O.K. - MicroWatt Controls
FRS 7./6 & FRS 5.Gas Pressure RegulatorInstallation InstructionsTable of ContentsUSACDNTable of Contents . . . . . . . . . . . . . . . . . . . . . . . .Approvals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Attention . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Specification . . . . . . . . . . . . . . . . . . . . . . . . . . . .Lock-up Pressure Parameters . . . . . . . . . . . . .Regulator Orifice Diameters . . . . . . . . . . . . . . .Mounting Preparation . . . . . . . . . . . . . . . . . . . .Mounting & Installation . . . . . . . . . . . . . . . . . . .Pressure Tap Connections . . . . . . . . . . . . . . . .Outlet Pressure Spring Selection . . . . . . . . . .Breather Plug . . . . . . . . . . . . . . . . . . . . . . . . . . .Vent Limiting Device & Vent Line ConnectionExternal Impulse . . . . . . . . . . . . . . . . . . . . . . . . .Outlet Pressure Adjustment . . . . . . . . . . . . . . .Spring Replacement . . . . . . . . . . . . . . . . . . . . .Flow Curve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Accessories & Replacement . . . . . . . . . . . . . . PagePagePagePagePagePagePage1 Repair Kits . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Page 1011233345667788910FRS 7./6 series are CSA Certified: ANSI Z21.18/CSA 6.3.FRS 5. series are CSA Certified: ANSI Z21.18/CSA 6.3.Commonwealth of Massachusetts Approved Product Approval code G1-1107-35MC Karl Dungs, Inc. FRS Gas Pressure Regulator Edition 2015.09 P/N 261398Attention1 10The installation and maintenanceof this product must be doneunder the supervision of an experienced and trained specialist.Never perform work if gas pressure or power is applied, or inthe presence of an open flame.Please read the instruction before installing or operating. Keepthe instruction in a safe place. Youfind the instruction also at www.dungs.com If these instructionsare not heeded, the result maybe personal injury or damage toproperty.SafetyfirstOn completion of work on thepressure regulator, perform aleakage and function test.IFGCCSAULANSINFPAThis product is intended forinstallations covered by, butnot limited to, the followingcodes and standards: NFPA 37,NFPA 86, NFPA 54, CSD-1, UL795, ANSI Z83.4, ANSI Z83.18,ANSI Z21.13, CSA B149.1, CSAB149.3 and CSA B149.6.O.K.Any adjustment and applicationspecific adjustment values mustbe made in accordance withthe equipment Explanation of symbols1, 2, 3 . Action InstructionNever close Breather hole!
SpecificationThe FRS series balance type, pressure regulator is a spring-loaded pressure regulator with adjustable setpointspring and an internal sensor for regulating output pressure.[PSI]Max. Operating Pressure (MOP)7 PSI (500 mbar) for FRS 7./6 series.10 PSI (680 mbar) for special versionsof FRS 7./6 series (see P/N’s below).7 PSI (500 mbar) for FRS 5. Flangedseries.5 PSI (350 mbar) applies to the CSACertification for FRS 7./6 and for FRS5. Flanged series. F 1600-40Output pressure rangeAdjustable with different springs1 to 80 in. W.C.FRS 5. Flanges series: 5 F to 160 F (-15 C to 70 C)for up to 7 PSI.Maximum pressure drop and gasvelocityGasesDry, natural gas, propane, butane;other noncorrosive gases. Suitablefor up to 0.1% by volume, dry H2S.A “dry” gas has a dew point lowerthan 15 F and its relative humidityis less than 60 %.Materials in contact with GasHousing: Aluminum & SteelSeals & Diaphragm: NBR-basedrubber.The maximum pressure drop is litmited by the celocity of the gas. Do notexceed a gas velocity of 30 meters/s.GasVent Limiting Device and Vent LineConnectionThe FRS/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 88-1 &ISO 23551-2.Venting required unlessotherwise accepted