Emerson CS800 Instruction Manual

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Instruction Manual Form 5837

November 2014

CS800 Series

CS800 Series Commercial / Industrial Pressure Reducing Regulators

P1235

TYPE CS800 REGULATOR

P1521

TYPE CS803 REGULATOR WITH TRUE-MONITOR™ PROTECTION

Figure 1. Typical CS800 Series Pressure Reducing Regulators

Table of Contents

Introduction ............................................................................1

Speci cations ........................................................................2

Principle of Operation ............................................................3

Installation and Overpressure Protection ............................10

Startup .................................................................................14

Adjustment...........................................................................14

Shutdown.............................................................................16

Maintenance and Inspection................................................16

Parts Ordering .....................................................................20

Parts List..............................................................................22

P1234

TYPE CS800IQ WITH HIGH CAPACITY RELIEF

P1692

TYPE CS804IT REGULATOR WITH INTEGRAL

TYPE VSX8 SLAM-SHUT MODULE

Introduction

Scope of the Manual

This Instruction Manual provides instructions for the installation, maintenance and parts ordering information of CS800 Series service regulators. Instructions and parts list for the Type TM600 Integral True-Monitor are found in Instruction Manual D103126X012. Instructions and parts list for the Type VSX8 slam-shut are found in Instruction Manual D103127X012.

D103124X012

www.fisherregulators.com

CS800 Series

Specications

The Specications section lists the specications for the CS800 Series regulators. The following information is stamped on the regulator at the factory: Type number, date of manufacture, spring range, orice size, maximum inlet pressure, maximum operating outlet pressure and outlet pressure. Exceeding any of these limits may damage regulator parts.

Available Congurations

See Table 1

Body Sizes, Material, End Connections and Pressure Ratings

(1)

See Table 3

Maximum Inlet Pressures

(1)

Emergency: 175 psig / 12.1 bar Operating: See Table 4

Maximum Outlet Pressure

(1)

Emergency Regulator Casing: 15 psig / 1.0 bar Integral Monitor Casing: 25 psig / 1.7 bar Integral Slam-shut Casing: 87 psig / 6.0 bar To avoid internal parts damage: 3 psig / 0.21 bar

differential above outlet pressure setting

Operating Pressure Ranges

(1)

Regulator: See Table 5 Integral True-Monitor™: See Tables 8 and 9 Slam-shut Module: See Tables 10 to 11

Secondary Seat™ Protection Outlet Pressures

See Table 7

Spring Case Vent Connection

Internal Relief: 1 NPT High Capacity Relief: 2-1/2 NPT

Internal Relief Performance

See Table 6

Token Relief Performance

Approximate Token Relief Start-to-Discharge:

See Table 6

Orice Sizes, Flow Coefcients and IEC Sizing Coefcients

See Table 4

1. The pressure/temperature limits in this Instruction Manual and any applicable standard or code limitation should not be exceeded.

2. Product has passed Emerson Process Management Regulator Technologies, Inc. (Emerson™) testing for lockup, relief start-to-discharge and reseal down to -40 degrees.

Pressure Registration

Internal or External

Temperature Capabilities

(1)(2)

-20 to 150°F / -30 to 66°C

According to European PED Directive that rates products to a minimum temperature of -4°F / -20°C and a maximum temperature of 140°F / 60°C:

-4 to 140°F / -20 to 60°C

Approximate Weight

With Threaded Body

Type CS800/CS820: 25 lbs / 11 kg Type CS803/CS823: 34 lbs / 16 kg Type CS804/CS824: 31 lbs / 16 kg Type CS805/CS825: 26 lbs / 12 kg Type CS806/CS826: 26 lbs / 12 kg

High-Pressure Types

For CS85x add 2 lbs / 1 kg to types listed above

With Flanged Body

Add 11 lbs / 5 kg to weights listed above

PED Conformity Statement and Information

Types CS800, CS804, CS820, CS824, CS850 and CS854 are in conformity with the Pressure Equipment

Directive PED 97/23/EC and are classied under

Category I for units without a slam-shut and Category IV for units with a slam-shut. See Table 2.

For Types CS800, CS820 and CS850, equipment and pipeline situated on outlet side of the regulator are either

- not subject to the PED (PS ≤ 0.5 bar) or

- subject to (PS > 0.5 bar) in which case they should

come under Category I maximum

PED Related Information

See Table 2

WARNING

Failure to follow these instructions or to properly install and maintain this equipment

could result in an explosion and/or re

causing property damage and personal injury or death.

Fisher

regulators must be installed, operated and maintained in accordance with federal, state and local codes, rules and regulations and Emerson™ instructions.

If the regulator vents gas or a leak develops in the system, service to the unit may be required. Failure to correct trouble could result in a hazardous condition.

Call a gas service person to service the

unit. Only a qualied person must install or

service the regulator.

Description

CS800 Series regulators are typically installed on industrial and commercial applications. See Table 1 for available

congurations. Constructions with External Registration, e.g., Type CS800EN, require an external control line.

The CS800 Series offers multiple forms of overpressure protection including:

Internal Relief - Minimizes downstream pressure buildup

by relieving gas through the diaphragm assembly and out the 1 NPT vent to atmosphere in the event of an overpressure situation.

C S 8

Table 1. Available Congurations

TYPE NUMBER

OUTLET PRESSURE CONSTRUCTION

0 Low Pressure Applications (Outlet Pressure: 3.5 to 30 in. w.c. / 9 to 75 mbar)

2 Medium Pressure Applications (Outlet Pressure: 1 to 5.5 psig / 0.07 to 0.38 bar)

5 High Pressure Applications (Outlet Pressure: 5 to 10 psig / 0.34 to 0.69 bar)

OVERPRESSURE PROTECTION MODULE

0 Without Overpressure Protection Module

3 With Integral True-Monitor Module

4 With Slam-shut Module

5 With Secondary Seat Protection

6 With Secondary Seat Protection with controlled bleed to indicate Secondary Seat is functioning

PRESSURE REGISTRATION

I Internal Registration

E External Registration

RELIEF

N Non-Relieving

R Internal Relief

Q High-Capacity Relief

T Token Relief

L Low Flow Token Relief

Example: Type Number CS800IR: Type CS800 regulator without Overpressure Protection Module with Internal Pressure

Registration and with Internal Relief.

1. High-pressure Construction is not available with True Monitor Protection, Secondary Seat Protection or Relief.

2. Available only with Internal Relief or High-Capacity Relief Constructions.

3. Available only with Non-Relieving or Token Relief Constructions.

4. Reference Instruction Manual D103126X012 for information regarding the Type TM600 Integral True-Monitor or Instruction Manual D103127X012 for Type VSX8 safety slam-shut module.

(4)

(3)

(4)

OPTIONS

CS800 Series

(1)

(2)

High Capacity Relief - Provides an increase in relief performance over basic internal relief via a 2-1/2 NPT vent

thereby offering a signicant improvement in the level of

overpressure protection to the downstream system in the event of an overpressure occurrence.

Integral True-Monitor™ Protection - Provides a monitoring regulator integrally mounted on the inlet side of the valve

body that assumes control of ow to the downstream system should the primary regulator cease to regulate ow.

Secondary Seat™ Protection - Provides a solution to the most common cause of regulators failing to shutoff by employing a secondary seating surface to provide shutoff

in the event the primary orice seating surface becomes

damaged or blocked.

Slam-Shut Protection - Discontinues gas service by shutting the gas off if there is an overpressure or underpressure condition.

Principle of Operation

Types CS800, CS820 and CS850 Base Regulators Operation

Refer to Figures 2 and 3. When downstream demand decreases, the pressure under the diaphragm increases. This pressure overcomes the regulator setting (which is set by the regulator control spring). Through the action of the pusher post assembly, lever and valve stem, the valve disk moves closer

to the orice and reduces gas ow. If demand downstream

increases, pressure under the diaphragm decreases. Spring force pushes the pusher post assembly downward, the valve

disk moves away from the orice and the gas ow increases

downstream as the regulator opens in response to the decreased pressure underneath the diaphragm.

The Type CS800IR regulator includes an internal relief valve for overpressure protection. If the downstream pressure

exceeds the regulator setting by 7 in. w.c. to 2.5 psig / 17 to

172 mbar (depending on the type number and main spring

used), the relief valve opens and excess gas is vented through the stabilizer vent in the upper spring case. Units with standard internal relief valve have 1 NPT vent size,

Figure 2, while units with high-capacity relief valve have

2-1/2 NPT vent size, Figure 3.

The Types CS800IT, CS800IL, CS800ET and CS800EL provide a low-capacity/token relief. Token relief provides relief from minor overpressure caused by nicks or dents on

the orice or by thermal expansion of gas in the downstream

line. Token relief also provides a token or signal, in the form of odor, that an overpressure situation is occurring.

Types CS803 and CS823 Integral True-Monitor Operation

Types CS803 and CS823 combine the operation of a conventional two-regulator wide-open monitor set into one body, see Figure 4. The Integral True-Monitor is installed on the inlet side of the body and serves to control downstream pressure in the situation where the Primary regulator can no longer regulate downstream pressure.

CS800 Series

Table 2. PED Information

TYPE DESCRIPTION BODY MATERIAL PED CATEGORY FLUID GROUP

CS800, CS820 and CS850 Base regulator Ductile Iron and WCC Steel I

CS804, CS824 and CS854

European EN Reference Standards EN 334, EN 14382

Table 3. Body Sizes, Materials, End Connections and Maximum Cold Working Pressure Ratings

Regulator with

Slam-shut Module

Ductile Iron and WCC Steel IV

Groups 1 and 2 according to PED 97/23/EC,

and 2nd family gas according to EN 437 or

other gases (compressed air, nitrogen).

The gas must be non-corrosive, clean

(ltration on inlet side necessary) and dry.

(5)

TYPE

BODY

MATERIAL

END

CONNECTION

BODY SIZE

PART NUMBER

FACE-TO-FACE

DIMENSION

In. DN In. mm psig bar

BODY INLET

PRESSURE RATING

1-1/4 - - - - GE25859X012 6.12 155

CS800, CS805, CS806, CS820,

CS825, CS826

and CS850

NPT

Gray Cast Iron

CL125 FF

Gray Cast Iron NPT 2

NPT

1-1/2 - - - - GE26296X012 6.12 155

(1)

- - - - GE26300X012 6.12 155

2 - - - - ERAA02462A0 7.5 191

2 50 GE26301X012 7.5 191

2 50 GE26303X012 10 254

(2)

- - - - ERAA02437A0 6.12 155 175 12.1

(4)

1-1/4

- - - - GE26306X012 6.12 155

1-1/2 - - - - ERAA02453A1 6.12 155

175 12.1

2 - - - - ERAA02437A1 6.12 155

250 17.2

232 16

290 20

(3)

, CS820

CS800

(3)

CS850

, CS803,

CS823, CS804,

CS824 and CS854

(3)

Ductile Iron

WCC Steel

Rp 2 - - - - ERAA02715A1 6.12 155

(4)

CL125 FF /

CL150 FF

2 50 GE48292X012 7.5

2 50 ERAA02711A1 10 254

2 50 ERAA02718A1 10.5 267

PN 10/16

NPT

2 50 GE48296X012 7.5

2 50 ERAA02719A1 10 254

(4)

1-1/4

- - - - GE26306X022 6.12 155

1-1/2 - - - - ERAA02453A2 6.12 155

(4)

2 - - - - ERAA02437A2 6.12 155

Rp 2 - - - - ERAA02715A2 6.12 155

191

(4)

CL150 RF 2 50 ERAA02720A2 10 254

PN 10/16 2 50 ERAA02719A2 10 254 232 16

1. Standard on Types CS800, CS820 and CS850.

2. Standard on Types CS803, CS804, CS823, CS824 and CS854.

3. If a ductile iron or steel body material is selected without an Integral True-Monitor™ or slam-shut Overpressure Protection (OPP) device, the port located at the bottom of the body will receive an aluminum plug.

