Singer PR-10159 Operating Instructions Manual

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Page 1

PR-10159 UL / ULC Pressure Reducing Valve

106-PR-10159

S106-PR-10159

A106-RP-10159

OPERATING INSTRUCTIONS MANUAL

TABLE OF CONTENTS PAGE

General Information / Operation 2

Installation 3-4

(S)106-PG – Single Chamber, Hydraulically Operated Valve 5-6

106-PR Pressure Reducing Pilot 7

Parts and Dimensions 8-11

SA106-PR-10159

WARNING:

1. Read and follow instructions carefully. Proper training and periodic review regarding the use of this equipment is essential to prevent possible serious injury and/or property damage. The instructions contained herein were developed for using this equipment on ttings manufactured by Mueller Co. only, and may not be applicable for any other use.

2. DO NOT exceed the pressure ratings of any components or equipment. Exceeding the rated pressure may result in serious injury and/or property damage.

3. Safety goggles and other appropriate protective gear should be used. Failure to do so could result in serious injury.

F 13902 3/19

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PR-10159 PRESSURE REDUCING VALVE

OVERVIEW

Model PR-10159 is a pilot operated pressure reducing valve designed to automatically reduce a high inlet pressure to a lower outlet pressure. The valve will maintain a relatively steady downstream pressure regardless of fluctuations in the supply pressure or flow rate.

Maximum Pressure

– For sizes up to and including 4", maximum inlet pressure is 300 psig.

– For the 6" and 8" sizes, the maximum inlet pressure is 300 psig.

– The outlet pressure setting range for all sizes is 30-165 psig and shall not exceed 175 psig.

NOTE: With any manufactured product there is a risk of malfunction in service, whether by operating conditions such as a plugged strainer or normal wear and tear. We recommend regular maintenance with frequency to suit the importance to customer's application. We draw attention to our warranty which limits our responsibility to defects in workmanship and materials only. Visit singervalve.com for warranty details.

General Information / Operation

Pilot

Fixed

Restriction

Strainer

OPERATION

Model PR-10159 reacts to changes in downstream pressure via Pilot. Since the capacity of Pilot is much larger than that of Fixed Restriction, the state of the pilot (open or closed) determines whether the Main Valve is open or closed. Refer to Model 106-PG 'Operation' for more details.

High Downstream Pressure

When there is no demand (and the downstream pressure is at, or higher than the setting of Pressure Reducing Pilot), Pilot closes.

Flow through the pilot circuit is then directed to the bonnet through

Fixed Restriction and Flow Stabilizer, pressurizing the bonnet and closing Main Valve.

Low Downstream Pressure

When flow is required, and downstream pressure is lower than the setting of Pilot, the pilot opens. Flow in the pilot circuit is greater from the bonnet to downstream. The bonnet therefore depressurizes, opening Main Valve.

At zero flow conditions, the maximum increase in downstream pressure will be within 10% of the set pressure or will not exceed 7 psi.

Modulating

Under flowing conditions below the set point of Pilot, the pilot reacts to small changes in downstream pressure and modulates the bonnet pressure (and Main Valve position) as required to keep the downstream pressure constant.

The speed of opening and closing of the main valve depends on the setting of Model 26 Flow Stabilizer. Refer to Model 26 instructions for details and adjustment.

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PR-10159 PRESSURE REDUCING VALVE

INSTALLATION AND ADJUSTING PROCEDURE

Installation

Installation is to be done in accordance with NFPA 13, the Standard for Installation of Sprinkler Systems, or NFPA 14, the Standard for Installation of Standpipe and Hose Systems, as applicable.

