Krom Schroder JSAV 100 Operating Instructions Manual

03250885

F

NL

I

E

TR CZ PL RUS H

Edition 10.12

D GB F NL I E

DK S N P GR

➔ www.docuthek.com

Operating instructions

Safety shut-off valve
JSAV 50 – 100

Translation from the German

© 2012 Elster GmbH

Contents

Safety shut-off valve JSAV 50 – 100 ........1

Contents ..............................1

Safety.................................1

Checking the usage .....................2

Type code .............................2

Part designations ........................2

Type label.............................. 2

Installation ............................2

Connecting the impulse line ..............3

Tightness test ..........................3

Checking the function ...................4

Checking the trip pressure p

Checking the tightness of the valve disc.......4

Setting the trip pressure p

Replacing the spring ....................4

Resetting..............................5

Replacing the measuring unit.............5

Replacing the valve disc .................6

Maintenance ...........................7

Technical data .........................7

Designed lifetime ........................ 7

Declaration of conformity ................8

Contact ...............................8

.............4

do

.............4

do

Safety

Please read and keep in a safe place

Please read through these instructions
carefully before installing or operating. Following the
installation, pass the instructions on to the opera-
tor. This unit must be installed and commissioned
in accordance with the regulations and standards
in force. These instructions can also be found at
www.docuthek.com.

Explanation of symbols

• , 1 , 2 , 3 ... = Action

▷ = Instruction

Liability

We will not be held liable for damage resulting from
non-observance of the instructions and non-com-
pliant use.

Safety instructions

Information that is relevant for safety is indicated in
the instructions as follows:

DANGER

Indicates potentially fatal situations.

WARNING

Indicates possible danger to life and limb.

CAUTION

Indicates possible material damage.

All interventions may only be carried out by qualified
gas technicians. Electrical interventions may only be
carried out by qualified electricians.

Conversion, spare parts

All technical changes are prohibited. Only use OEM
spare parts.

Transport

On receipt of the product, check that the delivery is
complete (see Part designations). Report any trans-
port damage immediately.

Storage

Store the product in a dry place. Ambient tempera-
ture: see Technical data.

Changes to edition 08.12

The following chapters have been changed:
– Declaration of conformity
– JSAV 25 – 40, see operating instructions

for safety shut-off valves JSAV 25 – 40 →
www.docuthek.com → Elster Kromschröder →
Products → 02 Pressure regulators → Safety
shut-off valves JSAV → Kind of document: Op-
erating instructions → JSAV 25 – 40

GB

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Checking the usage

JSAV

Safety shut-off valve for securing downstream fittings
against excess gas pressure.
This function is only guaranteed when used within
the specified limits – see page 7 (Technical data).
Any other use is considered as non-compliant.

Type code

Code Description

JSAV Safety shut-off valve
50 – 100 Nominal size
F
A

GB

40 Inlet pressure p
/1 Trip pressure p

-0 Without pressure test point

Part designations

2

3

4

1 Measuring unit
2 Breather screw plug
3 Impulse line connection
4 Inlet
5 Outlet
6 Arrow of direction of flow
7 Reset

8 Arrow of direction of reset

9 Reset lever

Type label

Max. inlet pressure, upper trip pressure pdo, ambient
temperature: see type label.

D-49018 Osnabrück, Germany

JSAV

Flange to ISO 7005

ANSI flange

= 4 bar (58 psig)

u max.

1

7

5

8

6

P

max:

u

Wh

:

o

p

:

do

AGo: +/- 10%

9

Installation

CAUTION

Please observe the following to ensure that the
JSAV is not damaged during installation:

– Sealing material, cuttings and other impurities

must not be allowed to get into the housing.

– We recommend installing a filter upstream of the

JSAV in order to protect it against impurities in
the pipe.

– The installation location must be dry. Do not

store or install the JSAV in the open air.

– Install the JSAV in the pipe free of mechanical

stress.

