Dungs FRSBV 20010 Series User manual

MF … 20
MC • Edition 2023.02 • No. 291 422 Rev. -2
1 … 20
Instruction Manual
FRSBV 20010…
FRSBV 5010…
The target group of this manual are specialised gas safety
and control technology personnel.They can assess the
work assigned to them and potential hazards on the basis
of their technical training, knowledge and experiences. In
accordance with the accepted rules of industrial safety only
these persons are permitted to carry out the installation,
start-up, adjustment and servicing of the equipment.
2. Warnings
Never perform work when gas
pressure or voltage is present.
Avoidopenre.Complywith
government regulations.
The device protect against vibrations
and mechanical impacts.
Execute all settings and setting values
subject to compliance with the user
manual for the machine connected.
Follow the accepted rules of industrial
safetyandtheaccidentprevention
regulations must be followed, if
necessarytakesafetymeasuresto
ensure the protection of persons.
Pipelines connected must be free
of dirt and fouling.
Placethisusermanualinaneasilyviewable
location in the installation room! Perform work
onlyafterthesafetyinstructionsinthisuser
manual have been read.
Thedevicemayonlybeoperated
in accordance with the operating
conditionsspeciedontherating
plate.
Checkthedevicefortransportdamage
prior to installation.
The device must not be used in areas
with heightened risk of earthquakes.
Protection against environmental and
climaticinuences(corrosion,rain,
snow,icing,moisture(e.g.dueto
condensation)), mould, UV radiation,
harmful insects, and toxic, corrosive
solutions/liquids(e.g.cutting/cool-
inguids)mustbeensured. Subject to
theinstallationsite,takesafetymeas-
uresmustwhennecessary.
The device must not be exposed
toanopename.Protectionagainst
lightening must be provided.
2.1 General warnings
1. Target group
Explanation of the characters
1, 2, 3, … = Take action
consecutively
• = Instruction

2 … 20
MC • Edition 2023.02 • No. 291 422 Rev. -2
2.2 Normal use
Normal use of the equipment is deemed to pertain
provided the following instructions are followed:
• Use of the equipment in gas transport and gas
distribution networks as well as in commercial and
industrial systems.
• Use in pressure regulating systems according to
EN 12186 and EN 12279.
• Use only with gases of the 1st, 2nd 3rd gas family
according to EN 437.
2.3 Risks in case of misuse
• The equipment is reliable in operation when used
normally.
• Personal or consequential material damage, nancial
damage or environmental damage cannot be ruled out
in the event of non-observance of the instructions.
• In the event of misuse or misapplication life and limb
of the operator is threatened and serious damage to
the device and other material assets is risked as well.
• Use only with dry and clean gases, no aggressive
media.
• Use only in accordance with the operating conditions
specied on the rating plate.
• Use only in good order and condition.
• Malfunctions and faults must be corrected immediately.
• Use only when following the instructions in this user
manual and the national regulations.

