Samson 3222/5857 series Service manual

Mounting and

Operating Instructions

EB 5866 EN

Translation of original instructions

Edition July 2016

Type3222/5857

Type3222/5757-3

Type3222/5757-7

Type3222/5825

Type3222/5725-7

Type3222/2780-1 Type3222/2780-2 with Type3760

Positioner

Electric Control Valves

Types 3222/5857, 3222/5824, 3222/5825, 3222/5757-3,

3222/5757-7, 3222/5724-3, 3222/5724-8, 3222/5725-3,

3222/5725-7, 3222/5725-8

Pneumatic Control Valves

Type3222/2780

2 EB 5866 EN

Note on these mounting and operating instructions

These mounting and operating instructions assist you in mounting and operating the device

safely. The instructions are binding for handling SAMSON devices.

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

later reference.

ÎIf you have any questions about these instructions, contact SAMSON‘s After-sales Service

Department (aftersalesser[email protected]).

The mounting and operating instructions for the devices are included in

the scope of delivery. The latest documentation is available on our website

(www.samson.de) > Product documentation. You can enter the document

number or type number in the [Find:] eld to look for a document.

Denition of signal words

Hazardous situations which, if not avoided,

will result in death or serious injury

Hazardous situations which, if not avoided,

could result in death or serious injury

Property damage message or malfunction

Additional information

Recommended action

DANGER

WARNING

NOTICE

Note

Tip

Contents

EB 5866 EN 3

1 Safety instructions and measures ...................................................................5

1.1 Notes on possible severe personal injury .........................................................8

1.2 Notes on possible personal injury ...................................................................9

1.3 Notes on possible property damage ..............................................................10

2 Markings on the device ...............................................................................11

2.1 Valve nameplate ..........................................................................................11

2.2 Actuator nameplate ......................................................................................11

3 Design and principle of operation ................................................................12

3.1 Fail-safe action ............................................................................................12

3.2 Versions ......................................................................................................14

3.3 Technical data .............................................................................................16

4 Preparation.................................................................................................22

4.1 Unpacking ..................................................................................................22

4.2 Transporting and lifting ................................................................................22

4.2.1 Transporting ................................................................................................22

4.2.2 Lifting ..........................................................................................................22

4.3 Storage .......................................................................................................22

4.4 Preparation for installation ............................................................................23

5 Mounting and start-up.................................................................................24

5.1 Installing the valve into the pipeline ...............................................................24

5.1.1 Checking the installation conditions ...............................................................24

5.1.2 Additional ttings .........................................................................................26

5.1.3 Installing the control valve .............................................................................26

5.2 Mounting the actuator onto the valve .............................................................27

5.2.1 Connecting the actuator ................................................................................27

5.2.2 Conguring the actuator ...............................................................................28

5.3 Quick check ................................................................................................28

6 Operation...................................................................................................29

7 Servicing.....................................................................................................30

7.1 Preparation for return shipment .....................................................................30

7.2 Ordering spare parts and operating supplies .................................................30

4 EB 5866 EN

Contents

8 Malfunctions ...............................................................................................31

8.1 Troubleshooting ...........................................................................................31

8.2 Emergency action ........................................................................................32

9 Decommissioning and disassembly ..............................................................33

9.1 Decommissioning .........................................................................................33

9.2 Removing the valve from the pipeline .............................................................33

9.3 Removing the actuator from the valve ............................................................34

9.4 Disposal ......................................................................................................34

10 Appendix....................................................................................................35

10.1 After-sales service ........................................................................................35

10.2 Certicates ..................................................................................................35

EB 5866 EN 5

Safety instructions and measures

1 Safety instructions and measures

Intended use

The SAMSON Type3222 Valve is designed for use in temperature control circuits in HVAC

plants (e.g. for DHW heating). The valve is primarily combined with the following SAMSON

actuators:

−As electric control valve: Type3222/5857, Type3222/5824, Type3222/5825,

Type3222/5757-3, Type3222/5757-7, Type3222/5724-3, Type3222/5724-8,

Type3222/5725-3, Type3222/5725-7 and Type3222/5725-8

−As pneumatic control valve: Type3222/2780

The valve with its actuator is designed to operate under exactly dened conditions (e.g. oper-

ating pressure, process medium, temperature). Therefore, operators must ensure that the con-

trol 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.

