Samson 3755 Service manual

Translation of original instructions
EB 8393 EN
Type 3755 (cast aluminum body)
Type 3755 (stainless steel body)
Edition November 2017
Type 3755 Pneumatic Volume Booster

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 8393 EN

Contents
EB 8393 EN 3
1 Safety instructions and measures ...................................................................5
1.1 Notes on possible personal injury ...................................................................7
1.2 Notes on possible property damage................................................................7
2 Markings on the device .................................................................................8
2.1 Article code...................................................................................................8
2.2 Nameplate....................................................................................................9
3 Design and principle of operation ................................................................10
3.1 Safety function.............................................................................................10
3.2 Versions ......................................................................................................12
3.3 Accessories .................................................................................................12
3.4 Spare parts/conversion kits ..........................................................................13
3.5 Technical data .............................................................................................14
3.6 Dimensions in mm........................................................................................16
3.6.1 Aluminum version........................................................................................16
3.6.2 Stainless steel version ...................................................................................17
4 Measures for preparation............................................................................19
4.1 Unpacking ..................................................................................................19
4.2 Transporting and lifting ................................................................................19
4.2.1 Transporting................................................................................................19
4.2.2 Lifting..........................................................................................................19
4.3 Storage.......................................................................................................19
5 Mounting and start-up.................................................................................20
5.1 Mounting position........................................................................................21
5.2 Pneumatic connections..................................................................................21
5.2.1 Supply air ...................................................................................................22
5.2.2 ExhaustportofType3755-2.........................................................................22
5.3 Start-up.......................................................................................................22
5.3.1 Adjusting the bypass restriction.....................................................................23
5.3.2 Tuning to the control loop requirements..........................................................23
5.4 Conversion..................................................................................................24
5.4.1 ConvertingType3755-1toType3755-2 .......................................................24
5.4.2 ConvertingType3755-2toType3755-1 .......................................................24

Contents
4 EB 8393 EN
6 Servicing.....................................................................................................26
6.1 Replacingthesinteredpolyethylenelterdisk .................................................26
6.2 Preparation for return shipment.....................................................................26
7 Malfunctions ...............................................................................................27
7.1 Emergency action ........................................................................................27
8 Decommissioning and disassembly ..............................................................28
8.1 Decommissioning.........................................................................................28
8.2 Removing the pneumatic volume booster........................................................28
8.3 Disposal......................................................................................................28
9 After-sales service .......................................................................................29

EB 8393 EN 5
Safety instructions and measures
1 Safety instructions and measures
Intended use
TheType3755PneumaticVolumeBoosterisusedtogetherwithpositionerstoincreasethe
positioningspeedofpneumaticactuatorswithaneffectivearea≥1000cm²oratravel
volume≥6l.
Thedeviceisdesignedtooperateunderexactlydenedconditions(e.g.operatingpressure,
temperature). Therefore, operators must ensure that the volume booster 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 volume booster 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
device for its intended purpose or for damage caused by external forces or any other
external factors.
ÎRefertothetechnicaldataforlimitsandeldsofapplicationaswellaspossibleuses.
Reasonably foreseeable misuse
TheType3755VolumeBooster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bySAMSON
Qualications of operating personnel
Thevolumeboostermustbemounted,startedupandserviced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.
Personal protective equipment
We recommend wearing the following protective equipment depending on the process
medium:
−Wear hearing protection when working on the volume booster or near the valve.
ÎCheck with the plant operator for details on further protective equipment.

6 EB 8393 EN
Safety instructions and measures
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 features
ThesafetyfunctionoftheType3755PneumaticVolumeBoosteristheemergencyventingon
demand.
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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, especially for installation, start-up and service work.
If inadmissible motions or forces are produced in the pneumatic actuator as a result of the
supply pressure level, it must be restricted using a suitable supply pressure reducing station.
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 documentation
The following documents apply in addition to these mounting and operating instructions:
−The mounting and operating instructions of the components on which the volume booster
is mounted (valve, actuator, positioner, etc.).

