Dungs FRSBV 10010 Series User manual

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User Manual
FRSBV 10010… / 20010…
FRSBV 5010… / 10005…
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

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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 and 2nd 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.
3.Certication/ EUdeclarationofconformity
• 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.

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EUdeclarationofconformity
B. Sc., MBA, Simon P. Dungs
Chief Operating Ocer
Urbach, 2020-06-08
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 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.
SpeciedrequirementsoftheEUtype-examination DIN33821(01.03.2009)
Termofvalidity/attestation 2029-11-13
19-0709-GDE
NotiedBody(EUtype-examination:ModuleB) DVGWCERTGmbH
Josef-Wirmer-Straße 1-3
D-53123 Bonn, Germany
Notied Body number: 0085
MonitoringoftheQMsystem(module D) DVGWCERTGmbH
Josef-Wirmer-Straße 1-3
D-53123 Bonn, Germany
Notied Body number: 0085

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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. Certication/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 Spring selection 8
6.5 Rating plate 9
7. Function 10
8. Dimensions 11
9. Installation 12
9.1 General information 12
9.2 Description of installation 13
9.3 Torques 14
10. Adjusting the triggering pressure 15
10.1 Spring replacement 16
10.2 Tools required 17
11. Flow tables 17

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5. List of abbreviations
Abbreviation Description
AC Accuracy class
SG Closing pressure group
KGFlow coecient
Rp Threaded connection
ClassA Safety pressure relief valve breather line, depending on the pressure relief line.
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

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6. Features
6.1. Technical data
Technical data FRSBV …
Device Safety pressure relief valve according to DIN 33821
Type FRSBV 10010… / 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 10010… 10 bar (1 000 kPa)
FRSBV 20010… 20 bar (2 000 kPa)
Trigger range 200 mbar to 8 bar (20-800 kPa)
Materials Main housing: Aluminium Al 2011 (FRSBV 100…) / steel F-114 (FRSBV 200…)
Diaphragm housing: Aluminium Al 2011 (FRSBV 100…) / 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 10005…
Typeofgas Family 1+2+3
Nominal diameters
Thread
Connecting threads according to BSP (ISO 228/1) or NPT (B1.20.1)
G ½" NPT ½"
Input pressure FRSBV 10005… 10 bar (1 000 kPa)
Trigger range 10 mbar to 5 bar (1-500 kPa)
Materials Main housing: Zamak Z-5
Diaphragm housing: Zamak Z-5
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 32 mbar to 2 bar (3.2-200 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

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6.2 Nomenclature
Using the FRSBV 10010 HD
as an example
FRSBV 100 10 HD NPT
Type Pressure relief valve
MOP 50 … 5 bar
100 … 10 bar
200 … 20 bar
Nominal diameter 05 G½"
10 G1"
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 10005 ND G½" ND 289261 SG 20 10-350 mbar
FRSBV 10005 HD G½" HD 289262 SG 10 100-5 000 mbar
FRSBV 5010 ND G1" ND 289263 SG 10 32-2 000 mbar
FRSBV 10010 HD G1" HD 289264 SG 10 200-8 000 mbar
FRSBV 20010 HD G1" HD 289265 SG 10 200-8 000 mbar
FRSBV 10005 ND NPT NPT ½" ND 289266 SG 20 10-350 mbar
FRSBV 10005 HD NPT NPT ½" HD 289267 SG 10 100-5 000 mbar
FRSBV 5010 ND NPT NPT 1" ND 289268 SG 10 32-2 000 mbar
FRSBV 10010 HD NPT NPT 1" HD 289269 SG 10 200-8 000 mbar
FRSBV 20010 HD NPT NPT 1" HD 289270 SG 10 200-8 000 mbar

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Setpoint range for springs FRSBV 10010… / 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
Green 290940 1.0 60 20 32-38
Red 290941 1.1 60 20 35-45
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 20 570-900
Brown 290949 3.0 50 20 750-1 300
Silver 290950 3.5 45 20 1 250-1 700
Grey 290951 3.8 45 20 1 600-2 000
6.4 Spring selection
Setpoint range for springs FRSBV 10005…
Spring colour Replacement
item number
Wire diameter
[mm]
Length
[mm]
Diameter
[mm]
Setpoint range [mbar]
ND HD
Green 290932 1.8 58 35.8 10-25 100-135
Black 290933 2.0 58 35.8 20-55 130-160
White 290934 2.4 58 35.8 40-120 155-240
Pink 290935 3.0 58 35.8 60-220 220-450
Blue 290936 3.5 58 35.8 150-350 400-1 000
Silver 290937 4.0 58 35.8 800-1 800
Red 290938 4.5 58 35.8 1 200-2 500
Purple 290939 5.5 58 35.8 2 200-5 000

