Page 1
Mounting and
Operating Instructions
EB 8135/8136 EN
Edition August 2016
Type3535 Three-way Valve with bellows seal and rod-type yoke (partial view)
Series V2001 Valves
Type3535 Three-way Valve for Heat
Transfer Oil
Page 2
Denition of signal words
DANGER!
Hazardous situations which, if not
avoided, will result in death or serious injury
WARNING!
Hazardous situations which, if not
avoided, could result in death or serious injury
NOTICE
Property damage message or malfunction
Note:
Additional information
Tip:
Recommended action
2 EB 8135/8136 EN
Page 3
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 K
VS
and CV coefcients, 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
Page 4
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 qualied
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 observed.
− 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 uhttp://www.samson.de.
− To ensure appropriate use, only use the valve in applications where the operating pres-
sure and temperatures do not exceed the specications used for sizing the valve at the ordering 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.
Page 5
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 before 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 identied 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.
Page 6
6 EB 8135/8136 EN
Design and principle of operation
2 Design and principle of oper-
ation
The Type3535 Three-way Valve has a modular design and can be combined with pneumatic 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 mixing 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 enters 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 area 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 connected to the actuator stem (8.1) by the stem
connector (7).
AB AABA
B
B
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
1 Valve 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-loaded for DN65 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
6 Plug stem
6.1 Stem connector nut
6.2 Lock nut
7 Stem connector
8.1 Actuator stem
8.2 Rod-type yoke
9 Nut
10.1 Sleeve
10.2 Short sleeve
10.3 Sleeve
12 Nut
12.1 Washer
12.2 Retaining washers
X Position for open-end
wrench
Page 7
EB 8135/8136 EN 7
Design and principle of operation
AB AA
BA
B
B
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 DN32 to 50, plug arrangement for mixing valve (left) and diverting valve
(right)
Page 8
8 EB 8135/8136 EN
Design and principle of operation
2.1 Technical data
Valve size DN 15 to 80 NPS½ to 3
Material
Spheroidal
graphite iron
EN-JS1049
Cast steel
1.0619
Stainless
steel
1.4408
Spheroidal
graphite
iron A395
Cast steel
A216 WCC
Stainless
steel A351
CF8M
Pressure rating PN16 · PN25 Class150 · Class300
Connection Flanges
EN1092-1 FormB1,
Ra3.2 to 12.5µm
EN1092-1, groove FormD
Raised face
Seat-plug seal Metal seal
Characteristic Linear
Rangeability 30:1 up to DN25 (NPS1) · 50:1 for DN32 (NPS1) and larger
Temperature range –10 to +350°C 14 to 660°F
Leakage class DINEN1349: 0.05% of K
VS
ANSI/FCI70-2: 0.05% of C
V
Compliance
·
2.2 Materials
Valve size DN 15 to 80 NPS½ to 3
Valve body
Spheroidal
graphite iron
EN-JS1049
Cast steel
1.0619
Stainless
steel
1.4408
Spheroidal
graphite
iron A395
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 ≤DN25: 1.4305 · ≥DN32: 1.4104 ≤NPS1: 1.4305 · ≥NPS1½: 1.4104
Plug 1.4305
Bellows seal 1.4541 · 1.4301
Packing PTFE
Body gasket Graphite on metal core
2.3 KVS and CV coefcients, seat diameters and travel
Valve size
DN 15 20 25 32 40 50 65 80
NPS ½ ¾ 1 – 1½ 2 2½ 3
K
VS
coefcients 4 6.3 8 16 20 32 50 80
C
V
coefcients 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
Page 9
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.
Î Observe 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 functions properly, the pipeline must be
straight and without any manifolds
or disturbances for a distance of at
least 6times the valve size (DN) upstream 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 depending 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 attached 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
Type2N 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 downstream of the valve to ensure that the plant
does not need to be shut down for maintenance. In addition, install a bypass line.
