Samson TROVIS 3731-3 Mounting And Operating Instructions
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Samson TROVIS 3731-3 Mounting And Operating Instructions

Electropneumatic ex d positioner with hart communication
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EB 8387-3 EN
Translation of original instructions
Type 3731-3 Electropneumatic Ex d Positioner
with HART
communication
®
Firmware version 1.61
Edition May 2017
EB + CD

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Summary of Contents for Samson TROVIS 3731-3

  • Page 1 EB 8387-3 EN Translation of original instructions Type 3731-3 Electropneumatic Ex d Positioner with HART communication ® Firmware version 1.61 Edition May 2017 EB + CD...
  • Page 2 Î For the safe and proper use of these instructions, read them carefully and keep them for later reference. Î If you have any questions about these instructions, contact SAMSON‘s After-sales Service Department (aftersalesservice@samson.de). The mounting and operating instructions for the devices are included in the scope of delivery.

  • Page 3: Table Of Contents

    Contents Safety instructions and measures ..............6 Notes on possible severe personal injury ............8 Notes on possible personal injury ..............9 Notes on possible property damage ..............9 Markings on the device ................11 Nameplate ....................11 Article code ....................12 Firmware versions ..................14 Design and principle of operation ..............15 Additional equipment ...................17 Communication ...................18 3.2.1...
  • Page 4 Contents 5.11 Electrical connections ...................49 5.11.1 Connecting the electrical power ..............51 5.11.2 Establishing communication ................51 Operating controls and readings ..............54 Rotary pushbutton ..................54 Serial interface ....................54 Readings .....................55 HART communication .................57 ® 6.4.1 Dynamic HART variables ................57 ® Operating the positioner ................59 Adapting the display direction ..............59 Limiting the signal pressure ................60 Checking the operating range of the positioner ..........61...
  • Page 5 Contents 11.3 Disposal ......................87 Appendix ....................87 12.1 After-sales service ..................87 12.2 Code list ......................88 12.3 Error codes ....................98 12.4 Selecting the characteristic ................105 Note The functions of the EXPERTplus Valve Diagnostics are described in the Operating Instructions u EB 8389. EB 8389 is included on the enclosed CD-ROM and is available on our website.

  • Page 6: Safety Instructions And Measures

    In case operators intend to use the positioner in other applica- tions or conditions than specified, contact SAMSON. SAMSON does not assume any liability for damage resulting from the failure to use the de- vice for its intended purpose or for damage caused by external forces or any other external factors.
  • Page 7 Î Check with the plant operator for details on further protective equipment. Revisions and other modifications Revisions, conversions or other modifications of the product are not authorized by SAMSON. They are performed at the user's own risk and may lead to safety hazards, for example. Fur- thermore, the product may no longer meet the requirements for its intended use.

  • Page 8: Notes On Possible Severe Personal Injury

    Safety instructions and measures Servicing explosion-protected devices If a part of the device on which the explosion protection is based needs to be serviced, the device must not be put back into operation until a qualified inspector has assessed it accord- ing to explosion protection requirements, has issued an inspection certificate or given the de- vice a mark of conformity. Inspection by a qualified inspector is not required if the manufac- turer performs a routine test on the device before putting it back into operation. Document the passing of the routine test by attaching a mark of conformity to the device.

  • Page 9: Notes On Possible Personal Injury

    Safety instructions and measures 1.2 Notes on possible personal injury WARNING Risk of personal injury due to moving parts on the valve. During initialization of the positioner and during operation, the actuator stem moves through its entire travel range. Injury to hands or fingers is possible if they are inserted into the valve. Î During initialization, do not insert hands or fingers into the valve yoke and do not touch any moving valve parts.
  • Page 10 Safety instructions and measures An incorrect electric signal will damage the positioner. A current source must be used to provide the electrical power for the positioner. Î Only use a current source and never a voltage source. Incorrect assignment of the terminals will damage the positioner and will lead to mal- function.

  • Page 11: Markings On The Device

    Input signal Shutdown limit Firmware Temperature limits in the test certificate Model List of options Var.-ID Firmware version Serial no. Model no. Configuration ID Serial number SAMSON AG D-60314 Frankfurt Made in Germany Note The nameplate layout may vary depending on the certification. EB 8387-3 EN...

  • Page 12: Article Code

    Safety instructions and measures 2.2 Article code Positioner Type 3731- 3 x x x x x x x 0 0 x 1 x 0 0 0 With LCD, autotune, HART communication ® Explosion protection ATEX II 2G Ex db IIC T6 Gb, II 2G Ex db eb IIC T6 Gb II 2G Ex db [ia Ga] IIC T6 Gb II 2G Ex ia IIC T6 Ga II 2D Ex tb IIIC T80°C DB IP6...
  • Page 13 Safety instructions and measures Positioner Type 3731- 3 x x x x x x x 0 0 x 1 x 0 0 0 Explosion protection certificate As specified in Table 11 on page 26 NEPSI Ex d IIC T6~T4; Ex de IIC T6~T4 (on request) IECEx Ex d IIC T6, T5, T4 Gb; Ex d e IIC T6, T5, T4 Gb; Ex tb IIIC T80°C Db IP66 EAC Ex On request Special applications Without Version compatible with paint (IP 41/NEMA 1)

  • Page 14: Firmware Versions

    Safety instructions and measures 2.3 Firmware versions Firmware revisions 1.41 1.42 After performing a cold start, the allocation of the fail-safe position AIR TO OPEN (AtO)/ AIR TO CLOSE (AtC) is not reset to the default setting. The setting is kept. 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).

