Installation, Operation, Maintenance Instructions
Pneumatic Diaphragm On-Off Actuators
Series 2, Types: P2, P3, P4
Flow Control Division
Kammer Control Valves
Index
1 Using Kämmer valves and actuators correctly.
2Unpacking
3 Installation
4 Quick check
5 Maintenance
6 Remove and install actuator
7 Reverse actuator action
8 Disassemble and assemble actuator
9 Troubleshooting chart
1 USING KÄMMER VALVES AND ACTUATORS
CORRECTLY
1.1 General
The following instructions are designed to assist in
unpacking, installing and performing maintenance as
required on Kämmer products. Product users and
maintenance personnel should thoroughly review this
bulletin prior to installing, operating or performing
any maintenance.
DANGER:
are designed for specific applications (e.g. with regard
to medium, pressure, temperature). For this reason
they should not be used in other applications without
first contacting the manufacturer.
1.2 Terms concerning safety
The safety terms DANGER, WARNING, CAUTION and
NOTE are used in these instructions to highlight
particular dangers and/or to provide additional
information on aspects that may not be readily
apparent.
DANGER:
and/or substantial property damage will occur if
proper precautions are not taken.
STOP!
WARNING:
and/or substantial property damage can occur if
proper precautions are not taken.
CAUTION:
or property damage can occur if proper precautions
are not taken.
KMEIM0001-00 - 8.03
In most cases Kämmer valves and actuators
indicates that death, severe personal injury
indicates that death, severe personal injury
indicates that minor personal injury and/
NOTE:
information, which may not be very obvious even to
qualified personnel. Compliance with other, not
particularly emphasised notes, with regard to
transport, assembly, operation and maintenance and
with regard to technical documentation (e.g. in the
operating instruction, product documentation or on
the product itself) is essential, in order to avoid faults,
which in themselves might directly or indirectly cause
severe personal injury or property damage.
1.3 Protective clothing
Kämmer products are often used in problematic
applications (e.g. extremely high pressures, dangerous, toxic or corrosive mediums). In particular
valves with bellows seals point to such applications.
When performing service, inspection or repair
operations always ensure, that the valve and actuator
are depressurised and that the valve has been cleaned
and is free from harmful substances. In such cases
pay particular attention to personal protection
(protective clothing, gloves, glasses etc.).
1.4 Qualified personnel
Qualified personnel are people who, on account of
their training, experience and instruction and their
knowledge of relevant standards, specifications,
accident prevention regulations and operating
conditions, have been authorised by those responsible
for the safety of the plant to perform the necessary
work and who can recognise and avoid possible
dangers.
1.5 Installation
DANGER:
serial-no. and/or the tag-no. to ensure that the valve/
actuator is correct for the intended application.
Do not insulate extensions that are provided for hot
or cold services.
Pipelines must be correctly aligned to ensure that the
valve is not fitted under tension.
indicates and provides additional technical
Before installation check the order-no,
1
Flow Control Division
Kammer Control Valves
1.6 Spare parts
Use only Kämmer original spare parts. Kämmer
cannot accept responsibility for any damages that
occur from using spare parts or fastening materials
from other manufactures. If Kämmer products
(especially sealing materials) have been on store for
longer periods check these for corrosion or deterioration before using these products. Fire protection for
Kämmer products must be provided by the end user.
1.7 Service / repair
To avoid possible injury to personnel or damage to
products, safety terms must be strictly adhered to.
Modifying this product, substituting nonfactory parts,
or using maintenance procedures other than outlined
in this instruction could drastically affect performance
and be hazardous to personnel and equipment, and
may void existing warranties. Between actuator and
valve there are moving parts. To avoid injury
Flowserve provides pinch-point-protection in the form
of cover plates, especially where side-mounted
positioners are fitted. If these plates are removed for
inspection, service or repair special attention is
required. After completing work the cover plates must
be refitted.
Apart from the operating instructions and the
obligatory accident prevention directives valid in the
country of use, all recognised regulations for safety
and good engineering practices must be followed.
