Samson 2406 Service manual

Translation of original instructions
EB 2522 EN
Type 2406 Excess Pressure Valve
Self-operated Pressure Regulators
Edition October 2021

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 2522 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 2522 EN
1 Safety instructions and measures ...................................................................4
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 ...............................................................................10
2.1 Regulator nameplate ....................................................................................10
2.2 Materialidenticationnumber ......................................................................10
3 Design and principle of operation ................................................................11
3.1 Technical data .............................................................................................13
4 Measures for preparation............................................................................18
4.1 Unpacking ..................................................................................................18
4.2 Transporting and lifting ................................................................................18
4.3 Storage.......................................................................................................19
4.4 Preparation for installation............................................................................19
5 Mounting and start-up.................................................................................20
5.1 Installing the valve into the pipeline ...............................................................20
5.1.1 Installation conditions...................................................................................20
5.1.2 Mounting orientation....................................................................................21
5.1.3 Additionalttings.........................................................................................21
5.2 Quick check ................................................................................................23
5.3 Putting the regulator into operation................................................................23
5.4 Adjust set point............................................................................................23
6 Servicing.....................................................................................................25
6.1 Preparation for return shipment.....................................................................26
6.2 Ordering spare parts and operating supplies .................................................26
7 Malfunctions ...............................................................................................27
7.1 Troubleshooting ...........................................................................................27
8 Decommissioning and removal ....................................................................28
8.1 Decommissioning.........................................................................................28
8.2 Removing the valve from the pipeline.............................................................28
8.3 Disposal......................................................................................................28
9 Annex.........................................................................................................29
9.1 After-sales service........................................................................................29
9.2 Certicates ..................................................................................................29

4 EB 2522 EN
Safety instructions and measures
1 Safety instructions and measures
Intended use
TheType2406ExcessPressure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ov-
ens. 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 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 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 2522 EN 5
Safety instructions and measures
Safety features
TheType2406Regulatordoesnothaveanyspecialsafetyfeatures.Whenrelievedofpres-
sure, the regulator is closed by the force of the set point springs.
Personal protective equipment
Werecommendcheckingthehazardsposedbytheprocessmediumbeingused(e.g.
uGESTIS(CLP)hazardoussubstancesdatabase).
− Provide protective equipment (e.g. safety gloves, eye protection) appropriate for the pro-
cess medium used.
− Wearhearingprotectionwhenworkingnearthevalve.Followtheinstructionsgivenby
the plant operator.
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, warning and caution notes in these
mounting and operating instructions, especially for installation, start-up and service work.
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.
Responsibilities of the operator
Operators are responsible for proper use 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,operatorsmustensurethatoperatingpersonnelorthirdpartiesarenotexposed
to any danger.

6 EB 2522 EN
Safety instructions and measures
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.
Referenced standards, directives 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. The EU declaration
ofconformityisincludedintheannexoftheseinstructions(seesection9.2).
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).
Referenced documentation
The following documents apply in addition to these mounting and operating instructions:
− Mounting and operating instructions for
e.g. Type2N/NI Strainer uEB1015
− Data sheets for
e.g. Type2N/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.).

EB 2522 EN 7
Safety instructions and measures
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.
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.

8 EB 2522 EN
Safety instructions and measures
WARNING
!
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 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.
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.
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 incorrectly attached lifting equipment.
ÎDo not attach lifting equipment to mounting parts (e.g. adjusting screw or control
line).

EB 2522 EN 9
Safety instructions and measures
NOTICE
!
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.

