Samson 2488 N Service manual

Mounting and
Operating Instructions
EB 3136 EN
Translation of original instructions
Edition December 2017
Type2488N/5857
Pressure-independent Control Valve (PICV)
Type2488N/5857

2 EB 3136 EN
Note on these mounting and operating instructions
These mounting and operating instructions assist you in mounting and operating the device
safely. The instructions are binding for handling SAMSON devices.
ÎFor the safe and proper use of these instructions, read them carefully and keep them for
later reference.
ÎIf you have any questions about these instructions, contact SAMSON‘s After-sales Service
Department (aftersalesser[email protected]).
The mounting and operating instructions for the devices are included in
the scope of delivery. The latest documentation is available on our website
(www.samson.de) > Product documentation. You can enter the document
number or type number in the [Find:] eld to look for a document.
Denition of signal words
Hazardous situations which, if not avoided,
will result in death or serious injury
Hazardous situations which, if not avoided,
could result in death or serious injury
Property damage message or malfunction
Additional information
Recommended action
DANGER
!
WARNING
!
NOTICE
!
Note
Tip

Contents
EB 3136 EN 3
1 Safety instructions and measures ...................................................................4
1.1 Notes on possible severe personal injury .........................................................6
1.2 Notes on possible personal injury ...................................................................7
1.3 Notes on possible property damage................................................................7
2 Markings on the device .................................................................................8
2.1 Nameplate for Type2488N Valve..................................................................8
3 Design and principle of operation ..................................................................9
3.1 Technical data .............................................................................................10
4 Measures for preparation ............................................................................14
4.1 Unpacking ..................................................................................................14
4.2 Transporting and lifting ................................................................................14
4.3 Storage.......................................................................................................15
4.4 Preparation for installation............................................................................16
5 Mounting and start-up .................................................................................16
5.1 Mounting position........................................................................................16
5.2 Additional ttings.........................................................................................17
5.3 Mounting the actuator ..................................................................................17
5.4 Electrical connection.....................................................................................18
5.5 Start-up.......................................................................................................19
6 Operation ...................................................................................................20
6.1 Adjusting the set points.................................................................................20
6.1.1 Flow rate.....................................................................................................20
7 Servicing.....................................................................................................21
7.1 Preparation for return shipment.....................................................................22
7.2 Ordering spare parts and operating supplies .................................................23
8 Malfunctions ...............................................................................................23
8.1 Decommissioning.........................................................................................24
8.2 Disposal......................................................................................................24
9 Appendix ....................................................................................................24
9.1 After-sales service........................................................................................24
9.2 Certicates ..................................................................................................25

4 EB 3136 EN
Safety instructions and measures
1 Safety instructions and measures
Intended use
The Type2488N/5857 Pressure-independent Control Valve (PICV) is intended for ow con-
trol of liquids up to 110°C. The Type2488N/5857 is mainly used in district heating supply
networks. The regulator and actuator are designed to operate under exactly dened condi-
tions (e.g. operating pressure, process medium, temperature). Therefore, operators must en-
sure that the regulator and actuator are only used in operating conditions that meet the spec-
ications used for sizing the devices at the ordering stage. In case operators intend to use the
devices 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 regulator is not suitable for the following applications:
−Use outside the limits dened during sizing and by the technical data
Furthermore, the following activities do not comply with the intended use:
−Use of non-original spare parts
−Performing service and repair work not described in these instructions
Qualications of operating personnel
The regulator must be mounted, started up, serviced and repaired by fully trained and quali-
ed personnel only; the accepted industry codes and practices are to be observed. Accord-
ing to these mounting and operating instructions, trained personnel refers to individuals who
are able to judge the work they are assigned to and recognize possible hazards due to their
specialized training, their knowledge and experience as well as their knowledge of the appli-
cable standards.

EB 3136 EN 5
Safety instructions and measures
Personal protective equipment
We recommend wearing the following protective equipment depending on the process medi-
um:
−Protective clothing, gloves and eyewear in applications with hot, cold and/or corrosive
media
−Wear hearing protection when working near the valve.
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. Furthermore, 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. They must observe all haz-
ard statements, warning and caution notes in these mounting and operating instructions, es-
pecially for installation, start-up and service work.
Responsibilities of the operator
The operator is responsible for proper operation and compliance with the safety regulations.
Operators are obliged to provide these mounting and operating instructions as well as the
referenced documents to the operating personnel and to instruct them in proper operation.
Furthermore, the operator must ensure that operating personnel or third persons are not ex-
posed to any danger.
Responsibilities of operating personnel
Operating personnel must read and understand these mounting and operating instructions
as well as the referenced documents and observe the specied hazard statements, warnings
and caution notes. Furthermore, the operating personnel must be familiar with the applicable
health, safety and accident prevention regulations and comply with them.

