Flowserve 3 Series P6 User Manual

Installation, Operation, Maintenance Instructions

Pneumatic Diaphragm On-Off Actuators

Series 3, Type: P6

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 Disassemble actuator
8 Assemble actuator
9 Reverse actuator action
10 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.

WARNING:

STOP!

jury and/or substantial property damage can occur if
proper precautions are not taken

CAUTION:

property damage can occur if proper precautions are
not taken.

In most cases Kämmer valves and actuators

indicates that death, severe personal injury

indicates that death, severe personal in-

.

indicates that minor personal injury and/or

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, dang-erous,
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:

rial-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, se-

KMEIM0004-00 - 08.03

1

1

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 deterior-ation
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 a

STOP!

certificate which confirms that the product has been

Before products are returned to Kämmer

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:

STOP!

tre of gravity of the valve may be above the lifting

If slings are used, be aware that the cen-

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 low­temperature 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.

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.

STOP!

WARNING:

Prevent other items of equipment from

making mechanical contact with the actuator housing.

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

2

(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 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 valve/actuator and repaint as necessary.
Warning:

STOP!

clean the actuator/valve with a damp cloth only.

5.5 Check gland nut for correct torque (see table 1).

To prevent a buildup of electrostatic charge

Flow Control Division

Kammer Control Valves

NOTE: With graphite packing, irregular movement of
the plug stem is normal.

STOP!

WARNING:

Keep hands, hair, clothing, etc. away from
all moving parts. Failure to do so can lead to serious
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.

DANGER:

On actuators with aluminium cases the
actuator springs must be renewed with original spare
parts every 10 years or after 50.000 operating hours
which ever occurs first.

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.

3

3

3

42
41

Flow Control Division

Kammer Control Valves

40
38
36
35
34
33
32
31

30
29
28

43

39
16
11
37

1
2
3
10

2

4

5
6

7
8
9
10

6

9
11

12

26

25
27

24

1 Pre-tension plate
2 Grooved pin, Ø 5 x 25
3 Diaphragm plate
4 Diaphragm
5 Plate
6 Split ring
7 Ring
8 Ring

9 Back-up ring
10 O-Ring
11 Bushing
12 Diaphragm housing
13 Yoke plate, top
14 Slotted nut

23

27

22
21

15 Yoke rod
16 Wiper ring
17 Screw, NAMUR
18 Yoke plate, lower
19 Spring washer, M16
20 Nut, M16
21 Coupling, kpl.
22 Travel indicator, assy.
23 Nut, M12
24 Actuator stem
26 Screw, M12 x 50
25 Spring housing
27 Vent plug
28 Sleeve

13
14
15
16
17
18
19
20

29 Screw, M5 x 10
30 Nut
31 Spring guide
32 Grooved pin, Ø 6 x 16
33 Guide bushing
34 Plate
35 Washer
36 Screw, M6 x 10
37 Snap ring
38 screw
39 Cap
40 Grooved pin, Ø 5 x 25
41 Threaded insert
42 Eyebolt
43 Spring

Fig. 1: On-Off actuator, Air-to-Open

4

Flow Control Division

Kammer Control Valves

6 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 in a designated workplace. However,
many service repairs and adjustments can be accomplished in the field while the actuator and valve body are still connected to each other.
Attention: The valve trim is a very sensitive assembly, take care not to damage it. Always remove and replace the actuator together with the top
yoke plate (13) and yoke rods (15).

6.1 REMOVE ACTUATOR FROM VALVE BODY

(refer to Figs. 1 + 2)

6.1.1 Shut off the air supply.

WARNING:

pressure and drain all fluids from the valve before

STOP!

Depressurise the line to atmospheric

working on the actuator. Failure to do so can cause
serious injury.

6.1.2 Remove the coupling (21) from the actuator stem

(24):

Loosen clamping screws (50) and expand the clamping
gap as required, apply air to the actuator to move the
actuator stem around 5% from it's end position. Screw
out the slotted nut (51) and drive the actuator stem out
of the coupling (by applying more air on “Air-to-Open”
or by venting air on “Air-to-Close”). Remove ring (52),
split ring (53) and slotted nut (51).

