Mankenberg DM 4 Installation instructions
Original operating manual
Pilot-controlled pressure regulators
Originalbetriebsanleitung
pilotgesteuerte Druckregelventile
DM
DM-4.X.222 Stand 18.07.2022 www.mankenberg.com
2
DM-4.X.222 Stand 18.07.2022 www.mankenberg.com
Table of contents EN
1 Introduction................................................................................................................................................. 4
2 Intended use ............................................................................................................................................... 4
3 Marking of the fitting.................................................................................................................................. 6
4 Safety instructions ..................................................................................................................................... 7
4.1 General precaution .............................................................................................................................. 7
4.2 Special safety instructions for the plant operator................................................................................. 7
4.3 Special hazards ................................................................................................................................... 7
5 Transport and storage ............................................................................................................................... 8
6 Installation................................................................................................................................................... 9
6.1 General notes ...................................................................................................................................... 9
6.2 Installation preparations....................................................................................................................... 10
6.3 Installation steps .................................................................................................................................. 11
7 Pressure testing the pipeline section....................................................................................................... 13
8 Initial start-up.............................................................................................................................................. 14
9 Normal operation........................................................................................................................................ 15
10 Maintenance................................................................................................................................................ 16
11 Troubleshooting help................................................................................................................................. 17
12 Information on REACH and RoHS ............................................................................................................ 20
12.1 Declaration on the REACH Regulation 1907/2006.............................................................................. 20
12.2 Declaration on the RoHS Directive 2011/65/EU .................................................................................. 20
13 Further information .................................................................................................................................... 20
14 Know How ................................................................................................................................................... 20
14.1 Tusk ..................................................................................................................................................... 20
14.2 Consideration of the design data ......................................................................................................... 21
14.3 Selecting valve type and nominal diameter ......................................................................................... 21
14.4 Selecting rated pressure and valve material........................................................................................ 21
14.5 Selecting the setting range .................................................................................................................. 21
14.6 Selecting elastomer materials.............................................................................................................. 21
14.7 Sense line (control line) ....................................................................................................................... 21
14.8 Protecting your system ........................................................................................................................ 21
14.9 Protecting the pressure reducing valve ............................................................................................... 21
14.10 Cut-off.................................................................................................................................................. 22
14.11 Stellited seat and cone ........................................................................................................................ 22
14.12 Mounting position................................................................................................................................. 22
14.13 Steam operation .................................................................................................................................. 23
14.14 Start-up................................................................................................................................................ 23
14.15 Setting the pressure............................................................................................................................. 23
14.16 Maintenance ........................................................................................................................................ 24
14.17 ............................................................................................................................................................. 24
Inhaltsverzeichnis DE
1 Einleitung .................................................................................................................................................... 25
2 Bestimmungsgemäße Verwendung.......................................................................................................... 25
3 Kennzeichnung der Armatur ..................................................................................................................... 27
4 Sicherheitshinweise................................................................................................................................... 28
4.1 Allgemeiner Sicherheitshinweis ........................................................................................................... 28
4.2 Spezielle Sicherheitshinweise für den Betreiber.................................................................................. 28
4.3 Besondere Gefahren ........................................................................................................................... 28
5 Transport und Lagerung............................................................................................................................ 29
6 Einbau.......................................................................................................................................................... 30
6.1 Allgemeines ......................................................................................................................................... 30
6.2 Vorbereitung zum Einbau .................................................................................................................... 31
6.3 Schritte beim Einbau............................................................................................................................ 32
