Samson 45-9 Service manual

Translation of original instructions
EB 3128 EN
Type 45-9 Flow Regulator
Self-operated Regulators
Edition April 2019

Note on these mounting and operating instructions
These mounting and operating instructions assist you in mounting and operating the device
safely. The instructions are binding for handling SAMSON devices.
ÎFor the safe and proper use of these instructions, read them carefully and keep them for
later reference.
ÎIf you have any questions about these instructions, contact SAMSON‘s After-sales Service
Department (aftersalesser[email protected]).
The mounting and operating instructions for the devices are included in
the scope of delivery. The latest documentation is available on our website
at www.samson.de > Service & Support > Downloads > Documentation.
Denition of signal words
Hazardous situations which, if not avoided,
will result in death or serious injury
Hazardous situations which, if not avoided,
could result in death or serious injury
Property damage message or malfunction
Additional information
Recommended action
DANGER
!
WARNING
!
NOTICE
!
Note
Tip
2 EB 3128 EN

Contents
EB 3128 EN 3
1 Safety instructions and safety measures .........................................................5
1.1 Notes on possible severe personal injury .........................................................8
1.2 Notes on possible personal injury ...................................................................8
1.3 Notes on possible property damage................................................................9
2 Markings on the device ...............................................................................11
2.1 Nameplate ..................................................................................................11
2.2 Nameplate position......................................................................................11
2.3 Material number..........................................................................................11
3 Design and principle of operation ................................................................12
3.1 Technical data .............................................................................................14
3.1.1 Process medium and scope of application......................................................14
4 Measures for preparation............................................................................19
4.1 Unpacking ..................................................................................................19
4.2 Transporting and lifting ................................................................................19
4.3 Storage.......................................................................................................19
5 Mounting and start-up.................................................................................20
5.1 Preparation for installation............................................................................20
5.2 Checking the installation conditions...............................................................21
5.2.1 Mounting position........................................................................................21
5.3 Additionalttings.........................................................................................22
6 Start-up and operation ................................................................................23
6.1 Start-up.......................................................................................................23
6.1.1 Installing the regulator..................................................................................23
6.1.2 Pipelineushing...........................................................................................24
6.1.3 Pressure test.................................................................................................24
6.2 Operation ...................................................................................................25
6.3 Starting up the plant.....................................................................................25
6.4 Adjusting the set point..................................................................................25
7 Maintenance ...............................................................................................29
7.1 Replacing the restriction................................................................................31
7.2 Replacing the seat and plug..........................................................................32

Contents
4 EB 3128 EN
7.3 Replacing the operating diaphragm ..............................................................33
7.4 Lubricants and sealants ................................................................................34
7.5 Tighteningtorquesandwidthacrossats .......................................................35
7.6 Accessories and tools ...................................................................................35
7.7 Preparation for return shipment.....................................................................36
7.8 Ordering spare parts and operating supplies .................................................36
8 Malfunctions ...............................................................................................36
9 Decommissioning and removal ....................................................................38
9.1 Decommissioning.........................................................................................39
9.2 Disposal......................................................................................................39
10 Appendix....................................................................................................39
10.1 After-sales service........................................................................................39
10.2 Spare parts .................................................................................................40
10.3 Certicates ..................................................................................................41

EB 3128 EN 5
Safety instructions and safety measures
1 Safety instructions and safety measures
Intended use
TheType45-9Regulatorisusedforowcontrol.Itismainlyusedindistrictheatingsupply
networksandindustrialplants.Theregulatorisdesignedtooperateunderexactlydened
conditions (e.g. operating pressure, process medium, temperature). Therefore, operators must
ensurethatthecontrollerisonlyusedinoperatingconditionsthatmeetthespecications
used for sizing the controller at the ordering stage. In case operators intend to use the device
inotherapplicationsorconditionsthanspecied,contactSAMSON.
SAMSON does not assume any liability for damage resulting from the failure to use the de-
vice for its intended purpose or for damage caused by external forces or any other external
factors.
ÎRefertothetechnicaldataandnameplateforlimitsandeldsofapplicationaswellas
possible uses.
Reasonably foreseeable misuse
The regulator is not suitable for the following applications:
−Useoutsidethelimitsdenedduringsizingandbythetechnicaldata
Furthermore, the following activities do not comply with the intended use:
−Use of non-original spare parts
−Performing service and repair work not described in these instructions
Qualications of operating personnel
The regulator must be mounted, started up, serviced and repaired by fully trained and quali-
edpersonnelonly;theacceptedindustrycodesandpracticesaretobeobserved.Accord-
ing to these mounting and operating instructions, trained personnel refers to individuals who
are able to judge the work they are assigned to and recognize possible hazards due to their
specialized training, their knowledge and experience as well as their knowledge of the appli-
cable standards.

