Dungs 273061 Instructions Manual Download Page 3

Page: 3 / 56

2 …56

MC • Edition 04.19 • No

. 278 349

3 … 56

EU Declaration of conformity

Produkt / Product

Produit / Prodotto

FRM 100065 - 100080

FRM 250065 - 250080 Medium Pressure Regulator 10 bar / 25 bar

Hersteller / Manufacturer

Fabricant / Produttore

Karl Dungs GmbH & Co. KG

Karl-Dungs-Platz 1

D-73660 Urbach, Germany

bescheinigt hiermit, dass die in die

ser Übersicht genannten Produkte

einer

EU-Baumusterprüfung

un-

terzogen wurden und die wesentli

chen Sicherheitsanforderungen der:

EU-Druckgeräterichtlinie

2014/68

in der gültigen Fassung erfüllen.

Bei einer von uns nicht freigegebe

nen Änderung des Gerätes verliert

diese Erklärung ihre Gültigkeit.

certifies herewith that the products

named in this overview were sub

jected to an EU type-examination

and meet the essential safety

requirements:

EU Pressure Equipment Directive

2014/68

as amended.

In the event of an alteration of the

equipment not approved by us this

declaration loses its validity.

certifie par la présente que le

produit mentionné dans cette vue

d'ensemble a été soumis à un

examen de type de l'UE et qu'il

est conforme aux exigences en

matières de sécurité des dernières

versions en vigueur de :

à la directive UE « Équipements

sous pression »

2014/68

Ce communiqué n'est plus valable

si nous effectuons une modification

libre de l'appareil.

Con la presente si certifica che i

prodotti citati in questa panoramica

sono stati sottoposti a una prova di

omologazione UE e che i requisiti

di sicurezza essenziali:

direttiva UE sulle attrezzatture

a pressione

2014/68

sono soddisfatti nella versione valida.

In caso di modifica dell'apparecchio

non ammessa, questa dichiarazione

perde di validità.

Prüfgrundlage der EU-Baumusterprüfung

Specified requirements of the EU type-examination

Base d'essai de l'examen de type de l'UE

Criteri di prova dell'omologazione UE

DIN EN 334 (01.07.2009)

DIN EN 14382 (01.07.2009)

Gültigkeitsdauer/Bescheinigung

Term of validity/attestation

Validité/certificat

Durata della validità/Attestazione

2024-09-12

CE-0085CP0256

Notifizierte Stelle (EU Baumusterprüfung: Modul B)

Notified Body (EU type-examination: Module B)

Organisme notifié (Examen de type de l‘UE: module B)

Organismo notificato (Esame UE del tipo: modulo B)

DVGW CERT GmbH

Josef-Wirmer-Straße 1-3

D-53123 Bonn, Germany

Notified Body number: 0085

Überwachung des QM-Systems (Modul D)

Monitoring of the QM system (module D)

Contrôle de la gestion de l‘assurance qualité (module D)

Monitoraggio del sistema QM (modulo D)

DVGW CERT GmbH

Josef-Wirmer-Straße 1-3

D-53123 Bonn, Germany

Notified Body number: 0085

B. Sc., MBA, Simon P. Dungs

Geschäftsführer / Chief Operating Officer

Directeur / Amministratore

Urbach, 2019-04-01

Summary of Contents for 273061

Page 1: ... be observed and if neces sary personal protective measures must be taken Connected line systems must be free from dirt and contamination Hang this instruction manual in a readily visible place inside the installation room Do not carry out any work until you have read the safety instructions of this in struction manual and are qualified to do so The device may only be operated in compliance with t...

Page 2: ...signated use the de vices are safe to operate Non observance of the regulations may result in personal injury or material damage financial damage or environ mental damage 3 Approval EU declaration of conformity Operator errors or misuse present risks to life and limb of the operators and also to the device and other material property Use with dry and clean gases only no aggressive media Use only i...

Page 3: ... est plus valable si nouseffectuonsunemodification libre de l appareil Con la presente si certifica che i prodotti citati in questa panoramica sono stati sottoposti a una prova di omologazione UE e che i requisiti di sicurezza essenziali direttiva UE sulle attrezzatture a pressione 2014 68 sonosoddisfattinellaversionevalida Incasodimodificadell apparecchio nonammessa questadichiarazione perde di v...

