Samson 2488 N, 5857 Mounting And Operating Instructions

Mounting and
Operating Instructions

EB 3136 EN

Translation of original instructions

Edition December 2017

Type2488N/5857

Pressure-independent Control Valve (PICV)

Type2488N/5857

2 EB 3136 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.

Î For the safe and proper use of these instructions, read them carefully and keep them for

later reference.

Î If you have any questions about these instructions, contact SAMSON‘s After-sales Service

Department ([e-mail]).

The mounting and operating instructions for the devices are included in
the scope of delivery. The latest documentation is available on our website
(www.samson.de) > Product documentation. You can enter the document

number or type number in the [Find:] eld to look for a document.

Denition 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

Contents

EB 3136 EN 3

1 Safety instructions and measures ...................................................................4

1.1 Notes on possible severe personal injury .........................................................6

1.2 Notes on possible personal injury ...................................................................7

1.3 Notes on possible property damage ................................................................7

2 Markings on the device .................................................................................8

2.1 Nameplate for Type2488N Valve .................................................................. 8

3 Design and principle of operation ..................................................................9

3.1 Technical data .............................................................................................10

4 Measures for preparation ............................................................................14

4.1 Unpacking ..................................................................................................14

4.2 Transporting and lifting ................................................................................14

4.3 Storage .......................................................................................................15

4.4 Preparation for installation ............................................................................16

5 Mounting and start-up .................................................................................16

5.1 Mounting position ........................................................................................16

5.2 Additional ttings .........................................................................................17

5.3 Mounting the actuator ..................................................................................17

5.4 Electrical connection .....................................................................................18

5.5 Start-up ....................................................................................................... 19

6 Operation ...................................................................................................20

6.1 Adjusting the set points .................................................................................20

6.1.1 Flow rate .....................................................................................................20

7 Servicing.....................................................................................................21

7.1 Preparation for return shipment .....................................................................22

7.2 Ordering spare parts and operating supplies .................................................23

8 Malfunctions ...............................................................................................23

8.1 Decommissioning .........................................................................................24

8.2 Disposal ......................................................................................................24

9 Appendix ....................................................................................................24

9.1 After-sales service ........................................................................................24

9.2 Certicates ..................................................................................................25

4 EB 3136 EN

Safety instructions and measures

1 Safety instructions and measures

Intended use

The Type2488N/5857 Pressure-independent Control Valve (PICV) is intended for ow con­trol of liquids up to 110°C. The Type2488N/5857 is mainly used in district heating supply
networks. The regulator and actuator are designed to operate under exactly dened condi-

tions (e.g. operating pressure, process medium, temperature). Therefore, operators must en­sure that the regulator and actuator are only used in operating conditions that meet the spec-

ications used for sizing the devices at the ordering stage. In case operators intend to use the
devices in other applications or conditions than specied, contact SAMSON.

SAMSON does not assume any liability for damage resulting from the failure to use the de­vice for its intended purpose or for damage caused by external forces or any other external
factors.

Î Refer to the technical data and nameplate for limits and elds of application as well as

possible uses.

Reasonably foreseeable misuse

The regulator is not suitable for the following applications:

− Use outside the limits dened during sizing 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 in these instructions

Qualications of operating personnel

The regulator 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 appli-

cable standards.

EB 3136 EN 5

Safety instructions and measures

Personal protective equipment

We recommend wearing the following protective equipment depending on the process medi­um:

− Protective clothing, gloves and eyewear in applications with hot, cold and/or corrosive
media

− Wear hearing protection when working near the valve.

Î Check 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. Furthermore, 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. They must observe all haz-

ard statements, warning and caution notes in these mounting and operating instructions, es­pecially for installation, start-up and service work.

Responsibilities of the operator

The operator is responsible for proper operation 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, the operator must ensure that operating personnel or third persons 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, the operating personnel must be familiar with the applicable
health, safety and accident prevention regulations and comply with them.

6 EB 3136 EN

Safety instructions and measures

Referenced standards and regulations

The regulators 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 in­cludes information about the applied conformity assessment procedure. This EU declaration
of conformity is included in the Appendix of these instructions (see section9.2).

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.

Î For connection to the equipotential bonding system, observe the requirements specied in

section 6.4 of EN60079-14 (VDE0165 Part 1).

Referenced documentation

The following documents apply in addition to these mounting and operating instructions:

− Mounting and operating instructions for the mounted actuator, e.g. uEB5857 for

Type5857 Actuator

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 device

components bursting.

Î Before starting any work on the device, depressurize all plant sections concerned

as well as the valve.

