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Dungs FRM 100025 ND Instruction Manual

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Instruction Manual
FRM 100025 - 100050

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 ... 68
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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Summary of Contents for Dungs FRM 100025 ND

  • Page 1: Target Group

    Instruction Manual FRM 100025 - 100050 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 commercial grade natural gas and commercial grade the following instructions are observed: LPG gases in the vaporized phase). • Use of the device in gas transport and gas distribution •...
  • Page 3 FRM 100025 - 100050 Medium Pressure Regulator 10 bar / 25 bar Produit / Producto FRM 250025 - 250050 Hersteller / Manufacturer Karl Dungs GmbH & Co. KG Fabricant / El fabricante Karl-Dungs-Platz 1 73660 Urbach, Germany bescheinigt hiermit, dass die certifies herewith that the pro- certifie par la présente que le...

  • 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 range 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 overpressure shut-off (OPSO) Response pressure group of the underpressure shut-off (UPSO) Accuracy class Safety shutoff valve (SAV) without housing (as spare part) Flow volume coefficient for natural gas Nominal diameter Fail-open If the main diaphram or the auxiliary pressure required for the actuation of the main valve fails, the main valve moves automatically to the open position.

  • 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 (e.g. manufactured gas (town gas), commercial grade natural gas and commercial grade LPG gases in the vaporized phase).

  • Page 7: Nomenclature

    6.2 Nomenclature Example ND SAV FRM 100025 ND / SAV ND Type Spring-loaded medium pressure regulator Maximum operating pressure 100 … 10 000 mbar (100 kPa) 4 018 "W.C (145 PSI) 250... 25 000 mbar (250 kPa) 2 500 "W.C. (360 PSI) Nominal diameter DN 25 (1")

  • Page 8: Adjustment Range

    DN 25 AC 5 SG 10 400 - 1 600 "W.C. 30-100 mbar 10 - 115 mbar 40 - 240 mbar FRM 100025 ND / SAV ND DN 25 AC 10 SG 20 AG 10 AG 10 12 - 40 "W.C.

  • Page 9: Accuracy Class / Lock-Up Pressure Class

    6.4 Accuracy class / lock-up pressure class Version Outlet pressure range Accuracy class [AC] Lock-up pressure FRM...ND 30 - 50 mbar / 12 - 20 "W.C. AC 15 + 15 mbar / 6 "W.C. 50 - 80 mbar / 20 - 32 "W.C AC 10 90 - 100 mbar / 36 - 40 "W.C.

  • Page 10: Selection Of Regulator Springs

    6.5 Selection of regulator springs Adjustment range, outlet pressure W Spring Order Wire ∅ Length ∅ Setpoint range colour number [mm] [mm] [mm] 30 - 40 mbar 90 - 110 mbar Silver 270341 12 - 16 "W.C. 36 - 44 "W.C. 40 - 55 mbar 110 - 170 mbar Green...

  • Page 11: Selection Of Sav Springs

    6.6 Selection of SAV springs Specific adjustment range, underpressure W Spring Order Wire ∅ Length ∅ Setpoint range colour number [mm] [mm] [mm] 10 - 32 mbar White 270353 10.0 4 - 12 "W.C. 24 - 40 mbar Yellow 270355 12.3 9 - 16 "W.C.

  • Page 12: Type Plate

    6.7 Type plate Regulator Abbrevia- Description tion Response pressure group of the overpressure shut-off (OPSO) Response pressure group of the underpressure shut-off (UPSO) Accuracy class Flow volume coefficient for natural gas Nominal diameter Fail-open If the main diaphram or the auxiliary pressure required for the actuation of the main valve fails, the main valve moves automatically to the open position.

  • Page 13: Function

    7. Function The pressure regulator’s function is to keep the outlet pressure constant, independent of changes in the inlet pressure and/or in the flow volume. In the depressurised state the regulator is open. The pressure regulator com- plies with the requirements of EN 334 as gas pressure regulator.

