Muller 858 Product guide

Operating and assembly instructions
Medium Pressure Regulator
Types 858/859 PS 25 bar
Contents
1. General
1.1 Information
2. Hazard warnings
2.1 Safety related terms
2.2 Safety advisory notice
2.3 Qualified personnel
2.4 Unauthorized alterations and spare parts
2.5 Permissible operating mode
2.6 Inadmissible operating mode
3. Handling
3.1 Transport
3.2 Storage
3.3 Handling prior assembly
4. Product specification
4.1 Overpressure safety shut-off device (OPSO)
4.2 Pressure regulator 1st stage
4.3 Pressure Relief Valve (PRV)
5. Connectors
5.1 Input connectors
5.2 Output connectors
6. Assembly
6.1 Information on hazards during installation,
operation and maintenance
6.2 Installation
6.3 Leak test
7. Operation
7.1 Initial commissioning
7.2 Decommissioning
7.3 Recommissioning
7.4 Fault clearance OPSO (SAV)
7.5 Maintenance
8. Cause and remedy of operating faults
8.1 Fault detection
8.2 Troubleshooting
9. Repairs
10. Warranty
11. Drawing (MDR-858)
12. Drawing (MDR-859)
13. Technical Specification (MDR-858/859)
1. General
Gas pressure regulators serve the purpose of reducing the
outlet pressure to a predetermined constant value regardless
of continuously changing flow rates and independently of
changing inlet pressures.
These operating and installation instructions provide the
information necessary to install and operate the medium
pressure regulator 858/859 safely and in the prescribed
manner.
Should difficulties arise which cannot be solved by means of
the operating instructions, further information should be
obtained from the manufacturer.
These operating instructions comply with the relevant valid
regulations and technical codes of the Federal Republic of
Germany. When using the medium pressure regulator types
858/859 outside the Federal Republic of Germany, the
operator or the person responsible for the design of the plant
must ensure that valid national regulations are observed. The
manufacturer reserves all rights to make technical
modifications and improvements at any time.
The use of these operating and assembly instructions
requires the user to be qualified as described in section 2.3
"Qualified personnel". The user must be instructed according
to the operating and assembly instructions. The operating and
assembly instructions must always be available at the place
of use of the plant.
1.1 Information
The medium pressure regulators type 858/859 consist of a 1st
stage regulator which reduces the unregulated pressure from
the liquid gas container to a fixed set outlet pressure and
keeps it constant. A pressure relief valve (OPSO= Over
pressure shut off) and optionally a pressure relief valve
(PRV= Pressure relief valve) are installed as safety
equipment.
2. Hazard warnings
2.1 Safety related terms
The terms DANGER, CAUTION and NOTE are used in these
operating instructions to indicate special hazards or unusual
information that requires specification.
DANGER! means that non-observance can
endanger life and/or cause considerable damage to
property.
CAUTION!means that there is a risk of injury and/or
damage to property if not observed.
NOTE!means that particular attention is drawn to
technical issues.
However, compliance with other transport, assembly,
operating and maintenance instructions and technical data
not specifically highlighted are equally essential in order to
avoid malfunctions which, in turn, may directly or indirectly
cause personal injury or damage to property.
2.2 Safety advisory notice
DANGER! Liquid gas
•Highly flammable
•Can cause explosions
•Danger to persons through skin contact
2.3 Qualified personnel
All persons involved in the installation, commissioning,
operation, maintenance and servicing of this pressure
regulator must
•be appropriately qualified (specialist
personnel)
•follow these operating instructions carefully
•consider the instruction manual as part of
the product
•keep the instructions for use throughout the
life of the product
•pass on the manual to any subsequent
owner or user of the product
WARNING!
Danger of injury in case of insufficient qualification!
Improper handling can lead to considerable personal
injury and material damage.

2.4 Unauthorized alterations and spare parts
Modification or alteration of the medium pressure regulator
types 858/859 is not permitted. Original drawings and
accessories authorised by the manufacturer serve for safety.
The use of other parts or unauthorised modifications to the
medium pressure regulator types 858/859 by third parties
invalidates the manufacturer's liability for the consequences.
2.5 Permissible operating mode
•liquid gas (gas phase), others on request
•ex zone 1 or 2
•under the container cover (above ground,
underground),
•in weather-protected outdoor areas,
•in buildings and special installation rooms (according
to TRF 2012)
•commercial and industrial facilities
2.6 Inadmissible operating mode
•ex-zone 0
•operating modes that deviate from the permissible
operating modes and technical data
3. Handling
3.1 Transport
During all transportation, the generally recognised rules of
technology and the accident prevention regulations must be
strictly observed.
Handle the goods to be transported with care. During
transport, the pressure regulator must be protected against
shocks, blows or vibration.