  • Page 15: Design And Principle Of Operation

    The electropneumatic Ex d positioner is accessories: mounted on pneumatic control valves and is − Direct attachment to SAMSON used to assign the valve position (controlled Type 3277-5 Actuator: variable x) to the control signal (set point w). Î See section 5.3 The positioner compares the electric control −...
  • Page 16 Design and principle of operation Serial Interface Ex d enclosure Control valve Analog position transmitter (optional) Travel sensor Display PD controller Actuation of forced venting (optional) A/D converter D/A converter Microcontroller Serial interface (SSP) i/p converter HART connection ® Air capacity booster Rotary pushbutton Pressure regulator Binary output (optional) Flow regulator...

  • Page 17: Additional Equipment

    Design and principle of operation 3.1 Additional equipment − Transmit switching state [default] The switching state of the binary input is Forced venting logged. The i/p converter is de-energized when no − Set on-site operation write protection operating voltage is applied to the corre- While the binary input is active, no set- sponding terminals. The positioner can no tings can be changed at the positioner.

  • Page 18: Communication

    The TROVIS-VIEW software enables the user to easily configure the positioner as well as view process parameters online. Note TROVIS-VIEW can be downloaded free of charge from our website at u www.samson. de > SERVICE & SUPPORT > Downloads > TROVIS-VIEW . EB 8387-3 EN...

  • Page 19: Accessories

    Design and principle of operation 3.3 Accessories Table 1: Direct attachment to Type 3277-5 (section 5.3) Mounting parts Order no. Standard version for actuators 120 cm² or smaller 1400-7452 Version compatible with paint for actuators 120 cm² or smaller 1402-0940 Accessories for actuator Order no. Old switchover plate for Type 3277-5xxxxxx.00 Actuator (old) 1400-6819 New switchover plate for Type 3277-5xxxxxx.01 Actuator (new) 1400-6822 New connecting plate for Type 3277-5xxxxxx.01 Actuator (new) G ...
  • Page 20 Design and principle of operation G ¼/G  1400-6446 Actuator (350 cm²), steel ¼ NPT/  NPT 1402-0913 G ¼/G  1400-6447 Actuator (350 cm²), stainless steel ¼ NPT/  NPT 1402-0914 G ¼/G  1402-0972 Actuator (355 cm²), steel ¼ NPT/  NPT 1402-0979 G ¼/G  1402-0973 Actuator (355 cm²), stainless steel ¼ NPT/  NPT 1402-0980 G ¼/G  1400-6448 Actuator (700 cm²), steel ¼ NPT/  NPT 1402-0915 G ¼/G  1400-6449 Actuator (700 cm²), stainless steel ¼ NPT/  NPT 1402-0916 G ¼/G ...
  • Page 21 Signal pressure restrictions (screw restriction (item no. 0390-1424) and brass restriction (item 1400-6964 no. 0390-1423)) Serial interface adapter (SAMSON SSP interface to RS-232 port on a computer) 1400-7700 Isolated USB interface adapter (SAMSON SSP interface to USB port on a computer) including 1400-9740 TROVIS-VIEW CD-ROM Table 6: Accessories for electrical connection Mounting parts Order no.

  • Page 22: Travel Tables

    Travel [mm] 5.0 to 25.0 120/175/240/350 7.0 to 35.0 355/700/750 10.0 to 50.0 Table 8: Attachment according to IEC 60534-6 (see section 5.5) SAMSON valves with Type 3271 Adjustment range at positioner Actuator Other control valves Actuator size Rated travel Min. travel Max. travel...

  • Page 23: Technical Data

    Design and principle of operation 3.5 Technical data Table 10: Type 3731-3 Positioner Type 3731-3 (technical data in test certificates additionally apply to explosion-protected devices) Rated travel Adjustable Direct attachment to Type 3277 Actuator: 3.6 to 30 mm Attachment according to IEC 60534-6-1: 3.6 to 300 mm Rotary actuators: 24 to 100° opening angle Travel range Adjustable Adjustable within the initialized travel/angle of rotation; travel can be restricted to 1/5 at the maximum...
  • Page 24 Use is possible on observing the requirements of IEC 61511 and the required hardware fault tolerance in safety-instrumented systems up to SIL 2 (single de- vice/HFT = 0) and SIL 3 (redundant configuration/HFT = 1). · Compliance Explosion protection Refer to Table 11 Communication Local communication SAMSON SSP interface and serial interface adapter Software requirements (SSP) TROVIS-VIEW with database module 3731-3 HART communication HART field communication protocol ® ® Impedance in HART frequency range: receiving approx. 455 Ω, sending ®...
  • Page 25 Design and principle of operation Operating voltage Switching capacity: 40 V DC/28 V AC/0.3 A Only for connection to Static destruction limit: NAMUR switching amplifier 45 V DC/32 V AC/0.4 A according to EN 60947-5-6 Optional binary input Galvanically isolated, optionally for detection of an externally applied voltage or for operation of an external floating contact · Switching behavior configured as required, default setting (see below) Voltage input function Polarity insensitive, 0 to 24 V DC voltage to be applied, input resistance 6.5 kΩ...
  • Page 26 Design and principle of operation Table 11: Summary of explosion protection approvals Type Certification Type of protection/comments Number PTB 11 ATEX 1014 X II 2G Ex db IIC T6 Gb, II 2G Ex db eb IIC T6 Gb Date 2019-04-08 II 2G Ex db [ia Ga] IIC T6 Gb EC type examina- II 2G Ex ia IIC T6 Ga tion certificate...
  • Page 27 Design and principle of operation Type Certification Type of protection/comments On request Number TC17747 Date 2018-09-12 Ex d IIC T6 Valid until 2021-09-11 EB 8387-3 EN...