4. Not available on Types CS804, CS824 and CS854.

5. The pressure/temperature limits in this Instruction Manual or any applicable standard or code limitation should not be exceeded.

Table 4. Inlet Pressure Ratings and Flow and Sizing Coefcients

MAXIMUM OPERATING INLET PRESSURE

ORIFICE SIZE

TO OBTAIN OPTIMUM PERFORMANCE

psig Setpoints In. w.c. Setpoints

In. mm psig bar psig bar psig bar C

1/4

(1)

6.4

(1)

125 8.6 125 8.6

3/8 9.5 125 8.6 125 8.6 110 3.8 29.5 0.55 0.90

1/2 13 100 6.9 100 6.9 210 7.2 29.5 0.55 0.93

5/8 16 80 6.5 60 4.1 320 10.1 31.8 0.64 0.88

3/4 19 80 6.5 60 4.1 450 13.3 34 0.73 0.84

7/8 22 60 4.1 50 3.4 600 16.7 36 0.82 0.81

(1)

(1)(2)

1-3/8

1. Not available on the Types CS805, CS806, CS825 and CS826.

2. Not available on the Types CS803 and CS823.

(1)

(1)(2)

30 2.1 25 1.7 765 20.1 38.1 0.92 0.77

15 1.0 15 1.0 1125 29.8 37.7 0.90 0.76

MAXIMUM

EMERGENCY INLET

PRESSURE

175 12.1

WIDE-OPEN FLOW

COEFFICIENTS

IEC SIZING COEFFICIENTS

50 2.1 24.6 0.38

0.89

0.99

CS800 Series

Table 5. Outlet Pressure Ranges

TYPE

OUTLET PRESSURE RANGE

In. w.c. mbar In. mm In. mm

3.5 to 6

(1)

9 to 15

(1)

COLOR CODE PART NUMBER

Red GE30337X012 0.15 3.8 6.8 173

5.5 to 8.5 13 to 21 Black GE30338X012 0.17 4.3 6.8 173

CS800, CS803, CS804, CS805

and CS806

5.5 to 8.5 13 to 21

8 to 12 20 to 30 Purple GE30339X012 0.17 4.3 7.4 188

Brown [Use with Low

Inlet (LIN) Option]

GE49043X012 0.16 4.1 8.3 211

10 to 16 25 to 40 White GE30340X012 0.18 4.6 7.4 188

14 to 30 35 to 75 Dark Green GE30341X012 0.20 5.2 7.5 191

CS820, CS823, CS824, CS825

and CS826

CS850 and

CS854

1. In order to achieve the complete spring range listed, in some applications it may be required to re-orient the actuator/spring case to point downward to utilize the weight of the

internal components.

1 to 2.5 psig 69 to 170 Dark Blue GE30342X012 0.25 6.4 7.5 191

1.5 to 3.5 psig 100 to 241 Orange GE46922X012 0.26 6.6 7.1 180

2.5 to 5.5 psig 170 to 380 Yellow GE30343X012 0.29 7.5 6.7 170

5 to 10 psig 345 to 690

Green with

White Stripe

GE30344X012 0.39 9.9 7.6 192

Table 6. Approximate Internal Relief Valve Start-to-Discharge Pressure above Setpoint

INTERNAL RELIEF AND

HIGH CAPACITY RELIEF

CONTROL

SPRING

SETPOINT SET RANGE

Start-to-Discharge Pressure

Range above Setpoint

In. w.c. mbar In. w.c. mbar In. w.c. mbar In. w.c. mbar In. w.c. mbar

GE30337X012 4 10 3.5 to 6 9 to 15 11 to 18 27 to 42 7 to 14 17 to 35 6 to 14 15 to 35

GE30338X012 7 17 5.5 to 8.5 13 to 21 11 to 18 27 to 42 7 to 14 17 to 35 6 to 14 15 to 35

GE49043X012

(LIN)

7 17 5.5 to 8.5 13 to 21 11 to 18 27 to 42 7 to 14 17 to 35 6 to 14 15 to 35

GE30339X012 11 27 8 to 12 20 to 30 11 to 18 27 to 42 7 to 14 17 to 35 6 to 14 15 to 35

GE30340X012 14 35 10 to 16 25 to 40 11 to 18 27 to 42 7 to 14 17 to 35 6 to 14 15 to 35

GE30341X012 1 psig 69 14 to 30 35 to 75

GE30342X012 2 psig 138

GE46922X012 3 psig 207

GE30343X012 5 psig 345

1. Low start-to-discharge option is only available on the main control spring ranges up to 10 to 16 in. w.c. / 25 to 40 mbar.

1 to

2.5 psig

1.5 to

3.5 psig

2.5 to

5.5 psig

70 to 170

100 to 240

170 to 380

7 in. w.c. to

1 psig

7 in. w.c. to

2 psig

7 in. w.c. to

2 psig

7 in. w.c. to

2.5 psig

17 to 69 - - - - - - - - 8 to 16 20 to 40

17 to 138 - - - - - - - -

17 to 170 - - - - - - - - 1 to 2 psig 69 to 138

Table 7. Secondary Seat™ Protection Outlet Pressures

TYPES CS805 AND CS825 TYPES CS806 AND CS826

Secondary Seat

CONTROL SPRING SPRING RANGE SETPOINT

Color Part Number In. w.c. mbar In. w.c. mbar In. w.c. mbar In. w.c. mbar In. w.c. mbar In. w.c. mbar

Black GE30338X012 5.5 to 8.5 13 to 21 7 17 11 27 12 30 25 62 23 57

Brown

GE49043X012 5.5 to 8.5 13 to 21 7 17 11 27 12 30 25 62 23 57

(LIN)

White GE30340X012 10 to 16 25 to 40 14 35 19 47 20 50 36 89 33 81

Dark

GE30341X012 14 to 30 35 to 75 1 psig 69 1.2 psig 83 1.3 psig 90 2.1 psig 0.14 bar 2 psig 0.14 bar

Green

Dark

GE30342X012

Blue

Yellow GE30343X012

1. Downstream pressure buildup with Secondary Seat xed bleed in operation and regulator relief valve relieving to atmosphere.

2. Outlet pressure values listed are at maximum operating inlet pressure rating per orice. See Table 4.

3. If the outlet pressure rises above setpoint exceeds 3 psig / 207 mbar, inspect internal parts and replace if damaged.

1 to

2.5 psig

2.5 to

5.5 psig

69 mbar to

0.17 bar

0.17 to

0.38 bar

2 psig 0.14 bar 2.6 psig 0.17 bar 2.6 psig 0.18 bar 3.8 psig 0.26 bar 3.7 psig 0.26 bar

5 psig 0.34 bar 6.3 psig 0.43 bar 6.3 psig 0.43 bar 7.4 psig 0.51 bar 8.2 psig 0.56 bar

Shut-off Pressure

Orice Size, In. / mm Orice Size, In. / mm

3/8 / 9.5 5/8 / 16 3/8 / 9.5 5/8 / 16

SPRING WIRE DIAMETER SPRING FREE LENGTH

TOKEN RELIEF

Low Start-to-Discharge

Start-to-Discharge Pressure

Option

(1)

Start-to-Discharge Pressure

Range above Setpoint

7 in. w.c. to

1 psig

0.5 to

1.5 psig

(2)

Downstream Build-up

Pressure

17 to 69

35 to 100

(1)(2)(3)

CS800 Series

Table 8. Primary Regulator and Integral True-Monitor™ Outlet Pressure Ranges without Token Relief

PRIMARY REGULATOR INTEGRAL TRUE-MONITOR

Type

CS803IN

and

CS803EN

CS823IN

and

CS823EN

Typical Setpoint

In. w.c. mbar In. w.c. mbar In. w.c. mbar In. w.c. mbar

4 10 GE30337X012 3.5 to 6 9 to 15 Red

7 17 GE30338X012 5.5 to 8.5 13 to 21 Black

7 17 GE49043X012 5.5 to 8.5 13 to 21

11 27 GE30339X012 8 to 12 20 to 30 Purple

14 35 GE30340X012 10 to 16 25 to 40 White

1 psig 69 GE30341X012

2 psig 138 GE30342X012 1 to 2.5 psig

3 psig 207 GE46922X012

5 psig 345 GE30343X012

Spring Part

Number

Spring Range

14 to

1.5 to

3.5 psig

2.5 to

5.5 psig

35 to 75

69 to

170

100 to

241

170 to

380

Spring

Color

Brown

(LIN)

Dark

Green

Dark

Blue

Orange

Yellow

Setpoint

14 35 GE30189X012 12 to 21 30 to 52 Blue

21 52 GE30196X012 18 to 30 45 to 75 Green

1 psig 69 GE30225X012 26 to 40 65 to 99 Orange

14 35 GE30189X012 12 to 21 30 to 52 Blue

21 52 GE30196X012 18 to 30 45 to 75 Green

1 psig 69 GE30225X012 26 to 40 65 to 99 Orange

14 35 GE30189X012 12 to 21 30 to 52 Blue

21 52 GE30196X012 18 to 30 45 to 75 Green

1 psig 69 GE30225X012 26 to 40 65 to 99 Orange

21 52 GE30196X012 18 to 30 45 to 75 Green

1 psig 69 GE30225X012 26 to 40 65 to 99 Orange

1.5 psig 103 GE30190X012

21 52 GE30196X012 18 to 30 45 to 75 Green

1 psig 69 GE30225X012 26 to 40 65 to 99 Orange

1.5 psig 103 GE30190X012

2 psig 138 GE30190X012

3.5 psig 241 GE35081X012

2.5 psig 172 GE30190X012

3 psig 207 GE35081X012

5 psig 345 GE30192X012

3.5 241 GE35081X012

4 276 GE30192X012

6 414 GE33121X012 4 to 7.5

7 483 GE33121X012 4 to 7.5

7.5 517 GE33121X012 4 to 7.5

Spring Part

Number

Spring Range

1.4 to

2.9 psig

1.4 to

2.9 psig

1.4 to

2.9 psig

1.4 to

2.9 psig

2.6 to

3.7 psig

1.4 to

2.9 psig

2.6 to

3.7 psig

3.6 to 6 psig

2.6 to

3.7 psig

3.6 to 6 psig

Spring

Color

97 to 200 Black

179 to

255

97 to 200 Black

179 to

255

248 to

414

179 to

255

248 to

414

276 to

517

276 to

517

276 to

517

276 to

517

Purple

Dark Blue

Purple

Dark Blue

Red

Type

CS803IT, CS803IL,

CS803ET and

CS803EL

CS823IT, CS823IL,

CS823ET and

CS823EL

CS800 Series

Table 9. Primary Regulator and Integral True-Monitor™ Outlet Pressure Ranges with Token Relief

PRIMARY REGULATOR INTEGRAL TRUE-MONITOR

Setpoint

In. w.c. mbar In. w.c. mbar In. w.c. mbar In. w.c. mbar

4 10 GE30337X012 3.5 to 6 9 to 15 Red

7 17 GE30338X012 5.5 to 8.5 13 to 21 Black

7 17 GE49043X012 5.5 to 8.5 13 to 21

11 27 GE30339X012 8 to 12 20 to 30 Purple

14 35 GE30340X012 10 to 16 25 to 40 White

1 psig 69 GE30341X012 14 to 30 35 to 75

2 psig 138 GE30342X012 1 to 2.5 69 to 170

3 psig 207 GE46922X012 1.5 to 3.5 100 to 241 Orange

5 psig 345 GE30343X012 2.5 to 5.5 170 to 380 Yellow

Spring Part

Number

Spring Pressure

Range

Spring

Color

Brown

(LIN)

Dark

Green

Dark Blue

Setpoint

21 52 GE30196X012 18 to 30 45 to 75 Green

1 psig 69 GE30225X012 26 to 40 65 to 99 Orange

21 52 GE30196X012 18 to 30 45 to 75 Green

1 psig 69 GE30225X012 26 to 40 65 to 99 Orange

21 52 GE30196X012 18 to 30 45 to 75 Green

1 psig 69 GE30225X012 26 to 40 65 to 99 Orange

1.5 psig 103 GE30190X012 1.4 to 2.9 psig 97 to 200 Black

1 psig 69 GE30225X012 26 to 40 65 to 99 Orange

1.5 psig 103 GE30190X012 1.4 to 2.9 psig 97 to 200 Black

2 psig 138 GE30190X012 1.4 to 2.9 psig 97 to 200 Black

3 psig 207 GE35081X012 2.6 to 3.7 psig 179 to 255 Purple

4 psig 276 GE30192X012 3.6 to 6 psig 248 to 414 Dark Blue

5 psig 345 GE30192X012 3.6 to 6 psig 248 to 414 Dark Blue

6 psig 414 GE33121X012 5.1 to 7.5 psig 352 to 517 Red

7 psig 483 GE33121X012 5.1 to 7.5 psig 352 to 517 Red

7.5 psig 517 GE33121X012 5.1 to 7.5 psig 352 to 517 Red

Spring Part

Number

Spring Pressure Range

Spring

Color

Table 10. Regulator and Slam-Shut Overpressure Shutoff (OPSO) Pressure Ranges

REGULATOR

Type

CS804

CS824

CS854 7 psig 483 5 to 10 psig 345 to 690 9 psig 621

1. For units equipped with Token Relief, if Non-Factory Slam-shut OPSO setpoints are specied, they must be higher than the Token Relief Start-to-Discharge values provided in Table 6.

