type 3510-1 and type 3510-7 pneumatic control valvessamsoncontrols.net/manuals/3510mn.pdf · 2016....
TRANSCRIPT
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Mounting andOperating Instructions
EB 8091 EN Edition July 2002Edition July 2002
Type 3510-1 and Type 3510-7Pneumatic Control Valves
Type 3510-7with120 cm²actuatorandintegratedpositioner
Type 3510-1with60 cm²actuator
Type 3510-1with120 cm²actuator
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Definition 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
NOTICEProperty damage message or mal-function
Note:Additional information
Tip:Recommended action
2 EB 8091 EN
1 Important safety instructions ..........................................................................32 Design and principle of operation ..................................................................43 Assembling and adjusting the valve and actuator ...........................................63.1 Signalpressureconnection.............................................................................63.2 Assemblyandadjustment...............................................................................84 Installation ....................................................................................................84.1 Mountingposition..........................................................................................85 Operation – Reversing the operating direction ................................................96 Troubleshooting.............................................................................................96.1 Replacingthepacking....................................................................................96.2 Replacingtheseatandplug..........................................................................127 Customer inquiries ......................................................................................14
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EB 8091 EN 3
Important safety instructions
1 Important safety instructions − Thevalveistobemounted,starteduporoperatedonlybytrainedandexperiencedper-sonnelfamiliarwiththeproduct.Accordingtothesemountingandoperatinginstructions,trainedpersonnelreferstoindi-vidualswhoareabletojudgetheworktheyareassignedtoandrecognizepossibledan-gersduetotheirspecializedtraining,theirknowledgeandexperienceaswellastheirknowledgeoftheapplicablestandards.
− Anyhazardsthatcouldbecausedinthevalvebytheprocessmedium,theoperatingpressure,thesignalpressureorbymovingpartsaretobepreventedbytakingappropri-ateprecautions.Toensureappropriateuse,onlyusethevalveinapplicationswheretheoperatingpres-sureandtemperaturesdonotexceedthespecificationsusedforsizingthevalveattheor-deringstage.
− Propershippingandstorageareassumed.
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 speci-fied in section 6.3 of EN 60079-14: 2011 (VDE 0165 Part 1).
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4 EB 8091 EN
Design and principle of operation
2 Design and principle of oper-ation
ThepneumaticcontrolvalveconsistsofaType 3510Micro-flowValve(withglobeorangle-stylebody)andaType 3271-5Pneu-maticActuator(Type 3510-1ControlValve)oraType 3277-5PneumaticActuator(Type 3510-7ControlValve).Themodulardesignallowstheactuatorstobeexchangedandaninsulatingsectionormetalbellowstobefittedtothestandardvalveversion.Themediumflowsthroughthevalveinthedirectionindicatedbythearrow.Theposi-
tionoftheplug(3)determinestheflowthroughthevalveseat(2).Theplugismovedbyachangeinthesignalpressureactingonthediaphragmoftheac-tuator.Theplugstem(6)isconnectedtotheactua-torstem(8.1)bythestemconnector(7)andissealedbyanadjustablePTFEpacking.
Fail-safe action:Dependingonhowthecompressionsprings (8.3)arearrangedintheactuator,thevalvehastwodifferentfail-safepositions:
Actuatorstemretracts
Actuatorstemextends
Type 3271-5Actuator(120 cm²)
Type 3271-55Actuator(60 cm²)
Actuatorstemretracts
Actuatorstemextends
Fig. 1: Type 3271-5 Actuator
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EB 8091 EN 5
Design and principle of operation
Actuator stem extends:Whenthesignalpressureisreducedortheairsupplyfails,thespringsmovetheactua-torstemdownwardsandclosethevalve.Thevalveopenswhenthesignalpressureisin-creasedenoughtoovercometheforceexert-edbythesprings.
Actuator stem retracts:Whenthesignalpressureisreducedortheairsupplyfails,thespringsmovetheactua-torstemupwardsandopenthevalve.Thevalvecloseswhenthesignalpressureisin-creasedenoughtoovercometheforceexert-edbythesprings.
