Samson Valve Series Service-Handbuch

Mounting and

Operating Instructions

EB 8135/8136 EN

Edition August 2011

Valve Series V2001

Three-way Valve for Heat Transfer Oil

Type 3535

Fig. 1 · Type 3535 Three-Way Valve with bellows seal and rod-type yoke (partial view)

2EB EB 8135/8136 EN

Safety instructions

General safety instructions

The valve is to be mounted, started up or serviced only by fully trained and

qualified personnel, observing the accepted industry codes and practices.

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

All safety instructions and warnings in these mounting and operating

instructions, particularly those concerning assembly, start-up and

maintenance, must be observed.

The valves fulfill the requirements of the European Pressure Equipment

Directive 97/23/EC. Valves with a CE marking have a declaration of

conformity that includes information about the applied conformity assessment

procedure. The declaration of conformity is available on request.

For appropriate operation, make sure that the control valve is only used in

areas where the operating pressure and temperatures do not exceed the

operating values which are based on the valve sizing data submitted in the

order. The manufacturer does not assume any responsibility for damage

caused by external forces or any other external influence!

Any hazards which could be caused in the control valve by the process

medium, operating pressure, signal pressure or by moving parts are to be

prevented by means of the appropriate measures.

Proper shipping and appropriate storage are assumed.

NOTICE

For installation and maintenance work on the valve, make sure the relevant

section of the pipeline is depressurized and, depending on the process

medium, drained as well. If necessary, allow the control valve to cool down

or warm up to reach ambient temperature prior to starting any work on the

valve.

Prior to performing any work on the valve, make sure the supply air and

control signal are disconnected or blocked to prevent any hazards that could

be caused by moving parts.

Special care is needed when the actuator springs are pretensioned. These

actuators are labeled correspondingly and can also be identified by three

long bolts at the bottom of the actuator. Prior to starting any work on the

valve, you must relieve the compression from the pretensioned springs.

Contents

1 Design and principle of operation. . . . . . . . . . . . . . . . . . . . 4

1.1 Technical data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

2 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6

2.1 Mounting position. . . . . . . . . . . . . . . . . . . . . . . . . . . . 6

2.2 Arrangement of control valve . . . . . . . . . . . . . . . . . . . . . . 6

2.3 Strainer and bypass. . . . . . . . . . . . . . . . . . . . . . . . . . . 6

3 Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8

4 Maintenance–replacing parts . . . . . . . . . . . . . . . . . . . . . . 8

4.1 Replacing the bellows seal . . . . . . . . . . . . . . . . . . . . . . . 10

4.1.1 Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10

4.1.2 Reassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11

4.2 Replacing the seat and plug . . . . . . . . . . . . . . . . . . . . . . 12

4.2.1 Mixing valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13

4.2.2 Diverting valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16

4.3 Tools and tightening torques . . . . . . . . . . . . . . . . . . . . . . 20

5 Nameplate descriptions . . . . . . . . . . . . . . . . . . . . . . . . 21

5.1 DIN version . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21

5.2 ANSI version . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21

6 Dimensions in mm and inches . . . . . . . . . . . . . . . . . . . . . 22

7 Customer inquiries . . . . . . . . . . . . . . . . . . . . . . . . . . 23

EB 8135/8136 EN 3

Contents

1 Design and principle of

operation

The Type 3535 Three-way Valve is con-

structed on the modular assembly principle

and can be combined with a pneumatic or

electric actuator as follows:

Valve Actuator

3535-P Pneumatic 3371-01xx

3535-IP Electropneumatic 3372-03xx

3535-E1 Electric 5824-30

3535-E3 3374

Design and principle of operation

4EB 8135/8136 EN

AB A AB A

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. 2 · Sectional drawing (DN 32 bis 50), plug arrangement for mixing valve (left) and diverting valve (right)

5.3 Seal

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 Sleeve (short)

10.3 Sleeve

12 Nut

12.1 Washer

12.2 Lock washers

X Position for open-end

wrench

1 Valve body

1.1 Nuts

1.2 Body 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 in DN 65

and higher)

4.3 Washer

5 Bellows seal with

plug stem

5.1 Coupling nut

5.2 Bellows housing

The plug arrangement determines whether

the three-way valve operates as mixing or

diverting valve.

In mixing valves, the media to be mixed en-

ter the valve at the ports A and B. The mixed

flow leaves through the port AB.

