Linde R545 Manuel utilisateur

IMPORTANT!

Read carefully before use! Keep the manual for future consultation!

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INSTRUCTION FOR USE

GEBRAUCHSANLEITUNG

4 PORT LINE REGULATOR

4 PORT LEITUNGSDRUCKREGLER

R545

SINGLE STAGE | BRASS CHROME PLATED | STAINLESS STEEL

EINSTUFIG | MESSING VERCHROMT | EDELSTAHL

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CONTENT

1 General......................................................................................................................................................................................... 4

1.1 Information about this instructions manual ...................................................................................................................... 4

1.2 Information about this line regulator ................................................................................................................................ 4

1.3 Explanation of symbols ........................................................................................................................................................ 5

1.4 Limitations of liability............................................................................................................................................................. 6

1.5 Copyright ................................................................................................................................................................................. 6

1.6 Spare parts .............................................................................................................................................................................. 6

1.7 Warranty provision ................................................................................................................................................................. 6

1.8 Customer service................................................................................................................................................................... 6

2 Safety ............................................................................................................................................................................................7

2.1 Intended use ............................................................................................................................................................................7

2.1.1 Structural changes at the line regulator ....................................................................................................................7

2.2 Fundamental risks .................................................................................................................................................................7

2.3 Operator’s responsibility..................................................................................................................................................... 8

2.4 Personnel requirements...................................................................................................................................................... 9

2.4.1 Qualifications................................................................................................................................................................. 9

2.4.2 Unauthorized personnel............................................................................................................................................ 9

2.4.3 Training .......................................................................................................................................................................... 9

2.5 Personal protective equipment........................................................................................................................................10

2.6 Behavior in case of ﬁre or accident ................................................................................................................................10

2.7 Environmental protection....................................................................................................................................................11

2.8 Signage ...................................................................................................................................................................................11

2.8.1 Signs that give orders .................................................................................................................................................11

2.8.2 Signs indicating bans.................................................................................................................................................11

2.8.3 Warning signs...............................................................................................................................................................11

3 Technical speciﬁcations ................................................................................................................................................12

3.1 Dimension – 4- Port SINGLE STAGE LINE REGULATOR.............................................................................................12

3.2 General information ............................................................................................................................................................12

3.3 Connection values...............................................................................................................................................................12

3.4 Performance value...............................................................................................................................................................13

3.5 Operating conditions ..........................................................................................................................................................13

4 Set-up and function..........................................................................................................................................................13

4.1 Overview – 4- Port LINE REGULATOR ............................................................................................................................13

4.2 Brief description...................................................................................................................................................................13

5 Transport, packaging and storage........................................................................................................................14

5.1 Safety information for transportation...............................................................................................................................14

5.2 Transport inspection ...........................................................................................................................................................14

5.3 Packaging ..............................................................................................................................................................................14

5.4 Storage ...................................................................................................................................................................................14

6 Installation and initial start-up...................................................................................................................................15

6.1 Safety notes for installation and initial start-up.............................................................................................................15

6.2 Preparation............................................................................................................................................................................15

6.3 Installation..............................................................................................................................................................................15

6.4 Required qualiﬁcations for initial start-up and cylinder changing...........................................................................15

6.5 Initial Start Up........................................................................................................................................................................15

6.5.1 Fill the process gas tubing with process gas .......................................................................................................15

6.5.2 Taking gas supply out of operation.......................................................................................................................15

6.6 Tests ........................................................................................................................................................................................15

7 Operation..................................................................................................................................................................................16

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8 Maintenance..........................................................................................................................................................................16

8.1 Safety notes for maintenance............................................................................................................................................16

8.2 Maintenance plan ................................................................................................................................................................16

8.3 Maintenance work ...............................................................................................................................................................16

8.3.1 Cleaning.........................................................................................................................................................................16

8.3.2 Requirements for maintenance ..............................................................................................................................16

8.3.3 Necessary maintenance........................................................................................................................................... 17

8.4 Measures following maintenance.................................................................................................................................... 17

