Mounting and Operating Instructions

EB 3134 EN Edition August 2015

Type 46-5 N

Self-operated Regulators

Type 46-5 N Differential Pressure and Flow Limiter

Definition of signal words

DANGER!Hazardous situations which, if not avoided, will result in death or seri-ous injury

WARNING!Hazardous situations which, if not avoided, could result in death or seri-ous injury

NOTICEProperty damage message or mal-function

Note:Additional information

Tip:Recommended action

2 EB 3134 EN

Contents

EB 3134 EN 3

1 General safety instructions .............................................................................42 Process medium and scope of application .......................................................53 Transportation and storage ............................................................................54 Design and principle of operation ..................................................................55 Installation ....................................................................................................71.1 Mounting position ..........................................................................................71.2 Strainer(filter)................................................................................................81.3 Shut-offvalve .................................................................................................81.4 Pressure gauge ..............................................................................................81.5 Controlline ...................................................................................................86 Operation .....................................................................................................91.1 Start-up .........................................................................................................91.2 Adjusting the set point ....................................................................................91.3 Decommissioning ...........................................................................................91.4 Sampleapplication ......................................................................................107 Maintenance and troubleshooting ................................................................128 Nameplate ..................................................................................................129 Service........................................................................................................1310 Dimensions and weights ..............................................................................1411 Technical data .............................................................................................15

4 EB 3134 EN

General safety instructions

1 General safety instructions − Allsafetyinstructionsandwarningsgiveninthesemountingandoperatinginstructions,particularlythoseconcerninginstallation,start-upandmaintenance,mustbestrictlyob-served.

− Thedevicemustbemounted,starteduporservicedbyfullytrainedandqualifiedperson-nelonly;theacceptedindustrycodesandpracticesaretobeobserved.Makesureem-ployeesorthirdpersonsarenotexposedtoanydanger.

− Accordingtothesemountingandoperatinginstructions,trainedpersonnelreferstoindi-vidualswhoareabletojudgetheworktheyareassignedtoandrecognizepossibledan-gersduetotheirspecializedtraining,theirknowledgeandexperienceaswellastheirknowledgeoftheapplicablestandards.

− ThedevicescomplywiththerequirementsoftheEuropeanPressureEquipmentDirective2014/68/EU.DeviceswithaCEmarkinghaveadeclarationofconformity,whichincludesinformationabouttheappliedconformityassessmentprocedure.Thisdeclarationofconformitycanbeprovidedonrequest.

− Toensureappropriateuse,onlyusethedeviceinapplicationswheretheoperatingpres-sureandtemperaturesdonotexceedthespecificationsusedforsizingthedeviceattheordering stage.

− Themanufacturerdoesnotassumeanyresponsibilityfordamagecausedbyexternalforcesoranyotherexternalfactors.

− Anyhazardsthatcouldbecausedintheregulatorbytheprocessmedium,operatingpressureorbymovingpartsaretobepreventedbytakingappropriateprecautions.

− Propertransport,storage,installation,operationandmaintenanceareassumed.

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 94/9/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 5

Process medium and scope of application

2 Process medium and scope of applicationDifferentialpressureandflowlimiterforlocalheatsuppliesandlargeheatingnet-works · Flowratesetpointsfrom0.1to1 m³/h · Differentialpressuresetpoints0.2 bar,0.3 baror0.5 bar · NominalpressurePN 10 · NominalsizeDN 15 · Suitablefortreatedwaterupto110 °Candnon-flammablegasesupto80 °C

Thevalvecloseswhenthedifferentialpressureexceedstheadjustedsetpoint.Theflowrateislimited.

3 Transportation and storageTheregulatormustbecarefullyhandled,transportedandstored.Protecttheregulatoragainstadverseinfluences,suchasdirt,moistureorfrost,duringstorageandtransportation.

4 Design and principle of operationSee Fig. 1 on page 6.Theregulatorbasicallyconsistsofavalvebody(1)withrestriction(11),seat(2)andplug(3)aswellasaclosingactuatorwithanoperatingdiaphragm(9).Theregulatorisdesignedtolimitthedifferentialpressuretoafixedvalue(0.2,0.3or0.5 bar)andtheflowratetotheadjustedsetpointinlocalheatsupplynetworksandheatingsystems.