1.1 Technical data

The amount of flow from A or B to AB and

vice versa is determined by the cross-sec-

tional area between the seats and plugs.

The position of the plugs (3, 3.1, 3.2)

changes in response to changes of the con-

trol signal acting on the actuator.

The plug stem is sealed by a bellows and an

additional packing (4.2) and connected to

the actuator stem (8.1) by the stem connec-

tor (7).

EB 8135/8136 EN 5

Design and principle of operation

Nominal size DN 15 to 80 NPS ½ to 3

Material Sph. gra-

phite iron

EN-JS1049

Cast steel

1.0619

Stainless

steel

1.4408

Spheriodal

graphite

iron A 395

Cast steel

A 216

WCC

Stainl. steel

A 351

CF8M

Nominal pressure PN 16 · PN 25 Class 150 · Class 300

End

connections Flanges EN 1092-1 Form B1,

Ra 3.2 to 12.5 µm

EN 1092-1, groove Form D Raised face

Seat and plug sealing Metal sealing

Characteristic Linear

Rangeability 30:1 up to DN 25/NPS 1 · 50:1 for DN 32/NPS 1½ or larger

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

Leakage rate DIN EN 1349:

0.05 % of KVS coefficient ANSI/FCI 70-2:

0.05 % of CVcoefficient

Materials

Nominal size DN 15 to 80 NPS ½ to 3

Valve body Spheriodal

graphite iron

EN-JS1049

Cast steel

1.0619

Stainless

steel

1.4408

Spheriodal

graphite iron

A 395

Cast steel

A 216

WCC

Stainl. steel

A 351

CF8M

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

Seat and plug Seat £DN 25: 1.4305 · ³DN 32: 1.4104 £NPS 1: 1.4305 · ³NPS 1½: 1.4104

Plug 1.4305

Bellows seal 1.4541 · 1.4301

Packing PTFE

Body gasket Graphite on metal core

2 Installation

Valve and actuator are supplied already as-

sembled by the manufacturer.

For more details on the actuator used,

please refer to the appropriate mounting

and operating instructions.

2.1 Mounting position

The valve can be mounted in any position.

However, the limitations due to the actuator

used must be strictly observed.

CAUTION!

The valve must be installed free of stress and

free of excessive vibrations. If necessary,

support the pipelines near the connections.

Do not install supports on the valve or on the

actuator. Thoroughly flush the pipeline prior

to installation of the valve.

Pipeline routing

To allow the control valve to work properly,

the pipeline upstream and downstream of

the valve must be straight and free of ob-

structions for a length of at least 6 times the

pipe diameter (DN). Contact SAMSON if

this length cannot be met during installation.

Clean out the pipeline thoroughly prior to in-

stalling the valve.

2.2 Arrangement of control valve

Depending on the task to be performed, the

control valve is arranged as illustrated in

Fig. 3.

How the plugs are arranged for mixing or

diverting valves is specified on the label at-

tached to the valve body.

Fail-safe action: Valve shuts off the heating

medium supply or opens the supply of cool-

ing medium.

2.3 Strainer and bypass

We recommend installing a SAMSON

Type 2 N Strainer upstream of the valve,

and upstream of both ports for mixing

valves.

In addition to a bypass line, shut-off valves

should be installed both upstream of the

strainer and downstream of the control valve

so that the plant need not be shut down for

maintenance routines.

Installation

6EB 8135/8136 EN

KVS and CVcoefficients, seat diameters and travel

Nominal size DN 15 20 25 32 40 50 65 80

NPS ½¾1 –1½ 2 2½3

Kvs coefficients 46.381620325080

Cvcoefficients 5 7.5 9.4 – 23 37 60 94

Seat diameter mm/in 24 mm · 0.94” 40 mm · 1.57” 65 mm · 2.56”

Travel mm/in 15 mm · 0.59” 15 mm · 0.59” 15 mm · 0.59”

EB 8135/8136 EN 7

Installation

Mixing service Diverting service

Temperature control Q = constant Flow rate control Q = 0 to 100 %

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

Heating using a mixing valve (FA) or cooling using a mixing valve (FE)

Installation in flow pipe Installation in return flow pipe

Heating using a diverting valve (FA) or cooling using a diverting valve (FE)

Installation in return flow pipe Installation in flow pipe

AAB

Flow

Return flow

Flow

Return flow

AAB

Flow

Return flow

AAB

Flow

Return flow

AAB

Flow

Return flow

Flow

Return flow

AAB

Flow

Return flow

AB A

Flow

Return flow

Fig. 3 · Typical applications

3 Operation

Operating instructions depend on the actua-

tor used. Refer to the mounting and operat-

ing instructions for the appropriate actuator.

