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Mounting and Operating Instructions EB 8384-2 EN

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4. 1 Lever 1 1 Nut 1 2 Disk spring 2 Follower pin Actuator stem 3 Follower clamp Symbol extends retracts Connecting plate T 11 Cover Marking 4 1227 E 20 Position sensor v 21 Mounting plate Fig 11 Mounting for Type 3277 5 Actuator and 3277 Actuator right EB 8384 2EN 29 Attachment to the control valve mounting parts and accessories Place the lever 1 in mid position and 2 6 2 Mounting the position sensor hold it in place Screw on the nut 1 1 with attachment according to 5 Place the follower clamp 3 on the actu IEC 60534 6 ator stem align and fasten it moking sure that the fastening screw rests in the For the required mounting parts as well as groove of the actuator stem the accessories refer to the order numbers 6 Place the mounting plate 21 together listed in Tables 6 and 7 on page 33 with the sensor onto the actuator yoke so 1 Place the lever 1 on the sensor in that the follower pin 2 rests on the top mid position and hold it in place of the follower clamp 3 It must rest on Unthread the nut 1 1 and remove the it with spring force lever together with the disk spring 1 2 Screw tight the mounting plate 21 onto from the sensor shaft the actuator yoke using both fixing 2 Screw the position sensor 20 onto the screws bracket 21 7 Mount cover 11 on the other side The
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10. p 7 7 21217 Actuator flange I 7 Fig 7 Mounting the coupling wheel with Type 3278 Attachment to the control valve mounting parts nd accessories Important Always use the connecting plate 6 included in the accessories fo connect i supply and output Never screw threaded parts directly into the housing Legends Figs 7 and 8 1 1 1 1 2 2 3 4 4 1 4 2 43 4 3 5 6 1 7 8 10 lever Nut Disk spring Follower pin Follower clamp Fig 7 Coupling wheel Screw Disk spring Scale plate Scale plate Actuator shaft Adapter for Type 3278 Seal rings Pressure gauge bracket Pressure gauge mounting kit Top pair of brackets 10 1 Bottom pair of brackets Fig 8 Attachment to rotary actuators Control valve opens clockwise EB 8384 2EN 25 Attachment to the control valve mounting parts and accessories 2 5 Reversing amplifier for double acting actuators For the use with double acting actuators the positioner must be fitted with a reversing amplifier The reversing amplifier is listed as an accessory in the Table 5 on page 15 The output signal pressure of the positioner is supplied at the output A1 of the reversing amplifier An opposing pressure which equals the req
11. 34 Supply pressure 34 Electrical 5 36 Switching amplis s as cas Wee eoe ae 37 Operation rx ox es E Sead 38 Operator controls and display 38 Enabling and selecting parameters AO Operating Modes san Al Automatic and manual operating 41 SAFE Fail safe position 42 Start up and settings 42 Determining the fail safe position 42 Setting the volume restriction 43 Limiting the signal pressure 43 Checking the operating range of the 43 npn FI DL 45 Initialization modes 2 2 csse 46 Start up via local interface 558 1 52 53 5 8 5 9 Zal 7 2 7 3 7 3 1 7 3 2 7 3 3 10 11 12 Contents Zero calibration po Era an aan 53 Reset to default values 54 Adjusting the limit switch 54 Quick start up guide 57 n x ehe nee 57 Non a er wees ke Be ae 58 Initialization 59 Simplest method MAX 59 Precise method NOM 59 Manual method 59 Retrofit
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14. 700 cm see Fig 4 1400 7453 Required piping with screw fittings for Actuator stem retracts or when the top diaphragm chamber is filled with air cm Steel 240 1400 6444 350 1400 6446 700 1400 6448 Stainless steel 1400 6445 1400 6447 1400 6449 Connection block with seals and screw 1400 8811 V4 NPT 1400 8812 Pressure gauge mounting kit output and supply St st Bs 1400 6950 St st St st 1400 6951 Attachment to NAMUR ribs or control valves with rod type yokes rod diameter 35 mm or smaller Table 3 according to IEC 60534 6 see Fig 5 Travel inmm Lever For actuators Order no 75 5 Type 3271 5 Actuator with 60 120 cm on Type 3510 1400 7457 Valve see Fig Without lever M on Actuators from other manufacturers and Type 3271 with u basic model 120 to 700 cm 14007434 14 to 100 L Actuators f other manufacturers and Type 3271 w 1400 cm 1400 7455 Actuators from other manufacturers and Type 3271 with n 2800 cm 120 mm travel 1490 7436 30 or 60 L Type 3271 Actuator with 2800 cm and 30 or 60 mm travel 1400 7466 Mounting brackets for Emerson and Masoneilan linear actuators 1400 6771 In addition a mounting kit acc to IEC 60534 6 is required depending on the travel See row above Connecting plate 1400 7461 Va 1400 7462 Accessories or pressure gauge bracket 7 G 14 1400 7458 NPT 1400 7459 Pressure g
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17. Direction of action Reversible Air consumption steady state Independent from supply pressure approx 110 Air delivery Actuator pressurized Actuator vented At Ap 6 bar gt 8 5 m 3 h at Ap 1 4 3 0 m h Ky 20 c 0 09 at Ap 6 bar lt 14 0 m 3 h at Ap 1 4 bar 4 5 m3 h Kymax 20 c 0 15 Permissible ambient temperature 20 to 80 C with metal cable gland 40 to 80 C The limits specified in the EC Type Examination Certificate additionally apply for explosion protected devices Influences Temperature lt 0 15 75 10 Supply air None Vibration lt 0 25 up to 2000 Hz and 4 g acc to IEC 770 Electromagnetic compatability Complying with EN 61000 6 2 EN 61000 6 3 and NAMUR Recommendation NE 21 Explosion protection Il 2 EEx ia IIC T6 12 D IP 65 T 80 or II 3 EEx nA II T II 3 D IP 65 80 C Degree of protection IP 65 Communication local SAMSON SSP interface and serial interface adapter Software requirements TROVIS VIEW with database module 3730 2 Binary contacts 1 fault alarm contact 2 software limit switches with configurable limit values reverse polarity protection Signal status No response Response Without explosion protection Conductive 348 Non conducting Ex protected version 22 mA 1 2 mA Operating voltage Positioners with model no 9000 only
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19. substitute configuration without initializa tion This initialization mode is an emergency mode The positioner parameters are esti mated and not determined by an initializa tion procedure so that a high stationary ac curacy cannot be expected You should always select a different initial ization mode if the plant allows it The initialization mode SUb is used to re place a positioner while the process is in op eration For this purpose the control valve is usually fixed mechanically in a certain posi tion or pneumatically by means of a pres sure signal which is routed to the actuator externally The blocking position ensures that the plant continues to operate with this valve position The spare positioner should not be initial ized If necessary reset the spare positioner using Code 36 After the old positioner has been replaced with a new one the following parameters must be entered pin position Code 4 nominal range Code 5 direction of action Code 7 and closing direction Code 34 The default travel limit of 100 Code 11 must be disabled with OFF In addition the blocking position Code 35 must be adjusted with the button so that it matches the position of the previously blocked valve The parameters Code 17 Tv Code 18 and the pressure limit Code 16 should re main set to their default values If the config uration data of the new positioner are 8384 2 49 Star
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21. See list of codes from page 62 onwards or cover plate of the positioner for a descrip tion of the menu codes 7 3 Initialization Important Perform a reset Code 36 prior to each ini tialization Turn Code 3 i turn gt ON turn Code 36 select RUN 1 Caution During initialization the valve runs through its whole range of travel angle of rotation 7 3 1 Simplest method MAX Mount and start up the positioner and press the INIT key READY The positioner adapts itself automatically to the maximum travel angle of rotation range of the control valve 7 3 2 Precise method Positioner adapts itself precisely to the nomi nal travel rotational angle of the control valve Mount and start up the positioner then pro ceed as follows Turn Code 3 i turn gt ON Quick start up guide turn amp Code 4 Select pin position J turn gt Code 5 Enter nominal travel range al turn Code 6 i select NOM 1 Press INIT key 7 3 3 Manual method MAN Initialization mode same as NOM but for start up of control valves with unknown nominal ranges The final position of travel angle of rotation valve open is en tered manually Mount and start up the positioner then pro ceed as follows gt Code 0 1 turn select MAN 1 turn gt Code J turn valve open position turn Code
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24. Note the travel table on page 13 Actuator with 120 cm Depending on the type of positioner attach ment the signal pressure is routed either left or right of the yoke through a bore to the actuator diaphragm Depending on the fail safe action of the actuator Actuator stem extends or Actuator stem retracts valve closes or opens if the supply air fails the switchover plate 9 must first be at tached to the actuator yoke Align the switchover plate with the corresponding symbol for left or right attachment according to the marking view looking onto the switchover plate l Mount connecting plate 6 or pressure gauge bracket 7 with pressure gauges onto the positioner making sure both seal rings 6 1 are seated properly 2 Remove vent plug 4 on the back of the positioner and close the signal pressure output Output 38 on the connecting plate 6 or on the pressure gauge bracket 7 with the stopper 5 included in the accessories 3 Place follower clamp 3 on the actuator stem align and screw tight so that the mounting screw is located in the groove of the actuator stem 4 Mount cover plate 10 with narrow side of the cut out opening Fig 3 on the 16 EB 8384 2 EN 5 left pointing towards the signal pressure connection Make sure that the bonded gasket 14 points towards the actuator yoke 15 mm travel Keep the follower pin 2 at lever M 1 on the back of the positioner i
25. Operating mode SAFE has been selected symbol S for the fail safe position appears Caution The valve moves to the fail safe position Once the positioner is initialized the current valve position is indicated on the digital dis play in If you want to return the valve from the fail safe position to the operating mode AUtO or MAN amp button must be pressed while Code 0 is active When the code number blinks turn the button to switch to the desired operating mode Press the button to confirm 42 EB 8384 2 EN 5 Start up and settings Note A summary about start up and operation can be found in section 7 on page 57 A leaflet including the same summary is also enclosed with the positioner Connect pneumatic supply air Supply 9 making sure the pressure is correct as described in section 3 1 Apply an electrical reference variable of A to 20 mA terminals 11 and 12 The voltage supply gt 19 V DC for version with a solenoid valve must be connected at terminals 81 und 82 Warning The signal pressure supplied may cause the actuator stem to move be aware of risk of injury 51 Determining fail safe position To adapt the positioner to the operating di rection of the actuator set slide switch to AIR TO OPEN or AIR TO CLOSE AIR TO OPEN Signal pressure opens the valve for fail safe position actuator stem extends valve closed AIR TO CLOSE Signal pressu
26. Ripple content of output signal 0 6 at 28 Hz acc to IEC 381 T1 Other influences Same as positioner Fault indication Can be issued with current signal lt 2 4 mA or gt 21 6 mA Inductive limit switch Type SJ 2SN Proximity Switch For connection to switching amplifier acc to EN 60947 5 6 Can be used in combination with a software limit switches External position sensor Nominal travel Adjustable same as positioner Cable Max 10 m with M12x1 connector designed for continuous flexing flame retardant acc to VDE 0472 reistant to oils lubricants as well as other corrosive media Ambient conditions Perm temperature 40 to 105 C the limits specified in the EC Type Examination Certificate additionally apply for explosion protected devices Vibration immunity up to 10 g in the range between 10 and 2000 Hz Degree of protection IP 67 Housing Die cast aluminum AlSi12 acc to DIN 1725 3 2582 chromated and Materials plastic coated special version CrNiMo 1 4581 External parts Stainless steel 1 4571 and 1 4301 Cable gland M20x1 5 black polyamide Weight Approx 1 0 kg 12 EB 8384 2 EN Attachment to the control valve mounting parts and accessories 2 Attachment to the control valve mounting parts and accessories The positioner can be attached either di recily to a SAMSON Type 3277 Actuator or according to IEC 60534 6 NAMUR
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28. me in m or angle 17 7 5 3 6 to 17 7 or rotary actuators 25 7 5 5 0 to 25 0 Note 35 15 0 7 0 to 35 4 If the pin distance has been selected 50 30 0 10 0 to 50 0 too small with Code 4 the device 70 40 0 14 0 to 70 7 switches to the SAFE mode for safety 100 60 0 20 0 to 100 0 reasons 200 120 0 40 0 to 200 0 90 90 0 24 0 to 110 0 10 Lower x limit Limitation of the travel angle of rotation downwards to the en OFF tered value the characteristic is not adapted 0 0 to 49 9 of the operating range The characteristic is not adapted to the reduced range See also ESC example in Code 11 11 Upper x limit Limitation of the travel angle of rotation upwards to the entered 100 value the characteristic is not adapted 50 0 to 120 0 100 of the operating range Example In some applications it makes sense to limit the valve travel e g if a certain minimum medium flow is required or a or OFF maximum flow must not be reached ESC The lower limit must be adjusted with Code 10 and the upper limit with Code 11 If a tight closing function has been set up it has priority over the travel limitation When set to OFF the valve can be opened past the nominal travel with a reference variable outside of the 4 to 20 mA range 12 w start Lower range value of the applicable reference variable range 0 0 to 75 0 0 0 of the must be smaller than the final value w end 0 4 mA reference variable range ES
