Samson 2489/58 Series Service manual

Translation of original instructions
EB 3135-2 EN
Edition April 2023
Type2489/58xx/2430 and Type2489/57xx/2430 Pressure-
independent Control Valves
Flow regulators with electric actuator and control thermostat

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 3135-2 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 3135-2 EN
1 Safety instructions and measures ...................................................................5
1.1 Notes on possible severe personal injury .........................................................9
1.2 Notes on possible personal injury .................................................................10
1.3 Notes on possible property damage..............................................................11
2 Markings on the device ...............................................................................12
2.1 Nameplates.................................................................................................12
2.1.1 Nameplate for Type 2489 Valve....................................................................12
2.1.2 Electric actuator nameplate...........................................................................12
2.2 Location of the nameplates ...........................................................................13
2.3 Materialidenticationnumber ......................................................................13
2.3.1 Type2489Valve..........................................................................................13
2.3.2 Electric actuator (with process controller)........................................................13
3 Design and principle of operation ................................................................14
3.1 Technical data .............................................................................................17
4 Measures for preparation............................................................................22
4.1 Unpacking ..................................................................................................22
4.2 Transporting and lifting ................................................................................22
4.3 Storage.......................................................................................................23
4.4 Preparation for installation............................................................................23
5 Mounting and start-up.................................................................................24
5.1 Mounting orientation....................................................................................24
5.2 Additionalttings.........................................................................................24
5.3 Mounting the control thermostat ....................................................................25
5.4 Mounting the electric actuator.......................................................................25
5.5 Electrical connection.....................................................................................27
5.6 Start-up.......................................................................................................27
6 Operation...................................................................................................28
6.1 Adjusting the set points.................................................................................28
6.2 Adjusting the control thermostat ....................................................................29
6.3 Adjustment without electric actuator...............................................................29
6.4 Adjustment with electric actuator...................................................................30

Contents
EB 3135-2 EN
6.4.1 Adjustment with electric actuator without fail-safe action .................................30
6.4.2 Adjustment with electric actuator with fail-safe action......................................30
7 Servicing.....................................................................................................32
7.1 Preparation for return shipment.....................................................................33
7.2 Ordering spare parts and operating supplies .................................................33
8 Malfunctions ...............................................................................................33
8.1 Decommissioning and removal......................................................................35
8.1.1 Decommissioning.........................................................................................35
8.2 Disposal......................................................................................................36
9 Annex.........................................................................................................37
9.1 After-sales service........................................................................................37
9.2 Tightening torques........................................................................................37
10 Certicates..................................................................................................38

EB 3135-2 EN 5
Safety instructions and measures
1 Safety instructions and measures
Intended use
TheType2489Pressure-independentControlValve(PICV)withconnectionforadditional
electricactuatorandcontrolthermostatisintendedfortheowandtemperaturecontrolof
liquidsupto150°C.ThecombinedType2489/5824or5827/2430ismainlyusedin
district heating supply networks. The regulators and actuators are designed to operate under
exactlydenedconditions(e.g.operatingpressure,processmedium,temperature).
Therefore, operators must ensure that the regulators and actuators are only used in operating
conditionsthatmeetthespecicationsusedforsizingthedevicesattheorderingstage.In
case operators intend to use the devices 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
device 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
− ModicationofpartsaswellasserviceorrepairworkonTÜV-testedType2489/5825-
x,Type2489/5827-AandType2489/TROVIS5725-x
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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specializedtraining,theirknowledgeandexperienceaswellastheir
knowledge of the applicable standards.

6 EB 3135-2 EN
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).
ÎProvide protective equipment (e.g. safety gloves, eye protection) appropriate for the pro-
cess medium used.
ÎWear 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SAM-
SON.Theyareperformedattheuser'sownriskandmayleadtosafetyhazards,forexam-
ple. Furthermore, the product may no longer meet the requirements for its intended use.
Safety features
TheType2489Pressure-independentControlValve(PICV)withanelectricactuatorwithout
fail-safe action does not have any special safety features.
TheType2489Pressure-independentControlValve(PICV)withanelectricactuatorwithfail-
safe action moves to a certain fail-safe position upon supply voltage failure. The fail-safe
actionofSAMSONactuatorsisspeciedontheactuatornameplate.
When relieved of pressure, the valve with an open restriction without electric actuator and
Type2430Thermostatisopenedbytheforceofthesetpointsprings.
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device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, 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.

EB 3135-2 EN 7
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.
Referenced standards, directives and regulations
The regulators comply with the requirements of the European Pressure Equipment Directive
2014/68/EUandtheMachineryDirective2006/42/EC.RegulatorswithaCEmarking
have a declaration of conformity which includes 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).

8 EB 3135-2 EN
Safety instructions and measures
Referenced documentation
The following documents apply in addition to these mounting and operating instructions:
—uEB1010 for Type1N and Type1NI Strainers
—uEB2430 for Type2430 Control Thermostat
—uEB5724and
uEB5724-8
for TROVIS5724-3/-8 or TROVIS5725-3/-8 Electric Actuators
for domestic hot water heating or for heating and cooling applica-
tions
—uEB5824-1and
uEB5824-2
for Type5824/5825 Electric Actuator
(three-step version or with digital positioner)
—uEB5827-1and
uEB5827-2
for Type5827 Electric Actuator
(three-step version or with digital positioner)
—uEB5757and
uEB5757-7
for TROVIS5757-3/5757-7 Electric Actuators
for domestic hot water heating or for heating and cooling applica-
tions
—uEB5857 for Type5857 Electric Actuator
(three-step version or with digital positioner)

EB 3135-2 EN 9
Safety instructions and measures
1.1 Notes on possible severe personal injury
DANGER
!
Risk of fatal injury due to electric shock.
ÎBeforeconnectingwiring,performinganyworkonthedeviceoropeningthede-
vice, disconnect the supply voltage and protect it against unintentional reconnec-
tion.
ÎOnly use power interruption devices that are protected against unintentional recon-
nection of the power supply.
ÎDo not remove any covers to perform adjustment work on live parts.
ÎDo not open the back housing cover.
ÎAvoidjetsofwater.(IP54)
The switching output L' may be live after the supply voltage has been connected.
ÎDo not touch the switching output L'.
ÎWhen the switching output is not used, deactivate it in function F16 ('Not active'
setting).
ÎRefer to the mounting and operating instructions of the electric actuator (with pro-
cess controller) for further information.
Risk of bursting in pressure equipment.
Valves and pipelines are pressure equipment. Improper opening can lead to device
components bursting.
ÎObserve the maximum permissible pressure for regulator and plant.
ÎBeforestartinganyworkonthedevice,depressurizeallplantsectionsaffectedas
well as the valve.
ÎDrain the process medium from all the plant sections affected as well as the valve.
ÎIf necessary, install a suitable overpressure protection in the plant section.
ÎWear personal protective equipment.

10 EB 3135-2 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 process medium can escape and, depending on
its properties, may lead to personal injury, e.g. 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-regula-
tion/.