Spectron Spectrolab LM71 User manual

User manual
Pressure regulator
LM71
12/2021

Contents Spectron Gas Control Systems GmbH
ii GES_LM71_1221
Contents
1 Introduction.................................................................................................................................................. 3
2 Description................................................................................................................................................... 4
2.1 Intended use ......................................................................................................................................... 4
2.2 Misuse .................................................................................................................................................. 4
2.3 Identification / label ............................................................................................................................... 4
2.4 Environment.......................................................................................................................................... 5
2.4.1 Temperatures............................................................................................................................. 5
2.4.2 Degree of cleanliness ................................................................................................................ 5
2.4.3 Emissions................................................................................................................................... 5
2.5 Standards and laws .............................................................................................................................. 5
3 Safety............................................................................................................................................................ 7
3.1 Basic information on the safety instructions ......................................................................................... 7
3.2 Safety instructions ................................................................................................................................ 8
3.3 Emergencies and safety devices .......................................................................................................... 10
3.4 Qualification of the operating and maintenance personnel................................................................... 10
4 Design and function .................................................................................................................................... 12
4.1 Design................................................................................................................................................... 12
4.2 Functional description........................................................................................................................... 13
4.3 Technical data ...................................................................................................................................... 14
4.4 Boundaries and interfaces .................................................................................................................... 14
5 Installation.................................................................................................................................................... 15
5.1 General information .............................................................................................................................. 15
5.2 Installation work .................................................................................................................................... 15
5.2.1 Connecting the incoming and outgoing lines ............................................................................. 15
5.3 Checking the armature ......................................................................................................................... 15
6 Commissioning............................................................................................................................................ 16
6.1 Preparations for commissioning ........................................................................................................... 16
6.2 Procedure for commissioning ............................................................................................................... 16
7 Operation...................................................................................................................................................... 17
7.1 Exchanging the process gas source..................................................................................................... 17
8 Maintenance, cleaning and repairs............................................................................................................ 19
8.1 General information on maintenance.................................................................................................... 19
8.2 Regular maintenance work and cleaning.............................................................................................. 20
9 Repair ........................................................................................................................................................... 21
9.1 General information on repair work ...................................................................................................... 21
9.2 Troubleshooting and fault rectification .................................................................................................. 22
10 Dismantling and disposal ........................................................................................................................... 23
10.1 General information on dismantling ...................................................................................................... 23
10.2 Returns ................................................................................................................................................. 23
10.3 Disposal ................................................................................................................................................ 24

Spectron Gas Control Systems GmbH Introduction | 1
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1 Introduction
This user manual is the original user manual for the Pressure regulator LM71 from Spectron
Gas Control Systems GmbH, referred to as Spectron.
The user manual is intended to facilitate correct and safe operation for the operating firm, and to
warn against misuse. It is intended for the qualified personnel and the operator of the facility.
WARNING
Incorrect operation
Incorrect operation of the system, e.g. due to instruction errors, can lead to personal injury or
damage to the system.
a) Access to the user manual by the operating and maintenance personnel must be absolutely
ensured at all times.
b) A copy of the system documentation including the user manual must therefore be kept
either on the system or in a suitable and accessible location.
This user manual contains information protected by copyright law. It must not be photocopied,
reproduced, translated or copied onto data carriers, either in full or in part, without prior author-
isation. Spectron retains all further rights.