2 … 20
MC • Edition 2023.02 • No. 291 422 Rev. -2
3 … 20
3.EUDeclarationofconformity
Produkt / Product
Produit / Producto FRSBV... Safetypressurereliefvalve
Hersteller / Manufacturer
Fabricant / El Fabricante KarlDungsGmbH&Co.KG
Karl-Dungs-Platz 1
73660Urbach,Germany
bescheinigt hiermit, dass die
in dieser Übersicht genannten
Produkte einer EU-Baumuster-
prüfung(Baumuster)unterzo-
gen wurden und die wesentlichen
Sicherheitsanforderungen der:
• EU-Druckgeräterichtlinie
2014/68/EU
in der gültigen Fassung erfüllen.
Bei einer von uns nicht freige-
gebenen Änderung des Gerätes
verliert diese Erklärung ihre
Gültigkeit.
Der oben beschriebene Gegen-
stand der Erklärung entspricht
den einschlägigen Harmoni-
sierungsrechtsvorschriften der
Union.
Die alleinige Verantwortung für
die Ausstellung dieser Konformi-
tätserklärung trägt der Hersteller.
certies herewith that the prod-
ucts named in this overview were
subjected to an EU-TypeExami-
nation(productiontype)and
meet the essential safety require-
ments:
• EU-Pressure Equipment
Directive “2014/68/EU”
as amended.
In the event of an alteration of the
equipment not approved by us
this declaration loses its validity.
The object of the declaration
described above conforms with
the relevant Union harmonisation
legislation.
This declaration of conformity is
issued under the sole responsi-
bility of the manufacturer.
certie par la présente que le
produit mentionné dans cette vue
d’ensemble a été soumis à un
examenUEdetype(typede
fabrication) et qu’il est conforme
aux exigences en matières de
sécurité des dernières versions
en vigueur de :
• Directive européenne
relative aux appareils sous
pression 2014/68/UE
Ce communiqué n’est plus
valable si nous eectuons une
modication libre de l’appareil.
L’objet décrit ci-dessus de la pré-
sente déclaration correspond aux
prescriptions légales applicables en
matière d’harmonisation de l’Union.
Le fabricant porte l’entière res-
ponsabilité pour l’établissement
de la présente déclaration de
conformité.
certica que los productos men-
cionados en este resumen han
sido sometidos a un examen UE
de tipo (tipo de producción) y
cumplenconlos requisitosmínimos
de seguridad de:
• Directiva de equipos a
presióndelaUE
2014/68/UE
en su versión vigente.
En caso de una modicación no
autorizada por nosotros, esta de-
claración pierde su validez.
El objeto de la declaración des-
crita anteriormente es conforme
a la legislación de armonización
pertinente de la Unión.
El fabricante es el único respon-
sable de la expedición de esta
declaración de conformidad.
PrüfgrundlagederEU-Baumusterprüfung(Baumuster)
SpeciedrequirementsoftheEU-TypeExamination( productiontype)
Base d‘essai de l‘examen UEdetype(typedefabrication)
RequisitosespecícosdelexamenUEdetipo(tipodeproducción))
DIN 33821
Gültigkeitsdauer/Bescheinigung
Termofvalidity/attestation
Validité/certicat
Periododevalidez/Certicado
2029-11-13
CE-0085CU0351
NotizierteStelle(EUBaumusterprüfung:ModulB)
NotiedBody(EUtype-examination:ModuleB)
Organismenotié(Examendetypedel‘UE:moduleB)
Organismonoticado(ExamentipoUE:MóduloB)
DVGWCERTGmbH
Josef-Wirmer-Straße 1-3
D-53123 Bonn, Germany
Notied Body number: 0085
ÜberwachungdesQM-Systems(Modul D)
MonitoringoftheQMsystem(module D)
Contrôledelagestiondel‘assurancequalité(module D)
SupervisióndelsistemadecalidadyseguridadmóduloD)
TÜV SÜD Industrie Service GmbH
Westendstraße 199
D-80686 München, Germany
Notied Body number: 0036
B. Sc., MBA, Simon P. Dungs
Geschäftsführer / Chief Operating Ocer
Directeur / Gerente
Urbach, 2023-02-08

4 … 20
MC • Edition 2023.02 • No. 291 422 Rev. -2
Product
FRSBV Safetypressurereliefvalve
Manufacturer KarlDungsGmbH&Co.KG▪Karl-Dungs-Platz 1 ▪D-73660Urbach/Germany
Certies herewith that the products named in this overview were subjected to a TypeExamination(productiontype)and meet the
essential safety requirements:
• ThePressureEquipmentSafetyRegulations,UKSI2016:1105(asamendedbyUKSI2019:969)
In the event of an alteration of the equipment not approved by us this declaration loses its validity.
The object of the declaration described above conforms with the relevant legislation.
This declaration of conformity is issued under the sole responsibility of the manufacturer.
SpeciedrequirementsoftheTypeExamination(productiontype) DIN 33821
Termofvalidity 2032-07-17
ApprovedBody 2016 No. 1105
TUV SUD BABT Unlimited
Octagon House,
Concorde Way, Segensworth North,
Fareham, Hampshire,
PO15 5RL, United Kingdom
Approved Body Number: 0168
MonitoringoftheQAsystem Conformity process adopted: Module B+D
B.Sc., MBA Simon P. Dungs,
Chief Operating Ocer
Urbach, 2023-02-08
3.Declarationofconformity

