Tcv-3035 Horno Regeneracion

7/27/2019 Tcv-3035 Horno Regeneracion

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M/CDKarlDungsInc.FRGR

atioRegulator/ZeroGovernorEdition2012.05P/N261401

Specication

Max. Operating Pressure (MOP)7 PSI (500 mbar)5 PSI (350 mbar) applies to the CSACertication.

Ambient / Fluid TemperatureFRG 7../6 series: +5 F to +160 F for up to 7 PSI for

regulating behavior(+/- 10 % of setpoint)

CSA Certied for -40F to +160 Ffor up to 5 PSI: Diaphragms are

suitable for the low temperature,but there may be out of rangeregulating behavior.

GasesDry, natural gas, propane, butane;other noncorrosive gases. Suitablefor up to 0.1 % by volume, dry H

2S.

A dry gas has a dew point lowerthan +15 F and its relative humidityis less than 60 %.Materials in contact with Gas

Housing: AluminumSeals & Diaphragm: NBR-basedrubber

F

0

-40

+160

FRG/6 Spring-loaded ratio regulator / zero governor with adjustable setpoint spring and dened counterspring. Internal

sensing of output pressure; air impulse line connection is standard.

Optimal Inlet Pressure RangeRatio Regulator: 3 to 80 in. W.C.(7 to 200 mbar)Zero Governor: 3 to 20 in. W.C.(7 to 50 mbar)Output Pressure RangeRatio Regulator: -4 to 60 in. W.C.(-10 to 150 mbar)

Zero Governor: -2 to 1 in. W.C.(-5 to 3 mbar)

Gas

Body Size Order No. Size

FRG 705/6 259-157 1/2 NPT

FRG 707/6 259-158 3/4 NPT

FRG 710/6 259-159 1 NPT

FRG 712/6 259-228 1 1/4 NPT

FRG 715/6 259-160 1 1/2 NPT

FRG 720/6 259-161 2 NPT

FRG 725/6 259-162 2 1/2 NPT

FRG 730/6 259-163 3 NPT

[PSI]

Vent Limiting Device and Vent LineConnectionThe FRG/6 has an internal, factoryinstalled vent limiter, which limitsthe escape of gas to less than 0.5CFH @ 5 PSI in case atmosphericdiaphragm ruptures. Vent limitingdevice also complies with EN 88 &ISO 2355-1. Venting required unlessotherwise accepted by the authority

having jurisdiction.


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Recommended Mounting ProcedureRegulator dome from vertically upright to lying horizontally

Mounting

If the ow is not in the same direction of the

arrows, the regulator will not operate properly.

Recommended Preparation The main gas supply must be shut o before starting the

installation. Read these installation instructions carefully.

Carefully examine the FRG/6 for shipping damage. Remove the two red plastic covers from the FRG/6 body.

Remove all dirt and debris before installing the FRG/6. Fail-ure to remove dirt/debris could result in damage or improperperformance.

Recommended Procedure to Mount the FRG/6

Install the FRG/6 with the gas ow matching the directionindicated by the arrows on the casting.

Mount the FRG/6 with the regulator vertical or horizontal. Use new, properly reamed and threaded pipe free of chips. Apply good quality pipe sealant, putting a moderate amount

on the male threads only. If using LP gas, use pipe sealantrated for use with LP gas.

Do not thread pipe too far. FRG/6 distortion and/or malfunc-tion may result from excess pipe in the valve body.

Apply counter pressure with a parallel jaw wrench only tothe ats of the FRG/6 when installing pipe.

Do not overtighten the pipe. Follow the maximum torque

values listed.

After installation is complete, perform a leak test.

As a proportionator, this is an air impulse line connection. Asa zero govenor, this is a breathing plug or a vent connection.

NOTE: All FRGs have a factory installed vent limiting device

under the regulator housing. Connection is G 1/4 for FRG705/6 to FRG 710/6 and G 1/2 for FRG 712/6 to FRG 730/6.G thread to NPT thread adapters are available. G 1/4 to

1/4NPT adapter (part number 231-944) and G 1/2 to 1/2NPT adapter (part number 231-945).

Pressure tap connection in inlet section, both sides 1/4 NPT. Pressure tap connection in outlet section, both sides 1/4 NPT.

