Mankenberg M-XTRA RP 824 Installation instructions

Original operating manual
pilot-operated pressure regulators
Originalbetriebsanleitung
pilotgesteuerte Druckregelventile
RP 824
RP 824-4.X.23 Stand 17.11.2023 www.mankenberg.com

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RP 824-4.X.23 Stand 17.11.2023 www.mankenberg.com
Table of contents EN
1 Introduction ................................................................................................................................................ 6
2 Intended use ............................................................................................................................................... 6
2.1 Misuse.................................................................................................................................................. 6
3 Applied standards and directives............................................................................................................. 7
4 Safety instructions..................................................................................................................................... 7
4.1 Explanation of the warning notices ...................................................................................................... 7
4.2 General precaution............................................................................................................................... 7
4.3 Special safety instructions for the plant operator ................................................................................. 7
4.4 Special hazards.................................................................................................................................... 8
5 Overview ..................................................................................................................................................... 10
6 Marking of the fitting.................................................................................................................................. 11
7 Transport and storage ............................................................................................................................... 11
8 Installation .................................................................................................................................................. 13
8.1 General notes....................................................................................................................................... 13
8.2 Installation preparations ....................................................................................................................... 13
8.3 Installation steps .................................................................................................................................. 14
9 Pressure testing the pipeline section....................................................................................................... 16
10 Commissioning .......................................................................................................................................... 17
11 Initial start-up.............................................................................................................................................. 18
12 Normal operation........................................................................................................................................ 20
13 Maintenance................................................................................................................................................ 21
14 Disassembly of the back pressure regulator........................................................................................... 22
15 Troubleshooting help................................................................................................................................. 22
16 Information on REACH and RoHS ............................................................................................................ 26
16.1 Declaration on the REACH Regulation 1907/2006 .............................................................................. 26
16.2 Declaration on the RoHS Directive 2011/65/EU .................................................................................. 26
17 Further information.................................................................................................................................... 26
18 Know How................................................................................................................................................... 26
18.1 Function ............................................................................................................................................... 26
18.2 Selecting valve type and nominal diameter.......................................................................................... 27
18.3 Selecting rated pressure and valve material ........................................................................................ 27
18.4 Selecting the setting range................................................................................................................... 27
18.5 Selecting elastomer materials .............................................................................................................. 27
18.6 Flow velocity......................................................................................................................................... 27
18.7 Sense line (control line)........................................................................................................................ 27
18.8 Protecting your system......................................................................................................................... 27
18.9 Protecting the back pressure regulator ................................................................................................ 28
18.10 Valve seat leakage............................................................................................................................... 28

18.11 Cut-off .................................................................................................................................................. 28
18.12 Stellited seat and cone......................................................................................................................... 28
18.13 Leakage line......................................................................................................................................... 28
18.14 Mounting position ................................................................................................................................. 28
18.15 Start-up ................................................................................................................................................ 28
18.16 Steam operation................................................................................................................................... 28
18.17 Setting the pressure ............................................................................................................................. 29
18.18 Maintenance......................................................................................................................................... 29
18.19 Valves free of oil and grease or silicone .............................................................................................. 29
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Inhaltsverzeichnis DE
1 Einleitung.................................................................................................................................................... 30
2 Bestimmungsgemäße Verwendung ......................................................................................................... 30
2.1 Fehlanwendung.................................................................................................................................... 30
3 Angewandte Normen und Richtlinien ...................................................................................................... 31
4 Sicherheitshinweise................................................................................................................................... 31
4.1 Erläuterung der Warnhinweise............................................................................................................. 31
4.2 Allgemeiner Sicherheitshinweis ........................................................................................................... 31
4.3 Spezielle Sicherheitshinweise für den Betreiber .................................................................................. 31
4.4 Besondere Gefahren............................................................................................................................ 32
5 Übersicht..................................................................................................................................................... 34
6 Kennzeichnung der Armatur..................................................................................................................... 35
7 Transport und Lagerung............................................................................................................................ 35
8 Einbau ......................................................................................................................................................... 38
8.1 Allgemeines.......................................................................................................................................... 38
8.2 Vorbereitung zum Einbau..................................................................................................................... 38
8.3 Schritte beim Einbau ............................................................................................................................ 39
9 Druckprüfung des Rohrleitungsabschnitts ............................................................................................. 41
10 Inbetriebnahme........................................................................................................................................... 42
11 Erste Inbetriebnahme................................................................................................................................. 43
12 Normalbetrieb............................................................................................................................................. 45
13 Wartung....................................................................................................................................................... 46
14 Demontage des Überströmventils............................................................................................................ 47
15 Hilfe bei Störungen .................................................................................................................................... 47
16 REACH- und RoHS-Auskunft .................................................................................................................... 51
16.1 Erklärung zur REACH-Verordnung 1907/2006 .................................................................................... 51
16.2 Erklärung zur RoHS-Richtlinie 2011/65/EU ......................................................................................... 51
17 Weitere Informationen ............................................................................................................................... 51
18 Know-How................................................................................................................................................... 51
18.1 Funktion ............................................................................................................................................... 51
18.2 Auswahl von Ventiltyp und Nennweite ................................................................................................. 52
18.3 Auswahl von Nenndruck und Werkstoff ............................................................................................... 52
18.4 Auswahl des Einstellbereichs............................................................................................................... 52
18.5 Auswahl der Elastomere ...................................................................................................................... 52
18.6 Strömungsgeschwindigkeit .................................................................................................................. 52
18.7 Steuerleitung ........................................................................................................................................ 52
18.8 Absicherung Ihres Systems ................................................................................................................. 52
18.9 Schutz des Überströmventils ............................................................................................................... 52
18.10 Sitzdichtheit.......................................................................................................................................... 53

