Universal Excess Pressure Valve

Type 41-73

Fig. 1 Type 41-73 Universal Excess Pressure Valve

Mounting and
Operating Instructions

EB 2517 EN
Edition September 2003
 Contents

Contents Page
1. Design and principle of operation . . . . . . . . . . . . . . . . . . . . . . 4
2. Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
2.1 Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
2.2 Mounting position . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
2.3 Control line, condensation chamber and screw joint with restriction . . . . . . 7
2.4 Strainer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
2.5 Shut-off valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
2.6 Pressure gauge . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
3. Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
3.1 Start-up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
3.2 Set point adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
4. Maintenance Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . 9
4.1 Replacing the operating diaphragm . . . . . . . . . . . . . . . . . . . . . 9
5. Description of nameplates . . . . . . . . . . . . . . . . . . . . . . . . . . 11
6. Dimensions in mm and weights . . . . . . . . . . . . . . . . . . . . . . . 12
7. Customer inquiries . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14

2 EB 2517 EN
 Safety instructions

General safety instructions

 The pressure regulator may only be mounted, started up or serviced by fully
trained and qualified personnel, observing the accepted industry codes and
practices. Make sure employees or third persons are not exposed to any
danger.
 The pressure regulator fulfils the requirements of the European Pressure Equip -
ment Directive 97/23/EC. Valves with a CE marking have a declaration of
conformity which includes information about the applied conformity assess -
ment procedure. The declaration can be viewed and downloaded on the Inter -
net at http://www.samson.de.
 For appropriate operation, make sure that the regulator is only used in areas
where the operating pressure and temperatures do not exceed the operating
values which are based on the valve sizing data submitted in the order.
The manufacturer does not assume any responsibility for damage caused by
external forces or any other external influence!
Any hazards which could be caused in the pressure regulator by the process
medium, the operating pressure or by moving parts are to be prevented by
means of the appropriate measures.
 Proper shipping and appropriate storage are assumed.
Caution!
 Self-operated regulators must not be put into operation before all compo -
nents, e.g. valve, actuator and control lines, have been mounted.
Open all control lines and check that they are correctly connected prior to
start-up.
 When removing the self-operated regulator from the pipeline, make sure the
sections of the pipeline that the control lines are connected to are also depress -
urized. If this is not possible, shut off the control lines.
 Allow the plant to fill slowly on start-up.
On pressurizing the plant to carry out a pressure test, make sure the dia -
phragm actuator is not damaged by the test pressure.
The maximum permissible pressure in the actuator must not be exceeded. Dis -
connect all external control lines.
 Make sure the regulators are frost protected when they are used to control
freezing process media, e.g. water. If the regulator is installed in locations sub -
ject to frost, the regulator must be removed from the pipeline when it is not
operated.

EB 2517 EN 3
 Design and principle of operation

1. Design and principle of operation Depending on the valve and actuator used,
the regulator can be extended to form a mil-
The Type 41-73 Excess Pressure Valve con- libar excess pressure valve or a safety ex-
sists of a Type 2417 Opening Valve and a cess pressure valve.
Type 2413 Actuator.
The valve and actuator are delivered as sep-
arate items and must be assembled accord-
ing to the instructions in section 2.1.
The excess pressure valve is used to main-
tain the pressure upstream of the valve at
an adjusted set point.
The process medium to be regulated flows
through the valve between the seat (2) and the
plug (3) in the direction indicated by the
arrow on the body. The position of the valve
plug determines the flow rate, and thus the
pressure ratio at the valve. The plug stem is
sealed by a frictionless metal bellows (5.1).
The upstream pressure p1 is transmitted
through the condensation chamber (18)
and the control line (17) to the operating 1 Valve body
diaphragm (12) and is converted into a po- 2 Seat
sitioning force. For actuator versions with 3 Plug
4 Balancing bellows
bellows, the pressure is transmitted to the 5 Plug stem
operating bellows (12.1). 5.1 Bellows seal
The positioning force is used to move the 6 Set point adjustment
valve plug according to the force of the posi- 7 Positioning springs
8 Bracket
tioning springs (7). The spring force is adju-
9 Fastening nuts
stable at the set point adjustment (6). 10 Actuator
The control valves with a Kvs value of 2.5 or 11 Actuator stem
higher feature a balancing bellows (4). The 12 Operating diaphragm
upstream pressure acts on the outer bellows 12.1 Operating bellows
13 Diaphragm plate
surface, the downstream pressure on the 14 Nut
inner bellows surface. As a result, the forces 15 Nuts and bolts
produced by the upstream and downstream 16 Control line connection (with screw joint with
pressures acting on the plug are balanced. restriction for steam)
17 Control line to be provided by the operator
(control line kit also available as accessory for
connection directly at the valve body)
18 Condensation chamber
19 Filler neck

