RMG 503 Manuale utente
Operation and Maintenance,
Spare Parts
Serving the Gas Industry - WORLDWIDE
Gas Pressure Regulator
RMG 503
503.20
edition 01/2003
valid for gas pressure regulator RMG 503 from serial no. 0207 31622
and integrated SAV system RMG 711 from serial no. 9706 19948
Contents
page
1. General matters 3
1.1 Safety notices 3
2. gas pressure regulator 4
2.1 Special operating notices 4
2.1.1 Commissioning 4
2.1.2 De-commissioning 4
2.2 Special maintenance notices 4
2.2.1 Screw tightening moments 4
2.2.2 Lubricants 4
2.3. Spare parts
2.3.1 Spare part drawings 5, 6
2.3.2 Spare parts list 7
3. Integrated SAV system RMG 711
3.1 Special operating notices 9
3.2 Special maintenance notices 9
3.2.1 Switch gear 9
3.2.2 Main valve 10
3.2.3 Screw tightening moments 10
3.2.4 Lubricants 10
3.3 Spare parts
3.3.1 Spare part drawings 11, 12, 13
3.3.2 Spare parts list 14, 15
3.3.3 Spare part drawings accessories 16
3.3.4 Spare parts list accessories 17
4. Parts for maintenance purposes 18
503.20 p.02
503.20 p.03
Safety indications are indicated by the following key words or symbols
indication used for:
For the gas pressure regulator with integrated SAV RMG 503 the detailed product information 503.00 is
available containing
technical data, designs and measurements as well as design descriptions and operating
notices
.
The pertinent subassemblies are described in separate operating and maintenance instructions:
regulator RMG 630/640 630.20
filter RMG 905 905.20
control unit K 10a / K 11a 672.20
control unit K 16 / K 17 / K 18 670.20
push button valve RMG 910a 910.20
push button valve RMG 913a 913.20
1. General matters
1.1 Safety notices
The RMG publication "General operating instructions for gas pressure regulators and safety devices" provides
information on installation, commissioning, and operation, and contains notices on fault removal.
For planning and maintenance of gas pressure regulators the relevant national regulations must be observed:
Germany: DVGW worksheets G 600, G 459/II, G 490/I, G 491 and G 495
The time intervals for maintenance works on the pressure reducer RMG 218 (D118aV) depend largely on the
operating conditions and the composition of the gas. Therefore, no fixed maintenance intervals are being
prescribed. It is recommended to keep to the maintenance cycles stated in the DVGW worksheet G 495.
During maintenance all components must be cleaned and thoroughly checked for safety. A visual
check is required even if irregularities were found during operation or functional checks.
The check must cover seals and membranes in particular as well as any guiding components. Damaged
components must be renewed.
The item numbers mentioned in the maintenance notices correspond to those in the spare part drawing and
spare parts list.
It is recommended to keep the parts marked "W" in the spare part drawings and spare part lists in stock for
maintenance purposes. These parts are listed on a separate sheet.
!Danger
!Caution
Note
danger to persons
danger to equipment and the environment
Important additional information
Open the startup valve.
The startup valve is used to achieve safe pressure compensation at the throttle
diaphragm.
2.1.1 Commissioning
Close outlet gate valve
Fully release the setpoint springs of the regulator RMG 630/640 in the regualting stage
and the load limiting stage (regulator RMG 630 only) by turning the setpoint adjustment
screw anti-clockwise.
Apply inlet pressure slowly.
The startup valve must always be closed again.
Adjust the setpoint value in the load limiting stage at the regulator RMG 630 to
approx. 10 bar above pa.
Adjust the output pressure in small steps by turning the setpoint adjustment screw
clockwise until the desired value has been reached. The load limiting pressure at the
RMG 630 will rise automatically.
2.1.2. De-commissioning
Turn the setpoint adjustment screw of the regulating stage anti-clockwise
Slowly close the outlet gate valve
2.2 Special maintenance notices
Due to the maintenance-friendly design the maintenance of the gas pressure regulator is principally limited
to checking the throttle diaphragm. This must be checked for wear and swelling and where necessary be renewed.
Prior to dismantling all gas supplied chambers must be depressurised.
The throttle diaphragm (306) must be inserted into the main valve body without
distortion.
Foam rings (314 and 319) from nominal width DN 80/150 are to be renewed with
every maintenance.
