Mounting and Operating Instructions EB 8026 EN
Contents
1. 3244 1 3244 7 Pneumatic Control Valves Type 3244 1 left and Type 3244 7 right Mounting and Operating Instructions EB 8026 EN Edition July 2014 Definition of signal words DANGER Hazardous situations which if not Property damage message or mal avoided will result in death or seri function ous Injury Note WARNING Additional information Hazardous situations which if not avoided could result in death or seri ous in SE Mp jury P R ecommended action 2 EB 8026 EN mm ie i Om BR CO NNNNN gt NO a U Contents General safety instructions eesseeseeesessocesoseseesocesocescesscesoeeseceoeesoessossseesesee 4 Design and principle of operation ssscssscsssssssssssscssssssssssnscssssssesssnseees 6 Assembling valve and actuator eee eee eee cesse eee e eere eene enne 8 Assembly and adjuskmen iiieei ture etis ini 8 T ET TT 9 ee TO TO Arrangement of the valve sese 9 Signal pressure line essen 9 PCIE 9 esie PE T T 10 12 Maintenance Replacing parts sscssscsssscsssscsssccsssscssssessscssescssssessesees 12 Sindara Valve Ver O aeren E 13 TT 13 SEO And Dee 14 Valve with insulating section or bellows 14 Ae el in2. as well and replace it 8 Apply a suitable lubricant and sealant to the thread and sealing cone of the seat rings as well as a suitable lubricant to the plug stem 9 Assemble in the reverse order Observe gt EB 029 EN for tightening torques of seat rings and nuts on the body flange Diverting valve DN 32 to 150 DN 15 to 25 as for mixing valves 5 Remove screws 3 2 and take the plug section 3 1 along with its seal off the plug 3 6 Proceed as described in items 6 to 9 for mixing valves When assembling the plug stem 3 1 check the seal and re new it if necessary Mixing and diverting valve 10 Loosely screw the lock nut 6 2 and stem connector nut 6 1 onto the plug stem 1 1 Mount the actuator Refer to section 3 1 12 Adjust the upper and lower bench range values See section 3 1 6 2 Valve with insulating sec tion or bellows seal 6 2 1 1 Unthread the stem connector nut 6 1 and lock nut 6 2 from the plug stem ex tension 6 3 2 Unscrew the threaded bushing 5 2 of the packing 3 Remove nuts 5 4 Packing 4 Carefully lift the bonnet 5 over the plug stem extension 5 Pull all the packing parts out of the pack ing chamber using a suitable tool 6 Replace damaged parts 7 Clean the packing chamber thoroughly 8 Remove gasket 5 1 in the intermediate piece 12 9 Carefully clean the sealing faces 10 Apply a suitable lubricant to all the parts and to th
3. the Type 3277 Actuator 7 For actuators with actuator stem ex tends fail safe action apply a signal pressure that corresponds to the lower bench range value e g 0 2 bar to the connection on the bottom diaphragm chamber For actuators with actuator stem re tracts fail safe action apply a signal pressure that corresponds to the upper bench range value e g 1 bar to the top diaphragm chamber connection 8 Screw on the stem connector nut 6 1 by hand until it touches the actuator stem 8 1 Then turn it a further 1 4 turn and secure this position with the lock nut 6 2 9 Position clamps of the stem connector 7 and screw them tight 10 Align the travel indicator 5 3 with the tip of the stem connector EB 8026 EN A Installation 4 1 Mounting position The valve can be mounted in any desired position However fo avoid increase wear at the packing install valves in DN 100 or larger in the upright position with the actua tor on top For valves fitted with an insulating section or bellows seal and for actuators weighing more than 50 kg the actuator needs to be supported or suspended Install the free of stress Pipeline routing To ensure that the control valve func tions properly the pipeline must be straight and without any manifolds or disturbances for a distance of at least 6 times the valve size DN upstream and downstream of the valve Con tact SAMSON if this di
4. piece 12 and secure with nuts 1 1 Observe tighten ing torques listed in the document 029 3 Insert new gasket 5 1 into the interme diate piece 4 Place on the valve bonnet 5 and fasten tight using the nuts and bolts 5 4 Ob serve tightening torques listed in EB 029 EN 5 Tighten the threaded bushing 5 2 6 Loosely screw the lock nut 6 2 and stem connector nut 6 1 onto the plug stem extension 6 3 or plug stem 7 Mount the actuator Refer to section 3 1 8 Adjust the upper and lower bench range values See section 3 1 17 Material number 7 Material number Guide bushing seat and plug have the fol lowing identifying marks Guide bushing groove on plane face groove 1 4104 Sharp recessed groove 1 4404 Flat recessed groove 2 4610 Seat The material number and article number is either stamped or engraved on the seat Stellite facing is marked by a stamped E Plug The article number is either stamped or en graved on the plug Note 1 For dimensions and weights of the valves refer to associated Data Sheet 3244 DIN or ANSI T 8026 EN Type 3246 Class 150 300 T 8046 3 EN SAMSON 8 Description of nameplates 3 9 1 CE marking or Art 3 Abs 3 where applicable ID of the notified body fluid group and category where applicable Type designation Device modification index Material Year of manufact
