MANUAL

ManualCompetence in Functional Safety
Solenoid valves for safety-instrumented systems –functional principle and typical applications

Binary converters
Diaphragms
Applications

SMART IN FLOW CONTROL.

Competence in Functional Safety
Solenoid valves for safety-instrumented systems

SAMSON
AIR TORQUE · CERA SYSTEM · KT-ELEKTRONIK · LEUSCHPFEIFFER · RINGO · SAMSOMATIC · STARLINE · VETECFounded in 1907, SAMSON has since become a worldwide leader in the manufacture of expertly engineered
control valves.
SAMSON has over 50 subsidiaries, amongst them noted
manufacturers of special valves.
With these subsidiaries, SAMSON is represented in over
80 countries to assist its customers on all continents.

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Competence in Functional Safety
Solenoid valves for safety-instrumented systems

Contents

1 Scope................................................................................................................................................................42 What makes SAMSOMATIC solenoid valves superior?.........................................................................................4
3 Functional principle of the electropneumatic binary converter...............................................................................54 Functional principle of solenoid valves with diaphragms......................................................................................65 Applications.......................................................................................................................................................75.1 Air purging of the actuator spring chamber to protect the actuator springs against corrosion.............................75.2 Emergency venting of an actuator.................................................................................................................85.3 Venting an actuator when the supply pressure falls below a minimum pressure.................................................95.4 Switching to a backup buffer tank when the air supply fails..........................................................................105.5 Reliable fail-safe action of actuators............................................................................................................ 115.6 Reliable fail-safe action of actuators with pressure monitoring....................................................................... 126 Appendix: Certificate ......................................................................................................................................133Competence in Functional Safety
Solenoid valves for safety-instrumented systems

1ScopeIn safety-instrumented systems, pneumatic valves are used to shut off or open pipelines. Solenoid valves are the interface between the electric control level and the pneumatic actuator. SAMSOMATIC has been active in developing andmanufacturing solenoid valves with a high reliability at a low power consumption for many years. The solenoid valves
meet the highest quality requirements and are suitable for use in safety-instrumented systems up to SIL 3 according toIEC 61511, up to SIL 4 according to IEC 61508 as well as PL e according to ISO 13849.

2What makes SAMSOMATIC solenoid valves superior?

1. Solenoid valves with diaphragms are preferably used in safety-instrumented systems. The decisive advantage
provided by diaphragms is that the solenoid valves operate reliably on demand and move the valve to the failsafe position even after the solenoid valves have remained static for long periods of time or when the booster
valves are slightly clogged with dirt.
2. An electropneumatic binary converter, which has proven reliable in service a million times over, working together
with a flapper/nozzle system, guarantees reliable switching even after it has remained static for long periods oftime.
3. By constantly purging the electronics compartment with instrument air, the solenoid valves are protected against
corrosion even when installed in damp or aggressive environments.
4. All solenoid valves are subjected to function and leak tests, minimizing the probability of failure on demand due todefective components or leaks.

4Competence in Functional Safety
Solenoid valves for safety-instrumented systems

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Functional principle of the electropneumatic binary converter

The electropneumatic binary converter is supplied with a constant supply pressure of 1.4 bar.
In the idle position, the flapper (2) is lifted off the outlet nozzle (3) by the spring (4), allowing a small rate of air to flow
through the outlet nozzle into the electronics compartment. This causes the pressure in the system to drop to a level atwhich the downstream booster valve is not activated (refer to section 4).
When the solenoid coil (1) is energized by an electric binary signal, the magnetic field causes the flapper (2) to bepushed downwards against the force of the spring (4) and the outlet nozzle (3) to be closed. As a result, the pressurein the system rises and the booster valve is switched to the operating position.
When the electric binary signal is deactivated, the booster valve is switched to the idle position again by the spring (4).
Advantages of the flapper/nozzle system
Reliable switching even after remaining static for long periods of time
No memory effect, as occurs in piezo elements for example
Switching behavior independent of the mounting position
Long service life (over 20 million switching cycles)
Low power consumption thanks to frictionless bearing of the flapper

