S S U
6 .010 .016 100 F 1 535 to 1 704 S S U 2 2 1 5 to 2 4 6 0 S S U
7 .010 .016
8 .010 .016
9 .011 .017
10 .011 .0 1 7
12 .013 .019
14 .015 .021

N o te : T h r u s t c o lla r c le a ra n c e f o r a ll s iz e R T B e a rin g s a re .0 1 5 - .0 2 6 ).

TABLE V
BEARING SPECIFICATIONS
Pillow Max. Speed Water Flow Air Flow Pressure drop Oil Flow Oil Volume*-
Block for Ring Rate (G.P.M.) Rate (C.F.M.) Req’d for Rate for
Size Oiling Air Cooling Circ. Oil FI. Oz. Qts. Approx. Liters Approx.
(r .p .m !) + ◄ ★ (P.S.I.) * (G.P.M.) ■ • • •

3 15 /16 2910 1.75 52 .19 3 .0 50 1 1/2 1.45

— T im — 5552 555 63 .22 3 .5 64 2 1.90
------ 4 15/16— -------5551------ 2 .5 0 77 .11 3 .5 90 2 3 /4 2 .7 0
5 7 /1 6 2107 3 .0 0 90 .12 5 .0 100 3 1/8 2 .9 5
---------- 5-------- ------- T0T0 ----- 450 104 .15 5 .5 132 4 1/8 3 .9 0
7 1637 5 .0 0 156 .40 6 .5 240 7 1/2 7 .1 0
---------- 5-------- 1435 6 .5 0 173 .50 7 .5 320 10 9 .5 0

t C o n v e rte d fro m 3 0 0 0 F .P .M . S p e e d s a b o v e 3 0 0 0 re q u ire C irc u la tin g O il. *

•w B a s e d o n 9 0 ° F a m b ie n t te m p e ra tu re a n d 9 0 ° F w a te r in le t te m p e ra tu re . C o o le r a m b ie n t a n d (or) w a te r in le t te m p e ra tu re s re q u ire le ss
flo w . P re s s u re d ro p a c ro s s b e a rin g — A p p ro x . 1 P .S .I.
★ B a s e d o n 9 0 ° F a m b ie n t a n d 9 0 ° F a ir in le t te m p e ra tu re s . C o o le r a m b ie n t a n d (or) a ir in le t te m p e ra tu re s re q u ire le s s flo w .
T M in im u m b a c k p re s s u re re q u ire d fo r p ro p e r a ir c irc u la tio n th ro u g h th e lin e r c o o la n t c h a m b e rs .
■ F lo w ra te re q u ire d a t 1 2 0 ° F o il in le t te m p e ra tu re , 9 0 ° F a m b ie n t te m p e ra tu re a n d a t 6 0 0 0 fp m s h a ft s p e e d u n d e r m a x im u m ra d ia l load.
S lo w e r s p e e d s a n d lig h te r lo a d s re q u ire le s s flo w .
► V o lu m e o f o il re q u ire d to fill p illo w b lo c k to to p o f c e n te r c irc le in o il g a g e . A p p lie s to b o th X C a n d P la in P illo w B lo cks.
• 3 2 fl. oz. = 1 q t. = .9 4 6 3 6 lite rs .

18

SLEEVOIL RT blocks are designed lor applica­
tions requiring a bearing with high thrust load
capacities. Both RT10 (plain) and RT20 (water or air
cooled) pillow blocks are available In expansion or
non-expansion types and can be modified lor cir­
culating oil.
Dodge Sleevoil RT20 Pillow Block Bearings
(Sizes 3 7/16" thru 12")
INSTALLATIO N
The installation of this bearing is essentially
the same as the XC bearing on Pg.16. The
difference is that the RT20 bearing has a
single thrust collar in the center with thrust
plates on each side. Proceed with installa­
tion per section 1-3 page 16, then:
4. Set liner base in housing base. When us­
ing circulating oil or a thermocouple make
sure the holes in the liner will align with the
holes in the housing when the pillow block
is assembled. Apply oil to the liner bear­
ing surface.
5. Inspect shaft to insure it is smooth (32
micro-inch or better), within commercial
tolerances and free of burrs or rough spots.
If bearing used is a nonexpansion (fixed)
type, check thrust collar for burrs and scrat­
ches. Use crocus cloth (not emery) to
smooth any scratches on thrust cottar
faces. If clamp-on type thrust collar is us­
ed, it should now be installed. Remove jam
screws and back off set screws so they do
not protrude into the I.D. of the thrust col­
lar. Remove clamp screws and make sure
joints of thrust collar are clean. Place both
halves of thrust collar into shaft groove and
tighten clamp screws alternately and even­
ly. The collar faces should be smooth with
no offsets at the split. Tighten the set
screws. Install and tighten the jam screws.
Oil shaft in the bearing area and set shaft
in place. The thrust collar must be centered
in the cavity of the liner base.
N O N -E X P A N S IO N U N IT
BABBITT FACED
THRUST PLATE
SPLIT THRUST
COLLAR
OIL RING
O q
0 0 / /
FIGURE 24
6. Place oil ring around outside of liner
base and over shaft. Install and peen oil
ring screws to insure they are secure. Make
sure rings rotate freely on shaft. Note: Do
not use oil rings if liner cap has baffles
installed in the oil ring grooves.
7. For Non-Expansion Bearings: Clean
one set of the babbitt faced thrust plates.
Note that the plates are matched halves
and must not be interchanged. Careful­
ly smooth any scratches on babbitted face
with crocus cloth (not emery cloth or
sandpaper). Oil plate halves generously.
First install the plate half without milled
slots in the steel back. Press the babbitted
face against the thrust collar and rotate
plate around shaft into liner cavity. Install
retainer washer in groove in liner base.
Rotate plate until stopped by retainer
washer, Place other thrust plate half (half
with two milled slots in steel back) against
thrust collar, making sure babbitt faces the
thrust collar. Clean and oil the second
thrust plate set and install in the same man­
ner. It may be necessary to move the shaft
slightly to obtain enough clearance in the
liner cavity to install the lower thrust plate
half. (Caution: the bearing is not yet fasten­
ed in place and can be moved).
Note: Thrust collar clearance for all size
RT Bearings are .015 - .026).
8. Apply oil to the bearing area of the liner
cap. Locate liner cap on liner base (cap is
not reversible on base). Make sure oil rings
rotate freely. End faces of liner should have
19
BABBITT FACED
THRUST PLATE
OIL RING
■ > o
o
n
no appreciable offset. Install and tighten
cap screws alternately. If liner cap on the
non-expansion bearing will not drop into
place, remove it and reposition thrust
plates tightly against thrust collar. Then re­
install liner cap.
9. Check alignment of pillow block by
noting clearance between housing bore
and shaft at each end of the housing —
clearance should be uniform within 1/32".
Use shims under base as required. Align­
ment of the pillow block should be as ac­
curate as possible. The self-alignment
feature of the unit is to compensate for nor­
mal shaft deflection and possible settling
of the supports. Tighten mounting bolts
securely. Shaft should rotate freely.
10. Wrap the O-ring (rubber cord) around
the shaft in the seal area and cut it to fit
the shaft. Disassemble one seal and place
one half on shaft with finger facing liner.
Locate O-ring in seal groove and rotate seal
half around shaft into housing base groove.
For most effective sealing, ends of O-ring
must meet. Cementing ends together is
recommended. Install other half of seal and
tighten screws. Install second seal in same
manner. _
Caution: If it ever becomes necessary to
remove liner cap, make certain that both
upper thrust plate halves remain in place
next to the thrust collar. If a plate half
should remain in the liner cap it can drop
from the liner and cause injury.
Solid Pillow Block Spherical Roller Bearings
(Link Belt Series B22400 or SKF Series SYR)

IMPORTANT — Read Carefully
These instructions are provided to aid in
the proper installation, operation and
maintenance of spherical roller bearing
units. They should be carefully read and
followed. Failure to do so may result In
unsatisfactory service as well as serious
D. Bolts — Housing mounting bolt
tightness is important to prevent the hous­
ing from shifting, and to adequately sup­
port loads.
E. Setscrews — Setscrews must be pro­
perly torqued to prevent the shaft from slip­
ping in the inner ring and to prevent loosen­
6. Final Positioning — Establish final shaft
position and secure locking collar or fixed
unit to shaft. Tighten collar setscrews to the
torque values given in Table VIII.
TABLE VIII - Setscrew Tightening Torque
Shaft Size (In.) Seating Torque (In./Lbs.) (1)

personal injury or property damage. ing during operation. % to 1 Vi 185

1VL to 2 325
F. Free Rotation and Alignment — Check
CAUTION for free rotation before machine start-up to 2'M to 2'A 460

assure that final alignment is proper. 2V.» to 3'/2 680

The reliability built in all Link-Belt bear­
ings can be realized in service only when
they are correctly selected, properly install­
ed, protected and maintained.
The correct selection of bearings or
mounted units requires that the magnitude
and nature of all loads, speeds, alignment,
mounting, operating requirements and
maintenance be adequately considered.
The selection of materials for and design
of housings, shafting, fasteners, seals and
accessories as well as provisions for in­
stallation and maintenance must follow
good engineering principles.
Housings must be selected and install­
ed with regard to the degree and direction
of the forces that will occur. Housings
should not be used under tension loads ex­
cept with adequate safety factors. For this
reason pillow blocks are best suited to
withstand radial loads passing through the
base. When heavy loads or shock loads are
possible, it is most important to mount a
unit so that the line of force passes direct­
ly into its base, or so that the unit is direct­
ly and substantially supported other than
through its mounting bolts. Where the line
of force falls outside the base, such as with
horizontal or uplift loads on pillow blocks,
serious housing and fastener deflection or
failure may occur. These conditions may
require designs using different materials,
fasteners, mounting design, stop bars, etc.
together with proper safety factors.
The following general points of installation
and operation are very im portant.
A. Cleanliness — Keep dirt, water and
metal chips off all parts.
Although bearings are alignable in hous­
ings, they will not “ self-align” in many
cases and destructive moment loads may
be imposed if initial installation alignment
is not provided.
G. Lubrication — Units designed for
relubrication must be ad equ ately
lubricated. A bearing not properly
lubricated can run to destruction and
possibly cause damage to other com­
ponents. Add grease slowly. Rapid applica­
tion may blow the seals and allow grease
to escape.
INSTALLATION
1. Check Shaft — Shafting must be clean,
round, straight, free of burrs and nicks and
of correct size. For the average installation
with moderate loads and speeds, the shaft
should measure as follows.
Shaft Recommended
Diameter Tolerance
3/4" thru 2" Nominal to minus .0005"
2 1/16" thru 5" Nominal to minus .0010"
2. Shaft Preparation — When frequent
removal of bearings is anticipated, file flats
on the shaft approximately 1/16" deep
under the collar setscrew locations. This
provides for easy removal, as bearings will
clear the burrs caused by correctly tighten­
ed setscrews.
3. Lubricate Shaft & Bearing Bore —
Coat the shaft and bearing bore with
grease or oil to facilitate assembly.
4. Assemble on Shaft — If it is necessary
to tap or press units on the shaft, use a
hardwood block, soft steel bar or tube
against the end of the inner ring. Do not
strike or exert pressure on housing or
seals.
39/ i to 5 1350
(1) Values can vary ± 5 %
Note: Satisfactory tightness can be obtained
using a standard hex wrench (50-52 minimum
RHN C ) and tightening until a slight permanent
twist is obtained in wrench for each screw.
7. Bolt Expansion or Other Unit to Sup­
port — If an expansion unit is used, posi­
tion the cartridge in the housing to allow
for adequate movement in the direction of
expected expansion. Align and shim the
housing as necessary to place the bearing
in the approximate centers of their hous­
ing alignment range. Bolt unit securely to
its support. (Reference step 5).
8. Final Mounting — Rotate shaft slowly,
under load if possible, for several revolu­
tions to properly center the roller elements
with respect to the raceways. Securely
tighten collar setscrews of remaining bear­
ing, following the same procedure as outlin­
ed under step 6.
9. Check System for Freedom of Rota­
tion — Any condition of strain, irregular
rotational torque, abnormal sound or vibra­
tion may be due to improper alignment, im­
proper location, bent shaft, distorted sup­
ports, etc. Installation should be recheck­
ed and corrections made as required.
The use of stop bars welded to the support
at each end of the units leaving about 1/32"
space for ease of assembly is good prac­
tice. Wedge shims in 1/32" space after
units are securely fastened. These bars
assure proper location of the units and pre­
vent shifting when loads are applied.

B. Careful Handling — Hammer blows or 5. Bolt Fixed or Locating Unit to Support

improper use of force can damage preci­
sion parts.
C. Shaft Fits — Bearings should have pro­
per fits on the shafts to minimize fret wear.
See installation instructions for shaft
tolerances.
Bolt fixed unit securely to its support.
Bolt grade selection is important on many
applications depending on load and shock
conditions. SAE Grade 5 mounting bolts
properly torque can be used. Grades over
SAE 5 should not be used with cast iron
housings.

20
LUBRICATION
TABLE IX - Grease Lubrication
Units are prelubricated but make sure Bearing
A m bient O perating
they have adequate grease. As a precau­ c o n d itio ns co n d itio ns operating Suggested
Use these greases
tem perature greasing
tion, if equipment is to be built and left idle in te rva l**
or e q u iva le nt
for any period of time prior to actual use, D irt M oisture Load Speed Low High
the units should be filled 100% full to pro­ L ig h t Slow 0 120 2 to 6 months
vide maximum protection from corrosion, C lean Dry to to
m edium medium 120 200 1 to 2 months
etc. The suggested relubrication schedule High q u a lity NLGI #1 or 2
under Table IX is a general guide. M oderate L ig h t Slow 0 120 1 to 4 w eeks m ulti-p u rpo se bearing greases
to Dry to to are generally satisfactory.
Dirty m edium m edium 120 200 1 to 7 days C onsultation w ith a
The specific conditions on an application reputable lu b rica n t supplier
Extreme Light Slow is recom m ended.
such as exact hours of operation, Dry to to 0 200
D a ily-flu sh ing
D irt o u t d irt
temperature, moisture, speed and dirt m edium m edium
govern the required lubrication cycle. This High
Mobil Oil Corp.,
can be determined by inspection of the hum idity Light Slow 1 to 4 w eeks
* D ire ct to to Mobilith AW-2
32 200 grease at
flushed out lubricant during a trial period w ater heavy m edium shutdow ns Texaco Inc., Premium RB2
of operation. Add grease slowly. Use a suf­ splash Shell Oil Co., Alvania EP2
ficient volume of grease to purge the bear­ Heavy 0 200 1 to 8 w eeks S hell O il Co., A lva n ia EP2
ing seals of old lubricant. It is preferable to Slow
very
to rotate bearings during relubrication heavy -2 0 120 1 to 8 w eeks S hell Oil Co., A lva n ia E P-RO
where good safety practice permits.
Amoco, Rykon No. 2
Light High 100 200 1 to 8 w eeks Mobil Oil Corp., Mobil- 1
Inspection of bearing installations at speed
grease 532
least every six months is recommended.
Any unusual noise or vibration change Possible L ig h t Slow 1 to 4 w eeks Mobil Oil Corp., Mobiltemp SHC32
frost to to -6 5 250 grease at Texaco Inc., 2346EP Low Temp
should be immediately investigated. heavy medium shutdow n Shell Oil Co., Aeroshell 7A
C lean Light Slow
Union Oil Co., Unoba EP2
to Dry to to 80 250 1 to 8 w eeks
m oderate m edium m edium Mobil Oil Corp., Mobiltemp 78

Clean Keystone L ubricants Co.,

to Dry No. 89
Light Slow 80 300 1 to 4 w eeks
dirty Dow C hem ical Co., DC44

'A dditional bearing protection or special sealing may be required.

"S u g g e s te d starting interval for maintenance program. Check grease condition for oiliness and dirt and
adjust greasing frequency accordingly. Watch operating temperatures. Sudden rises may show need for
grease or indicate over lubrication on higher speed applications.

Chicago Blower Corporation cannot be held responsible for performance of individual batches of grease.
Changes in lubricant specifications, performance, and lubricant guarantees are the responsibility of the
lubricant manufacturer.

Spherical Roller Adapter Bearing (Refer to pages 22 and 23)

IN B O A R D
LO CK F LO A T RANGF
W A SH ER OUTBOARD
F L O A T RANGE S T A B IL IZ IN G RIN G

LOCKNUT L O C K W ASH ER
SLEEVE SLEEVE
S C R IB E L IN E LOCKNUT

FAN FAN
W H E E L \J\ D R IV E

S C R IB E L IN E

FIGURE 25

21
Split Pillow Block Spherical Roller Bearings
(Link Belt Series 6800 or SKF Series SAF 22500)
IM PO RTANT — Read Carefully 3. Check Shaft — Shafting must be clean, 7. Tighten Bearings — Bearings must be
round, straight, free of burrs and nicks and mounted to achieve the required clearance
These instructions are provided to aid in of correct size. Shafts should measure as removal.
the proper installation, operation and follows:
maintenance of spherical roller bearing Shaft Recommended
units. They should be carefully read and Diameter Tolerance
followed. Failure to do so may result in
unsatisfactory service as well as serious 1 7/16" to 2 ” Nominal to minus .003"
personal injury or property damage. 2 1/16" to 4 " Nominal to minus .004"
4 1/16" to 6" Nominal to minus .005"
The following points of installation and 6 1/16" to 13" Nominal to minus .006"
operation are very important:
If felt “A” seals are used, be sure that any
A. Cleanliness — Keep dirt, water and
tool marks or ridges are removed under the
metal chips off all parts. seal area. For higher speed operation with
felt seals, shaft should be polished or a. Measure the initial built-in clearance
ground to 10-20 micro-inch finish. across the top rollers by sliding the largest
Careful Handling — Hammer blows,
overheating, or improper use of force can possible feeler gage between the rollers
damage precision parts. 4. Assembly on Shaft — Slide steel seal and outer ring raceway as shown in figure
rings if used, bearing, adapter and ac­ 26. A snug, or hard, feel is recommended.
C. A dapter Sleeve Tightening — Bear­ cessory parts on the shaft in the right order. It must be possible to remove the shim by
ings must be correctly forced up their See figure 25. Apply mixture of white lead pulling it straight out.
tapered adapter sleeves to obtain the and oil or a powdered dry lubricant to
recommended clearance removal. Im­ tapered surface and threads of adapter b. Tighten the locknut forcing the bearing
properly tightened bearing and adapter sleeve and to the inside (small) face of the up the tapered O.D. of the sleeve until the
assemblies may slip or turn on the shaft. locknut. bearing measured clearance is reduced by
See Table X. the amount shown in Table X. Follow the
B E A R IN G
LOCKW ASHER tightening procedures outlined in Step 8.
D. Bolts — Housing mounting bolt and cap LOCKNUT

bolt tightness is important to prevent the A D A P T E R S LE E V E T A B L E X B e a r in g C le a ra n c e R e d u c tio n

housing from shifting, and to adequately R e d u c t io n of
support loads. FAN SHAFT P illo w B lo c k R a n g e B e a r in g R a n g e C le a ra n c e , In.
M in , M an.

M U LTI 2 2 2 Q 9 L B K th ru 2 2 2 1 0 L B K .001 0 .0015

E. Free Rotation and Alignment — Check
6 8 2 3 th ru 6 8 2 8
LAHRINTH 6 8 2 9 t h ru 6 8 4 4 2 2 2 1 1 L B K th ru 2 2 2 1 6 L B K .001 0 .0020
for free rotation before machine startup to SEA L 6 8 4 5 t h ru 6 8 6 8 2 2 2 1 7 L B K th ru 2 2 2 2 4 L B K .001 5 .0025

assure that final alignment is proper. 6 8 6 9 th ru 6 8 9 2

6 8 9 3 t h ru 6 8 1 0 4
2 2 2 2 6 L B K th ru 2 2 2 3 2 L 8 K
2 2 2 3 4 1 B K t h ru 2 2 2 3 6 L B K
.0020
.002 5
.0030
.0035
M U L T I-L A B R IN T H S E A L FIGURE 25 6 8 1 0 5 t h ru 6 8 1 1 6 2 2 2 3 8 L B K t h ru 2 2 2 4 0 L B K .0025 .004 0

F. Lubrication — Units must be adequate­ 681 17 th ru 68128 22244LBK .0030 .005 0

ly lubricated. A bearing not properly 5. Position on Shaft — Locate the bear­

lubricated can run to destruction and ing and sleeve snugly on the shaft in the T A B L E XI F IN A L IN T E R N A L C L E A R A N C E
possibly cause damage to other com­ desired position. Fixed bearings are
ponents. See Table IX. located with the bearing face opposite the B e a r in q S iz e C le a ra n c e *
locknut up against the housing shoulder. 2 11/16 .0025 - .0035
INSTALLATIO N Expansion bearings are usually centered 2 15/16 .003 - .004
in the housing seat between the shoulders 3 3/16 .003 - .004
1. Preparation — Remove parts from car­ to allow for shaft expansion or contraction. 3 7/16 .003 - .004
ton but do not remove parts from individual A shaft with a pair of bearings normally has 3 15/16 .0035 - .0045
wrapping until ready to use. The preser­ one fixed and one expansion pillow block. 4 7/16 .004 - .0055
vative on the bearing is compatible with The fixed unit is usually located adjacent 4 15/16 .004 - .0055
most petroleum lubricants and normally to the drive. The fixed bearing takes any 5 7/16 .0045 - .006
need not be removed. Cap and base are thrust loads. In locating, take into account 5 15/16 .005 - .007
machined as matched units and are not in­ that tightening correctly will move the bear­ 6 7/16 .005 - .007
terchangeable. Mark each before taking ing further up the tapered sleeve. Do not 6 15/16 .0055 - .0075
apart to prevent mixing with other bases tighten locknut beyond finger tight at this 7 3/16 .0055 - .0075
or caps. time.
’ Clearance is measured between rollers and
outer race after mounting and tightening
2. Mount Housing Base — Use jack 6. Install Shaft Assembly — The shaft adapter. (Refer to Figure 26).
screws in dowel pin holes to disassemble with bearing assemblies may be lowered
base and cap. Avoid use of pry or wedge into housing bases before or after tighten­ 8. The preferred method of tightening for
at the split line. If oil cup or feed line is us­ ing the bearings, depending on accessibili­ easy installation and tor not damaging the
ed install at this time using sealant on all ty. Lower slowly and position bearings and bearing is illustrated in figures 27 and 28.
plumbing threads. Be sure housing support seals to engage housing base. If bearing Using a Spanner wrench, tighten the
plate is flat and free from warpage. Bolt outer rings become misaligned do not force locknut until snug. Hold the adapter sleeve
base to support square with the shaft. Draw back into position. Instead, carefully work from turning until firmly seated. Using a soft
up base mounting bolts snugly, but not to back by turning and sliding. Be sure that steel bar and a hammer, drive against the
final tightness. the inside of the housing is clean. face of the locknut as shown to relieve the
22
thread pressure. Retighten the locknut and 9. Secure Locknut — Bend a tang of the base. Finally, tighten or torque mounting
repeat until the correct adjustment lockwasher down into one of the locknut bolts securely. Up to SAE Grade 5 mount­
specified in Step 7 is obtained. Where slots. Use the slot which is most nearly lin­ ing bolts can be used, properly torqued to
space limitations prohibit the above ed up with a tang. On larger units with a mount cast iron housings. Up to SAE
method, use a heavy duty spanner wrench lockplate, engage the key of the lockplate Grade 8 mounting bolts can be used, pro­
and stroke on its handle with a hammer so in the adapter slot and bolt to the locknut. perly torqued, to mount cast steel
as to tighten the unit. This is more difficult Use wire to lock bolts. Insert "C ” spacer housings.
and requires care to avoid damaging the in fixed bearing housing, usually on locknut
lockwasher, locknut and housing machin­ side. GREASE LUBRICATION
ed surfaces. With large units a combina­
tion of both methods can be successfully 10. Lubricate — Lubricate before opera­ Grease lubrication is recommended
used. tion. Consult the sections on grease or oil wherever conditions in Table IX exist. For
lubrication. Refer to table IX. conditions which are not completely
covered, consult Chicago Blower Corpora­
11. Install Housing Cap — Apply non­ tion. The greases listed are for a general
hardening gasket compound to cap sur­ guide. A reputable lubricant manufacturer
faces which contact the base. (Especially should be consulted to confirm the lubri­
for oil lubrication). Tighten cap nuts or bolts cant selection and application.
securely.
If bearings require oil instead of grease
12. Com plete Assembly — With the due to high tip speeds, temperature or high
mounting bolts snug, check alignment and radial and axial thrust loads, see Table VI
freedom of rotation. The housing or shaft and VII on page 18 and see page 24.
clearance at the seals is small and can be
visually checked for uniformity all the way
around.

Align by shimming or shifting as

necessary. Use large area shims to avoid
distorting the housing and pinching the
bearing. Appropriate use of stop bars
against faces or ends of feet opposite the
direction of load or vibration to avoid shift­
ing of the housing is recommended. Dowel
pins can be equally effective if properly us­
ed. This is especially important where
loads are not directly down through the

Spherical Roller Adapter Bearing

.INBOARD
LOCK FLOAT RANGF
WASHER OUTBOARD
FLOAT RANGE STABILIZING RING
LOCKNUT LOCK WASHER
SLEEVE SLEEVE
SCRIBE LINE LOCKNUT

A '
FAN <( FAN
WHEEL ' DRIVE

SCRIBE LINE

FIGURE 29

23
OIL LUBRICATION
Oil Cup or Oil Bath Lubrication:
Oil cups can be applied to these units for
use as a self-contained oil bath system. Oil
bath lubrication is not recommended for
speeds above the catalog oil speed limits,
where excessive oil churning or misting oc­
curs, or where there is air flow across the
housing which will pull oil out through the
seals due to differential pressures.
Oil levels are controlled by sight gages, oil
cups, etc. These should be used in con­
junction with a vent or breather cap. Pro­
per static oil levels are shown in Table XII.
Cups or sight gages should be carefully
marked.
tween 100 and 150 Saybolt seconds (SSU)
at bearing operating temperature for oil exit
temperature on circulating systems. Slow
speed, heavily loaded bearings require
much higher viscosities.
Where starting temperatures are very low
compared to operating temperatures,
heaters may be necessary to provide oil
flow in the lines or to provide adequate
lubrication at start-up.
Maintenance and Lubrication:
Oil cup or bath systems require close at­
tention because of the limited amount of
oil in the system. Frequent changing of the
oil in these systems is necessary to avoid
lubricant breakdown.
Oil circulation systems, properly equipped
with safety devices require minimum atten­
tion after they are once satisfactorily ad­
justed. Frequency of changing the oil in the
system depends upon the severity of the
operation and size of the reservoir. In either
case summer and winter grades may be
necessary to stay within the recommend­
ed viscosity limits for good lubrication.

Circulating Oil Lubrication: Table XII - Static Oil Level

Oil circulation systems can be used under
L
a wider variety or under more extreme
operating conditions than any other lubrica­
Static oil level
tion method. They are especially valuable Bearing size A D below bearing center line
for high speed and high temperature ser­ High Low
vice to provide better lubrication and cooler Inches
operation.
17/16, Vk 21/4 7/l6 19/32 13/8
A complete circulation system includes the 111/16, 1% 21/2 9/l6 13/8 1O
il*15/32
use of pressure pump, a heat exchanger,
115/16, 2 2% 9/l6 11%2 15/8
or a method to cool oil, an adequate sump,
a filter to remove particles over 20 micron 23/l6 , 21/4 3 V2 1% 115/16
in size and safety devices such as pressure 3V32 21/4
27/,6 3/4 5/8
and temperature warning devices and filter
bypasses. It is also best to tap oversized 211/16 31/2 3/4 23/,6 2%2
drain holes in the base or to provide a suc­
•sCO

215/32
CO

215/16, 3 13/16 2 5/ i 6
tion pump to positively remove oil from the
35/16 4 3/4 215/32 25/8
housing. Oil should be removed from both
sides of the housings, but where speeds 37/ 16, 31/2 4Vz 7/e 225/32 215/16
are not high, one side is sufficient. 3%2
311/ 16, 315/16, 4 415/16 7/e 31/16
It is recommended that the circulation 43/16 51/4 1 35/l6 31/2
system have a separate motor so that the 47/l6 , 4y2 6 11/4 39/l6 33/4
oil flow can be started in advance of bear­
ing rotation. E xperim en tatio n with 415/16, 5 6 11/16 37/8 41/16
pressures, flow rates, temperatures and 53/16 6 5/ i 6 1Vl6 45/32 4H/32
viscosity is often necessary to establish the 57/16 1 415/32 431/32
611/16
best possible bearing lubrication.
515/ 16, 6 71/16 11/s 43/4 415/16
Oil Viscosity: 67/i6 71/2 iy 8 431/32 55/32
The required viscosity for good lubrication
615/16, 7 77/e 11/4 51/4 57/16
depends on starting tem peratu res,
operating temperatures, and speed. The 73/16 81/4 13/b 59/i6 53/4
recommended viscosity level for bearings
71/ 2, 715/ i 6, 8 91/z 21/2 65/32 611/32
operating within catalog speed limits is be­

Schematic Diagram of Circulating Oil System Dimension Guide

24
Record of Fan Installation
Job S ite_________________________ System
Fan Size _______________________ Chicago Blower Fan Serial No.
Design_____________ Class_______ _____ Fan Assembly Dwg.#___
Fan Rated CFM________ .Fan Rated Static Press. .Fan Rated BHP.
Maximum Operating T e m p .__ Fan Maximum Operation Speed
Size Bearings______________ Type ___________ MFG’R . __________
Size Coupling______________ Type ___________ MFG’R . __________
Motor HP._____________ RPM. .Frame Size. .MFG’R.
Date Fan Shipped______ Date Installation Completed. Date Fan Start.
Name CBC Service Engr. Name Millwright in Charge
Fan Purchased From ____ . Installing Contractor_____
Chicago Blower Local Sales Office Phone

Warranty
Chicago Blower warrants products of its manufacture to be free of defects in material and workmanship if properly installed, cared for, and
operated under normal conditions, and with competent supervision. This warranty is subject to the following terms and limitations:
(1) Chicago Blower’s obligation under this warranty is limited to replacing or repairing at its factory any defective part or parts which shall,
within one year after shipment thereof to the original purchaser, be returned to its factory with transportation charges prepaid, and such repair
or replacement of defective parts shall be the buyer’s sole and exclusive remedy, and Chicago Blower shall not be liable for injury to persons
or property. Should the goods prove so defective, however, as to preclude the remedying or warranted defects by repair or replacement, the
buyer s sole and exclusive remedy shall be the refund of the purchase price. In no event shall Chicago Blower be liable for incidental or
consequential damages.
(2) Chicago Blower shall not be liable for any such defective part or parts, or for any loss, damage, or any expenses of repairs when any
adjustment, alteration or repair shall have been made or attempted outside of its factory, except by its written consent previously obtained.
(3) No liability attaches for any corrosion or fouling caused by any foreign substance deposited therein or thereon.
(4) Inasmuch as no forms of construction, materials, alloys or coatings are known to us which will successfully resist all abrasion, erosion,
corrosion, or deterioration from excessive heat, Chicago Blower’s warranty does not extend to the life of any of its products or equipment
when subjected to conditions which cause such damages.
(5) Research undertaken by the A ir Movement and Control Association, Inc. in cooperation with test code committees of the engineering
societies, reveals thus far that no accurate or practical method of testing fans in the field has been developed by means of gas analysis
or by use of the Pitot tube or other instruments, since the values obtained from field tests vary so widely from actual results. Guarantees
of the performance of fans can only be made from laboratory tests conducted by the manufacturer in accordance with the "standard
test code for centrifugal and axial fans” approved jointly by the Air Movement and Control Association, Inc. and the American Society of
Heating, Refrigeration and A ir Conditioning Engineers, with cooperation from Committee No. 10 of the Power Test Code Committee
of the American Society of Mechanical Engineers.
(6) ALL WARRANTIES, EXPRESS OR IMPLIED, WITH RESPECT TO MOTORS, SWITCHES, CONTROLS OR ACCESSORIES, INCLUDING
THAT OF MERCHANTABILITY, ARE HEREBY EXCLUDED. However, these products are usually warranted separately by their respective
manufactures.
(7) Chicago Blower shall have no liability under the terms of this warranty or otherwise where the buyer undertakes the responsibility of mount­
ing the fan wheel directly to the motor or turbine shafts or where the buyer tests or runs the assembled fan without Chicago Blower having
the opportunity of checking and testing the assembled unit.
(8) Compliance with the provisions of OSHA, 1970, PL91-596 is the responsibility of the user of the equipment. Chicago Blower Corporation
does not warrant its products to be in compliance with OSHA.
(9) Due to the variety of applications for Chicago Blower products, the Corporation has no responsibility for suitability of the product for the
purchaser’s use. Responsibility of intended use is that of purchaser.
(10) ALL OTHER WARRANTIES, EXPRESS OR IMPLIED, INCLUDING ANY IMPLIED WARRANTY OF MERCHANTABILITY OR FITNESS
FOR A PARTICULAR PURPOSE, ARE HEREBY EXCLUDED.
(11) These warranty provisions may not be modified except by written agreement signed by an officer of Chicago Blower.

25
 gHICJitia BLOWER
PRODUCTS
Packaged
Ventilation
FOR EVERY A IR HANDLING REQUIREMENT Packaged
Farced Draft

DETAILED INFORMATION SUPPLIED UPON REQUEST

CHICAGO BLOWER CORPORATION

1675 Glen Ellyn Road • Glendale Heights, IL 60139 • Ptione (708) 858-2600

High Pressure Induced nr Forced

Industrial Air Air Supply Draft
Exhaust

‘C H IC A G O ” SALES ENGINEERS COAST TO COAST

ALABAMA F L O R ID A KANSAS M IS S O U R I O H IO TENNESSEE
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Peoria B e nton H a rb o r S c h e n e c ta d y P E N N S Y L V A N IA
COLORADO W E S T V IR G IN IA
R ockford D e tro it S yra cu se Erie
D en v er C h a rle s to n
G rand R apids U tic a H arris b u rg
C O N N E C T IC U T IN D IA N A
J ackson W a te rto w n P h ila d e lp h ia W IS C O N S IN
B rid g e p o rt E vansville
K a lam a zo o P itts burgh M ilw a u k e e

O
N O R T H C A R O L IN A
under H a rtfo rd
D IS T R IC T O F C O L U M B IA
Fort W a y n e
In d ia n a p o lis
Lansing
M u s k eg o n
C h a rlo tte R H O D E IS L A N D
S outh Bend G re e n s b o ro P ro vid e n ce
W a s h in g to n M IN N E S O T A
“Fans” or “Blowers” IO W A
D es M o in e s
D uluth
N O R TH DAKOTA
Fargo
S O U T H C A R O L IN A
G ree n v ille
M in n e a p o lis
St. Paul

You can buy Ians in Argentina, Australia, Benelux. Brazil, Canada, Chile. Colombia, France, Greece, Holland, India, Indonesia, Israel, Japan.
Malaysia. Mexico. Hew Zealand. Norway. Pakistan, Philippines, Portugal, Singapore, South Africa, Spain, Sweden, Taiwan, Turkey. Venezuela, and West Germany.
P R IN T E D IN U S A
iiirri-u M V itfw irf
 iw ft ih n a ^

BILL OF MATERIAL

mro f i S S j u OCSCfflPDON ASSy/PAXT §

T 1 A HOUSING ASSEMBLY B19 —3 —4031
T 2 B ROTOR ASSEMBLY B 1 9 - 5 —3 5 9 0 -2
2 3 C BEARING 2 1 1 /1 6 * 5 —2 - 5 - 6
1 4 D COUPLING
1 5 E MOTOR
± 8 F SILENCER
1 T 7 _G_ INLET CONE W/T/C 1 9 -4 -5 6 3 -2 4
T 8 IVC LINKAGE 1 9 -4 -7 1 7 -7 -5 0
1 i 9 ORAJN PLUG 1 1 /2
II 0 -2 -1 8 -4
I —1 10 FUNCED INLET B 1 9 - 4 - 8 3 -1 0
1 i 11 SHAFT BRG GUARD-DRIVE B19 - 9 - 3 6 9 6
1 12 ACCESS OOOR-SCROU. C l 9 -9 -2 1 1 2 -6
1 i 13
■
1
SHAFT SEAL-ORIVE B 1 9 - 7 - 1 6 3 9 -1
1 1 14 NAMEPLATE 0 -9 -1
1 1 15 NAMEPIATF 1 9 -9 -2 3 4
1 AR 16 PAINT CSC STD BLACK
AR 17 GASKET S K -9 -7 9
AR 18 CREASE - BEARING 2 -9 -4
19
20
21
8 24 22 HEX BOLT 1/2-13X2 1/4 7 -2 -1 -9 3
24 23 FLATWASHER 1 /2 7 -2 -2 1 -1 4
5
s 24 24 LOCKWASHER 1 /2 7 -2 -2 6 -1 4
O' 4 25 HEX BOLT 3/4-10X4 1/2 7 -2 -1 -1 3 9
e
o
4 26l HEX NUT 3 / 4 - 1 0 7 -2 -3 1 -7
2 8 27 FLATWASHER 3 / 4 7 -2 -2 1 -1 6
4 28 LOCKWASHER 3 / 4 7 -2 -2 6 -1 6
O
2 4 29 HEX BOLT 3/4-10X4 1/2 7 -2 -1 -1 3 9
5 4 30 HEX NUT 3 / 4 - 1 0 7 -2 -3 1 -7
1 1 /2 HALF CPLG. 3 8 31 FLATWASHER 3 / 4 7 -2 -2 1 -1 6
± 32 LOCKWASHER 3 / 4 7 -2 -2 6 -1 6
NOTES: FOR DRAIN
r - . 33
34
33 1 /8 A. HOUSING ASSEMBLY CONSISTS OF THE FOLLOWING:
- SCROLL SIDES - WELD CONTINUOUS - 5 / 1 8 HRS 35
- HSG BRACING - STITCH WELD - HRS _ 36 _
29 1 /8 - BRG. BASE * / OR - WELD CONT. OUT - HRS
- MOTOR BASE STITCH WELD IN.
WHEEL REMOVAL THRU INLET HOLE.

B. ROTOR ASSEMBLY CONSISTS OF A CORTEN AND HRS WHEEL

INTERFERENCE FIT ONTO A 2 7 / 1 6 OIA. SHAFT AT CAST
IRON WHEEL HUB.
C. BEARINGS ARE UNKBELT 6800 SERIES, OR EQUAL. SPHERICAL
29 1 /8 ROLLER. SPUT PILLOW BLOCK. 2 1 1 /1 6 BORE, C - 3 FIT,
2 BOLT MOWTONG, GREASE LUBRICATED. BEARINGS ARE FACTORY
VffrH Te x a c o M0LY1EX E P I2 CREASE. AT START UP
33 1 /8 USE PROPER GREASE PER BRG. MANUFACTURER'S INSTRUCTIONS.
ONE FIXED AND ONE FLOATING BEARING.
D. COUPLING IS A FALK STEELFlfX 1 100T10 BORED FOR
INTERFERENCE FIT ON THE FOLLOWING SHAFT OUV~TT S:
FAN SHAFT: 2 .6 8 7 0 /2 .6 8 6 0 WITH 5 / 8 X 5 / 1 6 u
r . £ 3 7 5 0 /3 .3 7 4 0 WITH 7 / 8 X 7 / 1 o <EtWAY
FJRNIS IED AND MOUNTED BY CBC.
E. MOTOR IS A MARATHON PREMIUM EFF. FURNISHED AND MOUNTED
BY CBC. MOTOR SPECS AND OPTIONS ARE AS FOLLOWS: "
21 - 445T FRAME - 2 5 0 HP - 1 800 RPM - 3 / 6 0 / + 6 0 VOLT ONE (1 ) U N IT R E Q U IR E D
- TEFC
F. INLET SILENCER IS A VAW MOOEL 89V R H B -22 FURNISHED TOTAL APPROX. UNIT WT. - 5818 LBS. (LESS MOTOR)
BY CBC ANO MOUNTED BY OTHERS. SEE SILENCER DRAWING r APPROX. MOTOR WT. « 1785 LBS.
FOR DETAILS. SIIZNCER OPTIONS ANO SPECS AS FOLLOWS: *■
- BIRDSCREEN. * APPROX. ROTOR WT. - 5 5 + LBS.
G. INLET VALUME CONTROL IS 9-BLAOED WITH LINKAGE T WHEEL OUTSIDE DIA. - 52T
SUITABLE FOR MANUAL OPERATION. ‘
INLET VOLUME CONTROL TORQUE - 120 FT-LB • 70T

"CAUTION TOLDWW UNLESS s-°- t

ctmmbc
196693 HOX | d s r P.O. f C R -7 4 4 3 5
PW» W PB.IUI NO S M H T . CUST- CLEAVER BROOKS I J®8 /. ■ "1 .
CLEAVER BROOKS
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xfi O NONE V - >/• FOB CON MINES CQRIP "< 1675 GUN ELLYN ROAD. CUNOALI HEIGHTS, L 60139
O) BHP
ov SP OPGL WR2
1PERFORMANCE

d MOMO110 RDM OCMd K tUUM M SMCMC CPU n/M N M W.C RPM ALT. title F A N A S S E M B L Y
n of swncoo set n k m oowce or council Mas r. r r n D QC9TY
ESfawr IB-FT2 OES 1903. SIZE 4900. CCW ROT. BAU Dl^CH
•S 9CW ON MS CMM. vam P S
o ms oocucnja to ta w m m v m Mattum 45509 28.95 1782 246.9 173 100 .0633 1030 ' 95 X . ARRGT 8.
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41870 25.29 1 /8 2 206.8 153 100 .0643 1030 DR-GACEK 1 2 -1 9 -9 4 DWG. NO. -

a: ^
a 3§ ■m m k n m » r a m m of ocwo l o w oar.
MAX HP — 250 MAX RPM > 1819
“ ■MEYER 1 2 -2 0 -9 4 B 1 9 — 0 — 2 0 9 1
IMAX TEMP - 1BO 1CT- FD 12 -9 4 ■ m — g — nn

W “3 8 13 CERTIFIED PRINT
 C leave rooks

C leaver-B ro o ks
C B -100
M IC R O P R O C E S S O R B A S E D B U R N E R
M A N A G E M E N T C O N T R O L W IT H
MESSAGE CENTER AND
S E L F -D IA G N O S T IC S

UV S canners

................■> ............K ill HI ..m m

UV S elf-C heck Scanner

W-?

UV Scanners IR Scanner

D e s c r ip tio n
The Cleaver-Brooks CB-I00 System is a microprocessor based, burner management control
system with seif-diagnostics, non-volatile memory and vocabulary of 42 different messages
which scroll out on the message center to provide the operator with status and failure mode
information.
The CB-100 is designed to provide the proper burner sequencing, ignition and flame monitoring
protection on automatically ignited oil, gas and combination fuel burners. In conjunction with
limit and operating controls, it programs the bumer/blower motor, ignition and fuel valves to
provide for proper and safe burner operation. On a safety shutdown, the message center will
advise the operator that the control is in “lockout” and scroll a message indicating the cause as
well as the position in the sequence it occurred.
interchangeable programmer and flame ampifier modules allow for complete versatility in
selection of control function, timing and flame scanning means. Functions such as pre-purge
timing, recycling interlocks, high fire proving interlock and trial for ignition timing of the pilot
and main flame are determined by the programmer module. The CB-100 can be used with ultra­
violet, autocheck infrared, or self-check ultraviolet flame scanners by choosing the proper ampli-
tlermodule.
The eighteen terminal wiring base allows for many functional circuits including motors, valves
and ignition transformers as well as multiple interlocks such as hi-purge, low purge, fuel valve
and running circuits. The CB-I00 uses the same wiring.base as the Fireye E-I00, D Series and C
Series Controls and is designed to be directly interchangeable with most models without
rewiring.

1
C le a v e r# 4 3 ro o k s

Additional functions of the CB-100 system include:

— A non-volatile memory which allows the control to remember its history and present position
even when power is interrupted.
— A constant flame signal read-out which eliminates the need for a DC voltmeter.
— Read-out of main fuel operational hours and complete cycles.
— A run/check switch which allows the operator to stop the program sequence in any of four
different positions.
— Remote Display Capability.

— A c A U T IO N !--------------------------------------- ------------------------------------------
While programmers are mechanically interchangeable in that they mate with a common
wiring base, you should select the correct model for your application. Inappropriate appli­
cation of a control could result in an unsafe condition hazardous to life and property.
Selection of a control for a particular application should be made by a competent profes­
sional, such as a boiler/bumer service technician licensed by a state or other government
agency.

CB-100
Specifications ___________ _____________________________
Supply Voltage: 120 VAC (+10%, -15%) 50/60 Hz
Power Consumption: 25 VA
Maximum Simultaneous Connected Load: 2000 VA
Operating Temperature Limits: - 40°F Minimum, +125°F Maximum
. - 40°C Minimum, +52°C Maximum
Humidity: 85% R.H. Maximum (Non-condensing)

Typical Maximum Rating Alternate Rating

Terminal Load @120V-60Hz(A) @120V-60Hz(B)

50 VA Pilot Duty 125 VA Pilot Duty

5.6 Pilot Valve(s) (Solenoid Valves) (Solenoid Valves)
Individually and Ignition plus 500 VA2 plus 250 VA
or Combined Transformers) (Transformer) (Transformer)
1250 VA Opening
500 VA Holding
250 VA (Motorized Valve)
7 Main Fuel Valve(s) Pilot Duty plus 65 VA
(Solenoid Valve) Pilot Duty
(Solenoid Valve)
Bumer/Blower 9.8 F.L.A. 240 VA Pilot Duty
M Motor 58.8 L.R.A. (Motor Starter Coil)
10-11-12-X Modulator 125 VA Pilot Duty
A Alarm 50. VA Pilot Duty

Terminal ratings may be selected from either column A or B: (select the rating from the column
for each terminal which best applies to the connected load on that terminal).
*F.L.A. = full load amps
L.R.A. = locked rotor amps

2 CB-100
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Electrical Ratings
VA ratings (not specified as pilot duty) permit the connection of transformers and similar devices
whose inrush current is approximately the same as their running current.
VA P ilo t D u ty ratings permit the connection of relays, solenoid valves, lamps, etc. whose total
operating load does not exceed the published rating and whose total inrush current does not
exceed 10 times the rating.
ratings are intended for motors. VA a n d VA P ilo t D u ty loads may be
R u n n in g a n d lo c k e d r o to r
added to a motor load provided the total load does not exceed the published rating.

r- /L W A R N IN G !-----------------------------------------------------------------------------------
This equipment is a Class B digital apparatus which complies with the Radio Interference
Regulations, CRC c. 1374.

- A c a u t i o n ! ----------------------------------------------------------------------------------
Published load ratings assume that no contact be required to handle inrush current more often
than once in 15 seconds. The use of control switches, solenoids, relays, etc. which chatter
will lead to premature failure of switches in the control. Similarly, the contacts cannot be
expected to handle short circuit currents without damage. It is important to run through a test
operation (with fuel shut off) following the tripping of a circuit breaker, a blown fuse, or any
known instance of chattering.

In applications which appear to have excessive electrical noise, it may be helpful to add an elec­
trical noise suppressor to the power supply of the control circuit.
We recommend the following: Fireye Part Number 60-2333, CORCOM Part Number 10VRI,
EM1 Filter or Cornell Dublier Part Number APFV-31.

Approvals
Underwriters Laboratories Inc.: Listed Guide MCCZ File MP1537
Canadian Standards Association: File #LR7989
Acceptable by: Industrial Risk Insurers (I.R.I.)
Factory Mutual Approved

r- A W A R N IN G !----------------------------------------------------------------------------------
This equipment generates, uses, and can radiate radio frequency energy, and if not installed
and used in accordance with the instructions manual, may cause interference to radio com­
munications. It has been tested and found to comply with the limits for a Class A computing
device pursuant to Subpart J of Part 15 of FCC Rules, which are designed to provide reason­
able protection against such interference when operated in a commercial environment.
Operation of this equipment in a residential area is likely to cause interference in which case
the user at his own expense will be required to take whatever measures which may be
required to correct the interference.

CB-100 3
C leave rooks

M ounting S c re w '

A m plifier M odule

P rogram m er M odule

Display M odule
C hassis only

Reset Button

W irin g Label

Serial N um ber Label

on Bottom

* The mounting screw must be removed to replace the Modules.

This screw must be used to prevent electrical shock or damage to
the control.

Cleaver** Brooks'

To remove cover, place your fingers and palms on each side and
pull forward as shown in the diagrams. Press down with thumbs
while pulling out with your palms and fingers. The cover will D ust Cover
snap off and can be snapped back into place easily.

4 CB-100
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F la m e M o n ito r O rd e rin g In fo r m a tio n

Mounting Screw

CB-100 consists of:

833-2591- chassis
833-2587 - dust cover
833-2586 - display module

Programmer Module Flame Amplifier Module

EP Series (See Page 6 for details)
{See Page 7 for details)

Wiring Base
833-2581 Surface Mtg. (shown)
833-2581 Cabinet Mtg.

NOTE: A lw a y s g ro u n d th e g re e n g ro u n d in g
s c r e w on th e w irin g b a se

CB-100 5
C leave rooks

Flam e A m plifier
Selection
C le a v e r-B ro o k s P/N D e s c rip tio n Use w ith S canner

833-2585 Standard UV Amplifier 817-2262,817-2263

833-2584 Autocheck Infrared Amplifier 817-2261
Self-Check UV Amplifier
833-2386
(For use on solid fuel burners only) 817-2124

Scanner
Selection
C le a v e r-B ro o k s P/N D e s c rip tio n Use w ith A m p lifie r

817-2261 Infrared 1/2" 90c angle mount 48" cable 833-2584

817-2262 UV 1/2" straight 36" flex conduit 833-2585
817-2263 UV 1/2" straight 72" flex conduit 833-2585
817-2124 Self-check UV 1" N.P.T. threads, 120V 833-2386

Flam e
Scanners

r- A c A U T IO N !----------------------------------------------------------------- ---------------------
The 817-2262 and 833-2263 ultra-violet flame scanners and associated amplifier modules
are non-self-checking UV systems and should be applied only to burners that cycle often
(e.g. a minimum of once per 12 hours) in order for the safety checking circuit to be exer­
cised. (see Operation). If component checking is required during burner operation for con­
stantly fired burners, utilize the self-checking ultra-violet flame scanner (817-2124) and
associated amplifier module (833-2386). ■

6 CB-100
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(T ^ CB-100
Programmer
Selection ___________________________________________________
The functional operation, flame failure response time, purge timings. Firing Rate motor circuit,
trial for ignition timings, recycling function and readout messages are determined by the pro­
grammer selected. A chart of the most common programmers is found below. Descriptive infor­
mation associated with the programmer selected is found on the bulletin for that programmer.
Take note of the programming sequence chart for each programming module for the proper
explanation of prepurge timings.
Fuel Valve Proof of Closure: All programmers provide for input from a fuel valve proof of
closure switch (fuel valve end switch).
Flame Failure Response Time (FFRT): All programmers have four seconds FFRT.
Post Purge: All programmers have 15 seconds post purge.

Proven High Proven Low

Prepurge Fire Pure Fire Start Intermittent Interrupted
C-B Timing Interlock Interlock Ignition Ignition/
P/N (Seconds) (D/8 CKT) (M/D CKT) Pilot Pilot

30
833-2583
^Supervised Yes Yes No Yes
833-2590 30* No Yes No Yes

Trial for Firing

Early Ignition/ Trial Running Rate
C-B Spark Pilot Ignition/Main Interlock Motor
P/N Termination (Seconds) (Seconds) (3/P CKT) Circuit

10 10 Non
833-2583 No 10 15 Yes
Recycle
10 I0
833-2590 No 10 15 Recycle Yes

< rs

CB-100 7
C le a v e r^ B ro o k s

Accessories
CB P/N Description For More Information

CB300 Expansion Module See Bulletin CB3001

833-2554,55,56 Remote display cables See Bulletin E8001
833-2564 Remote display mounting kit See Bulletin E8001
E500 Communication Interface See Bulletin E5001

Operation ____________________________________________________
The CB-100 provides the operator with a constant status read-out as well as diagnostic informa­
tion. It has 42 messages which are simple to understand and interpret.
For purposes of illustration, we will be looking at the 833-2583 Programmer functions and mes­
sages in this bulletin.
NON-RECYCLE RUNNING INTERLOCKS (3/P)
833-2583 PURGE TIME - 30 SEC. FLAME FAILURE RESPONSE TIME 4 SEC.

PROGRAMMING SEQUENCE
HFS LFS
11/13 CLOSED CLOSED FIRING L1/13
ON (0/ 8) (MD) PERIOD OFF
jttm
PURGE f MIN T
1 POST PURGE
30 SEC , 30 SEC , 15 SEC
T 5
E , • PTFI * MTFI • 1
R , i 10 SEC | 10 SEC 1 1
I 6
N ' MTFI i t
A ' 15 SEC * 1
L t
S
7 1 1
(MODULAR MOTOR CIRCUIT)

| HIGH (10-X) ' LOW (10-12) ! AUTO (10-11) I 1 LOW (10-12)

Note: P T F I - P ilo t tr ia l f o r ig n itio n M T F I - M a in b u r n e r tria l f o r ig n itio n

- /^ C A U T IO N S --------------------------------------------------------------------------------
On initial power-up and on restarts following a power failure, the display on the control will
not become active for 15 seconds.

Refer to the suggestions shown in this bulletin before proceeding to power the CB-100 system.
Items such as scanner installation, short circuit tests and safety information should be reviewed.

Start-U p (Norm al Cycle)

Note: F o r d ir e c t s p a r k ig n ite d o il b u rn e rs, su b stitu te th e w o r d s M a in -o il V a lv e f o r P ilo t Valve.

1. Constant 120 VAC should be available to the L1-L2 terminals only on the wiring base.
2. The operating control circuits (LI-13) will close, signaling the burner to start its firing
sequence.
3. Assuming the fuel valve end switch (13-3) is closed, the bumer/blower motor (terminal M)
circuit is energized. The running interlock (limit) circuit (3-P) will close (eg: all limits,
interlocks, etc. are proven).
4. The firing rate motor (Modulator Motor) is driven toward the high purge open damper posi­
tion (10-X ckt. made). -
5. When the firing rate motor reaches its open damper position, the Hi Purge switch closes
(D-8) and initiates the prepurge interval of 30 seconds. If the D-8 circuit d o e s n o t close, the
program will hold in this position for ten minutes waiting for it to close. If it does not, the
control will lockout.

8 CB-100
 C leave rooks

6. When the prepurge is completed, the firing rate motor is driven toward the low purge
damper position (10-12 ckt. made).
7. Following the minimum 30 second delay (to permit the firing rate motor to get to the low
fire position), the control will wait for the low fire switch (M-D) to close. When it closes,
the trial for ignition sequence will start. If after ten minutes, the M-D circuit is not closed,
the control will lockout.
8. The trial for ignition period begins with Terminal 5 and 6 being energized simultaneously.
This is known as PTFI (Pilot Trial for Ignition). This period is ten seconds in duration. If no
flame is detected after ten seconds, the control will de-energize Terminals 5 and 6 and lock­
out. If flame is detected during this 10 second period, the main flame trial for ignition
sequence will start.
Note: W h en th e fla m e is d etec ted , th e m e s s a g e c e n te r w ill p r o v id e a c o n s ta n t re a d o u t o f th e
signed strength.

Flame Signal
0-9 Not Acceptable
10 Minimum Acceptable
20-80 Normal

9. With flame proven at the end of PTFI, the main flame trial for ignition (MTFI) period
begins. Terminal 7 is energized. Terminal 5 is de-energized 10 seconds later and Terminal
6 is de-energized after another 5 seconds.
10. The firing rate motor is now sent to the auto position (10-11 ckt mode) and is under the
command of the proportional controller. The message center displays a read-out of the
flame signal.
Norm al Shutdown
1. When the operating control circuit (LI-13) opens, the main fuel valve is de-energized. The
firing rate motor is driven to the low purge position (10-12 ckt mode).
2. Following a 15 second post purge, the bumer/blower motor is de-energized. .
3. The burner is now off and the message center displays the burner operating history for two
minutes and then the message center displays the message “OFF.”
Lockouts ________ ________________________________________ ___
When a safety shutdown occurs, the control will display a message indicating L O C K O U T and
the reason for the lockout. The alarm circuit (Terminal “A”) will be energized. The non-volatile
memory will remember the status of the control even if a power failure occurs. By depressing
the button just above the display, the control can be reset. The button must be held down for one
second and then released. Very little force is required to do this. Do not press hard.
Safety Shutdown
1. If the running interlock circuit does not close, the control will lockout and the blower motor
will be de-energized.. If the interlock circuit opens during a start-up or firing period, all fuel
valves will be de-energized and the control will lockout.
2. If pilot flame is not detected during the 10 second trial for ignition period, the pilot valve
and ignition transformer will be de-energized and the control will lockout on safety.
3. If main flame is not detected at the end of the main flame trial for ignition period, all fuel
valves will be de-energized and the control will lockout on safety.
4. If the main flame fails during a firing cycle, all fuel valves will be de-energized within 4
seconds after loss of flame signal and the control will lockout on safety.'
5. A"flame seen at an improper time will cause a lockout.
6. Additional lockout messages and causes are described in the following pages.
Note: M a n u a l R e s e t is re q u ir e d fo llo w in g a n y s a fe ty sh u td o w n .

CB-100 9
 Note: D e p re ssin g the re s e t bu tton d u rin g a c y c le w ill c a u se th e c o n tr o l to sh u t th e b u rn e r
d o w n a n d recycle.

D e s crip tio n of Functions of O p e ra tin g C o n tro ls

1. Operating Controls: Generally pressure of temperature activated, the operating control
closes, causing the burner startup sequence to begin. When the operating control opens, the
burner shuts off. The operating control is connected in the LI-13 circuit on the wiring base.
2. Limit Switches: These are generally pressure, water level or temperature activated.
a. Recycle—when it is desired to stop the burner when the limit switch opens and restart
it when the limit switch reclosed, they are connected between Terminals LI and 13.
b. Non-Recycle—Limit switches may be connected in the circuit between Terminals 3
and P. If a limit switch opens during the trial for ignition or firing period, all fuel
valves will be de-energized and the control will lockout on safety. If the limit switch
opens ten seconds after the purge begins, the control will lockout on safety.
3. Fuel Valve End Switch Interlock: This is generally an integral switch mounted on the
main fuel valve and activated by the valve stem. It is connected between Terminal 3 & 13.
The fuel valve end switch interlock prevents a burner start-up if the valve stem is not in the
“valve closed” position.

- A c A U T IO N !----------------------------------------------------------------------------------------
The use of a Fuel Valve End Switch is recommended. All FLAME-MONITOR systems
have provision to accept the Fuel Valve End Switch Interlock. This will add additional safety
to prevent hazardous situations.

4. Purge Interlock: Generally a firing rate motor linkage position switch or a differential air-
pressure switch, that proves a maximum purge air flow rate. It is connected between
Terminals D and 8. The purge interlock proves that the purge air flow rate is at maximum
during the purge.
5. Running Interlocks: These generally are air flow switches, high and low fuel pressure
switches, oil temperature switches, atomizing media pressure switches, and excess smoke
density controls. These interlocks prove proper conditions for normal operation of the burn­
er. They are wired in series and connected between Terminals 3 and P.
6. Low Fire Start Interlock: Generally a firing rate motor linkage position switch or a
damper position switch, will prove both the linkage and dampers are in their proper posi­
tions to begin burner light off. This switch is connected between Terminals M and D.

10 CB-100
 Cleaver®® rooks
n LOGIC FLOW DIAGRAM DISPLAY MESSAGE
NORMAL CYCLE ....... 7
MODULATOR SENT
TO LOW FIRE
r
-CT POWER ON TERMINALS I I 4 12 "l___ .. OFF

OPERATING CONTROL CLOSED LI-13

ARE LIMITS LI TO 13 MADE? NO +

IL
YES

CE IS E YE S . MADE 13-3? NO LOCKOUT.

C 3 D

MODULATOR SENT
nr SLOWER STARTS M

FROM LOW TO
HIGH FIRE

cx IS AIR FLOW SWITCH MADE? 3-P NO LOCKOUT +

YES

I 7 IS HIGH FIRE INTERLOCK MADE? 6 -a "

YES
NO HOLD 10 MIN. THEN LOCKOUT*

MODULATOR SENT ...... 7

FROM HIGH FIRE HIGH FIRE PURGE COMPLETED IN 30 SEC.
TO LOW FIRE PURGE 14*
LOW FIRE PURGE COMPLETED IN 30 SEC.
NO HOLD 10 MIN. THEN LOCKOUT*
tC '
Lj E S LO W FIRE INTERLOCK MADE? M-D

| YES |
PTFI 3*
V.
SPARK 4 PILOT POWERED ON 5 4 6
NO LOCKOUT +

•j i? IS FLAME PROVEN Wl IHIN 10 SEC ? ........ P '

1 Y^S | --------------------------------------------- PTFI FLAME SIGNAL 15*

/
1 » MAIN FUEL POWERED ON 7 AT END OF PTFI 1

^ 1 ■■-1 ■« 5 CUT OUT 10 SEC. AFTER 7 CUT IN I MTFI FLAME SIGNAL 26*
MODULATOR SENT -------
6 CUT OUT 15 SEC AFTER 7 CUT IN
FROM LOW FIRE
TO AUTO NO LOCKOUT *
- L ie B FLAME PROYED?

"YE?
FLAME SIGNAL 26*
7 REMAINS POWERED

MODULATOR SENT
FROM AUTO TO DEMAND SATISFIED LI-130PENS
LOW FIRE POST PURGE 5*

7 DE-ENERGIZED

MODULATOR HELD
AT LOW FIRE --------------------- 20 8LOWER STOPS 15SEC AFTER L1-13 OPENS I----------- m BURNER ON 5 HRS 214 CYCLES

t r
* Timing In Seconds ** Flame Signal Strength Number From 0-99 These Lockout and Hold Messages are explained in the following pages

Note: M e s s a g e s m o r e th a n 8 c h a r a c te r s in le n g th w ill s c r o ll c o n tin u o u s ly fr o m r ig h t to le ft o n th e display.

CB-100 11
C le a v e i^ ^ B ro o k s @

833-2583 Program Module

Additional Messages _________ '_________________________________
HOLD MESSAGES DESCRIPTION
/ The running interlock circuit (3-P) has opened during the burner on period. This
H O LD 3-P RUN IN TLK O P E N message will be on the display for 15 sec. (post purge) and then the appropriate
4 \
lockout message will appear.
/
The running interlock circuit (3-P) has opened during the main trial for ignition
HO LD 3-P RUN IN T LK O P E N M TFI period. This message will be on the display for 1 sec. (post purge) and then the
4 \ appropriate lockout message will appear.

The running interlock circuit (3-P) has opened during the pilot trial for ignition
HO LD 3-P RUN IN T LK O P E N PTFI period. This message will be on the display for 15 sec. (post purge) and then the
/
appropriate lockout message will appear.
^ ------------------------------------------------------------------------- / The control has driven the firing rate motor to high purge and is waiting for the
i H O LD D-8 HI P U R G E O PEN high fire switch (D-8) to close. It will hold in this position for ten minutes and
\ then lockout if the D-8 circuit does not close.
7
The flame has been sensed sometime during the burner off time. This message
H O LD FALSE F LA M E 00 will hold for 60 seconds and display Flame Signal (00) strength. This can be
\ used as an aid in trouble shooting scanners and amplifiers.
7
A flame failure occurred during the main burner on period. The control will hold
H O LD FLA M E FA IL
this message for 15 sec. (post purge) and then lockout.
z1 \

7
No flame was proven during the main trial for ignition period. The control will
H O LD F U M E FA IL M TFI
hold this message for 15 sec. (post purge) and then lockout.
1 s
^ ------------------------------------------------------------------------- 7

H O LD F U M E FAIL PTFI
No flame was proven during the pilot trial for ignition period. The control will
hold this message for 15 sec. (post purge) and then lockout.
/
7

H O LD C H E C K S C A N N E R See description on page 15 for “LOCKOUT CHECK SCANNER”

l \

z The control has finished purge and the firing rate motor is driving to the low fire
HO LD M -D LO W P U R G E O P E N position waiting for that switch (M-D) to close. It will hold in this position for
ten minutes and then lockout if the M-D circuit does not close.
l \

ST 7

H O LD S C A N N E R N O IS E See description on page 14 for “LOCKOUT SCANNER NOISE”

7 ___________________________________________ \

\ ~ The control has sensed an excessive current or short circuit external to

H O LD S H O R T C IR C U IT Terminals 5,6, or 7. This message will hold for 15 sec. (post purge) and then the
T E R M IN A L 5, 6, O R 7 control will lockout on the second consecutive event and display the appropriate
message.

Note: M e s s a g e s m o r e th a n 8 c h a r a c te r s in le n g th w ill s c r o ll c o n tin u o u s ly f r o m r ig h t to le ft o n th e display.

12 CB-100
 C leavei^^B ro o ks'

O 833-2583 Program Module

Additional Messages
LOCKOUT MESSAGES DESCRIPTION

LO C K O U T 3-P RUN IN T K L O PEN

The running interlock circuit (3-P) has opened during the main burner on period.

LO C K O U T 3-P RUN IN TLK O P E N MTFI The running interlock circuit (3-P) has opened during the main trial for igni­
tion period.

LO C K O U T 3-P RUN ITLK O PEN PTFI The running interlock circuit (3-P) has opened during the pilot trial for ignition
period.

LO C K O U T 3-P RUN ITLK O P E N PTFI The running interlock circuit (3-P) has opened during the purge period or failed
to close within the first 10 sec. of purge.

LO C K O U T 13-3 FUEL V A L V E END The fuel valve end switch wired between terminals 13 & 3 switch open on the
wiring base opened during purge or at start up.

LO C K O U T D-8 HI P U R G E O PEN The control has held for more than 10 minutes waiting for the high fire switch
(D-8) to make.

L O C K O U T FALSE FLA M E A flame has been sensed by the scanner for more than 60 seconds during the
burner off time.

LO C K O U T FALSE F LAM E PU R G E A flame has been sensed by the scanner for more than 4 second during the
purge period.

LO C K O U T FLAM E FAIL A flame failure occurred during the main burner on period.

LO C K O U T FLAM E FA IL MTFI A flame failure occurred during the main trial for ignition period.

LO C K O U T FLAM E F A IL PTFI A flame failure occurred during the pilot trial for ignition period.

S Y S T E M ERROR
An internal failure has been detected in the programmer module. Replace it.
Check aiso for scanner wire routing near ignition noise.

N o te : M e s s a g e s m o r e th a n 8 c h a r a c te r s in le n g th w ith s c r o ll c o n tin u o u s ly fr o m rig h t to le ft o n th e d isp la y.

CB-100 13
Cleaver*Q* Brooks

833-2583 Program Module

Additional Messages _________
HOLD MESSAGES DESCRIPTION
\ >
The control has held for more than 10 minutes waiting for the low fire switch
LOCKOUT M-D LOW PURGE OPEN (M-D) to make.
N
/
This message appears because of ignition cable noise. Reroute scanner wires
away from high voltage ignition cables. Check for proper sparkgap. Check for
LOCKOUT SCANNER NOISE proper grounding of wiring base and power supply. Replace worn ignition cable
\ and/or faulty connections.
\ The control has sensed an excessive current or short circuit external to terminal
LOCKOUT SHO RT CIRCUIT 5, 6 or 7. Check for this short according to the procedure found in this bulletin
TERMINAL 5, 6, OR 7 on page 15 labeled “Before Installing the Control.” The control will lockout
/ upon sensing this twice in a row.

CHECK MESSAGES DESCRIPTION

The “Run-Check” switch is in the Check position and will hold indefinitely. The
CHECK D-8 HI PURGE
firing rate motor is being driven to the high purge position.
\
/
CHECK M-D LOW PURGE
The “Run-Check” switch has been placed in the Check position and will hold
indefinitely. The firing rate motor is being driven to the low purge position.
1/ M

The “Run-Check” switch has been placed in the “Check” position during the
pilot trial for ignition period. The flame signal strength will be displayed. The
C HEC K FLAME SIGNAL OO
control will lockout on safety only if no flame signal is sensed for a continuous
_____________________________________ k 30 seconds while the control is in this check position. The control will not
advance in the cycle until the switch is placed in the “run” position again.

The “Run-Check” switch has been placed in the “Check position during the
CHECK LOW FIRE FLAME SIGNAL 00 main burner on period and the firing rate motor has been driven to low fire. The
flame signal strength will he displayed as a number from 0-99 and is shown here
______________________ ;_______________ k by the symbols 00.

DIAGNOSTIC MESSAGES POSSIBLE CAUSE SOLUTION

— High Electrical Noise — Check for proper ground on

power supply
— Install noise suppressor on power supply
LOCKOUT CHECK AMPLIFIER — Defective Field Wiring — Make sure line phase on interlock
— Defective Field Wiring circuits is the same as found on
L1/L2 power supply to CB 100
— Defective Amplifier — Replace Amplifier
— Defective IR Scanner — Replace IR Cell

— Voltage On Terminal 7 at — Check wiring to Terminal 7

improper time. Defective
LOCKOUT CHECK C H A SSIS field wiring.
i — Defective Chassis — Replace Chassis (EB700)
— Defective Programmer — Replace Programmer
Note: M e s s a g e s m o r e th a n 8 c h a r a c te r s in le n g th w ith s c r o ll c o n tin u o u s ly f r o m rig h t to le ft o n th e d isplay.

14 CB-100
 rooks

n Programmer Additional
Messages ______________ ;______
DIAGNOSTIC MESSAGES POSSIBLE CAUSE SOLUTION

Voltage on Terminals 5 or 6 — Check field wiring to

LOCKOUT CHECK PROGRAMMER at an improper time Terminal 5 and 6
High Electrical Noise — Check for proper ground
on power supply
— Install noise suppressor
on power supply
I — Re-route scanner wires
i
away from high voltage
wiring
Fuel Changeover on Burners — Interrupt power when
with Direct Spark Oil changing fuels
— Install time delay relay
— Note write-up on page
15 of this bulletin
Failed Programmer — Replace Programmer
Worn Chassis — Replace Chassis
\ s
LOCKOUT CHECK SCANNER Scanner signal has been detected during the shutter closed time. This can be
caused by a faulty UV tube, faulty scanner, or lack of power to the scanner.
/ \
Before Installing
O the Control ____________________
I- /^ C A U T IO N ! ------------------
I Ensure that electric power is shut off.

If either a ground or a short circuit is detected, it must be eliminated before the control is
plugged into the wiring base and power turned on.
Test the electrical field wiring for short circuits and grounds. The recommended method requires
the use of an ohmmeter set on its lowest resistance scale.
Note: W h en u sin g u ltr a -v io le t o r in fr a -r e d sc a n n in g , b e su r e to r e m o v e a n y j u m p e r s o n th e
w irin g b a s e w h ich g r o u n d th e S 2 T erm in a l.

1. Touch the meter probes together and calibrate accurately to ensure a reliable test.
2. Disconnect the neutral wire (L2) from the control system at the power source. Clip one
meter test lead to the grounded green terminal on the lower right side of the wiring base and
with the other probe touch each other terminal. At no time should the meters show continu­
ity or read 0 ohms.
3. Reconnect the neutral wire (L2) at the power source. Remove the test probe from the
grounded terminal and reconnect it to Terminal L2 in the wiring base. With the other probe,
touch each other terminal. It is normal to obtain a resistance reading on the meter at some
terminals during this test as there are resistive loads (coils, transformers, lamps, etc.) con­
nected whose normal DC resistance may be less than 5 ohms. However, at no time should
the test meter read zero ohms.

r A c a u t io n ! ------------------- — ----------------------------------------------- - ■
O ' | Restore power for the following test.1

1. With CB-100 removed, measure voltage from L2 to all other terminals. Reading should be
zero on all terminals except LI.

CB-100 15
C le a v e r^ B ro o k s

Suggested Wiring Diagram for 833-2583 Programmer

•- Z t^ C A U T IO N !-----------------------------------------------------------------------------------
All safety limit switches should be approved as limit controls and should be wired directly in
the circuit of the Flame Safeguard control. The use of electronic switches to close interlock
circuits may cause erratic operation.*

*The purge interlock circuit is included in the 833-2583 Programmer Module only.

16 CB-100
 rooks

Extended
Prepurge
Occasionally it is necessary to extend the pre-purge timing on the Flame Safeguard Control to
greater than 30 seconds. This can be accomplished by adding a time delay relay in the L2/M and
D/8 circuit and wired in the following manner:
The maximum extended purge time will be 10 minutes. The maximum time delay setting should
be 9-1/2 minutes. If the time delay relay does not close the D-8 circuit within 10 minutes of the
start, the CB-100 will LOCKOUT and the message will be “LOCKOUT D-8 HI PURGE
OPEN.”

N.O. TIME DELAY CONTACT

TIME DELAY RELAY.

ADJUSTABLETIMINGUPTO
9V2 MINUTES

A uxiliary D evice In M-D-8 C ircuit a t Flam e M onitor Control

The function of the low fire start and high fire purge interlock circuits internally in THE CB-
100 unit is accomplished by highly reliable solid state electronic circuitry. This prohibits the
connection of power consuming devices (i.e. lamps, annunciators, relays, timers, etc.) to the
D or 8 terminals.
Combination
Fuel Burners
Note: A n im p o r ta n t s a fe ty fe a tu r e o f th e C B -1 0 0 s y s te m is th e a b ility to m o n ito r th e p r o p e r
tim e d o p e r a tio n o f c r itic a l te r m in a ls ; f u e l v a lv e te r m in a ls 5, 6 a n d 7 fo r in s ta n c e .
J u m p e r in g o f th e se te r m in a ls c o u ld th e re fo re c a u s e th e c o n tr o l to s e n s e a n u n u s u a l c o n ­
d itio n a n d L O C K O U T .

When changing fuels on combination fuel burners if DIRECT SPARK IGNITION is used, it is
normal to jumper these terminals. To assure that burner operation is not interrupted in this situa­
tion, you must do one of the following:
1. Interrupt power to L1/L2 momentarily when changing fuels, before the initial burner cycle
on the new fuel.
OR

2. Install a time delay relay contact in the jumper circuit which is timed to close 3 seconds
(minimum) after terminal 6 is energized. This method is only acceptable on programmers
labeled “12” or higher (i.e. datecode 8710-12.)

© (6X ®

DELAYCLOSED
Cleavei rooks"

In s t a llin g t h e
C o n tr o l

Electric power must be turned off during installation.

1. Check the electrical tabs on the bottom of the chassis— if they are bent out of position,
reposition them with your fingers so that they are in line as shown here.

2. Slide the slots at the bottom of the assembled control over the tabs on the wiring base. Push
the control into position. Insert a screwdriver through the hole in the top of the control and
tighten the retaining screw,
3. Electric power may now be turned on.

I n s t a l l a t i o n / T e s t i n g __ ____________________________________________________________
C heck-R un S w itc h
The C heck-R un switch is located on the top of the Programmer Module (note photograph) and
can be used to stop the control in its firing sequence at any time except during MTFI. If moved
during the MTFI period, it is non-functional and automatic programming continues. It is
designed to aid in set-up, start-up and check-out of the burner and its associated interlocks.
Following are the modes of operation:
1. When power is applied to the control (L1-L2) and the operating control circuit is closed
(LI -13), the purge period begins and the firing rate motor is sent to the H i P u rg e position .
It the C heck-R un Switch is moved to the C h eck position before the He Fire Switch (D-8) is
made and the 30 second purge ends, the control will display the message, C h eck D -8 P urge
00. The 0 0 indicated the purge timing, in seconds, that the control has completed before the
switch was moved to C heck. The control will hold in this position indefinitely to allow the
operator to make interlock switch and linkage adjustments. To continue in the cycle, move
the C heck-R un switch to Run to allow the control to advance.
2. If the C heck-R un switch is moved to the C h eck position after the purge period reaches 30
seconds, but before 60 seconds, the control will display C h eck M -D L o w P u rg e 00. The 0 0
indicates the purge timing in seconds, that the control was completed before the switch has
moved to the ch eck position. The control will hold in this position indefinitely to allow the
operator to make interlock switch and linkage adjustments. To continue the cycle, moving
the C heck-R un Switch to Run will allow the control to advance.
3. After the PTFI period has begun, switching back to the C h eck position will stop the pro­
gram in the PTFI period, allowing for pilot and/or scanner alignment adjustments to be
made. The control will display the message C h eck P F T I F lam e S ig n a l 0 0 where 0 0 equals
flame signal strength. It will hold in this position indefinitely as long as the flame signal
strength is above the threshold of 10. If it drops below 10 for thirty consecutive seconds,
lockout will occur and the message on the display will read F lam e F a il PFTI,,
4. Switching from run to ch eck during the burner on period will drive the modulator circuit to
low fire (10-X closes). This allows for low fire fuel-air adjustments and holding the burner A
at low fire. Consult your boiler/bumer instructions for low fire hold firing recommenda­
tions. The control will display C h eck L o w F ire F lam e S ig n a l 0 0 with 0 0 again indicating
flame signal strength.

18 CB-100
 C leave rooks3

As an aid adjusting the burner linkages, pilot, etc., a check-run selector is provided on the
Programmer Module.
O perational
Test

Before testing the control operation on the boiler, close the manual main shut-off fuel valve.
Failure to do this may cause injury or property damage.

1. Close the manual main shut-off fuel valve.

2. Recheck all limit circuit wiring for proper operation and correct connection.
3.. Confirm that the automatic main fuel valves are wired to terminal “7."’
4. Power the control and electronically check the proper sequence of operation according to
the O p e ra tio n section on page 8 of this bulletin.
5. After assuring yourself that all interlocks and valves are properly wired and that the
sequence of operation is correct, open the manual main shut-off fuel valve and proceed cau­
tiously through the boiler light off process. Check all safety interlocks for proper shut down
of the boiler.
When the installation and all burner adjustments are completed, the entire burner control system
should be tested in accordance with the burner manufacturer’s instructions. The procedure
should verify the correct operation of:
1. Each operating control (temperature, pressure, etc.).
2. Each limit switch (temperature, pressure, low water cut-off, etc.).
3. Each interlock switch (air-flow switch, high and low fuel pressure or temperature switches,
purge and low fire start switches, fuel valve proof of closure interlock, etc.).
4. Pilot flame failure response and lockout.
5. Main flame failure response and lockout.
6. Tight shut-off of all fuel valves.

V o lta g e T e s t

A c A U T IO N !---------------------- ------- ---------------------------------------------------------

PLive voltage is necessary to perform this test.

A Voltage Check is necessary to identify a potential probiem with the supply to the control. This
could be caused by an improperly sized or faulty transformer, faulty load coils or low entry volt­
age. Follow this procedure:
1. Using an AC voltmeter, monitor the LI-L2 supply throughout a complete burner cycle. The
acceptable voltage range is 102V-132V. At no time during the cycle should the voltage dip
below the minimum level.
2. Check other load terminal (M/L2, 5/L2, 6/L2, 7/L2) for voltage at improper times or
improper values.

CB-100 19
C le a v e rg # B ro o k s :

Test Checkout
Procedures
Norm al Pilot Flam e T est

- Z L C A U T IO N !-------------------------------------------------------------------------- — .....
Before making a pilot flame test; manually shut-off the fuel supply to the main burner.
1. At the start of PTFI, place the C h e c k -r u n switch in the c h e c k position.
2. Observe the pilot flame signal on the display. If the average signal is below the minimum of
10, readjust the pilot flame or realign the flame detector.
3. During the pilot flame test, if flame is not detected for a continuous 30 seconds, the control
will lockout. To re-establish the pilot flame trial for ignition (PTFI), manual reset of the
lockout switch is required, and a complete prepurge accomplished.
4. When UV flame detection is used, a test is required to verify that UV radiation from the
ignition spark is not being detected. To accomplish this, manually shut off both pilot and
main fuels. Initiate a normal start-up, and when the PTFI display comes on, observe the dis­
play which should read no signal more than 4. If more than 4 is observed, realign the UV
scanner, and/or shield the spark from the scanner’s view.
5. With all methods of flame detection, check pilot flame failure response by manually shut­
ting off the pilot fuel and then initiate a normal start-up. With no pilot flame present, the
control will de-energize the pilot assembly at the end of the trial for ignition interval, and
the control will lockout.
M ain Flam e T es t
Note: T h is te s t r e q u ir e s a n in te r r u p te d p ilo t. (A p ilo t th a t s h u ts o f f a fte r th e m a in fl a m e is
e s ta b lis h e d .)
1. Proceed through a normal startup. After the pilot flame is shut-off, observe the reading on
the display. If the signal reading is low, readjust main flame or realign detector.
2. Check main flame failure protection by manually shutting off the main fuel supply. Within
4 seconds after main flame goes out, the fuel valve will be de-energized. The alarm circuit
will be energized following safety lockout.
M inim um P ilot T es t

- Z IX C A U T IO N !-----------------------------------------------------------------------------------
The minimum pilot test must be accomplished by a trained and qualified burner technician.
This test assures that the flame detector will not detect a pilot flame too small to reliably light off
the main flame. The test should be made on every new installation and following any reapportion­
ing of the flame detector. This procedure should not be used on a direct spark ignited burner.
1. Turn off the main fuel supply manually.
2. At the start of PTFI, place the C h e c k -r u n switch in the c h e c k position.
3. Reduce the fuel supply to the pilot until the display reads below 10.
4. Slowly increase the fuel to the pilot until the display reads 10. This is minimum pilot flame
that the flame detector will reliably detect.
5. Place the C h e c k -r u n switch in the R u n position. When the main fuel safety shut-off valve is
energized, slowly open the manual main fuel valve.
6. Observe the light-off of the main flame. It must be smooth and normal.
- ^ C A U T I O N ! ----------------------------------------- ■
--------------------------- ;--------------
If the main;flame does not ignite immediately, shut-off the main fuel. Realign the detector to
require a larger minimum pilot flame.
7. Repeat the test until a reliable and smooth light-off occurs with the minimum pilot.
8. After this test is completed, increase the fuel to the pilot to its normal setting.

20 CB-100
 Cleavei rooks

S c a n n e r W iring
Care should be taken to see that ignitor cables and scanner cables are routed away from one
another on all installations. These cables, when crossed or run together, may interfere with the
proper operation of the flame safeguard control.
If you are experiencing erratic operation or inappropriate characters on the display during the
trial for ignition period, the cause is likely to be ignitor noise. Check for worn ignitor cable insu­
lation, broken or cut insulation or loose connectors at the electrode and transformers.

In s t a lla t io n -
U V S c a n n e rs ______ _________________________________________________ __

- A c AUTION! — ------------------------------------------------------------------------- --
The 817-2262 and 817-2263 ultra-violet flame scanners and associated amplifier modules are
non-self-checking UV systems and should be applied only to burners that cycle often (e.g. a
minimum of once per 12 hours) in order for the safety checking circuit to be exercised, (see
Operation). If component checking is required during burner operation for constantly fired
burners, utilize the self-checking ultra-violet flame scanners (817-2124) and associated
amplifier module (833-2386).

Where possible, obtain the burner manufacturer’s instructions for mounting the scanner. This
information is available for most standard burners. The scanner mounting should comply with
the following general instructions:1
1- Position the UV scanner within 18 inches of the flame to be monitored; the UV self-check
within 30 inches, closer if possible.
2. Select a scanner location that will remain within the ambient temperature limits of the UV
Scanner. If cooling is required, use an insulating coupling to reduce conducted heat.
3. The Scanners are designed to seal off the sight pipe up to 1 PSI pressure. Higher furnace
pressures should be sealed off. To seal off positive furnace pressure up to 100 PSI for UV1,
UV2 Scanners, install a quartz window coupling. Add cooling air to reduce the scanner
sight pipe temperature.
4. Install the scanner on a standard NPT pipe (UV: 1/2", UV self-check 1") whose position is
rigidly fixed. If the scanner mounting pipe sights through the refractory, do not extend it
more than halfway through. Swivel flanges are available if desired. The sight pipe must per­
mit an unobstructed view of the pilot and/or main flame, and both pilot and main flames
must completely cover the scanner field of view.

CB-100 21
C leave rooks®

Note: S in c e o il a n d g a s fla m e s ra d ia te m o r e u ltr a v io le t e n e r g y f r o m th e b a s e o f th e fla m e th a n

f r o m fu r t h e r o u t in th e fl a m e th is f a c t s h o u ld b e ta k e n in to c o n s id e ra tio n w h e n in sta llin g
th e s c a n n e r s ig h t p ip e .

- C A U T IO N !----------------------------------------------------------------------------------
The scanner must not sight the ignition spark directly, or any part of the burner that can
reflect the spark back to the scanner. The scanner must not see a pilot flame that is too small
to reliably ignite the main flame.

5. Smoke or unbumed combustion gases absorb ultraviolet energy. On installations with nega­
tive pressure combustion chambers, a small hole drilled in the sight pipe will assist in keep­
ing the pipe clean and free from smoke. The self-check scanner has a 3/8" plug in the
mounting flange that can be removed. For positive pressure furnaces, provide clean air to
pressurize the sight pipe, if necessary.
6. Two UV Scanners may be installed on the burner if it is necessary to view two areas to
obtain reliable detection of the flame. They should be wired in parallel. Only one repetitive
self-checking scanner may be installed on a burner.
7. To increase scanner sensitivity with UV Scanners, a quartz lens permits location of the
scanner at twice the normal distance. Use 1/2" x 1-1/2" pipe nipple between UV Scanner
and the coupling.
8. Request the assistance of local Cleaver-Brooks representative field office for recommenda­
tions of a proper scanner installation on a non-standard application.
Typical Scanner Installations

22 CB-100
 C leave rooks

Operation - 817-2124
Self-Checking
UV Scanner _____________________ ____ __________________________
Self-checking ultraviolet scanners should be used in applications where burner firing operation
is continuous or where the burner is on for long periods of time without recycling. In addition,
ultraviolet self-checking systems are mandatory in some locations.
The operation of this type of system consists of maintaining the flame scanning capability at all
times while also proving that the ultraviolet tube is firing properly. This is done periodically by
mechanically closing off the sight of the UV tube and checking to make sure that the flame sig­
nal goes away. A shutter assembly in the scanner performs this function. The diagram below
explains the process further. .
If the shutter assembly in the scanner fails, the tube is faulty, or there is insufficient power to the •
scanner, the CB-100 will LOCKOUT and display the following message L O C K O U T C H E C K
SC AN N ER.

. A lockout will result if a minimum signal is detected for three consecutive shutter closed periods.

SHUTTER OPEN 3.7 sec.

< ---- ►
SHUTTER CLOSED

— *> 0.4 sec. . TIME

n
Wiring - UV
Scanners
To connect the scanner to the control, the UV Scanner is supplied with 36" or 72" of flexible cable.
The UV self-check is supplied with four 72 lead wires. Install them in a suitable length of flexi­
ble armor cable and connect it to the control. A conduit connector is supplied with the scanner.
Connect black wires (shutter) to terminals LI, L2; red wires (UV tube) to terminals SI, S2.
If it is necessary to extend the scanner wiring, the following instructions apply:
Scanner wires should be installed in a separate conduit. The wires from several scanners may be
installed in a common conduit.
1. Selection of Wire
a. Use #14, 16 or 18 wire with 75°C, 600 volt insulation for up to 100 foot distances (sig­
nal loss approximately 20% at 100 feet).
b. Extended Scanner Wiring: For extended scanner wiring up to 500 feet, and for short­
er lengths to reduce signal loss, use a shielded wire (Belden 8254-RG62 coaxial cable,
or equal) for each scanner wire of UV and each red wire of the UV self-check scan­
ner. The ends of the shielding must be taped and not grounded.
c. Asbestos insulated wire should be avoided.
d. Multiconductor cable is not recommended without prior factory approval.
2. High voltage ignition wiring s h o u ld n o t be installed in the same conduit with flame detector
wires. '

CB-100 23
C le a v e i^ ^ B ro o k s @

Installation -
Infrared S c a n n e r ____________________ :_______________________________
Where possible, obtain the burner manufacturer's instructions for mounting the scanner, other­
wise proceed as follows:
A single scanner is used to detect both pilot and main flames. The sight pipe on which the scan­
ner mounts must be aimed so that the scanner sights a point at the intersection of main and pilot
flames.
Proper scanner positioning must assure the following:
a. Reliable pilot flame signal.
b. Reliable main flame signal.
c. A pilot flame too short or in the wrong position to ignite the main flame reliably, must
not be detected.
d. Scanner must have an unobstructed view of flame being monitored.
e. Flame being monitored must completely cover the scanner field of view.
f. To avoid nuisance shutdowns, it is important to avoid sighting hot refractory and to
keep scanner temperature low (below 125° F) (50°C).
g. When the proper position has been established, drill a hole through the furnace wall
and install a 4" to 8” length of threaded 1/2" black iron pipe on which to mount the
scanner.
h. When satisfactory sighting position has been confirmed by operating tests, the sight
tube should be firmly welded in place.

SCANNER MUST NOT SCANNER TARGET

ABOVE REFRACTORY
SIGHT REFRACTORY SCANNER
IINE-OF-SIGHT ) £ )

Wiring
Attach the cable supplied with the scanner to a junction box. Splice the cable wires to 8 pair of
wires not smaller than #18. Install the complete run in a separate conduit to the control.
Continuous conduit bonding between scanner and the control is mandatory! Scanner may be
located up to 100 feet from control. Do not pass scanner wiring through any junction box con­
taining other wires. Do not run other wires through scanner conduit. Asbestos insulated wire
should be avoided.
Keeping th e Scanner Cool
The Infrared Scanner (Temperature Limit 125° F) should never get too hot to grasp comfortably
in the hand. Keep the scanner cool by one or more of the following methods.
1. Use 6" to 8" length of pipe between scanner and hot furnace front plate.
2. Use insulating tube on the end of the iron pipe. •
3. Force air into sighting tube. Use a Sealing Union.
4. Make sure sighting tube does not extend more than halfway into refractory wall.

24 CB-100
 rooks
^ Maintenance Infrared and Ultraviolet Scanners
The Viewing area of the scanner must be kept clean . Even a small amount of contamination
will reduce the flame signal reaching the detector by a measurable amount. Wipe the viewing
area routinely using a soft cloth dampened with concentrated detergent.

Flame Signal Strength

Routine observation of the flame signal strength will forewarn any deterioration in the capability
of the flame detector or its application.

Contacts
There are no accessible contacts in the CB-100. Where contacts are used, their design assures
long trouble-free life when the load circuits arc maintained within the published load ratings.

Electrical Noise
In areas of excessive electrical noise, the installation of an electrical noise suppressor to the
power supply at the control circuit may be helpful.

Humidity
In areas of high humidity, the control chassis should be removed and placed in a dry atmosphere
when the system is expected to be out of service for an extended period.

Periodic Safety Check

It is recommended that a procedure be established to test the complete flame safeguard system at
n least once a month. This test should verify the proper operation of all limit switches and safety
interlocks as well as flame failure protection and fuel safety shutoff valve tightness.

Rotation
It is recommended that control and scanner units purchased as spares be installed periodically.

CB-100 25
Cleavei rooks
UV Scanner

CABLE
CABLE

Mounting U V Scanners

*
i­
*
*
*

GT I S
rr
T
/ STANDARD MOUNTING
*
*

26 CB-100
 rooks
Mounting U V Self-Check Scanner

CB-100 27
C leaver^B rooks

Warranties ------------------------------------------------------------------------------------------------
Standard Cleaver-Brooks parts warranties apply. Please contact your local authorized Cleaver-
Brooks office for additional information.

Cleaver-Brooks
P.O. Box 421
Milwaukee, WI 53201 Bulletin CB-7541
(414) 359-0600 01/93
 Universal Rotary Actuators
Type UP Pneumatic
(UP1/2/3/4/5/6)

A 0582
A0992

F ig u r e 2 . T y p e s U P 3 a n d U P 4 P n e u m a tic U n iv e r s a l R o ta r y
F ig u r e 1. T y p e U P 2 P n e u m a tic U n iv e r s a l R o ta r y A c tu a to r w ith
A c tu a to r w ith D o u b le - A c tin g P is to n P o w e r U n it
R o ta r y V a n e P o w e r U n it a n d T y p e A V C h a r a c te r iz a b l e P o s it io n e r

F e a tu re s

• Wide Range of Torque Ratings. Six actuator sizes standard positioner cam characteristics (for linear, square,
available in ratings from 122 to 6 3 7 2 Newton meters and square root relationship) or custom-shaped cam.
(90 to 4700 foot-pounds).
• Wide Environmental Applications. Com plete metal
■ Easy and Flexible Installation. Actuators can be enclosures offer superior strength, as well as high
placed in convenient locations and connected to the immunity to diverse atmospheres and process materials.
driven device by standard linkage components (refer
to Product Specification G 8 1 -5 -1 ).
• Quick and Smooth Transfer. Easily shifted from
automatic to manual control.
• Suitable for High Tem perature Environm ents.
Actuators can be used in am bient temperatures up to • Wide Range of Options Available. Factory installed
82°C (180°F), depending on the control input1. NEM A 4X enclosure, pneumatic or electric shaft position
transmitter, alarm/travel switches, air failure lock and
- Adjustable Relationship Between Control Signal heated enclosures are available.
and Output Shaft Position. Easily adjusted by use of

I
| Process C o n tro l ana
1 Some actuator/positioner combinations may have a slightly lower :il \/ A u t o m a t i o n Solutions
maximum operating temperature. Refer to the appropriate positioner
specification for temperature limitations.
 Operation
Bailey Type UP Pneumatic Universal Rotary Actuators
regulate dampers, fan inlet vanes, lever-operated valves,
turbine governors, fluid drives and other final control
elements (see Figure 3).

These actuators accept electric or pneumatic control

signals. This provides modulating or on/off control power
to position devices through mechanical linkage or by
direct coupling.

Types UP1 and UP2 actuators include a double-acting

rotary vane power unit. Types UP3, UP4, UP5 and UP6
actuators include a double-acting piston with a motion
conversion mechanism to convert linear to rotary motion.

Order the actuator with a positioner, or a single or

double acting on/off solenoid valve. Refer to Table 5 for
ordering information.

Actuators with a positioner include a Bailey Type AV

Characterizable Positioner. The positioner is a push-pull
action, force balance type control instrument. It offers a
variety of input ranges including 21 to 103 kilopascals (3
to 15 pounds per square inch gage), 21 to 186 kilopascals
(3 to 27 pounds per square inch gage), 4 to 20 milliamps,
or computer DDC, solid state or contact input.

The positioning function can be used for a unique

application. There are standard cams for linear, square,
or square root relationships. Custom shaping the cam
provides for specific positioning. A mechanical connection
to the actuator shaft feeds back the shaft position
movement. The positioner acts as a pneumatic relay.
Through a separate air supply, it produces the differential
pressure that moves the actuator into position.

Actuators with a solenoid valve provide on/off control.

In this case, positioning of the actuator is at either of the
extreme ends of travel (0 percent or 100 percent). The
solenoid valve is suitable for 120 VAC or 115/125 VDC
service, single or double acting.

Tables 1 through 4 present specification information

about the actuators. Table 5 includes the nomenclature
and ordering information. Installation information is
contained in Figures 17 through 21.

2
 Table 5. Nomenclature

POS. 3 4 5 7 8 9
Type UP □ □ □ □ □ □ UNIVERSAL ROTARY ACTUATORS TYPE UP PNEUMATIC (All metal enclosure)

RATED TORQUE
1 122 Nm (90 ft-lbs) @ 690 kPa (100 psig) Supply
2 610 Nm (450 ft-lbs) @ 690 kPa (100 psig) Supply
3 1085 Nm (800 ft-lbs) @ 690 kPa (100 psig) Supply
4 1958 Nm (1450 ft-lbs) @ 690 kPa (100 psig) Supply
5 3796 Nm (2800 ft-lbs) @ 690 kPa (100 psig) Supply
6 6373 Nm (4700 ft-lbs) @ 690 kPa (100 psig) Supply
ENCLOSURE RATING
NEMA 3R (standard)
NEMA 4X (for all except UP1, UP2 and UP30CDC and D)
CONTROL INPUT
0 None - Slave Drive (Type UP6 only)
A 21 to 103 kPa (3 to 15 psig) Characterizable Pneumatic Positioner, Type AV1121LJ0
B 21 to 186 kPa (3 to 27 psig) Characterizable Pneumatic Positioner, Type AV12 2 1 0 )
C 4 to 20 mA Characterizable l/P Positioner, Type AV23 (goes to 0% or 100% on loss of input signal)
D 4 to 20 mA Characterizable l/P Positioner, Type AV33 (holds position on loss of input signal)1
E Characterizable Pulse Input Positioner, Type AV44 (holds position on loss of input signal)1
4 4 to 20 mA Characterizable l/P Positioner, Type AP732100 (holds position on loss of input signal)
5 On/Off Solenoid Valve, 120 VAC, Single Acting
6 On/Off Solenoid Valve, 115/125 VDC, Single Acting
7 Characterizable Pulse Input Positioner, Type AP832100 (holds position on loss of input signal)
8 On/Off Solenoid Valve, 120 VAC, Double Acting
9 On/Off Solenoid Valve, 115/125 VDC, Double Acting
SHAFT POSITION TRANSMITTER
0 None
1 Electric, 4 to 20 mA (linear only)2
C 2 21 to 103 kPa (3 to 15 psig) Type AP432000 Pneumatic Position Transmitter Output
(for U P O D l through 9 only)3
3 4 to 20 mA Output, RQ10 Position Transmitter4
4 4 to 20 mA Output, RQ20 Position Transmitter with Limit Switches24
A Potentiometric Resistive Output Internal to Type AV Positioner (Types AV1, AV2 and AV3)
(for Types UPQUA through D only)5
4 to 20 mA Output Internal to Type AV Positioner (Types AV1, AV2 and AV3)
(for Types UPCElA through D only)5 v3
C 21 to 103 kPa (3 to 15 psig) Type AV Pneumatic Position Transmitter Output (for UPCXJA only) ■
D 21 to 186 kPa (3 to 27 psig) Type AV Pneumatic Position Transmitter Output (for U P H B only)36
M 20 to 100 kPa (2.9 to 14.5 psig) Output7
ALARM/TRAVEL SWITCHES
None
Included (4 SPDT switches)
AIR FAILURE LOCK
None
Included (for all except UP6dO)
HEATERS
0 None
1 Included3

NOTES:
1. Types AV3 and AV4 Characterizable Positioners were not yet available at the time this document was printed. Contact Bailey Controls Company
for current availability. ...
2. A 1 or 4 in the sixth position provides limit switches (included with the position transmitter) and requires a 1 in the seventh position.
3 Not available on Type UP1 actuators. . . . . .. . . __ _
4; Type RQ Position Transmitters are special orders. Contact an authorized Bailey Controls Company sales/service representative for more
information. „ .. , . .. .
L , 5 4 to 20 mA output position transmitter is built into the Type AV4 Characterizable Positioner as a standard feature.
6. The environmental rating on Types UP3 and UP4 actuators is a function of the environmental rating of the Type AV Pneumatic Position
Transmitter, since it is mounted outside the actuator enclosure. Refer to the appropriate Type AV specification for environmental ratings.
7. For use by Bailey Controls Company subsidiaries only.

8
 NOTES:
1. MINIMUM CLEARANCE FOR ADJUSTMENTS.
INSPECTION, MAINTENANCE AND OPERATION
REQUIRED.
2. MAXIMUM AMBIENT TEMP LIMIT “ 160* F ( 8 ? C).
(SO M E ACTUATOR/POSmONER COMBINATIONS MAY
HAVE A SLIGHTLY LOWER MAXIMUM AMBIENT
TEMP LIMIT. REFER TO THE APPROPRIATE
POSITIONER SPECIFICATION.)
4. IF SHIELDED CABLE IS USED, SHIELD GROUNDING
SHOULD BE CONSISTENT WITH SYSTEM REQUIREMENTS.
5. AFTER MOUNTING ACTUATOR IN PLACE, BUT BEFORE
TIGHTENING MOUNTING BOLTS, SHIM SO THAT
MOUNTING BOLTS, WHEN TIGHTENED, WILL NOT WARP
FRAME. TEST BY NOTING FREEDOM OF ACTUATOR IXV ER
S H A H WITH PISTON ROD CLEVIS PIN REMOVED SO
THAT PISTON IS DISCONNECTED.

TP20127A
TP20261A

F ig u r e 2 0 . T y p e U P 3 IU P 4 A c t u a t o r w ith P o s i t i o n e r o r S o le n o id V a lv e a n d P n e u m a ti c S h a f t P o s iti o n T r a n s m itte r O p tio n s

(P a g e 1 o f 2 )
18
 TP20181A

Figure 20. Type UP3IUP4 Actuator with Positioner or Solenoid Valve and Pneumatic Shaft Position Transmitter Options
(Page 2 of 2)

19
 Designs V150, V200, and V300

Fisher Controls Instruction Manual

Designs V150, V200, and

V300 Rotary Control Valves
through 12-Inch
FISHER December 1994 Form 5290

Contents
In tro d u c tio n .................................................. 1
Scope of M an u al................................................................1
Specifications ................................................................... 2
Description......................................................................... 3
In s ta lla tio n ................................................... 4
M a in te n a n c e ................................................ 8
Packing Maintenance ..................................................... 9
Stopping Leakage ......................................................... 9
Replacing Packing......................................................... 9
Disassem bly............................................................... 10
Assembly ....................................................................10
Replacing the Ball S e a l................................................. 12
D isassem bly................................................................. 12
A ssem bly........................................................................12
HD Metal Seal Lubrication .........................................15
Bearing and V-Notch Ball Maintenance .................... 15
D isassem bly................................................................. 15
Assem bly........................................................................16
Welded Taper Key Replacement .......................... 19
A ctu ato r M o u n tin g ............................................. 20
Determining Mounting Position .................................. 20
Determining Closed Position ...................................... 20
Parts O rd e rin g ......................................... 21
Parts K it s .................................................................... 26
Parts L i s t .................................................................... 29
ENVIRO-SEAL™ Packing System .............................33

Introduction
W5749-1
Scope of Manual
DESIGN V150 AND V300 VALVE
This instruction manual provides installation, operation,
maintenance, and parts information for the Design V 1 50 Figure 1. Design V150, V200, and V300 Valves
with Type 1052 Actuator
(1- through 12-inch sizes), V 2 00 (1- through 10-inch
sizes), and V300 (1 - through 12-incb;sizes) rotary con­ instruction manual titled E N V IR O -S E A L P acking S ys­
trol valves. For larger valves (14-, 16-, and 20-inch size), tem fo r V-Line a n d edisc® R o ta ry Valves. Refer to
refer to a separate instruction manual. For information separate manuals for information concerning the actua­
on ENVIRO-SEAL™ packing, see the Fisher Controls tor, positioner, and accessories.

This product m ay be covered by one or m ore of the following patents: 5,1 2 9,6 25 ; 5,1 3 1,6 66 ; 5,05 6,7 57 ; 5,23 0,4 98 ; and 5 ,2 9 9 ,8 1 2 or under pending patents.
E N V IR O -S E A L , Vee-Ball, and edisc are m arks owned by Fisher Controls International, Inc. All other trademarks are the property of their respective owners.

©Fisher Controls International, Inc. 1990, 1994; Ail Rights Reserved

 *
Designs V150, V200, and V300
FISHER

T a b le 1. S p e c ific a tio n s

Valve Sizes and End Connection Styles Flow Ring Construction (Bidirectional Flow): 5% of
valve capacity at full travel
Design V150: 1, 1-1/2, 2, 3, 4, 6, 8, 10, and 12-inch
Construction Materials
sizes (DN25 through DN300) with Class 150 raised-
face flanges or DIN PN10 or PN16 flanges as shown See table 5
in table 2 Material Temperature Capabilities*1)
Design V 200:1,1-1/2, 2, 3, 4, 6, 8, or 10-inch flange­
Composition Seals: -50 to 450 °F (-46 to 232 °C)
less valves that mate with ANSI Class 150, 300, or
HD Metal Seals: -50 to 550° F (-46 to 288°C)
600 raised-face flanges and sizes DN25 through
DN50 for DIN PN10 through PN100 flanges as shown Ceramic Micro-Notch Ball: -50 to 250°F (-46 to
in table 3 121 °C)
Design V300: 1, 1-1/2, 2, 3, 4, 6, 8,10, and 12-inch Flat Metal Seals or Flow Ring with PTFE Packing:
valves with Class 300 raised-face flanges, and sizes -50 to 450°F (-46 to 232°C)
DN25 through DN100 for DIN PN25 or PN40 flanges Flat Metal Seals or Flow Ring with Graphite Rib­
as shown in table 4 bon Packing: -325 to 800°F (-198 to 427°C)
PEEK/PTFE Bearings: -50 to 500° F (-46 to 260°C)
Flow Characteristic
Maximum Inlet Pressures*1)
Approximately equal percentage
Consistent with the pressure-temperature ratings in Standard Flow Direction
tables 2 (Design V150), 3 (Design V200) or 4 (Design
Forward (into the convex face of the V-notch ball)
V300), but do not exceed the material temperature
capabilities or the pressure drop limitations shown in Actuator Mounting
the bulletin*1
2). For CW2M (Hastelloy), and CG8M ■ Right-hand or ■ left-hand as viewed from up­
(317 stainless steel) valves, the pressure-temperature stream end of valve
tables are shown in the bulletin.
Maximum Bali Rotation
90 degrees
Maximum Shutoff Pressure/Temperature Ratings*1)
Valve/Actuator Action
Composition (TCM, TCM III, and TCM MIC), Flat With diaphragm or piston rotary actuator, field-revers­
Metal, and HD (Heavy Duty) Metal Ball Seals: Refer ible between: push-down-to-close (extending actuator
to the bulletin*2). For information on pressure classes, rod closes valve) and push-down-to-open (extending
contact your Fisher Controls sales office or sales rep­ actuator rod opens valve)
resentative.
Face-to-Face Dimensions
Design V200: Consistent with ISA S75.04 (standard),
Shutoff Classification ASME B16.10-short (optional for Class 150 only), and
IEC 534-3-2 (IEC 534-3-2 face-to-face dimensions
Composition Ball Seal (Forward Flow): Class VI are equivalent to S75.04 face-to-face dimensions)
per ANSI/FCI 70-2-1991 and per IEC 534-4, Amend­ Design V150 and V300: Consistent with ISA S75.04
ment 1 (1986) and IEC 534-3-2 (IEC 534-3-2 face-to-face dimen­
Flat Metal Ball Seal (Forward Flow): 0.01% of valve sions are equivalent to S75.04 face-to-face dimen­
capacity at full travel; Class IV per ANSI/FCI sions). The Design V150 valves are also available in
70-2-1991 and per IEC 534-4, Amendment 1 (1986) B16.10 (short) face-to-face dimensions.
HD (Heavy Duty) Metal Ball Seal (Bidirectional
Drive Shaft Diameters and Valve Assembly Weights
Flow): 0.01% of valve capacity at full travel; Class IV
per ANSI/FCI 70-2-1991 and per IEC 534-4, Amend­ Refer to the appropriate valve bulletin: 51.3:V150,
ment 1 (1986) 51.3:V200, or 51.3:V300
1. H ie pressure/temperature limits in this manual, and any applicable code or standard limitation, should not be exceeded.
2. Refer to the appropriate Bulletin 51.3:V15 0 ,5 1 .3:V200 or 51.3:V300 for additional information.
 Designs V150, V200, and V300

Table 2. Design V I50 Valve Sizes, End Connection Styles, and Ratings
V A L V E SIZE, VALVE BO D Y FLANG E
RA TIN G F A C E -T O -F A C E
IN C H E S (DN) M A T E R IA L C O M P A T IB IL IT Y D IM E N S IO N
1, 1-1/2, 2, 3, WCC steel (standard) ANSI Class 150 ASME/ANSI B16.34-1988 Class 150
4, 6, B, and and CF3M<1> raised-face flange
10 (DN 25 [316L stainless
through steel (SST)] DIN PN10 and PN16 DIN PN10 and PN16
DN250)
CG8M (317 SST) ANSI Class 150 See tables in Bulletin 51.3:V150
raised-face for maximum inlet pressure and temperature
DIN 1.0619 steel or DIN PN10 and PN16 DIN PN10 and PN16
DIN 1.4581 (SST)
12 (DN300) WCC steel (standard) ANSI Class 150 ASME/ANSI B16.34-1908 Class 150
andCF3M<1> raised-face
(316L SST) DIN PN16 DIN PN16 ISA S75.04 (standard)
CG8M (317 SST) ANSI Class 150 and IEC 534-3-2(1984)
See tables in Bulletin 51.3:V150
raised-face or ASME B16.10 Short
for maximum inlet pressure and temperature
(Optional)
DIN 1.0619 steel or DIN PN16 DIN PN16
DIN 1.4581 (SST)
1, 1-1/2, 2, 3, CW2M (Hastelloy C) ANSI Class 150 See tables in Bulletin 51,3:V150
4, 6, 8, and raised-face for maximum inlet pressure and temperature
1 0 (DN25
through CW2M DIN PN10 and PN16 DIN PN10 and PN16
DN250)
12 (DN300) CW2M ANSI Class 150 See tables in Bulletin 51.3:V150
raised-tace for maximum inlet pressure and temperature
CW2M DIN PN16 DIN PN16
1. C F 3 M is available in all areas as a special order and is the standard material offering from Fisher Controls in Europe.

BALL

DRIVE SHAFT

Figure 2. Typical Micro-Notch Ball and Shaft

For the 2-inch Design V150 valve, this manual covers only
valves with serial numbers 12551183 and higher. See the
note in the Parts List for further information.
Only personnel qualified through training or experience
should install, operate, and maintain Design V150, V200,
and V300 valves. If you have any questions about these
instructions, contact your Fisher Controls sales office or
sales representative before proceeding.
Description
The Design V150, V200, and V300 Vee-Ball® valves (fig­
ure 1) with a V-notch ball are used in throttling or on-off ser­
vice. The Design V200 is a flangeless construction for
installation between ANSI Class 150, 300, and 600
flanges. The Design V150 and V300 valves are raised-face
flanged constructions, and are available in ANSI Class
150, for Design V150 valves, or ANSI Class 300, for De­
sign V300 valves. The Design V150 and V300 valves have
integral ANSI or DIN flanges. The splined valve shaft of all
these valves connects to a variety of rotary-shaft actuators.
For very precise control of low flow rates (Cv of 8.4 or less),
the Micro-Notch construction (see figure 2) is available on
1-inch valves. There are three Micro-Notch ball materials
available: chrome-plated CG8M (317 stainless steel), solid
alloy 6, and solid VTC ceramic. A VTC ceramic HD seal is
standard with the VTC ceramic ball. For the CG8M and
alloy 6 constructions, pressure and temperature capabili­
ties are the same as for standard constructions. For the ce­
ramic construction, maximum temperature is 250°F
(121 °C).

3
r

Designs V150, V200, and V300

Table 3. Design V200 Valve Sizes, End Connection Styles, and Ratings
VALVE SIZE, VALVE BODY RATING FACE-TO-FACE DIMENSION
FLANGE COMPATIBILITY
INCHES MATERIAL
1 , 1 - 1 /2 & 2 W C C steel or CF3MO) ANSI Class 150/300/600^) ASME/ANSI B16.34-1988 Class 600 ANSI Class 150/300/600—
(DN25 (316L stainless steel) raised-face ISA S 75.04 (standard) and
through DIN PN 10-100 IEC 534-3-2(6), or
DIN PN 10-100
DN50) ANSI Class 1 5 0 -ASM E B16.10 Short
CG8M ANSI Class 150/300/600 S ee tables in Bulletin 5 1 .3:V200 for
(Optional)
(317 stainless steel) raised-face maximum inlet pressure and temperature
DIN 1.0619 steel or DIN PN 10-100 DIN PN 10-100
DIN 1.4581 stainless steel
3 and 4 W C C steel ANSI Class 150 raised-face ASME/ANSI B16.34-1988 Class 150 ISA S75.04 (standard) and
IEC 534-3-2(6) or ASME B16.10 Short
(Optional)
ANSI Class 300/600(4> ASME/ANSI B16.34-1988 Class 600<4> ISA S 75.04 (standard) or
raised-face IEC 534-3-2(6)
CG8 M ANSI Class 150 raised-face S ee tables in Bulletin 5 1 .3:V200 for ISA S75.04 (standard) and
(317 stainless steel) maximum inlet pressure and temperature IEC 5 3 4 - 3 -2 (6) or A s m E B16.10 Short
(Optional)
ANSI Class 300/600(5) S ee tables in Bulletin 5 1 .3:V200 for ISA S 75.04 (standard) or
raised-face maximum inlet pressure and temperature IEC 534-3-2(6)

6 and 8 W C C steel ANSI Class 150/300(6) ASME/ANSI B16.34-1988 Class 300(7> ANSI Class 150/300—
raised-face ISA S 75.04 (standard) and
IEC 5 3 4 - 3 - 2 (6), or ANSI Class 150—
CG8M ANSI Class 150/300(6) See tables in Bulletin 5 1 .3:V200 for
maximum inlet pressure and temperature B16.10 Short (Optional)
(317 stainless steel) raised-face
10 W C C steel ANSI Class 150 raised-face ASME/ANSI B16.34-1988 Class 150 ISA S75.04 (standard) and
IEC 5 3 4 - 3 -2 (6) or A s m E B16.10 Short
C G 8M ANSI Class 150 raised-face S ee tables in Bulletin 5 1 .3:V200 for
(Optional)
(317 stainless steel) maximum inlet pressure and temperature
1, 1-1/2 & 2 CW 2M ANSI Class 150/300/600(2) See tables in Bulletin 5 1 .3:V200 for ISA S 75.04 (standard) or
(DN25 through raised-face maximum inlet pressure and temperature IEC 534-3-2(6)
DN50) C W 2M (Hastelloy C) DIN PN 10-100 DIN PN 10-100

3, 4, and 6 C W 2M (Hastelloy C) ANSI Class 150 raised-face S ee tables in Bulletin 5 1 .3:V200 for ISA S 75.04 (standard) or
maximum inlet pressure and temperature IEC 534-3-2(6)
1 CF3M is available in all areas as a special order and is the standard material offering from Fisher Controls in Europe. . _
2. This valve body will mate with either ANSI Class 150,300, or 600 flanges. Pressure ratings of the valve body is ANSI Class 600. Do not exceed the rating of the mating flanges.
3. IEC 534-3-2 face-to-face dimensions are equivalent to S75.04 face-to-face dimensions. .
4 This valve body will mate with either ANSI Class 300 or 600 flanges. Pressure ratings of the valve body is ANSI Class 600. Do not exceed the rating of the mating flanges.
5 This valve body will mate with either ANSI Class 300 or 600 flanges. Pressure ratings are shown in bulletin. Do not exceed the rating of the mating flanges.
6 This valve body will mate with either ANSI Class 150 or 300 flanges. Pressure ratings are shown in bulletin. Do not exceed the rating of the mating flanges.
7 This valve bodv will mate with either ANSI Class 150 or 300 flanges. Pressure ratings of the valve body is ANSI Class 300. Do not exceed the rating of the mating flanges.

Installation CAUTION

Key numbers in this procedure are shown in figures 15

through 18, unless otherwise indicated.
When ordered, the valve configuration and
construction materials were selected to
meet particular pressure, temperature,
pressure drop, and controlled fluid condi­
tions. Because some valve/trim material
W ARNING combinations are limited in their pressure
drop and temperature ranges, do not apply
any other conditions to the valve without
first contacting your Fisher Controls sales
office or sales representative.
Personal injury or equipment damage
caused by sudden release of pressure may
result if the valve assembly is installed 1. If the valve is to be stored before installation, protect the
where service conditions could exceed ei­ flange mating surfaces and keep the body cavity dry and
ther the valve body rating or the mating pipe free of foreign material.
flange joint rating. To avoid such injury or
damage, provide a relief valvefor overpres­
sure protection as required by government 2. Install a three-valve bypass around the control valve as­
or accepted industry codes and good engi­ sembly if continuous operation will be necessary during in­
neering practices. spection and maintenance of the valve.

4
 Designs V150, V200, and V300

Table 4. Design V300 Valve Sizes, End Connection Styles, and Ratings
VALVE SIZE, INCHES
VALVE BODY MATERIAL FLANGE COMPATIBILITY RATING
(DN)0)
W C C Steel (standard) and CF3M<2) ANSI Class 300 raised-face A SM E/ANSI B16.34 Class 300
(316L stainless steel) DIN PN 25 or 40 DIN PN 25 or 40
1, 1-1/2,
2, 3, and 4 S ee tables in Bulletin 51.3:V300
C G 8M (317 stainless steel) ANSI Class 300 raised-face
(D N 25 through DN100) for maximum inlet pressure and temperature
DIN 1.0619 steel or
DIN PN 25 or 40 DIN PN 25 or 40
DIN 1.4581 stainless steel
W C C (standard) Steel and CF3M<2)
ANSI Class 300 raised-face ASME/ANSI B16.34 Class 300
(316L stainless steel)
6, 8, 10, and 12
S ee tables in Bulletin 5 1 ,3:V300
C G 8M (317 stainless steel) ANSI Class 300 raised-face
for maximum inlet pressure and temperature
1 ,1 -1 /2 , 2, 3, 4, and 6
C W 2M (Hastelloy C) ANSI Class 300 raised-face
(D N 25 through DN100) S ee tables in Bulletin 51.3:V300
1-1/4, 2, 3 and 4 for maximum inlet pressure and temperature
C W 2M (Hastelloy C) DIN PN 25 and 40
(D N 25 through DN100)
1. DN50, DN80, and DN100 are the only sizes offered in Design V300 in Europe.
2. CF3M is available in all areas as a special order and is the standard material offered from Fisher Controls in Europe.

3. The valve is normally shipped as part of a control valve Installing Design V150 and V300 valves:
assembly, with an actuator mounted on the valve. If the
valve and actuator have been purchased separately or if
the actuator has been removed, mount the actuator ac­
cording to the actuator mounting section and the appropri­ a. Install the Design V150 and V300 valve using studs
ate actuator instruction manual. Adjust actuator travel be­ (keys 32 and 33, not shown) and nuts to connect the
fore installing the valve because it is not possible to valve flanges to the pipeline flanges. The seal protector
determine the closed position (necessary for actuator ad­ ring (key 3) end of the valve requires longer line flange
justment) with the valve installed in the pipeline. studs (key 32) than standard. Do not attempt to use
standard-length line flange studs for the seal protector
4. Standard flow direction is with the seal protector ring
end of the valve. See tables in the parts list for keys 32
(key 3, figures 15 through 18) facing upstream. If possible,
and 33 for the required studs part numbers and table 6
install the valve in a horizontal pipeline with the drive shaft
for length of studs for the seal protector ring end of De­
horizontal and the V-notch ball closing in the downward
sign V150 and V300 valves. Lubricate the studs with
direction (see figure 1). The actuator can be right- or left-
Never-Seez Nickel Special or equivalent lubricant.
hand mounted in any of four positions as shown in figure
4. If necessary, refer to the appropriate actuator instruction
manual for installation and adjustment procedures.5
5. Be certain the valve and adjacent pipelines are free of b. Insert flat-sheet line flange gaskets (or spiral-wound
any foreign material that could damage the valve seating gaskets with compression-controlling center rings) that
surfaces. are compatible with the flowing media.

5
f

Designs V150, V200, and V300

Table 5. Standard Construction Materials

PART M A T E R IA L

Valve Body & Seal W C C steel, C G 8M (317 stainless steel),

Protector Ring or CF3M *1) (316L stainless steel) or C W 2M (Hastelloy C)
Flow Ring (C W 2M valve available with composition seal only)
Backup Ring (1 ,1 -1 /2 and 2-inch only) C G 8M , C F3M (1) o rC W 2M
V-Notch Ball Chromium-plated C G 8M , C G8M ,
Chromium-plated C F3M *1>, CF3M<1>, or CW 2M
Seal Composition TCM , TCM III, or TC M MIC
Flat Metal Seal, Shims, and Spring Seal S 31600 (316 stainless steel) or
S 30200 (302 stainless steel) for 12-inch valves only
HD (Heavy-Duty) Metal CF10SMnN*2> (Nitronic 60), CD7MCuN<3> (alloy 255
duplex stainless steel) or R 30006 (Alloy 6)
HD Seal W ave Spring N 07750 (Inconel X750)
HD Seal Radial Seal PTFE with N 10276 (Hastelloy C 276) spring
Bearings PEEK/Carbon-filled liner*4), S 44004 (440C stainless steel),
R 30006 (alloy 6), silver-plated R30006,
carbon-filled PTFE with N 10276 (Hastelloy C)
sleeve, or glass-filled PTFE with N 10276 sleeve
Thrust Washers S17400 (17-7PH stainless steel), Alloy 6B, or N 10276 (Hastelloy C)
Seal Retainer Gasket Laminated graphite
Packing PTFE V-ring with one carbon-filled PTFE ring*5), PTFE V-ring, or
graphite ribbon. Packing is available with or without live loading.
Shafts S 20910 (Nitronic 50), S 17400 (17-4PH stainless steel),
or N 10276 (Hastelloy C276)
Groove Pin S 31600 or N 10276
Taper Key R30006*5), S 20910, or N 10276
Taper Pin (1 ,1 -1 /2 , and 2-inch only) S20910 or N 10276
Pipe Plug S 31700, N10276, or S 31603 (316L stainless steel)
Seal Retainer Screws and Washers Stainless steel
Packing Follower and Packing Box Ring C F8M (316 stainless steel), N10276, or N10276
with separate S316Q0 packing box flange
Actuator Mounting Bolts and Nuts Grade 5 steel or strain-hardened B8M stainless steel
Spacer and Bushing S 31700, N 10276, or S 31603
Packing Follower Bolting and Optional Line Bolting SA-193-B7, SA-193-B7M , or strain-hardened SA-193-B8M
1. CF3M is available in all areas as a special order and is the standard material offered from Fisher Controls in Europe.
2. Recommended for lubricated and non-lubricated service and where corrosion properties sim ilar to 304 stainless steel are acceptable.
3. Recommended for lubricated service and where corrosion properties equal to or better than 317 stainless steel are required.
4. PEEK is poly-ether-ether-ketone.
5. The carbon-filled PTFE ring is used for grounding.
6. Standard material offered in North America.

