Krom Schroder JSAV 25 User manual

DK S N P GR
➔www.docuthek.com
D GB F NL I E
TR CZ PL RUS H
© 2012 Elster GmbH
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
• ,  ,  ,  ... = Action
▷= Instruction
Liability
We will not be held liable for damages 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.
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.
Contents
Operating instructions
Translation from the German
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0500 · Edition 0. Safety
Contents
Safety shut-off valve JSAV5 – 40
Safety shut-off valve JSAV5 – 40 .........
Contents ..............................
Safety.................................
Checking the usage .....................
Type code .............................2
Part designations ........................2
Type label..............................2
Installation ............................
Connecting the impulse line ..............
Tightness test ..........................
Checking the function ...................4
Checking the trip pressure .................4
Checking the tightness of the valve disc.......4
Setting the trip pressure .................4
Replacing the spring ....................4
Resetting..............................5
Replacing the measuring unit.............5
Replacing the valve disc .................6
Maintenance ...........................7
Technical data .........................7
Designed lifetime ........................8
Declaration of conformity ................8
Contact ...............................8

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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
5 – 40 Nominal size
R
N
F
Rp internal thread to ISO 7-1
NPT internal thread
Flange PN 16 to ISO7005
40 Max. inlet pressure pu= 4bar (58psig)
/
/
Upper trip pressure pdo
Upper and lower trip pressure pdo/pdu
-0
-
Without pressure test point
Screw plug at the inlet and outlet
Part designations
JSAV 5
4
1
2
6
7
5
3
JSAV 40
1
2
9
7
6
5 8
3
4
Measuring unit
Breather screw plug
Reset cap
4Impulse line connection
5Inlet
6Outlet
7Arrow of direction of flow
8Inlet pumeasuring connection
9Outlet pdmeasuring connection
Type label
▷Max. inlet pressurepu, upper trip pressurepdo
and lower trip pressurep
du
, ambient tempera-
tureT: see type label.
www.kromschroeder.com
D-49018 Osnabrück, Germany
JSAV
pu: 4 bar
pdu: 10 mbar (8..16)
pdo: 140 mbar (10..210)
T: -20 °C..+60 °C
Klasse A IS
CE-0085AS0202
www.kromschroeder.com
D-49018 Osnabrück, Germany
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. On the JSAV..R, only secure the valve by
holding the octagon at the inlet or outlet with a
suitable spanner. Risk of external leakage.
– Max. inlet pressure pu4bar (58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.
 JSAV..R: seal pipe with approved sealing material.
 Remove screw caps from the inlet and outlet on
the JSAV.
▷Note direction of flow.

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▷ 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
Connecting the impulse line
▷The connection flange is suitable for an impulse
line with a pipe diameter of 8mm.
21
3 4
Push union
nut and
compression
fitting onto
the impulse
line.
▷On the JSAV..T, remove the blind plug and con-
nect an NPT 1 /
8impulse line.
5 Install the impulse line and seal with approved
sealing material.
▷ Ensure that there is sufficient tube length for the
impulse line.
_> 5DN
JSAV
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.
N2= max. 6 bar
N2= max. 750 mbar
3
4