– Do not clamp the unit in a vice or use it as a

do

lever. Risk of external leakage.
– Max. inlet pressure p
– Installation in the vertical or horizontal position,

4bar (58 psig).

u max.

never upside down.

1 The housing must not be in contact with ma-

sonry. Minimum clearance 20 mm (0.78"). Ensure
that there is sufficient space for installation and
adjustment.

2 Insert seal between pipe and unit.
3 Remove the adhesive foil from the inlet and outlet

on the JSAV.

▷ Note direction of flow.

▷

We recommend installing a manual valve AKT25

in the pipe leading to the safety relief valve

VSBV25, so that the annual function check of
the safety shut-off valve JSAV can be carried out
without having to remove it.

TS=

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▷ To prevent the VSBV from being unintentionally

shut off, we recommend removing the manual
valve lever after commissioning and attaching
it to the pipe.

JSAV

_>

VSBV

5DN

Connecting the impulse line

▷

Remove the blind plug and connect an Rp¼
(¼ NPT) impulse line.

1 Install the impulse line and seal with an approved

sealing material.
Ensure that there is sufficient tube length for the

▷

impulse line.

Rp ¼ (¼ NPT)

0

Tightness test

WARNING

– An additional tightness test must be carried

out on the JSAV at all joints which have been
opened for maintenance work or replacement
of spare parts.

▷ Ensure that the valve seat of the JSAV is open,

see page 5 (Resetting).

1 Block the pipeline at the inlet and outlet.

▷ Note max. test pressure.

JSAV inlet and outlet: max. 6 bar (87psig),

impulse line: max. 750 mbar (10.9 psig).

2 Slowly apply test pressure.

0

p

do

p

d

3

GB

N2 = max. 6 bar

4

N2 = max. 750 mbar

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Checking the function

Checking the trip pressure pdo

The JSAV is checked for the required trip pressure pdo.
1 Vent the system.

▷ Ensure that the valve seat of the JSAV is open,

see page 5 (Resetting).
Ensure that the breather screw plug is screwed in.

▷

2 Close all manual valves at the inlet and outlet,

and in the relief line.

CAUTION

Please observe the following to ensure that the
regulator is not damaged during the function check:

GB

– Do not exceed the maximum outlet pressurep

of the regulator.

3 Increase the outlet pressure p

until the required trip pressure pdo is reached.

p

do

p

d

▷ The JSAV closes at the set trip pressure pdo.

4 5

▷

klack

The JSAV has closed successfully: to restart the

system, the JSAV must be opened again, see
page 5 (Resetting).

▷

The JSAV does not close at the required trip

pressure pdo and must be readjusted, see page

4 (Setting the trip pressure pdo).

Checking the tightness of the valve disc

▷ Ensure that the outlet is closed.

1 Vent the system.
2 Slowly open the manual valve at the inlet.
3 The outlet pressure p

d

on the regulator

d

0

must not rise.

Setting the trip pressure pdo

1 Select the trip pressure pdo according to the

outlet pressure pd of the pressure regulator.

500
450
400
350

[mbar]

300

do

p

250
200
150
100

50

d

20040 60 80 100 140 180 220 260 300 340

JSAV

2 Remove the breather screw plug.
3 Set the trip pressure pdo.

+–

4 Reset the JSAV, see page 5 (Resetting).
5 Check the required trip pressure pdo again, see

page 4 (Checking the function).

6 Screw the breather screw plug back in.

Replacing the spring

▷

Various trip pressure ranges can be achieved by

using different springs on the JSAV.

1 Choose a spring according to the required trip

pressure range.

