Samson 2488 N Service manual

Flow Regulator with Electric Actuator
Type 2488 N/5857
Mounting and
Operating Instructions
EB 3136 EN
Edition December 2011
Fig. 1 · Type 2488 N/5857 Flow Regulator with Electric Actuator

Contents Page
1 Design and principle of operation. . . . . . . . . . . . . . . . . . . . 4
2 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
2.1 Mounting position. . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
2.2 Strainer. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
2.3 Shut-off valves, pressure gauges . . . . . . . . . . . . . . . . . . . . . 5
2.4 Mounting the actuator. . . . . . . . . . . . . . . . . . . . . . . . . . 5
3 Electrical connection . . . . . . . . . . . . . . . . . . . . . . . . . . 6
4 Operation · Set point adjustment . . . . . . . . . . . . . . . . . . . . 7
5 Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
6 Nameplates . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
7 Dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
8 Technical data. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
9 Customer inquiries . . . . . . . . . . . . . . . . . . . . . . . . . . 11
2EB 3136 EN
Contents
CAUTION!
indicates a hazardous situation
which, if not avoided, could result in
death or serious injury.
Live parts are freely accessible!
NOTICE
indicates a property damage message.
Note: Supplementary explanations, informa-
tion and tips
Definitions of the signal words used in these instructions

Safety instructions
EB 3136 EN 3
General safety instructions
4
The flow regulator with electric actuator must be installed, started up and
serviced only by skilled or semi-skilled staff in accordance with good
engineering practice so that employees and third persons are not exposed to
danger.
All safety instructions and warnings given in these mounting and operating
instructions, particularly those concerning installation, start-up and
maintenance, must be strictly observed.
4
The regulator complies with the requirements of the European Pressure
Equipment Directive 97/23/EC. The declaration of conformity issued for a
valve bearing the CE marking includes information on the applied
conformity assessment procedure and will be provided on request.
4
To ensure appropriate use, only use the regulator in applications where the
operating pressure and temperatures do not exceed the operating values
specified in the order.
Note that the manufacturer does not assume any responsibility for damage
caused by external forces or any other external factors.
Take appropriate safety precautions to prevent hazards that may be caused
in the regulator by the process medium, operating pressure, signal pressure,
or moving parts.
4
Make sure the regulator is shipped and stored properly.
4
Depending on the field of application, allow the regulator to cool down or
warm up to reach ambient temperature prior to starting any work.
Always depressurize the relevant section of the plant and, if necessary, also
drain the pipeline prior to installing or servicing the regulator.
4
The electric actuator has been designed for use in electrical power
installations. Strictly observe the relevant safety regulations for wiring and
maintenance work.
4
Only use disconnect devices that are protected against accidental or
unintentional reconnection.
Take special care when making adjustments on live parts.
Do not remove the covers under any circumstances.

1 Design and principle of
operation
The device combines a Type 2488 N Flow
Regulator and a Type 5857 Electric Actuator.
The electric actuator is attached to the valve
by means of the connecting piece and allows
also the temperature to be controlled by
changing the position of the restriction in re-
sponse to the control signal received from an
electric control device. The medium flows
through the valve in the direction indicated
by the arrow on the valve body. The flow
rate depends on the flow passage defined by
the valve plug (3) and the restriction (11).
The integral positioning spring (5) determines
the upper differential pressure (0.2 bar). The
high pressure upstream of the restriction (11)
is transmitted to the high-pressure side of the
diaphragm actuator through the control line
(7). The low pressure downstream of the re-
striction acts on the low-pressure side of the
operating diaphragm (9) via a bore in the
valve plug. The differential pressure
generated by the restriction (special differen-
tial pressure) is converted into a positioning
force by the operating diaphragm. This force
is used to position the valve plug against the
force of the positioning spring (5). The flow
rate can be adjusted by turning the set point
screw (13).
4EB 3136 EN
Design and principle of operation
1
11
12
17
18
2
6
7
4
5
3
14
16
13
8
9
10
15
Fig. 2 · Schematic diagram
1 Valve body
2 Seat
3 Valve plug
4 Plug stem
5 Positioning spring
6 Diaphragm actuator
7 High-pressure control line
8 High-pressure side
9 Operating diaphragm
10 Low-pressure side
11 Restriction
12 Restriction stem
13 Set point screw
14 Connecting piece
15 Spring
16 Electric actuator
17 Coupling nut
18 Actuator stem