6.1.3 Attach a crane to the eye bolt (42) to support the
actuator and remove the nuts (20) from the yoke rods
(15). Vent the actuator.

WARNING:

“Air-to-Open” the actuator stem will extend and raise

STOP!

When the actuator is vented on version

the actuator!

Remove any tubing and raise the actuator from the
valve.

6.1.4 Loosen the coupling locknut and unscrew the coupling

24

(21) from the plug stem.

51

50

52

53

54

Fig. 2: Coupling

6.2 CONNECT ACTUATOR TO VALVE BODY

(refer to Figs. 1 + 2)

6.2.1 Screw the coupling (21) onto the plug stem until the
stem touches the thrust washer (54).

6.2.2 Mount the actuator onto the valve and secure the yoke
rods (15) to the yoke plate (18) using the nuts (20) and
lockwashers (19). Connect an air supply to the actuator
using a valve that can regulate the air to aerate and vent
the actuator.

6.2.3 Fit the slotted nut (51), ring (52) and split rings to the
actuator stem (on "Air-to-Open" versions retract the
stem by applying air).

6.2.4 Carefully enter the actuator stem into the coupling and
screw the slotted nut (51) into the coupling.

6.2.5 Screw the coupling anticlockwise onto the actuator
stem to achieve a pretension of 2 to 4 mm ensuring that
the NAMUR studs (17) are correctly positioned.

CAUTION:

Ensure that the plug assembly is not rotated
with the plug seated. This may cause irreparable dam­age to the seating faces.

6.2.6 Tighten coupling locknut, slotted nut (51) and clamp­ing screws (50).

6.2.7 As required reconnect all tubing.

7 DISASSEMBLE ACTUATOR

(see Fig. 1)

7.1 Disassemble body

7.1.1 Unscrew the 8/10 screws (38), crisscross, and in equal
measures until the actuator spring(s) (43) are fully
decompressed and the plate (34) is loose.

7.1.2 Remove plate (34), spring(s) (43) and spring guide
(31).

7.1.3 Loosen and remove the 24 flange screws/nuts (26/23).

7.1.4 Reattach the plate (34) to the spring housing (25). With
suitable lifting equipment attached to the eyebolt (42)
remove the spring housing (25).

7.1.5 Remove the actuator stem (24) complete with dia­phragm: lifting equipment can be used if an eyebolt is
fitted to the top of the actuator stem.

7.2 Disassemble diaphragm

7.2.1 Clamp the actuator stem below the diaphragm in a vice
(protect the stem against surface damage).

7.2.2 Loosen the lockscrew (29) and screw the nut (30)
clockwise onto the sleeve (28) (secure the sleeve from
rotating with a wrench across the flats on the lower
portion of the sleeve), until the split ring (6) can be
removed.

7.2.3 Remove sleeve (28), diaphragm plate (3), diaphragm
(4), plate (5) and split ring (6).

7.3 Disassemble actuator stem seal and guide

7.3.1 Diaphragm housing (12)

7.3.1.1 Remove ring (7) and press the calked ring (8) out to the
top.

7.3.1.2 Remove the seal kit consisting of backup rings (9) and
O-ring (10).

7.3.1.3 Remove wiper ring (16) and bushing (11).

7.3.2 Guide bushing (33)

2.3.2.1 Remove wiper ring (16) and bushing (11).

5

5

5

42
41

Flow Control Division

Kammer Control Valves

40
38
36
35
34
33
32
31

30
29
28

43

39
16
11
37

1
2
3
10

2

4

5
6

7
8
9
10

6

9
11

12

26

25
27

24

1 Pre-tension plate
2 Grooved pin, Ø 5 x 25
3 Diaphragm plate
4 Diaphragm
5 Plate
6 Split ring
7 Ring
8 Ring

9 Back-up ring
10 O-Ring
11 Bushing
12 Diaphragm housing
13 Yoke plate, top
14 Slotted nut

23

27

22
21

15 Yoke rod
16 Wiper ring
17 Screw, NAMUR
18 Yoke plate, lower
19 Spring washer, M16
20 Nut, M16
21 Coupling, kpl.
22 Travel indicator, assy.
23 Nut, M12
24 Actuator stem
26 Screw, M12 x 50
25 Spring housing
27 Vent plug
28 Sleeve

