Samson 46-7 Service manual

Translation of original instructions
EB 3131 EN
Type46-7
Type47-5
Type47-1 with manual adjuster
Types46-7, 47-5 and 47-1 Self-operated Regulators
Flow and Differential Pressure or Pressure Regulators
Edition September 2020

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 3131 EN

Contents
EB 3131 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..............................................................11
2 Markings on the device ...............................................................................13
2.1 Material numbers.........................................................................................13
3 Design and principle of operation ................................................................14
3.1 Mounting parts ............................................................................................17
3.2 Versions ......................................................................................................17
3.3 Technical data .............................................................................................18
4 Measuresforpreparation ............................................................................22
4.1 Unpacking ..................................................................................................22
4.2 Transporting and lifting ................................................................................22
4.3 Storage.......................................................................................................22
4.4 Preparation for installation............................................................................23
5 Mountingandstart-up.................................................................................24
5.1 Mounting orientation....................................................................................24
5.2 Additionalttings.........................................................................................25
5.3 Putting the regulator into operation................................................................26
6 Operation...................................................................................................27
6.1 Adjusting the set points.................................................................................27
6.1.1 Flow control.................................................................................................27
6.1.2 Differential pressure control...........................................................................30
7 Servicing.....................................................................................................31
7.1 Cleaning and replacing the plug ...................................................................33
7.2 Replacing the diaphragm .............................................................................34
7.3 Tightening torques........................................................................................36
7.4 Preparation for return shipment.....................................................................36
7.5 Ordering spare parts and operating supplies .................................................36

Contents
4 EB3131EN
8 Malfunctions ...............................................................................................36
9 Decommissioning and removal ....................................................................39
9.1 Decommissioning.........................................................................................40
9.2 Disposal......................................................................................................40
10 Annex.........................................................................................................40
10.1 After-sales service........................................................................................40
10.2 Certicates ..................................................................................................41

EB 3131 EN 5
Safety instructions and measures
1 Safety instructions and measures
Intended use
TheType46-7andType47-5Regulatorsaredesignedforowrateanddifferentialpressure
control.TheType47-1Regulatorisdesignedforowrateanddifferentialpressurecontrolor
owrateandpressurecontrol.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cationsusedforsizingthedevicesattheorderingstage.In
caseoperatorsintendtousethedevices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.
According 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 applicable standards.

6 EB3131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substances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. Plant operators and operat-
ingpersonnelmustobserveallhazardstatements,warningandcautionnotesinthese
mounting and operating instructions, especially 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substancesdatabase).
ÎObservesafetymeasuresforhandlingthedeviceaswellasrepreventionandexplosion
protection measures.
Safety features
TheTypes46-7,47-5and47-1Regulatorsdonothaveanyspecialsafetyfeatures.When
relieved of pressure and with open restriction, the regulators are 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 parties are not ex-
posed to any danger.
Theoperatorisadditionallyresponsibleforensuringthatthelimitsfortheproductdenedin
the technical data are observed. This also applies to the start-up and shutdown procedures.

EB 3131 EN 7
Safety instructions and measures
Start-up and shutdown procedures fall within the scope of the operator's duties and, as such,
are not part of these mounting and operating instructions. SAMSON is unable to make any
statements about these procedures since the operative details (e.g. differential pressures and
temperatures) vary in each individual case and are only known to the operator.
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. The EU declaration
ofconformityisincludedintheannexoftheseinstructions(seesection10.2).
Non-electric regulator versions whose bodies are not lined with an insulating material coat-
ing do not have their own potential ignition source according to the risk assessment stipulat-
edinEN13463-1:2009,section5.2,evenintherareincidentofanoperatingfault.There-
fore, such valve versions do not fall within the scope of Directive 2014/34/EU.
ÎForconnectiontotheequipotentialbondingsystem,observetherequirementsspeciedin
section6.4ofEN60079-14(VDE0165-1).
Referenced documentation
The following documents apply in addition to these mounting and operating instructions:
−Mounting and operating instructions for
e.g. Type1N/NIStrainer uEB1010
e.g. Type2N/NIStrainer uEB1015
−Mountingandoperatinginstructionsaswellasdatasheetsforadditionalttings
(e.g. shut-off valves, pressure gauges etc.).

