Flowserve 2 Series User manual

1
User Instructions Series 2, Type P2, P3, P4 - KMENIM0001-03 - 06.17
®
Pneumatic Diaphragm On-Off Actuators
Series 2, Types: P2, P3, P4
Installation
Operation
Maintenance Instructions
USER INSTRUCTIONS
FCD KMENIM0001-03 06/17
®

2
®User Instructions Series 2, Type P2, P3, P4 - KMENIM0001-03 - 06.17 ®®
Index
1 Using Kämmer valves and actuators correctly.
2 Unpacking
3 Installation
4 Quick check
5 Maintenance
6 Remove and install actuator
7 Reverse the actuator action
8 Disassemble and assemble valve
9 Trouble-shooting chart

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User Instructions Series 2, Type P2, P3, P4 - KMENIM0001-03 - 06.17
®
1 USING KÄMMERVALVES AND ACTUATORSCORRECTLY
1.1 General
The following instructions are designed to assist in unpa-
cking, installing and performing maintenance as required
on Kämmer products. Product users and maintenance
personnel should thoroughly review this bulletin prior to
installing, operating or performing any maintenance.
DANGER: In most cases Kämmer valves and actuators
are designed for specific applications (e.g. with regard
to medium, pressure, temperature). For this reason they
should not be used in other applications without first
contacting the manufacturer.
1.2 Terms concerning safety
The safety terms DANGER, WARNING, CAUTION and
NOTE are used in these instructions to highlight parti-
cular dangers and/or to provide additional information
on aspects that may not be readily apparent.
DANGER: indicates that death, severe personal injury
and/or substantial property damage will occur if proper
precautions are not taken.
WARNING: indicates that death, severe personal injury
and/or substantial property damage can occur if proper
precautions are not taken.
CAUTION: indicates that minor personal injury and/or
property damage can occur if proper precautions are
not taken.
NOTE: indicates and provides additional technical infor-
mation, which may not be very obvious even to quali-
fied personnel. Compliance with other, not particularly
emphasised notes, with regard to transport, assembly,
operation and maintenance and with regard to technical
documentation (e.g. in the operating instruction, product
documentation or on the product itself) is essential, in
order to avoid faults, which in themselves might directly
or indirectly cause severe personal injury or property
damage.
1.3 Protective clothing
Kämmer products are often used in problematic applica-
tions (e.g. extremely high pressures, dang-erous, toxic
or corrosive mediums). In particular valves with bellows
seals point to suchapplications.When performing service,
inspection or repair operations always ensure, that the
valve and actuator are depressurised and that the valve
has been cleaned and is free from harmful substances. In
such cases pay particular attention to personal protection
(protective clothing, gloves, glasses etc.).
1.4 Qualified personnel
Qualified personnel are people who, on account of
their training, experience and instruction and their
knowledge of relevant standards, specifications,
accident prevention regulations and operating condi-
tions, have been authorised by those responsible for
the safety of the plant to perform the necessary work
and who can recognise and avoid possible dangers.
1.5 Installation
DANGER: Before installation check the order-no,
serial-no. and/or the tag-no. to ensure that the valve/
actuator is correct for the intended application.
Do not insulate extensions that are provided for hot
or cold services.
Pipelines must be correctly aligned to ensure that the
valve is not fitted under tension.
1.6 Spare parts
Use only Kämmeroriginal spare parts.Kämmer cannot
accept responsibility for any damages that occur from
using spare parts or fastening materials from other
manufactures. If Kämmer products (especially seal-
ing materials) have been on store for longer periods
check these for corrosion or deterior-ation before
using these products. Fire protection for Kämmer
products must be provided by the end user.
STOP!

