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Instruction Manual
FRM-NOC

1 Target group

This manual is intended for personnel qualified in gas
safety and regulation technology, as well as personnel
trained or instructed by them.
The former are in a position to judge the work assigned
to the latter on the basis of their technical training,
knowledge and experience, as well as knowledge of the
relevant regulations, and are able to recognise potential
dangers. Only they are permitted to carry out assembly,
commissioning, settings and maintenance on the devices
in compliance with the recognised rules for occupational
safety.

2. Warnings

2.1 General warnings

The recognised occupational safety
rules and accident prevention
regulations must be observed and,
if necessary, 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
naked flames. Please observe public
regulations.
Prior to assembly, the device must be
inspected for transport damage.
The device must not be exposed to
naked flames. Protection against
lightning strikes must be guaranteed.
Connected line systems must be free
from dirt and contamination.
1 ... 76
Hang this instruction manual in a clearly visible
place inside the installation room! Do not carry out
any work until you have read the safety instructions
of this instruction manual and are qualified to do so.
Protection from environmental
impacts and weather conditions
(corrosion, rain, snow, icing,
humidity (e.g. by condensation),
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
conditions stated on the type plate.
The device must be protected from
vibrations and mechanical impacts.
The device must not be used in areas
with increased seismic risk.
Explanation of the symbols
1, 2, 3,... =
Act based on
the sequence
=
Instruction

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Summary of Contents for Dungs FRM-NOC 100 Series

  • Page 1: Target Group

    Instruction Manual FRM-NOC 1 Target group This manual is intended for personnel qualified in gas safety and regulation technology, as well as personnel trained or instructed by them. The former are in a position to judge the work assigned to the latter on the basis of their technical training, knowledge and experience, as well as knowledge of the relevant regulations, and are able to recognise potential Hang this instruction manual in a clearly visible...
  • Page 2: Designated Uses

    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: Declaration Of Conformity

    FRM-NOC 100... Medium Pressure Regulator 10 bar Produkt / Product Produit / Producto 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 prod- certifie par la présente que le...
  • Page 4 Medium Pressure Regulator 10 bar Product 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: •...
  • Page 5: Table Of Contents

    4. Table of contents Target group Warnings General warnings Designated uses Risks in the event of misuse Declaration of conformity Table of contents Abbreviations Features Technical data Nomenclature Adjustment ranges Accuracy class / closing pressure class Selection of regulating spring 6.5.1 For FRM-NOC 10010/10015/100025 6.5.2...
  • Page 6: Abbreviations

    14.5 SAV leakage test 14.6 Recommended maintenance intervals 15. Spare parts 15.1 Regulatory list of spare parts 15.2 List of spare parts SAV 15.3 Storage conditions 16. Tables of flow diagram 16.1 Tables of flow diagram AC 10 explanation 16.2 Valve flow coefficient K 5.
  • Page 7: Features

    6. Features 6.1 Technical data Technical data FRM-NOC Device Medium pressure regulator with spring loading in accordance with EN 334 Type of construction DS (differential range) 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 8: Nomenclature

    6.2 Nomenclature Example FRM-NOC 100025 ND / SAV ND 100 025 Type Medium pressure regulator spring-loaded Maximum operating pressure 100 … 10 000 mbar (1 000 kPa) 4 018 "W.C. (145 PSI) Nominal diameter 1" 11/2" 2" DN 25 DN 40 DN 50 Outlet pressure ranges Low pressure...
  • Page 9: Adjustment Ranges

    6.3 Adjustment ranges Type Connec- Ver- Closing Outlet pressure Monitoring depression Monitoring overpressure tion sion curacy pressure range W class* class* [AC] [SG] 20-100 mbar FRM-NOC 10010 ND Rp 1 10 % 20 % 10 % 10 % 8-40 "W.C. 80-400 mbar FRM-NOC 10010 MD Rp 1...
  • Page 10 Type Connec- Ver- Closing Outlet pressure Monitoring depression Monitoring overpressure tion sion curacy pressure range W class* class* [AC] [SG] 20-100 mbar 10-115 mbar 40-240 mbar FRM-NOC 100025 ND / SAV ND DN 25 10 % 20 % 10 % 10 % 8-40 "W.C.
  • Page 11: Accuracy Class / Closing Pressure Class

