GAS PRESSURE CONTROL UNIT TYPE 132

OUR DIVERSITY IS YOUR PROFIT.

Gas Pressure Regulator Type 132 Scope of Application Scope of type 132 gas pressure regulator is to maintain the output pressure at a constant level regardless of interferences such as changing input pressure and/or flow rate. It can be used for all gases according to DVGW worksheet G260 and all non-aggressive gases (Special design is available for aggressive gases, particularly gases from dumps or sewage processing plants). Characteristics • Connections according to customer require-

ments (including ANSI and special flanges) • Large inlet pressure range • Optional with integrated soundproofing

(attenuation approx. 10-20 dB) • Also available as differential and zero pressure

regulator • Overall length adaptable according to local

requirements • High regulating accuracy, short actuating time • Easy maintenance; on-site-maintenance

possible without removing unit • Single ply design => few parts subject to wear • Special version with operating temp. up to

250°C • Pressure compensated valve combination • Short outlet path required • Also as combination with safety shut-off valve

type 53N/H • Extremely low required minimum pressure

difference (Pe-Pa) • No special tools required DIN-DVGW Registration Numbers Nominal width

Pressure stage

Registration No.

DN 50 PN 25 94.01c713 DN 80 PN 25 94.02c713 DN 100 PN 16 94.03c713 DN 150 PN 16 94.04c713 DN 200 PN 16 94.05c713 DN 250 PN 16 94.06c713 DN 300 PN 10 94.07c713 DN 350 PN 10 94.08c713 DN 400 PN 10 94.09c713 DN 500 PN 10 94.10c713

Approved according to DIN 3380 "Gas Pressure Regulation Equipment for Input Pressures up to 100 Bar".

Technical Data Input pressure

up to 25 bar

Output pressure

up to 16 bar

Min. press. Difference

100 mbar 20 mbar*1 / 3 mbar*²

Nominal widths

DN 50; DN 65; DN 80; DN100; DN125; DN150; DN200; DN250; DN300; DN350; DN400; DN500

Type of connection

DIN flanges; ANSI flanges; Special flanges

Valve diameter

50 mm to 500 mm

Operating temperature

-15°C to +60°C*³

Medium

suitable for all gases according to DVGW worksheet G260 and all non-aggressive gases

Materials

Body St 37.0 / St 35.8 Diaphragm housing GGG 40 / St 37-2 Control regulator Al Control press. Reducer Al Inner parts Al, VA, Ms, Steel Diaphragms, O-rings Perbunan, Viton Cone valve Perbunan, Viton

*1 : With larger diaphragm housing *² : Version controlled by external pressure *³ : Special version up to 250 °C Adjustment Ranges Guide range [bar]

Drawing number

RG SG

Control Regulator DN 0,01 - 0,12 4-St-12/DN/4 10/5 20/10 0,12 - 0,30 4-St-12/DN/5 5 10 0,30 - 0,60 4-St-12/DN/6 2,5 5 0,60 - 0,75 4-St-12/DN/7 2,5 5 0,75 - 1,00 4-St-12/DN/8 1 2,5

Control Regulator DH 0,05 - 0,30 4-St-12/DH/4 5 10 0,30 - 1,00 4-St-12/DH/5 5 10 1,00 - 1,90 4-St-12/DH/6 5 10 1,90 - 2,90 4-St-12/DH/7 2,5 5 2,90 - 4,30 4-St-12/DH/8 2,5 5 4,30 - 7,50 4-St-12/DH/9 2,5 5

Other adjustment pressures available on request.

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Installation Dimensions

Outlet Inlet Valve-Ø L A B C D Weight *1 *1 *2 ∆p≥1.5 bar ∆p≥100mbar ∆p≤100mbar

DNOut DNIn [mm] [mm] [mm] [mm] [mm] [mm] [mm] [kg] 50-150 50-150 50-80 450 570 250 235 300 420 65

100 450 570 265 235 420 482 80 125 700 620 320 290 420 482 120 150 800 660 350 320 420 482 150

200 50-200 50-80 500 590 275 260 300 420 75 100 500 590 290 260 420 482 95 125 700 620 320 290 420 482 125 150 800 650 350 320 420 482 160 200 800 660 400 320 482 585 185

250 50-250 50-80 800 620 300 290 300 420 110 100-125 800 620 320 290 420 482 120 150 900 660 350 320 420 482 150 200 900 660 400 320 482 585 200

300 50-300 50-80 900 650 330 320 300 420 150 100-150 900 650 350 320 420 482 170 200 900 660 400 320 482 585 230

Other dimensions and valve sizes available on request! *1 : Units available with all flanges according to customer requirements *2 : Units available with other overall lengths

Line Connections

Standard Version

The flow direction and/or line connections can be changed on customer request.

⎫ for unsoldered, threaded ⎬ pipe fitting with cutting ring ⎪ according to DIN 2353 for ⎭ pipe dia. 12x1.5 mm

Ventilation G1/4 Measuring pulse

G1/4

Sockets G1/4

Flow direction left-right Ventilation in flow direction right Measuring pulse in flow direction right

3

Installation Type 132 gas pressure regulator can be installed vertically or horizontally in flow direction. When installed vertically it is necessary to mount the control regulator vertical beneath the control gear. Due to the specific design the test pulse can be installed behind the gas pressure regulator at an distance of 2-3 x DN outlet (5 x DNoutlet = better regulation group than specified). Design and Function of Type 132 Gas Pressure Regulator

4

Design The type 132 gas pressure regulator is composed of three assemblies: control regulator (I), pressure reducer (II) and control gear (III). The control regulator is available in DN and DH versions; DN is used on a standard basis for pressure range up to 50 mbar, DH for operating pressures greater than 50 mbar. The SR pressure reducer is used at a differential pressure of ∆p > 1.5 bar.

Function Inlet pressure (pe) flows between cone valve 5 and compensation diaphragm 3. The cone valve remains closed - even when the inlet pressure varies. Inlet pressure even reaches through control pressure line 15 pressure reducer 12 (with integrated microfilter), which limits the control pressure (application only for ∆p > 1.5 bar). It will be adjusted to the most favourable control characteristic between 0.2 and 1.0 bar above the outlet pressure (pa). Pressure gauge 11 serves for checking. The reduced pressure reaches control regulator 9. Control valve 7 is opened by tensioning spring 13 with the cross handle 10 - turning to the right increases outlet pressure. The control pressure reaches through control pressure line 6 into the diaphragm chamber where it acts on the operating diaphragm 1. The operating diaphragm lifts opening cone valve 5. The resulting outlet pressure (pa) reaches through pulse line 8 below control regulator diaphragm 14 lifting it when the set spring value is reached. This closes control valve 7. The control pressure is equalized to the output pressure via control nozzle 2 and exhaust line 4 and the cone valve 5 closes. The gas pressure regulator is in regulating position.

Starting apparatus After properly installing the regulator and connecting the pulse lines proceed as follows for start up: − Release tension of adjustment spring in control

regulator (and if necessary in control regulator pressure reducer).

− Slowly open inlet shut off valve; the outlet pressure should not increase.

− If necessary adjust control pressure on pressure reducer (approx. 0.2 bar to 1.0 bar above setting for outlet pressure).

− Slowly tension adjustment spring of control regulator until desired outlet pressure is reached.

− Slowly open outlet shut off valve and adjust to exact outlet pressure.

The gas pressure regulator is ready for operation.

Unit Layout The valve flow coefficient KG is the value of the flow rate q through gas pressure regulating equip-ment with control gear completely opened while pe = 2.013 bar abs. and pa = 1.013 bar abs.; measured under standard conditions on a test bench with air as flow medium. Valve flow coefficient KG for gas pressure regulator type 132 (converted to natural gas H)

Valve-Ø [mm]

KG - value [Nm³/h]

Valve-Ø [mm]

KG - value [Nm³/h]

50 2.200 150 20.000 65 3.700 175 27.000 80 5.700 200 36.000100 8.900 250 57.000125 13.700 300 81.000

Values for larger valve diameters available on request. The following equations enable to calculate the required KG value (for T<60°C): KG - value at subcritical pressure ratio pp

a

e≥ 0 53, : K q

p p pG

n

a e a=

−( ) [Nm³/h]

(qn in [Nm³/h]; pe and pa in [bar abs.]) KG - value at supercritical pressure ratio pp

a

e< 0 53, : K q

pG

n

e=

⋅ 2 [Nm³/h]

When other gases are used it is necessary to convert qn with the following corrective factors f: Medium f Medium f Ammonia 1,00 Methane 1,04 Butane 0,53 Town gas 1,18 C02 0,62 Oxygen 0,72 Nat. gas L 0,97 Nitrogen 0,78 Air 0,77 Hydrogen 3,02

Values for other mediums available on request.

Conversion equation: q qf

nnMedium

= [Nm³/h]

Calculation of nominal connection width:

[mm ]

qn : [Nm³/h]; p : [bar abs.]: vmax : [m/s]; T : [°C]

D q Tp v

nmin

max

, ( )=

⋅ ⋅ +⋅

1 3 273

vmax = max. permissible flow velocity Optimum valve diameter and nominal connection width can be calculated for each medium and unit with a computer program in our office.

5

External Pressure Control

Diaphragm Housing On Top

Primary Soundproofing

External Control Nozzle

Gas pressure regulators with external pressure control are used primarily when the pressure difference between pe and pa is not sufficient to control the regulator (fast enough). Regularly compressed air is used as external medium. Using external pressure controlled units it must be considered that a small quantity of the external pressure medium is consumed continuously (5-30 l/min depending on control pressure). Control function corresponds to the function described on page 5. When used with aggressive mediums ventilate piping to free atmosphere is to install. Units with diaphragm housings on top are preferred in two cases: a) When large quantities of condensate are expected, which would assemble on the diaphragms (for example with extremely moist gases). In such cases an additional condensate drain cock 1 can be installed. b) When an extremely short overall length with outlet downward is required (for example in cabinet systems). Control function corresponds to the function described on page 5. Dimensions x and y available on request. Expanding noises can be reduced approximate 10 - 20 dB with primary soundproofing. Additional installation is possible at any time. In such cases it is necassary that noise damping element 2 is held centered above valve 1 with holder 3. Screw 4 should extend approx. 2-3 mm above the edge of the body flange when installed with the rubber seal to ensure that sufficient pressure is present. An external control nozzle can be used − when contamination and clogging is expected, − a steel diaphragm housing is used, − easier and quicker accessibility to the control

nozzle is required. The control nozzle is designed on a standard basis with Ermeto connection 10L.

