Mounting and Operating Instructions EB 8072 EN
Contents
1. Ewe 26 Bellows bonnet 26 Plug for version with bellows seal 27 Bellows section with 28 Additional assembly instructions 2 2 ee 28 Balanced valves wc ee m gs 29 zoe Ba wd eee aw ee Ga we Oe de 29 o cack be hak OO ODO or a ee 29 Tightening torques 1120 1400 29 Spacer rings 1120 3074 30 Description 30 3291 Valve oo Coon 30 3277 31 3271 ss ex ee Sony ad 31 Customer inquiries 32 Dimensions and 32 Note Non electrical actuators and valves do not have their own potential ignition source according to the risk assessment in the rare incident of an operating fault corresponding to EN 13463 1 2001 paragraph 5 2 and therefore do not fall within the scope of the European Directive 94 9 EC EB 8072EN 3 General safety instructions 1 General safety instructions The control valve must only be mounted started up or serviced 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 operat ing instructions particularly those concern2. 8072 23 Maintenance Replacing parts 6 3 Valves with bellows section For valves with bellows section the bellows section containing the plug stem and bellows is mounted as one unit 29 Fig 22 Type 3291 with bellows section 6 3 1 Removing the actuator Remove the actuator as described in section 6 2 1 6 3 2 Disassembly 6 3 2 1 Bellows seal 1 Unscrew nut 14 and remove it 2 Lift complete bellows section assembly out of the body 3 Clamp the bellows section in a suitable apparatus to perform further work on it Do not apply a load to the bellows or twist it 6 3 2 2 Plug Valves up to NPS 112 1 Place an open end wrench on the flat tened area of the plug stem to hold it stationary and unscrew nut 6 from plug 29 2 Remove plug from hexagon end of the plug stem Fig 23 Plug for valves up to NPS 1 24 EB 8072 EN Valves NPS 2 and larger Bend back the edges of the lock plate 31 from the heads of the screws 34 Remove the screws 34 Unscrew the plug 29 from the plug stem and remove it 34 E 31 28 Fig 24 Plug for valves in NPS 2 and larger Maintenance Replacing parts 6 3 2 4 Plug stem with bellows Lift off top gasket 39 Lift the plug stem bellows assembly 37 upwards out of the be
3. Note Contact your nearest SAMSON sub sidiary or the SAMSON After sales Service department for information on suitable lubri cants Apply a suitable lubricant to the plug stem 5 in area where the PTFE packing is lo cated as well as to the individual parts of the PTFE packing 15 In valves with balanced plugs additionally apply lubricant to the pressure balancing sleeve and the bearing strip Note Do not apply lubricant to the packing parts or plug stem when a graphite packing is used Similarly do not apply lubricant to the pressure balancing sleeve or bearing strip when graphite pressure balancing parts are used in the valve Maintenance Replacing parts For corrosion protection and friction reduc tion apply a suitable grease to the following parts Threads of the bolts 13 32 threads and bearing face of the nuts 14 33 thread and sealing surface of the threaded bushing 8 threads of the stem connector nut 9 and lock nut 19 threads and screw head faces of the pressure balancing assembly 6 2 Replacing parts of standard version version with extension bonnet The instructions below describe the proce dure for the standard version with bonnet 2 The same procedure applies to the ver sion with extension bonnet 21 6 2 1 Removing the actuator The actuator and yoke must be removed to perform maintenance or repair on the valve Pneumatic actuator with fail safe action Actuato
4. Note The plug must be replaced if any slight damage to the seating surface cannot be removed by machining 5 Use a packing tool to pull all the packing parts PTFE V rings washers bushing 16 EB 8072 EN spring upwards out of the packing chamber Carefully clean the packing chamber 6 Check the parts for damage Replace any damaged parts 6 2 2 2 Assembly Note Prior to mounting the plug bonnet and packing renew all gaskets 127 126 17 at the seat 4 and seat retainer 124 For this you need to determine again the re quired thickness of the spacer ring up to NPS 4 or spacer rings NPS 6 or higher 6 2 3 Seat and or seat retainer flow divider St If parts such as the seat or seat retainer have been replaced with new ones due to leakage or wear we recommend replacing the packing at the same time see section 6 2 2 1 The flow divider St is used instead of the seat retainer 124 in versions with flow di vider The procedure to assemble or disas semble the valve is performed in the corre sponding manner 6 2 4 Disassembly 1 Unthread nut 14 2 Carefully lift the bonnet 2 with plug 5 and the plug stem out of the body 1 3 Remove all the parts from inside the valve body and place them in order on a flat surface Gasket 17 Spacer ring s 125 Gasket s 126 Seat retainer 124 or flow divider St Seat 4 Gasket 127 4 Clean spacer ring