29. rupting or switching circuits while energized is only allowed during in stallation maintenance or repair work For EEx equipment energy limit ed apparatus the standard EN 50021 1999 allows this type of equipment to be switched under nor mal operating conditions 36 8384 2 EN Caution The terminal assignment specified in the certificate must be adhered to Re versing the assignment of the electrical ter minals may cause the explosion protection to become ineffective Do not tamper with enameled screws inside or on the housing Note on the selection of cables and wires To install intrinsically safe circuits observe section 12 of the standard EN 60079 14 2003 VDE 0165 Part 1 To run multi core cables or lines with more than one intrinsi cally safe circuit section 12 2 2 7 of this standard applies An additional cable gland can be installed when connecting the device over two sepa rate cables Cable entries left unused must be sealed with blanking plugs Devices used at ambient temperatures down to 40 must have metal cable entries The wires for the reference variable must be connected to the terminals 11 and 12 lo cated in the housing Only use a current source Caution The erroneous connection of a volt age source of just around 7 V or around 2 V when connected to the wrong pole can damage the positioner In general it is not necessary to connect the positioner to a bo
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31. 1 Follow the instructions describing attachment 1 Place the lever 1 in mid position and to the standard positioner in section 2 4 hold it in place Unscrew the nut 1 1 Instead of the positioner attach the position and remove the standard attached lever sensor 20 with its mounting plate 21 M 1 together with the disk spring 1 2 from the sensor shaft 2 Screw the position sensor 20 onto the bracket 21 3 Replace the follower pin 2 normally at tached to the lever 1 with the metal fol lower pin 5 from the accessories and screw it into the hole for pin posi tion 90 1 Lever 1 1 Nut 1 2 Disk spring Fig 14 Positioner unit with sensor mounted on rotary actvators 2 Follower pin 20 Position sensor 21 Mounting plate 32 8384 2 EN Attachment to the control valve mounting parts and accessories Table 6 Mounting parts for position sensor Order no Direct attachment Mounting parts for actuators with 120 cm see Fig 11 left 1400 7472 Connecting plate 9 old for Actuator Type G 1 8 1400 6820 3277 5 00 1 8 1400 6821 Accessories actuator 120 cm Connecting plate new for Actuator Type 3277 5xxxxxx 01 new 1400 6823 Note Only new switchover and connecting plates can be used with new actuators Index 01 Old and new plates are not intercha
32. 3 Rotary pushbutton 8 Clamping plate 4 Marking 9 Plastic cover 5 Rotary switch 11 Connector 60 8384 2 EN mp Socket STI 11 Fig 18 Retrofitting an inductive limit switch 9 Maintenance The positioner does not require any mainte nance There are filters with a 100 mm mesh size in the pneumatic connections for supply and output which can be removed and cleaned if required The maintenance instructions of any up stream supply air pressure reducing stations must be observed Maintenance 10 Servicing explosion protected devices If a part of the positioner on which the ex plosion protection is based needs to be ser viced the positioner must not be put back into operation until an expert has inspected the device according to explosion protection requirements has issued a certificate stating this or given the device a mark of confor mity Inspection by an expert is not required if the manufacturer performs a routine check on the device prior to putting it back into oper ation The passing of the routine check must be documented by attaching a mark of con formity to the device Devices that have already been used outside of hazardous areas and are intended for use in hazardous areas in future must com ply with the safety demands placed on re paired devices Prior to operation they must be tested according to the specifications stipulated for Repairing explosion pro tected de
33. AA r o 4 51 8 IE N KX Fig 16 Display and operator controls SSP interface Switch for fail safe action of the actuator Volume restriction Rotary pushbutton 8384 2 39 Operation 4 2 Enabling and selecting parameters The codes which are marked with an aster isk in section 11 on page 62 onwards must be enabled with Code 3 before the as sociated parameters can be configured as described below 2 3 Code 3 Configuration LI m f not enabled 2 3 Configuration N N enabled gt From the current display turn the rotary pushbutton until Code 3 and OFF ap pear on the display Confirm Code 3 by pressing the but ton the code number blinks Turn button until ON appears Confirm setting by pressing the but ton Configuration is enabled and is indicated by symbol appearing on the display Now you can adjust the codes parameters and values for the control valve in any de sired order by turning the button Con firm settings by pressing the button 40 EB 8384 2 EN Note To cancel a value that you have just entered under a code turn the button until ESC appears on the display and press to con firm Can
34. appropriate storage are assumed Note The device with a CE marking fulfils the requirements of the Directives 94 9 EC ATEX and 89 336 EEC EMC The declaration of conformity can be viewed and downloaded on the Internet at http www samson de 4 EB 8384 2 EN Versions Article code 3730 2 X X X X X O0 00 0 Explosion protection Without 0 Il 2 EEx ia T6 I12DIP65T80 C 1 acc to ATEX Ex ia FM CSA 3 II 3 EEx na 116 3 DIP 5T80 C 8 acc to ATEX Additional equipment Inductive Without 0 limit switch With Type SJ 2 SN 1 0 Solenoid valve Without 0 SILA 24 V DC 4 Analog Without 0 position transmitter With 1 External Without 0 position sensor With 0 1 Diagnostics Expert 1 Expert extended diagnostics 2 Housing material Aluminum 0 Stainless steel 1 4581 0 1 Positioner for Without 0 Free of substances that 1 impair painted surfaces Exhaust air with pneum 2 connection 1 4 Special Without 0 versions 8384 2 5 Firmware modification Modifications of positioner firmware in comparison to previous versions Previous New 1 01 1 10 Via the serial interface and the serial interface adapter the positioner can be configured and operated using TROVIS VIEW software The following additional status indications were implemented Code 76 No emergency mode Code 77
35. before the mechanical stop OPEN CLOSED Adjusting the limit switch For CLOSED position 1 Initialize positioner 2 Use the MAN function to move the positioner to 5 see LC display 3 Adjust the tag using the yellow adjust ment screw 2 until the tag enters or leaves the field and the switching ampli fier responds You can measure the switching voltage as an indicator Contact function Tag leaving the field gt contact is made Tag entering the field gt contact is opened For OPEN position 1 Initialize positioner 2 Use the MAN function to move the positioner to 95 see LC display 3 Adjust the tag 1 using the yellow ad justment screw 2 until the tag enters or Adjustment screw 2 Tag 1 Proximity switch 3 Fig 17 Adjustment of the limit switch EB 8384 2EN 55 Adjusting the limit switch leaves the field of the proximity switch 3 You can measure the switching voltage as an indicator Contact function Tag leaving the field gt Contact is made Tag entering the field gt Contact is opened 56 EB 8384 2 EN 7 Quick start up guide 7 1 Mounting Direct attachment to SAMSON Type 3277 Actuator Travel mm Actuator cm Pin position 7 5 120 25 15 120 240 350 35 15 30 700 50 Note Standard delivery includes lever M ready assembled with the follower pin on 35 mm pin position for 15 mm travel To mount the position
36. boreholes with NPT and G threads Seal the threaded connection that is not used with the rubber seal and square plug Attachment to the control valve mounting parts and accessories 3277 Actuator with 240 to 700 2 The signal pressure is routed to the connec tion at the side of the actuator yoke for the 3 version Actuator stem extends For the fail safe position Actuator stem re tracts the connection on the top diaphragm case is used The connection at the side of the yoke must be fitted with a venting plug accessories Mounting the position sensor 1 Place the lever 1 on the sensor in mid position and hold it in place Unthread the nut 1 1 and remove the lever together with the disk spring 1 2 from the sensor shaft Screw the position sensor 20 onto the mounting plate 21 Depending on the actuator size and rated travel of the valve determine the required lever and position of the fol lower pin 2 from the travel table on page 13 The positioner is delivered with lever M in pin position 35 on the sensor If nec essary remove the follower pin 2 from its pin position and move it to the bore hole for the recommended pin position and screw tight Place the lever 1 and disk spring 1 2 on the sensor shaft Signal pressure Signal pressure Venting plug
37. direction of rotation when the valve is in its closed position 3 Screw coupling wheel and follower clamp tightly onto the actuator shaft using screw 4 1 and disk spring 4 2 4 Screw the bottom pair of brackets 10 1 with the bends pointing either to the in side or to the outside depending on the actuator size to the actuator case Posi tion top pair of brackets 10 and screw tight 24 8384 2 EN 5 Mount connecting plate 6 or pressure gauge bracket 7 with pressure gauges to the positioner making sure both O rings are seated properly For double acting springless rotary ac tuators a reversing amplifier is required to attach the positioner to the actuator see section 2 5 6 Unscrew the standard follower pin 2 from the positioner s lever M 1 Use the metal follower pin 5 included in the mounting kit and screw tight into the bore for pin position 90 7 Place positioner on the top pair of brackets 10 and screw tight Con sidering the actuator s direction of rota tion adjust lever 1 so that it engages in the slot of coupling wheel 4 with its follower pin see Fig 8 It must be guar anteed that the lever 1 is parallel to the long side of the positioner when the ac tuator is at half its angle of rotation 8 Stick scale plate 4 3 on the coupling wheel so that the arrow tip indicates the closed position and it can be easily read when the valve is installed
38. due to EMC distur Additional message at the fault bances Subsequently the device runs on default values alarm contact Remedy Return the positioner to SAMSON AG for repair 71 General parameters Parameter errors that are not critical for the control Remedy Confirm error Check and if necessary reset required parameters 72 Start up parameters Start up parameter errors Remedy Confirm error perform reset and re initialize the positioner EB 8384 2 EN 73 Code list 76 No emergency mode The travel measuring system of the positioner has a self moni toring function see Code 62 A controlled emergency mode is not available on certain actua tors such as double acting actuators For this reason the positioner moves into the fail safe position when a measuring error occurs During the initialization the positioner checks whether the actuator has such a function or not Remedy Merely information confirm if necessary No further action necessary 77 loading error Additional message at the fault alarm contact When the device starts operation for the first time after the input signal has been applied it carries out a self test HEStinG runs across the display If the device loads a program that does not correspond to that of the positioner the valve is moved into the fail safe position It is not possible to make the valve leave this fail safe position again by operat
39. function is triggered of the operating range ESC Testing the position transmitter Values can be entered in relation to the operating range The current actual value is used in initialized positioners locally as the start value bumpless changeover to the test mode On testing over software the entered simulation value is issued as the position feedback signal for 30 seconds position transmitter Code 29 30 31 can only be selected if the position transmitter optional is installed 32 Display special functions NO YES ESC Fault alarm via display and fault alarm contact for special func tions e g zero calibration initialization and position transmitter test Code 31 33 Display total valve travel NO YES ESC Fault alarm via display and fault alarm contact when the limit value for the total valve travel is exceeded 34 Closing direction CL CCL ESC CL Clockwise CCL Counterclockwise Turning direction in which the valve is moved to the Closed posi tion view onto the rotary switch motion when the positioner cover is open Needs only be entered in initialization mode SUb Code 6 35 Blocking position 0 mm ESC Entering the blocking position Distance up to the Closed position Only necessary in initialization mode SUb 68 8384 2 EN Code list 36 Reset Resets all parameters to default factory setting OFF R
40. standard in stalled lever M or require a lever size L or XL proceed as follows 5 Screw the follower pin 2 in the as signed lever bore pin position as listed in the table Only use the longer follower pin 2 included in the mounting kit 6 Place lever 1 on the positioner shaft and screw tight using the disk spring 1 2 and nut 1 1 Note If you have mounted a new lever 1 you must move it once all the way as far as it will go in both directions 7 Place positioner on the NAMUR bracket in such a manner that the follower pin 2 rests in the slot of the follower plate 3 3 1 Adjust the lever 1 correspond ingly Screw the positioner to the NAMUR bracket using both its fixing screws Attachment to the control valve mounting parts and accessories Attachment to rod type yoke Rods with max 35 mm rm Attachment to X NAMUR rib 3 1 16 Additional bracket for actuators with 2800 cm Por rt c Lever XL and L and travel 2 60 mm S C 14 N lever SL T 1 Nut 1 2 Disk spring 2 Follower pin 3 Follower plate 3 1 Follower plate 6 Connecting plate 61 Seal rings 7 Pressure gauge bracket 8 Pressure gauge mounting kit 9 Stem connector 9 Bracket 10 NAMUR bracket 1 Screw 14 Bolt 14 1 Screw Imp
