Samson 3244-1 Service manual

Mounting and
Operating Instructions
EB 8026 EN
Edition July 2014
Type 3244 1 (left) and Type 3244-7 (right)
Type 3244-1 and Type 3244-7
Pneumatic Control Valves

2 EB 8026 EN
Denition of signal words
DANGER!
Hazardous situations which, if not
avoided, will result in death or seri-
ous injury
WARNING!
Hazardous situations which, if not
avoided, could result in death or seri-
ous injury
NOTICE
Property damage message or mal-
function
Note:
Additional information
Tip:
Recommended action


Contents
EB 8026 EN 3
1 General safety instructions.............................................................................4
2 Design and principle of operation ..................................................................6
3 Assembling valve and actuator ......................................................................8
1.1 Assembly and adjustment ...............................................................................8
4 Installation....................................................................................................9
1.2 Mounting position..........................................................................................9
1.3 Arrangement of the valve ...............................................................................9
1.4 Signal pressure line........................................................................................9
1.5 Strainer, bypass .............................................................................................9
1.6 Test connection.............................................................................................10
5 Operation...................................................................................................12
6 Maintenance – Replacing parts ....................................................................12
1.1 Standard valve version.................................................................................13
1.1.1 Packing.......................................................................................................13
1.1.2 Seat and plug..............................................................................................14
1.2 Valve with insulating section or bellows seal...................................................14
1.2.1 Packing.......................................................................................................14
1.2.2 Seat and plug..............................................................................................16
1.2.3 Metal bellows ..............................................................................................17
1.2.4 Assembly ....................................................................................................17
7 Material number .........................................................................................18
8 Description of nameplates............................................................................18
9 Customer inquiries ......................................................................................19

4 EB 8026 EN
General safety instructions
1 General safety instructions
WARNING!
−The control valves are to be mounted, started up or serviced by fully trained and
qualied personnel only; the accepted industry codes and practices are to be ob-
served. Make sure employees or third persons are not exposed to any danger.
−All safety instructions and warnings given in these mounting and operating instruc-
tions, particularly those concerning installation, start-up and maintenance, must be
strictly observed.
−The control valves comply with the requirements of the European Pressure Equip-
ment Directive 97/23/EC. Valves with a CE marking have a declaration of confor-
mity which includes information about the applied conformity assessment proce-
dure. The Declaration of Conformity is available on request.
−To ensure appropriate use, only use the valve in applications where the operating
pressure and temperatures do not exceed the specications used for sizing the valve
at the ordering stage. The manufacturer does not assume any responsibility for
damage caused by external forces or any other external factors. Any hazards that
could be caused in the valve by the process medium, the operating pressure, the
signal pressure or by moving parts are to be prevented by taking appropriate pre-
cautions.
−Proper shipping and storage are assumed.
NOTICE
−For installation and maintenance, make sure the relevant section of the pipeline is
depressurized and, depending on the process medium, drained as well. Depending
on the eld of application, allow the valve to cool down or warm up to reach ambi-
ent temperature before starting any work on it.
−When working on the valve, make sure that the pneumatic air supply as well as the
control signal are disconnected to prevent any hazards caused by moving parts.
−Be particularly careful if the actuator springs of pneumatic control valves are pre-
loaded. Such actuators are labeled correspondingly and can also be identied by
three long bolts protruding from the bottom of the actuator. Before starting any
work on the valve, relieve the compression from the preloaded springs.

EB 8026 EN 5
General safety instructions
Note:
According to the ignition risk assessment performed in accordance with EN13463-1:
2001, section 5.2, the non-electrical actuators and valves do not have their own po-
tential ignition source even in the rare incident of an operating fault. As a result, they
do not fall within the scope of Directive 94/9/EC.
For connection to the equipotential bonding system, observe the requirements speci-
ed in section 6.3 of EN60079-14: 2011 (VDE0165 Part 1).
Note:
These Mounting and Operating Instructions are also valid for the Type3246 Three-
way Valve – Class150 and 300 in conjunction with the Data Sheet T8046-3EN.