by the authorityhaving jurisdiction.Body SizeSizeFRS 707/63/4“FRS 705/6FRS 710/6FRS 712/6FRS 715/6FRS 720/6FRS 725/6FRS 730/6FRS 5040 (internal pulse)FRS 5050 (internal pulse)FRS 5065 (internal pulse)FRS 5080 (internal pulse)FRS 5100 (internal pulse)FRS 5125 (internal pulse)FRS 5150 (internal pulse)Ambient / Fluid TemperatureFRS 7./6 series: 5 F to 160 F for up to 7 or10 PSI, depending on model, forregulating behavior( /- 10 % of setpoint) CSA Certified for -40 F to 160 F:Diaphragms are suitable for the lowtemperature, but there may be outof range regulating behavior.Droop and HysteresisHysteresis is less than 10 % for upto 7 PSI inlet.Average droop at 20:1 turndown is10 % for up to 7 PSI.Lock-up Rating The FRS meets the ANSI Z.21.80/CSA 6.22 as Class I, which allowslockup rating not more than 150 %or 5 in. W.C, whichever is greater. The FRS meets EN 88-1 as SG30,which allows lock-up as high as 30 % of the outlet pressure. See Lock-up Pressure Parameters on page 3 for more details.Order No. 7 PSI max.Order No. 10 PSI max.1/2“NPT2295952693181“NPT229609267005NPT1 1/4“ NPT1 1/2“ NPT2“NPT3“NPT2“DN (ISO) Flanged3“DN (ISO) Flanged5“DN (ISO) Flanged2 1/2“ NPT1 1/2“ DN (ISO) Flanged2 1/2“ DN (ISO) Flanged4“6“DN (ISO) FlangedDN (ISO) 009267011269324269327not availablenot availablenot availablenot availablenot availablenot availablenot availableMC Karl Dungs, Inc. FRS Gas Pressure Regulator Edition 2015.09 P/N 261398FRS2 10
Lock-up Pressure ParametersPer ANSI Z21.80, lock-up is defined as an outlet pressure notmore than 150 % or 5 in. W.C, whichever is greater, above thesetpoint after a downstream safety shutoff valve closes with 2seconds, and the two following conditions exists:1. outlet pressure is set to the highest set point of the spring,and2. the regulator is set to maximum capacity or flow at whichthe regulator will control lockup pressure within the acceptable limits.This means that in a given application, a lockup greater than150 % or 5 in. W.C could occur, depending out the inlet pressure, the outlet pressure of the regulator, the flow rate of theregulator, and the pipe volume downstream the regulator andupstream the safety shutoff valve.Regulator Orifice DiametersRegulator TypeOrifice Diameter (mm)FRS 707/634.0FRS 705/6FRS 710/6FRS 712/6FRS 715/6FRS 720/6FRS 725/628.039.043.543.557.568.0MC Karl Dungs, Inc. FRS Gas Pressure Regulator Edition 2015.09 P/N 261398Mounting Preparation3 10Mounting Preparation FRS 7./6 & FRS 5. Flanged The main gas supply must be shut off before starting theinstallation. Carefully examine the unit for shipping damage. Remove all dirt and debris before installing. Failure to remove dirt/debris could result in damage orimproper performance.Recommended Mounting ProcedureRegulator dome from vertically upright to horizontalIf the flow is not in the same direction of thearrows, the regulator will not operate properly.Per DUNGS, lock-up is 30 % of the outlet pressure setting after downstream shutoff valve slowly closes within 30seconds. Therefore, in a given application, a lockup greaterthan 30 % or 5 in. W.C could occur, depending out the inletpressure, the outlet pressure of the regulator, the flow rate ofthe regulator, and the pipe volume downstream the regulatorand upstream the safety shutoff valve.If in a given application the lock-up pressure is too high,employing one or more of the following should reduce thelock-up pressure:1. Increase the size of the regulator.2. Increase the pipe volume downstream the regulator andupstream the safety shutoff valve.3. Decrease the inlet pressure.4. Decrease the oulet pressure.5. Reduce the flow rate.6. Disconnect vent line, if installed.
