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Instructions
FRM 100065 - 100080 - 250065 - 250080
1. Target group
The target group of this manual is qualified personnel of the
gas safety and regulating technology. Due to their specialist
training, knowledge and experience, they should be capable
of evaluating the work assigned to them and recognising
possible dangers. Only they are permitted to carry out as-
sembly, commissioning, settings and maintenance on the
devices in compliance with the recognised rules for occupa-
tional safety.
2. Warnings
2.1 General warnings
The recognised occupational safety
rules and accident prevention regula-
tions must be observed and, if neces-
sary, personal protective measures must
be taken.
All adjustments and settings should only
be performed in accordance with the
instruction manuals of the connected
machines.
Never carry out work as long as gas
pressure or voltage is applied. Avoid
open fire. Please observe public regula-
tions.
Prior to assembly, the device must be
inspected for transport damage.
The device must not be exposed to open
fire. Protection against lightning strikes
must be guaranteed.
Connected line systems must be free
from dirt and contamination.
1 ... 56
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.
Protection from environmental impacts
and weather conditions (corrosion, rain,
snow, icing, humidity (e.g. by conden-
sation), mould, UV radiation, harmful
insects, poisonous, corrosive solutions/
liquids (e.g. cutting and cooling fluids
must be guaranteed. Depending on the
installation site, it may be necessary to
take protective measures.
The device may only be operated in
compliance with the operating condi-
tions stated on the type plate.
The device must be protected from vi-
brations and mechanical impacts.
The device must not be used in areas
with increased seismic risk.
Explanation of the symbols
1, 2, 3,... =
•
=
),
Order of
action
Instruction
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Table of Contents
Related Manuals for Dungs FRM 100065
Summary of Contents for Dungs FRM 100065
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Page 1: Target Group
Instructions FRM 100065 - 100080 - 250065 - 250080 1. Target group The target group of this manual is qualified personnel of the gas safety and regulating technology. Due to their specialist training, knowledge and experience, they should be capable of evaluating the work assigned to them and recognising possible dangers. -
Page 2: Designated Use
2.2 Designated use The device is used in accordance with its designated use if • Use with dry and clean gases only, no aggressive media. the following instructions are observed: • Use only in compliance with the operating conditions • Use of the device in gas transport and gas distribution stated on the type plate. - Page 3 FRM 100065 - 100080 Medium Pressure Regulator 10 bar / 25 bar Produit / Prodotto FRM 250065 - 250080 Hersteller / Manufacturer Karl Dungs GmbH & Co. KG Fabricant / Produttore Karl-Dungs-Platz 1 D-73660 Urbach, Germany bescheinigt hiermit, dass die in die- certifies herewith that the products certifie par la présente que le...
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Page 4: Table Of Contents
4. Table of contents Target group Warnings General warnings Designated use Risks in case of misuse Approval/EU Declaration of conformity Table of contents List of abbreviations Features Technical data Nomenclature Adjustment ranges Accuracy class / lock-up pressure class Selection of regulator springs Selection of SAV springs Type plate Function... -
Page 5: List Of Abbreviations
5. List of abbreviations Abbreviation Description Response pressure group of the upper response pressure Response pressure group of the lower response pressure Accuracy class Safety shutoff valve (without housing) Flow volume coefficient Nominal diameter Fail-open The firing valve moves automatically to the open position, if the main diaphragm or the auxiliary power required for the actuation of the firing valve fails IS/DS Type: integral strength range (IS) or differential strength (DS) -
Page 6: Features
6. Features 6.1. Technical data Technical data FRM … Device Spring-loaded medium pressure regulator according to EN 334 Type IS (FRM 100...) / DS (FRM 250...) Type of gas Family 1+2+3 Nominal diameters Connecting flanges PN 25 according to EN 1092-1 or ANSI 150 lbs (B16.5) Flange ANSI 2.5’’... -
Page 7: Nomenclature
DN 65 AC 5 SG 10 400-1500 mbar FRM 250065 UHD DN 65 AC 5 SG 10 1000-4000 mbar FRM 100065 MD / SAV MD DN 65 AC 5/10** SG 10/20** 90-420 mbar 35-400 mbar AG 10 180-800 mbar AG 10... -
Page 8: Accuracy Class / Lock-Up Pressure Class
6.4 Accuracy class / lock-up pressure class The AC and SG data, in compliance with EN 334, do not AC values of the table mentioned above refer to the maxi- make any statement about the modulation range. Knowl- mum admissible percentage deviation of the outlet pressure edge of the minimum and maximum volume flow is essential from the set nominal value, at which Q ≤... -
Page 9: Selection Of Regulator Springs