2 | Description Spectron Gas Control Systems GmbH
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2 Description
2.1 Intended use
Pressure regulator of type LM71 are suitable for flammable gases, non-flammable gases, non-
corrosive gases and for oxygen up to gas quality 6.0.
The permissible gas types and pressure ranges are each specified on the label (see "Identifica-
tion / label [}4]").
The equipment versions of the Pressure regulator without electrical components may be used in
an explosion hazard zone as they do not have separate ignition sources (ignition hazard as-
sessment according to DIN EN ISO 80079-36).
Pressure regulator with electrical components that are suitable for use in an explosion hazard
zone are marked on the label according to EU Directive 2014/34/EU.
To be able to use the Pressure regulator as intended, all persons working with it must comply
with the specifications of the relevant user manual.
The area in which hazards can occur when used as intended is the area around the Pressure
regulator. The danger zone changes depending on the system status and use.
2.2 Misuse
Any improper use constitutes misuse. Pressure regulator may only be used for the specified
gases and in the specified pressure range. Pressure regulator with electrical components
without marking according to EU Directive 2014/34/EU may not be used in an explosion hazard
zone.
Furthermore, the following operating conditions are regarded as misuse:
– Use for gases in their liquid phase
– Failure to carry out inspection and maintenance work
– Pressurisation in reverse (opposite to the flow direction)
– Operation with gases that are not specified on the label
– Operation outside the permissible technical limit values
– Failure to heed and comply with any applicable legal regulations and other provisions
– Non-observance of the user manual
– Failure to heed the information on the label and in the product data sheet
2.3 Identification / label
The label is located on the on the body of the Pressure regulator.
The label provides the following details:
Details Example
Project number PROJECT
Article description LM71-200-10-M-M-…
Inlet pressure P1 200 bar
Outlet pressure P2 10 bar
Gas type GAS TYPE

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2.4 Environment
2.4.1 Temperatures
Normal temperatures expected in a production area are assumed when operating the system:
-20°C to +60°C.
The air humidity must be below 60 % rel. humidity to prevent condensation. The operating tem-
perature depends on the gas used.
2.4.2 Degree of cleanliness
Access to the system and to the escape and rescue routes must not be blocked.
The product should be kept clean (dust-free).
A suitable purge gas must be used, taking into account the quality and properties of the process
gas.
Compressed air must be used for the control air at least class 5 according to ISO 8573-1.
2.4.3 Emissions
The A-rated sound pressure level does not exceed the value of 70 dB(A). It is not necessary to
wear hearing protection.
The waste gas line or a burst disc line must not end in areas where the escaping process gas
poses a hazard to persons or the environment.
Further emissions in the form of vibrations, radiation, vapours, dusts and waste water do not oc-
cur in the regular operation of the product.
2.5 Standards and laws
The design and construction of the Pressure regulator is subject to the following standards and
directives:
2006/42/EC Machinery Directive
2014/68/EU Pressure Equipment Directive
2014/34/EU ATEX directives
DIN EN ISO 12100:2010 Safety of Machinery
Safety data sheet for the gases used Process gas and auxiliary media
Various additional laws, regulations and guidelines must be complied with when handling pres-
surised gases. Find out about the laws, regulations and guidelines that apply in your location.
BetrSichV Betriebssicherheitsverordnung (Industrial
health and safety ordinance)
ProdSG Produktsicherheitsgesetz (Product Safety Law)
GefStoffV Gefahrstoffverordnung (Hazardous Substances
Ordinance)
TRGS 400, 407, 500, 720, 721, 722, 727,
745,746
Technische Regeln Betriebssicherheit (Tech-
nical Regulations on Operational Safety)
TRBS 1111, 2152, 3145, 3146 Technische Regeln Betriebssicherheit (Tech-
nical Regulations on Operational Safety)
DGUV Regulation 1 German Trade Association Principles of Pre-
vention
DGUV Rule 113-001 German Trade Association Rules on Explosion
Protection

2 | Description Spectron Gas Control Systems GmbH
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EIGA documents

Spectron Gas Control Systems GmbH Safety | 3
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3 Safety
3.1 Basic information on the safety instructions
The product complies with the recognised technical regulations. Nevertheless, knowledge of the
media used and their dangers as well as basic knowledge of the pressure control panel are pre-
requisites for safe and accident-free operation.
The user manual must be read and understood by every user. Instruction must be documented
in writing.
The safety instructions are to be regarded as a supplement to the applicable accident preven-
tion regulations and laws. Existing accident prevention regulations and laws must be observed
in all cases.
NOTICE
Hazards from the operating environment of the system can lead to injuries to persons.
a) No changes may be made to the system which result in a change in function.
b) It is not possible to outline and cover in this manual all hazards arising from the environment
or unforeseeable operating conditions of the system.
In the Safety Instructions chapter:
– Users are informed regarding hazards, residual risks and measures for risk reduction.
– The presentation of the safety instructions and the symbols is explained.
– Basic safety instructions to be observed in general are listed. Specific safety instructions are
listed in the relevant chapters.
DANGER
DANGER indicates an imminent danger. If not avoided, death or extremely serious injur-
ies will result.
WARNING
WARNING indicates a potential imminent danger. If not avoided, death or serious injury
could result.
CAUTION
CAUTION indicates a potentially imminent danger. If not avoided, minor or moderate in-
jury could result.
NOTICE
NOTICE indicates a potentially harmful situation. If not avoided, the system or property in
its vicinity could be damaged.