2.2.1 Screw tightening torques M
A
in Nm
screw
item no. 25/50 50/100 80/150 100/200
318 160 160 240 240
nominal width DN
components lubricants RMG part no.
all O rings and
diaphram tensioning bead silicon grease 00 027 081 (tube 0.1 kg)
all fastening screws
and pipe screw connections assembly grease 00 028 267
For designs with noise reduction
the correct position of the relief plates
(328) must be observed ->
The groove of the relief plates
must face upwards
503.20 p.04
2. Gas pressure regulator
2.1 Special operating notices
•
•
•
Caution
!
Note!
•
•
•
Note!
•
•
•
2.2.2 Lubricants
•
•
•
!Danger
503.20 p.05
2.3.1 Spare part drawings
1
4
5
4
5
4
5
8
6
5
7
cross section A - B
GDR element
safety cut-off
unit (SAV)
AB
503.20 p.06
313
312
311
310
W
306
305
304
W 303
302
315
316
318
350
320
327
328
313
312
311
310
W 306
305
304
W 303
302
314
W
315
316
318
350
319 W
320
327
328
DN 25/50 and DN 50/100
DN 80/150 and DN 100/200
A
M
A
M
with noise reductionwithout noise reduction
M
Observe torques in table on page 4!
WParts should be kept in stock for maintenance.
A
item
no. description quant W material DN 25/50 DN 50/100 DN 80/150 DN 100/200
RMG stock no.
1 body, version "-":
1 PN 40 1 GS 10 024 470 10 024 520 10 024 620
1 PN 40 / ANSI 600 RF 1 GS 10 024 477 10 024 527 10 024 627
1 ANSI 300 RF 1 GS 10 024 473 10 024 523 10 024 623
1 ANSI 300 RF / ANSI 600 RF 1 GS 10 024 478 10 024 528 10 024 628
1 ANSI 300 RJ 1 GS 10 024 474 10 024 524 10 024 624
1 ANSI 600 RF 1 GS 10 024 475 10 024 525 10 024 625
1 ANSI 600 RJ 1 GS 10 024 476 10 024 526 10 024 626
1body, version "a"
1 PN 40 1 GS 10 027 670
1 PN 40 / ANSI 600 RF 1 GS 10 027 677
1 ANSI 300 RF 1 GS 10 027 673
1 ANSI 300 RF / ANSI 600 RF 1 GS 10 027 678
1 ANSI 300 RJ 1 GS 10 027 674
1 ANSI 600 RF 1 GS 10 027 675
1 ANSI 600 RJ 1 GS 10 027 676
4 screw plug 3 St 00 026 175 00 026 175 00 026 175 00 026 175
5sealing ring 6 LM 00 018 842 00 018 842
5 sealing ring 5 LM 00 018 842 00 018 842
6 connecting piece 1 St 00 030 074 00 030 074 00 030 111 00 030 111
7 connecting piece 1 St 00 030 111 00 030 111 00 030 023 00 030 023
8 connecting piece 1 St 00 030 074 00 030 074 00 030 074 00 030 074
503.20 p.07
2.3.2. spare parts list
WParts should be kept in stock for maintenance purposes
material identifications
St ... steel LM ... light alloy SSt ... foam
NSt ... rustproof steel Ms ... brass K ... plastic
FSt ... spring steel Cu ... copper KG ... rubbery plastic
NFSt ... rustproof spring steel Bz ... bronze KGT ... rubbery plastic with coating
GS ... steel cast GLM ... light alloy cast KV ... rubber-like plastic material (NBR)
GGG ... steel cast with spheroidal graphite GMs ... brass cast KT ... special plastic (NBR)
GZn ... zink cast AlBz ... aluminium bronze PGL ... plexiglass
GBz ... bronze cast
503.20 p.08
item
no. description quant W material DN 25/50 DN 50/100 DN 80/150 DN 100/200
RMG stock no.
