Samson 2422 series Service manual

Mounting and
Operating Instructions
EB 2549 EN
Edition January 2016
Type2422/2425 Excess Pressure Valve
Self-operated Pressure Regulators
Type2422/2425 Excess Pressure Valve

Denition of signal words
DANGER!
Hazardous situations which, if not
avoided, will result in death or serious
injury
WARNING!
Hazardous situations which, if not
avoided, could result in death or seri-
ous injury
NOTICE
Property damage message or mal-
function
Note:
Additional information
Tip:
Recommended action

2 EB 2549 EN

Contents
EB 2549 EN 3
1 General safety instructions .............................................................................4
2 Process medium and scope of application .......................................................5
2.1 Transportation and storage .............................................................................5
3 Design and principle of operation ..................................................................6
4 Installation ....................................................................................................8
4.1 Assembly ......................................................................................................8
4.2 Mounting position ..........................................................................................9
4.3 Notes on installation ......................................................................................9
4.4 Control line, condensation chamber and needle valve .....................................10
4.5 Strainer .......................................................................................................11
4.6 Shut-off valve ...............................................................................................11
4.7 Pressure gauge ............................................................................................11
5 Operation ...................................................................................................12
5.1 Start-up .......................................................................................................12
5.2 Adjusting the set point ..................................................................................12
5.3 Decommissioning .........................................................................................13
6 Maintenance and troubleshooting ................................................................13
6.1 Replacing the operating diaphragm ..............................................................13
7 Nameplate ..................................................................................................14
8 Customer service .........................................................................................15
9 Dimensions .................................................................................................16
10 Technical data .............................................................................................18
Contents Page

4 EB 2549 EN
General safety instructions
1 General safety instructions
−The regulator must be mounted, started up or serviced by fully trained and
qualied personnel only; the accepted industry codes and practices are to
be observed. Make sure employees or third persons are not exposed to any
danger.
−All safety instructions and warnings given in these mounting and operating
instructions, particularly those concerning installation, start-up and mainte-
nance, must be strictly 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 dangers due to their specialized training, their
knowledge and experience as well as their knowledge of the applicable
standards.
−The regulators comply with the requirements of the European Pressure Equip-
ment Directive 97/23/EC. Devices with a CE marking have a declaration of
conformity, which includes information about the applied conformity assess-
ment procedure. This declaration of conformity can be provided on request.
−To ensure appropriate use, only use the regulator in applications where the
operating pressure and temperatures do not exceed the specications used
for sizing the regulator at the ordering stage.
−The manufacturer does not assume any responsibility for damage caused by
external forces or any other external factors.
−Any hazards that could be caused in the regulator by the process medium,
operating pressure or by moving parts are to be prevented by taking appro-
priate precautions.
−Proper transport, storage, installation, operation and maintenance are as-
sumed.
Note:
Non-electric actuators and control valve versions do not have their own
potential ignition source according to the ignition risk assessment stipulat-
ed in EN13463-1: 2009, section 5.2, even in the rare incident of an op-
erating fault. Therefore, they do not fall within the scope of Directive
94/9/EC. For connection to the equipotential bonding system, observe the
requirements specied in section 6.3 of EN60079-14 (VDE0165 Part 1).


EB 2549 EN 5
Process medium and scope of application
2 Process medium and scope of application
Pressure regulator for liquids, gases and vapors up to 350°C
For controlling the upstream pressure p1 to the adjusted set point. The valve opens when the
upstream pressure rises. The upstream pressure is transmitted to the actuator over a control line
that must be installed on site.
The pressure regulators are not shut-off devices guaranteeing tight shut-off. When closed, these
regulators can have a leakage rate of ≤0.05% of the KVS coefcient.
Overpressure protection must be installed in the plant.
WARNING!
Risk of injury and property damage due to high pressure in the plant.
A suitable overpressure protection must be installed on site in the plant section.
2.1 Transportation and storage
The regulator must be carefully handled, transported and stored. Protect the excess pressure
valve against adverse inuences, such as dirt, moisture or frost, during storage and transpor-
tation.
When regulators are too heavy to be lifted by hand, fasten the lifting sling at a suitable place
on the valve body.
WARNING!
Incorrectly attached lifting slings or supports.
Risk of injury and property damage due to valve falling.
Securely fasten slings or supports to the valve body and secure against slipping.

