Emerson Fisher 92s User manual

W4088-1

W4086-3

Type 92S Pilot-Operated Steam Regulators

▲ WARNING

Failure to follow these instructions or

to properly install and maintain this

equipment could result in an explosion,

re and/or chemical contamination

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 Process

Management Regulator Technologies,

Inc. 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.

Installation, operation and maintenance

procedures performed by unqualied

personnel may result in improper

adjustment and unsafe operation. Either

condition may result in equipment

damage or personal injury. Use qualied

personnel when installing, operating and

maintaining the Type 92S Pilot-Operated

Steam regulator.

Introduction

Scope of the Manual

This manual provides instruction for installation,

adjustment, maintenance and parts ordering

information for the Type 92S Pilot-Operated Steam

Regulator complete with Type 6492L, 6492H or

6492HT pilot. The Type 92S is also available with

a Type 6492HM or 6492HTM safety override pilot.

Accessories used with this valve, including any

pressure-loading device for a Type 6492L, 6492H,

6492HT, 6492HM or 6492HTM pilot with tapped spring

case, are covered in other manuals.

1 NPT STEEL MAIN VALVE WITH TYPE 6492H OR 6492HT PILOT

NPS 3 / DN 80 FLANGED CAST IRON

MAIN VALVE WITH TYPE 6492L PILOT

Figure 1. Type 92S Pilot-Operated Steam Regulator

Instruction Manual

D100637X012

January 2021

Type 92S

Specifications

The Specifications section lists the specifications for the Type 92S regulator. Specifications for a given regulator

as it originally comes from the factory are stamped on nameplates located on both the main valve body and pilot,

while the pilot control spring range is displayed on the pilot spring case.

Main Valve Body Sizes and End Connection Styles

Maximum Inlet and Pilot Supply Pressure(1)

Cast Iron Main Valve and Pilot: 250 psig /

17.2 bar or body rating limit, whichever is lower

Steel or Stainless steel Main Valve and Pilot:

300 psig / 20.7 bar or body rating limit, whichever

is lower

Minimum and Maximum Differential Pressures(1)

Outlet (Control) Pressure Ranges

See Table 2

Maximum Outlet Pressures(1)

See Table 3

Maximum Allowable Loading Pressure for Pilot

with Tapped Spring Case(1)

Combination of pilot control spring setting and spring

case loading pressure must not exceed 150 psig /

10.3 bar for Type 6492H pilot or 25 psig / 1.7 bar for

Type 6492L pilot and 250 psig for Type 6492HT

Pressure Registration

External through downstream control line

Maximum Material Temperature Capabilities(1)

Cast Iron Construction: 406°F / 208°C

Steel Construction: 500°F / 260°C

High Temperature Optional Steel and

Stainless Steel Construction: 650°F / 343°C

Main Valve Port Diameters and Flow Coefficients

See Table 1

Downstream Control Line Connections

NPS 1, 1-1/2 or 2 / DN 25, 40 or 50 Body Size:

1/4 NPT in main valve cylinder spacer

NPS 2-1/2, 3, 4 or 6 x 4 / DN 65, 80, 100 or

150 x 100(2) Body Size: 1/4 NPT in pilot body

Pilot Spring Case Vent

Standard: 1/8 in. / 3.2 mm drilled hole

Optional: 1/4 NPT tapping for pressure loading or

on-off service

Approximate Weights

BODY SIZE

END CONNECTION STYLES AND RATINGS

Cast Iron Body Steel or

Stainless Steel Body

1, 1-1/2 and 2 NPT NPT

NPS 1, 1-1/2, 2, 2-1/2, 3

and 4 / DN 25, 40, 50, 65,

80 and 100

CL125 FF or

CL250 RF

CL150 RF, CL300 RF,

CL600 RF or

PN 10/25/40

NPS 6 x 4 /

DN 150 x 100(2) Not Available

CL300 RF,

CL600 RF or

PN 16/25-40/64/100

BODY SIZE,

NPS / DN

MINIMUM

DIFFERENTIAL

PRESSURE

MAXIMUM

DIFFERENTIAL

PRESSURE

1, 1-1/2 and 2 /

25, 40 and 50 15 psi / 1.0 bar

200 psi / 13.8 bar or

body rating limit,

whichever is lower

2-1/2, 3, 4 and 6 x 4 /

65, 80, 100 and

150 x 100(2)

20 psi / 1.4 bar

175 psi / 12.1 bar or

body rating limit,

whichever is lower

BODY SIZE END

CONNECTION

STYLE

APPROXIMATE

WEIGHTS

NPS DN Lbs kg

1-1/2

NPT or Flanged

2 50 NPT

Flanged

2-1/2

100

Flanged

115

165

6 x 4(2) 150 x 100(2) Flanged CL300 335 152

CL600 435 197

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

2. The two-number designation indicates end connection size by trim size.

Table 1. Flow and Sizing Coecients(1)

