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.