219_20_gb_9812

Osterholzstrasse 45, D-34123 Kassel • GermanyTelephone (+49) 561 5007-0 • Fax (+49) 561 5007-107 • http://www.rmg.de

Operation and Maintenance,Spare Parts

219.20Edition 12/98

Serving the Gas IndustryWORLDWIDE

RMG REGEL + MESSTECHNIK GMBH

contents

1. General ............................................................................................................................................... 1.1 Appointed personell ............................................................................................................................. 1.2 safety notes .........................................................................................................................................

2. Special Operating Instructions .............................................................................................

3. Special Maintenance Instructions .......................................................................................

4. Spare parts RMG 219 (D 119a) .............................................................................................. 4.1 Spare Parts Drawing Diaphragm Assembly M with lever mechanism and screw connections .............. 4.2 Spare Parts Drawing for other Diaphragm Assemblies ........................................................................ 4.2.1 Spare Parts Drawing Diaphragm Assembly N .................................................................................. 4.2.2 Spare Parts Drawing Diaphragm Assembly F ................................................................................... 4.2.3 Spare Parts Drawing Diaphragm Assembly G .................................................................................. 4.2.1 Spare Parts Drawing Diaphragm Assembly GS ............................................................................... 4.2.1 Spare Parts Drawing Diaphragm Assembly V .................................................................................. 4.3 Spare Parts List RMG 219 (D 119a) - Part No.: 1 - 25 ...................................................................................................................................... - Part No.: 26 - 80.9 ................................................................................................................................. - Part No.: 91 - 155 .................................................................................................................................. - Part No.: 159 - 240 ................................................................................................................................ - Part No.: 241 - 296 ................................................................................................................................ - Part No.: 297 ......................................................................................................................................... - Material Key ...........................................................................................................................................

333

4

4

5577789

10

11121314151616

219.20 S.2 engl

1. General

219.20 S.3 engl

1.1 Appointed personell

ExpertsThanks to his technical training, his practical work and his experience, the expert has sufficient knowledge in the field of main-taining complete gas facilities as well as the single devices with their constructional elements and sub-groups. He must beacquainted with the purpose and the tasks of gas pressure regulating facilities, with the relevant laws, guidelines and generaltechnical rules, and must also be capable of deciding and acting on his own.

Qualified employeeThe qualified employee must posess special, proven knowledge for the certain task he is about to perform. He is acquaintedwith the general rules and regulations, and it is guaranteed that he can carry out tasks correctly when ordered to do so.

Instructed personA person trained to accomplish simple tasks.

Visual checks

Inspection

Functional tests

Maintenance / repairs

Putting into operation / re-starting

Operation using by-pass lines

instructed person qualified employee expert

We recommend to keep all parts marked "EV" in stock for maintenance availability.Note!

! Caution!

Note!

In addition to this leaflet 219.20 concerning "Operation and Maintenance, Spare Parts" of the pressure reducing valve D 119a(RMG 219), the brochure 219.00 gives full information about all relevant technical data, description of function, the availableversions, and dimensions.

The RMG brochure "General operating instructions for gas pressure regulators and safety devices" will be useful to fit the regu-lator into the line, put it into service and find faults that might disturb its operation. Please also check if the construction, set-up,supervision and maintenance of gas pressure regulating stations may be subject to special national regulations. These tech-nical rules should be observed strictly (Within Germany observe the DVGW worksheets G 490, G 491, G 495).

The frequency of periodical maintenance of gas pressure regulators and other components of the regulating line is stronglydependant on the prevailing service conditions, the type and composition of the gaseous medium, the ambient temperatureand on dust and dirt withing the pipe system. We therefore abstain from imposing any fixed intervals and would rather advisetesting out the necessary maintenance intervals, starting with short gaps (i.e. quarter of a year) for maintenance dismantling,and then increasing the intervals to a maximum of 2 years, if no defects within the spare parts show up.For maintenance all parts are to be cleaned and subjected to a thorough visual inspection. Complete dismantling together withvisual inspection should not be omitted when the course of operation or performance tests have shown lack of accuracy.Particular care should be given to the checking of sealings and diaphragms, as well as the closing spring and all movable parts.Damaged parts should be replaced by new ones.

