Mounting and Operating Instructions EB 8091 EN
Contents
1. N l 1 ous injury Vr NOTICE Property damage message or mal function Note Additional information Ip T Recommended action EB 8091 EN Important safety instructions Important safety instructions The valve is to be mounted started up or operated only by trained and experienced per sonnel familiar with the product According to these mounting and operating instructions trained personnel refers to indi viduals who are able to judge the work they are assigned to and recognize possible dan gers due to their specialized training their knowledge and experience as well as their knowledge of the applicable standards 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 appropri ate precautions To ensure appropriate use only use the valve in applications where the operating pres sure and temperatures do not exceed the specifications used for sizing the valve at the or dering stage Proper shipping and storage are assumed Note According to the ignition risk assessment performed in accordance with EN 13463 1 section 5 2 the non electrical actuators and 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 94 9 EC For connection to the equipotential bonding system observe the requirements spe2. s A ANN NI Actuator stem extends Actuator stem retracts EB 8091 EN Actuator stem extends When the signal pressure is reduced or the air supply fails the springs move the actua tor stem downwards and close the valve The valve opens when the signal pressure is in creased enough to overcome the force exert ed by the springs Body Screw Seat trim Seat Plug Seal Anti rotation fixture with trim consecutive number Nuts Packing rings Packing washer 5 Valve bonnet 5 1 Threaded bushing 5 2 Slotted nut 6 Yoke 6 1 Travel indicator scale 7 Stem connector 7 1 Stem connector nut 7 2 Stem connector sleeve 7 3 Lock nut 8 Actuator 8 1 Actuator stem 8 2 Slotted nut 8 3 Spring 8 4 Diaphragm 14 Connecting or switchover plate 14 1 Signal pressure routing for actuator stem extends 14 2 Signal pressure routing for actuator stem retracts 1 1 1 2 2 1 2 2 2 3 2 4 3 4 4 1 8 2 7 3 7 1 7 7 2 5 1 5 2 5 Fig 2 Micro valve with Type 3277 7 Actuator EB 8091 EN fi N us N IN N I TR Newlin Design and principle of operation Actuator stem retracts When the signal pressure is reduced or the air supply fails the springs move the actua tor stem upwards and open the valve The valve closes when the signal pressure is in creased enough to overcome the force exert ed by the springs sah ABQ ZZ ps4 nr IX NN N N N N N N N N N af N ie
3. 2 4 and 12 are secured by the washer 15 EB 8091 EN 10 1 1 12 13 15 16 Screw Plug Anti rotation fixture with trim consecutive number Valve bonnet Bellows seal bonnet insulat ing section Seal Seal Bellows seal Plug stem extension version with bellows seal or insulating section Anti rotation fixture Anti rotation fixture Screw Washer Test connection option Fig 5 Version with bellows seal EB 8091 EN 1 2 lt H NN Na EN a ZZA SD ASAAN ZAWA aoe ERY f 7 J I i 7 7 Z Nl X N VA EZ a Ses SS STS N IT Dz Ly Sex KA LN MA Troubleshooting K fal OU WS 2 N i D 4 Customer inquiries 7 Customer inquiries Please submit the following details Order number Type designation and configuration ID Var ID Globe or angle valve Nominal size and pressure of the valve Ks coefficient and consecutive number of the installed trim Pressure density viscosity and tempera ture of the process medium Flow rate in m3 h Direction of flow Bench range of the mounted actuator e g 0 2 to 1 bar ls a strainer installed Installation drawing Dimensions and weights Refer to Data Sheet gt T 8091 14 EB 8091 EN SAMSON AG MESS UND REGELTECHNIK Weism llerstra e 3 60314 Frankfurt am Main Germany Phone 49 69 4009 0 Fax 49 69 4009 1507 sa
4. SSS A BES N A N O S7 A Ri S FEN fr Ds L IN KA NI p ECLA P7777 Nee ana NAI T IV w ISIN N TANT II PN Vath LAE me F ANS Assembling and adjusting the valve and actuator Mounting accessories Direct attachment positioners can be mounted directly to the additional yoke of the Type 3277 Actuator Interface according to IEC 60534 6 NAMUR a mounting kit 1400 9031 allows the attachment of positioners limit switches solenoid gt valves and other valve accessories We rec ommend using an in sulating section or bel lows seal for flanged valves to provide more space to mount valve accessories 3 Assembling and adjusting the valve and actuator The different signal pressure connection of the actuators must be observed on assembly if the valve and actuator have not been as sembled by the manufacturer 3 1 Type 3510 1 Control Valve with Type 3271 5 Actuator gt Connect the signal pressure line for valves with actuator with actuator stem extends fail safe action to the connec tion on the bottom diaphragm case and for valves with actuator with actuator stem retracts fail safe action to the con nection on the top diaphragm case Signal pressure connection Type 3510 7 Control Valve with Type 3277 5 Actuator If the actuator is operated without a directly attached positioner a connecting plate ac cessories is req
