Instruction Manual

D103650X012 OS/80X Series

January 2015 - Rev. 00

Type OS/80X, OS/84X and OS/88X Slam-Shut Controller

summary
Introduction ......................................................................... 1

Characteristics..................................................................... 1

Labelling.............................................................................. 2

Dimensions and Weight....................................................... 2

Installation........................................................................... 3

Startup................................................................................. 3

Periodical Checks................................................................ 3

SEP Statement ................................................................... 3

ATEX Requirements ........................................................... 3

Maintenance........................................................................ 4 Figure 1. Type OS/80X-BP

Troubleshooting................................................................... 5

Parts Lists............................................................................ 6 Reinforced version available to be used with BM6X Series

slam-shut valves, and on BM5 DN 150 slam shut valve (e.g.
Schematic Assemblies........................................................ 7 OS/80X-BP-R).
The full range of OS/80X slam-shut controllers can be
installed in the following equipments:
BFL Series - Cronos Series - BM5 Series - BM6X Series
INTRODUCTION
This product has been designed to be used with fuel gases of
Scope of Manual 1st and 2nd family according to EN 437, and with other non
This manual provides installation, startup, maintenance, aggressive and non fuel gases. For any other gases, other
troubleshooting, and spare parts for the slam-shut than natural gas, please contact your local sales agent.
controller series OS/80X.
Characteristics
Product Description
Designed for pressure regulators and slam-shut valves Table 1. Technical Features
control, the following types are available:
• OS/80X SERVOMOTOR OVERPRESSURE UNDERPRESSURE
BODY SET RANGE SET RANGE BODY
Diaphragm actuator for minimum and/or maximum pressure. MODEL
RESISTANCE Wdo (bar) Wdu (bar) MATERIAL
(bar)
Version: BP, BPA-D, MPA-D and APA-D. Min. Max. Min. Max.
OS/80X-BP 5
• OS/84X - OS/88X 0.03 2 0.01 0.60 Aluminium
OS/80X-BPA-D 20
Piston actuator for minimum and/or maximum pressure.
OS/80X-MPA-D 0.50 5 0.25 4
Steel
• OS/80X-PN OS/80X-APA-D 2 10 0.30 7

Diaphragm actuator for minimum and/or maximum OS/84X

100
5 41 4 16
Brass
pressure, controlled by PRX-PN series pilots. OS/88X 18 80 8 70
OS/80X-PN 0.5 40 0.5 40 Steel
• OS/84X-PN OS/84X-PN 30 80 30 80 Brass
Piston actuator for minimum and/or maximum pressure,
controlled by PRX-PN series pilots. 1/4-inch NPT female threaded connections.

TM
OS/80X Series

labelling

BOLOGNA ITALY APPARECCHIO TIPO / DEVICE TYPE

O.M.T.

Note 1
MATRICOLA
SERIAL Nr. DN1
ANNO
YEAR Note 2 DN2
NORME ARMONIZ.
HARMONIZED STD. EN Wa Note 4 bar
CLASSE DI PERDITA
LEAKAGE CLASS Wao Note 5 bar
CLASSE FUNZIONALE
FUNCTIONAL CLASS Cg Wau Note 5 bar
FLUIDO GRUPPO
FLUID GROUP 1 pmax bar pao bar
PS PS
TS Note 3 °C body bar covers - bar PT= 1.5 x PS bar

Figure 2. Label for OS/80X Series

Note 1: See “Characteristics”

Note 2: Year of Manufacture
Note 3: Class 1: -10° to 60°C
Class 2: -20° to 60°C
Note 4: Specific set-point according to order
Note 5: See “Characteristics”

DIMENSIONS and weight

205 80

OFF

ON

RI ARMO OS/80X
270

ERGENZA
EM

RE S E T
E
ME C
Y

RGE N

155

OS/08X SERIES FULL RANGE WEIGHT: UP TO 7.5 kg

Figure 3. OS/80X Series Dimensions (mm)