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3.2 Safety instructions
The safety instructions are to be observed by all persons working on the system. The rules and
regulations for accident prevention applicable to the place of use are to be observed. The in-
struction of the operating and maintenance personnel on system safety must be documented.
Please pay special attention to this chapter to avoid accidents.
All measures and specifications in the safety data sheets must be implemented and observed.
DANGER
Gas leaks
If gas escapes on the product, contamination of persons, fires or explosions or the displacement
of atmospheric oxygen can occur! Serious or fatal injuries are possible.
a) Do not place pipelines and fittings under mechanical stress. Never use pipelines and com-
ponents as climbing aid or to secure other parts!
b) In the event of leaks, immediately secure the affected area!
c) Smoking and naked flame are strictly prohibited!
DANGER
Intended use
Operation of the product with gases other than those specified or outside the limits may result in
dangerous reactions in the system. Incorrect use poses considerable risks to operating person-
nel and the environment!
a) Only use the product for gases for which it was designed.
b) Only use the product in the specified limit values for pressure and withdrawal quantity.
c) Usage for another type of gas or outside the limit values is prohibited and constitutes mis-
use.
DANGER
Defective product
A defect on the product can result in unforeseeable operating conditions. Persons may be in-
jured.
a) The product may only be operated in technically perfect condition in compliance with all
chapters of the user manual.
b) Environmental protection laws and safety regulations must be observed.
WARNING
Displacement of atmospheric oxygen
In the event of inert gas leaks, displacement of atmospheric oxygen may occur. Danger of suf-
focation!
a) The operator must ensure adequate ventilation and airing in all rooms with gas installations
and monitor the oxygen content.

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WARNING
Repairs
If the product is not used as intended, unpredictable operating conditions may occur. Serious
personal injuries are possible.
a) Repairs may not lead to a change in function. The system may not be tampered with or
modified.
b) Before each repair, the system must be depressurised and flushed through.
c) Repairs are only permitted to be carried out by trained persons.
WARNING
Incorrect operation
Incorrect operation of the system, e.g. due to instruction errors, can lead to personal injury or
damage to the system.
a) Access to the user manual by the operating and maintenance personnel must be absolutely
ensured at all times.
b) A copy of the system documentation including the user manual must therefore be kept
either on the system or in a suitable and accessible location.
WARNING
Working on the product
If an accident occurs when working on the product, there is a considerable risk of injury.
a) Never work on the product unattended or unannounced.
b) Observe the site safety rules and permission procedure.
WARNING
Maintenance
Incorrect maintenance or maintenance work performed at the incorrect time can result in dam-
age to the system or injury to persons.
a) To avoid static charges, do not clean the product using dry cloths. Use damp cotton cloths.
b) The maintenance intervals are to be specified by the system operator as part of its risk as-
sessment.
c) Observe the maintenance intervals and maintenance guidelines from the manufacturer and
the applicable guidelines.
d) Components may only be replaced by spare parts of the same design. The specifications of
the component manufacturers must be complied with during installation.
CAUTION
Pressure relief lines
Discharge of hazardous media at the end of a pressure relief line or exhaust air line.
a) Pressure relief lines may not end in areas where the escaping process gas poses a hazard
to persons or the environment.
b) The position of the pressure relief line must be carefully checked taking into account the ma-
terial properties, main wind direction and other conditions.

