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NL
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03250885
D GB F NL I E
TR CZ PL RUS H
DK S N P GR
➔ www.docuthek.com
Operating instructions
Safety shut-off valve
JSAV 50 – 00
© 2016 Elster GmbH · Edition 09.16
Translation from the German
Contents
Safety shut-off valve
JSAV 50 – 00 ..........................
Contents ..............................
Safety.................................
Checking the usage .....................
Type code .............................2
Part designations ........................ 2
Type label.............................. 2
Installation ............................
Connecting the impulse line ..............
Connecting the breather line .............
Tightness test ..........................
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
Accessories ...........................7
Technical data .........................7
Designed lifetime ........................8
Logistics ..............................8
Certification ...........................8
Declaration of conformity ..................8
Eurasian Customs Union ..................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 operator. 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
• , , , ... = Action
▷ = Instruction
Liability
We will not be held liable for damage resulting from
non-observance of the instructions and non-compliant 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.
Changes to edition 0.5
The following chapters have been changed:
– Installation
– Setting the trip pressure p
– Certification
do
GB
GB-1
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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 – 00
T T-product
F
GB
A
50 Inlet pressure p
/ Over-pressure shut-off p
u max.
-0 No pressure test point
Part designations
2
3
4
Nominal size
Flange to ISO 7005
ANSI flange
= 5 bar (72.5psig)
1
10
7
5
8
6
Type label
Max. inlet pressure, upper trip pressure pdo, ambient
temperature: see type label.
D-49018 Osnabrück, Germany
P
max:
JSAV
u
Wh
:
o
p
:
do
AGo: +/- 10%
TS=
Installation
do
9
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
lever. Risk of external leakage.
– Max. inlet pressure p
– Installation in the vertical or horizontal position,
never upside down.
5bar (72.5 psig).
u max.
Measuring unit
Screw plug with position indicator
Connection for impulse line (closed with plastic
plug)
4 Inlet
5 Outlet
6 Arrow of direction of flow
7 Reset
8 Arrow of direction of reset
9 Reset lever
0 Connection for breather line (closed with plastic
plug)
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.
Remove the adhesive foil from the inlet and outlet
on the JSAV.
Insert seal between pipe and unit.
▷ Note direction of flow.
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▷
We recommend installing a manual valve AKT25
in the pipe leading to the safety relief valve
VSBV25, so that the annual function check of
the safety shut-off valve JSAV can be carried out
without having to remove it.
▷ 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 plastic plug in the “impulse line” connection and connect an Rp ¼ (¼NPT) pipe. We
recommend a pipe diameter of 12 x 1.5 mm.
Install the impulse line and seal with an approved
sealing material.
▷
Ensure that there is sufficient tube length for the
impulse line.
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).
Block the pipeline at the inlet and outlet.
▷ Note max. test pressure.
JSAV inlet and outlet: max. 6 bar (87psig),
impulse line: max. 750 mbar (10.9 psig).
Slowly apply test pressure.
0
p
do
p
d
3
GB
Rp ¼ (¼ NPT)
0
Connecting the breather line
▷
Remove the plastic plug in the “breather line”
connection and connect an Rp ¼ (¼NPT) pipe.
We recommend a pipe diameter of 12 x 1.5 mm.
Install the breather line and seal with approved
sealing material.
▷ Route the breather line to a safe area.
Rp ¼
(¼ NPT)
0
N2 = max. 7,5 bar (109 psig)
4
N2 = max. 750 mbar
GB-3
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Checking the function
+–
Checking the trip pressure pdo
The JSAV is checked for the required trip pressure pdo.
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.
▷
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 pressurep
of the regulator.
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. The
red “SHUT” mark is visible.
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 JSAV and outlet gas line are
closed.
Vent the system.
Slowly open the manual valve at the inlet.
The outlet pressure pd must not rise.
on the regulator
d
0
Setting the trip pressure pdo
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
Remove the screw plug.
▷
Set the trip pressure pdo according to the dia-
gram.
3
▷
If the JSAV has tripped, i.e. the “SHUT” mark
4
is visible, reset it – see page 5 (Resetting).
6 Check the required trip pressure pdo again, see
page 4 (Checking the function).
7 If the JSAV has been adjusted correctly, follow
the reverse procedure when reassembling.
Replacing the spring
▷
Various trip pressure ranges can be achieved by
using different springs on the JSAV.
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
Spring table
do
Marking Order No.
reddish
brown
orange/
yellow
orange/
green
VSBV
pd [mbar]
5
0 308 906 4
0 308 906 6
0 308 906 7
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+–
2
4 65
5
3 4
6 7
8 Set the required trip pressure pdo, see page 4
(Setting the trip pressure pdo).
9 Follow the reverse procedure when reassem-
bling.
0 After inserting the spring, take the spring’s label
from the packaging and stick it below the type
label on the JSAV.
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.
Press the reset lever and turn through 10° until
resistance can be felt.
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.
Depressurize the system.
The measuring unit is supplied with 1 O-ring and
▷
4 screws.
Ensure that the JSAV is closed. The red “SHUT”
mark must be visible.
▷
If the JSAV is open, apply pressure to the impulse
line to close the valve.
Detach the impulse and breather lines from the
JSAV.