5. Table 3 Selecting the spacer ring NOTICE For height compensation only one spacer ring can be used for valves sizes up to NPS 4 For valves in NPS 6 and larger sev eral spacer rings can be used as calculated in Table 3 or from the valve parts list 3 Carefully place the spacer ring 125 onto the gasket 126 between the seat retainer 124 and valve body 1 For valves in NPS 6 and larger place the gasket 126 and spacer ring 125 in alternating sequence until all the gas kets and spacer rings are installed Note The spacer rings must not rest on any part of the seating surface DF 6 of the valve body NPS js A Ideal height tiotal mm m Y to 1 1 2 6 1 A H2actual 0 1 1 3 4 12 1 A H2getval total 0 1 2 20 EB 8072 EN 6 2 5 4 Bonnet gasket 1 Place gasket 17 into the groove of the seat retainer and the body The gasket must not jut out over the seating surface DF 6 of the valve body 1 Fig 16 Gasket 17 on spacer ring 125 Note A slight height difference S exists be tween the bonnet gasket and the sealing sur face of the valve body Fig 17 Detailed view of bonnet gasket 27 Maintenance Replacing parts 6 2 5 5 Plug Note For valves with bellows section the bellows section bonnet and plug are ready assembled in one unit Proc
6. case for valves with actuator version Actuator stem retracts The bottom signal pressure connection of the Type 3277 Actuator is located at the side of the yoke of the bottom diaphragm case an Fig 4 Type 3277 with signal pressure connection at the side for Actuator stem extends EB 8072EN 11 Installation 4 5 Strainer and bypass We recommend installing a strainer up stream of the valve body We also recommend installing a shut off valve both upstream of the strainer and downstream of the valve as well as laying a bypass so that you do not need to shut down the plant for maintenance 4 6 Test connection A test connection at the top flange of a valve version with bellows seal allows the bellows seal to be monitored for leaks Particularly for liquids and vapors we rec ommend installing a suitable leak indicator at the test connection such as a contact pressure gauge an outlet into an open ves sel or an inspection window Fig 5 Test connection above the bellows seal 12 8072 EN 5 Operation e g reversing the fail safe action of the ac tuator etc For details refer to Mounting and Operat ing Instructions EB 8310 EN for Type 3271 and EB 8311 EN for Type 3277 Operation 6 Maintenance Replacing parts The control valve is subject to natural wear especially at the seat plug and packing Dep
7. the least amount of vibrations possible and without any stress 4 1 Mounting position The valve can be mounted in any desired position However vertical installation with the actuator pointing upwards is preferable for valves in NPS 4 and larger to facilitate maintenance For valves with extension bonnet or bellows seal or for actuators weighing more than 50 kg mount a suitable support or suspen sion for the actuator 4 2 Piping design To allow the control valve to work properly the pipeline upstream of the valve must be straight and free of obstructions for a length twice to 10 times of the pipe diameter NPS and the pipeline downstream of the valve for a length ot least 4 to 20 times of the pipe di ameter NPS depending on the process conditions or for process media containing solids Contact SAMSON if this length cannot be met during installation Clean out the pipeline thoroughly prior to in stalling the valve Installation 4 3 Valve insulation Control valves with bellows seal or extension bonnet can only be insulated up to the bon net flange of the valve body when the me dium temperature is below or above 220 C Valves used in applications according to NACE MR 0175 NACE MR 0103 or ISO 15156 must not be insulated 4 4 Signal pressure line Connect the signal pressure line to the bot tom diaphragm case for valves with actuator version Actuator stem extends and to the top diaphragm
8. value to be adjusted while the upper bench range value 1 bar corresponds to the upper bench range value The fail safe action Actuator stem extends FA or Ac tuator stem retracts FE is indicated on the Type 3271 and Type 3277 Actuator by the corresponding symbol 5 For actuators with Actuator stem ex tends apply a signal pressure to the bottom diaphragm chamber which cor responds to the lower bench range value e g 0 2 bar For actuators with Actuator stem re tracts apply a signal pressure to the top diaphragm chamber which corre sponds to the upper bench range value e g 1 bar 6 Thread the stem connector nut 9 by hand until it touches the actuator stem A7 Then turn it another turn and secure this position with the lock nut 10 7 Position the stem connector clamps A27 and fasten Align the travel indi cator scale 83 with the tip of the stem connector EB8072EN 7 Assembling valve and actuator Note on disassembling the actuator Before disassembling an actuator with fail safe action Actuator stem extends and particularly an actuator with preloaded springs apply a pressure to the signal pres sure connection S that slightly exceeds the lower bench range value see nameplate of the actuator to allow the nut A8 to be undone 3 2 Pretensioning springs in actuator version Actuator stem extends To achieve a greater positioning force the springs in actuators with Actu
