Samson 3222 Series Service manual

Translation of original instructions
EB 5866 EN
Type3222/… Electric and Pneumatic Control Valves
Edition April 2022
Type3222/5857
Type3222/5757-3
Type3222/5757-7
Type3222/5827 Type3222/5825
Type3222/2780-1 Type3222/2780-2 with Type3760
Positioner

Definition of signal words
Hazardous situations which, if not avoided,
will result in death or serious injury
Hazardous situations which, if not avoided,
could result in death or serious injury
Property damage message or malfunction
Additional information
Recommended action
DANGER
!
WARNING
!
NOTICE
!
Note
Tip
EB 5866 EN
Note on these mounting and operating instructions
These mounting and operating instructions assist you in mounting and operating the device
safely. The instructions are binding for handling SAMSON devices. The images shown in
these instructions are for illustration purposes only. The actual product may vary.
ÎFor the safe and proper use of these instructions, read them carefully and keep them for
later reference.
ÎIf you have any questions about these instructions, contact SAMSON‘s After-sales Service
([e-mail]).
Documents relating to the device, such as the mounting and operating
instructions, are available on our website at www.samsongroup.com >
Service & Support > Downloads > Documentation.

Contents
EB 5866 EN
1 Safety instructions and measures ................................................................1-1
1.1 Notes on possible severe personal injury ......................................................1-5
1.2 Notes on possible personal injury ................................................................1-6
1.3 Notes on possible property damage .............................................................1-8
2 Markings on the device ..............................................................................2-1
2.1 Valve nameplate .........................................................................................2-1
2.2 Actuator nameplate .....................................................................................2-1
3 Design and principle of operation ...............................................................3-1
3.1 Fail-safe action ...........................................................................................3-1
3.2 Versions .....................................................................................................3-3
3.3 Additional ttings ........................................................................................3-5
3.4 Technical data ............................................................................................3-6
4 Shipment and on-site transport ...................................................................4-1
4.1 Accepting the delivered goods .....................................................................4-1
4.2 Removing the packaging from the valve ........................................................4-1
4.3 Transporting and lifting the valve ..................................................................4-1
4.3.1 Transporting the valve .................................................................................4-1
4.3.2 Lifting the valve ...........................................................................................4-1
4.4 Storing the valve .........................................................................................4-2
5 Installation.................................................................................................5-1
5.1 Installation conditions ..................................................................................5-1
5.2 Preparation for installation ...........................................................................5-2
5.3 Mounting the device ....................................................................................5-3
5.3.1 Installing the valve into the pipeline ..............................................................5-4
5.3.2 Mounting the actuator onto the valve ............................................................5-4
5.3.3 Connecting the actuator ...............................................................................5-5
5.3.4 Conguring the actuator ..............................................................................5-5
5.4 Testing the installed valve .............................................................................5-5
5.4.1 Leak test .....................................................................................................5-6
5.4.2 Travel motion ..............................................................................................5-7
5.4.3 Fail-safe position .........................................................................................5-7
5.4.4 Pressure test ................................................................................................5-7
6 Start-up .....................................................................................................6-1
7 Operation..................................................................................................7-1

Contents
EB 5866 EN
8 Malfunctions ..............................................................................................8-1
8.1 Troubleshooting ..........................................................................................8-1
8.2 Emergency action .......................................................................................8-2
9 Servicing....................................................................................................9-1
9.1 Periodic testing ...........................................................................................9-1
10 Decommissioning .....................................................................................10-1
11 Removal ..................................................................................................11-1
11.1 Removing the valve from the pipeline ..........................................................11-1
11.2 Removing the actuator from the valve .........................................................11-2
12 Repairs ....................................................................................................12-1
12.1 Returning devices to SAMSON ..................................................................12-1
13 Disposal...................................................................................................13-1
14 Certicates...............................................................................................14-1
15 Annex......................................................................................................15-1
15.1 After-sales service .....................................................................................15-1