Immediately after receipt of the goods, the delivery must be
checked for completeness and transport damage. See also
section 9.0.
3.2 Storage
If the pressure regulator is not installed immediately upon
delivery, it must be stored properly.
Storage temperature -20°C to +60°C, dry, free of dirt and
protected from moisture.
3.3 Handling prior assembly
•Protect from weather influences such as wetness.
•Make sure that the product is free from dust and
foreign particles.
4. Product specification
4.1 Overpressure safety shut-off device (OPSO)
The overpressure safety shut-off device OPSO (Over-
Pressure Shut Off) is open during normal operation and has
the task of automatically shutting off the gas flow as soon as
the set response pressure is reached in order to protect
downstream equipment from impermissibly high pressure. It
must be opened manually after closing (see Restart OPSO).
4.2 Pressure regulator 1st stage
The 1st stage pressure regulator reduces the unregulated
pressure from the liquid gas container to a set outlet pressure.
4.2 Pressure Relief Valve (PRV)
The PRV (Pressure Relief Valve) is closed during normal
operation and is designed to automatically release the gas
flow with limited flow when the pressure in the system to be
protected reaches the set pressure. This is relieved via the
regulator's venting port. It closes again automatically when
the pressure drops below the set pressure.
The outlet opening must be protected against rainwater.
It is important to note that pressure regulators which
are operated inside a building, an enclosure or a
hazardous area must be provided with a vent line to
the outside.
Please observe this information, otherwise liquid gas
can escape in the building, which may lead to an
explosion.
Insect screen with filter screen must be screwed into
the vent on the regulator. It must be checked
regularly whether the screen is free from dirt. A
clogged screen can lead to increased or too low
outlet pressures and thus to a response of the
OPSO.
5. Connectors
5.1 Input connectors
•Cylindrical female threads:
G.37 = G 1/2”
•Soldering screw connection:
G.16
•POL connection:
G.9
•Cutting ring screw connection RVS:
G.22 = 12mm, 15mm, 18mm, 22mm, 28mm
Other connections on request!
5.2 Output connectors
•Cylindrical female threads:
H.22 = G 1/2”
•Cutting ring screw connection RVS:
H.8 = 12mm, 15mm, 18mm, 22mm, 28mm
•Press fitting PVS:
H.10
•Soldering screw connection LVS:
H.10
6. Assembly
6.1 Information on hazards during installation, operation
and maintenance
DANGER!
Safe operation of the pressure regulator is only
guaranteed if it is installed and commissioned by
qualified personnel (see point 2.3 "Qualified
personnel") in accordance with the warnings in this
operating manual. Proper use of tools and protective
equipment must be ensured. The operating
instructions of the pressure regulator must be
observed during all work on the pressure regulator or
when handling the pressure regulator.
6.2 Installation
In addition to the generally applicable installation guidelines,
the following points must be observed:
•accident prevention regulation DGUV 79 +80
(commercial sector)
•corresponding DVGW worksheets
NOTE!
The installation position of the pressure regulator
must be carried out according to the enclosed
support device. It is also important to note that the
installation position of the vents must be selected in
such a way that any water accumulation can drain
off.
The interior of the pipeline must be free of foreign
particles.
A tension-free installation must be ensured.
The pressure regulator must not serve as a fixed
point; it is supported by the pipeline system.
Observe flow direction (marked by an arrow on the
product).

The pressure regulator must be mounted and
protected in such a way that dripping water cannot
penetrate. When installing the regulator on an
underground liquid gas tank, we recommend a
ventilation set (Art. No.: 9 03 310 8 5 000 1). If the
pressure regulator is used outdoors, it must be
mounted under the protective cover of the tank or in
a protective box.
•When tightening the POL connection, avoid any
force being applied to the pressure regulator.
•Prevent sealant from getting into the gas-carrying
components.
•Always use suitable wrenches to counteract
threaded connections.
•After assembly, a careful leak test must be carried
out.
6.3 Leak test
CAUTION: The control device must not be
included in a strength test (design review) of the
entire installation.
•Close all shut-off valves of the connected devices.
•apply test pressure according to TRF 2012
•wait for temperature adjustment
•test duration 10 minutes (the pressure must not
drop)
•spray all connections with foaming agents (e.g. leak
detection spray) and check for leaks.
NOTE!
We recommend the leak test with our testing device
(Art. No.: 1 00 098 14 018 2).
DANGER!
•Before each commissioning of a new installation or
recommissioning of an installation after repairs or
modifications, the following must be ensured:
•proper completion of all installation/assembly work!
•commissioning only by "Qualified personnel "(see
point 2.3).
•passed leak test
7. Operation
7.1 Initial commissioning
After completion of the leak test the pressure regulator is
ready for operation.
