IBEDA PVGD User manual

Instruction Manual Safety Device
EN 02/16/04
Testing Unit
PVGD
IBEDA Sicherheitsgeräte
und Gastechnik GmbH & Co. KG
Bahnhofstrasse 27
D-53577 Neustadt/ Wied
Phone [phone], Fax: -31
email: [email protected]
For further information:
www. ibeda.com
7540
-
0140.EN

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Contents
Preamble ............................................................................................................................ 4
Transport ............................................................................................................................ 4
Function.............................................................................................................................. 4
User´s Technical knowledge and instruction........................................................................ 5
Type designation .................................................................................................... 6
Operating elements............................................................................................................. 6
Safety information .................................................................................................. 7
Intended use ....................................................................................................................... 7
Non-intended use................................................................................................................ 7
Explanation of safety alert signals ....................................................................................... 8
Safety alert signals.............................................................................................................. 8
General Safety Instructions ................................................................................................. 9
Instructions ....................................................................................................................... 10
DGUV ............................................................................................................................... 10
Standards ......................................................................................................................... 10
Laws ................................................................................................................................. 10
Technical regulations ........................................................................................................ 10
Individual safety instructions.............................................................................................. 11
Installation............................................................................................................. 12
Operating instruction ......................................................................................................... 12
Setup Operation.................................................................................................... 13
Tests before starting operation.......................................................................................... 13
Operational check of the flow test:..................................................................................... 13
Operational check of the gas reverse flow test: ................................................................. 14
Operation............................................................................................................... 15
Preparations for testing ..................................................................................................... 15
Test time ........................................................................................................................... 16
Test for gas reverse flow ................................................................................................... 17
Flow rate limits: ................................................................................................................. 18
Test for flow rate ............................................................................................................... 18
Test of the pressure-sensitive cut-off valve........................................................................ 19
Test results ....................................................................................................................... 19
Switch off............................................................................................................... 20
End of working day............................................................................................................ 20
Maintenance .......................................................................................................... 20
Troubleshooting.................................................................................................... 20
Repair21
Shutdown .............................................................................................................. 21
End of working day............................................................................................................ 21
Disposal................................................................................................................. 21
Accessories........................................................................................................... 22
Special accessories .......................................................................................................... 23
Legal notice........................................................................................................... 24
Attachment ............................................................................................................ 25
Spare parts list .................................................................................................................. 25
Manufacturer's declaration ................................................................................................ 25

Instruction Manual Safety Device
EN 02/16/04
Preamble
With your Testing Unit PVGD you have purchased a quality product.
Please read through this user manual carefully before installing and us-
ing your Testing Unit. Its purpose is to enable you to use the gas supply
system safely and properly.
The German version of this user manual is deemed to be the original.
Transport
Transport and handling has to be done carefully by qualified staff with
appropriate equipment. Storage of work equipment (temporary) has to
be at a temperature of +5°C to +35°C and has to be kept free from dust
and moisture.
Please check the goods for transport damage upon receipt. It is not
approved for use with damaged components.
Function
The testing unit PVGD is for the annual testing of flashback arrestors as
per EN730-1, EN730-2/ DIN EN ISO 5175-1; DIN EN ISO 5175-2.
The function of the following safety features can be tested:
• gas non-return valve
• pressure sensitive cut-off valve
Additionally, a flow rate comparison (old/new) can be made. The unit is
capable of testing flashback arrestors with a maximum flow rate of
20m³/h at a inlet pressure of 0.15 MPa (1.5 bar) (free flow)
The testing unit can accommodate flashback arrestors with a maximum
length of 200 mm and a diameter up to 50 mm. For larger sizes, special
adapters are needed.

