Operating Manua al for cylinder pressure regulators with purge device Series FE5/52/53-SP Series FE2-SP
Contents Contents... 2. Introduction... 3. General information... 3.2 Description of the Series FE5/52/53-SP and FE2-SP... 3.3 Intended use... 4.4 Personnel requirements... 5 2. For your safety... 5 2. Symbols used... 5 2.2 Essential safety information... 5 2.3 Safety devices... 6 3. Description... 8 3. Overview - structure... 8 3.2 Functional description... 0 3.3 Technical data... 0 3.4 Connection options... 3.5 Check valve in the purge gas inlet (9):... 4. Operation... 4. Labelling... 4.2 Installing the cylinder pressure regulator... 2 4.3 Putting the cylinder pressure regulator FE5/52/53-SP2A into operation... 3 4.4 Putting the cylinder pressure regulator FE5/52/53-SP2 and FE2-SP into operation... 3 4.5 Putting the cylinder pressure regulator FE5/52/53-SP3 into operation... 4 4.6 Changing the cylinder on cylinder pressure regulator FE5/52/53-SP2A... 5 4.7 Changing the cylinder on cylinder pressure regulator FE5/52/53-SP2 and FE2-SP... 5 4.8 Changing the cylinder on cylinder pressure regulator FE5/52/53-SP3... 6 4.9 Taking out of operation... 7 5. Faults... 7 6. Maintenance, cleaning and repairs... 8 6. Regular maintenance work and visual inspections... 8 6.2 Regular cleaning... 8 6.3 Repair information... 8 6.4 Returns... 8 2 GES_FE5-52-53SP+FE2SP_6.docx
. Introduction. General information Validity This Operating Manual applies to cylinder pressure regulators of Series FE5/52/53-SP and FE2-SP. Manufacturer Spectron Gas Control Systems GmbH Fritz-Klatte-Straße 8 D-65933 Frankfurt Deutschland / Germany Telephone: +49 69 3806-0 Fax: +49 69 3806-200 E-mail: info@spectron.de Internet: www.spectron.de Publication date October 206 Retention and completeness This Operating Manual is a component part of the cylinder pressure regulators of Series FE5/52/53-SP and FE2-SP and must be stored in a place where it is accessible to authorised persons at all times. Under no circumstances may chapters be removed from this Operating Manual. If the Operating Manual is lost or pages are missing in particular the chapter "For your safety," it/they must be replaced immediately. Copyright This Operating 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 authorisation. All rights reserved. Updates No update service is provided for this Operating Manual by Spectron Gas Control Systems GmbH. Changes to this Operating Manual may be made without further notification..2 Description of the Series FE5/52/53-SP and FE2-SP Cylinder pressure regulators of the FE5/52/53-SP and FE2-SP Series are single-stage cylinder pressure regulators with pressure gauges for measurement of the inlet and outlet pressure. The main task of the cylinder pressure regulator is to reduce the inlet pressure to the outlet pressure required for the specific application. The letters "SP" denote cylinder pressure regulators equipped with a purge device The purge device is used, for example, in applications where penetration of atmospheric gas into the gaswetted area of the downstream pipe system up to the connected equipment is not desirable, requiring purging of the atmosphere before the pipe system is connected. The purge device is also used to flush toxic or corrosive process gas from the pressure regulator before it is removed from the gas cylinder, e.g. when changing the cylinder, preventing such gases in unpurged fittings reaching the surrounding atmosphere. GES_FE5-52-53SP+FE2SP_6.docx 3
. Introduction.3 Intended use Intended use Cylinder pressure regulators of Series FE5/52/53-SP and FE2-SP are intended for use with corrosive gases up to quality 6.0. The permissible gases and pressure ranges are specified on the type plate. Cylinder pressure regulators reduce a variable inlet pressure to an outlet pressure which is as constant as possible. Introduction of pressure for the process gas is effected via the inlet screw fitting (e.g. cylinder connection). Appropriate measures must be taken to prevent the introduction of pressure via the pressure regulator outlet. Cylinder pressure regulators with the designation FE5/52/53-SP2A can be purged with the process gas via the two valves installed in the outlet. Cylinder pressure regulators with the designations FE5/52/53-SP2, FE5/52/53-SP3 and FE2-SP are equipped with an additional inlet valve, providing the option of purging the fitting with a separate purge gas. Pressure regulators without electrical components (such as a contact pressure gauge or pressure transducer) may be used in potentially explosive atmospheres, since they do not have a potential ignition source of their own (ignition hazard evaluated in accordance with DIN EN 3463-). The ignition hazard has to be taken into account with pressure regulators with electrical components. The ignition hazard must be evaluated based on the documentation for the respective electrical components, taking