Page 1
EB 3018 EN Translation of original instructions Type 42-36 E with Type 5825 Actuator Type 42-36 E with Type 3374 Actuator Type 42-36 E Pressure-independent Control Valve (PICV) With Type 5824, Type 5825, Type 3274 or Type 3374 Electric Actuator Edition November 2020...
Page 2
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.
Contents Safety instructions and measures ..............1-1 Notes on possible severe personal injury ............1-5 Notes on possible personal injury ..............1-6 Notes on possible property damage .............1-8 Markings on the device ................2-1 Valve nameplate ..................2-1 Actuator nameplate ..................2-1 Nameplate of the electric actuator ..............2-2 Location of the nameplates ................2-2 Material identification number ..............2-2 2.5.1...
Page 4
Removing the actuator from the valve ............11-2 11.2 Removing the regulator from the pipeline ............11-2 11.3 Removing the actuator from the valve ............11-2 Repairs ....................12-1 12.1 Returning devices to SAMSON ..............12-1 Disposal ....................13-1 Certificates ....................14-1 Annex......................15-1 15.1 Tightening torques ..................15-1 15.2 Lubricant ....................15-1...
In case operators intend to use the regulators in other applications or conditions than specified, 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.
Page 6
Î Check with the plant operator for details on further protective equipment. Revisions and other modifications Revisions, conversions or other modifications 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.
Page 7
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.
Page 8
Safety instructions and measures Î For connection to the equipotential bonding system, observe the requirements specified in section 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 e.g.
Safety instructions and measures 1.1 Notes on possible severe personal injury DANGER Risk of bursting in pressure equipment. Regulators and pipelines are pressure equipment. Impermissible pressure or improper opening can lead to regulator components bursting. Î Observe the maximum permissible pressure for regulator and plant. Î...
Safety instructions and measures 1.2 Notes on possible personal injury WARNING Risk of personal injury through incorrect operation, use or installation as a result of information on the regulator being illegible. Over time, markings, labels and nameplates on the regulator may become covered with dirt or become illegible in some other way.
Page 11
Î Wear protective clothing, safety gloves and eye protection. Damage to health relating to the REACH regulation. If a SAMSON device contains a substance which is listed as being a substance of very high concern on the candidate list of the REACH regulation, this circumstance is indi- cated on the SAMSON delivery note.
The lubricants to be used depend on the regulator material. Unsuitable lubricants may corrode and damage surfaces. Î Only use lubricants approved by SAMSON. When in doubt, consult SAMSON. Risk of leakage and regulator damage due to excessively high or low tightening torques.
Page 13
Risk of regulator damage due to the use of unsuitable tools. Certain tools are required to work on the regulator. Î Only use tools approved by SAMSON. When in doubt, consult SAMSON. Risk of the process medium being contaminated through the use of unsuitable lubricants and/or contaminated tools and components.
Page 14
Safety instructions and measures NOTICE Risk of actuator damage due to excessively high tightening torques. Observe the specified torques when tightening the mounting parts of the electric actua- tor. Excessive tightening torques lead to parts wearing out more quickly. Î Observe the specified tightening torques. Risk of actuator damage due to incorrect wiring of the binary inputs.
Page 15
Î To loosen and tighten the screws, only use the following screwdrivers: − TORX ® − TORX PLUS 10IP ® − Flat-blade screwdriver with 0.8 mm blade thickness and 4.0 mm blade width Note SAMSON's After-sales Service can support you concerning lubricant, tightening torques and tools approved by SAMSON. EB 3018 EN 1-11...
Page 16
Safety instructions and measures 1-12 EB 3018 EN...
Markings on the device 2 Markings on the device Several nameplates are affixed to the device. The nameplates are used to identify the sepa- rate regulator components (see section 2.1 to section 2.3). 2.1 Valve nameplate DIN version ANSI version ANSI version · DIN version Valve type Perm.
