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Mounting and Operating Instructions EB 8384-6

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3. ID 75 P innur 78 Zeno 78 79 eC HO 82 Enabling arid selecting parameters eb ey ER is 82 reor TE TEE T TT 82 Automatic and manual modes essent eterne enne 82 nel 83 84 Confirming error miessades auscstepenusi GRE basi ripa 85 Adjusting limit 86 Retrofitting inductive lirit COMIC idea aep 87 EB 8384 6 EN 10 11 12 13 14 15 15 1 16 Contents MAENOR 89 Servicing explosion protected devices ssscsssscsssscsssscsssscsscccssessssscessesees 89 Firmware update serial interface eee eeee eene 89 Maintenance calibration and work on equipment 90 os MI 91 DIMENSIONS ii 110 Fixing levels according to VDI VDE 3845 September 2010 113 Valve characteristic selection csccssscsssscssssssssscssscssssssssscssssssssscsseseees 114 EB 8384 6 EN 5 Note The functions of the EXPERTplus Valve Diagn
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8. 22 32 7 24 Attachment according to IEC 60534 6 sss 26 Attachment according to VDI VDE 3847 sss 28 Attachment to Type 3510 Micro flow Valve 34 Attachment to rotary actuators 34 36 Reversing amplifier for double acting actuators 38 Reversing amplifier 1079 1118 or 1079 1119 40 Attachment of external position sensor 42 Mounting the position sensor with direct 43 Mounting the position sensor with attachment according to IEC 60534 6 45 Mounting the position sensor to Type 3510 Micro flow Valve 46 Mounting on rotary aeludloES sostener 47 Mounting the leakage sensor cc cccscccsssccssseesseccssseessecesseceseeenseenteeeeseees 48 Attaching positioners with stainless steel 49 Air purging function for single acting actuators 6 49 Required mounting parts and accessories 50 COMIMECTIONS 55 PMEUMIGIIC COMNECHONS 95 Signal press re othe ann oe econ ene eee eee en D EB 8384 6 EN 3 Contents 5 1 2 5
9. 3 AA AN ESC Fault alarm ix 3 No HI LO ESC 98 The valve position limit relating to the operating range Alarm A1 responds when the value falls below the limit The valve position limit relating to the operating range Alarm A2 responds when the value falls below the limit Testing the software limit contact alarm A1 and A2 as well as the fault alarm contact A3 If the test is activated the contact is switched five times Software limit contact Al to 22 2 mA A2 2A Software limit contact A2 to 22 2 mA Fault alarm contact to lt 1 0 mA Operating direction of the position transmitter This 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 connected set point less than 3 6 mA the signal is 0 9 mA and 3 8 mA or 4 4 mA when the positioner has not been initialized When Code 32 YES the position transmitter issues the value as set in Code 30 during initialization or zero calibration When Code 32 No 4 mA is issued during a running autotune Select if and how faults that cause the fault alarm contact to be switched are also indicated at the position transmitter output ix 221 6 0 1 mA or LO ix 22 4 0 1 mA EB 8384 6 E
10. Switch AUTO MAN The positioner changes from the auto matic mode C3 AUTO to the manual mode 2 MAN or vice versa This function is not performed if the posi tioner is in the fail safe position mode SAFE EB 8384 6 EN Design and principle of operation Various diagnostic functions Details on EXPERTplus Valve Diagnostics in the Operating Instructions gt EB 8389 1 EN Additionally the external solenoid valve function can be selected if a non floating contact is configured External solenoid valve The voltage for an external solenoid valve is connected in parallel to terminals 31 32 This allows the switching state of the solenoid valve to be monitored Note The optional binary input can only be configured using the operator software e g TROVIS VIEW The switching state is transmitted when the switch is closed by default 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 by cable and piping for air 13 Design and principle of operation 3 6 Technical data Type 3730 6 Positioner technical data in test certificates additionally apply to explosion protected devices Adjustable Direct attachment to Type 3277 Actuator 3 6 to 30 mm Attachment according to IEC 60534 6 1 3 6 to 200 mm Attachment according to VDI VDE 3847 3 6 to 200 mm
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13. Turn Code 34 Press amp Code 34 blinks Turn W gt Closing direction CCL counter clockwise CL clockwise Press 69 Turn gt Code 35 Press eg Code 35 blinks Turn 5 gt Blocking position e g 5 mm read off at travel indicator scale of the blocked valve or measure with a ruler Set the fail safe position gt Set switch for closed position AIR TO OPEN or AIR TO CLOSE according to section 7 1 Set volume restriction as described in section 7 2 Start initialization gt Press INIT key The operating mode is changed to auto matic mode 3 77 Start up and settings Note Since initialization has not been completed the error code 76 no emergency mode and possibly al so error code 57 control loop may appear on the display These alarms do not influence the posi tioner s readiness for operation If the positioner shows a tendency to oscillate in automatic mode the parameters and T must be slightly corrected Proceed as fol lows gt Set T Code 18 to 4 If the positioner still oscillates the gain Kp Code 17 must be decreased until the positioner shows a stable behavior Zero point calibration Finally if process operations allow it the ze ro point must be calibrated according to sec tion 7 7 On correcting the zero point the valve moves again to the closed position 7 6 6 Tuning the KP input filter Changing the KP level Code 17 aff
14. CON ABAAaAaAKRWN NOTICE Only use the connecting plate 6 in cluded in the accessories to connect supply and output Never screw threaded parts directly into housing Fig 3 Direct attachment Signal pressure connection for Type 3277 5 Actuator with 120 cm EB 8384 6 EN 23 Attachment to the control valve Mounting parts and accessories 4 1 2 Type 3277 Actuator Required mounting parts and accesso ries Table 2 on page 51 Observe the travel table on page 21 Actuators with 175 to 750 cm effective ar eas see Fig 4 Mount the positioner on the yoke The signal pressure is routed to the actuator over the connection block 12 for actuators with fail safe action actuator stem extends internal ly through a hole in the valve yoke and for actuator stem retracts through an external pipe 1 Place follower clamp 3 on the actuator stem align it 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 Fig 4 on the left pointing towards the signal pressure connection Make sure that the gasket 14 points to wards the actuator yoke 3 For actuators with 355 700 or 750 cm remove the follower pin 2 on the M le ver 1 on the back of the positioner from pin position 35 reposition it in the hole for pin position 50 and screw tight For actuators 175 240 and 350 cm with 15 mm travel
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17. 1400 7458 Accessories Pressure gauge bracket 7 uod St steel brass 1400 6950 ressure gauge mountin o max 6 bar o 5 x St steel brass 1400 6951 Table 6 General accessories Reversing amplifier for double acting actuators Type 3710 Black plastic 6 to 12 mm clamping range 8808 1011 Blue plastic 6 to 12 mm clamping range 8808 1012 Cable gland M20 x 1 5 Nickel plated brass 6 to 12 mm clamping range 1890 4875 Nickel plated brass 10 to 14 mm clamping range 1922 8395 Stainless steel 1 4305 8 to 14 5 mm clamping range 8808 0160 Powder coated aluminum 0310 2149 Stainless steel 1400 4114 Retrofit kit for inductive limit contact 1 x SJ2 SN 1400 7460 DE EN delivered state 1990 0761 Cover plate with list of parameters and operating instructions 1990 3100 1990 3142 TROVIS VIEW 6661 with device module Type 3730 6 EB 8384 6 EN 53 Adapter M20x1 5 to V NPT Attachment to the control valve Mounting parts and accessories Table 6 General accessories Serial interface adapter SAMSON SSP interface to RS 232 port on a PC 1400 7700 lsolated USB interface adapter SAMSON SSP interface to USB port on a PC including 1400 9740 TROVIS VIEW CD ROM Table 7 Attachment of external position sensor Template for mounting position sensor on older mounting parts See note on page 42 1060 0784 Mounting parts for actuators with 120 cm See Fig 15 left 1400 7472 Connecting plate 9 old
18. 4 Place the reversing amplifier onto the connecting plate 6 and screw tight us ing both the special screws 1 1 5 Usea screwdriver 8 mm wide to screw the enclosed filters 1 6 into the connec tion boreholes A and Z NOTICE Air can escape uncontrolled from the signal pressure connection Do not unscrew the sealing plug 1 5 out of the reversing amplifier Note The rubber seal 1 4 is not required and can be removed when the seal ing plug is used D 6 After initialization set Code 16 Pressure limit to No Pressure gauge attachment The mounting sequence shown in Fig 14 re mains unchanged Screw a pressure gauge bracket onto the connections A and Z G4 1400 7106 Ya NPT 1400 7107 Pressure gauges for supply air Z and output A as listed in Table 1 to Table 7 Pressure gauge bracket EB 8384 6 EN Attachment to the control valve Mounting parts and accessories From the positioner Output 38 Supply 9 Control signals to the actuator Reversing amplifier 6 Connecting plate 1 1 Special screws 61 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 NN Y SP Output 38 Fig 14 Mounting a reversing amplifier 1079 1118 or 1079 1119 EB 8384 6 EN Al Attachment to the control valve Mounting parts and accessories 4 7 Attachment of external po Operation and setting are descri
19. 5 2 2 Establishing communica tion Communication between PC and positioner using an FSK modem or handheld communi cator if necessary using an isolation ampli fier is based on the HART protocol Viator FSK modem RS 232 No explosion protection Order no 8812 0130 PCMCIA No explosion protection Order no 8812 0131 USB No explosion protection Order no 8812 0132 Connection in safe area Connections the load impedance of the controller or control station is too low an isolation ampli fier must be connected between controller and positioner interfacing as for positioner connected in hazardous areas See Fig 21 If the positioner is used in hazardous areas an explosion protected isolation amplifier must to be used Using the HART protocol all connected control room and field units can be ad dressed individually using a point to point connection or the standard multidrop bus Point to point The bus address polling address must al ways be set to zero 0 Handheld communicator or dhs second FSK modem m LT T 4 to 20 mA Controller control station Explosion protected isolation amplifier Safe range Handheld communicator or second i FSK modem explosion protected Fig 21 Connection with FSK modem EB 8384 6 EN 59 Connections Standard bus multidrop In the standard bus multidrop mode the positio
20. Leakage sensor including cable and fixing screw 20 Binary input 3 External Without 0 position sensor With including 10 m connecting cable 1 1 Prepared for connection without sensor 2 Function Standard control valves 0 Emergency shutdown 3 8 mA 0 4 4 mA Housing material Aluminum standard Stainless steel 1 4581 2 Special application Without Version compatible with paint Version compatible with paint Attachment according to VDI VDE 3847 including interface Attachment according to VDI VDE 3847 prepared for interface O 8 8384 6 3 Design and principle of oper ation The electropneumatic positioner is mounted on pneumatic control valves and is used to assign the valve position controlled vari able x to the control signal reference vari able w The positioner compares the electric control signal of a control system to the travel or opening angle of the control valve and is sues a signal pressure output variable y for the pneumatic actuator The positioner consists of travel sensor sys tem 2 proportional to resistance an analog i p converter 6 with a downstream air ca pacity booster 7 and the electronics with microcontroller 5 The positioner is fitted with three binary con tacts as standard A fault alarm output indi cates a fault to the control room and two configurable software limit contacts are used to indicate the end positions of the valve The valve position
21. 10 1 on the back of the housing 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 position at the cap or rotary pushbutton 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 D Note applying to all types of attach ment except for direct attachment to Type 3277 5 The signal pressure output at the back must be sealed by the screw plug 4 order no 0180 1254 and the associated O ring order no 0520 0412 8 Mount cover 11 on other side Make sure that the vent plug is located at the bottom when the control valve is in stalled to allow any condensed water that collects to drain off EB 8384 6 EN Attachment to the control valve Mounting parts and accessories Symbols Actuator stem extends Right attachment Switchover plate 9 Left attachment Actuator stem 2 retracts 212 Signal pressure input for left attachment Marking Signal pressure input for right attachment Lever Nut Disk spring Follower pin Follower clamp Screw plug Sealing plug Connecting plate Seals Pressure gauge bracket Pressure gauge mounting kit Switchover plate actuator Cover plate Seal Cover Gasket Formed seal NO
22. The signal pressure can be blocked in the ac tuator by unscrewing the red retaining screw 20 and then turning the air blocker 19 on the bottom of the adapter block Attachment to Type 3277 Actuator see Fig 6 Required mounting parts and accesso ries Table 4 on page 52 Mount the positioner on the yoke as shown in Fig 6 The signal pressure is routed to the actuator over the connecting plate 12 for actuators with fail safe action actuator stem extends internally through a bore in the valve yoke and for actuator stem retracts through external piping Only the Y1 port is required for positioner attachment The Y2 port can be used for air purging of the spring chamber 1 Place follower clamp 3 on the actuator stem align it and screw tight so that the 28 mounting screw is located in the groove of the actuator stem 2 Place the adapter bracket 6 on the po sitioner and mount using the screws 6 1 Make sure that the seals are cor rectly seated For positioners with air purging remove the stopper 5 before mounting the positioner For positioners without air purging replace the screw plug 4 with a vent plug 3 For actuators with 355 700 750 cm2 remove the follower pin 2 on the M le ver 1 on the back of the positioner from pin position 35 reposition it in the hole for pin position 50 and screw tight For actuators 175 240 and 350 cm with 15 mm travel keep the follower
23. Automatic mode see section 8 2 1 The positioner is in closed loop operation and follows the mA signal SSAFE see section 8 2 2 The positioner vents the output The valve moves to the mechanical fail safe posi tion Bar graph In manual 2 and automatic C modes the bars indicate the set point deviation that de pends on the sign and the value One bar element appears per 1 set point devi ation If the positioner has not been initialized 2 blinks on the display bar graph indi cates the lever position in degrees in relation to the mid axis One bar element corre sponds to approximately a 5 angle of rota tion The fifth bar element blinks reading gt 30 if the permissible angle of rotation has 62 been exceeded Lever and pin position must be checked Status messages 1 Failure Maintenance demanded Mainte nance required blinks Out of specification These icons indicate that an error has oc curred A classified status can be assigned to each error Classifications include No message Maintenance required Maintenance de manded and Failure see section 14 gt Enable configuration This indicates that the codes marked with an asterisk in the code list section 14 are enabled for configuration see section 8 1 EB 8384 6 EN Operating controls and readings Maintenance demanded Maintenance required Fail safe position ac
24. During adjustment or testing the switching point must always be ap proached from mid position 50 To guarantee the switching under all ambient conditions adjust the switching point ap prox 5 before the mechanical stop OPEN CLOSED For CLOSED position 1 Initialize the positioner 2 Move the valve to 5 in the MAN mode see display 3 Adjust the tag at the yellow adjustment screw 2 until the tag enters or leaves the field and the switching amplifier re sponds You can measure the switching voltage as an indicator Contact function Tag leaving the field gt Proximity switch assumes low resistance Tag entering the field gt Proximity switch assumes high resistance For OPEN position 1 Initialize the positioner 2 Move the valve to 95 in the MAN mode see display 3 Adjust the tag 1 at the yellow adjust ment screw 2 until the tag enters or leaves the field of the proximity switch 3 EB 8384 6 EN Adjusting the limit contact You can measure the switching voltage as an indicator Contact function Tag leaving the field gt Proximity switch assumes low resistance Tag entering the field gt Proximity switch assumes high resistance 9 1 Retrofitting an inductive limit contact Required retrofit kit Order no 1400 7460 Limit contact Note The same requirements apply to ret rofitting an inductive limit contact as fo servicing the posi
25. ensuring a bumpless changeover The current position is displayed in 26 Adjust the manual set point Turn i gt Code 1 Press amp Code 1 blinks Turn until sufficient pressure has been built up in the positioner and the control valve moves to the required position EB 8384 6 EN Operation Note The positioner automatically returns to Code if no settings are made within 120 seconds but remains in the manual mode Switch to automatic mode Turn amp gt Code 0 Press amp Code 0 blinks Turn gt AUTO Press The positioner switches to automat ic mode 8 2 2 Fail safe position SAFE If you want to move the valve to the fail safe position determined during start up see sec tion 7 1 proceed as follows Turn WY gt Code 0 Press 60 display current operating mode AUTO or MAN Code 0 blinks Turn SAFE Press G9 display S The valve moves to the fail safe position If the positioner has been initialized the cur rent valve position in is indicated on the display 83 Operation Exit the fail safe position Turn gt Code 0 Press eg Code 0 blinks Turn and select the required operating mode AUTO or MAN Press 69 The positioner switches to the operating mode selected 8 3 Fault malfunction A status classification is assigned to all status and fault alarms in the positioner The de fault settings of the status
26. with 1400 6820 3277 5xxxxxx 00 Actuator 8 NPT 1400 6821 Direct attachment Connecting plate new with Type 3277 5xxxxxx 01 Actuator new 1400 6823 Mounting parts for actuators with 175 240 350 355 and 700 cm See Fig 15 1400 7471 right ate alia Mounting parts for attachment to NAMUR rib using or XL lever See Fig 16 1400 7468 Attachment to Type 3510 Micro Mounting parts for Type 3271 Actuator with 60 cm See Fig 17 1400 7469 flow Valve VDI VDE 3845 September 2010 see section 15 1 for details BEEN Actuator surface corresponds to fixing level 1 Size AAT to AAA with follower clamp and coupling wheel version with CrNiMo steel bracket See Fig 18 1400 7473 Size AAT to AAA heavy duty version 1400 9384 Attachment to Size AA5 heavy duty version e g Air Torque 10 000 1400 9992 Bracket surface corresponds to fixing level 2 heavy duty version 1400 9974 2 du SAMSON Type 3278 with 160 cm and VETEC Type S160 and Type R heavy du 1400 9385 ty version 1400 5891 SAMSON Type 3278 with 320 cm and VETEC Type 320 heavy duty version and 1400 9974 14007461 POENI 14007462 Pressure gauge bracket 7 Pressure gauge mounting kit up to max Stainless steel brass 1400 6950 6 bar output supply Stainless steel stainless steel 1400 6951 Bracket to mount the positioner on a wall Note The other fastening parts are to 0309 0111 be provided at th
