Samson 3964 Service manual

Translation of original instructions
EB 3964 EN
Type3964 Solenoid Pilot Valve with and without CNOMO adapter plate
Type3964 Solenoid Pilot Valve
Edition December 2011

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 3964 EN

Contents
EB 3964 EN 3
1 General information......................................................................................4
1.1 Model number and device index .....................................................................4
1.2 Technical data ...............................................................................................6
2 Installation....................................................................................................8
2.1 Devices with interface for direct mounting ........................................................8
2.2 Devices with CNOMO adapter plate without booster........................................9
2.3 Devices with CNOMO adapter plate and booster...........................................10
3 Pneumatic connection ..................................................................................10
3.1 Pilot supply..................................................................................................10
3.2 Devices with interface for direct mounting ......................................................11
3.3 Devices with CNOMO adapter plate.............................................................12
4 Electrical connection ....................................................................................12
4.1 Connecting cable.........................................................................................13
4.2 Devices for Zones 2 and 22..........................................................................13
4.3 Degree of protection.....................................................................................14
4.4 Manual override..........................................................................................14
4.5 Certicates ..................................................................................................14

4 EB 3964 EN
General information
1 General information
The devices are to be mounted, started up
or operated only by trained and experi-
enced personnel familiar with the devices.
According to these mounting and operating
instructions, trained personnel refers to indi-
viduals who are able to judge the work they
are assigned to and recognize possible haz-
ards due to their specialized training, their
knowledge and experience as well as their
knowledge of the applicable standards.
Explosion-protected versions of this device
must be operated only by personnel who has
undergone special training or instructions or
who is authorized to work on explosion-pro-
tected devices in hazardous areas.
Proper shipping and storage are assumed.
Fortechnicaldata,orderingspecications,
spare parts and accessories, see Data Sheet
uT3964.
1.1 Model number and device
index
The model number and device index are
speciedonthenameplate:
3964-XXXXXXXXXXXXX
Model number Device index
XX

EB 3964 EN 5
General information
Article code of the Type3964 Solenoid Pilot Valve
Type3964-XXXXXXXXXXXX000
Type of protection
No explosion protection 0
II2GExiaIIC(ATEX) 1
ExiaIIC(CSA)andAExiaIIC(FM) 3
II3GExnAIIT6Gc(ATEX) 8
Nominal signal
6VDC 1
12VDC 2
24VDC 3
24VAC 8
Manual override
Without manual override 0
Pushbutton 1
Pushbutton/switch 2
Mounting Interface for direct mounting 0
CNOMOadapterplate,30mm 1
KVS coefcient 0.01 without booster 0
0.02 including booster 1
Pressure reducer Without pressure reducer 0
Electrical connection
DeviceconnectoraccordingtoEN175301-803withoutcable
socket 0
Device connector according to general industry standard 1
DeviceconnectoraccordingtoEN175301-803withcable
socket 3
Degree of protection IP54 0
IP20 2
Pilot supply
1.4to2.0bar 0
3.0to3.6bar 1
3.0to8.0bar 2
Indicator Without indicator 0
Permissible ambient
temperature
–25to+60°C 0
–25to+80°C 1
–45to+80°C 2
–45to+60°C 3
Safety function Without safety function 0
SIL4 1
Special version Without special version 0 0 0

6 EB 3964 EN
General information
1.2 Technical data
Table1: General data
Design Solenoidwithapper/nozzleassembly,
diaphragm switching element with return spring as booster (optional)
Degree of protection IP20/IP54(without/withmountedcablesocket)
Material
Enclosure Polyamide PA6-3-T, black, polyoxymethylene, green (booster)
Adapter plate Black anodized aluminum
Screws Stainlesssteel1.4571
Springs Stainless steel 1.4310
Seals Silicone rubber, Perbunan
Diaphragms Chloroprenerubber57Cr868(booster,at–25to+60°C),
siliconerubber(booster,at–40to+60°C)
Ambient temperature See Electrical data and Pneumatic data
Mounting position Any desired position
Approx. weight
50 g,
100 g (with CNOMO adapter plate),
150 g (with CNOMO adapter plate and booster)
Table2: Pneumatic data
Pilot supply Medium Instrument air, free from corrosive substances
Pressure 1.4to2.0bar,3.0to3.6bar,3.0to8.0bar
Output signal
Without
booster
≥1.2barat1.4barpilotsupply,
≥1.8barat2.0barpilotsupply,
≥2.5barat3.6barpilotsupply
With booster Same pressure as pilot supply
Air consumption ≤60l/hat1.4barpilotsupplyinneutralposition
≤15l/hat1.4barpilotsupplyinoperatingposition
KVS 1) 0.01 (without booster),
0.02 (with booster)
Ambient temperature 2)
–45to+80°C,
–25to+60°C(boosterwithdiaphragmmadeofchloroprenerubber57Cr868),
–45to+60°C(boosterwithdiaphragmmadeofsiliconerubber)
Connection Connection for direct mounting, optionally with CNOMO adapter plate or
connecting plate
1) Theairowratewhenp1=2.4barandp2=1.0bariscalculatedusingthefollowingformula:
Q = KVS x 36.22 in m³/h.
2) The maximum permissible ambient temperature of the solenoid pilot valve depends on type of protection and
temperature class.