ÎRefer to the technical data and nameplate for limits and elds of application as well as

possible uses.

Reasonably foreseeable misuse

The control valve is not suitable for the following applications:

−Use outside the limits dened during sizing and in the technical data

−For Type3222/2780 Control Valve: use outside the limits dened by the valve accesso-

ries mounted on the control valve

Furthermore, the following activities do not comply with the intended use:

−Use of non-original spare parts

−Performing servicing and repair work not described in these instructions

6 EB 5866 EN

Safety instructions and measures

Qualications of operating personnel

The control valve must be mounted, started up, serviced, and repaired by fully trained and

qualied personnel only; the accepted industry codes and practices are to be observed. Ac-

cording to these mounting and operating instructions, trained personnel refers to individuals

who are able to judge the work they are assigned to and recognize possible hazards due to

their specialized training, their knowledge and experience as well as their knowledge of the

applicable standards.

Personal protective equipment

We recommend wearing the following protective equipment:

−Protective clothing and gloves in applications with hot or cold media

ÎCheck with the plant operator for details on further protective equipment.

Revisions and other modications

Revisions, conversions or other modications to the product are not authorized by SAMSON.

They are performed at the user's own risk and may lead to safety hazards, for example. Fur-

thermore, the product may no longer meet the requirements for its intended use.

Safety features

In combination with the Type5825 Electric Actuator and with the TROVIS5725-3, TRO-

VIS5725-7, and TROVIS5725-8 Electric Actuators with Process Controllers, the following

safety feature exists: upon failure of the power supply, the valve moves to a dened fail-safe

position (see section3.1). The direction of action of the fail-safe action is dened by the actu-

ator version (see associated actuator documentation).

In combination with the Type2780 Pneumatic Actuator, the following safety feature exists:

upon failure of the air supply, the valve moves to a certain fail-safe position (see section3.1).

The fail-safe action corresponds with the direction of action. The fail-safe action of SAMSON

actuators is specied on the actuator nameplate (see actuator documentation).

Warning against residual hazards

To avoid personal injury or property damage, plant operators and operating personnel must

prevent hazards that could be caused in the control valve by the process medium, the operat-

ing pressure, the signal pressure or by moving parts by taking appropriate precautions. They

must observe all hazard statements, warning and caution notes in these mounting and oper-

ating instructions, especially for installation, start-up, and servicing.

EB 5866 EN 7

Safety instructions and measures

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, operators must ensure that operating personnel or third persons are not ex-

posed to any danger.

Responsibilities of operating personnel

Operating personnel must read and understand these mounting and operating instructions as

well as the referenced documents and observe the hazard statements, warning, and caution

notes specied in them. Furthermore, the operating personnel must be familiar with the ap-

plicable health, safety and accident prevention regulations and comply with them.

Referenced standards and regulations

The control valves comply with the requirements of the European Pressure Equipment Direc-

tive 2014/68/EU. Valves with a CE marking have a declaration of conformity which in-

cludes information about the applied conformity assessment procedure. This declaration of

conformity is included in the Appendix of these instructions (see section10.2).

The electric actuators are designed for use in low voltage installations. For wiring, mainte-

nance, and repair, observe the relevant safety regulations.

Referenced documentation

The following documents apply in addition to these mounting and operating instructions:

−Mounting and operating instructions for mounted actuator, e.g. SAMSON actuators:

u EB5857 for Type5857

uEB5824-1/-2 for Type5824 and Type5825

uEB5757-X for TROVIS5757-X

uEB5724 for TROVIS5724-3 and TROVIS5725-3

uEB5724-8 for TROVIS5724-8 and TROVIS5725-8

uEB5725-7 for TROVIS5725-7

u EB5840 for Type2780

−For Type3222/2780 Control Valve: mounting and operating instructions for mounted

valve accessories (positioner, solenoid valve etc.)

