Samson 46-5 Service manual

Translation of original instructions
EB 3130 EN
Edition November 2018
Type46-5 and Type46-6 Differential Pressure Limiters with Flow
Limitation
Self-operated Regulators
Type46-5
Type46-6

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 3130 EN

Contents
EB 3130 EN 3
1 Safety instructions and measures ...................................................................5
1.1 Notes on possible severe personal injury .........................................................8
1.2 Notes on possible personal injury ...................................................................9
1.3 Notes on possible property damage..............................................................10
2 Markings on the device ...............................................................................11
2.1 Material number..........................................................................................11
3 Design and principle of operation ................................................................12
3.1 Versions ......................................................................................................14
3.2 Mounting parts ............................................................................................14
3.3 Technical data .............................................................................................14
3.3.1 Process medium and scope of application......................................................14
4 Measures for preparation............................................................................18
4.1 Unpacking ..................................................................................................18
4.2 Transporting and lifting ................................................................................18
4.3 Storage.......................................................................................................18
4.4 Preparation for installation............................................................................19
5 Mounting and start-up.................................................................................20
5.1 Mounting position........................................................................................20
5.2 Additionalttings.........................................................................................21
5.3 Start-up.......................................................................................................22
6 Operation...................................................................................................23
6.1 Adjusting the set points.................................................................................23
6.1.1 Adjusting the differential pressure limit...........................................................23
6.1.2 Adjustingtheowlimitation..........................................................................24
6.1.3 Based on a known plant pressure drop ..........................................................24
6.1.4 Based on an unknown plant pressure drop.....................................................25
6.2 Pressure conditions in the plant and at the regulator........................................26
6.3 Sample application ......................................................................................27

Contents
4 EB 3130 EN
7 Servicing.....................................................................................................31
7.1 Cleaning and replacing the plug ...................................................................32
7.2 Replacing the diaphragm .............................................................................33
7.3 Tightening torques........................................................................................34
7.4 Preparation for return shipment.....................................................................34
7.5 Ordering spare parts and operating supplies .................................................34
8 Malfunctions ...............................................................................................34
9 Decommissioning and disassembly ..............................................................36
9.1 Decommissioning.........................................................................................37
9.2 Disposal......................................................................................................37
10 Annex.........................................................................................................37
10.1 After-sales service........................................................................................37
10.2 Certicates ..................................................................................................38

EB 3130 EN 5
Safety instructions and measures
1 Safety instructions and measures
Intended use
TheType46-5andType46-6Regulatorsaredesignedtolimitthedifferentialpressureand
owrate.Theregulatorsaremainlyusedindistrictheatingsupplynetworksandindustrial
plants.Theregulatorandactuatoraredesignedtooperateunderexactlydenedconditions
(e.g. operating pressure, process medium, temperature). Therefore, operators must ensure
thattheregulatorandactuatorareonlyusedinoperatingconditionsthatmeetthespecica-
tions used for sizing the devices at the ordering stage. In case operators intend to use the de-
vices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 3130 EN
Safety instructions and 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.
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 3130 EN 7
Safety instructions and 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Annex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).

8 EB 3130 EN
Safety instructions and 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.
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.

EB 3130 EN 9
Safety instructions and measures
1.2 Notes on possible personal injury
WARNING
!
Crush hazard arising from moving parts.
The regulator contains moving parts (actuator and plug stems), which can injure hands
orngersifinsertedintothevalve.
ÎDonotinserthandsorngersbetweenthesetpointspringswhiletheregulatorisin
operation.
ÎBefore performing any work on the regulator, depressurize the plant. Disconnect or
shut off the external control line.
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.
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.

10 EB 3130 EN
Safety instructions and measures
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.
ÎObserve the maximum permissible pressure for regulator and plant.
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 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7.3.
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 3130 EN 11
Markings on the device
2 Markings on the device
1
23
45
6
7
8
9
10
1CongurationID
2 Model number
3 Date of manufacture
4 KVS/CV
5 Pressure rating PN or Class
6Differential pressure set point range in bar or
psi
7 Type designation
8 Flow rate set point range in m³/h or gal/min
9Maximumpermissibletemperaturein°Cor°F
10 Max.permissibledifferentialpressure∆pin
bar or psi
Fig.1: Nameplate
2.1 Material number
SpecifyingthecongurationID,youcancon-
tactustondoutwhichmaterialisused.The
congurationIDisspeciedonthename-
plate(1,congurationID).Formoredetails
onthenameplate,seeFig.1.