5. Type 3510 1 and Type 3510 7 Pneumatic Control Valves Type 3510 1 with 120 cm actuator Type 3510 7 with 120 cm actuator and integrated positioner Type 3510 1 with 60 cm actuator Mounting and Operating Instructions EB 8091 EN Edition July 2002 1 Important safety instructionS scsscsssscssssssscssssssssessscsscsssassssscssscssessenseses 3 2 Design and principle of operation 2 22 20s000e000nr0nnnennnennnennnennneennnennnnsnnennne 4 3 Assembling and adjusting the valve and actuator ccsssccsssscsssscessrecessnees 6 3 1 Signal pressure connection cccccsccesssccsseecssecesecesecessecesseceeecnseeceseeeeeeesaes 6 3 2 Assembly ond CG um ee 8 4 Pee lle ToT i PAP E P EAE E E EE A 8 4 1 Mounlo Posi Ois nie er 8 5 Operation Reversing the operating direction sseesooessosssocsssoessoessoossseseo 9 6 Troubleshooting ssscsssscssssssesssscssssccssssccsssscesssscssssecsssssesssecesssesssssesessnecs 9 6 1 Replacing the packing ys csnsinconsodonecistiadnrosionsareos death ooaaansaardtllacassarwailoncinnsoeniehaun 9 6 2 Replacing the seat and plug ccccccccccessccssecessecesseeessecessecessecesecesseeceseeesaes 12 7 Customer INgUINES ee error 14 Definition of signal words DANGER l 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
6. ci fied in section 6 3 of EN 60079 14 2011 VDE 0165 Part 1 EB 8091 EN 3 Design and principle of operation 2 Design and principle of oper ation The pneumatic control valve consists of a Type 3510 Micro flow Valve with globe or angle style body and a Type 3271 5 Pneu matic Actuator Type 3510 1 Control Valve or a Type 3277 5 Pneumatic Actuator Type 3510 7 Control Valve The modular design allows the actuators to be exchanged and an insulating section or metal bellows to be fitted to the standard valve version The medium flows through the valve in the direction indicated by the arrow The posi Actuator stem retracts NA IE MIR Type 3271 5 Actuator 120 cm Fig 1 Type 3271 5 Actuator I A TEEN 86 zz XX bal 7 Dn Vv AY KA tion of the plug 3 determines the flow through the valve seat 2 The plug is moved by a change in the signal pressure acting on the diaphragm of the ac tuator The plug stem 6 is connected to the actua tor stem 8 1 by the stem connector 7 and is sealed by an adjustable PTFE packing Fail safe action Depending on how the compression springs 8 3 are arranged in the actuator the valve has two different fail safe positions I Actuator stem extends Type 3271 55 Actuator 60 cm III III Pas N sO 7 ZS G S S A ZN S gt V 2 Z a Nd i CLLR SS Ben ry PY FF N VLLLLLLLILLLLLLLLL A 7 RSS N
7. d thoroughly rinse them Avoid medium residues in the valve s dead spaces Wear pro fective clothing When used at high temperatures allow the plant section to cool down to ambient temperature Shut off and lock supply air and control signals to prevent any haz ards due to moving valve parts gt Remove the valve from the pipeline be fore performing assembly work Note The seat and special tools required for installation as well as the neces sary tightening torques are listed in the document WA 029 A complete tool kit for the Type 3510 Micro flow Valve can be ordered separately or der no 1280 3050 6 1 In case of leakage at the packing the pack ing must be renewed as follows Replacing the packing 1 Place a wrench width across flats 17 on stem connector nut 7 1 and unscrew stem connector sleeve 7 2 with a sec ond wrench width across flats 17 For actuators with actuator stem ex tends apply approx 50 of the signal pressure range see nameplate fo the actuator to retract the actuator stem Troubleshooting Unscrew the bottom slotted nut 5 2 Re move actuator 8 including yoke 6 from the valve turning the slotted nut 5 2 so that a groove points towards the travel indicator scale 6 1 Remove the nuts 3 Take the stem con nector sleeve 7 2 off the plug stem Remove the screw 1 1 lift off the an ti rotation fixture 2 4 and unscrew the valve bo
