Mounting and Operating Instructions EB 5840 EN

Translation of original instructions
Type 2780‑1 and Type 2780‑2
Pneumatic Actuators
Type 2780‑1
Type 2780‑2
Mounting and
Operating Instructions
EB 5840 EN
Edition December 2017
Note on these mounting and operating instructions
These mounting and operating instructions assist you in mounting and operating the device
safely. The instructions are binding for handling SAMSON devices.
ÎÎ For the safe and proper use of these instructions, read them carefully and keep them for
later reference.
ÎÎ If you have any questions about these instructions, contact SAMSON‘s After-sales Service
Department (aftersalesservice@samson.de).
The mounting and operating instructions for the devices are included in
the scope of delivery. The latest documentation is available on our website
(www.samson.de) > Product documentation. You can enter the document
number or type number in the [Find:] field to look for a document.
Definition of signal words
! DANGER
Hazardous situations which, if not avoided,
will result in death or serious injury
! WARNING
Hazardous situations which, if not avoided,
could result in death or serious injury
2
! NOTICE
Property damage message or malfunction
Note
Additional information
Tip
Recommended action
EB 5840 EN
Contents
1
Safety instructions and measures....................................................................5
1.1
Notes on possible severe personal injury..........................................................7
1.2
Notes on possible personal injury....................................................................7
1.3
Notes on possible property damage.................................................................8
2
Markings on the control valve.......................................................................10
2.1
Actuator nameplate.......................................................................................10
3
Design and principle of operation.................................................................12
3.1
Direction of action.........................................................................................12
3.2
Signal pressure routing..................................................................................12
3.3
Fail-safe action.............................................................................................15
3.4
Technical data..............................................................................................15
4Measures.....................................................................................................17
4.1
Unpacking...................................................................................................17
4.2
4.2.1
4.2.2
Transporting and lifting.................................................................................17
Transporting.................................................................................................17
Lifting...........................................................................................................18
4.3
Storage........................................................................................................18
4.4
Preparation for installation.............................................................................19
5
Mounting and start-up..................................................................................20
5.1
Mounting the actuator onto the valve..............................................................20
5.2
Additional fittings..........................................................................................22
6Operation....................................................................................................23
6.1
Reversing the direction of action (fail-safe action)............................................23
7Servicing.....................................................................................................26
7.1
Replacing the diaphragm..............................................................................27
7.2
Return shipment............................................................................................28
7.3
Ordering spare parts and operating supplies..................................................28
8Malfunctions................................................................................................30
EB 5840 EN
3
Contents
9
Decommissioning and disassembly...............................................................31
9.1
Decommissioning..........................................................................................31
9.2
Removing the actuator from the valve.............................................................31
9.3
Relieving the spring compression....................................................................31
9.4
Disposal.......................................................................................................31
10Appendix.....................................................................................................32
10.1
After-sales service.........................................................................................32
10.2
Spare parts..................................................................................................32
4
EB 5840 EN
Safety instructions and measures
1 Safety instructions and measures
Intended use
The SAMSON Type 2780 Actuator is designed for operating a mounted globe valve. In com‑
bination with the valve, the actuator is used to shut off the flow of liquids, gases or vapors in
the pipeline. The actuator is suitable for throttling service and can be used in HVAC plants.
The actuator is designed to operate under exactly defined conditions (e.g. thrust, travel).
Therefore, operators must ensure that the actuator is only used in applications that meet the
specifications used for sizing the actuator at the ordering stage. In case operators intend to
use the actuator in other applications or conditions than specified, SAMSON must be con‑
tacted.
SAMSON does not assume any liability for damage resulting from the failure to use the de‑
vice for its intended purpose or for damage caused by external forces or any other external
factors.
ÎÎ Refer to the technical data and nameplate for limits and fields of application as well as
possible uses.
Reasonably foreseeable misuse
The actuator is not suitable for the following applications:
−− Use outside the limits defined during sizing and in the technical data
−− Use outside the limits defined by the accessories mounted on the actuator
Furthermore, the following activities do not comply with the intended use:
−− Use of non-original spare parts
−− Performing servicing and repair work not described in these instructions
Qualifications of operating personnel
The actuator must be mounted, started up, serviced, and repaired by fully trained and quali‑
fied personnel only; the accepted industry codes and practices are to be observed. Accord‑
ing to these mounting and operating instructions, trained personnel refers to individuals who
are able to judge the work they are assigned to and recognize possible hazards due to their
specialized training, their knowledge and experience as well as their knowledge of the appli‑
cable standards.
EB 5840 EN
5
Safety instructions and measures
Personal protective equipment
We recommend wearing the following personal protective equipment when handling the
Type 2780 Pneumatic Actuator:
−− Protective gloves when mounting or removing the actuator
Note
More information on the safe handling of the diaphragms installed in the pneumatic actuators is available in u http://www.samson.de/reach-en.html.