6 EB 3134 EN

Design and principle of operation

Fig. 1: Functional diagram of Type 46-5 N

13

11

12

10

9

8

1

2

3

4

5

6

147

1 Valvebody2 Seat3 Plug4 Plugstemwithhole5 Set point spring6 Actuator7 High-pressurecontrolline8 High-pressure side9 Operating diaphragm10 Low-pressureside11 Setpointscrew(restriction)12 Locknut13 Cap14 Angularscrewjoint

Turned into the planeofprojection

Themediumflowsthroughthevalveinthedirectionindicatedbythearrowonthevalvebody.Theflowrateisdeterminedbythear-eareleasedbythevalveplug(3)andtheadjustablerestriction(11).The high pressure upstream of the restriction is transmitted to the high-pressure side of the actuatorthroughthecontrolline(7)attachedoninstallingtheregulator.Thelowpressuredownstreamoftherestric-tionactsonthelow-pressureside(10)oftheoperatingdiaphragm(9)throughaholein

thevalveplug.Thedifferentialpressuregen-erated at the restriction is converted into a positioningforcebytheoperatingdia-phragm.Ifthisforceexceedstheforceoftheinstalledsetpointspring(5),thevalveclos-es.Inthesamemanner,thevalveopensifthepositioningforcefallsbelowthespringforce.Theflowrateisrestrictedbyturningthesetpointscrewtochangetheflowcross-sectionat the restriction.

EB 3134 EN 7

Installation

Fig. 2: Sample application (schematic)

5 Installation5.1 Mounting positionSee Fig. 1 on page 6.Theregulatorsareinstalledinthelow-pres-sureline.Thislineisalwaysthereturnflowpipeinlocalheatnetworks.

Standard installation · Installtheregulatorsinhorizontalpipelineswiththeactuatorfacingdown.

Thefollowinggenerallyapplies: − Chooseaplaceofinstallationthatallowsyoutofreelyaccesstheregulatorevenaftertheentireplanthasbeencomplet-ed.

− Installastrainer(e.g.SAMSONType 1 NI)upstreamoftheregulator(seesection 5.2).

− Thedirectionofflowmustmatchthedi-rectionindicatedbythearrowonthebody.

− Connectexternalcontrollinesatthesideofthemainpipe.Usethesuppliedangu-larscrewjointtoconnectittotheregula-tor(seesection 5.5).

NOTICEIncorrectly installed regulatorThe regulator can be damaged.Make sure the regulator is installed free of stress. Observe permissible mounting position.

–+

Returnflowpipe

Flowpipe

8 EB 3134 EN

Installation

5.2 Strainer (filter)Astrainerinstalledupstreamintheflowpipeholdsbackanydirtorotherforeignparti-cles.Forexample,theSAMSONType 1 NIStrainerissuitable(u T 1010). − Installthestrainerupstreamoftheregu-lator.

− Thedirectionofflowmustcorrespondtothearrowonthebody.

− Thefilterelementmustbeinstalledtohangdownwards.

− Remembertoleaveenoughspacetore-movethefilterelement.

5.3 Shut-off valveInstallahand-operatedshut-offvalvebothupstreamofthestrainerandattheoutletofthereturnflowpipe.Thisallowstheplanttobeshutdownforcleaningandmaintenance,andwhentheplantisnotusedforlongerperiods of time.

5.4 Pressure gaugeInstallapressuregaugeatasuitablepointtomonitorthepressuresprevailingintheplant.

5.5 Control lineAcontrollinewith6 mmpipediametermustbeadaptedandmountedonsite.RoutethecontrollineasindicatedinFig. 2.Anangularscrewjoint(14)forconnectingthecontrollinetotheactuator(6)issuppliedwiththeregulator.

Î Tomountthecontrolline,screwthescrewjointclockwise()intotheintendedholeonthehigh-pressureside(8)andalignit.

Note:Do not turn the screw joint back again. Otherwise, the connection may start to leak.

EB 3134 EN 9

Operation

6 OperationSee Fig. 1 on page 6.

6.1 Start-up Î Firststartuptheregulatoraftermountingallparts.

Î Makesurethecontrollineisopenandcorrectlyconnected.

Î Openalltheconsumersintheplant(minimumdragintheplant)toachievemaximumflowrate.

Note:On filling the plant, make sure the re-striction is open by turning the set point screw (11) counterclockwise () as far as it will go.