8. ed Do not insulate the bellows seal bonnet or insulating section 9 as well Test connection The version with bellows seal can be fitted with a test connection with G Y thread at the bellows seal bonnet to allow the tightness of the bellows to be monitored We recom EB 8091 EN Operation Reversing the operating direction mend installing a suitable leakage indicator when explosive media or media that are hazardous to health are used 5 Operation Reversing the operating direction If it becomes necessary to reverse the fail safe action of the actuator from actuator stem extends to actuator stem retracts or vice versa refer to the mounting and operat ing instructions of the actuator for details gt EB 8310 1 for Type 3271 5 gt EB 8310 1 for Type 3277 5 6 Troubleshooting External leakage can indicate that the pack ing is defective or the metal bellows is defec tive in a version with a bellows seal If the valve does not close tightly tight shut off may be impaired by dirt stuck between the seat and plug or by damaged facings We recommend removing the parts cleaning them and if necessary replacing them with new ones WARNING Risk of injury due to assembly work on a control valve that has not been made safe Depressurize the plant section in which the control valve is installed EB 8091 EN When media that are hazardous to health are used drain the pipeline and valve an
9. he seat trim parts 2 1 to 2 4 with a deviating Kys co efficient also exchange the anti ro tation fixture The required anti ro tation fixture is supplied together with the new seat trim A consecu tive number is written on it as on the seat and plug themselves to in dicate which trim parts belong to gether as well as the material Kys coefficient and characteristic Do not combine seats and plugs belonging to different trims Observe the assignment of seat thread and Kys coefficient see ta ble below Seat thread table M10 x 1 M16 x1 AVS Bas Ore coefficient 100 400 Version with insulating section or bellows seal After unscrewing the valve bonnet 5 gt In versions with insulating section re move the insulating section 9 from the valve body to allow the plug stem includ ing plug 2 2 to be unscrewed from the plug stem extension 10 1 gt In versions with bellows seals unscrew the bellows seal 10 together with plug stem extension 10 1 and plug 2 2 from the bellows seal bonnet 9 using a bellows wrench Unscrew the plug stem along with plug out of the plug stem extension and sepa rate the bellows seal bonnet from the valve body Before reassembling renew the seals 9 1 and 9 2 In addition secure bellows seal bonnet 9 or insulating section 9 as well as the valve bonnet using additional anti rota tion fixtures 11 and 12 The top anti rotation fixtures
10. ing upward Screw on nuts 3 Lock nuts against each other so that approx 1 mm of the thread is still visible 13 Place the actuator with yoke onto the valve bonnet and secure it with the slot ted nut 5 2 For actuators with actuator stem ex tends apply approx 50 of the signal pressure range see nameplate to the actuator using a pressure regulator to re tract actuator stem far enough to screw together the stem connector nut 7 1 and stem connector sleeve 7 2 14 Screw together stem connector sleeve 7 2 and stem connector nut 7 1 as tightly as possible Tighten lock nut 7 3 15 Check adjustment as described in sec tion 3 2 items 5 to 8 EB 8091 EN Troubleshooting WZ EBD 1 GJ 1 ZN Screw Seat trim Seat Plug Seal Anti rotation fixture Nuts Packing rings 4 1 Packing washer 5 Valve bonnet 5 1 Threaded bushing 5 2 Slotted round nut 6 Yoke 6 1 Travel indicator scale 7 Stem connector 7 1 Stem connector nut 7 2 Stem connector sleeve 7 3 Lock nut 8 1 Actuator stem SSS Vi LZZZTZ GIRL A Fig 4 Replacing the packing EB 8091 EN 11 Troubleshooting 6 2 Replacing the seat and plug Standard version gt For assembly and disassembly proceed as described in section 6 1 Additionally unscrew the seat 2 1 using a socket wrench NOTICE Risk of damage to the seat trim due to the incorrect exchange of the seat and plug On exchanging t
11. lates are not interchangeable Switchover New Order no 1400 6822 plate NOTICE A supply pressure above the maxi mum permissible limit will damage the actuator Do not allow the supply pressure to exceed the maximum permissible lim it Maximum permissible supply pressure Old Order no 1400 6819 _ Fail safe action actuator stem retracts Switchover New Order no 1400 6823 see table below Old G thread Order no 1400 6820 Zange pressure Old NPT thread Order no 1400 6871 Switchover plate Connecting plate Signal pressure Signal pressure Symbol Marking Actuator stem extends Actuator stem retracts Kariaseern left Attach Right Left Attach Right reiradis extends ment ment 22 A 12 2 pest Lg g Ea z y y v vy v vy Fig 3 Signal pressure connections EB 8091 EN 7 Installation Fail safe action actuator stem extends A bar 3 2 Assembly and adjustment For actuators with a switchover plate for at tachment of a positioner a suitable adapter needs to be connected to the hole at the side Alternatively the connecting plate Fig 3 right can be used 1 Loosely thread the lock nut 7 3 and stem connector nut 7 1 upward onto the plug stem Fig 2 2 Slide slotted nut 8 2 over the stem con nector nut and lock nut 3 Place actuator on valve yoke 7 and fas ten tight using slotted nut 8 2 For actuators with actuator stem ex tends apply approx 50 of the signal pre
