Samson 3271 Service manual

Translation of original instructions
EB 8310-6 EN
Mounting and
Operating Instructions
Edition March 2017
Type3271 and Type3277 Pneumatic Actuators
Actuator area: 240, 350, and 700cm²
Type3271
Type3277

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 8310-6 EN

Contents
EB 8310-6 EN 3
1 Safety instructions and measures ...................................................................5
1.1 Notes on possible severe personal injury .........................................................7
1.2 Notes on possible personal injury ...................................................................8
1.3 Notes on possible property damage................................................................9
2 Markings on the device ...............................................................................10
2.1 Actuator nameplate......................................................................................10
3 Design and principle of operation ................................................................11
3.1 Type3271...................................................................................................11
3.2 Type3277...................................................................................................12
3.3 Direction of action........................................................................................13
3.4 Signal pressure routing.................................................................................13
3.4.1 Type3271...................................................................................................13
3.4.2 Type3277...................................................................................................13
3.5 Fail-safe action ............................................................................................13
3.5.1 Version with direction of action "actuator stem extends" (FA) ...........................14
3.5.2 Version with direction of action "actuator stem retracts" (FE)............................14
3.6 Versions ......................................................................................................14
3.7 Technical data .............................................................................................15
4 Measures for preparation............................................................................19
4.1 Unpacking ..................................................................................................19
4.2 Transporting and lifting ................................................................................19
4.2.1 Transporting ................................................................................................20
4.2.2 Lifting..........................................................................................................20
4.3 Storage.......................................................................................................22
4.4 Preparation for installation............................................................................23
5 Mounting and start-up.................................................................................24
5.1 Mounting the actuator onto the valve.............................................................24
5.2 Preloading the springs..................................................................................27
5.2.1 Tensioning the springs ..................................................................................27
5.2.2 Increasing the actuator thrust ........................................................................27
5.2.3 Adapting the travel range.............................................................................28

Contents
4 EB 8310-6 EN
6 Operation...................................................................................................30
6.1 Throttling service..........................................................................................30
6.2 On/off service.............................................................................................30
6.3 Reversal of the direction of action..................................................................31
6.3.1 Reversal of the direction of action from stem extends to stem retracts ................31
6.3.2 Reversal of the direction of action from stem retracts to stem extends ................33
6.4 Version with handwheel................................................................................35
6.4.1 Extending the actuator stem manually............................................................35
6.4.2 Retracting the actuator stem manually............................................................35
6.5 Adjusting the travel stop ...............................................................................36
6.5.1 Bottom travel stop (minimum travel) ...............................................................36
6.5.2 Top travel stop (maximum travel) ...................................................................36
7 Servicing.....................................................................................................38
7.1 Replacing the diaphragm .............................................................................39
7.2 Replacing the actuator stem seals ..................................................................42
7.3 Preparation for return shipment.....................................................................44
7.4 Ordering spare parts and operating supplies .................................................45
8 Malfunctions ...............................................................................................46
9 Decommissioning and disassembly ..............................................................48
9.1 Decommissioning.........................................................................................48
9.2 Removing the actuator from the valve ............................................................48
9.3 Relieving the spring compression in the actuator.............................................48
9.4 Disposal......................................................................................................48
10 Annex.........................................................................................................50
10.1 After-sales service........................................................................................50
10.2 Spare parts .................................................................................................51

EB 8310-6 EN 5
Safety instructions and measures
1 Safety instructions and measures
Intended use
The SAMSON Type3271 and Type3277 Actuators are designed for operating a mounted
globe valve. In combination with the valve, the actuators are used to shut off the ow of liq-
uids, gases or vapors in the pipeline. Depending on the version, the actuators are suitable
for throttling or on/off service. The actuators can be used in processing and industrial plants.
The actuators are designed to operate under exactly dened conditions (e.g. thrust, travel).
Therefore, operators must ensure that the actuators are only used in applications that meet
the specications used for sizing the actuators at the ordering stage. In case operators intend
to use the actuators 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
valve 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 in the technical data
−Use outside the limits dened by the accessories mounted on 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.

6 EB 8310-6 EN
Safety instructions and measures
Personal protective equipment
We recommend wearing the following personal protective equipment when handling the
Type3271 and Type3277 Pneumatic Actuators:
−Protective gloves when mounting or removing the actuator
ÎCheck with the plant operator for details on further protective equipment.
Revisions and other modications
Revisions, conversions or other modications to 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.
Safety devices
The Type3271 and Type3277 Actuators do 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, the operating
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, 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 hazard statements, warning and caution
notes specied in them. Furthermore, the operating personnel must be familiar with the ap-
plicable health, safety and accident prevention regulations and comply with them.

