Mankenberg DM 462V Installation instructions

Original operating manual
Pressure reducing valve
Originalbetriebsanleitung
Druckminderventil
DM 462V / DM 462VG
DM 462V / DM 462VG-4.X.23 Stand 30.06.2023

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DM 462V / DM 462VG-4.X.23 Stand 30.06.2023
Table of contents EN
1 Intended use ............................................................................................................................................... 6
1.1 Area of application ............................................................................................................................... 6
1.2 Reasonably predictable misuse ........................................................................................................... 6
1.3 Changes and modifications.................................................................................................................. 6
2 General notes ............................................................................................................................................. 6
2.1 Warranty and liability............................................................................................................................ 6
2.2 Standards and guidelines applied ........................................................................................................ 6
2.3 Duties of the operator........................................................................................................................... 6
3 Safety........................................................................................................................................................... 7
3.1 Explanation of the warning notices ...................................................................................................... 7
3.2 Personnel qualification ......................................................................................................................... 7
3.3 Personal protective equipment............................................................................................................. 7
3.4 Structural modification.......................................................................................................................... 8
3.5 Environmental protection ..................................................................................................................... 8
4 Installation and commissioning................................................................................................................ 8
4.1 Plant requirements ............................................................................................................................... 8
4.1.1 Plant structure........................................................................................................................... 8
4.1.2 Application example.................................................................................................................. 9
4.1.3 Nozzle loads ............................................................................................................................. 9
4.2 Installation ............................................................................................................................................ 10
4.2.1 Preparation ............................................................................................................................... 10
4.2.2 Procedure ................................................................................................................................. 11
4.2.3 Further information.................................................................................................................... 11
4.3 Pressure resistance test....................................................................................................................... 11
4.3.1 Testing the pressure resistance of the plant............................................................................. 11
4.3.2 Tightness test of the valve ........................................................................................................ 11
4.4 Commissioning and setting the operating point ................................................................................... 12
4.4.1 Preparation ............................................................................................................................... 12
4.4.2 Procedure ................................................................................................................................. 12
4.4.3 Subsequent work ...................................................................................................................... 12
5 Operation .................................................................................................................................................... 13
6 Maintenance................................................................................................................................................ 14
6.1 DM 462V ............................................................................................................................................. 15
6.1.1 General view DM 462V ............................................................................................................. 15
6.1.2 Parts list DM 462V .................................................................................................................... 16
6.1.3 Maintenance schedule .............................................................................................................. 17
6.1.4 Test plan ................................................................................................................................... 17
6.1.5 Lubrication schedule ................................................................................................................. 17
6.1.6 Replacing the maintenance kit 462V ........................................................................................ 18
6.2 DM 462VG .......................................................................................................................................... 25
6.2.1 General view DM 462VG .......................................................................................................... 25
6.2.2 Parts list DM 462VG ................................................................................................................. 26
6.2.3 Maintenance schedule .............................................................................................................. 28
6.2.4 Test plan ................................................................................................................................... 28
6.2.5 Lubrication schedule ................................................................................................................. 28
6.2.6 Replacing the maintenance kit 462VG...................................................................................... 29
7 Decommissioning, removal and disposal................................................................................................ 35