4 EB 2517 EN
 Design and principle of operation

18 19
1

6
4

16 5.1

7
12.1 Pillar turned
90 into plane
of projection

9
Actuator with operating bellows (12.1)
for 5 to 10, 20 to 28 and 10 to 22 bar 17 8

15 11

12
10
16 13
14

DN 65 to 100

Fig. 2 Sectional drawings

EB 2517 EN 5
 Installation
2. Installation
2.1 Assembly
Valve and actuator can be assembled be-
fore or after the control valve has been in-
stalled in the pipeline.
Push the actuator (10) with the actuator
stem (11) through the hole in the bracket (8)
onto the spigot of the bellows seal (5.1).
Align and secure it with the nuts (9, width
across flats SW 17).
For actuators with metal bellows in sizes
DN 65 to 100, remove the bracket (8) from
the valve and unscrew the pillar.
Screw the pillar into the actuator flange.
Push the actuator onto the valve and secure
the pillar at the valve flange using nuts.
2.2 Mounting position
Caution!
Flush the pipeline thoroughly before install-
ing the regulator to ensure that any sealing
parts, weld spatter and other impurities car-
ried along by the process medium do not
impair the proper functioning of the valve,
above all the tight shut-off.
A strainer (SAMSON Type 2) must be in-
stalled upstream of the regulator (see sec-
tion 2.4).
Install the pressure reducing valve in a hori-
zontal pipeline. On installing the valve,
make sure the direction of flow corresponds
with the arrow on the body.
For media with a tendency to condensate,
install the pipeline with a slight downward
slope on both sides so that the condensate
can drain properly.
6 EB 2517 EN
If the pipeline upstream and downstream of
the valve is routed vertically upwards, an
automatic water drainage (SAMSON
Type 13E Steam Trap) is required.
Make sure you choose a place of installa-
tion that allows you to freely access the
regulator even after the entire plant has
been completed.
The regulator must be installed free of
stress. If necessary, support the piping near
the connections.
Caution!
Never attach supports directly to the valve
or actuator.
Do not install any devices (e.g. temperature
regulators or shut-off valves) which restrict
the cross-section of the pipe between the
pressure tapping point and the control valve.
If a bypass line is to be used, it must be con-
nected upstream of the pressure tapping
point. Install a shut-off valve in the bypass
line.
Standard mounting position for
medium temperatures above 0 C.
Not permissible for millibar excess
pressure valves!
Optional mounting position for gases
and liquids up to medium temperatures
of 80 C. Mandatory mounting posi-
tion for millibar excess pressure valves.
Not permissible.
 Installation

2.3 Control line, condensation Weld the line coming from the pressure tap-
chamber and screw joint with re- ping point to the 3/8" filler neck on the con-
densation chamber.
striction The condensation chamber must always be
A control line must be provided in the form installed at the highest point of the pipeline.
of a 3/8" pipe for steam and an 8 x 1 or Consequently, the control line between con-
6 x 1 mm pipe for air/water. densation chamber and actuator must also
be installed with a downward slope. In this
Control line kit: case, use a 3/8" pipe with screw gland.
A kit for tapping pressure directly at the
valve body is available as an accessory. Connect the control line to the upstream line
(p1) at least one meter away from the valve
Condensation chamber:
outlet (Fig. 3).
A condensation chamber is required for
liquids above 150 C as well as for steam.
Note!
The mounting position of the condensation
If the regulator tends to hunt, we recom-
chamber is indicated by an adhesive label
mend to mount a SAMSON screw joint with
on the chamber itself as well as by an
restriction on the control line connec-
arrow and the word "top" stamped onto the
tion (16).
top of the chamber.
This mounting position must be adhered to;
otherwise the safe functioning of the excess
pressure valve cannot be guaranteed.

1 2 3 4 5 6 7

1 Shut-off valve
2 Upstream pressure gauge
3 Strainer
4 Condensation chamber
Caution! 5 Excess pressure valve
Millibar excess pressure valves must be installed 6 Downstream pressure gauge
vertically with the actuator on top. 7 Shut-off valve

Fig. 3 Installation example

EB 2517 EN 7
 Operation
2.4 Strainer
The strainer must be installed upstream of
the excess pressure valve.
Make sure the direction of medium flow
corresponds with the direction indicated by
the arrow on the strainer. The filter element
must be vertically suspended. Remember to
leave enough space to remove it.
2.5 Shut-off valve
We recommend to install a hand-operated
shut-off valve both upstream of the strainer
and downstream of the regulator to be able
to shut down the plant for cleaning and
maintenance, and when the plant is not
used for longer periods of time.
2.6 Pressure gauge
To monitor the pressures in the plant, install
a pressure gauge both upstream and down-
stream of the regulator. Note that the press-
ure gauge on the upstream side should not
be installed upstream of the pressure tap-
ping point.
8 EB 2517 EN
3. Operation
3.1 Start-up
Caution!
For millibar excess pressure valves
(1200 cm2 actuator), the max. permissible
differential pressure is 10 bar. The max. per -
missible pressure at the actuator must not ex -
ceed 0.5 bar.
For regulating steam:
Unscrew filler neck (19) on the condensa-
tion chamber. Using either the included
plastic funnel or a jug, pour in water until it
starts to overflow.
Screw the filler neck back in and tighten it.
The excess pressure valve is now ready for
operation.
Open the hand-operated shut-off valves
slowly to prevent water hammer.
For regulating liquids:
To start up the excess pressure valve, open
shut-off valves slowly.
For actuators with an effective diaphragm
area of 640 cm2, loosen the vent screw.
Allow all the air to escape, then retighten it.
For temperatures above 150 C, the necess-
ary condensation chamber must first be
filled with the process medium.
3.2 Set point adjustment
The required upstream pressure (excess
pressure) is set by turning the set point ad-
justment (6) using an open-end wrench up
to DN 50 with width across flats SW 19
and for DN 65 and larger with SW 22.

