Samson 3275 Service manual

Mounting and
Operating Instructions
EB 8314 EN
Translation of original instructions
Edition February 2017
Type 3275 Pneumatic Piston Actuator
Actuator area: 314, 490, and 804cm²

2 EB 8314 EN
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
(www.samson.de) > Product documentation. You can enter the document
number or type number in the [Find:] eld to look for a document.
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

Contents
EB 8314 EN 3
1 Safety instructions and measures ...................................................................5
1.1 Notes on possible severe personal injury .........................................................7
1.2 Notes on possible personal injury ...................................................................7
1.3 Notes on possible property damage ................................................................8
2 Markings on the device .................................................................................9
2.1 Actuator nameplate ........................................................................................9
3 Design and principle of operation ................................................................10
3.1 Fail-safe action ............................................................................................11
3.2 Versions ......................................................................................................12
3.3 Technical data .............................................................................................12
4 Measures for preparation............................................................................14
4.1 Unpacking ..................................................................................................14
4.2 Transporting and lifting ................................................................................14
4.2.1 Transporting ................................................................................................14
4.2.2 Lifting ..........................................................................................................15
4.3 Storage .......................................................................................................15
4.4 Preparation for installation ............................................................................17
5 Mounting and start-up.................................................................................18
5.1 Mounting the actuator onto the valve .............................................................18
5.2 Additional ttings .........................................................................................20
6 Operation...................................................................................................21
7 Servicing.....................................................................................................22
7.1 Replacing parts subject to wear .....................................................................22
7.2 Leak-testing the actuator ...............................................................................27
7.3 Preparation for return shipment .....................................................................27
7.4 Ordering spare parts and operating supplies .................................................27
8 Malfunctions ...............................................................................................28
9 Decommissioning and disassembly ..............................................................30
9.1 Decommissioning .........................................................................................30
9.2 Removing the actuator from the valve ............................................................30
9.3 Disposal ......................................................................................................30

4 EB 8314 EN
Contents
10 Appendix....................................................................................................31
10.1 After-sales service ........................................................................................31

EB 8314 EN 5
Safety instructions and measures
1 Safety instructions and measures
Intended use
The Type3275 Pneumatic Piston Actuator is designed for operating a mounted globe valve.
In combination with the valve, the actuator is used to shut off and control the ow of liquids,
gases or vapors in the pipeline. The actuator is mainly used in combination with PSA valves
(e.g. SAMSON Type3241-PSA Valve).
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 applications 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, SAMSON must be con-
tacted.
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 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 8314 EN
Safety instructions and measures
Personal protective equipment
We recommend wearing the following personal protective equipment when handling the
Type3275 Pneumatic Piston Actuator:
−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3275 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 actuators 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.
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.

EB 8314 EN 7
Safety instructions and measures
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
1.1 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 (piston rod), 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.

8 EB 8314 EN
Safety instructions and measures
WARNING
!
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.
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 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).

EB 8314 EN 9
Markings on the device
2 Markings on the device
2.1 Actuator nameplate
The nameplate (A18) is attached to the base (A4) with rivets (A19). It includes all details re-
quired to identify the device:
1 Actuator area
2 Permissible supply pressure pmax in bar or psi
3Operating travel in mm
4Permissible temperature range
5Conguration ID
6 Serial number
7Bar code
8Date of manufacture (month and year)
A18
A19
A4
1
2
8
SAMSON 3275
7
8
Made in
Germany
Var-ID 6
3
Serial no.
4
5
Supply
Stroke
Temperature
A4 Base
A18 Nameplate
A19 Rivet
Fig.1: Nameplate of Type3275 Actuator

10 EB 8314 EN
Design and principle of operation
3 Design and principle of oper-
ation
The double-acting Type3275 Pneumatic
Piston Actuator with 314, 490, and 804cm²
actuator areas is mainly mounted on PSA
valves (e.g. Type3241-PSA).
The actuator mainly consists of the base
(A4), cover (A10), and piston (A9). The stem
connector clamps connect the actuator's pis-
ton rod (A1) with the plug stem of the globe
valve.
The signal pressure pst creates the force
F=pst·A at the piston surface A, which is
opposed by the corresponding counter-
pressure. The piston is pressurized with the
supply air over the two connections (S, G
3
/
8
or G½).
The actuators with 314 and 490cm²
actuator areas are xed to a yoke, which is
designed to accommodate a pneumatic or
electropneumatic positioner. See Fig.2.
A1
A2
A7
A8
A9
A3
S
S
A10
A4
A5
A5
A1 Piston rod
A2 Piston rod seal
A3 Plain bearing
A4 Base
A5 O-ring
A7 Piston seal
A8 Piston guide band
A9 Piston
A10 Cover
S Signal pressure connection
Yoke
Fig.2: Type3275 Actuator (314 and 490cm²)