ÎÎ Check with the plant operator for details on further protective equipment.
Revisions and other modifications
Revisions, conversions or other modifications to the product are not authorized by SAMSON.
They are performed at the user's own risk and may lead to safety hazards, for example. Fur‑
thermore, the product may no longer meet the requirements for its intended use.
Safety devices
The Type 2780 Actuator does not have any special safety equipment.
Warning against residual hazards
To avoid personal injury or property damage, plant operators and operating personnel must
prevent hazards that could be caused in the actuator by the process medium, the operating
pressure, the signal pressure or by moving parts by taking appropriate precautions. They
must observe all hazard statements, warning and caution notes in these mounting and oper‑
ating instructions, especially for installation, start-up, and servicing.
Responsibilities of the operator
The operator is responsible for proper operation and compliance with the safety regulations.
Operators are obliged to provide these mounting and operating instructions to the operating
personnel and to instruct them in proper operation. Furthermore, operators must ensure that
operating personnel or third persons are not exposed to any danger.
Responsibilities of operating personnel
Operating personnel must read and understand these mounting and operating instructions as
well as the specified hazard statements, warning and caution notes. Furthermore, the operat‑
ing personnel must be familiar with the applicable health, safety and accident prevention
regulations and comply with them.
6
EB 5840 EN
Safety instructions and measures
Referenced standards and regulations
According to the ignition risk assessment performed in accordance with EN 13463-1:2009,
section 5.2, the non-electrical actuators do not have their own potential ignition source even
in the rare incident of an operating fault. As a result, they do not fall within the scope of Di‑
rective 2014/34/EU.
ÎÎ For connection to the equipotential bonding system, observe the requirements specified in
section 6.4 of EN 60079-14 (VDE 0165 Part 1).
Referenced documentation
The following documents apply in addition to these mounting and operating instructions:
−− Mounting and operating instructions for the mounted valve
−− Mounting and operating instructions for mounted valve accessories (positioner, solenoid
valve etc.)
−− u WA 0029 for tools and lubricant
1.1 Notes on possible severe personal injury
! DANGER
Risk of bursting in the actuator.
Actuators are pressurized. Improper opening can lead to actuator components burst‑
ing.
ÎÎ Before starting any work on the actuator, depressurize all plant sections concerned
and the actuator.
EB 5840 EN
7
Safety instructions and measures
1.2 Notes on possible personal injury
! WARNING
Crush hazard arising from moving parts.
The actuator contains moving parts (actuator stem), which can injure hands or fingers if
inserted into the actuator.
ÎÎ Do not insert hands or finger into the yoke while the valve is in operation.
ÎÎ While working on the actuator, disconnect and lock the pneumatic air supply as well
as the control signal.
Risk of personal injury when the actuator vents.
While the valve is operating, the actuator may vent during closed-loop control or when
the valve opens or closes.
ÎÎ Install the control valve in such a way that the actuator does not vent at eye level.
ÎÎ Use suitable silencers and vent plugs.
ÎÎ Wear eye protection when working in close proximity to the control valve.
Risk of personal injury due to preloaded springs.
Actuators with preloaded springs are under tension. These actuators can be identified
by two long bolts protruding from the bottom of the actuator.
ÎÎ Before starting any work on the actuator, relieve the compression from the preload‑
ed springs (see section 9.3).
1.3 Notes on possible property damage
! NOTICE
Risk of actuator damage due to excessively high or low tightening torques.
Observe the specified torques on tightening actuator components. Excessively tight‑
ened torques lead to parts wearing out quicker. Parts that are not tightened far enough
may loosen.
ÎÎ Observe the specified tightening torques (u WA 0029).
8
EB 5840 EN
Safety instructions and measures
! NOTICE
Risk of actuator damage due to the use of unsuitable tools.
Certain tools are required to work on the actuator.
ÎÎ Only use tools approved by SAMSON (u WA 0029).
Risk of actuator damage due to the use of unsuitable lubricants.
The lubricants to be used depend on the actuator material. Unsuitable lubricants may
corrode and damage the valve surface.
ÎÎ Only use lubricants approved by SAMSON (u WA 0029).
EB 5840 EN
9
Markings on the actuator
2 Markings on the actuator
2.1 Actuator nameplate
The nameplate is stuck on the diaphragm
casing. It includes all details required to
identify the actuator:
1 Type designation
2 Configuration ID
3 Serial number
4 Permissible supply pressure pmax
5 Bench range in bar
6 Bench range in psi
7 Operating travel in mm
8 Symbol for manual override
9 Symbol indicating fail-safe action
Actuator stem extends (FA)
Actuator stem retracts (FE)
10 Date of manufacture (month and year)
SAMSON 2780
!
Pneumatic Actuator 120 cm²
See technical data for ambient temperature
Model
2
Var.-ID
Serial no.
4
Air supply max.
