Bell & Gossett HS 601G User Manual
INSTRUCTION MANUAL
!
HS-601
REVISION G
Hoffman Specialty
®
Pilot Operated Pressure and/or
Temperature Steam Regulators
Series 2000
WARNING
CAUTION
• Before using product, read and understand instructions.
• Save these instructions for future reference.
• All work must be performed by qualified personnel trained in the proper application,
installation, and maintenance of steam systems in accordance with all applicable codes
and ordinances.
• To prevent serious burns, wear heat resistant gloves when opening and closing steam
valves, or handling hot e
• To prevent serious personal injury from steam pipe blow down, connect a temporary
pipe between the steam pipe opening and a drain, or stand at least 100 ft. (30m) from
the front of the pipe opening.
• To prevent property damage, personal injury, or death, cap off the gate valves if they
are not connected to a drain and when they are not in use for test or pressure relief.
Failure to follow this warning could cause property damage, personal injury or death.
quipment.
WARNING
PLANNING THE INSTALLATION
Planning for the Main Valve Installation
1. The regulator main valve must be located in an
accessible straight run of horizontal piping.
OTE: Main valve must be installed with diaphragm
N
located on bottom, as shown in Main Valve Installation
illustration, page 3.
2. Allow clearance on top of the main valve to remove
the cover plate to inspect and service the valve.
3. Allow clearance under the main valve diaphragm
cover to replace diaphragms and drop out the stem
for service.
4. Piping should be sized per good engineering practice.
HVAC applications generally use 6,000 FPM velocity.
Industrial applications generally use 8,000 to 10,000
FPM.
5. Blow out all piping with steam or compressed air before
installing the main valve to remove mill scale and dirt.
6. Use long radius elbows in the low pressure piping.
Avoid the use of bull-headed tees.
7. Provide a bypass line with a globe valve to allow
inspection without interrupting service.
8. Install pressure gauges on inlet and outlet sides of
regulator to indicate system performance.
9. Install drip traps to prevent:
• Accumulation of condensate that can cause water
hammer and destroy the main valve and pilot
diaphragms.
• Slow response times that cause temperature or
pressure fluctuations.
10. Install "Y" Strainers in steam lines with the dirt pocket
turned to the side to prevent collection of condensate
that can be carried into the regulator and cause water
hammer.
11. Install pressure relief valves in accordance with local
nd national codes. The relief valve must be capable
a
of passing the full capacity of the regulator with its
largest seat trim.
Select the relief valve opening set point pressure
ased on the downstream pressure from the regulator.
b
The actual relief valve set point pressure depends on
the relationship of the flow (load) to the main valve
rated capacity.
For systems with spring or air pilots:
Determine the relief pressure set point pressure for
systems as follows:
Downstream Flow Relief valve
System (Load) opening set
Pressure (DSP) Condition point pressure
< 35 psig < 50% of capacity DSP + 5 psig
< 35 psig ≥ 51% of capacity (1.1 x DSP) + 5 psig
≥36 psig < 50% of capacity DSP + 10 psig
≥36 psig ≥ 51% of capacity (1.1 x DSP) + 10 psig
For systems with temperature pilots only:
The steam system relief valve opening set point
pressure is based on the supply steam inlet pressure
to the regulator and must be set as follows:
Supply Steam Relief valve
Inlet Pressure opening set
(SSIP) point pressure
< 35 psig SSIP + 5 psig
≥36 psig SSIP + 10 psig
12. Locate temperature regulators close to the temperature
sensing location. The temperature pilot capillary tube
must allow the sensing bulb to be fully inserted into
the system fluid.
Planning for the Pilot Installation
1. The pilot valves can be installed on either side of the
main valve. The main valve is shipped with the U-tubing
and the bleed orifice installed for left-hand side
mounting of the pilot valves. (U-tubing is mounted on
the right-hand side and the bleed orifice is installed
on the left-hand side.)
If right-hand side mounting of the pilot(s) is desired,
the U-tubing and the bleed orifice must be relocated
to the opposite sides of the main valve.
Note: Right-hand side and left-hand side positioning
is determined when the main valve inlet directly faces
the observer.
