Samson 2405 Series Service manual

Translation of original instructions
EB 2520 EN
Type2405 Pressure Reducing Valve
Self-operated Pressure Regulators
Edition December 2022

Definition 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
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. The images shown in
these instructions are for illustration purposes only. The actual product may vary.
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
([e-mail]).
Documents relating to the device, such as the mounting and operating
instructions, are available on our website at www.samsongroup.com >
Service & Support > Downloads > Documentation.

Contents
EB 2520 EN
1 Safety instructions and measures ...................................................................4
1.1 Notes on possible severe personal injury .........................................................7
1.2 Notes on possible personal injury ...................................................................8
1.3 Notes on possible property damage................................................................8
2 Markings on the device ...............................................................................10
2.1 Regulator nameplate ....................................................................................10
2.2 Location of the nameplate.............................................................................11
2.3 Materialidenticationnumber ......................................................................11
3 Design and principle of operation ................................................................12
3.1 Technical data .............................................................................................14
4 Measures for preparation............................................................................19
4.1 Unpacking ..................................................................................................19
4.2 Transporting and lifting ................................................................................19
4.3 Storage.......................................................................................................20
4.4 Preparation for installation............................................................................20
5 Mounting and start-up.................................................................................21
5.1 Installing the valve into the pipeline ...............................................................21
5.1.1 Installation conditions...................................................................................21
5.1.2 Mounting orientation....................................................................................22
5.1.3 Additionalttings.........................................................................................22
5.2 Quick check ................................................................................................24
5.3 Putting the regulator into operation................................................................24
5.4 Adjusting the set point..................................................................................24
6 Servicing.....................................................................................................25
6.1 Preparation for return shipment.....................................................................26
6.2 Ordering spare parts and operating supplies .................................................26
7 Decommissioning and removal ....................................................................27
7.1 Decommissioning.........................................................................................27
7.2 Removing the valve from the pipeline.............................................................27
8 Disposal......................................................................................................28
9 After-sales service .......................................................................................28
10 Certicates..................................................................................................29
10.1 Information on the UK sales region................................................................29

4 EB 2520 EN
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operatingconditionsthatmeetthespecicationsusedforsizingthedeviceattheordering
stage. In case operators intend to use the device in applications or conditions other than
those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 regulators are not suitable for the following applications:
− Useoutsidethelimitsdenedduringsizingandbythetechnicaldata
− Useoutsidethelimitsdenedbytheadditionalttingsmountedontheregulator
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
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 must be observed. According 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 spe-
cialized training, their knowledge and experience as well as their knowledge of the applica-
ble standards.

EB 2520 EN 5
Safety instructions and measures
Personal protective equipment
We recommend checking the hazards posed by the process medium being used (e.g.
uGESTIS(CLP)hazardoussubstancesdatabase).Dependingontheprocessmediumand/
or the activity, the protective equipment required includes:
− Protectiveclothing,safetyglovesandeyeprotectioninapplicationswithhot,coldand/or
corrosive media
− Wear hearing protection when working near the valve. Follow the instructions given by
the plant operator.
− Hard hat
− Safety harness, e.g. when working at height
− Safety footwear, if applicable ESD (electrostatic discharge) footwear
ÎCheckwiththeplantoperatorfordetailsonfurtherprotectiveequipment.
Revisions and other modications
Revisions,conversionsorothermodicationsof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, plant operators and operating personnel must
prevent hazards that could be caused in the regulator by the process medium, the operating
pressure or by moving parts by taking appropriate precautions. Plant operators and operat-
ing personnel must observe all hazard statements, warnings and caution notes in these
mounting and operating instructions.
Hazards resulting from the special working conditions at the installation site of the regulator
mustbeidentiedinariskassessmentandpreventedthroughthecorrespondingsafetyin-
structions drawn up by the operator.
We also recommend checking the hazards posed by the process medium being used (e.g.
uGESTIS(CLP)hazardoussubstancesdatabase).
ÎObservesafetymeasuresforhandlingthedeviceaswellasrepreventionandexplosion
protection measures.
These mounting and operating instructions deals with the standard version of the device.
Componentsofthedevicethatdiffertothoseusedforthestandardversiondescribedinthis
document can be exchanged with other certain SAMSON components. The residual hazards
of these components are described in the associated mounting and operating instructions
(see documents listed under 'Referenced documentation').

