Swagelok KPR Series Technical specifications

Pressure-Reducing Regulators
KPR Series Maintenance Instructions
Body Disassembly
1. Turn handle counterclockwise until it stops in
order to release the spring load.
2. Loosen cap ring with a 2 in. wrench, using the
flats to grip the cap ring. Remove cap assembly
and handle as one piece. In 0 to 500 psig
regulator assemblies, the range spring and spring
button will fall from the cap when it is lifted. Set
aside the range spring and spring button for later
use during reassembly.
3. Remove stop plate and diaphragm from body.
It may be necessary to tap the regulator at
an angle, by hand, to remove the diaphragm.
Set aside stop plate for later use. Discard the
diaphragm.
4. Remove seat retainer and seat (as one piece)
using a 5/8 in. socket wrench and discard both
components.
5. Pull poppet, poppet spring, and poppet
damper from body and discard. If poppet
damper remains in the body, invert the body and
use the poppet to loosen and remove the poppet
damper. Be careful not to scratch the inside of
the body.
Filter Disassembly
1. Remove the old inlet filter from the inlet port
(marked ‘HP’) using the filter pick tool. Discard
old filter.
NOTICE
Be careful not to scratch the sides of the inlet
port. Leakage could result.
CAUTION
Before servicing any installed regulator, you must depressurize the system and purge the regulator.
Kit Contents
■Inlet filter (1) ■ Poppet damper (1)
■ Poppet spring (1) ■ Poppet (1)
■ Seat (1) ■ Seat retainer (1)
■ Diaphragm (2 for 0 to 250 psig and 0 to 500 psig
regulator, 1 for all others)
■ Lubricant tube with MSDS (1)
Tool Requirements
■ Filter insertion tool
■Filter pick tool
■ 12.9 ft·lb (17.5 N·m, 1.8 m·kg) torque wrench
■ 129 ft·lb (175 N·m, 17.8 m·kg) torque wrench
■ 5/8 in. socket wrench
■ 2 in. wrench
Cap ring
Handle
Cap assembly
Stop plate
Diaphragm
Seat retainer
Seat
Poppet
Poppet spring
Poppet damper
Body
Inlet filter
Inlet port (marked ‘HP’)
Filter pick tool
Discard
inlet filter.
HP Inlet port

Body Reassembly
Note: Ensure the regulator body and all parts are
clean and free of damage.
1. Place the new seat into the new seat retainer
with the ID groove or boss pointing away from the
seat retainer. Apply a very light coat of provided
lubricant to the seat retainer threads.
2. Slip the new poppet spring and new poppet
damper onto the thicker end of the new poppet.
Fit the flat face of the poppet damper against the
poppet spring.
3. Invert the seat retainer/seat assembly and place
the thinner end of the poppet in the center of the
plastic seat.
4. Keeping the poppet/seat retainer assembly
inverted, invert the body and thread the new
seat retainer into the body. Tighten to 12.9 ft·lb
(17.5 N·m, 1.8 m·kg) torque with a 5/8 in. socket
on the torque wrench.
5. Install the new diaphragm
into the body with the large
convolution facing down into
the body. For 0 to 250 psig
and 0 to 500 psig regulators,
which use two diaphragms,
both diaphragms have the
same orientation.
6. Install the stop plate onto
the new diaphragm with
the boss on the stop plate
facing up, away from the diaphragm.
7. For 0 to 500 psig
regulators, place the
spring button into the
cap assembly with
the boss facing away
from the handle,
coned side up. Place the range spring into the
cap.
8. Lightly lubricate the body threads and place the
cap assembly on the body.
9. Thread the cap ring onto the body. Tighten cap
ring to 129 ft.·lb (175 N·m, 17.8 m·kg) torque
with a 2 in. wrench adapter on the torque wrench
using the flats to grip the cap ring.
10. Test the regulator for proper operation.
Swagelok—TM Swagelok Company
© 2004 — 2015 Swagelok Company
October 2015, R4
MS-CRD-KPRMAINT
Filter Reassembly
1. Insert the new inlet filter in the inlet port
(marked ‘HP’) using the filter insertion tool.
NOTICE
Do not insert the inlet filter with a sharp tool.
Damage to the filter could result.
Convolution on
diaphragm
Boss on
stop plate
Boss on
spring button Range spring
ID groove or boss on seat Seat in seat retainer
Lubricate
threads
For additional information, see www.swagelok.com.
Cap ring
Handle
Cap assembly
Stop plate
Diaphragm
Seat retainer (lightly lubricate threads)
Seat
Poppet
Poppet spring
Poppet damper
Body (lightly lubricate threads)
Inlet filter
Inlet port (marked ‘HP’)
Inlet port
Inlet lter
Filter insertion tool
HP