Markings on the device 2.3 Nameplate of the electric 2.5 Material identification actuator number See associated actuator documentation. 2.5.1 Type 2423 Valve 2.4 Location of the nameplates See the nameplate (11 for DIN/ANSI ver- sion, body material). For more details on the nameplate, see section 2.1.
Design and principle of operation 3 Design and principle of oper- ation Î See Fig. 3-1 and Fig. 3-2 The device combinations for the Type 42- 36 E consist of the Type 42-36 Pressure- independent Control Valve (PICV) and a Type 5824, Type 5825 or Type 3374 Electric Actuator or Type 3274 Electrohydraulic Actuator (depending on the valve size).
Page 20
Design and principle of operation Connection of an electric actuator Type 2423 Valve balanced by a bellows Type 2426 Actuator Fig. 3-1: Functional diagram of regulator, DN 15 to 250 with balancing bellows (without electric actuator) EB 3018 EN...
Page 21
Design and principle of operation Connection of an electric actuator Type 2423 Valve balanced by a diaphragm Type 2426 Actuator Fig. 3-2: Functional diagram of regulator, DN 65 to 250 with balancing diaphragm (without electric actuator) Legend for Fig. 3-1 and Fig. 3-2 Vent plug (DN 125 and 16 Diaphragm plate 3 Plug larger)
Page 22
Design and principle of operation Type 3374 Actuator · DN 65 to 100 Type 3274 or Type 3374 Actuator · DN 125 to 250 Electric actuator 1.1 Actuator stem 1.2 Stem connector 1.3 Hex nut 1.4 Manual adjuster Connecting piece 2.1 Stem 2.2 Lock nut 2.3 Set point adjuster 2.4 Dial plate 2.5 Groove mark 2.6 Locking screw...
Design and principle of operation 3.1 Additional fittings Bypass and shut-off valves We recommend installing a shut-off valve (1 Î See Fig. 3-4 and 6) both upstream of the strainer and downstream of the regulator and installing a Pressure gauges bypass line. The bypass ensures that the Install a pressure gauge (3 and 5) at suitable plant does not need to be shut down for ser- points to monitor the pressures prevailing in...
Design and principle of operation 3.2 Technical data Strainers We recommend installing a SAMSON The nameplates of the valve, actuator and strainer (2) upstream of the valve. It prevents electric actuator provide information on the solid particles in the process medium from valve and actuator versions (see the 'Mark- damaging the regulator.
Page 25
Design and principle of operation Leakage class Noise emissions The metal-seated regulator has the leakage SAMSON is unable to make general state- class I according to IEC 60534-4. ments about noise emissions. The noise emis- The soft-seated regulator has the leakage sions depend on the regulator version, plant class IV according to IEC 60534-4.
Page 26
Design and principle of operation Table 3-2: Materials · Material number according to DIN EN Type 2423 E Valve balanced by a bellows Pressure rating PN 16 PN 25 PN 16, 25 and 40 Spheroidal graphite Cast iron Cast steel Cast stainless Forged stainless Valve body iron EN-GJL-250 1.0619...
Page 27
Design and principle of operation Table 3-2: Materials · Material number according to DIN EN Type 3274 Electrohydraulic Actuator Housing, housing cover Die-cast aluminum Cylinder Hydraulic cylinder tube Piston Steel/NBR combination Piston stem C45, hard chrome-plated Actuator stem 1.4104 Hydraulic oil Special HLP, silicone-free Type 3374 Electric Actuator Enclosure and cover...
Page 28
Design and principle of operation Table 3-4: K coefficients, x values, flow rate set point ranges for water and max. per- missible differential pressures (valve balanced by a diaphragm) Type 2423 E Valve balanced by a diaphragm Valve size coefficients in m³/h value 0.35 Max.
