Samson 3241-1-Gas Service manual

Translation of original instructions
EB 8020 EN
Automatic Shut-off Valves for Gases
Type3241-1-Gas and Type3241-7-Gas
Valve classD
Edition February 2020
Type3241‑7‑Gas with Type3963 Solenoid Valve and Type3730 Positioner

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
Department ([e-mail]).
The mounting and operating instructions for the devices are included in
the scope of delivery. The latest documentation is available on our web‑
site at www.samsongroup.com > Service & Support > Downloads > Doc-
umentation.
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 8020 EN

Contents
EB 8020 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 ................................................................1‑5
1.3 Notes on possible property damage.............................................................1‑7
1.4 Warnings on the device...............................................................................1‑8
2 Markings on the device ..............................................................................2-1
2.1 Nameplate for gas version of the control valve ..............................................2‑1
2.2 Valve nameplate .........................................................................................2‑2
2.3 Actuator nameplate.....................................................................................2‑3
2.4 DVGW register number...............................................................................2‑3
2.5 Material numbers........................................................................................2‑3
3 Design and principle of operation ...............................................................3-1
3.1 Versions .....................................................................................................3‑4
3.2 Additional ttings........................................................................................3‑4
3.3 Valve accessories ........................................................................................3‑5
3.4 Technical data ............................................................................................3‑5
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 .................................................................................4‑2
4.3.2 Lifting the valve...........................................................................................4‑3
4.4 Storing the valve.........................................................................................4‑4
5 Installation.................................................................................................5-1
5.1 Installation conditions..................................................................................5‑1
5.2 Preparation for installation...........................................................................5‑2
5.3 Mounting the valve......................................................................................5‑3
5.3.1 Installing the valve into the pipeline ..............................................................5‑3
5.4 Testing the installed valve.............................................................................5‑4
5.4.1 Vent holes ..................................................................................................5‑5
5.4.2 Leak test.....................................................................................................5‑5
5.4.3 Travel motion..............................................................................................5‑5
5.4.4 Fail‑safe position.........................................................................................5‑5
5.4.5 Pressure test................................................................................................5‑6
6 Start-up .....................................................................................................6-1

Contents
EB 8020 EN
7 Operation..................................................................................................7-1
8 Malfunctions ..............................................................................................8-1
8.1 Troubleshooting ..........................................................................................8‑1
8.2 Emergency action .......................................................................................8‑2
9 Servicing....................................................................................................9-1
9.1 Periodic testing ...........................................................................................9‑3
9.2 Preparing the valve for service work .............................................................9‑6
9.3 Completing service work .............................................................................9‑6
9.4 Service work...............................................................................................9‑8
9.4.1 Replacing the gasket ...................................................................................9‑8
9.4.2 Cleaning the strainer...................................................................................9‑8
9.5 Ordering spare parts and operating supplies ................................................9‑9
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 Tightening torques, lubricants and tools ......................................................15‑1
15.2 Spare parts ..............................................................................................15‑1
15.3 After‑sales service.....................................................................................15‑4

EB 8020 EN 1-1
Safety instructions and measures
1 Safety instructions and measures
Intended use
The SAMSON Type3241G Globe Valve in combination with the Type3271 or Type3277
Pneumatic Actuator and a solenoid valve is designed to regulate the ow rate, pressure or
temperature of fuel gases in gas‑consuming equipment. The valve, actuator and solenoid
valve are designed to operate under exactly dened conditions (e.g. operating pressure, pro‑
cess medium, temperature). Therefore, operators must ensure that the control 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, 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
−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 in these instructions
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 (e.g. Gas Appliances Regulation (EU) 2016/426). Furthermore, the
operating personnel must be specially trained for the correct and safe handling of fuel gases
in gas‑consuming equipment.

1-2 EB 8020 EN
Safety instructions and measures
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 checking the hazards posed by the process medium being used (e.g.
uGESTIS (CLP) hazardous substances database). Depending on the process medium and/
or the activity, the protective equipment required includes:
−Protective clothing, gloves, eye protection and respiratory protection in applications with
hot, cold and/or corrosive media
−Wear hearing protection when working near the valve
−Hard hat
−Safety harness when working at height
−Safety footwear, ESD (electrostatic discharge) footwear, if necessary
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. Fur‑
thermore, the product may no longer meet the requirements for its intended use.
Safety features
−Upon supply air or control signal failure, the valve moves to a certain fail‑safe position
(see '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 associated actuator documentation).
−Valve classD: the safety control valves are tested according to DINEN161 (2013‑04).
In the event of a malfunction, the valves shut off the gas supply. They meet the strict leak‑
age requirements of Class D.
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.

EB 8020 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.
ÎObserve safety measures for handling the device as well as re prevention and explosion
protection 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, the operator 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 specied hazard statements, warnings
and caution notes. Furthermore, the operating personnel must be familiar with the applicable
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 Di‑
rective 2014/68/EU and the Machinery Directive 2006/42/EC. Valves with a CE mark‑
ing have a declaration of conformity which includes information about the applied con‑
formity assessment procedure. The 'Certicates' section contains this declaration of con‑
formity.
−Valve classD: the control valves meet the requirements of the previously valid European
Gas Appliance Directive 2009/142/EC and the currently valid Gas Appliances
Regulation (EU) 2016/426. The EC type examination certicate and EU declaration of
conformity are included in the 'Certicates' section.

1-4 EB 8020 EN
Safety instructions and measures
−The control valves meet the safety, construction and function requirements for automatic
shut‑off valves with gas burners, gas equipment and similar applications according to
DINEN161.
−According to the ignition risk assessment performed in accordance with EN13463‑
1:2009, section 5.2, the non‑electrical control valves do not have their own potential ig‑
nition source even in the rare incident of an operating fault. As a result, they do not fall
within the scope of Directive 2014/34/EU.
ÎFor connection to the equipotential bonding system, observe the requirements specied in
section6.4 of EN60079‑14 (VDE0165‑1).
Referenced documentation
The following documents apply in addition to these mounting and operating instructions:
−Mounting and operating instructions for the mounted actuator, e.g. uEB8310‑X for
Type3271 or Type3277 Pneumatic Actuator
−Mounting and operating instructions for mounted valve accessories (positioner, solenoid
valve etc.)
−uAB0100 for tools, tightening torques and lubricant

EB 8020 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.
1.2 Notes on possible personal injury
WARNING
!
Risk of burn injuries due to hot or cold components and pipelines.
Depending on the process medium, valve components and pipelines may get very hot
or cold and cause burn injuries.
ÎAllow components and pipelines to cool down or heat up.
ÎWear protective clothing and safety gloves.
Risk of hearing loss or deafness due to loud noise.
The noise emissions depend on the valve version, plant facilities and process medium.
ÎWear hearing protection when working near the valve.
Risk of personal injury due to exhaust air being vented.
While the valve is operating, the actuator or valve accessories may vent during closed‑
loop control or when the valve opens or closes.
ÎInstall the control valve in such a way that vent holes 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.

1-6 EB 8020 EN
Safety instructions and measures
WARNING
!
Crush hazard arising from moving parts.
The control valve contains moving parts (actuator and plug stem), 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 into
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.
Valves in combination with pneumatic actuators with preloaded springs are under ten‑
sion. 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 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. (chemical) burns.
ÎIf possible, drain the process medium from all the plant sections affected and the
valve.
ÎWear protective clothing, safety gloves, respiratory protection and eye protection.