into account their incorporation into the overall system, and Directives 204/34/EU (ATEX 4) and 999/92/EC (ATEX 37) must be observed. Foreseeable misuse The following operating conditions are deemed to constitute misuse: Operation with gases that are not specified on the type plate Use with gases in their liquid state Operation outside the permissible technical limit values Non-observance of the legal regulations and other provisions valid on-site Failure to comply with this Operating Manual Failure to carry out inspection and maintenance work Failure to heed the information on the type plate and in the product data sheet Pressurisation counter to the normal direction of flow The mixing of gases via the normal gas inlet and the purge gas inlet 4 GES_FE5-52-53SP+FE2SP_6.docx
. Introduction.4 Personnel requirements Definition of "authorised person" Authorised persons are persons with technical training, who have received technical instruction on the overall system and the associated hazards gas cylinder gas type gas cylinder valve pressure regulator and who have successfully completed training courses onn "The supply of pressurised gases." Tasks of the operating personnel Operating personnel must be able to recognisee and in as far as possible and permissible remedy faults and irregularities. Requirements for operating personnel In order to perform their tasks, operating personnel must meet the following requirements: The operating personnel must have received instruction in the operation of the pressuree regulator from an authorised person and must have read and understood this Operating Manual in its entirety. 2. For your safety 2. Symbols used Danger! This symbol warns that there is a "risk of fatal injury" or a health hazard for personnel. 2.22 Essential safety informationn Various laws, regulations, rules and directives apply when handling pressurised p gases and must be complied with, depending on the gas type. The following list lays no claim to be exhaustive; it merely represents a selectionn of important documents: EU Directive 2009/04/EC (Work Equipment Directive) Note! The following safety information is intended to supplement the applicable national accident prevention regulations and laws. Thee relevant accident prevention regulations and laws must always be complied with. EU Directive 999/92/EC (ATEX 37) EU Directive 98/24/EC (Dangerous Substances Directive) Industrial health and safety ordinance (implementationn of Directives 2009/04/EC in German law) Ordinance on hazardous substances (implementation of Directivee 98/24/EC and 999/92/EC in German law) TRBS (technical regulations on industrial safety and health) publications TRGS (German technical rules for f hazardous substances) publications GES_FE5-52-53SP+FE2SP_6.docxx 5
2. For your safety TRAS (technical regulations on plant safety) publications BGV A German trade association basic accident prevention regulations BGR 04 German trade association rules on explosion protection BGR 32 German trade association rules for the avoidance of ignition hazards resulting from electrostatic charges BGR 500 2.26 German trade association rules on welding, cutting and related work procedures BGR 500 2.3 German trade association rules for working on gas lines BGR 500 2.32 German trade association rules for the operation of oxygen systems BGR 500 2.33 German trade association rules for the operation of systems that handle gas 2.3 Safety devices The pressure regulator is equipped with an integrated relief valve to protect the fitting. The versions with outlet pressures >00 bar do not have a relief valve. The user must ensure there is a suitable safety device installed downstream! Note! The relief valve allows gas that has to be released as a result of an impermissible rise in the outlet pressure to be blown off. It does not function as the safety valve for the entire gas supply system. Caution! In the event of failure of the pressure regulator and its relief valve, a safety mechanism that meets the requirements of the regulations for operators must be incorporated to protect downstream fittings, pressure vessels and pipes from excess pressure. Danger! With combustible, toxic, corrosive and other gases that are harmful to health or the environment, an exhaust pipe must be connected to the relief valve to discharge the gas safely. The factory setting of the relief valve must not be changed! Possible hazard Risk of fatal injury! As cylinder pressure regulators with a purge device are predominantly used with toxic and/or corrosive gases, it must be ensured that the purged gases are safely discharged and disposed of correctly. Risk of fatal injury! If oxygen comes into contact with oil or grease, there is a risk of fire due to a chemical reaction. Risk of fatal injury! Gas escaping into the ambient air can ignite; there is a risk of fire and explosion. Measures for prevention Connect a pipe routing the purged gases to a recycling facility to the waste gas valves of the cylinder pressure regulator. Keep all components which come into contact with oxygen completely free of oil and grease. Smoking and naked flames are strictly prohibited in the vicinity of gas supply systems 6 GES_FE5-52-53SP+FE2SP_6.docx
