Dungs FRM 100025 User manual

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Edition 02.17 • No. 270 442
1 … 64
The target group of this manual is qualied personnel of the
gas safety and regulating technology. Due to their specialist
training, knowledge and experience, they should be capable
of evaluating the work assigned to them and recognising
possible dangers. Only they are permitted to carry out as-
sembly, commissioning, settings and maintenance on the
devices in compliance with the recognised rules for occupa-
tional safety.
Instruction manual
FRM 100025 - 100050
2. Warnings
Never carry out work as long as gas
pressure or voltage is applied. Avoid
open re. Please observe public regula-
tions.
The device must be protected from vi-
brations and mechanical impacts.
All adjustments and settings should only
be performed in accordance with the
instruction manuals of the connected
machines.
The recognised occupational safety
rules and accident prevention regula-
tions must be observed and, if neces-
sary, personal protective measures must
be taken.
Connected line systems must be free
from dirt and contamination.
Hang this instruction manual in a readily visible place
inside the installation room! Do not carry out any work
until you have read the safety instructions of this in-
struction manual and are qualied to do so.
The device may only be operated in
compliance with the operating condi-
tions stated on the type plate.
Prior to assembly, the device must be
inspected for transport damage.
The device must not be used in areas
with increased seismic risk.
Protection from environmental impacts
and weather conditions (corrosion, rain,
snow, icing, humidity (e.g. by conden-
sation), mould, UV radiation, harmful
insects, poisonous, corrosive solutions/
liquids (e.g. cutting and cooling uids),
must be guaranteed. Depending on the
installation site, it may be necessary to
take protective measures.
The device must not be exposed to open
re. Protection against lightning strikes
must be guaranteed.
2.1 General warnings
1. Target group
Explanation of the symbols
1, 2, 3,... = Order of
action
• = Instruction

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2.2 Designated use
The device is used in accordance with its designated use if
the following instructions are observed:
• Use of the device in gas transport and gas distribution
networks, commercial and industrial plants.
• Use in pressure regulator stations according to EN 12186
and EN 12279.
• Use with gases of the 1st and 2nd gas families according
to EN 437 only.
2.3 Risks in case of misuse
• If used in accordance with their designated use, the de-
vices are safe to operate.
• Non-observance of the regulations may result in personal
injury or material damage, nancial damage or environ-
mental damage.
3. Approval / declaration of conformity
• Operator errors or misuse present risks to life and limb of
the operators and also to the device and other material
property.
• Use with dry and clean gases only, no aggressive media.
• Use only in compliance with the operating conditions
stated on the type plate.
• Use in perfect condition only.
• Malfunctions and faults must be eliminated immediately.
• Use only in observance of the instructions given in this
instruction manual and of national regulations.

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4. Table of contents
1. Target group 1
2. Warnings 1
2.1 General warnings 1
2.2 Designated use 2
2.3 Risks in case of misuse 2
3. Approval/declaration of conformity 2
4. Table of contents 3
5. List of abbreviations 4
6. Features 5
6.1 Technical data 5
6.2 Nomenclature 6
6.3 Adjustment ranges 6
6.4 Accuracy class / lock-up pressure class 7
6.5 Selection of regulator springs 8
6.6 Selection of SAV springs 8
6.7 Type plate 9
7. Function 10
8. Dimensions 11
9. Installation 13
9.1 General information 13
9.2 Installation instructions 14
9.3 Torque 14
10. Integrated SAV 16
10.1 Function 16
10.2 Mounting on the regulator 17
11. Setting 18
11.1 Regulator setting 18
11.2 SAV setting 19
11.3 Calculation example of set values 20
11.4 Exchange of regulator springs 21
11.5 Exchange of SAV springs 23
11.5.1 Spring exchange Wdso 23
11.5.2 Spring exchange Wdsu 24
12. Commissioning and decommissioning 26
12.1 General information 26
12.2 Leakage test 26
12.3 Commissioning / unlocking / control of the set values 27
12.4 Recommissioning 29
12.5 Decommissioning 29
13. Faults and their causes 29
14. Maintenance 31
14.1 General information 31
14.2 Maintenance instructions of the regulator 33
14.2.1 Preparation 33
14.2.2 Replacement of the working diaphragm 33
14.2.3 Replacement of the control plate / valve seat 37
14.3 Maintenance instructions of the SAV 43
14.3.1 Preparation 45
14.3.2 Removal of the ASE from the housing 45
14.3.3 Check / replacement of the working diaphragm, MD/HD version 46
14.3.4 Check / replacement of the working diaphragm, ND version 49
14.3.5 Mounting of the ASE on the housing 50
14.4 Necessary tools 51
14.5 Leakage test 53
14.6 Recommended maintenance intervals 53
15. Spare parts 54
15.1 List of spare parts of the regulator 55
15.2 List of spare parts of the SAV 56
15.3 Complete regulator sets 57
15.4 Storage conditions 59
16. Flow volume tables 59
16.1 Natural gas ow volume table 60
16.2 Air ow volume tables 61
16.3 Valve ow volume coecient KG