6 EB 8026 EN
Design and principle of operation
2 Design and principle of oper-
ation
The Type3244-1 and Type3244-7 Pneu-
matic Control Valves consist of the
Type3244 Three-way Valve and either a
Type3271 or Type3277 Pneumatic Actua-
tor. The modular design allows the actuators
to be exchanged and an insulating section
or metal bellows to be tted to the standard
valve version.
Depending on the plug version, the three-
way valve can be used either as a mixing or
diverting valve (in DN 15 to 25, the plugs
are identical).
In mixing valves, the process media to be
mixed enter at valve ports Aand B. The
combined ow exits the valve at port AB.
In diverting valves, the process medium en-
ters at the valve port AB and the partial
ows exit at ports Aand B.
The ow rate from ports Aor Bto AB and
vice versa depends on the cross-sectional ar-
ea of ow between the seat (2.1, 2.2) and
plug (3) and, as a result, on the position of
the plug stem (6).
The plug (3) is moved by a change in signal
pressure acting on the diaphragm of the ac-
tuator.
The plug stem (6) and actuator stem (8.1)
are connected by the stem connector (7) and
sealed by a spring-loaded PTFE ring packing
(4.2).
Fail-safe position
Depending on how the compression springs
are arranged in the actuator, the valve has
two different fail-safe positions:
Actuator stem extends
When the pressure is relieved or the supply
air fails, the springs cause port B(mixing
valves) or port A(diverting valves) to close.
The valve ports Bor Aare opened against
the force of the springs when the signal pres-
sure increases.
Actuator stem retracts
When the pressure is relieved or the supply
air fails, the springs cause port B(mixing
valves) or port A(diverting valves) to open.
The valve ports Bor Aare closed against the
force of the springs when the signal pressure
increases.

EB 8026 EN 7
Design and principle of operation
8
8.2
8.1
1.1
1.2
6
AB A
B
5
5.3
7
6.1
6.2
5.2
4.2
4.1
2.1
3
2.2
8
8.1
8.2
7
1.1
5
6.1
6.2
6
1.2
2.1
2.2
3.1
3.2
AB A
B
3
1.1 Nuts 5.2 Threaded bushing
1.2 Gasket 5.3 Travel indicator scale
2.1 Top seat 6 Plug stem
2.2 Bottom seat 6.1 Stem connector nut
3 Plug 6.2 Lock nut
3.1 Plug section 7 Stem connector
3.2 Screw 8 Actuator
4.1 Spring 8.1 Actuator stem
4.2 Packing 8.2 Nut
5 Valve bonnet
Type3271 Actuator
Type3277 Actuator
Plug arrangement for mixing service,
in DN15 to 25 also for diverting service
Plug arrangement for diverting service
DN32 to 150
Fig.1: Sectional drawings