6.5 Selection of regulator springs Specific set range, outlet pressure W Spring colour Order Wire diameter Length Diameter Setpoint range [mbar] number [mm] [mm] [mm] Blue 270347 90-140 Black 270348 120-185 400-550 Purple 270349 10.0 180-280 540-850 1000-1300 Orange 270350 11.0 250-420 800-1150... -
Page 10: Type Plate
6.7 Type plate Regulator Regulator Regulator Made in Barcelona / Spain Made in Barcelona / Spain Made in Barcelona / Spain Made in Barcelona / Spain DIN EN334/CE-0085CP0256 DIN EN14382/CE-0085CP0255 DIN EN334/CE-0085CP0256 DIN EN14382/CE-0085CP0255 Regulator: FRM100080MD Regulator: FRM100080MD SAE: SAV100080MD SAE: SAV100080MD 1PDK276115 1PDK276115... -
Page 11: Function
7. Function The pressure regulator’s function is to keep the outlet pressure largely constant, independent of changes in the inlet pressure and/or in the flow volume. In the depressur- ised state the regulator is open. The pressure regulator complies with the requirements of EN 334 as direct acting gas pressure regulator. -
Page 12: Dimensions
8. Dimensions FRM... Type Order Dimensions [mm] Weight max. number [bar / kPa] [kg] FRM 100065 MD 277241 10 / 1000 FRM 100065 HD 277242 10 / 1000 FRM 250065 UHD 277243 25 / 2500 FRM 100080 MD 277244 10 / 1000... - Page 13 FRM... / SAV Type Order Dimensions [mm] Weight max. number [bar / kPa] [kg] FRM 100065 MD/SAV MD 273061 10 / 1000 FRM 100065 HD/SAV HD 276113 10 / 1000 FRM 250065 UHD/SAV UHD 276114 25 / 2500 FRM 100080 MD/SAV MD...
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Page 14: Installation
9. Installation 9.1 General information • This device can only be installed in • Flanges on the inlet side and outlet side of the connecting compliance with the rules and stand line are parallel. ards applicable and in accordance with •... -
Page 15: Installation Instructions
9.2 Installation instructions • The installation must be carried according to the installa- • Maximum flow velocity in the stablisation section: tion scheme specified below. ≤ 30 m/s. • Install the safety shutoff valve in the flow direction (arrow/ • Use steel pipe impulse lines D= 12 x 1.5 housing). -
Page 16: Torque
Mounting position 9.3 Torque Use adequate tools! Tighten the screws crosswise! The device must not be used as lever. max. max. max. ⅜ ½ ¾ 1 ½ 2 ½ 1600 2400 5000 6000 7600 max. [Nm] t 10 s max. [Nm] t 10 s Max. -
Page 17: Function Integrated Sav
10. Function integrated SAV SAV protects downstream fittings or lines against pres- sures that are too high or too low. As soon as the pre-set trip pressure falls below or exceeds a limit due to a fault, the SAV automatically interupts the gas flow. Under normal operating condition the SAV is open. -
Page 18: Setting
11. Setting 11.1 Regulator setting Setting of the outlet pressure The regulator is set using the adjusting screw B. 1. Remove 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 p is increased (+). -
Page 19: Sav Setting
11.2 SAV setting Switch-off setting in case of overpressure p 1. Remove the protective cap A. 2. Turn the external adjusting screw B using a socket wrench SW 22. 3. Turning clockwise: increase (+) in the upper shut down pressure p 4. -
Page 20: Calculation Example Of Set Values
11.3 Calculation example of set values Determination of the set values by means of a pressure graduation chart Selected regulator FRM 100065 MD / SAV MD Outlet pressure of the regulator p 200 mbar System-specific operating pressure downstream of the regulator p 500 mbar zul. -
Page 21: Replacement Of Regulator Springs
11.4 Replacement of regulator springs Release the setpoint spring E: unscrew the adjusting screw B counter-clockwise until it stops. Remove the protective cap A. (–) Unscrew the sealing cap C from the spring dome us- Remove the sealing cap C. ing a hinged hook wrench 90-155. -
Page 22: Replacement Of Sav Springs
Remove the spring washer D incl. ball. Remove the setpoint spring E from the spring dome F. 11.5 Replacement of SAV springs 7. Insert a new spring with a suitable adjustment range 8. Reattach the spring washer D incl. ball on the spring. 9. -
Page 23: Spring Exchange W
11.5.1 Spring replacement W Unscrew the adjusting spring B from the spring 1. Remove the spring E from the spring dome G. dome G using a tube/socket wrench SW 22. 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 reached. -
Page 24: Commissioning And Decommissioning
12. Commissioning and decommissioning 12.1 General information Prior to commissioning • The performance data on the type plate correspond to the ordering data. • Prevent explosive gas-air mixture: the room atmosphere must be monitored through gas con- centration measuring devices for the detection of gas leakages. •... -
Page 25: Commissioning / Unlocking/ Control Of The Set Values
12.3 Commissioning / unlocking/ control of the set values 1. Slowly open the shutoff valve on the inlet side. The 3. SAV unlocking: ball valve on the outlet side remains closed. 2. Monitor the pressure rise on the pressure gauge on the inlet side upstream of the device. - Page 26 Pressure release in the test section Creation of wind load Pos. Designation Pos. Designation Shut-off valve, inlet side Pressure gauge with pushbutton Venting ball valve Filter Pressure gauge with pushbutton Test burner Shut-off valve, outlet side Venting ball valve Hose Regulator with integrated SAV SBV with shutoff valve 26 …56...
