Samson 2479 Service manual

Translation of original instructions
EB 3132-3 EN
Type2479/2430 Differential Pressure and Temperature Regulator
with Flow Limitation
Self-operated Regulators
Edition June 2020

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 3132-3 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]).
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.samsongroup.com > Service & Support > Downloads >
Documentation.

Contents
EB 3132-3 EN 1
1 Safety instructions and measures ................................................................1-1
1.1 Notes on possible severe personal injury ......................................................1-4
1.2 Notes on possible personal injury ................................................................1-5
1.3 Notes on possible property damage.............................................................1-7
2 Markings on the device ..............................................................................2-1
2.1 NameplateofType2479Valve....................................................................2-1
2.2 NameplateofType2430ControlThermostat ................................................2-2
2.3 Location of the nameplate on valve and control thermostat .............................2-3
2.4 Materialidenticationnumber .....................................................................2-4
2.4.1 Type2479Valve.........................................................................................2-4
2.4.2 Type2430ControlThermostat .....................................................................2-4
3 Design and principle of operation ...............................................................3-1
3.1 Additionalttings........................................................................................3-4
3.2 Technical data ............................................................................................3-5
4 Shipment and on-site transport ...................................................................4-1
4.1 Accepting the delivered goods .....................................................................4-1
4.2 Removing the packaging from the regulator ..................................................4-1
4.3 Transporting and lifting the regulator............................................................4-1
4.4 Storing the regulator ...................................................................................4-2
5 Installation.................................................................................................5-1
5.1 Installation conditions..................................................................................5-1
5.2 Preparation for installation...........................................................................5-4
5.3 Installation..................................................................................................5-7
5.3.1 Installing the regulator.................................................................................5-7
5.3.2 Cleaningthepipeline ..................................................................................5-8
5.4 Testing the regulator ....................................................................................5-8
5.4.1 Leak test.....................................................................................................5-9
5.4.2 Pressure test................................................................................................5-9
5.5 Insulation .................................................................................................5-10
6 Start-up .....................................................................................................6-1
6.1 Start-up and putting the device back into operation .......................................6-2
6.2 Starting up the plant....................................................................................6-2
7 Operation..................................................................................................7-1
7.1 Adjusting the set points................................................................................7-1
7.2 Adjustmentoftheowrate ..........................................................................7-1
7.3 Adjusting the temperature............................................................................7-3

Contents
2 EB 3132-3 EN
8 Malfunctions ..............................................................................................8-1
8.1 Troubleshooting ..........................................................................................8-1
8.2 Emergency action .......................................................................................8-4
9 Servicing....................................................................................................9-1
9.1 Preparingthevalveforservicework .............................................................9-2
9.2 Installingtheregulatorafterservicework ......................................................9-2
9.3 Servicework...............................................................................................9-5
9.3.1 Replacingtheseatandplug.........................................................................9-5
9.3.2 Replacingtheactuator'soperatingdiaphragm ..............................................9-5
9.3.3 Replacingthecontrolthermostat...................................................................9-6
9.4 Orderingsparepartsandoperatingsupplies ................................................9-6
10 Decommissioning .....................................................................................10-1
11 Removal ..................................................................................................11-1
11.1 Removing the control thermostat.................................................................11-1
11.2 Removing the regulator from the pipeline....................................................11-1
12 Repairs ....................................................................................................12-1
12.1 Returning devices to SAMSON ..................................................................12-1
13 Disposal...................................................................................................13-1
14 Certicates...............................................................................................14-1
15 Annex......................................................................................................15-1
15.1 Tightening torques.....................................................................................15-1
15.2 Lubricant..................................................................................................15-1
15.3 Tools ........................................................................................................15-1
15.4 Spare parts ..............................................................................................15-2
15.5 After-sales service.....................................................................................15-4

EB 3132-3 EN 1-1
Safety instructions and measures
1 Safety instructions and measures
Intended use
TheSAMSONType2479/2430Regulatorisadifferentialpressureandtemperatureregula-
torwithowlimitation.ItconsistsofaType2479ValveandaType2430ControlThermo-
stat. The valve and control thermostat are delivered separately and must be assembled ac-
cording to the instructions in these mounting and operating instructions.
The self-operated regulator is mainly used to control the temperature and differential pressure
aswellaslimittheowrateindistrictheatingsupplynetworks.Liquidsandgasescanbe
controlled by the regulator.
Theregulatorisdesignedtooperateunderexactlydenedconditions(e.g.operatingpres-
sure, process medium, temperature). Therefore, operators must ensure that the regulator is
onlyusedinoperatingconditionsthatmeetthespecicationsusedforsizingtheregulatorat
the ordering stage. In case operators intend to use the regulators 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
− Useoutsidethelimitsdenedbytheadditionalttingsmountedontheregulator
Furthermore, the following activities do not comply with the intended use:
− Use of non-original spare parts
− Performing service and repair work not described
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spe-
cializedtraining,theirknowledgeandexperienceaswellastheirknowledgeoftheapplica-
ble standards.

