Medenus Df 100 Manual

©.201

Cellular Gas Filter

DF 100

Operating and Maintenance Instructions

Subject to technical modifications! Reprint prohibited!

©.201

Table of Contents

1 General Information 4

1.1 Warranty and Liability 4

1.2 Symbols, Notes 5

1.3 Terms, Abbreviations 5

2 Safety Instructions 6

2.1 Hazards of Handling the Device 6

2.2 Personnel Requirements 6

2.3 Country-Specific Requirements 6

2.4 Handover of the Operating and Maintenance Instructions 6

2.5 Safety in Operation 7

2.6 What To Do in Case of Danger 7

3 Responsibility of the Operator 7

4 Transport, Storage and Packaging 8

4.1 Transport 8

4.2 Storage 8

4.3 Packaging 8

5 Mounting and Commissioning 9

5.1 Safety Instructions and Preparation 9

5.2 Mounting 9

5.3 Leakage Test (Test for External Leakage) 10

5.4 Initial Commissioning / Recommissioning 10

5.5 Decommissioning 10

6 Maintenance 11

6.1 Maintenance Plan 11

6.2 Maintenance Procedure 11

6.3 Table of Screw Tightening Torques MA13

6.4 Lubricants Table 13

7 Troubleshooting 13

8 Replacement and Disposal 13

9 Spare Parts 14

9.1 Spare Parts Drawing DF 100 14

9.2 Parts for Maintenance Work 14

O-Rings 14

10 Notes 15

11 Declaration of Conformity 16

4

1 General Information

The personnel entrusted with installation, operation or maintenance of the cellular gas filter must

have completely read and understood beforehand the following documents:

• Cellular Gas Filter DF 100 Product Information

The product information contains technical data, dimensions and a description of the design and the mode of

operation.

• Cellular Gas Filter DF 100 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 requirement of safe operation is compliance with all safety instructions and guidelines specified in

these instructions. 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 the 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 in 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 the 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

• Observance of the maintenance instructions

• Properly performed repairs

• Supply lines without defects

• The use of original MEDENUS©spare parts 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

5

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:

DN Nominal width

MAScrew tightening torque

MOP Maximum operating pressure in a system

SBV Safety relief valve

DANGER

Note

NOTICE

This combination of symbol and signal word indicates a potentially hazardous

situation which may result in light injuries, damage to the device, the breakdown

of the system and material or environmental damage if not avoided.

This combination of symbol and signal word indicates an imminent hazardous

situation, resulting in death or serious injuries if not avoided.

This signal word highlights useful tips, recommendations, and information for

efficient and trouble-free operation.

6

2 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 Code of Practice 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 type plate 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 within the scope of 2014/34/EU (ATEX). The electronic accessories used comply with the ATEX requirements.

2.1 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.

2.2 Personnel Requirements

The device may only be mounted by qualified personnel.

Only authorised personnel in possession of the required qualification is allowed to perform settings or repairs on the

device.

2.3 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 must be observed and complied with.

2.4 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.

7

2.5 Safety in Operation

The device may only be used when all protective devices on the device or in the system are fully

functional.

At least once a year, the device must be inspected for externally visible damage and for proper functioning

by a representative of the manufacturer or by a qualified person.

A more frequent inspection may become necessary, depending on the system conditions.

2.6 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 company's work instructions.

3 Responsibility of the Operator

Operator An operator is a person who operates the device himself for commercial or economic purposes or hands

it over to a third party for use / application and is legally responsible for the safety of the user, personnel

or third parties.

The device is used in the industrial sector. Accordingly, the operator of the device is subject to the legal

obligations concerning 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 them in the form of operating

manuals for operating the device.

• During the entire time of use of the device, the operator must check whether the operating

manuals drawn up by him 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 to that, he must train the personnel at regular intervals and inform it

about the dangers.

• 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.

Therefore, the following applies:

• 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 functioning and completeness.

Operator's

obligations

8

4 Transport, Storage and Packaging

4.1 Transport

The device is delivered with flange protective 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 impact and shock.

