Concoa 830-9412 Owner's manual

Controls Corporation of America
1501 Harpers Road • Virginia Beach, VA 23454
To Order Call 1-800-225-0473 or 757-422-8330 • Fax [phone]
www.concoa.com
830-9412
830-9413
830-9414
Relief Valves
December 2009
Supercedes Septemeber 2004
INSTALLATION AND OPERATION INSTRUCTIONS
Certified ISO 9001
ADI 9902-B
®
Before Installing or Operating, Read and Comply with These Instructions

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USER RESPONSIBILITY
This equipment will perform in conformity with the description contained in
this manual and accompanying labels and/or inserts when installed, operated,
maintained, and repaired in accordance with the instructions provided. This
equipment must be checked periodically. Improperly working equipment
should not be used. Parts that are broken, missing, worn, distorted or
contaminated, should be replaced immediately. CONCOA recommends
that a telephone or written request for service advice be made to CONCOA
Customer Service in Virginia Beach, Virginia, PHONE: [phone],
FAX: [phone], or E-MAIL: [email protected].
This equipment or any of its parts should not be altered without prior
written approval by CONCOA. The user of this equipment shall have the
sole responsibility for any malfunction that results from improper use, faulty
maintenance, damage, improper repair, or alteration by anyone other than
CONCOA or a service facility designated by CONCOA.
CUSTOMER SERVICE
In the event of equipment failure, call CONCOA Customer Service. Please
be prepared to provide the model number and serial number of the equipment
involved, in addition to some details regarding its application.
CAUTION
1. Shut down gas supply, drain gas from relief valve and system before
any maintenance is performed.
2. When using a vise or wrench on the valve, use only enough torque
to hold or move the part. Be careful not to score or distort the body,
threads, or other parts.
3. For replacement parts, use only those CONCOA parts designed for
this relief valve.
INTRODUCTION
The CONCOA 9400 series brass high-flow relief valves in Figure 1 are
designed to be field adjustable and offer zero leakage up to 98% of the
nominal set pressure. The O-ring seal is encapsulated to prevent seat
extrusion due to cold flow characteristics. The in-line design offers ½” male
NPT inlet and ½” female NPT outlet for both the 9412 and 9413. The 9414
offers ¼” male NPT inlet and ½” female NPT outlet. Please refer to Table 1,
for material, pressure range and flow data.

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a
b
c d
9400
Series
Relief
Valve
Table 1
Part
Number
Material Seat Pressure
Range
Flow at 10% Pressure
Differential
830-9414 Brass Neoprene 80-120 PSIG 1,263 SCFH (N2 100 PSIG)
830-9413 Brass Viton 270-600 PSIG 12,864 SCFH (N2 420 PSIG)
830-9412 Brass Viton 130-310 PSIG 6,960 SCFH (N2 220 PSIG)
FIELD ADJUSTMENT
Note: The safety relief device should not be used as a control valve to regulate
the system operating pressure. Frequent activation will cause seat leak and
require excessive maintenance.
DO NOT ADJUST WHILE UNDER PRESSURE.
1. Maintain system-operating pressure at least 5-10% below the set pressure
of the relief valve. Operating too close to the valve set pressure will cause
seat leak and will shorten the time between valve maintenance.
2. To adjust the cracking pressure, a field test bench maybe constructed
using the following parts as shown in Figure 2 below:
a. 492-1312-01-580 0-750 PSIG regulator
601-3312-01-580 0-150 PSIG regulator
b. 529-0022-01-001 Reducing adapter
c. 533-9002 Needle valve
d. 830-5385 Brass ¼” tee
Figure 2
Figure 1

