Samson 3510 Mounting And Operating Instructions

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.

Î For the safe and proper use of these instructions, read them carefully and keep them for

later reference.

Î If 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 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 tempera­ture 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 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,
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.

Î Refer 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 8091-1 EN

Safety instructions and measures

Personal protective equipment

We recommend wearing the following protective equipment depending on the process medi­um:

− Protective clothing, gloves and eyewear in applications with hot, cold, and/or corrosive
media

− Wear hearing protection when working near the valve.

Î Check 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. Fur­thermore, 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 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 (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 operat­ing 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 oper­ating 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 ap­plicable 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 Direc­tive 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.

Î For 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.

Î Before starting any work on the control valve, depressurize all plant sections

concerned as well as the valve.

Î Drain the process medium from all the plant sections concerned as well as the

valve.

Î Wear 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.

Î Do not insert hands or nger into the yoke while the valve is in operation.
Î While 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.

Î Install the control valve in such a way that the actuator does not vent at eye level.
Î Use suitable silencers and vent plugs.
Î Wear 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 ten­sion. These control valves with SAMSON pneumatic actuators can be identied by the
long bolts protruding from the bottom of the actuator.

Î Before 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.

Î If possible, drain any process medium residues from the plant sections concerned as

well as from the valve and any dead cavities.

Î Thoroughly ush the pipelines. The plant operator is responsible for cleaning the

pipelines.

Î Wear 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.

Î Allow components and pipelines to cool down or heat up.
Î Wear 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 sec­tion2.3).

Î Only 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.

Î Flush the pipelines before start-up.
Î Observe 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.

Î Only 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 tight­ened torques lead to parts wearing out quicker. Parts that are too loose may cause leak­age.

Î Observe 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.

Î Only 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 cor­rode and damage the valve surface.

Î Only 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
8 PED (Pressure Equipment Directive), "Art. 4, Abs. 3"

ID of the notied body, uid group, and category

EB 8091-1 EN 11

Markings on the control valve

The details on the valve version are lasered
onto the valve body (see Fig.1).

2.2 Actuator nameplate

See associated actuator documentation.

2.3 Material number

The valve are marked as follows:

Seat

− Material number

− SAMSON consecutive number

Plug

− Material number

− SAMSON consecutive number

− K

VS

coefcient and characteristic

Anti-rotation xture (on the trim)

Î See Fig.2

− Plug material

− Seat material

− K

VS/CV

− Characteristic

− SAMSON consecutive number

Anti-rotation xture (on the bellows seal)

− Bellows material

− Nominal pressure

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.

Only install matching trim parts.

1
2
3
4

Plug 1.4404

1.4404
0,025 lin

Seat
kvs
4 711

1 Plug material
2 Seat material
3 K

VS

coefcient and characteristic

4 Consecutive number

Fig.2: Anti-rotation xture (on the trim)

NOTICE

!

12 EB 8091-1 EN

Design and principle of operation

3 Design and principle of oper-

ation

The Type3510 Micro-ow Valve is available
as either a globe or angle valve and is pref­erably combined with a SAMSON
Type3271 or Type3277 Pneumatic Actuator
with 120cm² actuator area. It can also be
combined with other actuators.

The seat (2.2) and plug (2.1) are installed in
the body (1). The plug stem is connected to
the actuator stem (A7) by the stem connector
and is sealed by an adjustable packing with
PTFE seal rings (34).

The anti-rotation xture (2.4) prevents a
loosening of the screw connection between
the valve body and intermediate piece (4).
Two anti-rotation xtures are used for ver­sions with an insulating section or bellows
seal: one anti-rotation xture between the
body and insulating section/bellows seal as
well as one anti-rotation xture between the
insulating section/bellows seal and interme­diate piece.

The springs in the pneumatic actuator 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 actuator 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 seat changes and determines
the ow rate through the valve.

3.1 Fail-safe positions

The fail-safe position depends on the actua­tor 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
air supply fails, the springs move the actua­tor stem downward and close the valve. The
valve opens when the signal pressure is in­creased enough to overcome the force exert­ed by the springs.

Actuator stem retracts (FE)

When the signal pressure is reduced or the
air supply fails, the springs move the actua­tor stem upwards and open the valve. The
valve closes when the signal pressure is in­creased enough to overcome the force exert­ed by the springs.

The actuator's direction of action can be re­versed, if required. Refer to the operating
and mounting instructions of the pneumatic
actuator, e.g. uEB8310-1 for Type3271
and Type3277 with 120cm² actuator area.

Tip

EB 8091-1 EN 13

Design and principle of operation

1 Body

2.1 Plug with plug stem

2.2 Seat

2.3 Body gasket

2.4 Anti-rotation xture
4 Intermediate piece
6 Fillister head screw
11 Slotted round nut
12 Threaded bushing (packing

nut)
13 Yoke
14 Travel indicator scale
20 Hexagon nut
34 Packing
A7 Actuator stem
A8 Ring nut
A27.1 Stem connector nut
A27.2 Bearing sleeve (bottom part of

the stem connector)
A27.3 Lock nut

6

2.4

2.3

1

2.2

12

14
13

A8
A7

A27.3
A27.1

A27.2

4

34

11

20

2.1

Fig.3: Type3510 Micro-ow Valve as globe valve with Type3271 Pneumatic Actuator

14 EB 8091-1 EN

Design and principle of operation

3.2 Versions

The modular design allows an insulating sec­tion or metal bellows to be tted to the stan­dard valve version.

If valve accessories (e.g. positioner, limit

switch etc.) are to be mounted to the valve
version with anges, we recommend mount­ing an insulating section or bellows seal. This

provides more space to mount valve accesso­ries.

Actuators

In these instructions, the preferable combina­tion with a Type3271 or Type3277 Pneu­matic 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.

Î Observe 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 associ­ated actuator documentation.

The basic pneumatic actuator can be re­placed by a pneumatic actuator with addi­tional handwheel or by an electric actuator.

3.3 Technical data

The nameplates on the valve and actuator
provide information on the control valve ver­sion. See section2.1 and the actuator docu­mentation.

More information is available in Data Sheet

uT8091-1.

Compliance

The Type3510 Valve bears the EAC mark of
conformity:

Temperature range

Depending on the version, the control valve
is designed for a temperature range from 14
to 428°F (–10 to +220°C). The use of an
insulating section or bellows seal extends the
temperature range from –325 to +842°F
(–196 to +450°C). Special materials are
available for temperatures up to 1200°F
(650°C).