7.1 Decommissioning................................................................................................................................. 35
7.1.1 Preparation ............................................................................................................................... 36
7.1.2 Procedure ................................................................................................................................. 36
7.1.3 Subsequent work ...................................................................................................................... 36
7.2 Removal ............................................................................................................................................... 36
7.2.1 Preparation ............................................................................................................................... 37
7.2.2 Procedure ................................................................................................................................. 37
7.3 Disposal ............................................................................................................................................... 37
8 Error search, troubleshooting and repair ................................................................................................ 38
8.1 Malfunctions ......................................................................................................................................... 38
8.1.1 Help in case of malfunctions ..................................................................................................... 38
9 Cleaning ...................................................................................................................................................... 39
9.1 Cleaning ............................................................................................................................................... 39
9.1.1 Preparation ............................................................................................................................... 39
9.1.2 Procedure ................................................................................................................................. 39
9.1.3 Subsequent activities ................................................................................................................ 39
9.1.4 Further information.................................................................................................................... 39
10 Information on REACH and RoHS ............................................................................................................ 39
10.1 Declaration on the REACH Regulation 1907/2006 .............................................................................. 39
10.2 Declaration on the RoHS Directive 2011/65/EU .................................................................................. 39
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Inhaltsverzeichnis DE
1 Bestimmungsgemäße Verwendung ......................................................................................................... 40
1.1 Einsatzbereich...................................................................................................................................... 40
1.2 Vernünftigerweise vorhersehbare Fehlanwendung.............................................................................. 40
1.3 Veränderungen und Modifikationen ..................................................................................................... 40
2 Allgemein .................................................................................................................................................... 40
2.1 Gewährleistung und Haftung................................................................................................................ 40
2.2 Verwendete Normen und Richtlinien.................................................................................................... 40
2.3 Betreiberpflichten ................................................................................................................................. 40
3 Sicherheit.................................................................................................................................................... 41
3.1 Erläuterung der Warnhinweise............................................................................................................. 41
3.2 Personalqualifikation ............................................................................................................................ 41
3.3 Persönliche Schutzausrüstung............................................................................................................. 41
3.4 Bauliche Veränderung.......................................................................................................................... 42
3.5 Umweltschutz....................................................................................................................................... 42
4 Einbau und Inbetriebnahme...................................................................................................................... 42
4.1 Anlagenvoraussetzungen..................................................................................................................... 42
4.1.1 Anlagenaufbau.......................................................................................................................... 42
4.1.2 Anwendungsbeispiel ................................................................................................................. 43
4.1.3 Stutzenlasten ............................................................................................................................ 44
4.2 Einbau .................................................................................................................................................. 44
4.2.1 Vorbereitung ............................................................................................................................. 44
4.2.2 Vorgehensweise ....................................................................................................................... 45
4.2.3 Weiterführende Informationen .................................................................................................. 45
4.3 Druckfestigkeitsprüfung........................................................................................................................ 45
4.3.1 Druckfestigkeitsprüfung der Anlage.......................................................................................... 45
4.3.2 Dichtheitsprüfung der Armatur .................................................................................................. 45
4.4 Inbetriebnahme und Betriebspunkt einstellen ...................................................................................... 46
4.4.1 Vorbereitung ............................................................................................................................. 46
4.4.2 Vorgehensweise ....................................................................................................................... 46
4.4.3 Anschließende Tätigkeiten........................................................................................................ 46
5 Betrieb......................................................................................................................................................... 47
6 Wartung....................................................................................................................................................... 48
6.1 DM 462V ............................................................................................................................................. 49
6.1.1 Übersicht DM 462V................................................................................................................... 49
6.1.2 Stückliste DM 462V................................................................................................................... 50
6.1.3 Wartungsplan............................................................................................................................ 51
6.1.4 Prüfplan..................................................................................................................................... 51
6.1.5 Schmierplan .............................................................................................................................. 51
6.1.6 Austausch des Wartungssatzes 462V ...................................................................................... 52
6.2 DM 462VG .......................................................................................................................................... 59
6.2.1 Übersicht DM 462VG ................................................................................................................ 59
6.2.2 Stückliste DM 462VG................................................................................................................ 60
6.2.3 Wartungsplan............................................................................................................................ 62
6.2.4 Prüfplan..................................................................................................................................... 62
6.2.5 Schmierplan .............................................................................................................................. 62
6.2.6 Austausch des Wartungssatzes 462VG ................................................................................... 63
7 Außerbetriebnahme, Demontage und Entsorgung................................................................................. 69

