Dungs FRM 100065 User manual

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MC • Edition 04.19 • No. 278 349
1 … 56
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.
Instructions
FRM 100065 - 100080 - 250065 - 250080
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 / EU 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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EU Declaration of conformity
Produkt / Product
Produit / Prodotto FRM 100065 - 100080
FRM 250065 - 250080 Medium Pressure Regulator 10 bar / 25 bar
Hersteller / Manufacturer
Fabricant / Produttore Karl Dungs GmbH & Co. KG
Karl-Dungs-Platz 1
D-73660 Urbach, Germany
bescheinigt hiermit, dass die in die-
ser Übersicht genannten Produkte
einer EU-Baumusterprüfung un-
terzogen wurden und die wesentli-
chen Sicherheitsanforderungen der:
EU-Druckgeräterichtlinie
2014/68
in der gültigen Fassung erfüllen.
Bei einer von uns nicht freigegebe-
nen Änderung des Gerätes verliert
diese Erklärung ihre Gültigkeit.
certies herewith that the products
named in this overview were sub-
jected to an EU type-examination
and meet the essential safety
requirements:
EU Pressure Equipment Directive
2014/68
as amended.
In the event of an alteration of the
equipment not approved by us this
declaration loses its validity.
certifie par la présente que le
produit mentionné dans cette vue
d'ensemble a été soumis à un
examen de type de l'UE et qu'il
est conforme aux exigences en
matières de sécurité des dernières
versions en vigueur de :
à la directive UE « Équipements
sous pression »
2014/68
Ce communiqué n'est plus valable
si nous eectuons une modication
libre de l'appareil.
Con la presente si certica che i
prodotti citati in questa panoramica
sono stati sottoposti a una prova di
omologazione UE e che i requisiti
di sicurezza essenziali:
direttiva UE sulle attrezzatture
a pressione
2014/68
sono soddisfatti nella versione valida.
In caso di modica dell'apparecchio
non ammessa, questa dichiarazione
perde di validità.
Prüfgrundlage der EU-Baumusterprüfung
Specied requirements of the EU type-examination
Base d'essai de l'examen de type de l'UE
Criteri di prova dell'omologazione UE
DIN EN 334 (01.07.2009)
DIN EN 14382 (01.07.2009)
Gültigkeitsdauer/Bescheinigung
Term of validity/attestation
Validité/certicat
Durata della validità/Attestazione
2024-09-12
CE-0085CP0256
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cato (Esame UE del tipo: modulo 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)
Monitoraggio del sistema QM (modulo D)
DVGW CERT GmbH
Josef-Wirmer-Straße 1-3
D-53123 Bonn, Germany
Notied Body number: 0085
B. Sc., MBA, Simon P. Dungs
Geschäftsführer / Chief Operating Ocer
Directeur / Amministratore
Urbach, 2019-04-01

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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/EU Declaration of conformity 2
4. Table of contents 4
5. List of abbreviations 5
6. Features 6
6.1 Technical data 6
6.2 Nomenclature 7
6.3 Adjustment ranges 7
6.4 Accuracy class / lock-up pressure class 8
6.5 Selection of regulator springs 9
6.6 Selection of SAV springs 9
6.7 Type plate 10
7. Function 11
8. Dimensions 12
9. Installation 14
9.1 General information 14
9.2 Installation instructions 15
9.3 Torque 15
10. Function integrated SAV 16
11. Setting 18
11.1 Regulator setting 18
11.2 SAV setting 19
11.3 Calculation example of set values 20
11.4 Replacement of regulator springs 21
11.5 Replacement of SAV springs 23
11.5.1 Spring exchange Wdso 23
11.5.2 Spring exchange Wdsu 23
12. Commissioning and decommissioning 24
12.1 General information 24
12.2 Leakage test 24
12.3 Commissioning / unlocking / control of the set values 25
12.4 Recommissioning 27
12.5 Decommissioning 27
13. Faults and their causes 27
14. Maintenance 29
14.1 General information 29
14.2 Maintenance instructions of the regulator 31
14.2.1 Preparation 31
14.2.2 Replacement of the working diaphragm 31
14.2.3 Replacement of the control plate / valve seat 35
14.2.4 Replacement of the compensation membrane 37
14.2.5 Replacement closing part SAV 38
14.3 Maintenance instructions of the SAV 40
14.3.1 Preparation 40
14.3.2 Removal of the ASE from the housing 40
14.3.3 Mounting of the ASE on the housing 41
14.4 Required tools 42
14.5 Leakage test 44
14.6 Recommended maintenance intervals 44
15. Spare parts 45
15.1 List of spare parts of the regulator 46
15.2 List of spare parts of the SAV 47
15.3 Storage conditions 48
16. Flow volume tables 49
16.1 Natural gas ow volume table 49
16.2 Air ow volume tables 50
16.3 Valve ow volume coecient KG 52