8 EB 8026 EN
Assembling valve and actuator
3 Assembling valve and actua-
tor
The basic pneumatic actuator can be re-
placed by a pneumatic actuator with addi-
tional handwheel or by an electric actuator.
A pneumatic actuator (with or without hand-
wheel) can be replaced by another pneumat-
ic actuator in a different size.
If the travel range of the actuator is larger
than the travel range of the valve, the springs
in the actuator are preloaded by SAMSON
so that the travel ranges match.
3.1 Assembly and adjustment
Proceed as follows if the valve and actuator
have not been assembled by SAMSON or if
the actuator is to be replaced by an actuator
of another type or size:
1. Loosen the lock nut(6.2) and stem con-
nector nut(6.1) on the valve.
2. Press the plug together with the plug stem
rmly into the seat ring. Thread down the
lock nut and stem connector nut.
3. Remove the clamps of the stem connector
(7) and the ring nut (8.2) from the actua-
tor (8).
4. Slide the ring nut over the plug stem.
5. Place the actuator onto the valve bonnet
(5) and secure it with the ring nut (8.2).
6. Read the bench range (or bench range
with preloaded springs) and the actua-
tor's fail-safe action from the actuator's
nameplate (e.g.0.2 to 1bar and "actua-
tor stem extends").
The lower value corresponds to the lower
bench range value (0.2bar) to be adjusted,
whereas the upper value corresponds to the
upper bench range value (1bar).
The fail-safe action "actuator stem extends"
or "actuator stem retracts" is marked by FA
or FE on the Type3271 Actuator, and by a
corresponding symbol on the nameplate of
the Type3277 Actuator.
7. For actuators with "actuator stem ex-
tends" fail-safe action, apply a signal
pressure that corresponds to the lower
bench range value (e.g. 0.2bar) to the
connection on the bottom diaphragm
chamber.
For actuators with "actuator stem re-
tracts" fail-safe action, apply a signal
pressure that corresponds to the upper
bench range value (e.g. 1bar) to the top
diaphragm chamber connection.
8. Screw on the stem connector nut(6.1) by
hand until it touches the actuator stem
(8.1). Then turn it a further ¼turn and
secure this position with the lock
nut(6.2).
9. Position clamps of the stem connector (7)
and screw them tight.
10.Align the travel indicator(5.3) with the
tip of the stem connector.

EB 8026 EN 9
Installation
4 Installation
4.1 Mounting position
The valve can be mounted in any desired
position. However, to avoid increase wear at
the packing, install valves in DN100 or
larger in the upright position with the actua-
tor on top.
For valves tted with an insulating section or
bellows seal and for actuators weighing
more than 50kg, the actuator needs to be
supported or suspended.
NOTICE
Install the valve free of stress.
Pipeline routing
To ensure that the control valve func-
tions properly, the pipeline must be
straight and without any manifolds or
disturbances for a distance of at least
6times the valve size (DN) upstream
and downstream of the valve. Con-
tact SAMSON if this distance cannot
be observed.
Flush the pipeline thoroughly before
installing the valve.
Note:
Only insulate control valves with in-
sulating section or bellows seal up to
the bonnet ange of the valve body
for medium temperatures below 0°C
and above 220°C.
Do not insulate valves mounted to
comply with NACE MR0175 require-
ments.
4.2 Arrangement of the valve
Install the valve as shown in Fig.2 depend-
ing on whether it is to be used for mixing or
diverting service.
The installation examples apply to standard
operation with fail-safe action "actuator stem
extends" for heating applications and "actu-
ator stem retracts" for cooling applications.
Fail-safe position
The valve shuts off the ow of the heating or
cooling medium.
The plug arrangement (i.e. either mixing or
diverting valve) is indicated on a label at-
tached to the valve body.
In DN15 to25, the plug arrangement is the
same for mixing and diverting valves.
4.3 Signal pressure line
Connect the signal pressure line for valves
with an actuator with "actuator stem ex-
tends" fail-safe action to the connection on
the bottom diaphragm case, and for valves
with an actuator with "actuator stem re-
tracts" fail-safe action to the connection on
the top diaphragm case.
In the Type3277 Actuator, the bottom signal
pressure connection is located at the side of
the yoke under the bottom diaphragm case.
4.4 Strainer, bypass
We recommend installing a SAMSON
Type2 Strainer upstream of the valve, and
upstream of both inlet ports in mixing valves.


10 EB 8026 EN
Installation
We recommend installing a shut-off valve
both upstream of the strainer and down-
stream of the valve to ensure that the plant
does not need to be shut down for mainte-
nance. In addition, install a bypass line.
4.5 Test connection
Versions with bellows seal (Fig.4) tted with
a test connection (G
1
/
8
) at the top ange al-
low the tightness of the bellows to be moni-
tored. Particularly for liquids and vapors, we
recommend installing a suitable leakage in-
dicator, such as a contact pressure gauge,
an outlet to an open vessel or an inspection
glass.