    6.4 Accuracy class / closing pressure class AC and SG data according to EN 334 do not constitute The AC values of the above table refer to the maximum a declaration with respect to the modulation range. For possible percentage deviation of the output pressure field use it is important to know the minimum and maxi- from the adjusted set-point, in which Q ≤...
  • Page 12: Selection Of Regulating Spring

    6.5 Selection of regulating spring 6.5.1 For FRM-NOC 10010 / 10015 / 100025 Outlet pressure adjustment range W Spring Item Nº Wire ∅ Length Adjustment range colour ∅ [mm] [mm] [mm] 20-35 mbar 287881 8-14 "W.C. 30-50 mbar White 287882 12-20 "W.C.
  • Page 13: For Frm-Noc 10020/100040/100050

    6.5.2 For FRM-NOC 10020 / 100040 / 100050 Outlet pressure adjustment range W Spring Item Nº Wire ∅ ∅ Length Adjustment range colour [mm] [mm] [mm] 20-25 mbar Yellow 287884 8-10 "W.C. 25-45 mbar Blue 287885 10-18 "W.C. 30-65 mbar Black 287886 12-26 "W.C.
  • Page 14: Selection Of Spring Sav

    6.6 Selection of spring SAV 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 15: 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 If the main diaphram or the auxiliary pressure required for the actuation of the main valve fails, the main valve Fail-open moves automatically to the open position.
  • Page 16: Function

    7. Function The pressure regulator has the task of maintaining con- If the outlet pressure drops, the force on the working dia- stant outlet pressure despite fluctuations in inlet pressure phragm F in the lower diaphragm shell C decreases also. and/or flow.
  • Page 17 Type UHD Type HD 17 … 76...
  • Page 18 ND, MD for Rp 1", Rp 1,5" and DN 25 ND, MD for Rp 2", DN 40, DN 50 18 … 76...
  • Page 19: Dimensions

    8. Dimensions FRM-NOC... 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 19 … 76...
  • Page 20 Item Nº Dimensions [mm] Weight Type max. [bar/kPa/PSI] [kg/lbs] FRM-NOC 10010 ND 279054 280236 10 / 1 000 / 145 1" -240 1/2 "G 1/4 "G 5/11.0 FRM-NOC 10010 MD 279055 280237 10 / 1 000 / 145 1" -240 1/2 "G 1/4 "G 5/11.0...
  • Page 21 FRM-NOC... / SAV 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 21 … 76...
  • Page 22 Item Nº Dimensions [mm] Weight Type max. [bar/kPa] [kg/lbs] FRM-NOC 10010 ND /SAV ND 279042 280224 10 / 1000 / 145 1" 1/2" G 1/4" G 7/15.4 FRM-NOC 10010 MD /SAV MD 279043 280225 10 / 1000 / 145 1" 1/2"...
  • Page 23: Assembly/Installation

    9. Assembly/installation 9.1 General information • Flanges on the inlet side and outlet side of the connect- • This device can only be installed in ing lines are parallel with the FRM flanges. compliance with the rules and stand- • The sealing surfaces of the flange are undamaged and ards applicable and in accordanc clean.
  • Page 24: Assembly Instructions

    9.2 Installation instructions • The installation must be carried out according to the • (When needed external impulse lines: steel pipe installation scheme specified below. D= 12 x 1.5, only with external pulse) • Installation of the safety shut-off valve in the flow •...
  • Page 25: 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 26: Torques

    • 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 27: Function Saftey Shut Off Valve (Sav And Ase)