41. the control valve with a NAMUR bracket 10 Refer to Table 3 on page 14 for the required mounting parts as well as the accessories with their order numbers Note the travel table on page 13 1 Screw the two bolts 14 to the bracket 9 1 of the stem connector 9 place the follower plate 3 on top and use the screws 14 1 to tighten Actuator size 2800 cm2 For a travel of 60 mm or smaller screw the longer follower plate 3 1 directly to the stem connector 9 For a travel ex ceeding 60 mm mount the bracket 16 first and then the follower plate 3 to the bracket together with the bolts 14 and screws 14 1 2 Mount NAMUR bracket 10 to the con trol valve as follows For attachment to the NAMUR rib use an screw 11 and toothed lock washer directly in the yoke bore For attachment to valves with rod type yokes use two U bolts 15 around the yoke Align the NAMUR bracket 10 accord ing to the embossed scale so that the slot of the follower plate 3 is centrally aligned with the NAMUR bracket at mid valve travel 20 EB 8384 2 EN 3 Mount connecting plate 6 or pressure gauge bracket 7 with pressure gauges 8 on the positioner making sure both seal rings 6 1 are seated properly 4 Select required lever size 1 M Lor XL and pin position according to the actua tor size and valve travels listed in the ta ble below Should you require a pin position other than position 35 with the
42. to SAMSON AG for repair 72 8384 2 EN Code list Error appendix 65 Hardware Additional message at the fault alarm contact A hardware error has occurred the positioner moves to the fail safe position SAFE Remedy Confirm error and return to the automatic operating mode or perform a reset and re initialize the device If this is not suc cessful return device to SAMSON AG for repair 66 Data memory Additional message at the fault alarm contact The writing of data to the data memory does not work anymore e g when the written data deviate from the read data Valve moves to the fail safe position Remedy Return the positioner to SAMSON AG for repair 67 Test calculation Additional message at the fault alarm contact The hardware positioner is monitored by means of a test calcula tion Remedy Confirm error If this is not possible return the positioner to SAMSON AG for repair Data error 68 Control parameter Control parameter error e g due to EMC disturbances Additional message at the fault alarm contact Remedy Confirm error perform reset and re initialize the positioner 69 parameter Parameter error of the digital potentiometer Additional message at the fault alarm contact Remedy Confirm error perform reset and re initialize the positioner 70 Calibration Error in the production calibration data e g
43. to con trol valves with cast yokes or rod type yokes as well as to rotary actuators according to VDI VDE 3845 For attachment to the various actuators cor responding mounting parts and accessories are required These are listed with their or der numbers in Tables 1 to 5 On attaching the positioner it is important to observe the assignment between lever and pin position according to the travels listed in the travel tables The tables show the maximum adjustment range at the positioner The travel that can be implemented at the valve is restricted by the pin position used and additionally by the actuator spring compression required The positioner is standard equipped with the lever M pin position 35 Note If the standard mounted lever M pin posi tion 35 is replaced the newly mounted le ver must be moved once all the way as far as it will go in both directions to adapt it to the internal measuring lever Travel table for direct attachment to Type 3277 Actuator Actuator size Rated travel Adjustment range at positioner Required Assigned Type cm mm Min Travel Max lever pin position 3277 5 a 120 7 5 5 17 6 M 25 3277 120 240 350 15 7 5 354 M 35 Actuators 700 30 10 50 M 50 Travel table for attachment according to IEC 60534 6 NAMUR SAMSON valves Other valves actuators Required Assigned cm Rated travel Min Travel Max lever pin p
44. when all shut off valves are closed Note The initalization procedure can be interrupted while running by pres sing StOP appears three se conds long and the positioner then moves to the fail safe position D Alternating displays M 9 X Initialization running Bar graph display indicating the progress of LI 1 the initialization G n Error 1 1 Initialization successful positioner in automatic operating mode 255 After a successful initialization the positioner runs in control operation indi cated by the C control symbol The control position in predetermined by the reference variable appears on the dis play 8384 2 45 Start up and settings A malfunctioning leads to the process being interrupted The 1 fault symbol appears on the display See section 5 7 on page 53 If the slide switch is set to AIR TO CLOSE the positioner with firmware version 1 10 or higher automatically switches to the direc tion of action increasing decreasing AN on successful completion of initialization This results in the following assignment be tween reference variable and valve position Fail safe positi Direction of Valve on action Closed at Open at Actuator stem extends FA 4 20 mA AIR TO OPEN Actuator stem retracts FE 20mA AmA AIR TO CLOSE The tight closing function is activa
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46. 10 Cover plate 10 1Seal ring Pressure gauge bracket Press gauge mounting kit 15 11 Cover 14 Gasket 15 Formed seal 1 1 1 2 EH Cut out of cover S T Important Always use the connecting plate 6 included in the accessories to connect supply and output Never screw threaded parts directly into the housing Fig 3 Direct attachment Signal pressure connection Type 3277 5 Actuator with 120 cm 8384 2 17 Attachment to the control valve mounting parts and accessories 2 1 2 Type 3277 Actuator Refer to Table 2 on page 14 or the required mounting parts as well as the accessories with their order numbers Note the travel table on page 13 Actuators with 240 to 700 cm The positioner can be mounted either on the left or on the right side of the yoke The sig nal pressure is routed to the actuator over the connection block 12 for actuators with fail safe action Actuator stem extends in ternally through a bore in the valve yoke and for Actuator stem retracts through ex ternal piping 1 Place follower clamp 3 on the actuator stem align and screw tight so that the mounting screw is located in the groove of the actuator stem 2 Mount cover plate 10 with narrow side of the cut out opening Fi
47. 3 1 turn 69 gt ON J turn Code 6 1 select MAN 1 Press INIT key Note Alter imposing the electrical reference vari able the positioner is in the last used oper ating mode Code 0 appears in the display If de has not yet been initialized the 7 symbol blinks EB 8384 2 59 8 Retrofitting an inductive limit switch Retrofitting an inductive limit switch Required retrofit kit Li 1 mit switch Order no 1400 7460 Take off the rotary pushbutton 3 and cap 1 unthread the five fixing screws 2 and lift off the plastic cover 9 Use a knife to cut an opening at the marked location 4 Push the connector 11 with cable through the opening and secure the proximity switch 7 on the cover with a dot of glue Remove the jumper at the socket 511 of the top board and insert the cable con nector 11 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 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 Important On start up of the positioner set the op tion inductive alarm under Code 38 from NO to YES 1 6 Metal tag 2 Screws 7 Proximity switch
48. 6 ach Interface 09 02 deus E 5 19 m converter Air capacity booster MER Pressure regulator 500000 R N20 Flow regulator O Volume restriction 11 Inductive limit switch 12 Solenoid valve s 12 n Fig 2 Functional diagram 13 Analog position transmitter 14 Software limit switches Alarm 1 2 15 Fault alarm output Alarm 3 16 Display 17 Solenoid valve control 18 Galvanic isolation 19 D A converter 20 Communication interface Optional EB 8384 2EN 9 Design and principle of operation Version with inductive limit switch The rotary shaft of the positioner carries an adjustable tag which actuates the installed proximity switch The optional inductive limit switch 11 leads to Al and the software limit switch which remains in operation leads to A2 Version with external position sensor In this version only the sensor is mounted to the control valve The positioner is located separately from the valve The connection of x and y signals to the valve is established via cable and air hosing only for non hazardous areas and without inductive limit switch 1 2 Technical data Positioner Nominal travel adjustable Direct attachment to Type 3277 3 6 to 30 mm attachment acc to IEC 60534 6 3 6
49. AIR TO OPEN or vented with AIR TO CLOSE of the span adjusted via This action always lead to the valve being completely opened Code 12 13 Codes 14 15 have priority over Codes 8 9 10 11 ESC Example Set the final position w gt to 99 for three way valves 16 Pressure limit The signal pressure can adopt the value of the applied supply OFF pressure at the maximum OFF or it can be limited in stages of 14 24 37 bar 1 4 2 4 or 3 7 bar This pressure limitation is already effective during the initializtation ESC Note After changing a pressure limit already set the actuator must be vented once e g by selecting the fail safe position over Code 0 17 KP step Displaying or changing Kp 0 to 17 7 Note on changing the Kp and Ty steps ESC During the initialization of the positioner the Kp and Ty values are optimized Should the positioner show a tendency for impermissibly high post pulse oscillation due to additional interference the Kp and Ty steps can be adapted after the initialization For this either the Ty step can be increased in increments until the desired response behavior is reached or when the maximum value of 4 is reached the Kp step can be decreased in incre ments CAUTION Changing the Kp step influences the system deviation This effect decreases as the step increases 8384 2 65 Code list 18 step Displaying or changing Ty 2 See note under step 1234 OFF A cha
50. C The reference variable range is the difference between w end and w start and must be Aw gt 25 4 mA For an adjusted reference variable range of 0 to 100 4 to 20 mA the control valve must move through its entire operating range from to 100 travel angle of rotation In split range operation the valves operate with smaller refer ence variables The control signal of the control unit to control two valves is divided such for instance that the valves move through their full travel angle of rotation at only half the input signal first valve set to O to 50 4 to 12 mA and second valve set to 50 to 100 212 to 20 mA reference variable 64 EB 8384 2 EN Code list 13 w end Upper range volue of the applicable reference variable range 25 0 to 100 0 100 0 of must be greater than w start the reference variable range 100 20 mA ESC 14 Final position w If w reaches up to 1 towards the final value that causes the 0 0 to 1 0 valve to close the actuator is immediately completely vented of the span adjusted with AIR TO OPEN or filled with air with AIR TO CLOSE Code 12 13 This action always lead to maximum tight closing of the valve OFF ESC Codes 14 15 have priority over Codes 8 9 10 11 15 Final position w If w reaches up to 99 towards the final value that causes the OFF valve to open the actuator is immediately completely filled with 50 0 to 100 0 air with
51. Electropneumatic Positioner Type 3730 2 Fig 1 Type 3730 2 Mounting and Operating Instructions EB 8384 2 EN Firmware version 1 20 Edition December 2004 Contents Contents 1 1 1 1 2 2 2 1 2 1 1 2 1 2 2 2 2 3 2 4 2 5 2 6 2 6 1 2 6 2 2 6 3 2 6 4 3 3 1 3 1 1 3 1 2 3 2 3 2 1 4 4 1 4 2 2 8384 2 EN Page Design and principle of operation 8 Additional equipment 9 MI rm 10 Attachment to the control valve mounting parts and accessories 13 Direct attachment os e AAO ee ne EH DDR 16 Type 32 7 5 Act dlor i s m RUE ew OR E e 16 3277 Act dlor 18 Attachment according to 6053446 20 Attachment to Type 3510 Micro flow Valve 22 Attachment to rotary 24 Reversing amplifier for double acting actuators 26 Attaching an external position sensor 28 Mounting the position sensor with direct attachment 28 Mounting the position sensor with attachment according to IEC 60534 6 30 Mounting the position sensor to Type 3510 Micro flow Valve 31 Mounting the position sensor to rotary actuators 32 5 reo de pos d we Se 34 Pneumatic connections 34 Signal pressure gauges
52. Program loading error Displays number of zero calibrations performed since the last initialization For initialization of AIR TO CLOSE actuators the direction of action Code 7 is automatically set to increasing decreasing Code 3 the activation period of the enabled configuration function was ex tended to 120 s 1 10 1 20 Electronics changed no new functions added 6 8384 2 EN EB 8384 2 EN ll Design and principle of operation 1 Design and principle of operation The electropneumatic positioner is mounted to pneumatic control valves and is used to assign the valve position controlled variable x to the control signal reference variable w The DC control signal received from a control unit is compared to the travel or rotational angle of the control valve and issues a signal pressure output variable The positioner is designed depending on the corresponding accessories for direct attachment to Type 3277 Actuators or for attachment to actuators according to IEC 60534 6 NAMUR Additionally a coupling wheel included in the accessories is required to transfer the ro tary motion for rotary actuators according to VDI VDE 3845 Springless rotary actuators require an ac cessory reversing amplifier to permit the powered operation in either direction The positioner basically consists of a travel sensor system that functions proportional to the resistance an analog i p module with downstr