1 Body1.1 Screw2 Seattrim2.1 Seat2.2 Plug2.3 Seal2.4 Anti-rotationfixturewith
trimconsecutivenumber3 Nuts4 Packingrings4.1 Packingwasher5 Valvebonnet5.1 Threadedbushing5.2 Slottednut6 Yoke6.1 Travelindicatorscale7 Stemconnector7.1 Stemconnectornut7.2 Stemconnectorsleeve7.3 Locknut8 Actuator8.1 Actuatorstem8.2 Slottednut8.3 Spring8.4 Diaphragm14 Connectingorswitchover
plate14.1 Signalpressureroutingfor
actuatorstemextends14.2 Signalpressureroutingfor
actuatorstemretracts
8.4
8.3
8
8.1
8.2
7.3
7.1
7.25.1
5.2
5
7
1414.1
14.2
6
6.1
3
4.141.12.42.3 22.22.11
Fig. 2: Micro-valve with Type 3277-7 Actuator
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6 EB 8091 EN
Assembling and adjusting the valve and actuator
Mounting accessories − Direct attachment:positionerscanbemounteddirectlytotheadditionalyokeoftheType 3277Actuator.
− Interface according to IEC 60534-6 (NAMUR): amountingkit(1400-9031)allowstheattachmentofpositioners,limitswitches,solenoidvalvesandothervalveaccessories.Werec-ommendusinganin-sulatingsectionorbel-lowssealforflangedvalvestoprovidemorespacetomountvalveaccessories.
3 Assembling and adjusting the valve and actuator
Thedifferentsignalpressureconnectionoftheactuatorsmustbeobservedonassemblyifthevalveandactuatorhavenotbeenas-sembledbythemanufacturer.
3.1 Signal pressure connectionType 3510-1 Control ValvewithType 3271-5Actuator
Î Connectthesignalpressurelineforvalveswithactuatorwith"actuatorstemextends"fail-safeactiontotheconnec-tiononthebottomdiaphragmcase,andforvalveswithactuatorwith"actuatorstemretracts"fail-safeactiontothecon-nectiononthetopdiaphragmcase.
Type 3510-7 Control ValvewithType 3277-5ActuatorIftheactuatorisoperatedwithoutadirectlyattachedpositioner,aconnecting plate(ac-cessories)isrequired.Inthiscase,thesignalpressureisrouteddirectlyoverthesignalpressureconnectionoftheconnectingplatetotheactuatordiaphragmchamber.
Î Turntheconnectingplatetoalignthecorrectsymbolforthefail-safeaction("actuatorstemextends"or"actuatorstemretracts")withthemarking.
Î Makeabsolutelysurethatthegasketfortheconnectingplateiscorrectlyinserted.
Î TheconnectingplatehasthreadedholeswithNPTandGthreads.Sealthecon-nectionthatisnotusedwiththerubbersealandsquareplug.
Actuator with directly attached positioner:Thesignalpressureistransmittedtothedia-phragmchamberthroughtheholesontheleftorrightsideoftheyokeandoveraswi-tchover plate(accessories).Thefail-safeac-tionoftheactuator("actuatorstemextends"or"actuatorstemretracts")determineshowtheswitchoverplatemustbealignedwiththemarking.
Î Turntheswitchoverplatetoalignthecor-rectsymbolforthefail-safeactionwiththemarking.Theattachmenteitherontheleftorrightsideoftheactuatorisdeterminedbytherequiredoperatingdirectionoftheposi-tioner(>>)or().
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EB 8091 EN 7
Assembling and adjusting the valve and actuator
Accessories:Switchoverplatesandconnectingplatesarelistedasaccessories.Actuatorswithdeviceindex.01(e.g.3277-531xxx20.01)(old=.00)areequippedwithnewconnectingplates.Oldandnewplatesarenotinterchangeable.
