MEDENUS RS 254, RS 255, RS 250, RS 251, R 101 Instructions Manual

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Gas pressure regulator RS 254 / RS 255

Operating and Maintenance Instructions

Subject to technical modifications!

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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 10

5.3 Leakage Test (Test for External Leakage) 11

5.4 Initial Commissioning / Recommissioning 12

5.5 Decommissioning 14

6 Maintenance 14

6.1 Maintenance Plan 14

6.2 Maintenance Procedure 15

6.3 Table of Screw Tightening Torques MA 16

6.4 Lubricants Table 16

6.5 Screw Retention 16

7 Troubleshooting 17

7.1 Gas Pressure Regulator 17

7.2 Safety Shut-Off Valve 18

8 Replacement and Disposal 19

9 Spare Parts 20

9.1 Spare Parts Drawing RS 254 / RS 255 DN 25 - DN200 20

9.2 Optional Spare Parts Drawing 21

9.3 Parts for Maintenance Work 22 Main diaphragm and O-ring 22 Intermediate Diaphragm 22 Valve plate 22 Valve Plate SSV / Diaphragm SSV 23 O-Ring and Sealing Ring Sets 23 Safety diaphragm 24

10 Notes 25

11 Declaration of Conformity 26

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 RS 254 / RS 255 Product Information

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

• Gas Pressure Regulator RS 254 / RS 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 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 GasDruckregeltechnik 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

1.2 Symbols, Notes

The instructions contain safety instructions marked with symbols to indicate possible consequences in case of nonobservance:

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.

NOTICE

DANGER

Note

1.3 Terms, Abbreviations

Terms and abbreviations are explained below:

ATC Acceptance test certificate DN Nominal width GPR Gas pressure regulator HDS High-pressure screw spindle

MA Screw tightening torque

pd Outlet pressure p outlet pressure MOP Maximum operating pressure in a system

Setpoint of the

SSV-Safety shut-off valve SRV Safety relief valve

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.

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. The device must be inspected by a representative of the manufacturer 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.

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 companies' 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.

Operator's obligations

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 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.

devices during the warranty period only

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.

4 Transport, Storage and Packaging

4.1 Transport

Note

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

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 ionising 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 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 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.

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.

DANGER

Note

DANGER

5.2 Mounting

• Remove packaging and protection from the connection flange surfaces.

• Install the device without twisting the pipeline. Tighten screws crosswise.

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

• In all installation positions other than horizontal, MEDENUS Gas-Druckregeltechnik GmbH must be consulted.

• The tightening torques of the flange connections and additional information is available in the DVGW GAS information issue no. 19 (Flanged Connections in Gas Installations).

Note

5.01 5.02 5.03

5.28

5.06 5.07 5.08

5.10

5.04

5.05

measuring point

5.11 5.125.09

5.13

measuring point

fig. 5.1

• A separate installation of the SSV breather line (item 5.07) is recommended.

• All breather lines (items 5.04 / 5.07) must be vented to the outside atmosphere.

• Breather lines (items 5.04 / 5.07) may not be required

if breather valves or safety diaphragms are being used.

• The measuring lines (items 5.05 / 5.08) 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.

• The maximum flow rate at the measuring point must not exceed 25 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 25 m/s are also possible. Please contact us.

• The measuring line must be connected to the pipeline separately, laterally or at the top for each device (1 gas pressure regulator (item 5.03); 1 integrated SSV (item 5.06).

• The SSV measuring line (Pos. 5.08) must always be connected to the measuring point in front of the first outletside shut-off valve (item 5.13).

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 installed in the gas pressure regulator and the first shut-off valve on the outlet side. This room must be checked using the a 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.

In direct-acting devices (without power supply), the outlet pressure acting on the actuator (limited by the SSV) should not be more than 0.5 bar above the set setpoint. This should be taken into account when specifying the response pressure of the upstream SSVs. Recommended upper response pressures:

• P

• Pd > 100 - 200 mbar P

• Pd > 200 - 1000 mbar P

• Pd > 1000 mbar P

For other countries:

≤ 100 mbar P

= Pd + 50 mbar

dso

= Pd + 100 mbar

dso

= Pd x 1.5

dso

= Pd + 500 mbar

dso

5.09

The relevant national and international standards shall apply.