53. Solenoid valve info Display only Yes No indicates whether a solenoid valve is installed 8384 2 EN 69 Code list Error codes Remedy Fault alarm symbol active when prompted Err appears If any fault messages exist they are displayed here Initizialization error indicated by the fault symbol on the display 50 x range The value supplied by the measuring signal is either too high or too low the measuring sensor is close to its mechanicol limit Pin positioned incorrectly Bracket slipped in case of NAMUR attachment or positioner is not central Follower plate incorrectly attached Remedy Check attachment and pin position set operating mode from SAFE to MAN and re initialize the positioner 51 gt range The measuring span of the sensor is too low Pin positioned incorrectly e Wrong lever A rotational angle smaller than 11 at the positioner shaft creates just an alarm An angle below 6 leads to the initialization being canceled Remedy Check attachment and re initialize the positioner 52 Attachment Positioner attachment incorrect Nominal travel angle Code 5 could not be achieved on initialization under NOM or SUB no tolerance downwards permissible e Mechanical or pneumatic error e g wrong lever selected or supply pressure too low to move to the required position or pneumatic fault Remedy Check attachment and supply pr
54. UN Note After setting RUN the positioner must be re initialized ESC 37 Position transmitter Display only Yes No indicates whether the position transmitter option is installed 38 Inductive alarm Indicates whether the inductive limit switch option is installed or NO YES not ESC 39 System deviation e info 99 9 to 999 9 75 Display only indicates the deviation from the set point position 40 Transit time Open info Display only O to 240 s 0 minimum opening time is determined during initialization 41 Transit time Closed info Display only 0 to 240 s 0 minimum closing time is determined during initialization 42 Auto w info Display only 0 0 to 100 0 of the span 4 to 20 mA indicates the supplied automatic reference variable corre sponding 4 to 20 mA 43 Firmware info Display only Xxxx indicates the current firmware version of the positioner 44 y info Display only blocked prior to initialization 0 OP After initialization indicates the actuator pressure in 0 to 100 to 100 corresponds to the pressure range which adjusts the travel angle range from 0 to 100 If the actuator pressure is bar e g due to tight closing on bottom or fail safe action O P appears on the display If the actuator pressure is higher than the pressure required for X 100 e g due to tight closing on top MAX appears on the display Value is determined during initialization 45
55. as NOM however for starting up valves with unknown nominal range In this mode the positioner expects the con trol valve to be moved manually to the de sired OPEN position prior to enabling the initialization procedure The upper range travel angle of rotation value is adjusted using the rotary pushbutton The positioner uses this OPEN position and the CLOSED position to calcu late the differential travel angle and accepts it as the operating range with the lower x range value and upper x range value be ing the limits Enable configuration 2 1 3 FN LI IN Default OFF Turn Code 3 press e turn gt ON press After enabling Turn Code 4 press turn Select pin position entered during installation press Turn Code 6 press turn 69 MAN press a 8 IM CONI Default Code 0 press e turn MAN press x 0 Default MAN Turn Code 1 press Code 1 blinks Y GE pes Im 00g d ies Turn until the valve reaches its OPEN po sition press Press INIT key to start initialization The initialization procedure may take several minutes depending on the actuator size as the valve moves through its entire travel angle of ro tation range Start up and settings SUb
56. ate 6 or a pressure gauge bracket 7 must be fixed to the housing de pending on the accessory chosen Make sure the seal rings 6 1 are correctly in serted see Fig 5 bottom right For the electric connection the connecting lead must be fitted with an M12x1 connec tor plug at one end The lead end without the plug can be shortened if required and wired to the connector included section 3 2 on page 36 The electrical and pneumatic connections between the sensor and the positioner unit may be a maximum of 10 meters Note In addition the instructions in section 3 1 and 3 2 apply for the pneumatic and electrical connection Operation and setting are described in sec tions 4 and 5 28 EB 8384 2 EN Fig 10 Positioner unit with sensor mounted on a micro flow valve 2 6 1 Mounting the position sensor with direct attachment Type 3277 5 Actuator with 120 cm The signal pressure from the positioner is routed over the signal pressure connection of the connecting plate 9 Fig 11 left to the actuator diaphragm chamber To proceed first screw the connecting plate 9 included in the accessories onto the actuator yoke Turn the connecting plate 9 so that the correct symbol for the fail safe position Actuator stem extends or Actuator stem retracts is aligned with the mark ing Fig 11 below Make sure that the gasket for the con necting plate 9 is correctly inserted The connecting plate has
57. ator where the supply pressure opens the valve fail safe position springs close valve switch position AIR TO OPEN For actuator where the supply pressure closes the valve fail safe position springs open valve switch position AIR TO CLOSE For positioners with an attached reversing amplifier for double acting rotary actuators section 2 5 switch position AIR TO OPEN The switch position is prompted prior to an initialization After an initialization has been completed changing the switch position does not have any effect on the operation of the positioner 38 8384 2 EN Volume restriction Q The volume restriction is used to adapt the air delivery to the actuator size Two fixed settings are possible depending on how the air is routed at the actuator For actuators smaller than 240 2 with a loading pressure connection at the side Type 3271 5 set restriction to MIN SIDE For a connection at the back Type 3277 5 set restriction to MIN BACK For actuators 240 cm and larger set to MAX SIDE for a side connection and to MAX BACK for a connection at the back Displays The LC display indicates symbols that are assigned to parameters codes and func tions The bar graph in the operating modes Man ual 7 and Automatic indicates the sys tem deviation that depends on the sign and the value One bar graph ele ment appears per 1 system deviation If the device has not yet been initialized
58. auge mounting output supply St st Bs 1400 6950 St st St st 1400 6951 14 8384 2 EN Attachment to the control valve mounting parts and accessories Table 4 Attachment to rotary actuators VDI VDE 3845 for all sizes of fixing level 2 see Figs 7 and 8 Mounti With foll VDI VDE 3845 for all sizes of fixing level 2 1400 7448 nd IN Tower for Type 3278 Actuator with 160 320 cm 1400 7614 parts and coupling wheel for Camflex II 1400 9120 Accessories Connecting plate 1400 7461 V4 NPT 1400 7462 or pressure gauge bracket 7 1400 7458 V4 NPT 1400 7459 Pressure gauge mounting kit output supply St st Bs 1400 6950 St st St st 1400 6951 Table 5 General accessories Accessories Pneumatic reversing amplifier for double acting 1079 1118 actuators Va NPT 1079 1119 Cable gland M20 x 1 5 Nickel plated brass 1890 4875 Adapter M 20 x 1 5 to 2 NPT aluminum 0310 2149 Retrofit kit for inductive limit switch 1x SJ 2 SN 1400 7460 VN German English standard 1190 0761 bs E with id parameters 1190 3100 English French 1190 3142 8384 2 15 Attachment to the control valve mounting parts and accessories 2 1 Direct attachment 2 1 1 Type 3277 5 Actuator Refer to Table 1 on page 14 for the required mounting parts as well as the accessories with their order numbers
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60. ble 17 25 35 50 mm on page 64 top 70 100 200 mm For initialization using NOM or SUb this pin position must be 90 for rotary actuators entered ESC 5 Nominal range For initialization using NOM or SUb the nominal travel angle of 15 0 mm or angle ESC rotation of the valve must be entered The permissible adjustment range depends on the pin position according to the table on page 64 After initialization has been successfully completed the maximum nominal travel angle reached on initialization is displayed 62 8384 2 EN Code list 6 mode Select the initialization mode MAX MAX Maximum range of the control valve travel angle of NOM the closure member from the CLOSED position to the MAN opposite stop in the actuator Sub NOM Nominal range of the control valve the travel angle of ZP the closure member measured from the CLOSED position ESC to the indicated OPEN position MAN Manual adjustment upper x range value SUb self adjustment emergency mode ZP Zero calibration 7 w x Direction of action of the reference variable w in relation to the 77 travel angle of rotation x increasing increasing or in AN creasing decreasing ESC Automatic adaptation AIR TO OPEN On completion of initialization the direction of action remains in creasing increasing 77 a globe valve opens as the mA signal increases AIR TO CLOSE On completion of initialization the direction of act
61. celing the setting ES Note If no settings are entered within 120 seconds the enabled configuration function becomes invalid and the display resets to Code 0 The code list on page 62 onwards in section 11 shows all parameters that can be ad justed including their description and their default settings Important After attaching the positioner to the valve as well as setting the fail safe position and the volume restriction it is sufficient for standard operation to press the initialization key in order to ensure optimum positioner opera tion section 5 5 on page 45 For this purpose the positioner must be op erated with its default values If necessary a reset must be carried out section 5 9 on page 50 4 3 Operating modes 4 3 1 Automatic and manual operating modes Prior to initialization If the positioner has not been initialized yet the automatic operating AUIO cannot be se lected The valve can only be positioned manually with the positioner To proceed turn 69 button clockwise until Code 1 appears then confirm Code 1 by pressing the button If both the code number and the hand sym bol are blinking the valve can be manually positioned by turning the 29 button This type of manual adjustment is used to check the operating range of the positioner see also section 5 4 on page 43 After initialization After successful ini
62. ching amplifier see section 3 2 1 must be connected to the out put the tag 1 is inside the field of the switch the switch assumes a high resistance If the tag is outside of the field the switch assumes a low resistance Normally the limit switch is adjusted such that it will provide a signal in both end posi tions of the valve The switch however can also be adjusted to indicate intermediate valve positions The desired switching function i e whether the output relay shall be picked up or re leased when the tag has entered the field has to be determined if necessary at the switching amplifier Note The inductive limit switch replaces the soft ware limit switch A1 with terminal assign ment 41 42 Each switching position can optionally be set to indicate when the tag has entered the field or when it has left the field The second software limit switch remains ef fective the function of the software limit switch A1 is disabled Software adaptation Code 38 inductive alarm is set to YES The inductive limit switch is connected to the terminals 41 42 The device is set up accordingly when deliv ered ex works SAMSON Setting the switching point Important During adjustment or testing the switching point must always be approached from mid position 50 5 To ensure safe switching under any ambient conditions the switching point should be adjusted to a value of approx 5
63. circuit To ensure the operating reliability of the positioner the amplifiers should comply with the limit values of the output circuits conforming to EN 60947 5 6 If the positioner is to be installed in hazard ous areas the relevant regulations must be observed Optional Optional I Al G 81 82 11 12 83 84 51 52 41 42 311 32 Tet tt Switching amplifier acc to EN 60947 5 6 j We hh eric td 24 V DC mA A3 Limit switches 2 wire transmitter solenoid Control signal Fault A2 Al supply unit for optional po valve indication Software Software sition transmitter only or inductive Fig 15 Electric connections EB 8384 2 EN 37 Operation 4 Operation Note A summary about operating and start up can be found in section 7 on page 57 A leaflet including the same summary is also enclosed with the positioner 4 1 Operator controls and display Rotary pushbutton The positioner is mainly operated with the rotary pushbutton Turn the amp button to select and set codes parameter and values Press it to confirm them Slide switch AIR TO OPEN or AIR TO CLOSE This switch is used to adapt the positioner to the operating direction of the actuator For actu