1-2 EB 3132-3 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).Dependingontheprocessmediumand/
or the activity, the protective equipment required includes:
ÎProtectiveclothing,safetyglovesandeyeprotectioninapplicationswithhot,coldand/or
corrosive media
ÎWear hearing protection when working near the valve. Follow the instructions given by
the plant operator.
ÎHard hat
ÎSafety harness when working at height
ÎSafetyfootwear,ESD(electrostaticdischarge)footwear,ifnecessary
ÎCheckwiththeplantoperatorfordetailsonfurtherprotectiveequipment.
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. Plant operators and operat-
ingpersonnelmustobserveallhazardstatements,warningandcautionnotesinthese
mounting and operating instructions.
Hazardsresultingfromthespecialworkingconditionsattheinstallationsiteoftheregulator
mustbeidentiedinariskassessmentandpreventedthroughthecorrespondingsafetyin-
structions drawn up by the operator.
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.
Safety features
TheType2479/2430Regulatordoesnothaveanyspecialsafetyfeatures.
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.Fur-
thermore, the product may no longer meet the requirements for its intended use.

EB 3132-3 EN 1-3
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.RegulatorswithaCEmarkinghaveanEUdeclarationofconformity,which
includes information about the applied conformity assessment procedure. This EU declaration
ofconformityisincludedinthe'Certicates'section.
AccordingtotheignitionriskassessmentperformedinaccordancewithEN13463-1:2009,
section 5.2, the non-electrical regulators do not have their own potential ignition source even
intherareincidentofanoperatingfault.Asaresult,theydonotfallwithinthescopeofDi-
rective 2014/34/EU.
ÎForconnectiontotheequipotentialbondingsystem,observetherequirementsspeciedin
section6.4ofEN60079-14(VDE0165-1).

1-4 EB 3132-3 EN
Safety instructions and measures
Referenced documentation
The following documents apply in addition to these mounting and operating instructions:
− Mounting and operating instructions for
e.g. Type1N/NI Strainer uEB1010
e.g. Type2N/NI Strainer uEB1015
e.g. Type2430 Control Thermostat uEB2430
− Datasheetsfor
e.g. Accessories for Series 43 Regulators uT2176
− Mountingandoperatinginstructionsaswellasdatasheetsforadditionalttings
(e.g. shut-off valves, pressure gauges etc.).
1.1 Notes on possible severe personal injury
DANGER
!
Risk of bursting in pressure equipment.
Regulators and pipelines are pressure equipment. Impermissible pressure or improper
opening can lead to regulator components bursting.
ÎObserve the maximum permissible pressure for regulator and plant.
ÎBeforestartinganyworkontheregulator,depressurizeallplantsectionsaffected
as well as the regulator.
ÎDraintheprocessmediumfromalltheplantsectionsaffectedaswellastheregula-
tor.
ÎIf necessary, a suitable overpressure protection must be installed in the plant sec-
tion.
ÎWear personal protective equipment.

EB 3132-3 EN 1-5
Safety instructions and measures
1.2 Notes on possible personal injury
WARNING
!
Risk of personal injury through incorrect operation, use or installation as a result of
information on the regulator being illegible.
Over time, markings, labels and nameplates on the regulator may become covered
withdirtorbecomeillegibleinsomeotherway.Asaresult,hazardsmaygounno-
ticed and the necessary instructions not followed. There is a risk of personal injury.
ÎKeep all relevant markings and inscriptions on the device in a constantly legible
state.
ÎImmediately renew damaged, missing or incorrect nameplates or labels.
Risk of hearing loss or deafness due to loud noise.
The noise emissions depend on the valve version, plant facilities and process medium.
ÎWear hearing protection when working near the valve. Follow the instructions giv-
en by the plant operator.
Risk of personal injury due to pressurized components and process medium being
discharged.
Incorrect opening of pressure equipment or mounting parts may lead to the process
medium escaping to the atmosphere.
ÎDonotloosenthecontrollinewhilethevalveispressurized.
Risk of burn injuries due to hot or cold components and pipelines.
Dependingontheprocessmedium,regulator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.

1-6 EB 3132-3 EN
Safety instructions and measures
WARNING
!
Damage to health relating to the REACH regulation.
If a SAMSON device contains a substance which is listed as being a substance of very
highconcernonthecandidatelistoftheREACHregulation,thiscircumstanceisindi-
cated on the SAMSON delivery note.
ÎInformation on safe use of the part affected uwww.samsongroup.com/en/
about-samson/material-compliance/reach-regulation/
Risk of personal injury due to residual process medium in the regulator.
While working on the regulator, 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 affected and the
regulator.
ÎWear protective clothing, safety gloves and eye protection.