BODY SIZE ORIFICE SIZE REGULATING

WIDE-OPEN CS

FOR RELIEF

SIZING

C1Km

IEC SIZING COEFFICIENTS

NPS DN In. mm XTFDFL

1 25 7/8 22 16 17.5

0.62

0.73

0.51

0.791-1/2 40 1-1/8 29 30 33 0.47

2 50 1-29/64 37 48 52 0.48

2-1/2 65 1-5/8 41 74 78

0.71

0.48

0.84

3 80 2-1/16 52 100 110 0.47

4 100 2-3/8 60 140 145 0.46

6 x 4 150 x 100 2-3/8 60 150 155 0.46

1. Cv= Csx 20 ÷ C1

Type 92S

PILOT TYPE OUTLET PRESSURE RANGES PART NUMBER COLOR CODE SPRING WIRE DIAMETER SPRING FREE LENGTH

psig bar In. mm In. mm

6492L

2 to 6

5 to 15

13 to 25

0.14 to 0.41

0.34 to 1.0

0.90 to 1.7

1E395627022

1D7455T0012

1E395727192

Yellow

Green

Red

0.207

0.234

0.283

5.26

5.94

7.19

2.50

2.62

2.44

63.5

66.5

62.0

6492H

10 to 30

25 to 75

70 to 150

0.69 to 2.1

1.7 to 5.2

4.8 to 10.3

1E395627022

1D7455T0012

1E395727192

Yellow

Green

Red

0.207

0.234

0.283

5.26

5.94

7.19

2.50

2.62

2.44

63.5

66.5

62.0

6492HT 15 to 100

80 to 250

1.0 to 6.9

5.5 to 17.2

14B9943X012

14B9942X022 Unpainted 0.282

0.375

7.16

9.53

2.50

63.5

Table 2. Outlet (Control) Pressure Ranges

CONSTRUCTION

MAXIMUM ALLOWABLE INLET PRESSURE MAXIMUM

OPERATING OUTLET

PRESSURE

MAXIMUM EMERGENCY OUTLET PRESSURE

Cast Iron Steel and

Stainless Steel Cast Iron Main Valve and

Pilot Body

Steel or Stainless Steel

Main Valve and

Pilot Body

psig bar psig bar psig bar

With Type 6492HT pilot - - - -

300 20.7

250 17.2 - - - -

300 psig / 20.7 bar or main

valve body rating limit,

whichever is lower

With Type 6492H pilot 250 17.2 150 10.3

250 psig / 17.2 bar or main

valve body rating limit,

whichever is lower

300 psig / 20.7 bar or main

valve body rating limit,

whichever is lower

With Type 6492L pilot 25 1.7 100 psig / 6.9 bar 100 psig / 6.9 bar

Table 3. Maximum Inlet and Outlet Pressures

TYPE SPRING RANGE SPRING COLOR PART NUMBER MINIMUM PRESSURE AT WHICH

MONITORING PILOT CAN BE SET

psig bar

6492HM

10 to 30 0.69 to 2.1 Yellow 1E395627022 5 psig / 0.34 bar over normal distribution pressure

25 to 75 1.7 to 5.2 Green 1D7455T0012

10 psig / 0.69 bar over normal distribution pressure

70 to 150 4.8 to 10.3 Red 1E395727192

6492HTM 15 to 100 1.0 to 6.9 Unpainted 14B9943X012

80 to 250 5.5 to 17.2 14B9942X022

Table 4. Safety Pilot Outlet (Control) Pressure Ranges

Description

The Type 92S pressure-reducing regulator for steam

service includes either a Type 6492H, 6492HT or

6492L pilot (Figure 1). Both pilots have a friction-

reducing bellows seal on the stem, and offer pressure-

setting adjustment plus sensitivity to downstream

pressure changes.

These pilots are available in either a standard version

with a drilled spring case vent or an optional version

with a tapped spring case vent and a sealed adjusting

screw for pressure-loading or on-off service. A 67 or

1301 Series regulator or 670 Series panel-mounted

regulator may be used to load the pilot of a version

for pressure-loading service, while a solenoid valve

may be used on the pilot of a version for on-off

service. A Type 6492HM or 6492HTM safety override

pilot is available for the Type 92S. The Type 6492H

or 6492HT pilot is used in a series installation with

the Type 6492HM or 6492HTM safety override

pilot installed on the upstream control valve. The

Type 6492HM or 6492HTM safety override pilot

senses pressure downstream of the second valve, and

prevents pressure from rising above safe operating

pressure in the event the downstream valve fails. This

system is approved by ASME B31.1-1989, 122.14.2.A,

and can replace an ASME safety valve when vent

piping is not practical and upstream steam pressure

does not exceed 400 psig / 27.6 bar. Local codes and

standards may require approval by an appropriate

authority prior to installation.

▲ WARNING

The Type 92S safety override system

does not provide positive shutoff in

dead end service. It is intended for

large distribution systems where steam

leakage will condense before steam

pressure builds up. Downstream piping

and components must be rated for

maximum upstream steam pressure for

dead end service. Failure to do so could

cause personal injury or death.