8 EB 3131 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.
ÎObserve the maximum permissible pressure for regulator and plant.
ÎBeforestartinganyworkonthedevice,depressurizeallplantsectionsaffectedas
well as the regulator.
ÎDrain the process medium from all the plant sections affected as well as the regula-
tor.
ÎIf necessary, a suitable overpressure protection must be installed on site in the plant
section.
ÎWear personal protective equipment.

EB 3131 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 stem), 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 through incorrect operation, use or installation as a result of
information on the regulator being illegible.
Over time, markings, labels and nameplates on the regulator may become covered with
dirtorbecomeillegibleinsomeotherway.Asaresult,hazardsmaygounnoticedand
the necessary instructions not followed. There is a risk of personal injury.
ÎKeep all relevant markings and inscriptions on the device in a constantly legible
state.
ÎImmediately renew damaged, missing or incorrect nameplates or labels.
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 affected and the
regulator.
ÎWear protective clothing, safety gloves and eye protection.
Risk of personal injury due to pressurized components and process medium being
discharged.
Incorrect opening of pressure equipment or mounting parts may lead to the process
medium escaping to the atmosphere.
ÎDonotloosenthecontrollinewhiletheregulatorispressurized.

10 EB 3131 EN
Safety instructions and measures
1.2 Notes on possible personal injury
WARNING
!
Risk of hearing loss or deafness due to loud noise.
The noise emissions depend on the regulator version, plant facilities and process medi-
um.
ÎWear hearing protection when working near the regulator.
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 warm up to the ambient tempera-
ture.
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.samsongroup.com/en/
about-samson/material-compliance/reach-regulation/

EB 3131 EN 11
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.
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 leakage and regulator damage due to excessively high or low tightening
torques.
Observethespeciedtorqueswhentighteningregulatorcomponents.Excessivetighten-
ing torques lead to parts wearing out more quickly. 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 appro-
priate 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 suit-
able inhibitors.

12 EB 3131 EN
Safety instructions and measures
1.3 Notes on possible property damage
NOTICE
!
ÎRisk of regulator damage due to incorrectly attached slings.
ÎDo not attach load-bearing slings to the regulator.
ÎRisk of regulator damage due to the use of unsuitable lubricants.
ÎThe lubricants to be used depend on the regulator material. Unsuitable lubricants
may corrode and damage surfaces.
ÎOnly use lubricants approved by SAMSON.
When in doubt, consult SAMSON.
ÎRisk of regulator damage due to the use of unsuitable tools.
ÎCertain tools are required to work on the regulator.
ÎOnly use tools approved by SAMSON.
When in doubt, consult SAMSON.
ÎRisk of the process medium being contaminated through the use of unsuitable lubri-
cants and/or contaminated tools and components.
ÎKeep the regulator and the tools used free from solvents and grease.
ÎMake sure that only suitable lubricants are used.

EB 3131 EN 13
Markings on the device
2 Markings on the device
1
23
45
6
7
8
9
10
1 Material number
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 numbers
SpecifyingthecongurationID,youcancon-
tactustondoutwhichmaterialisused.The
materialnumberisspeciedonthename-
plate (item 1). For more details on the name-
plate,seeFig.2.