EB 3964 EN 7
General information
Table3: Electric data
Type3964 -X1 -X2 -X3 -X8
Nominal signal UN
6VDC
max.27V1)
12VDC
max.25V1)
24VDC
max.32V1)
24VAC
max.36V1)
fN–48to62Hz
Switching point
ON
U80°C ≥4.8V ≥9.6V ≥18.0V 19to36V
I20°C ≥1.41mA ≥1.52mA ≥1.57mA ≥1.9mA
P20°C ≥5.47mW ≥13.05mW ≥26.71mW ≥0.04VA
OFF U–25°C ≤1.0V ≤2.4V ≤4.7V ≤4.5V
Impedance R20°C 2.6kΩ 5.5kΩ 10.7kΩ Approx.10kΩ
Temperatureinuence 0.4%/°C 0.2%/°C 0.1%/°C 0.1%/°C
Type of protection Ex ia IIC2) for use in hazardous areas (Zone1)
–
Type3964 -11 -12 -13
Maximumvalueswhenconnectedtoacertiedintrinsicallysafecircuit
Output voltage UiPairs of values Ui/Iiapplyto6,12,24VDCnominal
signals:
25V/150mA,27V/125mA,28V/115mA,
30V/100mA,32V/85mA
Output current Ii
Outer capacitance Ci≈0
Outer inductivity Li≈0
Ambient temperature in
temperature class
T6 –20to+60°C
T5 –20to+70°C
T4 –20to+80°C
Type of protection Ex nA II3) for use in hazardous areas (Zone2)
Type3964 -81 -82 -83
Ambient temperature in
temperature class
T6 –45to+60°C
T5 –45to+70°C
T4 –45to+80°C
Switching time ≤15ms
Temperatureinuence 0.4%/°C 0.2%/°C 0.12%/°C 0.15%/°C
Connection ConnectortypeCaccordingtoEN175301-803,distancebetweencontacts
8mm4)orindustrialstandardtypeC,distancebetweencontacts9.4mm5)
1) Maximumpermissiblevalueat100%dutycycle.ThemaximumpermissiblevalueUiapplies to explosion-
protected versions.
2) II2GExiaIICT6(Zone1)accordingtoECTypeExaminationCerticatePTB98ATEX2047
3) II3GExnAIIT6(Zone2)accordingtoStatementofConformityPTB06ATEX2193X
Note:amanufacturer'sdeclarationofuseinexplosiveatmospheres(Zone22)isavailableonrequest.
4) The cable socket with seal (option) is included in the scope of delivery.
5) The cable socket with seal is not included in the scope of delivery.

8 EB 3964 EN
Installation
2 Installation
Before installation, depressurize the relevant
plant section.
Do not open the enclosure.
Solenoid pilot valves with an interface for
direct mounting can be mounted on
connecting plates. Solenoid pilot valves with
CNOMO adapter plate can be mounted to
Type3756BoosterValvesandvalves
accordingtoISO5999-1.Observethe
corresponding mounting instructions (see
section2.1).
The valve can be mounted in any desired
position. To ensure reliable functioning, do
notcovertheexhaustairlterintegratedinto
the enclosure. Mount the cable socket in such
a way that the cable gland faces downward
(in cases where this is not possible, mount it
inthehorizontalposition).SeeFig.1.
On mounting, make sure that at least
300mmclearanceiskeptabovetheenclo-
sureandatleast200mmclearanceatthe
electrical connection.
Exhaust
airlter
Fig.1: Type3964·Installation
WARNING
!
2.1 Devices with interface for
direct mounting
−Type3964-XXX000X000XX
Push the device with interface for direct
mounting onto the connecting plate () un-
derneathofthexingscrewanduseahold-
er () and a hexagon socket screw () to
fasten it. Make sure the two O-rings are
seated properly on the interface of the con-
nectingplate(seeFig.2).
Any device spaces on the connecting plate
that are not used must be covered by a dum-
my plate () and the output port sealed by a
screw plug (). Push the dummy plate ()
underneaththeheadofthexingscrewand
use a holder () and a hexagon socket
screw ()tofastenit(seeFig.2).
The mounting accessories are included in
scope of delivery of the connecting plate.
The connecting plate () can be mounted
with two M3 cap screws on a mounting plate
or with one or two mounting bases () and
cap screws ()ona35mmtop-hatrail(see
Fig.2).