    10. Function Safety Shut off Valve (SAV+ASE) 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 28: Adjustment

    11. Adjustment 11.1 Adjusting the regulator Adjusting the outlet pressure (type UHD) The regulator is adjusted by turning the adjustment screw B. 1. Remove the protective cap A. 2. Turn the external adjusting screw B using the spanner size 24 mm. 3.
  • Page 29 Adjusting the outlet pressure (ND, MD, HD) The regulator is adjusted by turning the adjustment screw B. 1. Remove the protective 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 p 4.
  • Page 30: Adjusting The Sav

    11.2 Adjusting the SAV 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 31: Example Of Calculations Of Adjustment Values

    11.3 Example of calculations of adjustment values Determination of the setting values by means of a pressure graduation table Selected regulator FRM-NOC 100025 MD / SAV MD Outlet pressure of the regulator p 200 mbar (80 "W.C.) 500 mbar (200 "W.C.) System-specific operating pressure downstream of the regulator p perm Limiting pressure in case of fault...
  • Page 32: Regulating Spring Replacement

    11.4 Regulating spring replacement 11.4.1 Type UHD Unscrew adjustment screw E: Unscrew the adjust- Remove the protective cap A. ing nut B counterclockwise as far as it will go. (–) Remove from the spring housing F the shut-off cover C using a hook wrench 90-155 mm. Remove the cap C.
  • Page 33 Remove the adjustment spring E from the spring chamber F. Remove the disc from the spring D incl. ball. Never have your head above or near the 7. Insert a new spring with the appropriate adjustment aluminium cap when removing regulator range.
  • Page 34: Type Nd, Md And Hd

    11.4.2. Type ND, MD and HD Release the setpoint spring E: Completely loosen adjusting nut B counterclockwise. Remove the protective cap A. Remove the adjusting nut B. Remove the washer D. 34 … 76...
  • Page 35 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 desired initial spring tension is reached. Re-fit the protective cap A. Remove the adjustment spring E from the spring chamber F.
  • Page 36: Spring Replacement Sav

    11.5 Spring replacement SAV Remove the protective cap A. 11.5.1 Spring replacement W (–) Unscrew the adjusting spring B from the spring dome G using an open-ended wrench 22 mm. 36 … 76...
  • Page 37: Spring Replacement W

    1. Remove the spring E from the spring 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 Remove the white plastic washer D. preload is reached.
  • Page 38 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. Screw on the protective cap A again. 38 …...
  • Page 39: General Information

    12. Commissioning, decommissioning and recommissioning FRM-NOC or SAV 12.1 General information Prior to commissioning and recomissioning • The performance data on the type plate must correspond to the ordering data. • Prevent explosive gas-air mixture: the room atmosphere must constantly be monitored using appropriate gas concentration measuring devices for the detection of gas leakages.
  • Page 40: Commissioning/Unlocking/Control Of Adjustment Values

    12.4 Commissioning/unlocking/control of adjustment values 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. SAV resetting: ing, recommissioning or testing".
  • Page 41 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 42: Recommissioning

    The adjustment springs are not suitable for the application. Replace the adjusting spring. The valve head is damaged or worn. Replace the ASE or have it repaired by DUNGS. The seat of the valve is damaged. Replace the valve seat.
  • Page 43 Fault in the Possible causes Troubleshooting regulator Check the gas installation prior to the The regulator is not receiving gas. regulator. There is no gas The SAV is closed. Unlock the SAV. The regulator contains a spring with the wrong set point. Replace the set point spring.
  • Page 44: Maintenance

    14. Maintenance 14.1 General information Pos. Designation • The Pressure Equipment Directive (PED) requires the devices to be Protective cap checked at regular intervals to ensure Adjusting screw + washers the following in the long term: Safety Sealing plug and functioning of the device, high long-term utilisation ratios, resulting Spring disc with ball in minimum environmental impact.
  • Page 45 Type UHD 45 … 76...
  • Page 46 Type ND, MD for 1", 11/2" and DN 25 and type HD 46 … 76...
  • Page 47 Type ND, MD for 2", DN 40, DN 50 47 … 76...
  • Page 48: Regulatory Maintenance Instructions

