Type 3271 and Type 3277 Pneumatic Actuators. Actuator areas: 175 and 750 cm². Type 3271 Type Mounting and Operating Instructions EB EN

Transcription

1 Type 3271 and Type 3277 Pneumatic Actuators Actuator areas: 175 and 750 cm² Type 3271 Type 3277 Type 3271 and Type 3277 Pneumatic Actuators Mounting and Operating Instructions EB EN Edition October 2013

2 Contents Contents Page 1 Design and principle of operation Direct attachment in combination with Type Direction of action Signal pressure routing in Type Signal pressure routing in Type Fail-safe action Actuator stem extends Actuator stem retracts Type of application Throttling service On/off service Versions Standard version Version with adjustable mechanical travel stop Version with handwheel Operation Versions with mechanical travel stop Minimum travel limit Maximum travel limit Version with handwheel Adjusting the valve travel Maintenance Dissassembling the actuator Decompressing preloaded springs Removing the diaphragm plate assembly Dismantling the diaphragm plate assembly Assembly (depending on direction of action) Adjusting the position of the slotted nut Replacing seals and bearings Type Type Version with travel stops Version with handwheel Assembling the actuator EB EN

3 Contents 5.7 Reversing the direction of action (fail-safe action) Nameplate Dimensions and weights Customer inquiries General safety instructions The actuators may only be mounted, started up and operated by trained and experienced personnel familiar with this product. According to these mounting and operating instructions, trained personnel refers to individuals who are able to judge the work they are assigned to and recognize possible hazards due to their specialized training, their knowledge and experience as well as their knowledge of the relevant standards. Any hazards which could be caused by the signal pressure and moving parts of the actuator are to be prevented by means of appropriate measures. Proper shipping and appropriate storage are assumed. EB EN 3

4 Design and principle of operation 1 Design and principle of operation The SAMSON Type 3271 and Type 3277 Pneumatic Actuators are mounted on SAMSON Series 240, 250, 280 and 290 Valves. The actuators consist of two diaphragm cases (1 and 2), a rolling diaphragm (4) with diaphragm plate (5) and springs (10). The signal pressure (S) creates a force at the diaphragm surface which is counteracted by the springs (10) arranged in the actuator. The number of springs and their compression determine the bench range (signal pressure range) whereby the rated travel is directly proportional to the signal pressure. A maximum of 19 springs can be installed, partly fitted inside one another. The stem connector (27) connects the actuator stem (7) to the plug stem of the mounted valve. 1.1 Direct attachment in combination with Type 3277 This actuator version is fitted with an additional yoke on the bottom diapragm case. S Actuator stem retracts (air-to-close) (air applied in this diagram) Actuator stem extends (air-to-open) S Fig. 1 Sectional drawing of Type EB EN

5 Design and principle of operation This yoke is used for direct attachment of a positioner and/or limit switch to protect the travel pick-off against external influences. Refer to the mounting and operating instructions of the valve accessories to be mounted for more details on attachment and the required mounting parts. Actuator stem retracts (air-to-close) (air applied in this diagram) 1.2 Direction of action The direction of action is determined by how the springs and diaphragm plate are arranged in the actuator. For fail-safe action "Actuator stem retracts" (air-to-close), the signal pressure is connected to the loading pressure connection on the top diaphragm case (1) or (75) for the version with mechanical travel stop. Actuator stem extends (air-to-open) S Legend for Figs. 1 and 2 1 Top diaphragm case 2 Bottom diaphragm case 4 Diaphragm 42 5 Diaphragm plate 41 7 Actuator stem 8 Nut 10 Springs 16 Vent plug 17 O-ring 22 Bolt Stem connector 33 Nut 34 Slotted nut 35 Retainer 36 Spacing tube 40 Shaft sealing ring 41 Wiper 42 Plain bearing S Loading pressure connection S Fig. 2 Sectional drawing of Type 3277 EB EN 5

