Flowserve 4 Series User Manual

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Installation, Operation, Maintenance Instructions

Pneumatic and

Electropneumatic Actuators

Series 4, Types 37, 38, 39, 3D and 47, 48, 49, 4D

Flow Control Division

Kammer Control Valves

Index

1 Using Kämmer valves and actuators correctly. 2Unpacking 3 Installation 4 Quick check / Maintenance 5 Methode of operation 6 Remove and install actuator 7 Disassemble and assemble actuator 8 Calibration / Technical data

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:

In most cases Kämmer valves and actuators

indicates that death, severe personal injury

indicates that minor personal injury and/

or property damage can occur if proper precautions are not taken.

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,

KMEIM0006-00 - 08.03

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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.

Flow Control Division

Kammer Control Valves

4 QUICK CHECK / MAINTENANCE

4.1 QUICK CHECK

Before operating, check the valve as follows:

4.1.1 Open and close the valve, and observe the movement of the actuator stem. The movement must be smooth and linear.

4.1.2 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).

4.1.3 Check all air connections for leaks.

4.1.4 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.

4.1.5 Check fail-safe position. To do this, close supply pressure and observe whether the valve opens or closes as defined.

4.1.6 After use at fluctuating temperatures, re-tighten all bolt connections and check for leaks.

4.2 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“.

4.2.1 Examine gaskets for leaks and if necessary re-tighten bolts (see Fig. 1).

4.2.2 Check bellows gasket and test connection - if present

- for external leaks.

4.2.3 Check valve for damage caused by corrosive residues or corrosive vapours.

4.2.4 Clean valves and repaint as necessary.

STOP!

Warning:

clean the actuator/valve with a damp cloth only.

To prevent a buildup of electrostatic charge

4.2.5 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.

4.2.6 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.

4.2.7 Check all accessories for firm seating.

4.2.8 If possible, close supply pressure and check the failsafe position.

4.2.9 Check stem boot for wear.

4.2.10 Check actuator for leaks. To do this, spray housing, air connections and plug stem guide with leak spray and check for any bubble formation.

4.2.11 Clean plug stem.

4.2.12 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.

5 Method of operation (actuators with integral Kämmer positioner)

5.1 P/P Actuator

The actuator with integrated pneumatic positioner works on the force balance principal, which ensures that the position of the actuator stem is proportional to the value of the input signal (see figs. 1 and 2).

An increased signal to the double diaphragm assembly creates an unbalanced condition. The pilot valve then moves to cover the vent, increasing the positioner output pressure to the actuator diaphragm until the forces of the positioner spring and the double diaphragm are equal. The positioner output is then stabilized at an amount necessary to maintain the desired valve position.

Flow Control Division

Kammer Control Valves

Signal input

Fig. 1: P/P - Positioner

Supply

To actuator

Vent

Range adjustment screw

(max. 3 turns)

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Kammer Control Valves

Supply output to actuator diaphragm

Supply input

1.4–4.2 bar (20–60 psi)

Pilot plug (see detail below)

Signal input

0.2–1.0 bar (3–15 psi)

Double diaphragm

Adjusting nut

Seat ring

Vent

Positioner spring

Supply input

1.4 – 4.2 bar (20 – 60 psi)

Pilot valve

Supply to actuator diaphragm

Balancing plate

Pilot plug

Fig. 2: P/P - Positioner

Vent

5.2 I/P Actuator

The I/P transducer, which is an integral part of the actuator, converts the standard electric signal (0/4 – 20 mA) into a standard pneumatic signal (0.2 – 1.0 bar) by means of a system of light weight moving parts. This form of signal conversion is extremely insensitive to shocks. The pneumatic signal is supplied to the integrated pneumatic positioner.

The pneumatic positioner works on the force balance principal, which ensures that the position of the actuator diaphragm is always directly proportional to the value of the instrument input signal pressure (see figs. 3 and 4). An increased signal to the double diaphragm assembly creates an unbalanced condition. The pilot valve then moves to cover the vent, increasing the positioner output pressure to the actuator diaphragm until the forces of the positioner spring and the double diaphragm are equal. The positioner output is then stabilized at an amount necessary to maintain the desired valve position.

