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Instruction Manual
SAV 100065-100080
SAV 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, ... =
•
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consecutively
Instruction
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Summary of Contents for Dungs SAV 100065 MD
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Page 1: Target Group
Instruction Manual SAV 100065-100080 SAV 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. -
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: Declaration Of Conformity
Safety shut-off valve up to 25 bar Produkt / Product Produit / Producto SAV 250065-250080 Hersteller / Manufacturer Karl Dungs GmbH & Co. KG Fabricant / El Fabricante Karl-Dungs-Platz 1 73660 Urbach, Germany bescheinigt hiermit, dass die certifies herewith that the prod- certifie par la présente que le... - Page 4 Product SAV 250065-250080 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 a Type Examination (production type) and meet the essential safety requirements: • The Pressure Equipment Safety Regulations, UKSI 2016:1105 (as amended by UKSI 2019: 969) In the event of an alteration of the equipment not approved by us this declaration loses its validity.
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Page 5: Table Of Contents
4. Table of contents Target group Warnings General warnings Normal use Risks in case of misuse Declaration of conformity Table of contents List of abbreviations Features Technical data Nomenclature Adjustment ranges Spring selection Type plate Function Dimensions Assembly / Installation General instructions Description of installation Torques... -
Page 6: 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 Functional class: The SAV closes if the comparison diaphragm is damaged Class A or the auxiliary power supply has failed Regulator output pressure... -
Page 7: 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 (1 000 kPa) 250 …... -
Page 8: 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 9: Type Plate
6.5 Type plate Abbreviation Description Response pressure group of the upper response pressure Response pressure group of the lower response pressure Safety shut-off valve (without housing) Nominal diameter IS / DS Integral or variable strength range Operating temperature range -20T60 Class A Functional class: The SAV closes if the comparison diaphragm is damaged or the auxiliary power supply has failed... -
Page 10: 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 11: Dimensions
GE 12 - ½ with screw connection M16 for pipes 12x1.5 d Type Item number Dimensions [mm] Weight max. [bar / kPa] [kg] SAV 100065 MD 287898 287902 10 / 1 000 12x1.5 35.1 SAV 250065 UHD 279386 287903 25 / 2 500 12x1.5... -
Page 12: 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 com- order data. pliance with local regulations, obtain • Flanges on the in- and output side of the connecting permits required if necessary. -
Page 13: Description Of Installation
9.2 Description of installation • The installation must be carried according to the installa- • Maximum flow velocity in the stablisation section: tion scheme specified below, unless deviations required ≤ 30 m/s. by regulations. • Use steel pipe impulse lines: •... -
Page 14: 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 15: 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 mm. 3. Turning clockwise: Increasing (+) the upper shutdown pressure p 4. Turning anti-clockwise: Decreasing (-) the upper shutdown pressure p 5. -
Page 16: 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 mm from spring dome G. the spring dome G. 2. Insert a new spring. 3. -
Page 17: 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 mm 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 mm until the pre-tension required in the spring dome H is reached. -
Page 18: 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 19: Startup / Unlocking / Checking The Setting Values
11.3 Startup / unlocking / checking the setting values 1. Slowly open the shutoff valve on the inlet side per 2. Monitor the pressure rise on the pressure gauge on 12.2 “Initial applying pressure during commission- the inlet side upstream of the device. ing, recommissioning or testing”. - Page 20 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 20 … 32...
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Page 21: 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 22: 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 ef- ficiency and minimum environmental impact as a result. •... -
Page 23: 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 24 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. 24 … 32...
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Page 25: 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 mm. 25 … 32... -
Page 26: 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 mm. -
Page 27: Tools Required
13.3 Tools required Pressure Work step Tool designation Width across flats rating 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 13.4 Leakage test... -
Page 28: Leak Test
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 29: Replacement Parts
14.1 SAV replacement parts list Replacement Order Version 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 30 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 31: 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 32 DUNGS empfiehlt eine maximale Lagerzeit von 3 Jahren. DUNGS recommends a maximum storage time of 3 years. DUNGS recommande une durée de stockage maximale de 3 ans. DUNGS raccomanda un tempo massimo di stoccaggio di 3 anni. We reserve the right to make modifications in the course of technical development.
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