6

Motor Control

Inlet Pressure Protection

Differential or Balanced Pressure Control

Two Operating Pressures

Gas pressure regulators can be equipped with a servo-motor for electrically driven adjustment of output pressure. The servo-motors are available in two versions: I: Motor servo-drive, brand AUMA, 380 V AC, also available with design for explosion hazard areas; II: Motor servo-drive, brand RTK, 230 V AC, also 24 V DC and 380 V AC. Control function of the gas pressure regulator corresponds to the description on page 5.

Gas pressure regulators with inlet pressure protection can be used to prevent the pressure regulator from feeding medium to the outlet side when the inlet pressure drops below a certain value. Pressure switch point is to adjust by the control regulator UH (turning to right increases value). When inlet pressure decreases, check valve 2 prevents medium flowing from outlet side through control lines 3-1 into control pressure reducer SR (or directly into the inlet pressure) and damaging it. Gas pressure regulators with differential or balanced pressure control are used regulating the pressure of the main medium in relation to the pressure of a second medium. To prevent mixing of the two media A and B in the event of a diaphragm crack in the control regulator they are separated by two diaphragms 1 and 2. Requested differential or balanced pressure can be adjusted by cross handle 4 (turn right to increase value). By combining two control regulators and a solenoid valve it is possible to regulate two different outlet pressures (applications) with one gas pressure regulator. The DH1 control regulator is positioned to the lower pressure pa1; it is always in operation. By opening solenoid valve MV the second control regulator DH2 is activated and regulates the high pressure pa2. At pressure differences of pa2 - pa1 > 1 bar two control pressure reducers SR are required.

7

Design Type 132 Control Unit

x: Parts subject to wear; keep on hand for maintenance

8

Components for Type 132 Control Unit Item Quant. Units Designation Standard / drawing No. Material / remarks

1 1 Piece Bottom diaphragm housing 4-132-1/... GGG 40 / St 2 1 Piece Diaphragm plate, operat. diaphr. 4-132-2/... St, chromatic

x3 1 Piece Operating diaphragm 4-132-3/... Perbunan x4 1 Piece Control nozzle gasket 8 x 12 x 6 Perbunan 5 1 Piece Control nozzle 4-132-5 VA 6 1 Piece Bottom diaphragm ring 4-132-6/... St, chromatic 7 1 Piece Upper diaphragm ring 4-132-7/... St, chromatic

x8 3 Piec Hex. nut DIN 439, M16 St, galvanized 9 1 Piece Valve suspension 4-132-9/... VA

x10 1 Piece Circlip DIN 471, 16 x 1 Spring steel, galv. x11 2 Piece Sealing ring DIN 7603 A, 16 x 24 x 1.5 Cu x12 1 Piece O-ring 16 x 5 Perbunan x13 1 Piece Cone valve 4-132-13/... Al, Perbunan x14 1 Piece Retaining nut DIN 982, M16 St, galvanized x15 1 Piece Round cord seal ∅ 5 Perbunan 16 8/12 Piece Allen screw DIN 912, M12 x 20 / 30 8.8, galvanized 17 1 Piece Blind flange 4-132-17/... St, chromatic 18 1 Piece Operating diaphragm suspension 4-132-18/... Al 19 1 Piece Hex. nut DIN 431, G3/4 St, galvanized 20 1 Piece Diaphragm plate 4-132-20/... Al

x21 1 Piece Compensation diaphragm 4-132-21/... Perbunan 22 1 Piece Upper diaphragm housing 4-132-22/... GGG 40 / St 23 16 Piece Allen screw DIN 912, M10 x 30 8.8, galvanized 24 8 Piece Allen screw DIN 912, M12 x 45 8.8, galvanized

x25 8 Piece Sealing ring DIN 7603, 12 x 18 x 1.5 Cu x26 2 Piece Round cord seal ∅ 5 Perbunan 27 1 Piece Compensat. diaphr. suspension 4-132-27 Al 28 1 Piece Spring plate 4-132-28 St, chromatic 29 1 Piece Closing spring 4-132-29 Spring steel C, chrom.30 1 Piece Valve guide 4-132-30 St 31 1 Piece Body 4-132-31/... St 32 2 Piece Body flange 4-132-32/... St 33 2 Piece Allen screw DIN 912, M8 X 15 8.8, galvanized 34 1 Piece Diaphragm plate 4-132-34 St, chromatic

Special Maintenance Instructions Type 132 Control Unit Waiting control unit check cone valve 13 connection for leakage and diaphragms 3 and 21 for wear and solidity. To check cone valve 13 for leakage first release tension of adjustment spring of control regulator and close the shut off valve behind the gas pressure regulator. The pressure behind gas pressure regulator should no longer increase. To remove cone valve 13 first detach screws 16 and remove blind flange 17. Then loosen self-locking nut 14 while holding valve suspension 9 with another wrench (important).

When installing ensure that items 10, 11, 12, 14 and 15 are also replaced. In order to check operating diaphragm 3 first loosen screws 23 and remove the bottom diaphragm housing 1. After that operating diaphragm 3 can be screwed out together with diaphragm suspension 18 and checked. After loosening screws 24 upper diaphragm housing 22 can be removed and the compensating diaphragm 21 screwed out together with diaphragm suspension 27 and checked; during this operation hold middle hex. nut 8 with a wrench. When installing ensure that items 4, 25 and 26 are also replaced.

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Design Type DH, DN Control Regulator

x: Parts subject to wear; keep on hand for maintenance Items (2; 3; 4) only available complete

Special Maintenance Instructions Type DH, DN control regulator It is necessary to remove type DH and DN control regulators from the main unit for maintenance purposes. Before disassembling the control regulator always release the tension on the adjustment spring 12 with cross handle 17. During maintenance check diaphragm 8, the control regulator insert (2, 3, 4) and control valve 1 especially for wear. Diaphragm 8 can be removed together with suspension 7 and checked after loosening screws 19. When the spring cap 6 is unscrewed and screws 21 and 27 removed control valve can be screwed out of the control regulator insert (2, 3, 4), the insert removed and checked. The insert should be replaced every 5 years at the latest to ensure general operating safety. When assembling ensure that: - control valve 1 is screwed in up to approx. ¼ turn in front of the stop on the control regulator insert (2-4). - spring cap 6 is screwed on to the control regulator insert (2-4) only to the point that control valve 1 lifts approx. 2 mm from the seat of the regulator body 24 when the spring cap 6 is pushed down.

Components for DH, DN Control Regulator Item Quant. Units Designation Standard /drawing number Material / remarks

x1 1 Piece Control valve 4-St-1/D Ms x2 1 Piece Spring body 4-St-2 Bronze x3 1 Piece Valve suspension 4-St-3/D VA x4 1 Piece Brazing flange 4-St-4 VA 5 1 Piece Closing spring 4-St-5 VA-spring steel 6 1 Piece Spring cap 4-St-6 VA 7 1 Piece Diaphragm suspension 4-St-7 VA

x8 1 Piece Diaphragm 4-St-8/... Perbunan 9 1 Piece Diaphragm plate 4-St-9/... Al

10 1 Piece Washer DIN 125; 10.5x2.5; Form B St, galvanized 11 1 Piece Hex. nut DIN 439; M10; St, galvanized 12 1 Piece Adjustment spring 4-St-12/... Spring steel C,chromat.13 1 Piece Spring plate 4-St-13 St, chromatic 14 1 Piece Spindle seal 4-St-14 Perbunan 15 1 Piece Pressing ring 4-St-15 Ms 16 1 Piece Hex. nut DIN 431; G1/4; St, galvanized 17 1 Piece Cross handle with spindle 4-St-17 Ms; Duroplast 18 1 Piece Upper diaphragm housing 4-St-18/... Al 19 8 Piece Allen screw DIN 912; M6x20; 8.8, galvanized 20 1 Piece Bottom diaphragm housing 4-St-20/... Al 21 4 Piece Allen screw DIN 912; M6x25; 8.8, galvanized

x22 1 Piece O-ring 48 x 4 Perbunan x23 1 Piece O-ring 26 x 2 Perbunan 24 1 Piece Regulator body 4-St-24/D Al

x25 1 Piece O-ring 26 x 2 Perbunan 26 1 Piece Regulator base 4-St-26/D Al 27 4 Piece Allen screw DIN 912; M6x50; 8.8 8.8, galvanized

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Design Type SR Pressure Reducer

x: Parts subject to wear; keep on hand for maintenance Items (18, 19) only available complete

Special Maintenance Instructions Type SR pressure reducer Type SR pressure reducer with integrated sinter metal filter can be disassembled for maintenance works. For this purpose unscrew Ermeto fittings on the inlet and outlet. The unit can be checked for proper function on a test bench when removed. Before disassembling the pressure reducer always release the pressure on adjustment spring 8 with spindle 11. When servicing check especially diaphragm 6 for wear and filter element 21 for clogging. After loosening allen screws 10 top valve element 15 can be taken off and diaphragm 6 removed together with diaphragm suspension 5 and diaphragm plate 7 and checked. After loosening plug 1 filter element 21 can be removed together with valve insert 4. If the filter element no longer has a yellow/gold shimmer, replace it. The filter element should be changed every two year at the latest to ensure general operating reliability.

Components for Type SR Pressure Reducer Item Quant. Units Designation Standard / drawing number Material / remarks

1 1 Piece Plug 4-SR-1 Ms 2 1 Piece Compensation plate 18.5 x 6 Sponge rubber 3 1 Piece Spring pressure element 4-SR-3 VA 4 1 Piece Valve insert 4-SR-4 Ms 5 1 Piece Diaphragm suspension 4-SR-5 St, chromatic

x6 1 Piece Diaphragm 4-SR-6 Perbunan 7 1 Piece Diaphragm plate 4-SR-7 Al 8 1 Piece Adjustment spring 4-SR-8/... Spring steel C, chromat.9 1 Piece Spring plate 4-SR-9/... St, chromatic

10 4 Piece Allen screw DIN 912; M6 x 65 8.8, galvanized 11 1 Piece Spindle 4-SR-11 Ms 12 1 Piece Hex. nut DIN 431; G1/4 St, galvanized 13 1 Piece Pressing ring 4-St-15 Ms 14 1 Piece Spindle seal 4-St-14 Perbunan 15 1 Piece Upper valve element 4-SR-15 Al 16 1 Piece Bottom valve element 4-SR-16 Al

x17 1 Piece O-ring 17 x 1.5 Perbunan x18 1 Piece O-ring 2.9 x 1.78 Perbunan x19 1 Piece Control valve 4-SR-19 Ms 20 1 Piece Closing spring 4-SR-20 VA-spring steel

x21 1 Piece Filter element 4-SR-21 Sinter bronze x22 1 Piece O-ring 22 x 3 Perbunan x23 1 Piece Gasket 18.5 x 0.4 PTFE

11

safety shut-off valve TYPe 53 N/H

our diversity is Your ProfiT.