EB 3132-3 EN 1-7
Safety instructions and measures
1.3 Notes on possible property damage
NOTICE
!
Risk of regulator damage due to incorrectly attached slings.
ÎDonotattachload-bearingslingstotheactuatorhousing.
Risk of regulator damage due to unsuitable medium properties.
Theregulatorisdesignedforaprocessmediumwithdenedproperties.
ÎOnlyusetheprocessmediumspeciedforsizing.
Risk of regulator 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.
Risk of regulator damage due to the use of unsuitable lubricants.
The lubricants to be used depend on the regulator material. Unsuitable lubricants may
corrode and damage surfaces.
ÎOnly use lubricants approved by SAMSON.
When in doubt, consult SAMSON.
Risk of leakage and regulator damage due to excessively high or low tightening
torques.
Observethespeciedtorqueswhentighteningregulatorcomponents.Excessivetight-
ening torques lead to parts wearing out more quickly. Parts that are too loose may
cause leakage.
ÎObservethespeciedtighteningtorques(see'Tighteningtorques'inAnnex).
Risk of regulator damage due to the use of unsuitable tools.
Certaintoolsarerequiredtoworkontheregulator.
ÎOnly use tools approved by SAMSON.
When in doubt, consult SAMSON.

1-8 EB 3132-3 EN
Safety instructions and measures
NOTICE
!
Risk of the process medium being contaminated through the use of unsuitable lubri-
cants and/or contaminated tools and components.
ÎKeep the regulator and the tools used free from solvents and grease.
ÎMake sure that only suitable lubricants are used.
Risk of excess pressure damaging plant sections due to construction-related seat
leakage through the regulator.
ÎAlways install a safety device (e.g. safety excess pressure valve or safety relief
valve) in the plant.
Incorrect control due to the formation of ice on the regulator.
Mediumtemperaturesbelow0°Cmaycauseicetoformontheregulator,depending
on the air humidity. This may affect, in particular, the functioning of the plug or control
thermostat stem guide.
ÎPrevent the formation of ice by taking appropriate precautions (e.g. enclosure,
trace heater etc.). The plant operator is responsible for selecting and implementing
appropriateprecautions.Seethe'Installation'section.
Risk of irreparable regulator damage caused by the regulator components being
taken apart.
The control thermostat is an inseparable hydraulic unit consisting of a control thermo-
stat, capillary tube and temperature sensor. If these components are dismantled (e.g.
removal of the capillary tube), the regulator will be irreparably damaged and will no
longerbeabletofulllitscontroltask.
ÎDonotdismantletheregulator.
ÎOnly perform allowed activities on the regulator.
ÎContactSAMSON'sAfter-salesServicebeforereplacingspareparts.
SAMSON's After-sales Service can support you concerning lubricant, tightening torques
and tools approved by SAMSON.
Note

EB 3132-3 EN 2-1
Markings on the device
2 Markings on the device
Severalnameplatesareafxedtothedevice.Thenameplatesareusedtoidentifythesepa-
rateregulatorcomponents(seesection2.1andsection2.2).
2.1 Nameplate of Type2479 Valve
Nameplate on bodies made of red brass or spheroidal graphite iron
Nameplate for Type 2479 Valve
1Order number or year of
manufacture
2 Type designation
3Model number and material
number
4 Flow rate set point rangeinm³/h
5Differentialpressureatthe
restriction in bar
6Max.perm.differentialpressureΔp
in bar
7FlowcoefcientKVS
8Max.perm.temperaturein°C
9Pressure rating PN
3 1
2 4
5 6
789
Valvesize,pressureratingandthearrowindicatingthedirectionofowarecastintothebody.
Fig.2-1: Nameplate for Type 2479 Valve

2-2 EB 3132-3 EN
Markings on the device
2.2 Nameplate of Type2430 Control Thermostat
23
5
6
2004
0062
4
1
1 Model number
2 Type designation
3 Material number
4CEmarking
5Temperaturerangein°Cand°F
6Register number (type test according to
DINEN14597)
Fig.2-2: Nameplate of the Type2430 Control Thermostat

EB 3132-3 EN 2-3
Markings on the device
2.3 Location of the nameplate
on valve and control
thermostat
Red brass body Spheroidal graphite iron body
Location of the
nameplate
Location of the
nameplate
Top view
Type2430
Fig.2-3: Locations of the nameplates on the body

2-4 EB 3132-3 EN
Markings on the device
2.4 Material identication
number
2.4.1 Type 2479 Valve
The material is indicated on the body. Speci-
fying the material number, you can contact
ustondoutmoredetails.Thisisspecied
on the nameplate (item 3).
For more details on the nameplate, see sec-
tion2.1.
2.4.2 Type2430 Control
Thermostat
Specifying the material number, you can
contactustondoutwhichmaterialisused.
Thisisspeciedonthenameplate(item3).
For more details on the nameplate, see sec-
tion2.2.