6 EB 2549 EN
Design and principle of operation
3 Design and principle of op-
eration
See Fig.1 and Fig.2.
The Type2422/2425 Excess Pressure Valve
consists of the Type 2422 Valve and the
Type2425 Actuator. The Type2422 Valve is
available either balanced by a bellows or a
diaphragm.
The excess pressure valve is used to maintain
the pressure upstream of the valve to an ad-
justed set point. The valve opens when the up-
stream pressure rises.
The medium ows through the valve in the di-
rection indicated by the arrow. The position of
the plug (3) determines the ow rate across
the area released between plug and valve
seat (2). The plug stem (4) with the plug is
connected to the top diaphragm stem (8) of
the actuator (10).
The upstream pressure p
1
is regulated by the
positioning springs (11) and the set point ad-
juster (13). When relieved of pressure, the
valve is closed by the force of the set point
springs.
The upstream pressure p1 to be controlled is
tapped upstream of the valve and transmitted
over the control line to the operating dia-
phragm (9) where it is converted into a posi-
tioning force. This force is used to move the
valve plug according to the force of the posi-
tioning springs. When the force resulting from
the upstream pressure p1 rises above the ad-
justed set point, the valve opens proportional-
ly to the change in pressure.
The principle of operation of the
Type2422/2425 Excess Pressure Valve bal-
anced by a bellows or diaphragm only differs
concerning the pressure balancing. The valves
balanced by a diaphragm have a balancing
diaphragm (5.1) instead of a bellows (5). In
both cases, the forces created by the upstream
and downstream pressures that act on the
valve plug are balanced out.
The valves can be supplied with ow divider
StI or StIII. The valve seat must be replaced
on retrotting the ow divider.
The control of vapors and liquids above
150 °C is only possible with a Type 2422
Valve balanced by a bellows. In this case,
condensation chamber (20) is already in-
stalled in the control line1). The needle valve
(18) in the control line is open and lead-
sealed.
Before start-up, ll the condensation chamber
with the process medium at the lling opening
(21) until it overows.
_
1) Only in combination with a control line kit.
Otherwise, the condensation chamber must be
ordered separately (see uT2595).

EB 2549 EN 7
Design and principle of operation
Fig.1: Functional diagram of Type2422/2425 balanced by a bellows
Type 2422 Valve,
balanced by a
bellows
Type2425 Actuator
1
2
3
4
5
6
7
8
9
17
16
11
13
20 21
6.1
19
6.2
18
15
14
8.1
1 Type 2422 Valve
2 Seat (exchangeable)
3 Plug
4 Plug stem
4.1 Actuator stem
5 Balancing bellows
6 Bellows housing
6.1 Vent screw (640cm², bellows
housing)
6.2 Vent screw (connection to
actuator)
7 Coupling nut
8Top diaphragm stem
8.1 Nut
9Operating diaphragm
10 Type2424 Actuator
11 Positioning springs
13 Set point adjuster
14 Bottom diaphragm stem
15 Nuts and bolts
16 Nut
17 Diaphragm plate
18 Control line connection (for
steam including screw joint with
restriction and needle valve)
19 Control line
20 Condensation chamber for tem-
peratures above 150°C and for
steam
21 Filling opening with plug
p1Upstream pressure
p2Downstream pressure
p1p2