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5. List of abbreviations
Abbreviation Description
AGoResponse pressure group of the upper response pressure
AGuResponse pressure group of the lower response pressure
AC Accuracy class
ASE Safety shuto valve (without housing)
CvFlow volume coecient
DN Nominal diameter
Fail-open The ring valve moves automatically to the open position, if the main diaphragm or the
auxiliary power required for the actuation of the ring valve fails
IS Type: integral strength range
Class A Functional class: the SAV closes if the comparison diaphragm is damaged or the auxiliary power supply
has failed
MOP Maximum admissible operating pressure
pdOutlet pressure
pd, abs. Output pressure as absolute pressure
puInlet pressure
pu, abs. Inlet pressure as absolute pressure
pdo Upper response pressure
pdu Lower response pressure
pmax Maximum operating pressure
pzul. System-specic operating pressure according to the regulator
PN Nominal pressure of the ange
PS Maximum admissible pressure
SAV Safety shuto valve
SBV Safety relief valve
SG Lock-up pressure class
SN Serial number
SZ Closing pressure zone group
Tp. Operating temperature -20 °C ... +60 °C
Wds Specic guide range
Wdo Adjustment range for the upper response pressure through regulation of the
available adjusting springs
Wdu Adjustment range for the lower response pressure through regulation of the
available adjusting springs
Wdso Specic adjustment range of the adjusting spring installed for the upper response pressure
Wdsu Specic adjustment range of the adjusting spring installed for the lower response pressure

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6. Features
6.1. Technical data
Technical data FRM …
Device Spring-loaded medium pressure regulator according to EN 334
Type IS
(integral strength range)
Type of gas Family 1+2+3
Nominal diameters
Flange
Connecting anges PN 25 according to EN 1092-1 or ANSI 150 lbs (B16.5)
DN 25 40 50
ANSI 1’’ 1.5’’ 2’’
Admissible pressure load 10 bar (1000 kPa)
Max. inlet pressure 10 bar (1000 kPa)
Outlet pressure range 30 - 1500 mbar (3-150 kPa)
Minimum dierential pressure
(ND)
270 mbar (27 kPa)
Minimum dierential pressure
(MD)
350 mbar (35 kPa)
Minimum dierential pressure
(HD)
500 mbar (50 kPa)
Materials Main body housing: cast iron GGG 50 (GJS 400-18 on request)
Diaphragm housing: steel
Diaphragms: NBR
Ambient temperature -20 °C to + 60 °C
Technical data SAV …
Device Safety shuto valve in compliance with EN14382, class A
Type IS
Response time ≤ 2s
Adjustment range
below Wdu
10 - 1400 mbar (1-140 kPa)
Adjustment range
above Wdu
40 - 3500 mbar (4-350 kPa)
Materials Main body housing: cast iron GGG 50 (GJS 400-18 on request)
Diaphragm housing: Aluminium
Diaphragms: NBR