2. If Non-Factory OPSO setpoints are specied, the allowable OPSO setpoint cannot exceed the maximum of 3 psig / 207 mbar above the regulator setpoint in order to ensure no internal

parts damage from overpressure.

Factory Setpoint Spring Range Factory Setpoint

In. w.c. mbar In. w.c. mbar In. w.c. mbar In. w.c. mbar

4 10 3.5 to 6 9 to 15 19 47

7 17 5.5 to 8.5 14 to 21 22 55

7 (optional) 17 (optional) 5.5 to 8.5 14 to 21

11 27 8 to 12 20 to 30

14 35 10 to 16 25 to 40 30 75 24 to 78 60 to 190 GF02170X012 / Orange

14 (optional) 35 (optional) 10 to 16 25 to 40 2 psig 138

1 psig 69 14 to 30 35 to 75 2 psig 138

2 psig 138 1 to 2.5 psig 69 to 170 3.5 psig 241

3 psig 207

5 psig 345

1.5 to

3.5 psig

2.5 to

5.5 psig

100 to 241 5 psig 345

170 to 380 7 psig 483

25 62 16 to 44 40 to 110 GF02169X012 / Red

SLAM-SHUT DEVICE

Over Pressure Shut-off (OPSO)

(1)

Spring Range

12 to 25 30 to 60 GF02168X012 / Brown

1.4 to

4.1 psig

2 to 7.3 psig 138 to 503 GF02172X012 / Green

3.2 to

8.5 psig

5.8 to

13 psig

(2)

97 to 283 GF02171X012 / Pink

221 to 586 GF02173X012 / Silver

400 to 896 GF04353X012 / Yellow

Spring

Part Number

and Color

CS800 Series

Table 11. Regulator and Slam-Shut Underpressure Shutoff (UPSO) Pressure and Overpressure Shutoff (OPSO) Ranges

REGULATOR

FACTORY

TYPE

CS804

CS824

CS854 7 psig 483

1. If Non-Factory UPSO setpoints are specied, a minimum differential of 4 in. w.c. / 10 mbar between UPSO setpoint and regulator setpoint must be maintained in order to ensure a

secure latch of the Slam-Shut.

2. For units equipped with Token Relief, if Non-Factory Slam-shut OPSO setpoints are specied, they must be higher than the Token Relief Start-to-Discharge values provided in Table 6.

3. If Non-Factory OPSO setpoints are specied, the allowable OPSO setpoint cannot exceed the maximum of 3 psig / 207 mbar above the regulator setpoint in order to ensure no internal

parts damage from overpressure.

SETPOINT

In. w.c. mbar In. w.c. mbar In. w.c. mbar In. w.c. mbar In. w.c. mbar In. w.c. mbar

7 17 5.5 to 8.5

11 27 8 to 12

14 35 10 to 16

1 psig 69 14 to 30

2 psig 138

3 psig 207

5 psig 345

SPRING

RANGE

1 to

2.5 psig

1.5 to

3.5 psig

2.5 to

5.5 psig

5 to

10 psig

14 to

20 to

25 to

35 to

69 to

170

100 to

241

170 to

380

345 to

690

0.5 psig 35

1.75 psig 121

3.5 psig 241

Under Pressure Shut-off (UPSO) Over Pressure Shut-off (OPSO)

FACTORY

SETPOINT

3 7

6 15 25 62

9 22 30 75

1 psig 69

3 psig 207 7 psig 483

SPRING RANGE

(1)

2 to 12 5 to 30

0.36 to

2.3 psig

0.36 to

2.3 psig

1.5 to

7.3 psig

1.5 to

7.3 psig

25 to

160

25 to

160

100 to

500

100 to

500

SLAM-SHUT DEVICE

SPRING PART NUMBER AND

COLOR

T14168T0012 /

White

T14170T0012 /

Silver

T14170T0012 /

Silver

FA142869X12 /

Orange Stripe

FA142869X12 /

Orange Stripe

FACTORY

SETPOINT

22 55

2 psig 138

3.5 psig 241

5 psig 345

9 psig 621

(2)

SPRING RANGE

OVER UPSO

SETPOINT

17 to 28 42 to 69

1.3 to

3.1 psig

1.3 to

3.1 psig

2.7 to

5.5 psig

2.7 to

5.5 psig

(3)

90 to

214

90 to

214

186 to

379

186 to

379

SPRING PART

NUMBER AND

COLOR

GF02168X012 /

Brown

GF02170X012 /

Orange

GF02170X012 /

Orange

GF02171X012 /

Pink

GF02171X012 /

Pink

During normal operation the True Monitor™ is in a wideopen state as its setpoint is set higher than the primary regulator. See Tables 8 and 9 for guidance regarding the setpoints of the regulator and associated Integral Monitor sets. If the downstream pressure should rise to the setpoint of the True Monitor due to loss of pressure control by the primary regulator, the monitor will assume control and

regulate ow to the downstream system. If a Token relief is

present, the token relief will relieve a small amount of gas to the atmosphere as an indication that the Integral Monitor is controlling the downstream pressure.

Either internal or external downstream pressure registration is available. External pressure registration requires a

downstream sensing line. See the Type TM600 Integral True-Monitor Instruction Manual (D103126X012) for additional details of operation.

Types CS804, CS824 and CS854 Slam-Shut Operation

The Type VSX8 Slam-shut module on the CS804 Series regulators is a fast acting shutoff device that provides overpressure (OPSO) or overpressure and underpressure

(OPSO/UPSO) protection by completely shutting off the ow

of gas to the downstream system. See Tables 10 and 11 for guidance regarding the typical setpoint of the regulator

and associated OPSO and UPSO sets. The Type VSX8’s

actions are independent of the CS804 Series regulator and of variations to the inlet pressure. The Type VSX8 provides

the option of internal or external downstream pressure registration. External registration requires a downstream

sensing line. See Figure 11 for guidance regarding installation of the downstream control line.

The Type VSX8 shutoff disk is normally in the open (reset) position, see Figure 5. If the downstream pressure below the slam-shut diaphragm increases (or decreases) until it reaches the slam-shut setpoint, this diaphragm moves upward (or downward) to release the trip mechanism which allows the spring force on the stem to push the disk against

the seat, shutting off all gas ow. To reset the slam-shut after

gas has been shutoff; refer to Type VSX8 Instruction Manual (D103127X012) for additional details.

WARNING

In order for the Underpressure Shutoff (UPSO) of any slam-shut to be triggered, the downstream pipe pressure must drop below the UPSO setpoint. In the case of a downstream line break, numerous factors can prevent the downstream pipe pressure from decreasing below the slam-shut UPSO setpoint. These factors include the distance of pipe to the break, the diameter of the pipe, size of the break and the number of restrictions, such as valves, elbows and bends, downstream of the regulator and/ or slam-shut device. Due to these factors additional protections should be installed to

stop ow in the event of a line break.

CS800 Series

Type CS800EN Regulator

M1086

January 2008

Type CS800EN

INLET PRESSURE OUTLET PRESSURE ATMOSPHERIC PRESSURE

Type CS800EN Regulator

M1086

January 2008

Type CS800EN

INLET PRESSURE OUTLET PRESSURE ATMOSPHERIC PRESSURE

M1070

INLET PRESSURE OUTLET PRESSURE ATMOSPHERIC PRESSURE

DISK

CONTROL SPRING

SEAT/ORIFICE

ADJUSTING SCREW

VALVE STEM

PUSHER POST ASSEMBLY

LEVER

RELIEF VALVE STEM

RELIEF VALVE SPRING

Figure 2. Type CS800IR Internally Registered Regulator with Internal Relief Operational Schematic

DIAPHRAGM

ADJUSTING SCREW

CONTROL SPRING

DISK

VALVE STEM

SEAT/ORIFICE

M1071

INLET PRESSURE OUTLET PRESSURE ATMOSPHERIC PRESSURE

Figure 3. Type CS800IQ Internally Registered Regulator with High Capacity Relief Operational Schematic

LEVER

RELIEF VALVE SPRING

PUSHER POST ASSEMBLY

RELIEF VALVE STEM

DIAPHRAGM

CS800 Series

If the slam-shut device trips due to a lever disconnect failure of the main regulator, it is recommended that you check downstream equipment for damage prior to re-setting the slam-shut.

Types CS805 and CS825 with Secondary Seat™ Protection

CAUTION

Types CS805 and CS825 regulators do not have any means to alert when the Secondary Seat operates at lockup. Therefore, it is recommended that Internal relief or high-capacity relief are also selected or the addition of some other method of overpressure protection be added in the downstream system as discussed in the Overpressure Protection section.

Refer to Figure 6. The CS805 Series provides Secondary Seat Protection. As downstream demand decreases and downstream pressure rises to the regulator pressure lock-up value, the regulator will lock up. If, however, damage has occurred to the primary disk or

orice’s seating surface (seat) or debris has become lodged

between the primary disk and seat, the outlet pressure will continue to rise. This additional pressure causes the disk to apply additional force to the primary seat, which causes the Secondary Seat to move toward the secondary disk/sealing

surface. If downstream demand decreases to zero, then the

Secondary Seat will contact the sealing surface to provide

lockup. Refer to Table 7 for approximate lock-up values

provided by the Secondary Seat.

Types CS806 and CS826 Secondary Seat Protection with Bleed

When the Secondary Seat is providing lockup, the CS806 Series provides small bleed to the downstream system as an indication that the Secondary Seat is providing lockup. In the event that the primary seat and disk cannot provide lockup, the Secondary Seat will move into contact with a metal disk with a small drilled hole. This metal-tometal interface and bleed hole will allow a small amount of gas to bleed downstream thereby increasing outlet pressure until the Internal relief valve begins to discharge gas to the atmosphere. The odor of this discharged gas provides an indication that the regulator is relying on the Secondary Seat for overpressure protection. See Table 7 for the Downstream Pressure Buildup of the Internal relief acting in conjunction with the Type CS806 Secondary Seat Assembly.

Secondary Seat Protection Limitations

CAUTION

Overpresssure conditions can occur in the downstream piping when the Secondary Seat Protection is installed. The Secondary Seat

Protection serves only as a backup to the primary seat for lockup. Refer to the sections on Overpressure Protection and Maintenance.

Secondary Seat Protection does not provide additional overpressure protection in the event the secondary seat or disk is damaged by debris or contamination in the pipeline or from conditions that would cause the regulator to go wide-open.

Installation and Overpressure Protection

WARNING

Personal injury or system damage may result if this regulator is installed, without appropriate overpressure protection, where service conditions could exceed the limits given on the regulator nameplate.

Regulator installations should be adequately protected from physical damage.

