Samson 2405 Series Service manual

Mounting and
Operating Instructions
EB 2520 EN
Translation of original instructions
Edition June 2017
Self-operated Pressure Regulators
Type2405 Pressure Reducing Valve

2 EB 2520 EN
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
(www.samson.de) > Product documentation. You can enter the document
number or type number in the [Find:] eld to look for a document.
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

Contents
EB 2520 EN 3
1 Safety instructions and measures ...................................................................5
1.1 Notes on possible severe personal injury .........................................................7
1.2 Notes on possible personal injury ...................................................................7
1.3 Notes on possible property damage................................................................8
2 Markings on the device .................................................................................9
3 Design and principle of operation ................................................................10
3.1 Versions ......................................................................................................11
3.2 Technical data .............................................................................................12
4 Measures for preparation............................................................................16
4.1 Unpacking ..................................................................................................16
4.2 Transporting and lifting ................................................................................16
4.3 Storage.......................................................................................................16
4.4 Preparation for installation............................................................................17
5 Mounting and start-up.................................................................................18
5.1 Installing the valve into the pipeline ...............................................................18
5.1.1 Installation conditions...................................................................................18
5.1.2 Mounting position........................................................................................18
5.1.3 Additional ttings.........................................................................................19
5.2 Quick check ................................................................................................20
5.3 Putting the regulator into operation................................................................21
5.4 Adjusting the set point..................................................................................21
6 Servicing.....................................................................................................22
6.1 Preparation for return shipment.....................................................................22
6.2 Ordering spare parts and operating supplies .................................................23
7 Malfunctions ...............................................................................................24
7.1 Troubleshooting ...........................................................................................24
8 Decommissioning and disassembly ..............................................................25
8.1 Decommissioning.........................................................................................25
8.2 Removing the valve from the pipeline.............................................................25
8.3 Disposal......................................................................................................25

4 EB 2520 EN
Contents
9 Annex.........................................................................................................26
9.1 After-sales service........................................................................................26
9.2 Certicates ..................................................................................................26

EB 2520 EN 5
Safety instructions and measures
1 Safety instructions and measures
Intended use
The Type2405 Pressure Reducing Valve is used to control the pressure of ammable gases
used as a source of energy, e.g. in boilers, driers, vaporizers, heat exchangers or industrial
ovens. Alternatively, it can control the compressed air supply in process engineering applica-
tions.
The device is designed to operate under exactly dened conditions (e.g. operating pressure,
process medium, temperature). Therefore, operators must ensure that the device is only used
in applications that meet the specications used for sizing the device at the ordering stage. In
case operators intend to use the device 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 device is not suitable for use outside the limits dened during sizing and in the technical
data. Furthermore, the following activities do not comply with the intended use:
−Use as safety valve
−Use of non-original spare parts
−Performing service and repair work not described in these instructions
Qualications of operating personnel
The device 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. Accord-
ing 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 appli-
cable standards.

6 EB 2520 EN
Safety instructions and measures
Personal protective equipment
We recommend wearing the following protective equipment depending on the process medi-
um:
−Protective clothing, gloves, and eyewear in applications with hot, cold, and/or corrosive
media
ÎCheck with the plant operator for details on further protective equipment.
Revisions and other modications
Revisions, conversions or other modications to 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, operators and operating personnel must pre-
vent hazards that could be caused in the device by the process medium and operating pres-
sure by taking appropriate precautions. They must observe all hazard statements, warning
and caution notes in these mounting and operating instructions, especially for installation,
start-up, and service work.
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 persons are not ex-
posed to any danger.
Responsibilities of operating personnel
Operating personnel must read and understand these mounting and operating instructions as
well as the referenced documents and observe the hazard statements, warning and caution
notes specied in them. Furthermore, the operating personnel must be familiar with the ap-
plicable health, safety and accident prevention regulations and comply with them.
Referenced standards and regulations
The devices 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. This declaration of
conformity is included in the Appendix of these instructions (see section9.2).

EB 2520 EN 7
Safety instructions and measures
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 assessment 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 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 Part 1).
1.1 Notes on possible severe personal injury
DANGER
!
Risk of bursting in pressure equipment.
Control valves and pipelines are pressure equipment. Improper opening can lead to
valve components bursting.
ÎBefore starting any work on the control valve, depressurize all plant sections con-
cerned as well as the valve.
ÎTo prevent uncontrolled excess pressure, make sure that suitable overpressure pro-
tection is installed on site in the plant section.
ÎDrain the process medium from all the plant sections concerned as well as the
valve.
ÎWear personal protective equipment.
1.2 Notes on possible personal injury
WARNING
!
Risk of personal injury due to residual process medium in the valve.
While working on the valve, 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 concerned and the
valve.
ÎWear protective clothing, safety gloves, and eyewear.