5.10

Procedure

• Close the ball valves upstream of the valves and fittings (item

5.01).

• Close the downstream shut-off devices (item 5.13) (ball valves, solenoid or pneumatic valve).

• Depressurise the system (item 5.11).

• If there is a SRV (safety relief valve) in the controlled section and

the test pressure is higher than the relief pressure of the SRV (item

5.09), the line upstream of the SRV (item 5.10) must be closed.

• Raise the test pressure always slowly and steadily.

Note

fig. 5.2

While doing so, you must ensure:

Pressure in outlet chamber (item 5.12) ≤ Pressure in inlet chamber (item 5.02) 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 5.10) again.

5.09

5.10

NOTICE

Note

fig. 5.2.1

5.4 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 Acceptance Test Certificate (ATC)* and the type plate.

Prior to commissioning of the system, a functional test must be performed on the gas pressure

Note

Procedure (fig. 5.1)

• Close the ball valves upstream of the valves and fittings (item 5.01).

• Close the downstream shut-off devices (item 5.13) (ball valves, solenoid or pneumatic valve).

• Depressurise the system (item 5.11).

• Close venting ball valve (item 5.11).

• Slowly open ball valve upstream of the valves and fittings (item 5.01).

Note

regulator (GPR), if applicable, and the safety shut-off and safety relief valves.

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. The same is true of the outlet shut-off valve.

• Check the inner leakage of the SSV (item 5.06) by reading the pressure gauge installed downstream of the GPR (item 5.12).

• Unscrew the sealing cap (item 5.15) of the safety shut-off valve (SSV).

• Perform pressure compensation via the SSV by pulling at the pull knob (item

5.14) and allowing the SSV to engage. In GPR with bypass ball valve (item

5.28), open the ball valve (item 5.28) while pulling the pull knob (item 5.14) until the SSV engages to perform pressure compensation.

• A closing pressure corresponding to the set value is established on the GPR.

An SSV with underpressure shut-off can only be engaged if the

Note

• Testing the response pressure of the SSV by slowly increasing or decreasing the output pressure to response pressure.

• It may be necessary to correct the setpoint values of the response pressures. This is done by turning the SSV setpoint setting screws (items 5.17 / 5.19) to the right (pressure increase) or left (pressure decrease) in order to increase/ decrease the setpoint value.

Note

pressure at the measuring point exceeds the set value by at least the re-engagement differential.

The inner setting screw (item 5.17) sets the underpressure shut-off level (lower trigger level) and the outer setting screw (item 5.19) sets the upper trigger level.

5.14

5.15

fig. 5.3

5.16

5.17

5.18

5.19

*) Acceptance Test Certificate (ATC) available optionally

• Perform pressure compensation via the SSV again by pulling the pull knob (item 5.14) and allowing the SSV to engage.

5.14

fig. 5.4

• For the functional test of the GPR, let gas flow via the discharge line (venting) (item 5.11) to the outside atmosphere and read the set regulating pressure on the outlet pressure gauge (item 5.12).

• It may be necessary to correct the setpoint of the outlet pressure once again. This is done by turning the GPR setpoint setting screw (item 5.22) to the right or left, in order to increase and decrease the setpoint, respectively, after removal of the GPR sealing cap (item 5.21).

• After closing the discharge line (item 5.11), a constant closing pressure within the closing pressure class can be read on the outlet pressure gauge (item 5.12).

• Slowly open the shut-off valve (item 5.13), close the discharge line (item

5.11) and read the set regulating pressure on the outlet pressure gauge (item 5.12).

• It may be necessary to correct the setpoint of the outlet pressure once again.

• Screw on the sealing cap (item 5.15) of the safety shut-off valve (SSV) again.

• Screw on the GPR sealing cap (item 5.21) again.

5.21

fig. 5.5

Changing the control range

Switching to the control range of a different setpoint spring can be done for the SSV as well as for the GPR while the device is pressurised.

Gas pressure regulator

• Take off the sealing cap (item 5.21) and unscrew the setting screw (item

5.22).