All vents should be kept open to permit

free ow of gas to the atmosphere. Protect

openings against entrance of rain, snow, insects or any other foreign material that may plug the vent or vent line. For outdoor installations, point the spring case vent downward to allow condensate to drain (see Figure 8). This minimizes the possibility of freezing and of water or other foreign materials entering the vent and interfering with proper operation.

Under enclosed conditions or indoors, escaping gas may accumulate and be an explosion hazard. In these cases, the vent should be piped away from the regulator to the outdoors. See Vent Line Installation section for the recommended venting practices.

CAUTION

The CS800 Series regulators have an outlet pressure rating lower than their inlet pressure rating. If actual inlet pressure can exceed the outlet pressure rating, outlet overpressure protection is necessary. However, overpressuring any portion of the regulators beyond the limits in the

Specications section and referenced tables

may cause leakage, damage to regulator parts or personal injury due to bursting of pressure-containing parts.

Some type of external overpressure protection should be provided if inlet pressure will be high enough to damage downstream equipment. Common methods of external overpressure protection include relief valves, monitoring regulators, shut-off devices and series regulation.

CS800 Series

Type CS800EN Regulator

M1086

January 2008

Type CS800EN

INLET PRESSURE OUTLET PRESSURE ATMOSPHERIC PRESSURE

Type CS800EN Regulator

M1086

January 2008

Type CS800EN

INLET PRESSURE OUTLET PRESSURE ATMOSPHERIC PRESSURE

INTEGRAL MONITOR MODULE

M1074

INLET PRESSURE OUTLET PRESSURE ATMOSPHERIC PRESSURE

ADJUSTING SCREW

CONTROL SPRING

VALVE STEM

PUSHER POST ASSEMBLY

LEVER

SEAT/ORIFICE

RELIEF VALVE SPRING

DIAPHRAGM

Figure 4. Type CS803IT Internally Registered Primary Regulator with Internally Registered Integral Monitor Operational Schematic

UPSO SPRING

OPSO SPRING

DIAPHRAGM

SLAM SHUT DEVICE

M1075

INLET PRESSURE OUTLET PRESSURE ATMOSPHERIC PRESSURE

CONTROL LINE PORT

VALVE PLUG

ADJUSTING SCREW

CONTROL SPRING

SENSE TUBE

VALVE STEM

SEAT/ORIFICE

LEVER

RELIEF VALVE SPRING

PUSHER POST ASSEMBLY

DIAPHRAGM

Figure 5. Type CS804IT Internally Registered Regulator with Slam-Shut Module Operational Schematic

CS800 Series

If the regulator is exposed to an overpressure condition, it should be inspected for any damage that may have occurred. Regulator operation below these limits does not preclude the possibility of damage from external sources or from debris in the pipeline.

General Installation Instructions

Before installing the regulator,

• Check for damage, which might have occurred

during shipment.

• Check for and remove any dirt or foreign material,

which may have accumulated in the regulator body.

• Blow out any debris, dirt or copper sulfate in copper

tubing and the pipeline.

• Apply pipe compound to the external threads of the pipe

before installing the regulator.

Note

Applying pipe compound to internal threads can result in excess pipe compound collecting in the body of the regulator and potentially clog registration ports, affect

lockup or downstream equipment.

• Make sure gas ow through the regulator is in the same

direction as the arrow on the body. “Inlet” and “Outlet” connections are clearly marked.

• When designing a pressure reducing station using

a CS800 Series regulator, make an analysis if it is necessary to take into account the effects of wind, snow and temperature to avoid unnecessary load and

movement to the anges of the equipment.

• If needed, a support may be used under the piping and

regulator/slam-shut body to avoid excessive pressure

force on the regulator/slam shut.

Note

For Types CS805, CS825, CS806 and CS826 equipped with the white-colored disk, ensure that the open end of disk is oriented toward the downstream as indicated in Figure 7. If the body direction relative to the actuator is changed during installation, the orientation of the white disk must also be removed, turned and reinstalled to ensure the open

end faces downstream.

Installation Location

• The installed regulator should be adequately protected from

vehicular trafc and damage from other external sources.

• Install the regulator with the vent pointed vertically

down, see Figure 8. If the vent cannot be installed in

a vertically down position, the regulator must be installed under a separate protective cover. Installing the regulator

with the vent down allows condensation to drain, minimizes

the entry of water or other debris from entering the vent and

minimizes vent blockage from freezing precipitation.

• Do not install the regulator in a location where there

can be excessive water accumulation or ice formation, such as directly beneath a downspout, gutter or roof line of building. Even a protective hood may not provide adequate protection in these instances.

• Install the regulator so that any gas discharge through the vent or vent assembly is over 3 ft / 0.91 m away from any building opening.

Regulators Subjected to Heavy Snow Conditions

Some installations, such as in areas with heavy snowfall, may require a hood or enclosure to protect the regulator from

snow load and vent freeze over.

Downstream Control Line Installation

A CS800 Series regulator with an EN or ET in the type number has a blocked throat, an O-ring stem seal and a 3/4 NPT control line tapping in the lower diaphragm casing. A regulator with a downstream control line is used for monitoring installations or other applications where there is other equipment installed between the regulator and the pressure control point.

For types with an EN or ET in the type number, connect downstream control line tubing to the lower casing and run

the tubing a distance of approximately 6 times the outlet

piping diameter as shown in Figures 9, 10 and 11. For best results, the outer diameter of the control line tubing should be 3/8 in. / 9.5 mm or larger.

Downstream Control Line Installation with Integral True-Monitor™

Refer to Figure 10. When installing the Types CS803ET and CS803EN regulators, connect downstream control line tubing to the lower casing of the Primary Regulator and run the tubing

a distance of approximately 6 times the outlet piping diameter

downstream of the regulator outlet. Connect a second, separate downstream control line tubing to the lower casing of the Integral

Monitor and run the tubing a distance of approximately 6 times

the outlet piping diameter downstream of the Integral Monitor outlet. For best results, the outer diameter of the control line tubing for both the Primary Regulator and the Integral Monitor should be 3/8 in. / 9.5 mm or larger.

Installation with External Overpressure Protection

If the regulator is used in conjunction with a Type 289H relief valve, it should be installed as shown in Figure 8. The outside end of the vent line should be protected with a rainproof assembly. The Type 289H should be set 10 in. w.c. / 25 mbar higher than the outlet pressure setting of the regulator, up to 30 in. w.c. / 75 mbar outlet pressure. For pressure greater than this, set the Type 289H 0.75 psi / 52 mbar higher

CS800 Series

CONTROL SPRING

RELIEF V LVE STEM

VALVE STEM

Type CS800EN Regulator

M1086

January 2008

Type CS800EN

INLET PRESSURE OUTLET PRESSURE ATMOSPHERIC PRESSURE

PRIMARY ORIFICE

PRIMARY DISK

NORMAL OPERATION NORMAL LOCKUP DEBRIS OBSTRUCTING

SECONDARY SEATING SURFACE

SEATING SURFACE

SECONDARY SEAT DETAILED VIEW

RELIEF VALVE STEM

RELIEF VALVE SPRING

VALVE STEM

LOCKUP

ELASTOMERIC SECONDARY SEATING SURFACE

SECONDARY SEAT

LOCKUP

METALLIC SECONDARY ORIFICE SEATING SURFACE

TYPE CS806

SECONDARY SEAT WITH

CONTROLLED BLEED

CONTROL SPRING

SECONDARY SEAT DETAIL

M1072

INLET PRESSURE OUTLET PRESSURE ATMOSPHERIC PRESSURE

Figure 6. Type CS805IR with Secondary Seat Protection

RELIEF SEAT

IF ACTUATOR ORIENTATION IS CHANGED, THE WHITE DISK MUST BE REMOVED, TURNED AND INSTALLED WITH THE DISK OPENING DOWNSTREAM

P1423 GG00886_F

DOWNSTREAM

102

Figure 7. White Disk Orientation for use with Secondary Seat™ Protection

CS800 Series

than the outlet pressure setting of the regulator. See the 289 Series Instruction Manual (D100280X012) for more information.

Vent Line Installation

The CS800 Series regulators have a 1 or 2-1/2 NPT screened vent opening in the spring case. If necessary to vent escaping gas away from the regulator, install a remote vent line in the spring case tapping. Vent piping should be as short and direct as possible with a minimum number of bends and elbows. The remote vent line should have the largest practical diameter. Vent piping on regulators with internal relief must be large enough to

vent all relief valve discharge to atmosphere without excessive backpressure and resulting excessive pressure in the regulator. Ensure piping is properly supported to avoid excessive stress on

the regulator spring case.

The CS800 Series offers optional Token Relief that provides low-capacity relief which is located in the spring case of the Primary Regulator. If necessary to vent escaping gas away, install a remote vent line in the spring case tapping of the Primary Regulator as described above.

Periodically check all vent openings to be sure that they are not plugged.

CS800 Series outlet pressure ranges are shown in Table 5. Outlet pressure greater than 3 psi / 0.21 bar above setpoint may damage internal parts such as the diaphragm head and valve disk. The maximum emergency (casing) outlet

pressure is 15 psig / 1.0 bar.

Startup

CAUTION

Pressure gauges should always be used to monitor downstream pressure during Startup.

With the downstream system depressurized, perform the

following procedure to startup the regulator.

1. Check to see that all appliances are turned off.

2. Slowly open the upstream shut-off valve.

3. Check inlet and outlet pressure for correct values.

4. Check all connections for leaks.

5. Turn on utilization equipment and recheck the pressures.

Adjustment

Note

The range of allowable pressure setting is stamped on the nameplate. If the required setting is not within this range, substitute the correct spring (as shown in Table 5). If the spring is changed, change the nameplate to indicate the new pressure range.

Because of the weight of internal regulator parts, the Red spring, 3.5 to 6 in. w.c. / 9 to 15 mbar spring range (nominal 4 in. w.c. / 10 mbar setting) gives the best pressure control when the regulator spring barrel is pointed down. Spring barrel down orientation may require that vent piping or vent adaptors are installed to keep the vent pointed down.

For types that include the Integral Monitor module, refer to the Instruction Manual for Type TM600 Integral Monitor, document D103126X012, for Adjustment and Maintenance of the Integral Monitor. For types that include the Slam-shut module, refer to the Instruction Manual for Type VSX8 Slam-shut, document D103127X012, for Adjustment and Maintenance of the Slam-shut.

A pressure gauge should always be used to monitor downstream pressure while adjustments are being made.

1. Remove the closing cap (key 60, Figure 12).

WARNING

During setpoint adjustment, do not mistake the Token Relief Spring Nut (key 46) for the main spring adjusting screw. Turning the Token Relief Spring Nut will change the token relief setting and if rotated counterclockwise could result in gas discharge and possible personal injury.

2. To increase the outlet setting, turn the adjusting screw

(key 65, Figure 12) clockwise. To decrease the outlet setting, turn the adjusting screw counterclockwise.

3. Replace the closing cap or tighten the hex locknut.

Types CS803 and CS823 with Integral True-Monitor™ Module

When adjusting the primary regulator and integral True-Monitor for operation, ensure that the pressure differences between the primary regulator and the integral True-Monitor shown in Tables 8 and 9 are observed. For example, if the primary regulator setpoint is set at 7 in. w.c. / 17 mbar, then the integral monitor should be set at a minimum of 14 in. w.c. / 35 mbar or higher.

To test the integral monitor operation, the primary regulator

setpoint must be adjusted above the integral monitor’s

setpoint to simulate a failure of the primary regulator. If the

spring range of the primary regulator is sufciently high, it can simply be adjusted above the integral monitor’s setpoint

by following step 2 above. Otherwise, a different spring with

a setpoint higher than the integral monitor’s setpoint must

be installed to check the operation of the integral monitor. An alternative to using a higher set spring on the primary regulator is to attach a hand pump and gauge to the primary

regulator vent to pressure load it until its setpoint exceeds

that of the integral True-Monitor.