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3. Attach the relief valve to the outlet adapter on the tee-block. Remove
the adapter if the ¼” female NPT thread port is required.
4. Loosen the case of the relief valve approximately an 1/8 of a turn
counter-clockwise by applying torque at the hex flats located at both
ends of the valve.
5. Insert the appropriate Allen wrench into the female NPT outlet port
of the relief valve.
6. Turn the Allen wrench clockwise to increase cracking pressure and
counter clockwise to reduce.
7. Tighten the case by reversing step four (4).
8. Adjust the pressure of the 492-1312-01-580 to the desired relief point.
Observe the point at which the relief exhausts.
9. Open the needle valve a ¼ turn and back out the regulator-adjusting
knob until the outlet gauge pressure reads zero. If the relief valve
exhausts at the desired pressure go to step eleven (11). If further
adjustment is required, proceed to step ten (10).
10. Repeat steps four (4) through nine (9) until the desired cracking
pressure is obtained.
11. Valve is ready for installation.
INSTALLATION
Note: It is the end user's responsibility to ensure that the relief system
is properly designed by a professional engineer to meet the intended
requirements.
1. Be sure that all connections are secure and leak tight. Teflon tape
should be used on pipe fittings, but avoid impinging on the gas stream.
Before applying tape, inspect the NPT threads and if necessary, clean
the fitting to remove any dirt or thread sealant that remains. Start the
Teflon tape on the second thread as shown in Figure 3; make sure the
tape does not overlap the end of the thread. As the tape is wrapped
in the direction of the thread spiral (clockwise), pull tightly on the
end of tape so that it conforms to the thread. Apply two overlapping
layers and cut off excess tape.
Figure 3

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2. Install the 9400 series in a vertical position so the valve body is self-
draining. The inlet piping should be short as possible, with no elbows,
and equal to or greater than the size of the pressure relief valve inlet
connection.
3. The discharge piping should be equal to or greater than the size of the
pressure relief valve outlet connection so as to prevent backpressure
when relieving.The piping termination point must be in a safe location
and away from ignition sources. The termination point must be
positioned to prevent the accumulation of moisture. An appropriate
load-bearing device should support discharge piping, other than a
short tailpipe.
MAINTENANCE
The relief valve should be inspected every 12-18 months to ensure proper
working order. Depending on the service and the condition of the valve, the
inspection interval may be adjusted.

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Warranty Information
This equipment is sold by CONTROLS CORPORATION OF AMERICA under
the warranties set forth in the following paragraphs. Such warranties are extended
only with respect to the purchase of this equipment directly from CONTROLS
CORPORATION OF AMERICA or its Authorized Distributors as new merchandise
and are extended to the first Buyer thereof other than for the purpose of resale.
For a period of one (1) year from the date of original delivery (90 days in corrosive
service) to Buyer or to Buyer’s order, this equipment is warrantied to be free from
functional defects in materials and workmanship and to conform to the description of
this equipment contained in this manual and any accompanying labels and/or inserts,
provided that the same is properly operated under conditions of normal use and
that regular periodic maintenance and service is performed or replacements made in
accordance with the instructions provided. The foregoing warranties shall not apply if
the equipment has been repaired: other than by CONTROLS CORPORATION OF
AMERICA or a designated service facility or in accordance with written instructions
provided by CONTROLS CORPORATION OF AMERICA, or altered by anyone
other than CONTROLS CORPORATION OF AMERICA, or if the equipment has
been subject to abuse, misuse, negligence or accident.
CONTROLS CORPORATION OF AMERICA’s sole and exclusive obligation and
Buyer’s sole and exclusive remedy under the above warranties is limited to repairing
or replacing, free of charge, at CONTROLS CORPORATION OF AMERICA’s
option, the equipment or part, which is reported to its Authorized Distributor from
whom purchased, and which if so advised, is returned with a statement of the observed
deficiency, and proof of purchase of equipment or part not later than seven (7) days
after the expiration date of the applicable warranty, to the nearest designated service
facility during normal business hours, transportation charges prepaid, and which
upon examination, is found not to comply with the above warranties. Return trip
transportation charges for the equipment or part shall be paid by Buyer.
CONTROLS CORPORATION OF AMERICA SHALL NOT BE OTHERWISE
LIABLE FOR ANY DAMAGES INCLUDING BUT NOT LIMITED TO:
INCIDENTAL DAMAGES, CONSEQUENTIAL DAMAGES, OR SPECIAL
DAMAGES, WHETHER SUCH DAMAGES RESULT FROM NEGLIGENCE,
BREACH OF WARRANTY OR OTHERWISE.
THERE ARE NO EXPRESS OR IMPLIED WARRANTIES WHICH
EXTEND BEYOND THE WARRANTIES HEREINABOVE SET FORTH.
CONTROLS CORPORATION OF AMERICA MAKES NO WARRANTY OF
MERCHANTABILITY OR FITNESS FOR A PARTICULAR PURPOSE WITH
RESPECT TO THE EQUIPMENT OR PARTS THEREOF.

Certified ISO 9001
ADI 9902-B
Controls Corporation of America
1501 Harpers Road • Virginia Beach, VA 23454
To Order Call 1-800-225-0473 or 757-422-8330 • Fax [phone]
www.concoa.com