Turning clockwise increases the upstream
pressure, turning counterclockwise reduces
it. The pressure gauge located on the up-
stream pressure side allows the adjusted set
point to be monitored.
4. Maintenance Troubleshooting
The excess pressure valve is maintenance
free. Nevertheless, it is subject to natural
wear, particularly at the seat, plug and
operating diaphragm.
Depending on the operating conditions, the
regulator needs to be checked at regular in-
tervals to avoid possible malfunctions.
Details on faults and how to correct them
can be found in the table on page 10.
If a problem cannot be solved with the help
of the information specified in the table, con-
tact SAMSON.
Note!
If a repair is performed by the plant oper-
ator, make absolutely sure that no torque is
applied to the bellows seal (5.1) during as-
sembly or disassembly. Otherwise, the met-
al bellows would be destroyed.
Caution!
When working on the pressure regu-
lator, make sure the relevant section
of the pipeline is depressurized and,
depending on the process medium,
drained as well. For high tempera-
tures, allow the regulator to cool
down to ambient temperature be-
fore starting any work on it.
The control line must be interrupted
or shut off to avoid any hazards
which could be caused by moving
Maintenance Troubleshooting
parts of the regulator.
As valves are not free of cavities,
remember that residual process
medium might still be contained in
the valve. This applies in particular
to valve versions with a balancing
bellows.
It is recommended to remove the
valve from the pipeline.
4.1 Replacing the operating dia-
phragm
If the excess pressure deviates from the set
point considerably, check if the diaphragm
is leaking and, if necessary, replace it.
1. Shut down the plant by slowly closing
the shut-off valves. Relieve the relevant
section of the pipeline of pressure and,
if necessary, drain it as well.
2. Unscrew the control line (17) and clean
it.
3. Loosen the bolts (15) at the actuator
and remove the cover plate.
4. Unscrew the nut (14) and lift off the dia-
phragm plate (13).
5. Replace the operating diaphragm (12)
with a new one.
6. Proceed in the reverse order to reas-
semble the regulator. For start-up, pro-
ceed as described in section 3.1.
EB 2517 EN 9
 Maintenance Troubleshooting

Fault Possible reasons Solution

Pressure Pressure impulse on the actuator
exceeds the diaphragm not sufficient
adjusted set
Seat and plug worn out by
point
deposits or foreign particles
Pressure tapped in wrong location
When used to regulate steam:
Condensate chamber improperly
positioned or chamber too small
Control response too slow
Clean the control line and screw
joint with restriction
Disassemble the regulator and
exchange the damaged parts
Rebuild the control lines, do not
tap at pipe bends or necks
Reinstall or exchange the
condensation chamber, required
size for 160 cm2 actuators: 0.7 l,
for 320 cm2 and larger: 1.7 l
Install larger screw joint with
restriction at the diaphragm
actuator

Pressure drops Foreign particle blocks the plug Disassemble the regulator and
below the exchange the damaged parts
adjusted set
Valve installed against direction of Check direction of flow,
point
flow, see arrow on the body reinstall the valve
Pressure tapped in wrong location Rebuild the control line
When used to regulate steam: Reinstall the condensation chamber,
Condensation chamber improperly see Fig. 3 for mounting position
positioned
Jolting control Increased friction, e.g. due to Exchange the damaged parts
response foreign particles between the seat
and plug
Slow control Restriction in the actuator screw Install larger screw joint with
response joint too small restriction
Dirt in the control line Clean the control line
Upstream Valve too large Check sizing, choose smaller KVS
pressure hunts value if necessary
Restriction in the actuator screw Install smaller screw joint with
joint too large restriction
Inappropriate pressure tapping Choose appropriate pressure
point tapping point

10 EB 2517 EN
 Description of nameplates

High noise High flow velocity, cavitation Check sizing,

emission install a flow divider when used to
regulate steam and gases

5. Description of nameplates

Valve nameplates 1 Valve type

2 Model number
2 3 1 4 5 3 Model number index
4 Order number or date
SAMSON No Kvs 5 K85 value
bar DN PN p bar T C 8 Nominal size
Made in Germany
9 Nominal pressure
10 Perm. differential pressure
DIN version 8 9 10 11 12 11 Perm. temperature
12 Body material