Leakage class

Depending on the version, the following
leakage class according to ANSI/FCI70-2
or IEC60534-4 applies:

− Leakage class IV with metal seal

− Leakage class V for high-performance

metal seal

Tip

Note

Note

EB 8091-1 EN 15

Design and principle of operation

Noise emission

SAMSON is unable to make general state­ments about noise emission as it depends on
the valve version, plant facilities, and process
medium. On request, SAMSON can perform
calculations according to IEC60534,
Part8-3 and Part8-4 or VDMA24422 (edi­tion 89).

Risk of hearing loss or deafness due to loud
noise.

Wear hearing protection when working near

the valve.

WARNING

!

16 EB 8091-1 EN

Design and principle of operation

Dimensions and weights

Dimensions (in inch and mm) and weights (in lbs and kg)
The lengths and heights in the dimensional drawings are shown on p.18.

Dimensions and weights for Type3271 and Type3277 Pneumatic Actuators with 120cm²
actuator area can found in the Data Sheet uT8310-1.

Table1: Dimensions for Type3510 Valve

Connection

Female

thread

Welding ends Flanges

G/NPT/

Rc

1

/

8

to ¾

NPS½ NPS1 NPS½ NPS¾ NPS1

L

1)

Class 150

in

2.91”

74mm

7.25 7.25 7.25 7.25 7.25

mm 184 184 184 184 184

Class 300

in 7.50 7.75 7.50 7.62 7.75

mm 190 197 190 194 197

Class 600

in 8.00 8.25 8.00 8.12 8.25

mm 203 210 203 206 210

Class900/
Class1500

in 8.50 10.00 8.50 9.00 10.00

mm 216 254 216 229 254

Class 2500

in 10.38 12.12 10.38 10.75 12.12

mm 264 308 264 273 308

L1

1)

Class 150

in

1.33”

34mm

3.62 3.62 3.62 3.62 3.62

mm 92 92 92 92 92

Class 300

in 3.75 3.88 3.75 3.81 3.88

mm 95 99 95 97 99

Class 600

in 4.00 4.12 4.00 4.06 4.12

mm 101 105 101 103 105

Class900/
Class1500

in 4.25 5.00 4.25 4.50 5.00

mm 108 127 108 114 127

Class 2500

in 5.19 6.06 5.19 5.38 6.06

mm 132 154 132 137 154

Note

EB 8091-1 EN 17

Design and principle of operation

Connection

Female

thread

Welding ends Flanges

G/NPT/

Rc

1

/

8

to ¾

NPS½ NPS1 NPS½ NPS¾ NPS1

H1 120cm²

in 4.80

mm 122

H4

Insulating section
up to Class 2500

10.35”/263mm

Bellows seal up to

Class 600

10.35”/263mm

Bellows seal up to

Class 1500

14.37”/365mm

H2 or
ange Ø
D1

Class 150

in

0.90”

2)

23mm

2)

0.90”

2)

23mm

2)

0.90”

2)

23mm

2)

3.54 3.94 4.33

mm 90 100 110

Class 300

in 3.74 4.53 4.91

mm 95 115 125

Class 600

in 3.74 4.53 4.91

mm 95 115 125

Class900/
Class1500

in 4.72 5.12 5.91

mm 120 130 150

Class 2500

in 5.31 5.51 6.30

mm 135 140 160

1)

Face-to-face dimensions of anges according to DINEN558

2)

H2= 1.10” (28mm) with body material B574 N06455

18 EB 8091-1 EN

Design and principle of operation

Dimensional drawings

L

L1

SW50

57

SW46

L1

H4H2

H1

Type3510 as angle valve with

female thread

Type3510 as globe valve with

female thread, with bellows seal or insulat-

ing section

EB 8091-1 EN 19

Design and principle of operation

Type 3510 · Valve body with

anges and welding ends

L

L

L1

L1

L1

L1

ØD1

ØD1

Table2: Weights for Type3510 Valve

Connection

Female

thread

Welding

ends

Flanges

G/NPT/Rc

1

/

8

to ¾

NPS½,

NPS1

NPS½ NPS¾ NPS1

Valve
without
actuator

Class150

lbs 3.74 4.0 5.8 7.3 8.2

kg 1.7 1.8 2.6 3.3 3.7

Class 300

lbs 3.74 4.0 7.1 9.3 10.6

kg 1.7 1.8 3.2 4.2 4.8

Class 600

lbs 3.74 4.0 7.5 10.6 11.5

kg 1.7 1.8 3.4 4.8 5.2

Class900/
Class1500

lbs 3.74 4.0 14.4 16.8 19.2

kg 1.7 1.8 5.2 7.6 8.7

Class 2500

lbs – – 14.4 20 21.7

kg – – 6.5 9.0 9.8

Option­al

Insulating
section

lbs 1.2

kg 0.5

Bellows
seal

lbs 1.4

kg 0.6

20 EB 8091-1 EN

Measures for preparation

4 Measures for preparation

After receiving the shipment, proceed as fol­lows:

1. Check the scope of delivery. Compare
the shipment received against the deliv­ery note.

2. Check the shipment for transportation
damage. Report any damage to SAM­SON and the forwarding agent (refer to
delivery note).

4.1 Unpacking

Do not remove the packaging until immedi­ately before installing the valve into the pipe­line.

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.

4.2 Transporting and lifting

SAMSON's After-sales Service department

can provide more detailed transport and lift­ing instructions on request.

4.2.1 Transporting

The control valve can be transported using
lifting equipment (e.g. crane or forklift).

Î Leave the control valve in its transport

container or on the pallet to transport it.

Î Observe the transport instructions.

Transport instructions

− Protect the control valve against external
inuences (e.g. impact).

− Do not damage the corrosion protection
(paint, surface coatings). Repair any
damage immediately.

− Protect the control valve against moisture
and dirt.

− The permissible transportation tempera-
ture of standard control valves is –4 to
+149°F (–20 to +65°C).

Contact SAMSON's After-sales Service de­partment for the transportation temperatures
of other valve versions.

4.2.2 Lifting

Due to the low service weight, lifting equip­ment is not required to lift the control valve
(e.g. to install it into the pipeline).