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®User Instructions Series 2, Type P2, P3, P4 - KMENIM0001-03 - 06.17 ®®
Actuator
size
Clearance
(mm)
P2 140
P3 140
P4 140
P5 140
STOP!
1.7 Service / repair
To avoid possible injury to personnel or damage to
products, safety terms must be strictly adhered to.
Modifying this product,substituting nonfactory parts,
or using maintenance procedures other than outlined
in this instructioncould drastically affect performance
and be hazardous to personnel and equipment, and
may void existing warranties.
DANGER: Between actuator and valve there are
moving parts. To avoid injury Flowserve provides
pinch-point-protection in the form of cover plates,
especially where side-mounted positioners are fitted.
If these plates are removed for inspection, service or
repair special attention is required. After completing
work the cover plates must be refitted.
Apart from the operating instructions and the obliga-
tory accident prevention directives valid in the country
of use, all recognised regulations for safety and good
engineering practices must be followed.
WARNING: Before products are returned to Kämmer
for repair or service Kämmer must be provided with
a certificate which confirms that the product has
been decontaminated and is clean. Kämmer will not
accept deliveries if a certificate has not been provided
(a form can be obtained from Kämmer).
1.8 Storage
In most cases Kämmer Products are manufactured
from stainless steel. Products not manufactured
from stainless steel are provided with an epoxy resin
coating. This means that Kämmer products are well
protected from corrosion. Nevertheless Kämmer
products must be stored adequately in a clean, dry
environment. Plastic caps are fitted to protect the
flange faces toprevent the ingressof foreign materials.
These caps should not be removed until the valve is
actually mounted into the system.
1.9 Valve and actuator variations
These instructions cannot claim to cover all details of
all possible product variations, nor in particular can
they provide information for every possible example
of installation, operation or maintenance. This means
that the instructions normally include only the direc-
tions to be followed by qualified personal where the
product is being used for is defined purpose. If there
are any uncertainties in this respect particularly in
the event of missing product-related information,
clarification must be obtained via the appropriate
FLOWSERVE sales office.
2 UNPACKING
2.1 Each delivery includes a packing slip. When unpacking,
check all delivered valves and accessories using this
packing slip.
2.2 Larger valves/actuators can be lifted using slings on the
yoke rods or, if present, on the lugs provided for this
purpose. If slings are used, attach them so that the outer
tubing or attaching parts are not damaged.
WARNING: If slings are used, be aware that the centre
of gravity of the Valve/ actuator may be above the lifting
point. In this case, secure or support the valve against
rotating, to prevent damage or personnel injury.
2.3 Report transport damage to the carrier immediately.
2.4 In case of discrepancies, contact your nearest
FLOWSERVE sales office.
3 INSTALLATION
3.1 Clean tubing prior to installing.
3.2 If possible, install the valve/actuator in an upright
position (actuator on top), to ease maintenance. An
upright installation position is important with low-
temperature applications, in order to keep the distance
between the packing material and the medium as large as
possible. The packing material then retains the ambient
temperature as much as possible.
NOTE: Do not insulate extension bonnets that are provided
for hot or cold services
3.3 Make sure that sufficient overhead clearance above the
actuator is maintained, to allow for disassembly of plug
from the valve body (see following table).
3.4 If the valve is to be welded into the line, make sure that
the valve is shielded from excessive heat.
3.5 Connect supply pressure and signal lines. Control valves
are supplied with a positioner. The end connections for
supply pressure and signal are clearly marked. Actuator
and positioner are suitable for max. 4.2 bar (60 psi)
supply pressure. If the supply pressure exceeds the
pressure specified on the nameplate, a pressure reducing
station is required. If instrument air is not available,
install an oil separator/air filter in the air inlet line. All
connections must be leak free.
STOP!