Page 4: ... 23 12 Commissioning and decommissioning 24 12 1 General information 24 12 2 Leakage test 24 12 3 Commissioning unlocking control of the set values 25 12 4 Recommissioning 27 12 5 Decommissioning 27 13 Faults and their causes 27 14 Maintenance 29 14 1 General information 29 14 2 Maintenance instructions of the regulator 31 14 2 1 Preparation 31 14 2 2 Replacement of the working diaphragm 31 14 2 3...

Page 5: ...re pd abs Output pressure as absolute pressure pu Inlet pressure pu abs Inlet pressure as absolute pressure pdo Upper response pressure pdu Lower response pressure pmax Maximum operating pressure pzul System specific operating pressure according to the regulator PN Nominal pressure of the flange PS Maximum admissible pressure SAV Safety shutoff valve SBV Safety relief valve SG Lock up pressure cla...

Page 6: ...5 bar 2500 kPa FRM 100 10 bar 1000 kPa Outlet pressure range 90 4000 mbar 9 400 kPa Minimum differential pressure MD 350 mbar 35 kPa Minimum differential pressure HD UHD 500 mbar 50 kPa Materials Main body housing cast iron GGG 50 Diaphragm housing steel Diaphragms NBR Ambient temperature 20 C to 60 C Technical data SAV Device Safety shutoff valve in compliance with EN14382 class A Type IS FRM 100...

Page 7: ...20 mbar FRM 100065 HD DN 65 HD AC 5 SG 10 400 1500 mbar FRM 250065 UHD DN 65 UHD AC 5 SG 10 1000 4000 mbar FRM 100065 MD SAV MD DN 65 MD AC 5 10 SG 10 20 90 420 mbar 35 400 mbar AG 10 180 800 mbar AG 10 FRM 100065 HD SAV HD DN 65 HD AC 5 SG 10 400 1500 mbar 150 1400 mbar AG 5 500 3500 mbar AG 5 FRM 250065 UHD SAV UHD DN 65 UHD AC 5 SG 10 1000 4000 mbar 150 3000 mbar AG 5 1300 5000 mbar AG 5 FRM 10...

Page 8: ...he outlet pressure SG Lock up pressure class Qmin pu1 2 AC minimum flow volume at a specific inlet pressure pu lower limit of the volume flow at which the stable operating conditions for a given nominal value within the given operating temperature range Qmax pu1 2 AC maximum flow volume at a specific inlet pressure pu upper limit of the volume flow at which a given accuracy class for a given nomin...

Page 9: ...eter mm Length mm Diameter mm Setpoint range mbar MD HD UHD Blue 270356 2 0 55 12 3 35 110 Black 270357 2 3 55 12 3 50 250 Purple 270358 2 5 55 12 3 80 400 150 500 150 500 Orange 270359 2 8 55 12 3 300 1000 300 1000 Silver 270360 3 0 60 15 0 800 1400 800 1400 Pink 276126 3 5 60 15 0 1200 3000 Specific set range overpressure Wdso Spring colour Order number Wire diameter mm Length mm Diameter mm Set...

Page 10: ... for the upper response pressure Wdsu Specific adjustment range of the adjusting spring installed for the lower response pressure Regulator SAV Regulator SSD Made in Barcelona Spain DIN EN14382 CE 0085CP0255 SAE SAV100080MD S N 1PDK276115S00000000 IS class A AGu 10 AGo 10 yyyy mm dd 20T60 DN80 PN25 PS 10 bar 1000 kPa Wdo 1 3 5 bar 130 500 kPa Wdu 0 035 0 4 bar 3 5 40 kPa Wdsu 0 05 0 25 bar 5 25 kP...

Page 11: ... is reduced The flow volume decreased in this way reduces the outlet pressure until the set nominal value outlet pressure is reached again and a balance of forces at the working diaphragm F is established If the outlet pressure drops the force on the working diaphragm F in the lower diaphragm shell D decreases also The working diaphragm F is thus pushed down wards until the force of the setpoint s...

Page 12: ...RM 100065 MD 277241 10 1000 65 500 276 120 567 892 56 FRM 100065 HD 277242 10 1000 65 380 276 120 567 892 50 FRM 250065 UHD 277243 25 2500 65 380 276 120 567 892 52 FRM 100080 MD 277244 10 1000 80 500 298 120 567 892 58 FRM 100080 HD 277245 10 1000 80 380 298 120 567 892 53 FRM 250080 UHD 277246 25 2500 80 380 298 120 567 892 55 B ...

