Krom Schroder JSAV 50 User manual

03250885 Edition 10.12
DK S N P GR
➔www.docuthek.com
D GB F NL I E
TR CZ PL RUS H
© 2012 Elster GmbH
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
Operating instructions
Translation from the German
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Safety
Contents
Safety shut-off valve
JSAV 50 – 100
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 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
Technical data .........................7
Designed lifetime ........................ 7
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
50 – 100 Nominal size
F
A
Flange to ISO 7005
ANSI flange
40 Inlet pressure pu max. = 4 bar (58 psig)
/1 Trip pressure pdo
-0 Without pressure test point
Part designations
1
5
7
8
6
9
3 2
4
1Measuring unit
2Breather screw plug
3Impulse line connection
4Inlet
5Outlet
6Arrow of direction of flow
7Reset
8Arrow of direction of reset
9Reset lever
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. 4bar (58 psig).
– Installation in the vertical or horizontal position,
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.

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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.
_> 5DN
JSAV
VSBV
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.
0
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).
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
pdo
pd
N2= max. 750 mbar
N2= max. 6 bar
3
4

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Checking the function
Checking the trip pressure pdo
The JSAV is checked for the required trip pressure p
do
.
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:
– Do not exceed the maximum outlet pressurep
d
of the regulator.
3 Increase the outlet pressure pdon the regulator
until the required trip pressure pdo is reached.
0
pdo
pd
▷The JSAV closes at the set trip pressure pdo.
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 outlet is closed.
1 Vent the system.
2 Slowly open the manual valve at the inlet.
3 The outlet pressure pdmust not rise.
Setting the trip pressure pdo
1 Select the 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
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.
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
2 Remove the breather screw plug.
3 4
5 Insert new spring.
6 Follow the reverse procedure when reassem-
bling.
7 Set the required trip pressure p
do
, see page 4
(Setting the trip pressure pdo).

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8 Screw in the breather screw plug.
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
5
▷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.
5 76
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
▷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.
▷ 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.
7
6
4 5
3
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
8
12 1413
9
15 16
Insert new
O-rings from
the seal set.
Press the
spring wire
into the notch
in the plate.
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.
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 pu max. 4 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 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.
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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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
Elster GmbH
Postfach 28 09, D-49018 Osnabrück
Strotheweg 1, D-49504 Lotte (Büren)
T [phone]
F [phone]
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)
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