Samson 3785 series Mounting And Operating Instructions
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Samson 3785 series Mounting And Operating Instructions

Samson 3785 series Mounting And Operating Instructions

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PROFIBUS Positioner
Type 3785
PA device profile version 2.0
Fig. 1 · Type 3785 PROFIBUS Positioner
Mounting and
Operating Instructions
EB 8382-1 EN
Firmware version R 1.4x/K 1.6x
Edition July 2004

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  • Page 1 PROFIBUS Positioner Type 3785 PA device profile version 2.0 Fig. 1 · Type 3785 PROFIBUS Positioner Mounting and Operating Instructions EB 8382-1 EN Firmware version R 1.4x/K 1.6x Edition July 2004...

  • Page 2: Table Of Contents

    Contents Contents Page Design and principle of operation ....8 Optional accessories ......8 Communication.
  • Page 3 Proper shipping and storage are assumed. Note! Devices with a CE marking fulfil the requirements of the Directives 94/9/EC and 89/336/EEC. The declaration of conformity is available at http://www.samson.de and on request. EB 8382-1 EN...

  • Page 4: Tor", The Following Applies

    Firmware modifications Modifications of the firmware compared to the previous version Control R 1.23 R 1.31 Firmware adaptation for a new hardware version Hardware version device index .01 Control R 1.31 R 1.4 Actuator type When the actuator type is switched from "linear actuator" to "rotary actua- tor", the following applies: Initialization method .
  • Page 5 A bad set point status no longer causes the positioner to move the valve to fail-safe position in any case. Rather, the positioner's behavior is determined by the FSAVE_TYPE parameter. Using the serial interface, the positioner can be configured and operated with SAMSON's TROVIS-VIEW Configuration and Operator Interface software. EB 8382-1 EN...
  • Page 6 Technical data Positioner Travel Adjustable Direct attachment Type 3277 5 mm to 30 mm Acc. to IEC 60534-6 (NAMUR) 5 mm to 255 mm or 30° to 120° for rotary actuators Bus connection Fieldbus interface according to IEC 61158-2 Field unit according to FISCO (Fieldbus Intrinsically Safe Concept) Permissible operating voltage 9 to 32 V DC;...
  • Page 7 Data transmission acc. to PROFIBUS-PA, Profile Class B, version 2.0 acc. to DIN EN 50170 and DIN 19245, Part 4 (version 3.0 also available) Local interface SAMSON SSP interface for configuration and start-up Bus address Adjustable using software or microswitch, default upon delivery: 126 Accessories...

  • Page 8: Design And Principle Of Operation

    Design and principle of operation erate single pulses of changing widths). The Design and principle of opera- two valves cause the plug stem to move to a tion position corresponding to the reference vari- able. If there is no system deviation, both the The digital PROFIBUS-PA positioner is de- supply air valve and the exhaust air valve signed for attachment to pneumatic control...
  • Page 9 Design and principle of operation DIN EN 50170 and DIN 19245, Part 4. Customized configuration to adapt the Data is transmitted as bit-synchronous cur- positioner to other actuators can only be car- rent modulation at a transmission rate of ried out using communication. 31.25 kbit/s over twisted-pair cables ac- Configuration cording to IEC 61158-2.

  • Page 10: Attaching The Positioner

    2.1 Direct attachment to Type 3277 Actuator The positioner can be attached either directly to a SAMSON Type 3277 Actuator or ac- For selection of the required mounting parts, cording to NAMUR (IEC 60534-6) to control refer to Tables 1, 2 and 3 on page 13.
  • Page 11 Attaching the positioner Actuator stem extends Actuator stem retracts Internal signal pressure Signal pressure connection connection over piping Connection block Side view of connection block Vent with seal (new) with switch plate (old) Symbol "Actuator stem extends" Marking Symbol "Actuator stem retracts"...
  • Page 12 Attaching the positioner 7. Mount positioner so that the bore in the 240, 350 and 700 cm² actuators distance plate (15) is aligned with the 6. Check whether the tongue of the seal located in the bore of the actuator seal (17) is properly aligned at the side yoke.
  • Page 13 Attaching the positioner Actuator size Mounting kit Table 1 Required lever with associated clamp and distance plate cm² Order no. D1 (33 mm in length with clamp, 17 mm in height) 120 (G ¼) 1400-6790 120 (¼ NPT) 1400-6791 D1 (33 mm in length with clamp, 17 mm in height) 240 and 350 1400-6370 D2 (44 mm in length with clamp, 13 mm in height)

