Samson 42-10 RS Service manual

Translation of original instructions
EB 3009 EN
Type42-10RS Check Valve (backow protection)
Type42-10RS Check Valve (backow protection)
Self-operated Regulators
Edition April 2019

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
at www.samson.de > Service & Support > Downloads > Documentation.
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
2 EB 3009 EN

Contents
EB 3009 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 ..................................................................5
4 Installation....................................................................................................8
4.1 Mounting position ..........................................................................................8
4.2 Compensation chamber for steam ...................................................................8
4.3 Strainer .........................................................................................................9
4.4 Shut-off valve .................................................................................................9
4.5 Pressure gauge ..............................................................................................9
5 Operation.....................................................................................................9
5.1 Start-up .........................................................................................................9
5.1.1 Regulation of steam ......................................................................................10
5.1.2 Regulation of liquids .....................................................................................10
5.2 Set point adjustment .....................................................................................10
5.3 Decommissioning .........................................................................................10
6 Maintenance ...............................................................................................10
6.1 Tests ............................................................................................................12
7 After-sales service .......................................................................................12
8 Nameplates ................................................................................................13
9 Dimensions .................................................................................................14
10 Technical data.............................................................................................16

4 EB 3009 EN
General safety instructions
1 General safety instructions
−The device 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.
−To ensure appropriate use, only use the device in applications where the op-
erating pressure and temperatures do not exceed the specications used for
sizing the device 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 control valve versions whose bodies are not lined with an in-
sulating material coating do not have their own potential ignition source accord-
ing 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.
For connection to the equipotential bonding system, observe the requirements
specied in section 6.3 of EN60079-14: 2011 (VDE0165 Part 1).
!

EB 3009 EN 5
Process medium and scope of application
2 Process medium and scope of
application
Designed to protect saturated steam, nitro-
gen and compressed air networks against
backow from directly connected systems.
−Differential pressure set point
Δp = 0.2bar · 0.3bar1)/3psi·5psi1)
−Valve sizes DN15 to 250/NPS½ to 10
−Pressure rating PN25·40/
Class150·300
−Compressed air and nitrogen up to
80°C·150°C2)/175°F·300°F2)
−Saturated steam with compensation
chamber up to 220°C/430°F
−Liquids up to 80°C/175°F
1) DN200 and 250/NPS8 and 10 version
2) Version with FKM diaphragm
2.1 Transportation and storage
The device must be carefully handled, trans-
ported and stored. Protect the regulator
against adverse inuences, such as dirt,
moisture or frost, during storage and trans-
portation.
When regulators are too heavy to be lifted
by hand, fasten the lifting sling to a suitable
place on the valve body.
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.
3 Design and principle of oper-
ation
See Fig.1 on page7.
The regulator prevents owback from directly
connected systems. Observe the pressure
and temperature limits on the nameplate.
The regulator is open, provided the upstream
pressure is at least 0.2bar/0.3psi greater
than the downstream pressure. It closes auto-
matically when the downstream pressure ris-
es to or above the value of the upstream
pressure.
The regulator basically consists of the valve
(1) with seat (2) and plug (3) as well as the
opening actuator (10) with two diaphragms
(11).
WARNING
!

