Dresser RB 4000 User manual

RB 4000
Gas Pressure Regulator
Gasdruckregelgerät
3400992804
AC
Instruction Manual
Betriebsanleitung
Gas Regulators

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CONTENTS PAGE
Declaration of conformity ........................................................................................4
Important safety instructions ....................................................................................6
SSV 8500: description, resetting ........................................................................................7
SSV 8600: description, resetting .......................................................................................9
Installation .....................................................................................................11
Regulator start-up ..............................................................................................12
Maintenance ...................................................................................................12
Annex ..........................................................................................................21
- Sectional View .........................................................................................21
- Outlet Pressure Range .............................................................................................22
- Installation exemple ................................................................................................23
- Tools .................................................................................................................24
- Spare Part kits .......................................................................................................25
EN
DE
INHALTSVERZEICHNIS SEITE
Konformitätserklärung ...........................................................................................4
Sicherheitshinweise .........................................................................................14
Beschreibung/technische Daten .............................................................................14
SAV 8500: Beschreibung, Wiedereinrasten ................................................................15, 16
SAV 8600: Beschreibung, Wiedereinrasten ................................................................17, 18
Einbau Anleitung ............................................................................................19
Inbetriebnahme .............................................................................................20
Instandhaltung ..............................................................................................20
Anhang ......................................................................................................21
- Schnittbild ..........................................................................................21
- Ausgangsdruckbereich . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .22
- Beispielinstallation ...................................................................................23
- Werkzeuge ..........................................................................................24
- Ersatzteil-Kits ........................................................................................25

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Keep this manual easily accessible for all users.
IMPORTANT SAFETY INSTRUCTIONS:
»Only use for dry and clean gases. For use with aggres-
sive gases please contact Dresser Actaris Gas for special
versions.
For applications with Hydrogen, after maintenance,
purge the device with inert gas like nitrogen.
Never use with oxygen: Danger of explosion!
• Please respect all national standards and codes of
practices for installation, operation, testing and ser-
vice of gas regulators and of gas pressure regulating
stations.
• Before mounting please check the regulator for pos-
sible damage due to transport.The sealing surfaces
must be clean.
• Arrange enough room for the serving of the regulator.
• To protect the regulator from dirt a sieve or a lter is
recommended.
• The regulator must be installed tension free in the
piping.
• After installation please check the tightness of the
thread connection.
• The technical data given on the name plate must
be respected. If necessary safety devices must be
installed.
• Repairs and maintenance must be done by trained or
qualied personal. Only use original spare parts from
Dresser Actaris Gas. Afterwards a tightness test with
1.1 x PS must be performed. When changing pressure
containing parts their compliance with the PED must
be assured.
• If used with wet gas, internal and external effect of
corrosion has to be checked regularly and in case of
severe corrosion, the regulator has to be replaced.
• The device must be cleaned with a wet cloth only.
Please don’t use solvent or alcohol containing prod-
ucts to clean the regulator.
• Before removing the regulator please depressurise
completely. Some gas may still be inside the regula-
tor and the pipe, therefore sufcient ventilation is
required.
REMARKS FOR USE IN POTENTIALLY
EXPLOSIVEATMOSPHERES (ATEX):
• If lm of rust is possible (ying rust in the immediate
regulator surroundings), all outer aluminium parts have
to be protected accordingly (e.g. by varnish).
• The product must be electrically connected to ad-
equately earthed installation.
• For installation, removing or repair of the regulator on
site, only tools allowed for the corresponding explosion
area can be used.
• The regulator shall not be exposed to: ames, ionised
radiation and ultrasound.
• Ambient temp. conditions must be considered, includ-
ing possible additional heating eects due to other
devices in immediate vicinity.
• Gas pressure regulator according to DIN EN 334 - if not
equipped, with any electronic device - do not have a
potential ignition source and therefore are not in the
scope of European directive 2014/34/EU.
The RB 4000 pressure regulator is designed for gas supply
networks, district station regulation, industrial service
regulation, and all applications where accurate pressure
control, ease of adjustment, and fast response are re-
quired such as for burners, industrial ovens, boilers, etc.
It may be tted with an integrated safety shut-o device
type SSV 8500 or SSV 8600.
Accuracy class up to AC 5
Closing pressure class up to SG10
Operating temperature -20°C to +60°C
Ambient temperature -30°C to +60°C (body material)
Allowable pressure 25 bar
Max inlet pressure 19 bar
Outlet pressure DN 25 10 mbar to 2.5 bar
Others 10 mbar to 2.0 bar
TECHNICAL FEATURES