12 EB 3130 EN
Design and principle of operation
3 Design and principle of oper-
ation
The combined regulators basically consist of
a valve body (1) with restriction (1.2) and
balanced plug (3) as well as a closing actua-
tor (6) with an operating diaphragm (6.1).
InType46-5,thesetpointsprings(8)inte-
grated into the valve determine the set point.
Whereas,inType46-6,thesetpointcanbe
adjusted by the set point springs (8) on the
actuator.
The regulators are used to limit the differen-
tialpressureandowratetotheadjustedset
points. The valve closes when the differential
pressure(owrate)increases.
Themediumowsthroughthevalveinthe
direction indicated by the arrow. The areas
released by the restriction (1.2) and the
valveplug(3)determinetheowrateand
thedifferentialpressure∆p.Theupstream
pressure is transmitted to the operating dia-
phragm (6.1) in the actuator over an exter-
nally routed control line (11). The pressure
downstream of the restriction (1.2) is trans-
mitted through a hole in the plug to the
low-pressure side of the operating dia-
phragm. The resulting differential pressure
creates a positioning force at the diaphragm
which moves the plug depending on the
force of the valve spring (5) or set point
springs(8).Themaximumowrate(ow
limitation) is adjusted at the restriction (1.2)
using the set point screw (17). The cross-sec-
tion of the valve is changed in such a way
that the differential pressure and the differen-
tial pressure created at the restriction are
identicalwhentherequiredmaximumow
rate exists. An overload protection (excess
pressure limiter) (6.4) in the actuator protects
the seat and plug from overload during ex-
ceptional operating conditions that could
lead to valve or plant damage.
Legend for Fig.2
1 Valve body
1.1 Connection nut with seal and
welding end
1.2 Restriction
2 Seat
3 Plug
4 Plug stem
5 Valve spring
6 Actuator
6.1 Operating diaphragm
6.2 Actuator stem
6.3 Nut
6.4 Internal excess pressure limiter
(overload protection)
8 Set point springs
9 Spring plate
10 Set point adjuster for differential
pressure
11 Control line (high pressure)
14 Bottom section with manual adjuster
15 Screws
16 Locknut
17 Setpointscrewforowrate
(hexagonsocketscrewSW4)
18 Cap
19 Manual adjuster
20 Spindle
21 Support
25 Stopper for plug
x = Turned into the plane of projection

EB 3130 EN 13
Design and principle of operation
Type46-6·Bodywithscrewedends Type46-5·Flanged valve body
11
6.3
2
3
4
6.4
17
16
18
5
15
6.1
Dp
6
6.2
9
10
8
1
1.2
1.1
xDp
1
17
16
18
1.2
2
3
4
5,
8
6
11
6.3
6.1
15
6.4
x
25
Type46-5·Bodywithscrewedends
11
6.3
2
3
17
16
18
6.4
5,
8
4
6.1
15
Dp
6
1
1.2
1.1
x
6.1
15
6.4
6.3
6
9
20
21
19
11
Dp
x
8
14
Fig.2: Functional diagram of Type46-5 and Type46-6 with body with anges and screwed ends
Type46-6·Withmanualadjuster,DN15to32
Δpsetpointrange0.2to1bar

14 EB 3130 EN
Design and principle of operation
3.1 Versions
Type46-5andType46-6DifferentialPres-
sureLimiterswithFlowLimitationarede-
signedforinstallationinthereturnowpipe,
e.g. a district heating station with indirect
connection.
−Type46-5·Withxeddifferentialpres-
surelimitandadjustableowrate·With
internal overload protection (excess pres-
sure limiter) in the actuator
−Type46-6 · With adjustable differential
pressureandowlimitation·Withinter-
nal overload protection (excess pressure
limiter) in the actuator
3.2 Mounting parts
SeeTable1.
3.3 Technical data
3.3.1 Process medium and
scope of application
Differentialpressureandowratelimitation
for district heating systems with indirect con-
nection, extended piping systems and indus-
trialapplications·DN15to50·PN16/25
Suitable for liquids 1)upto150°Candgas-
esupto80°C
The valve closes when the differential pres-
surerises.Theowrateislimited.
_
1) The materials used in the regulator are also
resistant to high concentrations of glycol. Nev-
ertheless, 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.
Dimensions in mm · Weights in kg
The lengths and heights in the dimensional
drawingareshowninpage17.
Table1: Connecting parts
Valve size DN15 DN20 DN25 DN32 DN40 DN50
Welding ends1) 1400-6500 1400-6501 1400-6502 1400-6509 1400-6510 1400-6511
Threaded ends1) 1400-6503 1400-6504 1400-6505 1400-6512 1400-6513 1400-6514
Gasket 8413-3000 8413-3001 8413-3002 8413-3003 8413-3004 8413-3005
1) Pair including gaskets