5. screws 3 2 through valve port B from the plug and take the plug section 3 1 along with its seal off the plug 3 6 Remove nuts 1 1 EB 8026 EN 7 Lift the intermediate piece 12 along with the plug stem extension plug stem and plug 3 out of the valve body 1 8 Tightly screw the lock nut 6 2 and stem connector nut 6 1 onto the free thread ed end of the plug stem extension to hold the plug stem stationary 9 Unscrew the plug 3 out of the plug stem extension 6 3 10 If necessary replace the metal bellows with the plug stem extension See sec tion 6 2 3 11 Replace the seats See section 6 2 2 12 Apply a suitable lubricant to the plug stem 6 of the new plug 13 Check whether the two washers 6 4 are still in the plug stem extension 14 Screw the plug stem firmly into the plug stem extension 6 3 with a tightening torque of 50 Nm for 10 mm and 140 Nm for 16 mm 6 2 3 Metal bellows See section 6 2 2 follow items 8 to 10 for mixing valves and items 9 to 10 for diverting valves 1 Pull the plug stem extension with the met al bellows 6 6 welded onto it out of the intermediate piece 2 Clean the sealing faces on the intermedi ate piece 3 Slide the new plug stem extension with metal bellows into the intermediate piece 12 EB 8026 EN Maintenance Replacing parts 6 2 4 Assembly 1 Insert the new gasket 1 2 into the body 2 Place on the intermediate
6. the signal pressure or by moving parts are to be prevented by taking appropriate pre cautions Proper shipping and storage are assumed NOTICE For installation and maintenance make sure the relevant section of the pipeline is depressurized and depending on the process medium drained as well Depending on the field of application allow the valve to cool down or warm up to reach ambi ent temperature before starting any work on it When working on the valve make sure that the pneumatic air supply as well as the control signal are disconnected to prevent any hazards caused by moving parts Be particularly careful if the actuator springs of pneumatic control valves are pre loaded Such actuators are labeled correspondingly and can also be identified by three long bolts protruding from the bottom of the actuator Before starting any work on the valve relieve the compression from the preloaded springs EB 8026 EN General safety instructions Note D According to the ignition risk assessment performed in accordance with EN 13463 1 2001 section 5 2 the non electrical actuators and valves do not have their own po tential ignition source even in the rare incident of an operating fault As a result they do not fall within the scope of Directive 94 9 EC For connection to the equipotential bonding system observe the requirements speci lied in section 6 3 of EN 60079 14 2011 VDE 0165 Part 1 Note D These Mounti
7. 6 Nameplates of actuators EB 8026 EN 19 SAMSON AG MESS UND REGELTECHNIK Weism llerstra e 60314 Frankfurt am Main Germany Phone 49 69 4009 0 Fax 49 69 4009 1507 samson samson de www samson de EB 8026 EN 2014 11 20
8. Carefully clean the sealing faces in valve body and on the bonnet 10 Apply a suitable lubricant to all the pack ing parts and to the plug stem 6 11 Insert a new gasket 1 2 into the valve body 12 Place the valve bonnet over the plug stem onto the valve body and secure it with nuts 1 1 13 Carefully slide the packing parts 4 1 4 3 and 4 2 over the plug stem into the packing chamber Make sure you ob serve the proper order 14 Screw in the threaded bushing 5 2 and tighten it EB 8026 EN Maintenance Replacing parts 1 5 Loosely screw the lock nut 6 2 and stem connector nut 6 1 onto the plug stem 16 Mount the actuator Refer to section 3 1 17 Adjust the upper and lower bench range values See section 3 1 PTFE ring packing Washer Bonnet Threaded bushing Plug stem Fig 3 Packing 13 Maintenance Replacing parts 6 1 2 Seat and plug When replacing the seat and plug we also recommend replacing the packing 4 2 1 Unscrew the lock nut 6 2 and stem con nector nut 6 1 from the plug stem 2 Undo the threaded bushing 5 2 3 Remove body nuts 1 1 4 Carefully lift the valve bonnet 5 off the valve body over the plug stem 6 Mixing valve 5 Unscrew the top seat ring 2 1 using a SAMSON seat wrench 6 Lift out the plug stem 6 along with the plug 3 7 Check seating surfaces of the seat rings If necessary unscrew bottom seat ring 2 2
