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

), the valve is opened by the force of

the positioning springs.

The downstream pressure p

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

6.1

6.2

8.1

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.

Relieve the positioning springs of tension

by turning the set point adjuster (13).

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.

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

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

“ 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

“ 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

“ 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.

Relieve the spring assembly of tension by

turning the set point adjuster (13) coun-

terclockwise.

2. Unscrew the control line and clean it.

Undo the coupling nut (7) and remove the

actuator.

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.

Pull the diaphragm stems together with the

diaphragm plates and the diaphragm out

of the lower diaphragm case.

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!).

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

Made in Germany

˚C

bar

∅p

Made in Germany

Size

SAMSON

psi T˚F Cv Cl

910 11

710 11 12

psi

psi psi

size

cm²

Var.-ID No

SAMSON

sq.in

bar bar

Made in Germany

bar

2002

0062

97710

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

ØD

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



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

· 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: +49 69 4009-0 · Fax: +49 69 4009-1507

Internet: http://www.samson.de

EB 2547 EN

2014-04-02

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