9. when the signal pressure rises opposing the force of the springs Actuator stem retracts When the pressure is reduced or the supply air fails the actuator springs move the actu ator stem upwards and open the valve The valve closes when the signal pressure rises opposing the force of the springs Design and principle of operation 2 1 Transportation and storage These instructions provide information on the correct handling of valves during transporta tion storage and hoisting NOTICE Do not lift the control valve assembly using the actuator s lifting ring This lifting ring is only intended for lifting the actuator without the valve Attach the lifting support to the valve body Leave control valves in their transport container or on the pallet as long as pos sible Store valves in a dry place until installa tion The transport and storage temperature for valves must be kept between 20 and 65 C Protect the valves especially the dia phragm stem against knocks and vibra tions etc Any damage to corrosion protection paintwork oiled surfaces etc must be remedied immediately Always wear protective gloves clothing and eyewear when performing any work on the valve Never leave the load suspended in mid air Prior to lifting any valve always check the weight of the load in SAMSON s technical documentation Always use lifting equipment according to the actual load of the lifting goods EB8
10. 072EN 5 Design and principle of operation Carefully lift the load off the ground and check that all lifting supports are securely attached and that the control valve is well balanced Lift the control valve in the position in which it will be installed Lift the control valve at its center to pre vent it from tipping to one side For valves weighing over 25 kg make sure that mounting rings for chain hoists are fitted at an adequate height above the installation site Often it is recom mendable to use sliding rails or swivel arms with a hoist Remove the protective caps from the valve inlet and outlet shortly before in stalling the valve in the pipeline Make sure that the control valve is prop erly installed before removing the lifting supports Refer to the diagram showing how a valve can be lifted at the installation site Attach the slings around the valve body To keep the valve in the upright position and to prevent it from tipping attach a sling to the lifting ring of the actuator Fig 2 Safe lifting of the valve 6 8072 EN 3 Assembling valve and actuator Instead of a simple pneumatic actuator the valve can be operated by a pneumatic actu ator with additional handwheel or by an electric actuator The standard pneumatic actuator can be re placed with a larger or smaller
11. 127 Fig 7 Gasket 127 for seat bridge Fig 9 Installing the seat retainer 124 8072EN 17 Maintenance Replacing parts Align the seat retainer so that one of its openings faces the valve outlet 6 2 5 1 Height H1 To determine the height H1 between the in side seating surface DF 3 of the seat re tainer 124 and the outside seating surface DF 6 of the valve body 1 proceed as fol lows Write the values 1 to 3 down in Table 1 in the appropriate columns Calculate the mean value of H1 from these values and note it in the Hlacual column 3 Calculate the difference AH between the target height H 1iarger and the actual height H1 actual and note it in the appro priate column Fig 10 Determining the height H1 Fig 11 Detailed view of height H1 1 Measure height H1 at three locations distributed evenly around the circumfer ence of the valve body s neck Table 1 Determining the height H1 NPS Altarget Hlyguei Hlyalye2 value HI actual AH H target HI actual mm mm mm mm mm mm Yr to 1 4 8 5 1 2 5 1 3 5 1 4 5 1 9 9 8 10 1 18 EB 8072 EN 6 2 5 2 Gasket height H2 1 Prior to assembly measure the height H2actual of the new gasket 126 up to NP