Outlet nozzle (3)Spring (4)Flapper (2)+81

Solenoid coil (1)Nominal signal AC/DC–82

1.4 bar supply air

Downstream
booster valve

5Competence in Functional Safety
Solenoid valves for safety-instrumented systems

4

Functional principle of solenoid valves with diaphragms

The solenoid valves consist of an electropneumatic binary converter (refer to section 3) and a booster valve with return
spring. The supply pressure is applied to connection 4. Connection 3 is routed to the actuator. The actuator is vented
over connection 5.
The air supply for the electropneumatic binary converter is routed internally through connection 4 at the booster valve.
Connection 9 is sealed by a blanking plug. The pressure reducer (5) reduces the supply air pressure to 1.4 bar.
In the idle position, the flapper (2) is lifted off the outlet nozzle (3) by the spring (4). This causes a pressure lower than
the switch-on pressure of the booster valve to build up in the pressure divider, which consists of the restrictor (6) andoutlet nozzle (3).
When the solenoid coil (1) is energized by an electric binary signal, the outlet nozzle (3) is closed by the flapper (2)against the force of the spring (4). This causes the pressure in the pressure divider to rise above the switch-on pressureof the booster valve, switching it to the operating position.
After the solenoid coil is de-energized, the booster valve is switched to the idle position again by the return spring (7).
The solenoid valve can be converted to accept an external air supply at connection 9 by turning a flat gasket on theenclosure. This is necessary when the solenoid valve is mounted onto an actuator for modulating service and a constantcontrol pressure of at least 1.4 bar must be guaranteed at the electropneumatic binary converter.
Outlet nozzle (3)Electropneumatic
binary converter

Spring (4)Flapper (2)+81

Solenoid coil (1)Nominal signal AC/DC–82
Pressure reducer (5)9 Changeover toexternal supply

Restrictor (6)Exhaust air
5
3/2-way booster
valve with returnspring
4
Supply air/internal supply

Return spring (7)3Output toactuator

6Breather functionof spring chamber

Competence in Functional Safety
Solenoid valves for safety-instrumented systems

5Applications

5.1 Air purging of the actuator spring chamber to protect the actuator springs against
corrosion
Task
In safety-instrumented systems, valves often remain static in one position for long periods of time. During this time, theactuator springs are at risk of corroding if moisture enters the actuator.
Solution using a Type 3967 Solenoid Valve
The electronics compartment of the solenoid valve is constantly purged with instrument air through the flapper/nozzle
system (refer to section 3). This air purging is also guaranteed when the solenoid valve is energized. The electronics
compartment is directly connected to the actuator’s spring chamber over the NAMUR interface. The solenoid valve isvented at the enclosure cover by a filter check valve (with IP 65 degree of protection), which opens at a defined excesspressure. As a result, a minimal level of positive pressure constantly exists in the electronics compartment and the actuator spring chamber, preventing moisture from entering the spring chamber and inhibiting corrosion.

Rotary actuator withType 3967 Solenoid Valve

291Venting on theenclosure cover3

Air purging of the actuator
spring chamber
Supply air/internal supply

External supply

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Competence in Functional Safety
Solenoid valves for safety-instrumented systems

5.2 Emergency venting of an actuator
Task
In the event of failure, an actuator is to be vented independent of the control signal.
Solution
The actuator is often controlled by a positioner (A) and a solenoid valve (C) in a process control system. When the solenoid valve (C) is energized, the output of the pneumatic booster (B) is connected to the actuator. The pneumaticbooster (B) supplies the actuator with an air flow output whose pressure corresponds exactly to the signal pressure, except that it has a much higher volume. This increases the positioning speed even of large pneumatic actuators. In theevent of failure, the electric power supply is cut off by the process control system and the solenoid valve (C) is switchedto the fail-safe position. The actuator is vented independent of the output of the positioner (A) and pneumatic booster (B).
This solution can also be implemented for small actuators without a pneumatic booster (B).

CA

SIG
IN

B
OUT

A – SAMSON Type 3730-3 Positioner
B – SAMSON Type 3755 Pneumatic Booster
C – SAMSOMATIC solenoid valve (e.g. Type 3963-13100142111101000)

8Competence in Functional Safety
Solenoid valves for safety-instrumented systems

5.3

Venting an actuator when the supply pressure falls below a minimum pressure

Task
If the supply pressure level falls below a certain pressure, the actuator is to be vented and the valve moved to its fail-safe
position.
Solution using a solenoid valve and an electric pressure monitor or pressure limiter
In normal operation, the actuator is controlled by a positioner together with a solenoid valve (A). The supply pressure
is constantly monitored by an electric pressure monitor (B). When the supply pressure falls below a certain minimumpressure, the electric power supply is automatically cut off and the solenoid valve (A) is switched to fail-safe position.
The actuator is vented as a result. The electric signal is not reactivated immediately after the supply pressure increases
again due to the hysteresis of the pressure monitor (B).
An electric pressure limiter with internal interlock can also be used instead of the electric pressure monitor. In this case,the electric signal must be reactivated manually.
This solution can also be implemented for rotary actuators and on/off valves.

