Instruction Manual
TM
D103589X012
January 2015 - Rev.00
Type PS/79 and PS/80 Pilots
SUMMARY
Introduction ........................................................................ 1
Characteristics ................................................................... 1
Labelling ............................................................................ 2
Dimensions and Weights ................................................... 2
Installation ......................................................................... 2
Startup ............................................................................... 2
Periodic Checks ................................................................ 2
SEP Statement .................................................................. 2
ATEX Requirements .......................................................... 2
Maintenance ...................................................................... 3
Troubleshooting ................................................................. 4
Parts Lists .......................................................................... 4
Schematic Assemblies ....................................................... 6
INTRODUCTION
Scope of Manual
This manual provides installation, startup, maintenance, troubleshooting and spare parts for the pilot series PS/79 and PS/80.
Product Description
Designed for pressure regulators control, the following types
are available:
• PS/79 - single diaphragm pilot for pilot controlled gas
pressure regulator (active or wide-open monitor)
• PSO/79 - single diaphragm pilot for setting of rst
pressure reducing step of pilot controlled gas pressure
regulator (working monitor)
• REO/79 - single diaphragm pilot for setting of downstream
pressure reducing step of pilot controlled gas pressure
regulator (working monitor)
In case of failures, these pilots with double diaphragms will
cause a fail close reaction of the regulator.
RE/79 and RE/80 versions are in accordance with specic
requirements of Italian market applications.
Tightness cover version available on request (e.g. PS/79-D
and PS/80-D).
The full range of PS pilots can be installed in the following
pressure regulators:
FL Series - Cronos Series - EZH Series - 971 Model
This product has been designed to be used with fuel gases
of 1st and 2nd family according to EN 437, and with other
non aggressive and non fuel gases. For any other gases,
other than natural gas, please contact your local sales agent.
CHARACTERISTICS
REGULATOR
MONITOR
OR
PS/79 and PS/80
Figure 1. Type PS/79 and PS/80 Pilots
APPLICATION
WORKING MONITOR
REGULATOR
MONITOR
ALLOWABLE
PRESSURE
PS
(bar)
SET RANGE
W
d
(bar)
BODY AND
COVERS
MATERIAL
In case of failures, these pilots with single diaphragm will
cause a fail open reaction of the regulator.
• PS/80 - double diaphragm pilot for pilot controlled gas
pressure regulator (active or wide-open monitor)
• PSO/80 - double diaphragm pilot for setting of rst
pressure reducing step of pilot controlled gas pressure
regulator (working monitor)
• REO/80 - double diaphragm pilot for setting of
downstream pressure reducing step of pilot controlled gas
pressure regulator (working monitor)
PS/79 PSO/79 REO/79
100
PS/80 PSO/80 REO/80 1.5 - 40 *
(*) PS/79-AP and PS/80-AP versions are available on request with a set range up to 60 bar.
Table 1. Technical features
0.5 - 40 *
Steel
1/4” NPT female threaded connections.
All PS/ series pilots are supplied with a filter (5µ filtering
degree) and built-in pressure stabilizer, with the exception of
pilots PSO/79 and PSO/80.
PS/79 and PS/80
=x
LABELLING
BOLOGNAITALY
O.M.T.
MATRICOLA
SERIALNr.
ANNO
YEAR
NORMEARMONIZ.
HARMONIZED STD.
CLASSEDI PERDITA
LEAKAGECLASS
CLASSEFUNZIONALE
FUNCTIONALCLASS
FLUIDO GRUPPO
FLUIDGROUP
TS
Note 2
EN
Cg
pmax
1
PS
°C
body
Figure 2. Label for Type PS/79 and PS/80 Series
Note 1: See “Characteristics”
Note 2: Year of Manufacture
Note 3: Class 1: -10° to 60°C
Class 2: -20° to 60°C
Note 4: See “Characteristics”
APPARECCHIO TIPO /DEVICE TYPE
DN1
DN2
Wa
Wao
Wau
bar
PS
bar
covers
DIMENSIONS AND WEIGHTS
Table 2. Dimensions (mm) and weights (Kg)
Note 1
pao
bar PT
-
SEP STATEMENT
Emerson Process declares this product conforms to
Pressure Equipment Directive (PED) 97/23/EC.
Article 3 section 3 and was designed and manufactured in
bar
bar
bar
bar
PS bar
1.5Note 4Note 3
accordance with sound engineering practice (SEP).
Per Article 3 section 3, this “SEP” product must not bear the
CE marking.
ATEX REQUIREMENTS
WARNING
!
If the provisions of EN 12186 & EN 12279,
nationalregulations,ifany,andspecic
manufacturer recommendations are not
put into practice before installation and
if purge by inert gas is not carried out
before equipment’s start-up and shut-down
operations, a potential external and internal
explosive atmosphere can be present in
equipment & gas pressure regulating/
measuring stations/installations.
PS/79
full range
B
A 90 90
PS/80
full range
B 265 290
A
Weight 8 9
INSTALLATION
a. Check that data on the pilot’s plate are compatible with
actual working conditions.
b. Install in accordance with regulator instruction manual.
STARTUP
See the set-up and pilot adjustment instructions applying to
the equipment where the pilot is tted.
