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).

EB 3013 EN 11
Safety instructions and measures
NOTICE
!
Risk of regulator damage due to incorrectly attached slings.
ÎDo not attach load-bearing slings to the actuator housing.
Regulator damage due to condensed glycol.
In principle, the materials are also resistant to high concentrations of glycol. Neverthe-
less, glycol reacts when it comes into contact with metals and causes acids to form. We
cannot prevent this reaction.
ÎUse suitable inhibitors. The plant operator is responsible for the selection and use
of suitable inhibitors.

12 EB 3013 EN
Markings on the device
2. Markings on the device
Specications on
the actuator
Flange version
1Effective area in cm²
2Type
3CongurationID
4Index no.
6Pressure rating PN
7Valvesize
9Set point range in bar
10 Diaphragm material
2 3 1
10
6
4
7
9
Specications on
the valve
Flange version
1Type
2Model number index
3CongurationID
4Order number/date
5KVS coefcient
7ValvesizeDN
8Pressure rating PN
9Perm.differentialpressureΔpinbar
10 Perm.temperaturein°C
11 Body material
2314 5
1110987
Fig.1: Nameplates

EB 3013 EN 13
Design and principle of operation
2.1 Material identication
number
SpecifyingthecongurationID,youcan
contactustondoutwhichmaterialisused.
ThecongurationIDisspeciedonthe
nameplate ("Var.-ID"). For more details on
thenameplate,seeFig.1.
3. Design and principle of
operation
See Fig.2 and Fig.3.
The differential pressure regulators are de-
signed to maintain a constant pressure dif-
ference between the high pressure and low
pressure lines to an adjustable set point
(Type42-34)oraxedsetpoint(Type42-
38).Theowratecanbelimitedbythere-
striction integrated in the valve body.
The regulators consist of a valve and an ac-
tuator with adjustable restriction. Valve and
actuator are delivered separately and must
be assembled together on site using a cou-
pling nut (11).
Themediumowsthroughthevalveinthe
direction indicated by the arrow. The areas
released by the restriction (1.4) and the
valveplug(3)determinetheowrateand
thedifferentialpressure∆pplant across the
plant.Seesection7.2.
In fully balanced valves, the forces acting on
the valve plug created by the upstream and
downstream pressures are balanced by a
balancing bellows (5) or balancing dia-
phragm (5.1). Regulators balanced by a bel-
lows or a diaphragm only differ in the pres-
sure balancing principle applied. Valves bal-
ancedbyadiaphragm(DN65to250only)
have a balancing diaphragm (5.1) instead
of the balancing bellows (5). The down-
stream pressure p2acts on the bottom of the
diaphragm and the upstream pressure p1on
the top of the diaphragm. As a result, the
forces created by the upstream and down-
stream pressures acting on the plug are bal-
anced out.
TheregulatorsinDN15to100aretted
with a connecting piece (10) for the
low-pressure control line between the valve
and actuator.
To control the differential pressure, the high
pressure(ow)oftheplantistransmitted
over the high-pressure control line to the bot-
tom diaphragm chamber of the actuator. The
pressure downstream of the restriction (1.4)
is transmitted through the hollow plug stem
and the attached low-pressure control line to
the top diaphragm chamber of the actuator.
The differential pressure is converted into a
set point force at the operating diaphragm
(13) and used to move the plug according to
the force of the set point springs (16). De-
pending on the actuator version, the set
point springs installed in the actuator
(Type42-38)denethesetpointorthe
springs are mounted externally to allow the
setpointtobeadjusted(Type42-34).
Theowsetpointscrew(1.1)withthead-
justed restriction (1.4) is used to change the
cross-sectionalareaofowtoadjustthe
maximumowrate.
The force limiter (20) and internal excess
pressure limiter (21) protect the seat and
plug from overload during exceptional oper-
ating conditions.