6 Design and principle of operation For fail-safe action "Actuator stem extends" (air-to-open), the signal pressure is connected to the loading pressure connection on the bottom diaphragm case (2). The actuators's direction of action can be changed. To change it, the actuator must first be removed from the valve (refer to section 5.7 on how to reverse the direction of action) Signal pressure routing in Type 3271 In the Type 3271 Actuator with the fail-safe action "Actuator stem extends" (air-to-open), (Fig. 1, right), the signal pressure is connected to the bottom loading pressure connection (S) to fill the bottom diaphragm chamber with air, causing the actuator stem to move upwards, opposing the force of the actuator springs. In the Type 3271 Actuator with the fail-safe action "Actuator stem retracts" (air-to-close), (Fig. 1, left), the signal pressure is connected to the top loading pressure connection (S) to fill the top diaphragm chamber with air, causing the actuator stem to move downwards, opposing the force of the actuator springs Signal pressure routing in Type 3277 In the Type 3277 Actuator with the fail-safe action "Actuator stem extends" (air-to-open), (Fig. 2, right) the signal pressure is connected to the loading pressure connection at the side of yoke and routed through an hole in the yoke to fill the bottom diaphragm chamber with air, causing the actuator stem to move upwards opposing the force of the actuator springs. A positioner can be connected in this case by using a connection block. Additional piping to the actuator is not required (read positioner documentation for more details). In the Type 3277 Actuator with the fail-safe action "Actuator stem retracts" (fail-to-close) (Fig. 2, left) the signal pressure is connected to the top loading pressure connection (S) to fill the top diaphragm chamber with air, causing the actuator stem to move downwards, opposing the force of the actuator springs. 1.3 Fail-safe action When the signal pressure fails, the fail-safe action of the actuator depends on whether the springs are installed in the top or bottom diaphragm chamber Actuator stem extends When the signal pressure is reduced or the air supply fails, the springs move the actuator stem downwards and close the valve. The valve opens when the signal pressure is increased enough to overcome the force exerted by the springs Actuator stem retracts When the signal pressure is reduced or the air supply fails, the springs move the actuator stem upwards and open the valve. The valve closes when the signal pressure is increased enough to overcome the force exerted by the springs. 6 EB EN

7 Type of application 2 Type of application Note: Refer to the mounting and operating instructions of the corresponding valve for more details on how to mount the actuator on the valve or how to remove it. 2.1 Throttling service The Type 3271 and Type 3277 Pneumatic Actuators are designed for a maximum supply pressure of 6 bar. 2.2 On/off service To prevent the actuator from being damaged, do not let the supply pressure exceed the upper spring range value by more than 3 bar when the actuator is used for on/off service with the fail-safe action "Actuator stem retracts" (air-to-close). Example: Supply pressure in on/off service 3 Versions 3.1 Standard version The pneumatic actuator has an effective diaphragm area of 175 or 750 cm². The diaphragm casing (1 and 2) or (75) for the version with mechanical limit stop (2) are made of sheet steel with a plastic coating. 3.2 Version with adjustable mechanical travel stop Type 3271 and Type 3277 Actuators can be fitted with an adjustable mechanical travel stop to limit the minimum and maximum travel. 3.3 Version with handwheel Type 3271 and Type 3277 Actuators can be fitted with a handwheel. The handwheel is mounted on the top diaphragm case and is used to adjust the valve travel. Bench range Fail-safe action Max. supply pressure 0.2 to 1.0 bar 4 bar 0.4 to 2.0 bar Actuator stem retracts 5 bar 0.6 to 3.0 bar 6 bar Label actuators that have a reduced supply pressure with a sticker: "Max. supply pressure limited to... bar". The maximum supply pressure for actuators with fail-safe action Actuator stem extends (air-to-open) and mechanical travel stops should not exceed the upper spring range value by more than 1.5 bar. Fig. 3 Type 3271, 750 cm² diaphragm area with handwheel EB EN 7