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6.3 Adjustment range
Type Connec-
tion
Ver-
sion
Accuracy
class* [AC]
Lock-up pres-
sure
class* [SG]
Outlet pressure
range Wd
Lower switching point
SAV
Upper switching point SAV
Wdu AG Wdo AG
FRM 100025 ND DN 25 ND AC 10 SG 20 30-100 mbar
FRM 100025 MD DN 25 MD AC 5/10** SG 20 90-420 mbar
FRM 100025 HD DN 25 HD AC 5 SG 10 400-1500 mbar
FRM 100025 ND / SAV ND DN 25 ND AC 10 SG 20 30-100 mbar 10-115 mbar AG 10 40-240 mbar AG 10
FRM 100025 MD / SAV MD DN 25 MD AC 5/10** SG 20 90-420 mbar 35-400 mbar AG 10 180-800 mbar AG 10
FRM 100025 HD / SAV HD DN 25 HD AC 5 SG 10 400-1500 mbar 150-1400 mbar AG 5 500-3500 mbar AG 5
FRM 100040 ND DN 40 ND AC 10 SG 20 30-100 mbar
FRM 100040 MD DN 40 MD AC 5/10** SG 20 90-420 mbar
FRM 100040 HD DN 40 HD AC 5 SG 10 400-1500 mbar
FRM 100040 ND / SAV ND DN 40 ND AC 10 SG 20 30-100 mbar 10-115 mbar AG 10 40-240 mbar AG 10
FRM 100040 MD / SAV MD DN 40 MD AC 5/10** SG 20 90-420 mbar 35-400 mbar AG 10 180-800 mbar AG 10
FRM 100040 HD / SAV HD DN 40 HD AC 5 SG 10 400-1500 mbar 150-1400 mbar AG 5 500-3500 mbar AG 5
FRM 100050 ND DN 50 ND AC 10 SG 20 30-100 mbar
FRM 100050 MD DN 50 MD AC 5/10** SG 20 90-420 mbar
FRM 100050 HD DN 50 HD AC 5 SG 10 400-1500 mbar
FRM 100050 ND / SAV ND DN 50 ND AC 10 SG 20 30-100 mbar 10-115 mbar AG 10 40-240 mbar AG 10
FRM 100050 MD / SAV MD DN 50 MD AC 5/10** SG 20 90-420 mbar 35-400 mbar AG 10 180-800 mbar AG 10
FRM 100050 HD / SAV HD DN 50 HD AC 5 SG 10 400-1500 mbar 150-1400 mbar AG 5 500-3500 mbar AG 5
6.2 Nomenclature
Example
FRM 100025 ND / SAV ND
FRM 100 025 ND SAV ND
Type Spring-loaded medium pressure regulator
MOP 100 … 10.000 mbar
Nominal diameter DN 25 025
DN 40 040
DN 50 050
Pressure range, outlet pressure ND Low pressure
MD Medium pressure
HD High pressure
Safety device SAV Integrated safety shuto valve
Pressure range, trip pressure ND Low pressure
MD Medium pressure
HD High pressure
Flange type
ANSI
with standard PN-25
with ANSI 150 lbs
*Accuracy class / lock-up pressure class according to EN 334
**pd = 90-180 mbar: AC 10
pd= 180-420 mbar: AC 5

