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Operation and Maintenance, Spare Parts edition 05/1994 Serving the Gas Industry - WORLDWIDE 640.20 Pilot Pilot RMG 640 RMG 640
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Operation and Maintenance,Spare Parts edition 05/1994
Serving the Gas Industry - WORLDWIDE
640.20
The RMG Group of Companies on the internet: http://www.rmg.de
We supply you with productsWe supply you with productsfor gas pressure regulation:for gas pressure regulation:
We reserve the right for technical changes
PilotPilotRMG 640RMG 640
Serving the Gas Industry - WORLDWIDE
The other RMG Companies:The other RMG Companies:
Bryan Donkin RMG Gas Controls Ltd.Enterprise Drive, Holmewood, Chesterfield S42 5UZ, EnglandTelephone (++44) 1246 501-501 • Fax (++44) 1246 501-500gas pressure regulating equipment, below ground gas control modules
RMG REGEL + MESSTECHNIK GMBHOsterholzstrasse 45, D-34123 Kassel, GermanyTelephone (++49) 561 5007-0 • Fax (++49) 561 5007-107
gas pressure regulators and safety devices
RMG-GASELAN Regel + Meßtechnik GmbHJulius-Pintsch-Ring 3, D-15517 Fürstenwalde, GermanyTelephone (++49) 3361 356-60 • Fax (++49) 3361 356-836gas pressure regulating equipment, displacement meters, complete stations
RMG Messtechnik GmbHOtto-Hahn-Strasse 5, D-35510 Butzbach, GermanyTelephone (++49) 6033 897-0 • Fax (++49) 6033 897-130turbine meters, vortex meters, correctors, flow computers, odorizers
WÄGA Wärme-Gastechnik GmbHOsterholzstrasse 45, D-34123 Kassel, GermanyTelephone (++49) 561 5007-0 • Fax (++49) 561 5007-207design and assembly of gas pressure regulating and metering stations
Bryan Donkin RMG Co. of Canada Ltd.50 Clarke Street South, Woodstock, Ontario N4S 7Y5, CanadaTelephone (++1) 519 5398531 • Fax (++1) 519 5373339domestic regulators and safety devices
Karl Wieser GmbHAnzinger Strasse 14, D-85560 Ebersberg, GermanyTelephone (++49) 8092 2097-0 • Fax (++49) 8092 2097-10
Heinrich-Lanz-Strasse 9, D-67259 Beindersheim/Pfalz, GermanyTelephone (++49) 6233 3762-0 • Fax (++49) 6233 3762-40 data logging, monitor systems, danger alarm systems
Betriebsstelle Beindersheim
640.20 p.15640.20 p.02
1. General
In addition to this leaflet 640.20 concerning "Special Operating Instruction, Maintenance and Spare Parts" of the pilot RMG 640, the brochure 640.00 gives full information about all relevant technical data, description of function, the available versions, and dimensions. Relevant technical data can also be obtained from the latest RMG booklet.Please also refer to the leaflets of the main valve the pilot is connected to.
The RMG brochure "General Operating Instructions for Gas Pressure Regulators and Safety Devices" will be useful to fit the safety device 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 technical 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 strongly dependant on the prevailing service conditions, the type and composition of the gaseous medium, the ambient temperature and on dust and dirt withing the pipe system. We therefore abstain from imposing any fixed intervals and would rather advise testing out the necessary maintenance intervals, starting with short gaps for maintenance dismantling, and then increasing the intervals if there are no damages or signs of wear.
For maintenance all parts are to be cleaned and subjected to a thorough visual inspection. Complete dismantling together with visual 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.
The item numbers referred to in the maintenance instructions are identical with those of of the spare parts drawings and of the spare parts lists. We recommend to keep all parts that are specially marked in the spare parts lists in stock for prompt mainten-ance availability.
2. Special operating instructions
2.1 Start-up valve
The gas pressure regulators RMG 402, RMG 502 and RMG 503 are fitted with a start-up valve. This valve enables a quick pressure compensation at the regulating diaphragm, making the first pressurization.
• Open the start-up valve before pressurization.• After pressurization close the start-up valve again.
2.2 Adjusting the dosing screw
The dosing screw has a basic setting by RMG and in most cases needs no further adjustment. For reduction of the amplification and to reduce instable regulating behaviour turn the dosing screw anti-clockwise (max. 3 turns).