  • Page 14: Attachment According To Iec 60534-6

    (e.g. 3. Place housing with the plate (30) on ei- non-SAMSON actuators), make sure the ar- ther the right or left side of the valve rod row on the housing cover points towards the and screw the housing tight using control valve.
  • Page 15 Attaching the positioner Mounting position Attachment to NAMUR rib 24 25 21 20 Attachment to rods 18 Lever N1, N2 19 Pin 20 Plate 21 Clamp 22 Clamping plate 23 Screw 24 Pointer 25 Shaft 26 Lever of positioner 27a Transmission pin 27b Lock nut 28 Bracket 29 Studs...

  • Page 16: Presetting The Valve Travel

    Attaching the positioner 5. Measure distance between the center of the shaft (25) and the center of the pin (19). This value must later be entered when configuring the positioner. 2.2.2 Presetting the valve travel 1. Adjust shaft (25) in the adapter housing so that the black pointer (24) is aligned with the cast marking on the adapter housing.
  • Page 17 Attaching the positioner Table 4 Attachment IEC 60534-6 Control valve Travel [mm] With lever Order no. 7.5 to 60 1400-6787 N1 (125 mm) Valve with cast yoke NAMUR mounting kit 30 to 120 1400-6789 N2 (212 mm) Parts, see Fig. 4 20 to 25 1400-6436 20 to 25...

  • Page 18: Attachment To Rotary Actuators

    (see section 2.3.4). Non-SAMSON actuators If the positioner is attached to a SAMSON 1. Position complete intermediate piece (34, Type 3278 Rotary Actuator, the positioner's 42, 44 and 45) on the bracket (fixing...
  • Page 19 Attaching the positioner Attachment to SAMSON Type 3278 Actuator Attachment acc. to VDI/VDE 3845 Vent plug or filter check valve 33 Positioner 34 Intermediate piece 35 Lever with cam follower roll 36 Adapter 37 Transmission lever 38 Screws 39 Scale...

  • Page 20: Aligning And Mounting The Cam Disk

    Attaching the positioner In actuators with fail-safe position "Control 2.3.3 Aligning and mounting the valve open" (OPEN), pressurize the actuator cam disk with the max. signal pressure before aligning the cam disk. In rotary actuators with spring-return mecha- In springless actuators, connect the supply nism, the built-in actuator springs determine air.
  • Page 21 Control valve opens counterclockwise Control valve opens clockwise Fig. 6 · Aligning the cam disk Table 6 Rotary actuators (complete mounting parts, but without cam disk) SAMSON Type 3278 Actuator Attachment to Masoneilan actuators Attachment acc. to VDI/VDE 3845, 160 cm²...

  • Page 22: Reversing Amplifiers For Double-Acting Actuators

    Attaching the positioner 2.3.4 Reversing amplifiers for dou- Signal pressure connections : Connect output A to the signal pressure ble-acting actuators connection at the actuator that opens the For the use with double-acting actuators, the valve when the pressure increases. positioner must be fitted with a reversing am- : Connect output A to the signal pressure...
  • Page 23 Attaching the positioner From the positioner Output 38 Supply 9 Control signals Reversing amplifier to the actuator 1.1 Special screws 1.2 Gasket 1.3 Special nuts 1.4 Rubber seal 1.5 Plug 1.6 Filter 1.3 1.2 Fig. 7 · Mounting a reversing amplifier EB 8382-1 EN...