9 Troubleshooting.................................................................................................................................................................. 17

9.1 Safety notes for troubleshooting ...................................................................................................................................... 17

10 Dismantling and disposal...........................................................................................................................................19

10.1 Safety notes for dismantling and disposal....................................................................................................................19

10.2 Dismantling .........................................................................................................................................................................20

10.3 Disposal ...............................................................................................................................................................................20

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1. GENERAL

1.1. INFORMATION ABOUT THIS INSTRUCTIONS MANUAL

This instruction is only intended for use with line regulator product type:

• R545 - 4- Port Single Stage

Line regulators of this type are suitable to reduce a high supply pressure through dierent pressure stages.

These regulators were assembled into piping system permanently.

These instructions enable you to operate the system safely and eciently. These instructions form an integral

part of the system and must always be kept with the system and within easy reach of sta at all times.

Prior to commencing any work, the sta must read these instructions carefully and understand the contents.

Observance of all the safety information and instructions for operation that are contained in these instructions

is essential to ensure work safety.

Local accident prevention regulations and general safety regulations governing the use of the system must

also be observed.

Illustrations in these instructions serve to ensure a basic understanding of the system and may dier from

the actual version.

1.2. INFORMATION ABOUT THIS LINE REGULATOR

Line Regulators of this type are only suitable for gases deﬁned as standard gas. The maximum working pres-

sure for line regulator is 40bar.

Product Line (Purity 6.0 | brass chrome plated) (Purity 6.0 | stainless steel)

Precision Pressure regulator

with FKM Seat

•Suitable Gases

(including their mixtures)

•High Purity

•Inert

•Flammable

•Oxidizing

•Use for O2

•Not Suitable Gases

(including their mixtures)

• Corrosive

•Toxic

•Not for CO2, N20

•Suitable Gases

(including their mixtures)

• High Purity

• Inert

•Flammable

• Oxidizing (up to 200 bar)

•Corrosive (in doubt ask)

•Toxic (in doubt ask)

•Not Suitable Gases

(including their mixtures)

•Not for O2 above 200 bar

•Not for CO2, N20

•Not for NH3, SO2, H2S

Precision Pressure regulator

with EPDM Seat

•Suitable Gases

(including their mixtures)

•High Purity

•Inert

•Flammable

•Oxidizing

•Use for CO2, N20

• Not Suitable Gases

(including their mixtures)

• Corrosive

• Toxic

• Not for O2

(share greater than 21%)

• Hydrocarbons

•Suitable Gases

(including their mixtures)

•High Purity

• Inert

•Flammable

•Oxidizing

• Corrosive (in doubt ask)

•Toxic (in doubt ask)

•Use for CO2, N20

•Use for NH3, SO2, H2S

•Not Suitable Gases

(including their mixtures)

•Not for O2

(share greater than 21%)

• Hydrocarbons

This table is not exhaustive. For questions and ambiguities please contact manufacturer.

ENGLISH

INSTRUCTION FOR USE: 4 PORT LINE REGULATOR

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It is a single stage line regulator with metal diaphragm and four ports.

Created and approved as ISO7291, including oxygen test.

The line regulator consists of the regulator body, outlet gauge (4- Port Version).

Dierent inlet and outlet implementations (compression ﬁttings) are available.

1.3. EXPLANATION OF SYMBOLS

SAFETY INFORMATION Safety information is highlighted by symbols in these instruc-

tions. This safety information is preceded by signal words that

deﬁne the extent of risk.

DANGER!

This combination of symbol and signal word indicates

an immediately dangerous situation that will cause death

or severe injury if not avoided.

WARNING!

This combination of symbol and signal word indicates

a possibly dangerous situation that can cause death or severe

injury if not avoided.

BEWARE!

This combination of symbol and signal word indicates

a possibly dangerous situation that can cause minor injury

if not avoided.

NOTE!

This combination of symbol and signal word indicates

a possibly dangerous situation that can cause property

and environmental damage if not avoided.

TIPS AND RECOMMENDATIONS

This symbol highlights useful tips and recommendations,

together with help for ensuring ecient and trouble-free

operation.