Type 92S

A6553

A6552

Type 92S Self-Powered Control Valve

August 2007 Type 92S

PILOT SPRING

PILOT VALVE PLUG

PILOT INLET

SCREEN

MAIN VALVE

PISTONS

MAIN VALVE

SPRING

MAIN VALVE

PLUG

NPS 1, 1-1/2 OR 2 / DN 25, 40 OR 50 BODY SIZE MAIN VALVE BODY AND TYPE 6492H OR 6492HT PILOT

MAIN VALVE

PLUG

MAIN VALVE

STEM

PILOT INLET

SCREEN

MAIN VALVE

PISTON

PILOT VALVE

PLUG SPRING

LOADING PRESSURE

ATMOSPHERIC PRESSURE

OUTLET PRESSURE

NPS 2-1/2, 3, 4 OR 6 X 4 / DN 65, 80, 100 OR 150 X 100 BODY SIZE MAIN VALVE BODY AND TYPE 6492L PILOT

Figure 2. Type 92S Pilot-Operated Steam Regulator Operational Schematics

INLET PRESSURE

Type 92S

E0402

E0403

TYPE 6492H PILOT TYPE 6492H PILOT

TYPE 92S MAIN VALVE

TYPE 6492HM SAFETY

OVERRIDE PILOT

NPS 1, 1-1/2 AND 2 / DN 25, 40 AND 50 BODY SIZES

TYPE 92S PILOT-OPERATED PRESSURE REDUCING REGULATOR WITH SAFETY OVERRIDE PILOT

TYPE 92S MAIN VALVE TYPE 92S MAIN VALVE

TYPE 6492H PILOT

TYPE 6492HM SAFETY

OVERRIDE PILOT

TYPE 6492H PILOT

INLET PRESSURE

OUTLET PRESSURE

ATMOSPHERIC PRESSURE

LOADING PRESSURE

INTERMEDIATE PRESSURE

NPS 2-1/2, 3 AND 4 / DN 65 80 AND 100 BODY SIZES

TYPE 92S PILOT-OPERATED PRESSURE REDUCING VALVE WITH SAFETY OVERRIDE PILOT

Figure 2. Type 92S Pilot-Operated Steam Regulator Operational Schematics (continued)

Type 92S

Principle of Operation

Pilot supply pressure is piped from the main valve inlet

(Figure 2) to the pilot inlet connection. Downstream

pressure registers on the main valve pistons through the

downstream control line and then on the pilot diaphragm.

When increased downstream demand lowers the

downstream pressure to a valve below the setting of

the pilot control spring, this spring forces the pilot valve

plug open to increase the loading pressure on the

main valve pistons. At the same time, the increased

demand lowers the downstream pressure on the

main valve piston(s). This opens the main valve plug,

increasing flow to the downstream system to satisfy

the increased demand and to restore downstream

pressure to the setting of the pilot control spring.

Decreased downstream demand increases the

downstream pressure registered on the pilot

diaphragm. The increased pressure overcomes the

force of the pilot control spring and allows the pilot

valve plug spring to close the pilot valve plug. As the

pilot valve plug closes, excess loading pressure bleeds

to the downstream system through the pilot bleed

restriction. At the same time, decreased downstream

demand increases the downstream pressure

registered on the main valve piston(s). This allows

the main valve spring to close the main valve plug,

reducing flow to the downstream system in response

to the decreased demand.

With a pressure-loaded or on-off pilot, the operation is

the same as for a standard pilot except that the pilot

control spring force on the pilot valve plug is aided

by pneumatic pressure from the loading device or

solenoid valve.

Safety Override Pilot Principle of Operation

Once placed in operation, the upstream Type 6492H

or 6492HT pilot senses the intermediate pressure

between both valves, and the Type 6492HM or

6492HTM pilot senses downstream pressure of

the second valve. As demand for flow increases,

intermediate pressure will fall causing the Type 6492H

or 6492HT pilot to open. As the Type 6492H pilot

valve opens, loading pressure to the main valve

increases, opening the main valve.

The Type 6492HM or 6492HTM safety override

pilot remains open because its setpoint is above

the setpoint of the downstream valve. In the

unlikely event that the downstream valve fails open,

downstream pressure will rise above the downstream

valve’s setpoint.

This pressure is sensed by the Type 6492HM or

6492HTM safety override pilot. As downstream

pressure increases the safety override pilot closes,

reducing loading pressure to the main valve, which

positions the main valve to maintain downstream

pressure as specied per ASME Boiler and Pressure

Vessel Code, Section VIII.

In the event that the upstream valve fails, the

downstream regulator will prevent downstream

pressure from rising above safe operating levels.

It is recommended to install some type of warning

system, such as a sentinel relief valve, to warn the

operator that a valve has failed in the system. This

will prevent prolonged operation with one valve, which

could cause valve trim wear and noise associated with

operation at high di󰀨erential pressures.

When operating in most steam systems, valve

setpoints should be in strict accordance to ASME

Boiler and Pressure Vessel Code, Section VIII. The

Type 6492HM or 6492HTM safety override pilot should

be set at 10 psig / 0.69 bar or 10% above maximum

downstream operating pressure of the second valve,

whichever pressure is greater. For example, most

HVAC systems operate at 15 psig / 1.0 bar, so the

safety override pilot should be set no higher than

25 psig / 1.7 bar.

Installation

▲ WARNING

Personal injury, equipment damage

or leakage due to escaping steam or

bursting of pressure-containing parts

may result if this regulator is over

pressured or is installed where service

conditions could exceed the limits given

in the Specification section and on

the appropriate nameplates, or where

conditions exceed any ratings of the

adjacent piping or piping connections.

To avoid such injury or damage, provide

pressure-relieving or pressure-limiting

devices to prevent service conditions

from exceeding those limits.

Additionally, physical damage to the

regulator could result in personal injury

and property damage due to escaping

steam. To avoid such injury and damage,

install the regulator in a safe location.

