Type: Cocon 26 Dra-Lp/Mp: Und Erground Gas Regulation Station

SCHOONHOVEN NETHERLANDS
UND ERGROUND GAS REGULATION STATION
TYPE: COCON 26 DRA-LP/MP

OPERATORS MANUAL
Gorter Controls B.V.

Broeikweg 13
2871 RM SCHOONHOVEN
NETHERLANDS
Tel : 0031 182 387575
Fax : 0031 182 387272
Internet : www.gorter.nl Number : 80.98.15.01.03.01
E-mail : info@gorter.nl Version : July 13th, 2005
Operators manual
Table of Contents
Page:
1. Introduction 4
1.1 Gorter Controls 4

1.2 Commentary to Documentation 4
1.2.1 General 4
2. General 5
2.1 Types 5
2.2 Area of Application 5
2.3 Type Designation 6
2.4 Technical Data 7
2.5 Classification 8
3. General Safety Regulations 9
4. Function 10
4.1 What is COCON 26 10

4.2 Transcription 10
4.3 Operation 12
4.4 Automatic Operation 12
4.5 Maintenance 12
5. Assembly 13
5.1 Incoming Components Inspection 13

5.2 Standard Delivery 13
5.3 Assembly Regulations 14
5.3.1 Soil Condition and Foundation 15

5.3.2 Pit Dimensions 15
5.3.3 Placement of the Casing and Vent Pole 16
6. Operation 17
6.1 Start-up Operations 17
6.1.1 Given Value Adjustments of Monitor Control (S.S.V.) 18

6.1.2 Given Value Adjustments of Safety Relief Value (S.R.V.) 19
6.1.3 Adjustments of Given Value for the Regulator 19
6.1.4 Start-up Operations 19
6.2 Shut-down for Maintenance Work 20

6.3 Start-up Operations from previously adjusted Cartridge 20
6.4 Cartridge Change 21
6.5 Summer / Winter Operations 23
6.6 Alteration of Auxiliary Pressure 23
6.7 Change-over of Regulator Pilot Adjustment Spring RP-LP\MP 23
6.8 Closing Pressure of Regulator 23
6.9 Dust Filter 23
6.10 Sealing of Pit Cover 23
Gorter Controls B.V. Schoonhoven- The Netherlands

Operators manual underground gas pressure reducing station
Type: COCON26 DRA-LP/MP
Seite 2
Operators manual
Page:
7. Transport and Storage 24
7.1 Transport 24
7.2 Storage 24
8. Additional Information 24
8.1 Double-rail Version 24

8.2 Extension of Services 24
9. Mountings 25
Introduction: Mountings 25
10. Problems and Possible Solutions 25
Gorter Controls is not at all liable for possible imperfections despite the care taken during the compilation of
the text and illustrations.
Seite 3
Operators manual
1. Introduction
1.1 Gorter Controls

Gorter Controls is a prominent manufacturer of gas regulating stations and safety units. The range of
products by Gorter Controls is divided in:
- the Baai units, which are marked by their application on pressure levels higher than ANSI 150 and
- the SDM units, which are marked by their application on lower pressure levels of up to ANSI 150 and PN
16.
Please do not hesitate to contact us if you have any questions regarding the product, for which this
operators manual is specified, or any of our other products. Our address and telephone/fax number are:
Gorter Controls B.V.

Postcode 58
2870 AB Schoonhoven
Tel. : 0031 182 387575
Fax : 0031 182 387272
1.2 Commentary to Documentation

1.2.1 General
The technical documentation by Gorter Controls consists of the Operators Manual and Maintenance
Guidelines, which are directed at a specific component of these systems.
The identification of our technical documentation comprises 12 figures as shown on the title page.
The last two pages show the version no.
Please mention this number when referring to this documentation.
You can order this documentation by simply indicating this number.