14 EB 3131 EN
Design and principle of operation
3 Design and principle of oper-
ation
The combined regulators basically consist of
a valve body (1) with a balanced plug as
well as a closing actuator with two operating
diaphragms. The regulators are used to limit
thedifferentialpressureandowratetothe
set points adjusted at the actuator. The regu-
lator closes when the differential pressure or
owrateincreases.
Themediumowsthroughtheregulatorin
the direction indicated by the arrow. The ar-
eas released by the restriction (1.2) and the
plug(3)determinetheowrateandthedif-
ferentialpressure∆pordownstreampres-
sure p2(Type47-1).Thedifferentialpressure
∆pisconvertedbytherstoperatingdia-
phragm (6.1) and the differential pressure
createdattherestrictionbasedontheow
rate by the second operating diaphragm
(6.3) into a positioning force. The largest sig-
nal is always used to control the regulator.
Type46-7andType47-5
Tocontroltheowrate,thelowpressure
downstream of the restriction (1.2) is trans-
mitted through a hole in the plug (3) to the
top diaphragm chamber A. The high pres-
sure of V is transmitted through the attached
control line (11) to the diaphragm chamber
B.
To control the differential pressure, the high
pressureof∆pmustbetransmittedthrough
the external control line (13), which is at-
tached on the site of installation, to the bot-
tom diaphragm chamber D. The low pres-
sureof∆pisequaltothehighpressureof
˙
LegendforFig.2andFig.3
1Valve body
1.1 Connection nut with seal and welding end
1.2 Restriction
2 Seat
3 Plug with guide nipple
4 Plug stem
5 Valve spring
6 Actuator
6.1 First operating diaphragm
6.2 First actuator stem
6.3 Second operating diaphragm
6.4 Second actuator stem
7 Distance ring
8 Set point spring (differential pressure)
9 Spring plate
10 Set point adjuster (differential pressure)
11 Control line (+) V
12 Controlline(+)Δp
13 Externalcontrolline(+)Δp
14 Externalcontrolline(–)Δp
15 Screws
16 Locknut
17 Setpointscrew(owrate,SW4)
18 Cap
19 Manual adjuster (differential pressure)
20 Spindle
21 Support
22 Bottomsectionofthebody
23 Spring plate
24 Nut
25 Stopper for plug
AtoD=Diaphragmchambers
˙

EB 3131 EN 15
Design and principle of operation
1
1.1
2
(–) A
(+) B
11
13
(–) C
(+) D
∆p
8
9
10
15
7
6.4
6.3
5
3
4
1.2
17
16
18
V
.
6.1
6.2
11
13
DN15to32,setpointrange0.2
to0.6barand0.2to1bar,with
manualadjusterandscaleforΔp
set point adjustment.
Type47-5
Type46-7
19
24
8
6.1
23
22
21
20
13
Type47-1andType46-7
Fig.2: Type46-7 and Type47-5 Flow and Differential Pressure Regulator and manual adjuster

16 EB 3131 EN
Design and principle of operation
6.4
6.2
15
11
12
14
8
10
6.3
7
6.1
p2
p1
Type47-1
Flanged body
25
Fig.3: Type47-1 Flow and Differential Pressure or Pressure Regulator

EB 3131 EN 17
Design and principle of operation
the VandactsinthediaphragmchambersB
and C which are connected to each other.
Type47-1
Tocontroltheowrate,thelowpressureof
V downstream of the restriction (1.2) is
transmitted through a hole in the plug (3) to
the top diaphragm chamber A.
ThehighpressureofΔpistransmitted
through the attached control line (11) to the
diaphragmchamberB.Tocontrolthediffer-
entialpressure,thehighpressureofΔpis
transmitted through the attached control line
(12) to the bottom diaphragm chamber D.
Thelowpressureof∆pmustbetransmitted
through the external control line (14), which
is attached on the site of installation, to the
diaphragm chamber C.
WhentheType47-1isusedasaowregu-
lator and pressure reducer, diaphragm
chamber D is connected with the down-
stream pressure p2. The control line connec-
tion of diaphragm chamber C remains open
to the atmosphere.
˙
˙
3.2 Versions
Type46-7andType47-5FlowandDiffer-
entialPressureRegulator·Designedforthe
installation in the low-pressure pipe, e.g. re-
turnowpipeofadistrictheatingstation.
−Type46-7·Withadjustableowrate
and differential pressure set point · With
internal overload protection (excess pres-
sure limiter) in the actuator
−Type47-5·Withxeddifferentialpres-
suresetpoint·Adjustableowrateset
point · With internal overload protection
(excess pressure limiter) in the actuator
Type47-1FlowandDifferentialPressureor
Pressure Regulator·Designedforinstalla-
tioninthehigh-pressurepipe,e.g.ow
pipe.
−Type47-1·Withadjustableowrate
and differential pressure or pressure set
point
3.1 Mounting parts
SeeTable1.
Table1: Mounting 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atgasket

