MEDENUS RSP 254 Manual

© 05.2022
Operating and Maintenance Instructions
Gas Pressure Regulator
RSP 254 / RSP 255
Regulator
R 70-10 / R 70-20 / R 70-100
Actuator
AS 254 / AS 255

Subject to technical modifications! Reprint prohibited!
Connections R70
R70-100R70-10 R70-20
6.
9.
Connection
no. R70-10 R70-20 R70-100
1Inlet pressure line Inlet pressure line Inlet pressure line
2Setting pressure line Setting pressure line Setting pressure line
3Bypass line Bypass line Bypass line
Measurement line Measurement line Breather line
Breather
line
Pneumatic follow-
up setpoint (I/P
converter)
Breather line
Breather
line
Pneumatic follow-
up setpoint (I/P
converter)
6Measurement line
7
Pneumatic follow-
up setpoint (I/P
converter)
8Breather line
9
10
11
12
4
5

Design of the gas pressure regulator RSP
2
3
,Breather line
Inlet pressure line
Bypass line
Return line
Setting
pressure line
Closing spring Setpoint spring
Actuator
diaphragm
Compensating
diaphragm
Valve plate
I/P converter
1:2 pressure converter
Compressed air supply
Pneumatic
follow-up setpoint
Double-diaphragm system
Inlet pressure
Set pressure
Outlet pressure
Atmosphere
Follow-up setpoint
Regulator R 70-20/1 with pneumatic
1:2 follow-up setpoint converter
SSV
Gas pressure regulator RSP 254
with integrated SSV indirect-acting
Bypass setting
device
SSV switching pressure
Setpoint
setting
device
Measurement
line
4-20 mA
Actuator AS 254
1
4
5
7
8
SSV
measurement line
SSV control device

Table of Contents
1 General Information 6
1.1 Warranty and Liability 6
1.2 Symbols, Notes 7
1.3 Terms, Abbreviations 7
2 Application, Characteristics 8
2.1 Application 8
2.2 Characteristics 8
2.3 Types of Models (Options) 8
3 Reasonably Foreseeable Misuse 8
4 Safety Instructions 9
4.1 Hazards of Handling the Device 9
4.2 Personnel Requirements 9
4.3 Country-Specific Requirements 9
4.4 Handover of the Operating and Maintenance Instructions 9
4.5 Safety in Operation 10
4.6 What to Do in Case of Danger 10
5 Responsibility of the Operator 10
6 Transport, Storage and Packaging 11
6.1 Transport 11
6.2 Storage 11
6.3 Packaging 11
7 Mounting and Commissioning 12
7.1 Safety Instructions and Preparation 12
7.2 Mounting 13
7.3 Leakage Test (Test for External Leakage) 14
7.4 Initial Commissioning / Recommissioning 15
7.5 SSV Setpoint Spring Table - Control Device 17
7.6 Regulator Setpoint Spring Table 18
7.7 Decommissioning 19
8 Maintenance 19
8.1 Maintenance Plan 19
8.2 Maintenance Procedure 20
8.3 Table of Screw Tightening Torques MA21
8.4 Lubricants Table 21
9 Troubleshooting 22
9.1 Gas Pressure Regulator 22
9.2 Safety Shut-Off Valve 23
10 Replacement and Disposal 24
11 Spare Parts 25
11.1 Spare Parts Drawing Example: AS 254 DN080 25
11.2 Spare Parts Drawing Fine Filter FF 26
11.3 Spare Parts Drawing R-70-10/ R70-20/ R70-100 26
11.4 Parts for Maintenance Work Actuator 28
11.5 Parts for Maintenance Work Regulator 30
11.6 Parts for Maintenance Work Fine Filter FF 30

12 Accessories / Options 33
12.1 Noise Reduction 33
12.2 BV Breather Valve 35
12.3 RSD Restrictor Valve 36
12.4 Signal Transmitter/ Reed Contact 37
12.5 Inductive Signal Transmitter 40
12.6 SSV Remote Release 42
12.6 SSV Remote Release 44
12.7 Fine Filter FF 45
13 Tools 47
13.1 SSV Tightening Tool 47
Notes 47
Declaration of Conformity 50
Contact