Type 92S

16A7958-B

A2607-1

16A7958-B

16A1547-A

A3334

CONTROL LINE

CONNECTION CONTROL LINE

SHUTOFF VALVE

STRAINER

BLOCK

VALVE

VENT VALVE

BYPASS LINE

BLOC VALVE

AIR LOADING

REGULATOR

NEEDLE

VALVE

BLEED RESTRICTION (REQUIRED

ONLY IF THE LOADING REGULATOR

DOES NOT HAVE INTERNAL RELIEF)

STRAINER

CONTROL LINE

CONNECTION

CONTROL LINE

SHUTOFF VALVE

BLOCK

VALVE

BYPASS

LINE

BLOCK

VALVE

VENT

VALVE

WITH STANDARD PILOT

WITH PRESSURE-LOADED PILOT

6492 SERIES PILOT

TYPE 92S MAIN VALVE

TYPE 6492H PILOT

TYPE 92S MAIN VALVE

TYPE 6492H PILOT

TOP VIEW

TYPE 6492H PILOT

TYPE 92S MAIN VALVE

TYPE 6492H PILOT

TYPE 92S MAIN VALVE

TYPE 6492HM SAFETY

OVERRIDE PILOT

SIDE VIEW

Figure 3. Typical Installations

Type 92S

E0662

TYPE 6492H PILOT

TYPE 92S MAIN VALVE TYPE 92S MAIN VALVE

TYPE 6492HM SAFETY

OVERRIDE PILOT

TYPE 92S MAIN VALVE

TYPE 6492H PILOT

SIDE VIEW

BOTTOM VIEW

Figure 3. Typical Installations (continued)

BLOCK VALVE

GAUGE

TYPE 92S MAIN VALVE

TYPE 6492HM SAFETY

OVERRIDE PILOT

TYPE 6492H PILOT

GAUGE

BLOCK VALVE

GAUGE

BLOCK VALVE

NPS 1, 1-1/2 AND 2 / DN 25, 40 AND 50 BODY SIZES SAFETY OVERRIDE PIPING SCHEMATICS

Type 92S

E0663

BLOCK VALVE

TYPE 6492H PILOT

TYPE 92S MAIN VALVE

GAUGE GAUGE GAUGE

TYPE 6492H PILOT

TYPE 6492HM SAFETY

OVERRIDE PILOT

NPS 2-1/2, 3 AND 4 / DN 65, 80 AND 100 BODY SIZES SAFETY OVERRIDE PIPING SCHEMATICS

Figure 3. Typical Installations (continued)

BLOCK VALVE

1. Only personnel qualified through training and

experience should install, operate and maintain

a Type 92S regulator. Before installation, make

sure that there is no damage to, or debris in the

regulator. Also make sure that all tubing and piping

are clean and unobstructed.

2. A Type 92S regulator may be installed in any

orientation, as long as flow through the regulator

matches the direction of the arrow on the main

valve body. However, the regulator should not be

installed in a tall, vertical pipeline where condensate

could collect and create a pressure head affecting

regulator performance.

3. Apply steam-compatible pipe compound to

the external pipeline threads for a threaded

body, or use suitable line gaskets for a flanged

body. Use acceptable piping procedures when

installing regulator.

4. If continuous operation of the system is required

during inspection and maintenance, install a

three-valve bypass around the regulator. If the

flowing medium contains solids, install a properly

sized strainer upstream of the regulator.

Note

A clogged vent on the spring case of

a standard Type 6492H or 6492L pilot

may cause the regulator to function

improperly. Install and maintain a

regulator with a standard pilot so that

the spring case vent stays clear.

5. As shown in Figure 3, connect a control line as

large as possible but no smaller than 3/8 in. /

9.5 mm diameter bushed down to the 1/4 NPT

connection in the cylinder spacer NPS 1, 1-1/2

or 2 / DN 25, 40 or 50 body size or the pilot body

NPS 2-1/2, 3, 4 or 6 x 4 / DN 65, 80, 100 or 150 x

100 body size.

6. Locate the control line connection at least

10 pipe diameters away from the regulator or

swage and in a section of straight pipe.

7. Do not locate the control line connection in a gate,

plug or check valve, in an elbow, swage or other

area of the pipeline where turbulence or abnormal

velocities may occur or in a large-volume vessel

that can cause noticeable control lag.

8. Slope the control line away from the pilot to let

condensate drain into the pipeline.

9. Install a shutoff valve (not a needle valve) in the

control line to isolate the pilot during maintenance.

10. Install a pressure gauge in the control line, or near

the regulator, to aid in setting the outlet pressure.

11. With a pressure-loaded or on-off pilot, connect the

pressure-loading or on-off piping or tubing to the

1/4 NPT connection in the tapped pilot spring case.

12. The pressure setting of the regulator is

determined by:

• The pilot control spring adjustment on a

standard pilot, or

Type 92S

*Regulator Technologies recommends establishing setpoint by tightening the adjusting screw.

• The pressure-loading device in conjunction with

the control spring adjustment on a pressure-

loaded pilot. In both cases, check these settings

to make sure they are correct for the application.

Startup and Adjustment

Note

The maximum inlet pressure for a

specic construction is stamped on the

main valve nameplate. Use pressure

gauges to monitor upstream and

downstream pressures during startup.

Adjustment

On a regulator with any kind of Type 6492L, 6492H

or 6492HT pilot, loosen the hex nut (key 16, Figure 4).

