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).

EB 5840 EN 2-1
Markings on the device
2 Markings on the device
2.1 Actuator nameplate
The nameplate is stuck on the diaphragm
casing. It includes all details required to
identify the device:
1Type number
2Conguration ID
3Serial number
4 Permissible supply pressure pmax
5Bench range in bar
6 Bench range in psi
7 Operating travel in mm
8 Symbol for manual override
9Symbol indicating fail‑safe action
Actuator stem extends (FA)
Actuator stem retracts (FE)
10 Date of manufacture (month and year)
SAMSON 2780
Pneumatic Actuator 120 cm²
Model
Var.-ID Serial no.
Air supply max.
SAMSON AG D-60314 Frankfurt Made in Germany
See technical data for ambient temperature
!
1
9
2 3
4
7
5
6
8
10
Fig.2-1: Nameplate of Type2780 Actuator

2-2 EB 5840 EN

EB 5840 EN 3-1
Design and principle of operation
3 Design and principle of oper-
ation
The pneumatic actuators are used especially
for attachment to Type3222 and Type3213
Valves. In this case, force‑locking attachment
is used.
The actuators mainly consist of two dia‑
phragm cases, the actuator stem (A2/A5),
rolling diaphragm (A48) and springs (A25‑
29). The housings have an actuator area of
120cm² and are made of die‑cast alumi‑
num.
The signal pressure creates a force at the di‑
aphragm surface, which is opposed by the
springs in the actuator. The direction of ac‑
tion of the actuator stem depends on how the
springs are installed in the actuator. The
springs may be tted into one another.
The Type2780‑2 Actuator is designed for
the direct attachment of a positioner as stan‑
dard. A yoke is located on the bottom dia‑
phragm case for attachment of a pneumatic
or electropneumatic positioner.
3.1 Direction of action
The direction of action is determined by how
the springs and diaphragm plate are ar‑
ranged in the actuator.
With direction of action "actuator stem ex‑
tends", the compressed air is applied to the
signal pressure connection on the bottom di‑
aphragm case.
With direction of action "actuator stem re‑
tracts", the compressed air is applied to the
signal pressure connection on the top dia‑
phragm case.
The actuator's direction of action can be re‑
versed (see the 'Operation' section).
3.2 Signal pressure routing
Type2780-1x (see Fig.3-1)
In the "actuator stem extends" version, the
signal pressure is routed through the bottom
signal pressure connection (SFA) to the bot‑
tom diaphragm chamber. In the "actuator
stem retracts" version, the signal pressure is
routed through the top signal pressure con‑
nection (SFE) to the top diaphragm chamber.
Type2780-2x (see Fig.3-2 and Fig.3-3)
In the Type2780‑2 Actuator, the signal pres‑
sure is transmitted to the diaphragm cham‑
ber through the holes (SFA, SFE) on the left or
right side of the yoke and over a switchover
plate. The fail‑safe action of the actuator
("actuator stem extends" or "actuator stem
retracts") determines how the positioner must
be attached and the switchover plate must
be aligned.
The switchover plate needs to be turned to
align the correct symbol for the fail‑safe ac‑
tion with the marking. The attachment either
on the left or right side of the actuator is de‑
termined by the required direction of action
of the positioner (>> or <>).
If the actuator is operated without a position‑
er, a connecting plate is required instead of
the switchover plate. In this case, the signal
pressure is routed directly over the signal

3-2 EB 5840 EN
Design and principle of operation
A42 A53 A38 A39
A48
A40
A23 A1
A25
A20
SFE
SFA
Actuator stem extends Actuator stem retracts
Fig.3-1: Type2780‑1
Actuator stem extends Actuator stem retracts
A46
A5
A2
SFA
SFE
A23
A25-29A48
A8
A53
A38
A39
Switchover/
connecting plate:
A1 Actuator stem
A2 Lower actuator section
A5 Actuator stem
A8 Diaphragm case
A20 Vent plug
A23 Coupling nut
A25‑
29 Compression spring
A38 Metal plate
A39 Diaphragm plate
A40 Bottom diaphragm case
A42 Top diaphragm case
A46 Stop bushing
A48 Diaphragm
A53 Collar nut
SFA Signal pressure connection
(actuator stem extends)
SFE Signal pressure connection
(actuator stem retracts)
Fig.3-2: Type2780‑2

EB 5840 EN 3-3
Design and principle of operation
pressure connection of the connecting plate
to the actuator diaphragm chamber.
The connecting plate needs to be turned to
align the correct symbol for the fail‑safe ac‑
tion with the marking.
3.3 Fail-safe action
When the signal pressure is reduced or the
control signal fails, the fail‑safe position of
the control valve depends on whether the
springs are installed in the top or bottom di‑
aphragm chamber.
The listed fail‑safe actions apply to
SAMSON globe valves.
Note
Actuator stem extends
Left
attachment
Right
attachment
Actuator stem
extends retracts
Actuator stem retracts
Left
attachment
Right
attachment
Signal pressure input
(left attachment)
Connecting plateSwitchover plate
Symbol
Marking for
signal pressure
input
Signal pressure input
(right attachment)
Signal pressure
connection
Fig.3-3: Signal pressure connection over switchover plate or connecting plate in Type2780‑2

