Krom Schroder GDJ 15 User manual

2.1.1.2 Edition 12.10
DK S N P GR
➔ www.docuthek.com
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TR CZ PL RUS H
© 2008 – 2009 Elster GmbH
Please read and keep in a safe place
Please read through these instructions
carefully before installing or operating. Follow-
ing the installation, pass the instructions on to the
operator. These instructions can also be found at
www.docuthek.com.
Explanation of symbols
• , 1 , 2 ,  ... = Action
 = Instruction
Liability
We will not be held liable for damages resulting
from non-observance of the instructions and non-
compliant use.
Safety instructions
Information that is relevant for safety is indicated in
the instructions as follows:
DANGER
Indicates potentially fatal situations.
WARNING
Indicates possible danger to life and limb.
CAUTION
Indicates possible material damage.
All interventions may only be carried out by qualified
gas technicians. Electrical interventions may only be
carried out by qualified electricians.
Conversion, spare parts
All technical changes are prohibited. Only use OEM
spare parts.
Transport
On receipt of the product, check that the delivery is
complete (see Part designations). Report any trans-
port damage immediately.
Storage
Store the product in a dry place. Ambient tempera-
ture: see Technical data.
Operating instructions
Translation from the German
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Safety
Contents
Gas pressure regulators 60DJ,
J78R, GDJ
Gas pressure regulators 60DJ, J78R, GDJ . . 1
Contents ..............................1
Safety.................................1
Checking the usage . . . . . . . . . . . . . . . . . . . . . 2
Intended use ...........................2
Type code 60DJ.........................2
Type code J78R.........................2
Type code GDJ..........................2
Part designations........................2
Installation ............................2
Tightness test..........................
Changing the outlet pressure pa ..............
Maintenance...........................
Replacing the spring on J78R, GDJ . . . . . . . . 4
Replacing the diaphragms on J78R, GDJ . . . 4
Technical data..........................5
Declaration of conformity . . . . . . . . . . . . . . . 6
Spring table............................7
Contact ...............................8

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Checking the usage
Intended use
Gas pressure regulators 60DJ, J78R and GDJ serve
to maintain a constant outlet pressure p
a
despite
changing gas flow rates and inlet pressures p
e
in
gas pipelines.
This function is only guaranteed when used within
the specified limits – see [Technical data – p.5]. Any
other use is considered as non-compliant.
Type code 60DJ
Code Description
60DJ Gas pressure regulator
LFor air only (without approval)
ZSet to 80 mbar
Type code J78R
Code Description
J78R Gas pressure regulator
0
1
Without measuring connection
Screw plug at the inlet
-L For air only (without approval)
Type code GDJ
Code Description
GDJ Gas pressure regulator
15 – 50 Nominal size
RRp internal thread
04 pe max. 400 mbar
-0
-4
Without measuring connection
Pressure test nipple at the inlet
LFor air only (without approval)
Part designations
60DJ
1
3
4
5
6
2
J78R, GDJ 15
GDJ 20–50
1
3
4
5
6
6
2
7
1
3
4
5
6
6
2
7
1 Cover cap and adjusting screw
2 Type label
 Breather orifice
4 Inlet
5 Outlet
6 Arrow of direction of flow
7 Measuring connection for inlet pressure pe
Inlet pressure pe, outlet pressure pa and adjusting
range: see type label.
www.kromschroeder.com
D-49018 Osnabrück, Germany
GDJ
Installation
CAUTION
Please observe the following to ensure that the
gas pressure regulator is not damaged during in-
stallation:
Install the unit free of mechanical stress.
Sealing material, cuttings and other impurities must
not be allowed to get into the regulator housing.
The installation location must be dry. Do not install
the unit in the open air.
Installation in the vertical or horizontal position,
never upside down.
 The outlet pressure p
a
is set at the factory with the
spring dome pointing vertically upwards. If the
gas pressure regulator is installed with the spring
dome in the horizontal position, check and adjust
the outlet pressure pa, see [Changing the outlet
pressure pa – p.3].
1 Install a filter upstream of the unit, in order to
protect it against impurities in the pipe.
 The housing must not be in contact with masonry,
minimum distance 20 mm.
2 Remove the screw caps.
 Note direction of flow: see arrow on the housing.
 Install using approved sealing material.
 Use an appropriate spanner – do not used the
spring dome as a lever.

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Tightness test
Also after maintenance.
1 Block the pipeline at the inlet and outlet.
60DJ
2 Slowly apply inlet pressure pe – max. 100mbar.