7.1 Außerbetriebnahme ............................................................................................................................. 69
7.1.1 Vorbereitung ............................................................................................................................. 70
7.1.2 Vorgehensweise ....................................................................................................................... 70
7.1.3 Anschließende Tätigkeiten........................................................................................................ 70
7.2 Demontage........................................................................................................................................... 70
7.2.1 Vorbereitung ............................................................................................................................. 71
7.2.2 Vorgehensweise ....................................................................................................................... 71
7.3 Entsorgung........................................................................................................................................... 71
8 Fehlersuche, Störungsbeseitigung und Reparatur................................................................................. 72
8.1 Störungen............................................................................................................................................. 72
8.1.1 Hilfe bei Störungen ................................................................................................................... 72
9 Reinigung.................................................................................................................................................... 73
9.1 Reinigung ............................................................................................................................................. 73
9.1.1 Vorbereitung ............................................................................................................................. 73
9.1.2 Vorgehensweise ....................................................................................................................... 73
9.1.3 Abschließende Tätigkeit............................................................................................................ 73
9.1.4 Weiterführende Informationen .................................................................................................. 73
10 REACH- und RoHS-Auskunft .................................................................................................................... 73
10.1 Erklärung zur REACH-Verordnung 1907/2006 .................................................................................... 73
10.2 Erklärung zur RoHS-Richtlinie 2011/65/EU ......................................................................................... 73
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DM 462V / DM 462VG-4.X.231 Issue 30.06.2023
1 Intended use
The pressure reducing valve reduces fluctuating higher inlet pressure of a medium to an adjustable constant
outlet pressure, within a control deviation. The pressure reducing valve controls without auxiliary energy and
conveys the operating medium leakage-free.
The valve has been designed and built for the conditions specified in the order. The design criteria indicated on
the nameplate must correspond to the actual operating conditions. If the operating conditions or application
change, the manufacturer Mankenberg must be consulted!
Use only maintenance kits and spare parts from the company Mankenberg!
1.1 Area of application
» The fitting can be used for the following media:
Temperatures above 50 °C entail a reduced pressure resistance. This must be considered for the corresponding
material as per the nameplate in accordance with the DIN EN 1092 standard. The pressure stage specification
refers to 20 °C.
1.2 Reasonably predictable misuse
The valve is not a safety valve, equipment part with safety function or a shut-off device.
Additional loads must not be applied to the valve. For example, do not climb onto the installed valve or the
connected piping.
1.3 Changes and modifications
The supplied valve must not be modified or converted. Conversions are a safety risk and are carried out at the
operator’s own risk. The enclosed declaration of conformity loses its validity upon conversion.
2 General notes
This operating manual is intended as instructions for using the valve safely. It is binding for transport, storage,
installation, commissioning, operation, maintenance and repair. Only work described in this operating manual
may be carried out.
Observe notes and warnings!
2.1 Warranty and liability
Warranty and liability claims for personal injury and damage to property are excluded if they are attributable to
one of the following causes:
» Use other than the intended use
» Improper commissioning, operation and maintenance
» Failure to observe the warnings
» Unauthorized changes
2.2 Standards and guidelines applied
The product has been designed, manufactured, tested, labelled and documented in accordance with the
European Pressure Equipment Directive (DGRL) 2014/68/EU classification as per art. 4 para. 3 in accordance
with „good engineering practice“ and AD 2000.
2.3 Duties of the operator
The operator is responsible for ensuring compliance with safety measures as well as for proper operation and
maintenance.
The operator must ensure that:
» the intended use is guaranteed at all times;
» the system prerequisites are fulfilled;
» a faultless, functional condition of the product prevails;
» the operating manual is available to the personnel;

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» the personnel is qualified and equipped with the corresponding protective equipment;
» the compatibility between the medium and the valve and seal materials is ensured;
» safe handling of the operating medium is ensured (e.g. hazards from contamination, moisture).
3 Safety
3.1 Explanation of the warning notices
Safety and warning notices denote safety-related information. The operating manual differentiates between the
following hazard levels.
DANGER
Fatal injuries
Denotes a hazardous situation. Failure to observe these warnings may result in serious
injuries or death.
WARNING
Serious injuries
Denotes a hazardous situation. Failure to observe these warnings may result in serious
injuries.
CAUTION
Injuries
Denotes a hazardous situation. Failure to observe these warnings may result in minor or
midrange injuries.
NOTICE
Material damage
Denotes warnings of material damage and includes precautionary measures for preventing
damage.
3.2 Personnel qualification
Only trained and instructed specialist personnel may work with the valve.
These personnel must:
» be familiar with the valid accident prevention regulations,
» have read and understood the operating manual,
» adhere to the safety instructions provided in the operating manual
Untrained specialist personnel is trained by an experienced person. Transport, storage, commissioning,
maintenance and upkeep must be carried out exclusively by qualified and trained specialist personnel.
3.3 Personal protective equipment
During the different work operations on and with the valve, the personnel must wear personal protective
equipment, which is referred to separately in the individual sections of this manual.

