Samson 3966 Service manual

Translation of original instructions
EB 3966 EN
Edition March 2019
Type3966 Solenoid Valve

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 3966 EN

Contents
EB 3966 EN 3
1 Safety instructions and measures ...................................................................6
1.1 Notes on possible severe personal injury .........................................................9
1.2 Notes on possible personal injury ...................................................................9
1.3 Notes on possible property damage..............................................................10
2 Markings on the device ...............................................................................11
2.1 Nameplate ..................................................................................................11
2.2 Article code.................................................................................................12
2.3 Summary of explosion protection approvals...................................................14
3 Design and principle of operation ................................................................15
3.1 Accessories .................................................................................................16
3.2 Technical data .............................................................................................19
3.3 Dimensions in mm........................................................................................22
4 Measures for preparation............................................................................24
4.1 Unpacking ..................................................................................................24
4.2 Transporting ................................................................................................24
4.3 Storage.......................................................................................................24
5 Mounting and start-up.................................................................................25
5.1 Installation...................................................................................................25
5.1.1 DirectattachmentaccordingtoVDI/VDE3847 ..............................................26
5.1.2 RotaryactuatorsaccordingtoVDI/VDE3845................................................27
5.1.3 AttachmentaccordingtoIEC60534-6...........................................................27
5.2 Exhaust air feedback for single-acting actuators .............................................28
5.2.1 DirectattachmentaccordingtoVDI/VDE3847 ..............................................28
5.2.2 RotaryactuatorsaccordingtoVDI/VDE3845................................................28
5.2.3 AttachmentaccordingtoIEC60534-6...........................................................28
5.3 Pneumatic connections..................................................................................29
5.3.1 Connecting the supply air.............................................................................29
5.3.2 Port labeling................................................................................................29
5.3.3 Sizing of the connecting line .........................................................................29
5.3.4 Compressed air quality.................................................................................30
5.3.5 Pilot supply..................................................................................................30

Contents
4 EB 3966 EN
5.4 Electrical connections ...................................................................................31
5.4.1 ConditionsconcerningconnectionaccordingtoPTB08ATEX1024 .................31
5.4.2 Cable entry with cable gland ........................................................................32
5.4.3 Connect the electrical power .........................................................................33
6 Operation...................................................................................................33
7 Servicing.....................................................................................................33
7.1 Preparationforreturnshipment.....................................................................33
8 Malfunctions ...............................................................................................34
8.1 Emergencyaction ........................................................................................34
9 Decommissioning and removal ....................................................................35
9.1 Decommissioning.........................................................................................35
9.2 Removing the solenoid valve.........................................................................35
9.3 Disposal......................................................................................................35
10 Appendix....................................................................................................36
10.1 After-sales service........................................................................................36

EB 3966 EN 5

6 EB 3966 EN
Safety instructions and measures
1 Safety instructions and measures
Intended use
TheType3966SolenoidValveisusedtocontrolpneumaticactuatorswithNAMURinterface
accordingtoVDI/VDE3845,withintegralattachmentaccordingtoVDI/VDE3847orwith
NAMURribaccordingtoIEC60534.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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andservicedbyfullytrainedandqualied
personnel only; the accepted industry codes and practices are to be observed. 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
applicable standards.
Explosion-protected versions of this device must 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.

EB 3966 EN 7
Safety instructions and measures
Personal protective equipment
No personal protective equipment is required for the direct handling of the solenoid valve.
Work on the control valve may be necessary when mounting or removing the device.
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. To avoid personal injury or prop-
erty damage, plant operators and operating personnel must prevent hazards that could be
caused in the control valve by the process medium, the operating pressure, the signal pres-
sure or by moving parts by taking appropriate precautions. They must observe all hazard
statements, warning and caution notes in these mounting and operating instructions, espe-
cially for installation, start-up and service work.
If inadmissible motions or forces are produced in the pneumatic actuator as a result of the
supply pressure, it must be restricted using a suitable supply pressure reducing station.
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 to the operating
personnel and to instruct them in proper operation. Furthermore, the operator must ensure
that operating personnel or third persons are not exposed to any danger.
Responsibilities of operating personnel
Operating personnel must read and understand these mounting and operating instructions as
wellasthespeciedhazardstatements,warningandcautionnotes.Furthermore,theoperat-
ing personnel must be familiar with the applicable health, safety and accident prevention
regulations and comply with them.