EB 5866 EN 1-1
Safety instructions and measures
1 Safety instructions and measures
Intended use
The SAMSON Type3222 Valve is designed for use in temperature control circuits in HVAC
plants (e.g. for DHW heating). The valve is primarily combined with the following SAMSON
actuators:
−As an electric control valve: Type3222/5857, Type3222/5824, Type3222/5825,
Type3222/5827, Type3222/5757-3, Type3222/5757-7, Type3222/5724-3,
Type3222/5724-8, Type3222/5725-3 and Type3222/5725-8
−As a pneumatic control valve: Type3222/2780
The valve with its actuator is designed to operate under exactly dened conditions (e.g. oper-
ating pressure, process medium, temperature). Therefore, operators must ensure that the con-
trol valve is only used in operating conditions that meet the specications used for sizing the
valve at the ordering stage. In case operators intend to use the control valve in applications
or conditions other than those specied, contact SAMSON.
SAMSON does not assume any liability for damage resulting from the failure to use the de-
vice for its intended purpose or for damage caused by external forces or any other external
factors.
ÎRefer to the technical data and nameplate for limits and elds of application as well as
possible uses.
Reasonably foreseeable misuse
The control valve is not suitable for the following applications:
−Use outside the limits dened during sizing and by the technical data
−Type3222/2780 Control Valve: Use outside the limits dened by the valve accessories
connected to the valve
Furthermore, the following activities do not comply with the intended use:
−Use of non-original spare parts
−Performing service and repair work not described
Qualications of operating personnel
The control valve must be mounted, started up, serviced and repaired by fully trained and
qualied personnel only; the accepted industry codes and practices must be observed. Ac-
cording to these mounting and operating instructions, trained personnel refers to individuals
who are able to judge the work they are assigned to and recognize possible hazards due to

1-2 EB 5866 EN
Safety instructions and measures
their specialized training, their knowledge and experience as well as their knowledge of the
applicable standards.
Welding operations must only be performed by personnel who has the necessary qualica-
tion to perform the applied welding procedure and handle the materials used.
Explosion-protected versions of this device must be operated only by personnel who has un-
dergone special training or instructions or who is authorized to work on explosion-protected
devices in hazardous areas.
Personal protective equipment
We recommend wearing the following protective equipment:
−Protective clothing and gloves in applications with hot or cold media
ÎCheck with the plant operator for details on further protective equipment.
Revisions and other modications
Revisions, conversions or other modications of the product are not authorized by SAMSON.
They are performed at the user's own risk and may lead to safety hazards, for example.
Furthermore, the product may no longer meet the requirements for its intended use.
Safety features
In combination with the Type5825, Type5827-A and Type5827-E Electric Actuators as well
as with the TROVIS5725-3 and TROVIS5725-8 Electric Actuators with Process Controller,
the following safety feature exists: upon failure of the supply voltage, the valve moves to a
dened fail-safe position (see the 'Design and principle of operation' section). The direction
of action of the fail-safe action is dened by the actuator version (see associated actuator
documentation).
In combination with the Type2780 Pneumatic Actuator, the following safety feature exists:
upon failure of the air supply, the valve moves to a certain fail-safe position (see the 'Design
and principle of operation' section). The fail-safe action of the actuator is the same as its
direction of action and is specied on the nameplate of SAMSON actuators (see actuator
documentation).
Warning against residual hazards
To avoid personal injury or property damage, plant operators and operating personnel must
prevent hazards that could be caused in the control valve by the process medium, the operat-
ing pressure, the signal pressure or by moving parts by taking appropriate precautions. Plant
operators and operating personnel must observe all hazard statements, warning and caution
notes in these mounting and operating instructions.