6 EB 3128 EN
Safety instructions and safety measures
Personal protective equipment
We recommend checking the hazards posed by the process medium being used (e.g.
uGESTIS(CLP)hazardoussubstancedatabase).
ÎProvide protective equipment (e.g. safety gloves, eye protection) appropriate for the pro-
cess medium used.
ÎWear hearing protection when working near the valve.
ÎCheck with the plant operator for details on further protective equipment.
Revisions and other modications
Revisions,conversionsorothermodicationsoftheproductarenotauthorizedbySAMSON.
They are performed at the user's own risk and may lead to safety hazards, for example. Fur-
thermore, the product may no longer meet the requirements for its intended use.
Warning against residual hazards
To avoid personal injury or property damage, plant operators and operating personnel must
prevent hazards that could be caused in the device by the process medium, the operating
pressure or by moving parts by taking appropriate precautions. They must observe all haz-
ard statements, warning and caution notes in these mounting and operating instructions, es-
pecially for installation, start-up and service work.
We also recommend checking the hazards posed by the process medium being used (e.g.
uGESTIS(CLP)hazardoussubstancedatabase).
ÎObservesafetymeasuresforhandlingthedeviceaswellasrepreventionandexplosion
protection measures.
Safety features
TheType45-9Regulatordoesnothaveanyspecialsafetyfeatures.Whenrelievedofpres-
sure, the regulator is opened by the force of the set point springs.
Responsibilities of the operator
The operator is responsible for proper operation and compliance with the safety regulations.
Operators are obliged to provide these mounting and operating instructions as well as the
referenced documents to the operating personnel and to instruct them in proper operation.
Furthermore, the operator must ensure that operating personnel or third persons are not ex-
posed to any danger.

EB 3128 EN 7
Safety instructions and safety measures
Responsibilities of operating personnel
Operating personnel must read and understand these mounting and operating instructions as
wellasthereferenceddocumentsandobservethespeciedhazardstatements,warnings
and caution notes. Furthermore, the operating personnel must be familiar with the applicable
health, safety and accident prevention regulations and comply with them.
Referenced standards and regulations
TheregulatorscomplywiththerequirementsoftheEuropeanPressureEquipmentDirective
2014/68/EU.DeviceswithaCEmarkinghaveanEUdeclarationofconformity,whichin-
cludesinformationabouttheappliedconformityassessmentprocedure.ThisEUdeclaration
ofconformityisincludedintheAppendixoftheseinstructions(seesection10.2).
AccordingtotheignitionriskassessmentperformedinaccordancewithEN13463-1:2009,
section 5.2, the non-electrical regulators do not have their own potential ignition source even
in the rare incident of an operating fault. As a result, they do not fall within the scope of Di-
rective 2014/34/EU.
ÎForconnectiontotheequipotentialbondingsystem,observetherequirementsspeciedin
section6.4ofEN60079-14(VDE0165Part1).
Referenced documentation
The following documents apply in addition to these mounting and operating instructions:
−Mounting and operating instructions for
e.g. Type1N and Type1NI Strainers uEB1010EN
−Mounting and operating instructions as well as data sheets for additional components
(e.g. shut-off valves, pressure gauges etc.).

