Samson 2780-1 Service manual

Translation of original instructions
EB 5840 EN
Type2780-1 and Type2780-2 Pneumatic Actuators
Actuator area: 120cm²
Edition July 2019
Type2780‑1 Type2780‑2

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 5840 EN

Contents
EB 5840 EN 3
1 Safety instructions and measures ................................................................1-1
1.1 Notes on possible severe personal injury ......................................................1‑4
1.2 Notes on possible personal injury ................................................................1‑4
1.3 Notes on possible property damage.............................................................1‑6
2 Markings on the device ..............................................................................2-1
2.1 Actuator nameplate.....................................................................................2‑1
3 Design and principle of operation ...............................................................3-1
3.1 Direction of action.......................................................................................3‑1
3.2 Signal pressure routing................................................................................3‑1
3.3 Fail‑safe action ...........................................................................................3‑3
3.3.1 Version with direction of action "actuator stem extends".................................3‑4
3.3.2 Version with direction of action "actuator stem retracts" .................................3‑4
3.4 Accessories ................................................................................................3‑4
3.5 Technical data ............................................................................................3‑4
4 Shipment and on-site transport ...................................................................4-1
4.1 Accepting the delivered goods .....................................................................4‑1
4.2 Removing the packaging from the actuator ...................................................4‑1
4.3 Transporting and lifting the actuator .............................................................4‑1
4.3.1 Transporting the actuator.............................................................................4‑1
4.3.2 Lifting the actuator ......................................................................................4‑2
4.4 Storing the actuator.....................................................................................4‑2
5 Mounting ...................................................................................................5-1
5.1 Preparation for mounting.............................................................................5‑1
5.2 Mounting the actuator .................................................................................5‑1
5.2.1 Mounting the actuator onto the valve............................................................5‑2
5.2.2 Connecting the air supply............................................................................5‑3
6 Operation..................................................................................................6-1
6.1 Supply pressure in closed‑loop operation......................................................6‑2
7 Malfunctions ..............................................................................................7-1
7.1 Troubleshooting ..........................................................................................7‑1
7.2 Emergency action .......................................................................................7‑2

Contents
4 EB 5840 EN
8 Servicing and conversion work ...................................................................8-1
8.1 Periodic testing ...........................................................................................8‑2
8.2 Preparation for servicing or conversion work.................................................8‑3
8.3 Mounting the actuator on the valve after servicing or conversion work ............8‑3
8.4 Service work...............................................................................................8‑3
8.4.1 Replacing the diaphragm ............................................................................8‑3
8.5 Conversion work.........................................................................................8‑5
8.5.1 Reversing the direction of action (fail‑safe action) ..........................................8‑5
8.6 Ordering spare parts and operating supplies ................................................8‑6
9 Decommissioning .......................................................................................9-1
10 Removal ..................................................................................................10-1
10.1 Removing the actuator from the valve .........................................................10‑2
10.2 Relieving the spring compression in the actuator..........................................10‑2
11 Repairs ....................................................................................................11-1
11.1 Returning devices to SAMSON ..................................................................11‑1
12 Disposal...................................................................................................12-1
13 Appendix.................................................................................................13-1
13.1 Tightening torques, lubricants and tools ......................................................13‑1
13.2 Spare parts ..............................................................................................13‑1
13.3 After‑sales service.....................................................................................13‑4

EB 5840 EN 1-1
Safety instructions and measures
1 Safety instructions and measures
Intended use
The SAMSON Type2780 Actuator is designed for operating a mounted globe valve. In com‑
bination with the valve, the actuator is used to shut off the ow of liquids, gases or vapors in
the pipeline. The actuator is suitable for throttling service and can be used in HVAC plants.
The actuator is designed to operate under exactly dened conditions (e.g. thrust, travel).
Therefore, operators must ensure that the actuator is only used in operating conditions that
meet the specications used for sizing the actuator at the ordering stage. In case operators
intend to use the actuator 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 actuator is not suitable for the following applications:
−Use outside the limits dened during sizing and by the technical data
−Use outside the limits dened by the accessories connected to the actuator
Furthermore, the following activities do not comply with the intended use:
−Use of non‑original spare parts
−Performing service and repair work not described in these instructions
Qualications of operating personnel
The actuator 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. Accord‑
ing 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 appli‑
cable standards.