8 Operation 4 Operation NOTICE Only apply the signal pressure to the loading pressure connection (S) on the diaphragm chamber that does not contain the springs. The valid bench range or operating signal pressure range with which the actuator moves through its travel range, is written on the nameplate. It is important for a troublefree operation of the actuator that the vent plug (16) is not blocked. 4.1 Versions with mechanical travel stop Versions with a mechanical travel stop can be used to limit the minimum travel, maximum travel or both. 16 Vent plug 34 Slotted nut (top) 50 Actuator stem 70.1 Lock nut 70.2 Lock nut 73 Cap 75 Top diaphragm case 76 Shaft sealing ring 77 Dry bearing 78 Lock nut S Loading pressure connection 34 S S Actuator stem retracts (air-to-close) Actuator stem extends (air-to-open) Fig. 4 Type 3271 (partial view) with mechanical travel stop 8 EB EN

9 Operation Minimum travel limit 1. Undo lock nut (78) and unthread cap (73). 2. Undo lock nut (70.1). 3. Move actuator to the minimum travel position. 4. Screw bottom lock nut (70.2) as far as it will go. 5. Hold bottom lock nut (70.2) in place and use the top nut (70.1) to lock in position. 6. If you do not want the actuators's minimum travel to be limited, thread the nuts (70.1 and 70.2) to the bottom of the stem and lock them in place. 7. Screw on cap (73) and retighten lock nut (78) Maximum travel limit 1. Undo lock nut (78) and unthread cap (73). 2. Move actuator to the maximum travel position. 3. Screw on cap (73) as far as it will go and refasten using the lock nut (78). EB EN 9

10 Operation 4.2 Version with handwheel Adjusting the valve travel After undoing the lock nut (66), the handwheel (60) can be used to adjust the travel of the valve. Turn the handwheel clockwise to extend the actuator stem. If the actuator is to be actuated pneumatically again, make sure that the pointer (55) points to the groove in the coupling (51). Relock the handwheel using the lock nut (66) Type 3271 with 175 cm² diaphragm area Type 3271 with 750 cm² diaphragm area Legend for Figs. 5 and 6 1 Top diaphragm case 4 Diaphragm 5 Diaphragm plate 7 Actuator stem 8 Nut 10 Springs 17 O-ring 20 Bolt 21 Nut 23 Spring adjusting nut 25 Washer 33 Nut 35 Retainer 36 Spacing tube 40 Shaft sealing ring 42 Plain bearing 51 Coupling 55 Pointer 60 Handwheel 66 Lock nut Fig. 5 Type 3271 Pneumatic Actuator with handwheel 175 cm² and 750 cm² diaphragm areas 10 EB EN

11 Maintenance 5 Maintenance Should the actuator not work properly, you may need to replace parts that are subject to wear. NOTICE Special care is required when the actuator springs are preloaded. These actuators are labeled accordingly and can also be recognized by three long bolts protruding from the bottom diaphragm case. If the actuator is defective and cannot be operated by applying air to it, the preloaded springs must be fully decompressed before removing the actuator! 5.1 Dissassembling the actuator NOTICE The lifting ring on the top diaphragm case is only intended for mounting the pneumatic actuator or removing it from the valve. Do not use the lifting ring to lift the complete valve assembly (actuator and valve) Decompressing preloaded springs 1. Undo the nuts (21) from the short bolts (20) on the actuator casing and remove them. S Bolts used to unload the spring compression! Actuator stem retracts (air-to-close) (air applied in this diagram) Actuator stem extends (air-to-open) Fig. 6 Opening the Type 3271 Actuator EB EN 11

12 Maintenance 2. Unthread each nut (23) from the long bolts (22) by a few turns before proceeding to the neighboring nut. Continue this procedure until the springs are fully decompressed. 5.2 Removing the diaphragm plate assembly 1. Lift off top diaphragm case (1). 2. Remove springs (10) from actuator with fail-safe action "Actuator stem extends" (air-to-open). 3. Remove diaphgram plate (5) together with the diaphragm (4) and actuator stem (7) from the bottom diaphragm case. 4. For actuator with fail-safe action "Actuator stem retracts" (air-to-close), remove the now accessible springs. 5.3 Dismantling the diaphragm plate assembly cm² version Place a slotted nut wrench on the actuator stem (7) to hold the slotted nut stationary. 175 cm² version Type 3271: Use a box wrench to hold the nut on the actuator stem stationary Type 3277: Clamp the actuator stem in a vise with jaw covers. 2. Dismantle components in the following order: Diaphragm 5 Diaphragm plate 7 Actuator stem 17 O-ring 33 Nut 34 Slotted nut 35 Retainer 36 Spacing tube Actuator stem retracts (air-to-close) Actuator stem extends (air-to-open) Fig. 7 Diaphragm plate assembly for air-to-close and air-to-open versions 12 EB EN