With ANSI version

5 Size
2 3 1 4 5 8 Perm. differential pressure
9 Perm. temperature (F)
SAMSON No Size 10 Body material
psi
N p psi T F Cv Cl
Made in Germany 11 C8 value (K85 x 1.17)
12 ANSI Class (pressure rating)
ANSI version 8 9 10 11 12

Actuator nameplate 1 Model number

2 Model number index
2 3 4 3 Order number or date
1 12
4 Effective area
5 Labeling acc. to DIN
SAMSON sq.in 2002
Type No A cm 2 0062 6 Labeling acc. to ANSI
PN psi Size psi psi
DIN ANSI pmax bar DN bar bar
Made in Germany
7 Maximum perm. pressure
8 Nominal size
9 Differential pressure
5 6 7 8 9 10 11 10 Set point range
11 Diaphragm material
12 Year of manufacture

Fig. 4 Nameplates

EB 2517 EN 11
 Dimensions in mm and weights

6. Dimensions in mm and weights

DN 15 20 25 32 40 50 65 80 100
Set point range Length L 130 150 160 180 200 230 290 310 350
PN 16 464 556
bar L1 220 256 278 314 337 380 510
PN 40 471 570
Height H1 335 390 510 525
Height H3 55 72 100 120
0.005...0.03 Height H 435
Actuator D = 490 mm A = 1200 cm
0.025...0.05 Height H 435 490 610
Actuator D = 490 mm A = 1200 cm
0.05...0.25 Height H 445 500 620 635
Actuator D = 380 mm A = 640 cm
0.1...0.6 Height H 445 500 620 635
Actuator D = 380 mm A = 640 cm
0.2...1.2 Height H 430 480 600 620
Actuator D = 285 mm A = 320 cm
0.8...2.5 Height H 430 485 605 620
Actuator D = 225 mm A = 160 cm
2...5 Height H 410 465 585 600
Actuator D = 170 mm A = 80 cm
4.5...10 Height H 410 465 585 600
Actuator D = 170 mm A = 40 cm
8...16 Height H 410 465 585 600
Actuator D = 170 mm A = 40 cm
0.005...0.05 28.5 29.5 33.5 37.5 41 57 64
Weight for
0.05...0.6 22.5 23.5 29.5 31.5 35 51 58 67
cast iron PN 16 
0.2...2.5 16 18 23.5 25.5 29 45 52 61
Approx. kg
2...16 12 13 18.5 21 24 40 47 56

+10 % for cast steel PN 40 and spheroidal graphite iron PN 25

12 EB 2517 EN
 Dimensions in mm and weights

L1

H3

Conical
expansion piece
H1

H max. 215

D
25

EB 2517 EN 13
 Customer inquiries

7. Customer inquiries
If you have any questions regarding the
excess pressure valve, please submit the
following details (also see nameplate):
 Regulator type and nominal size
 Product and order number as specified
on the nameplate
 Pressure upstream and downstream of
the valve
 Flow rate in m3/h
 Has a strainer been installed?
 Installation drawing

14 EB 2517 EN
EB 2517 EN 15
 S/Z 2003-10

SAMSON AG MESS- UND REGELTECHNIK

Weismllerstrae 3 60314 Frankfurt am Main Germany
Phone: +49 69 4009-0 Fax: +49 69 4009-1507
Internet: http://www.samson.de EB 2517 EN
Universal Pressure Reducing Valve
Type 41-23

Fig. 1 Type 41-23 Universal Pressure Reducing Valve

Mounting and
Operating Instructions

EB 2512 EN
Edition September 2003
 Contents

Contents Page
1. Design and principle of operation . . . . . . . . . . . . . . . . . . . . . . 4
2. Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
2.1 Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
2.2 Mounting position . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
2.3 Control line, condensation chamber and screw joint with restriction . . . . . . 7
2.4 Strainer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
2.5 Shut-off valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
2.6 Pressure gauge . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
3. Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
3.1 Start-up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
3.2 Set point adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
4. Maintenance Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . 9
4.1 Replacing the operating diaphragm . . . . . . . . . . . . . . . . . . . . . 10
5. Description of nameplates . . . . . . . . . . . . . . . . . . . . . . . . . . 12
6. Dimensions in mm and weights . . . . . . . . . . . . . . . . . . . . . . . 14
7. Customer inquiries . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15