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6.4 Accuracy class / lock-up pressure class
Version Outlet pressure range Accuracy class [AC] Closing pressure
FRM...ND 30-50 mbar AC 15
pd + 15 mbar
50-80 mbar AC 10
90-100 mbar AC 5
FRM...MD 90-120 mbar AC 15
pd + 25 mbar
120-180 mbar AC 10
180-420 mbar AC 5
FRM...HD 400-450 mbar AC 10
pd + 50 mbar
450-500 mbar AC 5
500-1500 mbar AC 2.5
The AC and SG data, in compliance with EN 334, do not
make any statement about the modulation range. Knowl-
edge of the minimum and maximum volume ow is essen-
tial for the application in the eld. Therefore, the accuracy
values 'control quality' and 'lock-up pressure class' that can
be guaranteed at a volume ow of 1:10 were determined.
Abbrevia-
tion
Description
AC Accuracy class
pdOutlet pressure
pu1/2 Inlet pressure
pds Set nominal value of the outlet pressure
SG Lock-up pressure class
Qmin / pu1/2 AC minimum ow volume at a specic inlet pressure pu (lower limit of the volume ow at which the stable
operating conditions for a given nominal value within the given operating temperature range).
Qmax / pu1/2 AC maximum ow volume at a specic inlet pressure pu (upper limit of the volume ow at which a given ac-
curacy class for a given nominal value within the given operating temperature range).
The AC values of the table mentioned above refer to the
maximum admissible percentage deviation of the outlet
pressure from the set nominal value, at which Qmax / Qmin ≥ 10
is observed.
pd
Qmin, pu1
Q
pu1
Qmin, pu2 Qmax, pu1 Qmax, pu2
pu2
pds
pds x (1-AC/100)
pds x (1+SG/100)
pds x (1+AC/100)

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Adjustment range, outlet pressure Wdu
Spring colour Order
number
Wire diameter
[mm]
Length
[mm]
Diameter
[mm]
Setpoint range [mbar]
ND MD HD
Silver 270341 5.5 300 60 30-40 90-110
Green 270345 6.5 300 62 40-55 110-170
Yellow 270346 7.0 300 63 55-80 170-240
Blue 270347 8.0 300 65 80-100 240-330
Black 270348 9.0 300 68 330-420 400-580
Purple 270349 10.0 300 69 560-850
Orange 270350 11.0 300 71 800-1200
Pink 270352 12.0 300 73 1100-1500
Specic adjustment range, underpressure Wdsu
Spring colour Order
number
Wire diameter
[mm]
Length
[mm]
Diameter
[mm]
Setpoint range [mbar]
ND MD HD
White 270353 1.2 60 10.0 10-32
Yellow 270355 1.5 55 12.3 24-40
Blue 270356 2.0 55 12.3 30-115 35-110
Black 270357 2.3 55 12.3 50-250
Purple 270358 2.5 55 12.3 80-400 150-500
Orange 270359 2.8 55 12.3 300-1000
Silver 270360 3.0 60 15.0 800-1400
6.5 Selection of regulator springs
6.6 Selection of SAV springs
Specic adjustment range, overpressure Wdso
Spring colour Order
number
Wire diameter
[mm]
Length
[mm]
Diameter
[mm]
Setpoint range [mbar]
ND MD HD
Silver 270361 2.2 60 30.0 40-130
Green 270366 2.5 60 30.0 60-190 180-290
Red 270367 2.7 60 30.0 90-240 230-370
Yellow 270368 3.2 60 30.0 300-500
Blue 270369 3.5 60 30.0 400-800 500-1000
Black 270370 3.7 60 30.0 700-1300
Purple 270371 4.0 60 30.0 1000-1800
Orange 270372 4.5 60 30.0 1300-2500
Pink 270373 4.8 60 30.0 1800-3500

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6.7 Type plate
65
53
Abbrevia-
tion
Description
AGoResponse pressure group of the upper response pressure
AGuResponse pressure group of the lower response pressure
AC Accuracy class
CVFlow volume coecient for natural gas
DN Nominal diameter
Fail-open The mainvalve moves automatically to the open position, if the main diaphragm or the
auxiliary pressure required for the actuation of the main valve fails
IS SAV type: integral strength range
Class A Functional class: in case the membrane is damaged or in the event of a breakdown of the impulse line pres-
sure the SAV closes
pdOutlet pressure
puInlet pressure
PN Nominal pressure of the ange
PS Maximum admissible pressure
SAV Safety shuto valve
SG Lock-up pressure class
-20T60 Operating temperature -20 °C ... +60 °C
SN Serial number
Wds Specic guide range
Wdo Adjustment range for the upper response pressure through regulation of the
available adjusting springs
Wdu Adjustment range for the lower response pressure through regulation of the
available adjusting springs
Wdso Specic adjustment range of the adjusting spring installed for the upper response pressure
Wdsu Specic adjustment range of the adjusting spring installed for the lower response pressure
Regulator SAV
65
53