EB 5866 EN 1-3
Safety instructions and measures
Hazards resulting from the special working conditions at the installation site of the valve must
be identied in a risk assessment and prevented through the corresponding safety instruc-
tions drawn up by the operator.
Responsibilities of the operator
Operators are responsible for proper use and compliance with the safety regulations. Opera-
tors are obliged to provide these mounting and operating instructions as well as the refer-
enced documents to the operating personnel and to instruct them in proper operation. Fur-
thermore, operators must ensure that operating personnel or third parties are not exposed to
any danger.
Operators are additionally responsible for ensuring that the limits for the product dened in
the technical data are observed. This also applies to the start-up and shutdown procedures.
Start-up and shutdown procedures fall within the scope of the operator's duties and, as such,
are not part of these mounting and operating instructions. SAMSON is unable to make any
statements about these procedures since the operative details (e.g. differential pressures and
temperatures) vary in each individual case and are only known to the operator.
Responsibilities of operating personnel
Operating personnel must read and understand these mounting and operating instructions as
well as the referenced documents and observe the specied hazard statements, warnings
and caution notes. Furthermore, operating personnel must be familiar with the applicable
health, safety and accident prevention regulations and comply with them.
Referenced standards, directives and regulations
The control valves comply with the requirements of the European Pressure Equipment Direc-
tive 2014/68/EU. Valves with a CE marking have a declaration of conformity, which in-
cludes information about the applied conformity assessment procedure. The 'Certicates' sec-
tion contains this declaration of conformity.
The electric actuators are designed for use in low voltage installations. For wiring, mainte-
nance and repair, observe the relevant safety regulations.

1-4 EB 5866 EN
Safety instructions and measures
Referenced documentation
The following documents apply in addition to these mounting and operating instructions:
−Mounting and operating instructions for mounted actuator, e.g. SAMSON actuators:
uEB5857 for Type5857
uEB5824-1/-2 for Type5824 and Type5825
uEB5827-1/-2 for Type5827
uEB5757-X for TROVIS5757-X
uEB5724 for TROVIS5724-3 and TROVIS5725-3
uEB5724-8 for TROVIS5724-8 and TROVIS5725-8
uEB5840 for Type2780
−For Type3222/2780 Control Valve: mounting and operating instructions for mounted
valve accessories (positioner, solenoid valve etc.)
−When a substance is used in the device, which is listed as being a substance of very high
concern on the candidate list of the REACH regulation:
Information on safe use of the part affected
uwww.samsongroup.com > About SAMSON > Material Compliance > REACH
If a 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 indicated on the
SAMSON delivery note.

EB 5866 EN 1-5
Safety instructions and measures
1.1 Notes on possible severe personal injury
DANGER
!
Risk of bursting in pressure equipment.
Valves and pipelines are pressure equipment. Impermissible pressure or improper
opening can lead to valve components bursting.
ÎObserve the maximum permissible pressure for valve and plant.
ÎBefore starting any work on the control valve, depressurize all plant sections affect-
ed as well as the valve.
ÎDrain the process medium from all the plant sections concerned as well as the
valve.
Risk of fatal injury due to electric shock.
ÎDo not remove any covers to perform adjustment work on live parts.
ÎBefore performing any work on the device and before opening the device, discon-
nect the supply voltage and protect it against unintentional reconnection.
ÎOnly use power interruption devices that are protected against unintentional recon-
nection of the power supply.
ÎThe electric actuators are protected against spray water (IP54). Avoid jets of water.

1-6 EB 5866 EN
Safety instructions and measures
1.2 Notes on possible personal injury
WARNING
!
Crush hazard arising from moving parts.
The pneumatic control valve (Type3222/2780) contains moving parts (actuator and
plug stems), which can injure hands or ngers if inserted into the valve.
ÎDo not insert hands or nger into the yoke while the air supply is connected to the
actuator.
ÎBefore working on the control valve, disconnect and lock the pneumatic air supply
as well as the control signal.
ÎDo not impede the movement of the actuator and plug stem by inserting objects in-
to the yoke.
ÎBefore unblocking the actuator and plug stem after they have become blocked (e.g.
due to seizing up after remaining in the same position for a long time), release any
stored energy in the actuator (e.g. spring compression). See associated actuator
documentation.
Risk of personal injury due to preloaded springs.
Pneumatic control valves (Type3222/2780) using an actuator with preloaded springs
are under tension. These control valves with SAMSON pneumatic actuators can be
identied by the long bolts protruding from the bottom of the actuator.
ÎBefore starting any work on the actuator, relieve the compression from the preload-
ed springs (see associated actuator documentation).
Risk of hearing loss or deafness due to loud noise.
The noise emissions depend on the valve version, plant facilities and process medium.
ÎIf necessary, wear hearing protection when working near the valve.