Page 10
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
A
AB
B
A
AB
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
Page 11
EB 8135/8136 EN 11
Operation
4 Operation
The operating instructions only apply in conjunction with the actuator. Refer to the corresponding mounting and operating instructions.
5 Maintenance
The control valve is subject to normal wear,
especially at the seat, plug, bellows, and
packing.
Depending on the operating conditions,
check the valve at regular intervals to prevent possible failure before it can occur.
External leakage can indicate that the bellows seal or packing is defective.
If the valve does not close tightly, tight shutoff may be impaired by dirt stuck between
the seat and plug or by damaged facings.
Valves in DN15 to 25 have a one-pieced
plug, which is used for mixing and diverting
valves using the same arrangement.
In valves ≥DN32, two V-port plugs are
used. In mixing valves, the plugs are guided
in the seats from the inside. Whereas, in diverting valves, they are guided into the seats
from the outside.
To keep the exact position of the plug, spacer
sleeves are used to keep the plug on the plug
stem. The different arrangement for valves in
DN32 to 50 and for valves in DN65 and
80 as mixing and diverting valves is described in the section on assembly.
We recommend removing the parts, cleaning
them, and, if necessary, replacing them with
new ones.
WARNING!
− Before performing any work on the
control valve, make sure the relevant plant section has been depressurized and, depending on the
process medium, drained as well.
− When used at high temperatures,
allow the plant section to cool
down to ambient temperature.
− Make sure the electrical or pneu-
matic control signal for the actuator
is switched off. Remove the signal
pressure line of a pneumatic actuator.
− Valves are not free of cavities. As a
result, residual process medium
might still be contained in the
valve.
− We recommend removing the valve
from the pipeline.
NOTICE
Before performing any repair work,
remove the actuator from the valve.
Unscrew the screws on the stem con-
nector (7) and the nut (9). Lift the actuator off the valve (see Fig.1).
Note:
The required tightening torques are
specied in the following instructions.
Suitable seat wrenches are addition-
ally listed in section5.3.
Page 12
12 EB 8135/8136 EN
Maintenance
5.1 Replacing the bellows seal
If the packing leaks, this is due to a defective
bellows seal. In this case, the entire bellows
seal assembly must be replaced together
with the packing (4.2).
We recommend renewing the top gasket
(5.3) and bottom gasket (1.2) at the bellows
housing as well.
Mixing and diverting valves in DN32 to 80
differ in the arrangement of their plugs and
sleeves (see Fig.1). Valves in DN15 to 25
have the same plug and sleeve arrangement.
5.1.1 Disassembly
1. In valves ≤DN50, unscrew the lock nut
(6.2) and stem connector nut (6.1) from
the plug stem.
2. Unscrew the coupling nut (5.1) from the
bellows housing.
3. Remove nuts (1.1) and lift off the ange
(5.4).
4. Pull out the bellows housing (5.2) and
bellows seal as far as they will go. Place
an open-end wrench SW10 (≤DN50)
or SW13 (≥DN65) at the side on the
hexagon (X) or at the attened area of
the plug stem to hold the stem stationary.
Loosen the nut (12) and remove the
wrench.
5. Unscrew the nut (12). Remove the two retaining washers (12.2) and washer
(12.1).
6. DN15 to 25
Carefully pull the plug stem (6) together
with the bellows seal (5) and bellows
housing (5.2) out of the body from
above.
DN32 to 80
Keep hold of the bottom plug of diverting
valves or the bottom sleeve of mixing
valves on the plug stem. Use a long
screw (M8 for DN32 to 50 and M12 for
DN65 and 80) to keep the plugs (3.x)
and sleeves (10.x) in the right position.
Carefully pull the plug stem together with
the bellows seal (5) and bellows housing
(5.2) out of the body from above.
Guide the screw (to hold the plugs and
sleeves) into the valve body and push upwards, allowing the plugs and sleeves to
slide onto the screw.