  • Page 28: Dimensions In Mm

    Design and principle of operation 3.6 Dimensions in mm Output Supply ¼ NPT 2 x Female thread ½ NPT or M20x1.5 Attachment according to IEC 60534-6 (NAMUR) or connecting plate Pressure gauge bracket (only for G ¼) ¼ NPT or G ¼ EB 8387-3 EN...

  • Page 29: Fixing Levels According To Vdi/Vde 3845 (September 2010)

    Design and principle of operation Attachment to rotary actuators according to VDI/VDE 3845 Fixing level 1, AA1 to AA4 size, see section 3.7 Output Y Output Y Supply (9) Output Y Type 3710 Output Y Reversing Amplifier Ø101 3.7 Fixing levels according to VDI/VDE 3845 (September 2010) Fixing level 2 (bracket surface) Fixing level 1 (actuator surface) Actuator Size...
  • Page 30 EB 8387-3 EN...

  • Page 31: Measures For Preparation

    − Observe storage instructions. note. − Avoid long storage times. 2. Check the shipment for transportation − Contact SAMSON in case of different stor- damage. Report any transportation dam- age conditions or long storage periods. age. Storage instructions 4.1 Unpacking...

  • Page 32: Mounting And Start-Up

    Mounting and start-up 5 Mounting and start-up 5.1 Mounting position NOTICE NOTICE Risk of malfunction due to incorrect sequence Risk of damage to the positioner due to in- of mounting, installation and start-up. correct mounting position. Observe the prescribed sequence. −...
  • Page 33 Mounting and start-up Vent opening Fig. 2: Vent opening (back of the positioner) Fig. 3: Permissible mounting positions Fig. 4: M lever with pin position 35 EB 8387-3 EN...

  • Page 34: Type 3277-5 Actuator

    Mounting and start-up 5.3 Type 3277-5 Actuator on the positioner, making sure the two seals (6.1) are seated properly. Î Required mounting parts and accesso- 4. Remove screw plug (4) on the back of ries: Table 1 on page 19. the positioner and seal the signal pres- Actuator (120 cm²) sure output (38) at the positioner (or at the pressure gauge bracket (7) or con-...
  • Page 35 Mounting and start-up Lever Switchover plate (9) Symbols 1.1 Nut Actuator stem 1.2 Disk spring extends Follower pin Follower clamp Screw plug Left attachment Right attachment Stopper Connecting plate for G ¼ Actuator stem 6.1 Seals retracts Pressure gauge bracket Press. gauge mounting kit Switchover plate Signal pressure input for left...

  • Page 36: Type 3277 Actuator

    Mounting and start-up fastening screws. Check whether the fol- 3. Actuators (355, 700 and 750 cm²): lower pin (2) rests on top of the follower Remove the follower pin (2) from the pin clamp (3). The lever (1) must rest on the position 35 on M lever (1), reposition it follower clamp with spring force.
  • Page 37 Mounting and start-up Lever 12.1 Screw 12.2 Stopper or connection for Disk spring 10 14 external piping Follower pin Switch plate Follower clamp Gasket 11.1 Cover plate (G ¼) Molded seal Cover Gasket 11.1 Vent plug Bias spring (only with direct Connection block attachment) Cut-out of cover plate View C...

  • Page 38: Attachment According To Iec 60534-6 (Namur)

    Mounting and start-up 7. Actuators (175 cm²): unscrew the filter (3) on top and use the screws (14.1) for from the signal pressure input and first fastening. screw the screw restriction (accessories 2800 cm² and 1400 cm² actuators (120 mm travel): order no. 1400-6964/item no. 0390- 1424) into the signal pressure input be- – For a travel of 60 mm or smaller, fore screwing the filter back into the in- screw the longer follower plate (3.1) put.
  • Page 39 Mounting and start-up Attachment to Attachment to rod-type yoke: NAMUR rib rods with 20 to 35 mm diameter Lever Disk spring Follower pin Follower plate Additional bracket for Follower plate 2800 cm² actuators Connecting plate (only with travel ≥60 mm for G ¼) Seals XL and L lever Pressure gauge bracket 14.1 Pressure gauge mounting kit Stem connector...