7
Operating principle of the shut-o valve
The safety shut o device have the task of automatically
shutting o the gas ow in the downstream pipe system
as soon as the pressure value increase or decrease beyond
the preset values.
Shut-o valve with screw reset
The device consists of a valve body 10, a control head, a
diaphragm assembly 4 – 15 and a stem-valve plug assem-
bly 1218 which remain in a balanced position through a
mechanical ball latching system.
The shut-o valve is triggered when the pressure value
in the control chamber 5, that from the downstream pipe
ow into this chamber through the sensing line 15 in-
crease or decrease beyond the preset values, thus moving
from its balancing position. In this action the SSV measure-
ment diaphragm stem valve plug system switch. The stem
18 connected to the valve disc 12 triggers under the force
of the closing spring 13 the valve disc to the orice 8 by
cutting automatically the ow of gas.
SSV 8500 (FOR RB 4000 MODELS WITH INTEGRATED SSV 8500)
1
19
18
17
16
15
14
13
20
21
12
11
2
3
4
5
6
7
8
9
Item Description
1Screwing ring
2Cover
3Vent
4Diaphragm
5Control Chamber
6Flange
7Closing spring plate
8Valve seat / Orice
9Inlet chamber
10 Valve body
11 Outlet chamber
12 Valve disc
13 Closing spring
14 Lower diaphragm case
15 Sensing line Connection
16 Ball latching mechanism
17 OPSO spring
18 Stem
19 Cover
20 Screwing ring
21 UPSO spring
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Resetting of the shut-o valve
The shut-o valve must be reset only after having verifying
the reason for the intervention and after having re-estab-
lished normal conditions of work, proceeding as follows:
Resetting of the shut-o valve with screw reset
• Close the downstream stop valve
• Remove the cover 29, unscrewing it (g.a)
• Screw it upside down into the stem 28 until in comes
into contact with the cover (g.b)
• Continue to screw it slowly: with this operation (by-pass)
pressure lls the downstream pipe part
• Pull the cover outwards in order to permit the seating
of the balls on the stem: the shut-o valve is reset (g.c).
After these operations, screw the cover to it is housing
(g.d) and slowly open the downstream valve.
Fig. c Fig. d
Fig. a Fig. b
28 29

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Shut-o valve with screw reset
The device consists of a valve body 1, a control unit 2 used
to compare the pressure, a lever system 3 and a stem-valve
disc assembly 4. The shut o valve is triggered when the
pressure value to be checked in the control chamber 5 in-
creases or decreases beyond the preset values, thus mov-
ing from its balancing position.
In this action the diaphragm assembly 6 triggers the le-
ver system 3 by releasing the stem-valve disc assembly 4.
By effect of the force of the closing spring 7, the assembly
4 comes immediately into contact with the orice 8 inter-
rupts automatically the ow of gas.
SSV 8600 (FOR RB 4000 MODELS WITH INTEGRATED SSV 8600)
11
2
3
9
7
10
13
5
4
6
1
Shown body is for single SSV, for integrated SSV in one
body with the regulator all described items are identical.
Item Description
1Valve body
2Control unit
3Lever system
4Stem-valve disc assembly
5Control chamber
6Diaphragm assembly
7Closing spring
8Valve seat / Orice
9Screwing ring OPSO
10 Screwing ring UPSO
11 Resetting lever
12 Outlet chamber
13 By-pass
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• Close the downstream stop valve
• Slowly operate the resetting lever 27 clockwise until
the internal by-pass is open 26. This leads to lling the
downstream area 12 and the control chamber 19.
• When the pressure indicated on the manometer in-
stalled in the downstream pipe is stabilized, continue
to move the lever 27 in order to permit the connection
of the lever system 24; at this point the lever will remain
stable on the opening position.
After these operations, the shut-off valve is into opera-
tion and it is possible to proceed slowly with the opening
of the downstream valve
Shut-o Valve Adjustment
The shut-o valve is usually supplied with preset values
according the order. Should be necessary to modify the
calibration value, it must be considered that the modi-
cation can be eected only within the specic set range
of the spring installed, otherwise it is necessary to substi-
tute with a suitable spring to be selected referring to the
provided tables.
When the installed spring is appropriate to obtain the
required pressure, proceed as follows:
• Over pressure shut-o operation
Rotate in a clockwise direction the external screwing
ring 21, increases the set point value, or in a anticlockwise
direction to reduce it.
• Low pressure shut-o operation
Rotate in a clockwise direction the central screwing ring
to increase the set point value or in an anticlockwise di-
rection to reduce it.
Resetting of the shut-o valve with lever reset (Type SSV 8600)
26
24
27
21 22
19