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Instruction Manual
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 ... 60
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
Instruction Manual 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: Declaration Of Conformity
Medium Pressure Regulator 10 bar / 25 bar Produkt / Product Produit / Producto FRM 250065 - 250080 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 FRM 250065 - 250080 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: •...
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Page 5: Table Of Contents
4. Table of contents Target group Warnings General warnings Designated use Risks in case of misuse 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 6: 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 If the main diaphram or the auxiliary pressure required for the actuation of the main valve fails, the main Fail-open valve moves automatically to the open position. -
Page 7: 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 8: Nomenclature
AC 5 SG 10 400 - 1 600 "W.C. 90 - 420 mbar 35 - 400 mbar 180 - 800 mbar FRM 100065 MD / SAV MD DN 65 AC 5/10** SG 10/20** AG 10 AG 10 36 - 168 "W.C. -
Page 9: 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 10: Selection Of Regulator Springs
6.5 Selection of regulator springs Specific set range, outlet pressure W Spring colour Order num- Wire ∅ Length ∅ Setpoint range [mm] [mm] [mm] 90 - 140 mbar Blue 270347 65.0 36 - 56 "W.C 120 - 185 mbar 400-550 mbar Black 270348 68.0... -
Page 11: 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 12: 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 13: Dimensions
Optional with swagelok fitting for 1/2" tubing. Type Order Dimensions [mm] Weight max. number [bar / kPa/PSI] [kg] FRM 100065 MD 277241 10 / 1 000 / 145 1/2 "G 56 (123 lbs) ⊘ FRM 100065 HD 277242 10 / 1 000 / 145 1/2 "G... - Page 14 1/2" tubing. Type Order Dimensions [mm] Weight max. number [bar / kPa/PSI] [kg] FRM 100065 MD/SAV MD 273061 10 / 1 000 / 145 1/2 "G 71 (156 lbs) ⊘ FRM 100065 HD/SAV HD 276113 10 / 1 000 / 145 1/2 "G...
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Page 15: 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 16: 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, unless deviations required ≤ 30 m/s. by regulations. • Use steel pipe impulse lines: • Install the safety shutoff valve in the flow direction (ar- For versions using Ermeto screw connection 12 L: row/housing). -
Page 17: 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 18: 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 19: 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 20: Settings
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 mm. 3. Turning clockwise: the preload of the setpoint spring is increased and the outlet pressure p is increased (+). -
Page 21: 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 mm. 3. Turning clockwise: increase (+) in the upper shut down pressure p 4. -
Page 22: 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 (80 "W.C.) System-specific operating pressure downstream of the regulator p 500 mbar (200 "W.C.) -
Page 23: 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 mm. -
Page 24: 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 25: 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 mm. 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 mm until the desired spring preload is reached. -
Page 26: 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 27: Commissioning / Unlocking/ Control Of The Set Values
12.4 Commissioning / unlocking/ control of the set values 1. Slowly open the shutoff valve on the inlet side per 2. Monitor the pressure rise on the pressure gauge on 12.2 “Initial applying pressure during commission- the inlet side upstream of the device. ing, recommissioning or testing”. - Page 28 Never fix or tighten the resetting lever. The resetting lever must be able to swing down freely at all times. Obstruction can lead to malfunction or critical conditions. The re- setting lever can be removed if it cannot be ensured that it is not hindered in its move- ment.
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Page 29: 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 30 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 31: 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 32 32 …60...
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Page 33: 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 mm. - Page 34 FRM...HD/UHD FRM...MD 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. 34 …60...
- Page 35 FRM...HD/UHD FRM...MD SW 13 mm Loosen the nut J (M 8) using an open-ended wrench SW 13 mm. Loosen the nut J (M 8) using an open-ended wrench SW 13 mm. FRM...HD/UHD FRM...MD Remove the spring washer K. Remove the spring washer K. 35 …...
- Page 36 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 37: Replacement Of The Control Plate / Valve Seat
14.2.3 Replacement of the control plate / valve seat SW 17 mm Loosen the 8 screws AL using an open-ended wrench Make sure that SAV is tripped by pushing triggering size SW 17 mm. button. SW 27 mm SW 30 mm Loosen nut R using a tube wrench SW 27 mm fixing the control plate AJ with a tube wrench SW 30 mm. - Page 38 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. 38 …60...