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Page 27: Recommissioning
The adjusting springs are not suitable for the application. Replace the adjusting springs. Replace the ASE or have it repaired by The valve disc is damaged or worn out. DUNGS. The valve seat is damaged. Replace the valve seat. The SAV can be activated, The movable parts are contaminated with foreign particles. - Page 28 Fault on the regulator Possible causes Troubleshooting Check the gas installation upstream of the regu- The regulator contains no gas. lator. There is no gas. The SAV is closed. Unlock the SAV. The false setpoint spring is installed in the regulator. Replace the setpoint spring.
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Page 29: Maintenance
14. Maintenance 14.1 General information • The Pressure Equipment Direc- Pos. Designation tive (PED) requires the regulator to be Protective cap checked at regular intervals to ensure: O-ring safety and correct functioning of the Adjusting screw device, high long-term utilisation ratios, resulting in minimum environmental Sealing cap impact. - Page 30 30 …56...
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Page 31: Maintenance Instructions Of The Regulator
14.2 Maintenance instructions of the regulator 14.2.1 Preparation (–) 1. Loosen the impulse line and the vent line and remove them. Release the spring. 4. Unscrew the sealing cap C from the spring dome 2. Remove the protective cap A. using a jointed hook wrench 90-155. - Page 32 FRM...MD FRM...HD/UHD Remove the upper diaphragm shell F. Remove the upper diaphragm shell F. FRM...HD/UHD FRM...HD/UHD Remove the O-ring H. Remove the reducing washer I. 32 …56...
- Page 33 FRM...HD/UHD FRM...MD SW 13 Loosen the nut J (M 8) using an open-ended wrench SW 13. Loosen the nut J (M 8) using an open-ended wrench SW 13. FRM...HD/UHD FRM...MD Remove the spring washer K. Remove the spring washer K. 33 …...
- Page 34 FRM...MD FRM...HD/UHD Remove the safety spring L. Remove the safety spring L. FRM...HD/UHD FRM...MD Remove the working diaphram M from the guide rod Remove the working diaphram M from the guide rod N and check for signs of damage or wear. If neces- N and check for signs of damage or wear.
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Page 35: Replacement Of The Control Plate / Valve Seat
14.2.3 Replacement of the control plate SW 17 Loosen the 8 screws AL using an open-ended wrench Make sure that SAV is tripped by pushing triggering size SW 17. button. SW27 SW 30 Loosen nut R using a tube wrench SW 27 fixing the control plate AJ with a tube wrench SW 30. - Page 36 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. 36 …56...
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Page 37: Replacement Of The Compensation Membrane
14.2.4 Replacement of the compensation membrane SW 17 Loosen screws Y using an open-ended wrench Remove lower cover of the working diaphragm O. SW 17. Remove compensation guide support S. Remove upper compensation fixing disc U. 37 … 56... -
Page 38: Replacement Closing Part Sav
Replace compensation membrane T. 14.2.5 Replacement closing part SAV Remove the under compensation fixing disc V under the compensating membrane T. Remove bypass tubbing using an open-ended wrench SW 14. 38 …56... - Page 39 Remove o-ring Q. Remove intermediate housing P and O-rings Z and AA. Closing shell Closing spring Remove closing spring SAV. Replace closing shell SAV. 39 … 56...