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13. nnet 5 from the valve body Unscrew the threaded bushing 5 1 Pull the plug stem along with the plug 2 2 out of the valve bonnet 5 For versions with bellows seal or insu lating section separate the valve bonnet from the bellows seal bonnet or insulat ing section 9 The plug stem extension 10 1 Fig 5 remains fixed in the inter mediate piece Remove packing washers 4 1 and packing rings 4 from the packing chamber using a suitable tool Make sure the sealing faces do not get damaged Clean the packing chamber thoroughly Assembly Z Insert new packing rings Start with a white ring followed by two black rings and another white one Make sure that the butt joints of successive rings are not positioned on top of each other Insert packing washer s 4 1 Tighten threaded bushing 5 1 manually Slide plug stem with plug 2 2 into the valve bonnet as far as it will go Tighten threaded bushing 5 1 Make sure that a minimum gap of 1 3 mm between valve bonnet and threaded bushing is observed If this is not the case add the required number of packing washers 4 1 min 1 max 3 washers 10 Insert new seal 2 3 into the body Screw the valve bonnet into the body 11 Place the anti rotation fixture 2 4 on the valve bonnet ensuring that the screw 1 1 is inserted into the long hole Fas ten tight 12 Slide the stem connector sleeve 7 2 on to the plug stem with the thread fac
14. ssure range see nameplate to the actuator using a pressure regulator to re tract actuator stem far enough to screw together the stem connector nut 7 1 and stem connector sleeve 7 2 4 Screw together stem connector sleeve 7 2 and stem connector nut 7 1 as tightly as possible 5 Apply lower signal pressure range value to the signal pressure connection For a signal pressure range bench range for example 0 4 to 0 8 bar and an actuator with fail safe action actua tor stem extends the lower signal pres sure range value is 0 4 bar for actuator stem retracts it is 0 8 bar 6 Turn the stem connector 7 on actuator stem until the plug stem moves from the closed position at the corresponding low er range value To do so change the signal pressure each time at the pressure regulator and return to the lower range value 7 Fasten the lock nut 7 3 to secure the stem connector in this position 8 Align travel indicator scale 6 1 with the black ring on the stem connector A Installation 4 1 The valve can be mounted in any desired position Mounting position The following points must be observed during installation gt Install the valve free of stress If neces sary support the pipelines near the con nections gt Flush the pipeline thoroughly before in stalling the valve gt In valve versions with bellows seal or in sulating section installed in pipelines that are to be insulat
15. uired In this case the signal pressure is routed directly over the signal pressure connection of the connecting plate to the actuator diaphragm chamber gt Turn the connecting plate to align the correct symbol for the fail safe action actuator stem extends or actuator stem retracts with the marking gt Make absolutely sure that the gasket for the connecting plate is correctly inserted gt The connecting plate has threaded holes with NPT and G threads Seal the con nection that is not used with the rubber seal and square plug Actuator with directly attached positioner The signal pressure is transmitted to the dia phragm chamber through the holes on the left or right side of the yoke and over a swi tchover plate accessories The fail safe ac tion of the actuator actuator stem extends or actuator stem retracts determines how the switchover plate must be aligned with the marking gt Turn the switchover plate to align the cor rect symbol for the fail safe action with the marking The attachment either on the left or right side of the actuator is determined by the required operating direction of the posi tioner gt gt or lt gt EB 8091 EN Assembling and adjusting the valve and actuator Accessories Switchover plates and connecting plates are listed as accessories Actuators with device index 01 e g 3277 531xxx20 01 old 00 are equipped with new connecting plates Old and new p
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