2. Determine which pilot(s) are to be used for the installation. Multiple pilots can be used in combination on
one main valve. Mount the pilot(s) as follows:
• SLD Solenoid Pilot
Always mount closest to the main valve.
2
• SPS Spring or AP Air Pressure Pilots
When used in combination with other pilots,
always mount spring or air pilots furthest from
the main valve.
• STPA Temperature Pilot
When used with pressure pilot mount closest to
main valve.
When used with pressure and solenoid pilots –
mount between pressure and solenoid pilots.
• 315 PNT or 240PNT Pneumatic Temperature
Pilots
Mounted remotely from main valve.
• GT610-IP Electronic Pilot (used with customer
supplied temperature sensor and controller)
Mounted remotely from main valve.
3. Hardware kits containing steel pipe nipples and
copper tube lines are required to mount the pilots.
Refer to "Mounting Hardware for Pilot Installation"
Page 4.
N
10 Pipe
Diameters
O
M
H
F
G
E
J
L
P
R
S
Z
Y
X
W
U
V
T
B
A
C
K
D
INSTALLATION DETAIL
Main Valve Installation
1. Connect a steam line (A) from the steam supply to the
area where regulator valve is to be located. Install tee
fittings (B) for a bypass line, and (C) for the regulator
line.
Note: Drip traps prevent condensate from collecting in
the piping during light loads or when the regulator is
closed. Collected condensate in the piping ahead of
the regulator can cause water hammer when the
regulator opens.
2. Install a shut off valve (E) to allow servicing the trap.
3. Provide a dirt pocket ahead of the strainer to allow
large solids to drop out.
4. Install a drip trap (H), Y-strainer (F) equipped with a
screen and blow down valve (G).
5. Cap the blow down valve outlet to prevent steam
discharge due to accidental opening of valve.
6. Connect a horizontal pipe from tee (C).
7. Connect a reducer (D), if required, to reduce the
steam line to the pipe size of the main valve.
Use additional reducers when the pipe needs to be
reduced more than two pipe sizes. When noise is a
concern, reducers should not have more than a 15
degree taper.
8. Install shut off valve (J) and Y- strainer (K). Turn the
strainer so that the screen is horizontal to prevent
condensate from collecting in the screen pocket.
Condensate pockets can carry with the steam flow,
causing water hammer that can destroy the main
valve diaphragms.
9. Install a strainer blow down valve (L).
10. Cap the blow down valve outlet to prevent steam
discharge due to accidental opening of valve.
11. Install tee, siphon loop tube, petcock, and pressure
gauge.
On NPT sized regulator valves, install a pipe union (M)
12.
to allow regulator removal for service or replacement.
13. Use compressed air or steam to clean piping before
installing the regulator.
• Cap off the end of the steam line.
• Remove caps from the strainer blow down
valves (G) and (L).
• Turn on the steam or air to full pressure and allow
it to blow down for five minutes.
• Close off compressed air or steam.
• Allow piping to cool below 100˚F.
• Reinstall end of line caps on blow down valves.
• Remove cap from end of the steam line.
14. Install main valve (N) with the direction arrow pointing
to the low-pressure side outlet piping.
NPT sized regulator valves:
• Use pipe sealant on male threads only, keeping the
sealant out of the system.
• Use a wrench on the flats of the body to tighten
the joint.
• Use the wrench on the side of the body that is being
tightened to prevent stress and distortion on the body.
Flanged regulator valves:
• Inspect flange surfaces and gaskets.
• Tighten flange bolts using a star pattern. Uneven
bolting may cause steam leakage.
15. Install silencer orifice plate (when used) immediately
after the main valve:
NPT sized regulator valves: Install orifice plate
between two ASME flanges.
Flanged regulator valves: Install the orifice plate
between the valve flange and the outlet pipe flange.
16.
On NPT sized regulator valves, install a pipe union (O)
to allow regulator removal for service or replacement.
17. Install gate valve (P).
18. Install pipe tee (R) for bypass connection.
3
19. Install the bypass piping and globe valve (T).
1
2
4
3
5
1076
1
9
4
8
5
10
76
• Use the same size pipe for the bypass piping and
globe valve in the bypass line as the main valve (N)
to allow manual regulation during service of regulator.
Support piping to remove any stress from the
•
regulator valve body before connecting to the system.
