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.

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Individual safety instructions
DANGER
• Risk of explosion: All components on the flame spray systems
are to be kept free of oil, grease and other contaminants.
• Do not wear clothing that has been contaminated with oil or
grease. Be sure your hands are clean. Do not use and oint-
ments or gels.
• No access for unauthorised persons!
WARNING
• Check screw connections for leak tightness at the prescribed
intervals.
• The tested sealing materials in the valves and system parts
may not be replaced with other materials or products from oth-
er
manufacturers without being tested again.

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Installation
The Testing Unit is supplied ready for installation.
Ensure that the test unit is on a flat, sturdy surface.
Only the following test media are to be used:
• distilled water
• 100 µ filtered, dry and oil-free Compressed Air
or Nitrogen N2
with an inlet pressure between 0,4 and
0,7 MPa
(4
and 7 bar)
Operating instruction
• Fill distilled water into the plastic bottle that is delivered with
the spare parts kit.
• Turn the hand wheel (Item J) to position „off“.
• Connect the test item with suitable adapters (Item M).
• Fill distilled water into the funnel tube (Item E) at the top of the
glass tube scale for reverse flow (Item F). Excess water level
can be released by the brass tap (Item G) at the bottom of the
glass tube.
• Fit the plastic adapter (Pos. 410 - 412) to the connector (Item
B1) and the rubber adapter (Pos. 420) to the connector (Item
B2) of the clamping device (Item A1 and A2)

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Setup Operation
Each time before commissioning, a functional test must be carried out.
The connections and test adapters must be checked for damages and
gas tightness. The leak test must be done with a suitable leak detector
spray.
Tests before starting operation
Operational check of the flow test:
• Push the clamping device (Item A1 and Item A2)together
when having the adapters fitted but without having a test item
connected.
• Secure with the locking lever (Item D) and slightly close (short-
circuit) the adjusting wheel (Item C).
• Set the handwheel (Item J) on the front panel to the "gas flow"
position.
• Adjust the knurled screw of the throttle valve (Item L) on the
upper side of the device until the ball of the flow meter (Item
H) is suspended with the lower edge at the height of the scale
graduation "9". If the ball is not in the above-mentioned posi-
tion, the device must be checked by the manufacturer.
The verification of the function for the flow test and for the pressure-
sensitive cut-off valve test is complete.
ball

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Operational check of the gas reverse flow test:
• Set the handwheel (Item J) to the "CLOSED" position.
• Loosen the clamping device (Item A1 and Item A2)via the ad-
justing wheel (Item C) until a gap of 1 to 2 mm is set between
the connecting adapters (Item B).
• Set the handwheel (Item J) to the "REVERSE FLOW" posi-
tion.
• Check the water level of the gas reverse flow scale (Item F).
The upper edge of the float is at the height of the lower edge of
the recessed green marking. If the water level is too low, fill
with distilled water using the funnel (Item E). If the water level
is too high, drain the excess water via the drain screw (Item G)
• Now reduce the gap between the connecting adapters (Item
B) via the adjusting wheel (Item C) until the water level rises
on the gas reverse flow scale (Item F).
NOTE
Attention!Do not close the gap between the adapters completely
because otherwise a water loss will occur owing to rising bubbles.
The correct functioning is given if it is possible to exceed the green mark-
ing in approx. 5 seconds.
• Set the handwheel (Item J) to "CLOSED" position to complete
the function test
Float „Green“ Marking

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Operation
The safety devices have to be tested by a qualified and authorized per-
son at regulator intervals according to country specific regulations. They
have to be tested for gas tightness and gas return at least once a year.
The test results have to be recorded.
Preparations for testing
Test pieces of up to approx. 200 mm length and 50 mm diameter can be
tested by means of the test adaptors (Item B1and B2).
Samples of test adapters:
Inlet (Item B1) Test piece Outlet (Item B2))
Adapter Pos.-No. Direction of flow Adapter Pos.-No.
410 - 412
DGN
420
420
GG
410 - 412
410 - 412
DGNDK
440 - 451
(For the Pos.-Nos. please see section „Accessories–Standard accesso-
ries“)
For bigger test pieces, adapter with pair of hoses and coupling (Pos.465)
can be connected to the clamping device (Item A1 and A2). Once it is
connected, fix it with the locking lever (Item D).
Fit the test pieces by means of the pairs of connectors Pos.-No. 482 -
487 which are to be connected to the hose couplings.
For special designs, individual connectors are available, Pos.-No. 471-
481.