Î Drain the process medium from all the plant sections concerned as well as the

valve.
Î If necessary, install a suitable overpressure protection in the plant section.
Î Wear personal protective equipment.

EB 3136 EN 7

Safety instructions and measures

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. (chemical) burns.

Î If possible, drain the process medium from all the plant sections concerned and the

valve.

Î Wear protective clothing, safety gloves and eyewear.

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.

Î Allow components and pipelines to cool down or heat up.
Î Wear 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.

Î Flush the pipelines before start-up.
Î Observe the maximum permissible pressure for valve and plant.

Risk of valve damage due to unsuitable medium properties.

The valve is designed for process media with dened properties.

Î Only use process media specied for sizing the valve.

8 EB 3136 EN

Markings on the device

2 Markings on the device

2.1 Nameplate for Type2488N Valve

Nameplate for Type2488N Valve

1 Model number and conguration

ID

2 Order number or year of

manufacture

3 Type designation

4 Flow rate set point range in m³/h

5 Differential pressure at the

restriction in bar

6 Max. perm. differential pressure

Δp in bar

7 Flow coefcient K

VS

8 Max. permissible temperature in °C

9 Nominal pressure PN

1 2

3 4

5 6

7 8 9

Nameplate of Type5857 Actuator

1 Conguration ID
2 Serial number
3 Thrust
4 Rated travel
5 Transit time for rated travel
6 Power supply
7 Rated frequency
8 Power consumption
9 Input signal
10 Firmware version

Made in Germany

754

6

8

SAMSON 5857

Electric Actuator

s: t: f:U: P

:

Var.-ID
Serial-No.

1

2

F: 3

Made in Germany

94

6

8

SAMSON 5857

Electric Actuator
with digital positioner

s: In: U: P

:

Var.-ID
Serial-No.

1

Firmware-Version: 10

2

F: 3

Three-step version

Version with digital positioner

Fig.1: Nameplates for Type2488N Valve and Type5857 Actuator

EB 3136 EN 9

Design and principle of operation

3 Design and principle of oper-

ation

Î Refer to Fig.2

The pressure-independent control valve

(PICV) consists of the Type2488N Flow
Regulator and the Type5857 Electric Actua­tor. The valve is tted with a connecting

piece for connection of an electric actuator.
As a result, it is possible to transmit the con­trol signal of an electric control device to
achieve additional temperature control by
changing the restriction position. The medi-

um ows through the valve in the direction

indicated by the arrow on the valve body.
The ow rate is determined by the area re-

leased by the valve plug (3) and the adjust­able restriction (11).

The installed positioning spring (5) deter­mines the differential pressure across the re-

striction of 0.2bar. The pressure upstream of

the restriction (11) is transmitted over the
control line (7) to the upstream pressure side
of the actuator. The pressure downstream of
the restriction acts on the low-pressure side
of the operating diaphragm (9) through a
hole in the valve plug. The differential pres­sure generated at the restriction is converted
into a positioning force by the operating dia­phragm. This force is used to move the valve
plug depending on the force of the position-

ing spring (5). The ow rate is adjusted at

the set point screw (13).

1 Valve body
2 Seat
3 Plug
4 Plug stem
5 Positioning spring
6 Diaphragm actuator
7 Control line for upstream pressure

8 Upstream side

9 Operating diaphragm
10 Downstream side
11 Restriction
12 Restriction stem
13 Set point screw for ow control
14 Connecting piece
15 Spring
16 Type5857 Electric Actuator
17 Coupling nut

(max. 20Nm tightening torque)

18 Actuator stem

19 Manual adjuster

1

11

12

17

18

2

6
7

4
5

3

14

16

13

8

9

10

15

19

Fig.2: Functional diagram

10 EB 3136 EN

Design and principle of operation

3.1 Technical data

The regulator's nameplate contains informa­tion on the regulator version (see sec-

tion2.1).

Process medium and scope of application
The Type2488N/5857 Pressure-indepen-

dent Control Valve (PICV) is suitable for the
control of water and non-ammable gases.

− Non-ammable gases up to 80°C

− Liquids up to 110°C

The regulator is open when relieved of pres­sure. It closes when the downstream pressure
rises above the adjusted set point.

Compliance

The Type2488N/5857 Regulator bears
both the CE and EAC marks of conformity.

Temperature range

The Type2488N/5857 Regulator is de­signed for a temperature range from –10 to

+110°C (14 to 300°F).

Leakage class

All regulators have the leakage class I ac-

cording to IEC60534-4.

Noise emission

SAMSON is unable to make general state­ments about noise emission as it depends on
the valve version, plant facilities and process
medium. On request, SAMSON can perform

calculations according to IEC60534,
Part8-3 and Part8-4 or VDMA24422 (edi­tion89).