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6.5 Rating plate
Abbreviation Description
SG Closing pressure
AC Accuracy class
AG Response pressure group
Rp Thread diameter
-20T60 Operating temperature range
ClassA Functional class: The FRSBV is a safety valve with separate vent and safe relief connections.
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

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7. Function
The FRSBV type safety valve isa safetypressurereliefvalve
(SBV) with an adjustable response pressure. The response
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

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FRSBV …
8. Dimensions
A
C
D
E*
B
F
A
C
F
B
D
E*
* Space required for changing the spring
A
C
F
B
D
E*
FRSBV 5010…
FRSBV 10010… /
20010…
FRSBV 10005…
Type Item number p max.
[bar / kPa]
Thread
G
Dimensions [mm] Weight
[kg]
BSP NPT A B CD E F
FRSBV 10005 ND 289261 289266 10 / 1 000 ½" 116 75 18 111 211 G¼" 0.56
FRSBV 10005 HD 289262 289267 10 / 1 000 ½" 116 75 18 111 211 G¼" 0.56
FRSBV 5010 ND 289263 289268 5 / 500 1" 100 112 22 127 227 G¼" 0.89
FRSBV 10010 HD 289264 289269 10 / 1 000 1" 112 60 28 197 297 G¼" 2.50
FRSBV 20010 HD 289265 289270 20 / 2 000 1" 112 60 28 197 297 G¼" 6.15

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9.Installation
9.1Generalinstructions
• Installationonlyinaccordancewith
applicable policies and subject to
compliance with local regulations,
obtain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.

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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

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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

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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.
(+)

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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.

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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 Item number Width across the pipe
socketspannerats
FRSBV 10005 ND 289261 SW 27
FRSBV 10005 HD 289262 SW 27
FRSBV 5010 ND 289263 SW 14
FRSBV 10010 HD 289264 SW 30
FRSBV 20010 HD 289265 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

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Flowtables∆pFRSBV10005ND
0 5 10 15 20
100
200
300
400
500
600
112 mbar
18 mbar
206 mbar
300 mbar
Vn [m3/h] natural gas dv = 0.65
Input pressure [mbar]
Flowtables∆pFRSBV10005ND
20 40 60 80 100
1 000
2 000
3 000
4 000
5 000
6 000
7 000
8 000
5 000 mbar
3 393 mbar
1 787 mbar
180 mbar
0
Vn [m3/h] natural gas dv = 0.65
Input pressure [mbar]

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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
30 mbar
Vn [m3/h] natural gas dv = 0.65
Input pressure [mbar]
Flowtables∆pFRSBV10010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]

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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.
Safety-relevantcomponents Design related operating life CENstandard
Cyclenumber Time duration
[years]
Valve test systems 250 000 10 EN 1643
Gas pressure controller 50 000 10 EN 1854
Air pressure monitor 250 000 10 EN 1854
Gas failure switch N/A 10 EN 1854
Combustion manager 250 000 10 EN 298 (gas)
EN 230 (oil)
UV ame sensor 1N/A 10 000
operating hours ---
Gas pressure regulators 1N/A 15 EN 88-1
EN 88-2
Gas valve with valve test system 2After error detected EN 1643
Gas valve without valve test system 2
50 000-200 000
Depending
on the diameter
10 EN 161
Control system for gas and air supply N/A 10 EN 88-1
EN 12067-2
1 Decreasing performance on account of ageing
2 Gas families I, II, III
N/A not applicable
It is therefore necessary to replace
safety-relevant components once
their service life has elapsed.
Subject to technical modication in the interest of technical progress.
KarlDungsGmbH&Co.KG
Karl-Dungs-Platz 1
D-73660 Urbach,
Germany
Telephone +49(0)7181-804-0
Telefax +49(0)7181-804-166
E-mail:[email protected]
Internet:www.dungs.com
Headquartersaddress:
Karl Dungs, S.L.U.
Av.CanRoqueta15
Pol.Ind.CanRoqueta
E-08202 Sabadell,
Barcelona / Spain
Telephone [phone]
E-mail:info[email protected]
Internet:www.dungs.com
Subsidiary