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7. Function
The pressure regulator’s function is to keep the outlet
pressure largely constant, independent of changes in the
inlet pressure and/or in the ow volume. In the depressur-
ised state the regulator is open. The pressure regulator
complies with the requirements of EN 334 as gas pres-
sure regulator with standard strength range (IS) and zero
ow.
Main components
A Control plate
B Inlet pressure compensation diaphragm
C Lower diaphragm shell
D Lever system
E Impulse connection for the outlet pressure
F Working diaphragm
G Vent connection
H Setpoint spring
Depressurised state
The force of the setpoint spring H acts on the working
diaphragm F. In depressurised state there is no coun-
terforce acting in the lower diaphragm shell C, since no
overpressure is applied in the outlet range. The resulting
upward movement of the working diaphragm causes the
lever system D to be pushed downwards. In this way, the
control plate A is then pulled upwards and lifted from the
seat. The regulator is open.
Steady state
In case of increasing outlet pressure, the force on the
working diaphragm F in the diaphragm shell C increases
also. The working diaphragm F is thus pushed upwards
until the force of the setpoint spring His equal to that of
the outlet pressure. The upward movement of the work-
ing diaphragm F causes the lever system D to be pulled
upwards. In this way, the control plate A is then pushed
downwards and the valve gap is reduced. The ow vol-
ume decreased in this way reduces the outlet pressure
until the set nominal value (outlet pressure) is reached
again and a balance of forces at the working diaphragm F
is established.
If the outlet pressure drops, the force on the working dia-
phragm F in the lower diaphragm shell C decreases also.
The working diaphragm F is, thus, pushed downwards
until the force of the setpoint spring His equal to that of
the outlet pressure. The upward movement of the work-
ing diaphragm F causes the lever system D to be pushed
downwards. In this way, the control plate A is then pulled
upwards and the valve gap is reduced. The increased
ow volume increases the outlet pressure until the set
nominal value (outlet pressure) is reached again and a
balance of forces at the working diaphragm F is estab-
lished.
Inlet pressure compensation
Changes in the inlet pressure have no inuence on the
balance of forces. The inlet pressure is compensated by
the inlet pressure compensation diaphragm B. The inlet
pressure is then transferred in the chamber above the inlet
pressure compensation diaphragm Bthrough an opening at
the control plate A. At the control plate A, the inlet pressure
acts in the opening direction. At the inlet pressure compen-
sation diaphragm B, opposite to the control plate, the inlet
pressure acts in the closing direction. The surface of the
control plate, on which the inlet pressure acts from below,
has the same size as the admission pressure compensation
diaphragm B, on which the inlet pressure acts from above.
Therefore, both forces cancel each other. The inlet pressure
balance at the regulator is ensured.
A
B
C
D
F
G
H
E

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11 … 64
8. Dimensions
Type Order
number
p max.
[bar/kPa]
DN Dimensions Weight
[kg]
A B C D E F G
FRM 100025 ND 270272 10 / 1000 25 500 184 57 492 820 ⊘ 29.5-1/2“G ⊘12 38
FRM 100025 MD 270273 10 / 1000 25 380 184 57 492 820 ⊘ 29.5-1/2“G ⊘12 32
FRM 100025 HD 270274 10 / 1000 25 380 184 57 502 830 ⊘ 29.5-1/2“G ⊘12 36
FRM 100040 ND 270278 10 / 1000 40 500 223 69 505 830 ⊘ 29.5-1/2“G ⊘12 42
FRM 100040 MD 270279 10 / 1000 40 380 223 69 505 830 ⊘ 29.5-1/2“G ⊘12 36
FRM 100040 HD 270280 10 / 1000 40 380 223 69 515 840 ⊘ 29.5-1/2“G ⊘12 40
FRM 100050 ND 270284 10 / 1000 50 500 254 80 515 840 ⊘ 29.5-1/2“G ⊘12 49
FRM 100050 MD 270285 10 / 1000 50 380 254 80 515 840 ⊘ 29.5-1/2“G ⊘12 43
FRM 100050 HD 270286 10 / 1000 50 380 254 80 525 850 ⊘ 29.5-1/2“G ⊘12 47
FRM...
F
A
C
D
E
B
*Ermeto screw connection 12L: GE 12 - 1/4
with screw connection M16 for pipes 12 x 1.5
G*