6
© 05.2022
1 General Information
The personnel entrusted with installation, operation or maintenance of the gas pressure regulator must
have completely read and understood beforehand the following documents:
• Gas Pressure Regulator RSP 254 / RSP 255 Product Information
The product information contains technical data, dimensions and a description of the design and the mode of
operation.
• Gas Pressure Regulator RSP 254 / RSP 255 Operating and Maintenance Instructions
This document allows safe and efficient handling of the device and contains information on assembly,
commissioning, maintenance, troubleshooting, and repair according to regulations.
It is an integral part of the scope of delivery of the device, must be kept in close proximity of the device and
must be readily accessible to personnel at any time.
The basic prerequisite for safe working is compliance with all safety instructions and instructions for action
given in this manual. Accordingly, the information and instructions must be observed when working on the
device or on the gas line. In addition, the local occupational safety regulations and general safety regulations
for the application range of the device shall apply.
The figures in these instructions are provided for basic understanding and may differ from the actual design.
The contents of these instructions are protected by copyright. They may be used as part of operating the
device. Any other use and/or reproduction is not permitted without prior authorization by MEDENUS Gas-
Druckregeltechnik GmbH.
1.1 Warranty and Liability
Claims under warranty or liability for personal injury and material damage are generally void
if one or several of the following conditions are not observed:
• Work on the device during the warranty period may only be performed in consultation with the manufacturer
• Designated use of the device in accordance with the established conditions of use
• Proper installation, commissioning, operation and maintenance of the device
• Operation of the device with properly installed and functioning safety devices only
• Operating and maintenance instructions of the device or of the system
• Compliance with the maintenance instructions
• Properly performed repairs
• Supply lines without defects
• The use of original MEDENUS©spare parts (p. 25) and lubricants listed in these instructions or
• Force majeure
It is generally prohibited
• To perform constructive modifications on the device
• To keep using the device despite the detection of a defect

7© 05.2022
1.2 Symbols, Notes
The instructions contain safety instructions marked with symbols to indicate possible consequences in case of non-
observance:
1.3 Terms, Abbreviations
Terms and abbreviations are explained below:
DANGER
Note
ATTENTION
This combination of symbol and signal word indicates a potentially hazardous
situation which, if not avoided, may result in minor or moderate injury, damage
to the device, the breakdown of the system, and material or environmental
damage.
This combination of symbol and signal word indicates an imminent hazardous
situation which, if not avoided, will result in death or serious injury.
This signal word highlights useful tips, recommendations, and information for
efficient and trouble-free operation.
AC Accuracy class
AGo Upper response pressure
group
AGu Lower response pressure
group
BV Breather valve
HDS High-pressure spindle
KG(Valve) flow coefficient
pdOutlet pressure
pds Setpoint of the
outlet pressure
pdso Upper SSV response pressure
pdsu Lower SSV response pressure
PS Maximum allowable pressure
puInlet pressure
ρn Standard gas density
PdF Pneumatic follow-up setpoint from
I/P converter
Pd100 Outlet pressure R70-100
Pd20Outlet pressure R70-20
Pd20s Outlet pressure R70-10 with
pressure converter 1:2 for
follow-up setpoint adjustment
Pd10s Outlet pressure R70-10 with
1:1 follow-up setpoint adjustment
Pd10 Outlet pressure R70-10
QnStandard volumetric flow rate
RSD Throttle valve
RSS Switching valve
SSV Safety shut-off valve
SD Setting device
SG Closing pressure group
At Actuator
tuGas Gas inlet temperature
VS Valve seat
wuInlet gas velocity
wd Outlet gas velocity
Wdso Upper adjustment range (SAV)
Wdsu Lower adjustment range (SAV)
Δpwo Min. re-engagement difference
between upper
response pressure and
normal operating pressure
Δpwu Min. re-engagement difference
between lower
response pressure and
normal operating pressure
MOP Maximum operating pressure in
a system
MOPd Maximum operating pressure
upstream of
the system
FF Fine filter

