Samson V2001 Series Service manual

Mounting and

Operating Instructions

EB 8135/8136 EN

Edition August 2016

Type3535 Three-way Valve with bellows seal and rod-type yoke (partial view)

Series V2001 Valves

Type3535 Three-way Valve for Heat

Transfer Oil

Denition of signal words

DANGER!

Hazardous situations which, if not

avoided, will result in death or seri-

ous injury

WARNING!

Hazardous situations which, if not

avoided, could result in death or seri-

ous injury

NOTICE

Property damage message or mal-

function

Note:

Additional information

Tip:

Recommended action



2 EB 8135/8136 EN

Contents

EB 8135/8136 EN 3

1 General safety instructions.............................................................................4

2 Design and principle of operation ..................................................................6

2.1 Technical data ...............................................................................................8

2.2 Materials.......................................................................................................8

2.3 KVS and CV coefcients, seat diameters and travel.............................................8

3 Installation....................................................................................................9

3.1 Mounting position..........................................................................................9

3.2 Arrangement of the valve ...............................................................................9

3.3 Strainer and bypass.......................................................................................9

4 Operation...................................................................................................11

5 Maintenance ...............................................................................................11

5.1 Replacing the bellows seal............................................................................12

5.1.1 Disassembly ................................................................................................12

5.1.2 Assembly ....................................................................................................13

5.2 Replacing the seat and plug..........................................................................15

5.2.1 Mixing valve................................................................................................15

5.2.2 Diverting valve.............................................................................................19

5.3 Tools and tightening torques..........................................................................22

6 Description of nameplates............................................................................23

6.1 DIN version .................................................................................................23

6.2 ANSI version ...............................................................................................23

7 Dimensions in mm and inches......................................................................24

8 Customer inquiries ......................................................................................25

4 EB 8135/8136 EN

General safety instructions

1 General safety instructions

−The control valve must be mounted, started up, or serviced by fully trained and qualied

personnel only. Make sure employees or third persons are not exposed to any danger.

All safety instructions and warnings given in these mounting and operating instructions,

particularly those concerning installation, start-up and maintenance, must be strictly ob-

served.

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

rective 2014/68/EU. Valves with a CE marking have a declaration of conformity which

includes information about the applied conformity assessment procedure. The declaration

of conformity can be viewed and downloaded from uhttp://www.samson.de.

−To ensure appropriate use, only use the valve in applications where the operating pres-

sure and temperatures do not exceed the specications used for sizing the valve at the or-

dering stage. The manufacturer does not assume any responsibility for damage caused

by external forces or any other external factors. Any hazards that could be caused in the

valve by the process medium, the operating pressure, the signal pressure or by moving

parts are to be prevented by taking appropriate precautions.

−Proper shipping and storage are assumed.

EB 8135/8136 EN 5

General safety instructions

Note:

−For installation and maintenance, make sure the relevant section of the pipeline is depres-

surized and, depending on the process medium, drained as well. Depending on the eld

of application, allow the valve to cool down or heat up to reach ambient temperature be-

fore starting any work on it.

−When working on the valve, make sure that the pneumatic air supply or power supply as

well as the control signal are disconnected to prevent any hazards due to moving parts.

−Be particularly careful if the actuator springs of pneumatic control valves are preloaded.

Such actuators are labeled correspondingly and can also be identied by three long bolts

protruding from the bottom of the actuator. Before starting any work on the valve, relieve

the compression from the preloaded springs.

6 EB 8135/8136 EN

Design and principle of operation

2 Design and principle of oper-

ation

The Type3535 Three-way Valve has a mod-

ular design and can be combined with pneu-

matic or electric actuators (as described in

following):

Control valve Type ...

Actuator

3535-P Pneumatic 3371-01xx

3535-IP Electropneumatic 3372-03xx

3535-E1 Electric 5824-30

3535-E3 3374

Depending on the plug arrangement, the

three-way valve can be used either as a mix-

ing or diverting valve.