To apply pressure, use a hand pump at the meas-
uring connection of a neighbouring device.
 Since the 60DJ does not have zero shut-off, the
outlet pressure does not need to be applied
separately.
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7 Relieve the inlet pressure pe.
J78R, GDJ
2 Slowly apply inlet pressure pe.
(pe: ≤ 1.5 × pe max., see type label)
 Slowly apply outlet pressure pa.
(pa: ≤ 1.5 × pa max., see type label)
 To apply pressure, use a hand pump at the meas-
uring connections of the pressure regulator or
at the measuring connections of neighbouring
devices.
CAUTION
First apply the inlet pressure pe – then the outlet
pressure pa.
The inlet pressure pe must always be equal to or
higher than the outlet pressure pa.
In the event of non-compliance with the sequence,
the compensation diaphragm will reverse.
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8 Relieve the outlet pressure pa.
9 Relieve the inlet pressure pe.
Changing the outlet pressure pa
1 Measure the outlet pressure pa.
2 Remove the cover cap.
 Turn the setpoint adjuster:
60DJ,
J78R,
GDJ 15
GDJ 20–50 3 mm
 Clockwise: higher outlet pressure,
anti-clockwise: lower outlet pressure.
4 Clearly mark the adjusted value on the regulator.

If the required outlet pressure p
a
cannot be ad-
justed on J78R or GDJ, see [Replacing the spring
on J78R, GDJ – p.4]. No other springs are avail-
able for the 60DJ.
5 Replace the cover cap.
Maintenance
In order to ensure smooth operation: check the func-
tion annually, or every six months if operated with
biologically produced methane.
1 Request different outputs on the burner in order
to change the flow rate.
2 Close the manual valve at the inlet a little in order
to change the inlet pressure pe.
 Despite changing flow rates and inlet pressures
pe (within the capacity range of the pressure
regulator), the outlet pressure p
a
must remain
constant (±15%).
J78R, GDJ only
 Reduce the capacity to low-fire rate and close
the valve downstream of the pressure regulator.
 Approx. 30 seconds after the valve has been
closed, the outlet pressure p
a
should not increase
significantly.
All types
Check the tightness of the pressure regulator during
operation to detect possible leaks due to hardened
rubber materials.

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6 If a leak is found, replace the rubber materials –
see [Replacing the diaphragms on J78R, GDJ
– p.4].
7 Then check for tightness once again.
Replacing the spring on J78R, GDJ
Various outlet pressure ranges can be reached by
using different springs on J78R and GDJ:
1 Choose a spring according to the outlet pressure
range – see [Spring table – p.7].
2 Remove the cover cap.
J78R, GDJ 15
53 4
GDJ 20 – 50
WARNING
The taut spring can pop out when opening the
spring dome and lead to injury. Therefore, decom-
press the spring as far as it will go before open-
ing. Then turn back 5 x to relax the spring counter
bearing.
3 mm
5x
2
1
53 4
76
8 Insert new spring.
9 Follow the reverse procedure when reassembling.
All types
10 Set the outlet pressure – see [Changing the outlet
pressure pa – p.3].
11 Replace the cover cap.
12 After inserting the spring, take the spring’s label
from the packaging and stick it below the type
label on the pressure regulator.
1 Clearly mark the adjusted value of the outlet pres-
sure pa on the type label.
Replacing the diaphragms on J78R,
GDJ
Diaphragms and seals are subject to ageing, espe-
cially in the case of long-term use in the upper ambi-
ent temperature range. Spare parts can be found on
the “PartDetective” DVD.
 On the 60DJ, replace the complete pressure
regulator.
1 Shut off the gas supply.
J78R, GDJ 15
GDJ 15
6 7
42 3
5
11 1210
14 1513
98
16 Replace all diaphragms and sealing elements,
except the valve seat.
17 Follow the reverse procedure when reassembling.

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GDJ 20 – 50
3 mm
5x
2
1
1
2
6 7
42 3
5
11 12
10
14 15
16 17
13
98
18 Replace all diaphragms and sealing elements.
19 Follow the reverse procedure when reassembling.
All types
20 Check tightness and function – see [Maintenance
– p.3].
21 Set the outlet pressure – see [Changing the outlet
pressure pa – p.3].
22 Replace the cover cap.
Technical data
Types of gas: town gas, natural gas, LPG (gase-
ous) and biologically produced methane, 60DJ L,
J78R..L and GDJ..L for air only.
Pressure regulator to EN 88, Class A, Group 2
Ambient temperature: -20 to +60°C.
Housing: aluminium,
diaphragms: Perbunan.
60DJ Z
Inlet pressure pe: max. 100 mbar.
Outlet pressure pa: 35 – 90 mbar, set to 80mbar.
Weight: 0.11 kg.
Connecting thread: Rp 1/4 to ISO 7-1, DN 8.
Valve seat: POM,
valve disc: POM.
J78R
Measuring connection with screw plug Rp 1/8 at
the inlet on the right-hand side (option).
Inlet pressure pe: up to 100 mbar.
Outlet pressure pa: 6 – 55 mbar.
The outlet pressure pa is adjusted by inserting dif-
ferent springs, see [Spring table – p.7]. It is pre-set
at the factory to 20 mbar (black spring).
Weight: 0.52 kg.
Connecting thread: Rp 1/2 to ISO 7-1, DN 15.
Valve seat: Perbunan,
valve disc: POM.
GDJ
Inlet pressure pe: up to 400 mbar.
Outlet pressure ranges:
GDJ 15: 2 – 55 mbar,
GDJ 20 to 40: 5 – 160 mbar,
GDJ 50: 5 – 100 mbar.
The outlet pressure range is reached through the
use of different springs, see [Spring table – p.7].
The regulators are pre-set at the factory to 20
mbar.
Control range: 10:1.
Connecting thread: Rp to ISO 7-1.
Valve seat: aluminium,
valve disc: Perbunan.
Service life
The Pressure Equipment Directive (PED) and the
Energy Performance of Buildings Directive (EPBD)
demand regular checks on and maintenance of
heating systems, in order to ensure a high level of
use in the long term, a clean method of operation
and safe function.
The service life on which the construction is based,
hereinafter referred to simply as the “service life”,
is compiled from the relevant standards. You can
find further explanations in the applicable rules and
regulations and on the afecor website (www.afecor.
org).
This information on service life is based on using
the product in accordance with these operating
instructions.