8 EB 3966 EN
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accord-
ing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manu-
facturer 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 ex-
plosion-protected components only with original, routine-tested components by the manufac-
turer.
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theintrinsically
safe circuit.
Referenced standards and regulations
DeviceswithaCEmarkingfullltherequirementsoftheDirectives2014/30/EUand
2014/34/EU. This EU declaration of conformity is included in the Appendix of these instruc-
tions.
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.)

EB 3966 EN 9
Safety instructions and measures
1.1 Notes on possible severe personal injury
DANGER
!
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
(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EUtypeexaminationcerticate.
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.

10 EB 3966 EN
Safety instructions and measures
1.3 Notes on possible property damage
NOTICE
!
Risk of damage to the solenoid valve due to incorrect mounting position.
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.

EB 3966 EN 11
Markings on the device
2 Markings on the device
2.1 Nameplate
Version without explosion protection
SAMSON 3966
Solenoid valve U
N
=
See technical data for ambient temperature
Model 3966 - 000
Var.-ID
Serial no.
SAMSON AG D-60314 Frankfurt
Made in Germany
1
2
3
4 5
Version with explosion protection
SAMSON 3966
Solenoid valve U
N
* See technical data and explosion-protection certificate for
permissible ambient temperature and maximum values
for connection to certified intrinsically safe circuits.
Model 3966-110
Var.-ID Serial no.
SAMSON AG D-60314 Frankfurt
Made in Germany
0044
II 2 Ex ia IIC T6* Gb
II 2 D Ex ia IIIC T 80°C / Ex tb IIIC T 85°C* Db IP66
PTB 12 ATEX 2021
1
2
5
3 4
SAMSON 3966
Solenoid valve U
N
0044
Model 3966-210
Var.-ID Serial no.
SAMSON AG D-60314 Frankfurt Made in Germany
* See EC Type Exam. Certificate for further values
-55°C < Ta* < +60°C; P
max
< 4W
II 2 G Ex d IIC T6*
II 2 D Ex tD A21 IP66 T 80°C
PTB 08 ATEX 1024
1
2
5
3 4
1 Nominal signal
2 Article code
3CongurationID
4 Serial number
5 Device index

12 EB 3966 EN
Markings on the device
2.2 Article code
Solenoid valve Type3966- x x x x x x x x x x x x x x x x x
Type of protection
No explosion protection 0 0 0
ATEX
II 2 G Ex ia IIC T6 Gb
II2DExiaIIICT80°CDbIP66
II2DExtbIIICT85°CDbIP66
110
ATEX II 2 G Ex d IIC T6
II2DExtDA21IP66T80°C 210
FM AEx d IIC T6 … T4 2 3 0
CSA
Class I, Div 1 + 2, Groups A, B, C, D
Class II, Div 1 + 2, Groups E, F, G
Class III
Class1,Zone1,EXdIIC,T6...T4
ClassII,Zone21,EXtbIIICT85°C
Type4X,IP66
231
ATEX
II 3 G Ex ic IIC T6 Gc
II 3 G Ex nAc II T6 Gc
II3DExtcIIICT80°CDcIP66
81 0
Nominal signal
6VDC 1
12VDC 2
24VDC 3
120VDC 4
240VAC 5
120VAC 6
Manual override
Without 0
Pushbutton underneath the enclosure cover 1
Switching function
Without (pilot valve as spare part) 0
3/2-way function with spring-return mechanism 1
Attachment
Without (pilot valve as spare part) 0
RotaryactuatorswithNAMURinterfaceaccordingtoVDI/VDE3845 1
LinearactuatorswithNAMURribaccordingtoIEC60534,forpanel,
wall or rail mounting 2
MountingblockwithpositionerforSAMSONType3277Pneumatic
Actuator 3