• Make sure pipes and flanges are properly aligned to
revent stress on the regulator valve body.
p
20. Install pipe reducer (S) to increase the pipe size, if
necessary, to meet the velocity requirements.
Use additional reducers when the pipe needs to be
increased more than two pipe sizes.
21. Install a 1/4 NPT pipe tapping (U) at least 10 pipe
diameters downstream in a straight run of the
enlarged pipe for the pressure gauge and feedback
line (for spring and/or air pilots) connection.
PILOT INSTALLATION
Mounting Hardware for Pilot Installation
Note: For heat exchanger shell applications, it is
recommended that the feedback line and pressure
gauge be installed directly into the heat exchanger
shell.
22. Install pressure relief valve (V) in the downstream
iping as required by codes.
p
23. Install a tee fitting (W) for pressure feedback line.
4. Install a siphon loop tube (X), petcock (Y) and
2
pressure gauge (Z) in vertical port of tee fitting (W).
25. Connect system piping to complete the installation.
26. Refer to "Pilot Installation" for pilot mounting and
piping instructions.
Kit A – For spring or air pilots only or in combination with
temperature or solenoid pilots.
Kit B – For temperature pilot or solenoid pilot only.
Hardware Kit Components
No Part Description Kit A Kit B
1 L-Tubing; from main valve bottom XX
Elbow connection to tee fitting
Branch connection.
2 S-Tubing; from bleed orifice fitting X
to tee fitting on pilot.
3 Nipple, 1/4 NPT x 4" (101mm) X
4 Nipple, 1/4 NPT x 1-1/2" (38mm) (2) XX
5 Union Connection, 1/4 NPT Female XX
6 Tee fitting XX
7 L-fitting XX
8 Bushing X
9 J-Tubing; From bleed orifice fitting X
to tee fitting on pilot.
10 1/8" Tubing connector XX
4
1. L-Tube
C
D
A
B
Cut L- tube to appropriate A & B
dimensions listed on Tubing Length
chart.
No cutting is required if dimension is
marked with an *.
9. J-Tube
No cutting of J-tubes
s required
i
2. S-Tube
Cut S- tube to appropriate C & D dimensions listed on
Tubing Length chart.
No cutting is
required if dimension
is marked with an *.
Tubing Length
DIMENSIONS
ABCD
PILOT MAIN VALVE SIZE In mm In mm In mm In mm
1/2 NPT, 3/4 NPT, 1 NPT 6.0 152 7.6 178 6.4 163 3.5 89
1-1/4 NPT, 1-1/2 NPT 6.8 173 8.1 206 6.4 163 4.8 122
2 NPT, 2 (50) * 8.6 218 8.2 208 6.4 163 * 5.7 145
Spring or Air 2-1/2 (65) 10.6 269 9.1 231 6.4 163 5.9 150
3 (80) 11.2 284 9.4 239 6.4 163 6.4 162
4 (100) 13.0 330 10.3 262 6.4 163 7.9 200
6 (150) *16.6 422 12.3 312 6.4 163 * 9.5 241
1/2 NPT, 3/4 NPT, 1 NPT 6.0 152 11.3 287 *10.0 254 3.5 89
1-1/4 NPT, 1-1/2 NPT 6.8 173 11.7 297 *10.0 254 4.8 122
2 NPT, 2 (50) * 8.6 218 * 11.9 302 *10.0 254 * 5.7 145
Combination 2-1/2 (65) 10.6 269 12.8 325 *10.0 254 5.9 150
Pilots 3 (80) 11.2 284 13.1 333 *10.0 254 6.4 162
4 (100) 13.0 330 13.9 353 *10.0 254 7.9 200
6 (150) *16.6 422 * 14.9 378 *10.0 254 * 9.5 241
1/2 NPT, 3/4 NPT, 1 NPT 5.2 132 7.9 200
1-1/4 NPT, 1-1/2 NPT 6.0 152 8.6 218
2 NPT, 2 (50) 7.8 198 8.8 223
Temperature 2-1/2 (65) 9.8 249 9.7 246
3 (80) 10.4 264 10.0 254
4 (100) 12.2 310 10.9 277
6 (150) 15.8 401 12.0 305
* No cutting of tube length is required.
