Dungs SAV 100065 User manual

MF … 32
MC • Edition 05.20 • No. 291 429
1 … 32
The target group of this manual are specialised gas
safety and control technology personnel, trained persons
or persons instructed by them.
They can assess the work assigned to them and
potential hazards on the basis of their technical training,
knowledge and experiences, as well as knowledge of the
relevant regulations. In accordance with the accepted
rules of industrial safety only these persons are permitted
to carry out the installation, start-up, adjustment and
servicing of the equipment.
User Manual
SAV 100065 - 100080 - 250065 - 250080
2. Warnings
Never perform work when gas pres-
sure or voltage is present. Avoid open
re. Comply with government regula-
tions.
Protect the device against vibrations
and mechanical impacts.
Execute all settings and setting values
subject to compliance with the user
manual for the machine connected.
Follow the accepted rules of industrial
safety and the accident prevention
regulations must be followed, if neces-
sary take safety measures to ensure
the protection of persons.
Pipelines connected must be free of
dirt and fouling.
Place this user manual in an easily viewable
location in the installation room! Perform work
only after the safety instructions in this user
manual have been read.
The device may only be operated in
accordance with the operating condi-
tions specied on the rating plate.
Check the device for transport damage
prior to installation.
The device must not be used in areas
with heightened risk of earthquakes.
Protection against environmental and
climatic inuences (corrosion, rain,
snow, icing, moisture (e.g. due to
condensation)), mould, UV radiation,
harmful insects, and toxic, corrosive
solutions / liquids (e.g. cutting / cool-
ing uids) must be ensured. Subject to
the installation site, take safety meas-
ures when necessary.
The device must not be exposed to an
open ame. Protection against lighten-
ing must be provided.
2.1 General warnings
1. Target group
Explanation of the characters
1, 2, 3, … = Take action
consecutively
• = Instruction

2 … 32
MC • Edition 05.20 • No. 291 429
2.2 Normal use
Normal use of the equipment is deemed to pertain pro-
vided the following instructions are followed:
• Use of the equipment in gas transport and gas distribu-
tion networks as well as in commercial and industrial
systems.
• Use in pressure regulating systems according to
EN 12186 and EN 12279.
• Use only with gases of the 1st and 2nd gas family ac-
cording to EN 437.
2.3 Risks in case of misuse
• The equipment is reliable in operation when used
normally.
• Personal or consequential material damage, nancial
damage or environmental damage cannot be ruled out
in the event of non-observance of the instructions.
3. Certication / EU declaration of conformity
• In the event of misuse or misapplication life and limb of
the operator is threatened and serious damage to the
device and other material assets is risked as well.
• Use only with dry and clean gases, no aggressive
media.
• Use only in accordance with the operating conditions
specied on the rating plate.
• Use only in good order and condition.
• Malfunctions and faults must be corrected immediately.
• Use only when following the instructions in this user
manual and the national regulations.

2 … 32
MC • Edition 05.20 • No. 291 429
3 … 32
EU declaration of conformity
Product SAV 100…
SAV 250… Safety shut-o valve up to 25 bar
Manufacturer Karl Dungs GmbH & Co. KG
Karl-Dungs-Platz 1
D-73660 Urbach, Germany
certies herewith that the products named in this overview were subjected to an EU type-examination
and meet the essential safety requirements:
EU Pressure Equipment Directive
2014/68
as amended.
In the event of an alteration of the equipment not approved by us this declaration loses its validity.
Specied requirements of the EU type-examination DIN EN 14382 (01.07.2009)
Term of validity / attestation 2024-08-05
CE-0085CP0255
Notied Body (EU type-examination: Module B) DVGW CERT GmbH
Josef-Wirmer-Straße 1-3
D-53123 Bonn, Germany
Notied Body number: 0085
Monitoring of the QM system (module D) DVGW CERT GmbH
Josef-Wirmer-Straße 1-3
D-53123 Bonn, Germany
Notied Body number: 0085
B. Sc., MBA, Simon P. Dungs
Chief Operating Ocer
Urbach, 2020-05-15

