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.