Samson 3244 User manual

Translation of original instructions
EB 8026 EN
Edition August 2016
Type 3244 Valve · DIN and ANSI versions
In combination with an actuator,
e.g. a SAMSON Type3271 or Type3277 Pneumatic Actuator
Type3244 Valve with Type3271 Actuator (left) and Type3277 Actuator (right)

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
at www.samson.de > Service & Support > Downloads > Documentation.
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
2 EB 8026 EN

Contents
EB 8026 EN 3
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 control valve......................................................................12
2.1 Valve nameplate ..........................................................................................12
2.2 Actuator nameplate......................................................................................13
2.3 Material number..........................................................................................13
3 Design and principle of operation ................................................................14
3.1 Fail-safe positions ........................................................................................14
3.2 Versions ......................................................................................................16
3.3 Technical data .............................................................................................16
4 Measures for preparation............................................................................20
4.1 Unpacking ..................................................................................................20
4.2 Transporting and lifting ................................................................................20
4.2.1 Transporting ................................................................................................21
4.2.2 Lifting..........................................................................................................21
4.3 Storage.......................................................................................................22
4.4 Preparation for installation............................................................................23
5 Mounting and start-up.................................................................................24
5.1 Mounting the actuator onto the valve.............................................................24
5.2 Installing the valve into the pipeline ...............................................................25
5.2.1 Checking the installation conditions...............................................................25
5.2.2 Additional ttings.........................................................................................26
5.2.3 Installing the control valve.............................................................................28
5.3 Quick check ................................................................................................29
6 Operation...................................................................................................30
6.1 Working in manual mode.............................................................................30
7 Servicing.....................................................................................................32
7.1 Replacing the gasket ....................................................................................33
7.1.1 Standard version..........................................................................................33
7.1.2 Version with insulating section or bellows seal................................................35

Contents
4 EB 8026 EN
7.2 Replacing the packing..................................................................................35
7.2.1 Standard version..........................................................................................35
7.2.2 Version with insulating section.......................................................................36
7.3 Replacing the seat and plug..........................................................................38
7.4 Preparation for return shipment.....................................................................39
7.5 Ordering spare parts and operating supplies .................................................39
8 Malfunctions ...............................................................................................40
8.1 Troubleshooting ...........................................................................................40
8.2 Emergency action ........................................................................................41
9 Decommissioning and disassembly ..............................................................42
9.1 Decommissioning.........................................................................................42
9.2 Removing the valve from the pipeline.............................................................42
9.3 Removing the actuator from the valve ............................................................42
9.4 Disposal......................................................................................................42
10 Appendix....................................................................................................43
10.1 After-sales service........................................................................................43
10.2 Certicates ..................................................................................................43
10.3 Spare parts .................................................................................................49

EB 8026 EN 5
Safety instructions and measures
1 Safety instructions and measures
Intended use
The SAMSON Type3244 Three-way Valve in combination with an actuator, e.g. Type3271
or Type3277 Pneumatic Actuator, is designed as a mixing or diverting valve for use in pro-
cess engineering and industrial applications. The valve with its actuator is designed to oper-
ate under exactly dened conditions (e.g. operating pressure, process 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, 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
−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. 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.

6 EB 8026 EN
Safety instructions and measures
Personal protective equipment
We recommend wearing the following protective equipment depending on the process medi-
um:
−Protective clothing, gloves and eyewear in applications with hot, cold, and/or corrosive
media
−Wear 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 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 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 spec-
i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. They
must observe all hazard statements, warning and caution notes in these mounting and oper-
ating instructions, especially for installation, start-up, and service work.
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 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.

EB 8026 EN 7
Safety instructions and measures
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).
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 ignition 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 Part 1).
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
−For oxygen service: Manual uH01

8 EB 8026 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 as well as the valve.
ÎDrain the process medium from all the plant sections concerned 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 stems), which can injure
hands or ngers if inserted into the valve.
ÎDo not insert hands or nger 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 8026 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 concerned and the
valve.
ÎWear protective clothing, safety gloves, and eyewear.
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.
Risk of valve damage due to unsuitable medium properties.
The valve is designed for a process medium with dened properties.
ÎOnly use the process medium specied for sizing the valve.

10 EB 8026 EN
Safety instructions and measures
NOTICE
!
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 tight-
ened torques lead to parts wearing out quicker. Parts that are too loose may cause leak-
age.
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 valve surface.
ÎOnly use lubricants approved by SAMSON (uAB0100).

