Samson 3730-3 Mounting And Operating Instructions
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Samson 3730-3 Mounting And Operating Instructions

Series 3730 electropneumatic positioner with hart communication
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See also: Configuration Manual , Quick Manual
Series 3730
Type 3730-3 Electropneumatic Positioner
with HART
communication
®
Mounting and
Operating Instructions
EB 8384-3 EN (1300-1612)
Firmware version 1.56
Edition April 2016
EB + CD

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Summary of Contents for Samson 3730-3

  • Page 1 Series 3730 Type 3730-3 Electropneumatic Positioner with HART communication ® Mounting and Operating Instructions EB 8384-3 EN (1300-1612) Firmware version 1.56 Edition April 2016 EB + CD...
  • Page 2 Definition of signal words DANGER! NOTICE Hazardous situations which, if not Property damage message or mal- avoided, will result in death or seri- function ous injury Note:  WARNING! Additional information Hazardous situations which, if not avoided, could result in death or seri- Tip: ous injury Recommended action...

  • Page 3: Table Of Contents

    Contents Important safety instructions ................8 Article code ....................9 Design and principle of operation ..............10 Additional equipment ...................11 Communication ...................12 3.2.1 Configuration using the TROVIS-VIEW software ..........13 Technical data .....................14 Attachment to the control valve – Mounting parts and accessories ....20 Direct attachment ..................22 4.1.1 Type 3277-5 Actuator ..................22 4.1.2 Type 3277 Actuator ..................24...
  • Page 4 Contents 5.2.1 Switching amplifier ..................59 5.2.1 Establishing communication ................59 Operating controls and readings ..............61 6.1 Serial interface ....................63 HART communication .................63 ® 6.2.1 Dynamic HART variables ................64 ® Start-up and settings ...................66 7.1 Defining the fail-safe position ................66 7.2 Adjusting the volume restriction Q ..............67 7.3 Adapting the display direction ..............67 7.4 Limiting the signal pressure ................68 7.5 Checking the operating range of the positioner ..........68 7.6...
  • Page 5 Contents Code list .....................88 Dimensions in mm ..................106 15.1 Fixing levels according to VDI/VDE 3845 (September 2010) ......109 Valve characteristic selection ..............110 Test certificates ..................112 Index ......................149 Note:  The functions of the EXPERTplus Valve Diagnostics are described in the Operating Instructions EB 8389. EB 8389 EN is included on the enclosed CD-ROM and is available on our website.
  • Page 6 Firmware revisions 1.01 1.10 The HART protocol as per HART specification revision 5 is supported by default. ® The setting can be changed to HART revision 6 in the TROVIS-VIEW software. HART ® ® tools as well as AMS or handheld communicators are currently not supported by the revi- sion 6 version. The following status messages have been added: • Code 76 – No emergency mode • Code 77 – Program load error Reading indicates the number of zero calibrations performed since the last initialization. For initialization of "AIR TO CLOSE" actuators, the direction of action (Code 7) is auto- matically set to increasing/decreasing. Code 3, the activation period of the enabled configuration function has been extended to 120 s. 1.10 1.20 Electronics changed, no new functions added. 1.20 1.30 New EXPERTplus diagnostics functions (Code 48) added. Positioner in EXPERTplus version with extended diagnostics features. An initialization procedure in progress can be canceled by pressing the rotary pushbut- ton. The position transmitter (Code 37) and solenoid valve (Code 45) options are automati- cally detected.
  • Page 7 Firmware revisions 1.40 1.41 Internal revisions 1.41 1.42 Internal revisions 1.42 1.51 All EXPERTplus diagnostic functions are available without having to activate them in the positioner (u EB 8389 on EXPERTplus Valve Diagnostics). Optional binary input with following actions: • Transmit switching state • Activate local write protection • Switch between automatic and manual modes • Various diagnostic functions u EB 8389 (EXPERTplus valve diagnostics) The pressure limit (Code 16) is no longer automatically set during initialization. 1.51 1.54 Internal revisions 1.54 1.55 Analog input x option to connect commercially available position sensors with a 4 to 20 mA signal Code 4: the setting for 300 mm has been added to the pin position 1.55 1.56 Internal revisions EB 8384-3 EN...

  • Page 8: Important Safety Instructions

    Important safety instructions 1 Important safety instructions For your own safety, follow these instructions concerning the mounting, start-up and opera- tion of the device: − The device is to be mounted, started up or operated only by trained and experienced personnel familiar with the product. According to these mounting and operating instruc- tions, trained personnel is referred to as individuals who are able to judge the work they are assigned to and recognize possible dangers due to their specialized training, their knowledge and experience as well as their knowledge of the applicable standards. − Explosion-protected versions of this device are to be operated only by personnel who has undergone special training or instructions or who is authorized to work on explosion-pro- tected devices in hazardous areas. Refer to section 11. − Any hazards that could be caused in the valve by the process medium, the signal pres- sure or by moving parts are to be prevented by taking appropriate precautions. − If inadmissible motions or forces are produced in the pneumatic actuator as a result of the supply pressure level, it must be restricted using a suitable supply pressure reducing station. To avoid damage to any equipment, the following also applies: − Do not operate the positioner with the back of the positioner/vent opening facing up- wards. The vent opening must not be sealed when the positioner is installed on site. Vent opening − Proper shipping and storage are assumed. − Do not ground electric welding equipment near to the positioner. Note: The device with a CE marking fulfills the requirements of the Directive ...

  • Page 9: Article Code

    Article code 2 Article code Positioner Type 3730-3 x x x x x x x x 0 x 0 0 x 0 x x With display and autotune, HART communication ® Explosion protection Without ATEX II 2G Ex ia IIC T6, II 2D Ex tb IIIC T80°C IP66 Ex ia IIC T6; Class I, Zone 0; Class I, Groups A, B, C, D; Class II, Groups E, F, G; Class I, Zone 2; Class I, Div.2, Groups A, B, C, D; Class II, Div.2, Groups E, F, G Class I, Zone 0 AEx ia IIC; Class I, II, III, Div.1, Groups A, B, C, D, E, F G; Class I, Div.2, Groups A, B, C, D; Class II, Div.2, Groups F, G ATEX II 3G Ex nA II T6, II 3G Ex ic IIC T6, II 3D Ex tc IIIC T80°C IP66 Additional equipment...

  • Page 10: Design And Principle Of Operation

    Design and principle of operation 3 Design and principle of oper- i/p converter with a downstream air capacity booster (7) and the electronics with microcon- ation troller (5). The electropneumatic positioner is mounted The positioner is fitted with three binary con- on pneumatic control valves and is used to tacts as standard: A fault alarm output indi- assign the valve position (controlled vari- cates a fault to the control room and two con- able x) to the control signal (set point w). The figurable software limit contacts are used to electric signal from a controlling system is indicate the end positions of the valve. compared to the travel or the rotational angle The valve position is transmitted as a either of the control valve and a signal pressure an angle of rotation or travel to the pick-up (output variable y) is produced for the actua-...

  • Page 11: Additional Equipment

    Since this signal is issued independent of the agnostic and status messages, which allow positioner’s input signal (minimum current faults to be pinpointed quickly. 3.8 mA), the momentary travel/angle of ro- The positioner is suitable for the following tation is controlled in real-time. Additionally, types of attachment using the corresponding the position transmitter allows positioner accessories: faults to be indicated over a signal current of − Direct attachment to SAMSON <2.4 mA or >21.6 mA. Type 3277 Actuators Inductive limit contact − Attachment to actuators according to In this version, the rotary shaft of the posi- IEC 60534-6 (NAMUR) tioner carries an adjustable tag which actu- − Attachment according to VDI/VDE 3847 ates the built-in proximity switch. The option- − Attachment to Type 3510 Micro-flow al inductive contact (11) is connected to A1, Valve while the remaining software limit contact is − Attachment to rotary actuators according connected to A2.

  • Page 12: Communication

    Design and principle of operation External position sensor − Switch between AUTO/MAN The positioner changes from the auto- In this version, only the sensor is mounted to matic mode (AUTO) to the manual the control valve. The positioner is located mode (MAN) or vice versa. separately from the valve. The connection of x and y signals to the valve is established by This function is not performed if the posi- cable and piping for air (only without induc- tioner is in the fail-safe position mode tive limit contact). (SAFE). − Various diagnostic functions u EB 8389 Analog input x (EXPERTplus valve diagnostics) The analog input x option allows commer- cially available external linear or angle posi- Note: ...