EB 5866 EN 1-7
Safety instructions and measures
WARNING
!
Risk of personal injury due to exhaust air being vented.
While the valve is operating, the pneumatic control valve (Type3222/2780) vents
during closed-loop control or when the valve opens or closes.
ÎInstall the control valve in such a way that vent openings are not located at eye level
and the actuator does not vent at eye level in the work position.
ÎUse suitable silencers and vent plugs.
ÎWear eye protection when working in close proximity to the control valve.
Risk of personal injury due to residual process medium in the valve.
While working on the valve, residual process medium can escape and, depending on
its properties, may lead to personal injury, e.g. burns.
ÎIf possible, drain the process medium from all the plant sections affected and the
valve.
ÎWear protective clothing and safety gloves.
Risk of burn injuries due to hot components and pipelines.
Depending on the process medium, valve components and pipelines may get very hot
and cause burn injuries.
ÎAllow components and pipelines to cool down.
ÎWear protective clothing and safety gloves.
Exposure to hazardous substances poses a serious risk to health.
Certain lubricants and cleaning agents are classied as hazardous substances. These
substances have a special label and a material safety data sheet (MSDS) issued by the
manufacturer.
ÎMake sure that an MSDS is available for any hazardous substance used. If neces-
sary, contact the manufacturer to obtain an MSDS.
ÎInform yourself about the hazardous substances and their correct handling.

1-8 EB 5866 EN
Safety instructions and measures
WARNING
!
Risk of personal injury through incorrect operation, use or installation as a result of
information on the valve being illegible.
Over time, markings, labels and nameplates on the valve may become covered with dirt
or become illegible in some other way. As a result, hazards may go unnoticed and the
necessary instructions not followed. There is a risk of personal injury.
ÎKeep all relevant markings and inscriptions on the device in a constantly legible
state.
ÎImmediately renew damaged, missing or incorrect nameplates or labels.
1.3 Notes on possible property damage
NOTICE
!
Risk of damage to the electric control valve due to the supply voltage exceeding the
permissible tolerances.
The electric control valves are designed for use according to regulations for low-volt-
age installations.
ÎObserve the permissible tolerances of the supply voltage. See associated actuator
documentation.
Risk of valve damage due to contamination (e.g. solid particles) in the pipeline.
The plant operator is responsible for cleaning the pipelines in the plant.
ÎFlush the pipelines before start-up.
Risk of valve damage due to unsuitable medium properties.
The valve is designed for a process medium (e.g. water, oil, steam) with dened proper-
ties.
ÎOnly use the process medium specied for sizing the equipment.

EB 5866 EN 2-1
Markings on the device
2 Markings on the device
2.1 Valve nameplate
SAMSON 1
23
4 5
kvs 6 Δp 7
1 Type designation
2Conguration ID
3 Date of manufacture
4 Model number
5 Max. permissible temperature
6KVS coefcient
7 Max. perm. differential pressure
The nameplate (48) is afxed to the valve
body (see Fig.2-1).
48
Fig.2-1: Location of the nameplate
2.2 Actuator nameplate
See associated actuator documentation.