302 flow divider 1 LM 10 011 137 10 011 137 10 011 237 10 011 237
303 o-ring 1 W KG 00 020 508 00 020 508 00 021 184 00 021 184
304 insert 1 St 10 023 551 10 023 551 10 023 631 10 023 631
305 slotted valve part 1 LM 10 023 550 10 023 550 10 023 630 10 023 630
306 diaphragm 1 W KG 10 011 140 10 011 140 10 011 240 10 011 240
310 connecting piece 1 St 00 030 023 00 030 023 00 030 023 00 030 023
311 spring 1 NFSt 10 011 149 10 011 149 10 011 249 10 011 249
312 diaphragm cover 1 St 10 021 590 10 021 620 10 021 653 10 021 685
313 pan head screw 1 St 00 010 021 00 010 021 00 010 003 00 010 003
314 foam disc 1 W SSt 10 023 593 10 023 633
315 pan head screw 1 St 00 008 176 00 008 176 00 010 393 00 010 393
316 diaphragm plate 1 LM 10 011 138 10 011 138 10 011 238 10 011 238
318 pan head screw 10 St 00 010 555 00 010 555
318 pan head screw 24 St 00 010 601 00 010 601
319 foam disc 1 W SSt 10 023 592 10 023 632
320 pan head screw 4 St 00 010 361 00 010 361 00 010 097 00 010 097
327 locking washer 4 St 00 014 118 00 014 118 00 014 123 00 014 123
328 release plate 1 LM 10 023 510 10 023 510 10 023 589 10 023 589
350 locking washer 10 St 00 014 116 00 014 116
350 locking washer 24 St 00 014 139 00 014 139 00 014 139 00 014 139
3.1 Special operating notices
opening the safety shut-off valve (SAV)
To open the SAV main valve insert handle (712) into the corresponding bore of the disk (734) and turn.
503.20 p.09
•
3. Integrated SAV system RMG 711
With control units K 10a or K 11a the SAV main valve can only be opened
if the control units have first been engaged.
To engage the control units K 10a and K 11a screw off lid, turn upside-down, and screw lid on to the
switching rod inside the control unit. Then pull the switch rod upward to the stop (see also 672.20).
The control units K 10a and K 11a are fitted with an underpressure shut-off device.
They can only be engaged if the pressure at the measuring point corresponds to the
operating pressure.
•
Test switching of the control units K 10a and K 11a
Test switching must only take place if the control units K 10a
and K 11a have been fitted to the switch casing (710), otherwise mechanical damage
could result.
3.2 Special maintenance notices
3.2.1 switch gear
Prior to removing the switch bearing (707) the pressure piece (768) must be removed from
the switch casing (710).
Please note during assembly of the switch bearing:
- an angled double edge of the switch bearing must point towards the pressure piece (768).
(see 3.3.1 SAV system cross section A-A)
- the sliding ring (721) must be positioned below the switch bearing.
•
•
Caution
!
Note!
Note!
503.20 p.10
•
3.2.2 Main valve
valve flap (753)
To visually check the o-ring of the valve flap (754) remove cover (747) and open SAV (engage).
When inserting a new lubricated o-ring (774) into the groove of the valve flap (753) the
o-ring should initially be pressed into the groove at 3 - 4 points spaced equally along the diameter.
Only then should the o-ring be pressed in completely.
After separating the valve flap from the valve flap lever (750) the locking nut (752) must be
tightened with the correct torque and must further be secured using the splint (773).
closing springs (731)
2 grooves for receiving the closing springs are forned into the spring casing (733). The grooves
are required for the different reception of the closing springs in the desings
"right hand operation"
or
"left hand operation"
.
When inserting the closing springs, they should intially be placed into the spring casing (733).
The correct orientation of the springs as shown in figure 1 and 2 should be observed.
The closing springs are properly pre-tensioned when all 4 fastening screws (732) can be fitted to the
casing (approx. half a turn of the spring casing). The valve flap must be in the "closed" position.
•
•
•
figure 2 closing spring inserting position for
"left hand" operation
figure 1 closing spring inserting position for
"right hand" operation
Torque MAin Nm
DN Schrauben-Pos.-Nr.
708 732 745 752 800
3.2.3 Screw tightening moments
MA
3.2.4 Lubricants
25/50 8 8 40 8 -
50/100 8 8 75 12 -
80/150 20 20 160 40 10
100/200 20 20 160 40 10
components lubricants RMG part no.
manual actuator thread (767) assembly paste 00 027 091
all o-rings, sliding sleeves,
sliding faces and switch elements silicone grease 00 027 081 (tube 0.1 kg)
all fastening screws
and pipe screw connections assembly grease 00 028 267
Questo manuale è adatto per i seguenti modelli
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