Samson 3963 Series Service manual

Translation of original instructions
EB 3963 EN
Edition June 2018
Type3963 Solenoid Valves

Note on these mounting and operating instructions
These mounting and operating instructions assist you in mounting and operating the device
safely. The instructions are binding for handling SAMSON devices.
ÎFor the safe and proper use of these instructions, read them carefully and keep them for
later reference.
ÎIf you have any questions about these instructions, contact SAMSON‘s After-sales Service
Department (aftersalesser[email protected]).
The mounting and operating instructions for the devices are included in
the scope of delivery. The latest documentation is available on our website
at www.samson.de > Service & Support > Downloads > Documentation.
Denition of signal words
Hazardous situations which, if not avoided,
will result in death or serious injury
Hazardous situations which, if not avoided,
could result in death or serious injury
Property damage message or malfunction
Additional information
Recommended action
DANGER
!
WARNING
!
NOTICE
!
Note
Tip
2 EB 3963 EN

Contents
EB 3963 EN 3
1 Safety instructions and measures ...................................................................5
1.1 Notes on possible severe personal injury .........................................................8
1.2 Notes on possible personal injury ...................................................................9
1.3 Notes on possible property damage................................................................9
2 Markings on the device ...............................................................................10
2.1 Nameplate ..................................................................................................10
2.2 Article code.................................................................................................11
3 Design and principle of operation ................................................................14
3.1 Accessories .................................................................................................16
3.2 Technical data .............................................................................................18
3.3 Dimensions in mm........................................................................................26
4 Measures for preparation............................................................................40
4.1 Unpacking ..................................................................................................40
4.2 Storage.......................................................................................................40
5 Mounting and start-up.................................................................................41
5.1 Installation...................................................................................................41
5.2 Rail mounting ..............................................................................................42
5.2.1 Wall mounting.............................................................................................42
5.3 Mounting on rotary actuators with NAMUR interface......................................43
5.3.1 Mounting to linear actuators with NAMUR rib................................................43
5.3.2 MountingtolinearactuatorsusingCrNiMosteelpipetting............................45
5.3.3 MountingonmountingblockforSAMSONType3277PneumaticActuator......45
5.4 Pneumaticconnection...................................................................................47
5.4.1 Sizing of the connecting line .........................................................................47
5.4.2 Compressed air quality.................................................................................47
5.5 Changeover to external pilot supply over port 9 .............................................48
5.6 Exhaust air feedback....................................................................................50
5.7 Restrictors....................................................................................................50
6 Electrical connection ....................................................................................51
6.1 SwitchingamplieraccordingtoEN60079-25..............................................52
6.2 Cable entry with cable gland ........................................................................52
6.3 Connecting the electrical power ....................................................................53

Contents
4 EB 3963 EN
7 Operation...................................................................................................53
7.1 Degreeofprotection.....................................................................................53
7.2 Manualoverride..........................................................................................53
8 Servicing.....................................................................................................54
8.1 Preparationforreturnshipment.....................................................................54
9 Malfunctions ...............................................................................................55
9.1 Emergency action ........................................................................................55
10 Decommissioning and removal ....................................................................56
10.1 Decommissioning.........................................................................................56
10.2 Disposal......................................................................................................56
11 Appendix....................................................................................................57
11.1 After-sales Service .......................................................................................57