  • Page 24: Connections

    Connections Connections 3.1.1 Pressure gauges To monitor positioner operation, it is recom- 3.1 Pneumatic connections mended to connect pressure gauges for the supply air and signal pressure. The required The air connections are either ¼ NPT or G ¼ gauges are listed as accessories in Tables 3, tapped holes.

  • Page 25: Supply Air Pressure

    Connections 3.1.2 Supply air pressure 3.2 Electrical connections The required supply air pressure depends on For electrical installation, you are re- the bench range and the operating direction quired to observe the relevant (fail-safe action) of the actuator. The bench electrotechnical regulations and the range is indicated on the nameplate as a accident prevention regulations that...
  • Page 26 Connections Bus line Note on the selection of cables and wires The shielded PROFIBUS connecting cable To run several intrinsically safe circuits in one must be routed over the EMC-proof brass ca- multi-core cable, observe section 12 of ble gland (standard) of the positioner to the EN 60079-14;...

  • Page 27: Forced Venting

    Connections Refer to PROFIBUS-PA User and Installation 3.2.1 Forced venting Guideline (PROFIBUS User Organization document 2.091) for further information. For positioners with forced venting function, a voltage of 6 to 24 V DC must be applied to At the binary input, a passive floating con- the associated terminals.

  • Page 28: Limit Switches

    1400-7700). The positioner can be started up using the interface and 3.2.3 Establishing communication SAMSON's TROVIS-VIEW software. (bus address) It is no longer necessary to connect the de- vice to a PROFIBUS DP/PA segment. Only Communication between positioner, pro-...
  • Page 29 Connections Display and control component Controller/PLC/control system PROFIBUS-DP(E) RS 485 (Class 2 Master) (Class 1 Master) PROFIBUS-DP(E) RS 485 Termination Segment coupler PROFIBUS-PA IEC 61158-2 Termination 3785 3785 3785 3785 Fig. 10.1 · Connection of Type 3785 Positioners Controller/PLC/control system PROFIBUS-DP RS 485 Display and control component Class 1 Master)

  • Page 30: Operation

    Operation Operation 4.1 LED controls Two LEDs located inside the cover serve to Warning! monitor the positioner, indicating the Before putting the positioner into op- positioner's status during start-up, operation eration, carefully move the control and in the event of defects. valve to its end position by covering the hole (manually) on the cover plate The colors indicate the following:...

  • Page 31: Write Protection

    Operation 3. Set switch to desired position: 4.2 Write protection 1 ENABLED > function activated A microswitch marked "write protection" is 2 DISABLED > function deactivated located to the right of the seven bus address selector switches inside the hinged cover. 4.4 Default settings When it is activated (position ON), the positioner settings are write-protected so that...

  • Page 32: Adjusting Mechanical Zero

    Operation 4.4.1 Adjusting mechanical zero when the shut-off valves in the plant are closed or when the control valve Important! with the positioner has been removed Zero must be adjusted with the valve closed from the plant and is used on a test (for three-way valves with the actuator stem bench.
  • Page 33 Operation Set delay time to at least 30 s. Electric zero calibration If mechanical zero has shifted during the Enter tag identification. valve's operation, an electric zero calibration If necessary, configure the positioner can be carried out. To do so, press the further, e.g.

  • Page 34: Adjusting The Inductive Limit Switches

    Operation 4.5 Adjusting the inductive limit Adjusting the switching point The limit switches are marked GW1 and switches GW2 on the inside of the housing cover. Yel- The positioner version with inductive limit low tags and the associated adjustment switches has two adjustable metal tags that screws (Fig.

  • Page 35: Maintenance

    Maintenance Maintenance Servicing explosion-protected devices The positioner is maintenance free. Pneumatic connection 9/Supply contains a If a part of the positioner on which the explo- filter with a mesh size of 100 µm. Remove sion protection is based needs to be serviced, and clean the filter, if required.

