Emerson Sempell Series, STE 4 Operating Instructions Manual

SEMPELL SERIES STE 4 CONTROL DEVICE FOR SAFETY VALVES

Operating instructiOns

Before installation these instructions must be fully read and understood

Series

STE 4 Control device for safety valves with

pneumatic actuator.

1 DANGER AND WARNING INDICATIONS

The construction of the Sempell safety
valves and control devices corresponds to
the standard technology and the valid safety
regulations.
Nevertheless, improper use or improper
installation may cause risks for personnel
or can lead to restrictions in regard of the
operational safety. Therefore Sempell GmbH
recommends the operator of the valves to take
appropriate measures and make sure that
the present operating instruction is read and
understood by the assigned personnel.

Please observe the following points besides
the notes given in the text

• Danger of burning when in contact with safety
valves and connecting pipes while operating

at increased temperature.

• Disassembly of the safety valve only in case

of pressureless system and after cooling

down. Wait for official permission. Disconnect

electrical supply.

• Protection against risks caused by

evaporation also in case of pressureless
system; for information please contact the
responsible safety inspector.

• After assembly check all sealing points in

regard of tightness.

• Carry ear protection during adjustment,

ifnecessary.

• Danger of burning by discharge of small

amounts of possibly hot medium in case

of safety valves with open spring bonnet

(typeSO..., VSE 1, VSR 1, VSE 8).

• Danger of injury while discharging in case of

open discharge line.

• Extreme vibrations (chatter) can lead to an

inadmissible increase of operating pressure

with possibly destruction of the safety valve
or to destruction of the balanced bellows with

unintentional escape of medium.

Exclusion of liability

Sempell GmbH cannot be held liable in case

of improper maintenance and adjustment of

a Sempell valve, use of inadmissible spare
parts or utilities and in case of temporary or

permanent connection of equipment with the
safety valve which is not approved by us.

Application limits

It is only allowed to use the safety valves and the
control device according to the details of this
operating instruction and/or according to the
parameters and application data agreed in the
delivery contract (see nameplate).
The application of the valve has to take place
adequate to the medium tolerances of the used
materials.

Warnings for the operating and maintenance
personnel

Before commissioning and maintenance works
familiarise yourself with the legal accident
prevention regulations, the local safety
instructions and this operating instruction and
observe them.
Use safety valve, control device and their
individual parts and accessories only for the
purpose intended by us.
Work on the electrical systems or equipment
must only be carried out by an electrician
or instructed personnel under control and
supervision of an electrician according to the
electrotechnical regulations.

www.valves.emerson.com © 2017 Emerson. All rights reserved.

MA.330.02.0505.E

VCIOM-02238-EN 15/01

SEMPELL SERIES STE 4 CONTROL DEVICE FOR SAFETY VALVES

Operating instructiOns

2 DESCRIPTION OF COMPONENTS

For the following sections the connection

diagram section 9.2 is valid unless other
provided.

2.1 Description of the function

The type-tested control device STE 4 pilots

the on- and off-switch of the loading air or
lifting air of the spring-loaded safety valve with

pneumatic actuator.

Under power the 2/2 way solenoid valves
(Y1,Y2, Y3) are closed and the 3/2 way solenoid

valve (Y4) connects de-energized the pressure
space (H) of the pneumatic actuator for lifting

air with the atmosphere.

Via pressure regulator (R1), filter (F) and throttle
(D), the loading air is on the loading cavity (B) of
the pneumatic actuator. It causes an additional
closing force to the spindle of the spring-loaded

safety valve with pneumatic actuator.

The pressure gauge MB in the control unit

shows the loading pressure, the control lamps

(Y1, Y2, Y3, B) shine.

D2D1

A2A1 G2 D3 A3 G3G1

Opening

The pressure switches (D1, D2, D3) inserted
into the impulse unit are adjusted to the desired
set pressure. In case of exceeding set pressure,

the solenoid valves (Y1, Y2, Y3) installed into
the control unit become de-energized. These

solenoid valves (Y1, Y2, Y3) switch by means of

the contacts of the relay and are assigned to

the corresponding pressure switch

Additionally, each of the three solenoid valves
become simultaneous de-energized by means
of a relay contact released by each of the three

pressure switches (D1, D2, D3). The solenoid

valve (Y4) is energized.
The loading air is relieved through the solenoid
valves (Y1, Y2, Y3). The lifting air is built up by
the solenoid valve (Y4). The controlled safety
valve opens.
The relief of the loading air also occurs if only
one of the three solenoid valves (Y1, Y2, Y3)
opens.

