Mounting and Operating Instructions EB 8384-1 EN
Contents
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3. BE LS 1 Control valve 7 Air capacity booster 2 Travel sensor 8 Pressure regulator 3 controller 9 Flow regulator 4 A D converter 10 Volume restriction 5 Microcontroller 11 Limit switches 6 i p converter 12 Display Fig 2 Functional diagram 8384 1 EN 7 Design and principle of operation Positioner versions Explosion Without protection Applied amp Il 2 EEx ia IIC T6 Il 2 D IP 65 T 80 C acc to ATEX Intrinsically safe CSA FM applied for amp Il 3 G EEx nA nL II T6 13 D IP 65 T 80 C acc to ATEX 8 EB8384 1 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 to a SAMSON Type 3277 Actuator or according to IEC 60534 6 NAMUR 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 travel that can be implemented at the val
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6. 1 La 1 Lever 11 Nut 1 2 Disk spring 2 Follower pin 3 Follower clamp Fig 7 4 Coupling wheel 4 Screw 4 2 Disk spring 4 3 Scale plate 5 Actuator shaft Adapter for Type 3278 61 Seal rings 7 Pressure gauge bracket 8 Pressure gauge mounting kit 10 Top pair of brackets 10 1 Bottom pair of brackets Fig 8 Attachment to rotary actuators Control valve opens clockwise 8384 1 21 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 11 The output signal pressure of the positioner is supplied at the output A of the reversing amplifier An opposing pressure which equals the required supply pressure when added to the pressure at A1 is applied at output 2 The rule A2 Z applies Mounting 1 Mount the connecting plate 6 from the accessories in Table 4 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 special hollow screws 1 1 into the connecting
7. g 1 5 UPS d gen 6 Fig 9 Mounting a reversing amplifier i EB 8384 1 EN 23 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 bore with G 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 the positioner is attached directly to the 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 24 8384 1 EN 3 1 1 Signal pressure gauges To monitor the supply air Supply and sig nal pressure Output we reco
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9. a 33 Code list m Arena a dide SA Ra P 34 Maintenance loaa aaa e 38 Servicing explosion protected 5 38 Dimensions 2 39 Certificates aaa 40 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 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 8 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 appropriate storage are assumed Note The device with a CE marking
10. Travel is not achieved Supply pressure is too low actuator leaks incorrect travel adjusted or pressure limit function activated Remedy Check supply air positioner mounting and setting Re initialize the positioner 36 8384 1 EN Code list E7 Actuator does not move No supply air mounting blocked No input signal or input signal below 3 7 mA Remedy Check supply air positioner mounting and mA input signal Re initialize the positioner E8 Travel signal at lower limit Wrong pin position wrong lever wrong attachment direction when NAMUR attachment is used Remedy Check positioner mounting and re initialize the positioner E9 Travel signal at upper limit Wrong pin position wrong lever wrong attachment direction when NAMUR attachment is used Remedy Check positioner mounting and re initialize the positioner Not assigned E11 Hardware Defective ceramic oscillator positioner continues to run with an in ternal RC oscillator but it should be replaced as soon as possible Remedy Return positioner to SAMSON AG for repair E12 No factory calibration No factory calibration performed memory defective Remedy Return positioner to SAMSON AG for repair E13 Memory fault Fault in the memory management Remedy Return positioner to SAMSON AG for repair E14 Checksum error Data memory defective data memory Remedy
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13. Return positioner to SAMSON AG for repair E15 Checksum error calibration data Data memory defective Remedy Return positioner to SAMSON AG for repair 8384 1 EN 37 Maintenance 7 Maintenance The positioner does not require any mainte nance There are filters with a 100 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 38 8384 1 EN 8 Servicing explosion protected devices If a part of the positioner on which the explo sion protection is based needs to be serviced the positioner must not be put back into op eration until an expert has inspected the de vice according to explosion protection re quirements has issued a certificate stating this or given the device a mark of conformity Inspection by an expert is not required if the manufacturer performs a routine check on the device prior to putting it back into opera tion 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 comply with the safety demands placed on repaired devices Prior to operation they must be tested according to the specifications stipu lated for Repairing explos