27. x is transmitted as a ei ther an angle of rotation or travel to the pick up lever and to the travel sensor 2 and sup plied to an analog PD controller An A D converter 4 transmits the position of the valve to the microcontroller 5 The PD con troller 3 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 set point de viation the activation of the i p converter 6 is changed so that the actuator of the control valve 1 is pressurized or vented according ly over the downstream booster 7 This EB 8384 6 EN Design and principle of operation causes the valve plug to move to the position determined by the reference variable w The supply air is supplied to the booster 7 and the pressure regulator 8 An intermedi ate flow regulator 9 with fixed settings is used to purge the positioner and at the same time guarantees trouble free operation of the booster The output signal pressure supplied by the booster can be limited by software Both pressure sensors 23 and 24 monitors the supply pressure p and the sig nal pressure Poy The volume restriction Q 10 is used to opti mize the positioner The positioner is suitable for the following types of attachment using the corresponding accessories Direct attachment to SAMSON Type 3277 Actuator section 4 Attachment to actuators according to IEC 60
28. 1 3 9 2 5 2 1 5 2 2 6 1 6 2 6 3 7 1 fad 73 7 4 5 7 6 7 6 1 7 6 2 ers 7 6 4 700 7 6 6 7 7 7 8 8 1 8 2 8 2 1 8 2 2 8 9 9 9 1 9 1 _____ _ 55 Signal pressure output nens 56 5 Gonne 56 Siren Ko To HTTP TEE 58 Establishing 59 Operating controls and readingS cssccssscsssscsssccsssscsessessccssascsssssssesees 61 Serial MICE TEE 64 HARI Comat CAN OM RE eu CHE 64 Dynamic HARI 64 Slarrup dnd semings 66 Defining the valve closed position 66 Adjusting the volume restriction Eras rosas ted eiii 67 Adapting the display direction sess 67 Limiting the signal pressure ccccccscccessccsssccsssccssecessecesecessecesseesseeceseeesaes 67 Checking the operating range of the positioner 68 do Lo ER 69 MAX Initialization based on maximum 7 NOM Initialization based on nominal range 72 MAN Initialization based on a manually selected OPEN position 73 MAN2 Initialization based on manually selected end positions 74 SUB Suis shil
29. 4 with its follower pin Fig 11 It must be guaranteed that the lever 1 is parallel to the long side of the positioner when the actuator is at half its angle of rotation 8 Stick the 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 4 5 1 Fig 12 Required mounting parts and accesso ries Table 5 on page 53 Heavy duty version Both mounting kits contain all the necessary mounting parts The parts for the actuator size used must be selected from the mount ing kit Prepare actuator and mount required adapt er supplied by the actuator manufacturer if necessary 1 Mount the housing 10 onto the rotary actuator In case of VDI VDE attachment EB 8384 6 EN Attachment to the control valve Mounting parts and accessories 7 Only use the connecting plate 6 included in the ac and output Never screw threaded parts directly into housing Legend for Fig 10 and Fig 11 Lever 1 1 Nut 1 2 Disk spring Follower pin Follower clamp Fig 10 Control valve opens counterclockwise Coupling wheel Screw Control valve opens clockwise Disk spring Scale plate Actuator shaft Adapter for Type 3278 Connecting plate Seals Pressure gauge bracket Pressure gauge mounting kit Top pair of brackets Bottom pair of brackets Fig 11 Attachment to rotary actuators EB 8384 6 EN 37 Atta
30. D Perform the start up settings in the same se quence as described section 7 1 to sec tion 7 6 7 1 Defining the valve closed position Define the closed position of the valve 0 taking the valve type and the actuator s di rection of action into account Position the AIR TO OPEN AIR TO CLOSE slide switch accordingly AIR TO OPEN ATO setting Signal pressure opens the valve e g for fail close valve The AIR TO OPEN setting always applies to double acting actuators _ AIR TO CLOSE ATC setting Signal pressure closes the valve e g for fail open valve For checking purposes After successfully completing initialization the positioner dis play must read when the valve is closed and 100 when the valve is open If this is not the case change the slide switch position and re initialize the positioner EB 8384 6 EN Note The switch position is prompted prior to an initialization After an initial ization has been completed chang ing the switch position does not have any effect on the operation of the po sitioner 7 2 Adjusting the volume re striction Q MAX BACK MIN SIDE MIN BACK MAX SIDE Fig 25 Volume restriction Q MAX BACK MIN SIDE setting The volume restriction Q serves to adapt the air output capacity to the size of the actua tor BACK MIN SIDE setting for actua tors with a transit time 1 s e g linear actuators with an effective area smaller than
31. Depending on the air passage at the actua operated on site using the rotary pushbutton tor two fixed settings are available Volume restriction Q Turn Select codes and values For actuators smaller than 240 cm Press B Confirm setting Type 3271 5 select MIN SIDE AIR TO OPEN AIR TO CLOSE slide switch For actuators 240 cm and larger select AIR TO OPEN applies to a valve opening MAX SIDE for a side connection as the signal pressure increases AIR TO CLOSE applies to a valve closing as the signal pressure increases The signal pressure is the pneumatic pressure at the output of the positioner applied to the actuator AIR TO OPEN always applies to positioners with a mounted reversing amplifier for dou Initialization key Cap and rotary switch Metal tag of proximity switch SSP interface Switch for AIR TO OPEN AIR TO CLOSE SALVNIOV JAVA NOILNYO 2088 M 02 gt n Lo Su t 20 Volume restriction SS Rotary pushbutton Fig 23 Operating elements EB 8384 6 EN 61 Operating controls and readings Readings Icons assigned to certain codes parameters and functions are indicated on the display Operating modes 2 Manual mode see section 8 2 1 The positioner follows the manual set point Code 1 instead of the mA signal blinks The positioner is not initialized Operation only possible over manual set point Code 1
32. Maximum range For simple start up of valves with two init mode clearly defined mechanical end positions The positioner MAX NOM MAN determines travel angle of rotation of the closing member 2 SUB KP ZP ESC from the CLOSED position to the opposite stop in the actu ator Nominal range For all globe valves The positioner de termines travel angle of rotation of the closing member from the CLOSED position to the specified nominal range Manual setting 1 For all globe valves with unknown nominal range OPEN position The positioner deter mines travel angle of rotation from the manually selected OPEN position 100 25 to the CLOSED position Manual setting 2 For all globe valves with unknown nominal range OPEN and CLOSED position The posi tioner determines travel angle of rotation between the manually selected OPEN 100 25 and the manually se lected CLOSED position O Substitute calibration To replace a positioner while the plant is running with the least amount of disruption to the plant 92 EB 8384 6 EN Parameter Readings values default setting Initialization mode Direction of action w x AA AN ESC Lower travel angle range value lower x range value 0 0 to 80 0 of the nomi nal range ESC Specified in mm or angle provided Code 4 is activat ed Upper travel angle range value upper x range value 20 0 to 100 0 of the nominal range ESC Speci
33. T6 Class Zone O lt Number 2682094 Class Gruops A B C and D Date 06 02 2015 Class Il Groups E F and G Class Ill Type 4 Enclosure Ex Number PTB 10 ATEX 2007 EC type Il 2G Ex d ia IIC IIB T6 Gb mit Feldbarriere Typ 3770 1 examination Baie 18 08 2010 Il 2D Ex tb T80 C IP66 certificate Number IECExPTB 10 0057 ia IIC IIB 16 Ex IIC IIB 16 Date Ex tD A21 IP66 T80 C 18 EB 8384 6 EN Design and principle of operation Number RU C DE 08 B 00113 FAL Ex Date 15 11 2013 1Ex dlia Ga iiC 16 Gb X Valid until 14 11 2018 Ex Number PTB 10 ATEX 2008 X 3G Ex nA ic IIC T Gc Statement of Date 18 08 2010 Il 3D Ex tc T80 C Dc IP66 Conformity Number IECEx PTB 10 0058X Ex nA II T6 Ex nL IIC IIB T6 Dote Ex tD A22 IP66 T80 C Number GYJ12 1110X Ex nL IIC T4 T6 Ge Date 08 10 2012 Ex nA IIC T4 T6 Gc Valid until 07 10 2017 DIRASA MUR VO Number RU C DE 08 B 00113 2Ex nA IIC T Gc FAT Ex Date 15 11 2013 2Ex ic IIC T6 Valid until 14112018 Pete MC TOU C De POO EB 8384 6 EN 19 Attachment to the control valve Mounting parts and accessories 4 Attachment to the control valve Mounting parts and accessories NOTICE Risk of malfunction due to incorrect sequence of mounting installation and start up Keep the following sequence 1 Remove the protective film from the pneumatic connections 2 Mount the positioner on the control valve 3 Connect the su
34. Turn 69 gt zp gt Press INIT key Zero calibration starts The positioner moves the valve to the CLOSED position and recalibrates the internal electrical zero point 7 8 Reset to default settings A reset allows the positioner to be reset to the default settings To reset the positioner the options DIAG STD and DS are available in Code 36 Table 9 lists the reset functions Note 0 Code 36 DS is usually selected when the valve is mounted in another position or when the positioner is to be mounted to another valve Performing a reset does not necessar ily mean the positioner must be re initialized EB 8384 6 EN Start up and settings Enable configuration Turn 9 gt Code 3 display No Press amp Code 3 blinks Turn gt gt YES Press G9 display gt Reset start up parameters G 36 Reset Default No plea t d Turn 9 gt Code 36 display Press eB Code 36 blinks Turn DIAG STD DS Press H The parameters are reset depending on the option selected See following Toble 9 79 Start up and settings Table 9 Reset functions s0 65 Fail safe action lt Air supply failure lt Power supply failure of positioner Power supply failure of external solenoid valve ZI Z xa Ze Emergency mode Operating hours counter Device in operation Device switched on since initializati
35. and the serial interface adapter The operator soft ware is TROVIS VIEW version 4 with in stalled device module 3730 6 6 2 HART communication The positioner must be supplied with at least 3 6 mA The FSK modem must be connected in parallel to the current loop A DTM file Device Type Manager conform ing to the Specification 1 2 is available for communication This allows the device for example to be run with the PACTware oper ator interface All the positioner s parame ters are then accessible over the DTM and the operator interface For start up and settings proceed as de scribed in section 7 1 to 7 4 Refer to the code list in section 14 for the parameters necessary for the operator interface Note If complex functions are started in the positioner which require a long cal culation time or lead to a large quan tity of data being saved in the vola tile memory of the positioner the alert busy is issued issued by the DTM file This alert is not an error message and can be simply con firmed 64 Locking HART communication The write access for HART communication can be disabled over Code 47 This function can only be enabled or disabled locally at the positioner Write access is enabled by default Locking on site operation The on site operation including the INIT key can be locked over HART communication The word HART then blinks on the display when Code 3 is selected This locking
36. classification are listed in the code list D Note The assignment of the status classifi cation can be changed in the opera for software e g TROVIS VIEW ver sion 4 Refer to the Operating In structions for the valve diagnostics gt EB 8389 1 EN on the enclosed CD ROM for more details To provide a better overview the classified messages are summarized in a condensed state for the positioner according to the NAMUR Recommendation NE 107 The sta tus messages are divided into the following categories Failure The positioner cannot perform its control task due to a functional fault in the posi tioner itself or in one of its peripherals or an initialization has not yet been suc cessfully completed 84 Maintenance required The positioner still performs its control task with restrictions A maintenance demand or above average wear has been determined The wear tolerance will soon be exhausted or is reducing at a faster rate than expected Maintenance is necessary in the medium term Maintenance demanded The positioner still performs its control task with restrictions A maintenance demand or above average wear has been determined The wear tolerance will soon be exhausted or is reducing at a faster rate than expected Maintenance is necessary in the short term Out of specification The positioner is running outside the specified operating conditions D Note If an event is classifie
37. control valve Mounting parts and accessories 2 Place coupling wheel 4 with flat side facing the actuator on the follower clamp 3 Refer to Fig 11 to align slot so that it matches the direction of rotation when the valve is in its closed position 3 Fasten the coupling wheel 4 and follow er clamp 3 tightly onto the actuator shaft using screw 4 1 and disk spring 4 2 4 Fasten the bottom pair of brackets 10 1 with the bends pointing either facing to the inside or to the outside depending on the actuator size onto the actuator hous ing Position the top pair of brackets 10 and fasten 5 Mount connecting plate 6 or pressure gauge bracket 7 with pressure gauges on the positioner making sure the two seals are seated properly Double acting springless rotary actuators require the use of a reversing amplifier on the connection A T TE I ______ 7 27 gus GS ws 7 Fig 10 Mounting the coupling wheel on Type 3278 36 side of the positioner housing see section 4 6 6 Unscrew the standard follower pin 2 from the positioner s M lever 1 Use the metal follower pin 5 mm included in the mounting kit and screw tight into the hole for pin position 90 7 Place positioner on the top bracket 10 and fasten tight Taking the actuator s di rection of rotation into account adjust le ver 1 so that it engages in the slot of the coupling wheel
38. far as it will go in both directions EB 8384 6 EN Attachment to the control valve Mounting parts and accessories Travel tables Note The M lever is included in the scope of delivery S L XL levers for attachment according to IEC 60534 6 NAMUR are available as accessories see Table 3 Direct attachment to Type 3277 5 and Type 3277 Actuators Actuator size Rated travel Adjustment range at positioner d equire Assigned pin HE Travel m 1 50 250 0 Attachment according to IEC 60534 6 NAMUR SAMSON valves with Adjustment range at positioner Type 3271 Actuator Other control valves Actuator size Min travel Max travel Required Assigned pin cm position 60 and 120 with Type 3510 120 120 1 E 7007750 SEEE 10 t o Rotary actuators Assigned pin lever angle 1 2 5 10 1 The min max adjustment range is based on the NOM nominal range initialization mode EB 8384 6 EN 21 Attachment to the control valve Mounting parts and accessories 4 1 Direct attachment 4 1 1 Type 3277 5 Actuator Required mounting parts and accesso ries Table 1 on page 50 Observe the travel table on page 21 Actuator with 120 cm see Fig 3 Depending on the type of positioner attach ment the signal pressure is routed either left or right of the yoke through a hole to the ac tuator diaphragm Dependi
39. func tion can only be disabled over HART com munication On site operation is enabled by default 6 3 Dynamic HART variables The HARTS specification defines four dynam ic variables consisting of a value and an en gineering unit These variables can be as signed to device parameters as required The universal HART command 3 reads the dy namic variables out of the device This al lows manufacturer specific parameters to al so be transferred using a universal com mand In the Type 3730 6 Positioner the dynamic variables can be assigned as follows in the Device settings folder gt Positioner gt HART communication EB 8384 6 EN Operating controls and readings Table 8 Dynamic HART variables assignment Set point Set point Direction of action set point Direction of action set point i o t point after transit fi T 9B Set point after transit time specification specification Valve position Actual value process variable Set point deviation e Set point deviation e Absolute total valve travel Absolute total valve travel Binary input status 0 Not active 1 Active 255 Internal solenoid valve forced O De energized venting status 1 Energized 2 Not installed Condensed state No message 3 Failure 1 Maintenance requested 4 Out of specification 2 Maintenance demanded 7 Function check Leakage sensor sound level Differential pressure Diffe
40. is in stalled to allow any condensed water that collects to drain off EB 8384 6 EN Attachment to the control valve Mounting parts and accessories Lever Connection block Nut Screw Disk spring Stopper or connection for external piping Follower pin Switch plate Follower clamp Gasket Cover plate Formed seal Cover Gasket Vent plug M lever Cut out of cover plate 10 RN p f EE EE Actuator stem Retracts Extends ba Connection block old with switch plate 13 Actuator stem retracts Actuator stem extends Marking Fig 4 Direct attachment Signal pressure connection for Type 3277 Actuator with 175 to 750 cm EB 8384 6 EN 25 Attachment to the control valve Mounting parts and accessories 4 2 Attachment according to IEC 60534 6 Required mounting parts and accesso ries Table 3 on page 52 Observe the travel table on page 21 Fig 5 The positioner is attached to the control valve using a NAMUR bracket 10 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 for fastening Actuator sizes 2800 cm and 1400 cm with 120 mm travel Fora 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 16 first and then the fol lower plate 3 to the bracket togeth er with
41. plate s slot Follower plate not mounted properly Status classification Maintenance required Check attachment and pin position actione Re initialize positioner Ax lt range Insufficient measuring span of the sensor Pin not mounted properly Wrong lever mounted Pressure limit set too low An angle of rotation smaller than 16 at the positioner shaft only generates an alarm An angle below 9 leads to the initialization being canceled Status classification Out of specification Recommended Check attachment and pressure limit action e Re initialize positioner 102 EB 8384 6 EN Code list Error codes Condensed state message active when prompted ERR appears Recommended action When fault alarms exist they are displayed here Attachment The nominal range could not be achieved during initialization with NOM initialization mode the maximum travel angle reached is indicated on the display Wrong lever mounted Supply pressure too low valve cannot be moved to desired position Status classification Maintenance required Recommended e Check attachment and supply pressure action e Re initialize positioner Check supply pressure and install pneumatic volume booster if necessary Adjust travel angle stops action e Reduce hunting tendency e g restrict or open booster bypass Then re ini tialize the pos