7 Druckprüfung des Rohrleitungsabschnitts ............................................................................................. 34
8 Erste Inbetriebnahme................................................................................................................................. 35
9 Normalbetrieb ............................................................................................................................................. 36
10 Wartung....................................................................................................................................................... 37
11 Hilfe bei Störungen..................................................................................................................................... 38
12 REACH- und RoHS-Auskunft .................................................................................................................... 41
12.1 Erklärung zur REACH-Verordnung 1907/2006.................................................................................... 41
12.2 Erklärung zur RoHS-Richtlinie 2011/65/EU ......................................................................................... 41
13 Weitere Informationen................................................................................................................................ 41
14 Know-How................................................................................................................................................... 41
14.1 Funktion ............................................................................................................................................... 41
14.2 Berücksichtigung der Designdaten ...................................................................................................... 42
14.3 Auswahl von Ventiltyp und Nennweite................................................................................................. 42
14.4 Auswahl von Nenndruck und Werkstoff............................................................................................... 42
14.5 Auswahl des Einstellbereichs .............................................................................................................. 42
14.6 Auswahl der Elastomere...................................................................................................................... 42
14.7 Steuerleitung........................................................................................................................................ 42
14.8 Absicherung Ihres Systems ................................................................................................................. 42
14.9 Schutz des Druckminderventils ........................................................................................................... 42
14.10 Absperrung .......................................................................................................................................... 43
14.11 Panzerung ........................................................................................................................................... 43
14.12 Einbaulage........................................................................................................................................... 43
14.13 Betrieb mit Dampf................................................................................................................................ 44
14.14 Inbetriebnahme.................................................................................................................................... 44
14.15 Einstellung des Drucks ........................................................................................................................ 44
14.16 Wartung ............................................................................................................................................... 45
14.17 Einbauschemata.................................................................................................................................. 45
3
DM-4.X.222 Stand 18.07.2022 www.mankenberg.com
Original operating manual
Pilot-controlled pressure regulators DM
4
DM-4.X.222 Issue 18.07.2022 www.mankenberg.com
1 Introduction
This manual is intended to assist users of a MANKENBERG pressure-reducing, backpressure regulator,
vacuum control valve, differential pressure control valve or flow control valve during installation, operation and
maintenance. Read the manual thoroughly before installing or putting this valve into service.
2 Intended use
A MANKENBERG DM pressure-reducing valve is a device that is intended exclusively for automatically
regulating the outlet pressure of the medium (without any additional electrical/pneumatic energy) after it has
been installed in a pipeline system. The force of the outlet pressure acts on a control mechanism (diaphragm,
piston or bellows) and is in balance with the preload of a spring that has to be adjusted by the user to the
required value within the setting range of the valve.
A MANKENBERG UV backpressure regulator is a device that is intended exclusively for automatically
regulating the inlet pressure of the medium (without any additional electrical/pneumatic energy) after it has been
installed in a pipeline system. The force of the inlet pressure acts on a control mechanism (diaphragm, piston or
bellows) and is in balance with the preload of a spring that has to be adjusted by the user to the required value
within the setting range of the valve.
A MANKENBERG VV vacuum control valve is a modification of the pressure-reducing or backpressure
regulator, built to regulate pressures in vacuo. It only regulates the differential pressure to the atmosphere.
A MANKENBERG DV differential pressure control valve is a modification of the pressure reducing or back
pressure regulator, built to regulate differential pressures.
A MANKENBERG MR flow control valve is a modification of the pressure – reducing or backpressure
regulator, built to regulate flow rates.
danger
A pressure-reducing valve / backpressure regulator / differential pressure control valve / flow
control valve / vacuum control valve is not a safety valve. A suitable valve must be present in
the system to limit any excess pressure.
note
Pressure-regulating valves are generally supplied with a slackened spring and have to be
adjusted to the required pressure after being installed. The required pressure measuring
devices must be installed in an adequate distance in front of and behind the fitting.They are
not included in the supply schedule of MANKENBERG.
MANKENBERG planning documents are available to give users precise assistance in selecting and designing
the appropriate fitting, e.g.:
In the section < DM: Regulating valves for pressure>
<Design of pressure-regulating valves>
<Know-how on pressure-reducing valves / backpressure regulators>
<Type sheet DM... / UV... / VV... / DV... / MR...> with technical data and tables of the setting ranges and the
dimensions.>
Original operating manual
Pilot-controlled pressure regulators DM
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DM-4.X.222 Issue 18.07.2022 www.mankenberg.com
danger of
fatalities
These valves are no shut-off elements ensuring a tight closing of the valve. In accordance with
DIN EN 60534-4 and/or ANSI FCI 70-2 they may feature a leakage rate in closed position in
compliance with the leakage classes II – V:
Leakage class II (metal sealing double seat cone) = 0.5% Kvsvalue
Leakage class III (metal sealing cone) = 0,1 % Kvsvalue
Leakage class IV (PTFE seal cone) = 0,01 % Kvsvalue
Leakage class V (soft seal cone) = 1,8 x 10-5 x Δp x D* [l/h]
*D=seat diameter
Consequently, according to DIN EN ISO 2503 and DIN EN ISO 7291, a safety valve has to be
installed on the control side, which is dimensioned and adjusted in such a way that the lower
one of both pressure indications as mentioned below is relevant as response pressure:
- 1.5 times the maximum set pressure and/or (P out) of the valve (see nameplate), whichever
is the lowest
- PS out (see nameplate)
The response pressure of the safety valve should be abt. 40 % above the max. set pressure of
the pressure control valve.