  • Page 13: Configuration Using The Trovis-View Software

     TROVIS-VIEW software The HART device revision as well as ® the indicating and operating modules The positioner can be configured with supported by the Type 3730-3 Posi- SAMSON's TROVIS-VIEW Configuration tioner can be found on the SAMSON and Operator Interface. website: The positioner has for this purpose a serial interface to allow the RS-232 or USB port of a computer to be connected to it over an adapter cable. The TROVIS-VIEW software enables the user to easily configure the positioner as well as view process parameters online.

  • Page 14: Technical Data

    Design and principle of operation 3.3 Technical data The listed technical data may be restricted by the limits of the test certificate for Type 3730-3 Positioner explosion-protected devices. Direct attachment to Type 3277 Actuator 3.6 to 30 mm Attachment according to IEC 60534-6 3.6 to 300 mm (NAMUR) Valve Adjustable travel Attachment according to VDI/VDE 3847 3.6 to 300 mm Attachment to rotary actuators (VDI/ 24 to 100° opening angle VDE 3845) Travel Adjustable within the initialized travel/angle of rotation of the valve; travel can be...
  • Page 15 Design and principle of operation The listed technical data may be restricted by the limits of the test certificate for Type 3730-3 Positioner explosion-protected devices. Temperature ≤0.15 %/10 K Influenc- Supply air None Effect of vibration ≤ 0.25 % up to 2000 Hz and 4 g according to IEC 770 Complying with EN 61000-6-2, EN 61000-6-3, EN 61326-1 and NAMUR Rec- Electromagnetic compatibility ommendation NE 21 One M20 x 1.5 cable gland for 6 to 12 mm clamping range Electrical connections Second M20 x 1.5 threaded connection additionally available Screw terminals for 0.2 to 2.5 mm² wire cross-section Degree of protection IP 66/NEMA 4X...
  • Page 16 Type 3730-3 Positioner explosion-protected devices. Materials Die-cast aluminum EN AC-AlSi12(Fe) (EN AC-44300) acc. to DIN EN 1706 · Housing Chromated and powder paint coated · Special version: stainless steel 1.4581 External parts Stainless steel 1.4571 and 1.4301 Cable gland M20 x 1.5, black polyamide Weight Approx. 1.0 kg · Compliance Options for Type 3730-3 Positioner Solenoid valve · Approval acc. to IEC 61508/SIL 24 V DC · Reverse polarity protection · Static destruction limit 40 V U – 5.7 V Input Current consumption I = (corresponding to 4.8 mA at 24 V/114 mW) 3840 Ω Signal '0' (no response) <12 V (emergency shutdown at 0 V) Signal '1' (response) > 19 V Service life > 5 x 10...
  • Page 17 Design and principle of operation Options for Type 3730-3 Positioner External position sensor Valve travel Same as positioner 10 m · Flexible and durable · With M12x1 connector · Flame-retardant acc. to Cable VDE 0472 Resistant to oils, lubricants and coolants as well as other aggressive media Permissible ambient –60 to +105 °C with fixed connection between the positioner and position sensor · The temperature limits in the test certificate additionally apply for explosion-protected versions Immunity to vibration Up to 10 g in the range of 10 to 2000 Hz Degree of protection IP 67 Leakage sensor · Suitable for operation in hazardous areas Temperature range –40 to +130 °C Tightening torque 20 ±5 Nm Binary input · Galvanically isolated · Switching behavior configured over software (e.g. TROVIS-VIEW, DTM) Active switching behavior (default setting) Connection For external switch (floating contact) or relay contact Open-circuit voltage when contact is open: max. 10 V Electric data Pulsed DC current reaching peak value of 100 mA and RMS value of 0.01 mA when...
  • Page 18 Design and principle of operation Summary of explosion protection certificates for Type 3730-3 Positioner Type Certification Type of protection/comments IEx 13.0161 INMETRO Date 2013-08-28 Ex ia IIC T Gb Valid until 2016-08-27 STCC 0Ex ia IIC T6X; 2Ex s II T6X Valid until 2017-10-01 A/P/HQ/MH/104/1105 CCoE Date 2011-01-27 Ex ia IIC T6 Valid until 2016-01-26 PTB 02 ATEX 2174 II 2G Ex ia IIC T6 Gb; EC type...
  • Page 19 Design and principle of operation Type Certification Type of protection/comments PTB 03 ATEX 2180 X II 3G Ex nA II T6; II 3G Ex ic IIC T6; Date 2013-07-30 II 3D Ex tc IIIC T80°C IP66 Statement of conformity RU C-DE08.B.00113 2Ex nA IIC T6/T5/T4 Gc X; Date 2013-11-15 2Ex ic IIC T6/T5/T4 Gc X; Ex tc IIIC T80°C Dc X Valid until 2018-11-14 GYJ12.1487X Date 2012-10-08 Ex nL IIC T4~T6 Gc; Ex nA IIC T4~T6 Gc Valid until 2017-10-07 EB 8384-3 EN...

  • Page 20: Attachment To The Control Valve - Mounting Parts And Accessories

    3. Connect the supply air. fail-safe position and the required compres- 4. Connect the electrical power. sion of the actuator springs. 5. Perform the start-up settings. The positioner is equipped with the M lever (pin position 35) as standard. The positioner is suitable for the following types of attachment: − Direct attachment to SAMSON Type 3277 Actuator − Attachment to actuators according to IEC 60534-6 (NAMUR) − Attachment according to VDI/VDE 3847 − Attachment to Type 3510 Micro-flow Valve − Attachment to rotary actuators Fig. 2: M lever with pin position 35...
  • Page 21 [mm] Travel [mm] lever position 25.0 120/175/240/350 7.0 35.0 355/700/750 10.0 50.0 Attachment according to IEC 60534-6 (NAMUR) SAMSON valves with Adjustment range at positioner Type 3271 Actuator Other control valves Rated Actuator size travel Min. travel Max. travel Required Assigned pin [cm²]...

  • Page 22: Direct Attachment

    Attachment to the control valve – Mounting parts and accessories 4.1 Direct attachment Make sure that the gasket (14) points to- wards the actuator yoke. 4.1.1 Type 3277-5 Actuator 5. 15 mm travel: Keep the follower pin (2) on the M lever (1) on the back of the po- − Required mounting parts and accesso- sitioner in the pin position 35 (delivered ries: Table 1 on page 50 state).
  • Page 23 Attachment to the control valve – Mounting parts and accessories Lever Symbols Switchover plate (9) 1.1 Nut Actuator stem 1.2 Disk spring extends Follower pin Follower clamp Screw plug Left attachment Right attachment Sealing plug Actuator stem Connecting plate retracts 6.1 Seals Pressure gauge bracket Pressure gauge Signal pressure mounting kit input for left Switchover plate Signal pressure attachment (actuator)

  • Page 24: Type 3277 Actuator

    Attachment to the control valve – Mounting parts and accessories 4.1.2 Type 3277 Actuator Adjust the lever (1) correspondingly and open the positioner cover to hold the po- − Required mounting parts and accesso- sitioner shaft in position at the cap or ro- ries: Table 2 on page 51 tary pushbutton. The lever (1) must rest − Observe the travel table on page 21. on the follower clamp with spring force.
  • Page 25 Attachment to the control valve – Mounting parts and accessories Lever Connection block 1.1 Nut 12.1 Screw 1.2 Disk spring 12.2 Stopper or connection for external piping Follower pin Switch plate 10 14 Follower clamp Gasket Cover plate Formed seal Cover Gasket 11 11.1 11.1 Vent plug M lever Cut-out of cover plate (10) View C View A...

  • Page 26: Attachment According To Iec 60534-6

    Attachment to the control valve – Mounting parts and accessories 4.2 Attachment according to aligned with the NAMUR bracket at mid valve travel). IEC 60534-6 3. Mount connecting plate (6) or pressure − Required mounting parts and accesso- gauge bracket (7) with pressure gauges ries: Table 3 on page 52 on the positioner, making sure the two − Observe the travel table on page 21. seals (6.1) are seated properly. Fig. 5 4.
  • Page 27 Attachment to the control valve – Mounting parts and accessories Attachment to rod-type yoke Rods with 20 to 35 mm diameter Attachment to NAMUR rib Additional bracket for actuators with 2800 cm² and travel ≥60 mm Lever XL and L lever 1.1 Nut 1.2 Disk spring 14.1 Follower pin Follower plate 3.1 Follower plate Connecting plate 6.1 Seals Pressure gauge bracket Pressure gauge mounting Stem connector 9.1 Bracket NAMUR bracket Screw Bolt...

