Samson V2001 Series Service manual

Mounting and
Operating Instructions
EB 8135/8136 EN
Edition August 2016
Type3535 Three-way Valve with bellows seal and rod-type yoke (partial view)
Series V2001 Valves
Type3535 Three-way Valve for Heat
Transfer Oil

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

2 EB 8135/8136 EN

Contents
EB 8135/8136 EN 3
1 General safety instructions.............................................................................4
2 Design and principle of operation ..................................................................6
2.1 Technical data ...............................................................................................8
2.2 Materials.......................................................................................................8
2.3 KVS and CV coefcients, seat diameters and travel.............................................8
3 Installation....................................................................................................9
3.1 Mounting position..........................................................................................9
3.2 Arrangement of the valve ...............................................................................9
3.3 Strainer and bypass.......................................................................................9
4 Operation...................................................................................................11
5 Maintenance ...............................................................................................11
5.1 Replacing the bellows seal............................................................................12
5.1.1 Disassembly ................................................................................................12
5.1.2 Assembly ....................................................................................................13
5.2 Replacing the seat and plug..........................................................................15
5.2.1 Mixing valve................................................................................................15
5.2.2 Diverting valve.............................................................................................19
5.3 Tools and tightening torques..........................................................................22
6 Description of nameplates............................................................................23
6.1 DIN version .................................................................................................23
6.2 ANSI version ...............................................................................................23
7 Dimensions in mm and inches......................................................................24
8 Customer inquiries ......................................................................................25

4 EB 8135/8136 EN
General safety instructions
1 General safety instructions
−The control valve must be mounted, started up, or serviced by fully trained and qualied
personnel only. Make sure employees or third persons are not exposed to any danger.
All safety instructions and warnings given in these mounting and operating instructions,
particularly those concerning installation, start-up and maintenance, must be strictly ob-
served.
−The control valves comply with the requirements of the European Pressure Equipment Di-
rective 2014/68/EU. Valves with a CE marking have a declaration of conformity which
includes information about the applied conformity assessment procedure. The declaration
of conformity can be viewed and downloaded from uhttp://www.samson.de.
−To ensure appropriate use, only use the valve in applications where the operating pres-
sure and temperatures do not exceed the specications used for sizing the valve at the or-
dering 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 precautions.
−Proper shipping and storage are assumed.

EB 8135/8136 EN 5
General safety instructions
Note:
−For installation and maintenance, make sure the relevant section of the pipeline is depres-
surized and, depending on the process medium, drained as well. Depending on the eld
of application, allow the valve to cool down or heat up to reach ambient temperature be-
fore starting any work on it.
−When working on the valve, make sure that the pneumatic air supply or power supply as
well as the control signal are disconnected to prevent any hazards due to moving parts.
−Be particularly careful if the actuator springs of pneumatic control valves are preloaded.
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.

6 EB 8135/8136 EN
Design and principle of operation
2 Design and principle of oper-
ation
The Type3535 Three-way Valve has a mod-
ular design and can be combined with pneu-
matic or electric actuators (as described in
following):
Control valve Type ...
Actuator
3535-P Pneumatic 3371-01xx
3535-IP Electropneumatic 3372-03xx
3535-E1 Electric 5824-30
3535-E3 3374
Depending on the plug arrangement, the
three-way valve can be used either as a mix-
ing or diverting 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.
In diverting valves, the process medium en-
ters at the valve port AB and the partial
ows exit at ports A and B.
The ow rate from ports A or B to AB and
vice versa depends on the cross-sectional ar-
ea of ow between the seats and plugs.
The plug (3, 3.1, 3.2) is moved by changing
the control signal applied to the actuator.
The plug stem is sealed by a bellows seal
and an additional packing (4.2) and is con-
nected to the actuator stem (8.1) by the stem
connector (7).
AB AABA
BB
2.2
12.2
12
12.1
2.1
1
1.1
6
6.1
6.2
9
5.3
5
5.2
X
10.1
10.2
10.3
5.4
1.2
8.1
8.2
7
4
4.1
4.2
4.3
5.1
3.2
3.1
10.3
10.2
10.1
3.1
X
3.2
12
12.1
12.2
Fig.1: Sectional drawing DN32 to 50, plug arrangement for mixing valve (left) and diverting valve
(right)
1Valve body
1.1 Nuts
1.2 Gasket
2.1 Top seat
2.2 Bottom seat
3.1 Top plug
3.2 Bottom plug
4 Threaded bushing
4.1 Bushing
4.2 Packing (spring-load-
ed for DN65 and
larger)
4.3 Washer
5 Bellows seal with plug
stem
5.1 Coupling nut
5.2 Bellows housing
5.3 Gasket
5.4 Flange
6Plug stem
6.1 Stem connector nut
6.2 Lock nut
7 Stem connector
8.1 Actuator stem
8.2 Rod-type yoke
9Nut
10.1 Sleeve
10.2 Short sleeve
10.3 Sleeve
12 Nut
12.1 Washer
12.2 Retaining washers
XPosition for open-end
wrench