  • Page 40: Attachment To Type 3510 Micro-Flow Valve

    Mounting and start-up tor size and valve travel listed in the trav- 3. Screw the two pins (9.2) to the bracket el table on page 22. (9.1) of the stem connector (9), place the M lever with pin position 25 or 50: follower plate (3) on top and use the –...
  • Page 41 Mounting and start-up Lever 11.1 Disk spring Follower pin Follower plate Connecting plate Seals 12.1 Pressure gauge bracket Pressure gauge mounting kit Stem connector Bracket Screws Bracket 10.1 Screw Hexagon bar 10.1 11.1 Screws 12.1 Screws Insert screw restriction into signal pressure output (38).

  • Page 42: Attachment To Rotary Actuators

    (11) underneath, if neces- sary. 0390-1424) into the signal pressure out- put of the positioner (or the output of the 2. For SAMSON Type 3278 and VETEC pressure gauge bracket or connecting S160 Rotary Actuators, screw the adapt- plate).
  • Page 43 Actuator shaft or adapter Connecting plate (only for G ¼) 6.1 Seals 10.1 10.1 SAMSON Type 3278, Attachment according to VDI/VDE 3845 VETEC S160, VETEC R (Sept. 2010) Fixing level 1, AA1 to AA4 size, see section 3.7 Fig. 9: Attachment to rotary actuators EB 8387-3 EN...

  • Page 44: Reversing Amplifier For Double-Acting Actuators

    Mounting and start-up 5.8 Reversing amplifier for Actuator turning double-acting actuators counterclockwise For the use with double-acting actuators, the positioner must be fitted with a reversing am- plifier. We recommend using the Type 3710 Revers- ing Amplifier (see Mounting and Operating Instructions u EB 8392). If a different reversing amplifier (item no. 1079-1118 or 1079-1119) is used, follow the mounting instructions described in sec- Actuator turning tion 5.8.1.
  • Page 45 Mounting and start-up From the positioner Output 38 Supply 9 Control signals to the actuator Reversing amplifiers Special screws Gasket Special nuts Rubber seal Stopper Filter Fig. 11: Mounting a reversing amplifier (1079-1118 or 1079-1119) EB 8387-3 EN...

  • Page 46: Reversing Amplifier (1079-1118 Or 1079-1119)

    Mounting and start-up 5.8.1 Reversing amplifier Pressure gauge attachment (1079-1118 or 1079- The mounting sequence shown in Fig. 11 re- mains unchanged. Screw a pressure gauge 1119) bracket onto the connections A and Z. Î Do not unscrew the sealing plug (1.5) out Pressure gauge G ¼ 1400-7106 of the reversing amplifier.

  • Page 47: Pneumatic Connections

    Mounting and start-up 5.9 Pneumatic connections Read the maintenance instructions for up- stream pressure reducing stations. Blow through all air pipes and hoses thor- DANGER oughly before connecting them. Risk of fatal injury due to the formation of an explosive atmosphere. 5.10 Connecting the supply air Operators of the equipment must make sure that the operating medium cannot create po-...

  • Page 48: Signal Pressure Connection

    Mounting and start-up 5.10.1 Signal pressure connec- 5.10.3 Supply pressure tion The maximum input pressure (supply pres- sure) is: The signal pressure connection depends on how the positioner is mounted onto the actu- − Max. 7 bar for Types 3731-321/-327 ator: − Max. 6 bar for Type 3731-323 Type 3277 Actuator The required supply air pressure depends on the bench range and the actuator's direction Î...

  • Page 49: Signal Pressure (Output)

    Mounting and start-up If there are no specifications, calculate as Î For installation according to the type of follows: protection Ex db, seal cable entries left unused with plugs certified for this pur- Î Required supply pressure = Upper bench pose. range value + 1 bar Install the connecting cable properly so that 5.10.4 Signal pressure (output) it is protected against mechanical damage.
  • Page 50 Mounting and start-up Only the terminal compartment is to be The position transmitter is operated on a opened within the hazardous area to con- two-wire circuit. The usual supply voltage is nect it to a certified intrinsically safe circuit. 24 V DC. Taking the resistance of the supply leads into account, the voltage at the posi- Î...

  • Page 51: Connecting The Electrical Power

    Mounting and start-up 5.11.1 Connecting the electrical 5.11.2 Establishing communica- power tion 1. Unscrew the cover. Communication between computer and posi- tioner using an FSK modem or handheld 2. Guide the wires through the side cable communicator is based on the HART proto- ®...
  • Page 52 Mounting and start-up Note Communication errors may occur when the process controller/control station output is Controller/control station not HART -compatible. ® For adaptation, the Z box (order no. 1170- 2374) can be installed between output and Fig. 13: Adapting the output signal communication interface.
  • Page 53 Mounting and start-up Signal: (polarity insensitive) 4...20 mA HART ® Options: Two-wire transmitter supply unit for Binary output the position transmitter PLC DC/AC A B C A B C 11...35 V DC Forced venting Binary input Voltage input (polarity insensitive) A B C A B C N/ _ 0...24 V DC 0...40 V DC...