8 EB 2520 EN
Safety instructions and measures
WARNING
!
Risk of burn injuries due to hot or cold components and pipelines.
Depending on the process medium, valve components, and pipelines may get very hot
or cold and cause burn injuries.
ÎAllow components and pipelines to cool down or heat up.
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 indi-
cated on the SAMSON delivery note.
ÎInformation on safe use of the part affected, see uhttp://www.samson.de/reach-
en.html.
1.3 Notes on possible property damage
NOTICE
!
Risk of valve 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.
ÎObserve the maximum permissible pressure for valve and plant.
Risk of valve damage due to unsuitable medium properties.
The valve is designed for a process medium with dened properties.
ÎOnly use the process medium specied for sizing the valve.

EB 2520 EN 9
Safety instructions and measures
NOTICE
!
Risk of leakage and valve damage due to excessively high or low tightening
torques.
Observe the specied torques on tightening valve components.
Excessively tightened torques lead to parts wearing out quicker. Parts that are too loose
may cause leakage.
ÎObserve the specied tightening torques.
Risk of regulator damage due to incorrectly attached lifting equipment.
ÎDo not attach lifting equipment to mounting parts (e.g. adjusting screw or control
line).
Conversion from chromate coating to iridescent passivation
We at SAMSON are converting the surface treatment of passivated steel parts in our produc-
tion. 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 differ-
ent reections. Parts can have an iridescent yellow or silver color. This has no effect on corro-
sion protection. For further information go to uwww.samson.de/chrome-en.html.
Note

10 EB 2520 EN
Markings on the device
2 Markings on the device
SAMSON
4
6
231
789 11
5
10 Made in Germany
2009
xxxx
1 Type designation (2405)
2 Max. perm. operating pressure at the
actuator pmax
3Conguration ID
4 Order number or date
5 KVS coefcient
7 Set point range/spring force
8 Nominal size
9 Nominal pressure
10 Permissible differential pressure (across
the valve)
11 Perm. temperature
12 Body material
The CE marking only exists for versions in nominal sizes DN32 to 50.
Fig.1: Nameplate
Note

EB 2520 EN 11
Design and principle of operation
3 Design and principle of oper-
ation
The medium ows through the valve in the di-
rection indicated by the arrow. The position
of the plug (3) determines the cross-sectional
area of ow between the plug and seat (2).
In the pressureless state (control line not con-
nected and no pressure applied) the valve is
opened by the force of the set point springs
(7).
The downstream pressure p2to be controlled
is tapped downstream of the regulator and
transmitted over an external control line to
the control line connection (9) on the actua-
tor housing (6) where it is converted into a
positioning force by the diaphragm plate
with operating diaphragm (5). This force is
used to move the plug stem (4) and the valve
plug depending on the force of the set point
springs. The spring force can be adjusted at
the set point adjuster (8).
When the force resulting from the down-
stream pressure p2rises above the spring
force adjusted at the set point springs, the
valve closes proportionally to the change in
pressure.
In the version with pressure balancing, the
forces produced by the upstream and down-
stream pressures acting on the plug are elim-
inated by the balancing diaphragm (10).
The plug is fully balanced.
p1
p2
8
7
6
5
11
4
9
1
3
2
Fig.2: Type2405 Pressure Reducing Valve without pressure balancing · KVS 1.6 to 4 · Flow-to-open

12 EB 2520 EN
Markings on the device
p
1
p
2
p
1p
2
10
1 Valve body
2 Seat
3 Plug
4 Plug stem
5 Diaphragm plate with operating
diaphragm
6 Actuator housing
7 Set point spring
8Set point adjuster (screw SW27)
9Control line connection, G¼ tting
10 Balancing diaphragm
11 Leakage line connection (special version),
G¼ tting
Fig.3: Type2405 Pressure Reducing Valve
without pressure balancing · KVS
0.016 to 1 · Flow-to-close
Fig.4: Type2405 Pressure Reducing Valve with
pressure balancing · KVS 6.3 to 32
3.1 Versions
Type2405 Pressure Reducing Valve to con-
trol gases
Standard
−Temperature range from –20 to +60°C
−Set points from 5mbar to 10bar
−Nominal size DN15 to 50
−PN16 to 40
−Flanges
Options
−With pressure balancing (see Fig.4)
−Pressure tapping directly at the valve in-
stead of over an external control line
with 0.8 to 2.5bar, 2 to 5bar, and 4.5
to 10bar
−Temperature range from 0 to 150°C for
unbalanced versions with FKM dia-
phragm and FKM soft seal

