Samson series 43 Setup guide

Translation of original instructions
EB 2430 EN
Type2430 Control Thermostat
Series43 Self-operated Temperature Regulators
Edition October 2020
Type2430 Thermostat (adsorption principle)
mounted on a Type2432 Valve (Type43-2 Temperature
Regulator)
Type2430-3 Thermostat (vapor
pressure principle)

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.
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 2430 EN

Contents
EB 2430 EN
1 Safety instructions and measures ................................................................1-1
1.1 Notes on possible severe personal injury ......................................................1-5
1.2 Notes on possible personal injury ................................................................1-5
1.3 Notes on possible property damage .............................................................1-7
2 Markings on the device ..............................................................................2-1
2.1 Nameplate of control thermostat ..................................................................2-1
2.2 Location of the nameplate ............................................................................2-1
2.3 Material identication number .....................................................................2-2
3 Design and principle of operation ...............................................................3-1
3.1 Additional ttings ........................................................................................3-2
3.2 Technical data ............................................................................................3-3
4 Shipment and on-site transport ...................................................................4-1
4.1 Accepting the delivered goods .....................................................................4-1
4.2 Removing the packaging from the control thermostat......................................4-1
4.3 Transporting and lifting the control thermostat ...............................................4-1
4.4 Storing the control thermostat .......................................................................4-2
5 Installation.................................................................................................5-1
5.1 Installation conditions ..................................................................................5-1
5.2 Preparation for installation ...........................................................................5-4
5.3 Mounting ...................................................................................................5-6
5.4 Testing the control thermostat .......................................................................5-7
5.4.1 Leak test .....................................................................................................5-7
5.4.2 Pressure test ................................................................................................5-8
5.5 Insulation ...................................................................................................5-8
6 Start-up .....................................................................................................6-1
6.1 Start-up and putting the device back into operation .......................................6-2
6.1.1 Starting up the plant when vapors and liquids are controlled ..........................6-2
6.1.2 Starting up the plant when vapors are controlled ...........................................6-2
7 Operation..................................................................................................7-1
7.1 Adjusting the temperature set point ...............................................................7-1
8 Malfunctions ..............................................................................................8-1
8.1 Troubleshooting ..........................................................................................8-1
8.2 Emergency action .......................................................................................8-2

Contents
EB 2430 EN
9 Servicing....................................................................................................9-1
9.1 Preparing the valve for service work .............................................................9-3
9.2 Installing the control thermostat after service work .........................................9-3
9.3 Service work...............................................................................................9-3
9.4 Replacing the control thermostat ...................................................................9-4
9.5 Ordering spare parts and operating supplies ................................................9-4
10 Decommissioning .....................................................................................10-1
11 Removal ..................................................................................................11-1
11.1 Removing the control thermostat .................................................................11-1
12 Repairs ....................................................................................................12-1
12.1 Returning devices to SAMSON ..................................................................12-1
13 Disposal...................................................................................................13-1
14 Certicates...............................................................................................14-1
15 Annex......................................................................................................15-1
15.1 Tightening torques .....................................................................................15-1
15.2 Tools ........................................................................................................15-1
15.3 Lubricant ..................................................................................................15-1
15.4 Spare parts ..............................................................................................15-1
15.5 After-sales service .....................................................................................15-2

EB 2430 EN 1-1
Safety instructions and measures
1 Safety instructions and measures
Intended use
The SAMSON Type2430 Control Thermostat is a control thermostat that functions according
to the vapor pressure principle or the adsorption principle. It is used in combination with a
valve (Series43 Regulators).
The control thermostat functioning according to the adsorption principle is used for liquids,
gases and steam. The control thermostat functioning according to the vapor pressure princi-
ple (Type2430-3) is used in instantaneous water heaters. The control thermostats are used to
control the temperature of a plant in district heating supply networks to an adjusted set point.
The control thermostat is designed to operate under exactly dened conditions (e.g. operat-
ing pressure, temperature etc.). Therefore, operators must ensure that the control thermostat is
only used in operating conditions that meet the specications used for sizing at the ordering
stage. In case operators intend to use the control thermostat 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 control thermostat is not suitable for the following applications:
−Use outside the limits dened during sizing and by the technical data
−Use outside the limits dened by the additional ttings mounted on the control thermostat
Furthermore, the following activities do not comply with the intended use:
−Use of non-original spare parts
−Performing service and repair work not described
Safety features
The Type2430 Control Thermostat does not have any special safety features.