1-2 EB 5840 EN
Safety instructions and measures
Personal protective equipment
We recommend wearing the following personal protective equipment when handling the
Type2780 Pneumatic Actuator:
−Protective gloves and safety footwear when mounting or removing the actuator
−Eye protection and hearing protecting while the actuator is operating.
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.
Furthermore, the product may no longer meet the requirements for its intended use.
Safety devices
The Type2780 Actuator does not have any special safety equipment.
Warning against residual hazards
To avoid personal injury or property damage, plant operators and operating personnel must
prevent hazards that could be caused in the actuator by the process medium, stored spring
energy or by moving parts by taking appropriate precautions. They must observe all hazard
statements, warning and caution notes in these mounting and operating instructions.
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, the operator 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 5840 EN 1-3
Safety instructions and measures
Referenced standards and regulations
According to the ignition risk assessment performed in accordance with EN13463‑1:2009,
section 5.2, the non‑electrical actuators 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 Di‑
rective 2014/34/EU.
ÎFor connection to the equipotential bonding system, observe the requirements specied in
section 6.4 of EN60079‑14 (VDE0165 Part 1).
Referenced documentation
The following documents apply in addition to these mounting and operating instructions:
−Mounting and operating instructions for the mounted valve
−Mounting and operating instructions for mounted valve accessories (positioner, solenoid
valve etc.)
−uAB0100 for tools, tightening torques and lubricant

1-4 EB 5840 EN
Safety instructions and measures
1.1 Notes on possible severe personal injury
DANGER
!
Risk of bursting in the actuator.
Actuators are pressurized. Improper opening can lead to actuator components burst‑
ing.
ÎBefore starting any work on the actuator, depressurize all plant sections concerned
and the actuator.
1.2 Notes on possible personal injury
WARNING
!
Crush hazard arising from moving parts.
The actuator contains moving parts (actuator stem), which can injure hands or ngers if
inserted into the actuator.
ÎDo not touch the actuator stem or insert hands or nger into the yoke or beneath the
actuator stem while the air supply is connected to the actuator.
ÎWhile working on the actuator, disconnect and lock the pneumatic air supply as well
as the control signal.
ÎDo not impede the movement of the actuator stem by inserting objects into the yoke.
ÎBefore unblocking the actuator stem after it has become blocked (e.g. due to seizing
up after remaining in the same position for a long time), release any stored energy
in the actuator (e.g. spring compression). See 'Relieving the spring compression in
the actuator' in the 'Removal' section.

EB 5840 EN 1-5
Safety instructions and measures
WARNING
!
Risk of personal injury when the actuator vents.
The actuator is operated with air. As a result, air is vented during operation.
ÎInstall the control valve in such a way that vent holes are not located at eye level and
the actuator does not vent at eye level in the work position 1).
ÎUse suitable silencers and vent plugs.
ÎWear eye and hearing protection when working near the actuator.
Risk of personal injury due to preloaded springs.
Actuators with preloaded springs are under tension. These actuators are marked ac‑
cordingly by an adhesive label. Additionally, they can be identied by the longer bolts
with nuts protruding from the bottom diaphragm case. They allow the spring compres‑
sion to be relieved evenly when disassembling the actuator.
ÎBefore starting any work on the actuator, relieve the compression from the preload‑
ed springs. See 'Relieving the spring compression in the actuator' in the 'Removal'
section.
Risk of personal injury through incorrect operation, use or installation as a result of
information on the actuator being illegible.
Over time, markings, labels and nameplates on the actuator may become covered with
dirt or become illegible in some other way. As a result, hazards may go unnoticed and
the necessary instructions not followed. There is a risk of personal injury.
ÎKeep all relevant markings and inscriptions on the device in a constantly legible
state.
ÎImmediately renew damaged, missing or incorrect nameplates or labels.
1) If not described otherwise in the valve documentation, the work position for the control valve is the
front view looking onto the operating controls (including valve accessories).

1-6 EB 5840 EN
Safety instructions and measures
1.3 Notes on possible property damage
NOTICE
!
Risk of actuator damage due to excessively high or low tightening torques.
Observe the specied torques on tightening actuator components. Excessively tightened
torques lead to parts wearing out quicker. Parts that are not tightened far enough may
loosen.
ÎObserve the specied tightening torques (uAB0100).
Risk of actuator damage due to the use of unsuitable tools.
Certain tools are required to work on the actuator.
ÎOnly use tools approved by SAMSON (uAB0100).
Risk of actuator damage due to the use of unsuitable lubricants.
The lubricants to be used depend on the actuator material. Unsuitable lubricants may
corrode and damage the surface.
ÎOnly use lubricants approved by SAMSON (uAB0100).