64. e may cause damage to the valve the signal pressure must be limited Select Code 3 to enable configuration and then access Code 16 to set the pressure limit to 1 4 2 4 or 3 7 bar 5 4 Checking the operating range of the positioner To check the mechanical attachment and the proper functioning the valve should be moved through the operating range of the positioner in the manual operating mode with the manual reference variable X 0 Code 0 Select M 9 N manual operation Default MAN 5 3 EIS gt 1 Codel 11 2597 1 Turn the button until Code 0 then confirm Code 0 by pressing the button 2 Turn the button until MAN appears in the display i e manual operating mode confirm selected operating mode by pressing the button Position valve using the rotary pushbutton the current angle of rotation is indicated 8384 2 43 Start up and settings 3 Turn the button until Code I appears confirm Code 1 by pressing button If the selected pin position is smaller than in The hand symbol and Code 1 blink P tended for the respective travel range the 4 Position control valve by turning the positioner switches to the SAFE mode the button several times until pressure builds valve moves to the fail safe position see up and the control valve moves to its fi section 4 3 2 on page 42 Note nal positions so
65. e you are required to enter the pin position for the selected initialization modes NOM and SUb Remedy Enter pin position over Code 4 and nominal travel angle over Code 5 Re initialize the positioner Operating error indicated by the fau lt symbol on the display 57 Control loop Additional message at the fault alarm contact Control loop fault the control valve does not react within the tol erable times of the controlled variable tolerance band alarm Code 19 e Actuator mechanically blocked e Attachment of the positioner subsequently postponed e Supply pressure not sufficient Remedy Check attachment 58 Zero point Zero point incorrect Error may arise when the mounting posi tion linkage of the positioner moves or when the valve seat trim is worn especially with soft sealed plugs Remedy Check valve and mounting of the positioner If OK perform a zero calibration over Code 6 see section 5 8 on page 53 59 Auto correction Should an error occur in the data range of the positioner the self monitoring function recognizes it and automatically corrects it Remedy Automatic 8384 2 71 Code list 60 Fatal error Additional message at the fault alarm contact An error was detected in the data relevant for safety auto cor rection is not possible This may be due to EMC disturbances The control valve is moved to the fail safe
66. eam booster as well as the electronic unit with a microcontroller The positioner is fitted with three binary con tacts as standard A fault alarm output is used to indicate a fault to the control station and two configurable software limit switches to indicate the valve s end positions The position of the valve is transmitted as linear travel motion or angle of rotation via pick up lever and travel sensor 2 to an an alog PD controller 3 Simultaneously an A D converter 4 transmits the position of the valve to the microcontroller 5 The PD 8 8384 2 EN controller compares this actual position to the 4 to 20 mA DC control signal reference variable after it has been converted by the A D converter 4 In case of a system deviation the operation of the i p converter 6 is changed so that the actuator 1 is filled or vented via the downstream air capacity booster 7 This causes the closure member of the control valve to move to the position determined by the reference variable The pneumatic air capacity booster 7 and the pressure regulator 8 are provided with supply air An intermediate flow regulator 9 with fixed settings is used to purge the positioner and also guarantees trouble free operation of the pneumatic booster The out put signal pressure supplied by the booster can be limited over the software The volume restriction Q 10 is used to opti mize the positioner by adapting it to the ac tuator s
67. el angle of ro tation range Note For MAX initialization the positioner cannot indicate nominal travel angle of rotation in mm Code 5 remains disabled In addition the lower Code 8 and the up per Code 9 x range value can only be dis played and modified in 95 During MAX initialization an increased sys tem deviation undefined final position of the actuator in the upper control range may oc cur with some control valves due to the pneumatic actuator design If you want the display to indicate mm proceed as follows after configuration has been enabled Turn Code 4 press turn Select pin position entered during installation press If you now switch to Code 5 the nominal range appears in mm The lower and upper x range values for Code 8 and 9 are displayed in mm and can be adapted accordingly NOM Initialization based on nominal range Initialization mode for globe valves espe cially for valves with maximum ranges that are clearly greater than the required nomi nal range For this initialization mode the following parameters must be entered pin position Code 4 nominal travel angle Code 5 and if required the direction of action Code 7 The calibrated sensor enables the effective valve travel to be preset very accurately Start up and settings During the initialization procedure the positioner checks whether the control valve can move through
68. er lift the lever so that the follower pin rests on the follower clamp of the actuator stem NAMUR attachment Determine the maximum travel range of the control valve from the closed position to as far it will go in the other direction Select the lever to match the maximum travel range as well the next largest pin position and screw onto the shaft of the positioner Lever option pin distance see table on page 64 or cover plate on the positioner Screw the NAMUR bracket onto the valve yoke so that it is aligned centrally to the slot of the follower plate when the travel position is at 50 Quick start up guide Secure the positioner to the NAMUR bracket making sure that the follower pin is in the slot of the follower plate Make sure the lever can still move Attachment to rotary actuators Lever M pin position 90 Put the valve into the closed position de termine the opening direction Place the follower plate on the slotted ac tuator shaft and fasten it to the coupling wheel Attach the top pair of brackets and the bottom pair of brackets to the actuator Place the positioner on the brackets and screw tight making sure that the lever with its follower pin engages the slot of the coupling wheel while taking into ac count the opening direction It is important to make sure that the le ver s mid position corresponds to the mid travel of the valve lever s mid position the lever is parallel to the long side o
69. essure Re initialize the positioner Under certain circumstances it may be possible to check the maximum travel angle by entering the actual pin position and then performing an initialization under MAX After initialization has been completed the Code 5 indicates the maximum achieved travel or angle 53 time gt The initialization routine lasts too long The positioner returns to its previous operating mode No pressure on the supply line or there is a leak Supply air failure during initialization Remedy Check attachment and supply pressure Re initialize the positioner 70 EB 8384 2 EN Code list 54 Init Solenoid valve 1 A solenoid valve is installed Code 45 YES and was not or not properly connected so that an actuator pressure could not be built up The message appears when you attempt to initialize the positioner 2 If you attempt to initialize the device from fail safe position SAFE Remedy 1 Check connection and supply voltage of the solenoid valve 2 Set the MAN operating mode over Code 0 Then initialize the positioner Re 55 Transit time lt The actuator transit times determined during the initialization are so short that the positioner cannot adapt itself optimally Remedy Check the volume restriction setting as described in section 5 2 re initialize the positioner 56 Pin pos Initialization was canceled becaus
70. f the positioner casing Pneumatic connections Screw the threaded connections only into the attached connection block connect ing plate or pressure gauge block from the accessories 8384 2 57 Quick start up guide 7 2 Start up Connect pneumatic supply air 1 4 to 6 bar Apply an electrical reference variable 4 to 20 mA Set the fail safe position Position the slide switch according to fail safe position of the control valve AIR TO OPEN or AIR TO CLOSE Adapt the volume restriction Q to the actu ator size Only set the restriction for actuators 240 cm to MIN SIDE for connection at the side or MIN BACK for connection at the back Note After each change of the volume restriction setting the positioner must be re initialized Changing the reading direction of the display if necessary Turn Code 2 press e turn Display ok press 58 8384 2 EN Operation Selecting the parameters or values Each parameter has a code number which is shown in the display Use the button to select Turn the button to select parameters or val ues and then push to confirm Select and confirm ESC to prevent an en tered value from being accepted Enabling parameters Parameters that have a code marked with an asterisk can only be changed when they are enabled beforehand using Code 3 The configuration mode is shown in the dis play with the gt symbol
71. for connection to signal converter acc to EN 60947 5 6 All other versions also for connection to binary input of the PLC acc to EN 61131 Pmax 400 mW Only for connection to signal converter acc to EN 60 957 5 6 Solenoid valve SIL 4 approval acc to IEC 61508 24 V DC reverse polarity protection static destruction limit 40 V Input Current consumption Dee corresponding to 4 5 mA at 24 V 4020W Signal Signal 0 no pick up lt 15 V Signal 1 safe pick up gt 19 V Service life gt 2 x 107 switching cycles Implementation in safety relevant systems in compliance with IEC 61508 Probability of failure on demand of safety functions PFD 2 8 x 107 for a confidence level of 95 The safe failure fraction SFF according to Table in IEC 61508 2 is greater equal to 0 99 The valves are therefore suitable for implementation in safety related systems with a hardware fault tolerance of 1 or 2 up to and including SIL 4 8384 2 EN 11 Design and principle of operation Amele positon Two wire transmitter transmitter Supply voltage 12 to 30 V DC reverse polarity protection static destruction limit 40 V Output signal 4 to 20 mA Direction of action Reversible Operating range O to 100 of the travel range optional also for fault indication over 2 4 or 21 6 mA Characteristic Linear Hysteresis and HF influence Same as positioner
72. g 4 on the left pointing towards the signal pressure connection Make sure that the bonded gasket 14 points towards the actuator yoke 3 For actuators with 700 cm2 remove the follower pin 2 at lever M 1 on the back of the positioner from pin position 35 reposition it in the bore for pin posi tion 50 and screw tight For actuators 240 and 350 cm with 15 mm travel the follower pin 2 re mains in pin position 35 4 Insert formed seal 15 in the groove of the positioner casing 5 Place positioner on the cover plate in such a manner that the follower pin 2 18 8384 2 EN rests on the top of the follower clamp 3 Adjust the lever 1 correspondingly and open the positioner cover to hold the positioner shaft in position at the cap or the switch Fig 16 The lever 1 must rest on the follower clamp with spring force Mount the positioner on the cover plate 10 using the two fixing screws Make sure that the tip of the gasket 16 projecting from the side of the connec tion block 12 is positioned above the actuator symbol that corresponds with the actuator with fail safe action Actua tor stem extends or Actuator stem re tracts If necessary remove the three fixing screws and the cover Then repo sition the gasket 16 turned by 180 The previous version of the connection block Fig 4 bottom requires the switch plate 13 to be turned such that the cor responding actuator symbol points
73. imit change value only if necessary 2 B 7 Default 7 1 Default OFF gt Turn Code 17 Retain default Proceed as follows only if known Press turn Select press 3738 e Default 2 Turn Code 18 Retain default change only if known d Default CCL See Code 34 press turn Select closing direction Start up and settings counterclockwise and CL clockwise Direction of rotation which causes the valve to move to the CLOSED position view onto the rotary switch movement while positioner cover is open Press 2 35 mes Default 0 0 SU gt Turn Code 35 press turn Enter blocking position e g 5 mm read off at travel indicator scale of the blocked valve or measure with a ruler Press Set switch for fail safe position AIR OPEN or AIR TO CLOSE as described in section 5 1 on page 42 Set volume restriction as described in section 5 2 on page 43 Press INIT key The positioner switches to manual operation 2 35 The adjusted blocking posi an mm tion is indicated As initialization has not been carried out completely the error code 76 no emer 8384 2 51 Start up and settings gency mode and
74. ing both its hexagon screws 22 8384 2 EN Attachment to the control valve mounting parts and accessories 1 Lever 1 1 Nut 1 2 Disk spring 2 Follower pin 3 Clamp 6 Connecting clamp 6 1 Seal rings 7 Pressure gauge bracket 8 Pressure gauge mounting kit 10 Bracket 11 Screw Important Always use the connecting plate 6 included in the accessories to connect supply and output Never screw threaded parts directly into the housing Fig 6 Attachment to Type 3510 Micro flow Valve EB 8384 2 23 Attachment to the control valve mounting parts and accessories 2 4 Attachment to rotary actuators The positioner is mounted to the rotary actu ator using two pairs of double brackets Refer to Table 4 on page 15 for the required mounting parts as well as the accessories with their order numbers Prior to the attachment of the positioner to the SAMSON Type 3278 Rotary Actuator you have to mount the associated adapter 5 to the free end of the rotary actuator shaft Note During the installation of the positioner as described below it is imperative that the ac tuator s direction of rotation be observed 1 Place follower clamp 3 on the slotted actuator shaft or the adapter 5 2 Place coupling wheel 4 with flat side facing the actuator on the follower clamp 3 Refer to Fig 8 to align slot so that it matches the
