Ordan 5131 Instructions

REGULATOR
REPAIR KIT

FIELD REPAIR INSTRUCTIONS FOR 5101-BZR REGULATOR

PYRONICS, INC. DOES NOT RECOMMEND FIELD REPAIRS OF 5101-BZR REGULATORS. IT IS EXTREMELY DIFFICULT
TO GET THE SAME SETTING IN THE FIELD AS OPPOSED TO A FACTORY BUILT OR REBUILT UNIT. IN ADDITION,
THERE IS A POSSIBILITY OF THE REGULATOR BEING ASSEMBLED IN AN IMPROPER MANNER WHICH COULD
CREATE A HAZARDOUS CONDITION.
We realize, that on occasion, a situation develops that a field repair is the most practical solution.
The following instructions pertain to 3/4" through 3" size of 5101-BZR Regulators manufactured by Pyronics. The minimum repairs will
be considered initially, and then complete rebuild will be discussed. In the majority of cases the repair of a BZR Regulator will
require replacement of the main diaphragm. In this case, a partial disassembly is required.
1. Remove the bottom plug [item 13] from the regulator body [item 12] and inspect, as well as possible, the valve disc [item 25],
o-ring [item 31] and valve seat for dirt or damage. After inspection, push the valve firmly into the seat and block in this position.
A piece of Styrofoam or similar material can be used to hold the valve disc in place.
NOTE: If it is suspected that the valve disc or valve seat is damaged, a complete disassembly of the unit is necessary. Go to
step 17.
2. Snip the seal wire and remove cap [item 1]. Pull up gently on the spring adjusting screw [item 14] and unhook spring [item 17]. Drop
spring into spring housing [item 2]. CAUTION: Do not overstretch spring; stretch just enough to remove from adjusting screw.
3. Remove the spring housing [item 2] and spring [item 17].
4. Remove the top cover [item 3] to expose the diaphragm assembly. Inspect the top diaphragm pan [item 23]. It should be perfectly
smooth and flat. Remove the top nut [item 15] of the top diaphragm assembly. CAUTION: Hold the bottom nut [item 15] securely
since it is important that the bottom nut is not moved.
5. Remove the top pan and inspect the main diaphragm. Then inspect the bottom diaphragm pan.
6. Inspect the seal diaphragm for damage, however, do not remove the seal diaphragm unless it is absolutely necessary. At this point,
no further disassembly is required if you find that only the main diaphragm and/or pans have been damaged. Replace damaged parts.
If seal diaphragm is damaged, go to step 17.
7. See Section "B". Assemble lower diaphragm pan [item 23], with flange down, on valve stem [item 18], then main diaphragm
[item 7], fiber washer [item 22], top pan [item 23], with flange up, steel washer [item 21], lock washer [item 20], then upper nut
[item 15].
CAUTION: Align holes in diaphragm with holes in the bottom cover [item 8]. Diaphragm must be flat and free from wrinkles.
Hold bottom nut [item 15] stationary and tighten top nut [item 15].
8. It is extremely important that there is no twist in the seal diaphragm. To check for this twist, hold top pan [item 23] and rotate main
diaphragm assembly to the left until it becomes tight, mark position on bottom cover, then rotate to right and mark position on
bottom cover. The hole in the diaphragm should align with the cover holes midpoint between these two positions. If the position of
main diaphragm is not proper, loosen top nut [item 15], relocate main diaphragm and repeat procedure.
9. See Section "A". Assemble gaskets [item 6] below and above main diaphragm [item 7], then assemble bolts [item 5] up through
cover and gaskets.
10. Hook one end of spring [item 17] through hole in valve stem [item 18].
11. Assemble top cover [item 3] over bottom cover putting spring through center of top cover. Assemble nuts [item 26] finger tight
only.
CAUTION: Operation of combustion equip-
ment can be hazardous resulting in bodily in-
jury or equipment damage. Each burner should
be supervised by a combustion safeguard and
only qualified personnel should install, make
system adjustments and perform any required
service.
ORDAN THERMAL PRODUCTS LTD
Combustion Equipment & Controls for Industry
21 Amber St # 9, Markham Ontario Canada L3R 4Z3
Tel: (905) 475-9292 Fax: (905) 475-3286
www.ordanthermal.com
MODEL: 5131
Revision: 0
NOTICE: PYRONICS practices a
policy of continuous improvement in
the design of its products. It reserves
the right to change the specifcations
at any time without prior notice.