42. range Set point lower range value Lower range value 0 4 mA of the valid set point range w start This value must be smaller than the upper range value 0 0 to 75 0 ESC The set point range is the difference between Set point upper range value Set point lower range value The difference must be larger or equal to 25 4 mA When the set point range of 0 to 100 4 to 20 mA the valve moves through its entire operating range from O to 100 travel angle of rotation In split range operation the valves operate with smaller set points The control signal of the control unit to control two valves is divided such for instance that the valves move through their full travel an gle 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 Set point upper range val range value 100 20 mA of valid set point range ue w end This value must be greater than the lower range value 25 0 to 100 0 ESC 94 EB 8384 6 EN Code list Parameter Readings Dos t NO values default setting CLOSED end position end position w lt 0 0 to 49 9 1 0 of the span adjusted in Code 12 13 No ESC OPEN end position end po sition w gt 50 0 to 100 0 of the span adjusted in Code 12 13 No ESC Pressure limit 1 4 to 7 0 bar No ESC Do not activate pressure lim itation for double act
43. required See Fig 20 on page 51 Monitoring the voltage supply version with forced venting and solenoid valve The i p converter and the solenoid valve when installed are shut down whenever the voltage at terminals 81 82 falls below 12 V an input voltage of 24 V DC is re quired See Fig 20 on page 51 When the i p converter is switched off as part of the monitoring of the input signal or the voltage supply the fail safe position S is activated and is indicated on the positioner display If required the user can check the safety function using the software Details on EXPERTplus Valve Diagnostics in the Operating Instructions EB 8389 1 EN EB 8384 6 EN Design and principle of operation 3 2 Valve diagnostics The EXPERTplus valve diagnostics are inte grated into the positioner They provide in formation on the control valve and generate status messages which allow faults to be pinpointed quickly Details on EXPERTplus Valve Diagnostics in the Operating Instructions EB 8389 1 EN 11 Design and principle of operation 3 3 Communication The positioner is equipped with an interface for HART protocol Highway Addressable Remote Transducer for communication pur poses Data are transmitted in a superim posed frequency FSK Frequency Shift Key ing on the existing signal loop for the 4 to 20 mA reference variable Either a HART capable handheld communi cator or a computer with FSK mod
44. seals and screw Pressure gauge mounting kit up to max 6 bar output Stainless steel brass 1400 6950 supply St steel st steel 1400 6951 EB 8384 6 EN 51 Attachment to the control valve Mounting parts and accessories Table 3 Attachment to NAMUR ribs or control valves with rod type yokes 20 to 35 mm rod diameter to IEC 60534 6 Fig 5 and Fig 9 lever 75 Ss Type 3271 5 with 60 120 cm on Type 3510 Micro flow Valve Fig 9 1402 0478 M1 Actuators from other manufacturers and Type 3271 with 120 to 750 cm 1400 7454 tive areas 14 to 100 Actuators from other manvfacturers and Type 3271 with 1000 and 1400 1400 7455 60 cm Actuators from other manvfacturers and Type 3271 with 1400 120 and 2800 cm and with 120 mm travel Connecting plate 6 4 NPT 1400 7462 Type 3271 with 1400 120 and 2800 cm with 30 60 mm travel 1400 7466 7466 30 or 60 L GA 1400 7458 Mounting brackets for Emerson and Masoneilan linear actuators in addition a mounting kit according to IEC 60534 6 is required depending on the travel 1400 6771 Accessories Pressure gauge bracket 7 1 4 NPT 1400 7459 See rows above Stainless steel brass 1400 6950 Valtek Type 25 50 1400 9554 1400 7461 Pressure gauge mounting kit up to max 6 bar output suppl ea mp St steel st steel 1400 6951 1 M lever is mounted on basic device included in the scope of delivery Table 4 Attachment according to VDI VDE 3847 Fi
45. set point w is lower than 3 7 mA This state is indicated on the posi tioner display by LOW blinking Status classification No message Raise the current depending on version above the limit Recommended Check set point w If necessary restrict lower limit of current source to en action sure that a current below 3 7 mA cannot be issued 106 EB 8384 6 EN Code list Error codes Condensed state message active when prompted Err appears Recommended action When fault alarms exist they are displayed here i p converter Current circuit of i p converter interrupted Status classification Failure cannot be classified Return positioner to SAMSON for repair action EB 8384 6 EN 107 Code list Error appendix Error eet Recommended Condensed state message active when prompted Err appears action gt fault alarms exist they are displayed here Recommended action Confirm error and return to automatic mode or perform a reset and re initialize the positioner If this is not successful return positioner to SAMSON AG for repair tied Check calculation Hardware controller monitored by test calculation Additional indication at the fault alarm contact Recommended action s error If this is not possible return positioner to SAMSON AG for repair Data error Error codes Recommended Condensed state message active when prompted Err appears action When fault alarms exist they
46. 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 M8 screw 11 and toothed lock washer directly in the yoke hole For attachment to valves with rod type yokes use two U bolts 15 around the yoke Align the NAMUR bracket 10 according to the em bossed scale so that the follower plate 3 is shifted by half the angle range to the NAMUR bracket the slot of the follower plate is centrally 26 aligned with the NAMUR bracket ot mid valve travel 3 Mount connecting plate 6 or pressure gauge bracket 7 with pressure gauges on the positioner making sure the two seals 6 1 are seated properly 4 Select required lever size 1 M L or XL and pin position according to the actua tor size and valve travel listed in the trav el table on page 21 Should a pin position other than position 35 with the standard M lever be required or an L or XL lever size be required proceed as follows 5 Screw the follower pin 2 in the as signed lever hole pin position as speci fied in the travel table Only use the lon ger follower pin 2 included in the mounting kit E Place the lever 1 on the shaft of the po sitioner and fasten it 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 NAMUR bracket in such a manner that the fo
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48. 240 cm2 require a restricted air flow rate MIN BACK MAX SIDE setting for actua tors with a transit time 21 s the air flow rate does not need to be restricted Intermediate settings are not permitted NOTICE Malfunction due to changed start up settings EB 8384 6 EN Start up and settings Initialize an initialized positioner again after the position of the volume restriction has been changed 7 3 Adapting the display direc tion To adapt the reading on the display to the mounting situation of the actuator the dis play contents can be turned by 180 Reading direction for right attachment of pneumatic connections Reading direction for left attachment of pneumatic connections If the displayed data appear upside down proceed as follows Turn gt Code 2 Press amp Code 2 blinks Turn 5 gt Required reading direction Press to confirm reading direction 7 4 Limiting the signal pressure If the maximum actuator force may cause damage to the valve the signal pressure must be limited Enable configuration at the positioner before limiting the signal pressure 67 Start up and settings Note If no settings are entered within 120 seconds the enabled configuration function becomes invalid Enable configuration Default No Turn 9 2 Code 3 display No Press amp Code 3 blinks Turn YES Press display gt Limit the s
49. 384 6 EN SAMSON butterfly valve linear select charac teristic 3 Travel angle of rotation 100 Reference variable VETEC rotary plug valve linear select char acteristic 5 Travel angle of rotation 100 Reference variable Segmented valve ball linear select characteristic 7 Travel angle of rotation 100 Reference variable SAMSON butterfly valve equal percentage select characteristic 4 Travel angle of rotation 100 Reference variable VETEC rotary plug valve equal percentage se lect characteristic 6 Travel angle of rotation 100 Reference variable Segmented valve ball equal percentage select characteristic 8 Travel angle of rotation 100 Reference variable EleMy2SUNelg 001 yersuesapung susp uosi xps Aug east peye UBLUISS aui Jo 2523 JEISUESEpUNG euosiuuae uestre 9A UO Aq palqns eie SUON BEY spes Au pA ac eu aq JOU EYE CLUBS aiia pue jou PS uogeuuexs adi og 210 48948 2 08 punos 2 04 De Ot euloq eJnjonags uondo D 09 PENNE 2 08 tL 04 7 De 8 amp 7 S L JI EL XS i J 09 9L aue eumpJedus juasiquue suondo
50. 44 EB 8384 6 EN Attachment to the control valve Mounting parts and accessories 4 7 2 Mounting the position 120 to 350 cm actuators with 15 mm rated sensor with attachment travel For other actuator sizes or travels se o lect the lever and pin position from the travel according to table on page 21 L and XL levers are in IEC 60534 6 cluded in the mounting kit Required mounting parts and accesso 3 Place the lever 1 and disk spring 1 2 ries Table 7 on page 54 on the sensor shaft Place the lever in mid position and hold it in place Screw Fig 16 on the nut 1 1 1 Place the lever 1 on the position sensor Screw the two bolts 14 to the bracket in mid position and hold it in place Un 9 1 of the stem connector 9 place the thread the nut 1 1 and remove the lever follower plate 3 on top and use the together with the disk spring 1 2 from screws 14 1 for fastening th haft SAE 5 Place the bracket with the sensor at the 2 Screw the position sensor 20 onto the KAMUR ribin sudra monner bracket 21 follower pin 2 rests in the slot of the fol The standard attached M lever with the fol lower plate 3 then screw the bracket lower pin 2 at position 35 is designed for using its fixing screws onto the valve 20 21 11 12 Nut Disk spring Follower pin Follower plate Stem connector Bracket Pin Screws Position sensor Bracket am Fig 16 Moun
51. 534 6 NAMUR rib or attachment to rod type yokes All mounting kits from Table 3 can be used Connecting plate in stainless steel EB 8384 6 EN Attachment to rotary actuators All mounting kits from Table 5 can be used except for the heavy duty version Connect ing plate in stainless steel 4 10 Air purging function for sin gle acting actuators The instrument air leaving from the positioner is diverted to the actuator spring chamber to provide corrosion protection inside the actua tor The following must be observed Direct attachment to Type 3277 5 stem ex tends FA stem retracts FE The air purging function is automatically provided Direct attachment to Type 3277 175 to 750 cm FA Remove the stopper 12 2 Fig 4 at the black connection block and make a pneumatic connection to the spring chamber on the vented side NOTICE Mounting possibly incorrect when old powder paint coated aluminum connection blocks are used Mount old powder paint coated aluminum connection blocks as described in sections on Attach ment according to IEC 60534 6 NAMUR rib or attachment to rod type yokes and Attach ment fo rotary actuators FE The air purging function is automatically provided 49 Attachment to the control valve Mounting parts and accessories Attachment according to IEC 60534 6 NAMUR rib or attachment to rod type yokes and to rotary actuators The positioner requires an additiona
52. 534 6 NAMUR section 4 2 Attachment according to VDI VDE 3847 section 4 3 Attachment to Type 3510 Micro flow Valve section 4 4 Attachment to rotary actuators acc to VDI VDE 3845 section 4 5 Design and principle of operation Serial Interface 16 gt 1 ENA 04 X VNLUM IZA a Cee 888 5 x Depending m SR egi TN E 52 Ba CA 1 2 3 4 5 6 f 8 Control valve Travel sensor PD controller A D converter Microcontroller i p converter Air capacity booster Pressure regulator Flow regulator Volume restriction Inductive limit contact Solenoid valve Analog position transmitter or binary input Fig 1 Functional diagram 10 Software limit contacts A1 A2 Fault alarm output A3 LCD Actuation of solenoid valve Electrical insulation D A converter Communication interface HART connection Binary input BI Pressure sensor for supply air p Pressure sensor for signal pressure Forced venting Options EB 8384 6 EN 3 1 Safety function SIL The safety function is based on the shutdown of the i p converter 6 This causes the pneumatic actuator to be vented and the valve to move to its fail safe position Monitoring of the input signal The i p converter is switched off when the input signal of the positioner at terminals 11 12 falls below 3 8 mA or 4 4 mA de pending on the positioner version a signal range of 4 to 20 mA is
53. AMSON for repair 104 EB 8384 6 EN Code list Operational error Error Pe Condensed state message active when prompted Err appears Pe action When fault alarms exist they are displayed here 57 Control loop Control loop error the valve no longer follows the controlled variable within Additional indication at tolerable times tolerance band alarm Code 19 the fault alarm contact Actuator is blocked Positioner attachment has shifted subsequently Insufficient supply pressure Status classification Maintenance required Recommended Check attachment action Check supply pressure Mounting arrangement or linkage has slipped Valve trim particularly with soft seat is worn Status classification Maintenance required Check valve and positioner attachment Calibrate zero We recommend to re initialize the positioner if zero deviates by more than 5 Status classification Failure cannot be classified Internal device er The positioner goes to the fail safe position SAFE ror Additional indication at the fault alarm contact Status classification Failure cannot be classified Return positioner to SAMSON for repair action ii data The error is detected by automatic monitoring and corrected automatically memory EB 8384 6 EN 105 Code list Error codes Condensed state message active when prompted Err appears Recomm
54. Aud ayy Aq eie suoneJeye 1o speg A UO penao aq By pres eq JOU EUS ago ameus 8 I 9 9 jeeus 96 A fa pun Jeeg yor Bur Jg s 7 4 e A Ty amp b M 0102 gL snBny Biemuosuneig peuonueu spiepuejs eu UM Ag Ajajes pue qeu 08559 01 X 2002 X3 1V OL 81d 3 432 NOILVNIINYX3 3dAJ1 23 01 FINGSAHDS ueg pun Hiemyssuneig uosipexrsAud did PP SsodeOXSSzZ 01122 001 eepiesepung yeisuesapung euosiuuaa aed pay Sl eyndsip Jo aseo uj ji amp suesepung aubsiuuoo uosijexie ud eui Aq alqns ee Jo speg uoneieqe paenan sengiyen SY Pea eq JOU peys dwg erogjo pue aneus sjueuusgers 9 3 jeeus OU Tu x3 ad synodo peju ABieue uu ey peanbe sasn ON 19 jo adAL Bale Sy jo eprsino palesu eq eus sesnj aoejiajul JSS jenes eu 0 seues ui aq eys OF Xew Jo juano sn jeuiuou e
55. B 8384 6 EN 85 Adjusting the limit contact 9 Adjusting the limit contact The positioner version with an inductive limit contact has an adjustable tag 1 mounted on the axis of rotation which operates the proximity switch 3 For operation of the inductive limit contact the corresponding switching amplifier ac cording to EN 609475 6 see section 5 2 1 must be connected to the output circuit When the tag 1 is located in the inductive field of the switch the switch assumes a high resistance When it moves outside the field the switch assumes a low resistance Normally the limit contact is adjusted such that the fail safe position of the valve is indi cated when the contact s switching state changes Adjustment screw 2 Fig 26 Adjusting the limit contact 86 Metal tag 1 Note The inductive limit contact replaces the software limit contact A1 with ter minal assignment 41 42 Each switching position can optionally be set to indicate when the tag has en tered the field or when it has left the field The second software limit contact re mains effective the function of the software limit contact A1 is disabled D Software adaptation Code 38 inductive alarm is set to YES The inductive limit contact is connected to the ter minals 41 42 The device is set up ac cordingly in the delivered state Proximity switch 3 EB 8384 6 EN Adjusting the switching point D Note
56. HART communication PST appears on the display when the on site operation is locked by the time controlled partial stroke test In these cases codes can only read over the SSP interface When attaching the positioner to the control valve the follower pin must be inserted in the proper pin position on the lever depending on the travel angle For initialization using NOM nominal range or SUB substitute calibration the pin position must be entered For initialization using MAX MAN and 2 the pin position is not required however it is required under Code 5 to display the nominal range 91 Code list Code Parameter Readings Description NO values default setting Pin position Pin position Standard Adjustment range Code 4 Code 5 Code 5 If you select a pin position in 4 7 9 3 6 to 17 7 Code 4 that is too small the 25 49 5 0 to 25 0 positioner switches to SAFE 35 15 0 7 0 to 35 4 mode for reasons of safety 50 30 0 10 0 to 50 0 70 40 0 14 0 to 70 7 60 0 20 0 to 100 0 120 0 40 0 to 200 0 90 0 24 0 to 100 0 continued Nominal range For initialization using NOM nominal range or SUB substitute 15 0 mm or angle ESC calibration the nominal range must be entered The possible ad justment range depends on the pin position from the table for Code 4 After initialization to the maximum range MAX the maximum nominal travel angle reached on initialization is displayed Initialization mode
57. L ueg pun gid yesuesa pung eu siuyoo uosi exis Aud ANVIABSIS Blemuosunzig 91 LBE 00 Seresepung desussepung euosiuuoa UssyewreAud aad YS xO WALES aui ayndsip jo 2582 Heisuesopung eu Aq BACIdde are jo uongdeqe noya AUS pajejnouo eu rea you eys diues jeyo pue enjeubrs jnouyen serene uoneunuexe adA 23 L G YOOUS 7 du 28 9 vu svg A wes Jo vu Sgii A 8 ejes Ajeorsuuul o uonoeuuoa e x3 uonoejoud ed 4 du eg Mu OSs yu 09 A oze f noua ejes Ajeorsunnul pape e OL uomoeuuoo aol jo AAW Gc EB 8384 6 EN 28718 RT BABA yaube ZS L9 pue cpi Lp seua E ALI UTE Je 1 oS 2 08 2 08 2 SS 209 7 69L YW 26 2 92 7 0 09 De 55 aBuel AISSI ssep 2 s Shun Jo pue
58. N Code list Parameter Readings Description values default setting Us Position transmitter test Testing the position transmitter Values can be entered in relation to 10 0 to 110 0 of the op operating range erating range ESC default The momentary valve position is used in initialized positioners lo value is last indicated value cally as the start value bumpless changeover to the test mode On of the position transmitter testing over software the entered simulation value is issued as the position feedback signal for 30 seconds 3 Analog position transmitter Code 29 30 31 can only be selected if the position transmitter optional is installed Error message in case of Failure and Function check condensed state cause an Function check condensed error message to be generated 9 9 Failure condensed state causes an error message to be generated Error message in case of Maintenance required and Out of specifica Maintenance required and tion condensed state cause an error message to be gen Out of specification con erated Failure condensed state causes an error message to be YES No ESC generated Clockwise Counterclockwise Direction of rotation to reach the valve s CLOSED position view onto rotary switch with positioner cover open Note Needs only be entered in initialization mode SUB Code 6 Blocking position Distance to CLOSED po