2 Installation
2.1 Mounting position
4Install the flow regulator in a horizontal
pipeline with its diaphragm actuator sus-
pended downward.
4Make sure that the electric actuator is
above the valve body.
4Make sure that the medium flows through
the regulator in the direction indicated by
the arrow on the valve body.
NOTICE
Choose a point of installation which will pro-
vide easy access to the regulator after com-
pletion of the plant.
Flush the pipeline thoroughly before installa-
tion.
Make sure the permissible ambient tempera-
ture will not be exceeded. If the valve is to be
insulated, do not insulate the actuator and
the coupling nut. If necessary, use an exten-
sion piece (order no. 1690-6975). The valve
should not be insulated more than approx.
25 mm above the top edge of its body.
2.2 Strainer
Install a strainer (SAMSON Type 1 NI) up-
stream of the regulator to prevent sealing
particles, weld spatter, pipe scale, and other
impurities carried along by the process me-
dium from impairing the proper operation,
especially the tight shut-off of the valve.
4Make sure that the medium flows through
the strainer in the direction indicated by
the arrow on the strainer body.
4Install the strainer with the filter element
vertically suspended. Ensure that ample
space is available to remove the filter.
2.3 Shut-off valves, pressure
gauges
We recommend installing hand-operated
shut-off valves both upstream of the strainer
and downstream of the flow regulator. This
allows the plant to be shut down
(depressurized) for cleaning and mainte-
nance routines, or when it is not operated for
long periods of time.
To monitor the pressures prevailing in the
plant, install pressure gauges both upstream
and downstream of the flow regulator.
NOTICE
When carrying out a pressure test on the sec-
tion of the plant equipped with a pressure
regulator, prevent the diaphragm actuator
from being damaged by the test pressure by
using a test pressure which does not exceed
the maximum permissible pressure
D
p of the
actuator.
2.4 Mounting the actuator
See Fig. 2 on page 4.
Place the actuator (16) onto the valve con-
nection and manually fasten it using the cou-
pling nut (17).
EB 3136 EN 5
Installation

3 Electrical connection
See Figs. 2 and 3.
CAUTION!
When laying electric lines, strictly
observe the regulations governing the
erection of power installations
defined by DIN VDE 0100 as well as
the regulations specified by your
local power supply company.
Use a suitable power supply which
guarantees that no dangerous volt-
ages will reach the device in standard
operation or in case of a fault in the
system or any system parts.
Always switch off the power supply
first prior to connecting the actuator
to the electrical network. Make sure
the power cannot be switched on un-
intentionally.
The supply voltage is 230 V (±10 %) or 24 V
(±10 %), 50 Hz. Refer to EB 5857 EN for
more details.
Use the three-wire connecting cable attached
to the actuator to establish the electrical con-
nection (Fig. 3).
If a voltage is applied between the white and
the green cable, the motor will retract the ac-
tuator stem (18) into the actuator. The restric-
tion stem will be pushed upward by the
spring (15) and the flow rate will increase.
If, however, a control signal is applied to the
white and the brown cable, the actuator stem
extends. The restriction stem will be pushed
downward and the flow rate will decrease.
6EB 3136 EN
brwh gr
aL eL
L
N
Ce Ce
eL
aL
br bl ye gr rd or
24V, 50 Hz 0...10 V 0...10 V
_+_+
NL
Electrical connection
eL Actuator stem retracts
aL Actuator stem extends
Note: Decoupling capacitors Ce in the output cir-
cuit of the connected controller must not exceed a
value of 2.5 nF in order to guarantee the proper
functioning of the actuator.
brwh gr
aL eL
L
N
Ce Ce
eL
aL
Fig. 3 · Electrical connection

4 Operation · Set point
adjustment
See Fig. 2 on page 4.
The flow rate can be adjusted, both with and
without the electric actuator mounted. Prior to
adjusting the flow rate on a regulator with
the electric actuator mounted, make sure the
actuator stem (18) is retracted.
Note: Prior to starting up or pressurizing the
regulator, make sure that the restriction for
limiting the flow is open.
To adjust or alter the flow set point, proceed
as follows:
The set point adjustment is always based on
a closed restriction.
NOTICE
Use the SAMSON manual adjustment
(1790-8169) to close the restriction. Do not
use the set point screw (13).
Remove the manual adjustment again and
use an Allen key (4 mm) at the set point
screw (13) at the side to adjust the flow set
point.
4Determine the number of turns required
to set the desired flow rate from the dia-
gram (Fig. 4).
4Turn set point screw (13) counterclock-
wise the required number of turns.
For exact adjustment, check the set value
using a flow meter.
4Turn the set point screw (13) clockwise to
close the restriction and decrease the flow
rate.
4Turn the set point screw counterclockwise
to open the restriction and increase the
flow rate.
5 Troubleshooting
If the flow rate deviates considerably from
the adjusted set point, first check the control
line for any blockages.
If the valve does not seal properly, this may
be because tight shut-off is prevented by dirt
between the seat and plug or due to natural
wear. Check the regulator for leaks and re-
place it, if necessary.
EB 3136 EN 7
Operation · Set point adjustment
0.1 0.5 1
1
0
2
3
4
5
V
˚
m3/h
0.2 2
2.51.0Kvs
Fig. 4 · Adjustment diagram for flow rate
Turns of set point screw