WARNING:
for repair or service Kämmer must be provided with
STOP!
Before products are returned to Kämmer
a certificate which confirms that the product has been
decontaminated and is clean. Kämmer will not accept
deliveries if a certificate has not been provided (a form
can be obtained from Kämmer).
1.8 Storage
In most cases Kämmer Products are manufactured
from stainless steel. Products not manufactured from
stainless steel are provided with an epoxy resin
coating. This means that Kämmer products are well
protected from corrosion. Nevertheless, Kämmer
products must be stored adequately in a clean, dry
environment. Plastic caps are fitted to protect the
flange faces and to prevent the ingress of foreign
materials. These caps should not be removed until
the valve is actually mounted into the system.
1.9 Valve and actuator variations
These instructions cannot claim to cover all details
of all possible product variations, nor in particular
can they provide information for every possible
example of installation, operation or maintenance.
This means that the instructions normally include only
the directions to be followed by qualified personal
where the product is being used for is defined
purpose. If there are any uncertainties in this respect
particularly in the event of missing product-related
information, clarification must be obtained via the
appropriate FLOWSERVE sales office.
2 UNPACKING
2.1 Each delivery includes a packing slip. When unpacking, check all delivered valves and accessories using
this packing slip.
2.2 Larger valves can be lifted using slings on the yoke
rods or, if present, on the lugs provided for this
purpose. If slings are used, attach them so that the
outer tubing or attaching parts are not damaged.
WARNING:
If slings are used, be aware that the cen-
tre of gravity of the valve may be above the lifting
STOP!
point. In this case, secure or support the valve against
rotating, to prevent damage or personnel injury.
2.3 Report transport damage to the carrier immediately.
2.4 In case of discrepancies, contact your nearest
FLOWSERVE sales office.
3 INSTALLATION
3.1 Clean tubing prior to installing.
3.2 If possible, install the valve in an upright position
(actuator on top), to ease maintenance. An upright
installation position is important with low-temperature applications, in order to keep the distance between the packing material and the medium as large
as possible. The packing material then retains the
ambient temperature as much as possible.
NOTE:
Do not insulate extension bonnets that are pro-
vided for hot or cold services
3.3 Make sure that sufficient overhead clearance above
the actuator is maintained, to allow for disassembly
of plug from the valve body (see following table).
Actuator Clearance Actuator Clearance
size (mm) size (mm)
37/47 95 P2 140
38/48 140 P3 140
39/49 140 P4 140
39D/49D 140 P5 140
3.4 After installing, check direction of flow again. The
direction of flow is shown by the arrow on the
housing.
3.5 If the valve is to be welded into the line, make sure that
the valve is shielded from excessive heat.
3.6 Connect supply pressure and signal lines. Control
valves are supplied with a positioner. The end connections for supply pressure and signal are clearly
marked. Series 4 actuators and positioners are suitable for max. 4.2 bar (60 psi) supply pressure. If the
supply pressure exceeds the pressure specified on
the nameplate, a pressure reducing station is required. If instrument air is not available, install an oil
separator/air filter in the air inlet line. All connections
must be leak free.
2
Flow Control Division
Kammer Control Valves
4 QUICK CHECK
Before operating, check the valve as follows:
4.1 Open and close the valve, and observe the movement
of the actuator stem. The movement must be smooth
and linear.
4.2 Check for maximum stroke through change of signal
(for pneumatic positioners, 0.2 - 1.0 bar or corresponding split-range values; for IP positioners, 4-20
or 0-20 mA).
4.3 Check all air connections for leaks.
4.4 Tighten packing nut (see table 1).
Torque
Thread PTFE Grafoil
M20 x 1,5 1 3
M30 x 1,5 6 15
M38 x 1,5 15 35
M45 x 1,5 17 40
Table 1
NOTE:
An excessively tightened gland nut can cause
excessive packing wear and can hinder the free movement of the plug stem.