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15. 16 first and then the follower plate 3 to the bracket to gether 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 8 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 16 8384 1 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 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 m
16. Valve 8384 1 EN 19 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 11 for the required mounting parts as well as the accessories with their order numbers Prior mounting 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 direction of rotation when the valve is in its closed position 3 Screw coupling wheel and follower clamp tightly onto the actuator shaft us ing the 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 20 EB 8384 1 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
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18. 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 controller compares this actual position to the 4 20 mA DC control signal reference 6 EB8384 1 EN 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 output signal pressure supplied by the booster can be limited to 2 4 bar by activat ing the parameter P9 The volume restriction Q 10 is used to opti mize the positioner by adapting it to the ac tuator size Tight closing function The pneumatic actuator is completely filled with air or vented as soon as the reference variable falls below 1 or exceeds 99 95 see end positions set over parameters P10 and P11 Design and principle of operation n 12 5 MAN NL UN 8882 1
19. 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 screwdriver 8 mm wide to screw the enclosed filters 1 6 into the con necting boreholes A1 and Z 22 8384 1 EN Note The sealing plug 1 5 should not be un screwed 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 A1 Output A1 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 Attachment to the control valve mounting parts and accessories From the positioner Output 38 Supply 9 e gt Control signals lo 1 3 1 1 2 1 4 1 5 6 1 the actuator A2 1 Reversing amplifier 6 Connecting ring 1 1 Special screws 6 1 O rings 1 2 Gasket 6 2 Screws 1 3 Special nuts 6 1 6 6 2 1 4 Rubber seal 0 1 5 Sealing plug 1 6 Filter Fan Ho H Z 2 5 a MI
20. 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 8384 1 3 Technical data Positioner Nominal travel Direct attachment to Type 3277 3 75 to 30 mm Attachment acc to IEC 60534 6 5 200 mm Nominal angle Attachment acc to VDI VDE 3845 24 to 100 Travel range Adjustable within the rated travel nominal angle Reference variable w Signal range 4 to 20 mA split range 4 to 11 9 mA and 12 1 to 20 mA Static destruction limit 100 mA Minimum current 3 7 mA Load impedance 6 V corresponding to 300 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 bar up to supply pressure limitable to approx 2 4 bar via software Characteristic Selection 1 characteristic for globe valves 8 characteristics for opening angle Hysteresis lt 1 Sensitivity lt 0 1 Transit time lt 0 5 s for initialization not permissible adaptation over volume restriction Q Direction of action w x reversible Air consumption st state Independent from supply pressure approx 110 1 A
21. 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 plate 14 Gasket 3 Follower clamp i 15 10 14 10 Cover plate 15 Formed sea 11 Cover 16 Gasket 12 Connection block 1 3 11 ES 16 Actuator stem retracts extends Connection block old 13 with switch plate 13 retracts Actuator stem extends Marking Fig 4 Direct attachment Signal pressure connection for Type 3277 Actuator with 240 350 and 700 8384 1 EN 15 Attachment to the control valve mounting parts and accessories 2 2 Attachment according to IEC 60534 6 The positioner is attached to the control valve with a NAMUR bracket 10 Refer to Table 3 on page 11 for the required mounting parts as well as the accessories with their order numbers Note the travel table on page 9 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 2 For a travel of 60 mm or smaller screw the longer follower plate 3 1 directly to the stem connector 9 For a travel exceeding 60 mm mount the bracket