Flow Control Division

Kammer Control Valves

Signal

To actuator

Supply

Vent

Fig 3: I/P Positioner

Transducer

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Kammer Control Valves

Signal

0/4 – 20 mA

Signal input

0.2–1.0 bar (3–15 psi) Range adjustment screw

(max. 3 turns)

Double diaphragm

Adjusting nut

Seat ring

Supply output to actuator diaphragm

Supply input

1.4–4.2 bar (20–60 psi)

Pilot plug (see detail below)

Vent

Positioner spring

Supply input

1.4 – 4.2 bar (20 – 60 psi)

Pilot valve

Balancing plate

Fig. 4: I/P Positioner

Supply to actuator diaphragm

Vent

Pilot plug

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Kammer Control Valves

Series 47 / 48 / 49

(without positioner)

Series 37 / 38 / 39

(with positioner)

Fig. 5

5.3 Actuator Springs - (fig. 5 pos. 1)

Different actuator spring sets are available depending on the actuator thrust requirements and the fail position of the actuator. The appropriate spring set can be chosen from the spare parts list.

5.4 Zero Adjustment Locknut - (fig. 5 pos. 2)

The zero adjustment locknut is used as a mechanical stop so that the actuator just begins to travel when the desired signal is applied to the positioner.

5.5 Range Adjustment - (fig. 5 pos.3)

(Actuator with positioner only) The actuator travel is adjusted by means of the range adjustment screw. Turn the range adjustment screw so that the actuator stem travels the required distance in response to the positioner input signal.

5.6 Positioner Spring - (fig. 5 pos. 4)

(Actuator with positioner only) To change the signal range from full to split range the positioner spring must be changed.

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Kammer Control Valves

Examples: from 3-15 psi to 3-9 psi or 9-15 psi from 4-20 mA to 4-12 mA or 12-20 mA

Notice that split ranging on electro-pneumatic actuator is also done by means of the positioner spring.

After removal of the spring boot and retaining ring on older actuators or by removing the boot, positioner spring adjustment nut on newer actuators, the spring can be replaced.

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Kammer Control Valves

Air-to-open Air-to-close

5.7 Changing the Actuator Action

To change the actuator action from fail-open to fail-closed, or vice versa, the complete actuator must be reversed. Remove the yoke assembly and actuator cap, invert the actuator and replace all parts. If necessary, use other spring sets (see spare parts list) according to the actuator thrust requirements.

Fig. 6

Flow Control Division

Kammer Control Valves

Gasket

O - Ring

Connection "EXT"

For positioner without "EXT" cover on the reverse side exchange position of gasket and O-ring.

Fig. 7a

Special O - Ring

5.8 External Piping

When using solenoid valves (not NAMUR), lock-up valves, volume boosters, etc.; external piping is possible without the need of additional parts. Solenoid valves to NAMUR-standard (modified) can be bolted directly onto the positioner body.

Positioner without "EXT" cover on the reverse side:

Exchange position of gasket and O - ring (Fig. 7a). Remove the plugs marked "EXT" from the positioner body and diaphragm case. Accessories can now be piped between the positioner and diaphragm case.

Positioner with "EXT" cover on the reverse side:

Exchange the position of the O - ring and special O - ring in the "EXT" cover. (Fig. 7b) Remove the plugs marked "EXT" from the positioner body and diaphragm case. Accessories can now be piped between the positioner and diaphragm case.

Connection "EXT"

"EXT" cover

O - Ring

For positioner with "EXT" cover on the reverse side exchange position of O - ring and special O-ring.

Fig. 7b

Flow Control Division

Kammer Control Valves

Cap

Zero adjustment locknut

Upper coupling half

Lip serves as travel indicator

Actuator stem

Screw

Travel indicator

Plug stem locknut Packing gland nut

Actuator clamp nut

Valve plug stem

Coupling insert

Lower coupling half

Locknut

Plug stem

Valve/actuator with coupling

(see page 23)

Fig. 8: Typical actuator and valve configuration

Kammer Control Valves

6 GENERAL SERVICE INFORMATION

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.

Flow Control Division

6.1 REMOVING ACTUATOR FROM VALVE BODY

DANGER:

Depressurise the line to atmospheric pressure and drain all fluids from the valve before working on the actuator. Failure to do so can cause serious injury.