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Edition 02.17 • No. 270 442
Type Order
number
p max.
[bar/kPa]
DN Dimensions Weight
[kg]
A B C D E F G
FRM 100025 ND/SAV ND 270275 10 / 1000 25 500 184 232 492 1070 ⊘ 29.5-1/2“G ⊘12 40
FRM 100025 MD/SAV MD 270276 10 / 1000 25 380 184 229 492 1070 ⊘ 29.5-1/2“G ⊘12 34
FRM 100025 HD/SAV HD 270277 10 / 1000 25 380 184 236 502 1080 ⊘ 29.5-1/2“G ⊘12 38
FRM 100040 ND/SAV ND 270281 10 / 1000 40 500 223 243 505 1080 ⊘ 29.5-1/2“G ⊘12 44
FRM 100040 MD/SAV MD 270282 10 / 1000 40 380 223 239 505 1080 ⊘ 29.5-1/2“G ⊘12 38
FRM 100040 HD/SAV HD 270283 10 / 1000 40 380 223 247 515 1090 ⊘ 29.5-1/2“G ⊘12 42
FRM 100050 ND/SAV ND 270287 10 / 1000 50 500 254 252 515 1090 ⊘ 29.5-1/2“G ⊘12 51
FRM 100050 MD/SAV MD 270288 10 / 1000 50 380 254 248 515 1090 ⊘ 29.5-1/2“G ⊘12 45
FRM 100050 HD/SAV HD 270289 10 / 1000 50 380 254 256 525 1100 ⊘ 29.5-1/2“G ⊘12 49
FRM... / SAV
A
C
G*
E
B
*Ermeto screw connection 12L: GE 12 - 1/4
with screw connection M16 for pipes 12 x 1.5
DF

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13 … 64
9. Installation
9.1 General information
• This device can only be installed in
compliance with the rules and stand
ards applicable and in accordance with
the local regulations and authorisa -
tions.
• Install the device in a building or
housing, do not install it outdoors without suitable
protective measures!
• The lifting devices used must be suitable for the load
to be lifted.
• Enough installation space for operation and mainte-
nance has to be provided.
• It is recommended to install a lter with a pore size ≤
50 µm upstream of the regulator.
• The installation must not impair the functioning of
other components.
Check prior to installation!
• Shut-o valves both on the inlet and outlet side are
closed.
• Lines are free from combustible gas.
• Prevent explosive gas-air mixture: the room atmosphere
must be monitored for gas leakages.
• Ensure Ensure electrical continuity with use of suitable
bonding straps. Prevent contact voltage and ignitable
ashover.
• The performance data on the type plate corresponds to
the purchase ordering data.
• Flanges on the inlet side and outlet side of the connecting
line are parallel.
• The sealing surfaces of the ange are undamaged and
clean.
• The maximum inlet pressure of the system is lower than
the maximum admissible pressure of the regulator.
• Protective caps at the connection ange, if any, must be
removed.
• The minimum distances for the setting must be observed.
• The pipeline on the inlet side must be free of water and
dirt.
Note during installation!
• Mounting must be carried out in a tension-free state.
• Tighten the screws crosswise.
• Tightening torques must be observed.
• Vent lines and blow-o lines have to be positioned sepa-
rately.
• Vent lines and blow-o lines must lead outdoors: gases
must be able to escape to a non-hazardous environment.
• The impulse lines may not be shut o.
• The specied distance between the measuring points of
the impulse lines must be observed.
• The ow direction (arrow) on the housing must be fol-
lowed.