7. Carefully clean all the parts and check
them for damage. Replace the plug stem
together with the bellows seal and packing with new parts.
Page 13
EB 8135/8136 EN 13
Maintenance
AB
A
B
12.2
12
12.1
1.1
6.1
6.2
5.3
5
5.2
X
5.4
1.2
4.2
4.3
5.1
3.2
Fig.3: Mixing valve DN32 to 50
2.2
2.1
12.1
12.2
12
3
Fig.4: Mixing valve DN15 to 25
2.2
3.2
3.1
2.1
10.2
10.3
10.1
Fig.5: Mixing valve DN32 to 50
5.1.2 Assembly
Note:
Contact your nearest SAMSON subsidiary or the SAMSON After-sales
Service department for information
on suitable lubricants.
1. Apply a suitable lubricant to the gasket
(5.3) and thread on the bellows housing.
2. Insert the gasket (5.3) on the bellows
housing (5.2).
3. Push the bellows seal (5) together with
the plug stem into the bellows housing.
Tighten the coupling nut (5.1) by hand
only at rst.
4. Insert the gasket (1.2) into the valve
body.
5. DN15 to 25
Place the ready-assembled bellows seal
assembly on the valve body, while guiding the plug stem through the holes in the
plug.
Page 14
14 EB 8135/8136 EN
Maintenance
DN32 to 80
Gradually insert the plug stem of the
ready-assembly bellows seal assembly
(5) into the valve body, allowing the
plugs and sleeves to slide from the screw
(used to hold the plugs and sleeves) onto
the plug stem.
6. First place the washer (12.1) and then
the pair of serrated retaining washers
(12.2) onto the plug stem, making sure
the coarsely serrated surfaces of the retaining washers face each other and the
radial ribs face outwards. Thread the nut
(12) onto the plug stem by hand.
Note:
For valves in DN15 to 50, a special
tool designed to hold the washers
(12.1 and 12.2) can be ordered (see
section5.3). Especially on valves in
DN15 to 25, it is difcult to mount
the washers onto the plug stem due
to insufcient space.
7. Slightly pull out the bellows housing (5.2)
together with the bellows seal. Place an
open-end wrench at the side on the
hexagon or at the attened area (X) of
the plug stem to hold the stem stationary.
NOTICE
Do not twist the bellows.
8. Tighten the nut (12) to secure the plugs
and the sleeves:
Valve size
15 to 50 65 to 80
Nut (12) 15Nm 25Nm
9. Remove the open-end wrench.
10. Place on the ange (5.4) and align it
with the bellows housing (5.2), while
making sure the gasket (1.2) is correctly
positioned.
11. Fasten the nuts (1.1):
Valve size 15 to 25 32 to 50 65 to 80
Nuts (1.1) M10
10Nm
M12
30Nm
M16
90Nm
Tighten the coupling nut (5.1) with
80Nm tightening torque.
12. For DN15 to 50, thread the lock nut
(6.2) and stem connector nut (6.1) onto
the top end of the plug stem again. Adjust the stem connector nut (6.1) to keep
the dimension of 50mm from the top of
the bellows seal assembly (5) to the top
of the stem connector nut (6.1) after the
plug stem has been pushed completely
into the valve (see Fig.15).
13. Mount the actuator onto the valve according to the associated mounting and
operating instructions.
Page 15
EB 8135/8136 EN 15
Maintenance
5.2 Replacing the seat and
plug
When replacing the seat and/or plug, we
recommend renewing the gaskets (5.3, 1.2)
at the top and bottom of the bellows housing
as well.
5.2.1 Mixing valve
Disassembly
AB
A
B
12.2
12
12.1
1.1
6.1
6.2
5.3
5
5.2
X
5.4
1.2
4.2
4.3
5.1
3.2
Fig.6: Mixing valve DN32 to 50
2.2
2.1
12.1
12.2
12
3
Fig.7: Mixing valve DN15 to 25
12.1
12.2
12
11.1
11.2
11.3
11.4
3.1
3.2
Fig.8: Mixing valve DN65 and 80
1. In valves ≤DN50, unscrew the lock nut
(6.2) and stem connector nut (6.1) from
the plug stem.
