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Dungs FRM-NOC 100025 HD, Instruction Manual, Page: 4 / 76

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Dungs FRM-NOC 100025 HD Instruction Manual Download Page 4

4 … 76

MC • Edition 2022.08 • No

. 279 663 R

ev

. -0

Product

FRM-NOC 100...

Medium Pressure Regulator 10 bar

Manufacturer

Karl Dungs GmbH & Co. KG ▪ Karl-Dungs-Platz 1 ▪ D-73660 Urbach/Germany

Certifies herewith that the products named in this overview were subjected to a Type Examination (production type) 

and meet the 

essential safety requirements:

•  The Pressure Equipment Safety Regulations, UKSI 2016:1105 (as amended by UKSI 2019: 969)

In the event of an alteration of the equipment not approved by us this declaration loses its validity.

The object of the declaration described above conforms with the relevant legislation.

This declaration of conformity is issued under the sole responsibility of the manufacturer.

Specified requirements of the Type Examination (production type) 

DIN EN 334

DIN EN 14382

Term of validity

2032-07-13

Approved Body

2016 No. 1105

TUV SUD BABT Unlimited

Octagon House,

Concorde Way, Segensworth North,

Fareham, Hampshire,

PO15 5RL, United Kingdom

Approved Body Number: 0168

Monitoring of the QA system

Conformity process adopted: Module B+D

B.Sc., MBA Simon P. Dungs, 

Chief Operating Officer

Urbach, 2022-08-01

3. Declaration of conformity

Summary of Contents for FRM-NOC 100025 HD

Page 1: ...rules and accident prevention regulations must be observed and if necessary personal protective measures must be taken Connected line systems must be free from dirt and contamination Hang this instruc...

Page 2: ...n gas 2 3 Risks in the case of misuse If used in accordance with their designated use the devices are safe to operate Non observance of the regulations may result in per sonal injury or material damag...

Page 3: ...nous effectuons une modification libre de l appareil L objet d crit ci dessus de la pr sente d claration correspond aux prescriptions l gales applicables en mati re d harmonisation de l Union Le fabri...

Page 4: ...approved by us this declaration loses its validity The object of the declaration described above conforms with the relevant legislation This declaration of conformity is issued under the sole responsi...

Page 5: ...MD and HD 34 11 5 Spring replacement SAV 36 11 5 1 Spring replacement Wdso 36 11 5 2 Spring replacement Wdsu 37 12 Commissioning decomissioning and recomissioning of FRM NOC or SAV 39 12 1 General inf...

Page 6: ...embrane is damaged or in the event of a breakdown of the impulse line pres sure the SAV closes MOP Maximum admissible operating pressure pd Outlet pressure pd abs Output pressure as absolute pressure...

Page 7: ...20 4 000 mbar 2 400 kPa 8 1 600 W C 0 3 58 PSI Minimum inlet pressure ND 40 mbar 4 kPa 16 W C 0 6 PSI Minimum inlet pressure MD 160 mbar 16 kPa 64 W C 2 3 PSI Minimum inlet pressure HD 550 mbar 55 kP...

Page 8: ...5 PSI Nominal diameter 10 1 15 11 2 20 2 025 DN 25 040 DN 40 050 DN 50 Outlet pressure ranges ND Low pressure MD Medium pressure HD High pressure UHD Ultra high pressure Safety device SAV Integrated s...

Page 9: ...8 40 W C 10 115 mbar 4 46 W C 10 40 240 mbar 16 96 W C 10 FRM NOC 10015 MD SAV MD Rp 11 2 MD 10 20 80 400 mbar 32 161 W C 35 400 mbar 12 160 W C 10 180 800 mbar 72 321 W C 10 FRM NOC 10015 HD SAV HD R...

Page 10: ...r 400 1 600 W C 5 5 FRM NOC 100040 ND SAV ND DN 40 ND 10 20 20 100 mbar 8 40 W C 10 115 mbar 4 46 W C 10 40 240 mbar 16 96 W C 10 FRM NOC 100040 MD SAV MD DN 40 MD 10 20 80 400 mbar 32 161 W C 35 400...

Page 11: ...the adjusted set point in which Qmax Qmin 10 is observed pd Qmin pu1 Q pu1 Qmin pu2 Qmax pu1 Qmax pu2 pu2 pds pds x 1 AC 100 pds x 1 SG 100 pds x 1 AC 100 Abbrevia tion Description AC Accuracy class...

Page 12: ...Orange 274972 4 37 130 180 350 mbar 72 141 W C Pink 274973 4 3 37 130 200 400 mbar 80 161 W C White 2 287888 4 5 35 100 300 500 mbar 120 201 W C Yellow 2 287889 5 35 100 450 700 mbar 181 281 W C Blue...