Risk of hearing loss or deafness due to loud
noise.
Wear hearing protection when working near
the valve.

Dimensions and weights

Fig.3 as well as Table1 and Table2 provide

a summary of the dimensions and weights of

the Type2488N/5857 Regulator. The

lengths and heights in the dimensional draw-

ings are shown on p.13 onwards.

WARNING

!

EB 3136 EN 11

Design and principle of operation

Table1: Technical data for Type2488N Valve

Type 2488N Valve

Valve size DN15

Nominal pressure PN 10

Max. perm. differential pressure Δp 4bar

K

VS

coefcient

Standard version 2.5

Special version 1.0

Max. permissible temperature

Treated water 110°C

Non-ammable gases 80°C

Flow rate set point range/limitation for water with a
differential pressure at the restriction of 0.2bar

Standard version 0.3 to 1.0 m³/h

Special version 0.1 to 0.5 m³/h

Differential pressure at the restriction 0.2bar

Materials

Body CC499K

Plug 1.4301 with EPDM seal

Restriction Brass, free of dezincication

Diaphragm EPDM without fabric reinforcement

Weight

Valve Approx. 1.0kg

12 EB 3136 EN

Design and principle of operation

Table2: Technical data of Type5857 Actuator

Type5857 Actuator Version Three-step With digital positioner

Connection to valve Force-locking

Rated travel 6mm

Transit time for rated travel 20s 30/20

1)

/10s

Thrust 300N

Power supply

230V (±10%), 50Hz

24V (±10%), 50Hz

24V (±10%), 50Hz,

60Hz and DC

2)

Power consumption Approx. 3 VA 5VA

Manual override Yes

Permissible temperatures

Ambient 0 to 50°C

Storage –20 to +70°C

Medium 0 to 120°C

Degree of protection IP 42 according to EN60529

Class of protection II according to EN61140

Electromagnetic compatibility According to EN61000-6-2, EN61000-6-3 and EN61326

Compliance

·

Digital positioner –

Input signal

–

0 to 10V 1), Ri= 20kΩ

Position feedback 0 to 10V 1), RB= 1kΩ

Characteristic

Linear 1), equal percentage,

reverse equal percentage, user-

dened

Materials

Housing Plastic (PPO)

Coupling nut Brass · M32x1.5 connection

Intermediate insulating piece 1.4306, CW617N, PTFE, EPDM, FKM

Weight

Valve Approx. 0.7kg

1)

Default setting

2)

10 s applies to 24 V DC (–0 %, +10 %) for Transit time for rated travel setting.

EB 3136 EN 13

Design and principle of operation

Ø95

114

65

~65

120

ISO 228/1-G ¾

B

~70

Ø12

55

80

11

32

70

80

Intermediate insulating

piece

SW30

210

Ø21.3

SW30

129

G½

Welding ends Threaded ends

Fig.3: Dimensional drawings

14 EB 3136 EN

Measures for preparation

4 Measures for preparation

After receiving the shipment, proceed as fol­lows:

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 immedi­ately before installing the valve into the pipe­line.

4.2 Transporting and lifting

Due to the low service weight, lifting equip­ment is not required to lift and transport the
regulator (e.g. to install it into the pipeline).

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3.1).

Note

4.3 Storage

Risk of regulator damage due to improper
storage.

− Observe storage instructions.

− Avoid long storage times.

− Contact SAMSON in case of different stor-

age conditions or long storage periods.

We recommend regularly checking the de­vice 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 con­densation. 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3.1).

− Do not place any objects on the device.

NOTICE

!

Note

EB 3136 EN 15

Measures for preparation

Special storage instructions for elastomers

Elastomer, e.g. actuator diaphragm

− To keep elastomers in shape and to pre-
vent cracking, do not bend them or hang
them up.

− We recommend a storage temperature of

15°C for elastomers.

− Store elastomers away from lubricants,
chemicals, solutions and fuels.

SAMSON's After-sales Service department
can provide more detailed storage instruc­tions on request.

Tip

4.4 Preparation for installation

Proceed as follows:

Î Flush the pipelines.

The plant operator is responsible for clean­ing the pipelines in the plant.

Î Check the valve to make sure it is clean.
Î Check the valve and actuator to make

sure they are not damaged.

Î Check to make sure that the type desig-

nation, valve size, material, pressure rat­ing and temperature range of the valve
and actuator match the plant conditions

(size and pressure rating of the pipeline,

medium temperature, etc.).

Î Check any mounted pressure gauges to

make sure they function.