59. Required mounting parts and accesso on the nut 1 1 ries Table 7 on page 54 Follow the instructions describing attachment Fig 18 to the standard positioner in section 4 5 1 Place the lever 1 on the position sensor Instead of the positioner attach the position in mid position and hold it in place Un sensor 20 with its mounting plate 21 thread the nut 1 1 and remove the lever together with the disk spring 1 2 from the sensor shaft 2 Screw the position sensor 20 onto the mounting plate 21 3 Replace the follower pin 2 normally at tached to the lever 1 with the metal fol lower pin 5 mm from the accessories and screw it into the hole for pin position 90 Lever Nut Disk spring Follower pin Position sensor Mounting plate Fig 18 Mounting on rotary actuators EB 8384 6 EN 47 Attachment to the control valve Mounting parts and accessories 4 8 Mounting the leakage The M8 threaded connection on the NAMUR seisot rib should preferably be used to mount the sensor Fig 19 Fig 19 is Tip Normally the control valve is delivered with Xr If the positioner was mounted directly positioner and leakage sensor already onto the actuator integral attach mounted ment the NAMUR interfaces on ei If the leakage sensor is mounted after the ther side of the valve yoke can be valve has been installed or it is mounted on used to mount the leakage sensor to another control valve proceed as
60. Rotary actuators 24 to 100 opening angle Travel range Adjustable Adjustable within the initialized travel angle of rotation travel can be restricted to 1 5 at the maximum Reference Signal range 4 to 20 mA Two wire device reverse polarity protection Minimum span 4 mA variable w imit 3 6 mA for display Emergency venting at x3 8 mA or 4 4 mA depending on ver sion Load impedance 9 2 V corresponding to 460 Q at 20 mA Supply air 1 4 to 7 bar 20 to 105 psi Air quality acc Maximum particle size and density Class 4 Oil content Class 3 to ISO 8573 1 Pressure dew point Class or at least 10 K below the lowest ambient temperature edition 2001 to be expected 02 Signal pressure output O bar up to the capacity of the supply pressure Can be limited between 1 4 and 7 0 bar by software Characteris Adjustable Linear equal percentage reverse equal percentage tic User defined over operator software Butterfly valve rotary plug valve and segmented ball valve Linear equal percent age Deviation Air output Actuator filled 3 _ 3 B At 6 bar 8 5 m 3 h At Ap 1 4 bar 3 0 m h Ky 20 c 0 09 Actuator vented At Ap 6 bar 14 0 m 3 h At Ap 1 4 bar 4 5 3 Ky 0 15 Permissible ambient temperature 20 to 80 C for all versions 45 to 80 C with metal cable gland 25 to 80 C with inductive limit contact SJ2 S1N and metal cable gland The li
61. Series 3730 Type 3730 6 Electropneumatic Positioner with HART communication and pressure sensors COMMUNICATION PROTOCOL Mounting and Operating Instructions EB 8384 6 EN 1300 1623 Firmware version 1 03 Edition February 2015 Definition of signal words DANGER Hazardous situations which if not Property damage message or mal avoided will result in death or seri function ous Injury a Note WARNING Additional information Hazardous situations which if not avoided could result in death or seri ous in SE Mp jury 9 R ecommended action 2 EB 8384 6 EN 3 1 32 9 9 3 4 3 6 4 1 4 1 1 4 1 2 4 2 4 3 4 4 4 5 4 5 1 4 6 4 6 1 4 7 4 7 1 4 7 2 4 7 3 4 7 4 4 8 4 9 4 10 4 11 5 1 5 1 1 Contents Important safety instructions csscssscssssssscssssssnsessscseccssasssascsssessessenseses 7 RR M 8 Design and principle of operation Lese eese eese rennen eene 9 MOMEHOR 11 11 Sondeo oj 12 Configuration using the TROVIS VIEW software 12 Additional equipment sss eene 12 Ls TIS Foro o 14 Attachment to the control valve Mounting parts and accessories 20 GGG S M 22 Type 3277 Nr
62. Turn 9 gt Code 5 Press eg Code 5 blinks Turn Nominal travel of the valve Press 69 76 Select the initialization mode AR Li mum 4 an gt 4 9 Init mode Default MAX SN 65 Turn WY gt Code 6 Press 69 Turn SUB Press X to confirm the SUB as the initializa tion mode Enter the direction of action WA Direction of action Default i Ip Turn X9 gt Code 7 Press eg Code 7 blinks Turn gt Direction of action 77 7 Press 69 Deactivate travel limit Travel limit Default No Turn 29 Code 11 Press amp Code 11 blinks Turn gt Press eB EB 8384 6 EN Change pressure limit and control parame ters Note Do not change the pressure limit Code 16 Only change the control parameters K Code 17 and Code 18 if the settings of the the re placed positioner are known Pressure limit Default No Kp level Default 7 Ty level Default 2 Turn Code 16 17 18 Press eg Code 16 17 18 blinks Turn to set the control parameter select ed Press to confirm the setting EB 8384 6 EN Start up and settings Enter closing direction and blocking position Closing direction direction of ro tation causing the valve to move to the CLOSED position view on to positioner display Default CCL counterclockwise Blocking position Default 0
63. a NAMUR rib EB 8384 6 EN 33 Attachment to the control valve Mounting parts and accessories 4 4 Attachment to Type 3510 Micro flow Valve Fig 9 Required mounting parts and accesso ries Table 3 on page 52 Observe the travel table on page 21 The positioner is attached to the valve yoke using a bracket 1 Fasten the bracket 9 1 to the stem con nector 2 Screw the two bolts 9 2 to the bracket 9 1 of the stem connector 9 place the follower plate 3 on top and use the screws 9 3 for fastening 3 Mount the travel indication scale acces sories to the outer side of the yoke using the hex screws 12 1 ensuring that the scale is aligned with the stem connector 4 Fasten the hex bar 11 onto the outer side of yoke by screwing the M8 screws 11 1 directly into the holes on the yoke 5 Fasten the bracket 10 to the hex bar 11 using the hex screw 10 1 washer and tooth lock washer 6 Mount connecting plate 6 or pressure gauge bracket 7 with pressure gauges on the positioner making sure the two seals are seated properly 7 Unscrew the standard M lever 1 includ ing follower pin 2 from the positioner shaft 8 Take the S lever 1 and screw the follow er pin 2 in the hole for pin position 17 34 9 Place the S lever 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 bo
64. al Connecting plate G NPT Reversing amplifier 3710 see drawing of heavy duty version for dimensions 1079 1118 1079 1119 no longer available see drawing of light version for dimensions Fig 30 Attachment to rotary actuators acc to VDI VDE 3845 Sept 2010 fixing level 1 to AAA size 112 EB 8384 6 EN Dimensions in mm 15 1 Fixing levels according to VDI VDE 3845 September 2010 77777777 Fixing level 2 bracket surface 777777777 Fixing level 1 actuator surface ae B Actuator Dimensions in mm Sie 2d My D AAO 50 25 15 55forM5 66 50_ AAT 80 30 20 55forM5 96 50_ AA2 80 30 30 5 5forms 96 50_ s Flange type 05 according to DIN ISO 5211 EB 8384 6 EN 113 Valve characteristic selection 16 Valve characteristic selection The characteristics that can be selected in Code 20 are shown in following in graph form Note A characteristic can only be defined user defined characteristic using a worksta tion operator software e g TROVIS VIEW Linear select characteristic 0 Travel angle of rotation 100 Reference variable Equal percentage select characteristic 1 Reverse equal percentage select characteristic 2 Travel angle of rotation 100 Travel angle of rotation 100 Reference variable Reference variable 114 EB 8
65. are displayed here 5 No emergency mode The travel measuring system of the positioner has a self monitoring func tion see Code 62 An emergency mode open loop control is not available for certain ac tuators such as double acting actuators In this case the positioner changes to the fail safe position SAFE when a measuring error occurs Hardware e Initialization key jammed Additional indication at the A hardware error has occurred The positioner changes to the fail fault alarm contact safe position SAFE As long as the error exists no EXPERTplus diagnostic messages are logged Status classification Failure During the initialization the positioner automatically checks whether the actuator has such a function or not Status classification Status classification No message Recommended action information confirm if necessary further action required 108 EB 8384 6 EN Code list Diagnosis errors Error codes Recommended Condensed state message active when prompted Err appears When fault alarms exist they are displayed here Unassigned Collective error Messages generated in EXPERTplus The error does not have any direct effect on the positioner s functioning Status classification required cannot be classified Valve signature can during automatic plotting of the valve signature celed Error messages are not yet saved in a
66. at the seals are cor rectly seated For positioners with air purging remove the stopper 5 before mounting the positioner For positioners without air purging replace the screw plug 4 with a vent plug Select required lever size 1 M L or XL and pin position according to the actua tor size and valve travel listed in the trav el table on page 21 Should a pin position other than position 35 with the standard M lever be required or an or XL lever size be required proceed as follows Screw the follower pin 2 in the as signed lever hole pin position as speci fied in the travel table Only use the lon ger follower pin 2 included in the mounting kit Place the lever 1 on the shaft of the po sitioner and fasten it 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 31 Attachment to the control valve Mounting parts and accessories Insert the formed seal 6 2 in the groove of the adapter bracket Insert the formed seal 17 1 into the turnboard 17 and mount the turnboard to the adapter block 13 using the screws 17 2 Mount the blank plate 18 to the turn board using the screws 18 1 Make sure that the seals are correctly seated Note A solenoid valve can also be mount ed in place of the blank plate 18 The orientation of the turnboard 17 determines the mounting position of the solenoid valve Alternativel
67. ation Read only Min transit time CLOSED Minimum closing time determined during initialization Read only Set point Set point w used in automatic mode Read only 4 to 20 mA correspond to 0 to 100 Firmware version Device type and current firmware version displayed in alternating Read only sequence 100 EB 8384 6 EN Code list Code Parameter Readings Description NO values default setting Control signal y in in relation to the travel range determined during initialization The positioner builds up its maximum output pressure see description in Code 14 and 15 The positioner vents completely see description in Code 14 and 15 The positioner is not initialized Internal solenoid valve Indicates whether a solenoid valve forced venting is installed or forced venting not Read only If a voltage supply is connected at the terminals 81 82 YES and HIGH appear on the display in alternating sequence If a volt age supply is not connected actuator vented fail safe position in dicated on the display by the S icon YES and LOW appear on the display in alternating sequence Bus address Using the HART protocol all connected control room and field 0 to 15 ESC units can be addressed individually using a point to point connec tion the standard multidrop bus Point to point connection HART master device connected to one HART field unit With this connection the device address must al so be s
68. be used with new actuators Index 01 Old and new plates are not interchangeable Connecting plate 6 Accessories for Pressure gauge bracket 7 Pressure gauge mounting kit 8 up to max 6 bar output supply 50 EB 8384 6 EN Attachment to the control valve Mounting parts and accessories Table 2 Direct attachment to Type 3277 Actuator Fig 4 Order no Mounting Standard version for actuators 175 240 350 355 700 750 1400 7453 parts Version compatible with paint for actuators 175 240 350 355 700 750 cm 1402 0941 G 1402 0970 1 4 NPT NPT 1402 0976 1402 0971 4 NPT NPT 1402 0978 1400 6444 V4 NPT 8 NPT 1402 0911 1400 6445 4 NPT 8 NPT 1402 0912 GA4 G35 1400 6446 V4 NPT NPT 1402 0913 G 4 G 36 1400 6447 St steel Piping with screw fittings NPT 3e 1402 0914 for actuator stem retracts fail safe action GA G3 1402 0972 with air purging of the top diaphragm chamber Sigal Va NPT NPT 1402 0979 G4 G 1402 0973 4 NPT NPT 1402 0980 G 4 G 1400 6448 4 NPT NPT 1402 0915 1400 6449 4 NPT NPT 1402 0916 GA4 G35 1402 0974 4 NPT NPT 1402 0981 G 4 G 1402 0975 4 NPT s NPT 1402 0982 1400 8819 4 NPT 1402 0901 Steel St steel Steel St steel Steel Accessories 355 cm St steel Steel St steel Steel St steel Connection block with
69. bed sition sensor in sections 7 and 8 Since 2009 the back of the posi tion sensor 20 is fitted with two pins acting as mechanical stops for the lever 1 If this position sensor is mounted using old mounting parts two corresponding 8 mm holes must be drilled into the mounting plate bracket 21 A template is available for this pur Positioner unit with sensor mounted on a mi pose See Table 7 cro flow valve Required mounting parts and accesso ries Table 7 on page 54 In the positioner version with an external po sition sensor the sensor located in a separate housing is attached over a plate or bracket to the control valve The travel pick off corre sponds to that of a standard device The positioner can be mounted as required to a wall or a pipe For the pneumatic connection either a con necting plate 6 or a pressure gauge bracket 7 must be fixed to the housing depending on the accessory chosen Make sure the seals 6 1 are correctly inserted see Fig 5 bot tom right For the electrical connection a 10 meter con necting lead with M12x1 connectors is in cluded in the scope of delivery Note D n addition the instructions in sec lions 5 1 and 5 2 apply for the pneumatic and electrical connec lion 42 EB 8384 6 EN Attachment to the control valve Mounting parts and accessories 4 7 1 Mounting the position retracts is aligned with the marking sensor with direct attac
70. chment to the control valve Mounting parts and accessories place spacers 11 underneath if neces 5 Unscrew the standard follower pin 2 sary from the positioner s M lever 1 Attach 2 For SAMSON Type 3278 and VETEC the follower pin 5 mm included in 160 Rotary Actuators screw the adapt the mounting kit to pin position 90 6 Mount connecting plate 6 for required er 5 onto the free end of the shaft or connecting thread or pressure place adapter 5 1 onto the shaft of the VETEC R Actuator Place adapter 3 on gauge bracket 7 with pressure gauges to Type 3278 VETEC 160 and VETEC R on the positioner making sure the two Actuators For VDI VDE version this seals 6 1 are seated properly Dou ble acting springless rotary actuators re quire the use of a reversing amplifier on the connection side of the positioner housing refer to section 4 6 step depends on the actuator size 3 Stick adhesive label 4 3 onto the cou pling in such a manner that the yellow part of the sticker is visible in the window of the housing when the valve is OPEN 7 For actuators with a volume of less than 300 fit the restriction order 1400 6964 into the signal pressure output of the positioner or the output of the pressure gauge bracket or connecting Adhesive labels with explanatory sym bols are enclosed and can be stuck on the housing if required 4 Fasten coupling 4 on the slotted ac
71. d as No mes sage this event does not have any affect on the condensed state The condensed state appears on the display represented by the following icons Positioner display Text e g TUNE or EB 8384 6 EN Out of specifica 2 Maintenance quired Mainte nance demanded The message with the highest priority deter mines the condensed state in the positioner If fault alarms exist the possible source of Operation Turn gt gt YES Press C9 display gt Confirming error message error is displayed in Code 49 onwards In this case ERR appears on the display Turn gt Select the error code that you want to confirm Press The error message is confirmed Error caused by pin position Refer to the code list section 14 for possible causes and the recommended action Fault alarm output Failure as the condensed state causes the optional fault alarm output to be switched The Function check condensed state can also activate the fault alarm output Code 32 The Maintenance required Maintenance demanded condensed state and Out of specification can also activate the fault alarm output Code 33 8 3 1 Confirming error mes sages Enable configuration Note If no settings are entered within 120 seconds the enabled configuration function becomes invalid 9 gt Code 3 display No Press eg Code 3 blinks E
72. de scribed in following The start up of the leakage sensor is de aa S ribed in detail in the Operating Instructions bores for EXPERTplus Valve Diagnostics gt EB 8389 1 EN Risk of malfunction due to incorrect fastening Fasten the leakage sensor using a torque of 20 5 Nm a ys zt ig hl 1 Leakage sensor 2 Screw 3 Plug connection Fig 19 Mounting the leakage sensor 48 EB 8384 6 EN Attachment to the control valve Mounting parts and accessories 4 9 Attaching positioners with stainless steel housings Positioners with stainless steel housings re quire mounting parts that are completely made of stainless steel or free of aluminum Note The pneumatic connecting plate and pressure gauge bracket are available in stainless steel order numbers listed below The Type 3710 Pneumatic Re versing Amplifier is also available in stainless steel Connecting plate 1400 7476 stainless steel 1 4 NPT 1400 7477 Pressure gauge 1402 0265 bracket NPT 1400 7108 stainless steel Table 1 to Table 6 apply for attaching posi tioners with stainless steel housings with the following restrictions Direct attachment All mounting kits from Table 1 and Table 2 can be used The connection block is not re quired The stainless steel version of the matic connecting plate routes the air internal ly to the actuator Attachment according to IEC 60
73. de 4 blinks Turn gt Pin position on lever see relevant section on attachment Press 69 Select the initialization mode and enter end positions Init mode Default MAX EB 8384 6 EN POS1 end position 1 POS2 end position 2 Turn 29 gt Code 6 Press eg Code 6 blinks Turn 29 gt MAN2 Press to confirm the MAN2 as the initial ization mode POST and the current an gle position of the lever are indicated on the display in alternating sequence Turn clockwise in small steps until the re quired valve position is reached The valve must be moved with a monotonically in creasing signal pressure Press to confirm the valve position gt WAIT The valve position is adopted after the pressure settles POS2 and the current an gle position of the lever are indicated on the display in alternating sequence Turn 2 until the valve reaches its OPEN po sition Press to confirm the valve position WAIT Initialization can be started as soon as MAN2 is indicated again on the display Start initialization gt Press INIT key After initialization the tight closing function Code 14 is deactivated EB 8384 6 EN Start up and settings 7 6 5 SUB Substitute calibra tion A complete initialization procedure takes several minutes and requires the valve to move through its entire travel range several times This initialization mode however is a