6
 Designs V150, V200, and V300

DIMENSION
VALVE A M
SIZE, Standard ASME B16.10 B Standard Class 150
INCHES ISA Short Class Class
Class 150 ASME B16.10
S75.04<1> (Optional) 300 600
S75.04<1> Short (Optional)
Inches
1 4.00 5.00 2.25 6.94 7.94 7.94 7.94
1-1/2 4.50 6.50 2.50 7.44 9.44 8.81 8.81
2 4.88 7.00 2.25 8.31 10.56 9.31 9.31
3 6.50 8.00 3.44 10.00 11.25 11.00 11.25
4 7.62 9.00 3.62 11.25 12.62 12.00 13.50
6 9.00 10.50 4.69 13.50 15.00 14.25 - - .
8 9.56 11.50 4.69 13.50 15.50 15.25 ...
10 11.69 13.00 5.94 16.50 17.75 ... . ..

Millimeters
1 102 127 57 176 202 202 202
1-1/2 114 165 64 189 240 224 224
2 124 178 57 211 268 237 237
3 165 203 87 254 286 279 286
4 194 229 92 286 321 305 343
6 229 267 119 343 381 362 - - -
8 243 292 119 343 394 387 ...
10 297 330 151 419 451 . .. - - -
1. IEC 534-3-2 face-to-face dimensions are equivalent to S75.04 face-to-face dimensions.

Figure 3. Required Clearances for Installation of Design V200 Valves

6. Be sure the pipeline flanges are in line with each other. b. Install two studs in the flanges before you place the
valve in the line. Place the two studs so they will contact
the line-centering notches at the bottom of the valve
7. The Design V200 valve does not have flanges; the De­ body.
sign V150 and V300 valves have flanges.
c. Insert flat-sheet line flange gaskets (or spiral-wound
Installing Design V200 valves: gaskets with compression-controlling center rings) that
are compatible with the process fluid.

a. Install the Design V200 valve using long studs (key
32, figure 3) to connect the two pipeline flanges. Refer
to figure 3 for the size of studs required. Lubricate the
studs with Never-Seez Pure Nickel Special or equiva­
lent lubricant.
d. Place the valve on the two studs. Install all remain­
ing studs. Measure carefully to be sure the valve is cen­
tered on the pipeline flanges, and tighten the flange
stud nuts. Tighten the nuts in a criss-cross sequence to
be sure the flange gaskets are properly loaded.

7
r

Designs V150, V200, and V300

Table 6. Flange Stud Lengths Required for Seal Protector Ring End of Design V150 and V300 Valves
DESIGN V1S0 DESIGN V300
VALVE ISA S75.04 ASME B16.10 Short C lass 300 PN25 PN40
Face-to-Face Face-to-Face
Inches mm Inches mm Inches mm Inches mm Inches mm

1 3.00 76 4.00 102 3.5 89 3.25 83 3.25 83

1-1/2 3.25 83 5.25 133 4.00 102 3.75 95 3.75 95
2 3.62 92 5.88 149 4.38 111 4.25 108 4.25 108
3 4.00 102 5.50 140 5.12 130 4.56 116 4.56 116
4 4.38 111 5.88 149 5.38 137 4.88 124 4.88 124
6 4.62 117 6.25 159 5.88 149 5.62 143 5.62 143
8 5.00 127 7.00 178 6.44 164 5.69 145 6.25 159
10 5.38 137 6.75 171 7.25 184 6.12 155 6.88 175
12 5.62 143 6.38 162 7.75 197 6.31 160 7.19 183

e. Place the valve in the pipeline or between flanges.
Install all studs. Tighten the nuts in a criss-cross se­
quence to ensure the flange gaskets are properly
loaded.
Note
The valve drive shaft is not necessarily
grounded when installed in a pipeline. Per­
sonal injury or property damage could re­
sult—if the process fluid or the atmosphere
around the valve is flammable—from an ex­
plosion caused by a discharge of static
electricity from the valve components. If the
valve is installed in a hazardous area, elec­
trically bond the drive shaft to the valve
body.
8. For hazardous applications, attach the optional bonding
strap assembly (key 131, figure 5) to the valve drive shaft
(key 6) with the clamp (key 130, figure 5) and connect the
other end of the bonding strap assembly to the body with
the cap screw (key 23).
9. Connect pressure lines to the actuator as indicated in the
actuator instruction manual. When an auxiliary manual ac­
tuator is used with a power actuator, install a bypass valve
on the power actuator (if one is not supplied) for use duri.ig
manual operation.
ENVIRO-SEAL Packing System for V-Llne and edisc®
Rotary Valves for packing instructions.
Maintenance
Valve parts are subject to normal wear and must be in­
spected and replaced as necessary. The frequency of in­
spection and replacement depends upon the severity of
service conditions. Because of the care Fisher Controls
takes in meeting all manufacturing requirements (heat
treating, dimensional tolerances, etc.), use only replace­
ment parts manufactured or furnished by Fisher Controls.
W ARNING
The V-notch ball closes with a shearing, cut­
ting motion, which could result in personal
injury. To avoid injury, keep hands, tools,
and other objects away from the V-notch
ball while stroking the valve.
Avoid personal injury from sudden release
of process pressure. Before performing
any maintenance operations:
• Disconnect any operating lines pro­
viding air pressure, electric power, or a con­
trol signal to the actuator. Be sure the actua­
tor cannot suddenly open or close the
valve.

• Use bypass valves or completely shut

W ARNING
Personal injury could result from packing
leakage. Valve packing was tightened be­
fore shipment; however the packing might
require some readjustment to meet specific
service conditions.
off the process to isolate the valve from pro­
cess pressure. Relieve process pressure
from both sides of the valve. Drain the pro­
cess media from both sides of the valve.
• Vent the power actuator loading pres­
sure and relieve any actuator spring pre­
compression. .

If the valve has ENVIRO-SEAL live-loaded packing • Use lock-out procedures to be sure
installed, this initial re-adjustment will probably not be re­ that the above measures stay in effect while
quired. See the Fisher Controls instruction manual titled you work on the equipment.

8

Packing Maintenance
Key numbers in this procedure are shown in figures 15
through 18 unless otherwise indicated. A detail view of the
packing is also shown in figure 6.
If the valve is equipped with the ENVIRO-SEAL Packing
System, refer to the separate E N V IR O - S E A L P a c k in g
S y s te m fo r V -L in e a n d edisc R o ta r y V a lv e s instruction
manual.
Note
For the ENVIRO-SEAL Packing System, re­
fer to the Parts List section for: retrofit kits,
parts kits, and individual parts (see figure
6). Refer to the separate ENVIRO-SEAL
Packing System for V-Line and edisc
Rotary Valves instruction manual for main­
tenance instructions.
Designs V150, V200, and V300
Stopping Leakage
For PTFE V-ring packing, leakage around the packing fol­
lower (key 17) can be stopped by tightening the packing fol­
lower nuts (key 20).
If the packing is relatively new and tight on the drive shaft
(key 6), and if tightening the packing follower nuts does not
stop leakage, it is possible that the drive shaft is worn or
nicked so that a seal cannot be made. If the leakage comes
from the outside diameter of the packing, it is possible that
the leakage is caused by nicks or scratches on the packing
box wall. Inspect the drive shaft and packing box wall for
nicks or scratches while performing the following proce­
dure.
Replacing Packing
When using this Replacing Packing procedure, it is recom­
mended that the actuator not be removed from the valve
while the valve is still in the pipeline or between flanges.
Valve/actuator adjustments must be made with the valve
out of the pipeline. Refer to the D e te r m in in g C lo s e d P o s i­
tio n section of this manual.
9
Designs V150, V200, and V300

Disassembly

1. Isolate the control valve from the line pressure, release

pressure from both sides of the valve body, and drain the
process media from both sides of the valve. If using a pow­
er actuator, shut off all pressure lines to the power actuator,
release pressure from the actuator, and disconnect the
pressure lines from the actuator. Use lock-out procedures
to be sure that the above measures stay in effect while you
work on the equipment.

2. Remove line bolting, remove the control valve from the

pipeline, and place the actuator/valve assembly on a flat
surface with the seal protector ring facing up.

3. Remove the actuator cover. Note the orientation of the

actuator with respect to the body and the lever orientation
with respect to the valve drive shaft (see figure 4). Figure 5. Optional Shaft-to-Body Bonding Strap Assembly

follower (key 17) and a separate packing flange (key 40)

W ARNING that must be removed.

If the valve is equipped with the ENVIRO-SEAL packing

When the actuator is removed from the
valve, the V-notch ball/shaft assembly may
suddenly rotate, resulting in personal inju­
ry. To avoid injury, carefully rotate the
V-notch ball to the stable position after the
actuator is removed.
KB CAUTION
When removing the actuator from the valve,
do not use a hammer or similar tool to drive
the lever or actuator off the valve shaft.
Driving the lever or actuator off the valve
shaft could damage the V-notch ball, seal,
and valve.
If necessary, use a wheel puller to remove
the lever or actuator from the valve shaft. It
is okay to tap the wheel puller screw lightly
to loosen lever or actuator, but hitting the
screw with excessive force could damage
the V-notch ball, seal, and valve.
4. Remove the lever (do not loosen the actuator turnbuckle
adjustment), remove the actuator mounting screws and
nuts (keys 23 and 24), and remove the actuator. (If neces­
sary, refer to the actuator instruction manual for assis­
tance.)
5. If necessary, remove the bonding strap assembly before
attempting to remove the packing (see figure 5).
6. Remove the packing follower nuts and packing follower
(keys 20 and 17). For alloy constructions, there is a packing
system, refer to the E N V IR O - S E A L P a c k in g S y s te m fo r
V -L in e a n d edisc® R o ta r y V a lv e s instruction manual for
disassembly.
7. Remove the packing parts (keys 16, 35, 36, or 39 de­
pending on construction) using a formed wire hook with a
sharp end. Pierce the rings with the sharp end of the hook
in order to remove them. Do not scratch the drive shaft or
packing box wall; scratching these surfaces could cause
leakage. Clean all accessible metal parts and surfaces to
remove particles that would prevent the packing from seal­
ing.
Assembly
If the valve is equipped with the ENVIRO-SEAL packing
system, refer to the E N V IR O - S E A L P a c k in g S y s te m fo r
V -L in e a n d edisc® R o ta r y V a lv e s instruction manual for
assembly.
1. For 8-, 10-, and 12-inch, install the packing spacer (key
34) if it has been removed.
2. To help ensure correct centering of the V-notch bail (key
2) on the seal (key 11), make sure the ball or plug is closed
while you install or tighten new packing. Before installing
the packing, close the ball or plug. Insert a screw driver, pry
bar, or similar tool between the lower ear of the plug or ball
and the valve body. Use the pry to move the ball or plug
tightly against the thrust washer and bearing on the actua­
tor side of the valve. Keep the ball or plug in that position
until you have completed packing installation.
3. Install the new packing parts using the parts sequence
shown in figure 6. Install the packing follower (key 17). For
alloy constructions, there is a packing follower (key 17) and
a separate packing flange (key 40) that must be replaced.

10
 Designs V150, V200, and V300

P T F E V -R IN G PAC K IN G G R A P H IT E R IB B O N P A C K IN G
FO R V150, V200, A N D V300 FO R V150, V200, A N D V300
NOTES:
Q > INCLUDES ZINC WASHERS (KEY 36) FOR GRAPHITE
RIBBON PACKING ONLY.

STANDARD PACKING

Figure 6. Packing Arrangements

11
Designs V150, V200, and V300
4. Secure the packing follower with the packing follower
nuts (key 20). Tighten the nuts far enough to stop leakage
under operating conditions.
Note
If the valve is equipped with a bonding strap
assembly (figure 5), please re-install the as­
sembly.
5. Reconnect the actuator and lever in accordance with the
orientations that were noted in step 3 of the disassembly
procedures. If necessary, use figure 4 to identify the correct
index marks.
6. Refer to the appropriate actuator instruction manual to
complete actuator assembly and adjustment.
7. When the control valve is in operation, check the packing
follower for leakage and retighten the packing follower nuts
(key 20) as necessary.
Replacing the Ball Seal
Disassembly
Perform this procedure if the control valve is not shutting
off properly or if seal inspection is necessary. The actuator/
valve assembly must be removed from the pipeline; how­
ever, the actuator may remain mounted on the valve during
ball seal replacement procedure. Ball Seal Assembly de­
tails (with key numbers) are also shown in figure 7. Upon
inspection, if it is found that the V-notch ball, shaft, or bear­
ings need to be replaced, use this procedure to remove the
ball seal. Then, proceed to the V-notch Ball and Bearing
Maintenance procedures to replace the V-notch ball, bear­
ings, and shafts. After other procedures are complete, re­
turn to this procedure and begin with the assembly of the
ball seal steps.
Key numbers are shown in figures 15 through 18, unless
otherwise indicated.
Handle the seal protector ring, seal, and other parts care­
fully to prevent damage. A new gasket (key 15) is required
whenever the seal protector ring (key 3) is removed.
The flow ring construction does not use a seal, shims, or
spring seal. Use this procedure to remove the seal protec­
tor ring from flow ring constructions, but disregard any
instructions calling for the seal, shims, or spring seal.1
1. Isolate the control valve from process pressure and re­
lease pressure from the valve. If using a power actuator,
also shut off all pressure lines to the power actuator, re­
lease all pressure from the actuator.
12
[ FISHER*
2. Remove line bolting, remove the control valve from the
pipeline, and place the valve on a flat surface with the seal
protector ring facing up. Carefully rotate the V-notch ball to
the open position.
3. Remove protector ring screws and washers (keys 21
and 22). Carefully remove the seal protector ring and gas­
ket (keys 3 and 15). (For flow ring constructions, go to step
4. )
a. For valves with composition (TCM, TCM III, or
TCM MIC) seals, remove the seal (key 11) from the
valve body. For 1-, 1-1/2, and 2-inch valves, remove the
backup ring (key 42, figure 8) from the valve body.
b. For a flat metal seal, remove the spring seal, seal,
and shims (keys 13,11, and 12). (Note: It may be neces­
sary to re-use some of the original shims when reas­
sembling the flat metal seal.)
c. For an HD metal seal, once the protector ring has
been removed from the valve, push the metal seal (key
11) out of the seal protector ring (key 3). Remove the
wave spring and radial seal (keys 13 and 37).
• It might be necessary to remove the HD metal seal
by carefully tapping it with a soft punch and hammer. Take
care not to damage the seal protector ring.
• 3- through 12-inch valves, where the seal is diffi­
cult to push out, it is recommended that a seal removal
plate be used to press the HD metal seal out of the seal pro­
tector ring. Refer to figure 9 for dimensions of the seal re­
moval plate. (The seal removal plate is not required for 1-,
1-1/2, or 2-inch valves.)
• 10- and 12-inch valves: Remove the retaining
ring (key 41) in the seal protector ring. This retaining ring
is an octagonal-shaped support wire. To remove the retain­
ing ring, find one of the free ends of the ring. Use a screw­
driver or similar tool to pry inward and up until the ring is re­
moved.
4. Inspect the gasket and sealing surfaces on the valve
body (key 1 or 1A), the seal protector ring (key 3), V-notch
ball (key 2), and the retaining ring (key 41 for 10- and
12-inch valves only). Be sure the surfaces are not dam­
aged.
5. If replacement of the V-notch ball, shafts (keys 6 or 9),
or bearings (key 10) is needed, proceed to the Bearing and
V-notch Ball Maintenance procedure. If only the seal is to
be replaced, proceed to the assembly procedure below.
Assembly •
Refer to figures 7 and 8 for key number locations during
seal installation. Valve key number locations are shown in
figures 15 through 18.
 Designs V150, V200, and V300

COMPOSITION SEAL

SIZE 3- THROUGH 8-INCH

HD METAL BALL SEAL
SIZE 10- AND 12-INCH
HD METAL BALL SEAL

Figure 7. Ball Seal Assembly Detail.

SEAL PROTECTOR
SEAL PROTECTOR

C O M P O S ITIO N B A LL S E A L HD M E T A L B A LL S EA L

Figure 8. Design V150, V200, and V300 Sizes

1, 1-1/2, & 2-Inch Ball Seal Assembly

13
Designs V150, V200, and V300
VALVE SIZE, D IM E N S IO N A
IN C H ES Minimum-Maximum, Inches Minimum-Maximum, mm
3 2.990-3.000 75.9-76.2
4 3.740-3.750 95.0-95.3
6 4.990-5.000 126.7-127.0
8 6.240-6.250 158.5-158.8
10 8.365-8.375 212.5-212.7
12 10.365-10.375 263.3-263.5
Figure 9. HD Seal Removal Plate Dimensions
To help ensure correct centering of the V-notch ball (key 2)
on the seal (key 11), make sure the ball or plug is closed
while you install the flow ring or seal and seal protector ring.
Before installing the seal, close the ball or plug. Insert a
screw driver, pry bar, or similar tool between the lower ear
of the plug or ball and the valve body. Use the pry to move
the ball or plug tightly against the thrust washer and bear­
ing on the actuator side of the valve. Keep the ball or plug
in that position until you have completed seal installation.
1. Thoroughly clean all parts that are to be re-used and ob­
tain replacement parts. Be sure that all sealing surfaces
are in good condition without scratches or wear. If the valve
has been installed between line flanges and the flange
studs and nuts have been tightened, always replace the
gasket (key 15) with a new gasket.
W ARNING
The V-notch ball closes with a shearing, cut­
ting motion, which could result in personal
injury. To avoid injury, keep hands, tools,
and other objects away from the V-notch
ball while stroking the valve.
2. Carefully close the V-notch ball. Make sure it cannot ro­
tate during assembly. '■
3. For valves with composition ball seals:
14
a. 1-, 1-1/2, and 2-inch valves: Install the backup ring
(key 14). Install the composition seal (key 11) into the
valve body. Refer to figure 8.
• Install the gasket (key 15) on the valve body.
• Install the seal protector ring (key 3) into the valve
body. (Go to step 6 below.)
b. 3- through 12-inch valves: Install the composition
seal (key 11) into the valve body.
• Install the gasket (key 15) on the valve body.
• Install the seal protector ring (key 3) into the valve
body. (Go to step 6 below.)
4. For valves with flat metal seals:
• Install 12 shims in the valve and install the flat met­
al seal on top of the shims (see figure 7).
• Install the spring seal (key 13) on the flat metal seal
(key 11) with the convex side of the spring seal facing the
V-notch ball.
• Install the seal protector ring, and install the pro­
tector ring screws and washers (keys 21 and 22). Tighten
the screws.
• Add or remove shims under the ball seal as neces­
sary to obtain zero ball seal deflection as accurately as
possible.
Note
Zero ball seal deflection for a flat metal seal
is the point at which the addition of one
0.005-inch (0.13 millimeter) thick shim
causes contact between the V-notch ball
and ball seal to be broken. Hold the parts
tightly together when determining zero
deflection, or improper zero deflection
might result.
• After zero deflection is reached, remove the seal
protector ring, spring seal, seal and 4 shims. Final assem­
bly of control valve should not exceed a maximum of 9
shims for zero deflection. If more than 9 shims are required,
contact your Fisher Controls sales office or sales represen­
tative.
• When the above steps are complete, go to step 6
in this procedure.
5. For valves with HD metal seals:
a. For 1-, 1-1/2, 2-inch valves,
• Install the wave spring (key 13) onto the ball seal.

• Lubricate and install the radial seal (key 37) onto
the ball seal (key 11). Make sure the open side of the radial
seal faces away from the V-notch ball.
• Push the ball seal assembly into the seal protector
ring (key 3).
• Go to step 6 in this procedure.
b. For 3- through 8-inch valves,
• Lubricate and install the radial seal (key 37) into
the appropriate groove in the seal protector ring making
sure the open side of the radial seal faces away from the
ball.
• Install the wave spring (key 13) into the seal pro­
tector ring (key 3).
• Install the HD metal seal (key 11) into the seal pro­
tector ring (key 3), past the radial seal. While pushing it past
the radial seal, make sure the HD metal seal is level. Go to
step 6 in this procedure.
c. For 10- and 12-inch valves:
• Lubricate and install the radial seal (key 37) into
the appropriate groove in the seal protector ring making
sure the open side of the radial seal faces away from the
ball.
• Install the wave spring (key 13) into the seal pro­
tector ring (key 3).
• To install the retaining ring (key 41), find one of the
free ends of the ring. Insert the free end into the groove in
the seal protector ring. Work around the ring, pressing it
into the groove until the ring is completely in its groove.
• Install the HD metal seal (key 11) into the seal pro­
tector ring (key 3), past the radial seal. While pushing it past
the radial seal, make sure the HD metal seal is level.
The HD metal seal uses a retaining ring (key 41) for 10- and
12-inch sizes only. This retaining ring is an octagonal­
shaped support wire. Go to step 6 in this procedure.
6. Install a replacement gasket (key 15) on the valve body
(key 1 or 1A). Install the HD metal ball seal/seal protector
ring assembly into the valve body (key 1 or 1A).
7. Install washers (or clips), and screws that clamp the seal
protector ring to the valve body [keys 3,21, and 22; the De­
sign V200 valve uses clips (key 22) in place of washers].
8. If necessary, refer to the packing maintenance proce­
dures to install the packing. Install the actuator using the
Actuator Mounting procedures in this section. If necessary,
Designs V150, V200, and V300
refer to the valve adjust steps in the Actuator Mounting pro­
cedures, or to the appropriate actuator instruction manual.
To assist with break-in of the HD metal seals, it is recom­
mended that the V-notch ball and seal be lubricated using
the HD Metal Seal Lubrication procedures in this section.
HD Metal Seal Lubrication
To assist with break-in of the HD metal seals, lubricate the
face of the V-notch ball using Dow Corning 321 dry film lu­
bricant or equivalent molydisulfide.
Bearing and V-Notch Ball Maintenance
Procedures for disassembly and assembly of the bearings
and V-notch ball can not be accomplished until the ball seal
and valve packing are removed from the valve.
• Refer to the Replacing Packing procedures to re­
move the actuator, and to remove the packing from the
valve. When the packing disassembly steps are complete,
return to this section.
• Refer to the Replacing the Ball Seal procedures to
remove the seal from the valve.
Key numbers in this procedure are shown in figures 15
through 18, unless otherwise indicated. In the following
procedure, the taper key (key 4, figure 14) is used in 3-
through 12-inch valves, but the taper pin (figure 13) is used
in the 1-, 1-1/2, and 2-inch size valves and the taper pin (fig­
ure 12) is used in the 1-inch size valves with Micro-Notch
construction.
Disassembly
W ARNING
When the actuator is removed from the
valve, the V-notch ball/shaft assembly may
suddenly rotate, resulting in personal inju­
ry. To avoid injury, carefully rotate the
V-notch ball to the open position. Make sure
the ball will not rotate.
Once the shafts have been removed from the valve body,
the V-notch ball may fall. To avoid personal injury or dam­
age to the sealing surfaces, provide support forthe V-notch
ball to prevent it from falling as the shafts are being re­
moved.
1. Carefully rotate the V-notch ball to the'open position after
the actuator is disconnected. Make sure the ball will not ro­
tate (see warning above). Provide support for the V-notch
ball during the following disassembly.
15
 /■ ■>
Designs V150, V200, and V300

2. Unscrew the pipe plug (key 25).

3. Locate the small end of the taper pin (key 4, see figure
12 or 13) or taper key (key 4, see figure 14). Using a pin
punch on the smaller end of the taper pin or key, drive it out
of the V-notch ball (key 2) and drive shaft (key 6). Note:
driving the taper pin or taper key in the wrong direction will
tighten it.

• For tack welded taper keys, driving the taper key

out of the ball ear will shear the tack welding.

4. Working from the small end of the groove pin (key 7), use
a pin punch to drive the groove pin out of the V-notch ball
ear and follower shaft.

5. Pull the drive shaft (key 6) out of the actuator side of the
valve body. For 3-inch and larger valves with metal bear­
ings, remove the thrust washer (key 38). F o r i- , 1-1/2, and
W6134-1*
2-inch valves, remove the thrust washer (key 38) from
valves with composition or metal bearings. Figure 10. Ball/Attenuator Installation and Removal Method

drive them out with a slight pressure. Allow the bush­

6. Make sure the sealing surface of the V-notch ball is not
ings (key 5 or 8) to remain in the valve body.
damaged while removing the follower shaft. Use a punch
to push the follower shaft (key 9) into the center of the
b. For metal bearings, use a press and ram to remove
V-notch ball.
the drive shaft bearings out of the valve body. Refer to
figure 11 ram dimensions. The bushings (key 5 or 8) will
7. Removing the V-notch ball (key 2): normally remain in the valve body.

a. For V-notch ball without attenuator, carefully re­
move the follower shaft and V-notch ball from the valve
body, and for valves with metal bearings, remove the
thrust washer (key 38). Also, 1-, 1-1/2, and 2-inch
valves will require removing the thrust washer (key 38).
b. For V-notch ball with attenuator (sizes 4-through
12-inch valves), carefully remove the follower shaft
and V-notch ball from the valve body. For 4-inch valves,
remove the V-notch ball/attenuator through the inlet of
the valve. For 6-, 8-, 10-, and 12-inch valves, remove
the V-notch ball/attenuator through the outlet of the
valve. The 6-, 8-, 10-, or 12-inch V-notch ball/attenuator
will not come straight out of the valve body. Taking hold
of the follower shaft ear on the ball/attenuator, you must
position the scalloped edge of the attenuator against
the valve bore opening and then pivot, or roll, the
V-notch ball/attenuator out of the valve body (see figure
10). For valves with metal bearings, remove the thrust
washer (key 38).
8. Remove the packing box spacer (key 34) for 8-, 10-, and
12-inch valves.
9. Removing the bearings (key 10):
a. For composition bearings, remove the bearings by
hand. If the bearings are tight in the body, then pull or
• To remove the follower shaft bearings, use a blind-
hole bearing puller similar to CG2545AB, which is made by
Snap-On Tools. If you do not have such a tool, you can ma­
chine the bearing out.
• Another technique is to run a weld bead along the
full length of the inside of the bearing. As the bearing cools,
it will have a slightly smaller diameter and should be easier
to remove.
Note
For proper shutoff performance, the ball
and seal require the bearing (key 10) to be
positioned correctly. If you removed the
bearings (key 10), be sure to locate the new
bearings as shown in figure 11.
10. Thoroughly clean surfaces of all parts that are to be re­
used or obtain replacement parts.
Assembly
1. Inspect all sealing surfaces to ensure they are in good
condition and without scratches or wear.
2. Installing bearings (key 10):

16

a. For composition bearings, install the bearings by
hand. The bearing flanged end should touch the bush­
ing (key 5 or 8).
b. For metal bearings:
• Use a press and ram to install the bearings (key
10). Refer to figure 11.
• Press the bearings in until each bearing is flush
with the bushing (key 5 or 8). The acceptable tolerance for
bearing location is: flush with the bushing to 0.060 inches
(1.52 mm) inside the bushing. That is, the bearings should
not protrude into the flow cavity of the valve. They should
not be more than 0.060 inches (1.52 mm) inside the bush­
ing.
• Take care not to change the position of the bush­
ings (key 5 or 8) when pressing in new bearings (key 10),
otherwise the V-notch ball will not center in the valve body
and seal.
3. Installing the V-notch ball (key 2):
m W A R N IN G
The V-notch ball might be damaged if it is al­
lowed to fall into the valve body. To avoid
personal injury or damage to the sealing
surfaces, support the V-notch ball to pre­
vent it from falling into or out of the valve
body cavity.
Note
To ease assembly, the follower shaft (key 9)
should be inserted into the V-notch ball be­
fore installing the V-notch ball in the follow­
ing applications:
• 3-inch valve without ball/attenuator
• 4- through 12-inch valves with ball/at­
tenuator.
a. For V-notch ball without attenuator, carefully
install the V-notch ball into the valve body cavity.
b. For V-notch ball with attenuator (sizes 4 through
12-inch valves), carefully install the V-notch ball into
the valve body cavity. For 4-inch valves, install the
V-notch ball/attenuator through the inlet of the valve.
For 6-, 8-, 10-, and 12-inch valves, install the V-notch
ball/attenuator through the outlet of the valve. The 6-,
8-, 10-, or 12-inch V-notch ball/attenuator will not install
straight into the valve body. Taking hold of the follower
shaft ear on the ball/attenuator, you must position the
scalloped edge of the attenuator against the valve bore
Designs V150, V200, and V300
opening and then pivot, or roll, the V-notch ball/attenua­
tor into the valve body (see figure 10).
After you have installed the V-notch ball (key 2) into the
valve body assembly, firmly support the V-notch ball while
installing the shafts. .
4. Installing the follower shaft (key 9):
• For 4-inch and larger valves without attenua­
tor: Hold the washer (key 38, for metal bearings) in place.
Insert the follower shaft (key 9) through the V-notch ball,
and into the valve body bearing (key 10). Align the hole in
the follower shaft with the holes in the V-notch ball. Insert
the small end of the groove pin (key 9) into the hole in the
V-notch ball and into the follower shaft. The pin will hold the
parts in place while the drive shaft (key 6) is being installed.
• For 4- through 12-inch valves with ball/attenua­
tor: The follower shaft (key 9) should already have been in­
serted into the V-notch ball/attenuator before the ball was
put into the valve body. Hold the washer (key 38, for metal
bearings) in place. Insert the follower shaft (key 9) into the
valve body bearing (key 10). Align the hole in the follower
shaft with the holes in the V-notch ball. Insert the small end
of the groove pin (key 9) into the hole in the V-notch ball and
into the follower shaft. The pin will hold the parts in place
while the drive shaft (key 6) is being installed.
• For 3-inch valves: The follower shaft (key 9)
should already have been inserted into the V-notch ball be­
fore the ball was put into the valve body. Hold the washer
(key 38, for metal bearings) in place. Insert the follower
shaft (key 9) into the valve body bearing (key 10). Align the
hole in the follower shaft with the holes in the V-notch ball.
Insert the small end of the groove pin (key 9) into the hole
in the V-notch ball and into the follower shaft. The pin will
hold the parts in place while the drive shaft (key 6) is being
installed.
• For 1-, 1-1/2, and 2-inch valves: Insert the follow­
er shaft (key 9) through the pipe plug opening, through the
bearing (key 10) and into the V-notch ball. Align the hole in
the follower shaft with the holes in the V-notch ball. Insert
the small end of the groove pin (key 9) into the hole in the
V-notch ball and into the follower shaft. The pin will hold the
parts in place while the drive shaft is being installed.
5. Installing the drive shaft for valves with taper pins:
Note
• Make sure the drive shaft is free of oil
or grease, otherwise the taper pin will not
seat properly.
• Make sure to inspect the V-notch ball
and shaft carefully. The small end of the ta­
per pin must be inserted into the larger hole
side of the ball ear (or ball, for Micro-Notch
constructions), and into the large hole side
of the drive shaft (see figure 12 or 13).
17
Designs V150, V200, and V300

B EAR IN G RAM D IM E N S IO N S B U SH IN G RAM D IM EN SIO N S

VALVE Ram Lengths Ram D iam eters Ram D iam eters
SIZE,
L M D d D Long Ram d S ho rt Ram d
IN C H ES
Inches mm Inches mm Inches mm Inches mm Inches mm Inches mm Inches mm
7.930 201.42 3.750 95.25 0.900 22.86 0.750 19.05 1.110 28.19 0.750 19.05 0.900 22.86
3 &4
MlNTO MIN MIN MIN 0.890 22.61 0.740 18.80 1.100 27.94 0.740 18.80 0.890 22.61
9.750 247.65 3.750 95.25 1.150 29.21 1.000 25.40 1.360 34.54 1.000 25.40 1.150 29.21
6
MIN MIN MIN MIN 1.140 28.96 0.990 25.15 1.350 34.29 0.990 25.15 1.140 28.96
13.310 338.75 5.500 139.70 1.400 35.56 1.250 31.75 1.610 40.89 1.250 31.75 1.400 35.56
8
MIN MIN MIN MIN 1.390 35.31 1.240 31.50 1.600 40.64 1.240 31.50 1.390 35.31
15.620 396.75 5.500 139.70 1.400 35.56 1.250 31.75 1.610 40.89 1.250 31.75 1.400 35.56
10
MIN MIN MIN MIN 1.390 35.31 1.240 31.50 1.600 40.64 1.240 31.50 1.390 35.31
18.750 476.25 6.000 152.40 1.650 41.91 1.500 38.10 1.985 50.42 1.500 38.10 1.650 41.91
12
MIN MIN MIN MIN 1.640 41.66 1.490 37.85 1.975 50.17 1.490 37.85 1.640 41.66
1. MIN = Minimum.

VALVE D IM EN SIO N
SIZE, B C B C
INCHES Inches M illim eters
1.960 3.952 48.26 100.38
1.970 3.962 50.04 100.63
2.366 4.764 60.10 121.01
2.376 4.774 60.35 121.26
3.291 6.614 83.59 168.00
6
3.301 6.624 83.85 168.25
4.181 8.394 106.20 213.21
8
4.191 8.404 106.45 213.46
5.328 10.688 135.33 271.48
10
5.338 10.698 135.59 271.73
6.680 13.392 169.67 340.16
12
6.690 13.402 169.93 340.41

BUSHING (KEY 5) LOCATION

BEARING RAM
NOTE:
Q > DIMENSION B IS THE DISTANCE BETWEEN THE INCHES
GUIDE BUSHING AND THE CENTER OF DIAMETER A. (mm)

Ffgure 11. Metal Bearing Ram and Bushing Location

18

Figure 12. Taper Pin Installation for Design V150, V200, and
V300 Size 1-Inch Valves with Micro-Notch Construction
a. Hold the thrust washer (key 38) in place, insert the
drive shaft into the valve body bearing (key 10), and into
the V-notch ball ear (or ball, for Micro-Notch construc­
tions). Align the hole in the drive shaft with the holes in
the V-notch ball.
b. Insert the taper pin into the V-notch ball and drive
shaft as shown in figure 12 or 13.
Note
The taper pin will not fit correctly if inserted
in the wrong direction through the ball ear
(or ball, for Micro-Notch constructions) or
through the drive shaft. Make sure the drive
shaft and ball ear (or ball, for Micro-Notch
constructions) are in the correct orientation
for installing the pin.
6. Using a flat-end punch, drive the taper pin into the ball
ear (or ball, for Micro-Notch constructions) and drive shaft
until solid heavy contact is felt. Make sure the taper pin
spans the width of the ball ear (or ball, for Micro-Notch
constructions).
7. Using a flat end punch, drive the groove pin (key 7) into
the ball ear (or ball, for Micro-Notch constructions) and fol­
lower shaft until it is flat with the ball ear (or ball, for
Micro-Notch constructions) surface.
Note
Taper pins (figure 12 or 13) do not require
welding. Taper pins are used in the 1-, 1-1/2,
and 2-inch valves.
8. Installing the drive shaft (key 6) for valves with taper
keys: Refer to the following Welded Taper Key Replace­
ment procedures.
Designs V150, V200, and V300
Figure 13. Taper Pin Installation for Design V150, V200, and
V300 Sizes 1, 1-1/2, & 2-inch Valves.
Welded Taper Key Replacement
Current standard construction materials for all 3- through
12-inch valves require the taper key (key 4, figures 15,16,
and 18) to be tack welded in place using the following pro­
cedure. Use standard welding preparations when prepar­
ing parts for reassembly.
Note
Make sure the drive shaft (key 6) is free of oil
or grease, otherwise the taper key will not
seat properly.
1. Insert the taper key (key 4) into V-notch ball and drive
shaft (keys 2 and 6) as shown in figure 14. The taper key
inserts, with the flat side of the key, facing the drive shaft
(key 6).
2. Using a flat end punch, drive the groove pin (key 7) into
the ball ear and follower shaft until it is flat with the ball ear
surface.
3. Using a flat end punch, drive the taper key (key 4) into
the ball ear and drive shaft (key 6) until solid heavy contact
is obtained between the key and shaft.
4. Measure the position of the taper key head.
5. Drive the taper key in further using the minimum distance
shown in table 7.
6. Inspect the ball/shaft taper key connection to verify that
the taper key spans the entire shaft flat width. If not, the ta­
per key must be driven in further until this condition is satis­
fied. However, do not exceed the maximum depths shown
in table 8.
Note
When welding standard valves that have a
CG8M (317 SST) or CF3M (316L SST) ball,
use 309 or 309L filler rod material.
Alloy valve taper keys are normally not
welded.
19
Designs V150, V200, and V300

Table 7. Taper Key Minimum Depth

MINIMUM DEPTH TO DRIVE TAPER KEY
VALVE SIZE, INCHES AFTER INITIAL SOLID CONTACT,
INCHES (MM)
3, 4 ,6 0.188(4.8)
8 ,1 0, 12 0.219(5.6)

Table 8. Taper Key Maximum Depth

MAXIMUM DEPTH TO DRIVE TAPER KEY
VALVE SIZE, INCHES AFTER INITIAL SOLID CONTACT,
M IN IM U M E N G A G E M E N T OF
INCHES (MM)
TA P ER KEY
3 ,4 0.281 (7.1)
6 0.312(7.9)
8, 10 0.375(9.5)
12 0.406(10.3)

7. When the above conditions are met, tack weld the taper
key (key 4) to the ball ear on the head end of the key (see
figure 14). Use a:

• 1/8-inch diameter weld on 3- through 6-inch

valves,
• 3/16-inch diameter weld on an 8- through 10-inch TA P ER KEY
valves, and Figure 14. Taper Key Installation for 3-12 Inch Valves

• 1/4-inch diameter weld on 12-inch valves.
8. Refer to Ball Seal, Packing Maintenance, and other pro­
cedures as necessary to complete the assembly of the
valve.
Actuator Mounting
Use the appropriate actuator instruction manual and figure
4 of this manual when mounting the actuator or changing
actuator styles and positions.
To help ensure correct centering of the V-notch ball (key 2)
on the seal (key 11), be sure the ball is closed when mount­
ing the actuator. Do not use a hammer or other tool to drive
the actuator lever onto the valve shaft. Clean the valve
shaft and actuator lever splines to be sure the actuator le­
ver will slide on easily. If the lever does not slide on easily,
carefully wedge the ball solidly against the actuator-side
thrust washer using a screw driver or similar tool inserted
between the lower ear of the ball and the valve body. Keep
the wedge in place while installing the lever, but again, do
not drive on the lever. Remove the wedge after you have
clamped the actuator lever on the valve shaft and con­
nected the lever to the actuator piston rod or diaphragm
rod.
Determining Mounting Position
The actuator can be either right or left-hand mounted.
Note
Right-hand mounting—Actuator is on the
right side of the valve when viewed from
valve inlet.
Left-hand mounting—Actuator is on the left '
side of the valve when viewed from valve in­
let.
The preferred location of the V-notch ball is in the top of the
body when the valve is open. To convert from right to left
hand-mounting, turn the valve to position the actuator
mounting pad on the left and rotate the V-notch ball to the
top of the valve.
The number one V-notch controls flow on right-hand
mounting. Turn the valve 180 degrees, and rotate the
V-notch ball to the top of the valve to obtain left-hand
mounting. The number two V-notch controls flow for this
construction.
Determining Closed Position
1. The valve must be removed from the line to check the
position of the V-notch ball.
C T WARNING
The V-notch ball closes with a shearing, cut­
ting motion. To avoid personal injury, keep
hands, tools, and other objects away from
the V-notch ball while stroking the valve.
2. Rotate the V-notch ball to the closed position.
3. Follow the appropriate procedure.

20

On Valves Without Rotary Attenuator Installed
• When viewed from the body outlet, the ball is in the
proper position when both V-notches of the ball are cen­
tered between the machined diameter of the ledge that
supports the seal.
• The micro-notch ball closed position is approxi­
mately 5 degrees closed from the first point of flow. This
establishes the zero degree position for the ball.
On Valves With Rotary Attenuator Installed
• Remove the seal protector ring (key 3, figures 15,
16, or 18) and the seal. When viewed from the body out­
let, the ball, on sizes up to 6 inches, is in the proper posi­
tion when both V-notches of the ball are centered be­
tween the machined diameter of the ledge that supports
the seal.
Designs V150, V200, and V300
On 6-inch and larger sizes, the ball is in the proper posi­
tion when the V-notch and the rounded back edge are
centered between the machined diameter of the ledge
that supports the seal.
4. Adjust the actuator linkage as described in the appropri­
ate actuator instruction manual until the condition de­
scribed in step 3 exists. A line is stamped on the actuator
end of the drive shaft (figure 4) to indicate the V-notch ball
position.
Parts Ordering
A serial number is assigned to each valve and stamped on
the nameplate. Always refer to the valve serial number
when corresponding with your Fisher Controls sales office
or sales representative regarding spare parts or technical
information. When ordering replacement parts, also speci­
fy the complete 11-character part number from the parts
kits or parts list information.
21
Designs V150, V200, and V300

Figure 15. Design V150 Valve Assembly (3-12 Inch Sizes)

22
 Designs V150, V200, and V300

NOTE:
/f* \ KEYS 28, 30, 31, 32, 35 ANO 36 ARE NO T SHOW N.
42B4587-B

Figure 16. Design V200 Valve Assembly (3-10 Inch)

23
 F IS H E R 0
Designs V150, V200, and V300 -

NOTE: -
KEYS 30, 31, 32, 35 AND 36 ARE NOT SHOWN.
4482226‘A

Figure 17. Design V150Size 1, 1-1/2, and 2-Inch Valve (Details are Typical for Design V200 andV300 Valves
Except Design V200 Does Not Have Line Flanges)

24
 Designs V150, V200, and V300

C O M P O S ITIO N B EA RIN G M E T A L B EA RIN G M E T A L B EA RIN G

SIZE 8, 10, & 12 SIZE 8, 10, A 12 SIZE 3-6

NOTE: HD M E T A L SEAL-
KEYS 28, 30, 31, 32, 38 ANO 36 ARE N P T SHOW N. SIZE 10a 12
Figure 18. Design V300 Valve Assembly (3-12 Inch)

25
Designs V150, V200, and V300

Parts Kits for Design V I 50,

V200 and V300 Valves
Retrofit Kits for HD Metal Seal
Retrofit kits include parts to convert existing valves to the protector ring has a standard S75.04 or IEC 534-3-2
HD (heavy-duty) metal ball seal construction. The seal face-to-face dimension.
HD Metal Ball Seal Retrofit Kits for ISA S75.04 Face-to-Face Valves
VALVE SIZE, RETROFIT KIT NUMBER
INCHES FOR HD METAL BALL SEAL
CFIOSMnN DC7MCUN
For WCC Steel (Nitronic 60) (Alloy 255 Duplex SST)
Seal Protector Ring Seal Material Seal Material
— s m ----------------------------------------------------- RV150X0R 012 R V150XCR012
2(2) RV150X0R 152 RV150XC R 152
3 R V 150X0R 022 RV150XC R 022
4 RV150X0R 032 RV150XC R 032
6 RV150X0R 042 RV150XC R 042
8 R V150X 0R 052 R V150XCR052
10 RV150X0R 062 RV150XC R 062
12(3) RV150X0R 072 R V150XCR072

For CG8M (317 SST) CFIOSMnN DC7MCuN

Seal Protector Ring Seal Material Seal Material
2(1) R V 150X0R 082 RV150XC R 082
2(2) RV150X0R 162 RV150XC R 162
3 R V150X0R 092 R V150XC R 092
4 RV150X0R 102 RV150XC R 102
6 RV150X0R112 RV150XCR112
8 R V 150X0R 122 RV150XC R 122
10 RV150X0R 132 R V150XC R 132
12(3) R V 150X0R 142 RV150XC R 142

Parts Included In Kit

Quantltv in Kit
Key No. Description
3 Seal Protector Ring 1 1
11 Ball seal 1 1
13 W ave spring 1 1
15 Gasket 1 1
21 Retainer screw 2 or 4<4) 2 or 4(4)
22 Retainer washer 2 or 4<4) 2 or 4<4)
37 Radial seal 1 1
41(5) Retaining ring 1 1

1. V150’s only for serial numbers below 12551183.

2. V150’s for serial numbers 12551183 and above. All V200’s and V300’s.
3. Design V200 is not available in 12-inch sizes.
4. A quantity of 2 is supplied for 1- through 8-inch valves, and a quantity of 4 is supplied for 10- and 12-inch valve kits.
5. Retaining rings (key 41) are supplied for sizes 10- and 12-inch valve kits.

26
 Designs V150, V200, and V300

Repair Kits Design V150, V200, and V300

Valves

Seal repair kits include recommended spare parts forTCM, seal constructions. The following table indicates the repair
S31600 stainless steel, CFIOSMuN, or CD7MCuN ball kit part number and the quantity of parts included in the kit.
Design V150, V200, and V300 Repair Kits
KIT PART NUMBER
VALVE SIZE, INCHES Ball Seal Material

TCM — Alloy 6 CD7MCuN

(Alloy 255 Duplex SST)
1 R V150X00CA2 - - - RV150XHDAA2 RV150XH D C A 2
1-1/2 R V150X00CB2 . . . RV150XHDAB2 RV150XH D C B 2
Ball Seal Material
VALVE SIZE, INCHES S31600 CFIOSMnN CD7MCUN
TCM
(316 SST) (Nitronic 60) (Alloy 255 Duplex SST)
2(1) RV150X00C 12 R V150X00M 12 R V150X0H D 12 R V150XH D C 12
2(2) RV150X00C 82 - - - RV150X0H 082 R V150XH D C 82
3 RV150X00C 22 R V 150X 00M 22 R V150X0H D 22 RV150XH D C 22
4 RV150X00C 32 R V150X00M 32 R V150X0H D 32 R V150XH D C 32
6 R V 150X00C 42 R V150X00M 42 R V150X0H D 42 R V150XH D C 42
8 R V 150X00C 52 R V150X00M 52 R V150X0H D 52 R V150XH D C 52
10 R V 150X00C 62 R V150X00M 62 R V150X0H D 62 R V150XH D C 62
12 R V 150X00C 72 R V150X00M 72 R V150X0H D 72 R V150XH D C 72
Parts Included in Kit
Quantity in Kit
Key No. Description
11 Ball seal 1 1 1 1
12 Shim s e a l® — 4 ____

13 Spring seal — 1 — __
13 W ave spring . . . . . . 1 1
15 Gasket 1 1 1 1
37 Radial seal — — 1 1
21 Retainer screw 2 or 4<4> 2 or 4<4) 2 or 4<4) 2 or 4<4)
22 Retainer washer 2 or 4<4) 2 or 4<4) 2 or 4<4> 2 or 4<4>
1. VISO's only for serial num bers below 12551183.
2. V150’s for serial numbers 12551183 and above. All V200’s and V300’s.
3. Fewer shim seals are furnished in the parts kits than are used in the original construction of the valve. Most original shim seals can be reused.
4. A quantity of 2 is supplied for 2- through 8-inch valves, and a quantity of 4 is supplied for 10- and 12-inch valves.__________________________

27
Designs V150, V200, and V300

Retrofit Kits for ENVIRO-SEAL™ Packing Repair Kits for ENVIRO-SEAL ™ Packing
Retrofit kits include parts to convert existing V150, V200 Repair kits include valves parts for shallow (single packing
and V300 valves with shallow (single packing depth) pack­ depth) for ENVIRO-SEAL™ packing box construction. Re­
ing box to the ENVIRO-SEAL™ packing box construction. pair kits include single PTFE or graphite packing. See fol­
Retrofit kits include single PTFE packing. See following lowing table.
table.
ENVIRO-SEAL ™ Packing Retrofit Kits ENVIRO-SEAL ™ Packing Repair Kits
SHAFT DIAMETER*1) PART NUMBER SHAFT DIAMETER*1) PART NUMBER

Inches mm Single PTFE Graphite Inches mm PTFE Graphite

RR TYXRT0312 1/2 12.7 RR TYX000012 13B8816X012
1/2 12.7 R R TY XRT0012
R R TY XRT0022 RR TYXRT0322 5/8 15.9 R R TY X000022 13B8816X032
5/8 15.9
RR TYXRT0032 RR TYXRT0332 3/4 19.1 R R TY X000032 13B8816X052
3/4 19.1
RR TYXRT0052 R R TYXRT0352 1 25.4 RR TYX000052 13B8816X092
1 25.4
R R TY XRT0062 R R TYXRT0362 1-1/4 31.8 R R TYX000062 13B8816X112
1-1/4 31.8
RR TYXRT0372 1-1/2 58.1 R R TYX000072 13B8816X142
1-1/2 58.1 RR TYXRT0072
Parts Included In Kit Parts Included in Kit
Key Description Quantity Key Description Quantity
2 105 Packing set 1 1
100 Packing stud 2
106 Anti-extrusion washer 2 - - -( 2)
101 Packing nut 2 2
1. Diameter through the packing box.
102 Packing flange 1 1 2. Included in key 105.
103 Spring pack assembly 1 1
105 Packing set 1 1
106 Anti-extrusion washer 2 ...
107 Packing box ring*1) 1 1
... Tag 1 1
... Tie Cable 1 1
1. Diameter through the packing box.
2. Not required for all sizes of Design V150 and V200 or for V300 with 1-1/4 or 1-1/2
inch diameter shafts.

28
 Designs V150, V200, and V300

Parts List Key

2
Description
V-Notch Ball (Cont’d)
Part Number

Chrome-plated C F3M (for European Mfg.)

Design V 150 and V 300
Note 1-, 1-1/2, and 2-inch valves, see table
The 2-inch Design V150 valve was redesigned to allow for key 48
sharing of trim parts with the 2-inch Design V200 and 3 - inch 31B0727X032
V300 valves. There are no common parts between the 4 - inch 3 1 B 0667X032
older and newer 2-inch Design V150 valves. This 6-inch 41B0731X032
instruction manual covers only the newer 2-inch valve. 8-inch 4 1 B 0737X032
For the older design valve, use only the instruction 10-inch 4 1 B0715X032
manual that was originally furnished with the valve or 12-inch 41B4677X032
contact your Fisher Controls sales office or sales repre­ CW 2M (Hastelloy C)
sentative. The older design has serial numbers below 1-, 1-1/2, and 2-inch valves, see table
12551183. Also, the older design has a valve shaft diam­ for key 48
eter of 1/2 inch (12.7 mm) at the packing box; the newer
3- inch 3 1 B 0727X062
design has a valve shaft diameter of 5/8 inch (15.9 mm)
4- inch 3 1 B 0667X042
at the packing box.
6-inch 41B0731X042
Always reference the serial number of your valve when Alloy 6 V-notch ball w /CG8M chrome pi
corresponding with the Fisher Controls sales office or 1-, 1-1/2, and 2-inch valves, see table
sales representative. for key 48
3 - inch 3 1 B 0727X042
Note 4 - inch 31B0667X062
6-inch 41B0731X052
Sizes shown In inches are valve body sizes except 8-inch 4 1 B 0737X052
where indicated. 10-inch 4 1 B 0715X042
12-inch 41B 4677X072
2 V-Notch Ball with attenuator
Key Description Part Number C G 8M ball, C G 8M attenuator
1 or Body, Body-Bushing, or Body-Pipe Plug Assembly — 4-inch valve
Right-hand mounted 32B8732X012
1A If you need a body-bushing assembly 6-inch valve
as a replacement part, order Right-hand mounted 42B8713X012
by valve size, serial number, and Left-hand mounted 42B8734X012
desired material. Contact your Fisher 8-inch valve
Controls sales office or sales Right-hand mounted 42B 8718X012
representative for assistance. Left-hand mounted 42B 8735X012
2 V-Notch Ball 10-inch valve
C G 8M (317 stainless steel [SST]) Right-hand mounted 42B 8722X012
1-, 1-1/2, and 2-inch valves, see table Left-hand mounted 42B 8736X012
for key 48 12-inch valve
3 - inch 31B0727X022 Right-hand mounted 42B8727X012
4 - inch 31B0667X022 Left-hand mounted 42B8737X012
6-inch 4 1 B 0731X022 3 Seal Protector Ring S ee following tables
8-inch 4 1 B 0737X022
10-inch 4 1 B0715X 022 4* Taper Key
12-inch 41B 4677X022 R 30006 cobalt alloy 6 casting
Chrome-plated C G 8M 3 and 4-inch 12B9530X012
1-, 1-1/2, and 2-inch valves, see table 6-inch 12B9531X012
for key 48 8 and 10-inch 12B9532X012
3 - inch 31B0727X012 12-inch 12B9533X012
4 - inch 31B0667X012 N 10276 (Hastelloy C)
6-inch 41B0731X012 3 and 4-inch 11B0674X032
8-inch 41B0737X012 6-inch 11B0695X032
10-inch 41B0715X012 5 Bushing
12-inch 41B4677X012 Included in Key 1, Valve Body Assembly;
C F3M (316L S S T for European Mfg.) not field replaceable
1-, 1-1/2, and 2-inch valves, see table 6 Drive Shaft
for key 48 S 17400 (17-4PH stainless steel)
3 - inch 3 1 B0727X072 1-, 1-1/2, and 2-inch valves, see table
4 - inch 31B0667X082 for key 48
6-inch 4 1 B0731X072 3.and 4-inch 2 1 B0668X032
8-inch 4 1 B0737X062 6-inch 3 1 B 0732X032
10-inch 4 1 B 0715X062 8 and 10-inch 3 1 B0716X032
12-inch 4 1 B 4677X092 12-inch 31B4678X032

'Recommended, spare parts 29

Designs V150, V200, and V300

Key Description Part Number Key Description Part Number

6 Drive Shaft (Cont’d) 10* Bearing (2 req’d) (Cont’d)
S20910 Alloy 6B
1-, 1-1/2, and 2-inch valves, see table 2-inch 23B 6682X012
for key 48 3- and 4-inch 14A6546X012
3 and 4-inch 21B0668X012 6-inch 14A6547X012
6-inch 31B0732X012 8 and 10-inch 14A6548X012
8 and 10-inch 31B 0716X012 12-inch 14A6550X012
12-inch 31B 4678X012 Silver-plated alloy 6B
N 10276 1-inch 23B 0343X012
1-, 1-1/2, and 2-inch valves, see table 1-1/2 inch 23B6820X012
for key 48 2-inch 23B6683X012
21B0668X022 3- and 4-inch 14A6537X012
3 and 4-inch
31B 0732X022 6-inch 14A2498X012
6-inch
8 and 10-inch 14A6538X012
Groove Pin
S 3160 0 (316 stainless steel) 12-inch 14A 6539X 012
1 -inch 13B0345X012 Carbon-filled PTFE with N 10276 sleeve
1-1/2 inch and 2-inch 11B0705X012 1-inch 13B0349X012
18A6135X012 1-1/2 inch 13B6822X012
3- and 4-inch
18A6138X012 2-inch 13B6685X012
6-inch
11B 0738X012 3- and 4-inch 12B5944X012
8-inch
11B8596X012 6-inch 12B5945X012
10- and 12-inch
N 10276 Glass-filled PTFE with N 10276 sleeve
13B 0345X022 1-inch 13B 0349X042
1-inch
11B0705X022 1-1/2 inch 13B6822X012
1-1/2 inch and 2-inch
18A6135X022 2-inch 13B6685X022
3- and 4-inch
18A6138X032 3- and 4-inch 12B5944X042
6-inch
6-inch 12B5945X042
Follower Shaft 11* Composition Seal
S17400 TC M
13B 0336X032 1-inch 13B0339X012
1-inch
13B 6678X032 1-1/2 inch 13B6815X012
1-1/2 inch and 2-inch
11B0728X032 2-inch 13B6686X012
3 and 4-inch
11B0733X032 3-inch 13A2565X012
6-inch
11B0717X 032 4-inch 13A2585X012
8 and 10-inch
11B4679X032 6-inch 13A2619X012
12-inch
8-inch 13A2645X012
S 20910
13B0336X012 10-inch 13A2662X012
1-inch
13B6678X012 12-inch 13A2677X012
1-1/2 inch and 2-inch
3 and 4-inch 11B0728X012 TC M III
11B0733X012 1 -inch 13B0339X022
6-inch
11B0717X012 1-1/2 inch 13B6815X022
8 and 10-inch
11B4679X012 2-inch 13B6686X022
12-inch
3-inch 13A2565X032
N 10276
13B 0336X022 4-inch 13A2585X022
1 -inch
13B 6678X022 6-inch 13A2619X032
1-1/2 inch and 2-inch
11B0728X022 8-inch 13A2645X052
3 and 4-inch
11B0733X022 10-inch 13A2662X022
6-inch
12-inch 13A2677X022
10* Bearing (2 req'd)
Composition TC M m e
14B3351X012 1 -inch 13B0339X032
1-inch
14B3352X012 1-1/2 inch 13B6815X032
1-1/2 inch
14B3353X012 2-inch 13B6686X032
2-inch
14B3354X012 3-inch 13A2565X082
3- and 4-inch
14B3355X012 4-inch 13A2585X072
6-inch
14B3356X012 6-inch 13A2619X072
8 and 10-inch
12-inch 14B 3357X 012 11* Flat Metal Seal
S 44004 (440C stainless steel) S31600
23B 0342X022 3-inch 11B4688 X012
1 -inch
23B 6819X012 4-inch 11B5704X012
1-1/2 inch
23B 6682X022 6-inch 11B5708X012
2-inch
14A5698X012 8-inch 11B5712X012
3- and 4-inch
6-inch 14A4618X012 10-inch 11B5717X012
8 and 10-inch 14A5699X012 S 30200
12-inch '■ 14A6549X012 12-inch 11B5722X012
Alloy 6B
1 -inch 23B 0342X012
1-1/2 inch 23B6819X012

30 'Recommended spare parts

 Designs V150, V200, and V300

Description Part Number Key Description Part Number

t f ~^ HD (Heavy-Duty) Metal Ball Seal 14 Backup Ring (composition seal only) (Cont’d)
C FIO SM nN (Nitronic 60) stainless steel) CF3M , European Mfg.
2-inch 33B6676X012 1-inch 13B 0338X022
3-inch 34B4766X012 1-1/2 inch 13B6814X022
4-inch 34B4767X012 2-inch 13B6677X022
6-inch 34B4768X012 15* Gasket, graphite laminate
8-inch 34B4769X012 1-inch 13B0344X012
10-inch 34B3365X012 1-1/2 inch 13B6823X012
12-inch 34B3366X012 2-inch 13B6687X012
C D 7M C uN (alloy 255 duplex stainless steel) 3- inch 11B0660X012
1-inch 33B0341X022 4- inch 11B0672X012
1-1/2 inch 33B 6817X022 6-inch 11B0681X012
2-inch 33B6676X022 8-inch 11B0693X012
3-inch 34B4766X022 10-inch 11B0720X012
4-inch 34B4767X022 12-inch 11B4682X012
6-inch 34B4768X022 16* Packing Set, PTFE and carbon-filled PTFE V-ring
8-inch 34B4769X022 1-inch 12A9016X022
10-inch 34B3365X022 1-1/2 inch and 2-inch 1R 5795X0012
12-inch 34B3366X022 3 and 4-inch 12A8995X022
R 30006 cobalt alloy 6 casting 6-inch 12A8832X022
1-inch 33B0341X012 8 and 10-inch 12A8951X022
1-1/2-inch 33B6817X032 12-inch 12A8935X022
2-inch 33B6676X032 17 Packing Follower w/integral flange
3- inch 34B4766X032 CF8M (316 stainless steel)
4- inch 34B4767X032 1 -inch w/B8M Class 2 16A6078X012
6-inch 34B4768X032 1-1/2 inch 16A 6079X012
8-inch 34B4769X032 2-inch 16A6079X012
S 31700 (317 SST) w/alloy 6 overlay 3 and 4-inch 26A6080X012
10-inch 34B 3365X032 6-inch 26A6077X012
12-inch 34B 3366X032 8 and 10-inch 26A6081X012
Shim Seal, S 31600 (12 req’d) 12-inch 26A6088X012
Use w/flat metal seal only
3-inch 11B4689X012 17 Packing Follower w/o integral flange
4-inch 11B5706X012 N 10276
6-inch 11B5710X012 1-inch 12A9021X032
8-inch 11B5714X012 1-1/2 inch 12A8906X032
10-inch 11B5718X012 2-inch 12A8906X032
12-inch 11B5721X012 3 and 4-inch 12A 8982X032
Spring Seal, S 31600 6-inch 12A8821X042
Use w/flat metal seal only 19 Packing Follower Stud (2 req’d)
3- inch 21B 4687X012 SA-193-B7
4- inch 21B 5705X012 1-, 1-1/2, 2-, 3- and 4-inch 1E944131032
6-inch 21B 5707X012 6-inch 12A 8835X 012
8-inch 21B 5713X012 8 and 10-inch 12A8950X012
10-inch 21B 5716X012 12-inch 12A8926X012
12-inch 21B 5720X012 SA-193-B8M (B8M Class 2)(strain hardened)
W ave Spring, N 07750 Inconel (NACE(1>) 1-, 1-1/2, 2-, 3- and 4-inch 1E944135222
HD Metal Seal 6-inch 12A 8835X022
1-inch 23B 0347X012 8 and 10-inch 12A8950X022
1-1/2 inch 23B 6825X012 12-inch 12A8926X022
2- inch 23B 6689X012 N 01276
3- inch 24B 4760X012 1-, 1-1/2, 2-, 3 - and 4-inch 1E944140152
4-inch 24B 4761X012 6-inch 12A8835X072
6-inch 24B 4762X012 For NACE MR-01-75<1>, SA-193-B7M
8-inch 24B 4763X012 1-, 1-1/2, 2-, 3 and 4-inch 1E9441X00A2
10-inch 22B 4509X012 6-inch 12A8835X032
12-inch 22B 4514X012 8 and 10-inch 12A8950X032
12-inch 12A 8926X032
Backup Ring (composition seal only) 20 Packing Follower Nut (2 req’d)
CG8M SA-194-2H
1-inch 13B0338X012 1-, 1-1/2, 3- and 4-inch 1E944024112
1-1/2 inch 13B6814X012 6-inch 1A375324112
2-inch 13B6677X012 8 - through 12-inch . 1A341224112
CW 2M SA-194-8M "
1-inch 13B 0338X032 1-, 1-1/2, 2-, 3 - and 4-inch 1E 944035252
1-1/2 inch 13B6814X032 6-inch 1A 375335252
2-inch 13B 6677X032 8- through 12-inch 1A341235252

'Recomm ended spare parts

1. As detailed in National Association of Corrosion Engineers (NACE) standard MR0175.
31
Designs V150, V200, and V300 V

Key Description Part Number Key Description Part Number

20 Packing Follower Nut (2 req'd) (Cont’d) 33 Line Flange Stud (not shown)
N 10276 Design V 300 valve only See following table
1-, 1-1/2, 2-, 3- and 4-inch 1E944040152
6-inch 1A 3753X0062 34 Spacer, S 31700
NACE M R -01-75, SA-194-2H 8- and 10-inch 11B0719X012
1-, 1-1/2, 2-, 3- and 4-inch 1E9440X0012 12-inch 11B4681X012
6-inch 1A3753X0012 35* Packing Ring, graphite ribbon
8 - through 12-inch 1A3412X0012 1-inch (4 req’d) 12A 9134X012
21 Seal Protector Screw, 18-8 stainless steel (2 req’d) 1-1/2 and 2-inch (4 req’d) 12A9135X012
Designs V150 and V 300 3- and 4-inch (4 req’d) 12A9136X012
1-, 1-1/2, 2-, 3-inch (2 req’d) 1A8991X0032 6-inch (4 req’d) 12A9137X012
4-inch (2 req’d) 1R1938X0012 8- and 10-inch (4 req’d) 12A9138X012
6- and 8-inch (2 req’d) 11B0682X022 12-inch 12A9139X012
10- and 12-inch (4 req’d) 11B0682X022 36* Packing Washer, zinc
Design V200 1-inch (3 req’d) 14A8362X012
1-, 1-1/2, 2-, 3- and 4-inch (2 req’d) 1A8991X0022 1-1/2 and 2-inch 14A9771X012
6-, 8-, and 10-inch (2 req’d) 1A3816K0312 3- and 4-inch (3 req’d) 14A8363X012
6-inch (3 req’d) 14A8365X012
22 Seal Protector Clip, 18-8 stainless steel (2 req’d) 8- and 10-inch (3 req’d) 14A8366X012
Design V 200 12-inch (3 req’d) 14A8367X012
1-, 1-1/2, 2, 3-, and 4-inch 24B3040X012 37* Radial Seal, N 10276/PTFE/C G
6-, 8-, and 10-inch 22B 4975X012 Use w/HD Metal Ball Seal
22 Seal Protector Washer, 18-8 stainless steel 1-inch 13B0346X012
Designs V 150 and V300 1-1/2 inch 13B6824X012
1-, 1-1/2, 2-, and 3-inch (2 req'd) 1A 8518X0012 2-inch 13B6688X012
4-inch (2 req’d) 11B4671X012 3-inch 12B3779X012
6- and 8-inch (2 req’d) 1A3756X0012 4-inch 12B3783X012
10- and 12-inch (4 req’d) 1A3756X 0012 6-inch 12B3787X012
23 Actuator Mounting Screw (2 req’d) 8-inch 12B 4380X 012
pi steel 10-inch 12B4510X012
1- through 6-inch (4 req’d) 1A361624052 12-inch 12B4515X012
8- through 12-inch (4 req’d) 1R443624052
316 stainless steel (strain hardened) 38 Thrust W asher (1 req’d)
1- through 6-inch (4 req’d) 1A3616X0042 1-inch w/composition, Alloy 6B, S4404,
8- through 12-inch (4 req’d) 1R4436X0012 and Alloy 6B w/silver pi, or 13A2518X062
24 Actuator Mounting Nut (2 req’d) w/PTFE/carbon filled and
pi steel PTFE/glass filled bearing 13A2518X 052
1- through 6-inch (4 req’d) 1A377224112 1-1/2 and 2-inch w/composition,Alloy 6B,
8 - through 12-inch (4 req’d) 1A343324112 S4404, and Alloy 6B w/silver pi, or 13B6746X022
316 stainless steel w/PTFE/carbon filled and
1- through 6-inch (4 req’d) 1A377235252 PTFE/glass filled bearing 13B 6746X032
8- through 12-inch (4 req’d) 1A 343335252 Thrust W asher (4 req’d)
17-7PH stainless steel (for 440C bearings)
25 Pipe Plug 3- and 4-inch 13A 2570X012
1 - through 2-inch 6-inch 12B5437X012
Pipe plug is part of the body-pipe plug 8- and 10-inch 12B4573X012
for 1- through 2-inch sizes 12-inch 12B5943X012
3 - through 12-inch R 30006 (alloy 6B)
S 31700 (317 stainless steel) 1A767535092 3- and 4-inch 13A2570X122
N 10276 1A767540152 6-inch 12B 5437X022
26 Identification Nameplate, 18-8 stainless 8- and 10-inch 12B4573X022
steel 15A0460X012 12-inch 12B5943X022
Design V 200,1-in ch , (Mt’l) 15A0460X012 N 10276
27 Drive Screw, 18-8 S S T (2 req’d for 3- and 4-inch 13A 2570X042
forward flow; 4 req’d for reverse flow) 1A368228982 6-inch 12B 5437X032
28 Flow Arrow, 18-8 S S T (reverse flow only— 39* Packing Box Ring
not shown) 1V105938982 316 stainless steel
1-inch 16A6082X012
30 Nameplate, 18-8 S S T (not shown) 1-1/2 and 2-inch 16A6083X012
For valve bodies furnished without 3- and 4-inch 16A6084X012
actuator --- 6-inch 16A6085X012
31 Nameplate W ire, steel (not shown) N 10276
For valve bodies furnished without 1-inch _ 16A6082X092
actuator .. 1D 884799012 1-1/2 and 2-inch 16A6083X082
32 Line Flange Stud (not shown) S ee following tables 3- and 4-inch 16A 6084X072
6-inch 16A6085X092

32 ’ Recommended spare parts

 Designs V150, V200, and V300

Key Description Part Number Key Description Part Number

40 Packing Flange 103 Spring Pack Assembly
Use with C W 2M (Hastelloy) trim W/single and double PTFE packing
C F8M (316 stainless steel) 1-, 1-1/2, and 2-inch 12B8319X032
1-inch 11B9430X012 3- and 4-inch 12B8320X012
1-1/2 and 2-inch 12B9440X012 6-inch 12B8320X032
3- and 4-inch 12B5417X012 8- and 10-inch 12B8321X012
6-inch 12B5419X012 12-inch 12B8321X032
N 10276
1 -inch 31B 9432X022 105* Packing Set
1-1/2 inch and 2-inch 31B 9442X022 W/single PTFE packing
3- and 4-inch 12A8983X042 1-inch 12B7053X012
6-inch 12A 8822X042 1-1/2 and 2-inch 12B 7402X 012
3-inch 12B7414X012
41 Retaining Ring, N 07750 (alloy 750) 4-inch 12B7414X012
10-inch 22B 6526X012 6-inch 12B7438X012
12-inch 22B 6527X012 8- and 10-inch 12B7450X012
48 Ball-Shaft Assembly 12-inch 12B7462X012
1- through 2-inch S ee following table 106* Anti-Extrusion Ring (2 req’d)
130 Clamp, stainless steel W/single and double PTFE packing
Use for alternate electrical bonding 1-inch 12B7054X012
1 - through 6-inch 16A8717X012 1-1/2 and 2-inch 12B7406X012
8- through 12-inch 16A8714X012 3- and 4-inch 12B7418X012
131 Bonding Strap Assembly 6-inch 12B7442X012
Use for alternate electrical bonding 8- and 10-inch 12B 7454X 012
1- through 6-inch 17A6532X012 12-inch w/single PTFE packing only 12B7466X012
8-inch 17A 6532X022 107* Packing Box Ring
1 0 -and 12-inch 17A6532X032 W/single and double PTFE packing
100-113 S ee ENVIR O -SEA L parts below. 1-inch 16A6082X012
1-1/2 and 2-inch 16A6083X012
ENVIRO-SEAL™ Packing System 3- and 4-inch 16A6084X012
6-inch 16A6085X012
(figure 6) 108* Packing Ring (2 req’d)
100 Packing Flange Stud (2 req’d) W/double PTFE packing
1-, 1-1/2, 2-, 3-,4-in ch 1-inch 1H 7844X0012
Steel 11B3814X102 1-1/2 and 2-inch 1R 5794X0012
Stainless Steel 11B3814X012 3- and 4-inch 12A8992X022
6-inch 6-inch 12A8831X022
Steel 16A1061X 082 8- and 10-inch 12A8953X022
Stainless Steel 16A1061X 022
8- and 10-inch 109* Anti-Extrusion Ring (2 req’d)
Steel 1P 568231032 W/double PTFE packing
Stainless Steel 1P 568235222 . 1-inch w/2 (adapter rings) 12B7473X012
12-inch and w/2 (anti-extrusion rings) 12B7054X012
Steel 1P 568231032 1-1/2 and 2-inch w/2 (adapter rings) 12B7410X012
Stainless Steel 1P568235222 and w/2 (anti-extrusion rings) 12B7406X012
Packing Flange Nut (2 req’d) 3- and 4-inch w/double PTFE packing 12B7422X012
1-, 1-1/2, and 2-inch 6-inch w/double PTFE packing 12B7446X012
Steel 1E944024112 8- and 10-inch w/double PTFE packing 12B7458X012
Stainless steel 1E 944035252 110 Lantern Ring, w /1,1 -1 /2 , and 2-inch
3-, 4-, and 6-inch W/double PTFE packing
Steel 1A944024112 1-, 1-1/2, and 2-inch inch 12B7061X012
Stainless Steel 1E 944035252 3- and 4-inch 12B 7423X 012
8-, 10-, and 12-inch 6-inch 22B7447X012
Steel 1A341224112 8- and 10-inch 22B7459X012
Stainless Steel 1A341235252 111 Tag 23B6562X012
Packing Flange 112 Tie Cable 18A9401X012
1-, 1-1/2, and 2-inch 32B7777X012 113 Lubricant, N ever-Seez Nickel Special
3- and 4-inch 32B 7778X012 or Equivalent (not furnished with packing
6-inch 32B 7779X012 system)
8- and 10-inch 32B 7780X012
12-inch 32B 7781X012

'Recommended spare parts 33

Designs V150, V200, and V300

Key 3. Steel and Stainless Steel Seal Protector Ring for Composition, Flat Ball Seal, and for Flow Ring Constructions
USE W ITH FLAT METAL
USE W ITH TC M A N D TC M III SEA L
B A LL S E A L O R FLO W RING
VHkV k Vlfcbf
ASM E B16.10- DIN PN10 A S M E B16.10- DIN PN 10
IN C H ES S tandard S tandard
S hort &PN16 S hort & PN16
(M A TERIAL)*!) IS A S 75.04 ISA S 75.04
Face-to-Face ISA S 75.04 Face-to-Face IS A S 75.04
Face-to-Face Face-to-Face
(Optional)*2) Face-to-Face (Optional)*2) Face-to-Face
— 34B 1722X 012 34B 1726X 012 —
W C C (Steel) 34B 1720X 012 34B 1724X012
Newer — —
CG8M 34B 1720X 022 34B1724X 022 34B1722X 022 34B 1726X 022
Design*3) — —
CF3M*4) 34B 1720X 052 34B1724X 032 34B 1722X 032 34B1726X 032
1 — —
W C C (Steel) 33B 6602X012 33B6607X012 33B6604X012 33B6609X012
Older — —
CG8M 33B 6602X022 33B6607X022 33B6604X022 33B6609X022
Design*3) — —
CF3M<4> 33B 6602X032 33B6607X032 33B6604X042 33B6609X032
W C C (Steel) 34B1563X 012 34B1567X 012 — 34B1565X 012 34B 1569X 012 —
Newer — —
C G 8M 34B1563X 022 34B1567X 022 34B1565X 022 34B 1569X 022
Design*3) — —
CF3M<4> 34B 1563X 052 34B1567X 032 34B 1565X 032 34B 1569X 032
1-1/2 —
W C C (Steel) 33B 6806X012 33B6811X012 --------- ■ 33B6808X012 33B6813X012
Older — —
C G 8M 33B 6806X022 33B6811X022 33B6808X022 33B 6813X022
Design*3) — —
CF3M<4> 33B6806X062 33B6811X032 33B6808X042 33B 6813X032
W C C (Steel) 33B0992X012 33B6672X012 — 33B0994X012 33B 6674X012 —
2*5) C G 8M 33B0992X022 33B6672X022 — 33B0994X022 33B 6674X022 —

CF3M*4> 33B0992X062 33B6672X032 — 33B0994X032 33B 6674X032 —

W C C (Steel) 21B0658X012 31B0699X012 21B5701X012 30B6825X012 31B 5736X012 31B5743X012

3 CG8M 2 1 B0658X022 31B0699X022 21B5701X022 30B6825X022 3 1 B5736X022 31B 5743X022
CF3M<4> 2 1 B0658X042 31B0699X032 21B5701X032 30B6825X032 3 1 B5736X032 31B 5743X032
W C C (Steel) 21B0665X012 31B0701X012 21B0665X012 31B5703X012 31B 5737X012 31B5703X012
4 C G 8M 21B0665X022 31B0701X022 21B0665X022 31B 5703X022 31B 5737X022 3 1 B5703X022
CF3M<4> 21B0665X042 3 1 B0701X032 32B3790X032 31B 5703X032 31B 5737X032 3 1 B5703X032
W C C (Steel) 21B0678X012 31B0707X012 21B5726X012 31B5709X012 31B 5738X012 31B5744X012
6 C G 8M 2 1 B0678X022 31B0707X022 21B5726X022 31B5709X022 3 1 B 5738X022 31B5744X022
CF3M<4> 2 1 B0678X032 31B0707X032 2 1 B 5726X032 31B5709X032 31B 5738X032 31B5744X032
W C C (Steel) 31B 0686X012 31B0709X012 31B 5728X012 31B5711X012 31B 5739X012 31B 5745X012
8 C G 8M 3 1 B0686X022 3 1 B0709X022 31B 5728X022 3 1 B5711X022 3 1 B5739X022 31B 5745X022
CF3M<4> 31B 0686X032 3 1 B0709X032 31B 5728X032 31B5711X032 31B 5739X032 31B 5745X032
W C C (Steel) 31B 0713X012 31B0724X012 31B5731X012 31B5715X012 31B5740X012 31B 5746X012
10 C G 8M 3 1 B0713X022 31B0724X022 31B5731X022 31B5715X022 31B5740X022 31B 5746X022
CF3M*4) 3 1 B0713X 032 31B0724X032 31B 5731X032 3 1 B5715X032 3 1 B 5740X032 31B 5746X032
W C C (Steel) 31B 4675X012 31B4686X012 31B5734X012*®) 31B5719X012 31B5741X012 31B5747X012*6)
12<7> C G 8M 31B 4675X022 31B4686X022 31B5734X022*6) 31B5719X022 31B5741X022 3 1 B5747X022*6)
CF3M<4> 3 1 B4675X032 31B 4686X032 3 1 B5734X032*6) 3 1 B5719X032 31B5741X032 3 1 B5747X032*6)
1. For CW2M (Hastelloy C) material, see Key 3 in the parts list.
2. ASME B16.10 short is available only on Class 150 valves.
3. For a definition of older and newer designs for the 1- and 1*1/2 inch valves, see the note on page 37.
4. CF3M is available in all areas and is the standard material offering from Fisher Controls in Europe.
5. For a definition of older and newer designs for the 2* inch valves, see the note on page 30.
6. Use for DIN PN16 applications only.
7. Design V150 and V300 valves only.

34
 Designs V150, V200, and V300

Key 3. Alloy 6 Tip and CW2M Seal Protector Ring for

_____ Composition and Flow Ring Constructions
USE WITH COMPOSITION USE WITH FLOW RING
SEAL—ISA S75.04 CONSTRUCTION—ISA S75.04
VALVE SIZE, INCHES
FACE-TO-FACE ONLY FACE-TO-FACE ONLY
CW2M Alloy 6 Tlp/CG8M
1 Older Design!1) 33B 6602X032 _______

1 Newer Design!1) 34B 1720X 032 —

1-1/2 Older Design!1) 33B6806X032 ____ _

1-1/2 Newer Design!1) 34B1563X 032 —

2(2) 33B0992X012 —

3 21B0658X082 32B7289X012
4 21B0665X092 32B1475X 012
6 21B0678X072 32B7890X012
8 —
32B7891X012
10 —
32B4721X012
12 —
32B7892X012
1. For a definition of older and newer designs for the 1-and 1-1/2 inch valves, seethe note and table on page 37
2. For a definition of older and newer designs for the 2- inch valves, see the note on page 30.

35
Designs V150, V200, and V300

Note Key 3. Seal Protector Ring for HD Metal Ball Seal

USE WITH HD (HEAVY-
The older and newer designs of the 1- and DUTY) METAL SEAL
1-1/2 inch seal protector ring are functional­ ASME
ly the same, but are different lengths and INCHES Standard
B16.10-Short
(MATERIAL) ISA S75.04
not interchangeable. All 1- and 1-1/2 inch Face-to-Face
Face-to-Face
sizes of Design V150 and V300 valves are (Optional)®
the newer design. The change in seal pro­ Newer
W C C Steel 34B1721X012 34B1725X 012
C G 8M (317 SST) 34B1721X 022 34B 1725X 022
tector ring length affects 1- and 1-1/2 inch Design®
C F3M (316L S S T )® 34B1721X032 34B1725X 032
Design V200 valves only. To determine 1(2)
W CC 33B6603X012 33B6608X012
whether you have the older or newer de­ Older
C G 8M 33B6603X022 33B 6608X022
sign, measure the length of the seal protec­ D esign®
CF3M ® 33B6603X032 33B 6608X032
tor ring (key 3, figure 15) from its pipeline W CC 34B1564X012 34B 1568X 012
Newer
flange mating surface to its opposite end. If Design®
C G 8M 34B1564X022 34B 1568X 022
the measured dimension is equal to or long­ CF3M ® 34B1564X032 34B1568X 032
1-1/2<2)
er than the dimension below, the valve is the WCC 33B6807X012 33B 6812X012
Older
CG8M 33B6807X022 33B 6812X022
newer design: Design®
CF3M ® 33B6807X032 33B 6812X 032
W CC 33B0993X012 33B 6673X012
2(4) CG8M 33B0993X022 33B 6673X022
MEASUREMENT CF3M ® 33B0993X032 33B 6673X032
VALVE ASME B16.10 Short W CC 32B3776X012 32B 3789X012
ISA S75.04
SIZE, Face-to-Face Face-to-Face 3 C G 8M 32B3776X022 32B 3789X022
INCHES CF3M ® 32B3776X032 32B3789X032
Inches mm Inches mm
W CC 32B3780X012 32B3790X012
1 1.48 37.6 2.48 63.0 4 32B3780X022 32B3790X022
C G 8M
1-1/2 1.54 39.1 3.54 89.9 CF3M ® 32B3780X032 32B3790X032
W CC 32B 3784X012 32B3791X012
6 C G 8M 32B 3784X022 32B3791X022
CF3M ® 32B3784X032 32B3791X032
W CC 32B4378X012 32B4382X012
8 C G 8M 32B4378X022 32B4382X022
CF3M ® 32B4378X032 32B4382X032
WCC 32B4507X012 32B4508X012
10 C G 8M 32B4507X022 32B4508X022
CF3M ® 32B4507X032 32B 4508X032
W CC 32B4512X012 32B 4513X012
12(5) CG8M 32B4512X022 32B4513X 022
CF3M ® 32B4512X032 32B4513X 032
1. ASME B16.10 short is available only on Class 150 valves.
2. For a definition of older and newer designs for the 1- and 1-1/2 inch valves, see
the note on this Daa 3.
3. CF3M is available in all areas and is the standard material offering from Fisher
Controls in Europe.
4. For a definition of older and newer designs for the 2- inch valves, see the note on
page 30.
5. Designs V150 and V300 only.

36
 Designs V150, V200, and V300

Keys 32 and 33 Design V150 Line Flange Studs (Not Shown)

VALVE SIZE NUMBER SA-193-B8M CLASS 2
KEY NUMBER SA-193-B7 SA-193-B7M
Inch mm REQ’D (Strain Hardened)
Standard ISA S75.04 Face-to-Face
1 25 4 1A 420731012 1A 4207X 0012 1A 420735222
1-1/2 38 4 1H 397131012 1H 3971X0012 1H 397135222
2 50 4 1A 354431012 1A 3544X00A 2 1A 354435222
3 80 4 17A 0822X 012 17A 0822X022 17A 0822X032
4 100 8 1B 542131012 1B5421X0012 1B 5421X0022
6 150 8 1A 354331012 1A3543X00A2 1A3543X0062
8 200 8 1L119431012 1L1194X0082 1L119435222
10 250 12 1A 377131012 1A3771X0012 1A3771X00A2
12 300 12 1B 542331012 1B 5423X0022 1B 5423X0032
Optional ASME B16.10-Short Face-to-Face
Seal Protector End of Valve
1 25 4 1H 3972X0012 1H 3972X 0042 1H 3972X 0052
1-1/2 38 4 1H 989231012 1H 8992X 0022 1H9892X00A2
2 50 4 1N 956731012 1N 9567X 0022 1N 956735222
3 80 4 1J2246X0012 1J2246X 0032 1J2246X0022
4 100 8 1N 956731012 1N 9567X 0022 1N 956735222
6 150 8 11A7569X032 11A7569X022 11A7569X042
8 200 8 11A 7570X062 11A7570X012 11A7570X022
10 250 12 11B0740X012 11B0740X022 11B0740X032
12 300 12 1A 519531012 1A5195X0012 1A5195X0022
All Design V150 Valves
1 25 4 11A4596X 012 11A4596X042 11A4596X052
1-1/2 38 4 1A 420731012 1A4207X0012 1A 420735222
2 50 4 1J698131012 1J6981X 0022 1J6981X0012
3 80 4 1A 354431012 1A 3544X00A 2 1A 354435222
Key 33
4 100 8 1A 354431012 1A3544X00A2 1A 354435222
Opposite End of Valve
6 150 8 1B 542231012 1B 5422X0022 1B 5422X0032
8 200 8 1A 354331012 1A3543X00A2 1A 3543X0062
10 250 12 1A 376231012 1A 3762X0022 1A 3762X0012
12 300 12 1A 376231012 1A 3762X0022 1A 3762X0012

Key 32 Design V200 Line Flange Studs (not shown)

VALVE SIZE, ISA S 75.04 FACE-TO-FACE (S TA N D A R D ) A S M E B 16.10-S H O R T FACE-TO-FACE (O P TIO N A L)
IN C H ES , AND SA -193-B 8M SA -193-B 8M
S A -193-B 7 SA -193-B 7M S A -193-B 7 SA -193-B 7M
A N SI C LASS (S train H ardened) (S train H ardened)
1— 150 (4 req’d) 1U 440431012 1U 4404X0032 1U 440435222 1U 9597X0012 1U 9597X0042 1V9597X 0052
1— 300 & 600 (4 req’d) 1U 994831012 1U 9948X0032 1U 994835222 — — —

1-1/2— 150 (4 req'd) 1U 421631012 1U4216X 0032 1U421635222 13B8189X012 13B8189X022 13B8189X032
1-1/2— 300 & 600 (4 req'd) 1U 994931012 1U 9949X 0032 1U 994935222 — — —

2— 150 (4 req’d) 1U 995031012 1U 9950X 0032 1U995035222 1V9315X 0012 1V9315X0042 1V9315X0052
2— 300 (4 req’d) 1L480131012 1L4801X0012 1L480135222 — — —

2— 600 (4 req’d) 1U 995131012 1U 9951X 0032 1U995135222 — —

3— 150 (4 req’d) 1P589631012 1P 5896X0032 1P 589635222 13A2630X012 13A 2630X032 13A2630X022

3 — 300 (8 req’d) 1U 485931012 1U 4859X 0022 1U 485935222 — — —

3— 600 (8 req’d) 1P 577831012 1P 5778X0062 1P 577835222 — — —

4— 150 (8 req’d) 13A2630X012 13A 2630X032 13A2630X022 17A3076X012 17A 3076X032 17A 3076X042
4— 300 (8 req’d) 1L484131012 1L4841X0012 1L484135222 — — —

4— 600 (8 req’d) 13A2631X012 13A2631X022 13A2631X042 — — —

6— 150 (8 req’d) 1P572231012 1P 5722X0042 1P 572235222 1U 5287X 0012 1U5287X 0032 1U 5287X 0022
6— 300 (12 req’d) 1U 172631012 1U1726X 0032 1U172635222 — — —

8— 150 (8 req’d) 1P 572231012 1P 5722X0042 1P 572235222 15A 4797X 012 15A 4797X 022 15A 4797X032
8— 300 (12 req’d) 1R 440331012 1R 4403X 0042 1R 440335222 — — —

10— 150 (12 req’d) 1U 164631012 1U1646X 0032 1U164635222 1R 8854X 0022 1R 8854X0042 1R 8854X 0052

37
Designs V150, V200, and V300

Keys 32 and 33 Design V300 Line Flange Studs (Not Shown)

KEY 32 (SEAL PROTECTOR END OF VALVE) KEY 33 (OPPOSITE END OF VALVE)
VALVE SIZE, SA-193-B8M SA-193-B8M
INCHES (REQ’D) SA-193-B7 SA-193-B7M Class 2 SA-193-B7 SA-193-B7M Class 2
(Strain Hardened) (Strain Hardened)
1 (4) 1A354431012 1A3544X00A2 1A 354435222 1L515131012 1L5151X0022 1L5151X0052
1-1/2 (4) 1B 542231012 1B5422X0022 1B 5422X0032 1V 2217X0012 1V2217X0032 1V2217X0022
2 (8 ) 1A487531012 1A4875X0032 — 1A 354431012 1A354431332 —

3 (8 ) 1L119431012 1L1194X0042 1L119435222 1A 308831012 1A3088X0012 1A3088X0022

4 (8 ) 1A 572831012 1A5728X0012 1A5728X0022 1A 354331012 1A3543X00A2 1A3543X0062
6 (1 2 ) 1C 6098X0062 1C 6098X0022 1C 6098X0032 1A 572831012 1A5728X0012 1A5728X0022
8 (1 2 ) 1A 4520X0012 1A 4520X0042 1A4520X0052 1B 542331012 1B5423X0022 1B 5423X0032
1 0 (1 6 ) 1N 816531012 1N8165X0012 1N8165X0022 1B 231831012 1B2318X0042 1B2318X0012
1 2 (1 6 ) 1L9521X0012 1L9521X0Q62 1L9521X0042 1A 500931012 1A5009X0122 1A 5009X 0022

Key 48. Ball/Shaft Assembly for 1-, 1-1/2, and 2-Inch Valves
Ball Material CG8M CRPL0) CG8M CRPL CG8M CG8M CW2M
Shaft Material S20910 S17400 S20910 S17400 N10276
1-Inch 23B 7072X012 23B7072X022 23B7072X032 23B7072X042 23B7072X052
1-1/2 Inch 33B 7014X012 33B7014X022 33B7014X 032 33B 7014X042 33B7014X 052
2-Inch 33B7014X112 33B7014X122 33B7014X132 33B7014X142 33B7014X152
Ball Material R50550 CF3M(2> CRPL CF3M CRPL CF3M CF3M
Shaft Material (Cont.) R56400 S20910 S17400 S20910 S17400
1-Inch 23B 7072X062 23B 7072X072 23B 7072X082 23B 7072X092 23B7072X10?
1-1/2 Inch 33B7014X 062 33B 7014X072 33B7014X 082 33B7014X 092 33B7014X102
2-Inch 33B 7014X162 33B7014X172 33B 7014X182 33B 7014X192 33B7014X202
Ball Material CG8M<3> CG8MO) CG8M<3) CG8M<5)
Shaft Material (Cont.) S20910 (1/2-inch Spline) S17400 (1/2-Inch Spline) S20910 (1/2-lnch Spline) S17400 (1/2-lnch Spline)
1-Inch 23B7072X112 23B7072X122 - - - —

1-1/2 Inch 33B7015X 252 33B7015X262 33B7014X252 33B7014X262

2-Inch 33B7015X212 33B7015X222 33B7014X212 33B7014X222
1. Chrome-plated ball (CRPL).
2. CF3M is the standard material offered from Fisher Controls in Europe only.
3. Alloy 6 V-notch ball with CG8M chrome plate.

Key 48. Ball/Shaft Assembly for 1-Inch Valves with Micro-Notch Vee Ball<1)
Mounting Left-Hand Left-Hand Right-Hand Right-Hand
Ball Material CG8M CRPL<2> CG8M CRPL CG8M CRPL CG8M CRPL
Shaft Material S20910 S17400 S20910 S17400
1-inch 33B 9734X012 33B9734X022 33B 9735X012 33B9735X022
Mounting Left-Hand Left-Hand Right-Hand Right-Hand
Ball Material CF3M CRPL CF3M CRPL CF3M CRPL CF3M CRPL
Shaft Material S20910 S17400 S20910 S17400
1-inch 33B 9734X032 33B9734X042 33B9735X032 33B9735X042
1. For alloy 6 and VTC ceramic Micro-Notch ball materials, consult factory.
2. Chrome-plated ball (CRPL).______________________________________

38
Designs V150, V200, and V300

While this information is presented in good faith arid believed to be accurate, or any other matter with respect to the products, nor as a recommendation to
Fisher Controls does not guarantee satisfactory results from reliance upon such use any product or process in conflict with any patent. Fisher Controls reserves
information. Nothing contained herein is to be construed as a warranty o r guar- the right, without notice, to alter or improve the designs or specifications of the
antee, express o r implied, regarding the performance, merchantability, fitness products described herein.

For information, contact Fisher Controls:

Fisher Controls Marshalltown, Iowa 50158 USA Sao Paulo 05424 Brazil
Cernay 68700 France Singapore 2158

Printed in U.S.A. t e a Ct recycled paper

o
CONTAINER CORPORATION
UNIT No. W-3813
FUEL CONTROLLER.

ANALOG INPUTS.

Register Description Units Scale

XI Gas Drive Position 4-20 ma 0-100%

X2 Control From Master 1-5 vdc 0-100%

X3 From Air Controller 1-5 vdc 0-100%

X4 Oil Drive Position 4-20 ma 0-100%

X5

ANALOG OUTPUTS.
Y1 Control output to
Gas drive ma 4-20

Y2 To air controller VDC 1-5

Y3 Control output to
Oil drive ma 4-20

DIGITAL INPUTS.
Dll Release for modulation

DI2 Gas Fuel Select

DI3

DI4

DI5
DI6

DIGITAL OUTPUTS.
D01

D02

D03

D04

D05

D06

P REGISTERS.
Register Description Units Scale

P01 Velocity limiter for

output to oil drive 1/SEC 0-8000
signal increase

P02 Velocity limiter for

output to oil drive 1/SEC 0-8000
signal decrease

P03 Time average for gas position SEC 0-8000

P04 Time average for oil position SEC 0-8000

P05 Velocity limiter for

output to gas drive 1/SEC 0-8000
signal increase

P06 Velocity limiter for

output to gas drive 1/SEC 0-8000
signal decrease

POS

P09
P10

P ll

P12

P13

P14

P15

P16

P17

P18

P19

P20

P21

P22

P23

P24

P25

P26

P27

P28

P29

P30 Manual enable

T REGISTERS DESCRIPTION
TO1 Gas drive position through function generator

T02 Oil drive position through function generator

T03 Process variable

T04

T05

T06

T07

T08

T09

T10

T il

T12

T13

T14

T15

T16

T17

T18

T19

T20

T21

122

T23
o
T24

T25

T26

T27

T28

T29

T30
o
CONTAINER CORPORATION
UNIT No. W-3813
MASTER STEAM PRESSURE
CONTROLLER.

ANALOG INPUTS.

Register Description Units Scale

XI Steam Pressure PSIG 0 - 250

X2

O X3

X4

X5

ANALOG OUTPUTS.
Y1

Y2 Control Output VDC 1-5

Y3

DIGITAL INPUTS.
DU Release for modulation

DI2

O 013
DI4

DI5
DI6

DIGITAL OUTPUTS.

D01

D 02

D03

D04

D05

D06

P REGISTERS.
Register Description Units Scale

P01 Low fire hold PSIG 0 - 250

P02 Low fire hold

hysterisis PSIG 0 - 250

P03

P04

P05

P06

P07

P08

P09

P10

P ll

P12
P13

P14

P15

P16

P17

P18

P19

P20

P21

P22

P23

P24

P25

P26

P27

P28

P29

P30

T REGISTERS DESCRIPTION
T01

T02

T03
T04

T05

T06

T07

T08

T09

T10

T il

T12

T13

T14

T15

T16

T17

T18

T19

T20

T21

T22

T23

T24

T25

T26
 T27

T28

T29

T30

O
o
CONTAINER CORPORATION
UNIT No. W-3813
COMBUSTION AIR CONTROLLER

ANALOG INPUTS.

Register Description Units Scale

XI Air Drive Position 4-20 ma 0-100%

X2 Control From Master 1-5 vdc 0-100%

X3

X4 Fuel position 1-5 vdc 0-100%

X5

ANALOG OUTPUTS.
Y1 Control output to
air drive ma 4-20

Y2 Air position to fuel VDC 0-100%

controller

Y3
DIGITAL INPUTS.
D ll Release for modulation

DI2 Purge

DI3

DI4 Gas Fuel Selected

DI5 .

DI6
 DIGITAL OUTPUTS.
D01

D02

D03

D04

D05

D06

P REGISTERS.
Register Description Units Scale

P01 Time filter for air

Position sec 0-8000

P02

P03

P04 Velocity limiter output up 100/MIN

P05 Velocity limiter output down 100/MIN

P06 High output limit % 0-100

P07

P08

P09

P10

O P11
P12

P13
G

P14

P15

P16

P17

P18

P19

P20

P21

, P22

P23

P24

P25

P26

P27

P28

P29

P30 Manual enable

T REGISTERS DESCRIPTION
TO1 Air drive position through function generator

T02 Process variable (air drive position corrected with 0 2 trim)

T03 Control output from 0 2 trim

T04 Firing rate signal storage

T05 0 2 set point storage

T06

T07

T08

T09

T10

T il

T12

T13

T14

T15

T16

T17

T18

T19

T20

T21

T22

T23

T24

T25

T26
o
T27

T28

T29

T30

I
7 6 5 4 3
STEAM PRESSURE
TRANSMITTER

T/ AIR
DAM

T
4 3 2 1

STEAM PRESSURE
TRANSMITTER

IN S T R U M E N T A N D CONTROL SY ST E M S F U N C T IO N A L D IA G R A M
scalE
CONTAINER CORPORATION
SANTA CLARA, CA
N.T.S.
------ tXTE------- C leave r o o k s s= “
10-5-95
CU9401468 DRAvk
B MT CT200 DLDH118 260ST
m od el fuel s iz e pressure in s u r a n c e

SIZE 460 3 60 3 375

SHT 01 OF 01
c VOLTS_________ PHASE__________HERTZ

DRVG. NO. W-00381 3 PID 00

WIRE AMPACITY
 3582 and 3583 Series

F ish er C o n tro ls Instruction Manual

3582 Series Valve Positioners,

Type 3582i Valve Positioner, and
3583 Series Valve Stem
Position Transmitters
^
FISHER0- F e b ru a ry 1993 F o rm 5054

Contents
Introduction..................................................... 2
Scope of Manual ................................................... 2
Description .............................................................. 2
Type Number Descriptions ............................... 2
Specifications............................................................3
Installation.................................................... 5
M ounting.................................................................. 6
Changing Cam P osition......................................... 9
Pressure Connections ........................................... 9
Supply Connection............................................. 9
Output Connection............................................. 9
Instrument Connection....................................... 9
Diagnostic Connections......................................10
V e n t.......................................................................... 10
Electrical Connections for Type 3582i
Valve P ositioner..................................................11
Installation Of Type 582i Converter ..................... 12
Operating Information ................................ 13
Valve Positioner Cam Information ....................... 13
Valve Stem Position Transmitter Cam
Information .......................................................... 14
Valve Positioner Bypass Operation ..................... 14
Input Signal Ranges................................................15
Valve Positioner Split-Range O peration............... 15
Changing Valve Positioner A ction......................... 16
Changing Valve Stem Position Transmitter
Action .................................................................. 16

W5500
D 200138X012

CONTROL VALVE WITH CONTROL VALVE WITH CONTROL VALVE WITH

TYPE 3582 POSITIONER TYPE 3582i POSITIONER TYPE 3583 TRANSMITTER

Figure 1. Typical Mounting for the 3582 Series, Type 3582i,

and 3583 Series Positioners and Transmitters

©Fisher Controls International. Inc. 1989. 1993; All Rights Reserved

3582 and 3583 Series
Contents (Cont’d)
Calibration Of Valve Positioner Or Valve
Stem Position Transm itter......................... 17
Pre-Calibration Alignment ......................................17
Calibration................................................................ 18
Principle of O p eratio n................................ 18
3582 Series Valve Positioners .................... 18
Type 3582i Valve Positioner................................. 19
3583 Series Valve Stem Position Transmitters . .19
Maintenance ................................................. 20
Changing the Range Spring ................................. 20
Replacing Gaskets..................................................21
Replacing the Nozzle O-Ring ............................... 21
Introduction
Scope of Manual
This instruction manual includes installation, operation,
calibration, maintenance, and parts ordering informa­
tion for the 3582 Series pneumatic valve positioners, the
Type 3582i electro-pneumatic valve positioner, and the
3583 Series pneumatic valve stem position transmitters.
Refer to separate instruction manuals for information on
the control valve, actuator, and accessories.
Only personnel qualified through training or experience
should install, operate, or maintain the valve positioner
or valve stem position transmitter. If there are any
questions concerning the instructions in this manual,
contact your Fisher sales office or representative before
proceeding.
Description
The 3582 Series pneumatic valve positioners and the
Type 3582i electro-pneumatic valve positioner shown in
figure 1 are used with diaphragm-actuated, sliding-stem
control valve assemblies. The pneumatic valve position­
ers receive a pneumatic input signal from a control
device and modulate the supply pressure to the control
valve actuator. The positioner adjusts the actuator sup­
ply pressure to maintain a valve stem position propor­
tional to the pneumatic input signal.
The Type 3582i is an electro-pneumatic valve positioner,
consisting of a Type 582i electro-pneumatic converter
installed on a Type 3582 pneumatic valve positioner.
The Type 3582i valve positioner provides an accurate
valve stem position that is proportional to a dc current
input signal.
2
Removing and Replacing the R elay.....................22
Relay Maintenance................................................. 22
Adjusting the Flapper Pivot................................... 23
Replacing the Type 582i Converter
Primary O-Ring and F ilte r.................................23
Replacing the Type 582i Converter Housing
Cap O-Ring......................................................... 23
Removing the Type 582i Converter .....................23
Reassembling the Type 582i Converter...............23
Parts O rderin g..............................................24
Parts Kits ...................................................... 24
Parts List ...................................................... 24
The Type 582i electro-pneumatic converter is a modular
unit that can be installed at the factory or in the field.
However, do not plan to install a Type 582i converter on
an existing positioner until you contact your Fisher sales
office or representative for application assistance.
The Type 582i converter receives the dc current input
signal and, through a nozzle/flapper arrangement, pro­
vides a proportional pneumatic output signal. This pneu­
matic output signal provides the input signal to the
pneumatic valve positioner, eliminating the need for a
remote-mounted transducer.
The 3583 Series pneumatic valve stem position trans­
mitters are for use with sliding-stem diaphragm actua­
tors. These units provide an output signal that is directly
proportional to the valve stem position.
Refer to the type number description for a detailed
explanation of type numbers.
Type Number Descriptions
The following descriptions provide specific information
on the different valve positioner or valve stem position
transmitter constructions. If the type number is not
known, refer to the nameplate on the positioner. For the
location of the nameplate, refer to key 25 in figure 20.
Type 3582— Pneumatic valve positioner with bypass
and instrument, supply, and output pressure gauges.
Type 3582A— Pneumatic valve positioner without by­
pass and without pressure gauges
Type 3582C— Pneumatic valve positioner without by­
pass and with automotive tire valves instead of pressure
gauges
 3582 and 3583 Series

Type 3582D— Pneumatic valve positioner with bypass
and with automotive tire valves instead of pressure
gauges
Type 3582G— Pneumatic valve positioner without by­
pass and with instrument, supply, and output pressure
gauges
Type 3583— Pneumatic valve stem position transmitter
with supply and output pressure gauges
Type 3583C— Similar to the Type 3583 valve stem posi­
tion transmitter except with automotive tire valves in
place of pressure gauges

Type 3582i— Electro-pneumatic valve positioner with­

out bypass; with Type 582i converter; and with: supply
and output pressure gauges, automotive tire valves, or
pipe plugs
Type 582i— Electro-pneumatic converter with: supply
and output pressure gauges, automotive tire valves, or
pipe plugs. Used for conversion of a 4 to 20 milliampere
input signal to a 3 to 15 psig (0.2 to 1.0 bar) input signal
for the pneumatic valve positioner
Specifications
Specifications for the valve positioners are shown in
table 1. Specifications for the valve stem position trans­
mitters are shown in table 2.
Refer to the unit nameplate to determine the type of
positioner or transmitter, supply pressure, etc. A typical
nameplate is shown in figure 2.

T a b le 1. S p e c ific a tio n s fo r 3 5 8 2 S e r ie s a n d T y p e 3 5 8 2 i V a lv e P o s itio n e rs

Input Signal<1>, Input Bellows Pressure Rating'3)

3582 Series: See table 4 for minimum and maximum pressure
■ 3 to 15 psig (0.2 to 1.0 bar), ■ 5 to 25 psig ratings (allowable input signal) for each available
(0.3 to 1.7 bar), ■ 6 to 30 psig (0.4 to 2.0 bar), or range spring
■ split range, see table 5
Type 3582i: Maximum Steady-State Air Consumption'^3)
4 to 20 mA dc constant current with 30 V dc For 3582 Series
maximum compliance voltage, can be split 2 0 P s ig ( 1 .4 b a r ) S u p p ly : 14.0 scfh (0.38 normal
range, see table 5 m3/hr)
3 0 P s ig ( 2 . 0 b a r ) S u p p ly : 18.0 scfh (0.48 normal
Equivalent Circuit for Type 3582i m3/hr)
The Type 582i converter equivalent circuit is 120 3 5 P s ig ( 2 .4 b a r ) S u p p ly : 20.0 scfh (0.54 normal
ohms, shunted by three 5.6-volt zener diodes m3/hr)
(see figure 11) For Type 3582i Only
20 P s ig ( 1 .4 b a r ) S u p p ly : 17.2 scfh (0.46 normal
Output SignaK1) m3/hr)
Type: Pneumatic pressure as required by 3 0 P s ig ( 2 . 0 b a r ) S u p p ly ; 21.4 scfh (0.58 normal
actuator up to 95 percent of maximum supply m3/hr)
Action<1>: Field-reversible between ■ direct and 3 5 P s ig ( 2 .4 b a r ) S u p p ly : 23.8 scfh (0.64 normal
■ reverse within the pneumatic valve positioner m3/hr)

Supply Pressure'1) Maximum Supply Air Demand'1)

Recommended: 5 psi (0.3 bar) above actuator For 3582 Series and Type 3582i
requirement 2 0 P s ig ( 1 .4 b a r ) S u p p ly : 164.5 scfh (4.7 normal
Maximum: 50 psig (3.4 bar) or pressure rating of m3/hr)
actuator, whichever is lower 3 0 P s ig ( 2 . 0 b a r ) S u p p ly : 248.5 scfh (7.0 normal
m3/hr)
3 5 P s ig ( 2 .4 b a r ) S u p p ly : 285.5 scfh (8.1 normal
m3/hr)
- Continued

3
3582 and 3583 Series

T a b le 1. S p e c ific a tio n s fo r 3 5 8 2 S e r ie s a n d T y p e 3 5 8 2 i V a lv e P o s itio n e rs (C o n tin u e d )

Performance Electrical Classification for Type 3582i

For 3582 Series Please refer to the Hazardous Area
In d e p e n d e n t L in e a rity < 1>: ± 1 percent of output Classifications Bulletin for specific approvals.
signal span Also, refer to the nameplates shown in figure 2
H y s te re s is < 1>: 0.5 percent of span for the location of positioner or transmitter
For Type 3582i Only classification information and approval
In d e p e n d e n t L in e a rity (V : ± 2 percent of output descriptions.
signal span
H y s te re s is !1>: 0.6 percent of span Housing Classification for Type 3582i
When
E le c tr o m a g n e tic In te r fe r e n c e (E M I)< 1>: NEMA 3, IEC 529 IP54: Mounting orientation
tested per SAMA Standard PMC 33.1-1978, requires vent location to be below horizontal
change in steady-state deviation is less than +
1% in an electromagnetic field classified as 3- Pressure Gauges
abc with a field strength of 30 V/m. Positioner is
1-1/2 inch (40 mm) diameter with plastic case
tested with housing cap on and with external
and brass connection ■ triple scale (PSI, MPa,
field wiring in rigid metal conduit.
and bar) or ■ dual scale (PSI and kg/cm2)
For 3582 Series and Type 3582i
O p e n L o o p G a in (O u tp u t S ig n a l)< 1>:
Pressure Connections
■ 100 in the range of 3 to 15 psig (0.2 to 1.0
bar) 1/4-inch NPT female
■ 55 in the range of 6 to 30 psig (0.4 to 2.0 bar)
Electrical Connection for Type 3582i
Operating Influences*1) 1/2-14 NPT conduit connection
Supply Pressure, For 3582 Series Units: Valve
travel changes less than 0.25 percent per 2 psi Maximum Valve Stem Travel
(1.67 percent per bar) change in supply pressure 4-1/8 inches (105 mm); adjustable to obtain
Supply Pressure, For Type 3582i Units: Valve lesser travels with standard input signals
travel changes less than 1.5 percent per 2 psi
(3.62 percent per bar) change in supply pressure Characterized Cams
See characterized cams section
Operative Temperature Limits*1)
Standard Construction, For 3582 Series and Approximate Weight
Type 3582i Units: - 40 to + 160°F ( - 40 to 3582 Series Units: 5-1/2 pounds (2.5 kg)
4- 71 °C) Type 3582i: 8 pounds (3.6 kg)
High-Temperature Construction*2), For Types
3582A and C Only: 0 to + 220°F ( - 18 to
+ 104°C) without gauges
1. This term Is defined In ISA Standsrd S51.1-1979. 3. Scfh— standard cubic feet per hour (60°F and 14.7 psia); normal m3/hr— normal cubic
2. Do not exceed any of the pressure or temperature limits In this Instruction manual. meters per hour (0°C and 1.01325 bar, absolute).
Also, any applicable standard or code should not be exceeded.

P O S ITIO N E R O R T R A N S M IT T E R N A M E P L A T E T Y P E 5821 C O N V E R TE R N A M E P LA TE

Figure 2. Typical Nameplates

4

T a b le 2 . S p e c ific a tio n s fo r 3 5 8 3 S e r ie s V a lv e S te m P o s itio n T ra n s m itte rs
Input SignaK1)
4-1/8 inches (105 mm) of valve stem travel;
adjustable to obtain full output signal with lesser
stem travels
Output Signal*1)
Type: ■ 3 to 15 psig (0.2 to 1.0 bar), ■ 5 to 25
psig (0.3 to 1.7 bar), or ■ 6 to 30 psig (0.4 to 2.0
bar) pneumatic pressure
Action: Field-reversible between direct and
reverse
Output Bellows Pressure Rating)2)
See table 4 for minimum and maximum pressure
ratings (allowable input signal) for each available
range spring
Supply Pressure)1)
Recommended: 5 psi (0.3 bar) above upper limit
of output signal range
Maximum: 35 psig (2.4 bar) or pressure rating of
connected equipment, whichever is lower
Maximum Steady-State Air Consumption)1))2)
20 Psig (1.4 bar) Supply: 14.0 scfh (0.38 normal
m3/hr)
30 Psig (2.0 bar) Supply: 18.0 scfh (0.48 normal
m3/hr)
35 Psig (2.4 bar) Supply: 20.0 scfh (0.54 normal
m3/hr)
1. This term Is defined In ISA Standard S51.1-1979.
2. Do not exceed any of the pressure or temperature limits In this Instruction manual.
Also, any applicable standard or code should not be exceeded.
Installation
Note
All valve positioners and valve stem posi­
tion transmitters are shipped with foam rub­
ber packing material inside the case.
Remove the cover (key 33, figure 20) and
the packing material before attempting to
operate the unit. Make sure all vent open­
ings are clear before installation of the unit
and that they remain clear during use.
Typically, the positioner or transmitter is ordered with
the actuator. If so, the factory mounts the valve position­
er or valve stem position transmitter and connects the
valve positioner output to the actuator.. If a Type 67AFR
filter-regulator is specified, it may be integrally mounted
to the valve positioner or valve stem position
transmitter.
3582 and 3583 Series
Reference Accuracy)1)
± 1 percent of output signal span
Operating Influence)1)
Output signal changes 0.23 percent per 2 psig
(1.67 percent per bar) change in supply pressure
Operative Ambient Temperature Limits)1)
Standard Construction, 3583 Series: —40 to
+ 160 °F ( - 4 0 to + 71 °C)
High-Temperature Construction)2), Type 3583C
only: 0 to + 220 °F ( - 18 to + 104°C)
Pressure Connections
Supply and output pressure connections are
1/4-inch NPT female
Maximum Valve Stem Travel
4-1/8 inches (105 mm); adjustable to obtain full
output signal with lesser stem travels
Cam
Linear
Approximate Weight
5-1/2 pounds (2.5 kg)
3. Scfh— standard cubic feet per hour (60°F and 14.7 psia); normal m3/hr— normal cubic
meters per hour (0°C and 1.01325 bar, absolute).
Note
In some cases, alignment and calibration of
the valve positioner or valve stem position
transmitter at the factory may not be possi­
ble, and field alignment and calibration is
required. Before putting the valve position­
er or valve stem position transmitter into
service, check the operation of the unit to
be sure it is calibrated. If the valve position­
er or valve stem position transmitter re­
quires alignment or calibration, refer to the
appropriate calibration instructions in this
manual.
If the valve positioner or valve stem position transmitter
is ordered separately, disconnected, or removed from
the actuator, refer to the appropriate sections of this
manual for installation information.
3582 and 3583 Series

sH § >

TYPE 657, 6S7MO, 667, 667MO

SIZE 60 UP TO 2 IN (51 mm) TRAVEL

TYPE 613
SIZE 32
TYPE 657, 657MO, 667, 667MO TYPE 650, 656, 657-8
SIZE 100 ALL TRAVEL ALL SIZES
TYPE 667, 667MO, 667, 667MO TYPE 667MO
SIZE 80 2-1/16 TO 3 IN (62 TO 76 mm) SIZE 34, 45, 50, 60
TRAVEL TYPE 657-4, 667-4
TYPE 657MO, 667MO SIZE 70, 87 4 IN (102 mm) TRAVEL
SIZE 70, 87 3-1/16 TO 4 IN TYPE 667, 667
(76 TO 102 mm TRAVEL SIZE 70, 87 3-1/16 TO 4 IN (78 TO 102 mm) TRAVEL
TYPE 657-4MO, 667-4MO TYPE 657MO, 667MO TYPE 667
SIZE 70, 87 4 IN (102 mm) TRAVEL SIZE 70, 87 UP TO 3 IN (78 mm) TRAVEL SIZE 70, 87, 2-1/16 TO 3 IN (52 TO 78 mm) TRAVEL

NOTE:
KEY 55 (TUBING CONNECTOR) NOT SHOWN
41B8569-C SHT 1 AND 2
Figure 3. Mounting Assembly

provide spacers, if necessary, by cutting sections from

Mounting
Key numbers used in this procedure are shown in figure
3 except where indicated.
1. Figure 3 shows the various mounting parts required
for mounting on Fisher actuators. Mounting parts for
Fisher actuators that require spacers have the spacers
(key 50) included. Type 657 and 667 actuators, sizes 70
through 100, with or without a side-mounted handwheel,
use spacers (keys 97 and 102) between the stem con­
nector and the connector arm (key 48). On all other
actuators that use spacers, place the spacers (key 50)
between the mounting plate (key 63) and the actuator
mounting boss.
When mounting the valve positioner or valve stem posi­
tion transmitter on an actuator by another manufacturer,
1/2- or 3/8-inch pipe so that the "X” dimension matches
the value given in figure 6.
2. As shown in figures 3 and 4, attach the connector
arm (key 48) to the stem connector so that the connector
arm extends through the yoke legs on the side of the
lower mounting boss.
3. Attach the valve positioner or valve stem position
transmitter to the mounting plate (key 63) using the
holes shown in figure 5. .
4. Mount the Type 67AFR regulator:
• 3582 Series valve positioners and 3883 Series
valve stem position transmitters, mount the regulator
on the integral boss on the bypass block.

6
 3582 and 3583 Series

Table 3. 3582 and 3583 Series Mounting Information

MOUNTING
MAXIMUM MOUNTING TRAVEL MAXIMUM TRAVEL
ACTUATOR ACTUATOR ACTUATOR ACTUATOR HOLES
TRAVEL HOLES PIN TRAVEL PIN
TYPE SIZE TYPE SIZE SET NO.*1)
SET NO.*1) POSITION®
Inch mm Inch mm 657 667
20 3/4 19 2 Normal 30 3/4 19 3 4 Normal
513 & 513R
32 3/4 19 2 Normal 34 1-1/8 19 3 2 Normal
30 2 51 4 Inverted 40 1-1/2 38 2 3 Normal
656 40 3-1/2 89 4 Inverted 45 3/4 19 1 4 Inverted®
60 4 102 4 Inverted 45 2 51 1 1 Normal
657-4 Without 50 2 51 1 2 Normal
Side-Mounted 70 4 102 3 Inverted 657 & 667 60 2 51 1 2 Normal
Handwheel Without Side 2 51 2 1 Normal
Mounted 70 2- 1/16-3
52-76 3 2 Normal
657-4 With Handwheel
70 4 102 2 Inverted 3- 1/16-4
78-102 3 1 Inverted*4)
Side-Mounted
87 4 102 1 Inverted
Handwheel 80 3 76 2 2 Normal
30 2-1/8 54 3 Normal 2 51 2 2 Normal
34 2-1/8 54 3 Normal 87 2-1/16-3 52-76 2 2 Normal
40 3-1/8 79 3 Normal 3-1/16-4 78-102 3 1 Inverted*4)
40 3-1/2 89 3 Normal 100 4 102 4 4 Inverted
46 3-1/8 79 2 , Normal 34 3/4 19 2 2 Normal
657-8
46 4-1/8 105 2 Normal 40 1-1/2 38 1 2 Normal
47 3-1/8 79 2 Inverted 45 2 51 1 4 Normal
657 & 667
47 4-1/8 105 1 Inverted 50 2 51 4 1 Inverted*4)
With Side
60 4-1/8 105 4 Inverted 60 2 51 3 1 Inverted*4)
Mounted
70 4-1/8 105 2 Inverted 70 4 102 2 2 Inverted
Handwheel
667-4 Without 80 3 76 2 2 Normal
70 4 102 1 Normal
Side-Mounted 3 76 2 2 Normal
87 4 102 1 Normal 87
Handwheel 3-1/16-4 78-102 2 1 Inverted
1. The indicated set number should be considered a reference point only, due to the 3. Travel pin position for Type 6S7 is normal,
variables related to making up the stem connection. 4. Travel pin position for Type 667 is normal.
2. Normal position is shown In figure 4.

Figure 4. Isometric View Showing Motion Feedback Figure 5. Mounting Plate Used with 3582 Series Valve
Arrangement and Typical Stem Connection Positioners and 3583 Series Motion Transmitters

• Type 3582i valve positioners, mount the regulator

on the integral boss that is part of the Type 582i convert­ CAUTION
er housing.
5. As shown in figure 5, the mounting bracket has four To avoid equipment damage, be certain the
sets of holes for mounting the assembly to the actuator. connector arm clears the valve positioner
Refer to table 3 to determine which set of mounting or valve stem position transmitter case as
holes to use, then attach the assembly to the lower the actuator moves through its complete
mounting pad on the actuator. stroke.

7
3582 and 3583 Series

X
STEM
TRAVEL 3/8-lnch 1/2-lnch 3/4-lnch
(9.5 mm) Stem (12.7 mm) Stem (19.1 mm) Stem
Inches
1-1/8 or less 3.19 3.44 3.94
1-1/2 3.56 3.81 4.31
2 4.00 4.25 4.75
2-1/2 4.44 4.69 5.19
3 4.88 5.12 5.62
3-1/2 5.31 5.56 6.06
4 5.75 6.00 6.50
Millimeters
29 or less 81 87 100
38 90 97 109
51 102 108 121
64 113 119 132
76 124 130 143
89 135 141 154
102 146 152 165

Figure 6. Spacing for Mounting on Other

Than Fisher Actuators

6. Position the actuator to its mid-travel position using

a handwheel or manual loading regulator.

7. Slip the round end of the travel pin (key 60) into the
rotary shaft arm (key 2) slot as shown in figure 4.

8. Slide the square end of the travel pin into the pin
holder and pin lock (keys 61 and 59). Place the pin lock
and holder into the slot in the connector arm (key 48).
Screw the cap nut (key 62) onto the pin lock (key 59), but
do not tighten. NOTES:
[T> MAXIMUM ROTATION FROM MID-TRAVEL POSITION.

9. With the actuator at its mid-travel position, lift the [ 2 > ALIGN INDEX MARKS AS SHOWN FOR MID-TRAVEL POSITION.
70CA0750-C
rotary shaft arm so that the 0-degree index marks on the A2452-2

rotary shaft arm are aligned with the case index marks Figure 7. Rotary Shaft Arm and Case Index Marks
as shown in figure 7.

of travel, the 30-degree index marks on the rotary shaft

CAUTION
Never set the travel pin at a setting that is
less than the actual actuator stroke. Setting
the travel pin at a setting that is less than
the actual actuator stroke will cause the
cam to rotate more than 60 degrees, caus­
ing damage to the cam or other parts.
10. Position the travel pin so that it is perpendicular to
the connector arm and aligns with the correct actuator
stem travel index on the rotary shaft arm. Tighten the
cap nut (key 62 in figure 4).
11. Check the travel pin setting using the following
procedures:
e if a standard travel pin setting was made (that is,
with the travel pin setting equal to total actuator travel),
stroke the actuator to each end of its travel. At each end
arm should align with the case index marks. If the index
marks are not in line, loosen the cap nut (key 62) and
slide the travel pin (key 60) in the rotary shaft arm slot
until the 30-degree index marks align with the case
index marks. Be sure the travel pin remains perpendicu­
lar to the connector arm. After making this adjustment,
tighten the cap nut and re-check the arm at the mid­
travel position. If the 0-degree index marks are not in
line, repeat this procedure.
• If a special travel pin setting was made (that is,
with the travel pin setting greater than total actuator
travel), check the index marks using a procedure similar
to that for standard settings. The arm-will not rotate a full
60 degrees as the actuator is stroked, and the 30-
degree index marks on the cam will be short of aligning
with the case index marks. If necessary, adjust the travel
pin position so that the 30-degree marks are the same
distance from the respective case index mark at each
end of actuator travel.