1. Model S106-PR-10159 shall be installed on systems not exceeding the valve end configurations working capabilities.

2. Pressure gauges MUST be installed on the inlet and outlet piping of the valve.

3. If valve is for use with Standpipe and Hose Systems, refer to NFPA 14 for minimum installation requirements.

4. Refer to (S)106-PG 'Installation' for other installation requirements.

5. Installation with loosely held piping and/or elbows close to the valve may cause the valve to pulsate.

NOTE: For a valve intended for use in sprinkler systems, as indicated by NFPA 13:

A relief valve at least 1/2" (13 mm) in size with adequate drainage is to be installed on the downstream side of this valve. The relief valve must be set above the "lock-up" or "zero flow" shutoff pressure which is approximately between 4 to 10 psi higher than set pressure.

DIAGRAM 1. CONTROL VALVE SCHEMATIC

Adjustment

1. Open Isolating Valves (2), (5) and

(7) (if so equipped).

2. Crack outlet stop valve and slowly open inlet stop valve wide.

3. Bleed air from Main Valve bonnet. See (S)106-PG 'Installation'.

4. Open outlet stop valve wide.

5. Set reduced (downstream)

pressure by turning Pilot (6) adjusting screw: To increase pressure, turn adjusting screw clockwise.

- To reduce pressure, turn adjusting screw counter-clockwise.

NOTE: There must be flow through the valve when pressure is adjusted.

6. If the valve does not open (pressure remains low), check the adjustment of Pressure Reducing Pilot (6).

7. If the valve begins to oscillate or hunt, bleed air from Main Valve bonnet. See (S)106-PG 'Installation'.

Inlet

Outlet

NOTE: For dimension information and material specifications see component data sheets.

PARTS LIST

ID PART DESCRIPTION

1 Main Valve

2 Strainer J0098A

Tubing Option: Copper.

Fixed

Restriction

Pressure

Reducing Pilot

(S)106-PG or (S)

A106-PG

Model 161-PR,

Range 30-165 psi

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PR-10159 PRESSURE REDUCING VALVE

CARE / MAINTENANCE

Maintenance & Troubleshooting

Testing after installation is to be done in accordance with NFPA 13 or NFPA 14, or both NFPA 13 and 14, whichever is applicable, and tested periodically thereafter in accordance

TROUBLESHOOTING

PROBLEM CAUSE SOLUTION

1. Insufcient inlet pressure 1. Check inlet pressure source and increase as needed

2. Pressure in the bonnet not being released: 2. Try the following:

Valve Fails to Open

Valve Fails to Close

Pulsations Occurring

a) Isolating valves on pilot lines closed a) Open valves

b) Pilot components not functioning b) Refer to specic instructions on pilot components

c) Foreign material in pilot system c) Clear obstruction

1. Lack of pressure in bonnet due to: 1. Try the following:

a) Pilot components not functioning a) Refer to specic instructions on pilot components

b) Foreign material in pilot system b) Clear obstructions

c) Ruptured diaphragm c) Replace worn parts

d) Obstruction in the valve d) Remove obstructions

e) Worn main valve disc e) Replace disc

f) Plugged pilot strainer f) Flush strainer free of debris

1. Air in the bonnet 1. Vent air (refer to “Installation” #16)

2. Improper adjustments to pilot components 2. Refer to specic instructions on pilot components

3. Valve oversized 3. Smaller valve may be more suitable

with NFPA 25, the Standard for Inspection, Testing, and Maintenance for Water-Based Fire Protection Systems requirements.

In addition to service suggestions listed under NFPA 25 refer to (S)106-PG Service Suggestions.

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PR-10159 PRESSURE REDUCING VALVE

OVERVIEW

Model 106-PG Main Valve Body Parts

The 106-PG (flat diaphragm) and (S)106 -PG (single rolling diaphragm) valves (Pic. A) are the main valves used for Singer® control valve systems.

Unless otherwise specified, the valve is assembled with components suitable for water service up to 180° F (80° C). For other service conditions, contact your Singer representative.

OPERATION

Opening and Closing

The opening and closing action is performed by the inner valve assembly, controlled by the pressure in the bonnet chamber above the diaphragm.