74. e connection at the 7 Mount cover 11 on the other side side of the yoke must be fitted with a venting Make sure that the vent plug is located at plug accessories the bottom when the control valve is in Mounting the position sensor stalled to allow any condensed water that collects to drain off 1 Place the lever 1 on the sensor in mid position and hold it in place Un thread the nut 1 1 and remove the lever together with the disk spring 1 2 from the sensor shaft 2 Screw the position sensor 20 onto the mounting plate 21 3 Depending on the actuator size and rat ed valve travel determine which lever and position of the follower pin 2 is to be used from the travel table on page bil The positioner is delivered with the M lever in pin position 35 on the sensor If necessary remove the follower pin 2 from its pin position and move it to the hole for the recommended pin po sition and screw tight 4 Place the lever 1 and disk spring 1 2 on the sensor shaft Place the lever in mid position and hold it in place Screw on the nut 1 1 5 Place follower clamp 3 on the actuator stem align it and screw tight so that the mounting screw is located in the groove of the actuator stem 6 Place the mounting plate together with the sensor onto the actuator yoke so that the follower pin 2 rests on the top of the follower clamp 3 It must rest on it with spring force Fasten the mounting plate
75. e ibis iiis Device description for Type 3730 6 quirements communicator HART For PC DTM file according to specification 1 2 suitable for integrating the device into frame applications that support the use of FDT DTM e g PACTware See article code in section 2 Signal state No response 1 0 mA Response 22 2mA One fault alarm contact floating Signal state No response 22 2 mA No fault alarm Response 1 0 mA Fault alarm For connection to NAMUR switching amplifier acc to EN 60947 5 6 Housing Die cast aluminum EN AC AlSi12 Fe EN AC 44300 acc to DIN 1706 chro mated and powder paint coated Special version stainless steel 1 4581 External parts Stainless steel 1 4571 and 1 4301 Cable gland M20 x 1 5 black polyamide Weight Approx 1 0 kg k Conformity 8384 6 15 Design and principle of operation Options for Type 3730 6 Positioner Electronic forced venting Approval acc to IEC 61508 SIL 24 V Electrical isolation and reverse polarity protection Static destruction limit 40 V U 57V corresponding to 4 8 mA at Power consumption 2 3 84 kQ 24 V 114 mW lt 12 V emergency venting at 12 V Signal 1 response gt 19V Solenoid valve Approval acc to IEC 61508 SIL Input 24 V DC Reverse polarity protection Static destruction limit 40 V Signal 0 no response U 57 corresponding to 4 8 mA at Power consumpt
76. e site of installation as wall foundations vary from site to site 1 Only new connecting plates can be used with new actuators Index 01 Old and new plates are not interchange able 54 EB 8384 6 EN 5 Connections WARNING Risk of injury due to the actuator stem extending or retracting Do not touch or block the actuator stem NOTICE Malfunction due to incorrect se quence of mounting installation and start up Keep the following sequence 1 Remove the protective film from the pneumatic connections 2 Mount the positioner on the control valve 3 Connect the supply air 4 Connect the electrical power 5 Perform the start up settings 5 1 Pneumatic connections NOTICE Malfunction due to incorrect connec tion of the supply air Do not connect the compressed air directly to the threaded connections in the positioner housing Screw the screw fittings into the connecting plate pressure gauge mounting block or connection block from the accessories The pneumatic connections in the connecting plate pressure gauge mounting block and connection block are optionally designed as EB 8384 6 EN Connections a bore with NPT G thread Custom ary fittings for metal or copper tubing or plastic hoses can be used Risk of malfunction due to failure to comply with required air quality Only use supply air that is dry and free of oil and dust Read the maintenance instructions
77. e the positioner with the back of the positioner vent opening facing up wards The vent opening must not be sealed when the positioner is installed on site Vent opening Proper shipping and storage are assumed Do not ground electric welding equipment near to the positioner Note The device with a CE marking fulfills the requirements of the Directive 94 9 EC and the Directive 2004 108 EC The declaration of conformity is included on the enclosed CD ROM EB 8384 6 EN 7 Article code 2 Article code Positioner 3730 6x x x x x x x xx 00 With HART communication and pressure sensors Explosion protection ATEX Il 2G Ex ia IIC IIB T6 Il 2D Ex tb T6 IP66 110 IECEx Ex ia IIC IIB T6 Ex d ia IIC IIB T6 Ex tD A21 IP66 T80 C 111 GOST 1Ex ia IIC T6 Gb 1Ex tb T80 C Db IP66 113 FM IS Class 1 1111 Div 1 Gr ABCDEFG AEx ia IIC Class Zone 130 NI Class Div 2 Gr ABCD S Class Il Div 2 Gr FG ATEX Il Ex nA II T6 1 Ex ic IIC IIB T6 Il 3D Ex tc T80 C IP66 810 IECEx Ex nA II T6 Ex nL IIC IIB T6 Ex tD A22 IP66 T80 C 811 GOST 2Ex nA IIC Ge 2Ex ic T6 Gc 2Ex tc T8O C Dc IP66 813 Additional equipment Inductive limit contact Without 0 J2 SN NC contact 0 J2 S1N NO contact 2 Venting function Without 0 Solenoid valve 24 V DC 1 Forced venting 24 V DC 2 Additional equipment Without 0 Position transmitter
78. ects the set point deviation This effect can be com pensated for by tuning the input filter without having to re initialize the positioner Enable configuration 9 gt Code 3 display No Press eg Code 3 blinks Turn 29 YES Press G9 display gt 78 Tuning the input filter e Tuning the input filter Default MAX ge 0 X Turn X9 gt Code 6 Press eg Code 6 blinks Turn 9 gt KP Press INIT key to start the tuning During the tuning the valve moves through its whole range and the input filter is recali brated 7 7 Zero calibration In case of inconsistencies in the closed posi tion of the valve e g with soft seated plugs it might be necessary to recalibrate zero NOTICE The process is disturbed by the move ment of the actuator stem Do not perform zero calibration while the process is running First isolate the plant by closing the shut off valves Note The positioner must be connected to the supply air to perform the ze ro calibration A zero calibration is not possible if there is zero point shift of more than 5 In this case Code 54 is activated The positioner must be re initialized EB 8384 6 EN Enable configuration gt Code display No Press amp Code 3 blinks Turn lt gt YES Press display gt Perform zero calibration Init mode Default MAX Turn amp gt Code 6 Press eg Code 6 blinks
79. em can be used to establish communication and oper ate the positioner 3 4 Configuration using the TROVIS VIEW software The positioner can be configured with SAM SON s TROVIS VIEW Configuration and Operator Interface version 4 For this pur pose the positioner has a digital interface SSP to allow the RS 232 or USB port of a computer to be connected to it over an adapter cable The TROVIS VIEW software enables the user to easily configure the positioner as well as view process parameters online Note TROVIS VIEW can be downloaded free of charge from our website at http www samson de gt Services gt Software gt TROVIS VIEW 3 5 Additional equipment Inductive limit contact In this version the rotary shaft of the posi tioner carries an adjustable tag which actu ates the built in proximity switch The option al inductive contact 11 is connected to AT while the remaining software limit contact is connected to A2 Solenoid valve If the operating voltage for the solenoid valve 12 falls below 12 V the supply pres sure for the booster is vented to the atmo sphere As a result the actuator is vented and the control valve moves to the fail safe position In manual mode the manual set point is reset to 0 A different manual set point must entered again Forced venting If the voltage signal at terminals 81 82 falls below 12 V the i p converter 6 is de energized The positioner vents the ac
80. em retracts FE AIR TO CLOSE Fail open for globe and angle valves For tight closing valves the maximum signal pressure PStnax is roughly estimated as fol lows max d n Ap 4 A pst F bar d Seat diameter cm Ap Differential pressure across the valve bar A Actuator diaphragm area cm F Upper bench range value of the actuator bar If there are no specifications calculate as follows Required supply pressure Upper bench range value 1 bar 56 5 1 3 Signal pressure output The signal pressure at the output 38 of the positioner can be restricted to 1 4 bar 2 4 bar or 3 7 bar in Code 16 The limitation is not activated 7 0 bar by default 5 2 Electrical connections DANGER Risk of electric shock and or the for mation of an explosive atmosphere For electrical installation observe the relevant electrotechnical regulations and the accident prevention regula tions that apply in the country of use In Germany these are the VDE regu lations and the accident prevention regulations of the employers liability insurance The following regulations apply to in stallation in hazardous areas EN 60079 14 2008 VDE 0165 Part 1 Explosive Atmospheres Electrical Installations Design Selec tion and Erection WARNING Incorrect electrical connection will render the explosion protection un safe Adhere to the terminal assignment Do not undo the ename
81. ence TEST D1 70 Bar graph display indicating the progress of the initializa tion Initialization successfully com pleted Positioner in automatic mode C The time required for the initialization proce dure depends on the actuator transit time and can take a few minutes After a successful initialization the positioner runs in closed loop operation indicated by the G closed loop operation icon A malfunctioning leads to the process being canceled The initialization error appears on the display according to how it has been classified by the condensed state See sec tion 8 3 Note An error during the recording of the valve signature is indicated by Code 81 The valve signature does not affect closed loop operation Closed position AIR TO CLOSE IF the slide switch is set to AIR TO CLOSE the positioner automatically switches to the direc tion of action increasing decreasing 7N after initialization has been completed This results in the following assignment between reference variable and valve position EB 8384 6 EN Reference variable w Valve OPEN at The tight closing function has been activated Set Code 15 final position w gt to 99 for three way valves Direction of action Closed position Canceling an initialization process An initialization procedure in progress can be canceled by pressing the rotary pushbut ton STOP appears for three seconds on
82. ended action When fault alarms exist they are displayed here KP too low Proportional action coefficient Kp level lower than 3 was detected during ini tialization Note A Kp level lt 3 does not cause the initialization process to be canceled Status classification Maintenance required Recommended Activate volume restriction in positioner output actione Increase the bypass restriction setting of booster if installed Hardware error Error codes Condensed state message active when prompted Err appears Recommended action When fault alarms exist they are displayed here x signal Actuator s measured value recording failed Additional indication at Conductive plastic element defective the fault alarm contact The emergency mode on the display is indicated by a blinking closed loop op eration icon and 4 dashes instead of the position reading Note on the closed loop operation If the measuring system has failed the positioner is still in a reliable state The positioner switches to emergency mode where the position cannot be accurately controlled anymore However the positioner continues operation according to its set point so that the process remains in a safe state Status classification Maintenance demanded Return positioner to SAMSON for repair action 63 ISIL shutdown w Emergency shutdown of the i p block is implemented by 3 8 mA or 4 4 mA depending on the positioner version 2 The
83. er goes to the fail safe position SAFE After canceling the fail safe position SAFE see section 8 2 2 it is absolutely essential that you check the lever and pin position as described in section 4 WARNING Risk of injury due to the actuator stem extending or retracting Before exchanging the lever or changing the pin position disconnect the supply air and electrical auxiliary power Initialization NOTICE The process is disturbed by the move ment of the actuator stem Do not initialize the positioner while the process is running only perform an initialization during start up with the shut off valves closed A signal pressure above the maximum permissible limit will damage the valve Check the maximum permissible sig nal pressure of the control valve be fore starting initialization If neces sary limit the signal pressure by con necting an upstream pressure reduc ing valve EB 8384 6 EN Start up and settings Malfunction due to changed mount ing or installation circumstances Reset the positioner to its default set tings and re initialize it after the posi tioner has been mounted on to anoth er actuator or its mounting location has been changed Note When the write protection is acti vated initialization cannot be started During initialization the positioner adapts itself optimally to the friction conditions and the sig nal pressure required by the control valve The type and ex
84. et to O Standard multidrop bus Up to 15 field units connected in paral lel to a single pair of wires The master device distinguishes them by their preset addresses between 1 and 15 47 HART write protection When write protection is active device data can be read but not YES No ESC overwritten over HART communication Diagnostic parameters Details on EXPERTplus Valve Diagnostics in the Operating Instructions gt EB 8389 1 EN EB 8384 6 EN 101 Code list Note The error codes listed in following appear in the display corresponding to their status classification set over the condensed state Maintenance required Maintenance de manded gt Out of specification Z blinking Failure NY IF No message is as signed to the error code as the status classification the error is not included in the condensed state A status classification is assigned to every error code in the default setting The status classification of error codes can also be changed as required using an operator soft ware e g TROVIS VIEW Initialization errors Error codes Condensed state message active when prompted ERR appears Recommended action When fault alarms exist they are displayed here x gt range Value of measuring signal too high or too low the lever operates near its me chanical stops Pin not mounted properly NAMUR attachment bracket slipped or follower pin not properly seated on the follower
85. fications for servicing explosion protected devices Read section 13 for maintenance calibration and adjustment work inside and outside hazardous areas 12 Firmware update serial in terface Firmware updates on positioners currently in operation can be performed as follows When updates are performed by a service employee appointed by SAMSON the up date is confirmed on the device by the test mark assigned by SAMSON s Quality Assur ance In all other cases only plant operator per sonnel with written approval may perform updates Updates are to be confirmed by ap proved personnel on the device Laptops and PCs connected to the power supply must not be used without an addition al protective circuit This does not apply to laptops in battery op eration In this case it is assumed that a bat tery powered laptop runs briefly for software programming or testing purposes a Updates outside the hazardous area Remove the positioners from the plant Update them outside the haz ardous area 89 Maintenance calibration and work on equipment b Updates on site Updates on site are only permitted after the plant operator presented a signed hot work permit After updating has been completed add the current firmware to the nameplate this can be done using labels 13 Maintenance calibration and work on equipment Interconnection with intrinsically safe cir cuits to check or calibrate the equipmen
86. fied in mm or angle provided Code 4 is activat ed EB 8384 6 EN Code list Description Fine tuning of the input filter The valve moves through its entire valve range Zero calibration The zero point is recalibrated NOTICE Valve will temporarily be moved from its operat ing point to CLOSED position Direction of action of the set point in relation to the valve position AA Wincreasing increasing a globe valve opens as the set point increases AN Increasing decreasing a globe valve closes as the set point increases The direction of action is adapted to the change in closed direction as follows ATO AIR TO OPEN On completing initialization the direction of action remains increasing increasing 77 A globe valve opens as the reference variable increases AIR TO CLOSE On completing initialization the direc tion of action changes to increasing decreasing AN globe valve closes as the reference signal increases Lower range value for the travel angle of rotation in the operating range Nominal range and characteristic are automatically adapted The operating range is the actual travel angle of the valve and is limited by the lower travel angle range value Code 8 and the upper travel angle range value Code 9 Usually the operating range and the nominal range are identical The nominal range can be limited to the operating range by the lower and upper travel angle range values The val
87. for upstream pressure reducing stations Blow through all air pipes and hoses thoroughly before connecting them If 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 retracts For rotary actuators the manufacturer s specifications for connection apply 5 1 1 To monitor the supply air supply and signal pressure output we recommend mounting pressure gauges see accessories in Table 2 to Table 7 Signal pressure gauges 5 1 2 Supply pressure The required supply air pressure depends on the bench range and the actuator s operat ing direction fail safe action 55 Connections The bench range is written on the nameplate either as the spring range or signal pressure range depending on the actuator The direc tion of action is marked FA or FE or by a symbol Note PLOW is indicated under Code if the supply pressure p is lower than the upper spring range value deter mined during plotting of the valve signature Actuator stem extends FA AIR TO OPEN Fail close for globe and angle valves Required supply pressure Upper bench range value 0 2 bar at least 1 4 bar Actuator st
88. g 6 and Fig 8 Electropneumatic positioners with VDI VDE 3847 interface Type 3730 6 xxxxxxx0xx0700 Order no Interface adapter 1402 0257 Mounting kit for attachment to SAMSON Type 3277 Actuator 1402 0868 Mounting kit for attachment to SAMSON Type 3271 Actuator non SAMSON actua 1402 0869 tors Travel pick off for valve travel up to 100 mm 1402 0177 Travel pick off for 100 to 200 mm valve travel SAMSON Type 3271 Actuator only 1402 0178 52 EB 8384 6 EN Attachment to the control valve Mounting parts and accessories Table 5 Attachment fo rotary actuators Fig 10 and Fig 11 Attachment acc to VDI VDE 3845 September 2010 see section 15 1 for details Actuator surface corresponds to fixing level 1 Size AAT to AAA version with CrNiMo steel bracket 1400 7448 Size AAT to AAA heavy duty version 1400 9244 Size AA5 heavy duty version e g Air Torque 10 000 1400 9542 Bracket surface corresponds to fixing level 2 heavy duty version 1400 8815 Attachment for rotary actuators with max 180 opening angle fixing level 2 and di 1400 9873 Attachment to SAMSON Type 3278 with 160 320 cm CrNiMo steel bracket 1400 7614 Attachment to SAMSON Type 3278 with 160 cm and to VETEC Type 5160 Type R and 1400 9245 Type M heavy duty version Mounting 1400 5891 and 1400 9526 Attachment to Camflex II 1400 91 20 Connecting plate 6 Attachment to SAMSON Type 3278 with 320 cm and to VETEC Type 320 heavy duty version
