Samson 3241-1-Gas Service manual

Translation of original instructions
EB 8020-1 EN
Edition February 2020
Type3241-1-Gas and Type3241-7-Gas
Automatic Shut-off Valves for Gases
Valve classD and valve class E
Type3241‑7‑Gas with Type3963 Solenoid Valve and Type3730 Positioner
NOTICE on the scope of this document
These mounting and operating instructions
only apply to valves already in use.
For control valves of the valve class D, refer
to the updated mounting and operating
instructions uEB8020
They can be downloaded from our website
at
uwww.samsongroup.com > Service &
Support > Downloads > Documentation

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]).
The mounting and operating instructions for the devices are included
in the scope of delivery. The latest documentation is available on our
website at www.samsongroup.com > Service & Support > Downloads >
Documentation.
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 8020-1 EN

Contents
EB 8020-1 EN
1 Safety instructions and measures ...................................................................5
1.1 Notes on possible severe personal injury .........................................................8
1.2 Notes on possible personal injury ...................................................................8
1.3 Notes on possible property damage................................................................9
2 Markings on the device ...............................................................................12
2.1 Nameplate for gas version............................................................................12
2.2 Valve nameplate ..........................................................................................13
2.3 Actuator nameplate......................................................................................14
2.4 Other markings ...........................................................................................14
2.4.1 DVGW register number................................................................................14
2.4.2 Material numbers.........................................................................................14
2.5 Position of marking ......................................................................................14
3 Design and principle of operation ................................................................16
3.1 Fail‑safe positions ........................................................................................19
3.2 Versions ......................................................................................................19
3.3 Technical data .............................................................................................19
3.3.1 Common technical data................................................................................19
3.3.2 Technical data of version for valve classD......................................................23
3.3.3 Technical data of version for valve classE......................................................25
4 Measures for preparation............................................................................27
4.1 Unpacking ..................................................................................................27
4.2 Transporting and lifting ................................................................................27
4.2.1 Transporting ................................................................................................28
4.2.2 Lifting..........................................................................................................28
4.3 Storage.......................................................................................................30
4.4 Preparation for installation............................................................................31
5 Mounting and start-up.................................................................................32
5.1 Mounting the actuator onto the valve.............................................................32
5.2 Installing the valve into the pipeline ...............................................................32
5.2.1 Checking the installation conditions...............................................................32
5.2.2 Additional ttings.........................................................................................33
5.2.3 Installing the control valve.............................................................................34
5.3 Quick check ................................................................................................34
6 Operation...................................................................................................36

Contents
EB 8020-1 EN
7 Servicing.....................................................................................................37
7.1 Replacing the gasket ....................................................................................38
7.2 Other service work.......................................................................................39
7.3 Aligning the V‑port plug...............................................................................39
7.4 Cleaning the strainer....................................................................................40
7.5 Testing the control valve................................................................................40
7.6 Preparation for return shipment.....................................................................40
7.7 Ordering spare parts and operating supplies .................................................40
8 Malfunctions ...............................................................................................43
8.1 Troubleshooting ...........................................................................................43
8.2 Emergency action ........................................................................................44
9 Decommissioning and removal ....................................................................45
9.1 Decommissioning.........................................................................................45
9.2 Removing the valve from the pipeline.............................................................45
9.3 Removing the actuator from the valve ............................................................45
9.4 Disposal......................................................................................................45
10 Annex.........................................................................................................46
10.1 After‑sales service........................................................................................46
10.2 Certicates ..................................................................................................46
10.3 Spare parts .................................................................................................53

EB 8020-1 EN 5
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 condi‑
tions (e.g. operating pressure, process medium, temperature). Therefore, operators must en‑
sure 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 oth‑
er 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 mounted on the control 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.
According 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.
SAMSON does not assume any liability for personal injury or property damage caused by
untrained operating personnel.

6 EB 8020-1 EN
Safety instructions and measures
Personal protective equipment
We recommend checking the hazards posed by the process medium being used (e.g.
uGESTIS (CLP) hazardous substances database).
ÎProvide protective equipment (e.g. safety gloves, eye protection) appropriate for the pro‑
cess medium used.
ÎWear hearing protection when working near the valve.
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 devices
−Upon supply air or control signal failure, the valve moves to its fail‑safe position (see sec‑
tion3.1). 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).
−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.
−Valve classE: the safety control valves are tested according to DINEN161 (1996‑08). In
the event of a malfunction, the valves shut off the gas supply. The valves meet the strict
leakage requirements of Class E and are assigned to Valve Group 2.
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.
We also recommend checking the hazards posed by the process medium being used (e.g.
uGESTIS (CLP) hazardous substances database).
ÎObserve safety measures for handling the device as well as re prevention and explosion
protection measures.