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Operators manual
2. General
2.1 Comments
There are various versions of underground gas regulating systems, which differentiate from each other in
their composition of safety and control components. This documentation refers to the models COCON 26 DR
and COCON 26 DRA, which comprise the following active components:
COCON 26 DR
Gas Regulation Station (G.R.S)

2.3 Safety Shut-off Valve (S.S.V.)
COCON 26 DRA
Gas Regulation Station (G.R.S)

Safety Shut-off Valve (S.S.V.)
Safety Relief Valve (S.R.V.)
Each of the above-mentioned types again comprises of two versions, namely the LPD and MPD version,
which differentiate in their range of controlled outlet pressure.
The COCON is a complete gas regulation station including filter, inlet and outlet shut-off valves and vent
poles.
2.2 Area of Application

The COCON 26 is an underground gas regulation station for a max. inlet pressure of 16 bar and an outlet
pressure range of 20 m bar up to10 bar. The COCON 26 is mainly used in urban areas. This underground
gas regulation station requires only little space due to its compact construction - and the COCON 26 also
boasts the following advantages due to its underground area of application:
- No visual disturbance for the surrounding area

- No expensive measures for the elimination of environmental noise pollution
- Prevention of vandalism
Furthermore, all of COCONs internal components are assembled to a unit, which can be simply manually
reconstructed using a quick opening device, thus enabling an on-site change-over of the unit. The actual
maintenance of the exchanged unit can be carried out in the workshop without the gas supply having to be
disconnected during this period of time.

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Operators manual
2.3 Type Designations

Underground Gas Regulation Station (UGRS)
COCON 26 - YYY - xP
Outlet Pressure Range
LPD : 20 mbar to 1 bar

MPD : 1 to 10 bar
Version
DR with Gas Regulation Station (G.R.S)

DRA with G.R.S.

Safety Relief Valve (S.R.V.)
Nominal Width:
Inlet: DN50 PN 16
Outlet: DN150 PN 16
Type:
Example: COCON 26 DRA-LPD
A version of COCON with an inlet nominal width of 2 and outlet nominal width of 6 with G.R.S- S.S.V.
S.R.V. for a regulated outlet pressure range of 20 mbar to 1 bar
Type Designation of various components:

Regulator Pilot : RP-xP
Monitor Control (S.S.V.) : 050-xPD
Safety Relief Valve (S.R.V.) : AV-xP
xP stands for LP or MP, independent of the outlet pressure range of COCON.

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Operators manual
2.4 Technical Data
Medium : all non-aggressive gases.

(version for applications with aggressive media
on request)
Inlet Pressure : up to max. 16 bar
Operating Temperature : -15 to +50C
Outlet Pressure (pa) : min. 20 mbar

Diff. Pressure p : min. 0.3 mbar
Outlet Pressure Range (Wh) : from 20 mbar to 10 bar
Nominal Diameter Inlet : DN50

Nominal Diameter Outlet : DN150
Pressure Level : PN16
DIN DVGW Registration No. : DG-4375AT0143
Total Weight : approx. 350 kg

Weight of Cartridge : approx. 60 kg
Main Dimensions L x W x H : 890 x 890 x 1054 mm
Flange Inlet Ball Valve : 2, ANSI 150

Flange Outlet Valve : DN150, PN16
Pipe Connectors : DIN 2353
Pressure Gauge : for inlet and outlet pressure

Pressure Gauge : " BSP
Mounting of Type Plate
Casing : under pit cover

Cartridge : on the membrane cover
Regulator Pilot : on the regulator pilot
Data on the type plate
Casing : Name of manufacturer, type designation, serial number,

Max. operating pressure, year of construction
Cartridge : Name of manufacturer, type designation, serial number,
Max. operating pressure, set outlet pressure, year of
construction
Regulator Pilot : Name of manufacturer, type designation, spring number,
serial number, set outlet pressure, year of construction
Max. inlet pressure

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Operators manual
2.5 Classification
Regulator Pilot RP-LP
Pressure Range Accuracy Class (RG) Closing Pressure

Class (SG)
20 50 mbar RG10 SG30
50 -100 mbar RG5 SG20
100 -200 mbar RG5 SG10
0.200-1 bar RG2.5 SG10
Diagram 1: Specifications for Regulator LP version according to DIN3380
Regulator Pilot RP-MP
Pressure Range Accuracy Class (RG) Closing Pressure

Class (SG)
1-2.5 bar RG2.5 SG10
2.5-10 bar RG10 SG2.5
Diagram 2: Specifications for Regulator MP version according to DIN3380
Monitor Control: 050-LPD (S.S.V.)
Pressure Range Accuracy Class (AG)

20 -60 mbar AG10
60 -200 mbar AG5
200-1bar AG2.5
Diagram 3: Specifications for Shut-off Safety according to DIN3381
Monitor Control: 050-MPD (S.S.V.)

1-5 bar AG2.5
5-10 bar AG1
Diagram 4: Specifications for Shut-off Safety according to DIN3381
Safety Relief Valve: AV-LP (S.R.V.)