EB 8393 EN 7
Safety instructions and measures
1.1 Notes on possible personal injury
WARNING
!
Risk of injury due to high pressure inside device.
Thevolumeboosterispressurized.Improperremovaloftheinstalledvolumeboosteror
opening of the body can lead to device components bursting and cause serious injury.
ÎDepressurizethevolumeboosterbeforeremovingitoropeningthebody(disconnect
the signal pressure and protect it against unintentional reconnection).
High sound pressure level! Risk of damage to hearing.
If a noise-reducing element is not screwed into the exhaust port, the volume booster
generates a loud noise on venting.
ÎWear hearing protection.
1.2 Notes on possible property damage
NOTICE
!
Risk of damage to the volume booster due to contamination.
Incorrect handling may allow dirt or other foreign particles to enter the device and lead
to malfunctioning or damage.
ÎNo substances must be allowed to enter the device during mounting, transport or
storage.
Risk of damage to the volume booster due to incorrect mounting position.
The incorrect mounting position may allow dirt or other foreign particles to enter the de-
vice and lead to malfunctioning or damage.
ÎMount the volume booster with the vent opening facing downward or to the side
(exception:Type3755-2whentheexhaustportisscrewedtoapipe).
ÎIf the volume booster can become covered in snow, iced up or dirt can collect in the
device, it must be mounted with the exhaust side facing downward or protected by a
suitablexture/cover.
ÎWhen a screwed-on silencer is used, mount the volume booster with the silencer
facing downward.

8 EB 8393 EN
Markings on the device
2 Markings on the device
2.1 Article code
Pneumatic Volume Booster Type 3755- x x x 0 0 x x 0 0 x 0 0 0 0
Type
Low-noiseventingoverasinteredpolyethylenelter
disk 1 0 0
(Flanged-on) threaded exhaust port 2 3/5 0/1
Pneumatic connections
Supply air and actuator ISO 228 - G ¾,
signal ISO 228 - G ¼ 1
Supply air and actuator ¾-14 NPT, signal ¼-18 NPT 2
Exhaust version
Sinteredpolyethylenelterdisk 0
(Flanged-on)threadedexhaustportISO228-G1 3
(Flanged-on)threadedexhaustport1-11½NPT 5
Flowcoefcient
Supply air KVS = 2.5 m³/h, exhaust KVS = 2.5 m³/h 0
Dynamic response
Standard (normal control) 0
Bodymaterial
Aluminum 0
Stainless steel 1
Color
Gray-beige,structurednish,RAL1019
(aluminum body) 0
Without (stainless steel body) 1
Temperature range
Standardtemperature,–40to+80°C 0
Lowtemperatureversion,–55to+60°C 1

EB 8393 EN 9
Markings on the device
2.2 Nameplate
SAMSON 3755 Pneumatic Volume Booster
Model 3755-
Serial no.Var.-ID
Ambient temperature range
Supply max. 10bar/145psi
Signal max. 7bar/101.5psi
Output max. 7bar/101.5psi
kVS Supply
kVS Exhaust
Dynamic set Standard
2.5 m³/h
2.5 m³/h
SAMSON AG, Germany Made in Germany
SUP
SIG
OUT
EXH
1
2 3
4
5
1 Type designation
2CongurationID
3 Serial number
4 Temperature range
5Bodyversion

10 EB 8393 EN
Design and principle of operation
3 Design and principle of oper-
ation
TheType3755PneumaticVolumeBoosteris
used together with positioners to increase the
positioning speed of pneumatic actuators
withaneffectivearea≥1000cm²ora
travelvolume≥6l.
The pneumatic booster supplies the actuator
withanairowoutputwhosepressure
corresponds exactly to the signal pressure,
except that it has a much higher volume
output.
If the positioner signal to supply air to the
actuator increases, the pressure above the
diaphragm (1) increases. The differential
pressure at the diaphragm causes the supply
plug (2) to open, providing supply air up to
amaximumof10bartotheactuator.
In contrast, the signal to vent the actuator
causes the exhaust plug (3) to open. The
pressure in the actuator is relieved over the
exhaust port.
The bypass restriction screw (4) is used to
adjust the response of the pneumatic volume
booster to match the closed control loop
requirements. The setting of the bypass
restriction screw can be locked in position to
prevent it from being turned and can
additionally be lead-sealed.
Refertosection5.3.1onpage23 for
more details on how to adjust the bypass.
3.1 Safety function
ThesafetyfunctionoftheType3755
PneumaticVolumeBoosteristheemergency
venting on demand.