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Edition 02.17 • No. 270 442
9.2 Installation instructions
• The installation must be carried according to the installa-
tion scheme specied below.
• Install the safety shuto valve in the ow direction (arrow/
housing).
• Design a straight stablisation section with the equal
diameter.
• Make sure that the impulse tapping at the stablisation sec-
tion is clean and free from burrs. Distance > 5 x DN
Pos. Designation
1Shuto valve, inlet side (e.g. ball valve or buttery valve)
2Filter
3Welded part
4Pressure gauge, inlet side
5Regulator with integrated SAV
6Calming section
7SBV
8Ball valve
9Pressure gauge, outlet side
10 Test burner
11 Venting ball valve
12 Impulse line, SAV
13 Impulse line, regulator
14 Shuto valve, outlet side (e.g. ball valve or buttery valve)
15 Vent line regulator
16 Vent line SAV
17 Relief line SBV
• Maximum ow velocity in the stablisation section:
≤ 30 m/s.
• Use steel pipe impulse lines D= 12 x 1.5
• Avoid accumulation of condensate: install the impulse
lines with a gradient
12
3
4
5
8
6
79
11
10
12
12
Stabilisation section > 5 x DN
Installation drawing
13
14
15
16
17

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15 … 64
Mmax.
Tmax. Mmax.
FRM...
9.3 Torque
The device must not be used as lever.
Use adequate tools!
Tighten the screws crosswise!
[Nm]
18
19
ISO 7005-2
DN -- -- -- 25 40 50 65 80 100 125 150
Rp ⅜½ ¾ 11 ½22 ½-- -- -- --
Mmax.
[Nm] t 10 s 70 105 225 340 610 110 1600 2400 5000 6000 7600
Tmax.
[Nm] t 10 s 35 50 85 125 200 250 325 400 -- -- --
Max. torque system accessories
M … / G … M 4 M 5 M 6 M8 G ⅛ G ¼ G ½ G ¾
Mmax.
[Nm] t 10 s 2.5 Nm 5 Nm 7 Nm 15 Nm 5 Nm 7 Nm 10 Nm 15 Nm
Max. torque anged joint
Stud M 12 x 55
(EN 13611)
M 16 x 65
(DIN 939)
Mmax.
[Nm] t 10 s 30 Nm 60 Nm
Mounting position

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10. Integrated SAV
SAV protects downstream ttings or lines against pres-
sures that are too high or too low. As soon as the pre-set trip
pressure falls below or exceeds a limit due to a fault, the SAV
automatically interupts the gas ow. Under normal operating
condition the SAV is open.
If the equipment downstream of the regulator, including any
pipework, cannot safely operate or contain a pressure equal
to the highest supply pressure (inlet to regulator), a SAV
must be installed. The SAV is designed to shut down the gas
supply in the event of a fault condition.
The SAV complies with the requirements of EN 14382 as
safety shuto valve with standard strength range (IS).
Main components
A Valve disc
B Closing spring
C Ball catch / trigger mechanism
D Chamber with the pressure to be monitored
E Working diaphragm
F Push rod
G Setpoint spring for pdo
H Setpoint spring for pdu
I Protective cap
Function
Chamber D is connected to the outlet pressure via
a pulse line.
The pressure to be checked acts on the working diaphragm
E. The force of the setpoint springs G and H acts as counter-
force.
In case of an unbalance of forces (overpressure or un-
derpressure), the SAV is actuated and the gas supply is
blocked.
A
B
C
D
E
F
GH
I
10.1 Function

