Samson 2422 series Service manual

Mounting and
Operating Instructions
EB 2547 EN
Edition March 2014
Self-operated Pressure Regulators
Type2422/2424 Pressure Reducing Valve
Type 2422/2424 Pressure Reducing Valve

2 EB 2547 EN
Denition of the signal words used in these mounting and operating instructions
DANGER!
indicates a hazardous situation which,
if not avoided, will result in death or
serious injury.
WARNING!
indicates a hazardous situation which,
if not avoided, could result in death or
serious injury.
NOTICE
indicates a property damage message
or malfunction.
Note:
Additional information
Tip:
Recommended action


EB 2547 EN 3
Contents
Contents Page
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 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 gauges...........................................................................................11
5 Operation...................................................................................................12
5.1 Start-up.......................................................................................................12
5.2 Adjusting the set point..................................................................................12
5.3 Decommissioning.........................................................................................12
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

General safety instructions
4 EB 2547 EN
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 person-
nel 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. The declaration of conformity issued for a regula-
tor bearing the CE marking includes information on the applied conformity
assessment procedure. The declaration of conformity is available 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 stipulated
in EN13463-1: 2009, section 5.2, even in the rare incident of an operat-
ing fault. Therefore, they do not fall within the scope of Directive 94/9/EC.
For connection to the equipotential bonding system, observe the require-
ments specied in section 6.3 of EN60079-14 (VDE0165 Part 1).


Process medium and scope of application
EB 2547 EN 5
2 Process medium and scope of application
Pressure regulator for liquids, gases and vapors up to 350 °C
For controlling the downstream pressure p2to the adjusted set point. The valve closes when the
downstream pressure rises. The downstream pressure is transmitted to the actuator over a con-
trol 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!
Uncontrolled excess pressure in the plant can damage the diaphragm and may lead
to personal injury.
The maximum permissible pressure at the actuator must not exceed the pressure spec-
ied in Table 1.
2.1 Transportation and storage
The regulator must be carefully handled, transported and stored. Protect the regulator against
adverse inuences, such as dirt, moisture or frost before it is installed.
When regulators are too heavy to be lifted by hand, fasten the lifting sling at a suitable place
on the valve body.
WARNING!
Risk of injury due to valve falling!
Fasten the lifting sling only to the valve body and secure against slipping.

Design and principle of operation
6 EB 2547 EN
3 Design and principle of op-
eration
See Fig. 1 and Fig. 2.
The Type 2422/2424 Pressure Reducing
Valve consists of the Type2422 Valve and the
Type2424 Actuator. The Type2422 Valve is
available either balanced by a bellows or a
diaphragm.
The pressure reducing valve is used to main-
tain the pressure downstream of the valve to
an adjusted set point. The valve closes when
the downstream pressure rises.
The medium ows through the valve in the
direction indicated by the arrow. The posi-
tion 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 actuator stem (4.1) of the
actuator (10).
The downstream pressure p2is adjusted over
the positioning springs (11) and the set point
adjuster (13). When relieved of pressure
(p
1
=p
2
), the valve is opened by the force of
the positioning springs.
The downstream pressure p
2
to be controlled
is tapped downstream of the valve and trans-
mitted over the control line to the operating di-
aphragm (9) where it is converted into a po-
sitioning 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 downstream pressure p2rises above the
adjusted set point, the valve closes proportion-
ally to the change in pressure.
The principle of operation of the
Type 2422/2424 Pressure Reducing Valve
balanced by a bellows or diaphragm only dif-
fers concerning the pressure balancing. The
valves balanced by a diaphragm have a bal-
ancing diaphragm (5.2) 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 steam 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) is open and lead-sealed.
Before start-up, ll the condensation chamber
with process medium at the top ller opening.
__
1) Only in combination with a control line kit.
Otherwise, the condensation chamber must be
ordered separately (see uT2595 EN).