22. 00 7614 paris and coupling wheel fsi Comflex I 1400 9120 Accessories Connecting plate 1400 7461 V4 1400 7462 or pressure gauge bracket 7 1400 7458 V4 1400 7459 Pressure gauge mounting kit output supply Stainless steel Brass 1400 6950 Stainless steel Stainless steel 1400 6951 Table 5 General accessories Accessories Pneumatic reversing amplifier for double acting Gu 1079 1118 actuators V4 1079 1119 Cable gland M20 x 1 5 Nickel plated brass 1890 4875 Adapter M 20 x 1 5 to NPT aluminum 0310 2149 TT German English standard 1190 7930 m with f parameters English Spanish 1190 8212 EUN English French 1190 8132 EB 8384 1 EN 11 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 10 for the required mounting parts as well as the accessories with their order numbers Note the travel table on page 9 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 switc
23. Electropneumatic Positioner Type 3730 1 Fig 1 Type 3730 1 Mounting and Operating Instructions EB 8384 1 EN Firmware version 2 0x Edition February 2005 Contents Contents 2 EB 8384 1 EN Page Design and principle of operation 6 Attachment to the control valve mounting parts and accessories 9 Directattachment 2 12 Type 3277 5 Actuator 12 3277 2 14 Attachment according to 60534 6 16 Attachment to Type 3510 Micro flow Valve 18 Attachment to rotary actuators 2 a 20 Reversing amplifier for double acting actuators 22 Connections o goce s AO ce E RES 24 Pneumatic connections 24 Signal pressure gauges s 24 Supply 24 Electrical connections 26 s a u 2 Rom 28 Operalor cobirols sn wre ai are OG Bs 28 SMUD ee 29 Setting the volume restriction Q 29 Adopting the display 30 Determining the fail safe position 30 Setting other parameters 30 XUI PASE amp T en en oe ah re ee ee 31 PDT OO BR 32 Zero calibration dece san
24. 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 95 included in the accessories 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 the 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 scole 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 Actuator fla xx Fig 7 Mounting the coupling wheel with Type 3278 Attachment to the control valve mounting parts and accessories Lo Important Always use the connecting plate 6 included in the accessories fo connect supply and output Never screw threaded parts directly into the housing Legends Figs 7 and 8 Slot e
25. Note the travel table on page 9 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 including 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 using both its hexagon screws 18 8384 1 EN Attachment to the control valve mounting parts and accessories 1 Lever 11 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
26. anner 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 N Attachment to NAMUR rib 58 5 3 1 1 Additional bracket for actuators with 2800 cm BEN UM and travel 2 60 mm Vw 14 1 Lever Lever XL and L Nut 1 2 Disk spring 2 Follower pin 3 Follower plate 3 1 Follower plate 6 Connecting plate 6 1 Seal rings 7 Pressure gauge bracket 8 Pressure gauge mounting kit 9 Stem connector 9 1 Bracket 10 NAMUR bracket 11 Screw 14 14 1 Screw Important 15 U bolt Always use the connecting plate 6 included in the accessories to connect ee supply and output Never screw threaded parts directly into the housing Fig 5 Attachment according to IEC 60534 6 NAMUR 8384 1 EN 17 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 11 for the required mounting parts as well as the accessories with their order numbers
27. avel 4 20 mA SRLO SRHI P5 Characteristic Characteristic selection Characteristic 1 for globe valves 1108 Characteristic 1 to 8 with rotary actuators 90 1 1 Linear 5 Butterfly valve linear 2 Equal percentage 6 Butterfly valve eq percentage 3 Rotary plug linear 7 Segmented ball linear 4 Rotary plug eq percentage 8 Segmented ball eq percentage P Reference variable For split range operation SRLO low range 4 to 11 9 mA SRHI high range 12 1 to 20 mA 34 8384 1 EN Code list P7 w x Direction of action of the reference variable w to the travel rotational gt gt lt gt gt gt angle x increasing increasing or increasing decreasing P8 Gain On initializing the positioner the gain is set to the selected value 30 50 P9 Pressure limit The signal pressure can take on the same pressure as the supply air at maximum OFF or in the case that the maximum actuator force can damage the valve the pressure is limited to approx 2 4 bar P10 End position w lt Tight closing function ON OFF w reaches up to 1 towards the final value that causes the valve to close the actuator is immediately completely vented with ATO Air to open or filled with air with ATC Air to close This action always lead to maximum tight closing of the valve P11 End position w gt OFF Tight closing function If w reaches u