EB 8310-6 EN 7
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.)
−Safety Manual uSH8310 for use in safety-instrumented systems
−uAB0100 for tools, tightening torques, and lubricant
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.

8 EB 8310-6 EN
Safety instructions and measures
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 insert hands or ngers into the yoke while the valve is in operation.
ÎWhile working on the actuator, disconnect and lock the pneumatic air supply as well
as the control signal.
Risk of personal injury when the actuator vents.
While the valve is operating, the actuator may vent during closed-loop control or when
the valve opens or closes.
ÎInstall the control valve in such a way that the actuator does not vent at eye level.
ÎUse suitable silencers and vent plugs.
ÎWear eye protection when working in close proximity to the control valve.
Risk of personal injury due to preloaded springs.
Actuators with preloaded springs are under tension. They can be identied by the long
bolts protruding from the bottom of the actuator.
ÎBefore starting any work on the actuator, relieve the compression from the preload-
ed springs (see section9.3).
Damage to health relating to the REACH regulation.
If a SAMSON device contains a substance which is listed as being a substance of very
high concern on the candidate list of the REACH regulation, this circumstance is indicat-
ed on the SAMSON delivery note.
ÎInformation on safe use of the part affected, see uhttp://www.samson.de/reach-
en.html.

EB 8310-6 EN 9
Safety instructions and measures
1.3 Notes on possible property damage
NOTICE
!
Risk of actuator damage due to incorrectly attached slings.
ÎDo not attach load-bearing slings to the handwheel or travel stop.
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 valve surface.
ÎOnly use lubricants approved by SAMSON (uAB0100).

10 EB 8310-6 EN
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:
2Conguration ID
3Serial number
4 Actuator area
5Bench range in bar
6Bench range in psi
7Operating travel in mm
8Operating range in bar
9Operating range in psi
10 Permissible supply pressure pmax in bar
11 Permissible supply pressure pmax in psi
12 Symbol indicating fail-safe action
Actuator stem extends (FA)
Actuator stem retracts (FE)
Manual override
14 Connecting thread
15 Diaphragm material
16 Date of manufacture
7
4
14
15 12 6
5
8
9
10 11
SAMSON 3271
Made in Germany
Var-ID
3
2
Serial no.
16
Fig.1: Nameplate of Type3271 Actuator

EB 8310-6 EN 11
Design and principle of operation
3 Design and principle of oper-
ation
The SAMSON Type3271 and Type3277
Actuators with 240. 350, and 700cm² actu-
ator areas are mounted to Series 240, 250,
280, and 290 Valves (globe valves).
3.1 Type3271
The actuator mainly consists of two dia-
phragm cases (A1, A2), the diaphragm (A4)
with diaphragm plate (A5), and springs
(A10) (see Fig.2).
The signal pressure pst creates the force F =
pst · A at the diaphragm surface A which is
opposed by the springs (A10) in the actua-
tor. The bench range is determined by the
number of springs used and their compres-
A1 Top diaphragm
case
A2 Bottom diaphragm
case
A4 Diaphragm
A5 Diaphragm plate
A7 Actuator stem
A8 Ring nut
A10 Spring
A16 Vent plug
A26/27 Stem connector
clamp
S Signal pressure
connection
Version with direction of action
"actuator stem retracts" (FE)
Version with direction of action
"actuator stem extends" (FA)
S
A1
S
A4
A10
A7
A8
A26/27
A16
A2
A5
Fig.2: Type 3271 Pneumatic Actuator