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NOTICE
Lighting
Incorrect switching actions or confusion can occur due to inadequate lighting.
a) Ensure sufficient lighting in accordance with the statutory regulations.
3.3 Emergencies and safety devices
The operational local safety regulations of the system operator, such as the alarm plan, fire
safety regulations and the escape and rescue plans, apply in all cases for the operation of the
Pressure regulator.
When handling gases, all specifications from the safety data sheets must be followed. Local
emergency services should be informed of the gases used at the site of the system.
In the event of mechanical damage, the product must be put into a safe operating condition.
Pressure regulators and pressure control panels are equipped as standard with an integrated
relief valve to protect the armatures – except for variants with outlet pressures >100 bar. The
user must ensure there is a suitable safety device installed downstream, if not already included
with the equipment as standard.
NOTICE
The pressure relief valve or the burst disc are used to blow out gas that must be conveyed away
via a non-permitted pressure rise.
They do not function as a safety valve for the entire gas supply system.
CAUTION
Overpressure in downstream armatures, pressure vessels and pipelines in the
event of failure of the pressure regulator and its outlet pressure protection
To protect downstream armatures, pressure vessels and pipelines against excess pressure, a
safety device corresponding to the operating firm's regulations must be installed.
3.4 Qualification of the operating and maintenance
personnel
The intended user group is the system operator (user of the system) and the system mainten-
ance personnel.
Every person working on the system must be familiar with the functions and dangers associated
with the overall system. Instruction on the system is to be documented in writing.
Maintenance and repair work should only be carried out by specially trained personnel.
All operators, as well as personnel who regularly enter the area, must be trained on a minimum
of the following topics:
– Alarm rules at the site and conduct in the event of malfunctions and leaks
– Basic functions of the product
– User manual
– System documentation incl. manufacturer documentation
– Position of the safety devices

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GES_LM71_1221 11
– Safety data sheets on the process gas used
– Personal protective equipment
In addition, operators must have the requisite physical and mental skills to operate and maintain
the equipment.
Persons who do not meet this requirement (e.g. visitors), must not remain alone in the overall
system.
Operating personnel must use appropriate personal protective equipment for the activities to be
performed and the associated environmental hazards. The operational instructions and the spe-
cifications of the employers' liability insurance associations and the safety data sheets must be
complied with.

4 | Design and function Spectron Gas Control Systems GmbH
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4 Design and function
4.1 Design
1
3
4
5
2
Illustration1: Pressure regulator design LM71
The design described is an example. The product design may vary depending on the configura-
tion.
Item Description Short name Connection
1 Inlet: Cylinder connection, screw or female thread See data sheet or indi-
vidual configuration
2 Pressure setting PR
3 Outlet pressure gauge PG P2
4 Process gas connection
5 Label

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4.2 Functional description
Process gas
Illustration2: P&ID LM71
The intended use of the Pressure regulator LM71 is pressure relief of a gas from an inlet pres-
sure to a fixed or adjustable outlet pressure.
This pressure reduction is performed by the pressure regulator. It is equipped with a pressure
gauge to show the outlet pressure. The outlet pressure is set to the desired value by turning the
of the handwheel on the pressure regulator and must not exceed the defined maximum value
given on the label.
In the case of the single-stage pressure regulation present here, the set outlet pressure does
not remain completely constant and instead rises slightly as the inlet pressure decreases (e.g.
caused by a draining cylinder).

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4.3 Technical data
NOTICE
The technical data can be taken from the data sheet for the relevant product. If this is not avail-
able, you can view and download it at www.spectron.de.
The maximum input and output pressures and the gas type are given on the identification or la-
bel.
4.4 Boundaries and interfaces
The scope of supply includes the product as described in the "Design" chapter. The transfer
points to process gas, exhaust air and auxiliary media (incl. power supply) are the connections
on the pressure control panel or product.
The following areas and functions have not been included in the scope of supply from Spectron:
– other systems, lines and installations of the overall system
– Process gas source
– Exhaust air (this applies in particular to foreseeable problems, e.g. failure of the exhaust air
system)
– Supply of auxiliary media (compressed air, purge gas)
– Power supply
– Lighting
– Controller