2 EB 2512 EN
 Safety instructions

General safety instructions

 The pressure regulator may only be mounted, started up or serviced by fully
trained and qualified personnel, observing the accepted industry codes and
practices. Make sure employees or third persons are not exposed to any
danger.
 The pressure regulator fulfils the requirements of the European Pressure Equip -
ment Directive 97/23/EC. Valves with a CE marking have a declaration of
conformity which includes information about the applied conformity assess -
ment procedure. The declaration can be viewed and downloaded on the Inter -
net at http://www.samson.de.
 For appropriate operation, make sure that the regulator is only used in areas
where the operating pressure and temperatures do not exceed the operating
values which are based on the valve sizing data submitted in the order.
The manufacturer does not assume any responsibility for damage caused by
external forces or any other external influence!
Any hazards which could be caused in the pressure regulator by the process
medium, the operating pressure or by moving parts are to be prevented by
means of the appropriate measures.
 Proper shipping and appropriate storage are assumed.
Caution!
 Self-operated regulators must not be put into operation before all compo -
nents, e.g. valve, actuator and control lines, have been mounted.
Open all control lines and check that they are correctly connected prior to
start-up.
 When removing the self-operated regulator from the pipeline, make sure the
sections of the pipeline that the control lines are connected to are also depress -
urized. If this is not possible, shut off the control lines.
 Allow the plant to fill up slowly on start-up.
On pressurizing the plant to carry out a pressure test, make sure the dia -
phragm actuator is not damaged by the test pressure.
The maximum permissible pressure in the actuator must not be exceeded. Dis -
connect all external control lines.
 Make sure the regulators are frost protected when they are used to control
freezing process media, e.g. water. If the regulator is installed in locations sub -
ject to frost, the regulator must be removed from the pipeline when it is not
operated.

EB 2512 EN 3
 Design and principle of operation

1. Design and principle of oper- Depending on the valve and actuator used,
ation the regulator can be extended to form a mil-
libar pressure reducing valve, steam press-
The Type 41-23 Pressure Reducing Valve ure reducing valve or a safety pressure re-
consists of a Type 2412 Closing Valve and ducing valve.
a Type 2413 Actuator.
The valve and actuator are delivered as sep-
arate items and must be assembled accord-
ing to the instructions in section 2.1.
The pressure reducing valve is used to main-
tain the pressure downstream of the valve at
an adjusted set point.
The process medium to be regulated flows
through the valve between the seat (2) and the
plug (3) in the direction indicated by the
arrow on the body. The position of the valve
plug determines the flow rate, and thus the
pressure ratio at the valve. The plug stem is
sealed by a frictionless metal bellows (5.1).
The downstream pressure p2 is transmitted 1 Valve body
through the condensation chamber (18) 2 Seat
and the control line (17) to the operating 3 Plug
diaphragm (12) and is converted into a po- 4 Balancing bellows
5 Plug stem
sitioning force. For actuator versions with 5.1 Bellows seal
bellows, the pressure is transmitted to the 6 Set point adjustment
operating bellows (12.1). 7 Positioning springs
The positioning force is used to move the 8 Bracket
9 Fastening nuts
valve plug according to the force of the posi-
10 Actuator
tioning springs (7). The spring force is adju- 11 Actuator stem
stable at the set point adjustment (6). 12 Operating diaphragm
The control valves with a Kvs value of 2.5 or 12.1 Operating bellows
higher feature a balancing bellows (4). The 13 Diaphragm plate
14 Nut
upstream pressure acts on the outer bellows 15 Nuts and bolts
surface, the downstream pressure on the 16 Control line connection (with screw joint with
inner bellows surface. As a result, the forces restriction for steam)
produced by the upstream and downstream 17 Control line to be provided by operator
(control line kit also available as accessory for
pressures acting on the plug are balanced.
connection directly at the valve body)
18 Condensation chamber
19 Filler neck
20 Anti-rotation clip

4 EB 2512 EN
 Design and principle of operation

1
19
2

18
4

5
6

5.1
12.1
Pillar turned 17
90 into plane DN 15 to 50
of projection

20 Actuators with metal bellows for

9 5 to 10, 20 to 28 and 10 to 22 bar
8

10
15

11 16
12
13
14

DN 65 to 100

Fig. 2 Sectional drawings: valve with diaphragm actuator and actuators with operating bellows (12.1)

EB 2512 EN 5
 Installation
2. Installation
2.1 Assembly
Valve and actuator can be assembled be-
fore or after the control valve has been in-
stalled in the pipeline.
Push the actuator (10) with the actuator
stem (11) through the hole in the bracket (8)
onto the spigot of the bellows seal (5.1).
Align and secure it with the nuts (9, width
across flats SW 17).
For actuators with metal bellows in sizes
DN 65 to 100, remove the bracket (8) from
the valve and unscrew the pillar.
Screw the pillar into the actuator flange.
Push the actuator onto the valve and secure
the pillar at the valve flange using nuts.
2.2 Mounting position
Caution!
Flush the pipeline thoroughly before install-
ing the regulator to ensure that any sealing
parts, weld spatter and other impurities car-
ried along by the process medium do not
impair the proper functioning of the valve,
above all the tight shut-off.
A strainer (SAMSON Type 2) must be in-
stalled upstream of the regulator (see sec-
tion 2.4).
Install the pressure reducing valve in a hori-
zontal pipeline. On installing the valve,
make sure the direction of flow corresponds
with the arrow on the body.
For media with a tendency to condensate,
install the pipeline with a slight downward
slope on both sides so that the condensate
can drain properly.
6 EB 2512 EN
If the pipeline upstream and downstream of
the valve is routed vertically upwards, an
automatic water drainage (SAMSON
Type 13E Steam Trap) is required.
Make sure you choose a place of installa-
tion that allows you to freely access the
regulator even after the entire plant has
been completed.
The regulator must be installed free of
stress. If necessary, support the piping near
the connections.
Caution!
Never attach supports directly to the valve
or actuator.
Do not install any devices (e.g. temperature
regulators or shut-off valves) which restrict
the cross-section of the pipe between the
pressure tapping point and the control valve.
If a bypass line is to be used, it must be con-
nected downstream of the pressure tapping
point. Install a shut-off valve in the bypass
line.
Standard mounting position for
medium temperatures above 0 C.
Not permissible for millibar pressure
regulators!
Optional mounting position for gases
and liquids up to medium tempera-
tures of 80 C. Mandatory mounting
position for millibar pressure regula-
tors.
Not permissible.
Fig. 3 Mounting positions
 Installation