  • Page 36: How To Implement A Class 1 Profibus Master

    7.1 Device database files (GSD) The device data are provided as a text file (SAMS3785.GSD). It is available from SAMSON AG under order no. 1400-7417 on a 3½" 1.44 MB floppy disk or on the Internet at http://www.samson.de or http: //www.profibus.com.
  • Page 37 How to implement a Class 1 PROFIBUS Master Output value (Output) Byte 0 Octet 1 Octet 2 Octet 3 Octet 4 Octet 5 Sign, Exponent, exponent fraction Fraction Fraction RCAS_IN, value Status (floating point, IEEE) Variant 3: Module = READBACK + POS_D, SP; 0x96, 0xA4 Input value (Input) Byte 0 Octet 1...
  • Page 38 How to implement a Class 1 PROFIBUS Master Output value (Output) Byte 0 Octet 1 Octet 2 Octet 3 Octet 4 Octet 5 Sign, Exponent, exponent fraction Fraction Fraction SP, value Status (floating point, IEEE) Variant 5: Module = READBACK + POS_D + CHECKBACK, SP; 0x99, 0xA4 Input value (Input) Byte 0 Octet 1...
  • Page 39 How to implement a Class 1 PROFIBUS Master Output value (Output) Byte 0 Octet 1 Octet 2 Octet 3 Octet 4 Octet 5 Sign, Exponent, exponent fraction Fraction Fraction RCAS_IN, value Status (floating point, IEEE) Variant 7: Module = READBACK + RCAS_OUT + POS_D + CHECKBACK, SP + RCAS_IN; 0x9E, 0xA9 Input value (Input) Byte 0 Octet 1...

  • Page 40: Parameter Description

    How to implement a Class 1 PROFIBUS Master 7.3 Parameter description SP – Set point with status: Reference variable w in "Auto" operating mode The reference variable w of the positioner is preset by SP in automatic mode (AUTO). SP consists of a floating point value (4 bytes) and the associated status (1 byte). Value and status must be transferred together (data consistency = 5 bytes).
  • Page 41 How to implement a Class 1 PROFIBUS Master Simulation mode, i.e. value are not derived from the CB_SIMULATE process CB_DISTURBANCE Error, refer to DIAGNOSIS parameter for cause Error in internal positioner control loop (to be con- firmed by Class 2 master), indicated by LED, reset au- CB_CONTR_ERR tomatically when control loop monitoring no longer detects any errors...

  • Page 42: Coding Of Measured Value Status

    How to implement a Class 1 PROFIBUS Master 7.4 Coding of measured value status Measured value status The following status codes are used by the Type 3785 Positioner: Value is valid Substatus Condition Decimal value Configuration error Error in device configuration, value cannot be determined Device failure Device error: memory, electronics...
  • Page 43 How to implement a Class 1 PROFIBUS Master Good (non-cascade) Value is valid Substatus Condition Value Everything OK, no other status available Maintenance required Transit time monitoring active, zero point error ac- tive or total valve travel exceeded Set point status Good (non-cascade) Substatus Condition...

  • Page 44: Operating Modes

    How to implement a Class 1 PROFIBUS Master 7.5 Operating modes Possible operating modes The following operating modes are defined in the AO (Analog Output) profile: Automatic (Auto) Manual (Man) Remote Cascade (RCas) Local Override (LO) Out of Service (OS) The Type 3785 Positioner supports the following operating modes: Up to firmware version K 1.20: OS, AUTO...
  • Page 45 End position function EB 8382-1 EN...
  • Page 46 How to implement a Class 1 PROFIBUS Master Start-up (warm start) The response of the positioner to a warm start is determined by the FSAFE_TYPE parameter (fail-safe action). If FSAFE_TYPE is set to "control to fail-safe value", the positioner switches to automatic oper- ating mode and adjusts to the value determined by the FSAFE_VALUE parameter.