8
© 05.2022
2 Application, Character-
istics
2.1 Application
Gas pressure regulator (GDR), indirect-acting (operating with auxiliary power), for systems acc. to
DVGW work sheets G 491 (A) and G 600 (A) (TRGI).
Can be used as an equipment component on gas consumption facilities as defined in EC Directive EU/2016/426
Can be used for the gases defined in DVGW work sheet G 260 / G 262 and neutral non-aggressive gases.
(other gases on request)
2.2 Characteristics
3 Reasonably Foreseeable Misuse
2.3 Type of Models (Option)
 • Theregulatorsmustnotbeusedtocontrolliquids.
 • Theregulatorsmustnotbeusedintemperaturerangesbelow-20°Corabove60°C
 • Theregulatorsmustnotbeusedforpressurerangeshigherthanthepressure“PS“indicatedonthenameplate.
 • The regulators may only be used for the gases specified under item (2.1) Application in these operating
instructions.
Other gases, such as oxygen or hydrogen, must be explicitly stated on the nameplate.
Please consult the manufacturer before use.
 • Theregulatorsmustnotbeusedinhigh-temperatureareaswithoutanupstreamHTBfuse.
*) Categories C1 to C5-I are guaranteed without additional coatings.
For category C5-M, an epoxy resin coating is recommended.
• WithfinefilterFFupstreamoftheregulator
• Withpneumaticfollow-upsetpointfrom I/P converter
• Withbuilt-innoisereduction
• Optionallywithbreathervalve
• WithSSVmanualrelease
• WithelectricpositionindicatorSSV“Closed”viainductiveproximityinitiatororviaReedcontact
• WithSSVelectromagneticremotereleasewhenpowerisappliedorincaseofpowerfailure
• CoatingwithepoxyresininRALcolors
• SpecialmodelssuchasWobbecorrectionforburnercontrol
 • Regulatorwithdouble-diaphragmsystem
 • ModelaccordingtoDINEN334/14382
 • Integralpressure-tightmodel(IS)
 • GaspressureregulatorwithorwithoutintegratedSSV
 • Compactandmaintenance-friendlymodulardesign
 • SSVfunctionalclass,optionallyA(pds u + pds o) or B (pds o)
• Open-airmodel*

9© 05.2022
4 Safety Instructions
National accident prevention regulations and the system operator's safety regulations are not superseded by these
operating and maintenance instructions and must be taken into consideration with priority (in Germany, see, among
others, DVGW work sheets G 600, G 459/II, G 491 and G 495).
When performing work on the device, the current general and specific safety regulations must be observed.
The application limits of the device with respect to the medium, operating pressure and operating temperature can be
found on the nameplate affixed to the device or on the acceptance test certificate.
Using the device under different operating conditions must be agreed upon in consultation with MEDENUS Gas-
Druckregeltechnik GmbH.
The mechanical components of the device do not have any potential ignition sources of their own nor any hot surfaces
and are thus not covered by the scope of 2014/34/EU (ATEX). The electronic accessories used comply with the ATEX
requirements.
Special care is required when performing maintenance work! Spring-loaded parts are under mechanical stress!
4.1 Hazards of Handling the Device
MEDENUS©devices conform with current standards and directives, the recognized technical rules
and the recognized safety rules.
However, improper use can result in hazards to the user or to third parties. This can also result in damage to the device
or to the system.
This is why the device may only be used:
• in accordance with its designated use
• in perfect condition
• while observing the notes given in these operating and maintenance instructions, and inspection and
maintenance regulations, which apply to the functioning and safety of the overall system.
Malfunctions or faults must be eliminated immediately.
4.2 Personnel Requirements
The device may only be mounted by qualified personnel. Only authorized personnel with the required qualification is
allowed to perform settings or repairs on the device.
4.3 Country-Specific Requirements
The rules and regulations applicable at the place of use with respect to
• gas lines, installation of the gas system,
• gas supply,
• work on the gas system,
• accident prevention.
4.4 Handover of the Operating and Maintenance Instructions
The supplier of the system shall hand over these operating and maintenance instructions to the operator of the system
no later than during commissioning and training
of the operating personnel with the reminder to carefully store these instructions.

10
© 05.2022
4.5 Safety in Operation
The device may only be used when all protective devices on the device or in the system are fully functional.
The device must be inspected by a representative of the operator (item 5) or by a qualified person for externally visible
damage and for proper functioning at least once a year.
A more frequent inspection may become necessary, depending on the system conditions.
4.6 What to Do in Case of Danger
Information on what is to be done in case of danger and in case of accidents can be found in the respective operator's or
specialist companies' work instructions.
5 Responsibility of the Operator
Operator An operator is a person who operates the device himself/herself for commercial or economic purposes
or leaves it to a third party for use/application and is legally responsible for the safety of the user, the
personnel or third parties during operation.
The device is used in the commercial sector. The operator of the device is therefore subject to the legal
obligations for occupational safety. In addition to the safety instructions contained in these instructions,
the established maintenance intervals must be observed, taking into account the respective national
standard (alarm and hazard prevention plan).
In particular, the following applies:
• The operator is obliged to perform work on MEDENUS©devices during the warranty period only
after consultation with the manufacturer. Otherwise the claims under warranty will become
void.
• The operator must obtain information on the current occupational safety regulations and
determine additional hazards resulting from the special work conditions at the place of use
of the device in a risk assessment. The operator must implement the results in the form of
operating instructions for the device.
• During the entire time of use of the device, the operator must check whether the operating
instructions issued by him/her conform to the current state of the regulations and, if necessary,
adapt them.
• The operator must clearly regulate and define the responsibilities for installation, operation,
troubleshooting, maintenance and cleaning.
• The operator must ensure that all persons handling the device have read and understood these
instructions. In addition, the operator must train the personnel at regular intervals and inform
them about the hazards.
• The operator must make available to the personnel the required protective equipment and
oblige them to wear the required protective equipment.
• Moreover, the operator is responsible for the device always being in technically perfect condition.
• The operator must make sure that the maintenance intervals described in these instructions
are observed.
• The operator must have all safety devices checked regularly for functionality and completeness.
Operator
duties

