0/05 OPERATING INSTRUCTIONS for gas pressure regulators PN0 with integrated slam shut valve (SSV) and integrated limited capacity safety relief valve (RV) MR 25 F0, MR 25 SF0 p e 20 kpa - 0 MPa (0,2-0 bar) p as 2-50 kpa (20-500 mbar) MR 50 F0, MR 50 SF0 p e 20 kpa - 0 MPa ( 0,2-0 bar) p 2-50 kpa ( 20-500 mbar) as For natural gas, town gas, propane (gases to DVGW G 260 II) and air. Ambient temperature: -20 C to +60 C Installation, adjustment and maintenance ONLY by trained and authorized staff! WARNING: Incorrect handling during installation, adjustment, modification, functional testing and/or maintenance activities may cause injuries and/or material damage. Read the operating instructions prior to starting the installation. This unit must be installed and monitored in accordance with the rules in force. Maximum inlet pressure: p emax : MPa (0 bar) Set outlet pressure: p as : according to typeplate Slam shut setting pressures: p so : according to typeplate p su : according to typeplate We recommend installing a filter upstream of each unit. Each unit is equipped with a sieve in the inlet. Regulators witch are not installed should be supported in horizontal position to avoid damages on the diaphragm.
2 0/05 Install pressure regulator into the pipework (see also label on regulator) Remove sealing caps and/or foils from the connecting surfaces.the direction of the gas flow must coincide with the arrow on the housing. Test and ensure that the inside of the gas lines is clean. The pressure regulator can be installed both into vertical and horizontal pipes. Attention! If required, the setting of the outlet pressure must be corrected. As a rule, the factory adjustment is for horizontal installation with the diaphragm housing upwards. The housing must not touch any surrounding walls. Use only approved jointing compounds and approved gaskets. No jointing compound should be allowed to enter the gas pipe when installing the pressure regulator. Always use an appropriate spanner. Do not use chimney on top of diaphragm housing as a lever.. Install and connect exhaust line () and ventilation line (2) Connection exhaust line 5L (G/2 ); line diameter: DN 5 for line lengths up to m; DN 20 up to 5 m; DN 25 up to 0 m; DN 50 for lengths exceeding 5 m. Vent. line SSV: 2L (G/ ) Connect relief line using approved jointing compounds and lead it outdoors. Do not connect relief line with other function lines (if possible) and, as far as possible, use no or few elbows. If oscillation appears, remove the damping valve D in the exhaust connection. Connect sensing line () Connection thread: 2L (G/ ) Connect and install sensing line. Attention! for best operations, there should be a line of 5 DN between regulator and sensing connection. MR50: install an additional sensing line for the SSV Use approved jointing compounds. min 5 DN If oscillation appear, install separate damping valve For low capacities (flow rate q < 0% q max) there is no separate sensing line necessary. MR 50: change the regulator to internal impulse. MR25: there is no change necessary. Test impermeability D Damping valve Attention! The gas pressure regulator must not be included when carrying out the leak test for the overall system (if required, insert blinds). Pressurize gas pressure regulator inlet:. x p e max outlet:. x p as max (however, always lower than.0 bar) The inlet pressure must always be equal to or higher than the outlet pressure. Use detergents at the connections of pipe and sensing line to check for leaks. 2
0/05 Periodical Inspection / Maintenance The inspection and maintenance intervals correspond to gas and working conditions. For good efficiency and safety we recommend that the schedule of periodical inspection and maintenance should not exceed legal guidelines. In any case good technical standards must be respected. During maintenance all parts are to clean and to check visually. This applies particularly to all seals, diaphragms and guiding parts. Damaged parts are to replace. Assembly drawing, spare part lists, tools and torques you can find in chapter maintenance. After every maintenance work a tightness and function test is to perform. Starting and functional testing Reset slam shut valve (SSV) () Connect manometer to measure the outlet pressure. Open valve upstream of the pressure regulator. Close the valve downstream of the regulator. Check slam shut lock up: observe pressure reading; the pressure downstream must not rise. Unscrew and remove reset cap. Slightly pull reset cap; approx. mm, and observe pressure reading. The line downstream of the unit is now pressurizing. The outlet pressure will be stabilized at approx..2 x p as. Remove reset cap up to the stop and keep holding for approx. 0 seconds. Screw down reset cap again. Check lock up of the control valve: observe pressure reading; the outlet pressure must not rise. Cause consumption for a few seconds. Determine lock up pressure: maximum. x pas for lock up pressure class SG 0; maximum.2 x pas for lock up pressure class SG 20. Test RV set pressure: increase outlet pressure via feed line until the relief valve is actuated. Observe pressure reading. Check lock up of relief valve: without any additional gas supply, the outlet pressure must not fall below 0.9 x set pressure. Close relief line. Check setting of over pressure slam shut: increase outlet pressure via feed line (approx. mbar/s) until over pressure slam shut is tripping. Observe pressure reading. Lower outlet pressure and release slam shut. Open relief line. Only MR 25 SF..., MR 50 SF... Close valve upstream of the pressure regulator. Check setting of under pressure slam shut. Lower outlet pressure (approx. mbar/s) until under pressure slam shut is tripping. Observe pressure reading. Open valve upstream of the pressure regulator. Release slam shut. Open valve downstream of the pressure regulator.