89. ge Code 52 is generated gt After initialization check the direction of action Code 7 and if necessary change it 7 6 3 MAN Initialization based on a manually selected OPEN position Before starting initialization move the con trol valve manually to the OPEN position The positioner calculates the differential trav el angle from the OPEN and CLOSED posi tions and adopts it as the operating range with limits of lower travel angle range value Code 8 and upper travel angle range val ue Code 9 Enable configuration Note If no settings are entered within 120 seconds the enabled configuration function becomes invalid Enable configuration Default No Turn gt Code 3 display No Press eg Code 3 blinks EB 8384 6 EN Start up and settings Turn lt gt YES Press G9 display Enter the pin position Pin position Default No Turn gt Code 4 Press amp Code 4 blinks Turn 9 gt Pin position on lever see relevant section on attachment Press 69 Select the initialization mode ae NAC INI Init mode Default MAX G Turn amp gt Code 6 Press eg Code 6 blinks Turn gt MAN Press to confirm the MAN as the initial ization mode Enter OPEN position IL Manual set point IL current angle of rotation is im og indicated A L Turn X9 gt Code Press eg Code 0 blin
90. h Make absolutely sure that gasket for ment the connecting plate 9 is correctly insert Type 3277 5 Actuator with 120 cm Fig 15 ed The signal pressure from the positioner is The connecting plate has threaded holes routed over the signal pressure connection of with NPT and G threads Seal the thread the connecting plate 9 Fig 15 left to the ed connection that is not used with the actuator diaphragm chamber To proceed rubber seal and square plug first screw the connecting plate 9 included in the accessories onto the actuator yoke Type 3277 Actuator with 175 to 750 cm The signal pressure is routed to the connec tion at the side of the actuator yoke for the version with actuator stem extends fail safe Turn the connecting plate 9 so that the correct symbol for the fail safe action actuator stem extends or actuator stem pressure Vent plug Signal pressure Nut Disk spring Follower pin Follower clamp Connecting plate Cover Marking 1227 5 597 20 Position sensor Actuator stem extends retracts v Mounting plate Fig 15 Mounting for Type 3277 5 Actuator left and Type 3277 Actuator right EB 8384 6 EN 43 Attachment to the control valve Mounting parts and accessories action For the fail safe action actuator stem 21 onto the actuator yoke using both retracts the connection on the top dia fixing screws phragm case is used Th
91. ignal pressure Pressure limit Default No Turn gt Code 16 Press amp Code 16 blinks Turn until the required pressure limit ap pears Press X to confirm the pressure limit setting 7 5 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 set point manual mode with the 68 Select 2 manual mode Operating mode Default MAN Turn X9 gt Code Press eg Code 0 blinks Turn gt MAN Press C The positioner changes to the man ual mode 2 Check the operating range Manual set point w current angle of rotation is indicated Turn gt Code 1 Press eg Code 1 and blink Turn until the pressure in the positioner builds up and the control valve moves to its final positions so that the travel angle can be checked The angle of rotation of the lever on the back of the positioner is indicated A horizontal lever mid position is equal to 0 To ensure the positioner is working proper ly the outer bar elements must not blink while the valve is moving through the operat ing range Exit Code 1 by pressing the rotary pushbut ton 2 8384 6 EN 7 6 The permissible range has been exceed ed when the displayed angle is more than 30 and the outer right or left bar element blinks The position
92. ing ac tuators with closed position ATO Proportional action coeffi cient Kp level O to 17 7 ESC KP level changes affect the set point deviation This ef fect can be compensated for by tuning the input filter in Code 6 See section 7 6 6 Derivative action time Tv level 1 2 3 4 No ESC EB 8384 6 EN Limit of the set point w Actuators with fail safe action ATO are completely vented and ac tuators with fail safe action ATC are completely filled with air when the set point falls below the adjusted limit This action always lead to the tight closing of the valve Codes 14 15 have priority over Codes 8 9 10 11 Codes 21 22 have priority over Codes 14 15 Limit of the set point w Actuators with fail safe action ATO are completely filled with air and actuators with fail safe action ATC are completely vented when the set point exceeds the adjusted limit This action always lead to the valve to be opened to the maximum Codes 14 15 have priority over Codes 8 9 10 11 Codes 21 22 have priority over Codes 14 15 Example Set the end position w gt to 99 for three way valves Signal pressure to actuator can be limited After changing the pressure limit setting the actuator must be vent ed once e g by selecting the fail safe position During positioner initialization the values for Kp and Tv are opti mally set If the value for the KP level is below 3 the error code 61 is activated If the pos
93. ing initialization the positioner checks whether the control valve can move through the indicated nominal range travel or angle without collision If this is the case the indi cated nominal range is adopted with the lim its of travel angle range start Code 8 and travel angle range end Code 9 as the op erating range Enable configuration Note If no settings are entered within 120 seconds the enabled configuration function becomes invalid Default No 2 Code 3 display No Press amp Code 3 blinks Turn amp YES Press G9 display 72 Enter the pin position and nominal range met Pin position EST Default No o x S IC m 111 Nominal range locked when Code 4 No d 5 Turn gt Code 4 Press amp Code 4 blinks Turn 9 gt Pin position on lever see relevant section on attachment Press eB Turn X9 gt Code 5 Press eg Code 5 blinks Turn Nominal travel of the valve Press 69 Select initialization mode x S NIC WN Init mode Default Turn 9 gt Code 6 Press eg Code 6 blinks Turn NOM Press to confirm the NOM as the initial ization mode Start initialization Press INIT key EB 8384 6 EN If nominal range determined during initialization is smaller than the range entered in Code 5 initial ization is canceled and an error mes sa
94. ion 3 84 kQ 24 V 114 mW lt 12 V emergency venting at 12 V gt 19 gt 5 x 106 switching cycles Signal 0 no response Signal 1 response Service life Two wire transmitter Electrical isolation 12 to 30 V DC Reverse polarity protection Static destruction limit 40 V Ato 20 mA Reversible 10 to 114 Linear Analog position transmitter Power supply Output signal Operating direction Operating range Characteristic Hysteresis Same as positioner High frequency influence Same as positioner Other influences Same as positioner Fault alarm Can be issued as current signal 2 4 0 1 mA or 21 6 0 1 mA Leakage sensor Suitable for operation in hazardous areas 40 to 130 C 20 5 Nm Inductive limit contact For connection to switching amplifier acc to EN 60947 5 6 Can be used in combination with a software limit contact NAMUR NC contact NAMUR NO contact Temperature range Tightening torque SJ2 SN proximity switch External position sensor Same as positioner Cable 10 Flexible and durable With M12x1 connector Flame retardant acc to VDE 0472 Resistant to oils lubricants and coolants as well as other aggressive media Permissible ambient 60 to 105 C temperature Also observe the limits in the test certificate for explosion protected versions 16 EB 8384 6 EN Design and principle of operation Up to 10 g in the range of 10 to 2000 Hz Degree
95. is determined by aligning the groove of the adapter block 13 with the groove of the connecting plate 12 Fig 7 Actuator stem extends retracts 12 Connecting plate 13 Adapter block Fig 7 Fail safe position 9 Mount the adapter block 13 together with the connecting plate 12 to the ac tuator using the screws 13 1 10 Insert the vent plug 11 1 into the Exh connection 1 1 For fail safe action actuator stem ex tends seal the Y1 port with a blanking plug For fail safe action actuator stem re tracts connect the Y1 port to the signal pressure connection of the actuator 30 Place positioner on the adapter block 13 in such a manner that the follower pin 2 rests on the top of the follower clamp 3 Adjust the lever 1 corre spondingly and open the positioner cov er to hold the positioner shaft in position at the cap or rotary pushbutton The lever 1 must rest on the follower clamp with spring force Fasten the positioner to the adapter block 13 using the two fixing screws 6 3 Make sure the formed seal 6 2 is prop erly seated 12 Mount cover 11 on the other side to the yoke Make sure that the vent plug is lo cated at the bottom when the control valve is installed to allow any condensed water that collects to drain off EB 8384 6 EN Attachment to the control valve Mounting parts and accessories Attachment to NAMUR rib see Fig 8 Required mounting par
96. itioner Initialization In Internal solenoid valve forced venting not or improperly connected ternal solenoid 2 valve forced vent ing Status classification Maintenance required Recommended Check connection and supply voltage of solenoid valve forced venting action Re initialize positioner An attempt was made to initialize the device from fail safe position 2 Switch to manual mode Re initialize positioner Transit time not Actuator transit times detected during initialization are so short lt 0 3 s that reached optimal positioner tuning is impossible transit time lt Status classification Out of specification Recommended Activate volume restriction in positioner output Initialization time Timeout detected during initialization exceeded Valve takes too long to open umet e Valve cannot find fixed end stops e g when lined control butterfly valves are used Valve tends to hunt considerably action e Re initialize positioner EB 8384 6 EN 103 Code list Error codes Condensed state message active when prompted ERR appears Recommended action When fault alarms exist they are displayed here 1 Pin position not entered for nominal range or substitute SUB ini tialization 2 ATO ATC switch defective Status classification Maintenance required Recommended Enter pin position and nominal range action Re initialize positioner 2 Return positioner to S
97. itioner tends to overshoot impermissibly due to other dis turbances the KP and TV levels can be adapted accordingly after initialization Increment TV level until desired behavior is reached or when the maximum value of 4 is reached the KP level can be decreased in increments See Code 19 A change of the TV level has no effect on the set point deviation 95 Code list 96 Parameter Readings values default setting Tolerance band Used for error monitoring 0 1 to 10 0 5 0 of the the set point deviation is greater than selected tolerance band for operating range ESC a time longer than the lag time 30 s this causes the error code 57 control loop to be activated Note The lag time can only be set using the operator software Select characteristic Select characteristic See section 16 O to 9 ESC 0 Linear Equal percentage Reverse equal percentage SAMSON butterfly valve linear SAMSON butterfly valve equal percentage VETEC rotary plug valve linear VETEC rotary plug valve equal percentage Segmented ball valve linear Segmented ball valve equal percentage 2 3 4 5 6 7 8 9 User defined defined over operator software The time required to move through the operating range when opening the valve 0 to 240 s ESC This parameter can be used to increase the Min transit time OPEN The entered transit time does Code 40 not apply when fail safe ac Limitati
98. keep the follower pin 2 in pin position 35 4 Insert formed seal 15 into the groove of the positioner housing 5 Place positioner on the cover plate in such a manner that the follower pin 2 rests on the top of the follower clamp 3 24 Adjust the lever 1 correspondingly and open the positioner cover to hold the po sitioner shaft in position at the cap or ro tary pushbutton 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 is positioned to match the ac tuator symbol for the actuator s fail safe action actuator stem extends or actu ator stem retracts If this is not the case unscrew the three fastening screws and lift off the cover Turn the gasket 16 by 180 and re insert it The old connection block version Fig 4 bottom requires the switch plate 13 to be turned to align the actuator symbol with the arrow marking Place the connection block 12 with the associated seals against the positioner and the actuator yoke and fasten using the screw 12 1 For actuators with fail safe action actuator stem retracts ad ditionally remove the stopper 12 2 and mount the external signal pressure pipe Mount cover 11 on the other side Make sure that the vent plug is located at the bottom when the control valve
99. ks Turn gt MAN 73 Start up and settings Press Turn 9 gt Code 1 Press amp Code 1 blinks Turn clockwise in small steps until the re quired valve position is reached The valve must be moved with a monotonically in creasing signal pressure Press to confirm the OPEN position Start initialization gt Press INIT key After initialization the maximum travel 15 in dicated in mm or the maximum angle in in Code 5 7 6 4 MAN Initialization based on manually se lected end positions Before starting initialization move the con trol valve manually to the end positions The positioner calculates the travel angle differ ence from the positions that the valve moved to and adopts it as the operating range with limits of lower travel angle range value Code 8 and upper travel angle range val ue Code 9 Note JY This initialization mode can only be started when the valve position dif fers in the end positions and the posi tioner has not yet been initialized 74 Enable configuration Note If no settings are entered within 120 seconds the enabled configuration function becomes invalid qt i m Enable configuration cei Default No 3 f Turn 9 gt Code 3 display No Press amp Code 3 blinks Turn gt gt YES Press amp display gt Enter the pin position x S JC 7 Pin position Default No 2 Turn gt Code 4 Press amp Co
100. l port for the exhaust air that can be connected over Should other valve accessories be used which vent the actuator e g solenoid valve volume booster quick exhaust valve this ex haust air must also be included in the purg ing function The connection over the adapt er at the positioner must be protected with a check valve e g check valve 1 4 order 8502 0597 mounted in the piping Other wise the pressure in the positioner housing would rise above the ambient pressure and damage the positioner when the exhausting components respond suddenly piping An adapter available as an accesso ry is used for this purpose Threaded bushing G 4 0310 2619 M20 x 1 5 NPT 0310 2550 Note The adapter uses one of the M20 x 1 5 connections in the hous ing which means only one cable gland can be installed 4 11 Required mounting parts and accessories Table 1 Direct attachment to Type 3277 5 Actuator Fig 3 Standard version for actuators 120 cm or smaller 1400 7452 Mounting parts Version compatible with paint for actuators 120 or smaller 1402 0940 Old switchover plate for Type 3277 5xxxxxx 00 Actuator old 1400 6819 New switchover plate for Type 3277 5xxxxxx 01 Actuator new 1400 6822 Accessories for New connecting plate for Type 3277 5xxxxxx 01 Actuator new G and 1400 6823 actuator NPT St steel brass St steel st steel 1 Only new switchover and connecting plates can
101. lassification alarm required This classification can only be changed in the operator software e g TROVIS VIEW Switching mode of software limit contact alarms Al and A2 when activated when the positioner is initialized Explosion protected version according to EN 60947 5 6 0 Al 22 2 mA A2 lt 1 0 mA 1 A1 0 A2 lt 1 0 mA 2 1 gt 2 2 2 gt 2 2 mA 3 1 lt 0 2 gt 2 2 mA Version without explosion protection Al R 348 Q A2 non conducting A non conducting A2 non conducting Al R 348 Q A2 R 348 Q A non conducting 2 R 3480 When a positioner has not been initialized the software limit con tacts always register the signal as in the state of no response If there is no mA signal at the terminals 11 12 the software limit contacts both switch to lt 1 0 mA Ex or non conducting without explosion protection Note The fault alarm output always switches to lt 1 0 mA non conducting in case of a fault it has 2 2 mA R 348 Q when there is no fault 97 Code list Code Parameter Readings NO values default setting Limit A1 alarm limit 1 0 0 to 100 0 2 0 of the operating range No ESC The setting has no effect when an inductive limit con fact is installed Limit A2 alarm limit 2 0 0 to 100 0 98 0 of the operating range No ESC Alarm test Reading direction Standard Turned No No AT 2 2 Position transmitter
102. led screws in or on the housing Do not exceed the maximum per missible values specified in the EC EB 8384 6 EN type examination certificates when interconnecting intrinsically safe electrical equipment U or Ub l or P or Po Lor Lal Selecting cables and wires Observe clause 12 of EN 60079 14 VDE 0165 Part 1 for installation of the in trinsically safe circuits Clause 12 2 2 7 applies when running multi core cables and wires with more than one intrinsically safe circuit The radial thickness of the insulation of a conductor for common insulating materials e g polyethylene must not be smaller than 0 2 mm The diameter of an individual wire in a fine stranded conductor must not be smaller than 0 1 mm Protect the conductor ends against splicing e g by using wire end Connections ferrules When two separate cables or wires are used for connection an additional cable gland can be installed Seal cable entries left unused with plugs Fit equipment used in ambient temperatures below 20 C with metal cable entries Equipment for use in zone 2 zone 22 In equipment operated according to type of protection Ex nA non sparking equipment according to EN 60079 15 2003 circuits may be connected interrupted or switched while energized only during installation maintenance or repair Equipment connected to energy limited cir cuits with type of protection Ex nL ener gy limited equi
103. llower 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 mounting screws EB 8384 6 EN Attachment to the control valve Mounting parts and accessories Attachment to rod type yoke Rods with 20 to 35 mm diameter a EE M i Additional bracket for 16 actuators with 2800 cm and travel 260 mm lever 11 Nut XL and lever 1 2 Disk spring 1 2 Follower pin 3 Follower plate 3 1 Follower plate 6 Connecting plate 61 Seals 7 Pressure gauge bracket 8 Pressure gauge mounting kit 9 Stem connector 9 1 Bracket 10 NAMUR bracket 11 Screw 14 Bolt 14 1 Screws 15 U bolt NOTICE 16 Bracket and output Never screw threaded parts directly into housing Fig 5 Attachment according to IEC 60534 6 NAMUR EB 8384 6 EN 27 Attachment to the control valve Mounting parts and accessories 4 3 Attachment according to VDI VDE 3847 Type 3730 6 xxxxxxx0xx0600 and 3730 6 xxxxxxx0xx0700 Positioners with air purging of the actuator s spring chamber can be attached according to VDI VDE 3847 3730 6xxxxxxx0xx0000 Positioner without air purging of the actuator s spring chamber can be attached according to VDI VDE 3847 This type of attachment allows the positioner to be replaced quickly while the process is running by blocking the air in the actuator