5
A
D
10 Pipe
Diameters
C
B
Bleed Orifice
The function of the bleed orifice is to bleed steam off the
ain valve diaphragm when the pilot(s) close(s). A 1/16"
m
(1.6mm) diameter orifice is standard, and is installed in
he outlet side of the main valve when shipped. This
t
diameter orifice is used in most applications.
In special situations, the bleed orifice may be drilled out
to 3/32" (2.4mm) diameter to produce faster closing time
of the main valve and thus improve response time.
• A 3/32 in. (2.4mm) diameter orifice should NOT be
used in conjunction with a temperature pilot, as
accuracy of temperature control will be reduced.
Pilot Installation Detail
• Typical applications for 3/32 in (2.4mm) diameter
leed orifice may include:
b
– Pressure differential across the reducing valve is
0 psig (3.5 bar) or greater.
5
– High pressure PRV on a 2-stage pressure
reducing station.
– Pressure reducing valve with a fast acting
pneumatic temperature regulator downstream
of the main valve.
Applies to All Pilots
1. The pilot valve(s) can be installed on either side of the
main valve. The main valve is shipped with the U-
tubing and the bleed orifice installed for left-hand side
mounting of the pilot valve(s). If right-hand side
mounting of the pilot(s) is desired, the U-tubing and
the bleed orifice must be relocated to the opposite
sides of the main valve.
Note: Right-hand side and left-hand side positioning is
determined when the main valve inlet directly faces
the observer.
2. Make sure the bleed orifice is installed in the 1/8 NPT
tapping on the outlet end of the main valve on the
opposite side from the U-tubing. Remove the 1/8 NPT
pipe plug from the bleed orifice and replace it with a
1/8 NPT x 1/4" (6mm) OD tubing, straight compression
fitting (from the hardware kit).
3. Install the 1/4 NPT x 1-1/2" (38mm) nipple and half of
the union connection (from the hardware kit) on the
inlet end of the main valve.
6
Use the 1/4 NPT x 4" (101mm) nipple and the remaining
4.
half of the union connection (from the hardware kit) to
mount the first pilot. Mount additional pilots as
required using 1/4" steel pipe nipples.
5. Install the copper tee fitting (from the hardware kit) in
the 1/8 NPT signal tapping on the side of the last pilot
with the tee pointing down.
6.
Install the L-fitting (from the hardware kit) in the tapping
at the center of the main valve diaphragm cover.
Note: For steps 7 and 8, trim the length of the copper
tubing as required (see "Tubing Length Chart", page
5) to make a neat installation. Be sure to ream the
tube to the full tube diameter after cutting.
7. Install the S- or J-copper tubing (from the hardware
kit) from the tee fitting to the bleed orifice.
8. Install the L- copper tubing (from the hardware kit)
from the bottom of the tee fitting to the L-fitting in the
main valve diaphragm cover.
Outlet
Balance
Tube
Bleed
O
rifice
Signal
Feedback Line
Main Valve
Inlet
Pilot Inlet
S
pring
Pilot
Air Supply
Feedback Line
Balance
Tube
Outlet
Bleed
Orifice
Main Valve
Inlet
Pilot Inlet
Signal
AP Air
Pilot
Air PRV
Regulator
High Pressure
Supply Air
T
emperature
S
ensor
Balance
Tube
S
ignal
Temperature
Pilot
Outlet
Bleed
Orifice
Main Valve
I
nlet
Pilot Inlet
Spring/Air Pilots
!
!
Flow from System
Pipe Tee
Pipe Bushing
Sensing Bulb
1. The 1/4" feedback tapping must be connected to the
downstream piping for either a spring or air pressure
pilot:
• Use 1/4 black steel pipe for the feedback line (B).
• Install a 1/4 NPT shut off valve (D) and union (C)
in this line to allow service of the pilot while
operating the system on the by-pass line.
• The feedback line must pitch away from the pilot
to avoid erratic operation, excessive fouling and
eliminate water pockets.
2. When the regulator is used with a heat exchanger,
connect the feedback line (B) to the heat exchanger
shell. A tee fitting can be installed in the heat
exchanger for a vacuum breaker connection.