Procedure to Mount the FRS 7./6 Install the FRS./6 with the gas flow matching the directionindicated by the arrows on the casting. Mount the FRS./6 with the regulator dome vertical orhorizontal. Use new, properly reamed and NPT threaded pipe free ofchips. Apply good quality pipe sealant, putting a moderate amounton the male threads only. If using LP gas, use pipe sealantrated for use with LP gas. Do not thread pipe too far. FRS./6 distortion and/or malfunction may result from excess pipe in the valve body. Apply counterpressure with a parallel jaw wrench only tothe flats of the FRS./6 when installing pipe. Do not overtighten the pipe. Follow the maximum torquevalues listed. After installation is complete, perform a leak test using asoapy water solution.FRS 7./6 Threaded SeriesFRS 5. Flanged SeriesNPTpipe1/2”3/4”1”11/4”443 560 750 875Tmax[Ib-in]11/2” 2”94021/2”3”1190 1310 1310Do not overtorque threaded connection orbolts. Permanent damage will occur.Quickly opening the inlet manual shutoff valvecan permanently rupture the internal, balancing diaphragm. Install the FRS 5. with the gas flow matching the directionindicated by the arrows on the casting. Mount the FRS 5. with the regulator dome vertical orhorizontal. Insert seal inbetween flanges. Insert bolts, tighten in a star pattern to ensure uniform tightness. Do not overtighten bolts. Follow the maximum torque valueslisted. After installation is complete, perform a leak test using asoapy water solution.Bolts: as per DIN 939Tmax [Ib-in] 443NOTE: There are no limits for required pipe lengthsimmediately downstream of the FRS.If the flow is not in the same direction as thearrows, the FRS will not operate properly.MC Karl Dungs, Inc. FRS Gas Pressure Regulator Edition 2015.09 P/N 261398Mounting & Installation4 10
Pressure Tap ConnectionsPressure Taps - FRS 7./6 Threaded Version1 Vent/breather connectionFRS 705/6 - FRS 710/6, G 1/4 in.FRS 712/6 - FRS 730/6, G 1/2 in.2 External feedback pressure connectionFRS 705/6 - FRS 710/6, G 1/4 in. - one side.FRS 712/6 - FRS 730/6, G 1/4 in. - both sides.3 Upstream pressure connectionFRS 705/6 - FRS 710/6, 1/4 in. NPT - one side.FRS 705/6 - FRS 710/6, G 1/4 in. - one side.FRS 712/6 - FRS 730/6, 1/4 in. NPT - both sides.Field mountableadapter for ventconnectionG 1/4 to 1/4“ NPTOrder No. 231944G 1/2 to 1/2“ NPTOrder No. 2319454 Downstream pressure connectionFRS 705/6 - FRS 710/6, 1/4 in. NPT - one side.FRS 712/6 - FRS 730/6 1/4 in. NPT - both sides.Pressure Taps - FRS 5. Flanged VersionFRS Flanged1 Vent/breather connectionFRS 5040 - FRS 5150, G 1/2 in.2 External feedback pressure connectionFRS 5040 - FRS 5150, both sides G 1/4 in.See caution below.3 Upstream pressure connectionFRS 5040 - FRS 5150, both sides G 1/4 in.MC Karl Dungs, Inc. FRS Gas Pressure Regulator Edition 2015.09 P/N 2613984 Downstream pressure connectionFRS 5100 - 5125, both sides G 1/4 in.5 10When using external feeback pressure connection, the internal feedback tube must be sealedwith RTV.Field mountableadapter for ventconnectionG 1/4 to 1/4“ NPTOrder No. 231944G 1/2 to 1/2“ NPTOrder No. 231945
Outlet Pressure Spring SelectionOutlet Pressure Spring Selection (outlet pressure values are for horizontal pipe mounting)The output pressure is controlled by the force of the adjustable spring. The pressure regulator is supplied with the bluespring No. 4. By exchanging springs, other output pressures can be attained. Subtract 1”W.C. when mounted vertically.Spring Range (W.C.) 1 to 3.6Spring colorbrownNot CSA2 to 5white2.8 to 8orange4 to 12blue10 to 22red12 to 28yellow24 to 40black40 to 60pinkStandard60 to 80greyNot CSAFRS 825229826FRS 849229850FRS 707/6FRS 712/6, 229872229841229873FRS 720/6 & 81229882FRS 99229900FRS 17FRS 725/6, 730/6,5065, 5080FRS 229891243416Breather Plug All FRS’s have a breather plug that threads into the regulators’s vent connection.Do not removed plastic breather plug unlessventing outdoors is required.BreatherplugBreatherholeMC Karl Dungs, Inc. FRS Gas Pressure Regulator Edition 2015.09 P/N 261398This plug is not the vent limiter, and it prevents debris fromentering the upper chamber of the regulator. Debris in theupper chamber of the regulator could adversly affect regulator performance. The FRS regulator must also be able to exchange air throughthe breather hole in order to properly regulate. Do not plugthe breather hole. Clear out if necessary.6 10