104. mits in the type examination certificate additionally apply for explosion pro tected versions Influences Temperature 0 15 10 K Effect of vibration 0 25 up to 2000 Hz and 4 g according to IEC 770 14 EB 8384 6 EN Design and principle of operation Type 3730 6 Positioner technical data in test certificates additionally apply to explosion protected devices Electromagnetic com Complying with EN 61000 6 2 EN 61000 6 3 EN 61326 1 and NAMUR Recom patibility mendation NE 21 Electrical connections One M20 x 1 5 cable gland for 6 to 12 mm clamping range Second M20 x 1 5 threaded connection additionally exists Screw terminals for 0 2 to 2 5 mm wire cross sections Degree of protection IP 66 NEMA 4X Use in safety instrumented Suitable for use in safety instrumented systems up to SIL 2 single device HFT 0 systems according to and SIL 3 redundant configuration HFT 1 according to IEC 61511 IEC 61508 SIL Triggered by set point emergency venting depending on positioner ver sion at 3 8 mA or lt 4 4 mA By the optional solenoid valve emergency venting at V By the optional forced venting emergency venting at lt 12 V Communication local SAMSON SSP interface and serial interface adapter software requirement SSP TROVIS VIEW with database module 3730 6 Communication HART HART field communications protocol Impedance in HART frequency range Re ceiving 350 to 450 O Sending approx 115 O Sed
105. n emergency mode in which the control parameters are estimated and not deter mined by an initialization procedure As a result a high level of accuracy cannot be ex pected You should always select a different initialization mode if the plant allows it The substitute calibration is used to replace a positioner while the process is running For this purpose the control valve is usually fixed mechanically in a certain position or pneu matically by means of a pressure signal which is routed to the actuator externally The blocking position ensures that the plant continues to operate with this valve position The blocking position can also be the fail safe position when this condition is benefi cial for the temporary phase Perform a reset before re initializing the positioner if the substitute positioner has already been initialized Refer to sec tion 7 8 Enable configuration Note If no settings are entered within 120 seconds the enabled configuration function becomes invalid 75 Start up and settings Enable configuration Default No Turn gt Code 3 display No Press amp Code 3 blinks Turn lt gt YES Press G9 display gt Enter the pin position and nominal range Pin position Default No Nominal range locked when Code 4 No Turn gt Code 4 Press amp Code 4 blinks Turn gt Pin position on lever see relevant section on attachment Press eg
106. ner follows the analog current signal reference variable in the same manner as for point to point communication This oper ating mode is for example suitable for split range operation of positioners series con nection Fig 22 Adapting the output signal Controller control station The bus address polling address has to be within a range of 1 to 15 Note Communication errors may occur when the process controller control station output is not HART compati ble For adaptation the Z box order no 1170 2374 can be installed be tween output and communication in terface At the Z box a voltage of ap prox 330 mV is released corre sponds to 16 5 Q at 20 mA Alternatively a 250 Q resistor can be connected in series and a 22 pF capacitor can be connected in paral lel to the analog output The following must be observed The load for the controller output will increase as a result The insertion of a capacitor is not permissible for intrinsically safe cir cuits Ex ia energy limited circuits Ex nL and for the type of protec tion Ex nA 60 EB 8384 6 EN Operating controls and readings 6 Operating controls and read ble acting rotary actuators connections ac o cording to section 4 6 ings Rotary pushbutton The volume restriction serves to adapt the air The rotary pushbutton is located underneath output capacity to the size of the actuator the front protective cover The positioner is
107. ng on the fail safe action of the actuator actuator stem ex tends or actuator stem retracts valve clos es or opens upon supply air failure the swi tchover plate 9 must first be attached 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 1 Mount connecting plate 6 or pressure gauge bracket 7 with pressure gauges on the positioner making sure the two seals are seated properly 2 Remove screw plug 4 on the back of the positioner and seal the signal pres sure output 38 on the connecting plate 6 or on the pressure gauge bracket 7 with the stopper 5 included in the ac cessories 3 Place follower clamp 3 on the actuator stem align it 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 Fig 3 on the left pointing towards the signal pressure connection 22 Make sure that the gasket 14 points to wards the actuator yoke 5 15 mm travel Keep the follower pin 2 on the M lever 1 on the back of the po sitioner in the pin position 35 delivered state 7 5 mm travel Remove the follower pin 2 from the pin position 35 reposition it in the hole for pin position 25 and screw tight 6 Insert formed seal 15 into the groove of the positioner housing and insert the seal
108. non volatile memory They cannot be reset Status classification required Recommended action Restart the valve signature recording or start initialization including valve signature Unassigned PST FST A partial stroke test or full stroke test cannot be started or has been can celed Status classification message Recommended action Read out test status only in the operator software On off valve The transit time and breakaway time or the final travel angle value of the on off valve has changed Status classification message Recommended action Check valve and actuator SIL operator test failed Status classification Failure cannot be classified Recommended action Return positioner to SAMSON for repair action mo EB 8384 6 EN 109 Dimensions in mm 15 Dimensions in mm Attachment according to IEC 60534 6 Pressure gauge or connecting plate bracket Lever mm 5 17 External position sensor Fig 28 NAMUR and direct attachment 110 EB 8384 6 EN Dimensions in mm Attachment according to VDI VDE 3847 to Type 3277 Lever mm M 250 Attachment according to VDI VDE 3847 to a NAMUR g rib Fig 29 Attachment according to VDI VDE 3847 EB 8384 6 EN 111 Dimensions in mm Heavy duty version Output Yi Output Supply 9 Output Y Reversing Output Y gt amplifier optional Output Al Reversing amplifier option
109. of protection IP 67 Binary input Electrical isolation Switching behavior configured over software Active switching behavior default setting Connection For external switch floating contact or relay contact Electric dota Open circuit voltage when contact is open max 10 V Pulsed DC current reaching peak value of 100 mA and RMS value of 0 01 mA when contact is closed optet ON switching state default setting OFF switching state default setting Electric dato Voltage gt 6 lt l V OFF switching state default setting EB 8384 6 EN 17 Design and principle of operation Summary of explosion protection certificates for Type 3730 6 Positioner Number 10 2007 1 2G Ex ia IIC IIB T6 x Date 18 08 2010 Il 2D Ex tb T80 C IP66 EC type Number GYJ12 1109X examination Ex ia T4 T6 Ga Mer NM Date 08 10 2012 DIP A21 T4 16 Valid until 07 10 2017 Number IECExPTB 10 0057 Ex ia IIC IIB T6 Ex IIC IIB T6 Date 10 01 2011 Ex A21 IP66 T80 C Number GYJ12 1109X Ex ia Il CT4 T6 Ga Date 08 10 2012 DIOE Valid until 07 10 2017 Number RU C DE 08 B 00113 Ex ia IIC T Gb d 1 tb IIIC T80 C Db IP66 Valid until 14 11 2018 IS Class Div 1 Gr ABCDEFG Number 301 2394 AEx IIC Class Zone 0 Class Div 2 Gr ABCD S Class Il Div 2 Gr FG Enclosure Type 4X APPROVED Date 05 1 201 4 Ex ia TA T5
110. on lt lt 17 12121212 2 7 7 Device in operation since initialization Reading direction lt lt lt m m NI NI NIN lt lt x Fr fr mM m m NIE NI NI NIN 7 Proportional action coefficient Kp level Derivative action time Tv level zx xz zu zu xu zl s vnde cen rn I eae 1 et 1 80 8384 6 EN Start up and settings sw vs is sled chowcwrc iS Um YS ES inier ES Error message in case of condensed state Function check Um Error message in case of Maintenance required and Out of NO YES specification condensed states Ux NO ES NO 48 49 YES NO ES NO ves Diagnostics f EB 8389 1 EN EB 8384 6 EN 81 Operation 8 Operation WARNING Risk of injury due to the actuator stem extending or retracting Do not touch or block the actuator stem 8 1 Enabling and selecting pa rameters All codes and their meaning and default set tings are listed in the code list in section 14 Codes which are marked with an asterisk mus
111. on of the transit time Code 21 and 22 For some applica tion solenoid valve or forced tions it is recommendable to limit the transit time of the actuator to venting function are trig prevent it from engaging too fast in the running process gered Hor when the auxiliary Code 21 has priority over Code 15 energy fails The time required to move through the operating range when clos ing the valve 0 to 240 s ESC This parameter can be used to increase the Min transit time The entered transit time does CLOSED Code 41 not apply when fail safe ac Code 22 has priority over Code 14 tion solenoid valve or forced venting function are trig EB 8384 6 EN no Code list Parameter Readings Dace values default setting Absolute total valve travel 0 to 99 107 YES ESC Exponential reading from 9999 travel cycles onwards Total valve travel limit 1000 to 99 107 1 000000 ESC Exponential reading from 9999 travel cycles onwards Alarm mode O 1 2 3 ESC EB 8384 6 EN Totaled full valve travel cycle Can be reset to 0 in Code 36 STD and Code 36 DS Note The total valve travel is saved in a non volatile memory after every 24 full valve travel cycle Limit of total valve travel limit Total valve travel exceeded message is generated depending on selected status classification if the limit is exceeded Note The Total valve travel exceeded message has the default status c
112. on with shutdown at 4 4 mA gt 22 mA OVERLOAD reading on display 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 58 Depending on the version the positioner is equipped with inductive limit contacts and or a solenoid valve The position transmitter is operated on a two wire circuit The usual supply voltage is 24 V DC Taking the resistance of the supply leads into account the voltage at the posi tion transmitter terminals can be between 12 and 30 V DC Refer to Fig 20 or to the label on the termi nal block Accessories Cable glands M20 x 1 5 Order no Black plastic 6 to 12 mm clamping range 8808 1011 Blue plastic 6 to 12 mm clamping range 8808 1012 Nickel plated brass 6 to 12 mm clamping range 1890 4875 Nickel plated brass 10 to 14 mm clamping range 1922 8375 Stainless steel 1 4305 8 to 14 5 mm clamping range 8808 0160 Adapter M20 x 1 5 to NPT Powder coated aluminum 0310 2149 Stainless steel 1400 7114 5 2 1 For operation of the limit contacts switching amplifiers must be connected in the output 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 Switching amplifier EB 8384 6 EN Observe the relevant regulations for installa tion in hazardous areas
113. ostics are described in the Operating In structions EB 8389 1 EN These Instructions are included on the enclosed CD ROM and is available on our website EB 8384 6 EN Important safety instructions 1 Important safety instructions For your own safety follow these instructions concerning the mounting start up and opera tion of the device The device is to be mounted started up or operated only by trained and experienced personnel familiar with the product According to these mounting and operating instruc tions trained personnel is referred to as individuals who are able to judge the work they are assigned to and recognize possible dangers due to their specialized training their knowledge and experience as well as their knowledge of the applicable standards Explosion protected versions of this device are to be operated only by personnel who has undergone special training or instructions or who is authorized to work on explosion pro tected devices in hazardous areas Refer to section 11 Any hazards that could be caused in the valve by the process medium the signal pres sure or by moving parts are to be prevented by taking appropriate precautions lf inadmissible motions or forces are produced in the pneumatic actuator as a result of the supply pressure level it must be restricted using a suitable supply pressure reducing station To avoid damage to any equipment the following also applies Do not operat
114. oy Ajayes eue syn2um Iv A 09 JO A of n EUILUOL Jo e o dn Jauto A ojes 5 ajes ou 09 Jo ay Jo anjen yead e dn synas ejes Ajeoisuimul Mun pes JQUJO y woy pajos eonpeae pue pejoeuuooieju jeuongiledo eie Josues nouo ejes uonsod SU pue asepa dss jenes ey Ajddns eu Joy eu aps sies les oap eo jou d pue 1 rj senjea uenosjoud jo edA idu aui pepiacud ejes Ajeaisuiui payne peyeuuos eq jauonisod eu Jo 0LL 9 0 7e d L Osc n 20 5 n E Wud rv sen gA Burejedo A wen seues ui pejoeuuoo 0 72 edi pIe UIA 0 2 9 02 2 Od AL 52 129110519 4002 XALV OF 919 31V2IJILH32 NOLLVNINWVXS 3dAJ 23 OL uag pun syosiuyse yosijeyiskyd 2002 01 914 3172141330 NOLLVNIWVX3 3dAL 23 OL upg pun Blamyssuneig Je SuesepuNng euosiuuoe uosijeyrsAud did did EB 8384 6 EN ANIMAS 91 122 001 esl esepung 1
115. pin 2 in pin position 35 4 Insert the formed seal 6 2 in the groove of the adapter bracket 6 5 Insert the formed seal 17 1 into the turnboard 17 and mount the turnboard to the adapter block 13 using the screws 17 2 6 Mount the blank plate 18 to the turn board 17 using the screws 18 1 Make sure that the seals are correctly seated Note O A solenoid valve can also be mount ed in place of the blank plate 18 The orientation of the turnboard 17 determines the mounting position of the solenoid valve Alternatively a restrictor plate can be mounted gt AB 11 EN EB 8384 6 EN 11 1 12 12 1 Attachment to the control valve Mounting parts and accessories Disk spring Follower pin Follower clamp Screw plug Stopper Adapter bracket Screws Formed seal Screws Cover 18 Vent plug Connecting plate 19 Seal 20 Adapter block Screws Turnboard Formed seal Screws Blank plate Screws Air blocker Retaining screw Fig 6 Attachment according to VDI VDE 3847 to Type 3277 Actuator EB 8384 6 EN 29 Attachment to the control valve Mounting parts and accessories 7 Insert the screws 13 1 through the mid dle holes of the adapter block 13 8 Place the connecting plate 12 together with the seal 12 1 onto the screws 13 1 corresponding to the fail safe ac tion actuator stem extends or actuator stem retracts The fail safe action that applies
116. ping plate 7 Rotary switch 1 Connector Fig 27 Retrofitting an inductive limit contact 88 EB 8384 6 EN 10 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 11 Servicing explosion protected devices If a part of the device on which the explosion protection is based needs to be serviced the device must not be put back into operation until a qualified inspector has assessed it ac cording to explosion protection require ments has issued an inspection certificate or given the device a mark of conformity In spection by a qualified inspector is not re quired if the manufacturer performs a tine test on the device before putting it back into operation Document the passing of the routine test by attaching a mark of conformi ty to the device Replace explosion protected components only with original routine tested components from the manufacturer Devices that have already been operated outside hazardous areas and are intended for future use inside hazardous areas must comply with the safety requirements placed on serviced devices Before being operated EB 8384 6 EN Maintenance inside hazardous areas test the devices ac cording to the speci
117. pment according to EN 60079 15 2003 may be switched under normal operating conditions Switching amplifier 60947 5 6 24 V DC Forced vent ing solenoid Fault al valve 2 Software mA control signal optional Fig 20 Electrical connections EB 8384 6 EN Limit contacts Software optionally inductive Two wire transmitter Supply unit Al only for optional trans mitter 57 Connections The maximum permissible values specified in the statement of conformity and its ad denda apply when interconnecting the equipment with energy limited circuits in type of protection Ex nL IIC Cable entry Cable entry with M20 x 1 5 cable gland See section on Accessories for clamping range There is a second M20 x 1 5 threaded hole in the housing that can be used for addition al connection when required The screw terminals are designed for wire cross sections of 0 2 to 2 5 mm Tighten by at least 0 5 Nm The wires for the reference variable must be connected to the terminals 11 and 12 locat ed in the housing Only use a current source gt 3 6 mA Microprocessor and display active lt 3 7 mA LOW reading on display lt 3 8 mA Emergency shutdown version with shutdown at 3 8 mA gt 3 9 mA Actuator can be filled with air version with shutdown at 3 8 mA lt 4 4 mA Emergency shutdown version with shutdown at 4 4 mA gt 4 6 mA Actuator can be filled with air versi
118. pply air 4 Connect the electrical power 5 Perform the start up settings The positioner is suitable for the following types of attachment Direct attachment to SAMSON Type 3277 Actuator Attachment to actuators according to IEC 60534 6 NAMUR Attachment according to VDI VDE 3847 Attachment to Type 3510 Micro flow Valve Attachment to rotary actuators NOTICE Risk of malfunction due to incorrect mounting parts accessories or incor rect assignment of lever and pin posi tion Attach the positioner to the control valve only using the mounting parts and accessories as specified in Ta ble 1 to Table 6 Observe the type of attachment 20 Observe the assignment between le ver and pin position see travel tables on page 21 Lever and pin position The positioner is adapted to the actuator and to the rated travel by the lever on the back of the positioner and the pin inserted into the lever The travel tables on page 21 show the maximum adjustment range at the position er The travel that can be implemented at the valve is additionally restricted by the selected fail safe position and the required compres sion of the actuator springs The positioner is equipped with the M lever pin position 35 as standard NOTICE Risk of malfunction because the newly mounted lever has not been adapted to the internal measuring le ver Move the newly mounted lever 1 once all the way as
119. rential pressure o Q w NS 2 All active errors 16 On off error activated No errors 32 SIL test 1 Control loop 2 Zero 128 Total valve travel ex 4 too low ceeded 8 PST FST status 256 Operating mode not AUTO 64 Set point outside range E Q 8384 6 65 Start up and settings 7 Start up and settings NOTICE Malfunction due to incorrect se quence of mounting installation and start up Keep the following sequence 1 Remove the protective film from the pneumatic connections 2 Mount the positioner on the control valve 3 Connect the supply air 4 Connect the electrical power 5 Perform the start up settings Reading after connecting the electrical pow er supply gt blinks on the display when the positioner has not yet been initialized The reading in dicates the lever position in degrees in rela tion to the mid axis Reading when the positioner has not yet been initialized Code 0 appears on the display when posi tioner has been initialized The positioner is in the last active operating mode WARNING Risk of injury due to the actuator stem extending or retracting Do not touch or block the actuator stem 66 Note The positioner performs a test in the start up phase while following its au fomation task at the same time During the start up phase operation on site is unrestricted yet write ac cess is limited