  • Page 28: Attachment According To Vdi/Vde 3847

    Attachment to the control valve – Mounting parts and accessories 4.3 Attachment according to mounting screw is located in the groove of the actuator stem. VDI/VDE 3847 2. Place the adapter bracket (6) on the po- Type 3730-3xxx0xxxx0x0060xx and sitioner and mount using the screws Type 3730-3xxx0xxxx0x0070xx Positioners (6.1). Make sure that the seals are cor- with air purging of the actuator's spring rectly seated. For positioners with air chamber can be attached according to VDI/ purging, remove the stopper (5) before VDE 3847. mounting the positioner. For positioners Type 3730-3xxx0xxxx0x0000xx Positioner without air purging, replace the screw without air purging of the actuator's spring plug (4) with a vent plug. chamber can be attached according to VDI/ 3.
  • Page 29 Attachment to the control valve – Mounting parts and accessories 13.1 17.1 17.2 18 18.1 11.1 12.1 Exh. 6.2 6.1 Lever Disk spring Follower pin Follower clamp Screw plug Adapter block Stopper 13.1 Screws Adapter bracket Screws Turnboard Formed seal 17.1 Formed seal 17.2 Screws Screws Blank plate...
  • Page 30 Attachment to the control valve – Mounting parts and accessories 7. Insert the screws (13.1) through the mid- Place positioner on the adapter block dle holes of the adapter block (13). (13) in such a manner that the follower pin (2) rests on the top of the follower 8. Place the connecting plate (12) together clamp (3). Adjust the lever (1) corre- with the seal (12.1) onto the screws spondingly and open the positioner cov- (13.1) corresponding to the fail-safe ac- er to hold the positioner shaft in position tion "actuator stem extends" or "actuator at the cap or rotary pushbutton. stem retracts". The fail-safe action that applies is determined by aligning the The lever (1) must rest on the follower groove of the adapter block (13) with the clamp with spring force. groove of the connecting plate (12) Fasten the positioner to the adapter block (Fig. 7). (13) using the two fixing screws (6.3). Make sure the formed seal (6.2) is prop- Actuator stem erly seated. extends retracts 12.
  • Page 31 Attachment to the control valve – Mounting parts and accessories Attachment to NAMUR rib (see Fig. 8) on the rod and position the formed plate (15) on the opposite side. Use the nuts − Required mounting parts and accesso- and toothed lock washers to fasten the ries: Table 4 on page 52 formed plate onto the studs. Align the − Observe the travel table on page 21. marking on the NAMUR valve connec- 1. Series 240 Valves, actuator size up to tion (on the side marked '1') to 50 % 1400-60 cm²: Screw the two bolts (14) travel. to the bracket of the stem connector or 3. Place the adapter bracket (6) on the po- directly to the stem connector (depending sitioner and mount using the screws on the version), place the follower plate (6.1). Make sure that the seals are cor-...
  • Page 32 Attachment to the control valve – Mounting parts and accessories 5. Insert the formed seal (6.2) in the groove nection of the actuator. Seal the Y2 port of the adapter bracket. with a blanking plug. For double-acting actuators and actua- 6. Insert the formed seal (17.1) into the turnboard (17) and mount the turnboard tors with air purging, connect the Y2 to the adapter block (13) using the port of the adapter block to the signal pressure connection of the second actua- screws (17.2). tor chamber or spring chamber of the 7. Mount the blank plate (18) to the turn- actuator. board using the screws (18.1). Make sure that the seals are correctly seated. Note: ...
  • Page 33 Attachment to the control valve – Mounting parts and accessories 13.1 17.1 17.2 18.1 Exh. Lever 14.1 1.1 Nut 1.2 Disk spring Follower pin Follower plate 13.1 Screws 3.1 Follower plate 6.2 6.1 Bolt Blanking plug 14.1 Screws Stopper Formed plate Adapter bracket Bracket 6.1 Screws Turnboard...

  • Page 34: Attachment To Type 3510 Micro-Flow Valve

    − Observe the travel table on page 21. scale is aligned with the stem connector. The positioner is mounted to the rotary actu- 4. Fasten the hex bar (11) onto the outer ator using two pairs of brackets. side of yoke by screwing the M8 screws Prior to attaching the positioner to the (11.1) directly into the holes on the yoke. SAMSON Type 3278 Rotary Actuator, 5. Fasten the bracket (10) to the hex bar mount the associated adapter (5) to the free (11) using the hex screw (10.1), washer end of the rotary actuator shaft. and tooth lock washer. Note: 6. Mount connecting plate (6) or pressure  On attaching the positioner as de-...
  • Page 35 Attachment to the control valve – Mounting parts and accessories 12.1 11.1 10.1 Lever 1.1 Nut 1.2 Disk spring Follower pin NOTICE Follower plate Only use the connecting plate (6) in- Connecting plate cluded in the accessories to connect 6.1 Seals supply and output! Pressure gauge Never screw threaded parts directly bracket...

  • Page 36: Heavy-Duty Version

    Attachment to the control valve – Mounting parts and accessories 2. Place coupling wheel (4) with flat side side of the positioner housing (see section facing the actuator on the follower clamp 4.6). (3). Refer to Fig. 11 to align slot so that it 6. Unscrew the standard follower pin (2) matches the direction of rotation when the from the positioner's M lever (1). Use the valve is in its closed position. metal follower pin (Ø 5 mm) included in 3. Fasten the coupling wheel (4) and follow- the mounting kit and screw tight into the er clamp (3) tightly onto the actuator shaft hole for pin position 90°. using screw (4.1) and disk spring (4.2). 7. Place positioner on the top bracket (10) 4. Fasten the bottom pair of brackets (10.1) and fasten tight. Taking the actuator's di- with the bends pointing either facing to rection of rotation into account, adjust le- the inside or to the outside (depending on ver (1) so that it engages in the slot of the the actuator size) onto the actuator hous-...
  • Page 37 Attachment to the control valve – Mounting parts and accessories (7, 8) 10.1 NOTICE 80 mm Only use the connecting plate (6) included in the ac- cessories to connect supply and output! 130 mm Never screw threaded parts directly into housing! Slot Legend for Fig. 10 and Fig. 11...

  • Page 38: Reversing Amplifier For Double-Acting Actuators

    Attachment to the control valve – Mounting parts and accessories place spacers (11) underneath, if neces- 5. Unscrew the standard follower pin (2) sary. from the positioner's M lever (1). Attach the follower pin (Ø 5 mm) included in 2. For SAMSON Type 3278 and VETEC the mounting kit to pin position 90°. S160 Rotary Actuators, screw the adapt- 6. Mount connecting plate (6) for required er (5) onto the free end of the shaft or G ¼ connecting thread or pressure place adapter (5.1) onto the shaft of the gauge bracket (7) with pressure gauges VETEC R Actuator. Place adapter (3) on- on the positioner, making sure the two to Type 3278, VETEC S160 and VETEC R seals (6.1) are seated properly. Dou-...
  • Page 39 Screws Adhesive label Spacer Actuator shaft or adapter Adapter 10.1 10.1 Attachment acc. to VDE/VDI 3845 (Sept. SAMSON Type 3278 2010) fixing level 1, AA1 to AA4 size (see VETEC S160, VETEC R section 15.1) Fig. 12: Attachment to rotary actuators (heavy-duty version) EB 8384-3 EN...

  • Page 40: Reversing Amplifier (1079-1118 Or 1079-1119)

    Attachment to the control valve – Mounting parts and accessories The following applies to all reversing am- 2. Thread the special nuts (1.3) from the ac- plifiers: cessories of the reversing amplifier into the boreholes of the connecting plate. The signal pressure of the positioner is sup- plied at the output 1 of the reversing amplifi- 3. Insert the gasket (1.2) into the recess of er. An opposing pressure, which equals the the reversing amplifier and slide both the required supply pressure (Z) when added to hollowed special screws (1.1) into the and Z. the pressure at output 1, is applied at connecting boreholes A output 2. 4. Place the reversing amplifier onto the The following relationship applies: connecting plate (6) and screw tight us- Output 1 + Output 2 = Supply pressure (Z). ing both the special screws (1.1).
  • Page 41 Attachment to the control valve – Mounting parts and accessories From the positioner Output 38 Supply 9 Control signals to the actuator Reversing amplifier Connecting plate 1.1 Special screws 6.1 O-rings 1.2 Gasket 6.2 Screws 1.3 Special nuts 1.4 Rubber seal 1.5 Sealing plug 1.6 Filter Fig. 14: Mounting a reversing amplifier (1079-1118 or 1079-1119) EB 8384-3 EN...