11 © 05.2022
6 Transport, Storage and Packaging
6.1 Transport
The device is delivered with flange protection caps. They must be removed prior to installation.
Make sure that the device is transported horizontally using suitable lifting gear. The device must be
handled carefully and secured against impacts and knocks.
In case of transport damage, we will require the following information from the nameplate affixed to
the device:
• Fabrication number
Note
6.2 Storage
Equipment and spare parts must be stored under the following conditions:
• Do not store outdoors.
• Store in a dry and dust-free location.
• Store on a flat surface.
• Do not expose to aggressive media.
• Do not expose to ozone or ionizing radiation.
• Do not store adjacent to direct heat sources.
• Avoid mechanical vibrations.
• Storagetemperature:0to25°C.
• Relative air humidity: < 55 %.
Spare parts:
• Components susceptible to corrosion must be provided with a suitable preservative.
• Do not store O-rings and seals for more than 5 years even if stored properly.
• Spare parts must be stored in their original packaging until use.
Storage period for devices:
• Storage of the device for up to one year:
Store the gas pressure regulator in its original packaging and original condition at the time of supply. All
protective caps of the device must remain mounted.
• Storage of the device for more than 1 year (e.g. as a spare device):
Store the device in its original packaging and its original condition as delivered and check it for damage once
a year. Check the housing surface for dirt, damage and corrosion. If necessary, clean all external parts. After
5 years, all O-rings and seals must be replaced.
(Components of the spare parts set, see p. 25)
6.3 Packaging
• The individual packaged items have been packaged in view of the transport conditions to be expected.
• The symbols on the packaging must be observed during transport and storage.
• Only environmentally friendly materials have been used for packaging.
• The packaging is designed for protecting the individual components from transport damage, corrosion and
other damage until mounting. This is why the packaging must not be destroyed and only removed just prior to
mounting.

12
© 05.2022
7 Mounting and Commissioning
7.1 Safety Instructions and Preparation
Prior to starting work on pressurized components:
• Close all connections to the gas line.
• Depressurize all pressurized components. Also discharge residual energies.
• Defective components charged with pressure in operation must be replaced immediately by
an appropriate expert.
Prior to starting work, ensure sufficient clearance for mounting.
Before installing the device, check whether the performance data (nameplate) and the scope of
delivery coincide with the order or the system data, i.e., make sure that the provided devices are
suitable for their intended purpose. In particular, the inlet pressure of the system must be lower than
the maximum allowable pressure of the device.
Direct contact of gas valves and fittings or the control system with hardening masonry, concrete walls
or floors is not permitted. Provide suitable supports, working materials and protective equipment.
The minimum distances to the masonry etc. specified in the product information must be adhered to
(p. 15-17).
Prior to commissioning, make sure that all installation work has been carried out and completed
in accordance with the data and information given in these instructions and that no unauthorized
persons stay in the danger zone.
DANGER
Note
Note
DANGER
Preferred installation position
Note
Note
Note
7.2 Mounting
• Remove the packaging, flange protection caps and shipping braces.
• Check the device for wear and damage.
• Make sure that the device is installed free of stress. Make sure to observe the direction of flow
i.e., the arrow on the housing must point in the direction of flow.
• All breather lines (items 7.04 / 7.07) must be vented to the outside atmosphere.
• The measuring lines (items 7.05 / 7.08) must be connected in a pipeline section with a steady flow. There
must be no installations that cause flow interference such as shutters, expansions, manifolds, junctions,
isolation valves etc. directly upstream and downstream of the measurement point.
Gas pressure regulators Flange tightening torques
Screw size Screw tightening
torque MA
Screw size Screw tightening
torque MA
M6 8 Nm M12 60 Nm
M8 18 Nm M16 120 Nm
M10 36 Nm M20 190 Nm
M12 62 Nm
Tightening torques MA*)
*) For the assembly of the flange connections, the maximum torques specified by the flange and gasket manufacturers
must be observed. The values indicated here should be considered as approximate values.

