Samson 2488 N Service manual

Flow Regulator with Electric Actuator

Type 2488 N/5857

Mounting and

Operating Instructions

EB 3136 EN

Edition December 2011

Fig. 1 · Type 2488 N/5857 Flow Regulator with Electric Actuator

Contents Page

1 Design and principle of operation. . . . . . . . . . . . . . . . . . . . 4

2 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

2.1 Mounting position. . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

2.2 Strainer. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

2.3 Shut-off valves, pressure gauges . . . . . . . . . . . . . . . . . . . . . 5

2.4 Mounting the actuator. . . . . . . . . . . . . . . . . . . . . . . . . . 5

3 Electrical connection . . . . . . . . . . . . . . . . . . . . . . . . . . 6

4 Operation · Set point adjustment . . . . . . . . . . . . . . . . . . . . 7

5 Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7

6 Nameplates . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8

7 Dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9

8 Technical data. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10

9 Customer inquiries . . . . . . . . . . . . . . . . . . . . . . . . . . 11

2EB 3136 EN

Contents

CAUTION!

indicates a hazardous situation

which, if not avoided, could result in

death or serious injury.

Live parts are freely accessible!

NOTICE

indicates a property damage message.

Note: Supplementary explanations, informa-

tion and tips

Definitions of the signal words used in these instructions

Safety instructions

EB 3136 EN 3

General safety instructions

The flow regulator with electric actuator must be installed, started up and

serviced only by skilled or semi-skilled staff in accordance with good

engineering practice so that employees and third persons are not exposed to

danger.

All safety instructions and warnings given in these mounting and operating

instructions, particularly those concerning installation, start-up and

maintenance, must be strictly observed.

The regulator complies with the requirements of the European Pressure

Equipment Directive 97/23/EC. The declaration of conformity issued for a

valve bearing the CE marking includes information on the applied

conformity assessment procedure and will be provided on request.

To ensure appropriate use, only use the regulator in applications where the

operating pressure and temperatures do not exceed the operating values

specified in the order.

Note that the manufacturer does not assume any responsibility for damage

caused by external forces or any other external factors.

Take appropriate safety precautions to prevent hazards that may be caused

in the regulator by the process medium, operating pressure, signal pressure,

or moving parts.

Make sure the regulator is shipped and stored properly.

Depending on the field of application, allow the regulator to cool down or

warm up to reach ambient temperature prior to starting any work.

Always depressurize the relevant section of the plant and, if necessary, also

drain the pipeline prior to installing or servicing the regulator.

The electric actuator has been designed for use in electrical power

installations. Strictly observe the relevant safety regulations for wiring and

maintenance work.

Only use disconnect devices that are protected against accidental or

unintentional reconnection.

Take special care when making adjustments on live parts.

Do not remove the covers under any circumstances.

1 Design and principle of

operation

The device combines a Type 2488 N Flow

Regulator and a Type 5857 Electric Actuator.

The electric actuator is attached to the valve

by means of the connecting piece and allows

also the temperature to be controlled by

changing the position of the restriction in re-

sponse to the control signal received from an

electric control device. The medium flows

through the valve in the direction indicated

by the arrow on the valve body. The flow

rate depends on the flow passage defined by

the valve plug (3) and the restriction (11).

The integral positioning spring (5) determines

the upper differential pressure (0.2 bar). The

high pressure upstream of the restriction (11)

is transmitted to the high-pressure side of the

diaphragm actuator through the control line

(7). The low pressure downstream of the re-

striction acts on the low-pressure side of the

operating diaphragm (9) via a bore in the

valve plug. The differential pressure

generated by the restriction (special differen-

tial pressure) is converted into a positioning

force by the operating diaphragm. This force

is used to position the valve plug against the

force of the positioning spring (5). The flow

rate can be adjusted by turning the set point

screw (13).