8

Changing Cam Position
Refer to figure 20 for a typical cam illustration and key
number locations.
Note
• For Valve Positioners: The small arrow on
the cam must point in the direction of stem
movement with increasing actuator dia­
phragm pressure.
e For Valve Stem Position Transmitters: If
the arrow on the cam points up toward the
nozzle, output pressure increases with
downward stem movement. If the arrow
points down, output pressure decreases
with downward stem movement.
If the arrow is pointing in the wrong direc­
tion, use the following procedure to re­
move, reverse, and re-install the cam.
When mounting a valve positioner or valve stem position
transmitter, check to see if the correct cam (key 4) and
cam position has been selected. To change the cam or
cam position, unhook the extension spring (key 38), and
remove the cam bolt and locking nut (keys 6 and 45).
Remove the cam and spring retainer bracket (key 43).
To install the cam, screw the locking nut all the way onto
the cam bolt. Attach the cam and spring retainer bracket
to the shaft assembly with the cam bolt. Tighten the bolt
to secure the cam. Then, tighten the locking nut against
the spring retainer bracket. Hook the spring into the
spring retainer bracket.
Details on cam characteristics can be found in the cam
information portion of the operating information section.
Pressure Connections
W A R N IN G
Valve positioners and valve stem position
transmitters are capable of providing full
supply pressure to connected equipment.
To avoid personal injury and equipment
damage, make sure the supply pressure
never exceeds the maximum safe working
pressure of any connected equipment.
Pressure connections are shown in figure 8. All pres­
sure connections are 1/4-inch NPT female. Use 3/8-inch
tubing for all pressure connections. After pressure con­
nections have been made, turn on the supply pressure
and check all connections for leaks.
3582 and 3583 Series
Supply Connection
W A R N IN G
Personal injury or property damage may
occur from an uncontrolled process if the
supply medium is not clean, dry, oil-free, or
non-corrosive gas. Industry instrument air
quality standards describe acceptable dirt,
oil, and moisture content. Due to the vari­
ability in nature of the problems these influ­
ences can have on pneumatic equipment,
Fisher Controls has no technical basis to
recommend the level of filtration equipment
required to prevent performance degrada­
tion of pneumatic equipment. A filter or
filter regulator capable of removing parti­
cles 40 microns in diameter should suffice
for most applications. Use of suitable filtra­
tion equipment and the establishment of a
maintenance cycle to monitor its operation
is recommended.
Supply pressure must be clean, dry air or noncorrosive
gas. Use a Fisher Type 67AFR Filter Regulator, or
equivalent, to filter and regulate supply air. The filter
regulator can be mounted with the positioner. The sup­
ply pressure should be high enough to permit setting the
regulator 5 psi (0.3 bar) above the upper limit of the
appropriate pressure range, for example: 20 psig (1.4
bar) for a 3 to 15 psig (0.2 to 1.0 bar) range. However, do
not exceed the maximum allowable supply pressure of
50 psig (3.4 bar) nor the pressure rating of any connect­
ed equipment.
Connect the nearest suitable supply source to the 1/4-
inch NPT IN connection on the filter regulator (if fur­
nished) or to the 1/4-inch NPT SUPPLY connection on
the positioner block assembly.
Output Connection
A factory mounted valve positioner has the valve posi­
tioner output piped to the supply connection on the
actuator. If mounting the valve positioner in the field,
connect 3/8-inch tubing between the 1/4-inch NPT valve
positioner connection marked OUTPUT and the actua­
tor supply pressure connection. Connect the valve stem
position transmitter connection marked OUTPUT to an
instrument that indicates valve stem position.
Instrument Connection ■
For a 3582 Series pneumatic valve positioner connect
3/8-inch tubing from the control device to the 1/4-inch
NPT INSTRUMENT connection. If the control device is
mounted on the control valve assembly by the factory,
this connection is made.
9
 3582 and 3583 Series
FISHER®

T Y P E 3582i

.50

T Y P E 3582
(D IM EN SIO N S FO R T Y P E S 3582A,
C, D, A N D G A R E T H E SAM E)

Figure 8. Typical Dimensions and Connections

The Type 3582i electro-pneumatic valve positioner re­
quires a 4 to 20 milliampere dc current input signal from
the control device. A 1/2-inch NPT conduit connection is
provided for properly wiring electrical installations. For
more information, see the electrical connections
section.
Diagnostic Connections
To support diagnostic testing of valve/actuator/posi-
tioner/accessory packages, special connectors and
hardware are available. The hardware used includes 1/
8-inch NPT connector bodies and body protectors. If the
diagnostic connectors are ordered for a positioner with
gauges, 1/8-inch stems are also included.
10
Install the connectors on the 3582 block assembly or
Type 582i housing as shown in figure 9. Before installing
the connectors on the positioner, apply sealant to the
threads. Sealant is provided with the diagnostic connec­
tions and hardware.
Vent
W A R N IN G
If a flammable, toxic, or reactive gas is to be
used as the supply pressure medium, per­
sonal injury or property damage could re­
sult from fire or explosion of accumulated
 3582 and 3583 Series

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GAUGE
£

STEM
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P R O V ID E D W H E N
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Figure 9. Flowscanner Connections

gas or from contact with toxic, or reactive Also, be certain that the exhaust holes in the relay (key
gas. The positioner/actuator assembly 32 in figure 20) are kept open.
does not form a gas-tight seal, and when
the assembly is enclosed, a remote vent
line, adequate ventilation, and necessary
safety measures should be used. A remote Electrical Connections for Type 3582i
vent pipe alone cannot be relied upon to
V alve Positioner
remove all hazardous gas. Vent line piping
should comply with local and regional
codes and should be as short as possible W A R N IN G
with adequate inside diameter and few
bends to reduce case pressure buildup. For explosion-proof applications, discon­
nect power before removing the converter
housing cap.
CAUTION
For explosion-proof applications, install
When installing a remote vent pipe, take rigid metal conduit and a conduit seal no
care not to overtighten the pipe in the vent more than 18 inches (457 mm) from the
connection. Excessive torque will damage converter. Personal injury or property dam­
the threads in the connection. age might result from explosion if the seal
is not installed.
The vent opening at the back of the case marked VENT
should be left open to prevent pressure buildup inside For intrinsically safe installations, refer to
the case and to provide a drain hole for any moisture factory drawings or to instructions provided
that might collect inside the case. A screen is normally by the barrier manufacturer for proper wir­
installed in this opening to prevent blockage from debris ing and installation.
or insects.
Use the 1/2-inch NPT conduit connection on the Type
If a remote vent is required, the vent line must be as 582i converter housing for installation of field wiring. For
short as possible with a minimum number of bends and Class I, Division I explosion-proof applications, install
elbows. The vent connection is 3/8-inch NPT female. To rigid metal conduit and a seal no more than 18 inches
connect a remote vent, press out the screen and use (457 mm) from the converter. Also, install conduit ac­
3/8-inch tubing to provide a remote vent. The 582i has a cording to local and national electrical codes which
1/4-inch NPT female vent connection. apply to the application.

11
3582 and 3583 Series

4-20 m A ----------

60 Ohms

60 Ohms

Figure 11. Type 582i Input Equivalent Circuit

NOTE:
[ T > FOR TROUBLESHOOTING OR MONITORING OPERATION,
AN INDICATING DEVICE CAN BE A VOLTMETER ACROSS
A 250 OHM RESISTOR OR A CURRENT METER.
A387S*

Figure 10. Typical Field Wiring Diagram

Refer to figures 10, 11 and 12 when connecting field

wiring from the control device to the converter. Connect
the positive wire from the control device to the converter
positive ( + ) terminal, and the negative wire from the
control device to the converter negative ( —) terminal.
Do not overtighten the terminal screws. Maximum
torque is 4 Ibf-in. (0.45 N-m). Connect the converter
grounding terminal to an earth ground.
Figure 12. Type 582i Converter Wiring Connections

Installation Of Type 582i Converter0 >

e Use lock-out procedures to be sure that
the above measures stay in effect while
you work on the equipment.
W A R N IN G

Avoid personal injury from sudden release Note

of process pressure. Before mounting the
Type 582i converter:
e Disconnect any operating lines provid­
ing air pressure or a control signal to the
actuator. Be sure the actuator cannot sud­
denly open or close the valve.
e Use bypass valves or completely shut
off the process to isolate the valve from
process pressure. Relieve process pres­
sure on both sides of the valve. Drain the
process media from both sides of the valve.
e Vent actuator loading pressure and re­
lieve any actuator spring precompression.
12
Before planning to retrofit an installed 3582
Series positioner, refer to the positioner
mounting plate illustration shown in figure
5. Mounting plates with a three-hole mount­
ing pattern (positioner to mounting plate)
cannot support a Type 5821 converter. Do
not attempt to mount a Type 582i converter
on an existing 3582 Series positioner which
has a three-hole mounting pattern.
Isolate the control valve from the line pressure, release
pressure from both sides of the valve body, and drain
the process media from both sides of the valve. Use
lock-out procedures to be sure that the above measures
stay in effect while you work on the equipment.
1. Please contact your Fisher sales office or representative before planning to upgrade
any existing 3582 Series valve positioner by field Installation of a Type 582I electro­
pneumatic converter. Also, refer to this section of the instruction manual which
describes field installation of a Type 582I converter.

If a 3582 Series pneumatic valve positioner has previ­
ously been installed using a mounting plate with a five-
hole mounting pattern (positioner to mounting plate),
either at the factory or in the field, it can be upgraded to
a Type 3582i electro-pneumatic valve positioner by in­
stallation of a Type 582i converter. To install a Type 582i
converter, refer to the following instructions.
Note
Inspect the existing valve positioner to de­
termine the input signal range. If the input
signal range is not 3 to 15 psig, refer to the
appropriate sections of this manual de­
scribing input signal ranges and how to
change the range spring.
1. Inspect the positioner mounting plate. Be certain
that five screws fasten the positioner to the mounting
plate. Two additional screws fasten the plate to the
actuator.
When the positioner is correctly attached to the mount­
ing plate, proceed with the installation by taking the
control valve/actuator/positioner package out of
service.
2. Properly vent the actuator loading pressure and the
supply pressure. Disconnect the pressure tubing con­
nections to the valve positioner.
3. Remove the two screws (key 105 in figures 23 or 24)
holding the bypass block (key 34A in figures 23 or 24) to
the valve positioner case and remove the bypass block.
Save the screws to reattach the Type 582i converter.
4. Remove and discard the existing gasket (key 104 in
figures 23 or 24) between the bypass block and valve
positioner case.
5. Unpack the Type 582i converter to be installed.
6. Position the new gasket on the Type 582i converter
as shown in figure 26. Insert the existing screws (key
105 in figures 23 or 24) through the appropriate holes in
the Type 582i converter housing and new gasket.
7. Mate the converter and new gasket to the side of
the valve positioner case using the alignment pins on the
converter housing.
8. Tighten the screws.
9. Reconnect the pressure connections according to
the instructions given in the pressure connections sec­
tion of this manual.
10. Make the electrical connections according to the
instructions given in the electrical connections section
of this manual.
3582 and 3583 Series
11. Complete the standard calibration procedure de­
scribed in the calibration section of this manual.
12. Return the control valve package to service.
Operating Information
Instructions for setting the zero and span are found in
the calibration section.
V alve Positioner Cam Inform ation
Note
The small arrow on the valve positioner cam
must point in the direction of stem move­
ment with increasing actuator diaphragm
pressure. If the arrow is pointing in the
wrong direction, remove, reverse, and re­
install the cam.
Isolate the control valve and shut off pres­
sure lines to the valve positioner. Refer to
figure 20 for key number locations. Unhook
the spring (key 38), and remove the cam
bolt and locking nut (keys 6 and 45). Re­
move the cam (key 4) and spring retainer
bracket (key 43). To install the cam, screw
the locking nut all the way onto the cam
bolt. Attach the cam and spring retainer
bracket with the cam bolt. Tighten the bolt
to secure the cam. Then, tighten the locking
nut against the spring retainer bracket.
Hook the spring into the spring retainer
bracket.
When shipped from the factory, 3582 Series valve posi­
tioners and the Type 3582i valve positioner are
equipped with three cams, marked A, B, and C. Cam A,
the linear cam, is installed in the operating position.
Cams B and C, the characterized cams are attached to
the inside of the case.
Figure 13 shows resultant stem travel due to an incre­
mental instrument pressure change for each cam. In
figure 13, the curves are based on 60 degrees cam
rotation for 100 percent stem travel. At 50 percent of the
input signal span, for example, the stem will travel 50
percent with cam A, 68 percent with .cam B, and 32
percent with cam C. Figure 14 shows how the flow
characteristics change when using the cams with a
valve that has equal percentage characteristics. Figure
15 shows how the flow characteristics change when
using the cams with a valve that has linear
characteristics.
3582 and 3583 Series
CM832-A
Figure 13. Cam Characteristic Curves Figure 14. Flow Characteristics with
Different Cams and Equal
Percentage Valve Plug
When cam A is the operating cam, there is a linear
relationship between an incremental instrument pres­
sure change and the resultant valve stem travel. The
flow characteristic is that of the control valve. Installing
either cam B or C as the operating cam, changes the
relationship between the incremental instrument pres­
sure change and valve stem travel, thereby modifying
the valve flow characteristic.
V alve Stem Position Transm itter Cam
Inform ation
Note
If the small arrow on the valve stem position
transmitter cam points up toward the noz­
zle, output pressure increases with down­
ward stem movement. If the arrow points
down, output pressure decreases with
downward stem movement. If the arrow is
pointing in the wrong direction, remove,
reverse, and re-install the cam.
Isolate the control valve and shut off pres­
sure lines to the valve positioner. Refer to
figure 20 for key number locations. Unhook
the spring (key 38), and remove the cam
bolt and locking nut (keys 6 and 45). Re­
move the cam (key 4) and spring retainer
bracket (key 43). To install the cam, screw
the locking nut all the way onto the cam
bolt. Attach the cam and spring retainer
bracket with the cam bolt. Tighten the bolt
to secure the cam. Then, tighten the locking
nut against the spring retainer bracket.
Hook the spring into the spring retainer
bracket.
14
Figure 15. Flow Characteristics with
Different Cams and
Linear Valve Plug
The linear cam is the only cam available for the 3583
Series valve stem position transmitter. There is always a
linear relationship between stem travel and the stem
position transmitter output.
Valve Positioner Bypass Operation
Type 3582 and 3582D valve positioners are supplied
with a bypass assembly. A handle on the bypass assem­
bly permits selecting positioner or bypass operation.
Refer to figure 23 for key number locations.
CAUTION
Do not use bypass when the valve position­
er is reverse-acting or is in split-range oper­
ation. In these cases, bypassing the valve
positioner sends the input signal directly to
the actuator. Such a change will affect the
desired operation and possibly upset the
system. Use bypass only when the input
signal range is the same as the valve posi­
tioner output range required for normal ac­
tuator operation.
Labels on the bypass block (key 34A) and a pointer on
the bypass handle (key 34D) indicate if the input signal
from the instrument goes to the positioner or directly to
the control valve actuator. Push the bypass handle
toward the back of the positioner to-move the pointer
over the word POSITIONER. With the bypass handle in
this position, the input signal goes to the valve position­
er bellows and the output pressure of the valve position­
er goes to the actuator. Pull the bypass handle forward
to move the pointer over the word BYPASS. In this
positiori, the input signal goes directly to the actuator.
 3582 and 3583 Series

Table 4. Standard Instrument Input Signals and Range Springs

INSTRUMENT ALLOWABLE RANGE RANGE

STANDARD INPUT SIGNALS)
INPUT SIGNAL SPRING SPRING
SPAN PART NUMBER
RANGE Minimum Maximum COLOR
3-15 psig 12 psig 1 psig 21 psig
0.2-1.0 bar 0.8 bar 0.07 bar 1.4 bar Silver 1V621727012
4-20 mA<2) 16 mA ' 2 mA 22 mA
5-25 psig 20 psig 1 psig 30 psig
Green 1V621827012
0.3-1.7 bar 1.4 bar 0.07 bar 2.0 bar
6-30 psig 24 psig 1 psig 35 psig
Red 1V621927012
0.4-2.0 bar 1.6 bar 0.07 bar 2.4 bar
1. Minimum and maximum allowable input signals ensure functional operation.
2. For Type 3582I, only.

Note Table 5. Split-Range Capabilities

3582 SERIES POSITIONERS
A difference between the input signal pres­ 3 to 15 Psig or 6 to 30 Psig or
sure and the valve positioner output pres­ 0.2 to 1.0 Bar 0.4 to 2.0 Bar
sure could cause a transient bump in the Split Input Signal Input Signal
controlled system when the bypass handle Psig Bar Psig Bar
is moved to BYPASS. 3 to 9 0.2 to 0.6 6 to 18 0.4 to 1.2
Two-way 1.2 to 2.0
9 to 15 0.6 to 1.0 18 to 30
3 to 7 0.2 to 0.5 6 to 14 0.4 to 0.9
With a reverse-acting or split-range valve positioner, the
Three-way 7 to 11 0.5 to 0.7 14 to 22 0.9 to 1.5
bypass handle may be locked in the POSITIONER posi­ 11 to 15 0.7 to 1.0 22 to 30 1.5 to 2.0
tion so that bypass cannot be used. To lock the bypass TYPE 3582i POSITIONER
handle in the POSITIONER position, first shut off the
4 to 20 Milliampere
instrument and supply pressure to the valve positioner. Split
Input Signal
Then, remove the hex head shoulder screw from the 4 to 12
center of the handle. Remove the handle and rotate it Two-way
12 to 20
180 degrees and re-install it with the handle between the 4 to 9.3
two lugs cast on the bypass block. Replace the shoulder Three-way 9.3 to 14.7
screw. 14.7 to 20

Input Signal Ranges

Standard input signal ranges for valve positioners and
valve stem position transmitters are shown in table 4.
Changing from one standard range to another requires
changing the range spring. To change the range spring,
refer to the instructions for changing the range spring in
the maintenance section of this manual. Split-range
operation of 3582 Series valve positioners or the Type
3582i valve positioner normally does not require chang­
ing the spring. Refer to the section below for split-range
information.
V alve Positioner Split-R ange Operation
The 3582 Series valve positioners and the Type 3582!
valve positioner are suitable for split-range operations.
In split-range operation, the input signal, either pneu­
matic or dc current, from a single control device is split
between two or more control valves. No additional parts
are required to use an existing valve positioner for split-
range operation.
Table 5 shows some typical split-ranges for the valve
positioners.
To change to split-range operation, perform the pre­
calibration alignment procedures in the Calibration sec­
tion then perform the following steps. See figure 16 for
part locations.
1. Move the flapper assembly along the beam to in­
crease travel. The flapper assembly can be positioned
by hand or by using a screwdriver in the slot of the
flapper setting adjustment.
2. Vary the input signal, observing the span required
to stroke the valve completely.
3. Readjust the flapper assembly along the beam until
the desired change in input signal results in full valve
travel. For example, for a 3582 Series valve positioner
with a 3 to 15 psig (0.2 to 1.0 bar) input signal range
spring and a two-way split, a 6 psi (0.4 bar) change
should stroke the valve completely.
4. Apply an input signal equal to the low value of the
input signal range. For example, for a 3582 Series valve
positioner with a 3 to 9 psig (0.2 to 0.6 bar) input signal
range, set the input signal at 3 psig (0.2 bar).

15
3582 and 3583 Series
5. Adjust the nozzle until the actuator is at the starting
position (fully up or fully down depending on the action
selected) corresponding to the low input signal.
Note
The flapper must approach the nozzle
squarely at the midpoint value of the input
signal range for proper operation.
On some applications where the input sig­
nal span is comparatively small (as found
with split-range applications), the nozzle
adjustment may not be enough to set the
proper starting point. Also, some difficulty
may be experienced in keeping a valve
positioner from unloading when the input
signal continues to increase above the
split-range.
For example, for a 3 to 9 psig (0.2 to 0.6 bar)
input signal range, the input signal could
increase to 15 psig (1.0 bar). Continued
bellows travel due to the increased input
signal over the split-range would drive the
flapper into the nozzle. The impact could
possibly cause misalignment between the
flapper and nozzle. Such a misalignment, in
turn, could affect split-range calibration.
In these cases, adjust the follower assem­
bly screw in addition to the nozzle adjust­
ment to obtain satisfactory results.
Note
The 3582 Series valve positioners require a
relatively small percentage of the instru­
ment pressure span to obtain full valve
travel. With the travel pin set to equal the
valve travel, the input signal change re­
quired to fully stroke the valve can be re­
duced to 33 percent of normal input signal
change. With the travel pin set to a value
greater than the valve travel, the input sig­
nal change required to fully stroke the valve
can be reduced to a minimum of 20 percent
of normal input signal change.
Changing V alve Positioner Action
Converting a 3582 Series vatve positioner or Type 3582i
valve positioner from direct acting (an increasing input
signal, either pneumatic or electrical, increases output
pressure) to reverse acting (increasing input signal de­
creases output pressure) or vice versa requires no
additional parts. The position of the flapper assembly on
the beam determines the action. As shown in figure 16,
16
BEAM
BELLOWS ASSEMBLY
LOCKNUT
PIVOT PIN
BELLOWS
ASSEMBLY
PIVOT PIN
S E C TIO N A -A
Figure 16. Partial View for Beam Leveling and Calibration
the beam is divided into quadrants. The direct-acting
quadrant of the beam is labeled DIRECT and the re­
verse-acting quadrant is labeled REVERSE. To change
the positioner action, simply move the flapper assembly
to the opposite quadrant of the beam. Perform the
calibration procedures in the valve positioner calibration
section.
Changing V alve Stem Position
Transm itter Action
Refer to figure 20 for key number locations unless
otherwise indicated.
The flapper of the 3583 Series valve stem position
transmitter is always positioned in the reverse-acting
quadrant as shown in figure 19. To reverse the signal,
reverse the cam as follows:
i
1. Unhook the spring (key 38), and remove the cam
bolt (key 6), cam (key 4), and spring retainer bracket (key
43).
2. Screw the locking nut (key 45) all the way onto the
cam bolt.
Note
If The arrow stamped bn the cam points
toward the nozzle, output pressure in­
creases with downward stem movement. If
the arrow points down away from the noz­
zle, output pressure decreases with down­
ward stem movement.

3. Reverse the cam (key 4) from its original position.
Attach the cam and spring retainer bracket with the cam
bolt. Tighten the cam bolt to secure the cam. Then
tighten the locking nut against the spring retainer
bracket.
4. Hook the spring into the spring retainer bracket.
5. After reversing the cam, perform the calibration
procedures in the calibration of valve positioners and
transmitters section.
Calibration Of Valve Positioner
Or Valve Stem Position
Transmitter
Pre-Calibration Alignm ent
Note
The following procedures for pre-calibra­
tion alignment and calibration are applica­
ble for both the 3582 Series and the Type
3582i valve positioners and 3583 Series
valve stem position transmitters.
The purpose of alignment is to ensure the correct me­
chanical position of parts so the valve positioner can be
calibrated. Provide the appropriate supply pressure.
Also, provide an input signal to the positioner which can
be manually set at the midpoint of the desired input
signal range.
Refer to figure 16 for parts locations. Refer to figure 20
for key number locations unless otherwise indicated.
Position The flapper assembly by hand to different
settings on the beam assembly or by using a screwdriv­
er in the slot of the flapper setting adjustment.
Note
The beam is leveled at the factory prior to
shipment. Once the beam is leveled, no
additional leveling should be required un­
less the beam pivot pin or the bellows as­
sembly pivot pin are changed, the bellows
assembly or range spring are replaced, or
the valve positioner is changed to split
range operation.
To level the beam, proceed as follows:
Note
In the following steps, if it is not possible to
attain the required output pressure when
3582 and 3583 Series
adjusting a pivot point, adjust one of the
other pivot points slightly. Then, repeat the
original pivot adjustment. Continue this
process until the required output pressure
can be attained.
1. Stroke the actuator to its mid-travel position with a
handwheel or a manual loader. Refer to figures 4 and 7.
Lift the rotary shaft arm (key 2) so that the 0-degree
index marks on the rotary shaft arm align with the case
index marks as shown in figure 7. Then, position the
travel pin (key 60) so that it is perpendicular to the arm
and aligns with the appropriate total actuator travel
index mark on the rotary shaft arm. Tighten the locking
nut (key 62).
Note
Valve stem travels less than 1-1/8 inches
(29 mm) require that the travel pin be set at
the 1-1/8 inches travel index mark on the
rotary shaft arm.
2. Loosen the nozzle locknut and turn the nozzle
clockwise to its lowest position. Then screw the nozzle
out (counterclockwise) 2 turns and tighten the locknut.
3. Remove any loading pressure and/or disengage
any handwheel used to position the actuator. Connect
the necessary tubing from the valve positioner output to
the actuator pressure connection.
4. Connect the input to the valve positioner and set the
input signal value at midrange. For example, for a 3582
Series valve positioner with a 3 to 15 psig (0.2 to 1.0 bar)
input signal range, set the input signal at 9 psig (0.6 bar).
Then apply supply pressure to the valve positioner.
Note
For proper operation, the flapper must ap­
proach the nozzle squarely. Inspect the
nozzle/flapper alignment. Be sure the flap­
per is not loose, bent, or twisted.
5. Move the flapper assembly to zero on the beam
scale. The output pressure should be at the mid-point
value of the output pressure range. If not, loosen the
follower assembly screw locknut and adjust the follower
assembly screw until the output pressure is equal to the
mid-point value of the output pressurp range. Tighten
the locknut.
6. Move the flapper assembly to position 10 on the
direct-acting side of the beam scale. The output pres­
sure should be at the mid-point value of the output
pressure range. If not, loosen the bellows assembly
3582 and 3583 Series

Table 6. Minimum Travel with Given Pin Position

TRAVEL PIN MINIMUM TRAVEL

POSITION ALONG AVAILABLE
ROTARY SHAFT ARM Inch mm
1-1/8 1/4 6
1-1/2 5/16 8
2 7/16 11
2-1/2 1/2 13
3 5/8 16
4 7/8 22

locknut and adjust the bellows pivot pin until the output
pressure is equal to the mid-point value of the output
pressure range. Tighten the locknut.

7. Move the flapper assembly to the left to position 10

on the reverse-acting side of the beam. The output
pressure should be at the mid-point value of the output
pressure range. If not, loosen the beam pivot pin locknut
and adjust the beam pivot pin until the output pressure is
equal to the mid-point value of the output pressure
range. Tighten the locknut. Figure 17. Schematic Illustration of 3582 Series Positioner

8. Repeat steps 5, 6, and 7 to optimize alignment.

Recheck to make sure the flapper approaches the noz­
zle squarely. If it does not, adjust the nozzle and re-level
the beam. After alignment, the valve positioner is ready
for calibration.
the travel by moving the flapper assembly to a higher
number on the beam. If the desired stem travel occurs
before the input signal reaches the high value of the
input signal range, decrease the travel by moving the
flapper assembly toward a lower number on the beam.

5. Repeat steps 3 and 4 until the correct travel is

Calibration
achieved. Each time the flapper position is changed in
1. Shut off the supply pressure to the valve positioner. step 4, repeat step 3 to provide proper zero.
Connect or reconnect the necessary tubing from the
valve positioner output to the actuator supply connec­
Moving the flapper assembly toward zero on the beam
tion. Connect the input to the valve positioner and set
scale decreases stem travel. Table 6 lists the minimum
the input signal value at midrange.
stem travel available for different travel pin settings. For
example, with a travel pin setting of 2 the minimum stem
2. Move the flapper assembly to approximately posi­
travel possible, for the full input signal range, would be
tion 6 in the proper operating quadrant of the beam
7/16-inch (11 mm).
(direct or reverse acting), and apply supply pressure to
the valve positioner. The actuator should move close to
its mid-travel position. If it does not, first check for loose
linkage or improper cam installation. If the beam is not
properly leveled, a minor nozzle height adjustment
might be necessary to make the desired input signal
Principle of Operation
value correspond to the starting point of travel.
3582 Series V alve Positioners
3. Apply an input signal equal to the low value of the
input signal range. For example, for a 3582 Series valve The 3582 Series (the Type 3582 and Types 3582A, C, D,
positioner with a 3 to 15 psig (0.2 to 1.0 bar) input signal and G pneumatic valve positioners) accept a pneumatic
range, set the input signal at 3 psig (0.2 bar). Loosen the input signal from a control device. Figure 17 is an
nozzle locknut and adjust the nozzle until the actuator operational schematic for a direct-acting pneumatic
moves to the proper end of its travel. Changing the valve positioner.
nozzle position is intended only as a means of zero trim
adjustment. Whenever nozzle position is changed, the As shown in figure 17, in a diaphragm-actuated, sliding
zero reference point is changed. stem control valve package with a 3582 Series valve
positioner, supply pressure is connected to the Type
4. Apply an input signal equal to the high value of the 83L relay. A fixed restriction in the relay limits flow to the
input signal range and observe the actuator stem travel. nozzle so that when the flapper is not restricting the
If the stem travel is short of its expected range, increase nozzle, air can bleed out faster than it is being supplied.

18

4-20 MILLIAMPERE ■
Figure 18. Schematic Illustration of Type 3582/ Positioner
The input signal from the control device is connected to
the bellows. When the input signal increases, the bel­
lows expands and moves the beam. The beam pivots
about the input axis moving the flapper closer to the
nozzle. The nozzle pressure increases and, through
relay action, increases the output pressure to the actua­
tor. The increased output pressure to the actuator
causes the actuator stem to move downward. Stem
movement is fed back to the beam by means of a cam.
As the cam rotates, the beam pivots about the feedback
axis to move the flapper slightly away from the nozzle.
The nozzle pressure decreases and reduces the output
pressure to the actuator. Stem movement continues,
backing the flapper away from the nozzle, until equilibri­
um is reached.
When the input signal decreases, the bellows contracts
(aided by an internal range spring) and the beam pivots
about the input axis to move the flapper away from the
nozzle. Nozzle pressure decreases and the relay per­
mits the release of diaphragm casing pressure to atmo­
sphere. The actuator stem moves upward. Through the
cam, stem movement is fed back to the beam to reposi­
tion the flapper closer to the nozzle. When equilibrium
conditions are obtained, stem movement stops and the
flapper is positioned to prevent any further decrease in
diaphragm case pressure.
The principle of operation for reverse acting units is
similar except that as the input signal increases, the
diaphragm casing pressure is decreased. Conversely, a
decreasing input signal causes an increase in the pres­
sure to the diaphragm casing.
Type 3582i V alve Positioner'
As shown in figure 18, the Type 3582i electro-pneumatic
valve positioner has a Type 582i electro-pneumatic con­
verter attached to the valve positioner. The 582i con­
tains an l/P module which provides a pneumatic output
3582 and 3583 Series
Figure 19. Schematic Illustration o f 3583 Series Transmitter
proportional to a dc current input signal. The dc current
input operates coils in a force balanced beam system
which in turn, control bleed air through an integral
nozzle/flapper arrangement. The nozzle pressure pro­
vides the pneumatic input signal pressure used by the
pneumatic valve positioner.
3583 Series V alve Stem Position
Transm itters
3583 Series (Type 3583, 3583C) pneumatic valve stem
position transmitters are mechanically linked to the
valve stem in a diaphragm-actuated, sliding-stem con­
trol valve package. A change in the position of the valve
stem changes the output pressure produced by the
position transmitter. This signal is then piped to a report­
ing or recording device to indicate valve stem position.
The action of a valve stem position transmitter can be
changed by reversing the internal cam. The valve stem
position transmitter cam is supplied with an arrow
stamped on one side. The cam can be positioned to
obtain either increasing or decreasing output pressure
with downward stem motion. If the cam arrow points
toward the nozzle, the output pressure increases; if the
cam points away, the output pressure decreases with
downward stem motion. ‘
Figure 19 depicts a diaphragm actuator which produces
downward stem motion for increasing actuator pres­
sure. For a stem position transmitter, the flapper assem­
bly is always positioned in the reverse-acting quadrant
19
3582 and 3583 Series
of the beam. Supply pressure is connected to the Type
83L relay. A fixed restriction in the relay limits flow to the
nozzle so that when the flapper is not restricting the
nozzle, air can bleed out faster than it is being supplied.
As the pressure to the diaphragm actuator increases,
the valve stem moves downward, causing the internal
cam to rotate. Cam rotation causes the beam to pivot
about the input axis moving the flapper closer to the
nozzle. The nozzle pressure increases which, through
relay action, increases the output pressure.
The output pressure is also connected to the bellows.
As the output pressure increases, the bellows expands,
causing the beam to pivot about the feedback axis
moving the flapper slightly away from the nozzle until
equilibrium is reached. The position transmitter output
pressure is now proportional to the valve stem position.
As the pressure to the diaphragm actuator decreases,
the valve stem moves upward, causing the internal cam
to rotate. Cam rotation causes the beam to pivot about
the input axis moving the flapper away from the nozzle.
The nozzle pressure decreases which, through relay
action, decreases the output pressure. The bellows
contracts, causing the beam to pivot about the feedback
axis and moving the flapper closer to the nozzle until
equilibrium is reached. The position transmitter output
pressure is again proportional to the valve stem
position.
Maintenance
W A R N IN G
Avoid personal injury from sudden release
of process pressure. Before performing
any maintenance operations:
e Disconnect any operating lines provid­
ing air pressure, or a control signal to the
actuator. Be sure the actuator cannot sud­
denly open or close the valve.
• Use bypass valves or completely shut
off the process to isolate the valve from
process pressure. Relieve process pres­
sure on both sides of the valve.
• Use lock-out procedures to be sure that
the above measures stay in effect while
you work on the equipment.
For explosion proof applications, disconnect power
before removing the converter housing cap in an ex­
plosive atmosphere.
20
Due to normal wear or damage from external sources
(such as debris in the supply medium), periodic mainte­
nance or repair of the valve positioner or valve stem
position transmitter may be necessary. Maintenance of
these units consists of troubleshooting, removal for
inspection, and replacement of component parts.
CAUTION
When replacing components, use only
components specified by Fisher Controls.
Substitution with other components may
result in the positioner or transmitter no
longer meeting safety certification require­
ments. Also, always use proper component
replacement techniques. Improper tech­
niques and poor quality repairs can impair
the safety features of the device.
In case of operational difficulties, the valve positioner or
valve stem position transmitter should first be checked
to see that adjustments have been properly made. All
pressure lines and connections should be checked for
leaks.
The pneumatic relay and gaskets should also be in­
spected and replaced if necessary. If necessary, clean
or replace the relay restriction. Remove the restriction
assembly (key 9 in figure 25). Clean the restriction,
install a new O-ring (key 14 in figure 25) if necessary,
and replace the restriction assembly.
Instructions are given below for:
• changing the range spring;
• replacing gaskets, nozzle O-rings, and the relay;
• adjusting the flapper pivot;
• replacing the Type 582i converter primary O-ring
and filter;
• replacing the Type 582i converter cover O-ring;
• removing the Type 582i converter; and
• reassembling the Type 582i converter.
Changing the Range Spring
Unless otherwise noted, key number locations are
shown in figure 20.
The range spring is inside the bellows assembly. Stan­
dard range spring data is given in table 4. When an input
signal range is split to operate two or more control
valves, normally changing the range spring is not neces­
sary. The input signal range for the range spring is
stamped on the nameplate.

Perform the following procedure to change the range
spring In a valve positioner or valve stem position
transmitter.
1. Unhook the extension springs (keys 27, 77) from
the beam (key 29).
2. Loosen and remove the two screws (key 13), and
lock washers (key 12) that hold the bellows assembly
(key 7) in place.
3. Lift out the beam and bellows assembly. Be careful
not to lose the small O-ring (key 11).
4. Loosen the machine screw (key 10), and remove the
range spring (key 8).
5. Install a new range spring, making sure the small
end of the spring is against the spring seat (key 9).
Replace the spring seat and tighten the screw.
6. If the O-ring (key 11) is worn or damaged, replace it
with a new one after applying lubricant (key 94). Make
sure the O-ring is in place, then install the bellows
assembly, securing it with two mounting screws and
lock washers.
7. Install the beam over the pivots and hook the
springs to the beam.
8. Make any minor adjustments that may be neces­
sary to re-level the beam as outlined in the pre-calibra­
tion alignment procedures of the valve positioners or the
valve stem position transmitters calibration section. Af­
ter leveling the beam, calibrate the unit according to the
appropriate calibration instructions.
Replacing G askets
Unless otherwise noted, key numbers used in this pro­
cedure are shown in figures 23 and 24.
A gasket (key 34C) is located behind the bypass handle
(key 34D) of the 3582 Series valve positioners or mani­
fold (key 34D) of the 3583 Series valve stem position
transmitters.
1. Remove the screw (key 34G), and lift out the bypass
handle or manifold.
2. Remove the gasket.
3. Apply lubricant (key 94) to both sides of the replace­
ment gasket when used with the bypass assembly of the
3582 Series valve positioners. Do not apply lubricant to
the gasket when the bypass assembly is not used.
4. Set the new gasket in place on the four locating pins
and replace the bypass handle or manifold.
3582 and 3583 Series
The case gasket (key 104) is located between the case
(key 1 in figure 20) and the bypass block (key 34A) in a
3582 Series valve positioner or a 3583 Series valve stem
position transmitter or the housing of the Type 582i
converter (key 1 in figure 26).
5. Remove the two mounting screws (key 105 in fig­
ures 23 and 24; key 11 in figure 26) that hold the bypass
block or converter housing to the case and remove the
unit to expose the case gasket.
6. Install a new gasket and replace the bypass block
or converter housing.
Replacing the N ozzle O-Ring
Unless otherwise noted, key numbers are shown in
figures 21 and 22.
1. Remove the two screws (key 19C) that hold the
flapper and follower assembly (keys 19B and 19G) to the
adjustment arm (key 19A).
CAUTION
For proper operation, be careful not to bend
or twist the flapper or nick the nozzle orifice
during reassembly.
2. Carefully remove the flapper and follower assembly
for access to the nozzle (key 18 in figure 20).
3. Loosen the locking nut (key 71), and unscrew the
nozzle (key 18).
4. Remove the locking sleeve (key 72) from the nozzle
adaptor (key 3). The nozzle adaptor is bonded to the
positioner case with adhesive (key 96) and should not be
removed.
5. Inspect the O-ring (key 73) on the nozzle adapter
and replace the O-ring, if necessary. If replacing the O-
ring, apply lubricant (key 93) to the O-ring before install­
ing it on the nozzle adapter.
6. Reinstall the nozzle onto the nozzle adapter, leav­
ing the locking nut loose.
7. Replace the flapper and follower assembly. Make
sure the letter "T” on the flapper is visible from the front
of the positioner or transmitter.
8. Perform the pre-calibration alignment and calibra­
tion procedures in the Calibration of Valve Positioner or
Valve Stem Position Transmitter section.
21

3582 and 3583 Series
Removing and Replacing the Relay
Use the following procedure when removing or replac­
ing a relay assembly that requires maintenance, or when
installing a replacement relay assembly. Refer to figure
25 for key number locations.
1. For valve positioners using a bypass, direct action,
and a full-range input signal, place the positioner in
bypass operation by moving the bypass handle to BY­
PASS. Then, shut off the supply pressure. For all other
valve positioners and valve stem position transmitters,
isolate the control valve from the system and shut off all
pressure lines.
Note
A difference between input and valve posi­
tioner output pressure could cause a tran­
sient bump in the controlled system when
the bypass handle is moved to BYPASS.
2. Remove the Type 83L relay (key 32 in figure 20)
from the back of the case by loosening the two mounting
screws (key 10).
3. Reinstall the new relay assembly on the case, mak­
ing sure the O-rings (keys 13 and 15) are in place.
Secure with the two mounting screws (key 10).
4. Resume operation by moving the bypass handle to
the POSITIONER position or by connecting the valve
positioner or valve stem position transmitter and control
valve to the system.
Relay M aintenance
Use the procedure below to repair and replace the relay
assembly. Refer to figure 25 for key number locations.
Obtain the relay repair kit listed in the parts kits. This kit
provides the parts required to repair the relay assembly.
1. Remove the relay by performing steps 1 and 2 in the
relay removal and replacement procedure.
2. Remove the four screws (key 16) and separate the
relay base (key 1) from the exhaust block (key 2) by
inserting a screwdriver between the external casting
lugs and twisting.
3. Thread the mounting screws (key 10) out of the
exhaust block (key 2), then separate the exhaust block
from the output block assembly (key 4) and the output
block assembly from the relay cap (key 3).
4. Remove the diaphragm (key 8), diaphragm assem­
bly (key 7), spring (key 12), inner valve (key 6), gasket
(key 5) and spring (key 11).
22
N
V
FISHER
5. Remove the nozzle and adapter assembly (key 9)
and remove the O-rings (keys 14 and 19). Clean the
nozzle opening with solvent and blow dry with air. If the
opening is plugged, use a wire to clear the opening. Be
careful not to enlarge the hole. Then, clean with solvent
and blow dry with air.
6. Apply lubricant (key 20) to the O-rings (keys 14 and
19) before re-installing the nozzle and adapter assembly
into the relay base. Do not over tighten.
7. Fold the diaphragm assembly (key 7) over and push
it through the exhaust block (key 2). Set the diaphragm
assembly and exhaust block aside.
8. Invert the relay cap (key 3) and insert the mounting
screws (key 10) through the holes in the relay cap. Hold
the screws in place while assembling the remaining
parts. The screws serve as studs to keep the parts
aligned as they are assembled.
9. Install the spring (key 11). Align the holes in the
gasket with the holes in the cap. Also, be sure the tab on
the gasket aligns with the casting lug on the cap. Place
the gasket (key 5) on the relay cap. Set the inner valve
(key 6) on the spring.
10. Align the casting lugs and holes in the output block
assembly (key 4) with the casting lug and holes in the
reiay cap (key 3). Place the output block assembly on the
gasket. The inner valve will protrude through the valve
seat insert of the output block assembly. Install the
spring (key 12). Hold the assembled parts in place.
11. Ensure the tab on the diaphragm assembly (key 7)
aligns with the casting lug on the exhaust block (key 2).
With the casting lug on the exhaust block aligned with
the casting lug on the output block assembly, place the
diaphragm assembly and exhaust block over the output
block assembly so that the inner valve fits into the hole
in the diaphragm assembly. Screw the mounting screws
through the exhaust block. Hold the assembled parts in
place.
12. Ensure the holes in the diaphragm (key 8) align
with the holes in the exhaust block (key 2) and that the
tab on the diaphragm aligns with the casting lug on the
exhaust block. Place the diaphragm on the exhaust
block (key 2).
13. Align the casting lug on the relay base (key 1) with
the casting lug on the exhaust block (key 2). Place the
relay base on the diaphragm.
14. Insert the four screws (key 16) through the relay
base (key 1), exhaust block, output block assembly and
into the relay cap. Tighten evenly in an “X” pattern.
15. Install the relay assembly on the positioner case.
16. Apply supply pressure to the positioner case and
check the relay assembly for leaks with soap solution.

Adjusting the Flapper Pivot
Key numbers used in this procedure are shown in figure
22.
1. Loosen the two screws (key 19C).
2. Tighten the pivot pin (key 19L) by compressing the
upturned ears of the arm support (key 19K). Tighten the
screws (key 19C) and make sure the flapper (key 19B)
does not rub on the supports.
3. The flapper should be snug, but not constricting to
pivot action.
Replacing the Type 582i Converter
Prim ary O-Ring and Filter
Key numbers used in this procedure are shown in figure
26.
1. Locate and remove the nozzle restriction adaptor
assembly (key 4).
2. Inspect and replace, if necessary, the O-rings (keys
5 and 6). Apply lubricant (key 15) to the O-ring before
replacing.
3. Inspect and replace the filter cartridge (key 23).
Replacing the Type 582i Converter
Housing Cap O-Ring
Key numbers used in this procedure are shown in figure
26.
1. Unscrew and remove the converter housing cap
(key 2). Inspect and replace the O-ring (key 8), if neces­
sary. Apply lubricant (key 15) to the O-ring before
replacing.
Removing the Type 582i Converter
During the following converter removal procedures, re­
fer to figure 26 for key number locations.
CAUTION
The l/P module should never be disassem­
bled because the magnetism in the coils
will decrease permanently. If troubleshoot­
ing or alignment attempts indicate a faulty
l/P module, replace the module or return
the converter to your Fisher sales repre­
sentative or sales office for repair.
3582 and 3583 Series
Note
To check the operation of the l/P module,
remove the pipe plug (key 12), and connect
a pressure gauge. Provide a 20 psig supply
pressure to the converter. With a 4-milliam-
pere input signal the pressure output
should read 2.3 to 3.5 psig (0.16 to 0.24 bar).
With a 20-milliampere input signal the pres­
sure output should read 14.0 to 15.5 psig
(0.96 to 1.07 bar).
1. Turn off the input signal to the converter. Release all
supply pressure from the valve positioner.
2. Remove the housing cap (key 2).
3. Note the location of the wires, disconnect the field
wiring from the terminal block. Disconnect the ground­
ing wire from the external ground screw (key 10).
4. To remove the l/P module, remove the two screws
(key 9), and pull the module out of the housing. Inspect
the O-ring (key 6) and replace it, if necessary. Apply
lubricant (key 15) to the O-ring before replacing.
a. To remove the entire Type 582i converter from the
Type 3582i valve positioner, continue with steps 4
through 6.
b. To replace the l/P module only, obtain a replace­
ment l/P module listed in the parts list and refer to the
procedures for reassembling the Type 582i converter.
4. Disconnect the supply tubing, output tubing, and
electrical conduit from the converter.
5. If necessary, remove the Type 67AFR regulator by
removing the two screws (key 13). Then, remove the
regulator from the converter assembly. Inspect the O-
ring (key 3) and replace it if necessary. Apply lubricant
(key 15) to the O-ring before replacing.
6. Remove the two screws (key 11) holding the Type
582i converter to the valve positioner case. Remove the
converter from the valve positioner case (key 1 in figure
20). Inspect the gasket (key 20) and replace it if
necessary.
Reassem bling the Type 582i Converter
During the following converter reassembly procedures,
refer to figure 26 for key number locations.
1. If the Type 582i converter was removed from the
valve positioner, install a new gasket (key 20) between
the converter housing and the valve positioner case.
Attach the converter housing to the valve positioner
case with the screws (key 11) and tighten the screws.
23
3582 and 3583 Series

2. If the l/P module was removed from the Type 582i Parts Kits
converter, reinstall the l/P module in the converter hous­
ing. Secure the l/P module with the two screws (key 9). Description Part Number
Repair kit for positioner/transmitter
3. If other valve positioner components are removed, Kit contains keys 11, 16, 17, 33B, 34C, 34H, and 73.
refer to the appropriate reassembly procedures and This kit also contains keys 18C and 18E
for 3580 and 3581 Series positioners
assemble the valve positioner completely. For standard temperature applications R3580X00022
For high temperature applications R3580X00032
4. Reconnect the supply tubing, output tubing, and Repair kit for Type 582i electro-pneumatic converter
conduit to the valve positioner. Kit contains keys 3, 5, 6, 8, 20, and 23 R582X000012
Repair kit for Type 83L Relay
Kit contains keys 5, 6, 7, 8, 11, 13, 14, 15, and 19
5. Reconnect the wiring to the terminal block. Do not For Relays with std. const. R83LX000012
overtighten the terminal screws. Maximum torque is 4 For Relays with hi-temp. const. R83LX000022
Ibf-in. (0.45 N-m). Reconnect the grounding wire to the Replacement kit for Type 83L Relay
housing ground screw (key 10) and replace the cap (key Kit contains keys 10, 13, 15, 32
For 3582 Series, std. const. R3580XRS012
2). For 3582 Series, hi-temp. const. R3580XRH012
For 3583 Series, std. const. R3580XRS022
For 3583 Series, hi-temp. const. 32B0255X0E2
Note

To check the operation of the l/P module, Parts List

remove the pipe plug (key 12), and connect Note
a pressure gauge. Provide a 20 psig supply
pressure to the converter. With a 4-milliam- Parts in the following list are common to
pere input signal the pressure output both the 3582 Series valve positioners and
should read 2.3 to 3.5 psig (0.16 to 0.24 bar). the 3583 Series position transmitters, un­
With a 20-milliampere input signal the pres­ less identified by specific type or series
sure output should read 14.0 to 15.5 psig number.
(0.96 to 1.07 bar).
When replacing either extension spring
(key 27 or 77 in figure 20), check the springs
7. Plug the output connection and apply 35 psig (2.4 being used in the valve positioner or valve
bar) to the supply pressure connection. stem position transmitter. If one of the
springs has a red color code and the other
has a yellow color code, either spring could
CAUTION be replaced independently. If the springs
being used do not have color codes, both
Do not apply a signal greater than 35 milli- springs must be replaced.
amperes to the l/P module. Higher signal
values may damage the converter module.
Diagnostic Connections (figure 9)
8. Apply a 20 milliampere dc current input signal to the FlowScanner™ valve diagnostics system hook-up.
converter.
Includes connector body and body protector. If ordered
9. Check for leaks using a soap solution. Check any for units with gauges, a stem is also included. Also, part
components which were disassembled or number provides correct quantities of each item.
disconnected.
Description Part Number
For 3582 Series pneumatic valve positioners
For units w/gauges
Parts Ordering SST fittings 12B8045 X012
brass fittings 12B8045 X022
For units w/o gauges
SST fittings 12B8045 X032
A serial number is assigned to each valve positioner or brass fittings ' 12B8045 X042
valve stem position transmitter and is stamped on the For 3582I electro-pneumatic valve positioners
nameplate. Always refer to this number when corre­ For units w/gauges
sponding with your Fisher representative regarding SST fittings 12B8046 X012
brass fittings 12B8046 X022
spare parts or technical information. When ordering For units w/0 gauges
parts, also give the eleven-digit part number shown in SST fittings 12B8046 X032
the following parts list. brass fittings 12B8046 X042

24 FlowScanner is a mark owned by Fisher Controls International Inc.

 3582 and 3583 Series

f-s Positioner/Transm itter Common Parts Key Description Part Number

(figure 20) Note

Key Description Part Number Bypass block assembly (key 34) and parts are listed
1 Case Assembly 11B8556 X012 later in this parts list. Non-bypass block assembly (also
2* Shaft Assembly, SST/steel key 34) and parts are listed following the bypass block
For travel up to 2-1 /8 inch (54 mm) 15A9609 X012 assembly and parts.
For travel up to 4-inch (102 mm) 15A9609 X022
3 Nozzle Adaptor, SST 12A2613 X012 Parts 35, 36 and 37 are shown in figures 23 and 24.
4 Cam, SST
Cam A (For all types) 45A9614 X012
Cam B (For all except Types 3583, 3583C) 45A9615 X012 35 Pipe Plug, pi steel
Cam C (For all except Types 3583, 3583C) 45A9616 X012 Req'd when gauges are not used:
3 req'd for Type 3582, 3582A
5 Machine Screw, pi steel 1 req’d for Types 3583, 3583C 1D8293 28982
(3582 Series only, not shown) 1A7690 28982 36* Output Gauge, Dual Scale
6 Cam Bolt, 416 SST 12A2616 X012 Types 3582, 3582G, 3583
7* Bellows Assembly, brass 12A7360 X012 0-30 psig/0-2 kg/cm2 11B4040 X042
8 Range Spring, pi steel (also see table 4) 0-60 psig/0-4 kg/cm2 11B4040 X052
3 to 15 PSI (0.2 to 1.0 bar) 1V6217 27012 36* Output Gauge, Triple Scale
5 to 25 PSI (0.3 to 1.7 bar) 1V6218 27012 Types 3582, 3582G, 3583
6 to 30 PSI (0.4 to 2.0 bar) 1V6219 27012 0-30 psig/0-0.2 MPa/0-2 bar 11B4040 X012
0-60 psig/0-0.4 MPa/0-4 bar 11B4040 X022
9 Spring Seat, aluminum 12A7355 X012 37* Supply Gauge, Dual Scale
10 Machine Screw, pi steel 1B2856 28982 Types 3582, 3582G, 3583
11* O-Ring 0-30 psig/0-2 kg/cm2 11B4040 X042
Nitrile (std. const.) 1F4636 06992 0-60 psig/0-4 kg/cm2 11B4040 X052
Fluoroelastomer (hi-temp. const.) 1N5714 06382
12 Lockwasher, pi steel (2 req’d) 1H3223 28982 37* Supply Gauge, Triple Scale
Types 3582, 3582G, 3583
13 Machine Screw, pi steel (2 req'd) 1A3294 X0022 0-30 psig/0-0.2 MPa/0-2 bar 11B4040 X012
18 Nozzle, SST 0-60 psig/0-0.4 MPa/0-4 bar 11B4040 X022
3582 Series 12A9840 X012 38 Extension Spring, pi steel 12A2937 X012
3583 Series 12A9841 X012 39 Shipping Stop (not shown) 1V4517 06992
19 Flapper Sub-Assembly 13A1451 X012 42 Hex Nut, pi steel (2 req'd) 1A5735 28982

43 Spring Retainer Bracket, SST 25A9611 X012

Note 44 Gear Mounting Plate, aluminum 12A2611 X012
45 Locking Nut, aluminum 12A2618 X012
Parts 19A through 19L are shown in figure 22.
Note
19A Adjustment Arm, pi steel 2V6066 25182

19B Flapper, SST 13A1314 X012 Parts 46 and 47 are shown in figures 23 and 24.
19C Machine Screw, pi steel (2 req'd) 1V6056 28982
19D Flapper Arm, aluminum 23A1318 X012
19E Machine Screw, pi steel (2 req'd) 1A3450 28982 46* Instrument Gauge, Dual Scale
0-30 psig/0-2 kg/cm2
19F Flapper Spring, SST 13A1316 X012 (3-15 psig/0.2-1.0 kg/cm2 ranges) 11B4040 X042
19G Follower Assembly, 416 SST/nylon 1K3758 000A2 0-60 psig/0-4 kg/cm2
19H Hex Nut, pi steel 1A3303 28982 (5-25 psig/0.4-1.8 kg/cm2 ranges)
19J Lockwasher, pi steel 1H2671 28982 (6-30 psig/0.4-2.0 kg/cm2 ranges) 11B4040 X052

19K Arm Support, SST 13A1315 X012 46* Instrument Gauge, Triple Scale
19L Pivot Pin, 440C SST 13A1317 X012 0-30 psig/0-0.2 MPa/0-2 bar
20 Setting Adjustment Gear, nylon 2U9052 06162 (3-15 psig/20-100 kPa/0.2-1 bar ranges) 11B4040 X012
21 Flapper Assembly Retainer, SST 2U9053 36012 0-60 psig/0-0.4 MPa/0-4 bar
(5-25 psig/35-170 kPa/0.3-1.7 bar ranges) 11B4040 X022
23 Machine Screw, pi steel (2 req'd) 1A3450 28982 (6-30 psig/40-200 kPa/0.4-2 bar ranges) 11B4040 X022
25 Nameplate, aluminum 12B4376 X0A2 47 Test Connection
26 Self Tapping Screw, steel (2 req’d) 1P4269 28982 (3 req’d for Types 3582C, 3582D)
27 Extension Spring®, (2 req’d for Type 3583C) 1N9088 99012
pi steel, yellow color code 14A8214 X012 71 Locking Nut, aluminum 12A2615 X012
72 Locking Sleeve, aluminum 12A2619 X012
28 Machine Screw, pi steel (3 req’d) 1H7365 28982
29 Beam Sub-Assembly 12A8869 X022 73* O-Ring (2 req’d) *
30 Bellows Pivot Pin, SST . 12A7357 X012 Nitrile (std. const.) 10A0871 X012
32 Type 83L Relay— See “ Type 83L Relay" section Fluoroelastomer (hi-temp. const.) 14A0592 X012
of this parts list 75 Machine Screw, pi steel 1H2675 28992
76 Beam Pivot Pin, SST 12A7358 X012
33 Cover Assembly 77 Extension Spring®,
For all types, plastic 22B4905 X012 pi steel, red code color 14A8215 X012

* Recommended spare part.

2. Please read the note at the beginning of the Parts List section. 25
3582 and 3583 Series

S E C TIO N A -A

NOTE:
[T> APPLY A GOOD-QUALITY THREAD
LOCKING COMPOUND TO THE THREAD
OF THE NOZZLE ADAPTOR (KEY 3). S E C TIO N C-C
41BS55S-B

Figure 20. 3582 and 3583 Series Positioners and Transmitters Assembly Drawing

26
 3582 and 3583 Series

Key Description Part Number

78 Speed Nut, SST 12A0801 X012

93 Anti-seize Compound, Zink Plate No. 770<3>
1 pound (0.5 kg) can (not furnished
with positioner) 1M5240 06992
94 Lubricant, Dow Corning 111<4) Key Description Part Number
5.3 oz (0.1 kg) tube (not
furnished with positioner) 1M5282 06992 For Units Without Bypass (figure 24)
95 Lubricant, Lubriplate MAG-1 <5>
1 lb (0.45 kg) can (not 34 Non-Bypass Block Assembly
furnished with positioner) 1M1100 X0012 Std. const.
Types 3582A, 3582C, 3582G 21B8555 X012
96 Adhesive, Loctite No. 680<®> Types 3583, 3582C 21B8554 X012
50 cc bottle 1M3630 X0012 Hi-temp. const.
Types 3582A, 3582C 21B8555 X022
Note Type 3583C 21B8554 X022
34A Bypass Block, aluminum 41B5987 X012
Parts 104 and 105 shown in figures 23 and 24. Part 107 34C* Gasket
shown in figure 24. Std. const. 1V6062 04132
Hi-temp. const. 1V6062 X0012
34D Manifold
103* O-Ring, nitrile, (not shown) used with integrally 3582 Series, std. and hi-temp. const. 1V9429 08012
mounted Type 67AFR filter regulator 1E5914 06992 3583 Series, std. and hi-temp. const. 10A0746 X012
104* Case Gasket, 34G Cap Screw, pi steel 1J5241 28982
Std. const. 1U9078 04132
Hi-temp. const. 1U9078 X0012
105 Machine Screw, SST (2 req’d) 12B0909 X012
107 Pipe Plug, pi steel for Type 3583C 1A7675 24662 Type 83L Relay (figure 25)
108 Shipping tag (not shown) 1N5864 06992
1 Relay Base, aluminum
3582 Series 42B0245 X012
3583 Series 12B0246 X012
For Units With Bypass (figure 23) 2 Exhaust Block, aluminum 23A0141 X012
3 Relay Cap, aluminum 3U9019 08012
Note 4 Output Block Assembly
aluminum/SST 1U9006 000A2
Bypass block assembly (key 34) and parts are listed
below. Non-bypass block assembly (also key 34) and 5* Gasket
parts are listed following the bypass block assembly Nitrile/nylon (std. const.) 1V5579 02032
and parts. Polyacrylic/nylon (hi-temp. const.) 1V5579 X0042
6* Inner, Valve, SST 1U9016 35032
34 Block Assembly 7* Diaphragm Assembly
Types 3582, 3582D 21B8557 X012 Std. const. 1U9018 000A2
34A Bypass Block, aluminum 41B5987 X012 Hi-temp. const. 1U9018 X0072
34B Groove-Pin, pi steel (not shown) (4 req’d) 1L9428 28992 8* Diaphragm
34C* Bypass Gasket, cork 1V6062 04132 Nitrile/nylon (std. const.) 1V5578 02032
34D Bypass Handle, aluminum 2V6071 08012 Polyacrylic/nylon (hi-temp. const.) 1V5578 X0052

34E Spring, pi steel 1V6063 X0022 9 Nozzle & Adaptor Assembly "
34F Washer, polyethylene • 1V6061 06992 3582 Series 12B0247 X012
34G Screw, pi steel 1V6058 24642 3583 Series 12B0248 X012
34K Spring Seat, SST 1V6060 35032 10 Relay Mounting Screw, SST (2 req’d) 1U9012 38982
34L Spring Retainer, pi steel 11 Spring, SST 1P4204 37022
Types 3582, 3582D 1V6059 25072 12 Spring, pi steel 19A8907 X012
* Recommended spere pert.
3. Trademark of Armite Laboratories.
4. Trademark of Dow Corning Corp.
5. Trademark of Flake Brothers Refining Co.
6. Trademark of Locktite Corp. 27
3582 and 3583 Series

Figure 23. 3582 Series Block Assembly with Bypass

NOTE:
(T> PIPE PLUG (KEY 107) ON 3683 AND 3583C ONLY.
Figure 24. 3582 and 3583 Series Block Assemblies without Bypass

28
 3582 and 3583 Series

Figure 25. Type 83L Relay Sub-Assembly (Key 32)

Key Description Part Number Key Description Part Number

13* O-Ring
5* O-Ring, Nitrile 1P4207 06992
Nitrile (std. const.) 17A6891 X012 6* O-Ring, Nitrile (2 req’d) 1C8538 X0022
Fluoroelastomer (hi-temp. const.) 17A6891 X022 7 Tire Valve (not shown)
14* O-Ring
(2 req’d w/tire valve option) 1N9088 99012
Nitrile (std. const.) 1D1346 06992 8* O-Ring, Nitrile 1H8762 X0012
Fluoroelastomer (hi-temp. const.) 1D2899 X0022
15* O-Ring (3 req’d) 9 Machine Screw, 304 SST (2 req’d) 1A9021 X0012
Nitrile (std. const.) 1D6875 06992 10 Wire Retaining Screw (2 req’d) 16A2821 X012
fluoroelastomer (hi-temp. const.) 1N4304 06382 11 Machine Screw, SST (2 req’d) 12B0909 X012
16 Machine Screw, SST (4 req’d) 1A8176 X0012 12 Pipe Plug, steel (2 req'd w/pipe plug option) 1E8231 28982
18 Screen Insert, MONEL<7) (2 req’d) 13A0103 X012 13 Screw, pi steel, used with
19* O-Ring
integrally-mounted Type 67AFR
Nitrile (std. const.) 1D1347 06992 filter/regulator (2 req’d) 1C3988 24052
fluoroelastomer (hi-temp. const.) 1 N4239 06382 14* Supply Gauge, Dual Scale
20 Lubricant, Dow Corning 111 (not
0-30 psig/0-2 kg/cm2 11B4040 X042
furnished with positioner) 5.3 oz (0.1 kg) tube1M5282 06992 0-60 psig/0-4 kg/cm2 11B4040 X052
14* Supply Gauge, Triple Scale
0-30 psig/0-0.2 MPa/0-2 bar 11B4040 X012
Type 582i (figure 26) 0-60 psig/0-0.4 MPa/0-4 bar 11B4040 X022
15 Lubricant, Lubriplate MAG-1, 1 lb
—* l/P Module 33B7073 X012 (0.45 kg) can (not furnished with positioner) 1M1100 X0012
Housing 16 Anti-seize compound, Zink Plate No. 770
1/2-inch NPT conduit connection 21B5991 X012 1 pound (0.5 kg) can (not furnished
Cap, aluminum ' 31B2305 X012 with positioner) 1M5240 06992
O-Ring, nitrile, used with integrally-mounted 18 Self-Tapping Screw, SST (2 req'd)
Type 67AFR filter regulator 1P4269 28982
1E5914 06992 19 Nameplate, SST,
Nozzle Restriction Assembly,
without 3rd party approvals 11B5625 X0A2
Aluminum/Brass/Sapphire 13B7116 X012 20* Case Gasket, cork 1U9078 04132

* Recommended spare part.

7. Trademark of International Nickel Co.
29
3582 and 3583 Series

Key Description Part Number

21 Cable Gland, plastic,

for use with M20 housing 11B3870 X012
22* Output Gauge, Dual Scale
0-30 psig/0-2 kg/cm2 11B4040 X042
0-60 psig/0-4 kg/cm2 11B4040 X052
22* Output Gauge, Triple Scale
0-30 psig/0-0.2 MPa/0-2 bar 11B4040 X012
0-60 psig/0-0.4 MPa/0-4 bar 11B4040 X022
23* Filter 11B5996 X012
24 Vent Assembly 11B8279 X012

Mounting Parts
For Mounting 3582, 3582i, or 3583 Only
(figure 3)

Note

Part 48 also shown in figure 27.

48 Connector Arm, pi steel

Type 478 (Type 3583 only)
Size 40 30A4897 X012
Sizes 46 & 60 3V4796 25212
Type 513
Size 20 2V6722 25212
Size 32 2U9099 25212
Type 650
Size 30 20A5177 X012
Size 40 10A4870 X012
Size 60 10A4871 X012
Type 656
Sizes 30, 40, & 60 2V1705 25212
Types 657, 667
W/o side-mtd. h'wheel
Sizes 30 & 34 1U9101 000A2
Sizes 40 thru 100 2U9099 25212
W/side-mtd. h’wheel
Size 34 2V1889 25212
Sizes 40, 50, & 60 2U9095 25212
Size 45 & 46 2V1705 25212
Sizes 70 thru 100 2U9099 25212
48 Connector Arm, pi steel (Cont'd)
Type 657-4, 667-4 2U9099 25212
Type 657-8
Sizes 30 & 34 2V1889 25212
Sizes 40 thru 70 2V6724 25212
For Competitor's Actuators
3/8 to 3/4 stem 2U9095 25212
49 Washer, pi steel
Type 513
Size 20 (1 req’d)
5/16 inch (7.9 mm) stem 1B8659 28982
3/8 inch (9.5 mm) stem 1E7941 28992
Type 650, (2 req'd)
Size 30 1B8659 28982
Size 40 1K8995 25072
Size 60 1P5057 25072
Type 656, 1/2 inch (12.7 mm) stem
Sizes 30, 40, & 60 1K8995 25072
Type 657 (2 req'd.)
W/o side-mtd. h'wheel
Sizes 30 thru 70, & 100 ' 1D7162 28982
Sizes 80 & 87 1K8995 25072
W/side-mtd. h'wheel
Size 70 (KEY 12) OR TIRE VALVES (KEY 7).
up to 3-inch (76 mm) travel 1K8995 25072 31B5q<>5 E

3-1/16 to 4-inch (78 to 102 mm) travel 1D7162 28982 Figure 26. Type 582/ Converter

30
 3582 and 3583 Series

1U9101 000A 2 2 V 6724 25212 Key Description Part Number

50 Spacer, steel (Cont.d)
Type 657
W/o side-mtd. h’wheel
Sizes 70 & 87
3-1/16 to 4-inch (78 to 102 mm) travel 1C5590 24092
Size 80
2-1/16 to 3-inch (52 to 76 mm) travel 1J8307 24092
Size 100
2 U 90 9 5 25212
up to 2-1/2 inch (64 mm) travel 1J8307 24092
2-9/16 to 4-inch (65 to 102 mm) travel 1C5590 24092
W/side-mtd. h’wheel
Sizes 34, 50, & 60 1J8307 24092
2 V 1889 252 12
Size 45 & 46 1V1026 24092
Sizes 70 & 87 1R8019 24092
Size 80
2-1/16 to 3-inch (52 to 76 mm) travel 1J8307 24092
Size 100
up to 2-1 /2 inch (64 mm) travel 1J8307 24092
2-9/16 to 4-inch (65 to 102 mm) travel 1C5590 24092
2 V 6722 25212 2 U 90 9 9 252 12 Type 657-4
W/o side-mtd. h’wheel
Size 70 1C5590 24092
W/side-mtd. h'wheel
Size 70 & 87 1R8019 24092
Type 657-8
Sizes 30, 34, 47, & 70 1C5590 24092
Size 40 1N9524 24092
Sizes 46 & 60 1R8019 24092
Figure 27. Connector Arm (Key 48) Type 667
W/o side-mtd. h’wheel
Sizes 70 & 87
2- 1/16 to 3-inch (52 to 76 mm) travel 1J8307 24092
3- 1/16 to 4-inch (78 to 102 mm) travel 1R8019 24092
Key Description Part Number Size 80
2-1/16 to 3-inch (52 to 76 mm) travel 1J8307 24092
49 Washer, pi steel (Cont'd) Size 100
Sizes 80 & 87 1K8995 25072 up to 2-1/2 inch (64 mm) travel 1J8307 24092
Size 100 1D7162 28982 2-9/16 to 4-inch (65 to 102 mm) travel 1C5590 24092
Type 657-4 (2 req'd) W/side-mtd. h’wheel
W/o side-mtd. h’wheel Size 34 1J8307 24092
Size 70 1D7162 28982 Size 45 & 46 1V1026 24092
* W/side-mtd. h'wheel Sizes 70 & 87 1R8019 24092
Size 70 1D7162 28982 Size 80
Size 87 1K8995 25072 2-1/16 to 3-inch (52 to 76 mm) travel 1J8307 24092
Type 657-8 (2 req’d) Size 100
Sizes 30 & 34 1K8995 25072 up to 2-1/2 inch (64 mm) travel 1J8307 24092
Type 667 (2 req’d) 2-9/16 to 4-inch (65 to 102 mm) travel 1C5590 24092
W/o side-mtd. h'wheel Type 667-4
Sizes 30 thru 70, & 100 1D7162 28982 Sizes 70 & 87 1R8019 24092
Size 80 1K8995 25072
Size 87 52 Pipe Plug 1A6495 28992
up to 2-inch (51 mm) travel 1K8995 25072 54 Elbow, 3/8 inch, brass (specify quantity) 15A6002 X162
2-1/16 to 3-inch (52 to 76 mm) travel 1D7162 28982 55 Connector, 3/8 inch brass (not shown)
3-1/16 to 4/inch (78 to 102 mm) travel 1K8995 25072 (specify quantity) 15A6002 X202
W/side-mtd. h’wheel 56 Cap Screw, pi steel (2 req’d) 1C3988 24052
Size 70 57 Hex Nut (2 req'd) 1A3527 24122
up to 3 inch (76 mm) travel 1K8995 25072 58 Lockwasher (2 req'd) 1C2257 28982
3-1/16 to 4-inch (78 to 102 mm) travel 1D7162 28982 59 Pin Lock, SST
Size 80 & 87 1K8995 25072 Type 650, all sizes (none req'd)
Size 100 1D7162 28982 For all other types 1U9098 35032
Type 667-4 (2 req’d)
Size 70 1D7162 28982 60 Travel Pin, SST
Size 87 1K8995 25072 Type 650, Sizes 30, 40, & 60 (none req'd)
50 Spacer, steel (2 req’d) Type 657-8
Type 513, Size 32 1J8307 24092 Sizes 30 & 34 1U9096 46332
Type 650 Sizes 40 thru 70 ' 10A2167 X012
Sizes 30 & 60 ; 1J8307 24092 For all other types 1U9096 46332
Size 40 1C5590 24092 61 Pin Holder, SST
Type 656 1L2006 24092 Type 650, all sizes (none req’d)
For all other types 1U9097 35032

31
 3582 and 3583 Series

Key D e s c rip tio n Part N u m b e r Key D e s c rip tio n P a rt N u m b e r

62 Cap Nut, SST 70 Cap Screw, pi steel (2 req’d)
Type 650, Sizes 30, 40, & 60 (none req’d) Type 478 (Type 3583 only) 1A3816 24052
For all other types 1U9102 35032 Type 513 1A3816 24052
63 Mounting Plate, steel Type 650 1A3525 24052
Type 650, Sizes 30, 40, & 60 31B8553 X012 Type 656 1P7937 X0012
For all other types 31B5993 X012 Type 657
W/o side-mtd. h'wheel
64 Cap Screw, pi steel Sizes 30 thru 60 1A3816 24Q52
(3 req’d for Types 1250 and 1250R) Size 70
(5 req'd for all other types) 1A3816 24052 Up to 3-inch (76 mm) travel 1A3816 24052
Cap Screw, pi steel (2 req’d) 3-1/16 to 4-Inch (78 to 102 mm) travel 1A5534 24052
Type 513, Size 32 1B7624 24052 Size 80
Type 557 up to 2-inch (51 mm) travel 1A3816 24052
W/o side-mtd. h’wheel • 2-1/16 to 3-inch (52 to 76 mm) travel 1A3525 24052
Sizes 30, 34, & 40 1A3525 24052 Size 87
Size 70 up to 3-inch (76 mm) travel 1A3816 24052
up to 2-inch (51 mm) travel 1A3751 24052 3-1/16 to 4-inch (78 to 102 mm) travel 1A5534 24052
2-1/16 to 4-inch (52 to 102 mm) travel 1A9145 24052 Size 100
Size 80 up to 2-1/2 inch (64 mm) travel 1A3625 24052
2-1/16 to 3-inch (52 to 76 mm) travel 1U6256 31192 2-9/16 to 4-inch (65 to 102 mm) travel 1B7624 24052
Size 87, up to 2-inch (51 mm) travel 1A9503 24052 W/side-mtd. h'wheel
Size 100 Sizes 34, 50, & 60 1A3525 24052
up to 2-1/2 inch (64 mm) travel 1C3979 24052 Size 40 , 1A3816 24052
2-9/16 to 4-inch (65 to 102 mm) travel 1A6430 24052 Size 45 1C8702 24052
W/side-mtd. h’wheel Sizes 70 & 87 1B9896 24052
Size 70 Size 80
3/16 to 4-Inch (78 to 102 mm) travel 1B3664 24052 up to 2-inch (51 mm) travel 1A3816 24052
Size 87 2-1/16 to 3-inch (52 to 76 mm) travel 1A3525 24052
3-1/16 to 4-inch (78 to 102 mm) travel 1A9503 24052 Size 100
Size 80 up to 2-1/2 inch (84 mm) travel 1A3525 24052
2-1/6 to 3-inches (52 to 76 mm) travel 1U6256 31192 2-9/16 to 4-inch (65 to 102 mm) travel 1B7624 24052
Size 100 Type 657-4
up to 2-1/2 Inch (64 mm) travel 1C3979 24052 W/o side-mtd. h’wheel
2-9/16 to 4-inch (65 to 102 mm) travel 1A6430 24052 Sizes 70 & 87 1A5534 24052
Type 657-4 W/side-mtd. h’wheel
W/o side-mtd. h’wheel Sizes 70 & 87 1B9896 24052
Sizes 70 & 87 1A9145 24052 Type 657-8
W/ side-mtd. h’wheel Sizes 30, 34, 47, & 70 1A5534 24052
Size 70 1B3664 24052 Size 40 1C3988 24052
Size 87 1A9503 24052 Sizes 46 & 60 1B9896 24052
Type 667 Type 867
W/o side-mtd. h'wheel W/o side-mtd. h’wheel
Sizes 30, 34, & 40 1A3525 24052 Sizes 30 thru 60 1A3816 24052
Size 80 Sizes 70 & 87
2-1/16 to 3-inch (52 to 76 mm) travel 1U6256 31192 Up to 2-inch (51 mm) travel 1A3816 24052
Size 100 2-1/16 to 3-inch (52 to 76.mm) travel 1A3525 24052
Up to 2-1/2 inch (64 mm) travel 1C3979 24052 3-1/16 to 4-inch (78 to 102 mm) travel 1B9896 24052
2- 9/16 to 4-inch ,(65 to 102 mm) travel1A6430 24052 Size 80
W/side-mtd. h’wheel up to 2-inch (51 mm) travel 1A3816 24052
3- 1/6 to 4-inch (78 to 102 mm) 2-1/16 to 3-inch (52 to 76 mm) travel 1A3525 24052
Size 70 1B3664 24052 Size 100
Size 87 1A9503 24052 up to 2-1/2 inch (64 mm) travel 1A3525 24052
Size 80 2-9/16 to 4-inch (65 to 102 mm) travel 1B7624 24052
2-1/16 to 3-inch (52 to 76 mm) travel 1U6256 31192 W/side-mtd. h'wheel
Size 100 Size 34 1A3525 24052
up to 2-1/2 inch (64 mm) travel 1C3979 24052 Sizes 40, 50, 60 1A3816 24052
2-9/16 to 4-inch (65 to 102 mm) travel 1A6430 24052 Size 45 & 46 1C8702 24052
Size 70 & 87 1B9896 24052
66 Actuator Rod, pi steel (not shown) Size 80
Type 650 up to 2-inch (51 mm) travel 1A3816 24052
Size 30 10A5176 X012 2-1/16 to 3-inch (52 to 76 mm) travel 1A3525 24052
Size 40 10A4872 X012 Size 100
Size 60 10A4873 X012 up to 2-1/2 inch (64 mm) travel 1A3525 24052
67 Hex Nut, pi steel (not shown) 2-9/16 to 4-inch (65 to 102 mm) travel 1B7624 24052
Type 650, Size 30 (2 req'd) - 1A9463 24122 Type 667-4
Sizes 70 & 87 1B9896 24052
68 Anti-Torque Rod, steel (not shown) v For Competitor’s Actuators
Type 478 (Type 3583 only) 1V4738 24092 3/8 to 3/4 stem 1A3816 24052
69 Damper Control Swivel (not shown)
Type 650 (2 req'd) 10A4874 X012

32
 3582 and 3583 Series

Key D e s c rip tio n P a rt N u m b e r Key D e s c rip tio n P a rt N u m b e r

97 Spacer, steel (2 req’d) For Mounting 3582, 3582i, and 3583 on

T y p e 657 o r 667
W/ side-mtd. h’wheel Type 657 or 667 Actuator without Side-
Sizes 70 & 87 Mounted Handwheel
up to 2-inch (51 mm) travel 1R4093 24092
2- 1/16 to 3-inch (52 to 76 mm) travel 1R4095 24092
N o te
W/ or W/o side-mtd. h’wheel
Size 80
up to 2-inch (51 mm) travel 1R4096 24092 T h e fo llo w in g p a rts ( k e y n u m b e rs 48 th ro u g h 87) a re
98 Stud, continuous thread, steel (2 req’d) u s e d w h e n m o u n tin g b o th a 3582 S e r ie s p o s itio n e r a n d
T y p e 657 o r 667 a 3583 S e rie s tra n s m itte r o n a T y p e 657 o r 667 S iz e 45
W/ side-mtd. h’wheel a c tu a to r w ith o u t a s id e -m o u n te d h a n d w h e e l.
Sizes 70 & 87
up to 3-inch (76 mm) travel 1R1661 31012 48 Connector Arm, pi steel (2 req’d)
W/ or W/o side-mtd. h'wheel Sizes 30 & 34 1U9101 000A2
Size 80 Sizes 40 thru 100 2U9099 25212
up to 2-inch (51mm) travel 1R1661 31012 49 Washer, pi steel (4 req’d)
99 Hex Nut, pi steel (2 req'd) Sizes 30 thru 70, & 100 1D7162 28982
T y p e 657 o r 667 Sizes 80 & 87 1K8995 25072
W/ side-mtd. h’wheel 50 Spacer, steel (4 req'd)
Sizes 70 & 87 Size 100
up to 3-inch (76 mm) travel 1A3412 24112 up to 2-1 /2 inch (64 mm) travel 1J8307 24092
W/ or W/o side-mtd. h’wheel 59 Pin Lock, SST, all sizes (2 req'd) 1U9098 35032
Size 80 1A3412 24112
102 Spacer, steel 60 Travel Pin, SST, all sizes (2 req’d) 1U9096 46332
T y p e 657 61 Pin Holder, SST, all sizes (2 req'd) 1U9097 35032
Size 70 62 Cap Nut, SST, all sizes (2 req'd) 1U9102 35032
up to 2-inch (51 mm) travel (2 req’d) 1U4371 24092 63 Mounting Plate, steel, all sizes (2 req’d) 31B5993 X012
Size 87 64 Cap Screw, pi steel, all sizes (8 req’d) 1A3816 24052
up to 2-inch (51 mm) travel (2 req’d) 1R7623 24092 65 Cap Screw, pi steel (2 req’d)
Size 100
102 Spacer, steel (Cont'd) up to 2-1/2 inch (64 mm) travel 1C3979 24052
T y p e s 657 o r 667 70 Cap Screw, pi steel (4 req'd)
W/ side-mtd. h'wheel Sizes 30 thru 60 1A3816 24052
Size 70 Size 70
3- 1/16 to 4-inch (78 to 102 mm) travel Up to 3-inch (76 mm) travel 1A3816 24052
(4 req’d) 1R7370 24092 Size 80 1A3816 24052
Sizes 70 and 87 Size 100
up to 3-inch (76mm) travel (2 req’d) 1V6833 24092 up to 2-1/2 inch (64 mm) travel 1A3525 24052
Size 87 71 Stud, continuous thread, steel (not shown) (2 req’d)
3-1/16 to 4-inch (78 to 102 mm) travel, T y p e 657 o r 667
(2 req’d) 1R4096 24092 Sizes 30, 34, & 40 12A1491 X012
W/ or W/o side-mtd. h’wheel Sizes 45 thru 60 12A1493 X012
Size 80 (2 req'd) 1V6833 24092 Size 80 1U4216 31012
Size 100 T y p e 657
up to 2-1/2 inch (63.5 mm) travel (4 req’d) 10A2567 X012 Size 70
2-9/16 to 4-inch (65 mm to 102 mm)travel up to 3-inch (76 mm) travel 12A1492 X012
(2 req'd) 10A5252 X012 72 Hex Nut, pi steel (not shown) (4 req’d)
T y p e s 6 5 7 -4 o r 6 67 -4 - T y p e 657 o r 667
W/ side-mtd. h’wheel Sizes 30, 34, & 40 1E9440 24112
Size 70 (4 req’d) 1R7370 24092 Sizes 45 thru 60 1A3753 24122
Size 87 (2 req’d) 1R4096 24092 Size 80 1A3412 24122
T y p e 657
Size 70
up to 3-inch (76 mm) travel 1A3753 24122
102 Spacer
T y p e 657 o r 667
Size 80 (4 req'd) 1V6833 24092
Size 100
up to 2-1/2 inch (64 mm) travel (8 req’d) 10A2567 X012

33
3582 and 3583 Series

Key D e s c rip tio n P e rt N u m b e r Key D e s c rip tio n P a rt N u m b e r

For Mounting 3582, 3582i, and 3583 on 60 Travel Pin, SST 10A2167 X012
61 Pin Holder, SST 1U9097 35032
Type 657 or 667 Actuator with Side- 62 Cap Nut, SST 1U9102 35032
Mounted Handwheei (figure 28) 63 Mounting Plate, steel 31B5993 X012
64 Cap Screw, pi steel (5 req’d) 1A3816 24052
70 Cap Screw, pi steel (2 req’d) 1C8702 24052
N o te 79 Mounting Plate, steel 22A6848 X012
80 Hex Nut, pi steel, for T y p e 667 only (2 req'd) 1A3527 24122
81 Lockwasher, pi steel
T h e fo llo w in g p a rts ( k e y n u m b e rs 4$ th ro u g h 87) a re
T y p e 657 (2 req’d) 1C2257 28982
u s e d w h e n m o u n tin g b o th a 3582 S e r ie s p o s itio n e r a n d
T y p e 667 (4 req’d) 1C2257 28982
a 3583 S e r ie s tra n s m itte r o n a T y p e 657 o r 667 S iz e 45
82 Machine Screw, pi steel (2 req'd) 1V4058 28982
a c tu a to r w ith s id e -m o u n te d h a n d w h e e l.
83 Elastic Stop Nut, pi steel (not shown)
(2 req’d) 1J7192 28982
84 Connecting Linkage, pi steel 1R6839 99012
48 Connector Arm, pi steel 2V170525212 85 Cap Screw, pi steel, for T y p e 667 only
50 Spacer, steel (2 req'd) 1V102624092 (5 req’d) 1A5534 24052
54 Elbow, 3/8 inch, brass 15A6002X162 86 Spacer, pi steel for T y p e 667 only (5 req’d) 1C5590 24092
55 Connector, 3/8 inch brass (not shown) 15A6002X202 87 Cap Screw, pi steel for T y p e 667 only
59 Pin Lock, SST 1U909835032 (2 req’d) 1A3526 24052

While this information is presented in good faith and believed to be accurate, or any other matter with respect to the products, nor as a recommendation to
Fisher Controls does not guarantee satisfactory results from reliance upon such use any product or process in conflict with any patent. Fisher Controls reserves
information. Nothing contained herein is to be construed as a warranty or the right, without notice, to alter or improve the designs or specifications of
guarantee, express or implied, regarding the performance, merchantability, fitness the products described herein.

For information, contact Fisher Controls:

Fisher Controls Marshalltown, Iowa 50158 USA
Cernay 68700 France
Sao Paulo 05424 Brazil
Singapore 0512

Printed in USA foSSS recycledpaper

 4200 Series

F isher C o n tro ls Instruction Manual

4200 Series Electronic Position

Transm itters

FISHER
___________ F e b ru a ry 1993 F o rm 5596

Contents
Introduction .................................................................. 2
Scope of Manual ............ 2
Description ................................................................ 2
Specifications............................................................ 2

Installation .................................................................. 2
Mechanical Connections ......................................... 5
Sliding-Stem Actuator M o u ntin g .................. 5
Rotary-Shaft Actuator M o u ntin g .................. 5
Long Stroke Sliding-Stem Actuator
M ounting..................................................... 5
Electrical C onnections........................................... 6
Conduit .............................................................. 6
Field Wiring . .................................................... 6
Potentiometer A lig nm en t....................................... 8
Direct or Reverse A c tio n ....................................... 8

Operating Information ........................................... 8

Initial C onsiderations................................................8
Transmitter and Position Switch
Conditions.................................................... 10
Normal O peration.................................................... 12
Calibration .................................................................. 12
Test Equipment Required ......................................12
Test Connections to the Field Wiring
Compartment ...................................................... 12
Transmitter Circuit Calibration................................12
Zero Adjustment..............................................13
Span Adjustment ..................................... .13
High and Low Position Switch Adjustment ......... 14
Setting the High Position Switch ................. 14
Setting the High Position Switch
Deadband .......... 14
Setting the Low Position S w itch ................... 14
Setting the Low Position Switch
Deadband .......................... 15
Position Switch Circuit S h u to ff............................. 15
SLIDING-STEM
ACTUATOR MOUNTING ROTARY ACTUATOR MOUNTING
Figure 1. Typical 4200 Series Position Transmitters
Maintenance..................................................... ie
Troubleshooting Procedures................................. 17
Transmitter C irc u it..........................................17
Position Switch C ircuit................................... 23
Printed Wiring Board Removal and
Replacement........................................................ 23
Transmitter Printed Wiring B o a rd .................23
Field Circuit Printed Wiring Board ............... 24
Potentiometer Replacement ................................. 25

Principle of Operation ............................................15 Parts Ordering................................................. 26

Transmitter C irc u it.............................. 15
Position Switch C ircuit.................... 15 Parts Lists........................................................ 26

©Fisher Controls International, Inc. 1985. 1993; All Rights Reserved

4200 Series
Introduction
Scope of Manual
This instruction manual provides installation, operating,
calibration, maintenance, and parts ordering informa­
tion for the 4200 Series electronic position transmitters
(figure 1). Refer to separate instruction manuals for
information on the actuator and valve.
Only personnel qualified through training or experience
should install, operate, or maintain the 4200 Series
electronic position transmitters. If there are any ques­
tions concerning these instructions, contact your Fisher
Controls sales office or sales representative before
proceeding.
Description
The 4200 Series electronic position transmitters com­
bine Fisher Controls’ field-proven electronic and me­
chanical expertise in a versatile, accurate instrument. It
senses the position of a sliding stem actuator, rotary
actuator, vent, damper, or other device and sends a
standard (4 to 20 milliampere) output signal to an indi­
cating device. The 4200 Series transmitters are avail­
able as a transmitter only, as a transmitter with integral
high and low position switches, or with high and low
position switches only. Refer to the nameplate (figure 2)
to determine the type of transmitter. Use the type num­
ber and table 2 to determine the output travel available
from the transmitter.
When the instrument is mounted, the potentiometer
shaft (figure 3) is mechanically connected to the device
to sense mechanical motion. Except for the Type 4215
transmitter, all types of transmitters use a single potenti­
ometer for position input. The Type 4215 transmitter
uses dual potentiometers mounted on the same shaft
which allows for individual potentiometers for the trans­
mitter and the position switch circuits. For long stroke
applications, a multi-turn potentiometer attached to a
cable/pulley assembly is used to sense linear motion of
the actuator stem or other device.
For instruments equipped with position switches, the
high relay position switch can be set at any point of
travel. The low relay position switch can be offset from
the high relay position switch trip point by as little as
1/20 of the travel. In the event of a power loss both
position switch relays de-energize indicating loss of
transmitter power.
Specifications
Specifications for the 4200 Series transmitters are listed
in table 1.
2
FISHER®
[( ric u rD *1J ELECTRONIC
FISHER p0SIT|0N
TRANSMITTER
SERIAL NO
type[
OUTPUT
o
w
MAX supply
VOLTAGE 30 VDC
c
AMBIENT TEMP
-40*F TO 160*F
I9A7589 E
Figure 2. Typical Nameplate
Installation
When the 4200 Series transmitters are ordered with an
actuator, the factory mounts the transmitter and adjusts
the zero and span for the travel specified on the order.
Make field wiring connections as described in the elec­
trical connections procedure and fine tune the transmit­
ter to the application. Refer to the appropriate actuator
and valve instruction manuals to install the attached
assemblies.
If the transmitter has been ordered separately, or re­
moved for maintenance, perform the appropriate por­
tion of the mechanical, electrical connection, potenti­
ometer alignment, and calibration procedures.
The transmitter can be mounted in any of four positions.
Mount the transmitter vertically or horizontally depend­
ing on the application requirements. Refer to figures 21
through 28 for examples of typical actuator mounting
assemblies.
As an aid to installation, and to understand the transmit­
ter design in general, refer to figure 3 which shows the
location of the transmitter compartment and the field
wiring compartment. The transmitter compartment con­
tains the transmitter and/or the position switch circuit on
the printed wiring board, associated wiring assemblies,
adjustment potentiometers, and the potentiometer that
senses position. Remove the cover on the transmitter
compartment to gain access to this compartment. The
transmitter compartment is adjacent to the —j<]~
symbol on the housing.
 4200 Series

Table 1. Specifications

Available Configurations________________________ Reference Accuracy*1)_________________________

See table 2 ± 1 % of output span. Includes combined effects
of hysteresis, linearity, and deadband
Input Signal*1)_________________________________
Source: Single potentiometer is standard or a Repeatability*1)________________________________
dual potentiometer is available for the Type ± 0.25% of span
4215 only. Refer to table 3 for zero and span
limits Operating Influences*1)_________________________
Ambient Temperature*1): For a 100°F (56°C)
Output Signal<1>_______________________________ change in normal operating conditions,
Range*1): 4 to 20 milliampere dc transmitter maximum zero shift is ± 0.5%; maximum span
output (Type 4210, 4211, 4215, 4220, and 4221 shift is ± 0.75% of span
transmitters) Power Supply: Output signal changes less than
Load Impedance*1): 0 to 650 ohms with a + 24 ± 0.1% when operating terminal voltage varies
volts nominal dc power supply (transmitter only) between 11 and 30 volts dc
Output Current Limit: 30 milliamperes dc Electromagnetic Interference (EMI)*1>: When
maximum tested with the covers on per SAMA Standard
Switches: ON/OFF condition of high and low PMC33.1-1978, change in output span is less
position switch relay (SPDT) than ± 0.5% of span in an electromagnetic field
classified as 3-abc with a field strength of 30
Recommended Power Supply______ ;____________ V/m, which is approximately equivalent to a 5 W,
+ 24 volts dc nominal 20 to 1000 MHz radio transmitter operated 19
inches (0.5 m) from the instrument
Terminal Voltage*1)____________________________
Operating Conditions*1)
Transmitter Circuits Only: The voltages across
the terminals must not be greater than 30 nor
Normal and Transportation
less than 11 volts dc as the output current Condition Operative and Storage
Normal
varies from 4 to 20 milliamperes dc. Reference
Limits Limits
Position Switch Circuit With the Transmitter: Ambient - 4 0 to 160°F - 6 0 to 160°F 77°F
The terminal voltage must not be greater than Temperature ( - 4 0 to 71 °C) ( - 5 0 to 71 °C) (25°C)
30 nor less than 20 volts dc. The current Ambient
required is 80 milliamperes maximum. Relative 10 to 95% 10 to 95% 40%
Position Switch Circuit Without the Transmitter: Humidity
The terminal voltage must not be greater than
30 nor less than 20 volts dc. The current Mounting____________________________________
required is 50 milliamperes maximum. The instrument can be mounted on the actuator
of sliding stem or rotary valves or on other
Position Switch Relays________________________ devices
Type: Two single-pole, double-throw relays
(SPDT) Electrical Classification*2)_______________________
Service Rating: The relay rating is 5 amperes at Refer to the Hazardous Area Classifications:
either 30 volts dc or 120 volts ac (resistive load) FCS Final Control Elements Bulletin 9.2:001 and/
Life Expectancy: 100,000 operations at rated or the nameplates for specific approvals
load, or 50,000 operations at a typical inrush
current of 10 amperes with 120 volts ac lamp or Approximate Weight___________________________
motor load
Transmitter Without Mounting Bracket: 4
pounds (1.8 kg)
1. These terms are defined in ISA Standard S51.1-1979.

3
4200 Series

Table 2. Available Configurations

TRAVEL
ELECTRICAL DUAL
TYPE TRANSMITTER POSITION Standard Stroke Long Stroke
NUMBER Up to 4-1/8 Inchest1) Up to 24 Inchest1) POTENTIOMETER
SWITCHES
(Up to 105 mm) (Up to 610 mm)
4210 X X X — —

4211 X — X — —

4212 — X X — —

4215 X X X — X
4220 X X — X —

4221 X — — X —

4222 — X — X —

1. See table 3 for zero and apan limits.

Table 3. Zero and Span Limits

DEGREES OF mm
TYPE INCHES
POTENTIOMETER ROTATION CONNECTION!1)
NUMBER
Zero Span Zero Span Zero Span
4210 1 0 to 2 1/3 to 2 0 to 51 8 to 51
4211
0 to 90 15 to 90
4212 0 to 105 17 to 105
2 0 to 4-1/8 2/3 to 4-1/8
4215
4220 Small Pulley 0 to 12 4-1/8 to 12 0 to 305 105 to 305
4221 0 to 884 150 to 884
4222 Large Pulley 0 to 24 12 to 24 0 to 610 305 to 610
1. Refer to figures 21, 23, and 24 for locations of connections and pulleys.

19A7988-E
61910-3

Figure 3. Transmitter Dimensions

Except for a Type 4211 or 4221 transmitter, the field
wiring compartment contains a printed wiring board with
the terminal blocks (figure 4) for connecting field wiring
and associated cable assemblies. It also contains the
position switch relays which are mounted on the printed
wiring board. Remove the cap adjacent to the + and —
symbols on the housing to access this compartment.
For a Type 4211 or 4221 transmitter without position
switch circuits, the field wiring compartment contains a
barrier strip for installation of the transmitter field wiring
(figure 4).
Figure 3 shows the location of the ports into the field
wiring compartment. Two ports are available for routing
the transmitter and/or position switch wiring into the
transmitter housing. After transmitter installation, install
a plug the unused port. When installing, allow sufficient
space for removing the transmitter covers to perform
maintenance and make the wiring connections. Figure 3
also shows the basic transmitter outline dimensions.

4

M echanical Connections
Sliding-Stem Actuator Mounting
Use the following general procedures and figures 21,
22, or 23 to mount the transmitter on sliding-stem
actuators.
Refer to figure 21 for key number locations for this
example.
1. Bolt the stem mounting bracket and spacer (keys 34
and 39) to the stem connector on the actuator stem.
Replace the stem connector cap screws with the two
cap screws (key 35) furnished with the stem mounting
bracket.
2. If necessary, refer to the appropriate procedures in
the actuator instruction manual to reconnect the actua­
tor stem to the valve stem.
3. Fasten the stem bracket (key 33) to the stem mount­
ing bracket (key 34) with two cap screws (key 37)
centered in the slots of the stem bracket. Tighten the
cap screws slightly.
4. On the transmitter, install the pickup pin into the
lever assembly (key 30) in the position to match the
application. Refer to table 3 and figure 21.
5. Stroke the actuator to the mid position of the valve
travel.
6. Fit the pickup pin, located in the lever assembly (key
30), into the horizontal slot in the stem bracket (key 33).
Bolt the mounting plate (key 21) to the actuator with cap
screws, washers, and spacers (keys 23, 24, and 22)
using the two tapped holes in the side of the actuator
yoke.
7. Use the mounting plate slots, which allow the lever
assembly (key 30) and the operating arm (key 25) to be
nearly parallel, and position the long edge of the mount­
ing plate parallel with the actuator stem. Tighten the
bolts securely.
8. Loosen the two cap screws (key 37) connecting the
stem bracket (key 33) to the stem mounting bracket (key
34). Manually move the lever assembly (key 30) until its
center line is parallel with the center line of the operating
arm (key 25).
9. Tighten the two cap screws (key 37) in the slotted
holes.
10. Stroke the actuator to ensure that full travel is
allowed.1
11. Perform the electrical connection and potentiome­
ter alignment procedures.
4200 Series
Rotary-Shaft Actuator Mounting
Use the following general procedures and figures 24,
25, and 26 to mount the transmitter on rotary-shaft
actuators.
Refer to figure 24 for key number locations for this
example.
1. Install the transmitter on the mounting plate (key 21)
with two cap screws (key 32). The transmitter can be
mounted in any of four positions on the bracket. Tighten
the cap screws slightly.
2. On the actuator, attach the coupler plate assembly
(key 57) and travel indicator to the actuator shaft. This is
accomplished by removing two self-tapping screws and
travel indicator and replacing them with the self-tapping
screws and coupler plate assembly furnished with the
transmitter for the mounting application.
3. Install the mounting plate (key 21) on the actuator
using the four cap screws and washers (keys 23 and
24). The transmitter and bracket can be mounted in any
of four positions by using the cap screws (key 23) on the
face of the actuator hub.
4. Tighten the cap screws (key 23) slightly while align­
ing the potentiometer shaft on the transmitter with the
coupler plate assembly pin (key 57). When aligned,
tighten the four cap screws (key 23). Maintain this
alignment while tightening the two cap screws (key 32)
holding the transmitter to the mounting plate (key 21).
5. Slide the coupler (key 52) over the potentiometer
shaft and into the hole in the mounting plate (key 21).
Slide the coupling (key 54) onto the plate assembly pin
and attach the coupling to the plate assembly pin using
the set screw.
6. Slide the coupler (key 52) into the coupling (key 54),
and attach the coupler to the potentiometer shaft using
the set screw (key 53). The coupling should not be
deflected in any direction when installed. Do not tighten
the coupling set screw as it will be tightened during the
potentiometer alignment procedure.
7. Perform the electrical connections and potentiome­
ter alignment procedures.
Long Stroke Sliding-Stem Actuator Mounting
Use the following general procedures and figures 27
and 28 to mount the transmitter on long stroke sliding-
stem actuators. ‘
Refer to figure 27 for key number locations for this
example.
1. Stroke the actuator to mid-stroke.
5
4200 Series
2. Bolt the cable clip (key 60) to the stem connector on
the actuator stem. Do this by using replacement cap
screws for the stem connector, inserting them in the
cable clip (key 60) bracket, and tightening the screws on
the stem and cable clip (key 60).
3. If necessary, refer to the appropriate actuator in­
struction manual for the procedure to reconnect the
actuator stem to the valve stem.
4. Install the transmitter and mounting plate (key 63)
on the actuator.
5. Carefully pull the cable out of the spring motor, rest
it on the center thread of the pulley, and connect the end
of the cable to the cable clip (key 60).
6. Facing the slotted end of the potentiometer shaft,
wrap the cable twice in a clockwise direction so the
cable lies in the two middle threads (fourth and fifth) of
the pulley.
7. For installations requiring cable assembly covers,
refer to figure 27. Install the cable cover assembly (key
64) on to the mounting plate (key 63) with the two
machine screws (key 81). Depending on the actuator
type and size, additional screws are provided to attach
the other end of the cable cover assembly (key 64) to the
actuator.
8. Perform the electrical connections and potentiome­
ter alignment procedures.
Electrical Connections
Note
For intrinsically safe installations, refer to
factory drawings or to instructions supplied
by the barrier manufacturer for proper wir­
ing and installation.
Conduit
Install conduit using local and national electrical codes
which apply to the application.
W A R N IN G
For explosion-proof applications, install a
suitable conduit seal no more than 18 inch­
es (460 mm) from the transmitter. Personal
injury or property damage may result from
fire and explosion if the seal is not installed.
6
Field Wiring
Figure 4 shows typical field wiring connections into the
field wiring compartment. The transmitter is powered by
a + 24 volt dc power supply in series with an indicating
device. This same power source is used to power the
position switch circuits in units with the transmitter, or
the position switches in units without the transmitter. A
separate return is required for the relays when used with
the transmitter. For the position switch relay wiring,
keep in mind that during normal operating conditions,
relays K1 and K2 are energized, which connects the
common (C) terminal to the normally open (NO) terminal
(TB1 and TB2, figure 4). A tripped (or alarm) condition is
with the relay de-energized, which connects the C termi­
nal to the normally closed (NC) terminal. If power is
removed or lost from the power supply both relays are
de-energized which connects the common (C) terminals
to the normally closed terminals (NC). Before making
transmitter or position switch connections, ensure that
the power supply is turned off.
Note
Connect the transmitter grounding terminal
(key 58) to an earth ground. Improper
grounding of the position transmitter can
cause erratic operation.
Refer to figure 4 for location of connections.
1. Remove the cover from the field wiring compartment.
2. Bring the transmitter field wiring and/or position
switch wiring into the housing through one or both of the
ports.
3. Field wiring connections:
a. For a Type 4210, 4215, or 4220 transmitter with
position switches, connect a wire from the — terminal
of the power supply to the R terminal on TB3. Connect a
wire from the — terminal on the power supply to the
indicating device, and connect a wire from the indicating
device to the — terminal on TB3. Connect a wire from
the + terminal on the power supply to the + terminal
on the TB3. Provide wiring for the position switch indi­
cating device to match the application.
b. For Type 4212 and 4222 position switches with­
out a transmitter, connect a wire from the + terminal of
the power supply to the + terminal on TB3. Connect a
wire from the — terminal of the power supply to the R
terminal on TB3. Provide wiring for fhe position switch
indicating device to match the application.
c. For a Type 4211 or 4221 transmitter without
position switches. Connect a wire from the + terminal
of the power supply to the + terminal on the barrier
 4200 Series

FO R T Y P E 4210, 4215, O R 4220 T R A N S M IT T E R W IT H P O S ITIO N S W IT C H E S

A N D FO R T Y P E 4212 O R 4222 P O S ITIO N S W IT C H E S W IT H O U T T H E T R A N S M IT T E R

TRANSMITTER
FIELD WIRINQ FIELD WIRING

FO R T Y P E 4211 O R 4221 T R A N S M IT T E R W IT H O U T P O S ITIO N S W IT C H E S

NOTES: 3. DURING NORMAL CONDITIONS, RELAYS K1 AND K2 ARE

E > TYPE 4212 AND 4222 POSITION SWITCHES WITHOUT THE ENERGIZED, WHICH CONNECTS THE COMMON (C) TERMINAL TO THE
TRANSMITTER CIRCUIT DOES NOT REQUIRE AN INDICATING DEVICE NORMALLY OPEN (NO) TERMINAL. A TRIPPED (OR ALARM)
OR THE ASSOCIATED WIRING. CONDITION IS WITH THE RELAY(S) DE-ENERGIZED, WHICH
u > THE INDICATING DEVICE CAN BE A VOLTMETER ACROSS A 250 CONNECTS THE COMMON (C) TERMINAL TO THE NORMALLY CLOSED
OHM RESISTOR OR A CURRENT METER. (NC) TERMINAL.
49A7994-B
4947892-0
C0601-3

Figure 4. Wiring Connections

strip (key 11). Connect a wire from the - terminal of the a. Connect the high position switch field wiring
power supply to the indicating device, then from the from the high indicating device to TB1 on the field circuit
indicating device to the — terminal on the barrier strip. printed wiring board.

4. Connect the grounding terminal (key 58) to an earth
ground.
5. For a Type 4210, 4212, 4215, 4220, or 4222 instru­
ment with position switches, perform the following steps
to connect the position switch wiring:
b. Connect the low position switch field wiring from
the low indicating device to TB2 on the field circuit
printed wiring board.
6. If only one output port is used, screw the pipe plug
(supplied with the transmitter) into the unused port.

7

4200 Series
7. Perform the potentiometer alignment procedures.
Potentiom eter Alignm ent
This procedure adjusts the potentiometer to the center
of its electrical travel when the control valve actuator or
other device is at the center of its mechanical travel.
Refer to the Calibration section for the test equipment
required in this section.
W A R N IN G
On an explosion-proof instrument, remove
electrical power before removing the cov­
ers in a hazardous area. Personal injury or
property damage may result from fire or
explosion if power is applied to the instru­
ment with the covers removed, in a hazard­
ous area.
For intrinsically safe areas current monitor­
ing during operation must be with a meter
approved for hazardous areas.
Refer to figure 5 for component locations.
1. Remove power from the instrument.
2. Connect the digital voltmeter (DVM) leads as
follows:
a. For all transmitters (except a Type 4212 or 4222)
connect between TP3 ( + ) and TP4 ( —) on the printed
wiring board.
b. For a Type 4212 or 4222 transmitter, connect the
DVM between TP5 ( + ) and TP6 ( - ) .
3. Loosen the appropriate set screw connecting the
potentiometer shaft to the linkage:
a. For sliding stem applications, loosen the set
screw (key 26, figure 21) in the operating arm (key 30) on
the potentiometer shaft.
b. For rotary actuator applications, loosen the set
screw in the coupling (key 50, figure 24) on the potenti­
ometer shaft.
c. For long stroke applications, loosen the set
screw (key 87, figure 27) in the pulley (key 59) on the
potentiometer shaft.
4. Stroke the actuator or other device to the mid­
stroke position.
5. Apply power to the instrument.
8
f
V
6. While the device is in mid-stroke position, insert a
screwdriver blade into the slot in the end of the potenti­
ometer shaft (see figure 21), or turn the coupler (key 52,
figure 24) to turn the potentiometer shaft until the DVM
reads 1.25 ± 0.05 volts dc. This establishes the electri­
cal center of the potentiometer.
7. Tighten the appropriate set screw. Check that the
DVM reading has remained at 1.25 ± 0.05 volts dc.
8. Remove the power from the transmitter power
supply.
9. Remove the DVM leads from TP3 and TP4 (trans­
mitter signal) or TP5 and TP6 (position switch signal).
10. Refer to the direct or reverse action procedures.
Direct or Reverse Action
Direct action means, when looking at the slotted end of
the potentiometer shaft, a clockwise rotation of the shaft
produces an increasing output signal from the
transmitter.
Reverse action means, when looking at the slotted end
of the potentiometer shaft, a clockwise rotation of the
shaft produces a decreasing output signal from the
transmitter.
The transmitter produces a direct or reverse action
output signal depending on the location of the potenti­
ometer wires inserted in terminal block number 1 (TB1)
mounted on the transmitter printed wiring board. Refer
to figure 6 for the location of the wires and the wire color
sequence for direct action. For reverse action, ex­
change the positions of the brown and red wires.
Arrange wires on the terminal block (TB1) for either
direct or reverse action to match the application require­
ments; then repeat the potentiometer alignment
procedures.
Refer to the Calibration section to adjust the zero and
span of the transmitter and/or position switch circuits.
Operating Information
Initial Considerations
If the transmitter is ordered with an actuator, the trans­
mitter is factory calibrated to the length of travel speci­
fied on the order. If the transmitter is ordered sepa­
rately, it is necessary to adjust the zero and span as
described in the Calibration section so that the transmit­
ter operates properly in your specific application.
 4200 Series

A .F O R T Y P E 4210, 4215, O R 4220 T R A N S M IT T E R S W IT H P O S ITIO N S W ITC H E S

B .FO R T Y P E 4211 O R 4221 T R A N S M IT T E R W IT H O U T P O S ITIO N S W ITC H E S

ADJUSTMENT (R3)

_ S S S * C .F O R T Y P E 4212 O R 4222 P O S ITIO N S W IT C H E S W IT H O U T T R A N S M IT T E R

f-s .
Figure 5. Transmitter Printed Wiring Board Assemblies
(For More Information Refer to Figure 10)

9
4200 Series

F O R T Y P E 4210, 4215, O R 4220 T R A N S M IT T E R W IT H P O S ITIO N S W IT C H E S

A N D FO R T Y P E 4212 O R 4222 P O S ITIO N S W IT C H E S W IT H O U T T H E T R A N S M IT T E R

FO R T Y P E 4211 O R 4221 T R A N S M IT T E R W IT H O U T P O S ITIO N S W ITC H E S

NOTES:
[T> WIRES CONNECTED TO TB1 ARE SHOWN IN THE COLOR SEQUENCE FOR DIRECT
49A7W4-B ACTION. FOR REVERSE ACTION, THE COLOR SEQUENCE IS RED, ORANGE, AND BROWN
S S T (FROM LEFT TO RIGHT).

Figure 6. Instrument Assembly Details

If the transmitter is calibrated for a specific control valve
actuator travel, it is recommended that the procedures
in the Calibration section be performed to fine tune the
zero and span adjustments to the specific application.
circuit output controls relay K2, and the relay contacts
connect to TB2. The relationship between the transmit­
ter output, relay position switch outputs, and deadband
is shown in figure 7. Deadband is the difference be­
tween trip and reset points of a relay.

• A Type 4211 or 4221 transmitter (without position

Transmitter and Position Switch Conditions
• A Type 4210 or 4220 transmitter (with position
switches) obtains stem position from the input potenti­
ometer and circuit electronics to provide a 4 to 20
milliampere output. The transmitter output connects to a
terminal block mounted in the field wiring compartment.
The high position switch circuit output controls relay K1
mounted on the field circuit printed wiring board, and the
relay contacts connect to TB1. The low position switch
switches) obtains input information from the potentiom­
eter and provides a 4 to 20 milliampere output. The
transmitter output connects to the barrier strip (key 11,
figure 4) mounted in the field wiring compartment.
• A Type 4212 or 4222 position switch (without the
transmitter) obtains stem position from the input poten­
tiometer and provides position switch outputs from re­
lays K1 and K2 (figures 4 and 9). The high position

10
 4200 Series

NOTE:
[T> WHEN USING THE COMMON (C) AND THE NORMALLY CLOSED <NC) TERMINAL
CONNECTIONS, THE CONTACTS WILL BE CLOSED WHEN THE RELAY COIL IS DE-ENERGIZED.
A37B7

Trans­ Trans­
Actua­ Input mitter Actua­ Input mitter
Trans­ Actua­ Set Trans­ Set
tor Poten­ Current tor Poten­ Current
Type mitter tor Position Type mitter Position
Stem tiometer Output, Stem tiometer Output,
Action Style Switch Action Switch
Travel Rotation!11 Milli­ Travel Rotation!1> Milli­
ampere ampere
Down CW 20 Hi Down CW 20 Hi
A, D Direct
Up ccw 4 Lo 4210 Up ccw 4 Lo
Direct 4220 Up ccw 20 Hi
Up CW 20 Hi Reverse
B, C Down CW 4 Lo
4210 Down ccw 4 Lo
Down CW Hi
4220 Up ccw 20 Hi Direct N/A
A, D 4212 Up ccw Lo
Down CW 4 Lo 4222 Not available for position switches
Reverse Reverse
Down ccw 20 Hi without transmitter
B, C
Up CW 4 Lo Down CW 20 Hi
Direct
Down CW Hi Up ccw 4 Lo
A, D 4215
Up ccw Lo Down CW 4 Hi
Reverse
Direct N/A Up ccw 20 Lo
4212 Up CW Hi
4222 B, C 4211 Not required for transmitter without
Down ccw Lo 4221 position switches
Not available for position switches 1. Viewed from the potentiometer shaft end.
Reverse
without transmitter
Down CW 20 Hi FO R S LID IN G S TE M A C T U A T O R S
A, D
Up ccw 4 Lo
Direct
Up CW 20 Hi
B, C
Down ccw 4 Lo
4215
Down CW 4 Hi
A, D
Up ccw 20 Lo
Reverse
Up CW 4 Hi
B, C
Down ccw 20 Lo
4211
Not required for transmitter without position switches
4221
1. Viewed from the potentiometer shaft end.

FO R R O T A R Y A C T U A T O R S

(T ^ .
Figure 7. Transmitter and Position Switch Conditions

11
4200 Series
switch circuit output controls relay K1 mounted on the
field circuit printed wiring board and, the relay contacts
cohnect to TB1. The low position switch circuit output
controls relay K2 and, the relay contacts connect to
TB2. Deadband is the difference between trip and reset
points of a relay.
• A Type 4215 transmitter obtains position informa­
tion from a dual potentiometer on the same shaft, which
allows for individual potentiometers for the transmitter
circuit and the position switch circuits. The transmitter
input is from one of the potentiometers and its output
connects to TB3 (figure 6) mounted on the field circuit
printed wiring board. The position switch input is ob­
tained from the other potentiometer. The high position
switch circuit output controls relay K1 mounted on the
field circuit printed wiring board and the relay contacts
connect to TB1. The low position switch circuit output
controls relay K2 and the relay contacts connect to TB2.
The relationship between the transmitter output, relay
position switch outputs, and deadband is shown in
figure 7. Deadband is the difference between the trip
and reset points of a relay.
Normal Operation
W A R N IN G
On an explosion-proof instrument, remove
electrical power before removing the in­
strument covers in a hazardous area. Per­
sonal injury or property damage may result
from fire or explosion if power is applied to
the instrument with the covers removed, in
a hazardous area.
Once the instrument has been calibrated and placed in
operation, further adjustments should not be necessary.
The 4 to 20 milliampere output can be monitored during
operation (in a non-hazardous environment) by remov­
ing the cover and connecting a milliammeter between
TP1 ( + ) and TP2 ( —) on the printed wiring board (figure
5) on Type 4210, 4211,4215, 4220, or 4221 transmitter.
On Type 4212 or 4222 connect a voltmeter between TP5
( + ) and TP6 ( —) to measure potentiometer position.
For position switch circuits, the switching condition can
be monitored by observing the indicating device or using
an ohmmeter connected to the terminal blocks (TB1 and
TB2) in the field wiring compartment. Refer to the Cali­
bration section for the test setup.
Calibration
Calibration of the instrument consists of adjusting the
zero and span of the transmitter and/or adjusting the
12
high and low position switches for a specific travel. The
high and low position switches also have deadband
adjustments that are made during the calibration proce­
dures. Refer to figure 7 for transmitter and position
switch conditions.
For a Type 4212 or 4222 instrument with position switch
circuits only, refer to the high and low position switch
adjustment procedures in this section. For a transmitter
with or without position switch circuits, refer to the
transmitter circuit calibration procedures in this section.
If satisfactory results cannot be obtained during calibra­
tion, refer to the appropriate procedures in the Mainte­
nance section.
Test Equipment Required
The following test equipment is used in the calibration
and maintenance of the instrument:
• Digital voltmeter (DVM) that measures voltages in
the range of 0 to 30 volts dc with an accuracy of ± 0.25
percent.
• Power supply capable of supplying 20 to 30 volts dc
at 100 milliamperes.
• Resistor, 250 ohms, 0.1%, 0.5 watt or a greater
wattage.
Test Connections to the Field W iring
Compartment
The potentiometer must be aligned before the instru­
ment is calibrated. Also, the direct or reverse action
must be correct for your application. During calibration
in the field, use the power supply and indicating devices
provided for the application. For a bench check, setup
the transmitter as shown in figure 8.
Except for Type 4211 and 4221 transmitters, the field
circuit printed wiring board is used. A Type 4211 or 4221
transmitter uses a barrier strip (key 11, figure 4) mount­
ed in the field wiring compartment for field wiring con­
nections. For calibration and bench check of the 4211 or
4221 transmitter, make connections to the barrier strip
(key 11).
Transm itter C ircuit Calibration
W A R N IN G
For intrinsically safe areas, the current
monitoring across TP1 and TP2 during op­
eration must be with an approved meter.
Personal injury or property damage may
 4200 Series

FIE LD W IR IN G
C O M P A R TM E N T
NOTES:

t °> I
+ -
(T> CONNECT DVM TO TEST POINTS AS DIRECT BY CALIBRATION
AND MAINTENANCE PROCEDURES.
| T > INSURE THAT THE CONNECTOR ATTACHED TO J1 (VIEW A) IS NOT
REVERSED WHEN INSTALLING IT ON THE PRINTED WIRING BOARD.
I~F> THE INDICATING DEVICE CAN BE A VOLTMETER ACROSS A 250
49A7894-B OHM RESISTOR OR A CURRENT METER.
39A6158-F
B1948-3
DVM [ 4 > SEPARATE RETURN LEAD REQUIRED FOR RELAYS.

Figure 8. Bench Check Test Setup for Transmitter with Position Switches

result from fire or explosion if an approved 2. Remove the transmitter covers.

meter is not used in a hazardous area.
Calibration of the transmitter consists of adjusting the
zero and span for a 1 to 5 volt dc output across a 250
ohm resistor, or a 4 to 20 milliampere output current for
a specific travel. If necessary refer to the type number
on the nameplate to determine the configuration of the
transmitter.
For a Type 4210,4215, or 4220 transmitter with position
switches, the transmitter can be calibrated with or with­
out the position switch function being connected.
Note
3. Stroke the valve or device to the point of travel
where the transmitter output is to be 1.00 volt dc or 4
milliamperes dc.
4. Apply power to the instrument.
5. Adjust the zero potentiometer (R1, figure 5-A or
R15, figure 5-B) until the DVM reads 1.00 ± 0 .02 volts
dc, or until the milliammeter reads 4 milliamperes dc.
6. If necessary, connect the transmitter for bench
check as shown in figure 8.

If the transmitter is calibrated without the Span Adjustment

position switches being connected, the
1. Stroke the valve or device to the point of travel
transmitter has a small zero shift when the where the transmitter output is to be 5.00 volt dc or 20
switches are connected. milliamperes dc.

2. Adjust the span potentiometer (R2, figure 5-A or

For a Type 4211 or 4221 transmitter without position
switches, use a two wire system with the indicating
device installed as shown in figured.
Zero Adjustment
1. Remove power from the instrument.
R16, figure 5-B) until the DVM reads 5.00 ±0 .02 volts
dc, or until the milliammeter reads 20 milliamperes dc.
3. Some small interaction between the two adjust­
ments may occur. Repeat the zero and span adjustment
procedures until the error is within the application
requirements.

13
4200 Series
4. For a Type 4211 or 4221 transmitter without posi­
tion switches, calibration is complete. Refer to the instal­
lation and/or operating information to place the
transmitter in service.
5. If calibration is complete, replace the transmitter
covers. For transmitters with position switches, refer to
the high and low position switch adjustment procedure
below.
High and Low Position Switch
Adjustm ent
Note
The high position switch must be adjusted
before the low position switch. If the dead­
band of either the high or low position
switches exceeds the difference between
the setpoints of the high and low position
switches, it is possible for both position
switches to be on at the same time.
The following procedure sets the high and low position
switches, and the deadband for each of them. The high
position switch must be adjusted before the low position
switch. The operation of the position switches can be
detected by using the high and low position switch
indicating devices (figure 4) to monitor the operation of
the relays. Or, use an ohmmeter connected between the
normally closed (NC) and common (C) connections on
terminal block TB1 (high switch) or TB2 (low switch) to
observe relay switching action as directed by the
procedures.
The potentiometer alignment procedures must be per­
formed before calibrating the position switch circuits.
For transmitter and position switch switch conditions,
refer to figure 7 while performing the following
calibration:
1. If necessary, perform the potentiometer alignment
procedure.
2. Remove power from the instrument.
3. Remove the transmitter covers.
4. To provide an indication of switch conditions:
a. If the indicating device (figure 4) is used for
calibration, observe the high position indicating device.
b. If the indication devices are not used, remove
power from the instrument. Disconnect the position
switch field wiring from TB1 and TB2, and connect an
ohmmeter to TB1 between NC and C terminals (figure 4).
14
Note
The maximum number of turns for the po­
tentiometer is 25 turns from one end to the
other end of travel.
Turn both the high and low deadband potentiometers
(DBH, R4, and DBL, R5) fully counterclockwise to set
the deadbands to minimum and set the low position
switch potentiometer (LOW, R6) fully counterclockwise.
Setting the High Position Switch
For Type 4210,4220,4212,4222, and 4215 direct acting
transmitters, refer to figure 5-A or -C, for location of
adjustments.
1. Turn the high position switch potentiometer (HIGH,
R3) fully clockwise.
2. Stroke the valve or device to the point of travel
where the high position switch is to operate.
3. Apply power to the instrument.
4. Turn the high position switch potentiometer (R3)
slowly counterclockwise until the high position switch
trips, indicating a change in conditions, or until the
ohmmeter changes from a high resistance to a low
resistance reading.
5. The high position switch is now set.
Setting the High Position Switch Deadband
1. Slowly stroke the actuator or device between the
tripped and reset point of the high position switch.
Observe this by the changing conditions of the high
position switch, or by the changing conditions of the
ohmmeter. Note the differences in travel between the
trip point and reset points. This is the deadband of the
switch.
2. If it is necessary to increase the deadband, turn the
potentiometer (DBH, R4), clockwise.
3. Repeat steps 1 and 2 until the desired deadband
setting is obtained.
Setting the Low Position Switch
Note
Perform the high position switch adjust­
ment procedures before adjusting the low
position switch.