9. e plug stem extension 11 Insert new gasket 5 1 into the interme diate piece EB 8026 EN Maintenance Replacing parts Nuts Gasket Plug LJ Plug section Screws SS Packing Bonnet Gasket Threaded bushing Travel indicator scale Bolts Plug stem EIN SS pai NN NS 3 WA EE NV t K LL RSS 77728 8455 7 xa Stem connector nut rm Lock nut N 2 N LT Plug stem extension Washers DN 15 to 80 order no 8392 2317 DN 100 to 150 order no 8382 2321 Nut Metal bellows Test connection N Intermediate piece ads S i M Left mixing valve right diverting valve Fig 4 Version with bellows seal or insulating section A valve with insulating section does not contain a bellows 6 6 EB 8026 EN 15 Maintenance Replacing parts 12 Place the bonnet over the plug stem ex tension onto the intermediate piece and secure with bolts 5 4 See gt EB 029 EN for tightening torques 13 Carefully slide the packing parts 4 1 4 3 and 4 2 over the plug stem exten sion into the packing chamber Make sure you observe the proper order 14 Screw in the threaded bushing 5 2 and tighten it 15 Loosely screw the lock nut 6 2 and stem connector nut 6 1 onto the plug stem 16 Mount the actuator Refer to section 3 1 17 Adjust the upper and lower bench range values See section 3 1 6 2 2 Sea
10. flow pipe Flow pipe Flow pipe Return flow Return flow pipe pipe Flow pipe Flow pipe Return flow Return flow pipe pipe Fig 2 Typical installations EB 8026 EN 11 Operation 5 Operation e g reversing the operating direction etc Refer to the mounting and operating instruc tions of the pneumatic actuators gt 8310 EN for Type 3271 gt 8311 EN for Type 3277 6 Maintenance Replacing parts The control valve is subject to normal wear especially at the seat plug and packing De pending on the operating conditions check the valve at regular intervals to prevent pos sible failure before it can occur External leakage can indicate that the pack ing is defective or the metal bellows is defec tive in a version with a bellows seal If the valve does not close tightly tight shut off may be impaired by dirt stuck between the seat and plug or by damaged facings We recommend removing the parts cleaning them and if necessary replacing them with new ones Note Suitable seat wrenches and special tools as well as the associated tight ening torques are listed in the docu ment EB 029 EN Contact your nearest SAMSON sub sidiary or the SAMSON After sales Service department for information on suitable lubricants WARNING Before performing any work on the control valve make sure the rele vant plant section has been depres surized and depending on the proce
11. g EPEE EEO E T 14 16 Melall Be 17 ER REISE 17 PENI NUMDEr een 18 Description of nameplates sccssccsssccssscsssccesscccssscsssscessccsseccessecssssesees 18 Customer INGUINICS 19 8026 3 General safety instructions 1 General safety instructions WARNING The control valves are to be mounted started up or serviced by fully trained and qualified personnel only the accepted industry codes and practices are to be ob served Make sure employees or third persons are not exposed any danger All safety instructions and warnings given in these mounting and operating instruc tions particularly those concerning installation start up and maintenance must be strictly observed The control valves comply with the requirements of the European Pressure Equip ment Directive 97 23 EC Valves with a CE marking have a declaration of confor mity which includes information about the applied conformity assessment proce dure The Declaration of Conformity is available on request To ensure appropriate use only use the valve in applications where the operating pressure and temperatures do not exceed the specifications used for sizing the valve 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 valve by the process medium the operating pressure
12. heel or by an electric actuator A pneumatic actuator with or without hand wheel can be replaced by another pneumat ic actuator in a different size IF the travel range of the actuator is larger than the travel range of the valve the springs in the actuator are preloaded by SAMSON so that the travel ranges match 3 1 Assembly and adjustment Proceed as follows if the valve and actuator have not been assembled by SAMSON or if the actuator is to be replaced by an actuator of another type or size 1 Loosen the lock nut 6 2 and stem con nector nut 6 1 on the valve 2 Press the plug together with the plug stem firmly into the seat ring Thread down the lock nut and stem connector nut 3 Remove the clamps of the stem connector 7 and the ring nut 8 2 from the actua tor 8 4 Slide the ring nut over the plug stem 5 Place the actuator onto the valve bonnet 5 and secure it with the ring nut 8 2 6 Read the bench range or bench range with preloaded springs and the actua tor s fail safe action from the actuator s nameplate e g 0 2 to 1 bar and actua tor stem extends The lower value corresponds to the lower bench range value 0 2 bar to be adjusted whereas the upper value corresponds to the upper bench range value 1 bar The fail safe action actuator stem extends or actuator stem retracts is marked by FA or FE on the Type 3271 Actuator and by a corresponding symbol on the nameplate of