EB 3966 EN 13
Markings on the device
Solenoid valve Type3966- x x x x x x x x x x x x x x x x x
KVS 1)
Without (pilot valve as spare part) 0 0
0.9 0 1
Enclosure material
Aluminum 1
Pneumatic connection
Without (pilot valve as spare part) 0
G¼ 1
¼NPT 2
Pilot supply
Internal supply over port 1 (when mounted onto actuators for on/off service) 1
External supply over port 9 (when mounted onto actuators for throttling service or
mounting block with positioner) 2
Electrical connection
M20x1.5 cable entry 0 0
½NPTcableentry 0 1
Cable gland M20x1.5 made of black polyamide 1 0
Cable gland M20x1.5 made of blue polyamide 1 1
Cable gland M20x1.5, black polyamide (CEAG) 1 3
Cable gland M20x1.5, nickel-plated brass 1 4
Cable gland M20x1.5, nickel-plated brass, blue 1 5
Cable gland M20x1.5, blue polyamide (CEAG) 1 6
Degree of protection
IP66 1
Type4X 2
Ambient temperature 2)
–20to+80°C 0
–45to+80°C 1
Safety function
Without 0
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 depends on the permissible ambient temperature of the cable
gland, type of protection and temperature class.

14 EB 3966 EN
Markings on the device
2.3 Summary of explosion protection approvals
Certication Type of protection/comments
Type3966
-110
EC type examina-
tioncerticate
Number PTB10ATEX2021 II 2 G Ex ia IIC T6 Gb
II2DExiaIIICT80°CDbIP66
II2DExtbIIICT85°CDbIP66
Date 2013-05-27
-210
EC type examina-
tioncerticate
Number PTB08ATEX1024 II 2 G Ex d IIC T6
II2DExtDA21IP66T80°C
Date 2008-05-06
-230
FM Number 3037211 AEx d IIC T6 … T4
Date 2011-03-08
-231
CSA Number 70004606 Class I, Div 1 + 2, Groups A, B, C, D
Class II, Div 1 + 2, Groups E, F, G
Class III
Class1,Zone1,EXdIIC,T6...T4
ClassII,Zone21,EXtbIIICT85°C
Type4X,IP66
Date 2016-06-06
-810
EC type examina-
tioncerticate
Number PTB12ATEX2021 II 3 G Ex ic IIC T6 Gc
II 3 G Ex nAc II T6 Gc
II3DExtcIIICT80°CDcIP66
Date 2013-05-27

EB 3966 EN 15
Design and principle of operation
3 Design and principle of oper-
ation
The solenoid valve consists of an electro-
pneumatic binary converter with manual
override and integrated poppet valve actuat-
ed on one side with return spring.
The pilot supply for the electropneumatic bi-
nary converter is fed internally through port
1 or externally through port 9. By turning the
turnable gasket, the pilot supply can be
changed.
In the idle position, the armature is pressed
against the seat of the supply air port by the
spring. The solenoid coil is energized by an
electric binary signal which causes the
armature to be lifted out of the seat of the
supply air port against the force of the
spring and drawn into the exhaust air port.
This causes the pressure to rise above the
activation pressure of the integrated poppet
valve and switches it to the operating
position. After the solenoid coil is de-
energized, the integrated poppet valve is
switched to the idle position again by a
return spring.
+
–
Fig.1: Functional diagram
Nominal
signal
External
pilot supply
Port 9
Port 1
Port 3
Port 2