For air-to-open actuators start with 6.1.1

For air-to-close actuators start with 6.1.2.1

6.1.1 Remove the valve cap and nameplate. Turn the zero adjustment locknut until it just makes contact with the actuator spring case (this removes the spring force from the valve plug).

6.1.2 Valve/actuator without coupling

6.1.2.1 With a wrench, hold the actuator stem to prevent it from

rotating while using a second wrench to loosen the plug stem locknuts.

If the actuator stem is rotated the diaphragm will be

NOTE:

twisted and this may cause irreparable damage.

6.1.2.2 Loosen the packing gland nut and the actuator clamp nut.

6.1.2.3 Being sure not to turn the plug stem, rotate the actuator

assembly counterclockwise to disengage the actuator stem from the valve plug stem.

NOTE:

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

6.1.2.4 Lift the actuator assembly from the valve body subassembly. At the same time, remove the plug stem locknuts, the travel indicator disc, packing gland nut, and clamping nut.

6.1.3 Valve/actuator with coupling

6.1.3.1 With a wrench, hold the actuator stem to prevent it from

rotating while using a second wrench to loosen and remove coupling screws.

6.1.3.2 Remove the yoke rod nuts and lift actuator assembly from the valve.

6.2 CONNECTING ACTUATOR TO VALVE BODY

General Notes:

• The actuator must be calibrated before connecting it to the valve body. See section 3 "Calibration" of these instructions.

6.2.1 Valve/actuator without coupling

6.2.1.1 Place the actuator assembly onto the valve body

subassembly. At the same time, install the clamping nut, packing gland nut, plug stem locknuts, and the travel indicator disc.

6.2.1.2 "Air-to-open/fail-to-close" actuators only:

Rotate the actuator assembly clockwise, threading the actuator stem onto the plug stem until the yoke plate just makes contact with the bonnet flange, and the actuator is properly aligned for installation.

NOTE:

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

"Air-to-close/fail-to-open" actuators only:

Lift the plug stem to the actuator stem. Thread the plug stem into the actuator stem so that the distance "plug in seat", to "plug raised", is approximately the distance of the specified stroke.

6.2.1.3 Tighten the clamping nut and the packing gland nut (see valve service instructions for torque values).

6.2.1.4 Adjust the valve plug for seat off by threading the plug stem further into or out of the actuator stem.

rotate the plug stem while the valve is in the closed

NOTE:

position. Open the valve first, make the adjustment while the valve is open, and then close the valve to check for seat-off.

6.2.1.5 After final adjustments are made, lock the two stem nuts against the actuator stem and set the position of the travel indicator on the yoke rod.

6.2.2 Valve/actuator with coupling

6.2.2.1 Place actuator onto valve.

6.2.2.2 Screw on and tighten yoke rod nuts.

6.2.2.3 Fit the coupling screws finger tight.

6.2.2.4 Adjust the valve plug for seat off by threading the plug stem

further into or out of the coupling insert.

rotate the plug stem while the valve is in the closed

NOTE:

position. Open the valve first, make the adjustment while the valve is open, and then close the valve to check for seat-off

• All worn or damaged parts must be replaced. All parts to be reused should be cleaned for ease of reassembly.

6.2.2.5 After final adjustment tighten the coupling screws and set the position of the travel indicator on the yoke rod.

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Kammer Control Valves

10 9

8 6

4 2

Series 47 / 48 / 49

(without positioner)

Series 37 / 38 / 39

(with positioner)

Fig. 9

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Kammer Control Valves

7 ACTUATOR DISASSEMBLY and ASSEMBLY

7.1 ACTUATOR DISASSEMBLY

(refer to figs. 9 and 11) NOTE:

To help reassembly note or mark the rela-

tionship between the parts to be disassembled.

7.1.1 Remove yoke plate (1) and yoke rods (2). For actuators without positioner continue with

7.1.5.

7.1.2 Actuators without adjustable positioner spring

(see Fig. 9) Remove the positioner spring boot (3), retaining

ring (4), seating washer (5), and positioner spring (6).

Actuators with adjustable positioner spring

(see Fig. 15) Loosen the set screw in the positioner spring

adjusting nut and remove the nut. Remove boot and positioner spring.

7.1.3 Loosen and remove the positioner cover screws (7), positioner cover (8), double diaphgram (9) and balancing plate (10).