640.20 p.03640.20 p.14
640.20 p.13640.20 p.04
Basic diagram of the pilot RMG 640 with a main valve
inlet pressure gauge
dosing screw
start-up valve
connection for theinlet pressure line withRMG 502 / RMG 503
inlet pressure pe
3. Special maintenance instructions
pre-formed diaphragm (119, 169)
When fitting the diaphragm take care of the correct mounting position of the loop. (See spare parts drawings of the outlet pressure stage, pages 10, 12)
diaphragm plate (107, 154)
When tightening the closing cap (103, 167) and the hexagonal nut (123), secure the diaphragm plate against dis-tortion with a spanner size SW 24.
adjusting the diaphragm system (119)
For correct fitting of the diaphragm system into thevalve body bring the cross hole of the union piece(122) and the valve body (121) in alignment:Turn the diaphragm system clockwise and anti-clockwise to the stop, and mark these positionswith a pencil. Them turn the diaphragm systeminto the middle position.
outlet pressure gauge
breathing line
measuring line
bleed line
setpoint adjusting screwfor outlet pressure
connection for the bleed linewith RMG 502 / RMG 503
outlet pressure pa
pencilmarks:for the stops
for the central position
adjusting movementvalve bodydiaphragm
hexagon nut
4.5 Spare Parts List RMG 640 control unit with diaphragm measuring system
item RMG part no. for
no. description EV* material valve seat 3 mm
151 cover LM 10 011 768
152* piston, pre-assembled EV NFSt/NSt/KV 10 000 186
153 spring NSF 10 010 463
154 diaphragm plate LM 10 000 110
155* o-ring EV KG 00 020 225
156* valve insert EV LM 10 011 775
157 grooved dowel pin St 00 017 197
158 union piece NSt 10 011 773
159 spring housing LM 10 011 767
160 guiding pin St 10 011 772
161 spring plate NSt 10 011 774
162 spring FSt 10 010 444
163 axial disk (2 pcs.) St 00 026 385
164 axial needle bearing St 00 026 384
165 cylinder screw St 00 010 548
166 washer St 00 008 279
167 locking cap NSt 10 000 188
168* o-ring EV KG 00 020 332
169* pre-formed diaphragm EV KG 10 000 191
170* sealing insert EV KG 10 000 066
171 valve body LM 10 011 769
172* o-ring EV KG 00 020 416
173 metal harmonica, complete NSt/St 10 011 764
174* o-ring EV KG 00 020 317
175 washer St 00 006 157
176 cylinder screw St 00 010 318
180* o-ring EV KG 00 020 293
181 plate St 10 011 770
182 washer St 00 008 279
183 cylinder screw St 00 010 097
184* hexagon collar nut EV St/K 00 013 145
185 hexagon screw NSt 10 010 447
for connection to electric actuator
190 spring plate LM 10 011 795
191 ring LM 10 021 766
192* sealing EV K 10 021 765
193 plate, complete St/AlBz 10 000 079
194 washer St 00 014 156
195 cylinder screw St 00 010 150
196* o-ring EV KG 00 020 326
197 clutch device, pre-assembled St/NSt 10 010 538
*) parts marked with an asterisk (*) and with EV are to be kept in stock for maintenance
material key
St
FSt
NSt
... steel
... spring steel
... stainless steel
LM
Ms
PGl
... light metal
... brass
... plexiglass
K
KG
AlBz
... plastic material
... rubber-like plastic material
... aluminium bronze
640.20 p.05640.20 p.12
Union piece (158)
Grease the threaded plug of the completely assembled union piece with LOCTITE and screw it into the metal har-monica connection piston (173) so that the cross hole of the union piece is positioned 0.5 mm to 1 mm below the valve body cross hole (171).Attention: Both cross holes must be in alignment
Valve insert (105, 156)
Use the adjusting screw (124, 185) to get the diaphragm system in a position that will allow the valve insert to be fitted.
Base plate (1)
The connecting sides of the load limiting and the control unit base plate must be in alignment.
Spindle (25) of the amplifying valve
For finding the basic adjustment of the amplifying valve turn the spindle (25) until the spindle groove (filled with black) comes in line with the front edge of the sleeve (27) fixed into the guiding screw (26).