0/05 Change outlet pressure p as Attention! The outlet pressure range is covered by several adjusting springs. In case the desired outlet pressure cannot be adjusted by means of the built-in spring, the corresponding spring must be mounted. Activate consumer or cause consumption. Measure outlet pressure. 2 Unscrew sealing cap. Turn adjusting ring by means of special key or Allen key Clockwise: outlet pressure increases. Anticlockwise: outlet pressure decreases. Mark adjusted value of outlet pressure on the unit (xxx). Screw sealing cap tight. 2 xxx Change relief valve set pressure Attention! The relief valve set pressure must always be higher than the lock up pressure of the control valve and lower than the slam shut set over pressure. Measure outlet pressure. 2 Unscrew sealing cap. Turn adjusting ring by means of screw driver. Clockwise: set pressure increases. Anticlockwise: set pressure decreases. Test set pressure. Screw sealing cap tight. (Blocking RV: Turn adjusting ring clockwise as far as it will go) 2 Change slam shut set pressures Attention! The set pressure ranges are covered by several adjusting springs. In case the desired set pressure cannot be adjusted by means of the built-in spring, the corresponding spring must be mounted. Cause consumption for a few seconds. Measure outlet pressure. 2 Unscrew sealing cap. Turn adjusting ring by means of special key for over pressure slam shut and screw driver for under pressure slam shut. Clockwise: set pressure increases. Anticlockwise: set pressure decreases. Screw sealing cap tight. Test set pressure respectively set pressures. Mark adjusted values of set pressures on the unit (xxx). xxx 2
0/05 Maintenance and disassembly During maintenance all o-rings are to check. Exchange damaged or worn rubber parts.. Attention: use correct torques (see pages 6-8) check smooth operation of movable parts 5 Regulator Take off vent and sense lines. Unscrew top cap, take out adjusting ring and setting spring.. Disassemble top cover. Only MR50: Remove spring positioner. Remove adjusting nut of relief valve (RV), take out relief valve adjusting spring. Dismantle relief valve / working diaphragm assembly. Check o-ring and seat of RV and condition of working diaphragm if necessary take apart relief valve / working diaphragm assembly. Only MR50: Remove nut on valve spindle by means of two additional nuts which are screwed counter, afterwards: Remove diaphragm spacer (Aluminium). Check equalizing diaphragm. Dismantle bottom cover. Only MR50: Take out adapter ring (brass). Check o-rings at bottom cover and adapter ring Disassembly and check of valve seat (sealing edge and o-ring) with valve seat spanner, after that: take out valve spindle. Check valve plate. Assembly of the regulator is reverse to disassembly. Safety Shut-off Valve (SSV) Take off vent pipe (MR50: SSV sense line too). Unscrew SSV (MR50: incl. Adapter plate) off regulator body. Check o-rings. Check valve plate and valve seat. Dismantle SSV top cover completely. Disengage working diaphragm