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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)
KGFlow 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/DS Type: integral strength range (IS) or dierential strength (DS)
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
(FRM 100...) / DS (FRM 250...)
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 65 80
ANSI 2.5’’ 3’’
Admissible pressure load FRM 250... 25 bar (2500 kPa)/ FRM 100... 10 bar (1000 kPa)
Max. inlet pressure FRM 250... 25 bar (2500 kPa)/ FRM 100... 10 bar (1000 kPa)
Outlet pressure range 90-4000 mbar (9-400 kPa)
Minimum dierential pressure
(MD)
350 mbar (35 kPa)
Minimum dierential pressure
(HD/UHD)
500 mbar (50 kPa)
Materials Main body housing: cast iron GGG 50
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
(FRM 100...) / DS (FRM 250...)
Response time ≤ 2s
Adjustment range
below Wdu
35-3000 mbar (3,5-300kPa)
Adjustment range
above Wdo
180-5000 mbar (18-500 kPa)
Materials Main body housing: cast iron GGG 50
Diaphragm housing: Aluminium
Diaphragms: NBR

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6.3 Adjustment range
6.2 Nomenclature
Example FRM 100080 MD/ SAV MD FRM 100 080 MD SAV MD
Type Spring-loaded medium pressure regulator
MOP 100 … 10 000 mbar
250 ... 25 000 mbar
Nominal diameter 065 DN 65
080 DN 80
Pressure range, outlet
pressure
MD Medium pressure
HD High pressure
UHD Ultra high pressure
Safety device SAV Integrated shut-o valve
Pressure range, trip pressure MD Medium pressure
HD High pressure
UHD Ultra high pressure
Flange type
ANSI
with standard PN-25
with ANSI 150 lbs
Type Connec-
tion
Ver-
sion
Accuracy
class*
[AC]
Lock-up
pressure
class* [SG]
Outlet pressure
range Wd
Under pressure monitoring
SAV
Over pressure monitoring
SAV
Wdu AG Wdo AG
FRM 100065 MD DN 65 MD AC 5/10** SG 10/20** 90-420 mbar
FRM 100065 HD DN 65 HD AC 5 SG 10 400-1500 mbar
FRM 250065 UHD DN 65 UHD AC 5 SG 10 1000-4000 mbar
FRM 100065 MD / SAV MD DN 65 MD AC 5/10** SG 10/20** 90-420 mbar 35-400 mbar AG 10 180-800 mbar AG 10
FRM 100065 HD / SAV HD DN 65 HD AC 5 SG 10 400-1500 mbar 150-1400 mbar AG 5 500-3500 mbar AG 5
FRM 250065 UHD / SAV UHD DN 65 UHD AC 5 SG 10 1000-4000 mbar 150-3000 mbar AG 5 1300-5000 mbar AG 5
FRM 100080 MD DN 80 MD AC 5/10** SG 10/20** 90-420 mbar
FRM 100080 HD DN 80 HD AC 5 SG 10 400-1500 mbar
FRM 250080 UHD DN 80 UHD AC 5 SG 10 1000-4000 mbar
FRM 100080 MD / SAV MD DN 80 MD AC 5/10** SG 10/20** 90-420 mbar 35-400 mbar AG 10 180-800 mbar AG 10
FRM 100080 HD / SAV HD DN 80 HD AC 5 SG 10 400-1500 mbar 150-1400 mbar AG 5 500-3500 mbar AG 5
FRM 250080 UHD / SAV UHD DN 80 UHD AC 5 SG 10 1000-4000 mbar 150-3000 mbar Ag 5 1300-5000 mbar AG 5
*Accuracy class / Lock-up pressure class to EN 334 **pd = 90-180 mbar: AC 10, SG 20; pd= 180-420 mbar: AC 5, SG 10