Note

16 EB 3136 EN

Mounting and start-up

5 Mounting and start-up

5.1 Mounting position

Standard mounting position

Î Install the regulator in a horizontal pipe-

line with the diaphragm actuator (6) fac-

ing downward (see Fig.2).

Installation conditions

− Make sure that the regulator remains
freely accessible after the plant has been
completed.

− The electric actuator must be mounted
above the valve body.

− Install a strainer upstream of the regula-

tor (see section5.2).

− Make sure the direction of ow matches
the direction indicated by the arrow on
the body.

− Install the regulator free of stress.

− On insulating the valve, do not insulate
the actuator and the coupling nut as well.
If necessary, an intermediate insulating
piece (order no. 1690-6975) must be
used. The insulating limit is in this case

approx. 25mm above the top of the

valve body.

Possible malfunction and damage due to ad­verse weather conditions (temperature, hu­midity).

− Do not install the device outdoors or in

rooms prone to frost.

NOTICE

!

− Protect the regulator against frost if it is
used to control freezing media.

− Either heat the regulator or remove it from
the plant and completely drain the residual
medium.

5.2 Additional ttings

Strainer

A strainer installed upstream in the ow pipe

holds back any dirt or other foreign particles
carried along by the medium. For example,

the SAMSON Type1NI Strainer is suitable

(uT1010).

− Install the strainer upstream of the regu-

lator.

− Make sure the direction of ow matches

the direction indicated by the arrow on
the body.

− Install the strainer with the lter element

facing downward.

− Allow sufcient space to remove the lter.

Shut-off valve

Install a hand-operated shut-off valve both
upstream of the strainer and at the outlet of

the return ow pipe (see Fig.4). This allows

the plant to be shut down for cleaning and
maintenance, and when the plant is not used
for longer periods of time.

Pressure gauge

Install a pressure gauge at a suitable point to
monitor the pressures prevailing in the plant

(see Fig.4).

EB 3136 EN 17

Mounting and start-up

Type2488N/5825

5.3 Mounting the actuator

Î Refer to Fig.2
Î Place the actuator (16) on the valve con-

nection and hand-tighten the coupling
nut (17).

Indirect connection to district heating system with Type2488N/5825 PICV

Fig.4: Sample application

18 EB 3136 EN

Mounting and start-up

5.4 Electrical connection

Î See Fig.5 and Fig.2

Upon installation of the electric cables, you
are required to observe the regulations con­cerning power installations according to
DINVDE0100 as well as the regulations of
your local power supplier.
Use a suitable power supply which guaran­tees that no dangerous voltages reach the
device in normal operation or in the event of
a fault in the system or any other system
parts.
Connect the actuator to the electrical network
only after the power supply is rst switched
off. Make sure the power cannot be switched
on unintentionally.

A power supply of 230V (10%) or 24V
(10%), 50Hz is required (uEB5857 for

more details).

Î Connect the electric actuator using the

three-wire connecting cable (see Fig.5).

If voltage is applied to the white and
green wires, the actuator motor retracts

the actuator stem (18). The restriction

stem (12) is pushed upward by the

spring (15), causing the ow rate to rise.

In contrast, a control signal applied to
the white and brown wires causes the ac­tuator stem to extend. The restriction stem
(12) is pushed downward by the spring

(15), causing a lower ow rate.

WARNING

!

Three-step version

BNWH GN

aL eL

L

N

Ce Ce

eL

aL

BN BK YE GN RD OG

24 V, 50 Hz 0...10 V 0...10 V

_

+

_

+

NL

Version with positioner

BN BK YE GN RD OG

24 V, 50 Hz 0...10 V 0...10 V

_

+

_

+

NL

eL Actuator stem retracts

aL Actuator stem extends

Note: The interference suppression capacitors
Ce in the output circuit of the connected control-

ler must not exceed a value of 2.5nF to ensure

the proper functioning of the actuator.

Fig.5: Electrical connection

EB 3136 EN 19

Mounting and start-up

5.5 Start-up

Î First start up the regulator after mounting

all parts.

Î Make sure that the restriction (11) is

open while lling the plant. Remove the

electric actuator and turn the set point
screw for the ow control (13) counter­clockwise () as far as it will go (see

Fig.2).

Î Open the shut-off valves slowly over a

time period of several minutes, prefera-

bly starting from the return ow pipe.

Risk of valve damage due to a sudden pres­sure increase and resulting high ow veloci­ties.
Slowly open the shut-off valve in the pipeline
during start-up.

Pressure testing the plant

All plant components must be designed for
the test pressure. If necessary, remove the
regulator from the pipeline or remove the
control line (7) of the diaphragm actuator at
the valve and seal the open connection with

a blanking plug (see Table3).