4EB 3136 EN

Design and principle of operation

Fig. 2 · Schematic diagram

1 Valve body

2 Seat

3 Valve plug

4 Plug stem

5 Positioning spring

6 Diaphragm actuator

7 High-pressure control line

8 High-pressure side

9 Operating diaphragm

10 Low-pressure side

11 Restriction

12 Restriction stem

13 Set point screw

14 Connecting piece

15 Spring

16 Electric actuator

17 Coupling nut

18 Actuator stem

2 Installation

2.1 Mounting position

4Install the flow regulator in a horizontal

pipeline with its diaphragm actuator sus-

pended downward.

4Make sure that the electric actuator is

above the valve body.

4Make sure that the medium flows through

the regulator in the direction indicated by

the arrow on the valve body.

NOTICE

Choose a point of installation which will pro-

vide easy access to the regulator after com-

pletion of the plant.

Flush the pipeline thoroughly before installa-

tion.

Make sure the permissible ambient tempera-

ture will not be exceeded. If the valve is to be

insulated, do not insulate the actuator and

the coupling nut. If necessary, use an exten-

sion piece (order no. 1690-6975). The valve

should not be insulated more than approx.

25 mm above the top edge of its body.

2.2 Strainer

Install a strainer (SAMSON Type 1 NI) up-

stream of the regulator to prevent sealing

particles, weld spatter, pipe scale, and other

impurities carried along by the process me-

dium from impairing the proper operation,

especially the tight shut-off of the valve.

4Make sure that the medium flows through

the strainer in the direction indicated by

the arrow on the strainer body.

4Install the strainer with the filter element

vertically suspended. Ensure that ample

space is available to remove the filter.

2.3 Shut-off valves, pressure

gauges

We recommend installing hand-operated

shut-off valves both upstream of the strainer

and downstream of the flow regulator. This

allows the plant to be shut down

(depressurized) for cleaning and mainte-

nance routines, or when it is not operated for

long periods of time.

To monitor the pressures prevailing in the

plant, install pressure gauges both upstream

and downstream of the flow regulator.

NOTICE

When carrying out a pressure test on the sec-

tion of the plant equipped with a pressure

regulator, prevent the diaphragm actuator

from being damaged by the test pressure by

using a test pressure which does not exceed

the maximum permissible pressure

p of the

actuator.

2.4 Mounting the actuator

See Fig. 2 on page 4.

Place the actuator (16) onto the valve con-

nection and manually fasten it using the cou-

pling nut (17).

EB 3136 EN 5

Installation

3 Electrical connection

See Figs. 2 and 3.

CAUTION!

When laying electric lines, strictly

observe the regulations governing the

erection of power installations

defined by DIN VDE 0100 as well as

the regulations specified by your

local power supply company.

Use a suitable power supply which

guarantees that no dangerous volt-

ages will reach the device in standard

operation or in case of a fault in the

system or any system parts.

Always switch off the power supply

first prior to connecting the actuator

to the electrical network. Make sure

the power cannot be switched on un-

intentionally.

The supply voltage is 230 V (±10 %) or 24 V

(±10 %), 50 Hz. Refer to EB 5857 EN for

more details.

Use the three-wire connecting cable attached

to the actuator to establish the electrical con-

nection (Fig. 3).

If a voltage is applied between the white and

the green cable, the motor will retract the ac-

tuator stem (18) into the actuator. The restric-

tion stem will be pushed upward by the

spring (15) and the flow rate will increase.

If, however, a control signal is applied to the

white and the brown cable, the actuator stem

extends. The restriction stem will be pushed

downward and the flow rate will decrease.

6EB 3136 EN

brwh gr

aL eL

Ce Ce

br bl ye gr rd or

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

_+_+

Electrical connection

eL Actuator stem retracts

aL Actuator stem extends

Note: Decoupling capacitors Ce in the output cir-

cuit of the connected controller must not exceed a

value of 2.5 nF in order to guarantee the proper

functioning of the actuator.

brwh gr

aL eL

Ce Ce

Fig. 3 · Electrical connection

4 Operation · Set point

adjustment

See Fig. 2 on page 4.

The flow rate can be adjusted, both with and

without the electric actuator mounted. Prior to

adjusting the flow rate on a regulator with

the electric actuator mounted, make sure the

actuator stem (18) is retracted.