1.2 Security instructions

Security instructions are marked in the operating instructions by the following signal words or symbols:

used for:

risk of damaging equipment and environment

additional information

additional

2nd person

required

Tasks and workmen

torques

M in NmA

lubricants

element (grease slightly)

all o-rings,

mounting area of the diaphragms

gliding surfaces of the pistons

thread of the setpoint adjustment screw

or adjusting spindle

all screw connections

and pipe connections

lubricant

silicone grease

assembly paste

high pressure grease

part no.

00 027 081

00 027 091

00 027 058

torquehexagon screw

2. Special Operating Instructions

Setpoint alterations

Ton increase the setpoint turn the setpoint adjusting screw to the right. After alteration of the setpoint secuere the adjusting screw with the ring-nut (36, 93, 214) or the screw (80.5, 180.5).

Setpoint alterations for the integrated safety relief valve are not possible. The following fixed values are given: - approx. 5 bar for diaphragm assembly M, N, G, GS, F - approx. 10 bar for diaphragm assembly V

3. Special Maintenance instructions

• The connection between the lever and the lever yoke must be at a right angle: turn the diaphragm to the left and the right, and then place the diaphragm in the middle between the two stop positions.

219.20 S.04 engl

842, 75, 103,143, 189, 218

4. Spare Parts RMG 219 (D 119a)4.1 Spare Parts Drawing Diaphragm Assembly M with lever mechanism and screw con- nections

219.20 S.05 engl

278 279EV

280

with Ermeto connectionEO10 / EO12 / EO16

274

EV 275

270 269 267 273 271 EV

with connection acc. to DIN 477W21,8 x 1/14" -right-

37

28, 29

32

27

31 EV

39

295

35

36

33

42(turned 30°)

EV 30

265 241,242EV

240 18EV

13 17EV

•11 15 296EV

297

A

Awith connection acc. to DIN 477W21,8 x 1/14" -left-

280 4 EV(9 EV)

1(6)

•3(•8)

with connection G 3/4 a

with connection G 3/4 aand valve dia. 8 (dia. 10)

(26 only with valve F10)

290(291)

21 EV(25 EV)

•19(•24)

part nos. marked "•" are pre-fabricated sub-groups

with ball piston 2 mm(with ball piston 3,7 mm)

219.20 S.06 engl

EV 250

•255 EV

EV for 255

249

245

EV 246

243

28, 29

part nos. marked "*" are pre-fabricated sub-groups

view A - A

219.20 S.07 engl

4.2 Spare Parts Drawings for other diaphragm assemblies4.2.1 Spare Parts Drawing for diaphragm assembly N

4.2.2 Spare Parts Drawing for diaphragm assembly F

94

116

93

95

101 EV(only with diaphragm 0,5)

100 EV 91 98 96 117 115

28, 29

32

27

EV 31

103

107

28, 29

32

27

EV 31

219

EV 222

229

215

214

228

218

210

211

220

227 EV

212

216 217 230 223 EV

219.20 S.08 engl

4.2.3 Spare Parts Drawing for diaphragm assembly G

EV 180.4

180.2

180.1

140

122

135

EV 101(only with diaphragm 0,5)

