Samson 43-8 Service manual

Translation of original instructions

EB 2178 EN

Type43-8 Temperature Regulator with Hydraulic Controller

Edition May 2023

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 2178 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 2178 EN

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

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

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

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

2 Markings on the device .................................................................................9

2.1 Materialidenticationnumber ......................................................................10

3 Design and principle of operation ................................................................10

3.1 Technical data .............................................................................................11

3.1.1 Process medium and scope of application......................................................11

4 Measures for preparation............................................................................15

4.1 Unpacking ..................................................................................................15

4.2 Transporting and lifting ................................................................................15

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

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

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

5.1 Assembling the valve, hydraulic controller and control thermostat ....................16

5.2 Mounting positions.......................................................................................17

5.2.1 Installing the valve and hydraulic controller....................................................17

5.2.2 Installing the control thermostat .....................................................................19

5.3 Additionalttings.........................................................................................20

5.4 Start-up.......................................................................................................21

6 Operation...................................................................................................22

6.1 Adjusting the set point at the control thermostat..............................................22

7 Servicing.....................................................................................................23

7.1 Tightening torques and lubricant ...................................................................23

7.2 Preparation for return shipment.....................................................................23

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

9 Decommissioning and removal ....................................................................25

9.1 Decommissioning.........................................................................................26

9.2 Disposal......................................................................................................26

10 Annex.........................................................................................................27

10.1 After-sales service and spare parts ................................................................27

11 Certicates..................................................................................................27

4 EB 2178 EN

Safety instructions and measures

1 Safety instructions and measures

Intended use

TheType2438HydraulicControllerwithType2432ValveandType2430Control

Thermostat is designed for temperature control of the energy supply to heat generators (e.g.

heat exchangers) by closing the valve. The regulator is mainly used to control the temperature

in instantaneous water heaters in small district heating units.

Thedevicesaredesignedtooperateunderexactlydenedconditions(e.g.operating

pressure, process medium, temperature). Therefore, operators must ensure that the devices

areonlyusedinoperatingconditionsthatmeetthespecicationsusedforsizingthedevices

at the ordering stage. In case operators intend to use the devices 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devicesarenotsuitableforuseoutsidethelimitsdenedduringconguration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

Qualications of operating personnel

The devices 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 applicable standards.

EB 2178 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).

ÎProvide protective equipment (e.g. safety gloves, eye protection) appropriate for the pro-

cess medium used.

ÎWear hearing protection when working near the valve. Follow the instructions given by

the plant operator.

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 2178 EN

Safety instructions and measures

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 devices 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in-

cludes information about the applied conformity assessment procedure. The EU declaration

ofconformityisincludedintheannexoftheseinstructions(seesection11).

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).

Referenced documentation

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

− Mounting and operating instructions for the valve uEB2171

− Mounting and operating instructions for the control thermostat uEB2430-3

EB 2178 EN 7

Safety instructions and measures

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.

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

well as the valve.

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

ÎWear personal protective equipment.

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. 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https://www.samsongroup.com/reach-en.html.

8 EB 2178 EN

Safety instructions and measures

1.3 Notes on possible property damage

NOTICE

Risk of irreparable regulator damage caused by the regulator components being

taken apart.

The thermostat, set point adjuster and capillary tube form an inseparable hydraulic

unit. If these components are dismantled (e.g. removal of the capillary tube), the regu-

latorwillbeirreparablydamagedandwillnolongerbeabletofulllitsmonitoring

and control task.

ÎDo not dismantle the regulator.

ÎOnly perform allowed activities on the regulator.

ÎContactSAMSON'sAfter-salesServicebeforereplacingspareparts.

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.

ÎObserve the maximum permissible pressure for valve and plant.

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.

EB 2178 EN 9

Markings on the device

2 Markings on the device

Type2438 Hydraulic Controller

Specications on the valve

1Date of manufacture

2CongurationID

3Device index

2 – 3

2438 1

PN16 SAMSON

Type2430 Control Thermostat

Specications on the scaled cap on the adjustment knob to adjust the set point

1Model number/type designation

2CongurationID

3Setpointrangein°Cand°F

4Register number (type test

accordingtoDINEN14597)

SAMSON

2750-0

2430

1067861

...°C

...°F

TR(TL)

Type2432 Valve

Specications on the valve

1Type designation (valve)

2CongurationID

3Date of manufacture

4KVS/CV

5Max. permissible temperature

6Pressure rating (valve)

7Max.perm.differentialpressure∆p

SAMSON 1

2710 - 23

6 7

Fig.1: Nameplates

10 EB 2178 EN

Design and principle of operation

2.1 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(2)isspeciedonthename-

plate.

For more details on the nameplate, see

Fig.1.

3 Design and principle of

operation

TheType43-8Regulatorisusedtocontrol

the temperature of instantaneous water heat-

ers in small district heating units.

ThedevicesconsistoftheType2430Control

Thermostat (30) operating according to the

vaporpressureprinciple,theType2438

HydraulicController(20)theType2432

Valve(1).

Thetemperaturesensorislledwithaliquid

which evaporates depending on the tem-

perature. As a result, a pressure in propor-

tion to the temperature is created in the sen-

sor. This pressure is transferred through the

capillary tube (8) to the operating element

(13) and converted into a positioning force,

which is compared to the force of the set

point spring (10).

The force ratio causes the plug in the valve

(1) to move. Depending on the valve travel,

an annular gap forms between the seat (2)

andtheplug(3)thatdeterminestheow

rate of the heating water.

A temperature increase at the sensor causes

the valve plug to close, thus reducing the

owrateoftheheatingwater.

Upon tapping hot water, a pressure differ-

enceof∆p=p1– p2is created above the

bafeplate(6).Theresultingforceopposes

the force of the compression spring (7) that

acts in closing direction and causes the valve

to open. Once hot water tapping has been

completed, the pressure balance is restored.

The force of the compression spring causes

the valve plug to move in the closing direc-

tionandtheheatowisinterrupted.Atthe

same time, the temperature set point of the

thermostatdropsbyapprox.8K(optionally

15K)toreachthereducedidletemperature.

This prevents reheating with temperature

peaks as well as the supply lines from cool-

ing down.

This ensures that hot water is immediately

available for the next tapping.

Table1: Domestic water quality

DHW

pH Min. 7/max. 10

Chlorideconcentration Max.150mg/l

HCO –

SO 2-

>1.5

Carbonatehardness Min.5°dH(German

hardness)

Total hardness Max.12°dH

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