  • Page 42: Attachment Of External Position Sensor

    Attachment to the control valve – Mounting parts and accessories 4.7 Attachment of external po- pneumatic and electrical connec- tion. sition sensor Operation and setting are described in sections 7 and 8. − Since 2009, the back of the posi- tion sensor (20) is fitted with two pins acting as mechanical stops for the lever (1).

  • Page 43: Mounting The Position Sensor With Direct Attachment

    Attachment to the control valve – Mounting parts and accessories 4.7.1 Mounting the position retracts" is aligned with the marking (Fig. 15, below). sensor with direct at- − Make absolutely sure that the gasket for tachment the connecting plate (9) is correctly insert- Type 3277-5 Actuator with 120 cm² (Fig. 15) The signal pressure from the positioner is − The connecting plate has threaded holes routed over the signal pressure connection of with NPT and G threads. Seal the thread- ed connection that is not used with the the connecting plate (9, Fig. 15 left) to the actuator diaphragm chamber. To proceed, rubber seal and square plug.
  • Page 44 Attachment to the control valve – Mounting parts and accessories action. For the fail-safe action "actuator stem (21) onto the actuator yoke using both retracts" the connection on the top dia- fixing screws. phragm case is used. The connection at the 7. Mount cover (11) on the other side. side of the yoke must be fitted with a venting Make sure that the vent plug is located at plug (accessories). the bottom when the control valve is in- stalled to allow any condensed water Mounting the position sensor that collects to drain off. 1. Place the lever (1) on the sensor in mid-position and hold it in place. Un- thread the nut (1.1) and remove the lever together with the disk spring (1.2) from the sensor shaft. 2. Screw the position sensor (20) onto the mounting plate (21).

  • Page 45: Mounting The Position Sensor With Attachment According To Iec 60534-6

    Attachment to the control valve – Mounting parts and accessories 4.7.2 Mounting the position 120 to 350 cm² actuators with 15 mm rated travel. For other actuator sizes or travels, se- sensor with attachment lect the lever and pin position from the travel according to table on page 21. L and XL levers are in- IEC 60534-6 cluded in the mounting kit. 3. Place the lever (1) and disk spring (1.2) − Required mounting parts and accesso- on the sensor shaft. Place the lever in ries: Table 7 on page 54 mid-position and hold it in place. Screw Fig. 16 on the nut (1.1).

  • Page 46: Mounting The Position Sensor To Type 3510 Micro-Flow Valve

    Attachment to the control valve – Mounting parts and accessories 4.7.3 Mounting the position hole for pin position 17. Place the lever (1) and disk spring (1.2) on the sensor sensor to Type 3510 Mi- shaft. Place the lever in mid-position and cro-flow Valve hold it in place. Screw on the nut (1.1). − Required mounting parts and accesso- 4. Place follower clamp (3) on the valve ries: Table 7 on page 54 stem connector, align at a right angle and screw tight.

  • Page 47: Mounting On Rotary Actuators

    Attachment to the control valve – Mounting parts and accessories 4.7.4 Mounting on rotary ac- 4. Place the lever (1) and disk spring (1.2) on the sensor shaft. Place the lever in tuators mid-position and hold it in place. Screw − Required mounting parts and accesso- on the nut (1.1). ries: Table 7 on page 54 Follow the instructions describing attachment to the standard positioner in section 4.5. Fig. 18 Instead of the positioner, attach the position 1.

  • Page 48: Mounting The Leakage Sensor

    Attachment to the control valve – Mounting parts and accessories 4.8 Mounting the leakage The M8 threaded connection on the NAMUR rib should preferably be used to mount the sensor sensor (Fig. 19). Fig. 19 Tip: Normally, the control valve is delivered with If the positioner was mounted directly positioner and leakage sensor already onto the actuator (integral attach- mounted. ment), the NAMUR interfaces on ei- If the leakage sensor is mounted after the ther side of the valve yoke can be valve has been installed or it is mounted on-...

  • Page 49: Attaching Positioners With Stainless Steel Housings

    Attachment to the control valve – Mounting parts and accessories 4.9 Attaching positioners with Attachment to rotary actuators stainless steel housings All mounting kits from Table 5 can be used except for the heavy-duty version. Connect- Positioners with stainless steel housings re- ing plate in stainless steel. quire mounting parts that are completely 4.10 Air purging function for sin- made of stainless steel or free of aluminum. gle-acting actuators Note:  The instrument air leaving from the positioner The pneumatic connecting plate and is diverted to the actuator spring chamber to pressure gauge bracket are available provide corrosion protection inside the actua-...

  • Page 50: Required Mounting Parts And Accessories

    Attachment to the control valve – Mounting parts and accessories Attachment according to IEC 60534-6 Should other valve accessories be used (NAMUR rib or attachment to rod-type which vent the actuator (e.g. solenoid valve, yokes) and to rotary actuators volume booster, quick exhaust valve), this ex- haust air must also be included in the purg- The positioner requires an additional port for ing function. The connection over the adapt- the exhaust air that can be connected over er at the positioner must be protected with a piping. An adapter available as an accesso- check valve (e.g. check valve G ¼, order no. ry is used for this purpose: 8502-0597) mounted in the piping. Other- Threaded bushing G ¼ 0310-2619 wise the pressure in the positioner housing (M20 x 1.5) ¼ NPT...
  • Page 51 Attachment to the control valve – Mounting parts and accessories Table 2: Direct attachment to Type 3277 Actuator (Fig. 4) Order no. Standard version for actuators 175, 240, 350, 355, 700, 750 cm² 1400-7453 Mounting parts Version compatible with paint for actuators 175, 240, 350, 355, 700, 750 cm² 1402-0941 G  / G  1402-0970 ¼ Steel ¼ NPT/  NPT 1402-0976 175 cm² G ¼ / G  1402-0971 St. steel ¼ NPT/  NPT 1402-0978 G ¼ / G ...
  • Page 52 ¼ Accessories Pressure gauge bracket (7)  NPT 1400-7459 ¼ Stainless steel/brass 1400-6950 Pressure gauge mounting kit up to max. 6 bar (output/supply) St. steel/st. steel 1400-6951 M lever is mounted on basic device (included in the scope of delivery) In conjunction with Type 3273 Side-mounted Handwheel with 120 mm rated travel, additionally one bracket (0300-1162) and two countersunk screws (8330-0919) are required. Table 4: Attachment according to VDI/VDE 3847 (Fig. 6 and Fig. 8) Electropneumatic positioners with VDI/VDE 3847 interface (Type 3730-3xxx0xxxx0x0070xx) Order no. Interface adapter 1402-0257 Mounting kit for attachment to SAMSON Type 3277 Actuator with 175 to 750 cm² 1402-0868 Mounting Mounting kit for attachment to SAMSON Type 3271 Actuator or non-SAMSON 1402-0869 parts actuators Travel pick-off for valve travel up to 100 mm 1402-0177 Travel pick-off for 100 to 200 mm valve travel (SAMSON Type 3271 Actuator only) 1402-0178 EB 8384-3 EN...
  • Page 53 St. steel/brass 1400-6950 Pressure gauge mounting kit up to max. 6 bar (output/supply) St. steel/brass 1400-6951 Table 6: General accessories Order no. Reversing amplifier for double-acting actuators Type 3710 Black plastic (6 to 12 mm clamping range) 8808-1011 Blue plastic (6 to 12 mm clamping range) 8808-1012 Cable gland M20 x 1.5, Nickel-plated brass (6 to 12 mm clamping range) 1890-4875 Nickel-plated brass (10 to 14 mm clamping range) 1922-8395 Stainless steel 1.4305 (8 to 14.5 mm clamping range) 8808-0160 Powder-coated aluminum 0310-2149 Adapter M20x1.5 to ½ NPT Stainless steel 1400-7114 Retrofit kit for inductive limit contact 1 x SJ2-SN 1400-7460 DE/EN (delivered state) 1990-0761 Cover plate with list of parameters and operating instructions EN/ES 1990-3100 EN/FR 1990-3142 TROVIS-VIEW 6661 with Type 3730-3 device module EB 8384-3 EN...
  • Page 54 Attachment to the control valve – Mounting parts and accessories Table 6: General accessories Order no. Serial interface adapter (SAMSON SSP interface to RS-232 port on a PC) 1400-7700 Isolated USB interface adapter (SAMSON SSP interface to USB port on a PC) including 1400-9740 TROVIS-VIEW CD-ROM Table 7: Attachment of external position sensor Order no. Template for mounting position sensor on older mounting parts. See note on page 42 1060-0784 Mounting parts for actuators with 120 cm². See Fig. 15 (left). 1400-7472 G  1400-6820 Connecting plate (9, old) with Type 3277-5xxxxxx.00 Actuator  NPT 1400-6821 Direct attachment Connecting plate (new) with Type 3277-5xxxxxx.01 Actuator (new) 1400-6823 Mounting parts for actuators with 175, 240, 350, 355 and 700 cm². See Fig. 15...