9
7
1
SAMSON AG D-60314 Frankfurt
3
10
5
6
8
Made in Germany
Fig. 1: Nameplate of Type 2780 Actuator
10 EB 5840 EN
Markings on the actuator
EB 5840 EN
11
Design and principle of operation
3 Design and principle of operation
The pneumatic actuators are used especially
for attachment to Type 3222 and Type 3213
Valves. In this case, force-locking attachment
is used.
The actuators mainly consist of two dia‑
phragm cases, the actuator stem (A2/A5),
rolling diaphragm (A48), and springs (A2529). The housings have an actuator area of
120 cm² and are made of die-cast alumi‑
num.
The signal pressure creates a force at the di‑
aphragm surface, which is opposed by the
springs in the actuator. The direction of ac‑
tion of the actuator stem depends on how the
springs are installed in the actuator. A maxi‑
mum of six springs, partly fitted in one an‑
other, can be installed in the actuator.
The Type 2780-2 Actuator is designed for
the direct attachment of a positioner as stan‑
dard. A yoke is located on the bottom dia‑
phragm case for attachment of a pneumatic
or electropneumatic positioner.
3.1 Direction of action
The direction of action is determined by how
the springs and diaphragm plate are ar‑
ranged in the actuator. With direction of ac‑
tion "actuator stem retracts", the compressed
air is applied to the signal pressure connec‑
tion on the top diaphragm case. With direc‑
tion of action "actuator stem extends", the
compressed air is applied to the signal pres‑
12 sure connection on the bottom diaphragm
case.
The actuator's direction of action can be re‑
versed (see section 6.1).
3.2 Signal pressure routing
Type 2780-1x (see Fig. 2)
In the "actuator stem extends" version, the
signal pressure is routed through the bottom
signal pressure connection (SFA) to the bot‑
tom diaphragm chamber. In the "actuator
stem retracts" version, the signal pressure is
routed through the top signal pressure con‑
nection (SFE) to the top diaphragm chamber.
Type 2780-2x (see Fig. 3 andFig. 4)
In the Type 2780-2 Actuator, the signal pres‑
sure is transmitted to the diaphragm cham‑
ber through the holes (SFA, SFE) on the left or
right side of the yoke and over a switchover
plate. The fail-safe action of the actuator
("actuator stem extends" or "actuator stem
retracts") determines how the positioner must
be attached and the switchover plate must
be aligned.
Turn the switchover plate to align the correct
symbol for the fail-safe action with the mark‑
ing. The attachment either on the left or right
side of the actuator is determined by the re‑
quired direction of action of the positioner
(>> or <>).
If the actuator is operated without a position‑
er, a connecting plate is required instead of
the switchover plate. In this case, the signal
pressure is routed directly over the signal
EB 5840 EN
Design and principle of operation
A42
A53
A38 A39 A25
SFE
A48
A20
SFA
Fig. 2: Type 2780‑1
A40
A23
Actuator stem extends
A1
Actuator stem retracts
A53
A48 A25-29
A8
A39
A38
A46
A2
A5
SFA
SFE
Switchover/
connecting plate:
Actuator stem extends
A23
A1
Actuator stem
A2
Lower actuator section
A5
Actuator stem
A8
Diaphragm case
A20
Vent plug
A23
Coupling nut
A25Compression spring
29
A38
Metal plate
A39
Diaphragm plate
A40
Bottom diaphragm case
A42
Top diaphragm case
A46
Stop bushing
A48
Diaphragm
A53
Collar nut
SFA
Signal pressure connection
(actuator stem extends)
SFE
Signal pressure connection
(actuator stem retracts)
Actuator stem retracts
Fig. 3: Type 2780‑2
EB 5840 EN
13
Design and principle of operation
pressure connection of the connecting plate
to the actuator diaphragm chamber.
Turn the connecting plate to align the correct
symbol for the fail-safe action with the mark‑
ing.
Additional points that apply concerning the
connecting plate:
ÎÎ Make sure that the gasket for the con‑
necting plate is correctly inserted.
ÎÎ The connecting plate has threaded holes
with NPT and G threads. Seal the signal
pressure connection that is not used with
the rubber seal and square plug.
Accessories
Switchover plates and connecting plates are
listed as accessories.
With in‑
dex
Order no.
Switchover New
plate
Old
.01
1400-6822
.00
1400-6819
New
.01
1400-6823
G thread
.00
1400-6820
NPT thread
.00
1400-6821
Connect‑
ing plate
Switchover plate
Connecting plate
Signal pressure input
(right attachment)
Signal pressure
connection
Symbol
Signal pressure input
(left attachment)
Actuator stem extends
Left
attachment
Right
attachment
Marking for
signal pressure
input
Actuator stem retracts
Left
attachment
Right
attachment
Actuator stem
extends
retracts
Fig. 4: Signal pressure connection over switchover plate or connecting plate in Type 2780‑2
14 EB 5840 EN
Design and principle of operation
Note
Actuators with device index .01 are
equipped with new connecting plates. Old
and new connecting plates are not interchangeable.
