Fisher 1098-EGR User manual

Types 1098-EGR and 1098H-EGR
D100339X012
Instruction Manual
Form 5084
December 2008
www.emersonprocess.com/regulators
Types 1098-EGR and 1098H-EGR Pressure
Reducing Regulators
!
WARNING
Failure to follow these instructions or
to properly install and maintain this
equipment could result in an explosion,

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 Fisher 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

personnel may result in improper
adjustment and unsafe operation. Either
condition may result in equipment

personnel when installing, operating,
and maintaining the Types 1098-EGR and
1098H-EGR pressure reducing regulator.
Introduction
Scope of Manual
This manual describes and provides instructions
and parts list for Type 1098-EGR or 1098H-EGR
regulator complete with a standard P590 Series
lter and either a 6350 Series regulator, a 61 Series
pilot, or a Type Y600AM Pilot. The Type 1806 relief
valve is also covered when a 61 Series pilot is used.
Instructions and parts lists for monitoring pilots and
other equipment used with this regulator are found in
separate manuals.
Figure 1. Type 1098-EGR
W6956
Description
Types 1098-EGR and 1098H-EGR regulators provide
economical and accurate pressure control in a
wide variety of applications; natural gas distribution
systems; fuel gas supply to industrial boilers, furnaces,
ovens, and mixers; and large commercial/industrial
establishments such as shopping centers and schools.
They are also used in plant air service and in liquid
service where a slow stroking time (approximately
30 to 90 seconds) is desired on both opening and
closing the main valve.

The Specications section lists pressure limitations
and other specications for various Types 1098-EGR
and 1098H-EGR constructions. Specications for a
given regulator as it originally comes from the factory
are stamped on nameplates located on both the

Types 1098-EGR and 1098H-EGR
2
Body Sizes and End Connection Styles
See Table 1
Main Valve Maximum Inlet Pressure(1)
400 psig (27,6 bar) or body rating limit whichever
is lower
Maximum Pilot Supply Pressure(1,2)
600 psig (41,4 bar)
Outlet Pressure Ranges
See Table 2
Maximum and Minimum Differential Pressures
See Table 4
Actuator Sizes and Maximum Pressures
See Table 3
Main Valve Flow Characteristic
Linear (standard) or Quick opening
1. The pressure/temperature limits in this instruction manual or any applicable standard limitation should not be exceeded.
2. For stability or overpressure protection, a reducing regulator may be installed upstream of the pilot according to the Installation section.

Main Valve Flow Direction
In through the seat ring and out through the cage
Pressure Registration
External
Material Temperature Capabilities(2)
Nitrile (NBR):
-20° to 180°F (-29° to 82°C)
Fluorocarbon (FKM):
0° to 300°F (-18° to 149°C),
Water is limited to 0° to 180°F (-18° to 82°C)
Ethylenepropylene (EPR):
-20° to 275°F (-29° to 135°C)
Options
• NACE Construction
• Boiler Fuel Construction
• Aqueous Service Construction
• Monitor Conguration
• Noise Abatement Trim
BODY SIZE,
INCHES (DN) CAST IRON STEEL OR STAINLESS STEEL
1 or 2
(25 or 50) NPT, CL125 FF, or CL250 RF NPT, CL150 RF, CL300 RF, CL600 RF, BWE, SWE, or PN 16/25/40
3, 4, or 6
(80, 100 or 150) CL125 FF or CL250 RF CL150 RF, CL300 RF, CL600 RF, BWE, or PN 16/25/40
8 x 6 or 12 x 6
(200 x 150 or 300 x 150) - - - - CL150 RF, CL300 RF, CL600 RF, BWE, or PN 16/25/40
Table 1. Body Sizes and End Connection Styles
PILOT TYPE OUTLET (CONTROL) PRESSURE RANGES SPRING COLOR SPRING PART NUMBER
6351
3 to 20 psig
5 to 35 psig
35 to 100 psig
(0,21 to 1,4 bar)
(0,34 to 2,4 bar)
(2,4 to 6,9 bar)
Green
Silver
Red
1B986027212
1B788327022
1K748527202
6352 14-inches w.c. to 2 psig
2 to 10 psig
(35 mbar to 0,14 bar)
(0,14 to 0,69 bar)
Yellow
Black
14A9672X012
14A9673X012
6353 3 to 40 psig
35 to 125 psig
(0,21 to 2,8 bar)
(2,4 to 8,6 bar)
Yellow
Red
1E392527022
1K748527202
6354L(1)
6354M(2)
6354H
85 to 200 psig
175 to 220 psig
200 to 300 psig
(5,9 to 13,8 bar)(1)
(12,1 to 15,2 bar)(2)
(13,8 to 20,7 bar)(2)
Blue
Blue
Green
1L346127142
1L346127142
15A9258X012
61L
61LD
61LE
0.25 to 2 psig
1 to 5 psig
2 to 10 psig
5 to 15 psig
10 to 20 psig
(0,02 to 0,14 bar)
(0,07 to 0,34 bar)
(0,14 to 0,69 bar)
(0,34 to 1,0 bar)
(0,69 to 1,4 bar)
Red
Yellow
Blue
Brown
Green
1B886327022
1J857827022
1B886427022
1J857927142
1B886527022
61H 10 to 65 psig (0,69 to 4,5 bar) Green Stripe 0Y066427022
61HP
15 to 45 psig
35 to 100 psig
100 to 300 psig
(1,0 to 3,1 bar)
(2,4 to 6,9 bar)
(6,9 to 20,7 bar)
Yellow
Blue
Red
1E392527022
1D387227022
1D465127142
Y600AM
4 to 8-inches w.c.
7 to 16-inches w.c.
15-inches w.c. to 1.2 psig
1.2 to 2.5 psig
2.5 to 4.5 psig
4.5 to 7 psig
(10 to 20 mbar)
(17 to 40 mbar)
(37 mbar to 0,08 bar)
(0,83 to 0,17 bar)
(0,17 to 0,31 bar)
(0,31 to 0,48 bar)
Red
Olive Drab
Yellow
Light Green
Light Blue
Black
1B653827052
1B653927022
1B537027052
1B537127022
1B537227022
1B537327052
1. Without diaphragm limiter.
2. With diaphragm limiter.
Table 2. Outlet Pressure Ranges