6 EB 3009 EN
Design and principle of operation
The medium ows through the valve in the
direction indicated by the arrow. The posi-
tion of the valve plug (3) determines the dif-
ferential pressure over the cross-sectional ar-
ea released between the plug and seat (2).
At a differential pressure of
0.2bar/3.0bar1) (3psi/5psi)1), the valve
begins to open; at 0.35bar/0.55bar
(5psi/7psi), the valve is completely open.
At this point, the upstream pressure p1 must
be greater than the downstream pressure p2.
The regulator closes automatically when the
downstream pressure rises to or above the
value of the upstream pressure. The standard
plug is soft-seated to ensure tight shut-off
and to prevent backow from the plant into
the medium supply network.
The mounted control lines (14) transmit the
upstream and downstream pressures to the
actuator.
The actuator with two diaphragms (11)
offers increased safety and reliability of
functions. The operating diaphragm for
upstream pressure (11.1) is connected to the
valve input pressure, whereas the operating
diaphragm for downstream pressure (11.2)
is connected to the valve output pressure. A
bore with a mechanical diaphragm rupture
indicator (12) is located in the intermediate
ring located between the two diaphragms.
The pressure of response of the diaphragm
rupture indication is approximately
1.5bar/22psi. In the event of a diaphragm
rupture, the pressure in the space between
the two operating diaphragm starts to
1) DN200 and 250/NPS8 and 10 version
Legend Fig.1
1 Valve body
2 Seat
3 Plug
4 Plug stem
5Threaded connection for diaphragm
actuator
6Actuator stem
7 Diaphragm stem
10 Actuator housing
11 Two diaphragms
11.1 Operating diaphragm for upstream
pressure
11.2 Operating diaphragm for downstream
pressure
12 Diaphragm rupture indicator
13 Set point springs
14 Control line 8x1mm
15 Spacer bushing
16 Housing bolts (two long bolts opposite each
other, DN15 to 25/NPS½ to 1 only)
16.1 Top housing bolts
16.2 Bottom housing bolts
17 Diaphragm plate nut (outer)
17.1 Diaphragm plate nut (inner)
18 Pressure switch (optional)
19 Compensation chamber (optional)
20 Filler plug
increase. This causes the pin in the
diaphragm rupture indicator to be pushed
outwards and a red ring appears, indicating
the diaphragm rupture. The intact operating
diaphragm takes on the control task of the
ruptured diaphragm.
A pressure switch (18) can be optionally
mounted to the actuator to trigger an alarm.

EB 3009 EN 7
Design and principle of operation
Fig.1: Functional diagram·DN15 to 150/NPS½to 6
1
2
3
4
5
14
6
17
13.1
16.1
16.2
10
13
7
14
16
11
11.2
17.1
10.1
11.1
15
12
20
19
19
20
18

8 EB 3009 EN
Installation
4 Installation
See Fig.1 on page7.
Choose a place of installation that allows you
to freely access the regulator even after the
entire plant has been completed.
ÎInstall 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.
ÎInstall a strainer (e.g. SAMSON
Type2N/2NI) upstream of the regula-
tor to prevent any sealing parts, weld
spatter and other impurities carried
along by the process medium impairing
the proper functioning of the valve,
above all the tight shut-off.
4.1 Mounting position
The regulators are supplied ready for con-
nection.
ÎInstall the regulator in a horizontal pipe-
line.
1 Strainer
2 Type42-10RS Check
Valve (backow
protection)
3 Pressure gauge
4 Shut-off valve
p1Upstream pressure
p2Downstream pressure
Fig.2: Sample application
_
_
+
+
124
3
4
p1p2
3
ÎThe ow of direction must correspond
with the direction indicated by the arrow
on the valve body.
ÎDN15 to 150/NPS½ to 6: actuator
facing downward (see Fig.1 and
Fig.4).
DN200 to 250/NPS8 to 10: actuator
facing upward (see Fig.4).
Possible malfunction and damage due to ad-
verse weather conditions (temperature, hu-
midity).
Protect the regulator against frost if it is used
to control freezing media. Heat the regulator.
4.2 Compensation chamber for
steam
The mounting position of the compensation
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.
NOTICE
!