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User Instructions Series 2, Type P2, P3, P4 - KMENIM0001-03 - 06.17
®
4 QUICK CHECK:
Before operating, check the valve/actuator as follows:
4.1 Open and close the valve, and observe the movement
of the actuator stem. The movement must be smooth
and linear.
4.2 Check for maximum stroke through change of signal (for
pneumatic positioners, 0.2 - 1.0 bar or corresponding
split-range values; for IP positioners, 4-20 or 0-20 mA).
4.3 Check all air connections for leaks.
4.4 Tighten packing nut (see table 1).
NOTE: An excessively tightened gland nut can cause
excessive packing wear and can hinder the free move-
ment of the plug stem.
4.5 Check fail-safe position. To do this, close supply pressure
and observe whether the valve opens or closes as
defined.
4.6 After use at fluctuating temperatures, re-tighten all bolt
connections and check for leaks.
5 MAINTENANCE
Check valves/actuators for correct functioning at regular
intervals (at least once every 6 months) as follows. This
check can be made when installed and in many
cases without interrupting production. If internal defects
are suspected, see section „Disassembly and Assembly
of Valve“.
5.1 Examine gaskets for leaks and if necessary re-tighten
bolts (see Fig. 1).
5.2 Check bellows gasket and test connection - if present
- for external leaks.
5.3 Check valve for damage caused by corrosive residues
or corrosive vapours.
5.4 Clean valve/actuator and repaint as necessary.
Warning: To prevent a buildup of electrostatic charge
clean the actuator with a damp cloth only.
5.5 Check gland nut for correct torque (see table 1).
NOTE: An excessively tightened gland nut can cause
excessive packing wear and can hinder the free
movement of the plug stem.
5.6 If possible, open and close valve and check for
maximum stroke and smooth movement of the plug
stem. Irregular movement of the plug stem may
indicate internal defects.
NOTE: With graphite packing, irregular movement of
the plug stem is normal.
WARNING: Keep hands, hair, clothing, etc. away from
all moving parts. Failure to do so can lead to serious
injury.
5.7 Check all accessories for firm seating.
5.8 If possible, close supply pressure and check the
fail-safe position.
5.10 Check stem boot for wear.
5.11 Check actuator for leaks. To do this, spray housing,
air connections and plug stem guide with leak spray
and check for any bubble formation.
5.12 Clean plug stem.
5.13 Check air filter, if present, and if necessary replace
insert.
NOTE: For further information regarding service
and maintenance please contact your nearest
FLOWSERVE office.
Thread Torque Nm
PTFE Graphit
M20 x 1,5 1 3
M30 x 1,5 6 15
M38 x 1,5 15 35
M45 x 1,5 17 40
Table 1
STOP!

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®User Instructions Series 2, Type P2, P3, P4 - KMENIM0001-03 - 06.17 ®®
1
2
3
4
5
2
6
7
8
9
10
11
12
13
14
15
16
17
18
31
19
21
20
18
22
23
24
32
25
26
27
28
29
7
30
Fig. 1: Series 2 On-Off Actuator, Air-to-Open
1 Washer
2 Bushing
3 O-Ring 22 x 2
4 Guide
5 O-Ring 32,99 x 2,62
6 Lower body
7 Flange
8 Yoke plate
9 Nut M 38 x 1,5
10 Actuator stem
11 Yoke rod
12 Coupling half
13 Screw
14 Coupling insert
15 Nut
16 Yoke plate
17 Washer, Ø 6,4
18 Nut, M 6
19 Travel indicator, assy.
20 Screw M 6 x 25
21 (De)Compression screw
22 Upper body
23 Vent plug
24 Locknut
25 Spacer
26 Plate
27 Spring plate
28 Piston
29 Diaphragm
30 Spring set
31 Nut
32 Nut