3.3 Fail-safe action
When the signal pressure is reduced or the
control signal fails, the fail-safe position of
the control valve depends on whether the
springs are installed in the top or bottom di‑
aphragm chamber.
3.4 Technical data
The nameplate provide information on the
actuator version (see section 2.1).
Note
More information is available in Data Sheet
u T 5840.
Compliance
The Type 2780-1 and Type 2780-2 Pneu‑
matic Actuators bear the EAC mark of con‑
formity.
Actuator stem extends (FA)
When the signal pressure is reduced or the
control signal fails, the springs move the ac‑
tuator stem downward and close the globe
valve. The valve opens when the signal pres‑
sure is increased enough to overcome the
spring force.
Actuator stem retracts (FE)
When the signal pressure is reduced or the
control signal fails, the springs move the ac‑
tuator stem upward and open a mounted
globe valve. The valve closes when the signal
pressure is increased enough to overcome
the spring force.
EB 5840 EN
Ambient temperature
The permissible ambient temperature for
NBR diaphragm material is –35 to +80 °C.
Supply pressure
The maximum permissible supply pressure is
4 bar in throttling service.
Dimensions
Dimensions (see Fig. 5)
Weights
Version
Weight
Type 2780‑1
2 kg
Type 2780‑2
3.2 kg
15
Design and principle of operation
84
50.5
70
73.5
Ø168
Ø168
50.5
M32 x 1.5
M32 x 1.5
Fig. 5: Dimensional drawings
16 EB 5840 EN
Preparation
4 Preparation
4.2.1 Transporting
After receiving the shipment, proceed as fol‑
lows:
The actuator can be transported using lifting
equipment (e.g. crane or forklift).
1. Check the scope of delivery. Compare
the shipment received against the deliv‑
ery note.
ÎÎ Leave the actuator in its transport con‑
tainer or on the pallet to transport it.
2. Check the shipment for transportation
damage. Report any damage to
SAMSON and the forwarding agent (re‑
fer to delivery note).
4.1 Unpacking
Note
Do not remove the packaging until immediately before mounting.
Proceed as follows to lift and mount the actu‑
ator:
1. Remove the packaging from the actuator.
2. Dispose of the packaging in accordance
with the valid regulations.
ÎÎ Observe the transport instructions.
Transport instructions
−− Protect the actuator against external in‑
fluences (e.g. impact).
−− Do not damage the corrosion protection
(paint, surface coatings). Remove any
damage immediately.
−− Protect the actuator against moisture and
dirt.
−− The permissible transportation tempera‑
ture of standard control valves is –20 to
+65 °C.
Note
Contact SAMSON's After-sales Service department for the transportation temperatures
of other valve versions.
4.2 Transporting and lifting
Tip
SAMSON's After-sales Service department
can provide more detailed transport and lifting instructions on request.
EB 5840 EN
17
Preparation
4.2.2 Lifting
To mount the actuator, use lifting equipment
(e.g. crane or forklift) to lift it.
Lifting instructions
−− Secure slings against slipping.
−− Make sure the slings can be removed
from the actuator once it has been
mounted onto the valve.
−− Prevent the actuator from tilting or tip‑
ping.
−− Do not leave loads suspended when in‑
terrupting work for longer periods of
time.
−− Make sure that the slings attached to the
valve body bear the entire load (see
Fig. 6).
Lifting the entire control valve assembly
See associated valve documentation.
Tip
We recommend using a hook with safety
latch (see Fig. 6). The safety latch prevents
the slings from slipping during lifting and
transporting.
Fig. 6: Lifting points on the control valve (example)
4.3 Storage
! NOTICE
Risk of actuator damage due to improper
storage.
−−Observe storage instructions.
−−Avoid long storage times.
−−Contact SAMSON in case of different storage conditions or long storage periods.
Note
We recommend regularly checking the actuator and the prevailing storage conditions
during long storage times.
18 EB 5840 EN
Preparation
Storage instructions
−− When the valve and actuator are al‑
ready assembled, observe the storage
conditions for control valves. See associ‑
ated valve documentation.
−− Protect the actuator against external in‑
fluences (e.g. impact).
−− Do not damage the corrosion protection
(paint, surface coatings). Remove any
damage immediately.
−− Protect the actuator against moisture and
dirt. Store it at a relative humidity of less
than 75 %. In damp spaces, prevent con‑
densation. If necessary, use a drying
agent or heating.
−− Make sure that the ambient air is free of
acids or other corrosive media.
−− The permissible storage temperature of
standard control valves is –20 to +65 °C.
Note
Contact SAMSON's After-sales Service department for the storage temperatures of other valve versions.
Tip
SAMSON's After-sales Service department
can provide more detailed storage instructions on request.
4.4 Preparation for installation
Proceed as follows:
ÎÎ Check the actuator for damage.