Safety Shut Off Valve Type 53N/H Scope of Application Scope of type 53N/H safety shut off valve is to prevent impermissibly high pressure and/or low pressure from the system at the outlet side, e.g. a gas pressure regulation system. It can be used for all gases according to DVGW worksheet G260 and all non-aggressive gases. (Special versions are available for other gases). Characteristics • Connections according to customer require-

ments (including ANSI and special flanges) • Overall length adaptable to local situation at

customer request • High actuation accuracy, short actuating time • Integrated diaphragm rupture safety device • Integrated pressure compensation valve with

positive return • On-site-maintenance possible without removing

unit • Position of safety shut-off valve can be checked

visually (position of hand lever) • Single ply design => few parts subject to wear • Pressure compensated valve combination • All units with high/low pressure actuation • Also as combination with gas pressure regulator

type 132 • Position indicator and electrical remote control

possible with simple modification • Manual actuation can be retrofitted

(EMERGENCY-OFF) DIN-DVGW Registration Numbers Nominal width

Pressure stage

Registration No.

DN 80 PN 25 96.01 c 713 DN 100 PN 16 96.02 c 713 DN 150 PN 16 96.03 c 713 DN 200 PN 16 96.04 c 713 DN 250 PN 10 96.05 c 713 DN 300 PN 10 96.06 c 713 DN 350 PN 10 96.07 c 713 DN 400 PN 10 96.08 c 713 DN 500 PN 10 96.09 c 713

Approved according to DIN 3381 "Safety devices for gas supply systems without operating pressures up to 100 Bar".

Technical Data Permissible pressure

pmax up to 25 bar

Nominal widths

DN 80; DN100; DN150; DN200; DN250; DN300; DN350; DN400; DN500

Type of connection DIN flanges PN10 to PN40; ANSI flanges; special flanges

Valve diameter 80mm to 500mm

Operating temperature -15°C to +60°C

Medium suitable for all gases according to DVGW worksheet G260 and all non-aggressive gases

Materials Driving mechanism Measuring element Inner parts Diaphragm, O-rings Valve coating

Steel Al Al, VA, Ms, steel Perbunan Perbunan

Actuation time 0.2 - 0.5 s (dep. on PB, DN and measuring el.)

Adjustment Ranges Guide range [bar]

Drawing number

Wire-∅[mm]

AG

Movement N (pressure to high) 0,030 - 0,150 4-53-16/4x100 4,0 10/5 0,150 - 0,250 4-53-16/5x100 5,0 5 0,250 - 0,500 4-53-16/6x100 6,0 2,5

Movement N (pressure to low) 0,007 - 0,025 4-53-15/2,0x58 2,0 30 0,025 - 0,070 4-53-15/2,5x49 2,5 20

Movement H (pressure to high) 0,100 - 0,350 4-53-16/4x100 4,0 10/5 0,350 - 0,850 4-53-16/5x100 5,0 2,5 0,850 - 1,600 4-53-16/6x100 6,0 2,5 1,600 - 2,700 4-53-16/7x100 7,0 1 2,700 - 4,200 4-53-16/8x100 8,0 1 4,200 - 7,000 4-53-16/9x100 9,0 1

Movement H (pressure to low) 0,040 - 0,120 4-53-15/2,0x58 2,0 15 0,120 - 0,280 4-53-15/2,5x49 2,5 10 0,280 - 0,650 4-53-15/3,0x55.1 3,0 5 0,650 - 1,050 4-53-15/3,6x48.2 3,6 2,5 1,050 - 1,500 4-53-15/4,0x49 4,0 1

Other adjustment pressures available on request!

2

Installation Dimensions

DN Valve A*1 B C D*2 E F kg ∅*3 PN10 PN16 PN25 PN40 ANSI

150 ANSI 300

80 80 450 530 85 - 100,0 - 100,0 95,3 104,8 180 230 39 100 100 600 560 110 - 110,0 - 117,5 114,3 127,0 185 230 52 150 150 600 590 140 - 142,5 - 150,0 139,7 158,8 210 268 68 200 200 700 620 165 170,0 170,0 180,0 187,5 171,5 190,5 240 320 95 250 250 900 650 180 197,5 202,5 212,5 225,0 203,2 222,3 265 370 128 300 300 1000 675 205 222,5 230,0 242,5 257,5 241,3 260,4 280 430 186 350 350 1900 780 260 252,5 260,0 277,5 290,0 266,7 292,1 305 482 280 400 400 1900 800 260 282,5 290,0 310,0 330,0 298,5 323,4 355 585 504 500 500 2000 850 310 335,0 357,5 365,0 377,5 349,3 387,4 405 685 708

*1 : Units available with other overall length *2 : Units available with all flanges according to customer requirements *3 : Also available with smaller valve diameter (minimum valve dia.: 80 mm!)

Line Connections

Flow direction and/or line connections can be changed on customer request.

Ventilation G1/4 Measuring pulse

G1/4 ⎫ for unsoldered, threaded pipe ⎬ fitting with cutting ring accord. ⎭ to DIN 2353 for pipe-ø 12x1.5

Flow direction left-right Ventilation in flow direction right Measuring pulse in flow direction right Hand lever in flow direction front

Standard Version

3

Installation The safety shut-off valve type 53N/H can be installed horizontally with the measuring element (I) upright or vertically with the measuring element pointing to the side. When installed vertically the flow direction on units with valve diameter up to 150 mm can be from top to bottom or vice versa; on units with valve diameter greater than 150 mm the flow direction for units installed vertically must be from top to bottom. Design and Function of Safety Shutoff Valve Type 53N/H

4

Design Type 53N/H safety shut off valve is composed of three assemblies: measuring element (I), driving mechanism (II) and regulating unit (III). Measuring element is available in versions 53N and 53H; 53N is used on a standard basis for operating pressures up to 50 mbar, DH for operating pressures above 50 mbar.

Function Upper threshold pressure The pressure to be monitored reaches through the measuring pulse line 10 into diaphragm chamber 16. If the pressure increases to an impermissibly high value and exceeds the setting of the pressure spring 4, diaphragm 9 lifts together with release bushing 11. This releases the balls 12 so that release piston 13 together with the lower rod 14 snap up releasing pawl 15. Valve 19 closes.

Lower threshold pressure The pressure to be monitored reaches through the measuring pulse line 10 into diaphragm chamber 16. If the pressure decreases to an impermissibly low value and overcomes the setting of the low pressure spring 8, diaphragm 9 moves down together with release socket 11. The remaining operation corresponds to that described previously for the upper threshold pressure.

Diaphragm rupture safety device In the event of a diaphragm rupture the gas flows into spring chamber 5 and reaches through the ventilation line 7 into the atmosphere. The pressure in diaphragm chamber 16 thereby decreases. The remaining procedure corresponds to the sequence above for lower threshold pressure.

Starting Apparatus Before initial operation (opening) ensure that valves in back are closed. The integrated pressure compensation valve 18 can be opened by slowly lifting the hand lever 17 until resistance is felt. When the pressure in front and in back of the valve plate 19 has equalized slowly lift hand lever 17 further to the stop. The pressure to be monitored reaches through measuring pulse line 10 into diaphragm chamber 16 where it applies pressure to diaphragm 9. Press release piston 13 down with pushbutton 1 only after the operating pressure has been reached so that the balls 12 can catch. The release bushing 11 together with diaphragm 9 snap into the zero position. Pushbutton 1 can be released. Hand lever 17 can then be released slowly until the pawl 15 makes contact with the bottom rod 14. The safety shut-off valve is now ready for operation.

Adjustments To adjust the threshold pressures loosen and remove crown cover 2 with the special safety shut-off valve wrench. Upper threshold pressure The upper threshold pressure can be adjusted with the aid of the special safety shut-off valve wrench on spring plate 3. Turning to right increases the value. If the upper threshold pressure is set to above 3 bar adjust only in non-pressurized state after low pressure actuation, otherwise the diaphragm can be damaged. Lower threshold pressure Adjust lower threshold pressure with the special safety shut-off valve wrench (17 mm) on the dome spring plate 6. Turning to right increases the value. If the lower threshold pressure is set to above 150 mbar adjust only in non-pressurized state after low pressure actuation, otherwise the diaphragm can be damaged. The setting for the lower threshold pressure has a slight effect on the upper threshold pressure. For this reason check and - if necessary - correct the setting for the upper threshold pressure each time the lower threshold pressure is adjusted. Minimum pressure difference between operating pressure pb and special pressure ps: Guide range [bar]

Drawing number

∆pminps - pb [bar]

Measuring Element N (pressure too high) 0,030 - 0,150 4-53-16/4x100 0,020 0,150 - 0,250 4-53-16/5x100 0,020 0,250 - 0,500 4-53-16/6x100 0,030

Measuring Element N (pressure too low) 0,007 - 0,025 4-53-15/2,0x58 0,020 0,025 - 0,070 4-53-15/2,5x49 0,030

Measuring Element H (pressure too high) 0,100 - 0,350 4-53-16/4x100 0,040 0,350 - 0,850 4-53-16/5x100 0,040 0,850 - 1,600 4-53-16/6x100 0,080 1,600 - 2,700 4-53-16/7x100 0,150 2,700 - 4,200 4-53-16/8x100 0,200 4,200 - 7,000 4-53-16/9x100 0,300

Measuring Element H (pressure too low) 0,040 - 0,120 4-53-15/2,0x58 0,030 0,120 - 0,280 4-53-15/2,5x49 0,030 0,280 - 0,650 4-53-15/3,0x55.1 0,030 0,657 - 1,050 4-53-15/3,6x48.2 0,050 1,050 - 1,500 4-53-15/4,0x49 0,100

5

Safety Shut off Valve Position Indicator

Electronic Remote Control

Manual Actuation (Emergency-off)

An inductive acting sensor can be installed on the servo-drive housing for electronic remote indication of the safety shut off position. Screw sensor 1 onto retaining plate 2. Clamp contact head 3 with the aid of screw 5 and nut 4. (Insert screw 5 through clamping pin on hand lever). Interval A between the contact head 3 and sensor 1 should be 3-4 mm. Version: - Protective system (DIN 40050): IP 67 - Type of connection: DIN 19234; NAMUR OPTION: There are two versions of the isolating amplifier required for control of the sensor: - 230 VAC, 50 - 60 Hz - 24 VDC Each: (Eex ia) II C and with PTB certificate. A 3/2-way solenoid valve 1 can be installed on the servo-drive housing 3 for electronic remote control. Actuation during power failure: At normal state (solenoid with current) path II-III is open and the safety shut off valve measuring element ready for operation. If the voltage drops, solenoid 1 closes path II-III and simultaneously opens path I-II. Pressure of measuring element 2 is released into the atmosphere and the safety shutoff valve closes because of low pressure. OPTIONS: - with DVGW approval - explosion-proof version - for aggressive mediums - for 24 VDC or 230 VAC, 50 - 60 Hz

A 3/2-way pushbutton valve 1 can be installed on the servo-drive housing 3 for manual actuation (manual emergency-off). At normal state path II-III is open (automatic position) and the safety shut-off valve driving mechanism 2 is ready for operation. When actuated manually by pressing down button 4 on 3/2-way pushbutton valve 1, path III is closed and simultaneously path I-II is opened. The pressure of driving mechanism 2 is released into the atmosphere and safety shut-off valve closes because of low pressure. The 3/2-way pushbutton valve (manual emergency off) can be combined with the 3/2-way solenoid valve (electronic remote control). In this case it can be installed in series with the 3/2-way solenoid.