Torques table
Table of lubricants
Screw locking
item no. torqueMA in Nm
176 611, 114, 115, 165, 183 12103, 123, 167 20
item (to be greased slightly) lubricant RMG part no.
all o-rings, all sliding surfaces silicone grease 00 027 081
spring plate recesses (13, 108, 161)threads of cover (112) fitting paste 00 027 091threads of plate (181)
all fastenings and pipe screw connections high duty grease 00 027 058
item (to be covered slightly) screw locking RMG part no.
thread of locking cap (103, 167)thread of hexagon nut (123) LOCTITE 00 026 688thread of union piece (122, 158)
* parts marked with asterisk to be kept in stock for maintenance
4.6 Spare Parts Drawing RMG 640 control unit with metal harmonica type measuring system
standard version for connection toelectric actuator
640.20 p.11640.20 p.06
*) parts marked by an asterisk are to be kept in stock for maintenance
4. Spare Parts4.1 Spare Parts Drawing RMG 640 outlet pressure range Wh 1 bar to 40 bar with diaphragm type measuring unit
optional without / with outlet pressure gauge
drawings with outlet pressure gauge for:
overpressureprotectionsee 925.20
drawing for top without outlet pressure gauge:
sketch without filterand inlet connection
filter see905.20
control unit seepage 10
adjustable amplifying valve
(without filter and inlet connection)
4.5 Spare Parts List RMG 640 control unit with diaphragm measuring system
item RMG part no. for
no. description EV* material valve seat 3 mm
101 cover LM 10 000 190
102 pressure spring NFSt 10 010 463
103 locking cap NSt 10 000 188
104* o-ring EV KG 00 020 225
105* valve insert EV LM 10 000 061
106 grooved dowel pin St 00 017 197
107 diaphragm plate LM 10 000 110
108 spring plate LM
109 spring FSt
110 spring housing LM 10 000 062
111* sealing ring EV K 10 000 100
113 washer St 00 008 279
115 hexagon screw St 00 010 377
117* piston, pre-assembled EV NFSt/NSt/KV 10 000 186
118* o-ring EV KG 00 020 332
119* pre-formed diaphragm EV KG 10 000 191
120* sealing insert EV KG 10 000 066
121 valve body LM 10 000 137
122 union piece NSt 10 000 108
123 hexagon nut St 00 013 114
130 o-ring St 10 000 116
131 washer St 00 008 279
132 hexagonal screw St 00 006 493
133* hexagonal nut EV St/K 00 013 136
134 hexagonal screw NSt 10 002 795
for connection to electric actuator:
136 plate, pre-assembled St/AlBz 10 000 079
137 washer St 00 014 146
138 cylindrical screw St 00 010 150
139 clutch device, pre-assembled St/NSt 10 010 538
140* o-ring EV KG 00 020 326
*) parts marked with an asterisk (*) and with EV are to be kept in stock for maintenance
material key
St
FSt
NSt
... steel
... spring steel
... stainless steel
LM
Ms
PGl
... light metal
... brass
... plexiglass
K
KG
AlBz
... plastic material
... rubber-like plastic material
... aluminium bronze
640.20 p.07640.20 p.10
*) parts marked by an asterisk are to be kept in stock for maintenance
4.2 Spare Parts Drawing RMG 640 outlet pressure range Wh 20 bar to 90 bar with metal harmonica type measuring unit
optional without / with outlet pressure gauge
drawing with outlet pressure gauge:
drawing for top withoutoutlet pressure gauge:
control unit seepage 12filter see
905.20
sketch without filterand inlet connection
(without filter and inlet connection)
adjustable amplifying valve
* parts marked with asterisk to be kept in stock for maintenance
4.4 Spare Parts Drawing RMG 640 control unit with diaphragm measuring system
standard versionfor connection toelectric actuator
open
ed
640.20 p.09640.20 p.08
4.3 Spare Parts List RMG 640
item RMG part no. for RMG part no. for