INLET PRESSURE OUTLET PRESSURE

CS800 SERIES

REGULATOR

PROTECT VENT PIPE

WITH RAIN CAP

CS800 Series

2 NPT TYPE 289H

RELIEF VALVE

GE00886

REGULATOR VENT

POINTED DOWNWARD

Figure 8. CS800 Series Regulator Installed with the Vent Pointed Downward and with a Type 289H Relief Valve for High Capacity Relief

WIDE-OPEN MONITORING REGULATOR PRIMARY WORKING REGULATOR

INLET PRESSURE

OUTLET PRESSURE

UPSTREAM

BLOCK VALVE

Figure 9. CS800 Series Wide-open Monitor Control Line Installation

DOWNSTREAM

BLOCK VALVE

CS800 Series

CAUTION

When applying pressure to the regulator spring case through the vent, care must be taken not to exceed 3 psig / 0.21 bar, which is the maximum differential across the diaphragm.

Types CS804, CS824 and CS854 with Slam-shut Module

When adjusting the Primary Regulator and Slam-shut for operation, reference Tables 10 and 11 and the footnotes in

each table for the OPSO and OPSO/UPSO setpoints of the

slam-shut for the given regulator spring ranges.

CAUTION

Equipment installed downstream the Type VSX8 slam shut device can be damaged if the following procedure for resetting the Type VSX8 slam shut device is not followed. This equipment includes the integral

Type VSX8 or regulator congurations.

1. To properly reset the Type VSX8 Slam-shut after it has

been tripped to the closed position, insert a at-head

screwdriver into the position shown in Figure 8 on the backside of the reset button (refer to Type VSX8 Instruction Manual, key 30, Figure 8).

2. Slowly rotate the screwdriver to gradually pull the reset button (refer to Type VSX8 Instruction Manual, key 30) away from the Type VSX8 device. This slow movement allows for a slow bleed of the pressure across the

Type VSX8 Slam-shut’s disk and seat area. The operator

should be able to hear the pressure bleeding through the system.

3. When the pressure has equalized and the air bleeding sound has dissipated, completely pull the reset button (refer to Type VSX8 Instruction Manual, key 30) away from the Type VSX8 Slam-shut device by hand until the internal shut-off mechanism has been re-latched.

4. Once the operator feels the click of the re-latch occurring, completely push the reset button (refer to Type VSX8 Instruction Manual, key 30) back into its original position.

Shutdown

Installation arrangements may vary, but in any installation it is important that the valves be opened or closed slowly and that the outlet pressure be vented before venting inlet pressure to prevent damage caused by reverse

pressurization of the regulator. The steps below apply to the

typical installation as indicated.

1. Open valves downstream of the regulator.

2. Slowly close the upstream shut-off valve.

3. Inlet pressure should be released automatically downstream as the regulator opens in response to the lowered pressure on the diaphragm.

4. Close outlet shut-off valve.

Maintenance and Inspection

WARNING

To avoid personal injury or equipment damage, do not attempt any maintenance

or disassembly without rst isolating

the regulator from system pressure and relieving all internal pressure as described in “Shutdown” section.

Test the regulator that has been disassembled for repair to ensure that it is operating properly before being returned to service. Only parts manufactured by Emerson™ should be used for repairing Fisher® regulators. Restart gas utilization equipment according to normal Startup procedures.

Due to normal wear or damage that may occur from external sources, inspect and maintain this regulator periodically. The frequency of inspection and replacement of parts depends upon the severity of service conditions or the requirement of local, state and federal rules and regulations.

Perform periodic inspection on Wide-Open Monitor regulators, Integral True-Monitor™ or Slam-shut overpressure protection modules to ensure protection of the downstream system in the event of a failure to the primary regulator. This inspection must test that the wide open monitor, Integral True-Monitor or Slam-shut functions as intended.

Maintenance on CS800 Series with Secondary Seat™ Protection

Types CS805 and CS825 regulators do not have any means to alert when the Secondary Seat operates at lockup. A lock-up test can be done on the regulator to determine if the lock-up pressure has elevated to or near the values in Table 7, under the heading Types CS805 and CS825. If so, replace the regulator

primary disk and orice.

Internal relief operation on units equipped with Secondary Seat Protection is an indication that the Secondary Seat Protection on the Types CS805IR and CS805IQ may not be working and that the Types CS806IR and CS806IQ Secondary Seat may have closed. Maintenance should address any potential causes for internal relief operation as well as other regulator malfunctions separate from the Secondary Seat.

CS800 Series

Type CS800EN Regulator

M1086

January 2008

Type CS800EN

INLET PRESSURE OUTLET PRESSURE ATMOSPHERIC PRESSURE

Type CS800EN Regulator

M1086

January 2008

Type CS800EN

INLET PRESSURE OUTLET PRESSURE ATMOSPHERIC PRESSURE

M1209

INLET PRESSURE OUTLET PRESSURE ATMOSPHERIC PRESSURE

Figure 10. Externally Registered Types CS803 and CS823 Regulator and Integral True-Monitor™

Downstream Control Line Installation

INLET PRESSURE OUTLET PRESSURE ATMOSPHERIC PRESSURE

Figure 11. Externally Registered Types CS804, CS824 and CS854 Regulator and Slam-Shut

Downstream Control Line Installation

CS800 Series

Maintenance on CS800 Series

Disassembly to Replace Diaphragm (See Figures 12, 13 and 15)

1. See Figure 15. All Types except Type CS850, remove

the closing cap (key 60). Turn the adjusting screw (key 65) counterclockwise to ease spring compression. Remove adjusting screw and spring (key 38).

2. See Figure 15. Type CS850, loosen hex locknut

(key 107). Turn adjusting screw (key 65)

counterclockwise to ease spring compression. Unscrew

bonnet (key 104) and remove. Remove spring (key 38).

3. See Figure 12. Remove the nuts (key 16) and hex bolts

(key 15). Separate the upper spring case (key 1) from the lower casing (key 9).

Note

When disassembling a CS800 Series regulator, lift the upper spring case straight up in order to avoid hitting the stem (key 11).

4. See Figure 12. Slide the diaphragm head assembly

(key 55) away from the body (key 70) to unhook the pusher post (key 50) from the lever (key 10). Lift off the diaphragm head assembly.

5. See Figure 13. Non-Relieving units, unscrew the bolt

(key 45). The bolt threads in to the pusher post (key 50) and holds the non-relieving diaphragm assembly together.

Unscrewing the bolt will separate the diaphragm retainer

(key 47), the lower spring seat (key 43) and diaphragm assembly (key 55) and pusher post (key 50).

6. Reassemble in the reverse order of step ve. For the Token Relief Assembly, ensure the distance from the top of the diaphragm stem (key 44, Figure 13) to the top

of the token relief hex nut (key 46) is the same as before

disassembly. When assembling the diaphragm (key 55A) onto the diaphragm head (key 55B), apply a small amount

of adhesive on the outer at portion of the diaphragm head

that contacts the diaphragm, as indicated in Figure 13. Place the diaphragm head on the diaphragm and check to ensure the hole in the diaphragm head with the hole of the diaphragm are concentrically aligned.

7. Place the diaphragm assembly into position in the lower casing; make sure that the pusher post is hooked on the lever.

Note

See Figure 12. To ease in the process of inserting the diaphragm assembly into the lower case (key 9) and hooking it onto the lever (key 10), loosen the four body bolts (key 71). This will allow the lever to be rotated upward in order to slide the diaphragm assembly (key 55) onto the lever.

8. After the diaphragm assembly is hooked to the lever, rotate the diaphragm so that the diaphragm and lower casing holes are aligned.

9. Reassemble the remaining parts by following steps 1 to 3 in reverse order.

Note

See Figure 12, always tighten bolts in a cross pattern.

CAUTION

Use caution when unscrewing the relief valve stem as the relief valve spring is in compression.

See Figure 13. Internally Relieving units, unscrew the

relief valve stem (key 44). The relief valve stem threads into the pusher post (key 50) and holds the relieve assembly

together. Unscrewing the relief valve stem will separate the

E-Ring (key 48), the spring retainer (key 42), the relief spring (key 41), the lower spring seat (key 43) and the diaphragm assembly (key 55) onto the pusher post (key 50).

See Figure 13. Token Relieving units, measure and

note for reassembly, the distance between the top of the diaphragm stem (key 44) and the top of the token relief

hex nut (key 46). Unscrew token relief nut with a 13 mm

wrench. Remove the spring seat (key 42) and relief spring

(key 41). Unthread the second lower nut (key 46). Pull the

pusher post assembly (key 50) through the diaphragm assembly. Replace the pusher post O-ring (key 52) and

diaphragm stem O-ring (key 115). Unscrew the pusher

post nut (key 110), which allows for separation of the lower spring seat (key 43), diaphragm assembly (key 55) and the pusher post retainer (key 111).

Disassembly to Replace Valve Stem O-ring (For externally registered Types only, e.g., Type CS800EN) (See Figures 12, 14 and 15)

1. See Figure 12. Remove the four body bolts (key 71) and remove the body (key 70).

2. Check the body O-ring (key 19) for wear and replace as necessary.

3. See Figure 15.

a. All types except Type CS850, remove the closing

cap (key 60). Turn the adjusting screw (key 65) counterclockwise to ease spring compression. Remove adjusting screw and spring (key 38).

b. Type CS850, loosen hex locknut (key 107). Turn

adjusting screw (key 65) counterclockwise to ease

spring compression. Unscrew bonnet (key 104) and

remove. Remove spring (key 38).

4. See Figure 12. Remove the nuts (key 16) and hex bolts (key 15). Separate the upper spring case (key 1) from the lower casing (key 9).

CS800 Series

Note

When disassembling a CS800 Series regulator, lift the upper spring case straight up in order to avoid hitting the stem (key 11).

5. Slide the diaphragm head assembly (key 55) away from the body (key 70) to unhook the pusher post (key 50) from the lever (key 10). Lift off the diaphragm head assembly.

6. Remove the two lever retaining screws (key 14). Lift lever up slightly and then slide in the direction away from the body. Once the lever pin (key 13) has cleared the lower actuator the lever can be lowered and at the same time rotated upward to allow it to be removed from the slotted stem (key 11).

7. See Figure 14. Remove the disk retainer clip (key 36B) and then remove the disk assembly (key 36). Remove the stem (key 11) by sliding it in the direction away from the body.

8. Replace stem O-ring (key 12) making certain to apply lubricant.

9. Reassemble in the reverse order.

Note

When placing the diaphragm assembly into position in the lower casing, make sure that the pusher post is hooked on the lever. After the diaphragm assembly is hooked to the lever, rotate the diaphragm so that the diaphragm and lower casing holes are aligned.

See Figure 12, always tighten bolts in a cross pattern.

10. Reassemble the remaining parts by following steps 1 to 3 in reverse order.

Disassembly to Replace Valve Disk and

Orice (See Figure 12 and 17)

1. Remove the four hex bolts (key 71) which hold the lower spring case (key 9) to the body (key 70). Separate the lower spring casing from the body.

2. Check the body O-ring (key 19) for wear and replace as necessary.

Note

There are multiple disk assemblies based

on construction and these are identied by

color. See Tables 13, 14 and 15 for direction in selecting appropriate disk color. Product performance will be changed if the incorrect disk assembly is used.

3. Examine the disk assembly (key 36) for nicks, cuts and other damage. To replace, remove the disk retainer clip (key 36B) and slide the disk assembly off of the stem (key 11).

4. See Figure 17.

a. If the seating edge of the CS800 Series orice (key 25)

is nicked or rough, remove the orice from the body

using a 2 in. / 50 mm socket wrench.

b. If equipped with a CS805/CS806 Series

Secondary Seat orice assembly, see the following

section “Disassembly to Replace Valve Disk

and Secondary Seat orice assembly” for

maintenance instructions.

Note

If the orice is replaced with a different size,

change the nameplate to state the new size and maximum inlet pressure (see Table 4).

5. Replace O-ring (key 82). Apply anti-seize lubricant to the external threads of the new orice/orice assembly and reassemble into the body. Install the orice per Figure 17 and tighten the orice or orice subassembly

into the body per Figure 12.