8 EB 2549 EN
Installation
4 Installation
See Fig.1 and Fig.2.
4.1 Assembly
Valve and actuator can be assembled before
or after the valve has been installed in the
pipeline.
Î
Relieve the positioning springs of tension
by turning the set point adjuster (13).
ÎPlace the actuator on the bellows housing
and carefully screw it in as far as it will
go. Make sure the control line connection
points toward the upstream pressure side.
Î
Hold the actuator and fasten it to the bel-
lows housing using the coupling nut (7).
Fig.2: Functional diagram of Type2422/2425 balanced by a diaphragm
5.1 Balancing diaphragm
p1Upstream pressure
p2Downstream pressure
Type 2422 Valve,
balanced by a
diaphragm
Type2425 Actuator
5.1
P1P2

EB 2549 EN 9
Installation
4.2 Mounting position
Select the installation location making sure
that the regulator is installed at a distance of
at least six times the nominal size (DN) away
from pipe ttings or instruments that cause
ow turbulence (e.g. pipe bends, manifolds,
pressure measuring points or other valves).
They can change the ow conditions which
may lead to an instable control process espe-
cially in applications with gases, air or steam.
Contact SAMSON to obtain the TV-SK17041
documentation which contains more details on
installation requirements.
4.3 Notes on installation
Install the excess pressure valve in horizontal
pipelines.
−Flush the pipeline thoroughly before in-
stalling the regulator to ensure that no
impurities impair the proper functioning
of the valve, above all the tight shut-off.
−Direction of ow must match the direction
indicated by the arrow on the body.
−Install the regulator free of stress. If nec-
essary, support the pipeline near to the
connecting anges. Do not attach sup-
ports directly to the valve or actuator.
−Install a strainer upstream of the regula-
tor.
−Protect the regulator from icing up when
controlling media that can freeze. If nec-
essary, depressurize and drain the regu-
lator and remove it from the pipeline
while the plant is shut down.
Fig.3: Sample application
1
p
1
p2
3451
2
16
1 Shut-off valve
2 Upstream pressure
gauge
3 Strainer (lter)
4 Type2422/2425
Excess Pressure Valve
5 Downstream pressure
gauge
6 Bypass piping
p1Upstream pressure
p2Downstream pressure

10 EB 2549 EN
Installation
Mounting position
Valve balanced by a bellows/diaphragm
−Actuator facing downward
Pressure testing of the plant · The pressure
must not exceed the maximum permissible
pressure of the regulator and plant on testing
the pressure of the plant when the regulator is
already installed. An excessive test pressure
can damage the operating diaphragm in the
actuator.
NOTICE
Uncontrolled excess pressure in the
plant may damage the operating dia-
phragm.
The maximum permissible pressure at
the actuator must not exceed the pres-
sure specied in Table1.
Table1: Max. perm. pressure at actuator
Actuator area Max. perm. pressure
640cm² 1.5bar
320cm² 3bar
To prevent damage to the diaphragm, take
one of following precautions:
−Remove the regulator from the pipeline
or isolate the regulator in the pipeline
and install a bypass (see Fig.3) or
−Detach the control line and seal the
openings with end plugs or
−Install a shut-off valve in the control line.
4.4 Control line, condensation
chamber and needle valve
Control line · A control line must be provided
at the site of installation, e.g. a
3
/
8
“ pipe for
steam or an Ø8x1 or Ø6x1mm copper
pipe for air or water.
Connect the control line to the upstream line
(p1) at least one meter away from the valve in-
let. If a manifold is located upstream of the ex -
cess pressure valve, connect the valve to the
manifold, even if it is several meters away. If
the upstream line is extended by a conical ex-
pansion piece, connect the control line in the
expanded section of the line. Weld the control
line at the side in the middle of the pipe, in-
clining at a ratio of approximately 1:10 up to
the condensation chamber.
Weld the line coming from the pressure tap-
ping point to the
3
/
8
“ pipe socket on the cham-
ber. Install the condensation chamber at the
highest point of the pipeline. Consequently,
the control line between condensation cham-
ber and actuator must also be installed with a
downward slope. In this case, use a
3
/
8
“ pipe
with screw ttings.
If the control line connection is located below
the middle of the valve inlet ange, arrange
the condensation chamber at the same level
as the inlet ange. In this case, use a pipe
which is at least ½“ in size for the control line
from the tapping point to the condensation
chamber.
If the control line is connected above the mid-
dle of the valve inlet ange, install the conden-
sation chamber at the same level as the up-
stream pressure tapping point. The additional