4.5 Check fail-safe position. To do this, close supply
pressure and observe whether the valve opens or
closes as defined.
4.6 After use at fluctuating temperatures, re-tighten all
bolt connections and check for leaks.
5.5 Check gland nut for correct torque (see table 1).
NOTE:
An excessively tightened gland nut can cause
excessive packing wear and can hinder the free movement of the plug stem.
5.6 If possible, open and close valve and check for
maximum stroke and smooth movement of the plug
stem. Irregular movement of the plug stem may
indicate internal defects.
NOTE:
With graphite packing, irregular movement of
the plug stem is normal.
WARNING:
STOP!
all moving parts. Failure to do so can lead to serious
Keep hands, hair, clothing, etc. away from
injury.
5.7 Check all accessories for firm seating.
5.8 If possible, close supply pressure and check the failsafe position.
5.9 Check stem boot for wear.
5.10 Check actuator for leaks. To do this, spray housing,
air connections and plug stem guide with leak spray
and check for any bubble formation.
5.11 Clean plug stem.
5.12 Check air filter, if present, and if necessary replace
insert.
Note:
For further information regarding service and
maintenance please contact your nearest FLOWSERVE
office.
5 MAINTENANCE
Check valves for correct functioning at regular intervals (at least once every 6 months) as follows. This
check can be made when installed and in many
cases without interrupting production. If internal defects are suspected, see section „Disassembly and
Assembly of Valve“.
5.1 Examine gaskets for leaks and if necessary re-tighten
bolts (see Fig. 1).
5.2 Check bellows gasket and test connection - if present
- for external leaks.
5.3 Check valve for damage caused by corrosive residues
or corrosive vapours.
5.4 Clean valves and repaint as necessary.
Warning:
STOP!
clean the actuator/valve with a damp cloth only.
To prevent a buildup of electrostatic charge
3
21
Flow Control Division
Kammer Control Valves
20
18
22
23
24
32
25
26
27
30
28
29
7
1
17
18
31
19
2
3
4
5
2
6
7
8
9
10
11
12
13
14
15
1 Washer
2 Bushing
3 O-Ring 22 x 2
4 Guide
5 O-Ring 32,99 x 2,62
6 Lower body
7 Flange
8 Yoke plate
9 Nut M 38 x 1,5
10 Actuator stem
11 Yoke rod
12 Coupling half
13 Screw
14 Coupling insert
15 Nut
16 Yoke plate
17 Washer, Ø 6,4
18 Nut, M 6
19 Travel indicator, assy.
20 Screw M 6 x 25
21 (De)Compression screw
22 Upper body
23 Vent plug
24 Locknut
25 Spacer
26 Plate
27 Spring plate
28 Piston
29 Diaphragm
30 Spring set
31 Nut
32 Nut
Fig. 1: Series 1 On-Off Actuator, Air-to-Open
Service to the actuator is best performed when the actuator is removed from the valve body. For the purpose of these instructions,
consider the actuator as a separate subassembly with the procedures described in these instructions being performed on a bench.
However, many service repairs and adjustments can be accomplished in the field while the actuator and valve body are still connected
to each other.
6 REMOVING AND INSTALL ACTUATOR
6.1 REMOVING ACTUATOR
(refer to Fig. 1)
6.1.1 Shut off air supply.
WARNING:
and drain all fluids from the valve before working on the
STOP!
actuator. Failure to do so can cause serious injury.
6.1.2 Disconnect all tubing.
6.1.3 Remove 2 screws (13) and remove coupling (12).
6.1.4 Remove yoke rod retaining nuts (15) and lift actuator
assembly from the valve.
6.1.5 Remove coupling insert (14) and it’s locknut from plug stem.
NOTE:
plug seated. This may cause irreparable damage to the
seating faces.
6.2 INSTALL ACTUATOR
(refer to Fig. 1)
The actuator stem must be fully extended:
Actuators with air-to-open action must be fully vented.
Actuators with air-to-close action apply supply pressure.