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Page 39: Replacement Of The Compensation Membrane
14.2.4 Replacement of the compensation membrane SW 17 mm Loosen screws Y using an open-ended wrench Remove lower cover of the working diaphragm O. SW 17 mm. Remove compensation guide support S. Remove upper compensation fixing disc U. 39 … 60... -
Page 40: 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 mm. 40 …60... - Page 41 Remove O-Ring Q. Don’t use tools with sharpe edges to avoid damage. Remove intermediate housing P and O-Rings Z and AA. Closing shell Closing spring Remove closing spring SAV. Replace closing shell SAV. 41 … 60...
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Page 42: 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 20). (–) (–) 13.3.2 Removing the ASE from the housing... -
Page 43: Mounting Of The Ase On The Housing
Replace ASE. Loosen the 2 screws using an allen key SW 5 mm. 14.3.3 Mounting of the ASE on the housing Place the new O-Ring G in the turned groove on the housing M intended for this purpose. Screw the thread of the connecting piece into the housing using a hook wrench. -
Page 44: Necessary Tools
14.4 Required tools Pressure Work step Tool designation Wrench size rating Loosen the pulse lines. Open-ended spanner (A) MD/HD/UHD SW 24 Tube/socket wrench (B) SW 17 Release the setpoint springs. MD/HD/UHD Tube/socket wrench (B) SW 22 Loosen ASE from the housing. Internal hex key (C1) MD/HD/UHD SW 5... -
Page 45: Sav Leakage Test
Regulator Pressure Work step Tool designation Wrench size rating Loosen the pulse lines. Open-ended spanner (A) MD/HD/UHD SW 24 Open-ended spanner (A) SW 24 Release the setpoint springs. MD/HD/UHD Hinged hook wrench (D) 90-155 Open-ended spanner (A) SW 17 Replace the working diaphragm. MD/HD/UHD Open-ended spanner (A) SW 13... -
Page 46: Spare Parts
15. Spare parts 46 …60... -
Page 47: 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 48: 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 49: Storage Conditions
15.4 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 50: Natural Gas Flow Volume Table
5419 5567 5716 5865 3009 4267 5525 6469 7414 11708 FRM 100065 … DN 65 - max. flow volume [CFH] natural gas of density 0.81 kg/m³ (AC 10) FRM ... Inlet pressure 1.50 2.00 3.00 4.00 5.00 6.00 6.00 10.00 15.00... - Page 51 FRM 100080 … DN 80 - max. flow volume [Nm /h] natural gas of density 0.81 kg/m³ (AC 10) FRM ... [bar] 0,15 0,25 0,35 0,75 1,25 [bar] 1037 1249 1331 1414 1655 0,75 1008 1065 1282 1498 1579 1660 1753 1784 1188...
- Page 52 FRM 250065 UHD... DN 65 - max. flow volume [Nm FRM 250065 UHD... DN 65 - max. flow volume [Nm natural gas of density 0,81 kg/m (AC 5) natural gas of density 0,81 kg/m (AC 10) FRM ... FRM ... [bar] [bar] [bar]...
- Page 53 FRM 250065 UHD… DN 65 - max. flow volume [CFH] FRM 250065 UHD… DN 65 - 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]...
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Page 54: Air Flow Volume Tables
16.2 Air flow volume tables FRM 100065... DN 65 - max. air flow volume [Nm /h] (AC 10) FRM ... [bar] 0,15 0,25 0,35 0,75 1,25 [bar] 1137 1029 1085 1140 1204 1226 0,75 1045 1196 1251 1305 1270 1292... - Page 55 FRM 250065 UHD... DN 65 - max. air flow volume FRM 250065 UHD... DN 65 - max. air flow volume /h] (AC 5) /h] (AC 10) FRM ... FRM ... [bar] [bar] [bar] [bar] 1291 1625 1036 1209 1031 1367 1704 2051 1017...
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Page 56: 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 57 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 58 58 …60...
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- Page 60 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 60 …60...
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