Page 29
Design and principle of operation Table 3-6: Technical data ∙ Electric actuators for valve size DN 125 and larger Type 3274-11 and Type 3274-21 Electrohydraulic Actuators ∙ Type 3374-15 Electric Actuator Valve size DN 125 to 250 Type ... 3274-11 3274-21 3374-15 Fail-safe action Without With Without Rated travel 30 mm Transit time for rated travel 120 s...
Page 30
Dimensions and weights ∙ Type 42-36 E with Type 2423 E Valve balanced by a bellows Dimensional drawings · Type 2423 E Valve balanced by a bellows · DN 15 to 250 DN 15 to 50 DN 65 to 100 DN 125 to 250 Type 42-36 E with actuator Types 5824-10/20 Types 3374-11/-21 Types 3274-11/-21 Type 3374-15 Types 5825-10/20 Fig. 3-5: Dimensions of the regulators with a valve balanced by a bellows...
Page 31
Design and principle of operation Dimensions and weights ∙ Type 42-36 E with Type 2423 E Valve balanced by a bellows Dimensions in mm and With Type 5824-10/-20 or Type 5825-10/-20 With Types 3374-11/-21 weights Actuator Actuator Valve size Length L Height H1 Forged steel 1.4571 – –...
Page 32
Design and principle of operation Dimensions and weights ∙ Type 42-36 E with Type 2423 E Valve balanced by a diaphragm Dimensional drawings · Type 2423 E Valve balanced by a diaphragm · DN 65 to 100 Type 42-36 E with Type 5824-30 Electric Actuator Dimensions in mm and With Type 5824-30 Actuator weights Valve size DN Length L Height H...
Page 33
Dimensions and weights ∙ Type 42-36 E with Type 2423 E Valve balanced by a diaphragm Dimensional drawings · Type 2423 E Valve balanced by a diaphragm · DN 65 to 250 Type 42-36 E with Type 3274 Electrohydraulic Actuator Type 42-36 E with Type 3374 Electric Actuator Dimensions in mm Dimensions in mm With Types 3274-11/-21...
Page 34
Design and principle of operation 3-16 EB 3018 EN...
Shipment and on-site transport 4 Shipment and on-site trans- 4.2 Removing the packaging port from the regulator The work described in this section is only to The components (valve, actuator, electric ac- be performed by personnel appropriately tuator and, if applicable, control line) of the qualified to carry out such tasks.
Shipment and on-site transport 4.3 Transporting and lifting the WARNING regulator Risk of personal injury due to the regulator tipping. Î Observe the regulator's center of gravity. DANGER Î Secure the regulator against tipping over Danger due to suspended loads falling. or turning.
Shipment and on-site transport 4.3.2 Lifting the regulator hook) of the crane or forklift (see Fig. 4-1). To install a large regulator into the pipeline, 2. Carefully lift the regulator. Check wheth- use lifting equipment (e.g. crane or forklift) er the lifting equipment and accessories to lift it.
Î To keep elastomers in shape and to pre- Î Avoid long storage times. vent cracking, do not bend them or hang Î Contact SAMSON in case of different them up. storage conditions or longer storage Î Store elastomers away from lubricants, times.
Î Contact SAMSON if the mounting posi- easily access the device from the work posi- tion is not as specified above. tion.
Page 40
Fig. 5-1: Schematic drawing of mounting Needle valve position If the regulator tends to hunt, we recommend installing a needle valve in the control line in addition to the standard SAMSON screw Support or suspension joint with restriction. Note The plant engineering company is responsi-...
See the 'Markings on of the regulator. Therefore, we recommend the device' section for nameplate details. installing a strainer (e.g. SAMSON Type 2 NI) upstream of the regulator. − The requested or required additional fit- tings (see the 'Design and principle of...
Page 42
Installation Table 5-1: Inlet and outlet lengths min. min. a x DN b x DN Control line kit (see information under ‘Control line kit’ in section 5.1) Inlet length Outlet length State of process me- Valve conditions Inlet length a Outlet length b dium Ma ≤ 0.3...