If the lifting air is not switched on, the

controlled safety valve opens after the
reduction of the loading air like a spring-loaded
safety valve.

Closing

If the system pressure drops below the reseat
pressure of the pressure switches (D1, D2, D3),
the solenoid valves (Y1, Y2, Y3, Y4) switch back.

The supply of lifting air stops. The pressure
space (H) of the pneumatic actuator relieves to
atmosphere and the loading air in the loading
cavity (B) builds up again. The controlled safety
valve closes.

P1 E1 P2E2 P3E3

room. Incase of higher control air pressures
(lifting air) a second pressure regulator R2

will be used toreduce the loading air pressure
(accessory, see system circuit diagram with

pressure regulator R2).

2.2 Description of the construction

According to the specification, there are three
separated control lines in the control device
STE 4, that means three pulse generators

(pressure switches) and three control units
(solenoid valves) with each an independent

pressure sense connection.
For testing and/or repair purpose it is possible
to temporarily put one of the three control
lines out of operation by means of the valve
interlock(G).
The control device STE 4 consists of the
functional groups:

impulse unit A161, electric switch unit A162 and

pneumatic control unit A163.
The impulse unit is composed of the
connections for the pressure sense lines (E1,

E2, E3), the shut-off valves with interlock (A1,
A2, A3) and the pressure switches (D1, D2, D3).

The test connections (P1, P2, P3) are located
between the shut-off valves and the pressure
switches. The pressure switches contain two
micro switches so that opening and closing

pressure can be set independent from each

other (P-min, P-max).

Sliding pressure operation

Open the safety valve below the set pressure

by an electrical impulse from the control

ATTENTION!

The components of the impulse unit A161 are
under system pressure!

2

SEMPELL SERIES STE 4 CONTROL DEVICE FOR SAFETY VALVES

Operating instructiOns

The electric switch unit includes the equipment

for signal treatment and control. At the bottom

side is the connection for the power supply.
Protected by an inspection window, control
lamps and manual switches for working and
testing are on the front panel. Pressing the
switch “Lamp Test” en ergizes all control

lamps.

The pneumatic control unit contains the
connections for the compressed-air supply
of the pneumatic section through pressure
regulator (R1) and air filter (F) to three closed-

circuit 2/2 way solenoid valves (Y1, Y2, Y3); one
open-circuit 3/2 way solenoid valve (Y4) and

the pressure gauges for loading and lifting air
(MB,MH).
At the upper side are the connections of the
control lines to the pneumatic actuator.

P4 MHY4

P5R1

Y1 Y2 Y3 F

3

SEMPELL SERIES STE 4 CONTROL DEVICE FOR SAFETY VALVES

Operating instructiOns

3 TECHNICAL DATA SAFETY VALVE CONTROL

Manufacturer Sempell GmbH
Name Control Device
Series STE 4
Compressed-air supply Max. 8 bar, 12 bar as option
Operating pressure for the pneumatic actuator Max. 8 bar

Max. 12 bar for lifting air
(accessory with pressure regulator R2)

Air consumption at opening About 26 Nm3 at 5 bar
Ambient temperature Max. 60 °C

Protection class IP 55
Weight About 78 kg

Type tested approval mark no. TÜV.SV ...-846

Electric connections:

Control device:
Input voltage 230 V, 50 Hz - 24 V DC or 48 V DC as option
Solenoid valve coils:
Connecting voltage 230 V, 50 Hz - 24 V DC or 48 V DC as option

4 OPERATING INSTRUCTIONS

Switch on the control device STE 4 by the key
operated switch at the electric switch unit.
The white control lamp “Operation” shows the

operating state. The pointer of the measuring

instrument in the “Test” field is in the black
area “Operation”.

ATTENTION!

A change of the lead sealed pressure switch
adjustment must take place inthe presence of
the independent TÜVinspector (TRD 601, sheet 2,
section4.2.1).

4.1 Adjustment after installation

Before delivery the pressure switches are

pre-set to the desired set pressure and closing
pressure (see section 2.1). After the installation
of the system a resetting of the pressure

switches (D1, D2, D3) may be necessary

under operating conditions (e.g. because of
temperature changes or after maintenance

works).
Therefore connect a spindle pump with

calibrated pressure gauge (accessory) at one

of the test connections (P1, P2, P3). Apply the
desired set pressure to the pressure switch.

Because of the closed pertaining shut-off
valve (A1, A2, A3) the system pressure has no
influence. In doing so, temporarily prevent the
response of the safety valve by the pneumatic
actuator.

Procedures

• Open the front door of the electric switch
unit. Set test switch in the “Test” field into
position“Test 1”.