6 EB 2520 EN
Safety instructions and measures
Responsibilities of the operator
Operators are responsible for proper use and compliance with the safety regulations. Opera-
tors are obliged to provide these mounting and operating instructions as well as the refer-
enced documents to the operating personnel and to instruct them in proper operation. Fur-
thermore, operators must ensure that operating personnel or third parties are not exposed to
any danger.
Operatorsareadditionallyresponsibleforensuringthatthelimitsfortheproductdenedin
the technical data are observed. This also applies to the start-up and shutdown procedures.
Start-up and shutdown procedures fall within the scope of the operator's duties and, as such,
are not part of these mounting and operating instructions. SAMSON is unable to make any
statements about these procedures since the operative details (e.g. differential pressures and
temperatures) vary in each individual case and are only known to the operator.
Responsibilities of operating personnel
Operating personnel must read and understand these mounting and operating instructions as
wellasthereferenceddocumentsandobservethespeciedhazardstatements,warnings
and caution notes. Furthermore, operating personnel must be familiar with the applicable
health, safety and accident prevention regulations and comply with them.
Safety features
TheType2405Regulatordoesnothaveanyspecialsafetyfeatures.Whenrelievedofpres-
sure, the regulator is opened by the force of the set point springs.
Referenced standards, directives and regulations
The regulators comply with the requirements of the European Pressure Equipment Directive
2014/68/EU,MachineryDirective2006/42/EC,Directive2016No.1105Pressure
Equipment(Safety)Regulations2016andDirective2008No.1597SupplyofMachinery
(Safety)Regulations2008.RegulatorswithaCEmarkingand/orUKCAmarkinghavea
declaration of conformity, which includes information about the applied conformity
assessment procedure. This declaration of conformity is included in the annex of these
instructions(seesection10).
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 hazard assessment stipulated in
Clause5.2ofISO80079-36,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
Clause6.4ofEN60079-14(VDE0165-1).

EB 2520 EN 7
Safety instructions and measures
Referenced documentation
The following documents apply in addition to these mounting and operating instructions:
− Mounting and operating instructions for
e.g. Type2N or 2NI Strainer uEB1015
− Data sheets for
e.g. Type2N or 2NI Strainer uT1015
− Mounting and operating instructions as well as data sheets for additional components
(e.g. shut-off valves, pressure gauges etc.).
1.1 Notes on possible severe personal injury
DANGER
!
Risk of bursting in pressure equipment.
Valvesandpipelinesarepressureequipment.Improperopeningcanleadtovalve
components bursting.
ÎObserve the maximum permissible pressure for valve and plant.
ÎBeforestartinganyworkonthevalve,depressurizeallplantsectionsaffected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 affected as well as the valve.
ÎWear personal protective equipment.

8 EB 2520 EN
Safety instructions and measures
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mediumcanowoutofthevalveand,depend-
ing on its properties, cause personal injury, e.g. (chemical) burns.
ÎIf possible, drain the process medium from all the plant sections affected and the
valve.
ÎWear protective clothing, safety gloves and eye protection.
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 warm up to the ambient tempera-
ture.
ÎWear protective clothing and safety gloves.
Damage to health relating to the REACH regulation.
If a SAMSON device contains a substance listed as a substance of very high concern
onthecandidatelistoftheREACHregulation,thisisindicatedontheSAMSONdeliv-
ery note.
ÎInformation on safe use of the part affected uwww.samsongroup.com/en/about-
samson/material-compliance/reach-regulation/
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.

EB 2520 EN 9
Safety instructions and measures
NOTICE
!
Risk of regulator damage due to incorrectly attached slings.
ÎDo not attach load-bearing slings to the actuator housing.
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equipment.
Risk of leakage and valve damage due to excessively high or low tightening
torques.
Observethespeciedtorqueswhentighteningvalvecomponents.
Excessive tightening torques lead to parts wearing out more quickly. Parts that are too
loose may cause leakage.
ÎObservethespeciedtighteningtorques.
Risk of regulator damage due to the use of unsuitable lubricants.
The lubricants to be used depend on the regulator material. Unsuitable lubricants may
corrode and damage surfaces.
ÎOnly use lubricants approved by SAMSON.
When in doubt, consult SAMSON.
Risk of regulator damage due to the use of unsuitable tools.
Certaintoolsarerequiredtoworkontheregulator.
ÎOnly use tools approved by SAMSON.
When in doubt, consult SAMSON.
Risk of excess pressure damaging plant sections due to construction-related seat
leakage through the regulator.
ÎAlways install a safety device (e.g. safety excess pressure valve or safety relief
valve) in the plant.
SAMSON's After-sales Service can support you concerning lubricant, tightening torques
and tools approved by SAMSON.
Note

10 EB 2520 EN
Markings on the device
2 Markings on the device
The nameplate shown was up to date at the
time of publication of this document. The
nameplate on the device may differ from the
one shown.
2.1 Regulator nameplate
9
8
7
6
12
10 11 12 13
3
5
1517
16
14 4
18 19
20
21
The CE marking only exists for versions in valve sizes DN32 to 50.
Fig.1: Nameplate
1 Max. perm. operating
pressure at the actuator
2Materialnumber/
congurationID
3 Type
4 Production number
5 KVS/CV
6 Set point range
7Valvesize
8 Pressure rating
9 Perm. differential pressure
10 Perm. temperature
11 Bodymaterial
12 Serial number (if applicable)
13 TÜVregistrationno.(if
applicable)
14 Data Matrix code (if
applicable)
15 CEmarking(ifapplicable)
16 Countryoforigin
17 EAC,ifapplicable
18 UKCA,ifapplicable
19 Year of manufacture
20 Month of manufacture
21 IDofthecerticationbody
Note

EB 2520 EN 11
Markings on the device
2.2 Location of the nameplate
Location of
the nameplate
Fig.2: Nameplate of Type2405 Regulator
2.3 Material identication
number
See the nameplate (11, body material). For
more details on the nameplate, see sec-
tion2.1.