6

Type 53N/H Safety Shut off Valve with air pressure low, gas pressure low and high shut off

For industrial burner systems frequently a purely mechanical safety device is required in addition to (or instead of) an electronic monitoring device for the gas and air pressure. Safety shutoff valve type 53N/H with two additional control regulators fulfills this requirement in all three cases: protection against gas pressure being to high or to low and against to low air pressure (the measuring element automatically also provides a safety shutoff for air pressure to high). Air pressure to low Air pressure IV to be monitored reaches to nozzle 4 and air pulse line V into measuring element 3. Further operation and adjustment for low (and high) air pressure corresponds to the sequence described on page 5 for function and adjustments. Gas pressure to low Gas pressure I to be monitored reaches by gas pulse line II to control regulator 6, type DH. When gas pressure decreases to an impermissibly low value and overcomes the setting of the spring in control regulator 6, the valve in control regulator 6

opens and the air from measuring element 3 decreases through line VI-VII. Movement 3 actuates due to insufficient air, because the medium cannot flow through nozzle 4 quickly enough. Turning hand wheel 5 to the right increases the value. Gas pressure to high Gas pressure I to be monitored reaches by gas pulse line III to control regulator 2, type UH. When gas pressure increases to an impermissibly high value and overcomes the setting of the spring in control regulator 2, the valve in control regulator 2 opens and the air from measuring element 3 decreases through line VIII-IX. Measuring element 3 actuates due to low air pressure, because the medium cannot flow through nozzle 4 quickly enough. Turning hand wheel 1 to the right increases the value. Maintenance We recommend checking this combination of safety shut-off valve measuring element and additional

7

control regulators for proper function quarter-annually and servicing semi-annually.

7

Design measuring element type 53H

x: Parts subject to wear; keep on hand for maintenance Item (21; 25; 26) only available complete Item (6; 10; 11) only available complete Item (28; 40) only available complete

8

Parts for type 53H measuring element Item Quantity Unit Designation Standard / drawing number Material/remarks

1 1 Piece Aluminum flange 4-53-1 Al 2 1 Piece Guide 4-53-2 Ms 3 1 Piece Blind flange, H 4-53-3/H/... St, chromatic 4 1 Piece Perforated element 4-53-4 Ms 5 1 Piece Plate for socket element 4-53-5 Al

x6 1 Piece Socket element 4-53-6 Al 7 1 Piece Diaphr. housing, H, bottom 4-53-7/H Al

x8 1 Piece Diaphragm, H 4-53-8/H Perbunan 9 1 Piece Diaphragm plate, H 4-53-9/H Al

x10 1 Piece O-ring socket 4-53-10 Ms x11 1 Piece O-ring 6 x 2 Perbunan 12 1 Piece Middle rod 4-53-12 VA 13 1 Piece Rod guide 4-53-13 Al 14 1 Piece Spring dome 4-53-14 Al 15 1 Piece Spring, pressure too low 4-53-15 Spring steel C, chrom. 16 1 Piece Spring, pressure too high 4-53-16 Spring steel C, chrom. 17 1 Piece Spring plate, dome 4-53-17 St, chromatic 18 1 Piece Spring crown, H 4-53-18/H Al 19 1 Piece Upper rod 4-53-19 VA 20 1 Piece Spring plate 4-53-20 St, chromatic

x21 1 Piece Crown cover 4-53-21 Al 22 1 Piece Pushbutton 4-53-22 Al 23 1 Piece Upper spring 4-53-23 VA spring steel

x24 1 Piece O-ring 60 x 3 Perbunan x25 1 Piece O-ring 6 x 2 Perbunan x26 1 Piece O-ring socket 4-53-10 Ms 27 1 Piece Middle spring 4-53-27 VA spring steel

x28 1 Piece Release piston 4-53-35 V-St, chromatic 29 8 Piece Allen screw DIN 912 - M6 x 100 8.8, galvanized

x30 6 Piece Ball SKF - RB5 / G20 St x31 1 Piece Release socket 4-53-33 V-St, chromatic 32 4 Piece Machine screw DIN 84 - M4 x 10 8.8, galvanized 33 1 Piece Bottom spring 4-53-38 VA spring steel 34 4 Piece Machine screw DIN 84 - M4 x 10 8.8, galvanized

x35 1 Piece O-ring 90 x 4 Perbunan x36 1 Piece O-ring 16 x 2 Perbunan x37 1 Piece O-ring 6 x 2 Perbunan 38 4 Piece Allen screw DIN 912 - M6 x 16 8.8, galvanized

x39 1 Piece O-ring 6 x 2 Perbunan x40 1 Piece Bottom rod 4-53-45 VA

Special Maintenance Instructions Measuring element N/H The measuring element can be removed for maintenance. For this loosen the screws on blind flange 3 and remove the complete element. Function also can be checked in the deinstalled state. Before disassembling the element always release the pressure of high and low pressure springs. Observe the instructions in the section Adjustments (page 5). During maintenance check especially the diaphragm as well as the release socket and piston

for any damage. The entire upper section can be removed by loosening the allen screws on the spring crown, H 18 (or on upper diaphragm housing, N 11). Then press the middle rod 12 and simultaneously pull the entire unit up together with diaphragm 8 and socket element 6. Now it is possible to check and, if necessary, replace the parts mentioned previously. All moving parts should be oiled lightly with a suitable agent before reassembling. ⇒

9

Design measuring element type 53N

x: Parts subject to wear; keep on hand for maintenance Item (21; 25; 26) only available complete Item (6; 10; 28) only available complete Item (35; 45) only available complete

10

Parts for type 53N movement Item Quantity Units Designation Standard / drawing number Material / remarks

1 1 Piece Aluminum flange 4-53-1 Al 2 1 Piece Guide 4-53-2 Ms 3 1 Piece Blind flange, N 4-53-3/N/... St, chromatic 4 1 Piece Perforated element 4-53-4 Ms 5 1 Piece Plate for socket element 4-53-5 Al

x6 1 Piece Socket element 4-53-6 Al 7 1 Piece Diaphr. housing, N, bottom 4-53-7/N Al

x8 1 Piece Diaphragm, N 4-53-8/N Perbunan 9 1 Piece Diaphragm plate, N 4-53-9/N Al

x10 1 Piece O-ring socket 4-53-10 Ms 11 1 Piece Diaphr. housing N, upper 4-53-11 Al 12 1 Piece Middle rod 4-53-12 VA 13 1 Piece Rod guide 4-53-13 Al 14 1 Piece Spring dome 4-53-14 Al 15 1 Piece Spring, pressure too low 4-53-15 Spring steel C, chrom. 16 1 Piece Spring, pressure too high 4-53-16 Spring steel C, chrom. 17 1 Piece Spring plate, dome 4-53-17 St, chromated 18 1 Piece Spring crown, N 4-53-18/N Al 19 1 Piece Upper rod 4-53-19 VA 20 1 Piece Spring plate 4-53-20 St, chromatic

x21 1 Piece Crown cover 4-53-21 Al 22 1 Piece Pushbutton 4-53-22 Al 23 1 Piece Upper spring 4-53-23 VA spring steel

x24 1 Piece O-ring 6 x 2 Perbunan x25 1 Piece O-ring socket 4-53-10 Ms x26 1 Piece O-ring 60 x 3 Perbunan 27 1 Piece Middle spring 4-53-27 VA spring steel

x28 1 Piece O-ring 6 x 2 Perbunan 29 4 Piece Allen screw DIN 912 - M6 x 20 8.8, galvanized

x30 1 Piece O-ring 90 x 4 Perbunan 31 8 Piece Allen screw DIN 912 - M6 x 100 8.8, galvanized 32 1 Piece Spring plate, comp. springs 4-53-32 Al

x33 1 Piece Release socket 4-53-33 V-St, chromated 34 1 Piece Compensation spring 4-53-34 Spring steel C, chrom.

x35 1 Piece Release piston 4-53-35 V-St, chromatic x36 6 Piece Ball SKF / RB-5 / G20 St 37 4 Piece Machine screw DIN 84 - M4 x 10 8.8, galvanized 38 1 Piece Bottom spring 4-53-38 VA spring steel 39 4 Piece Machine screw DIN 84 - M4 x 10 8.8, galvanized

x40 1 Piece O-ring 16 x 2 Perbunan x41 1 Piece O-ring 140 x 3 Perbunan x42 1 Piece O-ring 6 x 2 Perbunan 43 4 Piece Allen screw DIN 912 - M6 x 16 8.8, galvanized

x44 1 Piece O-ring 6 x 2 Perbunan x45 1 Piece Bottom rod 4-53-45 VA

⇒ Continuation of page 9 Check O-ring 28 by applying pressure (operating pressure) below diaphragm 18. Any leakage at the bore can be found with a suitable leakage indicator. O-rings 42 and 44 (movement H: 37 and 39) can only be checked in the assembled state.

For this place servo-element body under operating pressure; then use a suitable leakage indicator to inspect the bore for the measuring pulse.