no. description EV* material 1 bar ... 40 bar 20 bar ... 90 bar
1 base plate LM 10 011 749 10 011 749
2 screwed socket St 00 030 111 00 030 111
3 cap nut St 00 030 803 00 030 803
4 cutting ring St 00 030 903 00 030 903
5 pressure gauge, optional:
for pressure rating PN 16 NSt/Ms 00 026 314
for pressure rating PN 25/ANSI 150 NSt/Ms 00 026 284
for pressure rating PN 40 NSt/Ms 00 026 282
for pressure rating ANSI 300 NSt/Ms 00 026 283 00 026 285
for pressure rating ANSI 600 NSt/Ms 00 026 285 00 026 285
6 screwed socket St 00 031 810 00 031 810
7 screwed socket St 00 031 609 00 031 609
8 locking cone St 00 032 004 00 032 004
9* sealing ring EV LM 00 018 842 00 018 842
10 washer St 00 008 279 00 008 279
11 hexagonal nut St 00 010 024 00 010 024
12 straight pipe St 00 032 101 00 032 101
13 spring plate, optional:
for Wh 1 bar to 10 bar LM 10 000 114
for Wh 5 bar to 40 bar LM 10 000 148
14 spring, optional:
for Wh 1 bar to 5 bar (yellow) FSt 10 000 063
for Wh 2 bar to 10 bar (brown) FSt 10 000 115
for Wh 5 bar to 20 bar (red) FSt 10 000 064
for Wh 10 bar to 40 bar (green) FSt 10 000 149
15 locking screw St 00 026 175 00 026 175
16 screwed socket St 00 030 074 00 030 074
17 cap nut St 00 030 804 00 030 804
18 cutting ring St 00 030 904 00 030 904
19 washer LM 10 010 479 10 010 479
20* o-ring (1 piece) EV KG 00 020 231 00 020 231
21* o-ring (4 pieces) EV KG 00 020 225 00 020 225
22* safety ring EV FSt 00 019 065 00 019 065
23* o-ring (1 piece) EV KG 00 020 283 00 020 283
24* o-ring (1 piece) EV KG 00 020 332 00 020 332
25 threaded rod NSt 10 000 145 10 000 145
26 guiding screw Ms 10 000 144 10 000 144
27 sleeve PGl 10 000 171 10 000 171
28 protective cap K 00 026 343 00 026 343
*) parts marked with an asterisk (*) and with EV are to be kept in stock for maintenance
material key
St
FSt
NSt
... steel
... spring steel
... stainless steel
LM
Ms
PGl
... light metal
... brass
... plexiglass
K
KG
... plastic material
... rubber-like plastic material
4.3 Spare Parts List RMG 640 (contd.)
item RMG part no. for RMG part no. for
no. description EV* material 1 bar ... 40 bar 20 bar ... 90 bar
optional without or with outlet pressure gauge
without outlet pressure gauge
30 cap nut St 00 030 804 00 030 804
31 cutting ring St 00 030 904 00 030 904
32 screwed socket St 10 009 683 10 009 683
33 dosing screw dia. 0.5 mm Ms 10 014 015 10 014 015
34* washer EV LM 00 018 842 00 018 842
with outlet pressure gauge for Wh 1 bar to 20 bar
35 outlet pressure gauge, optional:
with measuring range Wh 1 bar to 5 bar NSt/Ms 00 026 281
with measuring range Wh 2 bar to 10 bar NSt/Ms 00 026 314
with measuring range Wh 5 bar to 20 bar NSt/Ms 00 026 284
36 screwed socket St 00 031 810
37 overpressure protection, optional:
for Wh 1 bar to 5 bar 10 023 336
for Wh 2 bar to 10 bar 10 023 337
for Wh 5 bar to 20 bar 10 023 338
38 dosing screw dia. 0.5 mm Ms 10 014 015
39 screwed socket St 10 000 714
40* cutting ring EV LM 00 018 842
with outlet pressure gauge for Wh 10 bar to 90 bar
41 outlet pressure gauge NSt/Ms 00 026 282 00 026 285
42 screwed socket St 00 031 810 00 031 810
43 screwed socket St 00 030 455 00 030 455
44 cap nut St 00 030 804 00 030 804
45 cutting ring St 00 030 904 00 030 904
46 straight piece of pipe St 00 032 141 00 032 141
47 dosing screw dia. 0.5 mm Ms 10 014 015 10 014 015
48 screwed socket St 10 009 683 10 009 683
49* sealing ring EV LM 00 018 842 00 018 842
*) parts marked with an asterisk (*) and with EV are to be kept in stock for maintenance
material key
St
FSt
NSt
... steel
... spring steel
... stainless steel
LM
Ms
PGl
... light metal