    14.2 Regulatory maintenance instructions 14.2.1 Preparation Follow the steps shown in section 11.4 to extract the regulating spring. 14.2.2 Replace working membrane 14.2.2.1 Type UHD Loosen the screws G using an Allen key size 5 mm. Remove the upper membrane cover F. 48 …...
  • Page 49 Loosen the nut J (M 8) using a spanner size 13 mm. Remove the disc from the spring K. Remove 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 20 or 24 as Remove the safety spring L.
  • Page 50: Type Nd, Md For 1", 11/2", Dn25 And Type Hd

    14.2.2.2 Type ND, MD for 1", 11/2", DN25 and type HD Loosen the screws G using an Allen key size 5 mm. Replace the O-Ring H. Remove the upper membrane cover F. Remove the washer Z2. 50 … 76...
  • Page 51 Loosen the nut J using a spanner size 13 mm (15 mm for 1", 11/2" and DN 25 ND and MD). Remove the safety spring L. Remove the working membrane M from the guide rod N. Check the condition of the working mem- brane.
  • Page 52: Type Nd, Md For 2", Dn 40 Y Dn

    14.2.2.3 Type ND, MD for 2", DN 40 and DN 50 Loosen the screws G using an Allen key size 5 mm. Remove the upper membrane cover F. Loosen the nut J using a spanner size 13 mm. Remove the disc from the spring K. 52 …...
  • Page 53 Remove 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. Remove the safety spring L. Replace the O-Ring H. 53 …...
  • Page 54: Replace Valve Seat

    14.2.3 Replace valve seat 14.2.3.1 Type UHD Remove the screws O from the body X using Loosen the pulse line outlet of the SAV with a spanner size 13 mm (1", 11/2", DN 25) or 17 mm a spanner measuring 14 mm. (2"...
  • Page 55: Type Nd, Md For 1", 11/2", Dn25 And Type Hd

    Screw a new valve seat V of the desired size with Replace valve seat V: Unscrew from the body X the a new O-Ring W (maintenance set 3, 4, 5, 6 as re- valve seat V using the socket wrench. quired) onto the body X.
  • Page 56 Remove the regulator hood P from the body X. Replace the O-Ring Q. Replace valve seat V: Unscrew from the body X the Remove the seal assembly S. valve seat V using the socket wrench. 56 … 76...
  • Page 57: Type Nd, Md For 2", Dn 40 And Dn

    Screw a new valve seat V of the desired size with a new O-Ring W (maintenance set 3 or 4 as required) into the body X. 14.2.3.3 Type ND, MD for 2", DN 40 and DN 50 Loosen the pulse line outlet of the SAV with Remove the screws Y from the body X using a spanner measuring 14 mm.
  • Page 58 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. 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.
  • Page 59: Replace Control Plate

    14.2.4 Replace seal 14.2.4.1 Type UHD Loosen the nuts R. Remove the R nuts. Remove the fastening screwsT from the lever set with a size 4 mm Allen key. Remove the U clamping plates from the lever set. 59 … 76...
  • Page 60 Remove the lever set I. Remove the bottom cover O. Replace seal assembly S (maintenance set 8, 11, 13 or 16 as required). Replace the O-Ring Q. 60 … 76...
  • Page 61: Type Nd, Md For 1", 11/2", Dn 25 And Type Hd

    14.2.4.2 Type ND, MD for 1", 11/2", DN 25 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 Remove the fastening screws T from the lever set with a size 5 mm Allen key.
  • Page 62 Remove the lever set I. Remove the bottom cover O. Replace seal assembly S (maintenance set 9, 14, 21 or 22 as required). 62 … 76...
  • Page 63: Maintenance Sav

    14.3 Maintenance instructions SAV Pos. Designation Diaphragm shell Push rod O-Ring diaphragm shell Lower diaphragm disc Working diaphragm Bottom locking pressure adjustment spring Upper diaphragm disc (only in the version HD) Allen screws, 6 units. Spring dome ASE Top locking pressure adjustment screw Bottom locking pressure adjustment screw Protective cap ASE housing...
  • Page 64: Preparation