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User Instructions Series 2, Type P2, P3, P4 - KMENIM0001-03 - 06.17
®
STOP!
Service to the actuator is best performed when the actuator is removed from the valve body. For the purpose of these instructions, consider the
actuatoras a separate subassembly with the procedures described in these instructions being performed on a bench. However, many service repairs
and adjustments can be accomplished in the field while the actuator and valve body are still connected to each other.
Attention: The valve trim is a very sensitive assembly, take care not to damage it. Always remove and replace the actuator together with the top
yoke plate (18) and yoke rods (11).
6 REMOVING AND INSTALL ACTUATOR
6.1 REMOVING ACTUATOR
(refer to Fig. 1)
6.1.1 Shut off air supply.
WARNING:Depressurise the lineto atmospheric pressure
and drain all fluids from the valve before working on the
actuator. Failure to do so can cause serious injury.
6.1.2 Disconnect all tubing.
6.1.3 Remove 2 screws (13) and remove coupling (12).
6.1.4 Remove yoke rod retaining nuts (15) and lift actuator
assembly from the valve.
6.1.5 Remove coupling insert (14) and it’s locknut from plug
stem.
NOTE: Ensure that the plug assembly is not rotated with
the plug seated. This may cause irreparable damage to
the seating faces.
6.2 INSTALL ACTUATOR
(refer to Fig. 1)
The actuator stem must be fully extended:
Actuators with air-to-open action must be fully vented.
Actuatorswith air-to-close action apply supply pressure.
Manually depress the plug stem to ensure the plug is
fully seated.
6.2.1 Screw coupling insert locknut and coupling insert as far
as possible onto plug stem.
6.2.2 Place the actuator assembly on the valve engaging the
yoke rod threads in the lower yoke plate and ensuring
the actuator faces in the correct direction.
6.2.3 Unscrew the coupling insert until the yoke rods are raised
from the lower yoke plate by around 2 mm.
NOTE: Ensure that the plug assembly is not rotated with
the plug seated. This may cause irreparable damage to
the seating faces.
6.2.4 Refit the coupling (12), ensuring that the arrows, em-
bossed on the coupling halves, point upward towards
the actuator, and secure with 2 retaining screws (13).
6.2.5 Apply supply pressure resp. vent actuator to half stroke
and refit and tighten yoke rod retaining nuts (15).
6.2.6 Connect all tubing.
7 REVERSE THE ACTUATOR ACTION
(refer Fig. 1)
DANGER: Actuators with “spring-to-close” action
can be disassembled and reassembled by using
long (de)compression screws. A suitable press is
required to disassembled and reassemble actua-
tors with “spring-to-open” action or to reverse the
actuator action.
7.1 Reverse actuator action from spring-to-close to
spring-to-open
7.1.1 As required remove the actuator
from the valve as described in
section 6.1.
7.1.2 If long (de)compression screws
are not already fitted to the actuator:
on type P2 remove 3 equally spaced case retaining
screws(20), ontypesP3/P4remove 4 equally spaced
case retaining screws (20).
7.1.3 Insert 3/4 longer (de)compression screws (21) ac-
cording to table 2 and tighten the nuts hand tight.
Actuator Screw length
Type P2 50 mm
Type P3 70 mm
Type P4 110 mm
Table 2
Screw lengths for (de)compression screws
7.1.4 Remove all the remaining short case retaining screws
(20).
7.1.5 Unscrew the long nuts (31) on the long compression
screws (21) 3-4 threads at atime in clockwise rotation
until the actuator springs are fully decompressed and
the upper case is loose.
7.1.6 Remove the upper case half.
7.1.7 Secure the actuator stem (10) against rotating with
a wrench across the flats on the stem’s lower part
and remove the lock nut (24) and nut (32).
7.1.8 Remove following parts:
spacer (25), plate (26), spring plate (27), spring
set (30), piston (28) diaphragm (29) and washer
(1)
7.1.9 Replace the parts onto the actuator stem in reverse
order.

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®User Instructions Series 2, Type P2, P3, P4 - KMENIM0001-03 - 06.17 ®®
1
2
3
4
5
2
6
7
8
9
10
11
12
13
14
15
16
17
18
31
19
21
20
18
22
23
24
32
25
26
27
28
29
7
30
Fig. 1: Series 2 On-Off Actuator, Air-to-Open
1 Washer
2 Bushing
3 O-Ring 22 x 2
4 Guide
5 O-Ring 32,99 x 2,62
6 Lower body
7 Flange
8 Yoke plate
9 Nut M 38 x 1,5
10 Actuator stem
11 Yoke rod
12 Coupling half
13 Screw
14 Coupling insert
15 Nut
16 Yoke plate
17 Washer, Ø 6,4
18 Nut, M 6
19 Travel indicator, assy.
20 Screw M 6 x 25
21 (De)Compression screw
22 Upper body
23 Vent plug
24 Locknut
25 Spacer
26 Plate
27 Spring plate
28 Piston
29 Diaphragm
30 Spring set
31 Nut
32 Nut