Risk of damage to the diaphragm actuator
due to impermissible excess pressure.
The test pressure must not exceed the nomi­nal pressure at the actuator by 1.5 times on
testing the pressure of the plant when the
regulator is already installed.

NOTICE

!

NOTICE

!

Rinsing the plant

1. After lling the plant, rst completely
open the consumer

2. Adjust the maximum ow rate at the reg-

ulator (see section6.1.1).

3. Rinse out the pipeline at full ow rate for
several minutes.

4. Check the strainer (e.g. measure the
pressure drop) and clean it, if necessary.

Table3: Accessories

Accessories Item no.

Blanking plug 8323-0030

Seal 8412-0771

20 EB 3136 EN

Operation

6 Operation

6.1 Adjusting the set point

6.1.1 Flow rate

Î Completely open the control and shut-off

valves or the bypass valve in the plant.

To adjust or change the ow rate set point,
proceed as follows:

Always adjust the set point based on a
closed restriction.

Risk of damage to the restriction stem
through one-side loading while turning the
set point screw clockwise.
First turn the handwheel of the electric actua­tor to completely close the restriction.

1. To close the restriction (11), de-energize
the electric actuator (16).

2. Turn the manual adjuster (19) clockwise
() as far as it will go to close the re­striction.

3. Use a suitable tool (Allen key, SW4) to
turn the set point screw (13) clockwise
() as far as it will go.

4. Refer to Fig.6 to nd out how many
turns are required to set the ow rate.

5. Use a suitable tool (Allen key, SW4) to
turn the set point screw (13) by the re­quired number of turns. Turn it counter­clockwise () to open the restriction. The

ow rate rises.

NOTICE

!

6. Guide the wire through the lead-seal

hole and lead-seal it to x the adjusted
ow rate.

7. Reconnect the power supply to the elec­tric actuator (16).

For exact adjustment, verify adjusted value
with a heat or ow meter.

0.1

0.5

1

1

0

2

3

4

5

V

˚

m3/h

0.2

2

2.51.6K

vs

Turns of the set point screw

Fig.6: Adjustment diagram for ow rate

Tip

EB 3136 EN 21

Servicing

7 Servicing

The regulator does not require any mainte­nance. Nevertheless, it is subject to natural
wear, particularly at the seat, plug and oper­ating diaphragm. Depending on the operat­ing conditions, check the regulator at regular
intervals to avoid possible malfunctions.

SAMSON's After-sales Service department
can support you in drawing up an inspection
and test plan for your plant.

Risk of bursting in pressure equipment.
Valves and pipelines are pressure equip­ment. Improper opening can lead to device
components bursting.

− Before starting any work on the device, de-
pressurize all plant sections concerned as
well as the valve.

− Drain the process medium from all the
plant sections concerned as well as the
valve.

− If necessary, install a suitable overpressure
protection in the plant section.

− Wear personal protective equipment.

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.
(chemical) burns.

Tip

DANGER

!

WARNING

!

− If possible, drain the process medium from
all the plant sections concerned and the
valve.

− Wear protective clothing, safety gloves and
eyewear.

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.

− Allow components and pipelines to cool
down or heat up.

− Wear protective clothing and safety gloves.

Risk of regulator damage due to incorrect
servicing or repair.
Service and repair work must only be per­formed by trained staff.

Risk of regulator damage due to excessively
high or low tightening torques.
Observe the specied torques on tightening
regulator components. Excessively tightened
torques lead to parts wearing out quicker.
Parts that are too loose may cause leakage.
Observe the tightening torques specied in
Fig.2.

WARNING

!

NOTICE

!

NOTICE

!

22 EB 3136 EN

Malfunctions

The regulator was checked by SAMSON be­fore it left the factory.

− The product warranty becomes void if ser-
vice or repair work not described in these
instructions is performed without prior
agreement by SAMSON's After-sales Ser­vice department.

− Only use original spare parts by
SAMSON, which comply with the original
specications.

7.1 Preparation for return
shipment

Defective devices can be returned to
SAMSON for repair. Proceed as follows to
return devices to SAMSON:

1. Put the regulator out of operation (see

section8.1).

2. If necessary, decontaminate the regula-

tor. Remove any residual process medi­um.

3. Fill in the Declaration on Contamination,

which can be downloaded from our
website at uwww.samson.de > SERVICE

& SUPPORT > After-sales Service.

4. Send the device together with the lled-in

form to your nearest SAMSON subsidi­ary. SAMSON subsidiaries are listed on
our website at uwww.samson.de >
Contact.