10 EB 2522 EN
Markings on the device
2 Markings on the device
2.1 Regulator nameplate
SAMSON
4
6
231
789 11
5
10 Made in Germany
2009
xxxx
1 Type designation (2406)
2Max.perm.operatingpressureatthe
actuator pmax
3CongurationID
4 Order number or date
5 KVScoefcient
6 Set point range/spring force
7Valvesize
8 Pressure rating
9Permissible differential pressure (across
the valve)
10 Perm. temperature
11 Bodymaterial
Fig.1: Nameplate
The CE marking only exists for versions in
valve sizes DN32 to 50.
2.2 Material identication
number
See the nameplate (11, body material). For
more details on the nameplate, see sec-
tion2.1.
Note

EB 2522 EN 11
Design and principle of operation
3 Design and principle of
operation
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
closed by the force of the set point springs
(7).
The upstream pressure p1to be controlled is
tapped upstream of the regulator and trans-
mittedoveranexternalcontrollinetothe
control line connection (9) on the actuator
housing (6) where it is converted into a posi-
tioning force by the diaphragm plate with
operating diaphragm (5). The diaphragm
moves the plug over the plug stem (4) de-
pending 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upstream
pressure p1rises above the spring force ad-
justed at the set point springs, the valve
opens proportionally to the change in pres-
sure.
In the version with pressure balancing, the
forces produced by the upstream and down-
12
8
8
7
6
11
5
4
9
3
2
1
p1
p2
Fig.2: Type2406 Excess Pressure Valve without pressure balancing

12 EB 2522 EN
Design and principle of operation
10
p1
p2
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.3: Type2406 Excess Pressure Valve with pressure balancing

EB 2522 EN 13
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2406ExcessPressureValveisused
to maintain the pressure upstream of the reg-
ulator to an adjusted set point.
− For gases
− Temperature range from –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 closed when relieved of
pressure. The valve opens when the up-
stream 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2406 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.3)
− 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
Dimensions and weights
Table2andTable3provideanoverviewof
the dimensions and weights. The lengths and
heights in the dimensional drawings are
shownonpage16.
WARNING
!
Note
stream pressures acting on the plug are elim-
inated by the balancing diaphragm (10).
The plug is fully balanced.

14 EB 2522 EN
Design and principle of operation
Table1: Technical data
Valve size DN15 DN20 DN25 DN32, 40, 501)
Pressure rating (valve) PN16 · PN25 · PN40
KVScoefcients
Standard
4 6.3 8 32
Reduced KVSco-
efcients
0.1 · 0.25 · 0.4 ·
1 · 1.6 · 2.5
0.1 · 0.25 · 0.4 · 1
· 1.6 · 2.5 · 4
0.1 · 0.25 · 0.4 ·
1 · 1.6
· 2.5 · 4 ·
6.3
6.3 · 8 · 16 · 20
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.permissible
pressure at operating
diaphragm 3)
1200cm² 0.5bar
640cm² 1bar
320cm² 2bar
160cm² 3bar
80cm² 5bar
40cm² 15bar
Pressure balancing KVS = 0.1 to 4 Withoutbalancingdiaphragm
KVS = 6.3 to 32 Withbalancingdiaphragm
Pressure tapping Externalcontrolline·Directatthevalvebody(specialversion)
Control line connection G¼
1) Largervalvesizesonrequest
2) For unbalanced version with FKM diaphragm and FKM soft seal
3) Correspondstothemaximumdifferentialpressure

EB 2522 EN 15
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=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

16 EB 2522 EN
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oppo-
site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.4: Dimensions of Type2406

EB 2522 EN 17
Design and principle of operation
Table3: Weights in kg
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%

18 EB 2522 EN
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Table1).
NOTICE
!

EB 2522 EN 19
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 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
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Table1).
− 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 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.).
NOTICE
!
Note
Note

20 EB 2522 EN
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. Unless
the regulator is installed in locations
where no frost occurs, remove the regu-
lator from the pipeline when the plant is
shut down.
− Observe the permissible ambient tem-
peratures(seesectionTable1).
min.
2 x DN
min. 5 x DN
DN
22
1
p
1
p2
1
3
22 1
p1p2
1
4
3
2
min.
3 x DN
~10%slopeto
pressure tapping
point
~10%slopetopressure
tapping point
1 Shut-off valve
2 Pressure gauge
3 Strainer
4 Control line
Fig.5: Installation example