JEON RB Series Regulating System

Contents

1. Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3
2. Technical Data and Features . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3
3. Structure and Principle of Operation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4
4. Selection of Spring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5
5. Flow Chart (SCMH) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5
6. Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5
7. Usage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7
8. Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8
9. Assembly and Disassembly Points to Note . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9
10. Ordering Guide . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12

⚠️ WARNING

Failure to follow these instructions or to properly install and maintain this equipment could result in an explosion, fire and/or chemical contamination causing property damage and personal injury or death. Jeon regulators must be installed, operated and maintained in accordance with federal, state and local codes, rules and regulations and Emerson Process Management Regulator Technologies, Inc. instructions. If the regulator vents gas or a leak develops in the system, service to the unit may be required. Failure to correct trouble could result in a hazardous condition. Installation, operation and maintenance procedures performed by unqualified personnel may result in improper adjustment and unsafe operation. Either condition may result in equipment damage or personal injury. Call qualified personnel when installing, operating and maintaining the RB Series regulating system.

1. Introduction

The RB Series (wall-mountable) regulating box can be deployed for natural gas distribution systems in residential or commercial market segments. It is suitable for gas services including natural gas, manufactured gas, and liquefied petroleum gas. The basic types include Types RB, RBT, RBQ, and RBQT.

A typical model designation is structured as follows: RX 0.4 / 50 A - RB

• RX: Internal Code
• 0.4: Maximum Inlet Pressure, MPa
• 50: Rated Flow (SCMH)
• A: Structure Type (A for 1+0; B for 1+1; C for 2+0)
• RB: Gas Regulator Box Type (RB, RBT, RBQ, RBQT)

2. Technical Data and Features

Specifications:

• Inlet Pressure Range (P1)⁽¹⁾: 0.02 to 0.4 MPa / 2.9 to 58.0 psig
• Outlet Pressure Range (P2)⁽¹⁾: 1.5 to 30 KPa / 0.22 to 4.35 psig (Refer to Table 2 for available spring ranges)
• Regulating Accuracy: Up to AC 5
• Lockup Accuracy: Up to SG 10
• Slam-shut Accuracy: Up to AC 5
• Temperature Capability⁽¹⁾: -20 to 60°C / -4 to 140°F
• Body Size and End Connection: See Table 1

Features:

• Modular design
• Filter system
• Automatic overpressure micro relief
• Automatic overpressure shut off
• High-accuracy 2-stage regulator
• Designed for ease of operation and maintenance
• "Loose" inlet/outlet flange connections

⁽¹⁾ The pressure/temperature limits in this Manual and any applicable standard or code limitation for the valve should not be exceeded.

3. Structure and Principle of Operation

The RB Series regulator box comprises inlet and outlet ball valves, a filtration module, a regulator module, and a box body (as shown in Figures 1 and 2). The regulator module integrates shut-off, first-stage regulation, second-stage regulation, and micro relief functions.

Operational Concept (See Figure 3):

Gas flows through the first-stage regulator, stabilizing to an intermediate pressure. This intermediate pressure gas then passes to the second-stage regulator, which reduces the pressure to the desired outlet pressure, P2.

If P2 reaches the relief set pressure, the relief valve opens to vent sudden pressure increases caused by environmental temperature fluctuations or other factors. This mechanism prevents "false shutoff" or accidental tripping of the slam-shut valve during erratic pressure spikes, ensuring the pressure is maintained at the setpoint, P2.

When the slam-shut valve detects P2 exceeding its set pressure, a latching mechanism is released. A spring then assists in rapidly closing the valve, sealing the slam-shut orifice with a pad to cut off flow and prevent damage to downstream equipment.

After the cause of overpressure is corrected, pull and latch the reset bar to restore normal flow operation.

4. Selection of Spring

Regulator Spring Selection (Table 2)

Shut-off Selection (Table 3)

To avoid personal injury, property damage or equipment damage caused by bursting of pressure containing parts or explosion of accumulated gas, never adjust the control spring to produce an outlet pressure higher than the upper limit of the outlet pressure range for that particular spring. If the desired outlet pressure is not within the range of the control spring, install a spring of the proper range.

5. Flow Chart (SCMH)

Table 4. Flow Chart (SCMH)

Notes:

• The values shown above are the flow capacity at 3 kPa outlet pressure setting. For other outlet pressure settings, there is a very small difference in actual flow capacity.
• Flow capacity is based on 0.61 specific gravity, Natural Gas. If other media is used, multiply the shown data by: 1.17 for manufactured gas; 0.55 for butane; 0.63 for propane; 0.78 for air; 0.79 for nitrogen.

6. Installation

Installation, operation, and maintenance performed by non-qualified personnel may result in unsafe operation, equipment damage, or personal injury. Call a qualified personnel when installing, operating, and maintaining the unit.

The regulator installation and usage must only be carried out by qualified and trained personnel. Contact the company if you are not qualified. The company is not responsible for any consequences due to non-standard operations or usage compliance.