Types 1098-EGR and 1098H-EGR
3
ACTUATOR OUTLET (CONTROL) PRESSURE, PSIG (bar) EMERGENCY CASING PRESSURE, PSIG (bar)
Type Size
1098
30
40 (standard)
70
100 (6,9)
75 (5,2)
50 (3,5)
115 (7,9)
82 (5,7)
65 (4,5)
1098H 30 300 (20,7) 400 (27,6)
Table 3. Actuator Sizes and Maximum Pressures
Table 4. Maximum and Minimum Differential Pressures for Main Valve Selection
BODY SIZE,
INCHES (DN)
SPRING PART
NUMBER AND COLOR
MAXIMUM ALLOWABLE DIFFERENTIAL
PRESSURE, PSIG (bar)(1)
MINIMUM DIFFERENTIAL PRESSURE REQUIRED
FOR FULL STROKE, PSIG (bar)
Size 30 Actuator Size 40 Actuator Size 70 Actuator
1 (25)
14A9687X012 Green 60 (4,1) 3.5 (0,24) 2.5 (0,17) 1 (0,07)
14A9680X012 Blue 125 (8,6) 5 (0,34) 4 (0,28) 1.5 (0,10)
14A9679X012 Red 400 (27,6) or body rating limit, whichever is lower 7 (0,48) 5 (0,34) 2.5 (0,17)
2 (50)
14A6768X012 Yellow 20 (1,4) - - - - 2 (0,14) 1 (0,07)
14A6626X012 Green 60 (4,1) 4 (0,28) 3 (0,21) 1.5 (0,10)
14A6627X012 Blue 125 (8,6) 6 (0,41) 5 (0,34) 2 (0,14)
14A6628X012 Red 400 (27,6) or body rating limit, whichever is lower 11 (0,76) 10 (0,69) 3 (0,21)
3 (80)
14A6771X012 Yellow 20 (1,4) - - - - 2.5 (0,17) 1 (0,07)
14A6629X012 Green 60 (4,1) 5 (0,34) 4 (0,28) 2 (0,14)
14A6630X012 Blue 125 (8,6) 8 (0,55) 6 (0,41) 2.5 (0,17)
14A6631X012 Red 400 (27,6) or body rating limit, whichever is lower 14 (0,97) 11 (0,76) 4 (0,28)
4 (100)
14A6770X012 Yellow 20 (1,4) - - - - 3.5 (0,24) 1.3 (0,09)
14A6632X012 Green 60 (4,1) 10 (0,69) 5 (0,34) 2.5 (0,17)
14A6633X012 Blue 125 (8,6) 13 (0,90) 8 (0,55) 3 (0,21)
14A6634X012 Red 400 (27,6) or body rating limit, whichever is lower 22 (1,5) 13 (0,90) 5 (0,34)
6, 8 x 6, and 12 x 6
(150, 200 x 150,
and 300 x 150)
15A2253X012 Yellow 20 (1,4) - - - - 6 (0,41) 2.2 (0,15)
14A9686X012 Green 60 (4,1) 13 (0,90) 9.5 (0,66) 4 (0,28)
14A9685X012 Blue 125 (8,6) 19 (1,3) 14 (0,97) 6 (0,41)
15A2615X012 Red 400 (27,6) or body rating limit, whichever is lower 28 (1,9)(2) 19 (1,3) 8 (0,55)
1. Maximum inlet pressure is equal to set pressure plus maximum differential.
2. Requires special 6300 Series pilot construction without integral relief valve and with external Type 1806 40 psid (2,8 bar d) relief valve.
BODY SIZE,
INCHES (DN)
TYPE EGR
SPRING COLOR
SUPPLY PRESSURE, PSIG (bar)
Type Y600AM Spring Color
Red Olive Drab Yellow Green Light Blue Black
1 (25)
Green
Blue
Red
6
7
8
(0,41)
(0,48)
(0,55)
6
7
8
(0,41)
(0,48)
(0,55)
7
8
9
(0,48)
(0,55)
(0,62)
8
10
11
(0,55)
(0,69)
(0,76)
11
13
14
(0,76)
(0,90)
(0,97)
13
14
15
(0,90)
(0,97)
(1,0)
2 (50)
Green
Blue
Red
6
8
13
(0,41)
(0,55)
(0,90)
6
8
13
(0,41)
(0,55)
(0,90)
7
9
14
(0,48)
(0,62)
(0,97)
9
11
16
(0,62)
(0,76)
(1,1)
12
14
19
(0,83)
(0,97)
(1,3)
13
15
20
(0,90)
(1,0)
(1,4)
3 (80)
Green
Blue
Red
7
9
14
(0,48)
(0,62)
(0,97)
7
9
14
(0,48)
(0,62)
(0,97)
8
10
15
(0,55)
(0,69)
(1,0)
10
12
17
(0,69)
(0,83)
(1,2)
13
15
20
(0,90)
(1,0)
(1,4)
14
16
21
(0,97)
(1,1)
(1,5)
4 (100)
Green
Blue
Red
8
11
16
(0,55)
(0,76)
(1,10)
8
11
16
(0,55)
(0,76)
(1,1)
9
12
17
(0,62)
(0,83)
(1,2)
11
14
19
(0,76)
(0,97)
(1,3)
14
17
22
(0,97)
(1,2)
(1,5
15
18
23
(1,0)
(1,2)
(1,6)
6 (150)
8 X 6 (200)
Green
Blue
Red
13
17
22
(0,90)
(1,17)
(1,5)
13
17
22
(0,90)
(1,2)
(1,5)
14
18
23
(0,97)
(1,2)
(1,6)
15
20
25
(1,0)
(1,4)
(1,8)
18
23
28
(1,2)
(1,6)
(1,9)
20
24
29
(1,4)
(1,6)
(2,0)
1. The pressures shown in the table are the minimum supply pressures required by the pilot. If the inlet pressure is less than shown, an external pilot supply is necessary.
Table 5. Supply Pressure Settings Required for the Type 95H Regulator

Types 1098-EGR and 1098H-EGR
4
Figure 2. Operational Schematics
TYPE 61LD
A6563
TYPE 1806
A6641
TYPE 6351
TYPES 6352,
6353, 6354
6350 SERIES
INLET PRESSURE
INLET PRESSURE
OUTLET PRESSURE
OUTLET PRESSURE
LOADING PRESSURE
LOADING PRESSURE
ATMOSPHERIC PRESSURE
ATMOSPHERIC PRESSURE

Types 1098-EGR and 1098H-EGR
5
Figure 2. Operational Schematics (continued)
DETAIL OF TYPE 1098H ACTUATOR
DETAIL OF OPTIONAL
RESTRICTED CAPACITY CONSTRUCTION
W3161–1*
W3419–1
SCREW-ON
TRAVEL STOP
THREADED
SPRING SEAT
TYPE Y600AM WITH TYPE 95H SUPPLY REGULATOR
INLET PRESSURE
OUTLET PRESSURE
ATMOSPHERIC PRESSURE
LOADING PRESSURE
PILOT SUPPLY PRESSURE
M1008
95 SERIES
TYPE Y600AM
OPTIONAL:
TYPE 112 RESTRICTOR

Types 1098-EGR and 1098H-EGR
6
actuator and main valve body, while the pilot control
spring range is displayed on the pilot spring case, and
the pilot restriction code is stamped on the pilot body
(S = standard gain, L = low gain, and H = high gain).
Principle of Operation
The pilot-operated Types 1098-EGR and 1098H-EGR
regulators both use inlet pressure as the operating
medium, which is reduced through pilot operation to load
the actuator diaphragm. Outlet or downstream pressure
opposes loading pressure in the actuator and also
opposes the pilot control spring. The Type 1098-EGR
regulator operation schematic is shown in Figure 2.
In operation, assume that outlet pressure is below
the pilot control setting. Control spring force on
the pilot diaphragm thus opens the pilot valve plug
providing additional loading pressure to the actuator
diaphragm. This loading pressure forces the actuator
stem forward, opening the main valve plug via a bump
connection. The upward motion of the plug allows gas
to ow through the cage into the downstream system.
When downstream demand has been satised, outlet
pressure tends to increase, acting on the pilot and
actuator diaphragms. This pressure exceeds the pilot
control spring setting, moving the pilot diaphragm away
and letting the valve plug spring (Type 6351, 61 Series, or
Y600AM pilots) or bellows (Types 6352 through
6354M pilots) close the pilot valve plug (unbalanced in the
Type 6351 or 61 Series pilots but balanced in the
Types 6352 through 6354M pilot). Excess loading
pressure on the actuator diaphragm escapes downstream
through the bleed hole (Type 6351 pilot), bleed orice
(61 Series pilot), restriction (Types 6352 through
6354M pilots) or xed restrictor (Type Y600AM pilot).
Reduced actuator loading pressure permits the main
valve to close. The combination of main valve spring
force and valve plug unbalance provides positive valve
plug shutoff against the port and upper seals.
To protect the Type 1098 or 1098H actuator diaphragm
from excessive differential pressure, the 6300 Series
pilots have a relief valve that allows loading pressure to
bleed downstream at approximately 25 psig (1,7 bar)
differential across the actuator diaphragm. An external
relief valve (Type 1806) is required when differential is
higher than 25 psid (1,7 bar d) or when using the
61 or Y600A Series pilots.
40 PSI (2,8 bar) Relief Valve
A mounting assembly for a 40 psi (2,8 bar) differential
relief valve is available for the Type 1098-EGR. The
standard 25 psi (1,7 bar) differential relief valve
construction is integrally mounted between the loading
and downstream pressures in the 6351 through
6354 Series regulating pilots. Both differential relief
valves protect the main regulator diaphragm from
damage that may occur from too high differential
between the loading pressure and downstream pressure.
The 40 psi (2,8 bar) differential relief valve construction
is designed specically for the red main valve spring
selection in the 6-inch (DN 150) Type 1098-EGR-6354
with the size 30 actuator. This construction uses the
Type 1806H relief valve (with a setting of 40 psi
(2,8 bar)) to relieve excess loading pressure and does not
interfere with the normal operation of the regulator.
Installation and Startup
!
WARNING
Personal injury, equipment damage, or
leakage due to escaping accumulated
gas or bursting of pressure-containing
parts may result if this regulator is
overpressured or is installed where
service conditions could exceed the limits