1-2 EB 2430 EN
Safety instructions and measures
Qualications of operating personnel
The control thermostat must be mounted, started up and serviced 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.
Personal protective equipment
We recommend checking the hazards posed by the process medium being used (e.g.
uGESTIS (CLP) hazardous substances database). Depending on the process medium and/
or the activity, the protective equipment required includes:
ÎProtective clothing, safety gloves and eye protection in applications with hot, cold and/or
corrosive media
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 control thermostat by the process medium, the
operating pressure or by moving parts by taking appropriate precautions. Plant operators
and operating personnel must observe all hazard statements, warning and caution notes in
these mounting and operating instructions.
Hazards resulting from the special working conditions at the installation site of the control
thermostat must be identied in a risk assessment and prevented through the corresponding
safety instructions 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.

EB 2430 EN 1-3
Safety instructions and measures
These mounting and operating instructions cover the standard version of the devices and the
standard mounting parts. Components that differ to those described in this document can be
added or removed. Refer to the mounting and operating instructions of the components not
covered in this document for the safety instructions and measures that need to be observed.
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 control thermostat complies with the requirements of the European Pressure Equipment
Directive 2014/68/EU. Control thermostats with a CE marking have an EU declaration of
conformity, which includes information about the applied conformity assessment procedure.
This EU declaration of conformity is included in the 'Certicates' section.
According to the ignition risk assessment performed in accordance with EN13463-1:2009,
section 5.2, the non-electrical control thermostats do not have their own potential ignition
source even in the rare incident of an operating fault. As a result, they 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).

1-4 EB 2430 EN
Safety instructions and measures
Referenced documentation
The following documents apply in addition to these mounting and operating instructions:
−Mounting and operating instructions for
e.g. Temperature regulators for heating applications (Types43-1, 43-2,
43-5 and 43-7) uEB2171
e.g. Temperature regulators for cooling applications (Type43-6) uEB2172
e.g. Temperature regulators for mixing/diverting service (Type43-3) uEB2173
e.g. Type43-8 Temperature Regulator with Hydraulic Controller for
instantaneous water heaters
uEB2178
−Mounting and operating instructions as well as data sheets for additional ttings
(e.g. shut-off valves, pressure gauges etc.).

EB 2430 EN 1-5
Safety instructions and measures
1.1 Notes on possible severe personal injury
DANGER
!
Risk of bursting in the regulator.
Regulators and pipelines are pressure equipment. Impermissible pressure in the com-
ponents or improper opening of the regulator or control thermostat can lead to the
components bursting.
ÎObserve the maximum permissible pressure for the regulator, control thermostat
and plant.
ÎBefore starting any work on the regulator and control thermostat, depressurize all
plant sections affected.
ÎDrain the process medium from all the plant sections affected.
1.2 Notes on possible personal injury
WARNING
!
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www.samsongroup.com/en/
about-samson/material-compliance/reach-regulation/