  • Page 47: List Of Parameters

    The list of parameters following the overview is in alphabetical order and describes all positioner parameters that can be displayed or modified using PROFIBUS communication, e.g. on a PC. Manufacturer-specific parameters of the SAMSON Type 3785 PROFIBUS-PA Positioner are marked with (M). Parameter overview Device identification Tag identification .
  • Page 48 List of parameters Start-up Security locking ....SECURITY_LOCKING Cold start ..... . FACTORY_RESET Warm start .
  • Page 49 End pos. when reference variable is below limit value . SETP_CUTOFF_DEC End pos. when reference variable is above limit value . SETP_CUTOFF_INC Selection of characteristic ....CHARACT Type of characteristic .
  • Page 50 For rotary actuators, only attachment according to VDI/VDE 3845 (NAMUR) is possible. For details, refer to sections 2.1 and 2.2. States: 0 = Integral – attachment with SAMSON Type 3277 Linear Actuator 1 = NAMUR – attachment acc. to IEC 60534-6 (NAMUR) Default:...
  • Page 51 2 = Reverse equal percentage 3 = User-defined (will be supported in future firmware version) 4 = SAMSON butterfly valves: linear 5 = SAMSON butterfly valves: equal percentage 6 = VETEC rotary plug valves: linear 7 = VETEC rotary plug valves: equal percentage...
  • Page 52 List of parameters Indicates when the last maintenance was performed on the field Date of last maintenance device VALVE_MAINT_DATE Indicates dead band of the control characteristic between 0.1 and Dead band Xtot DEAD_BAND 10.0 % of the rated travel/nominal angle Default: 0.5 % Specifies reset criterion for active control loop monitoring.
  • Page 53 List of parameters Determines the assignment of reference variable to travel/angle Direction of action INCREASE_CLOSE (M) States: 0 = Increasing/increasing, valve opens when reference variable increases (for rotary plug valves, the actuator stem retracts) 1 = Increasing/decreasing, valve closes when reference variable increases (for rotary plug valves, the actuator stem extends) Default: If the reference variable exceeds the entered limit, the valve moves to-...
  • Page 54 List of parameters Functions as replacement value for set point (reference variable w or Fail-safe value, reference var. FSAFE_VALUE w_cas) when communication failure was detected Default: Firmware version, communication/control Firmware version SW_REVISION Hardware version, electronics/mechanics Hardware version HW_REVISION Indicates whether the optional forced venting function is installed Identification, forced venting IDENT_FORCED_VENTING (M) Read-only parameter, automatically set by the device...
  • Page 55 List of parameters An arrow on the positioner's cover plate indicates how to attach the Mounting position MOUNTING_POSITION (M) positioner to the actuator. (linear actuator) For direct attachment, the arrow must point towards the actuator. For NAMUR attachment, the arrow must point away from the actuator. States: 0 = Arrow points away from actuator 1 = Arrow points towards actuator...
  • Page 56 List of parameters The action determined by the FSAFE_TYPE parameter (fail-safe ac- Operating mode, current tion) is triggered by the following events: Operating mode, desired MODE_BLK / TARGET_MODE – Start-up of the positioner (warm start) (continued) – Elapsing of DP watchdog by interrupting the cyclic communica- tion with a Class 1 master (not applicable when communication is properly terminated) –...
  • Page 57 List of parameters Transit time Type of Rated travel/ KP_Y1 KP_Y2 actuator nom. angle Supply Exhaust Fail-safe action OPEN CLOSED – > 0.7 s > 0.7 s Closing > 0.7 s < 0.7 s Closing < 0.7 s > 0.7 s Rotary –...
  • Page 58 List of parameters Reset criterion for active control loop monitoring. Enter permissible de- Tolerance band TOLERANCE_BAND (M) viation for control loop monitoring. See also DELAY_TIME parameter. Range: 0.1 to 10.0 % Default: If the set point deviation e exceeds the tolerated overshoot, pulse adaptation re- Tolerated overshoot TOL_OVERSHOOT (M) duces the minimal pulses in operating direction that caused the overshooting.
  • Page 59 List of parameters For linear actuators with integrally attached positioner: determine Transmission code TRANSM_CODE (M) geometrical dimensions of the travel pick-off with integral attachment States: 1 = D1, lever length 64 mm 2 = D2, lever length 106 mm For rotary actuators: States: Max.
  • Page 60 List of parameters Specifies the valve design Valve type VALVE_TYPE States: 0 = Control valve with linear motion of the connecting element 1 = Control valve with rotary or part-turn motion of the element Default: Resets the field device (warm start) Warm start DEVICE_RESET_CMD States:...

