Samson EB 2519 EN Quick reference guide

Translation of original instructions
EB 2519 EN
Pressure limiters (PL) with a Type2401-2 Pressure Element and safe-
ty pressure limiters (SPL) with a Type2401-1 Pressure Element
For mounting on self-operated regulators
Edition June 2022

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 2519 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 2519 EN
1 Safety instructions and measures ...................................................................5
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 Nameplate of the pressure element..................................................................9
2.2 Valve nameplate ............................................................................................9
3 Design and principle of operation ................................................................10
3.1 Versions ......................................................................................................10
3.2 Technical data .............................................................................................12
4 Measures for preparation............................................................................15
4.1 Unpacking ..................................................................................................15
4.2 Transporting and lifting ................................................................................15
4.2.1 Transporting ................................................................................................16
4.2.2 Lifting..........................................................................................................16
4.3 Storage.......................................................................................................17
4.4 Preparation for installation............................................................................17
5 Mounting and start-up.................................................................................18
5.1 Mounting the pressure limiter on the valve......................................................18
5.2 Mounting the safety pressure limiter onto the valve .........................................19
5.3 Connecting the capillary tube........................................................................20
5.4 Installing the valve into the pipeline ...............................................................20
5.4.1 Mounting orientation....................................................................................20
5.4.2 Additionalttings.........................................................................................21
5.4.3 Installing the valve........................................................................................21
6 Operation...................................................................................................22
6.1 Adjusting the limit........................................................................................22
6.2 Unlocking after a fault..................................................................................23
6.2.1 Unlocking the pressure limiter .......................................................................23
6.2.2 Unlocking the safety pressure limiter..............................................................23
7 Servicing.....................................................................................................24
7.1 Preparation for return shipment.....................................................................24
7.2 Ordering spare parts and operating supplies .................................................24

4 EB 2519 EN
8 Decommissioning and removal ....................................................................25
8.1 Decommissioning.........................................................................................25
8.2 Removing the valve from the pipeline.............................................................25
8.3 Disposal......................................................................................................26
9 After-sales service .......................................................................................26
10 Certicates..................................................................................................27

EB 2519 EN 5
Safety instructions and measures
1 Safety instructions and measures
Intended use
Thepressurelimiter(PL)withType2401-2PressureElementandsafetypressurelimiter(SPL)
withType2401-1PressureElementareusedtolimitthemaximumpressureinheatgenera-
torsorheatexchangersbyclosingandlockingamountedvalve.Whenequippedwithaty-
petested control thermostat or safety thermostat, the device is also used to limit the tempera-
ture.
Thedeviceisdesignedtooperateunderexactlydenedconditions(e.g.operatingpressure,
process medium, temperature). Therefore, operators must ensure that the device is only used
inoperatingconditionsthatmeetthespecicationsusedforsizingthedeviceattheordering
stage. In case operators intend to use the device 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deviceis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device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.

6 EB 2519 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.
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, operators and operating personnel must pre-
venthazardsthatcouldbecausedinthedevicebytheprocessmediumandoperatingpres-
sure by taking appropriate precautions. Plant operators and operating personnel must ob-
serveallhazardstatements,warningandcautionnotesinthesemountingandoperatingin-
structions, 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.
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.
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.

EB 2519 EN 7
Safety instructions and measures
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 available on request.
Referenced documentation
The mounting and operating instructions of the mounted valve apply in addition to these
mounting and operating instructions.
1.1 Notes on possible severe personal injury
DANGER
!
Risk of bursting in pressure equipment.
The valve and pressure element are pressure equipment. Improper opening can lead to
device components bursting.
In the installed state, the spring in the operating element is preloaded. Incorrect dis-
mantling will release a high amount of energy, which may lead to serious injury.
ÎDo not dismantle the device.
ÎContact SAMSON's After-sales Service for support concerning maintenance or re-
pairworkorwhenmalfunctionsordefectsarise(seesection9).
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mediumcanowoutofthevalveand,depend-
ing on its properties, cause personal injury, e.g. (chemical) burns.
ÎIf possible, drain the process medium from all the plant sections affected and the
valve.
ÎWearprotectiveclothing,safetyglovesandeyeprotection.