4 … 20
MC • Edition 2023.02 • No. 291 422 Rev. -2
5 … 20
4. Table of contents
1. Target group 1
2. Warnings 1
2.1 General warnings 1
2.2 Normal use 2
2.3 Risks in case of misuse 2
3. Declarationofconformity 3
4. Table of contents 5
5. List of abbreviations 6
6. Features 7
6.1 Technical data 7
6.2 Nomenclature 8
6.3 Adjustment ranges 8
6.4 Spring selection 9
6.5 Type plate 10
7. Function 11
8. Dimensions 12
9. Installation 13
9.1 General information 13
9.2 Description of installation 14
9.3 Torques 15
10. Adjusting the triggering pressure 16
10.1 Spring replacement 17
10.2 Tools required 18
11. Flow tables 18

6 … 20
MC • Edition 2023.02 • No. 291 422 Rev. -2
5. List of abbreviations
Abbreviation Description
AC Accuracy class
SG Closing pressure group
KGFlow coecient
Rp Threaded connection
pdo Upper response pressure
pdu Lower response pressure
pmax Maximum operating pressure
PN Nominal ange pressure
PS Maximum permissible pressure
SBV Safety pressure relief valve
SN Serial number
SW Width across ats
Wdo Adjustment range for the upper response pressure by use of the adjusting springs available
Wdu Adjustment range for the lower response pressure by use of the adjusting springs available
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

6 … 20
MC • Edition 2023.02 • No. 291 422 Rev. -2
7 … 20
6. Features
6.1. Technical data
Technical data FRSBV …
Device Safety pressure relief valve according to DIN 33821
Type FRSBV 20010…
Typeofgas Family 1+2+3
Nominal diameters
Thread
Connecting threads according to BSP (ISO 228/1) or NPT (B1.20.1)
G1" NPT 1"
Input pressure FRSBV 20010… 20 bar (2 000 kPa)
Trigger range 200 mbar to 8 bar (20-800 kPa)
Materials Main housing: Steel F-114 (FRSBV 200…)
Diaphragm housing: Steel F-114 (FRSBV 200…)
Diaphragms: NBR according to EN 549
Ambient temperature -20 °C to +60 °C
Technical data FRSBV …
Device Safety pressure relief valve according to DIN 33821
Type FRSBV 5010…
Typeofgas Family 1+2+3
Nominal diameters
Thread
Connecting threads according to BSP (ISO 228/1) or NPT (B1.20.1)
G1" NPT 1"
Input pressure FRSBV 5010… 5 bar (5 000 kPa)
Trigger range 45 mbar to 2 bar (4.5-200 kPa)
Materials Main housing: Aluminium Al 2521, Al 2011
Diaphragm housing: Aluminium Al 2011
Diaphragms: NBR according to EN 549
Ambient temperature -20 °C to +60 °C

8 … 20
MC • Edition 2023.02 • No. 291 422 Rev. -2
6.2 Nomenclature
Using the FRSBV 5010 HD
as an example
FRSBV 50 10 HD NPT
Type Pressure relief valve
MOP 50 … 5 bar
200 … 20 bar
Nominal diameter 10 1"
Pressure ranges ND Low pressure
HD High pressure
Threadtype
NPT
With BSP thread
With NPT threads
6.3 Adjustment ranges
Type Threaded
connection
Version Item number Closing
pressure [SG]
Specic
adjustment range
FRSBV 5010 ND G1" ND 289263 SG 20 45-2 000 mbar
FRSBV 20010 HD G1" HD on request SG 20 200-8 000 mbar
FRSBV 5010 ND NPT NPT 1" ND 289268 SG 20 45-2 000 mbar
FRSBV 20010 HD NPT NPT 1" HD on request SG 20 200-8 000 mbar