In mixing valves, the process media to be

mixed enter at valve ports A and B. The

combined ow exits the valve at port AB.

In diverting valves, the process medium en-

ters at the valve port AB and the partial

ows exit at ports A and B.

The ow rate from ports A or B to AB and

vice versa depends on the cross-sectional ar-

ea of ow between the seats and plugs.

The plug (3, 3.1, 3.2) is moved by changing

the control signal applied to the actuator.

The plug stem is sealed by a bellows seal

and an additional packing (4.2) and is con-

nected to the actuator stem (8.1) by the stem

connector (7).

AB AABA

2.2

12.2

12.1

2.1

1.1

6.1

6.2

5.3

5.2

10.1

10.2

10.3

5.4

1.2

8.1

8.2

4.1

4.2

4.3

5.1

3.2

3.1

10.3

10.2

10.1

3.1

3.2

12.1

12.2

Fig.1: Sectional drawing DN32 to 50, plug arrangement for mixing valve (left) and diverting valve

(right)

1Valve body

1.1 Nuts

1.2 Gasket

2.1 Top seat

2.2 Bottom seat

3.1 Top plug

3.2 Bottom plug

4 Threaded bushing

4.1 Bushing

4.2 Packing (spring-load-

ed for DN65 and

larger)

4.3 Washer

5 Bellows seal with plug

stem

5.1 Coupling nut

5.2 Bellows housing

5.3 Gasket

5.4 Flange

6Plug stem

6.1 Stem connector nut

6.2 Lock nut

7 Stem connector

8.1 Actuator stem

8.2 Rod-type yoke

9Nut

10.1 Sleeve

10.2 Short sleeve

10.3 Sleeve

12 Nut

12.1 Washer

12.2 Retaining washers

XPosition for open-end

wrench

EB 8135/8136 EN 7

Design and principle of operation

2 Design and principle of oper-

ation

The Type3535 Three-way Valve has a mod-

ular design and can be combined with pneu-

matic or electric actuators (as described in

following):

Control valve Type ...

Actuator

3535-P Pneumatic 3371-01xx

3535-IP Electropneumatic 3372-03xx

3535-E1 Electric 5824-30

3535-E3 3374

Depending on the plug arrangement, the

three-way valve can be used either as a mix-

ing or diverting valve.

In mixing valves, the process media to be

mixed enter at valve ports A and B. The

combined ow exits the valve at port AB.

AB AA

2.2

12.2

12.1

2.1

1.1

6.1

6.2

5.3

5.2

10.1

10.2

10.3

5.4

1.2

8.1

8.2

4.1

4.2

4.3

5.1

3.2

3.1

10.3

10.2

10.1

3.1

3.2

12.1

12.2

Fig.1: Sectional drawing DN32 to 50, plug arrangement for mixing valve (left) and diverting valve

(right)

1Valve body

1.1 Nuts

1.2 Gasket

2.1 Top seat

2.2 Bottom seat

3.1 Top plug

3.2 Bottom plug

4 Threaded bushing

4.1 Bushing

4.2 Packing (spring-load-

ed for DN65 and

larger)