Contrarily to the Pressure Equipment Directive, Annex 1, Paragraph 7.3, the short-term
maximum excess pressure is limited to 5 % of the max. allowable pressure (see above).
Failure to observe this regulation means danger to life and limb and may cause damage
to the pressure-regulating valve.
caution
Pressure-regulating valves are generally supplied with an open bonnet to facilitate
maintenance.
Valves with a sealed bonnet and leakage line connectionv can be supplied for toxic or
hazardous media. In this case the user must make sure that a suitable leakage line is installed.
MANKENBERG valves are supplied as standard for screw-mounted or flange-mounted pipeline/tank
connections – also for special connections if required.
The upper limit of the permitted operating data for pressure and temperature is permanently marked on each
fitting supplied.
Pressure gauge option - The technical data of the pressure gauge (connection size and temperature) must
match those of the valve and the plant.
The valve is not ready for use in the delivered condition because the pressure gauge connection is open and no
pressure gauge is supplied. The technical tightness between pressure gauge connection and pressure gauge is
established by the operator.
Option vakuumfeste Ausführung - Die Armatur ist vakuumfest oder und damit begrenzt mit äußerem
Überdruck belastbar
Original operating manual
Pilot-controlled pressure regulators DM
6
DM-4.X.222 Issue 18.07.2022 www.mankenberg.com
3 Marking of the fitting
Each fitting bears the following markings as a minimum:
For Marking Remark
Remark MANKENBERG See section Further information [}20] for the address
Fitting design Pressure reducing valve +
type or
backpressure regulator +
type or
vacuum control valve +
type
differential pressure
control + type
flow control valve + type
Design name as per accompanying MANKENBERG
data sheet
Nominal diameter e.g. DN or G and
numerical value
Numerical value for DN in [mm], for G in [inches]
Nominal pressure PN or Class and numerical
value, or Ps
Numerical value for PN in [bar], for Class in [lbs/square
inch].
Unless otherwise indicated, all data give the
overpressure above atmospheric.
If 2 numerical values are given, these apply to the inlet
and outlet pressure.
Pressure range Pressure range and
numerical values
Max. permitted
temp.
Temperature and
numerical value
Temperatures above 50 °C entail a reduced pressure
resistance. This must be considered for the
corresponding material in accordance with the DIN EN
1092 standard
Body material e.g. CrNiMo steel CrNiMo steel = high-alloy austenitic steel
Flow direction Indicated by an arrow
ATEX protection
class
e.g. Ex II 2G IIB TX
-10°C<Ta<+80°C
only for devices with conformity certification according
to ATEX
The markings (in the case of fittings made of deep-drawn stainless steel, they are etched into the body) should
neither be covered nor painted over, so that the fitting remains identifiable.
Original operating manual
Pilot-controlled pressure regulators DM
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DM-4.X.222 Issue 18.07.2022 www.mankenberg.com
4 Safety instructions
4.1 General precaution
The same safety regulations apply to a fitting as to the system into which it is installed. These instructions only
give those safety recommendations that have to be additionally observed for the fitting.
4.2 Special safety instructions for the plant operator
The following requirements for the intended use of a fitting are not the responsibility of the manufacturer but
have to be guaranteed by the user:
» The fitting may only be employed for the purpose described in section Intended use [}4].
» Only competent specialist personnel may install, operate and service the fitting. Competent as defined in
these instructions refers to persons who, because of their training, specialist knowledge and professional
experience, are capable of correctly assessing and properly executing the work with which they are
entrusted and of recognizing and rectifying hazards.
» The pipeline system must be properly designed and installed so that the fitting can be mounted and
operated without any tension.
» The fitting must be properly installed in the correct mounting position.