EB 8314 EN 11
Design and principle of operation
The actuator with 804cm² area does need a
yoke (see Fig.3). The valve accessories are
mounted over the NAMUR interface.
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.
3.1 Fail-safe action
The double-acting piston actuator has no
springs. A dened nal position is not
reached when the signal pressure is reduced
or the air supply fails.
A1
A3
A7
A8
A9
A2
S
S
A10
A4
A1 Piston rod
A2 Piston rod seal
A3 Plain bearing
A4 Base
A7 Piston seal
A8 Piston guide band
A9 Piston
A10 Cover
S Signal pressure
connection
Fig.3: Type3275 Actuator (804cm²)

12 EB 8314 EN
Design and principle of operation
3.2 Versions
Type3275 Pneumatic Piston Actuator with
314, 490 or 804cm² actuator area:
−Standard version
Base and cover are coated with an alu-
minum alloy (3.3547, anodized).
−Version with side-mounted handwheel
The actuator can be combined with a
Type3273 Side-mounted Handwheel
with max. 30mm travel (uT8312).
−Special version with auxiliary spring
The actuator can be tted with an auxil-
iary spring to move the actuator to a de-
ned end position in the depressurized
state (e.g. upon supply air failure).
−Special version for temperatures down
to –40°C
3.3 Technical data
The nameplate provide information on the
actuator version (see section2.1).
More information is available in Data Sheet
uT8314.
Note
Table1: Technical data
Version Type 3275
Actuator area cm² 314 490 804
Supply pressure Max. 6bar 6bar 6bar
Rated travel mm 15 30 15 30 15 30
Travel volume cm³ 471 942 735 1470 1206 2412
Air connection G
3
/
8
G½ G½
Max. permissible leakage
(t≥0°C) 50cm³/min 58cm³/min 70cm³/min
Perm. temperature range for
continuous operation –30 to +80°C
Compliance

EB 8314 EN 13
Design and principle of operation
Table2: Dimensions in mm and weights in kg
Actuator Type 3275
Actuator area cm² 314 490 804
Rated travel mm 15 30 15 30 15 30
Travel volume cm³ 471 942 735 1470 1206 2412
£mm 220 280 350
H1 including lifting
eyelet mm 2251) 2501) 286
H2 mm 102 102 –
H3 (rod retracted) mm 60 y60 60
Air connection G
3
/
8
G½ G½
Weight kg 10 17 21
1) Different dimensions may arise with the special version (e.g. for low temperatures)
Dimensional drawings
Ø30
Ø16
H1H2H3
G
G

H1
H3
Ø22
Ø60
£
Type3275 with 314 and 490cm² actuator areas Type3275 with 804cm² actuator area

14 EB 8314 EN
Measures for preparation
4 Measures for preparation
After receiving the shipment, proceed as
follows:
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
(refer 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3.3 for weights.
Risk of actuator damage due to incorrectly
attached slings.
−The lifting eyelets on the cover are intend-
ed 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 eyelets.
−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.
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.
Note
DANGER
!
WARNING
!
NOTICE
!
Tip