Vent Limiting Device & Vent Line ConnectionVent Limiting DeviceThe FRS/6 series regulator contains an internal, factory installed vent limiting device, which limits the escape of gas toless than 0.5 CFH @ 5 PSI in case atmospheric diaphragmruptures. Venting required unless accepted by the authorityhaving jurisdiction.Vent Line Requirements Follow the local code for vent sizing and termination requirements. In the absence of local codes, follow NationalFuel Gas Code NFPA 54, the International Fuel Gas Codeor the CSA B149.1 installation code for venting requirements. Terminate the vent to an approved location. At the point of termination, the vent line must be protectedfrom insects and water intrusion. It is highly recommendto install an insect screen and terminate the pipe with theexit facing downwards to prevent rain water from entering.NOTE: For appliances using direct spark ignition, DUNGSrecommends using the FRS’s factory installed, internal ventlimiting device rather than installing a vent line.Vent linescan cause resistance or even feedback pressures thatincrease the lock-up pressure, potentially leading to hardlight-offs or even damaging the appliance.Installation Procedure If venting the regulator, the vent line is to be connected tothe upper dome of the FRS regulator as illustrated. Remove the beather plug. On indoor installations requiring venting outdoors, run thepiping as short and as direct as possible. The vent connecton is G 1/4 for FRS 705/6 to FRS 710/6 andG 1/2 for FRS 712/6 to FRS 730/6 and for all ISO flangedregulators. G 1/4 to 1/4”NPT adapters are available:(Order No. 231944) and G 1/2 to 1/2 NPT (Order No. 231945).MC Karl Dungs, Inc. FRS Gas Pressure Regulator Edition 2015.09 P/N 261398External Impulse7 10 When it is desirable to use the external impluse as the feedback for the regulator, the internal impluse must be plugged.Seal the interal impulse connection with a silicone or RTVsealant suitable for exposure to natural gas, propane, orbutane.ExternalImpulseConnectionIn the absence of venting codes and where venting is required, each regulator must be ventedseparately from all other vents. The external impulse must be properly terminated and madeof a durable, metal material that is suitable for gas service.Internal ImpulseSilicone or RTV sealantThe external impulse must terminate back intothe gas piping at a point that is upstream twosafety shutoff valves in series.
Outlet Pressure AdjustmentAdjusting the FRS outlet pressure1. Verify that the intended output pressure is within the springrange that is installed in the regulator by comparing thecolored outlet pressure label with the table on page 6.2. Remove the black cover.3. To increase outlet pressure, turn the adjustment spindleclockwise. To decrease the outlet pressure, turn the adjustment spindle counterclockwise.4. Always use an accurate pressure gauge connected downstream of the regulator to measure the actual outlet pressure as the FRS is mounted in the operating position.5. Reinstall the black adjustment cover.6. To prevent unauthorized adjustment, holes in the blackcover and the side of the regulator can be used to securea lead seal.Cover- Outlet pressure adjustmentCCW reduces outlet pressureCW increases outlet pressureTop View13 Remove the adjustment cover. Completely release the spring tension by turning theadjustment spindle completely counterclockwise with ascrewdriver, and remove the aluminum cap. Remove existing spring and insert new spring. Re-install the adjusment cover, and apply the new outletpressure label provided with new outlet pressure rangeonto the name plate. Reinstall the adjustment cover.Never have your head above or nearthe aluminum cap when removingregulator spring. The spring tensioncan be high enough to rapidly ejectthe aluminum cap with a large force.Adjustment coverAdjustment spindle foroutletpressure adjustmentAluminum Cap. Turn only to removeoutlet pressure springSpringBreather plugMC Karl Dungs, Inc. FRS Gas Pressure Regulator Edition 2015.09 P/N 261398Spring Replacement8 10
