Mounting and Operating Instructions EB 3134 EN
Contents
1. ISO 228 1 G 4 B Type of connection Threaded ends G 1 2 Welding ends Kys coefficient Standard version 2 5 Special version 1 0 PN 10 Max perm differential pressure Ap Max permissible temperature Treated water 110 C Non flammable gases 80 C Flow rate set point range for water with a differential pressure at restriction of 0 2 bar Standard version 0 2 to 1 m3 h Special version 0 12 to 0 5 m3 h Differential pressure set point optionally 0 2 0 3 0 5 bar Compliance CEM To achieve the maximum flow rate the differential pressure set point must be at least 0 2 bar higher than that of the plant Pressure conditions in the plant and at the regulator On selecting the differential pressure set point Ap pointy NOHE that the differential pressure set point results from the known pressure drop across the fully open plant and the differential pressure created at the restriction AP set point AP slant AP restriction To achieve the maximum flow rate the differential pressure set point must be at least 0 2 bar higher than that of the plant If the differential pressure set point is only 0 1 bar higher than the pressure drop across the fully open plant the maximum flow rate is reduced to 0 7 m3 h The minimum required differential pressure Apin across the valve is calculated as follows 2 Minimum differential pressure between flow and return pipes bar V point Differ2. Use the supplied angu lar screw joint to connect it to the regula tor see section 5 5 NOTICE Incorrectly installed regulator The regulator can be damaged Make sure the regulator is installed free of stress Observe permissible mounting position Installation 5 2 Strainer filter A strainer installed upstream in the flow pipe holds back any dirt or other foreign parti cles For example the SAMSON Type 1 Strainer is suitable gt T 1010 Install the strainer upstream of the regu lator The direction of flow must correspond to the arrow on the body The filter element must be installed to hang downwards Remember to leave enough space to re move the filter element 5 3 Shut off valve Install a hand operated shut off valve both upstream of the strainer and at the outlet of the return flow pipe This allows the plant to be shut down for cleaning and maintenance and when the plant is not used for longer periods of time 5 4 Pressure gauge Install a pressure gauge at a suitable point to monitor the pressures prevailing in the plant 5 5 Control line A control line with 6 mm pipe diameter must be adapted and mounted on site Route the control line as indicated in Fig 2 An angular screw joint 14 for connecting the control line to the actuator 6 is supplied with the regulator gt To mount the control line screw the screw joint clockwise into the intended hole o
3. conditions check the regulator at regular intervals to avoid possible malfunctions The SAMSON After sales Service depart ment provides support for maintenance and inspection work see section 9 8 Nameplate Fig 4 Nameplate 12 1 2 3 4 WARNING Before performing any work on the regulator make sure the relevant plant section has been depressurized and depending on the process medi um drained as well We recommend removing the valve from the pipeline When used at high temperatures al low the plant section to cool down to ambient temperature Disconnect or shut off the control line to prevent the risk of moving regula tor parts As valves are not free of cavities remember that residual pro cess medium might still be contained in the valve Configuration ID Var ID Type designation Model number Date of manufacture In the other fields Kys or Cy coefficient Max permissible temperature in C or F Differential pressure set point range in bar or psi Flow rate set point range in m3 h Max perm differential pressure Ap Nominal pressure PN or ANSI Class EB 3134 EN Service 9 Service Contact SAMSON s After sales Service department for support concerning maintenance or repair work or when malfunctions or defects arise E mail aftersalesservice samson de Addresses of SAMSON AG and its subsidiaries The addresses of SAMSON AG its subsidiaries representatives and service faci
4. Self operated Regulators Type 46 5 N Differential Pressure and Flow Limiter Type 46 5 N Mounting and Operating Instructions EB 3134 EN Edition August 2015 Definition of signal words DANGER Hazardous situations which if not Property damage message or mal avoided will result in death or seri function ous Injury a Note WARNING Additional information Hazardous situations which if not avoided could result in death or seri ous inj ae UP jury P R ecommended action 2 EB 3134 EN Aa OQ N 1 2 1 4 1 5 1 1 1 2 1 3 1 4 10 11 Contents General safety instructions eeueeesnsssonsensneenonsennnsennnsennnsennnssnnnnnnnnsnnnsnsnnnnssnennnne 4 Process medium and scope of application ssscssscssscsssssssscsscessessenseees 5 Transportation and storage esseeseessoesseesecescesscesocesoesseesocesoesscesoeeseeesessoee 5 Design and principle of operation 5 Installation ee ee nennen nn 7 MOUNING 7 Strainer 8 Shut off VINE scence 8 Pressure gt una nace eee ann acu ineeei Gener nuaceetes ee 8 8 GNM Ohne nee Bere Re 9 SIE OD ee ee 9 Ad sch na TS BON ee ee 9 DECOM IM S SUN Sample GPP GAN een 10 Maintenance and troubleshooting sssccsssscsssssccsssscssssccsssecesssecesssceesees 12 Namepl