13 Maintenance Actuator stem extends/air-to-open Nut (33) (or slotted nut (34, top) when a travel stop is fitted) Spacing tube (36) O-ring (17) Diaphragm plate (5) together with diaphragm (4) Retainer (35) Actuator stem retracts/air-to-close Nut (33) (or slotted nut (34, top) when a travel stop is fitted) Retainer (35) Diaphragm plate (5) together with diaphragm (4) O-ring (17) Spacing tube (36) 5.4 Assembly (depending on direction of action) Note: We recommend the following tools to assemble the actuator: Slotted nut wrench Order no O-ring sleeve Order no only for 175 cm²: Order no Prior to assembly, check all parts for damage and renew them, if necessary. The actuator stem (7) must be undamaged in the area where it slides on the plain bearing (42) and shaft sealing ring (40). The arrangement of the components is identical in both Type 3271 and Type 3277 Actuators. The actuator's direction of action is determined by the sequence of assembly on the actuator stem cm² version: Place a slotted nut wrench on the actuator stem (7) to hold the slotted nut stationary. 175 cm² version: Use a box wrench to hold the nut on the actuator stem of Type 3271 stationary. Clamp the actuator stem of Type 3277 in a vise with jaw covers. 2. Pull the diaphragm (4) onto the diaphragm plate (5) free of tension. 750 cm² version: Make sure that the elevations on the diaphragm are aligned with the centering locations for the springs on the diaphragm plate. 3. Assemble the components depending on the direction of action: Diaphragm 5 Diaphragm plate 7 Actuator stem 17 O-ring 7 33 Nut 34 Slotted nut 35 Retainer 36 Spacing tube Fig. 8 Assembly (actuator stem extends/air-to-open) EB EN 13

14 Maintenance Actuator stem extends/air-to-open Push the retainer (35) over the slotted nut (34) as illustrated. Guide the diaphragm plate (5) together with diaphragm (4) over the actuator stem, ensuring that the diaphragm is facing down and the spring chamber is aligned with threaded end of the actuator stem (facing upward). Mount the O-ring (17) using the O-ring sleeve. Push spacing tube (36) with its inside chamfer at the front, aligned with the O-ring, onto the actuator stem. Thread nut (33) (or slotted nut (34, top) when a travel stop is fitted) onto the actuator stem. Actuator stem retracts/air-to-close Push spacing tube (36) onto the actuator stem towards the slotted nut (34), making sure that the inside chamfer is aligned with the threaded end of the actuator stem (facing away from the slotted nut or pointing towards the O-ring). Mount the O-ring (17) using the O-ring sleeve (see page 12). Guide the diaphragm plate (5) together with diaphragm (4) over the actuator stem, ensuring that the spring chamber is aligned with the tip of the stem connector. Mount the retainer (35). Thread nut (33) (or slotted nut (34, top) when a travel stop is fitted) onto the actuator stem. 4 Diaphragm 5 Diaphragm plate 7 Actuator stem 17 O-ring 33 Nut 34 Slotted nut 35 Retainer 36 Spacing tube Tighten the nut (33) (or slotted nut (34, top) when a travel stop is fitted) using the following torque: 25 Nm for 175 cm² version 75 Nm for 750 cm² version. 5. Apply lubricant to the actuator stem in the area where the plain bearing is located: Version with NBR diaphragm material: lubricant ( ) Version with EPDM or PVMQ diaphragm material: lubricant ( ). Fig. 9 Assembly (actuator stem retracts/air-to-close) 14 EB EN