EB 2549 EN 11
Installation
pressure of the condensate head must be com-
pensated for by adjusting the set point to a
higher value.
Control line kit · A control line kit for tapping
pressure directly at the valve body is available
as an accessories part from SAMSON (for set
points ≥ 0.8bar). See uT2595.
Condensation chamber · A condensation
chamber is required for liquids above 150°C
as well as for steam. The mounting position of
the condensation chamber is indicated by an
adhesive label on the chamber itself as well as
by an arrow and the word "top" stamped on
the top of the chamber.
This mounting position must be adhered to;
otherwise the safe functioning of the excess
pressure valve cannot be guaranteed.
Needle valve · If the regulator tends to hunt,
install a needle valve at the control line con-
nection (18) in addition to the standard
SAMSON screw joint with restriction.
4.5 Strainer
Install the strainer upstream of the excess pres-
sure valve (see Fig.3).
−The direction of ow must correspond to
the arrow on the body.
−The lter element must be installed to
hang downwards or sideways for appli-
cations with steam.
Tip:
Remember to leave enough space to
remove the lter element.
4.6 Shut-off valve
Install a hand-operated shut-off valve both up-
stream 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 (see Fig.3).
4.7 Pressure gauge
Install a pressure gauge both upstream and
downstream of the regulator to monitor the
pressures prevailing in the plant (see Fig.3).
Install the pressure gauge on the upstream
side in front of the pressure tapping point.

12 EB 2549 EN
Operation
5 Operation
See Fig.1 and Fig.2.
5.1 Start-up
First start up the regulator after mounting all
parts. Make sure the control line is open and
correctly connected.
Fill the plant slowly with the process medium.
Avoid pressure surges. Open the shut-off
valves rst on the upstream pressure side. Af-
terwards, open all the valves on the consum-
er side (downstream of the regulator).
Regulation of steam
Observe the following points for applications
with steam:
−Before start-up, all pipes conveying the
process medium must be completely
drained and dry (to prevent steam ham-
mering).
−Before start-up, ll the condensation
chamber with water at the lling opening
(21) until it overows. Screw the plug
back in.
−Slowly start up the plant and allow time
for the pipes and valves to warm up.
Air and condensate must be allowed to es-
cape from the plant. Install steam trap (e.g.
SAMSON Type13 E) or air vent for steam-op-
erated systems (e.g. SAMSON Type3) at a
suitable location.
Regulation of liquids
To start up the excess pressure valve, open
shut-off valves slowly. Undo the vent screw
(6.1) in 640cm² actuators until all the air has
escaped. Tighten the screw again.
For temperatures above 150°C, rst ll the
condensation chamber with the process medi-
um.
5.2 Adjusting the set point
Adjust the required upstream pressure by
turning the set point adjuster (13).
Turn clockwise 
−The upstream pressure is increased (high-
er pressure set point)
Turn counterclockwise 
−The upstream pressure is reduced (lower
pressure set point)
When the force resulting from the upstream
pressure p1 rises above the adjusted set point,
the valve opens proportionally to the change
in pressure.
Tip:
Monitor the adjusted set point pres-
sure at the pressure gauge on the up-
stream pressure side.
Changing the set point range
The set point range is determined by the size
of the actuator and its positioning springs. The
set point range can only be changed by ex-
changing the entire actuator assembly. There-
fore, we recommend contacting us if you want
to change the set point range.