Flow CurveDN 150 (6”)DN 125 (5”)DN 100 (4”)NPT 3”DN 80NPT 2 1/2”DN 65NPT 2”DN 50 (2”)NPT 1 1/2NPT 1 1/4NPT 1NPT 3/4NPT 1/2Flow Curve (mechanically open) Using Natural Gas.10080605040Pressure Drop (in . W.C.)3020108654321100200300 400600 800 100020004000600010,00020,00040,000 60,000 100,000200,000 300,000MC Karl Dungs, Inc. FRS Gas Pressure Regulator Edition 2015.09 P/N 261398Flow of Natural Gas (cubic feet/hr)9 10Sizing an FRS for an application1) Based on desired maximum flow rate, intersect the FRS flow curve and determine corresponding pressure drop.2) Select a spring in the table on page 6 that fits within the desired outlet pressure for the application.3) Add the desired outlet pressure to the pressure drop determined in step one above. The sum of these is the requiredminimum inlet pressure to achieve the desired maximum flow rate.Example of sizing an FRS for an application1) Desired maximum flow rate 2,000 CHF and desired outlet pressure 12”WC2) From table on page 6, either the blue, red or yellow spring will work, because 12” of W.C. is within the range of thesesprings.3) 2000 CFH intersects the following curves and corresponding flow ratesFRS 707 16” of W.C. dropFRS 710 6.5” of W.C. dropFRS 712 2.7” of W.C. dropFRS 715 1.8 “ of W.C. dropAdding 12” to these values gives the following minimum inlet pressures required to achieve the flow rate up to 2000CFH with 12” of W.C. outlet pressure.FRS 707 requires minimum inlet pressure of 28” (16” 12” ) of W.C.FRS 710 requires minimum inlet pressure of 18.5” (6.5” 12” ) of W.C.FRS 712 requires minimum inlet pressure of 14.7” (2.7” 12” ) of W.C.FRS 715 requires minimum inlet pressure of 13.8” (1.8” 12” ) of W.C.
Accessories & ReplacementFRS Flange AccessoriesBody SizeFlangeDescription1 1/2“ ISO FlangedFRS 50402“FRS 5050ISO Flanged2 1/2“ ISO FlangedFRS 50652 1/2“ ISO to NPTFRS 5065FRS 50803“ISO Flanged4“ISO Flanged6“ISO Flanged3“FRS 5080FRS 51005“FRS 5125FRS 5150*ISO to NPTISO Flanged# of Holesper FlangeFlangeOrder No.Bolt size**BoltOrder No.***GasketOrder 7466267466267467267468030403When a control is used alone, one mating flange is needed for each end, for a total of two flanges. When one control is bolted to another, such asan FRS to a DMV dual modular safety valve, one mating flange is needed for each end, for a total of two flanges.** Includes one bolt, one lock washer, and one nut.*** One seal needed for each flange.Repair KitsRepair KitOrder No.Repair KitOrder No.FRS 705/6Not availableFRS 725/6 & 5065068940FRS 710/6Not availableFRS 5100091876Not availableFRS 707/6069005FRS 5125068932069013FRS 5150CSA Ra
FRS 5050 (internal pulse) 2“ DN (ISO) Flanged 065151 not available FRS 5065 (internal pulse) 2 1/2“ DN (ISO) Flanged 058792 not available FRS 5080 (internal pulse) 3“ DN (ISO) Flanged 079681 not available FRS 5100 (internal pulse) 4“ DN (ISO) Flanged 082552 not available
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1 10. C Karl uns, nc. FRS Line ressure Reulator Eition 016.0 / 61. FRS 7./6 series are CSA Certified: ANSI Z21.80 / CSA 6.22 Commonwealth of Massachusetts .
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accept Direct Digital Controls (DDC) for VAV pressure independent operation. The terminal unit controls are supplied by the controls contractor and either factory or field mounted and wired. For information concerning controls, components, sequence of operation, etc., please refer to the documentation provided by the controls contractor.
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