Note

Tip

Information

EB 8091-1 EN 21

Measures for preparation

4.3 Storage

Risk of valve damage due to improper stor­age.

− Observe storage instructions.

− Avoid long storage times.

− Contact SAMSON in case of different stor-
age conditions or long storage periods.

We recommend regularly checking the con­trol valve and the prevailing storage condi­tions during long storage periods.

Storage instructions

− Protect the control valve against external

inuences (e.g. impact).

− Do not damage the corrosion protection

(paint, surface coatings). Repair any
damage immediately.

− Protect the control valve against moisture

and dirt. Store it at a relative humidity of
less than 75%. In damp spaces, prevent
condensation. If necessary, use a drying
agent or heating.

− Make sure that the ambient air is free of

acids or other corrosive media.

− The permissible storage temperature of

standard control valves is –4 to +149°F
(–20 to +65°C).

Contact SAMSON's After-sales Service de­partment for the storage temperatures of oth­er valve versions.

− Do not place any objects on the control
valve.

Special storage instructions for elastomers

Elastomer, e.g. actuator diaphragm

− To keep elastomers in shape and to pre-
vent cracking, do not bend them or hang
them up.

− We recommend a storage temperature of
59°F (15°C) for elastomers.

− Store elastomers away from lubricants,
chemicals, solutions, and fuels.

SAMSON's After-sales Service department

can provide more detailed storage instruc­tions on request.

4.4 Preparation for installation

Proceed as follows:

Î Flush the pipelines.

The plant operator is responsible for clean­ing the pipelines in the plant.

Î Check the valve to make sure it is clean.
Î Check the valve for damage.

NOTICE

!

Note

Information

Tip

Note

22 EB 8091-1 EN

Measures for preparation

Î Check to make sure that the type desig-

nation, valve size, material, pressure rat­ing and temperature range of the valve
match the plant conditions (size and
pressure rating of the pipeline, medium
temperature etc.).

Î For steam applications, make sure that

the pipelines are dry. Moisture will dam­age the inside of the valve.

Î Check any mounted pressure gauges to

make sure they function.

Î When the valve and actuator are al-

ready assembled, check the tightening
torques of the bolted joints (uAB0100).
Components may loosen during trans­port.

EB 8091-1 EN 23

Mounting and start-up

5 Mounting and start-up

SAMSON valves are delivered ready for
use. In special cases, the valve and actuator
are delivered separately and must be assem­bled on site. The procedure to mount and
start up the valve are described in the follow­ing.

Risk of 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.

Observe the specied tightening torques

(uAB0100).

Risk of valve damage due to the use of un­suitable tools.

Only use tools approved by SAMSON
(uAB0100).

5.1 Mounting the actuator onto
the valve

Proceed as described in the actuator docu­mentation if the valve and actuator have not
been assembled by SAMSON:

− Remove the mounted actuator before
mounting the other actuator (see associat­ed actuator documentation).

− Preloading the actuator springs increases
the thrust of a pneumatic actuator and re­duces the travel range of the actuator (see
associated actuator documentation).

5.2 Installing the valve into the
pipeline

5.2.1 Checking the installation

conditions

Pipeline routing

The inlet and outlet lengths vary depending
on the process medium. To ensure the control
valve functions properly, follow the installa­tion instructions given below:

Î Observe the inlet and outlet lengths (see

Table3). Contact SAMSON if the valve
conditions or states of the medium pro­cess deviate.

Î Install the valve free of stress and with the

least amount of vibrations as possible. If
necessary, attach supports to the valve.

Î Install the valve allowing sufcient space

to remove the actuator and valve or to
perform service and repair work on
them.

NOTICE

!

NOTICE

!

Note

24 EB 8091-1 EN

Mounting and start-up

Mounting position

Generally, we recommend installing the
valve with the actuator upright and on top of
the valve.

Vent plug

Vent plugs are screwed into the exhaust air
ports of pneumatic and electropneumatic de­vices. They ensure that any exhaust air that
forms can be vented to the atmosphere (to
avoid excess pressure in the device). Further-

more, the vent plugs allow air intake to pre­vent a vacuum from forming in the device.

Î Locate the vent plug on the opposite side

to the workplace of operating personnel.

Î On mounting valve accessories, make

sure that they can be operated from the
workplace of the operating personnel.

Table3: Inlet and outlet lengths

Q

a x DN b x DN

State of process
medium

Valve conditions

Inlet

length a

Outlet

length b

Gas

Ma≤0.3 2 4

0.3≤Ma≤0.7 2 10

Vapor

Ma≤0.3

1)

2 4

0.3≤Ma≤0.7

1)

2 10

Saturated steam (percentage of condensate >5%) 2 20

Liquid

Free of cavitation/w<10m/s 2 4
Cavitation producing noise/w≤3m/s 2 4
Cavitation producing noise/3<w<5m/s 2 10
Critical cavitation/w≤3m/s 2 10

Critical cavitation/3<w<5m/s 2 20
Flashing – 2 20
Multi-phase – 10 20

1)

No saturated steam

Q Flow rate
a Inlet length
b Outlet length

EB 8091-1 EN 25

Mounting and start-up

The workplace of operating personnel is the
location from which the valve, actuator and

any mounted valve accessories can be ac­cessed to operate them.

5.2.2 Additional ttings

Strainers

We recommend installing a SAMSON
strainer upstream of the valve. It prevents sol­id particles in the process medium from
damaging the valve.

Bypass and shut-off valves

We recommend installing a shut-off valve
both upstream of the strainer and down­stream of the valve and setting up a bypass
line. The bypass ensures that the plant does
not need to be shut down for service and re­pair work on the valve.

Insulation

Only insulate control valves with insulating
section or bellows seal up to the bonnet
ange of the valve body for medium tem­peratures below 32°F (0°C) and above
428°F (220°C).

Do not insulate valves mounted to comply
with NACE MR0175 requirements.

Test connection

Versions with bellows seal tted with a test
connection (G

1

/

8

) at the top ange allow the
sealing ability of the bellows to be moni­tored.

Particularly for liquids and vapors as well as
explosive or hazardous substances, we rec­ommend installing a suitable leakage indica­tor (e.g. a contact pressure gauge, an outlet
to an open vessel or an inspection glass).

Risk of personal injury due to pressurized
components and process medium escaping
under pressure.

Do not loosen the screw of the test connec­tion while the valve is in operation.