  • Page 14: Dimensions

    Optional with swagelok fitting for 1/2" tubing. Type Order Dimensions Weight max. number [bar/kPa/PSI] [kg] FRM 100025 ND 270272 10 / 1 000 / 145 1/2 "G 38 (83.8 lbs) ⊘ FRM 100025 MD 270273 10 / 1 000 / 145 1/2 "G...
  • Page 15 US versions come standard with swagelok fitting for 1/2" tubing. Type Order p max. Dimensions Weight number [bar/kPa/PSI] [kg] FRM 100025 ND/SAV ND 270275 10 / 1 000 / 145 1 070 1/2 "G 40 (88.2 lbs) ⊘ FRM 100025 MD/SAV MD 270276...

  • Page 16: Installation

    9. Installation 9.1 General information • This device can only be installed in • Flanges on the inlet side and outlet side of the connect- compliance with the rules and stand- ing lines are parallel with the FRM flanges. ards applicable and in accordanc •...

  • Page 17: Installation Instructions

    9.2 Installation instructions • The installation must be carried according to the installa- section is clean and free from burrs. Distance > 5 x DN tion scheme specified below, unless deviations required • Maximum flow velocity in the stablisation section: by regulations.

  • Page 18: Vent Lines (Only U.s.a And Canada)

    Mounting position 9.3 Vent Lines (Only U.S.A and Canada) In addition to the requirements below, vent lines shall Requirements for Vent Line Length and Size for be installed in accordance with the applicable instal- FRM and SAV vents lation code (e.g. NFPA 86, NFPA 37, NFPA 54, B149.3, •...

  • Page 19: Torque

    • The vent line must discharge away from fresh air • If a vent line runs through a roof, verify that the vent intakes and from windows. See applicable fuel gas line terminates above the point where water and snow installation code (e.g.

  • Page 20: Safety Shut Off Valve (Sav And Ase)

    10. Safety Shut off Valve (SAV and ASE) 10.1 Function 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.

  • Page 21: Mounting An Ase To Frm Type Regulator

    10.2 Mounting an ASE to FRM type regulator 1. Loosen four hexagonal socket grub screws E (M 5x8) of the ASE C using an internal hex key SW 2.5 (2.5 mm). 2. Remove the base plate A from the housing using a hook wrench 60-90 mm.

  • Page 22: Settings

    11. Settings 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 mm. 3. Turning clockwise: the preload of the setpoint spring is increased and the outlet pressure p is increased (+).

  • Page 23: Sav Setting

    11.2 SAV setting Adjusting the upper (over) response pressure p setpoint 1. Remove the protective cap A. 2. Turn the external adjusting screw B using a socket wrench SW 22 mm. 3. Turning clockwise: increase (+) the upper (over) response pressure p setting.

  • Page 24: 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 100025 MD / SAV MD Outlet pressure of the regulator p 200 mbar (80 "W.C.) System-specific operating pressure downstream of the regulator 500 mbar (200 "W.C.) Limiting pressure in case of fault 550 mbar (220 "W.C.)

  • Page 25: 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 F Remove the sealing cap C. using a hinged hook wrench 90-155 mm.
  • Page 26 Remove the spring washer D incl. ball. Remove the setpoint spring E from the spring dome F. Never have your head above or near the 7. Insert a new spring with a suitable adjustment range aluminium cap when removing regulator 8.

  • Page 27: Replacement Of Sav Springs

    11.5 Replacement of SAV springs Remove the protective cap A. 11.5.1 Spring replacement W (–) Unscrew the adjusting spring B from the spring dome G using a tube/socket wrench SW 22 mm. 27 … 68...

  • Page 28: Spring Exchange W

    1. Remove the spring E from the spring dome G. 2. Install the new spring. 3. Tighten the adjust- ing screw B and the washer D in the spring dome G using an open- ended wrench until the required spring preload is reached.
  • Page 29 1. Remove the spring F from the spring dome. 2. Install the new spring. 3. Tighten the adjust- ing screw C in the spring dome H us- ing an open-ended wrench SW 17 mm until the desired spring preload is Screw on the protective cap A again.