EB 3963 EN 5
Safety instructions and measures
1 Safety instructions and measures
Intended use
TheType3963SolenoidValveismountedontopneumaticlinearorrotaryactuators
(depending on the version) to control them. Upon failure of the air supply, the solenoid valve
vents the actuator, causing the valve to move to the fail-safe position determined by the
actuator.Thedeviceisdesignedtooperateunderexactlydenedconditions(e.g.operating
pressure, temperature). Therefore, operators must ensure that the solenoid valve is only used
in applications where the operating conditions correspond to the technical data. In case
operatorsintendtousethesolenoidvalveinotherapplicationsorconditionsthanspecied,
contact SAMSON.
SAMSON does not assume any liability for damage resulting from the failure to use the de-
vice for its intended purpose or for damage caused by external forces or any other external
factors.
ÎRefertothetechnicaldataandnameplateforlimitsandeldsofapplicationaswellas
possible uses.
Reasonably foreseeable misuse
The solenoid valve is not suitable for the following applications:
−Useoutsidethelimitsdenedduringsizingandbythetechnicaldata
Furthermore, the following activities do not comply with the intended use:
−Use of non-original spare parts
−Performingmaintenanceactivitiesnotspecied
Qualications of operating personnel
The solenoid valve must be mounted, started up, serviced and repaired by fully trained and
qualiedpersonnelonly;theacceptedindustrycodesandpracticesaretobeobserved.Ac-
cording 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
applicable standards.
Explosion-protected versions of this device are to be operated only by personnel who has un-
dergone special training or instructions or who is authorized to work on explosion-protected
devices in hazardous areas.

6 EB 3963 EN
Safety instructions and measures
Personal protective equipment
Personalprotectiveequipmentisnotrequiredtomountoroperatethesolenoidvalve.Work
on the control valve may be necessary when mounting or removing the solenoid valve.
ÎObservetherequirementsforpersonalprotectiveequipmentspeciedinthevalvedocu-
mentation.
ÎCheck with the plant operator for details on further protective equipment.
Revisions and other modications
Revisions,conversionsorothermodicationsoftheproductarenotauthorizedbySAMSON.
They are performed at the user's own risk and may lead to safety hazards, for example. Fur-
thermore, the product may no longer meet the requirements for its intended use.
Warning against residual hazards
The solenoid valve has a direct effect on the control valve when it has been installed. To
avoid personal injury or property damage, plant operators and operating personnel must
prevent hazards that could be caused in the control valve by the process medium, the operat-
ing pressure, the signal pressure or by moving parts by taking appropriate precautions. They
must observe all hazard statements, warning and caution notes in these mounting and oper-
ating instructions, especially for installation, start-up and service work.
Responsibilities of the operator
The operator is responsible for proper operation and compliance with the safety regulations.
Operators are obliged to provide these mounting and operating instructions as well as the
referenced documents to the operating personnel and to instruct them in proper operation.
Furthermore, operators must ensure that operating personnel or third persons are not ex-
posed to any danger.
Responsibilities of operating personnel
Operating personnel must read and understand these mounting and operating instructions as
wellasthereferenceddocumentsandobservethespeciedhazardstatements,warnings
and caution notes. Furthermore, the operating personnel must be familiar with the applicable
health, safety and accident prevention regulations and comply with them.

EB 3963 EN 7
Safety instructions and measures
Servicing explosion-protected devices
If a part of the device on which the explosion protection is based needs to be serviced, the
devicemustnotbeputbackintooperationuntilaqualiedinspectorhasassessedit
accordingtoexplosionprotectionrequirements,hasissuedaninspectioncerticate,orgiven
thedeviceamarkofconformity.Inspectionbyaqualiedinspectorisnotrequiredifthe
manufacturer performs a routine test on the device before putting it back into operation.
Document the passing of the routine test by attaching a mark of conformity to the device.
Replace explosion-protected components only with original, routine-tested components by the
manufacturer.
Devices that have already been operated outside hazardous areas and are intended for fu-
ture use inside hazardous areas must comply with the safety requirements placed on serviced
devices. Before being operated inside hazardous areas, test the devices according to the
specicationsforservicingexplosion-protecteddevices.
Maintenance, calibration and work on equipment
ÎOnly use intrinsically safe current/voltage calibrators and measuring instruments for in-
terconnection with intrinsically safe circuits to check or calibrate the equipment inside or
outside hazardous areas.
ÎObservethemaximumpermissiblevaluesspeciedinthecerticatesforintrinsicallysafe
circuits.
Referenced standards and regulations
The solenoid valves comply with the requirements of Directives 2014/30/EU and 2014/35/
EU for not explosion-protected applications as well as Directive 2014/34/EU for explosion-
protected applications. The declaration of conformity includes information about the applied
conformity assessment procedure. This declaration of conformity is included in the appendix
of these instructions.
Referenced documentation
The following documents apply in addition to these mounting and operating instructions:
−The mounting and operating instructions of the components on which the solenoid valve
is mounted (valve, actuator, valve accessories etc.)
−Safety manual of the solenoid valve uSH3963