on the appropriate nameplate, 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 may result in personal injury
and property damage due to escaping
accumulated gas. To avoid such injury
and damage, install the regulator in a
safe location.
Standard Single-Pilot Regulator
(Figure 3)
Installations
A Type 1098-EGR or 1098H-EGR regulator bleeds
no gas to the atmosphere, making it suitable for
installation in pits or other enclosed locations without

Types 1098-EGR and 1098H-EGR
7
elaborate venting systems. This regulator can also be
installed in pits subject to ooding by venting the pilot
spring case above the expected ood level so that the
pilot diaphragm is exposed to atmospheric pressure.
Note
Normal pressure drop assists shutoff.
Therefore, leakage may result during any
reverse pressure drop condition.
1. Use qualied personnel when installing, operating,
and maintaining regulators. Before installing,
inspect the main valve, pilot, and tubing for any
shipment damage or foreign material that may
have collected during crating and shipment. Make
certain the body interior is clean and the pipelines
are free of foreign material. Apply pipe compound
only to the male pipe threads with a screwed
body, or use suitable line gaskets and good
bolting practices with a anged body.
With a weld end body, be sure to remove the
trim package, including the gasket, according
to the Maintenance section before welding
the body into the line. Do not install the trim
package until any post-weld heat treatment is
completed. If heat treating, prevent scale
build-up on all machined guiding and sealing
surfaces inside the body and at the bonnet
ange/body joint.
Note


the valve body.
2. Install a three-valve bypass around the regulator
if continuous operation is necessary during
maintenance or inspection. The pilot may be
eld-changed to the opposite-side mounting
position by swapping the pilot pipe nipple to the
opposite bonnet tapping.
!
WARNING
A regulator may vent some gas to
the atmosphere. In hazardous or

accumulate, and cause personal injury,

explosion. Vent a regulator in hazardous
gas service to a remote, safe location
away from air intakes or any hazardous
location. The vent line or stack opening
must be protected against condensation
or clogging.
3. To keep the pilot spring case vent from being
plugged or the spring case from collecting
moisture, corrosive chemicals, or other foreign
material, point the vent down or otherwise protect
it. To remotely vent the standard pilot, remove the
vent and install obstruction-free tubing or piping
into the 1/4-inch NPT vent tapping. Provide
protection on a remote vent by installing a screened
vent cap into the remote end of the vent pipe.
4. Run a 3/8-inch (9,5 mm) outer diameter or
larger pilot supply line from the upstream pipeline
to the lter inlet as shown in Figure 3. Do not
make the upstream pipeline connection in a
turbulent area, such as near a nipple, swage, or
elbow. If the maximum pilot inlet pressure could
exceed the pilot rating, install a separate reducing
regulator in the pilot supply line. Install a hand
valve in the pilot supply line, and provide vent
valves to properly isolate and relieve the pressure
from the regulator.
5. Attach a 1/2-inch NPT downstream pressure
control line downstream of the regulator in a
straight run of pipe, as shown in Figure 3.
Do not make the tap near any elbow, swage, or
nipple that might cause turbulence. Connect
the other end of the control line to the bonnet
connection. Install a hand valve in the control line
to shutoff the control pressure when the bypass is
in use.
6. If a quick acting solenoid is to be installed
downstream of the regulator, the regulator
and solenoid should be located as far apart
as practical. This maximizes the gas piping
volume between the regulator and solenoid
and improves the regulator response to quick
changing ow rates.
7. Consult the appropriate instruction manual for
installation of an optional Type 662 pneumatic
or electric remote control drive unit. For
optional remote pneumatic loading of a
6350 or 61 Series pilot, make the loading piping
connections to the 1/4-inch NPT vent connection.
Prestartup Considerations
Before beginning the startup procedures in this section,
make sure the following conditions are in effect:
• Block valves isolate the regulator.
• Vent valves are closed.
• Hand valves are closed.

Types 1098-EGR and 1098H-EGR
8
CAUTION
Introduce pilot supply pressure into
the regulator before introducing any
downstream pressure, or internal damage
may occur due to reverse pressurization
of the pilot and main valve components.
Always use pressure gauges to monitor downstream
pressure during startup. Procedures used in putting
this regulator into operation must be planned
accordingly if the downstream system is pressurized
by another regulator or by a manual bypass.
Note
For proper operation, pilot supply
pressure must exceed control pressure

the actuator nameplate as minimum
differential pressure.
The only adjustment necessary on a Type 1098-EGR
or 1098H-EGR regulator is the pressure setting of
the pilot control spring. Turning the adjusting screw
clockwise into the spring case increases the spring
compression and pressure setting. Turning the
adjusting screw counterclockwise decreases the spring
compression and pressure setting.
Pilot Adjustment
To adjust standard 6350 Series pilots: loosen the
locknut and turn the adjusting screw. Then tighten
the locknut to maintain the adjustment position. On
a standard Types 6352 through 6354M pilot, a closing
cap must be removed before adjustment and
replaced afterward.
!
WARNING
To avoid possible personal injury from
a pressure-loaded pilot, carefully vent
the spring case before removing the
closing cap. Otherwise, trapped loading
pressure could forcefully eject the freed
closing cap.
To adjust the 61 Series or Type Y600AM pilots:
remove the closing cap and turn the adjusting screw.
Any adjustments made should set the controlled
pressure within the appropriate spring range shown
in the Table 2.
CONTROL LINE
TYPE 1098-EGR OR 1098H-EGR REGULATOR
WITH STANDARD 6350 SERIES PILOT
VENT
FILTER
PILOT
SUPPLY
LINE
1/2-INCH (13 mm)
PIPE
1/2-INCH
(13 mm)
PIPE
TO PILOT LIGHT (IF
USED FOR BOILER
FUEL INSTALLATION)
48A6566-A
B1622
4 MAIN PIPE
DIAMETERS
10 MAIN PIPE DIAMETERS
Figure 3. Standard Single-Pilot Installation