... brass
... plexiglass
K
KG
... plastic material
... rubber-like plastic material
640.20 p.09640.20 p.08
4.3 Spare Parts List RMG 640
item RMG part no. for RMG part no. for
no. description EV* material 1 bar ... 40 bar 20 bar ... 90 bar
1 base plate LM 10 011 749 10 011 749
2 screwed socket St 00 030 111 00 030 111
3 cap nut St 00 030 803 00 030 803
4 cutting ring St 00 030 903 00 030 903
5 pressure gauge, optional:
for pressure rating PN 16 NSt/Ms 00 026 314
for pressure rating PN 25/ANSI 150 NSt/Ms 00 026 284
for pressure rating PN 40 NSt/Ms 00 026 282
for pressure rating ANSI 300 NSt/Ms 00 026 283 00 026 285
for pressure rating ANSI 600 NSt/Ms 00 026 285 00 026 285
6 screwed socket St 00 031 810 00 031 810
7 screwed socket St 00 031 609 00 031 609
8 locking cone St 00 032 004 00 032 004
9* sealing ring EV LM 00 018 842 00 018 842
10 washer St 00 008 279 00 008 279
11 hexagonal nut St 00 010 024 00 010 024
12 straight pipe St 00 032 101 00 032 101
13 spring plate, optional:
for Wh 1 bar to 10 bar LM 10 000 114
for Wh 5 bar to 40 bar LM 10 000 148
14 spring, optional:
for Wh 1 bar to 5 bar (yellow) FSt 10 000 063
for Wh 2 bar to 10 bar (brown) FSt 10 000 115
for Wh 5 bar to 20 bar (red) FSt 10 000 064
for Wh 10 bar to 40 bar (green) FSt 10 000 149
15 locking screw St 00 026 175 00 026 175
16 screwed socket St 00 030 074 00 030 074
17 cap nut St 00 030 804 00 030 804
18 cutting ring St 00 030 904 00 030 904
19 washer LM 10 010 479 10 010 479
20* o-ring (1 piece) EV KG 00 020 231 00 020 231
21* o-ring (4 pieces) EV KG 00 020 225 00 020 225
22* safety ring EV FSt 00 019 065 00 019 065
23* o-ring (1 piece) EV KG 00 020 283 00 020 283
24* o-ring (1 piece) EV KG 00 020 332 00 020 332
25 threaded rod NSt 10 000 145 10 000 145
26 guiding screw Ms 10 000 144 10 000 144
27 sleeve PGl 10 000 171 10 000 171
28 protective cap K 00 026 343 00 026 343
*) parts marked with an asterisk (*) and with EV are to be kept in stock for maintenance
material key
St
FSt
NSt
... steel
... spring steel
... stainless steel
LM
Ms
PGl
... light metal
... brass
... plexiglass
K
KG
... plastic material
... rubber-like plastic material
4.3 Spare Parts List RMG 640 (contd.)
item RMG part no. for RMG part no. for
no. description EV* material 1 bar ... 40 bar 20 bar ... 90 bar
optional without or with outlet pressure gauge
without outlet pressure gauge
30 cap nut St 00 030 804 00 030 804
31 cutting ring St 00 030 904 00 030 904
32 screwed socket St 10 009 683 10 009 683
33 dosing screw dia. 0.5 mm Ms 10 014 015 10 014 015
34* washer EV LM 00 018 842 00 018 842
with outlet pressure gauge for Wh 1 bar to 20 bar
35 outlet pressure gauge, optional:
with measuring range Wh 1 bar to 5 bar NSt/Ms 00 026 281
with measuring range Wh 2 bar to 10 bar NSt/Ms 00 026 314
with measuring range Wh 5 bar to 20 bar NSt/Ms 00 026 284
36 screwed socket St 00 031 810
37 overpressure protection, optional:
for Wh 1 bar to 5 bar 10 023 336
for Wh 2 bar to 10 bar 10 023 337
for Wh 5 bar to 20 bar 10 023 338
38 dosing screw dia. 0.5 mm Ms 10 014 015
39 screwed socket St 10 000 714
40* cutting ring EV LM 00 018 842
with outlet pressure gauge for Wh 10 bar to 90 bar
41 outlet pressure gauge NSt/Ms 00 026 282 00 026 285
42 screwed socket St 00 031 810 00 031 810
43 screwed socket St 00 030 455 00 030 455
44 cap nut St 00 030 804 00 030 804
45 cutting ring St 00 030 904 00 030 904
46 straight piece of pipe St 00 032 141 00 032 141
47 dosing screw dia. 0.5 mm Ms 10 014 015 10 014 015
48 screwed socket St 10 009 683 10 009 683
49* sealing ring EV LM 00 018 842 00 018 842