Note

7.2 Ordering spare parts and
operating supplies

Contact your nearest SAMSON subsidiary
or the SAMSON After-sales Service depart­ment for information on spare parts, lubri­cants and tools.

8 Malfunctions

The malfunctions listed in Table4 are caused

by mechanical faults and incorrect regulator

sizing. In the simplest case, the functioning

can be restored following the recommended
action. Special tools may be required for re­pair work.

Exceptional operating and installation condi­tions may lead to changed situations that
may affect the control response and lead to
malfunctions. For troubleshooting, the condi­tions, such as installation, process medium,
temperature and pressure conditions, must
be taken into account.

SAMSON's After-sales Service department
can help during troubleshooting. Further in-

formation is available in section9.1.

EB 3136 EN 23

Malfunctions

Table4: Troubleshooting

Malfunction Possible reasons Recommended action

Flow rate exceeds adjusted set
point

Leak between seat and plug

Remove valve from the pipeline
and clean seat and plug. Con­tact SAMSON for further action.

Defective operating diaphragm

Contact SAMSON's After-sales
Service department.

Control line with needle valve
blocked.

Remove control line and needle
valve. Clean them.

Valve too large for control task
(ow rate) or too small

(differential pressure)

Recalculate K

VS

and contact

SAMSON for further action.

Flow set point not reached.

Leak between seat and plug

Remove valve from the pipeline
and clean seat and plug. Con­tact SAMSON for further action.

Incorrect set point range
selected.

Check set point range and con­tact SAMSON for further action.

Safety device, e.g. pressure
limiter, has been triggered.

Check plant. Unlock safety de­vice.

Plant differential pressure too
low.

Compare differential pressure in
the plant with the plant’s drag.

Strainer blocked

Drain and clean lter of the

strainer.

Incorrectly installed valve

(direction of ow).

Install the regulator so that the
direction of ow matches the di­rection indicated by the arrow
on the body.

Control loop hunts. Valve too large for control task

Recalculate K

VS

and contact

SAMSON for further action.

Contact SAMSON's After-sales Service department for malfunctions not listed in the table
and when the malfunction cannot be remedied as described.

Note

24 EB 3136 EN

Appendix

8.1 Decommissioning

To decommission the regulator for service
and repair work or disassembly, proceed as
follows:

1. Close the shut-off valve on the upstream
side of the valve.

2. Close the shut-off valve on the down­stream side of the valve.

3. Completely drain the pipelines and
valve.

4. Depressurize the plant. Shut off or dis­connect the control line.

5. If necessary, allow the pipeline and de­vice to cool down or heat up.

6. Remove the valve from the pipeline.

8.2 Disposal

Î Observe local, national and internation-

al refuse regulations.

Î Do not dispose of components, lubricants

and hazardous substances together with

your household waste.

9 Appendix

9.1 After-sales service

Contact SAMSON's After-sales Service de­partment for support concerning service or
repair work or when malfunctions or defects
arise.

E-mail

You can reach the After-sales Service De­partment at [e-mail].

Addresses of SAMSONAG and its subsid­iaries

The addresses of SAMSON AG, its
subsidiaries, representatives and service
facilities worldwide can be found on the
SAMSON website (uwww.samson.de) or in
all SAMSON product catalogs.

To assist diagnosis and in case of an unclear
mounting situation, specify the following de-

tails (so far as possible). See section2:

− Device type and nominal size

− Model number and conguration ID

− Upstream and downstream pressure

− Temperature and process medium

− Min. and max. ow rate

− Is a strainer installed?

− Installation drawing showing the exact
location of the regulator and all the ad­ditionally installed components (shut-off
valves, pressure gauge, etc.)

9.2 Certicates

The EU declarations of conformity are in­cluded on the next pages.

EB 3136 EN 25

Appendix

SAMSON AKTIENGESELLSCHAFT
Weismüllerstraße 3 60314 Frankfurt am Main

Telefon: [phone] · T elefax: 069 4009-1 507
E-Mail: samson@sams on.de

Revision 03

Modul H/Module H, Nr./No. / N° CE-0062-PED-H-SAM 001-16-DEU-rev-A

SAMSON erklärt in alleiniger Verantwortung für folgende Produkte:/For the following products, SAMSON hereby declares

under its sole responsibility:

Ventile für Druck- Differenzdruck-, Volumenstrom- und Temperaturregler/Valves for pressure, differential pressure,
volume flow and temperature regulators

2333 (Erz.-Nr./Model No. 2333), 2334 (2334), 2335 (2335), 2336, 2373, 2375, 44-0B , 44-1B, 44-2, 44-3, 44-6B, 44-7, 44-8, 45-1, 45-2, 45-3,
45-4, 45-5, 45-6, 2468, 2478 (2720), 45-9, 46-5, 46-6, 46-7, 46-9, 47-1, 47-4, 47-5, 47-9, 2487, 2488, 2489, 2491, 2494, 2495 (2730), 2405,
2406, 2421 (2811), 2392, 2412 (2812), 2114 (2814), 2417 (2817), 2422 (2814), 2423 (2823)

die Konformität mit nachfolgender Anforderung/the conformity with the following requirement.