18.11 Absperrung........................................................................................................................................... 53
18.12 Panzerung............................................................................................................................................ 53
18.13 Leckleitung ........................................................................................................................................... 53
18.14 Einbaulage ........................................................................................................................................... 53
18.15 Inbetriebnahme .................................................................................................................................... 53
18.16 Betrieb mit Dampf ................................................................................................................................ 53
18.17 Einstellung des Drucks......................................................................................................................... 53
18.18 Wartung................................................................................................................................................ 54
18.19 Öl- und fett- bzw. silikonfreie Geräte.................................................................................................... 54
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Original operating manual
pilot-operated pressure regulators RP 824
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1 Introduction
This manual is intended to assist users of a Mankenberg pilot-controlled pressure reducing valve or back
pressure regulator during installation, operation and maintenance. Read the manual thoroughly before installing
or putting this valve into service.
Failure to follow the following instructions – particularly the cautionary and warning notes – may lead to
hazards and may invalidate the manufacturer's warranty. Mankenberg is at your service for any assistance and
queries. See section Further information [Page26] for the addresses.
Technical information is also available at www.mankenberg.com
2 Intended use
A pilot-controlled Mankenberg back pressure regulator UV is a device that is intended exclusively for self-
actingly regulating the inlet pressure of the medium (without any additional electrical/pneumatic energy) after it
has been installed in a pipeline system:
The force of the inlet pressure acts on a pilot valve. This controls the main valve so that if the inlet pressure falls
below the target value, the main valve is reduced (or closed) until the target value has been re-established. If
the inlet pressure increases above the target value, the main valve opens.
The pilot valve is integrated onto the main valve together with a throttle block. The throttle block contains 2 or 3
throttles for optimizing the regulation characteristics and 1 strainer. The desired target value for the setting
range must be set on the adjusting screw of the pilot valve.
NOTICE
A pilot-controlled pressure control valve does not begin to operate until Δp >
2bar;
the valve does not react if the difference from the target value is lower than this. If the control
function is to operate at a lower differential pressure, special models or normal pressure
reducing valves and back pressure regulators should be used.
The upper limit of the permitted operating data is permanently marked on the nameplate of each valve supplied
and must be observed.
Service life
The valve is designed for quasi-static operation. 1000 full load variations between 0 bar and PS max (PN or
MAWP) are permitted, based on the entire service life of the pressure vessel; see No. 1.4 AD 2000 sheet S 1.
Relevant pressure surges or dynamic loads are not permissible. The estimated service life is approx. 5 years.
2.1 Misuse
These valves are no shut-off elements ensuring a tight closing of the valve. In accordance with DIN EN 60534-4
and/or ANSI FCI 70-2 they may feature a leakage rate in closed position in compliance with the leakage classes
III.
A pilot-controlled pressure control valve is not a safety valve. A suitable valve must be present in the pipe
section to limit any excess pressure.
A safety valve has to be installed on the control side, which is dimensioned and adjusted in such a way that
the lower one of both pressure indications as mentioned below is relevant as response pressure:
- 1.5 times the maximum setting pressure or (Pout) of the valve (see nameplate)
- PSout (see nameplate)
The actuation pressure of the safety valve should be approx. 40% above the max. The setting value of the
pressure control valve.
The response pressure of the safety valve should be abt. 40 % above the max. set pressure of the pressure
control valve.

