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Electropneumatic PositionerType 3730-3
With HART communication
Mounting andOperating Instructions
EB 8384-3 ENFirmware version 1.3xEdition April 2005
Fig. 1 · Type 3730-3
Contents Page
1 Design and principle of operation . . . . . . . . . . . . . . . . . . . 81.1 Communication . . . . . . . . . . . . . . . . . . . . . . . . . . . . 91.2 Additional equipment . . . . . . . . . . . . . . . . . . . . . . . . . 91.3 Technical data . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
2 Attachment to the control valve – Mounting parts and accessories . . . 132.1 Direct attachment . . . . . . . . . . . . . . . . . . . . . . . . . . . 162.1.1 Type 3277-5 Actuator. . . . . . . . . . . . . . . . . . . . . . . . . 162.1.2 Type 3277 Actuator . . . . . . . . . . . . . . . . . . . . . . . . . . 182.2 Attachment according to IEC 60534-6 . . . . . . . . . . . . . . . . . 202.3 Attachment to Type 3510 Micro-flow Valve. . . . . . . . . . . . . . . 222.4 Attachment to rotary actuators . . . . . . . . . . . . . . . . . . . . . 242.5 Reversing amplifier for double-acting actuators . . . . . . . . . . . . . 262.6 Attaching an external position sensor . . . . . . . . . . . . . . . . . 282.6.1 Mounting the position sensor with direct attachment. . . . . . . . . . . 282.6.2 Mounting the position sensor with attachment according to IEC 60534-6 302.6.3 Mounting the position sensor to Type 3510 Micro-flow Valve . . . . . . 312.6.4 Mounting the position sensor to rotary actuators . . . . . . . . . . . . 32
3 Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 343.1 Pneumatic connections . . . . . . . . . . . . . . . . . . . . . . . . 343.1.1 Signal pressure gauges . . . . . . . . . . . . . . . . . . . . . . . . 343.1.2 Supply pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . 343.2 Electrical connections . . . . . . . . . . . . . . . . . . . . . . . . . 363.2.1 Switching amplifiers . . . . . . . . . . . . . . . . . . . . . . . . . . 383.2.2 Establishing communication . . . . . . . . . . . . . . . . . . . . . . 38
4 Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 404.1 Operator controls and display . . . . . . . . . . . . . . . . . . . . . 404.2 Enabling and selecting parameters . . . . . . . . . . . . . . . . . . 424.3 Operating modes . . . . . . . . . . . . . . . . . . . . . . . . . . . 434.3.1 Automatic and manual operating modes . . . . . . . . . . . . . . . . 434.3.2 SAFE – Fail-safe position . . . . . . . . . . . . . . . . . . . . . . . 44
5 Start-up and settings . . . . . . . . . . . . . . . . . . . . . . . . . 445.1 Determining the fail-safe position . . . . . . . . . . . . . . . . . . . 445.2 Setting the volume restriction Q . . . . . . . . . . . . . . . . . . . . . 455.3 Limiting the signal pressure . . . . . . . . . . . . . . . . . . . . . . 455.4 Checking the operating range of the positioner . . . . . . . . . . . . . 455.5 Initialization . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 475.5.1 Initialization modes . . . . . . . . . . . . . . . . . . . . . . . . . . 48
2 EB 8384-3 EN
Contents
5.6 Fault/failure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 555.7 Zero calibration . . . . . . . . . . . . . . . . . . . . . . . . . . . . 565.8 Reset to default values . . . . . . . . . . . . . . . . . . . . . . . . 565.9 Start-up via local interface (SSP) . . . . . . . . . . . . . . . . . . . . 575.10 Start-up over HART communication . . . . . . . . . . . . . . . . . . 57
6 Status and diagnostic alarms . . . . . . . . . . . . . . . . . . . . . 586.1 Standard EXPERT diagnostics . . . . . . . . . . . . . . . . . . . . . 586.2 Extended EXPERT+ diagnostics . . . . . . . . . . . . . . . . . . . . . 586.3 Classification of the status alarms and the condensed status . . . . . . . 59
7 Adjusting the limit switch . . . . . . . . . . . . . . . . . . . . . . . 62
8 Quick start-up guide . . . . . . . . . . . . . . . . . . . . . . . . . 648.1 Mounting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 648.2 Start-up. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 658.3 Initialization . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 668.3.1 Simplest method (MAX) . . . . . . . . . . . . . . . . . . . . . . . . 668.3.2 Precise method (NOM) . . . . . . . . . . . . . . . . . . . . . . . . 668.3.3 Manual method (MAN) . . . . . . . . . . . . . . . . . . . . . . . . 66
9 Retrofitting an inductive limit switch . . . . . . . . . . . . . . . . . . 67
10 Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68
11 Servicing explosion-protected devices . . . . . . . . . . . . . . . . . 68
12 Code list . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69
13 Setting with TROVIS-VIEW software – Parameter list . . . . . . . . . . 8513.1 General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8513.2 Starting TROVIS-VIEW and performing basic settings . . . . . . . . . . 8613.3 Setting the parameters. . . . . . . . . . . . . . . . . . . . . . . . . 8913.4 Parameter list . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90
14 Dimensions in mm . . . . . . . . . . . . . . . . . . . . . . . . . . 107
Test certificates . . . . . . . . . . . . . . . . . . . . . . . . . . . 108
EB 8384-3 EN 3
Contents
4 EB 8384-3 EN
Safety instructions
General safety instructions
The positioner may only be assembled, started up or operated by trainedand experienced personnel familiar with the product.According to these mounting and operating instructions, trained personnel isreferred to as individuals who are able to judge the work they are assignedto and recognize possible dangers due to their specialized training, theirknowledge and experience as well as their knowledge of the relevantstandards.