  • Page 61: Messages And Diagnostics

    Messages and diagnostics Messages and diagnostics The Type 3785 PROFIBUS-PA Positioner provides the best opportunities for diagnostics dur- ing the initialization phase. The positioner automatically conducts detailed tests to check the mounting position and valve response as well as to evaluate them based on the entered or preset parameters.
  • Page 62 Messages and diagnostics Zero point error (end position) This message indicates any change that exceeds the value determined during initialization or zero adjustment by more than ±5 %. Possible sources of error: – Worn-out valve seat or plug – Foreign particles between seat and plug The message is automatically reset when zero adjustment has been competed successfully.

  • Page 63: Extended Diagnostic Messages

    Messages and diagnostics Further information available This message indicates that extended diagnostic messages have been generated. 9.2 Extended diagnostic messages Binary input active This message indicates that the condition for activating the binary input has been fulfilled. Invalid start values for min. pulses in range 1 This message indicates that the pulse search for the 0 to 20 % range of the rated travel/an- gle by adapting the pulse-pause ration has not been completed yet.

  • Page 64: Checkback Messages

    Messages and diagnostics 9.3 CHECKBACK messages Fail-safe position (mode = Out of Service) This message indicates that fail-safe position was triggered by the positioner. This can be caused by selecting Out of Service mode, by activating the optional forced venting function or by a communication failure.
  • Page 65 Messages and diagnostics Control loop error This message indicates that the positioner fails to control within the adjusted tolerance band for error monitoring within the specified delay time. Possible sources of error: – Oscillation caused by the actuator working too fast (small travel volume) Remedy: reduce supply pressure (see section 3.1.2) or install signal pressure restriction.

  • Page 66: Messages During Initialization

    Messages and diagnostics 9.4 Messages during initialization Not defined This message indicates that the positioner has not yet been initialized or that a cold start was performed. The message is reset by confirmation. Canceled This message indicates that the initialization routine was aborted by the user. The message is reset by confirmation.
  • Page 67 Messages and diagnostics Incorrect selection of rated travel or transmission This message indicates that the maximum travel determined, which is issued in percent of the rated travel/angle, is smaller than the selected rated travel/angle. Warning! Initialization is not canceled. Possible sources of error: –...
  • Page 68 Messages and diagnostics Zero point error This message indicates that the zero point determined is outside the permissible tolerance of max. ±5 % around the absolute internal value for measurement. Initialization is canceled. To remove the error, adjust mechanical zero (see section 4.4.1). After that, make sure that the yellow position pin of the travel pick-off is roughly aligned with the white line marking zero on the cover plate.

  • Page 69: Dimensional Drawing

    Dimensional drawing G ¼ or ¼ NPT pneumatic connections M20 x1.5 (old PG 13.5) Direct attachment Output (38) 30.5 Supply (9) Reversing amplifier (optional) Attachment using intermediate piece for rotary actuators Fulcrum of actuator shaft IEC 60534-6 attachm.with adapter housing Output 1 (A1) 28.5 Output 2 (A2)

  • Page 70: Certificates

    EB 8382-1 EN...
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  • Page 84 SAMSON AG · MESS- UND REGELTECHNIK Weismüllerstraße 3 · 60314 Frankfurt am Main · Germany Phone: +49 69 4009-0 · Fax: +49 69 4009-1507 EB 8382-1 EN Internet: http://www.samson.de...

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