  • Page 55: Connections

    Connections 5 Connections a bore with ¼ NPT or G ¼ thread. Custom- ary fittings for metal or copper tubing or WARNING! plastic hoses can be used. Risk of injury due to the actuator stem extending or retracting. NOTICE Do not touch or block the actuator Risk of malfunction due to failure to stem. comply with required air quality. Only use supply air that is dry and free of oil and dust.

  • Page 56: Signal Pressure (Output)

    Connections 5.2 Electrical connections The bench range is written on the nameplate ei- ther as the spring range or signal pressure range depending on the actuator. The direction DANGER! of action is marked FA or FE, or by a symbol. Risk of electric shock and/or the for- Actuator stem extends FA (AIR TO OPEN) mation of an explosive atmosphere. For electrical installation, observe the Fail-close (for globe and angle valves): relevant electrotechnical regulations Required supply pressure = Upper bench and the accident prevention regula- range value + 0.2 bar, at least 1.4 bar.
  • Page 57 Connections Selecting cables and wires Cable entry Observe clause 12 of EN 60079-14: 2008 Cable entry with M20 x 1.5 cable gland, 6 (VDE 0165, Part 1) for installation of the in- to 12 mm clamping range. trinsically safe circuits. There is a second M20 x 1.5 threaded hole in the housing that can be used for addition- Clause 12.2.2.7 applies when running multi- al connection, when required. core cables and wires with more than one The screw terminals are designed for wire intrinsically safe circuit. cross-sections of 0.2 to 2.5 mm² (tightening The radial thickness of the insulation of a torque of screws 0.5 to 0.6 Nm). conductor for common insulating materials The wires for the set point must be connected (e.g. polyethylene) must not be smaller than to the terminals 11 and 12 located in the 0.2 mm. The diameter of an individual wire housing. in a fine-stranded conductor must not be smaller than 0.1 mm. Protect the conductor Only use a current source.
  • Page 58 Connections terminals can be between at least 12 and Accessories 30 V DC at the maximum. Cable glands M20 x 1.5 Order no. Refer to Fig. 20 or to the label on the termi- Black plastic nal block. (6 to 12 mm clamping range) 8808-1011 Blue plastic NOTICE (6 to 12 mm clamping range) 8808-1012 Malfunction due the current falling Nickel-plated brass below minimum current. (6 to 12 mm clamping range) 1890-4875 Do not allow the set point to fall be- Nickel-plated brass low 3.8 mA. (10 to 14 mm clamping range) 1922-8395 Stainless steel 1.4305...

  • Page 59: Switching Amplifier

    Connections 5.2.1 Establishing communica- Note:  tion In positioners for attachment accord- ing to VDI/VDE 3847, the terminal Communication between computer and posi- designation of the limit contacts tioner using an FSK modem or handheld 41/42 and 51/52 as well as the communicator (if necessary, using an isola- OPEN and CLOSED wording can be tion amplifier) is based on the HART® proto- changed by turning the terminal la- col.
  • Page 60 Connections mode is, for example, suitable for split-range Alternatively, a 250 Ω resistor can operation of positioners (series connection). be connected in series and a 22 μF capacitor can be connected in paral- The bus address/polling address has to be lel to the analog output. The load for within a range of 1 to 15. the controller output will increase as Note: a result. ...

  • Page 61: Operating Controls And Readings

    Operating controls and readings 6 Operating controls and Volume restriction Q readings The volume restriction serves to adapt the air output capacity to the size of the actuator. Rotary pushbutton Depending on the air passage at the actua- The rotary pushbutton is located underneath tor, two fixed settings are available. the front protective cover. The positioner is − For actuators smaller than 240 cm² and operated on site using the rotary pushbutton: with a signal pressure connection at the Turn : Select codes and values side (Type 3271-5), set restriction to MIN SIDE. Press : Confirm setting − For a connection at the back (Type 3277- AIR TO OPEN/AIR TO CLOSE slide switch 5), set restriction to MIN BACK.
  • Page 62 Operating controls and readings Manual mode Closed-loop operation Code Malfunction/fault Bar graph for set point deviation or lever position Designation Position Parameters Units Limit contact Limit contact alarm 1 alarm 2 Enable Fail-safe position active Maintenance demanded Configuration Maintenance required Blinking icon: out of specification Automatic Initialization in progress AUtO TunE Clockwise Class Available/active Counterclockwise Zero calibration Error Cancel Increasing/increasing ...

  • Page 63: Serial Interface

    In manual and automatic modes, the The positioner must be supplied with at least bars indicate the set point deviation that de- 4 mA. pends on the sign (+/–) and the value. One bar element appears per 1 % set point devi- The positioner can be connected directly to ation. the computer over the local serial interface and the serial interface adapter. If the positioner has not been initialized, ( blinks on the display), the bar graph indi- The operator software is TROVIS-VIEW with cates the lever position in degrees in relation installed device module 3730-3. to the mid-axis. One bar element corre- 6.2 HART communication sponds to approximately a 5° angle of rota- ® tion. The fifth bar element blinks (reading > The positioner must be supplied with at least 30°) if the permissible angle of rotation has 4 mA. The FSK modem must be connected in been exceeded. Lever and pin position must parallel to the current loop. be checked. A DTM file (Device Type Manager) conform- ing to the Specification 1.2 is available for communication. This allows the device, for EB 8384-3 EN...

  • Page 64: Dynamic Hart ® Variables

    If complex functions are started in the mand. positioner, which require a long cal- culation time or lead to a large quan- In the Type 3730-3 Positioner, the dynamic tity of data being saved in the vola- variables can be assigned by the DD or in tile memory of the positioner, the TROVIS-VIEW [Settings > Operation unit] as alert 'busy' is issued issued by the shown in Table 8.
  • Page 65 Operating controls and readings Table 8: Dynamic HART variables assignment ® Variable Meaning Unit Set point Set point Direction of action set point Direction of action set point Set point after transit time speci- Set point after transit time specification fication Actual value (process variable) Actual value (process variable) Set point deviation e Set point deviation e Absolute total valve travel Absolute total valve travel – Binary input status 0 = Not active – 1 = Active 255 = –/– Internal solenoid valve/forced 0 = De-energized – venting status 1 = Energized 2 = Not installed Condensed state 0 = No message...

  • Page 66: Start-Up And Settings

    Start-up and settings 7 Start-up and settings Do not touch or block the actuator stem. NOTICE Risk of malfunction due to incorrect Note:  sequence of mounting, installation The positioner performs a test in the and start-up. start-up phase while following its au- Keep the following sequence.

  • Page 67: Adjusting The Volume Restriction Q

    7.3 Adapting the display direc- ed air flow rate (MIN). tion − Actuators with a transit time ≥ 1 s do not require the air flow rate to be restricted To adapt the reading on the display to the (MAX). mounting situation of the actuator, the dis- The position of volume restriction Q also de- play contents can be turned by 180°. pends on how the signal pressure is routed at the actuator in SAMSON actuators: Reading direction for right at- − The SIDE position applies for actuators tachment of pneumatic con- with a signal pressure connection at the nections side, e.g. Type 3271-5. EB 8384-3 EN...

  • Page 68: Limiting The Signal Pressure

    Start-up and settings Limit the signal pressure: Reading direction for left at- tachment of pneumatic con- Pressure limit nections Default: No If the displayed data appear upside down, proceed as follows: Turn  Code 16 Turn  Code 2 Press , Code 16 blinks. Press , Code 2 blinks. Turn until the required pressure limit (1.4/2.4/3.7 bar) appears. Turn  Required reading direction Press to confirm the pressure limit setting. Press to confirm reading direction. 7.5 Checking the operating 7.4 Limiting the signal pressure range of the positioner...