13 © 05.2022
7.01
7.02
7.03
7.06 7.07
7.30
7.33
7.04
7.31
7.32
7.13
7.28
7.05
Measuring
point
Measuring
point
The illustration shows the gas pressure regulator RSP 255 with actuator AS 255, regulator R 70-20 with follow-up
setpoint, SSV with breather valve BV and fine filter FF (image detail)
I/P converter
7.08
7.11
7.12
Fine filter FF
Detail p.16
7.45
• The measuring point should be behind the regulator at a distance of at least 10x the regulator nominal size
DN or 5x the pipe nominal size DN.
• The maximum flow rate at the measuring point must not exceed 20 m/s, depending on the system conditions.
• In certain system circuits, such as gas control systems for gas motors and in gas burners, higher flow rates
than 20 m/s are also possible. Please contact us.
• The measuring line must be connected to the pipeline or to the measuring point separately, laterally or at the
top for each device (1 actuator (item 7.03); 1 gas pressure regulator (item 7.33); 1 integrated SSV (item 7.06)).
• The SSV measuring line (item 7.08) must always be connected upstream of the first shut-off valve (item 7.13)
on the outlet side in such a way
that it cannot be shut off.
Fig. 7.1
Connection
X
Y
Z
IA
I
A
DN
Nennweite /nominal
size
Anschluss Regler /connection
Regulator
Anschluss Regler
Öffnungsdurchmesser /
connection Regulator opening
diameter (mm)
Abmessung /
dimension
(mm)
RE 25 50 80 100 150 200
Impuls-
leitung /
impulse
line (I)
Atmungs-
leitung /
breathing
line (A)
R70-10/-20/-100
Funktion /
Atmungsleitung
(A1)
Impulsleitung / impulse line (I)
Atmungsleitung / breathing line (A)
Diaphragm cover Ø
330 385/390
RSP254
X330 214 232 - - - - RP3/8“ RP3/8“ RP1/4“ 4 6
385/390 - - 293 308 370 510
X1
R70-10
345 365 423 438 500 640R70-20
R70-100
Y 270 282 305 315 386 400
Z 230 230 310 350 480 600
Z1 480 480 502 514 462 570
RSP255
X
330 - - - - - -
385/390 - 292 370 441 - -
R70-10
- 422 500 571 - -
X1 R70-20
R70-100
Y - 305 311 386 - -
Z - 310 410 480 - -
Z1 - 501 520 542 - -
X1
A1

14
© 05.2022
U
S
G
a
s
-
D
r
u
c
k
r
e
g
e
l
g
e
r
ä
t
D
E
N
U
S
G
a
s
-
D
r
u
c
k
r
e
g
e
l
g
e
r
ä
t
7.10
7.09
7.10
7.09
While doing so, you must ensure:
Pressure in the inlet chamber Pu (item 7.02) ≥ pressure in the
outlet chamber Pd(item 7.12)
Pressure build-up always from the inlet side (inlet chamber)
Pressure reduction always from the outlet side (outlet chamber)
• After leakage test:
Open the ball valve in the SRV line (item 7.10) again.
For Germany:
According to DVGW work sheet G 491, the fully assembled system must be subjected to a leakage test with air or an inert
gas at the installation site, using 1.1 times the maximum operating pressure of the system (MOP).
An exception is the room between the actuator and the first shut-off valve on the outlet side. This room must be checked
using the test pressure corresponding to the maximum permissible pressure in the system in case of a malfunction (1.1
MOPd). In this test, all detachable connections must be checked using a foaming agent.
For other countries:
The relevant national and international standards shall apply
Procedure
• Close the ball valve upstream of the valves and fittings (item 7.01).
• Close the downstream shut-off devices (item 7.13) (ball valve,
solenoid or pneumatic valve).
• Depressurize the system (item 7.11).
• If there is a SRV (safety relief valve) in the controlled section and
the test pressure is higher than the response pressure of the
SRV (item 7.09), the line upstream of the SRV (item 7.10) must be
closed.
• Always increase the test pressure slowly and steadily.
• e.g.: 20 mbar/s
7.3 Leakage Test (Test for External Leakage)
The devices are subjected to a strength and leakage test ex works at MEDENUS Gas-Druckregeltechnik GmbH.
The leakage test in the fully assembled system must be performed prior to commissioning and following maintenance
work.
For the external leakage test in the fully assembled system, the following applies:
ATTENTION
Fig. 7.2
Fig. 7.2.1
Note