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The product must be serviced at regular intervals.
Once the specified service life has been reached,
the safety-related functions must be checked in
accordance with the section entitled [Maintenance
– p.3].
If the product passes the aforementioned function
tests, you can continue to use it until the next
scheduled maintenance operation. At this point,
these tests must be repeated.
If the product fails one of the aforementioned tests,
it must be replaced immediately.
This procedure applies to heating systems. For
thermoprocessing equipment, observe national
regulations.
Service life (based on date of manufacture) in
accordance with EN 13611 and EN 88 for 60DJ,
J78R and GDJ: 15 years.
Long-term use in the upper ambient temperature
range accelerates the ageing of the elastomer ma-
terials and reduces the service life (please contact
manufacturer).
Declaration of conformity
We, the manufacturer, hereby declare that the prod-
ucts 60DJ, marked with product ID No. C87AO7,
J78R, marked with product ID No. C87AO6, and
GDJ, marked with the product ID No. CE-0087AO22,
comply with the requirements of the listed Directives
and Standards.
Directives:
– 90/396/EEC
Standards:
– EN 88
The relevant products correspond to the type tested
by the notified body 0087.
 The air pressure regulators 60DJ L, J78R..L and
GDJ..L are not subjected to this Directive.
The production is subject to the surveillance pro-
cedure pursuant to DIN EN ISO 9001 according to
annex II, paragraph 3 of Directive 90/396/EEC.
Elster GmbH
Scan of the Declaration of conformity (D, GB) –
see www.docuthek.com

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Spring table
Outlet pressure pa
[mbar] Marking D [mm] d [mm] L [mm] Coils Order No.
J78R
6 – 9 green/red 21.8 1.2 40 12.5 03089041
9 – 17 yellow 21.8 1.2 42 10 03089042
15 – 23* black 22.6 1.2 54 11.5 03089043
22 – 31 orange 21.8 1.2 64 11 03089044
31 – 42 brown 22.0 1.3 65 10.5 03089045
42 – 55 light green/light blue 20.9 1.4 40 6.5 03089047
GDJ 15
2 – 6 yellow 21.8 1.2 42 10 03089075
10 – 20 black 21.6 1.2 54 11.5 03089076
16 – 28* orange 22.6 1.2 64 11 03089077
22 – 40 brown 22.0 1.3 65 10.5 03089078
40 – 55 light green/light blue 20.9 1.4 40 6.5 03089079
GDJ 20, GDJ 25
5 – 15 yellow 36 1.6 66.2 6.2 03089048
12.5 – 25* black 36.0 2.0 76 11 03089049
22.5 – 35 orange 35.8 1.8 99 9.7 03089050
25 – 75 yellow/black 35.8 2.3 68 5.5 03089051
70 – 100 pink/gold 36.0 2.5 80 7 03089052
90 – 160 yellow/orange 36.3 2.8 74 5.25 03089080
GDJ 40
5 – 15 red/yellow 36.2 2.2 84 12.5 03089053
12.5 – 25* red/black 36.3 2.3 89 10.5 03089054
22.5 – 35 red/orange 36.3 2.3 119 12 03089055
25 – 75 yellow/orange 36.3 2.8 74 5.25 03089056
70 – 100 pink/silver 36.6 2.8 100 7 03089057
90 – 160 grey/gold 36.6 3.1 98 5.75 03089081
GDJ 50
5 – 15 dark blue/yellow 36.6 2.6 80 10.5 03089058
12.5 – 25* dark blue/black 36.6 2.6 90 10 03089059
22.5 – 35 dark blue/orange 36.6 2.6 118 11 03089060
25 – 75 yellow/dark green 36.5 3.0 87 5.8 03089061
70 – 100 grey/gold 36.6 3.1 98 5.75 03089062
* Standard spring

Elster GmbH
Postfach 28 09, D-49018 Osnabrück
Strotheweg 1, D-49504 Lotte (Büren)
T [phone]
F [phone]
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If you have any technical questions, please contact
your local branch office/agent. The addresses are
available on the Internet or from ElsterGmbH.
We reserve the right to make technical modifications
in the interests of progress. [e-mail], www.kromschroeder.com
Contact