EB 8393 EN 11
Design and principle of operation
(Actuator)
(Supply)
(Exhaust)
2
5
1
4.1
4
3
6
1 Diaphragm
2 Supply plug
3 Exhaust plug
4Bypassrestrictionscrew
4.1 Lock nut
5Bypassduct1)
6 Duct for pressure balancing1)
1) Through hook-up in version with
stainless steel body
SIG Signal
SUP Supply air
OUT Output (to actuator)
EXH Exhaust air
Connections of aluminum version: Connections of stainless steel version:
Sectional drawing of version with aluminum body:
(the same principle applies to the version with stainless steel body):
Signal
Bypass
SU
P
SIG
OUT
EXH
SU
P
SIG
OUT
EXH
Fig.1: Pneumatic connections and sectional drawing

12 EB 8393 EN
Design and principle of operation
3.2 Versions
−Type 3755-1:
Pneumatic volume booster (cast
aluminum body) with low-noise sintered
polyethylenelterdisk(Fig.2)
−Type 3755-2:
Pneumatic volume booster (aluminum
body)withanged-onthreadedexhaust
port(Fig.3)
−Type 3755-2:
Pneumatic volume booster (stainless steel
body),threadedexhaustport(Fig.4)
3.3 Accessories
Screwed-on stainless steel silencer
Connecting thread Item no.
G1 8504-1009
1NPT 8504-1010
ÎWhen a screwed-on silencer is used,
mount the volume booster with the silenc-
er facing downward.
ÎMount the silencer properly using suit-
able tools and sealant to prevent thread
galling(seizure).
ÎIf the silencer can become covered in
snow, iced up or dirt can collect, it must
beprotectedbyasuitablexture/cover.
TheIP54degreeofprotectionisachieved
when the above mentioned requirements are
met.
Fig.2: Type 3755-1 (cast aluminum body)
Fig.3: Type 3755-2 (cast aluminum body)
Fig.4: Type 3755-2 (stainless steel body)

EB 8393 EN 13
Design and principle of operation
3.4 Spare parts/conversion kits
Aluminum version
Spare parts for bypass restriction screw Item no.
Stainless steel lock nut M8x1 8350-0469
Spare parts for Type 3755-1 (sintered polyethylene lter disk) Item no.
Sinteredpolyethylenelterdisk 0550-0825
Stainless steel retaining plate 0500-1401
Stainless steel M5x16 fastening screw 8333-2501
Spare parts for Type 3755-2 (anged-on threaded port) Item no.
Flanged-onthreadedexhaustportG1 0410-6315
Flanged-onthreadedport1NPT 0410-6488
O-ring74x3NBR70ShoreA 8421-0513
Stainless steel M5x25 fastening screw 8333-2503
Conversion kits including mounting parts (see section5.4)Item no.
ConversiontoType3755-1withsinteredpolyethylenelterdisk 1400-9991
ConversiontoType3755-2withanged-onportG1 1400-9988
ConversiontoType3755-2withanged-onthreadedexhaustport1NPT 1400-9989
Stainless steel version
Spare parts for bypass restriction screw Item no.
Stainless steel lock nut M8x1 8350-0469
Spare parts for body piping Item no.
Stainless steel shaped tube Ø8x1, bypass 0401-2537
Stainless steel shaped tube Ø8x1, pressure balancing 0401-2538
StainlesssteelscrewttingG¼Ø8 8582-0321
StainlesssteelscrewttingG
1
/
8
Ø8 8582-0380

14 EB 8393 EN
Design and principle of operation
3.5 Technical data
Pneumatic volume booster Type3755-1 Type3755-2 Type3755-2
Aluminum body Stainless steel body
Flowcoefcients
KVS Supply 2.5m³/h
KVS Exhaust 2.5m³/h
KVS Bypass 0.3m³/h
Closed loop control
Pressure ratio:
signal to output 1 : 1
Response pressure Standard temperature range: 80mbar
Low temperature range: 100mbar
Pressure
Supply Max.10bar·Max145psi
Actuator Max.7bar·Max101.5psi
Signal Max.7bar·Max101.5psi
Air quality acc. to
ISO8573-1
Maximumparticlesizeanddensity:Class4
Oil content: Class 3
Pressuredewpoint:Class3oratleast10Kbelowthelowestambient
temperature to be expected
Connecting thread
Supply (SUP) G ¾ (optionally ¾ NPT)
Actuator/output (OUT) G ¾ (optionally ¾ NPT)
Signal (SIG) G ¼ (optionally ¼ NPT)
Exhaust port (EXH) – G 1 (optionally 1 NPT)
Safety integrity level
Use in safety-instrumented
systems acc. to
IEC61508/IEC615111)
Suitable for use in safety-instrumented systems up to SIL 2: applies to
a single device
Suitable for use in safety-instrumented systems up to SIL 3: applies to
redundantcongurationofvalvesaccordingtoIEC61508
ÎSeeManufacturer'sDeclarationHE1193(availableonrequest)
1) Only suitable for the standard temperature range and with the aluminum body