  • Page 30: Commissioning, Decommissioning And Recommissioning Frm Or Sav

    12. Commissioning, decommissioning and recommissioning FRM or SAV 12. Commissioning, decommissioning and recommissioning FRM or SAV 12.1 General information Prior to commissioning and recommissioning • 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 concentration measuring devices for the detection of gas leakages.

  • Page 31: Sav Resetting And Setting Of Sav/Frm

    12.4 SAV resetting and setting of SAV/FRM 2. Monitor the pressure rise on the pressure gauge on 1. Slowly open the shutoff valve on the inlet side per the inlet side upstream of the device. 12.2 "Initial applying pressure during commission- 3.
  • Page 32 5.0 Initial Checking of the FRM outlet pressure 6.7 Once the SAV trips, read the upper (over) response 5.1 Before initially starting of the equipment, an initial pressure on the pressure gauge on the outlet side. check of the FRM outlet pressure setting shall be 6.8 If necessary, correct the SAV set points according to done.

  • Page 33: Recommissioning

    The adjusting springs are not suitable for the application. Replace the adjusting springs. Replace the SAV 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 34 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.

  • Page 35: 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: Adjusting screw safety and correct functioning of the Sealing cap device, high long-term utilisation ratios, resulting in minimum environmental Spring washer with ball impact.
  • Page 36 W ... 36 …68...

  • Page 37: 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. 4. Unscrew the sealing cap C from the spring dome 2. Remove the protective cap A. using a jointed hook wrench 90-155 mm. 3.
  • Page 38 FRM...MD/HD/UHD FRM...ND Remove the upper diaphragm shell F. Remove the upper diaphragm shell F. FRM...HD/UHD FRM...HD/UHD Remove the O-Ring H (HD version only). Remove the reducing washer I (HD version only). 38 …68...
  • Page 39 FRM...MD/HD/UHD FRM...ND Loosen the nut J (M 8) using an open-ended wrench Loosen the nut J (M 8) using an open-ended wrench SW 13 mm. SW 13 mm. FRM...MD/HD/UHD FRM...ND Remove the spring washer K. Remove the spring washer K. 39 …...
  • Page 40 FRM...ND FRM...MD/HD/UHD Remove the safety spring L. Remove the safety spring L. FRM...MD/HD/UHD FRM...ND 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.

  • Page 41: Replacement Of The Control Plate / Valve Seat

    14.2.3 Replacement of the control plate / valve seat Remove the lower diaphragm shell O from the housing X. To do this, the diaphragm shell O has to be turned carefully. 4 Loosen the screws Y. Remove the O-Ring Q from the lower diaphragm shell O. 41 …...
  • Page 42 Remove the control plate S from the control plate sleeve U and check it for damage. If necessary, Remove the assembly of the control plate S incl. the replace the control plate S incl. the sleeve U. sleeve U from the housing X. Remove the O-Ring T from the housing X.
  • Page 43 If necessary, replace the valve seat V: Tighten the new valve seat V with the new O-Ring screw out the valve seat V from the housing X by W (maintenance set 4) in the housing X. using a socket wrench. Place the new O-Ring T (maintenance kit 3 or 5) in Insert the control plate S with the sleeve U (mainte- the turned groove in the housing X.
  • Page 44 Insert the new O-Ring Q (maintenance kit 3, 4 or 5) Make sure that the connection pin R 45° is oriented in the turned groove in the lower diaphragm shell O opposite to the direction of the flow (non-aligned!) using grease if necessary to hold it in place. Put the diaphragm shell O in position: Secure the lower diaphragm shell O using the lower diaphragm disc P (to do this, the diaphragm disc is...
  • Page 45 When the connection pin R is locked in the lever sys- tem Z, both middle lever arms are pushed upwards ( ). To do this, ( ) push the lower diaphragm disc P downwards. Attention: Risk of crushing! 45 … 68...
  • Page 46 Reinsert the working diaphragm M on the guide rod N. Put on the safety spring L and the spring washer Fix the diaphram housing O by tightening the 4 K. Screw on the nut J (M 8). Tighten to the stop us- screws Y.