  • Page 69: Initialization

    Start-up and settings Check the operating range: Before exchanging the lever or changing the pin position, disconnect the supply air and electrical auxiliary Manual set point w power. (current angle of rotation is indicated) 7.6 Initialization Turn  Code 1 NOTICE Press , Code 1 and icon blink. The process is disturbed by the move- Turn until the pressure in the positioner ment of the actuator stem.
  • Page 70 Start-up and settings − Maximum range (MAX) (standard range) Initialization mode for simple start-up of Bar graph display indicating valves with two clearly defined mechani- the progress of the initializa- tion cal end positions, e.g. three-way valves (see section 7.6.1) − Nominal range (NOM) Initialization mode for all globe valves Initialization successfully com- pleted. Positioner in automatic (see section 7.6.2) mode ( ) − Manually selected range (MAN) Initialization mode for globe valves with The time required for the initialization proce- an unknown nominal range (see sec- dure depends on the actuator transit time and tion 7.6.3) can take a few minutes.

  • Page 71: Max - Initialization Based On Maximum Range

    Start-up and settings 7.6.1 MAX – Initialization Fail-safe position AIR TO CLOSE based on maximum If the slide switch is set to AIR TO CLOSE, the positioner automatically switches to the direc- range tion of action increasing/decreasing (äæ) after initialization has been completed. This The positioner determines travel/angle of ro- results in the following assignment between tation of the closing member from the set point and valve position: CLOSED position to the opposite travel stop and adopts this travel/angle of rotation as Set point the operating range from 0 to 100 %. Fail-safe Direction of Valve position action CLOSED Enable configuration: OPEN at Actuator stem...

  • Page 72: Nom - Initialization Based On Nominal Range

    Start-up and settings out collision. If this is the case, the indicated Press to confirm the MAX as the initial- nominal range is adopted with the limits of ization mode. travel/angle range start (Code 8) and trav- Start initialization: el/angle range end (Code 9) as the operat- Î Press INIT key. ing range. The nominal travel/angle of rotation is indi- Note:  cated in % after initialization. Code 5 (nomi- The maximum possible travel must al- nal range) remains locked. The parameters ways be greater than the nominal for travel/angle range start (Code 8) and travel entered. If this is not the case, travel/angle range end (Code 9) can also initialization is automatically can- only be displayed and modified in %.

  • Page 73: Man - Initialization Based On A Manually Selected Range

    Start-up and settings Enter the pin position and nominal range: Î After initialization, check the direction of action (Code 7) and, if necessary, change it. Pin position Default: No 7.6.3 MAN – Initialization based on a manually selected range Nominal range Before starting initialization, move the con- (locked when Code 4 = No) trol valve manually to the OPEN position. Turn the rotary pushbutton ( ) clockwise in Turn  Code 4 small steps. The valve must be moved with a monotonically increasing signal pressure. , Code 4 blinks. Press The positioner calculates the differential trav- Turn...

  • Page 74: Sub - Substitute Calibration

    Start-up and settings Enter the pin position: Press , Code 1 blinks. Turn until the valve reaches its OPEN po- sition. Pin position Default: No Press to confirm the OPEN position. Start initialization: Turn  Code 4 Î Press INIT key. Press , Code 4 blinks. 7.6.4 SUb – Substitute calibra- Turn  Pin position on lever (see relevant tion section on attachment) Press A complete initialization procedure takes several minutes and requires the valve to Select the initialization mode: move through its entire travel range several times. This initialization mode, however, is...
  • Page 75 Start-up and settings Turn  Pin position on lever (see relevant NOTICE section on attachment) Perform a reset before re-initializing the positioner if the substitute posi- Press tioner has already been initialized. Turn  Code 5 Refer to section 7.8. Press , Code 5 blinks. Turn  Nominal travel of the valve Enable configuration: Press Note:  Select the initialization mode: If no settings are entered within 120 seconds, the enabled configuration...
  • Page 76 Start-up and settings Deactivate travel limit: Press , Code 16/17/18 blinks. Turn to set the control parameter select- Travel limit Default: No Press to confirm the setting. Enter closing direction and blocking position: Turn  Code 11 Closing direction (direction of ro- Press , Code 11 blinks. tation causing the valve to move to the CLOSED position (view on- g No Turn to positioner display) Default: CCL (counterclockwise) Press Change pressure limit and control parame- ters:...

  • Page 77: Zero Calibration

    Start-up and settings The positioner switches to MAN mode. − Set T (Code 18) to 4. The blocking position is indicated. − If the positioner still oscillates, the gain K (Code 17) must be de- Note:  creased until the positioner shows a Since initialization has not been com- stable behavior.

  • Page 78: Reset To Default Settings

    Start-up and settings Enable configuration: Reset start-up parameters: Turn g Code 3, display: No Press , Code 3 blinks. Reset Default: No Turn  YES Press , display: Perform zero calibration: Turn g Code 36, display: ••–••– Press , Code 36 blinks.  Std Turn Init mode Default MAX Press All start-up parameters as well as the diag- nosis are reset to their default values. Turn  Code 6 Note: Press , Code 6 blinks.

  • Page 79: Operation

    Operation 8 Operation Turn to select the required code. Press to activate the selected code. The WARNING! code number starts to blink. Risk of injury due to the actuator Turn to select the setting. stem extending or retracting. Press to confirm the selected setting. Do not touch or block the actuator stem.

  • Page 80: Fail-Safe Position (Safe)

    Operation Note:  The positioner automatically returns Automatic mode to Code 0 if no settings are made within 120 seconds, but remains in the manual mode. Switching to manual mode (MAN) Switch to automatic mode Turn  Code 0 Press , Code 0 blinks. Turn ...

  • Page 81: Fault/Malfunction

    Operation Exit the fail-safe position − Maintenance required The positioner still performs its control Turn  Code 0 task (with restrictions). A maintenance Press , Code 0 blinks. demand or above average wear has Turn and select the required operating been determined. The wear tolerance will mode (AUtO or MAN). soon be exhausted or is reducing at a Press faster rate than expected. Maintenance is The positioner switches to the operating necessary in the medium term. mode selected. − Maintenance demanded The positioner still performs its control 8.3 Fault/malfunction task (with restrictions). A maintenance A status classification is assigned to all status demand or above average wear has...

  • Page 82: Confirming Error Messages

    Operation If the positioner has not been initialized, the Turn  YES maintenance alarm icon ( ) is displayed as Press , display: the positioner cannot follow its set point. Confirming error message: If fault alarms exist, the possible source of Turn  Select the error code that you error is displayed in Code 49 onwards. In want to confirm. this case, Err is displayed. Press The error message is confirmed. Example: Error caused by pin position Refer to the code list (section 14) for possible causes and the recommended action. Fault alarm output 'Maintenance alarm' as the condensed state causes the optional fault alarm output to be switched. − The 'Function check' condensed state can also activate the fault alarm output (Code 32).

  • Page 83: Adjusting The Limit Contact

    Adjusting the limit contact 9 Adjusting the limit contact however, can also be adjusted to indicate in- termediate valve positions. The positioner version with an inductive limit The required switching function, i.e. whether contact has an adjustable tag (1) mounted the output relay is to be picked up or re- on the axis of rotation, which operates the leased when the tag enters the field, must be proximity switch (3). selected at the switching amplifier, if re- For operation of the inductive limit contact, quired. the corresponding switching amplifier (see Note: section 5.2.1) must be connected to the out-  put circuit. The inductive limit contact replaces the software limit contact A1 with ter- When the tag (1) is located in the inductive minal assignment +41/–42.

  • Page 84: Retrofitting An Inductive Limit Contact

    Adjusting the limit contact Software adaptation Move the valve to 95 % in the MAN mode (see display). − Code 38 (inductive alarm is set to YES). Adjust the tag (1) at the yellow adjust- − The inductive limit contact is connected to ment screw (2) until the tag enters or the terminals +41/–42. leaves the field of the proximity switch − The device is set up accordingly in the (3). delivered state. You can measure the switching voltage Adjusting the switching point as an indicator. Contact function: Note:  During adjustment or testing, the −...
  • Page 85 Adjusting the limit contact 1. Take off the rotary pushbutton (3) and cap (1), unthread the five fastening screws (2) and lift off the plastic cover (9) together with the display, taking care not to dam- age the ribbon cable (between PCB and display). 2. Use a knife to cut an opening at the marked location (4). 3. Push the connector (11) with cable through the opening and secure the prox- imity switch (7) on the cover with a dot of glue. 4. Remove the jumper (8801-2267) at the socket X7 of the top board and insert the cable connector (11). 5. Guide the cable in such a manner that the plastic cover can be placed back onto the positioner. Insert the fixing screws (2) and screw tight. Attach the clamping plate (8) onto the proximity switch. 6. Attach the rotary switch (5). Make sure the flattened side of the positioner shaft is turned so that the rotary switch (5) can be attached with the metal tag next to the proximity switch. 7. On start-up of the positioner, set the op- tion inductive alarm under Code 38 from No to YES. Socket X7 (11) Metal tag Proximity switch...