Indicator: yellow control lamp in the “Test”

field blinks.

The lifting air to the pneumatic actuator is

temporarily switched off. The safety valve

remains fully operational.

Unlock and close the corresponding shut-off
valve (A1, A2 or A3) by means of interlock key.

Connect spindle pump with pressure gauge
at the test connection (P1 or P2 or P3) of the

previously closed shut-off valve (connections
see section 4.7.1).

4.2 Pre-setting

In case of a new adjustment or of great
deviations pre-set both micro switches of the
pressure switch (D1, D2, D3) approximately at

their set value first.

The precision pressure switches

Manocomb-Sem-2K have calibrated

nominal value scales for P-max and P-min
with an accuracy of ≤ 1%. By means of the
corresponding knurled-head screws pre-set
the switch points quite precise.

4.3 Set pressure control

Increase pressure with the spindle pump

connected to the test connection until the

control lamp P-max (red) flashes up. This is the
switch point. Register pressure reading on the

test gauge.

To change the switch point, turn the higher
knurled-head screw. Turn the adjusting screw
only a little when you are close to the switch
point. Lower excess pressure up to about 0bar

and then increase again until the pressure

switch actuates. Register pressure indicator
of the gauge again and correct switch point if

necessary.

Repeat procedures until the desired switch

pressure is reached.

In case of pressure decrease, the switching
band of the pressure switch with micro
switches can be determined. This is the
pressure difference between switch-on point
(flash up of the control lamp P-max) and
switch-back point (darken of the control lamp
P-max).

4

SEMPELL SERIES STE 4 CONTROL DEVICE FOR SAFETY VALVES

Operating instructiOns

4.4 Reseat pressure

Increase pressure with the spindle pump

connected at the test connection beyond the
desired closing pressure until the control

lamp P-min (yellow) shines. Slowly decrease
pressure until the control lamp P-min (yellow)
goes out. This is the switch point. Register

pressure reading of the gauge.

To change the switch point, turn the
corresponding adjusting screw. Turn adjusting
screw a little when approaching the switch
point. Lower excess pressure up to about 0 bar

and then increase again beyond the closing

pressure (control lamp P-min (yellow) shines).
Slowly decrease pressure until the pressure
switch actuates. Register pressure reading
of the gauge again and correct switch point if

necessary.

Repeat procedures until the desired switch

point is reached.

In case of pressure decrease the switching
band of the pressure switch with micro switch

can be determined. This is the pressure

difference between switch-on point (lighting
up of the control lamp P-min) and back switch
point (darken of the control lamp P-min).
After adjustment open the corresponding

shut-off valve again and lock it by means of the

interlock key. Put the cover on the pressure
switch and lead seal. Close front door again.
Switch back test switch of the electric switch
unit in the “Test” field.
Indicator: yellow control lamp in the field “Test”

does not signal.

4.5 Monitoring

Check daily the actual status of the control
device by visual check.

The actual function will be shown as follows:

• The safety valve is closed and loading air is

applied:

Electric switch unit:
white control lamp “Operation” shines. Gauge

reading is in the black area “Operation”.

Green lamps Y1, Y2, Y3 and B shine.

Pneumatic control unit:
gauge reading present at “Load” (MB).

Inspection window “Load” is green.

• The safety valve is opened and lifting air is

applied:

Electric switch unit:
white control lamp “Operation” shines. Gauge

reading is in the black area “Lifting”. Yellow
lamps Y4 and H shine. Red and yellow lamps

(P-min/P-max) 1 and/or 2 and/or 3 shine.
Pneumatic control unit:
gauge reading present at “Lifting” (MH).

Inspection window “Lifting” is green.

4.7 Testing

4.7.1 Check of pressure switch and operation of
the solenoid valves

For testing, one of the three pressure

switches (D1, D2, D3) can be separated from

the system by closing the unlocked shut-off
valve (A1,A2,A3) in the pressure sense line
(E1,E2,E3) by means of the valve interlock (G).

With a spindle pump with test gauge

(accessory) the desired set pressure can be
applied through the respective connection

(P1, P2, P3). Therefore connect the spindle
pump with a pressure hose and vice coupling

(Minimess Fa. Hydrotechnik) after removing the
knurled protective cap.

The control lamps P-min or P-max show the

gain of set and closing pressure (also see
sections4.3, 3.4).

If the safety valve shall not open during the

tests, set the test switch at field “Test” of the
control device in position “Test 1” to prevent the
opening of the 3/2 way solenoid valve (Y4) and

so the charge of the lifting air. At the same time

this switch position leads to the opening of only

the solenoid valve (Y1, Y2, Y3) assigned to the

specific pressure switch.