Types 1098-EGR and 1098H-EGR
9
Startup
1. Slowly open the pilot supply line hand valve.
2. Slowly open the upstream block valve and
partially open the downstream block valve for
minimum ow. Slowly open the hand valve in the
control line.
3. Adjust the pilot setting, if necessary.
4. Completely open the downstream block valve.
5. Slowly close the bypass valve, if any.
Dual-Pilot Boiler Fuel Control
Applications
Boiler Fuel Pressure Control
To enhance proper operation and adequate response
to negative pressure shock condition in low differential
pressure boiler fuel control applications, use the
Type 1098-EGR boiler fuel conguration:
• Type 1098-EGR with Type 6352 pilot
• Size 70 Actuator
• Quick Opening Cage
• Yellow Main Spring
• Type Y600AM or 627M Auxiliary Pilot mounted in
parallel with the Type 6352 pilot
To provide faster response, two pilots mounted
in parallel sense downstream pressure. To provide
faster response, two pilots mounted in parallel sense
the downstream pressure. The Type 6352 pilot is
the primary controlling pilot and the Type Y600AM
or 627M auxiliary pilot stands by until it senses a
negative pressure shock condition. The auxiliary
pilot opens, allowing additional ow into the actuator,
increasing the stroking speed and providing faster
response. See Figure 5 for schematic. The quick
opening cage allows maximum capacity at shorter
travels to decrease stroking time in opening and
closing directions. The service conditions should not
exceed 20 psig (1,4 bar) maximum inlet pressure and
10 psid (0,69 bar d) maximum differential pressure.
Figure 4. Typical Dual-Pilot Boiler Fuel Installation
48A6566-A
B1622
TYPE 1098-EGR REGULATOR WITH
STANDARD TYPE 6352 WORKING PILOT
CONTROL
LINE
1/2-INCH
(13 mm)
PIPE
TO PILOT
LIGHT
PILOT
SUPPLY LINE
1/2-INCH
(13 mm)
PIPE VENT
FILTER
TYPE Y600AM
AUXILIARY PILOT
VENT
4 MAIN PIPE DIAMETERS 10 MAIN PIPE DIAMETERS

Types 1098-EGR and 1098H-EGR
10
Supply the boiler pilot light gas with the Type 1098-EGR.
The pilot light gas supply line should branch off the
main fuel line downstream of the Type 1098-EGR and
include a separate regulator to control the nal pilot
light gas pressure, if required (see Figure 5). This
allows the Type 1098-EGR to have its main valve plug
just off the seat waiting for the sudden negative shock
created when the boiler solenoid valve is opened to
light the boiler to the low re load. This installation
practice signicantly increases the stroking speed of
the Type 1098-EGR. See Figure 5 for schematic.
SIZE CONSTRUCTION ORIFICE SPRING RANGES SPRING
NUMBER
SPRING
COLOR
MINIMUM PRESSURE
AT WHICH AUXILIARY
PILOT CAN BE SET
3/4-inch
(19 mm)
Type Y600AM 1/2-inch
(13 mm)
4 to 8-inches w.c. (10 to 20 mbar) 1B653827052 Red
1-inch w.c. (2 mbar) Under
working pilot setpoint
7 to 16-inches w.c. (17 to 40 mbar) 1B653927022 Olive Drab
15-inches w.c. to 1.2 psi (37 mbar to 0,08 bar) 1B537027052 Yellow
Type Y600AM 1/2-inch
(13 mm)
1.2 to 2.5 psi (0,08 to 0,17 bar) 1B537127022 Light Green
0.2 psig (0,01 bar) Under
working pilot setpoint
2.5 to 4.5 psi (0,17 to 0,31 bar) 1B537227022 Light Blue
4.5 to 7 psi (0,31 to 0,48 bar) 1B537327052 Black
Type 627M 1/2-inch
(13 mm) 5 to 10 psi (0,35 to 0,69 bar) 10B3076X012 Yellow 0.3 psig (0,02 bar) Under working pilot setpoint
Table 6. Auxiliary Pilot Selection (Fast Stroke Dual Pilot)
Note
Modulating solenoid load valves provide

one position to the other, effectively
preventing sudden pressure changes in
the system. Alternately, a snap-acting
solenoid valve can be furnished with a
characterized valve plug that, by allowing
maximum capacity to be reached at a
greater proportion of total travel, slows
the action slightly. This action does
not control shock as effectively as
modulating solenoid valves.
Installation
1. Perform the Standard Single-Pilot Regulator
Installation section through step 3, making sure
that the regulator is installed with the actuator
below the main valve as shown in Figure 4.
2. Run a 1/2-inch (13 mm) or larger pilot supply
line from the upstream pipeline to the 1/2-inch
NPT supply connection in the pipe tee as shown
in Figure 4. Do not make the connection in a
turbulent area, such as near a nipple, swage, or
elbow. If the maximum pilot inlet pressure could
exceed the pilot rating, install a separate regulator
in the pilot supply line, and provide vent valves so
that pressure can be properly isolated and relieved
from the regulator.
3. Attach a 1/2-inch NPT downstream
pressure control line ten pipe diameters
downstream of the regulator in a straight run
of pipe. Do not make the tap near any elbow,
swage, or nipple, which might cause turbulence.
E0711
Figure 5. Boiler Fuel Conguration
TYPE 1098-EGR SIZE 70
WITH QUICK OPENING CAGE
20 PSI (1,4 bar) MAXIMUM
TYPE Y600AM
AUXILIARY PILOT
TYPE 6352
WORKING PILOT

Types 1098-EGR and 1098H-EGR
11
Connect the other end of the control line to the
1/4-inch NPT connection in the control
pipe tee as shown in Figure 4. Install a hand
valve in the control line to shutoff the control
pressure when the bypass is in use. Also use
the hand valve to dampen out pulsations, which
may cause instability or cycling of the regulator.
4. Consult the appropriate instruction manual
for installation of an optional pneumatic or
electric remote control drive unit. For optional
remote pneumatic loading of a 6350 or
61 Series pilot, make the loading piping
connections to the 1/4-inch NPT vent connection.
Startup
1. Slowly open the pilot supply line hand valve.
2. Slowly open the upstream block valve and partially
open the downstream block valve for minimum ow.
3. Slowly open the hand valve in the control line
and make sure that the standby pilot is set
far enough below the working pilot so that
the standby pilot remains closed during normal
operation. For example, with nal desired settings
of 11-inches w.c. (27 mbar) for the working pilot
and 10-inches w.c. (25 mbar) for the standby
pilot, begin by reducing the working pilot setting
far enough below 10-inches w.c. (25 mbar) for
the working pilot to shutoff. Then set the standby
pilot for an outlet pressure of 10-inches w.c.
(25 mbar). Finally, set the working pilot for an
outlet pressure of 11-inches w.c. (27 mbar).
Table 6 shows how close the standby pilot can be
set to the working pilot setting.
4. Completely open the downstream block valve.
5. Slowly close the bypass valve, if any.
Working Monitor (Figure 7)
Installation
1. For both working monitor regulator and
working regulator, perform the Standard Single-
Pilot Regulator Installation section through step 6.
2. Connect another downstream pressure control
line and hand valve (Figure 7) to the monitoring
pilot according to the monitoring pilot instruction
manual. Attach a 1/2-inch NPT pressure control
line and hand valve from the intermediate
pressure pipeline to the working monitor regulator.
Pipe supply pressure between the monitoring pilot
and the working monitor regulator according to the
monitoring pilot manual.
For two typical monitoring pilots, Table 7 gives
the spread between normal distribution pressure
and the minimum pressure at which the working
monitor regulator can be set to take over if the
working regulator fails to open.
Startup
SAFTEY SHUTOFF VALVE
TO BOILER
FAST-ACTING
LOAD VALVE
TYPE
1098-EGR
GAS
SUPPLY
PILOT
GAS
SUPPLY
PILOT GAS
REGULATOR
TO PILOT LIGHT
E0710
Figure 6. Boiler Fuel Conguration Installation Guide
MONITORING PILOT INFORMATION MINIMUM PRESSURE AT WHICH
WORKING MONITOR
REGULATOR CAN BE SET
Construction Spring Range Spring Part Number
Type 161AYW and 150 psig (10,3 bar)
maximum allowable pilot inlet
3 to 12-inches w.c.
11 to 25-inches w.c.
(7 to 30 mbar)
(27 to 62 mbar)
1B653927022
1B537027052
3-inches w.c. (7 mbar) over normal
distribution pressure
0.9 to 2.5 psi
2.5 to 4.5 psi
4.5 to 7.0 psi
(0,06 to 0,17 bar)
(0,17 to 0,31 bar)
(0,31 to 0,48 bar)
1B537127022
1B537227022
1B537327052
0.5 psig (0,03 bar) over normal
distribution pressure
Type 627-109 and 150 psig
(10,3 bar) maximum allowable pilot
inlet for cast iron body or 750 psig
(51,7 bar) maximum allowable pilot
inlet for malleable iron or steel body
5 to 20 psig
15 to 40 psig
35 to 80 psig
(0,34 to 1,38 bar)
(1,0 to 2,8 bar)
(2,4 to 5,5 bar)
10B3076X012
10B3077X012
10B3078X012
3.0 psig (0,21 bar) over normal
distribution pressure
70 to 150 psig
130 to 200 psig
(4,8 to 10,3 bar)
(9,0 to 13,8 bar)
10B3079X012
10B3079X012
5.0 psig (0,34 bar) over normal
distribution pressure
Table 7. Working Monitor Performance

