Samson 42-34 Service manual

Translation of original instructions
EB 3013 EN
Type42-34 and Type42-8 Differential Pressure Regulators
with Flow Limitation
Self-operated Regulators
Type42-34
Type42-38
Edition April 2021

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 3013 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]).
Documents relating to the device, such as the mounting and operating
instructions, are available on our website at www.samsongroup.com >
Service & Support > Downloads > Documentation.

Contents
EB 3013 EN
1. Safety instructions and measures ...................................................................5
1.1 Notes on possible severe personal injury .........................................................8
1.2 Notes on possible personal injury ...................................................................9
1.3 Notes on possible property damage..............................................................10
2. Markings on the device ...............................................................................12
2.1 Materialidenticationnumber ......................................................................13
3. Design and principle of operation ................................................................13
3.1 Versions......................................................................................................16
3.2 Technical data .............................................................................................16
3.2.1 Process medium and scope of application......................................................16
4. Technical data .............................................................................................17
5. Measures for preparation............................................................................22
5.1 Unpacking ..................................................................................................22
5.2 Transporting and lifting ................................................................................22
5.2.1 Transporting ................................................................................................23
5.2.2 Lifting..........................................................................................................23
5.3 Storage.......................................................................................................24
5.4 Preparation for installation............................................................................25
6. Mounting and start-up.................................................................................25
6.1 Mounting positions.......................................................................................26
6.1.1 Pipeline routing............................................................................................27
6.1.2 Insulation ....................................................................................................28
6.2 Control line and needle valve........................................................................28
6.2.1 Control line .................................................................................................28
6.2.2 Needle valve ...............................................................................................29
6.3 Additionalttings.........................................................................................30
6.4 Installing the regulator..................................................................................31
6.5 Start-up.......................................................................................................31
7. Operation...................................................................................................33
7.1 Adjusting the set points.................................................................................33
7.1.1 Adjusting the differential pressure..................................................................33
7.1.2 Adjustingtheowlimitation..........................................................................34
7.1.3 Based on a known plant pressure drop..........................................................34
7.1.4 Based on an unknown plant pressure drop.....................................................35
7.2 Pressure conditions in the plant and at the regulator........................................36
7.3 Sample application......................................................................................37

Contents
EB 3013 EN
8. Servicing.....................................................................................................45
8.1 Replacing the operating diaphragm ..............................................................46
8.2 Tightening torques and lubricants..................................................................48
8.3 Preparation for return shipment.....................................................................49
8.4 Ordering spare parts and operating supplies .................................................49
9. Malfunctions ...............................................................................................49
10. Decommissioning and removal ....................................................................51
10.1 Decommissioning.........................................................................................51
10.2 Disposal......................................................................................................52
11. Annex.........................................................................................................52
11.1 After-sales service........................................................................................52
11.2 Certicates ..................................................................................................52

EB 3013 EN 5
Safety instructions and measures
1. Safety instructions and measures
Intended use
TheType42-34andType42-38Regulatorsaredesignedasdifferentialpressureregulators
withowlimitation.Theregulatorsaremainlyusedindistrictheatingsupplynetworkswith
indirect connection and industrial plants.
Thedevicesaredesignedtooperateunderexactlydenedconditions(e.g.operatingpres-
sure, process medium, temperature). Therefore, operators must ensure that the devices are
onlyusedinoperatingconditionsthatmeetthespecicationsusedforsizingthedevicesat
the ordering stage. In case operators intend to use the devices in other applications or condi-
tions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devicesarenotsuitableforuseoutsidethelimitsdenedduringcongurationandbythe
technical data. Furthermore, the following activities do not comply with the intended use:
− Use of non-original spare parts
− Performingserviceworknotspecied
Qualications of operating personnel
Thedevicesmustbemounted,startedupandservicedbyfullytrainedandqualiedperson-
nel only; the accepted industry codes and practices are to 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specialized
training, their knowledge and experience as well as their knowledge of the applicable stan-
dards.

6 EB 3013 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).
ÎProvide protective equipment (e.g. safety gloves, eye protection) appropriate for the pro-
cess medium used.
ÎWear hearing protection when working near the valve.
ÎCheck with the plant operator for details on further protective equipment.
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.
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device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, especially for installation, start-up and service work.
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42-34andType42-38Regulatorsdonothaveanyspecialsafetyfeatures.When
relieved of pressure, the valve is opened and closes as the differential pressure rises.
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.

EB 3013 EN 7
Safety instructions and measures
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 devices comply with the requirements of the European Pressure Equipment Directive
2014/68/EU. Devices with a CE marking have an EU declaration of conformity, which in-
cludes information about the applied conformity assessment procedure. The EU declaration
ofconformityisincludedintheannexoftheseinstructions(seesection11.2).
Non-electric valve versions whose bodies are not lined with an insulating material coating do
not have their own potential ignition source according to the risk assessment stipulated in
EN13463-1:2009,section5.2,evenintherareincidentofanoperatingfault.Therefore,
such valve versions do not fall within the scope of Directive 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).
Referenced documentation
The following documents apply in addition to these mounting and operating instructions:
− Mounting and operating instructions for an additional thermostat, e.g. uEB3019
− MountingandoperatinginstructionsforType2NIStrainer,e.g.uEB1015
− DatasheetforType2NIStrainer,e.g.uT1015

8 EB 3013 EN
Safety instructions and measures
1.1 Notes on possible severe personal injury
DANGER
!
Risk of personal injury due to process medium escaping.
The valve seal is opened when the actuator is removed from the valve. Residual pro-
cess medium can escape and, depending on its properties, may lead to personal inju-
ry, e.g. burns.
ÎDepressurizetheplant.
ÎDo not start up the regulator until all parts have been mounted.
ÎWear protective clothing, safety gloves and eye protection.
DANGER
!
Risk of bursting in pressure equipment.
Valves and pipelines are pressure equipment. Improper opening can lead to valve
components bursting.
ÎBeforestartinganyworkonthevalve,depressurizeallplantsectionsaffectedas
well as the valve.
ÎDrain the process medium from all the plant sections affected as well as the valve.
ÎWear personal protective equipment.

EB 3013 EN 9
Safety instructions and measures
1.2 Notes on possible personal injury
WARNING
!
Crush hazard arising from moving parts.
Theregulatorcontainsmovingparts,whichcaninjurehandsorngersifinsertedinto
the valve.
ÎDonotinserthandsorngersbetweenthesetpointspringswhiletheregulatoris
in operation.
ÎBeforeperforminganyworkontheregulator,depressurizetheplant.Disconnector
shut off the external control line.
Risk of personal injury due to residual process medium in the valve or actuator.
While working on the valve or actuator, residual process medium can escape and, de-
pending on its properties, may lead to personal injury, e.g. burns.
ÎIf possible, drain the process medium from all the plant sections affected and the
valve.
ÎWear protective clothing, safety gloves and eye protection.
Risk of burn injuries due to hot or cold components and pipelines.
Depending on the application, valve 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.
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https://www.samsongroup.com/en/about-samson/material-compliance/
reach-regulation/

10 EB 3013 EN
Safety instructions and measures
1.3 Notes on possible property damage
NOTICE
!
Risk of valve 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.
ÎObserve the maximum permissible pressure for valve and plant.
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 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tighteningtorquesspeciedinsection8.2.
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 actuator stem
guide(Type42-34).
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section6.1.2.
Risk of valve damage due to the use of unsuitable lubricants.
The lubricants to be used depend on the valve material. Unsuitable lubricants may cor-
rode and damage surfaces.
ÎOnlyuselubricantsapprovedbySAMSON(seesection8.2).