12. 8 Plug for valve in NPS 2 and higher Note Prior to mounting the bellows section with plug renew all gaskets and the spacer rings Refer to section 6 2 5 8072EN 27 Maintenance Replacing parts 6 3 3 4 Bellows section with plug 1 Place the plug into the seat 4 making sure that the large port of the plug faces the valve outlet 2 Place the bellows section on the body Make sure the gasket 17 does not move 3 Fasten the bellows bonnet with nuts 33 4 Unthread lock nut 10 from the plug stem and the threaded bushing 8 from the bellows bonnet 42 39 2x 33 6 3 3 5 Additional assembly 22 instructions Proceed to assemble nuts 14 packing 15 and threaded bushing 8 as described from section 6 2 5 6 onwards 29 Fig 29 Type 3291 with bellows seal 28 EB 8072 EN 6 4 Balanced valves The bonnet and plug of balanced valves are assembled and disassembled in the same manner as that of the valve with standard V port plug Refer to section 6 2 2 1 Any work on the plug itself must be performed by SAMSON only Otherwise the required leakage class cannot be guar anteed Appendix 7 Appendix 7 1 Tools The following tools and measuring equip ment are required for servicing the control valve Open end wrench Socket wrench Torque wrench Packing tool Caliper Dial indicator gauge with magnetic base Dept
13. S 4 or gaskets 126 NPS 6 or larger at three locations distributed evenly around the circumference of the valve body s neck H2 126 Fig 12 Determining height H2 of gasket 126 Write down the three values in Table 2 in the appropriate columns Calculate the mean value from these val ues and note it in the H2actual column Insert gasket 126 into the groove of the seat retainer 124 Table 2 Determining the height H2 Maintenance Replacing parts Fig 13 Inserting the gasket 126 Note For valves in NPS or larger gaskets 126 and spacer rings 125 are inserted into the groove of the seat retainer in alter nating sequence 126 Fig 14 Exact position of the gasket 126 Number of gaskets one gasket up to NPS 4 two gaskets from NPS 6 Li 1 mm H2 H2 H2 mm mm mm value 2 value 3 actual EB 8072EN 19 Maintenance Replacing parts 6 2 5 3 Spacer ring 1 Calculate the total height total of the re quired spacer rings 125 using the pre viously measured values and write down the result in Table 3 in the appropriate column Select the spacer rings for the required total height total using the List of Acces sories 1120 3074 Fig 15 Spacer ring 125 on gasket 126 125 7 124
14. Series 290 Type 3291 1 and Type 3291 7 Pneumatic Control Valves Fig 1 Type 3291 1 Control Valve Mounting and Operating Instructions EB 8072 EN Edition November 2011 Contents Contents 1 2 2 1 3 3 1 3 2 3 3 3 3 1 3 3 2 4 1 4 2 4 3 4 4 4 5 4 6 6 1 6 1 1 6 1 2 6 1 3 6 2 6 2 1 6 2 2 6 2 2 1 6 2 2 2 6 2 3 6 2 4 6 2 5 6 2 5 1 6 2 5 2 6 2 5 3 7 18 8072 EN General safety 5 4 Design and principle 5 Transportation and 5 Assembling valve and 7 Assembly and 7 Pretensioning springs in actuator version Actuator stem extends 8 Valve and actuator with different rated travels 8 Actuator version Actuator stem 8 Actuator version Actuator stem 10 Installation RR ER Ry EFE S 11 Mounting position 11 Piping design 11 11 Signal 11 Strainer 12 Test connection 12 Operdhon a E x eae dcx 13 Maintenance Replacing 13 13 Seal
15. actuator for all valve sizes If the travel range of the actuator is larger than that of the valve the actuator springs are preloaded by the manufacturer so that the travels match Each valve is supplied with parts required for a standard valve If another actuator is to be mounted on the valve the mounting parts must be ordered together with the actuator Refer to the documents 1600 0501 to 1600 0550 to find out which parts are re quired The originally used parts must then be replaced by the additionally ordered parts 3 1 Assembly and adjustment If the valve and actuator have not been pre assembled by the manufacturer or if the actuator of a valve is to be replaced by an actuator of another type or another size proceed as described below 1 Undo the lock nut 10 and stem connec tor nut 9 Firmly press the plug 5 together with the plug stem into the seat 4 Thread the stem connector nut 9 and lock nut 10 downwards 2 Remove stem connector clamps 27 and unscrew nut A8 from the actuator Assembling valve and actuator Slide the nut over the plug stem mount dust sleeve if necessary 3 Place actuator onto the yoke 3 and se cure with the nut A8 4 Read bench range or bench range with preloaded springs and fail safe action from the actuator s nameplate e g 0 2 to 1 bar and Actuator stem extends The lower value of the bench range 0 2 bar corresponds to the lower bench range