1

2

3

NPTpipe 3 1 1 1

2 2 3

Tmax

[Ib-in]443 752 1106 1770 1991 2213 2876 35If the ow is not in the same direction as the

arrows, the FRG/6 will not operate properly.

Pressure Taps/Air Impulse Line/Vent Connection

Test PortWhen low re bypass is us

only test ports on one scan be used.

2 3

Low re bypass option for 705/6 - 720/6P/N 225-256


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Application - Zero governor

For use with gas engines or premix burners, the FRG controlsow by reducing upstream gas pressure to zero or adjustable

to slightly above or below atmospheric pressure.

The outlet pressure is adjustable with the setpoint spring.

For Vmax

see ow diagram on page 6.

Outlet pressure

p2 [W.C.]

Vmax. at high fireV [CFH]

The above illustration shows adjustability (fuel biasing) of the FRG/6 when used as a zero governor. Refer to page 6 for siz-

ing FRG/6 at maximum ow rate.

Zero governor outlet pressure

Gas Equipment

Gas

FRG/6Mixer

Air Filter

Adjusting the FRG/6

1. For zero governor applications, the FRG should be ad-justed at low re only.

2. If the FRG is not owing enough gas at the maximum airow rate, the gas ow can be increased by any of the

following:a.) Increase the negative signal to the FRG.b.) Install a larger FRG.

Zero Governor Application

Do not mount the zero governor upside down.


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Application - Ratio Regulator

The FRG holds a constant gas/air ratioduring turndown by varying gas ow to

the burner in proportion to the combus-tion air ow. Adjustable for excess air

or gas.

Setup Procedure

When setting up the FRG/6 and burnerfor proper ratio at all ring rates, follow

the burner manufacturers instructions.The following procedure contains recom-

mended guidelines only, and they do notsupercede the burner manufacturersprocedures for setting up and adjusting

the FRG/6 to the burner.

Low Fire AdjustmentThe adjustable top loading spring on the

FRG/6 is a low re adjustment (see outletpressure adjustment on page 2). If the

tension on this spring is at a minumumand there is still too much gas ow at lowre, achieving a lower ow rate is possible

by reducing the air impluse line pressureto 2WC or less. If the air impluse line

pressure cannot be reduced, a lowerow rate can be acheived by installing

a smaller FRG/6.In order to achieve a low re ow rate inthe range of 20-100 CFH, a eld mount-

able low re bypass restrictor (225-256)is recommended. See Flow curve for

Low re bypass on page 5 for more

details. When using the low re bypassrestrictor, it is recommended that the top

loading spring be adjusted so that theFRG/6 regulating disc opens just as theimpulse line increases during the ramp-

up cycle. If the loading spring tension istoo small, there will be a delayed increase

of fuel ow as the air ow increase untilthe loading line pressure is greater than

the counterspring force, and the result

can be a lean burner over a small rangeof inputs near low re.

CAUTION: Multiple burners and lowre adjustment. It is not recommended

to use a control scheme or gas pipingscheme that does not equally distribute

the gas pressure to each burner at lowre. Examples of such shemes couldinclude using one FRG/6 to control the

gas ow to more than one burner, orusing one air control valve to feed two

FRGs and a second air control valve tofeed three FRGs. Such a control scheme

will likely not allow for optimal low readjustment at each burner.CAUTION: Purge and low re start.

A burner ( or set of burners) that lightimmediately after a purge that is longer

the 60 seconds can cause a 5-20 sec-ond (depending on the purge pressure)

slightly fuel rich condition at the low restart. If such a case occurs, it is recom-

mended that the loading line pressureduring the purge be vented, or thatligho be delayed just lone enough to

eliminate the slightly fuel rich condition

at the low re start.

High Fire Adjustment

Additional adjustments might be neeat high re, depending on the type

burner, piping arrangement, ow,impluse line pressure, and the mode

FRG/6 installed on the burner. NOThe burner might have an integrated limiting valve or an air balancing va

(see illustration below). If these areprovided on the burner, installing th

might be needed in order to achievecorrect ratio at high re.