Switchover plate
New Order no. 1400-6822
Old Orderno.1400-6819
Switchover plate
New Order no. 1400-6823
OldGthread Orderno.1400-6820OldNPTthread Orderno.1400-6821
NOTICEA 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 − Fail-safeaction"actuatorstemretracts":seetablebelow
Signal pressure range Adjusted to
Max. perm. pressure
0.2to1 0.4to0.8 2.5
0.4to2.0 0.8to1.6 3.3
1.4to2.3 1.7to2.1 3.8
2.1to3.3 2.4to3.0 4.7
Switchover plate Connecting plateSignalpressure
SignalpressureSignalpressure
Symbol
Marking
Actuatorstemextends ActuatorstemretractsAttach-ment
Left RightAttach-ment
Left RightActuatorstem
retracts extends
Fig. 3: Signal pressure connections
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8 EB 8091 EN
Installation
− Fail-safeaction"actuatorstemextends":4 bar
3.2 Assembly and adjustmentForactuatorswithaswitchoverplateforat-tachmentofapositioner,asuitableadapterneedstobeconnectedtotheholeattheside.Alternatively,theconnectingplate(Fig. 3,right)canbeused.1. Looselythreadthelocknut(7.3)and
stemconnectornut(7.1)upwardontotheplugstem(Fig. 2).
2. Slideslottednut(8.2)overthestemcon-nectornutandlocknut.
3. Placeactuatoronvalveyoke(7)andfas-tentightusingslottednut(8.2).Foractuatorswith"actuatorstemex-tends",applyapprox.50 %ofthesignalpressurerange(seenameplate)totheactuatorusingapressureregulatortore-tractactuatorstemfarenoughtoscrewtogetherthestemconnectornut(7.1)andstemconnectorsleeve(7.2).
4. Screwtogetherstemconnectorsleeve(7.2)andstemconnectornut(7.1)astightlyaspossible.
5. Applylowersignalpressurerangevaluetothesignalpressureconnection.Forasignalpressurerange(benchrange)forexample,0.4to0.8 barandanactuatorwithfail-safeaction"actua-torstemextends",thelowersignalpres-surerangevalueis0.4 bar;for"actuatorstemretracts"itis0.8 bar.
6. Turnthestemconnector(7)onactuatorstemuntiltheplugstemmovesfromthe
closedpositionatthecorrespondinglow-errangevalue.Todoso,changethesignalpressureeachtimeatthepressureregulator,andreturntothelowerrangevalue.
7. Fastenthelocknut(7.3)tosecurethestemconnectorinthisposition.
8. Aligntravelindicatorscale(6.1)withtheblackringonthestemconnector.
4 Installation
4.1 Mounting positionThevalvecanbemountedinanydesiredposition.
The following points must be observed during installation:
Î Installthevalvefreeofstress.Ifneces-sary,supportthepipelinesnearthecon-nections.
Î Flushthepipelinethoroughlybeforein-stallingthevalve.
Î Invalveversionswithbellowssealorin-sulatingsectioninstalledinpipelinesthataretobeinsulated: Donotinsulatethebellowssealbonnetorinsulatingsection(9)aswell.
Test connectionTheversionwithbellowssealcanbefittedwithatestconnection(withG1/8thread)atthebellowssealbonnettoallowthetightnessofthebellowstobemonitored.Werecom-
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EB 8091 EN 9
Operation – Reversing the operating direction
mendinstallingasuitableleakageindicatorwhenexplosivemediaormediathatarehazardoustohealthareused.
5 Operation – Reversing the operating direction
Ifitbecomesnecessarytoreversethefail-safeactionoftheactuatorfrom"actuatorstemextends"to"actuatorstemretracts"orviceversa,refertothemountingandoperat-inginstructionsoftheactuatorfordetails.uEB8310-1forType 3271-5uEB8310-1forType 3277-5
6 TroubleshootingExternalleakagecanindicatethatthepack-ingisdefectiveorthemetalbellowsisdefec-tive(inaversionwithabellowsseal).Ifthevalvedoesnotclosetightly,tightshut-offmaybeimpairedbydirtstuckbetweentheseatandplugorbydamagedfacings.Werecommendremovingtheparts,cleaningthem,and,ifnecessary,replacingthemwithnewones.
