Mallard IOM Series 5600

Installation, Operation, and Maintenance Instructions MODEL 5600 / 5600R

January 2005

CONTENTS 1.0 GENERAL 1.1 5600 Model Number Information ----------------------------------------------------------------------- 2 1.2 5600R Model Number Information --------------------------------------------------------------------- 3 1.3 Parts List ----------------------------------------------------------------------------------------------------- 4 1.4 Dimensions -------------------------------------------------------------------------------------------------- 6 1.5 Specifications ----------------------------------------------------------------------------------------------- 7 1.5.1 General -------------------------------------------------------------------------------------------- 7 1.5.2 Outlet Pressure Ranges 5600 ---------------------------------------------------------------- 7 1.5.3 Outlet Pressure Ranges 5600R -------------------------------------------------------------- 7 1.5.4 Maximum Inlet and Differential Pressure -------------------------------------------------- 8 1.5.5 Materials of Construction ---------------------------------------------------------------------- 8 2.0 INSTALLATION & SERVICE ------------------------------------------------------------------------------- 9 2.1 Installation and Startup ----------------------------------------------------------------------------------- 9 2.2 Diaphragm Replacement --------------------------------------------------------------------------------- 9

Model 5600 / 5600R Installation, Operation, and Maintenance Instructions

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1.0 GENERAL 1.1 5600 Model Number Information Sample Model Number: 5600 - 1 H D G - U 4 S

BODY SIZE CODE 1 1 2 2 STYLE CODE Low Pressure L High Pressure H BODY MATERIAL CODE WCC Carbon Steel W Ductile Iron D OUTLET PRESSURE RANGE CODE

Low Pressure: 3 to 10 psig (0.2 to 0.7 bar) A 8 to 20 psig (0.5 to 1.4 bar) B 17 to 30 psig (1.2 to 2.0 bar) C 27 to 40 psig (1.9 to 2.7 bar) D

High Pressure: 27 to 50 psig (1.9 to 3.4 bar) E 46 to 95 psig (3.2 to 6.5 bar) F 90 to 150 psig (6.2 to 10.3 bar) G 150 to 200 psig (10.3 to 13.7 bar) H 200 to 275 psig (13.7 to 18.9 bar) J 275 to 500 psig (18.9 to 34.5 bar) K TRIM MATERIAL CODE Brass / TFE (for pressure drops 200-1500 psi) T Brass / Nylon (for pressure drops up to 1500 psi) U Brass / Viton (for pressure drops below 200 psi) V Stainless Steel / TFE (for pressure drops 200-1500 psi) W Stainless Steel / Nylon (for pressure drops up to 1500 psi) X Stainless Steel / Viton (for pressure drops below 200 psi) Y PORT DIAMETER CODE 1/8 1 1/4 2 3/8 3 1/2" 4 3/16 5 OPTIONS CODE None S NACE N

1.2 5600R Model Number Information Sample Model Number: 5600R - 1 H D R - B 2 S

BODY SIZE CODE 1 1 2 2 STYLE CODE Low Pressure L High Pressure H BODY MATERIAL CODE WCC Carbon Steel W Ductile Iron D OUTLET PRESSURE RANGE CODE

Low Pressure: 3 to 8 psig (0.2 to 0.5 bar) L 6 to 17 psig (0.4 to 1.1 bar) M 15 to 22 psig (1.0 to 1.5 bar) N 20 to 35 psig (1.4 to 2.4 bar) P 27 to 50 psig (1.9 to 3.5 bar) Q

High Pressure: 30 to 70 psig ( 2.0 to 4.8 bar) R 50 to 95 psig ( 3.5 to 6.5 bar) S 75 to 175 psig ( 5.2 to 12.1 bar) T 150 to 250 psig (10.4 to 17.3 bar) W TRIM MATERIAL CODE Brass B Stainless Steel S PORT DIAMETER CODE 1/8 1 1/4 2 3/8 3 1/2 4 OPTIONS CODE None S NACE N


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1.3 Model 5600 Parts List


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1.3 Model 5600R Parts List


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1.5 Dimensions High Pressure 1 Connections

High Pressure 2 Connections

Low Pressure 1 Connections

Low Pressure 2 Connections


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1.6 Specifications

1.6.1 General

1.00 NPT Female End Connections 2.00 NPT Female

Maximum Emergency Outlet (Casing) Pressure 550 psig (37.8 bar) Operating Temperature Limits -20 to 150o F (-29 to 65o C)

1.6.2 Outlet Pressure Ranges, Model 5600

Model Outlet Pressure

Range, Psig

Maximum Outlet Pressure over

Pressure Setting3, psig

Maximum Emergency Outlet Pressure,

psig

3 to 10 8 to 20

17 to 30 Low Pressure

27 to 40

201

45

27 to 50 46 to 95

90 to 150 200 to 275

High Pressure

275 to 500

2002 550

1. This applies to outlet pressure settings below 25 psig only. For pressure setting above 25 psig, outlet pressure is limited to 45 psig the maximum emergency outlet pressure.