  • Page 47: Maintenance Instructions Of The Sav

    14.3 Maintenance instructions of the SAV Pos. Designation Diaphragm shell Push rod O-Ring of the diaphragm shell Lower diaphragm disc Working diaphragm Setpoint spring of the lower shut-down pressure Upper diaphragm disc (HD version only) Allen screw, 6 pieces Spring dome ASE Over pressure adjustment nut Under pressure adjustment nut Protective cap...

  • Page 48: Removing The Ase (Sav Mechanism Only) From The Housing

    14.3.2 Removing the ASE (SAV mechanism only) from the housing Loosen four hexagonal socket grub screws Remove the ASE Q from the housing using a hook (M5x8) using an internal hex key SW 2.5 mm. wrench 60-90 mm. Remove the ASE Q. 48 …68...

  • Page 49: Check / Replacement Of The Working Diaphragm, Md/Hd Version

    14.3.3 Mounting of the ASE on the housing Place the new O-Ring N (maintenance kit 4 or 5) in the turned groove in the housing M. Tighten the threads of the connecting piece O in the housing M using a hook wrench 60-90 mm. Fix the connecting piece O of the ASE Q using 4 hexagonal socket grub screws P (M5x8).

  • Page 50: Sav Leakage Test

    Wrench size (mm) Pressure Work step Tool designation rating DN 25 DN 40 DN 50 Loosen the pulse lines. Open-ended spanner (A) ND/MD/HD SW 22 SW 22 SW 22 Tube/socket wrench (B) SW 17 SW 17 SW 17 Release the setpoint springs. ND/MD/HD Tube/socket wrench (B) SW 22...

  • Page 51: Spare Parts

    15. Spare parts 51 … 68...

  • Page 52: List Of Spare Parts Of The Regulator

    270384 FRM 100025-100040 MD 270385 Working diaphragm with O-Ring FRM 100050 MD 296578 FRM 100025-100050 HD 270386 FRM 100025 ND FRM 100025 MD 270387 FRM 100025 HD Compen- FRM 100040 ND sation FRM 100040 MD 270388 unit with FRM 100040 HD...

  • Page 53: List Of Spare Parts Of The Sav

    15.2 List of spare parts of SAV Spare part Version Order number Spare part / image SAV 100025-100050 ND/MD/HD Protective on request SAV 6010-6020 ND/MD/HD SAV 100025 ND SAV 6010 ND 270375 SAV 6015 ND SAV 100025 MD SAV 6010 MD 270376 SAV 6015 MD SAV 100025 HD...

  • Page 54: Complete Regulator Sets

    15.3 Complete regulator sets Order Version Contents number FRM 100025 ND 271093 FRM 100025 MD 271094 FRM 100025 HD 271095 FRM 100040 ND 271096 FRM 100040 MD 271097 FRM 100040 HD 271098 54 …68...

  • Page 55: Accessories

    Order Version Contents number FRM 100050 ND 271099 FRM 100050 MD 271100 FRM 100050 HD 271101 15.4 Accessories Order Spare Part Version Contents number Adapter 1/4 "G to 1/4 "NPT SAV / ASE 231944 no picture available Adapter 1/2 "G to 1/2 "NPT 231945 no picture available Connector 1/4 "G to 1/2 "...

  • Page 56: Storage Conditions

    15.5 Storage conditions Basically, DIN 7716 (standards for storage, maintenance Proper storage and cleaning of rubber products) applies to the storage of • Storage temperature between 5° C and 20° C diaphragms and O-Rings. • No direct solar radiation • No direct heat sources in the storage area The ageing process mostly depends on •...