15 © 05.2022
7.17
7.16
7.19
7.18
7.14
7.15
7.14
7.4 Initial Commissioning / Recommissioning
Initial commissioning of the system components shall be carried out by the operator. For commissioning, please refer to
thedocumentslistedunderitem1“GeneralInformation”andthesystemoperator'sworkinstruction.
The devices delivered by MEDENUS Gas-Druckregeltechnik GmbH are factory-set to the operating data specified by the
customer. This data is listed on the type plate and the Acceptance Test Certificate (ATC).
Prior to commissioning of the system, a functional test must be performed on the gas pressure
regulator (GPR), if applicable, and the safety shut-off and safety relief valves.
Procedure (fig. 7.1) inlet shut-off device
• Close the ball valve upstream of the valves and fittings (item 7.01).
• Close the downstream shut-off devices (item 7.13) (ball valve, solenoid or pneumatic valve).
• Depressurize the system (item 7.11).
• Close the venting ball valve (item 7.11).
• Slowly open ball valve upstream of the valves and fittings (item 7.01) (pressure increase approx. 0.5 bar/s).
If the inlet shut-off device is equipped with a bypass, the latter must be slowly opened for pressure
compensation as step 1. This is followed by slowly opening the inlet shut-off valve which will close
the bypass.
• Check the inner leakage of the SSV (item 7.06) by reading the pressure gauge
installed downstream of the GPR (item 7.12).
• Unscrew the sealing cap (item 7.15) of the safety shut-off valve (SSV).
• On a GPR with bypass ball valve (item 7.28), carefully open the ball valve (item
7.28) of the bypass line while pulling the pull knob (item 7.14) until the SSV
engages to perform pressure compensation.
• A closing pressure corresponding to the set value is established on the GPR.
• Checking the upper response pressure of the SSV:
If an SRV is available in the section, close the ball valve in front of the SRV.
Increase the outlet pressure up to the upper response pressure by using
suitable means. Reduce the outlet pressure via adequate ventilation and
engage the SSV by pulling the pull knob.
Checking the lower response pressure of the SSV:
Via adequate venting, reduce the outlet section up to the lower
response pressure.
During the check, observe the manometer.
• It may be necessary to correct the setpoint values of the response pressures.
This is done by turning the SSV setpoint setting screws (items 7.17 / 7.19) to
the right (pressure increase) or left (pressure decrease) in order to increase/
decrease the setpoint value.
The inner setting screw (item 7.17) sets the underpressure shut-off
level (lower trigger level) and the outer setting screw (item 7.19) sets
the upper trigger level.
• Perform pressure compensation again via the SSV by carefully opening the
ball valve of the bypass valve (item 7.28) and pulling the pull knob (item 7.14)
and allow the SSV to engage.
Note
Note
Note
Fig. 7.3
Fig. 7.4