Manually depress the plug stem to ensure the plug is fully
4
seated.
Depressurise the line to atmospheric pressure
Ensure that the plug assembly is not rotated with the
16
6.2.1 Screw coupling insert locknut and coupling insert as far
as possible onto plug stem.
6.2.2 Place the actuator assembly on the valve engaging the yoke
rod threads in the lower yoke plate and ensuring the
actuator faces in the correct direction.
6.2.3 Unscrew the coupling insert until the yoke rods are raised
from the lower yoke plate by around 2 mm.
NOTE:
Ensure that the plug assembly is not rotated with
the plug seated. This may cause irreparable damage to the
seating faces.
6.2.4 Refit the coupling (12), ensuring that the arrows, embossed
on the coupling halves, point upward
towards the actuator, and secure with
2 retaining screws (13).
6.2.5 Apply supply pressure resp. vent
actuator to half stroke and refit and
tighten yoke rod retaining nuts (15).
6.2.6 Connect all tubing.
7 REVERSE THE ACTUATOR ACTION
(refer Fig. 1)
DANGER:
Actuators with “spring-to-close” action can be
disassembled and reassembled by using long
(de)compression screws. A suitable press is required to
disassembled and reassemble actuators with “spring-toopen” action or to reverse the actuator action.
7.1 Reverse actuator action from spring-to-close to spring-to-open
7.1.1 As required remove the actuator from the valve as described
in section 1.1.
7.1.2 If long (de)compression screws are not already fitted to
the actuator: on type P2 remove 3 equally spaced case
retaining screws (20), on types P3/P4 remove 4 equally
spaced case retaining screws (20).
7.1.3 Insert 3/4 longer (de)compression screws (21) according
to table 2 and tighten the nuts hand tight.
Actuator Screw length
Type P2 50 mm
Type P3 70 mm
Type P4 110 mm
Table 2
Screw lengths for (de)compression screws
7.1.4 Remove all the remaining short case retaining screws (20).
7.1.5 Unscrew the long compression screws (21) in equal
measures until the actuator springs are fully decompressed
and the upper case is loose.
7.1.6 Remove the upper case half.
7.1.7 Secure the actuator stem (10) against rotating with a
wrench across the flats on the stem’s lower part and remove
the lock nut (24) and nut (32).
7.1.8 Remove following parts:
spacer (25), plate (26), spring plate (27), spring set (30),
piston (28) diaphragm (29) and washer (1)
7.1.9 Replace the parts onto the actuator stem in reverse
order.
7.1.10 With a suitable press compress the spring set.
7.1.11 Secure the actuator stem (10) from rotating with a wrench
across the flats on the stem’s lower part and retighten the
nut (32) to the torque shown in table 2. Replace locknut
(24) and secure with loctite 221.
Actuator Torque
Type P2 20 Nm
Type P3 30 Nm
Type P4 35 Nm
Table 3 Torque value for nut (32)
7.1.12 Release the press and replace the upper case half.
7.1.13 Insert and tighten the case retaining screws (20) to a torque
value of 12 Nm
7.1.14 As required refit the actuator assembly to the valve as
described in section 1.2.
7.2 Reverse actuator action from spring-to-open to spring-to-close
7.2.1 As required remove the actuator from the valve as described
in section 1.1.
7.2.2 Remove all case retaining screws (20).
Flow Control Division
Kammer Control Valves
7.2.3 Remove the upper case half (22).
7.2.4 With a suitable press compress the spring set.
7.2.5 Secure the actuator stem (10) against rotating with a
wrench across the flats on the stem’s lower part and remove
the lock nut (24) and nut (32).
7.2.6 Remove following parts:
washer (1), diaphragm (29), piston (28), spring set (30),
spring plate (27), plate (26) and spacer (25).
7.2.7 Replace the parts onto the actuator stem in reverse
order.
7.2.8 Secure the actuator stem (10) from rotating with a wrench
across the flats on the stem’s lower part and retighten the
nut (32) to the torque shown in table 3. Replace locknut
(24) and secure with loctite 221.