120. sition 0 0 mm ESC Note Needs only be entered in initialization mode SUB Code 6 STD Resets start up Resets parameters to their default settings Resets diagnostics assessment Information parameters read only remain unchanged Re initialize positioner EB 8384 6 EN 99 Code list Code parameter Readings values default setting 36 DAG Reset diagnostics assessment Parameter settings reference values and logs remain unchanged The positioner does not need to be re initialized Ds Resets positioner to default settings Resets parameters to their default settings Resets diagnostics assessment Information parameters read only are deleted Re initialize positioner 37 Options Indicates which option terminals 31 and 32 Fig 20 is installed No No option installed POS Analog position transmitter dl Binary input LS Leakage sensor 4 to 20 mA x input When the binary input is used DI and HIGH or LOW status are displayed in alternating sequence When the leakage sensor is used LS and the detected sound level in dB are displayed in alternating sequence Inductive limit contact Indicates whether the inductive limit contact option is installed or No YES ESC neh Set point deviation e info Difference of the target position e w Read only Min transit time OPEN Minimum opening time determined during initializ
121. t be enabled with Code 3 before the as sociated parameters can be configured as described below Code 3 Configuration not enabled Configuration enabled Turn 9 gt Code 3 display No Press amp Code 3 blinks Change the setting in Code 3 Turn gt YES Press G9 display Configuration is enabled You can now configure codes one after the other 82 Turn to select the required code Press to activate the selected code The code number starts to blink Turn to select the setting Press to confirm the selected setting Note If no settings are entered within 120 seconds the enabled configura tion function becomes invalid and the display returns to Code 0 Cancel the setting E LC Jt uem To cancel a value before it is confirmed by pressing amp 9 proceed as follows Turn gt ESC Press 69 The entered value is not adopted Canceling the reading 8 2 Operating modes Automatic and manual modes 8 2 1 After initialization has been completed suc cessfully the positioner is in automatic mode AUTO EB 8384 6 EN Automatic mode _ IN I 2o 9 gt Code 0 Press G9 display Code 0 blinks 29 MAN Press The positioner changes to the man ual mode The manual mode starts using the last set point of the automatic mode
122. t in side or outside hazardous areas is to be performed only with intrinsically safe cur rent voltage calibrators and measuring in struments to rule out any damage to com ponents relevant to explosion protection Observe the maximum permissible values specified in the certificates for intrinsically safe circuits 90 EB 8384 6 EN 14 Code list Code list Code Parameter Readings Description NO values default setting Note Codes with marked with an asterisk must be enabled with Code 3 prior to configuration MAN Manual mode AUTO Automatic mode SAFE Fail safe position ESC Cancel 17 25 35 50 70 100 200 mm 90 with ro tary actuators 300 mm with piston actuators ESC EB 8384 6 EN Switchover from automatic to manual mode is bumpless Automatic mode only possible if positioner has been initialized Display Code 0 see section 6 The current travel angle is displayed in when the positioner is initialized If the positioner is not initialized the position of the le ver in relation to the longitudinal axis is indicated in degrees Note It can only be selected when Code 0 MAN Enables changing of data automatically deactivated when the ro tary pushbutton has not been operated for 120 seconds Codes marked with an asterisk can only be read and not overwritten when their configuration is not enabled HART blinks on the display when the on site operation is locked over
123. tent of auto tuning depends on the initialization mode selected Maximum range MAX standard range Initialization mode for simple start up of valves with two clearly defined mechanical end positions e g three way valves see section 7 6 1 Nominal range NOM Initialization mode for all globe valves see section 7 6 2 Manually selected OPEN position MAN Initialization mode for globe valves requir ing OPEN position to be entered manually see section 7 6 3 Manually selected end positions MAN2 Initialization mode for globe valves with manual entry of both positions see sec tion 7 6 4 69 Start up and settings Substitute calibration SUb This mode allows a positioner to be re placed while the plant is running with the least amount of disruption to the plant see section 7 6 5 Note For normal operation simply start ini tialization by pressing the INIT key af ler mounting the positioner on the valve and defining the fail safe posi tion and setting the volume restriction The positioner only needs to work with its default settings If necessary perform a reset see section 7 8 Alternating readings Initialization in progress Icon depending on initialization mode selected Bar graph indicating the progress of the initialization Alter the basic initialization the reference curve for the valve signature is recorded Code 48 hO YES Reading in alternating sequ
124. th directions 10 Place positioner on the bracket 10 in such a manner that the follower pin slides into the groove of the follower pin 3 Adjust the lever 1 correspondingly Screw the positioner to the bracket 10 using both its screws 4 5 Attachment to rotary actu ators Fig 11 Required mounting parts and accessories Table 5 on page 53 Observe the travel table on page 21 The positioner is mounted to the rotary actu ator using two pairs of brackets Prior to attaching the positioner to the SAMSON Type 3278 Rotary Actuator mount the associated adapter 5 to the free end of the rotary actuator shalt Note On attaching the positioner as de scribed below it is imperative that the actuator s direction of rotation is observed 1 Place follower clamp 3 on the slotted ac tuator shaft or adapter 5 EB 8384 6 EN Attachment to the control valve Mounting parts and accessories Only use the connecting plate 6 in cluded in the accessories to connect supply and output Never screw threaded parts directly into housing 1 2 1 S lever Fig 9 Attachment to Type 3510 Micro flow Valve EB 8384 6 EN N ila NN 2 Lever Nut Disk spring Follower pin Follower plate Connecting plate Seals Pressure gauge bracket Pressure gauge mounting kit Stem connector Bracket Bolt Screws Bracket Screw Hexagon bar Screws Screws 35 Attachment to the
125. the display and the positioner then changes to the fail safe position Exit the fail safe position again over Code 0 see section 8 2 2 MAX Initialization based on maximum range 7 6 1 The positioner determines travel angle of ro tation of the closing member from the CLOSED position to the opposite travel stop and adopts this travel angle of rotation as the operating range from 0 to 100 Enable configuration Note If no settings are entered within 120 seconds the enabled configuration function becomes invalid EB 8384 6 EN Start up and settings Default No EA Turn 9 gt Code 3 display No Press eg Code 3 blinks Turn lt gt YES Press G9 display gt Enter the pin position UNE lu o FG Pin position ucc Default No wei Turn gt Code 4 Press amp Code 4 blinks Turn gt Pin position on lever see relevant section on attachment Press 69 Select the initialization mode Default MAX 5 Z Turn X9 Code 6 Press 69 Turn MAX Press to confirm the MAX as the initial ization mode Start initialization Press INIT key 71 Start up and settings Alter initialization the maximum travel an gle of rotation Code 5 which was detected during initialization is indicated 7 6 2 NOM Initialization based on nominal range The calibrated sensor allows the exact valve travel to be measured very accurately Dur
126. ting according to IEC 60534 6 NAMUR EB 8384 6 EN 45 Attachment to the control valve Mounting parts and accessories 4 7 3 Mounting the position hole for pin position 17 Place the lever sensor to Type 3510 Mi 1 and disk spring 1 2 on the sensor shaft Place the lever in mid position and cro flow Valve hold it in place Screw on the nut 1 1 Required mounting parts and accesso 4 Place follower clamp 3 on the valve ries Table 7 on page 54 stem connector align at a right angle and screw tight 5 Position the bracket 21 with the position sensor on the valve yoke and screw tight making sure the follower pin 2 slides into the groove of the follower clamp 3 Fig 17 1 Place the lever 1 on the position sen sor in mid position and hold it in place Unscrew the nut 1 1 and remove the standard attached M lever 1 together with the disk spring 1 2 from the sen sor shaft 2 Screw the position sensor 20 onto the bracket 21 3 Select the S lever 1 from the accessories and screw the follower pin 2 into the lever Nut Disk spring Follower pin Follower clamp Position sensor Bracket Fig 17 Mounting on a micro flow valve 46 EB 8384 6 EN Attachment to the control valve Mounting parts and accessories 4 7 4 Mounting on rotary 4 Place the lever 1 and disk spring 1 2 on the sensor shaft Place the lever in tuators mid position and hold it in place Screw
127. tioner For explo sion protected positioners the re quirements in section 11 Servicing explosion protected devices need to be kept Check the Limit switch in ductive box on the nameplate after installing the limit comtact 1 Take off the rotary pushbutton 3 and cap 1 unthread the five fastening screws 2 and lift off the plastic cover 9 together with the display taking care not to dam age the ribbon cable between PCB and display 2 Use a knife to cut an opening at the marked location 4 3 Push the connector 11 with cable through the opening and secure the prox 87 Adjusting the limit contact imity switch 7 on the cover with a dot of glue Remove the jumper 8801 2267 at the socket X7 of the top board and insert the cable connector 11 DL HUE 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 proximily 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 On start up of the positioner set op tion inductive alarm under Code 38 from No to YES 79943 9 Socket X7 11 Cap Metal tag Screw Proximity switch Plastic cover Marking 6 7 Rotary pushbutton 8 Clam
128. tive _ Blinks Out of specification Configuration enabled Limit contact alarm 2 Limit contact mana i lt mam demi VN ZNI VAY oz UN Designation Position Bar graph for set point KEN in D M Paranee deviation or lever position Od Code Closed loop operation Manual mode Malfunction fault Automatic G blinking Emergency mode see error code 62 Clockwise Counterclockwise 2 blinking Positioner not initialized Error 5 Valve in mechanical fail safe position Cancel i ix higher than 21 6 mA Failure ix lower than 2 4 mA p Maint Maint i w lower hina 7 mA aintenance demanded Maintenance required Manual setting Z blinks Out of specification a blinks Write protection active over binary input option No Not available not active or commun edilon NOM Rated travel OVERLOAD w gt 22 mA O C and PST in alternating p lower than upper spring range sequence Write protection active time controlled PST value RES Reset SAFE Fail safe position SUB Substitute calibration TUNE Initialization in progress YES Available active ZP Zero calibration 0 bar No supply air PLOW AA Increasing increasing Increasing decreasing Fig 24 Display EB 8384 6 EN 63 Operating controls and readings 61 Serial interface The positioner must be supplied with at least 3 8 mA The positioner can be connected directly to the PC over the local serial interface
129. ts and accesso ries Table 4 on page 52 Observe the travel table on page 21 Series 240 Valves actuator size up to 1400 60 cm Screw the two bolts 14 to the bracket of the stem connector or directly to the stem connector depending on the version place the follower plate 3 on top and use the screws 14 1 to fasten it Type 3251 Valve 350 to 2800 cm Screw the longer follower plate 3 1 to the bracket of the stem connector or di rectly to the stem connector depending on the version Type 3254 Valve 1400 120 to 2800 Screw the two bolts 14 to the bracket 16 Fasten the bracket 16 onto the stem connector place the follow er plate 3 on top and use the screws 14 1 to fasten it Mount the positioner on the NAMUR rib as shown in Fig 8 For attachment to the NAMUR rib fas ten the NAMUR connection block 10 directly into the existing yoke bore using the screw and toothed lock washer 1 1 Align the marking on the NAMUR valve connection on the side marked 1 to 50 travel For attachment to valves with rod type yokes use the two U bolts 15 around the yoke Fasten the NAMUR connection block 10 directly into the existing yoke bore using the screw and toothed lock EB 8384 6 EN washer 11 Align the marking on the NAMUR valve connection on the side marked 1 to 50 travel Place the adapter bracket 6 on the po sitioner and mount using the screws 6 1 Make sure th
130. tua tor shaft or adapter 3 using screw 4 1 plate and disk spring 4 2 8 Place positioner on housing 10 and screw it tight Taking the actuator s direc Counterclockwise tion of rotation into account adjust lever 1 so that it engages in the correct slot with its follower pin Fig 13 4 6 Reversing amplifier for double acting actuators For the use with double acting actuators the positioner must be fitted with a reversing am plifier e g the SAMSON Type 3710 Revers ing Amplifier see Mounting and Operating Instructions EB 8392 If a different reversing amplifier item no Dose 1079 1118 or 1079 1119 is used follow the mounting instructions described in sec tion 4 6 1 15 Fig 13 Direction of rotation 38 EB 8384 6 EN Attachment to the control valve Mounting parts and accessories Lever 6 Connecting plate Fit restriction into signal pressure Nut only for G 1 4 output for actuators with 300 cm Disk spring 6 1 Seals volume 7 Pressure gauge bracket 8 Pressure gauge mounting kit Follower pin Adapter Coupling dd 10 Adapter housing Disk spring 101 Adhesive label 11 Actuator shaft adapter Adapter Screws Spacer dum SAMSON Type 3278 Attachment acc to VDE VDI 3845 Sept 7 L 5160 VETECR 2010 fixing level 1 AAT to size see section 15 1 ig 12 Attachment to rotar
131. tua tor causing valve to move to the fail safe po sition determined by the actuator indepen dent of the reference variable Analog position transmitter The position transmitter 13 is a two wire transmitter and issues the travel sensor signal as a 4 to 20 mA signal processed by the mi crocontroller Since this signal is issued inde pendent of the positioner s input signal the momentary travel angle of rotation is con trolled in real time Additionally the position transmitter allows positioner faults to be indi EB 8384 6 EN cated over a signal current of lt 2 4 mA or gt 21 6 mA Leakage sensor By upgrading the positioner with a leakage sensor it is possible to detect seat leakage when the valve is in the closed position De tails on EXPERTplus Valve Diagnostics in the Operating Instructions gt EB 8389 1 EN Binary input The optional binary input can be configured To connect a floating contact To connect a non floating contact 0 to 24 V By selecting a certain function one of the following actions can be activated Transmit switching state The switching state of the binary input is logged Activate local write protection After the first initialization a local write protection can be activated While the binary input is active no set tings can be changed at the positioner The positioner cannot be re initialized Enabling configuration over Code 3 is not active 7
132. ue is displayed or must be entered See also the example in Code 9 Upper range value for the travel angle of rotation in the operating range Nominal range and characteristic are automatically 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 set point is convert ed to the new limits O on the display corresponds to the adjusted lower limit and 100 26 to the adjusted upper limit 93 Code list Parameter Readings Bacar sien values default setting Lower travel angle limit Lower limitation of the travel angle of rotation to the entered val lower x limit ue 0 0 to 49 9 of the operat The characteristic is not adapted ing range No ESC Upper travel angle limit Upper limitation of the travel angle of rotation to the entered val upper x limit ue 50 0 to 120 0 100 of The characteristic is not adapted the operating range No Example In some applications it is better to limit the valve travel ESC e g if a certain minimum medium flow is required or a maximum flow must not be reached The lower limit must be adjusted with Code 10 and the upper limit with Code 11 If tight closing function has been set up it has priority over the travel limitation When set to No the valve can be opened past the nominal travel with a set point outside of the 4 to 20 mA
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134. www samson de EB 8384 6 EN 2015 02 24 English
135. y a restrictor plate can be mounted gt AB 11 EN Fasten the adapter block 13 to the NAMUR connection block using the screws 13 1 Insert the vent plug into the Exh connec tion 10 Place the positioner on the adapter block 13 in such a manner that the follower pin 2 rests on the top of the follower plate 3 3 1 Adjust the lever 1 corre spondingly Fasten the positioner to the adapter block 13 using the two fixing screws 6 3 Make sure the formed seal 6 2 is prop erly seated For single acting actuators without air purging connect the Y1 port of the adapter block to the signal pressure con 32 nection of the actuator Seal the Y2 port with a blanking plug For double acting actuators and actua tors with air purging connect the Y2 port of the adapter block to the signal pressure connection of the second actua tor chamber or spring chamber of the actuator EB 8384 6 EN 2 Disk spring Follower pin Follower plate Follower plate Blanking plug Stopper Adapter bracket Screws Formed seal Screws NAMUR con nection block Screw with toothed lock washer Adapter block Attachment to the control valve Mounting parts and accessories 14 15 16 17 17 1 17 2 18 18 1 19 20 Screws Bolt Screws U bolt Bracket Turnboard Formed seal Screws Blank plate Screws Air blocker Retaining screw Fig 8 Attachment according to VDI VDE 3847 to
136. y actuators heavy duty version EB 8384 6 EN 39 Attachment to the control valve Mounting parts and accessories The following applies to all reversing am plifiers The signal pressure of the positioner is sup plied at the output 1 of the reversing amplifi er An opposing pressure which equals the required supply pressure Z when added to the pressure at output 1 is applied at output 2 The following relationship applies Output 1 Output 2 Supply pressure Z Connect output 1 to the loading pressure connection on the actuator that causes the valve to open when the pressure rises Connect output 2 to the loading pressure connection on the actuator that causes the valve to close when the pressure rises Set slide switch on positioner to AIR TO OPEN Note How the outputs are marked depends on the reversing amplifier used Type 3710 Output 1 2 1079 1118 and 1079 1119 Output 1 2 4 6 1 Reversing amplifier 1079 1118 or 1079 1119 Fig 14 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 40 2 Thread the special nuts 1 3 from the ac cessories 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 slide both the hollowed special screws 1 1 into the connecting boreholes A and Z

Mounting and Operating Instructions EB 8384-6

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