15 Maintenance Adjusting the position of the slotted nut If the slotted nut (34) has been unthreaded from the actuator stem (7), e.g. during dismantling of the diaphragm plate assembly, follow the instructions below to readjust the position of the slotted nut: 1. Unthread the slotted nut (34) from the actuator stem (7) and clean both threads. 2. Thinly apply thread locking agent ( ) to thread area where the nut (34) will be located and mount the slotted nut (34) with its slot facing towards the stem connector end of the actuator stem. 3. Adjust the dimension x as shown in Figs. 10 and 11. Actuator Dimension x [mm] Diaphragm area Type 3271 X = Type 3277 X = cm² Type 3271 X = cm² Note: Allow for the thread locking agent to harden before continuing the actuator assembly ,2±0,1 X 225,2±0,1 X 7 Legend for Figs. 10 and 11 7 Actuator stem 34 Top diaphragm case Fig. 10 Adjusting the slotted nut position on Type 3271 Fig. 11 Adjusting the slotted nut position on Type EB EN 15

16 Maintenance 5.5 Replacing seals and bearings Due to wear or during repair work, replace the shaft sealing ring (40) as well as the wiper (41) and plain bearing (42), if necessary Type Remove the shaft sealing ring (40) using a suitable punch or hook. 2. Carefully install the new shaft sealing ring, making sure the sealing lip does not get damaged. 3. If necessary, replace the wiper (41) and plain bearing (42) using a suitable punch or piece of pipe. 4. Apply lubricant ( ) to parts (40), (41) and (42). 5. Reassemble actuator as described in section Type Remove the shaft sealing ring (40) using a suitable punch or hook. 2. Carefully install the new shaft sealing ring, making sure the sealing lip does not get damaged. 3. If necessary, replace the wiper (41) and both plain bearings (42) using a suitable punch or piece of pipe. 4. Apply lubricant ( ) to parts (40), (41) and (42). 5. Reassemble actuator as described in section Type Actuator stem 40 Shaft sealing ring Wiper 42 Plain bearing Type Fig. 12 Seals and bearings for Type 3271 and Type EB EN

17 Maintenance Version with travel stops The Type 3271 and Type 3277 Pneumatic Actuators can be optionally fitted with a mechanical travel stop. A shaft sealing ring and a dry bearing are located in the top diaphragm case (75). 1. Undo lock nut (78) and unscrew cap (73). 2. Remove both nuts (70). 3. Remove top diaphragm case as described in section Remove shaft sealing ring (76) and/or dry bearing (77) using a suitable punch or hook. 5. Install new dry bearing using a suitable piece of pipe. 6. Mount new shaft sealing ring, making sure the sealing lip does not get damaged Version with handwheel 1. Undo lock nut (66) and relieve the compression of the actuator springs (10, 11) by turning the handwheel (60). 2. Undo thraded pin (63) and unscrew connection nut (57) from the coupling (51) ,11 34 Slotted nut 70 Nuts 73 Cap 75 Top diaphragm case 76 Shaft sealing ring 77 Dry bearing 78 Lock nut 63 Threaded pin 66, 70 Lock nuts Fig. 13 Seals and bearings for travel stop 8 Nut 10, 11 Springs 51 Coupling 57 Connection nut 59 Yoke 60 Handwheel 63 Threaded pin 66 Lock nut Fig. 14 Handwheel, air-to-open version EB EN 17

