Samson 2405 Series Service manual

Translation of original instructions

EB 2520 EN

Type2405 Pressure Reducing Valve

Self-operated Pressure Regulators

Edition December 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 2520 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

(aftersalesservice@samsongroup.com).

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 2520 EN

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

1.1 Notes on possible severe personal injury .........................................................7

1.2 Notes on possible personal injury ...................................................................8

1.3 Notes on possible property damage................................................................8

2 Markings on the device ...............................................................................10

2.1 Regulator nameplate ....................................................................................10

2.2 Location of the nameplate.............................................................................11

2.3 Materialidenticationnumber ......................................................................11

3 Design and principle of operation ................................................................12

3.1 Technical data .............................................................................................14

4 Measures for preparation............................................................................19

4.1 Unpacking ..................................................................................................19

4.2 Transporting and lifting ................................................................................19

4.3 Storage.......................................................................................................20

4.4 Preparation for installation............................................................................20

5 Mounting and start-up.................................................................................21

5.1 Installing the valve into the pipeline ...............................................................21

5.1.1 Installation conditions...................................................................................21

5.1.2 Mounting orientation....................................................................................22

5.1.3 Additionalttings.........................................................................................22

5.2 Quick check ................................................................................................24

5.3 Putting the regulator into operation................................................................24

5.4 Adjusting the set point..................................................................................24

6 Servicing.....................................................................................................25

6.1 Preparation for return shipment.....................................................................26

6.2 Ordering spare parts and operating supplies .................................................26

7 Decommissioning and removal ....................................................................27

7.1 Decommissioning.........................................................................................27

7.2 Removing the valve from the pipeline.............................................................27

8 Disposal......................................................................................................28

9 After-sales service .......................................................................................28

10 Certicates..................................................................................................29

10.1 Information on the UK sales region................................................................29

4 EB 2520 EN

Safety instructions and measures

1 Safety instructions and measures

Intended use

TheType2405PressureReducingValveisusedtocontrolthepressureofammablegases

used as a source of energy, e.g. in boilers, driers, vaporizers, heat exchangers or industrial

ovens. Alternatively, it can control the compressed air supply in process engineering applica-

tions.

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 regulators are 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regulator

Furthermore, the following activities do not comply with the intended use:

− Use as safety valve

− 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.

EB 2520 EN 5

Safety instructions and measures

Personal protective equipment

We recommend checking the hazards posed by the process medium being used (e.g.

uGESTIS(CLP)hazardoussubstancesdatabase).Dependingontheprocessmediumand/

or the activity, the protective equipment required includes:

− Protectiveclothing,safetyglovesandeyeprotectioninapplicationswithhot,coldand/or

corrosive media

− Wear hearing protection when working near the valve. Follow the instructions given by

the plant operator.

− Hard hat

− Safety harness, e.g. when working at height

− Safety footwear, if applicable ESD (electrostatic discharge) footwear

ÎCheckwiththeplantoperatorfordetailsonfurtherprotectiveequipment.

Revisions and other modications

Revisions,conversionsorothermodicationsoftheproductarenotauthorizedbySAMSON.

They are performed at the user's own risk and may lead to safety hazards, for example. Fur-

thermore, the product may no longer meet the requirements for its intended use.

Warning against residual hazards

To avoid personal injury or property damage, plant operators and operating personnel must

prevent hazards that could be caused in the regulator by the process medium, the operating

pressure or by moving parts by taking appropriate precautions. Plant operators and operat-

ing personnel must observe all hazard statements, warnings and caution notes in these

mounting and operating instructions.

Hazards resulting from the special working conditions at the installation site of the regulator

mustbeidentiedinariskassessmentandpreventedthroughthecorrespondingsafetyin-

structions drawn up by the operator.

We also recommend checking the hazards posed by the process medium being used (e.g.

uGESTIS(CLP)hazardoussubstancesdatabase).

ÎObservesafetymeasuresforhandlingthedeviceaswellasrepreventionandexplosion

protection measures.

These mounting and operating instructions deals with the standard version of the device.

Componentsofthedevicethatdiffertothoseusedforthestandardversiondescribedinthis

document can be exchanged with other certain SAMSON components. The residual hazards

of these components are described in the associated mounting and operating instructions

(see documents listed under 'Referenced documentation').

6 EB 2520 EN

Safety instructions and 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.

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.

Safety features

TheType2405Regulatordoesnothaveanyspecialsafetyfeatures.Whenrelievedofpres-

sure, the regulator is opened by the force of the set point springs.