13
14
15
16
17
18
19
20

29 Screw, M5 x 10
30 Nut
31 Spring guide
32 Grooved pin, Ø 6 x 16
33 Guide bushing
34 Plate
35 Washer
36 Screw, M6 x 10
37 Snap ring
38 screw
39 Cap
40 Grooved pin, Ø 5 x 25
41 Threaded insert
42 Eyebolt
43 Spring

Fig. 1: On-Off actuator, Air-to-Open

6

Flow Control Division

Kammer Control Valves

8 ASSEMBLE THE ACTUATOR

(see Figs. 1 + 2)

8.1 Assemble diaphragm housing

8.1.1 Fit bushing (11) and wiper ring (16) to diaphragm
housing.

8.1.2 Enter backup ring (9), O-ring (10) and backup ring (9)
from the other side.

8.1.3 Fit the ring (8) and calk in three positions.

8.2 Assemble guide bushing (33)

8.2.1 Fit bushing (11) and wiper ring (16).

8.3 Assemble diaphragm

8.3.1 Clamp the actuator stem in a vice (protect the stem
against surface damage).

8.3.2 Fit the split rings (6) in the groove in the actuator stem
and place the plate (5) on top.

8.3.3 Fit the diaphragm (4) on top of the plate (5) ensuring
that the inner bead sits correctly in the groove ma­chined into the plate (5)

8.3.4 Place the O-ring (10) over the actuator stem until it sits
in the plate (5).

8.3.5 Place the diaphragm plate (3) over the actuator stem
(24) onto the diaphragm (4).

8.3.6 Place the sleeve (28) over the actuator stem. Screw the
nut (30) onto the sleeve (28) until the split ring (6) can
be fitted into the groove in the actuator stem. Rotate the
nut (30) anticlockwise to clamp the diaphragm and
torque the nut to the value shown in table 1. Tighten the
locking screw (29).

8.4 Assemble actuator

8.4.1 Place the ring (7) in the centre of the diaphragm
housing (12).

8.4.2 Fit the actuator stem assembly to the diaphragm hous­ing (12) ensuring the that outer bead of the diaphragm
sits correctly.

8.4.3 Replace Spring housing (25) and secure with 24 screws/
nuts (26/23) (torque values see table 1).

8.4.4 Replace spring guide (31) (if used). Replace spring(s)
(43) ensuring they are situated correctly within the
rollpins (2).

8.4.5 Place the plate (34), complete with cap (39) and guide
bushing (33), onto the springs and tighten the 8/10
screws (38), crisscross, and in equal measures until
the plate contacts the spring housing (torque values
see table 1).

WARNING:

STOP!

time. Grease the screws before fitting.

NEW SCREWS (38) must be used EVERY

9. REVERSE ACTUATOR ACTION

9.1 Remove cap (39), threaded insert (41) and eyebolt (42)
and refit to the reverse side.

Fastener Pos.

Torque value

Flange screws/nuts 26, 23 60 Nm
Screws 38 22 Nm max.*
Nut 30 190 Nm

Table 1: Torque values

* Torque value for strongest spring set

7

7

7

10 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
Germany USA Singapore 638824
Telephone: [phone] Telephone: [phone] Telephone: [phone]
Facsimile: [phone] Facsimile: [phone] Facsimile: [phone]

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Telephone: [phone] Telephone: [phone] Telephone: [phone] Telephone: [phone]
Facsimile: [phone] Facsimile: [phone] Facsimile: [phone] Facsimile: [phone]

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Jet Park Ext 3 P.O. Box 209
Boksburg
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South Africa Saudi Arabia
Telephone: [phone] Telephone: [phone]
Facsimile: [phone]/01/02 Facsimile: 9663 859 5284

©04.2002 Flowserve Corporation. Flowserve and Kämmer are trademarks of Flowserve Corporation

All data subject to change without notice

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