7.2.9 Release the press and replace the upper case half.
7.2.10 Insert 3/4 longer (de)compression screws (21) (see table
2) through the upper and lower actuator case halves and
tighten with long nuts (31) in equal measures until the
casing halves contact.
7.2.11 Insert and tighten all remaining short case retaining screws
(20) to a torque value of 12 Nm.
7.2.12 As required replace the long (de)compression screws/nuts
with the short screws/nuts.
7.2.13 As required refit the actuator assembly to the valve as
described in 1.2.
8 DISASSEMBLE AND ASSEMBLE ACTUATOR
(refer to fig. 1)
DANGER:
disassembled and reassembled by using long
(de)compression screws. A suitable press is required to
disassembled and reassemble actuators with “spring-toopen” action or to reverse the actuator action.
8.1 DISASSEMBLE ACTUATOR
8.1.1 Actuator action spring-to-close
8.1.1.1 As required remove the actuator from the valve as described
in section 1.1.
8.1.1.2 If long (de)compression screws are not already fitted to
the actuator: on type P2 remove 3 equally spaced case
retaining screws (20), on types P3/P4 remove 4 equally
spaced case retaining screws (20).
8.1.1.3 Insert 3/4 longer (de)compression screws (21) according
to table 1 and tighten the nuts hand tight.
8.1.1.4 Remove all the remaining short case retaining screws (20).
8.1.1.5 Unscrew the long compression screws (21) in equal
measures until the actuator springs are fully decompressed
and the upper case is loose.
8.1.1.6 Remove the upper case half.
8.1.1.7 Secure the actuator stem (10) against rotating with a
wrench across the flats on the stem’s lower part and remove
the lock nut (24) and nut (32).
8.1.1.8 Remove following parts:
spacer (25), plate (26), spring plate (27), spring set (30),
piston (28) diaphragm (29) and washer (1)
8.1.1.9 With a hooked spanner loosen and remove the slotted
nut (9).
8.1.1.10 Remove the guide (4) and upper yoke plate (8).
8.1.2 Actuator action spring-to-open
8.1.2.1 As required remove the actuator from the valve as described
Actuators with “spring-to-close” action can be
5
21
Flow Control Division
Kammer Control Valves
20
18
22
23
24
32
25
26
27
30
28
29
7
1
2
1 Washer
2 Bushing
3 O-Ring 22 x 2
4 Guide
5 O-Ring 32,99 x 2,62
6 Lower body
7 Flange
8 Yoke plate
9 Nut M 38 x 1,5
10 Actuator stem
11 Yoke rod
12 Coupling half
13 Screw
14 Coupling insert
15 Nut
16 Yoke plate
17 Washer, Ø 6,4
18 Nut, M 6
19 Travel indicator, assy.
20 Screw M 6 x 25
21 (De)Compression screw
22 Upper body
23 Vent plug
24 Locknut
25 Spacer
26 Plate
27 Spring plate
28 Piston
29 Diaphragm
30 Spring set
31 Nut
32 Nut
17
18
31
19
3
4
5
2
6
7
8
9
10
11
12
13
14
15
Fig. 1: Series 1 On-Off Actuator, Air-to-Open
in section 1.1.
8.1.2.2 Remove all case retaining screws (20).
8.1.2.3 Remove the upper case half (22).
8.1.2.4 With a suitable press compress the spring set.
8.1.2.5 Secure the actuator stem (10) against rotating with a wrench
across the flats on the stem’s lower part and remove the
lock nut (24) and nut (32).
8.1.2.6 Remove following parts:
washer (1), diaphragm (29), piston (28), spring set (30),
spring plate (27), plate (26) and spacer (25).
8.1.2.7 With a hooked spanner loosen and remove the slotted nut
(9).