+81
–82

B

9EPA

35 4

3p
1

2
24 V DCA – SAMSOMATIC solenoid valve (e.g. Type 3963-13100220111100000)
B – SAMSOMATIC Type 3994-0370-DWR-6 Electric Pressure Monitor, or alternatively
Type 3994-0370-DWR-6.206 Electric Pressure Limiter with internal interlock(adjustment range between 0.5 and 6 bar)

9Competence in Functional Safety
Solenoid valves for safety-instrumented systems

5.4

Switching to a backup buffer tank when the air supply fails

Task
After a supply air failure, the position of an on/off valve is to be maintained for a certain period of time.
Solution using a buffer tank for instrument air
In normal operation, the actuator is filled with air or vented by a solenoid valve (A) according to the process requirements. The required instrument air is supplied by a main supply air station. In the event that this air station fails, the air
supply is maintained by a backup buffer tank (B), which provides the solenoid valve (A) with instrument air. The continued operation of an on/off valve over a certain period can be guaranteed in this way. This allows repairs to be performed on the supply air station while the process is running or the plant to be shut down safely. The supply pressure
can be monitored by an electric pressure monitor (e.g. Type 3994-0370-DWR-6, not shown in the diagram) to signal
when the pressure falls below a certain limit.

A+81–82E

95 4P3DCB

A – SAMSOMATIC solenoid valve (e.g. Type 3963-13100120011100000)
B – Buffer tank (sized according to customer requirements)
C – Check valve
D – Safety valve

10Competence in Functional Safety
Solenoid valves for safety-instrumented systems

5.5

Reliable fail-safe action of actuators

Task
To achieve better reliability and possibly also a higher level of safety (SIL or PL) in safety-instrumented systems, thesolenoid valves must be designed in a redundant configuration. In this way, if one solenoid valve fails, the fail-safe action of the actuator is still guaranteed by a second solenoid valve. A hook-up of the solenoid valves in series or inparallel is used depending on the safety requirements. This usually involves complex hook-ups.
Solution using a redundancy plate
A redundancy plate allows two solenoid valves to be connected in series or in parallel without any additional hook-up.
The solenoid valves are mounted either on the left or right side to the NAMUR interfaces of the redundancy plate. The
redundancy plate can be directly attached to rotary actuators over a third NAMUR interface. An additional adapter
plate also allows a hook-up using threaded connections or the attachment of the solenoid valves to linear actuators witha NAMUR rib.
Advantages of the redundancy plate
Easy and quick mounting
Compact designCaptive fastening screws
Body made of powder-coated aluminum or stainless steelG or NPT threaded connections
Attachment to rotary actuators with NAMUR interface according to VDI/VDE 3845
Attachment to linear actuators with NAMUR rib according to IEC 60534-6-1Reliable fail-safe action to vent the actuator
91332V1291

Reliable fail-safe action to ﬁll the actuator with air

V2921339132V1291V2239111Competence in Functional Safety
Solenoid valves for safety-instrumented systems

5.6

Reliable fail-safe action of actuators with pressure monitoring

Task
To achieve better reliability and possibly also a higher level of safety (SIL or PL) in safety-instrumented systems, thesolenoid valves must be designed in a redundant configuration. In this way, if one solenoid valve fails, the fail-safe action of the actuator is still guaranteed by a second solenoid valve. However, it is not possible to identify which solenoidvalve has failed without pressure monitoring.
Solution using integrated pressure switches
The output pressure of the solenoid valves is constantly monitored by two integrated pressure switches. If an energizedsolenoid valve does not produce the minimum output pressure, an electric contact indicates this failure, for example tothe process control system. This not only allows the detection of a faulty solenoid valve, but enables the switching functions to be tested while the process is running, without changing the position of the process valve.

12Competence in Functional Safety
Solenoid valves for safety-instrumented systems

6Appendix: Certificates

Certificate no. V 60.09/14 Rev. 01
Types 3701, 3963 and 3967 Solenoid Valves with safety function
Suitable for use in safety-instrumented systems

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Competence in Functional Safety
Solenoid valves for safety-instrumented systems

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Competence in Functional Safety
Solenoid valves for safety-instrumented systems

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ManualCompetence in Functional Safety

SAMSOMATIC GMBH
Weismuellerstrasse 20–22 · 60314 Frankfurt am Main, Germany
Phone: +49 69 4009-0 · Fax: + 49 69 4009-1644
E-mail: samsomatic@samsomatic.de · Internet: www.samsomatic.de

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