(see 'Tightening torques' in Annex). NOTICE Risk of regulator damage due to the use of unsuitable tools. Î Only use tools approved by SAMSON (see 'Tools' in Annex). NOTICE Risk of regulator damage due to the use of unsuitable lubricants.
Installation 5.3.1 Installing the regulator Î Mounting the actuator 6. Fasten the actuator on the valve by tight- ening the coupling nut (11). Observe the Note alignment of the control line connection. Before installing the regulator, tighten the Observe the specified tightening torques stopper(s) at the side of the valve body using (see 'Tightening torques' in Annex).
Installation 5.3.2 Cleaning the pipeline We recommend additionally flushing the pipeline with installed regulator before start- Î Unscrew the control line (18) from the valve body. Î Seal the valve body with stoppers. Î Observe the mesh size of the upstream strainer for the maximum particle size.
Î Use a suitable voltage supply which SAMSON regulators are delivered ready for guarantees that no dangerous voltages use. To test the regulator functioning before reach the device in normal operation or...
The leak test must comply with the The plant operator is responsible for requirements of the national and internation- performing the pressure test. SAMSON's al standards that apply at the site of installa- After-sales Service can support you to plan tion.
Installation 5.5 Insulation To insulate cold systems, we recommend first filling the plant and carefully rinsing it. The regulator must not yet be insulated at this stage. 1. Start up the plant and adjust the set point (see the 'Start-up' section). 2.
Start-up 6 Start-up WARNING The work described in this section is only to Risk of burn injuries due to hot or cold com- be performed by personnel appropriately ponents and pipeline. qualified to carry out such tasks. Regulator components and the pipeline may become very hot or cold.
Start-up high flow velocities which can damage WARNING the valve. Risk of hearing loss or deafness due to loud 3. Check the regulator to ensure it functions noise. properly. Noise emission (e.g. cavitation or flashing) Before starting up the plant, make sure the may occur during operation caused by the following conditions are met: process medium and the operating condi-...
Operation 7 Operation WARNING WARNING Immediately after completing start-up or Crush hazard arising from moving parts. placing the regulator back into service (see The regulator contains moving parts (actua- the 'Start-up' section), the regulator is ready tor and plug stem), which can injure hands for use.
Operation 7.1 Set point adjustment Note The flow rate can be adjusted either when Observe the differential pressure across the the electric actuator is mounted on the valve restriction ∆p of 0.2 bar or 0.5 bar. It restriction or without a mounted electric actuator. is determined by the differential pressure springs (14) installed in the actuator (see the The flow rate set point is determined by the...
Page 53
Operation 7.2 Adjusting the flow rate with Type 5824 Electric Actuator 1. Retract the actuator stem (1.1) by turning 7.2.1 DN 15 to 50 the manual adjuster (1.4) counterclock- wise () or by applying a corresponding Type 5824 or Type 5825 Electric Actuator control signal from the control device. 2.
Page 54
Operation 4. Based on a closed restriction, turn the set 4. Turn the set point adjuster (2.3) counter- point adjuster counterclockwise () to clockwise () by the corresponding num- adjust the flow rate set point. ber of turns. 5. Check the flow rate at the heat meter and 5.
Page 55
Operation with Type 5824-30 or Type 3374 Actuator 2. Press the rod (2.1) downward to close the restriction (2.7). 1. Extend the actuator stem (1.1) all the 3. Loosen the locking screw (2.6) and turn way to close the restriction (2.7) using the set point adjuster (2.3) clockwise () the manual override (4 mm hex wrench) until the scale reading 0 is located above...
Page 56
Operation Î Adjustment with actuator · See Fig. 7-1 9. Extend the actuator stem (1.1) as far as it will go using the manual override. More details on the Type 3274 Electric Actu- 10. Position the stem connector clamps (1.2) ator in u EB 8340; more details on the and screw them tight.