The valve opens when:

a) Bonnet chamber is vented downstream with a minimal pressure drop of 10 psi across the main valve.

NOTE: This valve must be stored indoors, away from direct sunlight.

b) Bonnet chamber is vented to atmosphere with a minimal pressure drop of 5 psi across the main valve.

The valve closes when:

a) Bonnet is pressurized by upstream pressure or an external pressure (equal to or higher than line pressure), sealing the inner valve to the seat area tight.

Modulating

The valve can be made to modulate by varying the bonnet pressure between inlet pressure and outlet pressure. This is done by the pilot circuit.

INSTALLATION

1. Use washers under nuts when bolting valve flanges to pipe flanges to protect the Epoxy Coating.

2. It is recommended that valves be installed in a horizontal pipe with the bonnet up for more convenient access for maintenance. However, smaller valves (6" and smaller) may be installed in a vertical pipe if the order states the orientation.

3. A stable, continuous source of pressure is necessary to operate a pilot operated control valve.

4. Operating fluid must be clean and free of air.

5. Under high velocity conditions, when the pressure signal is located at main valve inlet, it may be adversely affected. When possible, a more suitable location should be used. For example, a relief valve will

operate more effectively and control more accurately if the operating pressure and sensing pressure is connected to the header.

6. Six pipe diameters of straight pipe on the inlet of any control valve is recommended but:

a) Fully open Gate Valve can be installed on the inlet of a valve, provided it is used as an isolating valve and never used in partially open condition.

b) A Butterfly Valve with stem horizontal cannot be installed in the inlet of a control valve unless operating pressure and sensing lines are connected upstream of the butterfly valve, in a location that gives true system pressure.

c) A Butterfly Valve with stem vertical can be installed in the inlet

of a control valve as long as velocity does not exceed 15 ft / sec. The butterfly valve can not be used for throttling. If problems develop at high flows, operating pressure and possible sensing can be connected upstream of the butterfly valve, in a location that gives true system pressure.

d) A Control Valve can be installed with no straight pipe on the inlet if the operating and sensing lines are connected to a location that gives true system pressure. The connection point should be made at the pipe center line to avoid air pick-up at the top of the pipe.

7. This valve is shipped with air pressure in the bonnet. Do not open the Bonnet Isolating Valve until the valve has been installed and ready for pressurization.

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PR-10159 PRESSURE REDUCING VALVE

(S)106-PG – Single Chamber, Hydraulically Operated Valve

INSTALLATION (CONT.)

8. It is possible that diaphragms may take a set after shipping and storage. It is highly recommended that Bonnet and Body Bolts or Nuts be tightened after installation but before pressurizing the valve. If a leak develops after pressurizing, de-pressurize the valve and tighten the bolts or nuts.

9. For most convenient operation and maintenance, line isolation valves should be installed.

10. A suitable bypass should be provided to allow for servicing of the valve without interrupting the flow.

MAINTENANCE

The Singer® Model (S)106-PG requires minimal maintenance.

All parts are accessible for inspection and repair without removing the valve from the line.

1. Close upstream and downstream isolating valves.

11. Install pressure gauges upstream and/or downstream of valve as appropriate. This will facilitate ease of setting the pilot system.

12. A strainer with a suitable basket should be installed ahead of the valve to protect it from foreign material.

13. Sufficient space should be provided around the valve for disassembly.

14. Flush system of all debris before installing the valve.

15. Check direction of flow (inlet of valve is marked OR an arrow

2. Disconnect body and bonnet pilot lines.

3. Remove bonnet. If bonnet does not come free readily, it can be pried loose with a small pry-bar.

4. Remove inner valve assembly for inspection. Do not remove seat ring

on the side of body indicates flow direction) and install the valve accordingly.

16. Vent air from the bonnet:

Valves with no Limit Switch:

Loosen pipe plug at the centre of the bonnet to bleed air. If equipped with position indicator, use bleedvalve on indicator.