8 EB 3128 EN
Safety instructions and safety measures
1.1 Notes on possible severe personal injury
DANGER
!
Risk of bursting in pressure equipment.
Regulators and pipelines are pressure equipment. Improper opening can lead to device
components bursting.
ÎObserve the maximum permissible pressure for regulator and plant.
ÎBeforestartinganyworkonthedevice,depressurizeallplantsectionsconcerned
as well as the regulator.
ÎDrain the process medium from all the plant sections concerned as well as the reg-
ulator.
ÎIf necessary, a suitable overpressure protection must be installed on site in the plant
section.
ÎWear personal protective equipment.
1.2 Notes on possible personal injury
WARNING
!
Risk of personal injury due to residual process medium in the regulator.
While working on the regulator, residual process medium can escape and, depending
on its properties, may lead to personal injury, e.g. (chemical) burns.
ÎIf possible, drain the process medium from all the plant sections concerned and the
regulator.
ÎWear protective clothing, safety gloves and eyewear.

EB 3128 EN 9
Safety instructions and safety measures
WARNING
!
Risk of burn injuries due to hot or cold components and pipelines.
Depending on the process medium, regulator components and pipelines may get very
hot or cold and cause burn injuries.
ÎAllow components and pipelines to cool down or heat up.
ÎWear protective clothing and safety gloves.
Damage to health relating to the REACH regulation.
If a SAMSON device contains a substance which is listed as being a substance of very
highconcernonthecandidatelistoftheREACHregulation,thiscircumstanceisindicat-
ed on the SAMSON delivery note.
ÎInformation on safe use of the part affected, see uwww.samson.de/reach-en.html.
1.3 Notes on possible property damage
NOTICE
!
Risk of regulator damage due to contamination (e.g. solid particles) in the pipeline.
The plant operator is responsible for cleaning the pipelines in the plant.
ÎFlush the pipelines before start-up.
Risk of regulator damage due to unsuitable medium properties.
Theregulatorisdesignedforprocessmediawithdenedproperties.
ÎOnlyuseprocessmediaspeciedforsizingthevalve.
Risk of regulator damage due to incorrectly attached slings.
ÎDo not attach load-bearing slings to the regulator.

10 EB 3128 EN
Safety instructions and safety measures
NOTICE
!
Risk of regulator damage due to the use of unsuitable lubricants.
The lubricants to be used depend on the regulator material. Unsuitable lubricants may
corrode and damage the surface.
ÎOnly use lubricants approved by SAMSON. When in doubt, consult SAMSON.
Risk of leakage and regulator damage due to excessively high or low tightening
torques.
Observethespeciedtorquesontighteningregulatorcomponents.Excessivelytight-
ened torques lead to parts wearing out quicker. Parts that are too loose may cause
leakage.
ÎObservethetighteningtorquesspeciedinsection7.5.
Risk of regulator damage due to the use of unsuitable tools.
Certain tools are required to work on the regulator.
ÎOnly use tools approved by SAMSON. When in doubt, consult SAMSON.
Incorrect control due to the formation of ice on the regulator.
Mediumtemperaturesbelow0°Cmaycauseicetoformontheregulator,depending
on the air humidity. This may affect, in particular, the functioning of the actuator stem
guide or set point adjuster.
ÎPrevent the formation of ice by taking appropriate precautions (e.g. enclosure,
trace heater etc.). The plant operator is responsible for selecting and implementing
appropriate precautions.
Regulator damage due to condensed glycol.
In principle, the materials are also resistant to high concentrations of glycol. Neverthe-
less, glycol reacts when it comes into contact with metals and causes acids to form. We
cannot prevent this reaction.
ÎUse suitable inhibitors. The plant operator is responsible for selecting and using
suitable inhibitors.

EB 3128 EN 11
Markings on the device
2 Markings on the device
2.1 Nameplate
1
23
45
6
7
8
9
10
1CongurationID
2 Model number
3 Date of manufacture
4 KVScoefcient
5 Pressure rating PN
6 Differential pressure set point range in bar
7 Type designation
8 Flow rate set point range in m³/h
9Maximumpermissibletemperaturein°C
10 Max.permissibledifferentialpressure∆pin
bar
Fig.1: Nameplate
2.3 Material number
The material designation can be found on
the cast body or you can contact us (the con-
gurationIDspecicationisneeded)tond
outwhichmaterialisused.Theconguration
IDisspeciedonthenameplate(1,congu-
ration ID). For more details on the name-
plate,seeFig.1.
2.2 Nameplate position
Thenameplateofallsizesisafxedtothe
body(seeFig.2).
Nameplate
position on
the bodies
Fig.2: Nameplate on the bodies