8 EB 2519 EN
Safety instructions and measures
WARNING
!
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.
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 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.
Risk of device damage due to incorrectly attached lifting equipment.
ÎDo not attach lifting equipment to mounting parts (e.g. capillary tube).

EB 2519 EN 9
Markings on the device
2 Markings on the device
2.1 Nameplate of the pressure element
6
1 3 4
5
7 8
SAMSON 2
1 Type 5 Unassigned
2 Material no. 6 Size(150/50)
3 Date of manufacture 7 Type test number (TÜV no.)
4 Unassigned 8 Adjustment range of limit value
The nameplate is located on the connecting element (8).
2.2 Valve nameplate
See associated valve documentation.

10 EB 2519 EN
Design and principle of operation
3 Design and principle of
operation
TheType2401-1orType2401-2Pressure
Element is used in combination with
Type2111,Type2119andType24221)
Valves to form a pressure limiter (PL) or
safety pressure limiter (SPL) respectively.
TheType2401-1/-2PressureElementwith
its connecting element (8) is connected to the
bottom section (4) of the valve using the cou-
pling nut (7).
The medium passes through the strainer (13)
and the capillary tube (12) to an operating
bellowsintheType2401-1/-2PressureEle-
ment (9). It is converted here into a position-
ing force which is compared to the force of
the set point spring.
The spring force depends on the limit
adjustment(10).Whenthepressurereaches
the adjusted pressure limit, the spring
mechanism in the connecting element (8) is
triggered. The spring mechanism moves the
pin (6) and the plug stem (5) attached to it,
closing and locking the valve (1).
Additionally,theType2401-1SafetyPres-
sure Limiter closes the valve when the mea-
suredpressurefallsbelow0.8bar(gauge
pressure).
TheType2401-1/-2PressureElementcan
only be reset and put back into operation
with a suitable tool (lever with order no.
1490-7399) after the fault has been reme-
died and the pressure has fallen below the
limit.
1) FormerlyType2114
Assembly tool
An assembly tool (0230-3752) to mount the
safety pressure limiter is included in the
scope of delivery.
Type test
TheType2401-1andType2401-2Pressure
Elements have been tested in conjunction
withavalvebytheGermantechnicalsur-
veillance association TÜV. More details on
the type test are available on request.
3.1 Versions
(Safety) thermostat
Additionally, a thermostat or safety thermo-
stat to regulate or limit the temperature can
bettedtotheconnectingelementwith
spring mechanism (8).
Electric signal transmitter
An additional electric signal transmitter for
remote transmission of the plant state can be
attached to the operating element with
springmechanism(seesection5.4.2).

EB 2519 EN 11
Design and principle of operation
1
2
3
4
4.1
5
6
7
8
91110
12
13
14
Type2111, Type2422 or Type2119 Valve 1)
1 Valve body
2Seat(exchangeable)
3 Plug
4 Bottom section
4.1 Balancing bellows
5 Plug stem with spring
Electric additional equipment
14 Electric signal transmitter (optional)
Type2401-1/-2 Pressure Element
6 Pin of operating element
7CouplingnutG1
8 Connecting element with spring mechanism
9Type2401-1orType2401-2PressureElement
10 Limit adjustment
11 ScrewttingwithType2401-1orType2401-2
Pressure Element
12 Capillary tube
13 Strainer
Fig.1: Pressure limiter consisting of valve and Type2401-1 or Type2401-2 Pressure Element