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6.4 Accuracy class / lock-up pressure class
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 essential
for the application in the eld. Therefore, the accuracy val-
ues 'control quality' and 'lock-up pressure class' that can be
guaranteed at a volume ow of 1:10 were determined. The
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
accuracy class for a given nominal value within the given operating temperature range).
AC values of the table mentioned above refer to the maxi-
mum admissible percentage deviation of the outlet pressure
from the set nominal value, at which Qmax ≤ 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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6.5 Selection of regulator springs
6.6 Selection of SAV springs
Specic set range, outlet pressure Wds
Spring colour Order
number
Wire diameter
[mm]
Length
[mm]
Diameter
[mm]
Setpoint range [mbar]
MD HD UHD
Blue 270347 8.0 300 65 90-140
Black 270348 9.0 300 68 120-185 400-550
Purple 270349 10.0 300 69 180-280 540-850 1000-1300
Orange 270350 11.0 300 71 250-420 800-1150 1100-1800
Pink 270352 12.0 300 73 1100-1500 1600-2500
Red 271132 14.0 300 77 2400-4000
Specic set range, underpressure Wdsu
Spring colour Order number Wire diameter
[mm]
Length
[mm]
Diameter
[mm]
Setpoint range [mbar]
MD HD UHD
Blue 270356 2.0 55 12.3 35-110
Black 270357 2.3 55 12.3 50-250
Purple 270358 2.5 55 12.3 80-400 150-500 150-500
Orange 270359 2.8 55 12.3 300-1000 300-1000
Silver 270360 3.0 60 15.0 800-1400 800-1400
Pink 276126 3.5 60 15.0 1200-3000
Specic set range, overpressure Wdso
Spring colour Order number Wire diameter
[mm]
Length
[mm]
Diameter
[mm]
Setpoint range [mbar]
MD HD UHD
Green 270366 2.5 60 30.0 180-270
Red 270367 2.7 60 30.0 230-370
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 1300-2500
Pink 270373 4.8 60 30.0 1800-3500 1800-3500
White 271115 5.0 60 30.0 2500-5000

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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
KGFlow 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/DS
FRM 100... IS (integral strength range) / FRM 250... DS (dierential strength)
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
Regulator SSD
Made in Barcelona / Spain
DIN EN14382/CE-0085CP0255
SAE:SAV100080MD
S.N.: 1PDK276115S00000000
IS class A AGu 10% AGo 10%
yyyy-mm-dd -20T60 DN80PN25
PS:10 bar / 1000 kPa
Wdo: 1,3 – 5 bar / 130–500 kPa
Wdu: 0,035 – 0,4 bar / 3,5 – 40 kPa
Wdsu: 0,05 –0,25 bar / 5 – 25 kPa
Wdso: 0,3 – 0,5 bar / 30 – 50 kPa
Made in Barcelona / Spain
DIN EN334/CE-0085CP0256
Regulator: FRM100080MD
S.N.: 1PDK276115S00000000
Kg 1150 / Medium CH4
IS fail-open SG 20% AC 5%
yyyy-mm-dd -20T60 DN80PN25
PS: 10 bar / 1000 kPa
Pin: 0,44 –10 bar / 44 –1000 kPa
Pout: 0,9 –0,42 bar / 9 – 42 kPa
Wds: 0,25 – 0,42 bar / 25 – 42 kPa
1PDK276115
S00000000
1PDK276115
S00000000
53
65
53
65
65
53
Regulator SSD
Made in Barcelona / Spain
DIN EN14382/CE-0085CP0255
SAE:SAV100080MD
S.N.: 1PDK276115S00000000
IS class A AGu 10% AGo 10%
yyyy-mm-dd -20T60 DN80PN25
PS:10 bar / 1000 kPa
Wdo: 1,3 – 5 bar / 130–500 kPa
Wdu: 0,035 – 0,4 bar / 3,5 – 40 kPa
Wdsu: 0,05 –0,25 bar / 5 – 25 kPa
Wdso: 0,3 – 0,5 bar / 30 – 50 kPa
Made in Barcelona / Spain
DIN EN334/CE-0085CP0256
Regulator: FRM100080MD
S.N.: 1PDK276115S00000000
Kg 1150 / Medium CH4
IS fail-open SG 20% AC 5%
yyyy-mm-dd -20T60 DN80PN25
PS: 10 bar / 1000 kPa
Pin: 0,44 –10 bar / 44 –1000 kPa
Pout: 0,9 –0,42 bar / 9 – 42 kPa
Wds: 0,25 – 0,42 bar / 25 – 42 kPa
1PDK276115
S00000000
1PDK276115
S00000000
53
65
53
65
3400