16. ator stem ex tends can be preloaded with up to 25 of their travel or bench range If the springs are preloaded with for exam ple 0 1 bar for a bench range of 0 2 to 1 bar the bench range is shifted by 0 1 bar to result in a bench range of 0 3 to 1 1 bar 0 1 bar corresponds to a preload of 12 5 When adjusting the valve the lower bench range is to be set to 0 3 bar Make sure the new bench range of 0 3 to 1 1 bar is indi cated on the nameplate as the bench range with preloaded springs 3 3 Valve and actuator with different rated travels 3 3 1 Actuator version Actuator stem extends NOTICE Valves that have a travel smaller than the rated travel of the actuator always need to use preloaded springs Example Valve with 30 mm rated travel and 1400 cm actuator with 60 mm rated travel 0 4 to 2 bar bench range 1 Set the signal pressure to 1 6 bar This pressure is slightly higher than the signal pressure of 1 2 bar required for tensioning the springs 1 2 to 2 bar range which corresponds to half the ac tuator travel 30 mm 2 Thread stem connector nut 9 until it touches the actuator stem A7 Legend for Fig 3 14 Nut Actuator Valve body 15 Packing Al Top diaphragm case 2 Bonnet 17 Gasket A2 Bottom diaphragm 3 Yoke 83 Travel indicator scale case 4 Seat 92 Nut 4 Diaphragm 5 Plug 124 Seat retainer 7 Diaphragm stem 7 Guide bushing 125 Spacer ring A8 Nut 8 Threaded bushing 126 Gaske
17. eed as de scribed in section 6 3 1 Apply a suitable lubricant to the plug stem 5 around the area where the PTFE packing will be located 2 Carefully insert the plug into the seat 4 and align it so that the large port faces the valve outlet port that will be first to release the flow rate when the valve starts to stroke NOTICE Do not apply any lubricant when a high temperature HT packing is used Fig 18 Inserting the plug 5 EB 8072EN 21 Maintenance Replacing parts 6 2 5 6 Bonnet 1 Carefully place bonnet over the plug stem onto the bonnet gasket 17 Apply a suitable lubricant to the threads of the stud bolts 13 and nuts 14 as well as to bearing face of the nuts Table 4 Tightening torques for nuts 14 Fig 19 Mounting the bonnet 2 Nes Tightening torque Nm Class 300 Class 600 Class 900 Vato 1 60 60 1 68 68 2 112 112 3 118 118 On request 4 100 100 6 296 296 8 On req 1040 Repeat this tightening procedure using 100 of the specified tightening torque Finally retighten all the nuts in clockwise order with the full tightening torque one last time Make sure the nuts are completely tight ened and cannot be turned any further 3 Tighten the nuts in a criss cross pattern applying 50 of the specified tighten ing torque Note The gasket 126 under the
18. ending on the application the valve needs to be checked regularly to prevent against possible failures 6 1 General If leakage occurs this could be caused by a damaged packing or a defective bellows seal If the valve does not seal properly the tight shut off may be impeded by dirt or other im purities caught between the seat and plug or by damaged seating surfaces Remove the parts clean them thoroughly and replace them with new ones if neces sary CAUTION Before servicing or disassembling the control valve depressurize the concerned section of the plant and drain it if necessary depend ing on the medium used Wait until the valve cools down to ambient temperature if the process medium is hot As valves are not free of cavities beware that there might still be residual medium in the valve This applies in particular for valve versions with extension bonnet and bellows seal We recommend removing the valve from the pipeline EB 8072EN 13 Maintenance Replacing parts NOTICE On performing any work on the valve first shut off the signal pressure disconnect the signal pressure line and remove the actua tor Note When mounting the valve bonnet the large port of the V port plug and one of the openings of the seat retainer must face the valve outlet 6 1 1 Sealing surfaces Make sure all sealing surfaces of the valve DF 1 to DF 10 are clean Check that newly inserted gas
19. h gauge with bridge 7 2 Tightening torques 1120 1400 Table 5 Tightening torques for nuts 14 according to document 1120 1400 Nes Tightening torque Nm Class 300 Class 600 Class 900 1 60 1 68 2 112 3 118 On request 4 100 6 296 8 On req 1040 EB8072EN 29 Description of nameplates 7 3 Spacer rings 1120 3074 Spacer rings are available for each valve size in sets containing seven rings ranging from 0 7 to 1 25 mm optionally made of 1 4404 A 240 316L or 1 4301 A 240 304 Table 6 Order numbers for spacer rings Sets as listed in accessories list 1120 3074 NPS 1 4404 1 4301 A 240 316L A 240 304 Va to 1 1120 3074 1120 3095 1 1120 3075 1120 3096 2 1120 3076 1120 3097 3 1120 3077 1120 3098 4 1120 3078 1120 3099 6 1120 3079 1120 3100 8 1120 3136 1120 3137 30 EB 8072 EN 8 _ Description of nameplates 8 1 Type 3291 Valve SAMSON 2 5 6 7 8 1 2 13 14 15 3 Fig 30 Valve nameplates 1 CE marking or Art 3 Abs 3 see article 3 8 3 of PED where appli cable 2 Identification no of notified body fluid group and category where applicable Type designation Modification index of valve Material Year of manvfacture Valve size NPS Permissible excess pressure at room tem perature PN bar or Class psi ON AN BR C 9 Order number with modificat