1-6 EB 2430 EN
Safety instructions and measures
1.2 Notes on possible personal injury
WARNING
!
Risk of personal injury through incorrect operation, use or installation as a result of
information on the control thermostat being illegible.
Over time, markings, labels and nameplates on the control thermostat may become
covered with dirt or become illegible in some other way. As a result, hazards may go
unnoticed and the necessary instructions not followed. There is a risk of personal inju-
ry.
ÎKeep all relevant markings and inscriptions on the device in a constantly legible
state.
ÎImmediately renew damaged, missing or incorrect nameplates or labels.
Risk of burn injuries due to hot or cold components and pipelines.
Depending on the process medium, the control thermostat 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.
Risk of re or explosion as a result of hydrocarbons escaping due to leakage in the
Type2430-3 Control Thermostat or Type2403 Safety Temperature Monitor.
A small quantity of a ammable mixture of hydrocarbons is used as the operating me-
dium in the Type2430-3 Control Thermostat (vapor pressure principle) and the
Type2403 Safety Temperature Monitor (STM).
ÎMount the control thermostat and safety temperature monitor in such a way that in
the event any operating medium escapes as a result of leakage, it cannot come in-
to contact with hot surfaces, sparks, open ames or other ignition sources.

EB 2430 EN 1-7
Safety instructions and measures
1.3 Notes on possible property damage
NOTICE
!
Risk of control thermostat damage due to incorrectly attached slings.
ÎDo not attach load-bearing slings to the control thermostat.
Risk of leakage and control thermostat damage due to excessively high or low tight-
ening torques.
Observe the specied torques when tightening control thermostat components. Exces-
sive tightening torques lead to parts wearing out more quickly. Parts that are too loose
may cause leakage.
ÎObserve the specied tightening torques (see 'Tightening torques' in Annex).
Risk of control thermostat damage due to the use of unsuitable tools.
Certain tools are required to work on the control thermostat.
ÎOnly use tools approved by SAMSON.
When in doubt, consult SAMSON.
Risk of the process medium being contaminated through the use of unsuitable lubri-
cants and/or contaminated tools and components.
ÎKeep the control thermostat components and the tools used free from solvents and
grease.
ÎMake sure that only suitable lubricants are used.
Incorrect control due to the formation of ice on the control thermostat.
Medium temperatures below 0°C may cause ice to form on the control thermostat, de-
pending on the air humidity. This may affect, in particular, the functioning of the plug
or control thermostat stem guide.
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 the 'Installation' section.

1-8 EB 2430 EN
Safety instructions and measures
1.3 Notes on possible property damage
NOTICE
!
Risk of irreparable damage to the control thermostat caused by the thermostat com-
ponents being taken apart.
The control thermostat is an inseparable hydraulic unit consisting of a control thermo-
stat, capillary tube and temperature sensor. If these components are dismantled (e.g.
removal of the capillary tube), the control thermostat will be irreparably damaged and
will no longer be able to fulll its control task.
ÎDo not dismantle the control thermostat.
ÎOnly perform allowed activities on the control thermostat.
ÎContact SAMSON's After-sales Service before replacing spare parts.
SAMSON's After-sales Service can support you concerning lubricant, tightening torques
and tools approved by SAMSON.
Note

EB 2430 EN 2-1
Markings on the device
2 Markings on the device
2.1 Nameplate of control thermostat
23
5
6
2004
0062
4
1
1Model number
2 Type designation
3 Conguration ID
4 CE marking
5 Temperature range in °C and °F
6Register number (type test according to
DINEN14597)
Fig.2-1: Nameplate of the control thermostat
2.2 Location of the nameplate
Location of the
nameplate
Top view
Type2430/-3
Fig.2-2: Nameplate position on the control thermostat

2-2 EB 2430 EN
Markings on the device
2.3 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 is specied on the name-
plate (‘Top view’/3).
For more details on the nameplate, see sec-
tion2.1.