2-2 EB 5866 EN

EB 5866 EN 3-1
Design and principle of operation
3 Design and principle of oper-
ation
The medium ows through the single-seated
globe valve in the direction indicated by the
arrow. The position of the plug determines
the ow rate across the area released be-
tween plug (1) and seat (5). The valve is
opened by the valve spring when the actua-
tor stem retracts. The plug is moved by
changing the control signal applied to the
actuator. The valve and actuator have a
force-locking connection.
A special version (see Fig.3-3) is available
for water above 150°C and steam.
3.1 Fail-safe action
When the Type3222 Valve is combined with
one of the following actuators, the valve
moves to the fail-safe position upon failure of
the air supply or supply voltage:
−Type5825, Type5827-A and
Type5827-E Electric Actuators
−TROVIS5725-3 and TROVIS5725-8
Electric Actuators with Process Controller
−Type2780 Pneumatic Actuator
One of two different fail-safe positions can
be assumed by the control valve:
−Actuator stem extends: upon supply volt-
age or air supply failure, the actuator
stem extends.
The TROVIS5725-3 and TROVIS5725-8
Electric Actuators with Process Controller in
the version with force-locking attachment
and the Type5827-A and Type5825
Electric Actuators with "actuator stem
extends" fail-safe action are tested by the
German technical surveillance association
TÜV according to DINEN14597 in
combination with the SAMSON Type3222
Valve. The registration number is available
on request.
−Actuator stem retracts: upon supply volt-
age or air supply failure, the actuator
stem retracts.
The fail-safe action of pneumatic actuators
can be reversed (see associated actuator
documentation). The fail-safe action of elec-
tric actuators (with process controller) is al-
ready determined at the ordering stage.
Note
Note

3-2 EB 5866 EN
Design and principle of operation
Fig.3-3: Type3222/5827, Type3222/5724-3 ·
Version for water above 150°C and steam
8
5
1
14
15
11
0
1 Plug
3Body
5 Seat
7 O-ring
8 Connecting piece
11 Guide nipple
14 Insulating section
15 Insulating pipe
1
5
3
7
Fig.3-1: Type3222/2780-1
1
5
3
7
11
Fig.3-2: Type3222/5857, Type3222/5757-
3, Type3222/5757-7

EB 5866 EN 3-3
Design and principle of operation
3.2 Versions
Electric actuators
The electric actuators can be controlled
either using a three-step signal or, in the
version with positioner, with continuous
signals adjustable in the range from 0 to
20mA or from 0 to 10V. Various electrical
accessories can be optionally installed.
Type5825, Type5827-A and Type5827-E
Actuators are able to perform a fail-safe ac-
tion. Refer to section Table 3-1.
Electric actuators with process controllers
Electric actuators with process controller are
a combination of an electric actuator and a
digital process controller. The
TROVIS5757-3, TROVIS5724-3 and
TROVIS5725-3 Electric Actuators with
Process Controller are suitable for DHW
applications. TROVIS5757-7 is suitable for
heating and cooling applications.
TROVIS5724-8 and TROVIS5725-8 have
two PID control modules and are ready-
wired for heating and cooling applications.
TROVIS5725-3 and TROVIS5725-8
Actuators are able to perform a fail-safe
action. Refer to section Table 3-1.
Pneumatic actuators
The Type2780-1 Pneumatic Actuator uses a
control signal from 0.4 to 1bar and
Type2780-2 uses a control signal from 0.4
to 2bar which is applied to the signal pres-
sure connection.
The pneumatic actuators require a supply
pressure of at least 0.2bar above the maxi-
mum bench range. All actuators are avail-
able for fail-safe action "Actuator stem ex-
tends (FA)" or "Actuator stem retracts (FE)".

3-4 EB 5866 EN
Design and principle of operation
Table 3-1: Available versions and possible combinations (valve/actuator)
Type/
TROVIS
Fail-safe action:
Actuator stem Valve size DN Thread size G
Extends Retracts 15 20 25 32 40 50 ½ ¾ 1
Electric actuators
5857 – – • • • – • • •
5824-10 2) – – • • • – • • •
5824-13 1) 2) – – • • • – • • •
5827-N1 – – • • • – • • •
5825-10 2) • – • • • – • • •
5825-13 1) 2) • – • • • – • • •
5827-A1 • – • • • – • • •
5825-15 2) – • • • • – • • •
5827-E1 – • • • • – • • •
5824-20 2) – – – • • • –
5824-23 2) – – – • • • –
5827-N2 – – – • • • –
5825-20 2) • – – • • • –
5825-23 2) • – – • • • –
5827-A2 • – – • • • –
5825-25 2) – • – • • • –
5827-E2 – • – • • • –
Electric actuators with process controller for domestic hot water heating
5757-3 – – • • • – • • •
5724-310 – – • • • – • • •
5725-310 • – • • • – • • •
5724-320 – – – • • • –
5725-320 • – – • • • –
Electric actuators with process controller for heating and cooling applications
5757-7 – – • • • – • • •
5724-810 – – • • • – • • •
5724-820 – – – • • • –
5725-810 • – • • • – • • •
5725-820 • – – • • • –