NOTICE
Prior to starting any work on the reg-
ulator or removing it from the pipe-
line, allow the relevant section of the
plant to cool down to working tem-
perature if high temperatures prevail
and make sure that the pipeline con-
cerned is depressurized and drained.
6 Nameplates
Nameplate of Type 2488 N Valve
8EB 3136 EN
Nameplates
Description of the nameplate:
1 Model number with index
2 Year of manufacture
3 Type
4 Flow set point range in m3/h
5 Upper differential pressure in bar
6 Max. perm. differential pressure in bar
7 Flow coefficient KVS
8 Max. perm. temperature in °C
9 Nominal pressure PN
12
23
56
79 8
Description of the nameplate:
1 Nominal thrust, rated travel
actuating time, electrical connection
2 Configuration ID
3 Serial number
Nameplate of Type 5857 Electric Actuator
1
SAMSON 5857
2
3
Electric Actuator
Made in Germany

EB 3136 EN 9
Dimensions
7 Dimensions
Ø95
114
65
~65
120
ISO 228/1-G ¾ B
~70
Ø12
55
80
11
32 70
SW30
129
G½
Threaded ends
SW30
210
Ø21.3
Welding ends
Soldering ends · Dimensions in mm
Internal Ø di 15 18
Length L 107 103
80
Intermediate
insulating piece
SW30
L
Ø21.3
di
Soldering ends
Fig. 5 · Dimensional drawings (dimensions in mm)

8 Technical data
Type 5857 Actuator
Rated travel 6 mm
Actuating time for rated travel 20 s
Nominal thrust 300 N
Supply voltage 230 V/24 V (±10 %)
50 Hz
Power consumption Approx. 3 VA
Perm. ambient temperature 0 to 50 °C
Perm. storage temperature –20 to 70 °C
Degree of protection IP 42
Noise immunity EN 61000-6-2
Noise emission EN 61000-6-3
Weight Approx. 0.7 kg
Materials
Body CC491K
Plug 1.4301 with EPDM
sealing ring
Restriction Brass resistant to
dezincification
Diaphragm EPDM without fabric
10 EB 3136 EN
Technical data
Type 2488 N Valve
Nominal size DN 15
Nominal pressure PN 10
Max. perm. diff. pressure Dp 4 bar
Flow coefficient KVS
Standard version
Special version 2.5 1.0
Max. perm. temperature
Treated water
Non-flammable gases 110 °C 80 °C
Flow set point range / flow lim-
itation for water at upper differ-
ential pressure of 0.2 bar
Standard version
Special version 0.3 to 1m3/h
0.1 to 0.5 m3/h
Upper differential pressure 0.2 bar
Materials
Body Plastic PPO
Coupling nut Brass
Intermediate insulating piece 1.4306, CW617N,
PTFE, EPDM, FPM

9 Customer inquiries
Should any malfunctions or any defect occur,
SAMSON's After-Sales Service is prepared
to help you on site.
You can also send the defective regulator di-
rectly to your local SAMSON representative
for repair. Addresses of SAMSON subsidiar-
ies, agencies and service centers are listed in
the product catalogs and in the Internet at
www.samson.de.
To allow SAMSON to find the fault and to
have an idea of the installation situation,
specify the following details (see nameplate):
4Type and nominal size of the regulator
4Model number with index
4Var.-ID and serial number of actuator
4Upstream and downstream pressure
4Process medium and its temperautre
4Minimum and maximum flow rate in
m³/h
4Has a strainer been installed?
4Installation drawing
EB 3136 EN 11
Customer inquiries

SAMSON AG · MESS- UND REGELTECHNIK
Weismüllerstraße 3 · 60314 Frankfurt am Main · Germany
Phone: [phone] · Fax: [phone]
Internet: http://www.samson.de EB 3136 EN
S/Z 2011-12