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10.2 Mounting on the regulator
1. Loosen four hexagonal socket grub screws (M 5x8) of
the ASE C using an internal hex key SW 2.5.
2. Remove the base plate Afrom the housing using a
hook wrench 60-90.
3. Remove the O-ring B.
4. Place the new O-ring B of the maintenance kit 6 on the
ASE C.
5. Screw the ASE C in the housing using a hook wrench
60-90.
6. Align the Ermeto screw connection D of the pulse con-
nection to the connection of the external pulse line.
7. Tighten four hexagonal socket grub screws (M5x8) in
the ASE C using an internal hex key SW 2.5.
C
A
B
B
D

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11. Setting
11.1 Regulator setting
Setting of the outlet pressure
The regulator is set using the adjusting screw B.
1. Remove the protective cap A.
2. Turn the adjusting screw B using an open-ended
wrench SW 24.
3. Turning clockwise: the preload of the setpoint spring is
increased and the outlet pressure pds is increased (+).
4. Turning counter-clockwise: the setpoint spring is re-
leased and the outlet pressure pds reduced (–).
5. After the setting: screw on the protective cap A again.
C
A
B
D
E
F
(–) (+)

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(+) (-)
11.2 SAV setting
Switch-o setting in case of overpressure pdo
1. Remove the protective cap A.
2. Turn the external adjusting screw B using a socket
wrench SW 22.
3. Turning clockwise: increase (+) in the upper shut down
pressure pdo.
4. Turning counter-clockwise: reduction (+) in the upper
shut down pressure pdo.
5. After the setting: screw on the protective cap A again.
Triggering setting in case of underpressure pdu
1. Remove the protective cap A.
2. Turn the internal adjusting screw C using a socket
wrench SW 17.
3. Turning clockwise: increase (+) in the lower shut down
pressure pdo.
4. Turning counter-clockwise: reduction (+) in the lower
shut down pressure pdo.
5. After the setting: screw on the protective cap A again.
Attention: The setting for lower triggering aects the
set value for upper triggering. Please set the vacuum
triggering, rst.
A mutual inuence of the pressure regulator and the safety shuto valve must be excluded.
Calculation of the recommended set values according
to the outlet pressure pd of the regulator
• The SAV must lock as soon as it reaches the 1.1 times
max. operating pressure according to the system speci-
cations.
• The set values of the SAV must be dened taking into
account the set values and tolerances
of the pressure regulator.
• The tolerances and set values of additional safety de-
vices must also be considered when setting of the SAV.
• In case of a fault or regular shut-down of the down-
stream shuto valve the SAV may not
be actuated. The upper shut down pressure should be
determined to avoid nuisance shut down (e.g. shut
down of downstream equipment)
pd ≤ 100 mbar
pdo = pd + 50 mbar
100 mbar < pd ≤ 200 mbar
pdo > pd + 100 mbar
pd > 200 mbar
pdo > pdx 1.5
A
B
C
F
E
G
D
(+) (-)

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11.3 Calculation example of set values
Determination of the set values by means of a pressure graduation chart
Selected regulator FRM 100025 MD / SAV MD
Outlet pressure of the regulator pd 2 0 0 m b a r
System-specic operating pressure downstream of the regulator pzul. 500 mbar
Limiting pressure in case of fault 550 mbar
Accuracy class AC 5
Response pressure group of the upper shut down pressure SAV AGo10
Response pressure group of the lower shut down pressure SAV AGu10
Response group of the SBV AG 5
Result
Device group Device data Pressure graduation
Safety devices
against excessive pressure
Gas pressure regulator
Safety device
against insucient pressure
AGo 10
SAV
AGo 10
AG 5
SBV
AG 5
440 mbar
400 mbar
360 mbar
315 mbar
300 mbar
285 mbar
pd=
pdo =
SG 20
AC 5
FRM
AC 5
210 mbar
200 mbar
190 mbar
pd=
240 mbar
AGu 20
SAV
AGu 20
60 mbar
50 mbar
40 mbar
pdu =
Limiting pressure in case of fault: 1.1 * pperm. 550 mbar