2.3 Control line, condensation
chamber and screw joint with re-
striction
A control line must be provided in the form
of a 3/8" pipe for steam and an 8 x 1 or
6 x 1 mm pipe for air/water.
Control line kit:
A kit for tapping pressure directly at the
valve body is available as an accessory.
Condensation chamber:
A condensation chamber is required for
liquids above 150 C as well as for steam.
The mounting position of the condensation
chamber is indicated by an adhesive label
on the chamber itself as well as by an
arrow and the word "top" stamped onto the
top of the chamber.
This mounting position must be adhered to;
otherwise the safe functioning of the press-
ure reducing valve cannot be guaranteed.
Weld the line coming from the pressure tap-
ping point to the 3/8" filler neck on the con-
densation chamber.
The condensation chamber must always be
installed at the highest point of the pipeline.
Consequently, the control line between con-
densation chamber and actuator must also
be installed with a downward slope. In this
case, use a 3/8" pipe with screw gland.
Connect the control line to the downstream
line (p2) at least one meter away from the
valve outlet (Fig. 4.1).

1 2 3 5 4 6 7

1 Shut-off valve
2 Upstream pressure gauge
3 Strainer
4 Condensation chamber
5 Pressure reducing valve
6 Downstream pressure gauge
7 Shut-off valve
8 Steam trap
Min.1/2"
4.1 Control line connection (pipeline)
4.3 Connection below
Caution! Millibar pressure regulators must be center of flange
installed vertically with the actuator on top.
6

1 2 3 5

Additional
8 condensate head

4.2 Control line connection (manifold) 4.4 Connection above center

of flange
Fig. 4 Installation examples with steam

EB 2512 EN 7
 Installation

If a manifold is located downstream of the 2.5 Shut-off valve

pressure reducing valve (Fig. 4.2), connect
the valve to the manifold, even if it is sev- We recommend to install a hand-operated
eral meters away. shut-off valve both upstream of the strainer
If the downstream pressure line behind the and downstream of the regulator to be able
valve is extended by means of a conical ex- to shut down the plant for cleaning and
pansion piece, always connect the control maintenance, and when the plant is not
line in the expanded section of the line. The used for longer periods of time.
control line must be welded at the side in
the middle of the pipe, inclining at a ratio 2.6 Pressure gauge
of approximately 1 : 10 up to the condensa-
tion chamber. To monitor the pressures in the plant, install
If the control line connection is located a pressure gauge both upstream and down-
below the center of the valve outlet flange, stream of the regulator. Note that the press-
the condensation chamber must be located ure gauge on the downstream side should
at the level of the outlet flange (Fig. 4.3). In not be installed upstream of the down-
this case, use a pipe which is at least 1/2" stream pressure tapping point.
in size for the control line from the tapping
point to the condensation chamber.
When the control line is connected above
the center of the valve outlet, install the con-
densation chamber at the level of the down-
stream pressure tapping point (Fig. 4.4).
The additional pressure of the condensate
head must be compensated for by adjusting
the set point to a higher value.
Needle valve:
If the regulator tends to hunt, we recom-
mend to install a needle valve in the control
line.

2.4 Strainer
The strainer must be installed upstream of
the pressure reducing valve.
Make sure the direction of medium flow
corresponds with the direction indicated by
the arrow on the strainer. The filter element
must be vertically suspended. Remember to
leave enough space to remove it.