12 EB 8310-6 EN
Design and principle of operation
sion, taking into account the rated travel. The
travel is proportional to the signal pressure
pst. The direction of action of the actuator
stem (A7) depends on how the springs are
installed in the actuator.
A maximum of 12 springs (240 and
350cm²) and a maximum of 18 springs
(700cm²), partly tted into one another, can
be installed in the actuator.
The stem connector clamps (A26/27) con-
nect the actuator stem (A7) with the plug
stem of the globe valve.
3.2 Type3277
The principle of operation is the same as that
of the Type3271 Actuator. The Type3277
Actuator is tted with an additional yoke on
the bottom diaphragm case (A2) (see Fig.3).
The yoke allows the direct attachment of a
positioner and/or limit switch. The benet of
this design is that the travel pick-off located
inside the yoke is protected against external
inuences.
Refer to the mounting and operating instruc-
tions of the valve accessories to be mounted
for more details on their attachment and the
accessories required.
Fig.3: Type 3277 Pneumatic Actuator
A1 Top diaphragm
case
A2 Bottom diaphragm
case
A4 Diaphragm
A5 Diaphragm plate
A7 Actuator stem
A8 Ring nut
A10 Spring
A16 Vent plug
A26/27 Stem connector
clamp
S Signal pressure
connection
Version with direction of action
"actuator stem retracts" (FE)
Version with direction of action
"actuator stem extends" (FA)
S
A1
S
A4
A10
A7
A8
A26/27
A16
A2
A5

EB 8310-6 EN 13
Design and principle of operation
3.3 Direction of action
The direction of action is determined by how
the springs (A10) and diaphragm plate (A5)
are arranged 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 section6.3).
3.4 Signal pressure routing
3.4.1 Type3271
In the "actuator stem extends" version, the
signal pressure is routed through the bottom
signal pressure connection (S) to the bottom
diaphragm chamber and moves the actuator
stem (A7) upward opposing the spring force
(see Fig.2, right).
In the "actuator stem retracts" version, the
signal pressure is routed through the top sig-
nal pressure connection (S) to the top dia-
phragm chamber and moves the actuator
stem (A7) downward opposing the spring
force (see Fig.2, left).
3.4.2 Type3277
In the "actuator stem extends" version, a sig-
nal pressure connection (S) is located on the
side of the yoke which is connected to the
bottom diaphragm chamber over an internal
hole (see Fig.3, right). The signal pressure
moves the actuator stem upward opposing
the spring force. A positioner can be con-
nected using a connection block at this point.
No additional piping to the actuator is re-
quired. Refer to the associated positioner
documentation for more details.
In the "actuator stem retracts" version, the
signal pressure is routed through the top sig-
nal pressure connection (S) to the top dia-
phragm chamber and moves the actuator
stem (A7) downward opposing the spring
force (see Fig.3, left).
3.5 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 Series240, 250, 280 and 290
Valves (globe valves).
Note

14 EB 8310-6 EN
Design and principle of operation
3.5.1 Version with direction of
action "actuator stem
extends" (FA)
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.
3.5.2 Version with direction of
action "actuator stem
retracts" (FE)
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.
3.6 Versions
The Type3271 and Type3277 Pneumatic
Actuators with 240, 350 or 700cm² actua-
tor area are available in the following ver-
sions:
−Standard version
The top and bottom diaphragm cases are
made of painted sheet steel.
−Corrosion-resistant version
The top and bottom diaphragm cases are
made of stainless sheet steel (1.4301).
−Additional (top-mounted) handwheel
The actuators can be tted with an addi-
tional (top-mounted) handwheel
(uT8312).
−Travel stop
The actuators as a special version can be
tted with a mechanically adjustable
travel stop. The travel is reduced by up to
50% in both directions of action (stem
extends or retracts).
−Side-mounted handwheel
The actuators can be combined with a
Type3273 Side-mounted Handwheel
with max. 30mm travel (uT8312).

EB 8310-6 EN 15
Design and principle of operation
3.7 Technical data
The nameplate provides information on the
actuator version (see section2.1).
More information is available in Data Sheet
uT8310-1.
Supply pressure
The maximum permissible supply pressure is
6bar in throttling service. See section6.2
for restrictions in on/off service.
Temperature range
The permissible temperature range depends
on the actuator service and diaphragm ma-
terial:
Diaphragm material Temperature range
Throttling service
NBR –35 to +90°C
–31 to +194°F
EPDM –50 to +120°C
–58 to +248°F
On/off service
NBR –20 to +90°C
–4 to +194°F
EPDM –40 to +120°C
–40 to +248°F
Compliance
The Type3271 and Type3277 Pneumatic
Actuators bear the EAC mark of conformity.
Note