2. This applies to outlet pressure settings below 350 psig only. For pressure settings above 350 psig, outlet pressure is limited to 550 psig, the maximum emergency outlet pressure.

3. Internal parts of the regulator may be damaged if the outlet pressure exceeds the pressure setting beyond the amounts shown.

1.6.3 Outlet Pressure Ranges, Model 5600R

Model Relief Pressure

Range, Psig

Maximum Relief (Inlet) Pressure

psig

Maximum Emergency Outlet Pressure

psig

3 to 8 6 to 17

15 to 22 20 to 35

Low Pressure

27 to 50

Set Pressure Plus 25 psig

45

30 to 70 50 to 95

75 to 175 High Pressure

150 to 250

Set Pressure Plus 250 psig 550

CAUTION Over-pressuring the 5600 regulator or the 5600R relief valve may result in valve damage or personal injury due to failure of pressure containing parts. Avoid over pressuring by providing over-pressure protection devices to prevent exceeding the operating pressure limits stated in the specifications of this product.

1.6.4 Maximum Inlet and Differential Pressures

Port Dia.

Maximum Allowable Inlet Pressure, psig1

Maximum Allowable Pressure Drop, psid

1/8 or 3/16 1500 1500 1/4 1500 1000 3/8 1000 500 1/2 750 250

1. The sum of the outlet pressure setting and the maximum allowable pressure drop determines the maximum allowable inlet pressure for a given installation. For example, with a 1/2 port diameter (maximum pressure drop of 250 psi) and a 400 psig outlet pressure setting, the maximum inlet pressure is 650 psig (250 psi plus 400 psig).

1.6.5 Materials of Construction

Part Material WCC C.S. Body, Spring Case &

Diaphragm Adapter Ductile Iron Inlet Adapter (5600) / Outlet Adapter (5600R) A105 C.S.

Brass Orifice 302 SST Brass Diaphragm Connector Head 302 SST Brass Holder w/TFE Disk Brass Holder w/Nylon Disk Brass Holder w/Viton Disk 302 SST Holder w/TFE Disk 302 SST Holder w/Nylon Disk

Valve Disk & Holder (5600) Oring Holder (5600R)

302 SST Holder w/Viton Disk Brass Valve Carrier 302 SST

Oring (5600R) Viton Lever C.S.

Buna-N w/embedded nylon fabric Diaphragm Viton w/embedded nylon fabric


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2.0 INSTALLATION & SERVICE

2.1 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 are clean they must

be free of 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 line. The regulator may be installed in any position: right side up, up

side down, vertical piping, diagonal piping, etc. The diaphragm case vent must be positioned to protect against flooding, drain water, ice formation, traffic, tampering, etc. The vent must be protected against nest-building insects to prevent vent blockage and to minimize the chances of foreign material collecting in the vent side of the regulator diaphragm.

5. Turn gas on very slowly.

CAUTION If an outlet block valve is used, it should be opened first. Do not overload the diaphragm with a sudden surge of inlet pressure. Monitor the outlet pressure during start-up to prevent an outlet pressure overload.

6. Make certain that there are no leaks and that all connections are tight. 7. Adjust setpoint (outlet pressure) by turning adjustment screw. Turn clockwise to increase and

counterclockwise to decrease. Be sure to tighten lock nut after adjustment is completed. Do not adjust when regulator is closed (no flow). Only adjust when gas is flowing through regulator.

8. The spring case housing vent connection is a potential escape path (in the event of a diaphragm rupture) for flammable gas. The Model 5600 / 5600R regulator must be located and/or piped so that potential discharge occurs in a safe area away from buildings, open flames, collection areas, arcing devices, etc. Regulators that are installed indoors or in a non-vented area must be vented to the outside. Simply run vent piping (minimum 1/4NPT) from the regulator vent connection to a non-hazardous location on the outside away from any potential sources of ignition. The outlet of the vent piping must allow for the free and unobstructed passage of air and gas.

9. For applications involving combustible gas with a specific gravity greater than 1.0 it is recommended that the gas be vented outdoors where the gas will not collect in low areas and away from possible ignition sources.

CAUTION Regulators are pressure control devices with numerous moving parts subject to wear. Regulator wear is dependent upon particular operating conditions. To assure continuous satisfactory operation, a periodic inspection schedule must be adhered to with the frequency of inspection determined by the severity of the service and applicable laws and regulations.

2.2 Diaphragm Replacement 1. Relieve spring tension by loosening the locknut and turning the adjustment screw

counterclockwise. 2. Unscrew hex head screws and remove spring case housing. 3. Disconnect diaphragm from lever, connector head and disassemble complete diaphragm

assembly. 4. Reassemble using a new diaphragm with the following cautions in mind:

Connector head is engaged to lever Diaphragm is centered Diaphragm is not twisted

5. Tighten the spring case housing hex head screws finger tight only. Tighten the adjusting screw until it begins to stretch the diaphragm, then 2 more turns.

6. Tighten the spring case housing hex head screws.

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Mallard IOM Series 5600