Richtlinie des Europäischen Parlaments und des Rates zur Harmonisierung der Rechtsvorschriften
der Mitgliedstaaten über die Bereitstellung von Druckgeräten auf dem Markt.

2014/68/EU vom 15.05.2014

Directive of the European Parliament and of the Council on the harmonization of the laws of the
Member States relating of the making available on the market of pressure equipment.

2014/68/EU of 15 May 2014

Angewandtes Konformitätsbewertungsverfahren für Fluide nach Art. 4(1)(c.ii) und (c.i) zweiter
Gedankenstrich.

Modul siehe

Tabelle

durch

certified by

Bureau Veritas

S. A. (0062)

Conformity assessment procedure applied for fluids according to Artic le 4(1)(c.ii) and (c.i), second
indent

See table for

module

Nenndruck

Pressure rating

DN

NPS

15½ 20¾ 251 32

1¼ 401½ 502 65- 803

1004 125- 1506 2008 250

10

300

12

400

16

PN 16 ohne/without

(1)

A

(2)(3)

H

PN 25 ohne/without

(1)

A

(2)(3)

H

PN 40 ohne/without

(1)

A

(2)(3)

H -

PN 100 und PN 160 ohne/without

(1)

H -

Class 150 ohne/without

(1)

A

(2)(3)

H -

Class 300 ohne/without

(1)

A

(2)(3)

H

Class 600 und Class 900 ohne/without

(1)

H -

(1) Das auf dem Stellgerät aufgebrachte CE-Zeichen hat keine Gültigkeit im Sinne der Druckgeräterichtlinie.

The CE marking affixed to the control valve is not valid in the sense of the Pressure Equipment Directive.

(2) Das auf dem Stellgerät aufgebrachte CE-Zeichen gilt ohne Bezeichnung der benannten Stelle (Kenn-Nr. 0062).

The CE marking affixed to the control valve is valid without specifying the notified body (ID number 0062).

(3) Die Identifikationsnummer 0062 von Bureau Veritas S.A. gilt nicht für Modul A.

The identification number 0062 of Bureau Veritas S.A. is not valid for Modul A.

Geräte, denen laut Tabelle das Konformitätsbewertungsverfahren Modul H zugrunde liegt, beziehen sich auf die

„Zulassungsbescheinigung eines Qualitätssic herungssystems“ ausgestellt durch die benannte Stelle.

Devices whose conformity has been assessed based on Module H refer to the certificate of approval for the quality management system

issued by the notified body

.

Dem Entwurf zu Grunde gelegt sind Verfahren aus:/The design is based on the procedures specified in the following standards:

DIN EN 12516-2, DIN EN 12516-3 bzw./or ASME B16.1, ASME B16.24, ASME B16.34, ASME B16.42

Das Qualitätssicherungssystem des Herstellers wird von folgender benannter Stelle überwacht:

The manufacturer’s quality management system is monitored by the following notified body:

Bureau Veritas S.A. Nr./No. 0062, Newtime, 52 Boulevard du Parc, IIle de la Jatte, 92200 Neuilly sur Seine, France

Hersteller:/Manufacturer: SAMSON AG, Weismüllerstraße 3, 60314 Frankfurt am Main, Germany

Frankfurt am Main, 08. Februar 2017/08 February 2017

Klaus Hörschken Dr. Michael Heß
Zentralabteilungsleiter/Head of Central Department Zentralabteilungsleiter/Head of Central Department
Entwicklung Ventile und Antriebe/R&D, Valves and Actuators Product Management & Technical Sales

-Konformitaetserklaerung_ Blatt-04_Modul-A_Modul-H_DE-EN_Rev.03_2017-02-08.docx

26 EB 3136 EN

Appendix

SAMSON AKTIENGESELLSCHAFT
Weismüllerstraße 3 60314 Frankfurt am Main

Telefon: [phone] · T elefax: 069 4009-1 507
E-Mail: samson@sams on.de

Revision 03

Modul H/Module H, Nr./No. / N° CE-PED-H-SAM 001-13-DEU-rev-A

SAMSON erklärt in alleiniger Verantwortung für folgende Produkte:/For the following products, SAMSON hereby declares

under its sole responsibility:

Ventile für Druck-, Differenzdruck-, Temperatur- und Volumenstromregler/Valves for pressure,
temperature, flowregulators and differential pressure regulators

Typ 2336, 2373, 2375, 44-1B, 44-2, 44-3, 44-4, 44-6B, 44-9, 45-1, 45-2, 45-3, 45-4, 45-6, (Erz.-Nr. 2720), 45-9, 47-4, 2488, 2489, (2730),
2405, 2406, 2421 (2811), 2412 (2812), 2417 (2817), 2422 (2814), 2423 (2823), 2423E (2823)

die Konformität mit nachfolgender Anforderung/the conformity with the following requirement

Richtlinie des Europäischen Parlaments und des Rates zur Harmonisierung der Rechtsvorschriften
der Mitgliedstaaten über die Bereitstellung von Druckgeräten auf dem Markt.

2014/68/EU vom 15.05.2014

Directive of the European Parliament and of the Council on the harmonization of the laws of the
Member States relating of the making available on the market of pressure equipm ent (see also
Articles 41 and 48).

2014/68/EU of 15 May 2014

Angewandtes Konformitätsbewertungsverfahren für Fluide nach Art. 4(1)(c. i) erster Gedankenstrich.

Modul siehe

Tabelle

durch

certified by

Bureau Veritas

S. A. (0062)

Conformity assessment procedure applied for fluids according to Article 4(1)(c.i), first indent See table for

module

Nenndruck

Pressure rating

DN

NPS

15½ 20¾ 251 32

1¼ 401½ 502 65- 803

1004 125- 1506 2008 250

10

300

12

400

16

PN 16 ohne/without

(1)

A

(2)(3)

- - - - - - - - -

PN 25 ohne/without

(1)

A

(2)(3)

H

PN 40 ohne/without

(1)

H -

PN 100 und PN 160 ohne/without

(1)

H - - - -

Class 150 ohne/without

(1)

A

(2)(3)

H -

Class 300 ohne/without

(1)

H

Class 600 und Class 900 ohne/without

(1)

H - - - -

(1) Das auf dem Stellgerät aufgebrachte CE-Zeichen hat keine Gültigkeit im Sinne der Druckgeräterichtlinie.

The CE marking affixed to the control valve is not valid in the sense oft the Pressure Equipment Directive.

(2) Das auf dem Stellgerät aufgebrachte CE-Zeichen gilt ohne Bezeichnung der benannten Stelle (Kenn-Nr. 0062).

The CE marking affixed to the control valve is valid without specifying the notified body (ID number 0062).

(3) Die Identifikationsnummer 0062 von Bureau Veritas S.A. gilt nicht für Modul A.

The identification number 0062 of Bureau Veritas S.A. is not valid for Modul A.

Geräte, denen laut Tabelle das Konformitätsbewertungsverfahren Modul H zugrunde liegt, beziehen sich auf die

„Zulassungsbescheinigung eines Qualitätssic herungssystems“ ausgestellt durch die benannte Stelle.

Devices whose conformity has been assessed based on Module H refer to the certificate of approval for the quality management system

issued by the notified body

.

Dem Entwurf zu Grunde gelegt sind Verfahren aus:/The design is based on the methods of:

DIN EN 12516-2, DIN EN 12516-3 bzw./or ASME B16.1, ASME B16.24, ASME B16.34, ASME B16.42

Das Qualitätssicherungssystem des Herstellers wird von folgender benannter Stelle überwacht:

The manufacturer’s quality management system is monitored by the following notified body:

Bureau Veritas S.A. Nr./No. 0062, Newtime, 52 Boulevard du Parc, IIle de la Jatte, 92200 Neuilly sur Seine, France

Hersteller:/Manufacturer: SAMSON AG, Weismüllerstraße 3, 60314 Frankfurt am Main, Germany

Frankfurt am Main, 08. Februar 2017/08 February 2017

Klaus Hörschken Dr. Michael Heß
Zentralabteilungsleiter / Head of Central Department Zentralabteilungsleiter / Head of Central Department
Entwicklung Ventile und Antriebe / R&D, Valves and Actuators Product Management & Technical Sales

-Konformitaetserklaerung_ Blatt-08_Modul-A_Modul-H_DE-EN_Rev.03_2017-02-08.docx

EB 3136 EN 27

SAMSON AG · MESS- UND REGELTECHNIK
Weismüllerstraße 3 · 60314 Frankfurt am Main, Germany
Phone: [phone] · Fax: [phone]
[e-mail] · www.samson.de

EB 3136 EN

2018-06-29 · English