by turning 90 and take it out. Check working diaphragm. Assembly of the Safety Shut-off valve is reverse to disassembly. Attention: Always carry out starting and functional testing according to the rules after maintenance (page ). EC declaration of conformity In our capacity as manufacturers, we hereby declare that the products MR25 F0, MR25 SF0, MR50 F0 and MR50 SF0 marked with identification No. CE/0085BM020, comply with the fundamental requirements of the following Directive: - 97/2/EC in conjunction with EN The relevant products correspond to the types tested by the notified body 0085 (DVGW). Comprehensive quality is guaranteed by a certified Quality Management System pursuant to DIN EN ISO 900:2000 according annex II, paragraph of Directive 90/96/EEC. ELSTER GmbH Mainz-Kastel, Germany
6 0/05 65 0. 0 98 68 65 2, - 2, Nm 2, - 2, Nm 50.2 50..0.9 7-25 Nm 2, - 2, Nm 25 20; 20.0; 20.2 70.0 70. 9,0-0,0 Nm 70.5 70.6 50.6 5.20 5.7 5.9 5..0 5.7 5.6 60 Spare Parts List: MR 25 PN 0 0 / 200.9 SSV valve seat 709 X.0* O-Ring 22x,5 DIN 55 T, SSV valve seat 00978 X 5..0 Valve spindle with balancing diaphragm and valve seat 7090080 X 5.6 Regulator valve seat Ø,7 mm 70077 X 5.7* O-Ring 0x,5 DIN 55 T, Regulator valve seat 00977 X 5.7 Balancing diaphragm 7090052 X 5.9 Gasket 700872 2x 5.20 O-Ring 6,75x,78 DIN 55 T, Limited capacity relief valve 0098 X 50.2 O-Ring 7x DIN 55 T, Botem 009200 X cover / housing 50. O-Ring 7x DIN 55 T, Balancing 00079 X diaphragm 50.6 Gasket x9,2x2 plug / external 62820 X sensing connector 65 Adjusting spring RV d=.8mm 702 8-90 mbar Adjusting spring RV d=.7mm 70052 5-25 mbar Adjusting spring RV d=2mm 70089 00-20 mbar ) Set ranges are offset to the outlet pressure (Pas) 70.0 Working diaphragm assembly 7009500 X 70. Working diaphragm 700952 X 70.5 Cardboard underneth balancing 70096 X diaphragm 70.6 Plate 7095 X 98 Washer underneath damping valve 060206 X 0 Damping valve assembly 7002208 X 20 Adjusting spring d=.6 Brown 700897 9-2 mbar Adjusting spring d=2 Lightblue 7008950 25-50 mbar Adjusting spring d=2 Darkblue 70005 5-70 mbar Adjusting spring d=2.5 Yellow 707779 55-0 mbar Adjusting spring d=.6 Anthracite 707667 20-00 mbar Adjusting spring d= Black 70856 250-500 mbar 20.2 Slip ring for adjusting spring 7009527 X 25 Unsiversal adjusting ring 70005 X 25 Adjusting ring for pas > 00 mbar 70095 X 0. O-Ring 27x2 DIN 55 T for top cap 0000 X 60.0 Safety shut-off valve MR 25 F 70808 X Safety shut-off valve MR 25 SF 70809 65 Seal white 70208 X - Sieve MR25 70026 X - Circlip MR25 07000 X
0/05 7 27 0 0 2 2 0-2 Nm 8-22 Nm 2..2 90 9 9 6,0-7,0 Nm 2, - 2, Nm 60 65 25 26 20 70.0 70. 70.2 70. 0-2 Nm 5 5.22 5.7 5.0 5.0 9 0 5.2 5. 5.7 5.6 Spare Parts List: MR 50 PN0 0 / 200.6 Plug G ¼ 7009787 X.7 Seal A x8x,5 0720 X 5.0 Outlet cartridge assembly 7088 Outlet cartridge assembly, int. Impuls 70558 X 5.0 Valve spindle assembly incl. valve 708 X seat 5.2* Valve plate 708 X 5.2 Valve plate hard 60 Shore 708258 X 5.