7.1.4 Remove the positioner (11). All inner positioner parts are now accessible for replacement or maintenance (

for positioner details see figs. 10 and

7.2 ACTUATOR ASSEMBLY

(refer to figs. 9 to 13)

7.2.1 Install the diaphragm and diaphragm plate on the actuator stem. Use Loctite® #242 on the threaded portion of the actuator stem where the clamping nut (14) is to be installed. Install and tighten the clamping nut, being sure not to kink the diaphragm.

7.2.2 Place the spring set into the spring case so that they sit in the recessed area of the case (15). Smaller diameter springs are placed inside of larger diameter springs.

7.2.3 Insert the actuator stem through the hole in the spring case (15).

7.2.4 Install the zero adjustment locknut (13) on the actuator stem and tighten it down fully to compressing the springs.

DANGER:

A press must be used to compress the springs when high thrust spring sets are installed or when actuator stroke is 40 mm.

7.2.5 Before inserting a new O-ring (16) in the diaphragm case, pack the O-ring groove with a multitemperature assembly paste

7.2.6 Replace the diaphragm gasket (17) and install the diaphragm case onto the spring case assembly.

7.2.7 Install and tighten all case screws (12), washers and nuts using a crisscross pattern.

7.1.5 Loosen and remove all case screws (12).

DANGER:

Actuators with high thrust spring sets and/or actuators with 40 mm (1.5") stroke must be held in a press to prevent possible injury when removing the case screws.

7.1.6 Unscrew the zero adjustment lock nut (13).

7.1.7 The spring case and diaphragm case can now be

separated, and the springs removed.

7.1.8 Holding the actuator stem, unscrew and remove the clamping nut (14) to service the actuator diaphragm and diaphragm plate.

Continued....

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Kammer Control Valves

Range adjustment pin

Positioner

Fig. 11

Signal orifice

Balancing plate

Balancing plate assembly

Fig. 12

Double diaphragm

Fig. 13

(7.4 Actuator assembly continued)

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Kammer Control Valves

7.4.8 to 7.4.11 for actuator with positioner only.

7.2.8 Assemble the positioner using new O-rings, gas-

kets and filters and install the positioner body (see figs. 11).

7.2.9 Install the balancing plate (10) so that the small hole fits over the plastic range adjustment pin (see fig.12), and the bevelled side faces the double diaphragm (flat side to positioner).

7.2.10 Install the double diaphragm assembly (9) aligning the small hole in the diaphragm with the hole in the diaphragm ring and the signal orifice in the positioner body (see fig. 13).

7.2.11 Actuator without adjustable positioner spring

(see Fig 9) Install the positioner cover (8), positioner cover

screws (7), positioner spring (6), seating ring (5), retaining ring (4), and positioner spring boot (3).

Actuator with adjustable positioner spring

(see Fig 15) Install the positioner cover, positioner cover

screws, positioner spring and positioner spring boot. Thread adjusting nut onto actuator stem and adjust roughly using the gauge (lower edge of adjusting nut the underside of positioner cover).

7.2.12 Refit yoke rods (2) and yoke plate (1). The actuator is now ready to be calibrated.

7.3 POSITIONER SERVICE

The KÄMMER integral positioner is designed to be a maintenance free unit. However; moisture, oil and dirt entering the positioner can dampen its performance, which will cause the need for maintenance and repair. When this happens, remove all internal parts and clean them thoroughly. Replace all O-rings, filters and damaged parts, and reassemble the positioner body according to fig. 11.

Positioners with integral I/P transducers are more sensitive to contaminants than those without. Therefore, it is very important that all parts to be reused are extremely clean and dry.

I/P transducer

To remove the I/P transducer, disconnect the wires from the terminal block and loosen the set screw (19) on the side of the positioner housing. The I/P transducer can then be pulled from the front of the positioner housing. The main cause of transducer malfunction is a polluted air supply. Filters are situated in the input and output orifices of the transducer and are readily accessible after removing the O-rings. Apart from the O-rings and filters the transducer contains no user serviceable parts. The transducer is factory adjusted to exactly 4 – 20 mA or 0 – 20 mA (documented by a sticker on the transducer cover) and an attempt to field calibrate is not recommended. For repair and/or calibration the transducer assembly should be returned to Kämmer.