EB 2549 EN 13
Maintenance and troubleshooting
5.3 Decommissioning
Close rst the shut-off valve on the upstream
side of the valve and then on the downstream
side of the valve.
6 Maintenance and trouble-
shooting
If the upstream pressure deviates considerably
from the set point, check the control line for
blockage and check the diaphragm for leak-
age.
In case of other causes, such as a damaged
seat or plug, we recommend contacting SAM-
SON's After-sales Service Department (see
section 8).
If the diaphragm is damaged, proceed as de-
scribed in section 6.1.
WARNING!
Risk of scalding due to hot process
medium escaping uncontrolled.
Allow the regulator to cool down be-
fore depressurizing and draining it
and remove it from the pipeline.
6.1 Replacing the operating dia-
phragm
See Fig.1 and Fig.2.
Shut down the plant by slowly closing the
shut-off valves. Depressurize the relevant sec-
tion of the pipeline and, if necessary, drain it
as well.
The actuator can be removed from the valve
without having to remove the valve from the
pipeline. However, in this case, do not forget
that the actuator cone seals off the bellows
housing. Consequently, the process medium
will drain out of the valve on removing the ac-
tuator.
1.
Relieve the spring assembly of tension by
turning the set point adjuster (13) counter-
clockwise.
2. Unscrew the control line and clean it.
3.
Undo the coupling nut (7) and remove the
actuator.
4.
Unscrew the set point adjuster (13). Re-
move bearing, bushing, spring(s) and
spring plate.
5.
Remove nuts and bolts (15). Lift the top
cover plate off the actuator stem.
6.
Pull the diaphragm stems together with the
diaphragm plates and the diaphragm out
of the lower diaphragm case.
7. Hold the bottom nut (16) stationary using
a socket wrench and unscrew the top dia-
phragm stem by loosening the nut (8.1)
(the nut is sealed with paint!).
8.
Take off the top diaphragm plate (17). Re-
place the operating diaphragm (9) with a
new one.
Proceed in the reverse order to reassemble the
regulator. For start-up, proceed as described
in section 5.1.

14 EB 2549 EN
Nameplate
7 Nameplate
Nameplates are attached to the valve and the actuator.
Valve nameplate
DIN version
ANSI version
Actuator nameplate
Fig.4: Nameplates
DIN version
1 Valve type
2 Model number with index
3 Conguration ID (Var.-ID)
4 Order number or date
5 KVS coefcient
7 Spring force/set point range
8Nominal size
9Nominal pressure
10 Perm. differential pressure
11 Perm. temperature
12 Body material
ANSI version
5 Valve size
7 Spring force
8Perm. differential pressure
9Perm. temperature (°F)
10 Body material
11 CV coefcient (KVS x 1.17)
12 ANSI class (pressure rating)
DIN/ANSI version
1 Effective area (DIN/ANSI)
2Type
3 Conguration ID (Var.-ID)
4 ID number
7 Valve size (DIN/ANSI)
9Set point range (DIN/ANSI)
10 Diaphragm material
SAMSON
DN
Made in Germany
˚C
T
bar
∅p
PN
K
vs
No
No
∅p
Made in Germany
Size SAMSON
psi T˚F Cv Cl
12
910 11
8
7
5
4
1
3
2
9
8
710 11 12
5
4
1
3
2
psi
psi psi
size
cm²
Var.-ID No
SAMSON sq.in
bar bar
DN
Made in Germany
bar
2002
0062
97710
1
3
2
9
4

EB 2549 EN 15
Customer service
8 Customer service
If malfunctions or defects occur, contact the SAMSON After-sales Service Department for sup-
port.
The addresses of SAMSON AG, its subsidiaries, representatives and service facilities world -
wide can be found on the SAMSON website, in all SAMSON product catalogs or on the back
of these Mounting and Operating Instructions.
Please send your inquiries to: ser[email protected]
To assist diagnosis, specify the following details (see section 7):
−Type and nominal size of the valve
−Model number and conguration ID (Var.-ID)
−Order number or date
−Upstream and downstream pressure
−Temperature and process medium
−Min. and max. ow rate in m³/h
−Is a strainer installed?
−Installation drawing showing the exact location of the regulator and all the additionally
installed components (shut-off valves, pressure gauge, etc.)