6 EB 3136 EN
Safety instructions and measures
Referenced standards and regulations
The regulators comply with the requirements of the European Pressure Equipment Directive
2014/68/EU. Devices with a CE marking have an EU declaration of conformity, which in-
cludes information about the applied conformity assessment procedure. This EU declaration
of conformity is included in the Appendix 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 risk assessment stipulated in
EN13463-1:2009, section5.2, even in the rare incident of an operating fault. Therefore,
such valve versions do not fall within the scope of Directive 2014/34/EU.
ÎFor connection to the equipotential bonding system, observe the requirements specied in
section 6.4 of EN60079-14 (VDE0165 Part 1).
Referenced documentation
The following documents apply in addition to these mounting and operating instructions:
−Mounting and operating instructions for the mounted actuator, e.g. uEB5857 for
Type5857 Actuator
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 device
components bursting.
ÎBefore starting any work on the device, depressurize all plant sections concerned
as well as the valve.
ÎDrain the process medium from all the plant sections concerned as well as the
valve.
ÎIf necessary, install a suitable overpressure protection in the plant section.
ÎWear personal protective equipment.

EB 3136 EN 7
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 process medium can escape and, depending on
its properties, may lead to personal injury, e.g. (chemical) burns.
ÎIf possible, drain the process medium from all the plant sections concerned and the
valve.
ÎWear protective clothing, safety gloves and eyewear.
Risk of burn injuries due to hot or cold components and pipelines.
Depending on the process medium, valve components and pipelines may get very hot
or cold and cause burn injuries.
ÎAllow components and pipelines to cool down or heat up.
ÎWear protective clothing and safety gloves.
1.3 Notes on possible property damage
NOTICE
!
Risk of valve damage due to contamination (e.g. solid particles) in the pipeline.
The plant operator is responsible for cleaning the pipelines in the plant.
ÎFlush the pipelines before start-up.
ÎObserve the maximum permissible pressure for valve and plant.
Risk of valve damage due to unsuitable medium properties.
The valve is designed for process media with dened properties.
ÎOnly use process media specied for sizing the valve.

8 EB 3136 EN
Markings on the device
2 Markings on the device
2.1 Nameplate for Type2488N Valve
Nameplate for Type2488N Valve
1Model number and conguration
ID
2 Order number or year of
manufacture
3 Type designation
4 Flow rate set point range in m³/h
5 Differential pressure at the
restriction in bar
6 Max. perm. differential pressure
Δp in bar
7Flow coefcient KVS
8 Max. permissible temperature in °C
9 Nominal pressure PN
1 2
34
5 6
789
Nameplate of Type5857 Actuator
1Conguration ID
2 Serial number
3 Thrust
4Rated travel
5 Transit time for rated travel
6 Power supply
7 Rated frequency
8Power consumption
9 Input signal
10 Firmware version
Made in Germany
754
6
8
SAMSON 5857
Electric Actuator
s: t: f:U: P
:
Var.-ID
Serial-No.
1
2
F: 3
Made in Germany
94
6
8
SAMSON 5857
Electric Actuator
with digital positioner
s: In: U: P
:
Var.-ID
Serial-No.
1Firmware-Version: 10
2
F: 3
Three-step version
Version with digital positioner
Fig.1: Nameplates for Type2488N Valve and Type5857 Actuator