2
 OS/80X Series

Installation SEP statement

a. Install the actuator in a covered area and protect it Emerson Process declares this product conforms to
against weather agents. Pressure Equipment Directive (PED) 97/23/EC.

b. Check that data on the plate are compatible with actual Article 3 section 3 and was designed and manufactured in
working conditions. accordance with sound engineering practice (SEP).
c. Make sure actuator is installed upright, i.e. screw Per Article 3 section 3, this “SEP” product must not bear the
(key 49) on top. CE marking.

caution
ATEX requirements
Mounting in any other way will jeopardize
actuator’s performance.
d. Carry out the connection of gas outlet (A). It must be ! Warning
derived from the pressure control piping, in a straight
tract, possibly far away from restrictions, curves or If the provisions of EN 12186 & EN 12279,
derivations, in order to avoid turbulence that can alter the national regulations, if any, and specific
trip pressure setpoints. manufacturer recommendations are not
put into practice before installation and
if purge by inert gas is not carried out
Startup before equipment’s start-up and shut-down
operations, a potential external and internal
a. Using lever, activate slam-shut by turning reset pin (key 6) explosive atmosphere can be present in
in the direction shown by the arrow. equipment & gas pressure regulating/
measuring stations/installations.
b. Wait until the pressure being controlled stabilizes and
then slowly release lever.
If a presence of foreign material in the pipelines is foreseen
c. Now repeat this procedure, make sure that levers and purge by inert gas is not carried out, the following
keep actuator properly set and that lever (key 33) is in procedure is recommended to avoid any possible external
horizontal position. ignition source inside the equipment due to mechanical
generated sparks:
Periodical Checks • drainage to safe area via drain lines of foreign materials, if
any, by inflow of fuel gas with low velocity in the pipe-work
It is recommended that actuator be efficiency checked periodically.
(5m/sec)
Cut-off Test In any case,
a. Cutoff the circuit by means of inlet and outlet valves and
disconnect the pressure control pipe (A). The Actuator • provisions of Directive 1999/92/EC and 89/655/EC shall
should cutoff at minimum pressure (only if so set). be enforced by gas pressure regulating/measuring station/
installation’s end user
b. Through the pressure control connection, use a small
pump or other appropriate means, to raise the pressure to • with a view to preventing and providing protection against
normal operating level. Reset actuator after cutoff in step a. explosions, technical and/or organizational measures
appropriate to the nature of the operation shall be taken
c. Simulate pressure increase until maximum pressure cutoff (e.g.: filling/exhausting of fuel gas of internal volume
value is reached. of the isolated part/entire installation with vent lines
d. Connect the pressure control actuator (A) and set the to safe area - 7.5.2 of EN 12186 & 7.4 of EN 12279;
circuit back to operating conditions by following the monitoring of settings with further exhaust of fuel gas to
instructions described in the Startup section. safe area; connection of isolated part/entire installation to
downstream pipeline; ….)
Valve-seal Check
• provision in 9.3 of EN 12186 & 12279 shall be enforced by
a. Slowly close the valve located downstream. pressure regulating/measuring station/installation’s end user

b. Press the “EMERGENCY” button. This will cause the • external tightness test shall be carried out after each
immediate closing of slam-shut device. reassembly at installation site using testing pressure in
accordance with national rules
c. Loosen a connector in the downstream line of the
slam-shut device or of the regulator. Check the • periodical check/maintenance for surveillance shall be
connector with soap and water, making sure there are carried out complying with national regulations, if any, and
no leaks; make any necessary repairs otherwise. specific manufacturer recommendations.