12 EB 2519 EN
Design and principle of operation
3.2 Technical data
The nameplates on the pressure element and valve provide information on the device version.
Seesection2.1andthevalvedocumentation.
Table1: Technical data · All pressure stated as gauge pressure in bar
Valves Type2111, Type2119, Type24221)
Valve size DN DN 15 20 25 32 40 50 65 80 100 125 150
Type2111 Data Sheet uT2111 –
Type2119 Data Sheet uT2133
Type24221) Data Sheet uT2121
Pressure rating PN16to40
Type2401-1/-2 Pressure
Element Size 50 2) Size 150 2)
Adjustment range of limit value 1to10bar
Permissible operating pressure 10bar
Permissible ambient
temperature Max.80°C
Permissible operating
temperature 200°C
Conformity
Capillary tube length Approx.2m
Strainer Type1NI,G½,PN16(uT1010)
Switching cycles according to
DINEN14597 500
Electric signal transmitter
Max.loadat230V(AC) 10Awithresistiveload
1) FormerlyType2114
2) Size50:Type2401-1/-2forvalveDN15to50|Size150:Type2401-1/-2forvalveDN65to
150
Dimensions and weights
Table2toTable4provideanoverviewofthedimensionsandweightsofthedifferentcombi-
nations (pressure element and valve). The lengths and heights in the dimensional drawings
areshownonpage14.
Dimensionsinmm·Weightsinkg

EB 2519 EN 13
Design and principle of operation
Table2: Type24221)/2401-1/-2
Port DN 15 20 25 32 40 50 65 80 100 125 150
Length L 130 150 160 180 200 230 290 310 350 400 480
H1 Without exten-
sion
225 300 355 460 590
With 365 440 495 600 730
Weight(PN16) 2) in
kg(approx.) 5 5.5 6.5 13 13.5 16 27 32 40 70 113
1) FormerlyType2114
2) +15%forPN25/40
Table3: Type2111/2401-1/-2
Port DN 15 20 25 32 40 50
–
Length L 130 150 160 180 200 230
H1 Without exten-
sion
2251)|822) 2251)|1522)
With 3651)
Weight(PN16) 1) in
kg(approx.) 4 4.5 5.5 13 13.5 16
1) Valve material: 1.0619 and stainless steel
2) Valvematerial:EN-GJS-400-18-LT,EN-GJL-250
3) +15%forPN25/40
Table4: Type2119/2401-1/-2
Port DN 15 20 25 32 40 50 65 80 100 125 150
Length L 130 150 160 180 200 230 290 310 350 400 480
H1 Without exten-
sion
235 245 320 355 395 500
With 375 385 460 495 535 640
Weight(PN16) 1) in
kg(approx.) 6 7 8.5 15 17 19 32 50 71 On request
1) +15%forPN25/40

14 EB 2519 EN
Design and principle of operation
Dimensional drawings
Type24221)/2401-1/-2
Type24221)/2401-1/-2 · 1.0619, stainless steel Type2119/2401-1/-2
L
G1
H1
H
G1
233
G ½
240
L
H2
233
H1
H
G1
G1
240
G ½
Type2111/2401-1/-2
EN-GJL-250,EN-GJS-400-18-LT
233
H1
H
G1
G1
L
240
G ½
1) FormerlyType2114

EB 2519 EN 15
Measures for preparation
4 Measures for preparation
After receiving the shipment, proceed as fol-
lows:
1. Check the scope of delivery. Compare
the shipment received with the delivery
note.
2. Check the shipment for transportation
damage. Report any damage to
SAMSON and the forwarding agent
(refer to delivery note).
4.1 Unpacking
Do not remove the packaging until immedi-
ately before installing the valve into the pipe-
line.
Proceed as follows to lift and install the de-
vice:
1. Remove the packaging from the device.
2. Dispose of the packaging in accordance
with the valid regulations.
4.2 Transporting and lifting
Danger due to suspended loads falling.
Stay clear of suspended or moving loads.
Risk of personal injury due to the device
tipping.
− Observe the device's center of gravity.
− Secure the device against tipping over or
turning.
Risk of lifting equipment tipping over and
risk of damage to lifting accessories due to
exceeding the rated lifting capacity.
− Only use approved lifting equipment and
accessories whose minimum lifting capaci-
ty is higher than the weight of the device.
− Refer to section3.2 or Data Sheet
uT2519 for weights.
Risk of valve damage due to incorrectly
attached slings.
− When lifting the device, make sure that the
slings attached to the valve body bear the
entire load.
− Observe lifting instructions (see sec-
tion4.2.2).
DANGER
!
WARNING
!
WARNING
!
NOTICE
!