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Checking the function
Checking the trip pressure
The JSAV is checked for the required trip pressure.
 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
d
of the regulator.
 Lower or increase the outlet pressurepdon the
regulator until the required trip pressurepdo or
pdu is reached.
0
p
d
p
d JSAV
▷The JSAV closes at the set trip pressure.
0
klack
pd
pd JSAV
klack pd
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 and must be readjusted, see page4
(Setting the trip pressure).
Checking the tightness of the valve disc
▷Ensure that the outlet is closed.
 Vent the system.
 Slowly open the manual valve at the inlet.
 The outlet pressure pdJSAV must not rise.
Setting the trip pressure
 Select the upper trip pressurepdo according to
the outlet pressurepdof the pressure regulator.
20
0
40 60 80 100 140 180 220 260 300 340
50
100
150
200
250
300
350
400
450
500
pd[mbar]
pdo [mbar]
VSBV
JSAV
 Remove the breather screw plug.
 Adjust the selected upper trip pressurepdo and
the lower trip pressurepdu. Determinepdu de-
pending on the system conditions.
+
–
pdo
pdu
4 Reset the JSAV, see page5 (Resetting).
5 Check the upper and lower trip pressure again,
see page4 (Checking the function).
Replacing the spring
▷ Various trip pressure ranges can be achieved by
using different springs on the JSAV.
 Choose a spring/springs according to the re-
quired trip pressure.
Spring table
Upper trip pressure pdo Marking Order No.
[mbar] ["WC]
18 – 60 7 – 23.4 black 03089068
50 – 80 19.5 – 31.2 orange 03089069
60 – 110 23.4 – 42.9 red 03089070
100 – 210* 39 – 81.9* dark green 03089071*
200 – 350 78 – 136.5 yellow 03089072
280 – 500 109.2 – 195 white 03089073
Lower trip pressure pdu Marking Order No.
[mbar] ["WC]
8 – 16* 3.12 – 6.24* light blue
03089082*
16 – 60 6.24 – 23.4 brown 03089083
60 – 150 23.4 – 58.5 violet 03089084
* Standard spring
Removing the spring(s)
 Depressurize the system.
▷
To be able to change the springs, we recommend
dismantling the measuring unit of the JSAV, see
page5 (Replacing the measuring unit).
 Once the measuring unit has been dismantled,
remove the listed indivdual parts from the meas-
uring unit one after the other.

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▷Attention! The individual parts are compressed.
Part designations
1
2
3
4
7
5
6
Breather screw plug
Counter bearing for spring pdo
Spring pdo
4Spring seat
5Counter bearing for spring pdu
6Spring pdu
7O-ring
Inserting new spring(s)
 Carefully clamp the measuring unit in the horizon-
tal position in a vice to ensure simple assembly
of the individual parts. The dome into which the
breather screw plug is screwed should be point-
ing upwards.
4 Re-insert and assemble the individual parts in the
dome in reverse order using tweezers or small
pincers.
▷Caution when inserting the counter bearing 5!
The smaller diameter must be inside the spring
pdu.
▷ The bars on the spring seat 4 must be posi-
tioned in the grooves of the dome.
▷Do not screw in the breather screw plug yet.
5 Fit the measuring unit. Ensure that the O-ring 7
has been re-inserted.
6 Connect the impulse line to the JSAV.
7 Adjust the required trip pressures, see page4
(Setting the trip pressure).
8 After inserting the springs, take the springs’ ad-
hesive labels from the packaging and stick them
below the type label on the JSAV.
9 Clearly mark the adjusted trip pressures pdo and
pdu on the adhesive label(s).
0 Screw in the breather screw plug.
 Check tightness and function, see page 3
(Tightness test) and page 4 (Checking the
function).
Resetting
▷ Ensure that the pressure of the impulse line is
between the upper and lower trip pressure.
 Remove the breather screw plug.
 Turn the reset cap and pull it approx. 1to2mm
(0.04to0.08") upwards. Pressure equalization
now takes place.
1–2mm
 Hold the reset cap in this position until the cap
can be pulled further upwards easily following
pressure equalization.
4 Pull the reset cap upwards until the valve disc
clicks into place. The JSAV is now fully open.
klack
5 Screw the reset cap back on.
▷Once the cap has been screwed on, the green
dot in the reset cap must be right at the top.
klack
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.
 Depressurize the system.
JSAV 5
▷
The measuring unit is supplied with the valve disc
assembled. 1O-ring and 4screws are enclosed.
 Detach the impulse line from the JSAV.
45
3
▷ Ensure that the O-ring is fitted in the new measur-
ing unit, see Figure5 .