4 Maintenance–replacing parts

The valve is subject to wear and tear, espe-

cially at the seat, plug, bellows seal and

packing.

Depending on the application conditions

that prevail, the valve must be inspected at

appropriately scheduled intervals to prevent

any problems before they occur.

If any leaks occur to the atmosphere, the

packing may leak. If the valve does not shut

off properly, this may be because tight

shut-off is prevented by dirt or other impuri-

ties between the seat and plug or because

their facings have been damaged.

Valves in DN 15 to 25 have a one-piece

plug with the same arrangement for both

mixing and diverting valves.

Valves in DN 32 and larger have two V-port

plugs. In mixing valves, the plugs move in-

wards into the seats, whereas the plugs of

the diverting valves move outwards into the

seats.

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 DN 32 to 50 and for valves in

DN 65 and 80 as mixing and diverting

valves is specified in the section on assem-

bly.

We recommend removing the parts, thor-

oughly cleaning them, and replacing them

with new parts, if necessary.

Operation

8EB 8135/8136 EN

CAUTION!

If you intend carrying out mainten-

ance work on the valve, first depres-

surize the relevant plant section and,

depending on the process medium,

drain it as well. Let the plant section

cool down to reach ambient tempe-

rature, if high temperatures prevail.

Prior to starting any work, discon-

nect the electric or pneumatic control

signal for the actuator. On pneuma-

tic actuators, additionally remove the

signal pressure line.

As the process medium cannot drain

completely out of the valve, be awa-

re that some of the process medium

could still be trapped in the valve.

We recommend that you remove the

valve from the pipeline.

Note:

The tightening torques and special tools re-

quired for installing and removing the seat

are listed in the table on page 20.

NOTICE

Prior to carrying out any repairs, always

separate the actuator from the valve by re-

moving screws on the stem connector (7)

and undoing the nut (9). Then lift the actua-

tor off the valve (see Fig. 2).

EB 8135/8136 EN 9

Maintenance–replacing parts

4.1 Replacing the bellows seal

If the packing leaks, this is due to a dam-

aged bellows seal.

The entire bellows assembly together with

the packing (4.2) must be replaced.

We recommend renewing the top seal (5.3)

and the bottom body gasket (1.2) of the bel-

lows housing as well.

Mixing and diverting valves in nominal sizes

DN 32 to 80 differ from one another in the

arrangement of their plugs and sleeves (see

Fig. 4), where as mixing and diverting

valves in nominal sizes DN 15 to 25 have

the same plug and sleeve arrangement.

4.1.1 Disassembly

1. Unscrew the stem connector nut (6.1)

and lock nut (6.2) from the plug stem of

valves in DN 50 or smaller.

2. Unscrew the coupling nut (5.1) from the

bellows housing. Remove the nuts (1.1)

and lift off the flange (5.4).

3. Pull the bellows housing (5.2) with the

bellows assembly out of the body as far

as they will go. Place an open-end

wrench (SW 10 for £DN 50 or SW 13

for ³DN 65) at the side on the hexagon

(X) or at the flattened area of the plug

stem to hold it stationary. Undo nut (12)

and remove wrench.

4. Unthread nut (12). Remove the two lock

washers (12.2) and washer (12.1).

5. DN 15 to 25:

Carefully pull the plug stem (6) together

with the bellows assembly (5) and bel-

lows housing (5.2) from the top out of

the valve body.

DN 32 to 80:

Keep the bottom plug of diverting valves

or the bottom sleeve of mixing valves on

the plug stem. Use a long screw (M8 for

nominal sizes DN 32 to 50 and M12 for

DN 65 and 80) to keep the plugs (3.x)

and sleeves (10.x) in the right order.

Carefully lift the plug stem together with

the bellows assembly (5) and bellows

Maintenance–replacing parts

10 EB 8135/8136 EN

AB A

12.2

12.1

1.1

6.1

6.2

5.3

5.2

5.4

1.2

4.2

4.3

5.1

3.2

Fig. 4 · Mixing valve DN 32 to 50

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