11

Design driving mechanism

x: Parts subject to wear; keep on hand for maintenance Items (9; 13) only available complete Items (6; 11; 25) only available complete

12

Parts for driving mechanism Item Quantity Units Designation Standard / drawing number Material/remarks

1 1 Piece Hand lever 4-53-110 St, chromated 2 1 Piece Clamping pin DIN 1481, 5 x 30 VA

x3 1 Piece Washer 17x26x0.4 PTFE 4 1 Piece Hex. nut DIN 431, G3/4 8, galvanized 5 1 Piece Retaining plate 4-53-105 St, chromated 6 1 Piece Brass bushing 4-53-117 MS 7 1 Piece Welding bushing 4-53-108 St

x8 1 Piece O-ring 26 x 3 Perbunan 9 1 Piece Shaft 4-53-116/... VA

x10 1 Piece O-ring 16 x 2.5 Perbunan 11 1 Piece Brass bushing 4-53-117 Ms 12 1 Piece Hex. nut DIN 934, M8 8, galvanized 13 1 Piece Cam 4-53-119 VA

x14 1 Piece Washer DIN 125, 8.4 Ms 15 1 Piece Pawl 4-53-112 VA 16 1 Piece Allen screw DIN 912, M8x40 8.8, galvanized 17 1 Piece Allen screw DIN 912, M6x10 8.8, galvanized

x18 1 Piece Torsion spring 4-53-102 VA spring steel 19 1 Piece Allen screw DIN 912, M8x40 8.8, galvanized

x20 2 Piece Washer DIN 125, 8.4 Ms 21 1 Piece Driver 4-53-111 VA 22 1 Piece Washer DIN 125, 8.4 Ms 23 1 Piece Hex. nut DIN 934, M8 8, galvanized

x24 1 Piece Washer 17x26x0.4 PTFE 25 1 Piece Neck mount 4-53-115/... St, chromated

Special Maintenance Instructions Driving mechanism During maintenance check driving mechanism for easy operation and leakage to the outside. If the spring force of torsion spring 18 has decreased, replace torsion spring. For this purpose loosen screw 16 so that torsion spring 18 can be pulled out of the holes in screws 17 and 18. When assembling ensure that the correct number of screws 14 is used. Tighten screw 16 only to the point that pawl 15 is still easy to move. Then counter with nut 12. In the rare case of external leakage, replace O-rings 8 and 10. For this purpose first remove driver 21 from cam 13. Pay attention to number of screws 20 and 22 here as well! Carefully drive out clamping pin 2 to remove hand lever 1.

Then loosen hex. nut 4 (36 mm) while holding neck mount 25 with an open end wrench (41 mm) on the machined surface for this purpose. The entire neck mount 25 can then be removed together with shaft 9 and cam 13. Then first pull shaft 9 slowly out of neck mount 25. The internal O-ring 10 can then be removed carefully with the aid of a bent marking needle. When installing the new O-ring ensure that a suitable tool is used to prevent damage. Pull off and replace outer O-ring 8. Reassemble in opposite order. Before reassembly oil the inner chamber of neck mount 25 with a suitable lubricant. The O-ring positioned in the groove of the body flange or the round cord seal should be replaced each time the driving mechanism is opened (by lifting the movement)

13

Layout Regulating Unit

x: Parts subject to wear; keep on hand for maintenance Items (1; 2; 3; 4; 5; 6; 10; 11) only available complete

14

Parts for Regulating Unit Item Quantity Units Designation Standard / drawing number Material/remarks

1 1 Piece Hex. nut DIN 985/8, M8 8, galvanized 2 1 Piece Washer 8x24x0.4 PTFE 3 1 Pair Torsion spring, li, re 4-53-213 Spring steel C, chrom. 4 1 Piece Sleeve 10x1x40 Precis. pipe DIN 2391 5 1 Piece Washer 8x24x0.4 PTFE 6 1 Piece Allen screw DIN 912, M8x60 8.8, galvanized

x7 1 Piece Hex. nut DIN 985/8, M8 8, galvanized 8 1 Piece Allen screw DIN 912, M8x55 8.8, galv., 40 mm long 9 1 Piece Divider wall (ellipse) 4-53-217/... St

10 1 Piece Rocker 4-53-212/... St, chromatic 11 1 Piece Valve insert 4-53-203/... St, chromatic

x12 1 Piece Valve plate 4-53-208/... St, chromatic 13 1 Piece Hex. nut DIN 934, M16 8, galvanized 14 1 Piece Lock washer DIN 137, 17x30x1.6, Form B St, galvanized 15 1 Piece Middle screw 4-53-209 St, chromatic 16 1 Piece Washer DIN 125, 13x24x2.5 St, galvanized

x17 1 Piece Hex. nut DIN 985/8, M12 8, galvanized x18 1 Piece O-ring 4∅ Perbunan 19 4 - 8 Piece Allen screw DIN 912, M6x20 / M8x20 8.8, galvanized

Special Maintenance Instructions Regulating unit When checking the function and servicing check the safety shut-off valve for leakage. In the event of leakage replace valve plate 12. The neck mount for the regulating unit should be removed first for better accessibility (see page 13). The entire valve insert (1-6, 10, 11) can be removed together with valve plate 12 after loosening screws 19. Then remove nut 13 and remove valve plate 12 together with middle screw 15 by lifting rocker 10. Loosen self-locking nut 17 and check valve seat on middle screw 15 for any damage. If damage is present also replace middle screw. When reassembling ensure that nut 17 is tightened only to the point that approx. 2 mm of clearance remains between valve 12 and the valve seat in middle screw 15. Moreover, observe concentricity to valve seat 11 when installing valve plate 12. If the spring force of the torsion springs 3 has decreased or if the valve seat on valve insert 11 is damaged, replace the entire unit (1-6, 10, 11). Do not disassemble unit (1-6, 10, 11) because the torsion springs 4 are under high tension and can cause injury. General Maintenance Instructions

For installation and equipment as well as monitoring and maintenance of safety shut-off fittings observe the corresponding regulations, particularly DVGW worksheet G490, G491 and G495. For monitoring and function controls we refer the reader to the accident prevention regulations for gas (VGB 61): "The contractor must ensure that system parts required for technical safety are checked for good condition and proper function at justifiable time intervals to be defined by the former, however, at least once annually". Regarding the intervals for maintenance work we refer the reader to the guidelines specified in DVGW worksheet G495. These intervals should not be exceeded under normal conditions. Under extreme conditions, e.g. frequent actuation, aggressive or hot gases, the intervals should be shortened as required after consultation with the manufacturer. Always perform maintenance work only on units when not under pressure and have maintenance performed only by trained personnel. Please indicate unit serial number on every inquiry or parts order!

15

safety relief valve TYPe 11

our diversity is Your ProfiT.

our diversity is Your ProfiT.

Safety Relief Valve SBV Type 11 Purpose The purpose of the type 11 safety relief valve is to automatically release gas flowing in a pressurize line as soon as the pressure in the protected system rises to the set actuating pressure. The safety valve closes automatically when the pressure in the protected system decreases to below the closing pressure. It can be used for all gases according to DVGW worksheet G260 and all non-aggressive gases. (Special versions are available for other gases). Characteristics • High actuation accuracy • Easy maintenance, because maintenance is

possible on site without removing the valve • Simple design => few parts subject to wear • No special tools required DIN-DVGW Registration Number Nominal width

Pressure stage

Registration No.

DN 15 PN 25 NG-4395AS0082 Approved according to DIN 3381 "Safety Devices for Gas Supply Systems with Operating Pressures up to 100 Bar". (Edition June 1984). Technical Data Permissible pressure

pmax. up to 25 bar

Valve diameter 8 mm

Operating temperature -15°C bis +60°C

Medium Suitable for all gases

according to DVGW worksheet G260 and all non-aggressive gases

Installation The type 11 safety valve can be installed in any desired position. The outlet should always exhaust into the atmosphere. Adjustment Ranges

Guide range [bar]

Drawing-number

Wire -∅ [mm]

AG Blow-outrate Q [Nm³/h]

0,03 - 0,30 4-SBV-3/4x100 4,0 10 26 0,30 - 0,90 4-SBV-3/5x100 5,0 5 53 0,90 - 1,80 4-SBV-3/6x100 6,0 2,5 78 1,80 - 2,90 4-SBV-3/7x100 7,0 2,5 108 2,90 - 4,50 4-SBV-3/8x100 8,0 1 153 4,50 - 8,00 4-SBV-3/9x100 9,0 1 222

Other adjustment pressures available on request! Installation Dimensions

∅ A [mm] B [mm] Weight [kg]

128 290 3,8 Line Connections Ventilation G1/4 for unsoldered, threaded pipe

fitting with cutting ring according to DIN 2353 for pipe dia. 12x1.5

Inlet Outlet

G1/2 for unsoldered, threaded pipe fitting with cutting ring according to DIN 2353 for pipe dia. 16x1.5

2

Layout

x: Spare parts; keep on hand for maintenance Items (2; 15) only available complete

Function The type 11 safety relief valve is a directly acting spring loaded unit (without auxiliary power). The pressure to be checked travels through the inlet line below diaphragm 13, which is spring loaded by spring 4. If the pressure increases to an impermissible level and surpasses the setting of spring 4, diaphragm 13 moves up lifting valve 2. The pressure flows through the outlet line into the atmosphere. When the pressure drops to below the set spring value, valve 2 closes with the aid of the spring force. Adjustment Adjustment can be accomplished with cross handle 10 and is possible under operating pressure. Turning to the right increases the setting. The values specified in the adjustment range table should not be exceeded. General Maintenance Instructions When installing and equipping as well as monitoring and servicing safety equipment always observe the applicable regulations, particularly the DVGW worksheets G490, G491 and G495. Always perform maintenance work only on units when not under pressure and have maintenance performed only by trained personnel.

Parts list for SBV Typ 11 Item Quant. Units Designation Standard / drawing number Material / remarks

1 1 each Bottom diaphragm housing 4-SBV-1 Al x2 1 each Valve 4-SBV-2 Ms 3 1 each Diaphragm plate 4-St-9/H Al 4 1 each Adjustment spring 4-SBV-3/... Spring steel C, chromat.5 1 each Spring plate 4-St-13 St, chromated 6 1 each Top diaphragm housing 4-St-18/H Al 7 1 each Hex. nut DIN 431, G1/4 St, galvanized 8 1 each Pressing ring 4-St-15 Ms 9 1 each Spindle seal 4-St-14 Perbunan

10 1 each Cross handle with spindle 4-St-17 Ms, Duroplast 11 1 each Hex. nut DIN 934, M10 St, galvanized 12 8 each Allen screw DIN 912, M6x20 8.8, galvanized

x13 1 each Diaphragm 4-St-8/H Perbunan 14 1 each Washer DIN 125, 10.5x2.5 St, galvanized

x15 1 each Valve seal ∅24x4 Perbunan Please indicate unit serial number on every inquiry or parts order!