EB 3136 EN 9
Design and principle of operation
3 Design and principle of oper-
ation
ÎRefer to Fig.2
The pressure-independent control valve
(PICV) consists of the Type2488N Flow
Regulator and the Type5857 Electric Actua-
tor. The valve is tted with a connecting
piece for connection of an electric actuator.
As a result, it is possible to transmit the con-
trol signal of an electric control device to
achieve additional temperature control by
changing the restriction position. The medi-
um ows through the valve in the direction
indicated by the arrow on the valve body.
The ow rate is determined by the area re-
leased by the valve plug (3) and the adjust-
able restriction (11).
The installed positioning spring (5) deter-
mines the differential pressure across the re-
striction of 0.2bar. The pressure upstream of
the restriction (11) is transmitted over the
control line (7) to the upstream pressure side
of the actuator. The pressure downstream of
the restriction acts on the low-pressure side
of the operating diaphragm (9) through a
hole in the valve plug. The differential pres-
sure generated at the restriction is converted
into a positioning force by the operating dia-
phragm. This force is used to move the valve
plug depending on the force of the position-
ing spring (5). The ow rate is adjusted at
the set point screw (13).
1Valve body
2 Seat
3 Plug
4Plug stem
5 Positioning spring
6 Diaphragm actuator
7 Control line for upstream pressure
8 Upstream side
9 Operating diaphragm
10 Downstream side
11 Restriction
12 Restriction stem
13 Set point screw for ow control
14 Connecting piece
15 Spring
16 Type5857 Electric Actuator
17 Coupling nut
(max. 20Nm tightening torque)
18 Actuator stem
19 Manual adjuster
1
11
12
17
18
2
6
7
4
5
3
14
16
13
8
9
10
15
19
Fig.2: Functional diagram

10 EB 3136 EN
Design and principle of operation
3.1 Technical data
The regulator's nameplate contains informa-
tion on the regulator version (see sec-
tion2.1).
Process medium and scope of application
The Type2488N/5857 Pressure-indepen-
dent Control Valve (PICV) is suitable for the
control of water and non-ammable gases.
−Non-ammable gases up to 80°C
−Liquids up to 110°C
The regulator is open when relieved of pres-
sure. It closes when the downstream pressure
rises above the adjusted set point.
Compliance
The Type2488N/5857 Regulator bears
both the CE and EAC marks of conformity.
Temperature range
The Type2488N/5857 Regulator is de-
signed for a temperature range from –10 to
+110°C (14 to 300°F).
Leakage class
All regulators have the leakage class I ac-
cording to IEC60534-4.
Noise emission
SAMSON is unable to make general state-
ments about noise emission as it depends on
the valve version, plant facilities and process
medium. On request, SAMSON can perform
calculations according to IEC60534,
Part8-3 and Part8-4 or VDMA24422 (edi-
tion89).
Risk of hearing loss or deafness due to loud
noise.
Wear hearing protection when working near
the valve.
Dimensions and weights
Fig.3 as well as Table1 and Table2 provide
a summary of the dimensions and weights of
the Type2488N/5857 Regulator. The
lengths and heights in the dimensional draw-
ings are shown on p.13 onwards.
WARNING
!

EB 3136 EN 11
Design and principle of operation
Table1: Technical data for Type2488N Valve
Type 2488N Valve
Valve size DN15
Nominal pressure PN 10
Max. perm. differential pressure Δp 4bar
KVS coefcient
Standard version 2.5
Special version 1.0
Max. permissible temperature
Treated water 110°C
Non-ammable gases 80°C
Flow rate set point range/limitation for water with a
differential pressure at the restriction of 0.2bar
Standard version 0.3 to 1.0 m³/h
Special version 0.1 to 0.5 m³/h
Differential pressure at the restriction 0.2bar
Materials
Body CC499K
Plug 1.4301 with EPDM seal
Restriction Brass, free of dezincication
Diaphragm EPDM without fabric reinforcement
Weight
Valve Approx. 1.0kg

12 EB 3136 EN
Design and principle of operation
Table2: Technical data of Type5857 Actuator
Type5857 Actuator Version Three-step With digital positioner
Connection to valve Force-locking
Rated travel 6mm
Transit time for rated travel 20s 30/20 1)/10s
Thrust 300N
Power supply 230V (±10%), 50Hz
24V (±10%), 50Hz
24V (±10%), 50Hz,
60Hz and DC 2)
Power consumption Approx. 3 VA 5VA
Manual override Yes
Permissible temperatures
Ambient 0 to 50°C
Storage –20 to +70°C
Medium 0 to 120°C
Degree of protection IP 42 according to EN60529
Class of protection II according to EN61140
Electromagnetic compatibility According to EN61000-6-2, EN61000-6-3 and EN61326
Compliance ·
Digital positioner –
Input signal
–
0 to 10V 1), Ri= 20kΩ
Position feedback 0 to 10V 1), RB= 1kΩ
Characteristic
Linear 1), equal percentage,
reverse equal percentage, user-
dened
Materials
Housing Plastic (PPO)
Coupling nut Brass · M32x1.5 connection
Intermediate insulating piece 1.4306, CW617N, PTFE, EPDM, FKM
Weight
Valve Approx. 0.7kg
1) Default setting
2) 10 s applies to 24 V DC (–0 %, +10 %) for Transit time for rated travel setting.