1. Install the regulator in ambient temperature, away from sources of fire and vibrations.
2. Check if the pipeline pressure is within the pressure range stated on the regulator nameplate.
3. Ensure the flow direction of the pipeline matches the arrow stamped on the regulator body.
4. Purge and clean the pipeline before installation.
5. Install the inlet and outlet pipeline end connections 155 mm / 6.10 in. apart (center to center). Recommended pipeline end connections should be ≥1.2 m / 3.94 ft. above ground level. The flange connection face leveling tolerance is 3 mm / 0.12 in.; exceeding this may cause leakage or damage to the regulator. Do not use excessive force when connecting flange ends. Sequentially tighten the inlet flanges before the outlet flanges. (Refer to Figure 5 for installation dimensions.)
6. Place a suitable space between the regulator and any equipment with quick alternating pressure (e.g., burner or solenoid valve) to prevent "false shutoff".

Note: Remove the regulator when the pipeline is undergoing pressure testing or purging to avoid damaging the regulator.

Table 5. Installation Dimensions of RB Series of Regulator Box

7. Usage

1. Commissioning Procedure

1. Ensure the slam-shut valve is in the open position. Use the handle to slightly open the outlet ball valve (See Figure 4).
2. Slowly turn the handle counterclockwise to open the ball valve.
3. Pause momentarily until the flow stabilizes.
4. Fully open the ball valve once the flow is stable.

2. Setting the Outlet Pressure

1. Slowly turn the adjustment screw cap to set the desired pressure. Turning clockwise increases outlet pressure; counterclockwise decreases it (See Figure 6).
2. Ensure the setpoint is within the spring pressure range; otherwise, the regulator may be damaged.

Note: While the regulator is in operation, do not open the test port valve, as this will increase the downstream pressure.

3. Setting the Slam-Shut Pressure

1. Slowly turn the adjustment nut with the handle to set the desired slam-shut set pressure. Turning clockwise increases the set pressure; counterclockwise decreases it.
2. Determine the set pressure using the test port valve.
3. Ensure both inlet and outlet ball valves are closed before taking measurements, then vent the gas inside the regulator. As a safety guideline, the slam-shut module set pressure should not exceed 1.5 times the regulator setpoint.
4. Unscrew the regulator adjustment cap (see Figure 3) if the user needs to vent regulator pressure.
5. Use a size 14 wrench to turn the adjustment nut. Turning clockwise increases the setpoint; counterclockwise decreases it. Vent pressure is recommended to be 1.3 times the regulator operating pressure.

Note: Calibrate the slam-shut set pressure by turning the adjustment nut. Ensure this is done when the spring is at its most relaxed length, then slowly compress it to the desired set pressure.

4. Reset the Slam-Shut Valve

1. Identify the root cause that activated the slam-shut valve.
2. Close the inlet ball valve to allow only a small flow into the regulator for inlet pressure build-up.
3. Close the outlet ball valve to allow only a small flow through the regulator (or completely close the outlet valve and slightly open the test port valve for a small outlet flow).
4. Pull the "Reset Bar" until a small flow through the regulator is achieved and maintained.
5. Wait for pressure to balance before and after the slam-shut valve. If there is resistance while pulling the "Reset Bar", stop pulling. If the regulator does not operate normally, close both inlet and outlet ball valves and diagnose the root cause. If the regulator operates normally, pull the "Reset Bar" (there should be no resistance) until it latches on again.
6. Slowly open the inlet and outlet ball valves, respectively. After troubleshooting, reset the slam-shut valve, then slightly open the outlet ball valve and then the inlet ball valve, observing if the regulator returns to normal operation. If normal operation resumes, fully open both inlet and outlet ball valves.

Notes:

• Do not attempt to reset the slam-shut valve with fully open inlet and outlet ball valves. This may cause personal injury and damage to the regulator.
• RB Series regulating boxes have OPSO (Over Pressure Shut Off) protection. For UPSO (Under Pressure Shut Off) protection, contact an authorized agent or sales company authorized by Emerson Process Management Regulator Technologies Inc.

8. Maintenance

1. General Maintenance

1. Ensure inlet and outlet ball valves are closed before any maintenance. Verify the slam-shut valve is open.
2. Open the test port valve to relieve pressure in the regulator. Avoid damaging diaphragm orifices and other components during disassembly/assembly.
3. Ensure all movable parts remain functional during assembly.
4. After re-installation, restore the regulator to its required setpoint.
5. Ensure all end connections are tightly sealed and leak-free.

Emerson provides training for maintenance personnel. For inquiries, contact the service department or authorized representatives.

2. Routine Maintenance

Routine maintenance checks should be performed by the user's managing department for regulators. The frequency should be determined by the user based on weather and usage parameters to ensure safe operations:

1. Use gas detection equipment or perform a "bubble check" to detect any leakage.
2. Check pressure gauge readings for the corresponding outlet pressure.
3. Clean the exterior of the regulator.

3. Regular Maintenance

Maintenance content involves selective checks depending on the actual situation.