Spectron Gas Control Systems GmbH Installation | 5
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5 Installation
5.1 General information
CAUTION
Injury or damage in the event of incorrect assembly or disassembly
Special steps are required for assembly and disassembly work on the product. Personal injuries
and damage to the product are possible.
a) Assembly and disassembly work may only be carried out by the installation engineer or ap-
propriately skilled specialist companies and persons.
b) The product is not permitted to be re-used following disassembly. All components must be
disposed correctly.
Depending on the type of gas, different requirements apply to the installation space of gas sup-
ply systems. It is essential to observe the legal regulations and trade association regulations,
and the information in the safety data sheets.
Familiarise yourself with the necessary work steps (see "Installation work [}15]") and prepare
the necessary tools.
5.2 Installation work
5.2.1 Connecting the incoming and outgoing lines
All lines must be connected in accordance with the applicable standards and specifications and
tested with purge gas (pressure test and leak test). The specifications on dimensioning of the
connections are described in the "Design" chapter.
1. Connect the process gas input of the pressure regulator to the gas source or the process
gas line. Do not use an adapter between the gas source valve and the cylinder or bundle
connection of the pressure regulator!
Observe the identification of the inputs (IN) and outputs (out) or the arrow for the flow direc-
tion.
2. Connect the process gas output of the pressure regulator to the process.
3. Connect the waste gas outlet of the pressure regulator to the waste gas lines, if necessary.
5.3 Checking the armature
Check all connections for leakage.

6 | Commissioning Spectron Gas Control Systems GmbH
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6 Commissioning
6.1 Preparations for commissioning
Purge the armature prior to initial commissioning! It is imperative to adhere to the direction of
the gas flow when doing this! You must not purge counter to the usual direction of flow (from the
tapping point to the process gas source), as this can flush debris resulting from the installation
work, for example, back into the armature.
The connecting threads and connecting surfaces of the gas source valves as well as the sealing
rings must be checked to ensure that they are in perfect condition.
Always turn shut-off valves as far as the stop when opening or closing them.
Make sure that:
– the fittings are marked for the corresponding gas type,
– all protective caps have been removed,
– the assembly has been correctly carried out and a leak test has been performed,
– all valves are closed (the red marking is visible in the handwheel window)
– the pressure regulator has been depressurised (if possible),
– the purge gas supply (only standard for SP4 and SP6) is in operation,
– the on-site exhaust gas system is functional at all times and is in operation,
– all shut-off armatures are checked for loose connections and
– the controller is in operation.
6.2 Procedure for commissioning
Flushing in the entire line network to the consumer must be implemented via a waste gas valve
on the process. To do this, refer to the system documentation for the consumer.
1. Close all valves and fully depressurise the pressure regulator by turning the of the hand-
wheel anticlockwise as far as it will go.
2. Open the process gas source valve and, if necessary, the downstream valves. Ensure that
the pressure regulator is not subjected to a pressure surge.
3. Slowly set the pressure regulator to the required outlet pressure. The process source pres-
sure and the gas type properties are to be taken into account here.
During regular operation, the system will be in supply mode.
For interrupting the supply or decommissioning, close all valves and fully depressurise the pres-
sure regulator by turning of the handwheel anti-clockwise as far as it will go.

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7 Operation
7.1 Exchanging the process gas source
NOTICE
Penetration of ambient air into the system
Each time you change the cylinder, ambient air gets into the connecting parts of the system. To
prevent the gas and the entire system from being contaminated, the connection must be purged
before gas is drawn from the cylinder again. In the case of non-toxic, non-corrosive gases, this
can be done by means of multiple pressure purges with process gas. In the case of corrosive or
toxic gases or gases that are hazardous in some other way, purging must be carried out with in-
ert gas.
WARNING
Gas source exchange
If a gas source exchange is performed incorrectly, gas leakage and poisoning of persons may
occur.
a) The gas source exchange are to be carried out by trained specialist personnel and never
unattended.
b) A pressure test must be conducted after each gas source exchange.
c) For each gas source exchange, a new seal suitable for the used gas is to be used.
d) Wear the personal protective equipment prescribed in the risk assessment.
With each gas source exchange, check the port for leak-tightness. We strongly recommend re-
placing the gasket every time the gas source is exchanged. Always turn the shut-off valves
slowly and as far as the stop when opening or closing them!
Removing the empty process gas source:
1. Close the process gas source valve.
2. Briefly open the venting valve or decrease the pressure via the process.
3. Ensure that the pressure gauges indicate 0 bar and thus that the pressure regulator is fully
relieved.
4. Fully release the adjustable pressure regulator.
5. Disconnect the process gas source connection.
6. Mount the sealing nut on the gas source valve and protective cap on the process gas
source.
7. Identify, secure and remove the empty process gas source.
Connecting the new process gas source:
1. Provide new process gas source, position in front of the bracket and secure using the safety
chain.
2. Remove and retain the protective cap and screw plug.
3. Check the port thread and gasket; a new gasket must be used each time the gas source is
exchanged.
4. Screw the process gas connection onto the gas source valve by hand and tighten it gastight
with a spanner.