EB 8020-1 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, 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. Valves with a CE marking have an EU declaration of conformity,
which includes information about the applied conformity assessment procedure. The EU
declaration of conformity is included in the annex of these instructions (see section10.2).
−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 Regula‑
tion (EU) 2016/426. The EC type examination certicate and EU declaration of confor‑
mity are included in the annex of these instructions (see section10.2).
−Valve classE: the control valves meet the requirements of the 90/396/EEC. This type ex‑
amination certicate is included in the annex of these instructions (see section10.2).
−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.
Referenced documentation
The following documents apply in addition to these mounting and operating instructions:
−Mounting and operating instructions for mounted actuator, e.g. uEB8310‑X for
Type3271 and Type3277 Actuators
−Mounting and operating instructions for mounted valve accessories (positioner, solenoid
valve etc.)
−uAB0100 for tools, tightening torques and lubricant

8 EB 8020-1 EN
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. Improper opening can lead to valve
components bursting.
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 affected as well as the valve.
ÎWear personal protective equipment.
1.2 Notes on possible personal injury
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 ngers into the yoke while the valve is in operation.
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 actuator vents.
While the valve is operating, the actuator 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.

EB 8020-1 EN 9
Safety instructions and measures
WARNING
!
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 and eye protection.
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.
1.3 Notes on possible property damage
NOTICE
!
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.
ÎObserve the maximum permissible pressure for valve and plant.

10 EB 8020-1 EN
Safety instructions and measures
NOTICE
!
Risk of valve damage due to unsuitable medium properties.
The valve is sized according to Gas Appliances Regulation (EU) 2016/426 (valve
classD) or the Directive 90/396/EEC (valve classE) for fuel gases.
ÎOnly use the process medium specied for sizing the valve.
Risk of leakage and valve damage due to excessively high or low tightening
torques.
Observe the specied torques on tightening control valve components. Excessively
tightened torques lead to parts wearing out quicker. Parts that are too loose may cause
leakage.
ÎObserve the specied tightening torques (uAB0100).
Risk of valve damage due to the use of unsuitable tools.
Certain tools are required to work on the valve.
ÎOnly use tools approved by SAMSON (uAB0100).
Risk of valve damage due to the use of unsuitable lubricants.
The lubricants to be used depend on the valve material. Unsuitable lubricants may cor‑
rode and damage the surface.
ÎOnly use lubricants approved by SAMSON (uAB0100).

EB 8020-1 EN 11

12 EB 8020-1 EN
Markings on the device
2 Markings on the device
2.1 Nameplate for gas version
SAMSON AG
Weismüllerstraße 3
D-60314 Frankfurt/M
Vanne de réglage
Meßstelle
Repère
TAG No.
Auftrags-Nr.
Order No.
NOde commande
Control ValveStellventil
Type
DN Material Kvs
Cv Characteristic
Isolierteil
mm Insulating section
Pièce d‘isolement
lin. on-off
Mischventil
Vanne Mélangeuse
Mixing Valve
%
Verteilventil
Diverting Valve
Vanne de Distribution
Strömungsteiler
Flow divider
Répartiteur de flux
Hub
Travel
Course
stellitiert
stellited
stellité
weich dichtend
soft seated
PTFE élanchéité
PTFE
Graphite
Balg
Soufflet
Bellows
entlastet
balanced
équilibré
PTFE
Graphite
Sitz/Kegel
Seat/Plug
Siège/Clapet
Presse-étoupe
Stopfbuchse
Stuffing box
Stellantrieb
Actuator
Servo-moteur cm²
Federbereich
Spring range
Gamme du ressort
Feder schließt
Spring closes
Ressort ferme
öffnet
opensopens
ouvre
Max. Stelldruck 6 bar
Max. signal pressure 87 psi
Pression de commande max.
Stelldruckbereich
Signal pressure range
Plage de pression de commande bar Δp max. = bar p2 = 0
Made in Germany
Medium
Fluid
Fluide
°C
Betriebstemp. t1
Operating temp.
Temp. de service
bar
Betriebsdruck p1abs
Operating pressure
Pression de service
PN
bar
1234 5
6 7 89 10
10 10
1211 13
11 11
14
14
15
15 16
16 17 18
19 20 20 21
22 23 24
25 26 27 28
Fig.1: Nameplate for gas version
1Type
2Conguration ID
3 (empty)
4 Order number
5Tag no.
6 Valve size:
DIN: DN · ANSI: NPS
7 Pressure rating:
DIN: PN · ANSI: CL
8Material
9 Flow coefcient:
DIN: KVS · ANSI: CV
10 Characteristic:
%: equal percentage · lin: linear · on‑off:
on/off service
11 Seat‑plug seal:
Material
Stellite® facing
Soft seal with PTFE
12 Valve travel in mm
13 Insulating section
14 Mixing or diverting valve
15 Packing:
PTFE
Graphite
16 Pressure balancing:
PTFE
Graphite
17 Bellows material
18 Flow divider
19 Actuator area in cm²
20 Direction of action
Fail‑close
Fail‑open
21 Max. signal pressure in bar
22 Bench range in bar
23 Signal pressure range in bar
24 Max. differential pressure in bar
25 Operating pressure in bar
26 Operating temperature in °C
27 Process medium
28 (empty)