EB 8393 EN 15
Design and principle of operation
Pneumatic volume booster Type3755-1 Type3755-2 Type3755-2
Aluminum body Stainless steel body
Degree of protection
Degree of protection
provided by body
accordingtoEN60529
IP 44 2) IP 66 3)
Compliance
Other operating parameters
Permissible ambient
temperature Standard temperature range: –40to+80°C
Low temperature range: –55to+60°C
Service life ≥1x107full strokes
Weight 2.1kg 2.4kg 5.2kg
Materials
Body Cast aluminum, powder paint coated
(RAL1019)
1.4404 and 1.4571
ENAC-43000KF
according to
DINEN1706
ENAC-43000KF
according to
DIN1706and
ENAW-5083-H112
according to
DINEN755-3
Exhaust side Silencer with sintered
polyethylenelterdisk
and stainless steel
retaining plate
Flanged-on threaded
port made of
aluminum, powder
coated(RAL1019)
Threaded port made
of stainless steel
Diaphragm Standard temperature range: VMQ
Low temperature range: PVMQ
Seat-plug seal VMQ
Other seals NBR
Other external parts 1.4404
2) Exhaust side facing downward or to the side
3) The following applies for Type 3755-2: body IP 66; the IP rating depends on how the venting is implemented (pipe,
silencer etc.).

16 EB 8393 EN
Design and principle of operation
3.6 Dimensions in mm
3.6.1 Aluminum version
107
155
70
52
15
Ø 105
Ø 120
180
Type 3755-1 with sintered
polyethylene lter disk for
low-noise venting
Type 3755-2
Flanged-on threaded exhaust port
connected to a pipe

EB 8393 EN 17
Design and principle of operation
3.6.2 Stainless steel version
max.190
100
60
67
Ø12.5 (2x)
90
95
165
9
15
25
11.5
76
SW46
Ø120
Ø90

18 EB 8393 EN

EB 8393 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 transportation dam-
age.
4.1 Unpacking
Do not remove the packaging if the volume
booster is to be transported to another loca-
tion or kept in storage.
Beforemountingthevolumebooster,pro-
ceed as follows:
1. Remove the packaging from the volume
booster.
2. Dispose of the packaging in accordance
with the valid regulations.
Risk of damage to the volume booster due to
foreign particles entering it.
Do not remove the protective lm until imme-
diately before mounting.
4.2 Transporting and lifting
4.2.1 Transporting
−Protect the volume booster against exter-
nalinuences(e.g.impact).
−Protect the volume booster against mois-
ture and dirt.
−Observe transport temperature depend-
ing on the permissible ambient tempera-
ture(seetechnicaldatainsection3.5).
4.2.2 Lifting
Due to the low service weight, lifting equip-
ment is not required to lift the volume booster.
4.3 Storage
Risk of damage to the volume booster due to
improper storage.
Observe storage instructions. Contact
SAMSON, if need be.
Storage instructions
−Protect the volume booster against exter-
nalinuences(e.g.impact,shocks,vi-
bration).
−Do not damage the corrosion protection
(coating).
−Protect the volume booster against mois-
ture and dirt. In damp spaces, prevent
condensation. If necessary, use a drying
agent or heating.
−Pack the volume booster in airtight pack-
aging.
Note
NOTICE
!
NOTICE
!

20 EB 8393 EN
Mounting and start-up
5 Mounting and start-up
ÎMount the volume booster with the com-
pressedairowingfromthesupplyport
to the actuator port as indicated by the
arrow on the body.
ÎThe volume booster is mounted between
the positioner and actuator.
To meet the requirements of safety instru-
mented systems (SIS), a solenoid valve can
also be connected between the pneumatic
volume booster and the pneumatic actuator
(Fig.6).
4
1
3
2
5
4
1
4
12 2
5
5
1 Positioner
2 Supply pressure regulator
3 Solenoid valve
4 Pneumatic actuator
5 Volume booster
Fig.5: Standard connection of the pneumatic volume booster for both fail-safe positions
Fig.6: Installation of the pneumatic volume booster with an additional solenoid valve