2. Unscrew the coupling nut (5.1) from the
bellows housing. Remove nuts (1.1) and
lift off the ange (5.4).
3. Pull out the bellows housing (5.2) and
bellows seal as far as they will go. Place
an open-end wrench SW10 (≤DN50)
or SW13 (≥DN65) at the side on the
hexagon (X) or at the attened area of
the plug stem to hold the stem stationary.
Loosen the nut (12) and remove the
wrench.
Page 16
16 EB 8135/8136 EN
Maintenance
4. Unscrew the nut (12). Remove the two retaining washers (12.2) and washer
(12.1).
In mixing valves DN32 to 80, pull bottom sleeve (10.3 or 11.4) off the plug
stem.
5. Lift the bellows housing (5.2) together
with the bellows seal (5) and carefully
pull the plug stem (6) out of the valve
body.
Pull the bellows seal (5) out of the bellows housing and remove the body gasket (1.2).
6. Carefully clean all the parts and check
them for damage. Renew defective parts.
7. In valves ≥DN32, remove sleeve (10.1
or 11.1).
Unscrew the top seat (2.1) using a suitable seat wrench (see section5.3).
8. DN15 to 25
Remove the plug (3) from the valve body.
DN32 to 50
Remove the top plug (3.1), sleeve (10.2),
and bottom plug (3.2) from the valve
body.
DN65/80
Remove the top plug (3.1), sleeves (11.2
and 11.3), and bottom plug (3.2) from
the valve body.
9. Unscrew the bottom seat (2.2) from the
valve body.
10. Carefully clean all the parts and check
them. If necessary, renew or machine
them.
Assembly
AB
A
B
12.2
12
12.1
1.1
6.1
6.2
5.3
5
5.2
X
5.4
1.2
4.2
4.3
5.1
3.2
Fig.9: Mixing valve DN32 to 50
2.2
2.1
12.1
12.2
12
3
Fig.10: Mixing valve DN15 to 25
Page 17
EB 8135/8136 EN 17
Maintenance
12.1
12.2
12
11.1
11.2
11.3
11.4
3.1
3.2
Fig.11: Mixing valve DN65 and 80
1. Apply a suitable lubricant to the gasket
(5.3) and thread on the bellows housing.
2. Insert the gasket (5.3) on the bellows
housing (5.2).
3. Push the bellows seal (5) together with
the plug stem into the bellows housing.
Tighten the coupling nut (5.1) by hand
only at rst.
4. Apply a suitable lubricant to the thread
and the sealing cone of the new or machined seats.
5. Use the seat wrench to screw in the bottom seat (2.2), observing the correct
tightening torques:
Valve size 15 to 25 32 to 50 65 to 80
Seat thread M32x1.5 M58x1.5 M90x1.5
Tightening
torque
120Nm 500Nm 1050Nm
6. DN15 to 25
Insert the plug (3) into the bottom seat
(2.2).
DN32 to 50
Insert the bottom plug (3.2) into the bottom seat (2.2).
Place the short sleeve (10.2) and top
plug (3.1) one after the other onto the
bottom plug. To x them into position, insert a long M8 screw through the bottom
plug.
DN65/80
Insert the bottom plug (3.2) into the bottom seat (2.2).
Place the two short sleeves (11.3 and
11.2) and top plug (3.1) one after the
other onto the bottom plug. To x them
into position, insert a long M12 screw
through the bottom plug.
7. Screw the top seat (2.1) into the body,
ensuring that the top plug can easily
slide into the seat. Refer to table in step 5
for the correct tightening torque.
8. Insert the gasket (1.2) into the top valve
ange.
9. DN15 to 25
Carefully place the bonnet onto the
valve, while guiding the plug stem into
the plug (3).