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The valve must not be operated in the delivery condition.
After installation, the pilot valve must be adjusted to the desired inlet or outlet pressure. The pressure gauges
required for this must not be mounted directly on the valve and are therefore not part of the delivery. Suitable
pressure gauges are required on the plant side for this purpose.
3 Applied standards and directives
The indicated product is designed according to the AD 2000 regulations without the data sheets S1 and S2.
4 Safety instructions
4.1 Explanation of the warning notices
Safety and warning notices denote safety-related information. The operating manual differentiates between the
following hazard levels.
DANGER
Fatal injuries
Denotes a hazardous situation. Failure to observe these warnings may result in serious
injuries or death.
WARNING
Serious injuries
Denotes a hazardous situation. Failure to observe these warnings may result in serious
injuries.
CAUTION
Injuries
Denotes a hazardous situation. Failure to observe these warnings may result in minor or
midrange injuries.
NOTICE
Material damage
Denotes warnings of material damage and includes precautionary measures for preventing
damage.
4.2 General precaution
The same safety regulations apply to a fitting as to the system into which it is installed. These instructions only
give those safety recommendations that have to be additionally observed for the fitting.
4.3 Special safety instructions for the plant operator
The following requirements for the intended use of a fitting are not the responsibility of the manufacturer but
have to be guaranteed by the user:
» he fitting may only be employed for the purpose described in section Intended use.
» The operator must ensure that the valve is only used with media for which both the valve and sealing
material are suitable.

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» Only competent specialist personnel may install, operate and service the fitting. Competent as defined in
these instructions refers to persons who, because of their training, specialist knowledge and professional
experience, are capable of correctly assessing and properly executing the work with which they are
entrusted and of recognizing and rectifying hazards.
» The pipeline system must be properly designed and installed so that the fitting can be mounted and
operated without any tension.
» The fitting must be properly installed in the correct mounting position.
» The recommended installation, as described in the relevant MANKENBERG data sheet <DM 8...> or <UV
8...>, must be used for the pipeline section into which the pilot-controlled pressure-regulating valve is
installed. All control and/or leakage lines that are required on the pressure-regulating valve must be laid
properly, in accordance with the accompanying MANKENBERG data sheet.
» A pressure-regulating valve with an open spring must be installed in such a way that it presents no risk of
crushing to the operating personnel.
» The usual flow rates should not be exceeded in the pipeline section during continuous operation, and
abnormal operating conditions such as vibrations, unusually high flow rates, etc. should be avoided or – if
unavoidable – clarified with the manufacturer in advance.
» The prevailing operating conditions must comply with the limits of the design data stated in the
MANKENBERG order confirmation.
» The corrosion protection for the fitting must be adapted to the local environmental conditions.
» The fitting must not be coated with thermal insulation.
Detailed notes are provided on some of these prerequisites in the following sections.
4.4 Special hazards
WARNING
Residues of toxic or hazardous media may result in serious injuries or death.
Before a valve is removed from the system or before a valve is dismantled but partially
remains in place, the pressure in the system on both the inlet and outlet side must be
completely reducedso that there is no uncontrolled flow of the medium out of the system.
In the case of toxic or hazardous media, the system must be completely drained before the
valve is removed.
»If a valve is removed from a system with a toxic medium and is taken out of the system:
The valve must be professionally decontaminated before being repaired.
WARNING
When the valve is being disassembled, the spring pretension can cause
serious or fatal injuries.
If a pressure control valve must be disassembled:
» Use the adjusting screw on the spring module to fully relieve the spring pressure by
turning it counterclockwise. When doing so, be sure to observe the notes in the Initial
start-up section!
» Either tightly close the two shut-off valves installed upstream and downstream of the
valve according to the Mankenberg installation diagram and bleed the pressure control
valve or depressurize the system section.
» Remove the valve from the piping.

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NOTICE
Malfunction due to closure of the breather hole
External influences, e.g. covering, clogging or sticking of the breather hole, may cause a
malfunction. The valve no longer regulates reliably.
» The breather hole must be kept open!
NOTICE
Malfunction possible due to external influences
External influences, e.g. pressure on the breather hole, can cause control deviations or
damage internal parts.
» When cleaning the external surface, do not hold the high-pressure steam cleaner or the
compressed air gun near the breather hole!