EB 3130 EN 15
Design and principle of operation
Table2: Technical data
Valve size DN15 DN20 DN25 DN321) DN401) DN501)
KVS coefcient 2.5 6.3 8 12.5 16 20
Special version 0.4·1·4–
Flanged body – 12.5 20 25
xFZ value (standard) 0.6 0.55 0.5 0.45
Flanged body – 0.45 0.45 0.4
Nominal pressure PN16·PN25 PN 25
Max. permissible differential
pressure∆pacrossthevalve 102)bar·20bar 16bar
Max. permissible temperature Forliquids130°C2)/150°C·Forairandnon-ammablegases80°C
Pressure above adjusted
differential pressure at which
internal excess pressure limiter
responds
0.5bar
Compliance ·
Differential pressure set point ranges
Type46-6·Continuously
adjustable set point 0.2to1·0.5to2bar
Type46-5·Fixedsetpoint 0.2,0.3,0.4or0.5bar
1) Additionalversion:valvewithangedbodymadeofspheroidalgraphiteiron(EN-GJS-400-18-LT)
2) ForPN16version
Table3: Flow rate set points for water in m³/h
Δpset
point
Δpplant Δprestriction
DN ... 15 20 25 32 401) 501)
KVS 0.4 12.5 4 6.3 812.5 16/202) 20/252)
0.2bar 0.1bar 0.1bar VMax. 0.14 0.45 0.85 1.8 2.6 3.0 7.1 8.9 10.7
Min. 0.01 0.12 0.2 0.5 0.8 0.8 2 3 4
0.5bar 0.3bar 0.2bar V Max. 0.2 0.65 1.2 2.5 3.6 4.2 10 12.5 14.12)
– – – 1.32) 2.32) 3.52) 5.82) 9.12) 14.12)
1) Additionalversion:valvewithangedbodymadeofspheroidalgraphiteiron(EN-GJS-400-18-LT)
2) Anincreaseinnoiselevelcanbeexpectedwhenthespeciedowratesareexceeded,evenifcavitationdoesnot
occur.
˙
˙

16 EB 3130 EN
Design and principle of operation
Table4: 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
L1 210 234 244 268 294 330
Weight,
approx. kg
46-5 1.6 1.7 1.8 3 5.5 6
46-6 2.0 2.1 2.2 3.2 10 10.5
With threaded ends
L2 129 144 159 192 206 228
Male thread A G½ G¾ G1 G1¼ G1½ G2
Weight,
approx. kg
46-5 1.6 1.7 1.8 3 5.5 6
46-6 2.0 2.1 2.2 3.2 10 10.5
With anges 1) 2) or with anged body (DN32 to 50)
L3 130 150 160 180 200 230
Weight,
approx. kg
46-5 3.0 3.7 4.3 6.2 9.5 11
46-6 3.4 4.1 4.7 6.4 14 15.5
1) PN16/25
2) FlangesarealreadymountedonvalvesinDN40and50.
Table5: Regulators without connecting parts · Dimensions in mm
Valve size DN15 DN20 DN25 DN321) DN401) DN501)
Pipe Ø d 21.3 26.8 32.7 42 48 60
WidthacrossatsSW 30 36 46 59 65 82
L65 70 75 100 110 130
H 65 85
H1 230 250 380
H2 160 180 -
H3 85 105 140
ØD 116 160
1) Additionalversion:valvewithangedbody
Thedimensionsandweightsofvalveswithangedbodies(DN32,40and50)arethesameasvalveswithscrewed-
onanges.

EB 3130 EN 17
Design and principle of operation
Dimensional drawings
Fig.3: Dimensional drawings
L3
L
L3
L
L2
SW
SW
H3
ØD
L
SW
G /
18
R
d
L1
H
Ø116
SW
L1
L
R
d
H2
H
G /
18
ØD
H1
H
L1
L
SW
R
d
G /
18
Type46-6·Connectionnutswithweldingends
Connection nuts with
anges
Type46-5·Connectionnutswithweldingends
Type46-6·Withmanualadjuster,DN15to32,
setpointrange0.2to1bar
Withangedbody
(DN32,40and50)
Connection nuts with
threaded ends

18 EB 3130 EN
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
SAMSON and the forwarding agent
(refer to delivery note).
4.1 Unpacking
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.
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3.3).
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

EB 3130 EN 19
Measures for preparation
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3.3).
−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
4.4 Preparation for installation
Proceed as follows:
ÎFlush the pipelines.
The plant operator is responsible for clean-
ing the pipelines in the plant.
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

20 EB 3130 EN
Mounting and start-up
5 Mounting and start-up
5.1 Mounting position
Standard mounting position
ÎInstall the regulator in a horizontal pipe-
line with the actuator (6) facing down-
ward(seeFig.2).
TheregulatorinnominalsizesDN15to25
can also be installed in vertical pipes.
Installation conditions
−Make sure that the regulator remains
freely accessible after the plant has been
completed.
−Install a strainer (e.g. SAMSON
Type1NI)upstreamoftheregulator(see
section5.2).
−Thedirectionofowmustmatchthedi-
rection indicated by the arrow on the
body.
−Connect external control lines at the side
ofthemainpipe(seeFig.6)
−Install the regulator free of stress.
Possible malfunction and damage due to ad-
verse weather conditions (temperature, hu-
midity).
−Do not install the device outdoors or in
rooms prone to frost.
−Protect the regulator against frost if it is
used to control freezing media.
−Either heat the regulator or remove it from
the plant and completely drain the residual
medium.
−In district heating plants, only install the
regulators in return ow pipes.
NOTICE
!
Fig.4: Sample application
M
_
+
35
1
3 4
2
11
1
p
2
p
∆p
min
1 Shut-off valve
2 Strainer
3 Pressure gauge
4Type46-5/Type46-6
5 Motorized valve
= = = Control line to be attached on installing the regulator in the pipeline
Flow pipe
Returnowpipe