Zero adjustment locknut

Dim. "A"

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Kammer Control Valves

Range adjustment screw

(max. 3 turns)

Positioner spring

Adjusting nut

Fig. 14: Dial gauge

Actuator stem

KÄMMER

Type

H 10

39D>

37/38/39

39D<

39D>

20 20

37/38/39

39D<

38-2

39D>

38-2

39D<

Gauge

Set screw

Adjust positioner spring with gauge

Fig. 15

KÄMMER

Type 39D>

37/38/39 39D< 39D>

37/38/39 39D<

38-2 39D>

38-2 39 39D<

Gauge (scale 1:1)

10 10 20

20 20

10 40

20 40 40

63 mm

8 Calibration

Calibrate actuator

(actuator without adjustable positioner spring)

8.1 Range adjustment

See nameplate for signal range, supply pressure and stroke.

8.1.1 Connect air supply to the "SUPPLY" port of the actuator and an adjustable signal source to the

"SIGNAL" connection. Attach a dial gauge to the actuator (see Fig 14).

8.1.2 Undo the zero adjustment locknut until it is a few threads free of the actuator housing. Set the signal to the low end value (e.g. 0,2 bar or 4 mA). Adjust the dial gauge to zero.

8.1.3 Set the signal to the high end value (e.g. 1,0 bar or 20 mA).

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Kammer Control Valves

8.1.4 Using the range adjusting screw set the actuator to full stroke + 1.5 mm (e.g. stroke 20 + 1.5 mm = 21.5 mm).

8.1.5 Make adjustment with the range adjusting screw as required until desired stroke is obtained

8.2 Zero adjustment

3.2.1 The zero adjustment can only be set after the final

range adjustment has been made.

8.2.2 Maintain the low end signal (e.g. 0.2 bar or 4 mA) and turn the zero adjustment locknut until it just makes contact with the actuator housing.

8.3 Calibrate actuator (actuator with adjustable positioner spring)

See nameplate for signal range, supply pressure and stroke.

8.3.1 Connect air supply to the "SUPPLY" port of the actuator and an adjustable signal source to the "SIGNAL" connection. Attach a dial gauge to the actuator (see Fig

14).

8.3.2 Undo the zero adjustment locknut until it is a few threads free of the actuator housing.

Loosen the set screw and thread the adjusting nut on the actuator stem until it's lower face is in alignment with the appropriate type designation on the gauge.

8.3.3 Set the signal to the low end value (e.g. 0.2 bar or 4 mA). Adjust the dial gauge to zero.

8.3.4 Set the signal to the high end value (e.g. 1.0 bar or 20 mA).

8.3.5 Using the range adjusting screw set the actuator to full stroke + 1.5 mm (e.g. stroke 20 + 1.5 mm = 21.5 mm).

8.3.6 Set signal and dial gauge to zero.

8.3.7 Set the signal to the low end value. Adjust the posi-

tioner spring adjusting nut to compress/decompress the positioner spring until the actuator stem rises 1.5 mm.

8.3.8 Set the signal to the high end value (e.g. 1.0 bar or 20 mA). Using the range adjusting screw set the actuator to full stroke + 1.5 mm (e.g. stroke 20 + 1.5 mm = 21.5 mm).

8.3.11 Check all adjustments for correctness.

8.4 Calibrate actuator/valve

8.4.1 Connect air supply to the "SUPPLY" port of the actua-

tor and an adjustable signal source to the "SIGNAL" connection. Undo the zero adjustment locknut until it is a few threads free of the actuator housing. Attach a dial gauge to the actuator and set it to zero.

8.4.2 Determine the instrument signal at which the plug should begin moving off the seat and apply that signal to the valve. If the plug stem does not begin to move at the predetermined signal, adjust the signal to midrange until the plug is off the seat, loosen the plug stem locknut and turn the plug stem in or out of the actuator stem.

For example, if the plug begins to move at a lower signal than the predetermined one, turn the plug stem out of the actuator stem. If the plug begins to move at a higher signal than the predetermined one, turn the plug into the actuator stem. Repeat this process until the actuator is calibrated as required and re-tighten the plug stem locknut. Adjust the zero adjustment locknut until it is 2 mm off the actuator and replace the actuator cap.