1. To provide an indication of switch condition:
a. If the indicating device (figure 4) is used for
calibration, observe the low position indicating device
during calibration.
b. If the indicating device is not used, remove pow­
er from the instrument. Connect an ohmmeter to TB2
between the NC and C terminals (figure 4).
2. Stroke the device to the point of travel where the
low position switch is to operate.
3. Apply power to the instrument.
4. Ensure that the low position switch potentiometer
(LOW, R6, figure 5-A or -C) is fully counterclockwise as
previously instructed.
5. Turn the low position switch potentiometer (R6)
slowly clockwise until the low position switch trips indi­
cating a change in conditions or, until the ohmmeter
changes from a high to a low resistance reading.
6. The low position switch is now set.
Setting the Low Position Switch Deadband
1. Slowly stroke the actuator or device between the
tripped and reset point of the low position switch. Ob­
serve this by the changing conditions of the low position
switch ID, or by the open and short readings on the
ohmmeter. Note the differences in travel between the
trip point and reset points. This is the deadband of the
low position switch.
2. If it is necessary to increase the deadband, turn
potentiometer (DBL, R5, figure 5-A or -C) clockwise.
3. Repeat steps 1 and 2 until the desired deadband
setting is obtained.
4. If adjustments are complete, remove power from
the instrument and, if necessary, disconnect the
ohmmeter. ' the current flow out of the transmitter. The current
5. Perform the installation and/or operating proce­
dures to place the transmitter in service and replace the
transmitter covers.
Position Switch C ircuit Shutoff
Refer to figure 5 for location of adjustments.
Certain conditions may require the position switch cir­
cuit capabilities to be shut off. To shut off the position
switches, turn the high position switch potentiometer
(HIGH, R3) fully clockwise, and turn the low position
4200 Series
switch potentiometer (LOW, R6) fully counterclockwise.
To restore the position switch circuits to operation,
follow the high and low position switch adjustment pro­
cedures described in this section.
Principle of Operation
The basic concept of the electronic position transmitter
can be understood by visualizing the entire transmitter
as a variable resistor in series with a load and connected
to a power supply as shown in figure 9. A linkage or
cable/pulley assembly transmits linear motion of the
device into rotary motion of the potentiometer. The
potentiometer is connected to the input of the transmit­
ter circuit. The voltage present at the wiper of the
potentiometer supplies input voltage to the electronic
circuitry in the transmitter to produce a current output.
The position switch circuit is driven by the same input
system as the transmitter (except for the Type 4215
transmitter). The position switch circuit acts as an elec­
tronic switch that controls two relays. The voltage pre­
sent at the wiper of the potentiometer is compared to
the settings of the high and low position switch setpoints
and provides an on or off condition for the relays.
Instruments that use a single element potentiometer use
the same element for both the transmitter input and the
input to the position switch circuits. A Type 4215 trans­
mitter with dual element potentiometers uses one ele­
ment of the potentiometer for the transmitter input and
the other element for the position switch circuit input. On
an instrument with position switches only, the single
element potentiometer is used for the position switch
circuit input. Each of the position switch circuit outputs
is connected to a relay on the field circuit printed wiring
board, and depending on the potentiometer position, the
relays are energized or de-energized.
Transm itter C ircuit
At all times, the current flow into the transmitter equals
flowing into the transmitter divides between a regulator
circuit and transistor Q1 (figures 10 and 11). The regula­
tor circuit establishes two voltages one of which is
(VREF). This voltage is applied across the input potenti­
ometer. The other voltage, (VREG) powers the hybrid
circuit.
Position Switch C ircuit
A regulated voltage is setup to power the position switch
circuit. The position switch circuit senses the position of
the potentiometer and triggers the appropriate position
switch relay (K1 or K2, figure 12) when travel reaches
15
4200 Series

MECHANICAL
CONNECTION
TO DEVICE

NOTES:
[ T > THIS EQUIVALENT CIRCUIT IS TYPICAL FOR ALL TYPES OF TRANSMITTERS. ___
GENERALLY, IF A PORTION OF THE CIRCUIT IS NOT USED, IT IS OMITTED.
[ 2 > THE INDICATING DEVICE CAN BE A VOLTMETER ACROSS A 250 OHM '
RESISTOR OR A CURRENT METER.
[ 3 > FIELD WIRING FOR POSITION SWITCHING CIRCUITS CAN BE A TWO OR THREE
WIRE SYSTEM DEPENDING ON THE APPLICATION REQUIREMENTS.
B1B48-2 [ 4 > SEPARATE RETURN LEAD REQUIRED FOR RELAYS.

Figure 9. Transmitter Operation

the trip points established by the adjustments. The Type

4215 transmitter uses dual potentiometers which allows
individual potentiometers for the transmitter circuit and
the position switch circuit.
Maintenance
W A R N IN G
On an explosion-proof instrument, remove
the electrical power before removing the
instrument covers in a hazardous area. Per­
sonal injury or property damage may result
from fire and explosion if power is applied
to the instrument with the covers removed,
in a hazardous area.
CAUTION
Electrostatic voltages present in the envi­
ronment may be transferred to the transmit­
ter printed wiring board which may cause
failure or degraded performance. Use ap­
propriate antistatic procedures when work­
ing with the printed wiring board to protect
the electronic circuits.
Because of the care Fisher Controls takes in meeting all
manufacturing requirements (heat treating, dimensional
tolerances, etc.), use only replacement parts manufac­
tured or furnished by Fisher Controls.

Test equipment for the following procedure is listed in
the Calibration section. Voltage references in this proce­
dure may vary depending on the temperature of the
instrument. The voltages below are taken at approxi­
mately 72°F (22°C) ambient temperature.
The following procedures consider the instrument as­
sembled with all components installed according to the
type number description. The following procedures can
be used in the field or for a bench check. Connect the
instrument as shown in figure 8 for bench check.

16
 4200 Series

NOTES: 4. TERMINAL BLOCK NUMBER 1 (TB1 j PROVIDES THE

[ T > COMPONENTS NOT INSTALLED IN TYPE 4212 AND 4222 TRANSMITTERS. CONNECTIONS FOR THE THREE WIRE CABLE ASSEMBLY FROM THE
[ T > JUMPER SELECTION TABLE POTENTIOMETER. ON A DUAL POTENTIOMETER SYSTEM, IT
PROVIDES THE TRANSMITTER INPUT ONLY.
TRANSMITTER WITH TRANSMITTER WITH 5. CONNECTOR J2 IS ONLY USED WITH A DUAL POTENTIOMETER
POSITION
JUMPER* SWITCHES AND SINGLE SWITCHES AND DUAL
SWITCH OR FOR POSITION SWITCHES WITHOUT TRANSMITTER CIRCUIT. IT
POTENTIOMETER POTENTIOMETER
NOT INSTALLED PROVIDES THE POSITION SWITCH CIRCUIT INPUT TO THE PRINTED
W1 NOT INSTALLED INSTALLED
INSTALLED NOT INSTALLED WIRING BOARD.
W2 NOT INSTALLED
NOT INSTALLED INSTALLED 6. THE TWO WIRE CABLE ASSEMBLY CONNECTED TO J1 IS USED
W3 INSTALLED
*SEE FIGURE 5 FOR JUMPER LOCATIONS ON THE PRINTED WIRING BOARDS. FOR THE TRANSMITTER OUTPUT SIGNAL (4 TO 20 MILLIAMPERES),
AND IS CONNECTED TO THE RFI FILTER.
3. THE THREE WIRE CABLE ASSEMBLY CONNECTED TO J3
PROVIDES THE POSITION SWITCH CIRCUIT OUTPUT TO RELAYS K1
4$A?2?2-C
B 19*7-2 AND K2 ON THE FIELD CIRCUIT PRINTED WIRING BOARD.

F ig u r e 10 . S c h e m a t ic D ia g r a m f o r T y p e 4 2 1 0 , 4 2 1 5 , o r 4 2 2 0 T r a n s m it t e r s w it h
P o s it io n S w it c h e s a n d f o r T y p e 4 2 1 2 a n d 4 2 2 2 P o s it io n S w it c h e s W it h o u t t h e T r a n s m it t e r

Troubleshooting Procedures
Use the interconnection diagrams shown in figures 13
through 16 to determine the transmitter internal wiring.
Transmitter Circuit
1. Verify that the instrument is receiving power, and
verify that the indicating device(s) are operating
correctly.
2 . If the transmitter is the problem, maintenance can
be performed by either sending the entire instrument to
the factory for repair, by replacing the printed wiring
board(s), or by replacing the potentiometer (key 5, fig­
ures 19 and 20) depending on which is defective.
3. Troubleshoot the transmitter circuit by measuring
the voltages.
4. Locations of test voltages designated by V1 and V2
(table 4) are also shown on the schematic diagrams and
on the printed wiring board assembly (figures 10, 11,
and 17).
5. Check the voltages V1 and V2 as described in table 4.

17
4200 Series

'T

TBI NO NC C TB2 NO NC C TB3 R

RVt
2 I 3 0 . BV
H > Kl (T > K2
*■
3 4 05 3 4
CR2
IN4002

CRI
I N40 02 CR3
-H 4 — IN 4 0 0 2
-H —
NOTE:
i RELAYS K1 AND K2 ARE SHOWN IN THE DE-ENERGIZED POSITION.

J1 ' 2 ‘ Jl (TRIPPED POSITION)

“I

Figure 12. Schematic Diagram for the Field Printed Wiring Board

18
 4200 Series

MECHANICAL
CONNECTION

NOTE:
O THE INDICATING DEVICE CAN BE
A VOLTMETER ACR088 A 250 OHM
RE8I8TOR OR A CURRENT METER.

29A6206-C
49A7272-C
00662-1

Figure 13. Interconnection Diagram for Type 4210 or 4220 Transmitter with
Position Switches and a Single Potentiometer

19
NOTE:
[T> THE INDICATING DEVICE CAN BE A VOLTMETER ACROSS A 250 OHM RESISTOR OR A CURRENT METER.
39A7301-C
CO066-1

Figure 14. Interconnection Diagram for Type 4211 or 4221 Transmitter without
Position Switches

20
 4200 Series

29A6206-C
49A7272-C
DO061 -2

Figure 15. Interconnection Diagram for Type 4212 or 4222 Position Switches
without the Transmitter

21
[ j > THE INDICATING DEVICE CAN BE
A VOLTMETER ACR088 A 260 OHM
RESISTOR OR A CURRENT METER.

26A6206C
49A7272-C
D0663-2

Figure 16. Interconnection Diagram for Type 4215 Transmitter with

Position Switches and a Dual Potentiometer

22

Table 4. Test Procedure
CONNECT DVM TO
STEP DVM READS
( + ) Lead ( - ) Lead
1
V1 TP4 5.9 to 6.3 V dc (VREG)
2 V2 TP4 2.46 to 2.54 V dc (VREF)
3 V3 TP6 14.1 to 16.1 V dc ( + 15)
4 V4 TP6 2.46 to 2.54 V dc (VREF2)
6. If either or both of the voltages are not present, field
repair of the instrument is not recommended. Either
replace the printed wiring board or return the instrument
to the factory for repair.
7. If these voltages are present, the potentiometer
may be the source of trouble.
8. Check the voltage between TP3 ( + ) and TP4 ( - )
as the position of the potentiometer is varied. For Type
4212 and 4222 transmitters, check the voltage between
TP5 and TP6 as the position of the potentiometer is
varied.
a. If the voltage does not vary with position, perform
the potentiometer (key 5, figure 19 or 20) alignment. If
the problem remains, replace the potentiometer.
b. If the potentiometer wiper voltage checks good,
but the transmitter output is constant or non-linear, the
problem may be due to improper potentiometer align­
ment. Perform the potentiometer alignment procedures:
then repeat step 8 above.
c. If the potentiometer voltage is present but the
transmitter output current does not change linearly as
the position of the potentiometer changes, replace the
transmitter printed wiring board, or return the transmit­
ter to the factory for repair.
Position Switch Circuit
1. Ensure that the position switch circuit is connected
correctly, and that the terminal marked R on the field
circuit printed wiring board is returned to the negative
terminal of the supply. Refer to figure 4 for wiring
connections.
2. Ensure that the power supply voltage is between 20
and 30 volts dc.
3. Check the voltages V3 and V4 as described in table
4 (figures 10 and 17): ; board into the transmitter compartment.
a. If either or both of the voltages are not present,
field repair of the instrument is not recommended. Re­
turn the instrument to the factory for repair.
4200 Series
b. If V3 and V4 are correct, continue with the follow­
ing steps:
4. Perform the high and low position switch calibration
procedures in the Calibration section.
5. If the position switches cannot be set, replace the
field circuit printed wiring board (figure 18) or return the
instrument to the factory for repair.
Printed W iring Board Removal and
Replacement
Transmitter Printed Wiring Board
Refer to figures 17 for component locations.
Removal:
1. Remove power from the transmitter.
2. With the transmitter compartment covers removed,
disconnect the connectors from J1, J2, and J3 if they are
used.
3. Note the locations of the wires, then disconnect the
wires from TB1.
4. Remove the three screws that hold the board in
place.
5. Grasp one of the components that protrudes from
the board, and gently lift the board from the transmitter
compartment.
6. Place the board on an insulated surface for repair or
replacement.
Replacement:
Note
When replacing connectors J1, J2, and J3
do not reverse the connector. The connec­
tor can be forced on in the opposite direc­
tion. Reversing any connector can cause
incorrect operation of the transmitter. Refer
to figure 8, view A, for proper insertion of
the connectors.
1. When the replacement board is ready, lower the
2. Insert and tighten the three screws.
3. Install plug connections that were removed.
23
 l®
4200 Series V

FOR TYPE 4210, 4215, OR 4220 TRANSMITTER FOR TYPE 4212 OR 4222 POSITION SWITCHES
WITH POSITION SWITCHES SST WITHOUT TRANSMITTER

F ig u r e 1 7 . T r a n s m it t e r P r in t e d W ir in g B o a r d s

4. Connect the red and black wires to the printed 3. Grasp one of the components that protrudes from
wiring board according to the transmitter type (figures the board and gently lift the board from the field wiring
13 through 16). compartment.

5. Perform the potentiometer alignment and calibra­ 4. Place the board on an insulated surface for repair or
tion procedures. replacement.

Field Circuit Printed Wiring Board
Removal:
Refer to figure 18 for component locations.
1. Note the locations of the field wires then disconnect
the wires from TB1, TB2, and TB3 (if they are all used).
2. Remove the three screws that hold the board in
place.
Replacement:
1. When the replacement board is ready, lower the
board into the transmitter compartment.
2. Insert and tighten the three screws and, install the
wiring connections that were removed.
3. The red and black power wires must be connected
to TB3 according to the transmitter type (figures 13
through 16),

24

Potentiometer Replacement
The potentiometer is mounted in a bushing (key 3) that is
threaded into the base of the transmitter housing (key 1,
figures 19 and 20) and is located in the transmitter
compartment. Remove the potentiometer as follows:
CAUTION
Remove the wiring assembly(ies) connect­
ed between the potentiometer and the
transmitter printed wiring board before re­
moving the bushing (key 3) from the trans­
m itter housing (key 1). Failure to
disconnect the wiring assembly(ies) may
result in damage to the wiring.
1. Remove power from the instrument.
2. Remove the covers (key 2, figure 19 or 20) from the
transmitter housing.
3. Note the location of the field wiring, and disconnect
the wiring from the field circuit printed wiring board, or
from the barrier strip (key 11, figure 20), mounted in the
field wiring compartment.
4. Remove the transmitter from its mounting.
5. Perform the transmitter printed wiring board remov­
al procedure.
6. Remove the bushing (key 3) from the housing (key 1).
4200 Series
7. Remove the potentiometer (key 5) from the bushing.
8. Inspect and, if necessary, replace the O-ring (key 15).
9. If necessary, remove the wiring assembly from the
old potentiometer and install it on the replacement po­
tentiometer.
10. When installing the replacement potentiometer
(key 5), apply adhesive (key 49) to the threads of the
potentiometer, making sure the adhesive does not
touch the potentiometer shaft.
11. Thread the potentiometer (key 5) into the bushing
until it contacts the bushing.
12. Slightly loosen the potentiometer until the potenti­
ometer shaft rotates freely, then allow the adhesive (key
49) to dry with the potentiometer shaft pointed up so the
adhesive does not contact the shaft.
13. When installing the bushing (key 3) in the transmit
ter housing, apply lubricant (key 50) to the bushing
threads.
14. Install the bushing in the transmitter housing and
tighten. Ensure free rotation of the potentiometer shaft.
15. Perform the printed wiring board replacement
procedure.
16. Perform the installation, potentiometer alignment,
and calibration procedures to return the transmitter to
service. .
25
4200 Series
FISHER®
___________

Figure 19. Housing Assembly for Type 4210, 4215, or 4220 Transmitter with Position Switches
and for Type 4212 or 4222 Position Switches without the Transmitter

Parts Ordering Key Description Part Number

5A Potentiometer
When corresponding with the Fisher Controls sales Type 4210, 4211, 4212 19A7586 X012
Type 4215 19A7587 X012
office or sales representative about this equipment, Type 4220, 4221, 4222 19A7588 X012
always mention the transmitter serial number. When 5B Wire Assembly (not Type 4212, 4222) 19A3896 X012
ordering replacement parts, refer to the part number of 5C Wire (not Type 4212, 4222) 13A0833 X012
each required part as found in the following parts lists.
5D Wire (not Type 4212, 4222) 13A0833 X032
5E Wire (not Type 4212, 4222) 13A0833 X022
5F Cable Tie, plastic (not Type 4212, 4222) 1V1121 06992
5G 3-Wire Connector (Type 4212, 4215, 4222 only),
Parts List solder pi brass 19A3897 X012

6 Machine Screw, pi steel

Type 4211, 4221 (3 req’d)
Transm itter Common Parts Type 4210, 4212, 4215, 4220, 4222 (6 req'd) 18A5263 X012
7 Split Washer, (Type 4211, 4221 only),
stainless steel (2 req’d) 610005 80X12
(Figures 19 and 20) 8 Spacer, plastic
Type 4211, 4221 (3 req’d)
Key Description Part Number Type 4210, 4212, 4215, 4220, 4222 (6 req’d) 18A5265 X012
9 Wire (red), (Type 4211, 4221 only),
1 Housing, aluminum 49A5654 X012 18 AWG x 2 inches (50.8 mm) 13A0817 T022
2 Cap, aluminum (2 req’d) 38A5251 X012
3 Bushing, aluminum 29A5653 X012 10 Wire (black), (Type 4211, 4221 only),
4 Feedthrough Assembly (not Type 4211, 4221) 29A7257 X012 18 AWG x 2 inches (50.8 mm) 13A0817 T072
11 Barrier Strip (Type 4211, 4221 only), plastic 1H2904 06992
5* Potentiometer Assembly 12 Machine Screw (Type 4211, 4221 only),
Type 4210, 4211 19A7629 X012 stainless steel (2 req’d) 590612 60X12
Type 4212 19A7632 X012 13 Barrier Marker Strip (Type 4211, 4221 only) 15A4793 X012
Type 4215 19A7630 X012
Type 4220, 4221 ‘ 19A7631 X012 14* O-Ring, nitrile (2 req'd) T12051 06562
Type 4222 19A7633 X012 15* O-Ring Bushing, nitrile 10A8931 X012
16 Solder Lug, (Type 4211, 4221 only)
Tin pi brass (2 req'd) 15A6903 X012
17 Insulating Washer, PTFE (2 req’d) (not shown) 14A7893 X012

26 ‘ Recommended spare part.

 4200 Series

Figure 20. Housing Assembly for Type 4211 or 4221 Transmitter without Position Switches

Key Description Part Number Key Description Part Number

18 Self Tapping Screw, pi steel (2 req’d) 1P4269 28982 24 Washer, pi steel (2 req’d) 1B8659 28982
19 RFI Filter
Type 4212, 4222 (1 req’d) 25 Operating Arm, pi steel 19A3811 X012
4210, 4211, 4215, 4220, 4221 (2 req’d) 11A7793 X012 26 Cap Screw, pi steel 1H3284 X0012
20 Pipe Plug (Type 4211, 4221 only), steel 0Z0201 28992 27 Square Nut, pi steel 16A6711 X022
43* Field Circuit Printed Wiring Board Assembly 39A6195 X012 29 Torsional Spring, zn pi steel 19A3812 X012
45* Transmitter Printed Wiring Board Assembly 30 Lever Assembly
Type 4210, 4220 39A6156 X022 Size 30 thru 130 w/ 2-1/8 inch (54 mm)
Type 4211, 4221 39A7236 X012 max travel 16A6705 X012
Type 4212, 4222 39A6156 X032 Size 80 thru 130 w/ 2-1/8 thru 4-1/8 inch
Type 4215 39A6156 X012 (54 thru 105 mm) max travel 16A6706 X012
49 Sealant See table 5 31 Shoulder Screw, stainless steel 10B5722 X012
50 Lubricant See table 5 32 Cap Screw, pi steel (2 req’d) 1C6312 24052
55 Pipe Plug (not shown), pi steel 1A3619 X0012 33 Stem Bracket, zn pi steel
Size 30 thru 130 with 2-1/8 inch (54 mm)
56 Machine Screw (not shown), pi steel max travel I6A6709 X012
Type 4212, 4222 only 17A3109 X012 Size 80 thru 130 w/ 2-1/8 thru 4-1/8 inch (54 thru
58 Wire Retainer, pi steel, (2 req'd) 16A2821 X012 105 mm) max travel 16A8277 X012
65 Nameplate w/o approval, aluminum 19A7589 X0A2 34 Stem Mounting Bracket, zn pi steel
67 2-Wire Connector 19A3898 X012 Size 30, 40, 45, 63, 64 16A0430 X012
Size 46, 60, 68, 80, 86, 130 27A5447 X012
Mounting Parts for Sliding Stem Size 100 21B5965 X012
35 Cap Screw, zn pi steel (2 req’d)
Actuators Size 30, 45 1A3525 24052
Size 40 1A5534 24052
Parts for Mounting the Transmitter on Size 64 1A3751 24052
Size 68, 80 10A5001 X012
Type 470 or 471 Actuator (figure 21) Size 100 1U6256 31192
21 Mounting plate, steel 36 Sleeve, stainless steel 16A0428 X012
Size 130 37A7900X012 37 Cap Screw, steel (2 req’d) _ 16A0429 X012
All other sizes . 37A5448 X012
22 Yoke Spacer, steel (2 req’d) 38 Stem Washer (2 req'd)
Size 30, 45 only 1F9067 24092 Size 30 thru 46, pi steel 1B8659 28982
23 Cap Screw, zn pi steel (2 req’d) Size 60 thru 64, zn pi steel 1D7162 28982
Size 30, 45 1A352624052 Size 68 thru 130, zn pi steel 1K8995 25072
size 40, 46 thru 130 1A381624052

‘ Recommended spare part. 27

 FISHER®1
4200 Series l

NOTE:
l~P> REFER TO TABLE 3 FOR INFORMATION ON PICKUP PIN CONNECTION
39A7768 C
B1951-3

Figure 21. Typical Transmitter Mounting on Type 470, 471, 470-7, 471-7, 657, or 667 Actuator

Key Description Part Number Key Description Part Number

39 Stem Spacer (2 req’d) 31 Shoulder Screw, heat treated stainless steel 10B5722 X012
Size 30, 45, steel 1F9067 24092 32 Cap Screw, pi steel (2 req’d) 1C6312 24052
Size 40, steel 1J8307 24092 33 Stem Bracket, zn pi steel 16A8277 X012
Size 64, steel 1U4371 24092 34 Stem Mounting Bracket, zn pi steel
Size 68, 80, zn pi steel 16A1367 X012 Size 40 thru 45, 64 16A0430 X012
Size 100, steel 1V6833 24092 Size 60 27A5447 X012
48 Lubricant See table 5
49 Sealant See table 5 35 Cap Screw, zn pi steel (2 req’d)
Size 40 1A5534 24052
51 Sealant See table 5 Size 45 1A3525 24052
Size 64 1A3751 24052
36 Sleeve, stainless steel 16A0428 X012
37 Cap Screw, steel (2 req’d) 16A0429 X012
Parts for Mounting the Transmitter on Type 38 Stem Washer (2 req’d)
Size 40, 45, pi steel 1B8659 28982
470-7 or 471-7 Actuator (figure 21) Size 60, 64, zn pi steel 1D7162 28982
21 Mounting plate, steel 37A5448 X012
23 Cap Screw, zn pi steel (2 req'd) 1A3816 24052 39 Stem Spacer, steel (2 req’d)
24 Washer, pi steel (2 req'd) 1B8659 28982 Size 40 1J8307 24092
25 Operating Arm, pi steel 19A3811 X012 Size 45 1F9067 24092
Size 64 1U4371 24092
26 Cap Screw, pi steel 1H3284 X0012 48 Lubricant See table 5
27 Square Nut, pi steel 16A6711 X012 49 Sealant . See table 5
29 Torsional Spring, zn pi steel ■. 19A3812 X012 51 Sealant See table 5
30 Lever Assembly 16A6706 X012

28
 4200 Series

Key Description Part Number Key Description Part Number

35 Cap Screw, zn pi steel (2 req’d)
Parts for Mounting the Transmitter on Type 585 Type 657 or 667
Size 30, 34, 40 17A8302 X012
or 585R Actuator (figure 22) Size 30, 34, 40 w/3582, 3590 12A3218 X012
12 Machine Screw, pi steel (2 req'd) 1A3319 28982 Size 45, 46, 50, 60 1A9359 24052
21 Mounting Plate, steel Size 45, 46, 50, 60 w/3582, 3590 1V6023 X0012
Size 25, 50 38A0649 X012 Type 657
Size 100 30B7649 X012 Size 70 w/3582, 3590 2-1/8 inch (54 mm)
23 Cap Screw, zn pi steel (4 req’d) 1C4732 24052 max travel 12A1492 X012
25 Operating Arm, pi steel 19A3811 X012 Size 70 w/o 3582, 3590 2-1/8 inch (54 mm) max
travel 1M6188 X0012
26 Cap Screw, pi steel 1H3284 X0012 Size 70 w/ or w/o 3582,3590 2-1/8 thru 4-1/8 inch
27 Square Nut, pi steel 16A6711 X022 54 thru 105 mm) max travel 1M6188 X0012
29 Torsional Spring, zn pi steel 19A3812 X012 Type 667
30 Lever Assembly Size 70 w/ or w/o 3582,3590 1M6188 X0012
Size 100 with 3/4 thru 2 1/8 inch travel 16A6705 X012 Type 657 or 667
Size 100 with 2 1/2 thru 4 inch travel 16A6706 X012 Size 70, 87 w/MO, w/3582, up to 3-inch travel 1U9597 X0032
Size 80, 87 18A6422 X022
30A Lever/Bearing Assembly for Size 25, 50 18A0645 X012 Size 80 w/3582, 3590 1R1259 31032
30B Transfer Pin, stainless steel 16A6707 X012 Size 100 1A3445 24052
30C Pickup Pin, stainless steel 16A6701 X012 36 Sleeve, stainless steel 16A0428 X012
31 Shoulder Screw, stainless steel 10B5722 X012 37 Cap Screw, steel (2 req’d) 16A0429 X012
32 Hex Cap Screw, pi steel (2 req'd) 1C6312 24052 38 Stem Washer (2 req’d)
36 Sleeve, stainless steel 16A0428 X012 Size 30, 34, 40, pi steel 1B8659 28982
40 Positioner Bracket, zn pi steel Size 45 thru 60, zn pi steel 1A3756 24022
Size 25, 50 28A0646 X012 Size 70 and 100 pi steel 1H7231 25072
Size 100 30B7617 X012 Size 80 and 87 zn pi steel 1A5189 25072
39 Stem Spacer, steel (2 req’d)
Size 30, 34, 40 1N8229 24092
P a rts fo r M o u n tin g th e T ra n s m itte r on Size 45 thru 60 17A8301 X012
Type 657 o r 667 A c tu a to r (fig u re 21) Size 70
Type 657 13A8282 X012
21 Mounting plate, steel 37A5448 X012 Type 667 17A8301 X012
Type 657 size 70 w/ or w/o 3582, 3590 27A7509 X012 Size 100 13A8282 X012
22 Yoke Spacer, steel (2 req’d) 48 Lubricant See table 5
Size 30 thru 40 1V1026 24092 49 Sealant See table 5
Size 45, 46 1R7939 X0012 51 Sealant See table 5
Size 50, 60 1L8872 24092
Size 70 1N8229 24092
23 Cap Screw, zn pi steel (2 req'd) Parts for Mounting the Transmitter on Type
Size 30 thru 40 1C8702 24052
Size 45, 46 1F9603 24052
1250 or 1250R Actuator (figure 23)
Size 50, 60 1B7624 24052 21 Mounting Plate, steel 49A7856 X012
Size 70 1A3525 24052 25 Operating Arm, zn pi steel 19A3811 X012
Size 80 thru 100 1A3526 24052 26 Cap Screw, pi steel 1H3284 X0012
24 Washer, pi steel (2 req’d) 27 Square Nut, pi steel 16A6711 X022
Size 30 thru 40 1B7162 28992
Size 45 thru 100 1B8659 28982 29 Torsional Spring, zn pi steel 19A3812 X012
30A Lever/Bearing Assembly, steel 18A0645 X012
25 Operating Arm, pi steel 19A3811 X012 30B Transfer Pin, stainless steel 16A6707 X012
26 Cap Screw, pi steel 1H3284 X0012 30C Pickup Pin, stainless steel 16A6701 X012
27 Square Nut, pi steel 16A6711 X022
29 Torsional Spring, zn pi steel 19A3812 X012 31 Shoulder Screw, stainless steel 10B5722 X012
32 Hex Cap Screw, pi steel (2 req’d) 1C3122 24052
30 Lever Assembly 33 Stem Bracket, steel
Size 30 thru 100 w/ 2-1 /8 inch (54 mm) Size 225, 450 30B6736 X012
max travel 16A6705 X012 Size 675 30B7385 X012
Size 70 thru 100 w/ 2-1/8 thru 4-1/8 inch 36 Sleeve, stainless steel 16A0428 X012
(54 thru 105 mm) max travel 16A6706 X012
31 Shoulder Screw, stainless steel 10B5722 X012 49 Sealant See table 5
32 Cap Screw, pi steel (2 req'd) 1C6312 24052 51 Sealant See table 5
33 Stem Bracket, zn pi steel 91 Cap Screw, pi steel (2 req’d)
Size 30 thru 100 w/ 2-1/8 inch (54 mm) W/positioner 10B6606 X012
max travel 16A6709 X012 W/o positioner „ 10B6605 X012
Size 70 thru 100 w/ 2-1/8 thru 4-1/8 inch 92 Washer, pi steel (2 req’d) 10B6609 X012
(54 thru 105 mm) max travel ■ 16A8277 X012
34 Stem Mounting Bracket, zn pi steel 93 U-Bolt, pi steel (2 req’d) 19A7930 X012
Size 30 thru 87 16A0430 X012 94 Hex Nut, pi steel (4 req’d) 19A4838 X022
Size 80, 100 27A5447 X012 95 Washer, pi steel (4 req’d) 10B6610 X012

29
4200 Series

STEM BROCKET VIEW

INDENT 1
INDENT 2
INDENT 3
INDENT 4
INDENT 5
INDENT 6
INDENT 7
INDENT 8

INDEX MRRK
INDENT TRAVEL
NUMBER Inches mm
1 3/4 19
2 1-1/8 29
3 1-1/2 38
4 2 51
5 2-1/2 64
6 3 76
7 ; 3-1/2 89
8 4 102

FOR SIZE 100

Figure 22. Typical Transmitter Mounting on Type 585 or 585R Actuator

30
 4200 Series

Key Description Pert Number Key Description Part Number

50 Lubricant See Table 5

Mounting Parts for Rotary Actuators 52 Coupler, stainless steel 10B7304 X012

53 Socket Set Screw, stainless steel 1B8568 X0022

54 Coupling, aluminum 17A8307 X012
Parts for Mounting the Transmitter on Type 57 Coupling Plate Assembly
1051,1052, or 1061, Actuator with Tandem Type 1051 Size 30, 40
Type 1052 Size 30, 40
Linkage (figure 24) Type 1061 Size 30 17A8310 X012
21 Mounting Plate, steel Type 1051 Size 60
Type 1051 Size 30 thru 60 Type 1052 Size 60, 70
Type 1052 Size 30 thru 70 Type 1061 Size 40, 60, 68 17A9006 X012
Type 1061 Size 30 thru 68 36A5913 X012 Type 1061 Size 80, 100, 130 17A9825 X012
32 Cap Screw, pi steel (2 req'd)
Type 1051, 1052 1C6312 24052
Type 1061 Size 80 thru 130 35A5864 X012

31
4200 Series
F IS H E R ®

49A7766-A

Figure 24. Typical Transmitter Mounting on Type 1051, 1052, or 1061 Actuator

Key Description Part Number Key Description Part Number

21 Mounting plate (Cont.)

Type 1063 Size 75
Parts for Mounting the Transmitter on Type Type 1064 Size 75
1052, Size 20 Only Actuator (figure 25) Type 1065 Size 75
Type 1066 Size 75 38A4477 X012
21 Mounting Plate, steel 39A2482 X012 Type 1061 Size 80, 100, 130 38A5864 X012
32 Cap Screw, pi steel (2 req'd) 1C6312 24052 32 Cap Screw, pi steel (2 req'd) 1C6312 24052
50 Lubricants and Sealants See table 5 50 Lubricant See table 5
52 Coupler, stainless steel 10B7304 X012 52 Coupler, stainless steel
Type 1051 Size 30, 40, 60
53 Socket Set Screw, stainless steel 1B8568 X0022 Type 1052 Size 20, 30, 40, 60, 70
54 Coupling, aluminum 17A8307 X012 Type 1061 Size 30, 40, 60, 68, 80, 100, 130 10B7304 X012
57 Coupling Plate Assembly 17A9148 X022 Type 1051 Size 33
Type 1052 Size 33
Type 1063 Size 20, 27, 75
Type 1064 Size 20, 75
Parts for Mounting the Transmitter on Type Type 1065 Size 20, 75
Type 1066 Size 20, 27, 75 10B7305 X012
1063,1064,1065,1066, or 1066R Actuator
without Tandem Linkage (figure 26) 53 Socket Set Screw, stainless steel 1B8568 X0022
54 Coupling, aluminum 17A8307 X012
21 Mounting Plate, steel 57 Coupling Plate Assembly
Type 1052 Size 20 39A2482 X012 Type 1052 Size 20 17A9148 X022
Type 1051 Size 30, 40, 60 Type 1051 Size 33
Type 1052 Size 30, 40, 60, 70 Type 1052 Size 33
Type 1061 Size 30, 40, 60, 68 38A5913 X012 Type 1063 Size 20, 27 #
Type 1051 Size 33 Type 1064 Size 20 *
Type 1052 Size 33 ' Type 1064 Size 20
Type 1063 Size 20, 27 Type 1065 Size 20
Type 1064 Size 20 Type 1066 Size 20, 27 17A9148 X022
Type 1065 Size 20 Type 1051 Size 30, 40
Type 1066 Size 20, 27 38A4476 X012 Type 1052 Size 30, 40
Type 1061 Size 30 17A8310 X012

32
 4200 Series

Figure 25. Typical Transmitter Mounting

on Type 1052, Size 20 Only Actuator

Key Description Part Number Key Description Part Number

57 Coupling Plate Assembly (Cont.) 80 Cap Screw, zn pi steel (2 req’d) 1B6065 24052
Type 1051 Size 60 81 Machine Screw, pi steel (3 req’d) 1B8776 28992
Type 1052 Size 60, 70
Type 1061 Size 40, 60, 68 17A9006 X012 82 Cap Screw, zn pi steel 1C2752 24052
Type 1061 Size 80, 100, 130 17A9825 X012 83 Lockwasher, pi steel 1C3162 28982
Type 1063 Size 75 87 Set Screw, pi steel 18A8378 X012
Type 1064 Size 75 88 Machine Screw, pi steel (2 req’d) 18A8508 X012
Type 1065 Size 75 89 Negator Spring Motor Assembly 18A8148 X012
Type 1066 Size 75 17A9147 X012

M ountin g P arts fo r Long S tro ke S lid ing Parts for Mounting the Transmitter oni Type
Stem A c tu a to rs 470--16 Actuator (figure 27)
32 Cap Screw, stainless steel (4 req’d) 1C6312 24052
59 Threaded Pulley, Delrin 500 18A8128 X012
Parts for Mounting the Transmitter on Type 320 60 Cable Bracket, stainless steel
Actuator (figure 27) Size 60 28A8136 X012
Size 68 28A8137 X012
32 Cap Screw, stainless steel (2 req’d) 1C6312 24052 Size 80, 100 28A8138 X012
59 Threaded Pulley, DelrinC) 18A8128 X012 63 Mounting Plate, steel 28A8135 X012
60 Cable Bracket, stainless steel
Size 60 18A8130 X012 64 Cable Cover Assembly
Size 80 18A8131 X012 Size 60 28A8144 X012
62 Extension Arm, cast iron Size 68 28A8456 X012
Size 60 28A8133 X012 Size 80, 100 28A8146 X012
Size 80 28A8134 X012 66 Spring Motor Cover, pi steel 28A8450 X012
70 Machine Screw, pi steel 1A3279 28982
63 Mounting Plate, steel 28A8132 X012 71 Hex Nut (Size 80, 100 only), zn pi steel 1A3412 24112
64 Cable Cover, stainless steel
Size 60 28A8451 X012 72 Hex Nut, zn pi steel . 1A3420 24152
Size 80 28A8452 X012 74 Hex Nut (Size 60, 68 only), zn pi steel (2 req’d) 1A3753 24112
66 Spring Motor Cover, pi steel ' 28A8450 X012 76 Hex Nut, zn pi steel 1A6622 28992
70 Machine Screw, pi steel 1A3279 28982 78 Cap Screw (Size 80, 100 only), zn pi steel 1A9503 24052
74 Nut, zn pi steel 1A3753 24112
76 Nut, pi steel 1A6622 28992

33
1. Trademark of E.l. du Pont Da Nemours Co.

4200 Series
Key Description
79 Cap Screw (Size 60,68 only), zn pi steel (2 req'd) 1B2275 24052
81 Machine Screw, pi steel (3 req’d)
82 Cap Screw, zn pi steel
83 Lockwasher, pi steel
87 Set Screw, pi steel
88 Machine Screw, pi steel (2 req'd)
89 Negator Spring Motor Assembly
Parts for Mounting the Transmitter on a Type
490 Actuator (figure 28)
32 Hex Cap Screw, pi steel, 2 req’d
35 Cap Screw or stud, pi steel
59 Threaded Pulley, Delrin
Yoke boss 5H, Cylinder size
5 to 10 inches (127 to 254 mm),
Max travel 12 inches (305 mm)
Yoke boss 5H, Cylinder size
12 and 14 (305 to 356 mm),
Max travel 12 inches (305 mm)
Yoke boss 7, Cylinder size
5 and 14 (127 to 356 mm),
Max travel 12 inches (305 mm)
Yoke boss 5H, Cylinder size
5 to 10 inches (127 to 254 mm),
Max travel 16 inches (305 mm)
Yoke boss 5H, Cylinder size
12 and 14 (305 to 356 mm),
Max travel 16 inches (406 mm)
Yoke boss 7, Cylinder size
5 and 14 (127 to 356 mm),
Max travel 16 inches (406 mm)
34
F IS H E R
Type 320 or 470-16 Actuator
Part Number Key Description Part Number
59 Threaded Pulley (Cont.)
1B8776 28992 Yoke boss 5H and 7, Cylinder size
1C2752 24052 5 and 14 (127 to 356 mm),
1C3162 28982 Max travel 20 inches (508 mm)
Yoke boss 5H and 7, Cylinder size
18A8378 X012 5 and 14 (127 to 356 mm),
18A8508 X012 Max travel 24 inches (610 mm) 18A8129 X012
18A8148 X012 61 Cable Clip, pi steel
Yoke boss 5H, Cylinder size
5 to 10 inches (127 to 254 mm),
Max travel 12 inches (305 mm)
Yoke boss 5H, Cylinder size
5 to 10 inches (127 to 254 mm),
Max travel 16 inches (305 mm) 28A8139 X012
1C6312 24052 Yoke boss 5H, Cylinder size
18A6422 X022 12 and 14 (305 to 356 mm),
Max travel 12 inches (305 mm)
Yoke boss 7, Cylinder size
5 and 14 (127 to 356 mm),
Max travel 12 inches (305 mm)
Yoke boss 5H, Cylinder size
12 and 14 (305 to 356 mm),
Max travel 16 inches (406 mm)
Yoke boss 7, Cylinder size
5 and 14 (127 to 356 mm),
18A8128 X012 Max travel 16 inches (406 mm)
Yoke boss 5H and 7, Cylinder size
5 and 14 (127 to 356 mm), -
■; Max travel 20 inches (508 mm)
Yoke boss 5H and 7, Cylinder size
5 and 14 (127 to 356 mm),
Max travel 24 inches (610 mm) 28A8140 X012
 1

4200 Series

Key Description Part Number

/
63 Mounting Plate (Cont.)
Yoke boss 5H, Cylinder size
12 and 14 (305 to 356 mm),
Max travel 16 inches (406 mm)
Yoke boss 7, Cylinder size
5 and 14 (127 to 356 mm),
Max travel 16 inches (406 mm)
Yoke boss 5H and 7, Cylinder size
5 and 14 (127 to 356 mm),
Max travel 20 inches (508 mm)
Yoke boss 5H and 7, Cylinder size
5 and 14 (127 to 356 mm),
Max travel 24 inches (610 mm) 28A8142 X012

68 Yoke Cover, steel, (not shown)

Yoke boss 5H, Cylinder size
5 to 10 inches (127 to 254 mm),
Max travel 12 inches (305 mm) 38A8458 X012
Yoke boss 5H, Cylinder size
5 to 10 inches (127 to 254 mm),
Max travel 16 inches (305 mm) 38A8458 X022
Yoke boss 5H, Cylinder size
12 and 14 (305 to 356 mm),
Max travel 12 inches (305 mm)
Yoke boss 7, Cylinder size
5 and 14 (127 to 356 mm),
Max travel 12 inches (305 mm) 38A8459 X012
Yoke boss 5H, Cylinder size
12 and 14 (305 to 356 mm),
Max travel 16 inches (406 mm)
Yoke boss 7, Cylinder size
5 and 14 (127 to 356 mm),
Max travel 16 inches (406 mm) 38A8459 X022
Yoke boss 5H and 7, Cylinder size
5 and 14 (127 to 356 mm),
Max travel 20 inches (508 mm) 38A8460 X012
Yoke boss 5H and 7, Cylinder size
5 and 14 (127 to 356 mm),
Max travel 24 inches (610 mm) 38A8460 X022
69 Lower Yoke Cover, steel, (not shown) 28A8147 X012
72 Hex Nut, steel 1A3420 24152
73 Hex Nut, stainless steel (2 req’d) 1A3412 24112

75 Cap Screw, pi steel, 4 req’d 1A3816 24052

77 Machine Screw, pi steel, (not shown)
20 & 24 inch (11 req’d)
12 to 16 inch (10 req’d) 1A8517 28982
81 Machine Screw, pi steel 1B8776 28992
83 Lockwasher, stainless steel 1C3161 28982
86 Washer, pi steel, (11 req'd) (not shown) 1F2303 28992
87 Set Screw, pi steel 18A8378 X012
Figure 28. Typical Transmitter Mounting
88 Machine Screw, pi steel 18A8508 X012
on a Type 490 Actuator
89 Negator Spring Motor Assembly 18A8148 X012
Key Description Pert Number
63 Mounting Plate, steel
Yoke boss 5H, Cylinder size
5 to 10 inches (127 to 254 mm),
Max travel 12 inches (305 mm)
Yoke boss 5H, Cylinder size
5 to 10 inches (127 to 254 mm),
Max travel 16 inches (305 mm) 28A8141 X012
Yoke boss 5H, Cylinder size
12 and 14 (305 to 356 mm),
Max travel 12 inches (305 mm) ..
Yoke boss 7, Cylinder size '
f 5 and 14 (127 to 356 mm),
Max travel 12 inches (305 mm)

35
4200 Series v

Table 5. Lubricants and Sealants

Key Part
Description
Number Number
Lubriplate!1) Mag-1 Lubricant, 0.9 pound
48 1M1100 X0012
(0.396 kg) can (not furnished with mounting)
Loctite® No. 242 Sealant, 0.3-inch3 (50
49 1M6159 X0012
cm3) bottle, (not furnished with transmitter)
Never-Seez® Lubricant, 1 gal (3.8 L)
50 1M5329 06992
can (not furnished with transmitter)
Loctite No. 222® Sealant, 0.06-inch3 (10 cm3)
51 1M5947 X0012
bottle (not furnished with mounting)
1. Tradem ark o f Fiske Brothers Refining Co.
2. Tradem ark o f Loctite Corp.
3. Tradem ark o f Never-Seez Corp.

While this information is presented in good faith and believed to be accurate, or a n y o th e r m a tte r w ith re s p e c t to th e p ro d u c ts , nor as a recommendation to
Fisher Controls does not guarantee satisfactory results from reliance upon such use any product or process in conflict with any patent. Fisher Controls reserves
information. N o th in g c o n ta in e d h e re in is to b e c o n s tru e d as a w a rra n ty o r the right, without notice, to alter or improve the designs or specifications of
g uarantee, e x p re s s o r im p lie d , re g a rd in g th e p e rfo rm a n c e , m e rc h a n ta b ility , fitn e s s the products described herein.

■— B ■* For in fo rm a tio n , c o n ta c t F is h e r C o n tro ls :

FISHER Fisher Controls Marshalltown, Iowa 50158 USA
Cernay 68700 France
Sao Paulo 05424 Brazil
Singapore 2158

□AilPRUIteOWITHl . .
Printed in USA I ^ I so yink I recycled pa'wr
 Bulletin 8100
y J*9 • ~ ^ ' i .■“ ■SiA.-r ■ ■£V*£«V ■ »*»V.
w et*--.•••* :'■■ .... " ■ •• . h-. -i. ^a' s. ->■■j i i c v r £ * n "V .
j j j j . t —^vji- . • _ • . -. ••?». .•’ !?!“, ''T j ’s r ^ f ’ S V '■*■'•' «sste»r-•••• .-*•••Vf-r.-r
■■■ - O A Q
'•>*-: K-. i M a x :o n UlA w
Shut-Off Valves

5-r;*'■v.'«*'
. i •••• ••••
★ M an u al R eset or M o to rize d
★ Large O p en /S h u t In d ic a to r
P roof-of-C losure, -O pening
p ening y ^ : r \. .
R o ta ta b le T op A s s e m b ly
]& ★ M e ta l-to -M e ta l S e a tin g ■->■■■*.

•» .1.*. •' . ** *•" • • . - * • .• •••’•.*•-»• " ,-y ,r%s«V .< '•'• » -( $£*'•' _

‘‘ • ..............* *-•*•- 1,1 ' *-■>‘ -"■ ■*'•.•

Normally-dosed valves. Powering of an Internal solenoid or magnetic clutch permits opening. Interruption of
power supply gives virtually instantaneous closure. Usted/approved for clean fuel gas service, suitable for
many other gases. Unlisted versions available for special applications, including some liquid services.

M axon practices a po lic y o f continuous product im provement, it reserves the right to alter specifications without p rio r notice.

CORPORATION
INDUSTRIAL COMBUSTION EQUIPMENT AND VALVES M U NC IE, IN D IA N A , U.S.A.
 P age 8100-2
c —
rp Typical Applications
M ax o n G A S S h u t-O ff V a lv e s are u se d in
b u rn er s ys te m fu e l s u p p ly lin e s on in d u s tria l
b o ile rs, fu rn a c e s , oven s, k iln s and o th e r
h e a tin g e q u ip m e n t, and a re d es ig n ed to s h u t
o ff th e fu e l a u to m a tic a lly a n d in s ta n tly upon
any b reak in th e e le c tric p o w e r or s a fe ty c irc u it.
T h ey are a ls o used fo r th e m a n u a l o r m o to riz ­
ed o p en in g a n d c lo sin g o f p ip e lines c arry in g a
v a rie ty o f g a s e s a n d liq u id s c o m m o n ly u se d in
Design Details
S e rie s 7000 e tc ..
L arge, tw o -c o lo r, open-shut in­
d ic a t o r © p rovides eas y id e n tific a ­
tio n o f valve p o s itio n . B uilt-in w ir­
in g c o m p a r tm e n t o r s trip ©
e lim in a te s need fo r extern a l ju n c ­
tio n box.
E n c lo su re © m e e ts N E M A 1, 2,
3, 3 R , and 4 and 12, and C SA 2, 3
a n d 4 s ta n d a rd s (w hen su itab le
e le c tric a l c o n n e c tio n s are m ade).
L O th ers L u b ric a tio n -fre e d es ig n m eans
m in im a l m a in te n a n c e re ­
q u ire m e n ts . F ie ld -ro ta ta b le to p
a s s e m b ly © provides fou r p osi­
M e ta l-to -m e ta l s e a tin g d o es n ’t
w e a r o ut, it “ w e a rs in .” D isc w ip es
v a lv e s e a t c le a n du rin g e a c h
o p e ra tio n .
R is in g s te m d e s ig n w it h
s tr a ig h t- t h r o u g h f lo w re d u c e s
p ressure drop. C h o o s e c as t iron or
Accessories
A lte rn a te P ip in g A rra n g e m e n ts s im p lify the
in s ta lla tio n o f th re a d e d v alves in w e ld e d or
fla n g e d -p ip in g .
A u x ilia ry S w itc h e s © (S P D T or DPD T) p rovide
‘p ro o f-o f-c lo su re ’ (m e e tin g F M re q u irem e n ts ) or
p ro o f-o f-o p en in g .
C o m p a n io n F la n g e S e ts (fla t-fa c e d ) fa c ilita te
th e in s ta lla tio n o f fla n g e d valves.
Tandem L in k a g e p e r m its s im u lta n e o u s
L t
M A^O N M axon practices a policy o f c ontin uous pro d u ct Improvement. It reserves the right to altar specifications w ith o u t p rio r notice.
CORPORATION Ik in llC T D IA rrtAABIICTirtKI
GAS S h u t-O ff V alves
ind u strial p ro cesses. T h ey c a n n o t b e o p en e d
until an in terlo c k in g s a fe ty o r c o n tro l c irc u it is
c o m p lete.
Use M o to rize d valves w h e re re m o te or “ un­
m a n n e d ” o p era tio n is n ee d ed . N o t re c o m m e n d ­
ed- for liquid a p p lic a tio n s in volving fre q u e n t
cycling. (U se O IL S h u t-O ff V a lv e s , Bui 8210.)
U se M a n u a l R eset valves w h e re " m a n n e d "
o p eratio n is required or p re fe rre d .
Top A ssem b ly
tio n s for c o m p le te p ip in g co n ve­
nience.
V a lv es d e s ig n a te d S e rie s 7000,
7 1 0 0 , e tc . fe a tu r e R ack &
P in io n /S o lid -S t a t e /M a g n e t ic
C lu tc h d es ig n . V a lv e s d e s ig n a te d
S e rie s 808, 818, 5000, 5100, e tc .
fe a tu re s o le n o id -a c tu a te d in tern al
la tc h in g m e c h a n is m .
Motorized valves only: d rive
m o to r op en s valve w ith in 6 or 14
s ec o n d s (d ep en d in g on s p e c ific
valve) w hen e n e rg ize d .
V alve Body
c a s t s te el body to m e e t jo b need s.
B uilt-in over-travel a t th e clo sed
p o s itio n is d e s ig n e d to g iv e
po sitive s hu t-o ff.
T e s t c o n n e c tio n s a re provided
both u p stre am and d o w n s tre a m o f
valve disc.
o p eratio n of tw o m an ual re se t valves.
T e rm in a l B lo ck © s im p lifie s w irin g in s ta lla ­
tion and aids e le c tric a l tro u b le -s h o o tin g . In ­
cluded w ith s eries 7000 V a lv es .
T rip D elay (TD) units a ssu re c o n tin u e d o p e ra ­
tion d e s p ite m o m e n ta ry p o w er in terru p tio n s.
W h e e l-a n d -C h a in A s s e m b lie s a llo w th e
o p era tio n of m an ual valves in o th e rw is e in a c ­
c es sib le overhead lo c a tio n s .
Covered by U.S. patents 3,082,627, 3,508,446 and 3,685,790.
72/85
E m IIDKACMT A R in \/A I\/CC
 Page 8100*5
GAS S h u t-O ff V a lv es
Capacities/Specifications
GAS Shut-Off valves incorporate threaded or flanged
bodies, depending on size. They are suitable for ambient and
fluid temperature ranges between-20*F/-28 C and 140 F/60 C
(for AC power supply) or 125*F/51*C (for DC operation)
Valve action is designed to provide aggressive closure
within one second of de-energizing the solenoid or clutch.
Manual reset valves may be opened anytime they are powered,
using a 2-stage latch and return motion. Motorized valves
allow flow to begin within one second of powering. Complete
opening is reached within 6 or 14 seconds, depending on the
version chosen.___________ _ _____ ___________ _________
Do not use motorized valves in applications requiring more
than one cycle per minute lor periods of 15 minutes or longer,
as such repeated cycling can overheat motor operator.
Valve specifications are summarized in the table below.
Listed series’ are sold for “clean fuel gases and oils , and
carry UL, FM and CGA listings/approvals. They are IRI ap-
provable. Unlisted series do not carry approvais/listings, and
the pressure limits shown apply only for selected worst-case
applications. An analysis of your fluid will determine the ac­
tual rating, trim and assembly number for your application.
________ . fin W7 n n e r a tio n . C h e c k to r c u rre n t s ta tu s .

Soecifications Listed Series Unlisted Set ies

Valve Body Manual Motortzac Max Psi Manual Motorizee Max Psi
Cv Reset ® Inlet Reset @ inlets
Size
808 5000 125 818 5100 30
*/4 19
20 808 5000 125 818 5100 30
1
44 808 5000 100 818 5100 30
1V*
53 808 5000 70 818 5100 20
1 ’/ l
86 808 5000 70 818 5100 15
2
127 808 5000 40 818 5100 10
2% 808-CP 5000-CP 50 818-CP 5100-CP 15
304
173 808 5000 30 — — —
3 808-CP 5000-CP 40 818-CP 5100-CP 10
432
808-CP 5000-CP 40 818-CP 5100-CP 10
551
4 7000 60 — 7100 5
903
765 808 — 30 818— 5
6 7000 50 7100 5
1230 ■-
© May be higher depending on application. Contact Maxon w ith tiu ld analysis.

To select a valve for YOUR application, use either Cy factor

calculations or the graphs at left, which show the approximate
a P at various flows. Typically, a P for gas flows should not ex­
ceed 10% of inlet pressure.
For gas flows at inlet pressures above the maximum in­
dicated on each graph, contact Muncie.
Alternate piping arrangements (listed below and shown on
dimensional pages) may be specified at extra cost in lieu of
standard threaded body, but the applicable pressure rating
will be the lower of the nominal valve rating or that of the
flanges used. Options include:
Cast Iron Bodies Steel Bodies
Fig. I Nipples only Fig. I Nipples only
Fig. II Nipples & welding cplgs Fig. II Nipples & welding cplgs^
Fig IV Nipples & slip-on figs* Fig. Ill Nipples & lap joint figs
Fig. IV Nipples & slip-on figs*
- -Your choice of 150, 300 or 600 psi ANSI raised-face flanges.
To order, specify cast iron valves “with threaded Sch80 nip­
ples added per Fig______ " (see above), steel bodied valves
“with Sch80 nipples socket-welded into the body before
assembly per Fig-----------" (see above).

2/86
 Page 8100-6 GAS S h u t-O ff Valves
Trim Specifications
Maxon GAS Shut-Off Valves carry a
2 -part trim identification (for example,
Trim 1-1).
The first part (a 1, 2, 3 or 4 before the
hyphen) identifies valve body and bonnet
material as shown in Table 1 below.
Check Maxon for current availability and
price of 3- and 4- bodies before ordering.
The second part (a 1 or 2 after the
hyphen) identifies the specific internals
used, as described in Table 2 and iden­
tified in the sketches at right. Note that
this information is furnished for iden­
tification, not for ordering parts.
I n t e r n a l tr im -1 is suitable for clean fuel
gases and oils (for example, natural gas,
propane, butane, clean atmosphere
gases, #1 and #2 fuel oil).
In t e r n a l tr im -2 is suitable for such
gases as coke oven, refinery, town or o ff­
gas, but may not be required for all non-
listed applications.

W A R N IN G : Do n o t a tte m p t field re p a ir o f valve

b o d y, top a s s e m b ly or m o to r drive u n it. A n y a lte ra ­
tio n s void a ll w a rra n tie s .

T ab le 1: Body © and B o nn et © S p e c ific a tio n s

Body Description Body 1- Body 2- Body 3- Body 4-
Material Cl, G3000, CL30 Cast Steel • Cl, G3000, CL 30 Cast Steel
ASTM Spec . A159 A216-WCB A159 A216-WCB
Special Coating - - Electroless Nickel-Ctd. Electroless Nickel-Ctd.

Table 2: Valve Internals

Item Trim: -1 Trim: -2
No. Description V4--2' 2 ’/ t ' , 3 ' 4*, 6 ' “C P "(2V ,--4’ ) J/.-.2' 4 ', 6" “CP” (2’/t*-4 ')
3 Seat 440-F SS 416 SS 303 SS 440-F SS 303 SS 303 SS 303 SS
(Hard-faced) (Hard Faced) (Hard Faced) (Hard Faced)
4 Disc 80-55-06 Dl 80-55-06 Dl 80-55-06 Dl 80-55-06 Dl 80-55-06 Dl * 80-55-06 Dl 80-55-06 Dl
(chr. pltd.) (chr. pltd.) (chr. pltd.)
5 Follow Ring Leadaloy Dl (ni. Pltd.) Low-C Stl Low-C Stl Leadaloy Low-C Stl Low-C Stl
(ni. pltd.) (ni. pltd.) (ni. pltd.) (chr. pltd.) (chr. pltd.) (chr. pltd.)
6 Seat O-Ring Buna N Buna N Buna N Buna N Viton Viton | Viton
7 Gasket O-Ring Buna N Buna N Buna N Buna N Viton Viton Viton
8 Wavy-Spring 302 SS 302 SS 302 SS 302 SS 302 SS 302 SS 302 SS
Washer
9 Stem Steel Steel Steel Steel Steel Steel Steel
(chr. pltd.) (chr. pltd.) (chr. pltd.) (chr. pltd.) (chr. pltd.) (chr. pltd.) (chr. pltd.)
10 Stem/Disk Pins 1070 CS 1070 CS — — 420 SS —
(hardened) (hardened)
11 Stem O-Ring (3) Buna N Buna N Buna N Buna N Viton Viton Viton
12 Striker Plate 17-7 SS 17-7 SS 17-7 SS 17-7 SS 17-7 SS 17-7 SS 17-7 SS
13 Bumper Buna N Buna N Buna N Buna N Buna N Buna N Buna N

M AkM O N U tx o n pra ctice s a p o lic y o l contin uous pro d u ct im p ro n m a n t. It reserves the rig h t to alter specifications w ith out p rio r notice.

CORPORATION
MUNCIE, IN D IA N A , U.S.A. INDUSTRIAL COMBUSTION EQUIPMENT AND VALVES
 1

GAS S h u t-O ff V a lv es Page 8100-7

Electrical Data
C G e n e ra l______________________ _____ —-----------------------
Each GAS Shut-Off Valve (except those denoted as Series 7000 or
A u xiliary S w itc h e s -----------------------------------------------------
VCS (Valve Closed Switch) is actuated at the end of the closing
stroke. VCS-1 is SPDT; VCS-2 Is DPDT.
7100) includes a solenoid for 120v or 240v AC operation. Other voltages VOS (Valve Open Switch) Is actuated at the end of opening stroke.
are available upon request (see replacement solenoid listing on Page
VOS-1 is SPDT; VOS-2 is DPDT.
8100-10), but may involve extra cost and/or extended delivery. Motorized valves include a VOS-1 and use NC contact as a motor limit
Top assembly enclosure meets NEMA 1,2, 3, 3R, 4 and 12 and CSA 2, switch. NO contact remains available for signal duty when compatible
3, 4 requirements. Electrical connections must be compatible with ap­ voltage is connected between terminals 2 (neutral) and 3 (hot). For addi­
plicable codes to maintain enclosure integrity.
tional contacts, specify VOS-2.
Terminal block (standard on Series 7000, optional on others) includes Good practice normally dictates that auxiliary switches in valves
1Z“rtumber-eoded positions. Any auxiliary switches specified are wired used for safety shut-off functions should be used for signal duty only,
as'shown below. Two additional terminals are provided if valve is
not to operate additional safety devices.
specified for direct DC powering of clutch or solenoid. In a block-and-bleed system, blocking valve and normally-open vent
All e x c e p t S e rie s 7 0 0 0 -------------------------------------------- — valve may be powered through the VCS of the main fuel shut-off valve,
Solenoid is energized whenever valve is powered. Solenoid holding but all three must be powered through the appropriate normally-open
VA is continuous once energized. Motor of motorized valves is powered flame relay contact.
only during the opening stroke. Use of a DC solenoid in valves 1 V i' and
smaller requires selection of an ‘unlisted' series, for example, Series
W irin g D ia g ram s -----------------------------------------------------
Each GAS Shut-Off Valve includes one of the wiring diagrams
818 Instead of 808. - reproduced below. Whichever diagram is appropriate, switch contacts
Volt-ampere (VA) ratings for GAS Shut-Off valves are shown in the
are shown with the valve in its fully shut position.
table below. Total VA of solenoid and switches (manual reset valves) or
Wiring above the terminal strip is Internal and present only when the
solenoid, motor and switches (motorized valves) must not exceed the
appropriate switches are specified. Wiring below is external.
limits shown on appropriate wiring diagram below. All wires (unless noted otherwise) are black and number-coded to
Valve AC Operation DC Operation match terminal strip. Terminals "2” and "DC-" are neutral, all others are
Type Size Series Opening Holding Opening Holding hot.
>/4 -3 808, 818 24 24 14 14
6 808, 818 40 40 20 20
40 40 14 14
CM
£

808CP, 818CP
V. - 3 5000, 5100 264 24 254 14
2 Vi - 4 5000CP, 5100CP 280 40 254 14
Motodzec
4 -6 7000, 7100 434 © 431 11
© 14 for 120 VAC, 22 for 240 VAC
© W ith AC motor to open, DC sol. to hold

S e rie s 7000 o n ly .
Valve timing for 4’ valve includes 10-second opening with 60HZ AC
power (12 seconds with 50HZ). The 6" valve opens within 12 seconds
with 60 HZ power (14 seconds with 50HZ).
For either size, flow begins within Vi second of powering, and
cushioned closure is complete within one second after interruption of
power.
Motor operator is energized only during the opening cycle. The
normally-closed contact of a limit switch breaks the motor circuit when
the full-open position is reached.
: -Power Input (normally 120v AC) is converted by the printed circuit
board (PCB) included in valve utility panel to 90v DC output to a
magnetic clutch that is energized whenever the valve is powered.
For operation on 240v AC power, valve must be ordered LESS #25375
utility panel and WITH #25977 utility panel, LESS #25379 motor and
WITH #25380 motor. A F o r S e rie s 8 08 , 818,
AC/DC operation is possible, with only DC required to maintain open
position. Drive motor must be powered by AC, but clutch may be 5000 & 5100 V a lv e s
operated by 48, 90 or 120v DC power supply. Contact Maxon for details (in clu d in g “ C P ” & “ -S”
and availability.
PCB components also act as a time delay, Introducing a 1/10th v ariatio n s)
second response lag upon AC power interruption, and preventing many
unwanted closures.

F o r S e rie s 700 0 & 7100

Valves; (in clu d in g “ -S”
v ariatio n s)

C-

2/86 M axon pra ctice s a p o lic y o f continuous pro d u ct im provem ent. It reserves the rig h t to alter specifications w ithout p rio r notice. M AMO N
CORPORATION
4
INDUSTRIAL COMBUSTION EQUIPMENT AND VALVES M U N C IE, IN D IA N A . U.S.A.
 P age 8100*8 GAS S h u t-O ff V alves

Assembly Numbers
< C o m p lete V a lv es
Assembly numbers (or complete valves are shown below.
Table 1 lists manual reset valves, Table 2 motorized. Read
down the center column to the required valve size, then
horizontally to the desired valve series and assembly number.
Note that valves may be ordered with or without a terminal
block assembly (to simplify wiring).
Listed valves (for clean fuel gases and oils) are to the left,
unlisted valves (for special services) to the right. An approx­
imate shipping weight is shown. SHADED AREA indicates
flanged valve bodies. All others are threaded. Valve bodies are
cast iron unless series designation includes ‘-S' for steel body.
Open/Shut indicator window can be positioned for best
viewing by choosing a suitable top assembly position. Options
are “ R" (Right), “L” (Left), “TO" (Toward) and "AW" (Away),
based on flow direction when viewing the Open/Shut indicator.
Motorized valves are available in two nominal timings.
Choose the 6-second version to meet short trial-for-ignition
periods, the 14-second version to minimize pressure surges
caused by valve opening. Each includes a VOS-1 SPDT proof-
of-opening switch (which acts as a motor limit) and motor
operator for 120v or 240v AC power. - •
For DC operation, ’/«’ through. 1 Vz.’. valves must be ordered
with a special spring retainer, solenoid and VOS switch (at ex­
tra cost) and are not UL-listed.
Alternate piping arrangements (if needed) should be ordered
as noted on Page 8100-5.

Table 1: M anual Reset Valves To order, specify:

Listed Valves (For Clean Fuel Gases & Oils) Valve Unlisted Valves (For Special Services) Quantity
Assembly Numbers Designation Size Sh. Wt. Designation Assembly Numbers Assembly Number
with Blk w/out Blk Series Trim (Inches) (lbs.) Series Trim with Blk w/out Blk Size & Series designation
22367 17931 808 1-1 V. 17 818 1-2 22369 20943 Description
22371 17932 808 1-1 1 17 818 1-2 22374 20944 Voltage & Top Assembly Position
22372 17956 808-S 2-1 17 818-S 2-2 22377 21621 Service ,
22378 17933 808 1-1 1V« 19 818 1-2 22380 20945 Accessories desired
22382 17934 808 1-1 1>/j 20 818 1-2 22385 20946 Serial No. (of existing valve, if
22383 17958 808-S 2-1 20 818-S 2-2 22388 21622 ordering parts)
22389 22269 808 1-1 2 31 818 1-2 22392 22272 For example: 2 #22371 1" Series 803
22390 22270 808-S 2-1 31 818-S 2-2 22395 22275 GAS Shut-Off valves w/terminal
22396 22276 808 1-1 — — — — — block, for 120/60 A C power, position
36912 36915 808: 1 -i . 2’/ i 70 — - — — ‘TO ’, (or natural gas @ 5 psi, with 2
22356 23293 808 CP 1-1 46 818 CP 1-2 23359 23296 #18429 VCS-2 Signal Switches.
23357 232S4- 808-S CP : 2-1 89 818-S CP f 2-2 23362 23299
22400 22280 808 1-1 — — — — —
23363 23300 808 CP T-1 3 50 818 CP 1-2 23366 23303
' 23364= 23301' 808-S CP 2-1 89 8 1 8 S C P " 2-2 ‘ ~ 23369". ' 23308
23370 23307 808 CP 1-1 4 123 818 CP - . 1-2 , 23373 , 23310;
- 2337t‘ 23308' 808-S CP 2-1 123 818-S CP 2-2 ■ 23376 23313
29415- 29421 808 1-1 6 135 818 . 1-2 29417 29423
29418T : 29424 80S-S 2-1 145 ■ 818-S 2-2 29420 29426

Table 2: M otorized Valves

Listed Valves (For Clean Fuel Gases & Oils) Valve Unlisted Valves (For Special Services) -
Assembly Numbers Designation Designation Assembly Numbers
Size
with Block w/out Block with Block w/out Block
Series Trim (Inches) (lbs.) Series Trim
6 sec. 14 sec. 6 sec. | 14 sec. 6 sec. 14 sec. 6 sec. 14 sec.
22407 22447 22287 22327 5000 1-1 >/. 23 5100 1-2 22409 22449 22289 22329
22411 22451 22291 22331 5000 1-1 1 23 51000 1-2 22414 22454 22294 22334
22412 22452 22292 22332 5000-S 2-1 23 5100-S 2-2 22417 22457 22297 22337
22418 22458 22298 22338 5000 1-1 1V. 24 5100 .1-2 22420 22460 22300 22340
22422 22462 22302 22342 5000 1-1 11/* 25 5100 1-2 22425 22465 22305 22345
22423 22463 22303 22343 5000-S 2-1 25 5100-S 2-2 22428 22468 22308 22348
22429 22469 22309 22349 5000 1-1 2 34 5100 1-2 22432 22472 22312 22352
22430 22470 22310 22350 5000-S 2-1 34 5100-S 2-2 22435 22475 22315 22355
22436 22476 22316 22356 5000 1-1 37 — — — — — —
36895 36896 36904 36905 5000 1-1 75 — — — — — —
1-1 2 Vs 50 5100 CP 1-2 23380 23401 23317 23338
23377 23398 23314 23335 5000 CP
23378 23399 23315 23336 5000-S CP 2-1 93 5100-S CP 2-2 23383 23404 23320 23341
22440 22480 22320 22360 5000 1-1 42 — — — — — —
23384 23405 23321 23342 5000 CP 1-1 3 53 5100 CP 1-2 23387 23408 23324 23345
23385 23406 23322 23343 5000-S CP 2-1 " - 95 . 5100-S CP 2-2 23390 23411 23327 23348
23391 23412 23328 23349 5000 CP 1-1 133 5100 CP 1-2 23394 23415 23331 23352
23392 23413 23329 23350 5000-S CP 2-1 4 133 5100-S CP 2-2 23397 23418 23334 23355
— 25384® — 7000 1-1 195 7100 1-2 — 28781® , .
— 25832® — 7000-S 2-1 195 7100-S 2-2 — 28783® T —
— ' 253850 . — 7000 1-1 ; 6 215 ' 7100 1-2 —. ■ 28782® ■• , .—
■' • 25833® - 7000-S 2-1 215 7100-S 2-2 — 28784®
0 1 0 seconds, not 14. 0 1 2 seconds, not 14.

M axon practices a p o lic y o f continuous product Improvement. It reserves the right to alter specifications w ithout p rio r notice.

CORPORATION
MUNCIE, IN D IA N A , U.S.A. INDUSTRIAL COMBUSTION EQUIPMENT AND VALVES
GAS S hut-O ff Valves Page 8100-9

Assembly Numbers
A uxiliary Sw itches: where two numbers are of 2 manual reset valves in a "block-and-bleed” con­
shown separated by a slash, use first number if VO S figuration. W hen ordering, specify intended center-to-
is not used: use second number if a V O S is used. center dimension between valves (allowable range is
Motorized valves include a VOS-1 switch (shown by 20" to 27"). Both valves must be in position "TO" or
SH A D ED AREA of table). To orderwith a VO S-2 "AW".
switch, specify "less & with" appropriate assembly W heel & Chain: allows operation of manual reset
numbers. valves in otherwise inaccessible overhead locations.
Hermetically-Sealed switches are rated for 1 amp, Handle is replaced by a wheel and attached chain
125v AC service. Motorized valves with these weighted on one end and with a paddle/handgrip on
switches do not carry listings/approvals, and must be other end. Lifting paddle lets weight rotate wheel,
designated as Series 5 1 0 0 ,7 1 0 0 , etc. thus latching valve. Pulling down on paddle then
High-capacity DC switches are rated for 10 amps. opens valve.
125v DC-AC service. All valves thus equipped do not Basic assembly includes 5' of chain (reaching
carry listings/approvals, and must be designated as slightly below pipe centerline). Additional chain, if
Series 8 1 8 ,5 1 0 0 ,7 1 0 0 , etc. needed, may be ordered in 1' increments (at extra
TD Units: Power supply must be 120v AC. Requires cost) as part #00035.
Solenoid Assembly "TD”, ordered by number shown. C om panion Flange Sets: include 2 flat-faced
T an d em Linkage: permits single-handed operation flanges, gaskets and necessary fasteners.
(For more accessory information, see catalog section 8900)
A u x ilia ry awucnes
Valve Description Standard Switches Herm. Sealed High Cap. DC
Tvpe Series/Size VCS-1 VCS-2 VOS-1 VOS-2 VCS-1 VOS-1 VCS-1 VOS-1
808 Others 18428/17541 18429/17542 19599 19620 19620 26686 76453 26460
Manual 818 6" AC or DC 23433/23436 23434/23437 [11 24470 26301 25296 26698 >-55 26461
Reset 3/4" -1-1/2" DC 19595/23462 19596/23463 19621 26302 19620 [21 26686 [41 26453 26460
808-CP, 818-CP 23433/23436 23434/23437 [11 24470 26301 25296 26698 26455 26461
4808, 5000, 5100 17541 17542 19599 [31 25467 [31 26447 26686 — —
5000-CP. 5100-CP 23436 23437 [11 . .24470 26301 25297 26698 26456 2c 161
Motorized 7000. 7100 25595 27252 25377 25846 27232 27231 — —
5100 3/4" -1-1/2" 23462 23463 19621 26302 26447 [51 26686 [41 26454 26,60
m 2-3" 17541 17542 19599 25467 26447 26686 26454 2.4c0

bracket,WITH#!9582bracket f-orneia installation,cupt/z iromwanu. [oj ro r o/h - ■ vai ves, usemwi w>ui ui «Mu u ,
1 or *2$302 VOS-2. [4] Specify switch assembly LESS #21978 bracket. WITH #19582 bracket [5] Specify valve LESS #18412 bracket.
WITH #19582 bracket. For field installation, dip 1/4" from wand.

"TD” Trip Delay Units, Tandem Linkage, Wheel & Chain

TD (Trip Delav) Unit Tandem Linkage Wheel & Chain
Valve Chassis TD with Required Position* Position Single Tandem
Type Size Only Enclosure Solenoid "TO" "AW” Valve Valves
"CP" All HI 36587 [3125307 37757 24000 24001 24872 ...

3/4" -1-1/2" [21 36587 [3123806 37743 17644 18372 16226 17829
Others 2” - 3" m 36587 r3123805 37749 17645 18373 16227 17830
6" (808. 818) ril 36587 [31 25307 37757 . . . ... 24872 —

[1] Order req'd. #384210.6 amp Slo-Blo fuse kit separately. [2] Order req'd. #384221.25 Slo-BIo fuse kit separately. [3] Includes
appropriate fuse kit

Companion Flange Sets

125# C.I.Threaded 150# Steel Threaded 150# Steel Slip-On
Pipe Sh.W t. Asby. Pipe Sh.W t. Asby. Pipe Sh.W t. Asby.
Size Lbs. No. Size Lbs. No. Size Lbs. No.
4" 37 20206 2-1/2" 22 20339 2-1/2" 22 20340
6" 46 20207 3" 24 20342 3" 24 20343
4" 35 20208 4" 35 20210
6" 46 20209 6" 46 20211

12/86 M axon practices a po lic y o f continuous product improvement. It reserves the right to a Iter specilicetions w ithout p rio r notice. M A

CORPORATION
INDUSTRIAL COMBUSTION EQUIPMENT AND VALVES M U N C IE, IN D IA N A , U.S.A.
 Page 8100-10 GAS S h u t-O ff Valves

Assembly Numbers
; -.v
eplacement Parts "I &? >I?C */?
When ordering replacement parts, always specify For hazardous duty locations (Series 5 1 0 0 ,5 1 0 0 -
the serial number of the valve for which they are C P only), 120v AC operator is available without
intended. (You'll find it stamped into the nameplate.) thermal overload protection (eliminating an arcing
R eplacem ent so len o id kits: "Current" valve contact). For 2-1/2 second timing, specify #37 46 5
series include those whose serial numbers start with instead of standard #35938. For 6 second timing,
two digits (indicating year of manufacture) followed by specify #37466 instead of standard # 35 94 0. For 14
the letter "M" or "A”. “Old" valve series include those second timing, specify #37 46 7 instead of standard
with a serial number starting with a letter. #35942.
R eplacem ent m o to r o p e ra to rs : W hen Not applicable to most 3 /4 ” through 1-1/2" sizes
ordering, identify the manufacturer's nam e marked on built in 1985 or earlier.
the old motor as well as valve serial number.

Replacement Solenoid Kits

"Current " Series "Old" Series
Type Voltage 3/4 to 1-1/2" 2 to 3" 800, 808
808, 818 808, 818 All "CP" 6" 808 818, 4800
5000, 5100 5000, 5100 4808, 4818
24 21025 22049 25885 25885 21025
48 35886 35887 35888 35888 35886
120 17555 f51 22055 f51 23243 T51 23243 r51 17555
240 21026 22056 23244 [5] 23244 [5] 21026
AC 360 35889 35890 35891 35891 35889
480 21027 22052 35892 35892 21027
600 [2] 21028 22053 35893 35893 21028
100 ■ 35894 35895 35896 35896 35894
208 35897 35898 35899 35899 35897
24 26439 [1] 22059 23421 — _
48 26506 [1] 26504 26503 31463 [3] ...

DC 120 25125 [1] 22060 23422 31464 [4] 25125

240 26440rn 24882 24883 —
26440
For TD Units 120v AC 37743 37749 37757 37757 —

[1] Must be unlisted (Series 818 or 5100) if DC Solenoid is used [2] Requires designation as unlisted series (818,5100) [3] Replacement only.
For field conversion to 48v DC specify #29652 [4] Replacement only. For field conversion to 120v DC specify #29651 [5] If used with “TD“
Unit, see appropriate solenoid kit on previous page.

Replacement Motor Operators

Description Assembly Number
Timing f41 Type Voltage All Series 5000, 5100 All ‘All Series Old Series
Normal Alternate "CP" 7000, 7100 4800. 4808. 4818
2-1/2 sec. AC [1] 120 35938 — — — —

240 35939 — —

AC 120 35940 [2] 24S85 35940 — —

240 35941 [21 24886 35941 — . . .

6 sec. 24 36648 —
36648 — . . .

DC [5] 48 36650 — 36650 — . . .

120 33119 — 33119 — . . .

AC 120 35942 [2] 24887 35942 32093 (3] 24887

240 35943 [21 24888 35943 32094 [31 24888
14 sec. 24 36649 — 36649 — . . .

DC [5] 48 36651 —
36651 — . . .

120 36701 — 36701 — —

f [1] Requires designation as unlisted Series 5100 [2] For 1-1/2" valves or smaller, identify date of manufacture from serial number stamped
. into nameplate. If Serial No. starts with '84' or lower, use alternate. If Serial No. starts with '85' contact Maxon with number to determine
"appropriate operator. [3] Timing is 10 seconds for 4" valve, 12 seconds for 6" valve. [4] Nominal timings: the
actual time required for valve to reach full-open position will vary with voltage, valve size, temperature, inlet
pressure and valve body condition, etc. [5] For non-listed valve series only.

M AMO N M u o n pra ctice s a p o lic y o l continuous p ro d u c t Improvement. It reserves ths right to s lie r sp e cltlcstlo n s w ith o u t p rio r notice.

CORPORATION
M U NC IE. IN D IA N A . U.S.A. INDUSTRIAL COMBUSTION EQUIPMENT AND VALVES
 GAS S h u t-o ff V a lv es Page 8100-21

Dimensions(Nominal, in Inches)

For Va" - 3 " 8 0 8 ,8 1 8 , 5 0 0 0 ,5 1 0 0 V a lv e s (e x c e p t “ C P ”) ____ For 4 ", 6" S eries 7 0 0 0 ,7 1 0 0 V alves

o
r Page 8100-22 GAS S h u t-O ff V alves

...more Dimensions
(Nominal, In Inches)

O For 2 V i " - 4" ‘C P ’, 6" 808, 81 8 version s

‘TO’

Size Strlas A
f i 9. B C 0 _§3_ E? Ft p2 G H J K L M N P R S T
2’/j CP 80S(S), 818(S) 2 4.38 14.56 6.94 2.38 4.19 9.94 5.69 2.50 5.00 2.25 10.62 fO.94 15.12 17.25 —

2ViCP 808(S), 818(S) 2A 4.38 14.56 8.94 2.38 4.19 9.94 5.69 — 3.75 7.50 2.25 10.62 10.94 15.12 17.25 3.50 2.75 0.75 4
2V4CP 5000(S)t 5100(S) 2 4.3B 14.56 8.94 2.38 4.19 9.94 — 7.44 2.50 5.00 2.25 10.62 —

2’/aCP 5000(S), 5100(S) 2A 4.38 14.56 8.94 2.38 4.19 9.94 — 7.44 3.75 7.50 2.25 10.62 — — — 3.50 2.75 0.75 4
3CP 80S(S), 81 S(S) 2 5.19 15.31 8.94 2.38 4.19 9.94 5.69 — 2.75 5.50 2.56 10.62 10.94 15.12 17.25
3CP 808(S), 818(S) 2A 5.19 15.31 8.94 2.38 4.19 9.94 5.69 — 4.00 8.00 2.56 10.62 —
3.75 3.00 0.75 4
3CP 5000(S), 5100(S) 2 5.19 15.31 8.94 2.38 4.19 9.94 — 7.44 2.75 5.50 2.56 10.62 10.94 15.12 17.25
3CP 5000<S). 510CHS) 2A 5.19 15.31 8.94 2.38 4.19 9.94 — 7.44 4.00 8.00 2.56 10.62 — — — 3.75 3.00 0.75 4
4CP 808(3), 818(S) 2A 5.44 15.31 8.94 2.38 4.19 9.94 5.69 — 4.50 9.00 2.56 10.62 10.94 15.12 18.00 4.50 3.75 0.75 8
4CP 5000(S), 5100(S) 2A 5.44 15.31 8.94 2.38 4.19 9.94 — 7.44 4.50 9.00 2.56 10.62 — — 4.50 3.75 0.75 8
6 808(S), 818(S) 2A 7.31 20.75 8.94 2.38 4.19 9.94 6.03 - 5.25 10.50 3.25 10.62 13.94 21.12 26.44 5.50 4.75 0.88 8

M A^O N Maxon p ra c tic e s a p o lic y o 1 contin u o u s p ro d u c t Improvement. It reserves the rig h t to a lte r specifications w ith out p rio r notice.

C O R P O R A T IO N
MUNCIE, INDIANA, U.S.A. INDUSTRIAL COMBUSTION EQUIPMENT A N n VAIVP<;
GAS S h u t-o ff Valves Page 8100-23

. . . more Dimensions
(Nominal, in Inches)

A lte rn a te P iping A rra n g e m e n ts (lor Cast Iron valve bodies, w/THREADED Sch. 80 nipples)

Valve Fiaure I Figure II Figure IV With 150 lb. R.F. Flanges With 300 or 600 lb. R.F. Flanges
Size Ai Bi A2 b2 A3 b3 C D E F C D E F
Va 7.12 14.25 8.06 16.12 7.38 14.75 2.75 3.88 .62 4 3.25 4.62 .75 4
1 7.06 14.12 8.19 16.38 7.31 14.62 3.12 4.25 .62 4 3.50 4.88 .75 4
■P/j 7.12 14.25 8.38 16.75 7.38 14.75 3.88 5.00 .62 4 4.50 6.12 .88 4
2 7.25 14.50 8.88 17.75 7.50 15.00 4.75 6.00 .75 4 5.00 6.50 .75 8
2% 7.50 15.00 9.12 18.25 7.75 15.50 5.50 7.00 .75 4 5.88 7.50 .88 8
3 7.47 14.94 9.22 18.44 7.72 15.44 6.00 7.50 .75 4 6.62 8.25 .88 8

A lte rn a te P iping A rra n g e m e n ts (for Steel Valve bodies, w/SOCKET- WELDED Sch. 80 nipples)

Face-to-face tolerance for Alternate

Piping Arrangements is ±.060’

C (d ia .)

D (d ia.)

E -(hole d ia m .)
.
F-(no. o f h o les )

-B i-------- -A h — b 3— H h-------- b 4-
_ b 2---------- -
F ig. Fig. Fig
Ml Ill IV 22 Vz'

Valve Figure I Figure II Figure III Figure IV With 150 lb. R.F. Flanges With 300 or 600 lb. R.F. Flanges
Size A1 Bi a2 b2 a3 b3 A4 b4 C D E F C D E F
1 7.00 14.00 8.12 16.25 5.25 10.50 7.25 14.50 4.25 3.12 .62 4 4.88 3.50 .75 4
11/i 6.64 13.88 8.19 16.38 5.19 10.38 7.19 14.38 5.00 3.88 .62 4 6.12 4.50 .88 4
2 7.00 14.00 8.62 17.25 7.25 14.50 7.25 14.50 6.00 4.75 .75 4 6.50 5.00 .75 8

P ipe t h n i d i o n th lc p ip e conform to NPT (ANSI S tan d a rd B2.1)

2/86 M axon practices a p o lic y o l contin uous pro d u ct im provem ent. It reserves the right to alte r specifications w ith out p rio r notice. M AMO N
CORPORATION
INDUSTRIAL COMBUSTION EQUIPMENT AND VALVES M U NC IE, IN D IA N A , U.S.A.
r

M tx o n p rtc U c ts t p o lic y o l contin uous pro d u ct Im p m n m s n t. II rsssrvss Ihs rig h t to s lts r spocilic s tlo n s w ithout p rio r notics.

CORPORATION
MUNCIE, IN D IA N A , U.S.A. INDUSTRIAL COMBUSTION EQUIPMENT AND VALVES
GAS S h u t-O ff V a lv e s Page 8100-25

Component Identification
General Maintenance & Spare Parts ------
All GAS Shut-Off Valves should be electrically tripped and To determine suggested spare parts, identify series
cycled at least monthly, preferably as part of a complete designation and serial number from the valve's nameplate
periodic inspection for all safety-related equipment. In this (which should resemble those shown below). Refer to the ap­
way, operating personnel will become familiar with normal propriate accompanying illustration and legend to identify
valve operation and recognize any change. suggested spare parts.
These Maxon valves are designed for long trouble-free ser­ To order, specify:
vice. Because their proper operation is so important, produc­ 1. Quantity
tion and testing are very carefully controlled in our factory. 2. Assembly number (as cataloged elsewhere)
Only those items shown as suggested spare parts should be 3. Description
considered field replaceable.____________________ .________ 4. Voltage (if applicable)
WARNING: Do not attempt field repair of valve body, top 5. Full nameplate Information (from existing valve, in­
assembly or motor drive unit. Any alterations void all warranties. eluding serial number and voltage)

Series 808,818,5000, 5100, etc. (includes steel-bodied versions)

J 5 U

(Manual Reset)

Series 808CP, 818CP, 5000CP, 5100CP, etc . (includes steel-bodied versions)

(Manual Reset) (Motorized)

Series 7000,7100 etc__ Designations___ Nameplate ____ _ Legend _______

(Includes steel-bodied versions) (as shown on nameplate)® (shown for listed valves- 7000,
7100 et a ll slig h tly different) ® Nameplate
Space © Motor Operator
3" 5000-SD | CP | 2
© Solenoid Kit
VCS Used® © VCS Signal Switch
I------------- CP Body © VOS Signal Switch
- ■ • DC Solenoid © Printed Circuit Board (PCB)
--------- Steel Body
------Valve Series
Valve Size (NPT)
Q S w itch Legend ® Nameplate
0 No S w itch designation does not
1 VCS-1 Switch reflect accessory 4 S liv e r litt e r in g
1H VCS-1 Items or VOS o n b la c k b a c k g ro u n d
(Herm. Seeled) switches.
2 VCS-2 Sw itch
2H VCS-2
(Herm. Seeled)

2186 M ix o n pra ctice s a p o lic y o f contin u o u s p ro d u c t im provem ent. It reserves the right to li t e r speclticetions w ith out p rio r notice. MA
CORPORATION [
INDUSTRIAL COMBUSTION EQUIPMENT AND VALVES M U N C IE, IN D IA N A , U.S.A. j
 Page 8100-26 GAS S h u t-O ff V alves

Top Assembly Rotation

General______ ■ ________________ Series 7000,7100, etc.
Maxon GAS Shut-Off Valves should be ordered in a con­
figuration compatible with planned piping, but if open/shut in­
dicator is not visible when valve is installed, top assembly can
be rotated (In 90* increments) by following procedure below.

Series 808,818,5000,5100, etc._________

(Includes steel-bodled versions)

NOTE: Open/Shut Indicator of these valves should never

face upward. Motor sideplate (motorized valves only)
should always be vertical.____________________________
1. Shut off all electrical power to valve and clos^ upstream
gas or oil cock.
2. Remove side cover © (or terminal access plate, if used)
and disconnect incoming lead wires (tag carefully for
reassembly).
3. Remove conduit and leads.
4. Note position of signal switch wand (if used) using sketch
on Page 8100-25 as reference.
5. Remove body screws © (two or four depending on valve
size) with 5/16* 12-point box wrench (3/8* for valves 2* and
larger).
6. Gently lift top assembly ® not more than 1/2*, just
enough to break the seal between valve body © and the
Buna “N" rubber gasket._______________________ _
WARNING: Lifting too far may dislodge some small
parts, requiring complex reassembly and retesting by
trained factory personnel. _________________
7. Carefully rotate top assembly © about 30* beyond, and
then back to the desired position, in a plane parallel to the
top of body casting © . This should align open/shut in­
dicator with its window and the latch arm roller of
operating mechanism with its pedestal.
8. Align screw clearance holes in valve body © with the cor­
responding tapped holes in the bottom of top assembly
©.
9. Reinsert body screws © , carefully engaging threads, and
tighten securely.
10. Reconnect conduit and electrical leads then check that
signal switch wand has not been disengaged and that in­
terference does not exist at open/shut indicator._________
| Failure to do so can result in extensive valve damage.
11. Energize valve and cycle several times from closed, in­
termediate and full-open positions to prove it operates
properly.
12. Replace side cover plate © (or terminal access cover) and
place valve in service.
1. Shut off all electrical power to valve and close upstream
gas cock.
2. Remove wiring access plate © , disconnect incoming lead
wires (tag carefully for reassembly), then remove com­
plete top cover assembly © cutting wire seal if still in
place.
3. Remove conduit and leads.
4. Note position of signal switch wand (if used) using sketch
on Page 8100-25 as reference. .
5. Remove the four body screws © with 9/16* box wrench.
6. Gently lift top assembly © not more than 1/2", just
enough to break the seal between valve body © and the
Buna “ N” rubber gasket.
7. Carefully rotate top assembly © slightly beyond, and then
back to the desired position, in a plane parallel to the top
of the body casting © .
8. Align screw clearance holes in valve body © with cor­
responding tapped holes in the bottom of top assembly
©•
9. Reinsert body screws © , engaging threads carefully, then
tighten securely.
10. Reconnect conduit and electrical leads, then check that
signal switch wand has not been disengaged and that an
interference does not exist at the open/shut indicator.
I Failure to do so can result In extensive valve damage. |
11. Energize and cycle valve several times from closed, in­
termediate and fully-open positions to prove it operates
properly.
12. Replace top cover and place valve in service.
|

MAMON M tx o n practices a p o lic y o f contin uous p ro d u c t improvamant. It rasaoraa the rig h t to attar specifications w ith out p rio r notice.

k
CORPORATION
MUNCIE, INDIANA, u . s .a . INDUSTRIAL COMBUSTION EQUIPMENT AND VALVES l
 Page 8100-27
GAS S h u t-O ff V alves

T od Assembly Replacement
(fo r 4 " , 6 " S e rie s 7000, 7100 V a lv e s e t al)

T o rem ove o ld to p a s se m b ly

1 . S h u t o ff u p stre am g as cock.
2 . S h u t o ff all e le c tric pow er to valve.
3 . R em o v e te rm in a l a c c es s plate. (M a k e certain
v alv e is in s h u t p o sitio n .
4 . R em o v e in c o m in g lead w ires from te rm in a l
b lo ck .
[5 . T a g le a d s fo r reassem bly.
6 . R em o ve c o n d u it and le a d s ....................................

7 . R em o ve to p cover. (Tw o of tw elve s crew s are

s e a le d . B rea k s ea l and rem ove screw s.)
8. L ift co v er s tra ig h t up to avoid d a m a g e to
m e c h a n is m .
9 . R em o v e lo c k s p a ce r, shock pad w a sh e r, and
s h o c k p ad . (P reven t spring re ta in e r from tu rn ­
ing w h ile rem o vin g lock s p a ce r by in sertin g
pin o r A lle n w re n c h into 1/« ” d ia m e te r ho le.
Pin w ill s to p p o ss ib le spring re ta in e r ro tatio n
w hen lo c k s p a c e r is u n t h r e a d e d . )

R em o v e fo u r hex head m o u n tin g s crew s

(3/8 ”-16 N .C .) w h ic h hold top a ss em b ly to up­
p er fla n g e o f valve bonnet.
11. L ift to p a s s e m b ly o f valve b o n n et. (Spring w ill
s ta y in p la c e and hold valve c lo sed .)

M axon practices a p o lic y o t contrnuous pro d u ct im provem ent It reserves the nght to alter specifications w ithout p rio r notice.
MA$Q N
7/83
CORPORATION
INDUSTRIAL COMBUSTION EQUIPMENT AND VALVES M U NCIE, IN D IA N A . U.S.A.
 Page 8100-28 GAS S h u t-O ff V a lv e s

Top Assembly Replacement (Cont’d)

o in s ta ll n e w to p a s s e m b ly
1 . M a tc h sam e size top assem bly and valve body
th e n re a s s e m b le by reversing pro ced u re.
2 . F o r o p tio n a l in s ta lla tio n of 6 " top a ss em b ly
on 4 ” valve body, see su p p le m e n ta l in s tru c ­
t i o n s .
a. S lid e new top assem b ly o n to valve body,
b . R e-in stall and tig h ten hex h ead m o u n tin g
s cre w s (3/8” -16 N .C .) into lo w er portion of
to p a s s e m b ly and snug w ith w ren ch ,
0
c . R e p la c e sh o ck pad and sho ck pad
w a sh e r, and lock spacer o n to valve s te m
and tig h te n . (6’’ valve will have o ne roll pin
fo r lim it s w itch e s; 4 ” valve w ill have tw o
roll pins fo r lim it sw itch.)
3. A lw a y s o p e ra te valve e le c tric a lly several
tim e s a fte r re as se m b ly and c h e ck c a re fu lly
fo r c o rre c t o p era tio n .
4 . R e p la c e top co v er and term in al acc es s p la te .
(50”-lbs. torque required on each scre w or b o lt
to in sure tig h t seal).

_________ M is m a tc h in g S iz e s
T o p a s s e m b lie s fo r 6 ” valves d eliver m ore th ru s t
and travel th a n th e ir 4 ” cou n terp arts. H o w ever,
th e y c an be m o u n te d on a 4” valve body and
m o d ifie d fo r c o rrec t op eratio n. -
C o n v e rse ly , a 4 ” to p assem b ly could be m o u n te d
on a 6 ” v alve body b u t w ould hot d elive r a d e q u a te
th ru s t o r travel. N o m o d ifica tio n s a re a v a ila b le .
T h is a rra n g e m e n t should not be a tte m p te d .
1 . P roceed to in s ta ll 6 ” top on 4 ” body s am e as
4 " to 4 ” but s to p prior to rem o u ntin g to p
cover. '
2. In s ta ll 5 /3 2 ” x 2 V i” roll pin as show n in
p h o to g ra p h . T h is pin w ill a c tu a te m o tor lim it
s w itc h (not sho w n ) 3/ i " early and c o m p e n s a te
fo r s h o rte r travel required for 4 ” valve body.
3 . C o m p le te re m ain d e r o f in s ta lla tio n s am e as
fo r 4 ” top a ssem b ly.
4. A lw a y s o p e ra te valve e le c tric a lly several
tim e s and c h e c k c arefu lly for correct o p e ra ­
tio n b efo re retu rn in g to service.

MA N U tx o n p r e d ic ts t p o lic y o f continuous product Improvement. It n s s n s s ths rig h t to s lts r sp o c lllc s tio n s w ith out p rio r not/co.

CORPORATION =
MUNCIE, INDIANA, u . s . a . INDUSTRIAL COMBUSTION EQUIPMENT AND VALVES
GAS S h u t-o ff V a lv e s Page 8100-29

Field Instructions
[A", 6 ' Series 7000 Valves et al)

© T o p C o ve r
© O p e n -S h u t In d ic a to r
® P rin ted C irc u it B o ard (PC B )
© M o to r M o u n tin g S c re w s (4)
© M o to r S u b -a s s e m b ly
© S p a d e T e r m in a ls
© C lu tc h S h a ft
© S e t C o lla r

M an u al O p e n in g ------------------------------ -
T o o p en v a lv e m a n u a lly (w ith in o p e ra tiv e m o to r
o p e ra to r b u t fu n c tio n in g PC B a n d c lu tc h ):
1. D e -e n e rg ize v a lv e .
2. R em o ve to p c o v e r © .
3. R em o ve q u ic k -c o n n e c tin g le a d s fro m the
m o to r s p a d e te rm in a ls © . T a p e e n d s o f leads
to in s u la te , th e n tu c k th e lo o s e en d s into
p la s tic w irin g g u id e s on m o u n tin g p an el.
4. R em o ve m o u n tin g s c re w s © .
5. R em o ve m o to r s u b -a s s e m b ly © .
6. L o o sen s e t s c re w to re m o ve s e t c o lla r © from
s h a ft © .
7. P o w e r th e v a lv e . C a u tio n ; D o n o t m a k e c o n ­
ta c t w ith P C B © c o m p o n e n ts n o r w ith any
o th e r b a re w ire s o r c o n n e c tio n s .
8. U se Va ” o p e n -e n d w re n c h to tu rn c lu tc h s h a ft
© c lo c k w is e (w h e n fa c in g e n d o f s h a ft) to
o pen v a lv e . C o n tin u e c ra n k in g u n til o p en -sh u t
in d ic a to r © s h o w s fu ll-o p e n (a p p ro x im a te ly
six (6) s h a ft re v o lu tio n s w ith 6 " valve, five (5)
w ith 4" v alv e). V O S s w itc h is n o w a c tu a te d .
9. R em o ve w re n c h a n d re p la c e s e t c o lla r © .
R e p la c e to p c o v e r © . T o rq u e a ll s cre w s and
b o lts to 5 0 in . lb s . to a s s u re tig h t s ea l.
10. V a lv e w ill re m a in o p e n w h ile p o w e re d and w ill
c lo se w h e n d e -e n e rg iz e d , d u e to th e m a g n e tic
c lu tc h .
M o to r R e p la c e m e n t ______________
T o re p lac e m o to r drive u n it and spu r g e a r s u b ­
assem b ly:
1. D e-en erg ize valve.
2. R em ove to p co v er © .
3. R em ove q u ick -c o n n e c tin g leads from th e
m o to r s p a d e te rm in a ls © . T a p e end s of le ad s
to in s u la te , th e n tu c k th e loose en d s in to
p la s tic w irin g g u id e s on m o u n tin g p an el.
4. R em ove m o to r m o u n tin g s crew s © .
5. R em ove m o to r su b -as se m b ly © .
6. C h ec k th a t v o lta g e specs on valve n a m e p la te
and re p la c e m e n t m o to r correspond to p o w er
supply, th e n in s ta ll new m o to r and spu r g e a r
su b -assem b ly.
7. R ec o n n e c t q u ic k -c o n n e c tin g lead s to m o to r
s p a d e te rm in a ls .
8. C h e c k fo r p ro p er valve o p era tio n .
9. R ep la ce to p c o v e r using 50 in. lbs. o f to rq u e
on e ac h b o lt to insure a tig h t seal.

7/85 Maxon practices a policy of continuous product improvement. It reserves the right to Biter specifications without prior notice. M A A o n
CORPORATION
INDUSTRIAL COMBUSTION EQUIPMENT AND VALVES M U N C IE, IN D IA N A , U.S.A.
 Page 8100-30 GAS S h u t-o ff V alves

Trouble-shooting (4’ , 6 ' Series 7000 Valves et al) w

T o p Cover
P rin ted C irc u it Board
T erm in al B lock
Valve-open S w itc h
(VOS-1 shown)
© Roll Pin (a c tu a te s V O S -1 ,-2)
© M o to r O p erato r
© VCS-1 M o u n tin g H o les
© V C S -2 M o u n tin g H o le s
© M a g n e tic C lu tc h A sby
A cc es s C over

If m o to r is in o p erative, c h e c k f o r If m a g n e tic c lu tc h p u lls in , b u t s lip s, c h e c k for:

1. N O V O L T A G E T O M O T O R : C h e c k L i a n d L2 1. H IG H G A S PR E S S U R E : L o c a te c a u s e and c o r­
and m otor c o n n e c tio n s . rect, c lo s e s u p p ly lin e th e n b le ed o ff u p stre am
2. L O W V O L T A G E T O M O T O R : C h e c k L i a n d L2 pressure and c y c le valve several tim e s b efo re
and m otor c o n n e c tio n s . resto rin g to s erv ic e.
3. M O T O R L IM IT S W IT C H F A IL U R E : R e p la c e 2. E X T R E M E IN T E R N A L B O D Y D IR T C O N D I­
VOS-1 or V O S -2 as n e c e s s a ry . T IO N : R em o ve from , line, c le a n th o ro u g h ly ,
/ 4. M O T O R B U R N E D O U T : R e p la c e m o to r re lu b ric a te v alve body in te rn a ls w ith K ey sto n e
o p erator, o bserving c a re fu lly fo r c o n tin u o u s 84-H g re a s e or e q u a l. T e s t fo r le a k a g e b efo re
o p eratio n (see b elo w ).s; p la c in g b a c k in s erv ic e.
5. M O T O R G E A R T R A IN B IN D IN G : R e p la c e 3. G E A R M A L F U N C T IO N : C h e c k fo r b in d in g ,
m o to r operator. broken rack, bro ken o r lo o se g ears.
4. O IL O N C L U T C H : R e p la c e e n t ir e to p
I f m o to r op erates c o n tin u o u s ly , c h e c k f o r a s s e m b ly . (S ee Page 8100-27, 28 fo r p ro­
1. R O L L PIN © N O T A C T U A T IN G V O S : B en d cedure)
V O S w and up s lig h tly.
2. V O S N O T B R E A K IN G C IR C U IT : R e p la c e
VOS-1 or VO S-2.

If m a g n e tic c lu tc h d o es n o t p u ll in , c h e c k f o r
1. N O V O L T A G E T O P R IN T E D C IR C U IT B O A R D :
C h e c k PCB te rm in a ls 1 a n d 2.
2. NO VO LTAG E OR LO W V O LTA G E TO
C L U T C H : C h e c k PCB te rm in a ls 3 a n d 4.
9 0V D C required. R e p la c e P C B if in p u t v o lta g e
is O .K .
3. CLUTCH F A IL U R E : R e p la c e e n t ir e to p
assem b ly. (See Page 8 10 0-27 , 28 fo r p ro ­
cedure)

M AMO N
CORPORATION
4 M «xon p re c tlc e s * p o lic y o t co n tin u o u s p roduct Improvement. It reserves the rig h t to s lte r specllicstions w ith out p rio r notice.

M U N C IE, IN D IA N A , U.S.A. INDUSTRIAL COMBUSTION EQUIPMENT AND VALVES i

GAS S h u t-O ff V alves
Installation Instructions
G e n era l C o n s id e ra tio n s : Motorized valves open
u n atte n d ed upon being pow ered; but manual
reset valves sh o u ld be lo c a te d so th a t o perator is
en c o u rag e d to o b serve m ain fla m e ig nition a fter
op en in g valve.
T im e lag b e tw e e n valve a ctio n and flam e
response is re d u c ed w h en valve is lo cated near
burner, re d u c in g le n g th and sto rag e cap ac ity of
d o w n s tre a m pip in g .
V a lv es a re u su a lly in s ta lle d upright in horizon­
tal piping. O th e r o rie n ta tio n s are a c c e p ta b le sub-
e c t to th e c o n d itio n s o u tlin e d below :_____________
N O T E : F o r all e x c e p t S e rie s 7000 and 7100,
O P E N /S H U T in d ic a to r o f th e s e valves should
never fad e u p w a rd . M o to r s id e p la te of m otorized
versions s h o u ld a lw a y s be v ertic al._____________
V a lv es a re to le ra n t o f adverse a m b ien t c o n d i­
tions; but, as w ith any o th e r e le c tric /m e c h a n ic a l
e q u ip m e n t, try to s e le c t a lo c atio n th a t is cool,
c le a n and dry.
Exposed m e ta l s u rfa c e s of valve are alu m in u m ,
c a s t iron, or c a s t s te e l --- all p ainted. Cover
g asketin g m a te ria l is N e o p re n e , or equal. Any
s u b s ta n c e in th e a tm o s p h e re surrounding the
valve w h ic h is h a rm fu l to th e s e m a te ria ls w ill have
an adverse e ffe c t upon th e valve exterior.
P re s s u re L im ita tio n s : O b s e rv e n a m e p la te
p re s s u re ra tin g s . If in le t p re s s u re to th e
a s s o c ia te d g as p re ss u re re g u lato r is g reater than
th a t for w h ic h v alve is c a ta lo g -ra te d , ad d itio n al
p ro te c tio n in th e form o f a pressure relief valve
a n d /o r tw o -s ta g e p ressure re g u latio n should be
provided.
T e m p e ra tu re L im ita tio n s : R efer to catalo g or
n a m e p la te fo r s p e c ific lim ita tio n s o f valve. S hield
valve to p ro te c t fro m h e a t (in clu d in g severe solar
or ra d ian t e xp o su re ) if n ec es s ary . D o not e xp ec t
norm al v alve o p e ra tio n at a m b ie n ts below fre e z­
ing if th e re is e x c e s s iv e m o is tu re in the gas, or if
w a te r h as b een p e rm itte d to e n te r top assem b ly
throu g h , fo r e x a m p le , a c o n d u it c o n n ectio n .
Piping th e V a lv e: B ody is u n id ire ctio n al and
m u st be o rie n te d in lin e so th a t flo w through valve
agrees w ith b o d y m a rk in g . F ie ld -ro tate top
ass em b ly if n ecessary; s ee c a ta lo g Page 8100-26
fo r in s tru c tio n s .
Use o f Teflon tape (if approved locally) in­
c reases th e p o s s ib lity o f th rea d o ver-engagem ent.
U se c a u tio n , s in c e even s te e l valve bodies can be
cracked u n d e r th e s e c o n d itio n s .
Good piping practice d ic ta te s th a t piping be in­
d e p e n d e n tly s u p p o rted so th a t valve bodies are
n ot p la ce d in a b ind.
INDUSTRIAL COMBUSTION EQUIPMENT AND VALVES
Page 8100-31
C le a r fuel line of e x c es sive a m o u n ts of fo reig n
m a tte r such as line s c a le , w e ld in g b ea d s, m e ta l
c u ttin g s, etc. C o n s id e r a s u ita b le s tra in e r in
cases of doubt.
T es tin g the Piping: F o llo w a p p lic a b le cod es,
but, to avoid d a m a g e to valve in tern a l c o m ­
ponents, DO N O T U SE W A T E R as a te s t m e d iu m .
W iring the V alve: All w irin g m ust co m p ly w ith
all a p p lica b le c o d e s and s ta n d a rd s. S u p p ly
voltag e m ust ag ree w ith n a m e p la te v o lta g e, ±
1 0% AC or DC. L o w er v oltag e m ay prevent
plunger seatin g n ec es s ary for p ositive la tc h in g .
For d eta ile d e le c tric a l d a ta and valve in tern al w ir­
ing diagram , refer to c a ta lo g Page 8100-11/12
and/or d ia g ram in valve cover.
Motorized G A S S h u t-O ff V alves in c o rp o ra te an
a u to m a tic -re s e t te m p e ra tu re -s e n s itiv e d e v ic e
w h ich breaks th e c u rren t to th e m o tor w h en th e
w in d in g te m p e ra tu re e xc ee d s ab o u t 2 3 0 ° F /1 1 0 ° C .
V alves m ust be in te rlo c k e d w ith all s a fe ty -lim it
d evices in a c c o rd a n c e w ith all a p p lic a b le cod es,
stan dard s and th.e a u th o rity having ju ris d ic tio n
over the s a fe ty re q u irem e n ts for th e o verall in ­
s ta lla tio n .
M a in ta in in te g rity o f upper enclo sure; use d u st-
and w a te r-tig h t e le c tric a l c o n n e cto rs. U se c a b le
s ealin g grips w ith s tra in re lie f for cord or c a b le .
C o n s id e r in tern al s ea lin g d evice on c o n d u it.
P re-O p era tio n al E xercisin g : Prior to initial start­
up and with upstream gas cock closed, operate
valve electrically for 10-15 cycles. This not only
provides electrical check, but also wipes disc and
seat free of any accumulated foreign matter._____
Valve was production-tested when manufactured; if it
Is inoperative, make sure it is being powered properly.
M ain S ystem S h u t-o ff: A lw ays use a fu e l co c k
or s im ilia r m a n u a l valve.
In s ta n ta n e o u s C lo su re: S tan d ard G A S S h u t-O ff
V alves p rovide v irtu a lly in s ta n ta n e o u s c lo su re
upon in terru p tio n o f p o w er supply. If valve is
equ ip p ed w ith o p tio n a l “T D " tim e d e la y unit,
clo su re tim e is e x te n d e d to 1-3 s ec o n d s . In s ta n ­
tan e o u s shu td o w n (by-passing " T D ” fu n c tio n ) can
be provided by fo llo w in g in s tru c tio n s provided
w ith “T D ” unit.
m u n c ie , In d ia n a , u .s .a .
r Page 8100-32

Operating Instructions
All G A S S h u t-O ff V a lv es c lo se agg ressively
w ith in a fra c tio n o f a secon d w h en de-energ ized .
Motorized valves begin o p en in g c y c le im ­
m e d iately upon being pow ered; m o tor runs only
until full-o p en po sitio n is re ac h ed . W e ll-d e fin e d
holding a c tio n m a in ta in s full-o p en positio n .
Manual reset valves require tw o p o sitive a c ­
tions to open: a h alf-ro ta tio n o f h an d le to la tc h in­
GAS S h u t-O ff V alves

eq u ip p e d w ith W h e e l-a n d -C h a in A s s e m b ly . In ­
s tru c tio n s to open valve are on h an d g rip . L o c a te
c o u n ter-w e ig h t o verh ead a t p ip e level so o p e ra to r
c a n n o t use it to fo rc e la tc h in g o f valve.
N e v e r open valve u n til all e s s e n tia l a llie d e q u ip ­
m en t is o p era tive and c o m b u s tio n e n c lo s u re has
been purged for a t le a s t fo u r a ir c h a n g e s . F a ilu re
of valv e to open in d ic a te s th a t it is n ot p o w ered .
• *-i

ternal m e c h a n is m , and a reversed h alf-ro ta tio n of C h e c k th is first, th e n c h e c k s o le n o id , m o to r.

handle to o pen valve. V a lv e can be o p en e d fa s t or
slowly, but e xp erien c ed o p era to rs o fte n try to syn­
chronize o p en in g rate w ith g as pressure re g u lato r
resp o n se. In s tru c tio n s fo r o p en in g are on
o p erating sid e of top cover.
R em o tely lo cated m a n u a l reset valves m ay be
M a n u a l valves m ay be c lo s e d m a n u a lly , b u t
e le c tric a l clo su re is p referred.
M a in system s h u t-o ff s h o u ld a lw a y s be a c ­
c o m p lis h e d w ith a fu e l c o c k o r s im ila r m a n u a l
valve.

Maintenance Instructions
M axon G A S S h u t-O ff V a lv es are e n d u ran ce-
tested fa r in excess o f th e m o st s trin g e n t re­
Insurance Authorities Agree . . .
q u irem en ts o f the vario u s approval a g e n cies .
----- that the safety of any industrial fuel-burning
They are d es ig n ed fo r lo n g life even if fre q u e n tly
installation is dependent upon well-trained
cycled, and to be as m a in te n a n c e - and tro ub le- operators who are able to follow instructions, and to
free as p o ss ib le . Prior to s h ip m e n t, valves are c o n ­ react properly in cases of emergency. Their
nected e le c tric a lly and c yc led a t 1 5 0 % m a xim u m knowledge of, and training on, the specific installa­
pressure rating w h ile being le ak -te sted .___________ tion are both vital to safe operation.
Eveiy valve is o p era tive and h as zero le a k a g e Safety controls may get out-of-order without
w hen it leaves o ur p la n t! ___________________ the operator becoming aware of it unless shut­
downs result. Production-minded operators have
Top A s s e m b ly c o m p o n e n ts , in c lu d in g m o to r of been known to by-pass faulty controls without
m otorized valves, req uire no field lu b ric a tio n and reporting the trouble.
should never be o iled . Continued safe operation of any installation is
As w ith any e le c tric a l co m p o n e n t, a u x iliary then assured only if the plant management
s w itch e s, s o len o id s and drive m o tors m ay e ven tu ­ carefully develops an exact schedule for regular
ally fa il. V a lv e .w ill fa il safe; th e s e c o m p o n e n ts periodic inspection of all safety controls, in­
can be re p lac ed in th e fie ld .______________ . sisting that it then be rigidly adhered to.
A main gas shut-off cock should be located
Field re p a ir of body and la tc h in g m e c h a n is m , upstream from all other fuel train piping com­
and fie ld re p la c e m e n t o f body and la tc h ponents and used to shut off all flow of fuel for
m e ch a n ism c o m p o n e n ts is n ot re co m m e n d ed . servicing and other shut-downs.
U n au tho rized field a lte ra tio n s o f valve b ody, top All safety devices should be tested at least mon­
ass em b ly o r m o tor drive u n it void all w a rra n tie s . thly*, and more often if deemed advisable. Periodic
Valve le a k tes t, p erfo rm ed w ith valve in lin e as testing for tightness of manual or motorized shut-off
valve closure is equally essential.
prescribed by ju ris d ic tio n a l a u th o ritie s , is stro n g ­
'p e r NFPA 86AB • Appendix C (1985)
ly en co u rag ed and should be d o n e on a reg ularly
sch ed u led basis. In rare in s ta n c e s w h e re valve a p ­
pears to be leakin g , p erfo rm "P re -O p e ra tio n a l Ex­
e rc is in g ” (se e In s ta lla tio n In s tru c tio n s ) and
retest. If le ak ag e has not sto p p ed , rem ove valve
from service. .
C ertain M axo n valve d esig n s no lo n g er d ffered
may require perio dic lu b ric atio n . C o n ta c t M&xon
w ith valve serial n u m b er (from n a m e p la te ) for
specific re co m m e n d atio n s.
Operating personnel should become familiar with characteristic opening/closing action of
the valve. Should operation ever become sluggish, remove valve from service and contact
" Maxon (or rebuilding/replacement recommendations.
Address inquires to: Maxon Corporation, Muncie, Indiana 47302, (317) 284-3304, Telex RCA 275-581.
„ Always include Valve Serial Number to insure positive identification.

O N M ix o n practices s policy o f continuous product im provem ent. It reserves the rig h t to alter specifications w ith o u t p rio r notice.

CORPORATION
MUNCIE, IN D IA N A , U.5.A. INDUSTRIAL COMBUSTION EQUIPMENT AND VALVES
 Types 1051 & 1052 with F & G Mounting

/H > K 0 e
g tfs v ttiv e - fc r v fm L

Fisher Controls ____ J u s *

Instruction Manual
type 1051 &1052 Size 40,
60, & 70 Rotary~Actuafor
with Styles F & G Mounting
Adaptations
March 1995 Form 5062

Contents
In tro d u c tio n .............................................................1
Scope of Manual......................................................... 1
Description.................................................................. 2
Specifications .............................................................3
In s ta lla tio n .............................................................. 3
Actuator Mounting ..................................................... 3
Valve Flow Direction ..................................................4
Loading Connection....................................................5
A d ju s tm e n t ........................................................... 5
Turnbuckle Adjustment .............................................. 5
Type 1052 Spring Adjustment ...................................6
Principle o f O p e ra tio n .................................... 7
M a in te n a n c e ........................................................... 7
Disassembly ...............................................................7
Assem bly.................................................................... 9
Figure 1. Type 1052 Actuator Mounted on Design V150
Changing A ctu ato r M o u n tin g .................... 11 Vee-BalF Valve with a Type 3510J Positioner
Top-M ounted Handw heels an d
A djustable Travel Stops ............................ 13
Adjustable Down Travel Stop...................... 27
Principle of Operation for Handwheels.................... 13 Pipe-Away Vent Parts ..............................27
Handwheel Maintenance.......................................... 13
Locking M e c h a n is m ..................................... 15
Installing the Locking Mechanism ............................15 Introduction
Operating the Locking Mechanism ..........................15
P ipe-A w ay Vent ............................................ 16 Scope of Manual
Parts O rd e rin g .................................................. 17
This instruction manual includes installation, adjustment,
maintenance, and parts ordering information for the Type
Parts Kits ........................................................ 17 1051 (size 40 and 60) and Type 1052 (Size 40, 60, and 70)
Top Mounted Handwheel Retrofit Kits pneumatic piston rotary actuator with F and G mounting
Pipe-Away Vent Retrofit K its.....................................17 adaptations (see figure 1). The G mounting adaptation is
for Type 7600 and 9500 valves, and all other e d is c ® or
Parts L i s t .................................... 17 V-line™ valves that use the F mounting adaptation. Also,
D100319X012

Common Parts ......................................................... 17 this instruction manual provides information for the option­
Top-Mounted Handwheel ........................................ 25 al top-mounted handwheel, up and down travel stops, lock­
Adjustable Up Travel Stop .......................................25 ing mechanism, and pipe-away vent.

VEE-BALL, V-LINE, and ed is c are marks owned by Fisher Controls International, Inc.

®Fisher Controls International, Inc. 1976,1995; All Rights Reserved


Types 1051 & 1052 with F & G Mounting
Table I.Type 1051 and 1052 Actuator Specifications
Operation
Direct Acting: Increasing loading pressure extends
the diaphragm rod out of the spring barrel
Service:
Type 1051: For on-off or throttling service with posi­
tioner
Type 1052: For on-off or throttling service with or with­
out a positioner
Actuator Sizes
Type 1051 : 40 and 60
Type 1052: 40, 60, and 70
Maximum Diaphragm Casing Pressure
Size 40: 65 psig (4.5 bar)
Size 60: 40 psig (2.8 bar)
Size 70: 55 psig (3.8 bar)
Maximum Valve Shaft Rotation
90 degrees rotation (standard) travel stop, or 60 de­
grees (optional) travel stop for Type 1051 and 1052
actuators, or 75 degrees (optional) travel stop for
Type 1052 actuators
Valve Shaft Diameters, Inches (mm)
Size 40: 1/2 (12.7), 5/8 (15.9), 3/4 (19.1), 7/8 (22.2), 1
(25.4), or 1-1/4 (31.8)
Size 60: 3/4 (19.1), 7/8 (22.2), 1 (25.4), 1-1/4 (31.8),
1-1/2 (38.1), 1-3/4(44.5), or 2 (50.8)________________
Instructions for the control valve, positioner, accessories,
and other sizes of actuators are covered in separate
instruction manuals. This manual provides information for
Styles F and G mounting methods used to mount Fisher
Controls rotary actuators on Fisher Controls valves.
Top-Mounted handwheels can be applied for infrequent
service as a manual handwheel actuator. Also, an adjust­
able up travel stop can be added to the actuator to limit its
stroke in the upward direction, or an adjustable down travel
stop can be added to limit actuator stroke in the downward
direction.
2
FISHER
Size 70: 1-1/4 (31.8), 1-1/2 (38.1), 1-3/4 (44.5), or 2
(50.8)
Stroking Time
Dependent on actuator size, rotation, spring rate, ini­
tial spring compression, and supply pressure. If strok­
ing time is critical, consult the Fisher Controls sales
office or sales representative
Material Temperature Capabilities
Nitrile Diaphragm: - 4 0 to 180°F (-4 0 to 82°C)
Silicone Diaphragm: - 4 0 to 3 0 0 °F (-4 0 to 149°C)
Nitrile O-Rings: - 4 0 to 180°F (-4 0 to 82°C), Nitrile
O-rings are used in optional top-mounted handwheel,
adjustable down travel stop, and adjustable up travel
stop assemblies
Travel Indication
Graduated disk and pointer combination located on
actuator end of valve shaft
Pressure Connections
Standard: 1/4 in. NPT female
Optional: 1/2 or 3/4-inch NPT female, and 3/4-inch
NPT for pipe-away vent
Mounting Positions
See figure 4
Approximate Weights
See table 2
Additional Specifications
For casing pressure ranges and for material identifica­
tion of the parts, see the parts list
Only personnel qualified through training or experience
should install, operate, and maintain this actuator. If you
have any questions concerning these instructions, contact
your Fisher Controls sales office or sales representative
before proceeding.
Description
The Type 1051 and 1052 diaphragm rotary actuators are
pneumatic spring-return actuators for qse with rotary-shaft
control valves. The Type 1051 actuator can be used for on-
off service, or it can be used for throttling service when
equipped with a valve positioner. The Type 1052 actuator
can be used for on-off service, or it can be used for throttling
 Types 1051 & 1052 with F & G Mounting

Table 2. Approximate Actuator Weights

TYPE 1051 TOP-MOUNTED

TYPE 1052
SIZE HANDWHEEL
Lb Kg Lb Kg Lb Kg
40 94 43 99 45 16 7.3
60 197 89 203 92 24 11
70 — — 272 123 47 21

pressure does not exceed the diaphragm

casing pressure limits listed in table 1. Use
pressure-limiting or pressure-relieving de­
vices to prevent the diaphragm casing pres­
sure from exceeding these limits.