4 … 32
MC • Edition 05.20 • No. 291 429
4. Table of contents
1. Target group 1
2. Warnings 1
2.1 General warnings 1
2.2 Normal use 2
2.3 Risks in case of misuse 2
3. Certication / EU declaration of conformity 2
4. Table of contents 4
5. List of abbreviations 5
6. Features 6
6.1 Technical data 6
6.2 Nomenclature 6
6.3 Adjustment ranges 7
6.4 Spring selection 7
6.5 Rating plate 8
7. Function 9
8. Dimensions 10
9. Assembly / Installation 11
9.1 General instructions 11
9.2 Description of installation 12
9.3 Torques 13
10. Upper / lower adjustment range 14
10.1 Recommended setting values 14
10.2 Spring replacement 15
10.2.1 Replacement of the spring for upper response pressure Wdso 15
10.2.2 Replacement of the spring for lower response pressure Wdsu 16
11. Startup and shutdown 17
11.1 General instructions 17
11.2 Leak test 17
11.3 Startup / unlocking / checking the setting values 18
11.4 Restarting 20
11.5 Shutdown 20
12. Malfunctions and their causes 20
13. Maintenance 21
13.1 General instructions 21
13.2 Maintenance instructions 22
13.2.1 Replacement of the SAV closing element 22
13.2.2 Preparation 24
13.2.3 Removing the ASE from the housing 24
13.2.4 Installing the ASE on the housing 25
13.3 Tools required 26
13.4 Leak test 27
13.5 Recommended maintenance intervals 28
14. Replacement parts 28
14.1 SAV replacement parts list 29
14.2 Storage conditions 29
15. Flowtables 30
15.1 Flow table for natural gas 30
15.2 Flow table for air 30
15.3 Valve ow coecient KG31

4 … 32
MC • Edition 05.20 • No. 291 429
5 … 32
5. List of abbreviations
Abbreviation Description
AGo Response pressure group of the upper response pressure
AGu Response pressure group of the lower response pressure
ASE Safety shut-o valve (without housing)
KGFlow coecient
DN Nominal diameter
IS / DS Integral or variable strength range
Class A Functional class: The SAV closes if the comparison diaphragm is damaged
or the auxiliary power supply has failed
pdRegulator output pressure
pdo Upper response pressure
pdu Lower response pressure
pmax Maximum operating pressure
PN Nominal ange pressure
PS Maximum permissible pressure
SAV Safety shut-o valve
SBV Safety pressure relief valve
SN Serial number
SW Width across ats
Wdo Adjustment range for the upper response pressure by use of the adjusting springs available
Wdu Adjustment range for the lower response pressure by use of the adjusting springs available
Wdso Specic adjustment range of the adjusting spring installed for the upper response pressure
Wdsu Specic adjustment range of the adjusting spring installed for the lower response pressure

6 … 32
MC • Edition 05.20 • No. 291 429
6. Features
6.1 Technical data
Technical data SAV …
Device Safety shut-o valve according to EN 14382, class A
Type SAV 100… IS / SAV 250… DS
Response time < 2 s
Type of gas Family 1+2+3
Nominal diameters
Flange
Connecting anges PN 25 according to EN 1092-1 or ANSI 150 lbs (B16.5)
DN 65 80
ANSI 2.5" 3"
Input pressure SAV 100… 10 bar (1 000 kPa)
SAV 250… 25 bar (2 500 kPa)*
Lower adjustment range
Wdu
35 mbar to 3 000 mbar
Upper adjustment range
Wdo
180 mbar to 5 000 mbar
Materials Main housing: Cast iron GGG 50
Diaphragm housing: Aluminium
Diaphragms: NBR
Ambient temperature -20 °C to +60 °C
* 19 bar (1 900 kPa) with anges ANSI 150
6.2 Nomenclature
Using the SAV 100065 MD
as an example
SAV 100 065 MD ANSI
Type Safety shut-o valve
MOP 100 … 10 000 mbar
250 … 25 000 mbar
Nominal diameter 065 DN 65
080 DN 80
Output pressure
ranges
MD Medium pressure
UHD Ultra high pressure /
high pressure
Flange type
ANSI
with standard PN 25
with anges ANSI 150 lbs

6 … 32
MC • Edition 05.20 • No. 291 429
7 … 32
6.3 Adjustment ranges
Specic adjustment range, underpressure Wdsu
Spring
colour
Item number Wire diameter
[mm]
Length
[mm]
Diameter
[mm]
Setpoint range
[mbar]
MD UHD
Blue 270356 2.0 55 12.3 35-110
Black 270357 2.3 55 12.3 50-250
Purple 270358 2.5 55 12.3 80-400 150-500
Orange 270359 2.8 55 12.3 300-1 000
Silver 270360 3.0 60 15.0 800-1 400
Pink 276126 3.5 60 15.0 1 200-3 000
Specic adjustment range, overpressure Wdso
Spring
colour
Item number Wire diameter
[mm]
Length
[mm]
Diameter
[mm]
Setpoint range
[mbar]
MD UHD
Green 270366 2.5 60 30.0 180-290
Red 270367 2.7 60 30.0 230-370
Yellow 270368 3.2 60 30.0 300-500
Blue 270369 3.5 60 30.0 400-800 500-1 000
Black 270370 3.7 60 30.0 700-1 300
Purple 270371 4.0 60 30.0 1 000-1 800
Orange 270372 4.5 60 30.0 1 300-2 500
Pink 270373 4.8 60 30.0 1 800-3 500
White 271115 5.0 60 30.0 2 500-5 000
6.4 Spring selection
Type Connection Version Item
number
Lower switching point Upper switching point
Wdu AG Wdo AG
SAV 100065 MD DN 65 MD 287898 35-400 mbar AG 10 180-800 mbar AG 10
SAV 250065 UHD DN 65 UHD 279386 150-3 000 mbar AG 5 500-5 000 mbar AG 5
SAV 100080 MD DN 80 MD 287900 35-400 mbar AG 10 180-800 mbar AG 10
SAV 250080 UHD DN 80 UHD 279387 150-3 000 mbar AG 5 500-5 000 mbar AG 5
SAV 100065 MD ANSI ANSI 2.½" MD 287902 35-400 mbar AG 10 180-800 mbar AG 10
SAV 250065 UHD ANSI ANSI 2.½" UHD 287903 150-3 000 mbar AG 5 500-5 000 mbar AG 5
SAV 100080 MD ANSI ANSI 3" MD 287905 35-400 mbar AG 10 180-800 mbar AG 10
SAV 250080 UHD ANSI ANSI 3" UHD 287906 150-3 000 mbar AG 5 500-5 000 mbar AG 5

