Samson EB8048-2 Service manual

Translation of original instructions
EB 8048-2/-3 EN
Type3349-7 Control Valve with
Type3730 Electropneumatic Positioner
Type3349/3379 Control Valve with
Type3724 Positioner
Edition March 2017
Type3349 Aseptic Angle Valve with USP-VI diaphragm
In combination with an actuator,
e.g. a SAMSON Type3271 or Type3277 Pneumatic Actuator or
Type3379 Pneumatic Actuator

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 8048-2/-3 EN

Contents
EB 8048-2/-3 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 ......................................................................................10
2.3 Material number ..........................................................................................10
3 Design and principle of operation ................................................................12
3.1 Fail-safe positions ........................................................................................12
3.2 Versions ......................................................................................................15
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 .......................................................................................................23
4.4 Preparation for installation ............................................................................24
5 Mounting and start-up.................................................................................26
5.1 Mounting the actuator onto the valve .............................................................26
5.1.1 Version with Type3271 or Type3277 Actuator ..............................................26
5.1.2 Version with Type3379 Actuator ..................................................................27
5.2 Installing the valve into the pipeline ...............................................................28
5.2.1 Checking the installation conditions ...............................................................28
5.2.2 Installing the control valve .............................................................................30
5.3 Preparing for operation ................................................................................30
5.4 Quick check ................................................................................................31
6 Operation...................................................................................................32
6.1 CIP (cleaning-in-place) .................................................................................33
6.2 SIP (sterilization-in-place) .............................................................................33

Contents
4 EB 8048-2/-3 EN
7 Servicing.....................................................................................................34
7.1 Version with Type3271 or Type3277 Actuator ..............................................35
7.1.1 Replacing the packing ..................................................................................35
7.1.2 Replacing the diaphragm and plug ...............................................................37
7.2 Version with Type3379 Actuator ..................................................................39
7.2.1 Replacing the packing ..................................................................................39
7.2.2 Replacing the diaphragm and plug ...............................................................40
7.3 Checking the concentricity of the plug to the plug stem ....................................42
7.4 Preparation for return shipment .....................................................................42
7.5 Ordering spare parts and operating supplies .................................................43
8 Malfunctions ...............................................................................................44
8.1 Troubleshooting ...........................................................................................44
8.2 Emergency action ........................................................................................45
9 Decommissioning and disassembly ..............................................................46
9.1 Decommissioning .........................................................................................46
9.2 Removing the valve from the pipeline .............................................................46
9.3 Removing the actuator from the valve ............................................................47
9.4 Disposal ......................................................................................................47
10 Annex.........................................................................................................48
10.1 After-sales service ........................................................................................48
10.2 Certicates ..................................................................................................49
10.3 Spare parts .................................................................................................50

EB 8048-2/-3 EN 5
Safety instructions and measures
1 Safety instructions and measures
Intended use
The SAMSON Type3349 Angle Valve in combination with an actuator (e.g. Type3271,
Type3277 or Type3379 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 ap-
plications (e.g. in the pharmaceutical and food industries).
The valve with its actuator is designed to operate 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, contact SAMSON.
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.
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.

6 EB 8048-2/-3 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 features
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
exposed 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 8048-2/-3 EN 7
Safety instructions and measures
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
Directive 2014/68/EU. 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 or uEB8315 for Type3379 Actuator
−Mounting and operating instructions for mounted valve accessories (positioner, solenoid
valve etc.) e.g. uEB8395 for Type3724 Positioner
−uAB0100 for tools, tightening torques, and lubricant
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 8048-2/-3 EN
Safety instructions and measures
1.2 Notes on possible personal injury
WARNING
!
Crush hazard arising from moving parts.
The Type3349-1 or Type3349-7 Pneumatic 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 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.
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.

EB 8048-2/-3 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
!
Risk of contamination of the process medium through the use of unsuitable lubricant
and/or contaminated tools and components.
ÎKeep the valve and the tools used free from solvents and grease.
ÎMake sure that only suitable lubricants are used.
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).
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).

10 EB 8048-2/-3 EN
Safety instructions and measures
NOTICE
!
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
The details on the valve version are lasered
onto the front and back of the valve body
(see Fig.1). No nameplate is used.
2.2 Actuator nameplate
See associated actuator documentation.
2.3 Material number
The seat and plug of the valves have an arti-
cle number written on them. Specifying this
article number, you can contact us to nd out
which material is used.
Body
inscription
Fig.1: Body inscription