Sensus 496 User manual

Caution
Warning
Installation and Start-Up
1. Remove the shipping plugs from both the regulator inlet and
outlet connections.
2. Make certain that the inside of the piping and the regulator
inlet and outlet connections are clean. The connections must
be free or dirt, pipe dope and other debris.
3. Use pipe joint material only on the male threads of the pipe
being connected to the regulator. Do not use pipe joint
material on the female threads of the regulator.
4. Install the regulator in the piping. Make certain that the gas
ow through the regulator is in the direction as indicated by
the arrow on the regulator body.
The regulator may be installed in any position: right side up,
upside down, vertical piping, diagonal piping, etc., If required
the diaphragm case may be rotated 360° in 90° increments.
IN-G-REG-1307-1212-02-A*
Model 496
Domestic Service Regulator Installation and Maintenance Instructions
To rotate the 496 diaphragm case, detach the diaphragm
case from the body by removing the two body-to-diaphragm
case screws. After repositioning the diaphragm case to
the desired position, reinstall the body-to-diaphragm case
screws. Ensure that the body-to-diaphragm screws are
sufciently tightened to reseal the regulator. 35-50 ft-lbs.
of torque is recommended. The diaphragm case vent (11)
should be positioned to minimize the chances of moisture
collecting on the vent side of the diaphragm. The upper
diaphragm case (4) may be rotated to a downward position
by removing the ange screws (10).
The diaphragm case vent must be positioned to protect
against ooding, rain, ice formation, trafc, tampering, etc.
The vent must be protected against nest building animals,
bees, insects, etc. to prevent vent blockage and minimize the
chances for foreign material from collecting in the vent side
of the regulator diaphragm. If required, the upper diaphragm
case may be rotated by removing the upper-to-lower case
ange screws and rotating the upper diaphragm case to the
desired position. Reinstall the diaphragm ange screws and
tighten to hold the diaphragm case in position and reseal,
ensuring proper seal and verifying no leaks by using a soap
and water solution or other utility-approved method.
Do not overload the diaphragm with a sudden surge of inlet
pressure. Turn the gas on very slowly. If an outlet stop is
used, it should be opened rst. Monitor the outlet pressure
during start-up to prevent an outlet pressure overload.
5. Turn the gas on very slowly.
6. Make certain that all connections are tight, ensure proper
seal and verify no leaks by using a soap and water solution
or other utility-approved method.
7. If necessary, adjust outlet pressure (set point) by removing
cap (1) and turning adjustment spring button (2). Turn
clockwise to increase and counter-clockwise to decrease
outlet pressure. Only adjust when gas is owing through
regulator. Be sure to reinstall cap.
1- Spring Cap
2- Adjustment Ferrule
3- Spring
4- Upper Case
8 - Diaphragm Assembly
9- Valve Stem
5- Body
7- Valve
6- Orifice
10 - Flange Screws
11 - Vent
The Model 496 is a general purpose gas pressure
regulator for natural gas, air, CO2, propane, butane,
nitrogen, and other gases. It can be used for gas
service to homes, commercial establishments and
small industries as well as burners, unit heaters,
boilers, and other equipment. All regulators include
an internal relief valve.
Only qualied personnel should install or service a regulator.
Regulators should be installed, operated, and maintained
in accordance with applicable codes and regulations, and
Sensus instructions.
If the regulator vents uid or a leak develops in the system,
it indicates that service is required. Failure to take the
regulator out of service immediately may create a hazardous
condition. Personal injury, equipment damage, or leakage
due to escaping uid or bursting of pressure-containing
parts may result if this regulator is over pressured or is
installed where service conditions could exceed published
specication limits, 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 (as required by the appropriate
code, regulation, or standard) to prevent service conditions
from exceeding limits.
Additionally, physical damage to the regulator could result in
personal injury and property damage due to escaping uid.
To avoid such injury and damage, install the regulator in a
safe location.
*This document replaces RM-1307-R2

805 Liberty Boulevard
DuBois, PA 15801
1-800-375-8875
For more information, visit us at sensus.com/gas
Caution
Caution
Model 496
Domestic Service Regulator Installation and Maintenance Instructions
I
It is the user’s responsibility to assure that all regulator vents
and/or vent lines exhaust to a non-hazardous location away
from ANY POTENTIAL sources of ignition. Where vent lines
are used, it is the user’s responsibility to assure that each
regulator is individually vented and that common vent lines
ARE NOT used.