28. c to EN 61131 Prax 400 mW max Only for connection to NAMUR signal converter acc to EN 60 957 5 6 8384 1 EN 5 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 y The positioner is designed depending on the corresponding accessories for direct attach ment to Type 3277 Actuators or for attach ment 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 downstream booster as well as the electronic unit with a microcontroller The positioner is fitted with two adjustable software limit switches as standard 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
29. control valve The type and extent of self adaptation de pends on the preset parameters MAX is the default setting for the nominal range Code P4 During the initialization process the positioner determines the travel rotational angle of the closing ele ment from the CLOSED position as far as it will go in the other direction Note For standard operation after the positioner is mounted on the valve and the volume re striction has been set and the fail safe posi tion has been checked over Code P2 start initialization over Code P15 to ensure the optimal functioning of the positioner The positioner works with its standard set tings default settings 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 when all shut off valves are closed Start up Start initialization by activating Code P15 as follows TIT JL INA I BSD Turn until Code P15 appears Press button 6 seconds long 6 5 4 3 2 1 is counted down on the display Initialization has started the display blinks Note The time required for the initialization procedure depends on the actuator transit time and can take a few minutes E After a successful initialization the positioner runs in control operation indi cated by the control symbol and cont
30. e of the positioner casing 14 EB 8384 1 EN Place positioner on the cover plate 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 11 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 Actuator stem extends or Actuator stem retracts If necessary remove the three fixing screws and the cover Then reposition the gasket 16 turned by 180 The previous version of the con nection block Fig 4 bottom requires the switch plate 13 to be turned such that the corresponding actuator symbol points to the marking 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
31. e position of the control valve over Code P2 to ATO Air to open or ATC Air to close Lj rm until Code P2 appears Press to confirm P2 P2 blinks Turn until the required fail safe position appears Press to confirm the setting Default ATO 5 4 Setting other parameters The table below lists all the parameter codes and their default settings If you want to change the default setting of a parameter proceed in the same manner as previously described More details concerning the parameter codes can be found in section 6 Parameter codes The positioner must be re initialized when the setting is changed Default setting PO Display with status indication P9 Pressure limit 2 4 bar OFF Reading direction PIO End position w lt ON pon Fail safe position ATO ATC P11 End position w gt OFF Pin position 35 P12 Limit value Al switching threshold 2 Nominal range MAX P13 Limit value A2 switching threshold 98 P5 Characteristic 1 14 Display of reference variable w P6 Reference variable 4 20 mA P15 INIT Start initialization P7 w x direction of action gt gt P16 ZERO Start zero calibration P8 Gain K 50 30 8384 1 EN 5 5 Initialization During initialization the positioner adapts it self optimally to the friction conditions and the signal pressure demand of the