16 EB 8310-6 EN
Design and principle of operation
Dimensions and weights
The dimensions and weights are listed in
Table1. The lengths and heights in the
dimension diagrams are shown on
page17 onwards.
Table1: Dimensions in mm and weights in kg
Actuator Type 3271 3277
Actuator area cm² 240 350 700 240 350 700
Height
H62 82 134 65 82 135
H1 300 302 490 400 420 590
H2max 345 365 540 445 465 640
H4ratedFA 75 75 90 75 75 90
H4maxFA 78 78 95 78 78 95
H4maxFE 78 85 104 78 85 104
H5 – – – 101 101 101
H6 34 34 34 34 34 34
H7 – – 65 – – 65
Travel limitation H8 75 85 115 75 85 115
Yoke width L – – – 70 70 70
Diameter
ØD 240 280 390 240 280 390
ØD1 180 250 315 180 250 315
ØD2 10 16 16 16 16 16
Ød (thread) M30x1.5 M30x1.5
Air connection aG¼
¼NPT
G
3
/
8
3
/
8
NPT
G
3
/
8
3
/
8
NPT
G¼
¼NPT
G
3
/
8
3
/
8
NPT
G
3
/
8
3
/
8
NPT
a2 –
–
–G
3
/
8
G
3
/
8
G
3
/
8
Weight
Without
handwheel 5 8 22 9 12 26
With
handwheel 9 13 27 13 17 31

EB 8310-6 EN 17
Design and principle of operation
Dimensional drawings
a
a
H
H6
H4
ØD
ØD2
Ød
H7
H
a2
H5
H4
H6
a
ØD
ØD2
Ød
Standard version of Type3271 (700cm²) Standard version of Type3277 (240, 350cm²)
L
a
a
HH8
H6
H4
ØD
ØD2
Ød
Type3277 (side view) Type3271 with travel stop

18 EB 8310-6 EN
Design and principle of operation
ØD1
ØD
ØD2
55
Ød
H
H1
H4
H6
H5
a2
H2
a
Type3277 with handwheel

EB 8310-6 EN 19
Measures for preparation
4 Measures for preparation
After receiving the shipment, proceed as fol-
lows:
1. Check the scope of delivery. Compare
the shipment received against the deliv-
ery note.
2. Check the shipment for transportation
damage. Report any damage to
SAMSON and the forwarding agent (re-
fer to delivery note).
4.1 Unpacking
Do not remove the packaging until immedi-
ately before mounting.
Proceed as follows to lift and mount the actu-
ator:
1. Remove the packaging from the actuator.
2. Dispose of the packaging in accordance
with the valid regulations.
4.2 Transporting and lifting
Hazard due to suspended loads falling.
Stay clear of suspended or moving loads.
Risk of lifting equipment tipping and risk of
damage to lifting accessories due to exceed-
ing the rated lifting capacity.
−Only use approved lifting equipment and
accessories whose minimum lifting capaci-
ty is higher than the weight of the actuator.
−Refer to section3.7 for weights.
Risk of actuator damage due to incorrectly
attached slings.
−The welded-on lifting eyelet on the top dia-
phragm case is intended for mounting and
removing the actuator as well as lifting the
actuator without valve. Do not lift the entire
control valve assembly using the lifting
eyelet.
−Do not attach load-bearing slings to the
travel stop.
−Observe lifting instructions (see sec-
tion4.2.2).
SAMSON's After-sales Service department
can provide more detailed transport and lift-
ing instructions on request.
Note
DANGER
!
WARNING
!
NOTICE
!
Tip

20 EB 8310-6 EN
Measures for preparation
4.2.1 Transporting
The actuator can be transported using lifting
equipment (e.g. crane or forklift).
ÎLeave the actuator in its transport con-
tainer or on the pallet to transport it.
ÎObserve the transport instructions.
Transport instructions
−Protect the actuator against external in-
uences (e.g. impact).
−Do not damage the corrosion protection
(paint, surface coatings). Repair any
damage immediately.
−Protect the actuator against moisture and
dirt.
−Observe permissible temperatures (see
section3.7).
4.2.2 Lifting
To mount a large actuator, use lifting equip-
ment (e.g. crane or forklift) to lift it.
Lifting instructions
−Secure slings against slipping.
−Make sure the slings can be removed
from the actuator once it has been
mounted onto the valve.
−Prevent the actuator from tilting or tip-
ping.
−Do not leave loads suspended when in-
terrupting work for longer periods of
time.
−Make sure that the additional sling be-
tween the lifting eyelet and rigging
equipment (hook, shackle etc.) does not
bear any load when lifting control valves
larger than DN150 with the actuator al-
ready mounted. The sling only protects
the control valve from tilting while being
lifted. Before lifting the control valve,
tighten the sling. The slings attached to
the valve body must bear the entire load
(see Fig.5).