Rinsing the plant ·Afterfillingtheplant,firstcompletelyopentheconsumers.Setthemax-imumflowcross-section(byturningthesetpointscrewcounterclockwise()asfarasitwillgo).Rinseoutthepipelineatfullflowrateforseveralminutes.Checktheinstalledstrainer(e.g.bymeasuringthepressuredrop).Cleanthestrainer,ifnecessary.

6.2 Adjusting the set pointIfabypassisinstalledintheplant,itmustbeclosed.

Note:Set point adjustment is always based on a closed restriction (11).

1. Unscrewthecap(13).2. Undothelocknut(12)andturntheset

pointscrew(11)usinga4 mmAllenkey. Î Turnclockwise:

Therestrictioncloses.Theflowratedrops. Î Turncounterclockwise:

Therestrictionopens.Theflowraterises.UsethediagraminFig. 3asaguideforad-justment.3. Afteradjustment,screwtightthelocknut

andscrewbackonthecap(13).

6.3 DecommissioningPreferablyclosefirsttheshut-offvalveontheupstreamsideofthevalveandthenonthedownstreamsideofthevalve.

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Operation

6.4 Sample applicationAdjustingtheflowlimitation(medium:water)whenthepressurelossacrosstheplantisknown.

Note:Set point adjustment is always based on a closed restriction (11).

Known: − A Type 46-5 N, KVS = 1.0,flowrate

range from 0.12 to 0.5 m³/histobeusedtolimittheflowrateintheplantto0.3 m³/h.

− Thepressuredropacrosstheplant(Δpplant)is0.15 bar.

− Thedifferentialpressuresetpointis0.3 bar.

− DeterminetheadjustmentvaluesusingtheadjustmentdiagraminFig. 3.

To be determined:Howmanyturnsofthesetpointscrewarenecessarytolimittheflowrate?

Solution:Sequence:points A to Eindiagram(Fig. 3).ThecalculationisbasedonthepressuredropΔpintheplant,therefore,thisvaluemustbeknown.Δp = 0.15 barisspecifiedintheexampleandcorrespondswithpoint A in the dia-gram.Thedifferentialpressureattherestric-tion(Δprestriction)assumedtobe0.15 barintheexample,mustbeaddeduptothelineofthedifferentialpressuresetpointof0.3 bar.AlinerepresentingthisvalueisdrawnfromAacrosstotherightandresultsinpoint B.Averticallineisdrawnfrompoint Buntilitreachesthelimitingcurvefortheflowrate(intheexample,itis0.3 m³/h).Thisispoint C.Thehorizontallineisdrawnfrompoint C acrosstothecurverelevantforKVS=1.0;this is point D.Whenalineisdrawnverticallyupwardsfrom point D,thisresultsinpoint Ewhichin-dicateshowmanyturnsofthesetpointscrewarerequired.Theexampleshowsthataround4 turns are required.Basedonaclosedrestriction,turnthesetpointscrew(11)approximatelyfourturnscounterclockwise to open the restriction.

EB 3134 EN 11

Operation

Fig. 3: Adjustment diagram for flow limitation

Flowrateranges Possiblerange DifferentialpressureattherestrictionΔprestrictioninbar

FixeddifferentialpressuresetpointPressurelossacrosstheplantΔpplantinbar

Turnsofthesetpointscrew

Adju

stmen

t dia

gram

for w

ater

0.6

0.40.3

0.10.2

0.3

0.5

7 6 5 4 3 2 1

0.06

0.18

0.30

0.42

0.54

0.66

0.78

0.90

1.02

1.14

0.40.2

A B

CD

E

0.5

V [m3/h]˚

Kvs 1.0

Kvs 2.5

12 EB 3134 EN

Maintenance and troubleshooting

7 Maintenance and trouble-shooting

Theregulatordoesnotrequireanymainte-nance.Nevertheless,itissubjecttonaturalwear,particularlyattheseat,plugandoper-ating diaphragm.Iftheflowratesdeviatesconsiderablyfromthesetpoint,firstcheckthecontrollineforblockage.Furthermore,theseatandplugmayleakduetodirtparticlesornaturalwear.Therefore,checktheregulatorandre-placeit,ifnecessary.Dependingontheoperatingconditions,checktheregulatoratregularintervalstoavoidpossiblemalfunctions.TheSAMSONAfter-salesServicedepart-ment provides support for maintenance and inspectionwork(seesection 9).