20 50 mbar AG10*
50 -90 mbar AG5
90 -150 mbar AG2.5
0.15-1 bar AG1
Diagram 5: Specifications for AV-LP according to DIN3380

* at 20 mbar inactive neutral zone 25%
Safety Relief Valve: AV-MP (S.R.V.)
Relief Pressure Range Accuracy Class (AG)
1-2.5 bar AG2.5

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Operators manual
2.5-10 bar AG1
Diagram 6: Specifications for AV-MP
3. General Safety Regulations
ATTENTION:
- Please read this Operators Manual carefully before starting operations.
- Only qualified and authorised personnel are able to carry out operations on the underground gas
regulation station.
- Please use ear plugs, protective goggles and heavy-duty gloves.
- Please ensure that the direct surroundings are always well-lit in the dark or during twilight when
carrying out on-site maintenance work.
- Please ensure that there is enough ventilation in the surroundings of the station when removing the
internal component. The vapours emitting from the inner components can be harmful to your health.
- Please take your back into account when assembling and disassembling the cartridge. Kneel down
and keep your back straight. Use lifting equipment if necessary or carry out the work with a
colleague.
DANGER TO LIFE: Do not smoke or use any open flame within a 10 m radius of the
underground gas regulation station.

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Operators manual
4. Function
4.1 What is COCON 26
The COCON 26 is an underground gas regulation station for a max. inlet pressure (pe) of 16 bar and an
outlet pressure of 20 mBar to10 bar.
Minimal differential pressure p whereby the station works on 0.3 bar.
The station is manufactured out of cast iron, steel, aluminium, bronze and plastics.
4.2 Transcription
(see figure 1 page 11)
The underground gas regulation system comprises of two main components:
- The casing (01).

- The underground regulation station and safety unit.
Note: The underground regulation station and safety unit is regarded as cartridge in the text.
A ball valve (02) is mounted to the inlet side of the casing. The handles of the ball valve prevent the Plexiglas
cover (03) from opening when the ball valve is opened. The pit cover (04), with hole, closes the Plexiglas
cover.
A dust filter (05) is mounted to the bottom of the cartridge.

The gas regulation station is fitted with a regulator (06).
The gas flows through a safety unit:
- The safety unit comprise a safety shut-off valve (07) and monitor control (08). The monitor control
has an emergency-stop button and mounted to the top of the cartridge. When the outlet pressure is
too high the safety shut-off valve shuts with the help of a recoil spring.
The regulator pilot from the regulator controls the required outlet pressure.
A shut-off relay (09) is mounted to the outlet of the casing. The relay can be operated without having to open
the Plexiglas cover. It is not possible to open the Plexiglas cove when the relay is opened.
A safety relief valve can be installed.

Pressure displays for telemetering are also available. The gas regulation station is fitted out with two
pressure gauges. The pressure gauges are for the inlet and outlet pressure.
The pressure gauges are located under the Plexiglas cover and you can see them when the Plexiglas cover
is open.
Two handles are fixed to the cartridge so that you can easily remove this cartridge.

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Operators manual
Figure 1
01 Casing
02 Ball Valve DN50
03 Plexiglas Cover
04 Pit Cover
05 Dust Filter
06 Regulator
07 Safety Shut-off Valve
08 Slamshut device
09 Butterfly valve
10 Handles

Seite 11
Operators manual
4.3 Operation
Regulator
The gas flows through the ball valve into the casing: The dust filter prevents the dust from entering the
cartridge. The gas continues to flow through the opened safety shut-off valve to the regulator.
The outlet pressure has been set by the regulator pilot.
The higher the amount of gas required, the further the regulator is opened.
Safety Shut-off Valve

The safety shut-off valve cuts off the gas supply when the outlet pressure surpasses the set given value for
the outlet pressure.
The safety shut-off valve is reset by pressing the red display button.
Figure 2
Inlet Ball Valve

Filter - Filter
Sicherheitsabsperrventil Safety Shut-off Valve
Regler - Regulator
Ausgangsklappe Discharge Pipe
The cartridge can only have a positive effect when
- there are no gas leakages in the system.

- there is no dirt in the pipes.
- there is no moisture in the casing.
4.4 Automatic Operation

The cartridge works completely automatically when the cartridge has been correctly installed and adjusted.
The safety shut-off valve should be used to shut off the gas supply in case of any possible problems.
4.5 Maintenance
Normal maintenance is recommended although the cartridge contains comparatively few movable parts.

