Samson 3222/5857 series Service manual

Mounting and
Operating Instructions
EB 5866 EN
Translation of original instructions
Edition July 2016
Type3222/5857
Type3222/5757-3
Type3222/5757-7
Type3222/5825
Type3222/5725-7
Type3222/2780-1 Type3222/2780-2 with Type3760
Positioner
Electric Control Valves
Types 3222/5857, 3222/5824, 3222/5825, 3222/5757-3,
3222/5757-7, 3222/5724-3, 3222/5724-8, 3222/5725-3,
3222/5725-7, 3222/5725-8
Pneumatic Control Valves
Type3222/2780

2 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.
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
Department (aftersalesser[email protected]).
The mounting and operating instructions for the devices are included in
the scope of delivery. The latest documentation is available on our website
(www.samson.de) > Product documentation. You can enter the document
number or type number in the [Find:] eld to look for a document.
Denition 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

Contents
EB 5866 EN 3
1 Safety instructions and measures ...................................................................5
1.1 Notes on possible severe personal injury .........................................................8
1.2 Notes on possible personal injury ...................................................................9
1.3 Notes on possible property damage ..............................................................10
2 Markings on the device ...............................................................................11
2.1 Valve nameplate ..........................................................................................11
2.2 Actuator nameplate ......................................................................................11
3 Design and principle of operation ................................................................12
3.1 Fail-safe action ............................................................................................12
3.2 Versions ......................................................................................................14
3.3 Technical data .............................................................................................16
4 Preparation.................................................................................................22
4.1 Unpacking ..................................................................................................22
4.2 Transporting and lifting ................................................................................22
4.2.1 Transporting ................................................................................................22
4.2.2 Lifting ..........................................................................................................22
4.3 Storage .......................................................................................................22
4.4 Preparation for installation ............................................................................23
5 Mounting and start-up.................................................................................24
5.1 Installing the valve into the pipeline ...............................................................24
5.1.1 Checking the installation conditions ...............................................................24
5.1.2 Additional ttings .........................................................................................26
5.1.3 Installing the control valve .............................................................................26
5.2 Mounting the actuator onto the valve .............................................................27
5.2.1 Connecting the actuator ................................................................................27
5.2.2 Conguring the actuator ...............................................................................28
5.3 Quick check ................................................................................................28
6 Operation...................................................................................................29
7 Servicing.....................................................................................................30
7.1 Preparation for return shipment .....................................................................30
7.2 Ordering spare parts and operating supplies .................................................30

4 EB 5866 EN
Contents
8 Malfunctions ...............................................................................................31
8.1 Troubleshooting ...........................................................................................31
8.2 Emergency action ........................................................................................32
9 Decommissioning and disassembly ..............................................................33
9.1 Decommissioning .........................................................................................33
9.2 Removing the valve from the pipeline .............................................................33
9.3 Removing the actuator from the valve ............................................................34
9.4 Disposal ......................................................................................................34
10 Appendix....................................................................................................35
10.1 After-sales service ........................................................................................35
10.2 Certicates ..................................................................................................35

EB 5866 EN 5
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 electric control valve: Type3222/5857, Type3222/5824, Type3222/5825,
Type3222/5757-3, Type3222/5757-7, Type3222/5724-3, Type3222/5724-8,
Type3222/5725-3, Type3222/5725-7 and Type3222/5725-8
−As 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 applications that meet the specications used for sizing the valve at
the ordering stage. In case operators intend to use the control valve in other applications or
conditions than specied, SAMSON must be contacted.
SAMSON does not assume any liability for damage resulting from the failure to use the
valve 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 in the technical data
−For Type3222/2780 Control Valve: use outside the limits dened by the valve accesso-
ries mounted on the control valve
Furthermore, the following activities do not comply with the intended use:
−Use of non-original spare parts
−Performing servicing and repair work not described in these instructions

6 EB 5866 EN
Safety instructions and measures
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 are to 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
their specialized training, their knowledge and experience as well as their knowledge of the
applicable standards.
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 to the product are not authorized by SAMSON.
They are performed at the user's own risk and may lead to safety hazards, for example. Fur-
thermore, the product may no longer meet the requirements for its intended use.
Safety features
In combination with the Type5825 Electric Actuator and with the TROVIS5725-3, TRO-
VIS5725-7, and TROVIS5725-8 Electric Actuators with Process Controllers, the following
safety feature exists: upon failure of the power supply, the valve moves to a dened fail-safe
position (see section3.1). The direction of action of the fail-safe action is dened by the actu-
ator 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 section3.1).
The fail-safe action corresponds with the direction of action. The fail-safe action of SAMSON
actuators is specied on the actuator nameplate (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. They
must observe all hazard statements, warning and caution notes in these mounting and oper-
ating instructions, especially for installation, start-up, and servicing.