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Page 40: Maintenance Instructions Of The Sav
14.3 Maintenance instruction of the SAV 14.3.1 Preparation Make sure that SAV is tripped by pressing 1. Remove the impulse and triggering button.. vent lines. 2. Remove the protective cap A. 3. Release the setpoint springs at the adjusting screws B and C (page 19). (–) (–) 13.3.2 Removing the ASE from the housing... -
Page 41: Mounting Of The Ase On The Housing
Replace ASE. Loosen the 2 screws using an allen key SW 5. 14.3.3 Mounting of the ASE on the housing Install new ASE in its position and put back 2 bolts using an allen key SW 5. Install again resetting lever in his position and fix with circlip on the shaft. Put back again setting spring for over and under pressure tripping value. -
Page 42: Required Tools
14.4 Required tools Wrench size Pressure Work step Tool designation rating DN 65 DN 80 Loosen the pulse lines. Open-ended spanner (A) MD/HD/UHD SW 24 SW 24 Tube/socket wrench (B) SW 17 SW 17 Release the setpoint springs. MD/HD/UHD Tube/socket wrench (B) SW 22 SW 22 Loosen ASE from the housing. - Page 43 Regulator Wrench size Pressure Work step Tool designation rating DN 65 DN 80 Loosen the pulse lines. Open-ended spanner (A) MD/HD/UHD SW 24 SW 24 Open-ended spanner (A) SW 24 SW 24 Release the setpoint springs. MD/HD/UHD Hinged hook wrench (D) 90-155 90-155 Open-ended spanner (A)
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Page 44: Leakage Test
14.5 Leakage test After maintenance or repair work, the device must be checked for internal and external leakages. 1. Test gases of the leakage test: air or inert gases. 2. Upstream and downstream shutoff valves must be closed. 3. Test pressure > blow-off pressure SBV: block the line upstream of the SBV. -
Page 45: Spare Parts
15. Spare parts 45 … 56... -
Page 46: List Of Spare Parts Of The Regulator
Spare part / image Protective FRM 100065-100080 270396 FRM 250065-250080 FRM 100065-100080 MD 277997 Working diaphragm with O-ring FRM 100065 - 100080 HD 277998 FRM 250065 - 250080 UHD FRM 100065 277999 FRM 250065 Control plate with shaft FRM 100080... -
Page 47: List Of Spare Parts Of The Sav
15.2 List of spare parts of SAV Spare part Version Order number Spare part / image Closing SAV 100065 - 100080 278003 shell SAV SAV 250065 - 250080 SAV 100065 - 100080 MD 278006 ASE with o-ring SAV 100065 - 100080 HD 278007 SAV 250065 - 250080 UHD Bypass... -
Page 48: Storage Conditions
15.3 Storage conditions Basically, DIN 7716 (standards for storage, maintenance • Ozone and cleaning of rubber products) applies to the storage of • Stress conditions of the components diaphragms and O-rings. Proper storage The ageing process mostly depends on • Storage temperature between 5°... -
Page 49: Flow Volume Tables
16.1 Natural gas flow volume tables FRM 100065 … DN 65 - max. flow volume [Nm /h] natural gas of density 0.81 kg/m³ (K FRM ... [bar] 0,15 0,25 0,35 0,75 1,25 [bar] 1493 1427 1350 1257 1146 1012 0,75... - Page 50 FRM 250065 UHD... DN 65 - max. flow volume [Nm /h] natural gas of density 0,81 kg/m FRM ... [bar] [bar] 2244 3174 2508 3887 3546 2746 4489 4343 3883 2965 5048 5015 4756 4193 3169 5607 5607 5492 5135 4481 3361 7844...
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Page 51: Air Flow Volume Tables
16.2 Air flow volume tables FRM 100065... DN 65 - max. air flow volume [Nm /h] (K FRM ... [bar] 0,15 0,25 0,35 0,75 1,25 [bar] 1206 1154 1091 1016 0,75 1538 1510 1477 1437 1390 1335 1272 1198 1112... - Page 52 FRM 250065 UHD... DN 65 - max. air flow volume [Nm /h] (K FRM ... [bar] [bar] 1814 2565 2027 3142 2866 2219 3628 3510 3138 2396 4080 4054 3844 3389 2561 4532 4532 4438 4151 3622 2716 6340 6340 6340 6340 6274...
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Page 53: Valve Flow Volume Coefficient K
1.24 1.00 1.00 16.3 Valve flow volume coefficient K Type -value FRM 100065... 2600 FRM 100080... 3200 The valve flow volume coefficient K f FRM is equal to the flow volume for a completely open firing valve with an absolute inlet pressure of p = 2.01325 bar and absolute outlet pressure of p... - Page 54 We reserve the right to make modifications in the course of technical development. Head of office and factory Subsidiary Karl Dungs, S.L.U. Karl Dungs GmbH & Co. KG Av. Can Roqueta Nº 15 Karl-Dungs-Platz 1 Pol. Ind. Can Roqueta D-73660 Urbach,...
- Page 55 55 … 56...
- Page 56 Subsidiary Karl Dungs, S.L.U. Karl Dungs GmbH & Co. KG Av. Can Roqueta Nº 15 Karl-Dungs-Platz 1 Pol. Ind. Can Roqueta D-73660 Urbach, E-08202 Sabadell Germany Barcelona/Spain Phone +49 (0)7181-804-0 Phone +34 935 647-550 +49 (0)7181-804-166 e-mail: info.e@dungs.com e-mail: info@dungs.com Internet: www.dungs.com...
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