3

overflow reGulator TYPe 92-99

our diversity is Your ProfiT.

Overflow regulator Type 92 - 99 Overflow regulators ensure a pressure level, e.g. the discharge pressure of a compressor, an intake pressure or even a differential pressure against exceeding under or over a pressure limit. Type designation 92 to 99 describes the respective safe-ty variant. All types are based on the same valve body. The different functions are realised by allocation of the control devices, their combination and type of con-nection. All series 92 to 99 overflow regulators open during start-up of the connected pressure system. This is advantageous for compressor machines since they do not have to start against the discharge pressure of the system. Basic design of the overflow regulators equates to R+A pressure control valves which are approved for all gases according to DVGW standard G 260. Devices with suitable materials and special fittings are available for other gases – especially aggressi-ve gases. Properties • Flange connections according to customer re-

quirements (including ANSI- and special flan-ges)

• Primary noise dampening for reducing expansi-on (attenuation approx. 10 - 20 dB) in option

• Available with blow-off muffler for reducing flow noises (attenuation approx. 10 - 20 dB)

• Wide supply pressure range • Valve length adjustable to match local cir-

cumstances • Corner model E, through-feed model and speci-

al designs available on request • Pressure balanced valve mechanism by use of a

compensating diaphragm • High adjustment accuracy, short reaction time,

even lower pressure differences possible • Low-maintanance; on-site maintanance possible

without removing of the valve, no special tools required

• Single ply design, few wearing parts • Special design H up to 250°C operating tempe-

rature possible • Independent of external energy • Assembly of the active pipes and presetting of

the switch points in the works

Technical data Supply pressure Up to 30 bar

Minimal pressure difference

100 mbar; 20 mbar with enlarged working diaphragm

Nominal diameters DN 50 bis DN500; larger width on request

Connection flanges DIN-, ANSI- and special flanges

Valve diameter 50 mm to 500 mm

Operating temperature -15°C to +130°C; 250°C (H-Design)

Medium Gases according to DVGW-Standard G260 and all non-aggressive gases; other gases in special design

Materials Body Steel/stainless steel Diaphragm housing Cast steel / Steel /

Stainless steel Control regulator Aluminium/Stainless st. Inner parts Aluminium/Steel

Brass/Stainless steel Diaphragm, O-Rings Perbunan, Viton Cone valve Perbunan, Viton, Teflon

Setting ranges Pressure range [bar]

Drawing-number

RG SG

Control regulator UN/DN/DUN 0,01 - 0,12 4-St-12/DN/4 5/2,5 10/5 0,12 - 0,30 4-St-12/DN/5 2,5 5 0,30 - 0,60 4-St-12/DN/6 1 2,5 0,60 - 0,75 4-St-12/DN/7 1 2,5 0,75 - 1,00 4-St-12/DN/8 1 2,5

Control regulator UH/DH/DUH 0,05 - 0,30 4-St-12/DH/4 2,5 5 0,30 - 1,00 4-St-12/DH/5 2,5 5 1,00 - 1,90 4-St-12/DH/6 2,5 5 1,90 - 2,90 4-St-12/DH/7 1 2,5 2,90 - 4,30 4-St-12/DH/8 1 2,5 4,30 - 7,50 4-St-12/DH/9 1 2,5

Control regulator RUHH für high pressure 7,50 - 30,0 4-St-12/RUHH/ 1 2,5

Other setting pressures available on request !

Seite 2

Installation Dimensions Type 94E und 94

Inlet Outlet Valve-Ø L1/L2 *² A *² L B D Weight *1 *1 appr. appr. ∆p≥100mbar ∆p≤100mbar ca.

DNEin DNAus [mm] [mm] [mm] [mm] [mm] [mm] [mm] [kg] 50-150 50-150 50-80 200/200 850 450 650 300 420 55

100 200/200 850 450 650 420 482 70 125 200/200 850 500 730 420 482 75 150 250/250 900 700 750 420 482 110

50-200 200 50-80 250/250 950 500 700 300 420 75 100 950 500 700 420 482 90 125 950 500 730 420 482 95 150 1000 700 750 420 482 130 200 1000 700 750 482 585 160

50-250 250 50-80 280/280 1080 700 730 300 420 110 100-125 1080 700 730 420 482 120 150 1080 800 750 420 482 140 200 1130 800 750 482 585 180

50-300 300 50-80 320/320 1130 800 750 300 420 130 100-150 420 482 150 200 482 585 180

Other dimensions and valve sizes available on request *1 : Units available with all flanges according to customer requirements *2 : Units available with other overall lengths

Line Connections Standard Version

Flow direction Up-right / left-right Ventilation in Flow direction right Measur. Pulse in Flow direction left

Flow off in Flow direction right *3 It is possible to install additional two sockets G1/4 or G1/2 at the unit Flow direction and/or line connections can be

Ventilation G1/4 Meas.Pulse G1/4 Sockets *3 G1/4

Unsold., threaded pipe fitting with cutting ring acc. to DIN 2353 for pipe-Ø 10 x 1,5 mm

changed on customer request

Seite 3

Design and Function of Type 94E (94) Overflow Regulator

Installation All overflow regulators can be installed vertically or horizontally in flow direction. If installed vertically it is only necessary to mount the control regulator vertical beneath the control gear. Only qualified personal is allowed to do start up and maintenance. For demounting of the regulator all parts must be pressureless.

External Control Nozzel

Seite 4

Design As example for all overflow regulators type 94E is shown beneath with control regulator (I) and control gear (II). The control regulator is available in UH/UN/DUH/DUN and DH/DN for pressure range up to 1 bar respectively 7,5 bar. Control regulator RUHH is used for operating pressure greater than 7,5 bar. Scope of application Protection of compressor discharge pressure in overpressure range (conrol regulator UH/UN). Function Inlet pressure (pe) is applied under cone valve 5 and as well via control pipe 4 on compensation diaphragm 3 and under working diaphragm 1; via throttle 2 also in the upper chamber of the diaphragm. When starting up the compressor, that means increasing inlet pressure, overflow regulator opens because the pressure above working diaphragm 1 increases less fast than in the lower diaphragm chamber due to throttle 2. Cone valve 5 closes when the pressure in both diaphragm chambers has equalized. If inlet pressure, which reaches control regulator via control pipe 8 exceeds the set value of adjustment spring 13, control valve 7 opens and allows gas to flow from upper diaphragm chamber through control pipe 6. This creates a differential pressure at working diaphragm 1, which causes cone valve 5 to open. Discharge pressure is set by using hand wheel 10. Turning it to the right increases pressure.

Starting apparatus After properly installing the regulator proceed as follows for start up: − Release tension of adjustment spring in control

regulator − Close pressure side shut-off valve − Start up compressor − Slowly tension adjustment spring of control

regulator until desired discharge pressure is reached

− Secure hand wheel with locknut The overflow regulator is ready for operation. Slowly open pressure side shut-off valve again. Attention The line connection of the ventilation hole must end outside in the open air. Because in case of a crack at the diaphragm, witch belongs to the control regulator, it will be possible, that gas flow through the line connection of the ventilation hole. Unit Layout

The valve flow coefficient KG is the value of the flow rate q through fully opened control regulator while pe = 2.013 bar abs. and pa = 1.013 bar abs.; measured under standard conditions on a test bench with air as flow medium. Valve flow coefficient KG for overflow regulator type 92 - 99 (related to air)

Valve-Ø [mm]

KG - value [Nm³/h]

Valve-Ø [mm]

KG - value [Nm³/h]

50 1.700 150 15.400 65 2.800 175 20.800 80 4.400 200 27.700100 6.800 250 43.900125 10.500 300 62.400

Values for larger valve diameters available on request. The following equations enable to calculate the required KG value: KG - value at subcritical pressure ratio pp

a

e≥ 0 53, : K q

p p pG

n

a e a=

−( ) [Nm³/h]

(qn in [Nm³/h]; pe and pa in [bar abs.]) KG - value at supercritical pressure ratio pp

a

e< 0 53, : K q

pG

n

e=

⋅2 [Nm³/h]

When other gases are used, it is necessary to convert qn with the following corrective factors f: Medium f Medium f Ammonia 1,30 Methane 1,35 Butane 0,69 Municipal gas 1,53 C02 0,81 Oxygen 0,94 Nat. gas L 1,26 Nitrogen 1,01 Air 1,30 Hydrogen 3,92

Values for other mediums available on request.

Conversion equation: q qf

nnMedium

= [Nm³/h]

Calculation of nominal connection with:

[mm]

qn : [Nm³/h]; p : [bar abs.]: vmax : [m/s]; T : [°C]

D q Tp v

nmin

max

, ( )=

⋅ ⋅ +⋅

1 3 273

vmax = max. permissible flow velocity Optimum valve diameter and nominal connection width can be calculated for each medium and unit with a computer program in our office.

Seite 5

Overflow regulator Type 92/92E

Scope of Application - Securing discharge pressure in overpressure

range (Control regulator UH/UN) - Securing intake pressure in overpressure range

(Control regulator DH/DN) Function Inlet pressure (pe) is applied under cone valve 5 and as well via control pipe 4 on compensation diaphragm 3 and under working diaphragm 1; via throttle 2 also in the upper chamber of the diaphragm. When starting up the compressor, that means increasing inlet pressure, overflow regulator opens because the pressure above working diaphragm 1 increases less fast than in the lower diaphragm chamber due to throttle 2. Cone valve 5 closes when the pressure in both diaphragm chambers has equalized. Securing discharge pressure: If inlet pressure, which reaches control regulator via control pipe 8 exceeds the set value of adjustment spring 13, control valve 7 opens and allows gas to flow from upper diaphragm chamber through control pipe 6. This creates a differential pressure at working diaphragm 1, which causes cone valve 5 to open. Discharge pressure is set by using hand wheel 10. Turning it to the right increases pressure. Securing intake pressure: If compressor intake pressure, which reaches under diaphragm 17 of control regulator DH via control pipe 18 falls below

the set value of adjustment spring 15, control valve 19 opens and allows gas to flow from upper diaphragm space via control pipe 6. This creates a differential pressure at working diaphragm 1, which causes cone valve 5 to open. Intake pressure is set by using hand wheel 14. Turning it to the right increases pressure. Starting apparatus After properly installing the regulator proceed as follows for start up: - Open shut-off valve on compressor intake side - Close pressure side shut-off valve - Close control regulator DH for intake pressure,

meaning relax adjustment spring completely - Open control regulator UH for discharge

pressure, meaning relax adjustment spring completely

- Start up compressor - Set discharge pressure at control regulator UH

as for type 94 - Do not switch off compressor - Slightly open shut-off valve on pressure side - Slowly close the shut-off valve on intake side

until the desired intake pressure is reached - Slowly tension (turn to right) adjustment spring

of control regulator DH until switch point is reached

- Secure handwheel with locknut The overflow regulator is ready for operation. Slowly open intake and pressure side shut-off valves again.