EB 5866 EN 7
Safety instructions and measures
Responsibilities of the operator
The operator is responsible for proper operation and compliance with the safety regulations.
Operators are obliged to provide these mounting and operating instructions as well as the
referenced documents to the operating personnel and to instruct them in proper operation.
Furthermore, operators must ensure that operating personnel or third persons are not ex-
posed to any danger.
Responsibilities of operating personnel
Operating personnel must read and understand these mounting and operating instructions as
well as the referenced documents and observe the hazard statements, warning, and caution
notes specied in them. Furthermore, the operating personnel must be familiar with the ap-
plicable health, safety and accident prevention regulations and comply with them.
Referenced standards 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. This declaration of
conformity is included in the Appendix of these instructions (see section10.2).
The electric actuators are designed for use in low voltage installations. For wiring, mainte-
nance, and repair, observe the relevant safety regulations.
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:
u EB5857 for Type5857
uEB5824-1/-2 for Type5824 and Type5825
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
uEB5725-7 for TROVIS5725-7
u EB5840 for Type2780
−For Type3222/2780 Control Valve: mounting and operating instructions for mounted
valve accessories (positioner, solenoid valve etc.)

8 EB 5866 EN
Safety instructions and measures
1.1 Notes on possible severe personal injury
DANGER
!
Risk of bursting in pressure equipment.
Control valves and pipelines are pressure equipment. Improper opening can lead to
valve components bursting.
ÎBefore starting any work on the control valve, depressurize all plant sections
concerned and the valve.
ÎDrain the process medium from all the plant sections concerned as well as the
valve.
ÎWear personal protective equipment.
Risk of 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 power supply 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.

EB 5866 EN 9
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.
ÎWhile working on the control valve, disconnect and lock the pneumatic air supply
as well as the control signal.
Risk of personal injury when the pneumatic actuator vents.
While the valve is operating, the pneumatic actuator (Type2780) may vent during
closed-loop control or when the valve opens or closes.
ÎInstall the control valve in such a way that the actuator does not vent at eye level.
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 concerned and the
valve.
ÎWear protective clothing and 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 gloves.

10 EB 5866 EN
Safety instructions and measures
1.3 Notes on possible property damage
NOTICE
!
Risk of damage to the electric control valve due to the power supply 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 power supply. See associated actuator
documentation.
Risk of valve damage due to contamination (e.g. solid particles) in the pipeline.
The plant engineering company is responsible for cleaning the pipelines in the plant.
ÎFlush the pipelines before start-up.
ÎObserve the maximum permissible pressure for valve and plant.
Risk of valve damage due to unsuitable medium properties.
The valve is designed for a process medium with certain properties (e.g. water, oil,
steam).
ÎOnly use the process medium that meets the specications used for sizing the valve.

EB 5866 EN 11
Markings on the device
2 Markings on the device
2.1 Valve nameplate
SAMSON 1
2 3
4 5
kvs 6 Δp 7
1 Type designation
2 Con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.1).
48
Fig.1: Location of the nameplate
2.2 Actuator nameplate
See associated actuator documentation.

12 EB 5866 EN
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.4) 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 up upon fail-
ure of the air supply or power supply:
−Type5825 Electric Actuator
−TROVIS5725-3 and TROVIS5725-7
Electric Actuators with Process Control-
lers
−Type 2780 Pneumatic Actuator
The control valve has two different fail-safe
positions:
−Actuator stem extends: upon power sup-
ply or air supply failure, the actuator
stem extends.
The TROVIS5725-3, TROVIS5725-7, and
TROVIS8725-8 Electric Actuators with Pro-
cess Controllers in the version with
force-locking attachment and the Type5825
Electric Actuator with "actuator stem ex-
tends" fail-safe action are tested by the Ger-
man 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 power sup-
ply 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 controllers) is al-
ready determined at the ordering stage.
Note
Note

