Flowserve 3 Series P7 User Manual

Installation, Operation, Maintenance Instructions

Pneumatic Diaphragm On-Off Actuators

Series 3, Type: P7

Index

1 Using Kämmer valves and actuators correctly.
2Unpacking
3 Installation
4 Quick check
5 Maintenance
6 Remove and install actuator
7 Disassemble and assemble actuator
8 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: i

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

ndicates that death, severe personal in-

indicates that minor personal injury and/or

1.3 Protective clothing

1.4 Qualified personnel

1.5 Installation

NOTE: i

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.

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.).

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.

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.

ndicates and provides additional technical

Before installation check the order-no, se-

Flow Control Division

Kammer Control Valves

KMEIM0005-00 - 08.03

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:

STOP!

for repair or service Kämmer must be provided with a

Before products are returned to Kämmer

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:

tre of gravity of the valve may be above the lifting

STOP!

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 (see following table).

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 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.

STOP!

Warning:

clean the actuator/valve with a damp cloth only.

To prevent a buildup of electrostatic charge

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.

STOP!

WARNING:

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.

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.

3

45
44
43

Flow Control Division

Kammer Control Valves

46
13

11
42
41

40
39

38
36
35
34

47
33

40

1

2

9
7

5

3

37

4

4

22

5
6
7
8

21

9
10

32
31

30

29

23

28
27

26
25

24

1 Diaphragm plate
2 Diaphragm
3 Diaphragm ring
4 Plate
5 Split ring
6 Sleeve
7 Ring
8 Back-up ring

9 Bushing
10 Diaphragm housing
11 Wiper ring
12 Yoke plate, upper
13 Screw, M20 x 45
14 Screw, NAMUR
15 Coupling, assy. M24
16 Yoke plate, lower, Ø 75

20

19
18

17

17 Nut, M20
18

Travel indicator, assy.
19 Yoke rod, 410 mm long
20 Nut, M16
21 O-Ring
22 Screw, M12 x 30

23-32 Spring set

24 Washer
25 Sleeve
26 Bushing
27 Sleeve
28 Spring plate, lower
29 Spring, external
30 Spring, internal.
31 Spring plate, upper
32 Screw, M16 x 140

11
12

13
14
15
16

33 Plate
34 Sleeve
35 Adjusting sleeve
36 Slotted nut, M68 x 1,5
37 Locking plate
38 Sleeve
39 Spring housing
40 Vent plug
41 Screw, M16 x 70
42 Actuator stem
43 Cap
44 Grooved pin
45 Flange
46 Eye bolt
47 Pre-tension plate

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

4

Flow Control Division

Kammer Control Valves

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 (12) and yoke rods (19).

6 REMOVE AND INSTALL ACTUATOR

6.1 REMOVE ACTUATOR

(refer to figs. 1 + 2)

6.1.1 Shut off the air supply.

WARNING:

pressure and drain all fluids from the valve before

STOP!

working on the actuator. Failure to do so can cause

Depressurise the line to atmospheric

serious injury.

6.1.2 Remove the coupling (15) from the actuator stem
(42):

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 (46) to support the
actuator and remove the nuts (17) from the yoke
rods (19). 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 (15) from the plug stem.

42

51

50

52

53

54

Fig. 2: Coupling

6.2 INSTALL ACTUATOR

(refer to Figs. 1 + 2)

6.2.1 Screw the coupling (15) 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 (19) to the yoke plate (16) using the nuts
(17). 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 (14) are correctly positioned.

NOTE:

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 AND ASSEMBLE ACTUATOR

7.1 Diassemble actuator

7.1.1 Remove the 36 flange screws and nuts M16 (41/20)

and lift off the spring housing (39).

7.1.2 Remove the pre-tension plate (47) (only for actua-

tors with additional pre-tensioning), the spring plate
(33) and the pre-tensioned spring packs (23).

7.1.3 Remove actuator stem complete with diaphragm (2)

and diaphragm plate (1). Store with diaphragm fac­ing upwards (be careful not to damage the dia­phragm.

Disassemble diaphragm

7.1.4 Unscrew the 24 screws M12x30 (22) and lift off the

diaphragm.

7.1.5 Reverse the assembly so that the adjustung sleeve

(35) is facing upward.

7.1.6 Straighten the locking plates (37) and screw the

slotted nuts down (clockwise) until the split ring (5)
can be removed from the groove in the actuator
stem (secure the actuator stem against falling
through).

7.1.7 Remove sleeve ( 38), adjusting sleeve (35) complete

with slotted nuts (36) and locking plates ( 37),
Sleeve (34) and plate (4).