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5 Overview
Pilot valve
Throttle unit
Main valve
Throttle
Non-return
valve
Strainer
D1 Time response of the control layout
D2 Opening speed of the main valve
D3 Opening speed of the main valve
The pressure control valve consists of main valve and a pilot valve for upstream pressure control as well as a
throttle block with strainer and integrated throttle valves.
When depressurized, the main valve is closed by a pre-tensioned pressure spring.
During commissioning, the fluid enters the inlet side of the main valve and via throttle D3 into the control
chamber and via throttle D2 into the regulating chamber of the main valve.
Closed position: If the inlet pressure is below the set value, the pilot valve is held closed by its spring. The
control pressure in the regulating chamber of the main valve corresponds to the inlet pressure. The main valve
is closed by the spring.
Control position: When the inlet pressure has reached the set value, the pilot valve opens slightly and control
fluid flows to the valve outlet. The restrictor D1 will cause the control pressure to drop. The piston will move into
a position in which the opening and closing forces are in balance.
Open position: If the inlet pressure exceeds the set value, the pilot valve opens completely. More control fluid
flows off, causing the differential pressure of throttle D1 to increase. The pressure in the regulating chamber
drops. The upstream pressure overcomes the control pressure and closing spring and opens the valve.
The opening speed of the main valve can be influenced by the adjustable damping throttles D2 and D3. The
timing behavior of the entire control system is influenced by the control throttle D1.

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6 Marking of the fitting
Each fitting bears the following markings as a minimum:
For Marking Remark
Manufacturer MANKENBERG See section Further information [Page26] for the
address
Fitting design Pressure-reducing + type or
Back pressure regulator + type
Design name as per accompanying
MANKENBERG data sheet
Nominal diameter e.g. DN or G and numerical
value
Numerical value for DN in [mm], for G in [inches]
Nominal pressure PN or Class and numerical
value
Zahlenwert für PN in [bar], für Class in [lbs/square
inch]
Numerical value for PN in [bar], for Class in [lbs/
square inch]. Unless otherwise indicated, all data
give the overpressure above atmospheric.
If 2 numerical values are given, these apply to the
inlet and outlet pressure.
Pressure range Pressure range and numerical
values
Max. permitted
temp.
Temperature and numerical
value
Temperatures above 50 °C entail a reduced
pressure resistance. This must be considered for
the corresponding material in accordance with the
DIN EN 1092 standard
Body material e.g. CrNiMo steel CrNiMo steel = high-alloy austenitic steel
Flow direction Indicated by an arrow
The markings (in the case of fittings made of deep-drawn stainless steel, they are etched into the body) should
neither be covered nor painted over, so that the fitting remains identifiable.
7 Transport and storage
NOTICE
Transport damage due to impacts
The moving internal parts of the valve can be damaged by impacts.
»Even packed valves should be transported free of impacts!
NOTICE
Pilot-operated pressure control valves in intermediate flange design with
slotted disks are particularly sensitive to impact and dirt
The protective packaging at the body must not be damaged during transport and storage.

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NOTICE
Qualified personnel required
Personnel must be trained to properly transport, secure, lift and lower the valve.
»In the case of a valve that can no longer be transported by hand, the harness must
be attached to the body (nozzle) at a suitable point.
The harness must not be fastened to any attachments under any circumstances!
A Mankenberg valve must be handled, transported and stored carefully:
» The valve must be transported and stored in its protective packaging until it is installed.
» When stored before installation, the valve must be stored in closed spaces and protected from harmful
influences such as dirt, moisture and frost.
» In special cases, the valve is supplied free of oil, grease or silicone and is marked accordingly. During
storage and handling (especially during subsequent unpacking), such a valve must not come into contact
with oil/grease/silicone.
» The valve usually has functional and/or sealing parts made of elastomer materials. These do not have an
unlimited shelf life.
NOTICE
Malfunctions and leakage possible due to exceeding the storage period
Ensure proper storage conditions and closed packaging! After a longer period of storage of
the valve, the complete maintenance set must be replaced, see section Replacing the
service kit.
» ISO 2230 describes storage conditions for elastomers in detail and specifies the
permissible storage period.
»Functional and sealing parts must be replaced in good time before the end of the
storage period. They are available from Mankenberg as a "maintenance kit". Refer also
to section Troubleshooting help.
NOTICE
Corrosion possible due to ferritic dust.
Mankenberg valves of small and medium nominal diameters are mainly made of stainless
steel (high-alloy CrNiMo steel).
These valves – if, under exceptional circumstances, they are stored unpacked – must be
protected from ferritic dustto avoid corrosion.
CAUTION
Damage due to overturning
The valve can normally not stand on its own:
Handle with care so that the valve does not tip over during transport/storage.