12 EB 2520 EN
Design and principle of operation
3 Design and principle of oper-
ation
Themediumowsthroughthevalveinthe
direction indicated by the arrow. The posi-
tion of the plug (3) determines the cross-sec-
tionalareaofowbetweentheplugandthe
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). The dia-
phragm moves the plug over the plug stem
(4) 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.
p1
p2
8
7
6
11
5
4
9
2
3
1
12
Fig.3: Type2405 Pressure Reducing Valve without pressure balancing · KVS 1.6 to 4 · Flow-to-
open

EB 2520 EN 13
Design and principle of operation
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.
p
1
p
2
p
1p
2
10
1Valvebody
2 Seat
3 Plug
4 Plug stem
5Diaphragm plate with operating dia-
phragm
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
12 Cap
Fig.4: Type2405 Pressure Reducing Valve
without pressure balancing · KVS
0.016 to 1 · Flow-to-close
Fig.5: Type2405 Pressure Reducing Valve with
pressure balancing · KVS 6.3 to 32

14 EB 2520 EN
Design and principle of operation
3.1 Technical data
The valve and actuator nameplates provide
information on the valve and actuator ver-
sions(seesection2.1).
Process medium and scope of application
TheType2405PressureReducingValveis
used to maintain the pressure downstream of
the valve to an adjusted set point.
− For gases
− Temperature range –20 to +60°C
− Set points from 5mbar to 10bar
− ValvesizeDN15 to 50
− Pressure ratings from PN16 to 40
The regulator is open when relieved of pres-
sure. The valve closes when the downstream
pressure rises.
Temperature range
Dependingonhowtheregulatoriscong-
ured, it can be used up to temperatures of
60°C(Table1).
Temperaturerangefrom0to150°Cforun-
balanced versions with FKM diaphragm and
FKM soft seal
Leakage class
The soft-seated regulator has the leakage
classIVaccordingtoIEC60534-4.
Noise emissions
SAMSON is unable to make general state-
ments about noise emissions. The noise emis-
sions depend on the regulator version, plant
facilities, process medium and operating
conditions.
Risk of hearing loss or deafness due to loud
noise.
Wear hearing protection when working near
the regulator.
The Type2405 Regulator is not a safety
valve. If necessary, a suitable overpressure
protection must be installed on site in the
plant section.
Options
− Withpressurebalancing(seeFig.5)
− 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
WARNING
!
Note

EB 2520 EN 15
Design and principle of operation
Dimensions and weights
Table2providesasummaryofthedimensionsandweights.Thelengthsandheightsinthe
dimensionaldrawingsareshownonpage17.
Table1: Technical data
Valve size DN15 DN20 DN25 DN32 DN40 DN50
Pressure rating (valve) PN16·PN25·PN40
KVS
coefcients
Standard
4.0 6.3 8.0 16 20 32
Reduced KVS
coefcients
0.016·
0.04·0.1·
0.25·0.4·
1.0·1.6·
2.5
0.016·
0.04·0.1·
0.25·0.4·
1.0·1.6·
2.5·4.0
0.016·
0.04·0.1·
0.25·0.4·
1.0·1.6·
2.5·4.0·
6.3
1.6·2.5·
4.0·6.3·
8.0
1.6·2.5·
4.0·6.3·
8.0·16
1.6·2.5·
4.0·6.3·
8.0·16·
20
Max. perm. differential pressure 10bar·12bar 1)
Max. permissible temperature
range (medium temperature) –20to+60°C(0to+150°C) 2)
Leakageclassacc.toIEC60534-4 Soft-seated,minimumClassIV
Conformity · ·
Set point ranges
5to15mbar5)·10to30mbar5)·25to60mbar5)·
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)
5) The set point range cannot be combined with the following KVScoefcients:16·20·32

16 EB 2520 EN
Design and principle of operation
Table2: Dimensions in mm
Valve 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=485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=485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 17
Design and principle of operation
Dimensional drawings
DN15 to 25 DN32 to 50
H
ØD
L
H2
min. 150 mm
H
ØD
H2
L
min. 150 mm
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
Fig.6: Dimensions of Type2405

18 EB 2520 EN
Design and principle of operation
Table3: Weights in kg1)
Valve 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 19
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 with the delivery
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3.1).
NOTICE
!

20 EB 2520 EN
Measures for preparation
4.3 Storage
Risk of regulator damage due to improper
storage.
− Observe the storage instructions.
− Avoid long storage times.
Contact SAMSON in case of different stor-
age conditions or longer storage times.
We recommend to regularly check the device
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
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3.1).
− Do not place any objects on the device.
NOTICE
!
Note
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that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