NOTE:

Do not turn the plug stem when the plug is seated; otherwise, the plug and seat ring may be damaged.

8.5 Calibrate actuators without a positioner

8.5.1 With no air supply to the actuator, adjust the zero

adjustment locknut until dimension "A" as shown in the table below is achieved.

Actuator Stroke Dimension “A”

size (mm)

47 48 / 49 48 / 49

Inch mm

/8 10 35

/4 20 25

/8 10 55

/4 20 45

48 / 49 11/2 40 25

49D 11/2 40 55

8.3.9 Repeat adjustments 8.3.3 to 8.3.8 until both adjust- ments are correct.

8.3.10 Set signal to zero and tighten the set screw in the adjusting nut. Set the signal to the low end value. Set the dial gauge to zero and tighten zero adjustment locknut, until the dial gauge pointer just moves (nut contacts the actuator housing) and then a further 1/4 turn ( around 3/10 mm pretension).

8.6 TECHNICAL DATA

Flow Control Division

Kammer Control Valves

Actuator without positioner Actuator with P/P positioner Actuator with I/P positioner

47 48 49 49D 37 38 39 39D IP-37 IP-38 IP-39 IP-39D

Diaphragm area cm

80 200 500 2 x 500 80 200 500 2 x 500 80 200 500 2 x 500 Thrust max. kg 160 400 1000 2000 160 400 1000 2000 160 400 1000 2000 Stroke mm 10/20 10/20 10/20/4010/20/40 10/20 10/20 10/20/4010/20/40 10/20 10/20 10/20/40 10/20/40 Time at stroke10 mm s* 0.1 0.25 0.5 1 0.5 1 2.5 5 0.5 1 2.5 5 20 mm s* 0.2 0.5 1 2 1 2 5 10 1 2 5 10 40 mm s* – – 2 4 – – 10 20 – – 10 20

Signal range 3 – 15 psi 3 – 15 / 3 – 9 / 9 – 15 psi 0/4 – 20, 4 – 12, 12 – 20 mA or rev.

0.2 – 1.0 bar 0.2 – 1.0 / 0.2 – 0.6 / 0.6 – 1.0 bar – 20 – 60 kPa 20 – 100 / 20 – 60 / 60 – 100 kPa –

Input resistance – – 260/170 Ohm** Inductivity / Capacitance – – negligible (≈0) Spring range see appropriate spare parts list see appropriate spare parts list see appropriate spare parts list Supply pressure 20 – 60 psi 20 – 60 psi 20 – 60 psi

1.4 – 4.2 bar 1.4 – 4.2 bar 1.4 – 4.2 bar

140 – 420 kPa 140 – 420 kPa 140 – 420 kPa

Accuracy – ±1% = 1% Hysteresis – < 1% = 1% Operating sensitivity – – = 0.1%

< <

Amplification factor – 50 50 Supply pressure influence – 0.4% / 0.1 bar 0.4% / 0.1 bar Air consumption at 1,4 bar – 0.6 Nm3 / h 0.6 Nm3 / h

Electrical protection – – EEx ia C T6, PTB No. Ex-93.C. 2104X

Suitable for connection to intrinsical

safe circuits with I max.

= 60 mA (T6) thru 150 mA (T4)

Housing protection – – IP 54

Allowable ambient temp. – 30 to + 80 °C (-22 to +176° F)

Actuator action air-to-open / air-to-close, reversible Installation position optional Air supply dry and oil-free (instrument air)

* Stroking time with 1.4 bar supply pressure. ** Transducer adjustable = 260 Ohm, not adjustable = 170 Ohm

Flow Control Division

Kammer Control Valves

Spring

set No.