7 | Operation Spectron Gas Control Systems GmbH
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5. Open the process gas source valve, build up pressure, and close it again. Check using leak
test spray whether the process gas port is leak-tight.
6. Slowly open the gas source valve.
The pressure regulator is ready for supply.

Spectron Gas Control Systems GmbH Maintenance, cleaning and repairs | 8
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8 Maintenance, cleaning and repairs
8.1 General information on maintenance
WARNING
Noise emission
When working on pressurised pneumatic supply, significant noise emission can occur. Acute
and chronic loss of hearing may result.
a) Never perform work on the pressurised pneumatic supply without hearing protection.
b) Only replace the silencers when the supply is unpressurised.
WARNING
Incorrect operation
Incorrect operation of the system, e.g. due to instruction errors, can lead to personal injury or
damage to the system.
a) Access to the user manual by the operating and maintenance personnel must be absolutely
ensured at all times.
b) A copy of the system documentation including the user manual must therefore be kept
either on the system or in a suitable and accessible location.
WARNING
Working on the product
If an accident occurs when working on the product, there is a considerable risk of injury.
a) Never work on the product unattended or unannounced.
b) Observe the site safety rules and permission procedure.
WARNING
Maintenance
Incorrect maintenance or maintenance work performed at the incorrect time can result in dam-
age to the system or injury to persons.
a) To avoid static charges, do not clean the product using dry cloths. Use damp cotton cloths.
b) The maintenance intervals are to be specified by the system operator as part of its risk as-
sessment.
c) Observe the maintenance intervals and maintenance guidelines from the manufacturer and
the applicable guidelines.
d) Components may only be replaced by spare parts of the same design. The specifications of
the component manufacturers must be complied with during installation.

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CAUTION
Injury or damage in the event of incorrect assembly or disassembly
Special steps are required for assembly and disassembly work on the product. Personal injuries
and damage to the product are possible.
a) Assembly and disassembly work may only be carried out by the installation engineer or ap-
propriately skilled specialist companies and persons.
b) The product is not permitted to be re-used following disassembly. All components must be
disposed correctly.
NOTICE
Lighting
Incorrect switching actions or confusion can occur due to inadequate lighting.
a) Ensure sufficient lighting in accordance with the statutory regulations.
Correctly performed and timely maintenance increases the service life, ensures availability and
helps to avoid undesirable downtimes. Depending on the gas type, the components are subject
to different maintenance intervals. Observe the stipulations from the applicable directives.
Servicing and maintenance measures are only permitted to be carried out by competent spe-
cialist companies and persons.
Maintenance work should be documented by the operator. The documentation should indicate
who carried out which work and when (proof of maintenance).
It is only permitted to use original spare parts or equivalent spare parts as well as suitable tools:
The recommended maintenance and test intervals are to be observed! (Also observe the manu-
facturer's documents)
The causes of possible defects are to be investigated, e.g. damage, unusual noises, overheat-
ing, etc.
Before beginning maintenance work, the pressure control panel must be purged (see "Interrup-
tions to operation for more than 48 hours"). After completing the works, a re-commissioning pro-
cess must be carried out (see "Commissioning [}16]").
8.2 Regular maintenance work and cleaning
For components in which the tests reveal wear or even malfunctions, repairs or component re-
placement must be carried out by competent specialist companies and persons.
Components Test Interval
Filter Replace filter Replacement with insufficient flow
rate
All Visual inspection for corrosion,
damage and correct fastening Func-
tional test
Functional test
Leakage test
At least annually and before each
commissioning process
Earthing Visual inspection for damage and
correct fastening
At least annually
The product should be cleaned on a regular basis. Heavy soiling can lead to malfunctions.
Only clean the product as necessary using a damp, lint-free and clean cloth, without cleaning
agent.