  • Page 54: Operating Controls And Readings

    : select codes and values The positioner must be supplied with at least Press : confirm setting 4 mA. The local SAMSON SSP interface of the po- 6.2 Serial interface sitioner needs to be connected over an The serial interface connection is located un- adapter (see Table 5 on page 21) to the...

  • Page 55: Readings

    Operating controls and readings 6.3 Readings − Status messages : Maintenance alarm Icons assigned to certain codes, parameters : Maintenance demanded/Mainte- and functions are indicated on the display nance required (see Fig. 17). blinks: Out of specification Operating modes: These icons indicate that an error has oc- −...
  • Page 56 Operating controls and readings Closed-loop operation Manual mode Malfunction/ Code fault Bar graph for set point deviation or lever position Unit Limit contact Limit contact Alarm 1 Alarm 2 Configuration enabled Fail-safe position active Condensed state: maintenance required/ maintenance demanded Readings and their meaning: AUtO Automatic Increasing/increasing...

  • Page 57: Hart ® Communication

    Operating controls and readings 6.4 HART communication 6.4.1 Dynamic HART ® ® variables The positioner must be operated with at least 3.8 mA. The HART specification defines four dynam- ® A DTM file (Device Type Manager) conform- ic variables consisting of a value and an en- ing to the Specification 1.2 is available for gineering unit. These variables can be as- communication.
  • Page 58 Operating controls and readings Table 12: Dynamic HART variables assignment ® Variable Meaning Unit Set point Direction of action set point Set point after transit time specification Valve position Set point deviation e Absolute total valve travel – Binary input status 0 = Not active 1 = Active –...

  • Page 59: Operating The Positioner

    Operating the positioner 7 Operating the positioner NOTICE Risk of malfunction due to incorrect sequence of mounting, installation and start-up. Keep the following sequence. 1. Remove the protective caps from the pneumatic connections. 2. Mount the positioner on the valve. 3.

  • Page 60: Limiting The Signal Pressure

    Operating the positioner 7.2 Limiting the signal pressure If the maximum actuator force may cause damage to the valve, the signal pressure must be limited. Î Do not activate pressure limitation for double-acting actuators (AIR TO OPEN (AtO) fail- safe position). Default setting is 'No'. Enable configuration at the positioner before limiting the signal pressure.

  • Page 61: Checking The Operating Range Of The Positioner

    Operating the positioner 7.3 Checking the operating range of the positioner To check the mechanical attachment, the valve should be moved through the operating range of the positioner in the manual mode (MAN) with the manual set point w. Select manual mode (MAN): 1.

  • Page 62: Determining The Fail-Safe Position

    Operating the positioner WARNING Risk of personal injury due to moving parts on the valve. Injury to hands or fingers is possi- ble if they are inserted into the valve. − While the process is running, do not insert hands or fingers into the valve yoke and do not touch any moving valve parts.

  • Page 63: Initializing The Positioner

    Operating the positioner For checking purposes: after initialization is completed, the positioner display must read 0 % when the valve is closed and 100 % when the valve is open. If this is not the case, adapt the closing direction and re-initialize the positioner. 7.5 Initializing the positioner WARNING Risk of injury by exposed moving parts on the positioner, actuator or valve. Do not touch or block exposed moving parts. NOTICE The process is disturbed by the movement of the actuator or valve.
  • Page 64 Operating the positioner − Substitute calibration (SUB) This mode allows a positioner to be replaced while the plant is running, with the least amount of disruption to the plant (see section 7.5.4). Note An initialization procedure in progress can be canceled by pressing the rotary pushbutton. StOP is displayed for three seconds and the positioner changes to the fail-safe position (SAFE).

  • Page 65: Initialization Based On Maximum Range (Max)

    Operating the positioner 7.5.1 Initialization based on maximum range (MAX) The positioner determines travel/angle of rotation of the closing member from the CLOSED position to the opposite travel stop and adopts this travel/angle of rotation as the operating range from 0 to 100 %. Enable configuration: If no settings are entered within 120 seconds, the enabled configuration function becomes in- valid. 1. Turn until Code 3 appears (reading: No). Enable configuration , Code 3 blinks. 2. Press Default: No 3. Turn until YES appears. 4. Press to confirm (reading: Select the initialization mode: 1.

  • Page 66: Initialization Based On Nominal Range (Nom)

    Operating the positioner Start initialization: 1. Turn until Code 0 appears. 2. Press , Code 0 blinks. Initialization until Init appears. Press 3. Turn . The fail-safe position setting AtO or AtC is dis- Fail-safe position played. reading 4. Keep pressed down for six seconds. Ini- tialization starts after the progress indica- tion has stopped.
  • Page 67 Operating the positioner Note The maximum possible travel must always be greater than the nominal travel entered. If this is not the case, initialization is automatically canceled (error message Code 52) because the nominal travel could not be achieved. Enable configuration: If no settings are entered within 120 seconds, the enabled configuration function becomes in- valid.
  • Page 68 Operating the positioner Select the initialization mode: 1. Turn until Code 6 appears. 2. Press , Code 6 blinks. Initialization mode until NOM appears. 3. Turn Default: MAX 4. Press to confirm the NOM initialization mode. Start initialization: 1. Turn until Code 0 appears. , Code 0 blinks. 2. Press Initialization 3.