Temperature Pilots
CAUTION
Temperature pilot bulb will be immersed in the heated
fluid. Before immersing, check compatibility of copper
bulb with heated fluid. Failure to insure compatibility
may cause property damage.
CAUTION
System should be supplied with overheat protection
(such as temperature relief valve or aquastat solenoid
combination) at 10˚F over set temperature. Failure to follow this warning may result in property damage, personal
injury, or death.
1. When only a temperature pilot is used, the outlet
tapping port must be reduced. Use the 1/8 x 1/4
NPT bushing (from the hardware kit) in the 1/4 NPT
outlet.
2. Insert the sensing bulb so the full length of the bulb
is exposed to the fluid whose temperature is being
controlled.
a) Use a 1/2 NPT compression fitting to install the
bulb at the outlet of instantaneous heaters and
in the middle of storage tanks.
b) The preferred bulb mounting when installed in
the system piping is illustrated below:
3. For air pilot installations, connect the regulated air
pressure supply to the top of the pilot bonnet.
c) Optional dry well (separable socket) allows the
sensing bulb to be removed from the tank or
piping without draining the system.
• When using a dry well, coat the bulb with high
temperature grease or heat transfer compound,
to aid heat transfer.
• Make sure that bulb and dry well are fully
inserted into the fluid being controlled.
7
Temperature and Spring Pilot Combination
Spring Pilot
O
utlet
B
alance Tube
S
elf-Contained
Temperature
Pilot
Bleed
O
rifice
Main Valve
I
nlet
P
ilot Inlet
Air Supply
Feedback Line
Balance
Tube
Outlet
Bleed
Orifice
Main Valve
Inlet
Pilot Inlet
S
ignal
A
P Air
Pilot
Temperature
Sensor
315 PNT
T
emperature
Pilot
Air PRV
Regulator
High Pressure
Supply Air
Main
Branch
Supply
Air Port
Branch
Air Port
y
y
y
y
y
y
y
y
y
y
y
y
y
y
y
y
y
yy
yy
yyy
y
Signal Port
Reverse Acting
Signal Port
1/2" NPT
Direct Acting
Signal Port
Pneumatic Temperature and Air Pilot
Combination
1. Install the temperature pilot next to the main valve.
2. Install a 1/4" NPT nipple between the outlet tapping
port of the temperature pilot and the inlet port of the
spring pilot.
3. The 1/4" feedback tapping port of the spring pilot
must be connected to the downstream piping:
• Use 1/4 black steel pipe for the feedback line.
• Install a 1/4 NPT shut off valve and union in the
feedback line to allow service of the pilot while
operating the system on the by-pass line.
• The feedback line must pitch away from the pilot to
avoid erratic operation and excessive fouling and to
eliminate water pockets.
4. When the regulator is used with a heat exchanger,
connect the feedback line (B) (see illustration on
page 6 to the heat exchanger shell. A tee fitting can
be installed in the heat exchanger for a vacuum
breaker connection.
5. Insert the sensing bulb of the temperature pilot so the
full length of the bulb is exposed to the fluid whose
temperature is being controlled.
a) Use a 1/2 NPT compression fitting to install the
bulb at the outlet of instantaneous heaters and in
the middle of storage tanks.
b) The preferred bulb mounting when installed in the
8
system piping is illustrated on page 7.
c) Optional dry well (separable socket) allows the
sensing bulb to be removed from the tank or piping
without draining the system.
• When using a dry well, coat the bulb with high
• Make sure that bulb and dry well are fully inserted
temperature grease or heat transfer compound,
to aid heat transfer.
into the fluid being controlled.
Series 315 PNT Pilot
1. Connect a regulated air supply to the "Reverse
Acting" inlet port of the 315 PNT pneumatic
temperature pilot.
2. Do not plug the "Direct Acting" inlet port of the
pneumatic temperature pilot. This port serves as
an air bleed.
3. Connect the output "Signal" port of the pneumatic
temperature pilot to the top of the AP-1A or AP-4A
pneumatic air pilot.
Series 240 PNT Pilot
1. Connect a regulated air supply to the "Supply Air"
port of the 240 PNT pneumatic temperature pilot.
2. Connect the output "Branch Air" port of the pneumatic
temperature pilot to the top of the AP-1A or AP-4A
pneumatic air pilot.
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