  • Page 86: Maintenance

    The maintenance instructions of any up- 12 Firmware update (serial in- stream supply air pressure reducing stations terface) must be observed. Firmware updates on positioners currently in operation can be performed as follows: 11 Servicing explosion-protected When updates are performed by a service employee appointed by SAMSON, the up- devices date is confirmed on the device by the test If a part of the device on which the explosion mark assigned by SAMSON’s Quality Assur- protection is based needs to be serviced, the ance. device must not be put back into operation In all other cases, only plant operator per- until a qualified inspector has assessed it ac- sonnel with written approval may perform cording to explosion protection require- updates. Updates are to be confirmed by ap- ments, has issued an inspection certificate or proved personnel on the device.

  • Page 87: Maintenance, Calibration And Work On Equipment

    Maintenance, calibration and work on equipment Updates on site: Updates on site are only permitted after the plant operator presented a signed hot work permit. After updating has been completed, add the current firmware to the nameplate; this can be done using labels. 13 Maintenance, calibration and work on equipment Interconnection with intrinsically safe cir- cuits to check or calibrate the equipment in- side or outside hazardous areas is to be performed only with intrinsically safe cur- rent/voltage calibrators and measuring in- struments to rule out any damage to com-...

  • Page 88: Code List

    Code list 14 Code list Code Parameter – Readings/ Description values [default setting] Note: Codes with marked with an asterisk (*) must be enabled with Code 3 prior to configuration. Operating mode Switchover from automatic to manual mode is bumpless. In fail-safe position, the S icon is displayed. [MAN] Manual mode In MAN and AUtO mode, the system deviation is represented by the AUtO Automatic mode bar graph elements. SAFE Fail-safe position The reading indicates the valve position or angle of rotation in % when the positioner is initialized. If the positioner is not initialized,...
  • Page 89 Code list Code Parameter – Readings/ Description values [default setting] Nominal range Nominal valve travel or opening angle must be entered for nominal (NOM) or substitute (SUb) initialization. mm or angle °, ESC The possible adjustment range depends on the pin position from the table for Code 4. Indicates maximum travel/angle reached during initialization after initialization has been successfully completed. Init mode Select the initialization mode MAX: Travel/angle of the closure member from the CLOSED posi- [MAX] Maximum range tion to the opposite stop in the actuator. NOM Nominal range NOM: Travel/angle of the closure member measured from the MAN Manual setting CLOSED position to the indicated OPEN position. Emergency mode MAN: Manually selected range Zero calibration SUb: Substitute calibration (without initialization)
  • Page 90 Code list Code Parameter – Readings/ Description values [default setting] Travel/angle range end Upper range value for travel/angle in nominal or operating range (upper x-range value) The value is displayed or must be entered. 20.0 to [100.0 %] of the The characteristic is adapted. nominal range, ESC Example: The operating range is modified, for example, to limit the Note: Specified in mm or range of a control valve which has been sized too large. For this angle ° provided Code 4 is function, the entire resolution range of the set point is converted to activated. the new limits. 0 % on the display corresponds to the adjusted lower limit and 100 % to the adjusted upper limit.
  • Page 91 Code list Code Parameter – Readings/ Description values [default setting] 13* w-end The upper range value of the set point range must be greater than lower range value (w-start). 25.0 to [100.0 %] of the set point range, ESC 100.0 % = 20 mA 14* Reference variable range If the set point w reaches up to the entered percentage at the final start (w-start) value that causes the valve to close, the actuator is immediately com- pletely vented (with AIR TO OPEN) or filled with air (with AIR TO 0.0 to 49.9 %, [1.0 %] of CLOSE). This action always lead to maximum tight-closing of the the span adjusted in valve. Code 12/13, No, ESC Codes 14/15 have priority over Codes 8/9/10/11. Codes 21/22 have priority over Codes 14/15. 15* Reference variable range If the set point w reaches up to the entered percentage at the final end (w-end) value that causes the valve to open, the actuator is immediately filled with air (with AIR TO OPEN) or completely vented (with AIR TO 50.0 to 100.0 % of the CLOSE). This action always lead to the valve being completely span adjusted in opened.
  • Page 92 Determination of the tolerance band in relation to the operating the operating range, ESC range. Associated lag time (30 s) is a reset criterion. If a transit time is determined during initialization which is six times longer than 30 s, the six-fold transit time is accepted as the lag time. 20* Characteristic Select characteristic Linear [0] to 9, ESC Equal percentage Reverse equal percentage SAMSON butterfly valve, linear SAMSON butterfly valve, equal percentage VETEC rotary plug valve, linear VETEC rotary plug valve, equal percentage Segmented ball valve, linear Segmented ball valve, equal percentage User-defined (defined over operator software) Note: The various characteristics are listed in the Appendix (section 16). 21* Required transit time Time required to move through the operating range when the valve OPEN (w ramp open) opens.
  • Page 93 Code list Code Parameter – Readings/ Description values [default setting] 22* Required transit time Time required to move through the operating range when the valve CLOSED (w ramp closed) closes. [0] to 240 s, ESC Code 22 has priority over Code 14. NOTICE: The function is not activated when the fail-safe function or solenoid valve is triggered nor upon failure of the auxiliary power. 23* Total valve travel Totaled full valve travel cycle Can be reset to 0 by selecting ESC.
  • Page 94 Code list Code Parameter – Readings/ Description values [default setting] 25* Alarm mode Switching mode of software limit contact alarms A1 and A2 when activated (when the positioner is initialized). 0 to 3, [2], ESC 1) Explosion-protected version according to EN 60947- 0: A1 ≥ 2.2 mA A2 ≤ 1.0 mA 1: A1 ≤ 1.0 mA A2 ≤ 1.0 mA 2: A1 ≥ 2.2 mA A2 ≥ 2.2 mA 3: A1 ≤ 1.0 mA A2 ≥ 2.2 mA 2) Version without explosion protection 0: A1 R = 348 Ω Non-conducting 1: A1 Non-conducting Non-conducting 2: A1 R = 348 Ω R = 348 Ω 3: A1 Non-conducting R = 348 Ω When a positioner has not been initialized, the software limit con- tacts always register the signal as in the state of no response. If there is no mA signal at the terminals 11/12, the software limit contacts both switch to ≤ 1.0 mA (Ex) or non-conducting (without ex- plosion protection). Note: The fault alarm output always switches to ≤ 1.0 mA/non-con- ducting in case of a fault;...
  • Page 95 Code list Code Parameter – Readings/ Description values [default setting] 28* Alarm test Test of software limit contact alarms A1 and A2 as well as of fault alarm contact A3. Reading direction: If the test is activated, the contact is switched five times. Standard Turned RUN 1/1 RUN: software limit contact A1 to ≥2.2 mA [No] [No] RUN 1 1 RUN RUN 2/2 RUN: software limit contact A2 to ≥2.2 mA RUN 2 2 RUN RUN 3/3 RUN: fault alarm contact A3 to ≤1.0 mA RUN 3 3 RUN 29* Position transmitter x/ix Operating direction of the position transmitter: it indicates assign- ment between travel/angle position and output signal i based on [ää], äæ, ESC CLOSED position. The operating range (see Code 8) of the valve is represented by the 4 to 20 mA signal. Values exceeding or falling below the limits 2.4 to 21.6 mA can be represented. When the positioner has not been mounted (reference variable smaller than 3.6 mA), the signal is 0.9 mA and 3.8 mA the position- er has not been initialized. When YES is set in Code 32, the position transmitter issues the value as per Code 30 during initialization or...
  • Page 96 Code list Code Parameter – Readings/ Description values [default setting] 32* Error message in case of YES: Error message also in case of 'Function check' condensed 'Function check' con- state densed state 'Function check' condensed state does not cause an error [YES], No, ESC message to be issued Note: Regardless of the condensed state, the fault alarm output al- ways switches when the error codes 57, 58, 60, 62 and 64 to 70, 76 are issued.
  • Page 97 Code list Code Parameter – Readings/ Description values [default setting] 39 Set point deviation e info Read only –99.9 to 99.9 % Indicates the deviation from the target position (e = w – x). 40 Transit time Open info Read only [0] to 240 s Minimum opening time determined during initialization. 41 Transit time Closed info Read only [0] to 240 s Minimum closing time determined during initialization. Auto-w info Read only 0.0 to 100.0 % of the Indicates the applied automatic set point with corresponding 4 to span 20 mA signal.
  • Page 98 Code list Note:  The error codes listed in the following appear in the display corresponding to their status classification set over the condensed state (Maintenance required/Maintenance demanded: , Out of specification: blinking, Maintenance alarm: ). If “No mes- sage” is assigned to the error code as the status classification, the error is not in- cluded in the condensed state.
  • Page 99 Code list Error codes – Condensed state message active, when prompted, Err appears. Recommended action When fault alarms exist, they are displayed here. 52 Attachment • Invalid positioner attachment. • Nominal travel/angle (Code 5) could not be achieved during NOM initial- ization (no tolerance downwards permissible). • Mechanical or pneumatic fault, e.g. wrong lever selected or supply pressure too low to move to the required position. Status [Maintenance required] classification Recommended Check attachment and supply pressure. Re-initialize the positioner. action Under certain circumstances, it may be possible to check the maximum travel/ angle by entering the actual pin position and then performing a MAX initial- ization. After initialization has been completed, the Code 5 indicates the maximum achieved travel or angle. 53 Initialization time Initialization takes too long. The positioner returns to the previous operating exceeded mode.
  • Page 100 Code list Error codes – Condensed state message active, when prompted, Err appears. Recommended action When fault alarms exist, they are displayed here. 55 Transit time too Actuator transit times detected during initialization are so short that optimal short positioner tuning is impossible. (transit time <) Status [Maintenance required] classification Recommended Check the volume restriction setting as described in section 7.2. Re-initialize the action positioner. 56 Pin position Initialization canceled because selected NOM and SUB initialization modes re- quire the pin position to be entered. Status [Maintenance required] classification Recommended Enter pin position over Code 4 and nominal travel/angle over Code 5. Re-ini- action tialize the positioner. Operational error Error codes –...
  • Page 101 The positioner switches to emergency mode where the position cannot be accurately controlled anymore. However, the po- sitioner continues operation according to its set point so that the process re- mains in a safe state. Status classification [Maintenance demanded] Recommended Return positioner to SAMSON AG for repair. action EB 8384-3 EN...
  • Page 102 Additional indication at position (SAFE). the fault alarm contact! Status classification [Maintenance alarm] Recommended action Confirm error and return to automatic mode, or perform a reset and re-initialize the positioner. If this is not successful, return positioner to SAMSON AG for repair. Data memory No more data can be written to the memory, e.g. because written data deviate from read data. The valve moves to the fail-safe position. Additional indication at the fault alarm contact! Status classification Maintenance alarm (cannot be classified) Recommended action Return positioner to SAMSON AG for repair. Check calculation Hardware controller monitored by test calculation. Additional indication at the fault alarm contact! Status classification [Maintenance alarm] Recommended action Confirm error. If this is not possible, return positioner to SAMSON AG for repair. EB 8384-3 EN...
  • Page 103 Recommended action Confirm error, perform a reset and re-initialize the positioner. Calibration Error in data from production calibration. The positioner continues oper- ation with cold start values. Additional indication at the fault alarm contact! Status classification [Maintenance required] Recommended action Return positioner to SAMSON AG for repair. General parameters Error in parameters not critical to control operation. Status classification [Maintenance required] Recommended action Confirm error. Check and, if necessary, change the settings of the re- quire parameters. Internal device Internal device error error 1...
  • Page 104 Status classification [No message] Recommended action Merely information, confirm, if necessary. No further action required. Software loading When the positioner starts operation for the first time after the FF signal error has been applied, it carries out a self-test (tEStinG runs across the dis- play). If the positioner loads the wrong software, the valve moves to the fail- safe position. It is not possible to make the valve leave this fail-safe posi- tion again. Maintenance alarm (cannot be classified) Status classification Interrupt fieldbus signal and restart the positioner. Recommended action If not successful, return positioner to SAMSON AG for repair. Error in option parameters. Option parameters [Maintenance required] Status classification Recommended action Return positioner to SAMSON AG for repair. EB 8384-3 EN...
  • Page 105 Code list Diagnosis errors Error codes – Recommended Condensed state message active, when prompted, Err appears. action When fault alarms exist, they are displayed here. Diagnostic messages Messages generated by the extended diagnostics Status classification Maintenance required (cannot be classified) Diagnostic Error in parameters not critical to control operation. parameters Status classification Maintenance required (cannot be classified) Recommended action Confirm error. Check and, if necessary, perform a new reference test. Reference graphs Error occurred during plotting the reference graphs for drive signal y steady-state or drive signal y hysteresis. • Reference test canceled • Reference line for drive signal y steady-state or drive signal y hyster- esis was not adopted.

