Fisher 1098H-EGR User manual
Types 1098-EGR and 1098H-EGR
D100339X012
Instruction Manual
Form 5084
July 2011
!
®
This manual describes and provides instructions and
parts list for Type 1098-EGR or Type 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
Figure 1. Type 1098-EGR
W6956
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.
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.
Types 1098-EGR and 1098H-EGR
2
See Table 1
400 psig / 27,6 bar or body rating limit whichever
is lower
600 psig (41,4 bar)
See Table 2
See Table 4
See Table 3
Linear Whisper Trim®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.
The Specications section lists pressure limitations and other specications for various Types 1098-EGR and
1098H-EGR constructions. Specications for a given regulator as it originally comes from the factory are stamped
on nameplates located on both the 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).
In through the seat ring and out through the cage
External
-20° to 180°F / -29° to 82°C
0° to 300°F / -18° to 149°C,
Water is limited to 0° to 200°F / -18° to 93°C
-20° to 275°F / -29° to 135°C
• NACE Construction
• Boiler Fuel Construction
• Aqueous Service Construction
• Monitor Conguration
• Noise Abatement Trim
Table 1. Body Sizes and End Connection Styles
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, or BWE
Types 1098-EGR and 1098H-EGR
3
Table 3. Actuator Sizes and Maximum Pressures
Table 4. Maximum and Minimum Differential Pressures for Main Valve Selection
1098
30
40
70
100
75
50
6,9
5,2
3,4
115
82
65
7,9
5,6
4,5
1098H 30 350 24,1 400 27,6
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 3 0,21 1.5 0,10
14A9679X012 Red 400(3) 27,6(3) 7 0,48 5 0,34 2.5 0,17
2 50
14A6768X012 Yellow 20 1,4 - - - - - - - - - - - - - - - - 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(3) 27,6(3) 11 0,76 10 0,69 3 0,21
3 80
14A6771X012 Yellow 20 1,4 - - - - - - - - - - - - - - - - 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(3) 27,6(3) 14 0,97 11 0,76 4 0,28
4 100
14A6770X012 Yellow 20 1,4 - - - - - - - - - - - - - - - - 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(3) 27,6(3) 22 1,5 13 0,90 5 0,34
6, 8 x 6,
or 12 x 6
150, 200 x 150,
or 300 x 150
15A2253X012 Yellow 20 1,4 - - - - - - - - - - - - - - - - 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(3) 27,6(3) 28(2) 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.