‘ \
155553 ACTUATOR
Actuator Mounting
SERIAL NO. 1 1 type | .... 1
^P R E S S UNITSl 1 U
Use the following steps to connect a valve body and an ac­
] «■» m
IN IT IA L SETi 1 OPER RANQE| tuator.
........... 1
ACTION | 1 ROTATION | | DEO
V J Key numbers are shown in figure 9 for Type 1051 actuators
126401
B -A S HT 1 and in figure 10 for Type 1052 actuators.
Figure 3. Nameplate
1. Isolate the control valve from the line pressure, release
pressure from both sides of the valve body, and drain the
service when equipped with or without a valve positioner. process media from both sides of the valve. Remove ac­
The Type 1052 actuator spring is adjustable (see figure 2). tuator supply pressure, and use lock-out procedures to be
sure that the above measures stay in effect while you work
on the equipment.
Specifications
Specifications are shown in table 1. Specifications for ac­ K 8 W ARNING
tuator operation, as it originally comes from the factory, are
stamped on the nameplate (see figure 3) attached to the
actuator. See the WARNING at the beginning of the
Maintenance section for more information.

2. Remove the tubing or piping from the top of the actuator.

Installation
When an actuator and valve body are shipped together, the
actuator is normally mounted on the valve. Follow the
valve body instructions when installing the control valve in
the pipeline, and then perform the procedures presented in
the Loading Connection portion of this Installation section.
If the actuator is shipped separately or if it is necessary to
mount the actuator on the valve, perform the procedures
presented in the Actuator Mounting portion of this section.
And, if the actuator requires a pipe-away vent, or if a retrofit
pipe-away kit needs to be installed, refer to the Pipe-Away
Vent sub-section at the end of the Maintenance section in
this manual.
3. Unscrew cap screws and washers (keys 34 and 63),
and remove cover (key 33).
4. Refer to figure 4 for available mounting styles and posi­
tions. The actuator is normally positioned vertically with
the valve in a horizontal pipeline (see figure 1).
Note
Due to its weight, the Type 1052 size 70 ac­
tuator must be externally supported if
mounted in the horizontal position.

C T W ARNING
To avoid personal injury or property dam­
age caused by bursting of pressure-retain­
ing parts, be certain the diaphragm casing
5. When mounting the actuators, make sure that the bush­
ing (key 67) and valve shaft are in-line so that the bushing
will slide onto the valve shaft without damage.
6. Mount the actuator on the valve body and secure it with
the valve mounting screws. For butterfly valves, useabolt-

3
 Types 1051 & 1052 with F & G Mounting ■
FISHER9 -

Table 3. Recommended Bolting Torques marks, and slide the lever into place (see figure 4). Clamp
ACTUATOR SIZE with the cap screw (key 28).
KEY 40 60 70
NUMBER 13. Rotate the lever (key 27) to align with the rod end bear­
Ibf-ft N-m Ibf-ft N-m Ibf-ft N-m ing (key 17). This connection can be aided by moving the
3 and 6 20 27 20 27 20 27 actuator off its up travel stop with a regulated air source and
6 and 8 30 41 30 41 75 102 adjusting the turnbuckle (key 57) slightly.
9 25 34 75 102 75 102
25 34 45 61 75 102 14. Apply sealant (key 77) or equivalent thread-locking
16
120 163 200 271
compound to the threads of the cap screw (key 18).
18 60 81
21 17 23 50 68 50 68 15. Connect the lever (key 27) and the rod end bearing
25 25 34 60 81 60 81 (key 17) with the cap screw and hex nut (keys 18 and 19).
28 60 81 120 163 200 271
34 25 34 60 81 60 81
40 7 9 7 9 7 9 Note
54 34 25 34
25 34 25 Tighten the cap screw (key 18) to the recom­
(Handwheel)
54 mended bolt torque shown in table 3.
20 27 49 66 51 69
(down stop)
163
16. Note the valve position and direction of rotation. Posi­
58 75 102 120 163 120
tion the travel indicator (key 37) accordingly.
141 30 41 30 41 60 81
a. If no handwheel actuator is to be used, position trav­
ing torque of 30 lbf*ft (41 N«m) for 1/2 through 1-inch (12.7 el indicator (key 37) according to the valve position just
through 25.4 mm) diameter valve shafts, use 100 lbf»ft (135 noted. Replace the cover (key 33), and secure with
N»m) for 1-1/4 and 1-1/2 inch (31.8 and 38.1 mm) diameter washers and cap screws (keys 34 and 63). If holes in
valve shafts, and use 135 lbf»ft (183 N»m), for 1-3/4 and the cover and housing (key 20) do not align, temporarily
2-inch (44.5 and 50.5 mm) diametervalve shafts. For other loosen cap screws (key 23), and shift the housing
valve types, refer to the appropriate valve body instruction slightly. Do not stroke the actuator while the cover is off.
manual for bolting torques for these cap screws.

b. If a manual handwheel actuator is to be used, refer

to the separate handwheel actuator instruction manual
CAUTION
for mounting instructions.

17. Replace the cover (key 33), and secure with cap
Refer to table 3 for actuator bolt torque re­
screws and washers (keys 34 and 63). If the holes in the
quirements. Exceeding any torque require­
cover and housing (key 20) do not align, use a regulated air
ment may impair the safe operation of this
source to move the actuator slightly off the up travel stop.
actuator by causing broken or damaged
If the hole alignment cannot be obtained in this manner,
parts.
temporarily loosen the cap screws (key 23), and shift the
housing slightly. Do not stroke the actuator while the cover
7. Screw the left-hand threaded locknut (key 58) onto the
is off.
diaphragm rod (key 10) as far as possible.
18. Follow the instructions given in the Adjustment section
8. Screw the turnbuckle (key 57) as far as it will go onto the for correct actuator turnbuckle adjustment before proceed­
actuator rod. ing to the Loading Connection portion of this section.

9. Screw the locknut (key 16) as far as it will go onto the

rod end bearing (key 17). Thread this assembly completely Valve Flow Direction
into the turnbuckle (key 57). Valve construction can change the flow direction for a con­
trol valve assembly. It is important to observe the flow
10. If the lever (key 27) is attached to the rod end bearing, direction in all valve applications before installing the valve
remove the cap screw and hex nut (keys 18 and 19). in the pipeline (see figure 5). Refer to the appropriate valve
bulletin.
11. If the Type 1052 spring adjustment has been changed,
complete the Initial Setting portion of the Adjustment sec­
Note '
tion before proceeding. ;
Observe all warnings and cautions pro­
12. Consult the appropriate valve body instruction manu­ vided in the appropriate valve instruction
al, Installation section for lever/valve shaft orientation manual Installation section.

4
 Types 1051 & 1052 with F & G Mounting

VALVE SERIES OR DESIGN STYLE A STYLE B

MOUNTING ACTIONS) V100, V150, 8510,5822, CV500

V200, V250, 8532,8560 &
V300 7600, & 9500 V500
PDTC A B A
Right-Hand
PDTO B A B
PDTC C C D
Left-Hand
PDTO D D C
1. PDTC— Push-down-to-ciose, and PDTO— Push-down-to-open.

RIGHT-HAND MOUNTING

STYLE D STYLE C

POSITION 1 IS STANDARD; POSITIONS 2 THROUGH 4

(SHOWN IN DOTTED LINES) ARE ALTERNATES.
43AeS05-A
A1576-5

NOTE:
| T > BY FISHER CONTROLS DEFINITION:
• FORWARD FLOW IS INTO THE FACE SIDE O F THE DISK, OR THE BALL
SEALING SURFACE.
• REVERSE FLOW IS INTO THE HUB SIDE O F THE DISK OR BALL.
• SOME VALVES CONSTRUCTIONS REQUIRE REVERSE FLOW FOR HIGH
PRESSURE SHUT-OFF. THE MOUNTING INFORMATION PROVIDED IN FISHER
CONTROLS TYPE 8532 OR 8522 MANUAL IS BASED ON REVERSE FLOW.
• REFER TO TH E APPROPRIATE VALVE CONSTRUCTION DETAILS BEFORE
MOUNTING THE ACTUATOR ON THE VALVE, OR THE VALVE IN THE PIPELINE.

Figure 4. Mounting Styles and Positions

Loading Connection the pressure connection to the actuator will normally be

1. Connect the loading pressure piping to the pressure
connection in the top of the diaphragm casing.
a. For size 40 through 60 actuators: Run either
1/4-inch pipe or 3/8-inch tubing between the 1/4-inch
pressure connection and the instrument.
made at the factory.
3. When the control valve is completely installed and con­
nected to the instrument, check for correct action (air-to-
open or air-to-close) to match the controlling instrument.
For successful operation, the actuator stem and valve shaft
must move freely in response to the loading pressure
change on the diaphragm.

b. For size 70 actuators: Run either pipe or tubing be­

tween the pressure connection and the instrument. If
necessary, remove the 1/4-inch bushing in the pressure
connection to increase connection size.
Adjustment

2. Keep the length of pipe or tubing as short as possible

to avoid transmission lag in the control signal. If an acces­
sory (such as a volume booster or a valve positioner) is
used, be sure that the accessory is properly connected to
the actuator. If a valve positioner is part of the assembly,
Turnbuckle Adjustment
Correct turnbuckle adjustment ensures that the valve is
correctly closed when the actuator is against its travel
stops. The turnbuckle adjustment is the only adjustment
necessary on the Type 1051 actuator.

5
r
Types 1051 & 1052 with F & G Mounting
Figure 5. Mounting Styles and Positions
Key numbers are shown in figure 9 for Type 1051 actuators
and in figure 10 for Type 1052 actuators.
For accurate adjustment to the zero-degree valve disk or
ball position, remove valve from pipeline. Refer to the
valve body instruction manual for instructions.
A regulated air supply will be required to stroke the actua­
tor. Consult table 4 for the sizes of the three open-end
wrenches required for this procedure.
1. Remove the access plate (key 59). Also remove the
machine screws (key 60), if present.
Note
For the most accurate adjustment of the ac­
tuator, do not remove cover (key 33) during
this procedure.
2. Loosen the lower locknut (key 16).
3. Make sure the actuator housing (key 20) is clear of any
tools or other instruments that could obstruct the actuator
stroke path. Pressure diaphragm casing enough to stroke
the actuator down so that the left-hand threaded upper
locknut (key 58) is accessible through the access opening.
Loosen the locknut.
4. Use one of the following:
6
Table 4. Wrench Size Required for Turnbuckle
Adjustment, Inches___________
ACTUATOR TURN­ LOWER UPPER
BUCKLE LOCKNUT LOCKNUT
Type Size (KEY 57) (KEY 16) (KEY 58)
1051 & 40 1-1/8 3/4 1-1/8
1052 60 1-5/16 15/16 1-5/16
1052 70 1-5/16 1-1/8 1-5/16
a. Push-down-to-close — Slowly stroke the actuator
to the down travel stop. Consult the appropriate valve
body instruction manual for determining the closed
position of the valve. Adjust the turnbuckle (key 57) un­
til the valve is in the closed position. Lock this adjust­
ment with the left-hand threaded locknut (key 58).
Stroke the actuator to the mid-travel position, and tight­
en the locknut (key 16).
b. Push-down-to-open — Consult the appropriate
valve body instruction manual for determining the
closed position. Release all pressure from the dia­
phragm casing, making sure the diaphragm is against
its up travel stop. Be sure that the optional handwheel
is adjusted to its topmost position so that the zero posi­
tion of the actuator and valve can be reached simulta­
neously. Check the valve position. Stroke the actuator
so the turnbuckle (key 57) is accessible through the ac­
cess opening. Adjust the linkage. Release pressure to
the actuator, and check the new adjustment. Continue
this procedure until the valve is in the closed position
when the actuator is resting on its up travel stop. Stroke
the actuator to the mid-travel position, and tighten lock­
nut (key 16). Stroke the actuator, and tighten left-hand
threaded locknut (key 58).
5. Replace the access plate (key 59).
6. Loosen the*self-tapping screws (key 38), and adjust the
travel indicator (key 27). Re-tighten the self-tapping
screws.
Type 1052 Spring Adjustment
Initial Setting
The Type 1052 nameplate specifies an initial spring set­
ting, which is the initial setting adjusted into the actuator
spring. Initial setting is the casing pressure at which the di­
aphragm and diaphragm rod begin to move away from the
up travel stop with the actuator disconnected from the
valve. (With the actuator connected to the valve and pres­
sure applied to the valve, a higher pressure will be required
to start actuator travel).
The initial setting was selected (based upon the service
conditions specified when the actuator was ordered) so
that, when the actuator and valve are in service, the valve
will seat properly and full travel will be obtained within a dia­
phragm casing range of 0 to 1 8 ,0 to 3 3 ,0 to 40, or 0 to 55
psig (0 to 1.2, 0 to 2.3, 0 to 2.8, or 0 to 3.8 bar) depending
on specific actuator size and construction.

If the actuator has been disassembled or if the spring ad­
justment was changed, and it is desired to match the initial
setting stated on the nameplate, make sure the rod end
bearing (key 17, figure 10) has been disconnected from the
lever (key 27, figure 10). Adjust the spring so that the dia­
phragm rod just starts to travel at the spring set pressure
specified on the nameplate.
Be sure the rod end bearing does not hit the lever as the
diaphragm and diaphragm rod move away from the up trav­
el stop. To adjust the spring, insert a round rod into one of
the holes in the lower bearing seat (key 73, figure 10). Hole
diameter is 3/8-inch (9.5 mm) for size 40 actuators,
5/8-inch (15.9 mm) for size 60 actuators, and 3/4-inch (10.1
mm) for size 70 actuators. Rotate the bearing seat to move
it toward the casings (keys 1 and 2, figure 10) to increase
initial setting or away from the casings to decrease initial
setting.
Stroking Range
The initial spring setting listed on the nameplate has been
determined to be the optimum setting, and it is not recom­
mended to make spring adjustments that will cause this
value to change or be exceeded. For push-down-to-open
valve action, the initial spring setting is the maximum allow­
able to provide the maximum spring closing force. Any in­
crease of this setting will over-stress the spring at full travel.
For push-down-to-close valve action, the initial spring set
has been determined to be the optimum balance between
the air to close and the spring to open breakout torque.
If the Type 1052 actuator is to be changed from one valve
action to another (i.e., push-down-to-close to push-down-
to-open), first, refer to the initial spring compression values
listed in the parts list table (key 11) of this manual to deter­
mine the proper initial spring setting; then, adjust the unit
according to the procedures in the Initial Settings portion
of the Type 1052 Spring Adjustment section.
Principle of Operation
The diaphragm rod moves down as loading pressure is in­
creased on top of the diaphragm. As the loading pressure
is decreased, the spring forces the diaphragm rod upward.
The spring and diaphragm have been selected to meet the
requirements of the application and, in service, the actua­
tor should produce full travel of the valve with the dia­
phragm pressure as indicated on the nameplate.
Consult the separate positioner instruction manual for ac­
tuator principle of operation with positioner.
Types 1051 & 1052 with F & G Mounting
Maintenance
Actuator parts are subject to normal wear and must be in­
spected and replaced as necessary. The frequency of in­
spection and replacement depends upon the severity of
service conditions. Instructions are given below for adjust­
ment, disassembly, and assembly of parts.
W ARNING
Avoid personal injury or property damage
from sudden release of process pressure or
uncontrolled movement of parts. Before
performing any maintenance operations:
• Disconnect any operating lines pro­
viding air pressure, electric power, or a con­
trol signal to the actuator. Be sure the ac­
tuator cannot suddenly open or close the
valve.
• Use bypass valves or completely shut
off the process to isolate the valve from pro­
cess pressure. Relieve process pressure
from both sides of the valve. Drain the pro­
cess media from both sides of the valve.
• Vent the power actuator loading pres­
sure and relieve any actuator spring pre­
compression.
• Use lock-out procedures to be sure
that the above measures stay in effect while
you work on the equipment.
Key numbers are shown in figure 9 for Type 1051 actuators
and in figure 10 for Type 1052 actuators.
Disassembly
The following procedure describes how to completely dis­
assemble the actuator. When inspecting and replacing
parts, perform only those steps necessary to accomplish
the repair.
Do not, under ordinary circumstances, remove the cap
screws (keys 7, 8, and 21) at this time. Use the following
disassembly steps if removal is necessary.
CAUTION
Cap screw (key 18) must be disengaged
from the lever (key 27) before removing the
diaphragm casing (key 1). Failure to do so
will allow the spring precompression to ro-
7

Types 1051 & 1052 with F & G Mounting
tate the valve beyond its fully open or
closed position. This could cause damage
to the valve components and/or seal.
1. Isolate the control valve from the line pressure, release
pressure from both sides of the valve body, and drain the
process media from both sides of the valve. Remove ac­
tuator supply pressure, and use lock-out procedures to be
sure that the above measures stay in effect while you work
on the equipment.
a W ARNING
See the WARNING at the beginning of the
Maintenance section for more information.
2. Remove the tubing or piping from the top of the actuator.
3. Remove the positioner, if one is used. If necessary, re­
fer to the positioner instruction manual for removal instruc­
tions.
4. Unscrew the cap screws and washers (keys 34 and 63),
and remove the cover (key 33).
5. Remove the retaining ring (key 30), and slide the hub
(key 29) from the cover. If necessary, remove the travel in­
dicator (key 37) from the hub (key 29).
6. Inspect, and if necessary, replace the cover bushing
(key 31). Remove the travel indicator scale (key 35) by re­
moving the self-tapping screws (key 36). Press the bush­
ing out of the cover (key 34).
7. Remove the cap screw and hex nut (keys 18 and 19).
8. Make note of the lever/valve shaft orientation, and then
loosen the cap screw (key 28).
C T CAUTION
When removing the actuator from the valve,
do not use a hammer or similar tool to drive
the lever (key 27) off the valve shaft. Driving
the lever could damage internal valve parts.
On some valve types, driving the lever off
the shaft could move the valve disk or ball
and bearings away from the centered posi­
tion, causing subsequent damage to valve
parts as the valve is operated*
If necessary, use a wheel puller to remove
the lever. It is okay to tap the wheel puller
8
FISHER0
- J
screw lightly to loosen the lever, but hitting
the screw with excessive force could also
damage valve parts or disrupt the centered
position of the valve disk and bearings.
9. Rotate the handwheel (if one is used) counterclockwise
until the handwheel is not compressing the spring (key 11).
W ARNING
To avoid personal injury from pre-com­
pressed spring force suddenly thrusting
the upper diaphragm casing (key 1) away
from the actuator, relieve Type 1052 spring
compression, or carefully remove Type
1051 casing cap screws by following the
instructions presented in the next steps be­
fore proceeding further.
10. To relieve spring compression:
a. For Type 1051 actuators:
• Loosen, but do not remove, all casing cap screws
and hex nuts (keys 5 and 6). Make sure there is no spring
force to the upper diaphragm casing.
• Unscrew and remove the cap screws and hex nuts
(keys 5 and 6), and then remove the upper diaphragm cas­
ing and the diaphragm (key 3).
b. For Type 1052 actuators:
• Insert a round rod into one of the holes in the lower
bearing seat (key 73). Use the rod to rotate the lower bear­
ing seat, and move it away from the actuator casings. Con­
tinue rotating the lower bearing seat until spring compres­
sion is completely removed. Rod hole diameter is 3/8 inch
(9.5 mm) for size 40 actuators, 5/8 inch (15.9 mm) for size
60 actuators, and 3/4 inch (19.1 mm) for size 70 actuators.
• Unscrew and remove the cap screws and hex nuts
(keys 5 and 6), and then remove the upper diaphragm cas­
ing and the diaphragm (key 3).
11. Removing the diaphragm plate (key 4):
a. For Type 1051 actuators:
• Pull the diaphragm plate (key 4) and attached parts
out of the actuator. The spring (key 11), diaphragm rod (key
10), cap screw (key 9), spring seat (key 13), hex nut (key
58), turnbuckle (key 57), hex nut (key 16), and rod end
bearing (key 17) will be attached to the diaphragm head as­
sembly.
• The diaphragm plate (key 4) may be wedged
against the diaphragm rod (key 10), thereby preventing the

spring compression from being relieved as the cap screw
(key 9) is loosened.
m W ARNING
Dislodge the diaphragm plate (key 4) from
the diaphragm rod (key 10) before com­
pletely removing the cap screw (key 9). Fail­
ure to check for this condition could cause
personal Injury due to the sudden release of
spring compression.
• Dislodge the diaphragm plate (key 4) from the dia­
phragm rod (key 10) by loosening the cap screw (key 9)
one full turn and tapping the underside of the diaphragm
plate until it follows the cap screw as it is being removed.
Failure to check for this condition before completely remov­
ing the cap screw (key 9) could cause personal injury due
to the sudden release of spring compression.
• Slowly remove the cap screw (key 9) while making
sure that the diaphragm head assembly is following the cap
screw disassembly. Note— Make sure that spring load is
zero before the cap screw is completely removed. If neces­
sary, separate the remaining parts of the assembly.
b. For Type 1052 actuators:
(1.) Remove the rod end bearing (key 17), the hex
nut (key 16), turnbuckle (key 57), and the hex nut (key 58)
from the diaphragm rod (key 10).
(2.) Pull the diaphragm plate (key 4) and attached
parts out of the actuator. Then remove the cap screw (key
9) to separate the diaphragm plate and the diaphragm rod.
(3.) Proceed as appropriate:
• For Size 40 and 60 actuators: Remove the actuator
spring (key 11) from the actuator. If H is necessary to re­
move the adjustor (key 74) from the spring barrel during
this procedure, heat the base of the adjustor to 3 5 0 °F
(177°C ) long enough for the thread-locking compound
(key 77) to lose its holding strength. Then, unscrew the ad­
justor from the spring barrel. If the spring seat and the low­
er bearing seat (keys 13 and 73) are to be replaced, un­
screw the lower bearing seat from the adjustor, and then
remove the thrust bearing and the bearing races (keys 71
and 72) from the lower bearing seat.•
• For Size 70 actuators: Remove the actuator spring
(key 11) from the actuator. Remove the cap screws (key
21) then, remove the spring barrel (key 1£) from the actua­
tor housing. If it is necessary to remove the spring adjust­
ment parts, loosen the set screw (key 75), and unscrew the
spring adjustor (key 74) from the spring barrel (key 12).
Types 1051 & 1052 with F & G Mounting
12. Unscrew the cap screws (key 23), and remove the ac­
tuator housing assembly (key 20).
13. Unbolt the mounting yoke (key 22) from the valve
body.
14. Check the bushing (key 67) in the mounting yoke.
Press out and replace the bushing if necessary.
Assembly
This procedure assumes that the actuator was completely
disassembled. If the actuator was not completely disas­
sembled, start these instructions at the appropriate step.
This procedure also assumes that the valve is removed
from the pipeline for ease in actuator assembly and adjust­
ment.
Key numbers are shown in figure 9 for Type 1051 actuators
and in figure 10 for Type 1052 actuators.
1. Installing the spring barrel (key 12):
a. For Type 1051 actuators: Place the spring barrel on
the housing (key 2). Secure the spring barrel with cap
screws (key 21). Tighten the cap screws to the torque
value shown in table 3.
b. ForType 1052 actuators: If the spring barrel (key 12)
was removed from the housing (key 20), align the
spring barrel to the housing as described below to en­
sure that the offset hole in the base of the spring barrel
will be located properly.
• For Size 40 and 60 actuators: Note that one of the
accessory mounting bosses on the spring barrel is closer
to the diaphragm end of the spring barrel. Place the spring
barrel on the housing with the upper boss (the one closer
to the diaphragm end) on the same side as the boss located
on the housing (see figures 9 and 10). This ensures proper
positioning of the offset hole. Secure the spring barrel with
cap screws (key 21). On final assembly, tighten the screws
to the torque value shown in table 3.
• For Size 70 actuators: The spring barrel need not
be aligned in any particular position when placing it on the
housing.
Note
Replacement mounting yokes (key 22) for
use with some valves are available only as
assemblies that also include the bushing
(key 67). However, replacement bushings
are also available separately (see the parts
list; keys 22 and 67). .
2. If the bushing (key 67) was removed, press in the new
bushing. The end of the bushing should be flush with the
bottom of the recess in the mounting yoke (key 22).
9
 Types 1051 & 1052 with F & G Mounting
3. Slide the mounting yoke over the valve shaft, and se­
cure it to the valve with the valve mounting cap screws.
4. Tighten the valve mounting cap screws to the bolting
torque listed below:
• For butterfly valves, use a bolting torque value of
30 lbf»ft (41 N«m) for 1/2-inch through 1-inch (12.7 to 25.4
mm) diameter valves shafts; 100 lbf»ft (135 N»m) for 1-1/4
and 1-1/2 inch (31.8 and 38.1 mm) diameter valve shafts;
and 135 lbf*ft (183 N»m) for 1-3/4 and 2-inch (44.5 and 50.8
mm) diameter shafts.
• For other valve types, refer to the appropriate
valve body instruction manual for bolting torques for these
cap screws.
m CAUTION
Refer to table 3 for bolting torques for actua­
tor bolts and cap screws. Exceeding any
torque requirement may impair the safe op­
eration of the actuator.
Note
If the cap screw key number is shown in
table 2, torque the cap screws to the value
shown in the table for final assembly.
5. Refer to figure 4 for the desired orientation of the hous­
ing (key 20). Secure the housing to the mounting yoke with
cap screws (key 23).
6. Coat with Lubriplate MAG-1 (key 93) or equivalent lubri­
cant on the cap screw threads (key 9), and the tapered end
of the diaphragm rod (key 10).
7. Proceed as appropriate:
a. For Type 1051 actuators (see figure 9)
• Assemble the diaphragm rod, spring seat (key 13),
spring (key 11), and diaphragm plate (key 4), and secure
with the cap screw (key 9). Tightening the cap screw will
compress the spring. Be certain the tapered end of the dia­
phragm rod is seated in the corresponding hole in the dia­
phragm plate, that the spring is seated in the spring seat,
and that the cap screw is tightened to the torque specified
in table 3.•
• Install the hex nut (key 58), turnbuckle (key 57),
hex nut (key 16), and rod end bearing (key 17) onto the dia­
phragm rod.
10
• Be certain the travel stops (key 8) are located as
shown in figure 6.
• Install the diaphragm plate and attached parts into
the actuator.
• Be sure the warning nameplate (key 56) is in place.
Install the diaphragm (key 3) and the upper diaphragm cas­
ing (key 1). Install the cap screws and hex nuts (keys 5 and
6). Tighten the cap screws evenly in a crisscross pattern
to compress the spring and secure the upper diaphragm
casing. Refer to table 3 for torque values.
b. For Type 1052 actuators:
• For actuator designs without a set screw (key 75),
in the spring barrel (key 12): if the adjustor and attached
parts were removed, first clean and then lubricate the up­
per threads of the adjustor (key 12) with a lubricant (key 76)
or equivalent as shown in figure 10. Install the lower bear­
ing seat (key 73), the thrust bearing (key 71), the thrust
bearing races (key 72), and the spring seat (key 13) onto
the adjustor.
• First, clean and then coat the lower end of the ad­
justor with sealant (Key 77) or equivalent thread-locking
compound as shown in figure 10, and install the entire as­
sembly into the spring barrel (key 12). Let the adjustor
stand undisturbed for at least two hours after installation to
allow the thread-locking compound to cure.
CAUTION
Apply lubricant to the upper threads and
thread-locking compound to the lower
threads of the adjustor. Do not overlap the
coat of lubricant with the coat of thread­
locking compound since this will adversely
affect the performance quality of both sub­
stances.
• For actuator designs with a set screw (key 75), if
the adjustor (key 74) and attached parts were removed, lu­
bricate the threads of the adjustor with the lubricant (key
76) or equivalent. Install the lower bearing seat (key 73),
the thrust bearing (key 71), the thrust bearing races (key
72), and the spring seat (key 13) onto the adjustor. Install
this assembly into the spring barrel (key 12). Secure the
adjustor with the set screw (key 75).
8. Coat the tapered end of the diaphragm rod (key 10) and
the threads of the cap screw (key 9) with the lubricant (key
76) or equivalent. Bolt the diaphragm plate to the dia­
phragm rod.
9. Be certain the travel stops (key 8) are located as shown
in figure 6.

Figure 6. Travel Stop Orientation
10. Install the spring (key 11) into the spring barrel. Install
the diaphragm plate and diaphragm rod into the actuator.
Attach the hex nut (key 58), turnbuckle (key 57), hex nut
(key 16), and rod end bearing (key 17) to the diaphragm
rod.
11. Installing the diaphragm:
• Place the upper diaphragm casing (key 1) on the
lower diaphragm casing (key 2). If necessary, rotate the
lower bearing seat (key 73) so that the upper diaphragm
casing travel stop will not contact the diaphragm when the
casing cap screws and nuts (key 5 and 6) are tightened.
• Secure the upper diaphragm casing with the cap
screws and hex nuts (keys 5 and 6). Be sure the warning
nameplate is in place on the casing. Tighten the nuts on
the cap screws to the torque value shown in table 3.
12. For Type 1052 actuators, complete the Initial Setting
portion of the Adjustment section before proceeding.
13. Consult the appropriate valve body instruction manual
for lever/valve shaft orientation marks, and slide the lever
(key 27) into place; see figure 10 for correct lever operating
clearance. Clamp with the cap screw (key 28). (Note: Key
28 is not shown in figure 5. The location is available in fig­
ure 10).
14. Rotate the lever (key 27) to align with the rod end bear­
ing (key 17). This connection can be aided by carefully
stroking the actuator off its up travel stop with a regulated
air source.
15. Apply sealant (key 77) or equivalent thread-locking
compound to the threads of the cap screw (key 18).
16. Connect the lever (key 27) and the rod end bearing
(key 17) with the cap screw and hex nut (keys 18 and 19).
Tighten the nut on the cap screw (see table 3).
Types 1051 & 1052 with F & G Mounting
17. Coat the bearing surfaces of the hub (key 29), and cov­
er (key 33) with lubricant (key 76) or equivalent. Install the
bushing (key 31) and hub into the cover. Secure with the
retaining ring (key 30).
18. Install the travel indicator scale (key 35), and secure
it with the self-tapping screws (key 36). Then install the
travel indicator (key 37), and secure it with the self-tapping
screws (key 38).
19. Note the valve disk or ball position, and direction of
rotation. Position the travel indicator (key 37) accordingly.
20. Replace the cover (key 33), and secure with cap
screws and washers (keys 34 and 63). If the holes in the
cover and housing (key 20) do not align, use a regulated air
source to move the actuator slightly off the up travel stop.
If hole alignment cannot be obtained in this manner, tempo­
rarily loosen cap screws (key 23), and shift the housing
slightly. Do not stroke the actuator while the cover is off.
21. If a valve positioner is to be used, consult the separate
valve positioner instruction manual for proper positioner
installation.
22. Follow the instructions in the Adjustment section for
correct actuator turnbuckle adjustment.
Changing Actuator Mounting
The actuator is normally positioned vertically in a horizon­
tal pipeline. However, there are four possible mounting
styles and four possible positions for each style (see figure
4).
Note •
Due to its weight, the Type 1052, size 70 ac­
tuator must be externally supported if
mounted in the horizontal position.
11
 Types 1051 & 1052 with F & G Mounting
Correct lever/valve shaft positioning is important to ensure
proper valve action. Consult the appropriate valve body
instruction manual.
Style A is right-hand mounted, while style D is left-hand
mounted. In all other ways, the styles A and D are identical.
Style B is right-hand mounted, while style C is left-hand
mounted. In all other ways, the styles B and C are identical.
Use the following procedure along with figures 9 and 10, for
key number references, to convert from styles A and D to
styles B and C or visa versa or to change the mounting
position.
1. Isolate the control valve from the line pressure, release
pressure from both sides of the valve body, and drain the
process media from both sides of the valve. Remove ac­
tuator supply pressure, and use lock-out procedures to be
sure that the above measures stay in effect while you work
on the equipment.
W ARNING
See the WARNING at the beginning of the
Maintenance section for more information.
2. Remove the tubing or piping from the top of the actuator.
3. Remove the cover (key 33) by unscrewing and remov­
ing the cap screws and washers (keys 34 and 63).
4. Unscrew cap screw (key 18). Loosen cap screw (key
28).
C T CAUTION
When removing the actuator from the valve
body, do not use a hammer or similar tool to
drive the lever (key 27) or actuator off the
valve shaft. Driving the lever or actuator
could damage internal valve parts. On
some valve types, driving the lever (key 27)
could move the valve disk and bearings
away from the centered position causing
subsequent damage to valve parts.
If necessary, use a wheel pullqr to remove
the lever. It is okay to tap the wheel puller
screw lightly to loosen the lever, but hitting
the screw with excessive force could also
12
-
FISHER®
damage valve parts or disrupt the centered
position of the valve disk and bearings.
5. If changing styles,
• Unscrew cap screws (key 23), and remove the ac­
tuator housing (key 20) from the mounting yoke (key 22).
• Rotate the housing 180 degrees, maintaining the
appropriate position (1 ,2 , 3, or 4), and place the actuator
onto the mounting yoke (key 22).
6. If changing positions, unscrew cap screws (key 23),
and rotate the actuator housing to the desired position.
Note
Consult table 3 for appropriate bolt torques.
7. Secure actuator housing (key 20) to the mounting yoke
(key 22) with cap screws (key 23).
8. Consult the appropriate valve body instruction manual
for lever/valve shaft orientation marks, and slide the lever
(key 27) into place; see figure 4 for correct lever operating
clearance. Clamp with the cap screw (key 28).
9. Rotate the lever (key 27) to align with the rod end bear­
ing (key 17). This connection can be aided by stroking the
actuator off its up travel stop with a regulated air source.
10. Apply sealant (key 77) or equivalent thread-locking
compound to the threads of the cap screw (key 18).
11. Connect the lever (key 27) and the rod end bearing
(key 17) with the cap screw and hex nut (keys 18 and 19).
This connection can be aided by stroking the actuator from
its up travel stop with a regulated air source.
Note
Tighten cap screw (key 18) to the recom­
mended bolt torque shown in table 3.
12. Note the valve position and direction of rotation. Posi­
tion the travel indicator (key 37) accordingly. Replace the
cover (key 33), and secure it with cap screws and washers
(keys 34 and 63).
• If the holes in the cover and housing (key 20) do not
align, use a regulated air source to move the actuator
slightly off the up travel stop.
• If hole alignment cannot be obtained in this man­
ner, temporarily loosen cap screws (key 23) and shift the
housing slightly. Do not stroke the actuator while the cover
is off.

13. Follow the instructions given in the Adjustment section
for correct actuator turnbuckle adjustment.
Top-Mounted Handwheels and
Adjustable Ttavel Stops
Principle of Operation for Handwheels
Note
If repeated or daily manual operation is ex­
pected or desired, the unit should be
equipped with a manual handwheel actua­
tor. Refer to the separate manual hand­
wheel actuator instruction manual for
mounting instructions.
Top-Mounted Handwheel Assembly is attached to a spe­
cial upper diaphragm casing (key 1, figures 10 and 10) with
cap screws (key 141, figure 11). A hex nut (key 137, figure
11) locks the handwheel in position.
Turning the handwheel (key 51, figure 11) clockwise into
the upper diaphragm casing forces the pusher (key 135,
figure 11) against the diaphragm and diaphragm plate
(keys 3 and 4, figures 9 and 10) to compress the spring (key
11, figures 9 and 10) and move the diaphragm rod down­
ward.
Turning the handwheel counterclockwise allows the actua­
tor spring to move the diaphragm rod upward.
• If the valve is push-down-to-close, full opening can
be restricted by positioning the handwheel at the desired
position.
• If the valve is push-down-to-open, full closing of the
valve can be restricted by use of the handwheel. ’ 12) and the adjustable down travel stop assembly (figure
Adjustable Up Travel Stop (figure 12) limits the actuator
stroke in the upward direction. To make adjustments, first
relieve actuator loading pressure before removing the clos­
ing cap (key 187) as it is a pressure retaining part. Remove
the closing cap (key 187). Also, for size 70 actuators, the
hex nut (key 137) must be loosened. Then turn the stem
(key 133) clockwise into the diaphragm case to move the
actuator stem downward or counterclockwise to allow the
spring to move the actuator stem upward.•
• If the valve has push-down-to-close action, full
opening can be restricted by the position of the adjustable
travel stop. Or,
Types 1051 & 1052 with F & G Mounting
• If the valve has push-down-to-open action, full
closing can be restricted by the position of the adjustable
travel stop.
For size 70, tighten the hex nut and replace the closing cap
after adjustment.
Adjustable Down Travel Stop (figure 13) limits the actua­
tor stroke in the downward direction. To make adjust­
ments, first relieve actuator loading pressure before re­
moving the closing cap (key 187) as it is a pressure
retaining part. Remove the closing cap (key 187). Loosen
the hex jam nut (key 189) and either turn the hex nut (key
63 for size 40 and 70 actuators; or key 54 for size 60 actua­
tors) down on the stem (key 133) to limit travel, or up on the
stem to allow more travel. Lock the jam nut against the hex
nut, and replace the closing cap after the adjustment has
been made.
Handwheel Maintenance
If loading pressure seems to be leaking from either the
handwheel or adjustable up stop, the O-rings (key 138 and
139, figures 11 and 12) may need replacement. If the ad­
justable down stop leaks, the O-ring (key 139, figure 13)
may need replacement or possibly the closing cap (key
187, figurel 3) is not tight. To tighten the closing cap, apply
a good grade of thread sealant to the closing cap threads.
For ease of operation, the stem (key 133, figures 11, 12,
and 13) threads may need an occasional application of lu­
bricant (key 241) or equivalent. A grease fitting (key 169,
figuresl 1 and 12) is provided for this purpose in the size 70.
The size 70 may also need to have the thrust bearing (key
175, figures 11 and 12) packed with lubricant (key 241) or
equivalent. Travel stops for the smaller casings can be lu­
bricated between the stem and pusher (key 135, figures 11
and 12) with the lubricant (key 241) or equivalent.
The following disassembly procedures are separated
where appropriate between the top-mounted handwheel
and adjustable up travel stop assemblies (figures 11 and
13) .
1. Isolate the control valve from the line pressure, release
pressure from both sides of the valve body, and drain the
process media from both sides of the valve. Remove ac­
tuator supply pressure, and use lock-out procedures to be
sure that the above measures stay in effect while you work
on the equipment.
W ARNING
See the WARNING at the beginning of the
Maintenance section for more information.
13
 Types 1051 & 1052 with F & G Mounting
2. Remove the tubing or pipe from the handwheel body
(key 142, figures 11,12, and 13).
W ARNING
To avoid personal injury from the pre-com­
pressed spring force thrusting the upper di­
aphragm casing (key 1, figures 9 and 10)
away from the actuator, either relieve Type
1052 spring compression, or carefully re­
move Type 1051 casing cap screws by fol­
lowing the instructions that are referenced
in the steps below before removing the cas­
ing.
3. Relieve all actuator spring compression by following the
procedures presented in the disassembly portion of the ac­
tuator maintenance section. Then, rotate either the hand­
wheel (key 51, figure 11) or the travel stop stem (key 133,
figures 12 and 13) counterclockwise until the handwheel or
travel stop assembly is no longer compressing the spring.
C T CAUTION
For Type 1051 actuators with e d is c valves
and push-down-to-open action, the cap
screw (key 18, figure 9) should be disen­
gaged from the lever (key 27, figure 10) be­
fore removing the diaphragm casing (key 1,
figure 9) as specified in the following steps.
Failure to do so will allow the spring pre­
compression to rotate the valve beyond its
closed position. This could cause damage
to the valve seal, seat, or other valve com­
ponents.
4. Proceed as appropriate:
For Adjustable Up Travel Stops,
a. Remove the upper diaphragm casing (key 1, figures
9 and 10) by following steps 1 ,3 ,7 ,9 ,1 0 , and 11 of the
Disassembly portion of the Actuator maintenance sec­
tion.
b. Remove the cap screws (key 141, figures 11 and
12), and separate the assembly from the upper casing.
c. Loosen the locknut (key 137, figure 11), or remove
the closing cap (key 187, figure 12).
14
V
d. Turnthestem (key133,figures11 and 1 2 )clockwise
out of the body. On handwheel assemblies, the cotter
pin and hex nut (keys 247 and 54, figure 11) will have
to be removed so that the handwheel (key 51, figure 11)
and locknut can be taken off the stem first.
e. Remove and inspect the O-rings (keys 138 and 139,
figures 11 and 12); replace them if necessary.
f. To complete disassembly:
For sizes 40 and 60: Drive out the groove pin (key
140, figures 11 and 12), and slide the pusher (key 135, fig­
ures 11 and 12) off the stem.
For size 70: The pusher unit is held to the stem by
a retaining screw (key 174, figures 11,12 or 13). Removing
the retaining screw and pusher exposes the thrust bearing
(key 175, figures 11 and 12) for inspection.
For Adjustable Down Travel Stops,
Key numbers are shown in figure 13 unless otherwise
noted.
a. Remove the closing cap (key 187), and unscrew the
jam nut and hex nut (keys 189 and 63 for size 40 and
70 actuators; or keys 189 and 43 for size 60 actuators)
off the stem (key 133).
b. Remove the upper diaphragm casing (key 1, figures
9 and 10) and travel stop body (key 142) by following
steps 1 ,3 , 7, 9 ,1 0 , and 11 of the Disassembly portion
of the Actuator maintenance section.
c. Unscrew cap screws (key 141), and remove the
body from the diaphragm case.
d. Check the condition of the O-ring (key 139), and re­
place it if necessary.
e. Loosen the hex nut (key 54), and then unscrew the
travel stop stem (key 133) out of the actuator stem. The
lower diaphragm plate (key 82) can now be removed
and the rest of the actuator disassembled.
5. Reassemble in the reverse order of the disassembly
steps being sure to apply lubricant as previously men­
tioned and as shown by the lubrication boxes (key 241) in
figures 9 and 10. For size 70 handwheels or up travel stop
assemblies, coat the threads of the retaining screws (key
174, figures 11,12, or 13) with sealant (Key 77) or equiva­
lent thread-locking compound.
6. Readjust the spring to obtain the appropriate travel stop
restriction by following the procedures presented in the
introductory portion of this section, and then return the unit
to operation.
 Types 1051 & 1052 with F & G Mounting

5. Make sure the jam nut (key 128) is threaded onto the
threaded bolt before threading it into the housing.

6. After the bolt is threaded into the housing, install the

groove pin (key 127) into the end of the bolt. (Note: The
groove pin will prevent the threaded bolt from being totally
un-threaded from the actuator housing.)

7. Make sure that the bolt is not threaded in so far that it

will interfere with re-assembly of the actuator.

8. Reassemble actuator using assembly procedure in

Maintenance section of this manual.

9. Make sure the actuator diaphragm rod is retracted fully.

This will be the locked position of the valve. For a push-
down-to-close valve and actuator, the valve will be fully
open when locked. For a push-down-to-open valve and
actuator, the valve will be fully closed when locked.

10. Screw the threaded bolt into the housing until it con­
tacts the actuator lever cap screw.
Figure 7. Type 1051 and 1052 Actuator Locking Mechanism
(Size 40, 60, and 70)
11. Insert the padlock (not furnished by Fisher Controls) to
connect the mounting plate (key 123) with the lower locking
disk on the mounting plate assembly (key 124). You might
Locking Mechanism have to back off the lower locking disk a slight amount to
line up the holes for the padlock.

Installing the Locking Mechanism 12. Tighten the jam nut (key 128) against the mounting
plate.
1. Isolate the control valve from the line pressure, release
pressure from both sides of the valve body, and drain the 13. Refer to-the operating instruction below.
process media from both sides of the valve. Remove ac­
tuator supply pressure, and use lock-out procedures to be
sure that the above measures stay in effect while you work
Operating the Locking Mechanism
on the equipment.

To Unlock the Actuator

1. Remove the padlock. Loosen the jam nut (key 128),
W ARNING
and unscrew the threaded bolt until it is stopped by the
groove pin (key 127) in the threaded bolt.
See the WARNING at the beginning of the
Maintenance section for more information. Note
For normal operation of the actuator, the
2. To add the locking mechanism to an existing actuator,
threaded bolt must be unscrewed far
purchase the required parts from Fisher Controls. The re­
enough so that the actuator lever will not
quired parts are the locking mechanism and a modified ac­
contact the bolt in normal actuator opera­
tuator housing. Part numbers are shown in the parts list.
tion.
3. To remove old housing, disassemble actuator using dis­ 2. If you are going to leave the bolt threaded into the hous­
assembly procedures in the Maintenance section of this ing, lock it by tightening the jam nut (key 128) against the
manual. mounting plate so that it cannot be screwed into the hous­
ing and interfere with normal actuator operation.
4. Attach the mounting plate (key 123) to the modified
housing (key 20) as shown in figure 7. Attach it with the cap
screw (key 129). Make sure the hole in the center of the
To Lock the Actuator
mounting plate lines up with the large tapped hole in the 1. Make sure the actuator diaphragm rod is retracted fully.
housing. This will be the locked position of the valve. For a push-

15
 Types 1051 & 1052 with F & G Mounting
down-to-close valve and actuator, the valve will be fully
open when locked. For a push-down-to-open valve and
actuator, the valve will be fully closed when locked.
2. Make sure the jam nut (key 128) is loose. Then, screw
the threaded bolt into the housing until it contacts the head
on the cap screw of the actuator lever.
3. Rotate the threaded bolt until one of the holes in the low­
er locking disk (which is welded to the bolt) is in line with
the hole in the mounting plate (key 123). Tighten the jam
nut against the mounting plate.
4. Lock the plate and disk together with a padlock. (The
padlock is not furnished by Fisher Controls.)
Pipe-Away Vent
Some applications require venting of gas from the rotary
actuator housing. The 3610 Series positioners vent into
the actuator housing, and from there, the gas has numer­
ous avenues of escape.
Retrofit kit part numbers are provided in the parts list sec­
tion, at the end of this manual, to modify an actuator for the
vent piping.
Note
This modification is NOT intended to be a
leak-proof or pressure-tight design. It is in­
tended to aid in containing the gas that
vents from the positioner and allow for con­
nection of piping to carry it away.
Take care that adequate vent pipe size is used. This is par­
ticularly important with the larger size actuators that have
fast stroking speed requirements. In these situations, large
quantities of gas can be vented very quickly through the
positioner, and adequate pipe-away capability must be ob­
tained. Keep the vent piping as short as possible with few
bends.
Refer to the actuator disassembly and assembly steps to
gain access to the following parts. Replacement parts for
pipe-away vents are provided at the end of the parts list.
Key numbers are shown in figure 8 unless otherwise noted.
Bushings— Remove the mounting yoke bushing (key 67),
and the end plate cover bushing (key 31, figures 9 and 10).
Replace them with the pipe-away vent parts, as shown in
figure 8. The mounting yoke bushing (key 132) is a two-
piece bushing with an O-ring (key 133). The end plate cov­
er completes the assembly with a two-piece bushing (key
134) with an O-ring (key 135).
16
Travel Indicator— A gasket (key 136) is placed under the
travel indicator plate. Remove the indicator plate (key 37,
figures 9 and 10), install the gasket (key 136) as shown in
figure 8.
Access Plate Assembly— A modified metal access plate
assembly (key 137) is provided with a 3/4-inch NPT vent
connection as shown in figure 8. If the actuator had a plas­
tic access plate, it will be necessary to drill and tap the ac­
tuator housing to install the machine screws (key 138) as
shown in figure 8. Use the drilling and tapping pattern
shown in figure 8, or use the holes in the access plate as
a template to mark holes.
When finished with all maintenance procedures requiring
the access plate assembly (key 137) to be removed, use
the sealant (key 139, or equivalent) provided with the kit to
seal the plate in place.
Housing Vent Plug— A vent is provided in the housing de­
sign. To plug this opening, the pipe-away vent kit provides
a hex pipe plug (key 140) for this opening, as shown in fig­
ure 8. Install the hex plug (key 140) into this opening and
tighten it.
Accessories Mounting Boss — If accessories are not
installed on the mounting boss, install cap screws (key
143) to plug openings. The location to install the cap
screws (key 143) is shown in figure 8. A mounting boss is
located on both sides of the spring barrel (key 12, figure 9
and 10).
Type 1052 Spring Barrel Access Cover— For field con­
version of Type 1052 actuators, attach the cover (key 141)
over the spring barrel adjustment opening with self-tapping
screws (key 142). Use key 141 as a drilling template. Drill
size is 0.104 inches (A #37 drill) (2.6 mm) by 0.38-inches
(9.6 mm) deep.
W W ARNING
If a flammable, toxic, or reactive gas is be­
ing used as a supply medium, personal in­
jury or property damage could result from
fire or explosion of accumulated gas. A re­
mote vent pipe cannot be relied upon to
vent all gases from the installed location.
Provide adequate ventilation for the actua-
tor/positioner assembly. Comply with local
and regional codes, and keep the vent pipe­
line as short as possible with few bends.
Refer to the Parts Kit section, Pipe-Away Kit for retrofit kit
numbers for modification of units in the field.
 Types 1051 & 1052 with F & G Mounting

NOTE:
IF ACCESSORIES ARE M Q I INSTALLED ON THE MOUNTING NOTE:
BOSS, INSTALL CA P SCREW S (KEY 143) TO
FOR FIELD CONVERSION OF TYPE 1052 ACTUATORS
PLUG OPENINGS. A MOUNTING BO SS IS LOCATED ON ATTACH COVER (KEY 141) OVER THE SPRING BARREL
BOTH SIDES OF THE SPRING BARREL.
ADJUSTMENT OPENING W ITH SELF-TAPPING SCREWS
32A9326-F
(KEY 142). USE KEY 141 A S A DRILLING TEMPLATE.
ACCESSORIES MOUNTING BOSS USE DRILL SIZE 0.104-INCH (A #37 DRILL) (2.0 m m ) BY
0.38-INCH (9.6 m m ) DEEP.
□ APPLY SEALANT
34B4646-B

TYPE 1052 SPRING BARREL

ACCESS COVER

INSTALL THE HEX HEAD PLUG (KEY 140) INTO THE VENT OPENING
LOCATED IN THE ACTUATOR HOUSING.
40B3M6-B

HOUSING VENT PLUG LOCATION

DEEP (3.7 TO 4.0 BY 14.2 m m ). TA P SIZE IS

10-24 UNC-2B BY 0.38-INCH (9.6 m m ) DEEP,
4 HOLES.
34B4646-B

DRILLING AND TAPPING PATTERN

ACCESS PLATE ASSEMBLY

NOTE:
FOR FIELD CONVERSION, DRILL AN D TAP HOLE PATTERN
IF HOUSING HAS A NON-METALLIC ACCESS PLATE. USE
KEY 137 A S A DRILLING TEMPLATE IF DESIRED. OR, USE
THE DIMENSIONS PROVIDED IN TH IS FIGURE FOR DRILLING
AND TAPPING.
□ APPLY SEALANT
34B4646-B

MOUNTING YOKE AND COVER ASSEMBLY INCH

ACCESS PLATE ASSEMBLY (mm)

Figure 8. Pipe-Away Vent Assembly

"Recommended spare parts

17
 ✓

Types 1051 & 1052 with F & G Mounting

Parts Ordering Pipe-Away Vent Retrofit Kit Numbers

SHAFT TYPE TYPE
KIT PART KIT PART
DIAMETER 1051 1052
NUMBER NUMBER
When corresponding with your Fisher sales office or sales Inches mm SIZE SIZE
representative about this equipment, refer to the serial 30 34B4646X152
1/2 12.7 40 34B4646X022
number found on the actuator nameplate (figure 3 and key 40 34B4646X162
41, figures 9 and 10). Also, specify the complete 11-char­ 30 34B4646X172
5/8 15.9 40 34B4646X032
acter part number from the following parts list when order­ 40 34B4646X182
ing replacement parts. The Size 70 actuator is available 30 34B4646X192
only in Type 1052 actuators. 40 34B4646X042
3/4 19.1 40 34B4646X202
60 34B4646X052 60 34B4646X212
40 34B4646X062 40 34B4646X222
7/8 22.2
60 34B4646X072 60 34B4646X232
40 34B4646X082 40 34B4646X242
1 25.4
60 34B4646X092 60 34B4646X252
Parts Kits 40 34B4646X102 40 34B4646X262
1-1/4 31.8 60 34B4646X272
60 34B4646X112
34B4646X282
Top-Mounted Handwheel Retrofit Kits 70
60 34B4646X292
1-1/2 38.1 60 34B4646X122
70 34B4646X302
KIT PROVIDES PARTS TO ADD ATOP-MOUNTED HAND­
60 34B4646X312
WHEEL. KIT NUMBER 1 INCLUDES THE HANDWHEEL 44.5 60 34B4646X132
1-3/4
ASSEMBLY ONLY. KIT NUMBER 2 INCLUDES KIT NUM­ 70 34B4647X322
BER 1 AND A NEW UPPER CASE (KEY 1) THAT IS RE­ 60 34B4646X332
QUIRED TO MOUNT THE HANDWHEEL ASSEMBLY. 2 50.8 60 34B4646X142
70 34B4647X342

Kit Number 1
Key Description Part Number Qty
SIZE 40 38A1213X032 1 Parts List
SIZE 60, PUSH-DOWN-TO-CLOSE 38A1213X062 1
SIZE 60, PUSH-DOWN-TO-OPEN 38A1213X052 1 Common Parts (Figures 9 and 10)
SIZE 70 TYPE 1052 ONLY CV8010X0052 1
Key Description Part Number Qty
1 CASING, UPPER (PL STEEL)
STANDARD
SIZE 40 2L441828992
Kit Number 2 SIZE 60 30A0055X012
Part Number Qty SIZE 70 2N126628992
Description
38A1213X072 1 W/HANDWHEEL, ADJ UP OR DOWN STOP
SIZE 40
38A1213X022 1 SIZE 40 2E806325062
SIZE 60, PUSH-DOWN-TO-CLOSE
38A1213X042 1 SIZE 60 2E847425062
SIZE 60, PUSH-DOWN-TO-OPEN
CV8010X0062 1 SIZE 70 2N131025062
SIZE 70 TYPE 1052 ONLY
DIAPHRAGM CASING, LOWER (STEEL ZN PL)
SIZE 40 2E806325062
SIZE 60 2E847425062
SIZE 70 2N127125062
DIAPHRAGM, MOLDED (NITRILE/NYLON)
STANDARD, W/HANDWHEEL, OR W/ADJ UP STOP
Pipe-Away Vent Retrofit Kit SIZE 40 2E670002202
SIZE 60 2E859702202
SIZE 70 2N 126902202
VENT-AWAY KITS INCLUDES: ACCESS PLATE, TWO- W/ADJ DOWN STOP
PIECE BUSHING, TWO O-RINGS, GASKET, AND THE SIZE 40 2E669902202
APPLICATION OF A SEALANT (SEALANT SUPPLIED SIZE 60 2E859802202
WITH RETROFIT KIT). FOR TYPE 1052, AN ADDITIONAL 2N 130902202
SIZE 70
COVER PLATE AND SCREWS ARE REQUIRED FOR THE
STANDARD, W/HANDWHEEL,
SPRING ADJUSTMENT ACCESS. (SEE FIGURE 8).
MOLDED (SILICONE/POLYESTER)
W/UP STOP
SIZE 40 2E6700X0012
SIZE 60 2E8597X0032
SIZE 70 2N1269X0012

18
 Types 1051 & 1052 with F & G Mounting

Key Description Part Number Qty Key Description Part Number Qty
3* DIAPHRAGM, MOLDED (NITRILE/NYLON) (Cont’d) 8 STOP, TRAVEL (STEEL)
STANDARD, W/HANDWHEEL, TYPES 1051 OR 1052
W/DOWN STOP SIZE 40, 60 DEGREE ROTATION 1E806724092 2
SIZE 40 2E6699X0042 1 SIZE 40, 90 DEGREE ROTATION 1H591724092 2
SIZE 60 2E8598X0012 1 SIZE 60, 60 DEGREE ROTATION 16A6535X012 2
SIZE 70 2N1309X0012 1 SIZE 60, 90 DEGREE ROTATION 16A4120X012 2
SIZE 70, 90 DEGREE ROTATION 1P406624092 2
4 DIAPHRAGM HEAD (CAST IRON) TYPE 1052 ONLY
SIZE 40 2V939919042 1 SIZE 60, 75 DEGREE ROTATION 16A7829X012 2
SIZE 60 20A1336X012 1 SIZE 70, 75 DEGREE ROTATION 16A5631X012 2
SIZE 70 2N 127019042 1 9 SCREW, CAP, HEX SOCKET
5 SCREW, CAP, HEX HD (STEEL ZN PL) STEEL (NOT REQ’D W/ADJ DOWN STOP)
SIZES 40 (12 REQ’D), 60 (16 REQ’D) & TYPE 1051
SIZES 70 (24 REQ’D) 1A582824052 24 SIZE 40 12A9460X012 1
6 NUT, HEX (STEEL ZN PL) SIZE 60 12A9461X012 1
SIZE 40 1A346524122 16 TYPE 1052
SIZE 60 1A346524122 24 SIZE 40 1E760432992 1
SIZE 70 1A346524122 28 SIZES 60 & 70 1E775432982 1
7 SCREW, CAP, HEX HD (STEEL ZN PL) 10 DIAPHRAGM ROD, SST *
SIZE 40 1A368424052 4 TYPE 1051
SIZE 60 1A368424052 6 NOTE— ROD AND SPRING SEAT (KEY 13) AVAILABLE
SIZE 70 1N129328992 10 AS AN ASSEMBLY ONLY FOR SIZES 40 AND 60. TYPE
1052 ACTUATOR DOES NOT USE AN ASSEMBLY.

'Recommended spare parts 19

 Types 1051 & 1052 with F & G Mounting
F ISH E R ®
-

Figure 9. Typical Type 1051 Actuator Assembly (Continued)

Key Description Part Number Qty Key Description Part Number Qty
10 DIAPHRAGM ROD, SST 16 NUT, HEX (STEEL ZN PL)
TYPE 1051 SIZE 40 1A353724122 1
SIZE 40 12A9652X022 1 SIZE 60 1A354024122 1
SIZE 60 12A9652X032 1 SIZE 70 1A351124122 1
TYPE 1052 17 BEARING, ROD END (STEEL/PTFE)
SIZE 40 25A6968X012 1 TYPE 1052
SIZE 60 25A6969X012 1 SIZE 40 1E561699012 1
SIZE 70 26A9173X012 1 SIZE 60 1R440899012 1
11 SPRING SEE FOLLOWING TABLE SIZE 70 1R587699012 1
18 SCREW, CAP, HEX HD (STEEL ZN PL)
12 SPRING BARREL (CAST IRON) SIZE 40 1A361524052 1
TYPE 1051 SIZE 40 32A9325X022 1 SIZE 60 12A9519X012 1
TYPE 1051 SIZE 60 42A9327X022 1 SIZE 70 12A9458X012 1
TYPE 1052 SIZE 40 48A2485X012 1 19 NUT, HEX, JAM (STEEL ZN PL)
TYPE 1052 SIZE 60 48A2484X012 1 SIZE 40 1A3412 24122 1
TYPE 1052 SIZE 70 46A9171X012 1 SIZE 60 1A343324122 1
13 SPRING SEAT (STEEL) SIZE 70 1A5993 24122 1
TYPE 1051 SEE FOLLOWING TABLE 20 HOUSING (CAST IRON) *
TYPE 1052 TYPE 1051 SIZE 40 48A5245X012 1
SIZE 40 18A2483X012 1 TYPE 1051 SIZE 60 48A5246X012 1
SIZE 60 18A2477X012 1 TYPE 1052 SIZE 40 48A5245X012 1
SIZE 70 16A9174X012 1 TYPE 1052 SIZES 6 0 & 7 0 48A5246X012 1

20
 Types 1051 & 1052 with F & G Mounting

Figure 10. Typical Type 1052 Actuator Assembly

Key Description Part Number Qty Key Description Part Number Qty
20 MODIFIED HOUSING (FOR USE WITH LOCK-OUT DEVICE) 27 LEVER SEE FOLLOWING TABLE
CAST IRON
TYPE 1051 SIZE 40 33B0139X012 1 28 SCREW, CAP, HEX HD (STEEL ZN PL)
TYPE 1051 SIZE 60 33B0138X012 1 SIZE 40 1A340924052 1
TYPE 1052 SIZE 40 33B0139X012 1 SIZE 60 12A9405X012 1
TYPE 1052 SIZES 60 & 70 33B0138X012 1 SIZE 70 1A430224052 1
29 HUB SEE FOLLOWING TABLE
21 SCREW, CAP, HEX HD (STEEL ZN PL) 30 RING, RETAINING, EXT (CARBON STEEL/ZN PL)
SIZE 40 1A352624052 4 SIZE 40 12A9409X012 1
SIZE 60 1A418624052 4 SIZES 60 & 70 12A9455X012 1
SIZE 70 1A418624052 4 31* BUSHING -
22 YOKE, MOUNTING SEE FOLLOWING TABLE SIZE 40 12A9373X012 1
23 SCREW, CAP, HEX HEAD (STEEL ZN PL) SIZES 60 & 70 12A9374X012 1
SIZE 40 1A336924052 4
SIZES 60 & 70 1A340924052 4

‘ Recommended spare parts 21

Types 1051 & 1052 with F & G Mounting

Figure 10. Typical Type 1052 Actuator Assembly (Continued)

22
 Types 1051 & 1052 with F & G Mounting

Description Part Number Qty Key Description Part Number Qty

COVER (ALUMINUM/CHROMATE) 35 SCALE, INDICATOR, [STAINLESS STEEL (SST)l
STANDARD W/0 HANDWHEEL
SIZE 40 22B8469X012 1 SIZE 40 28A8533X012 1
SIZES 60 & 70 22B8471X012 1 SIZES 60 & 70 28A8492X012 1
W/FYBC5 SWITCH W/O TYPE 3610J POSITIONER 36 SCREW, SELF TAPPING
SIZE 40 26A8343X012 1 CARBON STEEL-PLATED
SIZES 60 & 70 36A8344X012 1 FOR ALL SIZES 1B561528982 2
W/TYPE 3710 POSITIONER 37 TRAVEL INDICATOR (SST)
W/PURGE W/O HANDWHEEL
SIZE 40 22B8469X012 1 W/O SWITCHES
SIZES 60 & 70 22B8471X012 1 SIZE 40 28A8534X012 1
W/O PURGE SIZES 60 & 70 28A8495X012 1
SIZE 40 22B8470X012 1 W/TYPE 304 OR TYPE 4200
SIZES 60 & 70 22B8472X012 1 SIZE 40 28A8489X012 1
SIZES 60 & 70 28A8496X012 1
SCREW, CAP, HEX HD W/1 OR 2 GO SWITCHES SW
CARBON STEEL-PLATED SIZE 40 28A8534X012 1
W/O SWITCHES SIZES 60 & 70 28A8495X012 1
SIZE 40 1A336924052 4 W/BZE6-2RN OR DTE6-2RN SW
SIZES 60 & 70 1A340924052 4 SIZE 40—90 DEG 28A8490X012 1
W/NAMCO OR LSA/LSX SWITCHES SIZES 60 & 70—90 DEG 28A8494X012 1
SIZES 60 & 70 18A8737X012 2 W/MICRO SW. 90 DEG SW
W/TYPE 304 OR TYPE 4200 SIZE 40 28A8490X012 1
SIZE 40 1C403824052 4 SIZES 60 & 70 28A8494X012 1
SIZES 60 & 70 1A453324052 4 W/NAMCO OR LSA/LSX SW
SCREW, CAP, HEX HD (Cont’d) SIZE 40 28A8534X012 1
CARBON STEEL-PLATED SIZES 60 & 70 28A8495X012 1
W/TYPE PMV
SIZE 40 1C403824052 4 38 SELF-TAPPING SCREW (STEEL ZN PL)
SIZES 60 & 70 1A453324052 4 W/O HANDWHEEL OR W/O SWITCHES 1B561528982 2
W/1 OR 2 GO SWITCHES (SW) W/TYPE 304 OR TYPE 4200 1B5613X0012 2
SIZE 40 1A336924052 2 38 MACHINE SCREW (STEEL ZN PL)
SIZES 60 & 70 1A340924052 2 W/BZE6-2RN OR DTE6-2RN
W/TYPE 1076 SIZE 40 SIZE 40—90 DEG 1B290524052 2
W/O SWITCHES OR W/MICRO<2>SW. 1A336924052 4 SIZE 60—90 DEG 1A381624052 2
W/TYPE 1076 SIZES 60 & 70 W/MICRO SW. 90 DEG
W/O SWITCHES OR W/MICRO SW. 1A340924052 4 SIZE 40 1A579724052 2
W/TYPE 1076 W/GO SWITCHES SIZE 60 1A381624052 2
SIZE 40— 1 SW. 3 W/1 OR GO SWITCHES
SIZE 40— 2 SW. 1A336924052 2 W/NAMCO OR LSA/LSX
SIZES 60 & 70— 1 SW. 3 FOR ALL SIZES 1B285628982 2
SIZES 60 & 70—2 SW. 1A340924052 2 39 PLATE, COVER (STEEL)
W/TYPE 1076 W/NAMCO OR LSA, LSX SW USE W/O TYPE 3610J OR 3620J
SIZE 40— 1 SW. 1A344524052 2 POSITIONER 22A9359X012 1
SIZE 40— 2 SW. 1A344524052 4 40 SCREW, CAP, HEX HD (STEEL ZN PL)
SIZES 60 & 70— 1 SW. 1A340924052 2 W/O TYPE 3610J/3620J POSITIONER 1C275224052 4
SIZES 60 & 70—2 SW. 1A344424052 4
41 NAMEPLATE (SST)
W/BZE6-2RN OR DTE6-2RN SW FOR ALL SIZES 12B6401X0A2 1
SIZE 40— 90 DEG 1A336924052 4 42 SCREW, DRIVE (SST)
SIZES 60 & 70—90 DEG 1A340924052 4 FOR ALL SIZES 1A368228982 4
W/MICRO SW. W /90DEG 56 WARNING LABEL
SIZE 40— 1 SW. 1A336924052 4 TYPE 1051
SIZE 40— 2 SW. 1A336924052 4 SIZE 40 12A9530X012 1
SIZES 60 & 70— 1 SW. 1A340924052 4 SIZE 60 12A9531X012 1
SIZES 60 & 70—2 SW. 1A340924052 4 TYPE 1052
W/NAMCO OR LSA/LSX SW FOR ALL SIZES 19A6264X012 1
SIZE 40 1A344524052 2 57 TURNBUCKLE (STEEL ZN PL)
SIZE 40 1A336924052 2 SIZE 40 22A9625X012
SIZES 60 & 70 1A340924052 2 SIZE 60 22A9624X012 1
W/TYPE 3710 POSITIONER SIZE 70 22A9630X012 1
SIZE 40 1A336924052 4
SIZES 60 & 70 1A340924052 4 58 NUT, HEX, JAM (STEEL ZN PL) .
SIZE 40 ' 12A9629X012 1
SIZES 60 & 70 1R438924122 1

23
 Types 1051 & 1052 with F & G Mounting

TOP-MOUNTED HANDWHEEL ASSEMBLY FOR TOP-MOUNTED HANDWHEEL ASSEMBLY FOR

SIZE 30, 40, AND 60 ACTUATORS SIZE 70 ACTUATOR

Figure 11. Top-Mounted Handwheel Assemblies

Key Description Part Number Qty Key Description Part Number Qty
59 PLATE, ACCESS 76 LUBRIPLATE MAG-1, LUBRICANT OR EQUIVALENT
FOR ALL SIZES 38A4712X012 1 (NOT FURNISHED W/ACTUATOR) ---
63 WASHER, PLAIN (STEEL ZN PL) 77 LOCTITE 271 SEALANT OR EQUIVALENT
TYPE 1051 W/TYPE 304 OR TYPE 4200 (NOT FURNISHED W/ACTUATOR) ---
SIZE 40 1H723125072 4 78 SCREW, CAP, HEX HD (STEEL)
SIZES 60 & 70 1A518925072 2 USE W/BUTTERFLY VALVES
67* BUSHING SEE FOLLOWING TABLE STYLE G
3/8 & 1/2-INCH (9.5 &
71 BEARING, THRUST (STEEL) 12.7 mm) SHAFTS 1A341824052 2
TYPE 1052 SIZE 40 10A4636X012 1 5 /8 - 1 -INCH (15.9 -
TYPE 1052 SIZE 60 1N888799012 1 25.4 mm) SHAFTS 1A341824052 4
TYPE 1052 SIZE 70 16A9175X012 1 1-1/4 & 1-1/2 INCH (31.8 &
72 BEARING RACE (STEEL) 81.1 mm) SHAFTS 1A544424052 4
TYPE 1052 SIZE 40 10A4635X012 2 1-3/4 INCH (44.5 mm) SHAFT 1A544424052 4
TYPE 1052 SIZE 60 1N888899012 2 2-INCH (50.4 mm) SHAFT 1A544424052 4
TYPE 1052 SIZE 70 16A9182X012 2
73 BEARING SEAT 82 DIAPHRAGM HEAD, LOWER (STEEL/CHROMATE)
CAST IRON ZN PL TYPE 1051
TYPE 1052 SIZE 40 18A2482X012 1 SIZE 40 W/ADJ DOWN STOP 1E682744022 1
TYPE 1052 SIZE 60 18A2479X012 1 SIZE 60 W/ADJ DOWN STOP 1E845544022 1
STEEL SIZE 70 W/ADJ DOWN STOP 16A9181X012 1
TYPE 1052 SIZE 70 16A9176X012 1 83 PLUG, PROTECTIVE (POLYETHYLENE)
74 SCREW, ADJUSTING (STEEL ZN PL) TYPE 1052 SIZE 70 1E878406992 1
TYPE 1052 SIZE 40 18A2480X012 1 123 MOUNTING PLATE, (SST) 13B0415X012 1
TYPE 1052 SIZE 60 18A2476X012 1 124 MOUNTING PLATE ASSY (SST) 23B0412X012 1
TYPE 1052 SIZE 70 26A9172X012 1
127 GROOVE PIN (SST) ' 1D542335032 1
75 SET SCREW, HEX SOCKET (CARBON STEEL) JAM NUT (SST) 1A5993X0032 1
128
TYPE 1052 SIZE 70 1C345128992 1 CAP SCREW (SST) 1A3816K0012 1
129
— PIPE BUSHING (NOT SHOWN) PL STEEL
FOR TYPE 1052, SIZE 70 ONLY 1C379026232 1

24 •Recommended spare parts

 Types 1051 & 1052 with F & G Mounting

Key
Top-Mounted Handwheel (Figure 11) Description Part Number Qty
246 SPACER, (STEEL)
Key Description Part Number Qty SIZE 60 11B7132X012 1
51 HANDWHEEL (CAST IRON) SIZE 70 11B7133X012 1
SIZE 40 16A0956X012 1 247 PIN, COTTER, (SST)
SIZE 60 PUSH-DOWN-TO-CLOSE 38A2309X012 1 SIZES 40 & 60 1B108438992 1
SIZE 60 PUSH-DOWN-TO-OPEN 38A2310X012 1 SIZES 70 1J340238992 1
SIZE 70 2A193719042 1
54 NUT, HEX, SLOTTED (STEEL)
SIZE 40 & 60 11B5952X012 1 Adjustable Up Travel Stop (Figure 12)
SIZE 70 11B7131X012 1 Key Description Part Number Qty
133 STEM (BRONZE) 133 STEM (BRONZE)
SIZE 40 27A9643X012 1 SIZE 40 27A9651X012 1
SIZE 60 27A9642X012 1 SIZE 60 27A9647X012 1
SIZE 70 27A9664X012 1 SIZE 70 27A9666X012 1
135 PLATE, PUSHER 135 PLATE, PUSHER
CARBON STEEL/ZN PL CARBON STEEL/ZN PL
SIZE 40 1F117999012 1 SIZE 40 1F117999012 1
STEEL SIZE 60 1F118399012 1
SIZE 60 1F118399012 1 CAST IRON
CAST IRON SIZE 70 1R679619022 1
SIZE 70 1R679619022 1 137 NUT, TRAVEL STOP (BRASS)
137 NUT, HEX, JAM, (STEEL) SIZE 40 18A1272X012 1
SIZES 40 & 60 18A2300X012 1 SIZE 70 18A2304X012 1
SIZE 70 18A2301X022 1 138* O-RING, (NITRILE)
138* O-RING, (NITRILE) SIZE 40 1D237506992 1
SIZE 40 1D237506992 1 SIZE 60 1B885506992 1
SIZE 60 1B885506992 1 SIZE 70 1C415706992 1
SIZE 70 1C415706992 1
139* O-RING, (NITRILE) 139* O-RING, (NITRILE)
SIZE 40 1D267306992 1 SIZE 40 1D267306992 1
SIZE 60 1D547106992 1 SIZE 60 1D547106992 1
SIZE 70 1D269106992 1 SIZE 70 1D269106992 1
140* PIN, GROOVE, 140* PIN, GROOVE
CARBON STEEL-PLATED CARBON STEEL-PLATED
SIZE 40 1F118028992 1 SIZE 40 1F118028992 1
S31600 (316 SST) S31600 (316 SST)
SIZE 60 1B627035072 1 SIZE 60 1B627035072 1
141 SCREW, CAP, HEX HD (STEEL ZN PL) 141 SCREW, CAP, HEX HD (STEEL ZN PL)
SIZE 40 1A368424052 6 SIZE 40 1A368424052 6
SIZE 60 1A368424052 8 SIZE 60 1A368424052 8
SIZE 70 1N129328992 12 SIZE 70 1N129328992 12
142 BODY (CAST IRON) 142 BODY, (CAST IRON)
SIZE 40 2N168719012 1 SIZE 40 2N 168719012 1
SIZE 60 2K949419012 1 SIZE 60 2K949419012 1
SIZE 70 37A9662X012 1 SIZE 70 37A9662X012 1
164 BODY EXTENSION (STEEL)
164 BODY EXTENSION (STEEL) SIZE 40 17A9658X012 1
SIZE 40 17A9658X012 1 SIZE 60 17A9657X012 1
SIZE 60 17A9657X012 1
169 GREASE FITTING 169 GREASE FITTING
SIZE 70 1L847828992 1 SIZE 70 1L847828992 1
171 WASHER, PLAIN (CARBON STEEL) OR 171 SPACER (SST)
SPACER S41600 (416 SST) SIZE 60 10A0057X012 1
SIZE 60 10A0057X012 1 174 RETAINING SCREW, (STEEL)
174 RETAINING SCREW (STEEL) SIZE 70 1R679724092 1
SIZE 70 1R679724092 1 175 BEARING, THRUST (CARBON STEEL)
SIZE 70 1N838099012 1
175 BEARING, THRUST (CARBON STEEL)
SIZE 70 1N838099012 1 176 BEARING RACE, THRUST (CARBON STEEL)
176 BEARING RACE, THRUST TYPE 1052, SIZE 70 ONLY 1N838199012 2
TYPE 1052, SIZE 70 ONLY 1N838199012 2 187 TRAVEL STOP CAP
241 LUBRIPLATE MAG-1, LUBRICANT OR EQUIVALENT SIZE 40 1V136914012 1
(NOT FURNISHED W/TRAVEL STOP) — SIZE 60 1U290514012 1
242 LOCTITE 271 SEALANT OR EQUIVALENT SIZE 40 ' 1U956314012 1
(NOT FURNISHED W/TRAVEL STOP)v - - - 241 LUBRIPLATE MAG-1, LUBRICANT OR EQUIVALENT
(NOT FURNISHED W/TRAVEL STOP) —

'Recommended spare parts 25

 Types 1051 & 1052 with F & G Mounting

ADJUSTABLE UP TRAVEL STOP FOR ADJUSTABLE UP TRAVEL STOP FOR

SIZE 40 ACTUATORS SIZE 60 ACTUATORS

□ APPLY LUBRICANT/SEALANT
CV8067-E

ADJUSTABLE UP TRAVEL STOP FOR SIZE 70

. TYPE 1052 ACTUATORS

Figure 12. Adjustable Up Travel Stops

26
 1051 & 1052 with F & G Mounting

Key Description Part Number Qty

SIZE 60 1A368424052 8
SIZE 70 1N129328992 12
142 TRAVEL STOP BODY (CAST IRON)
SIZE 40 36A6248X012 1
SIZE 60 36A6249X012 1
SIZE 70 36A9177X012 1
187 TRAVEL STOP CAP (BRASS)
SIZE 40 1P860814012 1
SIZE 60 1U290514012 1
SIZE 70 26A9179X012 1
189 NUT, HEX, JAM (STEEL ZN PL)
TYPE 1051
SIZE 40 1A352424122 1
SIZE 60 1A599324122 1
TYPE 1052
SIZE 40 1A353724122 1
.... SIZE 60 1A351124122 1
SIZE 70 1A351124122 2
241 LUBRIPLATE MAG-1, LUBRICANT OR EQUIVALENT
(NOT FURNISHED W/TRAVEL STOP) —

Pipe-Away Vent (figure 8)

COMPLETE RETROFIT KITS ARE LISTED AT THE BE­
Figure 13. Adjustable Down Travel Stop GINNING OF THE PARTS LIST. USE THIS LISTING FOR
INDIVIDUAL REPLACEMENT PARTS

Key Description Part Number Qty Key Description Part Number Qty
242 LOCTITE 271 SEALANT OR EQUIVALENT 132 LINED BUSHING (STEEL/PTFE) YOKE SIDE
(NOT FURNISHED W/TRAVEL STOP) - - - 1/2-INCH (12.7 mm) DIA. SHAFT 1U902599402 2
5/8-INCH (15.9 mm) DIA. SHAFT 14B4642X012 2
3/4-INCH (19.1 mm) DIA. SHAFT F1918348112 2
Adjustable Down Travel Stop (Figure 13) 7/8-INCH (22.2 mm) DIA. SHAFT 14B4631X012 2
1-INCH (25.4 mm) DIA. SHAFT 14B4632X012 2
Key Description Part Number Qty 1-1/4 INCH (31.8 mm) DIA. SHAFT 14B4633X012 2
54 NUT, HEX (STEEL ZN PL) 1-1/2 INCH (38.1 mm) DIA. SHAFT 14B4634X012 2
TYPE 1051 1-3/4-INCH (44.5 mm) DIA. SHAFT 14B4635X012 2
SIZE 40 1A341224122 1 2-INCH (50.8 mm) DIA. SHAFT G1668548112 2
SIZE 60 1A368124122 2 133 O-RING (NITRILE)
TYPE 1052 1/2-INCH (12.7 mm) DIA. SHAFT 1J4888X0052 1
SIZE 40 1A413224122 1 5/8-INCH (15.9 mm) DIA. SHAFT 11A8741X052 1
SIZE 60 1A375424122 2 3/4-INCH (19.1 mm) DIA. SHAFT 1F4636X0032 1
SIZE 70 1A351124122 2 7/8-INCH (22.2 mm) DIA. SHAFT 10A3805X012 1
63 FLANGE NUT (CARBON STEEL-PLATED) 1-INCH (25.4 mm) DIA. SHAFT 10A8217X042 1
TYPE 1051 1-1/4 INCH (31.8 mm) DIA. SHAFT 14A6981X012 1
SIZE 40 15A9617X012 1 1-1/2 INCH (38.1 mm) DIA. SHAFT 1F1153X0012 1
TYPE 1052 1-3/4-INCH (44.5 mm) DIA. SHAFT 1P1676X0012 1
SIZE 70 16A9178X012 1 2-INCH (50.8 mm) DIA. SHAFT ' 10A3800X012 1
133 TRAVEL STOP STEM [S30300 (303 SST)] 134 BUSHING (STEEL/PTFE) HUB SIDE
TYPE 1051 SIZE 30/40
SIZE 40 17A1804X012 1 1/2- TO 7/8-INCH (12.7 TO 22.2 mm)
SIZE 60 17A1805X012 1 DIA. SHAFT 14B3503X012 2
TYPE 1052 SIZE 40
SIZE 40 16A6692X012 1 1- TO 1-1/4 INCH (25.4 TO 31.8 mm)
SIZE 60 16A6693X012 1 DIA. SHAFT 14B3503X012 2
SIZE 70 16A9180X012 1 SIZE 60
134 WASHER (PLAIN CARBON STEEL) 3/4- TO 2-INCH (19.1 TO 50.8 mm)
SIZE 40 , 16A1352X012 1 DIA. SHAFT 14B4310X012 2
SIZE 60 15A7932X012 1 135 O-RING (NITRILE) HUB SIDE
SIZE 70 1E833628992 1 SIZE 30/40
1/2- TO 7/8-INCH (12.7 TO 22.2 mm) 1K594906562 1
139* O-RING (NITRILE) . SIZE 40
SIZE 40 1D267306992 1 1- TO 1-1/4 INCH (25.4 TO 31.8 mm)
SIZE 60 1D547106992 1 DIA. SHAFT 1K594906562 1
SIZE 70 10269106992 1 SIZE 60
141 SCREW, CAP, HEX HD (STEEL ZN PL) 3/4- TO 2-INCH (19.1 TO 50.8 mm)
SIZE 40 1A368424052 6 DIA. SHAFT .... 1U2504X0042 1

'Recommended spare parts

27
 Types 1051 & 1052 with F & G Mounting

Key Description Part Number Qty Key 11. Spring!1) for Type 1051 Actuator Only (Steel)
136 TRAVEL IND GASKET (NEOPRENE)
Key 13. Spring Seat*1) for Type 1051 Actuator Only (Steel)
SIZE 30 & 40
CASING KEY 11 KEY 13
1/2 TO 7/8, 1-1/4-INCH DIA. SHAFT 14B4642X012 1 ACTUATOR
SIZE 60
PRESSURE SPRING PART SPRING SEAT
SIZE
7/8- TO 2-INCH DIA SHAFT 14B4643X012 Psig Bar NUMBER PART NO.
1
137 ACCESS PLATE ASSEMBLY 12B8745X012 1 40 1L217427042 12A9447X012
138 MACHINE SCREW (STEEL PL) 1A340828992 4
Oto 18 0 to1.2 1K162727082 12A9450X012
139 PERMATEX BLUE RTV OR EQUIVALENT 60 1N937327082 12A9448X012
SLICONE GASKET, #6B, 3 OZ. TUBE 1N937327082 12A9449X012
FURNISHED WITH RETROFIT KIT 1M1466X0012 1L217327042
40 12A9446X012
140 PLUG (STEEL) 1A767524662 1 1P637127082 12A9447X012
141 SPRING BARREL COVER TYPE 1052 ONLY (STEEL)
0 to 33 0 to 2.3 1K162827082 12A9448X012
SIZE 30 24B7526X012 2 1K162827082 12A9449X012
SIZE 40 24B7516X012 2 60
1N937327082 12A9448X012
SIZE 60 24B7517X012 2 1N937327082 12A9449X012
SIZE 70 24B7518X012 2
40 1L217327042 12A9446X012
142 SELF-TAPPING SCREW (SST)
Oto 40 0 to 2.8 1K162827082 12A9448X012
SIZE 30 & 40 1J336728982 4 60
SIZE 60 1K162829082 12A9449X012
1J336728982 5
SIZE 70 1J336728982 8 Oto 55 0 to 3.8 40 1L217327042 12A9446X012
143 CAP SCREW (STEEL ZN PL) 0.2 to
3 to 15 60 1K162727082 12A9450X012
SIZE 30 1C275224052 8 1.0
SIZE 40 & 70 1C275224052 4 1L217327042 12A9446X012
SIZE 60 40
1C275224052 2 0.2 to 1P637127082 12A9447X012
3 to 30
2.1 1k612827082 12A9449X012
60
1N937327082 12A9449X012

Key 27. Lever (Ductile Iron)

ACTUATOR SHAFT DIAMETER
PART NUMBER
SIZE Inches mm
1/2 12.7 32A9567X012<1>
5/8 15.9 32A9568X012<1>
40 3/4 19.1 32A9569X012<1>
7/8 & 1 22.2 & 25.4 32A9570X012
1-1/4 31.8 32A9571X012
3/4 19.1 32A9589X012<2)
7/8 & 1 22.2 & 25.4 32A9590X012<2)
60 1-1/4 31.8 32A9591X012<2>
1-1/2 38.1 32A9592X012
1-3/4 & 2 44.5 & 50.8 34A5322X012
1-1/4 31.8 32A9575X012<3)
70 1-1/2 38.1 32A9576X012
1-3/4 & 2 44.5 & 50.8 32A9679X012
1. Use 1-1/4 inch (31.8 mm) size lever w/Type 1076 handwheel actuator.
2. Use 1-3/4 & 2 (44.5 & 50.8 mm) size 60 lever w/Type 1076 handwheel actuator.
3. Use 1-3/4 & 2 inch (44.5 & 50.8 mm) size 70 lever w/Type 1076 handwheel
actuator.

28
 Types 1051 & 1052 with F & G Mounting

Key 11. Spring*1) for Type 1052 Actuators Only (Steel)

INITIAL SPRING COMPRESSION KEY 11
CASING PRESSURE ACTUATOR Push-down-to-open Push-down-to-close SPRING PART
SIZE NUMBER
Psig Bar Psig Bar Psig Bar
3.0 0.2 3.0 0.2 1L217427042
40 1P637127082
4.3 0.3 3.0 0.2
3.7 0.3 3.0 0.2 1K162727082
60 0.2 1N937327082
3.5 0.2 3.0
4.3 0.3 4.3 0.3 1P637127082
40 6.0 0.4 3.0 0.2 1L217327042
4.4 0.3 3.0 0.2 1N844027082
Oto 33 0 to 2.3 3.5 0.2 3.5 0.2 1N937327082
60 7.0 0.5 3.0 0.2 1K162827082
6.8 0.5 3.0 0.2 1P270227042
70 10.1 0.7 3.0 0.2 1R676027082
4.4 0.3 3.0 0.2 1N844027082
40 0.2 1L217327042
6.0 0.4 3.0
Oto 40 0 to 2.8 6.8 0.5 3.0 0.2 1P270227042
60 0.2 1K162827082
7.0 0.5 3.1
70 10.1 0.7 3.3 0.2 1R676027082
40 4.4 0.3 3.5 0.2 1N844027082
70 10.1 0.7 10.1 0.7 1R676027082
40 — — 3.0 0.2 1L217427042
u IU 10 1K162727082
60 3.7 0.3 3.0 0.2
4.3 0.3 4.3 0.3 1P637127082
40 6.0 0.4 3.0 0.2 1L217327042
— — 3.0 0.2 1N844027082
3 to 30 0.2 to 2.1 3.5 0.2 3.5 0.2 1N937327082
60 7.0 0.5 3.0 0.2 1K162827082
— — 3.0 0.2 1P270227042
70 10.1 0.7 3.0 0.2 1R676027082
1. For more detailed ordering information concerning spring selection to obtain the torque required by the valve, consult your Fisher Control sales office or sales representative.

Keys 22 and 67<1>- Mounting Yoke Assembly

ACTUATOR VALVE SHAFT DIAMETER KEY 22 YOKE KEY 67
VALVE DESIGN CAST IRON BUSHING, PTFE
SIZE Inches mm
1/2 12.7 12A9799X0A2 — 1U902599402
5/8 15.9 12A9799X0B2 — 12A9555X012
3/4 19.1 12A9799X0C2 — 12A9556X012
7/8 22.2 12A9799X0E2 — 12A9557X012
1 25.4 12A9799X0G2 — 12A9775X012
CV500, V100, V150, V200, V250, 1-1/4 31.8 12A9799X112 — 12A9558X012
3/4 19.1 12A9799X0D2 ___ 12A9556X012
7800 (2-12 Inch) for F Mounting 12A9557X012
60 7/8 22.2 12A9799X0F2 —

1 25.4 12A9799X0H2 — 12A9775X012

1-1/4 • 31.8 12A9799X0J2 12A9558X012
1-1/2 38.1 12A9799X0K2 12A9559X012
60 and 70 12A9799X0L2 10A3848X012
1-3/4 44.5
2 50.8 12A9799X0M2 12A9715X012
1/2 12.7 — 32A9755X012 1U902599402
5/8 15.9 — 32A9742X012 12A9555X012
40 3/4 19.1 — 32A9743X012 12A9556X012
1 25.4 — 32A9757X012 12A9575X012
1-1/4 31.8 — 32A9746X012 12A9558X012
7600 and 9500 for G Mounting 3/4 19.1 — 32A9750X012 12A9556X012
60 32A9778X012 12A9775X012
1 25.4 —

1-1/4 31.8 — 32A9753X012 12A9558X012

1-1/2 38.1 — 32A9754X012 12A9559X012
60 and 70 — 35A9704X012 12A9560X012
1-3/4 44.5
2 50.8 35A9705X012 ■ 12A9561X012
1. The yokes in this column are available as yoke-bushing assemblies, However, the bushings are available as replacement parts.

29
 Types 1051 & 1052 with F & G Mounting

Key 29 Hub, (S41600 Stainless Steel)

W/TYPE 3555T,
VALVE SHAFT DIAMETER STANDARD OR
NAMCO LIMIT
W/TYPES 304 & 3552 W/MICRO
ACTUATOR SIZE SWITCHES, MICRO
OR W/GO-71360 SWITCHES*1)
mm SWITCHES
Inches SWITCH
LSA& LSX
1/2 12.7 22A9496X012 22A9706X012 24A3380X012
5/8 15.9 22A9419X012 22A9701X012 24A3211X012
3/4 19.1 22A9497X012 22A9704X012 24A2188X012
40
7/8 & 1 22.2 & 25.4 22A9486X012 22A9705X012 24A3245X012
1-1/4 31.8 22A9498X012 22A9703X012 - ' '
3/4 19.1 22A9499X012 22A9708X012 23A7813X012
60 22A9420X012 22A9710X012 22A9633X012
7/8 & 1 22.2 & 25.4
1-1/4 31.8 22A9500X012 22A9709X012 22A9547X012
60 & 70 1-1/2 38.1 22A9501X012 22A9707X012 22A9550X012
1-3/4 & 2 44.5 & 50.4 22A6358X012 25A1600X012 ' - -
1. Part number does not include Micro Switch LAS or LSX.

While this information is presented in good faith arid believed to be accurate, or any other matter with respect to the products, nor as a recommendation to
Fisher Controls does not guarantee satisfactory results from reliance upon such use any product or process in conflict with any patent. Fisher Controls reserves
information. Nothing contained herein is to be construed as a warranty or guar­ the right, without notice, to alter or improve the designs or specifications of the
antee, express or implied, regarding the performance, merchantability, fitness products described herein.

For information, contact Fisher Controls:

Fisher Controls Marshalltown, Iowa 50158 USA
Cemay 68700 France
Sao Paulo 05424 Brazil
Singapore 2158

Printed In U.S.A. w recycled paper

 361OJ and 3620J Series

Fisher Controls Instruction Manual

361 OJ and 3620J Series

Positioners

FISHER0
____________ March 1993 Form 5208

Contents
Introduction ........................................ 2
Scope of Manual ................................... 2
Description .......................................... 2
Type Number Description ....................... 2
Specifications ........................................ 3
Installation ........................................... 4
Mounting Type 3610J, 361OJP, 3620J, and
3620JP Positioners .............................. 5
Changing Cams— Actuator Styles A, B, C, and D 6
Mounting Type 3611JP and 3621JP
Positioners ....................................... 7
Installing Type 3622 Electro-Pneumatic Converter 7
Changing Positioner T yp e s....................... 7
Pressure Connections .............................. 8
Supply Connection...............................11
Output Connections..................... 11
Instrument Connection...........................11 36Z0JP POSITIONER WITH TYPE 1061
Diagnostic Connections......................... 11 ACTUATOR AND DESIGN V600 VALVE
Vent Connection.................................... 12
Electrical Connections for 3620J Series
Positioners ....................................... 12
Calibration .......................................... 1 2
Minor Loop Gain Adjustment ..................... 13
Crossover Adjustment............................. 14
Zero and Span Adjustments.......................14
Changing Positioner Action........................ 15
Changing to Direct Action.......................15
Changing to Reverse Action ....................16
Split Range Operation............................. 16
Characterized Cams for Type 3610J, 3610JP,
3620J, and 3620JP ............................. 17
Principle of O p eratio n ......................... 1 7
Maintenance ....................................... 23
Positioner Disassembly ............................ 23
Removing the Positioner from the Actuator . .23
Disassembling the Bypass Valve .............. 24
Disassembling the Gauge B lock............... 24 TYPE 3610J POSITIONER AND BY P A SS VALVE
Disassembling the Type 3622 Electro-Pneumatic WITH TYPE 1052 ACTUATOR, AND edisc VALVE
Converter ......................................24
Disassembling the Feedback Lever Assembly 25 Figure 1. Typical Positioners

©Fisher Controls International, Inc. 1984, 1993; All Rights Reserved

361OJ and 3620J Series

Contents (Continued)
Disassembling the Reversing Plate and Gasket25
Disassembling the Relay........................25
Disassembling the Summing Beam Assembly .25
Disassembling the Nozzle Assembly .......... 26
Disassembling the Input Module............... 26
Positioner Reassembly ............................ 26
Assembling the Input Module .................. 26
Assembling the Nozzle Assembly.............. 27
Assembling the Summing Beam Assembly . . .27
Assembling the Relay ...........................28
Assembling the Reversing Plate and Gasket . ,29
Assembling the Gauge Block .................. 29
Assembling the Type 3622 Electro-Pneumatic
Converter ......................................29
Assembling the Feedback Lever Assembly .. .30
Assembling the Bypass Valve Assembly..... 30
Changing Positioner T yp e s........................31
Parts O rderin g .................................... 32
Parts Kits .......................................32
Parts List ....................................... 32
Diagnostic Connections............................ 32 Figure 2. Type 3621JP Positioner with Type 585 Actuator
and Design CE Valve
Positioner Common Parts ..........................33
Type 3622Electro-Pneumatic Converter ..........35
Type Number Description
Introduction The following descriptions provide specific information
on the different positioner constructions. If the type
Scope of Manual number is not known, refer to the nameplate on the
positioner. For the nameplate location, refer to key 157,
This instruction manual includes installation, operation, figure 23.
calibration, maintenance, and parts ordering informa­
tion for the 361 OJ and 3620J Series positioners, (i.e. Type 361 OJ: A single-acting pneumatic rotary valve
3610J, 3610JP, 3611JP, 3620J, 3620JP, and 3621JP positioner for use with Type 1051 and 1052 actuators.
Series positioners). This manual also provides field
installation information for the Type 3622 electro-pneu­ Type 3610JP: A double-acting pneumatic rotary valve
matic converter. Refer to separate instruction manuals positioner for use with Type 1061 and 1069 actuators.
for information on the actuator and control valve.
Type 3611JP: A double-acting pneumatic sliding stem
Only personnel qualified through training or experience valve positioner for use with Type 585 and 585R
should install, operate, or maintain the positioner. If actuators.
there are any questions concerning the instructions in
this manual, contact your Fisher sales office or sales Type 3620J: A single-acting electro-pneumatic rotary
representative before proceeding. valve positioner for use with Type 1051 and 1052
actuators.
Description Type 3620JP: A double-acting electro-pneumatic rotary
The Type 361 OJ or 3610JP pneumatic and the Type valve positioner for use with Type 1061 and 1069
3620J or 3620JP electro-pneumatic positioners are actuators.
used with diaphragm rotary actuators and with piston
rotary actuators as shown in figure 1. The Type 3611 JP Type 3621JP: A double-acting electro-pneumatic sliding
and 3621 JP positioners are used with the Type 585 or stem valve positioner for use with Type 585 and 585R
585R sliding stem actuators as shown in figure 2. actuators.

The positioner mounts integrally to the actuator housing
and provides a valve ball, disk, or plug position for a
specific input signal. The positioner accepts either a
pneumatic or milliampere input signal. Refer to the type
number description for a detailed explanation of type
numbers.
2
Type 3622: An electro-pneumatic converter used for
conversion of a 4 to 20 milliampere dc input signal to a 3
to 15 psig (0.2 to 1.0 bar) input signal for the pneumatic
positioner. Use this unit in combination with a Type
3610J, 3610JP, or 3611JP positioner to make a Type
3620J, 3620JP or a 3621 JP positioner.

Table 1. Specifications
Unless otherwise specified, the specifications
listed are for all positioner type numbers
Available Configurations
Refer to the type number description
Input Signal*1)
Type 3610J, 3610JP, and 3611JP:
Standard: ■ 3 to 15 psig (0.2 to 1.0 bar), ■ 6 to
30 psig (0.4 to 2.0 bar), or ■ split range, see
table 3
Adjustable: Zero is adjustable from 1 to 22 psig
(0.07 to 1.5 bar) for standard valve rotations or
valve travels. Span is adjustable from 3.2 to 28.8
psi (0.2 to 2.0 bar) for standard valve rotations
or valve travels. Location of adjustments are
shown in figure 11
Type 3620J, 3620JP, and 3621 JP: 4 to 20 mA
dc constant current with 30 V dc maximum
compliance voltage. Split range is also available,
see table 3.
Equivalent Circuit
Type 3620J, 3620JP, and 3621 JP: 120 ohms
shunted by three 5.6 V zener diodes
Output Signal*1)
Pneumatic pressure as required by the actuator
up to full supply pressure
Action*2): Field-reversible between ■ direct and
■ reverse within the pneumatic positioner
Typical Performance for Type 3610J, 3610JP,
3620J, and 3620JP Positioners with Type 1051,
1052, and 1061 Actuators
Independent Linearity*1)
Direct-Acting Type 3610J and 3620J: ± 1.5% of
output span
Reverse-Acting Type 3610J and 3620J: ± 0.75%
of output span
Direct-Acting Type 3610JP and 3620JP: ± 1.25%
of output span
Reverse-Acting Type 3610JP and 3620JP:
± 0.5% of output span
Hysteresis*1)
Type 3610J: 1.0% of output span
Type 3620J: 0.75% of output span
Type 3610JP: 0.5% of output span
Type 3620JP: 0.6% of output span
Deadband*1): 0.1% of input span
Electromagnetic Interference (EMI)*1>
Type 3620J and 3620JP: When tested per SAMA
Standard PMC 33.1-1978, change in steady-
state deviation is less than ± 1% in an
electromagnetic field classified as 3-abc with a
field strength of 30 V/m. Positioner is tested
with cover on and with external wiring in rigid
metal conduit.
- Continued -
361 OJ and 3620J Series
Refer to table 2 for typical performance for Type
3611JP and 3621 JP Positioners
Maximum Supply Air Demand*3)
Type 3610J and 3620J:
20 Psig (1.4 bar) Supply: 490 scfh (13 normal
m3/hour)
35 Psig (2.4 bar) Supply: 640 scfh (17 normal
m3/hour)
Type 3610JP, 3620JP, 3611JP, and 3621 JP:
75 Psig (5.2 Bar) Supply: 1380 scfh (37 normal
m3/hour)
100 Psig (6.9 Bar) Supply: 1700 scfh (46 normal
m3/hour)
Operating Influences*1* for Type 3610J, 3610JP,
3620J, and 3620JP
Supply Pressure Sensitivity: A 10% change in
supply pressure changes the valve shaft
position less than the following percentages of
valve rotation:
Type 3610J and 3620J: 1.0% at 20 psig supply
pressure
Type 3610JP and 3620JP: 1.5% at 60 psig
supply pressure
Supply Pressure*1*
Minimum Recommended: 5 psig (0.3 bar) above
actuator requirement
Maximum: 150 psig (10.3 bar)
Steady-State Air Consumption*3)
Type 3610J: 15 scfh (0.40 normal m3/hour) at 20
psig (1.4 bar) supply pressure
Type 3610JP: 24 scfh (0.64 normal m3/hour) at
100 psig (6.9 bar) supply pressure
Type 3620J: 18.2 scfh (0.49 normal m3/hour) at
20 psig (1.4 bar) supply pressure
Type 3620JP: 35.0 scfh (0.93 normal m3/hour) at
100 psig (6.9 bar) supply pressure
Operative Temperature Limits*1*
- 40 to 180°F ( - 40 to 80°C)
Housing Classification for Type 3620J, 3620JP, and
3621JP
NEMA 3R, IEC 529 IP14; Mounting orientation
requires vent location to be below horizontal
Electrical Classification for Type 3620J, 3620JP,
and 3621JP
Refer to the Hazardous Area Classification
bulletin for specific approvals
Pressure Connections
1/4-inch NPT female
3
361 OJ and 3620J Series

T a b le 1. S p e c ific a tio n s (C o n tin u e d )

Conduit Connection for Type 3620J, 3620JP, and Sliding Stem Valve Travel
3621JP________________________________ Inches mm
1/2-inch NPT female 7/16 11
3/4 to 2 19 to 51
Rotary Valve Rotation_____________________ 1-1/8 to 2 29 to 51
2 to 4 51 to 102
60 or 90 degrees

Approximate Weight________________________
361 OJ Series: 5.6 pounds (2.5 kg)
3620J Series: 8.0 pounds (3.6 kg)
1. This term is defined in ISA Standard S51.1:1979. 3. Scfh— standard cubic feet per hour (60°F and 14.7 psia). Normal cubic meters per
2. For direct action, an increasing input signal extends actuator rod. For reverse hour (0°C and 1.01325 bar absolute).
action, an increasing input signal retracts actuator rod.

Table 2. Typical Performance Specifications<1> for Type 3611JP and Type 3621JP Positioners with Type 585 and 585R Actuators
Size 100 Actuator Size 100 Actuator
Characteristic Size 25 Actuator Size 50 Actuator*9)
Standard with Boosters*2)
Deadband*1-3) 0.1% of input span 0.1% of input span 0.1% of input span 0.1% of input span

Step Response*1'4'6) 0.3 seconds 0.3 seconds 2 seconds 0.3 seconds

Steady-State Air 0.4 scfm 0.4 scfm 0.4 scfm 0.4 scfm
Consumption*3'5-8) (0.01 normal m3/min) (0.01 normal m3/min) (0.01 normal m3/min) (0.01 normal m3/min)
Hysteresis*3) 0.5% of output span 0.5% of output span 0.5% of output span 0.5% of output span

Terminal-Based Linearity*3'7) 1% of output span 1% of output span 1% of output span 1% of output span
Frequency Response*1'3) ( — 6 dB) 2 Hz 2 Hz 0.2 Hz 2 Hz

Supply Pressure Sensitivity 10% change in supply pressure changes the actuator stem position less than 0.1%
1. Performance tests are based on 100 psig (6.9 bar) supply pressure and lightest 14.7 psia). Normal m3/m in-cubic m eters per minute (0°C and 1.01325 bar),
actuator springs. Performance w ill vary with other pressures and springs. 6. Type 3621JP positioner step response equals 0.4 seconds.
2. Equipped w ith tw o Type 2625 boosters with 1/2 inch supply and exhaust ports. 7. Type 3621JP positioner term inal-based linearity equals ±2 .2 5 % . •
3. These term s are defined in ISA Standard S51.1-1979. 8. Type 3621 JP positioner steady-state air consumption equals 0.58 scfm (0.02 normal
' 4. Step response is the tim e for the actuator to reach 63 percent o f expected travel after m3/min). ......................... , „ . ..
a 10 percent step change in input signal. 9. Size 50 actuator was tested with optional high frequency response parallel flexure
5. At 100 psig (6.9 bar) supply pressure. Scfm — standard cubic feet per minute (60°F and (key 179).

Specifications • Disconnect any operating lines provid­

ing air pressure, electric power, or a control
Specifications )or the valve positioners are shown in signal to the actuator. Be sure the actuator
table 1. Performance specifications for the Type 3611 JP cannot suddenly open or close the valve.
and 3621 JP positioners are shown in table 2.
• Use bypass valves or completely shut
off the process to isolate the valve from
Installation process pressure. Relieve process pres­
sure on both sides of the valve. Drain the
Normally, a positioner is shipped with the actuator. If so,
process media from both sides of the valve.
the factory mounts and calibrates the positioner and
connects the positioner to actuator tubing. If the posi­
tioner is ordered separately from the actuator, perform • Vent the power actuator loading pres­
the appropriate mounting procedure, and follow the sure and relieve any actuator spring
Calibration procedures in this instruction manual. Refer precompression.
to the appropriate instruction manuals for actuator and
valve mounting procedures. • Use lock-out procedures to be sure that
the above measures stay in effect while
you work on the equipment.
W A R N IN G
Avoid personal injury from sudden release • For 3620J Series positioners used in
of process pressure. Before mounting the hazardous areas, disconnect power before
positioner: removing the converter cap.

4
 361 OJ and 3620J Series

i it' i I
^ = 2 3

□ __ D
m

ACTUATOR WITHOUT POSITIONER

STYLE B OR C

ACTUATOR AND POSITIONER WITH

ACTUATOR COVER REMOVED

Figure 3. Typical Mounting Details for 361 OJ and 3620J Series

Positioners on Rotary Actuators

Mounting Type 361 OJ, 361OJP, 3620J, 2. Remove the positioner plate from the actuator
housing.
and 3620JP Positioners
During the following mounting procedures, refer to fig­
ure 3 for part locations. Refer to figure 26 for key 3. For actuator styles A and D, proceed to the note
number locations unless otherwise indicated.1 before step 7. For actuator styles B and C, continue with
step 4.
1. Mark the positions of the travel indicator and actua­
tor cover. Then, remove the actuator travel indicator
machine screws, travel indicator, and actuator cover 4. Disconnect the actuator turnbuckle from the lever
cap screws. arm.

5
361 OJ and 3620J Series
Note
Do not change the position of the rod end
bearing on the end of the turnbuckle.
5. Loosen the lever clamping bolt in the lever.
6. Mark the lever/valve shaft orientation, and remove
the lever.
Note
Cams A, B, and C have the letter D (direct
acting) on one side and the letter R (reverse
acting) on the other side. Always install the
cam with the letter D on the same side as
the cam mounting screw heads (key 83 in
figure 3).
7. Install the desired cam (key 82) on the actuator lever
with the cam mounting screws (key 83). Cams B and C
use the cam adjustment indicator (key 84) between the
screw heads and the cam. Align the cam adjustment
indicator with the desired total valve rotation indication
on the cam. Cam A does not use the cam adjustment
indicator and does not require adjustment.
8. For actuator styles A and D, proceed to step 11. For
actuator styles B and C, continue with step 9.
9. Slide the lever/cam assembly (cam side first) onto
the valve shaft. Orient the lever with the shaft as noted in
step 6, and tighten the lever clamping bolt.
Note
Refer to the appropriate actuator instruc­
tion manual to determine the distance re­
quired between the housing face and the
lever face and to determine the proper
tightening torque for the lever clamping
bolt.
10. Connect the turnbuckle and the lever arm.
11. Remove the positioner cover (key 41) from the
positioner. Slide the positioner into the actuator housing
so the cam roller (key 39) rests on the cam. Insert and
tighten the socket head screws (key 54) to secure the
positioner to the actuator housing.
12. Replace the actuator cover and the travel indicator
in the positions that were marked in step 1.
Note
To aid cover alignment on the Type 1051
and 1052 actuators, use a regulated air
source to move the actuator slightly away
6
from its upper travel stop. If hole alignment
is still not possible, temporarily loosen the
cap screws that secure the housing to the
mounting yoke, and shift the housing slight­
ly. Do not completely stroke the actuator
while the cover is removed.
Changing Cams—
Actuator Styles A, B, C, and D
During the following procedures, refer to figure 3 for
part locations and refer to figure 26 for key number
locations unless otherwise indicated.
1. Mark the positions of the travel indicator and actua­
tor cover. Then, remove the actuator travel indicator
machine screws, travel indicator, and actuator cover
cap screws.
2. Remove the positioner plate from the actuator
housing.
3. For actuator styles A and D, proceed to the note
before step 7. For actuator styles B and C, continue with
step 4.
4. Disconnect the actuator turnbuckle from the lever
arm.
Note
Do not change the position of the rod end
bearing on the end of the turnbuckle.
5. Loosen the lever clamping bolt in the lever.
6. Mark the lever/valve shaft orientation, and remove
the lever.
Note
Cams A, B, and C have the letter D (direct
acting) on one side and the letter R (reverse
acting) on the other side. Always install the
cam with the letter D on the same side as
the cam mounting screw heads (key 83 in
figure 3).
7. Install the desired cam (key 82) on the actuator lever
with the cam mounting screws (key 83). Cams B and C
use the cam adjustment indicator (key 84) between the
screw heads and the cam. Align the cam adjustment
indicator with the desired total valve rotation indication
on the cam. Cam A does not use the cam adjustment
indicator and does not require adjustment.
8. For actuator styles A and D, proceed to step 11. For
actuator styles B and C, continue with step 9.

9. Slide the lever/cam assembly (cam side first) onto
the valve shaft. Orient the lever with the shaft as noted in
step 6, and tighten the lever clamping bolt.
Note
Refer to the appropriate actuator instruc­
tion manual to determine the distance re­
quired between the housing face and the
lever face and to determine the proper
tightening torque for the lever clamping
bolt.
10. Connect the turnbuckle and the lever arm.
11. Replace the actuator cover and the travel indicator
in the positions that were marked in step 1.
Note
To aid cover alignment on the Type 1051
and 1052 actuators, use a regulated air
source to move the actuator slightly away
from its upper travel stop. If hole alignment
is still not possible, temporarily loosen the
cap screws that secure the housing to the
mounting yoke, and shift the housing slight­
ly. Do not completely stroke the actuator
while the cover is removed.
Mounting Type 3611JP and 3621 JP
Positioners
Refer to figure 4 for part locations. Refer to figure 27 for
key number locations unless otherwise indicated.
1. Refer to the appropriate actuator instruction man­
ual. Loosen the four screws, and remove the front yoke
cover plate from the actuator.
2. Stroke the actuator from the top stop to the bottom
stop, and record the travel distance.
3. Loosen the four captive cover screws and remove
the positioner cover (key 41, figure 26).
4. Refer to the appropriate actuator instruction man­
ual. Loosen the four screws, and remove the actuator
blanking plate.
5. Attach the positioner adapter (key.113) to the actua­
tor with four socket head screws (key 54).
6. Disconnect the positioner range spring (key 150 in
figure 23) from the range spring hanger (key 130 in
figure 23).
361 OJ and 3620J Series
7. Attach the roller (key 175) and washers (key 184,
size 100 actuator only) to the adjuster assembly (key
174) and secure with the retaining ring (key 172).
8. Apply pressure to the actuator piston and move the
actuator to approximately the mid-travel position.
9. Install the positioner on the actuator so the feed­
back lever assembly (key 117) is under the stem bracket
and secure the positioner to the adapter (key 113) with
the four socket head screws (key 54).
10. With the actuator still at mid-travel and the top
edge of the feedback lever assembly perpendicular to
the actuator stem, install the adjuster assembly/roller in
the appropriate stem bracket slot with the button head
screw (key 173) so the roller is centered over the correct
actuator travel marked on the feedback lever assembly
(key 117 or 170) as shown in figure 4.
11. Tighten the button head screw (key 173) and re­
place the range spring (key 150 in figure 23).
12. For size 100 actuators with greater than a 2-inch
(51 mm) travel, install the feedback lever spring (key
185).
13. Replace the positioner cover.
14. Replace the front actuator cover plate.
15. Discard the actuator blanking plate and the four
screws.
Installing the Type 3622 Electro-Pneu­
matic Converter
If installing the converter on an existing pneumatic posi­
tioner, refer to the gauge block disassembly procedures
in the Maintenance section. The converter module re­
places the original pneumatic gauge block. Refer to the
the Type 3622 Electro-pneumatic converter assembly
procedure to install the converter. When calibrating the
electro-pneumatic positioner for a 4 to 20 milliampere dc
input range, use the range spring hole that corresponds
to a 3 to 15 psig (0.2 to 1.0 bar) input range (12 psig (0.8
bar) span). See figure 13 for the range spring hole
selection.
Changing Positioner Types
All 3610J and 3620J Series positioners have the same
basic construction. For the Type 3611JP or Type
3621 JP, a parallel flexure (key 179 in figure 11) is added
(not required on Type 585 size 100 actuator). When
changing positioner types, other parts may require
changing, such as the nozzle assembly (key 116 in
figure 23), the feedback lever assembly (key 117 or 170
in figure 27), and the range spring (key 150 in figure 23).
7
361 OJ and 3620J Series
Figure 4. Typical Mounting Details for Type 3611JP and 3621JP Positioners
on 585 Series Actuators
Refer to the parts list for part number identification.
Changing parts may require partial disassembly and
reassembly as described in the Maintenance section.
Figure 5 illustrates the slight difference in nozzle assem­
blies between the single-acting (Type 361 OJ and 3620J)
and double-acting (Type 3610JP, 3620JP, 3611JP and
3621 JP) positioners. See the Changing Positioner
Types procedure in the Maintenance section for addi­
tional information.
Pressure Connections
To complete the installation of a 361 OJ or 3620J Series
positioner requires connecting tubing and fittings be­
tween the positioner and the actuator. The fittings,
tubing, and mounting parts required depend on the type
8
number and optional equipment: such as filter, regula­
tor, and bypass valve. Positioner pressure connection
locations are shown in figure 6. All pressure connec­
tions to the 361 OJ and 3620J Series positioners are 1/4-
inch NPT female. Use 3/8-inch tubing or 1/4-inch pipe
for all tubing connections. Refer to the vent section for
remote vent connections.
W A R N IN G
The positioner is capable of providing full
supply pressure to connected equipment.
To avoid personal injury and equipment
damage, make sure the supply pressure
never exceeds the maximum safe working
pressure of any connected equipment.
 361 OJ and 3620J Series

Figure 5. Nozzle Block Assembly

TYP E 3610J POSITIONER W ITH BYPASS ASSEMBLY

NOTE: INCH
IT> INSTRUMENT; OUTPUT, AND SUPPLY CONNECTIONS ARE 1/4-INCH NPT. (nun)

Figure 6. Typical Mounting Dimensions and Connections

9
361 OJ and 3620J Series

19A1442-C TYP E 3610J AND 3610JP POSITIONER

NOTE: *
|T>INSTRUMENT, OUTPUT, AND SUPPLY CONNECTIONS INCH
ARE 1/4-INCH NPT. (mm)

Figure 6. Typical Mounting Dimensions and Connections (Continued)

10
 361 OJ and 3620J Series

Supply Connection

W A R N IN G

Personal injury or property damage may

occur from an uncontrolled process if the
supply medium is not clean, dry, oil-free, or
non-corrosive gas. Industry instrument air
quality standards describe acceptable dirt,
oil, and moisture content. Due to the vari­
ability in nature of the problems these influ­
ences can have on pneumatic equipment, Figure 7. Flowscanner Diagnostic System Connections
Fisher Controls has no technical basis to for Type 3610J and 3610JP Positioners
recommend the level of filtration equipment
required to prevent performance degrada­
tion of pneumatic equipment. A filter or
filter regulator capable of removing parti­
cles 40 microns in diameter should suffice
for most applications. Use of suitable filtra­
tion equipment and the establishment of a
maintenance cycle to monitor its operation
is recommended.

Supply pressure must be clean, dry air or noncorrosive

gas. Use a Fisher Type 67AFR Filter Regulator, or
equivalent, to filter and regulate supply air. The Type
67AFR filter regulator can be integrally mounted with the
positioner. Use 3/8-inch tubing or 1/4-inch pipe for the
supply line.
The supply pressure should be high enough to permit
setting the regulator 5 psi (0.3 bar) above the upper limit
of the appropriate pressure range, for example: 20 psig
(1.4 bar) for a 3 to 15 psig (0.2 to 1.0 bar) range.
However, do not exceed the maximum allowable supply
pressure of 150 psig (10.3 bar) nor the pressure rating of
any connected equipment. Also, make sure supply pres­
sure to the actuator does not cause the actuator to
exceed the maximum allowable torque or thrust of the
specific valve.
Output Connections
For the Type 3610J or 3620J positioner, the OUTPUT A
connection must be plugged. Connect the OUTPUT B
connection to the actuator diaphragm casing connec­
tion. Figure 6 shows a positioner with a bypass valve.
When the bypass valve is used, connect the OUTPUT
connection on the bypass valve to the diaphragm casing
connection on the actuator. A manifold in the bypass
body adapter internally connects OUTPUT B to the
bypass valve. Use 3/8-inch tubing between the actuator
and the positioner.
For the Type 3610JP or 3620JP positioner, connect the
OUTPUT A connection to the lower actuator cylinder
connection and the OUTPUT B connection to the upper
actuator cylinder connection. Figure 1 shows the posi­
tioner connected to a piston actuator. Use 3/8-inch
tubing between the actuator and positioner.
Figure 8. Flowscanner Diagnostic Connections for
Type 3620J and 3620JP Positioners
For the Type 3611 JP or 3621 JP positioner, connect the
OUTPUT A connection to the lower actuator cylinder
connection and the OUTPUT B connection to the upper
actuator cylinder connection. Figure 2 shows the posi­
tioner connected to a Type 585 actuator. Use 3/8-inch
tubing between the actuator and the positioner.
Instrument Connection
Use 3/8-inch tubing to connect the output from the
control device to the INSTRUMENT connection on a
pneumatic positioner. For the electro-pneumatic posi­
tioner, refer to the electrical connections section.
Diagnostic Connections
To support diagnostic testing of valve/actuator/posi-
tioner/accessory packages, special connectors and
hardware are available. The hardware used includes 1/8-
inch NPT connector bodies and body protectors. If the
diagnostic connectors are ordered for a positioner with
gauges, 1/8-inch stems are also included.
Install the connectors on the 3610J Series positioner
gauge block or bypass block assembly as shown in
figure 7. For the Type 3620J Series positioners, install
the connectors on the Type 3622 housing as shown in
figure 8. Before installing the connectors on the posi­
tioner, apply sealant to the threads. Sealant is provided
with the diagnostic connections and hardware.

11
 361 OJ and 3620J Series

Vent Connection
The 361 OJ and 3620J Series positioner relays exhaust
actuator pressure through the positioner case and into
the Type 1051,1052,1061, and 1069 actuator housings.
These actuator housings provide a 1/4-inch NPT con­
nection and a screen is normally installed in this connec­
tion to prevent blockage from debris or insects.
Restricting this vent area can produce a pressure build­
up in the case and degrade positioner performance.
There also is a 1/4-inch NPT connection on the Type
3622 converter housing where the vent (key 28) is
installed. Type 585 and 585R actuators do not have a 1/
4-inch vent connection.

NOTE:
FOR TROUBLESHOOTING OR MONITORING OPERATION,
W A R N IN G
AN INDICATING DEVICE CAN BE A VOLTMETER ACROSS
A 250 OHM RESISTOR OR A CURRENT METER.
If a flammable gas is used as the supply A5577

pressure medium and the positioner/actua- Figure 9. Typical Field Wiring Diagram
tor is in an enclosed area, personal injury or
property damage could result from fire or
explosion of accumulated gas. The posi-
tioner/actuator assembly does not form a 4-20 mA .

gas-tight seal, and a remote vent line is

recommended. However, a remote vent line
« cannot be relied upon to remove all hazard­
ous gas, and leaks may still occur. Provide
' adequate ventilation and necessary safety
measures. Vent line piping should comply
with local and regional codes and should be
as short as possible with adequate inside
diameter and few bends to reduce case
pressure buildup.
Figure 10. Circuit Schematic
If a remote vent is required, the vent line must be as
short as possible with a minimum number of bends and
For intrinsically-safe installations, refer to
elbows. Vent line piping should have a minimum inside
Fisher loop schematics or to instructions
diameter of 3/4 inches (19 mm) for runs up to 20 feet (6.1
provided by the barrier manufacturer for
m) and a minimum inside diameter of 1 inch (25 mm) for
proper wiring and installation.
runs from 20 to 100 feet (6.1 to 30.5 meters).
Use the 1/2-inch NPT (or M20 thread) conduit connec­
tion for field wiring installation. Refer to figures 9 and 10
Electrical Connection for 3620J Series when connecting field wiring from the control device to
the converter. Connect the positive wire from the control
Positioners device to the converter + terminal and the negative
wire from the control device to the converter - termi­
W A R N IN G nal. Do not overtighten the terminal screws. Maximum
torque is 4 Ibf-in. (0.45 N-m).
For explosion-proof applications, discon­
nect power before removing the Type 3622
converter cap. Calibration
For Class I, Division 1 explosion-proof ap­ The following calibration procedures are for pneumatic
plications, install rigid metal -conduit and a positioner adjustment. For Type 3620J, 3620JP, or
conduit seal no more than 18 inches (457 3621 JP positioners, there are no adjustments within the
mm) from the Type 3622 converter. Person­ converter portion of the positioner. All adjustments are
al injury or property damage may result accomplished within the pneumatic portion of the
from explosion if the seal is not installed. positioner.