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Operators manual
5. Assembly
5.1 Incoming Components Inspection
- Check the underground gas regulation station on delivery to ensure it complies with the sent
confirmation of order.
- Check the shipment for any damages possibly occurring during transport.
- Please inform us within 48 hours of receiving the order If any damages are determined.
5.2 Standard Delivery

Also see Figure 3.
The COCON26 standard delivery comprises:
- Casing
- Completely mounted and functional internal component
- Completely mounted instrument piloting for components on the vent pole (3)
- Tubes (4)* for vent pole connection
- Special key to open the pit cover lock
- Extended socket wrench for the removal of the cartridge
*
In the case of COCON-DR there are 2 tubes and in the case of COCON-DRA there are three tubes each of which are 2
m in length (longer tubes are available on request).
The following items are available on request:
- Pressure Pick-off
- Minimess Connections
- Recommended grease
- Supply and discharge collecting pipe lines for multi-rail versions
- Test Casing
- Proximity switch on safety shut-off valve for "closed" position signal
- Foundation Plate

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Operators manual
5.3 Assembly Regulations
Figure 3: Dimensions in mm
1. View of COCON 26
2. Foundation Plate
3. Vent pole
4. Various tube connections, venting 2x, safety relief device 1x
5. View of vent pole connections

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Operators manual
5.3.1 Soil Condition and Foundation

Depending on the condition of the soil, a foundation is to be mounted to prevent the station from sinking. A
foundation plate (2) is necessary with the following soil compositions:
- Organic soil compositions such as peat, humus and gardening soil.

- Extremely fine grained soils (clay plates) like clay, bolder clay, sandy soil and compost.
We also suggest you use a foundation plate under the underground regulation station with fine grained soil
compositions like clay, sandy soil, silt and loess. Please use concrete as the foundation material.
A foundation plate is not necessary with medium grained soil compositions such as sand, gravel sand, wind
borne sand and sandy plates.
The thickness of the foundation plate must be a minimum of 100 mm. Please ensure that you not only take
the weight of the station into account, but also the additional weight (i.e. the parking of a car on the pit cover)
when calculating the thickness of the foundation plate.
The width and length of the foundation plate must be a minimum of 1x1 metres. Ensure that the top of the
foundation plate is horizontal.
5.3.2 Pit Dimensions

The depth of the pit depends on the thickness of foundation plate. Always keep to the next rule of thumb
when calculating the depth of the pit.
Depth of Pit = 1054 + df
Enter the thickness of the foundation plate in mm for df. The number '1054' is the distance from the bottom of
the casing to the top of the pit cover frame.
Example:
The depth of a pit should amount to 1054 + 100 = 1154 mm if you require the top
of the underground regulation station to be equal to ground level.
Dig a funnel-shaped hole. This way you can easily mount the pipe to the casing. Mount the pipes tension
free to the mounting clamps.

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Operators manual
5.3.3 Placement of the Casing and Vent pole
Note: Use a lifting device, hook and two slings to install the casing.
Place a roofing construction over the station in case of wind and rain. This will
prevent moisture and dirt from entering the station. The area under the roofing
construction should be well ventilated.
Support the opened pit cover by wind force 8 and above by means of a wind hook.
1. Close the Plexiglas cover and pit cover.

2. Put the slings around the plate to which the pit cover frame is attached.
3. Lift the casing carefully. Ensure that the middle of the casing hangs above the middle of the pit.
4. Lower the casing carefully onto the foundation plate.
5. Place the seal ring DN50 between the supply pipe flange and ball valve flange.
6. Mount the supply pipe flange to the ball valve flange with four threaded bolts M16, four nuts M16 and
eight washers. The washers are located between the supply pipe flange and the bolt heads and
between the ball valve flange and the nuts.
7. Mount the discharge pipe flange to the outlet flange of the casing with eight nuts M20 and sixteen
washers. The washers are located between the discharge pipe flange and the bolt heads and
between the outlet flange and the nuts.
Note: Insulate the flange connections with lagging in order to prevent the corrosion of the
fastening material.
We suggest you put a clamp around the gas regulation station. This prevents the pit cover of the station from
being blocked by cars, for example. Please use galvanised piping.
8. Fill the place between the station and the pit with soil till just under the vent connections on the
COCON casing. Pat down the soil firmly.
9. Place the vent pole (3) approx. 0.5 m away from the casing and ensure that it finally sticks approx. 1
(or 3)* metres out of the ground.
10. Mount the two supplied " tubes (4) between the central vent connections 1 and 2 on the COCON
casing and the connections 1 and 3 on the vent pole with couplings.
11. In the case of COCON-DRA: Mount a " tube between the vent connection 3 on the COCON casing
and the connection 2 on the vent pole with couplings.
12. Fill the place between the station and the pit with soil till ground level. Pat down the soil firmly.
*short vent pole = 1 metre, long vent pole = 3 metres.