16 EB 3966 EN
Design and principle of operation
3.1 Accessories
General accessories
Designation Order no.
¼”screwplug,stainlesssteel 0070-0799
¼”screwplug,nickel-platedbrass 0070-0804
ScrewplugG¼(forpneumaticconnection) 0070-0858
Screwplug¼NPT(forpneumaticconnection) 0070-0862
NBRO-ring14x1.5(for¼”screwplug) 8421-0070
VMQ switching diaphragm (for poppet valve) 0520-1428
¼”lter(forscrewingintotheports) 0550-0213
Stainless steel restriction (for screwing into port 1) 0570-0390
NBRO-ring7.5x2(forNAMURinterface,2pcs.required) 8421-0273
NBR O-ring 16x2 (for NAMUR interface, 2 pcs. required) 8421-0364
NBR O-ring 40x2 (inner seal between pilot valve and poppet valve) 8421-1002
NBR O-ring 56x2 (middle seal between pilot valve and poppet valve) 8421-0124
NBRO-ring70x2(externalsealbetweenpilotvalveandpoppetvalve) 0520-0099
NBRO-ring18x2(forcablegland) 8421-0067
HexagonsocketscrewISO4762,M5x20,stainlesssteel(forfasteningthepilotvalve
onto the poppet valve, 4 pcs. required)
8333-1265
WasherISO7089-5,stainlesssteel(forhexagonsocketscrews,4pcs.required) 8390-0061
Clamp, nickel-plated brass, with ground symbol (for equipotential bonding terminals) 8804-0322
SlottedpanheadscrewISO1580,M4x8,nickel-platedbrass(forequipotential
bonding terminals)
8330-0688
SpringwasherDIN128,B4form,stainlesssteel(forequipotentialbondingterminals) 8392-0654
HexagonsocketscrewDIN7984,M4x10,stainlesssteel(tolocktheenclosurecover) 8333-0774
NBR turnable gasket (to convert internal/external pilot supply) 0430-1151
Fasteningplate,aluminum,powdercoated,graybeigeRAL1019(forturnablegas-
ket)
0360-2785
Fastening plate, stainless steel (for turnable gasket) 0360-3693
CapscrewwithslotISO1207,M3x8,stainlesssteel(forfasteningplate) 8333-0095

EB 3966 EN 17
Design and principle of operation
Designation Order no.
Cable gland (without explosion protection, Ex i, Ex nA)
M20x1.5, black polyamide 8808-1011
M20x1.5, blue polyamide 8808-1012
M20x1.5, black polyamide (CEAG) 8808-0178
M20x1.5, blue polyamide (CEAG) 8808-0179
M20x1.5, nickel-plated brass 1890-4875
M20x1.5, nickel-plated brass, blue 1890-4876
AdapterM20x1.5to½NPTmadeofaluminum,powdercoated,graybeige
RAL1019
0310-2149
MountingbaseaccordingtoEN60715includingstainlesssteelmountingmaterial
ForG-prolerail32(2pcs.required) 1400-5930
For35mmtop-hatrailmounting(2pcs.required) 1400-5931
Mounting plate for wall mounting including stainless steel mounting material 1400-6726
Filtercheckvalvewithsinteredpolyethylenelterdiskpolyethylenefornoisereduc-
tion,
¼”connection,stainlesssteel,degreeofprotectionIP66 1790-7253
¼”connection,stainlesssteel,degreeofprotectionNEMA4 1790-9646
Accessories for direct attachment to Type3277 Linear Actuators
Designation Order no.
MountingblockforSAMSONType3277PneumaticActuator
G¼connection 1400-8817
¼NPTconnection 1400-8818
Pressure gauge mounting block, 1x Output and 1x Supply, made of stainless steel/
brass (for mounting block)
1400-6950
240cm²actuatorarea,zinc-platedsteel 1400-6444
240cm²actuatorarea,stainlesssteel 1400-6445
350cm²actuatorarea,zinc-platedsteel 1400-6446
350cm²actuatorarea,stainlesssteel 1400-6447
700cm²actuatorarea,zinc-platedsteel 1400-6448
700cm²actuatorarea,stainlesssteel 1400-6449