7 Install the new O-ring in the housing.
8 Follow the reverse procedure when reassem-
bling.
9 Connect the impulse and breather lines to the
JSAV.
0 Check tightness and function, see page 3
(Tightness test) and page 4 (Checking the
function).
GB
~10°
Hold the reset lever in this position until the lever
can be easily turned further following pressure
equalization.
Press and turn the reset lever until the valve disc
opens and clicks into place and the “SHUT” mark
is no longer visible.
▷ The red “SHUT” mark must not be visible once
the valve disc has clicked into place.
▷ The JSAV is ready for operation.
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Replacing the valve disc
4 5
3
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.
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. The red “SHUT”
mark must be visible.
GB
▷
If the JSAV is open, apply pressure to the impulse
line to close the valve.
Detach the impulse and breather lines from the
JSAV.
9
10
12 1413
Press the
spring wire
into the notch
in the plate.
11
6
Press the
reset lever and
turn until the
valve disc is
on top.
WARNING
Risk of injury!
– The spring wire is under high stress.
15 16
Insert new
O-rings from
the seal set.
7
7 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.
8 Connect the impulse and breather lines.
9 Check tightness and function, see page 3
(Tightness test) and page 4 (Checking the
function).
GB-6
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Maintenance
In order to ensure smooth operation: check the function and tightness of the JSAV every year, or every
six months if operated with biogas, 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).
Accessories
Position switch for remote indication
The position switch can be used for electronic posi-
tion checks.
Order No.: 03151185
Part designations
1
3
2
Position switch
Aluminium turned part
Lock nut
Two washers and another lock nut which are included
in the delivery are not required.
Ensure that the JSAV is open. The red “SHUT”
mark is not visible.
2
3
4
8 Screw in the position switch until the switching
point is reached and then screw in a further half
a turn.
▷
See the drawing labelled “Contacts” in the en-
closed position switch installation and connec-
tion instructions for measuring the switching
point.
9 Prevent the position switch from rotating using
the fitted lock nut.
0 Wire the position switch.
See the drawing labelled “Contacts” in the en-
▷
closed position switch installation and connec-
tion instructions for the electrical wiring.
After wiring, check for correct functioning, see
page 4 (Checking the function).
Technical data
Gas type: natural gas, town gas, LPG (gaseous),
biogas (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. 7.5 bar (109 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).
Storage temperature:
-15 to +40°C (5 to 104°F).
Connection for housing:
JSAV..F: flange to ISO 7005,
JSAV..A: ANSI flange.
Connection for impulse and breather lines:
Rp ¼ (¼ NPT).
Housing: GGG 40.
Diaphragm: NBR,
valve seat: aluminium,
valve stem: stainless steel,
valve disc: aluminium with vulcanized NBR seal.
5 bar (72.5 psig).
u max.
GB
5
6
7
GB-7
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Designed lifetime
This information on the designed lifetime is based on
using the product in accordance with these operating
instructions. Once the designed lifetime has been
reached, safety-relevant products must be replaced.
Designed lifetime (based on date of manufacture) in
accordance with DIN EN 14382 Safety devices for
gas pressure regulating stations and installations:
15 years.
You can find further explanations in the applicable
rules and regulations and on the afecor website
(www.afecor.org).
This procedure applies to heating systems. For
thermoprocessing equipment, observe local regu-
GB
lations.
Logistics
Transport
Protect the unit from external forces (blows, shocks,
vibration). On receipt of the product, check that the
delivery is complete, see page 2 (Part designations). Report any transport damage immediately.
Storage
Store the product in a dry and clean place.
Storage temperature: see page 7 (Technical data).
Storage time: 6 months before using for the first
time. If stored for longer than this, the overall service
life will be reduced by the corresponding amount of
extra storage time.
Packaging
The packaging material is to be disposed of in accordance with local regulations.
Disposal
Components are to be disposed of separately in
accordance with local regulations.
Certification
Declaration of conformity
We, the manufacturer, hereby declare that the prod-
ucts JSAV 50 – 100, marked with the product ID No.
CE-0085CO0530, comply with the requirements of
the listed Directives and Standards.
Directives:
– Gas Appliances Directive (2009/142/EC)
– Pressure Equipment Directive (97/23/EC),
ClassB, with over-pressure shut-off
Standards:
– DIN EN 14382 (07/09)
The relevant product corresponds to the type tested
by the notified body 0085.
The production is subject to the surveillance procedure pursuant to DIN EN ISO 9001 according to
Directive 2009/142/EC Annex II paragraph 3 and
Directive 97/23/EC Annex III Module D.
Elster GmbH
Scan of the Declaration of conformity (D, GB), see
www.docuthek.com.
Eurasian Customs Union
The product JSAV meets the technical specifications
of the Eurasian Customs Union.
Contact
Contact
If you have any technical questions, please contact
your local branch office/agent. The addresses are
available on the Internet or from ElsterGmbH.
We reserve the right to make technical modifications
in the interests of progress.
Strotheweg 1, D-49504 Lotte (Büren)
Elster GmbH
Tel. +49 541 1214-0
Fax +49 541 1214-370
info@kromschroeder.com, www.kromschroeder.com
GB-8
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