32. he positioner re initialized to remedy this problem 32 8384 1 EN Reset error codes The error codes EO E8 and can be reset as follows ERR ESL E E t tO ESL OIN Turn button until the error code appears press button ESC appears turn button RST appears press button to reset error The resetting procedure can be canceled by pressing amp button when ESC appears Canceling the fail safe position The fail safe position indicated on the display can be canceled over Code PO When the status indication PO appears on the display Press ESC appears turn 69 RST appears press to reset fail safe position The positioner starts to run again with its original settings Start up 5 7 Zero calibration In case of inconsistencies in the closing posi tion of the valve e g with soft sealed plugs it may necessary to recalibrate zero Start the zero calibration by activating Code P16 as follows TEE P16 O Turn button until Code PI6 appears Press button 6 seconds long 6 5 4 3 2 1 is counted down on the dis play Zero calibration has started the display blinks The positioner moves the control valve to the CLOSED position and recalibrates the inter nal electric zero point When the zero calibration has been suc cessfully completed the positioner returns to contr
33. hover plate with the corresponding symbol for left or right attachment according to the marking view looking onto the switchover plate 1 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 12 EB 8384 1 EN 4 Mount cover plate 10 with narrow side of the cut out opening Fig 3 on the left pointing towards the signal pressure connection Make sure that the bonded gasket 14 points towards the actuator yoke 5 15 mm travel Keep the follower pin 2 at lever M 1 on the back of the positioner in 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 6 Insert formed seal 15 in the groove of the positioner casing 7 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 pos
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35. ion protected de vices 9 Dimensions in mm Dimensions in mm Pressure gauge or connecting plate bracket 210 NAMUR attachment Lever mm S 17 50 100 200 Direct attachment M20 x 1 5 Attachment to rotary actuators VDI VDE 3845 for all sizes of fixing level 2 Connecting plate or 14 U option Reversing amplifier Output A2 8384 1 EN 39 POLLEN Bramyasunnsg 1182 0 001 9ajpsapung ujsunsopung ayastuypaj psyoxisiud Hpisubsopung YpstjpyIsAyg ou Jo posouddy sppuxg sjopouos saBupt Kup pnoy ut paonpoudes eq Ajuo appaia p ad 23 SML prjpAur oap DOs 50102414109 uonpunupxg 2881 53 Bu Bunmu s Japso 9 7005 Indy 61 Biomypsunoug zjnupssuorsojdx3 alayssBunsalzi414107 2 08159 dI AZ II Pub 9151 5 9211 e BuivoJo eut pys jueuirdinbe eut jo 21 8109114189 siu jou ib sjueuieainbe esu yuauidinbs Sii Jo Ajddns pup eu 94 A ddp siy 53 6 76
36. ir delivery Actuator pressurized Actuator vented At Ap 6 bar gt 8 5 m 3 h at Ap 1 4 bar 3 0 m 3 h Kymax 20 0 09 at 6 bar lt 14 0 m 3 h at Ap 1 4 bar 4 5 m 3 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 10 Supply air None Vibration lt 0 25 up to 2000 Hz and 4 acc to IEC 770 Electromagnetic compatibility Complying with requirements specified in EN 61000 6 2 EN 61000 6 3 and NAMUR Recommendation NE 21 Explosion protection 9 Il 2 EEx ia IIC T6 Il 2 D IP 65 T 80 or amp II 3 G EEx nA nL IIC T6 II 3 D IP 65 T 80 Degree of protection IP 65 Materials Die cast aluminum GD AlSi12 acc to DIN 1725 3 2582 chromated and plastic coated External parts Stainless steel 1 4571 and 1 4301 Weight Approx 1 kg B 8384 1 EN Technical data Binary contacts 2 software limit switches with configurable limit values 0 5 steps with reverse polarity protection Signal status No response Response Without explosion protection Conductive 348 0 Non conducting Explosion protected version gt 2 1 mA lt 1 2 Operating voltage For connection to binary input of the PLC ac
37. irectly into the housing Fig 3 Direct attachment Signal pressure connection for Type 3277 5 Actuator with 120 cm 8384 1 EN 13 Attachment to the control valve mounting parts and accessories 2 1 2 Type 3277 Actuator Refer to Table 1 on page 10 for the required mounting parts as well as the accessories with their order numbers Note the travel table on page 9 Actuators with 240 to 700 cm2 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 Fig 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 groov
38. ition at the cap or the switch Fig 11 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 8 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 5 Attachment left Symbols Actuator stem extends right Actuator stem retracts 1 1 1 2 3 4 5 6 6 1 7 8 9 Switchover plate 9 i E Attachment _ Y Signal pressure y input for left Signal attachment Marking input for right attachment 10 10 1 Lever Nut Disk spring Follower pin Follower clamp Vent plug Stopper Connecting plate Seal rings Pressure gauge bracket Press gauge mounting kit Switchover plate f actuator Cover plate Seal ring Cover Gasket Formed seal 1 1 1 2 Cut out of cover Important Always use the connecting plate 6 included in the accessories to connect supply and output Never screw threaded parts d