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Operators manual
6. Operation
6.1 Start-up Operations
Note: Place a roofing construction over the station in case of wind and rain. This way
you will prevent moisture and dirt from entering the station. Pay attention
that the area under the roofing construction is well ventilated. Support the opened pit cover
by wind force 8 and above by means of a wind hook.
Figure 4 is a top view of the station with the open cover.
Figure 4
This approach can be applied in situations, in which the station has not already been adjusted (i.e. after
maintenance to the cartridge or a station, which is to be newly installed) or in situations, in which the set
values of the regulator and the safety units have been greatly altered.
Warning
Never put the regulating system into operation by opening the discharge pipe. This results in
unnecessary, one-sided force being put on the regulating membranes and valves.
The start-up operation from a depressurised situation can be a relatively inactive procedure
and your actions should thus be adapted appropriately!

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Operators manual
Initial Situation:
Also see Figure 1.
COCON pit cover and Plexiglas cover opened, inlet and outlet valve closed.
The station between the inlet (02) and outlet valve (09) is furthermore depressurised.
The safety shut-off valve is closed (red reset button on the monitor control is switched off).
Regulating screw of shut-off valve is fastened tightly.

Regulating screw of monitor control is fastened tightly.
Regulating screw of regulator pilot is loosened completely.
6.1.1 Given Value Adjustments of Monitor control (S.S.V.)
1. Open the input ball valve slowly (02), figure 1.
2. Slowly apply pressure to the component in front of the regulator pressing the red reset button of
the monitor control.
3. The pressure in front of the regulator will equal the pressure in front of the shut-off valve in a certain
moment. Press the red reset button in completely so that the monitor control is reset.
4. Fasten the regulating screw of the regulator pilot slowly (to the right). The outlet pressure
increases slowly, as can be seen on the pressure gauge on the COCON outlet. Continue until the
outlet pressure and given value on the shut-off unit are equal.
5. Now turn the regulating screw on the monitor control back slowly until the device connects and the
safety shut-off valve shuts off. The red reset button on the monitor control is now off, see Figure
1.
6. Now turn back the regulating screw on the regulator pilot by three turns.
7. Now collect some gas / air / nitrogen from the hand air blowing unit on the COCON outlet and wait
until the outlet pressure is at 80% of the given value of the safety shut-off value then close the
manual air blowing unit.
8. Now reset the safety shut-off valve by pressing the red reset button.
Attention! The internal bypass is activated in the first millimetres when you press the red
button. Only the pressure in front of and behind the safety shut-off valve is equal can you continue
pressing the red button and the shut-off device will be reset and the valve opened. Be patient and do
not use any force!
9. Now fasten the regulating screw on the regulator pilot again slowly until the safety shut-off valve
responds. Check the value and adjust the given value of the monitor control if necessary by turning
the regulating screw.
10. Repeat points 7 till 9 a few times to ensure that the correct given value has been adjusted and then
screw the appropriate protective butterfly valve to the spring casing or above the red reset button.

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Operators manual
6.1.2 Given Value Adjustments - Safety Relief Valve (S.R.V.)

Only valid for the COCON26-DRA
1. Remove the hose connected to connection 2 from the relief pipe (outlet, atmospheric).
2. Ensure that the safety shut-off valve has been reset.
3. Retract some gas / air / nitrogen via the manual air blowing unit and set the outlet pressure via the
pilot regulating screw so that this meets the given value of the safety shut-off valve.
4. Ensure that the flow rate can be observed on the atmospheric outlet of the safety shut-off valve. You
can, for example, use a simple vadometer for this; a tube which is connected to the outlet on one
side and which is attached to a water container on the other side is among the possibilities.
5. Now turn the regulating screw 1 on the safety shut-off valve back slowly until a small flow rate on the
outlet of the safety relief valve can be observed.
6. Now turn the regulating screw on the regulator pilot so far until the outlet pressure is at approx. 80
% of the given value of the blow-off safety device.
7. The flow rate on the outlet of the safety relief valve should now be on zero. Check that this is the
case.
8. Now turn the regulating screw on the regulator pilot again and check the adjusted given value of the
safety relief valve and readjust it if necessary.
9. Repeat points 6 till 8 a few times to check the given value and secure the regulating screw with the
appropriate nut.
6.1.1 Given Value Adjustments - Regulator