Note: Prior to starting up or pressurizing the

regulator, make sure that the restriction for

limiting the flow is open.

To adjust or alter the flow set point, proceed

as follows:

The set point adjustment is always based on

a closed restriction.

NOTICE

Use the SAMSON manual adjustment

(1790-8169) to close the restriction. Do not

use the set point screw (13).

Remove the manual adjustment again and

use an Allen key (4 mm) at the set point

screw (13) at the side to adjust the flow set

point.

4Determine the number of turns required

to set the desired flow rate from the dia-

gram (Fig. 4).

4Turn set point screw (13) counterclock-

wise the required number of turns.

For exact adjustment, check the set value

using a flow meter.

4Turn the set point screw (13) clockwise to

close the restriction and decrease the flow

rate.

4Turn the set point screw counterclockwise

to open the restriction and increase the

flow rate.

5 Troubleshooting

If the flow rate deviates considerably from

the adjusted set point, first check the control

line for any blockages.

If the valve does not seal properly, this may

be because tight shut-off is prevented by dirt

between the seat and plug or due to natural

wear. Check the regulator for leaks and re-

place it, if necessary.

EB 3136 EN 7

Operation · Set point adjustment

0.1 0.5 1

m3/h

0.2 2

2.51.0Kvs

Fig. 4 · Adjustment diagram for flow rate

Turns of set point screw

NOTICE

Prior to starting any work on the reg-

ulator or removing it from the pipe-

line, allow the relevant section of the

plant to cool down to working tem-

perature if high temperatures prevail

and make sure that the pipeline con-

cerned is depressurized and drained.

6 Nameplates

Nameplate of Type 2488 N Valve

8EB 3136 EN

Nameplates

Description of the nameplate:

1 Model number with index

2 Year of manufacture

3 Type

4 Flow set point range in m3/h

5 Upper differential pressure in bar

6 Max. perm. differential pressure in bar

7 Flow coefficient KVS

8 Max. perm. temperature in °C

9 Nominal pressure PN

Description of the nameplate:

1 Nominal thrust, rated travel

actuating time, electrical connection

2 Configuration ID

3 Serial number

Nameplate of Type 5857 Electric Actuator

SAMSON 5857

Electric Actuator

Made in Germany

EB 3136 EN 9

Dimensions

7 Dimensions

Ø95

114

~65

120

ISO 228/1-G ¾ B

~70

Ø12

32 70

SW30

129

G½

Threaded ends

SW30

210

Ø21.3

Welding ends

Soldering ends · Dimensions in mm

Internal Ø di 15 18

Length L 107 103

Intermediate

insulating piece

SW30

Ø21.3

Soldering ends

Fig. 5 · Dimensional drawings (dimensions in mm)

8 Technical data

Type 5857 Actuator

Rated travel 6 mm

Actuating time for rated travel 20 s

Nominal thrust 300 N

Supply voltage 230 V/24 V (±10 %)

50 Hz

Power consumption Approx. 3 VA

Perm. ambient temperature 0 to 50 °C

Perm. storage temperature –20 to 70 °C

Degree of protection IP 42

Noise immunity EN 61000-6-2

Noise emission EN 61000-6-3

Weight Approx. 0.7 kg

Materials

Body CC491K

Plug 1.4301 with EPDM

sealing ring

Restriction Brass resistant to

dezincification

Diaphragm EPDM without fabric

10 EB 3136 EN

Technical data

Type 2488 N Valve

Nominal size DN 15

Nominal pressure PN 10

Max. perm. diff. pressure Dp 4 bar

Flow coefficient KVS

Standard version

Special version 2.5

1.0

Max. perm. temperature

Treated water

Non-flammable gases 110 °C

80 °C

Flow set point range / flow lim-

itation for water at upper differ-

ential pressure of 0.2 bar

Standard version

Special version 0.3 to 1m3/h

0.1 to 0.5 m3/h

Upper differential pressure 0.2 bar

Materials

Body Plastic PPO

Coupling nut Brass

Intermediate insulating piece 1.4306, CW617N,

PTFE, EPDM, FPM

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