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8 Installation
8.1 General notes
The same installation regulations apply to a valve as to the system into which it is installed. The following
additional notes apply:
» Section Transport and storage should also be observed during transport to the installation site.
» The installation site to allow perfect functioning of a valve should be a section of pipe without any flow
disruptions, without any angles and without any restrictors/shut-off devices close to the valve, either
upstream and downstream (optimum distance = 10 x DN). If this does not apply, the installation situation
should be checked with the plant operator and/or Mankenberg.
» The statics of the pipeline must be designed so as to take account of the weight of the valve, particularly
those with an eccentric mass. If required the pipeline may have to be properly supported on both sides next
to the valve (or at the valve itself) – particularly in the case of valve with a substantial mass and especially if
vibrations are to be expected in the system.
» When the valve is supported, it is important to check that all functioning parts (adjusting screws, springs)
remain capable of moving freely and are not blocked.
» The valve must not be coated with thermal insulation.
NOTICE
Possible damage due to overheating
Failure to observe this instruction can cause damage to the valves and thus to the piping
system.
» A valve that is operated at a medium temperature above 130°C needs undisrupted
removal of heat if it is to function perfectly.
» The upper limit of the permissible operating data, pressure and temperature, must not be
exceeded.
» To protect internal functional parts (e.g. the seat) against damage and/or blockages, it may be necessary to
install a strainer and/or filter upstream of the valve.
NOTICE
Contaminated medium can damage the valve or impair its function
A filter or screen can be used to protect the valve in the pipeline section. The mesh size of
the filter is determined by the operator in accordance with the operating conditions.
8.2 Installation preparations
» It is necessary to ensure that a valve is not installed unless it matches the operating conditions in terms of
function, pressure and temperature range, body material as well as connection type and dimensions.

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DANGER
Danger due to use other than the intended use
Failure to observe this instruction may cause severe or fatal injury or damage to the
pipework.
A valve must not be operated if its permitted pressure and temperature range is inadequate
for the operating conditions—see the "Intended use" chapter and the markings on the valve.
For an application outside this range, consult the manufacturer.
» Newly installed tanks or pipeline sections must be thoroughly rinsed and cleaned before commissioning.
» The corrosion protection for the valve must be adapted to the local conditions.
» Before installing a pressure control valve, it is necessary to make sure that the pipeline section complies
with the recommended installation, as described in the relevant Mankenberg data sheet. In particular, a
safety valve and a suitable strainer should be installed upstream of the valve.
NOTICE
Note on installing the sense line
For pilot-operated pressure control valves, a sense line has to be laid between the pressure
control valve and the pipeline by the operator - this is described in the above-mentioned
recommended installation.
Please note:
» Only use sense lines made of metal, not of plastics
» Distance from the valve/sense line connection to the pipeline ≥ 10x pipeline diameter
» When the medium is steam, lay the sense line with the gradient falling towards the valve
» The sense line should match the connection on the valve.
» If necessary, install a throttle to avoid vibration.
The pressure control valve should first be adjusted to the operating conditions after installation in the pipe, i.e.
during initial start-up – see section Initial start-up [Page18].
However, it is necessary to ensure before installation that there is sufficient space for the appropriate socket or
open-jawed spanner above/below the adjusting screw.
NOTICE
Horizontal installation position required
As a general rule, pressure control valves should be installed in horizontal lines so that the
pilot valve points upwards.
8.3 Installation steps
Valves should only be finally unpacked at the installation site and inspected for damage prior to assembly.
Damaged valves must not be installed.
It is necessary to ensure that the covers have been removed from all the connection branches before
installation.