• Pull out the spring plate (item 5.24) with ball (item 5.23) and spring (item

5.25) and replace the spring with one that fits.

• Screw in the spring plate (item 5.24), the ball (item 5.23) and the setting screw (item 5.22) again.

• Set the desired setpoint and screw on the sealing cap (item 5.21) again.

Safety shut-off valve

• Remove the sealing cap (item 5.15) and screw off the pull knob (item 5.14) for changing the spring of the underpressure shut-off device (item 5.16).

• Screw off the corresponding setting screw (items 5.17 / 5.19) for the upper or lower trigger level.

• Pull out the spring (item 5.16 / 5.18) and replace it with one that fits.

• Screw in the setting screw (item 5.17 / 5.19) again and fasten the pull knob

(item 5.14) on the spindle again.

• Set the desired setpoint and screw on the sealing cap (item 5.15).

5.22

5.23

5.24

5.25

fig. 5.6

The SSV closes if the overpressure setpoint spring (upper trigger level) is removed from a pressurised system.

fig. 5.7

Note

5.5 Decommissioning

For decommissioning, please refer to the documents listed under item 1 "General Information" and the system operator's work instruction.

Procedure (fig. 5.1)

• Slowly close the outlet shut-off valve (item 5.13) or

• Close the ball valves upstream of the valves and fittings (item 5.01).

• Depressurise the system (item 5.11).

• Close venting ball valve (item 5.11).

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 observe initially the maintenance periods according to the data given in 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.

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 9.3 for maintenance work.

Interval Maintenance activities Personnel

Replacing O-rings Replacing diaphragms

When required

Replacing the valve plate Replacing sealing rings for the connections of the breather lines and

measuring lines

Qualified person

6.2 Maintenance Procedure

The maintenance procedure is described in detail step-by-step in our video tutorial and our pictorial descriptions. 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

NOTICE

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.

For recommissioning, please refer to the relevant manufacturer's documentation of the gas pressure regulator installed in the system or chapter 1 and 5.4 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.

DANGER

Note

6.3 Table of Screw Tightening Torques MA

RS 254 / 025 RS 254 / 050

Item no. Exception

51 M8 / 18 Nm M10 / 36 Nm

54 M6 / 8 Nm M8 / 18 Nm

RE 205 M10 / 36 Nm

DN 200 M12 / 62 Nm

RS 254 / 080 RS 254 / 100 RS 255 / 050

M8 / 18 Nm M10 / 36 Nm

M8 / 18 Nm M10 / 32 Nm

RS 254 / 150 RS 254 / 200 RS 255 / 080 RS 255 / 100

6.4 Lubricants Table

Components (apply a thin layer) Lubricants

All O-rings Syntheso Proba 270

All fastening and locking screws Anti Seize AS 450

Balls Unisilkon TK 44N2

6.5 Screw Retention

Components (apply a thin layer) Adhesive and sealing agent

Stud bolts Loctite-648

fig. 6.1

7 Troubleshooting

7.1 Gas Pressure Regulator

Description of the error Possible cause Elimination

Actuator dirty or damaged

Static sealing elements defective Replace O-rings Closing pressure too high No closing pressure

Unstable outlet pressure curve (vibrations, pulsation)

Control deviation too large

Inadmissible pressure peak Dynamic closing pressure too high

Noise

Gas escapes through breather line

*) Excessive damping limits the actuation speed. **) Normal flow noise does not constitute a fault. However, this noise can be reduced by installing a noise reduction device.

Clamping of the compensating

diaphragm has come off

Compensating membrane is damaged

or mounted incorrectly.

Valve plate has become disconnected

from the valve stem

Device is working in the closing

pressure range

Vibration resonance in the control

system

Unfavourable connection of the

measuring line

Sluggishness of the device due to dirt Subject device to maintenance

Main diaphragm or compensating

diaphragm defective or mounted

incorrectly

Wrong regulator size selected

Wrong setpoint spring selected

Wrong control cone selection

Inlet pressure supply is insufficient

(pressure losses in the supply line too

high)

Damping of the device too high

Control system too dynamic

Closing speed of downstream shut-off

devices too high

Gas velocity too high Check regulator design

Sluggishness of the device due to dirt

/ wear

Fastening of the main diaphragm has

come off

Main diaphragm is damaged or has

been mounted incorrectly

Internal leakage gas SRV is set too low

or is not tight

Check valve plate (seal) and valve seat for damage and dirt, replace valve plate, if necessary

Check compensating diaphragm for fastening, damage, and correct fit, replace it, if necessary.

