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.
10 EB 3134 EN
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
1 2
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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: [email protected] 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 [email protected] · www.samson.de EB 3134 EN 20
15-08-28·English
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