18 EB 3131 EN
Design and principle of operation
Flow and differential pressure regulators with
Type5824 or Type5825 Electric Actuator or
Type2430 Control Thermostat.
In these regulators, the signal of an electric
control device can be applied to achieve
additional temperature control by altering
the restriction position. See Mounting and
Operating Instructions uEB3135-2,
uEB5824-1, uEB5824-2 or uEB2430.
Note 3.3 Technical data
Min.differentialpressureΔpmin
The minimum required differential pressure
Δpmin across the regulator is calculated as
follows:
Δpmin = Δprestriction +
(
V
)
2
KVS
·
Δpmin Minimum differential pressure across
the regulator in bar
Δprestriction Differential pressure created at the
restrictionformeasuringtheowrate
V
·Adjustedowrateinm³/h
KVS Flowcoefcientinm³/h
Dimensions in mm · Weights in kg
The lengths and heights in the dimension di-
agramsareshownonpages20and
21.
Table2: Materials · Material number according to DINEN
Housing RedbrassCC499K(Rg5)·SpheroidalgraphiteironEN-GJS-400-18-
LT1)
Pressure rating PN16·PN25
Seat Stainless steel 1.4305
Plug PN 25 Brass,resistanttodezincication,withEPDMsoftseal2)
PN16 Brass,resistanttodezincicationandplasticwithEPDMsoftseal
Valve springs Stainless steel 1.4310
Restriction Brass,freeofdezincication
Operating diaphragm EPDM with fabric reinforcement 2)
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 3131 EN 19
Design and principle of operation
Table3: Technical data
Valve size DN15 DN20 DN25 DN323) DN403) DN503)
KVS coefcient 0.41) 11) 2.5 41) 6.3 8 12.5 16/203) 20/253)
XFz value 0.6 0.55 0.55/0.453) 0.45/
0.43)
Pressure rating PN16/25 PN 25
Max.permissibledifferentialpressure∆p
across the regulator 102)/20bar 16bar
Max. permissible temperature Liquids:130°C2)/150°C·Airandnitrogen:150°C4)
Pressure above adjusted diff. pressure set
point at which internal excess pressure
limiterresponds(Types46-7,47-5)
0.5bar
Conformity ·
Differential pressure set point ranges
Type46-7andType47-1:continuously
adjustable
0.2to0.6bar
0.2to1bar
0.5to2bar
0.2to0.5bar
0.2to1bar
0.5to2bar
Types47-5·Fixedsetpoint 0.2bar·0.3bar·0.4bar·0.5bar
1) Special versions
2) ForPN16version
3) Additionalversion:regulatorwithangedbodymadeofspheroidalgraphiteiron
(EN-GJS-400-18-LT)
4) OnlyinPN25versionanddiaphragmandsealsmadeofFKM
Table4: Regulator without connecting parts
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
Connection R G¾ G1 G1¼ G1¾ G2 G2½
WidthacrossatsSW 30 36 46 59 65 82
LengthL 65 70 75 100 110 130
H 65 85
H1
Type46-7 248 265 415
Type47-1 265 285 425
Type47-5 108 125 175
H2 Type46-7 185 205 –
Type47-1 200 220
H3 75 95
ØD 116 160
1) Additionalversion:regulatorwithangedbody

20 EB 3131 EN
Design and principle of operation
Table5: Regulator with connecting parts · Dimensions in mm
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
Type46-7 2.6 2.7 2.8 4 12 12.5
Type47-1
Type47-5 2.2 2.3 2.4 3.5 6.2 6.7
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
Type46-7 2.6 2.7 2.8 4 12 12.5
Type47-1
Type47-5 2.2 2.3 2.4 3.5 6.2 6.7
Withanges1) 2)orwithangedbody(DN32to50)
L3 130 150 160 180 200 230
Weight,
approx.
kg
Type46-7 4.0 4.7 5.3 7.2 16.0 17.5
Type47-1
Type47-5 3.6 4.3 4.9 6.7 10.2 11.7
1) PN16/25
2) FlangesarealreadymountedonregulatorsinDN40and50.
Dimensional drawings
SW
L
L3
A
SW
L
L2
H3
25
Connectionnutswithanges Connection nuts with threaded
ends
Versionwithscaledcapforow
rate set point adjustment