SPECIAL SAFETY

INFORMATION

The following symbols are used in the safety information

to draw your attention to particular risks.

DANGER!

This combination of symbol and signal word indicates an im-

mediately dangerous situation involving electrical current.

Ignoring such a warning could result in severe or fatal injuries.

6/44

1.4. LIMITATIONS OF LIABILITY

All of the information and notes in these instructions have been compiled in accordance with applicable

standards and regulations. They reﬂect best engineering practice and our years of experience.

The manufacturer accepts no liability for damages in the following instances:

• Failure to observe these instructions

• Utilization of the system for any other than the intended purpose

• Operation by untrained sta

• Unauthorized modiﬁcations

• Technical modiﬁcations

• Use of unlicensed spare parts

• Working with the gas supply panel when any safety device is broken or not functional mounted or safety

devices don’t work correctly

• Improper control of components, connections and gaskets, which are wearing parts.

• Incorrect reparations

• Violation of temperature limits, which are dedicated in the datasheet during operation or storage

• In case of disaster or force majeure

The actual scope of supply may dier from the explanations and illustrations in these instructions following

the incorporation of new technical changes.

The obligations stipulated in the supply agreement, our general terms and conditions of business, the manu-

facturer’s terms and conditions of supply and the statutory regulations in force at the time of contract conclu-

sion apply.

1.5. COPYRIGHT

The contents of these instructions are protected by copyright. They may be used in connection with the

operation of the system. Any other use above and beyond the aforementioned is only permitted with the

written consent of the manufacturer.

1.6. SPARE PARTS

WARNING!

• Risk of injury from using incorrect spare parts!

• The use of incorrect or defective spare parts can result in risks for the operating sta and in damages,

malfunctions or total failure of the system.

• Only use original spare parts from the manufacturer or spare parts authorized by the manufacturer.

• Always consult the manufacturer if in doubt.

LOSS OF WARRANTY

• The manufacturer’s warranty lapses if unauthorized spare parts are used.

1.7. WARRANTY PROVISION

In principle, our "General Terms and Conditions of Sale and Delivery" shall apply. These are available to the

customer at the latest since the conclusion of the contract.

1.8. CUSTOMER SERVICE

Please do not hesitate to provide us with information and experiences gained through use; we welcome any

valuable input that will help to improve our products.

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2. SAFETY

This section provides an overview of all the important safety aspects to ensure the protection of your sta

and the safe and trouble-free operation of the equipment. Further safety information relating to speciﬁc tasks

can be found in the sections on the individual life cycle phases.

2.1. INTENDED USE

The R545 line regulator is only usable for the deﬁned standard gases and pressures observing the given

temperature range. The nominal ﬂow is 5 m/h (Air).

Intended use also includes compliance with all the information in these instructions and compliance with

reparation, maintenance working, type label and data sheets.

Any use other than, or above and beyond, the intended use constitutes improper use.

WARNING!

• Danger from improper use!

• Improper use of the system can lead to dangerous situations.

• Never use the line regulator with liquid ﬂuids.

2.1.1. STRUCTURAL CHANGES AT THE LINE REGULATOR

Without written approval of supplier no extensions, additions or alternations are allowed on the line regulator.

Line regulator which are not in perfect condition have to be changed immediately.

Cleaning of line regulator and disposal of residues

Used line regulator which are ready for reparation has to be purged with an inert gas before.

Noise Generation

In some cases when speciﬁc inﬂuence quantities collaborate together, e.g. ﬂow and pressure range can

cause noise generation or the gas itself. If this happens please contact supplier.

2.2. FUNDAMENTAL RISKS

The following section addresses the residual risks that may arise, even if the system is used properly.

Observance of the safety information included below and in other sections of these instructions is mandatory

in order to reduce the risk of injury and property damage and to avoid dangerous situations.

DANGER!

• Gases can be life threatening!

• Gases can supersede the oxygen in air. This can result in death by asphyxiation. Oxygen produces a

strongly oxidizing eect.