Referenced standards, directives and regulations

The regulators comply with the requirements of the European Pressure Equipment Directive

2014/68/EU,MachineryDirective2006/42/EC,Directive2016No.1105Pressure

Equipment(Safety)Regulations2016andDirective2008No.1597SupplyofMachinery

(Safety)Regulations2008.RegulatorswithaCEmarkingand/orUKCAmarkinghavea

declaration of conformity, which includes information about the applied conformity

assessment procedure. This declaration of conformity is included in the annex of these

instructions(seesection10).

Non-electric valve versions whose bodies are not lined with an insulating material coating do

not have their own potential ignition source according to the hazard assessment stipulated in

Clause5.2ofISO80079-36,evenintherareincidentofanoperatingfault.Therefore,such

valveversionsdonotfallwithinthescopeofDirective2014/34/EU.

ÎForconnectiontotheequipotentialbondingsystem,observetherequirementsspeciedin

Clause6.4ofEN60079-14(VDE0165-1).

EB 2520 EN 7

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. Type2N or 2NI Strainer uEB1015

− Data sheets for

e.g. Type2N or 2NI Strainer uT1015

− Mounting and operating instructions as well as data sheets for additional components

(e.g. shut-off valves, pressure gauges etc.).

1.1 Notes on possible severe personal injury

DANGER

Risk of bursting in pressure equipment.

Valvesandpipelinesarepressureequipment.Improperopeningcanleadtovalve

components bursting.

ÎObserve the maximum permissible pressure for valve and plant.

ÎBeforestartinganyworkonthevalve,depressurizeallplantsectionsaffectedas

well as the valve.

ÎTo prevent uncontrolled excess pressure, make sure that suitable overpressure pro-

tection is installed on site in the plant section.

ÎDrain the process medium from all the plant sections affected as well as the valve.

ÎWear personal protective equipment.

8 EB 2520 EN

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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.

Risk of burn injuries due to hot or cold components and pipelines.

Depending on the process medium, valve components and pipelines may get very hot

or cold and cause burn injuries.

ÎAllow components and pipelines to cool down or warm up to the ambient tempera-

ture.

ÎWear protective clothing and safety gloves.

Damage to health relating to the REACH regulation.

If a SAMSON device contains a substance listed as a substance of very high concern

onthecandidatelistoftheREACHregulation,thisisindicatedontheSAMSONdeliv-

ery note.

ÎInformation on safe use of the part affected uwww.samsongroup.com/en/about-

samson/material-compliance/reach-regulation/

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.

EB 2520 EN 9

Safety instructions and measures

NOTICE

Risk of regulator damage due to incorrectly attached slings.

ÎDo not attach load-bearing slings to the actuator housing.

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 regulator damage due to the use of unsuitable lubricants.

The lubricants to be used depend on the regulator material. Unsuitable lubricants may

corrode and damage surfaces.

ÎOnly use lubricants approved by SAMSON.

When in doubt, consult SAMSON.

Risk of regulator damage due to the use of unsuitable tools.

Certaintoolsarerequiredtoworkontheregulator.

ÎOnly use tools approved by SAMSON.

When in doubt, consult SAMSON.

Risk of excess pressure damaging plant sections due to construction-related seat

leakage through the regulator.

ÎAlways install a safety device (e.g. safety excess pressure valve or safety relief

valve) in the plant.

SAMSON's After-sales Service can support you concerning lubricant, tightening torques

and tools approved by SAMSON.

Note

10 EB 2520 EN

Markings on the device

2 Markings on the device

The nameplate shown was up to date at the

time of publication of this document. The

nameplate on the device may differ from the

one shown.

2.1 Regulator nameplate

10 11 12 13

1517

14 4

18 19

The CE marking only exists for versions in valve sizes DN32 to 50.

Fig.1: Nameplate

1 Max. perm. operating

pressure at the actuator

2Materialnumber/

congurationID

3 Type

4 Production number

5 KVS/CV

6 Set point range

7Valvesize

8 Pressure rating

9 Perm. differential pressure

10 Perm. temperature

11 Bodymaterial

12 Serial number (if applicable)

13 TÜVregistrationno.(if

applicable)

14 Data Matrix code (if

applicable)

15 CEmarking(ifapplicable)

16 Countryoforigin

17 EAC,ifapplicable

18 UKCA,ifapplicable

19 Year of manufacture

20 Month of manufacture

21 IDofthecerticationbody

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