16 EB 2519 EN
Measures for preparation
4.2.1 Transporting
The device can be transported using lifting
equipment (e.g. crane or forklift).
ÎLeave the device in its transport container
or on the pallet to transport it.
ÎObserve the transport instructions.
Transport instructions
− Protectthedeviceagainstexternalinu-
ences (e.g. impact).
− Do not damage the corrosion protection
(paint, surface coatings). Repair any
damage immediately.
− Protect the device against moisture and
dirt.
− Observe the permissible ambient tem-
peratures(seesection3.2).
4.2.2 Lifting
To install a large valve into the pipeline, use
lifting equipment (e.g. crane or forklift) to lift
it.
Lifting instructions
− Secure slings against slipping.
− Make sure the slings can be removed
from the valve once it has been installed
into the pipeline.
− Prevent the device from tilting or tipping.
− Do not leave loads suspended when in-
terrupting work for longer periods of
time.
− Makesurethattheaxisofthepipelineis
alwayshorizontalduringliftingandthe
axisoftheplugstemisalwaysvertical.

EB 2519 EN 17
Measures for preparation
4.3 Storage
Risk of device damage due to improper
storage.
− Observe the storage instructions.
− Avoid long storage times.
Contact SAMSON in case of different stor-
age conditions or longer storage times.
We recommend regularly checking the de-
vice and the prevailing storage conditions
during long storage periods.
Storage instructions
− Protectthedeviceagainstexternalinu-
ences (e.g. impact).
− Do not damage the corrosion protection
(paint, surface coatings). Repair any
damage immediately.
− Protect the device against moisture and
dirt. Store it at a relative humidity of less
than75%.Indampspaces,preventcon-
densation. If necessary, use a drying
agent or heating.
− Make sure that the ambient air is free of
acids or other corrosive media.
− Observe the permissible ambient tem-
peratures(seesection3.2).
− Do not place any objects on the device.
4.4 Preparation for installation
ÎFlush the pipelines.
The plant operator is responsible for clean-
ing the pipelines in the plant.
ÎCheck the valve to make sure that it is
clean.
ÎCheck the valve for damage.
ÎCheck to make sure that the type desig-
nation,valvesize,material,pressurerat-
ing and temperature range of the valve
matchtheplantconditions(sizeand
pressure rating of the pipeline, medium
temperature etc.).
NOTICE
!
Note
Note

18 EB 2519 EN
Mounting and start-up
5 Mounting and start-up
TheType2401-1/-2PressureElementisin-
stalled in the pipeline in combination with a
Type2111,Type2119,Type24221) or
Type2423ValvetoformaType2xxx/2401-
/-2 Pressure Limiter.
− Type2111/2401-1/-2 withType2111
GlobeValve
− Type2118/2401-1/-2 withType2119
Three-way Valve
− Type2422/2401-1/-2 withType24221)
GlobeValve
− Type2423/2401-1/-2 withType2423
GlobeValve
The pressure element can also be used in
combinationwithSeries42DifferentialPres-
sure and Flow Regulators.
Toconnecttheactuator(Type2424,2427,
2428 or 2429) to the connecting element of
theType2401-1/-2PressureLimiter,asepa-
ratingpieceisrequired(seeTable5).
ÎBefore installation, remove the snap ring
on the pin of the separating piece.
Table5: Separating pieces
Separating piece · Version Order no.
Brass · For water 1590-9948
Stainless steel · For water 1590-7703
Stainless steel · For oil 1590-7704
5.1 Mounting the pressure
limiter on the valve
TheType2401-2PressureLimiter(PL)and
valve are delivered separately and must be
fastened together before installing the valve
in the pipeline. The tension of the spring
mechanism is relieved in the delivered state
and the pin (6) of the spring mechanism
sticks out of the device. The pressure limiter
is locked.
1. Screw the assembly tool (M, 0230-3752)
onto the connecting element (8) (see
Fig.2).
2. Clampthepressurelimiterrmlyontothe
assembly tool (M).
3. Place the lever for unlocking at the pins
at the side on the connecting element (8)
(seeFig.3).Pulltheleverupwarduntil
the spring mechanism is tensioned. The
side pins are pushed downward and the
spring assembly compressed. The pres-
sure limiter is unlocked.
4. Remove the assembly tool (M).
5. Place on coupling nut (7) and tighten.
6. Connect the capillary tube (12) to the
pressure prevailing at the unit or to a
separate compressed air connection (see
section5.3).
7. Connect other mounting parts, if applica-
ble.
1) FormerlyType2114