8 … 20
MC • Edition 2023.02 • No. 291 422 Rev. -2
9 … 20
Setpoint range for springs FRSBV 20010…
Spring colour Replacement
item number
Wire diameter
[mm]
Length
[mm]
Diameter
[mm]
Setpoint range [mbar]
HD
Green 290952 3.5 110 35 200-1 000
Red 290953 4.0 100 35 250-1 500
White 290954 4.5 100 35 300-2 000
Yellow 290955 5.0 100 35 500-3 000
Blue 290956 5.5 100 35 750-4 000
Black 290957 6.0 100 35 1 000-8 000
Setpoint range for springs FRSBV 5010…
Spring colour Replacement
item number
Wire diameter
[mm]
Length
[mm]
Diameter
[mm]
Setpoint range [mbar]
ND
Yellow 290942 1.3 60 20 45-65
Black 290943 1.5 60 20 65-95
Purple 290944 1.6 60 20 85-125
Pink 290945 1.8 60 20 125-185
White 290946 2.2 60 20 185-350
Blue 290947 2.5 50 20 350-580
Orange 290948 2.8 50 20 580-1 000
Silver 290950 3.5 45 20 1 000-1 700
Grey 290951 3.8 45 20 1 600-2 000
6.4 Spring selection

10 … 20
MC • Edition 2023.02 • No. 291 422 Rev. -2
6.5Typeplate
Abbreviation Description
SG Closing pressure
AC Accuracy class
AG Response pressure group
Rp Thread diameter
-20T60 Operating temperature range
PS Maximum permissible pressure
SBV Safety pressure relief valve
SN Serial number
Wus Adjustment range of the spring installed for the lower response pressure
50
30

10 … 20
MC • Edition 2023.02 • No. 291 422 Rev. -2
11 … 20
7. Function
TheFRSBVtypesafetyvalveisasafetypressurereliefvalve
(SBV)withanadjustableresponsepressure. Theresponse
pressure results from the force that the movable parts exert
on the adjusting spring installed.The full response pressure
range can be covered by changing the adjusting springs.
The valve has an internal response pressure tap.
Main components
AHousing
BRegulating cup
CPush rod
DWorking diaphragm
EIntermediate housing
FUpper protective cover
GUpper diaphragm case
HVent connection
IAdjusting spring
JAdjusting nut
KProtective cap
A
B
C
D
E
F
G
H
p1
p2
I
K
J

12 … 20
MC • Edition 2023.02 • No. 291 422 Rev. -2
FRSBV …
8. Dimensions
A
C
D
E*
B
F
* Space required for changing the spring
A
C
F
B
D
E*
FRSBV 5010…
FRSBV 20010…
Type Item number p max.
[bar / kPa]
Thread
G
Dimensions [mm] Weight
[kg]
BSP NPT A B CD E F
FRSBV 5010 ND 289263 289268 5 / 500 1" 100 112 22 127 227 G¼" 0.89
FRSBV 20010 HD on request on request 20 / 2 000 1" 112 60 28 197 297 G¼" 6.15

12 … 20
MC • Edition 2023.02 • No. 291 422 Rev. -2
13 … 20
9. Installation
9.1 General instructions
• Installationonlyinaccordancewith
applicable policies and subject to
compliance with local regulations, ob-
tainpermitsrequiredifnecessary.
• Install the device in a building or
enclosure, no outdoor installation
absentappropriatesafetymeasures!
• Fit the working range with conventional safe-
guards.
• The lifting gear used must be suited for the loads
to be lifted.
• Providesucientinstallationspaceformainte-
nance and cleaning.
• The installation must not impair the operation of
other components.
Checkbeforeinstalling!
• The in- and output side shut-o valves are closed.
• The line is combustion gas free.
• Prevent a gas / air mixture: Monitor the room
atmosphere for leaking gas on an ongoing basis
using suitable gas concentration testers.
• Ensure electrically conductive bridging. Prevent touch
voltage and ignitable spark discharge.
• The rating plate's performance data agree with the
order data.
• The maximum input pressure of the system is less than
the maximum permissible pressure of the valve.
• Remove the connecting threads' protective cap –
if present.
• Maintain minimum clearances for adjustment.
• The input side pipeline is free of dirt and water.
Bear in mind during installation!
• Lay the air feed and extraction lines separately.
• Route the ventilation lines into the open:The gas has
to be able to escape into safe surroundings.
• Pay attention to the ow direction (arrow) on the
housing.