16
© 05.2022
The bypass line (item 7.31) is used to reduce the set pressure via the outlet
pressure line (p. 13, item 7.45) if necessary.
In order to open the actuator (p. 13, item 7.03) when the gas flow quantity
increases, the set pressure through the regulator (item 7.33) must be increased.
If the gas flow quantity decreases, the actuator (p. 13, item 7.03) must be closed
accordingly. For this, the regulator (item 7.33) reduces the set pressure and the
excess set pressure in the diaphragm assembly of the actuator is reduced via
the bypass line (item 7.31). The discharge velocity via the bypass line (item
7.31) can be set continuously with the help of the bypass setting device (item
7.44). The factory-set bypass setting device (item 7.44) has been opened by 4
turns, i.e. 2 mm.
To increase the discharge velocity, the bypass setting device (item 7.44) must
be opened by turning the restrictor screw (item 7.45) in counterclockwise
direction. To reduce the discharge velocity, the bypass setting device must be
closed by turning the restrictor screw in clockwise direction.
• For the functional test of the GPR, let gas or other suitable media flow via the discharge line to the outside
atmosphere and read the set regulating pressure on the outlet pressure gauge (item 7.12).
• After closing the discharge line, a constant closing pressure within the closing pressure class can be read on
the outlet pressure gauge (item 7.12).
• Slowly open the outlet shut-off device (item 7.13) (0.5 bar/s).
• Screw on the sealing cap (item 7.15) of the safety shut-off valve (SSV) again.
Changing the control range
Switching to the control range of a different setpoint spring can be done for the SSV while the device is pressurized.
Safety shut-off valve
The SSV closes if the overpressure setpoint spring (upper trigger level) is removed from a pressurized system.
Setting the gas pressure regulator:
Unscrew the protection cap (item 7.43) from the R70 and change the outlet pressure (Pd) by rotating the setpoint setting
device (item 7.40). While doing this, observe the outlet pressure displayed on the manometer (p. 13, item 7.12) of the
outlet pressure side.
Turning clockwise - pressure increase
Turning counterclockwise - pressure reduction
For a precise setting, the gas on the outlet side must freely escape. Otherwise the closing pressure is also taken into
account. If the desired outlet pressure cannot be set with the mounted spring, it may be necessary to replace the control
spring in the regulator (R70).
7.4.1 Bypass line, bypass setting device
Replacing the control spring (R70)
• Release the control spring by turning the setpoint setting device (7.40)
counterclockwise.
• Remove the sealing cover (item 7.41) from the diaphragm assembly (R70) (4x M6) and
pay attention to the O-ring in the housing.
• Insert a suitable setpoint spring (item 7.42) and close the cover.
• Set the desired outlet pressure (Pd) as specified above.
• Screw the protection cap (item 7.43) again onto the R70.
7.40
7.41
7.42
7.43
7.33
7.44
7.30
7.45
7.31

17 © 05.2022
7.5 SSV setpoint spring table - Control device direct-acting
*) Standard spring
RSP 254: DN 25 - 100 / RSP 255: DN 50 - 80
small ball lock
MD MD-R HD
to Wds o 300 mbar to Wds o 3500 mbar to Wds o 16000 mbar
Spring data
Lower
response
pressure
Upper response
pressure
Lower response
pressure
Upper response
pressure
Lower response
pressure
Upper response
pressure
Spring
no.
Color
[RAL]
Wds u
[mbar]
Δpwu
[mbar]
wdso
[mbar]
Δpwo
[mbar]
Wds u
[mbar]
Δpwu
[mbar]
wdso
[mbar]
Δpwo
[mbar]
Wds u
[mbar]
Δpwu
[mbar]
wdso
[mbar]
Δpwo
[mbar]
FE 900 1028
FE 901 VA 2002 20 - 120* 500
FE 902 VA 6010 0 - 12* 40 24 - 74 90 120 - 310* 500
FE 903 5015 4 - 14 40 36 - 78 90 160 - 316 500
FE 904 VA 9005 8 - 18 40 58 - 110 90 200 - 400 500
FE 905 VA 9010 18 - 42 40 110 - 160 90 416 - 650 500
FE 906 4002 48 - 70 40 162 - 250 90 560 - 940 500
FD 910 1028 35 - 45 40 100 - 135 50
FD 911 2002 45 - 80 40 130 - 250 50
FD 912 6010 70 - 120 40 220 - 360 50
FD 913 5015 100 - 170 40 320 - 510 50
FD 914 9005 140 - 230 40 440 - 700 50
FD 915 9010 210 - 300 40 630 - 1130 50 2200 - 4000 300
FD 916 3020 1060 - 1750 50 3400 - 4750 300
FD 917 5010 1420 - 2520 50 4700 - 7400 300
FD 918 9006 1850 - 3200 50 7200 - 12100 300
FD 919 4002 2800 - 3500 50 11700 - 16000 300
RSP 254: DN 150 - 200 / RS 255: DN 100
large ball lock
MD MD-R HD
to Wds o 300 mbar to Wds o 3500 mbar to Wds o 16000 mbar
Spring data Lower response
pressure
Upper response
pressure
Lower response
pressure
Upper response
pressure
Lower response
pressure
Upper response
pressure
Spring
no.
Color
[RAL]
Wds u
[mbar]
Δpwu
[mbar]
wdso
[mbar]
Δpwo
[mbar]
Wds u
[mbar]
Δpwu
[mbar]
wdso
[mbar]
Δpwo
[mbar]
Wds u
[mbar]
Δpwu
[mbar]
wdso
[mbar]
Δpwo
[mbar]
FM 400 1028 10 - 40* 30 20 - 180* 60 0 - 250 500
FM 402 6010 35 - 115 30 155 - 380 60 150 - 1000* 500
FM 404 9005 60 - 245 30 200 - 950 90 650 - 2050 500
FL 412 6010 40 - 180 50 145 - 670 180 380 - 1400 500
FL 413 5015 70 - 300 50 270 - 1230 180 800 - 2800 500
FL 415 9010 1200 - 3500 180 3200 - 5500 500
FL 417 4010 4500 - 16000 500