8 EB 5866 EN

Safety instructions and measures

1.1 Notes on possible severe personal injury

DANGER

Risk of bursting in pressure equipment.

Control valves and pipelines are pressure equipment. Improper opening can lead to

valve components bursting.

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

concerned and the valve.

ÎDrain the process medium from all the plant sections concerned as well as the

valve.

ÎWear personal protective equipment.

Risk of electric shock.

ÎDo not remove any covers to perform adjustment work on live parts.

ÎBefore performing any work on the device and before opening the device, discon-

nect the power supply and protect it against unintentional reconnection.

ÎOnly use power interruption devices that are protected against unintentional recon-

nection of the power supply.

ÎThe electric actuators are protected against spray water (IP54). Avoid jets of water.

EB 5866 EN 9

Safety instructions and measures

1.2 Notes on possible personal injury

WARNING

Crush hazard arising from moving parts.

The pneumatic control valve (Type3222/2780) contains moving parts (actuator and

plug stems), which can injure hands or ngers if inserted into the valve.

ÎWhile working on the control valve, disconnect and lock the pneumatic air supply

as well as the control signal.

Risk of personal injury when the pneumatic actuator vents.

While the valve is operating, the pneumatic actuator (Type2780) may vent during

closed-loop control or when the valve opens or closes.

ÎInstall the control valve in such a way that the actuator does not vent at eye level.

ÎUse suitable silencers and vent plugs.

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

Risk of personal injury due to 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. burns.

ÎIf possible, drain the process medium from all the plant sections concerned and the

valve.

ÎWear protective clothing and gloves.

Risk of burn injuries due to hot components and pipelines.

Depending on the process medium, valve components, and pipelines may get very hot

and cause burn injuries.

ÎAllow components and pipelines to cool down.

ÎWear protective clothing and gloves.

10 EB 5866 EN

Safety instructions and measures

1.3 Notes on possible property damage

NOTICE

Risk of damage to the electric control valve due to the power supply exceeding the

permissible tolerances.

The electric control valves are designed for use according to regulations for low-volt-

age installations.

ÎObserve the permissible tolerances of the power supply. See associated actuator

documentation.

Risk of valve damage due to contamination (e.g. solid particles) in the pipeline.

The plant engineering company is responsible for cleaning the pipelines in the plant.

ÎFlush the pipelines before start-up.

ÎObserve the maximum permissible pressure for valve and plant.

Risk of valve damage due to unsuitable medium properties.

The valve is designed for a process medium with certain properties (e.g. water, oil,

steam).

ÎOnly use the process medium that meets the specications used for sizing the valve.

This manual suits for next models

Table of contents

Popular Control Unit manuals by other brands

Festo

Festo Compact Performance CP-FB6-E Brief description

Elo TouchSystems

Elo TouchSystems DMS-SA19P-EXTME Quick installation guide

JS Automation

JS Automation MPC3034A user manual

JAUDT

JAUDT SW GII 6406 Series Translation of the original operating instructions

Spektrum

Spektrum Air Module System manual

BOC Edwards

BOC Edwards Q Series instruction manual

KHADAS

KHADAS BT Magic quick start

Etherma

Etherma eNEXHO-IL Assembly and operating instructions

PMFoundations

PMFoundations Attenuverter Assembly guide

GEA

GEA VARIVENT Operating instruction

Walther Systemtechnik

Walther Systemtechnik VMS-05 Assembly instructions

Altronix

Altronix LINQ8PD Installation and programming manual

Eaton

Eaton Powerware Series user guide

WAGO

WAGO 750-407/040-000 manual

Sony

Sony CCU-590 Operation manual

Graco

Graco 25D614 instructions

Task Force Tips

Task Force Tips YE-RF-900 Instructions for installation, safe operation and maintenance

Shini

Shini SPV-U Series manual