In cases where the high re rate is rich, partially close the gas limiting valocated downstream of the FRG/6

order to achieve proper ratio. This justment reduces the gas pressure in

burner without aecting the air pressRe-adjust the low re ratio if needed

In cases where the high ring rate is lean, rst verify that the inlet gas press

to the FRG/6 is and remains at least 2Whigher than the air impluse line pressat high re. If there is suitable inlet

pressure to the FRG/6, then more to the burner can be accomplished

either installing a larger FRG/6 orpartially closing the air balancing va

located downstream of the control vato achieve proper ratio; this adjustmreduces the air pressure in the bur

and increases the impulse line presson the FRG/6. Re-adjust the low

ratio if needed.

Adjusting the FRG/6See out pressure adjustment on pag

Buttery Control Valve

Bias(Low Fire adjustment ONLY)

FRG/6Gas Limiting Valve(High Fire Adjustment)

Air Balancing Valve(High Fire Adjustment)

Burner

Two pipediameters MIN. Five pipe diameters MIN.

Air impusleloading line

Ratio Regulator Application

The size of the air impulse

line should match the FRG/6air impulse line connection. Itshould be as short as possible

with as few bends as possible

The low re air impulse linepressure should be between

0.2 and 1.0 In. W.C.

Do not mount the FRG

upsidedown.


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40

30

20

10

0.95 (gas) : 1 (air)

225-256

Mounting the Low Fire Bypass

1. Remove the pressure tap plate with a

Torx driver size T20.2. Line up the low re bypass making

sure that the O-ring is seated cor-rectly. Reinstall with the screws fromthe pressure tap mounting plate.

3. Perform a leak test after torquing thelow re bypass.

Adjusting the Low Fire Bypass

1. Remove the black cover

2. With a slotted screwdriver turn theadjustment screw clockwise for LESS

gas and counter clockwise for MOREgas ow.

3. Secure cap with a wire seal.

Low re bypass Flow adjustmentMounting of low re bypass

The above illustration shows that the air impulse line can be adjusted to achieve excess air, excess gas, or on ratio at low

re. However, the air impulse line slightly exceeds the gas outlet pressure at high re rate.

Flow Curve for Low re bypass

Ratio Regulator Biasing Curve

Low Fire Bypass

Ratio Regulator Biasing Curve

Low re bypass max. Torque

1.85 Lb-in.

The low re bypass is factory

set for maximum ow.

, Please note: only FRG 705/6 - 720/6


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Cover Top View

Adjusting the FRG/61. Remove the black cover.

2. To increase outlet pressure turn the adjustment spindleclockwise, to decrease the outlet pressure turn the adjust-

ment spindle counterclockwise.3. Always use an accurate pressure guage connected down

stream from the requlator to measure the actual outletpressure.

4. Reinstall the black cover.5. After adjusting the set point for normal operation check tosee that the gas pressure regulator operates as intended.

6. Use holes in the black cover and the side of the regulatorto secure a lead seal to prevent unauthorized adjustment.

Outlet Pressure Adjustment

13

An internal adjustment limits (but does not pre-vent) the risk of a gas rich ame.


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Pressure Drop for other Gases

To determine the pressure drop when using a gas other than

natural gas, use the ow formula below and f value locatedin the table below to determine the corrected ow rate in

CFH through the valve for the other gas used. For example,

when using propane, divide the volume (CFH) of propane

required for the application by the calculated value f (f = 0.66for propane). Use this corrected ow rate and the ow curve

on the next page to determine pressure drop for propane.

Density of Natural gas

Density of gas usedf =

Type of gas Density[kg/m3]

s.g. f

Natural gas 0.81 0.65 1.00

Butane 2.39 1.95 0.58

Propane 1.86 1.50 0.66

Air 1.24 1.00 0.80

Determining equivalent ow through valves using another gas

Vgas used

= VNatural gas

x f

FRG/6 Flow Curve

A minimum of 3 in. W.C. p is required when sizing at maximum ow capacity for optimal control on high turndown

applications (40:1). A 2 in. W.C. p can be applied for sizing if a lower turndrown (in the range of 10:1) is required.Sizing the FRG/6 using a 1 in. W.C. p or less is not recommended for most applications.


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Tcv-3035 Horno Regeneracion

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