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NOTICE
Observe the flow direction!
The test piece is clamped in directly or via test adapter so that its
flow direction conforms with that of the test device.
NOTICE
Only 100 µfiltered, dry, oil-free compressed air or Nitrogen (N2),
with an input pressure of between 0,4 and 0,7 MPa (4 and 7 bar),
may be used as the test medium.
Use distilled water.
Test time
The following test times are to be considered when testing the gas re-
turn:
Nominal
diameter
Thread size Test time Model
≤ DN15
bis G1/2
30 sec
DGN; DG; DGNK;
DGNDK;
DS1000; DG-U; DG-
U-DK
GG, GT, TT, NKST,
NKSG,
DKST, DKSG, SRT,
SR, SHT;
DG91N; DG91;
DG91UA;
DS2000;
> DN15 ≤ DN32
G1/2 bis G1 1/4
15 sec.
DEMAX; SIMAX;
ESF-N;
ESF; GRS; GRV
> DN32 ≤ DN50
G1 1/2 bis G2
10 sec.
SIMAX4-20; GRS;
GRV;
ESF
The gas return test has passed if the ball inside the glass tube does not
go beyond the green marking during the given test time.

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Test for gas reverse flow
• Set the handwheel (Item J) to the "CLOSED" position.
• Connect the test piece to the clamping device (Item A1 and
Item A2)directly or via a test adapter. Please ensure that the
flow direction of the test piece and the testing equipment is the
same.
• Push the clamping device (Item A1 and Item A2)together,
secure with the locking lever (Item D) and turn the adjusting
wheel (Item C) until the test piece is tightly clamped.
Now start the test:
• Set the handwheel (Item J) to "GAS REVERSE FLOW".
• Read the test result on the gas reverse flow scale (Item F):
No gas reverse flow or permitted gas
reverse flow
has occurred if the "green" marking of the reverse flow scale
(Item F) is not exceeded by the water level set to the lower
edge. Please see the table „test time“ for the test times appli-
cable for the individual models.
Gas reverse flow
has occurred if the upper edge of the marking is reached with-
in a time period stated in the table.

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Flow rate limits:
The limits specified here for the individual types are guidelines.
The test pieces should indicate a flow rate that is greater than or equal to
the limit.
Series Model Limit*
100 DGN, DG, DGNK, DGNDK,
DS1000, DG-U, DG-U-DK
ca. 5,0
200 GG, GT, TT, NKST, NKSG,
DKST, DKSG, SRT, SR, SHT
ca. 4,5
300 DG91N, DG91, DG91UA ,
DS2000
ca. 6,5
GRS, GRV, ESF, ESF-N,
DEMAX, SIMAX, SIMAX4-20
No test for gas flow
* The value is read at the lower edge of the ball on the flow meter.
Test for flow rate
• Set the handwheel (Item J) to "THROUGH FLOW".
• The flow rate value can now be read on the flow meter (Item
H).
The limits for too low flow rates depend on the type of test piece and are
listed in the above table.
The specifications relate to the lower edge of the float.
Complete test:
• Set the handwheel (Item J) to "CLOSED"
• Loosen the adjusting wheel (Item C) until the test piece can be
removed.

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Test of the pressure-sensitive
cut-off valve
• Insert the test piece (DS2000/DS1000) into the clamping de-
vice (Item A1 and Item A2) opposite to the flow arrow.
• Push the clamping device (Item A1 and Item A2)together,
secure with the locking lever (Item D) and turn the adjusting
wheel (Item C) until the test piece is tightly clamped.
Now start the test:
• Set the handwheel (Item J) to "THROUGH FLOW".
The pressure set in the PVGD increases to 0.12 MPa (1.2
bar) and the safety device comes into operation.
Complete test:
• Set the handwheel (Item J) to the "CLOSED" position.
• Turn the adjusting wheel (Item C) until the test piece can be
removed.
Test results
Test for gas reverse flow has not been passed:
The safety device has to be exchanged.
Test of the pressure sensitive shut-off valve has not been passed:
The safety device has to be exchanged.
Flow test – Flow rate is not sufficient:
The safety device has to be exchanged.
All tests passed:
The safety device can still be used
NOTE
Before commissioning the tested safety devices, they must be
checked for tightness.
• This tightness check must be carried out when installed and with
maximum operating pressure.
• The safety device is sprayed with leak detector spray. No bub-
bles must form.

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Switch off
End of working day
1. Set the handwheel (Item J) to the "CLOSED" position
2. Close the supply of the test medium (nitrogen/compressed air).
Release the pressure and loosen the connection to the test
equipment (Item M).
3. Drain the distilled water via the drain screw (Item G) of the gas
reverse flow scale (Item F).
Maintenance
The testing unit PVGD is maintenance-free.
However, the way of testing, as well as the extent and the test period,
which is applicable to the work equipment or to systems requiring in-
spections, must comply with the operator’s risk assessment or safety
evaluation.
(For Germany the BetrSichV and TRBS1201 are applicable)
The test adapters must be checked for damages and gas tightness be-
fore starting operation.
Troubleshooting
• No functional test is possible
The test equipment is not operational:
Check the connection and the adapter of the test medium.
There is no water in the gas reverse flow scale.
The handwheel is in the "CLOSED" position.