4.3 Washer

5 Bellows seal with plug

stem

5.1 Coupling nut

5.2 Bellows housing

5.3 Gasket

5.4 Flange

6Plug stem

6.1 Stem connector nut

6.2 Lock nut

7 Stem connector

8.1 Actuator stem

8.2 Rod-type yoke

9Nut

10.1 Sleeve

10.2 Short sleeve

10.3 Sleeve

12 Nut

12.1 Washer

12.2 Retaining washers

XPosition for open-end

wrench

8 EB 8135/8136 EN

Design and principle of operation

2.1 Technical data

Valve size DN 15 to 80 NPS½ to 3

Material

Spheroidal

graphite iron

EN-JS1049

Cast steel

1.0619

Stainless

steel

1.4408

Spheroidal

graphite

iron A395

Cast steel

A216 WCC

Stainless

steel A351

CF8M

Pressure rating PN16 · PN25 Class150 · Class300

Connection Flanges

EN1092-1 FormB1,

Ra3.2 to 12.5µm

EN1092-1, groove FormD

Raised face

Seat-plug seal Metal seal

Characteristic Linear

Rangeability 30:1 up to DN25 (NPS1) · 50:1 for DN32 (NPS1) and larger

Temperature range –10 to +350°C 14 to 660°F

Leakage class DINEN1349: 0.05% of KVS ANSI/FCI70-2: 0.05% of CV

Compliance ·

2.2 Materials

Valve size DN 15 to 80 NPS½ to 3

Valve body

Spheroidal

graphite iron

EN-JS1049

Cast steel

1.0619

Stainless

steel

1.4408

Spheroidal

graphite

iron A395

Cast steel

A216 WCC

Stainless

steel A351

CF8M

Valve bonnet Cast steel S235JR (St 37) 1.4408 Cast steel S235JR (St 37) 1.4408

Seat ≤DN25: 1.4305 · ≥DN32: 1.4104 ≤NPS1: 1.4305 · ≥NPS1½: 1.4104

Plug 1.4305

Bellows seal 1.4541 · 1.4301

Packing PTFE

Body gasket Graphite on metal core

2.3 KVS and CV coefcients, seat diameters and travel

Valve size DN 15 20 25 32 40 50 65 80

NPS ½¾ 1 – 1½ 22½ 3

KVS coefcients 4 6.3 8 16 20 32 50 80

CV coefcients 5 7.5 9.4 –23 37 60 94

Seat Ø mm/in 24/0.94 40/1.57 65/2.56

Travel mm/in 15/0.59 15/0.59 15/0.59

EB 8135/8136 EN 9

Installation

3 Installation

Valve and actuator are delivered ready

mounted.

Refer to the corresponding mounting and

operating instructions for more details on the

actuator used.

3.1 Mounting position

The valve can be mounted in any desired

position.

ÎObserve the restrictions for the actuator

used.

NOTICE

Install the valve free of stress and

with the least amount of vibrations as

possible. If necessary, support the

pipelines near the connections. Do

not attach supports directly to the

valve or actuator.

Pipeline routing

To ensure that the control valve func-

tions properly, the pipeline must be

straight and without any manifolds

or disturbances for a distance of at

least 6times the valve size (DN) up-

stream and downstream of the valve.

Contact SAMSON if this distance

cannot be observed.

Flush the pipeline thoroughly before

installation of the valve.

3.2 Arrangement of the valve

Install the valve as shown in Fig.2 depend-

ing on whether it is to be used for mixing or

diverting service.

The plug arrangement (i.e. either mixing or

diverting valve) is indicated on a label at-

tached to the valve body.

Fail-safe action: the valve shuts off the ow

of the heating medium or opens the ow of

the cooling medium.

3.3 Strainer and bypass

We recommend installing a SAMSON

Type2N Strainer upstream of the valve, and

upstream of both inlet ports in mixing valves.

We recommend installing a shut-off valve

both upstream of the strainer and down-

stream of the valve to ensure that the plant

does not need to be shut down for mainte-

nance. In addition, install a bypass line.

10 EB 8135/8136 EN

Installation

Mixing service

Temperature control Q = constant

Diverting service

Temperature control Q=0 to 100%

Fail-safe action: FA = Actuator stem extends, FE = Actuator stem retracts

Heating with mixing valve (FA) or cooling with mixing valve (FE)

Installation in ow pipe Installation in return ow pipe

AAB

Flow pipe

Return ow

pipe

Flow pipe

Return ow

pipe

AAB

Flow pipe

Return ow

pipe

Flow pipe

Return ow

pipe

Heating with diverting valve (FA) or cooling with diverting valve (FE)

Installation in return ow pipe Installation in ow pipe

AAB

Flow pipe

Return ow

pipe

Flow pipe

Return ow

pipe

AB A

Flow pipe

Return ow

pipe

Flow pipe

Return ow

pipe

Fig.2: Typical installations

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