EB 3009 EN 9
Operation
This mounting position must be adhered to;
otherwise the safe functioning of the regula-
tor cannot be guaranteed.
4.3 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2N/2NI Strainer is suit-
able (uT1010).
ÎDo not use the strainer to permanently
lter the process medium.
ÎInstall a strainer upstream of the regula-
tor.
ÎThe ow of direction must correspond
with the direction indicated by the arrow
on the valve body.
ÎThe lter element must be installed to
hang downward.
Remember to leave enough space to remove
the lter element for cleaning.
4.4 Shut-off valve
Install a hand-operated shut-off valve both
upstream of the strainer and downstream of
the regulator (see Fig.2). This allows the
plant to be shut down for cleaning and
maintenance, and when the plant is not used
for longer periods of time.
Tip
4.5 Pressure gauge
Install a pressure gauge both upstream and
downstream of the regulator to monitor the
pressures prevailing in the plant.
5 Operation
5.1 Start-up
First start up the regulator after mounting all
parts.
ÎFor steam applications, make sure that
the pipelines are dry. Moisture will dam-
age the inside of the valve.
ÎEnsure that all valves downstream of the
regulator are open.
ÎOpen the shut-off valves preferably start-
ing from the downstream of valve. Slowly
open the valves in small steps waiting a
few minutes in between.
ÎRaise the plant pressure in steps of
5bar/70psi.
ÎWait several seconds after each rise in
pressure before continuing.
The test pressure must not exceed the nomi-
nal pressure of the valve by 1.5 times on test-
ing the pressure of the plant when the regu-
lator is already installed.
Note
NOTICE
!

10 EB 3009 EN
Maintenance
The pressure must not exceed the maximum
permissible constant operating pressure or
pressure acting on one side (see section10).
The lowest pressure always applies and re-
stricts the maximum test pressure.
5.1.1 Regulation of steam
ÎUnscrew ller plug (20, width across ats
13) on the compensation chamber. Use
the included plastic funnel or a jug to
pour in water until it starts to overow.
Screw the ller plug back in and tighten
it (25Nm). The regulator is now ready
for operation. Open the hand-operated
shut-off valves slowly to prevent water
hammer.
5.1.2 Regulation of liquids
ÎTo start up the regulator, open shut-off
valves slowly.
5.2 Set point adjustment
The user cannot adjust the set point.
The regulator is delivered with a ready ad-
justed set point of 0.2bar/3psi (DN15 to
150/NPS½ to 6) or 0.3bar/5psi (DN200
and 250/NPS8 and 10) and has been test-
ed.
The regulator is open, provided the upstream
pressure is greater than the downstream
pressure by at least the ready adjusted set
point. It closes automatically when the down-
stream pressure rises to or above the value
of the upstream pressure.
5.3 Decommissioning
Close the shut-off valves starting from the
ow pipe side.
6 Maintenance
The regulators do not require any mainte-
nance. Nevertheless, they are subject to nat-
ural wear, particularly at the seat, plug and
two diaphragms.
Depending on the operating conditions,
check the regulator regularly to detect and
rectify possible malfunctions at an early
stage.
If a diaphragm rupture is indicated and the
operating diaphragm is defective,
SAMSON's After-Sales Service department
can assist you.
Before performing any work on the regula-
tor, make sure the relevant plant section has
been depressurized and, depending on the
process medium, drained. We recommend
removing the valve from the pipeline.
Depending on the eld of application, allow
the valve to cool down or heat up to reach
ambient temperature before starting any
work on it.
Disconnect or shut off the control line.
As valves are not free of cavities, remember
that residual process medium might still be
contained in the valve.
Details on faults and how to remedy them
can be found in Table1.
WARNING
!