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Then the valve should be inspected to ensure that it is clean. Interior parts must be free of liquid (e.g.
condensate): if necessary, connecting branches should be cleaned before installation with clean compressed
air.
The type and dimensions of the line or tank connections must match the valve to be installed and be flush with
the connecting surfaces of the valve as well as in a parallel plane to the valve itself.
CAUTION
If installed against the direction of the arrow, the valve will not perform its
intended function.
The valve is marked with an arrow; the flow in the pipe section must correspond to the
marked flow direction.
The valve must be installed without any tension. In the case of an already installed system, the geometry of the
pipeline must match the face-to-face length of the valve.
NOTICE
Tension from the piping can cause damage to the valve
It is necessary to ensure that no stresses are transferred from the pipeline to the valve,
even under operating conditions.
» A Mankenberg valve made of "high grade" or "high grade pure" stainless steel (austenite, e.g. 1.4404 or
1.4435) does not need any surface protection for normal environmental atmosphere and for normal weather
conditions.
» External parts of the valve made of low-alloy or non-alloy materials that are supplied ex-works with a primer
have to be provided with a suitable coating by the customer.
» A pressure control valve should first be adjusted during the initial start-up by setting the adjusting screw on
the pilot valve to the operating conditions – see section Initial start-up [Page18].
NOTICE
Never paint over the markings on the valve (laser marking on the body or nameplate).
In addition, the following applies to the pipeline connection: with flanges:
NOTICE
Gaskets are required for installation
The sealing surfaces on the valve body are designed according to the order confirmation.
The corresponding gaskets are normally not included in the scope of delivery.
During installation, centre the valve by means of the flange screws on the mating flange before the screws are
tightened.
Additional notes for the pipe connection with welding ends:

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NOTICE
Gaskets are required for installation
The sealing surfaces on the valve body are designed according to the order confirmation.
The corresponding gaskets are normally not included in the scope of delivery.
Additional notes for the pipe connection with welding ends:
» Properly performed welding must ensure that no significant tension is transferred to either the section of
pipeline or the body of the valve.
» Under no circumstances may the body of the valve exceed the temperature marked on it; otherwise the
sealing and functional parts will be damaged and the whole valve will become unusable.
NOTICE
When a valve with a body made of "high-grade" or "high-grade pure" deep-drawn parts
(recognizable by the body connection with clamps) is being welded in, the welded joint must
be made with special care; it is advisable to keep the body cool with a damp cloth during the
process.
Failure to observe these instructions may result in warpage of the valve body: Even
0.000394 in / 0.1 mm of permanent warpage in the seat area can render the valve
unusable.
9 Pressure testing the pipeline section
The valve has already been pressure-tested by the manufacturer. The following points should be observed
when conducting a pressure test on a pipeline section with a pressure control valve installed:
Back pressure regulator:
The test pressure must not exceed 1.5 times the max. adjustable pressure.
e.g. a setting range of 4 to 8 bar results in a max. permitted test pressure of 8 bar x 1.5 = 12 bar.
Under no circumstances may the test pressure exceed 1.5 times the value marked “PN” or “Class” on
the body.
If any leakage occurs on the valve, section Troubleshooting help should be observed.
NOTICE
If the pipe section is flushed and/or dried after assembly or pressure testing, it must be
ensured that the valve is not damaged by corrosion or excessive temperature.

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10 Commissioning
Pilot valve
Throttle unit
Main valve
Throttle
Non-return
valve
Strainer
D1 Time response of the control layout
D2 Opening speed of the main valve
D3 Opening speed of the main valve
Before leaving the factory the valve has been tested for leaks and correct function. The valve is supplied with its
spring released. During commissioning the inlet side should be slowly opened ensuring that the fluid is carried
away from the outlet side. Pressure surges should be avoided.
To accelerate the filling and bleedin of the control chamber during start up, the throttles D1, D2 and D3 should
be fully opened. To bleed the overflow valve the bleed screws on the attenuator block and valve cover should
be slacked.
Do not remove these screw! Tighten the bleed screws as soon as no more air bubbles escape.
The thottle valves D1, D2 and D3 in the attenuator block are used to adapt the overflow valve to the system
operating conditions.
Basic setting (at the factory):
Control throttle D1 opened approximately 0.5 turns; Attenuation throttle D2, D3 opened approximately 1 turns
NEVER CLOSE THE RESTRICTOR VALVES FULLY!
The valve opens as the inlet pressure increases. Subsequently, the required inlet pressure should be set using
the pilot valve adjusting screw while there is a flow of fluid through the valve.
Tightening the screw increases the outlet pressure; slackening the screws reduces the inlet pressure.

