Krom Schroder JSAV 50 Manual de usuario

DK S N P GR

➔www.docuthek.com

D GB F NL I E

TR CZ PL RUS H

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

• ,  ,  ,  ... = 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.

Changes to edition 0.5

The following chapters have been changed:

– Installation

– Setting the trip pressure pdo

– Certiﬁcation

Operating instructions

GB-1

03250885

Translation from the German

Safety

Contents

Safety shut-off valve

JSAV 50 – 00

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 pdo .............4

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

Setting the trip pressure pdo .............4

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

GB-2

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

Nominal size

TT-product

Flange to ISO 7005

ANSI ﬂange

50 Inlet pressure pu max. = 5 bar (72.5psig)

/ Over-pressure shut-off pdo

-0 No pressure test point

Part designations

Measuring unit

Screw plug with position indicator

Connection for impulse line (closed with plastic

plug)

4Inlet

5Outlet

6Arrow of direction of ﬂow

7Reset

8Arrow of direction of reset

9Reset lever

0 Connection for breather line (closed with plastic

plug)

Type label

Max. inlet pressure, upper trip pressure pdo, ambient

temperature: see type label.

D-49018 Osnabrück, Germany

JSAV

TS=

Pumax:

Who:

pdo:

AGo: +/- 10%

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

lever. Risk of external leakage.

– Max. inlet pressure pu max. 5bar (72.5 psig).

– Installation in the vertical or horizontal position,

never upside down.

 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.

GB-3

▷

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.

▷To prevent the VSBV from being unintentionally

shut off, we recommend removing the manual

valve lever after commissioning and attaching

it to the pipe.

_> 5DN

JSAV

VSBV

Connecting the impulse line

▷

Remove the plastic plug in the “impulse line” con-

nection and connect an Rp ¼ (¼NPT) 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.

Rp ¼ (¼ NPT)

Connecting the breather line

▷

Remove the plastic plug in the “breather line”

connection and connect an Rp ¼ (¼NPT) 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)

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 (87psig),

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

 Slowly apply test pressure.

pdo

N2= max. 7,5 bar (109 psig)

N2= max. 750 mbar

GB-4

Checking the function

Checking the trip pressure pdo

The JSAV is checked for the required trip pressure p

 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:

– Do not exceed the maximum outlet pressurep

of the regulator.

 Increase the outlet pressure pdon the regulator

until the required trip pressure pdo is reached.

pdo

▷

The JSAV closes at the set trip pressure pdo. The

red “SHUT” mark is visible.

klack

4 5

▷

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 pdmust not rise.

Setting the trip pressure pdo

 Select the trip pressure pdo according to the

outlet pressure pdof the pressure regulator.

40 60 80 100 140 180 220 260 300 340

100

150

200

250

300

350

400

450

500

pd[mbar]

pdo [mbar]

VSBV

JSAV

 Remove the screw plug.

▷

Set the trip pressure pdo according to the dia-

gram.

+–

▷

If the JSAV has tripped, i.e. the “SHUT” mark

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.

Spring table

Trip pressure pdo Marking Order No.

[mbar] [psig]

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

60 – 170* 0.9 – 2.5 reddish

brown 0 308 906 4

120 – 220 1.74 – 3.2 crimson 0 308 906 5

190 – 400 2.8 – 5.8 orange/

yellow 0 308 906 6

300 – 550 4.35 – 8 orange/

green 0 308 906 7

* Standard spring

GB-5

+–

3 4

6 7

8 Set the required trip pressure p

, 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.

~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.

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.

4 65

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-6

Replacing the valve disc

▷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.

▷

If the JSAV is open, apply pressure to the impulse

line to close the valve.

 Detach the impulse and breather lines from the

JSAV.

4 5

Press the

reset lever and

turn until the

valve disc is

on top.

WARNING

Risk of injury!

– The spring wire is under high stress.

10 11

12 1413

15 16

Insert new

O-rings from

the seal set.

Press the

spring wire

into the notch

in the plate.

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-7

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 biogas, see page 4

(Checking the function) and page 3 (Tightness

test).

▷

In the case of malfunctioning, check the measur-

ing 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

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.

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 pu max. 5 bar (72.5 psig).

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.

GB-8

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

in the interests of progress.

Elster GmbH

Strotheweg 1, D-49504 Lotte (Büren)

Tel. +49 541 1214-0

Fax +49 541 1214-370

info@kromschroeder.com, www.kromschroeder.com

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-

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 designa-

tions). 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 ac-

cordance 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),

ClassB, 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 pro-

cedure 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

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