Page 13: ...n 274983 6 50 260 130 250 mbar 52 100 W C Blue 2 274985 7 50 240 200 350 mbar 80 141 W C Black 2 274986 8 50 240 300 400 mbar 120 161 W C White 287888 4 5 35 100 300 500 mbar 120 201 W C Yellow 2 2878...

Page 14: ...321 563 W C Pink 276126 3 5 60 15 0 1 200 3 000 mbar 482 1 205 W C Specific adjustment range overpressure Wdso Spring colour Order number Wire mm Length mm mm Setpoint range ND MD HD UHD Silver 27036...

Page 15: ...e event of a breakdown of the impulse line pressure the SAV closes pd Outlet pressure pu Inlet pressure PN Nominal pressure of the flange PS Maximum admissible pressure SAV Safety shutoff valve slam s...

Page 16: ...of the setpoint spring B is equal to that of the outlet pressure The upward movement of the working dia phragm F causes the lever system D to be pulled upwards In this way the control plate A is then...

Page 17: ...MC Edition 2022 08 No 279 663 Rev 0 17 76 A B C D E A B C D E F Type UHD F Type HD...

Page 18: ...18 76 MC Edition 2022 08 No 279 663 Rev 0 A B C D F E A B C D E F ND MD for Rp 2 DN 40 DN 50 ND MD for Rp 1 Rp 1 5 and DN 25...

Page 19: ...MC Edition 2022 08 No 279 663 Rev 0 19 76 8 Dimensions FRM NOC F A C D E B Option external line Only on request Ermeto screw connection 12 L GE 12 1 4 with screw connection M 16 for pipes 12 x 1 5 G...

Page 20: ...255 1 2 G 1 4 G 11 24 3 FRM NOC 10020 UHD 279067 280247 10 1 000 145 2 210 156 61 345 670 1 2 G 1 4 G 16 35 2 Type Item N pmax bar kPa PSI DN Dimensions mm Weight kg lbs DN NPS A B C D E F G FRM NOC...

Page 21: ...MC Edition 2022 08 No 279 663 Rev 0 21 76 FRM NOC SAV A C G E B Option external line Only on request Ermeto screw connection 12 L GE 12 1 4 with screw connection M 16 for pipes 12 x 1 5 D F...

Page 22: ...4 G 13 28 7 FRM NOC 10020 UHD SAV UHD 279053 280235 10 1000 145 2 210 156 250 345 670 1 2 G 1 4 G 18 39 7 Type Item N pmax bar kPa DN Dimensions mm Weight kg lbs DN NPS A B C D E F G FRM NOC 100025 ND...

Page 23: ...se 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...

Page 24: ...Shut off valve inlet side e g ball valve or butterfly valve 2 Filter 3 Welded part 4 Pressure gauge inlet side 5 Regulator with SAV integrated 6 Stabilisation section 7 Pressure gauge outlet side 8 P...

Page 25: ...h the SAV vent or a relief valve vent Do not manifold the SAV vent with a relief valve vent Do not manifold other vents of similar devices regula tor to regulator relief valve to relief valve etc unle...

Page 26: ...umulation on the roof does not cover or isolate the termination point from the atmosphere To limit the consequences of rain or debris getting into the vent always turn the outlet of the vent down towa...

Page 27: ...st 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 A Valve dis...

Page 28: ...Remove the protective cap A 2 Turn the external adjusting screw B using the spanner size 24 mm 3 Clockwise rotation Increases the initial tension of the adjustment spring thus increasing the outlet pr...

Page 29: ...rotective cap A 2 Turn the external adjusting screw B using the Allen key size 3 Clockwise rotation Increases the initial tension of the adjustment spring thus increasing the outlet pres sure pds 4 Co...

Page 30: ...W C pdo pd x 1 5 A B C F E G D Adjusting the upper over response pressure pdo setpoint 1 Remove the protective cap A 2 Turn the external adjusting screw B using a socket wrench SW 22 mm 3 Turning cloc...

Page 31: ...over shut down pressure SAV AGo 10 Response pressure group of the lower under shut down pressure SAV AGu 10 Response group of the SBV AG 5 Result Device group Device data Pressure graduation Safety d...

Page 32: ...placement B Remove the protective cap A A 2 Unscrew adjustment screw E Unscrew the adjust ing nut B counterclockwise as far as it will go 1 11 4 1 Type UHD Remove from the spring housing F the shut of...

Page 33: ...djustment range 8 Place the disc D with the ball back on the spring 9 Screw on the shut off cap C again on the spring dome Tighten the adjusting screw B until the desired spring pre load is reached Re...

Page 34: ...22 08 No 279 663 Rev 0 11 4 2 Type ND MD and HD Remove the protective cap A A 1 B 2 Release the setpoint spring E Completely loosen adjusting nut B counterclockwise B 3 Remove the adjusting nut B Remo...