*) parts marked with an asterisk (*) and with EV are to be kept in stock for maintenance
material key
St
FSt
NSt
... steel
... spring steel
... stainless steel
LM
Ms
PGl
... light metal
... brass
... plexiglass
K
KG
... plastic material
... rubber-like plastic material
640.20 p.07640.20 p.10
*) parts marked by an asterisk are to be kept in stock for maintenance
4.2 Spare Parts Drawing RMG 640 outlet pressure range Wh 20 bar to 90 bar with metal harmonica type measuring unit
optional without / with outlet pressure gauge
drawing with outlet pressure gauge:
drawing for top withoutoutlet pressure gauge:
control unit seepage 12filter see
905.20
sketch without filterand inlet connection
(without filter and inlet connection)
adjustable amplifying valve
* parts marked with asterisk to be kept in stock for maintenance
4.4 Spare Parts Drawing RMG 640 control unit with diaphragm measuring system
standard versionfor connection toelectric actuator
open
ed
640.20 p.11640.20 p.06
*) parts marked by an asterisk are to be kept in stock for maintenance
4. Spare Parts4.1 Spare Parts Drawing RMG 640 outlet pressure range Wh 1 bar to 40 bar with diaphragm type measuring unit
optional without / with outlet pressure gauge
drawings with outlet pressure gauge for:
overpressureprotectionsee 925.20
drawing for top without outlet pressure gauge:
sketch without filterand inlet connection
filter see905.20
control unit seepage 10
adjustable amplifying valve
(without filter and inlet connection)
4.5 Spare Parts List RMG 640 control unit with diaphragm measuring system
item RMG part no. for
no. description EV* material valve seat 3 mm
101 cover LM 10 000 190
102 pressure spring NFSt 10 010 463
103 locking cap NSt 10 000 188
104* o-ring EV KG 00 020 225
105* valve insert EV LM 10 000 061
106 grooved dowel pin St 00 017 197
107 diaphragm plate LM 10 000 110
108 spring plate LM
109 spring FSt
110 spring housing LM 10 000 062
111* sealing ring EV K 10 000 100
113 washer St 00 008 279
115 hexagon screw St 00 010 377
117* piston, pre-assembled EV NFSt/NSt/KV 10 000 186
118* o-ring EV KG 00 020 332
119* pre-formed diaphragm EV KG 10 000 191
120* sealing insert EV KG 10 000 066
121 valve body LM 10 000 137
122 union piece NSt 10 000 108
123 hexagon nut St 00 013 114
130 o-ring St 10 000 116
131 washer St 00 008 279
132 hexagonal screw St 00 006 493
133* hexagonal nut EV St/K 00 013 136
134 hexagonal screw NSt 10 002 795
for connection to electric actuator:
136 plate, pre-assembled St/AlBz 10 000 079
137 washer St 00 014 146
138 cylindrical screw St 00 010 150
139 clutch device, pre-assembled St/NSt 10 010 538
140* o-ring EV KG 00 020 326
*) parts marked with an asterisk (*) and with EV are to be kept in stock for maintenance
material key
St
FSt
NSt
... steel
... spring steel
... stainless steel
LM
Ms
PGl
... light metal
... brass
... plexiglass
K
KG
AlBz
... plastic material
... rubber-like plastic material
... aluminium bronze
640.20 p.05640.20 p.12
Union piece (158)
Grease the threaded plug of the completely assembled union piece with LOCTITE and screw it into the metal har-monica connection piston (173) so that the cross hole of the union piece is positioned 0.5 mm to 1 mm below the valve body cross hole (171).Attention: Both cross holes must be in alignment
Valve insert (105, 156)
Use the adjusting screw (124, 185) to get the diaphragm system in a position that will allow the valve insert to be fitted.
Base plate (1)
The connecting sides of the load limiting and the control unit base plate must be in alignment.