39. mmend 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 nameplate either as spring range or signal pressure range 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 4 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 pstmox is roughly estimated as fol lows d x Ap Pstmax F Connections d Seat diameter cm Ap Differential pressure across the valve bar Actuator diaphragm 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 Output 38 of the positioner can be limited to approx 2 4 bar by setting the parameter P9 ON 8384 1 25 Connections 3 2 Electrical connections N For electrical installation you are re quired to observe the relevant elec trotechnical regulations and the acci dent p
40. ode list Error codes Zero error With tight closing function w lt set to ON 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 P16 see section 5 7 or select the error code and reset with RST Displayed and INIT values are not identical Parameter codes were changed after the initialization had been com pleted Remedy Select the error code and reset with RST E2 Positioner has not been initialized Remedy Set parameter and initialize the positioner over Code P15 Kp setting Positioner hunts Volume restriction set incorrectly too much gain Remedy Check the volume restriction setting as described in section 5 1 Limit gain Kp over Code 8 Re initialize the positioner Transit time is too fast The transit times of the actuator determined during initialization are so short under 0 5 second that the positioner cannot adapt itself well enough Remedy Check the volume restriction setting as described in section 5 1 Re initialize the positioner E5 Standstill detection is Supply pressure is too low or varies Mounting incorrect not possible Remedy Check supply air and positioner mounting Re initialize the positioner
41. ol operation status indication Canceling zero calibration The zero calibration can be canceled by pressing 49 The positioner then moves to the fail safe position indicated by the display A new zero calibration can be started di rectly afterwards EB 8384 1 EN 33 Code list 6 Code list Code Display values default setting Description Parameter codes The positioner must be re initialized when the setting is changed PO Status indication showing basic information Canceling the fail safe position with RST is possible Reading direction The reading direction of the display is turned by 180 P2 ATO ATC Parameter to adapt the positioner to how the control valve functions ATO Air to open valve CLOSED in fail safe position Air to close valve OPEN in fail safe position P3 Pin position The follower pin must be inserted into the correct pin position 17 25 35 50 70 according to the valve travel angle of rotation select as per travel 100 200 mm 90 tables on page 9 P4 Nominal range The possible adjustment range can selected in stages depending MAX on the selected pin position 17 from 3 75 to 10 6 o amm 2 from 5 3 to 15 0 setting 35 35 from 7 5 21 2 7 5 8 92 10 6 12 6 50 15 0 17 8 21 2 70 from 15 0 to 42 4 100 from 21 2 to 60 0 200 from 42 4 to 120 For 90 Maximum range only if 90 MAX Maximum possible tr
42. on 12 of the standard 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 voltage 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 bonding conductor Should this be required however this conductor can be connected inside the device For operation of the limit switches 3730 11 13 18 Positioners switching amplifiers which comply with EN 60947 5 6 must be connected to termi nals 41 42 and 51 52 in the output circuit If the positioner is to be installed in hazard ous areas the relevant regulations must be observed Refer to Fig 10 for the terminal assignment Note The minimum permissible reference variable should not fall below 3 7 mA Connections Accessories Plastic cable gland M20 x 1 5 Black Order no 1400 6985 Blue Order no 1400 6986 Nickel