Valves with Limit Switch:

Refer to Drawing and use bleed screw to vent air.

unless inspection shows that it is damaged or debris is found below the guide assembly. Be very careful not to damage the epoxy coating when removing and installing the inner valve assembly.

5. Replace worn or defective parts as necessary and reassemble.

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PR-10159 PRESSURE REDUCING VALVE

DESCRIPTION / OPERATION

161-PR Pressure Reducing Pilot

Model 161-PR is a direct acting, spring and diaphragm type pressure reducing pilot. The valve is held open by an adjustable spring.

INSTALLATION / ADJUSTMENT

1. Install the Pilot as shown in the enclosed schematic or drawing.

2. Note the direction of flow and install the valve accordingly.

3. The valve should be installed with the adjusting screw pointing up.

MAINTENANCE

Disassembly

1. Close upstream and downstream

isolating valves.

2. Remove the entire pilot from the system.

3. Remove the adjusting screw.

4. Remove the Body Screws and

remove the spring casing assembly.

5. Loosen the diaphragm if it adheres to the body and remove the Stem / Yoke assembly. Be careful to avoid damage to the stem as

Operation

The setpoint of the Model 161-PR is determined by the compression of Spring. The spring provides

Adjustment

1. Turning the Adjusting Screw (#17,

page 10) clockwise increases the setting of the pilot, providing a higher downstream pressure.

2. Turning Adjusting Screw counter-clockwise decreases the setting of the pilot, providing a lower downstream pressure.

any additional friction between the Stem and Guide Bushing can affect performance.

Inner Valve Replacement

1. Hold the Inner Valve hex in

a vise and use a screwdriver or similar tool to turn the Yoke.

Diaphragm Replacement

1. Hold the inner valve hex in a

vise and use a screwdriver to turn the stem counter-clockwise using the slot at the top of Stem.

a constant downward force on diaphragm, while the outlet pressure acting under the diaphragm opposes the spring, which closes valve.

Note: Range of adjustments and corresponding pressures are also shown on the name plate on the body of the pilot.

SPRING RANGE (PSI)

30 – 165 26

If required, use a secondscrewdriver or similar tool at the Yoke to prevent the yoke from turning. When doing so, take extra care to avoid damage to the stem guiding surface.

2. Replace the diaphragm in the same orientation as the original one, straddling the legs of the yoke.

Assembly

Reassembly is the reverse of disassembly. Ensure that parts are replaced in the sequence shown on the drawing.

ADJUSTMENT

(PSI / TURN)

TESTING PROCEDURE

1. Connect a source of air or water to the inlet.

2. Attach a 3/8" line with a pressure gauge and shut-off valve to the outlet.

3. Back off the adjusting screw, then proceed to turn it in. The gauge should show an increase within the range marked on the valve.

4. Open the shut-off valve slightly and bleed flow to atmosphere. Pressure should drop slightly and return to setting when the shut-off valve is closed. This check should be repeated at various settings.

TROUBLESHOOTING

PROBLEM CAUSE SOLUTION

Main Valve Fails to Open 1. Pilot setting too low 1. Raise setting (turn adjusting screw clockwise)

1. Pilot setting too high 1. Lower setting (turn adjusting screw counter-clockwise)

Main Valve Fails to Close

2. Obstruction on seat 2. Locate and remove obstruction

3. Ruptured diaphragm 3. Replace diaphragm

4. Worn inner valve 4. Replace inner valve

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PR-10159 PRESSURE REDUCING VALVE