» The recommended installation, as described in the relevant MANKENBERG data sheet, must be used for
the pipeline section into which the pressure-regulating valve is installed. All control and/or leakage lines that
are required on the pressure-regulating valve must be laid properly, in accordance with the accompanying
MANKENBERG data sheet.
» A pressure-regulating valve with an open spring must be installed in such a way that it presents no risk of
crushing to the oerating personnel.
» The usual flow rates should not be exceeded in the pipeline section during continuous operation, and
abnormal operating conditions such as vibrations, unusually high flow rates, etc. should be avoided or – if
unavoidable – clarified with the manufacturer in advance.
» The prevailing operating conditions must comply with the limits of the design data stated in the
MANKENBERG order confirmation.
» The corrosion protection for the fitting must be adapted to the local environmental conditions.
» The fitting must not be coated with thermal insulation.
Detailed notes are provided on some of these prerequisites in the following sections.
4.3 Special hazards
danger of
fatalities
Before a fitting is removed from the system or before a fitting is dismantled but partially
remains in place, the pressure in the system on both the inlet and outlet side must be
completely reduced so that there is no uncontrolled flow of the medium out of the system. In
the case of toxic or hazardous media, the system must be completely drained before the fitting
is removed.
Caution is required with residues that might continue flowing.
danger of
being
crushed
Only valves with open spring:
It is necessary to ensure on site, by an appropriate installation or by providing safety devices
and/or positioning a clearly visible warning sign in accordance with the regulations of EN 292
(formerly accident prevention regulations), that effective protection is afforded against
objects catching on an exposed spring in the pressure-regulating valve.
If required, MANKENBERG will assist in selecting a suitable type with closed bonnet.
Original operating manual
Pilot-controlled pressure regulators DM
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DM-4.X.222 Issue 18.07.2022 www.mankenberg.com
danger of
fatalities
If a pressure-regulating valve has to be dismantled:
The following must be observed at all costs: First release the tension fully on the spring by
turning the setting screw on the spring module anticlockwise. DWhen doing so, be sure to
follow the notes in section Initial start-up [}14]!
Then either seal off the two shut-off valves installed before and after the fitting in accordance
with the MANKENBERG installation recommendation and vent the pressure-regulating valve
or remove the pressure from the section of the system and then remove the fitting from the
pipeline.
caution
If a fitting is removed from a system with a toxic medium and is taken out of the plant:
it must be properly decontaminated before repair.
5 Transport and storage
A fitting must be handled, transported and stored with care:
» The fitting must be transported and stored in its protective packaging until it is installed.
caution
The fitting has moving internal parts.
Even packaged fittings should be transported smoothly without any shocks.
caution
In the case of a fitting that can no longer be transported by hand, the lifting gear must be
attached to a suitable position on the housing (branches).
Under no circumstances may the lifting gear be affixed to any attachments (adjusting
screw, handwheel or accessories).
» When the fitting is stored prior to installation, it should be kept in closed rooms and protected against
harmful influences such as dirt, moisture and frost.
» In special cases, the fitting is supplied free of oil, grease or silicone and is marked accordingly. A fitting such
as this must not come into contact with oil/grease/silicone during storage and handling (particularly when
subsequently unpacked).
» A MANKENBERG fitting generally has functional and/or sealing parts made of elastomer materials. These
cannot be stored for an unlimited period.
note
ISO 2230 describes the storage conditions for elastomers in detail and specifies the
permissible storage period.
Functional and sealing parts must be replaced well before the storage period expires.
They are available from MANKENBERG as a “service set”. See also Section Troubleshooting
help [}17].
note
MANKENBERG fittings of small and medium nominal diameters are largely made of stainless
steel (high-alloy CrNiMo steel).
If, under exceptional circumstances, fittings are stored in a unpacked state, they must be
protected against ferritic dust to avoid corrosion.
Original operating manual
Pilot-controlled pressure regulators DM
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DM-4.X.222 Issue 18.07.2022 www.mankenberg.com
note
The fitting is generally not capable of standing alone:
The spring module may have a greater weight/volume than the basic body with its pipe
connections.
Handle with care so that the fitting does not tip over during transport/storage..
» Pressure-regulating valves are generally supplied with a slackened spring. The spring must not be
pretensioned by means of the adjusting screw until after it has been installed, during initial start-up.
