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User Manual
SAV 100065 - 100080 - 250065 - 250080
1. Target group
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.
2. Warnings
2.1 General warnings
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.
Execute all settings and setting values
subject to compliance with the user
manual for the machine connected.
Never perform work when gas pres-
sure or voltage is present. Avoid open
fire. Comply with government regula-
tions.
Check the device for transport damage
prior to installation.
The device must not be exposed to an
open flame. Protection against lighten-
ing must be provided.
Pipelines connected must be free of
dirt and fouling.
1 ... 32
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.
Protection against environmental and
climatic influences (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 fluids) must be ensured. Subject to
the installation site, take safety meas-
ures when necessary.
The device may only be operated in
accordance with the operating condi-
tions specified on the rating plate.
Protect the device against vibrations
and mechanical impacts.
The device must not be used in areas
with heightened risk of earthquakes.
Explanation of the characters
1, 2, 3, ... =
•
=
Take action
consecutively
Instruction
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Table of Contents
Related Manuals for Dungs SAV 100065
Summary of Contents for Dungs SAV 100065
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Page 1: Target Group
User Manual SAV 100065 - 100080 - 250065 - 250080 1. Target group 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... -
Page 2: Normal Use
2.2 Normal use Normal use of the equipment is deemed to pertain pro- • Use only with dry and clean gases, no aggressive vided the following instructions are followed: media. • Use of the equipment in gas transport and gas distribu- •... - Page 3 SAV 100… Safety shut-off valve up to 25 bar SAV 250… Manufacturer Karl Dungs GmbH & Co. KG Karl-Dungs-Platz 1 D-73660 Urbach, Germany certifies herewith that the products named in this overview were subjected to an EU type-examination and meet the essential safety requirements:...
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Page 4: Table Of Contents
4. Table of contents Target group Warnings General warnings Normal use Risks in case of misuse Certification / EU declaration of conformity Table of contents List of abbreviations Features Technical data Nomenclature Adjustment ranges Spring selection Rating plate Function Dimensions Assembly / Installation General instructions Description of installation... -
Page 5: List Of Abbreviations
5. List of abbreviations Abbreviation Description Response pressure group of the upper response pressure Response pressure group of the lower response pressure Safety shut-off valve (without housing) Flow coefficient 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 Regulator output pressure... -
Page 6: Features
Diaphragm housing: Aluminium Diaphragms: Ambient temperature -20 °C to +60 °C * 19 bar (1 900 kPa) with flanges ANSI 150 6.2 Nomenclature SAV 100065 MD MD ANSI Using the as an example Type Safety shut-off valve 100 … 10 000 mbar 250 …... -
Page 7: Adjustment Ranges
180-800 mbar AG 10 SAV 250080 UHD DN 80 279387 150-3 000 mbar AG 5 500-5 000 mbar AG 5 SAV 100065 MD ANSI ANSI 2.½" 287902 35-400 mbar AG 10 180-800 mbar AG 10 SAV 250065 UHD ANSI ANSI 2.½"... -
Page 8: Rating Plate
6.5 Rating plate Made in Barcelona / Spain 0085 DIN EN14382/CE-0085CP0255 SAE: SAV 100080 MD S.N.: 1PDK287900S00000001 class A 11-10-19 DN80 -20T60 PN25 10 bar 1,3-5 bar / 130-500 kPa Wdo: Wdu: 0,035-0,4bar / 3,5-40 kPa Wdsu: 0,05-0,25bar / 5-25 kPa Wdso: 0,3-0,5bar / 30-50 kPa Abbreviation... -
Page 9: Function
7. Function The SAV protects downstream fittings 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 flow automatically. Under normal oper- ating conditions the SAV is open. -
Page 10: Dimensions
GE 12 - ½ with screw connection M16 for pipes 12x1.5 d Type Item number Dimensions [mm] Weight max. [bar / kPa] [kg] ANSI SAV 100065 MD 287898 287902 10 / 1 000 12x1.5 35.1 SAV 250065 UHD 279386 287903 25 / 2 500 12x1.5... -
Page 11: Assembly / Installation
9. Assembly / Installation 9.1 General instructions • Installation only in accordance with • The rating plate's performance data agree with the applicable policies and subject to order data. compliance with local regulations, • Flanges on the in- and output side of the connecting obtain permits required if necessary. -
Page 12: Description Of Installation
9.2 Description of installation • Carry out the installation according to the installation • The diaphragm turns on its own axis for the positioning layout indicated below. required of the Ermeto. • Install the safety pressure relief valve in the direction •... -
Page 13: Torques
Installation position 9.3 Torques Use suitable tools! Tighten screws crosswise! Do not use the device as a lever! max. max. max. ⅜ ½ ¾ 1½ 2½ 1 600 2 400 5 000 6 000 7 600 max. [Nm] t 10 s max. -
Page 14: Upper / Lower Adjustment Range
10. Upper / lower adjustment range Setting value for shutdown at overpressure p 1. Remove protective cap A. 2. Turn outer setscrew B with socket spanner SW 22. 3. Turning clockwise: Increasing (+) the upper shutdown pressure p 4. Turning anti-clockwise: Decreasing (-) the upper shutdown pressure p 5. -
Page 15: Spring Replacement
10.2 Spring replacement Remove protective cap A. 10.2.1 Replacement of the spring for upper response pressure p Unscrew setscrew B with socket spanner 1. Remove spring E from SW 22 from spring dome G. the spring dome G. 2. Insert a new spring. 3. -
Page 16: Replacement Of The Spring For Lower Response Pressure W
10.2.2 Replacement of the spring for lower response pressure p 1. Remove setscrew C with spanner wrench SW 17 from the inner spring dome H. 2. Remove spring F from the spring dome. 3. Insert a new spring. 4. Screw setscrew C in with spanner wrench SW 17 until the pre-tension required in the spring dome H is reached. -
Page 17: Startup And Shutdown
11. Startup and shutdown 11.1 General instructions Prior to startup • The rating plate's performance data agree with the order data. • Prevent explosive gas / air mixture. Monitor the room atmosphere for leaking gas on an ongoing basis using suitable gas concentration testers. •... -
Page 18: Startup / Unlocking / Checking The Setting Values
11.3 Startup / unlocking / checking the setting values 1. Slowly open the shut-off valve on the input side. 3. Unlocking the SAV: The ball valve on the output side remains closed. 2. Monitor the increase in pressure on the pressure gauge on the input side upstream of the device. - Page 19 Item Designation Item Designation One-way shut-off valve SBV with shut-off valve Filter Pressure gauge with push-button cock Pressure gauge with push-button cock Ventilation ball valve Ventilation ball valve Test burner Shut-off valve on the output side Pressure regulator Hose 19 … 32...