EB 3136 EN 13
Design and principle of operation
Ø95
114
65
~65
120
ISO 228/1-G ¾
B
~70
Ø12
55
80
11
32
70
80
Intermediate insulating
piece
SW30
210
Ø21.3
SW30
129
G½
Welding ends Threaded ends
Fig.3: Dimensional drawings

14 EB 3136 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.
4.2 Transporting and lifting
Due to the low service weight, lifting equip-
ment is not required to lift and transport the
regulator (e.g. to install it into the pipeline).
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).
Note
4.3 Storage
Risk of regulator damage due to improper
storage.
−Observe storage instructions.
−Avoid long storage times.
−Contact SAMSON in case of different stor-
age conditions or long storage periods.
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3.1).
−Do not place any objects on the device.
NOTICE
!
Note

EB 3136 EN 15
Measures for preparation
Special storage instructions for elastomers
Elastomer, e.g. actuator diaphragm
−To keep elastomers in shape and to pre-
vent cracking, do not bend them or hang
them up.
−We recommend a storage temperature of
15°C for elastomers.
−Store elastomers away from lubricants,
chemicals, solutions and fuels.
SAMSON's After-sales Service department
can provide more detailed storage instruc-
tions on request.
Tip
4.4 Preparation for installation
Proceed as follows:
ÎFlush the pipelines.
The plant operator is responsible for clean-
ing the pipelines in the plant.
ÎCheck the valve to make sure it is clean.
ÎCheck the valve and actuator to make
sure they are not damaged.
ÎCheck to make sure that the type desig-
nation, valve size, material, pressure rat-
ing and temperature range of the valve
and actuator match the plant conditions
(size and pressure rating of the pipeline,
medium temperature, etc.).
ÎCheck any mounted pressure gauges to
make sure they function.
Note

16 EB 3136 EN
Mounting and start-up
5 Mounting and start-up
5.1 Mounting position
Standard mounting position
ÎInstall the regulator in a horizontal pipe-
line with the diaphragm actuator (6) fac-
ing downward (see Fig.2).
Installation conditions
−Make sure that the regulator remains
freely accessible after the plant has been
completed.
−The electric actuator must be mounted
above the valve body.
−Install a strainer upstream of the regula-
tor (see section5.2).
−Make sure the direction of ow matches
the direction indicated by the arrow on
the body.
−Install the regulator free of stress.
−On insulating the valve, do not insulate
the actuator and the coupling nut as well.
If necessary, an intermediate insulating
piece (order no. 1690-6975) must be
used. The insulating limit is in this case
approx. 25mm above the top of the
valve body.
Possible malfunction and damage due to ad-
verse weather conditions (temperature, hu-
midity).
−Do not install the device outdoors or in
rooms prone to frost.
NOTICE
!
−Protect the regulator against frost if it is
used to control freezing media.
−Either heat the regulator or remove it from
the plant and completely drain the residual
medium.
5.2 Additional ttings
Strainer
A strainer installed upstream in the ow pipe
holds back any dirt or other foreign particles
carried along by the medium. For example,
the SAMSON Type1NI Strainer is suitable
(uT1010).
−Install the strainer upstream of the regu-
lator.
−Make sure the direction of ow matches
the direction indicated by the arrow on
the body.
−Install the strainer with the lter element
facing downward.
−Allow sufcient space to remove the lter.
Shut-off valve
Install a hand-operated shut-off valve both
upstream of the strainer and at the outlet of
the return ow pipe (see Fig.4). This allows
the plant to be shut down for cleaning and
maintenance, and when the plant is not used
for longer periods of time.
Pressure gauge
Install a pressure gauge at a suitable point to
monitor the pressures prevailing in the plant
(see Fig.4).