Page 13: ...65 500 276 135 567 892 71 FRM 100065 HD SAV HD 276113 10 1000 65 380 276 135 567 892 65 FRM 250065 UHD SAV UHD 276114 25 2500 65 380 276 135 567 892 67 FRM 100080 MD SAV MD 276115 10 1000 80 500 298 135 567 892 73 FRM 100080 HD SAV HD 276116 10 1000 80 380 298 135 567 892 68 FRM 250080 UHD SAV UHD 276117 25 2500 80 380 298 135 567 892 70 A C E D B ...

Page 14: ...ith use of suitable bonding straps Prevent contact voltage and ignitable flashover The performance data on the type plate corresponds to the purchase ordering data Flanges on the inlet side and outlet side of the connecting line are parallel The sealing surfaces of the flange are undamaged and clean The maximum inlet pressure of the system is lower than the maximum admissible pressure of the regul...

Page 15: ...let side e g ball valve or butterfly valve 2 Filter 3 Welded part 4 Pressure gauge inlet side 5 Regulator with integrated SAV 6 Calming section 7 SBV 8 Ball valve 9 Pressure gauge outlet side 10 Test burner 11 Venting ball valve 12 Impulse line SAV 13 Impulse line regulator 14 Vent line connection regulator 15 Vent line connection SAV 16 Relief line connection SBV Maximum flow velocity in the stab...

Page 16: ...00 125 150 Rp 1 1 2 2 Mmax Nm t 10 s 70 105 225 340 610 110 1600 2400 5000 6000 7600 Tmax Nm t 10 s 35 50 85 125 200 250 325 400 Max torque system accessories M G M 4 M 5 M 6 M8 G G G G Mmax Nm t 10 s 2 5 Nm 5 Nm 7 Nm 15 Nm 5 Nm 7 Nm 10 Nm 15 Nm Max torque flanged joint Stud M 12 x 55 EN 13611 M 16 x 65 DIN 939 Mmax Nm t 10 s 30 Nm 60 Nm Mounting position Mmax Tmax Mmax ...

Page 17: ...be installed The SAV is designed to shut down the gas supply in the event of a fault condition The SAV complies with the requirements of EN 14382 as safety shutoff valve Main components 1 Shutter case 2 Closing spring 3 Trigger mechanism 4 Chamber with the pressure to be monitored 5 Working diaphragm 6 Push rod 7 Setpoint spring for pdo 8 Setpoint spring for pdu 9 Protective cap Function Chamber 4...

Page 18: ... the protective cap A 2 Turn the adjusting screw B using an open ended wrench SW 24 3 Turning clockwise the preload of the setpoint spring is increased and the outlet pressure pds is increased 4 Turning counter clockwise the setpoint spring is re leased and the outlet pressure pds reduced 5 After the setting screw on the protective cap A again C A B D E F ...

Page 19: ...for lower triggering affects the set value for upper triggering Please set the vacuum triggering first A mutual influence of the pressure regulator and the safety shutoff valve must be excluded Calculation of the recommended set values according to the outlet pressure pd of the regulator The SAV must lock as soon as it reaches the 1 1 times max operating pressure according to the system speci fica...

Page 20: ...sponse pressure group of the upper shut down pressure SAV AGo 10 Response pressure group of the lower shut down pressure SAV AGu 10 Response group of the SBV AG 5 Result Device group Device data Pressure graduation Safety devices against excessive pressure Gas pressure regulator Safety device against insufficient pressure AGo 10 SAV AGo 10 AG 5 SBV AG 5 440 mbar 400 mbar 360 mbar 315 mbar 300 mbar...

Page 21: ...lator springs Unscrew the sealing cap C from the spring dome us ing a hinged hook wrench 90 155 B Remove the protective cap A A 2 F C 3 4 Release the setpoint spring E unscrew the adjusting screw B counter clockwise until it stops Remove the sealing cap C C 1 ...

Page 22: ...6 7 Insert a new spring with a suitable adjustment range 8 Reattach the spring washer D incl ball on the spring 9 Reinsert the sealing cap C in the spring dome F Tighten the adjusting screw B until the required spring preload is reached Reinsert the protective cap A 11 5 Replacement of SAV springs Remove the protective cap A A 1 ...