6. Reassemble the regulator in reverse order of the above steps. O-ring (key 28, Figure 12) on end of stem (key 11) should be lubricated before replacing the disk assembly. This O-ring is not a pressure retaining part but keeps the disk holder from rattling on the stem.

Note

See Figure 12, always tighten bolts in a cross pattern.

Disassembly to Replace Valve Disk and Secondary Seat™ Orice Assembly (See Figure 12)

1. Remove the four hex bolts (key 71) which hold the lower spring case (key 9) to the body (key 70). Separate the lower spring casing from the body.

2. Check the body O-ring (key 19) for wear and replace as necessary.

Note

There are multiple disk assemblies based on

construction and these are identied by color.

See Tables 13, 14 and 15 for direction in selecting appropriate disk color. Product performance will be changed if the incorrect disk assembly is used.

If the White disk is selected, the open side of the disk must be directed toward the outlet of the body as indicated in Figure 7.

3. Examine the disk assembly (key 36) for nicks, cuts and other damage. To replace, remove the disk retainer clip (key 36B) and slide the disk assembly off of the stem (key 11).

4. See Figure 18. Remove the orice assembly from the body using a 2 in. / 50 mm socket wrench.

CS800 Series

Table 12. Adjustment Tools

KEY NUMBER PART DESCRIPTION ADJUSTMENT TOOL

15 Hex Bolt 1/2 in. / 13 mm Socket

16 Nut 1/2 in. / 13 mm Socket

25 Orice/Seat 2 in. / 50 mm Socket

44 Relief Valve Stem 9 mm Socket or Adjustable End Wrench

45 Bolt, Diaphragm Assembly 1/2 in. / 13 mm Socket

60 Closing Cap 2 in. / 50 mm Socket

7/8 in. Hex/Allen Wrench

Adjusting Screw, up to 2.5 psig / 0.17 bar spring range

Adjusting Screw, 2 to 5.5 psig / 0.17 to 0.38 bar spring range 1/2 in. / 13 mm Socket Driver Extension

Adjusting Screw, above 5 psig / 0.35 bar spring range 15/16 in. / 24 mm or Adjustable End Wrench

71 Body Bolt 1/2 in. / 13 mm Socket

72 1/4 NPT Pipe Plug 1/4 in. Hex/Allen Wrench

1. Use of Adjustment tool is optional.

2 in. / 50 mm Socket

1/2 in. / 13 mm Socket

Large Flat head Screw Driver

Inspect the primary seating surface as well as the

secondary seating surface and sealing surface. If nicks or other damage are present, start to disassemble the Secondary Seat™ assembly by removing the internal

retaining ring (key 25D) with retaining ring pliers. Use

care when removing the internal retaining ring as the

spring (key 25F) is compressed and will exert force on

the Secondary Seat disk (key 25C).

5. Remove the Secondary Seat disk (key 25C), spring

(key 25F) and double sided orice (key 25B). Finally, remove the orice O-ring (key 25E). Lubricate O-ring with extreme low temperature bearing grease or similar lubricant

that maintains its lubrication properties at cold temperatures

and replace O-ring. Insert the new double-sided orice

(key 25B), then the spring (key 25F), ensuring that the larger

diameter opening is contacting the shelf of the orice.

6. Replace the Secondary Seat disk (key 25C). See Figure 18.

a. For Types CS805 and CS825 ensure that the

rubber/Nitrile (NBR) sealing surface is facing the

Secondary Seating surface of the orice.

b. For Types CS806 and CS826, ensure that the hole in

the center of the disk that acts as the spring seat is facing the spring.

7. Press the disk inside the housing (key 25A) to allow the internal retaining ring to be reinserted.

Note

If the orice is replaced with a different size,

change the nameplate to state the new size and maximum inlet pressure (see Table 4).

8. Replace O-ring (key 82). Apply anti-seize lubricant to the external threads of the new orice/orice assembly and reassemble into the body. Install and tighten the orice

per Figure 12.

9. Reassemble the regulator in reverse order of the above steps. O-ring (key 28) on end of stem (key 11) should be lubricated before replacing the disk assembly. The O-ring is not a pressure retaining part but keeps the disk holder from rattling on the stem.

Note

See Figure 12, always tighten bolts in a cross pattern.

Regulator Reassembly

It is recommended that a good quality pipe thread sealant

be applied to pressure connections and ttings and a good

quality lubricant be applied to all O-rings. Also apply an

anti-seize compound to the adjusting screw threads and

other areas as needed. Reference Figures 12 through 18 to determine the recommended lubricant/sealant/adhesive for these parts. All lubricants/sealants/adhesives must be selected such that they meet the temperature requirements.

When reassembling, torque bolts and fasteners per torque values are indicated on Figures 12 through 18. Some

relaxation from initial torque values may occur. Always

tighten bolts in a cross pattern.

Parts Ordering

The type number, orice size, spring range and date

of manufacture are stamped on the nameplate. Always provide this information in any correspondence with

your local Sales Ofce regarding replacement parts or

technical assistance.

When ordering replacement parts, reference the key number and the 11-digit Part Number of each needed part as found in the following parts list. Separate repair part kits containing all recommended elastomer spare parts are available.

CS800 Series

Table 13. CS800 Series Disk Color Selection

PRESSURE

REGISTRATION

TYPE

BODY SIZE SPRING RANGE

In. DN In. w.c. mbar

1-1/4

and

and 403.5 to 30 9 to 75 All Materials All Connections Black GE29773X022 RCS800XBLK2

1-1/2

3.5 to 6 9 to 15 All Materials All Connections Green GE29773X042 RCS800XGRN2

Internal

CS800

2 50

5.5 to 8.5

and 8 to 12

10 to 16 and

14 to 30

CS820

and

All Sizes 1 to 10 psig 69 to 690 All Materials All Connections Black GE29773X022 RCS800XBLK2

CS850

External All All Sizes All All Materials All Connections Black GE29773X022 RCS800XBLK2

1. The 3.5 to 30 in. w.c. / 9 to 75 mbar spring range indicates that all of the springs within this range are applicable.

2. Repair kit includes O-ring (key 19), disk assembly (key 36) and O-ring (key 62).

Table 14. CS803 and CS804 Series Disk Color Selection

PRESSURE

REGISTRATION

TYPE

CS803

and

CS804

Internal

CS823, CS824

and

CS854

External All All Sizes All All Materials All Connections Black GE29773X022 RCS800XBLK2

1. The 3.5 to 30 in. w.c. / 9 to 75 mbar spring range indicates that all of the springs within this range are applicable.

2. Repair kit includes O-ring (key 19), disk assembly (key 36) and O-ring (key 62).

BODY SIZE SPRING RANGE

In. DN In. w.c. mbar

1-1/2 40 3.5 to 30 9 to 75 All Materials All Connections Black GE29773X022 RCS800XBLK2

3.5 to 6 9 to 15 All Materials All Connections Green GE29773X042 RCS800XGRN2

5.5 to 8.5

2 50

and 8 to 12

10 to 16 and

14 to 30

All Sizes 1 to 10 psig 69 to 690 All Materials All Connections Black GE29773X022 RCS800XBLK2

(1)

13 to 21 and

20 to 30

25 to 40 and

35 to 75

(1)

13 to 21 and

20 to 30

25 to 40 and

35 to 75

BODY

MATERIAL

Gray Cast

Iron

Ductile Iron or

WCC Steel

END

CONNECTION

DISK

COLOR

All Connections Blue GE29773X032 RCS800XBLU2

Flanged Blue GE29773X032 RCS800XBLU2

Threaded Dark Gray GE29773X082 RCS800XGRY2

DISK

ASSEMBLY

PART NUMBER

REPAIR KIT

All Materials All Connections Green GE29773X042 RCS800XGRN2

BODY

MATERIAL

Ductile Iron or

WCC Steel

Gray Cast

Iron

END

CONNECTION

DISK

COLOR

Flanged Blue GE29773X032 RCS800XBLU2

Threaded Dark Gray GE29773X082 RCS800XGRY2

All Connections Blue GE29773X032 RCS800XBLU2

DISK

ASSEMBLY

PART NUMBER

REPAIR KIT

All Materials All Connections Green GE29773X042 RCS800XGRN2

(2)

Table 15. CS805 and CS806 Series Disk Color Selection

PRESSURE

REGISTRATION

TYPE

BODY SIZE SPRING RANGE

In. DN In. w.c. mbar

1-1/4 32

CS805

Internal

and

CS806

1-1/2 40

2 50

3.5 to 30 9 to 75

CS825

and

All Sizes 1 to 5.5 psig 70 to 380

CS826

External All All Sizes All All Materials All Connections Black GE29773X022 RCS800XBLK2

1. The 3.5 to 30 in. w.c. / 9 to 75 mbar spring range indicates that all of the springs within this range are applicable.

2. White/White Dot disk requires the open end to be directed downstream with the direction of ow.

3. Repair kit includes O-ring (key 19), disk assembly (key 36) and O-ring (key 62).

(1)

BODY

MATERIAL

Gray Cast

Iron

Gray Cast

Iron

END

CONNECTION

All Connections

DISK

COLOR

Yellow/

White Dot

Green/

White Dot

White/

White Dot

Yellow/

White Dot

DISK

ASSEMBLY

REPAIR KIT

PART NUMBER

GE29773X062 RCS800XYEL2

GE29773X092 RCS800XGR22

GE29773X052 RCS800XWHT2

(2)

GE29773X062 RCS800XYEL2

(3)

CS800 Series

Parts List

Key Description Part Number

Regulator Repair Kit Disk Assembly Repair Kit [Disk Assembly Repair Parts kit includes O-ring (key 19), disk assembly (key 36) and O-ring (key 62). See Table 13, 14 and 15 Orice Repair Kit [Orice Repair Parts kit includes keys 25 (Orice) and 82 (O-ring).]

1/4 in. / 6.4 mm orice size GE31286X012

3/8 in. / 9.5 mm orice size GE31287X012 1/2 in. / 13 mm orice size GE31288X012 5/8 in. / 16 mm orice size GE31289X012 3/4 in. / 19 mm orice size GE31290X012 7/8 in. / 22 mm orice size GE31291X012 1 in. / 25 mm orice size GE31292X012 1-3/8 in. / 35 mm orice size GE31294X012 True-Monitor™ Repair Kit [When ordering repair kits for Types CS803 and CS823, it is necessary to order both a Primary Regulator Repair Kit found on Tables 13, 14 and 15 and a True Monitor Repair Kit. See the Type TM600 Instruction Manual for details on which parts are included.] RTM600X0012

Secondary Seat™ Repair Kit [Disk or Backplate Repair Parts kit includes disk or backplate (key 25C), O-ring (key 25E) and

O-ring (key 82). Orice Assembly Repair Parts kit includes orice assembly (key 25) and

O-ring (key 82).]