13. ng and Operating Instructions are also valid for the Type 3246 Three way Valve Class 150 and 300 in conjunction with the Data Sheet T 8046 3 EN EB 8026 EN 5 Design and principle of operation 2 Design and principle of oper ation The Type 3244 1 and Type 3244 7 Pneu matic Control Valves consist of the Type 3244 Three way Valve and either a Type 3271 or Type 3277 Pneumatic Actua tor The modular design allows the actuators to be exchanged and an insulating section or metal bellows to be fitted to the standard valve version Depending on the plug version the three way valve can be used either as a mixing or diverting valve in DN 15 to 25 the plugs are identical In mixing valves the process media to be mixed enter at valve ports A and B The combined flow exits the valve at port AB In diverting valves the process medium en ters at the valve port AB and the partial flows exit at ports A and B The flow rate from ports A or to AB and vice versa depends on the cross sectional ar ea of flow between the seat 2 1 2 2 and plug 3 and as a result on the position of the plug stem 6 The plug 3 is moved by a change in signal pressure acting on the diaphragm of the ac tuator The plug stem 6 and actuator stem 8 1 are connected by the stem connector 7 and sealed by a spring loaded PTFE ring packing 4 2 Fail safe position Depending on how the compression springs are arranged in the actuator
14. recommend installing a SAMSON Type 2 Strainer upstream of the valve and upstream of both inlet ports in mixing valves Installation We recommend installing a shut off valve both upstream of the strainer and down stream of the valve to ensure that the plant does not need to be shut down for mainte nance In addition install a bypass line 4 5 Test connection Versions with bellows seal Fig 4 fitted with a test connection s at the top flange al low the tightness of the bellows to be moni tored Particularly for liquids and vapors we recommend installing a suitable leakage in dicator such as a contact pressure gauge an outlet to an open vessel or an inspection glass 10 EB 8026 EN Installation Mixing service Diverting service Temperature control Q constant Flow control Q O to 100 Fail safe action FA Actuator stem extends FE Actuator stem retracts In heating applications with FA the heating medium flow is shut off in the fail safe position in cooling applications with FE cooling is maintained in the fail safe position Heating with mixing valve FA or cooling with mixing valve FE Installation in flow pipe Installation in return flow pipe AB Flow pipe Flow pipe Return flow Return flow pipe pipe Flow pipe Flow pipe Return flow Return flow pipe pipe Heating with diverting valve FA or cooling with diverting valve FE Installation in return flow pipe Installation in
15. ss medium drained as well When used at high temperatures allow the plant section to cool down to ambient temperature Valves are not free of cavities Therefore there might still be resid val medium in the valve This ap plies to valve versions with bellows seal or insulating section in particu lar We recommend removing the valve from the pipeline Before starting any work on the valve body disconnect the signal pressure and remove the actuator Removing the actuator from the valve D Note When removing an actuator with actuator stem extends fail safe ac tion from a valve and especially an actuator with preloaded springs ap ply a signal pressure that is slightly higher than the lower bench range value see actuator nameplate to the bottom signal pressure connection so that the ring nut 8 2 can be un screwed 1 Remove the stem connector 7 and un screw the ring nut 8 2 EB 8026 EN 2 Remove the actuator from the valve bon net Standard valve version 6 1 6 1 1 1 Unscrew the lock nut 6 2 and stem con nector nut 6 1 from the plug stem 2 Unscrew the threaded bushing 5 2 3 Remove body nuts 1 1 4 Lift the valve bonnet 5 off the valve body over the plug stem Packing 5 Pull all the packing parts out of the pack ing chamber using a suitable tool Replace damaged parts Clean the packing chamber thoroughly Remove gasket 1 2