14 EB 3013 EN
Design and principle of operation
Type42-34·Type42-38·DN15 to 250·Balanced by a bellows
16
17
14
13
15
18
19
11
12.1
10
9
8
5
7
20
21
4
1
3
2
1.2
1.4
1.1
1.3
+
_
9.1
22
12.2
+
_
21
18
19
16, 20
12.1
11
13
Type2428 Actuator
Type42-38
DN15to100
Type2424 Actuator
Type2423 Valve,
balanced by a
bellows
Type42-34
DN15to250
Fig.2: Functional diagram of valve balanced by a bellows
1 Valve body
1.1 Flow set point adjustment
(set point screw)
1.2 Lock nut
1.3 Cap
1.4 Restriction
2 Seat
3 Plug
4 Plug stem
5 Balancing bellows
7 Spring
8 Screw plug (balanced by a bel-
lows,DN125andlarger)
9 Low-pressure control line (up to
DN100)
9.1 Low-pressureconnection(DN125
and larger)
10 Connectingpiece(uptoDN100)
11 Coupling nut
12.1 Diaphragm stem
12.2 Diaphragm stem
13 Operating diaphragm
14 Actuator housing
15 Screws
16 Set point springs
17 Set point adjustment for differential
pressure (set point adjuster)
18 Nut
19 Diaphragm plate
20 Force limiter
21 Internal excess pressure valve
22 Blanking plug at side

EB 3013 EN 15
Design and principle of operation
DN65 to 100·Balancedbyadiaphragm DN125 to 250·Balancedbyadiaphragm
Type2423Valve,balancedbyadiaphragm
1
2
3
p
1
5.1
4
1.3
1.1
1.2
1.4
p2
1
2
3
p1
5.1
12.1
4
11
1.3
1.1
1.2
1.4
p2
+
_
12.2
Type2424Actuator
Type2423Valve,balancedbyadiaphragm
Type2424Actuator Type2428Actuator
Type42-34 Type42-38 Type42-34
1 Valve body
1.1 Flow rate set point screw
1.2 Lock nut
1.3 Cap
1.4 Restriction
2 Seat
3 Plug
4 Plug stem
5.1 Balancing diaphragm
11 Coupling nut
12.1 Diaphragm stem
12.2 Diaphragm stem
Fig.3: Functional diagram of valve balanced by a diaphragm, DN65 to 100 and DN125 to 250
Optional

16 EB 3013 EN
Design and principle of operation
3.1 Versions
Type42-34andType42-38Differential
Pressure Regulators with Flow Limitation are
designedforinstallationinthereturnow
pipe, e.g. a district heating station with indi-
rect connection.
− Type42-34 · With adjustable differential
pressurelimitandowlimitation·With
internal overload protection (excess pres-
sure limiter) in the actuator
− Type42-38·Withxeddifferentialpres-
sureandadjustableowlimitation·
With internal overload protection (excess
pressure limiter) in the actuator
Regulator congurations
Type42-34withconnectingpiece(DN15to
100)
Consisting of:
Valve —Type2423,balanced
Actuator —Type2424adjustablesetpoint
Type42-38 with connecting piece
Consisting of:
Valve —Type2423,balanced
Actuator —Type2428xedsetpoint
The regulators consist of a valve and an ac-
tuator with adjustable restriction. They con-
trol the differential pressure to the set point
adjustedattheactuatorandlimittheow
rate to the value adjusted at the restriction.
3.2 Technical data
3.2.1 Process medium and
scope of application
Differentialpressurecontrolandowrate
limitation for district heating systems with in-
direct connection, extended piping systems
and industrial applications.
Forowratefrom0.05 to 520m³/h
Differential pressure set points from 0.1 to
1.5bar
ValvesizesDN15 to 250·PN16 to 40
Suitable liquids from 5 to 150°C
Max. 150°C
The valve closes when the differential pres-
surerises.Theowrateislimited.
_
1) The materials used in the regulator are also
resistant to high concentrations of glycol.
Nevertheless, glycol reacts when it comes into
contact with metals and causes acids to form.
We cannot prevent this reaction. Therefore,
prevent it through the use of suitable
inhibitors.
Dimensions in mm · Weights in kg
The lengths and heights are shown in the di-
mensionaldrawingsinFig.4toFig.5.

EB 3013 EN 17
Technical data
4. Technical data
Table1: Technical data·Type42-34 and Type42-38
Type 2423 Valve balanced by a bellows
Type 42-34 42-38
Valvesize DN15to250 DN15to100
Pressure rating PN16,25or40
Pressure at which
internal excess
pressure limiter
responds
A=160cm² 1.2bar 0.6bar
A=320cm² 0.6bar 0.3bar
A=640cm² 0.3bar –
Max. permissible tem-
perature
Valve body See pressure-temperature diagram in uT3000
Actuator 1) Liquids150°C
Set point ranges 0.1to0.6bar·0.2to1bar
0.5to1.5bar 0.2bar·0.3bar·0.4bar·0.5bar
Leakage class according to
IEC60534-4 ≤0.05%ofKVScoefcient
Conformity ·
Type2423 Valve, balanced by a diaphragm
Type 42-34
Valvesize DN65to250
Pressure rating PN16,25or40
Pressure at which
internal excess pressure
limiter responds
A=160cm² 1.2bar
A=320cm² 0.6bar
A=640cm² 0.3bar
Max. permissible
temperature
Valve body 150°C
Actuator 1) Liquids150°C
Differential pressure or pressure set
point ranges 0.1to0.6bar·0.2to1bar·0.5to1.5bar
Leakage class according to
IEC60534-4 ≤0.05%ofKVScoefcient
Conformity ·
1) Higher temperatures on request