2. For your safety Risk of fatal injury! The pressure regulator may be damaged by unauthorised changes or modifications and may no longer work as intended. There is a risk of the system malfunctioning, catching fire or being damaged. Risk of fatal injury! If gases other than those specified on the type plate are used, there is a risk of the system malfunctioning, catching fire or being damaged. Risk of fatal injury! Where the pressure regulator is operated with combustible, toxic or corrosive gases, the respective gas can escape into the environment if the relief valve is triggered. No changes or modifications may be made without the written approval of the manufacturer's authorised technical experts. Use only for the gases indicated on the device. If there are no gas types specified on the pressure regulator, the manufacturer must be consulted to establish which gases it can be used with. On no account may the pressure regulator be put into operation without this information. The relief valves of pressure regulators for combustible, toxic or corrosive gases must be equipped with a pipeline routing the escaping gases to a safe and legally compliant recycling facility. Risk of fatal injury! Gas escaping in an uncontrolled manner in closed rooms can reduce the oxygen content in the air to a potentially fatal level. The blow-off pipe of systems operated in closed rooms must be routed into the open air. Toxic, corrosive or otherwise environmentally harmful gases must be disposed of in accordance with the applicable regulations. Risk of fatal injury! Oxygen escaping in an uncontrolled manner in closed rooms can lead to a dangerous rise in the oxygen content in the air, increasing the risk of clothing and objects igniting. Risk of fatal injury! If components which are not suitable for the pressure range of the cylinder pressure regulator are connected, they may rupture under the pressure load. If the pressure regulator is used outside the specified ambient temperature range, there is a risk of the system malfunctioning, catching fire or being damaged. Dirt particles getting into the pressure regulator can damage it or cause it to malfunction. Incorrect handling and improper use may result in danger to the user and other persons and damage to the equipment. Route the blow-off pipe of oxygen systems operated in closed rooms into the open air, and avoid open flames. In addition, observe the instructions in EIGA document NL 79/04/D. All accessories to be connected (screw fittings, pipes, fittings etc.) must be suitable for the pressure range specified on the type plate of the cylinder pressure regulator. Do not use in ambient temperatures below 30 C or over +60 C. It must be ensured that no dirt particles of any kind can get into the pressure regulator. For this reason, there is a filter incorporated into the process gas inlet of the pressure control panel. Use and handle the pressure regulator only as described in this Operating Manual. If the connecting surfaces or gaskets of the fittings are damaged or missing, there is a danger of gas escaping in an uncontrolled manner. Check the connecting surfaces for damage, and do not install if the connecting surfaces are damaged or gaskets are missing. GES_FE5-52-53SP+FE2SP_6.docx 7
3. Description 3. Overview - structure Cylinder pressure regulator FE5/52/53-SP2A (with valve combination for purging with process gas) 3 5 7 2 PI 2Abgas PI 6 Verbraucher 4 8 Abgas Cylinder pressure regulator FE5/52/53-SP2 (with valve combination for purging with purge gas) 3 5 2 7 PI 2Abgas PI 6 Verbraucher 9 4 Spülgas 8 GES_FE5-52-53SP+FE2SP_6.docx
3. Description Cylinder pressure regulator FE5/52/53-SP3 (with valve combination for purging with purge gas) 3 5 7 2 9 6 PI 2Abgas PI Verbraucher 4 8 Spülgas Abgas Cylinder pressure regulator FE2-SP (with valve combination for purging with purge gas) 3 4 5 2 7 PI 2Abgas PI Verbraucher 6 Spülgas 9 Pos. Designation Description Gas cylinder valve In accordance with the applicable national standard 2 Cylinder connection In accordance with the applicable national standard 3 Inlet pressure gauge Indicates the current cylinder or inlet pressure. 4 Relief valve Protects the cylinder pressure regulator against excess pressure. 5 Outlet pressure gauge Indicates the current outlet pressure. 6 Handwheel Used to set the outlet pressure. 7 Process gas valve Used to close off the process gas pipe 8 Waste gas valve Used to close off the waste gas line 9 Purge gas valve Used to close off the purge gas line GES_FE5-52-53SP+FE2SP_6.docx 9