3
OS/80X Series

Maintenance Reassembly
Reassemble all parts by reversing the steps in the general
Routine actuator maintenance entails simply periodic maintenance section. As you proceed, make sure all parts
checking of the diaphragm on the Type OS/80X (the piston move freely without friction. If necessary, lubricate them with
lip seal on the Type OS/84X) and the movement of the Molykote 55 M. Make sure to:
levers, i.e. they should move freely with a minimum of
friction. If necessary, lubricate pins with “Molykote 55 M”. a. Narrow the gap between nuts (key 30 and 18) so that levers
(key 33, 36, and 20) have minimum play yet move freely
! Warning without friction.

b. Before mounting minimum spring (key 54), register

For a successful job it is indispensable to use
position of lever (key 33) by means of nut (key 70),
qualified personnel, possibly calling on our
locking it into place with locknut (key 69).
Technical Support Representatives. Before starting
maintenance, disconnect impulse connection (A) Note
to make sure there is no gas under pressure in the
pilot. When maintenance operations are finished The lever (key 33) is in proper position when
check the tightness with suds. it is exactly horizontal and in the center of
the groove of lever (key 36).
Replacing Diaphragm (OS/80X Series only)
c. Now remount lever assembly (key 17 and 2), balls
a. Remove screws (key 27) and cover (key 61). (key 10), keeping them in their seat with grease, and
stem (key 6), which is to be turned so the balls enter
b. Replace diaphragm (key 62). their seats. The stem and lever assembly should now
be tightly fitted together.
c. To remount diaphragm, coat it with grease, set it in place
around the edge of cover (key 61) and evenly tighten d. Remount bushing (key 13), make sure that the dowels are
screws (key 27) to ensure proper sealing. firmly set in the grooves of the stem (key 6).
Replacing O-ring (Type OS/84X and OS/88X only)
e. Repeatedly check if pilot resets properly and, lastly,
a. Remove plug (key 61) and extract piston (key 68) from body remount minimum spring (key 54).
(key 60).
f. Always check pilot setting.
b. Replace O-ring (key 67) and lip seal (key 66).
Minimum and Maximum Setting
c. Reassemble by reversing the above procedures.
a. Make sure that the lever (key 33) is in horizontal position
General Maintenance when pilot is reset. If necessary, use nut and locknut
(key 69 and 70) to adjust (see step b, Reassembly
a. Remove screws (key 40) and casing (key 47).
section).
b. Remove dowels (key 12) and bushing (key 13).
b. Use ring nut (key 50) to completely load maximum
c. Slide off pin (key 6), lever assembly (key 17 and 2), balls pressure spring (key 53). Loosen screw (key 49) to
(key 10) and shim ring (key 15). Wash parts, replace any completely relieve minimum pressure spring (key 54).
if worn.
c. Disconnect pressure control pipe (A).
d. Remove nuts (key 18), levers (key 20 and 36) and springs
d. Through the pressure control connection, use a small
(key 37 and 21).
pump or other appropriate means to raise the pressure to
e. Remove nut (key 30), screw (key 29) and lever (key 33). normal operating level.

f. Remove minimum register screw (key 49), maximum e. Reset pilot and reduce the pressure until it reaches
register ring (key 50) and springs (key 53 and 54). minimum cutoff level.

g. Remove cover (key 61) on OS/80X Series, or body f. Use register (key 49) to load spring (key 54) slowly until pilot is
(key 60) on Types OS/84X and OS/88X, and proceed as triggered.
directed in replacing diaphragm/O-ring section.
g. Repeat procedures (d) and (e) above, making any
h. Remove nut (key 70) and locknut (key 69), then slide off necessary adjustment in the setting.
stem assembly (key 57).
h. Bring pressure back to normal values.
i. Loosen dowel (key 3), unscrew ring (key 9), remove ball
i. Reset pilot and raise the pressure until it reaches
holder (key 5) and check seals (key 4 and 8) for wear.
maximum cutoff level.
l. Clean all parts with petrol, replace any if worn.

4
 OS/80X Series

k. Using ring nut (key 50), slowly unload spring (key 53) until

cut-off point is reached.

l. Repeat procedures (h) and (i) above, making any

adjustment necessary in the setting.