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Description of the personal protective equipment
The following explains the personal protective equipment:
Protective gloves
The heat-repellent protective gloves are used to protect against hot pipelines and against
crushing. The protective gloves are needed during the assembly and disassembly work on
the pipeline.
Safety shoes
Safety shoes protect the feet from crushing, falling parts and slipping on slippery surfaces.
Safety goggles
The safety goggles are used to protect the eyes from hot, cold, aggressive or caustic
medium, during assembly, disassembly and maintenance, when working with cutting tools.
Protective clothing
The close-fitting protective clothing serves to protect the body from hot, cold, aggressive or
caustic media.
3.4 Structural modification
Structural modifications to the entire scope of delivery may impair the safety of the product. For this reason,
structural modifications are impermissible and must never be carried out without prior consultation with the
manufacturer. Modification causes any attached declaration of conformity to lose its validity.
3.5 Environmental protection
Materials causing groundwater pollution, such as greases, oils, coolants and solvent-based cleaning fluids, must
not be released into the environment.
4 Installation and commissioning
The following chapter describes the installation and adjustment of the valve.
4.1 Plant requirements
The plant must meet the requirements for safe use of the product.
Plant structure
For safe operation of the valve in the plant, the basic requirements must be met. In the following chapter, a
functional structure is described in more detail. The layout is in the responsibility of the operator.

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Application example
Illustration1:
1 Strainer 5 Pressure gauge
2 Shut-off valves 6 Connecting a leak line
3 Pressure reducing valve* 7 Bypass
4 Safety valve
Strainer
Optional, for fluids with particles.
Shut-off valves
Shut-off devices must be provided upstream and downstream of the pressure reducing valve for installation,
maintenance and tight system closure. When closing the shut-off devices, the valve upstream of the pressure
reducing valve must always be closed first. A bypass may be necessary for emergency operation.
Pressure reducing valve
The pressure reducing valve reduces the fluctuating higher inlet pressure of an operating medium to an
adjustable constant outlet pressure within a control deviation Pressure reducing valves are not shut-off devices
which ensure a tight valve closure.
Safety valve
For safety reasons, a safety valve must be installed on the outlet pressure side of the valve. It is dimensioned
and adjusted so that the maximum permissible outlet pressure (MAWP outlet) of the valve is not exceeded, see
nameplate.
Pressure gauge
A pressure gauge must be installed downstream of the pressure reducing valve in order to start up and adjust
the pressure reducing valve and to check whether the pressure reducing valve is depressurized.
Bypass for maintenance
For emergency operation or pressure tests in the plant, or for maintenance of the valve, a bypass is
recommended.
Nozzle loads
The forces and moments from the table of nozzle loads below are absorbed via the connections of the pipeline.
Forces and moments exceeding these values must be absorbed by other measures taken by the operator. The
support may only be provided at the connections and not at the body itself.

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Specification of nozzle loads
There are a maximum of six components of additional external loads: FX, FY, FZ, MX, MY, MZ.
Torsion is only significant for very large nozzle diameters and very small cylinder wall thickness. Lateral forces
are of secondary importance.
4.2 Installation
DANGER
Danger from pressurized medium streaming out
Assembly work on system parts that are under pressure may lead to serious injuries.
Work on the valve must only be carried out on pressure-free pipes, and pressure
applications must be excluded during the work! In cases of maintenance, installation and
removal, the piping must be emptied. Before starting work, perform a pressure
compensation. Wear personal protective equipment, protective gloves, safety eyewear and
hearing protection.
NOTICE
Risk of material damage due to tensions, vibrations and oscillations.
Tensions, vibrations and oscillations during ongoing operation may cause damage to the
valve. The valve must be installed free of stress, vibrations and oscillations.
NOTICE
Risk of material damage due to incorrect installation position
Installation in vertical pipelines causes control inaccuracies and increased wear.
The valve must be installed horizontally, with the bonnet pointing upwards or downwards!
NOTICE
Qualified personnel required
The personnel must be trained to assemble and install the valve properly.
Preparation
» The installation site should be a horizontal section of the pipe without any flow disruptions. Elbows, shut-off
valves or any other thottling point close to the valve, either upstream or downstream, should be avoided.
» The valve must be installed with sufficient space to set the adjusting screw!NOTICE!
» The plant is depressurized, shut off valves are secured and marked.
» Pipelines have been flushed and there are no foreign objects > 0.5 mm present in the system. Connections
on the system side are clean and flat.
» The valve is clean and undamaged.
»CAUTION!Do not install damaged valves! Contact the manufacturer, see section Contact.
» The packaging and plastic plugs are removed.