EB 3964 EN 9
Installation
Fixing screw
Accessories and spare parts Order no.
Connecting plate For two
valves
For four
valves
1890-5789 1890-5790
1× Dummy plate 1400-7588
1× Blanking plug M5x4 If required
1× Holder 1400-7587
1× M2.5x8 hexagon
socket screw
ISO4762
2 pieces 4 pieces
Included in the scope of
delivery of the
connecting plate
1× Mounting base for
35mmtop-hatrail 1400-5931
1 piece 2 pieces
1× Cap screw
ISO1207–M3×8 If required
Fig.2: Type3964·Accessories
2.2 Devices with CNOMO
adapter plate without
booster
−Type3964-XXX100X00XXX
Devices with CNOMO adapter plate are
mounted using two hexagon socket screws
and two spring washers onto the
boostervalve(seeFig.3).Makesurethetwo
O-rings are seated correctly at the CNOMO
interface of the booster valve.
The mounting accessories are included in
scope of delivery.

2x M4x16 hexagon socket screw
ISO4762
2x spring washer B4
Fig.3: Type3964 with CNOMO adapter
plate without booster

10 EB 3964 EN
Pneumatic connection
2.3 Devices with CNOMO
adapter plate and booster
−Type3964-XXX110X00XXX
Devices with CNOMO adapter plate and
booster are mounted using two hexagon
socket screws and two spring washers 
ontotheboostervalve(seeFig.4).Make
sure the two O-rings are seated correctly at
the CNOMO interface of the booster valve.
The mounting accessories are included in
scope of delivery.

2x M4x22 hexagon socket screw
ISO4762
2x spring washer B4
Fig.4: Type3964 with CNOMO adapter
plate and booster
3 Pneumatic connection
Run and attach the connecting lines and
screw joints according to good professional
practice. Check them for leakage and dam-
age at regular intervals and repair them, if
necessary. Before starting any repair work,
depressurize any open connecting lines.
The maximum permissible pilot supply pres-
sure must not be exceeded.
3.1 Pilot supply
Medium
Instrument air, free from corrosive substances
Pressure
RefertoTable5onpage12
Table4: Compressed air quality
Compressed air quality according to ISO8573-1
Particle size
and quantity
Oil content Pressure dew point
Class 4 Class 3 Class 3
≤5µmand
1000/m³
≤1mg/m³ –20°Coratleast10K
below the lowest
ambient temperature to
be expected
WARNING
!

EB 3964 EN 11
Pneumatic connection
3.2 Devices with interface for
direct mounting
−Type3964-XXX000X000XX
The connecting plate is used for pneumatic
connection(seeFig.5).
PreferablyttheoutputportswithM5screw
ttingsfor1.8×1mmhose() and the pilot
supply port with an M5 male connector for
4×1mmhose(). Use an M5 seal () for
all connections.
1.8×1mmhoses(orderno.8082-0049)
and4×1mmhoses(orderno.8082-0355)
ensure reliable connection. Short switching
times can be achieved by keeping the hose
length as short as possible.
Topreventdirtparticlesentering,alter()
with30µmmeshsizeisinstalledinthepilot
supplyport.Whenthelterisblocked,re-
move the screw plug () and seal () from
thelterinsert() and use a screwdriver
(4.5mmblade)tounscrewthelter().
Cleanorexchangethelter.