  • Page 69: Initialization Based On A Manually Selected Range (Man)

    Operating the positioner 7.5.3 Initialization based on a manually selected range (MAN) Before starting initialization, move the control valve manually to the OPEN position. Turn the rotary pushbutton clockwise in small steps. The valve must be moved with a monotonically in- creasing signal pressure. The positioner calculates the differential travel/angle from the OPEN and CLOSED positions and adopts it as the operating range with limits of travel/an- gle range start (Code 8) and travel/angle range end (Code 9).
  • Page 70 Operating the positioner Enter the pin position: 1. Turn until Code 4 appears. 2. Press , Code 4 blinks. Pin position 3. Turn to select pin position on lever (see Default: No relevant section on attachment). 4. Press to confirm. Select the initialization mode: 1. Turn until Code 6 appears.

  • Page 71: Substitute Calibration (Sub)

    Operating the positioner 7.5.4 Substitute calibration (SUB) A complete initialization procedure takes several minutes and requires the valve to move through its entire travel range several times. In the SUB initialization mode, the control pa- rameters are estimated and not determined by an initialization procedure. As a result, a high level of accuracy cannot be expected.
  • Page 72 Operating the positioner Enter the pin position and nominal range: 1. Turn until Code 4 appears. 2. Press , Code 4 blinks. Pin position 3. Turn to select pin position on lever (see Default: No relevant section on attachment). 4. Press to confirm. 5. Turn until Code 5 appears.
  • Page 73 Operating the positioner Change pressure limit and control parameters: Do not change the pressure limit (Code 16). Only change the control parameters K (Code 17) and T (Code 18) if the settings of the replaced positioner are known. 1. Turn until Code 16/17/18 appears. Pressure limit 2. Press , Code 16/17/18 blinks. Default: No 3.
  • Page 74 Operating the positioner Start initialization: 1. Turn until Code 0 appears. 2. Press , Code 0 blinks. Initialization 3. Turn until Init appears. Press . The fail-safe position setting AtO or AtC is dis- played. Fail-safe position reading 4. Keep pressed down for six seconds. Ini- tialization starts after the progress indica- Progress until tion has stopped.
  • Page 75 Operating the positioner Cancel the blocking position and change to automatic mode (AUTO): For the positioner to follow its set point again, the blocking position must be canceled and the positioner must be set to automatic mode as follows: 1. Turn until Code 1 appears.

  • Page 76: Zero Calibration

    Operating the positioner 7.6 Zero calibration In case of inconsistencies in the closing position of the valve, e.g. with soft-seated plugs, it might be necessary to recalibrate zero. WARNING Risk of injury by exposed moving parts on the positioner, actuator or valve. Do not touch or block exposed moving parts.

  • Page 77: Reset To Default Settings

    Operating the positioner Perform zero calibration: 1. Turn until Code 6 appears. 2. Press , Code 6 blinks. Initialization mode until ZP appears. 3. Turn Default: MAX 4. Press to confirm. 5. Turn until Code 0 appears. , reading: MAN, Code 0 blinks. 6. Press until Init appears. Press 7.
  • Page 78 Operating the positioner Reset start-up parameters: 1. Turn until Code 36 appears (reading: ••–••–). Reset 2. Press , Code 36 blinks. Default: No until Std appears. 3. Turn 4. Press to confirm. All start-up parameters as well as the diag- nosis are reset to their default values. Note Code 36 - diAG allows just the diagnosis data (EXPERTplus) to be reset EB 8389).

  • Page 79: Operation

    Operation 8 Operation WARNING Risk of injury by exposed moving parts on the positioner, actuator or valve. Do not touch or block exposed moving parts during operation. 8.1 Enabling and selecting parameters All codes and their meaning and default settings are listed in the code list in section 12.2 on page 88 onwards. Codes which are marked with an asterisk must be enabled with Code 3 before the associat- ed parameters can be configured as described below. 1. Turn until Code 3 appears (reading: Code 3: No).

  • Page 80: Operating Modes

    Operation Cancel the setting: To cancel a value before it is confirmed (by pressing ) proceed as follows: until ESC appears. 1. Turn Canceling the reading 2. Press to confirm. The entered value is not adopted. 8.2 Operating modes 8.2.1 Automatic (AUTO) and manual (MAN) modes After initialization has been completed successfully, the positioner is in Automatic mode automatic mode (AUTO, reading: ...
  • Page 81 Operation Adjust the manual set point 1. Turn until Code 1 appears. 2. Press , Code 1 blinks. 3. Turn until sufficient pressure has been built up in the positioner and the control valve moves to the required position. Note The positioner automatically returns to Code 0 if no settings are made within 120 seconds, but remains in the manual mode.