Page 23: ...all the new spring 3 Tighten the adjusting screw C in the spring dome G using a tube socket wrench SW 17 until the desired spring preload is reached 4 Reinsert the protective cap A F G 1 Remove the spring E from the spring dome G 2 Install the new spring 3 Tighten the adjusting screw B and plastic washer D in the spring dome G using a tube socket wrench SW 22 until the desired spring preload is re...

Page 24: ...ves must be closed 3 Release the test section Check the presence of gas and safely release to the atmosphere 4 Test pressure blow off pressure SBV block the line upstream of the SBV 5 Connect the test section to the test device and apply pres sure 6 Test pressure 1 1 x system specific operating pressure Maximum PS of the device Different pressure ratings of the system must be taken into account 7 ...

Page 25: ...tlet side on the pressure gauge 6 6 Avoid inadmissible high pressure on the outlet side Stop applying pressure immediately after the SAV has tripped 3 1 Press the bypass button valve Check increase in downstream pressure until setpoint pressure is achieved Then stop pressing bypass buton valve 3 2 Operate hand lever to open the valve 6 7 Read the upper response pressure on the pressure gauge on th...

Page 26: ...load 1 2 3 4 5 6 7 8 9 10 11 Pos Designation 1 Shut off valve inlet side 2 Filter 3 Pressure gauge with pushbutton 4 Venting ball valve 5 Regulator with integrated SAV 6 SBV with shutoff valve Pos Designation 7 Pressure gauge with pushbutton 8 Venting ball valve 9 Test burner 10 Shut off valve outlet side 11 Hose ...

Page 27: ... line The impulse line is leaky Seal the impulse line The impulse line is broken Replace the impulse line The impulse pressure is outside the adjustment range Set the shut down pressure of the SAV The adjusting springs are not suitable for the application Replace the adjusting springs The SAV can be activated but not sealed The valve disc is damaged or worn out Replace the ASE or have it repaired ...

Page 28: ...d Replace the admission pressure compensation diaphragm The O rings in the regulator are damaged Replace the O rings of the regulator The O rings of the SAV are damaged Replace the O rings of the SAV During operation the outlet pressure corresponds to the inlet pressure The pulse impulse is not installed Close the impulse line The pulse impulse is blocked Check the impulse line The pulse impulse i...

Page 29: ...ber parts Prior to maintenance Shut off valves both on the inlet and outlet side are closed Lines are unstressed and free from combustible gas Prevent explosive gas air mixture the room atmosphere must constantly be monitored through gas concentration measuring devices for the detection of gas leakages SAV is in the closing position Original spare parts are available Pos Designation A Protective c...

Page 30: ...30 56 MC Edition 04 19 No 278 349 ...

Page 31: ...14 2 2 Replacement of the working diaphragm 4 Unscrew the sealing cap C from the spring dome using a jointed hook wrench 90 155 5 Remove the spring washer D incl ball and the setpoint spring E 1 Loosen the impulse line and the vent line and remove them Release the spring 2 Remove the protective cap A 3 Completely release the setpoint E spring at the adjusting screw B using an open ended wrench SW ...

Page 32: ... 56 MC Edition 04 19 No 278 349 3 Remove the upper diaphragm shell F Remove the O ring H Remove the reducing washer I F H I Remove the upper diaphragm shell F FRM HD UHD FRM MD FRM HD UHD FRM HD UHD 5 4 F ...

Page 33: ...349 33 56 Loosen the nut J M 8 using an open ended wrench SW 13 Remove the spring washer K J K 6 FRM HD UHD FRM MD FRM HD UHD FRM MD 7 Loosen the nut J M 8 using an open ended wrench SW 13 Remove the spring washer K J K SW 13 ...

Page 34: ... signs of damage or wear If neces sary reassemble a new working diaphragm M maintenance kit 2 L M FRM HD UHD FRM MD FRM HD UHD FRM MD 8 9 Remove the safety spring L Remove the working diaphram M from the guide rod N and check for signs of damage or wear If neces sary reassemble a new working diaphragm M maintenance kit 2 M L ...