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11 Initial start-up
DANGER
Danger due to pressure and temperature range beyond permitted limits
Failure to observe this instruction may cause severe or fatal injury or damage to the
pipework.
Do not operate a valve whose approved pressure and temperature range is not sufficient for
the operating conditions - see section Intended use and markings on the valve. For an
application outside this range, consult the manufacturer, Mankenberg.
» For correct operation, the system pressure must be within the range of the marked
working pressure of the valve.
» In case of doubt, contact the Mankenberg service department.
For addresses, see the Further information [Page26] section.
The valve is supplied with no tension on the spring – hence no defined response pressure has been set in the
factory. During initial start-up, the valve must be adjusted to the system parameters.
The adjusting screw on the pilot valve should be tensioned for this purpose: Clockwise rotation (when looking
onto the adjusting screw) has the following effect:
on the pressure reducing valve: the outlet pressure increases.
on the back pressure regulator: the inlet pressure increases.
The set value to be set by means of the adjusting screw shall be defined by the operator of the system and must
be calibrated with the aid of a pressure gauge on the plant side (or some other pressure monitoring device).
NOTICE
Malfunction due to maximum or minimum setting of the adjusting screw
The valve opens or closes completely. The setpoint pressure range to be controlled is
exceeded. The pressures to be controlled exceed / fall below the specifications on the
nameplate.
» Never fully remove the adjusting screw
» Do not screw in the adjusting screw as far as it will go
NOTICE
At the beginning or shortly after initial commissioning, the screen or filter element of the filter
should be cleaned to prevent the filter from clogging.
NOTICE
After initial commissioning:
Check tightness of screwed body parts, re-seal if necessary. If necessary, consult
Mankenberg for tightening torques.
Check the leakage line for leaking medium.

Original operating manual
pilot-operated pressure regulators RP 824
19
RP 824-4.X.231 Issue 17.11.2023 www.mankenberg.com
To speed up the filling and emptying of the control and regulating chamber during start up, the throttles D1, D2
and D3 should be fully opened. To bleed the pressure reducing valve, slightly undo the bleeding screw on the
throttle block. Do not unscrew it completely! Tighten the bleeding screw again when no more air comes out.
The throttles D1, D2 and D3 are for adjusting the control valve to the operating conditions of the system.
Basic setting (at the factory)
» control throttle D1 is opened by approx. 1 revolution
» damping throttle D2, D3 opened by approx. 2 revolutions
NOTICE
Never fully close the throttles!

Original operating manual
pilot-operated pressure regulators RP 824
20
RP 824-4.X.231 Issue 17.11.2023 www.mankenberg.com
12 Normal operation
WARNING
Danger due to fluid incompatibility
It is necessary to ensure that the selected materials for the parts of the valve in contact with
the fluid are suitable for the fluid in use. The manufacturer accepts no liability for any
damage due to corrosion due to aggressive media on parts made of unsuitable materials.
Failure to observe this regulation may mean danger to life an limb and may cause
damage to the pipeline system and to the valve.
WARNING
Danger due to fluid when operating with damaged sense line
The sense lines between the pressure control valve and the pipeline must be free from
damage.
Damage to this control line may result in danger to life and limb and may impair the
function of the pressure control valve or even lead to complete failure.
NOTICE
Damage to the interior of the piping system and the valve due to blocking possible.
The valve has functional parts that must maintain their ease of movement. Make sure that
the parts in contact with the medium do not freeze and are not blocked by deposits or dirt.
Comply with the maintenance intervals.
NOTICE
Changes may result in damage to the pressure control valve
Pressure control valves are designed for the operating point as per the order. This operating
point can be occasionally adjusted on-site by means of the adjusting screw. The adjusting
screw setting must never be changed permanently (e.g. by attaching a control drive).
NOTICE
Incorrect setting of the throttles can cause damage to the system
Pilot-controlled pressure control valves are designed for the operating point in accordance
with the order. The throttle block has 2 or 3 integrated trottles with which the operating
reponse to pressure fluctuations can be influenced.
A properly designed pressure control valve works automatically and does not need any form of auxiliary energy.
For optimum control accuracy, the desired response pressure should be within the upper part of the setting
range of the pressure control valve. In case of doubt, contact the Mankenberg service department. For
addresses, see section Further information [Page26].
It is recommended that the valve should be inspected to ensure that it is functioning correctly after each new
start-up.