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11 … 56
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 direct acting
gas pressure regulator.
Main components
AControl plate
BControl plate shaft
CInlet pressure compensation diaphragm
D Lower diaphragm shell
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 D, since no
overpressure is applied in the outlet range. The resulting
downward movement of the working diaphragm causes
the control plate shaft B to be pushed downwards. In this
way, the control plate A is also moved downwards and
separated 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 D 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 working
diaphragm F causes the control plate shaft B to be pulled
upwards. In this way, the control plate A is also pushed
upwards and the valve gap is reduced. The ow volume
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 Fis
established.
If the outlet pressure drops, the force on the working
diaphragm F in the lower diaphragm shell D decreases
also. The working diaphragm F is, thus, pushed down-
wards until the force of the setpoint spring His equal to
that of the outlet pressure. The downward movement of
the working diaphragm F causes the control plate shaft B
to be pushed downwards. In this way, the control plate A
is also moved downwards and the valve gap is increased.
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 established.
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 C. The inlet
pressure is then transferred in the chamber below the inlet
pressure compensation diaphragm Cthrough 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 C, 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 top, has
the same size as the admission pressure compensation
diaphragm C, on which the inlet pressure acts from below.
Therefore, both forces cancel each other. The inlet pressure
balance at the regulator is ensured.
A
CE
H
F
B
G
D

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8. Dimensions
FRM...
A
C
D
E
B
Type Order
number
p max.
[bar / kPa]
DN Dimensions [mm] Weight
[kg]
ABC D E
FRM 100065 MD 277241 10 / 1000 65 500 276 120 567 892 56
FRM 100065 HD 277242 10 / 1000 65 380 276 120 567 892 50
FRM 250065 UHD 277243 25 / 2500 65 380 276 120 567 892 52
FRM 100080 MD 277244 10 / 1000 80 500 298 120 567 892 58
FRM 100080 HD 277245 10 / 1000 80 380 298 120 567 892 53
FRM 250080 UHD 277246 25 / 2500 80 380 298 120 567 892 55
B

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13 … 56
FRM... / SAV
Type Order
number
p max.
[bar / kPa]
DN Dimensions [mm] Weight
[kg]
ABC D E
FRM 100065 MD/SAV MD 273061 10 / 1000 65 500 276 135 567 892 71
FRM 100065 HD/SAV HD 276113 10 / 1000 65 380 276 135 567 892 65
FRM 250065 UHD/SAV UHD 276114 25 / 2500 65 380 276 135 567 892 67
FRM 100080 MD/SAV MD 276115 10 / 1000 80 500 298 135 567 892 73
FRM 100080 HD/SAV HD 276116 10 / 1000 80 380 298 135 567 892 68
FRM 250080 UHD/SAV UHD 276117 25 / 2500 80 380 298 135 567 892 70
A
C
E
D
B

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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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15 … 56
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 Vent line connection regulator
15 Vent line connection SAV
16 Relief line connection 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
7
911
10
12
Stabilisation section > 5 x DN
Installation drawing
13
15
14
16

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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
Mmax.
Tmax. Mmax.

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17 … 56
10. Function 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.
Main components
1 Shutter case
2Closing spring
3 Trigger mechanism
4 Chamber with the pressure to be monitored
5 Working diaphragm
6 Push rod
7 Setpoint spring for pdo
8 Setpoint spring for pdu
9 Protective cap
Function
Chamber 4 is connected to the outlet pressure via
a pulse line.
The pressure to be checked acts on the working diaphragm
5. The force of the setpoint springs 7 and 8 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.
1
2
3
4
5
6
7
9
8

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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 100065 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