EB 2430 EN 3-1
Design and principle of operation
3 Design and principle of oper-
ation
ÎSee Fig.3-1
The Type 2430 Control Thermostat with set
point adjuster, capillary tube and tempera-
ture sensor is mounted to a valve (Series43
Regulators). The control thermostat for stan-
dard temperature control operates according
to the adsorption principle. The control ther-
mostat for instantaneous water heating oper-
ates according to the vapor pressure princi-
ple.
The temperature of the medium creates a
pressure in the sensor (19) which is propor-
tional to the measured temperature. This
pressure is transferred through the capillary
tube (10) to the operating element (13) and
converted into a positioning force. The valve
stem is moved by the operating bellows (9)
and pin of the operating element (12).
By turning the set point adjuster (8), the
point of response and the set point are
changed over the spring (7).
The control thermostat operating according
to the adsorption principle is lled with CO2,
whereas the control thermostat operating ac-
cording to the vapor pressure principle con-
tains a hydrocarbon mixture.
Due to their design, control thermostats func-
tioning according to the adsorption principle
can be mounted in any position. The design
of vapor pressure thermostats necessitates a
certain mounting position of the sensor and
use without thermowell.
Version with safety thermostat
When a Type2439 or Type2403 Safety
Thermostat is attached to the control thermo-
stat, this combination functions as a safety
temperature limiter (TR/STL) or a safety tem-
perature monitor (TR/STM).
Details in mounting and operating instruc-
tions
uEB2185 (STL); uEB2083 (STM).

3-2 EB 2430 EN
Design and principle of operation
15
14
7
8
9
12
13
10
16
18
17
20
19
Type2430 Control Thermostat Sensor (adsorption
principle) (standard)
Sensor (vapor pressure
principle)
7 Set point spring
8 Set point adjuster
9Operating bellows
10 Capillary tube
12 Pin of operating element
13 Operating element
14 Lead-seal hole
15 Coupling nut
16 Screw
17 Seal with clamping rings
18 Screw gland
19 Temperature sensor
20 Thermowell (optional)
Fig.3-1: Functional diagram of Type2430 Control Thermostat
3.1 Additional ttings
Thermometer
Install a thermometer (4) downstream of the
regulator to monitor the temperature prevail-
ing in the plant.
Insulation
Control thermostats can be insulated to re-
duce heat energy transfer. Refer to the in-
structions in the 'Installation' section.

EB 2430 EN 3-3
Design and principle of operation
3.2 Technical data
The nameplate on the control thermostat pro-
vides information on the version (see the
'Markings on the device' section).
Process medium and scope of application
Temperature regulators for district heating
systems, heat generators, heat exchangers
and other HVAC and industrial applications.
The Type2430 Control Thermostat is de-
signed to maintain the temperature to the
adjusted set point.
−Suitable for liquids, gases and steam
−Temperature set points from 0 to
150°C/32 to 300°F
Conformity
The Type2430 Control Thermostat bears the
CE mark of conformity.
Noise emissions
SAMSON is unable to make general state-
ments about noise emissions. The noise emis-
sions depend on the regulator version, plant
facilities, process medium and operating
conditions.
Temperature range
Depending on how the Type2430 Control
Thermostat is congured, it can be used up
to max. 150°C/300°F. Permissible ambient
temperature –20 to +80°C/–4 to 176°F
(see Table 3-1).
Dimensions and weights
Table 3-3 provides a summary of the dimen-
sions and weights. The lengths and heights
in the dimensional drawings are shown on
page3-4.
Table 3-1: Technical data · All pressures in bar (gauge)
Type2430 Control Thermostat
Set point range1)
(continuously adjustable)
DIN 0 to 35°C · 25 to 70°C · 40 to 100°C
50 to 120°C·70 to 150°C
ANSI 32 to 95°F·77 to 158°F·104 to 212°F
122 to 248°F·158 to 302°F
Capillary tube 2m·5m2)/6.56ft·16.4ft2)
Max. perm. temperature at the sensor 50K above the adjusted set point
Permissible ambient temperature range –20 to +80°C3)/–4 to +176°F3)
Perm. pressure at sensor PN25/Class150
Permissible pressure at thermowell PN40 or 1002)/Class300 or 6002)
Conformity
1) Further set point ranges on request
2) Special version
3) At temperatures below freezing: ice formation may
damage the plant and especially the valve