Types 1098-EGR and 1098H-EGR
12
On a working monitor installation (Figure 7), be sure
that the second-stage working regulator is set to
operate at a pressure lower than the Type 1098-EGR
or 1098H-EGR working monitor regulator. To do this,
increase the setting of the monitoring pilot until the
working pilot is in control of the intermediate pressure
and the second-stage working regulator is in control
of the downstream pressure. If this is not done,
the monitoring pilot tries to take control of the
downstream pressure.
1. Slowly open the upstream block valve and
the hand valves in both pilot supply lines. This
energizes both pilots so that their setpoints can
be adjusted. Partially open the downstream block
valve for minimum ow.
2. To enable intermediate pressure adjustment with
the working monitor regulator, slowly open the
hand valve in the intermediate pressure control line.
3. To enable downstream pressure adjustment with
the second-stage working regulator, slowly open
the hand valve in the control line to this regulator.
4. Adjust the setting of the monitoring pilot to
establish the desired emergency downstream
pressure, which is to be maintained in the event
of open failure of the second-stage working
regulator. The emergency downstream pressure
should exceed the desired downstream pressure
by at least the amount listed in Table 7. The steps
followed to set the monitoring pilot may vary with
each piping situation; however, the basic method
remains the same. The following sub steps a
and b may be used as examples for setting the
monitoring pilot:
a. Increase the outlet pressure setting of the
second-stage working regulator until the
monitoring pilot takes control of the downstream
pressure. Adjust the monitoring pilot setting
until the desired emergency downstream
pressure is achieved. Then, readjust the second-
stage working regulator to establish the desired
downstream pressure.
b. Install special piping (not shown in
Figure 7) so that the monitoring pilot senses
the intermediate pressure. The intermediate
pressure then appears to the monitoring pilot as
if it were increased downstream pressure,
and the monitoring pilot controls and reduces
the intermediate pressure. Adjust the monitoring
pilot setting until the desired emergency
downstream pressure is achieved at the
intermediate pressure stage. Then slowly
close the special piping, and open up the
monitoring downstream control line for
normal service.
Figure 7. Typical Working Monitor Installation
26A4298-A
A2118-2
UPSTREAM
PRESSURE
VENT VALVE
UPSTREAM
BLOCK VALVE
HAND VALVE
TYPE 161AYW OR 627-109
MONITORING PILOT
TYPE 1098-EGR
OR 1098H-EGR
WORKING
MONITOR
REGULATOR
HAND
VALVE
VENT
VALVE
STANDARD 6350 SERIES PILOT FOR
TYPE 1098-EGR OR 1098H-EGR REGULATOR
SECOND STAGE
REGULATOR
HAND VALVE
VENT VALVE
DOWNSTREAM
BLOCK VALVE
DOWNSTREAM
PRESSURE
HAND VALVE
INTERMEDIATE
PRESSURE
VENT VALVE
WORKING MONITOR

Types 1098-EGR and 1098H-EGR
13
5. Slowly open the downstream block valve.
6. Slowly close the bypass valve, if any.
NOTICE
Adjustment Recommendations for
Monitor Applications
Low amplitude/high frequency monitor trim oscillations
can occur if the monitor regulator pressure setting is
adjusted too closely to the working regulator pressure
setting and/or if the monitor pilot supply regulator
pressure setting is adjusted too closely to the monitor
regulator pressure setting. The monitor pressure
setting should be adjusted so it is at minimum 2
times the pilot proportional band pressure above the
working regulator pressure setting. The monitor pilot
supply pressure setting should be adjusted so it is at
minimum 5 psig (0,34 bar) plus the monitor minimum
differential pressure above the working regulator
pressure setting. These adjustments must be made
such that other governing pressure limits, such as
casing ratings, pilot maximum differential pressures, or
regulatory limits, are not exceeded.
Wide-Open Monitor (Figure 8)
Installation
1. For both the wide-open monitoring regulator and
the working regulator, perform the Standard
Single-Pilot Regulator Installation section
through step 6.
2. Connect the control line of the wide-open
monitoring regulator (Figure 8) to downstream
piping near the working regulator control line
connection. During normal operation the wide-
open monitoring regulator stands wide-open
with the pressure reduction being taken across
the working regulator. Only in case of working
regulator failure does the wide-open monitoring
regulator take control at its slightly higher setting.
Startup
Repeat this procedure in turn for each regulator in
the installation.
1. Slowly open the pilot supply line hand valve.
2. Slowly open the upstream block valve and
partially open the downstream block valve for
minimum ow.
Figure 8. Typical Wide-Open Monitor Installations
FLEXIBLE WIDE-OPEN MONITOR ARRANGEMENT THAT PERMITS
WIDE-OPEN MONITOR TO BE EITHER UPSTREAM OR DOWNSTREAM
MINIMUM PIPING WIDE-OPEN MONITOR ARRANGEMENT THAT
REQUIRES WIDE-OPEN MONITOR ALWAYS TO BE UPSTREAM
16A4296-A 16A4297-A
PILOT SUPPLY REGULATOR