6 Installation
6.1 General notes
The same installation regulations apply to a fitting as to the system into which it is installed. The following
additional notes apply:
» Section Transport and storage [}8] should also be observed during transport to the installation site.
» The installation site to allow perfect functioning of a fitting should be a section of pipe without any flow
disruptions, without any angles and without any restrictors or shut-off devices close to the fitting, either
upstream or downstream (optimum distance = 10 x DN). If this does not apply, the installation situation
should be checked with the plant operator and/or MANKENBERG.
» The statics of the pipeline must be designed so as to take account of the weight of the fitting – particularly
those with an eccentric mass. If required, the pipeline may have to be properly supported on both sides next
to the fitting (or at the fitting itself) – particularly in the case of fittings with a substantial mass and especially
if vibrations are to be expected in the system. When the fitting is supported, it is important to check that all
functioning parts (adjusting screws, springs) remain capable of moving freely and are not blocked.
» The fitting must not be coated with thermal insulation.
» The fitting must not be coated with thermal insulation.
caution
A fitting that is operated at a medium temperature above 130°C needs undisrupted removal of
heat if it is to function perfectly.
Failure to observe this instruction may cause damage to the fitting and hence in the
pipeline system as well.
» To protect internal functional parts (e.g. the seat) against damage and/or blockages, it may be necessary to
install a strainer and/or filter upstream of the fitting.
note
The mesh size of the sieve/filter for protecting against aggregates in the pipe section should be
selected by the plant operator according to the operating conditions.
Failure to observe this instruction may impair the function of the fitting and lead to
damage.
Original operating manual
Pilot-controlled pressure regulators DM
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DM-4.X.222 Issue 18.07.2022 www.mankenberg.com
6.2 Installation preparations
» It is necessary to ensure that a fitting is not installed unless its matches the operating conditions in terms of
function, pressure and temperature, range, body material as well as connection type and dimensions.
danger of
fatalities
No fitting may be operated that does not have a sufficient pressure and temperature range for
the operating conditions – see section Intended use [}4] and markings on the fitting. The
manufacturer MANKENBERG should be consulted in the case of any applications outside of
this range.
Failure to observe this regulation may mean danger to life and limb and may cause
damage to the pressure-regulating valve.
» Newly installed tanks and pipeline sections must be thoroughly rinsed and cleaned before commissioning
» The corrosion protection for the fitting must be adapted to the local conditions.
» A pressure-regulating valve with an exposed spring must be installed in such a way that it presents no risk
of crushing to the operating personnel.
danger of
being
crushed
Only valves with open spring:
It is necessary to ensure on site, by an appropriate installation (e.g. not freely accessible) or
providing safety devices and/or positioning a clearly visible warning sign in accordance with
the regulations of EN 292 (formerly accident prevention regulations), that effective protection is
afforded against objects catching on an exposed spring in the pressure-regulating valve.
If required, MANKENBERG will assist in selecting a suitable type with closed bonnet.
Failure to observe this instruction: danger of crushing for the operating personnel
» Before installing a pressure-regulating valve, it is necessary to make sure that the pipeline section complies
with the recommended installation, as described in the relevant MANKENBERG data sheet. In particular, a
safety valve and a suitable strainer should be installed upstream of the fitting.
» Pressure-regulating valves are supplied with a slackened spring:
– in this state of delivery, a pressure reducing valve DM is fully opened and immediately shuts at minimum
outlet pressure.
– in this state of delivery, an backpressure regulator UV is fully closed and immediately opens at minimum
inlet pressure.
– in this state of delivery, a differential pressure control valve, a flow control valve or a vacuum control
valve responds as a pressure reducing valve or backpressure regulator, according to design.
note
In some model series, a control line has to be laid between the pressure-regulating valve and
the pipeline by the customer – this is described in the above-mentioned recommended
installation.
Please note: Only use control lines made of metal, not of plastic!
- distance of valve/connection of control line to the pipeline ≥ 10x pipe-ø
- when the medium is steam, lay the control line at an angle, with the gradient falling towards
the valve, see (catalogue) section <Know How Pressure-reducing valves>.>.
The control line should match the connection on the fitting.
- if required, install a throttle to avoid vibration.
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7
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