5. ale 12 SEIVICE ee ee een 13 Dimensions Weights ssscsssscsssccssssssscssssssssscssssscsencesssssssescsenseees 14 Technical dal sessa 15 3134 3 T General safety instructions General safety instructions All safety instructions and warnings given in these mounting and operating instructions particularly those concerning installation start up and maintenance must be strictly ob served The device must be mounted started up or serviced by fully trained and qualified person nel only the accepted industry codes and practices are to be observed Make sure em ployees or third persons are not exposed to any danger According to these mounting and operating instructions trained personnel refers to indi viduals who are able to judge the work they are assigned to and recognize possible dan gers due to their specialized training their knowledge and experience as well as their knowledge of the applicable standards The devices comply with the requirements of the European Pressure Equipment Directive 2014 68 EU Devices with a CE marking have a declaration of conformity which includes information about the applied conformity assessment procedure This declaration of conformity can be provided on request To ensure appropriate use only use the device in applications where the operating pres sure and temperatur
6. ential pressure created at restriction for measuring the flow VS rate Differential pressure set point in bar Differential pressure pressure loss when the plant is completely Phlant open in bar Adjusted flow rate in m3 h Kys Valve flow coefficient in m3 h EB 3134 EN 15 SAMSON AG MESS UND REGELTECHNIK Weism llerstra e 60314 Frankfurt am Main Germany Phone 49 69 4009 0 Fax 49 69 4009 1507 samson samson de www samson de EB 3134 EN 2015 08 28 English
7. es do not exceed the specifications used for sizing the device at the ordering stage The manufacturer does not assume any responsibility for damage caused by external forces or any other external factors Any hazards that could be caused in the regulator by the process medium operating pressure or by moving parts are to be prevented by taking appropriate precautions Proper transport storage installation operation and maintenance are assumed Note Non electric valve versions whose bodies are not lined with an insulating material coating do not have their own potential ignition source according to the risk assess ment stipulated in EN 13463 1 2009 section 5 2 even in the rare incident of an operating fault Therefore such valve versions do not fall within the scope of Directive 9A 9 EC For connection to the equipotential bonding system observe the requirements speci fied in section 6 3 of EN 60079 14 2011 VDE 0165 Part 1 EB 3134 EN Process medium and scope of application 2 Process medium and scope of application Differential pressure and flow limiter for local heat supplies and large heating net works Flow rate set points from 0 1 to 1 m3 h Differential pressure set points 0 2 bar 0 3 bar or 0 5 bar Nominal pressure PN 10 Nominal size DN 15 Suitable for treated water up to 110 C and non flammable gases up to 80 C The valve closes when the differential pressure exceeds the adjusted set point The fl
8. lities world wide can be found on the SAMSON website gt www samson de in all SAMSON product catalogs or on the back of these Mounting and Operating Instructions To assist diagnosis and in case of an unclear mounting situation specify the following details Device type and nominal size Model number or configuration ID Var ID on the nameplate Upstream and downstream pressure Temperature and process medium Min and max flow rate in m3 h ls a strainer installed Installation drawing showing the exact location of the regulator and all the additionally installed components shut off valves pressure gauge etc Note 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 from parts that have been subjected to different surface treatment methods This means that the surfaces of some parts show different reflections Parts can have an iridescent yellow or silver color This has no effect on corrosion protection For further information go to www samson de chrome en html EB 3134 EN 13 Dimensions and weights 10 Dimensions and weights Type 46 5 N Weight without accessories approx 0 85 kg SW30 With threaded ends With welding ends Fig 5 Dimensional drawings 14 EB 3134 EN Technical data 11 Technical data Nominalsize
9. n the high pressure side 8 and align it Note Do not turn the screw joint back again Otherwise the connection may start to leak EB 3134 EN 6 Operation See Fig 1 on page 6 1 gt First start up the regulator after mounting all parts Start up gt Make sure the control line is open and correctly connected gt Open all the consumers in the plant minimum drag in the plant to achieve maximum flow rate Note striction is open by turning the set point screw 11 counterclockwise O as far as it will go Rinsing the plant After filling the plant first completely open the consumers Set the max imum flow cross section by turning the set point screw counterclockwise O as far as it will go Rinse out the pipeline at full flow rate for several minutes Check the installed strainer e g by measuring the pressure drop Clean the strainer if necessary EB 3134 EN On filling the plant make sure the re Operation 6 2 Adjusting the set point If a bypass is installed in the plant it must be closed Note Set point adjustment is always based on a closed restriction 11 1 Unscrew the cap 13 2 Undo the lock nut 12 and turn the set point screw 11 using a 4 mm Allen key gt Turn clockwise The restriction closes The flow rate drops gt Turn counterclockwise The restriction opens The flow rate rises Use the diagram in Fig 3 as a guide f