12 EB 3128 EN
Design and principle of operation
3 Design and principle of oper-
ation
Theowregulatorbasicallyconsistsofa
valve body (1) with restriction (8.5), bal-
anced plug (3) as well as a closing actuator
(6) with an operating diaphragm (6.1). The
differential pressure springs (5) installed in
thevalvebodydeterminetheowrate.
The regulator is designed to maintain the
owrateattheadjustedsetpointinheating
and district heating systems. The valve closes
whentheowraterises.
Themediumowsthroughtheregulatorin
the direction indicated by the arrow. The ar-
eas released by the adjustable restriction
(8.5) and the valve plug (3) determine the
owrate.Thedifferentialpressuresprings
(5) determine the differential pressure across
therestrictionof0.2bar.
The upstream pressure is transmitted to the
upstream pressure side of the operating dia-
phragm (6.1) in the actuator over the control
line (11). The pressure downstream of the re-
striction (8.5) is transmitted through a hole in
the plug to the downstream pressure side of
the operating diaphragm. The resulting dif-
ferential pressure creates a positioning force
at the operating diaphragm (6.1) which
moves the plug depending on the force of
the differential pressure spring (5). The maxi-
mumowrateisadjustedattherestriction
(8.5) using the set point screw (8.3). The
cross-section of the valve is changed in such
a way that the differential pressure and the
differential pressure created at the restriction
are identical when the required maximum
owrateexists.
PN16·DN15 to 25
11.1 7 6.1
Legend for Fig.3 and Fig.4
1Valvebody
1.4 Coupling nut
2 Seat
3Guidenipplewithplug
3.1 Plug balancing
3.5 Plug nipple
3.6 Seal
4 Plug stem
5Differential pressure
springs
6 Actuator
6.1 Operating diaphragm
7 Diaphragm case
8 Connecting piece
8.1 Restriction stem
8.2 Lock nut
8.3 Set point screw
8.4 Lead-seal hole
8.5 Restriction
8.6 Cap
8.7 Seal
11 Control line
11.1 Screwtting
15 Screws
Fig.3: Functional diagram of Type45-9

EB 3128 EN 13
Design and principle of operation
PN25·DN15 to 25
11 4
3
5
6
15
6.1
2
1.4
1
8.5
8.2
8.3
8.6
8
8.1
8.4
8.7
7
3.6
3.1
11.1
PN25·DN32 to 50
11 4
3.6
3.5
6
15
6.1
2
1
8.5
8.4
8.3
8.6
8
8.1
8.2
8.
7
7
3
3.1
5
11.1
Fig.4: Functional diagram of Type45-9

14 EB 3128 EN
Design and principle of operation
3.1 Technical data
3.1.1 Process medium and
scope of application
Flow control for district heating systems, ex-
tended piping systems and industrial appli-
cations
−Suitable for gases and liquids
−Max. temperature for liquids1) 150°C
−Max. temperature for gases
80°C·150°C2)
−Flow range, max. 14.1m³/h
−Differential pressure across the restriction
∆prestriction0.2bar
−ValvesizeDN15 to 50
−Pressure rating PN16 and 25
Thevalvecloseswhentheowrateexceeds
the adjusted set point.
_
1) The materials used in the regulator are also
resistant to high concentrations of glycol.
Nevertheless, glycol reacts when it comes into
contact with metals and causes acids to form.
We cannot prevent this reaction. Therefore,
prevent it by using suitable inhibitors.
2) Suitable for air and nitrogen with diaphragm
LuftandsealsmadeofFKMandPN25
version
Noise emission
SAMSON is unable to make general state-
ments about noise emission as it depends on
the regulator version, plant facilities, process
medium and operating conditions.
Risk of hearing loss or deafness due to loud
noise.
Wear hearing protection when working near
the regulator.
The Type45-9 Regulator is not a safety
valve. If necessary, a suitable overpressure
protection must be installed on site in the
plant section.
Dimensions in mm · Weights in kg
The lengths and heights in the dimensional
drawingsareshowninpage17onwards.
WARNING
!
Note