Explosion-protected versions of this positioner may only be operated bypersonnel who have undergone special training or instructions or who areauthorized to work on explosion-protected devices in hazardous areas.Refer to section 11 on Servicing explosion-protected versions.
Any hazards that could be caused by the process medium, the operatingpressure, the signal pressure or by moving parts of the control valve are tobe prevented by means of the appropriate measures.
If inadmissible motions or forces are produced in the actuator as a result ofthe supply pressure level, it must be restricted by means of a suitable supplypressure reducing station.
Proper shipping and appropriate storage are assumed.
Note! The device with a CE marking fulfils the requirements of the Directives94/9/EC (ATEX) and 89/336/EEC (EMC).The declaration of conformity can be viewed and downloaded on theInternet at http://www.samson.de.
EB 8384-3 EN 5
Versions
Article code Type 3730-3 X X X X X 0 0 X 0 X 0 0 X 0 X X
Explosion protectionWithout
II 2 G EEx ia IIC T6/II 2 D IP 65 T 80 °Cacc. to ATEXCSA/FM intrinsically safe/non incendive
II 3 G EEx na II T6 / II 3 D IP 65 T 80 °Cacc. to ATEX
01
38
Additional equipment
Inductivelimit switch
WithoutWith Type SJ 2-SN
01 0
Sol. valve SIL 4 Without24 V DC
04
Analogposition transmitter
WithoutWith
01
ExternalPosition sensor
WithoutWith 0
01
Diagnostics EXPERTEXPERT+ (extended)
12
Housing material AluminumStainless steel 1.4581 0
01
Positioner forspecialapplications
Without
Free of substances thatimpair painted surfaces
Exhaust air with pneum.connection ¼ NPT
0
1
2
Special versions Without
IECEx 1
0
0
0
1
0
2
6 EB 8384-3 EN
Firmware modification
Modifications of positioner firmware in comparison to previous versions
Previous New
1.00 1.10
The HART protocol as per HART specification Revision 5 is supported by de-fault setting.The setting can be changed to HART Revision 6 over TROVIS-VIEW. HARTtools as well as AMS or handheld communicators are currently not supportedby the Revision 6 version.
The following additional status indications were implemented:Code 76 - No emergency modeCode 77 - Program loading errorDisplays number of zero calibrations performed since the last initialization.
For initialization of "AIR TO CLOSE" actuators, the direction of action (Code7) is automatically set to increasing/decreasing.
Code 3, the activation period of the enabled configuration function wasextended to 120 s.
1.10 1.20
Electronics changed, no new functions added.
1.20 1.30
New EXPERT+ diagnostics functions (Code 48) addedPositioner in EXPERT+ version with extended diagnostics features.
A running initialization can be canceled by pressing the pushbutton.
The options position transmitter (Code 37) and solenoid valve (Code 45) areautomatically recognized.
EB 8384-3 EN 7
Firmware modification
1 Design and principle ofoperation
The electropneumatic positioner is mountedto pneumatic control valves and is used toassign the valve position (controlledvariable x) to the control signal (referencevariable w). The DC control signal receivedfrom a control unit is compared to the travelor rotational angle of the control valve andissues a signal pressure (output variable y).