EB 3009 EN 11
Maintenance
Table1: Troubleshooting
Malfunction Possible reasons Recommended action
The valve does not fully open.
The differential pressure exceeds
the set point.
Insufcient upstream pressure
pulses on the actuator dia-
phragm
Clean the control line and the
screw joint with restriction.
Two diaphragms defective
(check the diaphragm rupture
indicator).
Replace operating diaphragms.
Seat and plug worn down by
deposits or foreign particles.
Replace damaged parts or
contact SAMSON's After-sales
Service department.
Strainer blocked Clean strainer.
Valve too small Recalculate CV/KVS coefcient
and contact SAMSON.
The valve does not close. The
differential pressure drops be-
low the set point.
Seat and plug damaged impair-
ing tight shut-off.
Remove valve from the pipeline
and clean parts. Contact
SAMSON's After-sales Service
department if the regulator is
defective.
Valve too large Recalculate CV/KVS coefcient
and contact SAMSON.
Control line downstream of
valve blocked.
Clean the control line and the
screw joint with restriction.
Jerky control response. Increased friction, e.g. due to
foreign particles between seat
and plug.
Remove valve from the pipeline
and clean parts.
Control loop hunts. Valve too large Recalculate CV/KVS coefcient
and contact SAMSON.
If faults cannot be remedied following the recommended action in the table, contact
SAMSON (see section7).

12 EB 3009 EN
Maintenance
7 After-sales service
Contact SAMSON's After-sales Service de-
partment for support concerning service or
repair work or when malfunctions or defects
arise.
E-mail address
SAMSON's After-sales Service department:
aftersalesser[email protected]
Addresses of SAMSONAG and its subsid-
iaries
The addresses of SAMSON AG, its subsid-
iaries, representatives and service facilities
worldwide can be found on the SAMSON
website, in all SAMSON product catalogs or
on the back of these Mounting and Operat-
ing Instructions.
To assist diagnosis and in case of an unclear
mounting situation, specify the following de-
tails:
−Device type and nominal size
−Order number/date and product number
−Conguration ID
−Upstream and downstream pressure
−Medium temperature and process medi-
um
−Min. and max. ow rate in m³/h
−Is a strainer installed?
−Installation drawing showing the exact
location of the regulator and all the ad-
ditionally installed components (shut-off
valves, pressure gauge etc.)
6.1 Tests
Detailed test instructions uSH3009
They describe testing in the workshop and in
the installed state.
The maintenance intervals depend on the in-
tervals between regular testing and the
scope of the testing. A ve-year interval has
proven suitable under normal operating and
ambient conditions. We recommend replac-
ing parts subject to wear on performing this
maintenance work.

EB 3009 EN 13
Nameplates
8 Nameplates
Nameplates are attached to the valve and the actuator.
DIN version
ANSI version
Valve nameplate
SAMSON
DN
bar
Made in Germany
˚C
T
bar
∆p
PN
Kvs
No
No
∆p
Made in Germany
Size
SAMSON psi
Npsi T˚F Cv Cl
12
910 11
8
5
4
1
3
2
9
8
10 11 12
5
4
1
3
2
Valve
1 Valve type
2 Model number
3 Conguration ID
4 Order number or date
5KVS coefcient
8Valve size
9Nominal pressure
10 Perm. differential pressure in bar
11 Perm. temperature in °C
12 Body material
ANSI version
5Valve size
8Perm. differential pressure in psi
9Perm. temperature in °F
10 Body material
11 CV coefcient (KVS x 1.17)
12 Class (pressure rating)
Actuator
1 Actuator area (DIN/ANSI)
2Type
3 Conguration ID
4 ID number
5Year with CE marking
6Max. perm. pressure pmax (DIN/
ANSI)
7Associated valve; valve size
(DIN/ANSI)
9Set point range (DIN/ANSI)
10 Diaphragm material
psi
psi
size EPDM
cm²
Var.-ID No
SAMSON
Pmax
sq.in
bar
DN
Made in Germany
bar
2002
0062
97410
5
1
3
2
6
Actuator nameplate
Fig.3: Nameplates