3. Should not exceed the body rating limit. Use this pressure value or the body rating limit, whichever is lower.
Table 2. Outlet Pressure Ranges
psig bar
6351
3 to 20
5 to 35
35 to 100
0,21 to 1,4
0,35 to 2,4
2,4 to 6,9
Green
Unpainted
Red
1B986027212
1B788327022
1K748527202
6352 14-inches w.c. to 2 psig
2 to 10
35 mbar to 0,1 bar
0,14 to 0,69
Yellow
Black
14A9672X012
14A9673X012
6353 3 to 40
35 to 125
0,21 to 2,8
2,4 to 8,6
Yellow
Red
1E392527022
1K748527202
6354L(1) 85 to 200 5,9 to 13,8 Blue 1L346127142
6354M(2) 175 to 220 12,1 to 15,2 Blue 1L346127142
6354H(2) 200 to 300 13,8 to 20,7 Green 15A9258X012
61L
61LD
61LE
7-inches w.c. to 2 psig
1 to 5
2 to 10
5 to 15
10 to 20
17 mbar to 0,1 bar
0,07 to 0,3
0,14 to 0,69
0,35 to 1,0
0,69 to 1,4
Red
Yellow
Blue
Brown
Green
1B886327022
1J857827022
1B886427022
1J857927142
1B886527022
61H 10 to 65 0,69 to 4,5 Green Stripe 0Y066427022
61HP
15 to 45
35 to 100
100 to 300
1,0 to 3,1
2,4 to 6,9
6,9 to 20,7
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
1.2 to 2.5
2.5 to 4.5
4.5 to 7
10 to 20 mbar
17 to 4 mbar
37 mbar to 0,08 bar
0,08 to 0,17
0,17 to 0,31
0,31 to 0,48
Red
Unpainted
Yellow
Green
Light Blue
Black
1B653827052
1B653927022
1B537027052
1B537127022
1B537227022
1B537327052
1. Without diaphragm limiter.
2. With diaphragm limiter.
Types 1098-EGR and 1098H-EGR
4
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 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 satised, 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 Type 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 pilots). Excess loading pressure on the
actuator diaphragm escapes downstream through the
bleed hole (Type 6351 pilot), bleed orice (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 imbalance 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 psi / 1,7 bar or when using the
61 Series or Y600AM pilots.
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 specically for the red main valve spring
selection in the NPS 6 / 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.
Table 5. Supply Pressure Settings Required for the Type 95H Regulator
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
1,1
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 or 8 x 6 150 or
200 x 150
Green
Blue
Red
13
17
22
0,90
1,2
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
1,7
18
23
28
1,2
1,6
1,9
20
24
29
1,4
1,7
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.
Types 1098-EGR and 1098H-EGR
5
Figure 2. Operational Schematics
A6563
A6641
Types 1098-EGR and 1098H-EGR
6
!
Installations
A Type 1098-EGR or Type 1098H-EGR regulator
bleeds no gas to the atmosphere, making it suitable for
installation in pits or other enclosed locations without
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.
Figure 2. Operational Schematics (continued)
M1008
Types 1098-EGR and 1098H-EGR
7
Figure 4. Typical Dual-Pilot Boiler Fuel Installation
48A6566-A
B1622
Figure 3. Standard Single-Pilot Installation
48A6566-A
B1622
Types 1098-EGR and 1098H-EGR
8
1. Use qualied 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 external 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
buildup on all machined guiding and sealing
surfaces inside the body and at the bonnet
ange / body joint.
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.
!
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 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 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 shut off 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 NPT vent connection.
Pre-startup 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
9
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.
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
Loosen the
locknut and turn the adjusting screw. Then tighten
the locknut to maintain the adjustment position. On
a standard Types 6352 through 6354M pilots, closing
cap must be removed before adjustment and
replaced afterward.
!
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.
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.
Applications
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 conguration:
• 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 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 psi / 0,69 bar
maximum differential pressure.
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 6). 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 high re load. This installation
practice signicantly increases the stroking speed of
the Type 1098-EGR. See Figure 6 for schematic.
Types 1098-EGR and 1098H-EGR
10
E0711
Figure 5. Boiler Fuel Conguration
E0710
Figure 6. Boiler Fuel Conguration Installation Guide
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 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 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.
Connect the other end of the control line to the
1/4 NPT connection in the control pipe tee as
shown in Figure 4. Install a hand valve in the
control line to shut off 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 6350 or
61 Series pilots, make the loading piping
connections to the 1/4 NPT vent connection.
Types 1098-EGR and 1098H-EGR
11
Figure 7. Typical Working Monitor Installation
26A4298-A
A2118-2
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 shut off. 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.
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 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
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.
Types 1098-EGR and 1098H-EGR
12
Table 6. Auxiliary Pilot Selection (Fast Stroke Dual Pilot)
Table 7. Working Monitor Performance
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 was 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.