Spindle (25) of the amplifying valve
For finding the basic adjustment of the amplifying valve turn the spindle (25) until the spindle groove (filled with black) comes in line with the front edge of the sleeve (27) fixed into the guiding screw (26).
Torques table
Table of lubricants
Screw locking
item no. torqueMA in Nm
176 611, 114, 115, 165, 183 12103, 123, 167 20
item (to be greased slightly) lubricant RMG part no.
all o-rings, all sliding surfaces silicone grease 00 027 081
spring plate recesses (13, 108, 161)threads of cover (112) fitting paste 00 027 091threads of plate (181)
all fastenings and pipe screw connections high duty grease 00 027 058
item (to be covered slightly) screw locking RMG part no.
thread of locking cap (103, 167)thread of hexagon nut (123) LOCTITE 00 026 688thread of union piece (122, 158)
* parts marked with asterisk to be kept in stock for maintenance
4.6 Spare Parts Drawing RMG 640 control unit with metal harmonica type measuring system
standard version for connection toelectric actuator
640.20 p.13640.20 p.04
Basic diagram of the pilot RMG 640 with a main valve
inlet pressure gauge
dosing screw
start-up valve
connection for theinlet pressure line withRMG 502 / RMG 503
inlet pressure pe
3. Special maintenance instructions
pre-formed diaphragm (119, 169)
When fitting the diaphragm take care of the correct mounting position of the loop. (See spare parts drawings of the outlet pressure stage, pages 10, 12)
diaphragm plate (107, 154)
When tightening the closing cap (103, 167) and the hexagonal nut (123), secure the diaphragm plate against dis-tortion with a spanner size SW 24.
adjusting the diaphragm system (119)
For correct fitting of the diaphragm system into thevalve body bring the cross hole of the union piece(122) and the valve body (121) in alignment:Turn the diaphragm system clockwise and anti-clockwise to the stop, and mark these positionswith a pencil. Them turn the diaphragm systeminto the middle position.
outlet pressure gauge
breathing line
measuring line
bleed line
setpoint adjusting screwfor outlet pressure
connection for the bleed linewith RMG 502 / RMG 503
outlet pressure pa
pencilmarks:for the stops
for the central position
adjusting movementvalve bodydiaphragm
hexagon nut
4.5 Spare Parts List RMG 640 control unit with diaphragm measuring system
item RMG part no. for
no. description EV* material valve seat 3 mm
151 cover LM 10 011 768
152* piston, pre-assembled EV NFSt/NSt/KV 10 000 186
153 spring NSF 10 010 463
154 diaphragm plate LM 10 000 110
155* o-ring EV KG 00 020 225
156* valve insert EV LM 10 011 775
157 grooved dowel pin St 00 017 197
158 union piece NSt 10 011 773
159 spring housing LM 10 011 767
160 guiding pin St 10 011 772
161 spring plate NSt 10 011 774
162 spring FSt 10 010 444
163 axial disk (2 pcs.) St 00 026 385
164 axial needle bearing St 00 026 384
165 cylinder screw St 00 010 548
166 washer St 00 008 279
167 locking cap NSt 10 000 188
168* o-ring EV KG 00 020 332
169* pre-formed diaphragm EV KG 10 000 191
170* sealing insert EV KG 10 000 066
171 valve body LM 10 011 769
172* o-ring EV KG 00 020 416
173 metal harmonica, complete NSt/St 10 011 764
174* o-ring EV KG 00 020 317
175 washer St 00 006 157
176 cylinder screw St 00 010 318
180* o-ring EV KG 00 020 293
181 plate St 10 011 770
182 washer St 00 008 279
183 cylinder screw St 00 010 097
184* hexagon collar nut EV St/K 00 013 145
185 hexagon screw NSt 10 010 447
for connection to electric actuator
190 spring plate LM 10 011 795
191 ring LM 10 021 766
192* sealing EV K 10 021 765
193 plate, complete St/AlBz 10 000 079
194 washer St 00 014 156
195 cylinder screw St 00 010 150
196* o-ring EV KG 00 020 326
197 clutch device, pre-assembled St/NSt 10 010 538
*) parts marked with an asterisk (*) and with EV are to be kept in stock for maintenance
material key
St
FSt
NSt
... steel
... spring steel
... stainless steel
LM
Ms
PGl
... light metal
... brass
... plexiglass
K
KG
AlBz
... plastic material
... rubber-like plastic material
... aluminium bronze
1. General
In addition to this leaflet 640.20 concerning "Special Operating Instruction, Maintenance and Spare Parts" of the pilot RMG 640, the brochure 640.00 gives full information about all relevant technical data, description of function, the available versions, and dimensions. Relevant technical data can also be obtained from the latest RMG booklet.Please also refer to the leaflets of the main valve the pilot is connected to.