16 EB 2549 EN
Dimensions
9 Dimensions
Fig.5: Dimensions ∙Type2422/2424∙Balanced by a bellows
L
H2
H1
H
ØD
Type2422/2425∙Balanced by a
bellows
Dimensions in mm and weights in kg∙The values in parentheses apply to temperatures from 220 to 350°C
Nominal size DN125 DN150 DN200 DN250
Length L 400mm 480mm 600mm 730mm
Height H1 460 (600)mm 590 (730)mm 730 (870)mm
Height H2 145mm 175mm 235mm 260mm
0.05 to 0.25 Height H 990 (1130)mm 1120 (1260) 1260 (1400)mm
Actuator ØD=380mm, A=640cm²
0.1 to 0.6 Height H 990 (1130)mm 1120 (1260)mm 1260 (1400)mm
Actuator ØD=380mm, A=640cm²
0.2 to 1.0 Height H 990 (1130)mm 1120 (1260)mm 1260 (1400)mm
Actuator ØD=380mm, A=640cm²
0.5 to 1.5 Height H 940 (1080)mm 1070 (1210)mm 1210 (1350)mm
Actuator ØD = 285mm, A = 320cm²
1.0 to 2.5 Height H 940 (1080)mm 1070 (1210)mm 1210 (1350)mm
Actuator ØD=285mm, A=320cm²
Weight, approx. 1) (valve with actuator) for cast iron, PN16
0.05 to 1.0 135kg 116kg 286kg 296kg
0.5 to 1.5/1 to 2.5 125kg 110kg 280kg 290kg
1) +10% for cast steel, spheroidal graphite iron and stainless steel
Set point ranges in bar

EB 2549 EN 17
Dimensions
Fig.6: Dimensions · Type2422/2425∙Balanced by a diaphragm
H2
H
L

Dimensions in mm and weights in kg
Nominal size DN125 DN150 DN200 DN250
Length L 400mm 480mm 600mm 730mm
Height H 720mm 745mm 960mm 960mm
Height H2 145mm 175mm 260mm 260mm
Weight (actuator with valve), approx.
0.05 to 1bar 80kg 94kg 239kg 249kg
0.5 to 2.5bar 75kg 88kg 233kg 243kg
Type2422/2425∙Balanced by a diaphragm

18 EB 2549 EN
Technical data
10 Technical data
Table2: Technical data of Type2422 Valve and Type2425 Actuator
Type 2422 Valve
Nominal pressure PN16, 25 or 40
Nominal size DN125 DN150 DN200 DN250
Max. permissible
temperature
Valve balanced by a
bellows
Metal seal: 350°C · PTFE soft seal: 220°C · EPDM or FPM soft seal:
150°C · NBR soft seal: 80°C 1)
Valve balanced by a
diaphragm 150°C
Leakage class according to IEC60534-4 ≤0.05% of KVS coefcient
Type2425 Actuator
Set point ranges 0.05 to 0.25bar
· 0.1 to 0.6bar · 0.2 to 1.0bar
0.5 to 1.5bar·1.0 to 2.5bar2)
Max. perm.
pressure at actu-
ator
Effective diaphragm
area 320cm² 640cm²
Pressure 3bar 1.5bar
Max. permissible temperature Gases 80°C at the actuator
1)
· Liquids 150°C, with condensation
chamber max. 350°C · Steam with condensation chamber max. 350°C
1) For oxygen max. 60°C
2) Set point ranges above 2.5bar, seeuT2552 · Type2335 Excess Pressure Valve

EB 2549 EN 19
Technical data
Note:
Conversion from chromate coating to iridescent passivation
We at SAMSON are converting the surface treatment of passivated steel parts in our
production. 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 different reections. Parts can have an iridescent yellow or silver color. This
has no effect on corrosion protection.
For further information go to uwww.samson.de/chrome-en.html


SAMSON AG · MESS- UND REGELTECHNIK
Weismüllerstraße 3 · 60314 Frankfurt am Main, Germany
Phone: [phone] · Fax: [phone]
[email protected] · www.samson.de
EB 2549 EN 2016-03-11 · English