43. p to 99 towards the final value that causes the valve to open the actuator is immediately completely filled with air with ATO Air to open or vented with ATC Air to close This action always lead to the valve being completely opened P12 Switching point A1 O to 100 2 Software limit value A1 is displayed or can be changed in relation to the operating range steps of 0 5 P13 Switching point A2 O to 100 98 Software limit value A2 is displayed or can be changed in relation to the operating range steps of 0 5 P14 Display only indicates the reference variable applied in O to 100 corresponding 4 to 20 mA P15 Start The initialization process can be interrupted by pressing the rotary initialization pushbutton The control valve moves to its fail safe position Over parameter code PO the fail safe position can be canceled again and the positioner then starts with the original setting Also after a power supply failure the positioner starts with its orig inal setting P16 Start The zero calibration process can be interrupted by pressing the ro zero calibration tary pushbutton The control valve moves to its fail safe position Over parameter code PO the fail safe position can be canceled again and the positioner then starts with the original setting Also after a power supply failure the positioner starts with its orig inal setting EB 8384 1 EN 35 C
44. plated brass Order no 1890 4875 Adapter M20 x 1 5 to Ya Aluminum powder coated Order no 0310 2149 N 11 12 mA control signal Fig 10 Electrical connections e 2 51 52 41 42 Explosion protected version Connection M switching amplifiers acc to EN 60947 5 6 Version without explosion protection Connection to PLC binary input acc to EN 61131 Limit switches 8384 1 27 4 Operation The positioner is mainly operated with the rotary pushbutton The volume restriction must be set first to adapt the air delivery 4 1 Operator controls Rotary pushbutton Turn the button to select a parameter code PO to P16 and then press it to con firm the parameter code selected If you want to change a parameter value 6 turn the button to select the required valve Then press the button to confirm the value Note Parameter codes that have been changed are first saved in the EEPROM protected against power failure when the display re turns to the status indication mode button to Code PO or wait three minutes until the display returns automatically The parameter code is not saved perma nently as long as symbol appears at the top of the display Note The positioner must be re initialized after the parameter codes P2 P3 P4 and P8 have been changed Limi
45. revention regulations that ap ply in the country of use In 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 Io P or Po C or C and Lo For EEx nA equipment non sparking apparatus the standard EN 50021 1999 specifies that connecting inter 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 26 8384 1 EN Caution The terminal assignment specified in the cer tificate must be adhered to Reversing the assignment of the electrical terminals may cause the explosion protection to become in effective 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 secti
46. rol position in predetermined by the refer ence variable on the display Initialization successfully completed positioner runs in control operation A malfunctioning leads to the process being interrupted The fault symbol appears on the display See section 5 6 for details Canceling initialization The initialization can be canceled by press ing The positioner then moves to the fail safe position indicated by S on the dis play A new initialization can be started directly afterwards EB 8384 1 EN 31 Start up 5 6 Faults On the occurrence of a fault the fault sym bol appears at the bottom of the display By turning the button past Code PO or P16 the respective error code EO to E15 to gether with ERR appear on the display Refer to the code list in section 6 for the cause of the errors and how to remedy them Example If for instance a travel has been entered over Code P4 nominal range which is larger than the maximum valve travel possi ble the initialization process would be inter rupted error code E2 because the rated travel would not have been reached error code E The valve moves to the fail safe position S indicated on the display S zi Display of the fault indicati on P 5 ERR EXC t 6 h The nominal range Code P4 must be changed and t
47. t switch Fail safe position i S Q SERERE 888 O Parameter Control Fault code error operation Fig 11 Operator controls and display Values not yet saved in EEPROM Cap Positioner shaft Actuator symbol Volume restriction Rotary pushbutton 28 8384 1 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 See section 5 1 for more details Display The LC display indicates symbols that are assigned to codes and functions The bar graph indicates the system deviation that depends on the sign and the value One bar graph element appears per 1 system deviation If the positioner is not initialized the lever position in degrees in relation to the longitu dinal axis is indicated instead of the system deviation One bar graph element corre sponds to approximately a 5 angle Ifthe fault symbol appears on the dis play turn the 9 button until ERR appears to view the error code s EO to E15 Refer to section 5 6 for details Start up 5 Start up Warning Do not perform a start up while the process is running On applying supply air and the elec tric control signal the control valve may move through its entire travel range rotational angle range de pending on the setting Connect the supply air Suppl