Have the set and closing pressure adjustment

checked once a year by an inspector.

ATTENTION!

A change of the lead sealed pressure switch
adjustment must take place inthe presence of
the independent TÜVinspector (TRD 601, sheet 2,
section4.2.1).

4.6 TROUBLE SHOOTING

Malfunction Cause Remedies

Loading air is
prematurely dropped

Pressure switch adjustment changed Pressure switch adjustment see chapter 4
Control line “Load” leaky Eliminate leaking point in the control line

Tube fittings leaky Retighten tube fittings
Electric supply deactivated Check electric connections

5

SEMPELL SERIES STE 4 CONTROL DEVICE FOR SAFETY VALVES

Operating instructiOns

• Check of the control legs 1 to 3

- Adjustment of the control air pressure to

2bar

Check of the pressure gauge “Load”

- Test switch into position “Test 1”

Signal lamp (orange) lights up.

• Check of control leg 1 (pressure switch D1,

solenoid valve Y1)

- Unlock and close shut-off valve A1.

- Slowly apply pressure to test connection P1
up to the response of the pressure switch.

Read corresponding pressure P-max at the

test gauge. Solenoid valve Y1 powerless. Drop

of the loading air; indicator at the pressure

gauge “Load” < 0.2 bar; no lifting air. Indicator
pressure gauge “Lifting” 0 bar, ampere meter
in position “Test 1”.

- Slowly drop pressure until the pressure
switch switches back.

Read corresponding pressure P-min at the

test gauge. Solenoid valve Y1 is energized and

closes. Loading air will be charged. Indicator
pressure gauge “Load” 2 bar.

- Open and lock shut-off valve A1.

• Check of control leg 2 (pressure switch D2,

solenoid valve Y2)

- Unlock and close shut-off valve A2.

- Slowly apply pressure to test connection P2
up to the response of the pressure switch.

Read corresponding pressure P-max at the

test gauge. Solenoid valve Y2 powerless. Drop

of the loading air; indicator at the pressure

gauge “Load” < 0.2 bar; no lifting air. Indicator
pressure gauge “Lifting” 0 bar, ampere meter
in position “Test 1”.

- Slowly drop pressure until the pressure
switch switches back.

Read corresponding pressure P-min at the

test gauge. Solenoid valve Y2 is energized and

closes. Loading air will be charged. Indicator
pressure gauge “Load” 2 bar.

- Open and lock shut-off valve A2.

• Set back to working conditions

- Turn test switch into position “Operation”.

Set control air pressure at normal operating
pressure.

Signal lamp (orange) goes out. Control at the

pressure gauge “Load”.

4.7.2 Check of the displacement force reserve of
solenoid valves Y1, Y2 and Y3

The solenoid valves (Y1, Y2, Y3) consist of a
electric actuated pilot valve and a pneumatic
actuated control valve.
At the electric actuated pilot valve, pressing the

respective push-button in the electric switch
unit lowers the operating tension up to a value
where a faultless solenoid has to switch. A

pressure drop of the loading air at the pressure

gauge (MB) shows the switching. The lifting air

is not actuated.

As the extent of the loading air pressure
counteracts the switch safety of the solenoid
valve check with the highest possible control

pressure.
By means of the magnetic actuated pilot valve
the pilot pressure is released. In case of the
pneumatic actuated control valve the height of

the air pressure brings about the switch safety.

To prove the displacement force reserve on the

control valve check with the lowest possible

control pressure (operation test according to
section 4.7.1).
Control the displacement force reserve at the

solenoid valves by pressing the switches at
a highest possible air pressure. Afterwards
control according to section 4.7.1 at lowered air

pressure.
The loading air pressure has to drop

top<0.2bar for all tests.

Once a year an inspector has to test the

displacement force reserves with the same

pressures.

Potentiometer Switch

• Check of control leg 3 (pressure switch D3,

solenoid valve Y3)

- Unlock and close shut-off valve A3.

- Slowly apply pressure to test connection P3
up to the response of the pressure switch.

Read corresponding pressure P-max at the

test gauge. Solenoid valve Y3 powerless. Drop

of the loading air; indicator at the pressure

gauge “Load” < 0.2 bar; no lifting air. Indicator
pressure gauge “Lifting” 0 bar, ampere meter
in position “Test 1”.

- Slowly drop pressure until the pressure
switch switches back.

Read corresponding pressure P-min at the

test gauge. Solenoid valve Y3 is energized and

closes. Loading air will be charged. Indicator
pressure gauge “Load” 2 bar.

- Open and lock shut-off valve A3.

6