  • Page 57: Natural Gas Flow Volume Table

    16.1 Natural gas flow volume tables FRM 100025 … DN 25 - max. flow volume [Nm /h] natural gas of density 0,81 kg/m³ (AC 10) FRM ... [bar] 0,03 0,05 0,075 0,15 0,25 0,35 0,75 1,25 [bar] 0,75 1051 1157 1157 1157 1057...
  • Page 58 FRM 100040 … DN 40 - max. flow volume [Nm /h] natural gas of density 0,81 kg/m³ (AC 10) FRM ... [bar] 0,03 0,05 0,075 0,15 0,25 0,35 0,75 1,25 [bar] 0,75 1060 1082 1000 1057 1016 1116 1030 1236 1104 1262 1165...
  • Page 59 FRM 100050 … DN 50 - max. flow volume [Nm /h] natural gas of density 0,81 kg/m³ (AC 10) FRM ... [bar] 0,03 0,05 0,075 0,15 0,25 0,35 0,75 1,25 [bar] 0,75 1011 1119 1000 1142 1055 1116 1073 1037 1020 1023 1178...
  • Page 60 FRM 250025 UHD… DN 25 - max. flow volume FRM 250025 UHD… DN 25 - max. flow volume /h] natural gas of density 0,81 kg/m³ (AC 5) /h] natural gas of density 0,81 kg/m³ (AC 10) FRM ... FRM ... [bar] [bar] [bar]...
  • Page 61 FRM 250050 UHD… DN 50 - max. flow volume FRM 250050 UHD… DN 50 - max. flow volume /h] natural gas of density 0,81 kg/m³ (AC 5) /h] natural gas of density 0,81 kg/m³ (AC 10) FRM ... FRM ... [bar] [bar] [bar]...
  • Page 62 FRM 250025 UHD… DN 25 - max. flow volume [CFH] FRM 250025 UHD… DN 25 - max. flow volume [CFH] natural gas of density 0,81 kg/m³ (AC 5) natural gas of density 0,81 kg/m³ (AC 10) FRM ... FRM ... Inlet pressure Inlet pressure [PSI]...
  • Page 63 FRM 250050 UHD… DN 50 - max. flow volume [CFH] FRM 250050 UHD… DN 50 - max. flow volume [CFH] natural gas of density 0,81 kg/m³ (AC 5) natural gas of density 0,81 kg/m³ (AC 10) FRM ... FRM ... Inlet pressure Inlet pressure [PSI]...

  • Page 64: Air Flow Volume Tables

    16.2 Air flow volume tables FRM 100025... DN25 - max. air flow volume [Nm /h] (AC 10) FRM ... [bar] 0,03 0,05 0,075 0,15 0,25 0,35 0,75 1,25 [bar] 0,75 1068 1068 1068 1068 1068 1068 1068 1068 1068 1068 1068 1068 1068...
  • Page 65 FRM 100050... DN50 - max. air flow volume [Nm /h] (AC 10) FRM ... [bar] 0,03 0,05 0,075 0,15 0,25 0,35 0,75 1,25 [bar] 0,75 1056 1077 1067 1062 1080 1088 1004 1204 1076 1230 1136 1219 1227 1129 1322 1077 1060 1062...
  • Page 66 FRM 250040 UHD... DN40 - max. air flow volume FRM 250040 UHD... DN40 - max. air flow volume /h] (AC 5) /h] (AC 10) FRM ... FRM ... [bar] [bar] [bar] [bar] 1193 1060 1377 1078 1178 1540 1245 1116 1648 2154 1779...

  • Page 67: Valve Flow Volume Coefficient K

    The maximum indicated volume flow refers to natural gas with a density 0.81 kg/m or to air with a density of 1.24 kg / m 15 °C under standard conditions. In case of different types of gases, a conversion of the volume flow according to the equation below is carried out.
  • Page 68 Gas families I, II, III N/A not applicable We reserve the right to make modifications in the course of technical development. Head of office and factory Karl Dungs GmbH & Co. KG Karl-Dungs-Platz 1 73660 Urbach, Germany Phone +49 7181-804-0 +49 7181-804-166 e-mail: info@dungs.com...

This manual is also suitable for:

Frm 100025 mdFrm 100025 hdFrm 250025 uhdFrm 100025 nd/sav ndFrm 100025 md/sav mdFrm 100025 hd/sav hd ... Show all

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