Samson 43-8 Service manual

Translation of original instructions
EB 2178 EN
Type43-8 Temperature Regulator with Hydraulic Controller
Edition May 2023

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 2178 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 2178 EN
1 Safety instructions and measures ...................................................................4
1.1 Notes on possible severe personal injury .........................................................7
1.2 Notes on possible personal injury ...................................................................7
1.3 Notes on possible property damage................................................................8
2 Markings on the device .................................................................................9
2.1 Materialidenticationnumber ......................................................................10
3 Design and principle of operation ................................................................10
3.1 Technical data .............................................................................................11
3.1.1 Process medium and scope of application......................................................11
4 Measures for preparation............................................................................15
4.1 Unpacking ..................................................................................................15
4.2 Transporting and lifting ................................................................................15
4.3 Storage.......................................................................................................15
4.4 Preparation for installation............................................................................16
5 Mounting and start-up.................................................................................16
5.1 Assembling the valve, hydraulic controller and control thermostat ....................16
5.2 Mounting positions.......................................................................................17
5.2.1 Installing the valve and hydraulic controller....................................................17
5.2.2 Installing the control thermostat .....................................................................19
5.3 Additionalttings.........................................................................................20
5.4 Start-up.......................................................................................................21
6 Operation...................................................................................................22
6.1 Adjusting the set point at the control thermostat..............................................22
7 Servicing.....................................................................................................23
7.1 Tightening torques and lubricant ...................................................................23
7.2 Preparation for return shipment.....................................................................23
8 Malfunctions ...............................................................................................23
9 Decommissioning and removal ....................................................................25
9.1 Decommissioning.........................................................................................26
9.2 Disposal......................................................................................................26
10 Annex.........................................................................................................27
10.1 After-sales service and spare parts ................................................................27
11 Certicates..................................................................................................27

4 EB 2178 EN
Safety instructions and measures
1 Safety instructions and measures
Intended use
TheType2438HydraulicControllerwithType2432ValveandType2430Control
Thermostat is designed for temperature control of the energy supply to heat generators (e.g.
heat exchangers) by closing the valve. The regulator is mainly used to control the temperature
in instantaneous water heaters in small district heating units.
Thedevicesaredesignedtooperateunderexactlydenedconditions(e.g.operating
pressure, 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 applications or
conditionsotherthanthose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 and repair work not described
Qualications of operating personnel
The devices must be mounted, started up, serviced and repaired by fully trained and
qualiedpersonnel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 standards.

EB 2178 EN 5
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. Follow the instructions given by
the plant operator.
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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,warnings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.
These mounting and operating instructions deals with the standard version of the device.
Componentsofthedevicethatdiffertothoseusedforthestandardversiondescribedinthis
documentcanbeexchangedwithothercertainSAMSONcomponents.Theresidualhazards
of these components are described in the associated mounting and operating instructions
(see documents listed under 'Referenced documentation').

6 EB 2178 EN
Safety instructions and measures
Responsibilities of the operator
Operators are responsible for proper use and compliance with the safety regulations.
Operators are obliged to provide these mounting and operating instructions as well as the
referenced documents to the operating personnel and to instruct them in proper operation.
Furthermore, 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 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).
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hazardassessmentstipulatedin
Clause5.2ofISO80079-36,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
Clause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 the valve uEB2171
− Mounting and operating instructions for the control thermostat uEB2430-3

EB 2178 EN 7
Safety instructions and measures
1.1 Notes on possible severe personal injury
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.
1.2 Notes on possible personal injury
WARNING
!
Risk of personal injury due to residual process medium in the valve.
While working on the valve, residual process medium can escape and, depending 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 process medium, 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 listed as a substance of very high concern
onthecandidatelistoftheREACHregulation,thisisindicatedontheSAMSONdeliv-
ery note.
ÎInformation on safe use of the part affected
uhttps://www.samsongroup.com/reach-en.html.