16. stance cannot be observed Flush the pipeline thoroughly before installing the valve Note Only insulate control valves with in sulating section or bellows seal up to the bonnet flange of the valve body for medium temperatures below 0 C and above 220 C Do not insulate valves mounted to comply with NACE MRO175 require ments EB 8026 EN Installation 4 2 Arrangement of the valve Install the valve as shown in Fig 2 depend ing on whether it is to be used for mixing or diverting service The installation examples apply to standard operation with fail safe action actuator stem extends for heating applications and actu ator stem retracts for cooling applications Fail safe position The valve shuts off the flow of the heating or cooling medium The plug arrangement i e either mixing or diverting valve is indicated on a label at tached to the valve body In DN 15 to 25 the plug arrangement is the same for mixing and diverting valves 4 3 Signal pressure line Connect the signal pressure line for valves with an actuator with actuator stem ex tends fail safe action to the connection on the bottom diaphragm case and for valves with an actuator with actuator stem re tracts fail safe action to the connection on the top diaphragm case In the Type 3277 Actuator the bottom signal pressure connection is located at the side of the yoke under the bottom diaphragm case 4 4 Strainer bypass We
17. t and plug When replacing the seat and plug we also recommend replacing the packing 4 2 and gasket 5 1 To prevent damage the valve with bellows seal make sure that no torque is transferred to the bellows which is connected to the intermedi ate piece A valve with insulating section does not contain a bellows We recommend using a SAMSON clamping tool 1 Unscrew the lock nut 6 2 and stem con nector nut 6 1 from the plug stem 2 Undo the threaded bushing 5 2 3 Remove the bolts 5 4 4 Carefully lift the bonnet 5 over the plug stem extension 6 3 from the intermedi ate piece 1 2 Mixing valve 5 Insert SAMSON plug tool through valve port B to hold the plug stationary Un screw nut 6 5 using a socket wrench 6 Tightly screw the lock nut 6 2 and stem connector nut 6 1 onto the free thread ed end of the plug stem extension 6 3 to hold the plug stem stationary 7 Use the SAMSON plug tool to unscrew the plug out of the plug stem extension 8 Undo the nuts 1 1 on the body 9 Lift the intermediate piece 12 together with the plug stem extension 6 3 out of the valve body 10 If necessary replace the metal bellows with the plug stem extension see sec tion 6 2 3 11 Unscrew the top seat 2 1 12 Remove the plug from the valve body 13 Unscrew the bottom seat 2 2 Diverting valve DN 32 to 150 DN 15 to 25 as for mixing valves 5 Unscrew
18. the valve has two different fail safe positions Actuator stem extends When the pressure is relieved or the supply air fails the springs cause port B mixing valves or port A diverting valves to close The valve ports B or A are opened against the force of the springs when the signal pres sure increases Actuator stem retracts When the pressure is relieved or the supply air fails the springs cause port B mixing valves or port A diverting valves to open The valve ports B or A are closed against the force of the springs when the signal pressure increases EB 8026 EN Nuts Gasket Top seat Bottom seat Plug Plug section Screw Spring Packing Valve bonnet 3271 ND fa Ak CZ L ny 7 Design and principle of operation Threaded bushing Travel indicator scale Plug stem Type 3277 Actuator Stem connector nut Lock nut Er a 8 Stem connector Actuator Actuator stem Nut N Lo cw N 7 lt e VAS NNSNNNNNNNJ m X S ST TS SCR 2 1 A A N EB Plug arrangement for diverting service a DN 32 to 150 eo Plug arrangement for mixing service in DN 15 to 25 also for diverting service Sectional drawings EB 8026 EN Assembling valve and actuator 3 Assembling valve and actua tor The basic pneumatic actuator can be re placed by a pneumatic actuator with addi tional handw
19. ure Valve size DIN DN ANSI NPS Perm operating gauge pressure at room temperature DIN PN ANSI CL Order no with modification index Order pos Flow coefficient DIN Kys ANSI Cy Characteristic equal percentage Lin linear DIN A Z quick opening ANSI O C quick opening Plug seal ME metal ST Stellite plated Ni nickel plated PT Soft seal with PTFE PK Soft seal with PEEK Version M mixing valve V diverting valve 15 Flow divider I or Fig 5 Nameplate for valve 18 EB 8026 EN Customer inquiries SAMSON 9 Customer inquiries Hl 5 F 6 7 Please submit the following details Order number Type designation Type position and nominal size of the Modification index valve Effective area Fail safe action di FA Actuator stem extends ee FE Actuator stem retracts Flow rate in m3 h Travel Bench range of the mounted actuator Bench range spring range e g 0 2 to 1 bar Bench range with preloaded springs Is a strainer installed Pressure and temperature of the process Installation drawing Model No Serial No Pneum Stellantrieb Hub Pneum actuator cm Stroke Servo monteur pneum Course Federbereich Spring range Plage des ressorts Stelldruckbereich Signal pressure range Plage avec pr contrainte 20 feo Wo Zuluft max 6 bar Begrenzt auf Air supply 90 psi Up to Air d alimentation Limit Made in France bar Fig
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