710 711 712 713 714 715 716 717 722 723 724 725 726 727 810 811 812 813 814 815 816 817 820 821 822 823 824 825 826 827 921 922 923 924 925 926 927 941 942 943 944 945 946 947

Spring range

(bar)

0,2 - 1,0 0,3 - 0,9 0,5 - 1,1 1,0 - 1,9 1,0 - 2,2 1,5 - 2,7 1,5 - 3,0 2,0 - 3,8 0,5 - 1,1 0,9 - 1,9 1,0 - 2,2 1,3 - 2,7 1,4 - 3,0 1,8 - 3,8 0,2 - 1,0 0,3 - 0,9 0,5 - 1,1 1,0 - 1,9 1,0 - 2,2 1,5 - 2,7 1,5 - 3,0 2,0 - 3,8 0,2 - 1,0 0,3 - 0,9 0,5 - 1,1 0,9 - 1,9 1,0 - 2,2 1,3 - 2,7 1,4 - 3,0 1,8 - 3,8 0,3 - 0,9 0,5 - 1,1 1,0 - 1,9 1,0 - 2,2 1,5 - 2,7 1,5 - 3,0 2,0 - 3,8 0,3 - 0,9 0,5 - 1,0 0,8 - 1,6 0,9 - 1,9 1,2 - 2,3 1,3 - 2,6 1,7 - 3,3

Spring set consists of:

Qty.

3 3 3 3 6 3 6 6 3 3 6 3 6 6 3 3 3 3 6 3 6 6 3 3 3 3 6 3 6 6 3 3 3 6 3 6 6 3 3 3 6 3 6 6

Part No.

37 10 10 37 10 40 37 10 20 37 10 20 37 10 20 37 10 20 37 10 20 37 10 20 37 20 20 37 20 20 37 20 20 37 20 20 37 20 20 37 20 20 38 10 10 38 10 40 38 10 20 38 10 20 38 10 20 38 10 20 38 10 20 38 10 20 38 20 10 38 20 40 38 20 20 38 20 20 38 20 20 38 20 20 38 20 20 38 20 20 39 20 40 39 20 20 39 20 20 39 20 20 39 20 20 39 20 20 39 20 20 39 40 40 39 40 20 39 40 20 39 40 20 39 40 20 39 40 20 39 40 20

Colour

code

S B B B B B B B B B B B B

S B B B B B B

S B B B B B B S B B B B B B S B B B B B B

Dimensions *

Ø Dm / Ø d / L o

20,5 / 3,20 x 42,5 23,0 / 3,20 x 45,0 22,0 / 3,20 x 48,3 22,0 / 3,20 x 48,3 22,0 / 3,20 x 48,3 22,0 / 3,20 x 48,3 22,0 / 3,20 x 48,3 22,0 / 3,20 x 48,3 26,0 / 2,75 x 56,7 26,0 / 2,75 x 56,7 26,0 / 2,75 x 56,7 26,0 / 2,75 x 56,7 26,0 / 2,75 x 56,7 26,0 / 2,75 x 56,7 35,5 / 5,60 x 62,5 32,0 / 5,00 x 65,0 39,0 / 5,60 x 68,3 39,0 / 5,60 x 68,3 39,0 / 5,60 x 68,3 39,0 / 5,60 x 68,3 39,0 / 5,60 x 68,3 39,0 / 5,60 x 68,3 40,0 / 5,00 x 65,0 36,5 / 4,50 x 70,0 42,5 / 5,30 x 76,7 42,5 / 5,30 x 76,7 42,5 / 5,30 x 76,7 42,5 / 5,30 x 76,7 42,5 / 5,30 x 76,7 42,5 / 5,30 x 76,7 55,0 / 8,00 x 110 66,0 / 9,00 x 116,7 66,0 / 9,00 x 116,7 66,0 / 9,00 x 116,7 66,0 / 9,00 x 116,7 66,0 / 9,00 x 116,7 66,0 / 9,00 x 116,7 57,0 / 7,00 x 120 67,0 / 7,20 x 138 67,0 / 7,20 x 138 67,0 / 7,20 x 138 67,0 / 7,20 x 138 67,0 / 7,2 0x 138 67,0 / 7,20 x 138

Qty.

6 3 6

Part No.