75. ing the positioner Remedy Interrupt current and restart positioner Otherwise return the positioner to SAMSON AG for repair 78 Options parameter Errors in options parameters e g due to EMC disturbances Remedy Return the positioner to SAMSON AG for repair 74 8384 2 EN 12 Dimensions in mm bracket Pressure gauge or connecting plate 210 VDI VDE 3845 for all sizes of fixing level 2 Connecting plate 2 NPI Attachment to rotary actuators co 4 ib N i Direct attachment NAMUR attachment position sensor Lever mm S 17 M 50 L 100 XL 200 gt N N M20 x 1 5 External Output 38 Supply 9 Output AT Reversing amplifier Outout A2 option P 8384 2 75 Giomupsunbag 01 186 4 COL eajsopung oupsiuoo tpstjexis ud atpsiuupa tpstjosisud jo oncuddo Jod ayy Sanba 10 soap pepnput ejnpeus saBupup sii eq 15244495 eddy 23 B19 28 nup seio juo addy 53
76. ion changes to increasing decreasing 7N a globe valve closes as the mA signal increases 8 Lower x range value Lower range value for the travel angle of rotation in the nominal 0 0 to 80 0 0 0 of the nominal range Specified in mm or angle provided Code 4 is set ESC or operating range The operating range is the actual travel angle of the control valve and is limited by the lower x range value Code 8 and the upper x range value Code 9 Usually the operating range and the nominal range are iden tical The nominal range can be limited to the operating range by the lower and upper x range values Value is displayed or must be entered The characteristic is adapted See also the example in Code 9 9 Upper x range value 20 0 to 100 0 100 0 nominal range Specified in mm or angle provided Code 4 is set ESC Upper range travel angle of rotation in the nominal or operating range Value is displayed or must be entered The characteristic is adapted Example The operating range is modified for example to limit the range of a control valve which has been sized too large For this function the entire resolution range of the reference variable is converted to the new limits on the display corresponds to the set lower limit and 100 to the set upper limit 8384 2 EN 63 Code list Pin position table Pin position Standard Adjustment range Code 4 Code 5 Code 5
77. ith the closing po sition of the valve e g with soft sealed plugs it may become necessary to recalibrate the zero point Enable configuration 2 3 Default OFF Turn Code 3 press turn 69 gt ON press After enabling Code 6 press amp turn ZP press Press INIT key Default MAX Zero calibration is started the positioner moves the control valve to the CLOSED posi tion and readjusts the internal electrical zero point The valve briefly moves from the cur rent travel angle of rotation position to the closed position EB 8384 2 53 Adjusting the limit switch 5 9 Reset to default values This function resets all parameters to the fac tory default values see list of codes in sec tion 11 Enable configuration a 3 MIN Default OFF gt Code 3 press turn gt ON press After enabling G 36 LINI Default OFF Code 36 press turn gt RUN press All parameters are reset and can recon figured 54 EB 8384 2 EN 6 _ Adjusting the limit switch The positioner version with inductive limit switch has one adjustable tag 1 mounted on the shaft which operates the proximity switch 3 For operation of the inductive limit switch the corresponding swit
78. ize Serial interface The positioner is equipped with an interface to allow the SAMSON TROVIS VIEW Con figuration and Operator Interface software to transmit data and parameters over an adapter cable from the RS 232 interface of a computer to the positioner 1 1 Additional equipment As an option the device can be additionally equipped with a solenoid valve for forced venting an analog position transmitter an inductive limit switch or an external position sensor Version with solenoid valve If the operating voltage for the solenoid valve 12 fails the supply pressure for the i p module is vented to the atmosphere The positioner can no longer operate and the control valve moves to the fail safe position determined by the actuator independent of the reference variable Design and principle of operation Positioner with position transmitter The position transmitter 13 is a two wire transmitter and issues the travel sensor sig nal as a 4 to 20 mA signal processed by the microcontroller Since this signal is issued independent of the positioner s input signal min current 3 8 mA the actual travel angle of rotation is controlled in real time Additionally the position transmitter provides the possibility of signaling a positioner fault over a signal current of lt 2 4 mA or gt 21 6 mA Control valve Travel sensor PD controller A D converter Microcontroller Serial 20 1
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80. listed in Tables 6 and 7 on page 33 1 Place the lever 1 in mid position and hold it in place Unscrew the nut 1 1 and remove the standard attached lever M 1 together with the disk spring 1 2 from the sensor shaft 2 Screw the position sensor 20 onto the bracket 21 3 Select the lever S 1 from the accesso ries and screw the follower pin 2 into the hole for pin position 17 Place the lever 1 and disk spring 1 2 on the sensor shaft Place the lever 1 in mid position and hold it in place Screw on the nut 1 1 Place the follower clamp 3 on the stem connector align it at a right angle and screw tight Position the bracket 21 with the posi tion sensor on the valve yoke and screw tight making sure the follower pin 2 slides into the groove of the follower clamp 3 1 Lever 1 1 Nut 1 2 Disk spring 2 Follower pin 3 Follower clamp 20 Position sensor 21 Bracket Fig 13 Mounting a micro flow valve EB 8384 2 31 Attachment to the control valve mounting parts and accessories 2 6 4 Mounting the position sensor 4 to rotary actuators For the required mounting parts as well as the accessories refer to the order numbers listed in Tables 6 and 7 on page 33 Place the lever 1 and disk spring 1 2 on the sensor shaft Place the lever 1 in mid position and hold it in place Screw on the nut 1
81. n the pin position 35 deliv ered state 7 5 mm travel Remove the follower pin 2 from the pin position 35 reposition it in the bore for pin position 25 and screw tight Insert formed seal 15 in the groove of the positioner casing Place positioner on the cover plate 10 in such a manner that the follower pin 2 rests on the top of the follower clamp 3 Adjust the lever 1 correspondingly and open the positioner cover to hold the positioner shaft in position at the cap or the switch Fig 16 The lever 1 must rest on the follower clamp with spring force Mount the positioner on the cover plate 10 using the two fixing screws During the installation make sure that the seal ring 10 1 is inserted in the bore of the intermediate plate Mount cover 11 on the other side Make sure that the vent plug points downwards when the control valve is in stalled to allow any condensed water that collects to drain off Attachment to the control valve mounting parts and accessories Lever Nut Disk spring Symbols b Switchover plate 9 52 Actuator stem 1221 extends DH Y Follower pin Follower clamp Vent plug Stopper Attachment left Attachment right ff Connecting plate Actuator stem mE a retracts 3 P v Seal rings v v Signal pressure input for left Signal pressure Switchover plate attachment Marking input for right for actuator attachment
82. nding conductor Should this be required however this conductor can be connected inside the device Depending on the version the positioner is equipped with inductive limit switches and or a solenoid valve The position transmitter is operated on a two wire circuit The usual supply voltage is 24 V DC Considering the resistance of the supply leads the voltage at the position transmitter terminals can be between 12 and 30 V DC Refer to Fig 15 or the label on the terminal strip for terminal assignment Note The minimum permissible reference variable should not fall below 3 8 mA for operating the positioner Accessories Plastic cable gland M20 x 1 5 Black Order no 1400 6985 Blue Order no 1400 6986 Nickel plated brass Order no 1890 4875 Adapter M20 x 1 5 to Vo NPT Aluminum powder coated Order no 0310 2149 Connection for version with external posi tion sensor The terminal assignment is fixed by the con nector of the connecting lead Connections Shorten the connecting lead to the re quired length and strip the insulation off Route the strands to the following con tacts of the free connector Contact Cable color 1 Brown 2 White 3 Blue 4 Black shielding 5 Green yellow Connect the fixed M12x1 plug connector to the position sensor and the mounted connector to the positioner unit 3 2 1 Switching amplifiers For operation of the limit switches switching amplifiers must be connected in the output
83. nge of the Ty step has no effect on the system deviation ESC 19 Tolerance band Used for error monitoring 0 1 to 10 0 5 of the operating range Determination of the tolerance band in relation to the operating range ESC Associated lag time 30 s is a reset criterion If during initialization a transit time is determined which is 6 times 30 s the fold transit time is accepted as lag time 20 Characteristic Select the characteristic 0 to 9 0 0 Linear 5 Rotary plug valve linear ESC 1 Equal percentage 6 Rotary plug valve eq perc 2 Reverse equal percentage 7 Segmented ball valve linear 3 Butterfly valve linear 8 Segmented ball valve eq p 4 Butterfly valve eq percentage 9 User defined Definition over SAMSON TROVIS VIEW software 21 w ramp Open The time required to pass through the operating range when the O to 240 s 0 ESC valve opens Limitation of the transit time Code 21 and 22 For some applications it is recommendable to limit the transit time of the actuator to prevent it from engaging too fast in the running process 222 w ramp Closed The time required to pass through the operating range when the valve closes 23 O to 240 s 0 ESC Total valve travel O to 9999 0 subsequently 10E3 99E7 RES ESC Totaled double valve travel Can be reset to O via RES 24 LV total valve travel 1000 to 9999 100 000 subsequently 10E3 99E7ESC Limit
84. ngeable Direct attachment Mounting parts for actuators with 240 350 and 700 cm see Fig 11 right 1400 7471 NAMUR attachment Mounting parts for attachment to NAMUR rib w lever Land XL see Fig 12 1400 7468 a n Mounting parts for Type 3510 Micro flow Valve see Fig 13 1400 7469 micro flow valves Attachment to rotary Mounting parts with follower clamp and coupling wheel see Fig 14 1400 7473 actuators Table 7 Postioner accessories Order no Connecting plate 6 ou 1409 7401 eee Va NPT 1400 7462 Vs 1400 7458 Accessories or pressure gauge bracket 7 gt 1400 7459 St steel B 1400 6950 Pressure gauge mounting kit 8 output and supply Mis 1400 8951 EB 8384 2EN 33 Connections 3 Connections 3 1 Pneumatic connections Caution The threads in the positioner housing are not designed for direct air connection The screw glands must be screwed into the connecting plate the pressure gauge mount ing block or the connection block from the accessories The air connections are option ally designed as a bore with thread The customary fittings for metal and copper pipes or plastic hoses can be used Note The supply air must be dry and free from oil and dust The maintenance instructions for upstream pressure reducing stations must be observed Blow through all air tubes and hoses thor oughly prior to connecting them If
85. ns d Seat diameter cm Ap Differential pressure across the valve bar Actuator diaphragm area cm2 Upper bench range of the actuator bar If there are no specifications calculate as follows Required supply pressure Upper bench range value 1 bar Note The signal pressure at the output Out put 38 of the positioner can be limited to 1 4 2 4 or 3 7 bar over Code 16 or the pressure limit can be deactivated MAX 8384 2 35 Connections 3 2 Electrical connections For electrical installation you are quired to observe the relevant elec trotechnical regulations and the acci dent prevention regulations that ap ply in the country of use Ih Germa ny these are the VDE regulations and the accident prevention regula tions of the employers liability insu rance association The following standards apply for in stallation in hazardous areas EN 60079 14 2003 VDE 0165 Part 1 Electrical apparatus for ex plosive gas atmospheres and EN 50281 1 2 1999 VDE 0165 Part 2 Electrical apparatus for use in the presence of combustible dust For the interconnection of intrinsical ly safe electrical equipment the per missible maximum values specified in the EC type examination certifica te apply U or Up I or l P or Po C or and Lo For EEx nA equipment non sparking apparatus the standard EN 50021 1999 specifies that connecting inter
86. ortant 15 Always use the connecting plate 6 included in the accessories to connect 16 Bracket supply and output Never screw threaded parts directly into the housing Fig 5 Attachment according to IEC 60534 6 NAMUR EB 8384 2 21 Attachment to the control valve mounting parts and accessories 2 3 Attachment to Type 3510 Micro flow Valve The positioner is attached to the valve yoke using a bracket Refer to Table 3 on page 14 for the required mounting parts as well as the accessories with their order numbers Note the travel table on page 13 1 Place clamp 3 on the valve stem con nector align at a right angle and screw tight 2 Screw bracket 10 to the valve yoke us ing two screws 11 3 Mount connecting plate 6 or pressure gauge bracket 7 with pressure gauges to the positioner making sure both seal rings 6 1 are seated properly 4 Unscrew the standard installed lever M 1 induding follower pin 2 from the positioner shaft 5 Take lever S 1 and screw follower pin 2 in the bore for pin position 17 6 Place lever S on the positioner shaft and screw tight using the disk spring 1 2 and nut 1 1 Move lever once all the way as far as it will go in both directions 7 Place positioner on the bracket 10 in such a manner that the follower pin slides into the groove of the clamp 3 Adjust the lever 1 correspondingly Screw the positioner to the bracket 10 us