ÎÎ Check to make sure that the type desig‑
nation, material, and ambient tempera‑
ture range of the actuator match the
plant conditions.
ÎÎ Check the pressure gauge installed on
valve accessories to make sure it func‑
tions.
ÎÎ When the valve and actuator are al‑
ready assembled, check the tightening
torques of the bolted joints
(u WA 0029). Components may loosen
during transport.
−− Do not place any objects on the actuator.
Special storage instructions for elastomers
Elastomer, e.g. actuator diaphragm
−− To keep elastomers in shape and to pre‑
vent cracking, do not bend them or hang
them up.
−− We recommend a storage temperature of
15 °C for elastomers.
−− Store elastomers away from lubricants,
chemicals, solutions, and fuels.
EB 5840 EN
19
Mounting and start-up
5 Mounting and start-up
SAMSON control valves are delivered ready
for use. In special cases, the valve and actu‑
ator are delivered separately and must be
assembled on site. The procedure to mount
and start up the actuator are described in
following.
! NOTICE
Risk of actuator damage due to excessively
high or low tightening torques.
Observe the specified torques on tightening
actuator components. Excessively tightened
torques lead to parts wearing out quicker.
Parts that are not tightened far enough may
loosen.
Observe the specified tightening torques
(u WA 0029).
! NOTICE
Risk of actuator damage due to the use of
unsuitable tools.
Only use tools approved by SAMSON
(u WA 0029).
Note
See associated valve documentation for additional mounting instructions.
5.1 Mounting the actuator onto
the valve
Tip
The valve and actuator are assembled with
special attention paid to the actuator's bench
range and direction of action. These details
are specified on the actuator nameplate (see
section 2.1).
1. Unscrew the nut (12) at the valve.
2. Press the plug together with the plug stem
firmly into the seat ring.
3. Thread the nut (12) downward.
4. Remove the coupling nut (A23) at the ac‑
tuator.
5. Slide the coupling nut (A23) over the
plug stem (15).
6. Place the actuator on the valve. Fasten
the actuator stem (A1) and plug stem
(15) together using the coupling nut
(A23) (tightening torque 20 Nm).
7. Determine the lower and upper signal
pressure range values:
The lower signal pressure range value is
the same as the minimum value of the
bench range.
The upper signal pressure range value is
the same as the maximum value of the
bench range.
8. Select the correct signal pressure connec‑
tion as described in section 3.2 and pro‑
ceed depending on the direction of ac‑
tion as follows:
Proceed as follows if the valve and actuator
have not been assembled by SAMSON:
20 EB 5840 EN
Mounting and start-up
A40
A1
A23
12
1
20
15
32
5
3
1
Guide nipple
20
Compression spring
3
Valve body
32
Plug
5
Seat
A1
Actuator stem
12
Nut
A23 Coupling nut
15
Plug stem
A40 Bottom diaphragm case
Fig. 7: Type 2780‑1 Pneumatic Actuator on Type 3213 Valve
EB 5840 EN
21
Mounting and start-up
Actuator stem extends
Apply lower signal pressure range value
to the signal pressure connection.
Actuator stem retracts
Apply upper signal pressure range value
to the signal pressure connection.
5.2 Additional fittings
Vent plug
Vent plugs are screwed into the exhaust air
ports of pneumatic devices. They ensure that
any exhaust air that forms can be vented to
the atmosphere (to avoid excess pressure in
the device). Furthermore, the vent plugs al‑
low air intake to prevent a vacuum from
forming in the device.
ÎÎ Locate the vent plug on the opposite side
to the workplace of operating personnel.
ÎÎ On mounting valve accessories, make
sure that they can be operated from the
workplace of the operating personnel.
Note
The workplace of operating personnel is the
location from which the valve, actuator and
any mounted valve accessories can be accessed to operate them.
22 EB 5840 EN
Operation
6 Operation
! WARNING
Crush hazard arising from moving parts (actuator stem).
Do not insert hands or finger into the yoke
while the valve is in operation.
! WARNING
Risk of personal injury when the actuator
vents.
Wear eye protection when working in close
proximity to the control valve.
! NOTICE
Operating disturbed by a blocked actuator
stem.
Do not impede the movement of the actuator
stem by inserting objects into its path.
! NOTICE
−−Only apply the signal pressure to the diaphragm chamber of the actuator that does
not contain any springs.
−−It is essential that air can pass through the
vent plug (A20) for the Type 2780-1 Actuator to work properly.
6.1 Reversing the direction of
action (fail-safe action)
The direction of action (and fail-safe action)
of pneumatic actuators can be changed. The
fail-safe action is indicated on the nameplate
by a symbol (see section 2.1).
Actuator stem extends (FA)
Actuator stem retracts (FE)
! DANGER
Risk of bursting in the actuator.
Actuators are pressurized. Improper opening
can lead to actuator components bursting.
Before starting any work on the actuator, depressurize all plant sections concerned and
the actuator.