3. Description 3.2 Functional description Cylinder pressure regulators of the FE5/52/53-SP and FE2-SP Series are single-stage cylinder pressure regulators with pressure gauges for measurement of the inlet and outlet pressure. The main task of the cylinder pressure regulator is to reduce the inlet pressure to the outlet pressure required for the specific application. The maximum inlet pressure depends on the specific application and will normally vary during operation. The outlet pressure should remain as constant as possible. The outlet pressure is set via the pressure regulator handwheel. The fittings described here are equipped with various valves depending on the variant (see diagrams in Section 3.) for purging of the cylinder pressure regulator itself or the connected pipe system. The purging process serves three essential purposes above all in the context of gas applications for sensitive processes and / or with toxic / corrosive gas applications:. In certain processes for which specific gas atmospheres are required, it is necessary to prevent the surrounding atmosphere penetrating into the pipe system connected downstream of the pressure regulator, as a disturbance in the process associated with the gas application would otherwise be caused. This is prevented by purging with process gas or purge gas. 2. Before opening a gas supply system operated with toxic or corrosive gases on the side of the surrounding atmosphere, it must be ensured that these gases cannot escape into the environment, as there is otherwise a risk of injury to personnel or damage to property. The purging process also prevents this undesirable outcome. 3. Purging fittings used with corrosive gases also extends the service life of the fittings. The correct procedure for carrying out the purging processes is described in detail for each type of cylinder pressure regulator in Sections 4.2 to 4.8. 3.3 Technical data Note! The technical data can be taken from the Spectron data sheet for the relevant product. If this is not available, you can view and download it at www.spectron.de. The maximum inlet and outlet pressures and the gas type are indicated on the type plate. 0 GES_FE5-52-53SP+FE2SP_6.docx
3. Description 3.4 Connection options Inlet connection for process gas: Connection nozzle as per order specification and matching the gas cylinder valve Outlet, process gas valve (7): /4" NPT female thread Outlet, waste gas valve (8): /4" NPT female thread Outlet, relief valve (4): /4" NPT female thread Inlet connection, purge gas valve (9): /4" NPT female thread Screw fittings can now be screwed into the connection thread while applying opposing force to the valve, and the pipeline for process gas, waste gas and purge gas connected via these fittings. 3.5 Check valve in the purge gas inlet (9): To ensure that process gas cannot enter the purge gas line, we recommend the installation of a check valve (e.g. depending on the gas type, Spectron Part Nos. 77085 or 770856 or 7709538) in the inlet connection of the purge gas valve. The arrow indicating the flow direction points towards the purge gas valve. 4. Operation 4. Labelling Labelling example Gas type: NO FE5-SP3-200-0-DIN 8-NO P: 200 bar P2: 0 bar Note! Verification of successful leakage and functional testing is embossed on the reverse side of the cylinder pressure regulator. The labelling of the cylinder pressure regulator must indicate the gas type which is to be used! If the gas type is not specified on the type plate, the attached gas-type adhesive labels must be affixed before the device is put into operation for the first time. Warning! The cylinder pressure regulator may only be labelled with the gas type for which it was ordered. GES_FE5-52-53SP+FE2SP_6.docx
4. Operation 4.2 Installing the cylinder pressure regulator Caution! It is imperativee to check that the connection threads and connecting surfaces of the gas cylinder valves and the gaskets are in perfectt condition. Step Activity Make sure that the cylinder pressure regulator is labelled for the correspondingg gas type and that the connectionn of the gas cylinder valve is cleann and showss no signs of damage. 2 Connect the cylinder pressure regulator to the still closed gas cylinder valve. To do this, use an open-end wrench of the same size as thee union nut on the cylinder connection (2). 