18
© 05.2022
7.6 Regulator Setpoint Spring Table
Ph Pressure of the auxiliary pressure stage of the follow-up setpoint (0-6 bar)
Pd100 Outlet pressure R70-100
Pd20Outlet pressure R70-20
Pd20s Outlet pressure R70-20 with 1:2 follow-up setpoint adjustment
Pd10 Outlet pressure R70-10
Pd10s Outlet pressure R70-10 with 1:1 follow-up setpoint adjustment
R70-100 R70-20 R70-10 Spring data
Pd100 [mbar] Pd20 [mbar] Pd20s [mbar] (1:2) Pd10 [mbar] Pd10s [mbar] (1:1) Spring no. Color [RAL]
0-37 0-180
Pd20s=Pd10+Ph*2 Pd10s=Pd10+Ph
FD 911 2002
30-85 150-400 300-850 FD 912 6010
55-160 250-750 550-1600 FD 913 5015
100-260 550-1250 1000-2600 FD 914 9005
200-460 1000-2250 2000-4600 FD 915 9010
400-620 2000-3000 4000-6200 FD 917 5010
3000-6500 6000-13000 FD 918 9006

19 © 05.2022
8 Maintenance
8.1 Maintenance Plan
The following sections describe the maintenance work required for optimal and trouble-free operation of the device.
If increased wear is detected during regular inspections, the required maintenance intervals must be shortened in
accordance with the actual wear.
For any questions on maintenance work and intervals, please contact the manufacturer.
The intervals for monitoring and maintenance work are strongly dependent on the operating situation and the condition
of the gas. This is why no fixed intervals can be given. For Germany, it is recommended that the maintenance periods as
specified in DVGW work sheet G 495 are observed initially. For each system, this must be followed by determining the
maintenance interval independently on a medium-term basis.
During maintenance work, the components must be cleaned and subjected to a thorough visual inspection. This is also
necessary if irregularities in the operating behavior have been detected during operation or during functional tests.
Damaged parts and O-rings dismounted during dismantling must be replaced with new ones.
The item numbers mentioned in chapter 8.2 (Maintenance Procedure) correspond to those listed in the
spare parts drawings and spare parts lists.
It is recommended to stock the parts listed in chapter 11.5 for maintenance work.
Interval Maintenance work Personnel
According to
the data given in
DVGW work sheet
G 495
or when required
Replacing O-rings
Qualified personReplacing diaphragms
Replacing the valve plate
7.7 Decommissioning
Fordecommissioning,pleaserefertothedocumentslistedunderitem1“GeneralInformation”andthesystemoperator's
work instruction.
Procedure (fig. 7.1)
• Slowly close the outlet shut-off valve (item 7.13) and
• Close the ball valve upstream of the valves and fittings (item 7.01).
• Depressurize the system (item 7.11). (Venting is always performed via the outlet side Pu ≥ Pd)
• Close the venting ball valve (item 7.11).
Note

20
© 05.2022
8.2 Maintenance Procedure
Instructions for our products can be found in the download area of our website. Should you have any problems, please
feel free to contact us directly.
If components have been removed, make sure they are mounted correctly, reinstall all fastening
elements and observe the screw tightening torques (8.3 Table of Screw Tightening Torques MA).
Prior to recommissioning, observe the following:
• Make sure that all maintenance work has been carried out and completed in accordance
with the data and information given in these instructions.
• Make sure that no unauthorized persons stay in the danger zone.
• Make sure that all covers and safety devices have been installed and are working properly.
• Perform a leakage test according to the procedure described under 7.3.
For recommissioning, please refer to the relevant manufacturer's documentation of the
gas pressure regulator installed in the system or chapter 1 and 7.4 as well as the work instructions of the system
operator, and the other safety regulations for the system in which the regulator is installed.
To guarantee smooth operation, we recommend always keeping a maintenance set in reserve.
ATTENTION
DANGER
Note
*) The recommended values may differ depending on the device/lubrication