Dungs SAV 100065 Manuale utente

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

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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

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

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.

10 … 32

MC • Edition 05.20 • No. 291 429

8. Dimensions

SAV …

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

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