EB 3128 EN 15
Design and principle of operation
Table1: Technical data
Valve size DN 15 20 25 322) 402) 502)
KVScoefcient 0.41) 1.01) 2.5 4.01) 6.3 8.0 12.5 16.0 20.0
Flanged body – 12.5 20.0 25.0
xFZ value 0.6 0.55 0.5 0.45
Flanged body – 0.45 0.40
Pressure rating PN16·PN25 PN 25
Max. permissible
differential pressure
∆pacrossthevalve
10bar3)/20bar 16bar
Max. permissible
medium temperature Liquids130°C(PN16)·150°C(PN25)·Nitrogenandair80°C·150°C4)
Permissible ambient
temperature 0to+50°C
Compliance ·
Flow rate set point ranges for water in m³/h
Diff.
pressure
at the
restriction
Δprestriction
0.2bar
–––0.1 to
1.35)
0.1 to
2.35)
0.1 to
3.55)
0.3 to
5.85)
0.4 to
9.15)
0.4 to
14.15)
0.01
to 0.2
0.02
to
0.64
0.02
to 1.2
0.1 to
2.5
0.1 to
3.6
0.1 to
4.2
0.3
to 10
0.4 to
12.5
0.4
to 15
0.3bar –––0.1
to 3 –0.1 to 5 –––
3) Special versions
4) Additionalversion:Valvewithangedbodymadeofspheroidalgraphiteiron
5) ForPN16version
6) DiaphragmandsealsmadeofFKM(PN25only)
7) Anincreaseinnoiselevelcanbeexpectedwhenthespeciedowratesareexceeded,evenif
cavitation does not occur.

16 EB 3128 EN
Design and principle of operation
The minimum required differential pressure
Δpmin across the valve is calculated as follows: Δpmin =Δprestriction +
(
V
)
2
KVS
·
Δpmin Minimum differential pressure in bar across the valve
Δprestriction Differentialpressurecreatedattherestrictionformeasuringtheowrate
V
·Adjustedowrateinm³/h
KVS Valveowcoefcientinm³/h
Table2: Materials
Body Red brass CC499K (Rg5) · Spheroidal graphite iron EN-GJS-400-18-LT1)
Seat Stainless steel 1.4305
Plug PN 25 Brass(resistanttodezincication)withEPDM2) soft seal
PN16 Brass,resistanttodezincicationandplasticwithEPDMsoftseal
Diaphragm
case
PN 25 RedbrassCC499K(Rg5)·SpheroidalgraphiteironEN-GJS-400-18-LT1)
PN16 Stainless steel 1.4301
Valvespring Stainless steel 1.4310
Restriction Brass,freeofdezincication
Operating diaphragm EPDM2) with fabric reinforcement
Seals EPDM2)
1) AdditionalversioninDN32,40and50:valvewithangedbodymadeofspheroidalgraphite
iron
2) SpecialversioninPN25,e.g.formineraloils:FKM

EB 3128 EN 17
Design and principle of operation
Dimensional drawings
ød
R
L
L1
SW
H
H1
ØD
H1
H
ØD
L3
Red brass valve with welding ends (standard version) Valvemadeofspheroidalgraphiteiron
withanges(DN32,40and50)
A
L
L2
SW
L
L3
SW
With threaded ends Withscrew-onanges(DN15to25)
Fig.5: Dimensional drawings