Safety guard

To reduce the crush hazard arising from
moving parts (actuator and plug stem), a
safety guard can be installed.

Valve accessories

A mounting kit is required to mount position­ers, limit switches, solenoid valves or other
valve accessories. The mounting kit (item no.
1400-9031) can be ordered from
SAMSON. Refer to the mounting and oper­ating instructions of the corresponding de­vice for a description on how to mount it.

5.2.3 Installing the control
valve

Version with female thread or anges

1. Close the shut-off valve in the pipeline

while the valve is being installed.

2. Remove the protective caps from the

valve ports before installing the valve.

Note

WARNING

!

26 EB 8091-1 EN

Mounting and start-up

3. Lift the valve to the site of installation.
Observe the ow direction through the
valve. The arrow on the valve indicates
the direction of ow.

4. Make sure that the correct gaskets are
used on the end connections.

5. Bolt the pipe to the valve free of stress.

6. Depending on the eld of application,
allow the valve to cool down or heat up
to reach ambient temperature before
start up.

7. Slowly open the shut-off valve in the
pipeline after the valve has been in­stalled.

Risk of valve damage due to a sudden pres­sure increase and resulting high ow veloci­ties.

Slowly open the shut-off valve in the pipeline

during start-up.

8. Check the valve to ensure it functions
properly.

Version with welding ends

1. Proceed as described for Version with
female thread or anges (steps 1 to 3).

2. Completely retract the actuator stem to
protect the plug from sparks during weld­ing.

3. Weld the valve free of stress into the
pipeline.

4. Proceed as described for Version with fe­male thread or anges (steps 6 to 8).

5.3 Quick check

SAMSON valves are delivered ready for
use. To test the valve's ability to function, the
following quick checks can be performed:

Tight shut-off

1. Close the valve.

2. Slowly open the shut-off valve in the
pipeline.

Risk of valve damage due to a sudden pres­sure increase and resulting high ow veloci­ties.

Slowly open the shut-off valve in the pipeline

during start-up.

3. Check the valve for leakage (visual in­spection).

Travel motion

The movement of the actuator stem must be
linear and smooth.

Î Open and close the valve, observing the

movement of the actuator stem.

Î Apply the maximum and minimum con-

trol signals to check the end positions of
the valve.

Î Check the travel reading at the travel in-

dicator scale.

Fail-safe position

Î Shut off the signal pressure line.
Î Check whether the valve moves to the

fail-safe position.

NOTICE

!

NOTICE

!

EB 8091-1 EN 27

Mounting and start-up

Adjustable packing

1. Tighten the threaded bushing gradually
(by turning it clockwise) until the packing
seals the valve.

Risk of valve damage due to the threaded
bushing tightened too far.

Make sure that the plug stem can still move

smoothly after the threaded bushing has
been tightened.

2. Open and close the valve several times.

3. Check the valve for leakage to the atmo­sphere (visual inspection).

4. Repeat steps 1 and 2 until the packing
completely seals the valve.

If the adjustable packing does not seal prop-

erly, contact SAMSON's After-sales Service

department.

Pressure test

During the pressure test, make sure the fol­lowing conditions are met:

− Retract the plug stem to open the valve.

− Observe the maximum permissible pres-

sure for valve and plant.

The plant operator is responsible for per­forming the pressure test. SAMSON's Af­ter-sales Service department can support you
to plan and perform a pressure test for your
plant.

NOTICE

!

Note

Note

28 EB 8091-1 EN

Operation

6 Operation

Immediately after completing mounting and
start-up (see section5), the valve is ready for
use.

Crush hazard arising from moving parts
(actuator and plug stem).

Do not insert hands or nger into the yoke
while the valve is in operation.

Risk of personal injury when the actuator

vents.

Wear eye protection when working in close
proximity to the control valve.

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.
Wear protective clothing and safety gloves.

Operation disturbed by a blocked actuator
or plug stem.

Do not impede the movement of the actuator

or plug stem by inserting objects into their
path.

6.1 Working in manual mode

Valves tted with actuators with a handwheel
can be manually closed or opened in case of
supply air failure.

Î For normal closed-loop operation, move

the handwheel to the neutral position.

WARNING

!

WARNING

!

WARNING

!

NOTICE

!

EB 8091-1 EN 29

30 EB 8091-1 EN

Servicing

7 Servicing

The control valve is subject to normal wear,
especially at the seat, plug, and packing.
Depending on the operating conditions,
check the valve at regular intervals to pre­vent possible failure before it can occur.

SAMSON's After-sales Service department
can support you to draw up an inspection

plan for your plant.

We recommend removing the valve from the
pipeline for service or repair work (see sec­tion9.2).

Risk of bursting in pressure equipment.
Control valves and pipelines are pressure
equipment. Improper opening can lead to
bursting of the valve.

− Before starting any work on the control
valve, depressurize all plant sections con-

cerned as well as the valve.

− Drain the process medium from all the
plant sections concerned as well as the

valve.

− Wear personal protective equipment.

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.

− If possible, drain any process medium resi-
dues from the plant sections concerned as

well as from the valve and dead cavities.

− Thoroughly ush the pipelines. The plant
operator is responsible for cleaning the
pipelines.

− Wear protective clothing, safety gloves,

and eyewear.

Risk of burn injuries due to hot or cold com­ponents and pipeline.
Valve components and the pipeline may be­come very hot or cold. Risk of burn injuries.

− Allow components and pipelines to cool

down or heat up.

− Wear protective clothing and safety gloves.

Risk of valve damage due to incorrect servic­ing or repair.

Service and repair work must only be

performed by trained staff.

Risk of 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.

Observe the specied tightening torques
(uAB0100).

Tip

DANGER

!

WARNING

!

WARNING

!

NOTICE

!

NOTICE

!

EB 8091-1 EN 31

Servicing

Risk of valve damage due to the use of un­suitable tools.

Only use tools approved by SAMSON

(uAB0100).

Risk of valve damage due to the use of un­suitable lubricants.

Only use lubricants approved by SAMSON
(uAB0100).

The control valve was checked by SAMSON

before it left the factory.

− Certain test results (seat leakage and leak

test) certied by SAMSON lose their validi­ty when the valve body or actuator hous-

ing is opened.

− The product warranty becomes void if ser-

vice or repair work not described in these
instructions is performed without prior
agreement by SAMSON's After-sales Ser-

vice department.