143

180.3

180.6

180.5

180.9 EV

180.7

180.8

28, 29

146 137EV

124 257 132 120 131 133EV

155 159

219.20 S.09 engl

4.2.4 Spare Parts Drawing for diaphragm assembly GS

EV 180.4

180.2

180.1

185

162

175

189

165

180.3

180.6

180.5

180.9 EV

180.7

180.8

28, 29

192 177EV

164 172 120 171 173EV

204 205

219.20 S.10 engl

4.2.5 Spare Parts Drawing for diaphragm assembly V

EV 80.4

80.2

80.1

62

68

75

EV 60

EV 73

63

64

80.3

80.6

71

80.9 EV

80.5

80.8

28, 29

80.7

4.3 Spare Parts List RMG 219

item description number EV material RMG part no.no. needed1 piston guide with piston HH2, consisting of: 1 NSt/Ms 10 014 421- piston guide 1 Ms 10 014 425- piston HH2 1 NSt 10 014 4223 lever joint, pre-assembled for valve HH2, consisting of: 1 NSt/Ms 10 019 418- lever, pre-assembled 1 NSt 10 014 427- lever rod 1 Ms 10 014 428- lever axle 2 NSt 10 014 451- split pin 2 NSt 00 015 034- ball piston with ball 1 NSt/Ms 10 014 4174 sealing washer 1 EV LM 00 018 8116 piston guide for piston H 3.7 1 NSt/Ms 10 014 438- piston guide 1 Ms 10 015 306- piston H 3.7 1 NSt 10 014 4368 lever joint, pre-assembled for piston H 3.7, consisting of: 1 NSt/Ms 10 019 420- lever, pre-fabricated 1 NSt 10 014 427- lever rod 1 Ms 10 014 428- lever axle 2 NSt 10 014 451- split pin 2 NSt 00 015 034- ball piston with ball 1 NSt/Ms 10 014 4429 sealing washer 1 EV LM 00 018 81111 lever joint, pre-ass. for piston F2/F3.7/F5.5, consisting of: 1 NSt/Ms 10 014 452- lever, pre-assembled 1 NSt 10 014 427- lever rod 1 Ms 10 014 428- lever axle 2 NSt 10 014 451- piston 1 Ms 10 014 454- split pin 2 NSt 00 015 034

13 piston, at option:- piston F 2 1 Ms 10 014 458- piston F 3.7 1 Ms 10 014 462- piston F 5.5 1 Ms 10 014 466

15 piston guide 1 Ms 10 014 47017 sealing washer 1 EV KG 10 014 47318 sealing ring 1 EV LM 00 018 81119 lever joint, pre-assembled for valve F 8, consisting of: 1 NSt/Ms 10 014 477- lever, pre-assembled 1 NSt 10 014 427- lever rod 1 Ms 10 014 428- lever axle 2 NSt 10 014 451- piston 1 Ms 10 014 481- split pin 2 NSt 00 015 034

21 sealing washer 1 EV KG 10 014 48524 lever joint, pre-assembled for valve F 10, consisting of: 1 NSt/Ms 10 014 489- lever, pre-assembled 1 NSt 10 014 427- lever rod 1 Ms 10 014 428- lever axle 2 NSt 10 014 451- piston 1 Ms 10 014 491- split pin 2 NSt 00 015 034

25 sealing washer 1 EV KG 10 014 495

219.20 S.11 engl

item description number EV material RMG part no.no. needed26 button headed screw 1 Ms 00 008 60827 nozzle 1 St 10 007 63928 cap nut 1 St 00 030 80529 compression joint 1 St 00 030 90428 cap nut 1 St 00 030 80529 compression joint 1 St 00 030 90430 diaphragm, complete 1 EV - 10 017 696- diaphragm plate 1 St 10 014 983- diaphragm 1 EV KG 10 014 989- lever yoke 1 NSt 10 014 993- spring plate 1 LM 10 017 697- hexagonal shouldered nut 1 St 00 013 138- sealing ring 1 EV KG 00 008 068

31 sealing ring 1 EV LM 00 018 68832 dosing screw 1 Ms 10 005 09633 spring, at option:- F 0 1 FSt 10 016 654- F 1 1 FSt 10 016 655- F 2 1 FSt 10 015 005

35 spring compensation piece 1 St 10 016 65636 lock nut 1 St 10 014 99637 regulating screw 1 Ms 10 014 99939 lid 1 LM 10 014 98842 hexagonal headed screw 6 St 00 010 11660 diaphragm 1 EV KG 10 014 98962 hexagonal shouldered nut 1 St 00 013 13863 connecting piece 1 LM 10 014 52264 lever yoke 1 NSt 10 014 99368 lower spring plate 1 LM 10 014 94271 spring, at option:- F 1 1 FSt 10 014 957- F 2 1 FSt 10 014 958- F 3 1 FSt 10 014 959- F 4 1 FSt 10 014 960- F 5 1 FSt 10 014 961- F 6 1 FSt 10 014 962- F 7 1 FSt 10 014 963- F 8 1 FSt 10 014 964

73 sealing ring 1 EV KG 10 015 45075 hexagon nut 6 St 00 010 13580 lid "V", complete 1 - 00 006 898