8. The vent connection is an escape path for the regulated
gas. Depending upon the type of gas, it could be
ammable as with natural gas and propane. Therefore,
the vent connection needs to be located and/or piped so
that potential discharge occurs in a safe area away from
buildings, open ames, collection areas, arcing devices, etc.
Regulators that are installed indoors or in a non-vented
area must be vented to the outside. Run vent piping from
the regulator vent connection to a non-hazardous location
on the outside away from any potential sources of ignition.
Since the Model 496 regulator is equipped with internal relief
valves (IRV), the vent piping must be vent connection size
or larger and its length be as short and direct as possible
to a safe area. This is to assure the venting of the internal
relief valve discharge to the atmosphere without excessive
pressure increase in the regulator and downstream piping.
The outlet of the vent piping must allow for free and
unobstructed passage of air and gas and must be protected
against the potentials listed in instructions #4, #8 and #9.
9. For outdoor installations, it is recommended that the
regulator be installed so that the regulator vent faces
downward to avoid the potential for water and other foreign
matter entering the regulator and interfering with the proper
operation of the regulator.
Regulators are pressure control devices with numerous
moving parts subject to wear that is independent upon
particular operating conditions. To assure continuous
satisfactory operation, a periodic inspection schedule must
be adhered with the frequency of inspection determined by
the severity of service and applicable laws and regulations.
Servicing
1. To access valve (7), orice (6), or diaphragm assembly (8),
rst remove spring compression by unscrewing the spring
cap (1) and spring adjustment ferrule (2). Remove spring (3)
from regulator.
2. For access to the valve (7) and orice (6), remove body-to-
diaphragm case screws from body (5) with a 1/2” standard
socket (or standard screwdriver) and remove diaphragm
case assembly from body (5).
3. To replace valve pad (7), simply pull off of valve stem (9) and
replace with new pad.
4. To replace orice (6), unscrew from body using a 7/8” hex
socket wrench. Apply sealant on threads of orice when
installing replacement orice. The replacement orice must
be installed at 50-60 ft-lbs. of torque.
5. To replace diaphragm assembly, remove ange screws (10)
and disassemble diaphragm assembly. Make certain all
parts are reassembled in their correct order and all threads
and joints are tightened evenly and rmly.
6. Before reassembling body to diaphragm case, make certain
that the o-ring is in position. Ensure proper seal and verify
no leaks by using a soap and water solution or other utility-
approved method..
Over Pressurization Protection
Protection must be provided for the downstream piping
system and the regulator’s low pressure chambers to assure
against the potential for over pressurization due to a regulator
malfunction or a failure of the regulator to lock up. The
allowable over-pressurization is the lowest of the maximum
pressures permitted by federal codes, state codes, Sensus
Bulletin RDS-1498, or other applicable standards. The methods
of providing over-pressure protection could be a relief valve,
a monitor regulator, a shut-off valve device or similar device.
Buried Service
The Model 496 regulator is not recommended for buried
service.
Temperature Limits
The Model 496 regulator can be used for the owing
temperature of -20° F to 150° F (-28.9° C to 65.5° C).
Maximum Emergency Pressures
The maximum pressure the regulator inlet may be subjected
under abnormal conditions without causing damage to the
regulator is: Maximum Inlet Pressure plus 50 psi.
The maximum pressure to which the regulator case may be
subjected under abnormal conditions without causing damage
to the internal parts of the regulator is: Set point plus 3 psi.
If the outlet pressure exceeds this pressure, the regulator must
be removed from service and carefully inspected. Damaged
or otherwise unsatisfactory parts must be replaced before
returning the regulator to service.
The maximum outlet pressure that can be safely contained
in the diaphragm case is 10 psi (safely contained means no
leakage as well as no bursting.)
All products purchased and services performed are subject to Sensus’ terms of sale, available at either; http://na.sensus.com/TC/TermsConditions.pdf or 1-800-METER-IT.
Sensus reserves the right to modify these terms and conditions in its own discretion without notice to the customer.
This document is for informational purposes only, and SENSUS MAKES NO EXPRESS WARRANTIES IN THIS DOCUMENT. FURTHERMORE, THERE ARE NO IMPLIED
WARRANTIES, INCLUDING WITHOUT LIMITATION, WARRANTIES AS TO FITNESS FOR A PARTICULAR PURPOSE AND MERCHANTABILITY. ANY USE OF THE
PRODUCTS THAT IS NOT SPECIFICALLY PERMITTED HEREIN IS PROHIBITED.
© 2012 Sensus USA Inc.