THEREFORE:

• Sucient ventilation is absolutely essential.

• Installation only through certiﬁed company.

• Observe ATEX directive.

ATTENTION!

• Risk of injury from environment!

There can be malfunctions on component due to condensation and/ or icing.

THEREFORE:

• Observe suitable temperatures.

• Protect component from liquids from outside

• Protect component from dust from outside

• Protect component from weather conditions

• Grounding has to be mounted properly

8/44

WARNING!

• Risk of injury from using oil and grease!

Oil and grease must never be used in gas regulating systems. Oil and grease are highly inﬂammatory and

can react violently to certain pressurized gases.

THEREFORE:

• Never use oil and grease

WARNING!

• Risk of injury from residual energy stored in the system!

If handled incorrectly, pressurized components can move uncontrollably and cause severe injury. If handled

incorrectly or defective, pressurized components can leak gas under high pressure and cause severe or

even fatal injuries.

BEFORE STARTING WORK WITH THESE COMPONENTS:

• Installation only through certiﬁed company.

• Always wear protective goggles when working.

• Always wear ear protection.

• Make sure the equipment is depressurized. Also make sure the residual energy is discharged.

• Always ensure that gas cannot leak unintentionally.

• Make sure that defective components that are pressurized during operation are immediately replaced by

trained sta.

WARNING!

• Danger of accident!

Due to wrong installation there can be serious or even mortal injuries.

THEREFORE:

• During installation the component should be kept safe

• Never throw the component

Pressurised components are only for intended use.

If there are mechanical damages at tubing or components the whole system has to be put in a safe condi-

tion. Aected area has to be blocked. Troubles which could inﬂuence safety, have to be eliminated through

qualiﬁed sta or supplier.

Especially with gases failure in pressure regulator could happen. Indications for defective regulator is no ﬂow

or immediately rising outlet pressure. In this case system has to be regulating and the relevant department

for maintenance has to be informed. Never close exhaust piping.

2.3. OPERATOR’S RESPONSIBILITY

OPERATOR

The operator is the person who operates the system for commercial or business purposes or who provides

the system for use/application by a third party, and who bears legal product responsibility for protecting the

user, sta or third parties during operation.

OPERATOR’S DUTIES

The system is used for commercial purposes. The operator of the system is therefore subject to legal work

safety obligations.

Compliance with the safety, accident prevention and environmental protection regulations that apply for the

use of the system is mandatory, in addition to the safety information in these instructions.

THE FOLLOWING APPLIES IN PARTICULAR:

• The operator must be aware of the applicable work safety regulations and must perform a risk assessment

to identify risks that may occur as a result of the speciﬁc working conditions at the site where the system

is operated. The operator must use this assessment as the basis for compiling instructions for operating

the system.

• During the entire period in which the system is operated, the operator must ensure that these operating

instructions comply with the latest regulations, and must update the instructions if necessary.

• The operator must assign clear and speciﬁc responsibility for installation, operation, troubleshooting,

maintenance and cleaning.

9/44

• The operator must ensure that all members of sta who work with the system have read and understood

these instructions. The operator must also ensure that these members of sta are trained at regular inter-

vals and are aware of the risks.

• The operator must provide the sta with the requisite protective equipment and bindingly obligate the

sta to wear the necessary protective equipment.

In addition, the operator is responsible for ensuring full technical reliability of the system at all times.

AS SUCH, THE FOLLOWING APPLIES:

• The operator must ensure compliance with the maintenance intervals speciﬁed in these instructions.

• The operator must ensure that all safety equipment is regularly inspected for functional reliability and

completeness.

2.4. PERSONNEL REQUIREMENTS

2.4.1. QUALIFICATIONS

The various tasks described in these instructions constitute diering requirements in respect of the qualiﬁca-

tions of the sta charged with performing these tasks.

WARNING!

• Danger if sta is insuciently qualiﬁed!

• Insuciently qualiﬁed sta is not able to assess the risks associated with the system and expose both

themselves and others to the risk of severe or fatal injury.