18 52

7 5

Two Piece Seat &

Bottom Guide Detail

One Piece Seat &

Bottom Guide Detail

17 44

PARTS LIST

ID DESCRIPTION MATERIAL

1 Body

2 Bonnet

3 Seat Ring

4 Stem Stainless Steel

5 Disc Retainer

6 Resilient Disc EPDM or Buna-N

7 Inner Valve

8* Diaphragm EPDM or Buna-N

9 Clamp Plate

10 Stem Nut Brass B-16

11 Spring Stainless Steel

12 Guide Bushing Brass B-16

13 Stem Cap

14* Seat Ring Seal Buna-N

15* Stem Cap Seal Buna-N

16 Bonnet Bolt Stainless Steel

18 Stem Screw Stainless Steel

19 Bottom Guide

45*

46 Locating Pin Stainless Steel

49*

51 Bonnet Washer Stainless Steel

Seat Ring

Screws

Seat Retaining

Washer

Diaphragm

Seal

Disc Retainer

Seal

Stem Cap

Washer

Stainless Steel (See

Stainless Steel 2

Bronze (See Note

Parts

Ductile

Iron / NAB / SS

Ductile

Iron / NAB / SS

Note 2)

Ductile Iron (See

Note 3)

Ductile

Iron / NAB / SS

Ductile

Iron / NAB / SS

Ductile

Iron / NAB / SS

Ductile Iron &

Stainless Steel

(See Note 1)

Buna-N

Stainless Steel

*Recommended spare parts (included in Rebuild Kit).

NOTES:

1. Not required on size 2 - 1/2", (One piece seat ring and guide, shown as item 3).

2. On sizes 2 - 1/2"– 8" items 3 & 19 may be one piece; material - Stainless Steel.

3. On sizes 2 - 1/2" & 3", material is brass B-16. On size 4", material is bronze.

4. On size 3", material is bronze B-62.

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SINGER

PR-10159 PRESSURE REDUCING VALVE

DIMENSIONS

Dimensions

106-PG & A106-PG GLOBE GLOBE & ANGLE ANGLE

A D E C B E F

2 - 1/2"

65 mm

80 mm

100 mm

150 mm

200 mm

NPT / BSPT

150F / PN10, PN16, PN25,

PN40

300F

NPT / BSPT

150F

300F

PN10, PN16,

PN25, PN40

150F / PN10,

PN16, PN25,

PN40

300F

150F / PN10,

PN16

300F / PN25,

PN40

150F / PN10,

PN16

300F / PN25,

PN40

11"

279 mm

11"

279 mm

11.63"

295 mm

13.50"

343 mm

12"

305 mm

13.25"

337 mm

12.25"

311 mm

15"

381 mm

15.63"

397 mm

20"

508 mm

21"

533 mm

25.38"

645 mm

26.38"

670 mm

3.38"

86 mm

3.50"

89 mm

3.75"

95 mm

3.68" 94 mm

3.75"

95 mm

4.13"

105 mm

7.50"

191 mm

7.50"

191 mm

7.50"

191 mm

8" 203 mm

4" 102 mm 8" 203 mm

4.60"

117 mm

5.09"

129 mm

5.60"

142 mm

6.34"

161 mm

7.63"

194 mm

7.88"

200 mm

9.15"

232 mm

9.15"

232 mm

11.75"

299 mm

11.75"

299 mm

14.91"

379 mm

14.91"

379 mm

8.19"

208 mm

8.19"

208 mm

8.19"

208 mm

5.50"

140 mm

5.50"

140 mm

5.88"

149 mm

9.25" 235 mm6.63" 168 mm

9.25"

235 mm

9.25"

235 mm

9.25"

235 mm

10.88"

276 mm

10.88"

276 mm

16.63"

422 mm

16.63"

422 mm

21.63"

549 mm

21.63"

549 mm

6" 152 mm 8" 203 mm

6.38"

162 mm

6.38"

162 mm

7.50"

191 mm

7.88"

200 mm

10"

254 mm

10.50"

267 mm

12.75"

324 mm

13.25"

337 mm

7.50"

191 mm

7.50"

191 mm

7.50"

191 mm

8" 203 mm

9.15"

232 mm

9.15"

232 mm

11.75"

299 mm

11.75"

299 mm

14.91"