8 EB 2512 EN

3. Operation
3.1 Start-up
Caution!
For millibar pressure reducing valves
(1200 cm2 actuator), the max. permissible
differential pressure is 10 bar. The max. per -
missible pressure at the actuator must not ex-
ceed 0.5 bar.
For regulating steam:
Unscrew filler neck (19) on the condensa-
tion chamber. Using either the included
plastic funnel or a jug, pour in water until it
starts to overflow.
Screw the filler neck back in and tighten it.
The pressure reducing valve is now ready
for operation.
Open the hand-operated shut-off valves
slowly to prevent water hammer.
For regulating liquids:
To start up the pressure reducing valve,
open shut-off valves slowly.
For actuators with an effective diaphragm
area of 640 cm2, loosen the vent screw.
Allow all the air to escape, then retighten it.
For temperatures above 150 C, the necess-
ary condensation chamber must first be
filled with the process medium.
3.2 Set point adjustment
The required downstream pressure is set by
turning the set point adjustment (6) using an
open-end wrench up to DN 50 with width
across flats SW 19 and for DN 65 and
larger with SW 22.
Turning clockwise increases the downstream
Operation
pressure, turning counterclockwise reduces
it. The pressure gauge located on the down-
stream pressure side allows the adjusted set
point to be monitored.
4. Maintenance Troubleshooting
The pressure reducing valve is maintenance
free. Nevertheless, it is subject to natural
wear, particularly at the seat, plug and
operating diaphragm.
Depending on the operating conditions, the
regulator needs to be checked at regular in-
tervals to avoid possible malfunctions.
Details on faults and how to correct them
can be found in the table on page 10.
If a problem cannot be solved with the help
of the information specified in the table, con-
tact SAMSON.
Note!
If a repair is performed by the plant oper-
ator, make absolutely sure that no torque is
applied to the bellows seal (5.1) during as-
sembly or disassembly. Otherwise, the met-
al bellows would be destroyed.
When disassembling the valve, set the anti-
rotation clip (20, Fig. 2 left) to "unlock". On
reassembly set the clip back to "lock". Also
observe the note on the bracket (8).
EB 2512 EN 9
 Maintenance Troubleshooting
Caution!
When working on the pressure regu-
lator, make sure the relevant section
of the pipeline is depressurized and,
depending on the process medium,
drained as well. For high tempera-
tures, allow the regulator to cool
down to ambient temperature be-
fore starting any work on it.
The control line must be interrupted
or shut off to avoid any hazards
which could be caused by moving
parts of the regulator.
As valves are not free of cavities, re-
member that residual process me-
dium might still be contained in the
valve. This applies in particular to
valve versions with a balancing bel-
lows.
It is recommended to remove the
valve from the pipeline.
Fault Possible reasons
Pressure Pressure impulse on the actuator
exceeds the diaphragm not sufficient
adjusted set
Seat and plug worn out by
point
deposits or foreign particles
Pressure tapped in wrong location
When used to regulate steam:
Condensation chamber
improperly positioned or chamber
too small
Control response too slow
10 EB 2512 EN
4.1 Replacing the operating dia-
phragm
If the downstream pressure deviates from
the set point considerably, check if the dia-
phragm is leaking and, if necessary, re-
place it.
1. Shut down the plant by slowly closing
the shut-off valves. Relieve the relevant
section of the pipeline of pressure and,
if necessary, drain it as well.
2. Unscrew the control line (17) and clean it.
3. Loosen the bolts (15) at the actuator
and remove the cover plate.
4. Unscrew the nut (14) and lift off the dia-
phragm plate (13).
5. Replace the operating diaphragm (12)
with a new one.
6. Proceed in the reverse order to reas-
semble the regulator. For start-up, pro-
ceed as described in section 3.1.
Solution
Clean the control line and screw
joint with restriction
Disassemble the regulator and
exchange the damaged parts
Rebuild the control lines, do not
tap at pipe bends and necks
Reinstall or exchange the
condensation chamber, required
size for 160 cm2 actuators: 0.7 l,
for 320 cm2 and larger: 1.7 l
Install larger screw joint with
restriction at the diaphragm
actuator

Pressure drops Foreign particle blocks the plug
below the
adjusted set
Valve installed against direction of
point
flow, see arrow on the body
Pressure tapped in wrong location
Valve or KVS value too small
Control response too slow
When used to regulate steam:
Condensation chamber
improperly positioned
Jolting control Increased friction, e.g. due to
response foreign particles between seat and
plug
Slow control Restriction in the actuator
response screw joint too small
Dirt in the control line
Upstream Valve too large
pressure hunts
Restriction in the actuator
screw joint too large
Inappropriate pressure tapping
point
High noise High flow velocity, cavitation
emission
Maintenance Troubleshooting
Disassemble the regulator and
exchange the damaged parts
Check direction of flow,
reinstall the valve
Rebuild the control line
Check sizing, install larger valve if
necessary
Install larger needle valve at the
diaphragm actuator
Reinstall the condensation
chamber; see Fig. 3 for mounting
position
Exchange the damaged parts
Install larger screw joint with
restriction
Clean the control line
Check sizing, choose smaller KVS
value if necessary
Install smaller screw joint with
restriction
Choose an appropriate pressure
tapping point
Check sizing,
install a flow divider when used to
regulate steam and gases
EB 2512 EN 11
 Description of nameplates

5. Description of nameplates

Valve nameplates

2 3 1 4 5 1 Valve type
2 Model number
SAMSON No Kvs 3 Model number index
bar DN PN p bar T C 4 Order number or date
Made in Germany
5 K85 value
8 Nominal size
DIN version 8 9 10 11 12
9 Nominal pressure
10 Perm. differential pressure
11 Perm. temperature
12 Body material
2 3 1 4 5 With ANSI version
5 Size
SAMSON No Size
8 Perm. differential pressure
psi
N p psi T F Cv Cl
Made in Germany 9 Perm. temperature (F)
10 Body material
ANSI version 8 9 10 11 12 11 C8 value (K85 x 1.17)
12 ANSI Class (pressure rating)