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Procedure
1. Place and align the valve in the pipeline.
NOTICE!Observe flow direction! The arrow on the body must point in the direction of flow.
2. Insert the gasket and fix the connections on both sides.
The gasket must not protrude into the flow-through area!
3. Tighten the wing screws hand-tight.
NOTICE!The nozzle loads of the valve must not be exceeded.
4. Connect leakage line in case of hazardous fluids.
Further information
»Nozzle loads [Page9]
»
4.3 Pressure resistance test
Testing the pressure resistance of the plant
NOTICE
There is a risk of material damage due to a plant test with excessive pressure.
For safety reasons, it is not permissible to test the pressure resistance of the plant at the
customer’s facility with the valve installed.
Carry out the pressure test using the bypass or replace the valve with a pipe during the
pressure test.
Tightness test of the valve
The pressure, seat tightness and function test of the valve has already been carried out by the manufacturer
Mankenberg prior to the delivery.
Depending on the type of medium, a suitable leak detection fluid must be used during the tightness test.
NOTICE
Risk of material damage due to excessive inlet pressure.
Excessive plant pressure will damage the valve. Do not exceed the maximum inlet pressure
specified on the nameplate!
Preparation
» The pressure reducing valve has been installed.
» The plant was installed and adjusted according to the installation diagram.
» The safety valve is in operation and secures the outlet pressure side of the plant.
» The shut-off devices located upstream and downstream are closed.

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4.4 Commissioning and setting the operating point
NOTICE
Warning of material damage by non-tensioned spring in the valve
The spring is not preloaded in the delivery condition, the valve is not ready for operation. The
inlet pressure to be controlled must be set via the adjusting screw in the valve.
Preparation
» The tightness test has been completed.
» The upstream-sided shut-off device is open.
» The downstream-sided shut-off device is closed.
» The spring is released. Unscrew the adjusting screw (1) until it is still in the thread but there is no longer any
noticeable resistance to rotation. Further unscrewing would cause the adjusting screw to fall out.
Procedure
1. Slowly open the outlet-sided shut-off device until the volume flow to be controlled has been reached.
2. Set the outlet pressure with the help of the adjusting screw.
– Turning clockwise increases the outlet pressure to be controlled.
– Turning counterclockwise reduces the outlet pressure to be controlled.
3. Check the outlet pressure to be controlled via the downstream-sided pressure indicator.
Subsequent work
» Perform a visual function check.

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5 Operation
After commissioning, a correctly designed and adjusted valve operates self-actingly within its setting range and
does not require any auxiliary energy.
WARNING
Warning against hot or cold surfaces
Risk of burns when touching hot or cold surfaces or leaking medium from the valve. The
surface of the valve can be hot or cold because of hot or cold medium! Wear personal
protective equipment, according to the medium: skin or eye protection. Observe the
operator's safety measures.
NOTICE
Risk of material damage caused by frost
Frozen liquids can cause unreliable control behavior, failure or damage to the valve.
If the valve is installed in rooms that are not frost-free, suitable measures must be taken
during plant shutdowns.