37 10 30

37 10 30 37 10 30 37 10 30

37 20 30

37 20 30 37 20 30 37 20 30

38 10 30

38 10 30 38 10 30 38 10 30

38 20 30

38 20 30 38 20 30 38 20 30

39 20 30

39 20 30 39 20 30 39 20 30

39 40 30

39 40 30 39 40 30 39 40 30

Colour

code

Ø Dm / Ø d / L o

14,0 / 2,2 x 56,7

19,7 / 2,2 x 60,0

26,5 / 4,0 x 76,7

26,5 / 3,6 x 80

43 / 6,3 x 133,3

45,7 / 5,25 x 148

Dimensions *

* All dimensions in mm

Colour code: W = White

(Each spring is marked with a spot of paint)

B = Blue R = Red S = Black

∅ d

∅ Dm

Positioner spring

Flow Control Division

Kammer Control Valves

∅ Dm

∅ d

Part - No. Spring range Spring range Stroke Lo ø Dm ød

[bar] [mA] [mm] [mm] [mm] [mm]

0 36 00 10 00 0.2 - 1.0 0/4 - 20 10 39.75 20.0 2.0 0 36 00 20 00 0.2 - 0.6 0/4 - 10/12 10 42.5 20.0 1.6 0 36 00 30 00 0.2- 1.0 0.6 - 1.0 0 36 00 40 00 0.2 - 0.6 0/4 - 10/12 20 60.0 22.5 1.5 0 36 00 50 00 0.2- 1.0 0.6 - 1.0 0 36 00 60 00 0.2 - 0.6 0/4 - 10/12 40 100 21.0 1.4 0 36 00 70 00 0.6 - 1.0 10/12 - 20 40 140.0 18.7 1.4

0/4 - 20 10/12 - 20

20 10 55.5 19.5 1.7

40 20 85.0 20.5 1.6

Flow Control Division

Kammer Control Valves

Coupling for actuators with 2 yoke rods Coupling for actuators with 3 yoke rods

Upper coupling half M6 Part-No. 0 37 01 06 00

Coupling insert M 4 Part-No. 0 37 01 08 00 Coupling insert M 6 Part-No. 0 37 01 09 00 Coupling insert M 10 Part-No. 0 37 01 10 00

Screw, M 4 x 12 (2x) Part-No. 0 10 02 05 00

Lower coupling half Part-No. 0 37 01 07 00

Coupling assy. M 6 / M 4 Part-No. 0 37 01 03 00 Coupling assy. M 6 / M 6 Part-No. 0 37 01 01 00 Coupling assy. M 6 / M 10 Part-No. 0 37 01 02 00

Upper coupling half M10 Part-No. 0 36 01 06 00

Coupling insert M 6 Part-No. 0 36 01 09 00 Coupling insert M 10 Part-No. 0 36 01 08 00

Screw, M 6 x 20 (2x) Part-No. 0 10 02 22 00

Lower coupling half Part-No. 0 36 01 07 00

Coupling assy. M 10 / M 6 Part-No. 0 36 01 01 00 Coupling assy. M 10 / M 10 Part-No. 0 36 01 02 00

Flow Control Division

Kammer Control Valves

Regional Headquarters

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Manderscheidtstr. 19 1350 N. Mt. Springs Prkwy. 12 Tuas Avenue 20 45141 Essen Springville, UT 84663 Germany USA Singapore 638824 Telephone: +49 (0) 201 8919 5 Telephone: +1 801 489 8611 Telephone: +65 862 3332 Facsimile: +49 (0) 201 8919 662 Facsimile: +1 801 489 3719 Facsimile: +65 862 4940

Main Sales Offices (Europa, Middle east, Africa)

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von-Braun-Straße 19a 12, av. du Québec Station Road Allee du Quartz 1 48681 Ahaus 91965, Courtaboeuf Cedex Pershore, Worcestershire CH-2300 La-Chaux-de Fonds Germany France England WR102BZ Switzerland Telephone: +49 (0) 2561 6860 Telephone: +33 (0) 1 60 923 251 Telephone: +44 (0) 1386 55 45 51 Telephone: +41 (0) 32 925 9700 Facsimile: +49 (0) 2561 68648 Facsimile: +33 (0) 1 60 923 299 Facsimile: +44 (0) 1386 55 49 68 Facsimile: +41 (0) 32 926 5422

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Cnr. Bismit and Granier Str. C/O Saleh & Abdulaziz Abahsain Jet Park Ext 3 P.O. Box 209 Boksburg 1459 Gauteng Al Khobar 31952 South Africa Saudi Arabia Telephone: +27 397-3150 Telephone: 9663 857 3442 Facsimile: +27 397-5300/01/02 Facsimile: 9663 859 5284

All data subject to change without notice

Flowserve 4 Series User Manual

Specifications and Main Features

Frequently Asked Questions

User Manual