EB 8020-1 EN 13
Markings on the device
2.2 Valve nameplate
2019
1817
16
14 1513121110
8
76
4
5
2
1
Fig.2: Inscriptions on the valve nameplate
Item Inscription meaning
1 Data Matrix code
2Type designation
4 Material
5Month and year of manufacture
6 Valve size:
DIN: DN · ANSI: NPS
7 Pressure rating:
DIN: PN · ANSI: CL
8Serial number Order number/item
10 Flow coefcient:
DIN: KVS · ANSI: CV
11 Characteristic:
%: equal percentage · LIN: linear
mod-lin: modified linear
NO/NC: on/off service
12 Seat‑plug seal:
ME: metal · HA: carbide metal
ST: metal base material with Stellite® facing
KE: ceramic · PK: PEEK soft seal
13 Seat code (trim material): on request
14 Pressure balancing:
DIN: D · ANSI: B
Version:
M: mixing valve · V: flow‑diverting valve
Item Inscription meaning
15 Noise reduction:
1:ow divider(ST)1 · 2:ST2 · 3:ST3
1/PSA:ST1 standard and integrated in
seat for PSA valve ·
AC-1/AC-2/AC-3/AC-5:AC trim, versions
1 to 5 · LK: perforated plug · LK1/LK2/
LK3:perforated plug with ow divider ST1
to ST3 · MHC1:multi‑hole cage
CC1:Combi Cage · ZT1:Zero Travel
16 Country of origin
17 PSA version:
PSA
18 Cage/seat style:
CC: clamped cage, clamped seat
SF: suspended cage, anged seat
FF: anged cage, anged seat
19 CE marking
20 ID of the notied body
PED: Pressure Equipment Directive
G1/G2: gases and vapors
Fluid group1= hazardous
Fluid group2= other
L1: liquids
Fluid group1= hazardous
Fluid group2= other
I/II/III: Category 1 to 3

14 EB 8020-1 EN
Markings on the device
2.3 Actuator nameplate
See associated actuator documentation.
2.4 Other markings
2.4.1 DVGW register number
Typ 3241-G
DVGW-PIN
Klasse D, p zul.
Zul. Außentemp. –20…+60°C
0085
Fig.3: DVGW register number
2.4.2 Material numbers
The seat and plug of the valves have an item
number written on them. Specifying this item
number, you can contact us to nd out which
material is used. Additionally, a seat code is
used to identify the trim material. This seat
code is specied on the nameplate. For more
details on the nameplate, see section2.2.
2.5 Position of marking
The nameplate for the gas version (210) is
afxed to the actuator.
The valve nameplate (80) is afxed to the
ange.
The actuator nameplate (A100) is stuck on
the diaphragm casing (Fig.4).
The plate with the DVGW register number
(212) is afxed to the bellows seal.
210
80
A100
212
Fig.4: Markings on the control valve

EB 8020-1 EN 15

16 EB 8020-1 EN
Design and principle of operation
3 Design and principle of oper-
ation
The Type3241G Valve is a single‑seated
globe valve. It is combined with a SAMSON
Type3271 or Type3277 Pneumatic Actua‑
tor, solenoid valve and strainer (see Fig.5).
Optionally, a positioner can be used.
The seat (4) and plug with plug stem (5) are
installed in the body (1). The plug stem is
screwed to the plug stem with bellows seal
(37). The plug stem is sealed by the metal
bellows and the packing (15). The stem con‑
nector clamps (A26/27) connect the actua‑
tor stem (A7) of the mounted actuator.
The bellows seal (22) is tted with a test con‑
nection (42). It can be used to monitor the
sealing ability of the bellows.
A strainer installed upstream of the valve
body. It prevents solid particles in the pro‑
cess medium from damaging the valve. The
strainer is not required when a central strain‑
er facility is installed.
For special versions made of A216WCC or
A351CF8M in Class300: as a DIN version
of the Type2NI Strainer is only available, a
central strainer facility must be installed
when an ANSI version is used.
The springs in the pneumatic actuator are lo‑
cated either above or below the diaphragm
depending on the selected fail‑safe action
(see section3.1). A change in the signal
pressure acting on the diaphragm causes the
plug to move. The actuator size is deter‑
mined by the diaphragm area.
The process medium ows through the strain‑
er and the valve in the direction indicated by
the arrow. A rise in signal pressure causes
the force acting on the diaphragm in the ac‑
tuator to increase. The springs are com‑
pressed. Depending on the selected direction
of action, the actuator stem retracts or ex‑
tends. As a result, the plug position in the
seat changes and determines the ow rate
through the valve.
The signal pressure pst is applied to the pilot
valve whose coil is connected to the safety
interlock circuit (switch 14, Fig.6 and
Fig.7). During operation, the coil is ener‑
gized and the signal pressure pst acts on the
diaphragm. In the event of a malfunction,
the pilot valve is activated and the pressure
acting on the diaphragm is relieved, causing
the control valve to quickly close.
Note