Tighten nut under the valve plate

Check regulator design

Install restrictor plate in breather line Install baffle plate in measuring line Continue closing restrictor in measuring line by turning clockwise * Install a harder spring (setpoint spring of the next higher control range) Check setting of gas consumption devices Use of throttle valve RSD (optional accessory) Select a measuring point with steady flow, check measuring point

Check diaphragm and replace if necessary

Check controller design, setpoint spring / control cone and replace if necessary

Increase inlet pressure Check pipeline cross-section Check built-in filter Continue opening restrictor in measuring line by turning anticlockwise Remove restrictor plate from breather line Check breather lines and dimension them larger, if necessary. Replace breather valve with safety diaphragm or breather line

Reduce closing speed of shut-off device

Perform maintenance on actuator If worn-out mechanically, replace it, if necessary

Check diaphragm for fastening, damage and correct fit

Correct settings of leakage gas SRV Check O-ring for damage and dirt, replace if necessary

Note

7.2 Safety Shut-Off Valve

Description of the error Possible cause Elimination

Actuator dirty or damaged No internal tightness in closed position

SSV cannot be opened No pressure compensation at actuator

SSV does not engage

Permissible response pressure group is exceeded Irregularities in response behaviour

Gas escapes through breather line

Pressure compensation valve (internal

bypass) in the actuator dirty or sealing

elements damaged

Difference between response pressure

and operating pressure or between

upper and lower response pressure is

too small

Only in case of underpressure

switching: Diaphragm

in the control device defective or

incorrectly installed

Pressure at the measuring point too

high or low (only with underpressure

switching)

Sluggishness of the trigger

mechanism due to dirt / wear

Difference between response pressure

and operating pressure or between

upper and lower response pressure is

too small

Diaphragm in the control device

incorrectly installed

Sluggishness of the trigger

mechanism due to dirt / wear

Diaphragm clamping has become

loose

Diaphragm is damaged or has been

mounted incorrectly

O-ring sealing (item 35) dirty or

damaged

Check valve seat and valve plate (seal) for damage and dirt

Check O-rings in the pressure compensation valve or at the SSV spindle and replace them, if necessary

Pressure compensation by opening the bypass ball valve (item 5.28)

Correct response pressure settings consider required re-engagement differential (see RS 254 / 255 product overview)

Check diaphragm and replace it, if necessary

Lower or increase pressure at measuring point to operating value (GPR setpoint value)

Service switching device and replace it, if worn-out mechanically

Correct response pressure settings consider required re-engagement differential (see RS 254 / 255 product overview) *

Check whether diaphragm is twisted

Service switching device and replace it, if worn-out mechanically

Check diaphragm for fastening, damage and correct fit Check O-ring and replace it, if necessary

*) The pressure differences between GPR, SSV and system SRV must consider the response and closing pressure groups as well as the re-engagement differentials of the devices in order to avoid any unintended SRV switching.

Note

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 compatible manner. During dismounting, components that may present a risk of injury by contamination depending on the medium are removed. Depending on the processed medium, the components must be properly decontaminated. Components capable of diffusion (diaphragm, 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:

NOTICE

MEDENUS Gas-Druckregeltechnik GmbH Saßmicker Hammer 40 D-57462 Olpe

In addition, we are always interested in information and experience resulting from the application and which can be valuable for improving our products.

Phone +49 (0) 2761 / 82788-0 Fax +49 (0) 2761 / 82788-9

E-Mail info@medenus.de Internet www.medenus.de

9 Spare Parts

9.1 Spare Parts Drawing RS 254 / RS 255 DN 25 - DN200

9**

*) 1x O-ring at RE 160 / 205 / 275 / 385 **) 4x O-ring at RE 320 / 390 8x O-ring at RE 485

fig. 9.1

9.2 Optional Spare Parts Drawing

RS 254 / 255 shown with safety diaphragm

fig. 9.2

fig. 9.3

RS 254 / 255 shown with HDS high-pressure

screw spindle

fig. 9.4

RS 254 / 255 shown with noise reduction

Noise reduction

9.3 Parts for Maintenance Work

Main diaphragm and O-ring

Item

no.

