Samson 3510 Service manual

Mounting and
Operating Instructions
EB 8091-1 EN
Translation of original instructions
Edition September 2016
Type3510-1 (left) and Type3510-7 (right) Pneumatic Control Valves
Type3510 Micro-ow Valve
In combination with an actuator,
e.g. a SAMSON Type3271 or Type3277 Pneumatic Actuator
ANSI version

2 EB 8091-1 EN
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
(www.samson.de) > Product documentation. You can enter the document
number or type number in the [Find:] eld to look for a document.
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

Contents
EB 8091-1 EN 3
1 Safety instructions and measures ...................................................................5
1.1 Notes on possible severe personal injury .........................................................7
1.2 Notes on possible personal injury ...................................................................8
1.3 Notes on possible property damage................................................................9
2 Markings on the control valve......................................................................10
2.1 Body inscription...........................................................................................10
2.2 Actuator nameplate......................................................................................11
2.3 Material number..........................................................................................11
3 Design and principle of operation ................................................................12
3.1 Fail-safe positions ........................................................................................12
3.2 Versions ......................................................................................................14
3.3 Technical data .............................................................................................14
4 Measures for preparation............................................................................20
4.1 Unpacking ..................................................................................................20
4.2 Transporting and lifting ................................................................................20
4.2.1 Transporting ................................................................................................20
4.2.2 Lifting..........................................................................................................20
4.3 Storage.......................................................................................................21
4.4 Preparation for installation............................................................................21
5 Mounting and start-up.................................................................................23
5.1 Mounting the actuator onto the valve.............................................................23
5.2 Installing the valve into the pipeline ...............................................................23
5.2.1 Checking the installation conditions...............................................................23
5.2.2 Additional ttings.........................................................................................25
5.2.3 Installing the control valve.............................................................................25
5.3 Quick check ................................................................................................26
6 Operation...................................................................................................28
6.1 Working in manual mode.............................................................................28
7 Servicing.....................................................................................................30
7.1 Replacing the gasket ....................................................................................31
7.1.1 Standard version..........................................................................................31
7.1.2 Version with insulating section.......................................................................31

4 EB 8091-1 EN
Contents
7.1.3 Version with bellows seal..............................................................................34
7.2 Replacing the packing..................................................................................36
7.3 Replacing the seat and plug..........................................................................38
7.3.1 Standard version..........................................................................................38
7.3.2 Version with insulating section.......................................................................39
7.4 Preparation for return shipment.....................................................................40
7.5 Ordering spare parts and operating supplies .................................................41
8 Malfunctions ...............................................................................................42
8.1 Troubleshooting ...........................................................................................42
8.2 Emergency action ........................................................................................43
9 Decommissioning and disassembly ..............................................................44
9.1 Decommissioning.........................................................................................44
9.2 Removing the valve from the pipeline.............................................................44
9.3 Removing the actuator from the valve ............................................................45
9.4 Disposal......................................................................................................45
10 Appendix....................................................................................................45
10.1 After-sales service........................................................................................45
10.2 Spare parts .................................................................................................46

EB 8091-1 EN 5
Safety instructions and measures
1 Safety instructions and measures
Intended use
The SAMSON Type3510 Micro-ow Valve in combination with an actuator (e.g. Type3271
or Type3277 Pneumatic Actuator) is designed to regulate the ow rate, pressure or tempera-
ture of liquids, gases or vapors. The micro-ow valve is suitable for controlling low ow
rates, e.g. in pilot plants and technical research facilities. The valve with its actuator is de-
signed to operate under exactly dened conditions (e.g. operating pressure, process medi-
um, temperature). Therefore, operators must ensure that the control valve is only used in ap-
plications 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 8091-1 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 8091-1 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.
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8310-1 for
Type3271 and Type3277 Pneumatic Actuator with 120cm² actuator area
−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
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.

8 EB 8091-1 EN
Safety instructions and measures
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.
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 any process medium residues from the plant sections concerned as
well as from the valve and any dead cavities.
ÎThoroughly ush the pipelines. The plant operator is responsible for cleaning the
pipelines.
ÎWear protective clothing, safety gloves, and eyewear.

EB 8091-1 EN 9
Safety instructions and measures
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.
1.3 Notes on possible property damage
NOTICE
!
Incorrect control due to a combination of trim parts that do not match each other.
The trim parts (seat, plug, anti-rotation xture, and body gasket) are matched to exactly
t each other. The trim parts are delivered together and marked accordingly (see sec-
tion2.3).
ÎOnly install matching trim parts.
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.
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).

10 EB 8091-1 EN
Markings on the control valve
NOTICE
!
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).
2 Markings on the control valve
2.1 Body inscription
SAMSON 3510
1 2
4
6
5
3
8
7
Fig.1: Body inscription
1 Valve size:
DIN: DN · ANSI: NPS· JIS: DN…A/B
2 Pressure rating:
DIN: PN · ANSI: CL · JIS: K
3 Flange/end connection type
4 Material
5 Order number and position number in the order
For after-sales service orders: AA prex
6 Heat number
7 Month and year associated with EAC symbol
8PED (Pressure Equipment Directive), "Art. 4, Abs. 3"
ID of the notied body, uid group, and category