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Page 20: Restarting
The adjusting springs are not suitable for the application. Replace the adjusting springs. Replace the ASE or have repaired by The valve disc is damaged or worn out. DUNGS. The valve seat is damaged. Replace the valve seat. The SAV switches on, The movable parts are fouled with foreign particles. -
Page 21: Maintenance
13. Maintenance 13.1 General instructions • The Pressure Equipment Directive (PED) requires a regular inspection of the equipment to guarantee the following over the long term: safety and function of the device, high degree of efficiency and minimum environmental impact as a result. •... -
Page 22: Maintenance Instructions
13.2 Maintenance instructions 13.2.1 Preparation Make sure that the SAV is closed by pressing 1. Detach and remove the the trigger button. pulse and vent lines. 2. Remove protective cap L. 3. Undo setscrews J and K to release the adjusting springs. - Page 23 Closing spring Remove the upper diaphragm case P and seals Z and AA. Remove the SAV closing spring. Closure sleeve Remove the SAV closure sleeve. 23 … 32...
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Page 24: Removing The Ase From The Housing
13.2.3 Removing the ASE from the housing Remove the Remove the retaining ring. reset lever. Remove the ASE. Unscrew both screws with the Allen wrench SW 5. 24 … 32... -
Page 25: Installing The Ase On The Housing
13.2.4 Installing the ASE on the housing • The replacement ASE has to be installed on a reinforced section on the housing: Place the ASE at an angle of about 25° to its normal position. 25° Release the ASE with the push-button. Place the ASE in its position and tighten both screws with an Allen wrench SW 5. -
Page 26: Tools Required
13.3 Tools required Width across flats Pressure Work step Tool designation rating DN 65 DN 80 Detaching the pulse line. Spanner wrench (A) MD / UHD Pipe socket spanner (B) Releasing the adjusting springs. MD / UHD Pipe socket spanner (B) Removing the ASE from the housing Allen wrench (C) MD / UHD... -
Page 27: Recommended Maintenance Intervals
13.5 Recommended maintenance intervals 1. The maintenance intervals are subject to the system- 3. In order to guarantee system availability we recom- specific operating and environmental conditions, gas mend a functional check once a month and main- quality, condition of the pipelines, etc. tenance once a year. -
Page 28: Sav Replacement Parts List
Replacement part / image part number SAV closure SAV 100065 - 100080 278003 sleeve SAV 250065 - 250080 SAV 100065 - 100080 MD 278006 ASE with O-ring SAV 100065 - 100080 278007 SAV 250065 - 250080 Bypass push- SAV 100065 - 100080 HD... - Page 29 15. Flow tables Flow tables ∆p SAV DN 65 Recommended operating range Based on +15 ºC, 1 013 mbar, dry Max. pressure difference ∆p = 500 mbar Max. flow velocity = 50 m/s 300 400 500 800 1 000 2 000 3 000 4 000 8 000 10 000 20 000...
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Page 30: Flowtables
Flow tables ∆p SAV DN 80 Recommended operating range Based on +15 ºC, 1 013 mbar, dry Max. pressure difference ∆p = 500 mbar Max. flow velocity = 50 m/s 300 400 500 800 1 000 2 000 3 000 4 000 8 000 10 000 20 000 °... - Page 31 (EPBD) require a regular inspection heating installations only and not of heat generators to guarantee a high to thermal process applications. degree of efficiency long term and DUNGS recommends replacing minimum environmental impact as a components according to the fol- result. lowing table:...
- Page 32 Headquarters address: Subsidiary GmbH & Co. KG Karl Dungs, S.L.U. Karl-Dungs-Platz 1 Av. Can Roqueta 15 D-73660 Urbach Pol. Ind. Can Roqueta Germany E-08202 Sabadell Telephone +49 (0)7181-804-0 Barcelona, Spain Telefax +49 (0)7181-804-166 Telephone +34-935647550 e-mail: info@dungs.com e-mail: info.e@dungs.com Internet: www.dungs.com Internet: www.dungs.com...
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