EB 8314 EN 15
Measures for preparation
−Protect the actuator against moisture and
dirt.
−Observe permissible temperatures (see
section3.3).
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 valves. 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.4).
Lifting the actuator (without valve)
Risk of actuator damage due to incorrectly
attached slings.
The lifting eyelets on the cover are intended
for mounting and removing the actuator as
well as lifting the actuator without valve. Do
not lift the entire control valve assembly us-
ing the lifting eyelets.
1. Attach a sling to the lifting eyelets of the
actuator and to the rigging equipment
(e.g. hook) of the crane or forklift (see
Fig.4).
2. Carefully lift the actuator. Check whether
the lifting equipment and accessories can
bear the weight.
3. Move the actuator at an even pace to the
mounting site.
4. Mount the actuator to the valve. See sec-
tion5.1.
5. Remove slings after mounting.
We recommend using a hook with safety
latch (see Fig.4). The safety latch prevents
the slings from slipping during lifting and
transporting.
Lifting the entire control valve assembly
ÎSee associated valve documentation for
instructions on how to lift a control valve.
4.3 Storage
Risk of actuator damage due to improper
storage.
−Observe storage instructions.
−Avoid long storage times.
−Contact SAMSON in case of different stor-
age conditions or long storage periods.
NOTICE
!
Tip
NOTICE
!

16 EB 8314 EN
Measures for preparation
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).
−Do not damage the corrosion protection
(paint, surface coatings). Repair any
damage immediately.
−Protect the actuator against moisture and
dirt. Store it at a relative humidity of less
than 75%. In damp spaces, prevent con-
densation. If necessary, use a drying
agent or heating.
−Make sure that the ambient air is free of
acids or other corrosive media.
−Observe permissible temperatures (see
section3.3).
−Do not place any objects on the actuator.
Note
Fig.4: Lifting points on the actuator Fig.5: Lifting points on the control valve
(example)

EB 8314 EN 17
Measures for preparation
SAMSON's After-sales Service department
can provide more detailed storage instruc-
tions on request.
4.4 Preparation for installation
Proceed as follows:
ÎCheck the actuator for damage.
ÎCheck to make sure that the type
designation, material and temperature
range of the actuator match the ambient
conditions (temperatures etc.).
ÎCheck the pressure gauge installed on
valve accessories to make sure it func-
tions.
ÎWhen the valve and actuator are al-
ready assembled, check the tightening
torques of the bolted joints (uAB0100).
Components may loosen during trans-
port.
Tip

18 EB 8314 EN
Mounting and start-up
5 Mounting and start-up
SAMSON control valves are delivered ready
for use. In special cases, the valve and actu-
ator are delivered separately and must be
assembled on site. The procedure to mount
and start up the actuator are described in
following.
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.
Observe the specied tightening torques
(uAB0100).
See associated valve documentation for ad-
ditional mounting instructions.
5.1 Mounting the actuator onto
the valve
Proceed as follows if the valve and actuator
have not been assembled by SAMSON:
Remove the mounted actuator before mount-
ing the other actuator (see section9.2).
The valve and actuator are assembled with
special attention paid to the actuator's bench
range and direction of action. These details
are specied on the actuator nameplate (see
section2.1).
1. Loosen the lock nut (10) and stem con-
nector nut (9) on the valve.
2. Press the plug together with the plug stem
rmly into the seat ring.
3. Thread down the lock nut and stem con-
nector nut.
4. Remove the clamps of the stem connector
(A26/27) and the ring nut (A208) from
the actuator.
5. Slide the ring nut over the plug stem.
6. Place the actuator onto the valve bonnet
(2) and secure it with the ring nut.
7. Apply a signal pressure to the actuator to
extend the piston rod.
8. Screw on the stem connector nut (9) by
hand until it touches the piston rod (A1).
9. Turn the stem connector nut a further
quarter turn and secure this position with
the lock nut (10).
10. Position clamps of the stem connector
(A26/27) and screw them tight.
11. Align the travel indicator (84) with the tip
of the stem connector clamp.
NOTICE
!
Note
Note
Tip

EB 8314 EN 19
Mounting and start-up
Yoke
2 Valve bonnet
9Stem connector nut
10 Lock nut
84 Travel indicator scale
A1 Piston rod
A26/27 Stem connector clamps
A208 Ring nut
A1
A208
A26/2
7
84
9
10
2
Fig.6: Type 3275 Piston Actuator with 490cm² actuator area mounted on a Type3241-PSA Valve

20 EB 8314 EN
Mounting and start-up
5.2 Additional ttings
Valve accessories
Valve accessories are either mounted on the
yoke (314 and 490cm²) or over the
NAMUR interface (804cm² only).
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.
Auxiliary spring
The actuator can be tted with an auxiliary
spring to move the actuator to a dened end
position in the depressurized state (e.g. upon
supply air failure).