14 … 20
MC • Edition 2023.02 • No. 291 422 Rev. -2
9.2 Description of installation
• Carry out the installation according to the
installation layout indicated below.
• Install the safety pressure relief valve in the
direction of ow (arrow / housing).
• Maximum ow velocity in the stabilisation section:
≤ 30 m/s.
• SBV drain pipeline 1" pipe.
Item Designation
1Input side shut-o valve (e.g. ball valve or shut-o ap)
2 Filter
3 Reducing adapter
4 Input side manometer
5 Controller
6 Stabilisation section
7SBV
8 Ball valve
9 Output side manometer
10 Pressure tap
11 Pulse tap, SAV
12 Pulse tap, controller
13 Solenoid valve
14 Compensator
• Prevent the accumulation of condensate: Lay the pulse
lines on an incline.
1
2
3
4
5
6
7
8
9
10
11
12
13
Stabilisation section > 5 x DN
Installationlayout
14

14 … 20
MC • Edition 2023.02 • No. 291 422 Rev. -2
15 … 20
9.3 Torques
Do not use the device as a lever!
Use suitable tools!
[Nm]
18
19
Rp 1
Mmax.
[Nm] t 10 s 340
Tmax.
[Nm] t 10 s 125
Max.torqueofsystemaccessories
DN -- -- -- 25 40 50 65 80
M… / G… M4 M5 M6 M8 G⅛ G¼ G½ G¾
Mmax.
[Nm] t 10 s 2.5 Nm 5 Nm 7 Nm 15 Nm 5 Nm 7 Nm 10 Nm 15 Nm
Installation position

16 … 20
MC • Edition 2023.02 • No. 291 422 Rev. -2
10. Adjusting the triggering pressure
1
Remove protective cap A.
A
4
2
B
Turn outer adjusting nut
Bwith SW 22 socket
spanner. Turn clock-
wise to increase (+) the
triggering pressure.
(+)
3
Turn outer adjusting
nut Bwith SW 14
socket spanner. Turn
anti-clockwise to re-
duce (-) the triggering
pressure.
(-)
After the adjustment:
Screw protective cap Aback on.
(+)

16 … 20
MC • Edition 2023.02 • No. 291 422 Rev. -2
17 … 20
3
10.1 Spring replacement
4
C
1
Remove protective cap A.
A
2
Turn outer adjusting
nut Banti-clockwise
with SW 14 socket
spanner until it is com-
pletely unscrewed.
(-)
Remove adjusting nut B.
B
1. Remove spring C
from the spring dome.
2. Insert a new spring.
3. Screw adjusting nut B
in with SW 14 socket
spanner until the pre-
tension required in
the spring dome is
reached.

18 … 20
MC • Edition 2023.02 • No. 291 422 Rev. -2
10.2 Tools required
• The threshold level is adjusted and the spring replaced for all ve pressure relief valve types in the same way.
They dier only in the spanner used for the adjusting nuts' thread.
• A pipe socket spanner is needed for every FRSBV type:
FRSBVtype Width across the pipe
socketspannerats
FRSBV 5010 ND SW 14
FRSBV 20010 HD SW 30
11. Flow tables
Type of gas
Natural gas
City gas
LPG
Air
dv
0.65
0,47
1.67
1.00
f
1.24
1,46
0.77
1.00
Air density
spec. weight of the gas used
f =
°
Vgas used = V air x f
°Spec.
weight
[kg/m3]
0.81
0,58
2.08
1.24

18 … 20
MC • Edition 2023.02 • No. 291 422 Rev. -2
19 … 20
Flowtables∆pFRSBV5010ND
1 000
2 000
3 000
4 000
5 000
6 000
7 000
0100 200 300 400 500
1 343 mbar
2 000 mbar
689 mbar
45 mbar
Vn [m3/h] natural gas dv = 0.65
Input pressure [mbar]
Flowtables∆pFRSBV20010HD
2 000
4 000
6 000
8 000
10 000
12 000
0 500 1 000 1 500 2 000
8 000 mbar
5 467 mbar
2 933 mbar
400 mbar
Vn [m3/h] natural gas dv = 0.65
Input pressure [mbar]