1. Ensure for the collection via the manual air blowing unit hand on the COCON outlet.
2. Bring the outlet pressure to the given value of the regulator by adjusting the regulating screw of the
regulator pilot and then fasten the regulating screw with the appropriate nut.
3. Slowly close the manual air blowing unit and check the closing pressure. The outlet pressure is
not to further increase after a few minutes.
6.1.4 Start-up Operations

1. The active components have now been adjusted and you can now slowly open the discharge pipe
(09-Figure 1) after having tested for external leakages.
2. Check again whether the manual air-blowing device is closed at both inlet and outlet and put on the
Plexiglas cover.
3. If necessary, slightly grease the pit cover seal on both sides with Dow Corning Silicone Compound
7 (recommended), then close the pit cover and lock it with the key provided.

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Operators manual
6.2 Shut-down for Maintenance Work

Also see Figure 1.
Note: The regulating screw of the regulator pilot should not be slackened off during or before the regulating
system is depressurised.
1. Open the pit cover (04).
2. Close the input ball valve (02) via the lever. Wait until the pressure in the pipe in front of the
regulator corresponds with the network pressure. Then close the discharge pipe (09) via the lever. Lock the
levers.
The regulator will take over the control of a possible second rail.
3. Remove the Plexiglas cover (03).
4. Depressurise the station by opening the manual air blowing unit at the pit inlet and outlet.
6.3 Start-up Operations of previously adjusted Cartridge

This procedure can be applied when the various given values of the cartridge have already been adjusted
and there is no talk of a new adjustment or readjustment.
Initial Situation: The COCON is depressurised between the inlet ball valve (02) and the discharge pipe
(09) and the safety shut-off valve is closed (The red reset button on the monitor control is off!)
1. Slowly open the inlet ball valve
2. Slowly apply pressure to the regulator component by slightly pressing the red reset button on the
monitor control.
3. The outlet pressure will now slowly increase. The safety shut-off valve can be completely opened
when the outlet pressure complies with the given value of the regulator by completely pressing the
red reset button.
4. Check the operation and tightness of the regulator by opening the outlet of the manual air blowing
unit and by slowly closing it again after 20 seconds. Check the given value of the regulator!
5. Now slowly open the discharge pipe via the lever.

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Operators manual
6.4 Change of Cartridge
The position numbers refer to Figure 1 when not otherwise shown.
Figure 5: Simplified view of COCON with open pit cover
1. Winged Nut
2. Plexiglas Cover
3. Handles of Cartridge
4. Discharge Pipe Lever
5. Measuring Sleeve Bolt

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Operators manual
1. Carry on as described in Shut Down for Maintenance Work.

2. Check once again if the station is depressurised. Check the pressure gauges for this. You should
also check whether the levers have been secured.
See Figure 5.
3. Disassemble the measuring sleeves with the extended socket wrenches supplied by loosening the
bolts (5) with hexagon sockets.
It could be easier if you loosen some couplings on the measuring sleeves.
4. Remove the two bolts from the COCON and put them in a clean place so that they dont fall into the
casing at a later date.
Figure 6: Additional tool for the (dis)assembly of the cartridge
5. Now place the additional tool (see figure 6) over the handles.
6. Turn the whole cartridge anti-clockwise till the lock flange is visible on the perimeter of the cartridge.
7. Now carefully pull the cartridge upwards, preferably with a colleague.
8. Pay attention not to damage the two double seal rings.
9. Now take the new cartridge and grease the double seal ring well with the recommended
Parker Super Lub Silicone grease.
10. Lower the cartridge perpendicularly into the casing. Ensure that the double seal rings are not
damaged.
Pay attention to the direction of the cartridge; you should thus view the arrow on the cartridge
casing. Ensure that the cartridge outlet is fitted with a lock above a lock recess in the COCON
casing in such a way that the measuring sleeve conforms to the outlet when turned clockwise.
11. Now turn the handles (3) of the cartridge clockwise till the fixing drill holes of the measuring sleeve
are directly above the COCON casing.
12. Remove the additional tool (Figure 6)
13. Fasten the 2 bolts (5) of the measuring sleeve (pay attention to the seal ring!) with the socket wrench
supplied. Never tighten these bolts with force as you could otherwise damage the threaded hole in
the COCON casing! If they are difficult to tighten, then there is either dirt on the bolts or the drill
holes are not correctly positioned opposite each other.
14. You can carry on as described in paragraph 6.1 Start-up Operation prior to adjustment or
readjustment of the given values of the various components.
When the correct given value of the cartridge has already been set in the on-site workshop you can carry on
as described in paragraph 6.3 Start-up Operations of Previously Adjusted Gas Regulating and Safety Unit.