  • Page 82: Fail-Safe Position (Safe)

    Operation 8.2.2 Fail-safe position (SAFE) If you want to move the valve to the fail-safe position determined during start-up (see sec- tion 7.4), proceed as follows: 1. Turn until Code 0 appears. 2. Press , Code 0 blinks, display: current operating mode (AUtO or MAN). until SAFE appears. 3.
  • Page 83 Operation − Maintenance alarm The positioner cannot perform its control task due to a functional fault in the positioner it- self or in one of its peripherals or an initialization has not yet been successfully complet- − Maintenance required The positioner still performs its control task (with restrictions). A maintenance demand or above average wear has been determined.

  • Page 84: Confirming Error Messages

    Operation Example: Î Refer to the code list (see section 12.2) for possible causes and the recommended ac- Example: tion. Pin position error 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). − The 'Maintenance required/Maintenance demanded' condensed state can also activate the fault alarm output (Code 33). 8.3.1 Confirming error messages Enable configuration: 1.

  • Page 85: Servicing

    9.1 Preparation for return ship- ment Note Defective positioners can be returned to The positioner was checked by SAMSON SAMSON for repair. before it left the factory. Proceed as follows to return devices to − The product warranty becomes void if ser-...

  • Page 86: Malfunctions

    Malfunctions 10 Malfunctions 11 Decommissioning and disas- sembly Malfunctions are indicated on the display by error codes. Section 12.3 lists possible error messages and recommended action. DANGER The error codes appear on the display corre- Risk of fatal injury due to ineffective explo- sponding to their status classification set over sion protection. the condensed state (Maintenance required/ The explosion protection becomes ineffective Maintenance demanded:...

  • Page 87: Removing The Positioner

    Addresses of SAMSON AG and its subsid- We are registered with the iaries German national register for waste electric equipment (stiftung The addresses of SAMSON AG, its subsid- ear) as a producer of electrical iaries, representatives and service facilities and electronic equipment, worldwide can be found on the SAMSON WEEE reg. no.: DE 62194439...

  • Page 88: Code List

    Decommissioning and disassembly 12.2 Code list Code Parameter – Readings/val- Description ues [default setting] Note: Codes with marked with an asterisk (*) must be enabled with Code 3 prior to configuration. Operating mode Manual mode [MAN], AUtO, SAFE, ESC AUtO Automatic mode SAFE Fail-safe position Cancel In MAN and AUtO mode, the system deviation is represented by...
  • Page 89 Decommissioning and disassembly Code Parameter – Readings/val- Description ues [default setting] Enable configuration Enables changing of data (automatically deactivated when the ro- tary pushbutton has not been operated for 120 seconds). Codes [No], YES, ESC marked with an asterisk (*) can only be read and not overwritten when their configuration is not enabled. HART blinks on the display when the on-site operation is locked over HART communication.
  • Page 90 Decommissioning and disassembly Code Parameter – Readings/val- Description ues [default setting] Initialization mode MAX: Maximum range of the control valve, the travel/angle of the closure member from the CLOSED position to the [MAX], NOM, MAN, SUB, opposite stop in the actuator. ZP, ESC NOM: Nominal range of the control valve, the travel/angle of the closure member measured from the CLOSED position to the indicated OPEN position.
  • Page 91 Decommissioning and disassembly Code Parameter – Readings/val- Description ues [default setting] Travel/angle range end Upper range value for travel/angle in nominal or operating (upper x-range value) range. 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 Specified in mm or angle ° range of a control valve which has been sized too large.
  • Page 92 Decommissioning and disassembly Code Parameter – Readings/val- Description ues [default setting] 13* Set point, upper range Upper range value (100 % = 20 mA) of valid set point range value (w-end) This value must be greater than the lower range value. 25.0 to [100.0 %] of the set point range, ESC 14* Set point cutoff decrease If the set point w reaches up to the entered percentage at the final value that causes the valve to close, the actuator is immediately 0.0 to 49.9 %, [1.0 %], No, completely vented (with AIR TO OPEN) or filled with air (with AIR TO CLOSE).
  • Page 93 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* Select 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: Characteristics (see section 12.4) 21* Transit time OPEN (w ramp...
  • Page 94 Decommissioning and disassembly Code Parameter – Readings/val- Description ues [default setting] 24* Total valve travel limit Total valve travel limit. The fault alarm and wrench icon appear on the positioner display. 1000 to 99x10 [1,000000], ESC Exponential reading from 9999 travel cycles onwards Binary output This code allows you to find out on site whether the positioner has an optional binary output or not. When a binary output exists, its...
  • Page 95 Decommissioning and disassembly Code Parameter – Readings/val- Description ues [default setting] 29* Position transmitter x/ix Operating direction of the optional position transmitter: it indicates how the travel/angle position is assigned to the output signal i, [], , ESC based on the fail-safe position. The operating range (see Code 8) of the valve is represented by the 4 to 20 mA signal. The signal is 0.9 mA when a positioner has not been connected (set point less than 3.6 mA) and 3.8 mA when the positioner has not been initialized. 30* Fault alarm ix Select if and how faults that cause the fault alarm contact to be switched are also indicated at the position transmitter output.
  • Page 96 Decommissioning and disassembly Code Parameter – Readings/val- Description ues [default setting] 34* Closing direction Clockwise CCL: Counterclockwise CL, [CCL], ESC Lever's turning direction for travel pick-off which causes the CLOSED position of the control valve to be reached (view onto the positioner display). Only necessary with SUB initialization mode.
  • Page 97 Decommissioning and disassembly Code Parameter – Readings/val- Description ues [default setting] y info Control signal y [%] in relation to the travel range determined during initialization Read only MAX: The positioner builds up its maximum output pressure, see description in Code 14 and 15. The positioner vents completely, see description in Code 14 and 15. – – –: The positioner is not initialized. Forced venting status Indicates whether the option is installed or not.