379 mm

14.91"

379 mm

102 mm

4.31"

110 mm

4.63" 118 mm

102 mm

4.38"

111 mm

4.38"

111 mm

127 mm

5.31"

135 mm

152 mm

6.50"

165 mm

203 mm

8.50"

216 mm

Page 10

PR-10159 PRESSURE REDUCING VALVE

161-PR Pressure Reducing Pilot Parts & Dimensions

PARTS LIST

Max

Inlet

3/8" NPT

ID DESCRIPTION MATERIAL

1 Body Stainless Steel

2 Diaphragm EPDM

3 Outlet Connector Stainless Steel

4 Stem Stainless Steel

5 Inner Valve

6 Yo ke Stainless Steel

7 Clamp Plate Stainless Steel

Outlet

3/8" NPT

8 Spring Casing Stainless Steel

9 Retaining Ring Stainless Steel

10 Guide Bushing Delrin

Casing Screw

13 Spring Spring Steel

14 Spring Step (2) Stainless Steel

16 Locknut Stainless Steel

17 Adjusting Screw Stainless Steel

18 Seat Ring Stainless Steel

19 Seat Ring Seal Buna-N

20 Plug, 1/2 NPT Brass

(8)

Stainless Steel and

EPDM

Stainless Steel

FIXED RESTRICTION

1/4"

NPT

Outlet

3/8" NPT

3 - 3/16" Ø

1/4" NPT

"A" Ø

"A" DIAMETER

1/16" (1.6 mm)

3/32" (2.4 mm)

1/8" (3.2 mm)

1/4" (6.4 mm)

7/64" (2.8 mm)

3/16" (4.8 mm)

NO. OF ID GROOVES

STAINLESS STEEL 303

PART NUMBER

M1009E-SS M1009E-S3

M1149E-SS M1149E-S3

M1010E-SS M1010E-S3

M1997A-SS M1997A-S3

M2023A-SS M2023A-S3

M1813B-SS M1813B-S3

STAINLESS STEEL 316

PART NUMBER

Page 11

PR-10159 PRESSURE REDUCING VALVE

Strainer – Parts & Dimensions

1/4" NPT

3/8" NPT

Flow In

1- 9/16"

(40 mm)

Sensing or Gauge

Connection

Model J0097A

3/8" NPT

Flow In

Flow Out

3/8" NPT

Flow Out

3/8" NPT

PARTS LIST

ID DESCRIPTION MATERIAL

1 Body Stainless Steel 316

2 Screen Retainer Stainless Steel 316

Screen (40

5 Blow Down Plug Stainless Steel 316

Mesh)

Screen Retainer

Seal

Stainless Steel 316

Buna-N

3" (76 mm)

Model J0098A

Page 12

833.367.6835 – www.singervalve.com – [email protected] INTERNATIONAL – 1.423.490.9555 – www.mueller-international.com – [email protected]

Mueller refers to one or more of Mueller Water Products, Inc. a Delaware corporation (“MWP”), and its subsidiaries. MWP and each of its subsidiaries are legally separate and independent entities when providing products and services. MWP does not provide products or services to third parties. MWP and each of its subsidiaries are liable only for their own acts and omissions and not those of each other. MWP brands include Mueller®, Echologics®, Hydro Gate®, Hydro-Guard®, HYMAX®, Jones®, Krausz®, Mi.Net®, Milliken®, Pratt®, Singer®, and U.S. Pipe Valve & Hydrant. Please see muellerwp.com/brands and krauszusa.com to learn more.

Copyright © 2019 Mueller SV, Ltd. All Rights Reserved. The trademarks, logos and service marks displayed in this document are the property of Mueller Water Products, Inc., its afliates or other third parties. Products marked with a section symbol (§) are subject to patents or patent applications. For details, visit www.mwppat.com. These products are intended for use in potable water applications. Please contact your Mueller Sales or Customer Service Representative concerning any other application(s).