3-4 EB 2430 EN
Design and principle of operation
Table 3-2: Materials · Material number according to DINEN
Type2430 Control Thermostat
Set point adjuster PTFE, glass ber reinforced
Screw gland EPDM soft seal for water·NBR soft seal for oil
Temperature
sensor
Capillary tube Copper
Thermowell Copper or stainless steel 1.4310
Table 3-3: Dimensions in mm and weights in kg
Type2430 Control Thermostat
DIN ANSI
For valve size DN15 to 25 DN32 to 50 ½NPT to 1NPT
Screw gland S G½ G¾ ½NPT
Length LF and LFa 185mm 220mm 7.28inch
LFt 190mm 7.48inch
Ø dT12mm 19mm 0.47inch
Ø dFa 9.5mm 16mm 0.37inch
Ø dFt 12mm 0.47inch
Weight of Type2430 Control Thermostat
Control thermostat (approx.) 0.7kg/1.5lb
Thermowell (approx.) 0.2kg/0.4lb
Dimensional
drawings
LFt
ØdFt
LT
ØdT
S
LFa
ØdFa
Control
thermostat
Sensor with thermowell
(adsorption principle)
Standard sensor with
screw gland
(adsorption principle)
Sensor for instantaneous water
heating (vapor pressure principle)
Fig.3-2: Dimensions in mm

EB 2430 EN 4-1
Shipment and on-site transport
4 Shipment and on-site trans-
port
The work described in this section is only to
be performed by personnel appropriately
qualied to carry out such tasks.
4.1 Accepting the delivered
goods
After receiving the shipment, proceed as fol-
lows:
1. Check the scope of delivery. Check that
the specications on the nameplate
match the specications in the delivery
note. See the 'Markings on the device'
section for nameplate details.
2. Check the shipment for transportation
damage. Report any damage to
SAMSON and the forwarding agent
(refer to delivery note).
3. Determine the weight and dimensions of
the units to be lifted and transported in
order to select the appropriate lifting
equipment and lifting accessories. Refer
to the transport documents and the 'De-
sign and principle of operation' section.
4.2 Removing the packaging
from the control thermostat
The control thermostat is delivered as single
component.
ÎDo not open or remove the packaging
until immediately before lifting to install
the control thermostat into the pipeline.
ÎLeave the control thermostat in its trans-
port container or on the pallet to trans-
port it on site.
ÎDispose and recycle the packaging in
accordance with the local regulations.
4.3 Transporting and lifting the
control thermostat
Due to the low service weight, lifting equip-
ment is not required to lift and transport the
control thermostat (e.g. to install it into the
pipeline).
ÎLeave the control thermostat in its trans-
port container or on the pallet to trans-
port it.
ÎObserve the transport instructions.
Transport instructions
ÎProtect the control thermostat against
external inuences (e.g. impact).
ÎDo not damage the corrosion protection
(paint, surface coatings). Repair any
damage immediately.
ÎProtect the control thermostat against
moisture and dirt.
ÎThe permissible ambient temperature of
the control thermostat is between –20
and +80°C/–4 to +175°F.

4-2 EB 2430 EN
Shipment and on-site transport
4.4 Storing the control thermo-
stat
Risk of damage to the control thermostat
due to improper storage.
ÎObserve the storage instructions.
ÎAvoid long storage times.
ÎContact SAMSON in case of different
storage conditions or longer storage
times.
Storage instructions
ÎProtect the control thermostat against ex-
ternal inuences (e.g. impact).
ÎSecure the control thermostat in the
stored position against slipping or tip-
ping over.
ÎDo not damage the corrosion protection
(paint, surface coatings). Repair any
damage immediately.
ÎProtect the control thermostat against
moisture and dirt. Store it at a relative
humidity of less than 75%. In damp
spaces, prevent condensation. If neces-
sary, use a drying agent or heating.
ÎMake sure that the ambient air is free of
acids or other corrosive media.
ÎThe permissible storage temperature of
the control thermostat is between –20
and +65°C/–4 to +150°F.
ÎDo not place any objects on the control
thermostat.
NOTICE
!
We recommend regularly checking the con-
trol thermostat and the prevailing storage
conditions during long storage periods.
SAMSON's After-sales Service can provide
more detailed storage instructions on re-
quest.
Note
Tip