5. Slowly open the downstream block valve.
6. Slowly close the bypass valve, if any.
3/4
NPT
Type Y600AM 1/4 6,4
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 Unpainted
15-inches w.c. to 1.2 psi 37 mbar to 0,08 bar 1B537027052 Yellow
1.2 to 2.5 0,08 to 0,17 1B537127022 Green 6-inches w.c. / 14 mbar
Under working
pilot setpoint
2.5 to 4.5 0,17 to 0,31 1B537227022 Light Blue
4.5 to 7 0,31 to 0,48 1B537327052 Black
Type 627M 1/2 13 5 to 10 0,34 to 0,69 10B3076X012 Yellow
8-inches w.c. / 21 mbar
Under working
pilot setpoint
Type 161AYW pilot and 150 psig /
10,3 bar maximum allowable
pilot inlet pressure
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
25-inches w.c. to 2.5 psi
2.5 to 4.5 psi
4.5 to 7 psi
62 mbar to 0,17 bar
0,17 to 0,31
0,31 to 0,4
1B537127022
1B537227022
1B537327052
14-inches w.c. / 34 mbar over
normal distribution pressure
Type 627-109 pilot and 150 psig /
10,3 bar maximum allowable pilot
inlet pressure for cast iron body
or 750 psig / 51,7 bar maximum
allowable pilot inlet pressure for
malleable iron or steel body
5 to 20
15 to 40
35 to 80
0,34 to 1,4
1,0 to 2,8
2,4 to 5,5
10B3076X012
10B3077X012
10B3078X012
3.0 psig / 0,21 bar over
normal distribution pressure
70 to 150
130 to 200
4,8 to 10,3
9,0 to 13,8 10B3079X012 5.0 psig / 0,34 bar over
normal distribution pressure
Types 1098-EGR and 1098H-EGR
13
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 two
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.
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.
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.
Figure 8. Typical Wide-Open Monitor Installations
16A4296-A 16A4297-A
Types 1098-EGR and 1098H-EGR
14
Figure 10. Seat Ring / Cage Removal or Installation
Using Body as Holding Fixture
W2772-1
W3012-1*
Figure 9. Trim Package Removal
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.
As well as applying to a single-pilot regulator (Figure 3),
the steps in this procedure are also 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.
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.
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 Regulator Technologies takes in meeting all
manufacturing requirements (heat treating, dimensional
tolerances, etc.), use only replacement parts
manufactured or furnished by Regulator Technologies.
The stem O-rings (key 6, Figure 14) on the Type 1098
or 1098H actuator can be lubricated during regularly
scheduled maintenance, using the grease tting
(key 28, Figure 14). Stem O-rings can be checked
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 (key 13, Figure 14) are updated to
accurately indicate any eld changes in equipment,
materials, service conditions, or pressure settings.
Types 1098-EGR and 1098H-EGR
15
!
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.
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 (key 1) 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
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.
10C1212
Figure 11. Types 1098-EGR and 1098H-EGR Travel
Indicator Assembly
4. Coat the cage seating surface of the valve body
(key 1) web and the body ange (key 2) 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
(key 3) or stud bolt nuts (key 29, not shown).
No particular trim package orientation in the body
is required.
Replacing Travel Indicator Assembly
The Types 1098-EGR and Type 1098H-EGR travel
indicator assemblies now incorporate a redesigned
O-ring retainer (key 6), Polytetrauoroethylene (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.
Types 1098-EGR and 1098H-EGR
16
F
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 200 217 to 271
6, 8 x 6, 12 x 6 150, 200 x 150,
300 x 150 275 to 300 373 to 407
Type EGR Main Valve Cap Screw (key 3) Torque
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 foot-pounds / 54 N•m.
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.
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 (key 2)
loose from the valve body (key 1).
3. Use the valve body (key 1) as a holding xture
if desired. Flip the body ange (key 2) 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 (key 16) part, unscrew the
seat ring (key 13) from the cage (key 11) and the
cage from the body ange (key 2). 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 Trim® 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 (key 2) or gain access
to the spring (key 9), indicator stem (key 10), stem
O-ring (key 7), spring seat (key 28), E-ring
(key 23), or optional travel stop (key 32), 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 (key 12) and upper
seals (key 15) were removed they are installed
in their retaining slots with the grooved sides
facing out. Also lubricate any other surfaces as
necessary for ease of installation. No further main
valve maintenance is necessary if just the
indicator tting (key 5) and attached parts
were removed.
7. Install the plug O-ring (key 20) and piston ring
(key 14) onto the valve plug (key 16). Insert the
valve plug into the body ange (key 2), install the
cage (key 11) plus upper seal (key 15) and O-ring
(key 17) into the body ange and then install the
Types 1098-EGR and 1098H-EGR
17
seat ring (key 13) plus port seal (key 12) into the
cage. Apply a thin coating of lubricant to seals
for protection during assembly. Use the valve
body (key 1) 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 (key 2) if
it was anchored on the body. Coat the cage
(key 11) seating surfaces of the valve body
(key 1) web and the body ange (key 2) 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
(key 3) screws or stud bolt nuts (key 29, not
shown). Except on the NPS 1 / 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 (key 2) and stem
O-rings (key 7) and the bushings are installed in
the indicator tting (key 5). Orient the spring seat
(key 28) as shown in Figure 12, and attach it with
the E-ring (key 23) to the slotted end of the
indicator stem (key 10). Install the travel stop
(key 32) (if used) on the spring seat, and then
install the spring (key 9).