8.1.2.8 Remove the guide (4) and upper yoke plate (8).
8.2 ASSEMBLE ACTUATOR
(refer to Figs. 1 and 2)
8.2.1 Actuator action spring-to-close
8.2.1.1 Insert the guide (4) into the lower body half.
8.2.1.2 Replace the upper yoke plate ensuring that the nose in the
lower body rests in the bore of the upper yoke plate (see
fig. 2).
8.2.1.3 Refit the slotted nut (9) and tighten with a hooked
spanner.
6
16
Fig. 2: Anti-rotation device
8.2.1.4 Refit the actuator stem (10), washer (1), diaphragm (29),
piston (28), spring set (30), spring plate (27), plate (26)
and spacer (25)
8.2.1.5 Secure the actuator stem (10) from rotating with a wrench
across the flats on the stem’s lower part and retighten the
nut (32) to the torque shown in table 2. Replace locknut
(24) and secure with loctite 221.
8.2.1.6 Replace the upper case half.
8.2.1.7 Insert 3/4 longer (de)compression screws (21) (see table
2) through the upper and lower actuator case halves and
tighten with long nuts (31) in equal measures until the
casing halves contact.
8.2.1.8 Insert and tighten all remaining short case retaining screws
(20) to a torque value of 12 Nm.
Flow Control Division
Kammer Control Valves
8.2.1.9 As required replace the long (de)compression screws/nuts
with the short screws/nuts.
8.2.1.10 As required refit the actuator assembly to the valve as
described in 1.2.
8.2.2 Actuator action spring-to-close
8.2.2.1 Insert the guide (4) into the lower body half.
8.2.2.2 Replace the upper yoke plate ensuring that the nose in
the lower body rests in the bore of the upper yoke plate
(see fig. 2).
8.2.2.3 Refit the slotted nut (9) and tighten with a hooked
spanner.
8.2.2.4 Refit the actuator stem (10), spacer (25), plate (26),
spring plate (27), spring set (30), piston (28), diaphragm (29) and washer (1).
8.2.2.5 With a suitable press compress the spring set.
4.2.6 Secure the actuator stem (10) from rotating with a wrench
across the flats on the stem’s lower part and retighten the
nut (32) to the torque shown in table 3. Replace locknut
(24) and secure with loctite 221.
8.2.2.7 Release the press and replace the upper case half.
8.2.2.8 Insert and tighten the case retaining screws (20) to a
torque value of 12 Nm
8.2.2.9 As required refit the actuator assembly to the valve as
described in section 1.2.
8.3 NAMUR ACCESSORIES
(see Fig. 3)
8.3.1 Accessories according to NAMUR can be fitted by
flanging them to the yoke. A special coupling half with
threaded bosses is available to connect the actuating
lever (see spare parts list for part-no.).
Fig. 3: NAMUR coupling half
7
9 Troubleshooting chart
Problem Possible cause Corrective Action
Stem pulsates 1. Unstable air supply 2. Adjust air supply
2. Vent or passage blocked 3. Clean vent or passage
Actuator slow 1. Air supply too low 1. Adjust air supply
2. Diaphram case leaks air 2. Seal diaphram case
3. Spring case vent blocked 3. Renew vent
Actuator will not 1. Air supply too low 1. Adjust air supply
return to end 2. Broken actuator spring 2. Renew all actuator springs
position 3. Actuator movement blocked 3. Dissassemble actuator and check
Actuator will not 1. Actuator not vented 1. Vent actuator
return to the 2. Broken actuator spring 2. Renew all actuator springs
failsafe position 3. Actuator movement blocked 3. Dissassemble actuator and check
Flow Control Division
Kammer Control Valves
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45141 Essen Springville, UT 84663
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Telephone: +49 (0) 201 8919 5 Telephone: +1 801 489 8611 Telephone: +65 862 3332
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Telephone: +27 397-3150 Telephone: 9663 857 3442
Facsimile: +27 397-5300/01/02 Facsimile: 9663 859 5284
8
©03.2002 Flowserve Corporation. Flowserve and Kämmer are trademarks of Flowserve Corporation
All data subject to change without notice
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