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.
− When media that are hazardous to health are used, drain the pipeline and valve and thoroughly rinse them. Avoid medium residues in the valve's dead spaces. Wear pro-tective 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.
Î Removethevalvefromthepipelinebe-foreperformingassemblywork.
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 Replacing the packingIncaseofleakageatthepacking,thepack-ingmustberenewedasfollows:1. Placeawrench(widthacrossflats17)on
stemconnectornut(7.1)andunscrewstemconnectorsleeve(7.2)withasec-ondwrench(widthacrossflats17).Foractuatorswith"actuatorstemex-tends",applyapprox.50 %ofthesignalpressurerange(seenameplate)totheactuatortoretracttheactuatorstem.
http://www.samson.de/pdf_en/e83101en.pdfhttp://www.samson.de/pdf_en/e83101en.pdf
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10 EB 8091 EN
Troubleshooting
2. Unscrewthebottomslottednut(5.2).Re-moveactuator(8)includingyoke(6)fromthevalve,turningtheslottednut(5.2)sothatagroovepointstowardsthetravelindicatorscale(6.1).
3. Removethenuts(3).Takethestemcon-nectorsleeve(7.2)offtheplugstem.
4. Removethescrew(1.1),liftoffthean-ti-rotationfixture(2.4)andunscrewthevalvebonnet(5)fromthevalvebody.
5. Unscrewthethreadedbushing(5.1).Pulltheplugstemalongwiththeplug(2.2)outofthevalvebonnet(5).For versions with bellows seal or insu-lating section: separatethevalvebonnetfromthebellowssealbonnetorinsulat-ingsection(9).Theplugstemextension(10.1,Fig. 5)remainsfixedintheinter-mediatepiece.
6. Removepackingwashers(4.1)andpackingrings(4)fromthepackingchamberusingasuitabletool.Makesurethesealingfacesdonotgetdamaged.Cleanthepackingchamberthoroughly.
Assembly:7. Insertnewpackingrings.Startwitha
whitering,followedbytwoblackringsandanotherwhiteone.Makesurethatthebuttjointsofsuccessiveringsarenotpositionedontopofeachother.
8. Insertpackingwasher(s)(4.1).Tightenthreadedbushing(5.1)manually.
9. Slideplugstemwithplug(2.2)intothevalvebonnetasfarasitwillgo.Tightenthreadedbushing(5.1).
Makesurethataminimumgapof1.3 mmbetweenvalvebonnetandthreadedbushingisobserved.Ifthisisnotthecase,addtherequirednumberofpacking washers (4.1)(min.1,max.3washers).
10.Insertnewseal(2.3)intothebody.Screwthevalvebonnetintothebody.
11.Placetheanti-rotationfixture(2.4)onthevalvebonnet,ensuringthatthescrew(1.1)isinsertedintothelonghole.Fas-tentight.
12.Slidethestemconnectorsleeve(7.2)on-totheplugstemwiththethreadfacingupward.Screwonnuts(3).Locknutsagainsteachother,sothatapprox.1 mmofthethreadisstillvisible.
13.Placetheactuatorwithyokeontothevalvebonnetandsecureitwiththeslot-tednut(5.2).Foractuatorswith"actuatorstemex-tends",applyapprox.50 %ofthesignalpressurerange(seenameplate)totheactuatorusingapressureregulatortore-tractactuatorstemfarenoughtoscrewtogetherthestemconnectornut(7.1)andstemconnectorsleeve(7.2).
14.Screwtogetherstemconnectorsleeve(7.2)andstemconnectornut(7.1)astightlyaspossible.Tightenlocknut(7.3).
15.Checkadjustmentasdescribedinsec-tion 3.2,items5to8.