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User Instructions Series 2, Type P2, P3, P4 - KMENIM0001-03 - 06.17
®
7.1.10 With a suitable press compress the spring set.
7.1.11 Secure the actuator stem (10) from rotating with a wrench
across the flats on the stem’s lower part and retighten the
nut (32) to the torque shown in table 3. Replace locknut
(24) and secure with loctite 221.
Actuator Torque
Type P2 20 Nm
Type P3 30 Nm
Type P4 35 Nm
Table 3 Torque value for nut (32)
7.1.12 Release the press and replace the upper case half.
7.1.13 Insert and tighten the case retaining screws (20) to a
torque value of 12 Nm
7.1.14 As required refit the actuator assembly to the valve as
described in section 6.2.
7.2 Reverse actuator action from spring-to-open to spring-
to-close
7.2.1 As required remove the actuator from the valve as de-
scribed in section 6.1.
7.2.2 Remove all case retaining screws (20).
7.2.3 Remove the upper case half (22).
7.2.4 With a suitable press compress the spring set.
7.2.5 Secure the actuator stem (10) against rotating with a
wrench across the flats on the stem’s lower part and
remove the lock nut (24) and nut (32).
7.2.6 Remove following parts:
washer (1), diaphragm (29), piston (28), spring set
(30), spring plate (27), plate (26) and spacer (25).
7.2.7 Replace the parts onto the actuator stem in reverse
order.
7.2.8 Secure the actuator stem (10) from rotating with a wrench
across the flats on the stem’s lower part and retighten the
nut (32) to the torque shown in table 3. Replace locknut
(24) and secure with loctite 221.
7.2.9 Release the press and replace the upper case half.
7.2.10 Insert 3/4 longer (de)compression screws (21) (see table
2) through the upper and lower actuator case halves
and tighten with long nuts (31) 3-4 threads at a time in
clockwise rotation until the casing halves contact.
7.2.11 Insert and tighten all remaining short case retaining
screws (20) to a torque value of 12 Nm.
7.2.12 As required replace the long (de)compression screws/
nuts with the short screws/nuts.
7.2.13 As required refit the actuator assembly to the valve as
described in 6.2.
8 DISASSEMBLE AND ASSEMBLE ACTUATOR
(refer to fig. 1)
DANGER: Actuators with “spring-to-close” action
can be disassembled and reassembled by using
long (de)compression screws. A suitable press is
required to disassembled and reassemble actua-
tors with “spring-to-open” action or to reverse the
actuator action.
8.1 DISASSEMBLE ACTUATOR
8.1.1 Actuator action spring-to-close
8.1.1.1 As required remove the actuator from the valve as
described in section 1.1.
8.1.1.2 If long (de)compression screws are not already fitted
to the actuator: on type P2 remove 3 equally spaced
case retaining screws (20), on types P3/P4 remove
4 equally spaced case retaining screws (20).
8.1.1.3 Insert 3/4 longer (de)compression screws (21) ac-
cording to table 1 and tighten the nuts hand tight.
8.1.1.4 Remove all the remaining short case retaining screws
(20).
8.1.1.5 Unscrew the long nuts (31) on the long compression
screws (21) 3-4threads at a timein clockwise rotation
until the actuator springs are fully decompressed and
the upper case is loose.
8.1.1.6 Remove the upper case half.
8.1.1.7 Secure the actuator stem (10) against rotating with
a wrench across the flats on the stem’s lower part
and remove the lock nut (24) and nut (32).
8.1.1.8 Remove following parts:
spacer (25), plate (26), spring plate (27), spring
set (30), piston (28) diaphragm (29) and washer
(1)
8.1.1.9 With a hooked spanner loosen and remove the
slotted nut (9).
8.1.1.10 Remove the guide (4) and upper yoke plate (8).
8.1.2 Actuator action spring-to-open
8.1.2.1 As required remove the actuator from the valve as
described in section 1.1.
8.1.2.2 Remove all case retaining screws (20).
8.1.2.3 Remove the upper case half (22).
8.1.2.4 With a suitable press compress the spring set.
8.1.2.5 Secure the actuator stem (10) against rotating with
a wrench across the flats on the stem’s lower part
and remove the lock nut (24) and nut (32).