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6 Maintenance
Product Maintenance procedure
DM 462V
Replacing the maintenance kit 462V
[Page18]
DM 462VG
Replacing the maintenance kit 462VG
[Page29]

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6.1 DM 462V
General view DM 462V

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DM 462V / DM 462VG-4.X.231 Issue 30.06.2023
Parts list DM 462V
Item Qty. Designation Maintenance kit
1 1 Body (angled design)
1 1 Body (straight design)
2 1 cone
6 1 Diaphragm disc
10 1 Spring module
11 1 Bonnet
12 1 Adjusting screw
15 1 Cone stem
17 1 O-ring *
18 1 O-ring *
19 1 Diaphragm *
20 1 Protection foil *
21 1 Cone stem
23 1 Cover (angled design)
23 1 Cover (straight design)
27 1 Spring washer *
28 1 Hexagon nut
31 2 O-ring *
35 1 O-ring *
53 1 Piston
56 1 Profile clamp
57 1 O-ring *
58 1 Seal *
67 2 Turcite B-band *
70 1 Profile clamp

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Maintenance schedule
The self-acting function of the valve requires maintenance for proper operation. It is important that maintenance
work is planned and carried out at periodic intervals.
Depending on the properties of the fluid and the operating conditions in the plant, maintenance must be carried
out annually or even at shorter intervals.
The maintenance schedule is a recommendation to be supplemented as it proved/has proven to be effective for
the user under the operating conditions.
Kind of maintenance Work to be performed Interval
Replace the
maintenance kit
Perform a visual check of the functional parts, change
the maintenance kit, if necessary.
yearly
Lubrication Lubricate the valve yearly
All dynamically stressed O-rings are designed for an operating life of at least two years. Under extreme
operating conditions (dirt particles, corrosion, etc.), severe wear may occur, requiring shorter maintenance
intervals.
Test plan
Tests during operation
The self-acting valve requires regular checks for proper operation.
Action Work to be performed Interval
Visual check Visual function control monthly
Visual check Check for corrosion. monthly
Visual check Check for leakage. monthly
Visual check Check for damage and deformation. monthly
Lubrication schedule
Lubrication and sealing recommendation
Lubricant Application
Winix 5950 O-rings, guide belts, seal element and piston seals
WINIX 5650 (with NSF H1 approval) in the food sector
, O-rings, guide belts, seal element and piston seals
OKS 252 screw connections

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Replacing the maintenance kit 462V
CAUTION
Pretension of the spring at the bonnet
During disassembly, the spring preload of the bonnet may cause an impact and injury to
personnel.
» Release the spring prior to opening.
CAUTION
Risk of splashing due to medium
When screw connections are opened or screws are loosened, there is a risk of medium
spraying out.
» Perform pressure equalization prior to opening the valve.
NOTICE
The maintenance kit does not comprise standard parts.
Dimensions and material specification of standard parts such as screws, nuts, washers
should be taken from the part to be replaced or from the parts list. If the material cannot be
determined, contact the manufacturer Mankenberg.
Tools Tool required for
Allen key SW 8 Profile clamp item 56
Allen key SW 10 Setting the pressure, item 12
Open-ended spanner SW 7 Lower part of cone stem, item 21
Upper part of cone stem, item 15
Open-ended spanner SW 13 Profile clamp item 56
Open-ended spanner SW 19 Cone, item 2
Claw key SW19 Hexagon nut, item 28

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1)
Depressurize the valve, release the spring
completely, for this purpose unscrew the adjusting
screw M 12 (item 12) counterclockwise.
Remove O-ring (item 57) from the adjusting screw.
57
12
11
56
2)
After releasing the hexagon socket screws and
removing the profile clamp (item 56), the bonnet
(item 11) is carefully pulled off upwards.
11
53
58
1
3)
Dismount profile clamp (item 70) and cover (item 23)
with O-ring (item 35).
53
58
35
23
70

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4)
Remove hexagon nut M12 (item 28) with spring
washer (item 27) and pull the piston off upwards.
When loosening the hexagon nut, the stem (item 21)
may have to be secured against rotation by holding
it in place with a suitable tool.
28
27
53
31
58
5)
Remove diaphragm (item 19) with protective foil
(item 20), diaphragm disc (item 6) and, if installed,
the gasket (item 58) and O-ring (item 31).
Carefully pull the stem assembly (item 21)
downwards out of the body.
31
1
6
20
19
58
21