The positioner is designed depending on thecorresponding accessories for directattachment to Type 3277 Actuators or forattachment to actuators according toIEC 60534-6 (NAMUR).
Additionally, a coupling wheel included inthe accessories is required to transfer the ro-tary motion for rotary actuators according toVDI/VDE 3845.Springless rotary actuators require an ac-cessory reversing amplifier to permit thepowered operation in either direction.
The positioner basically consists of a travelsensor system that functions proportional tothe resistance, an analog i/p module withdownstream booster as well as the electronicunit with a microcontroller.The positioner is fitted with three binary con-tacts as standard: A fault alarm output isused to indicate a fault to the control stationand two configurable software limit switchesto indicate the valve’s end positions.The position of the valve is transmitted aslinear travel motion or angle of rotation viapick-up lever and travel sensor (2) to an an-alog PD controller (3). Simultaneously, anA/D converter (4) transmits the position ofthe valve to the microcontroller (5). The PD
controller compares this actual position tothe 4 to 20 mA DC control signal (referencevariable) after it has been converted by theA/D converter (4).In case of a system deviation, the operationof the i/p converter (6) is changed so thatthe actuator (1) is filled or vented via thedownstream air capacity booster (7). Thiscauses the closure member of the controlvalve to move to the position determined bythe reference variable.The pneumatic air capacity booster (7) andthe pressure regulator (8) are provided withsupply air. An intermediate flow regulator(9) with fixed settings is used to purge thepositioner and also guarantees trouble-freeoperation of the pneumatic booster. The out-put signal pressure supplied by the boostercan be limited over the software.The volume restriction Q (10) is used to opti-mize the positioner by adapting it to the ac-tuator size.
Serial interface
The positioner is equipped with an interfaceto allow the SAMSON TROVIS-VIEW Con-figuration and Operator Interface softwareto transmit data and parameters over anadapter cable from the RS-232 interface ofa computer to the positioner. Refer tosection 13.
To detect any valve faults at an early stage,the positioner can optionally be equippedwith EXPERT+ valve diagnostics. You can ac-cess the functions provided by EXPERT+
valve diagnostics over TROVIS-VIEW soft-ware and over the DTM file of the device.Refer to Data Sheet T 8388 EN for more de-tails on EXPERT+ valve diagnostics. Instruc-tions on how to operate the software can be
8 EB 8384-3 EN
Design and principle of operation
found in the Operating InstructionsEB 8388 EN.
1.1 Communication
The positioner is equipped with an interfacefor HART protocol (Highway AddressableRemote Transducer) for communication pur-poses. Data are transmitted in a superim-posed frequency (FSK = Frequency ShiftKeying) on the existing signal loop for the 4to 20 mA reference variable.
Either a HART capable handheld communi-cator or a PC with FSK modem can be usedto establish communication and operate thepositioner.
1.2 Additional equipment
As an option, the device can be additionallyequipped with a solenoid valve for forcedventing, an analog position transmitter, aninductive limit switch or an external positionsensor.
Version with solenoid valve
If the operating voltage for the solenoidvalve (12) fails, the supply pressure for thei/p module is vented to the atmosphere. Thepositioner can no longer operate and thecontrol valve moves to the fail-safe positiondetermined by the actuator, independent ofthe reference variable.
EB 8384-3 EN 9
Design and principle of operation
Fig. 2 · Functional diagram
1 Control valve2 Travel sensor3 PD controller4 A/D converter5 Microcontroller6 i/p converter7 Air capacity booster8 Pressure regulator9 Flow regulator10 Volume restriction11* Inductive limit switch12* Solenoid valve13* Analog position transmitter14 Software limit switches
Alarm 1/215 Fault alarm output
Alarm 316 Display17* Solenoid valve control18* Galvanic isolation19 D/A converter20 Communication interface21 HART modulation* Optional
w
x
Q
%S
mm
GG
PD
SerialInterface 16
13
15
A2
A3
A1
112
4
21 FSK
20
195
312
6
7
8
10
1
14
14
w
xy
24V DC
9
17 18
Positioner with position transmitter
The position transmitter (13) is a two-wiretransmitter and issues the travel sensor sig-nal as a 4 to 20 mA signal processed by themicrocontroller.Since this signal is issued independent of thepositioner’s input signal (min. current3.8 mA), the actual travel/angle of rotationis controlled in real-time. Additionally, theposition transmitter provides the possibilityof signaling a positioner fault over a signalcurrent of <2.4 mA or >21.6 mA.