Turn the adjusting screw (key 15, Figure 4) clockwise

or into the spring case to increase the downstream

pressure. Turn the adjusting screw counterclockwise

or out of the spring case to decrease the downstream

pressure. When the required downstream pressure is

maintained for several minutes, tighten the hex nut to

lock the adjusting screw in position.

On a regulator with a pressure-loaded Type 6492L,

6492H or 6492HT pilot, also refer to the instruction

manual of the pressure-loading device for downstream

pressure adjustment procedures. Make sure that the

combined pilot control spring setting pressure and

spring case loading pressure do not exceed 25 psig /

1.7 bar for the Type 6492L pilot, 150 psig / 10.3 bar

for the Type 6492H pilot, or 25 psig / 17.2 bar for the

Type 6492HT. For example, a 5 psig / 0.34 bar spring

setting and a 10 psig / 0.69 bar pressure loading result

in a regulator pressure of 15 psig / 1.0 bar.

Safety Override Pilot Startup

and Adjustment

1. Loosen adjusting screws of the Type 6492HM

or 6492HTM safety override pilot and Type 6492H

or 6492HT intermediate pilot on the upstream

valve until there is no spring load. The screws

should turn freely by hand.

2. Loosen the adjusting screw of the Type 6492H

or 6492HT pilot on the downstream valve until there

is no spring load.

3. Tighten the Type 6492HM or 6492HTM safety

override pilot of the upstream valve all the way in to

its highest spring setting.

4. Tighten the Type 6492H or 6492HT pilot of

the upstream valve all the way in to its highest

spring setting.

5. Tighten the Type 6492H or 6492HT pilot

of the downstream valve to the desired

downstream pressure.

6.* Loosen the Type 6492H or 6492HT

intermediate pilot on the upstream valve to the

desired intermediate pressure (normally 50% of

inlet pressure).

7. Loosen the Type 6492HM or 6492HTM safety

override pilot of the upstream valve until there is

no spring load.

8. Tighten the Type 6492H or 6492HT pilot of the

downstream valve all the way in to its highest

spring setting.

9. Tighten the Type 6492HM or 6492HTM safety

override pilot of the upstream valve to desired

pressure as specified per ASME Boiler and

Pressure Vessel Code, Section VIII.

10.* Loosen the Type 6492H or 6492HT pilot of the

downstream valve to the desired downstream

pressure setpoint.

Startup with New Regulator Installation

1. Remove all pilot control spring compression by

turning the adjusting screw out of the spring case

according to the adjustment procedure.

2. Slowly open the upstream block valve.

3. Open the downstream block valve.

4. Open the control line shutoff valve.

Note

Before finally adjusting the pilot setting,

allow enough time for the pilot and

main valve to heat up and boil off any

condensate buildup.

5. If a bypass is used, slowly close the bypass line

block valve.

6. Perform the adjustment procedure until the

downstream pressure reaches the desired setting.

Type 92S

Startup with Existing Regulator

Installation After Normal Shutdown

1. Open the upstream and downstream block valves

and let the regulator take over control at the

existing pilot control spring setting.

2. If a bypass line is used, slowly control the bypass

line block valve.

Shutdown

1. If a bypass line is used, slowly open the

bypass line block valve while monitoring the

downstream pressure.

2. Close the control line shutoff valve.

3. Close the downstream block valve.

4. Close the upstream block valve.

5. If a pressure-loaded or on-off pilot is used, close

the needle valve to the pilot.

6. Vent the regulator and control line to release any

trapped pressure.

Maintenance

Regulator parts are subject to normal wear and

must be inspected periodically and replaced

as necessary. The frequency of inspection

and replacement depends upon the severity of

service conditions and upon applicable codes and

government regulations.

▲ WARNING

To avoid personal injury resulting

from sudden release of pressure,

isolate the regulator from all pressure

and cautiously release trapped

pressure from the regulator before

attempting disassembly.

Types 6492L, 6492H, 6492HT, 6492HM

and 6492HTM Pilots

These procedures are to be performed if inspecting,

cleaning, or replacing any pilot parts, or if cycling,

erratic control, or too high or too low an outlet

(control) pressure is noted. Perform only those

procedures in this section required to correct the

problem. Refer to Figure 4 for key numbers unless

otherwise noted.

Note

Before performing any maintenance,

loosen the hex nut (key 16), if used,

and turn the adjusting screw (key 15) or

handwheel (key 38) counterclockwise

until all compression is removed from

the control spring (key 12). Remove

the pilot from the pipe nipple and

connectors (keys 82 and 83, Figure 6).

1. Unscrew the valve guide (key 2). Remove the

screen (key 77), inner valve (key 4), valve spring

(key 3) and stem (key 7). Unscrew the seat ring

(key 5). Examine the seat ring and plug seating

surfaces for damage.

2. Clean and replace parts as necessary. Apply

sealant to the seat ring threads. Thread the seat

ring into place and tighten it to between 19 and

25 ft-lbs / 26 and 34 N•m of torque.

3. Handle the parts carefully and place the valve

spring (key 3) in the valve guide (key 2). Slide the

inner valve (key 4) over the spring and into the

valve guide. Place the screen (key 77) onto the

valve guide. Place the stem (key 7) in the center

hole of the valve guide. Apply sealant to the valve

guide threads and screw the guide plus attached

parts into the body (key 1).