Types CS805 and CS825 Secondary Seat

without Bleed

Disk or Backplate Repair Parts Kit For use with 3/8 and 1/2 in. /

9.5 and 13 mm orice sizes RCS805X0022

For use with 5/8, 3/4 and 7/8 in. /

16, 19 and 22 mm orice sizes RCS805X0032 Orice Assembly Repair Parts Kit

3/8 1/2 in. / 13 mm orice size RCS805RFC12 5/8 in. / 16 mm orice size RCS805RFC58 3/4 in. / 19 mm orice size RCS805RFC34 7/8 in. / 22 mm orice size RCS805RFC78 Types CS806 and CS826 Secondary Seat with Bleed Disk or Backplate Repair Parts Kit For use with 3/8 and 1/2 in. /

9.5 and 13 mm orice sizes RCS806X0022 For use with 5/8, 3/4 and 7/8 in. /

16, 19 and 22 mm orice sizes RCS806X0032 Orice Assembly Repair Parts Kit

3/8 in. / 9.5 mm orice size RCS806RFC38 1/2 in. / 13 mm orice size RCS806RFC12 5/8 in. / 16 mm orice size RCS806RFC58 3/4 7/8 in. / 22 mm orice size RCS806RFC78

Slam shut Repair Kit See Type VSX8 Instruction Manual D103127X012

in. / 9.5 mm orice size RCS805RFC38

in. / 19 mm orice size RCS806RFC34

Key Description Part Number

1 Upper Spring Case, Aluminum 1 NPT vent size GE26101X012 2-1/2 NPT vent size GE26102X012

2 Vent Screen, Stainless steel

1 NPT vent size T1121338982 2-1/2 NPT vent size GE29700X012

3 Retaining Ring

1 NPT vent size, Zinc-plated steel T1120925072 2-1/2 NPT vent size, Stainless steel GE29714X012

4 Stabilizer Guide, Stainless steel 1 NPT vent size GE27061X012 2-1/2 NPT vent size GE27028X012

5 Stabilizer 1 NPT vent size GE46735X012 2-1/2 NPT vent size GE27034X012

6 Stabilizer Spring, Stainless steel 1 NPT vent size GE35010X012 2-1/2 NPT vent size GE29718X012

7 Stabilizer Retainer Ring, Steel/Nitrile (NBR) 1 NPT vent size GE46526X012 2-1/2 NPT vent size GE46547X012

8 Stabilizer screw (3 required), Zinc-plated steel GE29724X012

9 Lower Spring Case, Aluminum Internal Sensing GE26104X012

External Sensing GE46833X012

10 Lever, Steel GE27408X012

11 Stem, Stainless steel GE27021X012

12* O-ring, Nitrile (NBR) (external sensing only) GE29753X012

13 Lever Pin, Steel GE29701X012

14 Lever Pin Screw, Plated steel (2 required) GE30039X012

15 Hex head cap screw, Steel (12 required) GE29973X012

16 Nut, Steel (10 required) GE30042X012

17 Union Ring, Aluminum GE26416X012

18 Snap Ring, Music wire GE27018X012

19* O-ring, Nitrile (NBR) GE29755X012 25* Orice, Aluminum Standard (For congurations without Secondary Seat Assembly) 1/4 in. / 6.4 mm GE29702X012 3/8 in. / 9.5 mm GE29703X012 1/2 in. / 13 mm GE29704X012 5/8 in. / 16 mm GE29705X012 3/4 in. / 19 mm GE29706X012 7/8 in. / 22 mm GE29707X012 1 in. / 25 mm GE29708X012 1-3/8 in. / 35 mm GE29710X012

25* Orice Assembly, Brass/Nitrile (NBR) For congurations with Secondary Seat Assembly

For Types CS805 and CS825 without Bleed 3/8 in. / 9.5 mm GE29965X012 1/2 in. / 13 mm GE29968X012 5/8 in. / 16 mm GE29985X012 3/4 in. / 19 mm GE29986X012 7/8 in. / 22 mm GE29987X012 For Types CS806 and CS826 with Bleed 3/8 in. / 9.5 mm GE29970X012 1/2 in. / 13 mm GE29972X012 5/8 in. / 16 mm GE29989X012 3/4 in. / 19 mm GE29990X012 7/8 in. / 22 mm GE29991X012

*Recommended spare part

CS800 Series

Key Description Part NumberKey Description Part Number

25A Housing, Brass 3/8 in. / 9.5 mm GE29940X012 1/2 in. / 13 mm GE29940X012 5/8 in. / 16 mm GE29947X012 3/4 in. / 19 mm GE29947X012 7/8 in. / 22 mm GE29947X012

25B Orice, Brass

3/8 in. / 9.5 mm GE29941X012 1/2 in. / 13 mm GE29942X012 5/8 in. / 16 mm GE29948X012 3/4 in. / 19 mm GE29949X012 7/8 in. / 22 mm GE29950X012

25C* Disk Types CS805 and CS825 without bleed GE29943X012 Types CS806 and CS826 with bleed GE32017X012

25D Internal Ring, Zinc-plated steel GE29945X012

25E* O-ring, Nitrile (NBR) 3/8 in. / 9.5 mm GE29958X012 1/2 in. / 13 mm GE29958X012 5/8 in. / 16 mm GE29756X012 3/4 in. / 19 mm GE29756X012 7/8 in. / 22 mm GE29756X012

25F Spring, Music wire or Stainless steel 3/8 in. / 9.5 mm GE29944X012 1/2 in. / 13 mm GE29944X012 5/8 in. / 16 mm GE29951X012 3/4 in. / 19 mm GE29951X012 7/8 in. / 22 mm GE29951X012

26 Overpressure Protection Orice, Aluminum For congurations with True-Monitor™ GE30327X012 For congurations with Slam-shut GE32066X012

27 Overpressure Protection Orice O-ring, Nitrile (NBR) For congurations with True-Monitor or Slum-shut GE32723X012

28 O-ring, Nitrile (NBR) GE01439X012

36* Disk Assembly (See Tables 13, 14 and 15, Disk Color Selection) Black GE29773X022 Blue GE29773X032 Green GE29773X042 Dark Gray GE29773X082 Green/White Dot GE29773X092 White/White Dot GE29773X052 Yellow/White Dot GE29773X062

36B Retaining Disk Clip, Stainless steel GE33709X012

38 Spring See Table 5

41 Relief Valve Spring, Stainless steel Token Relief (Standard Flow) GE48120X012 Token Relief (Low Flow) GE48120X012 Standard Relief (High Capacity Relief) GE30347X012 Low Start-to-Discharge for Standard Relief (High Capacity Relief) GE48120X012

42 Upper Spring Retainer Token Relief (Low Flow), Zinc-plated steel GE46956X012 Token Relief (Standard Flow), Zinc-plated steel GE46956X012

Standard Relief (High Capacity Relief), Aluminum GE27059X012 Low Start-to-Discharge for Standard Relief (High Capacity Relief), Aluminum GE27059X012

43 Lower Spring Seat, Aluminum Non-relief GE27025X012 Token Relief (Standard Flow) GE27025X012 Token Relief (Low Flow) GE27025X012 Standard Relief (High Capacity Relief) GE26111X012 Low Start-to-Discharge for Standard Relief (High Capacity Relief) GE26111X012

44 Relief Valve Diaphragm Stem

Token Relief (Low Flow), Zinc-plated steel ERAA00767A0 Token Relief (Standard Flow), Zinc-plated steel ERAA00767A0

Standard Relief (High Capacity Relief) Aluminum GE27058X012 Low Start-to-Discharge for Standard Relief (High Capacity Relief), Aluminum GE27058X012

45 Hex Head Bolt, Steel Types CS800 and CS820 GE32061X012 Type CS850 GE29974X012

46 Token Relief Nut, Steel Token Relief (Low Flow) GE30042X012 Token Relief (Standard Flow) GE30042X012

47 Diaphragm Retainer, Aluminum Types CS800 and CS820 No Relief GE27027X012 Token Relief (Standard Flow) ERAA00916A0 Type CS850 GE47664X012

48 Retaining E-Ring, Copper Standard Relief (High Capacity Relief) GE33106X012 Low Start-to-Discharge for Standard Relief (High Capacity Relief) GE33106X012

50 Pusher Post No Relief, Aluminum GE44924X012 Token Relief (Standard Flow), Aluminum GE44947X012 Token Relief (Low Flow), Zinc-plated steel GE46958X012 Standard Relief (High Capacity Relief), Aluminum GE44947X012 Low Start-to-Discharge for Standard Relief (High Capacity Relief), Aluminum GE44947X012

52* Pusher Post O-ring, Nitrile (NBR) Token Relief (Low Flow) only GE47389X012

53 Pusher Post Pin, Stainless steel GE29761X012

54 Roller Pin, Brass GE27060X012

55 Diaphragm Assembly Types CS800 and CS820 GE29775X012 Type CS850 GE47296X012

55A* Diaphragm, Nitrile (NBR) GE29721X012

55B Diaphragm Head, Zinc-plated steel Types CS800 and CS820 GE27019X012 Type CS850 GE46996X012

56 Pusher Post Pin Retaining Ring, Steel GE33772X012

57 Spring Pin, Zinc-plated steel Token Relief (Low Flow) only GE33668X012

60 Closing Cap (Types CS800 and CS820 only), Aluminum Gray GE26109X012 Red GE26109X022

62* O-ring, Nitrile (NBR) GE29750X012

65 Adjusting Screw For Types CS800 and CS820, Aluminum Spring ranges up to 2.5 psig / 170 mbar GE26108X012 For Type CS820, Brass Spring ranges above 2.5 psig / 170 mbar GE47294X012

For Type CS850, Zinc-plated steel GE27026X012

*Recommended spare part

CS800 Series

TORQUE: 10 TO 13 FT-LBS / 14 TO 18 N•m

INSTALL TORQUE:

63 TO 90 IN-LBS /

7.1 TO 10 N•m MINIMUM RELAXATION TORQUE:

GG00886_F

PROPER TIGHTENING OF BOLTS IN CROSS PATTERN

APPLY LUBRICANT (L) / SEALANT (S) L1 = ANTI-SEIZE LUBRICANT S1 = THREAD SEALANT WITH PTFE

1. Lubricant and sealant must be selected such that they meet the temperature requirements.

(1)

45 IN-LBS / 5.1 N•m

PROPER TIGHTENING OF BOLTS IN CROSS PATTERN

Figure 12. CS800 Series Regulator Assemblies

Key Description Part Number Key Description Part Number

70 Body See Table 3

71 Bolt, Steel (4 required) GE29974X012

72 Pipe Plug Plated steel 1C333528992 Stainless steel 1C3335X0012

74 Blanking Plug, Aluminum For Ductile Iron and Steel Bodies, non-Overpressure Protection service only GE31255X012

75 O-ring, Nitrile (NBR) For Ductile Iron and Steel Bodies, non-Overpressure Protection service only GF03442X012

*Recommended spare part

76 Half Flange (2 required), Steel For Ductile Iron and Steel Bodies, non-Overpressure Protection service only GF01942X012

77 O-ring, Nitrile (NBR) For Ductile Iron and Steel Bodies, non-Overpressure Protection service only GF03443X012

80 Screw (4 required), Steel For Ductile Iron and Steel Bodies, non-Overpressure Protection service only GE38176X012 81 Spring Pin, Plated carbon steel For ductile iron and steel bodies not common to the Type CS804 GE32722X012

81 Sense Tube

For congurations with Slam Shut ERAA02440A0 For congurations with True-Monitor™ ERAA03562A0

NOTE DIRECTION OF RETAINER RING INSTALLATION

L1 L2

CS800 Series

81006265

GG00886_F

108 109

SECTION A - A

36A

36D

NOTE DIRECTION OF RETAINER RING INSTALLATION

36C

36B

108

109

NOTE DIRECTION OF VENT SPRING INSTALLATION

TORQUE: 15 TO 25 IN-LBS /

GG00886_F

APPLY LUBRICANT (L) L1 = ANTI-SEIZE LUBRICANT L2 = EXTREME LOW TEMPERATURE BEARING GREASE

1. Lubricants must be selected such that they meet the temperature requirements.

(1)

1.7 TO 2.8 N•m

Figure 12. CS800 Series Regulator Assemblies (continued)

2-1/2 NPT VENT ASSEMBLY

TORQUE: 15 TO 25 IN-LBS /

1.7 TO 2.8 N•m

CS800 Series

TYPE CS800/CS820 NON-RELIEF

55B

55A

TYPE CS800/CS820 NON-RELIEF

NOTE DIRECTION OF RETAINER RING INSTALLATION SEE DETAIL

55B

55A

55B

55A

RETAINER RING INSTALLATION

TYPE CS850 NON-RELIEF

TYPE CS800/CS820 NON-RELIEF

TORQUE: 50 TO 60 IN-LBS /

5.6 TO 6.8 N•m

NOTE DIRECTION OF RETAINER RING INSTALLATION SEE DETAIL

TORQUE: 50 TO 60 IN-LBS /

5.6 TO 6.8 N•m

TORQUE: 50 TO 60 IN-LBS /

5.6 TO 6.8 N•m

TYPE CS850 NON-RELIEF

55B

55A

55B

55A

NOTE DIRECTION OF RETAINER RING INSTALLATION

SEE DETAIL

NOTE DIRECTION OF

RETAINER RING INSTALLATION DETAIL

GG00886_F

APPLY ADHESIVE (A)

NOTE: APPLY ADHESIVE ON THE FLAT SURFACE OF THE DIAPHRAGM PLATE THAT CONTACTS THE DIAPHRAGM, TOWARD THE OUTER PERIMETER,

1. Adhesive must be selected such that it meets the temperature requirements.

AND AWAY FROM THE CENTER HOLE.