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6 Follow the reverse procedure when reassembling.
7 Connect the impulse line to the JSAV.
8 Check tightness and function, see page 3
(Tightness test) and page 4 (Checking the
function).
JSAV 40
▷
The measuring unit is supplied with the valve disc
assembled. 1O-ring and 4screws are enclosed.
 Detach the impulse line from the JSAV.
45
6
3
8
9
7
▷ Ensure that the O-ring is fitted in the new measur-
ing unit, see Figure9 .
0 Replace the O-ring on the housing. The O-ring
is part of the seal set.
▷ The seal set is available separately as a spare part.
 Follow the reverse procedure when reassembling.
 Connect the impulse line to the JSAV.
 Check tightness and function, see page 3
(Tightness test) and page 4 (Checking the
function).
Replacing the valve disc
▷ The valve disc has to be replaced if the JSAV
is leaking.
▷We recommend cleaning the O-ring seats and
lightly greasing the O-rings with Klüber Nontrop
ZB91DIN before installation.
 Depressurize the system.
JSAV 5
▷The valve disc is supplied with a complete seal
set. We recommend replacing all seals.
 Detach the impulse line from the JSAV.
5
17
15
9
4
18
3
19
67
10
8
11
10
12
16
13
14
First insert
the washer
into the valve
disc, and then
the O-ring.
▷ Ensure that the O-ring is fitted in the new measur-
ing unit, see Figure6 .
7 Follow the reverse procedure when reassembling.
8 Connect the impulse line to the JSAV.
9 Check tightness and function, see page 3
(Tightness test) and page 4 (Checking the
function).
JSAV 40
▷The valve disc is supplied with a complete seal
set. We recommend replacing all seals.
 Detach the impulse line from the JSAV.

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5
6
14
11
15
13
4
3
8
12
7
9 10
10
Im Ventil-
teller zuerst
die Scheibe,
dann den
O-Ring
einsetzen.
5
6
14
11
15
13
4
3
8
12
7
9 10
10
Im Ventil-
teller zuerst
die Scheibe,
dann den
O-Ring
einsetzen.
▷ Ensure that the O-ring is fitted in the new measur-
ing unit, see Figure .
5
6
14
11
15
13
4
3
8
12
7
9 10
10
First insert
the washer
into the valve
disc, and then
the O-ring.
▷ Replace the O-rings on the housing and the
valve seat.
19
24
1716
18
25
20 21
22 23
 Follow the reverse procedure when reassembling
using the O-rings from the seal set.
 We also recommend replacing the sealing rings
on the pressure test points.
4 Connect the impulse line.
5 Check tightness and function, see page 3
(Tightness test) and page 4 (Checking the
function).
Maintenance
In order to ensure smooth operation:
Check the function 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 pressure pu4bar (58psig).
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 pressures pre-set at the factory to:
pdo: 120 mbar,
pdu: 10mbar.
Trip pressure ranges, 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..R: Rp internal thread to ISO 7-1,
JSAV..N: NPT internal thread,
JSAV..F: PN 16 flange to ISO 7005.
Connection for impulse line:
DN8 (NPT1 /
8).
Housing: AlSi,
diaphragm: NBR,
valve seat: aluminium,
valve stem: stainless steel,
valve disc: steel with vulcanized NBR seal.

Elster GmbH
Postfach 28 09, D-49018 Osnabrück
Strotheweg 1, D-49504 Lotte (Büren)
T [phone]
F [phone]
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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. [e-mail], www.kromschroeder.com
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).
Declaration of conformity
We, the manufacturer, hereby declare that the prod-
ucts JSAV 25 – 40, marked with product ID No. CE-
0085AS0202, comply with the requirements of the
listed Directives and Standards.
Directives:
– 2009/142/EC
– 79/23/EC
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 proce-
dure according to annex II, paragraph 3 of Directive
2009/142/EC and annex II, module D of Directive
97/23/EC.
Elster GmbH
Scan of the Declaration of conformity (D, GB), see
www.docuthek.com.
Contact