Actuator nameplate 1 Model number

2 Model number index
2 3 3 Order number or date
1 4 12
4 Effective area
5 Labeling acc. to DIN
SAMSON sq.in 2002
Type No A cm 2 0062 6 Labeling acc. to ANSI
PN psi Size psi psi
DIN ANSI pmax bar DN bar bar
Made in Germany
7 Maximum perm. pressure
8 Nominal size
9 Differential pressure
5 6 7 8 9 10 11 10 Set point range
11 Diaphragm material
12 Year of manufacture

Fig. 5 Nameplates

12 EB 2512 EN
EB 2512 EN 13
 Dimensions in mm and weights

6. Dimensions in mm and weights

DN 15 20 25 32 40 50 65 80 100
Set point range Length L 130 150 160 180 200 230 290 310 350
PN 16 464 556
bar L1 220 256 278 314 337 380 510
PN 40 471 570
Height H1 335 390 510 525
Height H3 55 72 100 120
0.005...0.03 Height H 435
Actuator D = 490 mm A = 1200 cm
0.025...0.05 Height H 435 490 610
Actuator D = 490 mm A = 1200 cm
0.05...0.25 Height H 445 500 620 635
Actuator D = 380 mm A = 640 cm
0.1...0.6 Height H 445 500 620 635
Actuator D = 380 mm A = 640 cm
0.2...1.2 Height H 430 480 600 620
Actuator D = 285 mm A = 320 cm
0.8...2.5 Height H 430 485 605 620
Actuator D = 225 mm A = 160 cm
2...5 Height H 410 465 585 600
Actuator D = 170 mm A = 80 cm
4.5...10 Height H 410 465 585 600
Actuator D = 170 mm A = 40 cm
8...16 Height H 410 465 585 600
Actuator D = 170 mm A = 40 cm
0.005...0.05 28.5 29.5 33.5 37.5 41 57 64
Weight for
0.05...0.6 22.5 23.5 29.5 31.5 35 51 58 67
cast iron PN 16 
0.2...2.5 16 18 23.5 25.5 29 45 52 61
Approx. kg
2...16 12 13 18.5 21 24 40 47 56

+10 % for cast steel PN 40 and spheroidal graphite iron PN 25

14 EB 2512 EN
 Customer inquiries

L1

H3

Conical expansion
piece

H1 max. 215
H
25

7. Customer inquiries
If you have any questions regarding the
pressure reducing valve, please submit the
following details (also see nameplate):
 Regulator type and nominal size
 Product and order number as specified
on the nameplate
 Pressure upstream and downstream of
the valve
 Flow rate in m3/h
 Has a strainer been installed?
 Installation drawing

EB 2512 EN 15
 S/Z 2003-10

SAMSON AG MESS- UND REGELTECHNIK

Weismllerstrae 3 60314 Frankfurt am Main Germany
Phone: +49 69 4009-0 Fax: +49 69 4009-1507
Internet: http://www.samson.de EB 2512 EN
Accessories
Intermediate Tank for
Controllers
Type 39-2 (2392), Type 41-23 (2412/2413) and
Type 41-73 (2417/2413)
and Actuators
Types 2415, 2418, 2424, 2425, 2426, 2427 and 2429

1. Application
To ensure proper functioning of the controller
versions listed above, an intermediate tank is
to be installed in each associated control line.
This tank is intended to protect the operating
diaphragm of the connected actuator when
steam and liquids above 150 C are control-
led.

Edition January 1995 Mounting and operating instructions

EB 2595 E
2. Installation
The control line is to be installed laterally at
the pipe in the middle of the pipeline or dis-
tributor. This line is to be installed with a
steady upward slope (1:10) towards the in-
termediate tank.
The mounting position of the tank is indicated
by a label marked with an arrow and the
word "top" impressed on top of the tank. This
mounting position is coercive to ensure safe
operation of the controller.
Weld the control line coming from the tap-
ping point to the R 3/8 pipe socket of the in-
termediate tank.
The intermediate tank must always be in-
stalled at the highest point of the control line.
This means, the control line connecting the in-
termediate tank and the diaphragm chamber
of the actuator is to be also installed with a
downward slope.
SAMSON AG MESS- UND REGELTECHNIK
Weismllerstrae 3 D-60314 Frankfurt am Main
Postfach 10 19 01 D-60019 Frankfurt am Main
Telefon (0 69) 4 00 90 Telefax (0 69) 4 00 95 07
3. Operation
To place the intermediate tank into service,
remove the filler plug at the tank and the vent
screw at the diaphragm actuator.
Then, use the enclosed plastics funnel tube or
a can having a bent spout to fill water (in case
of steam control) through the associated filler
socket into the intermediate tank. Fill up
water until it escapes at the vent hole.
Tighten vent screw at the actuator and fill up
water until it spills over at the filler socket of
the tank.
Reinstall filler plug and screw it tight.
If liquids are controlled, fill up the intermedi-
ate tank with the corresponding medium.
S/C 01.95
EB 2595 E