EB 8026 EN 11

12 EB 8026 EN
Markings on the control valve
2 Markings on the control valve
2.1 Valve nameplate
6 8
12 13
10 11
14 15 16 17 18
1…5 9
SAMSON
20
Fig.1: Valve nameplate
1…5 PED (Pressure Equipment Directive), "Art. 4, Abs. 3"
ID of the notied body, uid group, and category
6 Type designation
8Material
9Year of manufacture
10 Valve size:
DIN: DN · ANSI: NPS· JIS: DN…A/B
11 Pressure rating:
DIN: PN · ANSI: CL · JIS: K
12 Order no. with modication index
For after-sales service orders: AA prex
13 Position in order
For after-sales service orders: conguration ID
14 Flow coefcient:
DIN: KVS · ANSI: CV · JIS: CV
15 Characteristic:
Lin: linear
16 Seat/plug seal:
ME: metal (see section3.3)
HA: carbide metal
ST: Stellite® facing
17 Seat code (trim material) · On request
18 Version:
Mixing valve: M · Diverting valve: V
20 Country of origin

EB 8026 EN 13
Markings on the control valve
The valve nameplate (80) is afxed to the
ange (see Fig.2).
80
Fig.2: Nameplate on the ange
2.2 Actuator nameplate
See associated actuator documentation.
2.3 Material number
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 (17). For
more details on the nameplate, see sec-
tion2.1.

14 EB 8026 EN
Design and principle of operation
3 Design and principle of oper-
ation
The Type3244 is a three-way valve which
can be used either as a mixing or diverting
valve. The design of the mixing and divert-
ing valves in sizes DN15 to 25 (NPS½ to
1) is identical. The Type3244 Valve is pref-
erably combined with a SAMSON
Type3271 or Type3277 Pneumatic Actuator
(see Fig.3). It can also be combined with
other actuators.
The two seats (4 and 141) and plug with
plug stem (5) are assembled in the body (1).
The plug stem is connected to the actuator
stem (A7) by the stem connector clamps
(A26/27) and is sealed by a spring-loaded
V-ring packing (15). The springs in the pneu-
matic actuator (A) are located 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 ac-
tuator size is determined by the diaphragm
area.
The medium ows through the valve in the
direction indicated by the arrow. A rise in
signal pressure causes the force acting on
the diaphragm in the actuator to increase.
The springs are compressed. Depending on
the selected direction of action, the actuator
stem retracts or extends. As a result, the plug
position in the seats changes and determines
the ow rate through the valve.
In mixing valves, the process media to be
mixed enter at valve ports A and B. The
combined ow exits the valve at port AB (see
Fig.3).
In diverting valves, the process medium en-
ters at the valve port AB and the partial
ows exit at ports A and B (see Fig.4).
3.1 Fail-safe positions
The fail-safe position depends on the actua-
tor used.
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
power supply fails, the springs move the ac-
tuator stem downward, closing port Bin the
mixing valve or port A in the diverting valve.
Legend for Fig.3 and Fig.4
1 Body
2 Flange
4Top seat
5Plug (with plug stem)
8Threaded bushing
(packing nut)
9 Stem connector nut
10 Lock nut
14 Nuts
15 Packing
17 Body gasket
84 Travel indicator scale
141 Bottom seat
A7 Actuator stem
A8 Ring nut
A26/
27 Stem connector clamps

EB 8026 EN 15
Design and principle of operation
Fig.3: Type3244 Valve (as mixing valve)
with Type3271 Pneumatic Actuator
Fig.4: Type3244 Valve (as diverting valve)
AB A
B
141
5
4
14
9
A26/27
5
4
1
2
15
8
10
A8
A7
141
17
84
A
AB
B

16 EB 8026 EN
Design and principle of operation
Actuator stem retracts (FE)
When the signal pressure is reduced or the
power supply fails, the springs move the ac-
tuator stem upward, closing port Ain the
mixing valve or port B in the diverting valve.
The actuator's direction of action can be re-
versed, if required. Refer to the mounting
and operating instructions of the pneumatic
actuator:
uEB8310‑X for Type3271 and Type3277
3.2 Versions
The modular design allows an insulating sec-
tion or bellows seal to be tted to the stan-
dard valve version.
Actuators
In these instructions, the preferable combina-
tion with a Type3271 or Type3277 Pneu-
matic Actuator is described. The pneumatic
actuator (with or without handwheel) can be
replaced by another pneumatic actuator in a
different size, but with the same travel.
ÎObserve the maximum permissible actu-
ator force.
If the travel range of the actuator is larger
than the travel range of the valve, the spring
assembly in the actuator must be preloaded
so that the travel ranges match. See associ-
ated actuator documentation.
The basic pneumatic actuator can be re-
placed by a pneumatic actuator with addi-
tional handwheel or by an electric actuator.
3.3 Technical data
The nameplates on the valve and actuator
provide information on the control valve ver-
sion. See section2.1 and the actuator docu-
mentation.
More information is available in Data Sheet
uT8026.
Compliance
The Type3244 Valve bears both the CE and
EAC marks of conformity.
Temperature range
Depending on the version, the control valve
is designed for a temperature range from
–10 to +220°C (14 to 428°F). The use of
an insulating section or bellows seal extends
the temperature range from –196 to
+450°C (–325 to +842°F).
Noise emission
SAMSON is unable to make general state-
ments about noise emission as it depends on
the valve version, plant facilities, and pro-
cess medium.
Tip
Note
Note