Seite 6

Overflow Regulator Type 95/95E

Scope of Application - Securing discharge pressure in overpressure

range (Control regulator UH/UN) - Securing intake pressure in underpressure range

(Control regulator DUH/DUN)

Function Inlet pressure (pe) is applied under cone valve 5 and as well via control pipe 4 on compensation diaphragm 3 and under working diaphragm 1; via throttle 2 also in the upper chamber of the diaph-ragm. When starting up the compressor, that means inc-reasing inlet pressure, overflow regulator opens because the pressure above working diaphragm 1 increases less fast than in the lower diaphragm chamber due to throttle 2. Cone valve 5 closes when the pressure in both diaphragm chambers has equalized. Securing discharge pressure: If inlet pressure, which reaches control regulator via control pipe 8 exceeds the set value of adjustment spring 13, control valve 7 opens and allows gas to flow from upper diaphragm chamber through control pipe 6. This creates a differential pressure at working di-aphragm 1, which causes cone valve 5 to open. Discharge pressure is set by using hand wheel 10. Turning it to the right increases pressure. Securing intake pressure: If compressor intake pressure, which reaches above diaphragm 17 of control regulator DUH via control pipe 18 exceeds

the set value of adjustment spring 15, control valve 19 opens and allows gas to flow from upper diaph-ragm space via control pipe 6. This creates a diffe-rential pressure at working diaphragm 1, which causes cone valve 5 to open. Intake pressure is set by using hand wheel 14. Turning it to the right increases underpressure. Starting apparatus After properly installing the regulator proceed as follows for start up: - Open shut-off valve on compressor intake side - Close pressure side shut-off valve - Close control regulator DUH for intake pressu-

re, meaning tension adjustment spring - Open control regulator UH for discharge pres-

sure, meaning relax adjustment spring - Start up compressor - Set discharge pressure at control regulator UH

as for type 94 - Do not switch off compressor - Slightly open shut-off valve on pressure side - Slowly close the shut-off valve on intake side

until the desired intake pressure is reached - Slowly relax (turn to left) adjustment spring of

control regulator DH until control regulator switch point is reached

- Secure handwheel with locknut The overflow regulator is ready for operation. Slow-ly open intake and pressure side shut-off valves again.

Seite 7

Overflow Regulator Type 96/96E

Scope of Application - Securing intake pressure in underpressure range

(Control regulator DUH/DUN) Function Inlet pressure (pe) is applied under cone valve 5 and as well via control pipe 4 on compensation diaphragm 3 and under working diaphragm 1; via throttle 2 also in the upper chamber of the diaph-ragm. When starting up the compressor, that means inc-reasing inlet pressure, overflow regulator opens because the pressure above working diaphragm 1 increases less fast than in the lower diaphragm chamber due to throttle 2. Cone valve 5 closes when the pressure in both diaphragm chambers has equalized. If compressor intake pressure, which reaches abo-ve diaphragm 11 of control regulator DUH via control pipe 8 exceeds the set value of adjustment spring 13, control valve 7 opens and allows gas to flow from upper diaphragm space via control pipe 6. This creates a differential pressure at working di-aphragm 1, which causes cone valve 5 to open.

Intake pressure is set by using hand wheel 10. Turning it to the right increases underpressure. Starting apparatus After properly installing the regulator proceed as follows for start up: - Open shut-off valve on compressor intake side - Close control regulator DUH/DUN for intake

pressure, meaning tension adjustment spring - Slightly open pressure side shut-off valve - Start up compressor - Slowly close the shut-off valve on intake side

until the desired intake pressure is reached - Slowly relax (turn to left) adjustment spring of

control regulator DH until control regulator switch point is reached

- Secure handwheel with locknut The overflow regulator is ready for operation. Slow-ly open intake and pressure side shut-off valves again.

Seite 8

Other Types, Variants und Accessories By combining the control regulators and different connection modes, additional regulator types for different applications can be realised. Special models and purposeful accessories allow a diverse range of tasks to be solved.

Overflow Regulator Type 97E/97 Scope of Application Securing differential pressure between discharge and intake pressure. (Control Regulator DUH/DUN) Overflow Regulator Type 99E/99 Scope of Application Securing intake pressure In overpressure range (Control Regulator DH/DN)

Hot Gas Model Diaphragm materials Perbunan und Viton limit the possibility of using the overflow regulator for high gas temperatures due to their lacking high temperature resistance. Therefore, for media temperatures above 180°C up to around 250°C, the hot gas model – identified by the additional symbol H in type designation – is used. The diaphragm housing is installed on the regulator housing using spacers so that the media temperature is not applied directly to the diaphragms

Seite 9

Starting Relief

Primary Sound Absorption

Blowout Silencer

Motor Controled Set Value Adjustment

The construction of starting relief is shown using overflow regulator type 94E as example. The addi-tional attached 2/2-Way Solenoid Valve is current-less open. When starting the plant, the overflow regulator is forced to open by the opened solenoid valve and no impermissible overpressure can form on pressure side of the compressor. After the plant rated output (compressor speed) is reached, solenoid valve is closed by release of current and the overflow regulator moves into nor-mal position. If control voltage fails the overflow regulator is forced open and thus realises the safety function for voltage drop. According to the pressure ratio of the overflow re-gulator high sound intensity can result during ex-pansion. This expansion sound can be reduced approx. 10 – 20 dB by installing a ring-shaped, spongy filling body around the cone valve. Subse-quent installation in the works is also possible using hold down clamp 3 and allen screws 4. Blow out noise from overflow regulators opening into atmosphere, can effectively be reduced by a directly flange-mounted silencer. This sound absorber only generate low pressure drop and work in a relatively wide frequency range. They are designed for special application and attain sound reduction up to 20 dB. Outlet-Flange L ABS [mm] Di [mm] Da [mm] DN 50 - 150 1500 200 360 > DN 150 Special Design

For applications with changing pressure ratios or plants with changing operating modes the control-device of the overflow regulator can be equipped with a motor actuator instead of the hand wheel. Using the motor drive, set value of the control regu-lator and with this response pressure can be vari-fied while running plant.

Seite 10

External Control Nozzle

Piston Valve K

Position Indicator

Changing Operating Modes or Gases

External control nozzle is used when: - soiling and blockaging is expected or a moist gas

is used, - steel diaphragm housing or control regulator

RUHH is used, - an easier and faster accessibility to the control

nozzle is required. The connections of the control nozzle are produced with Ermeto-Pipes 10L as a standard. For gas pressure above 7,5 bar piston valve in combination with control regulator RUHH is used (addition K in type designation). The piston replaces the compensating diaphragm while having the same function and due to ist design it is capable to equalise large pressure ratios between supply and discharge pessure without deformation. The indicator for optical or electronic signalling of the valve position can be installed optional at each overflow regulator type. The position of the working diaphragm suspension is transferred mechanically to the indicator. The indicator can be fitted with a limit switch to generate an electronic signal e.g. for a control panel or a monitoring device. By combining several control devices and cicuitry with solenoid valves it is possible to realise different pressures or operating cases with one overflow regulator. When handling e.g. two operating modes with a regulator type 94 the control device UH1 is set to the higher pressure and normally in function. Control device UH2 with a lower set value becomes active when solenoid valve MV is opened. In case of more than two operating modes or other regulator types adequate installation is required.

Seite 11

Design Control Gear

Special Maintenance Instructions Performing a maintenance the control gear has to be checked on sealed closure of cone valve 13, for wear of the diaphragms 3 and 18 and on tightness against atmosphere. Cone valve 13 is tight, if by running plant no remarkable temperature increase occurs or no audible overflow occurs (prescribed set value is not reached). To remove cone valve 13 first screws 25 have to be undone and diaphragm housing can be removed. After that working diaphragm 3 can be unscrewed. Releasing screws 19 compensating diaphragm 18 together with valve suspension 9, valve guide 7 and cone valve 13 can be removed as a whole. Now all wearing parts have to be replaced. When installing it is to insure that items 4, 11, 12, and 20 are exchanged too. Cone valve 13 has to stand centrally on the valve seat so that during the assembly compensator diaphragm 18 automatically centers itself in the lower diaphragm housing 23. When installing working diaphragm 3 the prescribed maximum valve run has to be achieved again. Following equation as a rule of thumb can be used:

Valve Run[mm] = ValveØ [mm] X 0,25

The valve run is measured between working diaphragm suspension 27 and the upper diaphragm housing 1.

Seite 12

Special Maintenance Instructions Control Regulator

Control Regulator For maintanance the control regulator has to be dismantled from the main device. Each time before taking apart the regulator, the adjustment spring 12 has to be relaxed by turning cross handle 17 to the left. Especially diaphragm 8, spring body 2, valve suspension 3, flange 4 and control valve 1 have to be checked for wear. By undoing screws 19 the diaphragm 8 with suspension 7 can be removed and checked. By unscrewing spring cap 6 and undoing screws 21 and 27 as well as nut 28 directly above the control valve 1 it can be unscrewed from controller set (2,3,4). The set can be removed and has to be checked. To maintain general operating safety the set should be replaced every three years latest. When installing it is to insure that items 4, 11, 12, and 20 are exchanged too. Cone valve 13 has to stand centrally on the valve seat so that during the assembly compensator diaphragm 18 automatically centers itself in the lower diaphragm housing 23. When installing working diaphragm 3 the prescribed maximum valve run has to be achieved again. Following equation as a rule of thumb can be used: The valve run is measured between working diaphragm suspension 27 and the upper diaphragm housing 1. When assembling it has to be ensured that: - control valve 1 is screwed up until approx. ¼ turns before the limit of the controller set (2,3,4), - spring cap 6 is only screwed on controller set (2,3,4) so wide that when pressing spring cap 6 the loosely placed regulator base 26 is lifted approx. 2 mm from the seat of regulator body 24 by control valve 1.