20. ing assembly start up and main tenance must be observed The control valves fulfill the requirements of the European Pressure Equip ment Directive 97 23 EC Valves with a CE marking have a declaration of conformity that includes information about the applied conformity assess ment procedure For appropriate operation make sure that the control valve is only used in areas where the operating pressure and temperatures do not exceed the op erating values which are based on the valve sizing data submitted in the or der The valve must be given adequate time to warm up or cool down ac cording to the prevailing ambient and operating conditions The manufac turer 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 me dium operating pressure signal pressure or by moving parts are to be pre vented by means of the appropriate measures Proper shipping and appropriate storage of the control valve are assumed CAUTION For installation and maintenance work on the valve make sure the relevant section of the pipeline is depressurized and depending on the process me dium 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
21. ing surfaces 2 els 14 Measuring 15 Rude Ete rege dendi era 15 Replacing parts of standard version version with extension bonnet 15 Removing the 15 Packingandplug s stagas en 16 Disassembly 16 Assembly 222222 e n 16 Seat and or seat retainer flow divider 81 16 UE UR e ee ee ed 16 Assembly 17 Height His soeg 2 obe SE ent enacted Fe genet 18 Gasket 2 19 Spacerring 22e 20 6 2 5 4 6 2 5 5 6 2 5 6 6 2 5 7 6 2 5 8 6 3 6 3 1 6 3 2 6 3 2 1 6 3 2 2 6 3 2 3 6 3 2 4 6 3 3 6 3 3 1 6 3 3 2 6 3 3 3 6 3 3 4 6 3 3 5 6 4 7 1 7 2 7 3 8 1 8 2 8 3 10 Contents B nnet gasket ns a seen ue Eq 21 d PC 21 Bonnet cas ox wa ba OE H 345 oe dd E Rp VERSA 22 POCKING lt os 23 Threaded bushing m 3 8443 246 23 Valves with bellows section 22s 24 Removing 24 Disassembly 2 ee 24 Bellows seal 24 Pluges A ded EEUE s uw 24 Bellows bonnet 25 Plug stem with 25 Assembly NN EET ETT a TT 26 Bellows sachen
22. ion index 10 Position of item in order 11 Flow coefficient Kys or 12 Characteristic equal percentage Lin linear DIN A Z quick opening ANSI O C 13 Sealing ME metal PT soft sealing with PTFE 14 Pressure balanced DIN D or ANSI B 15 Flow divider 8 2 Type 3277 Actuator The nameplates of the Type 3277 and Type 3271 Pneumatic Actuators is made of plastic and stuck to the diaphragm case The labels contain all the details required for identification SAMSON 3277 ea 1 5 27 bar T 22 39 psi m WD 1234567 a bar Serialno 1234 Gemary Pmax bar 90psi Fig 31 Actuator nameplate 8 3 Type 3271 Actuator SAMSON 3771 NBR E St 22 39psi aa WD 1234567 a bar Serialno 1234 sedo Gemary 6bar 9Opsi Fig 32 Actuator nameplate Manufacturer and type designation Configuration ID Var ID as bar code and written form Serial number Country of production Effective diaphragm area in cm Diaphragm material NBR or EPDM Symbol for fail safe action Actuator stem extends in the example Description of nameplates or Actuator stem retracts Bench range in bar and psi Symbol for rated travel in mm Bench range with preloaded springs Thread for pneumatic connection G NPT or Rc Permissible supply air pressure pmax in bar and psi EB 8072EN 31 Customer inquiries 9 Customer inqui
23. kets are un damaged free of burrs from punching and properly seated If new spacer rings are required they must also be free of burrs and flat Note Only one spacer ring 125 and one gasket 126 may be used for valves up to NPS 4 for height compensation Several spacer rings 125 and gaskets 126 can be used for valves in NPS 6 or larger The rings and gaskets must be in stalled in alternating sequence NOTICE To prevent damage to the internal parts sealing surfaces and threads proceed care fully while assembling or disassembling the valve During all work performed on the valve strictly observe the specified tightening torques in Table 5 according to document 1120 1400 DF 10 DF 8 und 9 DF 5 DF 4 L m DF3 DF 7 ZAR LE RL DF 2 DF 1 Fig 6 Sealing surfaces DF 1 to DF 14 EB 8072 EN 6 1 2 Measuring equipment To measure the heights only use measuring equipment that remains aligned at an angle to the dimension to be measured Appropri ate measuring equipment includes for ex ample a dial indicator gauge with magnetic base vernier depth gauge or depth gauge with bridge To measure the gaskets a caliper may also be used provided the wider jaws and not the blades are used for measuring Make absolutely sure that no pressure is exerted on the gasket to prevent the gasket from be coming deformed 6 1 3 Lubricant