  • Page 98: Error Codes

    Decommissioning and disassembly 12.3 Error codes Initialization errors Error codes: recommended Condensed state message active, when prompted, Err appears. action When fault alarms exist, they are displayed here. 50 x > range Value of measuring signal too high or too low; the lever operates near its mechanical stops. • Pin not mounted properly • NAMUR attachment: bracket slipped or follower pin not properly seated on the follower plate's slot.
  • Page 99 Decommissioning and disassembly Error codes: recommended Condensed state message active, when prompted, Err appears. action When fault alarms exist, they are displayed here. 53 Initialization time ex- Initialization cycle takes too long. ceeded (init time >) • No pressure in supply line or pneumatic leakage • Supply air failure during initialization Status classification [Maintenance required] Recommended action Check attachment and air supply line.
  • Page 100 Decommissioning and disassembly Operational errors Error codes: recommended Condensed state message active, when prompted, Err appears. action When fault alarms exist, they are displayed here. 57 Control loop Control loop error, the valve no longer follows the controlled variable within tolerable times (tolerance band alarm Code 19). Additional alarm at the fault •...
  • Page 101 However, the positioner continues operation according to its set point so that the process remains in a safe state. Status classification [Maintenance demanded] Recommended action Return positioner to SAMSON for repair. 63 w too low The set point w is lower than 3.7 mA. This error arises whenever the pow- er source that drives the positioner does not comply with the standard.
  • Page 102 The valve moves to the fail-safe position (SAFE). Additional indication at the fault alarm contact Status classification Maintenance alarm (cannot be classified) Recommended action Return positioner to SAMSON for repair. 67 Test calculation Hardware controller monitored by test calculation. Additional indication at the fault alarm contact...
  • Page 103 [Maintenance required] Recommended action Confirm error and perform a reset. Re-initialize the positioner. Inter- Internal device error nal device error 1 Status classification [Maintenance required] Recommended action Return positioner to SAMSON for repair. HART 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 required parameters.
  • Page 104 Recommended action Interrupt current signal and restart the positioner. Return the regulator to SAMSON for repair if the problem persists. Option parameters Error in option parameters. Status classification [Maintenance required] Recommended action Return positioner to SAMSON for repair. Diagnosis errors Error codes: recommended Condensed state message active, when prompted, Err appears. action When fault alarms exist, they are displayed here.

  • Page 105: Selecting The Characteristic

    Decommissioning and disassembly 12.4 Selecting the characteristic 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 workstation/operat- ing software (e.g. TROVIS-VIEW). Linear (select characteristic: 0) Travel/angle [%] Set point [%]...
  • Page 106 Decommissioning and disassembly SAMSON butterfly valve, equal percentage SAMSON butterfly valve, linear (select characteristic: 3) (select characteristic: 4) Travel/angle [%] Travel/angle [%] Set point [%] Set point [%] VETEC rotary plug valve, linear VETEC rotary plug valve, equal percentage (select characteristic: 5) (select characteristic: 6) Travel/angle [%]...
  • Page 107 EB 8387-3 EN...
  • Page 108 EB 8387-3 EN...
  • Page 109 EB 8387-3 EN...
  • Page 110 EB 8387-3 EN...
  • Page 111 EB 8387-3 EN...
  • Page 112 EB 8387-3 EN...
  • Page 113 EMC 2014/30/EU +A1:2011, EN 61326-1:2013 RoHS 2011/65/EU EN 50581:2012 Hersteller / Manufacturer / Fabricant: SAMSON AKTIENGESELLSCHAFT Weismüllerstraße 3 D-60314 Frankfurt am Main Deutschland/Germany/Allemagne Frankfurt / Francfort, 2017-07-29 Im Namen des Herstellers/ On behalf of the Manufacturer/ Au nom du fabricant.
  • Page 114 Explosion Protection 2014/34/EU (ab/from 2016-04-20) EN 61241-1:2004 RoHS 2011/65/EU EN 50581:2012 Hersteller / Manufacturer / Fabricant: SAMSON AKTIENGESELLSCHAFT Weismüllerstraße 3 D-60314 Frankfurt am Main Deutschland/Germany/Allemagne Frankfurt / Francfort, 2017-07-29 Im Namen des Herstellers/ On behalf of the Manufacturer/ Au nom du fabricant.
  • Page 115 EB 8387-3 EN...
  • Page 116 EB 8387-3 EN SAMSON AKTIENGESELLSCHAFT Weismüllerstraße 3 · 60314 Frankfurt am Main, Germany Phone: +49 69 4009-0 · Fax: +49 69 4009-1507 samson@samson.de · www.samson.de...

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