3 Connect the following lines to the pressure regulator: processs gas pipe to the outlet thread of the process gas valve (7) waste gas line to the outlet thread of the relief valve (4) waste gas line to the outlet thread of the waste gas valve v (8) (only on FE5/52/53-SP2A and FE5/52/53-SP3) purge gas line to the inlet thread of the purge gas valve (9) ( only on FE5/52/53-SP2 and FE5/52/53-SP3 and FE2-SP) The NPT screw fittings to be inserted here must be wrappedd with PTFEE tape. The first thread must be left free of PTFE tape. 4 5 For oxygen or other gases with an oxidation potential greater g thann air, only use PTFE tape thatt has BAM approval. In the case of gases with combustible e, oxidising, toxic or corrosive characteristics, ensure safe discharge and subsequentt disposal of the waste gas in accordance with the relevant legislation. Then check all connections for leakage using suitable means. Warning! In the case of cylinder pressure regulators, it is not permissible to use adapters between the gas cylinder valve and the inlet of the cylinder pressure regulator. All connected accessories must be compatible with the gas type and suitable for the pressure range of thee cylinder pressure regulator model used. It is also imperative to ensure that the connection between the fitting and accessories is correct and in accordance with the forces and media used. If you are unsure about the suitabilityy of the accessories, you can contact our product consultants (see the back of this Operating Manual). 2 GES_FE5-52-53SP+FE2SP_6.docx
4. Operation 4.3 Putting the cylinder pressure regulator FE5/52/53-SP2A into operation Step Activity Turn the handwheel (6) anti-clockwise to relieve the regulator spring of the cylinder pressure regulator and close all valves (7 and 8) attached to the cylinder pressure regulator by turning the handwheel clockwise. 2 Open the gas cylinder valve for the process gas () so that process gas can flow into the pressure regulator and set the desired outlet pressure for the pressure regulator via its handwheel (6). 3 Now slowly open the process gas valve (7), allowing the process gas to flow into the pipe system and to the connected equipment 4 Close the gas cylinder valve () and open the waste gas valve (8), routing the process gas to the recycling facility via the connected waste gas line. Close the waste gas valve (8) again immediately. 5 Close the process gas valve (7). 6 Repeat steps 7 to 0 (pressure purging with process gas) at least 5 times. 7 Open the gas cylinder valve () one final time. If necessary, correct the set outlet pressure at the pressure regulator again by turning the handwheel (6) and then slowly open the process gas valve (7) to allow the process gas to flow slowly into the downstream pipe system. The cylinder pressure regulator is now ready for operation. 4.4 Putting the cylinder pressure regulator FE5/52/53-SP2 and FE2-SP into operation Step Activity Turn the handwheel (6) anti-clockwise to relieve the regulator spring of the cylinder pressure regulator and close all valves (7 and 9) attached to the cylinder pressure regulator by turning the handwheel clockwise. Check that purge gas pressure is available, e.g. by opening the gas cylinder valve on the purge gas cylinder. 2 Slowly open the purge gas valve (9) so that purge gas flows into the cylinder pressure regulator, and set the desired outlet pressure for the pressure regulator via its handwheel (6). 3 Now slowly open the process gas valve (7), allowing the purge gas to flow into the pipe system and to the connected equipment (purging the line as far as the connected equipment). 4 Close the purge gas valve (9) and open a waste gas valve installed near the connected equipment to route the purge gas to the recycling facility via the connected waste gas line. Note: Depending on the structure of the gas supply system, purging can also be carried out through the connected equipment. In this case, the recommended duration of this type of purging depends on the individual parameters of the pipe system (pressure, length and diameter) and, of course, also on the experience of the plant personnel. GES_FE5-52-53SP+FE2SP_6.docx 3
4. Operation 5 Close the process gas valve (7). 6 Repeat steps 3 to 5 (so-called pressure purging) at least 5 times. 7 Open the gas cylinder valve for the process gas (), allowing process gas to flow into the pressure regulator. 8 If necessary, correct the set outlet pressure at the pressure regulator by turning the handwheel (6) and then slowly open the process gas valve (7) to allow the process gas to flow slowly into the downstream pipe system. The cylinder pressure regulator is now ready for operation. 4.5 Putting the cylinder pressure regulator FE5/52/53-SP3 into operation Step Activity Turn the handwheel (6) anti-clockwise to relieve the regulator spring of the cylinder pressure regulator and close all valves (7, 8 and 9) attached to the cylinder pressure regulator by turning the handwheel clockwise. Check that purge gas pressure is available, e.g. by opening the gas cylinder valve on the purge gas cylinder. 2 Slowly open the purge gas valve (9) so that purge gas can flow into the cylinder pressure regulator, and set the desired outlet pressure for the cylinder pressure regulator via its handwheel (6). 3 Now slowly open the process gas valve (7), allowing the purge gas to flow into the pipe system and to the connected equipment (purging the line as far as the connected equipment). 4 Close the purge gas valve (9) and open the waste gas valve (8), routing the purge gas to the recycling facility via the connected waste gas line. Close the waste gas valve (8) again immediately. 