Design and principle of operation
EB 2547 EN 7
Fig. 1: Functional diagram of Type 2422/2424 balanced by a bellows
Type 2422 Valve
balanced by a
bellows
Type2424
Actuator
1
2
3
6.1
6
5
4
6.2
7
8
8.1
9
11
12
13
18
17
15
16
19
21
20
p1p2
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 (bellows housing)
6.2 Vent screw (connection to
actuator)
7 Coupling nut
8 Top diaphragm stem
8.1 Nut
9 Operating 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 350 °C and
for steam
21 Filler plug
p1Upstream pressure
p2Downstream pressure

Installation
8 EB 2547 EN
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).
Î Place the actuator on the bellows hous-
ing and carefully screw it in as far as it
will go. Make sure the control line connec-
tion points toward the downstream pres-
sure side.
Î
Hold the actuator and fasten it to the bel-
lows housing using the coupling nut (7).
Fig. 2: Functional diagram of Type2422/2424 balanced by a diaphragm
5.1 Balancing diaphragm
p1Upstream pressure
p2Downstream pressure
Type 2422 Valve
balanced by a
diaphragm
Type2424
Actuator
5.1
P1P2

Installation
EB 2547 EN 9
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 pressure reducing valve in horizon-
tal 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 regu-
lator.
−Protect the regulator from icing up when
controlling media that can freeze. If nec-
essary, depressurize and drain the reg-
ulator and remove it from the pipeline
while the plant is shut down.
Fig. 3: Typical application
1
P1P2
23 451
1 Shut-off valve
2 Upstream pressure gauge
3 Strainer
4 Type 2422/2424 Pressure Reducing
Valve
5 Downstream pressure gauge
p1Upstream pressure
p2Downstream pressure

Installation
10 EB 2547 EN
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 test-
ing the pressure of the plant when the regula-
tor is already installed. An excessive test pres-
sure can damage the operating diaphragm in
the actuator.
WARNING!
Uncontrolled excess pressure in the
plant can damage the diaphragm and
may lead to personal injury.
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 provid-
ed 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/water.
Connect the control line to the downstream
line (p2) at least one meter away from the
valve outlet. If a manifold is located down-
stream of the pressure reducing valve, connect
the valve to the manifold, even if it is several
meters away. If the downstream line behind
the valve is extended by a conical expansion
piece, connect the control line in the expand-
ed section of the line. Weld the control line at
the side in the middle of the pipe, inclining at
a ratio of approximately 1:10 up to the con-
densation 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 be-
low the middle of the valve outlet ange, ar-
range the condensation chamber at the same
level as the outlet ange. In this case, use a
pipe which is at least ½“ in size for the con-
trol line from the tapping point to the conden-
sation chamber.
If the control line is connected above the mid-
dle of the valve outlet ange, install the con-
densation chamber at the same level as the

Installation
EB 2547 EN 11
downstream pressure tapping point. The ad-
ditional pressure of the condensate head must
be compensated 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).
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 pressure
reducing 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 pressure re-
ducing 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
upstream 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 gauges
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 downstream
side behind the downstream pressure tapping
point.

Operation
12 EB 2547 EN
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 medi-
um. Avoid pressure surges. Open the shut-off
valves rst on the upstream pressure side. Af-
terwards, open all the valves on the consumer
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 ller opening
(21) until it overows. Reattach plug.
−Slowly start up the plant and allow time
for the pipes and valves to warm up.
Air and condensate must be allowed to
drain from the plant. Install steam trap (e.g.
SAMSON Type13 E) or air vent for steam-
operated systems (e.g. SAMSON Type3) at a
suitable location.
Regulation of liquids
To start up the pressure reducing valve, open
shut-off valves slowly. When a 640 cm² actu-
ator is used, unscrew vent screw (6.1) to allow
any air to escape and then retighten screw.
For temperatures above 150°C, rst ll the
condensation chamber with the process me-
dium.
5.2 Adjusting the set point
Adjust the required downstream pressure by
turning the set point adjuster (13).
Turn clockwise 
−The downstream pressure is increased
(higher pressure set point)
Turn counterclockwise 
−The downstream pressure is reduced
(lower pressure set point)
When the force resulting from the downstream
pressure p2rises above the adjusted set point,
the valve closes proportionally to the change
in pressure.
Tip:
Monitor the adjusted set point pres-
sure at the pressure gauge on the
downstream 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.
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.