1. Regular operational pressure check:
   1. Connect a pressure gauge at the regulator's test port.
   2. Open the test port valve, then slowly close the regulator outlet ball valve.
   3. Wait for 3 minutes and record the gauge reading.
   4. Check if the pressure reading is within the operational range. If it is, no further steps are needed for this check.

9. Assembly and Disassembly Points to Note

A. Removing the Box Cover (See Figure 8)

1. Unlock and swing open the cover by 90°.
2. Lift up the cover to remove it.

B. Removing the Filter Element (See Figure 3)

1. Vent pressure out of the regulator.
2. Use a size 4 hex-key to remove the screws and the filter cap. (Note: Be careful of the spring inside springing out when the cap is detached.)
3. Pull the ring attached on the filter to remove the filter element.

C. Removing Slam-Shut Parts (See Figure 9)

1. Use the provided tools to turn the adjustment nut until it is level with the bonnet.
2. Use a size 4 hex-key to remove the screws and the slam-shut module.
3. Unscrew the reset bar nut.
4. Lift open the slam-shut bonnet (note the 5 ball bearings that may fall out) and remove the reset bar.
5. Use a spring collar tool (JB/T3411.47) to remove the $7 spring collar on the orifice pad, thus removing the orifice pad. (During this process, ensure the reset bar is not bent due to excessive force.)
6. Use a size 9 wrench to loosen the clamping nut to remove the diaphragm.

D. Removing the First Stage Regulator Orifice Pad

1. Follow Step "C" to remove the slam-shut module.
2. Use a size "A" spring collar tool (place it into the holes and turn counterclockwise) to remove the first stage regulator orifice pad.

E. Removing the First Stage Regulator Diaphragm (See Figure 10)

1. Unscrew the bolts and screws with a size 13 wrench (GB/T4388) connecting the inlet and outlet ball valves.
2. Remove the regulator.
3. Follow Step "D" to remove the first stage regulator orifice pad.
4. Remove the diaphragm assembly.
5. Use a size 17 wrench to loosen the balancing shaft and connection shaft, then remove the diaphragm.
6. During reassembly, apply downward pressure onto the cover and screw in all screws slightly before tightening them. Ensure the entire diaphragm is NOT displaced out of the cover before completely tightening all screws.

F. Removing the Second Stage Regulator Diaphragm (See Figure 11)

1. Unscrew the adjustment screw cap.
2. Use a size 4 wrench to unscrew the surrounding nuts and bolts.
3. Open the bonnet and remove the diaphragm. Hold onto the diaphragm and second stage regulator components while removing them from the regulator body.
4. Use a size 14 wrench to unscrew the second stage diaphragm nut and remove the diaphragm.

G. Removing the Second Stage Regulator Orifice Pad (See Figures 12 and 13)

1. After completing step "F", use a Phillips screwdriver to unscrew 2x M3 screws holding the Lever in position.
2. Remove the lever.
3. Use the special tool to unscrew the regulator cap.
4. Remove the second stage orifice pad assembly.
5. Use a Phillips or flat screwdriver to unscrew the M5 screws holding the second stage orifice pad assembly; remove the orifice pad.
6. During reassembly of the second stage regulator, first assemble the orifice pad assembly, then place the lever and screw back the M3 screws to hold it in position.
7. Hold the orifice pad to allow the lever to return to the lifted position while placing the diaphragm back into its original position in the body.
8. Follow the diagram below (Figure 13) and adjust until the rectangular slot faces are in the direction shown, and slot the lever back onto the diaphragm attachment.
9. Place back the bonnet and tighten it with nuts and bolts.
10. Clean all parts before placing them back into the regulator body.
11. Apply appropriate grease onto all seal-tight elements (O-rings, diaphragm, etc.) and contact surfaces before reassembly.

10. Ordering Guide

The ordering guide uses a code structure to specify regulator configurations. Example: RB 25 B1 C4 B1 F1 E

Troubleshooting Guide (Table 6)

Spare Parts Package of RB Series of Regulator Box (Table 7)

Diagram Descriptions

Company Information and Disclaimer

Emerson Process Management

Asia Pacific Pte Ltd
1 Pandan Crescent
Singapore 128461
T: +65 6777 8211
F: +65 6770 8028

Emerson Process Management Chennai Ltd
Plot No. 5, 6, 7 and 8 Self Help Industrial Estate
Keelkattalai, Chennai, India - 600117
T +91 44 4903 4405
F +91 44 4903 4400

FISHER JEON Gas Equipment (Chengdu) Co., Ltd
No. 9, Wukedong 2nd Road, Wuhou Science Technic Park,
Chengdu, 610045, P.R. China
T: (028) 85360000 F: (028) 85371201
Service T: (028) 85366930 or (028) 85360000 Ext. 1613

费希尔久安输配设备(成都)有限公司
地址:中国四川成都市武侯科技园武科东二路9号
总机:(028)85360000 传真:(028)85371201
服务热线:(028)85366930或(028)85360000分机1613
邮编:610045

www.emerson.com

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