7.1.8 Remove the actuator stem (42) from the underside

of the diapragm housing (1) and remove the plate
(4) and split ring (5).

5

45
44
43

Flow Control Division

Kammer Control Valves

46
13

11
42
41

40
39

38
36
35
34

47
33

40

1

2

9
7

5

3

37

4

4

22

5
6
7
8

21

9
10

32
31

30

29

23

28
27

26
25

24

1 Diaphragm plate
2 Diaphragm
3 Diaphragm ring
4 Plate
5 Split ring
6 Sleeve
7 Ring
8 Back-up ring

9 Bushing
10 Diaphragm housing
11 Wiper ring
12 Yoke plate, upper
13 Screw, M20 x 45
14 Screw, NAMUR
15 Coupling, assy. M24
16 Yoke plate, lower, Ø 75

20

19
18

17

17 Nut, M20
18

Travel indicator, assy.
19 Yoke rod, 410 mm long
20 Nut, M16
21 O-Ring
22 Screw, M12 x 30

23-32 Spring set

24 Washer
25 Sleeve
26 Bushing
27 Sleeve
28 Spring plate, lower
29 Spring, external
30 Spring, internal.
31 Spring plate, upper
32 Screw, M16 x 140

11
12

13
14
15
16

33 Plate
34 Adjusting sleeve
35 Adjusting sleeve
36 ASlotted nut, M68 x 1,5
37 Locking plate
38 Sleeve
39 Spring housing
40 Vent plug
41 Screw, M16 x 70
42 Actuator stem
43 Cap
44 Grooved pin
45 Flange
46 Eye bolt
47 Pre-tension plate

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

6

Flow Control Division

Kammer Control Valves

Disassemble actuator stem seal and guide

7.1.9 Remove calked ring (7).

7.1.10 Remove seal kit consisting of backup rings (8) and
O-ring (21).

7.1.11 Remove wiper ring (11) and bushing (9).

7.1.12 Remove calked ring (7), bushing (9) and wiper ring
(11) from Spring housing (39).

7.2 ASSEMBLE ACTUATOR

Assemble actuator stem seal and guide

7.2.1 Fit bushing (9) and wiper ring (11) to spring and
diapragm housings (10/39).

7.2.2 Enter backup ring (9), O-ring (21) and back up ring
(9) from the other side of diaphragm housing.

7.2.3 Fit rings (7) to spring and diapragm housings and
calk in 4 positions with a punch.

Assemble actuator stem and diaphragm

7.2.4 Clamp the lower part of the actuator stem (42) in a
vice (protect the stem against surface damage).

7.2.5 Fit split ring (5) to lower groove and replace plate
(4) with O-ring (21).

7.2.6 Fit diaphragm plate (1), plate (4), sleeve (34) and
adjusting sleeve (35) to actuator stem (42).

7.27 Screw two slotted nuts (36) with two locking plates
(37) between them onto adjusting sleeve (35). Re­place the sleeve (38) and screw down the slotted
nuts until the split ring (5) can be fitted into the
groove in the actuator stem.

7.2.8 Screw the top slotted nut (36) anticlockwise
against the sleeve (38) until the diaphragm plate (1)
is tightly clamped to the actuator stem (42). Secure
the top slotted nut with the second slotted nut and
in turn secure both nuts by bending the locking
plates.

7.2.9 Reverse the assembly (diaphragm side upward);
Replace the diaphragm (2) and diaphragm plate (3)
and srcure with 24 screws M12x30 (22) to the dia­phragm plate (1) (torque value see table 2).

Assemble actuator

7.2.10 Place the sleeve (6) in the centre of the diaphragm
housing (10).

7.2.11 Fit the actuator stem assembly to the diaphragm
housing (10) ensuring that the outer bead of the
diaphragm sits correctly

7.2.12 Replace the washer (24).

7.2.13 Place the spring packs (23) on the washers (24) .

7.2.14 Place the plate (33) over the spring packs (23).

7.2.15 Replace the spring housing assembly (39) with cap
(43) and eye bolt (46) and secure with 36 screws/
nuts M16 (41/20) (torque value see table 2).

7.3 Inspection
Function:

Conduct five open / close cycles and check for
smooth operation.

Leakage:

Test pressure 6,6 bar (hold time 13 min).
Spray actuator stem entries and all housing joints

with leak spray and check for leaks.

Fastner

Pos.

Torque value

Flange 41, 20 120 Nm
Diaphragm ring 22 60 Nm

Table 2: Torque values

7

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

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

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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

8