Page 35: ...ring E from the spring chamber F 5 6 Insert a new spring with the appropriate adjustment range 7 Place the washer D back on the spring 8 Screw the adjusting nut B back into the spring dome until the d...

Page 36: ...022 08 No 279 663 Rev 0 11 5 Spring replacement SAV 11 5 1 Spring replacement Wdso 1 Unscrew the adjusting spring B from the spring dome G using an open ended wrench 22 mm B Remove the protective cap...

Page 37: ...ring dome G 2 Install new spring 3 Tighten the adjusting screw B and the washer D in the spring dome using an open ended wrench size 22 mm until the required spring preload is reached 4 E 11 5 2 Sprin...

Page 38: ...v 0 3 1 Remove the spring F from the spring dome 2 Install new spring 3 Tighten the ad justing screw C in the spring dome H using a wrench size 17 mm until the desired spring preload is reached H F 4...

Page 39: ...setting or block the line upstream of the SBV and test at 1 1 x system specific operating pressure maximum PS of the device 7 Observe the waiting time necessary for the pressure com pensation pressur...

Page 40: ...e 3 6 Once the operating pressure setting of the pressure regulator on the outlet side is reached the SAV can be reset by pulling the protective cap A to its me chanical stop and until it locks in pla...

Page 41: ...outlet side using a pressure gauge 6 6 Avoid inadmissible high pressure on the outlet side Stop applying pressure immediately after the SAV has tripped 6 7 Once the SAV trips read the upper over resp...

Page 42: ...or does not respond The pulse line is not connected Connect install the pulse line The pulse line is clogged Clean the pulse line The pulse line has leaks Seal the pulse line The pulse line is damage...

Page 43: ...utlet pressure corresponds to the inlet pressure The pulse line is not connected Install the pulse line The pulse line is closed Check the pulse line The pulse line has leaks Seal the pulse line The w...

Page 44: ...ts Do not use alcohol based or solvent containing cleaning solutions for cleaning the device Greases adhesives sealing material must be ap proved Prior to maintenance Shut off valves both on the inlet...

Page 45: ...MC Edition 2022 08 No 279 663 Rev 0 45 76 Type UHD X Y Q S W V M C A B D E G F J K L N P H O R U I...

Page 46: ...46 76 MC Edition 2022 08 No 279 663 Rev 0 Type ND MD for 1 11 2 and DN 25 and type HD M B A E G F L N H X Y Q S W V Z2 O I T Z1 J...

Page 47: ...MC Edition 2022 08 No 279 663 Rev 0 47 76 Type ND MD for 2 DN 40 DN 50 M B D E G F J K L N H X Y Q S W V O I T...

Page 48: ...maintenance instructions 14 2 1 Preparation 14 2 2 Replace working membrane Follow the steps shown in section 11 4 to extract the regulating spring 14 2 2 1 Type UHD 1 Loosen the screws G using an Al...

Page 49: ...r size 13 mm Remove the disc from the spring K K 4 Remove the safety spring L L 5 Remove the working membrane M from the guide rod N Check the condition of the working membrane If necessary use a new...

Page 50: ...n 2022 08 No 279 663 Rev 0 1 Loosen the screws G using an Allen key size 5 mm G 2 Remove the upper membrane cover F F 14 2 2 2Type ND MD for 1 11 2 DN25 and type HD H 7 Replace the O Ring H Z2 3 Remov...

Page 51: ...or 1 11 2 and DN 25 ND and MD J 6 Remove the working membrane M from the guide rod N Check the condition of the working mem brane If necessary use a new working membrane M maintenance set 17 18 19 or...

Page 52: ...9 663 Rev 0 3 Loosen the nut J using a spanner size 13 mm J Remove the disc from the spring K K 4 14 2 2 3 Type ND MD for 2 DN 40 and DN 50 1 Loosen the screws G using an Allen key size 5 mm G 2 Remov...

Page 53: ...move the working membrane M from the guide rod N Check the condition of the working membrane If necessary use a new working membrane M maintenance set 21 or 22 as appropriate when reassembling H 7 Rep...

Page 54: ...1 Loosen the pulse line outlet of the SAV with a spanner measuring 14 mm 14 2 3 1 Type UHD 2 Remove the screws O from the body X using a spanner size 13 mm 1 11 2 DN 25 or 17 mm 2 DN 40 DN 50 3 O 4 Re...

Page 55: ...valve seat V Unscrew from the body X the valve seat V using the socket wrench 6 Screw a new valve seat V of the desired size with a new O Ring W maintenance set 3 4 5 6 as re quired onto the body X 1...