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®User Instructions Series 2, Type P2, P3, P4 - KMENIM0001-03 - 06.17 ®®
Fig. 3: NAMUR coupling half
Abb. 2: Anti-rotation device
8.1.2.6 Remove following parts:
washer (1), diaphragm (29), piston (28), spring
set (30), spring plate (27), plate (26) and spacer
(25).
8.1.2.7 With a hooked spanner loosen and remove the
slotted nut (9).
8.1.2.8 Remove the guide (4) and upper yoke plate (8).
8.2 ASSEMBLE ACTUATOR
(refer to Figs. 1 and 2)
8.2.1 Actuator action spring-to-close
8.2.1.1 Insert the guide (4) into the lower body half.
8.2.1.2 Replace the upper yoke plate ensuring that the
nose in the lower body rests in the bore of the
upper yoke plate (see fig. 2).
8.2.1.3 Refit the slotted nut (9) and tighten with a hooked
spanner.
8.2.1.4 Refit the actuator stem (10), washer (1), dia-
phragm (29), piston (28), spring set (30), spring
plate (27), plate (26) and spacer (25)
8.2.1.5 Secure the actuator stem (10) from rotating with a
wrench across the flats on the stem’s lower part and
retighten the nut (32) to the torque shown in table
2. Replace locknut (24) and secure with loctite 221.
8.2.1.6 Replace the upper case half.
8.2.1.7 Insert 3/4 longer (de)compression screws (21) (see
table 2) through the upper and lower actuator case
halves and tighten with long nuts (31) 3-4 threads
at a time in clockwise rotation until the casing halves
contact.
8.2.1.8 Insert and tighten all remaining short case retaining
screws (20) to a torque value of 12 Nm.
8.2.1.9 As required replace the long (de)compression
screws/nuts with the short screws/nuts.
8.2.1.10 As required refit the actuator assembly to the valve
as described in 6.2.
8.2.2 Actuator action spring-to-close
8.2.2.1 Insert the guide (4) into the lower body half.
8.2.2.2 Replace the upper yoke plate ensuring that the nose
in the lower body rests in the bore of the upper yoke
plate (see fig. 2).
8.2.2.3 Refit the slotted nut (9) and tighten with a hooked
spanner.
8.2.2.4 Refit the actuator stem (10), spacer (25), plate (26),
spring plate (27), spring set (30), piston (28), dia-
phragm (29) and washer (1).
8.2.2.5 With a suitable press compress the spring set.
4.2.2.6 Secure the actuator stem (10) from rotating with a wrench
across the flats on the stem’s lower part and retighten the
nut (32) to the torque shown in table 3. Replace locknut
(24) and secure with loctite 221.
8.2.2.7 Release the press and replace the upper case half.
8.2.2.8 Insert and tighten the case retaining screws (20) to a
torque value of 12 Nm
8.2.2.9 As required refit the actuator assembly to the valve as
described in section 6.2.
8.3 NAMUR ACCESSORIES
(see Fig. 3)
8.3.1 Accessories according to NAMUR can be fitted by flanging
them to the yoke. A special coupling half with threaded
bosses is available to connect the actuating lever (see
spare parts list for part-no.).

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User Instructions Series 2, Type P2, P3, P4 - KMENIM0001-03 - 06.17
®
Problem Possible cause Corrective action
Stem pulsates 1 Unstable air supply 1 Check air supply
2 Vent or passage blocked 2 Clean vent or passage
Actuator slow 1 Air supply too low 1 Adjust air supply
2 Diaphram case leaks air 2 Seal diaphram case
3 Spring case vent blocked 3 Renew vent
Actuator will not return
to end position
1
2
3
Air supply too low
Broken actuator spring
Actuator movement blocked
1
2
3
Adjust air supply
Renew all actuator springs
Dissassemble actuator and check
Actuator will not return
to the failsafe position
1
2
3
Actuator not vented
Broken actuator spring
Actuator movement blocked
1
2
3
Vent actuator
Renew all actuator springs
Dissassemble actuator and check
9 TROUBLESHOOTING CHART

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®User Instructions Series 2, Type P2, P3, P4 - KMENIM0001-03 - 06.17 ®®
Germany
Flowserve Essen GmbH
Schederhofstr. 71
45145 Essen
Deutschland
Tel.: [phone]
Fax: [phone]
USA
Flowserve Corporation
1300 Parkway View Drive
Pittsburgh, PA 15205
USA
Tel.: [phone]
Fax: [phone]
Singapore
Flowserve Pte Ltd
12 Tuas Avenue 20
Singapore, 638824
Singapore
Tel.: [phone]
Fax: [phone]
®
Yout contact:
All data subject to change without notice
©03.2002 Flowserve Corporation. Flowserve and Kämmer are trademarks of Flowserve Corporation