5 Close the process gas valve (7). 6 Repeat steps 2 and 5 (pressure purging with purge gas) at least 5 times. 7 Open the gas cylinder valve for the process gas () so that process gas can flow into the pressure regulator. 8 Now slowly open the process gas valve (7), allowing the process gas to flow into the pipe system and to the connected equipment 9 Close the gas cylinder valve () and open the waste gas valve (8), routing the process gas to the recycling facility via the connected waste gas line. Close the waste gas valve (8) again immediately. 0 Close the process gas valve (7). Repeat steps 7 to 0 (pressure purging with process gas) at least 5 times. 2 Open the gas cylinder valve () one final time. If necessary, correct the set outlet pressure at the pressure regulator again by turning the handwheel (6) and then slowly open the process gas valve (7) to allow the process gas to flow slowly into the downstream pipe system. The cylinder pressure regulator is now ready for operation. 4 GES_FE5-52-53SP+FE2SP_6.docx
4. Operation 4.6 Changing the cylinder on cylinder pressure regulator FE5/52/53-SP2A Step Caution! Each time you change the cylinder, check that the gasket is in perfect condition and replace it if necessary. Activity Close the process gas valve (7) of the cylinder pressure regulator and the gas cylinder valve () of the gas cylinder which is to be replaced. 2 Relieve the cylinder pressure regulator via the waste gas valve (8) and check that both pressure gauges show 0 bar. 3 Relieve the pressure regulator by turning the handwheel (6) anti-clockwise. 4 Disassemble the pressure regulator from the gas cylinder valve and connect the new gas cylinder. 5 Slowly open the gas cylinder valve () and set the desired outlet pressure for the cylinder pressure regulator via its handwheel (6). 6 Carry out pressure purging of the cylinder pressure regulator with process gas. To do this, close the gas cylinder valve (), open the waste gas valve (8) to drain the process gas from the cylinder pressure regulator and close the waste gas valve again immediately. 7 Repeat steps 7 to 0 (pressure purging with process gas) another 4 times. 8 Open the gas cylinder valve () one final time. If necessary, correct the set outlet pressure at the pressure regulator again by turning the handwheel (6) and then slowly open the process gas valve (7) to allow the process gas to flow slowly into the downstream pipe system. The cylinder pressure regulator is now ready for operation. 9 Check the gas cylinder connection (2) and all other detachable connections for leakage. 4.7 Changing the cylinder on cylinder pressure regulator FE5/52/53-SP2 and FE2-SP Step Caution! Each time you change the cylinder, check that the gasket is in perfect condition and replace it if necessary. Activity Close the gas cylinder valve () and the process gas valve (7) and slowly open the purge gas valve (9) to allow purge gas to flow into the pressure regulator. 2 Open the process gas valve (7) to drain the purge gas from the cylinder pressure regulator again. Close the process gas valve. 3 Open the purge gas valve (9) again to allow purge gas to flow into the pressure regulator. Then close the purge gas valve (9) again. 4 Open the process gas valve (7) to drain the purge gas from the cylinder pressure regulator again. Close the process gas valve (7). GES_FE5-52-53SP+FE2SP_6.docx 5
4. Operation 5 Repeat steps 3 and 4 another 4 times. 6 Relieve the cylinder pressure regulator by turning the handwheel (6) anti-clockwise and check that both pressure gauges show 0 bar. 7 Disassemble the pressure regulator from the gas cylinder valve and connect the new gas cylinder. 8 Proceed as described in steps 2 to 6 of Section 4.4 to put the pressure regulator into operation again. 9 Check the gas cylinder connection (2) and all other detachable connections for leakage. 4.8 Changing the cylinder on cylinder pressure regulator FE5/52/53-SP3 Caution! Each time you change the cylinder, check that the gasket is in perfect condition and replace it if necessary. Step Activity Close the process gas valve (7) of the cylinder pressure regulator and the gas cylinder valve () of the gas cylinder which is to be replaced. 2 Relieve the cylinder pressure regulator via the waste gas valve (8) and close the valve again. 3 Open the purge gas valve (9) to allow purge gas to flow into the pressure regulator. Then close the purge gas valve (9) again. 4 Relieve the cylinder pressure regulator via the waste gas valve (8) and close the valve again. 5 Repeat steps 3 and 4 another 4 times. 6 Relieve the cylinder pressure regulator by turning the handwheel (6) anti-clockwise and check that both pressure gauges show 0 bar. 7 Disassemble the pressure regulator from the gas cylinder valve and connect the new gas cylinder. 