Trip pressure p

[mbar] [psig]

35 – 70 0.51 – 1.02 light blue 0 308 906 3

60 – 170* 0.9 – 2.5

120 – 220 1.74 – 3.2 crimson 0 308 906 5

190 – 400 2.8 – 5.8

300 – 550 4.35 – 8

* Standard spring

2 Remove the breather screw plug.

3 4

Spring table

do

Marking Order No.

reddish

brown

orange/

yellow

orange/

green

VSBV

pd [mbar]

0 308 906 4

0 308 906 6

0 308 906 7

5 Insert new spring.
6 Follow the reverse procedure when reassem-

bling.

7 Set the required trip pressure pdo, see page 4

(Setting the trip pressure pdo).

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8 Screw in the breather screw plug.

5

5 76

9 After inserting the spring, take the spring’s label

from the packaging and stick it below the type
label on the JSAV.

10 Clearly mark the adjusted value of the trip pres-

sure pdo on the sticker.

Resetting

▷ Ensure that the impulse line is depressurized.

CAUTION

Please observe the following to ensure that the
JSAV is not damaged during resetting:

– Turn the reset lever gently and do not go further

than specified.

1 Remove the breather screw plug.
2 Press the reset lever and turn through 10° until

resistance can be felt.

~10°

3 Hold the reset lever in this position until the lever

can be easily turned further following pressure
equalization.

4 Press and turn the reset lever until the valve disc

opens and clicks into place.

klack

▷ The pin in the measuring unit must be at the top

after the valve disc has clicked into place.

6 Screw in the breather screw plug.

▷ The JSAV is ready for operation.

Replacing the measuring unit

▷

The measuring unit has to be replaced if the
JSAV no longer opens or can no longer be reset.

▷ We recommend cleaning the O-ring seats and

lightly greasing the O-rings with Klüber Nontrop

ZB91 DIN before installation.

1 Depressurize the system.

The measuring unit is supplied with 1 O-ring and

▷

4 screws.

2 Ensure that the JSAV is closed.
3 Remove the breather screw plug.

▷

The pin in the measuring unit must be at the

bottom when the JSAV is closed.

▷

If the JSAV is open, apply pressure to the impulse
line to close the valve.

4 Detach the impulse line from the JSAV.

8 Install the new O-ring in the housing.
9 Follow the reverse procedure when reassem-

bling.

10 Connect the impulse line to the JSAV.
11 Check tightness and function, see page 3

(Tightness test) and page 4 (Checking the
function).

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Replacing the valve disc

8

▷ The valve disc has to be replaced if the JSAV is

leaking or has been damaged during resetting.

▷ We recommend cleaning the O-ring seats and

lightly greasing the O-rings with Klüber Nontrop

ZB91 DIN before installation.

1 Depressurize the system.

▷

We also recommend replacing the entire seal set
and the bellows when replacing the valve disc.

▷ The seal set with bellows is available separately

as a spare part.

▷ Ensure that the JSAV is closed.

GB

▷

The pin in the measuring unit must be at the

bottom when the JSAV is closed.

▷

If the JSAV is open, apply pressure to the impulse
line to close the valve.

2 Detach the impulse line from the JSAV.

3

6

4 5

Press the
reset lever and
turn until the
valve disc is
on top.

7

Press the
spring wire
into the notch
in the plate.

9

10

11

12 1413

15 16

Insert new
O-rings from
the seal set.

17 Follow the reverse procedure when reassembling

using the new valve disc and the O-rings from
the seal set.

▷

To ensure that the valve disc is pushed onto
the seat by the spring, the spring wire must be

released from the notch in the plate and rest

against the housing wall.

WARNING

Risk of injury!

– The spring wire is under high stress.

18 Connect the impulse line.
19 Check tightness and function, see page 3

(Tightness test) and page 4 (Checking the
function).

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Maintenance

In order to ensure smooth operation: check the func-
tion and tightness of the JSAV every year, or every
six months if operated with biologically produced
methane, see page 4 (Checking the function)
and page 3 (Tightness test).