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EB 8091 EN 11
Troubleshooting
1 Body1.1 Screw2 Seattrim2.1 Seat2.2 Plug2.3 Seal2.4 Anti-rotationfixture3 Nuts4 Packingrings4.1 Packingwasher5 Valvebonnet5.1 Threadedbushing5.2 Slottedroundnut6 Yoke6.1 Travelindicatorscale7 Stemconnector7.1 Stemconnectornut7.2 Stemconnectorsleeve7.3 Locknut8.1 Actuatorstem
7.3
8.1
7.1
7.2
5.1
5.2
5
7
6
6.1
3
4.1
4
2.4
1.1
2.3
2.22
2.1
1
Fig. 4: Replacing the packing
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12 EB 8091 EN
Troubleshooting
6.2 Replacing the seat and plug
Standard version: Î Forassemblyanddisassembly,proceedasdescribedinsection 6.1.Additionally,unscrewtheseat(2.1)usingasocketwrench.
NOTICERisk of damage to the seat trim due to the incorrect exchange of the seat and plug. − On exchanging the seat trim (parts 2.1 to 2.4) with a deviating KVS 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, KVS coefficient and characteristic. − Do not combine seats and plugs belonging to different trims. − Observe the assignment of seat thread and KVS coefficient (see ta-ble below).
Seat thread tableSeatthread M10x1 M16x1KVScoefficient 0.0001to0.4
0.63to1.6
PNmax. 400 100
Version with insulating section or bellows seal:Afterunscrewingthevalvebonnet(5)
Î Inversionswithinsulatingsection,re-movetheinsulatingsection(9)fromthevalvebodytoallowtheplugsteminclud-ingplug(2.2)tobeunscrewedfromtheplugstemextension(10.1).
Î Inversionswithbellowsseals,unscrewthebellowsseal(10)togetherwithplugstemextension(10.1)andplug(2.2)fromthebellowssealbonnet(9)usingabellowswrench.Unscrewtheplugstemalongwithplugoutoftheplugstemextensionandsepa-ratethebellowssealbonnetfromthevalvebody.
Beforereassembling,renewtheseals(9.1and9.2).Inaddition,securebellowssealbonnet(9)orinsulatingsection(9)aswellasthevalvebonnetusingadditionalanti-rota-tionfixtures(11and12).Thetopanti-rotationfixtures(2.4and12)aresecuredbythewasher(15).
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EB 8091 EN 13
Troubleshooting
1.1 Screw2.2 Plug2.4 Anti-rotationfixturewith
trimconsecutivenumber5 Valvebonnet9 Bellowssealbonnet/insulat-
ingsection9.1 Seal9.2 Seal10 Bellowsseal10.1 Plugstemextension(version
withbellowssealorinsulatingsection)
11 Anti-rotationfixture12 Anti-rotationfixture13 Screw15 Washer16 Testconnection(option)
9.1
132.4
1512
11
16
9.2
10
10.1
9
1.1
2.2
Fig. 5: Version with bellows seal
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14 EB 8091 EN
Customer inquiries
7 Customer inquiriesPleasesubmitthefollowingdetails: − Ordernumber − TypedesignationandconfigurationID(Var.-ID)
− Globeoranglevalve − Nominalsizeandpressureofthevalve,
KVScoefficientandconsecutivenumberoftheinstalledtrim
− Pressure,density,viscosityandtempera-tureoftheprocessmedium
− Flowrateinm³/h − Directionofflow − Benchrangeofthemountedactuator(e.g.0.2to1 bar)
− Isastrainerinstalled? − Installationdrawing
Dimensions and weightsRefertoDataSheetuT8091
http://www.samson.de/pdf_en/t80910en.pdf
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SAMSON AG · MESS- UND REGELTECHNIKWeismüllerstraße 3 · 60314 Frankfurt am Main, GermanyPhone: +49 69 4009-0 · Fax: +49 69 [email protected] · www.samson.de EB 8091 EN 201
5-04
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