4. Remove the pipe plug (key 74). Then remove

the bleed restriction (key 76) on Types 6492L,

6492H and 6492HT or the pipe plug (key 94) on

Types 6492HM and 6492HTM. Clean and replace

the bleed restriction or pipe plug as necessary.

5. Apply sealant to the threads of the bleed restriction

(key 76) or pipe plug (key 94) and install.

6. Apply sealant to the threads of the pipe plug

(key 74). Thread the pipe plug into place and tighten

using 5 to 15 ft-lbs / 7 to 20 N•m of torque.

7. Remove the cap screws (key 17), spring case

(key 14), control spring (key 12) and upper spring

seat (key 13) from the body.

8. Remove the lower spring seat (key 11, Types 6492H

and 6492HT pilots only) or diaphragm plate

assembly (key 24, Type 6492L pilot only),

diaphragms (key 10) and diaphragm gasket

(key 18) from the body. Inspect and clean the

diaphragm gasket and replace if necessary.

9. Unscrew the bellows retainer (key 8) and remove

the bellows (key 9). Replace worn parts as

necessary, and install the bellows and bellows

retainer. Tighten the bellows retainer to between

19 and 25 ft-lbs / 26 and 34 N•m.

Type 92S

10. Install the diaphragm gasket. Install both

diaphragms with their raised preformed centers

facing toward the spring case.

11. Lubricate the upper spring seat and the

exposed threads of the adjusting screw. Install

the lower spring seat (key 11, Types 6492H

and 6492HT pilots only) or diaphragm plate

assembly (key 24, Type 6492L pilot only), control

spring (key 12), upper spring seat (key 13) and

spring case (key 14). Insert and tighten the cap

screws (key 17) to between 12 and 18 ft-lbs /

16 and 24 N•m of torque, using a crisscross

bolting pattern.

12. When pilot maintenance is complete, refer to

the Startup section to put the regulator back in

operation and adjust the pressure setting.

Type 92S Main Valve

Perform these procedures if replacing the piston(s),

cylinder(s), stem(s), seals, valve plug or seat ring.

All key numbers are referenced in Figure 5 except

where otherwise indicated. Instructions are given for

complete disassembly and assembly. Disassemble

the main valve only as far as necessary to complete

the required maintenance. Then, begin the assembly

procedure at the appropriate step.

Note

The regulator may remain in the pipeline

during maintenance procedures unless

the main valve body is replaced or

removed for repairs.

Whenever a gasket seal is disturbed by

removing or shifting gasketed parts, a

new gasket should be installed upon

reassembly. This is necessary to ensure

a good gasket seal.

Disassembly

1. Disconnect all tubing and remove the pilot from the

main valve.

2. Remove the cap screws (key 3, not shown) from

a cast iron body or stud nuts (key 4) from a steel

body, and lift off the body flange.

3. For NPS 1, 1-1/2 and 2 / DN 25, 40 and 50

body sizes, remove the top cylinder (key 17),

and pull out the top piston with attached stem

and other parts. Remove the hex nut (key 41),

lockwasher (key 40), top ring retainer (key 26)

and top piston ring (key 25) from the top piston

(key 24).

4. For NPS 1, 1-1/2 and 2 / DN 25, 40 and 50

body sizes, lift off the cylinder spacer (key 21), and

remove the stem seal retainer (key 23) and stem

seal (key 22) from the spacer.

5. Remove the cylinder (key 17), piston (key 24) with

attached parts and spiral wound gasket (key 8).

6. Remove the cotter pin (key 16, NPS 1, 1-1/2

and 2 / DN 25, 40 and 50 body sizes only), stem

nut (key 15), lower stem (key 9) with hex head,

valve plug (key 6), piston ring retainer (key 26),

piston ring (key 25), bottom piston ring retainer

(key 26, applicable for all sizes), piston (key 24),

spring (key 12), piston spacer (key 11), cage

(key 5) and seat ring (key 7).

7. If Noise Attenuation is used, remove the plug

spacer (key 33, NPS 2 / DN 50 body size only),

deflector (key 36, NPS 2 / DN 50 body size only),

and screen (key 37).

8. Either remove the retaining ring (key 14), or

remove the spring seat, washer and O-ring

(keys 32, 34 and 38), if it is necessary to remove

the baffle (key 13).

Assembly

1. Inspect and replace parts as necessary, making

sure that the hollow passage in the upper stem

(key 20, NPS 1, 1-1/2 and 2 / DN 25, 40 and

50 body sizes only) is free from debris.

2. Install a spiral wound gasket (key 8) into the body

(key 1).

3. When installing a new valve plug and/or a new

seat ring or lower stem, lap the seating surfaces

together outside the body. Use a commercial lapping

compound or a mixture of solidified vegetable oil and

600-grit or finer silicon carbide or aluminum oxide.

Note

If a Noise Attenuation is used, install the

screen (key 37), the deflector (key 36,

NPS 2 / DN 50 body size only) and the

plug spacer (key 33, NPS 2 / DN 50 body

size only) where appropriate in the

following step.

4. Secure the hex head at the lower stem (key 9) in a

vise. Install the valve plug (key 6), seat ring (key 7)

and cage (key 5).

