Mounting and Operating Instructions EB 3009 EN
Contents
1. 4 Lift off the top diaphragm plate and dia phragm 11 1 together with the bottom diaphragm plate Pull out the spacer bushing 18 Maintenance 5 Unthread nut 17 1 while holding the stem stationary with a suitable tool Re place bottom diaphragm 11 2 Proceed in reverse order to reassemble Observe the tightening torques specified in Fig 4 Proceed as described in section 3 1 for start up 4 1 1 Testing in the workshop Detailed test instructions 1700 0336 are available on request Perform leakage and function tests after re placing the diaphragms To proceed install the valve with actuator and control lines into a suitable setup that allows the test pressure to be applied Note Flow of direction Arrow on body a Internal leakage test shut off between seat and plug Apply compressed air at 0 1 bar to port A flow side Open port B return flow side DN Test pressure Leakage max b External leakage test Apply compressed air at 10 bar to port A flow side Tightly seal port B return flow side The valve body should show no signs of leakage EB3009EN 7 Maintenance c Function test Port A flow side Apply a test pressure of p 0 3 bar The plug should open d Backflow prevention function test DN Test pressure Port A is open Apply compressed air at 0 1 bar to port return flow side Slowly increase the pressure to 10 bar2. 11 1 is connected to the valve inlet pressure whereas the operating diaphragm for low pressure 11 2 is connected to the valve outlet pres sure There is a hole with a mechanical diaphragm rupture indication 12 in the intermediate ring located between the two diaphragms The pressure of response of the diaphragm rupture indication is approximately 1 5 bar If the diaphragm ruptures the pressure be tween the diaphragms will increase and cause the pin of the diaphragm rupture indi cation to move outward until the red marking appears to indicate the diaphragm rupture The undamaged operating diaphragm will then take over the function of the damaged operating diaphragm A pressure switch 15 can be optionally at tached to the actuator to trigger an alarm 2 Installation Choose the place of installation that allows you to freely access the regulator after the en tire plant has been completed NOTICE The valve must be installed free of stress If necessary support the pipe near the connect ing flanges However do not attach the sup ports directly at the valve or actuator Flush the pipeline thoroughly before installa tion To prevent any sealing parts weld spatter or other foreign matter carried along by the pro cess medium from impairing the proper func tioning of the valve in particular tight shut off install a strainer e g SAMSON Type 2 NI upstream of the regulator 2 1 Install the regulator in a
3. Check for leakage at the seat Table 1 Troubleshooting Problem Possible cause 0 1 bar Bubble tight 10 bar Bubble tight Solution Valve does not fully open Differential pressure rises above the adjusted set point Valve does not close Differential pressure drops below the adjusted set point Insufficient pressure can be tapped on high pressure side connected to the actuator Clean control line and screw fitting Two diaphragms defective see diaphragm rupture indicator Replace diaphragm see section 4 1 Seat and plug worn due to de posits or foreign matter Replace damaged parts or contact SAMSON Strainer blocked up Clean strainer filter Valve sized too small Seat and plug damaged mean ing a tight shut off is no longer possible Valve sized too big Recalculate coefficient and contact SAMSON Remove valve from pipeline and clean parts Contact SAMSON if still defec tive Recalculate coefficient and contact SAMSON Control line on low pressure side blocked Clean control line and screw joint Jerky control performance Increased friction e g due to foreign matter lodged between seat and plug Remove valve from pipeline and clean parts Control loop hunting 8 Eb 3009 EN Valve sized too big Recalculate Kys coefficient and contact SAMSON Description of the nameplates 5 _ Desc
4. Self operated Pressure Regulators Check Valve Type 42 10 RS Backflow Prevention Type 42 10 RS Check Valve Mounting and Operating Instructions EB 3009 EN Edition January 2013 Contents Contents 1 Design and principle of operation 4 2 5 2 Mounting D 2 2 2 4G eae we ea de See EER eed wee eee 9 2 3 Additional installation instructions 2 3 6 3 1 DON ee 6 3 2 Set point adjustment 6 383 DECOMMISSIONING uve x dom oq och Roy XP xe m c voy bh o A xd a 6 4 Maintenance 6 4 Replacing the diaphragm 6 4 1 1 Testing in the workshop 7 5 Description of the nameplates 9 6 Dimensions and weights 10 6 1 s s lt a u a ec ee 12 7 Customer service 2 2 13 2 EB 3009 EN Safety instructions General safety instructions The regulators must be mounted started up and serviced by fully trained and qualified personnel only observing the accepted industry codes and practices Make sure employees or third persons are not exposed any danger All safety instructions and warnings in these instructions p