Page 56: ...22 08 No 279 663 Rev 0 3 4 5 6 Replace valve seat V Unscrew from the body X the valve seat V using the socket wrench Remove the regulator hood P from the body X Replace the O Ring Q Remove the seal as...

Page 57: ...e desired size with a new O Ring W maintenance set 3 or 4 as required into the body X 1 Loosen the pulse line outlet of the SAV with a spanner measuring 14 mm 2 14 2 3 3 Type ND MD for 2 DN 40 and DN...

Page 58: ...V Unscrew from the body X the valve seat V using the socket wrench 5 Screw a new valve seat V of the desired size with a new O Ring W maintenance set 5 or 6 as required onto the body X 3 6 Replace th...

Page 59: ...663 Rev 0 59 76 14 2 4 Replace seal 14 2 4 1 Type UHD 1 2 Loosen the nuts R 3 4 Remove the R nuts Remove the fastening screwsT from the lever set with a size 4 mm Allen key Remove the U clamping plate...

Page 60: ...60 76 MC Edition 2022 08 No 279 663 Rev 0 7 8 5 6 Remove the lever set I Remove the bottom cover O Replace the O Ring Q Replace seal assembly S maintenance set 8 11 13 or 16 as required I O Q S...

Page 61: ...and type HD See section 14 2 3 2 steps 1 to 5 and replace with maintenance kit 7 8 10 12 13 as appropriate 14 2 4 3 Type ND MD for 2 DN 40 and DN 50 1 2 Remove the fastening screws T from the lever s...

Page 62: ...62 76 MC Edition 2022 08 No 279 663 Rev 0 5 3 4 Remove the bottom cover O Replace seal assembly S maintenance set 9 14 21 or 22 as required Remove the lever set I I O S...

Page 63: ...om locking pressure adjustment spring G Upper diaphragm disc only in the version HD H Allen screws 6 units I Spring dome ASE J Top locking pressure adjustment screw K Bottom locking pressure adjustmen...

Page 64: ...he protec tive cap L 3 Release the adjusting springs at the adjust ing screws J and K 2 14 3 2 Removing the ASE SAV mechanism only from the housing 14 3 1 Preparation Loosen the four hexago nal socket...

Page 65: ...he ASE on the body 1 Insert a new O Ring N maintenance set 4 or 5 into the groove provided in the housing M 2 Screw the thread of the connecting piece O onto the body M using a hook wrench 60 90 mm 3...

Page 66: ...66 76 MC Edition 2022 08 No 279 663 Rev 0 14 4 Tools required A B C2 D C1...

Page 67: ...1810 D 60 90 60 90 60 90 4 Replace the working membrane in the ASE Internal hex key C2 ND MD HD 4 4 4 SAV Work step Tool designation Pressure rating Wrench size mm DN 25 DN 40 DN 50 1 Loosen the pulse...

Page 68: ...ng functional and leakage testing of SAV 1 The maintenance intervals depend on the system specific operating and environmental conditions gas quality state of the pipelines etc 2 The maintenance inter...

Page 69: ...FRM NOC10010 15 XX 287755 4 KIT SHELL M 30 ORING FRM NOC100025 XX 287756 5 KIT SHELL M 45 ORING FRM NOC10020 040XX 287757 6 KIT SHELL M 56 ORING FRM NOC100050 XX 287758 7 SEAL O Ring BODY AND COVER FR...

Page 70: ...773 13 MEMBRANE 1000422 20 40 50 MD MEMBRANE JOINT FRM NOC10020 040 050 MD 287774 14 MEMBRANE 1000413 20 40 50 HD MEMBRANE SPACER JOINT FRM NOC10020 040 050HD 287775 15 MEMBRANE 1000424 20 40 50 UHD M...

Page 71: ...humidity Ozone Stress condition of the component 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 Tensi...

Page 72: ...andard density of pn 0 83 kg m3 and and a gas inlet temperature of t 15 C The mass flow through a nozzle increases with a constant inlet pressure and a decrease in pressure after the nozzle until it r...

Page 73: ...ore fiamma UV1 N A 10 000 h3 Gasdruckregelger te1 Gas pressure regulators1 Dispositifs de r glage de pression du gaz1 Regolatori della pressione del gas1 N A 15 EN 88 1 EN 88 2 Gasventil mit Ventilpr...

Page 74: ...74 76 MC Edition 2022 08 No 279 663 Rev 0...

Page 75: ...MC Edition 2022 08 No 279 663 Rev 0 75 76...

Page 76: ...Edition 2022 08 No 279 663 Rev 0 Karl Dungs GmbH Co KG Karl Dungs Platz 1 73660 Urbach Germany Phone 49 7181 804 0 Fax 49 7181 804 166 e mail info dungs com Internet www dungs com Head of office and...

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