    14.3.1 Preparation (–) (–) 1. Loosen the pulse lines and the vent lines and remove them. 2. Remove the protec- tive cap L. 3. Release the adjusting springs at the adjust- ing screws J and K. 14.3.2 Removing the ASE (SAV mechanism only) from the housing Loosen the four hexago- nal socket grub screws Remove the ASE Q from...
  • Page 65: Assembly Of The Ase On The Body

    Remove the ASE Q. 14.3.3 Assembly of the ASE on the body Insert a new O-Ring N (maintenance set 4 or 5) into the groove provided in the housing M. Screw the thread of the connecting piece O onto the body 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 66: Tools Required

    14.4 Tools required 66 … 76...
  • Page 67 Wrench size (mm) Pressure Work step Tool designation rating DN 25 DN 40 DN 50 Loosen the pulse line. Open-ended wrench (A) ND/MD/HD Socket wrench (B) Release the adjusting springs. ND/MD/HD Socket wrench (B) Internal hex key (C1) Separate the ASE from the ND/MD/HD Jointed hook wrench with pins according to body...
  • Page 68: Sav Leakage Test

    14.5 SAV Leakage test Go to section "12. Commissioning, decomissioning and recommissioning for FRM-NOC or SAV" for per- forming functional and leakage testing of SAV. 14.6 Recommended maintenance intervals 1. The maintenance intervals depend on the system- 3. It is recommended to perform a functional test on a specific operating and environmental conditions, gas monthly base and carry out maintenance works every quality, state of the pipelines, etc.
  • Page 69: Spare Parts

    15. Spare parts 15.1 Regulatory list of spare parts Spare part/ Spare part Version Item Nº illustration FRM-NOC10010/12/025 ND/MD TOP COVER ALUMINI CAP 287754 FRM-NOC10010/15/20/025/040/050 HD TOP COVER UHD FRM-NOC100XXX UHD 270396 FRM-NOC10010/15 XX 287755 SHELL M.22 + O-Ring FRM-NOC100025 XX 287756 SHELL M.30 + ORING FRM-NOC10020/040XX...
  • Page 70: List Of Spare Parts Sav

    Spare part/ Spare part Version Item Nº illustration MEMBRANE(1000411) 10/15/25 ND + FRM-NOC10010/15/025 ND 287769 MEMBRANE JOINT MEMBRANE(1000412) 10/15/25 MD + FRM-NOC10010/15/025 MD 287770 MEMBRANE JOINT MEMBRANE(1000413) 10/15/25 HD + FRM-NOC10010/15/025 HD 287771 MEMBRANE MEMBRANE(1000414) 10/15/25 UHD + FRM-NOC10010/15/025 UHD 287772 MEMBRANE JOINT MEMBRANE(1000421) 20/40/50 ND +...
  • Page 71: Storage Conditions

    15.3 Storage conditions Basically, DIN 7716 (guidelines for storage, maintenance and cleaning of rubber products) applies to the storage of diaphragms and O-Rings. The ageing process depends Proper storage mainly on the following factors: • Storage temperature between 5 °C and 20 °C •...
  • Page 72 The maximum flow rate indicated refers to natural gas with a density of 0.81 kg/m or to the air with a density of 1.24 kg/m at 15 °C under normal conditions. In the case of different types of gases, a conversion of the volume flow according to the equation shown below is carried out.
  • Page 73 DUNGS empfiehlt eine maximale Lagerzeit von 3 Jahren. DUNGS recommends a maximum storage time of 3 years. DUNGS recommande une durée de stockage maximale de 3 ans. DUNGS raccomanda un tempo massimo di stoccaggio di 3 anni. We reserve the right to make modifications in the course of technical development.
  • Page 74 74 … 76...
  • Page 75 75 … 76...
  • Page 76 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 Internet: www.dungs.com 76 … 76...

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