! WARNING
Risk of personal injury due to preloaded
springs.
Actuators with preloaded springs are under
tension. They can be identified by the long
bolts protruding from the bottom of the actuator.
Before starting any work on the actuator, relieve the compression from the preloaded
springs (see section 9.3).
! NOTICE
Risk of malfunction due to incorrect details
on the nameplate after the reversal of the direction of action.
EB 5840 EN
23
Operation
After reversal, the symbol and configuration
ID on the nameplate are no longer valid.
Contact SAMSON to request a new nameplate.
Note
The actuator's direction of action can only be
reversed after it has been removed from the
valve. See section 9.2 on how to remove the
actuator.
Reversal of the direction of action from
stem extends to stem retracts
1. If necessary, remove the actuator from
the valve. See section 9.2.
2. Undo the nuts and bolts on both cases
(A42, A40).
A42
A53
3. Lift off the top diaphragm case (A42)
and remove springs (A25).
4. Pull the actuator stem (A1) together the
diaphragm plate (A39), diaphragm
(A48), metal plate (A38), and bushing
(A46) out of the bottom diaphragm case
(A40).
5. Completely unscrew the collar nut (A53),
while holding the actuator stem (A1) sta‑
tionary using a suitable tool which can‑
not damage the sealing.
6. Remove the diaphragm plate (A39) to‑
gether with the diaphragm (A48) and
metal plate (A38) from the actuator stem
(A1) and place them back on again
turned over.
7. Tighten the collar nut (A53).
A38 A39 A25
A1
Actuator stem
A20
Vent plug
A23
Coupling nut
A25
Compression spring
A38
Metal plate
A20
A39
Diaphragm plate
A40
Bottom diaphragm case
SFA
A42
Top diaphragm case
A48
Diaphragm
A53
Collar nut
SFA
Signal pressure connection
(actuator stem extends)
SFE
Signal pressure connection
(actuator stem retracts)
SFE
A48
A40
A23
Actuator stem
extends
A1
Actuator stem
retracts
Fig. 8: Type 2780‑1
24 EB 5840 EN
Operation
8. Apply a suitable sealant and lubricant to
the actuator stem (A1).
2. Undo the nuts and bolts on both cases
(A42, A40).
9. Turn over the top diaphragm case (A42)
and place the actuator stem (A1) togeth‑
er with the ready-assembled diaphragm
parts inside it.
3. Lift off the top diaphragm case (A42).
10.Slide the bushing (A46) over the actuator
stem (A1).
11.Place the springs (A25) in the top dia‑
phragm case (A42), centering them in
the intended recesses.
12.Place on the bottom diaphragm case
(A40).
13.Fasten the top and bottom diaphragm
cases (A42, A40) together with the nuts
and bolts.
14.In Type 2780‑1, remove the vent plug
(A20) and screw it into the bottom signal
pressure connection (SFA).
The actuator springs, which now push
against the diaphragm plate from below,
cause the actuator stem to retract. The
signal pressure is connected to the top
connection (SFE) on the top diaphragm
case. As a result, the actuator stem ex‑
tends opposing the spring force as the
signal pressure increases.
15.Affix a new nameplate with changed
symbol and new configuration ID to the
actuator.
Reversal of the direction of action from
stem retracts to stem extends
1. If necessary, remove the actuator from
the valve. See section 9.2.
EB 5840 EN
4. Pull the actuator stem (A1) together the
diaphragm plate (A39), diaphragm
(A48), metal plate (A38), and bushing
(A46) out of the bottom diaphragm case
(A40).
5. Completely unscrew the collar nut (A53),
while holding the actuator stem (A1) sta‑
tionary using a suitable tool which can‑
not damage the sealing.
6. Remove the diaphragm plate (A39) to‑
gether with the diaphragm (A48) and
metal plate (A38) from the actuator stem
(A1) and place them back on again
turned over.
7. Tighten the collar nut (A53).
8. Apply a suitable sealant and lubricant to
the actuator stem (A1).
9. Slide the bushing (A46) over the actuator
stem (A1).
10.Place the actuator stem (A1) together
with the ready-assembled diaphragm
parts into the bottom diaphragm case
(A40).
11.Place the springs (A25) in the bottom di‑
aphragm case (A40), centering them in
the intended recesses.
12.Place on the top diaphragm case (A42).
13.Fasten the top and bottom diaphragm
cases (A42, A40) together with the nuts
and bolts.
25
Operation
14.In Type 2780‑1, screw the vent plug
(A20) into the top signal pressure con‑
nection (SFE).
The actuator springs, which now push
against the diaphragm plate from above,
cause the actuator stem to extend. The
signal pressure is connected to the bot‑
tom connection (SFA) on the bottom dia‑
phragm case. As a result, the actuator
stem retracts opposing the spring force
as the signal pressure increases.
15.Affix a new nameplate with changed
symbol and new configuration ID to the
actuator.