The RMG brochure "General Operating Instructions for Gas Pressure Regulators and Safety Devices" will be useful to fit the safety device 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 technical 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 strongly dependant on the prevailing service conditions, the type and composition of the gaseous medium, the ambient temperature and on dust and dirt withing the pipe system. We therefore abstain from imposing any fixed intervals and would rather advise testing out the necessary maintenance intervals, starting with short gaps for maintenance dismantling, and then increasing the intervals if there are no damages or signs of wear.
For maintenance all parts are to be cleaned and subjected to a thorough visual inspection. Complete dismantling together with visual 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.
The item numbers referred to in the maintenance instructions are identical with those of of the spare parts drawings and of the spare parts lists. We recommend to keep all parts that are specially marked in the spare parts lists in stock for prompt mainten-ance availability.
2. Special operating instructions
2.1 Start-up valve
The gas pressure regulators RMG 402, RMG 502 and RMG 503 are fitted with a start-up valve. This valve enables a quick pressure compensation at the regulating diaphragm, making the first pressurization.
• Open the start-up valve before pressurization.• After pressurization close the start-up valve again.
2.2 Adjusting the dosing screw
The dosing screw has a basic setting by RMG and in most cases needs no further adjustment. For reduction of the amplification and to reduce instable regulating behaviour turn the dosing screw anti-clockwise (max. 3 turns).
640.20 p.03640.20 p.14
640.20 p.15640.20 p.02
Operation and Maintenance,Spare Parts edition 05/1994
Serving the Gas Industry - WORLDWIDE
640.20
The RMG Group of Companies on the internet: http://www.rmg.de
We supply you with productsWe supply you with productsfor gas pressure regulation:for gas pressure regulation:
We reserve the right for technical changes
PilotPilotRMG 640RMG 640
Serving the Gas Industry - WORLDWIDE
The other RMG Companies:The other RMG Companies:
Bryan Donkin RMG Gas Controls Ltd.Enterprise Drive, Holmewood, Chesterfield S42 5UZ, EnglandTelephone (++44) 1246 501-501 • Fax (++44) 1246 501-500gas pressure regulating equipment, below ground gas control modules
RMG REGEL + MESSTECHNIK GMBHOsterholzstrasse 45, D-34123 Kassel, GermanyTelephone (++49) 561 5007-0 • Fax (++49) 561 5007-107
gas pressure regulators and safety devices
RMG-GASELAN Regel + Meßtechnik GmbHJulius-Pintsch-Ring 3, D-15517 Fürstenwalde, GermanyTelephone (++49) 3361 356-60 • Fax (++49) 3361 356-836gas pressure regulating equipment, displacement meters, complete stations
RMG Messtechnik GmbHOtto-Hahn-Strasse 5, D-35510 Butzbach, GermanyTelephone (++49) 6033 897-0 • Fax (++49) 6033 897-130turbine meters, vortex meters, correctors, flow computers, odorizers
WÄGA Wärme-Gastechnik GmbHOsterholzstrasse 45, D-34123 Kassel, GermanyTelephone (++49) 561 5007-0 • Fax (++49) 561 5007-207design and assembly of gas pressure regulating and metering stations
Bryan Donkin RMG Co. of Canada Ltd.50 Clarke Street South, Woodstock, Ontario N4S 7Y5, CanadaTelephone (++1) 519 5398531 • Fax (++1) 519 5373339domestic regulators and safety devices
Karl Wieser GmbHAnzinger Strasse 14, D-85560 Ebersberg, GermanyTelephone (++49) 8092 2097-0 • Fax (++49) 8092 2097-10
Heinrich-Lanz-Strasse 9, D-67259 Beindersheim/Pfalz, GermanyTelephone (++49) 6233 3762-0 • Fax (++49) 6233 3762-40 data logging, monitor systems, danger alarm systems
Betriebsstelle Beindersheim