7.2 Decommissioning
If the supply and consumption system is to be taken out of
operation, all shut-off valves must be closed and the pipe
system drained. All open connections must be secured with a
suitable seal.
7.3 Recommissioning
When recommissioning the regulator, make sure that all the
relevant steps are repeated as described in section 6.1 to
section 6.3.
If recommissioning is not possible, the manufacturer must be
informed.
7.4 Fault clearance OPSO (SAV)
If the OPSO has locked, indicated by the visual indicator
(red), the following steps are required:
•Close the tapping valve on the liquid gas container
•Relieve the pressure on the pressure regulator (inlet
and outlet side)
•Turning off the OPSO display
•Place OPSO plunger with the enclosed lever tool on
the red indicator and pull it out until it engages
•Open the gas sampling valve after rectifying the fault
7.5 Maintenance
If the points in section 6 are observed, the pressure regulator
is maintenance free.
8. Cause and remedy of operating faults
8.1 Fault detection
DANGER!
When troubleshooting, the hazard warnings
under 2 must be observed.
•If the faults cannot be rectified using the following
table "Troubleshooting (8.2)", the manufacturer must
be consulted.
•In case of malfunctions of the function or the
performance, it must be checked whether the
installation work has been carried out and completed
according to these operating instructions.
•The information on pressure, temperature, and
direction of flow as well as the operating conditions
must correspond to the data sheet or the technical
data on the type plate.
8.2 Troubleshooting
Fault
Measures
Gas smell
Caution: Fire and
explosion hazard!
Keep calm, close the gas supply, open
windows and doors, do not operate
any electrical switches, contact a
specialist.
Consumption
appliance on fault
After depressurising the system,
connect the "Müller test unit" to the
appropriate test connections on the
regulator and take measurements:
•inlet pressure (upstream
pressure before the
controller stage)
•outlet pressure (idle
pressure, consuming device
not in operation
•outlet pressure (flow
pressure, consumer unit in
operation)
Then compare the values with the
technical data of the regulator and
the consumer unit.
No gas flow
Open shut-off valves, check level
indicator if necessary,
OPSO is closed (see
Recommissioning OPSO), check the
filter in the inlet connection as well
as the vent openings and clean if
necessary or contact the
manufacturer.
OPSO is constantly
falling or cannot be
unlocked
Pressure regulator is defective,
please replace
NOTE!
Before carrying out assembly and repair work,
please observe Section 10

9. Repairs
In order to ensure the proper functioning of the installation
under normal operating conditions, it is recommended to
replace the device before 10 years have elapsed since the
date of manufacture.
The 10 years is a recommendation that can be replaced by
national laws or technical regulators, taking into account the
operating conditions of integrated safety devices and
maintenance schedules.
According to DGUV 79:
The Contractor must ensure that parts of consumable
equipment that are subject to wear and aging are replaced
after a maximum of 8 years. This does not apply if the proper
condition has been confirmed by an expert.
10. Warranty
The scope and period of warranty is defined in the version of
the "General Terms and Conditions" of Müller Gastechnik
GmbH valid at the time of delivery.
All information and notes in this manual have been compiled
taking into account the applicable standards and regulations,
the state of the art and our many years of expertise and
experience. The manufacturer accepts no liability for
damages due to:
•Non-compliance with the instructions
•Unintended use
•Use of untrained personnel
•Unauthorised conversion
•Technical changes
•Use of non-approved spare parts. The actual scope
of delivery may differ from the explanations and
illustrations described here in the case of special
versions, the use of additional ordering options or
due to the latest technical changes.
11. Drawing (MDR-858)
1. inlet connection POL
2. pressure regulator 1st stage
3. adjusting screw (outlet pressure adjustment)
4. exhaust vent medium pressure regulator
5. outlet connection
6. testing device form G 1/4".
7. visual indication OPSO (SAV)
8. vent opening OPSO (SAV)
9. overpressure safety shut-off device OPSO (SAV)
12. Drawing (MDR-859)
1. inlet connection POL
2. pressure regulator 1st stage
3. sealing plug
4. exhaust vent medium pressure regulator
5. outlet connection
6. testing device form G 1/4
7. exhaust vent OPSO (SAV)
8. visual indication OPSO (SAV)
9. overpressure safety shut-off device OPSO (SAV)
13. Technical Specification (MDR-858/859)
Max. permissible
pressure: PS 25
Response
pressure
OPSO:
1-4 bar
to
4,7 bar
Nominal flow
Mg: 10 kg/h
Response
pressure PRV:
1.7 bar
to
5,0 bar
Inlet pressure
p: 3-16 bar
Connection at
inlet: Pol
Nominal outlet
pressure pd: 1-4 bar
Connection at
outlet: G 1/2”
Temperature
range
-40 °C
to
+50 °C