• Ensure that all works are only performed by sta qualiﬁed for the speciﬁc task.

• Keep insuciently qualiﬁed people out of the work area.

The works must always be assigned only to individuals who can be trusted to perform the works reliably.

People with impaired reactions, e.g. as a result of drugs, alcohol or medication, must not be allowed to

perform works.

These instructions deﬁne the qualiﬁcations below that are necessary for the respective tasks:

GAS ENGINEER:

Have a professional training, skills and experience and the knowledge of the pertinent standards and regula-

tions to perform works on gas systems and to identify potential hazards. Gas engineers are trained speciﬁ-

cally for the site where they work and are familiar with all relevant standards and regulations.

TECHNICIAN

Have the professional training, skills and experience and the knowledge of the pertinent standards and regu-

lations to perform the assigned works and to identify and avoid potential hazards.

2.4.2. UNAUTHORIZED PERSONNEL

WARNING!

• Risks associated with unauthorized personnel in the hazard and work areas can be life threatening!

• Unauthorized individuals without the qualiﬁcations described in this section are not familiar with the risks

in the work area. As such, they are in danger of severe or even fatal injury.

• Keep unauthorized personnel away from the hazard and work area.

• If in doubt, approach individuals and instruct them to leave the hazard and work area.

• Stop any work while unauthorized individuals are in the hazard and work area.

2.4.3. TRAINING

The operator must train the sta at regular intervals. A training log must be maintained for purposes of better

tracking and must contain the following information, at least:

• Date of training

• Names of trained sta

• Contents of the training session

• Name of trainer

• Signatures of the sta members in training and of the trainer

10/44

2.5. PERSONAL PROTECTIVE EQUIPMENT

Personal protective equipment protects sta from safety and health hazards while working.

Various tasks on and associated with, the system necessitate the use of personal protective equipment,

which is described in more detail in the individual sections of these instructions.

BREATHING APPARATUS

To protect against harmful gases, vapors, dust and similar materials and media.

Breathing apparatus (e.g. compressed air respirator) must be used when an oxy-

gen content of at least 17% in the ambient air is not guaranteed or when the limit

of a hazardous substance in the ambient air is exceeded more than 100-fold.

Breathing apparatus may only be worn by people who have been specially trained

in the use.

BREATHING APPARATUS, DEPENDENT ON AIR CIRCULATION

To protect against harmful gases, vapors, dust and similar materials and media.

Breathing apparatus must be worn if a permissible limit is exceeded 100-fold.

The breathing apparatus may only be used when the oxygen content in the ambi-

ent air measures at least 17%.

PROTECTIVE GOGGLES

To protect the eyes against airborne parts and splashes of liquid.

CHEMICAL-RESISTANT GLOVES

To protect the hands from aggressive substances.

Make sure the protective gloves are leak-proof before wear. Before taking the

gloves o, clean them and then store them in a well ventilated location.

PROTECTIVE GLOVES

To protect the hands against abrasion, scrapes, pricks or deeper injuries and con-

tact with hot or cold surfaces.

EAR PROTECTION

Protects the ears from too loud noises and prevents acoustic trauma.

2.6. BEHAVIOR IN CASE OF FIRE OR ACCIDENT

PREVENTIVE MEASURE

• Always be prepared for ﬁres and accidents!

• Always keep ﬁrst aid equipment (kit, blankets, etc.) and ﬁre extinguishing equipment in working order and

close to hand.

• Familiarize the sta with accident reporting, ﬁrst aid and emergency procedures.

• Keep the access routes free for emergency service vehicles.

MEASURES IN THE EVENT OF FIRE OR ACCIDENT

• If there is no risk to your own safety, remove people from the danger zone.

• Administer ﬁrst aid if necessary.

• Notify the ﬁre brigade and/or emergency service.

• In the event of ﬁre: If there is no risk to your own safety, use ﬁre extinguishing equipment to ﬁght the ﬁre

until the ﬁre brigade arrives.

• Inform the person responsible at the location.

• Make sure the access routes are free for emergency service vehicles.

• Direct the emergency service vehicles.

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