48. tainl steel St steel 1400 6951 10 EB 8384 1 EN Attachment to the control valve mounting parts and accessories Attachment to NAMUR ribs or control valves with rod type yokes rod diameter 35 mm or smaller m according to IEC 60534 6 see Fig 5 Travel in mm Lever For actuators Order no 75 5 Mara 5 Actuator with 60 120 cm on Type 3510 Valve see 1400 7457 519 50 En Actuators from other manufacturers and Type 3271 with 120 to 1400 7454 700 cm model 14 100 L Actuators from other manufacturers and Type 3271 with 1400 1400 7455 4010200 X Actuators from other manufacturers and Type 3271 with 2800 cm2 1400 7456 120 mm travel 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 Accessories Connecting plate 1400 7461 Va 1400 7462 or pressure gauge bracket 7 1400 7458 Va 1400 7459 Pressure gauge mounting kit output supply St steel Brass 1400 6950 St steel St steel 1400 6951 Table 4 Attachment to rotary actuators VDI VDE 3845 for all sizes of fixing level 2 see Figs 7 and 8 Mount With foll VDI VDE 3845 for all sizes of fixing level 2 1400 7448 Sand In Tower for Type 3278 Actuator with 160 320 cm 14
49. 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 5 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 1 8 1400 6820 for the Connecting plate old for Actuator Type 3277 5xxxxxx 00 old 1 8 NPT 1400 6821 nn 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 interchangeable Connecting plate 6 1400 7461 V4 1400 7462 Accessories or pressure gauge bracket 7 1400 7458 V4 NPT 1400 7459 for the positioner Pressure gauge mounting kit 8 output and Stainless steel Brass Stainless steel St steel supply 1400 6950 1400 6951 Table 2 Direct attachment to Type 3277 Actuator Mounting parts for actuators with 240 350 and 700 cm see Fig 4 1400 7453 m 2 Steel Stainless steel feura piin vih rev gr ac Zio chamber is filled with air en 29 1400 6447 Accessories E 700 1400 6448 1400 6449 Connection block with seals and screw 1400 8811 V4 NPT 1400 8812 Pressure gauge mounting kit output and supply Stainless steel Brass 1400 6950 S
50. ve is restricted by the pin position used and additionally by the actuator spring compression required The travel range listed in the travel tables can only achieved if the nominal range is set to MAX The positioner is standard equipped with the lever 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 and 120 7 5 4 8 20 M 25 3277 120 240 350 15 6 8 35 4 M 35 Actuators 700 30 9 5 50 M 50 Travel table for attachment according to IEC 60534 6 NAMUR SAMSON valves Other valves actuators Required Assigned cm Rated travel mm Min Travel Max lever 60 and 120 with Type 3510 Valve 7 5 3 4 17 6 17 120 7 5 4 8 25 M 25 3271 120 240 350 15 6 8 35 4 M 35 Actuator 700 1400 2800 15 and 30 30 9 5 50 M 50 1400 2800 60 13 5 70 8 L 70 1400 2800 60 19 100 L 100 2800 120 38 200 XL 200 Rotary actuators Opening angle 24 to 100 M 90 EB 8384 1 EN 9 Attachment to the control valve mounting parts and accessories Table 1 Direct attachment
51. y 9 the electric reference variable 4 to 20 mA terminals 11 and 12 Note For most applications the positioner is ready for operation with its default set tings provided it is attached properly The positioner just needs to be initialized af ter the volume restriction has been set and the fail safe position has been determined 5 1 Setting the volume restriction Q 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 Note The positioner must re initialized if the volume restriction setting is changed after the positioner has already been initialized 8384 1 EN 29 Start up 5 2 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 Turn button until Code P1 appears press button to confirm the selected code P1 blinks 11 4 LJ Reading direction for right I 1 attachment of pneumatic connections PR Turn button until the display is adjusted to the desired direction then confirm rea ding direction by pressing the button 5 3 Determining the fail safe position Set the fail saf
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