In case of transport damage, we will require the following information from the type plate affixed to

the device:

• Type of device

• Device model

• Year of construction / fabrication number

Note

4.2 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 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 7 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 cellular gas filter 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 original condition at the time of supply and check it for damage

once a year. Check the housing surface for dirt, damage and corrosion. If necessary, clean all external parts.

After 7 years, all O-rings and seals must be replaced.

4.3 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 be removed just prior

to mounting.

9

5 Mounting and Commissioning

5.1 Safety Instructions and Preparation

Prior to starting work on pressurised components:

• Close all connections to the gas line.

• Depressurise all pressurised components. Also discharge residual energies.

• Defective components that are subject to pressure in operation must be replaced

immediately by a suitable qualified person.

Prior to starting work, ensure sufficient clearance for mounting.

Before installing the device, check whether the performance data (type plate) 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.

A direct contact of gas valves and fittings, i.e., the control system, with hardening masonry, concrete

walls or floors is not allowed. Provide suitable supports, working materials, and protective equipment.

Take into account the minimum clearances for maintenance as stated in the product information.

Before installing the device in the pipeline, check whether a shut-off device that interrupts the gas

flow supply to the device has been mounted upstream and downstream of the device to be installed.

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 unauthorised

persons stay in the danger zone.

5.2 Mounting

Remove packaging and protection from the connection flange surfaces.

Install the device without twisting the pipeline.

Make sure to observe the direction of flow, i.e., the arrow on the housing must point in the direction

of flow.

In installation positions other than horizontal, MEDENUS Gas-Druckregeltechnik GmbH must be

consulted.

The tightening torques of the flange connections and additional information are available in the DVGW

GAS Information Bulletin No. 19 (Flanged Connections in Gas Installations).

DANGER

Note

DANGER

Note

10

5.3 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:

For Germany:

According to DVGW Code of Practice 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 of the gas pressure regulator installed in the system and the first shut-

off valve on the outlet side. This room must be checked using a test pressure corresponding to the maximum possible

setpoint of the gas pressure regulator. 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.

• Close the downstream shut-off devices (ball valves, solenoid or pneumatic valve).

• Depressurise the system.

• If the test pressure is higher than the relief pressure of the safety relief valve (SRV), the line upstream of the

SRV must be closed.

• Connect the testing device to measuring points upstream and downstream of the gas pressure regulator.

• Always increase the test pressure slowly and steadily.

While doing so, you must ensure:

Pressure in outlet chamber ≤pressure in inlet chamber

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 again.

5.4 Initial Commissioning / Recommissioning

For commissioning, please refer to the relevant manufacturer's documentation of the gas pressure regulator installed

in the system and the work instructions of the system operator.

5.5 Decommissioning

For decommissioning, please refer to the relevant manufacturer's documentation of the gas pressure regulator installed

in the system and the work instructions of the system operator.

Note

NOTICE

11

6 Maintenance

6.1 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 to initially observe the maintenance periods according to

the data given in the DVGW Code of Practice G 495. 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 behaviour have been detected during operation

or during functional tests. The check must cover in particular the filter insert and the seals.

Damaged parts and O-rings dismounted during dismantling must be replaced with new ones.

The item numbers mentioned in chapter 6.2 (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 9.5 on page 18 for maintenance work.

Interval Maintenance activities Personnel

When required

Replacing the filter cartridge

Qualified person

Replacing the O-ring between the cover and the housing

Replacing the O-ring for sealing the filter cartridge

Replacing the O-ring for sealing the valve seat

Replace the O-ring between the hood / spacer and the housing

Replacing the O-ring between the hood and the spacer

Replacing the sealing of the connection of the differential pressure device

6.2 Maintenance Procedure

If components have been removed, make sure they are mounted correctly, reinstall all fastening

elements and observe the screw tightening torques.

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 unauthorised persons stay in the danger zone.

• Make sure that all covers and safety devices have been installed and are working properly.