15 O-ring 1 O-029 O-033 O-029 O-041 O-042 O-042 O-043

16 Diaphragm 1 M-111 M-121 M-141 M-122 M-132 M-152 M-162 M-172

Name Quantity

pcs.

Main diaphragm set

order number:

RS 254 / 025 RS 254 / 050

RE 160 RE 205 RE 320 RE 205 RE 275

M-111 MS-121 MS-141 MS-122 MS-132 MS-152 MS-162 MS-172

RS 254 / 080; RS 254 / 100; RS 255 / 050

RS 255 / 080; RS 254 / 150; RS 255 / 100; RS 254 /

200

RE 385 /

390 MB

RE 385 /

390

GMB

Intermediate Diaphragm

Item

no.

12 Diaphragm 1

Name Quantity

pcs.

Valve RS 254 / 025

RS 254 / 050

17.5 M-001

27.5 M-002 M-003

32.5 M-004* M-005

42.5 M-006 M-007 M-007

52.5 M-008** M-009 M-009 65 M-010 M-010 85 M-011 M-011 95 M-012 M-012

115 M-013

RS 254 / 080 RS 254 / 100 RS 255 / 050

RS 255 / 080 RS 254 / 150

RS 255 / 100

RS 254 / 200

RE 485

Valve plate

Item

no.

6 Valve plate 1

*) only in RS250 / 050 **) only in RS250 / 100 and RS251 / 050

Name Quantity

pcs.

Valve RS 254 / 025

17.5 VT-001

27.5 VT-002 VT-003

32.5 VT-004* VT-005

42.5 VT-006 VT-006 VT-006

52.5 VT-007** VT-007 VT-007 65 VT-008 VT-008 85 VT-009 VT-009 95 VT-010 VT-010

115 VT-011

RS 254 / 050

RS 254 / 080 RS 254 / 100 RS 255 / 050

RS 255 / 080 RS 254 / 150

RS 255 / 100

RS 254 / 200

Valve Plate SSV / Diaphragm SSV

Item

no.

30 Valve plate 1 VT-201 VT-202 VT-206 VT-208 VT-210 34 Diaphragm 1 M-201 M-201 M-201 M-202 M-202

Name Number Exception RS 254 / 025

RS 254 / 050

RS 254 / 080 RS 254 / 100 RS 255 / 050

RS 255 / 080 RS 254 / 150

RS 255 / 100

RS 254 / 200

O-Ring and Sealing Ring Sets

Item

no.

2 O-ring

4 O-ring 1 O-014 O-018 O-037 O-044 O-046

7 O-ring 1 O-007 O-009 O-009 O-009 O-009

8 O-ring 1

9 O-ring

10 NBR-ring

11 O-ring 1

14 NBR-ring 2

17 O-ring 1 O-008

20 O-ring 1

Name Quantity

pcs.

1 O-014 O-018 O-036 O-044 O-046

2 DN 50 O-014

2 before 1992 O-036

1 O-019 O-039 O-040 O-031 O-031

8 RE 485 O-003 O-003

Exception RS 254 / 025

RS 254 / 050

O-014 O-035 O-038 O-026 O-026

RE 320 O-004

RE 320 O-002

RE 390 O-002

N-001 N-002 N-002 N-002 N-002

Valve 27.2 N-001

Valve 17.5

Valve 27.2 O-007

Cast

sealing

cap

No NBR-

ring

O-007 O-009 O-009 O-009 O-009

N-001 N-003 N-003 N-003 N-003

O-015 O-015 O-036 O-036 O-036

O-014 O-014 O-015 O-015 O-015

RS 254 / 080 RS 254 / 100 RS 255 / 050

RS 255 / 080 RS 254 / 150

RS 255 / 100

RS 254 / 200

21 O-ring 1 O-012 O-012 O-016

24 O-ring 1 O-007 O-009 O-009 O-009 O-009

25 O-ring 1 O-001 O-001 O-001

32 O-ring 1 O-007 O-007 O-007 O-009 O-009

35 O-ring 1 O-007 O-007 O-007 O-009 O-009

36 O-ring 1 O-013 O-013 O-013 O-014 O-014

O-ring set

order number:

OS-001 OS-002 OS-003 OS-004 OS-005

O-016 O-016

Safety diaphragm

Item

no.