* O-Ring 9 x NBR 70 Shore 00959 X 5.7* O-Ring 5 x,5 NBR 70 Shore 009095 X 5.22* O-Ring x 2 NBR 70 Shore 00998 X 9* O-Ring 7 x 2 NBR 70 Shore 0096 X 0 Valve seat 708 X * O-Ring 90 x 2,5 NBR 70 Shore 00965 2 x 2* O-Ring 58 x 2,5 NBR 70 Shore 0096 X * O-Ring 2 x 2,5 NBR 70 Shore 00955 X 5* Balancing diaphragm 7085 X 70.0 Working diaphragm assembly 70850 X 70.2* O-Ring 26 x 2,5 NBR 70 Shore 0095 X 70.* O-Ring 2 x NBR 70 Shore 009550 X 70.* Working diaphragm 70852 X 0.0 Damping valve assembly 7002208 X Washer for damping valve 060206 X ) Set ranges are offset to the outlet pressure (Pas) 20 Adjusting spring d=2.7mm White 708 20-0 mbar Adjusting spring d=.2mm Yellow 7082 25-50 mbar Adjusting spring d=.6mm Green 708 5-00 mbar Adjusting spring d=mm Blue 708 90-200 mbar Adjusting spring d=.5mm Red 7085 50-00 mbar Adjusting spring d=5mm Brown 7086 250-00 mbar Adjusting spring d=5.mm Black 7087 50-500 mbar 2 Spring positioner 7085 X 25 Adjusting ring 700289 X Adjusting ring >00 mbar 70855 26 Slip ring for adjusting spring 70067 X 27* O-Ring 6x2 DIN 55T for top cap 00920 X 0 Top cap 7002890 X 2 Adjusting spring RV d=.8mm 702 8-0 mbar Adjusting spring RV d=.7mm 70052 6-5 mbar Adjusting spring RV d=2mm 70089 0-20 mbar 60.0 Safety shut-off valve MR 50 F 7088 X Safety shut-off valve MR 50 SF 70882 65 Seal white 70208 X 90 Sieve MR 50 700555 X 9 Circlip 00258 X 9* O-Ring 5x2,5 DIN 55T, SSV 0098 X Adapter 207 Sense line SSV, internal impuls 70559 X 208 Connection piece, internal impuls 000897 2 x
8 0/05 7 5 6 7 2.2 0 2.0 0,5 -,0 Nm 2 0.0 8 8.0 6 7 20,5-2,0 Nm 5 6 0. Spare Parts List: SAV for MR PN0 0 / 200 - SSV SV O 25 (MR 25 F) 7055 - SSV SV O/U 25 (MR 25 SF) 705 - SSV SV O 50 (MR 50 F) 7070 - SSV SV O/U 50 (MR 50 SF) 70702 O-Ring,2 x,9 NBR 70 Shore 00997 X 6 SSV reset knob 7095 X 7 Circlip for SSV reset knob 062709 X 8 O-Ring x2 NBR 70 Shore at guiding 00998 X liner 0 O-Ring 28,x,78 NBR 70 Shore at 00909 X conection part SSV-Valve plate MR 25 70288 X SSV-Valve plate MR 50 705 X 5 O-Ring,78x,02 NBR 70 Shore in 0000 X SSV valve plate 6 Clip for valve plate fixing 70076 X 7 Gasket in SSV valve plate 7026 X 8.0 Trip mechanism assembly SSV O 7022 X 8.0 Trip mechanism assembly SSV O/U 70226 X 20 relief spring 700576 X 2.0 diaphragm holder assembly (incl. 70099 X working diaphragm) 2.2 Working diaphragm SSV 70089 X Adjusting spring "O" Orange 700895-67 mbar Adjusting spring "O" White 7008955 59-8 mbar Adjusting spring "O" Lightblue 7008956 7-276 mbar Adjusting spring "O" Yellow 7008957 26-70 mbar Adjusting spring "O" Black 70896 50-900 mbar 2 Adjusting ring over set pressure up to 00 mbar 70076 P so >=00 mbar 2 Adjusting ring over set pressure exceeding 00 mbar 7007626 P so < 00 mbar 5 Adjusting spring "U" Yellow 70087 6-8 mbar Adjusting spring "U" White 7008959 6-9 mbar Adjusting spring "U" Lightblue 7008960 7-6 mbar 6 Adjusting ring under set pressure 7007625 X 0.0 Top cap 70070 X 0. O-Ring 22x2 NBR 70 Shore at top cap 00920 X 7 O-Ring 7,65x,78 NBR 70 Shore at impulse hole 000 X ELSTER HANDEL GmbH Steinernstr. 9-2, D-55252 Mainz-Kastel, Tel.: +9 6/605-0, Fax.: +9 6/605-90 www.elster.com