8 EB 3963 EN
Safety instructions and measures
1.1 Notes on possible severe personal injury
DANGER
!
Risk of electric shock.
Before starting up the solenoid valve, electrical installation work must be performed. An
electric shock due to incorrect work practices may cause death.
ÎBefore connecting wiring, performing any work on the device or opening the device,
disconnect the power supply and protect it against unintentional reconnection.
ÎFor electrical installation, observe the relevant electrotechnical regulations and the
accident prevention regulations that apply in the country of use.
ÎInGermany,observetheVDEregulationsandtheaccidentpreventionregulationsof
the employers’ liability insurance.
Risk of fatal injury due to the formation of an explosive atmosphere.
Incorrect installation, operation or maintenance of the solenoid valve in potentially ex-
plosive atmospheres may lead to ignition of the atmosphere and cause death.
ÎThefollowingregulationsapplytoinstallationinhazardousareas:EN60079-14:
2008(VDE0165,Part1).
ÎInstallation, operation or maintenance of the solenoid valve must only performed by
personnel who has undergone special training or instructions or who is authorized
to work on explosion-protected devices in hazardous areas.
ÎObservethetypeofprotectionandtheconditionsforcontrolspecictothetypeof
protectionaccordingtotheECtypeexaminationcerticate.

EB 3963 EN 9
Safety instructions and measures
1.2 Notes on possible personal injury
WARNING
!
Risk of personal injury due to moving parts on the valve.
During operation and when the solenoid valve is triggered, the actuator stem moves
throughitsentiretravelrange.Injurytohandsorngersispossibleiftheyareinserted
into the valve.
ÎWhilethevalvemoves,donotinserthandsorngersintothevalveyokeanddonot
touch any moving valve parts.
1.3 Notes on possible property damage
NOTICE
!
Risk of damage to the solenoid valve due to incorrect mounting position.
ÎDo not mount the solenoid valve with the vent opening facing upward.
ÎDo not seal the vent opening when the device is installed on site.
Risk of damage to the solenoid valve due to impermissible pressures.
ÎDo not connect a supply pressure to the solenoid valve that exceeds the maximum
supply pressure.
Incorrect assignment of the terminals will damage the solenoid valve and will lead to
malfunction.
For the solenoid valve to function properly, the prescribed terminal assignment must be
observed.
ÎConnect the electrical wiring to the solenoid valve according to the prescribed termi-
nal assignment.

10 EB 3963 EN
Markings on the device
2 Markings on the device
2.1 Nameplate
Versions without explosion protection (example)
SAMSON
3963 -
Solenoid valve
U
N
=
See technical data for ambient temperature
Model 3963 -
Var.-ID
Serial no.
SAMSON AG D-60314 Frankfurt Made in Germany
1
2
3
4
5
6
Versions with explosion protection (example)
Solenoid valve
U
n
=
SAMSON
3963-
* See technical data and explosion-protection certificate
for permissible ambient temperature and maximum
values for connection to certified intrinsically safe circuits.
Model 3963 -
Var.-ID Serial no.
SAMSON AG D-60314 Frankfurt Made in Germany
1
26
3
4 5
7
1Productdesignation
2 Nominal signal
3 Model no.
4CongurationID
5 Serial number
6 Compliance
7Type of protection (for explosion-protected devices)