EB 8135/8136 EN 7
Design and principle of operation
2 Design and principle of oper-
ation
The Type3535 Three-way Valve has a mod-
ular design and can be combined with pneu-
matic or electric actuators (as described in
following):
Control valve Type ...
Actuator
3535-P Pneumatic 3371-01xx
3535-IP Electropneumatic 3372-03xx
3535-E1 Electric 5824-30
3535-E3 3374
Depending on the plug arrangement, the
three-way valve can be used either as a mix-
ing or diverting 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.
AB AA
BA
BB
2.2
12.2
12
12.1
2.1
1
1.1
6
6.1
6.2
9
5.3
5
5.2
X
10.1
10.2
10.3
5.4
1.2
8.1
8.2
7
4
4.1
4.2
4.3
5.1
3.2
3.1
10.3
10.2
10.1
3.1
X
3.2
12
12.1
12.2
Fig.1: Sectional drawing DN32 to 50, plug arrangement for mixing valve (left) and diverting valve
(right)
1Valve body
1.1 Nuts
1.2 Gasket
2.1 Top seat
2.2 Bottom seat
3.1 Top plug
3.2 Bottom plug
4 Threaded bushing
4.1 Bushing
4.2 Packing (spring-load-
ed for DN65 and
larger)
4.3 Washer
5 Bellows seal with plug
stem
5.1 Coupling nut
5.2 Bellows housing
5.3 Gasket
5.4 Flange
6Plug stem
6.1 Stem connector nut
6.2 Lock nut
7 Stem connector
8.1 Actuator stem
8.2 Rod-type yoke
9Nut
10.1 Sleeve
10.2 Short sleeve
10.3 Sleeve
12 Nut
12.1 Washer
12.2 Retaining washers
XPosition for open-end
wrench

8 EB 8135/8136 EN
Design and principle of operation
2.1 Technical data
Valve size DN 15 to 80 NPS½ to 3
Material
Spheroidal
graphite iron
EN-JS1049
Cast steel
1.0619
Stainless
steel
1.4408
Spheroidal
graphite
iron A395
Cast steel
A216 WCC
Stainless
steel A351
CF8M
Pressure rating PN16 · PN25 Class150 · Class300
Connection Flanges
EN1092-1 FormB1,
Ra3.2 to 12.5µm
EN1092-1, groove FormD
Raised face
Seat-plug seal Metal seal
Characteristic Linear
Rangeability 30:1 up to DN25 (NPS1) · 50:1 for DN32 (NPS1) and larger
Temperature range –10 to +350°C 14 to 660°F
Leakage class DINEN1349: 0.05% of KVS ANSI/FCI70-2: 0.05% of CV
Compliance ·
2.2 Materials
Valve size DN 15 to 80 NPS½ to 3
Valve body
Spheroidal
graphite iron
EN-JS1049
Cast steel
1.0619
Stainless
steel
1.4408
Spheroidal
graphite
iron A395
Cast steel
A216 WCC
Stainless
steel A351
CF8M
Valve bonnet Cast steel S235JR (St 37) 1.4408 Cast steel S235JR (St 37) 1.4408
Seat ≤DN25: 1.4305 · ≥DN32: 1.4104 ≤NPS1: 1.4305 · ≥NPS1½: 1.4104
Plug 1.4305
Bellows seal 1.4541 · 1.4301
Packing PTFE
Body gasket Graphite on metal core
2.3 KVS and CV coefcients, seat diameters and travel
Valve size DN 15 20 25 32 40 50 65 80
NPS ½¾ 1 – 1½ 22½ 3
KVS coefcients 4 6.3 8 16 20 32 50 80
CV coefcients 5 7.5 9.4 –23 37 60 94
Seat Ø mm/in 24/0.94 40/1.57 65/2.56
Travel mm/in 15/0.59 15/0.59 15/0.59

EB 8135/8136 EN 9
Installation
3 Installation
Valve and actuator are delivered ready
mounted.
Refer to the corresponding mounting and
operating instructions for more details on the
actuator used.
3.1 Mounting position
The valve can be mounted in any desired
position.
ÎObserve the restrictions for the actuator
used.
NOTICE
Install the valve free of stress and
with the least amount of vibrations as
possible. If necessary, support the
pipelines near the connections. Do
not attach supports directly to the
valve or actuator.
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) up-
stream and downstream of the valve.
Contact SAMSON if this distance
cannot be observed.
Flush the pipeline thoroughly before
installation of the valve.
3.2 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 plug arrangement (i.e. either mixing or
diverting valve) is indicated on a label at-
tached to the valve body.
Fail-safe action: the valve shuts off the ow
of the heating medium or opens the ow of
the cooling medium.
3.3 Strainer and bypass
We recommend installing a SAMSON
Type2N Strainer upstream of the valve, and
upstream of both inlet ports in mixing valves.
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.

10 EB 8135/8136 EN
Installation
Mixing service
Temperature control Q = constant
Diverting service
Temperature control Q=0 to 100%
Fail-safe action: FA = Actuator stem extends, FE = Actuator stem retracts
Heating with mixing valve (FA) or cooling with mixing valve (FE)
Installation in ow pipe Installation in return ow pipe
AAB
B
A
AB
B
Flow pipe
Return ow
pipe
Flow pipe
Return ow
pipe
A
AB
B
AAB
B
Flow pipe
Return ow
pipe
Flow pipe
Return ow
pipe
Heating with diverting valve (FA) or cooling with diverting valve (FE)
Installation in return ow pipe Installation in ow pipe
AAB
B
AAB
B
Flow pipe
Return ow
pipe
Flow pipe
Return ow
pipe
A
AB
B
AB A
B
Flow pipe
Return ow
pipe
Flow pipe
Return ow
pipe
Fig.2: Typical installations