EB 3132-3 EN 3-1
Design and principle of operation
3 Design and principle of oper-
ation
ÎSeeFig.3-1andFig.3-2
The regulator consists of the Type2479
Valve with restriction, seat and plug and the
closing actuator with operating diaphragm
as well as the Type2430 Control Thermo-
stat with set point adjuster, capillary tube
and temperature sensor.
The regulator is used to maintain the differ-
ential pressure and temperature to their ad-
justedsetpoints.Theowratecanbelimited
by the restriction (1.2) integrated in the valve
body.
Versionsforsafetyequipmentareadditional-
lyequippedwithaType2403SafetyTher-
mostat(assafetytemperaturemonitorDPR/
TR/STM)orwithaType2439SafetyTem-
perature Limiter (as safety temperature limit-
erDPR/TR/STL).Seedocumentslistedunder
'Referenceddocumentation'inthe'Safetyin-
structionsandmeasures'section.
Themediumowsthroughthevalveinthe
direction indicated by the arrow on the valve
body.Theowrateisdeterminedbythear-
ea released by the plug (3) and the adjust-
able restriction (1.2).
Thehighpressureoftheplant(owpipe)is
transmitted to the high-pressure side of the
actuator through the control line (11) mount-
ed on site. The low pressure downstream of
the restriction acts on the low-pressure side
of the operating diaphragm (6.1) through a
hole in the plug.
The differential pressure generated across
the restriction is converted into a positioning
force by the operating diaphragm. This force
is used to move the plug depending on the
force of the set point spring (5).
The temperature of the medium creates a
pressure in the temperature sensor. This pres-
sure is transferred to an operating bellows
(23) through a capillary tube (24) where it is
converted into a positioning force. This force
moves the plug (3) over the pin of the oper-
ating element (8), dependent on the force of
the spring (21) loaded by the set point ad-
juster (22).
The largest signal is always used to control
the regulator.
The valve closes as the controlled variable
rises.

3-2 EB 3132-3 EN
Design and principle of operation
14
13
12
11
1
1.2
1.1
2
3
4
5
6.1
7
6
8
10
20
24
25
21
22
23
26
26
Fig.3-1: Functional diagram of regulator, DN32 to 50

EB 3132-3 EN 3-3
Design and principle of operation
6
3
1
1.1
11
1.2
12
8
22
20
25
24
10
7
6.1
6.2
2
23
21
26
6.3
Fig.3-2: Functional diagram of regulator, DN15 to 25
Legend for Fig.3-1 and Fig.3-2
1Valvebody
1.1 Connectionnutwithsealand
welding end
1.2 Restriction
2 Seat
3Guidenipplewithplugsection
4 Plug stem
5 Set point spring
6 Actuator
6.1 Operating diaphragm unit
6.2 Overload protection
6.3 Actuator cover
7 Housing screws
8 Pin of operating element
10 Couplingnut
11 Controlline
12 Set point screw
13 Lock nut
14 Cap
20 Controlthermostat
21 Set point spring
22 Set point adjuster (tempera-
ture)
23 Operating bellows
24 Capillarytube
25 Temperature sensor with
packing
26 Lead-seal hole

3-4 EB 3132-3 EN
Design and principle of operation
3.1 Additional ttings
ÎSeeFig.3-3
Pressure gauges
Install a pressure gauge (3 and 5) at suitable
points to monitor the pressures prevailing in
the plant.
Bypass and shut-off valves
We recommend installing a shut-off valve (1
and 6) both upstream of the strainer and
downstream of the regulator and installing a
bypass line. The bypass ensures that the
plant does not need to be shut down for ser-
vice and repair work on the regulator.
5
56271
8 3
+
–
4
∆pmin Minimum differential pressure across the valve in bar
∆prestriction Differentialpressurecreatedattherestrictionformeasuringtheowrateintheregulator
V Adjustedowrateinm³/h
KVS Valveowcoefcientinm³/h
·
The minimum required plant differential pressure
∆pmin across the valve is calculated as follows: Δpmin=Δprestriction +
(
V
)
2
KVS
·
Fig.3-3: Type2479/2430 (installation example)
Legend
1 Shut-off valve
2 Strainer
3Pressuregauge(owpipe)
4Type2479/2430
5Pressuregauge(returnow
pipe)
6 Shut-off valve
7Controllinemountedonsite
8Temperature sensor with
capillary tube