− Only use original spare parts by

SAMSON, which comply with the original
specications.

7.1 Replacing the gasket

7.1.1 Standard version

1. Remove the actuator from the valve. See
associated actuator documentation.

2. Loosen the slotted nut (11) at the valve.
Remove the yoke (13) from the interme­diate piece (4).

3. Unscrew the llister head screw (6) on
the anti-rotation xture (2.4). Remove the
anti-rotation xture (2.4) from the inter­mediate piece (4).

4. Unscrew the intermediate piece (4) from
the body (1). Remove the intermediate
piece (4) together with plug (2.1) from
the body (1).

5. Remove gasket (2.3). Carefully clean the
sealing faces in the body (1) and on the
intermediate piece (4).

6. Insert a new gasket (2.3) into the body.

7. Apply a suitable lubricant to the thread
of the intermediate piece.

8. Place the intermediate piece (4) together
with the plug (2.1) onto the body. Use a
suitable tool to screw it into the body (1).
Observe tightening torques.

9. Push the anti-rotation xture (2.4) over
the intermediate piece (4) and lock it in
place with the llister head screw (6).

10. Place the yoke (13) onto the intermediate
piece (4) and secure with slotted nut
(11). Observe tightening torques.

11. Mount actuator. See associated actuator
documentation.

7.1.2 Version with insulating

section

1. Remove the actuator from the valve. See
associated actuator documentation.

NOTICE

!

NOTICE

!

Note

32 EB 8091-1 EN

Servicing

1 Body

2.1 Plug with plug stem

2.2 Seat

2.3 Body gasket

2.4 Anti-rotation xture
4 Intermediate piece
6 Fillister head screw
11 Slotted round nut
12 Threaded bushing (packing

nut)
13 Yoke
14 Travel indicator scale
20 Hexagon nut
34 Packing
A7 Actuator stem
A8 Ring nut
A27.1 Stem connector nut
A27.2 Bearing sleeve (bottom part of

the stem connector)
A27.3 Lock nut

6

2.4

2.3

1

2.2

12

14
13

A8
A7

A27.3
A27.1

A27.2

4

34

11

20

2.1

Fig.4: Type3510 Micro-ow Valve as globe valve with Type3271 Pneumatic Actuator

EB 8091-1 EN 33

Servicing

2. Loosen the slotted nut (11) at the valve.
Remove the yoke (13) from the interme­diate piece (4).

3. Loosen the llister head screw (23) and
hexagon nut (26).

4. Remove the top section of the top anti-ro­tation xture (24.2) from the intermedi­ate piece (4).

5. Unscrew the intermediate piece (4) out of
the insulating section (7) and carefully lift
it off the plug stem extension (22).

6. Remove the washer (27) from the insulat­ing section (7).

7. Remove the bottom section of the top an­ti-rotation xture (24.2) from the insulat­ing section (7).

8. Remove the seal (5). Carefully clean the
sealing faces in the intermediate piece
(4) and insulating section (7).

9. Loosen the llister head screw (6) on the
bottom anti-rotation xture (24.1). Re­move the anti-rotation xture from the in­sulating section (7).

23

25
26

22
7

24.2

27

24.1

5

24.2

4

Fig.5: Type3510 with insulating section

Legend for Fig.5

4 Intermediate piece
5 Seal
7 Insulating section
22 Plug stem extension
23 Fillister head screw

24.1 Bottom anti-rotation xture

24.2 Top anti-rotation xture (two-piece)
25 Washer
26 Hexagon nut
27 Washer

34 EB 8091-1 EN

Servicing

10. Unscrew the insulating section (7) from
the body (1). Remove the insulating sec­tion (7) together with the plug (2.1) and
plug stem extension (22) from the body
(1).

11. Remove gasket (2.3). Carefully clean the
sealing faces in the valve body (1) and
on the insulating section (7).

12. Insert a new gasket (2.3) into the body.

13. Apply a suitable lubricant to the thread
of the insulating section (7).

14. Place the insulating section (7) together
with the plug (2.1) and plug stem exten­sion (22) onto the body. Use a suitable
tool to screw it into the body (1). Ob­serve tightening torques.

15. Push the anti-rotation xture (24.1, with
'insulating section' inscribed on it) from
the top over the insulating section (7)
and lock it in place with the llister head
screw (6).

16. Push the bottom section of the top an­ti-rotation xture (24.2, without inscrip­tion) with its bent end facing downward
onto the insulating section (7).

17. Insert the new seal (5) into the insulating
section (7).

18. Place the washer (27) on the insulating
section (7).

19. Apply a suitable lubricant to the thread
of the intermediate piece (4).

20. Carefully place the intermediate piece (4)
over the plug stem extension (22) onto
the insulating section (7). Use a suitable

tool to screw it in. Observe tightening
torques.

It must be possible to turn the washer (27)

easily after the intermediate piece is fastened

tight. It must not be clamped down.

21. Push the top section of the top anti-rota­tion xture (24.2, with 'plug, seat' etc.
inscribed on it) with the bent end facing
upward over the intermediate piece (4).

22. Insert the llister head screw (23) through
both parts of the anti-rotation xture
(24.2). Push the washer (25) from below
onto the screw and lock in place with the
hexagon nut (26).

23. Place the yoke (13) onto the intermediate
piece (4) and secure with slotted nut
(11). Observe tightening torques.

24. Mount actuator. See associated actuator
documentation.

7.1.3 Version with bellows

seal

1. Remove the actuator from the valve. See
associated actuator documentation.

2. Loosen the slotted nut (11) at the valve.
Remove the yoke (13) from the interme­diate piece (4).

3. Loosen the llister head screw (23) and
hexagon nut (26).

4. Remove the top section of the top anti-ro­tation xture (24.2) from the intermedi­ate piece (4).

Note

EB 8091-1 EN 35

Servicing

23

25
26

3.1
7

24.2

27

3.5

3.4

30

24.2

4

Fig.6: Type3510 with bellows seal and test

connection

5. Unscrew the intermediate piece (4) out of
the bellows seal (7) and carefully lift it off
the plug stem (3.1).

6. Remove the washer (27) from the bellows
seal (7).

7. Remove the bottom section of the top an­ti-rotation xture (24.2) from the bellows
seal (7).

8. Remove the seal (3.4). Carefully clean
the sealing faces in the intermediate
piece (4) and bellows seal (7).

9. Loosen the llister head screw (6) on the
bottom anti-rotation xture (3.5).

10. Version without test connection: remove
the anti-rotation xture (3.5) from the
bellows seal (7).

11. Unscrew the bellows seal (7) from the
body (1). Remove the bellows seal (7) in­cluding plug (2.1) from the body (1).

Version with test connection: pull the an­ti-rotation xture (3.5) downward to re­move it.