26 EB 5840 EN
Servicing
7 Servicing
! DANGER
Risk of bursting in the actuator.
Actuators are pressurized. Improper opening
can lead to actuator components bursting.
Before starting any work on the actuator, depressurize all plant sections concerned and
the actuator.
! WARNING
Risk of personal injury due to preloaded
springs.
Actuators with preloaded springs are under
tension. They can be identified by the long
bolts protruding from the bottom of the actuator.
Before starting any work on the actuator, relieve the compression from the preloaded
springs (see section 9.3).
! NOTICE
Risk of actuator damage due to incorrect
service or repair.
−−Do not perform any service or repair work
other than the activities described in this
section on your own. Contact SAMSON's
After-sales Service department.
−−Service and repair work must only be performed by staff trained for this purpose.
! NOTICE
Risk of actuator damage due to excessively
high or low tightening torques.
EB 5840 EN
Observe the specified torques on tightening
actuator components. Excessively tightened
torques lead to parts wearing out quicker.
Parts that are not tightened far enough may
loosen.
Observe the specified tightening torques
(u WA 0029).
! NOTICE
Risk of actuator damage due to the use of
unsuitable tools.
Only use tools approved by SAMSON
(u WA 0029).
! NOTICE
Risk of actuator damage due to the use of
unsuitable lubricants.
Only use lubricants approved by SAMSON
(u WA 0029).
Note
−−The product warranty becomes void if servicing or repair work not described in
these instructions is performed without prior agreement by SAMSON's After-sales
Service department.
−−Only use original spare parts by
SAMSON, which comply with the original
specifications.
Tip
SAMSON's After-sales Service department
can support you to draw up an inspection
plan for your plant.
27
Servicing
7.1 Replacing the diaphragm
Version with fail-safe action "actuator stem
extends" (FA)
1. If necessary, remove the actuator from
the valve. See section 9.2.
2. Undo the nuts and bolts on both cases
(A42, A40).
3. Lift off the top diaphragm case (A42)
and remove springs (A25).
4. Unscrew the collar nut (A53).
5. Remove the diaphragm plate (A39) to‑
gether with the diaphragm (A48), metal
plate (A38), and actuator stem (A1) out
of the bottom diaphragm case (A40).
6. Place a new diaphragm on the metal
plate (A38). Place on the diaphragm
plate (A39).
7. Check the sealing element on the collar
nut (A53). If necessary, renew it.
8. Apply a suitable sealant and lubricant to
the actuator stem (A1).
9. Insert the actuator stem (A1) together
with the diaphragm plate (A39), dia‑
phragm (A48), and metal plate (A38) in‑
to the bottom diaphragm case (A40).
10.Tighten the collar nut (A53).
11.Place the springs (A25) in the bottom di‑
aphragm case (A40), centering them in
the intended recesses.
12.Place on the top diaphragm case (A42).
13.Fasten the top and bottom diaphragm
cases (A42, A40) together with the nuts
and bolts.
28 14.Mount the actuator on the valve (see sec‑
tion 5.1).
Version with fail-safe action "actuator stem
retracts" (FE)
1. If necessary, remove the actuator from
the valve. See section 9.2.
2. Undo the nuts and bolts on both cases
(A42, A40).
3. Lift off the top diaphragm case (A42).
4. Unscrew the collar nut (A53).
5. Remove the diaphragm plate (A39) to‑
gether with the diaphragm (A48), metal
plate (A38), and actuator stem (A1) out
of the bottom diaphragm case (A40).
6. Place a new diaphragm on the metal
plate (A38). Place on the diaphragm
plate (A39).
7. Check the sealing element on the collar
nut (A53). If necessary, renew it.
8. Apply a suitable sealant and lubricant to
the actuator stem (A1).
9. Insert the actuator stem (A1) together
with the diaphragm plate (A39), dia‑
phragm (A48), and metal plate (A38) in‑
to the bottom diaphragm case (A40).
10.Tighten the collar nut (A53).
11.Place on the top diaphragm case (A42).
12.Fasten the top and bottom diaphragm
cases (A42, A40) together with the nuts
and bolts.
13.Mount the actuator on the valve (see sec‑
tion 5.1).
EB 5840 EN
Servicing
7.2 Return shipment
Defective actuators can be returned to SAM‑
SON for repair.
Proceed as follows to return valves to SAM‑
SON:
1. Put the control valve out of operation.
See associated valve documentation.
2. Remove the actuator from the valve (see
section 9.2).
3. Send the actuator to your nearest SAM‑
SON subsidiary. SAMSON subsidiaries
are listed on our website at
u www.samson.de > Contact.
7.3 Ordering spare parts and
operating supplies
Contact your nearest SAMSON subsidiary
or the SAMSON After-sales Service depart‑
ment for information on spare parts, lubri‑
cants, and tools.
Spare parts
See section 10.2 for details on spare parts.