12
 361 OJ and 3620J Series

MINOR LOOP
GAIN CROSSOVER
ADJUSTMENT ADJUSTMENT
DIRECT/
REVERSE
PLATE
(KEY

ZERO
ADJUSTMENT
(KEY

BEAM
(KEY
COARSE
SPAN

RANGE
SPRING
(KEY
FINE SPAN
ADJUSTMENT
(KEY

RANGE AND WASHER FLEXURE

SPRING W4901-1" (KEYS 180 AND 181) (KEY 179)
HANGER
(KEY
TYPE 3611JP AND 3621JP POSITIONERS
W 4900-1*

TYPE 3610J, 3610JP, 3620J, AND 3620JP POSITIONERS

Figure 11. Calibration Adjustments

ACTUATOR “ X ” D IM E N S IO N
W A R N IN G TYPE N UM BER In c h e s mm

1 0 5 2 /2 0 7 /8 22
Avoid personal injury or equipment damage 1 0 5 1 , 1 0 5 2 /3 0 , 33 , a n d 4 0 1 5 /1 6 24
from sudden release of process fluid. Be­ 1 0 5 1 , 1 0 5 2 /6 0 1 -3 /8 35
fore calibration: 1 0 5 2 /7 0 1 -1 /2 38
• Isolate the valve from the process, and 1 0 6 1 /3 0 1 3 /1 6 21
• Release process pressure. 1 0 6 1 /4 0 7 /8 22
1 0 6 1 /6 0 1 5 /1 6 24
1 0 6 1 /8 0 1 -1 /1 6 27
Refer to figure 23 for key number locations. Adjust­
1 0 6 1 /1 0 0 1 -1 /8 29
ments are shown in figure 11.
1 0 6 9 /1 0 0 1 -3 /4 44

5 8 5 /2 5 , 5 0 a n d 100 1 -5 /1 6 33

Minor Loop Gain Adjustment r — GAIN ADJUSTMENT

PLATE
Figure 11 shows the minor loop gain adjustment loca­
tion. The minor loop gain adjustment allows tuning of the
positioner transient response to the application without
significantly affecting the static operating performance.

The minor loop gain adjustment is factory set for a

positioner shipped with the actuator. The adjustment
varies the dynamic gain of the positioner to match the
specific size and characteristic of the actuator. Addition­
al adjustment should be made to suit the particular
application requirement. Figure 12. Minor Loop Gain Adjustment

The minor loop gain may require adjustment if the

positioner was not installed on the actuator by the
factory, or if installing the positioner on an actuator
other than the type for which the positioner was original­
ly set up. As shown in figure 12, the adjustment is made
by moving the flexure adjustment (key 156) along the top
flexure. The table in figure 12 and a label inside the
positioner cover (key 41 in figure 26) recommend flexure
adjustment starting positions for various actuator types.
Start with the flexure adjustment set to the recommend­
ed starting distance from the gain adjustment plate, the
X dimension in figure 12. To adjust the minor loop gain,
proceed as follows:

13
361 OJ and 3620J Series
1. Unscrew the four captive cover screws and remove
the cover (key 41, figure 26).
2. Refer to figures 11 and 12 and identify the gain
adjustment plate, the flexure adjustment (key 156), and
the X dimension between the plate and the adjustment.
3. Loosen the flexure adjustment socket head screw
(key 55 in figure 12) and slide the flexure adjustment on
the flexures to increase or decrease the X dimension.
Moving the flexure adjustment in the direction of the
arrow on the top flexure (decreasing the X dimension)
slows the positioner response. Moving the flexure ad­
justment in the opposite direction speeds up the posi­
tioner response.
4. Tighten the flexure adjustment screw and check the
positioner response. Repeat step 3 if readjustment is
required.
5. Replace the cover.
Crossover Adjustment
1. Unscrew the four captive cover screws and remove
the cover (key 41, figure 26).
2. If the positioner does not have pressure gauges:
a. For Type 361 OJ or 3620J, connect a pressure
gauge to OUTPUT A.
b. For Type 361 OJP, 3611JP, 3620JP, and 3621 JP
positioners, connect pressure gauges to OUTPUT A
and OUTPUT B.
3. Apply supply pressure.
4. Apply an input signal (pneumatic or electrical) to the
positioner to position the actuator at approximately mid­
travel. The actuator should not be under load during
crossover adjustment.
5. Perform the crossover adjustment as follows:
Note
Large step changes may cause the supply
pressure gauge reading to momentarily
drop.•
• Type 3610J or 3620J positioner— Using a screw­
driver, turn the crossover adjusting screw (key 13, figure
11) counterclockwise until the OUTPUT A pressure
gauge reads zero pressure; then turn it clockwise until
full supply pressure is obtained. Once supply pressure
is obtained, turn the adjusting screw an additional four,
360-degree turns clockwise. The gauge will read supply
pressure.
14
• Type 361OJP, 3611JP, 3620JP, or 3621 JP posi­
tioner— Using a screwdriver, turn the crossover adjust­
ing screw (key 13) until the sum of the OUTPUT A and
OUTPUT B pressures is 140 to 160 percent of supply
pressure. Clockwise rotation increases the OUTPUT A
and OUTPUT B pressures.
Note
This note and steps a and b below apply
only to the Type 3610JP, 3611JP, 3620JP,
and 3621 JP positioners.
Make sure that neither the OUTPUT A pres­
sure or the OUTPUT B pressure equal the
supply pressure when adjusting the cross­
over screw. If either pressure is equal to
supply, an accurate crossover setting can­
not be achieved. This may occur with the
Type 3611 JP or 3621 JP due to the spring(s)
in the 585 or 585R actuator. If one of the
cylinder pressures equals supply pressure
when adjusting the crossover, do one or
both of the following:
a. Move the actuator to some position other than
mid-travel. This new position must be in the direction
which decreases the difference between OUTPUT A
and OUTPUT B (the direction which reduces compres­
sion of the actuator springs). The actuator or valve must
not be contacting a stop, but must be somewhere
between the up and down stops. With the lower differ­
ential between the OUTPUT A and OUTPUT B pres­
sures, it should be possible to adjust the crossover with
neither the OUTPUT A pressure or OUTPUT B pressure
equal to supply pressure. If not, the supply pressure
must be increased.
b. Increase supply pressure noting the limitations
in the Supply Connection section and repeat the cross­
over adjustment. The actuator or valve must not contact
the stop, but must be somewhere between the up and
down stops. Increase supply pressure sufficiently, so
that a crossover setting can be achieved with neither
Cylinder output pressure equal to supply pressure.
6. Replace the cover.
Zero and Span Adjustments
1. Unscrew the four captive cover screws, and remove
the cover (key 41 in figure 26).
2. Use the table in figure 13 to select the desired
coarse span adjustment (figure 13 is valid for only
standard valve travel/range spring combinations as
shown). Insert one end of the range spring (key 150 in
figure 23) into the hole on the range spring hanger (key
130) as shown in figure 13. Insert the other end of the
range spring into the hole selected on the summing
beam assembly (key 123 in figure 13).
 361 OJ and 3620J Series

FINE SPAN
C O A R S E S P A N A D J U S T M E N T !1) ADJUSTMENT
M in im u m a n d M a x im u m
H o le In p u t S pan*2)
Num ber
P sig B ar m A dc

1 3.2 to 4.6 0.2 to 0.3 4.3 to 6.1

2 4.6 to 7.4 0.3 to 0.5 6.1 to 9.9
3 7.4 to 14.0 0.5 to 1.0 9.9 to 16.0
4 14.0 to 21.0 1.0 to 1.5 —
5 21.0 to 28.8 1.5 to 2.0 —

1. This table is valid only for the following valve travel/range spring combinations: 90
degrees/18A7845X012 (blue), 60 degrees/18A5118X012 (red), 3/4 through 4
inches (19 through 51 mm)/18A7845X012 (blue), and 7/16 inch (11 mm)/
18A7845X012 (blue).
2. Contact the Fisher sales office or sales representative or the factory for travels or
input spans not shown for the range spring/hoie number combination.

Figure 13. Span Adjustment

Note 7. Repeat steps 4, 5, and 6 until the actuator stroke

corresponds to the input signal range.
As an example of hole selection in the
summing beam assembly, a 3 to 15 psig 8. Replace the cover on the positioner.
(0.2 to 1.0 bar) input signal is a span of 12
psi or 0.8 bar (15 psig —3 psig = 12 psi). A
span of 12 psi is between 7.4 and 14, there­
fore, the range spring should be placed in
hole number 3.
Changing Positioner Action
This section explains how to change the positioner
action from direct to reverse or reverse to direct. With
Note direct action, the actuator stem extends as the input
signal to the positioner increases. With reverse action,
Be sure the range spring hanger (key 130) the actuator stem retracts as the input signal to the
passes under the feedback lever assembly positioner increases.
(key 117) as shown in figure 13.

W A R N IN G

3. Apply supply pressure. Avoid personal injury or equipment damage

from sudden release of process fluid and
4. Apply an input signal equal to the low value of the improper valve operation. Before reversing
input signal range; for example, if the input signal range the action:
is 3 to 15 psig (0.2 to 1.0 bar), apply 3 psig (0.2 bar).
• Isolate the valve from the process,

5. Rotate the zero adjustment screw (key 143, figure • Release process pressure,
11) until the actuator is at the starting point position (fully
up or down depending on the action selected) corre­ • Vent the actuator loading pressure, and
sponding to the low input signal. Clockwise rotation of
the zero adjustment screw retracts the actuator stem. • Disconnect positioner supply pressure.

6. Slowly increase the input signal toward the high end

of the input signal range and observe the actuator
stroke. If the actuator stroke is short of its expected
range, increase the travel by rotating the fine span
adjustment screw (key 128 in figure 11) counterclock­
wise with a screwdriver. If the actuator reaches the end
of its desired travel with an input signal less than the
high value of the input signal range, decrease the travel
by rotating the fine span adjustment screw clockwise
with a screwdriver.
Changing to Direct Action
1. Unscrew the four captive cover screws, and remove
the cover (key 41, figure 26).
2. Loosen the reversing plate screw (key 49, figure
23), and adjust the reversing plate (key 23, figure 11) to
expose the letter D and cover the letter R. Tighten the
screw.

15
361 OJ and 3620J Series

Table 3. Split-Ranging Capabilities

3610J SERIES POSITIONERS*1)
3 to 15 Psig or 6 to 30 Psig or
0.2 to 1.0 Bar 0.4 to 2.0 Bar
Split Input Signal Input Signal
Psig Bar Psig Bar
3 to 9 0.2 to 0.6 6 to 18 0.4 to 1.2
Two-way
9 to 15 0.6 to 1.0 18 to 30 1.2 to 2.0
3 to 7 0.2 to 0.5 6 to 14 0.4 to 0.9
Three-way 7 to 11 0.5 to 0.7 14 to 22 0.9 to 1.5
11 to 15 0.7 to 1.0 22 to 30 1.5 to 2.0
3620J SERIES POSITIONERS*1)
Split 4 to 20 Milliampere dc Input Signal
4 to 12
Two-way ■
12 to 20
4 to 9.3
Three-way 9.3 to 14.7
14.7 to 20
1. This table is only valid for the following standard valve rotation or valve travel/range X012 (blue).
spring combinations: 90° rotation/18A7845 X012 (blue), 60° rotation/18A5118 X012 2. Contact the Fisher sales office or sales representative or the factory for input signal
(blue), or 3/4-through 4-inch travel/18A7645 X012 (blue), 7/16-inch travel/18A7845 ranges not listed.

Note or less, a change to reverse action also requires that the

counter spring (key 125 in figure 23) be removed and
Direct acting Type 361 OJ and 3620J Series discarded. To remove the counter spring, remove the
positioners require use of the counter machine screw (key 127 in figure 23), the spring seat
spring (key 125, figure 23). Reverse acting (key 126 in figure 23), and the counter spring (key 125 in
Type 3610J and 3620J Series positioners figure 23). Then replace the spring seat and machine
set up for 60 degree valve rotation, or re­ screw.
verse acting Type 3611 JP and 3621 JP posi­
tioners set up for 7/16-inch (11 mm) 4. If using characterized cam B or C, refer to the
actuator travel do not require use of the Changing Cams procedures.
counter spring. Refer to the parts list for the 5. Perform the zero and span adjustment procedure.
counter spring part number to be ordered.
6. Replace the cover.
3. To install the counter spring (key 125 in figure 23),
remove the machine screw (key 127 in figure 23), and
the spring seat (key 126 in figure 23). Then install the Split-Range Operation
counter spring and replace the spring seat and machine
screw. Note

4. If using characterized cam B or C, refer to the Split-range operation, as described in this

Changing Cams procedures. section, is accomplished with one range
spring for standard valve travel/range
5. Perform the zero and span adjustment procedure. spring combinations.

6. Replace the cover.
Changing to Reverse Action
1. Unscrew the four captive cover screws, and remove
the cover (key 41 in figure 26).
2. Loosen the reversing plate screw (key 49 in figure
23), and adjust the reversing plate (key 23 in figure 11) to
expose the letter R and cover the letter D.
3. For Type 361 OJ and 3620J positioners set up for 60
degree valve rotation, or for Type 3611JP and 3621 JP
positioners set up for 7/16-inch (11 mm) actuator travel
Split-range operation is possible with the 361 OJ and
3620J Series positioners. With split-range operation,
the input signal from a single control device is split
between two or three control valves. The positioners will
fully stroke the actuator with an input signal span of 3.2
psig (0.2 bar) minimum to 28.8 psig (2.0 bar). The zero
adjustment of the positioner is continuously adjustable
between 1 and 22 psig (0.07 to 1.5 bar).
Table 3 shows some typical split ranges for the position­
ers, and the table in figure 13 shows the correct range
spring mounting hole for the desired coarse span ad­
justment. Contact the Fisher sales office or sales repre­
sentative, or the factory for input signal ranges not
shown in table 3.

16
 361 OJ and 3620J Series

Note

As an example of hole selection in the

summing beam assembly, a 3 to 9 psig (0.2
to 0.6 bar) input is a span of 6 psi or 0.4 bar
(9 psig - 3 psig = 6 psi). A span of 6 psi is
between 4.6 and 7.4, therefore, the range
spring should be placed in hole number 2.

Characterized Cams for Type 361 OJ,

361 OJP, 3620J, and 3620JP A2264-2 PERCENT OF RATED INPUT SIGNAL

The Type 361 OJ, 361 OJP, 3620J, and 3620JP position­ Figure 14. Input Signal Versus Valve Rotation
ers are available with any one of three cams: a linear
cam (cam A) and two characterized cams (cams B and
C).

When the linear cam is used, there is a linear relation­

ship between an incremental input signal change and
the resultant valve rotation. The flow characteristic is
that of the control valve.

When either of the characterized cams are used, the

relationship between an incremental input signal change
and the valve rotation is changed. Curves illustrating the
relationship between the input signal and the valve
rotation, and between the input signal and the flow
characteristic of an equal percentage valve, are shown
in figures 14, 15, and 16.

REVERSE 100 90 80 70 60 SO 40 30 20 10 0
33A4959-A PERCENT OF RATED INPUT SIGNAL
A1581-3

Principle of Operation
Figure 15. Flow Characteristics for the Various Cams When
Used With an Equal Percentage Characteristic,
Push-Down-to-Open Valve
The 361 OJ Series positioners accept a pneumatic input
signal and the 3620J Series positioners accept a dc
current input signal from a control device. The 3620J
Series electro-pneumatic positioners use a Type 3622
converter to provide a pneumatic input to the pneumatic PUSH DOWN TO CLOSE
portion (361 OJ Series) of the positioner. The 361 OJ
Series positioners are force-balanced instruments that
provide a control valve position proportional to the
pneumatic input signal. The following describes the
principle of operation for the Type 361 OJP and 3620JP
positioners. The principle of operation for the Type
361 OJ and 3620J positioners is similar except relay A is
not used. The principle of operation for the Type 3611 JP
and 3621 JP positioners is similar except the feedback
linkage does not use a cam.

Refer to the schematic diagrams shown below:

• Type 361 OJ— figure 17
• Type 361 OJP— figure 18 33A4960-A
A1582-3 PERCENT OF RATED INPUT SIGNAL
• Type 3611JP— figure 19
• Type 3620J— figure 20 Figure 16. Flow Characteristics for the Various Cams When
• Type 3620JP— figure 21 Used With an Equal Percentage Characteristic,
• Type 3621 JP— figure 22 Push-Down-to-Close Valve

17
361 OJ and 3620J Series
Figure 17. Schematic of the Type 361 OJ Positioner
For direct action, input signal pressure from a control
device is channeled to cavity A in the input module. An
increase in input signal pressure results in a downward
force on the summing beam, pivoting the summing
beam counterclockwise. This moves the flapper slightly
toward the nozzle, increasing the nozzle pressure. As
nozzle pressure increases, the relay beam pivots clock­
wise, causing relay B to increase upper cylinder pres­
sure and Relay A to exhaust lower cylinder pressure of
the actuator to atmosphere.
As a result, the actuator rod extends and the actuator
rotary shaft rotates clockwise. This causes the feed­
back lever to pivot clockwise and the force applied to the
summing beam by the range spring increases. This
force, which opposes the downward force on the sum­
ming beam caused by the increasing input signal pres­
sure, continues to increase until the summing beam
torques are in equilibrium. At this point, the valve shaft is
in the correct position for the specific input signal
applied.
For reverse action, input signal pressure is channeled to
both cavities A and B. An increase in input signal pres­
18
sure results in an upward force on the summing beam,
pivoting the summing beam clockwise and causing relay
B to exhaust upper actuator cylinder pressure to atmo­
sphere and relay A to increase lower actuator cylinder
pressure. As a result, the actuator rod retracts and the
actuator rotary shaft rotates counterclockwise. This
causes the feedback arm to pivot counterclockwise
reducing the force applied to the summing beam by the
range spring.
As the valve shaft rotates counterclockwise, the range
spring force on the summing beam continues to reduce
until the summing beam torques are in equilibrium. At
this point, the valve shaft is in the correct position for the
specific input signal applied.
The 3620J Series positioner is a combination of a 361 OJ
Series positioner with a Type 3622 electro-pneumatic
converter. The electro-pneumatic converter provides a
3 to 15 psig (0.2 to 1.0 bar) output pressure proportional
to the 4 to 20 milliampere dc input signal. The 3 to 15
psig (0.2 to 1.0 bar) output pressure becomes the input
signal pressure to the 3610J Series pneumatic
positioner.
 361 OJ and 3620J Series

SUPPLY PRESSURE

lg°g°i NOZZLE PRESSURE

B3E3 INPUT SIGNAL

0 2 3 OUTPUT SIGNAL

OUTPUT SIGNAL

Figure 18. Schematic of the Type 361 OJP Positioner

19
361 OJ and 3620J Series

MINOR LOOP
GAIN ADJ

Figure 19. Schematic of the Type 3611JP Positioner

20
 361 OJ and 3620J Series

CROSS-OVER ADJ

SUPPLY PRESSURE

ISgSIl NOZZLE PRESSURE

BtttH INPUT SIGNAL

OUTPUT SIGNAL

END VIEW OF
ROTARY SHAFT-

Figure 20. Schematic of the Type 3620J Positioner

21
361 OJ and 3620J Series

E g g SUPPLY PRESSURE

IS°g°l NOZZLE PRESSURE

§SS INPUT SIGNAL

E 2 3 OUTPUT SIGNAL

I I OUTPUT SIGNAL

Figure 21. Schematic of the Type 3620JP Positioner


Figure 22. Schematic of the Type 3621JP Positioner
Maintenance
Positioner parts are subject to normal wear and must be
inspected and replaced as necessary. The frequency of
inspection and replacement depends upon the severity
of service conditions. The following procedure de­
scribes disassembly and reassembly of the positioner.
When inspection or repairs are required, disassemble
only those parts necessary to accomplish the task.
When reassembly is complete, make adjustments as
described in the Calibration section.
Due to the care Fisher Controls takes in meeting all
manufacturing requirements (heat treating, dimensional
tolerances, etc.), use only replacement parts manufac­
tured by Fisher.
W A R N IN G
Avoid personal injury or equipment damage
from sudden release of process fluid. Be­
fore disassembly:
• Isolate the valve from the process,
e Release process pressure, and
e Vent the actuator loading pressure.
361 OJ and 3620J Series
Positioner Disassembly
Removing the Positioner from the
Actuator
Refer to figure 26 or 27 for key number locations, unless
otherwise indicated, while removing the positioner from
the actuator.
1. Release all pressure to the positioner. Disconnect
the supply, instrument, and output tubing.
2. Unscrew the four captive cover screws and remove
the cover (key 41).
3. For the 3611 JP or the 3621 JP mounted on a Type
585 or 585R, size 100 with a 2- through 4-inch (51-
through 102-mm) travel only, disconnect the extension
spring (key 185) from the feedback lever.
4. Unscrew the four socket head screws (key 54), and
remove the positioner from the actuator or positioner
adaptor (key 113,—the positioner adaptor is used only
on selected actuator types and sizes).
23
361 OJ and 3620J Series
Disassembling the Bypass Valve
Refer to figure 24 for key number locations while disas­
sembling the bypass valve.
1. Remove all pressure from the positioner. Discon­
nect the supply, instrument, and output tubing.
2. Remove the four socket head screws (key 169), and
lift the bypass body (key 161) and bypass body gasket
(key 163) from the bypass body adaptor (key 162).
Inspect the gasket and replace if necessary.
3. Remove the wire tie (key 166) and the retaining ring
(key 165).
4. With a gentle pulling and turning motion, slide the
bypass lever assembly (key 160) from the bypass body
(key 161). Inspect the O-rings (keys 159, 167, and 168)
for nicks or wear and replace if necessary. Apply lubri­
cant (key 153) to the O-rings before replacement.
5. Remove the two socket head screws (key 54) and
remove the bypass body adaptor (key 162) and adaptor
gasket (key 164) from the gauge block (key 158).
6. Inspect the adaptor gasket (key 164) and replace if
necessary.
Disassembling the Gauge Block
Refer to figure 24 for key number locations, unless
otherwise indicated, while disassembling the gauge
block.
1. If the positioner has a bypass valve, perform steps
1, 5, and 6 of the disassembling the bypass valve
procedures.
2. Release all pressure from the positioner. Discon­
nect the supply, instrument, and output tubing.
3. Remove all gauges [key 79 (not shown), 80, and 81 ],
pipe plugs (key 72 and 78), or tire valves (key 73, not
shown) from the gauge block (key 158).
4. Remove the two socket head screws (key 187) and
remove the gauge block from the positioner case (key
11&A, figure 23). Inspect the four O-rings (key 159) and
replace if necessary. Apply lubricant (key 153) to the
O-rings before replacement.
Disassembling the Type 3622 Electro­
Pneumatic Converter
Refer to figure 28 for key number locations while disas­
sembling the converter.
24
Note
To check the operation of the electro-pneu­
matic converter, remove the pipe plug (key
37 in figure 28), and connect a pressure
gauge. Provide a 20 psig (1.4 bar) supply
pressure to the positioner. For a 4-milliam-
pere dc input signal, the pressure gauge
should read 2.5 to 3.5 psig (0.17 to 0.23 bar).
For a 20-milliampere dc input signal, the
pressure gauge should read 14.0 to 15.5
psig (0.96 to 1.07 bar).
1. Turn off electrical power to the converter. Release
all supply pressure from the positioner.
2. Remove the cap (key 20), and disconnect the field
wiring from the terminal block.
a. If a grounding wire is used inside the housing
compartment, disconnect the wire from the interior
housing ground screw (key 31).
b. If an exterior grounding wire is used, disconnect
the grounding wire from the external ground screw (key
31).
3. To remove the converter module, remove the two
screws (key 30) and pull the module out of the housing.
Inspect the O-ring (key 26) and replace it, if necessary.
a. If removing the Type 3622 electro-pneumatic
converter assembly from the pneumatic positioner, con­
tinue with steps 4 through 6. Or,
b. If replacing the converter module only, obtain a
replacement converter module and refer to the assem­
bling the Type 3622 electro-pneumatic converter proce­
dure. If replacing the converter module, calibrate the
pneumatic portion of the positioner by performing the
calibration procedures after module replacement. There
is no converter module calibration.
4. Disconnect the supply tubing, output tubing, and
conduit from the converter.
5. If the optional Type 67AFR filter regulator is used,
remove the two screws (key 89 in figure 25), and remove
the filter regulator from the converter assembly. Inspect
the O-ring (key 190 in figure 25) and replace if neces­
sary. Apply lubricant (key 17) to the O-ring before
replacement.
6. Remove the two socket head screws (key 35) and
remove the converter from the positioner case (key
115A in figure 23). Inspect the four O-rings (key 36) and
replace them if necessary. Apply lubricant (key 17) to the
O-rings before replacement.

Disassembling the Feedback Lever
Assembly
Refer to figure 26 for key number locations, unless
otherwise indicated, while disassembling the feedback
lever assembly.
For Type 1051, 1052, 1061, 585, and 585R actuators:
1. Remove the range spring (key 150 in figure 23).
2. Turn the positioner over and unscrew the four ma­
chine screws (key 43) and remove the feedback lever
assembly (key 117) from the positioner.
3. Remove the range spring hanger (key 130 in figure
23) and the span adjustment screw (key 128 in figure 23)
from the feedback lever assembly (key 117) by removing
the retaining ring (key 129 in figure 23) and threading the
span adjustment screw out of the spring hanger.
4. Remove the E-ring (key 61) and separate the pillow
blocks (key 35), the spring (key 70), the spacer (key 149)
and the mandrel (key 148) from the feedback lever
assembly. For the Type 3610J, 361 OJP, 3620J, and
3620JP positioners only, unscrew the hex nut (key 60)
and remove the follower post (key 38) and roller (key 39).
5. Press out the two flange bearings (key 37) from the
pillow blocks (key 35). Inspect them for wear and re­
place if necessary.
Disassembling the Reversing Plate and
Gasket
1. Remove the reversing plate screw (key 49 in figure
23), the reversing plate (key 23 in figure 23), and the
gasket (key 24 in figure 23). Inspect the gasket, and
replace if necessary.
Note
When installing the gasket (key 24 in figure
23), ensure it is not reversed. Install the
gasket so the slot in the case assembly
(key 115A in figure 23) aligns with one of
the three holes in the gasket (key 24 in
figure 23).
Disassembling the Relay
During the following relay disassembly procedures, re­
fer to figure 23 for key number locations.
361 OJ and 3620J Series
1. Loosen the socket head screw (key 55) and remove
the flexure adjustment (key 156) by carefully sliding it off
the end of the two flexures (on earlier positioners, a
stick-on label will have to be removed from the top
flexure prior to removing the flexure adjustment). For
Type 3611JP or 3621 JP positioners only, remove the
two socket head screws and lockwashers (keys 180 and
181) and the parallel flexure (key 179) (not used on
positioners for Type 585 size 100 actuators).
2. Unscrew the 12 machine screws (key 47) and lift the
relay manifold (key 9) and relay beam assembly (key
122) from the positioner.
3. Remove the relay nozzle diaphragm assembly (key
8) and relay supply diaphragm assembly (key 7). Inspect
them for wear and replace if necessary.
4. Unscrew the two screws (key 50) that hold the
nozzle relay head (key 14) and the supply relay head
(key 15), and separate them from the relay beam assem­
bly (key 122).
5. Loosen the two set screws (key 57) in the relay
manifold (key 9) and remove the pivot pin (key 10) and
relay beam assembly (key 122) from the relay manifold.
6. Turn the positioner over and remove the two body
plugs (key 115E) and body plug gaskets (key 115F). The
valve plug springs (key 115H), valve plug shrouds (key
115K), and valve plugs (key 115G) are now exposed and
can also be removed. Inspect the valve plugs for wear
and replace if necessary. Inspect the body plug gaskets
(key 115F) and replace if necessary.
7. Unscrew the 10 machine screws (key 115J), and
remove the pressure plate (key 115C) and gasket (key
115D). Inspect the pressure plate gasket and replace if
necessary.
Disassembling the Summing Beam
Assembly
During the following summing beam disassembly proce­
dures, refer to figure 23 for key number locations.
1. Loosen the socket head screw (key 55) and remove
the flexure adjustment (key 156) by carefully sliding it off
the end of the two flexures (on earlier positioners, a
stick-on label will have to be removed from the top
flexure prior to removing the flexure adjustment). For
Type 3611JP or 3621 JP positioners only, remove the
two socket head screws and lockwashers (keys 180 and
181) and the parallel flexure (key 179) (not used on
positioners for Type 585 size 100 actuators).

361 OJ and 3620J Series
Note
Early Type 3611JP positioners do not have
the parallel flexure described in step 1. The
parallel flexure should be added if absent.
This may require a new summing beam
assembly (key 123) and relay beam assem­
bly (key 122) if these parts are not drilled
and tapped to accept the parallel flexure.
See figure 23 for the location of the parallel
flexure mounting screws.
2. Remove the range spring (key 150).
3. Relieve the tension on the zero spring (key 141) by
rotating the zero adjustment screw (key 143) fully clock­
wise. Remove the two screws (key 139) which retain the
zero spring bracket (key 144). Remove the zero spring
bracket, the zero adjustment screw, and the spring seat
(key 142). Remove the spring seat from the zero adjust­
ment screw by rotating the screw counterclockwise.
4. Unscrew the counter spring screw (key 127), and
remove the counter spring seat (key 126) and the
counter spring (key 125).
5. Remove the machine screw (key 140) while holding
the hex diaphragm connector (key 135) with an open
end wrench to prevent rotation (rotation of the dia­
phragm connector will damage the input diaphragms).
6. Remove the two summing beam mounting screws
(key 124). Lift the summing beam assembly (key 123)
from the positioner case.
7. Remove the flapper (key 18) from the summing
beam assembly by removing the flapper screw and
washer (keys 51 and 176).
Disassembling the Nozzle Assembly
During the following nozzle assembly disassembly pro­
cedures, refer to figure 23 for key number locations.
1. Perform steps 1 through 5 of the Disassembling the
Summing Beam Assembly procedure.
2. Unscrew the two captive machine screws (key 45) in
the nozzle block (key 146) and remove the nozzle block.
Inspect the two O-rings (key 64) and replace them if
necessary. Apply lubricant (key 153) to the O-rings
before replacement.
CAUTION
To avoid damage to the nozzle during the
next step, be careful not to apply force to
the exposed nozzle primary orifice. Excess
force may loosen or crack the orifice.
26
■V
FISHER
Vi
3. Remove the nozzle (key 116) from the nozzle block
(key 146) by carefully pushing on the nozzle tip with the
thumb or other soft object until the base of the nozzle
begins to protrude from the back of the nozzle block.
Grasp the base of the nozzle and pull the nozzle from
the nozzle block. Inspect the O-rings (keys 120 and 121)
and replace them if necessary. Apply lubricant (key 153)
to the O-rings before replacement.
4. Remove the core and wire assembly (key 147) from
the nozzle block (key 146) by unscrewing the core from
the nozzle block.
Disassembling the Input Module
During the following input module disassembly proce­
dures, refer to figure 23 for key number locations.
1. Perform steps 1 through 5 of the disassembling the
summing beam assembly procedure.
2. Unscrew the remaining two input module machine
screws (key 177) and remove the input diaphragm
flange (key 138).
3. Remove the following as an assembly: the lower
and upper diaphragms (keys 118 and 119), the lower
and upper diaphragm plates (keys 132 and 134), the
diaphragm spacer (key 133), the diaphragm connector
(key 135), the diaphragm spacer (key 137), and the
sealing screw (key 136). To disassemble this sub-as­
sembly, unscrew the sealing screw (key 136) from the
diaphragm connector (key 135) and separate the parts.
Inspect the diaphragms and sealing screw O-ring and
replace if necessary [earlier positioners use a standard
machine screw instead of a sealing screw; replace the
old standard screw with a sealing screw (key 136).]
Positioner Reassembly
Assembling the Input Module
Refer to figure 23 for key number locations while assem­
bling the input module.
1. Orient the input module sub-assembly parts as
shown in figure 23 and tighten the sealing screw (key
136) into the diaphragm connector (key 135).
2. Apply a light lubricant silicone spray to the sealing
ribs on the lower and upper input diaphragms (keys 118
and 119). See figure 23 for location. The lubricant is
important to prevent damage to the scaling ribs during
assembly and subsequent leakage.
3. Place the input module sub-assembly into the posi­
tioner case (key 115A) and align the four lower dia­
phragm (key 118) screw holes with the four screw holes

in the positioner case. Ensure that the hole in the lobe of
the lower diaphragm is aligned with the instrument air
passageway in the positioner case.
4. Install the two input module machine screws (key
177) in the two holes not used to mount the zero spring
bracket (key 144) and tighten. These are the two shorter
screws of the four which mount the input module.
5. If the nozzle assembly was previously removed,
perform the assembling the nozzle assembly
procedure.
6. Perform the assembling the summing beam assem­
bly procedure and then, continue with steps 7 through 9
below.
7. If the reversing plate (key 23) was previously re­
moved, install the gasket (key 24) and reversing plate,
and reversing plate screw (key 49). When installing the
gasket, make sure one of the three gasket holes is over
the exhaust slot in the positioner case (key 115A). Adjust
the reversing plate so the letter R is showing and the
letter D is entirely covered. Tighten the screw (key 49).
8. Connect an air line to the positioner instrument
connection and apply 35 psig (2.4 bar). Check the input
module sealing surfaces for air leaks using a soap
solution or other suitable solution compatible with nitrile
rubber.
9. If reverse action is required, leave the reversing
plate (key 23) as it is. If direct action is required, loosen
the machine screw (key 49) and rotate the reversing
plate so the letter D is showing and the letter R is entirely
covered. Tighten the screw (key 49).
Assembling the Nozzle Assembly
Refer to figure 23 for key number locations while assem­
bling the nozzle assembly.
1. Thread the core and wire assembly (key 147) back
into the nozzle block (key 146) if previously removed.
2. Apply a very light coat of lubricant (key 153) to the
nozzle O-rings (keys 120 and 121). The lubricant must
be applied very sparingly to avoid accidental plugging of
the nozzle primary orifice.
3. Assemble the nozzle (key 116) into the nozzle block
(key 146) with a gentle pushing and twisting motion to
avoid nicking the O-rings. To fully seat the nozzle, align
the flat at the nozzle base with the flat cast into the
underside of the nozzle block.
4. Apply a very sparing amount of lubricant (key 153)
to the two O-rings (key 64) and install them into the
positioner case (key 115A).
361 OJ and 3620J Series
5. Place the nozzle block (key 146) on the positioner
case and tighten the two captive nozzle block mounting
screws (key 45).
6. Perform the assembling the summing beam assem­
bly procedure.
Assembling the Summing Beam Assembly
Refer to figure 23 for key number locations while assem­
bling the summing beam.
1. Install the flapper (key 18) into the summing beam
assembly (key 123) with the flapper screw and washer
(keys 51 and 176) so that the letter A is visible as shown
figure 23.
2. If the nozzle (key 116) has been removed, perform
the assembling the nozzle assembly procedure.
3. If the relay beam assembly (key 122) is removed,
perform steps 1 through 7 of the assembling the relay
beam assembly procedure.
4. Place the summing beam assembly (key 123) in the
positioner case (key 115A) and ensure the summing
beam assembly flexure is under the relay beam (key
122) flexure.
5. Loosely install the two summing beam mounting
screws (key 124).
6. The summing beam assembly (key 123) must simul­
taneously align with the relay beam assembly (key 122)
and diaphragm connector (key 135) as follows:
a. Depress the summing beam assembly (key 123)
until the flapper lightly touches the nozzle, then slide the
summing beam assembly such that the hole for the
machine screw (key 140) is centered over the tapped
hole in the diaphragm connector (key 135).
b. While keeping the above hole centered, slide the
summing beam assembly such that the summing beam
assembly flexure is aligned with the relay beam assem­
bly flexure along its entire length.
c. While maintaining the above orientations, tighten
the two mounting screws (key 124).
d. After tightening the mounting screws check the
alignments described in steps a and b and repeat if
necessary.
For optimum positioner performance, be sure the sum­
ming beam assembly is aligned as described.
7. While holding the hex diaphragm connector (key
135) with an open end wrench to prevent rotation (rota-
27

361 OJ and 3620J Series
tion of the diaphragm connector may damage the input
diaphragms or twist them and reduce positioner perfor­
mance), install the machine screw (key 140).
8. Install the counter spring (key 125), counter spring
seat (key 126), and counter spring screw (127) and
tighten. Ensure that the counter spring seat does not rub
against the summing beam assembly (key 123) as the
summing beam assembly pivots.
9. If the zero adjustment spring seat (key 142), zero
spring bracket (key 144), and zero adjustment screw
(key 143) were previously disassembled, place a light
amount of lubricant (key 153) on the zero adjustment
screw threads for smooth zero adjustment, insert the
zero adjustment screw through the zero spring bracket,
and thread the zero adjustment spring seat onto the
zero adjustment screw.
10. Place the zero spring (key 141) and zero spring
bracket (key 144) on the positioner input module and
ensure that the zero spring ends are centered on the
seats. Ensure that the tab on the zero adjustment spring
seat (key 142) is inserted in the anti-rotator slot in the
zero spring bracket. Insert the two machine screws (key
139) through the zero spring bracket, carefully com­
press the zero spring by pushing down on the zero
spring bracket, and tighten the screws in the positioner
case.
11. If the feedback lever assembly (key 117 or 170 in
figure 26) was previously removed, perform the assem­
bling the feedback lever assembly procedure; then,
continue with steps 13 through 15 below.
12. Install the range spring (key 150). Refer to figure
13 for the correct summing beam hole number.
13. Assemble the flexure adjustment (key 156) onto
the two minor loop feedback flexures. Slide the flexure
adjustment along the entire length of the flexures, mak­
ing sure it does not rub against the relay at any point. If
contact is made with the relay or diaphragm edges at
any point, remove the flexure adjustment, loosen the
twelve machine screws (key 47), slide the relay manifold
slightly to provide clearance and tighten the machine
screws (key 47). Perform steps 2 through 5 of the
disassembling the summing beam assembly procedure
and loosen the two machine screws (key 124). Perform
steps 4 through 10 of the assembling the summing
beam assembly procedure. Assemble the flexure ad­
justment on the minor loop feedback flexures and check
for clearance.
14. Slide the flexure adjustment (key 156) to the prop­
er X dimension per figure 12 and tighten the socket head
screw (key 55). For Type 3611JP and 3621 JP position­
ers only, install the parallel flexure (key 179) with the two
socket head screws and lockwashers (keys 180 and
181). The parallel flexure is not used on positioners with
Type 585 size 100 actuators.
28
FISHER®
Assembling the Relay
Refer to figure 23 for key number locations while assem­
bling the relay.
1. Replace the pressure plate gasket (key 115D) and
pressure plate (key 115C) with the ten machine screws
(key 115J). Visually align the two large holes in the
pressure plate with the two stainless steel pressed-in
valve seats in the positioner case (key 115A) and tighten
the machine screws.
2. Install the valve plugs (key 115G), valve plug springs
(key 115H), and valve plug shrouds (key 115K) in the two
relay holes. Place the body plug gaskets (key 115F) on
the body plugs (key 115E) and tighten in the positioner
case.
3. If the pivot pin (key 10) was removed from the relay
manifold (key 9), apply a light coat of lubricant (key 153)
to the pin and slide it into the relay manifold and relay
beam assembly (key 122). Position the pivot pin so it is
flush with the left side of the relay manifold as viewed in
figure 11, and tighten the two set screws (key 57). The
pivot pin must not rub against the flexure adjustment
(key 156).
4. Assemble the supply relay head (key 15) and nozzle
relay head (key 14) onto the relay beam assembly (key
122) with the two machine screws (key 50), but do not
tighten the screws. The nozzle relay head is the larger in
diameter of the two and is installed in the large manifold
hole. Insert the nozzle relay head holder from the repair
kit through the larger manifold hole and into the nozzle
relay head (key 14). Insert the supply relay head holder
from the repair kit through the smaller manifold hole and
into the supply relay head (key 15). Tighten the two
machine screws (key 50). Remove the nozzle relay head
holder and supply relay head holder from the manifold.
The nozzle relay head (key 14) and supply relay head
(key 15) are now correctly aligned in the center of the
manifold holes.
5. Dimple the relay nozzle diaphragm (key 8) and relay
supply diaphragm (key 7). Place both diaphragms in the
positioner case (key 115A) with the fabric side of the
diaphragms showing and align the diaphragm holes with
the mounting holes in the positioner case.
6. Carefully place the relay manifold/beam assembly
over the relay diaphragms. Ensure the relay diaphragms
are lying flat and the diaphragm edges are not doubled
over. Ensure that the diaphragm convolutions are cen­
tered in the relay manifold holes and are not pinched.
The relay beam assembly (key 122) flexure must be on
top of the summing beam assembly (key 123) flexure as
shown figure 12).
7. Install the twelve relay manifold machine screws
(key 47), but do not tighten them.
r
8. If the summing beam assembly (key 123) is re­
moved, perform the assembling the summing beam
assembly procedure, steps 1 through 12. Then, contin­
ue with steps 9 through 11 below.
9. Slide the relay manifold (key 9) slightly if necessary,
to visually align the relay beam assembly (key 122)
flexure with the summing beam assembly (key 123)
flexure along their entire length. Tighten the twelve
machine screws (key 47).
10. Assemble the flexure adjustment (key 156) onto
the two minor loop feedback flexures. Slide the flexure
adjustment along the entire length of the flexures mak­
ing sure it does not rub against the relay at any point. If
contact is made with the relay or diaphragm edges at
any point, remove the flexure adjustment, loosen the
twelve machine screws (key 47), slide the relay manifold
slightly to provide clearance and tighten the machine
screws (key 47). Perform steps 2 through 5 of the
disassembling the summing beam assembly procedure
and loosen the two machine screws (key 124). Perform
steps 4 through 10 of the assembling the summing
beam assembly procedure. Assemble the flexure ad­
justment on the minor loop feedback flexures and check
for clearance.1
11. Check the supply relay head (key 15) and nozzle
relay head (key 14) to ensure they are centered in the
diaphragms. If not, loosen the connecting screws (key
50) and center.
12. Slide the flexure adjustment (key 156) to the prop­
er X dimension per figure 12 and tighten the socket head
screw (key 55). For Type 3611JP and 3621 JP position­
ers only, install the parallel flexure (key 179) with the two
socket head screws and lockwashers (keys 180 and
181). The parallel flexure is not used on positioners for
Type 585 size 100 actuators.
Assembling the Reversing Plate and
Gasket
Refer to figure 23 for key number locations while assem-
| bling the reversing plate and gasket.
1. Install the reversing plate gasket (key 24) and re­
versing plate (key 23) with the reversing plate screw (key
j1 49). When installing the gasket, make sure one of the
three gasket holes is over the exhaust slot in the posi­
tioner case (key 115A). If direct action is required, adjust
the reversing plate so the letter D is showing and the
letter R is entirely covered. If reverse action is required,
' adjust the reversing plate so the letter R is showing and
the letter D is entirely covered. Tighten the screw (key
49).
361 OJ and 3620J Series
Assembling the Gauge Block
Refer to figure 24 for key number locations, unless
otherwise indicated, while assembling the gauge block.
1. Apply lubricant (key 153) to the four O-rings (key
159) and install in the positioner case (key 115A in figure
23). Attach the gauge block (key 158) with the two
socket head screws (key 187). During assembly of the
gauge block, ensure that the O-rings stay in place to
avoid leaks.
2. Assemble gauges [keys 79 (not shown), 80, and 81 ],
pipe plugs (keys 72 and 78), or tire valves (key 73, not
shown) as applicable to the gauge block (key 158). Apply
sealant (key 154) to the threads of the gauges, pipe
plugs, or tire valves.
3. If other positioner components are removed, refer
to the appropriate reassembly procedures and assem­
ble the positioner completely.
4. Plug the relay A and relay B output connections and
apply 30 psig (2.0 bar) to the instrument connection and
35 psig (2.4 bar) minimum supply pressure to the supply
connection.
5. Using soap solution or some other solution compat­
ible with nitrile rubber, check the gauge block O-rings
and any other O-rings, gaskets, or diaphragms which
were disassembled for leaks.
Assembling the Type 3622 Electro-Pneu­
matic Converter
Refer to figure 28 for key number locations, unless
otherwise indicated, while assembling the converter.
1. If the Type 3622 electro-pneumatic converter was
removed from the pneumatic positioner, apply lubricant
(key 17) to the four O-rings (key 36), and install the O-
rings in the case (key 115A in figure 23). Ensure that the
O-rings remain in place. Attach the converter assembly
to the case with the two socket head screws (key 35)
and tighten the socket head screws.
2. Install gauges (key 43), pipe plugs (key 37), or tire
valves (key 41, not shown) as applicable to the convert­
er. Apply sealant (key 39) to the threads of the gauges,
pipe plugs or tire valves.
3. If the converter module was removed from the
pneumatic positioner, apply lubricant (key 17) to the
O-ring (key 26) and insert the converter module into the
housing.
4. Replace the two screws (key 30) and tighten them.
29

361 OJ and 3620J Series
5. If other positioner components are removed, refer
to the appropriate reassembly procedures and assem­
ble the positioner completely.
6. Connect the supply tubing, output tubing, and con­
duit to the converter.
7. Connect the wiring to the terminal block by using
installation procedures.
a. If an internal grounding wire is used inside the
housing compartment, connect the wire to the housing
ground screw (key 31) and replace the cap (key 20).
b. If an exterior grounding wire is used, connect the
grounding wire to the exterior ground screw (key 31).
8. Plug relay A and relay B output connections and
apply 35 psig (2.4 bar) to the supply pressure connec­
tion. Apply a 20 milliampere dc input signal to the
converter.
9. Check for leaks using a soap solution or other
solution compatible with nitrile; check the O-rings (key
36) and any other components which were disassem­
bled or disconnected.
10. If the converter module was replaced, calibrate the
pneumatic portion of the positioner by performing the
procedures in the Calibration section. There is no con­
verter module calibration.
Assembling the Feedback Lever Assembly
Refer to figure 26 for key number locations while assem­
bling the feedback lever assembly.
For Type 1051, 1052, 1061, 585, and 585R actuators:
1. Press the two flange bearings (key 37) into the
pillow blocks (key 35) if removed.
2. Assemble the mandrel (key 148), the spacer (key
149), the spring (key 70), and the pillow blocks (key 35)
onto the feedback lever assembly (key 117) and install
the E-ring (key 61). For Type 3610J, 3610JP, 3620J, and
3620JP positioners only, assemble the roller (key 39)
and follower post (key 38) onto the feedback lever
assembly and tighten the hex nut (key 60).
3. If the span adjustment screw (key 128 in figure 23)
was disassembled, lightly coat the threads with lubricant
(key 153) and insert the span adjustment screw into the
feedback lever assembly (key 117) and thread into the
spring hanger (key 130 in figure 23). Ensure the tip of the
span adjustment screw is in the guide hole and install
the retaining ring (key 129 in figure 23).
30
f is h e r )
4. Assemble the feedback lever assembly (key 117)
onto the positioner case (key 115A in figure 23) by
attaching the pillow blocks (key 35) with the four ma­
chine screws (key 43).
5. Turn the positioner over and install the range spring
(key 150 in figure 23). Refer to figure 13 for the correct
summing beam hole number.
Assembling the Bypass Valve Assembly
Refer to figure 24 for key number locations while assem­
bling the bypass valve assembly.
1. If the gauge block (key 158) is removed, perform the
assembling the gauge block procedure.
2. Assemble the adaptor gasket (key 164) and bypass
body adaptor (key 162) onto the gauge block (key 158)
and tighten the two socket head screws (key 54).
3. Apply lubricant (key 153) to the O-rings (keys 159,
167, and 168) sparingly and install the O-rings on the
bypass lever assembly (key 160). The two center O-
rings are retained in the bypass lever assembly by
applying a slight twist to the O-ring with the thumb and
first finger while pushing the O-ring into place.
4. Install the bypass lever assembly (key 160) into the
bypass body (key 161) with a gentle twisting and push­
ing motion to reduce the chance of nicking an O-ring.
5. Install the retaining ring (key 165) and the wire tie
(key 166).
6. Assemble the bypass body (key 161) and the by­
pass body gasket (key 163) onto the bypass body
adaptor (key 162) with the four socket head screws (key
169). Ensure that the holes in the gasket are aligned with
the holes in the bypass body. If the gasket is installed
upside down, the bypass valve will not work.
7. If the reversing plate (key 23 in figure 23) is re­
moved, install the reversing plate gasket (key 24 in
figure 23) and reversing plate (key 23 in figure 23) with
the reversing plate screw (key 49 in figure 23). When
installing the gasket, make sure one of the three gasket
holes is over the exhaust slot in the positioner case (key
115A in figure 23). If direct action is required, adjust the
reversing plate so the letter D is showing and the letter R
is entirely covered. If reverse action is required, adjust
the reversing plate so the letter R is showing and the
letter D is entirely covered. Tighten the screw (key 49).
8. If the input module is removed, perform the assem­
bling the input module procedure.
9. Plug the relay A and relay B output connections and
apply 35 psig (2.4 bar) to the Instrument connection.

Using soap solution or some other solution compatible
with nitrile rubber, check the bypass assembly for leaks
at the gasket and O-ring seals while rotating the bypass
lever to both BYPASS and POSITIONER.
Changing Positioner Types
Changing a Type 361 OJ to a 361 OJP Positioner,
Changing a Type 3620J to a 3620JP Positioner,
or Vice Versa:
1. The nozzle (key 116 in figure 23) must be changed.
The Type 361 OJ, 361 OJP, 3620J, and 3620JP nozzles
can be identified by referring to figure 5. Refer to the
disassembling the nozzle assembly and assembling the
nozzle assembly maintenance procedures.
2. The supply and output gauges [keys 79 (not shown)
and 81 in figure 24] must be changed and possibly the
instrument gauge (key 80 in figure 24) depending on the
instrument input signal. Apply sealant (key 154) to the
threads of the gauges.
3. The feedback lever assembly (key 117 in figure 26)
may need to be changed or altered depending on actua­
tor type and size. Refer to keys 117,170,171,75,76,77,
and 99 in the parts list. To change from key 117 to 170,
or vice versa, refer to the disassembling the feedback
lever assembly and assembling the feedback lever as­
sembly maintenance procedures.
4. The cam (key 82 in figure 26) may need to be
changed depending on actuator type and size. If the
cam is changed, two screws (key 83 in figure 26) may
also be required and possibly a cam adjustment indica­
tor (key 84 in figure 26). The cam adjustment indicator is
only used with the characterized cams B or C. Refer to
the Changing Cams procedure.
5. A positioner adaptor may be required depending on
actuator type and size. Refer to key 113 in the parts list.
If the positioner adaptor is required, four socket head
screws (key 54 in figure 26) will also be required for
mounting.
6. Changing from a Type 361 OJP to a 361 OJ or a Type
3620JP to a 3620J requires a pipe plug (key 78 in figure
24) to plug output A. Apply sealant (key 154) to the
threads of the pipe plugs.
Changing a Type 361 OJP to a 3611JP Positioner,
Changing a Type 3620JP to a 3621 JP Positioner,
or Vice Versa:1
1. Change the feedback lever assembly (key 117 or
170 in figure 26) as described in the disassembling the
feedback lever assembly and assembling the feedback
lever assembly maintenance procedures.
361 OJ and 3620J Series
2. Changing from a Type 3610JP to a 3611JP or a
Type 3620JP to a 3621 JP requires the following feed­
back parts: keys 172,173,174,175,184 (Type 585, size
100 only), and 185 [Type 585, size 100 with 2- through 4-
inch (51- through 102-mm) travels only, see figure 27].
3. Changing from a Type 361 OJP to a 3611JP, or a
Type 3620JP to a 3621JP requires installing a parallel
flexure (key 179 in figure 23). The parallel flexure is not
used on positioners for Type 585 size 100 actuators.
Earlier Type 3611JP positioners do not have this part.
Therefore, the summing beam assembly (key 123 in
figure 23) or relay beam assembly (key 122 in figure 23)
or both may be required if they are not drilled and tapped
to accept this parallel flexure. Refer to figure 23 for the
location of the required tapped holes. The following
parts are required: keys 179,180, and 181 in figure 23.
4. Changing from a Type 3610JP to a 3611JP or a
Type 3620JP to a 3621 JP requires a positioner adaptor
(key 113 in figure 27). Use four socket head screws (key
54 in figure 27) to mount the adaptor.
5. Changing from a Type 3611JP to a 3610JP or a
Type 3621JP to a 3620JP requires the following feed­
back parts: keys 38, 39, and 60 in figure 26.
6. Changing from a Type 3611JP to a 3610JP or a
Type 3621 JP to a 3620JP requires a cam (key 82 in
figure 26). Two screws (key 83 in figure 26) mount the
cam and a cam adjustment indicator (key 84 in figure
26— used only with characterized cams B or C). Refer to
the Mounting Type 3610J, 361 OJP, 3620J, and 3620JP
Positioners procedures for correct cam mounting.
7. Changing from a Type 3611JP to a 3610JP or a
Type 3621 JP to a 3620JP may require additional feed­
back parts depending on actuator type and size. Refer
to keys 75,76, 77,99, and 171 in the parts list and figure
26 to determine if they are required.
8. The instrument gauge (key 80 in figure 24) may
need to be changed depending on the input signal.
Apply sealant (key 154) to the threads of the gauge.
Changing a Type 3610J to a 3611JP Positioner,
Changing a Type 3620J to a 3621 JP Positioner,
or Vice Versa:
1. Change the feedback lever assembly (key 117 in
figure 26) by performing the disassembling the feedback
lever assembly and assembling the feedback lever as­
sembly maintenance procedures.
2. The nozzle (key 116 in figure 23) must be changed.
Refer to the parts list for the correct nozzle assembly
part number. Refer to figure 5 to identify the Type 3610J,
3620J, 3611 JP, and 3621 JP nozzles. Refer to the disas­
sembling the nozzle assembly and assembling the noz­
zle assembly maintenance procedures.
 FISHER®
___________
361 OJ and 3620J Series

3. The supply and output gauges [keys 79 (not shown)
and 81 in figure 24] must be changed and possibly the
instrument gauge (key 80 in figure 24) depending on the
input signal. Apply sealant (key 154) to the threads of the
gauges.
4. Changing from a Type 361 OJ to a 3611JP or a Type
3620JP to a 3621 JP requires the following feedback
parts: keys 172,173,174,175,184 (Type 585, size 100
only), and 185 [Type 585, size 100 with 2- through 4-inch
(51- through 102-mm) travels only, see figure 27].
Parts Kits
Key Description Part Number
For Type 3610J w/o bypass and 3620J (kit contains
keys 7, 8, 10, 18, 24, 64, 115D, 115F, 115G, 115H,
116, 118, 119, 120, 121, 136, 159, instructions,
and supply and nozzle relay head holders) R3610J X0022
For Type 361 OJ w/bypass (kit contains keys 7, 8,
10, 18, 24, 64, 115D, 115F, 115G, 115H, 116,
118, 119, 120, 121, 136, 159, 163, 164, 167, 168,
instructions, and supply and nozzle relay
head holders) R3610J X0012

For Type 361 OJP, 3611JP, 3620JP, and 3621 JP (kit

5. Changing from a Type 3610J to a 3611 JP or a Type
3620J to a 3621 JP requires installing a parallel flexure
(key 179 in figure 23). The parallel flexure is not used on
positioners for Type 585 size 100 actuators. Earlier
Type 3611JP positioners do not have this part. There­
fore, the summing beam assembly (key 123 in figure 23)
or relay assembly (key 122 in figure 23) or both may be
required if they are not drilled and tapped to accept this
parallel flexure. The following parts are required: keys
179, 180, and 181 in figure 23.
contains keys 7, 8, 10, 18, 24, 64, 115D, 115F,
115G, 115H, 116, 118, 119, 120, 121, 136, 159,
instructions, and supply and nozzle relay head
holders) R3610JPX012
For Type 3610J bypass valve (kit contains
keys 54, 164, and bypass valve assembly
38A5114T012 R3610JXBP12
For Type 3622 converter (kit contains keys 22,
23, 24, 26, 27, 29, and 36 for converter and
key 12 for converter module) R3622X00012

6. Changing from a Type 3610J to a 3611 JP or a Type

3620JP to a 3621 JP may require a positioner adaptor Parts List
(key 113 in figure 26). Use four socket head screws (key
Key Description Part Number
54 in figure 26) to mount the adaptor.
Diagnostic Connections
7. Changing from a Type 3611 JP to a 3610J or a Type
3621 JP to a 3620J requires the following feedback FlowScanner™ valve diagnostics system hook-up
parts: keys 38, 39, and 60 in figure 26.
Includes connector body and body protector. If ordered for units with
gauges, a stem is also included. Also, the part number provides the
8. Changing from a Type 3611JPto a 3610J or a Type correct quantities of each item.
3621 JP to a 3620J, requires a cam (key 82 in figure 26).
Mount the cam with two screws (key 83 in figure 26) and
a cam adjustment indicator (key 84— used only with
For units w/gauges
characterized cams B or C in figure 26). Refer to the SST Fittings 12B8048 X012
Mounting Type 3610J, 361 OJP, 3620J, and 3620JP Po­ Brass fittings 12B8048 X022
sitioners procedures for correct cam mounting. For units w/o gauges
SST Fittings 12B8048 X032
Brass fittings 12B8048 X042
9. Changing from a Type 3611 JP to a 3610J or a Type For Type 361 OJP Positioners
3621 JP to a 3620J requires a pipe plug (key 78 in figure For units w/gauges
SST Fittings 12B8050 X012
24) to plug output A. Apply sealant (key 154) to the 12B8050 X022
Brass fittings
threads of the pipe plug. For units w/o gauges
SST Fittings 12B8050 X032
Brass fittings 12B8050 X042
For Type 3620J Positioners
For units w/gauges
SST Fittings 12B8049 X012
Brass fittings 12B8049 X022
For units w/o gauges
Parts Ordering SST Fittings 12B8049 X032
Brass fittings 12B8049 X042
For Type 3620JP Positioners
When corresponding with the Fisher sales office or For units w/gauges
SST Fittings 12B8051 X012
sales representative about this equipment, always men­ Brass fittings 12B8051 X022
tion the positioner serial number. When ordering re­ For units w/o gauges
placement parts, refer to the part number of each SST Fittings 12B8051 X032
Brass fittings 12B8051 X042
required part as found in the following parts list.

32 FlowScanner is a mark owned by Fisher Controls International Inc.

 361 OJ and 3620J Series

Key D e s c rip tio n P a rt N u m b e r Key D e s c rip tio n P a rt N u m b e r

Positioner Common Parts 79* Supply gauge, plastic case w/brass chrome
plated conn (w/supply gauge option)
Triple scale
7* Relay supply diaphragm assembly, 0 to 30 psig/0 to 0.2 MPa/0 to 2 bar 11B4036 X012
nltrile/stainless steel 28A2165 X012 0 to 60 psig/0 to 0.4 MPa/0 to 4 bar 11B4036 X022
8* Relay nozzle diaphragm assembly, 0 to 160 psig/0 to 1.1 MPa/ 0 to 11 bar 11B4036 X032
nltrile/stainless steel 28A2166 X012
9 Relay manifold, aluminum 38A2101 X022 80* Instrument gauge, plastic case w/brass chrome plated conn
10 Pivot pin, steel/ENC 18A2155 X022 Triple scale
0 to 30 psig/0 to 0.2 MPa/0 to 2 bar 11B4036 X012
13 Crossover screw, stainless steel 18A2153 X022 0 to 60 psig/0 to 0.4 MPa/0 to 4 bar 11B4036 X022
14 Nozzle relay head, aluminum 18A2157 X012 81* Output gauge, plastic case w/brass chrome
15 Supply relay head, aluminum 18A2158 X012 plated conn (2 req'd)
18* Flapper, stainless steel 18A2112 X022 Triple scale
0 to 30 psig/0 to 0.2 MPa/0 to 2 bar 11B4036 X012
23 Reversing plate, aluminum 28A2107 X022 0 to 60 psig/0 to 0.4 MPa/0 to 4 bar 11B4036 X022
24* Reversing plate gasket, neoprene 28A2145 X022 0 to 160 psig/0 to 1.1 MPa/0 to 11 bar 11B4036 X032
35 Pillow block, aluminum, (2 req'd) 13A1535 X012 82 Cam, stainless steel
37 Flange bearing, RulonC), (2 req’d) 13A1592 X012 w/Type 1051, size 40 or 60
w/Type 1052, size 40, 60, or 70
38 Follower post, stainless steel w/Type 1061, size 30 through 68
For Type 3610J, 3610JP, 3620J, and 3620JP 13A1656 X012 Cam A (linear) 33A1613 X012
39 Roller, stainless steel Cam B (direct acting)/Cam C (reverse acting)43A1614 X012
For Type 3610J, 3610JP, 3620J, and 3620JP 13A1657 X012 Cam C (direct acting)/Cam B (reverse acting)43A1615 X012
41 Cover assembly, plastic w/Type 1052 size 20
(including cover screws) 18A2128 X012 Cam A (linear) 36A4653 X012
43 Machine screw, pi steel (4 req’d) 11B8040 X012 Cam B (direct acting)/Cam C (reverse acting)47A5776 X012
Cam C (direct acting)/Cam B (reverse acting)47A2670 X012
45 Access cover screw, pi steel (2 req'd) 13A1586 X012 w/Type 1051, size 33
47 Machine screw, pi steel (12 req'd) 10A0893 X012 w/Type 1052, size 33
49 Machine screw, pi steel 1B4638 X0012 Cam A (linear) 30B1529 X012
50 Machine screw, pi steel (2 req’d) 11B8042 X012 Cam B (direct acting)/Cam C (reverse acting)40B1540 X012
Cam C (direct acting)/Cam B (reverse acting)40B1538 X012
51 Machine screw, pi steel 11B8042 X012 w/Type 1061 size 80 or 100
54 Cap screw, pi steel, (number required per assembly Cam A (linear) 33A1648 X012
varies; maximum req’d for any assembly is 8)1P7146 X0022 Cam B (direct acting)/Cam C (reverse acting)43A1649 X012
55 Machine screw, stainless steel 11B4322 X012 Cam C (direct acting)/Cam B (reverse acting)43A1650 X012
56 Self tapping screw, pi steel (2 req'd) 1P4269 28982 w/Type 1069 size 100
Cam A (linear) 48A8031 X012
57 Set screw, pi steel (2 req'd) 1F3536 X0012 Cam B (direct acting)/Cam C (reverse acting)48A8032 X012
60 Hex nut Cam C (direct acting)/Cam B (reverse acting)48A8033 X012
For Type 3610J, 361 OJP, 3620J and 3620JP 83 Machine screw, pi steel (2 req’d)
pi steel 1A8396 28982 w/Type 1051, size 40 or 60 13A1618 X012
61 E-ring, pi steel 1E4553 28982 w/Type 1052, size 40, 60, or 70 13A1618 X012
64* O-ring, nitrile, (2 req’d) 1H2919 06992 w/Type 1061, size 30 through 68 13A1618 X012
w/Type 1052, size 20 or 33 13A1617 X012
70 Spring, pi steel 1J3949 27012 w/Type 1051, size 33 13A1617 X012
72 Pipe plug, pi steel w/Type 1061, size 80 or 100 1B2905 24052
(None req'd w/supply gauge option) w/Type 1069, size 100 1B2905 24052
1 req'd for gauge option w/o supply gauge
or tire valve option 84 Cam adjustment indicator, stainless steel
4 req’d w/o gauges or tire valves, w/pipe For Type 3610J, 3610JP, 3620J, and 3620JP
plug option 1D8293 28982 (w/Cams B or C only, not req’d w/Cam A
73 Tire valve, w/tire valve option (3 req’d) 1N9088 99012 or w/Type 1069, size 100)
w/Type 1051, size 33, 40 or 60 13A1629 X012
75 Machine screw, pi steel (2 req'd) w/Type 1052, size 20, 33, 40, 60, or 70 13A1629 X012
For Type 361 OJP and 3620JP w/Type 1061, size 30 through 68 13A1629 X012
w/Type 1061, size 80 or 100 1D7132 24192 w/Type 1061, size 80 or 100 13A1652 X012
87 Tubing connector, (specify quantity
76 Follower arm extension, stainless steel required) (not shown)
For Type 361 OJP and 3620JP Brass, 1/4-inch NPT x 3/8-inch O.D. 15A6002 X202
w/Type 1061, size 80 or 100 13A1651 X012 Stainless steel, 1/4-Inch NPT x
77 Hex nut, pi steel (2 req'd), 3/8-inch O.D. 15A6002 X602
For Type 3610JP and 3620JP 88 Tubing elbow (specify quantity
w/Type 1061, size 80 or 100 1A6622 28992 required) ,
78 Pipe Plug, steel Brass, 1/4-inch NPT x 3/8-inch O.D. 15A6002 X162
For Type 3610J and 3620J w/o bypass 1C3335 28992 Stainless steel, 1/4-inch NPT x
3/8-inch O.D. 15A6002 X612
89 Cap screw, pi steel (2 req'd) 1C1970 24052
92 Lockwasher, pi steel (2 req’d) 1C2257 28982

'Recommended spare part.

1. Trademark of E.l. duPont Nemours Co. 33
361 OJ and 3620J Series

Key D e s c rip tio n P a rt N u m b e r Key D e s c rip tio n P a rt N u m b e r

99 Lockwasher, stainless steel (2 req'd) 135 Diaphragm connector, aluminum 18A7830 X012
For Type 361 OJP and 3620JP 136 Sealing screw, stainless steel/fluorsilicone 10B8014 X012
w/Type 1061 size 80 or 100 1K6236 38992 137 Diaphragm spacer, aluminum 38A7831 X012
109 Lubricant, Never-Seez®, 1 gal 138 Input diaphragm flange, aluminum 28A7832 X012
(3.81 liter) can (not furnished with the
positioner) 1M5239 06992 139 Machine screw, pi steel (2 req’d) 10B6188 X012
113 Positioner adaptor, aluminum 140 Machine screw, pi steel 1A9021 25072
For Type 3610J and 3620J 141 Zero spring, pi steel 18A7833 X012
w/Type 1051, size 33 46A4666 X032 142 Spring seat, stainless steel 19A4898 X012
w/Type 1052, size 20 and 33 46A4666 X032
For Type 361 OJP 143 Zero adjustment screw, stainless steel 19A4897 X012
w/Type 1069 size 100 46A4666 X032 144 Zero spring bracket, stainless steel 28A7838 X022
For Type 3611JP and 3621 JP 146 Nozzle block, aluminum 38A7840 X012
w/Type 585 and 585R 46A4666 X032 147 Core & wire assembly, stainless steel 18A7841 X012
115 ,Valve seat assembly, aluminum/stainless
steel (includes keys 115A, 115B, 115C, 148 Mandrel, Ryton 18A7843 X012
115D, 115E, 115F, 115G, 115H, 115J, & 115K)28A7802 X022 149 Spacer, phenolic 18A7844 X012
150 Range spring, pi steel
115A Case assembly [includes case (key 115A) and (color coded blue) 18A7845 X012
valve seats (key 115B), (color coded red) 18A5118 X012
aluminum/stainless steel 58A7803 X022 (color coded yellow) 18A7846 X012
115C Pressure plate, aluminum 48A2106 X012 151 Warning label, plastic film 18A7847 X012
115D* Pressure plate gasket, neoprene 38A2167 X022
115E Body plug, aluminum (2 req'd) 1B7975 X0012 153 Lubricant, Lubriplate® MAG-1 (not
furnished with positioner) 1 lb (0.45 kg) can 1M1100 X0012
115F* Body plug gasket, composition, (2 req’d) 1C4957 04022 154 Sealant, John Crane® PLS No. 2, 1 lb
115G Valve plug, stainless steel, (2 req’d) 18A2152 X022 (0.45 kg) can (not furnished with positioner) 1M3307 06992
115H Valve plug spring, stainless steel, (2 req’d) 19A6274 X022 155 Pipe Nipple, steel 1B2927 38322
115J Machine screw, pi steel (10 req'd) 11B8039 X012 156 Flexure adjustment, Ryton 29A0181 X032
157 Nameplate, stainless steel 12B4505 X0A2
115K Shroud, stainless steel (2 req’d) 19A6030 X012
116* Nozzle assembly, stainless steel/synthetic 158 Gauge block, for Type 3610J, 3610JP,
sapphire and 3611JP only, aluminum 46A5911 X022
For Type 3610J and 3620J 18A7792 X012 159* O-Ring, (4 req’d w/gauge block, or
For Type 361 OJP, 3620JP, 3611JP, 5 req'd w/gauge block and
and 3621JP 18A7794 X012 bypass valve, nitrile 11A8741 X052
117 Feedback lever assembly, stainless steel 160 Bypass lever assembly, Ryton 18A5117 X012
For Type 3610J, 3610JP, 3620J, and 3620JP 161 Bypass body, aluminum 38A5114 X012
w/Type 1051, all sizes, except size 33 18A7796 X012
w/Type 1052, all sizes, except size 20 and 3318A7796 X012 162 Bypass body adapter, aluminum 46A5908 X022
w/Type 1051, size 33 18A7798 X012 163* Bypass body gasket, nitrile 16A5910 X012
w/Type 1052, size 20 and 33 18A7798 X012 164* Adapter gasket, nitrile 26A5909 X032
w/Type 1061, size 30 through 100 18A7796 X012 165 Retaining ring, stainless steel 1R6631 38992
For Type 3611JP and 3621 JP
w/Type 585, size 25 and 50 29A4633 X012 166 Wire tie, nylon 16A5907 X012
See key 170 for Type 585, size 100 and 167* O-ring, nitrile 1J4888 X0052
Type 1069, size 100 168* O-ring, nitrile, (2 req’d) 11B8085 X012
118* Lower input diaphragm, nitrile 28A7804 X012 169 Machine screw, steel, (4 req’d) 1H3284 32992

119* Upper input diaphragm, nitrile 28A7805 X012 170 Feedback lever assembly, stainless steel
120* O-Ring, nitrile 1D1346 06992 For Type 3611JP and 3621JP
121* O-Ring, nitrile 1C8546 06992 w/Type 585, size 100
122 Beam assembly, stainless steel/plastic 18A9042 X012 3/4 to 2-inch travel (19 to 51 mm) 20B7077 X012
2 to 4-inch travel (51 to 102 mm) 20B7656 X012
123 Summing beam assembly, stainless steel 38A7809 X022 For Type 361 OJP and 3620JP
124 Machine screw, pi steel (2 req’d) 1V4131 X0012 w/Type 1069, size 100 28A8622 X012
125 Counterspring, pi steel 18A7817 X012 171 Torsion spring, pi steel
126 Spring seat, Ryton® 18A7818 X012 For Type 3610J and 3620JP
w/Type 1069, size 100 19A0758 X012
127 Machine screw, pi steel 10B6188 X012 172 Retaining ring, pi steel
128 Span adjustment screw For Type 3611JP and 3621 JP 1H1538 28982
stainless steel 18A7820 X022 173 Button head screw, pi steel
129 Prong-lock ring, pi steel 18A7823 X012 For Type 3611JP and 3621 JP 19A3799 X012
130 Range spring hanger, stainless steel 28A7824 X012
174 Adjuster assembly, stainless steel
131 Instruction label, plastic film , 18A7825 X012 For Type 3611 JP and 3621 JP '
132 Lower diaphragm plate, aluminum 18A7827 X012 w/Type 585, size 25 or 50 19A3795 X012
133 Diaphragm spacer, Ryton 28A7828 X012 w/Type 585, size 100 11B1187 X012
134 Upper diaphragm plate, aluminum 18A7829 X012 175 Roller, stainless steel
For Type 3611JP and 3621 JP 19A3798 X012

‘ Recommended spare part.

2. Trademark of Never Seez Corp.
3. Trademark of Phillips Petroleum Co.
4. Trademark of Fiske Brothers Refining Co.
34 5. Trademark of Crane Packing Co.
 361 OJ and 3620J Series

Key D e s c rip tio n P a rt N u m b e r Key D e s c rip tio n P a rt N u m b e r

176 Lockwasher, pi steel 1B4653 28982 23* O-ring, nitrile 1E5914 06992
177 Machine screw, pi steel (2 req’d) 10B6187 X012 24* O-ring, nitrile, used w/o integrally
mounted Type 67AFR filter regulator 11B2308 X012
178 Anti-seize Compound, 25 Nozzle restriction, Aluminum/synthetic sapphire13B7116 X012
Zink Plate No. 770<6>
5 pound (2.27 kg) can (not furnished 26* O-ring, nitrile 1P4207 06992
with positioner) 1M5240 06992 27* O-ring, nitrile (2 req’d) 1C8538 X0022
179 Parallel flexure, stainless steel, 28 Vent, plastic/stainless steel 11B8279 X012
For Type 3611JP and 3621 JP 29* O-ring, nitrile 1H8762 X0012
w/Type 585, size 25 or 50 29A7553 X012
w/Type 585, size 50 30 Machine screw, stainless steel, (2 req'd) 1A9021 X0012
For high frequency response 21B5997 X012 31 Wire retaining screw, pi steel, (2 req'd) 16A2821 X012
None req'd for Type 585 size 100 32 Nameplate, non-approved,
180 Machine screw, pi steel (2 req'd) stainless steel 10B9777 X012
For Type 3611JP and 3621 JP 33 Drive screw, stainless steel (2 req'd) 1P4269 28982
w/Type 585, size 25 or 50 13A7134 X012
None req’d for Type 585 size 100 35 Cap screw, pi steel (2 req’d) 1N4006 28982
181 Lockwasher, pi steel (2 req'd) 36* O-ring, nitrile, (4 req'd) 11A8741 X052
For Type 3611JP and 3621 JP 37 Pipe plug, pi steel, use only when specified
w/Type 585, size 25 or 50 actuator 18A3666 X012 w/o gauges or tire valves (3 req’d) 1D8293 28982
None req'd for Type 585 size 100 w/o gauges and w/tire valves (1 req’d) 1D8293 28982
184 Washer, pi steel (2 req'd) 38* Supply gauge, plastic case w/brass chrome
For Type 3611JP or 3621 JP plated conn (w/supply gauge option)
w/Type 585, size 100 11B1197 X012 Triple scale
185 Extension spring, pi steel 0 to 30 psig/0 to 0.2 MPa/0 to 2 bar 11B4306 X012
For Type 3611JP or 3621 JP 0 to 60 psig/0 to 0.4 MPa/0 to 4 bar 11B4306 X022
w/Type 585, size 100, w/2-4 inch 0 to 160 psig/0 to 1.1 MPa/0 to 11 bar 11B4306 X032
(51-102 mm) travel 10B7658 X012
187 Machine screw, pi steel (2 req'd) 1N4006 28982 39 Sealant, John Crane Plastic Lead Seal<5>
188 Adhesive, Loctite<7) 242, 50 cc bottle 1 pound (0.5 kg) can (not furnished
(not furnished with positioner) 1M6159 X0012 with positioner) 1M3307 06992
190 O-ring 1E5914 06992
191 Pipe Plug 40 Cap screw, pi steel, used w/ integrally
plated steel 1A7675 24662 mounted Type 67AFR filter regulator (2 req’d)1C3988 24052
stainless steel 1A7675 35072 41 Tire valve, use only when specified, (2 req’d) 1N9088 99012
42 Lubricant, Never-Seez Nickel Lubricant*®),
4 pound (1.8 kg) can (not furnished with
Type 3622 Electro-Pneumatic Converter positioner) 1M5539 X0012
Converter module 33B7073 X012 43* Output gauge, plastic case w/brass chrome
plated conn (2 req’d)
17 Lubricant, Lubriplate!4) MAG-1 (not Triple scale
furnished with positioner) 1 lb (0.45 kg) can 1M1100 X0012 0 to 30 psig/0 to 0.2 MPa/0 to 2 bar 11B4306 X012
19 Housing, aluminum 0 to 60 psig/0 to 0.4 MPa/0 to 4 bar 11B4306 X022
1/2-inch NPT conduit connection 22B0905 X012 0 to 160 psig/0 to 1.1 bar/0 to 11 bar 11B4306 X032
M20 thread conduit connection 22B4901 X012 48 Pipe plug, steel, use w/integrally mounted
20 Cap, aluminum 31B2305 X012 Type 67AFR filter regulator 1C3335 28992
21 Filter plug, used w/o integrally mounted 49 Cable gland, plastic
Type 67AFR filter regulator, stainless steel 11B2306 X012 M20 thread conduit connection 11B3870 X012
22* Filter, 40 micron cellulose, used w/o integrally
mounted Type 67 AFR filter regulator 11B2307 X012

‘ Recommended spare part.

4. Trademark of Fiske Brothers Refining Co.
5. Trademark of Crane Packing Co.
6. Trademark of Armite Laboratories.
7. Trademark of Loctite Corp. 35
 ■

361 OJ and 3620J Series

SECTION D-D

3610J A N D 3620J S E R IES P O S ITIO N E R S

F R O N T V IE W W IT H C O V E R R EM O VE D

Figure 23. Positioners Assembly

36
 361 OJ and 3620J Series

S8A701O-T SHT 4

□ APPLY LUBRICANT
OR SEALANT
NOZZLE/FLAPPER

Figure 23. Positioners Assembly (Continued)

37
 FISHER®
361 OJ and 3620J Series

38
 361 OJ and 3620J Series

T Y P E 3610J A N D 3 6 1 0 JP P O S ITIO N E R

BYPASS VA LVE ASSEM BLY

FO R T H E 3610J P O S ITIO N E R S

□ APPLY LUBRICANT OR SEALANT

NOTE:
[T> KEY 78 IS USED FOR TYPE 3610J ONLY.

U > GAUGES MAY BE REPLACED BY PIPE PLUGS (KEY 72) OR

TIRE VALVES (KEY 73).

T Y P E 3611 JP P O S ITIO N E R

r W IT H G A U G ES

Figure 24. Gauge Block and Bypass Valve Assemblies

39
 FISHER*]
361 OJ and 3620J Series

NOTES:
|T> THIS PIPE PLUG IS USED ONLY WITH TYPE 3620J.
[T > SEE FIGURE 28 FOR TYPE 3622 KEY NUMBERS.

3620J S ER IES P O S ITIO N E R S

W IT H G A U G ES A N D
IN T E G R A L M O U N TE D
FILTE R / R E G U LA TO R

Figure 25. 3620J Series Positioner with Integral Mounted Filter/Regulator


T Y P E 3610J A N D 3620J P O S ITIO N E R S
F O R T Y P E 1051 A C T U A T O R S
SIZE 40 A N D 60
F O R T Y P E 1052 A C T U A T O R S
SIZE 40, 60, A N D 70
T Y P E 361 0 JP A N D 3620JP P O S ITIO N E R S
F O R T Y P E 1061 A C T U A T O R S
SIZE 30-60
T Y P E 361 0 JP A N D 3 62 0 JP P O S ITIO N E R S
F O R T Y P E 1061 A C T U A T O R S
S IZE 80-100
Figure 26. Feedback Assemblies for Type 361 OJ, 361 OJP, 3620J, and 3620JP Positioners
361 OJ and 3620J Series
T Y P E 3610J A N D 3620J P O S ITIO N E R S
FO R T Y P E 1051 A C T U A T O R
SIZE 33
FO R T Y P E 1052 A C T U A T O R S
SIZE 20 A N D 33
T Y P E 3610J A N D 3620J P O S ITIO N E R S
FO R A L L T Y P E 1051 A N D 1052 A C T U A T O R S
T Y P E 361 0 JP A N D 362 0 JP P O S ITIO N E R S
FO R T Y P E 1061 A C T U A T O R S
SIZE 30-60
T Y P E 361 0 JP A N D 362 0 JP P O S ITIO N E R S
FO R T Y P E 1069 A C T U A T O R S
size 100
41
361 OJ and 3620J Series

FO R T Y P E 585 SIZE 25 A N D 50
A C T U A T O R S (BACK V IE W )

NOTE:
Q > FOR THE STEM BRACKET ASSEMBLY, REFER TO THE
ACTUATOR INSTRUCTION MANUAL.

FO R T Y P E 585 SIZE 100 A C T U A T O R S

(SEE B ACK V IE W A B O VE )

Figure 27. Feedback Assemblies for Type 3 6 1 1JP and 3621JP Positioners

42
 361 OJ and 3620J Series

3620J S ER IES P O S ITIO N E R S

T Y P E 3 62 1 JP P O S ITIO N E R
W IT H G A U G ES

□ APPLY LUBRICANT OR SEALANT

NOTE:
Q > GAUGES MAY BE REPLACED BY PIPE PLUGS (KEY 37)
OR TIRE VALVES (KEY 41)

Figure 28. Type 3622 Electro-Pneumatic Converter Assembly

43
361 OJ and 3620J Series

While this information is presented in good faith and believed to be accurate, o r ,a n y o t h e r m a t t e r w it h r e s p e c t to t h e p r o d u c t s , nor as a recommendation to
Fisher Controls does not guarantee satisfactory results from reliance upon such use any product or process in conflict with any patent. Fisher Controls reserves
information. N o th in g c o n t a in e d h e r e in is t o b e c o n s t r u e d a s a w a rr a n ty o r the right, without notice, to alter or improve the designs or specifications of
g u a ra n te e , e x p r e s s o r im p lie d , r e g a r d in g th e p e r fo rm a n c e , m e r c h a n t a b ilit y , f it n e s s the products described herein.

■ ■ F o r in fo r m a tio n , c o n t a c t F is h e r C o n tr o ls :
FISHER Fisher Controls Marshalltown, Iowa 50158 USA Sao Paulo 05424 Brazil
- Cernay 68700 France Singapore 0512

r a A lPMTIDWITMl . .
Printed in U SA I ^ I s o y in k I recycled paper
 Types 1098-EGR & 1098H-EGR

Fisher Controls Instruction Manual

Type 1098-EGR & 1098H-EGR

Pilot-Operated Regulators

FISHER*
M ay 1987 F o rm 5084

Contents

Introduction...................................................... 2
Scope of M anual ................................................................2
Product D e s c rip tio n ........................................................... 2
S p e c ific a tio n s ....................................................................... 2

Installation and Startup................................. 3

Standard Single-Pilot Regulator ...................................3
In s ta lla tio n ..........................................................................3
Prestartup C o n s id e ra tio n s .......................................... 6
Pilot A d ju s tm e n t..............................................................6
S tartup ...............................................................................g
D ual-Pilot Boiler Fuel Control Regulator ............... 6
In s ta lla tio n ....................................................................... 6
Prestartup C o n s id e ra tio n s ....................................... 7
Pilot A d ju s tm e n t............................................................. 8
Startup ...............................................................................8
W orking M o n ito r .................................................................. 8
In s ta lla tio n ....................................................................... 8
Prestartup C o n s id e ra tio n s ....................................... 8
Pilot A d ju s tm e n t........................................................ 10
Startup ......................................................................... 1 0
W ide-O pen M onitor ...................................................... 10
In s ta lla tio n .................................................................... 1 0
Prestartup C o n s id e ra tio n s ..................................... 10
Pilot A d ju s tm e n t........................................................ 11
Startup ......................................................................... 11

Shutdown........................................................ 12 T Y P E 1098H-EGR-6354L
Single-Pilot, Dual-Pilot R egulator or W ide-O pen R E G U LA TO R
M onitor ..................................................... 12
Figure 1. Typical Regulator Constructions
W orking M o n ito r ............................................................. 12

Principle of Operation Type 6352 Through 6354M P ilots......................... 16

Type 61LD Pilot and Type1806Relief Valve .. 16
Maintenance................................................. 13 Type 1098 or 1098H Actuator and PHot Mounting
Design EGR Main Valve ..................................... 14 Parts ................................................. 17
D100339 X012

Replacing Quick-Change Trim Package........ 14

Replacing Trim P a rts ....................................... 14 Parts Ordering..................................................18
P590 Series F ilte r.................................................. 15
Type 6351 Pilot .................................................... 18 Parts L is t................ i ft

©Fishar Controls International, Inc. 1977, 1979, 1982, 1987; All Rights Reserved
Types 1098-EGR & 1098H-EGR

Introduction
Scope of Manual
This manual describes and provides instructions and
parts list for a Type 1098-EGR or 1098H-EGR regulator
(figure 1) complete with standard P590 Series filter and
either a 6350 Series regulator or a Type 61LD pilot. The
Type 1806 relief valve also is covered when a Type 61 LD
pilot is used. However, instructions and parts lists for
monitoring pilots and other equipment used with this
regulator are found in separate manuals.
Product Description
Type 1098-EGR and 1098H-EGR regulators provide
economical, accurate pressure control in a wide variety
of applications such as gas distribution systems, heat­
treating furnaces, and boiler plants. They are also used
in plant air service and in liquid service where a slow
stroking time (approximately 30 to 90 seconds) is de­
sired on both opening and closing the main valve. The
Type 1098-EGR regulator is used with a Type 6351,
6352, 6353 or the 61 series pilot. The Type 1098H-EGR
regulator is used with a Type 6351,6352, 6353, 6354H,
6354L, or 6354M pilot.
Specifications
Table 1 lists specifications for various Type 1098-EGR
and 1098H-EGR constructions. Specifications for a giv­
en regulator as it originally comes from the factory are
stamped on nameplates (figure 2) located on the actua­
tor and main valve body, while the pilot control spring
range appears on the pilot spring case and the pilot
restriction code is stamped on the pilot body.

Table 1. Specifications

BODY SIZES AND END OUTLET (CONTROL) Type 6351 Pilot: ■ 3 to 20 psig
CONNECTION STYLES PRESSURE RANGES!4) (0.21 to 1.4 bar) with green spring
■ 5 to 35 psig (0.34 to 2.4 bar)
Body Size, End Connection
Material Rating!1) with cadmium spring or ■ 35 to
Inch Style
Cast iron NPT screwed Class 250B 100 psig (2.4 to 6.9 bar) with red
1, 2
spring
NPT screwed, butt­
WCB steel Class 600 Type 6352 Pilot: ■ 2 inch wc to 2
welding, or socketwelding
Flat-face flanged Class 125B psig (5 to 140 mbar) with yellow
Cast iron spring or ■ 2 to 10 psig (140 to
Raised-face flanged Class 250B
2, 3, 4, 6, 690 mbar) with black spring
Class 150,
8x6 Raised-face flanged 300, or 600 Type 6353 Pilot: ■ 3 to 40 psig
WCB steel
Class 600
(0.21 to 2.8 bar) with yellow
Buttwelding
spring or ■ 35 to 125 psig (2.4 to
8.6 bar) with red spring
MAXIMUM MAIN 400 psig (28 bar) or body rating Type 6354L Pilot: 85 to 200 psig
VALVE INLET limit, whichever is lower, except (5.9 to 14 bar) with blue spring
PRESSURE!1) 20 psig (1.4 bar) for boiler fuel and no diaphragm limiter
installations as shown in table 2 Type 6354M Pilot: 175 to 220
psig (12 to 15 bar) with blue
MAXIMUM PILOT 600 psig (41 bar) spring and diaphragm limiter
SUPPLY Type 6354H Pilot: 200 to 300 psig
PRESSURE!1-2) (14 to 21 bar) with green spring
and diaphragm limiter
Type 61 LD Pilot: ■ 0.25 to 2 psig
PILOT RESTRICTION!3) (0.017-0.138 bar) with red spring
■ 1 to 5 psig (0.069-0.34 bar) with
RESTRICTION yellow spring B 2 to 10 psig
TYPE
NUMBER
GAIN Letter (0.138-0.69 bar) with blue spring
Used Color Code
Code ■ 5 to 15 psig (0.34-1.02 bar) with
6351 Standard No None None brown spring B 1 0 to 20 psig
Standard Yes Green S (0.69-1.4 bar) wjth green spring
Low for liquid service
6352 No None L MAXIMUM AND See table 2
and/or broader
through
proportional bands MINIMUM
6354M
High for narrower
Yes Red H DIFFERENTIAL
proportional bands PRESSURES

2
 Types 1098-EGR & 1098H-EGR

Table 1. Specifications (Continued)

ACTUATOR SIZES PORT DIAMETERS

AND MAXIMUM AND TRAVELS
ACTUATOR
PRESSURES!1) PORT TRAVEL
BODY SIZE, DIAMETER Standard Restricted Capacity
OUTLET (CONTROL) EMERGENCY INCH
ACTUATOR
PRESSURE CASING PRESSURE Inch mm Inch mm Percentage of Inch mm
SIZE Flow Capacity
Psig Bar Psig Bar 1 1-5/16 33.3 3/4 19 — _______
30 100 6.9 115 7.9
Type 1098 40 75 5.2 82 5.7 30 3/8 10
2 2-3/8 60.3 1-1/8 29
70 50 3.4 65 4.5 70 5/8 16
Type 1098H 30 300 21 400 28 3 3-3/8 85.7 1-1/2 38 40 7/8 22
4 4-3/8 111.1
2 51 40 1 25
6 &8 x 6 7-3/16 182.6
MAIN VALVE FLOW ■ Linear (standard) or ■ quick­
CHARACTERISTIC opening
APPROXIMATE
ACTUATOR BODY SIZE, INCH
WEIGHTS (WITH SIZE 1 2 3 4 6
MAIN VALVE FLOW STANDARD SINGLE­
In through seat ring and out PILOT Lb
DIRECTION through cage 30 55 75 115 165 350
CONSTRUCTION)
Type 1098 40 65 85 125 175 360
70 140 160 200 250 435
MATERIAL Standard Elastomers: —20 to Type 1098H 30 80 100 140 190 375
TEMPERATURE 150°F ( - 2 9 to 66°C) Kg
CAPABILITIES!1) High-Temperature Elastomers: 0 30 25 34 52 75 159
to 300°F ( - 18 to 149°C), except Type 1098 40 29 39 57 79 163
0 to 180°F ( - 1 8 to 82°C) for 70 64 73 91 113 197
water service Type 1098H 30 36 45 64 86 170
1 The pressure/temperature limits in this manual, and any applicable standard stream of the pilot according to the Installation section.
limitation, should not be exceeded. p --* numbers
3. Restriction part -----'------------- -— ■-iii **■---------
are gTven’ The parts iist
2. For stability or overpressure protection, a reducing regulator may be installed up­ 4. Pilot control
ol spring part numbers are given in the parts list.

Installation and Startup lated gas. To avoid such injury and dam­
age, install the regulator in a safe location.

W ARNING Standard Single-Pilot Regulator

Personal injury, equipment damage, or Installations
leakage due to escaping accumulated gas
or bursting of pressure-containing parts A Type 1098-EGR or 1098H-EGR regulator bleeds no
may result if this regulator is overpressured gas to atmosphere, making it suitable for installation in
or is installed where service conditions pits and other enclosed locations without elaborate
could exceed the limits given in tables 1 venting systems. This regulator also can be installed in
and 2 and on the appropriate nameplate, or pits subject to flooding, by installing a special antiflood
where conditions exceed any ratings of the breather vent or by venting the pilot spring case above
adjacent piping or piping connections. To the expected flood level so that the pilot diaphragm can
avoid such injury or damage, provide pres­ be referenced to atmospheric pressure.
sure-relieving or pressure-limiting devices
(as required by Title 49, Part 192, of the U.S. Note
Code of Federal Regulations, by the Nation­
al Fuel Gas Code Title 54 of the National On the Design EGR main valve, normal
Fire Codes of the National Fire Protection pressure drop assists shutoff. Therefore,
Association, or by other applicable codes) leakage may result during any reverse
to prevent service conditions from exceed­ pressure drop condition.
ing those limits.
1. Use qualified personnel when installing, operating,
Additionally, physical damage to the regu­ and maintaining regulators. Before installing, inspect
lator could resulst in personal injury and the main valve, pilot, and tubing for any shipment dam­
property damage due to escaping accumu- age or foreign material that may have collected during

3
Types 1098-EGR & 1098H-EGR

Table 2. Maximum and Minimum Differential Pressures for Main Valve Spring Selection
Low-differential boiler
fuel installation Type
1098-EGR requiring
CONSTRUCTION quick-opening cage All Other Constructs ns
and limited to 20
psig (1.4 bar) max
inlet pressure
400 psig (28 bar)
MAXIMUM ALLOWABLE 20 psig (1.4 bar) 60 psi (4.1 bar) 125 psi (8.6 bar) or body rating limit,
DIFFERENTIAL PRESSURE whichever is lower
Size 40 Actuator Not available 2.5 psi (0.17 bar) 4 psi (0.28 bar) 5 psi (0.34 bar)
1 Inch Body Size 30 Actuator Not available 3.5 psi (0.24 bar) 5 psi (0.34 bar) 7 psi (0.48 bar)
Size 70 Actuator 1.0 psi (0.069 bar) 1 psi (0.069 bar) 1.5 psi (0.10 bar) 2.5 psi (0.17 bar)
Size 40 Actuator Not available 3 psi (0.21 bar) 5 psi (0.34 bar) 10 psi (0.69 bar)
2 Inch Body Size 30 Actuator Not available 4 psi (0.28 bar) 6 psi (0.42 bar) 11 psi (0.76 bar)
Size 70 Actuator 1.0 psi (0.069 bar) 1.5 psi (0.10 bar) 2 psi (0.14 bar) 3 psi (0.21 bar)
MINIMUM 4 psi (0.28 bar) 6 psi (0.41 bar) 11 psi (0.76 bar)
Size 40 Actuator Not available
3 Inch Body Size 30 Actuator Not available 5 psi (0.34 bar) 8 psi (0.55 bar) 14 psi (0.97 bar)
PRESSURE
REQUIRED FOR Size 70 Actuator 1.0 psi (0.069 bar) 2 psi (0.14 bar) 2.5 psi (0.17 bar) 4 psi (0.28 bar)
FULL STROKE 5 psi (0.34 bar) 8 psi (0.55 bar) 13 psi (0.90 bar)
Size 40 Actuator Not available
4 Inch Body Size 30 Actuator Not available 10 psi (0.69 bar) 13 psi (0.90 bar) 22 psi (1.5 bar)
Size 70 Actuator 1.3 psi (0.090 bar) 2.5 psi (0.17 bar) 3 psi (0.21 bar) 5 psi (0.34 bar)
Size 40 Actuator Not available 9.5 psi (0.66 bar) 14 psi (0.97 bar) 19 psi (1.3 bar)
6, 8 x 6 Inch Body Size 30 Actuator Not available 13 psi (0.90 bar) 19 psi (1.3 bar) 28 psi (1.9 bar)C>
Size 70 Actuator 2.2 psi (0.15 bar) 4 psi (0.28 bar) 6 psi (0.42 bar) 8 psi (0.55 bar)
Yellow, except green Green Blue Red
MAIN V/M.VE SPRING COLOR CODE<2> for 1 inch body
1. Requires special 6350 Series pilot construction with Type 1806H relief valve.
2. Spring part numbers are given in the parts list.

crating and shipment. Make certain the body interior is prevent scale buildup on all machined guiding and seal­
cleah and the pipelines are free of foreign material. ing surfaces inside the body and at the bonnet flange/
Apply pipe compound only to the male pipe threads with body joint.
a screwed body, or use suitable line gaskets and good
bolting practices with a flanged body.
Note
With a weld end body, be sure to remove the trim
package, including the gasket (key 4, figure 11), accord­ All Type 1098-EGR and 1098H-EGR regula­
ing to the Maintenance section before welding the body tors should be installed so that flow through
into the line. Do not install the trim package until any the main valve matches the flow arrow at­
post-weld heat treatment is completed. If heat treating, tached to the valve body.

4

2. Install a three-valve bypass around the regulator if
continuous operation is necessary during maintenance
or inspection.
The standard pilot mounting position is shown in figure
1, the pilot may be field-changed to the opposite-side
mounting position by swapping the pilot pipe nipple to
the opposite bonnet tapping.
W ARNING
A regulator may vent some gas to the atmo­
sphere. In hazardous or flammable gas ser­
vice, vented gas may accumulate, and
cause personal injury, death, or property
damage due to fire or explosion. Vent a
regulator in hazardous gas service to a
remote, safe location away from air intakes
or any hazardous location. The vent line or
stack opening must be protected against
condensation or clogging.
3. To keep the pilot spring case vent from being
plugged or the spring case from collecting moisture,
corrosive chemicals, or other foreign material, point the
vent down or otherwise protect it. Vent orientation may
be changed by removing the spring case and remount­
ing it on the pilot body or on a standard Type 6352
through 6354M pilot by twisting the vent (key 35, figure
13, or key 13, figure 14) in the spring case. To remotely
Types 1098-EGR & 1098H-EGR
vent a standard Type 6352 through 6354M pilot, remove
the vent and install obstruction-free tubing or piping into
the 1/4-inch NPT vent tapping. The Type 61 LD pilot is
vented by installing the vent piping in place of the pipe
plug (Key 22, figure 18). Then remove the closing cap
assembly (key 5, figure 18) in order to remove the
machine screw from inside the closing cap and tightly
install it in the vent hole in the center of the closing cap.
Provide protection on a remote vent by installing a
screened vent cap into the remote end of the vent pipe.
4. Run a 3/8-inch outer diameter or larger pilot supply
line from the upstream pipeline to the filter inlet as
shown in figure 3, bushing the line down to fit the 1/4-
inch NPT filter connection. Do not make the upstream
pipeline connection in a turbulent area, such as near a
nipple, swage, or elbow. If the maximum pilot inlet
pressure could exceed the pilot rating, install a separate
reducing regulator in the pilot supply line. Install a hand
valve in the pilot supply line, and provide vent valves to
properly isolate and relieve the pressure from the regu­
lator.
5. Attach a 1/2-inch NPT downstream pressure con­
trol line downstream of the regulator in a straight run of
pipe as shown in figure 3. Connect the other end of the
control line to the bonnet connection. Do not make the
tap near any elbow, swage, or nipple that might cause
turbulence. Install a hand valve in the control line to shut
off the control pressure when the bypass is in use.
5
Types 1098-EGR & 1098H-EGR
6. If a quick acting solenoid is to be installed down­
stream of a regulator, the regulator and solenoid should
be located as far apart as practical. This will maximize
the gas piping volume between the regulator and sole­
noid and improve the regulator response to quick
changing flow rates.
7. Consult the appropriate instruction manual for in­
stallation of an optional pneumatic or electric remote
control drive unit. For optional remote pneumatic load­
ing of a 6350 Series or 61 LD pilot, make the loading
piping connections to the 1/4-inch NPT vent connection.
Prestartup Considerations
Before beginning the startup procedures in this section,
make sure the following conditions are in effect:
• Block valves isolate the regulator.
• Vent valves are closed.
• Hand valves are closed.
CAUTION
Introduce pilot supply pressure into the
regulator before introducing any down­
stream pressure, or internal damage may
occur due to reverse pressurization of the
pilot and main valve components.
Always use pressure gauges to monitor
downstream pressure during startup. Pro­
cedures used in putting this regulator into
operation must be planned accordingly if
the downstream system is pressurized by
another regulator or by a manual bypass.
Note
For proper operation, pilot supply pressure
must exceed control pressure by the mini­
mum amount specified on the actuator
nameplate as minimum differential pres­
sure.
The only adjustment necessary on a Type 1098-EGR or
1098H-EGR regulator is the pressure setting of the pilot
control spring. Turning the adjusting screw clockwise
into the spring case increases the spring compression
and pressure setting. Turning the adjusting screw coun­
terclockwise decreases the spring compression and
pressure setting.
6
Pilot Adjustment
To adjust standard 6350 Series pilots: loosen the lock­
nut (key 11, figure 13, or key 10, figure 14), and turn the
adjusting screw (key 10, figure 13, or key 9, figure 14).
Then tighten the locknut to maintain the adjustment
position. On a standard Type 6352 through 6354M pilot,
a closing cap (key 28, figure 14) must be removed before
adjustment and replaced afterward.
W ARNING
To avoid possible personal injury from a
pressure-loaded Type 61 LD pilot, carefully
vent the spring case before removing the
closing cap. Otherwise, trapped loading
pressure could forcefully eject the freed
closing cap.
To adjust the Type 61 LD pilot: remove the closing cap
(key 5, figure 18) and turn the adjusting screw (key 6,
figure 18). Any adjustments made should set the con­
trolled pressure within the appropriate spring range
shown in the Specifications table.
Startup
1. Slowly open the hand valve in the pilot supply line.
2. Slowly open the upstream block valve, and partially
open the downstream block valve for minimum flow.
3. Slowly open the hand valve in the control line.
4. Adjust the pilot setting if necessary.
5. Completely open the downstream block valve.
6. Slowly close the bypass valve, if any.
Dual-Pilot Boiler Fuel Control Regulator
Installation
1. Perform the Standard Single-Pilot Regulator Instal­
lation section through step 3, making sure that the
regulator is installed in a horizontal pipeline with the
actuator below the main valve as shown in figure 4.
2. Run a 1/2-inch outer diameter or larger pilot supply
line from the upstream pipeline to the 1/2-inch NPT
supply connection in the pipe tee as shown in figure 4.
Do not make the connection in a turbulent area, such as
near a nipple, swage, or elbow. If the maximum pilot
inlet pressure could exceed the pilot rating, install a
separate reducing regulator in the pilot line. Install a
hand valve in the pilot supply line, and provide vent
valves so that pressure can be properly isolated and
relieved from the regulator.

3. Attach a 1/2-inch NPT downstream pressure con­
trol line ten pipe diameters downstream of the regulator
in a straight run of pipe. Connect the other end of the
control line to the 1/4-inch NPT connection in the control
line pipe tee as shown in figure 4. Do not make the tap
near any elbow, swage, or nipple which might cause
turbulence. Install a hand valve in the control line to shut
off the control pressure when the bypass is in use. Also
use the hand valve to dampen out pulsations which may
cause instability or cycling of the regulator.
4. Consult the appropriate instruction manual for in­
stallation of an optional pneumatic or electric remote
control drive unit. For optional remote pneumatic load­
ing of a 6350 Series or Type 61 LD pilot, make the
loading piping connections to the 1/4-inch NPT vent
connection.
Prestart Considerations
Before beginning the startup procedures in this section,
make sure the following conditions are in effect:
• Block valves isolate the regulator.
• Vent valves are closed.
• Hand valves are closed.
Types 1098-EGR & 1098H-EGR
CAUTION
Introduce pilot supply pressure into the
regulator before introducing any down­
stream pressure, or internal damage may
occur due to reverse pressurization of the
pilot and main valve components.
Always use pressure gauges to monitor
downstream pressure during startup. Pro­
cedures used in putting this regulator into
operation must be planned accordingly if
the downstream system is pressurized by
another regulator or by a manual bypass.
Note
For proper operation, pilot supply pressure
must exceed control pressure by the mini­
mum amount specified on the actuator
nameplate as minimum differential pres­
sure.
The only adjustment necessary on a Type 1098-EGR or
1098H-EGR regulator is the pressure setting of the pilot
control spring. Turning the adjusting screw clockwise
7

Types 1098-EGR & 1098H-EGR
into the spring case increases the spring compression
and pressure setting. Turning the adjusting screw coun­
terclockwise decreases the spring compression and
pressure setting.
Pilot Adjustment
To adjust standard 6350 Series pilots: loosen the lock­
nut (key 11, figure 13, or key 10, figure 14), and turn the
adjusting screw (key 10, figure 13, or key 9, figure 14).
Then tighten the locknut to maintain the adjustment
position. On a standard Type 6352 through 6354M pilot,
a closing cap (key 28, figure 14) must be removed before
adjustment and replaced afterward.
W ARNING
To avoid possible personal injury from a
pressure-loaded Type 61 LD pilot, carefully
vent the spring case before removing the
closing cap. Otherwise, trapped loading
pressure could forcefully eject the freed
closing cap.
To adjust the Type 61 LD pilot: remove the closing cap
(key 5, figure 18) and turn the adjusting screw (key 6,
figure 18). Any adjustments made should set the con­
trolled pressure within the appropriate spring range
shown in the Specifications table.
Startup
1. Slowly open the hand valve in the pilot supply line.
2. Slowly open the upstream block valve, and partially
open the downstream block valve for minimum flow.
3. Slowly open the hand valve in the control line and
make sure that the standby pilot is set far enough below
the working pilot so that the standby pilot remains
closed during normal operation. For example, with final
desired settings of 11 inches wc (27 mbar) for the
working pilot and 10 inches wc (25 mbar) for the standby
pilot, begin by reducing the working pilot setting far
enough below 10 inches wc (25 mbar) for the working
pilot to shut off. Then set the standby pilot for an outlet
pressure of 10 inches wc (25 mbar). Finally, set the
working pilot for an outlet pressure of 11 inches wc (27
mbar).
Table 3 shows how close the standby pilot can be set to
the working pilot setting.
4. Completely open the downstream block valve.
5. Slowly close the bypass valve, if any.
8
FISHER
Working Monitor
Installation
1. For both the working monitor regulator and the
working regulator, perform the Standard Single-Pilot
Regulator Installation section through step 6.
2. Connect another downstream pressure control line
and hand valve (figure 5) to the monitoring pilot accord­
ing to the monitoring pilot instruction manual. Attach a
1/2-inch NPT intermediate pressure control line and
hand valve from the intermediate pressure pipeline to
the working monitor regulator. Pipe supply pressure
between the monitoring pilot and the working monitor
regulator according to the monitoring pilot manual.
For two typical monitoring pilots, table 4 gives the
spread between normal distribution pressure and the
minimum pressure at which the working monitor regula­
tor can be set to take over if the working regulator fails
open.
Prestartup Considerations
Before beginning the startup procedures in this section,
make sure the following conditions are in effect:
• Block valves isolate the regulator.
• Vent valves are closed.
• Hand valves are closed.
C A U TIO N
Introduce pilot supply pressure into the
regulator before introducing any down­
stream pressure, or internal damage may
occur due to reverse pressurization of the
pilot and main valve components.
Always use pressure gauges to monitor
downstream pressure during startup. Pro­
cedures used in putting this regulator into
operation must be planned accordingly if
the downstream system is pressurized by
another regulator or by a manual bypass.
Note
For proper operation, pilot supply pressure
must exceed control pressure by the mini­
mum amount specified on the actuator
nameplate as minimum differential pres­
sure.
 Types 1098-EGR & 1098H-EGR

Table 3. Standby Pilots for Boiler Fuel Control Applications

S T A N D B Y P I L O T I N F O R M A T IO N M IN IM U M P R E S S U R E A T
C o n s tru c tio n W H IC H S T A N D B Y P I L O T
S p rin g R a n g e S p rin g P a rt N u m b e r CAN BE SET
3 to 8 inch wc (8 to 20 mbar)<1> 1B6358 27052®
Type Y600P with 5 to 15 inch wc (12 to 38 mbar)<1) 1B6539 27022® 1 inch wc (2.5 mbar)
3/8 inch (9.5 mm) port diameter 11 to 28 inch wc (27 to 68 mbar)<1> 1B5370 270520) under working pilot set point
and 150 psig (10 bar) 1 to 2-1/2 psig (0.069 to 0.17 bar® 1B5371 27022®
maximum allowable pilot inlet 2-1/4 to 4-1/2 psig (0.16 to 0.31 bar)® 0.2 psig (14 mbar)
1B5372 27022®
4-1/2 to 7 psig (0.31 to 0.48 bar)® 1B5373 27052® under working pilot set point
Type 621-107 with 3/8 inch (9.5 mm)
port diameter and 150 psig (10 bar)
maximum allowable pilot inlet for cast iron body 5 to 10 psig (0.34 to 0.69 bar) 1D8923 27022 0.3 psig (21 mbar)
or 750 psig (52 bar) maximum allowable pilot under working pilot set point
inlet for malleable iron or steel body
1. With standard diaphragm plate.
2. With heavy diaphragm plate.

Table 4. Working Monitor Performance

M O N IT O R IN G P I L O T I N F O R M A T IO N
C o n s tru c tio n
Type Y600M with
1/8 inch (3.2 mm) port diameter
and 150 psig (10 bar)
maximum allowable pilot inlet
Type 621-109 with 1/8 inch (3.2 mm)
port diameter and 150 psig (10 bar)
maximum allowable pilot inlet for cast iron body 25 to 60 psig (1.7 to 4.1 bar)
or 750 psig (52 bar) maximum allowable pilot
inlet for malleable iron or steel body
t. With large diaphragm plate.
2. With small diaphragm plate.
S p rin g R a n g e S p rin g P a rt N u m b e r
5 to 15 inch wc (12 to 38 mbar) 1B6539 27022
11 to 28 inch wc (27 to 68 mbar) 1B5370 27052
1 to 2-1/2 psig (0.069 to 0.17 bar) 1B5371 27022
2-1/4 to 4-1/2 psig (0.16 to 0.31 bar) 1B5372 27022
4-1/2 to 7 psig (0.31 to 0.48 bar) 1B5373 27052
5 to 15 psig (0.34 to 1.0 bar) 1D8923 27022
10 to 25 psig (1.0 to 1.7 bar) 1D7515 27022
20 to 35 psig (1.4 to 2.4 bar) 1D6659 27022
1D7555 27142
40 to 80 psig (2.8 to 5.5 bar) 1E5436 27142
80 to 150 psig (5.5 to 10 bar)
1P9013 271420)
130 to 200 psig (9.0 to 14 bar) 1P9013 27142®
M IN IM U M P R E S S U R E A T
W H IC H W O R K IN G M O N IT O R
R EG U LA TO R C AN BE S E T
3 inch wc (7 mbar)
over normal distribution pressure
0.5 psig (0.034 bar)
over normal distribution pressure
30 psig (0.21 bar)
over normal distribution pressure
5.0 psig (0.34 bar)
over normal distribution pressure

Figure 5. Typical Working Monitor Installation

9
Types 1098-EGR & 1098H-EGR
The only adjustment necessary on a Type 1098-EGR or
1098H-EGR regulator is the pressure setting of the pilot
control spring. Turning the adjusting screw clockwise
into the spring case increases the spring compression
and pressure setting. Turning the adjusting screw coun­
terclockwise decreases the spring compression and
pressure setting.
Pilot Adjustment
To adjust all standard 6350 Series pilots: loosen the
locknut (key 11, figure 13, or key 10, figure 14), and turn
the adjusting screw (key 10, figure 13, or key 9, figure
14). Then tighten the locknut to maintain the adjustment
position. On a standard Type 6352 through 6354M pilot,
a closing cap (key 28, figure 14) must be removed before
adjustment and replaced afterward.
W ARNING
To avoid possible personal injury from a
pressure-loaded Type 61 LD pilot, carefully
vent the spring case before removing the
closing cap. Otherwise, trapped loading
pressure could forcefully eject the freed
closing cap.
To adjust the Type 61 LD pilot: remove the closing cap
(key 5, figure 18) and turn the adjusting screw (key 6,
figure 18). Any adjustments made should set the con­
trolled pressure within the appropriate spring range
shown in the Specifications table.
Startup
On a working monitor installation (figure 5), be sure that
the second-stage working regulator is set to operate at
a pressure lower than the Type 1098-EGR or 1098H-
EGR working monitor regulator. To do this, increase the
setting of the monitoring pilot until the working pilot is in
control of the intermediate pressure and the second-
stage working regulator is in control of the downstream
pressure. If this is not done, the monitorfng pilot tries to
take control of the downstream pressure.
1. Slowly open the upstream block valve and the hand
valves in both pilot supply lines. This energizes both
pilots so that their setpoints can be adjusted. Partially
open the downstream block valve for minimum flow.
2. To enable intermediate pressure adjustment with
the working monitor regulator, slowly open the hand
valve in the intermediate pressure control line.
3. To enable downstream pressure adjustment with
the second-stage working regulator, slowly open the
hand valve in the control line to this regulator.
10
4. Adjust the setting of the monitoring pilot to establish
the desired emergency downstream pressure, which is
to be maintained in the event of open failure of the
second-stage working regulator. The emergency down­
stream pressure should exceed the desired down­
stream pressure by at least the amount listed in table 4.
The steps followed to set the monitoring pilot may vary
with each piping situation; however, the basic method
remains the same. The following substeps a and b may
be used as examples for setting the monitoring pilot:
a. Increase the outlet pressure setting of the sec­
ond-stage working regulator until the monitoring pilot
takes control of the downstream pressure. Adjust the
monitoring pilot setting until the desired emergency
downstream pressure is achieved. Then readjust the
second-stage working regulator to establish the desired
downstream pressure.
b. Install special piping (not shown in figure 5) so
that the monitoring pilot senses the intermediate pres­
sure. The intermediate pressure then appears to the
monitoring pilot as if it were increased downstream
pressure, and the monitoring pilot controls and reduces
the intermediate pressure. Adjust the monitoring pilot
setting until the desired emergency downstream pres­
sure is achieved at the intermediate pressure stage.
Then slowly close the special piping, and open up the
monitoring downstream control line for normal service.
5. Slowly open the downstream block valve.
6. Slowly close the bypass valve, if any.
Wide-Open Monitor
Installation
1. For both the wide-open monitoring regulator and
the working regulator, perform the Standard Single-Pilot
Regulator Installation section through step 6.
2. Connect the control line of a wide-open monitoring
regulator (figure 6) to downstream piping near the work­
ing regulator control line connection. During normal
operation the wide-open monitoring regulator stands
wide open with the pressure reduction being taken
across the working regulator. Only in case of working
regulator failure does the wide-open monitoring regula­
tor take control at its slightly higher setting.
Prestartup Considerations
Before beginning the startup procedures in this section,
make sure the following conditions are in effect:
 Types 1098-EGR & 1098H-EGR

FL E X IB LE W ID E -O P E N M O N ITO R A R R A N G E M E N T T H A T P E R M ITS M IN IM U M P IPIN G W ID E -O P E N M O N ITO R A R R A N G E M E N T T H A T R EQ U IR E S

W ID E -O P E N M O N IT O R T O BE E ITH E R U P S TR E A M O R D O W N S T R E A M W ID E -O P E N M O N ITO R A L W A Y S T O BE U P S TR E A M

Figure 6. Typical Wide-Open Monitor Installations

• Block valves isolate the regulator. Pilot Adjustment

• Vent valves are closed. To adjust all standard 6350 Series pilots: loosen the
locknut (key 11, figure 13, or key 10, figure 14), and turn
• Hand valves are closed. the adjusting screw (key 10, figure 13, or key 9, figure
14). Then tighten the locknut to maintain the adjustment
position. On a standard Type 6352 through 6354M pilot,
a closing cap (key 28, figure 14) must be removed before
adjustment and replaced afterward.
CAUTION
Introduce pilot supply pressure into the W ARNING
regulator before introducing any down­
stream pressure, or internal damage may To avoid possible personal injury from a
occur due to reverse pressurization of the pressure-loaded Type 61 LD pilot, carefully
pilot and main valve components. vent the spring case before removing the
closing cap. Otherwise, trapped loading
Always use pressure gauges to monitor pressure could forcefully eject the freed
downstream pressure during startup. Pro­ closing cap.
cedures used in putting this regulator into
operation must be planned accordingly if To adjust the Type 61 LD pilot: remove the closing cap
the downstream system is pressurized by (key 5, figure 18) and turn the adjusting screw (key 6,
another regulator or by a manual bypass. figure 18). Any adjustments made should set the con­
trolled pressure within the appropriate .spring range
shown in the Specifications table.

Note Startup
For proper operation, pilot supply pressure Repeat this procedure in turn for each regulator in the
installation.
must exceed control pressure by the mini­
mum amount specified on the actuator
nameplate as minimum differential pres­ 1. Slowly open the hand valve in the pilot supply line.
sure.
2. Slowly open the upstream block valve, and partially
open the downstream block valve for minimum flow.

3. Slowly open the hand valve in the control line and

The only adjustment necessary on a Type 1098-EGR c
1098H-EGR regulator is the pressure setting of the pile
control spring. Turning the adjusting screw clockwisi
into the spring case increases the spring compressioi
and pressure setting. Turning the adjusting screw coun
terclockwise decreases the spring compression am
pressure setting.
adjust the pilot setting if necessary. Set the monitoring
regulator at a slightly higher control pressure than the
working regulator.
4. Completely open the downstream block valve.
5. Slowly close the bypass valve, if any.

11

Types 1098-EGR & 1098H-EGR
Shutdown
Installation arrangements 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 pilot or main valve. The following
steps apply to the typical installation as indicated.
Single-Pilot, Dual-Pilot Regulator or
Wide-Open Monitor
As well as applying to a single-pilot regulator (figure 3),
the steps in this procedure also are valid for a dual-pilot
regulator (figure 4) or a wide-open monitoring installa­
tion (figure 6) and just need to be repeated for each
regulator in such an installation.
1. Slowly close the downstream block valve. If the
control line is downstream of the block valve, also close
the hand valve in the control line.
2. Slowly close the upstream block valve and the hand
valve in the pilot supply line.
3. Slowly open the vent valve in the downstream pipe­
line. If the control line is downstream of the block valve,
also open the vent valve in the control line. Permit all
pressure to bleed out.
4. Slowly open the vent valve in the upstream pipeline.
Permit all pressure to bleed out of both the piping and
the pilot.
Working Monitor
1. Slowly close the downstream block valve and the
hand valve in the downstream pressure control line.
2. Slowly close the upstream block valve and the hand
valves in both pilot supply lines.
3. Slowly open all vent valves and permit ail pressures
to bleed out of the piping and regulators.
Principle of Operation
The pilot-operated Type 1098-EGR and Type 1098H-
EGR regulators both use inlet pressure as the operating
medium, which is reduced through pilot operation to
load the actuator diaphragm. Outlet or downstream
pressure opposes loading pressure in the actuator and
also opposes the pilot control spring. The operation of
each regulator is the same, and the Type 1098-EGR
regulator operation schematic is shown in figure 7.
12
N
FISHER
Vi
In operation, assume that outlet pressure is below the
pilot control setting. Control spring force on the pilot
diaphragm thus opens the pilot valve plug (Type 6351
pilot) or relay orifice (Type 61 LD pilot), providing addi­
tional loading pressure to the actuator diaphragm. This
diaphragm loading pressure opens the main valve plug,
supplying the required gas to the downstream system.
When downstream demand has been satisfied, outlet
pressure tends to increase, acting on the pilot and
actuator diaphragms. This pressure exceeds the pilot
control spring setting, moving the pilot diaphragm away
and letting the valve plug spring (Type 6351 or Type
61 LD pilots) or bellows (Type 6352 through 6354M pilot)
close the pilot valve plug (unbalanced in the Type 6351
or Type 61 LD pilots but balanced in the Type 6352
through 6354M pilot). Excess loading pressure on the
actuator diaphragm escapes downstream through the
bleed hole (Type 6351 pilot), bleed orifice (Type 61 LD
pilot), or restriction (Type 6352 through 6354M pilot).
Reduced actuator loading pressure permits the main
valve to close. The combination of main valve spring
force and valve plug unbalance provides positive shutoff
of the valve plug against the port and upper seals.
To protect the Type 1098 or 1098H actuator diaphragm
from excessive differential pressure, all 6300 series and
61 LD pilots have a relief valve that allows loading pres­
sure to bleed downstream at approximately 25 psi (1.7
bar) differential across the actuator diaphragm.
A dual-pilot regulator (figure 7) also operates similarly to
a single-pilot regulator. In addition, the large ports of the
standby pilot open to quickly supply additional loading
pressure to the Type 1098 diaphragm. This extra load­
ing pressure strokes the main valve quickly in order to
satisfy rapid load changes in the boiler system.
A working monitor system (figure 5) reduces pressure
and throttles while the working monitor regulator is in
operation. If the working regulator fails open, the work­
ing monitor regulator takes over the entire pressure
reduction function. The working monitor concept allows
observation of the performance of the first-stage regula­
tor at all times.
As long as the second-stage working regulator main­
tains normal downstream pressure, the monitoring pilot
stays wide open. This permits inlet pressure to go
straight through to the working monitor pilot for reduc­
tion to actuator loading pressure.
Downstream pressure is piped back to the monitoring
pilot. As long as the downstream pressure is less than
the monitoring pilot setting, the working pilot controls
the actuator to maintain intermediate pressure. If the
second-stage working regulator fails open, the down­
stream pressure increases to the setting of the monitor­
ing pilot (slightly higher than the original downstream
pressure). The monitoring pilot takes control and the

16A4297-A
17A9161-A
B1617
Figure 7. Principle of Operation Schematics
working monitor pilot throttles down the loading pres­
sure to the working monitor regulator actuator. This
actuator will move the valve plug and control the down­
stream pressure at the emergency level. Thus, down­
stream equipment is protected against a major
overpressure condition without disrupting service or
venting gas to the atmosphere.
Maintenance
Regulator parts are subject to normal wear and must be
inspected and replaced as necessary. The frequency of
inspection and replacement of parts depends upon the
severity of service conditions or the requirements of
local, state, and federal regulations. Due to the care
Fisher takes in meeting all manufacturing requirements
(heat treating, dimensional tolerances, etc.), use only
replacement parts manufactured or furnished by Fisher.
Types 1098-EGR & 1098H-EGR
jSSZ TO BURNER
> PILOT LIGHT
DUAL PILOT BOILER FUEL INSTALLATION
The stem O-rings on the Type 1098 or 1098H actuator
can be lubricated annually, using the grease fitting (key
28, figure 20). Stem O-rings can be checked for damage
during normal operation by line pressure leakage or
unexpected grease extrusion from the actuator vent
(key 27, figure 20). All O-rings, gaskets, and seals
should be lubricated with a good grade of general-
purpose grease and installed gently rather than forced
into position. Be certain that the nameplates are updat­
ed to accurately indicate any field changes in equip­
ment, materials, service conditions, or pressure
settings.
W A R N IN G
To avoid personal injury resulting from sud­
den release of pressure, isolate the regula­
tor from all pressure and cautiously release
trapped pressure from the regulator before
attempting disassembly.
13
 FISHER 0
Types 1098-EGR & 1098H-EGR

BODY FLANGE
CAGE SCREWS INTO
BODY FLANGE

SEAT RING
SCREWS INTO CAGE

Figure 8. Trim Package Removal

D esign EGR M ain V alve

Replacing Quick-Change Trim Package

Perform this procedure if the entire trim package (figure
8) is replaced. Key numbers for both the complete main
valve and its trim package are referenced in figure 11.
Some replacement trim package assembly numbers are
listed in a table in the parts list.