8 Slowly open the purge gas valve (9) so that purge gas flows into the cylinder pressure regulator, and set the desired outlet pressure for the cylinder pressure regulator via its handwheel (6). Then close the purge gas valve (9) again. 9 Open the waste gas valve (8) to drain the purge gas from the cylinder pressure regulator again. Then close the waste gas valve (8) again. 0 Repeat steps 8 and 9 another 4 times. Slowly open the gas cylinder valve () and if necessary, correct the desired outlet pressure for the cylinder pressure regulator via its handwheel (6). Now close the gas cylinder valve () again. 2 Open the waste gas valve (8) to drain the process gas from the cylinder pressure regulator again. Then close the waste gas valve (8) again. 3 Repeat steps and 2 another 4 times. 4 Now slowly open the gas cylinder valve () again, then also slowly open the process gas valve, allowing the process gas to flow into the downstream pipe system, and check that all detachable connections are gastight. 6 GES_FE5-52-53SP+FE2SP_6.docx
4. Operation 4.9 Taking out of operation Taking out of operation or interrupting operation for a short period If you are only interrupting work for a very brief period, it is sufficient to merely close the gas cylinder valve. Taking out of operation or interrupting operation for a longer period Carry out the steps described for your cylinder pressure regulator in the respective section "Changing the cylinder on cylinder pressure regulator FE SP." However, do not carry out the step in which the pressure regulator is released! To continue operation after an interruption, carry out the steps listed after the omitted step. 5. Faults Faults/cause Gas is blown off from the relief valve. Impermissible increase in the outlet pressure. The pressure regulator is making noises. This indicates a defect in the regulator insert. The pressure regulator is frozen. This indicates that too much gas is being withdrawn. There is a leak. This indicates a defect in a pressure regulator component. The outlet pressure level is unstable and is not adhering to the usual range of variation. This indicates that too much gas is being withdrawn. Remedy Close all valves immediately. Have the pressure regulator inspected immediately by the manufacturer or an authorised specialist company. Close all valves immediately. Have the pressure regulator inspected immediately by the manufacturer or an authorised specialist company. Reduce the amount of gas drawn or if technically, chemically, physically possible install an upstream gas preheater. Close all valves immediately. Have the pressure regulator inspected immediately by the manufacturer or an authorised specialist company. Reduce the amount of gas drawn. It is also possible that there is dirt in the inlet filter. In this case, the pressure regulator must be checked by the manufacturer or an authorised specialist company. GES_FE5-52-53SP+FE2SP_6.docx 7
6. Maintenance, cleaning and repairs 6. Regular maintenance work and visual inspections Regular maintenance work To ensure problem-free and reliable operation, the pressure regulator should be inspected by an expert once a year. Regular visual inspections Visual inspection of all parts for Damage Correct functioning Leaks Integrity/stability Corrosion Interval Regular inspections at intervals of 2 months and each time the device is put into operation make an important contribution to the cost-effectiveness and preservation of the value of the fittings. Note! If you find defects during the visual inspection, do not put the pressure regulator into operation. Have the pressure regulator inspected immediately by the manufacturer or an authorised specialist company. 6.2 Regular cleaning Warning! Detergents or disinfectants can corrode and ruin gaskets inside the fittings. Do not use cleaning agents or disinfectants! Heavy soiling can lead to malfunctions. If it becomes necessary to clean the pressure regulator, use only a damp, lint-free cloth. 6.3 Repair information Caution! Repairs may only be carried out by specialist personnel in authorised repair workshops. After repairs, the entire pressure regulator must be checked in accordance with the original Spectron inspection instructions. Safe and reliable operation can only be guaranteed if original spare parts are used. Note! The manufacturer accepts no liability for damage resulting from unauthorised repairs or modifications carried out by the user or third parties without the express written approval of the manufacturer. 6.4 Returns If the pressure regulator is returned to the manufacturer for testing, maintenance or repair, and it has been in contact with corrosive or toxic gases, it is imperative that it is purged with inert gas. 8 GES_FE5-52-53SP+FE2SP_6.docx
Spectron Gas Control Systems GmbH Fritz-Klatte-Straße 8 65933 Frankfurt Deutschland / Germany Telephone: +49 69 3806-0 Fax: +49 69 3806-200 E-mail: info@spectron.de Internet: www.spectron.de