Note
Whenever minimum or maximum pressure
setting is not required, omit corresponding
steps.

Troubleshooting

Table 2. Troubleshooting for OS/80X Series Actuator

SYMPTOMS Cause ACTIONS

The actuator impulse intake (A) is not

Check connections (A)
connected properly

Downstream pressure coincides with the

Actuator does not remain set Check slam-shut settings
maximum or minimum slam-shut settings

Diaphragm (62) is damaged

To be replaced
(Lip seal (66) on types OS/84X, OS/88X)

5
OS/80X Series

PARTS LISTS

Type OS/80X Series Slam-Shut Controller

(See Figure 4)
Item Description Item Description

 1 Plate   39 Locking pin

  2 Releasing bushing  40 Screw

 3 Screw   41 Indicator pin

 4* Gasket   42 On-Off indicator

  5 Balls holder  43 Button

 6 Stem  44* O-ring

 7 Roller  45 Spring

 8* O-ring  46 Gasket

  9 Reloading nut  47 Casing

  10 Ball - Roller  48 Screw

 11 Roller   49 Minimum pressure adjusting screw

 12 Screw   50 Maximum pressure adjusting nut

  13 Reloading bushing   51 Pipe assembly

 14* O-ring  52 Washer

 15 Ring  53 Spring

  17 Reloading lever unit  54 Spring

  18 Self-locking nut   55 Lower spring holder unit

 19 Washer   56 Elastic ring

  20 Return lever   57 Stem unit

 21 Spring  58 Spring

 22 Fulcrum   59 Plate holding stem unit

 24 Label   60 Top cover

 26 Nut   61 Lower cover

 27 Screw  62* Diaphragm

  28 Reloading pin  63 Screw

 29 Screw  64 Block

  30 Self-locking nut  65* O-ring

 31 Washer   66* Lip seal

  32 Plate fulcrum  67* O-ring

 33 Lever  68 Piston

 34 Screw  69 Nut

 35 Cone  70 Locknut

  36 Releasing lever  71 Microswitch

 37 Spring   73* Gasket (only for BP, BPA-D, MPA-D)

 38 Plug  74 Filter

Rubber parts marked with (*) are supplied in the “spare parts
kit”, recommended as stock.

To order the kit it is necessary to communicate to us the type

of the slam-shut controller and its serial number.

6
 OS/80X Series

40
71

detail of type os/80x with microswitch Section d-d

20 21 22

19

18 OFF

1 ON
17
2

3
15 4
RIA RMO OS 80X
5
ERGENZA
6 EM

RESET
7 E
ME
RGENC
Y

10
14 13 12 11

section C-C

LM/1389

Figure 4. OS/80X Series Slam-Shut Controller Detailed Assembly (Standard Version)

7
OS/80X Series

41 42 19 18 43 44 45 29

30

31

32

38 22 37 35 34 26

section a-a

46 47 48 49 50 51

C 39 36 B
52

53

54
D D
52
A

24
55
33
OMT

70 56
69 57
28
48 58
73 59

60
A
62

61

A
27 26 B
section b-b
LM/1389

Figure 4. OS/80X Series Slam-Shut Controller Detailed Assembly (Standard Version) (continued)

8
 OS/80X Series

65 34 59 63 64 60 62 61 74 65 34 59 63 64 60 62 61 74

27

73

27

type os/80x-apa-d detail type os/80x-mpa-d detail

34 59 63 64 60 66 67
65 34 59 63 64 60 62 61 74

73

27

68 61

type os/80x-Bpa-d detail type os/84x detail

34 59 63 64 60 66 67

68 61

type os/88x detail

LM/1389

Figure 4. OS/80X Series Slam-Shut Controller Detailed Assembly (Standard Version) (continued)

9
OS/80X Series

10
OS/80X Series

11
OS/80X Series

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