NOTICE

DANGER

For recommissioning, please refer to the relevant manufacturer's documentation of the gas pressure regulator installed

in the system, the work instructions of the system operator, and the other safety regulations of the system in which the

filter has been installed.

12

6.2 Maintenance Procedure

As a functional test, a pressure loss measurement for the flow resistance can be carried out. Limit

value for a contaminated filter cartridge: 0.8 to 1 bar

• Close fittings upstream and downstream of the filter. Depressurise the filter.

• Dismount the hood. To do so, unscrew the Allen screws on the hood. Exception for DN 25: Unscrew the hood.

• Remove O-ring (item 8) inside the housing or hood. Clean the O-ring groove and insert a new greased O-ring

into the groove.

• Pull out the filter cartridge towards the top and check whether it is dirty. If necessary, the filter cartridge must

be cleaned or replaced.

• For DN 150 / DN 200: Dismount the spacer. To do so, unscrew the Allen screws (item 55) at the spacer. Remove

the O-ring (item 8) from the housing or from the spacer.

To lower the dismounting dimension for the nominal widths of DN 150 and DN 200, the filter cartridge

and the spacer should be removed together.

• Clean the O-ring grooves and insert new, greased O-rings into the grooves.

• Dismount the cover. To do so, unscrew the Allen screws (item 52) from the cover. It may be necessary to clean

the cover.

• Remove the O-ring (item 4) from the housing. Clean the O-ring groove and insert a new greased O-ring into

the groove.

• Remount the cover. To do so, screw down the Allen screws (item 52) at the cover crosswise, using a torque

wrench. (see table 6.3)

• Place the cleaned or new filter cartridge in the valve seat. The filter cartridges DN 25 and DN 100 comprise a

centring ring at one end guaranteeing the correct fit of the cartridge in the valve seat. During installation, the

centring ring is located at the bottom inside the filter.

• For DN 150 / DN 200: Mount the spacer. To do so, screw down the Allen screws (item 55) at the spacer crosswise,

using a torque wrench. (see table 6.3)

To lower the mounting dimension for the nominal widths of DN 150 and DN 200, the filter cartridge

and the spacer should be inserted together.

• Place the hood and tighten the Allen screws (item 50) crosswise, using a torque wrench. Exception for DN 25:

Screw in the hood (item 50) and tighten it, using a torque wrench. (see table 6.3) When screwing in, exert a

slight pressure on the hood. The filter cartridge is oversized and, due to the leak tightness to be achieved, it

must be slightly compressed.

• The maintenance parts in the differential pressure measuring instrument are only replaced when necessary.

• Open the valves and fittings upstream and downstream of the filter and check for leak tightness (using a

foaming agent).

To guarantee smooth operation, we recommend always keeping a maintenance set in reserve.

Note

13

6.3 Table of Screw Tightening Torques MA

Item

No. DF100 / 025 DF100 / 050 DF100 / 080

DF100 / 100 DF100 / 150 DF100 / 200

50 M12 / 62 Nm M10 / 36 Nm

52 M8 / 18 Nm M10 / 36 Nm M10 / 36 Nm M12 / 62 Nm M12 / 62 Nm

55 M10 / 36 Nm M8 / 18 Nm M12 / 62 Nm M10 / 36 Nm

The screw positions are indicated on page 14.

6.4 Lubricants Table

Components (apply a thin layer) Lubricants Article number

All O-rings Syntheso Proba 270 Syntheso Proba 270

All fastening and locking screws Anti Seize AS 450 AS-450

7 Troubleshooting

Description of the error Possible cause Elimination Personnel

Differential pressure across

the filter too high Filter cartridge dirty Replace filter cartridge

Qualified

person

Dust in the system Filter cartridge defective Replace filter cartridge

O-ring damaged Replace O-ring

Leakage towards the

outside O-ring damaged Replace O-ring

Faulty differential pressure

display Pressure gauge or Reed contact defective Replace pressure gauge*

or Reed contact

8 Replacement and Disposal

After the device has reached the end of its useful life, it must be dismounted and disposed of in an

environmentally compatiblemanner. Duringdismounting, componentsthat maypresenta riskof injuryby contamination,

depending on the medium, are removed. Depending on the processed medium, the

components must be properly decontaminated. Components capable of diffusion (filter cartridge,

O-ring etc.) may have to be taken to a special disposal unit, depending on the medium used.