Page 35: ...e sure that SAV is tripped by pushing triggering button 2 Loosen the 8 screws AL using an open ended wrench size SW 17 3 Remove the lower cover AM and o ring AK 4 AM AK AL SW 17 Loosen nut R using a tube wrench SW 27 fixing the control plate AJ with a tube wrench SW 30 SW 30 SW27 ...

Page 36: ...36 56 MC Edition 04 19 No 278 349 7 6 5 Take out the guide rode N and the bottom control plate AJ with a hammer For safety hold the control plate from below with your hand so that it does not fall ...

Page 37: ...2 O 3 4 S U Y Loosen screws Y using an open ended wrench SW 17 Remove lower cover of the working diaphragm O Remove compensation guide support S Remove upper compensation fixing disc U 14 2 4Replacement of the compensation membrane SW 17 ...

Page 38: ...9 No 278 349 5 1 Remove the under compensation fixing disc V under the compensating membrane T 2 Remove bypass tubbing using an open ended wrench SW 14 T Replace compensation membrane T 14 2 5Replacement closing part SAV V ...

Page 39: ...MC Edition 04 19 No 278 349 39 56 3 5 6 AA 4 Q Closing shell Remove o ring Q Remove closing spring SAV Replace closing shell SAV Closing spring Remove intermediate housing P and O rings Z and AA Z P ...

Page 40: ... Preparation Remove circlip Remove resetting lever 1 Remove the impulse and vent lines 2 Remove the protective cap A 3 Release the setpoint springs at the adjusting screws B and C page 19 Make sure that SAV is tripped by pressing triggering button 1 14 3 Maintenance instruction of the SAV ...

Page 41: ...ll new ASE in its position and put back 2 bolts using an allen key SW 5 2 Install again resetting lever in his position and fix with circlip on the shaft 3 Put back again setting spring for over and under pressure tripping value 3 Replace ASE Loosen the 2 screws using an allen key SW 5 ...

Page 42: ...ating Wrench size DN 65 DN 80 1 Loosen the pulse lines Open ended spanner A MD HD UHD SW 24 SW 24 2 Release the setpoint springs Tube socket wrench B MD HD UHD SW 17 SW 17 Tube socket wrench B SW 22 SW 22 3 Loosen ASE from the housing Internal hex key C1 MD HD UHD SW 5 SW 5 A B C2 D C1 E SAV ...

Page 43: ... ended spanner A MD HD UHD SW 24 SW 24 Hinged hook wrench D 90 155 90 155 3 Replace the working diaphragm Open ended spanner A MD HD UHD SW 17 SW 17 Open ended spanner A SW 13 SW 13 4 Replace the control plate Tube socket wrench B Hammer E MD HD UHD SW 30 SW 30 5 Loosen bypass pipe Open ended spanner A MD HD UHD SW 14 SW 14 6 Replace closing shell SAV Open ended spanner A MD HD UHD SW 17 SW 17 Reg...

Page 44: ...sary for the pressure com pensation according to the system specific volumes External leakage 7 Use a suitable leak detection spray on the device 8 Monitor the foam formation Internal tightness 9 Remove the pressure in the test section downstream of the device 10 Monitor the increase in pressure on the outlet side pres sure gauge accuracy 0 1 mbar 11 Once the leakage test has been carried out open...

Page 45: ...MC Edition 04 19 No 278 349 45 56 B C K L M 15 Spare parts A D E F G H I J ...

Page 46: ...ing FRM 100065 100080 MD 277997 FRM 100065 100080 HD FRM 250065 250080 UHD 277998 3 Control plate with shaft FRM 100065 FRM 250065 277999 FRM 100080 FRM 250080 278000 4 Compen sating membrane FRM 100065 FRM 250065 278001 FRM 100080 FRM 250080 278002 5 Kit O rings FRM 100065 100080 FRM 250065 250080 278004 6 Protective cap SAV 100065 100080 SAV 250065 250080 278005 D F G F B A C B C E F H I D E D B...

Page 47: ... shell SAV SAV 100065 100080 SAV 250065 250080 278003 8 ASE with o ring SAV 100065 100080 MD 278006 SAV 100065 100080 HD SAV 250065 250080 UHD 278007 9 Bypass push button valve SAV 100065 100080 SAV 250065 250080 278008 10 Nozzle Set 7pc Ø 1 5 3 mm 270712 J K I L 15 2 List of spare parts of SAV H ...