▷ In the case of malfunctioning, check the

measuring unit and valve disc and replace if
necessary.
Selecting spare parts:
see free PartDetective DVD:
www.kromschroeder.com → Products →
DVD → PartDetective, (D/GB).
Replacing spare parts:
see page 5 (Replacing the measuring unit),
see page 6 (Replacing the valve disc).

▷

After carrying out maintenance work or replacing

spare parts, check for tightness and function,
see page 3 (Tightness test) and page 4
(Checking the function).

Technical data

Gas type: natural gas, town gas, LPG (gaseous),
biologically produced methane (max. 0.02 %-by-
vol. H2S) or air.

The gas must be dry in all temperature conditions

and must not contain condensate.
Max. inlet presure p
Max. test pressure for testing the JSAV:
temporarily < 15 min. 6 bar (87 psig).
Max. test pressure for testing the impulse line:

temporarily < 15 min. 750 bar (10.8 psig).
Trip pressure pdo set at the factory:
120 mbar (46.8 "WC).

Adjusting range for trip pressure pdo, see page

4 (Replacing the spring), Spring table.

Accuracy group: AG 10.

Ambient temperature:

-15 to +60°C (5 to 140°F).
Connection for housing:
JSAV..F: flange to ISO 7005,
JSAV..A: ANSI flange.
Connection for impulse line: Rp ¼ (NPT ¼).
Housing: GGG 40.
Diaphragm: NBR,
valve seat: aluminium,
valve stem: stainless steel,
valve disc: aluminium with vulcanized NBR seal.

4 bar (58 psig).

u max.

Designed lifetime

The Pressure Equipment Directive (PED) and the

Energy Performance of Buildings Directive (EPBD)
demand regular checks on and maintenance of
heating systems in order to ensure a high level of
use in the long term, a clean method of operation
and safe function.

The service life on which the construction is based,

hereinafter referred to simply as the “designed
lifetime”, is compiled from the relevant standards.

You can find further explanations in the applicable

rules and regulations and on the afecor website
(www.afecor.org).

This information on the designed lifetime is based on

using the product in accordance with these operat-
ing instructions.

The product must be serviced at regular intervals.

Once the specified designed lifetime has been
reached, the safety-related functions must be
checked in accordance with the section entitled

“Maintenance”.

If the product passes the aforementioned function
tests, you can continue to use it until the next sched-
uled maintenance operation. At this point, these tests
must be repeated.
If the product fails one of the aforementioned tests,
it must be replaced immediately.

This procedure applies to heating systems. For

thermoprocessing equipment, observe national
regulations.
Designed lifetime (based on date of manufacture) in
accordance with DIN EN14382 Safety devices for
gas pressure regulating stations and installations:

Designed lifetime

Switching cycles Time [years]

JSAV – 15

Long-term use in the upper ambient temperature
range accelerates the ageing of the elastomer ma-
terials and reduces the service life (please contact
manufacturer).

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Declaration of conformity

We, the manufacturer, hereby declare that the prod-
ucts JSAV 50 – 100, marked with the product ID No.
CE-0085AR0246, comply with the requirements of
the listed Directives and Standards.

Directives:
– 90/396/EEC
– 97/23/EC

Standard:
– DIN 3381 (06/84)

GB

The relevant product corresponds to the type tested

by the notified body 0085.

The production is subject to the surveillance pro-

cedure pursuant to DIN EN ISO 9001 according to

annex II, paragraph 3 of Directive 90/396/EEC and

annex III, module D of Directive 97/23/EC.

Elster GmbH

Scan of the Declaration of conformity (D, GB), see

www.docuthek.com.

Contact

Contact

If you have any technical questions, please contact

your local branch office/agent. The addresses are

available on the Internet or from ElsterGmbH.

We reserve the right to make technical modifications

Elster GmbH
Postfach 28 09, D-49018 Osnabrück
Strotheweg 1, D-49504 Lotte (Büren)

T [phone]

F [phone]

in the interests of progress. [e-mail], www.kromschroeder.com

GB-8