22 O-ring 1 O-029 O-033 O-029 O-041 O-042 O-043

23 Diaphragm 1 M-123 M-143 M-123 M-133 M-163 M-173 26 O-ring 1 O-013 O-013 O-013 O-013 O-013 O-013

Name Quantity

pcs.

Safety diaphragm set

order number:

RS 254 / 025 RS 254 / 050

RE 205 RE 320 RE 205 RE 275

MS-123 MS-143 MS-123 MS-133 MS-163 MS-173

RS 255 / 080; RS 254 / 150; RS 255 / 100; RS 254 / 200

RS 254 / 080; RS 254 / 100; RS 255 / 050

RE 385 /

390

Example:

Name Type

Gas pressure

regulator:

Spare parts according to tables in 9.3

RS254 080 390* 27,5 MD-R MB* SM...

DN -

nominal width

RE -

Control device

D - nozzle (valve

diameter)

SSV

Control unit

Main-

diapraghm

RE 485

Option

Main diaphragm and O-ring: MS-152 Intermediate diaphragm: M-003 Valve plate: VT-003 Valve plate SSV: VT-202 Diaphragm SSV: M-201 O-ring and sealing ring set: OS-002 Safety diaphragm: MS-163

The allocation of individual parts is done according to the item no. in the tables in 9.3, conforming to the spare parts drawings in 9.1 and 9.2.

When ordering, please state the serial number from the type plate.

Example Composition of the factory number

16 10 - 123 / 01

Year

Month

Note

Position (Request / the confirmation)

The replacement of parts must be performed only by trained and authorized persons.

*) When selecting the main diaphragm set for control device RE 385 / 390, a distinction has to be made between MB and GMB. The GMB diaphragm is standard equipment and is therefore not mentioned separately in the controller designation.

Continuous no.

NOTICE

10 Notes

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

Declaration of Conformity

(Summary)

Manufacturer: Medenus Gas-Druckregeltechnik GmbH Address: Saßmicker Hammer 40

D-57462 Olpe-Saßmicke

herewith declares that the products:

R 254 / RS 254 / RP 254 / RSP 254 R 255 / RS 255 / RP 255 / RSP 255

Gas Pressure regulator (spring-loaded proportional regulator), optionally with safety shut-off valve (SSV) for upper and lower shut-off pressure, and / or with pilot support, have been subjected to an EC-type exam ination 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 report: CE-0085 / AZ17/304/4308/210 V2

The EC type examination i s bas ed on the harmon i zed European Standards and/or national standards as well as the Euro p ea n directives and / or re g u l ati o ns :

2014/68/EU A III B EC Pressure Equipment Directive (15.05.2014) GAR (EU) 2016/4 2 6 A II I B EC G as A p p li anc es Regulation (09.03.2016)

DIN EN 334 (01.07.2009) DIN EN 14382 (01.07.2009)

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

CE-0085AQ0882 model R 254 / RS 254 / RP 254 / RSP 254 CE-0085AQ0883 model R 255 / RS 255 / RP 255 / RSP 255

-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

ging Director

Mana

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 this document in your language.

German:

http://medenus.de/files/upload/ downloads/RS254/ BWA_RS254_255_de.pdf

English:

http://medenus.de/files/upload/ downloads/RS254/ BWA_RS254_255_en.pdf

MEDENUS Gas-Druckregeltechnik GmbH Fon +49 (0)2761 82788-0

Fax +49 (0)2761 82788-9 Saßmicker Hammer 40 / D-57462 Olpe info@medenus.de

www.medenus.de

MEDENUS RS 254, RS 255, RS 250, RS 251, R 101 Instructions Manual

Specifications and Main Features

Frequently Asked Questions

User Manual