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Operators manual
6.5 Summer / Winter Operations

If a station has to be made ready for operation due to a seasonal decrease in demand, then we recommend
that you lower the given value of the regulator so that the operational safety is ensured. You just have to
open the pit cover and remove the Plexiglas cover in order to attain this. You can now open the regulating
screw using a hex head wrench in order to shut down the stations gas delivery.
6.6 Alteration of Auxiliary Pressure

The stabilising pressure, also known as auxiliary pressure, is the regulated pressure of the first regulator
level of the regulator pilot RP-LP/MP. This regulated value is fixed and can be altered by changing the
spring. The regulator pilot always comes equipped with a set spring supplied by Gorter Controls b.v. This
spring is set in such a way that it is sufficient in almost all situations. A lower or higher stabilising pressure
could be sporadically requested, mostly in cases, in which the regulator is too active or inactive. If this is the
case we would ask you to contact Gorter Controls b.v. so that we can determine the correct stabiliser spring
for your specific situation.
6.7 Change-over of Regulator Pilot Adjustment Spring RP-LP\MP

The situation could arise in which you would like to change over the adjustment spring of the regulator pilot,
because you want to attain another regulated outlet pressure or influence the regulator pilot performance.
You simply have to loosen the regulating screw and then the screw-in spring holder protection nut in the
spring casing in order to carry out this change-over. It is not necessary to depressurise the installation! The
control path should however be put out of operation (see the beginning of paragraph 6.2) and then adjusted
via the manual air blowing unit on the COCON outlet.
6.8 Regulator Closing Pressure

You can simply test the tightness of the regulator by slowly closing the pit discharge pipe.
The outlet pressure should not continue to rise after a few minutes. If this is still the case then there are
leakages via the regulator pilot or regulator (aside from other possible leakages).
6.9 Dust Filter
1. Carry on as in paragraph 6.4 Change-over of Gas Regulating Station and Safety Unit for
disassembly.
2. You can remove the dust filter by simply loosening the nuts, if the interior component has already
been disassembled.
3. Mount a new filter cartridge and tighten the nuts again.
4. Test the double seal rings for damages and dirt. When necessary, replace them. After replacement
grease these seal rings with Parker Super Lub Silicone (recommended).
5. Carry on as in paragraph 6.4 Change-over of Gas Regulating Station and Safety Unit.
6.10 Sealing of Pit Cover

The pit cover seal comprises of two components: One component is found in the cover and the other
component on the top of the casing. When working on the COCON you should ensure that these sealings
are not damaged. Both parts have been slightly greased in order to prevent possible sticking through
freezing in winter. Thats why pollution could stick to these sealings during work. You should therefore
carefully test the sealings before closing the pit cover again. If dirt occurs, then remove the sealings with a
clean cloth and re-grease with Dow Corning Silicone Compound 7.

Seite 23
Operators manual
7. Transport and Storage

7.1 Transport
- Flanges are to be fitted out with caps to protect all clothing during transport.
- When lifting, you should ensure that the auxiliary lifting equipment is suitable for the weight
of the components as stated in the technical specifications of this manual.
7.2 Storage
- The station is to be stored in clean surroundings with low levels of vibration and moisture.
- A conservation layer preventing oxidation is to be applied to replacement cartridges in
storage.
8. Additional Information
8.1 Double-rail Version

The dimensions shown in Figure 7 should be taken into consideration in case you require a version of the
COCON for application on double rails.
Figure 7
8.2 Extension of Services

You can attach numerous gas regulating stations parallel to each other for services larger than the maximum
COCON 26 services.