  • Page 106: Dimensions In Mm

    Dimensions in mm 15 Dimensions in mm Attachment according to IEC 60534-6 Pressure gauge or connecting plate External bracket position sensor Lever (see Fig. 31) Direct attachment M20 x 1.5 Output (38) Supply (9) Fig. 28: NAMUR and direct attachment EB 8384-3 EN...
  • Page 107 Dimensions in mm Attachment according to VDI/VDE 3847 to Type 3277 Lever (see Fig. 31) Attachment according to VDI/VDE 3847 to a NAMUR Fig. 29: Attachment according to VDI/VDE 3847 EB 8384-3 EN...
  • Page 108 Dimensions in mm Heavy-duty version Output Y Output Y Supply (9) Reversing Output Y Output Y amplifier (optional)* Ø 101 Light version Output A1 Supply (9) Reversing Output A2 amplifier (optional)* Connecting plate G ¼ or ¼ NPT * Reversing amplifier Type 3710 (see drawing of heavy-duty version for − dimensions) 1079-1118/1079-1119, no longer available − (see drawing of light version for dimensions) Fig. 30: Attachment to rotary actuators acc.

  • Page 109: Fixing Levels According To Vdi/Vde 3845 (September 2010)

    Dimensions in mm Lever 10...17 17 mm 25 mm 33 mm 25 mm 50 mm 66 mm 70 mm 100 mm 116 mm 100 mm 200 mm 216 mm Fig. 31: Lever 15.1 Fixing levels according to VDI/VDE 3845 (September 2010) Fixing level 2 (bracket surface) Fixing level 1 (actuator surface) Actuator Dimensions in mm Size Ød 5.5 for M5 5.5 for M5 5.5 for M5 ØD 5.5 for M5 5.5 for M5 6.5 for M6 * Flange type F05 according to DIN EN ISO 5211...

  • Page 110: Valve Characteristic Selection

    Valve characteristic selection 16 Valve characteristic selection The characteristics that can be selected in Code 20 are shown in the following in graph form. Note:  A characteristic can only be defined (user-defined characteristic) using a worksta- tion/operating software (e.g. TROVIS-VIEW). Linear (select characteristic: 0) Travel/ angle of rotation [%] Reference variable [%] Equal percentage (select characteristic: 1) Reverse equal percentage (select characteristic: Travel/ angle of rotation [%] Travel/ angle of rotation [%] Reference variable [%] Reference variable [%]...
  • Page 111 SAMSON butterfly valve linear (select SAMSON butterfly valve equal percentage characteristic: 3) (select characteristic: 4) Travel/ angle of rotation [%] Travel/ angle of rotation [%] Reference variable [%] Reference variable [%] VETEC rotary plug valve linear (select VETEC rotary plug valve equal percentage...

  • Page 112: Test Certificates

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  • Page 149: Index

    Index Index Configuration At the positioner ...... 79 With TROVIS-VIEW ......13 Accessories ........ 50–52 Connections Additional equipment Electric ........... 56 External position sensor ....12 Pneumatic ........55 Leakage sensor ....... 12 Controlled variable ....... 10 Limit contact ........11 Solenoid valve ........ 11 Default settings ........ 78 AIR TO OPEN/AIR TO CLOSE slide switch ..........
  • Page 150 Index Reversing amplifier ....... 38 Leakage sensor ........12 Rotary pushbutton ........ 61 Attachment ........ 48 Limit contact Select characteristic .... 92, 110–111 Electrical connection ......56 Serial interface ....... 13, 86 Setting ........ 83–84 Signal pressure Limit.......... 68 Maintenance ........ 86 Signal pressure gauges ......55 Malfunction ........ 81–82 Software update ........ 86 Manual mode ........
  • Page 152 SAMSON AG · MESS- UND REGELTECHNIK Weismüllerstraße 3 · 60314 Frankfurt am Main, Germany Phone: +49 69 4009-0 · Fax: +49 69 4009-1507 EB 8384-3 EN samson@samson.de · www.samson.de...

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