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

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

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).

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

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

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().

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

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-

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

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.

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

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).

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

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

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SAMSON AG · MESS- UND REGELTECHNIKWeismüllerstraße 3 · 60314 Frankfurt am Main, GermanyPhone: +49 69 4009-0 · Fax: +49 69 4009-1507samson@samson.de · www.samson.de EB 8091 EN 201

5-04

-13·English