EB 2520 EN 13
Markings on the device
3.2 Technical data
Table1: Technical data
Nominal size DN15 DN20 DN25 DN32, 40, 50
Nominal pressure (valve) PN16 · PN25 · PN40
KVS
coefcients
Standard
4 6.3 8 32
Reduced KVS coefcients
0.016 · 0.04
0.1 · 0.25 · 0.4
1 · 1.6 · 2.5
0.016 · 0.04
0.1 · 0.25 · 0.4
1 · 1.6 · 2.5 · 4
0.016 · 0.04
0.1 · 0.25 · 0.4
1 · 1.6 · 2.5 · 4
6.3
1.6 · 2.5 · 4
6.3 · 8 · 16
20
Max. permissible differential pressure 10bar · 12bar 1)
Max. permissible temperature range
(medium temperature) –20 to +60°C (0 to +150°C) 2)
Leakage class according to IEC60534-4 Soft-seated, minimum Class IV
Set point ranges 5 to 15mbar · 10 to 30mbar · 25 to 60mbar · 50 to 200mbar · 0.1 to
0.6bar · 0.2 to 1bar · 0.8 to 2.5bar · 2 to 5bar · 4.5 to 10bar
Max. perm.
pressure at
operating
diaphragm
1200cm² 0.5bar
640cm² 1bar
320cm² 2bar · 10bar 3)
160cm² 3bar · 16bar 3)
80cm² 5bar · 16bar 3)
40cm² · 2 to 5bar 10bar · 16bar 3)
40cm² · 4.5 to 10bar 15bar · 16bar 3)
Pressure
balancing
KVS=0.016 to 4 Without balancing diaphragm
KVS=6.3 to 32 With balancing diaphragm
Pressure tapping External4)
Control line connection G ¼
1) Version with set points from 0.1 to 10bar
2) For unbalanced versions with FKM diaphragm and FKM soft seal
3) Version with force limiter
4) Special version with pressure tapping directly at the valve (see section3.1)

14 EB 2520 EN
Markings on the device
Table2: Dimensions in mm
Nominal size DN15 DN20 DN25 DN32 DN40 DN50
Length L 130 150 160 180 200 230
Height H2 Forged steel 53 – 70 – 92 98
Other materials 44 72
Set point range
5 to 15mbar Height H Without balancing 325 370
With balancing 352 377
Actuator ØD = 490mm, A = 1200cm²
10 to 30mbar
Height H Without balancing 318 366
With balancing 345 370
Actuator ØD = 380mm,
A = 640cm²
ØD = 490mm,
A = 1200cm²
25 to 60mbar Height H Without balancing 318 366
With balancing 345 370
Actuator ØD=380mm, A=640cm²
50 to 200mbar Height H Without balancing 318 366
With balancing 345 370
Actuator ØD = 285mm, A = 320cm²
0.1 to 0.6bar Height H Without balancing 318 366
With balancing 345 370
Actuator ØD = 285mm, A = 320cm²
0.2 to 1bar Height H Without balancing 318 366
With balancing 345 370
Actuator ØD = 225mm, A = 160cm²
0.8 to 2.5bar Height H Without balancing 330 365
With balancing 356 369
Actuator ØD = 170mm, A = 80cm²
2 to 5bar Height H Without balancing 333 368mm
With balancing 359 373mm
Actuator ØD = 170mm, A = 40cm²
4.5 to 10bar Height H Without balancing 437 485
With balancing 463 489
Actuator ØD = 170mm, A = 40cm²

EB 2520 EN 15
Markings on the device
Dimensional drawings
DN15 to 25 DN32 to 50
H
ØD
H2
H
ØD
L
L
H2
Control line connection G¼, for A = 40, 80,
160, and 320cm²
Control line connection G ¼, for A = 640 and
1200cm²
The control line connection is turned by 90° in the drawing. The connection is normally located
opposite the side with the arrow indicating the direction of ow.
G¼ tting
Control line connection at the side of the actuator
housing
Control line connection on the bottom of the
actuator housing

16 EB 2520 EN
Markings on the device
Table3: Weights in kg
Nominal size DN15 DN20 DN25 DN32 DN40 DN50
Set point range
5 to 15mbar 28 40
10 to 30mbar 18 40
25 to 60mbar 14 30
50 to 200mbar 14 26
0.1 to 0.6bar 14 26
0.2 to 1bar 10 22
0.8 to 2.5bar 8 20
2 to 5bar 8 20
4.5 to 10bar 9 21
1) Body made of cast steel 1.0619: +10%

