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