Note
Figure 9 . Exploded View o f Full-Capacity
Trim Package Assembly
All disassembly, trim change, and reas­
sembly steps in this section may be per­
formed with the regulator in the main line
and without disconnecting pilot supply or
control lines. 4. Coat the cage seating surfaces of the valve body
web and the body flange seating surfaces of the valve
body neck with a good grade of general-purpose
1. Remove the cap screws (key 3) with a cast iron grease. Install the trim package, and secure it evenly
body, or remove the stud bolt nuts (key 29, not shown) with the cap screws or stud bolt nuts. No particular trim
with a steel body. Pry the body flange (key 2) loose from package orientation in the body is required.
the valve body (key 1), and lift out the trim package.

2. Perform any required inspection, cleaning, or main­

tenance on the exposed surfaces of the valve body or
trim package. Replace the gasket (key 4) or cage O-ring
(key 17) as necessary.
3. On a pre-built replacement trim package, check
indicator zeroing by unscrewing the indicator protector
(key 19) and seeing if the flange of the indicator nut (key
22) lines up evenly with the bottom marking on the
indicator scale (key 18). If not, remove the indicator
scale and separate the indicator nut and hex nut (key 8).
Hold the indicator scale against the indicator fitting (key
5) with the scale base resting against the shoulder of the
fitting, and turn the indicator nut until its flange is aligned
with the bottom scale marking. Then lock both nuts
against each other, and install the indicator scale and
protector.
Replacing Trim Parts
Perform this procedure if inspecting, cleaning, or replac­
ing individual parts in a trim package. Key numbers are
referenced in figure 11. An exploded view of a standard
full-capacity trim package only is shown in figure 9.
Note
Access to the spring (key 9), flange O-ring
(key 21), travel indicator parts, or optional
travel stop (key 32) in step 1 can be gained
without removing the body flange (key 2).

14
 Types 1098-EGR & 1098H-EGR

1. Remove the indicator fitting (key 5) and attached

parts. Proceed to step 5 if only maintenance on the
fitting or attached parts is performed.

2. Remove the cap screws (key 3) with a cast iron

body, or remove the stud bolt nuts (key 29, not shown)
with a steel body, and pry the body flange loose from the
valve body (key 1).

3. Use the valve body as a holding fixture if desired.

Flip the body flange over, and anchor it on the valve
body as shown in figure 10, removing the pipe plug (key
31) first if necessary.

4. To gain access to the port seal (key 12), upper seal

(key 15), or valve plug parts, unscrew the seat ring (key
13) from the cage (key 11) and the cage from the body
flange. For leverage, a wrench handle or similar tool may
be inserted into the seat ring slots (figure 10) and a strap
wrench may be wrapped around a standard or a Whis­
per Trim® cage, or a soft bar may be inserted through
the windows of a standard cage. To remove the piston
ring (key 14) and/or plug O-ring (key 20), remove the
valve plug (key 16) from the body flange, insert a screw­
driver into the precut foldover area of the piston ring,
and unfold the piston ring. Proceed to step 6 if no further
maintenance is necessary.
5. To replace the body flange or gain access to the
spring, indicator stem (key 10), stem O-ring (key 7),
spring seat (key 28), E-ring (key 23), or optional travel
stop, remove the indicator protector (key 19) and indica­
tor scale (key 18). Since some compression is left in the
spring, carefully remove the flanged nut (key 22) and hex
nut (key 8). A screwdriver may be inserted through the
press-fit bushing (key 6) to remove the stem O-ring
without removing the bushing. If necessary, unscrew
the travel stop (if used), and unclip the E-ring from the
indicator stem.
6 . Replace and lubricate parts such as the gasket (key
4) and cage O-ring (key 17) as necessary, making sure
that if the port and upper seals were removed they are
installed in their retaining slots with the grooved sides
facing out. Also lubricate any other surfaces as neces­
sary for ease of installation. No further main valve
maintenance is necessary if just the indicator fitting and
attached parts were removed.
7. Install the plug O-ring (key 20) and piston ring (key
14) onto the valve plug. Insert the valve plug into the
body flange, install the cage plus upper seal and O-ring
into the body flange, and then install the seat ring plus
port seal into the cage. Use the valve body as a holding
fixture during this step as shown in figure 10, and insert
a wrench handle or similar tool into the seat ring slots for
leverage when tightening the seat ring and cage.
8 . Remove the upside-down body flange if it was
anchored on the body. Coat the cage seating surfaces
of the valve body web and the body flange seating
W2772-1
Figure 10. Seat Ring/Cage Removal or Installation
Using Body as Holding Fixture
surfaces of the valve body neck with a good grade of
general-purpose grease. Install the body flange on the
body, and secure it evenly with the cap screws or stud
bolt nuts. Except on the 1-inch body, which does not use
it, the pipe plug (key 31) must be installed in the side
tapping of the flange for proper operation.
9. Make sure that the flange and stem O-rings and the
bushings are installed in the indicator fitting. Orient the
spring seat as shown in figure 11, and attach it with the
E-ring to the slottedd end of the indicator stem. Install a
travel stop (if it is used) on the spring seat, and then
install the spring.
10. Being careful not to cut the stem O-ring with the
stem threads, install the indicator fitting down over the
indicator stem until resting on the spring. Install the hex
nut and then the flanged indicator nut on the indicator
stem, pushing on the fitting if necessary to provide
sufficient stem thread exposure. To maintain clearance
for indicator part installation, draw up the spring seat by
turning the hex nut down on the stem until the threads
bottom.
11. Install the indicator fitting with attached parts into
the body flange. Back the hex nut off until the spring
completely closes the valve plug against the port and
upper seals, as indicated by stem threads showing
between this nut and the fitting. Hold the indicator scale
against the fitting with the scale base resting against the
shoulder of the fitting, and turn the indicator nut until its
flange is aligned with the bottom scale marking. Then
lock both nuts against each other, and install the indica­
tor scale and protector.
P590 Series Filter
Perform this procedure to clean or replace filter parts in
a standard Type P593-1 or P594-1 filter assembly. Re­
move the following as shown in figure 12: filter body (key
Types 1098-EGR & 1098H-EGR
1), machine screw (key 4), gasket (key 7), two flat
washers (key 5), and filter element (key 2).
Upon reassembly, one of the flat washers must go
between the filter element and filter head (key 3) and the
other must go between the filter element and gasket.
Use a good grade of pipe thread sealant on the filter
head pipe threads as shown by L.S. in figure 12.
Type 6351 Pilot
Perform this procedure if changing the control spring for
one of a different range, or if inspecting, cleaning, or
replacing any other pilot parts. Pilot key numbers are
referenced in figure 13 and mounting key numbers in
figure 15, 16, or 17.
Note
The body assembly (key 1) may remain on
the pipe nipple (key 23, figure 15, or key 39,
figure 16) unless the entire pilot is replaced.
The optional spring case (key 2) for a Type
661 electric remote control drive unit may
remain installed during maintenance.
1. To gain access to the diaphragm assembly (key 7),
control spring (key 9), or spring seat (key 8), loosen the
locknut (key 11, not used with Type 661 mounting), and
turn the adjustment screw (key 10) out until compres­
sion is removed from the spring. Remove the machine
screws (key 12), and separate the body assembly from
the spring case.
2. Inspect the removed parts, and replace as neces­
sary. Make sure the registration and bleed holes in the
pilot body are free from debris. After assembly, make
sure of the proper control spring setting according to the
Startup section, and re-mark the spring case if neces­
sary.
3. To replace the valve plug (key 4), remove the body
plug (key 3) and body plug gasket (key 23). Be careful to
keep the valve plug spring (key 6) and valve plug spring
seat (key 5) from falling out and possibly getting lost
while removing the valve plug. Inspect the removed
parts, and replace as necessary. Make sure the valve
plug seating surfaces are free from debris.
Type 6352 Through 6354M Pilots
Perform this procedure if changing the control spring for
one of a different range, or if inspecting, cleaning, or
replacing any other pilot parts. Pilot part key numbers
are referenced in figure 14. Mounting key numbers are
referenced in figure 15 for single-pilot constructions and
in figure 16 or 17 for dual-pilot constructions.
16
FISHER®
_____________
Note
The body (key 1) may remain on the pipe
nipple (key 23, figure 15 or key 39, figure
16) unless the entire pilot is replaced.
1. To gain access to the diaphragm assembly (key 5),
diaphragm limiter (key 23) if used, control spring (key 6),
restriction (key 22), stem guide (key 8), or spring seat
(key 7), remove the closing cap (key 11), loosen the
locknut (key 10), and turn the adjusting screw (key 9)
counterclockwise until compression is removed from
the spring. Remove the machine screws (key 14), and
separate the body from the spring case (key 2).
2. Inspect the removed parts, and replace as neces­
sary. Make sure the restriction and the registration hole
in the body are free from debris. After assembly, make
sure of the proper control spring setting according to the
Startup section, and re-mark the spring case if neces­
sary.
3. To replace the valve plug (key 4) or bellows O-ring
(key 17), remove the body plug (key 3) and body plug
gasket (key 12). Be careful to keep the bellows assem­
bly (key 16) from falling out and possibly getting lost
while removing the valve plug. Inspect the removed
parts, and replace as necessary. Make sure the valve
plug seating surfaces are free from debris.
Type 61 LD Pilot and Type 1806 Relief
Valve
Perform this procedure if changing the control spring for
one of a different range, or if inspecting, cleaning, or
replacing relief valve or any other pilot parts. Pilot part
key numbers are referenced in figure 18 and mounting
part and relief valve key numbers in figure 19.
1. Remove the pilot from the pipe nipple (key 14)
unless just the control spring is to be changed.
2. To gain access to the control spring or other inter­
nal parts, remove the closing cap assembly (key 5) and
relieve control spring (key 7) compression by turning the
adjusting screw (key 6) counterclockwise. Change the
control spring and install the adjusting screw and clos­
ing cap assembly if no other maintenance will be per­
formed. Make sure of the proper control spring setting
according to the Installation and Startup section, and
restamp the nameplate if necessary.
3. For any other internal maintenance, relieve control
spring compression according to step 2. Then remove
the cap screw (key 20) and separate the pilot into three
sections; spring case (key 1), body (key 2), and dia­
phragm case (key 3).

4. To inspect the two diaphragm (keys 14 and 15)
thoroughly, remove the diaphragm nut (key 11), hex nut
(key 19), and the upper and lower diaphragm plates (key
16 and 17). The projecting prong in the body may be
used as the restraining member to keep the yoke from
turning while removing the nuts. Also inspect the O-ring
(key 12), and replace any parts as necessary.
5. Take the yoke (key 4) and attached parts out of the
body to examine the disk holder assembly (key 9).
Remove the relay orifice (key 8) to check for clogging
and replace if necessary.
6. To replace the disk holder assembly, first unscrew
the bleed orifice (key 10). Remove it and the associated
parts. Then unscrew the disk holder assembly from the
bleed valve (key 26) to gain access to the relay spring
(key 13). Clean or replace any parts as necessary before
reassembling.
7. Upon reassembly, pay particular attention to the
following assembly suggestions.
a. Before replacing the diaphragm case or spring
case, be sure the yoke assembly is positioned so that it
will not bind or rub on the prong in the relay body.
b. Avoid wrinking the diaphragms when replacing
the diaphragm case and spring case.
c. Replace the diaphragm case, carefully working
the upper diaphragm (key 14) into the recess in the
diaphragm case. If the diaphragm case rocks with re­
spect to the pilot body, the diaphragm is probably wrin­
kled.
d. Replace the spring case, using care to smooth
the lower diaphragm (key 15) evenly into the recess in
the pilot body.
e. Install the eight cap screws, tightening them 5. Lubricate both stem O-rings (key 6) with grease,
down evenly in a crisscross pattern to avoid crushing
the diaphragm. Recommended final torque on these cap
screws in 10 to 12 foot pounds (14 to 16 N.m).
8. After assembly, make sure of the proper control
spring setting according to the Installation and Startup
section, and restamp the nameplate (key 27) if
necessary.
9. To gain access to the Type 1806 relief valve (key
17), disconnect the relief tubing at the connector fitting valve body.
(key 21) and unscrew the relief valve. Make sure the
spring closes the ball, or replace the relief valve if
necessary. Install the relief valve back in the pipe tee
(key 16) and reconnect the relief tubing (key 18) and
connector fitting.
Types 1098-EGR & 1098H-EGR
Type 1098 and 1098H Actuator and Pilot
Mounting Parts
Perform this procedure if changing the actuator or in­
specting, cleaning, or replacing actuator and/or pilot
mounting parts. Actuator part key numbers are refer­
enced in figure 20, and mounting part key numbers in
figure 15, 16, or 17 unless otherwise indicated.
1. The actuator and pilot(s) may be removed and re­
placed as a unit by disconnecting the control line and
pilot supply line.
2. Access to all internal parts except the stem O-rings
(key 6) may be gained without removing the bonnet (key
3) or upper diaphragm case (key 2) from the main valve
or the pilot(s) from the bonnet pipe nipple (key 23, figure
15, or keys 37 and 39, figure 16). Disconnect the loading
tubing (key 24, figure 15, 16, or 17) from the actuator
elbow fitting (key 25, figure 15, or key 41, figure 16), and
with a Type 61 LD pilot also disconnect the relief tubing
(key 18, figure 19) from the fitting tee.
3. Remove the cap screws (key 10), nuts (key 11),
lower diaphragm case (key 1), diaphragm (key 7), and
diaphragm plate (key 8). To separate the stem (key 12)
from the diaphragm plate (key 8), remove the stem cap
screw (key 9).
4. To remove the Type 1098 case O-ring (key 5),
unscrew the four case cap screws (key 4), remove the
upper diaphragm case (key 2), and remove the case
O-ring.
To remove the Type 1098 and Type 1098H stem
O-rings (key 6), remove the pilot(s) and pipe nipple(s) if
necessary. Unscrew either the Type 1098 bonnet (key 3)
or the Type 1098H upper diaphragm case (key 2), and
remove the O-rings.
and install them in either the Type 1098 bonnet (key 3) or
in the Type 1098H upper diaphragm case (key 2).
For the Type 1098H actuator, thread the upper dia­
phragm casing into the main valve body.
For the Type 1098 actuator, lubricate the case O-ring
(key 5), and install it in the bonnet (key 3). Line up the
holes in the upper diaphragm casing and the bonnet;
insert and tighten the four case cap screws to secure
the parts together. Thread the bonnet into the main
6. Secure the diaphragm plate to the stem with the
stem cap screw (key 9). Lay the entire diaphragm,
diaphragm plate, and stem assembly into the lower
diaphragm case so the diaphragm convolution laps up
17
Types 1098-EGR & 1098H-EGR

over the diaphragm plate according to figure 20. Then
install the stem slowly up into the bonnet to prevent
stem or O-ring damage, and secure the lower dia­
phragm case to the upper diaphragm case with the cap
screws and nuts. Tighten the cap screws and nuts
evenly in a crisscross pattern to avoid crushing the
diaphragm.
7. Grease the stem O-rings through the grease fitting
(key 28) until excess grease starts coming out the vent
(key 27).
8. Install the pipe nipple(s) and pilot(s) if they were
removed during maintenance. Connect the actuator
loading tubing if it was disconnected.
Parts Ordering
Each Type 1098-EGR or 1098H-EGR regulator is as­
signed a serial number or F.S. number which can be
found on the nameplates (figure 2). Refer to this number
when contacting your Fisher sales office or sales repre­
sentative for assistance, or when ordering replacement
parts.
When ordering a replacement part, be sure to include
the complete 11-character part number from the follow­
ing parts list. Some commonly used trim packages can
be ordered according to the 11-character assembly
number given in the parts kits listed in the parts list.

P a rt N u m b e r Key D e s c rip tio n P a rt N u m b e r

Parts List Key D e s c rip tio n

125 Psi (8.6 bar) spring color blue 1 Valve Body (Continued)
Cast Iron Body Flange Class 150 RF
1-inch 25A3170 X032 1 inch 34A6355 X012
N o te 2-inch 25A3170 X082 1 inch (NACE) 34A6355 X042
3-inch 25A3170 X142 2 inch 34A6765 X012
E x c e p t w h e r e in d ic a te d , s i z e s 4-inch 25A3170 X192 2 inch (NACE) 34A6765 X022
s h o w n a r e v a lv e b o d y s iz e s . 6-inch 25A3170 X282 3 inch 34A6773 X012
Steel Body Flange 3 inch (NACE) 34A6773 X032
1-inch 25A3170 X432 4 inch 34A6776 X012
2-inch 25A3170 X382 4 inch (NACE) 34A6776 X032
3-inch 25A3170 X462 6 inch 34A6998 X012
4-inch 25A3170 X492 6 inch (NACE) 34A6998 X032
Design EGR Main Valve 6-inch 25A3170 X342 8 x 6 inch 38A4214 X012
(figure 11) 400 Psi (28 bar) spring color red 8 x 6 inch (NACE) 38A4214 X022
Cast Iron Body Flange Class 300 RF
Key D e s c rip tio n P a rt N u m b e r 1-inch 25A3170 X052 1 inch 34A6754 X012
2-inch 25A3170 X112 2 inch 34A6766 X012
Parts kit (included are: gasket, key 4; 3-inch 25A3170 X172 2 inch (NACE) 34A6766 X032
stem O-ring, key 7; port seal, key 12; 4-inch 25A3170 X242 3 inch 34A6774 X012
piston ring, key 14; upper seal, 6-inch 25A3170 X312 3 inch (NACE) 34A6774 X022
key 15; cage O-ring, key 17; plug Steel Body Flange 4 inch 34A6777 X012
O-ring, key 20; and indicator 1-inch 25A3170 X442 4 inch (NACE) 34A6777 X032
fitting O-ring, key 21) 2-inch 25A3170 X332 6 inch 34A6993 X012
2-inch R63EG X00022 3-inch 25A3170 X472 6 inch (NACE) 34A6993 X022
3-inch R63EG X00032 4-inch 25A3170 X502 8 x 6 inch 38A5825 X012
4-inch R63EG X00042 6-inch 25A3170 X522 8 x 6 inch (NACE) 38A5825 X032
6-inch R63EG X00062 Class 600 RF
1 inch 34A6755 X012
2 inch 34A6767 X012
Parts kit, Quick Change Trim Assembly 1 Valve Body 2 inch (NACE) 34A6767 X032
(included are: body flange, key 2; Cast Iron 3 inch 34A6775 X012
linear cage, key 11; spring, key 9; NPT screwed 3 inch (NACE) 34A6775 X022
valve plug, key 16; seat ring, 1 inch 34A6351 X012 4 inch 34A6778 X012
key 13; travel indicator, key 10; 2 inch 34A6763 X012 4 inch (NACE) 34A6778 X022
and standard elastomers) Class 125B FF 6 inch 34A6997 X012
60 Psi (4.1 bar) spring color green 1 inch 34A6353 X012 6 inch (NACE) 34A6997 X022
Cast Iron Body Flange 2 inch 34A5694 X012 8 x 6 inch 39A7068 X012
1-inch 25A3170 X012 3 inch 34A5695 X012 8 x 6 inch (NACE) 39A7068 X022
2-inch 25A3170 X102 4 inch 34A5703 X012 Socket weld
3-inch 25A3170 X152 6 & 8 x 6 inch 34A6999 X012 1 inch 36A3941 X012
4-inch 25A3170 X222 Class 250B RF 2 inch 36A3945 X012
6-inch 25A3170 X272 1 inch 34A6354 X012 Schedule 40 butt weld
Steel Body Flange 2 inch 34A5672 X012 1 inch 36A3942 X012
1-inch 25A3170 X422 3 inch 34A5657 X012 2 inch _ 36A3944 X012
2-inch 25A3170 X452 4 inch 34A5642 X012 3 inch ' 36A3947 X012
3-inch 25A3170 X372 6 & 8 x 6 inch 34A7000 X012 4 inch 36A3949 X012
4-inch 25A3170 X482 WCB steel, heat-treated 6 & 8 x 6 inch 36A3952 X012
6-inch 25A3170 X512 NPT screwed Schedule 80 butt weld
1 inch 34A6352 X012 1 inch 36A3943 X012
2 inch 34A6764 X012 2 inch 36A3946 X012
2 inch (NACE)<1> 34A6764 X022 3 inch 36A3948 X012
4 inch 36A3950 X012
6 & 8 x 6 inch 36A3951 X012
18 1. National Association of Corrosion Engineers (NACE) standard MR-01-75.
 Types 1098-EGR & 1098H-EGR

Q U IC K -C H A N G E T R IM P A C K A G E A S S E M B L Y

D E T A IL O F O P T IO N A L R E S T R IC T E D -
C A P A C IT Y C O N S T R U C T IO N

Figure 11. Design EGR Main Valve

Key D e s c rip tio n P a rt N u m b e r Key D e s c rip tio n P a rt N u m b e r Key D e s c rip tio n P a rt N u m b e r

Body Flange Cap Screw, zn pi steel (use w/cast 4*<2) Gasket, composition
Cast iron, ENC<2> iron body)
1 inch 1 inch 14A6785.X012
24A6761 X012 1 inch (4 req'd) 1R2811 24052
2 inch 2 inch 14A5685 X012
25A3168 X012 2 inch (8 req’d) 1A4533 24052
3 inch 3 inch 14A5665 X012
24A9034 X012 3 inch (8 req’d) 1A4541 24052
4 inch 4 inch 14A5650 X012
25A2309 X012 4 inch (8 req’d) 1A4857 24052
6 & 8 x 6 inch 6 & 8 x 6 inch 14A6984 X012
34A8172 X012 6 & 8 x 6 inch (12 req’d) 1U5131 24052 5(2) Indicator Fitting, pi steel
WCB steel, ENC, heat-treated Stud Bolt, steel (use w/steel body)
1 inch 1 inch 14A6758 X012
24A6779 X012 (not shown)
1 inch (NACE) 1 inch (NACE) 14A6758 X022
24A6779 X032 1 inch (4 req’d) 1R2848 31012
2 inch 2, 3, & 4 inch 14A9689 X012
25A2254 X012 2 inch (8 req’d) 1K2429 31012
2 inch (NACE) 2, 3, & 4 inch (NACE) 14A9689 X042
25A2254 X022 3 inch (8 req’d) 1A3781 31012
3 inch 6 & 8 x 6 inch 24A8183 X012
25A2300 X012 4 inch (8 req’d) 1R3690 31012
3 inch (NACE) 6 & 8 x 6 inch (NACE) 24A8183 X022
25A2300 X022 6 & 8 x 6 inch (12 req’d) 1A3656 31012 6(2) Bushing
4 inch 24A9032 X012
4 inch (NACE) 416 stainless steel 14A5677 X012
24A9032 X022
6 & 8 x 6 inch 410 stainless steel
34A7152 X012
(NACE) 14A5677 X022
6 & 8 x 6 inch (NACE) 34A7152 X022
‘ Recommended spare part.
2. Part included in trim package assembly which can be ordered according to the carts
kit trim package.
19
 F IS H E R Y
Types 1098-EGR & 1098H-EGR lr J

Key Description Part Number Key Description Part Number Key Description Part Number

7* Stem O-Ring 11 Cage (Continued) 13*® Seat Ring (Continued)

Nitrile® 1D6875 06992 WCB steel, ENC, heat-treated 8 x 6 inch 7-3/16 inch (183 mm)
Fluoroelastomer 1N4304 06382 1 inch 24A6783 X022 port (NACE) 38A4216 X022
1 inch (NACE) 24A6783 X032 14*® Piston Ring
8(2) Hex Nut, pi steel 1A6622 28992 2 inch 24A5669 X022 1 inch, TFE (clear) 14A6786 X012
9(2) Spring, steel 2 inch (NACE) 24A5669 X032 2 inch, TFE (clear) 14A5675 X012
20 psi (1.4 bar) maximum drop 3 inch 24A5654 X022 3 inch, TFE (clear) 14A5660 X012
yellow 3 inch (NACE) 24A5654 X042 4 inch, TFE (clear) 14A5645 X012
2 inch 14A6768 X012 4 inch 24A5639 X022 6 & 8 x 6 inch, glass-filled TFE
3 inch 14A6771 X012 4 inch (NACE) 24A5639 X032 (yellow) 14A6985 X022
4 inch 14A6770 X012 6 inch 24A6990 X022 15* Upper Seal
6 & 8 x 6 inch 15A2253 X012 6 & 8 x 6 inch Nitrile® (standard)
60 psi (4.1 bar) maximum drop (NACE) 24A6990 X032 1 inch 14A6789 X012
green Whisper Trim 2 inch 24A5674 X012
1 inch 14A9687 X012 416 stainless steel 3 inch 24A5659 X012
2 inch 14A6626 X012 1 inch 24A2043 X012 4 inch 24A5644 X012
2 inch (NACE) 16A5501 X012 2 inch 24A5707 X012 6 & 8 x 6 inch 14A8176 X012
3 inch 14A6629 X012 3 inch 24A5708 X012 Fluoroelastomer
3 inch (NACE) 16A5503 X012 4 inch 24A5709 X012 1 inch 14A8187 X012
4 inch 14A6632 X012 6 & 8 x 6 inch 24A8174 X012 2 inch 25A7413 X012
4 inch (NACE) 16A5506 X012 316 stainless steel (NACE) 3 inch 25A7376 X012
6 & 8 x 6 inch 14A9686 X012 2 inch (NACE) 24A5707 X022 4 inch 25A7468 X012
6 & 8 x 6 inch 3 inch (NACE) 24A5708 X032 6 & 8 x 6 inch 14A8185 X012
(NACE) 16A5510 X012 4 inch (NACE) 24A5709 X022
125 psi (8.6 bar) maximum drop 6 & 8 x 6 inch 16*® Valve Plug, heat-treated
blue (NACE) 24A8174 X022 416 stainless steel
1 inch 14A9680 X012 Quick Opening, cast iron, ENC 1 inch 14A6780 X012
1 inch (NACE) 10B1882 X012 1 inch 37A7211 X012 2 inch 24A6772 X012
2 inch 14A6627 X012 2 inch 37A7212 X012 3 inch 24A9421 X012
2 inch (NACE) 16A5995 X012 3 inch 37A7213 X012 4 inch 24A8182 X012
3 inch 14A6630 X012 4 inch 37A7214 X012 6 & 8 x 6 inch 24A6992 X012
3 inch (NACE) 16A5996 X012 6 & 8 x 6 inch 37A7215 X012 316 stainless steel (NACE)
4 inch 14A6633 X012 1 inch (NACE) 14A6780 X022
4 inch (NACE) 16A5997 X012 12* Port Seal 2 inch (NACE) 24A6772 X032
6 & 8 x 6 inch 14A9685 X012 Nitrile® standard 3 inch (NACE) 24A9421 X022
6 & 8 x 6 inch 1 inch 14A6788 X012 4 inch (NACE) 24A8182 X022
(NACE) 16A5999 X012 2 inch 24A5673 X012 6 & 8 x 6 inch (NACE) 24A6992 X022
400 psi (28 bar) maximum drop 3 inch 24A5658 X012 17* Cage O-Ring
red 4 inch 24A5643 X012 Nitrile® (standard)
1 inch 14A9679 X012 6 & 8 x 6 inch 14A8175 X012 1 inch 10A7777 X012
2 inch 14A6628 X012 Fluoroelastomer 2 inch 10A7779 X012
2 inch (NACE) 16A5499 X012 1 inch 14A8186 X012 3 inch 14A5688 X012
3 inch 14A6631 X012 2 inch 25A7412 X012 4 inch 10A3481 X012
3 inch (NACE) 16A5500 X012 3 inch 25A7375 X012 6 & 8 x 6 inch 18A2556 X022
4 inch 14A6634 X012 4 inch 25A7469 X012 Fluoroelastomer
4 inch (NACE) 16A5998 X012 6 & 8 x 6 inch 14A6996 X012 1 inch 10A7778 X012
T

15A2615 X012 2 inch 10A7779 X022

CO

6 & 8 x 6 inch Seat Ring

6 & 8 x 6 inch 416 stainless steel 3 inch 10A3441 X012
(NACE) 16A6000 X012 1 inch, 1-5/16 inch 4 inch 10A3483 X012
10(2) Indicator Stem (33 mm) port 24A6781 X012 6 & 8 x 6 inch 18A2556 X032
Stainless steel 2 inch, 2-3/8 inch 18 Indicator Scale, plastic
1 inch 14A6756 X012 (60 mm) port 24A5670 X012 1 inch® 14A6759 X012
2 inch 14A6994 X012 3 inch, 3-3/8 inch 2 inch® 14A5678 X012
3 inch 14A6995 X012 (86 mm) port 24A5655 X012 3 inch® 14A5662 X012
4 inch 14A8179 X012 4 inch, 4-3/8 inch 4 inch
6 & 8 x 6 inch 14A6986 X012 (111 mm) port 24A5640 X012 w/2 inch (51 mm)
316 stainless steel (NACE) 6 inch, 7-3/16 inch travel® 14A5647 X012
1 inch (NACE) 14A6756 X022 (183 mm) port 24A6989 X012 w/1-1/2 inch (38 mm)
2 inch (NACE) 14A6994 X022 8 x 6 inch 7-3/16 inch travel 14A5662 X012
3 inch (NACE) 14A6995 X022 (183 mm) port 38A4216 X012 6 & 8 x 6 inch® 14A5647 X012
4 inch (NACE) 14A8179 X022 316 stainless steel (NACE) 19 Indicator Protector
6 & 8 x 6 inch (NACE) 14A6986 X022 1 inch, 1-5/16 inch (33 mm) Zn pi steel
11 Cage port (NACE) 24A6781 X022 1 & 2 inch® 14A8180 X012
Linear 2 inch, 2-3/8 inch (60 mm) 3, 6 & 8 x 6 inch® 14A6769 X012
Cast iron, ENC® port (NACE) 24A5670 X022 4 inch® w/2 inch
1 inch 24A6783 X012 3 inch, 3-3/8 inch (86 mm) (51 mm) travel 14A6769 X012
2 inch 24A5669 X012 port (NACE) 24A5655 X022 PI steel
3 inch 24A5654 X012 4 inch, 4-3/8 inch (111 mm) 4 inch w/1 -1/2 inch
4 inch 24A5639 X012 port (NACE) 24A5640 X022 (38 mm) travel 14A5664 X012
6 & 8 x 6 inch 24A6990 X012 6 inch, 7-3/16 inch (183 mm)
port (NACE) 24A6989 X022

•Recommended spare part.

2. Part included in trim package assembly which can be ordered according to the parts
20 kit trim package.
 Types 1098-EGR & 1098H-EGR

Key Description Part Number

20* Plug O-Ring
Nitrile® (standard)
1 inch 14A6981 X012
2 inch 14A5686 X012
3 inch 1V3269 06562
4 inch 14A5688 X012
6 & 8 x 6 inch 1K8793 06992
Fluoroelastomer
1 inch 14A8188 X012
2 inch 14A5686 X022
3 inch 1V3269 X0042
4 inch 10A3441 X012
6 & 8 x 6 inch 1V5476 06382
21* Indicator Fitting O-Ring
Nitrile®
1 inch 10A8931 X012
2, 3, & 4 inch 10A3800 X012
6 & 8 x 6 inch 1F2629 06992 Figure 12. Standard P590 Series Filter Assembly
Fluoroelastomer
1 inch 10A0811 X012
2, 3, & 4 inch 1R7276 06382
6 & 8 x 6 inch Key Description Part Number Key
1P4877 06382 Description Part Number
22(2) Flange Nut, pi steel 14A5693 X012
23(2) 32 Travel Stop, galvanized zn pi steel 7*
E-Ring Gasket, composition 1F8268 04022
stainless steel (not used w/full capacity trim) 11 NACE Tag (Type P593-1 only) (NACE)
14A8181 X012
2 inch 18-8 stainless steel
1577 steel, heat treated
(NACE) 30% capacity 14A9677 X012 (not shown) 19A6034 X012
14A8181 X022
70% capacity 14A9676 X012 12 Tag Wire (Type P593-1 only) (NACE)
24 3 inch, 303 stainless steel
Drive Screw, stainless steel
(4 req’d) 40% capacity 14A9671 X012 (NACE) 1U7581 X0022
1A3682 28982
25 Flow Arrow, 4 inch,
stainless steel 40% capacity 14A9670 X012
1V1059 38982 6 inch, Type 6351 Pilot
26 Body Rating Plate, stainless steel
40% capacity
(not shown) 13A2353 X012 33
14A9682 X012
NACE Tag (not shown) (NACE)
(figure 13)
28 Spring Seat
Full capacity trim® 18*8 stainless steel
Parts kit (included are: valve plug,
(NACE) 19A6034 X012
zinc plated steel key 4; valve spring, key 6; diaphragm
1 inch 14A6982 X012 assembly, key 7; body plug gasket,
34 Tag Wire (not shown) (NACE)
2, 3, & 4 inch 15A2206 X012 key 23 and for the P590 Series Filter,
6 & 8 x 6 inch 304 stainless steel
14A8177 X012 filter element, key 2; and gasket,
(NACE) 1U7581 X0022
Heat-treated wrought steel (NACE) key 7) R6351 X00012
1 inch (NACE) 14A6982 X022 Body Assembly
2 inch, 3 inch, 4 inch Standard P590 Series Aluminum w/brass
(NACE) 15A2206X022 bushing 1B7971 X0092
6 & 8 x 6 inch Filter (figure 12) Aluminum w/315 stainless
(NACE) 14A8177X022 steel bushing (NACE) 1B7971 X0232
Restricted capacity trim, heat-treated, 1 Filter Body Brass w/brass
416 stainless steel Type P594-1, brass 1E3124 14012 bushing 1B7971 X0112
2, 3, & 4 inch 14A9678 X012 Type P593-1, 316 stainless steel w/303 stainless
6 inch 14A9688X012 aluminum 1E3124 09012 steel bushing 1B7971 X0122
2, 3, & 4 inch aluminum (NACE) 1E3124 09012 Spring Case, aluminum
(NACE) 14A9678X012 2* Filter Element, w/untapped vent
6 & 8 x 6 inch cellulose 1E3126 06992 (standard) 2B7974 08012
(NACE) 14A9688X012 cellulose (NACE) 1E3126 06992 w/1/4 inch NPT tapped vent (for use
3 Filter Head
w/Type 661 mtg) 13A0166 X012
29 Hex Nut Steel (use w/steel body) Type P594-1, brass 1E3125 14012 Body Plug
(not shown) Type P593-1, Aluminum 1B7975 09032
1 inch (4 req’d) 1C3306 24072 aluminum 1E3125 09012 Brass 1B7975 14012
2 inch (8 req’d) 1A3772 24072 aluminum (NACE) 1E3125 09012 316 Stainless steel 1B7975 35072
3 inch (8 req’d) 1A3760 24072 4 Machine Screw
Stainless steel (NACE) 1B7975 09032
4 inch (8 req’d) 1A3520 24072 Type P594-1, brass 1J5002 18992 4* Valve Plug
6 & 8 x 6 inch Type P593-1, Nitrile w/brass
(12 req’d) 1A440924072 aluminum 1J5002 09012 stem 1D5604000A2
31(2) pjpe p|ug aluminum (NACE) 1J5002 09012 Nitrile w/stainless steel
zinc plated steel 1A7675 24662 stem . 1D5604 000B2
steel (NACE) 5 Washer (2 req’d)
Fluoroelastomer w/brass
2,3, or 4 inch (NACE) 1A7675 24012 Type P594-1, brass 1J5000 18992 stem 1N379871662
6 or 8 x 6 inch (NACE) 1B5731 X0012 Type P593-1,
Fluoroelastomer w/stainless steel
aluminum 1J5000 10062 stem 1N3798000C2
aluminum (NACE) 1J5000 10062

'Recommended spare part.

^ kitWm^oacka n trim Packa9e assembly which can be ordered according to the parts
21
Types 1098-EGR & 1098H-EGR

Figure 13. Type 6351 Pilot Assembly

Key Description Part Number Key Description Part Number Key Description Part Number

4 Inner Valve, 304 stainless 12 Machine Screw, pi steel

(6 req’d)
.
1B7839 28982
Type 6352 Through
steel/nitrile (NACE) 1D5604 000B2
5 Valve Plug Spring Seat 22 Body Inlet Pipe Nipple, 6354M Pilot (figure 14)
Aluminum (use w/brass galvanized zn pi steel (use W/P590
stem) 1E5322 11032 Series filter) 1C4882 26232 Parts kit (included are: valve plug,
316 stainless steel (use w/stainless steel (NACE) 1C4882 X0032 key 4; diaphragm assembly, key 5;
steel stem) 1L2511 35072 22 Spring Case Vent Pipe Nipple, body plug gasket, key 12; bellows
316 stainless steel galvanized zn pi steel (use w/Type O-ring, key 17; closing cap gasket,
(NACE) 1L2511 35072 661 mtg) 1C6789 26232 key 20; and for the P590 Series
6 Valve Plug Spring, 23* Body Plug Gasket, Filter, filter element, key 2; and
stainless steel 1B7979 37022 composition 1C4957 04022 gasket, key 7)
heat-treated alloy 600 Type 6352 R6352 X00012
(UNS N07750) 19A2860 X012 24 P590 Series Filter (parts listed under Type 6353 R6353 X00012
7* Diaphragm Assembly (includes zn pi separate heading) Type 6354 R6354 X00012
steel diaphragm plate) Type P594-1, brass & cellulose Body
Nitrile w/aluminum pusher (standard) AJ5004 000A2 Aluminum 35A6228 X012
post 1B7980 000B2 Type P593-1, aluminum & Brass 35A6224 X012
Fluoroelastomer w/aluminum cellulose AJ5004 T0012 Steel 35A6226 X012
pusher post 1B7980 000C2 25 Sealant Loctite N. 516 (one pint can, 316 stainless steel 39A5971 X012
Nitrile w/stainless steel not supplied) 1M1137X0012 Aluminum (NACE) 35A6228 X012
post 1B7980 X00A2 35 Type Y602-13 Vent Assembly, zinc 316 stainless steel
Nitrile diaphragm w/stainless steel w/stainless steel screen (use w/Type (NACE) 39A5971 X012
pusher post & diaphragm 661 mtg) 17A6572 X042 Spring Case
plate (NACE) 1B7980 X0112 42 Relief Valve Assembly Aluminum
Aluminum/stainless steel Use w/closing cap 25A6220 X012
8 Upper Spring Seat, zn pi 25 psi (1.7 bar Use w/o closing
steel 1B7985 25062 differential) 16A5929 X022 cap 15A1581 X012
9 Control Spring, Cd pi steel 42 Aiuminum/302 stainless steel (NACE) Use w/Type 661
3 to 20 psig (0.21 to 1.4 bar) range, 25 psi (1.7 bar mtg 26A6790 X012
green 1B9860 27212 differential) 16A5929 X042 Brass 25A6790 X012
5 to 35 psig (0.34 to 2.4 bar) range, Steel 25A6223 X012
cadmium 1B7883 27022 316 Stainless steel 28A9277 X012
35 to 100 psig (2.4 to 6.9 bar) range, Aluminum (NACE) 25A6220 X012
red 1K7485 27202 316 stainless steel
10 Adjusting Screw, pi steel (not used (NACE) . 28A9277 X012
w/Type 661 mtg) 10A2099 X012
11 Locknut, zn pi steel (not used w/Type
661 mtg) 1A9463 24122

22 ‘ Recommended spare part.

 Types 1098-EGR & 1098H-EGR

C O M P L E TE T Y P E 6352, 6353, O R 6354L P IL O T D E T A IL O F T Y P E 6354H O R 6354M P IL O T

Figure 14. Type 6352 Through 6354M Pilot Assemblies

Key Description Part Number Key Description Part Number Key Description Part Number
3 Body Plug
Aluminum Body Plug Gasket
15A6221 X012 35 to 125 psig (2.4 to 6.9 bar),
Brass Composition 1C4957 04022
15A6221 X022 red 1K748527202
Steel Composition (NACE) 1C4957 04022
15A6221 X032 Type 6354L
316 stainless steel 15A6221 X042 85 to 200 psig (5.9 to 14 bar), 13
Aluminum (NACE) Type Y602-12 Vent Assembly, plastic
15A6221 X012 blue 1L346127142
316 stainless steel w/stainless steel
Type 6354M screen 27A5516 X012
(NACE) 15A6221 X042 175 to 220 psig (12 to 15 bar), 14
4* Valve Plug & Stem Assembly, Machine Screw (6 req'd)
blue 1L346127142 Steel 1H4217 28992
nitrile disc 17-4PH stainless steel PI steel
w/stainless steel Type 6354H
stem 15A6207 X012 For aluminum spring case w/o
200 to 300 psig (14 to 21 bar), closing cap 1H2676 28982
316 stainless steel stem green 15A9258X012
(NACE) 15A6207 X052 For Type 661 mtg 1E9752 28982
7 Spring Seat 15 Relief Valve Assembly
Zn pi steel (for Types 6352 & Aluminum/stainless steel
5* Diaphragm Assembly 6353) 1B7985 25062 25 psi (1.7 bar)
Type 6352 w/natural rubber PI steel (for Type 6354L, 6354M,
diaphragm 15A6216 X012 differential 16A5929 X052
or 6354H) 1K1558 28982 Aluminum/302 stainless
Fluoroelastomer diaphragm 8 Stem Guide steel for 25 psi (1.7 bar)
(NACE) 15A6216 X132 416 stainless steel,
Type 6353 w/nitrile differential (NACE) 16A5929 X042
heat-treated 15A6222 X012 16 Bellows Assembly, stainless steel/
diaphragm 15A6216 X022 410 stainless steel
Type 6354L, 6354M, or 6354H nickel 15A6202 X012
(NACE) 15A6222 X022
w/neoprene
17* Bellows O-Ring,
diaphragm 15A6216 X032 9 Adjusting Screw
6 Control Spring nitrile 1D6825 06992
Zn pi steel (for Types 6352 & 19 P590 Series filter (parts listed under
Zn pi steel 6353) 1H3050 28982
Type 6352 separate heading)
PI steel (for aluminum spring case Type P594-1, brass & cellulose
2 inch wc to 2 psig (5 to 140 mbar), w/closing cap & Type 6354L, (standard) AJ5004 000A2
yellow 14A9672 X012 6354M, or 6354H) 1B7986 28982 Type 593-1, aluminum
2 to 10 psig (0.14 to 0.69 bar), 10 Locknut, zn pi steel 1A9463 24122
black 14A9673 X012 & cellulose AJ5004 T0012
11 Closing Cap 20 ’ Closing Cap Gasket,
2 inch wc to 2 psig (5 to 140 mbar), Aluminum 1H2369 X0012 composition * 15A6218 X012
yellow (NACE) 14A9672 X012 Brass 1H2369 14012 21 Pipe Nipple
2 inch wc to 2 psig (5 to 140 mbar), Steel 1H2369 X0022
black (NACE) 14A9673 X012 Galvanized zn pi steel 1C4882 26232
316 stainless steel 1H2369 X0032 Noncorrosive, NACE steel
Type 6353
3 to 40 psig (0.21 to 2.8 bar), (NACE) 1C4882 X0032
Corrosive, 316 stainless steel
yellow 1E3925 27022
(NACE) 1C4882 X0042

‘ Recommended spare part.

23
Types 1098-EGR & 1098H-EGR

Key Description Part Number

22 Restriction, pi steel (not used for

low-gain construction)
Standard gain (indicated by S
stamped on pilot body), No. 51 drill
size or 0.067 inch (1.7 mm)
diameter, green 17A2030 X012
High gain for narrower proportional
bands (indicated by H stamped on
pilot body), No. 57 drill size or
0.043 inch (1.09 mm) diameter,
red 17A2029 X012
22 Restriction, NACE construction
316 stainless steel
(not used for low-gain construction)
Standard gain (indicated by S
stamped on pilot body),
No. 51 drill size or 0.067 inch
(1.7 mm) diameter, green
color code 17A2030 X022
High gain for narrowerproportional Figure 15. Single-Pilot Mounting Parts
bands (indicated by H stamped on
pilot body), No. 57 drill size
or 0.043 inch (1.09 mm)
diameter, red color Key Description Part Number Key Description Part Number
code 17A2029 X022
23 Diaphragm Limiter, aluminum (for 7 Control Spring, steel pi 25 P590 Series filter (parts listed under
Types 6354H or 1/4-2 psig (0.017-0.138 bar) range, separate heading)
6354M) 15A9259 X012 red spring 1B8863 27022 Type P594-1, brass & cellulose
26 NACE Tag (Type 6352 only), NACE 1-5 psig (0.069-0.34 bar) range, (standard) AJ5004 000A2
18-8 stainless steel yellow spring 1J8578 27022 Type 593-1, aluminum
(not shown) 19A6034 X012 2-10 psig (0.138-0.69 bar) range, & cellulose AJ5004 T0012
blue spring 1B8864 27022 26 Bleed Valve, 416 stainless
27 Tag Wire (Type 6352 only), NACE 5-15 psig (0.34-1.02 bar) range, steel 1H9516 35132
303 stainless steel brown spring 1J8579 27142 27 Nameplate, aluminum 14A1711 X012
(not shown) 1U7581 X0022 10-20 psig (0.69-1.4 bar) range, 28* Gasket, neoprene 1P7533 06992
green spring 1B8865 27022 30 Pipe Plug, cast iron
8 Relay Orifice, (2 req’d) 1A3619 19012
Type 61 LD Pilot stainless steel 1C5201 35032 35 Spring Seat, steel (used only with
Type 661 mtg) 1J4284 24092
(figure 18) 9 Disk Holder Assembly
Brass/nitrile 50 Drive Screw, steel, pi
(standard) 1B8868 000A2 (2 req'd) 1E9530 28982
Parts kit (included are: relay orifice,
key 8; disk holder assembly, key 9; Stainless steel/nitrile
(corrosive) 1B8868 000B2
bleed orifice, key 10; O-ring, key 12
10 Bleed Orifice,
Standard Single-Pilot
relay spring, key 13; upper relay
diaphragm, key 14; lower relay stainless steel 1B8873 35032 Mounting Parts
11 Diaphragm Nut
diaphragm, key 15; bleed valve,
key 26; and closing cap gasket, Brass 1B9895 14012 (figures 15 & 19)
key 28) R61LDX00012 Stainless Steel 1B9895 35072
1 Spring Case, cast iron 1B9839 19012 12* O-ring, nitrile 1B8855 06992
N o te
2 Body, cast iron 2J5819 19012 13 Relay Spring, 302 stainless
3 Diaphragm Case, steel 1E6436 37022 K e y n u m b e r s 14 th ro u g h 22 a re
Cast iron 2C5186 19012 14* Upper Diaphragm, o n ly fo r m o u n tin g a T y p e 61 L D
4 Yoke Nitrile 1B8852 02052 p ilo t.
Zinc 1D6625 44012 15* Lower Diaphragm,
Cast iron 1B9840 19012 Nitrile 1B8860 02052
5 Closing Cap Assembly (includes keys 16 Upper Diaphragm Plate, 14 Pipe Nipple, galvanized
5a, 5b, 5c and 5d) AD5586 000A2 Steel 1B9893 25072
zn pi steel 1F7315 26012
5A Screen, stainless steel (not used with 17 Lower Diaphragm Plate, 15 Pipe Nipple, galvanized
Type 661 mtg) 1B6335 38392 Steel 1B9894 25072
zn pi steel 1F7302 26012
5B Snap Ring, stainless steel (not used 18 Spring Seat, steel, cd pi 1B8862 25072 16 Pipe Tee, Malleable iron 1A4736 21992
with Type 661 mtg) 1B6336 38992 19 Hex Nut, steel, cd pi 1A3403 24122 17 Type 1806 Relief Valve, SST ball and
5C Machine Screw, steel (not used with 20 Cap Screw, steel, spring
Type 661 mtg) 1D5589 28992 (8 req’d) 1B9896 24052
Brass body and spring
5D Closing Cap, zinc (not used with 22 Pipe Plug, steel (not used with seat AF5001 X00A2
Type 661 mtg) 2D3715 44012 Type 661 mtg) 1A6495 28992
Aluminum body and spring
6 Adjusting Screw, zinc (not used with 23 Vent Screen, alloy 400 (used only with seat AF5001 X0012
Type 661 mtg) 1B5379 44012 Type 661 mtg) 0L0783 43062
Stainless steel body and
24 Pipe Nipple, steel spring seat AF5001 X0022
zinc pi 1C4882 26232

24 ‘ Recommended spare part.

 Types 1098-EGR & 1098H-EGR

Key Description Part Number Key Description Part Number Key Description Part Number
18 Relief Tubing
Copper 14A9457 X012 Boiler Fuel Installation Type 1098 and 1098H
Aluminum
Steel
14A9457 X032 Dual-Pilot Mounting Actuators (figure 20)
14A9457 X022
Stainless steel 14A9457 X042 Parts (figure 16)
19 Tee Fitting Parts kit (included are: casing O-ring,
Brass 16 Pipe Tee, galvanized malleable key 5; stem O-ring, key 6; and
14A9056 X012
Steel iron (4 req’d) 1A4736 21992 diaphragm, key 7)
14A9056 X032
Stainless steel 21 Tubing Connector, pi steel Size 30 R1098 X00302
14A9056 X042
20 Loading Tubing (3 req’d) 15A6002 X462 Size 40 (standard) R1098 X00402
Copper 24 Tubing, steel 050021 2401W Size 70 R1098 X00702
24A9459 X012
Aluminum 30 Mounting Bracket, steel (for Type 1 Lower Diaphragm Case
24A9459 X032
Steel 621-107) 1H3504 X0012 Type 1098
24A9459 X022
Stainless steel Size 30, zn pi steel 2E8007 28992
24A9459 X042
21 Connector Fitting 31 Cap Screw, zn pi steel (2 req’d) Size 40, steel 24A7155 X012
Brass (for Type 621-107) 1A5828 24052 Size 70, zn pi steel 2N1266 28992
1H8682 18992
Aluminum 32 Cap Screw, zn pi steel (2 req’d) Type 1098H
1J9886 11992
Steel (for Type 621-107) 1K7646 24052 Size 30, WCB steel 36A8537 X012
1J1395 28992
Stainless steel 37 Pipe Nipple, galvanized NACE Construction
1L9272 38992
22 Elbow Fitting zn pi steel 1F7315 26012 Type 1098
Brass 38 Pipe Nipple, galvanized zn pi steel Size 30, heat-treated zinc
1L2497 18992
Aluminum (5 req’d for Type Y600P; 4 req’d for plated steel
1K5654 11992
Steel Type 621-107) 1K2015 26022 (NACE) 2E8007 X0022
1J1396 28992
Stainless steel Size 40, NACE steel 24A7155 X032
1N6856 38992
23 Pipe Nipple, galvanized zn pi steel 39 Pipe Nipple, galvanized Size 70, NACE steel 2N1266 X0022
zn pi steel 1C5599 26232 Type 1098H (size 30
Size 30 or 40 actuator 1C2100 26232
Size 70 actuator 41 Tubing Elbow pi steel (3 req’d for Type only), heat-treated
19A7858 X012
Pipe Nipple, NACE construction Y600P; 5 req’d for Type WCB steel (NACE) 36A8537 X022
621-107) 15A6002 X472 2 Upper Diaphragm Case
Size 30 or 40 actuator
Aluminum 43 Pipe Bushing, pi steel Type 1098
1C2100 X0022
(4 req’d) 1C3790 26232 Size 30
316 stainless steel 1C2100 X0012
Size 70 actuator 44 Pipe Bushing, steel 1A3424 28992 Steel 25A7340 X012
Aluminum Wrought steel
19A7858 X022
45 Pipe Bushing, galvanized (NACE) 25A7340 X022
316 stainless steel 19A7858 X032
24 Loading Tubing zn pi steel 1K2895 28992 Size 40
Steel (standard) 47 Female Union, malleable zinc plated steel 24A5680 X012
Size 30 or 40 iron 1B5405 21992 Wrought steel
actuator 48 Pipe Plug, steel 1A3692 24492 (NACE) 24A5680 X022
14A9458 X022 Size 70
Size 70 actuator 050021 2401W 49 Led-Plate<3> No. 250 Sealant,
Stainless steel 5 lb (2.3 kg) can (not furnished zinc plated steel 25A2607 X012
Size 30 or 40 w/regulator) 1M5240 06992 Wrought steel
actuator (NACE) 25A2607 X022
14A9458 X042
Type 1098H
Size 70 actuator 050198 3807W Working Monitor Dual­
Copper Size 30
Size 30 or 40 Pilot Mounting Parts WCB steel 36A8535 X012
actuator Heat-treated WCB steel
14A9458 X012 (figure 17) (NACE) 36A8535 X022
Size 70 actuator 050021 1701W
Aluminum 3 Bonnet (for Type 1098 only)
22 Tubing Elbow, pi steel 15A6002 X472 Steel 24A5681 X012
Size 30 or 40 24 Tubing, steel 050021 2401W Wrought steel (NACE) 24A5681 X022
actuator 14A9458 X032 30 Mounting Bracket, 4 Cap Screw (for Type 1098 only)
Size 70 actuator 050021 1107W steel 1H3504 X0012 Zinc plated steel 1D5287 24952
NACE construction 31 Cap Screw, zn pi steel B7M zinc plated steel
Size 30 or 40 actuator
(2 req’d) 1A5828 24052 (NACE) 1D5298 X0012
Aluminum 14A9458 X032 5* Casing O-Ring
304 stainless steel 14A9458 X042 32 Cap Screw, zn pi steel Nitrile (not req’d for
Size 70 actuator (specify main valve (2 req’d) 1K7646 24052 Type 1098H) 1F9141 06992
type number and body size) 34 Flared Nut, Fluoroelastomer 1F9141 X0012
Aluminum 050021 1107W zn pi steel 1D6921 24272
304 stainless steel 050198 3807W 35
25 Tubing Connector, 6* Stem O-Ring (2 req’d)
Elbow Fitting (2 req’d)
brass 1D6922 14012 Nitrile 1C7822 06992
PI steel (standard) 15A6002 X472 36 Pipe Bushing, steel Fluoroelastomer 1K7561 06382
Stainless steel 15A6002 X612 (2 req’d) 1A3424 28992 7* Diaphragm, nitrile
Brass 15A6002 X162
Aluminum Size 30 2E7919 02202
15A6002 X402
Aluminum (NACE) Size 40 2E6700 02202
15A6Q02 X402
316 stainless steel Size 70 . 2N1269 02202
(NACE) 15A6002 XC72
26 Pipe Bushing
Malleable iron 1B2928 21992
Steel (NACE) 1B2928 X0032

‘ Recommended spare part.

3. Trademark of Armite Laboratories.
25
Types 1098-EGR & 1098H-EGR

26
 Types 1098-EGR & 1098H-EGR

Figure 17. Dual-Pilot Mounting Parts for Working Monitor Regulator

Key Description Part Number Key Description Part Number Key Description Part Number
8 Diaphragm Plate 10 Cap Screw, zn pi steel 316 stainless steel (NACE)
Cast iron Type 1098 1 inch main valve body
Size 30 15A7339 X012 Size 30 (12 req’d) 1E7603 24052 (NACE) 14A6757X022
Size 40 14A5682 X012 Size 40 (16 req’d) 1E7603 24052 2 inch main valve body
Size 70 15A2606 X012 Size 70 (28 req’d) 1A5828 24052 (NACE) 14A5683X022
Heat-treated WCB steel (NACE) Type 1098H 3 inch main valve body
Type 1098 Size 30 (12 req’d) 1A9155 24052 (NACE) 14A5663X022
Size 30 19A7317 X012 11 Hex Nut, zn pi steel 4 inch main valve body
Size 40 19A7318 X012 Type 1098 (NACE) 14A5648X022
Size 70 19A7319 X012 Size 30 (12 req'd) 1A3465 24122 6 inch main valve body
Type 1098H (size 30 Size 40 (16 req’d) 1A3465 24122 (NACE) 14A6987X022
only) 19A7317 X012 Size 70 (28 req'd) 1A3465 24122 8 x 6 inch main valve body
9 Stem Cap Screw Type 1098H (NACE) 18A4217X022
Plated steel Size 30 (12 req’d) 1A3403 24122 13 Nameplate, stainless steel (not shown)
Size 30 or 40 1L5454 28982 12 Stem Size 30 25A8373X012
Size 70 11B1768 X012 17-4PH stainless steel Size 40 24A5704 X012
Grade 8 black steel (NACE) 1 inch 14A6757 X012 Size 70 25A8374 X012
Type 1098 (NACE) 2 inch 14A5683 X012
Size 30 or 40 3 inch 14A5663 X012 26 NACE Tag, 18-8 stainless steel
(NACE) 1L5454 X0012 4 inch 14A5648 X012 (not shown) 19A6034 X012
Size 70 (NACE) 11B1768 X022 6 inch 14A6987 X012 27 Type Y602-12 Vent
Type 1098H (size 30 8 x 6 inch 18A4217 X012 Assembly 27A5516 X012
only) (NACE) 1L5454 X0012 27 Tag Wire, 303 stainless steel
(not shown) (NACE) 1U7581 X0022
28 Grease Fitting, steel 1L8478 28992

27
Types 1098-EGR & 1098H-EGR

20* 6326-0

F ig u re 18. T y p e 6 1 L D P ilo t A s s e m b ly

F ig u re 19. T y p e 6 1 L D P ilo t a n d T y p e 1 8 0 6 R e lie f V alve

M o u n tin g

F ig u re 2 0 . T y p e 1 0 9 8 a n d 1 0 9 8 H A c tu a to r A s s e m b lie s

While this information is presented in good faith and believed to be accurate,
Fisher Controls does not guarantee satisfactory results from reliance upon such
information. N o th in g c o n ta in e d h e re in is to b e c o n s tru e d as a w a rra n ty o r
g uarantee, e x p re s s o r im p lie d , re g a rd in g th e p e rfo rm a n c e , m e rc h a n ta b ility , fitn e s s
nor as a recommendation to
o r a n y o th e r m a tte r w ith re s p e c t to th e p ro d u c ts ,
use any product or process in conflict with any patent. Fisher Controls reserves
the right, without notice, to alter or improve the designs or specifications of
the products described herein.

F o r in fo rm a tio n , c o n ta c t F is h e r C o n tro ls :
Fisher Controls Marshalltown, Iowa 50158 USA
Cernay 68700 France
Sao Paulo 05424 Brazil
Singapore 0512

iw hw pw th I
Printed in USA I ^ I sovimki recycled paper
 7
Y600 Series

Fisher Controls Instruction Manual

Y600 Series Pressure

Regulators

FISHER®
_____________ June 1986 Farm 1389

Introduction

Scope of Manual
T h is m anual d e scrib e s and p ro vid e s instructions and
parts lists fo r T y p e Y600, Y6 0 0 C , Y600 M , Y600 P, and
Y6 0 0 R p re s s u re regulators. Instructions and parts lists
fo r oth e r eq u ip m ent u se d w ith th e se regulators are
fou n d in sep arate m anuals.

Product Description
T h e Y600 S e ries p re s s u re reducing re gu la tors (figure 1)
m a y be applied as sw itching va lve s , re la y o r p ressu re
loading regulators, o r m onitoring regu la tor pilots, and
are d escrib ed a s follow s: F ig u re 1. T y p e Y 6 0 0 P re s s u re R e g u la to r

T y p e Y600— S eif-op era te d regulator w ith internal regis­

tration requiring n o d o w n stre a m control line.

T y p e Y6 0 0 C — S e lf-op era ted regu la tor with blocked

throat (but no O -rin g stem seal) a nd dia ph ra gm case
a s s e m b ly ta p p e d 1/2 -inch N P T fo r c o n tr o l line
connection.

T y p e Y600 M — S e lf-op era ted m onitoring regulator pilot

with quick d u m p bleed and d ia p h ra gm ca se a sse m b ly
tapped 1/2-inch N P T fo r control line connection.

T y p e Y6 0 0 P — S elf-op era te d re gu la tor w ith blocked

throat, O -rin g stem seal to p re ve n t leakage arou n d the
stem , and dia ph ra gm ca se a s s e m b ly tapped 1/2-inch
N P T fo r control line connection.

T y p e Y6 0 0 R — T y p e Y6 0 0 w ith internal relief va lve.

Specifications
T a b le 1 g ive s s o m e general Y6 0 0 S e rie s regulator rat­
ings and other specifications. Individual regulator data is
stam ped on the closing cap (figure 2) as it c o m e s from
the factory.

<DFisher C o n tro ls In te rn a tio n a l. In c. 197S. 1996; A ll R ig h ts R eserved

 FISHER 9
Y600 Series v .

T a b le 1. S p e c if ic a t io n s

BODY SIZES (INLET X ■ 3/4 x 3/4, ■ 3/4 x 1 , B 1 x 1 , e i bar differential) above outlet.
OUTLET) AND END x 1-1/4, or ■ 1-1/4 x 1-1/4 inch pressure setting
CONNECTION STYLE*1) NPT screwed
MATERIAL — 20°F to 150°F ( — 29°C to
MAXIMUM 150 psig (10.3 bar) TEMPERATURE 66°C)
ALLOWABLE INLET CAPABILITIES*2)
PRESSURE*2)
SPRING CASE 1/4 inch NPT
OUTLET PRESSURE See table 2 CONNECTION
RANGES*2)
DIAPHRAGM CASE 1/2 inch NPT
ALLOWABLE OUTLET Emergency (Casing): 20 psig (1.4 CONNECTION
PRESSURES*2) bar)
Maximum Operating to Avoid In- APPROXIMATE 13 pounds (6 kg)
temal Part Damage: 2 psi (0.14 WEIGHT
1 End connections threaded to various national or international thread standards can 2. Th« prassura/tamparatura limits in mis manual, and any applicable coda o f standard
usually be supplied: consult the Fisher sales office or sales representative. limitations, should not b« axcsadad.

Note
Installation
If the regulator is shipped mounted on an­
other unit, install that unit according to the
W A R N IN G appropriate instruction manual.

Personal injury, property damage, equip­

ment damage, or leakage due to escaping 1. O n ly p e rso n n e l qualified th ro u g h training and e i p F
gas or bursting of pressure-containing rience sho uld install, op erate, and m aintain a regulator.
parts may result if this regulator is over­ F o r a regu la tor that is sh ip p e d sep a ra te ly, m ake sure
pressured or is installed where service con­ that there is n o d a m a g e to, o r foreig n material in, the
ditions could exceed the limits given in regulator. A ls o en su re that all tubing and piping h ave
table 1, or where conditions exceed any been b low n free.
ratings of the adjacent piping or piping con­
nections. To avoid such injury or damage, 2. T h e regu la tor m a y b e installed in a n y position as
provide pressure-relieving or pressure-lim­ long as the flo w th ro ug h the b o d y is in the direction
iting devices (as required by the appropri­ indicated b y the a rro w ca st o n th e b o d y. If continuous
ate code, regulation, or standard) to operation is required during inspection o r m aintenance,
prevent service conditions from exceeding install a th re e -va lve b yp a s s a ro u n d the regulator.
those limits.

Additionally, physical damage to the regu­ W A R N IN G

lator could cause personal injury or proper­
ty damage due to escaping gas. To avoid A regulator may vent some gas to the atmo­
such injury or damage, install the regulator sphere. In hazardous or flammable gas ser­
in a safe and well ventilated location vice, vented gas may accumulate and
cause personal injury, death, or property
R egu la to r op eration w ithin ratings d o e s not preclude the damage due to fire or explosion. Vent a
possibility of d a m a g e from d e b ris in the lines o r from regulator in hazardous gas service to a
external s o u rce s. A re gu la tor sh o u ld be inspected for remote, safe location away from air intakes
d am a ge periodically and after a n y o ve rp re s s u re condi­ or any hazardous area. The vent line or
tion. K e y n u m b ers referenced in this section are sh o w n stack opening must be protected against
in figures 3 th ro ug h 7. condensation or clogging.

z

T a b le 2 . O u tle t (C o n tro l) P re s s u re R a n g e s
Control Outlet Pressure Range
Typo Spring with Spring Case
Numb«r Color Above Diaphragm
P in k 1 to 3 In c h e s W C (2 to 7 m ba r)
O ra n g e 1-1/3 t o 4-2/3 in c h e s w c (3 to 11 m b a r)
3 t o 8 in c h e s w c (7 t o 19 m ba r)
Red
3-1/2 to 6 in c h e s w c (8 to 14 m b a r)
P u rp le
Y600,
B ro w n 5-1/2 t o 8 In c h e s w c (13 to 19 m b a r)
Y600C,
O liv e d ra b 5 t o 15 in c h e s w c (12 to 37 m b a r)
Y6 0 0P ,
Y e llo w 11 to 2 8 in c h e s w c (26 to 67 m b a r)
L ig h t g r e e n 1 to 2-1/2 p s ig (69 to 173 m ba r)
L ig h t b lu e 2-1/2 to 4-1/2 p s ig (0.2 to 0.3 bar)
B la c k 4-1/2 t o 7 p s ig (0.3 to 0.5 bar)
Red 3 to 5 in c h e s w c (7 to 12 m b a r)
O liv e d ra b 5 to 12 in c h e s w c (12 to 29 m b a r)
Y e llo w 11 to 2 5 in c h e s w c (26 to 60 m b a r)
Y600M 1 t o 2-1/2 p s ig (69 t o 173 m ba r)
L ig h t g r e e n
L ig h t b lu e 2-1/2 to 4-1/2 p s ig (0.2 to 0.3 b ar)
B la c k 4-1/2 to 7 p s ig (0.3 to 0.5 bar)
1. Control spring part num Mrs ara given in tha parts Ust_________________________
3. B e certain that the ve n t (key 65) is not positioned so
that it can collect m oisture w h ich m a y drain into the
spring case. T h e d ia ph ra gm c a se a ssem b ly (key 20)
m a y be rotated to a n y o f fo u r p osition s with respect to
the b o d y in o rd e r to obtain desired positioning. Perform
b o d y area m aintenance p ro ce d u re steps 1 and 3
through 10 to rotate the d ia ph ra gm ca se assem bly.
4. T h e T y p e Y6 0 0 C , Y600 M , and Y600 P regulators
require a d o w n stre a m control line. B e sure to install this
control line b e fo re putting the regulator into operation.
T h e d o w n stre a m control line pipe should be at least 1/2
inch in dia m eter and conn ected to a straight section of
outlet piping 5 to 10 pipe diam eters d o w n strea m of the
regulator. A han d va lve should be installed in a straight
section of the control line. T h is hand va lve can be
throttled d o w n to d am p en ou t pulsations w hich m ay
ca use instability o r cycling o f the regulator.
Startup and Adjustment
A Y600 S e rie s regu la tor can be placed in operation b y
s lo w ly introducing inlet p re ssu re . T h e regulator takes
control w h e n d o w n stre a m p re s s u re is established.
T h e regulator h a s been adjusted at the fa ctory to p ro­
vid e a p p ro xim a te ly the redu ced p re ssu re requested on
the order. W ith a sprin g -loa d ed regulator, the p ressu re
setting m a y b e adjusted to a va lu e within the spring
range s h o w n in table 2. T o adjust the p ressu re setting,
perform the follow ing step s (key num bers are refer­
enced in figures 3 th rough 7):
Y600 Series
Approximate Point Above
Outlet Pressure Range ' Outlet Pressure Setting at
with Spring Case Which Type Y600R Internal
Below Diaphragm Relief Starts to Discharge
1/2 to 2-1/2 in c h e s w c (1 to 6 m b a r)
2/3 to 4 In c h e s w c (2 t o 10 m b a r)
2-1/2 to 7-1/2 in c h e s w c (6 to 18 m b a r)
11 to 17 in c h e s w c
3 to 5-1/2 in c h e s w c (7 to 13 m b a r)
(17 to 4 2 m b a r)
5 to 7-1/2 in c h e s w c (12 to 18 m b a r)
4-1/2 to 14-1/2 in c h e s w c (11 to 3 6 m b a r)
10-1/2 to 27-1/2 in c h e s w c (25 to 6 6 m b a r)
1 to 2-1/2 p s ig (69 to 173 m b a r) 1/2 to 1-1/2 p s i
2-1/2 to 4-1/2 p s ig (0.2 to 0.3 bar) (35 to 100 m b a r)
1/2 to 2 p si
4-1/2 to 7 p s ig (0.3 to 0 .5 bar) (35 t o 140 m b a r)
2-1/2 to 4-1/2 in c h e s w c (6 to 11 m b a r)
4-1/2 to 11-1/2 in c h e s w c (11 to 2 8 m b a r)
10-1/2 to 24-1/2 in c h e s w c (25 to 59 m b a r)
1 to 2-1/2 p s ig (69 to 173 m b a r)
2-1/2 to 4-1/2 p s ig (0.2 to 0 .3 bar)
4-1/2 to 7 p s ig (0.3 to 0 .5 bar)
- - ------
1. R e m o ve the closing ca p (key 3).
2. U s e a 1-inch (25.4 m m ) h e x ro d to turn the adjusting
s c re w (key 2) either clo ckw ise to in cre ase outlet p re s ­
su re o r co un terclo ckw ise to d e c re a s e outlet p ressu re .
W A R N IN G
To avoid personal injury, property damage,
or equipment damage caused by bursting
of pressure containing parts or explosion of
accumulated gas, never adjust the control
spring to produce an outlet pressure higher
than the upper limit of the outlet pressure
range for that particular spring. If the de­
sired outlet pressure is not within the range
of the control spring, install a spring of the
proper range according to the diaphragm
and spring case area section of the mainte­
nance procedure.
3. After m aking the adjustm ent and replacing the clo s­
ing cap, the closing cap can be w ire d to the spring case
(key 23) to d isco u ra g e tam pering.
Shutdown
First close the nea rest u pstream shu toff va lv e and then
close the nea rest d o w n stre a m shutoff va lve to ven t the
regulator p rop erly. N ext, o p e n the ve n t va lve betw een
3

Y600 Series
the regulator and the d o w n stre a m shutoff va lve n earest
to it. All p re s s u re b etw e en these shutoff va lve s is re­
leased th ro u g h the o p e n ve n t va lve , since a Y6 0 0 S eries
re gu la tor rem a in s o p e n in re s p o n s e to the d ecreasin g
d o w n stre a m p re ssu re . •
Maintenance
R e g u la to r parts are subject to norm al w e a r and m u st be
in spe cted and replaced as n e c e ss a ry. T h e fre q u e n c y of
inspection and replacem ent of parts d e p e n d s o n the
s e ve rity o f se rvic e conditions and upon applicable
c o d e s and g o ve rn m e n t regulations.
W A R N IN G
T o a v o id p e rs o n a l in ju ry, p ro p e rty d a m a g e ,
o r e q u ip m e n t d a m a g e c a u s e d b y s u d d e n
re le a s e o f p re s s u re o r e x p lo s io n o f a c c u ­
m u la te d g a s , d o n ot a ttem p t a n y m a in te­
n a n c e o r d is a s s e m b ly w ith o u t first isolating
th e re g u la to r fro m s y s te m p re s s u re and
re lie vin g all internal p re s s u re fro m the
re gu la tor.
K e y n u m b e rs are referenced in figures 3 th rough 7
u nless o th e rw is e noted.
Body Area
T h is p ro c e d u re is fo r gaining a cce ss to the d isk a sse m ­
bly, sea t ring, b o d y gasket, split ring, and pitot tube if
used. All p re s s u re m u st be released from the diaphragm
ca se a ss e m b ly, and the disk a ss e m b ly m ust be open,
b e fo re th ese step s can be perform ed .
1. U n s c re w the union nut (key 19) from the b o d y (key
28) and re m o ve the dia ph ra gm ca se a ss e m b ly (key 20)
and split ring (key 17). W ith a T y p e Y600 (figure 3) or
Y 6 0 0 R (figure 7) regulator, the dia ph ra gm ca se a sse m ­
bly (key 20 ) m u st be tipped to w a rd the b o d y outlet to
allow re m o va l clearance for the pitot tube (key 76).
2. Inspect and replace the seat ring (key 27) if n eces­
s a ry. Lu bricate the th re ad s of the replacem ent seat ring
w ith a g o o d g ra d e of pipe thread sealant and install with
29 to 37 fo o t-p o u n d s (39 to 50 N«m) of torque.
3. R e m o v e the cotter pin o r g ro o v e pin (key 14) if it is
n e c e s s a ry to replace the disk a ss e m b ly (key 25), the
T y p e Y6 0 0 (figure 3) o r Y6 0 0 R (figure 7) pitot tube (key
76), o r the T y p e Y600M (figure 5) bleed disk spring (key
106), stem O -rin g (key 15), bleed d isk w a s h e r (key 105),
and bleed disk (key 104). T h e bleed disk (key 104) m ay
be turned o v e r to u se the other side.
4
FISHER
4 T o replace o r reposition the T y p e Y600 o r Y6 0 0 R ,
pitot tube (key 76, figure 3 o r 7), re m o ve the pitot tube 'V-'-
s c re w s (key 77), install the pitot tube s o that it points i n t t ^ J f ,
the outlet of the b o d y (key 28) after the dia ph ra gm ca se i.
a ss e m b ly (key 20) is installed, and se cu re with the pitot t
tube s c re w s (key 77). j-
5. W ith the T y p e Y600M regu la tor (figure 5), install the
bleed disk (key 104), bleed d isk w a s h e r (key 105), stem
O -rin g (key 15 ), and bleed d isk sp rin g (key 106).
6. Install the d isk a sse m b ly (key 25) and secu re it with
the cotter pin o r g ro o ve pin (key 14).
7. If n e ce ssa ry, install the replace m e nt b o d y gasket
(key 16) into the b o d y (key 28).
8. Slide the union nut (key 19) as far as it will g o onto
the dia ph ra gm ca se a ss e b m ly (key 20). Install both
h a lve s of the split ring (key 21) into the slots of the ;
dia ph ra gm ca se a sse m b ly (key 20) and secu re them b y ;
sliding the union nut d o w n o n the split ring.
9. Install the d iaphragm c a se a ss e m b ly (key 20) with
the attached split ring (key 21) and union nut (key 19) so
that the pitot tube (key 76 if used) fits into the outlet of
the b o d y (key 28), and the d ia p h ra gm c a se pin (key 20C)
fits into o n e of the four slots sp a ce d equally a rou n d the
b o d y opening.
10. Tig h te n the union nut (key 19) until the d ia p h r a jy
ca se a ss e m b ly (key 20) is se cu re on the b o d y (key 28).
Diaphragm and Spring Case Area
T h is p roce du re is for gaining a cce ss to the spring,
diaphragm , le ve r a sse m b ly stem , and T y p e Y6 0 0 P stem
O -rin g. All p re s s u re m ust be relea sed from the dia­
p hrag m ca se a sse m b ly b e fo re th ese steps can be
perform ed .
N o te
A n y T y p e 661 re m o te co n trol d rive unit
u s e d w ith a Y600 S e rie s re g u la to r m u st be
re m o ve d fro m the s p rin g c a s e (k e y 23) b e ­
fo re th e s e s te p s ca n b e p e rfo rm e d .
1. R e m o ve the closing ca p (key 3) if used, and turn the
adjusting s c re w (key 2) c o u n terclo ckw ise until all co m ­
p re ssio n is re m o ve d from the control spring (key 1).
2. R e m o ve the h e x nuts (key 22, not show n), cap
s c re w s (key 21), spring ca se (key 23), and control spring
(key 1). If the o n ly further m aintenance is to change the
control spring (key 1), skip to step 9— after m a k in g ? " ^
y o u h a ve com plied with the inform ation in the
p receding that step.

3. R e m o v e the d ia p h ra gm o r d ia ph ra gm a ss e m b ly
(key 5) plus attached p arts b y tilting them s o that the
p u sh e r p o s t (ke y 8, fig u res 3 th ro u g h 6) o r relief va lve
seat (key 33, fig u re 7) slip s off th e le ve r a ss e m b ly (key
9). T o separate the d ia p h ra gm o r d ia ph ra gm a ss e m b ly
(key 5) fro m the attached parts, u n s c re w the ca p s c re w
(key 30) fro m the p u s h e r p o s t (ke y 8, fig u re s 3 th ro ug h 6)
fo r a T y p e Y6 0 0 , 600C, 600P, o r 600M regulator, o r
u nscrew -the relief va lve sp rin g h o ld e r (key 30, figure 7)
from the relief v a lv e sea t (ke y 33) fo r a T y p e Y6 0 0 R
regulator. If th e o n ly fu rth er m aintenance is to replace
the d ia ph ra gm p a rts o r ch a n g e th e control sp rin g (key
1), skip to step 7.
4. T o replace th e le ve r a s s e m b ly (key 9), re m o ve the
m achine s c re w s (key 11). T o re p la ce the stem (key 13)
o r the T y p e Y 6 0 0 P stem O -rin g (ke y 15, figure 6), also
perform b o d y a re a m aintenance p ro c e d u re ste p s 1 and
3, and pull the ste m (key 13) o u t o f the dia ph ra gm ca se
a ss e m b ly (key 20). W ith a T y p e Y 6 0 0 P regulator, grea se
the replace m e nt stem O -rin g (ke y 15, figure 6) with a
g o od g ra d e o f e la s to m e r lubricant and install it on the
stem (key 13).
5. Install the stem (key 13) into the d ia ph ra gm case
a ss e m b ly (key 20) and p e rfo rm b o d y area m aintenance
p roce d u re s te p s 5 th ro u g h 10 a s n e ce ssa ry.
6. Install the le v e r a s s e m b ly (ke y 9) into the stem (key
13) and se c u re the le ve r a s s e m b ly (key 9) w ith the
m achine s c re w s (key 11).
Note
The diaphragm parts installed in the follow­
ing step must be matched to the control
spring (key 1) that will be installed in step 9.
Be sure to check that the part numbers of
the diaphragm or diaphragm assembly (key
5), diaphragm plate (key 24), and relief
valve spring (key 67, figure 7) match the
control spring (key 1) part number as given
in the parts list.
7. P e rfo rm o n e of the follow in g p roce du re s:
a. F o r a T y p e Y600 , Y 6 0 0 C , Y600M , o r Y600 P
regulator (figures 3 th ro u g h 6), install the dia ph ra gm cap
s c re w (key 30) o n the control sp rin g seat (key 4), dia­
p hrag m plate (ke y 24) a nd d ia p h ra gm (key 5), plus the
lo w e r d ia ph ra gm plate g a s k e t (key 7, not sh o w n ) and
lo w e r d ia p h ra gm plate (key 6, n ot sho w n) if the stainless
steel constru ction is u se d. C o a t the top surface of the
p u sh e r p ost (key 8) w ith a g o o d gra d e of adh esive
ga sket sea ler and se c u re it to the dia ph ra gm cap screw
(key 30) with 30 to 45 fo o t-p o u n d s (3 to 5 N.m ) o f torque.
Y600 Series
b. F o r a T y p e Y6 0 0 R regu la tor (figure 7), co at the
relief va lve sp rin g holder (key 30) w ith a g o o d g ra d e of
a d h e sive g a sk e t sea ler and install o n it the relief va lve
spring (key 67) and d ia ph ra gm a s s e m b ly (key 5). plus
the relief va lve guide (key 34, not sh o w n ) if the stainless
steel constru ction is u se d. S e c u re th e relief va lv e seat
(key 33) to the relief va lve sp rin g h o ld e r with 30 to 45
fo o t-p o u n d s (3 to 5 N .m ) o f torque.
8. Install the p u sh e r p o st (key 8, fig u re s 3 th rough 6) o r
the relief va lve sea t (key 33, figure 7) plus attached
d ia ph ra gm parts on to the le ve r a s s e m b ly (key 9).
Note
The control spring (key 1) installed in the
following step must be matched to the dia­
phragm parts installed in step 7. Be sure to
check that the part numbers of the dia­
phragm or diaphragm assembly (key 5),
diaphragm plate (key 24), arid relief valve
spring (key 67, figure 7) if used, match the
control spring part number as given in the
parts list.
9. Install the spring c a se (key 23) a nd control spring
(key 1) on the dia ph ra gm c a se a s s e m b ly (key 20) s o that
the ve n t a ss e m b ly (key 65) is co rrectly oriented, and
secu re them w ith the cap s c re w s (key 21) and h e x nuts
(key 22, not sh o w n ) to fingertightness only.
10. T u rn the adjusting s c re w (key 2) clo ckw ise until
there is e n o u g h control sp rin g (key 1) force to p ro vid e
p ro p e r slack to the d ia ph ra gm o r d ia ph ra gm a ss e m b ly
(key 5). U sin g a c riss c ro ss pattern, finish tightening the
cap s c re w s (key 21) and h e x nuts (key 22, not sh o w n ) to
55 to 75 fo o t-p o u n d s (6 to 8 N .m ) o f torq ue. T h e n finish
turning the adjusting s c re w (key 2) to the desired outlet
p re s s u re setting.
11. Install a replacem ent closing ca p ga sket (key 35) if
n e ce ssa ry, and then install either the closing cap (key 3)
o r the T y p e 661 rem ote control d rive unit.
Parts Ordering
W h e n co rre s p o n d in g w ith the F is h e r sales office o r
sales represen ta tive a b o u t this regulator, include the
typ e n u m b er and all oth e r pertinent inform ation stam ped
on the closing cap. S p e cify the e leven -ch a ra cter part
n u m b er w h e n orderin g n e w parts fro m the follow ing
parts list.
5
 FISHER8
Y600 Series

Parts List (figures 2

through 7)

Kay Description • Part Number

Parts Kits for Types Y600, Y600C, &

Y600P only (included are Keys 5,14,
16, 25, and 35) for other than sour
gas corrosion resistance applications
W/nitrile & brass parts
For 3/32 thru 7/16-inch (2.4 thru
11.1 mm) seat ring port
diameters RY600 X00012
For 1/2 or 9/15-inch (12.7 or
14.3 mm) seat ring port
diameter RY600 X00022
W/nitrile & stainless steel parts
For 3/32 thru 7/16-inch (2.4 thru
11.1 mm) seat ring port
diameters RY600 X00032
For 1/2 or 9/16-inch (12.7 or
14.3 mm) seat ring port
diameter RY600 X00042
1 Control Spring, pi
steel See following table
2 Adjusting Screw
When regulator not used w/Type 661,
Zinc 1B5379 44012
When regulator used w/Type 661,
Heat-treated 416 stainless F ig u re 3. T y p e Y 6Q 0 R e g u la to r A s s e m b ly
steel 14A7998X012
3 Closing Cap -
For cast iron spring case assembly
Plastic for spring-loaded
regulator T11069X0012
Steel for pressure-loaded
regulator 1E422724092
For steel spring case assembly.
Steel 1E422724092
For stainless steel spring case
assembly, stainless
steel 1E4227 35072
4 Control Spring Seat (not for Type
Y600R), pi steel 1B6363 25062

5* Diaphragm (not for Type Y600R)

For spring-loaded regulator
Nitrile 1C943002072
Fluoroelastomer 1C9430 02332
For pressure-loaded regulator,
Nitrile/antiwick 1C9430 X0062
5* Diaphragm Assembly (for Type Y600R
only), nitrile diaphragm & steel
diaphragm plate See following table
6 Lower Diaphragm Plate (for use only
w/stainless steel disk assy—
not shown)
To provide sour gas corrosion
resistance capability!1)
(for Type Y600 only).
Monel® 0V0039 X0022
For other than sour gas corrosion
resistance applications (not used
w/Type Y600R). stainless
steel 0V0039 35032
7 Lower Diaphragm Plate Gasket (for
use only w/stainless steel disk
assy— not shown or used w/Type
Y600R),
composition 1A3487 04022
m S S X iff*National Association of Corrosion Enginaars (NACE) standard
’ MH-01-7S. . ,„
2. Trademark of International Nickel Co.
6
 Y600 Series

D e s c rip tio n P a rt N um ber

Pusher Post (not for Type Y600R)

For aluminum or brass disk assy.
Zinc 1A7966 44022
For stainless steel disk assy.
Stainless steel OV0038 35072
9 Lever Assembly
To provide sour gas corrosion
resistance capability
Steel? •• 1B5375 X0022
Stainless steel 1B5375 X0032
For other than sour gas corrosion
resistance applications
Steel w/cd pi brass 1B5375 OOOA2
302 stainless steel 1B5375 OOOB2
11 Machine Screw (2 req'd)
For aluminum or brass disk assy,
pi steel 1A3319 28982
For stainless steel disk assy.
Stainless steel 1A8684 35042
13 Stem
To provide sour gas corrosion
resistance capability (for Type Y600
only), stainless
steel 1A8327 X00A2
For other than sour gas corrosion
resistance applications
For Type Y600, Y600C, or Y600R
For aluminum or brass disk assy.
Brass 1A8327 14012
For stainless steel disk assy,
Stainless steel 1A8327 35172 34A11S14
For Type Y600M, stainless A 3 64*1

steel 14A0634 X012 F ig u re 5 . T yp e Y 6 0 0 M M o n ito r R e g u la to r P ilo t A s s e m b ly

For Type Y600P
For aluminum or brass disk assy,
brass 1E3755 14012
For stainless steel disk assy,
stainless steel 1E3755 35172
14 Cotter Pin (not for Type Y600M)
To provide sour gas corrosion
resistance capability (for Type
Y600 only), stainless
steel 1A8665 37022
For other than sour gas corrosion
resistance applications
For aluminum or brass disk assy.
Brass 1A4040 18992
For stainless steel disk assy,
Stainless steel 1A8665 37022
14 Groove Pin (for Type Y600M only),
303 stainless steel 1D7991 38992
15* O-Ring (not for use w/Type Y600,
Y600C, or Y600R), nitrile
For Type Y600M 1D1917 06992
For Type Y600P 1D2899 06992
16* Body Gasket,
composition 1A8325 04032

17 Split Ring. Cd pi steel 1A8326 48722

19 Union Nut
To provide sour gas corrosion
resistance capability (for Type
Y600 only)
For steel diaphragm case assy,
Steel 1E4711 24092
For stainless steel diaphragm
case assy, stainless QK -G A S K A L A C
LS - LEAD SEAL
steel 1N6878 35072
CN$94frC
****■’ F ig u re 6. T y p e Y 6 0 0 P R e g u la to r A s s e m b ly

7
'Recommended spare p e rt
 Y600 Series.

Key Description Part Number INTERNAL

RELIEF
19 Union Nut (Continued) VALVE
ASSEMBLY
For other than sour gas corrosion
resistance applications
For cast iron diaphragm case assy.
Malleable iron 1E4711 19062
For steel diaphragm case assy,
Steel 1E4711 24092
For stainless steel diaphragm case
assy, stainless
steel 1N6878 35072
20 Diaphragm Case Assembly (includes
case pin 20C)
To provide sour gas corrosion
resistance capability (for Type
Y600 only) '
Steel 30B2578 X032
Stainless steel 30B2578 X042
For other than sour gas corrosion
resistance applications
For Type Y600 or Y600R
Cast iron 3D4166 X0022
Steel 30B2578 X032
Stainless steel 30B2578 X042
For Type Y600C or Y600P r 7 m7
Cast iron 3E3700 000A2 (77
Steel 30B2895 X032
Stainless steel 30B2895 X042
For Type Y600M,
Cast iron 34A0637 X012
0
20C Diaphragm Case Pin, GK -G A S K A L A C
1A9184 48712 LS - LEAD SEAL
pi carbon steel
31A031&-O
A3350-1

21 Diaphragm Case Cap Screw, pi steel F ig u re 7. T y p e Y 6 0 0 R R e g u la to r A s s e m b ly

(8 req'd) 1A3508 24052
22 Hex Nut (not shown), Cd pi steel
(8 req’d) 1E9853 24142
23 Spring Case Key Description Part Number
Key Description Part Number
To provide sour gas corrosion
25* Disk Assembly (Continued) 25* Disk Assembly (Continued)
resistance capability (for Type
For 1/2 or 9/16-inch (12.7 or Brass disk holder & TFE
Y600 only)
Steel 1B6365 X0352 disk 1A6328 OOOF2
14.3 mm) seat ring
Stainless steel 1B6365 X0362 port diameter Stainless steel disk holder &
For other than sour gas corrosion Aluminum disk holder & nitrile nitrile disk 1A8328 000A2
resistance applications disk 1C4248 000B2 ' Stainless steel disk holder &
For Type Y600, Y600C, Y600P, or Aluminum disk holder & fluoroelastomer
fluoroelastomer disk 1A8328 000M2
Y600R
Cast iron • 1B6365 X0342 disk 1C4248 X0182 Stainless steel disk holder &
Steel 1B6365 X0352 Stainless steel disk holder & nylon disk 1A8328 X0052
Stainless steel 1B6365 X0362 nitrile disk 1C4248 X0222 Stainless steel disk holder &
For Type Y600M, Stainless steel disk holder & TFE disk 1A8328 OOOD2
Cast iron 1B6365 X0342 fluoroelastomer For 1/2 or 9/16-inch (12.7 or
Diaphragm Plate (not for Type Y600R), disk 1C4248 X0192 14.3 mm) seat ring port
24
pi steel See following table For other than sour gas corrosion diameters
resistance applications Brass disk holder & nitrile
Type Y600M w/1/8-inch (3.2 mm) disk 1C4248 000C2
25* Disk Assembly
To provide sour gas corrosion seat ring port dia only, brass Brass disk holder &
resistance capability (for Type disk holder & nitrile fluoroelastomer
disk 14A0632 X012 disk 1C4248 X0C.2
Y600 only)
For 3/32 thru 7/16-inch (2.4 thru Type Y600, Y600C, Y600P, or Brass disk holder & nylon
11.1 mm) seat ring port diameters disk 1C4248 000G2
Y600R
Aluminum disk holder & nitrile For 3/32 thru 7 / 16 -inch (2.4 thru Brass disk holder & TFE
disk 1A8328 000N2 11.1 mm) seat ring port disk 1C4248X0022
Aluminum disk holder & diameters Stainless steel disk holder &
fluoroelastomer Brass disk holder & nitrile nitrile disk 1C4248 000A2
disk 1A8328 X0122 disk 1A8328 000C2 Stainless steel disk holder &
Stainless steel disk holder & fluoroelastomer
Brass disk holder &
nitrile disk 1A8328 X0262 fluoroelastomer disk 1C4248X0052
Stainless steel disk holder & disk 1A8328 X0012 Stainless steel disk holder &
fluoroelastomer Brass disk holder & nylon nylon disk 1C4248 X0062
disk 1A8328 X0212 disk 1A8328 X0022 Stainless steel disk holder &
TFE disk 1C4248 00002

8
•Recommended spare part.
 Y600 Series

Key D e s c r ip tio n P a rt N u m b e r Key D e s c rip tio n P a rt N u m b e r Key D e s c r ip t io n P a rt N u m b e r

27 S e a t R in g 27 S e a t R in g (C o n tin u e d ) 30 R e lie f V a lv e S p rin g H o ld e r (fo r T y p e

T o p r o v id e s o u r g a s c o rro s io n S ta in le s s ste e l Y 6 0 0 R o n ly), b r a s s 1C3231 14012
re s is ta n c e c a p a b ility (fo r T y p e 3/32-inch (2.4 m m ) p o rt 33 R e lie f V a lv e S e a t (fo r T y p e Y 6 0 0 R o n ly)
Y 6 0 0 o n ly) d ia m e te r 0R0441 35032 F o r b r a s s d is k a s s y ,
A lu m in u m 1/8-inch (3.2 m m ) p o rt B ra s s 2 B 5 4 1 9 44012
3/32-inch (2.4 m m ) p o rt d ia m e te r 1 A9 3 6 7 35032 F o r s ta in le s s s te e l d is k a s s y ,
d ia m e te r 0R0441 09022 3/16 -in ch (4.8 m m ) p o rt S ta in le s s s te e l 1 D 5 6 4 8 35032
1/8-inch (3.2 m m ) p o rt d ia m e te r 0 09912 35032 34 R e lie f V a lv e G u id e (fo r T y p e Y 6 0 0 R
d ia m e te r 1A 9 3 6 7 09012 1/4-inch (6.4 m m ) p o rt w / s ta in le s s s te e l d is k a s s y o n ly —
3/16 -in c h (4.8 m m ) p o rt d ia m e te r 0 B 0 4 2 0 35032 n o t s h o w n ) , s ta in le s s
d ia m e te r 009912 09012 5/16 -in ch (7.9 m m ) p o rt s te e l 1 D 5 6 4 9 14012
1/4-inch (6.4 m m ) p o rt d ia m e te r 0BO421 35032 35’ C lo s in g C a p G a s k e t,
d ia m e te r 0 B 0 4 2 0 09012 3/8-inch (9.5 m m ) p o rt n e o p re n e 1 P 7 5 3 3 06992
5/16 -in c h (7.9 m m ) p o rt d ia m e te r 0 B 0 4 2 2 350 3 2
d ia m e te r 0B0421 09012 7/16-inch (11.1 m m ) p o rt 65 V e n t A s s e m b ly , p la stic
3/8-inch (9.5 m m ) p o rt d ia m e te r 1 A8 3 4 6 35032 T y p e Y 6 0 2 -1 1 f o r u p -p o in tin g
d ia m e te r 0 B 0 42 2 09012 1/2-inch (12.7 m m ) p o rt s p rin g c a s e 1 7A 5 5 1 5 X 0 1 2
7/16-inch (11.1 m m ) p o rt d ia m e te r 1 A 9 2 8 8 35032 T y p e Y 6 0 2 -1 fo r d o w n -p o in tin g
d ia m e te r 1A 8 3 4 6 X 0 0 1 2 9/16 -in ch (14.3 m m ) p o rt s p rin g c a s e 17A6570X012
1/2-inch (12.7 m m ) p o rt d ia m e te r 1 C 4 2 5 2 35032 67 R e lie f V a lv e S p rin g (fo r T y p e Y 6 0 0 R
d ia m e te r 1A9 2 88 09012 28 Body o n ly), pi ste e l S e e fo llo w in g ta b le
9/16 -in c h 14.3 m m ) p o rt T o p ro v id e s o u r g a s c o rro s io n 76 P ito t T u b e (fo r T y p e Y 6 0 0 o r Y 6 0 0 R
d ia m e te r 1 C4 2 5 2 X 0 0 1 2 re s is ta n c e ca p a b ility (fo r T y p e o n ly)
S ta in le s s ste e l Y 6 0 0 o n ly) F o r a lu m in u m o r b ra s s d is k a s s y ,
3/32-inch (2.4 m m ) p o rt S te e l Z in c 2 D 8371 44012
d ia m e te r 0R0441 X 0 0 1 2 3/4 x 3/4-inch F o r s ta in le s s ste e l d is k a s s y ,
1/8-inch (3.2 m m ) p o rt s iz e 1 E1 6 2 7 X 0 0 3 2 S ta in le s s ste e l 1 D 2 9 1 6 0 00 A 2
d ia m e te r 1 A9 3 67 X 0 0 2 2 3/4 x 1 -in ch s iz e 1 0A 0 0 9 7 X 0 3 2 77 P ito t T u b e S c r e w (fo r T y p e Y 6 0 0 o r
3/16 -in c h (4.8 m m ) p o rt 1 x 1 -in ch s iz e 1J6 9 11 X 0 0 3 2 Y 6 0 0 R o n ly ) (4 r e q ’d)
d ia m e te r 0 09912 X 0 0 1 2 1 x 1-1/4 in c h s iz e 1J6 9 1 2 X 0 0 1 2 F o r a lu m in u m o r b r a s s d is k a s s y ,
1/4-inch (6.4 m m ) p o rt S ta in le s s ste e l C d pi s te e l 1 D 8 8 4 3 24052
d ia m e te r 0B0420 X0012 3/4 x 3/4-inch F o r s ta in le s s ste e l d is k a s s y .
5/16 -in c h (7.9 m m ) p o rt s iz e 1 E 1 6 27 33092 S ta in le s s ste e l 1 D 9 6 8 4 38992
d ia m e te r 0B0421 X 0 0 1 2 3/4 x 1 -in ch s iz e 1 0A 0 0 9 7 X 0 2 2
3/8-inch (9.5 m m ) p o rt 1 x 1 -in ch s iz e 1J6 9 11 33092 92 D ia p h ra g m P ro te c to r (n ot s h o w n ) , T F E
d ia m e te r 0B0422 X0012 1 x 1-1/4 in c h s iz e 1J6 9 1 2 33092 (u s e o n ly w h e n
7/16-inch (11.1 m m ) p o rt F o r o th e r th a n s o u r g a s c o rro s io n sp e c ifie d ) 1 K 8 8 0 8 06242
d ia m e te r 1A8346 X0022 re s is ta n c e a p p lic a tio n s 104 B le e d D is k A s s e m b ly (fo r T y p e Y 6 0 0 M
1/2-inch (12.7 m m ) p o rt C a s t iro n o n ly), 3 0 3 s ta in le s s s te e l &
d ia m e te r 1A9 2 88 X 0 0 1 2 3/4 x 3/4-inch s iz e 1 D 2 9 1 1 19012 nitrile 1 4A 0 6 3 6 X 0 1 2
9/16 -in c h 14.3 m m ) p o rt 3/4 x 1 -in ch s iz e 1 D 2 9 1 4 19012 105 B le e d D is k W a s h e r (fo r T y p e Y 6 0 0 M
d ia m e te r 1C4252 X0022 1 x 1 -in ch s iz e 1 D 2 9 1 2 19012 o n ly), pi c a rb o n s te e l 1 4A 0 63 3 X 0 1 2
F o r o th e r th a n s o u r g a s c o rro s io n 1 x 1-1/4 in c h s iz e 1 D 2 9 1 5 19012 1 06 B le e d D is k S p rin g (fo r T y p e Y 6 0 0 M
re s is ta n c e a p p lic a tio n s 1-1/4 x 1-1/4 in ch . o n ly), 3 0 2 s ta in le s s
T y p e Y 6 0 0 M w/1/8-inch (3.2 m m ) Size 1 D 2 9 1 3 19012 ste e l 1 U 5 5 0 6 37022
p o rt d ia m e te r o n ly B ra s s
B ra s s 1 A9 3 67 14012 3/4 x 3/4-inch s iz e 1D2911 12012 116 N A C E T a g (n o t s h o w n ) , 18-8 s ta in le ss
’ S ta in le s s ste e l 1 A9 3 67 35032 3/4 x 1 -in ch s iz e 1 D 2 9 1 4 X 0 0 1 2 ste e l 19A6034 X012
T y p e Y6 0 0 , Y6 0 0 C , Y600P, o r 1 x 1 -in ch s iz e 1 D 2 9 1 2 12012 117 T a g W ire (n ot s h o w n ) , 303 s ta in le s s
Y600R 1 x 1-1/4 in c h s iz e 1 D 1 91 5 X 0 0 1 2 ste e l 1U7581 X 0 0 2 2
B ra ss 1-1/4 x 1-1/4 inch
3/32-inch (2.4 m m ) p o rt s iz e 1 D 2 91 3 X 0 0 1 2
d ia m e te r 0R0441 14012 S te e l
1/ 8-inch (3.2 m m ) p o rt 3/4 x 3/4-inch s iz e 1 E1 6 2 7 22012
d ia m e te r 1 A9367 14012 3/4 x 1 -in ch s iz e 1 0A 0 0 9 7 X 0 1 2
3/16 -in c h (4.8 m m ) p o rt 1 x 1 -in ch s iz e 1J6911 22012
d ia m e te r 009912 14012 1 x 1-1/4 in c h s iz e 1 J6 9 1 2 22012
1/4-inch (6.4 m m ) p o rt S ta in le s s ste e l
d ia m e te r 0 B 0 4 2 0 14012 3/4-inch s iz e 1 E1 6 2 7 33092
5/16 -in c h (7.9 m m ) p o rt 3/4 x 1 -in ch s iz e 1 0A 0 0 9 7 X 0 2 2
d ia m e te r 0B0421 14012 1 -in ch s iz e 1J6 9 11 33092
3 / 8-inch (9.5 m m ) p o rt 1 x 1-1/4 in c h s iz e 1 J6 9 1 2 33092
d ia m e te r 0 B 0 4 2 2 14012 30 D ia p h ra g m C a p S c r e w (n ot fo r T y p e
7 /16-inch (11.1 m m ) p o rt Y 6 0 0 R ), pi Steel 1 A 3 0 9 0 24052
d ia m e te r 1 A8 3 46 14012
1/2-inch (12.7 m m ) p o rt
d ia m e te r 1 A9 2 88 14012
9/16 -in c h (14.3 m m ) p o rt
d ia m e te r 1C4 2 5 2 14012
 FISHER9
Y600 Series

K e y s 1, 5, & 67 T y p e Y 6 0 0 R C o n tro l S p rin g , D ia p h ra g m A s s e m b ly , & Re' e f V a lv e S p rin g

C O N T R O L S P R IN G C O L O R KEY 1 KEY 5 K E Y 67
C O D E (S E E T A B L E 2
FO R O U TLE T R e lie f V a l v e S p rin g
C o n tro l S p rin g D ia p h ra g m A s s e m b ly
PRESSURE RANGES)
P in k 1 B S584 27212
O ra n g e 1 B 5 58 5 27052
Red 1 B 6 53 8 27052
P u rp le 1 08 0 3 0 27052 1 B 6425 X0 0 1 2 1 C 1 7 3 4 270 2 2
B ro w n 1 B 8 38 7 27052
O liv e d ra b 1B6539 27022
Y e llo w 1 B 5 37 0 27052
L ig h t g re e n 1B5371 27022
L ig h t b lu e 1 B 5372 27022 1 B 6424 X 0 0 1 2 1 B 5 41 3 270 2 2
B la ck 1 B 5373 27052

K e y s 1 & 2 4 T y p e Y 6 0 0 , Y 6 0 0 C , Y 6 0 0 M , o r Y 6 0 0 P C o n tro l S p rin g & D ia p h ra g m P la te

C O N T R O L S P R IN G C O L O R KEY 1 K E Y 24
C O D E (S E E T A B L E 2
T Y P E NUM BER
FO R O U TLE T D ia p h ra g m P la te
C o n tro l S p rin g
PRESSU R E RANGES)
Y600, Y6 0 0C , P in k 1 B 5584 27212
Y600P O ra n g e 1B5585 27052
Y600, Y6 0 0C , 1 B 6538 27052
Red
Y600M , Y600P
0 04082 250 6 2
Y600. Y600C, P u rp le 1 D 8030 27052
Y600P B ro w n 1 B 8387 27052
O liv e d ra b 1B6539 27022
Y e llo w 1 B 5370 27052
Y600, Y6 0 0C ,
U g h t g re e n 1B5371 27022
Y600M , Y600P
L ig h t b lu e 1 B 5372 27022 0 Y 0 3 6 7 250 6 2
B la ck 1 B 5373 27052

While this information is presented in good faith and believed to be accurate, or any other matter with respect to the products, nor as a recommendation to
Fisher Controls does not guarantee satisfactory results from reliance upon such use any product or process in conflict with any patent. Fisher Controls reserves
information. Nothing contained herein is to be construed as a warranty or the right, without notice, to alter or improve the designs or specifications of
guarantee, express or implied, regarding the performance, merchantability, fitness the products described herein.

For information, contact Fisher Controls:

FISHER' Fisher Controls Marshalltown, Iowa 50158 USA
Cernay 68700 France
Sao Paulo 05424 Brazil
Singapore 0512

p tp e r
Printed in USA
 TH IS DRAWING IS P R O P E R TY O F C L E A V E R -B R O O K S DIVISION
I T IS S U B J E C T T O C H A N G E W IT H O U T N O T IC E . A N D IS N O T T O B E C O P IE D O R U S E D IN A N Y W A Y D E T R IM E N T A L T O T H E C O M P A N Y .
S U G G E S T IO N S A N O IN F O R M A TIO N C O N T A IN E D O N T H IS D R A W IN G A R E N O T IN T E N D E D T o S U P P L A N T L O C A L C O D E S .

4
3
 2 1
BILL OF MATERIALS

ELECTRICAL P A ID ITEM QUAN. MANUFACTURER P /N DESCRIPTION

MNEMONIC DESIGNATION

ASHCRO FT 8 5 0 -1 2 5 2 PRESSURE GAUGE. 3* DIAL. 0 -3 C T W.C.

PI 1 1 RANGE. 1/4' N PT BOTTOM CONNECTION
MOL. 1490A

2 GEMINI 9 4 1 -2 1 0 4 VALVE. BALL TY P E . 3/4' NPT. BRASS

HV 2
MDL. 8 6 — 1—R T— 1—L

VALVE. SOLENOID. NORMALLY CLOSED

GPV BSV 3 2 ASCO #8215G30 9 4 8 -3 2 2
FULL PO R T, 120/1/60 C O IL 3/4' N P T

VALVE. SOLENOID. NORMALLY OPEN

GPW BSV 4 1 ASCO #8215G33 9 4 8 -3 2 3 3 / 4 'PORT. 120/1/60 C O IL 3/4' NPT

1 GEMINI 9 4 1 -2 1 0 5 VALVE. BALL TYP E. 1/4' NPT. BRASS

HV 5
M D L 86— 1—R T - 1 - W o

REGULATOR. PILOT GAS PRESS. 3 / 4 'N PT

PCV 6 1 FISHER Y 6 0 0 -2 9 1 8 -7 0 9
3/16T ORIFICE, 11'TO 28TSPRING RANGE

p
iv\ CD

\ )

SCALE
INTAINER CORPORATION N .T .S .
DATE C le a v e r ^ ffe B r o o k s “E E S ?
,HTA C U R A , CA 1 1 /2 2 /9 4 , AOUfrB
CHCMMB* ST1ATF0TO(0MT
19401468 Wwn—
ts s i C 3 PILOT GAS TRAIN
SIZE CT BURNER NFPA 85

SHT 01 OF 01
B DRWG. NO. W — 0 0 3 8 1 3P G 01
 Types 298C & 298T

Fisher Controls Instruction Manual

Type 298C & 298T

Direct-Acting Gas Regulators

FISHER®
F orm 5 0 5 1

Supersedes Forms 302 and 2457

W A RN IN G

Regulators should be installed, operated, and

maintained in accordance with federal, state,
and local codes, rules and regulations, and
Fisher instructions.

If the regulator vents gas or a leak develops in

the system, it indicates that service is required.
Failure to take the regulator out of service im­
mediately may create a hazardous condition.

Call a serviceman in case of trouble. Only a

qualified person must install or service the
regulator.

Introduction
This manual pertains only to the Type 298C and 298T F ig u r e 1. Type 2 9 8 T -E K -6 1 L
actuators and commonly used pilots as described below.
Valve body maintenance is not covered except as necessary
to remove the actuator from the valve body. The instruction
manual for the specific valve body design should be con­
sulted for detailed valve body maintenance and parts order­ Type 61 HH— Extra high pressure pilot with spring range of
ing information. 35 to 100 psi.

Type 298C— Heavy duty actuator for large size valves.
Effective diaphragm area is 2 5 0 sq. in. Diaphragm casings
are cast steel.
Type 298T— Standard actuator with deep drawn steel
casings. Available in sizes 30, 4 0 , 50, 60, and 70.
Type 61 L— Low pressure pilot with spring ranges of 1/4 to
2 psi, 1 to 5 psi, 2 to 10 psi, 5 to 15 psi and 10 to 20 psi.
Type 61 H— High pressure pilot with spring range of
65 psi.
Thus, a combination of the above designations will denote
the complete regulator including the pilot and body design.
For example, a complete Type designation might be: Type
298T-E K -61L as shown in figure 1.
Type P594-1— Filter used to protect the pilot orifice against
dirt or chips in the pilot supply gas.
Type 1806— Relief valve incorporated to protect the
diaphragm from being over pressured. Relieves at ap­
10 to proximately 1 5 psi differential across diaphragm. Installed in
Type 298T actuator or in pilot with Type 298C actuator.

©Fisher Controls International, Inc. 1995; All Rights Reserved 5/74

 Types 298C & 298T
Principle of Operation
A schematic drawing of the Type 298T-EK-61 H is shown in
figure 2. This regulator is constructed so that the pilot bleeds
gas to the downstream pipe line, eliminating the necessity of
an atmospheric bleed.
The upstream or inlet pressure is utilized as the operating
medium for the pilot. The downstream pressure is the con­
trol pressure for the pilot and actuator.
In operation, assume that the reduced pressure is below the
setting of the pilot control spring. The diaphragms and yoke
assembly would then have a lower pressure on the top side
than that for which the control spring is set. Thus, the spring
force would cause the diaphragms and yoke assembly to
move upward, opening the relay orifice and supplying ad­
ditional loading pressure into the pilot body and through the
loading connection to the bottom side of the actuator
diaphragm.
This creates a higher pressure on the bottom side of the ac­
tuator diaphragm than before thus forcing the diaphragm
upward. This motion opens the valve plug, supplying the
required gas to the downstream system.
2
When the gas demand in the downstream system has been
satisfied, the reduced pressure tends to increase. The in­
creased pressure acts on the top of the diaphragms and yoke
assembly and on top of the actuator diaphragm. This
pressure exceeds the pilot spring setting and forces the
diaphragms and yoke assembly down, closing the relay
orifice. The loading pressure on the actuator diaphragm
bleeds through a small slot provided in the pilot exhaust
valve seat to the downstream system. When rapid valve plug
closure is required by unusual control conditions, the ex­
haust valve opens for increased bleed rate, and the actuator
spring moves the valve plug toward its seat to decrease the
gas flow to the downstream system.
Installation
The Types 298C and 298T bleed no gas to atmosphere,
making them suitable for installation in pits and other
enclosed locations without an elaborate venting system.
They can also be installed in pits which are subject to
flooding by venting the breather opening of the pilot valve
above the flood level so that the pilot setting can be in
reference to atmospheric pressure.

W ARN IN G
As is the case with most regulators, the Types
298C and 298T have an outlet pressure rating
lower than the inlet pressure rating. The
recommended pressure limitations are stamped
on the regulator nameplate. Some type of over
pressure protection is needed if the actual inlet
pressure exceeds the maximum operating outlet
pressure rating. Over pressure protection should
also be provided if the regulator inlet pressure is
greater than safe working pressure of the
downstream system or equipment.
Regulator operation below the maximum
pressure limitations does not preclude the
possibility of damage from external sources or
from debris in the line. The regulator should be
inspected for damage after any over pressure
condition.
Check the unit for shipment damage and see that the body is
clean inside. Blow out all pipelines to remove pipe scale and
chips. The pilot, differential relief valve, and associated tub­
ing were removed for protection during shipment. Remount
these parts according to the proper mounting drawing
(figure 11, 12, 13, or 14). It is recommended that a strainer
be installed upstream of the main valve to protect the
regulator while in service.
When installing the unit in line, make sure the flow through
the valve body is in the same direction as indicated by the
arrow attached to it. Use accepted piping and bolting prac­
tice to make up the installation. Before installing welding-
end bodies having a composition seat, remove the elastomer
seating parts to avoid heat damage.
If continuous operation is required during inspection or
maintenance, install a conventional three-valve bypass
around the regulator.
If the maximum allowable inlet pressure to the pilot, as
stated on the pilot nameplate, is less than the pilot supply
pressure source, install a regulator in the pilot supply line.
Install hand valves (not furnished) in the pilot supply line and
downstream control line and provide vent valves as in­
dicated in figure 2 so that pressure can be properly isolated
and relieved from the unit.
Run a 1/4" pilot supply line from the Type P594-1 filter to
the upstream pipe line. Do not make the connection in any
turbulent area such as near a nipple, swage, or elbow.
Types 298C & 298T
Attach a 1/2" pressure control line four to eight pipe
diameters downstream of the regulator in a straight run of
pipe. If it is impossible to comply with this recommendation
due to the piping arrangement. It may be better to make the
control line tap nearer the regulator outlet rather than
downstream of a header or block valve. Do not make the tap
near any elbow, swage, or nipple which might cause tur­
bulence. Connect the other end of the control line to the
pilot or pipe fitting as indicated in figures 11, 12, 13, or 14.
If the regulator is installed out of doors, the vent in the pilot
must be protected from moisture entering or any obstruction
which might cause pilot malfunction.
The Type 61 L and 61 H pilots can be vented to an outside
location using a 1/4" vent line. This line should also be rain­
proof and protected with a screened fitting. To remotely vent
a Type 61 H, simply remove the vent assembly (key 23,
figure 5) and install the vent line. The low pressure pilot is
vented by installing the vent line in place of the pipe lug (key
22, figure 4). Then remove the closing cap assembly (key 5,
figure 4) in order to remove the machine screw from inside
the closing cap and tightly install it in the vent hole in the
center of the closing cap. Venting the Type 61HH requires a
special tapped spring case.
To Put Into Operation
CAUTION
Pilot supply pressure must be introduced into
the unit prior to introduction of any downstream
pressure or internal damage may occur due to
reverse pressurization of the pilot and main
valve components.
When the installation is complete, open and close the
indicated valves in the sequence specified. It is assumed in
the procedures outlined below that the following conditions
exist prior to operation:
1. Block valves isolate the unit.
2. Vent valves are closed.
3. Hand valves are closed. *
4. A bypass, if any, is in operation.
3
 Types 298C & 298T

Approximate pressure settings are made at the factory as
specified on the customer's order. Adjustments may be re­
quired after putting the unit in operation. Follow the steps
below in conjunction with figure 2 to begin operation.
1. Slowly open hand valve A.
2. Very slowly open the upstream block valve.
3. Slowly open the downstream block valve.
4. Slowly open hand valve B.
5. Slowly close the bypass valve, if any.
To Take Out of Operation
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 pressuriza­
tion of the pilot. The steps below apply to the typical in­
stallation as shown in figure 2.
1. Slowly close the downstream block valve. If the control
line is downstream of the block valve, also close hand valve
B.
2. Slowly close the upstream block valve and hand valve
A.

3. Slowly open vent valve 2. If the control line is

downstream of the block valve, also open vent valve 3. Per­
Note mit all pressure to bleed out.

For proper operation, pilot supply pressure must 4. Slowly open vent valve 1.
exceed control pressure by the minimum
amount specified on the nameplate as
"minimum differential pressure.” Maintenance

Adjustm ents W ARN IN G

The only adjustment necessary is the spring setting of the
pilot. To change the regulator pressure setting, loosen the
locknut (key 34, figures 5 or 6) or remove the closing cap
(key 5, figure 4) and turn the adjusting screw (key 6). Turn­
ing the adjusting screw clockwise (into the spring case) in­
creases the controlled pressure setting; turning it
counterclockwise (out of the spring case) decreases the con­
trolled pressure setting. Any adjustments made should set
the controlled pressure within the appropriate spring range
shown in the table below. Then tighten the locknut to main­
tain the adjustment screw position or replace the Type 61L
closing cap.
Reduced Pressure Ranges
Before attempting any maintenance or
disassembly procedures, be sure the unit is
completely isolated from system pressure and
that all pressure is relieved from the body, ac­
tuator, and pilot as described in "To Take Out of
Operation."
Types 61L and 61H Pilots
The Type 61 L assembly is shown in figure 4, and the Type
61H is shown in figure 5.
1. Remove all tubing connected to the pilot. The pilot may
be completely removed from the actuator or left connected
to the mounting bar or one nipple, whatever is most con­
venient.

Pilot Reduced Color Spring

Type Pressure Range Code Drawing Number 2. Loosen the hex nut (key 34) and relieve control spring
1/4 - 2 psi Red 1B 886327022 (key 7) compression by turning the adjusting screw (key 6)
1 - 5 psi Yellow 1J8578 27022 counterclockwise. If working with a Type 61 L, the closing
61L Blue 1B8864 27022
2 - 10 psi cap (key 5) must be removed first.
Series Brown 1J8579 27142
5 - 1 5 psi
10 - 2 0 psi Green 1B 886527022
Green 3. Remove the eight cap screws (key'20) and separate the
61 H 10 - 6 5 psi 0Y0664 27022
Stripe pilot into three sections: spring case (key 1), body (key 2),
61HH' 3 5 - 1 0 0 psi Red 1K 748527202 and diaphragm case (key 3).

4

4. To inspect the two diaphragms (keys 14 and 15)
thoroughly, remove the diaphragm nut (key 11) and hex nut
(key 19) and the upper and lower diaphragm plates (keys 16
and 17). The projecting prong in the pilot body may be used
as the restraining member to keep the yoke from turning
while removing the nuts. Also inspect the O-ring (key 12).
5. Take the yoke (key 4) and attached parts out of the pilot
body to examine the disc holder assembly (key 9).
6. To replace the disc holder assembly, first unscrew the
orifice (key 10). Remove it and the associated parts. Then
unscrew the disc holder assembly from the bleed valve.
7. Before reassembly inspect the diaphragms, the O-ring,
and the disc holder assembly.
8. Reassemble the pilot in the reverse order of the above
disassembly instructions paying particular attention to the
following assembly suggestions.
8.1 Before replacing the diaphragm case or spring
case, be sure the yoke assembly is positioned so that it will
not bind or rub on the prong in the relay body.
8.2 Avoid wrinkling the diaphragms when replacing
the diaphragm case and spring case.
8.3 Replace the diaphragm case, carefully working the
upper diaphragm (key 14) into the recess in the diaphragm
case. If the diaphragm case rocks with respect to the pilot
body, the diaphragm is probably wrinkled.
8.4 Replace the spring case using care to smooth the
lower diaphragm (key 15) evenly into the recess in the pilot
body.
8.5 Install the eight cap screws tightening them evenly
to avoid crushing the diaphragm. Make several circuits in a
criss-cross pattern with a final bolt torque of 10 to 12 ft-lbs.
Type 61HH Pilot
Key numbers identified with the Type 61 HH pilot will be
found on figure 6.
1. Disconnect all tubing and piping necessary to con­
veniently disassemble the pilot.
2. Loosen the locknut (key 34) and turn the adjusting
screw (key 6) counterclockwise to relieve control spring (key
7) compression.
3. Remove the machine screws (key 48) and take off the
spring case (key 1), control spring, and spring seat (key 35).
4. After removing the other six machine screws (key 46),
take off the diaphragm case (key 3).
Types 298C & 298T
5. Unscrew the hex nuts (key 19) and remove the large
and small diaphragm plates (keys 16 and 17) and both
diaphragms (key 14). Be careful to not lose the small O-ring
(key 12).
6. Two machine screws (key 47, not shown) fasten the
yoke cap (key 42) to the yoke (key 4). Remove these screws
and take out the yoke and yoke cap.
7. Unscrew the orifice (key 10) and take out the inner
valve (key 26), valve spring seat (key 45), and valve spring
(key 13).
8. Inspect all parts and replace those showing damage or
excessive wear.
Reassembly the pilot in the following order:
8.1 Place the valve spring, spring seat, and inner valve
in the body and screw in the orifice all the way.
8.2 Place the lower diaphragm on the yoke, slip the
O-ring into place, put on the small diaphragm head, and
secure the assembly with the locknut.
8.3 Connect the yoke cap to the yoke then make up
the upper diaphragm assembly by slipping the diaphragm
over the yoke cap threads, replacing the large diaphragm
head, and securing with the hex nuts.
8.4 Make certain the yoke is square with respect to the
cross member of the pilot valve body (key 2) and that it can
move freely and does not bind on the body.
8.5 Replace the diaphragm case, control spring (key
7), spring seat (key 35), and spring case.
Converting the Pilot
To change a Type 61 L pilot to a Type 61 H pilot, replace the
relay diaphragm and all parts below it except the hex nut
with comparable high pressure parts. The Type 61 L parts
are: lower diaphragm, relay head, pipe plug, spring case,
adjusting screw, closing cap, closing cap gasket, control
spring, and spring seat (keys 15, 17, 22, 1, 6, 5, 28, 7,
and 18, figure 4). The Type 61 H parts are: lower diaphragm,
relay head, spring case, adjusting screw, control spring,
spring seat, vent assembly, and hex nut (keys 15, 17, 1,
6, 7, 18, 35, 23, and 34, figure 5).
When converting from a Type 61H to a Type 61L, specify
the control spring range desired, see the table above.
A Type 61 L or 61H-can not be converted to a Type 61 HH.
The entire pilot assembly must be replaced.
5
 Types 298C & 298T
Type 298T-Disassembly
Note
The actuator instructions which follow are keyed
to Type 298T component parts, figures 8, 9, and
10. The instructions also apply to the Type
298C actuator, figure 7, but the individual part
key numbers do not coincide.
1. To inspect or replace the main diaphragm (key 3), first
remove the spring case cap (key 8) or the adjusting screw
(key 60, figure 10) and unscrew the travel indicator stem
(key 26).
2. Remove the relief valve tubing (key 25) and pilot
loading tubing (key 27). Disconnect both the pilot supply
line and the downstream control line to the pilot and remove
the pilot.
3. Remove the diaphragm case cap screws and nuts (keys
29 and 30). Lift off the spring (key 6) and upper diaphragm
casing/spring case unit (keys 1 and 7).
4. Remove the stem locknut (key 18) and unscrew the
diaphragm head and diaphragm assembly off stem (key 5).
5. If examination reveals the necessity of replacing the
diaphragm, loosen the locking clamp set screws (key 39),
remove the adaptor locknut (key 15), separate the
diaphragm from the diaphragm head (key 4), and install the
new diaphragm.
6. To continue disassembly, first apply grease to the stem
threads to avoid damaging the O-rings (keys 20 and 38).
6.1 With Type 298T actuator sizes 30 through 60, un­
bolt the body from the distance piece and lift it off over the
valve stem. Then unscrew the seal bushing (key 19) to
replace the O-rings.
6.2 The Type 298T size 70 attaches directly to a stan­
dard Fisher valve body bonnet. Unbolt the bushing retainer
(key 100, figure 10) and remove the locknut (key 98, figure
10 ).
6.2.1 Lift off the lower casing and adapator (key
96, figure 10). Also remove and inspect the O-ring (key 101,
figure 10).
6.2.2 Unbolt the bonnet (key 32, figure 10) from
the valve body and lift it off the valve stem.
6
6.2.3 Use a hook to pull or a rod to push the
bushings (key 19, figure 10) out of the bonnet. Be careful to
avoid scratching the O-ring seal surface in the bonnet.
At this point body disassembly can be accomplished by
following the steps in the appropriate valve body instruction
manual.
If maintenance is required only on the valve body, the ac­
tuator and valve plug can be removed as an assembly. In
most cases, this will require the use of a hoist in order to
carefully handle the pieces. On all bodies except the Design
EK, simply unbolt the distance piece from the body and
carefully lift the actuator and valve plug straight out of the
body. If the actuator is mounted on a Design EK valve body,
hoist the actuator only far enough to insert a screwdriver
into the slot on the outer circumference of the cage retainer.
Pry up on the cage retainer to raise it slightly so that the up­
per seal can flex out of the way as the valve plug is pulled
through it.
Type 298T-Reassembly
If the actuator and valve plug have been lifted out of the
Design EK valve body as an assembly, first place the gaskets
on top of the cage retainer and slide the cage retainer onto
the valve plug. Then check the upper seal for equal engage­
ment around the lip of the cage retainer.
Brush some lubricant (a good grade of general-purpose
grease) around the body chamber so the cage retainer O-ring
can slide smoothly into the body. Then very carefully, so that
the valve plug seat is not damaged, lower the actuator-valve
plug assembly into the valve body. Evenly tighten the hex
nuts.
To reassemble the actuator onto an already assembled valve
body with the valve plug and stem assembly installed, follow
the steps below. Use a good grade of general-purpose
grease wherever lubricant is mentioned. When replacing
O-rings, be sure the O-ring groove is clean and undamaged.
Also, keep the valve stem threads greased to avoid damage
to the O-rings when they slide over the valve stem.
1. Bolt the distance piece or bonnet to the valve body,
paying attention to how the tubing will be oriented. If the
lower casing (key 2) was removed, check the O-ring (key 12
or 13). Be sure to replace the bonnet O-ring (key 101, figure
10) on the size 70. Then replace the lower casing.
2. Install the necessary O-rings (keys 38 and 22) in the
sealing bushing (key 19) and replace the sealing bushing
into the distance piece or bonnet (key‘32).
 Types 2 9 8 C & 298T

Note
(T ^
The sealing bushing cavity in the bonnet used
with the size 70 must be handpacked with
grease during reassembly. The stem seal on the
other acuator sizes can be greased using the
grease fitting (key 21), but this is not to be done
on the size 70 since there is no vent (key 58).