Seite 24
Operators manual
9. Mountings
Introduction: Mountings
This chapter describes the parts of the gas regulation station which are not standard, but which can be
delivered.
Various mountings are:

- Complete cartridge (with regulator pilot, safety shut-off valve)
- Pressure transmitter for inlet pressure
- Pressure transmitter for outlet pressure
- Differential pressure gauge
- Proximity switch for "closed" position on monitor control
- Lifting tool for the (dis)assembly of the cartridge
- Test unit (special casing)
- Inlet and outlet collecting pipe lines for double rail version
10. Problems and Possible Solutions

In case of any faults, you can determine how to clear such faults according to the following list.
Problem 1 : Outlet pressure is too high.
Cause a : The regulator pilot has not been correctly adjusted.

Solution a : Reset the regulator pilot.
Cause b : The main membrane of the cartridge is damaged.

Solution b : Replace the main membrane.
Problem 2 : Outlet pressure is too low.
Cause a : The regulator pilot has not been correctly adjusted.

Cause b : Delta pressure p is too small.

Solution b : Increase the inlet pressure.
Cause c : Filter cartridge is extremely polluted.

Solution c : Replace the filter cartridge with a spare filter cartridge.
Problem 3 : Customers receive no gas.
Cause a : The regulator pilot of the gas regulation station has not been correctly adjusted.
Cause b : Safety unit is closed.

Solution b : Check the gas regulation casing, regulator pilot and the
monitor control as well as the safety relief valve. Replace the damaged parts if
necessary
Problem 4 : Dust in the casing of the cartridge.
Cause : Filter cartridge is polluted.

Solution : Replace the dirty filter cartridge with a spare filter cartridge.

Seite 25

Type: Cocon 26 Dra-Lp/Mp: Und Erground Gas Regulation Station

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SCHOONHOVEN NETHERLANDS

UND ERGROUND GAS REGULATION STATION

TYPE: COCON 26 DRA-LP/MP

Gorter Controls B.V.

1.1 Gorter Controls 4

3. General Safety Regulations 9

4.1 What is COCON 26 10

5.1 Incoming Components Inspection 13

5.3.1 Soil Condition and Foundation 15

6.1 Start-up Operations 17

6.1.1 Given Value Adjustments of Monitor Control (S.S.V.) 18

6.2 Shut-down for Maintenance Work 20

Gorter Controls B.V. Schoonhoven- The Netherlands

7. Transport and Storage 24

8.1 Double-rail Version 24

10. Problems and Possible Solutions 25

1.1 Gorter Controls

Gorter Controls B.V.

1.2 Commentary to Documentation

The last two pages show the version no.

Please mention this number when referring to this documentation.

You can order this documentation by simply indicating this number.

Gorter Controls B.V. Schoonhoven- The Netherlands

Gas Regulation Station (G.R.S)

Gas Regulation Station (G.R.S)

2.2 Area of Application

- No visual disturbance for the surrounding area

Gorter Controls B.V. Schoonhoven- The Netherlands

2.3 Type Designations

Outlet Pressure Range

LPD : 20 mbar to 1 bar

DR with Gas Regulation Station (G.R.S)

DRA with G.R.S.

Example: COCON 26 DRA-LPD

Type Designation of various components:

xP stands for LP or MP, independent of the outlet pressure range of COCON.

Gorter Controls B.V. Schoonhoven- The Netherlands

2.4 Technical Data

Medium : all non-aggressive gases.

Outlet Pressure (pa) : min. 20 mbar

Nominal Diameter Inlet : DN50

DIN DVGW Registration No. : DG-4375AT0143

Total Weight : approx. 350 kg

Flange Inlet Ball Valve : 2, ANSI 150

Pipe Connectors : DIN 2353

Pressure Gauge : for inlet and outlet pressure

Mounting of Type Plate

Casing : under pit cover

Data on the type plate

Casing : Name of manufacturer, type designation, serial number,

Gorter Controls B.V. Schoonhoven- The Netherlands

Pressure Range Accuracy Class (RG) Closing Pressure

Diagram 1: Specifications for Regulator LP version according to DIN3380

Regulator Pilot RP-MP

Pressure Range Accuracy Class (RG) Closing Pressure

Diagram 2: Specifications for Regulator MP version according to DIN3380

Monitor Control: 050-LPD (S.S.V.)

Pressure Range Accuracy Class (AG)

Diagram 3: Specifications for Shut-off Safety according to DIN3381

Monitor Control: 050-MPD (S.S.V.)

Pressure Range Accuracy Class (AG)

Diagram 4: Specifications for Shut-off Safety according to DIN3381

Safety Relief Valve: AV-LP (S.R.V.)