18 Maintenance 3. Knock out locking pin (62) and remove ring (54). 4. Unscrew top slotted round nut (8) and lift off yoke (59). 5.6 Assembling the actuator 1. Assembly components depending on the actuator's direction of action: Actuator stem extends/air-to-open Clamp bottom diaphragm case (2) in a vise. Guide ready-assembled actuator stem into the plain bearing (42) of the diaphragm case (2), making sure that the shaft sealing ring (40) does not get damaged. Insert springs (10) onto the diaphragm plate, centering them in the intended recesses. Carefully place the top diaphragm case (1) onto it or insert the ready-assembled diaphragm case (75) for version with travel stop onto the actuator stem, making sure that the shaft sealing ring (76) does not get damaged. Actuator stem retracts/air-to-close Clamp top diaphragm case (1 or 75) in a vise as shown below. This ensures that the position of the springs (10) remains unchanged. Guide ready-assembled actuator stem together with diaphragm plate into the the Actuator stem retracts (air-to-close) 1 Top diaphragm case 2 Bottomdiaphragm case 7 Actuator stem 8 Nut 10 Springs 20 Bolt Fig. 15 Assembling the actuator 21 Nut 25 Washer 27 Clip 40 Shaft sealing ring 42 Plain bearing Actuator stem extends (air-to-open) 18 EB EN

19 Maintenance top diaphragm case (1) or into the ready-assembled diaphragm case (75) for version with travel stop, making sure that the shaft sealing ring (76) does not get damaged. Insert springs (10) onto the diaphragm plate, centering them in the intended recesses. Carefully push the bottom diaphragm case (2) together with plain bearing over the actuator stem, making sure that the shaft sealing ring (40) does not get damaged. 2. Align holes of diaphragm. 3. Align air connections to ensure that they are arranged above each other on the same side. 4. If necessary, insert required clamping bolts (22) through the holes in the diaphragm cases and thread nuts (23) with washers until they rest on the diaphragm case. Hold bolt heads stationary and tighten nuts in an even pattern until the diaphragm is clamped between both diaphragm cases. 5. Insert the short clamping bolts and attach nuts (21) and washers (25). 6. Tighten all nuts with 12 Nm (175 cm²) or 25 Nm (750 cm²) in a criss-cross pattern. 7. Mount the actuator onto the valve following instructions in the mounting and operating instructions of the valve. Tighten the fastening nut (8) with a torque of 150 Nm on mounting the actuator. 5.7 Reversing the direction of action (fail-safe action) The direction of action, i.e. fail-safe action, of pneumatic actuators can be changed. Prior to proceeding, the actuator must first removed from the valve (read mounting and operating instructions of the associated valve). The currently valid fail-safe action "Actuator stem extends" or "Actuator stem retracts" is specified on the nameplate by the corresponding symbol. Remove the handwheel parts of actuators with handwheel as described in section Disassemble the actuator and diaphragm plate assembly as described in sections 5.1 to Assemble the diaphgram plate assembly as described in section 5.4 depending on the direction of action. 3. Assemble the actuator as described in section 5.6. Note: Mark the changed fail-safe action on the nameplate! EB EN 19

20 Nameplate 6 Nameplate The plastic nameplates for Type 3271 and Type 3277 Pneumatic Actuators are stuck on the diaphragm case. They include all details required to identify the actuator: 7 Dimensions and weights Refer to the Data Sheets T /-4/-5/-6 EN for Type 3271 or Type 3277 Actuator with 175 or 750 cm² effective diaphragm area for dimensions and weights. SAMSON 3271!"#$%&' Var-ID Serial no Made in Germany cm² NBR- 15 mm G pmax 6 bar / 90psi bar psi bar psi Fig. 16 Nameplate 350 cm² Manufacturer and model type Configuration ID (Var-ID) as bar code and in plain text Serial number Country of origin Diaphragm area in cm² Diaphragm material NBR, EPDM or PVMQ Symbol indicating fail-safe action Bench range in bar und psi Symbol indicating operating travel in mm Signal range with preloaded springs Thread for pneumatic connection in G, NPT or Rc Permissible supply pressure p max in bar and psi 20 EB EN

21 Customer inquiries 8 Customer inquiries Please specify the following details on making inquiries: Type und model number Effective diaphragm area Bench range (spring range) in bar Actuator version and direction of action Your address Please send your inquiries to: service@samson.de Tools Slotted nut wrench Order no O-ring sleeve Order no only for 175 cm² Order no EB EN 21

22 22 EB EN

23 EB EN 23

24 SAMSON AG MESS- UND REGELTECHNIK Weismüllerstraße Frankfurt am Main Germany Phone: Fax: Internet: EB EN