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.

8 Nameplate

Fig. 4: Nameplate

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1 ConfigurationID(Var.-ID)2 Typedesignation3 Modelnumber4 Date of manufacture

Intheotherfields:KVS or CVcoefficientMax.permissibletemperaturein°Cor°FDifferentialpressuresetpointrangeinbarorpsiFlowratesetpointrangeinm³/hMax.perm.differentialpressureΔpNominalpressurePNorANSIClass

EB 3134 EN 13

Service

9 ServiceContactSAMSON'sAfter-salesServicedepartmentforsupportconcerningmaintenanceorrepairworkorwhenmalfunctionsordefectsarise.E-mail: aftersalesservice@samson.deAddresses of SAMSON AG and its subsidiariesTheaddressesofSAMSONAG,itssubsidiaries,representativesandservicefacilitiesworld-widecanbefoundontheSAMSONwebsite(u www.samson.de)inallSAMSONproductcatalogsoronthebackoftheseMountingandOperatingInstructions.Toassistdiagnosisandincaseofanunclearmountingsituation,specifythefollowingdetails:

− Devicetypeandnominalsize − ModelnumberorconfigurationID(Var.-ID)onthenameplate − Upstreamanddownstreampressure − Temperature and process medium − Min.andmax.flowrateinm³/h − Isastrainerinstalled? − Installationdrawingshowingtheexactlocationoftheregulatorandalltheadditionallyinstalledcomponents(shut-offvalves,pressuregauge,etc.)

Note:Conversion from chromate coating to iridescent passivationWe 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 u www.samson.de/chrome-en.html

14 EB 3134 EN

Dimensions and weights

10 Dimensions and weights

Fig. 5: Dimensional drawings

Type 46-5 NWeightwithoutaccessories,approx.0.85 kg

WithweldingendsWith threaded ends

65

~65

65

ISO 228/1-G ¾ B

Ø95

SW30

129

G½

SW30

210

Ø21

.3

EB 3134 EN 15

Technical data

11 Technical dataNominal size DN 15Connection ISO 228/1-G ¾ BTypeofconnection ThreadedendsG ½ · WeldingendsKVS coefficient

Standard version 2.5Specialversion 1.0

Nominalpressure PN10Max.perm.differentialpressureΔp 4 barMax.permissibletemperatureTreatedwater 110 °CNon-flammablegases 80 °C

xFZvalue 0.43Flowratesetpointrangeforwaterwithadifferentialpressureatrestrictionof0.2 bar

Standard version 0.2to1 m³/hSpecialversion 0.12to0.5 m³/h

Differentialpressuresetpoint1),optionally 0.2 · 0.3 · 0.5 barCompliance  · 

1) Toachievethemaximumflowrate,thedifferentialpressuresetpointmustbeatleast0.2 barhigherthanthatoftheplant.

Pressure conditions in the plant and at the regulatorOnselectingthedifferentialpressuresetpointΔpset point,notethatthedifferentialpressuresetpointresultsfromtheknownpressuredropacrossthefullyopenplantandthedifferentialpressure created at the restriction.Δpset point = Δpplant+ ∆prestriction

Toachievethemaximumflowrate,thedifferentialpressuresetpointmustbeatleast0.2 barhigherthanthatoftheplant.Ifthedifferentialpressuresetpointisonly0.1 barhigherthanthepressuredropacrossthefullyopenplant,themaximumflowrateisreducedto0.7 m³/h.TheminimumrequireddifferentialpressureΔpminacrossthevalveiscalculatedasfollows:

Δpmin = Δpset point+ ( V )2

KVS

· Δpmin Minimumdifferentialpressurebetweenflowandreturnpipesinbar

ΔprestrictionDifferentialpressurecreatedatrestrictionformeasuringtheflowrate

Δpset point Differentialpressuresetpointinbar

ΔpplantDifferentialpressure(pressureloss)whentheplantiscompletelyopeninbar

V Adjustedflowrateinm³/hKVS Valveflowcoefficientinm³/h

·

SAMSON AG · MESS- UND REGELTECHNIKWeismüllerstraße 3 · 60314 Frankfurt am Main, GermanyPhone: +49 69 4009-0 · Fax: +49 69 4009-1507samson@samson.de · www.samson.de EB 3134 EN 20

15-08-28·English