24. llows section 22 The second gasket 39 at the bottom is now accessible 6 3 2 3 Bellows bonnet 1 Unthread stem connector nut 9 and lock nut 10 Unscrew threaded bushing 8 Remove nuts 33 for bellows bonnet 101 Hold the plug stem stationary and lift off the bellows bonnet If necessary use a suitable tool to re move the packing 4 Fig 25 Assembly consisting of plug stem and bellows 37 and bellows bonnet 101 EB 8072EN 25 Maintenance Replacing parts 6 3 3 Assembly Gaskets and sealing surfaces Check gasket 39 and the sealing surface of the bellows section 22 bellows bonnet 101 and the plug stem bellows assembly 37 for damage Renew them if necessary 6 3 3 1 Bellows section 1 Insert the first gasket 39 bottom into the bellows section 22 making sure it rests properly on the seating surface DF 11 2 Carefully insert the plug stem bellows assembly 37 from the top into the bel lows section making sure the seating Fig 26 Mounting the plug stem with bellows 37 26 8072 EN surface DF 12 of the bellows lies flat on the gasket 39 Place the second gasket 39 top flat on the seating surface DF 13 of the plug stem bellows assembly 37 Apply a suitable lubricant to the area what will later become the packing area 6 3 3 2 Bel
25. lows bonnet 1 Carefully guide the bellows bonnet 101 over the bellows plug stem assembly Place the second gasket 39 DF 14 flat on the seating surface Apply a suitable lubricant to the thread and sealing face of the threaded bush ing 8 Screw it into the bonnet and hand tighten the bellows bonnet so that the plug stem with bellows 37 can still turn Thread lock nut 10 onto the plug stem 37 to protect the bellows against ex panding too far Fasten the bellows bonnet 101 onto the bellows section 22 using the nuts 33 and bolts 32 Tighten nuts 33 only slightly to allow the plug stem bellows assembly to still turn easily in ready as sembled state 6 3 3 3 Plug for version with Use required tightening torques according to bellows seal document 1120 1400 Valves up to NPS 112 1 Thread nut 6 by hand as far as it will go onto the plug stem 37 Place plug 29 onto the hexagon end of the plug stem Place an open end wrench on the flat tened area of the plug stem to hold it stationary Screw nut onto plug Fig 27 Plug for valves up to NPS 1 Maintenance Replacing parts Valves in NPS 2 and higher 1 Screw plug 29 with associated washer or lock plate 31 onto the plug stem 2 Tighten screw 34 to fasten the plug over the clamping washer 28 and flange 27 3 Bend any edges of the lock plate 31 over the heads of the screws Fig 2
26. or blocked to prevent any hazards that could be caused by moving parts Special care is needed for pneumatic control valves when the actuator springs are pretensioned These actuators are labeled correspondingly and can also be identified by three long bolts protruding from the bottom of the actuator Prior to starting any work on the control valve relieve the compres sion from the pretensioned springs 4 EB 8072 EN 2 Design and principle of operation The Type 3291 1 and Type 3291 7 Pneu matic Control Valves consist of the Type 3291 Globe Valve with clamped in seat combined with either a Type 3271 or a Type 3277 Pneumatic Actuator with integral positioner and or limit switch attachment The process medium flows through the valve in the direction indicated by the arrow The position of the plug determines the flow rate across the seat Its position is determined by changes in the signal pressure acting on the actuator diaphragm The plug stem is connected to the diaphragm stem by the stem connector The stems are sealed by a spring loaded PTFE V ring packing or an adjustable high temperature HT packing Fail safe position Depending on how the springs are arranged in the actuator the control valve assumes one of two different fail safe positions Actuator stem extends When the pressure is reduced or the supply air fails the actuator springs move the actu ator stem downwards and close the valve The valve opens
27. r stem extends 1 Remove clamp A27 2 Apply a pressure to the bottom signal pressure connection that slightly exceeds the lower bench range value see name plate As a result the actuator stem lifts off the plug stem making the actuator stem line free of tension 3 Undo nut 92 and lift the actuator to gether with yoke off the valve Pneumatic actuator with fail safe action Actuator stem retracts Proceed in the same manner as described for actuator with fail safe action Actuator EB 8072EN 15 Maintenance Replacing parts stem extends However pressure does not need to be applied to the signal pressure connection 6 2 2 Packing and plug If the process medium leaks from the threaded bushing 8 this means the pack ing is leaking A damaged or blocked PTFE packing must be replaced If a high temperature HT packing is in stalled the threaded bushing 8 can be slightly retightened to stop the packing from leaking As soon as the valve leaks constantly check the plug and seat Clean machine or re place the plug and seat as required 6 2 2 1 Disassembly 1 Remove threaded bushing 8 and nuts 14 from the bonnet 2 2 Carefully lift the bonnet 2 with plug 5 and the plug stem off the body 1 3 Unscrew stem connector nut 9 and lock nut 10 from the plug stem 4 Pull the plug together with plug stem from underneath out of the bonnet Carefully check the sealing surface