20 … 20
MC • Edition 2023.02 • No. 291 422 Rev. -2
The Pressure Equipment Directive
(PED) and the Directive on the energy
performance of buildings (EPBD) require
a regular inspection of heat generators
to guarantee a high degree of eciency
long term and minimum environmental
impact as a result.
It is therefore necessary to replace
safety-relevant components once
their service life has elapsed.
We reserve the right to make modications in the course of technical development.
Sicherheitsrelevante Komponente
Safetyrelevantcomponent
Composantrelatifàlasécurité
Componentirilevantidalpuntodivistadellasicurezza
Konstruktionsbedingte Lebensdauer
Designed Lifetime
Durée de vie prévue
Durata di vita di progetto
Norm
Standard
Norme
Norma
Dauerhafte
Lagertemperatur
Durable storage
temperature
Température de
stockage permanente
Temperatura di
stoccaggio
permanente
Zyklenzahl
Operatingcycles
Cycled’opération
Numero di cicli di
funzionamento di progetto
Jahre
Years
Année
Anni
Ventilprüfsysteme / Valve proving systems /
Systèmes de contrôle de vannes / Sistemi di controllo valvole 250 000 10 EN 1643
0…45 °C
32…113 °F
Gas / Gas / Gaz / Gas
Druckwächter / Pressure switch / Manostat / Pressostati 50 000 10 EN 1854
Luft / Air / Air / Aria
Druckwächter / Pressure switch / Manostat / Pressostati 250 000 10 EN 1854
Gasmangelschalter / Low gas pressure switch /
Pressostat gaz basse pression / Pressostati gas di minima pressione N/A 10 EN 1854
Feuerungsmanager / Automatic burner control /
Dispositif de gestion de chauage / Gestione bruciatore 250 000 10 EN 298 EN 230
UV-Flammenfühler1
Flame detector (UV probes)1
Capteur de ammes UV1
Sensore amma UV1
N/A 10 000 h3---
Gasdruckregelgeräte1
Gas pressure regulators1
Dispositifs de réglage de pression du gaz1
Regolatori della pressione del gas1
N/A 15 EN 88-1
EN 88-2
Gasventil mit Ventilprüfsystem2
Gas valve with valve testing system2
Vanne de gaz avec système de contrôle de vanne2
Valvola del gas con sistema di controllo valvola2
nach erkanntem Fehler
after error detection
après détection d’erreur
dopo segnalazione di errore
EN 1643
Gasventil ohne Ventilprüfsystem2
Gas valve without valve testing system2
Vanne de gaz sans système de contrôle de vanne2
Valvola del gas senza sistema di controllo valvola2
DN ≤ 25 200 000
25 < DN ≤ 80 100 000
80 < DN ≤ 150 50 000
10 EN 161
Gas-Luft-Verbundsysteme / Gas-air ratio control system /
Systèmes combinés gaz/air / Sistemi di miscelazione gas-aria N/A 10 EN 88-1 EN 12067-2
1 Nachlassende Betriebseigenschaften wegen Alterung / Performance decrease due to ageing /
Réduction de performance due au viellissement / Riduzione delle prestazioni dovuta all’invecchiamento
2 Gasfamilien II, III / Gas families II, III / Familles de gaz II, III / per i gas delle famiglie II, III
3 Betriebsstunden / Operating hours / Heures de service / Ore di esercizio
N/A nicht anwendbar / not applicable / ne peut pas être utilisé / non può essere usato
Lagerzeiten / Storage times / Périodes de stockage / Tempi di stoccaggio
Lagerzeiten≤1Jahr verkürzen nicht die konstruktionsbedingte Lebensdauer.
Storagetime≤1year does not reduce the designes lifetime.
Lespériodesdestockage≤1an ne réduisent pas la durée de vie liée à la conception.
Itempidistoccaggio≤1anno non riducono la durata di vita legata al design.
DUNGS empehlt eine maximale Lagerzeit von 3 Jahren.
DUNGS recommends a maximumstoragetimeof3years.
DUNGS recommande une durée de stockage maximale de 3 ans.
DUNGS raccomanda un tempo massimo di stoccaggio di 3 anni.
KarlDungsGmbH&Co.KG
Postfach 12 29
D-73602 Schorndorf
e-mail [e-mail]
Internet www.dungs.com
KarlDungsGmbH&Co.KG
Karl-Dungs-Platz 1
D-73660Urbach,Germany
Telefon[phone]
Telefax [phone]
Hausadresse
HeadOcesandFactory
UsineetServicesAdministratifs
AmministrazioneeStabilimento
Briefadresse
Postal address
Adresse postale
Indirizzare la corrispondenza a