3. Lubricate the O-ring (key 38, or 20 if size 70) and in­

stall it in the adaptor (key 14). Also lubricate O-ring (key 17)
and slide it onto the adaptor with the diaphragm (key 3).

4. Place the diaphragm plate (key 4) on the adaptor and

diaphragm and secure with the adaptor locknut (key 15).
Then tighten the set screws (key 39) against the adaptor.

5. Turn the diaphragm assembly onto the valve stem.

With the valve plug seated, locate the diaphragm assembly D IA P H R A G M D IM E N S IO N A C A S E O .D .
as shown in figure 3. C A S E S IZ E IN C H IN C H E S
2 9 8 T -3 0 1 /1 6 1 1 -3 /8
6. Lock the assembly in position with the stem lock clamp 2 9 8 T -4 0 3 /1 6 1 3 -1 /8
(key 16) and hex nut (key 18). Then install the lower spring
2 9 8 T -5 0 5 /1 6 16
seat (key 40) if required.
2 9 8 T -6 0 5 /1 6 1 8 -5 /8
2 9 8 T -7 0 7 /8 2 1 -1 /8
7. Place the upper casing assembly (key 1) on the lower
casing with the tubing bosses aligned. 298C 1 3 /1 6 2 3 -5 /8

8. Tuck in the diaphragm and install the casing cap screws Figure 3. D iaphragm Plate A d ju stm e n t
(key 29).

CAUTION
Be sure there are no wrinkles in the diaphragm
which will cause damage or leakage.
9. Tighten nuts (key 30) on four of the cap screws which
are about 90° apart. Then tighten all of the bolts in succes­
sion around the bolt circle.
10. Install the travel indicator stem (key 26) into the valve
stem and insert the main spring (key 6) in the actuator.
11. Lubricate the O-ring (key 10), slide it on the spring
case cap (key 8).
12. Install the spring case cap and compress the spring
until the cap is metal-to-metal with the spring case'(key 7).
With a size 70 actuator the cap is held in place by cap
screws (key 50) and the spring is compressed by turning the
adjusting screw (key 60) down metal-to-metal.
Troubleshooting
Cycling— If cycling occurs, check to make certain that the
control line connection has not been made at a point of tur­
bulent flow. Assuming this is not the case, while the system
is in operation, slowly throttle down hand valve B (figure 2)
in the control pressure line (do not close it completely) until
stable control is attained. Cycling should cease with the in­
troduction of this measurement lag. If it does not, reduce the
pilot supply pressure with a regulator.
Erratic Operation— Clogging of the pilot orifice or filter may
be indicated. Isolate and vent regulator and lines as describ­
ed in "To Take Out of Operation.” Inspect pilot as described
above and clean out the filter.
Insensitive or Mushy Operation— Loss of main diaphragm
resilience or other main diaphragm damage may be in­
dicated. Isolate and vent regulator and lines as described
before inspecting actuator.

13. With the valve plug on its seat, adjust the travel in­
dicator scale to read properly.
14. On all but the size 70, grease the stem seal through
/ “ 'N the zerk fitting (key 21) until excess grease starts coming out
' the vent (key 58).
Serial Number
The serial number of each unit is stamped on the nameplate
on the regulator spring case as well as on the pilot. Always
refer to this serial number when communicating with your
Fisher sales representative concerning replacement parts or
technical information.

7
 Types 298C & 298T

PARTS LIST Key Description Part Number Key Description Part Number

9* Disc Holder Assembly 19 Hex Nut, steel Cd pi 1A 3 4 0 3 24122

Key ' Description Part Number
Brass/nitrile (std) 1B8868 000A2 20 Cap Screw, steel
SST/nitrile (corrosive) 1B8868 OOOB2 (8 req’d) 1B9896 24052
Tvoe 61L and 61H Pilots 10 Bleed Orifice, SST
1 Spring Case, cast iron Single pilot 1B 887335032 22 Pipe Plug, steel
61 L Series 1 B 9 8 3 9 19012 11 Diaphragm Nut 61 L Series 1A6495 28992
Type 61 H Brass (standard) 1 B 9 8 9 5 14012 23 Y602-1 Vent Assembly
Standard 1B9841 19012 316 SST (corrosive) 1B 989535072 Type 61 H EMY602X1-A1
W/closing cap 1 H 2 3 2 6 19012 12* O-Ring, nitrile 1B 885506992 24 Pipe Nipple, steel Zn pi 1C 488226232
2 Body, cast iron 2J5819 19012 25 Filter Assembly
3 Diaphragm Case, 13 Relay Spring, 302 SST P594-1 (standard) EMP590X1-A2
Cast iron 2 C 5 1 8 6 19012 Type 61 L P593-1 (corrosive) EMP590X1-A1
4 Yoke To 300 psi 1C9115 37022
Zinc (standard) 1D6625 44012 Over 300 psi 1 N 8 5 9 1 37022 26 Bleed Valve, 416 SST
Cast iron (corrosive) 1 B 9 8 4 0 19012 Type 61 LD 1E6436 37022 Types 61 L, LE 1D9867 35132
Type 61 LE 1C911537022 Type 61 LD 1H9516 35132
5 Closing Cap Type 61 H Type 61 H 1D 9 8 6 7 35132
61 L Series, SST/zinc AD5586 000A2 To 300 psi 1C911537022 27 Nameplate, brass 1 D 9 5 9 7 18992
Type 61 H, brass Over 300 psi 1N 8 5 9 1 37022 28* Gasket,
(not shown) 1 H 2 3 6 5 14012 14* Upper Diaphragm, 61 L Series, neoprene 1P753306992
6 Adjusting Screw Nitrile 1B 88 5 2 02052 Type 61 HH w/closing cap
61 L Series, zinc 1B5379 44012 15* Lower Diaphragm (not shown) 1B4870 99202
Type 61H, steel pi 61 L Series, nitrile 1B8860 02052 30 Pipe Plug, cast iron 1 A 3 6 1 9 19012
10-35 psi 1A 5 0 0 5 28982 Type 61H, neoprene 1B8942 02192
10-50 psi 1B 212028982 16 Upper Relay Head, steel 31 Nameplate, brass
10-65 psi 1A 2 7 9 1 28982 Types 61 L, LD 1B 989325072 6 1 L Series 1 D 2 8 3 6 18992
W/closing cap 1J881 5 24102 Type 61 LE 1D 558425072 34 Hex Nut, steel Cd pi
7 Control Spring, steel pi Type 6 1 H 1D5584 25072 Type 61H 1A 352424112
61 L Series 35 Spring Seat, Type 61H
1/4-2 psi (red) 1B8863 27022 17 Lower Relay Head, steel Standard, zinc 0W 0193 44022
1-5 psi (yellow) 1 J 857827022 61 L Series 1B 989425072 W/closing cap, steel 1D 5 5 8 5 25072
2-10 psi (blue) 1B 886427022 Type 61 H 1D5583 25072
5-15 psi (brown) 1J8579 27142 18 Spring Seat, steel Cd pi 41 Adaptor, Type 61 H w/closing cap
10-20 psi (green) 1B8865 27022 61 L Series 1B 886225072 Steel (not shown) 1J8816 24092
Type 61 H 0Y0664 000A2 Type 61 H 1D 558525072
8 Relay Orifice, SST
Single pilot 1C 520135032

8 'Recommended Spare Parts

 Types 298C & 298T

Key D e s c rip tio n P a rt N u m b e r

Type61H H Pilot
1 Regulator Bonnet
Standard, aluminum 2B 7 9 7 4 08012
W/closing cap, brass 1H2372 000A2
2 Body, cast iron 2 D 3 1 8 2 19012
3 Diaphragm Case,
Cast iron 1D3185 19012
4 Yoke, bronze 1D8769 12012

5 Closing cap, brass

(Not shown) 1 H 2 3 6 9 14012
6 Adjusting Screw, steel Pi
To 75 psi 1V9709 X0012
To 100 psi 1B 798628982
W/closing cap 1H 3 0 5 0 28982
7 Control Spring, steel Cd pi
35-100 psi (red) 1K 748527202
10 Orifice, SST 1D3181 35032

12* 0-Ring, nitrile 1C 983906992

13 Valve Spring, 302 SST 1B7979 37022
14* Diaphragm, neoprene
(2 req'd) 1D 317702112
16 Diaphragm Plate, steel (spring side)
(1-1/4" O.D.) 1D317624092

17 Diaphragm Plate, steel

(1-1/8" O.D.) 1D7676 24092
19 Hex Nut, steel Cd pi
(2 req'd) 1A3465 24122
22 Pipe Plug, steel 1A 649528992
24 Pipe Nipple, steel Zn pi 1C4882 26232

25 Filter Assembly
P594-1 (standard) EMP590X1-A2
P593-1 (corrosive) EMP590X1-A1
26* Inner Valve, Key D e s c rip tio n P a rt N u m b e r Key D e s c rip tio n P a rt N u m b e r
Brass/nitrile 1D5604000A2
27 Nameplate, aluminum 1 D 8 6 9 1 11992 4 Spring, steel 19 Distance Piece
34 Hex Nut, steel Cd pi 1A9463 24122 Aluminum/lt. green 1F7142 271 12 Design KB
Aluminum/yellow 1F1 729 271 12 Cast iron
35 Spring Seat, steel 1B7985 25062 Aluminum/tan 1H 6 7 5 1 27112 6" body 1H4910 19022
42 Yoke Cap, bronze 1 D 7 6 7 5 12012 Aluminum/brown 1F17 2 8 27 0 9 2 8" body 1 D 6 1 5 0 19022
45 Valve Spring Seat, Aluminum/purple 1E9215 27092 10" body 2 K 2 8 5 7 19022
Aluminum 1E5322 11032 Steel, WCB
46 Machine Screw, steel 5 Upper Spring Seat, 6" body 1D9321 22012
(6 req'd) 1A7822 28982 Steel 1E9217 24092 8" body 1D 615222012
6 Lower Spring Seat, 10" body 2 F 2 4 8 6 22012
47 Machine Screw, steel Steel 1J548824092 12" body 3H8281 22012
(2 req'd) not shown 1C5911 28982 7 Adaptor Locknut, steel 1F7296 24092 Designs ED, EK, and ET
48 Machine Screw, steel 8 Adaptor, ductile iron 1 F 7 2 9 5 19312 Steel, WCB
(6 req’d) 1B2752 28982 2" body 3V 9195X0012
50 Drive Screw, SST 9 Diaphragm Plate, steel 1J5489 25032 3" body 3V9740 XOOA2
(2 req'd) not shown 1A3682 28982 11* 0-Ring, nitrile 1C7821 06992 4" body 3V 6119 X00A2
12* Diaphragm, neoprene 1J7833 02112 6" body 20A614 4X012
13 Stem Guide Bushing, 20 Cap Screw, steel pi
17-4PH SST 1K5928 35012
Type 298C Actuator 21
(20 req'd)
Hex Nut, steel Cd pi
1A5516 24052

14* O-Ring, nitrile (20 req'd) 1A 413224122

1 Lower Diaphragm Casing, (2 req'd) 1D 237506992
Steel 3F2464 22012 15 Seal Bushing,
2 Upper Diaphragm Casing, 17-4PH SST 1P769235012 22 Cap Screw, steel pi
Steel 3F2471 22012 16* O-Ring, nitrile 1J4151 06992 (8 req'd) 1A 453324052
3 Loading Screw, brass 17* Seal (2 req'd) 1L2491 06992 23 Nameplate, aluminum 1 J 9 8 4 5 11992
W/o trav. ind. 1 E 9 2 1 6 14012 25 Drive Screw, SST
W/trav. ind. 1 H 4 3 4 6 14012 18* Gasket, asbestos 1D6196 04022 (4 req'd) 1A3682 28982

'Recommended Spare Parts

9
 Types 2 9 8 C & 298T

Key D e s c rip tio n P a rt N u m b e r

26 Stem, VSC 1L7500, 316 SST )

Designs EK, ED, and ET
2” body 1V1684 35162
3" body 1V 1 6 8 5 35162
4" body 10A977 8X062
6 " body 10A977 8X052
Design KB body
6" body 1 K8589 35162
8 " body 1K 858935162
10" body 1K 859035162
12" body 1R2816 X00A2

30 Travel Stop, steel (3 req'd)

3/4" travel 1J5615 24092
1-1/8" travel 1J5614 24092
1-1/2" travel 1J5613 24092
2" travel 1J5490 24092
32 Guide Bushing
Top Guided
6" or 8" body
Brass 1 B 8 5 8 9 14042
316 SST 1B 858935072
10" body
Brass 1B8550 14042
316 SST 1B 855035072
Port Guided
6" or 8" body
Brass 1C4998 X0012
316 SST 1C4998 X0022
10" body
Brass 1C3521 X0032
316 SST 1C3521 X0042
35 Nameplate, brass
(Not shown) 1F1370 18992
38' 0-Ring, nitrile 1D 2 6 2 0 06992

39 Set Screw, steel

(2 req'd) 1H 5 0 3 5 28992
40 Hex Nut, steel Cd pi 1A 3 7 5 4 24122
41 Stem Locking Clamp,
Steel 1 F7297 24092
45A Vent Insert, zinc 0W 0843 44022

45B Screen Monelt Key D e s c rip tio n P a rt N u m b e r Key D e s c rip tio n P a rt N u m b e r

(Not identified) 0W 0844 43062
68 Cap, aluminum 1L2908 09012 4 Diaphragm Plate, cast iron
46 Zerk Fitting 1L8478 28992
69 0-Ring, nitrile Size 30 2 H 7 9 2 3 19042
(2 req'd) 1E5914 06992 Size 40 2 H 7 9 3 9 19042
70 Gasket, Size 50 2F7290 19042
Travel Indicator- Copper/asbestos 1A 5 8 3 9 99212 Size 60 2 F 7 3 1 2 19042
Type 298C Size 70 2P4055 19042

59 Body, ductile iron 2 L 2 9 8 5 19172 Type 29 8T Actuator 5* Valve Stem - see following table
60 Glass, glass 1L2993 06992 6 Spring, steel
61 Disc Nut 1F730506992 1 Upper Diaphragm Casing, steel pi Sizes 3 0 ,4 0
62 Stem, aluminum 1J5679 09022 Size 30 2E7922 25062 Aluminum/tan 1J783927112
Size 40 2 E 8 0 6 3 25062 Aluminum/lt. blue 1H 8 2 6 2 27032
63 Plate, SST Size 50 3E8316 25062 Aluminum/purple 1H8261 27032
5/8" 1E833038982 Size 60 2E8474 25062 Aluminum/orange 1F3616 27032
3/4" 1E8331 38992 Size 70 2 N 1 2 7 1 25062 Aluminum/dk. green 1K 509827032
7/8" 1H 1 4 7 8 38992 2 Lower Diaphragm Casing, steel pi Sizes 50, 60
1-1/8” 1E8332 38992 Size 30 2E8011 25062 Aluminum/orange 1H 2 9 7 3 27112
1-1/2" 1E833338992 Size 40 2 E 6 8 2 6 25062 Aluminum/lt. green 1F7142 27112
2" 1E833438992 Size 50 3F6498 25062 Aluminum/yellow 1F1729 27112
64 Gasket, neoprene Size 60 3 F 6 9 9 9 25062 Aluminum/tan 1H6751 27112
(2 req’d) 1L2992 03012 Size 70 2N1310 25062 Aluminum/brpwn 1F17 2 8 27 0 9 2
65 Machine Screw, steel pi 3 Diaphragm Size 70
(8 req'd) 1A3319 28982 Size 30, nitrile 2 H 7 9 3 6 02202 Aluminum/orange 1P4057 27112
66 Hex Nut, steel Cd pi 1A3420 24152 Size 40, nitrile 2 H 7 9 3 7 02202 Aluminum/lt. green 1 P4058 27112
Size 50, neoprene 2F7289 02102 Aluminum/yellow 1P4059 27112
67 Cover, plastic Size 60, neoprene 2F7311 02102 Aluminum/tan 1P4060 27082
(2 req’d) 1L2921 05032 Size 70, nitrile 2P4054 02202 Aluminum/brown 1P4061 27082

* Recommended Spare Parts

10 tTradem ark of International Nickel Co,

 Types 298C & 298T

Key 5" Valve Stem, 316 SST

BODY S IZ E 3 0 A N D *4 0 A C T U A T O R S S IZ E 5 0 A N D 6 0 A C T U A T O R S S IZ E 7 0 A C T U A T O R
D E S IG N S IZ E , 1 / 2 " S te m 1 / 2 " S te m 3 /4 " S te m 3 /4 " S te m 3 /4 " S te m 3 / 4 ” S tem
IN. 1 /2 " V S C t 3 /8 " V S C t 3 /4 " V S C t 1 /2 " V S C t 3 /4 " V S C t 1 /2 " V S C t
1 1V5361 35162 1V973735162 _ _
1-1/2 1V536135162 1V9737 35162 — 1V9734 35162 _ _
1-1/2 x 1 1V9739 35162 1V973335162 — __ — —

2 1V1680 35162 — 1V16 8 435162 1V9736 35162 12A 2452X012 1 2 A 2 4 5 1X012

2x1 1V5361 35162 1V9737 35162 — _ _ _
2-1/2 1V1681 35162 — 1 V 168535162 1 V 973535162 12A 2452X012 1 2 A 2 4 5 1X012
ED, 2-1/2 x 1-1/2 1V5361 35162 1V973735162 — 1 V 973435162 _ _
EK, 2-1/2 x 2 — — — — 12A 2452X012 1 2 A 2 4 5 1X012
ET 3 1V5361 35162 ~ 1V168535162 1V973535162 12A 2452X012 1 2 A 2 4 5 1X012
3x2 1V 168035162 — 1 V 168435162 1 V 973635162 12A 2452X012 1 2 A 2 4 5 1X012
3 x 2-1/2 — — — — 12A 2452X012 1 2 A 2 4 5 1X012
4 10A271 7X012 — 1 V 168735162 1 V 973835162 12A 2452X022 1 2 A 2 4 5 1X022
4 x 2-1/2 1V I 681 35162 — 1V 168535162 1V 973535162 12A245 2X012 1 2 A 2 4 5 1X012
4x3 — — — — 12A 2452X022 1 2 A 2 4 5 1X022
6 — — 1V1687 35162 1V 9 7 3 8 35162 12A 2452X022 12A245 1X022
6x4 — — 1V 1 6 8 7 35162 1V 9 7 3 8 35162 12 A 2 4 5 2X022 1 2 A 2 4 5 1X022
4x2 — — — — 12A 2452X012 1 2 A 2 4 5 1X012
6x4 — — — — 12 A 2 4 5 2X022 1 2 A 2 4 5 1X022
8x4 — — — — 12A 2452X022 1 2 A 2 4 5 1X022
EWT
8x6 — — ~ — 12A245 2X022 1 2 A 2 4 5 1X022
12x6 — — — 12A 2452X022 1 2 A 2 4 5 1X022
6 — ■ — 1K8587 35162 — 12A 2452X032 1 2 A 2 4 5 1X022
KB 8 — — 1K 858735162 — 12 A 2 4 5 2X032 1 2 A 2 4 5 1X022
10 — — — — 12A245 2X042 1 2 A 2 4 5 1X022
t Valve Stem Connection

Key Description Part Number Key Description Part Number Description Part Number
7 Spring Case, cast iron 17* O-Ring, nitrile Sizes 50, 60 (4 req'd)
Sizes 30, 40 2V167’6 19012 Sizes 30, 40 1D5439 06562 5/8" travel 1E8273 24092
Sizes 50, 60 2 V 1 6 7 4 19012 Sizes 50, 60 (2 req'd) 1D 262006992 3/4" travel 1E8318 24092
Size 70 3 P 4 0 6 2 19022 Size 70 1D2620 06992 7/8" travel 1F8632 24092
8 Spring Case Cap, cast iron 18 Hex Nut, steel Cd pi 1-1/8" travel 1E831924092
Sizes 30, 40 2L2906 19012 1/2" stem 1A413 2 2 4 1 2 2 1-1/2" travel 1E8064 24092
Sizes 50, 60 2 L 2 9 0 7 19012 3/4" stem 1A 375424122 2" travel 1E8321 24092
Size 70 2 P 4 0 6 4 19022 19 Seal Bushing, brass Size 70 (3 req'd)
Sizes 30, 40 1V1678 14012 1-1/8" travel 1N 1 2 8 9 24092
9 Travel Indicator Cap, aluminum Sizes 50, 60 1 V 1 6 7 7 14012 1-1/2" travel 1N129024092
Sizes 30-60 1L2908 09012 Size 70 (2 req'd) 12A 2 0 5 7X012 2" travel 1N 1 2 9 1 24092
10' O-Ring, nitrile 20* 0-Ring, nitrile 2-1/2" travel 1R9542 24092
Sizes 30, 40 1H 792806992 Sizes 50, 60, 70 1C7821 06992 3" travel 1N 129224092
Sizes 50, 60 1F7294 06992 4" travel 1P 4 06624092
Size 70 1L3159 06992
21 Zerk Fitting, Sizes 30-60 Relief Valve Assembly
11 Hex Bushing, iron 1B2928 21992
(For Design E) 1A7009 99012 Type 1806,
12* O-Ring, nitrile
22 O-Ring, nitrile, sizes 30-60 Brass/ SST AF5001 X00A2
Sizes 50, 60 1K8793 06992
Size 70 (2 req'd) W/Design E 1C5622 06992
1D2691 06992 Relief Valve Tubing, copper
23 Upper Travel Stop, steel
Size 30 (3 req'd) Size 30 1J3978 000A2
13* 0-Ring, nitrile, sizes 30-60
7/16" travel 1F 536724092 Size 40 1J4037 000A2
(2 req'd sizes 30, 40) 1L4799 06992 Size 50
5/8" travel 1H7 9 3324092 1F7300 000A2
14 Adaptor, ductile iron
3/4" travel 1E7979 24092 Size 60 1F7313 000A2
Sizes 30, 40 1 H 7 9 2 9 19312
7/8" travel 1E7925 24092 Size 70 1P4067000A2
Sizes 50, 60, 70 1 F 7 2 9 5 19312
1-1/8" travel 1F8475 24092 Travel Indicator Stem
15 Adaptor Locknut, steel
Size 40 |3 req'd) Size 30 aluminum 1J6231 09022
Sizes 30, 40 1H 7 9 3 1 24092
5/8" travel 1H7 9 4 024092 Size 40 aluminum
Sizes 50, 60, 70 1F729624092
3/4" travel 1E8065 24092 7 /1 6 " to
16 Stem Lock Clamp, steel
7/8" travel 1E8066 24092 1-1/8" travel' 1J6232 09022
Sizes 30, 40 1H 7 9 3 2 24092
1-1/8" travel 1H 7 9 7 6 24092 1-1/2" travel 1 K7443 09022
Sizes 50, 60, 70 1 F7297 24092
1-1/2" travel 1F3932 24092 Sizes 50, 60
Aluminum 1H7716 09022
Size 70, SST 1U5711 35172

■Recommended Spare Parts

11
 Types 298C & 298T

Figure 8. Type 2 9 8 T A c tu a to r Size 3 0 or 4 0 Figure 9. Type 2 9 8 T A c tu a to r Size 5 0 or 6 0

Key Description Part Number Key Description Part Number Key Description Part Number
28 Male Connector (2 req'd) 2-1/2" body Size 70 for Design EW
Brass (standard) 1 D 6 9 2 2 14012 Cast iron 3V1649 19022 4" x 2" body
Aluminum (corrosive) 1 J 9 8 8 6 11992 WCB steel 3V1647 22012 Cast iron 2R3311 19022
29 Cap Screw, steel pi 3" body WCB steel 2R3304 22012
Size 30 (12 req'd) 1E 7 60324052 Cast iron 3 V 1 6 5 3 19022 6" x 4" and 8" x 4" bodies
Size 40 (16 req’d) 1E 7 60324052 WCB steel 3V1651 22012 Cast iron 2 R 3 6 7 4 19022
Size 50 (20 req'd) 1A 6 7 5 1 24052 4" body WCB steel 2 R 3 6 6 7 22012
Size 60 (24 req'd) 1A6751 24052 Cast iron 3V1657 19022 8" x 6" and 12"x6 " bodies
Size 70 (28 req’d) 1A 582824052 WCB steel 3V1655 22012 Cast iron 3 U 5096 19022
6 " body WCB steel 3 U5094 23022
30 Hex Nut, steel Cd pi (same Cast iron 3 V 1 6 6 1 19022 Sizes 30-60 for Design KB
quantity as key 29) 1A 346524122 WCB steel 3V1659 22012 6" body
31 Cap Screw, steel pi 32 Bonnet Cast iron 31A394 4X012
Sizes 3 0 ,4 0 (9 req'd) 1A 368424052 Size 70 for Design E WCB steel 31A394 3X012
Sizes 50, 60 (10 req'd) 1A 368424052 2-1/2" body 8" body
Size 70 (21 req'd) 1N129328992 Cast iron 2R3857 19022 Cast iron 3 1 A 3 9 4 7X012
32 Distance Piece WCB steel 2 R 3 8 5 2 22012 WCB steel 31A394 8X012
Sizes 30-60 for Design E 3" body Size 70 for Design KB
1" body Cast iron 2 R 3 4 9 4 19022 6 " body
Cast iron 3V5365 19022 WCB steel 2 R 3 4 8 9 22012 Cast iron 3K4394 19022
WCB steel 3V5363 22012 4" body WCB steel 3K4391 22012
1-1/2" body Cast iron 2R3674 19022 8" body
Cast iron 3 V 5 3 6 9 19022 WCB steel 2 R 3 6 6 7 22012 Cast iron 3K3505X0012
WCB steel 3 V 5 3 6 7 22012 6" body WCB steel 3K3518 22012
2" body Cast iron 3 U5 0 9619012 10" body
Cast iron 3V1645 19022 WCB steel 3 U 5 0 9 4 23022 Cast iron 3K2850 19022
WCB steel 3V164 3 22 0 1 2 WCB steel 3 K 2 8 6 6 22012

‘ Recommended Spare Parts

12
 Types 298C & 298T

Key Description Part Number

34 Hex Nut, steel Cd pi 1A3420 24152

35 Nameplate, aluminum 1 J 9 8 4 5 11922
36 Nameplate, brass 1 F 1 3 7 0 18992
37 Drive Screw, SST
(6 req'd) 1A 368228982

38* O-Ring, nitrile

Sizes 30, 40 (3 req'd) 1C7822 06992
Sizes 50, 60 (2 req'd) 1D 2 3 7 5 06992
Size 70 (2 req’d) 1C7821 06992
39 Set Screw, steel
(2 req'd) 1H 5 0 3 5 28992
40 Lower Spring Seat, steel
Size 40 1H 7 9 7 7 24092
45 Travel Indicator Glass, glass
Size 3 0 ,4 0 1L2909 06992
Size 50, 60 1L2922 06992

46 Travel Indicator. SST

7/16" travel
Sizes 3 0 ,4 0 1E8076 38992
5/8" travel
Sizes 3 0 ,4 0 1E8077 38982
Sizes 50, 60 1E8330 38982
3/4" travel
Sizes 3 0 ,4 0 1E8081 38992
Sizes 50, 60 1E8331 38992
7/8" travel
Sizes 3 0 ,4 0 1H 1 4 7 9 38992
Sizes 50, 60 1H 1 4 7 8 38992
1-1/8" travel
Sizes 3 0 ,4 0 1E8082 38992
Sizes 50, 60 1E833238992
Size 70 1N 6 9 4 6 38992
1-1/2" travel
Size 40 1E8083 38992
Sizes 50, 60 1E8333 38992
Size 70 1U 3 7 2 5 38982
2 " travel
Sizes 50, 60 1E8334 38992
Size 70 1U 3 7 2 8 38982 Key Description Part Number Key Description Part Number
2-1/2" travel, size 70 1U 3 8 9 7 38982
3" travel, size 70 1U 3 7 2 6 38982 60 Adjusting Screw, cast iron M ounting Parts
4" travel, size 70 1U 3 7 2 7 38982 Size 70 2 U 5 7 1 0 19022
47 Machine Screw, steel pi 61* 0-Ring, nitrile Types 61L or 61H on Type 298C
Size 70 (2 req'd) 1H 9 7 6 7 28982 Size 70 1J4889 06992 10 Differential Relief Valve
48 Travel Indicator Disc Nut 62 Spring Seat, cast iron Type 1806, brass/SST AF5001 X00A2
Plastic 1F7305 06992 Size 70 1 N 1 2 9 6 19052 24 Pipe Nipple, steel 1B819326012
50 Cap Screw, steel pi 67 Protection Cap 27 Pipe Nipple, steel 1C488226232
Size 70 (12 req'd) 1A 3 4 0 9 24052 Sizes 30-60 1F5425 06992 28 Pipe Tee,
Malleable iron 1C 597519062
51* 0-Ring, nitrile 96 Adpator, cast iron
Sizes 3 0 ,4 0 1D2620 06992 Size 70 22A205 6X012 29 Male Connector, brass
52 Retainer, aluminum 97 Spacer, steel (3 req’d) 1 D 6 9 2 2 14012
Sizes 30-60 1L2910 09012 Size 70 11A 2838X012 33 Male Elbow, brass 1 D 6 9 2 4 18992
52 Bushing, SST 98 Locknut, steel 36 Relief Valve Tubing Ass’y
Size 70 1F2620 35032 Size 70 1E832723062 Copper/steel 1H 5656 000A2
53 Gasket, neoprene (2 req'd) 99 Cap Screw, steel pi 37 Pilot Loading Tubing Ass'y
Sizes 30-60 1L2911 03012 Size 70 (2 req'd) 12A 2059X012 Copper/steel 2H 5657000A2

54 Travel Ind. Cover, plastic (2 req'd) 100 Bushing Retainer, steel

Size 70
Sizes 30, 40
Sizes 50, 60
1L2912 05032
1L2921 05032 101* O-Ring, nitrile
12A 2058X012
1K1810 06992
Type 61HH on Type 298C
55 Machine Screw, steel pi (8 req'd) 102 Packing Box Ring, 316 SST 10 Differential Relief Valve
Sizes 30-60 1A 331928982 Size 70 1 J 873335072 Type 1806,
56* 0-Ring, nitrile 103* Lower Wiper, TFE Brass/steel * AF5001 X00A2
Sizes 30-60 (2 req'd) 1E5914 06992 Size 70 1J872306992 71 Pipe Nipple, steel
Size 70(1 req’d) 1D1917 06992 (Not shown) 1C 488226232
58 Type Y602-12 Vent Ass’y, 104 Pipe Plug, steel Cd pi 72 Tee, malleable iron 1C 597519062
Zinc/Monel 1C8937 000A2 Size 70 1A 767524662 74 Pipe Nipple, steel
(2 req'd) 1B3526 26012

* Recommended Spare Parts 13

 Types 298C &298T

Figure 11. Type 6 1 L o r 6 1 H P ilo t M ou n tin g Figure 13. Type 6 1 L o r 6 1 H P ilo t M o unting
on Type 2 9 8 C A c tu a to r on Type 2 9 8 T A ctu a to r

CONNECT TO

CONTROL LINE
CONNECTION

Figure 12. Type 61 H H P ilo t M ou n tin g Figure 14. Type 61 H H P ilot M o u n ting
on Type 2 9 8 C A c tu a to r on Type 2 9 8 T A ctu a to r

Key Description Part Number Key Description Part Number Key Description Part Number

76
77
Male Elbow, brass
Flared Nuts, steel pi
1 D 6 9 2 4 18992 Type 61L or 61H on Type 298T Type 61HH on Type 298T
(6 req'd) 1D 6 9 2 1 24272 11 Hex Bushing, iron 1B2928 21992 11 Hex Bushing, iron 1B2928 21992
78 Male Connector, brass 27 Pilot Loading Tubing, copper 27 Pilot Loading Tubing Ass'y,
(5 req'd) 1 D 6 9 2 2 14012 Size 30 3J3979 000A2 Copper/steel 1D9079000A2
79 Tubing, copper Size 40 3J4038 000A2 28 Male Connector
(Specify length) 050021 1701W Size 50 3F7301 000A2 Brass (standard) 1D6922 14012
Size 60 3F7314 000A2 Aluminum (corrosive) 1J9886 11992
81 Pipe Cross, iron Size 70 3P4068 000A2 33 Pipe Nipple, steel 1K279426012
(2 req'd) 1A 953721992 28 Male Connector (2 req'd)
82 Mounting Bar, steel 1 E6342 24092 Brass (standard) 1 D 6 9 2 2 14012 77 Elbow Fitting, brass 1D6924 18992
83 Pipe Bushing, steel pi Aluminum (corrosive) 1 J 9 8 8 6 11992 91 Pipe Nipple, steel 1B8193 26012
(3 req'd) 1C 379026232 33 Pipe Nipple, steel 94 Tee, iron 1A4736 21992
Sizes 30. 40, 50 1F730226012
Size 60 1F7315 26012
Size 70 1H4029 26012

'Recommended Spare Parts

While this information is presented in good faith and believed to be accurate,
Fisher Controls does not guarantee satisfactory results from reliance upon such
information. N o th in g c o n ta in e d h e re in is to b e c o n s tru e d as a w arra n ty o r
g uarantee, e x p re s s o r im p lie d , re g a rd in g th e p e rfo rm a n c e , m e rc h a n ta b ility , fitn e s s
nor as a recommendation to
o r a n y o th e r m a tte r w ith re s p e c t to th e p ro d u c ts ,
use any product or process in conflict with any patent. Fisher Controls reserves
the right, without notice, to alter or improve the designs or specifications of
the products described herein.

F o r in fo rm a tio n , c o n ta c t F is h e r C o n tro ls :
FISH ER’) Fisher Controls Marshalltown, Iowa 50158 USA
Cernay 68700 France
Sao Paulo 05424 Brazil
Singapore 0512

Printed in USA ►recycled paper

 Types 95L & 95H

Fisher Controls Instruction Manual

T y p e 9 5 L and 9 5 H P re ssu re
R e g u lato rs

July 1990 Form 1151

W A R N IN G
R egu la to rs sho uld be installed, operated,
and m aintained in a c c o rd a n c e with federal,
state, and local c o d e s, rules and re g u la ­
tions, and F is h e r instructions.

If the regulator ve n ts g a s or a leak d e ve lo p s

in the s yste m , it in d ica tes that s e rvic e is
required. Failure to ta ke the regu la tor out of
s e rvic e im m e d ia te ly m a y create a h a za rd ­
ou s condition.

Call a s e rvic e m a n in c a se of trouble. O n ly a

qualified p e rso n m u st install or s e rvic e the
regulator.

In tro d u c tio n

Type 95L and 95H self-contained pressure regulators

are suitable for pressure control of steam, air, gas,
water, oil, and similar fluids requiring constant outlet
pressures between 2 and 150 psig. Typical Type 95L Figure 1. Type 95L Flanged Body (Bottom),
and 95H regulators are shown in figure 1. NPT Body (Top Left), and 95H
Pressure Regulators

D e s c rip tio n T y p e 95H — Basically same as 95L, but permits higher

T y p e 95L — Pressure reducing regulator suitable for
controlling many gasses and liquids. Iron, steel or stain­
less steel bodies are available. Reduced pressure range
is from 2 to 30 psig with three different springs available.
Body sizes 1/4 through 1-inch NPT, 1/2 through 1-inch
ANSI classes 150 and 300 flanges, and 1/2 through 1-
inch socket weld end connections are available. The
standard orifice sizes are 1/4, 3/8 and 9/16-inch diame­
ter, dependent on body sizes.
reduced pressure ranges from 15 to 150 psig for the 1/4,
1/2, 3/4 and 1-inch sizes. Also available in 1-1/2 and 2-
inch NPT, ANSI class 150 or 300, or socket weld bodies
with a 1-1 /16-inch orifice to give reduced pressure
ranges from 5 to 150 psig.
P rin c ip le O f O p e ra tio n
Pressure in the controlled system (regulator outlet pres­
sures) registers beneath the diaphragm of the regulator
and opposes the force provided by the pre-determined

© fish er Controls International Inc. 1954, 1990; All Rights Reserved

Type 95L & 95H

spring com p ression . W h en regulator spring force e x ­ Table 1. Reduced Pressure Ranges
ceeds diaphragm force exerted b y the outlet pressure, Spring Type 95L Type 95H
Body
the spring will keep the stem p ressed d ow n , th ereb y Size, Color Reduced Reduced
co m p ressin g the va lve spring and holding the va lve plug Inches Code Pressure Range Pressure Range
a w a y from the orifice to perm it additional flow to the Yellow 2 to 6 psi 15 to 30 psi
1/4, 1/2,
dow n strea m system . 3/4, 1
Green 5 to 15 psi 25 to 75 psi
Red 13 to 30 psi 70 to 150 psi
A s outlet p ressure increases to the setting of the regula­ Lt. Blue — 5 to 80 psi
tor spring, the diaphragm is raised, and the va lve spring 1-1/2 or Lt. Gray — 60 to 120 psi
2 Yellow — 100 to 140 psi
m o ve s the va lve plug clo se r to the orifice to prevent Black — 120 to 150 psi
additional build-up of outlet pressure.

Table 2. Maximum Inlet Pressure and Temperature

Installation Body
Diaphragm and Maximum Inlet
Type Valve Plug Pressure and
Material
Number Material Temperature
Clean out all pipelines before installation of the regulator
and check to be sure the regulator has not been dam ­ 95H and 95L Cast Iron Neoprene 250 psi; 180°F
95H and 95L Cast Iron Stainless Steel 250 psi; 410°F
aged o r collected foreign material during shipping. A p ­ Cast Steel Stainless Steel 300 psi; 450°F
95H and 95L
ply pipe com pound to the m ale pipe threads and install 95H and 95L Cast Steel Neoprene 300 psi; 180°F
the regulator in a n y position desired, but be sure flow 95H and 95L Cast Iron Fluoroelastomer 250 psi; 300°F
through the b o d y is in the direction indicated b y the 95H and 95L Cast Steel Fluoroelastomer 300 psi; 300°F
a rro w cast on the body.
also be provided if the regulator inlet p ressure is greater
than th e s a fe w o r k in g p re s s u re of d o w n s tre a m
Note equipm ent.
It is important that the regulator be installed R egulator operation b elow the m axim um p ressure limi­
so that the vent hole in the spring case is tations d oes not preclude the possibility of dam age from
unobstructed at all times. For outdoor in­ external sou rces o r from debris in the line. T h e regulator
stallations, the regulator should be located should be inspected for dam age after a ny o ve r pressure
away from vehicular traffic and positioned condition as stated on the nameplate.
so that water, ice, and other foreign materi­
als cannot enter the spring case through
the vent. Avoid placing the regulator be­
neath eaves or downspouts, and be sure it Startup
is above the probable snow level.
T h e regulator is set at the factory for the reduced
p ressure specified on the order, s o no initial adjustm ent
O n 1-1/2 or 2-inch T y p e 95H regulators, the spring case should be required to give the desired results. 'With
vent is tapped s o a ven t line can be connected to p rovide p rop er installation com pleted and relief va lve s prop erly
venting to a rem ote location. O n 1/4,1/2,3/4 and 1-inch adjusted, slo w ly open the upstream and d ow nstream
T y p e 95H b o d y s ize s the tapped ven t option is available shutoff va lves.
on request. T h e e xp o s e d end of the ven t pipe should be
protected with a w ea th er and insect resistant vent,
assem bly. Adjustment
All ven ts and rem ote ven t lines should be checked T h e factory setting of the regulator can be varied within
periodically to en sure that th ey are unobstructed. the p ressure range stam ped on the nam eplate. T o
change the outlet p ressure, loosen the locknut (key 17,
figure 2, 3, o r 4) and turn the adjusting s cre w (key 15,
figure 2, 3, o r 4) clockw ise to increase outlet pressure,
Over Pressure Protection or counterclockw ise to decrease it. M onitor the outlet
p ressure with a test ga uge during the adjustm ent. Tig h t­
A s is the case with m ost regulators, the T y p e 95L and en the locknut to maintain the desired setting.
95H regulators have an outlet p ressu re rating lo w er than
the inlet p ressu re rating. T h e recom m ended pressure All regulator springs can be backed off to provide ze ro
limitations are stam ped on the regulator nameplate. outlet. R ecom m en ded outlet p ressu re ranges available,
S o m e typ e of o ve r p ressu re protection is needed if the m axim um inlet p ressu re s and tem peratures, m axim um
actual inlet p ressu re e xc e e d s the m axim um operating e m ergen cy outlet pressures, and color codes of the
outlet p ressure rating. O v e r p ressu re protection should respective springs are sh o w n in tables 1 through 3.
 Type 95L & 95H

Table 3. Maximum Emergency Outlet Pressure 2. Inspect the seating surface of the va lve plug, being
MAXIMUM EMERGENCY sure that the com position surface (or polished steel
BODY AND OUTLET AND SPRING surface) of the va lve plug is not dam aged. R eplace if
REGULATOR
SPRING CASE CASE PRESSURE dam age is noted.
TYPE
MATERIALS
Psig Bar
Cast Iron 50 3.5 3. Inspect the seating ed ge of the orifice (key 3). If
95L Cast Steel or dam age is noted, u n scre w the orifice from the b o d y and
125 8.6 replace it with a n e w part. T o rq u e per table 4. If no
Stainless Steel
Cast Iron 250<1> 17.2 further m aintenance is required, reassem ble the regula­
95H Cast Steel or tor in the re ve rse of the a b o ve steps. W h en installing the
300 20.7
Stainless Steel va lve plug guide (key 5) coat the threads and sealing
1. Maximum outlet pressure for 1-inch 95H is 165 psig. surface with sealant to en sure an adequate m etal-to-
metal seal. R e a sse m b ly torque per table 4.
Table 4. Torque Specifications
4. If diaphragm dam age is suspected, o r to inspect the
Body Size, Spring Case Orifice Plug Guide diaphragm or other internal parts, loosen the locknut
Inches Ft-Lbs Ft-Lbs Ft-Lbs
(key 17) and turn the adjusting s cre w (key 15) to re m o ve
1/4 4.5 - 5.0 8 - 12 42 - 58 all spring com pression.
1/2 10 - 13 29 - 35 70 - 90
3/4 - 1 24 - 30 33 - 42 130 - 160
1-1/2 - 2 40 - 50 140 - 170 170 - 200 Steps 5 and 6 apply tp the T y p e 95L and s ize s 1/4 to 1-
inch T y p e 95H. If the unit being d isassem bled is a 1-1/2
to 2-inch size T y p e 95H, proceed to S teps 7 and 8.

5. R e m o ve the diaphragm case cap s cre w s (key 16)

Shutdown
C lose the upstream shutoff va lve. C lose dow n strea m
shutoff valve. O p e n bleed va lve betw een the regulator
and the d ow n strea m shutoff va lve. W ithout changing
regulator spring adjustm ent, all p re ssu re betw een the
upstream and d ow n strea m shutoff va lve s will be re­
leased through the bleed valve, since the T y p e 95L or
95H o p e n s in re s p o n s e to the d e c re a s e d ou tlet
pressure.
and lift off the spring case (key 2). R e m o ve the upper
spring seat (key 9) and regulator spring (key 11). O n 1/4
to 1-inch s ize s T y p e 95H units only, re m o ve the low er
spring seat (key 8). O n 95L units, re m o ve the diaphragm
head a ssem b ly (key 21).
6. R e m o ve the diaphragm (s) and exam in e fo r dam age.
R eplace if dam age is noted. N ote that if the diaphragm is
metal, tw o diaphragm s should be used.

7. R e m o ve the diaphragm -diaphragm head assem bly. It

can be d isassem bled for inspection of the diaphragm
(key 12) and tw o small diaphragm gaskets (key 47) or O -
Maintenance ring (key 45). R e m o ve the locknut (key, 31) from the
push er post (key 30) and separate the assem bly. A n 0 -
ring is used to seal around the p ush er post if a c o m p osi­
tion diaphragm is used, and the gaskets are used with
W A R N IN G stainless steel diaphragm s.

Before disassembling the regulator, isolate
it from the pressure system and release all
pressure from the regulator as specified in
the section Shutdown.
D ue to norm al w e a r that m a y occur, parts m ust be
periodically inspected and replaced if necessary. T h e
fre q u en cy of inspection d ep en ds on the severity of
service conditions. T h is section includes instructions for
d isa ssem b ly and replacem ent of parts. All k e y num bers
refer to figures 2, 3, and 4.
1. U n scre w the va lve plug guide (key 5) from the b o d y
(key 1). T h e va lve plug spring (key 10) and the va lve plug
(key 4) will norm ally co m e out of the b o d y along with the
va lve plug guide. O n 1-1/2 o r 2-inch units the stem (key
6, figure 4) will also com e out of the regulator body.
8. U n screw and re m o ve the stem guide bushing (key 7).
An O -ring (key 51) held in place b y the packing follow er
(key 50) can then be exam ined for dam age.
9. W ith diaphragm (s) rem oved , check to be sure the
p ressure registration hole (pitot tube, ke y 20, in 3/4 inch
and larger sizes) is com pletely open and free of all
obstructions.
10. If the unit has stainless steel diaphragm s, replace
the large diaphragm gasket (key 19). Install both dia­
phragm s with their raised preform ed centers facing
tow ard the spring case.
11. R ea ssem b le in the re ve rse of the a b o ve p roce­
dures. Lubricate the upper spring seat and the e xp o se d
threads of the adjusting sc re w with A n ti-S e ize lubricant.

3
Type 95L & 95H

B efore tightening cap sc re w (key 16) be sure to install Key Description Part Number
the adjusting screw , if com pletely re m o ved , and turn it
2 Spring Case— See following table
d o w n s o that diaphragm slack is obtained. T h is allows 3* Orifice
p rop er positioning of the diaphragm to perm it full travel 416 SST (for metal seat)
of the va lve plug. T o rq u e diaphragm cap sc re w s per 1/4-inch body 1E3916 46172
table 4. C om plete rea ssem b ly p roce du re s and turn the 1/2-inch body 1E3950 46172
3/4 and 1-inch body 1E3980 46172
adjusting s c re w to produce the desired outlet pressure.
1-1/2 and 2-inch body, Type 95H only 2P7870 46172
Tigh ten the locknut to maintain the desired setting. Brass (for composition seat)
1/4-inch body 1E3932 14012
1/2-inch body 1E3962 14012
Parts Ordering 3/4 and 1-inch body
416 SST (for composition seat)
1E3995 14012

1-1/2 and 2-inch body, Type 95H only 1P7860 35132

W h en co rresp on ding with y o u r Fisher sales office or
NACE, 316 stainless steel
sales representative about this equipm ent, a lw a ys refer­ For composition seat
ence the equipm ent serial num b er or F S num ber that 1/2-inch body 1E3962 35072
can be found on the nam eplate. '3/4 and 1-inch body 1E3995 35072

4* Valve Plug— See Following Table

W h en ordering replacem ent parts, reference the key
num ber of each needed part as found in the following 5 Valve Plug Guide
parts list. Separate kits containing all recom m ended Brass
spare parts are available. 1/4-inch body 1E3918 14012
1/2-inch body 1E3952 14012
3/4 and 1-inch body 1E3982 14012
1-1/2 and 2-inch body, Type 95H only 1U4041 X0022
Parts List 416 SST '
1/4-inch body 1E3918 35132
Note 1/2-inch body 1E3952 35132
3/4 and 1-inch body 1E3982 35132
1-1/2 and 2-inch-body, Type 95H only 1U4041 35132
In this parts list, parts marked NACE are intended for
NACE, 316 stainless steel
corrosion-resistant service as detailed in the National
Composition seat
Association of Corrosion Engineers (NACE) standard
1/2-inch body 1E3952 35072
MR-01-75.
3/4 and 1-inch body 1E3982 35072

Description Part Number 6 Stem Assembly

Stainless steel ■
Parts Kit (Included are keys 3, 4, 10, 12, 1/4-inch body 1F2113 000A2
1/2-inch body • 1F2114 000A2
and 19)
Type 95H 3/4 and 1-inch body 1F2115 000A2
For Composition, Trim 2 NACE, 316 stainless steel
1/4-inch body R95HX 000012 Composition seat
R95HX 000022 1/2-inch body 1F2114 X0082
1/2-inch body
3/4 and 1-inch body R95HX 000032 3/4 and 1-inch body 1F2115 X0072
For Composition, Trim 3A Stem, stainless steel, Type 95H only
1/4-inch body R95HX 000102 1-1/2 and 2-inch body 1P7853 35232
1/2-inch body R95HX 000112
3/4 and 1-inch body , R95HX 000122 T Stem Guide Bushing
1-1/2 and 2-inch body R95HX 000042 Stainless steel
For Metal Trim 1/4 and 1/2-inch body 1E3922 35132
1/4-inch body R95HX 000052 3/4 and 1-inch body 1E3985 35132
1/2-inch body R95HX 000062 1-1/2 and 2-inch body, Type 95H only 1P7854 35132
3/4 and 1-inch body R95HX 000072 NACE, 316 stainless steel
1-1/2 and 2-inch body R95HX 000082 Composition seat
Extra parts for 1-1/2 and 2-inch body 1/2-inch body 1E3922 35072
include keys 45, 47, 51 and 52 3/4 and 1-inch body 1E3985 35072
Type 95L
For Composition, Trim 2 8 Lower Spring Seat Type 95H only,
1/4-inch body R95LX 000012 Aluminum
1/2-inch body R95LX 000022 1/4-inch body 1E3923 09012
3/4 and 1-inch body R95LX 000032 1/2-inch body 1E3954 08012
For Composition, Trim 3A 3/4 and 1-inch body 1E3986 08012
1/4-inch body R95LX 000102 Steel
1/2-inch body R95LX 000112 1-1/2 and 2-inch body • 1P7877 24152
3/4 and 1-inch body R95LX 000122
For Metal Trim 9 Upper Spring Seat, Steel
1/4-inch body R95LX 000042 1/4-inch body 1B7985 25062
1/2-inch body R95LX 000052 1/2-inch body 1D6671 25072
3/4 and 1-inch body R95LX 000062 3/4 and 1-inch body 1E3987 25072
1 Regulator Body— See following table 1-1/2 and 2-inch body
(Type 95H) 1P7876 24092

4 •Recommended spare part.

 Type 95L & 95H

PITOT TUBE USED IN

3/4” & 1” SIZES ONLY

Figure 2. Type 95L, Sizes 1/4 to 1-Inch Stainless Steel Trim

Key D e s c rip tio n P a rt N u m b e r Key D e s c rip tio n P a rt N u m b e r

10 Valve Plug Spring 16 Cap Screw, Steel

Stainless steel 1/4-inch body
1/4-inch body 1E3924 37022 Type 95L (10 req’d), Type 95H (6 req’d) 1A4078 24052
1/2-inch body 1E3955 37022 1/2-inch body
3/4 and 1-inch body 1E3988 37022 Type 95L (10 req’d), Type 95H (8 req’d) 1A3816 24052
1-1/2 and 2-inch body 3/4 and 1-inch body
(Type 95H) 1P7858 37012 Type 95L (12 req’d), and
NACE, InconelO) Cast iron, Type 95H (8 req’d) 1A3369 24052
1/2-inch body 19A2861 X012 Steel, Type 95H (8 req’d) 1A3418 24052
3/4 and 1-inch body ' 1P8443 X0012 1-1/2 and 2-inch, Type 95H (8 req’d) 1K5684 28982
11 Regulator Spring— See following table
12* Diaphragm— See following table 17 Jam Nut, Steel
1/4-inch body 1A3522 25122
13 Nameplate, Aluminum 11A5496 X0A2 1/2-inch body 1A3537 24122
14 Diaphragm Protector, TFE 3/4 and 1-inch body 1A3192 24122
1/4-inch body 1-1/2 and 2-inch body 1A3681 24112
Type 95L 11A512 6X012 18 Drive Screw, Stainless steel
Type 95H 11A512 9X012 (2 req’d) 1A3682 28982
1/2-inch body 19* Diaphragm Gasket, Composition
Type 95L 11A512 7X012 (Use with metal diaphragm)
Type 95H 11A513 0X012 1/4-inch body
3/4 and 1-inch body Type 95L 1E3940 04022
Type 951- 11A512 8X012 Type 95H 1E3931 04022
Type 95H 11A513 1X012 1/2-inch body
15 Adjusting Screw, Steel Type 95L 1E3970 04022
1/4-inch body 1E6399 28992 Type 95H _ 1E3961 04022
1/2-inch body 1D9954 48702 3/4 and 1-inch body "
1/2-inch body with handwheel 1J4964 28982 Type 95L 1E3904 04022
3/4 and 1-inch body 1A3308 28982 Type 95H 1E3993 04022
1-1/2 and 2-inch body 1A6801 28992 1-1/2 and 2-inch body
Type 95H 1P7879 04022

'Recommended spare part.

1. Trademark of International Nickel Co. 5
Type 95L & 95H

Figure 3. Type 95H, Sizes 1/4 to 1-Inch

Composition Trim

Key Description Part Number Key Description Part Number

20 Pitot Tube, The following parts are for the

3/4 and 1-inch body 1-1/2 and 2-inch Type 95H only
Copper 1E3994 17012
304 Stainless steel 1E3994 38072 30 Pusher Post, Stainless steel
NACE, 316 stainless steel Composition seat 1P7849 35132
Composition seat 1E3994 38092 Metal seat 1P7851 35132
1-1/2 and 2-in'ch body 31 Locknut, Steel 1P7887 24122
304 Stainless steel, Type 95H only 1P7856 38072 45* O-Ring, Nitrile (Use with neoprene
21 Diaphragm Head Assembly, Type 95L only diaphragm 1C7822 06992
Aluminum and stainless steel 47* Diaphragm Gasket, Composition
1/4-inch body 1E3936 X0012 Use with metal diaphragm
1/2-inch body 1E3967 X0012 (2 req’d) 1P7880 04022
3/4 and 1-inch body 1E3907 X0012
48 Diaphragm Head, Steel
22 Adjusting Screw Assembly (2 req’d) 1P7882 25012
Steel (for tee-handle construction) 49 Lockwasher, Steel 1A4878 28992
1/4-inch body 1F2236 000A2 50 Packing Follower
3/4 and 1-inch body 1F2238 000A2 416 Stainless steel 1P7855 35232
1-1/2 and 2-inch body 1V4372 X0012 51* O-Ring, TFE 1P7859 06242
23 Handwheel, Zinc
1/2-inch bbdy 1J4961 44012 52 Spring, Stainless steel 1P7857 37012
24 Machine Screw, Steel (handwheel 54 Valve Plug Base,
construction) 1A8517 28982 416 Stainless steel 1U4040 46172
56 NACE Tag . 19A6034 X012
25 Lockwasher, Steel (handwheel 57 Tag Wire 1U7581 X0022
construction) 1A3523 32992

6 ‘ Recommended spare part.

 Type 95L & 95H

(47

METAL TRIM

COMPOSITION TRIM

Figure 4. Type 95H, Sizes 1-1/2 and 2 Inch

Key 1 Regulator Body, NPT

BODY TYPE 95L TYPE 95H

SIZE, BODY MATERIAL BODY MATERIAL
INCHES Cast Iron Steel SST WCB Steel (NACE) Cast Iron Steel SST WCB Steel (NACE)
1/4 1E3911 19012 1J1277 22012 1J1277 33092 1E3910 19012 1J1273 22012 1J1273 33092
1/2 2E3945 19012 2L9080 22012 2L9080 33092 2L9080 X0062 1E3943 19012 2L9077 22012 2L9077 33092 2L9077 X0062
3/4 2E3974 19012 2E8637 22012 2E8637 33092 2E8637 X0112 2E3972 19012 2E4084 22012 2E4084 33092 2E4084 X0092
1 2E3975 19012 2E8638 22012 2E8638 33092 2E8638 X0012 2E3973 19012 2E4085 22012 2E4085 33092 2E4085 X0012
1-1/2 3P7843 19012 3P7843 22012 3P7843 33092
2 3P7842 19012 3P7842 22012 3P7842 33092

'Recommended spare part. 7

 Type 95L & 95H

Key 1 Regulator Body, ANSI Class 150 & 300 Flanges

TYPE 95L TYPE 95H
BODY MATERIAL BODY MATERIAL
BODY
SIZE, Steel Stainless Steel Steel Stainless Steel
INCHES ANSI Class ANSI Class
150 300 150 300 150 300 150 300
1/2 2V5673 X0022 20A4569 X012 2V5673 X0012 20A4569 X022 16A6787 X012 12B5376 X012 16A6787 X022 12B5376 X022
3/4 2V4262 X0012 20A3088 X012 2V4262 X0022 20A3088 X032 2V9941 X0012 20A4013 X012 2V9941 X0032 20A4013 X022
1 2V3546 X0052 2U7969 X0022 2V3546 X0012 2U7969 X0092 2V3879 X00A2 2V3944 X0012 2V3879 X0012 2V3944 X0042
—
1-1/2 — — — 1V4939 X0012 2V3881 X0012 1V4939 X0032 2V3881 X0062
2 — — — — 2V5703 X0012 20A1091 X012 2V5703 X0032 20A1091 X022

Key 1 Regulator Body, Socket Weld

BODY TYPE 95L TYPE 95H

SIZE, BODY MATERIAL BODY MATERIAL
INCHES Steel Stainless Steel Steel Stainless Steel
1/2 2P5185 22012 2P5185 X0012 2N6939 22012 2N6939 X0012
3/4 2K6327 22012 2K6327 33092 2H8520 22012 2H8520 X00A2
1 2H1606 000A2 2H1606 X00A2 2F4855 22012 2F4855 X0012
1-1/2 — — 3V3880 22012 3V3880 33092
2 — — 3V2796 22012 3V2796 X0012

Key 2 Spring Case

BODY SIZE, VENT TYPE 95L TYPE 95H

INCHES STYLE Cast Iron Steel Cast Iron Steel
Drilled 2E3913 19012 2J1279 22012 2E3912 19012 2J1275 22012
1/4
Tapped 2L4427 19012 2L4428 22012 2L4429 19012 2L4430 22012
Drilled 3J4963 19012 3L4161 22012 2J4962 19012 2L4163 22012
1/2
Tapped 3L4421 19012 3L4422 22012 2L4419 19012 2L4420 22012
Drilled 4E3979 19012 4E5929 22012 3E3978 19012 3E4087 22012
3/4 or 1
Tapped 4L4610 19012 4L4609 22012 3L4608 19012 3L4607 22012
Drilled — — — —

1-1/2 or 2
Tapped — — 4P7840 19012 3P7904 22012

8
 Type 95L & 95H

Key 4 Valve Plug

VALVE PLUG BODY SIZE, (INCHES)

MATERIAL 1/4 1/2 3/4 and 1 1-1/2 and 2
416 SST 1E3917 46172 1E3951 46172 1E3981 46172 1U4037 46172
Brass/Neoprene 1E3933 000C2 1E3963 OOOA2 1E3996 OOOA2 1U4039 X0052
416 SST/Nitrile — — — 1U4039 000A2
Brass/Fluoroelastomer 1E3933 X0082 1E3963 X0072 1E3996 X0072 —

416 SST/Fluoroelastomer 1E3933 X0102 1E3963 X0092 1E3996 X0092 1U4039 X00A2
Brass/TFE 1E3933 X0032 1E3963 X0022 1E3996 X0022 —

416 SST/TFE 1E3933 000A2 1E3963 000D2 1E3996 000E2 —

Monel*1* 1E3917 50192 1E3951 46222 — 1U4037 X0052

316 SST (NACE) — 1E3963 X0012 1E3996 X0012 “ “ “
416 SST/Neoprene 1E3933 OOOE2 1E3963 000B2 1E3996 000B2 —

1. Trademark of International Nickel Company.

Key 11 Regulator Spring

VALVE SPRING OUTLET PRESSURE

SPRING RANGE, PSIG
SIZE, COLOR
PART NUMBER
INCH CODE 95L 95H
1E3925 27022 Yellow 2 - 6 15 - 30
1/4 1E3926 27012 Green 5 - 15 25 - 75
1E3927 27142 Red 13 - 30 70 - 150
1E3956 27022 Yellow 2 - 6 15 - 30
1/2 1D7455 27142 Green 5 - 15 25 - 75
1E3957 27192 Red 13 - 30 70 - 150
3/4 1E3989 27022 Yellow 2 - 6 15 - 30
or 1E3990 27142 Green 5 - 15 25 - 75
1 1E3991 27162 Red 13 - 30 70 - 150
1E7953 27082 Lt. Blue 5 - 80
1-1/2 60 - 120
1E7954 27082 Lt. Gray
or Yellow — 100 - 140
1E7933 27082
2 120 - 150
1P7888 27082 Black

Key 12 Diaphragm

BODY SIZE, DIAPHRAGM MATERIAL

INCHES 302 SST Neoprene Fluoroelastomer Monel*1* (2 req’d)
Type 95L
1/4 1E3939 36012 (1 req'd) 1E3941 02112 1E3941 02402 (1 req’d) 1E3939 41012
1/2 1E3969 36012 (2 req'd) 1E3971 02112 1E3971 02402 (2 req’d) 1E3969 41012
3/4 and 1 1E3905 36012 (2 req'd) 1E3903 02112 1E3903 02332 (2 req'd) 1E3905 41012
Type 95H
1/4 1E3928 36012 (2 req'd) 1E3935 02112 1E3935 02402 (1 req'd) 1E3928 41012
1/2 1E3958 36012 (2 req’d) 1E3966 02112 1E3966 02402 (2 req'd) 1E3958 41012
3/4 and 1 1E3992 36012 (2 req'd) 1D3999 02112 1E3999 02402 (2 req'd) 1E3992 41012
1-1/2 and 2 1P7878 36012 (2 req'd) 1P7881 02192 11A1347 X012 (2 req’d) 1P7878 X00A2
1. Trademark of International Nickel Company.

9
Type 95L & 95H FISHER

While this information is presented in good faith and believed to be accurate, or any other matter with respect to the products, nor as a recommendation to
Fisher Controls does not guarantee satisfactory results from reliance upon such use any product or process in conflict with any patent. Fisher Controls reserves
information. Nothing contained herein is to be construed as a warranty or the right, without notice, to alter or improve the designs or specifications of
guarantee, express or implied, regarding the performance, merchantability, fitness the products described herein.

For information, contact Fisher Controls:

Fisher Controls Marshalltown, Iowa 50158 USA Sao Paulo 05424 Brazil
Cernay 68700 France Singapore 0512

Printed in USA I^ISoyiwkI recycled paper

 Types 67AF and 67AFR

Fisher Controls Instruction Manual

Type 67AF and 67AFR Filter

Regulators

FISHER®
____________ M a rc h 1986 F o rm 5144

Introduction

Scope of Manual
This manual describes and provides instructions and
parts lists for Type 67AF and 67AFR regulators. Al­
though sometimes shipped separately for line or panel
mounting, these regulators are usually shipped installed TYPE
on other equipment. Instructions and parts lists for other S7AF OR
S7AFR
equipment, as well as for other 67 Series regulators not REGULATOR
covered in this manual, are found in separate manuals.

Product Description
Type 67AF and 67AFR self-operated, aluminum-body,
filter regulators provide constant reduced pressures in a
variety of applications. They are commonly used as
supply pressure regulators for pneumatic instruments
as shown in figure 1.

A Type 67AF or 67AFR regulator with a cellulose or

stainless steel filter removes particles greater than
0.0016 inch (0.040 mm) in diameter, or with a glass filter
removes particles greater than 0.0004 inch (0.010 mm)
in diameter.

The Type 67AFR regulator additionally has an integral

low-capacity internal relief valve. In this construction,
the stem seats against a soft-seated orifice in the dia­
phragm assembly. A downstream pressure increase
above the outlet pressure setting moves the diaphragm
assembly off the stem, venting the excess pressure
through a hole drilled or tapped in the spring case.

Specifications
D100251 X012

Table 1 gives some general Type 67AF and 67AFR

regulator ratings and other specifications. A label on the
spring case gives the recommended and actual control
spring range for a given regulator as it comes from the Figure 1. Type 67AF or 67AFR Regulator
factory. Mounted on Control Valve Assembly
Types 67AF and 67AFR

T a b le 1. S p e c ific a tio n s

BODY SIZE ANO END 1/4-inch NPT screwed INTERNAL RELIEF Low capacity for seat leakage
CONNECTION STYLE PERFORMANCE (TYPE only; external relief valve must be
67AFR REGULATOR provided if inlet pressure can ex­
MAXIMUM 250 psig (17 bar) ONLY) ceed maximum emergency outlet
ALLOWABLE INLET pressure
PRESSURE!1)
TEMPERATURE Nitrile Parts: -2 0 ° F to 150°F
OUTLET PRESSURE 3 to 100 psig (0.21 to 6.9 bar) with CAPABILITIES!1) ( - 29°C to 66°C)
RANGES the springs shown in parts list key Fluoroelastomer Parts: 0°F to
9 350°F ( — 18°C to 177°C)
MAXIMUM 50 psig (3.4 bar) over outlet pres­
EMERGENCY OUTLET sure setting, or 100 psig (7.6 bar), PRESSURE Internal
PRESSURE!1) whichever is greater REGISTRATION
1. The pressure/temperature limits in this manual, and any applicable code or standard
limitations, must not be exceeded.

Installation Note

If the regulator is shipped mounted on an­

other unit, install that unit according to the
W A R N IN G appropriate instruction manual.

Personal injury, property damage, equip­

ment damage, or leakage due to escaping 1. Only personnel qualified through training and expe­
gas or bursting of pressure-containing rience should install, operate, and maintain a regulator.
parts may result if this regulator is over­ For a regulator that is shipped separately, make sure
pressured or is installed where service con­ that there is no damage to, or foreign material in, the
ditions could exceed the limits given in regulator. Also ensure that all tubing and piping have
table 1, or where conditions exceed any been blown free.
ratings of the adjacent piping or piping con­
nections. To avoid such injury or damage, 2. Install the regulator so that flow is from the IN to the
provide pressure-relieving or pressure-lim­ OUT connection as marked on the regulator body. Cut­
iting devices (as required by the appropri­ out dimensions for a panel-mounting regulator are
ate code, regulation, or standard) to shown in figure 2.
prevent service conditions from exceeding
those limits. A Type 67AFR regulator, be­ 3. For best filter drainage, orient the drain valve (key
cause of its low-capacity internal relief, 17, figure 2) to the lowest possible point on the filter cap
does provide very limited downstream (key 25, figure 2). This orientation may be improved by
overpressure protection, but it should not rotating the filter cap with respect to the body assembly
be considered complete protection against (key 1, figure 2).
overpressure.

Additionally, physical damage to the regu­ W A R N IN G

lator could cause personal injury or proper­
ty damage due to escaping gas. To avoid A regulator may vent some gas to the atmo­
such injury or damage, install the regulator sphere. In hazardous or flammable gas ser­
in a safe location. vice, vented gas may accumulate and
cause personal injury, death, or property
damage due to fire or explosion. Vent a
Regulator operation within ratings does not preclude the regulator in hazardous gas service to a
possibility of damage from debris in the lines or from remote, safe location away from air intakes
external sources. A regulator should be inspected for or any hazardous area. The vent line or
damage periodically and after any overpressure stack opening must be protected against
condition. condensation or clogging.

2

✓ '■“N 4. A clogged spring case vent hole may cause the
' regulator to function improperly. To keep this vent hole
from being plugged (and to keep the spring case from
collecting moisture, corrosive chemicals, or other for­
eign material) orient the vent to the lowest possible point
on the spring case or otherwise protect it. Inspect the
vent hole regularly to make sure it has not been plugged.
Spring case vent hole orientation may be changed by
rotating the spring case with respect to the body. A Type
67AF or 67AFR regulator with a tapped spring case may
be remotely vented by installing obstruction-free tubing
or piping into the 1/4-inch NPT vent tapping. Provide
protection on a remote vent by installing a screened vent
cap in the remote end of the vent pipe.
5. For use in regulator shutdown, install upstream and
downstream vent valves or provide some other suitable
means of properly venting the regulator inlet and outlet
pressures.
6. If using pipe, apply a good grade of pipe compound
to the pipe threads before making the connections.
7. Install tubing or piping into the 1/4-inch NPT inlet
connection on the body assembly (key 1, figure 2) and
also into the 1/4-inch NPT body outlet connection, un­
less this connection already has been factory-piped to
another unit.
Startup and Adjustment
Key numbers are referenced in figure 2.
1. With proper installation completed and downstream
equipment properly adjusted, slowly open the upstream
and downstream shutoff valve while using pressure
gauges to monitor pressure.
'"x
2. Regulator outlet pressure may be monitored on a
gauge installed at some point downstream from the
regulator, such as the supply pressure gauge of a
pneumatic instrument for which the regulator is provid­
ing reduced pressure. Or, outlet pressure may be moni­
tored on a gauge (key 21, not shown) installed on the
body of a regulator with a tapped side outlet. If the
regulator has no gauge but the side outlet is tapped and
plugged, the pipe plug (key 21, not shown) may be
removed and a gauge temporarily installed for
monitoring.
W A R N IN G
To avoid personal injury, property damage,
or equipment damage caused by bursting
Types 67AF and 67AFR
of pressure containing parts or explosion of
accumulated gas, never adjust the control
spring to produce an outlet pressure higher
than the upper limit of the outlet pressure
range for that particular spring. If the de­
sired outlet pressure is not within the range
of the control spring, install a spring of the
proper range according to the diaphragm
parts maintenance procedure.
Note
Each regulator is factory-set for the pres­
sure setting specified on the order. If no
setting was specified, outlet pressure was
factory-set at the midrange of the control
spring.
3. If outlet pressure adjustment is necessary, monitor
outlet pressure with a gauge during the adjustment
procedure. A standard Type 67AF or 67AFR regulator is
adjusted by loosening the locknut (key 11, if used) and
turning the adjusting screw or handwheel (key 10) clock­
wise to increase, or counterclockwise to decrease, the
outlet pressure setting. Then, tighten the locknut (if
used) to maintain the adjustment position. On some
regulators, a closing cap (key 28, not shown) must be
removed before adjustment and replaced afterward.
Shutdown
First close the nearest upstream shutoff valve and then
close the nearest downstream shutoff valve to vent the
regulator properly. Next, open the vent valve between
the regulator and the downstream shutoff valve nearest
to it. All pressure between these shutoff valves will be
released through the open vent valve, since a Type
67AF or 67AFR regulator remains open in response to
the decreasing downstream pressure.
Maintenance
Regulator parts are subject to normal wear and must be
inspected and replaced as necessary. The frequency of
inspection and replacement of parts, depends on the
severity of service conditions and upon applicable
codes and government regulations. Open the drain
valve (key 17, figure 2) periodically to empty accumulat­
ed moisture from the filter cap (key 25, figure 2).
3
Types 67AF and 67AFR
FISHER®

adjusting screw or handwheel (key 10) until compres­

W A R N IN G
sion is removed from the control spring
(key 9).
To avoid personal injury, property damage,
or equipment damage caused by sudden
2. Remove the machine screws (key 12) and separate
release of pressure or explosion of accu­
the spring case (key 2) from the body assembly (key 1).
mulated gas, do not attempt any mainte­
Remove the control spring seat and control spring (keys
nance or disassembly without first isolating
8 and 9).
the regulator from system pressure and
relieving all internal pressure from the
3. Remove the diaphragm assembly (key 7) and in­
regulator.
spect the diaphragm.
Note
4. Install the diaphragm assembly (key 7) and push
down on it to see if the plug/stem assembly (key 4)
If sufficient clearance exits, the body as­
strokes smoothly and approximately 1/16 inch (2 mm).
sembly (key 1) may remain mounted on
other equipment or in a line or panel unless
the entire regulator will be replaced.
Note
Key numbers are referenced in figure 2 unless other­ In step 5, if installing a control spring of a
wise noted. different range from the one that was re­
moved, be sure to delete the spring range
Filter Elem ent and Trim Parts originally appearing on the control spring
label (key 20, not shown) and indicate the
1. Use a 12-point socket wrench to remove the cap new spring range.
screws (key 18). Remove the filter cap and gasket (keys
25 and 19).
5. Stack the control spring and control spring seat
2. The retainer assembly and filter element (keys 43 (keys 9 and 8) onto the diaphragm assembly (key 7).
and 29) may come off with the filter cap; if not, remove
these parts to let the plug spring (key 6), plug spring seat 6. Install the spring case (key 2) on the body assembly
(key 5), and plug/stem assembly (key 4) drop freely from (key 1) with the vent oriented to prevent clogging or
the body.
entrance of moisture. Install the machine screws (key
12) and torque to 5 to 7 foot-pounds (7 to 9 N«m).
3. Inspect the removed parts, replace as necessary,
and make sure the plug seating surfaces are free from 7. When all maintenance is complete, refer to the
debris. A dirty filter element may be cleaned with solvent startup and adjustment section to put the regulator back
and blown dry.
into operation and adjust the pressure setting. Tighten
the locknut if used (key 11), and install the closing cap if
4. Apply a good grade of lubricant to the gasket (key used (key 28, not shown).
19) before installing it. Stack the gasket, retainer assem­
bly, filter element, plug spring, plug spring seat, and
plug/stem assembly (keys 19, 43, 29, 6, 5, and 4) on the
filter cap (key 25). Install the filter cap with stacked parts Parts Ordering
into the body assembly (key 1) and secure with the cap
screws (key 18). When corresponding with the Fisher sales office or
sales representative about this regulator, include the
type number and all other pertinent information stamped
Diaphragm Parts
on the bottom of the filter cap and on the control spring
1. Remove the closing cap if used (key 28, not shown), label. Specify the eleven-character part number when
loosen the locknut if used (key 11), and back out the ordering new parts from the following parts list.

4
 Types 67AF and 67AFR

Parts List (figure 2) Key Description Part Number Key Description Part Number

4* Plug/Stem Assembly (Continued) 7* Diaphragm Assembly (Continued)

For other than sour gas corrosion For other than sour gas corrosion
Key Description Part Number resistance applications resistance applications
Nitrile plug w/brass Nitrile diaphragm w/brass relief
Parts Kit (included are keys 4, 5, 6, 7, stem 1D5604 000A2 valve seat & soft molded
17, 19, and 29) Nitrile plug w/stainless steel insert 19A7667 X012
For Type 67AF regulator w/o stem 1D5604000B2 Nitrile diaphragm w/stainless
internal relief Fluoroelastomer plug w/brass steel relief
With nonbrass parts to provide stem 1N379871662 valve seat & soft molded
sour gas corrosion resistance Fluoroelastomer plug w/stainless insert 19A7667 X022
capability!1) R67AF X00N12 steel stem 1N3798 000C2 Fluoroelastomer diaphragm w/
With brass parts for other than sour All-brass plug and brass relief
gas corrosion resistance stem 1C750314012 valve seat & soft molded
applications R67AF X00012 All-stainless steel plug and insert 19A7667 X042
For Type 67AFR regulator w/internal stem 1C750335032 Fluoroelastomer diaphragm w/
relief stainless steel relief valve
With nonbrass parts to provide 5* Plug Spring Seat seat & soft molded
sour gas corrosion resistance For use w/stainless steel stem and to insert 19A7667 X052
capability R67AFR X0N12 provide sour gas corrosion 8 Control Spring Seat
With brass parts for other than sour resistance capability, 316 To provide sour gas corrosion
gas corrosion resistance stainless steel 1L2511 35072 resistance capability,
applications R67AFR X0012 For use w/brass stem and for other heat-treated AISI
than sour gas corrosion steel 1B7985 X0012
1 Body Assembly resistance applications, For other than sour gas corrosion
To provide sour gas corrosion aluminum 1E5322 11052 resistance applications, Zn pi
resistance capability, aluminum 6* Plug Spring steel 1B7985 25062
w/316 stainless steel bushing To provide sour gas corrosion
One outlet 15A5969 X052 resistance capability, 9 Control Spring See following table
Two outlets 15A5969 X062 lnconel<2> 19A2856 X012 10 Adjusting Screw, pi steel
For other than sour gas corrosion For other than sour gas corrosion For spring casew/o closing
resistance applications resistance applications, 302 cap 1B7986 28982
Aluminum w/brass bushing stainless steel 1C1273 37022 For spring case w/closing
One outlet 15A5969 X012 7* Diaphragm Assembly cap 1H3050 28982
Two outlets 15A5969 X032 For Type 67AF regulator w/o internal 10 Handwheel
Aluminum w/304 stainless steel relief For 1-hole panel mtg, Zn pi
bushing To provide sour gas corrosion steel 20B2830 X012
One outlet 15A5969 X022 resistance capability, nitrile For 3-hole panel mtg
Two outlets 15A5969 X042 diaphragm w/heat- Zinc 1B7992 000A2
2 Spring Case treated AISI steel diaphragm Chrome pi steel 1U1715 000C2
W/drilled-hole vent, plate and control spring 11 Locknut (not used w/panel mtg spring
aluminum 2B7974 08012 seat guide 1B7980 X0112 case, pi steel 1A9463 24122
W/1/4-inch NPT vent tapping For other than sour gas corrosion
To provide sour gas corrosion resistance applications 11 Mounting Nut (for use only w/1-hole
resistance capability, Nitrile diaphragm w/pl steel panel mtg spring case), 303
aluminum 25A6220 X012 diaphragm plate and control stainless steel 10B2657 X012
For other than sour gas corrosion spring seat 12 Machine Screw, pi steel (6 req'd)
resistance applications, brass guide 1B7980 000B2 To provide sour gas corrosion
W/o closing cap 1E1674 000A2 Fluoroelastomer diaphragm w/pl resistance capability and for 1-hole
W/closing cap 10A3075 X012 steel diaphragm plate and panel mtg & 1/4-inch NPT tapped
For 1-hole panel mtg, control spring spring cases 1B2752 28982
aluminum 20B0667 X012 seat guide 1B7980 000C2 For all other
For 3-hole panel mtg, zinc For Type 67AFR regulator w/internal constructions 1B7839 28982
w/stainless steel relief 14 Mounting Screw (for use only w/3-hole
bushing 3B9855 000B2 To provide sour gas corrosion panel mtg spring case), steel
4* Plug/Stem Assembly resistance capability, nitrile (2 req’d) 1C2760 28992
To provide sour gas corrosion diaphragm w/aluminum
resistance capability, nitrile relief valve seat & soft
plug w/stainless molded insert 19A7667 X032
steel stem 1D5604 000B2

* Recommended spare part.

1- detailed in National Association of Corrosion Engineers (NACE) standard
MR-01 *75.
2. Trademark of International Nickel Co.
Types 67AF and 67AFR

DRILL 0.19 INCH

(4.9 mm) HOLES
FOR 10-24 SCREW
SIZE

0.39 (9.9)
THREAD LENGTH

INCH
3-HOLE PANEL MOUNTING DETAIL (mm)

NOTES:
[T>0.72 (18.3) SPRING CASE PANEL BOSS.
[2>1.47 TO 1.48 (37.4 TO 37.7) SPRING CASE PANEL BOSS.

30B3644-A
35A9M1-C
B2005

Figure 2. Type 67AF and 67AFR Regulator Assemblies

Key Description Part Number Key Description Part Number Key Description Part Number

17* Drain Valve 21 Pipe Plug (for use only w/2-outlet 21 Pressure gauge (for use only
To provide sour gas corrosion body—not shown) w/2-outlet
resistance capability, To provide sour gas corrosion body—not shown)
aluminum 1K4189 OOOB2 resistance capability, hex head, 0 to 30 psig<3> 1J9460 99012
For other than sour gas corrosion Cd pi steel 1A7675 24662 0 to 60 psig<3) 1J9752 99012
resistance applications For other than sour gas corrosion 0 to 100 psig(3> 1J9753 99012
Aluminum 1K4189 000B2 resistance applications 0 to 160 psig<3> 1J9754 99012
Brass 1K4189 18992 Hex head, 25 Filter Cap, aluminum 35A5963 X012
Stainless steel AH3946 000B2 Cd pi Steel 1A7675 24662 28 Closing Cap .
Square head, brass 1A5726 14012 For use w/tapped spring
18 Cap Screw, Cd pi steel Socket head, steel 1C3335 28992 case 25A6220 X012
(4 req'd) 1K7647 24052 to provide sour gas corrosion
19* Gasket, neoprene 1C1280 03012 resistance capability,
20 Control Spring Label (not shown), aluminum 1H2369 X0012
paper See following table

'Recommended spare part.

6 3. Consult your Fisher sales office or sales representative for gauges in other units.
 Types 67AF and 67AFR

COMPLETE REGULATOR WITHOUT CLOSING CAP

Figure 2. Type 67AF and 67AFR Regulator Assemblies (Continued)

Key Description Part Number Key Description Part Number Key Description Part Number
28 Closing Cap (Continued) 43 Retainer Assembly 44 NACE Tag (for use only on
For use w/tapped spring To provide sour gas corrosion constructions w/sour
case 10A3075 X012 resistance capability, Zn pi gas corrosion resistance
for other than sour gas corrosion steel retainer capability—not
resistance applications, w/lnconel spring 17A9423 X022 shown), 18-8 stainless
brass 1H2369 14012 For other than sour gas corrosion steel . 19A6034 X012
29* Filter Element resistance applications, pi steel 45 Tag Wire (for use only w/NACE tag key
0.0004-inch (0.010 mm) rating, retainer w/302 stainless steel 44—not shown), 304 stainless
glass 17A1457 X012 spring 17A9423 X012 steel 1U7851 X0012
0.0016-inch (0.040 mm) rating
Cellulose 1F2577 06992
Stainless steel 15A5967 X012

•Recommended spare part. 7

Types 67AF and 67AFR

Keys 9 and 20 Type 67AF Control Spring and Control Spring Label

OUTLET PRESSURE RANGE CONTROL

CONTROL SPRING KEY 9
U.S. Units, Psig Metric Units, Bar SPRING
SERVICE, MATERIAL
With Panel-Mtg With All Other With Panel-Mtg With All Other LABEL
Part Number Color Code KEY 20
Spring Case Spring Cases Spring Case Spring Cases
3 to 18 3 to 20 0.21 to 1.2 0.21 to 1.4 1B9860 27212 Green 1C3763 06032
5 to 30 5 to 35 0.34 to 2.1 0.34 to 3.4 1B7883 27022 Cad plated 1C3764 06032
All, pi steel
30 to 50 30 to 60 2.1 to 3.4 2.1 to 4.1 1B7884 27022 Blue 1C3766 06032
35 to 80 35 to 100 2.4 to 5.5 2.4 to 6.9 1K7485 27202 Red 1C3765 06032

Keys 9 and 20 Type 67AFR Control Spring and Control Spring Label

OUTLET PRESSURE RANGE CONTROL

U.S. Units, Psig Metric Units, Bar SPRING
SERVICE, MATERIAL
With Panel-Mtg With All Other With Panel-Mtg With All Other LABEL
Part Number Color Code KEY 20
Spring Case Spring Cases Spring Case Spring Cases
For sour gas _ _ _ _ _ _
5 to 35 0.34 to 3.4 19A2852 X012 Cad plated 1C3764 06032
corrosion resistance — —
30 to 60 2.1 to 4.1 19A2854 X012 Blue 1C3766 06032
capability, Inconel
For other than 3 to 18 3 to 20 0.21 to 1.2 0.21 to 1.4 1B9860 27212 Green 1C3763 06032
sour gas corrosion 5 to 30 5 to 35 0.34 to 2.1 0.34 to 3.4 1B7883 27022 Cad plated 1C3764 06032
resistance applications, 30 to 50 30 to 60 2.1 to 3.4 2.1 to 4.1 1B7884 27022 Blue 1C3766 06032
pi steel 35 to 80 35 to 100 2.4 to 5.5 2.4 to 6.9 1K7485 27202 Red 1C3765 06032

While this information is presented in good faith and believed to be accurate, or a n y o t h e r m a t t e r w it h r e s p e c t t o th e p r o d u c t s , nor as a recommendation to
Fisher Controls does not guarantee satisfactory results from reliance upon such use any product or process in conflict with any patent. Fisher Controls reserves
information. N o t h in g c o n t a in e d h e r e in is t o b e c o n s t r u e d a s a w a rr a n ty o r the right, without notice, to alter or improve the designs or specifications of
g u a ra n te e , e x p r e s s o r im p lie d , r e g a r d in g th e p e r f o r m a n c e , m e r c h a n t a b ilit y , f itn e s s the products described herein.

F o r in fo r m a tio n , c o n t a c t F is h e r C o n tr o ls :

Fisher Controls Marshalltown, Iowa 50158 USA

Cernay 68700 France
Sao Paulo 05424 Brazil
Singapore 0512

F M m phiinto witw , .
Printed in USA I ^ I so y in k I recycled paper
 Cleave rooks
ELECTRICAL NOMENCLATURE
MNEMONIC DESCRIPTION MNEMONIC DESCRIPTION

A BMPS Blower Motor Purge Switch

A Amber (Color Of Pilot Light) BMR Blower Motor Relay
AAFL Atomizing Air Failure Light BMS Blower Motor Starter
AAFR Atomizing Air Failure Relay BMSI Blower Motor Starter Interlock
AAPL Atomizing Air Proven Light BMSS Boiler Master Selector Switch
AAPS Atomizing Air Proving Switch BS Burner Switch
AAPS-B Atomizing Air Proving Switch- Burner BSS Boiler Selector Switch
AAPS-C Atomizing Air Proving Switch- Compressor BWPM Booster Water Pump Motor
AASS Atomizing Air Selector Switch BWT Booster Water Thermostat
AB Alarm Bell
ACCR Air Compressor Control Relay CAFL Combustion Air Failure Light
ACM Air Compressor Motor CAFR Combustion Air Failure Relay
ACMCB Air Compressor Motor Circuit Breaker CAP Capacitor
ACMF Air Compressor Motor Fuses CAPS Combustion Air Proving Switch
ACMS Air Compressor Motor Starter CCCB Control Circuit - Circuit Breaker
ACMSI Air Compressor Motor Starter Interlock CCF Control Circuit Fuse
AH Alarm Horn CCRS Control Circuit Reset Switch
ALFR Assured Low Fire Relay CCT Control Circuit Transformer
ALWCO Auxiliary Low Water Cutoff CIPL Changeover In Progress Light
AM Ammeter CL Canopy Light
AMS Atomizing Media Switch CLS Canopy Light Switch
APR Air Purge Relay COPS Changeover Pressure Switch
APV Air Purge Valve COR Changeover Relay
AR Alarm Relay COTD Changeover Time Delay
AS Auxiliary Switch (Suffix) CPOL Control Power on Light
ASR Alarm Silencing Relay CR Control Relay
ASS Alarm Silencing Switch CSSS Control System Selector Switch
ASV Atomizing Steam Valve CWPM Circulating Water Pump Motor
ATS Alarm Test Switch CWPMCB Circulating Water Pump Motor Circuit Breaker
AWCBDS Auxiliary Water Column Blowdown Switch CWPMF Circulating Water Pump Motor Fuses
B CWPMS Circulating Water Pump Motor Starter
B Blue (Color of Pilot Light) CWPMSI Circulating Water Pump Motor Starter Interlock
BC Bias Control CWPR Circulating Water Pump Relay
BDCS Breeching Damper Closed Switch CWPS Circulating Water Pump Switch
BDOS Breeching Damper Open Switch CWSV Cooling Water Solenoid Valve
BDRS Blowdown/Reset Switch n
BFPL Boiler Feed Pump Light D Denotes Digester Gas Equipment (Prefix)
BFPM Boiler Feed Pump Motor DCVM Direct Current Voltmeter
BFPMCB Boiler Feed Pump Motor Circuit Breaker DG Draft Gauge
BFPMF Boiler Feed Pump Motor Fuses DGHPV Digester Gas Housing Purge Valve
BFPMS Boiler Feed Pump Motor Starter DHWC Deaerator High Water Control
BFPS Boiler Feed Pump Switch DHWL Deaerator High Water Light
BFTS Back Flow Temperature Switch DHWR Deaerator High Water Relay
BHS Boiler - Header Switch DISC Disconnect (Entrance Switch)
BIOL Boiler in Operation Switch DLWC Deaerator Low Water Control
BIOR Boiler In Operation Relay DLWL Deaerator Low Water Light
BM Blower Motor DLWR Deaerator Low Water Relay
BMCB Blower Motor Circuit Breaker DM Damper Motor '
BMCR Blower Motor Control Relay DMT Damper Motor Transformer
BMF Blower Motor Fuses DNS Day-Night Switch
BMPR Blower Motor Power Relay DODE Delay On Deenergization (Timer)

C23-3862 Rev 8/95 Page 1

MNEMONIC DESCRIPTION MNEMONIC DESCRIPTION
DOE Delay On Energization (Timer) HFAV High Fire Air Valve
DPS Damper Positioning Switch HFGV High Fire Gas Valve
DS Door Switch HFL High Fire Light
HFOV High Fire Oil Valve
E
EDS Emergency Door Switch HFPS High Furnace Pressure Switch
ESS Emergency Stop Switch HFS High Fire Switch
ETM Elapsed Time Meter HFS-A High Fire Switch - Air
c HGPL High Gas Pressure Light
FADM Fresh Air Damper Motor HGPR High Gas Pressure Relay
FADR Fresh Air Damper Relay HGPS High Gas Pressure Switch
FD Flame Detector HHFL Header High Fire Light
FDJB Flame Detector Junction Box HHLFC Header High-Low Fire Control
FDPS Flow Differential Pressure Switch H/LWA High Low Water Alarm
FFA Flame Failure Alarm HLC High Limit Control
FFL Flame Failure Light HLFC High-Low Fire Control
FFR Flame Failure Relay HLPC High Limit Pressure Control
FGR Flue Gas Recirculation HLTC High Limit Temperature Control
FGRCDTD Flue Gas Recirculation Cool Down Time Delay HMC Header Modulating Control
FGRCPS Flue Gas Recirculation Cam Position Switch HOPL High Oil Pressure Light
FGRFM Flue Gas Recirculation Fan Motor HOPR High Oil Pressure Relay
FGRFMS Flue Gas Recirculation Fan Motor Starter HOPS High Oil Pressure Switch
FGRFMSI Flue Gas Recirculation Fan Motor Starter Interlock HOLC Header Operating Limit Control
FGRMVLS Flue Gas Recirculation Manual Valve Limit Switch HOTL High Oil Temperature Light
FGRTD Flue Gas Recirculation Time Delay HOTR High Oil Temperature Relay
FORS First Out Reset Switch HOTS High Oil Temperature Switch
FPM Feed Pump Motor HPCO High Pressure Cutoff
FPMS Feed Pump Motor Starter HSPC High Steam Pressure Control
FPR Feed Pump Relay HSPL High Steam Pressure Light
FPS Feed Pump Switch HSPR High Steam Pressure Relay
FRI Firing Rate Interface HSTC High Stack Temperature Control
FRP Firing Rate Potentiometer (02 Trim) HSTL High Stack Temperature Light
FS Flow Switch HSTR High Stack Temperature Relay
FSS Fuel Selector Switch HSTS High Stack Temperature Switch
FSSM Flame Signal Strength Meter HWAR High Water Alarm Relay
FVEL Fuel Valve Energized Light HWC High Water Control
FVL Fuel Valve Light HWCO High Water Cutoff
FVR Fuel Valve Relay HWL High Water Light
1
FWC Feed Water Control
FWVT Feed Water Valve Transformer (I.C.) Instantaneously Closed
G (I.O.) Instantaneously Open
G Green (Color Of Pilot Light) IL Ignition Light
GGL Gauge Glass Light INT Interval (Timer)
GOL Gas Operation Light IR Ignition Relay
GOR Gas-Oil Relay IT Ignition Transformer
i
GOS Gas-Oil Switch
GOR Gas-Oil Relay JPP Jackshaft Position Potentiometer
1
GPS Gas Pressure Sensor
GPV Gas Pilot Valve LAMPS Low Atomizing Media Pressure Switch
GPW Gas Pilot Vent Valve LASPS Low Atomizing Steam Pressure Switch
GR Gas Relay LDL Load Demand Light
GSSV Gas Sensor Solenoid Valve LDPS Low Differential Pressure Switch
GVEL Gas Valve Energized Light LDS Low Draft Switch
GVTS Gas Valve Test Switch LFAV Low Fire Air Valve
H LFGV Low Fire Gas Valve '
HATC High Ambient Temperature Control LFHTD Low Fire Hold Time Delay
HBWTC High Boiler Water Temperature Control LFL Low Fire Light
HBWTL High Boiler Water Temperature Light LFOV Low Fire Oil Valve

Page 2
MNEMONIC DESCRIPTION MNEMONIC DESCRIPTION
LFPS Low Fire Pressure Switch MOV Main Oil Valve
LFR Low Fire Relay MOVAS Main Oil Valve Auxiliary Switch
LFS Low Fire Switch MOVEL Main Oil Valve Energized Light
LFS-A Low Fire Switch - Air MPC Modulating Pressure Control
LFS-F Low Fire Switch - Fuel MPCB Main Power Circuit Breaker
LFS-G Low Fire Switch - Gas MPP Manual Positioning Potentiometer
LFS-0 Low Fire Switch - Oil (MR) Manual Reset
LFTC Low Fire Temperature Control MTC Modulating Temperature Control
LGPL Low Gas Pressure Light MVA Make-Up Valve Actuator
LGPR Low Gas Pressure Relay N
LGPS Low Gas Pressure Switch N Denotes Natural Gas Equipment (Prefix)
LLPC Low Limit Pressure Control (N.C.) Normally Closed
LLPR Low Limit Pressure Relay (N.O.) Normally Open
LLR Lead Lag Relay NFL No Flow Light
LLTC Low Limit Temperature Control NFR No Flow Relay
LLTR Low Limit Temperature Relay NGHPV Natural Gas Housing Purge Valve
LOPL Low Oil Pressure Light 0
LOPR Low Oil Pressure Relay ODA Outlet Damper Actuator
LOPS Low Oil Pressure Switch ODM Outlet Damper Motor
LOTL Low Oil Temperature Light ODMAS Outlet Damper Motor Auxiliary Switch
LOTR Low Oil Temperature Relay ODMT Outlet Damper Motor Transformer
LOTS Low Oil Temperature Switch ODS Oil Drawer Switch
LPAPS Low Plant Air Pressure Switch OH Oil Heater
LPCO Low Pressure Cutoff OHCB Oil Heater Circuit Breaker
LPS Limit Proximity Switch OHF Oil Heater Fuses
LPSR Limit Proximity Switch Relay OHR Oil Heater Relay .
LRS Local-Remote Switch OHS Oil Heater Switch
LSPAR Low Steam Pressure Alarm Relay OHT Oil Heater Thermostat
LSPC Low Steam Pressure Control OLC Operating Limit Control
LSPL Low Steam Pressure Light OLPC Operating Limit Pressure Control
LSPR Low Steam Pressure Relay OL’S Overloads
LSPS Low Steam Pressure Switch OLTC Operating Limit Temperature Control
LTS Lamp Test Switch OMPM Oil Metering Pump Motor
LWA Low Water Alarm OMPMF Oil Metering Pump Motor Fuse
LWAR Low Water Alarm Relay OMPMR Oil Metering Pump Motor Relay
LWCO Low Water Cutoff OOL Oil Operation Light
LWL Low Water Light OPM Oil Pump Motor
LWR Low Water Relay OPMCB Oil Pump Motor Circuit Breaker
LWRR Low Water Reset Relay OPMF Oil Pump Motor Fuses
M OPMS Oil Pump Motor Starter
MA Milli-amp OPPM Oil Purge Pump Motor
MAS Manual - Automatic Switch OPR Oil Purge Relay
MAM Micrometer OPRL Oil Pump Running Light
MC Modulating Control OPRS Oil Pressure Sensor
MCS Manual Control Switch OPS Oil Pump Switch
MDM Modulating Damper Motor OPSPM Oil Pump Supply Pump Motor
MDMAS Modulating Damper Motor Auxiliary Switch OPV Oil Purge Valve
MFC Manual Flame Control (Potentiometer) OR Oil Relay
MFGRTS Minimum Flue Gas Temperature Switch ORV Oil Return Valve
MFVL Main Fuel Valve Light OSOV Oil Shutoff Valve
MFWV Motorized Feed Water Valve OSPS 0 2 Set Point Switch
MGV Main Gas Valve OSS Oil Selector Switch
MGVAS Main Gas Valve Auxiliary Switch OT Outdoor Thermostat .
MGVEL Main Gas Valve Energized Light OTS Oil Temperature Sensor
MGW Main Gas Vent Valve OV Oil Valve
MLC Modulating Level Control OVAS Oil Valve Auxiliary Switch
(MOM) Momentary OVEL Oil Valve Energized Light

Page3
 MNEMONIC DESCRIPTION MNEMONIC DESCRIPTION
P SS Selector Switch
P Denotes Propane Gas Equipment (Prefix) ssc Sequencing Step Controller
PAASV Plant Air Atomizing Solenoid Valve SSL Safety Shutdown Light
PAPS Purge Air Proving Switch SSR Solid State Relay
PC Pump Control SSV SpanSolenoid Relay
PCL Purge Complete Light STHWC Surge Tank High Water Control
PCR Pump Control Relay STHWL Surge Tank High Water Light
PFCC Power Factor Correction Capacitor STHWR Surge Tank High Water Relay
PFFL Pilot Flame Failure Light STLWC Surge Tank Low Water Control
PFFR Pilot Flame Failure Relay STLWL Surge Tank Low Water Light
PFPS Positive Furnace Pressure Switch STLWR Surge Tank Low Water Relay
PHGPS Pilot High Gas Pressure Switch . T
PIPL Purge in Progress Light (T.C.) Timed Closed
PLC Programmable Logic Controller (T.O.) Timed Open
PLGPS Pilot Low Gas Pressure Switch TB Terminal Block
POL Power On Light T/C Thermocouple
POV Pilot Oil Valve TC Time Clock
PPL Pre-Purging Light TCR Time Clock Relay
PPR Post Purge Relay TD Time Delay
PPTD Post Purge Time Delay TDAS Time Delay Auxiliary Switch
PR Program Relay TFWR Transistorized Feedwater Relay
PRPTD Pre-Purge Time Delay TPL Transfer Pump Light
PS Power Supply TPM Transfer Pump Motor
PSF Power Supply Fuse TPMCB Transfer Pump Motor Circuit Breaker
PSS Pump Selector Switch TPMF Transfer Pump Motor Fuses
PSV Purge Solenoid Valve TPMS Transfer Pump Motor Starter
PT Purge Timer TPS Transfer Pump Switch
PTS Pump Transfer Switch U
PUCR Purge Complete Relay UVFD Ultra-Violet Flame Detector
PUR Purge Relay V
D V Voltmeter
R Red (Color of Pilot Light) VDR Voltage Differential Relay
RAR Remote Alarm Relay W
RATD Remote Alarm Time Delay W White (Color of Pilot Light)
RES Resistor WC Water Column
RML Run Mode Light WCBDS Water Column Blow Down Switch
RMR Release To Modulate Relay WF Water Feeder
RS Range Switch WFNL Water Flow Normal Light
RSR Remote Start Relay WLC Water Level Control
RTD Resistance Temperature Detector WO Denotes Waste Oil Equipment (Prefix)
c WTS Water Temperature Sensor
SBFPL Stand By Feed Pump Light Y
SBFPM Stand By Feed Pump Motor Y Yellow (Color of Pilot Light)
SBFPMCB Stand By Feed Pump Motor Circuit Breaker
SBFPMF Stand By Feed Pump Motor Fuses
SBFPMS Stand By Feed Pump Motor Starter
SBOV Surface Blow Off Valve
SBPS Sootblower Pressure Switch
SBR Sootblower Relay
SC Scanner
SCTS Supervisory Cock Test Switch
SDL Steam Demand Light
SHT Steam Heater Thermostat
SHV Steam Heater Valve
SLCL Safety Limits Complete Light
SPIR Safety Pump Interlock Relay
SPS Steam Pressure Sensor

Page 4
CRANE
_______ ®

STOP CHECK ■ F o r in s ta lla tio n b e tw e e n b o ile r s s u p p ly in g th e s a m e s te a m

h e a d e r, a n d p o s itio n e d w ith p re s s u re u n d e r th e d is c . S t r a ig h t ­

VALVES w a y is f o r h o r iz o n ta l o r v e r tic a l lin e s w ith u p w a r d f lo w . A n g le

v a lv e s a re f o r " h o r iz o n t a l- d o w n w a r d ” o r '‘u p w a r d - h o r iz o n t a l’’
flo w .
CLASS 250 ■ T h e s e v a lv e s w ill p e r fo r m th e f o u r f o llo w in g im p o r ta n t f u n c tio n s :

21/2" to 10" 1. A c t a s a n a u t o m a t ic - n o n - r e t u r n v a lv e b y p r e v e n tin g a b a c k ­

f lo w o f s te a m fr o m m a in h e a d e r to b o ile r in c a s e b o ile r fa ils .
2. A s s is t in c u t t in g o u t b o ile r , w h e n c e a s in g t o fir e . In t h is c a s e ,
Flanged Y Pattern v a lv e d is c a u t o m a t ic a lly c lo s e s a n d p re v e n ts h e a d e r p re s s u re
No. 28E fr o m e n te r in g b o ile r.
Bolted Bonnet
3. A s s is t in r e tu r n in g b o ile r to s e rv ic e a fte r a s h u td o w n .
4. P re v e n t b a c k f lo w o f s te a m fr o m h e a d e r in to a b o ile r w h ic h
No. 28E, Straightway h a s b e e n s h u t d o w n a n d is a c c id e n ta lly o p e n e d .
No. 30E, Angle ■ B o d y a n d b o n n e t a re h ig h - s tr e n g t h c a s t ir o n c o n f o r m in g to
A S T M A 1 2 6 , C la s s B. V a lv e s c a n b e o r d e r e d w ith t w o V i" b o d y
d r a in s f o r e a s y re m o v a l o f c o n d e n s a te .
RATINGS
■ D is c s o n s iz e s u p to 5 ” a re s o lid A S T M B61 b ro n z e . L a r g e r s iz e s
Temp. Pst Non-Shock a re c a s t ir o n w ith A S T M B61 b ro n z e s e a tin g fa c e a n d t h r o t t lin g
F.
lip . D is c s c a n b e r e g r o u n d . S te m is n ic k e l- p la te d s te e l.
-20 to 150° 500
200 460 ■ P is to n - ty p e , c y lin d r ic a l- s h a p e d d is c o p e ra te s in a r e n e w a b le
225 440 c a s t ir o n lin e r a n d is t h e o n ly p r e s s u r e - a c tu a te d p a rt. T h e lin e r
250 415 w ith a s e lf- c o n ta in e d d a s h p o t to c u s h io n th e d is c a ls o h o ld s th e
275 395
s h o u ld e r - ty p e b ro n z e b o d y s e a t rin g in p o s itio n .
300 375
325 355 ■ V a lv e s 6 ” a n d s m a lle r h a v e a c o n v e n tio n a l m a lle a b le ir o n
350 335 h a n d w h e e l. L a rg e r s iz e s h a v e a c a s t s te e l, h a m m e r - b lo w w h e e l.
375 315
400 290 ■ V a lve s c o m p ly w ith th e a p p lic a b le r e q u ire m e n ts o f A N S I B 1 6 .1 ,
425 270 C la s s 2 5 0, f o r e n d fla n g e s a n d A N S I 8 1 6 .1 0 , C la s s 2 5 0, f o r fa c e -
450 250
to - fa c e d im e n s io n s . E n d fla n g e s h a ve a Vie" ra is e d fa c e fin is h e d
w ith c o n c e n tr ic g ro o v e s .

■ S ee c h a r t o n p a g e s 5 9 a n d 60 f o r s iz in g .

Weights
D J! ■*- c — -
and
Dimensions n
. .. _ _ I _ . .

4--------------- A ---------------- r
— B — -------------------D ---------------- ►

W e ig h t- Pounds Dimensions— inches

Valve 28E 30E

N.P.S. 28E 30E
No. 30E A* c t Ef G B* . D t Ft G

2 'h 103 86 13.00 5.00 15.75 9.00 5.75 14.50 13.25 9.00
3 140 123 14.75 7.25 19.75 10.00 6.25 16.50 14.75 10.00
4 226 186 17.00 7.75 21.75 10.00 7.00 18.50 16.25 10.00
5 307 250 19,00 10.50 25.75 14.00 7.88 22.00 19.50 14.00
6 420 340 21.50 11.75 29.25 16.00 8.75 25.50 22.50 16.00
8 737 640 26.00 16.25 36.75 20.00 10.50 33.25 28.75 20.00
10 1250 1025 30.00 17.75 41.75 20.00 12.25 37.75 32.50 20.00
Dimensions "A" and “ B" include 'U " raised face on end flanges. t Valve open.
CRANE
___ ®

Bolted Bonnet
Stop-Check Valves
Since stop-check valves have a floating disc member, it is
important the valve be sized to provide full disc lift under
flow conditions prevailing during the major portion of the
service life. If the valve is too large, the disc will float in a
partially open position and may cause fluttering of the disc
and rapid wear. Conversely, if the valve is too small, pressure
drop will be excessive.
The chart on the opposite page is a graphical presentation
of flow data determined by test. Its use offers a simple
method of determining the best size of stop-check valve, as
well as the pressure drop under varying conditions of flow,
without any computation.
How to Use the Chart
Shown on Page 57
2. From that point, draw another line through the valve size,
for example the 8-inch size, and establish a point on Index 2.
Now move horizontally to the diagonal pressure drop line on
the right side. Where these lines intersect, the pressure drop
is 7.5 psi for the 8-inch, Class 250globe valve and 8.5 psi for
the 8-inch Class 250 angle valve.
Chart solutions resulting in a point on Index 2 that falls
below the Line A-A for Class 250 valves indicate the disc will
not be fully lifted under the flow conditions used. Operation
under such conditions is not recommended but, at times,
must be tolerated for short periods during the low loads.
3. Enter the chart where Line A-A intersects Index 2 for
Class 250 valves. Move diagonally upward through the size
being investigated (8-inch) and establish a second point on
index 1. From this point, extend a line to the specific volume
established in Step 1 and at its intersection with the flow rate
line, read 48,000 Lb/H as the minimum flow rate at which the
disc will be in the fully lifted position. The pressure drop at
this flow rate is 1.9 psi for globe and 2.1 psi for angle valves.

4. Repeat Steps 2 and 3 for other possible valve sizes,

Given: Steam Pressure-Temperature . . . 250 psig @ 450F
tabulate results, and make size selection on basis of
Flow Rate . . . Typical Daily Demand Curve
pressure drop and duration of partial disc lift considerations.

Valve P ress, d r o p @ M a x . M in . R o w R ate (o r

S ize F lo w rate (1 0 0 0 0 0 # /H r.), psi. W id e o p e n va lve

(Inches) Globe Angle #/H r.

6 20.5 22.5 26500

8 7.5 8.5 48000

10 3.3 3.6 74000

Dotted lines on Demand Curve indicate minimum flow rates

cc 12 6 12 6 12 for wide open 8" and 10" valves.
Midnight AM Noon PM Midnight

T IM E OF DAY

Find: Valve Catalog No. and the best size for above
installation.
Solution 5. The best choice for this example would be the 10" size
because pressure drop is much lower and duration of
1. Enter the Temperature chart at 450F. Move vertically
partially lifted disc is only slightly greater than for the 8" size.
upward to the curved line for 250 psi, then horizontally to the
right to establish a point on the specific volume scale. From
this point, draw a line through the flow rate being investi­ 6. Pressure drop for any intermediate flow condition can be
gated (100,000 Lb/H) and establish a point on Index 1. determined as outlined in Steps 1 and 2.
cn Selecting the Proper Size-Determining Pressure Drop
C RANEe _ .
’ Recom m endations for Installation of
Y-Pattern Stop-Check Valves

DRAIN

As shown in these diagrams, Crane y-pattern

stop-check valves used in a boiler installation
can be positioned for horizontal or upward flow.
The proper method for draining is shown for each
position. Tapped and plugged drain holes can be
furnished when specified. For top efficiency, be
to-horizontal flow. sure the proper size valve is used.
 CRANE
Accessories and Parts

Wheels and Handles

T a b le b e lo w in c lu d e s h o le s iz e (p) a n d h u b le n g th (v) of
o p e ra to rs .
W h e e ls o r h a n d le s w ith s a m e h o le s iz e a n d s a m e h u b le n g th
a re in te r c h a n g e a b le . W h e n s u b s titu tin g a s iz e la r g e r th a n
re g u la rly fu rn is h e d , th e e ffe c t o f in c re a s e d p o w e r o b ta in e d m u s t
b e c o n s id e r e d . R e c o m m e n d a tio n s o n re q u e s t. —( p i— p —i

S p e c ify o p e ra to r s ty le a n d s iz e ...o r th e c a ta lo g n u m b e r a n d s iz e Square H ole Hexagon Hole

o f th e v a lv e . Wheel or H andle Wheel
"Tolal taper is ¥ *" per foot.

SIZES, WEIGHTS AND DIMENSIONS

Wheel Dimensions Wheel Dimensions

Size Weight (a) Weight
(a) Each Size Each S tyle F Wheel Style M Wheel
( in c h e s ) <b > (P) M ( in c h e s ) ip ) (V) Square Hole Threaded Hole

Style D Wheel, Square H o l e Style E Wheel, H e x . H o l e Non-heat Aluminum or iron. Round rim. Malleable iron.
For small bronze and iron For No. 459 gate only,
3% .6 — .35 .44 6 2.4 .99" .69" globe, angle and gate valves.
4ft 1.0 — .37 .62 7 3.5 .99 .69
6 2.5 — .56 .87 8 4.0 1.16 .75
7 3.5 — .63 1.00 9 6.0 1.35 .87
8 4,3 - .69 1.06 10 6.7 1.54 .87
9 5.8 .75 1 19
12 8.7 1.86 1.00
t io - s 6.8 — .81 ■37 14 12.0 2.05 1 .0 6
110-L 7.0 — .87 1.37 16 15.0 2.31 1.19
12 8.6 — .94 1.50 18 20.0 2.38 1.31
14 12.9 — 1.00 1.62 20 23.0 2.75 1.31
16 14.3 - 1.13 1.75 22 32.0 3.27 1.50
18 19.5 — 1.25 1.87 24 40.0 3.46 1.62
20 22.5 — 1.31 2.12 27 47.0 3.53 1.69
22 33.0 — 1.44 2.37 30 64.0 4.03 1.75
24 38.0 — 1.50 2.44 36 115.0 4.56 2.19
27 47.0 — 1.75 2,50 142 140.0 5.16 2.75
30 85.0 — 1.87 2.75 142 140.0 5.75 2.75
36 148.0 — 2.00 3.25
42 168.0 - 2.50 3.50 Style M Wheel, Tl- r e a d e d H o l e 20" dla. & smaller —-----a-------- 12" dia. & larger

3 ft* .6 — - Style D W heel— Square Hole

Sty e F Whee , Squar e H o l e
3 ft .7 — —
3 ft .8
Oval rim, malleable iron. For larger size bronze, iron,
1ft .04 _ .20 .30 globe, angle, and gate (not OS&Y gate).
4ft .8 — —
1% .07 .24 .35
4’ f t . .9
t 2Yi. .09 - .24 ,35
t 2ft* .09 — .29 .35
2ft* .12 — .32 .40
2% .20 - .35 .44

t 3 ft. .26 — .35 .44

t 3’/ . .26 — .40 .44
3ft .37 — .42 .44
4ft « .50 — .45 .56
4 ft .70 — .53 .62
5ft 1.10 — .53 .62

20" dia. & smaller * ° " 22" dia. & larger

f D a g g e r m a r k in d i c a t e s w h e e ls o r h a n d le s m a d e w i t h t w o s iz e s o f s q u a r e s Style E W heel —Hexagon Hole
o r h e x a g o n s . W h e n o r d e r in g s u c h s iz e s , always i n c l u d e t h e s iz e a n d c a t a lo g
n u m b e r o f t h e v a lv e o n w h i c h t h e w h e e l o r h a n d l e w i l l b e u s e d . Oval rim, malleable iron, Similar to Style D. Used on OS&Y iron,

59
|CRANE

WEDGE
GATE VALVES ■ H e a v y d u t y v a lv e s f o r s te a m , w a te r, n o n - c o r r o s iv e o il, a n d o t h e r
f lu id s th a t d o n o t c o r r o d e b ro n z e o r iro n .

CLASS 250 ■ B o d y a n d b o n n e t a re h ig h - s tr e n g t h c a s t ir o n c o n f o r m in g t o
A S T M A 1 2 6 , C la s s B.
2"to 12" ■ B r o n z e s e a t r in g s a re s c re w e d in to th e b o d y a n d c a n
re m o v e d f o r re p la c e m e n t w h e n n e c e s s a ry .
be

Bronze Trim ■ T a p e r e d s o lid w e d g e ir o n d is c w ith b r o n z e f a c e s is g u id e d

th ro u g h o u t its tra v e l to im p ro v e d is c life b y e lim in a tin g p re m a tu re
No. 3E
c o n ta c t w ith th e s e a tin g s u rfa c e s . In th e 2 " th ro u g h 3 " s iz e s , th e
Non-Rising Stem d is c is s o lid b ro n z e .
No. 3E, Flanged
■ S te e l s te m in N o . 7E is id e a l f o r h ig h e r te m p e r a t u r e s e r v ic e s o r
w h e r e c o p p e r - b e a r in g m a te ria l w o u ld b e u n d e s ir a b le .
Outside Screw & Yoke ■ M a n g a n e s e b ro n z e s te m s in N o . 3 E a n d 7'/2E h a v e e x c e lle n t
No. 7E, Flanged re s is ta n c e t o w e a r a n d s tr e n g th to w ith s ta n d to r s io n a l a n d
No. 7V2E, Flanged te n s ile s ta in s .

ft A ll v a lv e s a re r e g u la r ly f u r n is h e d w ith h a n d w h e e ls , b u t c a n b e
s u p p lie d w ith m a n u a l g e a r, h y d r a u lic o r m o t o r o p e r a to r s w h e n
RATINGS o rd e re d .
Temp. ■ A ll v a lv e s c o m p ly w ith a p p lic a b le r e q u ire m e n ts o f S ta n d a rd s
F. Psi Non-Shock
-20(0 150° 500 A N S I B 1 6 .1 , A N S I B 1 6 .1 0 , a n d M S S S P -7 0 .
200 460 ■ N o . 3 E a n d 7 1/sE a ls o m e e t F e d e ra l S p e c . W W -V -5 8 B , T y p e I,
225 440
415 C la s s 2 m a te ria l a n d d e s ig n r e q u ire m e n ts .
250
275 395 ■ V a lv e s c a n b e e q u ip p e d w ith b y -p a s s e s w h e n s p e c ifie d . B y ­
300 375
p a s s v a lv e s w ill be o f a m a te r ia l c o m p a t ib le w ith t h e m a in v a lv e .
325 355
350 335
■ V a lv e s 6 " a n d la rg e r h a ve b o s s e s c a s t in to th e b o d ie s a n d b o n ­
375 315
n e ts , a n d c a n b e e q u ip p e d w ith ta p s a n d d ra in s to p re v e n t flu id s
400 290
425 270 fro m a c c u m u la tin g a n d p o s s ib ly c a u s in g d a m a g e . O rd e rs m u s t
450 250 s p e c ify lo c a tio n o f ta p s a n d d ra in s .

Wsights
and
Dimensions
Weight— Pounds Dimensions— Inches

Valve
N.P.S. 3E 7E & Vh E
3E 7E 7VsE
A B C A B C
2 47 51 51 8 .5 0 11.94 8 .0 0 8 .5 0 1 5 .0 6 8 .0 0
2Vz 84 91 91 9 .5 0 1 2 .9 4 8 .0 0 ' 9 .5 0 1 6 .6 9 8 .0 0
3 113 12 0 120 11.12 1 4 .5 0 1 0 .00 11.12 18.75 1 0 .0 0
4 175 185 185 1 2 .0 0 1 7 .3 8 1 2 .00 12.00 2 3 .4 4 1 2 .00
5 — — 28 0 — — — 15 ,00* 2 9 .7 5 * 14 .00*
6 33 5 36 5 36 5 1 5 .8 8 2 3 .0 0 16.00 1 5 .8 8 3 1 .7 5 1 6 .0 0
8 54 5 600 600 1 6 .5 0 3 0 .7 5 2 0 .0 0 16.50 3 9 .8 8 1 8 .0 0
10 850 — 92 0 1 8 .00 3 6 .0 0 22.00 18.00 5 2 .7 5 2 2 .0 0
12 1300 — 14 00 1 9 .75 3 9 .7 5 2 4 .0 0 19.75 6 0 .0 0 2 4 .0 0

No. 3E No. 7E "ET dimension is with valve open. *No. 7ViE only 42
 4 3 I

ITEM REQ. D E S C R IP T IO N
1 1 FLANG E, W E L D IN G NECK, 1 0 "-3 0 0 # R .F .
2 1 F L A N G E . W E L D IN G N E C K , 8 ” - 3 0 0 # R .F .
3 1 R E D U C E R . C O N C E N T R IC . 1 0 " X 8 11
IT IS SUBJECT TD CHANGE V1THDUT NOTICE; AND IS NOT TO BE COPIED OR USED IN ANY WAY DETRIMENTAL TO THE COMPANY.

4 1 P IP E . 1 0 ;f P IP E S IZ E X 2 3 .5 ” LG .
5 2 R IN G . W ELD B A C K IN G . 10”
6 1 R IN G , W ELD B A C K IN G , 8"
SUGGESTIONS AND INFORMATION CONTAINED ON THIS DRAWING ARE NDT INTENDED TO SUPPLANT LOCAL CODES.
THIS DRAWING IS PROPERTY OF CLEAVER-BROOKS DIVISION

CONTAINER
SANTA CLA
C U 940146*
\ 2 1

CD

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