Seite 13

overflow reGulator TYPe 86

our diversity is Your ProfiT.

2

Overflow Regulator Type 86 Task The Type 86 overflow regulator always ensures that suction pressure does not drop, that means it opens when suction pressure drops below a specified level during the start-up of the open suction system in order to protect excess strain on upstream containers or compressors. Due to the existing low-pressure conditions (p < 0.5 bar (ü)) the Type 86 overflow regulator is not subject to the application of Pressure Equipment Directive 97/23/EC, but naturally it is designed and manufactured in compliance with applicable engineering practices. Consequently, the Type 86 equipment may fundamentally, with regard to the documentation, not be furnished with a declaration of conformity! Features • Connections tailor-made to customer

specifications (also ANSI and special flanges). • Structural height well-adaptable to onsite

conditions. • Pressure-compensated valve-setting

mechanism by use of a compensation diaphragm. • High regulating accuracy, short response time, and also low pressure differences can be regulated.

• Service-friendly, onsite maintenance with disassembly of the device is possible, no special tools needed.

• Simple construction, few parts subject to wear. • Special model type H up to 250ºC operating

temperature possible. • Not dependent on external energy. • Assembly of the differential pressure pipe and

presetting of the switch points take place in the factory.

• Compliance with the noise emission requirements of the setup area by means of optional soundproofing versions.

• No-load start-up possible with optional equipping with electromagnetic valve.

Technical data Inlet pressure Atmospheric pressure Min. pressure difference

100 mbar; 20 mbar with enlarged operating diaphragm

Nominal width DN 80 – 300 (others on request)

Connection type DIN, ANSI and special flange

Valve diameter 50 mm to 200 mm Operating temperature -15°C to +130°C;

250°C (H model type) Medium Air, if needed other

gases on request Materials Body Steel/high-grade steel Diaphragm casing Cast steel/steel Control regulator Aluminium/high-grade

steel Inner parts High-grade steel Diaphragms, o-rings Perbunan, Viton Cone valve Perbunan, Viton Soundproofing (optional)

Firstly at the valve, reduction of approx. 5 dB(A) Secondary (coaxial to filter element), reduction of approx. 10 dB(A)

Adjustment Ranges Guide range [bar]

Drawing number

RG SG

Control regulator DUH 0.05 – 0.30 4-St-12/DH/4 2.5 5 0.30 – 1.00 4-St-12/DH/5 2.5 5 1.00 – 1.90 4-St-12/DH/6 2.5 5 1.90 – 2.90 4-St-12/DH/7 1 2.5 2.90 – 4.30 4-St-12/DH/8 1 2.5 4.30 – 7.50 4-St-12/DH/9 1 2.5

Other set pressure ranges on request!

3

Function (see Illustration 1.1) If a compressor is started up in a plant, a certain low pressure = operating suction pressure is reached in the upstream network, to which the ÜSR 86 is usually connected via a nipple 15. The bottom diaphragm chamber (compensation diaphragm 3 at the top or operating diaphragm 4 at the bottom) is now equally pressurised with this operating suction pressure through a vertical and horizontal drill hole in the hollow spindle 2. At the same time a low-pressure equalisation takes place via the control nozzle 5, so that the operating suc-tion pressure is finally also present in the top diaphragm chamber (operating diaphragm 4 at the top). The operating suction pressure consistently operates on the control diaphragm 7 of the control regulator 18 via the control line 6. If the operating suction pressure increases to an unacceptable level, which is determined via the setting of the spring 8, the control valve 9 opens and via the pipeline 10 ensures that atmospheric pressure exists in the top chamber after a short period of time. The pressure difference that is created on the operating diaphragm 4 in this way – against the closing force of the spring 17 – opens the cone valve 11. The adjustment takes place on the adjustment knob 11 of the regulator. Turning it to the right reduces the absolute pressure by strengthening the force of the spring. The suction pressure is very precisely regulated via a control regulator of Type DUH with only very little deviations with the favourable regulation group of 1 – 2.5. Right turn = low pressure increase Initial operation Warning! The suction line must be completely without pressure during installation – risk of injury! The Type 86 regulator is supplied ready for operation. The installation position can be randomly chosen. However, the control regulator must always be installed vertically, in other words, independent from the final installation position. In order to take a test pulse from a calm-flow zone, the pulse line 6 must be connected to the pressure line approximately 3 to 5 x D Connection Pipe, whereby

the opening in the bottom diaphragm casing must be closed. Warning! The intake opening (complete lateral surface) of the filter must be protected against materials that can block it at all costs! Maintenance instructions (See Illustration1.1/2 or Parts List 1.1/2) Warning! The overflow regulator should only be installed or serviced and repaired by expert technical staff. The overflow regulator must be operated and repaired in compliance with all applicable international standards and regulations and according to manual supplied by R + A Terschüren GmbH. Suction filter replacement In the scope of the maintenance regularly performed by R + A, the filter is examined and replaced if necessary. Electromagnetic valve: the operating manual, being part of the delivery of the Type 86, of the optionally installed electromagnetic valve must be adhered to. Potential malfunctions: - Regulator does not close:

Cause: Control nozzle 5 blocked, (optional) electromagnetic valve or control regulator valve leaking

- Regulator leaking:

Cause: Valve seal destroyed, foreign object between cone valve 1 and valve seat

- Regulator does not open: Cause: Operating diaphragm 4 leaking

4

Components for the Type 86 Actuator

x1 1 Piece Cone valve 4-132-13/ St, Perbunan / Viton 2 1 Piece Hollow spindle - St / VA

x3 1 Piece Compensation diaphragm - Perbunan / Viton x4 1 Piece Operating diaphragm 4-132-3/ Perbunan / Viton 5 1 Piece Control nozzle 4-132-5 / 4-94-5 VA 6 1 Piece Control line - St, galvanised 7 1 Piece Control diaphragm see p. 5, Item x 8 8 1 Piece Set-point spring see p. 5, Item 12 9 1 Piece Control valve see p. 5, Item x 1

10 1 Piece Control line - St, galvanised 11 1 Piece Hand knob - St, PET 12 1 Piece Vertical column - St 13 1 Piece Self-locking hexagonal nut DIN 985 St, galvanised

Item Quantity

Unit Description Standard / drawing number

Material / Comment

Parts List 1.1 – x: Keep consumables or parts subject to wear in stock Illustration 1.1 – Type 86, maintenance-related parts

Test pulse G1/4

Type DUH control regulator

Ventilation G1/4 Sintered metal filter

Inlet G1/4

Intake filter

The opening blocks when this design/ construction is selected

from calm-flow zone

Sleeve

5

Type DUH control regulator construction

Illustration 1.2 x: Keep consumables or parts subject to wear in stock Item (2; 3; 4) only supplied complete

Special maintenance instructions Type DUH control regulator The control regulator must be disassembled from the main device for maintenance purposes. Prior to every disassembly of the control regulator it is essential to relieve the tension on the set-point spring 12 with the aid of the cross handle 17. During maintenance the diaphragm 8, the control regulator element (2, 3, 4) and the control valve 1 must be specially checked for wear. By loosening the screws 19 the diaphragm 8 can be removed with the suspension 7 and inspected. When the spring cap 6 is unscrewed and screws 21 and 27 removed, the control valve 1 can be screwed out of the control regulator insert (2, 3, 4), the element removed and examined. The element should be replaced every 5 years at the latest to ensure general operating safety. When assembling ensure that: - The control valve 1 is screwed in up to approx. ¼ turn in front of the stop on the control regulator element (2, 3, 4). - The spring cap 6 is screwed onto the control regulator element (2, 3, 4) only to the point that the control valve 1 lifts approx. 2 mm from the seat of the regulator body 24 when the spring cap 6 is pushed down.

Item Quantit

y Unit Description Standard / drawing number Material / Comment

x1 1 Piece Control valve 4-St-1/U//a Ms x2 1 Piece Spring body 4-St-2 Bronze x3 1 Piece Valve suspension 4-St-3/U VA x4 1 Piece Brazing flange 4-St-4 VA 5 1 Piece Closing spring 4-St-5 VA spring steel 6 1 Piece Spring cap 4-St-6 VA 7 1 Piece Diaphragm suspension 4-St-7 VA

x8 1 Piece Diaphragm 4-St-8/... Perbunan 9 1 Piece Diaphragm plate 4-St-9/... Al

10 1 Piece Washer DIN 125; 10.5x2.5; Form B St, galvanised 11 1 Piece Hexagonal nut DIN 439; M10; St, galvanised 12 1 Piece Set-point spring 4-St-12/... Spring steel C,

chromatic 13 1 Piece Spring plate 4-St-13 ST, chromatic 14 1 Piece Spindle seal 4-St-14 Perbunan 15 1 Piece Pressing ring 4-St-15 Ms 16 1 Piece Hexagonal nut DIN 431; G1/4; St, galvanised 17 1 Piece Cross handle with spindle 4-St-17 Ms; Duroplast 18 1 Piece Top diaphragm casing 4-St-18/... Al 19 8 Piece Allen key screw DIN 912; M6x20; 8.8, galvanised 20 1 Piece Bottom diaphragm casing 4-St-20/... Al 21 4 Piece Allen key screw DIN 912; M6x25; 8.8, galvanised

x22 1 Piece O-ring 48 x 4 Perbunan x23 1 Piece O-ring 26 x 2 Perbunan 24 1 Piece Regulator body 4-St-24/U Al

x25 1 Piece O-ring 26 x 2 Perbunan 26 1 Piece Regulator base 4-St-26/U//a Al

Ventilation G1/4

Test pulse G1/4

Outlet G1/4

Inlet G1/4

6

27 4 Piece Allen key screw DIN 912; M6x50; 8.8 8.8, galvanised Parts list 1.2

OUR PRODUCT PROGRAM

OUR ADMISS IONS

COMPETENCE IN GAS!

DIN-DVGW

• Gas-Take Over Stations• Gas-Regulaton Cabinets• Station Accessories• Gas-Pressure Regulators• Safety Shut Off Valves

• Safety Relief Valves• Overflow Regulatores• Vaccum Regulatores• Differential Pressure Regulators• Special Design Regulators

Certified accordingto DIN EN ISO 9001

Production of Gas StationsDVG W (working paper) G493/1

Maintenance of Gas StationsDVG W (working paper) G493/2

W2 Armaturen GmbH

Dr.-Alfred-Herrhausen-Allee 44a | 47228 Duisburg, Germany T (020 65) 77 09 60 | F (020 65) 77 09 66 | info@w2-armaturen.de | www.w2-armaturen.de