10. Being careful not to cut the stem O-ring (key 7)
with the stem threads, install the indicator tting
(key 5) down over the indicator stem (key 10)
until resting on the spring (key 9). Install the hex
nut (key 8) and then the anged indicator nut
(key 22) on the indicator stem, pushing on the
tting if necessary to provide sufcient stem
thread exposure. To maintain clearance for
indicator part installation, draw up the spring seat
(key 28) by turning the hex nut down on the stem
until the threads bottom.
11. Install the indicator tting (key 5) with attached
parts into the body ange (key 2). Back the hex
nut off until the spring completely closes the
valve plug (key 16) against the port (key 12) and
upper seals (key 15), as indicated by stem
threads showing between this nut and the tting.
Hold the indicator scale (key 18) against the
tting with the scale base resting against the
shoulder of the tting, and turn the indicator nut
(key 22) until its ange is aligned with the bottom
scale marking. Then lock both nuts against each
other, and install the indicator scale and
protector (key 19).
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.
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 24, 25, 26, or 28.
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) counterclockwise until compression
is removed from the spring. Remove the machine
screws (key 12), and separate the body assembly
(key 1) from the bonnet (key 2).
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.
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.
Types 1098-EGR and 1098H-EGR
18
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
and the inner valve assembly on the body
plug assembly (key 3), and install the body plug
assembly with stacked parts into the body.
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 24 for
single-pilot constructions and in Figures 26 and 28 for
dual-pilot constructions.
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.
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 25.
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 (key 4) 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 orice (key 8) to check
for clogging and replace if necessary.
6. To replace the disk holder assembly, rst
unscrew the bleed orice (key 10). Remove it
and the associated parts. Then unscrew the disk
(key 9) 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.
7. Upon reassembly, pay particular attention to the
following assembly suggestions.
Types 1098-EGR and 1098H-EGR
19
a. Before replacing the diaphragm case (key 2)
or spring case (key 1), 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 (key 14 and 15)
when replacing the diaphragm case (key 2) and
spring case (key 1).
c. Replace the diaphragm case (key 2), 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 (key 1), using care to
smooth the lower relay diaphragm (key 15)
evenly into the recess in the pilot body.
e. Install the eight cap screws (key 20), tightening
them down evenly in a crisscross pattern to
avoid crushing the diaphragm. Recommended
nal torque on these cap screws is 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.
Body Area
This procedure is for gaining access to the disk assembly,
orice, and body O-ring. All pressure must be released
from the diaphragm casing, and the disk assembly must
be open, before these steps can be performed. Part key
numbers are referenced in Figure 21.
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).
3. Inspect and replace the orice (key 5) if
necessary. Protect the orice seating surface
during disassembly and assembly. Lubricate the
threads of the replacement orice with proper
amount of anti-seize lubricant and install with 29 to
38 foot-pounds / 39 to 52 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. Install the disk assembly (key 13) and secure it
with the cotter pin (key 15).
6. Place backup ring (key 48) into the body (key 1).
Then place the body seal O-ring (key 11) into
the body.
7. 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 / 9,5 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 according to
the Installation and Startup section, and restamp
the nameplate if necessary. 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) from the pusher post
(key 8). If the only maintenance needed is to replace
the diaphragm parts, skip to step 7.
Types 1098-EGR and 1098H-EGR
20
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), also
perform Body Area Maintenance 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) 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 / 9,5 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).
This section includes instructions for disassembly and
assembly of replacement parts. All key numbers refer
to Figure 23.
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 (key 4),
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 orice (key 3).
If damaged, unscrew the orice 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.
This manual suits for next models
1
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