Lubricant
Details on suitable lubricants can be found in
the document u WA 0029.
Tools
Details on suitable tools can be found in the
document u WA 0029.
EB 5840 EN
29
Malfunctions
8 Malfunctions
Depending on the operating conditions, check the actuator at certain intervals to prevent
possible failure before it can occur. Operators are responsible for drawing up a test plan.
Tip
SAMSON's After-sales Service department can support you to draw up an inspection plan
for your plant.
Troubleshooting
Malfunction
Possible reasons
Recommended action
Actuator stem does not move on
demand.
Actuator is blocked.
Check attachment.
Unblock the actuator.
Insufficient signal pressure
Check the signal pressure.
Check the signal pressure line for
leakage.
Actuator stem does not stroke
through its complete travel
range.
Signal pressure not connected to
the correct diaphragm chamber.
See section 3.2.
Insufficient signal pressure
Check the signal pressure.
Check the signal pressure line for
leakage.
Valve accessories incorrectly set.
Check the actuator without valve
accessories.
Check the settings of the valve
accessories.
Note
Contact SAMSON's After-sales Service department for malfunctions not listed in the table.
30 EB 5840 EN
Decommissioning and disassembly
9 Decommissioning and disassembly
! DANGER
Risk of bursting in the actuator.
Actuators are pressurized. Improper opening
can lead to actuator components bursting.
Before starting any work on the actuator, depressurize all plant sections concerned and
the actuator.
! WARNING
Risk of personal injury due to preloaded
springs.
Actuators with preloaded springs are under
tension. They can be identified by the long
bolts protruding from the bottom of the actuator.
Before starting any work on the actuator, relieve the compression from the preloaded
springs (see section 9.3).
9.1 Decommissioning
To decommission the actuator for service and
repair work or disassembly, proceed as fol‑
lows:
1. Put the control valve out of operation.
See associated valve documentation.
9.2 Removing the actuator
from the valve
1. Put the control valve out of operation.
See associated valve documentation.
2. Undo the coupling nut (A23) on the actu‑
ator stem (A1) and plug stem (15).
3. Lift the actuator off the valve.
4. Slide the coupling nut (A23) onto the ac‑
tuator stem (A1) and tighten it.
5. Screw tight the nut (12) on the valve.
9.3 Relieving the spring compression
1. Undo the short nuts and bolts on the dia‑
phragm cases.
2. Undo the the long nuts and bolts on the
diaphragm cases evenly in a crisscross
pattern.
9.4 Disposal
ÎÎ Observe local, national, and internation‑
al refuse regulations.
ÎÎ Do not dispose of components,
lubricants, and hazardous substances
together with your other household
waste.
2. Disconnect the pneumatic air supply to
depressurize the actuator.
EB 5840 EN
31
Appendix
10Appendix
10.2Spare parts
1
Actuator stem
2
Lower actuator section
5
Actuator stem
8
Top diaphragm case
9
Bushing
10
Bushing
20
Vent plug
23
Coupling nut
25-29
Compression spring
37
Threaded bushing
38
Metal plate
39
Diaphragm plate
The addresses of SAMSON AG, its subsid‑
iaries, representatives, and service facilities
worldwide can be found on the SAMSON
website, in all SAMSON product catalogs or
on the back of these Mounting and Operat‑
ing Instructions.
40
Bottom diaphragm case
42
Top diaphragm case
45
Seal
46
Stop bushing
48
Diaphragm
51
Hexagon bolt
Required specifications
52
Hexagon nut
53
Hexagon nut (collar nut)
54
Washer
55
Washer
57
Radial shaft seal
58
Dry bearing
59
Hexagon nut (preloading)
65
Hexagon bolt (preloading)
10.1After-sales service
Contact SAMSON's After-sales Service de‑
partment for support concerning servicing or
repair work or when malfunctions or defects
arise.
E-mail
You can reach the After-sales Service De‑
partment at aftersalesservice@samson.de.
Addresses of SAMSON AG and its subsidiaries
Please submit the following details:
−− Order number and position number in
the order
−− Type, model number, actuator area, trav‑
el and bench range (e.g. 0.4 to 1 bar) of
the actuator
−− Direction of action
−− Type designation of mounted valve.
−− Installation drawing
32 EB 5840 EN
Appendix
65
51
54
59
52
42
53
38
39
25
48
20
40
46
23
55
9
1
Type 2780‑1 Actuator
EB 5840 EN
33
65
51
54
59
52
45
45
25–29
53
38 39
8
48
46
57
58
5
2
37
55
10
23
Type 2780‑2 Actuator
34 EB 5840 EN
EB 5840 EN
35
Weismüllerstraße 3 · 60314 Frankfurt am Main, Germany
Phone: +49 69 4009-0 · Fax: +49 69 4009-1507
samson@samson.de · www.samson.de
EB 5840 EN
2018-02-06 · English
SAMSON AG · MESS- UND REGELTECHNIK
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