DN32 to 50
Slide the sleeve (10.1) over the plug
stem. Carefully place on the bonnet,
while guiding the plug stem through the
top plug (3.1), sleeve (10.2), and bottom
plug (3.2) and, at the same time, remove
the M8 screw.
Page 18
18 EB 8135/8136 EN
Maintenance
Slide the sleeve (10.3) onto the plug stem
from underneath.
DN65 and 80
Slide the sleeve (11.1) over the plug
stem. Carefully place on the bonnet,
while guiding the plug stem through the
top plug (3.1), two sleeves (11.2 and
10.3), and bottom plug (3.2) into the
body and, at the same time, remove the
M12 screw.
Slide the sleeve (11.4) onto the plug stem
from underneath.
10. First place the washer (12.1) and then
the pair of serrated retaining washers
(12.2) onto the plug stem, making sure
the coarsely serrated surfaces of the retaining washers face each other and the
radial ribs face outwards. Thread the nut
(12) onto the plug stem by hand.
Note:
For valves in DN15 to 50, a special
tool designed to hold the washers
(12.1 and 12.2) can be ordered (see
section5.3). Especially on valves in
DN15 to 25, it is difcult to mount
the washers onto the plug stem due
to insufcient space.
11. Slightly pull out the bellows housing (5.2)
together with the bellows seal. Place an
open-end wrench at the side on the
hexagon or at the attened area (X) of
the plug stem to hold the stem stationary.
NOTICE
Do not twist the bellows.
12. Tighten the nut (12) to secure the plugs
and the sleeves:
Valve size
15 to 50 65 to 80
Nut (12) 15Nm 25Nm
13. Remove the open-end wrench.
14. Place on the ange (5.4) and align it
with the bellows housing (5.2), while
making sure the gasket (1.2) is correctly
positioned.
15. Fasten the nuts (1.1):
Valve size 15 to 25 32 to 50 65 to 80
Nuts (1.1) M10
10Nm
M12
30Nm
M16
90Nm
Tighten the coupling nut (5.1) with
80Nm tightening torque.
16. For DN15 to 50, thread the lock nut
(6.2) and stem connector nut (6.1) onto
the top end of the plug stem again. Adjust the stem connector nut (6.1) to keep
the dimension of 50mm from the top of
the bellows seal assembly (5) to the top
of the stem connector nut (6.1) after the
plug stem has been pushed completely
into the valve (see Fig.15).
17. Mount the actuator onto the valve according to the associated mounting and
operating instructions.
Page 19
EB 8135/8136 EN 19
Maintenance
5.2.2 Diverting valve
Disassembly
1. In valves ≤DN50, unscrew the lock nut
(6.2) and stem connector nut (6.1) from
the plug stem.
2. Unscrew the coupling nut (5.1) from the
bellows housing. Remove nuts (1.1) and
lift off the ange (5.4).
3. Pull out the bellows housing (5.2) and
bellows seal as far as they will go. Place
an open-end wrench SW10 (≤DN50)
or SW13 (≥DN65) at the side on the
hexagon (X) or at the attened area of
the plug stem to hold the stem stationary.
Loosen the nut (12) and remove the
wrench.
4. Unscrew the nut (12). Remove the two retaining washers (12.2) and washer
(12.1).
5. Pull the bellows seal (5) out of the bellows housing and remove the body gasket (1.2).
6. Carefully clean all the parts and check
them for damage. Renew defective parts.
7. DN15 to 25
Unscrew the top seat (2.1). Remove the
plug (3) from the valve body. Take out
the bottom seat (2.2).
DN32 to 50
Remove the top plug (3.1) and the three
sleeves (10.1, 10.2, 10.3) from the valve
body.
DN65/80
Remove the top plug (3.1) and the four
sleeves (11.1, 11.2, 11.3, 11.4) from
the valve body.
8. DN32 to 80
Unscrew the top and bottom seat (2.1,
2.2) using a suitable seat wrench (see
section5.3) from the valve body.