Types 1098-EGR and 1098H-EGR
14
3. Slowly open the hand valve in the control line
and adjust the pilot setting if necessary. Set
the monitoring regulator at a slightly higher control
pressure than the working regulator.
4. Completely open the downstream block valve.
5. Slowly close the bypass valve, if any.
Shutdown
Installation arrangements 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 pilot or main valve. The following
steps apply to the typical installation as indicated.
Single-Pilot, Dual-Pilot Regulator, or
Wide-Open Monitor
As well as applying to a single-pilot regulator (Figure 3),
the steps in this procedure also are valid for a dual-
pilot regulator (Figure 4), or a wide-open monitoring
installation (Figure 8) and just need to be repeated for
each regulator in such an installation.
1. Slowly close the downstream block valve. If the
control line is downstream of the block valve, also
close the hand valve in the control line.
2. Slowly close the upstream block valve and the
hand valve in the pilot supply line.
3. Slowly open the vent valve in the downstream
pipeline. If the control line is downstream of the
block valve, also open the vent valve in the control
line. Permit all pressure to bleed out.
4. Slowly open the upstream pipeline vent valve.
Allow all pressure to bleed out of both the piping
and the pilot.
Working Monitor
1. Slowly close the downstream block valve and the
hand valve in the downstream pressure control line.
2. Slowly close the upstream block valve and the
hand valves in both pilot supply lines.
3. Slowly open all vent valves and permit all pressures
to bleed out of the piping and regulators.
Maintenance
Regulator parts are subject to normal wear and must be
inspected and replaced as necessary. The frequency
of inspection and replacement of parts depends upon
the severity of service conditions or the requirements
of local, state, and federal regulations. Due to the care
Fisher®takes in meeting all manufacturing requirements
(heat treating, dimensional tolerances, etc.), use only
replacement parts manufactured or furnished by Fisher.
The stem O-rings on the Type 1098 or 1098H actuator
can be lubricated annually, using the grease tting
(key 28, Figure 14). Stem O-rings can be checked
Figure 10. Seat Ring/Cage Removal or Installation
Using Body as Holding Fixture
W2772-1
BODY FLANGE
W3012-1*
SEAT RING
SCREWS INTO CAGE
CAGE SCREWS INTO
BODY FLANGE
Figure 9. Trim Package Removal

Types 1098-EGR and 1098H-EGR
15
for damage during normal operation by line pressure
leakage or unexpected grease extrusion from the
actuator vent (key 27, Figure 14). All O-rings, gaskets,
and seals should be lubricated with a good grade of
general-purpose grease and installed gently rather
than forced into position. Be certain that the
nameplates are updated to accurately indicate any eld
changes in equipment, materials, service conditions, or
pressure settings.
!
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.
Design Type EGR Main Valve
Replacing Quick-Change Trim Package
Perform this procedure if the entire trim package
is replaced. Key numbers for both the complete
main valve and its trim package are referenced in
Figures 12 and 13. Some replacement trim package
assembly numbers are listed in a table in the parts list.
Note
All disassembly, trim change, and
reassembly steps in this section may be
performed with the regulator in the main
line and without disconnection pilot
supply or control lines.
1. Remove the cap screws (key 3) with a cast iron
body or remove the hex nuts (key 29, not
shown) with a steel body. Pry the body ange
(key 2) from the valve body (key 1) and lift out the
trim package.
2. Perform any required inspection, cleaning, or
maintenance on the exposed surfaces of the valve
body or trim package. Replace the gasket (key 4)
or cage O-ring (key 17) as necessary.
3. On a pre-built replacement trim package, check
indicator zeroing by unscrewing the indicator
protector (key 19) and seeing if the ange of
10C1212
Figure 11. Types 1098-EGR and 1098H-EGR Travel
Indicator Assembly
the indicator nut (key 22) lines up evenly with
the bottom marking on the indicator scale
(key 18). If not, remove the indicator scale
and separate the indicator nut and hex nut
(key 8). Hold the indicator scale against
the indicator tting (key 5) with the scale base
resting against the shoulder of the tting, and
turn the indicator nut until its ange is aligned
with the bottom scale marking. Then lock both
nuts against each other, and install the indicator
scale and protector.
4. Coat the cage seating surface of the valve body
web and the body ange seating surfaces of the
valve body neck with a good grade of general-
purpose grease. Install the trim package, and
secure it evenly with the cap screws or stud
bolt nuts.
No particular trim package orientation in the body
is required.
19
10
37
35
7
21
6
9
28
23
36
5
8
22
18

Types 1098-EGR and 1098H-EGR
16
Replacing Travel Indicator Assembly
The Types 1098-EGR and 1098H-EGR travel indicator
assemblies now incorporate a redesigned O-ring
retainer (key 6), Polytetrauoroethylene (PTFE)
backup rings (key 36), and an additional indicator
tting (key 35).
When performing maintenance on the original
Type 1098-EGR or 1098H-EGR body ange,
travel indicator replacement is recommended. The
redesigned travel indicator assembly is incorporated
into all Quick-Change Trim kits (e.g. 25A3170X012)
and on the Travel Indicator Kits (see table by size).
The elastomer repair kits contain the components for
the redesigned travel indicator assembly.
1. Remove the travel indicator assembly by
removing lower indicator tting (key 5) from the
body ange (key 2).
2. Coat the threads of the lower indicator tting
(key 5) with a good grade of general-purpose grease.
3. Install travel indicator assembly (10C1212), torque
to 40-inch-pounds.
4. Check indicator zeroing by unscrewing the
indicator protector (key 19) and seeing if the
ange of the indicator nut (key 22) lines up evenly
with the bottom marking on the indicator scale
(key 18). If not, remove the indicator scale
and separate the indicator nut and hex nut
(key 8). Hold the indicator scale against the
indicator tting (key 5) with the scale base
resting against the shoulder of the tting, and turn
the indicator nut until its ange is aligned with
the bottom scale marking. Then lock both nuts
against each other, and install the indicator scale
and protector.
Replacing Trim Parts
Perform this procedure when inspecting, cleaning, or
replacing individual trim package parts. Key numbers
are referenced in Figures 12 and 13.
Note

O-ring, travel indicator parts, or
optional travel stop (key 32) in step 1
can be gained without removing the

1. Remove the indicator tting (key 5) and attached
parts. Proceed to step 5 if only maintenance on
the tting or attached parts is performed.
2. Remove the cap screws (key 3) on a cast iron
body or remove the hex nuts (key 29, not shown)
on a steel body, and pry the body ange loose
from the valve body (key 1).
3. Use the valve body as a holding xture if desired.
Flip the body ange over, and anchor it on the
valve body as shown in Figure 10, removing the
pipe plug (key 31) rst if necessary.
4. To gain access to the port seal (key 12), upper seal
(key 15), or valve plug part, unscrew the seat ring
(key 13) from the cage (key 11) and the cage from
the body ange. For leverage, a wrench handle
or similar tool may be inserted into the seat
ring slots (Figure 10) and a strap wrench may be
wrapped around a standard or a Whisper TrimTM
cage, or a soft bar may be inserted through the
windows of a standard cage. To remove the piston
ring (key 14) and/or plug O-ring (key 20), remove
the valve plug (key 16) from the body ange, insert
a screwdriver into the precut fold over area of
the piston ring, and unfold the piston ring. Proceed
to step 6 if no further maintenance is necessary.
5. To replace the body ange or gain access to the
spring, indicator stem (key 10), stem O-ring
(key 7), spring seat (key 28), E-ring (key 23),
or optional travel stop, remove the indicator
protector (key 19) and indicator scale (key 18).
Since some compression is left in the spring,
carefully remove the anged nut (key 22) and hex
nut (key 8). A screwdriver may be inserted
through the press-t bushing (key 6) to remove the
stem O-ring without removing the bushing. If
necessary, unscrew the travel stop (if used), and
unclip the E-ring from the indicator stem.
6. Replace and lubricate parts such as the gasket
(key 4) and cage O-ring (key 17) as necessary,
making sure that if the port and upper seals were
removed they are installed in their retaining slots
with the grooved sides facing out. Also lubricate
SIZE, INCHES (DN) m)
1 (25) 75 to 95 (102 to 129)
2 (50) 55 to 70 (75 to 95)
3 (80) 100 to 130 (136 to 176)
4 (100) 160 to 210 (217 to 285)
6, 8 x 6, 12 x 6
(150, 200 x 150, 300 x 150) 375 to 425 (509 to 577)
Type EGR Cap Screw (key 3) Torque, FOOT-POUNDS (N•m)