Legend for Fig.6

3.1 Plug stem with bellows

3.4 Seal (on intermediate piece)

3.5 Bottom anti-rotation xture
4 Intermediate piece
7 Bellows seal
23 Fillister head screw

24.2 Top anti-rotation xture (two-piece)
25 Washer
26 Hexagon nut
27 Washer
30 Test connection

36 EB 8091-1 EN

Servicing

12. Remove gasket (2.3). Carefully clean the
sealing faces in the valve body (1) and
on the bellows seal (7).

13. Insert a new gasket (2.3) into the body.

14. Apply a suitable lubricant to the thread
of the bellows seal (7).

15. Version with test connection: slide the
bottom anti-rotation xture (3.5, with
'bellows' inscribed on it) downward onto
the bellows seal (7).

The anti-rotation xture must be pushed onto
the bellows seal in such a way that its fasten-

ing hole is located directly over the threaded

hole in the body after the bellows seal is

bolted on.

16. Place the bellows seal (7) together with
the plug (2.1) onto the body. Use a suit­able tool to screw it into the body (1).
Observe tightening torques.

Version without test connection: slide the
anti-rotation xture (3.5, with 'bellows'
inscribed on it) from the top over the bel­lows seal (7).

17. Lock the anti-rotation xture (3.5) in
place with the llister head screw (6).

18. Push the bottom section of the top an­ti-rotation xture (24.2, without inscrip­tion) with its bent end facing downward
onto the bellows seal (7).

19. Insert the new seal (3.4) into the bellows
seal (4).

20. Place the washer (27) on the bellows seal
(7).

21. Apply a suitable lubricant to the thread
of the intermediate piece (4).

22. Carefully place the intermediate piece (4)
over the plug stem (3.1) onto the bellows
seal (7). Use a suitable tool to screw it in.
Observe tightening torques.

It must be possible to turn the washer (27)

easily after the intermediate piece is fastened

tight. It must not be clamped down.

23. Push the top section of the top anti-rota­tion xture (24.2, with 'plug, seat' etc.
inscribed on it) with the bent end facing
upward over the intermediate piece (4).

24. Insert the llister head screw (23) through
both parts of the anti-rotation xture
(24.2). Push the washer (25) from below
onto the screw and lock in place with the
hexagon nut (26).

25. Place the yoke (13) onto the intermediate
piece (4) and secure with slotted nut
(11). Observe tightening torques.

26. Mount actuator. See associated actuator
documentation.

7.2 Replacing the packing

Risk of control valve damage due to incorrect
service or repair.

The packing can only be replaced when all
the following conditions are met:

− The valve does not have a bellows seal.

Note

Note

NOTICE

!

EB 8091-1 EN 37

Servicing

To replace the packing in other valve ver-

sions, contact SAMSON's After-sales Service

department.

1. Remove the actuator from the valve. See
associated actuator documentation.

2. Loosen the slotted nut (11) at the valve.
Remove the yoke (13) from the interme­diate piece (4).

3. Unscrew hex nuts (20) and remove the
stem connector parts.

4. Unscrew the threaded bushing (12).

5. Pull all the packing parts out of the pack­ing chamber using a suitable tool.

6. Renew damaged parts. Clean the pack­ing chamber thoroughly.

7. Apply a suitable lubricant to all the pack­ing parts.

8. Carefully slide the packing parts over the
plug stem into the packing chamber us­ing a suitable tool. Observe the proper
sequence (see Fig.7).

9. Screw in the threaded bushing (12) and
tighten it. Observe tightening torques.

10. Version without insulating section: place
the sleeve (A27.2) on the plug stem
(2.1).

Version with insulating section: place
the sleeve (A27.2) on the plug stem ex­tension (22).

11. Thread on the hex nuts (20) and tighten
them. Observe tightening torques.

12. Place the yoke (13) onto the intermediate
piece (4) and secure with slotted nut
(11). Observe tightening torques.

13. Mount actuator. See associated actuator
documentation.

8 Seal (white)
9 Seal (black)

10 Packing washer

12 Threaded bushing
34 Packing

12

9

8

10

8

12

8

10

34

Fig.7: Adjustable packing: PTFE-compound and white PTFE seal rings (left) · White PTFE seal rings

(right)

38 EB 8091-1 EN

Servicing

7.3 Replacing the seat and
plug

Risk of control valve damage due to incorrect
service or repair.

Seat and plug can only be replaced when all
the following conditions are met:

− The valve does not have a bellows seal.

To replace seat and plug in other valve ver-

sions, contact SAMSON's After-sales Service

department.

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 anti-rotation xture
must also be exchanged on replacing the

seat and plug. The trim parts are delivered
together and marked accordingly (see sec-

tion2.3).

Only install matching trim parts.

Risk of damage to the facing of the seat and
plug due to incorrect service or repair.

− Always replace both the seat and plug.

− Only install matching trim parts (see sec-

tion2.3).

7.3.1 Standard version

1. Remove the actuator from the valve. See
associated actuator documentation.

2. Loosen the slotted nut (11) at the valve.
Remove the yoke (13) from the interme­diate piece (4).

3. Unscrew the llister head screw (6) on
the anti-rotation xture (2.4). Remove the
anti-rotation xture (2.4) from the inter­mediate piece (4).

4. Unscrew the intermediate piece (4) from
the body (1). Remove the intermediate
piece (4) together with plug (2.1) from
the body (1).

5. Replace gasket as described in sec­tion7.1.1.

6. Unscrew the hex nuts (20) from the plug
stem (2.1). Remove the stem connector
parts.

7. Unscrew the threaded bushing (12).

8. Replace the packing. See section7.2.

9. Unscrew the seat (2.2) using a suitable

tool.