Page 57
Operation Type 5824 or Type 5825 Actuator Type 3374 Actuator Type 3274 or Type 3374 Actuator Restriction DN 15 to 50 Restriction DN 65 to 100 Restriction DN 125 to 250 Electric actuator 1.4 Manual adjuster 2.3 Set point adjuster 2.7 Restriction 1.1 Actuator stem Connecting piece 2.4 Dial plate 11 Coupling nut 1.2 Stem connector 2.1 Rod...
Page 58
Operation Table 7-1: Flow set point ranges for water · Type 2423 E, balanced by a bellows Set point ranges in m³/h with ... DN 15 DN 20 DN 25 DN 32 DN 40 DN 50 Differential pressure at the restriction 0.5 to 2 0.5 to 3 0.8 to 3.5 2 to 7 3 to 11 3 to 16...
Page 59
Operation Table 7-2: Flow set point ranges for water · Type 2423 E · Balanced by a bellows or dia- phragm Set point ranges in m³/h with ... DN 65 DN 80 DN 100 Differential pressure at the restriction 5 to 28 7 to 35 10 to 63 1) Δp...
Page 60
Operation Table 7-3: Flow set point ranges for water · Type 2423 E, balanced by a bellows Set point ranges in m³/h with ... DN 125 DN 150 DN 200 DN 250 DP at the restriction Δp = 0.2 bar 40 to 80 50 to 120 70 to 180 90 to 220 restriction DP at the restriction Δp...
Page 61
Operation Table 7-4: Flow set point ranges for water · Type 2423 E, balanced by a diaphragm Set point ranges in m³/h with ... DN 125 DN 150 DN 200 DN 250 Differential pressure at the restriction 40 to 90 50 to 140 70 to 220 90 to 260 Δp = 0.2 bar...
Î Remove foreign particles. Foreign particles blocking the plug Î Replace damaged parts. Î Contact SAMSON's After-sales Service. Î Replace the damaged seat and plug. Flow rate exceeds Seat and plug are worn or leak. adjusted set point.
Page 64
Î Check the sizing. Loud noises High flow velocity, cavitation Î Install larger regulator, if necessary. Leakage at the actua- Defective operating diaphragm Î Replace damaged diaphragm. Note Contact SAMSON's After-sales Service for malfunctions not listed in the table. EB 3018 EN...
3. Rectify those malfunctions that can be remedied based on the instructions SAMSON's After-sales Service can support provided here. Contact SAMSON's you in drawing up an inspection and test After-sales Service in all other cases.
Servicing 9 Servicing WARNING The regulator does not require any mainte- Risk of burn injuries due to hot or cold com- nance. Nevertheless, it is subject to natural ponents and pipeline. wear, particularly at the seat, plug and oper- Regulator components and the pipeline may ating diaphragm and electric actuator.
Page 68
Risk of regulator damage due to the use of SAMSON's After-sales Service can support unsuitable tools. you in drawing up an inspection and test Î Only use tools approved by SAMSON plan for your plant. (see 'Tools' in Annex). NOTICE Risk of regulator damage due to the use of unsuitable lubricants.
Page 69
Servicing Connection of an electric actuator Type 2423 Valve balanced by a bellows Type 2426 Actuator Fig. 9-1: Functional diagram for regulators, DN 15 to 250 with balancing bellows EB 3018 EN...
Page 70
Servicing Connection of an electric actuator Type 2423 Valve balanced by a diaphragm Type 2426 Actuator Fig. 9-2: Functional diagram for regulators, DN 65 to 250 with balancing diaphragm EB 3018 EN...
Page 71
Servicing Type 3374 Actuator · DN 65 to 100 Type 3274 or Type 3374 Actuator · DN 125 to 250 Electric actuator 1.1 Actuator stem 1.2 Stem connector 1.3 Hex nut 1.4 Manual adjuster Connecting piece 2.1 Rod 2.2 Lock nut 2.3 Set point adjuster 2.4 Dial plate 2.5 Groove mark 2.6 Locking screw 2.7 Restriction 11 Coupling nut...