87. osition 60 and 120 with e 7 5 3 6 17 6 S 17 120 VES 5 0 17 6 M 25 Antrieb 120 240 350 15 7 5 35 4 M 35 Typ 3271 700 1400 2800 15 and 30 30 10 50 M 50 1400 2800 60 14 0 70 8 L 70 1400 2800 60 20 0 100 L 100 2800 120 40 0 200 XL 200 Rotary actuators Opening angle 24 to 100 M 90 EB 8384 2EN 13 Attachment to the control valve mounting parts and accessories Table 1 Direct attachment to Type 3277 5 Actuator Order no Mounting parts For actuators with 120 cm effective diaphragm area 1400 7452 Switchover plate old for Actuator Type 3277 5xxxxxx 00 old 1400 6819 Switchover plate new for Actuator Type 3277 5xxxxxx 01 new 1400 6822 Accessories Connecting plate for additional attachment of a solenoid valve G 1 8 1400 6820 for the Connecting plate old for Actuator Type 3277 5xxxxxx 00 old 1 8 NPT 1400 6821 Connecting plate new for Actuator Type 3277 5xxxxxx 01 new 1400 6823 Old and new plates are not interchangeable Note Only new switchover and connecting plates can be used with new actuators Index 01 Accessories Connecting plate 6 1400 7461 V4 NPT 1400 7462 for the or pressure gauge bracket 7 G V4 1400 7458 Va 1400 7459 Pressure gauge mounting kit 8 output supply St st Bs 1400 6950 St st St st 1400 6951 Table 2 Direct attachment to Type 3277 Actuator Accessories Mounting parts for actuators with 240 350 and
88. ositioner to the way it is attached to the valve 8384 2 EN Initialization 5 5 During initialization the positioner adapts it self optimally to the friction conditions and the signal pressure demand of the control valve The type and extent of self adaptation de pends on the set initialization mode see section 5 5 1 MAX is the default setting for initialization based on the maximum nominal range If configuration is enabled via Code 3 Code 6 can be used to change to other initializa tion modes If the positioner has been initialized once al ready it will automatically go to the operat ing mode used last after the electrical refer ence variable is applied Code 0 appears on the display On initializing the positioner for the first time the hand symbol appears on the display Start up and settings Note Every time you re initialize the positioner it should be reset to its basic setting including the default values Refer to section 5 9 on page 50 The initialization process can be started by pressing the INIT key with a suitable tool Note The time required for the initialization pro cedure depends on the running time of the actuator and can take a few minutes Warning During the initialization the control valve moves through its entire tra vel angle of rotation range Therefo re do not start initialization while a process is running but only during start up
89. position Remedy Reset over Code 36 Re initialize the positioner Hardware error indicated by the fau lt symbol on the display 62 x signal Additional message at the fault alarm contact Determination of the measured value for the actuator has failed Conductive plastic element is defective The positioner continues to run in emergency mode but should be replaced as soon as possible The emergency mode on the display is indicated by a blinking control symbol and 4 dashes instead of the position indication Note on the control If the measuring system has failed the positioner is still in a reli able state The positioner switches to emergency mode where the position cannot be accurately controlled anymore However the positioner continues operation according to its reference variable signal so that the process remains in a safe state Remedy Return the positioner to SAMSON AG for repair 63 w too small The reference variable is much smaller than 4 mA 0 occurs if the power source that drives the positioner does not comply with the standard This state is indicated on the positioner display by a blinking LOW Remedy Check reference variable If necessary limit the current source downwards so that no values below 4 mA can be issued 64 i p converter y The circuit of the i p converter has been interrupted Remedy Cannot be remedied Return the positioner
90. possibly also error code 57 may appear on the display These indications do not influence the positioner s readiness for operation Canceling the blocking position For the positioner to follow its reference variable again the blocking position must be canceled and the positioner must be set to automatic operation AUIO as follows Press Code I press turn in order to move valve slightly past the blocking position then cancel me chanical blocking Press Turn Code 0 press amp Code 0 blinks Turn until AUIO appears on the display Press to confirm the operating mode The positioner switches to automatic opera tion The current valve position is indicated in Note If the positioner shows a tendency to oscil late in automatic operating mode the pa rameters Kp and Ty must be slightly cor rected Proceed as follows Set Ty to 4 Code 18 If the positioner still oscillates the gain Kp Code 17 must be decreased until the positioner shows a stable behavior 52 8384 2 EN Zero point correction Finally if process operations allow it the zero point must be adjusted according to section 5 8 on page 53 Caution The positioner automatically moves to zero point 5 6 Start up via local interface SSP The positioner must be supplied with at least 4 mA The positioner can be connected directly to the PC via the local serial interface and the se
91. re closes the valve for fail safe position actuator stem retracts valve open The switch position is prompted prior to an initialization After an initialization has been completed changing the switch position does not have any effect on the operation of the positioner 5 2 Setting the volume restriction Q For actuators smaller than 240 cm with a loading pressure connection at the side Type 3271 5 set restriction to MIN SIDE For a connection at the back Type 3277 5 set restriction to MIN BACK For actuators 240 cm and larger set to MAX SIDE for a side connection and to MAX BACK for a connection at the back Note The positioner must re initialized if the volume restriction setting is changed after the positioner has already been initialized Adapting the display The data representation on the positioner display can be turned by 180 If the displayed data appear upside down proceed as follows E e Reading direction for right attachment of pneumatic connections Reading direction for left attachment of pneumatic connections 239 Turn the button until Code 2 appears and press the button to confirm Code 2 Code 2 blinks e Start up and settings Turn button until the display is ad justed to the desired direction then con firm reading direction by pressing the button 5 3 Limiting the signal pressure If the maximum actuator forc
92. rial interface adapter Order no 1400 7700 Use the TROVIS VIEW software with 3730 2 device module installed All device parameters can be accessed via the software For start up and settings proceed as de scribed in section 5 Note Depending on the firmware installed in the positioner a certain minimum version of the TROVIS VIEW device module is required for communication IF you have already installed the software you can download updates at www samson de Support amp Downloads TROVIS VIEW Updates 5 7 Faults In case of a fault the fault symbol ap pears at the top of the display in the left hand corner Additionally for some faults a signal is issued via the fault alarm contact see error code list To access the error codes turn but ton past the Code 50 Err appears on the display with the respec tive error code For the cause of the fault and its remedy re fer to the codes listed in section 11 es 56 Display indicating an error code S After an error code has occurred you should first try to confirm it as follows Enable configuration Turn 9 Code 3 press turn gt ON press Turn until the error code number ap pears then press to confirm it Should the error occur again read the rem edy instructions in the error code list Start up and settings 5 8 Zero calibration In case of discrepancies w
93. see section 4 3 1 the lever position in degrees in relation to the longitudinal axis is indi cated instead of the system deviation One bar graph element corresponds to approxi mately a 5 angle of rotation If the fifth element blinks value displayed gt 30 the permissible angle of rotation has been exceeded Lever and pin position must be checked Operation Displays and their meaning Initialization in progress Zero calibration Increasing increasing Increasing decreasing Blinking Controlled operation Blinking Not initialized AUIO Automatic mode MAX Maximum range TunE CL Clockwise NO Not available YES Available CCL Counterclockwise Nominal travel ZP Err Error ON ON ESC Escape OFF OFF an HI ix greater than 21 6 mA RES Reset as LO ix smaller than 2 4 m RUN Start LOW low SAFE _Fail safe position G MAN Manual mode Sub Substitute calibration 2 Fault Manual operation Control operation Code s T Designation I 2 65 8 B Bar graph for a system deviation Position or lever position Parameter E Units Limit switch Alarm 1 Limit switch Alarm 2 2 2 Limit value of total Fail safe position enabled travel exceeded active Initialization key Cap or rotary switch Metal tag of proximity switch 4 off Xo z BIS zos 59 16 S 2 88 ji Ja 88
94. standard attached lever M with the fol Make sure that the vent plug points lower pin 2 at position 35 is designed for downwards when the control valve is in 120 240 and 350 cm actuators with stalled to allow any condensed water 15 mm rated travel that collects to drain off 2021 1 1 1 2 14 1 3 14 9 1 9 1 Lever 1 1 Nut 1 2 Disk spring 2 Follower pin _ 3 Follower plate 9 Stem connector e cS 91 Bracket 14 Bolt 14 1 Screws 20 Position sensor 21 Bracket Fig 12 Mounting according to IEC 60534 6 NAMUR 30 EB 8384 2 EN Attachment to the control valve mounting parts and accessories For other actuator sizes or travels select the lever and pin position from the travel table on page 13 Lever L and XL are included in the mounting kit 3 Place the lever 1 and disk spring 1 2 on the sensor shaft Place the lever 1 in mid position and hold it in place Screw on the nut 1 1 4 Screw both bolts 14 to the bracket 9 1 of the stem connector 9 Attach the follower plate 3 and fix with the screws 14 1 5 Place the bracket with the sensor at the NAMUR rib in such a manner that the follower pin 2 rests in the slot of the fol lower plate 3 then screw the bracket using its fixing screws onto the valve 2 6 3 Mounting the position sensor to Type 3510 Micro flow Valve For the required mounting parts as well as the accessories refer to the order numbers
95. switches alarm A1 and A2 in addition Reading direction to the fault alarm contact A3 Standard Turned If the test is activated the respective limit switches five times OFF OFF RUN1 1 RUN Software limit switch A1 RUN 1 1 RUN RUN2 2 RUN Software limit switch A2 RUN 2 2 RUN RUN3 3 RUN Fault alarm contact A3 RUN 3 3 RUN ESC ESC 8384 2 67 Code list 29 Position transmitter x ix 3 AN ESC Operating direction of the position transmitter indicates how the travel angle position is assigned to the output signal i based on the 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 a positioner has not been initialized reference variable less than 3 6 mA the power consumption of the feedback signal is effective current approx 1 8 mA When YES is set in Code 32 the position transmitter issues the value as per Code 30 during initialization or zero calibration When NO is set in Code 32 4 mA is issued during a running self adaptation 30 Fault alarm ix OFF HI LO ESC Used to select whether faults causing the fault alarm contact to switch should also be signaled through the position transmitter output and how they should be signaled HI ix gt 21 6 mA LO ix lt 2 4 mA 31 Position transmitter test 10 0 to 110 0 x before the
96. t up and settings known it is recommended to accept its Kp and values After setting the AIR TO OPEN CLOSE switch for the fail safe position setting the volume restriction and pressing the INIT key the positioner calculates its configuration data on the basis of the blocking position and the closing direction as well as the other entered data The positioner switches to manual operation subsequently the blocking position should be canceled as described on page 52 Enable configuration A 3 MN gt Default OFF Code press e turn gt ON press After enabling 35 Turn Code 4 press press Select pin position entered dur ing installation press Default OFF gt 50 8384 2 EN 2 5 I50 Default 15 Turn Code 5 press turn Enter nominal travel angle press Zug ade gt Turn Code 6 press 69 turn Sub press Bo Default gt Default Code 7 press turn e Retain direction of action select AN Press N DEF Turn Code 11 press turn Deactivate travel limit press Default 100 0 2 OF F gt Turn Code 16 Retain default value for pressure l
97. ted Set Code 15 final position w gt to 99 for three way valves Further settings relevant for the valve can be entered subsequently 5 5 1 Initialization modes After enabling configuration with Code 3 and accessing Code 6 you can choose one of the initialization modes MAX NOM MAN or SUb to start initialization ZP the zero calibration is described in sec tion 5 8 on page 53 Initialization based on maximum range Initialization mode for simplified start up The positioner determines travel angle of rotation of the closing member from the CLOSED position to the opposite side and 46 8384 2 EN adopts this travel angle of rotation as the operating range from 0 to 100 For control valves whose maximum range exceeds the effective travel angle of rotation range nominal range you should reduce the operating range maximum range sub sequently to the required nominal range with Code 9 upper x range value to reach optimum control results Enable configuration MN LI IN Default OFF Code 3 press Tun gt ON press After enabling 2 b M V 1 IH gt Turn 69 Code 6 press gt MAX press Press INIT key to start initialization Default MAX The initialization procedure may take several minutes depending on the actuator size as the valve moves through its entire trav
