Samson 3965 Service manual

Translation of original instructions
EB 3965 EN
Edition April 2019
Type3965 Solenoid Valve Island

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 3965 EN

Contents
EB 3965 EN 3
1 Safety instructions and safety measures .........................................................5
1.1 Notes on possible severe personal injury .........................................................8
1.2 Notes on possible personal injury ...................................................................9
1.3 Notes on possible property damage................................................................9
2 Markings on the device ...............................................................................10
2.1 Nameplate..................................................................................................10
2.2 Article code.................................................................................................10
3 Design and principle of operation ................................................................14
3.1 Accessories .................................................................................................16
3.2 Technical data .............................................................................................18
3.3 Dimensions..................................................................................................22
4 Measures for preparation............................................................................28
4.1 Unpacking ..................................................................................................28
4.2 Transporting ................................................................................................28
4.3 Storage.......................................................................................................28
5 Mounting and start-up.................................................................................29
5.1 Installation...................................................................................................29
5.1.1 Installation conditions...................................................................................29
5.1.2 Useinhazardousareasofzones21and22..................................................30
5.2 Pneumatic connection...................................................................................31
5.2.1 Sizing of the connecting line .........................................................................31
5.2.2 Compressed air quality.................................................................................31
5.2.3 Connections for pilot supply and operating medium........................................32
5.2.4 Exhaust port ................................................................................................33
5.3 Electrical connection.....................................................................................33
5.3.1 Selecting cables and wires............................................................................34
5.3.2 Conditions concerning connection .................................................................34
5.3.3 Electric status indication................................................................................36
5.3.4 Electrical connection with single connectors....................................................37
5.3.5 Electrical connection with common cable........................................................38
5.3.6 Electrical connection with multi-pole connector ...............................................40

Contents
4 EB 3965 EN
6 Operation...................................................................................................42
6.1 Manual override..........................................................................................42
7 Servicing.....................................................................................................42
7.1 Exchanging solenoid pilot valves...................................................................42
7.1.1 Exchanging solenoid pilot valves with single connector ...................................42
7.1.2 Exchanging solenoid pilot valves with common cable or multi-pole connector ...44
7.2 Returns........................................................................................................45
8 Malfunctions ...............................................................................................46
9 Decommissioning and removal ....................................................................47
9.1 Decommissioning.........................................................................................47
9.2 Disposal......................................................................................................47
10 Appendix....................................................................................................48
10.1 After-sales service........................................................................................48
10.2 Certicates ..................................................................................................48

EB 3965 EN 5
Safety instructions and safety measures
1 Safety instructions and safety measures
Intended use
TheType3965SolenoidValveIslandisusedforthecentralcontrolofpneumaticactuatorsin
chemicalandpharmaceuticalplants.Thedeviceisdesignedtooperateunderexactlydened
conditions (e.g. operating pressure, temperature). Therefore, operators must ensure that the
solenoid valve island is only used in applications where the operating conditions correspond
to the technical data. In case operators intend to use the solenoid valve island in other appli-
cations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 solenoid valve island 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 island 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.
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.

6 EB 3965 EN
Safety instructions and safety measures
Personal protective equipment
Personal protective equipment is not required to mount or operate the solenoid valve island.
Work on the control valve may be necessary when mounting or removing the solenoid valve.
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 island has a direct effect on the control valve when it has been installed.
To avoid personal injury or property 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 pressure or by moving parts by taking appropriate
precautions. They must observe all hazard statements, warning and caution notes in these
mounting and operating instructions. Furthermore, the intended purpose may involve the use
of the device in hazardous areas. All work on the device must only be performed when no
potentially explosive atmosphere is present.
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, operators 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 3965 EN 7
Safety instructions and safety 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
according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
manufacturer 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 explosion-protected components only with original, routine-tested components by the
manufacturer.
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intrinsicallysafe
circuits.
Referenced standards and regulations
The solenoid valve islands comply with the requirements of Directives 2014/30/EU and
2014/35/EU for applications without explosion protection as well as Directive 2014/34/EU
for explosion-protected applications. The declaration of conformity includes information
about the applied conformity assessment procedure. This declaration of conformity is includ-
ed in the appendix of these instructions.
Referenced documentation
The following documents apply in addition to these mounting and operating instructions:
−Data sheet uT3965
−The mounting and operating instructions of the components on which the solenoid valve
island is mounted (valve, actuator, valve accessories etc.)

8 EB 3965 EN
Safety instructions and safety measures
1.1 Notes on possible severe personal injury
DANGER
!
Risk of electric shock.
Before starting up the solenoid valve island, electrical installation work must be per-
formed. An electric shock due to incorrect work practices may cause death.
ÎBefore connecting wiring, performing any work on the device or opening the device,
disconnect the power supply and protect it against unintentional reconnection.
ÎFor electrical installation, observe the relevant electrotechnical regulations and the
accident prevention regulations that apply in the country of use.
ÎInGermany,observetheVDEregulationsandtheaccidentpreventionregulationsof
the employers’ liability insurance.
Risk of fatal injury due to the ignition of an explosive atmosphere.
Incorrect installation, operation or maintenance of the solenoid valve island in potential-
ly explosive atmospheres may lead to ignition of the atmosphere and cause death.
ÎThefollowingregulationsapplytoinstallationinhazardousareas:EN60079-14:
2008(VDE0165,Part1).
ÎInstallation, operation or maintenance of the solenoid valve island 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ECtypeexaminationcerticate.

EB 3965 EN 9
Safety instructions and safety measures
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 island is triggered, the valve 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.
1.3 Notes on possible property damage
NOTICE
!
Risk of damage to the solenoid valve island due to impermissible mounting position.
ÎDo not mount the solenoid valve island with the vent opening facing upward.
ÎDo not seal the vent opening when the device is installed on site.
Risk of damage to the solenoid valve island due to impermissible pressures.
ÎDo not connect a supply pressure to the solenoid valve island that exceeds the maxi-
mum supply pressure.
Incorrect assignment of the terminals will damage the solenoid valve island and will
lead to malfunction.
For the solenoid valve island to function properly, the prescribed terminal assignment
must be observed.
ÎConnect the electrical wiring to the solenoid valve island according to the prescribed
terminal assignment.

10 EB 3965 EN
Markings on the device
2 Markings on the device
2.1 Nameplate
SAMSON 3965
UnV DC / V AC 50/60 Hz
See technical data for ambient temperature
Solenoid Valve Island
SAMSON AG D-60314 Frankfurt Made in Germany
Model 3965 - 110
Var.-ID
Serial no.
4
2
3
1
8
Fig.1: Versions without explosion protection
(example)
SAMSON 3965-1
UnV DC
0044
See technical data and explosion-protection
certificate for permissible ambient temperature
and maximum values for connection to certified
intrinsically safe circuits.
PTB 05 ATEX 2044 X
II 2 D Ex tb IIIC T 80 °C IP 65
II 2 G Ex ia IIC T6*
Solenoid Valve Island
SAMSON AG D-60314 Frankfurt Made in Germany
Model 3965 - 110
Var.-ID Serial no.
4
*Ui≤V;
5
*Pi≤mW;
7
*Ii≤mA;
6
Ci≈0 nF; Li≈ 0 µH
23
1
*
Fig.2: Versions with explosion protection
(example)
Legend
1 Model number
2CongurationID
3 Serial number
4 Nominal signal
5Voltage
6 Current
7 Capacity
8 Data Matrix code
2.2 Article code
Article code and device index
The article code and device index are speci-
edonthenameplate:
3965-XXXXXXXXXXXXXXX XX
Model number Device index
Structure of the article code
See following three pages.