14 EB 3009 EN
Dimensions
9 Dimensions
L
H2H1
H
ØD
L
H1
H2
H
ØD
Type42-10RS
NPS½ to 6/DN15 to 150
Type42-10RS
NPS8 and 10/DN200 and 250
Fig.4: Dimensions
Table2: Dimensions and weights · DIN version
Valve size DN 15 20 25 32 40 50 65 80 100 125 150 200 250
Length L 130 150 160 180 200 230 290 310 350 400 480 600 730
Height H1 225 300 355 460 590 730
Height
H2
Other
materials 55 72 100 120 145 175 260
Forged steel 53 –70 –92 98 – – – – – –
Height H 550 600 800 830 1000 1144
Actuator ØD=285mm · A=320cm² ØD=390mm · A=640cm²
Weight, approx. kg 26 26.5 28 35 35.5 39.5 59.5 65.5 75 110 165 410 470

EB 3009 EN 15
Dimensions
Table3: Dimensions and weights · ANSI version
Valve size NPS ½¾ 1 1½ 22½ 3 4 6 8 10
DN 15 20 25 40 50 65 80 100 150 200 250
Length L
Class
150
inch 7.25 8.75 10 10.9 11.75 13.9 17.75 21.4 26.5
mm 184 222 254 276 298 352 451 543 673
Class
300
inch 7.5 7.6 7.75 9.25 10.5 11.5 12.5 14.5 18.6 22.4 27.9
mm 191 194 197 235 267 292 318 368 473 568 708
Height H inch 19.7 23.6 31.5 32.7 39.4 44.9
mm 550 600 800 830 1000 1144
Height H1 inch 8.6 11.8 14 23.2 28.7
mm 225 300 355 590 730
Height H2 inch 1.8 2.8 3.9 4.5 6.9 10.2
mm 45 72 98 113 175 260
Actuator ANSI ØD=11.2”·A=50in² ØD=15.4”·A=100in²
DIN ØD=285mm·A=320cm² ØD=390mm·A=640cm²
Weight,
approx.
Class
150
lb 57 58 62 78 87 131 144 165 360 893 1025
kg 26 26.5 28 35.5 39.5 59.5 65.5 75 165 405 465
Class
300
lb 60 61 65 82 91 137 151 173 376 900 1040
kg 27 27.5 29.5 37 41.5 62 68.5 78.5 170.5 410 470

16 EB 3009 EN
Technical data
10 Technical data
Type2421RS Valve
Valve size NPS ½¾ 1 – 1½ 22½ 3 4 – 6 8 10
DN 15 20 25 32 40 50 65 80 100 125 150 200 250
CV and KVS
coefcient
CV4.5 7.5 9.4 –37 37 60 94 145 –330 490 585
KVS 4 6.3 816 20 32 50 80 125 125 280 420 500
Pressure rating Class150 or 300/PN25 or 40
Max. constant operating
pressure 360psi/25bar
Max. perm. pressure acting
on one side 650psi/45bar
Leakage class 1) according
to IEC60534-4 (ANSI/
FCI70-2)
Leakage class VI
Max. permissible
temperature
With EPDM diaphragm in
actuator
175°F/80°C for air, gases and water
430°F/220°C for steam with compensation chamber
With FKM diaphragm in
actuator 300°F/150°C for air and gases
Compliance
Type2420RS Actuator
Actuator area 50in²/320cm² 100in²/640cm²
Fixed differential pressure
set point Δp
NPS½ to 6/DN15 to 150 3psi/0.2bar
NPS8 and 10/DN200
and 250 5psi/0.3bar
Max. permissible
temperature
With EPDM diaphragm 175°F/80°C for air, gases and water
430°F/220°C for steam with compensation chamber
With FKM diaphragm 300°F/150°C for air and gases
Compliance
1) Terms for control valve sizing according to IEC60534 (ANSI/FCI70-2): FL = 0.95, XT = 0.75

EB 3009 EN 17

18 EB 3009 EN

EB 3009 EN 19

2019-05-09 · English
SAMSON AKTIENGESELLSCHAFT
Weismüllerstraße 3 · 60314 Frankfurt am Main, Germany
Phone: [phone] · Fax: [phone]
[email protected] · www.samson.de
EB 3009 EN