PERIODIC CHECKS
If a presence of foreign material in the pipelines is foreseen
and purge by inert gas is not carried out, the following
procedure is recommended to avoid any possible external
ignition source inside the equipment due to mechanical
generated sparks:
• drainage to safe area via drain lines of foreign materials, if
any, by inow of fuel gas with low velocity in the pipe-work
(5m/sec)
In any case,
• provisions of Directive 1999/92/EC and 89/655/EC shall
be enforced by gas pressure regulating/measuring station/
installation’s end user
• with a view to preventing and providing protection against
explosions, technical and/or organizational measures
appropriate to the nature of the operation shall be taken
(e.g. : lling/exhausting of fuel gas of internal volume
of the isolated part/entire installation with vent lines
to safe area - 7.5.2 of EN 12186 & 7.4 of EN 12279 ;
monitoring of settings with further exhaust of fuel gas to
safe area ; connection of isolated part/entire installation to
downstream pipeline; ….)
• provision in 9.3 of EN 12186 & 12279 shall be enforced
by pressure regulating/measuring station/installation’s end
user
Slowly close the outlet slam-shut and check line pressure
between it and regulator.
A slight increase in pressure should be detected: this results
from overload due to closing, and is followed by pressure stabilization. If outlet pressure continues to rise, then seal is defective. Check if leak is coming from regulator or pilot, and service.
2
• external tightness test shall be carried out after each
reassembly at installation site using testing pressure in
accordance with national rules
• periodical check/maintenance for surveillance shall be
carried out complying with national regulations, if any, and
specic manufacturer recommendations.
PS/79 and PS/80
MAINTENANCE
CAUTION
Servicingshouldbecarriedoutbyqualied,
skilled personnel only. For further information,
please contact our Technical Support
Representatives or our authorized dealers.
Before servicing, cut off regulator inlet and outlet and release
any trapped pressurized gas. Use suds to check that there
are no leaks.
Replacing Filter
a. Remove the screws (key 41), cover (key 59), and replace
felt (key 61). Reassemble by reversing the above sequence.
Replacing Stabilizer Diaphragm and Seal Pad
a. Remove screws (key 41), cover (key 64), spring (key 47)
and diaphragm assembly (key 48, 49, 50, 51, 52, and 53).
Replace diaphragm if necessary.
b. Unscrew seat (key 54) and replace pad holder (key 56).
c. Reassemble by reversing the above sequence, make sure
not to “pinch” O-rings (key 55).
Replacing Valve Seal Pads
a. Remove plug (key 27) and seat (key 30). Slide out spring
(key 32), pad holder unit (key 34) and forked stem (key 35).
b. Replace pad holder (key 34) and O-ring (key 37).
c. Reassemble by reversing above sequence.
g. Replace diaphragms (key 10) and all seals.
h. Proceed as directed in the replacement of lter, stabilizer
diaphragm, seal pad, and valve seal pads.
Reassembly
Lubricate the static O-rings with a thin layer of Molykote
55 M, be very careful not to damage the O-rings when
reassembling. No other pilot parts are to be lubricated.
Reassemble parts by reversing the above steps. As you
proceed, make sure that parts move freely and without
friction. In addition:
a. Once lever (key 39) and stem (key 13) have been
mounted, check that, with stem (key 13) against body
(key 25), clearance between forked stem (key 35) and
registered (A) of lever (key 39) is 0.2 to 0.3 mm. If not,
use register to correct.
CAUTION
The above clearance can be checked by
gently pulling stem (key 13) upward. Use
the proper tool to make sure that the top
plate (key 9) is on the same plane as that
supporting the diaphragm (key 10) in the
body (key 25).
b. Mount diaphragm (key 10) and screw on plate (key 9),
rst by hand then with box wrench, (always holding upper
diaphragm (key 10) rmly in place) in order to avoid
damage to stem (key 13) and levers below.
c. Holding plate (key 9) rmly in place with box wrench,
tighten nut (key 6).
General Maintenance
a. Completely release spring (key 5) by turning the adjusting
screw (key 1) counterclockwise.
b. Remove screws (key 7) and cover (key 4).
c. Keep plate (key 9 or 75 for the AP version) blocked with
a box wrench, unscrew nut (key 6). This must be done
exactly as described to prevent damage to or breaking of
safety valve (key 20).
d. Unscrew plate (key 9 or 75 for the AP version) from stem
(key 13) remove parts (key 10, 11 and 12 or 76, 78, 10, 77
and 12 for the AP version).
e. For PS/80 and PS/80-AP version:
Unscrew plate (key 9 or 75 for the AP version) from stem
(key 13)remove parts (key 10, 68, 69, 11 and 12 or 76, 78,
68, 69, 10, 77 and 12 for the AP version).
f. Slide off split pin (key 40). Remove locknut (key 16) with
appropriate wrench and slide out parts (key 17, 18, 19
and 20). Make sure that the surface of seat (key 26) which
is sealed by pad (key 21) is in proper condition.
d. Before remounting cover (key 4), center diaphragm as
follows:
• Mark a reference point (with pencil) on the diaphragm;
turn it to the right without forcing and mark another
reference on body.
• Now turn diaphragm to the left and mark a further reference.
• Position the diaphragm mark midway between the two
marks on the body.
e. Tighten all screws uniformly to ensure proper sealing.
CAUTION
The pilot has a wide range of self-adjustment
values. However, given actual operating
conditions, it may necessary to assist it at
timesbyndingthebestsettingofregister/
pin screw (key 29) or the most suitable
calibration jet (key 15).
3
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