Samson 42-24 Service manual

Mounting and

Operating Instructions

EB 3003 EN

Edition July 2015

Self-operated Pressure Regulators

Differential Pressure Regulators (closing)

Type42-24·Type42-28

Type42-24 Differential Pressure Regulator Type42-28A Differential Pressure Regulator

Denition of signal words

DANGER!

Hazardous situations which, if not

avoided, will result in death or seri-

ous injury

WARNING!

Hazardous situations which, if not

avoided, could result in death or seri-

ous injury

NOTICE

Property damage message or mal-

function

Note:

Additional information

Tip:

Recommended action



2 EB 3003 EN

Contents

EB 3003 EN 3

1 General safety instructions.............................................................................4

2 Process medium and scope of application.......................................................5

3 Transportation and storage............................................................................5

4 Design and principle of operation ..................................................................6

5 Installation....................................................................................................9

5.1 Mounting position..........................................................................................9

5.2 Strainer (lter)..............................................................................................10

5.3 Shut-off valve...............................................................................................10

5.4 Pressure gauge ............................................................................................10

5.5 Control line, compensation chamber and needle valve....................................11

6 Operation...................................................................................................12

6.1 Start-up.......................................................................................................12

6.2 Adjusting the set point..................................................................................12

6.3 Decommissioning.........................................................................................12

7 Maintenance and troubleshooting ................................................................13

7.1 Replacing the operating diaphragm ..............................................................15

8 Customer inquiries ......................................................................................15

9 Nameplate..................................................................................................16

10 Appendix....................................................................................................17

10.1 Technical data .............................................................................................17

10.2 Dimensions..................................................................................................20

4 EB 3003 EN

General safety instructions

1 General safety instructions

−All safety instructions and warnings given in these mounting and operating instructions,

particularly those concerning installation, start-up and maintenance, must be strictly ob-

served.

−The device must be mounted, started up or serviced by fully trained and qualied person-

nel only; the accepted industry codes and practices are to be observed. Make sure em-

ployees or third persons are not exposed to any danger.

−According to these mounting and operating instructions, trained personnel refers to indi-

viduals who are able to judge the work they are assigned to and recognize possible dan-

gers due to their specialized training, their knowledge and experience as well as their

knowledge of the applicable standards.

−The devices comply with the requirements of the European Pressure Equipment Directive

2014/68/EU. Devices with a CE marking have a declaration of conformity, which includes

information about the applied conformity assessment procedure.This declaration of conformi-

ty can be provided on request. This declaration of conformity can be provided on request.

−To ensure appropriate use, only use the device in applications where the operating pres-

sure and temperatures do not exceed the specications used for sizing the device at the

ordering stage.

−The manufacturer does not assume any responsibility for damage caused by external

forces or any other external factors.

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

pressure or by moving parts are to be prevented by taking appropriate precautions.

−Proper transport, storage, installation, operation and maintenance are assumed.

Note:

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 assess-

ment 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

94/9/EC.

For connection to the equipotential bonding system, observe the requirements speci-

ed in section 6.3 of EN60079-14: 2011 (VDE0165 Part 1).



EB 3003 EN 5

Process medium and scope of application

2 Process medium and scope of application

Differential pressure regulators for district heating systems, extended heating systems and in-

dustrial applications

Differential pressure set points Δp from 0.05 to 10bar · Valves DN15 to 250 · Nominal

pressure PN16 to 40 · Suitable for liquids and vapors from 5 to 350°C as well as for air

and non-ammable gases up to 80°C

The valve closes when the differential pressure rises.

3 Transportation and storage

The regulator must be carefully handled, transported and stored. Protect the regulator against

adverse inuences, such as dirt, moisture or frost, during storage and transportation.

Note:

Before installing the regulator, tighten the blanking plug(s) at the side in the valve

body using a suitable box wrench.

Torque: 50Nm for G¼, 70Nm for G

When regulators are too heavy to be lifted by hand, fasten the lifting sling to a suitable place

on the valve body.

WARNING!

Incorrectly attached lifting slings or supports.

Risk of injury and property damage due to valve falling.

Securely fasten slings or supports to the valve body and secure against slipping.

WARNING!

Do not attach lifting slings or supports to mounting parts, such as control line etc.

The valve can fall or mounting parts may be damaged.

Securely fasten slings or supports to the body of the valve and secure against slip-

ping.



6 EB 3003 EN

Design and principle of operation

Regulator congurations

Regulator =Valve +Actuator

Type42-24 Type2422 balanced Type2424 adjustable set point

Type42-28 Type2422 balanced Type2428 xed set point

1) Type2422 Valve, balanced by a diaphragm, DN65 to 250 only

4 Design and principle of oper-

ation

See Fig.1 on page7.

The differential pressure regulators are de-

signed to maintain a constant pressure differ-

ence between the high pressure and low

pressure lines to an adjustable set point

(Type42-24) or a xed set point (Type42-

28).

The regulators basically consist of a valve

with seat (2) and plug (3) and a closing ac-

tuator (Type2424 or Type 2428) with an op-

erating diaphragm (13).

Valve and actuator are delivered separately

and must be assembled on site using a cou-

pling nut (11).

The medium ows through the valve between

the plug (3) and the seat (2) in the direction

indicated by the arrow. The position of the

valve plug determines the differential pres-

sure prevailing across the plant.