5. articularly those concerning installation start up and maintenance must be observed The regulator complies with the requirements of the European Pressure Equip ment Directive 97 23 EC The Declaration of Conformity issued for devices bearing the CE marking includes information on the applied conformity as sessment procedure and is available on request To ensure appropriate use only use the regulator in applications where the op erating pressure and temperatures do not exceed the operating values speci fied in the order Note that the manufacturer does not assume any responsibility for damage caused by external forces or any other external influences Any hazards which could be caused in the regulator by the process medium or operating pressure are to be prevented by means of appropriate measures Proper shipping and appropriate storage are assumed Note The non electric actuators and valve versions do not have their own potential ignition source according to the ignition risk assessment stipulated in EN 13463 1 2009 section 5 2 even in the rare incident of an operating fault Therefore they do not fall within the scope of Directive 9A 9 EC For connection to the equipotential bonding system observe the requirements specified in EN 60079 14 2009 VDE 0165 Part 1 section 6 3 3009 3 Design and principle of operation 1 Design and principle of operation The regulator controls the differential pres su
6. en open the shut off valves slowly Raise the plant pressure in steps of 5 bar Wait sev eral seconds after each rise in pressure before continuing NOTICE When pressure testing the pipelines with the regulator installed make sure the test pres sure does not exceed 1 5 times the nominal pressure The maximum permissible pressure in actua must not be exceeded The lowest pressure always applies 3 2 Set point adjustment The regulator is delivered with the differential pressure set point fixed at 0 2 bar 3 3 Decommissioning Close the shut off valves starting with flow pipe high pressure line in any order 4 Maintenance 6 3009 EN The regulator is maintenance free but is sub ject to wear and tear especially at the seat plug and two diaphragms Depending on the application conditions that prevail the regulator must be inspected at ap propriately scheduled intervals to prevent any problems before they occur Detailed test instructions 1700 0336 are available on request Refer to Table 1 on page 8 for troubleshoot ing Contact SAMSON if any problems can not be remedied Proceed as described in section 4 1 when the diaphragm rupture indicator is triggered or when one of the diaphragms is defective NOTICE Prior to carrying out any work on the regula depressurize and drain the correspond ing section of the plant Depending on the application first allow the relevant section of the p
7. for re pair Addresses of SAMSON subsidiaries agencies and service centers are listed in the product catalogs and in the Internet at www samson de To allow SAMSON to find the fault and to have an idea of the installation situation specify the following details refer to the nameplate Type nominal size and set point range of the regulator Order number Model number of valve and actuator Inlet pressure and outlet pressure Process medium and its temperature Min and max flow rate Min and max medium temperature Sketch of the installation with exact position of regulator and all additional installed com ponents shut off valves pressure gauges etc EB 3009 13 14 3009 EN EB3009EN 15 SAMSON AG MESS UND REGELTECHNIK Weism llerstraBe 3 60314 Frankfurt am Main Germany Phone 49 69 4009 0 Fax 49 69 4009 1507 Internet http www samson de EB 3009 EN S Z 2013 02 Conversion from chromate coating to iridescent passivation D Conversion from chromate coating to iridescent passivation We at SAMSON are converting the surface treatment of passivated steel parts in our production As a result you may receive a device assembled parts that have be en subjected to different surface treatment methods This means that the surfaces of so me parts show different reflections Parts can have an iridescent yellow or silver color This has no effect on corrosion protection For further inf
8. horizontal pipeline as illustrated in Fig 1 with the actuator sus pended downwards Make sure the direction of flow corresponds with the arrow on the valve body Mounting position Fig 1 Typical installation Installation NOTICE Protect the regulator against frost if it is used to control freezing media In cases where the regulator is installed in rooms not free of frost it must be removed from the pipeline when the plant is shut down 2 2 Strainer Make sure that the medium flow corresponds with the direction indicated by the arrow on the strainer body Install the strainer with the filter element vertically suspended Ensure that ample space is available to remove the filter 2 3 Additional installation instructions We recommend the installation of hand oper ated shut off valves both upstream of the strainer and downstream of the regulator This allows the plant to be shut down for cleaning and maintenance routines or when it is not operated for extended periods Install pressure gauges upstream and downstream of the valve to monitor the pressures prevail ing in the plant Strainer Type 42 10 RS Pressure gauge Shut off valve Upstream pressure Downstream pressure EB3009EN 5 Operation Maintenance 3 Operation 3 1 First start up the regulator after mounting all the components Start up Make sure the control lines are correctly con nected Open all the valves on the consumer side Th