For NPS 1, 1-1/2 and 2 / DN 25, 40 and 50 body

sizes, install the baffle (key 13) and the retaining

ring (key 14). Then, install the piston spacer

(key 11) down through the baffle until it makes

contact with the valve plug.

Type 92S

For NPS 2-1/2, 3 and 4 / DN 65, 80 and 100 body

sizes, install the plug spacer (key 33), baffle

(key 13), O-ring, washer, spring seat and piston

spacer (keys 38, 34, 32 and 11). Then, install the

cylinder (key 17), spring (key 12) and secure with

piston (key 24), piston ring (key 25), with its open

end pointing out, piston ring retainer (key 26) and

stem nut (key 15).

For the NPS 1, 1-1/2 and 2 / DN 25, 40 and

50 body sizes, lock the stem nut (key 15) in place

with a cotter pin (key 16), but do not fold the pin

ends up on top of the stem since this can interfere

with loading pressure registration through the top

stem passage.

5. Install the main piston cage assembly with

attached parts into the body. Coat the edge of the

main cylinder (key 17) with sealant and install a

new cylinder gasket (key 18) onto this edge.

6. Install a new body gasket (key 19) onto the

appropriate edge of the body.

7. For NPS 1, 1-1/2 and 2 / DN 25, 40 and 50

body sizes, install the stem seal (key 22) onto the

cylinder spacer (key 21) in the orientation shown

in Figure 5, and secure with the stem seal retainer

(key 23). Coat the serrated edge of the spacer

with sealant and install the spacer edge-side-down

over the bottom cylinder.

8. For NPS 1, 1-1/2 and 2 / DN 25, 40 and 50 body

sizes, coat both serrated edges of the top cylinder

(key 17) with sealant, install new cylinder gaskets

(key 18) on these edges and install the cylinder.

9. For NPS 1, 1-1/2 and 2 / DN 25, 40 and 50 body

sizes, install the top piston ring (key 25) with its

open end pointing out, ring retainer (key 26) and

stem (key 20) on the top piston. Secure these

parts with the lockwasher and hex nut (keys 40

and 41). Install the top piston plus attached parts

stem-first through the stem seal until the top stem

contacts the bottom stem.

10. Install the body flange (key 2) on the body, and

secure with the cap screws (key 3, not shown) for

a cast iron body or with the stud nuts (key 4) for a

steel body.

11. Install the pilot and connect all tubing as shown in

Figure 6.

12. When all maintenance is complete, refer to the

Start-up section to put the regulator back into

operation and adjust the pressure setting.

Parts Ordering

The type number, orifice size, spring range and date of

manufacture are stamped on the nameplate. Always

provide this information in any correspondence with

your local Sales Office regarding replacement parts or

technical assistance.

When ordering replacement parts, reference the key

number of each needed part as found in the following

parts list. Separate kit containing all recommended

spare parts is available.

Parts List

Types 6492L, 6492H and 6492HT Pilots

(Figure 4)

Key Description Part Number

Repair Kits (included are keys 4, 5, 7, 8, 9,

10 and 18)

Type 6492L pilot R6492LX0012

Types 6492H and 6492HT pilots R6492HX0012

1 Body

Cast iron

Type 6492L pilot 32A0404X012

Type 6492H pilot 22A0403X012

Steel

Type 6492L pilot 32A0404X052

Types 6492H and 6495HT pilots 22A0403X052

Stainless steel

Type 6492L pilot 32A0404X062

Types 6492H and 6492HT pilots 22A0403X072

2 Valve Guide, Stainless steel

For Cast iron and Steel bodies 1E391835132

For Stainless steel body 1E391835072

3 Valve Spring, Stainless steel 1E392437022

4* Inner Valve, Stainless steel

For Cast iron and Steel bodies 1F967446172

For Stainless steel body 1F9674X0012

5* Orice, Stainless steel

For Cast iron and Steel bodies 1H564446172

For Stainless steel body 1H5644X0012

7* Valve Stem, Stainless steel

For Cast iron and Steel bodies 1F967835132

For Stainless steel body 1F9678X0012

8* Bellows Retainer

For Cast iron and Steel bodies, Brass 1F971214012

For Stainless steel body, Stainless steel 1F9712X0012

9* Bellows

For Cast iron and Steel bodies, Brass 1F971318992

For Stainless steel body, Stainless steel 1F9713X0012

10* Diaphragm, Stainless steel (2 required)

Type 6492L pilot ERCA00490A0

Types 6492H and 6492HT pilots ERCA00459A0

11 Lower Spring Seat

(Types 6492H and 6492HT pilots only)

Type 6492H, Aluminum 1J9140X0032

Type 6492HT, Steel

Steel body 1J9140X0022

Stainless steel body 14B9948X012

*Recommended spare parts

Type 92S

Types 6492L, 6492H and 6492HT

Pilots (Figure 4) (continued)

Key Description Part Number

12 Control Spring, Plated steel

(see Table 1 for outlet pressure ranges)