Remove the bottom plug (3.2) from the
valve body.
9. Carefully clean all the parts and check
them. If necessary, renew or machine
them.
1.1
6.1
6.2
5.3
5
5.2
X
5.4
1.2
4.2
4.3
5.1
Fig.12: Valve bonnet with bellows seal
Page 20
20 EB 8135/8136 EN
Maintenance
Assembly
1. Apply a suitable lubricant to the gasket
(5.3) and thread on the bellows housing.
2. Place on the gasket (5.3) and push the
bellows seal (5) together with the plug
stem into the bellows housing (5.2).
Tighten the coupling nut (5.1) by hand at
rst.
3. Apply a suitable lubricant to the thread
and the sealing cone of the new or machined seat.
4. DN15 to 25
Screw in the bottom seat (2.2) and tighten:
Valve size 15 to 25
Seat thread M32x1.5
Tightening torque 120Nm
Place the plug (3) in the bottom seat.
Screw in the top seat (2.1), ensuring that
the plug can slide into the seat from underneath. Tighten the top seat with the
same tightening torque.
DN32 to 50
Insert the bottom seat (3.2) into the valve
body. Use the seat wrench to screw in
the bottom seat (2.2) and top seat (2.1)
one after the other.
Valve size 32 to 50
Seat thread M58x1.5
Tightening torque 500Nm
Place the top plug (3.1) and three sleeves
(10.1, 10.2, 10.3) onto the plug stem
one after the other.
DN65 and 80
Insert the bottom seat (3.2) into the valve
body. Use the seat wrench to screw in
the bottom seat (2.2) and top seat (2.1)
one after the other:
2.2
2.1
10.1
10.2
10.3
3.2
3.1
12.1
12.2
12
11.1
11.2
11.3
11.4
2.1
3.1
3.2
2.2
Fig.13: Diverting valve DN32 to 50 Fig.14: Diverting valve DN65 and 80
Page 21
EB 8135/8136 EN 21
Maintenance
Valve size 65 to 80
Seat thread M90x1.5
Tightening torque 1050Nm
Place the top plug (3.1) and four sleeves
(11.1, 11.2, 11.3, 11.4) onto the plug
stem one after the other.
5. For diverting valves in DN32 and larger,
insert the bottom plug into the bottom
seat.
Insert the gasket (1.2) into the body
ange. Carefully guide the plug stem (6)
into the bellows housing (5.2).
Hold the bottom plug in the seat to push
the plug stem in the middle through the
plug bore.
6. First place the washer (12.1) and then
the pair of serrated retaining washers
(12.2) onto the plug stem, making sure
the coarsely serrated surfaces of the retaining washers face each other and the
radial ribs face outwards. Thread the nut
(12) onto the plug stem by hand.
Note:
For valves in DN15 to 50, a special
tool designed to hold the washers
(12.1 and 12.2) can be ordered (see
section5.3). Especially on valves in
DN15 to 25, it is difcult to mount
the washers onto the plug stem due
to insufcient space.
7. Slightly pull out the bellows housing (5.2)
together with the bellows seal. Place an
open-end wrench at the side on the
hexagon (X) or at the attened area of
the plug stem to hold the stem stationary.
NOTICE
Do not twist the bellows.
8. Tighten the nut (12) to secure the plugs
and the sleeves:
Valve size
15 to 50 65 to 80
Nut (12) 15Nm 25Nm
9. Remove the open-end wrench.
10. Place on the ange (5.4) and align it
with the bellows housing (5.2), while
making sure the gasket (1.2) is correctly
positioned.
11. Fasten the nuts (1.1):
Valve size 15 to 25 32 to 50 65 to 80
Nuts (1.1) M10
10Nm
M12
30Nm
M16
90Nm
Tighten the coupling nut (5.1) with
80Nm tightening torque.