EB 3136 EN 17
Mounting and start-up
Type2488N/5825
5.3 Mounting the actuator
ÎRefer to Fig.2
ÎPlace the actuator (16) on the valve con-
nection and hand-tighten the coupling
nut (17).
Indirect connection to district heating system with Type2488N/5825 PICV
Fig.4: Sample application

18 EB 3136 EN
Mounting and start-up
5.4 Electrical connection
ÎSee Fig.5 and Fig.2
Upon installation of the electric cables, you
are required to observe the regulations con-
cerning power installations according to
DINVDE0100 as well as the regulations of
your local power supplier.
Use a suitable power supply which guaran-
tees that no dangerous voltages reach the
device in normal operation or in the event of
a fault in the system or any other system
parts.
Connect the actuator to the electrical network
only after the power supply is rst switched
off. Make sure the power cannot be switched
on unintentionally.
A power supply of 230V (10%) or 24V
(10%), 50Hz is required (uEB5857 for
more details).
ÎConnect the electric actuator using the
three-wire connecting cable (see Fig.5).
If voltage is applied to the white and
green wires, the actuator motor retracts
the actuator stem (18). The restriction
stem (12) is pushed upward by the
spring (15), causing the ow rate to rise.
In contrast, a control signal applied to
the white and brown wires causes the ac-
tuator stem to extend. The restriction stem
(12) is pushed downward by the spring
(15), causing a lower ow rate.
WARNING
!
Three-step version
BNWH GN
aL eL
L
N
Ce Ce
eL
aL
BN BK YE GN RD OG
24 V, 50 Hz 0...10 V 0...10 V
_+_+
NL
Version with positioner
BNWH GN
aL eL
L
N
Ce Ce
eL
aL
BN BK YE GN RD OG
24 V, 50 Hz 0...10 V 0...10 V
_+_+
NL
eL Actuator stem retracts
aL Actuator stem extends
Note: The interference suppression capacitors
Ce in the output circuit of the connected control-
ler must not exceed a value of 2.5nF to ensure
the proper functioning of the actuator.
Fig.5: Electrical connection

EB 3136 EN 19
Mounting and start-up
5.5 Start-up
ÎFirst start up the regulator after mounting
all parts.
ÎMake sure that the restriction (11) is
open while lling the plant. Remove the
electric actuator and turn the set point
screw for the ow control (13) counter-
clockwise () as far as it will go (see
Fig.2).
ÎOpen the shut-off valves slowly over a
time period of several minutes, prefera-
bly starting from the return ow pipe.
Risk of valve damage due to a sudden pres-
sure increase and resulting high ow veloci-
ties.
Slowly open the shut-off valve in the pipeline
during start-up.
Pressure testing the plant
All plant components must be designed for
the test pressure. If necessary, remove the
regulator from the pipeline or remove the
control line (7) of the diaphragm actuator at
the valve and seal the open connection with
a blanking plug (see Table3).
Risk of damage to the diaphragm actuator
due to impermissible excess pressure.
The test pressure must not exceed the nomi-
nal pressure at the actuator by 1.5 times on
testing the pressure of the plant when the
regulator is already installed.
NOTICE
!
NOTICE
!
Rinsing the plant
1. After lling the plant, rst completely
open the consumer
2. Adjust the maximum ow rate at the reg-
ulator (see section6.1.1).
3. Rinse out the pipeline at full ow rate for
several minutes.
4. Check the strainer (e.g. measure the
pressure drop) and clean it, if necessary.
Table3: Accessories
Accessories Item no.
Blanking plug 8323-0030
Seal 8412-0771

20 EB 3136 EN
Operation
6 Operation
6.1 Adjusting the set point
6.1.1 Flow rate
ÎCompletely open the control and shut-off
valves or the bypass valve in the plant.
To adjust or change the ow rate set point,
proceed as follows:
Always adjust the set point based on a
closed restriction.
Risk of damage to the restriction stem
through one-side loading while turning the
set point screw clockwise.
First turn the handwheel of the electric actua-
tor to completely close the restriction.
1. To close the restriction (11), de-energize
the electric actuator (16).
2. Turn the manual adjuster (19) clockwise
() as far as it will go to close the re-
striction.
3. Use a suitable tool (Allen key, SW4) to
turn the set point screw (13) clockwise
() as far as it will go.
4. Refer to Fig.6 to nd out how many
turns are required to set the ow rate.
5. Use a suitable tool (Allen key, SW4) to
turn the set point screw (13) by the re-
quired number of turns. Turn it counter-
clockwise () to open the restriction. The
ow rate rises.
NOTICE
!
6. Guide the wire through the lead-seal
hole and lead-seal it to x the adjusted
ow rate.
7. Reconnect the power supply to the elec-
tric actuator (16).
For exact adjustment, verify adjusted value
with a heat or ow meter.
0.1 0.5 1
1
0
2
3
4
5
V
˚
m
3
/h
0.2 2
2.51.6Kvs
Turns of the set point screw
Fig.6: Adjustment diagram for ow rate
Tip