Types 1098-EGR and 1098H-EGR
17
any other surfaces as necessary for ease of
installation. No further main valve maintenance
is necessary if just the indicator tting and
attached parts were removed.
7. Install the plug O-ring (key 20) and piston ring
(key 14) onto the valve plug. Insert the valve
plug into the body ange, install the cage plus
upper seal and O-ring into the body ange and
then install the seat ring plus port seal into the
cage. Apply a thin coating of lubricant to seals
for protection during assembly. Use the valve
body as a holding xture during this step as
shown in Figure 10, and insert a wrench handle
(or similar tool) into the seat ring slots for
leverage when tightening the seat ring and cage.
8. Remove the upside-down body ange if it was
anchored on the body. Coat the cage seating
surfaces of the valve body web and the body
ange seating surfaces of the valve body neck
with a good grade of general-purpose grease.
Install the body ange on the body, and secure
it evenly with the cap screws or stud bolt nuts.
Except on the 1-inch (DN 25) body, which does
not use it, the pipe plug (key 31) must be
installed in the side tapping of the ange for
proper operation.
9. Make sure that the ange and stem O-rings
and the bushings are installed in the indicator
tting. Orient the spring seat as shown in
Figure 12, and attach it with the E-ring to the
slotted end of the indicator stem. Install the
travel stop (if used) on the spring seat, and then
install the spring.
10. Being careful not to cut the stem O-ring with
the stem threads, install the indicator tting down
over the indicator stem until resting on the
spring. Install the hex nut and then the anged
indicator nut on the indicator stem, pushing on
the tting if necessary to provide sufcient stem
thread exposure. To maintain clearance for
indicator part installation, draw up the spring
seat by turning the hex nut down on the stem
until the threads bottom.
11. Install the indicator tting with attached parts
into the body ange. Back the hex nut off
until the spring completely closes the valve plug
against the port and upper seals, as indicated
by stem threads showing between this nut and
the tting. Hold the indicator scale against the
tting with the scale base resting against the
shoulder of the tting, and turn the indicator
nut until its ange is aligned with the bottom
scale marking. Then lock both nuts against each
other, and install the indicator scale and protector.
P590 Series Filter
Perform this procedure to clean or replace lter parts
in a standard Type P593-1 or P594-1 lter assembly.
Remove the following (as shown in Figure 15): lter
body (key 1), machine screw (key 4), gasket (key 7),
two at washers (key 5), and lter element (key 2).
Upon reassembly, one of the at washers must go
between the lter element and lter head (key 3) and
the other must go between the lter element and
gasket. Use a good grade of pipe thread sealant on
the lter head pipe threads.
Type 6351 Pilot
Perform this procedure if changing the control spring
for one of a different range, or if inspecting, cleaning, or
replacing any other pilot parts. Pilot key numbers are
referenced in Figure 16 and mounting key numbers in
Figure 25, 26, 27, or 29.
Note
The body assembly (key 1) may remain
on the pipe nipple (key 23, Figure 25,
or key 39, Figure 29) unless the entire
pilot is replaced. The optional bonnet
(key 2) for a Type 662 electric remote
control drive unit may remain installed
during maintenance.
1. To gain access to the diaphragm assembly
(key 7), control spring (key 9), or spring seat
(key 8), loosen the locknut (key 11, not used
with Type 662 mounting), and turn the adjusting
screw (key 10) out until compression is removed
from the spring. Remove the machine screws
(key 12), and separate the body assembly from the
spring case.
2. Inspect the removed parts and replace as
necessary. Ensure the registration and bleed
holes in the pilot body are free of debris. After
assembly, make sure of the proper control spring
setting according to the Startup section and
remark the spring case if necessary.

Types 1098-EGR and 1098H-EGR
18
3. To replace the valve plug (key 4), remove the
body plug (key 3) to let the valve spring
(key 6) and inner valve assembly (key 4) drop
freely from the body (key 1). Inspect the removed
parts, replace if necessary. Make sure the plug
seating surfaces are free from debris. Inspect
body plug O-ring (key 3), replace if necessary.
Type 6351 pilots manufactured before May 1999
need to have the body plug gasket and the body
plug replaced with a new body plug assembly
(key 3), which includes the body plug and the
body plug O-ring. Install the body plug O-ring
over the body plug. Stack the valve spring (key 6)
and the inner valve assembly (key 4) on the body
plug assembly (key 3), and install the body plug
assembly with stacked parts into the body (key 1).
Types 6352 through 6354M Pilots
Perform this procedure if changing the control spring
for one of a different range, or if inspecting, cleaning,
or replacing any other pilot parts. Pilot part key
numbers are referenced in Figure 17. Mounting
key numbers are referenced in Figure 25 for
single-pilot constructions and in Figures 27 and 29 for
dual-pilot constructions.
Note
The body (key 1) may remain on the
pipe nipple (key 23, Figure 25 or key 39,
Figure 29) unless the entire pilot
is replaced.
1. To gain access to the diaphragm assembly (key 5),
diaphragm limiter (key 23) if used, control spring
(key 6), restriction (key 22), stem guide (key 8), or
spring seat (key 7), remove the closing cap (key 11),
loosen the locknut (key 10), and turn the adjusting
screw (key 9) counterclockwise until compression
is removed from the spring. Remove the machine
screws (key 14), and separate the body from the
spring case (key 2).
2. Inspect the removed parts, and replace
as necessary. Make sure the restriction and the
registration hole in the body are free from debris.
After assembly, make sure of the proper control
spring setting according to the Startup section,
and remark the spring case if necessary.
3. To replace the valve plug (key 4) or bellows
O-ring (key 17), remove the body plug (key 3)
and body plug gasket (key 12). Be careful to
keep the bellows assembly (key 16) from falling
out and possibly getting lost while removing the
valve plug. Inspect the removed parts, and replace
as necessary. Make sure the valve plug seating
surfaces are free from debris.
61 Series Pilot and Type 1806 Relief Valve
Perform this procedure if changing the control spring
for one of a different range, or if inspecting, cleaning,
or replacing relief valve or any other pilot parts. Pilot
part key numbers are referenced in Figures 18
and 19 and mounting part and relief valve key
numbers in Figure 26.
1. Remove the pilot from the pipe nipple (key 24)
unless just the control spring is to be changed.
2. To gain access to the control spring or other
internal parts, remove the closing cap assembly
(key 5) and relieve control spring (key 7)
compression by turning the adjusting screw
(key 6) counterclockwise. Change the control
spring and install the adjusting screw and
closing cap assembly if no other maintenance
will be performed. Make sure of the proper
control spring setting according to the Installation
and Startup section, and restamp the nameplate
if necessary.
3. For any other internal maintenance, relieve control
spring compression according to step 2. Then
remove the cap screw (key 20) and separate the
pilot into three sections; spring case (key 1), body
(key 2), and bottom cover (key 3).
4. To inspect the two diaphragms (keys 14 and 15)
thoroughly, remove the diaphragm nut (key 11), hex
nut (key 19), and the upper and lower relay heads
(keys 16 and 17). The projecting prong in the body
may be used as the restraining member to keep
the yoke from turning while removing the nuts. Also
inspect the O-ring (key 12), and replace any parts
as necessary.
5. Take the yoke (key 4) and attached parts out of
the body to examine the disk holder assembly
(key 9). Remove the relay orice (key 8) to check
for clogging and replace if necessary.
6. To replace the disk holder assembly, rst
unscrew the bleed orice (key 10). Remove it
and the associated parts. Then unscrew the disk
holder assembly from the bleed valve
(key 26) to gain access to the relay spring
(key 13). Clean or replace any parts as necessary
before reassembling.