EB 5866 EN 13
Design and principle of operation
1
5
3
7
1 Plug
3 Body
5 Seat
7 O-ring
8 Connecting piece
11 Guide nipple
14 Insulating section
15 Insulating pipe
1
5
3
7
11
8
5
1
14
15
11
Fig.2: Type3222/2780-1
Fig.3: Type3222/5875, Type3222/5757-3,
Type3222/5757-7 · Version for water,
oil, and liquids
Fig.4: Type3222/5824, Type3222/5724-3 · Version
for water above 150°C and steam

14 EB 5866 EN
Design and principle of operation
3.2 Versions
Intermediate insulating piece
An intermediate insulating piece is available
for insulated pipes.
Electric actuators
The electric actuators can be controlled ei-
ther using a three-step signal or, in the ver-
sion 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 Actuator is able to perform a fail-
safe action. Refer to Table1.
Electric actuators with process controllers
Electric actuators with process controllers 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 domestic hot water heating.
TROVIS5757-7 and TROVIS5725-7 are
suitable for heating and cooling applica-
tions.
TROVIS5724-8 and TROVIS5725-8 have
two PID control modules and are ready-
wired for heating and cooling applications.
TROVIS5725-3, TROVIS5725-7, and
TROVIS5725-8 Actuators are able to per-
form a fail-safe action (see Table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)".

EB 5866 EN 15
Design and principle of operation
Table1: Available versions and possible combinations (valve/actuator)
Type/TRO-
VIS
Fail-safe action:
Actuator stem Nominal size DN Thread size G
Extends Retracts 15 20 25 32 40 50 ½ ¾ 1
Electric actuators
5857 – – • • • – • • •
5824-10 – – • • • – • • •
5824-13 1) – – • • • – • • •
5825-10 • – • • • – • • •
5825-13 1) • – • • • – • • •
5825-15 – • • • • – • • •
5824-20 – – – • • • –
5824-23 – – – • • • –
5825-20 • – – • • • –
5825-23 • – – • • • –
5825-25 – • – • • • –
Electric actuators with process controllers 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 – – – • • • –
5725-710 • – • • • – • • •
5725-715 – • • • • – • • •
5725-720 • – – • • • –
5725-725 – • – • • • –
5725-810 • – • • • – • • •
5725-820 • – – • • • –
Pneumatic actuators
2780-1 • • •••••••••
2780-2 • • •••••••••
1) Version with half transit time

16 EB 5866 EN
Design and principle of operation
3.3 Technical data
The nameplates on the valve and actuator provide information on the control valve version.
See section2.1 and the associated actuator documentation.
Table2: Technical data for Type3222
Nominal size
Globe valve with male thread connec-
tion or with anged body
DN 15 20 25 32 40 50
Connection size
Globe valve with female thread G ½ ¾ 1 – – –
Nominal pressure 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)
Compliance ·
Version for water, oil and other liquids
Max. permissible temperature 150°C 1)
Max. permissible differential pressure ∆p
Type5824/5825, TROVIS5724-3/
5724-8/5725-3/ 5725-7/5725-8,
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, TROVIS5724-3/
5724-8/5725-3/5725-7/5725-8,
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5.1.2, 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

EB 5866 EN 17
Design and principle of operation
Table3: Nominal sizes and KVS coefcients
Nominal 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
G ½ ¾ 1 – – –
KVS coefcients 4 1) · 3.6 2) 6.3 1) ·
5.7 2)
8 1) ·
7.2 2) 16 1) 20 1) 25 1)
Reduced KVS coefcients
0.1· 0.16 · 0.25
· 0.4 · 0.63 ·
1.0 · 1.6 · 2.5
1.0 · 1.6 · 2.5 ·
4 1) · 3.6 2) 10 3) – –
Rated travel
mm 6 6 6 12 12 12
1) Version with male thread connection or with anged body
2) Version with female thread
3) 6mm rated travel
Table4: Materials
Valve body CC499K (CuSn5Zn5Pb2-C)
Version with anged body EN-GJS-400-18-LT (GGG-40.3)
Seat Stainless steel 1.4305
Plug 1.4305/CW602N with soft seal
1.4305 with 0.1≤KVS≤2.5
Valve spring Stainless steel 1.4310K
Packing EPDM/FPM (FKM) · Oil-resistant version: FPM
Welding ends St 37
Threaded ends CC491K (red brass)
Screwed-on anges St 37.2
Noise emission
SAMSON is unable to make general statements about noise emission as it depends on the
valve version, plant facilities, and process medium. On request, SAMSON can perform cal-
culations according to IEC60534, Part8-3 and Part8-4 or VDMA24422 (edition89).