8 … 32
MC • Edition 05.20 • No. 291 429
6.5 Rating plate
Abbreviation Description
AGo Response pressure group of the upper response pressure
AGu Response pressure group of the lower response pressure
ASE Safety shut-o valve (without housing)
DN Nominal diameter
IS / DS Integral or variable strength range
-20T60 Operating temperature range
Class A Functional class: The SAV closes if the comparison diaphragm is damaged
or the auxiliary power supply has failed
pmax Maximum operating pressure
PN Nominal ange pressure
PS Maximum permissible pressure
SAV Safety shut-o valve
SBV Safety pressure relief valve
SN Serial number
SW Width across ats
Wdo Adjustment range for the upper response pressure by use of the adjusting springs available
Wdu Adjustment range for the lower response pressure by use of the adjusting springs available
Wdso Specic adjustment range of the adjusting spring installed for the upper response pressure
Wdsu Specic adjustment range of the adjusting spring installed for the lower response pressure
30
50
Made in Barcelona / Spain
DIN EN14382/CE-0085CP0255
SAE:
S.N.:
class A AGu AGo
-20T60 PN25
PS:
Wdo:
Wdu:
Wdsu:
Wdso:
IS 10% 10%
DN80
10 bar
1,3-5 bar / 130-500 kPa
0,035-0,4bar / 3,5-40 kPa
SAV 100080 MD
0
,
3-0
,
5bar / 30-50 kPa
0,05-0,25bar / 5-25 kPa
1PDK287900S00000001
11-10-19
0085

8 … 32
MC • Edition 05.20 • No. 291 429
9 … 32
7. Function
The SAV protects downstream ttings or lines
against pressures that are too high or too low.
Immediately the pre-set trip pressure falls be-
low or exceeds a limit due to a fault, it interrupts
the gas ow automatically. Under normal oper-
ating conditions the SAV is open.
If the output side of the gas pressure regulator
and / or the ttings and devices of the succeed-
ing gas line section, including its equipment up
to the gas-consuming device, are not designed
for the highest supply pressure (input pressure
to the gas pressure regulator in case of an er-
ror), an SAV must be installed in order to shut
the gas supply down before the gas pressure
becomes too high.
The SAV complies with the requirements of
EN 14382 as a safety shut-o valve.
Main components
1Regulating cup sleeve
2Closing spring
3Trigger mechanism
4Chamber with the pressure to be monitored
5Working diaphragm
6Push rod
7Setpoint spring for pdo
8Setpoint spring for pdu
9Protective cap
Function
Chamber 4 is connected to the output pressure
via a pulse line.
The pressure to be controlled acts on the work-
ing diaphragm 5. The force of setpoint springs
7and 8acts as a counterforce.
In case of an unbalance of forces (overpres-
sure or underpressure) the SAV is actuated and
the gas supply is blocked.
1
2
3
4
5
6
7
9
8

10 … 32
MC • Edition 05.20 • No. 291 429
8. Dimensions
SAV …
A
C
B
Type Item number p max.
[bar / kPa]
DN Dimensions [mm] Weight
[kg]
DN ANSI A B C D F
SAV 100065 MD 287898 287902 10 / 1 000 65 300 276 135 12x1.5 138 35.1
SAV 250065 UHD 279386 287903 25 / 2 500 65 300 276 135 12x1.5 142 35.1
SAV 100080 MD 287900 287905 10 / 1 000 80 300 298 135 12x1.5 138 37.9
SAV 250080 UHD 279387 287906 25 / 2 500 80 300 298 135 12x1.5 142 37.9
D**
** Ermeto screw connection 12L:
GE 12 - ½ with screw connection M16
for pipes 12x1.5 d
F