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