8 EB 2178 EN
Safety instructions and measures
1.3 Notes on possible property damage
NOTICE
!
Risk of irreparable regulator damage caused by the regulator components being
taken apart.
The thermostat, set point adjuster and capillary tube form an inseparable hydraulic
unit. If these components are dismantled (e.g. removal of the capillary tube), the regu-
latorwillbeirreparablydamagedandwillnolongerbeabletofulllitsmonitoring
and control task.
ÎDo not dismantle the regulator.
ÎOnly perform allowed activities on the regulator.
ÎContactSAMSON'sAfter-salesServicebeforereplacingspareparts.
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 valve damage due to unsuitable medium properties.
Thevalveisdesignedforaprocessmediumwithdenedproperties.
ÎOnlyusetheprocessmediumspeciedforsizingtheequipment.
Risk of leakage and valve damage due to excessively high or low tightening
torques.
Observethespeciedtorqueswhentighteningvalvecomponents.
Excessive tightening torques lead to parts wearing out more quickly. Parts that are too
loose may cause leakage.
ÎObservethespeciedtighteningtorques.

EB 2178 EN 9
Markings on the device
2 Markings on the device
Type2438 Hydraulic Controller
Specications on the valve
1Date of manufacture
2CongurationID
3Device index
2 – 3
2438 1
PN16 SAMSON
Type2430 Control Thermostat
Specications on the scaled cap on the adjustment knob to adjust the set point
1Model number/type designation
2CongurationID
3Setpointrangein°Cand°F
4Register number (type test
accordingtoDINEN14597)
SAMSON
2750-0
2430
1067861
...°C
...°F
TR(TL)
1
2
3
4
Type2432 Valve
Specications on the valve
1Type designation (valve)
2CongurationID
3Date of manufacture
4KVS/CV
5Max. permissible temperature
6Pressure rating (valve)
7Max.perm.differentialpressure∆p
SAMSON 1
2710 - 23
45
6 7
Fig.1: Nameplates

10 EB 2178 EN
Design and principle of operation
2.1 Material identication
number
SpecifyingthecongurationID,youcancon-
tactustondoutwhichmaterialisused.The
congurationID(2)isspeciedonthename-
plate.
For more details on the nameplate, see
Fig.1.
3 Design and principle of
operation
TheType43-8Regulatorisusedtocontrol
the temperature of instantaneous water heat-
ers in small district heating units.
ThedevicesconsistoftheType2430Control
Thermostat (30) operating according to the
vaporpressureprinciple,theType2438
HydraulicController(20)theType2432
Valve(1).
Thetemperaturesensorislledwithaliquid
which evaporates depending on the tem-
perature. As a result, a pressure in propor-
tion to the temperature is created in the sen-
sor. This pressure is transferred through the
capillary tube (8) to the operating element
(13) and converted into a positioning force,
which is compared to the force of the set
point spring (10).
The force ratio causes the plug in the valve
(1) to move. Depending on the valve travel,
an annular gap forms between the seat (2)
andtheplug(3)thatdeterminestheow
rate of the heating water.
A temperature increase at the sensor causes
the valve plug to close, thus reducing the
owrateoftheheatingwater.
Upon tapping hot water, a pressure differ-
enceof∆p=p1– p2is created above the
bafeplate(6).Theresultingforceopposes
the force of the compression spring (7) that
acts in closing direction and causes the valve
to open. Once hot water tapping has been
completed, the pressure balance is restored.
The force of the compression spring causes
the valve plug to move in the closing direc-
tionandtheheatowisinterrupted.Atthe
same time, the temperature set point of the
thermostatdropsbyapprox.8K(optionally
15K)toreachthereducedidletemperature.
This prevents reheating with temperature
peaks as well as the supply lines from cool-
ing down.
This ensures that hot water is immediately
available for the next tapping.
Table1: Domestic water quality
DHW
pH Min. 7/max. 10
Chlorideconcentration Max.150mg/l
HCO – 3
SO 2-
4
>1.5
Carbonatehardness Min.5°dH(German
hardness)
Total hardness Max.12°dH