10. Apply a suitable lubricant to the thread
and the sealing cone of the new seat.

11. Screw in the seat (2.2) using a suitable
tool. Observe tightening torques.

12. Pull the plug with plug stem (2.1) out of
the intermediate piece (4).

13. Apply a suitable lubricant to the new
plug stem (2.1) and thread of the inter­mediate piece (4).

14. Slide the new plug with plug stem (2.1)
into the intermediate piece (4).

NOTICE

!

NOTICE

!

NOTICE

!

EB 8091-1 EN 39

Servicing

15. Place the intermediate piece (4) together
with the plug (2.1) onto the body. Use a
suitable tool to screw it into the body (1).
Observe tightening torques.

16. Push the anti-rotation xture (2.4) over
the intermediate piece (4) and lock it in
place with the llister head screw (6).

17. Place the yoke (13) onto the intermediate
piece (4) and secure with slotted nut
(11). Observe tightening torques.

18. Screw in the threaded bushing (12) and
tighten it. Observe tightening torques.

19. Place sleeve (A27.2) on the plug stem
(2.1).

20. Thread on the hex nuts (20) and tighten
them. Observe tightening torques.

21. Mount actuator. See associated actuator
documentation.

7.3.2 Version with insulating

section

1. Remove the actuator from the valve. See
associated actuator documentation.

2. Loosen the slotted nut (11) at the valve.
Remove the yoke (13) from the interme­diate piece (4).

3. Loosen the llister head screw (23) and
hexagon nut (26).

4. Remove the top section of the top anti-ro­tation xture (24.2) from the intermedi­ate piece (4).

5. Unscrew the intermediate piece (4) out of
the insulating section (7) and carefully lift
it off the plug stem extension (22).

6. Remove the washer (27) from the insulat­ing section (7).

7. Remove the bottom section of the top an­ti-rotation xture (24.2) from the insulat­ing section (7).

8. Replace the packing. See section7.2.

9. Replace seal as described in sec-

tion7.1.2.

10. Loosen the llister head screw (6) on the
bottom anti-rotation xture (24.1). Re­move the anti-rotation xture from the in­sulating section (7).

11. Unscrew the insulating section (7) from
the body (1). Remove the insulating sec­tion (7) together with the plug (2.1) and
plug stem extension (22) from the body
(1).

12. Replace gasket as described in sec­tion7.1.2.

13. Unscrew the seat (2.2) using a suitable
tool.

14. Apply a suitable lubricant to the thread
and the sealing cone of the new seat.

15. Screw in the seat (2.2) using a suitable
tool. Observe tightening torques.

16. Unscrew the plug with plug stem (2.1)
from the plug stem extension (22) and
pull it out of the insulating section (7).

17. Apply a suitable lubricant to the end of
the plug stem of the new plug (2.1).

18. Slide the new plug with plug stem (2.1)
into the insulating section (7) and screw
it onto the plug stem extension (22). Ob­serve tightening torques.

40 EB 8091-1 EN

Servicing

19. Apply a suitable lubricant to the thread
of the insulating section (7).

20. Place the insulating section (7) together
with the plug (2.1) and plug stem exten­sion (22) onto the body. Use a suitable
tool to screw it into the body (1). Ob­serve tightening torques.

21. Push the anti-rotation xture (24.1, with
'insulating section' inscribed on it) from
the top over the insulating section (7)
and lock it in place with the llister head
screw (6).

22. Push the bottom section of the top an­ti-rotation xture (24.2, without inscrip­tion) with its bent end facing downward
onto the insulating section (7).

23. Place the washer (27) on the insulating
section (7).

24. Apply a suitable lubricant to the thread
of the intermediate piece (4).

25. Carefully place the intermediate piece (4)
over the plug stem extension (22) onto
the insulating section (7). Use a suitable
tool to screw it in. Observe tightening
torques.

It must be possible to turn the washer (27)

easily after the intermediate piece is fastened

tight. It must not be clamped down.

26. Push the top section of the top anti-rota­tion xture (24.2, with 'plug, seat' etc.
inscribed on it) with the bent end facing
upward over the intermediate piece (4).

27. Insert the llister head screw (23) through
both parts of the anti-rotation xture
(24.2). Push the washer (25) from below
onto the screw and lock in place with the
hexagon nut (26).

28. Place the yoke (13) onto the intermediate
piece (4) and secure with slotted nut
(11). Observe tightening torques.

29. Mount actuator. See associated actuator
documentation.

7.4 Preparation for return ship-

ment

Defective valves can be returned to
SAMSON for repair.

Proceed as follows to return valves to
SAMSON:

1. Put the control valve out of operation (see
section9).

2. Decontaminate the valve. Remove any
residual process medium.

3. Fill in the Declaration on Contamination,
which can be downloaded from our
website at uwww.samson.de > Services
> Check lists for after sales service >
Declaration on Contamination.

4. Send the valve together with the lled-in
form to your nearest SAMSON subsidi­ary. SAMSON subsidiaries are listed on
our website at uwww.samson.de >
Contact.

Note

EB 8091-1 EN 41

Servicing

7.5 Ordering spare parts and
operating supplies

Contact your nearest SAMSON subsidiary
or the SAMSON After-sales Service depart­ment for information on spare parts, lubri­cants, and tools.

Spare parts

See section10.2 for details on spare parts.

Lubricant

Details on suitable lubricants can be found in
the document uAB0100.

Tools

Details on suitable tools can be found in the
document uAB0100.

42 EB 8091-1 EN

Malfunctions

8 Malfunctions

Depending on the operating conditions, check the valve at certain intervals to prevent possi­ble failure before it can occur. Operators are responsible for drawing up an inspection plan.

SAMSON's After-sales Service department can support you to draw up an inspection plan

for your plant.

8.1 Troubleshooting

Malfunction Possible reasons Recommended action

Actuator or plug stem does not
move on demand.

Actuator is blocked. Check attachment.

Unblock the actuator.

Signal pressure too low Check the signal pressure.

Check the signal pressure line for
leakage.

Actuator or plug stem does not
move through the whole range.

Signal pressure too low Check the signal pressure.

Check the signal pressure line for
leakage.

The valve leaks to the atmo­sphere (fugitive emissions).

The packing is defective. Replace packing (see sec-

tion7.2) or contact SAMSON's
After-sales Service department.

Packing tightened incorrectly. See section5.3, Adjustable

packing. Contact SAMSON's Af­ter-sales Service department
when it continues to leak.

Version with bellows seal: the
metal bellows seal is defective.

Contact SAMSON's After-sales
Service department.