EB 2519 EN 19
Mounting and start-up
5.2 Mounting the safety
pressure limiter onto the
valve
TheType2401-1SafetyPressureLimiter
(SPL) and valve are delivered separately and
must be fastened together before installing
the valve in the pipeline. The tension of the
spring mechanism is relieved in the delivered
state and the pin (6) of the spring mecha-
nism sticks out of the device. The safety pres-
sure limiter is locked.
Compressed air is required to mount the
safety pressure limiter.
1. Screw the assembly tool (M, 0230-3752)
onto the connecting element (8) (see
Fig.2).
2. Clampthesafetypressurelimiterrmly
onto the assembly tool (M).
3. Connect the capillary tube (12) to the
pressure prevailing at the unit or to a
separate compressed air connection (see
section5.3).
4. Applyapressureofatleast1barand
approx.0.5barbelowtheadjustedlimit
to the connection of the capillary tube.
5. Place the lever for unlocking at the pins
at the side on the connecting element (8)
(seeFig.3).Pulltheleverupwarduntil
the spring mechanism is tensioned. The
side pins are pushed downward and the
spring assembly compressed. The safety
pressure limiter is unlocked.
6. Remove the assembly tool (M).
7. Place on coupling nut (7) and tighten.
8. Connect other mounting parts, if applica-
ble.
Note
6 Pin of operating element
7 Coupling nut
8 Connecting element
M Assembly tool 0230-3752
M
6
7
8Pin
Lever for unlocking
Item no. 1490-7399
Unlock
Fig.2: Assembly tool and pressure element Fig.3: Lever for unlocking

20 EB 2519 EN
Mounting and start-up
5.3 Connecting the capillary
tube
Proceed as follows:
ÎAdditional steps to be performed before-
hand (liquids and vapors)
The capillary tube must not contain any com-
pressible air when used with liquids or va-
pors as the process medium.
1. Use a plastic funnel or jug to pour water
intotheopenscrewttingofthecapil-
larytubeuntilitstartstooverow.
ÎSteps to be performed afterwards (liq-
uids, gases and vapors)
2. Insertsealsintothescrewtting.Ob-
serve correct sequence according to
Fig.4.
3. AG½connectingsleevemustbetted
for tapping the pressure in the secondary
circuit(seeFig.1).Thestrainerofthe
capillary tube is bolted on tightly at this
11
16
15 12
11 Screwtting
12 Capillary tube
15 Gasket(WIKAType910.17)
16 Brass gasket
Screw ttingforexistingstrainers
withG
3
/
8
connection when a new
(safety) pressure limiter is to be
installed
Pipe at inlet Strainer at outlet Material no.
12mm G
3
/
8
8582-0329
Fig.4: Gaskets at the screw tting
point. The capillary tube must be run in
such a way that it cannot be damaged.
4. Screw the strainer and pressure element
tightly together.
5.4 Installing the valve into the
pipeline
5.4.1 Mounting orientation
ÎChoose a place of installation that allows
you to freely access the device even after
the entire plant has been completed.
ÎInstallthevalveinhorizontalpipelines.
ÎInstall the device with the connecting ele-
ment hanging downward.
ÎDuringinstallation,observetheowdi-
rection through the valve. The arrow on
thevalveindicatesthedirectionofow.
ÎObserve the permissible ambient tem-
peratures(seesection3.2).