12. For DN15 to 50, thread the lock nut
(6.2) and stem connector nut (6.1) onto
the top end of the plug stem again. Adjust the stem connector nut (6.1) to keep
the dimension of 50mm from the top of
the bellows seal assembly (5) to the top
of the stem connector nut (6.1) after the
plug stem has been pushed completely
into the valve (see Fig.15).
13. Mount the actuator onto the valve according to the associated mounting and
operating instructions.
Page 22
22 EB 8135/8136 EN
Maintenance
5.3 Tools and tightening torques
Valve size
DN 15 to 25
NPS½ to 1
DN32 to 50
NPS1½ to 2
DN65 to 80
NPS2½ to 3
Seat wrench with order
number
1280-3010 1280-3011 1280-0305
Holding tool 1280-3059 for washer (12.1) and anti-rotation xture (12.2)
Tightening torques (±10%)
Valve seat 120Nm (M32x1.5) 500Nm (M58x1.5) 1050Nm (M90x1.5)
Nut (12) 15Nm 25Nm
Body nut (1.1) 10Nm (M10) 30Nm (M12) 90Nm (M16)
Coupling nut (5.1) 80Nm
Page 23
EB 8135/8136 EN 23
Description of nameplates
6 Description of nameplates
The DIN or ANSI versions have different specications on the nameplates.
6.1 DIN version
SAMSON
DN
bar
Made in Germany
˚C
T
bar
∆p
PN
K
vs
No
12
11
9
8
5
4
1
3
2
1 Valve type
2 Model number
3 Model number index
4 Order number or date
5 K
VS
coefcient
8 Nominal size
9 Nominal pressure
11 Permissible temperature [°C]
12 Body material
6.2 ANSI version
SAMSON
DN
bar
Made in Germany
˚C
T
bar
∆p
PN
K
vs
No
No
∆p
Made in Germany
Size
SAMSON
psi
N
psi
T
˚F
Cv
Cl
12
11
9
8
5
4
1
3
2
9
10
11
12
5
4
1
3
2
1 Valve type
2 Model number
3 Model number index
4 Order number or date
5 Valve size
9 Permissible temperature [°F]
10 Body material
11 C
V
coefcient
12 Pressure rating (Class)
Page 24
24 EB 8135/8136 EN
Dimensions in mm and inches
7 Dimensions in mm and inches
DIN version
DN L (mm) H (mm) H2 (mm)
15 130
235
70
20 150 80
25 160 85
32 180
245
100
40 200 105
50 230 120
65 290
350
130
80 310 140
ANSI version
NPS
L (in)
H (in)
H2 (in)
Class 150 Class 300 Class 150 Class 300
½
7.25
7.50
9.25
3.62
3.76
¾ 7.62 3.82
2 7.75
9.65
3.88
1½ 8.75 9.25 4.37 4.63
2 10.00 10.50 5.00 5.26
2½ 10.78 11.50
13.78
5.43 5.75
3 11.75 12.50 5.87 6.26
Page 25
EB 8135/8136 EN 25
Customer inquiries
50(1.96)
H
H2
L
Dimension applies to
plug stem pushed into
the valve body
Fig.15: Dimensional drawing of Type3535
8 Customer inquiries
Please submit the following details:
− Type designation (see nameplate)
− Order number (see nameplate)
− Serial number
− Version and nominal size of the valve
− Pressure and temperature of the process
medium
− Flow rate in m³/h
− Bench range (signal pressure range)
(e.g. 1.4 to 2.3bar with a pneumatic actuator)
− Installation drawing
Page 26
26 EB 8135/8136 EN
Page 27
EB 8135/8136 EN 27
Page 28
SAMSON AG · MESS- UND REGELTECHNIK
Weismüllerstraße 3 · 60314 Frankfurt am Main, Germany
Phone: +49 69 4009-0 · Fax: +49 69 4009-1507
samson@samson.de · www.samson.de
EB 8135/8136 EN
2016-10-14 · English
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