28. ries 10 Dimensions and weights If you encounter any problems please sub Refer to the associated Data Sheet for di mit the following details mensions and weights of the valve versions Order number and item number on or Type 3291 ANSI version der gt Data Sheet T 8072 1 EN Type product number nominal size and version of the valve Pressure and temperature of the process medium Flow rate Bench range of the actuator e g 0 2 to 1 bar Has a strainer been installed Installation drawing 32 8072 EN EB 8072EN 33 34 88072 8072 35 SAMSON AG MESS UND REGELTECHNIK Weism llerstra e 3 60314 Frankfurt am Main Germany Phone 49 69 4009 0 Fax 069 4009 1507 Internet http www samson de EB 8072 EN 2014 07
29. s seat retainer and seat Check these parts for damage Machine or replace the seat retainer and seat if necessary Note First determine the required thickness of the spacer ring s Only after this it is possible to know whether they can be reused The gaskets must be replaced at any rate 6 2 5 Assembly Note When assembling internal parts read the instructions concerning the sealing sur face section 6 1 1 and measuring equip ment section 6 1 2 1 Insert new gasket 127 of the seat bridge 2 Carefully place the seat 4 through the valve body s neck onto the gasket 127 Maintenance Replacing parts of the seat bridge Make absolutely sure that the seating surface and mating sur face do not get damaged The seat has a clear amount of clear ance within the seat bridge and is aligned centrally to the valve body s neck Fig 8 Installing the seat 4 3 Insert the seat retainer 124 into the body as centrally as possible Other wise it may get stuck in the area of the valve body s neck If it does get stuck the seat retainer can be aligned centrally using a soft rubber hammer until it is fur ther inserted into the body Carefully insert the seat retainer into the seat aligning the seat centrally To check whether the seat retainer sits cor rectly on the seating surface slightly lift and lower the seat retainer
30. spacer ring yields meaning tightening the nuts once is not sufficient Fig 20 Tightening the nuts 14 Repeatedly retighten the nuts with 50 of the specified tightening torque until the nuts cannot be turned any further Repeat this tightening procedure using 75 of the specified tightening torque 22 8072 EN 6 2 5 7 Packing 1 Apply a suitable lubricant to the individ ual parts of the PTFE packing 2 Carefully slide all the packing parts 15 over the plug stem into the packing chamber in the bonnet Make absolutely sure that they are inserted in the correct order Maintenance Replacing parts Note The number of spacer bushings to be used depends on the valve size NPS which determines the size of the packing chamber 6 2 5 8 Threaded bushing 1 Apply a suitable lubricant to the thread and sealing surface of the threaded bushing 8 2 Slide threaded bushing over the plug stem and screw it into the bonnet Note When a high temperature HT pack ing is used only tighten the threaded bush ing a little If the medium leaks out at the threaded bushing you can retighten the threaded bushing slightly 3 When a PTFE packing is installed tighten the threaded bushing Mount the yoke and actuator as described in section 3 1 Fig 21 Packing 15 and threaded bushing 8
31. t Al Venting 9 Stem connector nut 127 Gasket A27 Stem connector clamp 10 Lock nut S Signal pressure 13 Stud bolt connection 8 EB8072EN Assembling valve and actuator 125 126 Fig 3 Type 3291 1 Control Valve EB8072EN 9 Assembling valve and actuator 3 Secure the position with lock nut 10 and attach stem connector as described in section 3 1 4 Enter the 1 6 to 2 4 bar bench range valid for the mounted valve on the nameplate of the actuator 3 3 2 Actuator version Actuator stem retracts Note The springs in the actuator version Actuator stem retracts cannot be pre loaded CAUTION Actuators which have been preloaded by the manufacturer with out an attached valve are marked by a label In addition you will notice three ex tended bolts on the bottom dia phragm case They enable you to evenly relieve the compressed springs when disassembling the ac tuator If a valve is to be attached to a larger actua tor rated travel of actuator larger than the rated travel of the valve only the first half of the bench range of the actuator can be used Example Valve with 30 mm rated travel and 1400 cm actuator with 60 mm rated travel 0 2 to 1 bar bench range A useable bench range of 0 2 to 0 6 bar is available for the half valve range 10 EB 8072 EN 4 Installation NOTICE The valve must be installed with
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