1.3 Technical data
Version with inductive limit switch
The rotary shaft of the positioner carries anadjustable tag which actuates the installedproximity switch.The optional inductive limit switch (11) leadsto A1 and the software limit switch, whichkeeps its function, leads to A2.
Version with external position sensor
In this version, only the sensor is mounted tothe control valve. The positioner is locatedseparately from the valve.The connection of x and y signals to thevalve is established via cable and air hosing(only for non-hazardous areas and withoutinductive limit switch).
10 EB 8384-3 EN
Design and principle of operation
Positioner
Nominal travel,adjustable
Direct attachment to Type 3277: 3.6 to 30 mm, attachment acc. to IEC 60534-6:3.6 to 200 mm or 24° to 100° opening angle for rotary actuators
Travel range Adjustable within the nominal travel/nominal angle, max. ratio 1 : 5
Reference variable w Signal range 4 to 20 mA, 2-wire unit, reverse polarity protection,min. span 4 mA, static destruction limit 100 mA
Minimum current 3.6 mA for display, 3.8 mA for operation
Load impedance ≤ 8.2 V (corresponding to 410 Ω at 20 mA)
Supply air
Supply pressure from 1.4 to 6 bar (20 to 90 psi),Air quality acc. to ISO 8573-1 Edition 2001: Max. particle size and density: Class 4Oil content: Class 3, pressure dew point: Class 3 or at least 10 K beneath the lowestambient temperature to be expected
Signal pressure (output) 0 bar up to supply pressure, limitable to 1.4/2.4/3.7 ±0.2 bar via software
Characteristic,user-defined adjustableover operating software
Linear/equal percentage/reverse equal percentage/butterfly valve linear/butterfly valve eq. percentage/rotary plug valve linear/rotary plug valve eq. percent-age/segmented ball valve linear/segmented ball valve eq.percentageDeviation from terminal-based conformity ≤ 1 %
Hysteresis ≤ 0.3 %
Sensitivity ≤ 0.1 %
EB 8384-3 EN 11
Design and principle of operation
Transit time Separately adjustable up to 240 seconds for supply air and exhaust air
Direction of action Reversible
Air consumption, steadystate
Independent from supply pressure approx. 110 ln/h
Air deliveryActuator pressurizedActuator vented
At ∆p = 6 bar: ≥ 8.5 mn3/h, at ∆p = 1.4 bar: 3.0 mn
3/h KVmax (20 °C) = 0.09at ∆p = 6 bar: ≤ 14.0 mn
3/h, at ∆p = 1.4 bar: 4.5 mn3/h KVmax (20 °C) = 0.15
Permissible ambienttemperature
–20 to +80 °C, with metal cable gland –40 to +80 °CThe limits specified in the EC Type Examination Certificate additionally apply forexplosion-protected devices.
Influences Temperature: ≤ 0.15 %/10 K Supply air: NoneVibration: ≤ 0.25 % up to 2000 Hz and 4 g acc. to IEC 770
Electromagneticcompatability Complying with EN 61000-6-2, EN 61000-6-3 and NAMUR Recommendation NE 21
Explosion protection
II 2 G EEx ia IIC T6 / II 2 D IP 65 T 80 °C orII 3 G EEx nA II T6 / II 3 D IP 65 T 80 °C
IECEx ia IIC T6 / IP 54 and IP 65 T 80 °CFM/CSA intrinsically safe Class I, II, III, Division 1, Group A, B, C, D, E, F, G, T6FM/CSA non incendive Class I, Division 2, Group A, B, C, D, T6
Degree of protection IP 65
Communication (local) SAMSON SSP interface and serial interface adapter
Software requirements TROVIS-VIEW with database module 3730-3
Communication (HART)HART® field communication protocolImpedance in the HART frequency range: receive 350 to 450 Ω,send: approx. 155 Ω
Software requirements(HART)
For handheld communicator: device description for 3730-3,For PC: DTM file acc. to Specification 1.2, suitable for integrating the positioner inframe applications that supports the FDT/DTM concept (e.g. PACTware);other integration options (e.g. AMS, PDM) available.