10. ngular screw joint 1 2 4 5 6 7 8 9 7 Fig 1 Functional diagram of Type 46 5 N plane of projection the valve plug The differential pressure gen erated at the restriction is converted into a positioning force by the operating dia phragm If this force exceeds the force of the installed set point spring 5 the valve clos es In the same manner the valve opens if the positioning force falls below the spring force The flow rate is restricted by turning the set point screw to change the flow cross section at the restriction med ZI ZS 9 CIZ 4 ZZ 22 ae EB 3134 EN 5 Installation 5 1 Mounting position See Fig 1 on page The regulators are installed in the low pres sure line This line is always the return flow pipe in local heat networks Standard installation Install the regulators in horizontal pipelines with the actuator facing down The following generally applies Choose a place of installation that allows you to freely access the regulator even after the entire plant has been complet ed Flow pipe gt Return flow pipe lt q Fig 2 Sample application schematic EB 3134 EN Installation Install a strainer e g SAMSON Type 1 NI upstream of the regulator see section 5 2 The direction of flow must match the di rection indicated by the arrow on the body Connect external control lines at the side of the main pipe
11. nt B until it reaches the limiting curve for the flow rate in the example it is 0 3 m3 h This is point The horizontal line is drawn from point across to the curve relevant for Kys 1 0 this is point D When a line is drawn vertically upwards from point D this results in point E which in dicates how many turns of the set point screw are required The example shows that around 4 turns are required Based on a closed restriction turn the set point screw 11 approximately four turns counterclockwise U to open the restriction EB 3134 EN Operation Pressure loss across the plant AP plant IN bar Fixed differential pressure set point 0 0 5 0 4 0 3 Turns of the set point screw 0 2 7 6 Adjustment diagram for water Flow rate ranges Possible range 0 2 O0 4Differential pressure at the restriction Ap ricion in bar Fig 3 Adjustment diagram for flow limitation EB 3134 EN 11 Maintenance and troubleshooting 7 Maintenance and trouble shooting The regulator does not require any mainte nance Nevertheless it is subject to natural wear particularly at the seat plug and oper ating diaphragm If the flow rates deviates considerably from the set point first check the control line for blockage Furthermore the seat and plug may leak due to dirt particles or natural wear Therefore check the regulator and re place it if necessary Depending on the operating
12. or ad justment 3 After adjustment screw tight the lock nut and screw back on the cap 13 6 3 Decommissioning Preferably close first the shut off valve on the upstream side of the valve and then on the downstream side of the valve Operation 6 4 Sample application Adjusting the flow limitation medium water when the pressure loss across the plant is known Note Set point adjustment is always based on a closed restriction 11 Known A Type 46 5 N Kys 1 0 flow rate range from 0 12 to 0 5 m h is to be used to limit the flow rate in the plant to 0 3 m3 h The pressure drop across the plant Ap jon is 0 15 bar The differential pressure set point is 0 3 bar Determine the adjustment values using the adjustment diagram in Fig 3 To be determined How many turns of the set point screw are necessary to limit the flow rate Solution Sequence points A to E in diagram Fig 3 The calculation is based on the pressure drop Ap in the plant therefore this value must be known Ap 0 15 bar is specified in the example and corresponds with point A in the dia gram The differential pressure at the restric tion Ap ectiction assumed to be 0 15 bar in the example must be added up to the line of the differential pressure set point of 0 3 bar A line representing this value is drawn from A across to the right and results in point B A vertical line is drawn from poi
13. ow rate is limited 3 Transportation and storage The regulator must be carefully handled transported and stored Protect the regulator against adverse influences such as dirt moisture or frost during storage and transportation 4 Design and principle of operation See Fig 1 on page The regulator basically consists of a valve body 1 with restriction 11 seat 2 and plug 3 as well as a closing actuator with an operating diaphragm 9 The regulator is designed to limit the differential pressure to a fixed value 0 2 0 3 or 0 5 bar and the flow rate to the adjusted set point in local heat supply networks and heating systems EB 3134 EN 5 Design and principle of operation The medium flows through the valve in the direction indicated by the arrow on the valve body The flow rate is determined by the ar ea released by the valve plug 3 and the adjustable restriction 11 The high pressure upstream of the restriction is transmitted to the high pressure side of the actuator through the control line 7 attached on installing the regulator The low pressure downstream of the restric tion acts on the low pressure side 10 of the operating diaphragm 9 through a hole in Valve body Seat Plug Plug stem with hole Set point spring Actuator High pressure control line High pressure side Operating diaphragm 10 Low pressure side 11 Set point screw restriction Turned into the 12 Lock nut 13 Cap 14 A
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