18 EB 3128 EN
Design and principle of operation
Table3: Regulator with connecting parts · Dimensions in mm and weights in kg
Valve size DN15 DN20 DN25 DN32 DN40 DN50
With welding ends
Length L1 210 234 244 268 294 330
Weight, approx. kg 1.6 1.7 1.8 3 5.5 6
With threaded ends
Length L2 129 144 159 192 206 228
Male thread A G1½ G¾ G1 G1¼ G1½ G2
Weight, approx. kg 1.6 1.7 1.8 3 5.5 6
With anges 1) or with anged body(DN32to50)
Length L3 130 150 160 180 200 230
Weight, approx. kg 3 3.7 4.3 6.2 9.5 11
1) PN16/25
Thedimensionsandweightsofvalveswithangedbodies(DN32,40and50)arethesameasvalveswith
screwed-onanges.
Table4: Regulators without connecting parts · Dimensions in mm
Valve size DN15 DN20 DN25 DN32 DN40 DN50
Connecting thread R G¾ G1 G1¼ G1¾ G2 G2½
Pipe Ød 21.3 26.8 32.7 42 48 60
Widthacrossats
SW
30 36 46 59 65 82
Length L 65 70 75 100 110 130
H65 65 65 85 85 85
H1 85 85 85 105 140 140
ØD 116 116 116 116 160 160

EB 3128 EN 19
Measures for preparation
4 Measures for preparation
After receiving the shipment, proceed as fol-
lows:
1. Check the scope of delivery. Compare
the shipment received with the delivery
note.
2. Check the shipment for transportation
damage. Report any damage to SAM-
SON and the forwarding agent (refer to
delivery note).
4.1 Unpacking
Risk of regulator damage due to foreign par-
ticles entering the valve.
The protective caps tted on the valve's inlet
and outlet prevent foreign particles from en-
tering the valve and damaging it.
Do not remove the protective caps until im-
mediately before installing the valve into the
pipeline.
Do not remove the packaging until immedi-
ately before installation.
Proceed as follows to lift and install the de-
vice:
1. Remove the packaging from the device.
2. Dispose of the packaging in accordance
with the valid regulations.
NOTICE
!
Note
4.2 Transporting and lifting
Due to the low service weight, lifting equip-
ment is not required to lift and transport the
regulator (e.g. to install it into the pipeline).
Transport instructions
−Protectthedeviceagainstexternalinu-
ences (e.g. impact).
−Do not damage the corrosion protection
(paint, surface coatings). Repair any
damage immediately.
−Protect the device against moisture and
dirt.
−Observe the permissible ambient tem-
peratures(seesection3.1).
4.3 Storage
Risk of regulator damage due to improper
storage.
−Observe storage instructions.
−Avoid long storage times.
−Contact SAMSON in case of different stor-
age conditions or long storage periods.
We recommend regularly checking the de-
vice and the prevailing storage conditions
during long storage periods.
NOTICE
!
Note

20 EB 3128 EN
Mounting and start-up
Storage instructions
−Protectthedeviceagainstexternalinu-
ences (e.g. impact).
−Do not damage the corrosion protection
(paint, surface coatings). Repair any
damage immediately.
−Protect the device against moisture and
dirt. Store it at a relative humidity of less
than75%.Indampspaces,preventcon-
densation. If necessary, use a drying
agent or heating.
−Make sure that the ambient air is free of
acids or other corrosive media.
−Observe the permissible ambient tem-
peratures(seesection3.1).
−Do not place any objects on the device.
Special storage instructions for elastomers
Elastomer,e.g.diaphragm
−To keep elastomers in shape and to pre-
vent cracking, do not bend them or hang
them up.
−We recommend a storage temperature of
15°Cforelastomers.
−Store elastomers away from lubricants,
chemicals, solutions and fuels.
SAMSON's After-sales Service department
can provide more detailed storage instruc-
tions on request.
Tip
5 Mounting and start-up
5.1 Preparation for installation
Proceed as follows:
ÎFlush the pipelines.
The plant operator is responsible for clean-
ing the pipelines in the plant.
Any impurities carried along by the process
medium may impair the proper functioning
of the regulator. We recommend installing a
strainer (e.g. SAMSON Type1NI) upstream
of the ow regulator.
ÎCheck the regulator to make sure it is
clean.
ÎCheck the regulator for damage.
ÎCheck to make sure that the type desig-
nation, valve size, material, pressure rat-
ing and temperature range of the regula-
tor match the plant conditions (size and
pressure rating of the pipeline, medium
temperature etc.).
ÎCheck any mounted pressure gauges to
make sure they function.
Note
Note