Gasket worn out. Replace body gasket (see sec-

tion7.1) or contact SAMSON's
After-sales Service department.

Increased ow through closed
valve (seat leakage)

Dirt or other foreign particles de­posited between the seat and
plug.

Shut off the section of the pipe­line and ush the valve.

Valve trim, particularly with soft
seat, is worn.

Replace seat and plug (see sec­tion7.3 or contact SAMSON's
After-sales Service department).

Tip

EB 8091-1 EN 43

Malfunctions

8.2 Emergency action

Upon supply air or control signal failure, the
valve moves to its fail-safe position (see sec­tion3.1).

The plant operator is responsible for emer­gency action to be taken in the plant.

In the event of a valve malfunction:

1. Close the shut-off valves upstream and

downstream of the control valve to stop
the process medium from owing
through the valve.

2. Check the valve for damage. If neces-

sary, contact SAMSON's After-sales Ser­vice department.

Putting the valve back into operation after
a malfunction

Î Slowly open the shut-off valves. Allow

the process medium to slowly ow into
the valve.

Contact SAMSON's After-sales Service department for malfunctions not listed in the table.

Note

44 EB 8091-1 EN

Decommissioning and disassembly

9 Decommissioning and disas-

sembly

Risk of bursting in pressure equipment.
Control valves and pipelines are pressure
equipment. Improper opening can lead to
bursting of the valve.

− Before starting any work on the control
valve, depressurize all plant sections con-

cerned as well as the valve.

− Drain the process medium from all the
plant sections concerned as well as the

valve.

− Wear personal protective equipment.

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.

− If possible, drain any process medium resi-
dues from the plant sections concerned as

well as from the valve and dead cavities.

− Thoroughly ush the pipelines. The plant
operator is responsible for cleaning the
pipelines.

− Wear protective clothing, safety gloves,

and eyewear.

Risk of burn injuries due to hot or cold com­ponents and pipeline.
Valve components and the pipeline may be­come very hot or cold. Risk of burn injuries.

− Allow components and pipelines to cool

down or heat up.

− Wear protective clothing and safety gloves.

9.1 Decommissioning

To decommission the control valve for service
and repair work or disassembly, proceed as
follows:

1. Close the shut-off valves upstream and
downstream of the control valve to stop
the process medium from owing
through the valve.

2. Completely drain the pipelines and
valve.

3. Disconnect and lock the pneumatic air
supply to depressurize the actuator.

4. If necessary, allow the pipeline and valve
components to cool down or heat up.

9.2 Removing the valve from

the pipeline

Version with female thread or anges

1. Put the control valve out of operation (see
section9.1).

DANGER

!

WARNING

!

WARNING

!

EB 8091-1 EN 45

Appendix

2. Unfasten the valve or unbolt the ange
joint.

3. Remove the valve from the pipeline (see
section4.2).

Version with welding ends

1. Put the control valve out of operation (see
section9.1).

2. Cut the pipeline in front of the weld
seam.

3. Remove the valve from the pipeline (see
section4.2).

9.3 Removing the actuator

from the valve

See associated actuator documentation.

9.4 Disposal

Î Observe local, national, and internation-

al refuse regulations.

Î Do not dispose of components, lubri-

cants, and hazardous substances togeth­er with your other household waste.

10 Appendix

10.1 After-sales service

Contact SAMSON's After-sales Service de­partment for support concerning service or
repair work or when malfunctions or defects
arise.

E-mail

You can reach the After-sales Service De­partment at [e-mail].

Addresses of SAMSONAG and its subsid­iaries

The addresses of SAMSON AG, its subsid­iaries, representatives, and service facilities
worldwide can be found on the SAMSON
website, in all SAMSON product catalogs or
on the back of these Mounting and Operat­ing Instructions.

Required specications

Please submit the following details:

− Order number and position number in
the order

− Type, model number, nominal size, and
valve version

− Consecutive number of installed trim

− Pressure, density, viscosity and tempera-

ture of the process medium

− Flow rate in cu.ft/min or m³/h

− Direction of ow

− Bench range of the actuator (e.g. 0.2 to

1bar)

− Is a strainer installed?

− Installation drawing

46 EB 8091-1 EN

Appendix

10.2 Spare parts

1 Body
2 Trim

2.1 Plug with plug stem

2.2 Seat

2.3 Body gasket

2.4 Anti-rotation xture
3 Bellows (assembly)

3.1 Plug stem with bellows

3.2 Seal

3.3 Bellows nut

3.4 Seal (on intermediate piece)

3.5 Bottom anti-rotation xture
4 Intermediate piece
5 Seal
6 Fillister head screw
7 Bellows seal or insulating section

8 Seal
9 Seal

10 Packing washer
11 Slotted round nut
12 Threaded bushing (packing nut)
13 Yo ke
14 Travel indicator scale
15 Retaining plate
16 Countersunk screw
17 Bearing sleeve
18 Disk spring
19 Packing washer
20 Hexagon nut
21 Snap ring
22 Plug stem extension
23 Fillister head screw

24.1

Bottom anti-rotation xture

24.2

Top anti-rotation xture (two-piece)

25 Washer

26 Hexagon nut
27 Washer
29 Seal for test connection
30 Screw plug
32 Yoke (ready mounted)
34 Packing
37 Lower part of the stem connector

(assembly)

Trims (2.1 to 2.4) and metal bellows (3.1 to

3.5) are only available as spare parts as as­semblies (2 and 3).
The seal rings (2.3 and 3.4) are also avail-

able separately.

Note

EB 8091-1 EN 47

Appendix

Ch:

WNR

Ch. Nr.:

WNR

PN 400

SAMSON 3510

PN 400

Ch:

WNR

PN 400

Ch:

WNR

PN 400

Ch:

WNR

14

15

16

13

20
21
19

18

17

8
9
9

10

8

2.4

2.2

2.3

2.1

4

6

24.2

27

24.2

27

3.4

3.3

3.1

3.2

3.5

29
30

6

7

3

11

26
5

24.1

7

6

22

25

12

34

2

1

32

37

23

25
26

23

24.2

SAMSON AG · MESS- UND REGELTECHNIK
Weismüllerstraße 3 · 60314 Frankfurt am Main, Germany
Phone: [phone] · Fax: [phone]
[e-mail] · www.samson.de

EB 8091-1 EN

2017-05-16 · English