If no return or disposal agreement has been reached, dismantled components should be recycled:

• Metals should be scrapped

• The remaining components should be disposed of after sorting according to material.

For technical information, please contact our customer service:

MEDENUS Gas-Druckregeltechnik GmbH

Saßmicker Hammer 40

D-57462 Olpe

Phone +49 (0) 2761 / 82788-0

Fax +49 (0) 2761 / 82788-9

In addition, we are always interested in information and experience resulting from the application and

which can be valuable for improving our products.

E-Mail [email protected]

Internet www.medenus.de

NOTICE

*) If the connection lines are equipped with ball valves, the pressure gauge can be

replaced during operation.

14

8

4

52

55

50

9 Spare Parts

9.1 Spare Parts Drawing DF 100

60

Filter cartridge

Spacer

Housing

Cover

Hood

9.2 Parts for Maintenance Work

O-rings

Item

no.

Name Quantity

pcs.

DF100 / 025 DF100 / 050 DF100 / 080 DF100 / 100 DF100 / 150 DF100 / 200

4 O-ring 1 O-014-T O-036-T O-036-T O-044-T O-045-T O-045-T

8 O-ring 1 O-016-T O-021-T O-023-T O-027-T

2 O-030-T O-041-T

O-ring set

order number: OS-041 OS-042 OS-043 OS-044 OS-045 OS-046

Filter cartridge

Item

no.

Name Quantity

pcs.

DF100 / 025 DF100 / 050 DF100 / 080 DF100 / 100 DF100 / 150 DF100 / 200

60 Filter

cartridge

1FP-101 FP-102 FP-103 FP-104 FP-105 FP-106

DF 100 DN 150

shown

15

..............................................................................

10 Notes

16

..............................................................................

10 Notes

17

..............................................................................

10 Notes

18

Declaration of Conformity

Manufacturer: Medenus Gas-Druckregeltechnik GmbH

Address: Saßmicker Hammer 40

D-57462 Olpe-Saßmicke

herewith declares that the product:

DF 100 Cellular Gas Filter

have been subjected to an EC-type examination

and conform to the basic requirements of the directives

GAR (EU) 2016/426 EC-Gas Appliances Regulation and

2014/68/EU A III B EC-Pressure Equipment Directive in the respective current version.

Test reports: CE-0085 / AZ 17/346/4356/210

CE-0085 / AZ

14/108/4501/121

The EC type examination is based on the harmonized European Standards

and/or national standards as well as the European directives and / or regulations:

2014/68/EU A III B EC Pressure Equipment Directive (15.05.2014)

GAR (EU) 2016/426 A III B EC Gas Appliances Regulation (09.03.2016)

Marking (PIN) according to Pressure Equipment Directive and Gas Appliances Regulation

CE-0085CP0531

-0085

The quality assurance system (module D) is monitored by the DVGW.

Registration No. Pressure Equipment Directive SD-0085BQ0510

Registration No. Gas Appliances Regulation SE-0085BQ0510

Olpe-Saßmicke,

22.03.2018

Martin Clemens

Managing Director

19

Deutsch:

http://medenus.de/files/upload/

downloads/DF100/BWA_DF100_de.pdf

Englisch:

http://medenus.de/files/upload/

downloads/DF100/BWA_DF100_en.pdf

In the download area of our homepage, this document is available in different languages. You can use the following

QR codes and links to go directly to the corresponding documents.

MEDENUS Gas-Druckregeltechnik GmbH

Tel. +49 (0)2761 82788-0

Fax +49 (0)2761 82788-9

Sassmicker Hammer 40 / D-57462 Olpe

[email protected]

www.medenus.de

MEDENUS DF 100 Manual

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