Accessories and spare parts Order no.
M5 male connector fo
4x1mmhose 0790-6123
M5screwttingfor
1.8×1mmhose 0230-2066
M5 seal 0790-6118
Filter 0550-0652
Filter insert 0320-1964
ScrewplugDIN908–G¼ 8323-0032
Seal13.5×17×1.5 8414-0140
Fig.5: Type3964 with interface for direct
mounting

12 EB 3964 EN
Electrical connection
3.3 Devices with CNOMO
adapter plate
−Type3964-XXX100X000XX
The air is connected over the CNOMO inter-
faceattheboostervalve(seeTable5).
Table5: Connection data for booster valves
with CNOMO interface
Version
Pres-
sure Port
Valve
size
Type...BoosterValve
3756-1XX1XXXX1) 2.4 to
3.6bar
9DN4
4DN10
3756-1XX0XXXX
2.4 to
3.6bar 9DN4
1.4 to
1.6bar 1DN6
Valvesaccordingto
ISO5599-11)2)
2.4 to
3.6bar
12 and
14 3)
1) OnlyforType3964-XXXX10XXX0XXSolenoidPilot
Valveswithbooster
2) See technical data provided by the valve
manufacturer for the minimum pressure
3) See technical data provided by the valve
manufacturer for the valve size
4 Electrical connection
For electrical installation, observe the rele-
vant electrotechnical regulations and the ac-
cident prevention regulations that apply in
the country of use. In Germany, these are
the VDE regulations and the accident pre-
vention regulations of the employers’ liability
insurance.
The following regulations apply to instal-
lation in hazardous areas: EN60079-
14:2008 (VDE 0165, Part1) Explosive At-
mospheres– Electrical Installations Design,
Selection and Erection.
The specications in the EC Type Examina-
tion Certicate PTB98ATEX2047 for
Zone1 (see page15) and the Statement
of Conformity PTB01ATEX2193X for
Zone2 (page20) apply for connection to
intrinsically safe current circuits.
WARNING
!

EB 3964 EN 13
Electrical connection
4.1 Connecting cable
A connector type C according to
EN175301-803(distancebetweencontacts
8mm)oraconnectortypeCaccordingto
industrial standard (distance between con-
tacts9.4mm)isusedfortheelectricalcon-
nection.
Observe clause12 of EN60079-14: 2008
(VDE0165,Part1)forinstallationofthe
intrinsicallysafecircuits.Clause12.2.2.7
applies when running multi-core cables and
wires with more than one intrinsically safe
circuit.
Preferably use connecting lines with mini-
mum0.5mm²conductorcross-sectionand
3.5to6mmoutsidediameter.
The radial thickness of the insulation of a
conductor for common insulating materials
(e.g. polyethylene) must not be smaller than
0.2mm.Thediameterofanindividualwire
inane-strandedconductormustnotbe
smallerthan0.1mm.Protecttheconductor
ends against splicing, e.g. by using wire-end
ferrules.

1
2
Fig.6: Wiring diagram for connector
Adhere to the terminal assignment. Switch-
ing the assignment of the electrical terminals
may cause the explosion protection to be-
come ineffective.
Do not loosen enameled screws in or on the
housing.
The maximum permissible values specied in
the EC type examination certicates apply
when interconnecting intrinsically safe elec-
trical equipment (Ui or U0, li or I0, Pior P0, Ci
or C0and Lior L0). See page15.
4.2 Devices for Zones 2 and
22
In equipment operated according to type of
protectionExnAII(non-sparkingequipment)
accordingtoEN60079-15:2003,circuits
may be connected, interrupted or switched
while energized only during installation,
maintenance or repair.
Equipment connected to energy-limited cir-
cuitswithtypeofprotectionExnL(ener-
gy-limited equipment) according to
EN60079-15:2003maybeswitchedunder
normal operating conditions.
Themaximumpermissiblevaluesspeciedin
the statement of conformity or its addenda
(seepage13) apply when interconnecting
the equipment with energy-limited circuits in
typeofprotectionExnLIIC.
WARNING
!

14 EB 3964 EN
Electrical connection
4.3 Degree of protection
The degree of protection (according to
IEC60529: 1989) is only guaranteed when
the cable socket is mounted with seal under-
neath it and the connections have been
properly mounted.
4.4 Manual override
The solenoid pilot valves can be optionally
ttedwithamanualoverride() to allow
the device to be manually operated when a
nominalsignalisnotavailable(seeFig.7).
Use solenoid pilot valves without manual
override for safety circuits.
4.5 Certicates
Thecerticatesvalidatthetimewhenthese
instructions were published are included on
the next pages.
Thelatestcerticatescanbefoundonour
website (www.samson.de > Product selector
>Valveaccessories>Producttype>Down-
loads>Certicates).
WARNING
!
WARNING
!
Manual override:
– Press pushbutton with a pin
–Useascrewdriver(4.5mmblade)to
push and turn the pushbutton/switch
clockwiseby90°.Tounlock,turnitin
the other direction.
Fig.7: Type3964 with manual override

EB 3964 EN 15

16 EB 3964 EN

EB 3964 EN 17

18 EB 3964 EN

EB 3964 EN 19

20 EB 3964 EN