EB 5866 EN 3-5
Design and principle of operation
3.3 Additional ttings
Strainers
We recommend installing a SAMSON
Type2NI Strainer upstream of the valve. It
prevents solid particles in the process medi-
um from damaging the valve.
ÎRefer to the instructions in the 'Installa-
tion' section.
Bypass and shut-off valves
We recommend installing a shut-off valve
both upstream of the strainer and down-
stream of the valve and installing a bypass
line. The bypass ensures that the plant does
not need to be shut down for service and re-
pair work on the valve.
Intermediate insulating piece
An intermediate insulating piece (1990-
1712) must be used under the following con-
ditions:
−For medium temperatures from –15°C
(red brass) or –10°C (EN-GJS-400-18-
LT) to +5°C (actuators according to
Table 3-1)
−In networks with a constant medium
temperature >135°C (TROVIS5724-3,
TROVIS5724-8, TROVIS5725-3,
TROVIS5725-8, Type5824, Type5825
and Type5827 Actuators)
−For liquids >120°C (TROVIS5757-3,
TROVIS5757-7 and Type5857 Actua-
tors)
ÎRefer to the instructions in the 'Installa-
tion' section.
Type/
TROVIS
Fail-safe action:
Actuator stem Valve size DN Thread size G
Extends Retracts 15 20 25 32 40 50 ½ ¾ 1
Pneumatic actuators
2780-1 • • • • • • • • • • •
2780-2 • • • • • • • • • • •
1) Version with half transit time
2) The product will be discontinued in the near future. See Data Sheet uT5827 for replacement device.

3-6 EB 5866 EN
Design and principle of operation
3.4 Technical data
The nameplates on the valve and actuator provide information on the control valve version.
See the 'Markings on the device' section and the associated actuator documentation.
Table 3-2: Technical data for Type3222
Valve size
Globe valve with male thread
connection or with anged body
DN 15 20 25 32 40 50
Connection size
Globe valve with female thread G½ ¾ 1 – – –
Pressure rating PN 25
Seat-plug seal Metal seal for KVS ≤2.5
Soft seal for KVS ≥3.6
Rated travel mm 6 12
Rangeability 50 : 1
Leakage class according to IEC60534-4 Class I (≤0.05% of KVS coefcient)
Conformity ·
Version for water, oil and other liquids
Max. permissible temperature 150°C 1)
Max. permissible differential pressure ∆p
Type5824/5825/5827,
TROVIS5724-3/5724-8/
5725-3/5725-8, Type2780
bar 20 20 20 12/164) 12 12
Type5857, TROVIS5757-3,
TROVIS5757-7 bar 20 20 20 – – –
Version for water above 150°C and steam
Max. permissible temperature 200°C
Max. permissible differential pressure ∆p
Type5824/5825/5827,
TROVIS5724-3/5724-8/
5725-3/5725-8, Type2780
bar 20 · 10 with 3.6≤KVS ≤8 8 8 8
Type5857, TROVIS5757-3,
TROVIS5757-7 bar 202) · 53) 5 5 –––
1) Use an intermediate insulating piece (see section3.3, “Intermediate insulating piece”)
2) Differential pressure with KVS = 1 and 1.6
3) Differential pressure with KVS = 2.5 and 4
4) Applies to KVS = 10