EB 8026 EN 17
Design and principle of operation
Dimensions and weights
Table1 to Table4 provide a summary of the dimensions and weights of the standard version
of Type3244 Valve as well as the version with insulating section or bellows seal. The lengths
and heights in the dimensional drawings are shown on p.19.
The associated actuator documentation applies to actuators, e.g. for SAMSON pneumatic
actuators:
uT8310‑1 for Type3271 and Type3277 Actuators up to 750cm² actuator area
Table1: Dimensions of the standard version of Type3244 Valve (DIN version)
Valve DN 15 20 25 32 40 50 65 80 100 125 150
Lmm 130 150 160 180 200 230 290 310 350 400 480
H1 mm 235 270 360 375
H2 mm 70 80 85 100 105 120 130 140 150 200 210
Note
Risk of hearing loss or deafness due to loud
noise.
Wear hearing protection when working near
the valve.
WARNING
!

18 EB 8026 EN
Design and principle of operation
Table2: Dimensions of the standard version of Type3244 Valve (ANSI version)
Valve DN 15 20 25 40 50 65 80 100 150
NPS ½ ¾ 1 1½ 2 2½ 3 4 6
L
Class 150 mm 184 184 184 222 254 276 298 352 451
in 7.25 7.25 7.25 8.75 10.00 10.88 11.75 13.88 17.75
Class 300 mm 190 194 197 235 267 292 318 368 473
in 7.50 7.62 7.75 9.25 10.50 11.50 12.50 14.50 18.62
H1 mm 235 270 360 375
in 9.25 10.63 14.17 14.76
H2
Class150 mm 92 92 92 111 127 138 149 176 225.50
in 3.62 3.62 3.62 4.37 5.00 5.43 5.87 6.93 8.88
Class 300 mm 95 97 98.50 117.50 133.50 146 159 184 236.50
in 3.76 3.82 3.88 4.63 5.26 5.75 6.26 7.24 9.31
Table3: Dimensions for version with insulating section or bellows seal
Valve DN 15 20 25 32 40 50 65 80 100 125 150
NPS ½ ¾ 1 – 1½ 2 2½ 3 4 – 6
H4
Insulating
section/
bellows seal
mm 420 455 645 655
in 16.54 17.91 25.39 25.79
Long
insulating
section/
bellows seal
mm 725 760 895 900
in 28.54 29.92 35.24 35.43

EB 8026 EN 19
Design and principle of operation
Dimensional drawings
L
H1H2
H4
Standard version of Type3244 Type3244 with insulating section or bellows seal
Table4: Weights of Type3244 Valve · Without actuator
Valve DN 15 20 25 32 40 50 65 80 100 125 150
NPS ½ ¾ 1 – 1½ 2 2½ 3 4 – 6
Standard version kg 6 7 813 15 17 31 37 49 95 135
lbs 13 15.5 17.5 28.7 33 37.5 68 82 108 210 298
Ver-
sion
with
Insulating
section/
bellows
seal
kg 910 11 19 21 23 40 45 68 120 165
lbs 20 22 24 42 46.3 50.7 88 99 150 265 364
Long in-
sulating
section/
bellows
seal
kg 13 14 15 23 25 27 44 49 76 128 173
lbs 28.7 30.9 33 50.7 55 59.5 97 108 168 282 382

20 EB 8026 EN
Measures for preparation
4 Measures for preparation
After receiving the shipment, proceed as fol-
lows:
1. Check the scope of delivery. Compare
the shipment received against the deliv-
ery note.
2. Check the shipment for transportation
damage. Report any damage to
SAMSON and the forwarding agent (re-
fer to delivery note).
4.1 Unpacking
Do not remove the packaging until immedi-
ately before installing the valve into the pipe-
line.
Proceed as follows to lift and install the
valve:
1. Remove the packaging from the valve.
2. Dispose of the packaging in accordance
with the valid regulations.
Risk of valve damage due to foreign parti-
cles entering the valve.
The protective caps tted on the valve's inlet
and outlet prevent foreign particles from en-
tering the valve and damaging it.
Do not remove the protective caps until im-
mediately before installing the valve into the
pipeline.
4.2 Transporting and lifting
Hazard due to suspended loads falling.
Stay clear of suspended or moving loads.
Risk of lifting equipment tipping and risk of
damage to lifting accessories due to exceed-
ing the rated lifting capacity.
−Only use approved lifting equipment and
accessories whose minimum lifting
capacity is higher than the weight of the
valve (including actuator, if applicable).
−Refer to section3.3 or Data Sheet
uT8026 for weights.
Risk of personal injury due to control valve
tipping.
−Observe the valve's center of gravity.
−Secure the valve against tipping over or
turning.
Risk of valve damage due to incorrectly at-
tached slings.
The welded‑on lifting eyelet on SAMSON
actuators is only intended for mounting and
removing the actuator as well as lifting the
actuator without valve. Do not use this lifting
eyelet to lift the entire control valve assembly.
Note
NOTICE
!
DANGER
!
WARNING
!
WARNING
!
NOTICE
!