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User´s Technical knowledge
and instruction
Safety devices are only to be used by people over the age of 18, who
are physically qualified, have required knowledge and were instructed by
a qualified person. Documented training instruction is recommended to
be done at periodical intervals, at least once a year.
WARNING
Authorised persons are persons who have the required specialist
knowledge for testing the working materials through their professional
training, their professional experience and their contemporary
professional occupation.
(Germany Operational Safety Ordinance (TRBS 1203)

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Type designation
Operating elements
Position:
A1 Adjustable clamping device
A2 Fixed clamping device
B1 Connection for test adapters (Inlet)
B2 Connection for test adapters (Outlet)
C Adjusting wheel
D Locking Lever
E Funnel
F Reverse flow scale
G Drain screw
H Flowmeter
J Handwheel
L Throttle valve
M Connection Test Medium

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Safety information
This Testing Unit is in correspondence with the current state-of-the-art
and accepted technical rules as well as with requirements of current
standards and regulations.
WARNING
No modifications are allowed to be done without manufacturer’s
authorisation.
Intended use
This testing unit is just for the testing of the safety elements of flashback
arrestors. Only distilled water is to be used with the equipment as well as
100 µ filtered, dry and oil-free Compressed Air or Nitrogen (N2) as test-
ing medium.
The equipment may only be utilised for this stated purpose.
An intended use also includes the observance of all information in this
user manual, the adherence to recurring tests and the observance of the
type plates and the data sheets.
Non-intended use
Every use which goes beyond the intended use:
• e. g. use with other pressure, other media and fuel gas- Oxy-
gen/air mixtures.
• Use with gases in liquid phase is prohibited.
• Use at temperatures below -20° C° and above +70° C

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Explanation of safety
alert signals
Any information which is marked with a safety notice warns of danger
and has to be followed in order to avoid injuries and damages.
Safety alert signals
DANGER
Imminent danger!
Death or severe injuries can result from non-observance.
WARNING
A possibly dangerous situation!
Death or severe injuries can result from non-observance.
CAUTION
A dangerous situation!
Death or severe injuries can result from non-observance.
NOTICE
Notice for proper handling.
Device error can result from non-observance

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General Safety Instructions
WARNING
The local legislation has to be considered.
Regarding the (Germany) Betr.SichV, part 2, §12 the operator has
to display the user manual
WARNUNG
Regarding the (Germany) DGUV rule 100-500 paragraph 2.33 it is
only allowed for skilled people to operate gas manifold systems.
Skilled people are instructed in:
Knowledge of handling dangerous gases
Knowledge of handling the instruction manual
Knowledge of the safety instructions
Knowledge of first aid
Knowledge of how to use the personal protective equipment
The date of the user's instruction has to be documented in writing.
The user has to confirm his instruction by signature.

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Instructions
Please follow the local national instructions, standards and laws
(for Germany as follows):
2014/34/9/EU Equipment and protective systems intended for use in potentially explo-
sive atmospheres (recast) (ATEX-Directive)
2006/42/EG Machinery Directive
2014/68/EU Pressure Equipment Directive
2014/30/EU Electromagnetic compatibility
DGUV
(German Employers' Liability Insurance Association Rules and Regulations)
Rule 100-500, Chap.2.26 Welding, cutting and related processes
Rule 100-500, Chap.2.33 Gases
Standards
DIN EN ISO 3821 Rubber hoses
DIN EN 560 Hose connections
DIN EN 561 Quick-action couplings
DIN EN ISO 5171 Pressure gauge
DIN EN ISO 5175-1 Safety devices incorporating a flame (flashback) arrestor
DIN EN 730-2 Safety devices not incorporating a flame (flashback) arrestor
DIN EN ISO 5175-2 Safety devices not incorporating a flame (flashback) arrestor
DIN EN ISO 2503 Pressure regulator for gas cylinders up to 300 bar
EN ISO 14114 Acetylene cylinders - Manifolds
DIN EN ISO 9090 Gas tightness
DIN EN ISO 9539 Materials
Laws
ProdSG Product Safety Act
BetrSichV Ordinance on Industrial Safety and Health
GefStoffV Ordinance of Hazardous Substances
BlmSchG German Federal Emissions Protection Law
Technical regulations
TRG Technical regulations pressure gases
DVS-Data-Sheet DVS 0221, DVS 2307, DVS 2314, DVS 2304, DVS 2312 etc.