EB 8020-1 EN 17
Design and principle of operation
Pst
4
5
1
22
37
14
2
10
9
842
15
17
A26/27
A7 Pilot valve
Strainer
1 Body
2Flange
4 Seat
5Plug (with plug stem)
8Threaded bushing (packing nut)
9 Stem connector nut
10 Lock nut
14 Body nut
15 Packing
17 Body gasket
22 Bellows seal
37 Plug stem with metal bellows
42 Test connection
A7 Actuator stem
A26/27 Stem connector clamps
Fig.5: Type3241‑1‑Gas Automatic Shut‑off Valve

18 EB 8020-1 EN
Design and principle of operation
Voltage
Pst
2
13
11
14
11 Pilot valve
13 Positioner
14 Switch for safety
interlock circuit
Fig.6: Functional diagram showing version without positioner
Voltage
Pst
2
1
13
3
11
14
Fig.7: Functional diagram showing version with positioner

EB 8020-1 EN 19
Design and principle of operation
3.1 Fail-safe positions
The fail‑safe position depends on the mount‑
ed actuator.
Depending on how the compression springs
are arranged in the pneumatic actuator, the
valve has two different fail‑safe positions:
Actuator stem extends (FA)
When the signal pressure is reduced or the
air supply fails, the springs move the
actuator stem downward and close the
valve. The valve opens when the signal
pressure is increased enough to overcome
the force exerted by the springs.
Actuator stem retracts (FE)
When the signal pressure is reduced or the
air supply fails, the springs move the
actuator stem upwards and open the valve.
The valve closes when the signal pressure is
increased enough to overcome the force
exerted by the springs.
The "stem retracts" direction of action is only
permitted for a certain version designated
for valve classE. See Table9.
3.2 Versions
Actuators
ÎTo select a suitable actuator, see Table6
(valve classD) or Table9 (valve classE).
3.3 Technical data
The nameplate provides information on the
control valve version (see section2.1).
3.3.1 Common technical data
−DIN DVGW test mark
The valves were typetested by TÜV (Ger‑
man technical surveillance association)
and received the test mark by DVGW
(German Technical and Scientic Associ‑
ation for Gas and Water) as specied in
Table5 or Table8.
−Compliance
The Type3241G Valve bears both the
CE and EAC marks of conformity.
−Leakage class
Leakage class according to DINEN161
Note

20 EB 8020-1 EN
Design and principle of operation
Noise emissions
SAMSON is unable to make general state‑
ments about noise emissions. The noise emis‑
sions depend on the valve version, plant fa‑
cilities and process medium.
Risk of hearing loss or deafness due to loud
noise.
Wear hearing protection when working near
the valve.
WARNING
!
Table1: Materials (material numbers according to DINEN)
Valve DN15 to 150
(NPS½ to 6) DN15 to 80 Strainer
Body1) Cast steel
1.0619 Cast stainless steel 1.4408 Forged steel 1.0460
Forged stain‑
less steel
1.4571
Cast steel
1.0619 Cast stainless steel 1.4408
Valve bonnet 1.0460 1.4404 1.0460 1.4404
Standard strainer insert
and dual strainer insert
1.4401
Seat and plug 1.4404
Plug with soft seal, PTFE seal with 15% glass ber
Guide bushing 1.4104 1.4404 1.4104 1.4404
Packing V‑ring packing: PTFE with carbon · Spring: 1.4310
Intermediate piece 1.0460 1.4404 1.0460 1.4404
Metal bellows 1.4571
Body gaskets Graphite on metal core
1) Special version: A216 WCC or A351 CF8M in Class300. As a DIN version of the Type2NI Strain‑
er is only available, a central strainer facility must be installed.