98. that the travel angle of rotation can be checked The permissible range has been ex ceeded when the displayed angle is higher than 30 and the outer right or left bar graph element blinks If this is the case it is absolutely neces sary to check lever and pin position as described in section 2 5 Initialize positioner as described in sec tion 5 5 Simplified start up For most applications the positioner with its default settings is ready for operation provided it has been properly attached After the fail safe position and the volume restriction have been set the positioner only needs to be initialized by pressing the INIT key Caution Prior to starting the initialization procedure check the maximum permissible supply pressure of the control valve to prevent the valve from being damaged On initialization the positioner supplies the maximum available supply pressure If necessary restrict the signal pressure by using a pressure reducing valve upstream of the control valve Initialization is run in default mode MAX section 5 5 1 During this process the positioner adapts itself optimally to the maximum travel angle of rotation range The only parameter that must be checked is the direction of action i e whether the default setting Code 7 to increasing increasing matches the application or whether it must be changed The initialization modes described in following serve to individually adapt and optimize the p
99. the indicated nominal range travel or angle without collision In case of a positive result the indicated nominal range is adopted with the limits of lower x range and upper x range values as the operating range Note The maximum possible travel must always be greater than the nominal travel entered If this is not the case the initialization is interrupted error indication Code 52 be cause the nominal travel is not achieved Enable configuration 2 3 Default OFF Turn Code 3 press turn gt ON press After enabling PEE 35 Turn Code 4 press turn Select pin position entered dur ing installation press e Default OFF gt 8384 2 47 Start up and settings a Mn Default 15 150 Code 5 press turn amp Enter nominal valve travel press 2 b Default SEEN o N 1 Code 6 press turn NOM press Press INIT key to start initialization The initialization procedure may take several minutes depending on the actuator size as the valve moves through its entire travel angle of ro tation range 48 8384 2 EN MAN Initialization based on nominal range with default upper x range value by means of manual adjustment Initialization mode just
100. the positioner is attached directly to the Type 3277 Actuator the connection of the positioner s output pressure to the actuator is fixed For attachment according to IEC 60534 6 NAMUR the signal pressure can be routed to either the top or bottom di aphragm chamber of the actuator depend ing on the actuator s fail safe action Actua tor stem extends or Actuator stem re tracts For rotary actuators the manufacturer s specifications for connection apply 34 8384 2 EN 3 1 1 Signal pressure gauges To monitor the supply air Supply and sig nal pressure Output we recommend that pressure gauges be attached see accesso ries in Tables 1 to 5 3 1 2 Supply pressure The required supply air pressure depends on the bench range and the actuator s oper ating direction fail safe action The bench range is registered on the name plate either as spring range or signal pres sure range depending on the actuator die The direction of action is marked FA or FE or by a symbol Actuator stem extends FA Air to open ATO Fail safe position Valve Closed for globe and angle valves Required supply pressure Upper bench range value 0 2 bar minimum 1 4 bar Actuator stem retracts FE Air to close ATC Fail safe position Valve Open for globe and angle valves For tight closing valves the maximum signal pressure pstmax is roughly estimated as fol lows d n Ap pstmax F Connectio
101. tialization in the MAX NOM or MAN mode section 5 5 1 the positioner is in the automatic control operation mode 2 0 255 Standard Operation Switching to manual operating mode Over Code 0 press the 69 button appears in the display Code 0 blinks Turn button until MAN appears am am me Mm UCU Press amp button to confirm the hand symbol appears and then the current position in MONI Turn button until Code 1 appears 3 2 i 255 255 Press button to confirm Code 1 blinks The positioner is in the manual operating mode 7 The switchover is smooth since the manual operating mode starts up with the set point last used during automatic operating mode The required valve position can be adjusted by turning the 9 button Note Switching from manual to automatic operat ing mode works in the same manner First you must reset the positioner to Code 0 and set it to automatic mode AUIO and con firm 8384 2 41 Start up and settings 4 3 2 SAFE Fail safe position If you want to move the valve to fail safe po sition proceed as follows Select Code 0 press the button AUIO or MAN appears on the display Code 0 blinks Turn the button until SAFE appears CE ik SRFE Press the button to confirm this setting
102. ting an inductive limit switch 2 222 2222 20 60 Maintenance 61 Servicing explosion protected 5 61 Code ee eae E 62 Dimensions in mm 75 Test certificates 76 8384 2EN 3 Safety instructions General safety instructions The positioner may only be assembled started up or operated by trained and experienced personnel familiar with the product According to these mounting and operating instructions 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 relevant standards Explosion protected versions of this positioner may only be operated by personnel who have undergone special training or instructions or who are authorized to work on explosion protected devices in hazardous areas Refer to section 10 on Servicing explosion protected versions Any hazards that could be caused by the process medium the operating pressure the signal pressure or by moving parts of the control valve are to be prevented by means of the appropriate measures If inadmissible motions or forces are produced in the actuator as a result of the supply pressure level it must be restricted by means of a suitable supply pressure reducing station Proper shipping and
103. to 200 mm or 24 to 100 opening angle for rotary actuators Travel range Adjustable within the nominal travel nominal angle max ratio 1 5 Reference variable w Signal range 4 to 20 mA 2 wire unit reverse polarity protection min span 4 mA static destruction limit 100 mA Minimum current 3 6 mA for display 3 8 mA for operation Load impedance Version without explosion protection lt 6 V corresponding to 300 at 20 mA Explosion protected version lt 7 V corresponding to 350 at 20 mA Supply air Supply pressure from 1 4 to 6 bar 20 to 90 psi Air quality acc to ISO 8573 1 Max particle size and density Class 4 Oil content Class 3 pressure dew point Class 3 or at least 10 K beneath the lowest ambient temperature to be expected Signal pressure output O bar up to supply pressure limitable to 1 4 2 4 3 7 0 2 bar via software Characteristic user defined adjustable over operating software Linear equal percentage reverse equal percentage butterfly valve linear butterfly valve eq percentage rotary plug valve linear rotary plug valve eq percen tage segmented ball valve linear segmented ball valve eq percentage Deviation from terminal based conformity 1 Hysteresis 0 3 26 Sensitivity 0 1 76 10 EB 8384 2 EN Design and principle of operation Transit time Separately adjustable up to 240 seconds for supply air and exhaust air
104. to the marking 7 Place the connection block 12 with the associated seal rings against the positioner and the actuator yoke Screw it tight using the fixing screw 12 1 For actuators with fail safe action Actuator stem retracts additionally remove the stopper 12 2 and fit on the external signal pressure piping Mount cover 11 on the other side Make sure that the vent plug points downwards when the control valve is in stalled to allow any condensed water that collects to drain off Attachment to the control valve mounting parts and accessories 1 Lever 12 1 Screw 1 1 Nut 12 2 Stopper or connection for 1 2 Disk spring external piping 2 Follower pin 13 Switch plote 3 Follower clamp 14 Gasket 10 Cover plate 15 Formed seal 11 Cover 16 Gasket 12 Connection block Lever M Il ur Actuator stem retracts extends 13 Connection block old 117 with switch plate 13 Stem retracts Stem extends Marking Fig 4 Direct attachment Signal pressure connection for Type 3277 Actuator with 240 350 and 700 cm EB 8384 2EN 19 Attachment to the control valve mounting parts and accessories 2 2 Attachment according to IEC 60534 6 The positioner is attached to
105. uired supply pressure when added to the pressure at is applied ot output 2 The rule A2 Z applies Mounting 1 Mount the connecting plate 6 from the accessories in Table 5 to the positioner Make sure that both O rings 6 1 are seated correctly 2 Thread the special nuts 1 3 from the accessories of the reversing amplifier into the boreholes of the connecting plate 3 Insert the gasket 1 2 into the recess of the reversing amplifier and push both the hollowed special screws 1 1 into the connecting boreholes A1 and Z 4 Place the reversing amplifier onto the connecting plate 6 and screw tight us ing both the special screws 1 1 5 Use a screwdriver 8 mm wide to screw the enclosed filters 1 6 into the con necting boreholes A1 and Z 26 8384 2 EN Note The sealing plug 1 5 in the Type 3730 Positioner should not be unscrewed out of the reversing amplifier The rubber seal 1 4 is not required and can be removed when the sealing plug is used Signal pressure connections Output leading to the signal pressure connection at the actuator which opens the valve when the pressure increases Aa Output A2 leading to the signal pressure connection at the actuator which closes the valve when the pressure increases Set slide switch on positioner to AIR TO OPEN Attachment to the control valve mounting parts and accessories From the positioner Output 38 S
106. upply 9 e e LI I Er bana gl M lt H E 1 Control signals to 13111214 L5 1 6 1 the actuator A2 1 Reversing amplifer 6 Connecting ring 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 Supply 9 HT SE F Aq Fig 9 Mounting reversing amplifier EB 8384 2 EN 27 Attachment to the control valve mounting parts and accessories 2 6 Attaching an external position sensor Refer to Table on page 33 for a list of the mounting parts as well as the accessories re quired for mounting the position sensor Accessories for the pneumatic connection to the positioner housing can be found in Ta ble 7 In the positioner version with an external position sensor the sensor placed in a sepa rate housing is attached over a plate or bracket to the control valve The travel pick off corresponds to that of a standard device The positioner unit can be mounted as re quired to a wall or a pipe For the pneumatic connection either a con necting pl
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108. value of total valve travel If the limit value is exceeded the fault symbol and the wrench symbol appear Exponential display for 10 000 travel cycles onwards 66 8384 2 EN Code list 25 Alarm mode Switching mode of software limit switches alarm A1 and A2 in 0 to 3 2 responding state when positioner initialized ESC 1 Explosion protected version according to EN 60947 5 6 0 gt 2 1 mA A2 lt 1 2mA 1 1 lt 1 2 2 lt 1 2 mA 2 A12 2 1 mA gt 2 1 mA 3 A1 lt 1 2 gt 2 1 mA 2 Version without explosion protection 0 348 Q A2 Non conducting 1 Non conducting A2 Non conducting 2 R 348 0 A2 348 3 Al Non conducting A2 3480 When positioner has not been initialized the software limit switches 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 switches both switch to lt 1 2 mA signal Ex or non conducting without explosion protection 26 Limit value Al Displaying or changing the software limit value A1 in relation to OFF the operating range 0 0 to 100 0 2 0 of the Setting has no effect when an inductive limit switch has been in operating range stalled ESC 27 Limit value A2 Displaying or changing the software limit value A2 in relation to OFF the operating range 0 0 to 100 0 98 0 of the operating range ESC 28 Alarm Test Testing the software limit
109. vices EB 8384 2EN 61 Code list 11 Code list Code Parameter Display values Dat no default setting escription Important Codes with marked with an asterisk must be enabled with Code 3 prior to configuration 0 Operating mode AUO Automatic mode MAN Manual mode MAN SAFE Fail safe position ESC Escape AUO Switchover from automatic to manual mode is smooth SAFE In fail safe mode the symbol S appears on the display ESC In MAN and AUIO mode the system deviation is represented by the bar graph elements When the positioner is initialized the numerical display indicates the valve position or the angle of rotation in otherwise the po sition of the sensor in relation to the central axis is displayed in degrees 1 Manual w Adjust the manual set point with the rotary pushbutton the 0 to 100 0 current travel angle is displayed in 5 when the positioner is ini of the nominal range tialized otherwise the sensor position in relation to the central axis is indicated in degrees 2 Reading direction The reading direction of the display is turned by 180 Normal or upside down ESC 3 Enable configuration Activates the option to modify data automatically deactivated OFF ON ESC when the rotary pushbutton has not been operated for 120 s 4 Pin position The follower pin must be inserted into the correct pin position ac OFF cording to the valve travel angle of rotation select as per ta

Mounting and Operating Instructions EB 8384-2 EN

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