18 EB 3966 EN
Design and principle of operation
Accessories for attachment according to IEC60534-6
Designation Order no.
Adapter plate for linear actuators with NAMUR rib according to IEC 60534-6-1, for
panel,wallorrailmounting,includingstainlesssteelmountingmaterial,ltersin
ports and screw plug made of stainless steel with NBR O-ring in port 9,
Aluminum,powdercoated,graybeigeRAL1019,G¼connection 1400-9598
Aluminum,powdercoated,graybeigeRAL1019,¼NPTconnection 1400-9599
Stainlesssteel,G¼connection 1400-9600
Stainlesssteel,¼NPTconnection 1400-9601
Mountingpartsforvalveswithrod-typeyokes(18to32mmroddiameter) 1400-5342
Accessories for attachment to rotary actuators
Designation Order no.
For KVScoefcient0.9;AdapterplateforNAMURinterface½onNAMURrib½
Aluminum,powdercoated,graybeigeRAL1019 1380-1652

EB 3966 EN 19
Design and principle of operation
3.2 Technical data
Technical data
General data
Design Solenoidwithapper/nozzleassemblyandpoppetvalve
Material
Enclosure Aluminum,powdercoated,graybeigeRAL1019(pilotvalve),
Black anodized aluminum (poppet valve), stainless steel (optional)
Mounting plate for internal/
external pilot supply
Aluminum,powdercoated,graybeigeRAL1019orstainlesssteel(optional)
Gaskets and diaphragms Nitrile butadiene rubber (NBR), vinyl methyl silicone rubber (VMQ)
External parts Stainless steel
Electromagnetic compatibility ComplyingwithEN61000-6-2,EN61000-6-3andNAMURRecommendation
NE21
Degree of protection IP66,Type4X
Explosion protection Seesection2.3onpage14.
Electrical connection M20x1.5(½NPT)
Cable entry To a two-pole screw terminal and two equipotential bonding terminals (inside and
outside)
Connecting cable Wirecross-section0.2to2.5mm²(exible)or0.2to4mm²(rigid)
Pneumatic connection G¼(¼NPT)andNAMURinterface¼”accordingtoVDI/VDE3845
Ambient temperature 1) –20to+80°C
–45to+80°C
Weight, approx. 1.60kg,
1.95kgwithaluminumadapterplate
1) The maximum permissible ambient temperature depends on the permissible ambient temperature of the cable
gland, type of protection and temperature class.

20 EB 3966 EN
Design and principle of operation
Pneumatic data
Design Plug/seat poppet valve with return spring
Switching function 3/2-way function,
can be connected as normally closed (NC) or normally open (NO)
KVS 1)
Normally closed (NC) 0.35(supplyowdirectionfrom1to2includingrestriction)
0.90(supplyowdirectionfrom1to2withoutrestriction)
0.90(exhaustowdirection2to3)
Normally open (NO) 0.90(supplyowdirectionfrom3to2)
0.90(exhaustowdirectionfrom2to1withoutrestriction)
0.35(exhaustowdirectionfrom2to1includingrestriction)
Compressed air quality
accordingtoISO8573-1
Particle size and density: Class 4 · Oil content: Class 3,
Pressuredewpoint:Class3oratleast10Kbelowthelowestambienttemperatureto
be expected
Flow rate At least 1.6 times greater KVScoefcientthantheKVScoefcientofthedevice
Pilot supply pressure
Internal (1) 1.4to6.0bar
External (9) 1.4to6.0bar(with0to6.0baroperatingpressure),
1.9to6.0bar(with0to10.0baroperatingpressure)
Operating pressure 0to6.0bar2)
0to10.0bar3)
Air consumption of the pilot
valvewith1.4barpilot
supply
≤25l/h(inoperatingposition)
≤80l/h(inidleposition)
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) With internal pilot supply
3) Withexternalpilotsupply,operatingpressuremax.6.0barwithtypeofprotectionExd