Yellow 1E395627022

Green 1D7455T0012

Red 1E395727192

13 Upper Spring Seat, Plated steel

Cast iron and Steel bodies 1D667125072

Stainless steel body 14B9951X012

14 Spring Case

Standard Cast iron

Type 6492L pilot 3J496319012

Type 6492H pilot 2J496219012

Tapped Cast iron

Type 6492L pilot 3L442119012

Type 6492H pilot 2L441919012

Standard Steel

Type 6492L pilot 3L416122012

Types 6492H and 6492HT pilots 2L416322012

Tapped Steel

Type 6492L pilot 3L442222012

Types 6492H and 6492HT pilots 2L442022012

Standard Stainless steel

Type 6492L pilot 3L4161X0022

Types 6492H and 6492HT pilots 2L416333092

Tapped Stainless steel

Type 6492L pilot 3L4422X0012

Types 6492H and 6492HT pilots 2L4420X0012

15 Adjusting Screw (standard spring case only),

Zinc-plated steel

Standard 1D995448702

Handwheel 1J496428982

16 Hex Nut (standard spring case only),

Zinc-plated steel 1A353724122

17 Cap Screw, Steel, Plate

(10 required for Type 6492L pilot and

8 required for Types 6492H and 6492HT pilots)

Type 6492L

Cast iron and Steel bodies 1A381624052

Stainless steel 1A3816X0152

Type 6492H

Cast iron and Steel bodies 1A381624052

Stainless steel 1A3816X0152

Type 6492HT

Steel 1A3816X0242

Stainless steel 1A3816X0152

18* Diaphragm Gasket

Type 6492L pilot, Composition 1E397004022

Type 6492H pilot ERCA00485A0

Type 6492HT, Graphite ERCA00485A1

24 Diaphragm Plate Assembly, Aluminum/Steel/

Stainless steel (Type 6492L pilot only) 1E3967X0012

74 Pipe Plug, Steel 0Z020128992

76 Bleed Restriction, Stainless steel 19A2612X012

77 Screen, Stainless steel 16A1512X012

78 Reducing Bushing,

Cast iron and Steel bodies, steel 1C379026232

Stainless steel body, Stainless steel 1C3790X0012

87 Sealing Washer, Carbon steel

(tapped spring case only) 1V205699012

Types 6492HM and 6492HTM Safety

Override Pilots (Figure 4)

Key Description Part Number

1 Pilot Valve Body

Steel 22A0403X052

Stainless steel 22A0403X072

2 Valve Guide

Steel 1E391835132

Stainless steel 1E391835072

3 Valve Spring, Stainless steel 1E392437022

4 Inner Valve

Steel 1F967446172

Stainless steel 1F9674X0012

5 Orice

Steel 1H564446172

Stainless steel 1H5644X0012

7 Valve Stem

Steel 1F967835132

Stainless steel 1F9678X0012

8 Bellows Retainer

Steel 1F971214012

Stainless steel 1F9712X0012

9 Bellows

Steel 1F971318992

Stainless steel 1F9713X0012

10 Diaphragm, Stainless steel (2 required) ERCA00459A0

11 Lower Spring Seat, Aluminum

Type 6492HM 1J9140X0032

Type 6492HTM

Steel 1J9140X0022

Stainless steel 14B9948X012

12 Spring

Type 6492HM, Steel

10 to 30 psig / 0.69 to 2.1 bar, Yellow 1E395627022

25 to 75 psig / 1.72 to 5.2 bar, Green 1D7455T0012

70 to 150 psig / 4.8 to 10.3 bar, Red 1E395727192

Type 6492HTM, Stainless steel

15 to 100 psig / 1.0 to 6.9 bar, Unpainted 14B9943X012

80 to 250 psig / 5.5 to 17.2 bar, Unpainted 14B9942X022

13 Upper Spring Seat

Type 6492HM, Zinc-plated steel 1D667125072

Type 6492HTM, Carbon-plated steel 14B9951X012

14 Spring Case

Steel

With standard adjusting screw 2L416322012

With sealed adjusting screw 2L442022012

Stainless steel

With standard adjusting screw 2L416333092

With sealed adjusting screw 2L4420X0012

15 Set Screw, Zinc-plated steel

Standard 1D995448702

Handwheel 1J496428982

Sealed Adjusting screw 1D995448702

16 Hex Nut, Zinc-plated steel 1A353724122

17 Cap Screw (8 required)

Type 6492HM

Steel 1A381624052

Stainless steel 1A3816X0152

Type 6492HTM

Steel 1A3816X0242

Stainless steel 1A3816X0152

18* Diaphragm Gasket

Type 6492HM, Composition ERCA00485A0

Type 6492HTM, Graphite ERCA00485A1

34 Machine Screw for use with Handwheel,

Carbon-plated steel 16A5763X012

*Recommended spare parts

Type 92S

Types 6492HM and 6492HTM Safety

Override Pilots (Figure 4) (continued)

Key Description Part Number

38 Handwheel 1J496144012

39 Lock Washer for use with Handwheel, Alloy steel 1A352332992

74 Pipe Plug

Steel 0Z020128992

Stainless steel 0Z020135072

77 Screen, Stainless steel 16A1512X012

78 Reducing Bushing

Steel 1C379026232

Stainless steel 1C3790X0012

87 Sealed Adjusting Screw Sealing Washer 1V205699012

94 Pipe Plug, Stainless steel 1E823135042

95 Warning Label 19B0429X0A2

Types 6492HM and 6492HTM Safety Pilot

Mounting Parts (Figure 6)

Key Description Part Number

81 Tubing, Stainless steel (2 required) - - - - - - - - - - -

82 Pipe Nipple

NPS 1, 1-1/2 or 2 / DN 25, 40 or 50 body size

Steel - - - - - - - - - - -