Maintenance and troubleshooting
EB 2547 EN 13
6 Maintenance and trouble-
shooting
If the downstream pressure deviates consid-
erably from the set point, check the control
line for blockage and check the diaphragm
for leakage.
In case of other causes, such as a damaged
seat or plug, we recommend contacting
SAMSON's customer service (see section 8).
If the diaphragm is damaged, proceed as de-
scribed in section 6.1.
WARNING!
Hot process medium can escape un-
controlled on dismantling the regula-
tor. Risk of scalding.
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 for-
get that the actuator cone seals off the bel-
lows housing. Consequently, the process me-
dium will drain out of the valve on removing
the actuator.
1.
Relieve the spring assembly of tension by
turning the set point adjuster (13) coun-
terclockwise.
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. Undo nuts and bolts (15). Lift the top cov-
er 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 di-
aphragm 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.

Nameplate
14 EB 2547 EN
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
3Conguration ID (Var.-ID)
4 Order number or date
5KVS 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
8 Perm. differential pressure
9 Perm. temperature (°F)
10 Body material
11 CV coefcient (KVS x 1.17)
12 ANSI Class (pressure rating)
DIN/ANSI version
1Effective area (DIN/ANSI)
2 Type
3Conguration ID (Var.-ID)
4 ID number
7Valve 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

Customer service
EB 2547 EN 15
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.)

Dimensions
16 EB 2547 EN
9 Dimensions
Fig. 5: Dimensions ∙Type2422/2424∙Balanced by a bellows
L
ØD
H2
H1
H
Type2422/2424∙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 910 (1050)mm 1040 (1180)mm 1180 (1320)mm
Actuator ØD = 285mm, A = 320cm²
1 to 2.5 Height H 910 (1080)mm 1070 (1210)mm 1180 (1350)mm
Actuator ØD=285mm, A=320 cm²
Weight 1) based on cast iron, PN16, approx.
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 forged steel
Set point ranges in bar

Dimensions
EB 2547 EN 17
Fig. 6: Dimensions · Type2422/2424∙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 93kg 238kg 248kg
0.5 to 2.5bar 75kg 87kg 232kg 242kg
Type2422/2424∙Balanced by a diaphragm

Technical data
18 EB 2547 EN
10 Technical data
Type 2422 Valve
Nominal pressure PN16, 25 or 40
Nominal size DN125 DN150 DN200 DN250
Max. perm.
temperature
Valve balanced
by a bellows
Metal seal: max. 350°C · PTFE soft seal: max. 220°C · EPDM or
FPM soft seal: max. 150°C · NBR soft sealing: max. 80°C 1)
Valve balanced
by a diaphragm EPDM soft seal, max. 150°C
Leakage class according to
IEC60534-4 ≤ 0.05 % of KVS coefcient
Type2424 Actuator
Set point ranges 0.05 to 0.25 bar · 0.1 to 0.6 bar · 0.2 to 1 bar
0.5 to 1.5 bar ·1 to 2.5 bar 2)
Max. perm.
pressure at
actuator
Effective
diaphragm area 320cm² 640cm²
Pressure 3bar 1.5bar
Max. permissible temperature
Gases 350 °C, however, max. 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 EN·Type 2333 Pressure Reducing Valve

SAMSON AG · MESS- UND REGELTECHNIK
Weismüllerstraße 3 · 60314 Frankfurt am Main, Germany
Phone: [phone] · Fax: [phone]
Internet: http://www.samson.de
EB 2547 EN 2014-04-02