Page 48: ...ubber products applies to the storage of diaphragms and O rings The ageing process mostly depends on the following factors Temperature Thermal radiation Solar radiation Humidity Relative humidity Ozone Stress conditions of the components Proper storage Storage temperature between 5 C and 20 C No direct solar radiation No direct heat sources in the storage area No exposure to ozone Tension free sto...

Page 49: ... 10082 10082 10082 10082 10082 10082 10082 9 11200 11200 11200 11200 11200 11200 11200 11200 11200 11200 11200 11200 11200 10 12319 12319 12319 12319 12319 12319 12319 12319 12319 12319 12319 12319 12319 FRM MD HD pd bar pu bar 0 1 0 15 0 2 0 25 0 3 0 35 0 4 0 4 0 5 0 75 1 1 25 1 5 0 5 1837 1757 1661 1547 1411 1245 1035 745 0 75 2342 2300 2249 2188 2116 2033 1936 1824 1693 1 2756 2738 2712 2680 26...

Page 50: ...19030 19030 19030 18 21267 21267 21267 21267 21267 21267 21267 20 23504 23504 23504 23504 23504 23504 23504 22 25741 25741 25741 25741 25741 25741 25741 25 29097 29097 29097 29097 29097 29097 29097 FRM UHD pd bar pu bar 1 1 5 2 2 5 3 3 5 4 1 5 2762 2 3906 3086 2 5 4784 4365 3379 3 5525 5346 4779 3649 3 5 6213 6173 5853 5161 3900 4 6901 6901 6759 6320 5516 4136 6 9655 9655 9655 9655 9553 9248 8718 ...

Page 51: ...48 8148 8148 8148 8148 9 9052 9052 9052 9052 9052 9052 9052 9052 9052 9052 9052 9052 9052 10 9956 9956 9956 9956 9956 9956 9956 9956 9956 9956 9956 9956 9956 FRM MD HD pd bar pu bar 0 1 0 15 0 2 0 25 0 3 0 35 0 4 0 4 0 5 0 75 1 1 25 1 5 0 5 1485 1420 1342 1250 1140 1006 837 602 0 75 1893 1859 1818 1768 1711 1643 1565 1474 1369 1 2227 2213 2192 2166 2133 2095 2049 1996 1936 1477 1 5 2796 2796 2796 ...

Page 52: ...0805 20805 20805 25 23517 23517 23517 23517 23517 23517 23517 FRM UHD pd bar pu bar 1 1 5 2 2 5 3 3 5 4 1 5 2233 2 3157 2494 2 5 3867 3528 2731 3 4465 4321 3863 2949 3 5 5021 4989 4731 4171 3152 4 5578 5578 5463 5108 4458 3343 6 7803 7803 7803 7803 7721 7475 7046 8 10029 10029 10029 10029 10029 10029 9965 10 12254 12254 12254 12254 12254 12254 12254 12 14479 14479 14479 14479 14479 14479 14479 14 ...

Page 53: ...1325 bar The KG value value refers to natural gas with a density ratio of d 0 64 according to a standard density of pn 0 83 kg m3 and gas inlet temperature of t 15 C The mass flow through a nozzle increases at constant upstream pressure with sinking pressure downstream of the nozzle until it reaches its maximum at critical pressure ratio and remains constant from that moment on At constant outlet ...

Page 54: ... 000 10 EN 1854 Low gas pressure switch N A 10 EN 1854 Automatic burner control 250 000 10 EN 298 Gaz EN 230 Oil Flame detector UV probes 1 N A 10 000 Operating hours Gas pressure regulators1 N A 15 EN 88 1 EN 88 2 Gas valve with valve testing system2 after error detection EN 1643 Gas valve without valve testing system2 50 000 200 000 depends on diameter 10 EN 161 Gas air ratio control system N A ...

Page 55: ...MC Edition 04 19 No 278 349 55 56 ...

Page 56: ...73660 Urbach Germany Phone 49 0 7181 804 0 Fax 49 0 7181 804 166 e mail info dungs com Internet www dungs com Subsidiary Karl Dungs S L U Av Can Roqueta Nº 15 Pol Ind Can Roqueta E 08202 Sabadell Barcelona Spain Phone 34 935 647 550 e mail info e dungs com Internet www dungs com ...

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