80.1 lid size V 1 GLM 10 015 00680.2 regulating spindle, complete 1 NSt/Ms/FSt 10 014 94980.3 hexagonal ring-nut 1 NSt 10 014 95480.4 o-ring 1 EV KG 00 020 33180.5 flat-headed screw 1 St 00 005 88880.6 split pin 1 St 00 006 64680.7 threaded adapter 1 St 10 007 63980.8 dosing screw 1 Ms 10 005 09680.9 sealing ring 1 EV LM 00 018 688

219.20 S.12 engl

item description number EV material RMG part no.no. needed91 diaphragm plate 1 St 10 016 67193 hexagonal threaded ring 1 LM 10 014 90094 regulating screw 1 Ms 10 014 91095 lid, pre-fabricated 1 GLM 10 014 89896 lever yoke 1 NSt 10 016 67498 hexagon nut 1 St 00 013 138

100 diaphragm, optional:- up to 60 mbar 1 EV KG 10 016 676- up to 200 mbar 1 EV KG 10 016 678- up to 500 mbar 1 EV KG 10 016 677

101 sealing ring 2 EV P 10 014 979103 hexagonal headed screw 10 St 00 006 179107 hexagon nut 10 St 00 003 399115 spring, at option:

- F 1 1 FSt 10 014 926- F 2 1 FSt 10 015 469- F 3 1 FSt 10 016 660- F 4 1 FSt 10 014 516- F 5 1 FSt 10 015 161

116 spring compensating piece, optional:- up to 120 mbar 1 NSt 10 014 932- up to 500 mbar 1 St 10 014 933

117 spring plate, optional:- for F 1 1 LM 10 016 679- for F 2 and F 3 1 LM 10 017 661- for F 4 and F 5 1 LM 10 016 681

120 gear plate 1 FSt 00 014 107122 hexagon nut 1 NSt 10 014 696124 diaphragm plate 1 St 10 014 820131 lever yoke 1 NSt 10 016 683132 diaphragm plate 1 Ms 10 014 971133 sealing ring 1 EV KG 00 020 693135 lower spring plate 1 LM 10 014 942137 diaphragm, at option:

- up to 40 mbar 1 EV KG 10 014 905- up to 100 mbar 1 EV KG 10 014 967- up to 1 bar 1 EV KG 10 014 968- up to 2 bar 1 EV KG 10 014 970

140 spring, at option:- F 1 1 FSt 10 014 957- F 2 1 FSt 10 014 958- F 3 1 FSt 10 014 959- F 4 1 FSt 10 014 960- F 5 1 FSt 10 014 961- F 6 1 FSt 10 014 962- F 7 1 FSt 10 014 963- F 8 1 FSt 10 014 964

143 hexagonal headed nut 1 0 St 00 010 135146 hexagon nut 1 0 St 00 003 399155 diaphragm support ring (for F4 to F 8) 1 LM 10 016 687

219.20 S.13 engl

item description number EV material RMG part no.no. needed159 holding screw (for F 4 to F 8) 3 Ms 10 016 688162 hexagon nut 1 NSt 10 014 696164 diaphragm plate 1 St 10 014 981165 intermediate ring 1 LM 10 014 980171 lever yoke 1 NSt 10 016 683172 diaphragm plate 1 Ms 10 014 971173 sealing ring 1 EV KG 00 020 693175 lower spring plate 1 LM 10 014 942177 diaphragm 1 EV KG 10 014 970180 lid "G", complete 1 - 00 006 895

180.1 lid size G 1 GLM 10 014 955180.2 regulating spindle, complete 1 NSt/Ms/FSt 10 014 949180.3 hexagonal ring-nut 1 NSt 10 014 954180.4 o-ring 1 EV KG 00 020 331180.5 flat-headed screw 1 St 00 005 888180.6 split pin 1 St 00 006 646180.7 threaded adapter 1 St 10 007 639180.8 dosing screw 1 Ms 10 005 096180.9 sealing ring 1 EV LM 00 018 688185 spring, optional:

- F 7 1 FSt 10 014 963- F 8 1 FSt 10 014 964

189 hexagonal headed spring 10 St 00 010 024192 hexagon nut 10 St 00 003 399204 diaphragm support ring 1 LM 10 016 687205 holding screw 3 Ms 10 016 688210 lid 1 GLM 10 015 462211 intermediate ring 1 GLM 10 016 691212 diaphragm plate 1 LM 10 015 465214 threaded ring 1 LM 10 014 900215 regulating screw 1 Ms 10 014 910216 lever yoke 1 NSt 10 016 674217 hexagonal shouldered nut 1 St 00 013 138218 hexagonal headed screw 12 St 00 010 135219 cylinder screw 6 St 00 010 055220 hexagon nut 12 St 00 003 399222 sealing ring 6 EV LM 00 018 818223 sealing ring 1 EV KG 00 008 032227 diaphragm, at option:

- up to 16 mbar 1 EV KG 10 015 466- up to 40 mbar 1 EV KG 10 015 468

228 spring, at option:- F 1 1 FSt 10 014 926- F 2 1 FSt 10 015 469

229 spring compensating plate 1 NSt 10 014 932230 spring plate 1 St 10 015 471240 housing, at option:

- housing for valve dia. 2 to 8 mm 1 GLM 10 016 694- housing for valve dia. 10 1 GLM 10 016 695

219.20 S.14 engl

item description number EV material RMG part no.no. needed241 sealing ring, at option:

- for valve dia. 2 to 8 mm 1 EV LM 00 018 814- for valve ø10 1 EV LM 00 004 428

242 sealing ring 1 EV LM 00 018 815243 sealing screw 1 St 10 015 023245 cylindrical pin, at option:

- for housing F, M, V 1 NSt 00 017 049- for housing G, GS, N 1 NSt 00 017 122

246 sealing ring 2 EV LM 00 018 796249 sealing screw 1 Ms 10 016 698250 sealing ring 2 EV LM 00 018 818255 safety relief valve, at option:

- response pressure approx. 5 bar 1 - 10 019 427- response pressure approx.. 10 bar 1 - 10 019 428

consisting of:- relief valve housing 1 LM 10 014 073- intermediate piece 1 St 10 015 036- valve cone 1 Ms 10 014 078- setpoint spring for approx. 5 bar 1 NSt 10 014 077- setpoint spring for approx. 10 bar 1 NSt 10 016 712- sealing washer 1 EV KG 10 014 082

257 housing, at option:- for valve dia. 2 to 8 mm 1 GLM 10 016 703- for valve dia. 10 mm 1 GLM 10 016 644

265 connection W 21,8x1/14" "left" 1 - 10 015 039267 intermediate piece 1 Ms 10 015 046269 lock nut 1 Ms 10 015 052270 connecting piece 1 Ms 10 015 054271 sealing ring 1 EV LM 00 018 507273 connection W 21,8x1/14" "right" 1 Ms 10 015 058274 cap nut 1 Ms 10 015 061275 sealing ring 1 EV K 00 002 831278 screw connection, at option:

- E 10 1 St 00 030 008- E 12 1 St 00 030 010- E 16 1 St 00 030 015

279 sealing ring, at option:- for E 10 and E 12 1 EV LM 00 018 688- for E 16 1 EV LM 00 018 684

280 intermediate piece, at option for valve dia. 2 to 5.5 mm:- for E 10 and E 12 1 Ms 10 015 071- for E 16 1 Ms 10 015 075- for G 3/4 "male" 1 Ms 10 016 726

290 valve connection, optional for valve dia. 8 mm:- valve connection G 3/4 "male" 1 Ms 10 015 094- valve connection G 1/2 "female" 1 Ms 10 015 090

291 valve connection, optional for valve dia. 10 mm:- valve connection G 3/4 "male" 1 Ms 10 014 906- valve connection G 1/2 "female" 1 Ms 10 015 100

295 intermediate piece G 3/4 "male" 1 Ms 10 016 757296 sealing ring 1 EV LM 00 004 428

219.20 S.15 engl

item description number EV material RMG part no.no. needed297 threaded adapter, at option:

- E 16 1 St 00 030 015- E 20 1 St 00 030 017- E 22 1 St 00 030 018

note! parts marked EV are to be kept in stock for maintenance

material abbreviations:AlBz aluminiumbronzeBz bronzeFSt spring steelGBz cast bronzeGGG cast metal with nodular graphitGLM cast light metalGMs cast brassGZn cast zincK plastic materialKG rubber-like plastic materialKGFP rubber-like plastic material with special coatingFP special plastic materialFPM rubber-like plastic materialLM light metalMS brassNFSt stainless spring steelNSt stainless steelPGl plexiglassSt steel

219.20 S.16 engl