Samson 3249 Service manual

Translation of original instructions
EB 8048 EN
Edition December 2019
Type3249 Aseptic Angle Valve
In combination with an actuator,
e.g. a SAMSON Type3271 or Type3277 Pneumatic Actuator
Ball body version Special version with packing
Type3249 Valves with Type3277 Actuator and integral 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 8048 EN

Contents
EB 8048 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..............................................................10
2 Markings on the device ...............................................................................12
2.1 Body inscription...........................................................................................12
2.2 Actuator nameplate......................................................................................12
2.3 Material numbers.........................................................................................12
2.4 Label when an adjustable packing is installed ................................................12
3 Design and principle of operation ................................................................14
3.1 Fail-safe positions ........................................................................................14
3.2 Versions ......................................................................................................15
3.3 Additional ttings.........................................................................................17
3.4 Technical data .............................................................................................18
4 Shipment and on-site transport ....................................................................22
4.1 Accepting the delivered goods ......................................................................22
4.2 Removing the packaging from the valve.........................................................22
4.3 Transporting and lifting the valve...................................................................22
4.3.1 Transporting the valve ..................................................................................23
4.3.2 Lifting the valve............................................................................................24
4.4 Storing the valve..........................................................................................25
5 Mounting ....................................................................................................26
5.1 Installation conditions...................................................................................26
5.2 Preparation for installation............................................................................27
5.3 Mounting the device.....................................................................................28
5.3.1 Mounting the actuator onto the valve.............................................................29
5.3.2 Installing the valve into the pipeline ...............................................................29
5.4 Testing the installed valve..............................................................................30
5.4.1 Leak test......................................................................................................31
5.4.2 Travel motion...............................................................................................32
5.4.3 Fail-safe position..........................................................................................32
5.4.4 Pressure test.................................................................................................32
6 Start-up ......................................................................................................33
7 Operation...................................................................................................35
7.1 CIP (cleaning-in-place) .................................................................................36
7.2 SIP (sterilization-in-place) .............................................................................36

Contents
EB 8048 EN
8 Malfunctions ...............................................................................................37
8.1 Troubleshooting ...........................................................................................37
8.2 Emergency action ........................................................................................38
9 Servicing.....................................................................................................39
9.1 Periodic testing ............................................................................................41
9.2 Preparing the valve for service work..............................................................41
9.3 Mounting the valve after service work............................................................42
9.4 Service work................................................................................................43
9.4.1 Replacing the diaphragm and plug ...............................................................43
9.4.2 Replacing the packing..................................................................................44
9.5 Ordering spare parts and operating supplies .................................................44
10 Decommissioning ........................................................................................45
11 Disassembly................................................................................................47
11.1 Removing the valve from the pipeline.............................................................48
11.2 Removing the actuator from the valve ............................................................48
12 Repairs .......................................................................................................49
12.1 Returning devices to SAMSON .....................................................................49
13 Disposal......................................................................................................50
14 Certicates..................................................................................................51
15 Annex.........................................................................................................54
15.1 Tightening torques, lubricants and tools .........................................................54
15.2 Spare parts .................................................................................................54
15.3 After-sales service........................................................................................56

EB 8048 EN 5
Safety instructions and measures
1 Safety instructions and measures
Intended use
The SAMSON Type3249 Angle Valve in combination with an actuator (e.g. Type3271 or
Type3277 Pneumatic Actuator) is designed to regulate the ow rate, pressure or temperature
of liquids, gases or vapors. The angle valve is suitable for use in aseptic applications (e.g. in
the pharmaceutical and food industries).
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 operating conditions 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 applica-
tions 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.

6 EB 8048 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). 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
Check 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
The fail-safe position of the control valve upon air supply or control signal failure depends on
the actuator used (see associated actuator documentation). When the valve is combined with
a SAMSON Type3271 or Type3277 Pneumatic Actuator, the valve moves to a certain fail-
safe position upon supply air or control signal failure (see section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.
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.
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.

EB 8048 EN 7
Safety instructions and measures
Furthermore, the operator must ensure that operating personnel or third persons are not
exposed to any danger.
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.
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 meet the requirements in the Regulation (EC) No.1935/2004 for materi-
als and articles intended to come into contact with food
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. Section14 contains
this declaration of conformity.
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0165-1).
Referenced documentation
The following documents apply in addition to these mounting and operating instructions:
−See Data Sheet uT8048 for technical data as well as dimensions and weights
−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

8 EB 8048 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. 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.

EB 8048 EN 9
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
tension. 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.

10 EB 8048 EN
Safety instructions and measures
WARNING
!
Risk of personal injury through incorrect operation, use or installation as a result of
information on the valve being illegible.
Over time, markings, labels and nameplates on the valve may become covered with dirt
or become illegible in some other way. As a result, hazards may go unnoticed and the
necessary instructions not followed. There is a risk of personal injury.
ÎKeep all relevant markings and inscriptions on the device in a constantly legible
state.
ÎImmediately renew damaged, missing or incorrect nameplates or labels.
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.
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.
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).