(1)

Figure 13. CS800 Series Diaphragm and Relief Assemblies

Key Description Part Number

82* O-ring, Nitrile (NBR) GE30397X012

90 Nameplate - - - - - - - - - - -

91 Warning Label - - - - - - - - - - -

93 PED / EN 334 Information Label - - - - - - - - - - -

100 Lockwire, Stainless steel T12315T0022

103 Thrust Washer, CS820 Series

2.5 psig to 5.5 psig / 170 to 380 mbar spring only GE47292X012

104 Bonnet, Zinc-plated steel Type CS850 only GE26812X012

105 Upper Spring Seat, Zinc-plated carbon steel Type CS850 only GE26809X012

106 Ball Bearing, Stainless steel Type CS850 only GE33131X012

Key Description Part Number

107 Locknut, Steel (Type CS850 only) GE49038X012

108 Stem Rivet, Stainless steel GE45994X012

109 Retaining Ring, Steel GE33772X012

110 Pusher Post Nut, Zinc-plated steel Token Relief (Low Flow) only GE46959X012

111 Pusher Post Retainer, Aluminum Token Relief (Low Flow) only GE46957X012

115 Diaphragm Stem O-ring, Nitrile (NBR) Token Relief (Low Flow) only GE49041X012

TORQUE: 50 TO 60 IN-LBS /

5.6 TO 6.8 N•m

CS800 Series

TYPE CS800/CS820 STANDARD/HIGH CAPACITY RELIEF

MEASURE THIS DISTANCE AND NOTE FOR REASSEMBLY

TORQUE: 50 TO 60 IN-LBS /

5.6 TO 6.8 N•m

DO NOT

LUBRICATE

TYPE CS800/CS820 STANDARD FLOW TOKEN RELIEF

55B

55A

NOTE DIRECTION OF RETAINER RING INSTALLATION

SEE DETAIL

TORQUE: 50 TO 60 IN-LBS /

5.6 TO 6.8 N•m

55B

55A

NOTE DIRECTION OF

RETAINER RING INSTALLATION SEE DETAIL

TORQUE: 50 TO 60 IN-LBS /

5.6 TO 6.8 N•m

115

110

TYPE CS800/CS820 TOKEN RELIEF LOW FLOW

RETAINER RING INSTALLATION DETAIL

MEASURE THIS DISTANCE AND NOTE FOR REASSEMBLY

DO NOT LUBRICATE

55B

55A

111

NOTE DIRECTION OF RETAINER RING INSTALLATION SEE DETAIL

NOTE DIRECTION OF RETAINER RING INSTALLATION

GG00886_F

APPLY LUBRICANT (L) / SEALANT (S) / ADHESIVE (A)

L2 = EXTREME LOW TEMPERATURE BEARING GREASE S2 = MEDIUM STRENGTH THREADLOCKER SEALANT A = ADHESIVE

NOTE: APPLY ADHESIVE ON THE FLAT SURFACE OF THE DIAPHRAGM PLATE THAT CONTACTS THE DIAPHRAGM, TOWARD THE OUTER PERIMETER,

AND AWAY FROM THE CENTER HOLE.

1. Lubricant, sealant and adhesive must be selected such that they meet the temperature requirements.

(1)

Figure 13. CS800 Series Diaphragm and Relief Assemblies (continued)

CS800 Series

36A

36D

GG00886_F

APPLY LUBRICANT (L) L1 = ANTI-SEIZE LUBRICANT L2 = EXTREME LOW TEMPERATURE BEARING GREASE

1. Lubricants must be selected such that they meet the temperature requirements.

36C

NOTE DIRECTION OF RETAINER RING INSTALLATION

(1)

36B

Figure 14. CS800 Series External Registration

108

109

SECTION A - A

109

NOTE DIRECTION OF RETAINER RING INSTALLATION

108

MAXIMUM TORQUE:

9 FT-LBS / 12 N•m

100

TYPE CS800 TYPE CS820

GG00886_F

APPLY LUBRICANT (L) L1 = ANTI-SEIZE LUBRICANT L2 = EXTREME LOW TEMPERATURE BEARING GREASE

1. Lubricants must be selected such that they meet the temperature requirements.

(1)

Figure 15. CS800 Series Control Spring Adjustment Assemblies

MAXIMUM TORQUE:

9 FT-LBS / 12 N•m

100

103

104

MAXIMUM TORQUE: 9 FT-LBS / 12 N•m

CS800 Series

100

107

105

GG00886_F

APPLY LUBRICANT (L) L1 = ANTI-SEIZE LUBRICANT L2 = EXTREME LOW TEMPERATURE BEARING GREASE

1. Lubricants must be selected such that they meet the temperature requirements.

(1)

Figure 15. CS800 Series Control Spring Adjustment Assemblies (continued)

TORQUE: 4 TO 6 FT-LBS /

5.4 TO 8.1 N•m

106

GRAY CAST IRON BODIES

WITHOUT OVERPRESSURE PROTECTION

APPLY LUBRICANT (L) / SEALANT (S) L1 = ANTI-SEIZE LUBRICANT L2 = EXTREME LOW TEMPERATURE BEARING GREASE S1 = THREAD SEALANT WITH PTFE

1. Lubricants and sealants must be selected such that they meet the temperature requirements.

(1)

Figure 16. CS800 Series Body Congurations

GRAY CAST IRON/DUCTILE IRON/STEEL BODIES

WITH OVERPRESSURE PROTECTION

CS800 Series

TYPE TM600 TRUE-MONITOR ASSEMBLY

FOR TYPE CS803 FINAL ASSEMBLY

TORQUE: 25 TO 35 FT-LBS / 34 TO 47 N•m

TYPE TM600 TRUE-MONITOR ASSEMBLY

FOR TYPE CS803 FINAL ASSEMBLY

TORQUE: 25 TO 35 FT-LBS /

34 TO 47 N•m

TYPE TM600 TRUE MONITOR ASSEMBLY FOR TYPE CS803 FINAL ASSEMBLY

APPLY LUBRICANT (L) / SEALANT (S) L1 = ANTI-SEIZE LUBRICANT L2 = EXTREME LOW TEMPERATURE BEARING GREASE S2 = MEDIUM STRENGTH THREADLOCKER SEALANT

1. Lubricants and sealants must be selected such that they meet the temperature requirements.

(1)

Figure 17a. CS800 Series Integral True-Monitor™ Module and Orice Assemblies

CS800 Series

TYPE VSX8 SLAM SHUT ASSEMBLY FOR TYPE CS804 FINAL ASSEMBLY

APPLY LUBRICANT (L) / SEALANT (S) L1 = ANTI-SEIZE LUBRICANT L2 = EXTREME LOW TEMPERATURE BEARING GREASE S2 = MEDIUM STRENGTH THREADLOCKER SEALANT

1. Lubricants and sealants must be selected such that they meet the temperature requirements.

(1)

INSTALL HAND TIGHT

TORQUE: 25 TO 35 FT-LBS / 34 TO 47 N•m

TAKE CARE NOT TO DAMAGE SENSE TUBE WHEN INSTALLING REGULATOR INTO PIPELINE

Figure 17b. CS800 Series Slam-shut Module and Orice Assemblies (continued)

APPLY LUBRICANT (L) / SEALANT (S) L1 = ANTI-SEIZE LUBRICANT L2 = EXTREME LOW TEMPERATURE BEARING GREASE

1. Lubricants and sealants must be selected such that they meet the temperature requirements.

STANDARD ORIFICE AND STANDARD DISK ASSEMBLY

(1)

Figure 18. CS800 Series Base Orice and Secondary Seat™ (For Types CS805 and CS806) Assemblies

36B

CS800 Series

L22582

SECONDARY SEAT™ STANDARD ORIFICE

EXTREME LOW TEMPERATURE BEARING GREASE OR COMPARABLE LUBRICANT THAT MAINTAINS ITS LUBRICATION PROPERTIES AT COLD TEMPERATURES

25E

25A

SEALING SURFACE

GG00886_F

25F

25C

25B

PRIMARY SEATING SURFACE

SECONDARY SEATING SURFACE

NOTE: RUBBER INSTALLED THIS SIDE

25D

25E

25A

SEALING SURFACE

EXTREME LOW TEMPERATURE BEARING GREASE OR COMPARABLE LUBRICANT THAT MAINTAINS ITS LUBRICATION PROPERTIES AT COLD TEMPERATURES

25F

25C

25D

25B

PRIMARY SEATING SURFACE

SECONDARY SEATING SURFACE

NOTE: VENT DISK C’BORE INSTALLED THIS SIDE

TYPE CS805 SECONDARY SEAT ORIFICE ASSEMBLY (DETAILED VIEW) TYPE CS806 SECONDARY SEAT ORIFICE ASSEMBLY (DETAILED VIEW)

APPLY LUBRICANT (L) L1 = ANTI-SEIZE LUBRICANT L2 = EXTREME LOW TEMPERATURE BEARING GREASE

1. Lubricants must be selected such that they meet the temperature requirements.

(1)

Figure 18. CS800 Series Base Ori ce and Secondary Seat (For Types CS805 and CS806) Assemblies (continued)

Industrial Regulators

Emerson Process Management Regulator Technologies, Inc.

USA - Headquarters McKinney, Texas 75070 USA

Tel: +1 800 558 5853

Outside U.S. +1 972 548 3574

Asia-Paci c

Shanghai 201206, China Tel: +86 21 2892 9000

Europe Bologna 40013, Italy Tel: +39 051 419 0611

Middle East and Africa

Dubai, United Arab Emirates

Tel: +971 4811 8100

For further information visit www.emersonprocess.com/regulators

Natural Gas Technologies

Emerson Process Management Regulator Technologies, Inc.

USA - Headquarters McKinney, Texas 75070 USA

Tel: +1 800 558 5853

Outside U.S. +1 972 548 3574

Asia-Paci c

Singapore 128461, Singapore Tel: +65 6770 8337

Europe Bologna 40013, Italy Tel: +39 051 419 0611 Chartres 28008, France Tel: +33 2 37 33 47 00

Middle East and Africa

Dubai, United Arab Emirates

Tel: +971 4811 8100

TESCOM

Emerson Process Management Tescom Corporation

USA - Headquarters Elk River, Minnesota 55330-2445, USA

Tels: +1 763 241 3238 +1 800 447 1250

Europe Selmsdorf 23923, Germany Tel: +49 38823 31 287

Asia-Paci c

Shanghai 201206, China Tel: +86 21 2892 9499

The distinctive swirl pattern cast into every actuator

casing uniquely identi es the regulator as part of the

Fisher® brand Commercial Service Regulator family and assures you of the highest-quality engineering, performance and support traditionally associated with Fisher®, Francel™ and Tartarini™ regulators. Visit www.fishercommercialservice.com to access interactive applications.

The Emerson logo is a trademark and service mark of Emerson Electric Co. All other marks are the property of their prospective owners. Fisher is a mark owned by Fisher Controls International LLC, a business of Emerson Process Management.

The contents of this publication are presented for informational purposes only, and while every effort has been made to ensure their accuracy, they are not to be construed as warranties or

guarantees, express or implied, regarding the products or services described herein or their use or applicability. We reserve the right to modify or improve the designs or speci cations of such

products at any time without notice.

Emerson Process Management Regulator Technologies, Inc. does not assume responsibility for the selection, use or maintenance of any product. Responsibility for proper selection, use and maintenance of any Emerson Process Management Regulator Technologies, Inc. product remains solely with the purchaser.

Emerson CS800 Instruction Manual

Specifications and Main Features

Frequently Asked Questions

User Manual