Types 1098-EGR and 1098H-EGR
19
7. Upon reassembly, pay particular attention to the
following assembly suggestions.
a. Before replacing the diaphragm case or spring
case, be sure the yoke assembly is positioned
so that it will not bind or rub on the prong in the
relay body.
b. Avoid wrinkling the diaphragms when replacing
the diaphragm case and spring case.
c. Replace the diaphragm case, carefully working
the upper relay diaphragm (key 14) into the
recess in the diaphragm case. If the diaphragm
case rocks with respect to the pilot body, the
diaphragm is probably wrinkled.
d. Replace the spring case, using care to smooth
the lower relay diaphragm (key 15) evenly into
the recess in the pilot body.
e. Install the eight cap screws, tightening them
down evenly in a crisscross pattern to avoid
crushing the diaphragm. Recommended nal
torque on these cap screws in 10 to
12 foot-pounds (14 to 16 N•m).
8. After assembly, make sure of the proper control
spring setting according to the Installation and
Startup section, and restamp the nameplate
(key 27) if necessary.
9. To gain access to the Type 1806 relief valve,
disconnect the relief tubing at the connector
tting and unscrew the relief valve. Make sure
the spring closes the ball, or replace the relief
valve if necessary. Install the relief valve back
in the pipe tee (key 16) and reconnect the relief
tubing (key 18) and connector tting.
Type Y600AM Pilot
Body Area
This procedure is for gaining access to the disk
assembly, orice, body O-ring, and pitot tube if used.
All pressure must be released from the diaphragm
casing, and the disk assembly must be open, before
these steps can be performed.
1. Remove the cap screws (key 2) and separate the
diaphragm casing (key 4) from the body (key 1).
2. Remove and inspect the body seal O-ring (key 11)
and the backup ring (key 48). See Figure 22.
3. Inspect and replace the orice (key 5) if
necessary. Protect the orice seating surface
during disassembly and assembly. Lubricate the
threads of the replacement orice with a good
grade of light grease and install with 29 to
37 foot-pounds (39 to 50 N•m) of torque.
4. To replace the disk assembly (key 13), remove the
cotter pin (key 15). If not necessary, skip to step 7.
5. To replace the pitot tube (key 32, Figures 21)
on the Type Y600A, remove the machine
screws (key 33), install the new pitot tube, and
secure with the machine screws. Position the
pitot tube so that it points into the outlet of the
body (key 1) by rotating the guide insert (key 18).
6. Install the disk assembly (key 13) and secure it
with the cotter pin (key 15).
7. Place backup ring (key 48) into the body (key 1).
Then place the body seal O-ring (key 11) into the
body. See Figure 21.
8. Place the diaphragm casing (key 4) on the body
(key 1). Secure the the diaphragm casing to the
body with the cap screws (key 2) using 7 to
9 foot-pounds (9 to 12 N•m).
Diaphragm and Spring Case Area
This procedure is for gaining access to the spring,
diaphragm, lever assembly stem, and Type Y600AM
stem O-ring. All pressure must be released from the
diaphragm casing before performing these steps.
1. Remove the closing cap (key 22), and turn the
adjusting screw (key 35) counterclockwise to
remove the compression from the spring (key 6).
2. If the only maintenance is to change the control
spring, take out the control spring and replace
with the desired spring. Turn the adjusting screw
(key 35) clockwise to compress the spring to the
desired outlet pressure setting. Skip to step 11.
3. If further maintenance to the internal diaphragm
casing parts is required, remove the hex nuts
(key 23, not shown) and cap screws (key 24).
Remove the diaphragm (key 10) plus attached
parts by tilting them so that the pusher post (key 8)
slips off the lever assembly (key 16). To separate
the diaphragm from the attached parts, unscrew
the cap screw (key 38, Figures 21 and 22) from
the pusher post (key 8). If the only maintenance
needed is to replace the diaphragm parts, skip
to step 7.
4. To replace the lever assembly (key 16), remove
the machine screws (key 17). To replace the
stem (key 14) or stem O-ring (key 30, Figures 21
and 22), also perform Body Area Maintenance

Types 1098-EGR and 1098H-EGR
20
procedure steps 1 and 4, and pull the stem
(key 14) out of the diaphragm casing (key 4).
Grease the replacement stem O-ring (key 30,
Figures 21 and 22) with a good grade of lubricant
and install it on the stem (key 14).
5. Install the stem (key 14) into the diaphragm
casing (key 4) and perform Body Area
Maintenance procedure steps 6 through 8
as necessary.
6. Install the lever assembly (key 16) into the stem
(key 14) and secure the lever assembly with the
machine screws (key 17).
7. Hold the pusher post (key 8) and place diaphragm
assembly parts on the pusher post in the following
order: diaphragm (key 10), diaphragm head
(key 7), lower spring seat (key 50), and washer
(key 36), and secure with diaphragm cap screw
(key 38) using 7 to 9 foot-pounds (9 to 12 N•m)
of torque.
8. Install the pusher post (key 8) and attached parts
onto the lever (key 16).
9. Install the control spring (key 6) and spring case
(key 3) on the diaphragm casing (key 4) so that the
vent assembly (key 26) is correctly oriented, and
secure them with the cap screws (key 24) and hex
nuts (key 23) to nger tightness only.
10. Turn the adjusting screw (key 35) clockwise
until there is enough control spring (key 6) force
to provide proper slack to the diaphragm
(key 10). Using a crisscross pattern, nish
tightening the cap screws (key 24) and hex nuts to
5 to 6 foot-pounds (6,8 to 8,1 N•m) of torque. Finish
turning the adjusting screw to the desired outlet
pressure setting.
11. Install the closing cap (key 22).
Type 95H Supply Pressure Regulator
This section includes instructions for disassembly and
assembly of replacement parts. All key numbers refer
to Figure 24.
1. Unscrew the valve plug guide (key 5) from the
body (key 1). The valve plug spring (key 10) and
the valve plug (key 4) will normally come out of
the body along with the valve plug guide.
2. Inspect the seating surface of the valve plug,
being sure that the composition surface (or
polished steel surface) of the valve plug is not
damaged. Replace if damaged.
3. Inspect the seating edge of the orice (key 3).
If damaged, unscrew the orice from the body
and replace it with a new part. If no further
maintenance is required, reassemble the
regulator in the reverse of the above steps. When
installing the valve plug guide (key 5) coat the
threads and sealing surface with sealant to ensure
an adequate metal-to-metal seal.
4. To inspect the diaphragm (key 12) or other
internal parts, loosen the locknut (key 17) and
turn the adjusting screw (key 15) to remove all
spring compression.
5. Remove the diaphragm case cap screws
(key 16) and lift off the spring case (key 2).
Remove the upper spring seat (key 9) and
regulator spring (key 11). Remove the lower
spring seat (key 8).
6. Remove the diaphragm (key 12) and examine for
damage. Replace if damaged.
7. With diaphragm removed, check to be sure the
pressure registration hole is completely open and
free of all obstructions.
8. Reassemble in reverse order of the previous
steps. Lubricate the upper spring seat (key 9)
and the exposed threads of the adjusting screw
(key 15). Before tightening cap screws (key 16)
be sure to install the adjusting screw, if completely
removed, and turn it down to obtain diaphragm
slack. This allows proper positioning of the
diaphragm to permit full travel of the valve plug
(key 4). Complete reassembly procedures and
temporarily install a gauge in place of the pipe plug
(key 52). Turn the adjusting screw to produce the
desired outlet pressure values shown in Table 2.
Tighten the locknut to maintain the desired setting.
Types 1098 and 1098H Actuator and Pilot
Mounting Parts
Perform this procedure if changing the actuator
or inspecting, cleaning, or replacing actuator
and/or pilot mounting parts. Actuator part key