3-4 EB 5840 EN
Design and principle of operation
3.3.1 Version with direction of
action "actuator stem ex-
tends"
When the signal pressure is reduced or the
control signal fails, the springs move the ac‑
tuator stem downward and close the globe
valve. The valve opens when the signal pres‑
sure is increased enough to overcome the
spring force.
3.3.2 Version with direction of
action "actuator stem re-
tracts"
When the signal pressure is reduced or the
control signal fails, the springs move the ac‑
tuator stem upward and open a mounted
globe valve. The valve closes when the signal
pressure is increased enough to overcome
the spring force.
3.4 Accessories
Switchover plate/connecting plate
Switchover plates and connecting plates are
listed as accessories.
With in‑
dex Order no.
Switchover
plate
New .01 1400-6822
Old .00 1400‑6819
Connect‑
ing plate
New .01 1400-6823
G thread .00 1400‑6820
NPT thread .00 1400‑6821
Actuators with device index .01 are
equipped with new connecting plates. Old
and new connecting plates are not inter‑
changeable.
Vent plugs
Vent plugs are screwed into the exhaust air
ports of pneumatic and electropneumatic de‑
vices. They ensure that any exhaust air that
forms can be vented to the atmosphere (to
avoid excess pressure in the device). Further‑
more, the vent plugs allow air intake to pre‑
vent a vacuum from forming in the device.
3.5 Technical data
The nameplate provides information on the
actuator version (see the 'Markings on the
device' section).
More information is available in Data Sheet
uT5840.
Temperature range
The permissible ambient temperature for
NBR diaphragm material is –35 to +80°C.
Supply pressure
The maximum permissible supply pressure is
4bar in throttling service.
Note
Note

EB 5840 EN 3-5
Design and principle of operation
Ø168
70
Ø168
84
M32 x 1.5
M32 x 1.5
50.5
50.5 73.5
Fig.3-4: Dimensional drawings
Compliance
The Type2780‑1 and Type2780‑2 Pneu‑
matic Actuators bear the EAC mark of con‑
formity.
Dimensions
Dimensions (see Fig.3‑4)
Weights
Version Weight
Type2780‑1 2kg
Type2780‑2 3.2kg

3-6 EB 5840 EN

EB 5840 EN 4-1
Shipment and on-site transport
4 Shipment and on-site trans-
port
The work described in this section is only to
be performed by personnel qualied for the
assignment accordingly.
4.1 Accepting the delivered
goods
After receiving the shipment, proceed as fol‑
lows:
1. Check the scope of delivery. Check that
the specications on the actuator name‑
plate match the specications in the de‑
livery note. See 'Markings on the device'
section for nameplate details.
2. Check the shipment for transportation
damage. Report any damage to
SAMSON and the forwarding agent
(refer to delivery note).
3. Determine the weight and dimensions of
the units to be lifted and transported in
order to select the appropriate lifting
equipment and lifting accessories. Refer
to the transport documents and 'Techni‑
cal data' section.
4.2 Removing the packaging
from the actuator
Observe the following sequence:
ÎDo not open or remove the packaging
until immediately before mounting the
actuator.
ÎDispose and recycle the packaging in ac‑
cordance with the local regulations.
4.3 Transporting and lifting the
actuator
Risk due to suspended loads falling.
ÎStay clear of suspended or moving
loads.
ÎClose off and secure the transport paths.
Risk of lifting equipment tipping over and
risk of damage to lifting accessories due to
exceeding the rated lifting capacity.
ÎOnly use approved lifting equipment and
accessories whose minimum lifting ca‑
pacity is higher than the weight of the
actuator (including the packaging, if ap‑
plicable).
Our after‑sales service can provide more
detailed transport and lifting instructions on
request.
4.3.1 Transporting the actu-
ator
ÎLeave the actuator in its packaging to
transport it.
ÎObserve the transport instructions.
Transport instructions
−Protect the actuator against external in‑
uences (e.g. impact).
DANGER
!
WARNING
!
Tip

4-2 EB 5840 EN
Shipment and on-site transport
−Do not damage the corrosion protection
(paint, surface coatings). Repair any
damage immediately.
−Protect the actuator against moisture and
dirt.
−Observe permissible temperatures (see
'Technical data' in the 'Design and prin‑
ciple of operation' section).
4.3.2 Lifting the actuator
To mount the actuator onto the valve, use lift‑
ing equipment (e.g. crane or forklift) to lift it.
Lifting instructions
−Use a hook with safety latch to secure the
slings from slipping during lifting and
transporting.
−Secure slings on the object to be trans‑
ported against slipping.
−Make sure the slings can be removed
from the actuator once it has been
mounted on the valve.
−Prevent the actuator from tilting or tip‑
ping.
−Do not leave loads suspended when in‑
terrupting work for longer periods of
time.
a) Lifting the actuator (without
valve)
1. Carefully lift the actuator. If necessary,
check whether the lifting equipment and
accessories can bear the weight.
2. Move the actuator at an even pace to the
mounting site.
3. Mount the actuator to the valve (see the
'Mounting' section).
4. Remove slings after mounting.
b) Lifting the entire control valve
assembly
ÎSee associated valve documentation for
instructions on how to lift a control valve.
4.4 Storing the actuator
Risk of actuator damage due to improper
storage.
ÎObserve the storage instructions.
ÎAvoid long storage times.
ÎContact SAMSON in case of different
storage conditions or long storage peri‑
ods.
We recommend regularly checking the actu‑
ator and the prevailing storage conditions
during long storage times.
Storage instructions
−When the valve and actuator are al‑
ready assembled, observe the storage
conditions for control valves. See associ‑
ated valve documentation.
−Protect the actuator against external in‑
uences (e.g. impact).
NOTICE
!
Note