The Type2422 Valve is balanced. The forces

acting on the valve plug created by the up-

stream and downstream pressures are bal-

anced by a balancing bellows (5) or balanc-

ing diaphragm 1) (5.1).

The principle of operation of the regulator

balanced by a bellows or diaphragm only

differs concerning the pressure balancing.

Valves balanced by a diaphragm have a

balancing diaphragm (5.1) instead of the

balancing bellows (5). The downstream pres-

sure p2 acts on the bottom of the diaphragm

and the upstream pressure p1 on the top of

the diaphragm. As a result, the forces creat-

ed by the upstream and downstream pres-

sures acting on the plug are balanced out.

1Valve body

2 Seat

3Plug

4 Plug stem

5Balancing bellows

5.1 Balancing diaphragm (DN65 to 250)

11 Coupling nut

12 Diaphragm stem

13 Operating diaphragm

14 Diaphragm case

15 Nuts and bolts

16 Set point springs

17 Set point adjuster (set point nut)

18 Nut

19 Diaphragm plate

20 Control line

21 Overload protection (force limiter with

internal excess pressure limiter)

EB 3003 EN 7

Design and principle of operation

Fig.1: Functional diagrams of Type42-24 and Type42-28

Type42-24 Type42-28

5.1

P1P2

Type42-24

Type2428 Actuator

Type2424 Actuator

Type2422 Valve, balanced by a diaphragm

(DN65 to 250)

Type2424 Actuator

Type2422 Valve, balanced by a bellows

(DN15 to 250)

8 EB 3003 EN

Design and principle of operation

The differential pressure across the plant is

transmitted over the high pressure and low

pressure lines to the operating diaphragm

(13) where it is converted into a positioning

force. This force moves the plug according to

the force of the set point springs (16).

The set point springs are mounted inside the

actuator for a xed set point (Type42-28).

These springs can be adjusted externally for

an adjustable set point (Type42-24).

Control lines (20) mounted on site transfer

the high pressure and low pressure in all ver-

sions.

Type2424 and Type2428 Actuators are

equipped with an overload protection (21). It

prevents a rise in differential pressure during

extreme operating conditions (e.g. vacuum

at the heat exchanger) by opening an inter-

nal excess pressure limiter. As a result, plants

and the regulator itself are protected against

excessively high differential pressures.

EB 3003 EN 9

Installation

5 Installation

The Type42-24 and Type42-28 Regulators

are designed for installation in the high

pressure (ow) line of the plant.

The Type42-24 and Type42-28 Regulators

are designed for installation in the low pres-

sure (return ow) line of the plant.

ÎChoose a place of installation that allows

you to freely access the regulator even af-

ter the entire plant has been completed.

ÎInstall a strainer (e.g. SAMSON

Type2N) upstream of the regulator (see

section5.2).

ÎFlush the pipeline thoroughly before in-

stalling the regulator to ensure that any

sealing parts, weld spatter and other im-

purities carried along by the process me-

dium do not impair the proper function-

ing of the valve, above all the tight shut-

off.

ÎThe direction of ow must match the di-

rection indicated by the arrow on the

body.

NOTICE

Incorrectly installed regulator

The pressure regulator can be dam-

aged.

−Make sure the regulator is installed

free of stress.

−Do not attach supports (if required)

directly to the valve or actuator. At-

tach the supports near to the con-

necting anges.

−Observe permissible mounting po-

sition.

5.1 Mounting position

See Fig.1 on page7.

See Fig.2 for permissible mounting positions.

Standard mounting position · Install valve

without actuator in a horizontal pipeline with

the connection for the actuator facing down-

wards. Make sure the medium ows through

the valve in the direction indicated by the ar-

row.

Fig.2: Permissible mounting positions

Connect the actuator to the valve bottom sec-

tion using the coupling nut (11).

Balanced by a bellows or

diaphragm

−Standard mounting position

All versions

Balanced by a bellows

−Above 80°C

−Steam applications

Balanced by a bellows

−All versions DN15 to 80

plus up to max. 80°C

Balanced by a diaphragm

−All versions up to max. 80°C

Balanced by a bellows

−Versions with xed plug

guide

10 EB 3003 EN

Installation

SW 13

Valve bottom

section

Screw plug

Do not remove!

Plug stem

DN125 to 250 only

Fig.3: Valve bottom section with plug stem

5.2 Strainer (lter)

Install the strainer upstream of the regulator.

The direction of ow must correspond to the

arrow on the body. The lter element must

be installed to hang downwards or sideways

for applications with steam. Remember to

leave enough space to remove the lter ele-

ment.

5.3 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.

5.4 Pressure gauge

Install a pressure gauge both upstream and

downstream of the regulator to monitor the

pressures prevailing in the plant. Install the

pressure gauge on the downstream side be-

hind the downstream pressure tapping point

(not between the tapping point and the

valve).

Fig.4: Typical installations (control lines to be installed on site are represented by a dashed line)

2237

651

(+) (+)

(–)

Type42-24/42-28 in a ow pipe Type42-24/42-28 in a return ow pipe

1Shut-off valve

2 Strainer

3Differential pressure regulator

4 Compensation chamber (e.g. for steam applications)

5Pressure gauge

6Needle valve (optional)

7Motorized valve

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