18 EB 3013 EN
Technical data
Table2: Data of Type2423 Valve
Type 2423 Valve balanced by a bellows
Valve size DN 15 20 25 32 40 50 65 80 100 125 150 200 250
Valve travel 10mm 16mm 22mm
KVS coefcient 4 6.3 8 16 20 32 50 80 125 190 280 420 500
xFZ value 0.65 0.6 0.55 0.45 0.4 0.35 0.3
Max. perm.
differential pressure
∆p
25bar 20bar 16bar 12bar 10bar
Type2423 Valve, balanced by a diaphragm
Valve size DN 65 80 100 125 150 200 250
KVS coefcient 50 80 125 250 380 650 800
xFZ value 0.4 0.35 0.3
Max. perm. differential
pressure∆p 10bar 12bar 10bar

EB 3013 EN 19
Technical data
Dimensional drawing
Type42-34 Type42-38
H1
H
L
ØD
H2
H1
H
L
ØD
H2
Fig.4: Regulator with Type2423 Valve balanced by a bellows
H2
H
L
H1
ØD
H2
H
L
H1
ØD
Fig.5: Regulator with Type2423 Valve, balanced by a diaphragm

20 EB 3013 EN
Technical data
Table3: Dimensions in mm and weights · Type2423 Valve balanced by a bellows
Valve size DN 15 20 25 32 40 50 65 80 100 125 150 200 250
Length L 130 150 160 180 200 230 290 310 350 400 480 600 730
Height H1 285 360 415 460 590 730
Height
H2
Other
materials 115 135 195 220 290 325 335 380
1.4571 113 – 130 – 155 161 –
Type24-38 · Balanced by a bellows
0.2bar
0.3bar
0.4bar
0.5bar
Height H 3) 450 525 585 –
Actuator ØD=225mm,A=160cm² ØD=285mm,
A=320cm² –
Weight 1) 11.5 12 13 19.5 20 22.5 45 50 58 –
Type24-34 · Balanced by a bellows
0.1 to
0.6bar
Height H 3) 670 745 800 990 1120 1260
Actuator ØD=225mm,A=160cm² 2) ØD=285mm,
A=320cm² ØD=390mm,A=640cm²
Weight 1) 16 16.5 17.5 24 24.5 27 46 51 59 135 185 425 485
0.2 to
1bar
Height H 3) 670 745 800 990 1120 1260
Actuator ØD=225mm,A=160cm² 2) ØD=390mm,A=640cm²
Weight 1) 16 16.5 17.5 24 24.5 27 42 47 55 135 185 425 485
0.5 to
1.5bar
Height H 3) 670 745 800 880 1040 1210
Actuator ØD=225mm,A=160cm² 2) ØD=285mm,A=320cm²
Weight 1) 16 16.5 17.5 24 24.5 27 42 47 55 125 175 415 475
1) TheweightappliestotheversionwiththematerialspecicationsEN-GJL-250/PN16.Add+10%forspheroidal
graphiteironEN-GJS-400-18-LT/PN25,caststeel1.0619/PN40and1.4571.
2) Optionally with 320 cm² actuator
3) Minimumclearancerequiredtoremovetheactuator:+100mm
Table4: Dimensions in mm and weights·Type42-34 · Type2423 Valve balanced by a
diaphragm
Valve size DN65 DN80 DN100 DN125 DN150 DN200 DN250
Length L 290 310 350 400 480 600 730
Height H 3) 635 655 780 805 1020
Height H2 195 220 290 325 335 380
Weight 1), approx. 47kg2) 52kg2) 62kg2) 95kg 115kg2) 290kg2) 305kg2)
1) TheweightappliestotheversionwiththematerialspecicationsEN-GJL-250/PN16.Add+10%forallother
materials.
2) With640cm²actuator
3) Minimumclearancerequiredtoremovetheactuator:+100mm