18 EB 5866 EN
Design and principle of operation
Dimensions and weights
Table5 provides a summary of the dimensions and weights of the valve. The lengths and
heights in the dimension diagrams are shown on page19 onwards.
Table5: Dimensions and weights for Type3222 Valve
Valves with male thread connection
Nominal size DN 15 20 25 32 40 50
Length L mm 65 70 75 100 110 130
Height H2 mm 45.5 45.5 45.5 94 94 94
Version for water above 150°C
and steam or version with
intermediate insulating piece
140 140 140 185 185 185
Height H3 mm 30 30 30 55 55 55
Valves with welding ends
Thread size R G ¾ 1 1¼ 1¾ 2 2½
Pipe Ød mm 21.3 26.8 33.7 42 48 60
Width across ats SW 30 36 46 59 65 82
Length L1 mm 210 234 244 268 294 330
Weight without actuator kg (approx.) 1.4 1.8 2.3 4.0 4.4 6.8
Version for water above 150°C
and steam or version with
intermediate insulating piece
1.9 2.3 2.8 4.5 4.9 7.3
Valves with threaded ends
Length L2 mm 129 144 159 180 196 228
Male thread A G ½ ¾ 1 1¼ 1½ 2
Width across ats SW 30 36 46 59 65 82
Weight without actuator kg (approx.) 1.4 1.8 2.3 4.0 4.4 6.8
Version for water above 150°C
and steam or version with
intermediate insulating piece
1.9 2.3 2.8 4.5 4.9 7.3
Valves with anges
Width across ats SW 30 36 46 59 65 82
Length L3 mm 130 150 160 180 200 230
Weight without actuator kg (approx.) 2.5 3.4 4.1 6.9 7.7 10.7
Version for water above 150°C
and steam or version with
intermediate insulating piece
3.0 3.9 4.6 7.4 8.2 11.2

EB 5866 EN 19
Design and principle of operation
Valves with female thread
Connection size G ½ ¾ 1 –
Width across ats SW 30 36 46 –
Length L4 mm 65 75 90 –
Female thread G ½ ¾ 1–
Weight without actuator kg (approx.) 1.2 1.4 1.5 –
Version for water above 150°C
and steam or version with
intermediate insulating piece
1.7 1.9 2.0 –
Valves with anged body
Nominal size DN 15 20 25 32 40 50
Height H2 mm 45.5 45.5 45.5 94 94 92
Length L3 mm 130 150 160 180 200 230
Weight without actuator kg (approx.) 2.5 3.4 4.1 6.9 8.4 11.6
Version for water above 150°C
and steam or version with
intermediate insulating piece
3.0 3.9 4.6 7.4 8.9 12.1
Dimensional drawings
SW
L2
A
SW
L4
G
80
Version with threaded ends Version with female thread Intermediate
insulating
piece
SW
L3
L3
H2
Version with anges Version with anges

20 EB 5866 EN
Design and principle of operation
Dimension diagrams for electric control valves
Ø12
55
80
11
L
L1
H2
114 x 70
H3
R
d
SW
L
L1
146 x 103*
113
H2
H3
R
d
SW
Type3222/5857: DN15 to 25
Type3222/5757-3: DN15 to 25
Type3222/5757-7: DN15 to 25
Type3222/5824: DN15 to 50
Type3222/5825: DN15 to 50
Type3222/5724-3: DN15 to 50
Type3222/5724-8: DN15 to 50
Type3222/5725-3: DN15 to 50
Type3222/5725-7: DN15 to 50
Type3222/5725-8: DN15 to 50
* Dimensions for Types 5824-x3, 5825-x3
Actuators:
146 x 136
146 x 103*
113
L
L1
H2 + 80
H3
R
d
SW
Version for water above 150°C and steam
Type3222/5824: DN15 to 50
Type3222/5825: DN15 to 50
Type3222/5724-3: DN15 to 50
Type3222/5724-8: DN15 to 50
Type3222/5725-3: DN15 to 50
Type3222/5725-7: DN15 to 50
Type3222/5725-8: DN15 to 50
* Dimensions for Types 5824-x3, 5825-x3
Actuators:
146 x 136