Servicing 9.1 Preparing the valve for 9.2 Installing the regulator service work after service work 1. Lay out the necessary material and tools Î Put the regulator back into operation (see to have them ready for the service work. the 'Start-up' section). Make sure the re- quirements and conditions for start-up or 2.
Replacing the seat and plug Î See Fig. 9-1 and Fig. 9-2 To replace seat and plug, contact Note SAMSON's After-sales Service. Read the mounting and operating instruc- Further information is available in Annex tions of actuators with fail-safe action (see ('After-sales service').
Do not exchange the operating diaphragm plate nut (17). Observe the specified in an FDA-compliant regulator version. tightening torques (see 'Tightening SAMSON's After-sales Service can support torques' in Annex). you to perform such service work. 2. Place on the actuator case.
Servicing 9.3.4 Replacing the electric Î See Fig. 9-3 actuator Removing the Type 5824 or 5825 Electric Actuator 1. Put the regulator out of operation (see WARNING WARNING the 'Decommissioning' section). Observe the relevant safety regulations on mounting or removing the electric actuator. 2.
1. Place the electric actuator on the valve Contact your nearest SAMSON subsidiary and fasten tight the hex nut (1.3). Ob- or SAMSON's After-sales Service for infor- serve the specified tightening torques mation on spare parts, lubricants and tools. (see 'Tightening torques' in Annex).
Decommissioning 10 Decommissioning Î Only perform the electrical connection after switching off the supply voltage. The work described in this section is only to Make sure the supply voltage cannot be be performed by personnel appropriately switched on again unintentionally. qualified to carry out such tasks.
Page 78
Decommissioning WARNING WARNING WARNING Risk of hearing loss or deafness due to loud Risk of personal injury due to residual pro- noise. cess medium in the regulator. Noise emission (e.g. cavitation or flashing) While working on the regulator, residual may occur during operation caused by the process medium can escape and, depending process medium and the operating condi- on its properties, may lead to personal in-...
Removal 11 Removal WARNING WARNING The work described in this section is only to Risk of personal injury due to residual be performed by personnel appropriately process medium in the regulator. qualified to carry out such tasks. While working on the regulator, residual process medium can escape and, depending on its properties, may lead to personal in- WARNING...
Removal 11.1 Removing the actuator 11.2 Removing the regulator from the valve from the pipeline 1. Support the regulator to hold it in place Note when separated from the pipeline (see Read the mounting and operating instruc- the 'Shipment and on-site transport' sec- tions of actuators with fail-safe action (see tion).
Î Do not perform any repair work on your send you a return merchandise authori- own. zation (RMA). Î Contact SAMSON's After-sales Service 3. Attach the RMA (together with the for repair work. Declaration on Decontamination) to the outside of your shipment so that the 12.1 Returning devices to...
Disposal 13 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. EB 3018 EN 13-1...
Certificates 14 Certificates The EU declarations of conformity are in- cluded on the next pages: − EU declaration of conformity in compli- ance with Pressure Equipment Directive 2014/68/EU on page 14-2. EB 3018 EN 14-1...
Page 86
Certificates 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-, 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.
Page 87
Certificates 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.
SW 12 40 to 640 cm² Control line connection (19) – 40 to 640 cm² 15.2 Lubricant SAMSON's After-sales Service can support you concerning lubricants and sealants ap- proved by SAMSON. 15.3 Tools SAMSON's After-sales Service can support you concerning tools approved by SAMSON.
You can reach our after-sales service at actuator. aftersalesservice@samsongroup.com. Addresses of SAMSON AG and its subsid- iaries The addresses of SAMSON, its subsidiaries, representatives and service facilities worldwide can be found on our website (u www.samsongroup.com) or in all...