EB 2520 EN 17
Measures for preparation
4 Measures for preparation
After receiving the shipment, proceed as fol-
lows:
1. Check the scope of delivery. Compare
the shipment received against the deliv-
ery note.
2. Check the shipment for transportation
damage. Report any damage to
SAMSON and the forwarding agent
(refer to delivery note).
4.1 Unpacking
Do not remove the packaging until immedi-
ately before installing the valve into the pipe-
line.
Proceed as follows to lift and install the de-
vice:
1. Remove the packaging from the device.
2. Dispose of the packaging in accordance
with the valid regulations.
4.2 Transporting and lifting
Due to the low service weight, lifting equip-
ment is not required to lift and transport the
device (e.g. to install it into the pipeline).
Risk of valve damage due to incorrectly at-
tached lifting equipment.
Do not attach lifting equipment to mounting
parts (e.g. adjusting screw or control line).
Transport instructions
−Protect the device against external inu-
ences (e.g. impact).
−Do not damage the corrosion protection
(paint, surface coatings). Repair any
damage immediately.
−Protect the device against moisture and
dirt.
−Observe the permissible ambient tem-
peratures (see section3.2).
4.3 Storage
Risk of regulator damage due to improper
storage.
−Observe storage instructions.
−Avoid long storage times.
Contact SAMSON in case of different stor-
age conditions or long storage periods.
We recommend regularly checking the de-
vice and the prevailing storage conditions
during long storage periods.
Storage instructions
−Protect the device against external inu-
ences (e.g. impact).
−Do not damage the corrosion protection
(paint, surface coatings). Repair any
damage immediately.
−Protect the device against moisture and
dirt. Store it at a relative humidity of less
NOTICE
!
NOTICE
!
Note

18 EB 2520 EN
Measures for preparation
than 75%. In damp spaces, prevent con-
densation. If necessary, use a drying
agent or heating.
−Make sure that the ambient air is free of
acids or other corrosive media.
−Observe the permissible ambient tem-
peratures (see section3.2).
−Do not place any objects on the device.
4.4 Preparation for installation
ÎFlush the pipelines.
The plant operator is responsible for clean-
ing the pipelines in the plant.
ÎEnsure that there is no liquid, e.g. con-
densed water, inside the regulator. If nec-
essary, blow out the connecting parts
with clean compressed air.
ÎCheck the valve to make sure it is clean.
ÎCheck the valve for damage.
ÎCheck to make sure that the type desig-
nation, valve size, material, pressure rat-
ing, and temperature range of the valve
match the plant conditions (size and
pressure rating of the pipeline, medium
temperature etc.).
Note

EB 2520 EN 19
Mounting and start-up
5 Mounting and start-up
5.1 Installing the valve into the
pipeline
5.1.1 Installation conditions
−Choose a place of installation that allows
you to freely access the regulator even
after the entire plant has been complet-
ed.
−The type and dimensions of the pipeline
and tank connections must suit the regu-
lator.
−Make sure the direction of ow matches
the direction indicated by the arrow on
the body.
−Install the regulator free of stress and
with the least amount of vibrations as
possible. If necessary, support the pipe-
line near to the connecting anges. Do
not attach supports directly to the valve
or actuator.
−Protect the regulator from icing up when
controlling media that can freeze. Re-
move the regulator from the pipeline
when the plant is shut down if the regula-
tor is not installed areas free from frost.
−Observe the permissible ambient tem-
peratures (see section3.2).
5.1.2 Mounting position
Standard
Preferably install the regulator in a horizon-
tal pipeline. The actuator housing with set
point adjuster must face upwards.
Fig.5: Installation in horizon-
tal pipelines
ÎInstall the control line to the tapping
point with an approx. 10% slope to al-
low any condensing liquid to ow back
into the tank or pipe.
Options
Alternatively, the valve can be installed in a
vertical pipeline. The actuator housing with
set point adjuster must face sideways.
Fig.6: Installation in vertical
pipelines
Control deviations due to alternative installa-
tion.
System deviations may arise when the regu-
lator is installed in vertical pipelines.
NOTICE
!

20 EB 2520 EN
Mounting and start-up
5.1.3 Additional ttings
Strainer
We recommend installing a strainer (e.g.
SAMSON Type2N) upstream of the regula-
tor. It prevents solid particles in the process
medium from damaging the valve.
ÎInstall the strainer upstream of the tem-
perature regulator. The arrow on the
valve indicates the direction of ow.
ÎFor installation in vertical pipeline: install
the strainer with the lter element facing
downwards.
ÎInstall the lter with sufcient space avail-
able to remove the lter.
ÎCheck the strainer at regular intervals
and clean it, if necessary.
Shut-off valve
Install a hand-operated shut-off valve both
upstream of the strainer and downstream of
the regulator. This allows the plant to be shut
down for cleaning and maintenance, and
when the plant is not used for longer periods
of time.
Pressure gauges
Install a pressure gauge both upstream and
downstream of the regulator to monitor the
pressures prevailing in the plant.
min.
6 x DN
min. 12 x DN
DN
22 1
p1
1
211
p1p2
3
3
24
4
p
2
min.
5 x DN
~10% slope to
pressure tap-
ping point
~10% slope to pressure
tapping point
1 Shut-off valve
2 Pressure gauge
3 Strainer
4 Control line
Fig.7: Sample application