9. lant to cool down or warm up reach ambient temperatures As valves are not free of cavities there might still be residual medium in the valve 4 1 Note Replacing the diaphragm We recommend replacing both diaphragms when the diaphragm rupture indicator is trig gered or when one of the diaphragms is de fective The valve does not need to be removed from the pipeline to replace the diaphragms After shutting off and draining the corresponding section of the plant unscrew the control lines 14 To separate the actuator from the valve body 1 undo the coupling nut 5 and re move the diaphragm actuator 10 How to proceed NOTICE Remove the actuator housing 10 together with the intermediate ring 10 1 The installed set point springs 13 and force limiter springs 13 1 are still compressed Unscrew first the short housing screws 16 1 and then the long screws 16 2 in an even manner 1 Unthread screws 16 1 and lift the top part off the actuator housing 2 Unthread screws 16 2 and remove the intermediate ring 10 1 together with the two diaphragms 11 1 11 2 while pull ing the diaphragm stem 7 off the bottom diaphragm housing 3 Disassemble the double diaphragm 11 with the diaphragm plates enough to be able to replace the two diaphragms 11 1 11 2 To do so unthread top diaphragm plate nut 17 while holding the bottom dia phragm stem or opposite nut stationary with a suitable tool
10. ormation go to www samson de chrome en html
11. r actuator Actuator stem Diaphragm stem Actuator housing Intermediate ring Two diaphragms Operating diaphragm for high pressure Operating diaphragm for low pressure Diaphragm rupture indication Set point spring s Force limiting springs Control line 8 x 1 mm Pressure switch option Housing screws two screws opposite each IZA other DN 15 to DN 25 only 20Nm Top housing screws Bottom housing screws Diaphragm plate nut external Diaphragm plate nut inside Spacer bushing Fig 4 Sectional diagram 3009 11 6 1 Technical data Type 2421 RS Valve Nominal size 40 50 65 Kys coefficient 20 32 50 Nominal pressure PN 25 or 40 Max perm continuous 25 bur operating pressure Max perm pressure on 45 one side Leakage class acc to IEC 60534 4 Leakage rate VI Max perm temperature 150 C Type 2420 RS Actuator Diaphragm area of actuator Differential pressure set 0 2 bar point fixed Max permissible temperature Air and gases up to 80 C Terms for valve sizing according to IEC 60534 0 95 0 75 12 EB 3009 EN Customer service 7 Customer service Should any malfunctions or any defect occur SAMSON s After Sales Service is prepared to help you on site You can also send the defective regulator directly to your local SAMSON representative
12. re to the set point adjusted and prevents backflow from directly connected systems Observe the pressure and temperature limits on the nameplate The regulator is open provided the upstream pressure is at least 0 2 bar greater than the downstream pressure It closes automatically when the downstream pressure rises to or above the value of the upstream pressure The regulator basically consists of the valve 1 with seat and plug as well as the opening actuator 10 with two diaphragms 11 The medium flows through the valve in the di rection indicated by the arrow The position of the valve plug 3 determines the differen tial pressure across the free area between the plug 3 and the seat 2 At a differential pressure of 0 2 bar the valve begins to open and at 0 35 bar the valve is fully open At this point the upstream pres sure 1 compressed air or nitrogen network pressure must be greater than the down stream pressure p2 The valve closes automat ically when the downstream pressure rises to or above the value of the upstream pressure The standard plug is soft seated to ensure tight shut off and to prevent backflow from the plant into the compressed air or nitrogen net work The mounted control lines 14 transmit the high pressure and low pressure to the actuator The actuator with two diaphragms 11 pro vides increased functional safety The operat EB 3009 EN ing diaphragm for high pressure
13. ription of the nameplates Both the valve and actuator have a nameplate Valve nameplates DIN version Valve type Model number with index Configuration ID Var ID Order number or date Kys coefficient Nominal size Nominal pressure Perm differential pressure Perm temperature Body material ANSI version 5 Nominal size 8 Perm differential pressure 9 Perm temperature F 10 Body material 11 Gy Kys x 1 17 12 ANSI Class pressure rating Actuator nameplate Effective area DIN ANSI Type Configuration ID Var ID ID number Year of production with CE marking Max perm pressure Pmax DIN ANSI Nominal size of associated valve DIN ANSI Set point range DIN ANSI Diaphragm material Fig 2 Nameplates EB 3009 EN 9 Dimensions and weights 6 _ Dimensions and weights Type 42 10 RS Dimensions in mm and weights in kg Nominal size DN Length L 180 200 230 Height H1 Other materials Height H2 Forged steel z Height H 830 1000 Actuator D 285 mm A 320 cm D 390 mm A 640 cm weighing 25 m a e 77 To t Fig 3 Dimensions and weights 10 Eb 3009 EN Dimensions and weights Sectional diagram 77 7 7 77 A A AA A M YA mi N LA d IS SN SS N f ie Se js pec c WSS NIA ZZ C GG SY N SSSAAA Valve body Seat Plug Plug stem Threaded connection fo
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