Binary contacts 1 fault alarm contact,2 software limit switches with configurable limit values, reverse polarity protection
Signal statusNo response:
Response:
Without explosion protectionConductive (R = 348 Ω)Non-conducting
Ex.-protected version:≥ 2.1 mA≤ 1.2 mA
Operating voltage
Positioners with model no. ../9000 only for connection tosignal converter acc. to EN 60947-5-6.All other versions also for connection to binary input ofthe PLC acc. to EN 61131, Pmax = 400 mW
Only for connection tosignal converter acc. toEN 60 957-5-6
12 EB 8384-3 EN
Design and principle of operation
Solenoid valve SIL 4 approval acc. to IEC 61508
Input
24 V DC reverse polarity protection, static destruction limit 40 V;
Current consumption I =U 5.6 V4020−
Ω(corresponding to 4.5 mA at 24 V)
Signal Signal "0" no pick-up ≤ 15 V Signal "1" safe pick-up >19 V
Service life >5 x 105 switching cycles
Implementation insafety-relevant systems incompliance withIEC 61508
Probability of failure on demand of safety functions PFD < 2.8 x 10-7 for a confidencelevel of 95 %.The safe failure fraction (SFF) according to Table A1 in IEC 61508-2 is greater orequal to 0.99. The valves are therefore suitable for implementation in safety-relatedsystems with a hardware fault tolerance of 1 or 2 up to and including SIL 4.
Analog position transmitter Two-wire transmitter
Supply voltage 12 to 30 V DC, reverse polarity protection, static destruction limit 40 V
Output signal 4 to 20 mA
Direction of action Reversible
Operating range 0 to 100 % of the travel range, optional also for fault indication over 2.4 or 21.6 mA
Characteristic Linear
Hysteresis andHF influence Same as positioner
Ripple content of outputsignal 0.6 % at 28 Hz acc. to IEC 381 T1
Other influences Same as positioner
Fault indication Can be issued with current signal < 2.4 mA or > 21.6 mA
Inductive limit switch Type SJ 2SN Proximity Switch
For connection to switching amplifier acc. to EN 60947-5-6. Can be used in combination with a software limit switch.
External position sensor
Nominal travel Adjustable same as positioner
Cable Max. 10 m with M12x1 connector, designed for continuous flexing, flame retardantacc. to VDE 0472, reistant to oils, lubricants as well as other corrosive media
Ambient conditionsPerm. temperature: –40 to +105 °C, the limits specified in the EC Type ExaminationCertificate additionally apply for explosion-protected devices.Vibration immunity: up to 10 g in the range between 10 and 2000 Hz
Degree of protection IP 67
MaterialsHousing: Die-cast aluminum GD AlSi12 acc. to DIN 1725 (3.2582), chromated andplastic coated, special version. CrNiMo (1.4581); External parts: Stainless steel1.4571 and 1.4301. Cable gland M20x1.5, black polyamide
Weight Approx. 1.0 kg
2 Attachment to the controlvalve – Mounting parts andaccessories
The positioner can be attached either di-rectly to a SAMSON Type 3277 Actuator oraccording to IEC 60534-6 (NAMUR) to con-trol valves with cast yokes or rod-type yokesas well as to rotary actuators according toVDI/VDE 3845.
For attachment to the various actuators, cor-responding mounting parts and accessoriesare required. These are listed with their or-der numbers in Tables 1 to 5.
On attaching the positioner, it is importantto observe the assignment between leverand pin position according to the travelslisted in the travel tables.
The tables show the maximum adjustmentrange at the positioner. The travel that canbe implemented at the valve is restricted bythe pin position used and additionally by theactuator spring compression required.The positioner is standard equipped with thelever M (pin position 35).
Note!If the standard mounted lever M (pin posi-tion 35) is replaced, the newly mounted le-ver must be moved once all the way as faras it will go in both directions to adapt it tothe internal measuring lever.
EB 8384-3 EN 13
Attachment to the control valve – Mounting parts and accessories
Travel table for direct attachment to Type 3277 Actuator
Type3277-5
and3277
Actuators
Actuator sizecm2
Rated travelmm
Adjustment range at positionerMin. Travel Max.
Requiredlever
Assignedpin position
120 7.5 5 17.6 M 25
120/240/350 15 7.5 35.4 M 35
700 30 10 50 M 50
Travel table for attachment according to IEC 60534-6 (NAMUR)
SAMSON valves Other valves/actuators Requiredlever
Assignedpin position
Type 3271Actuator
cm2 Rated travel mm Min. Travel Max.
60 and 120 withType 3510 Valve 7.5 3.6 17.6 S 17
120 7.5 5.0 17.6 M 25
120/240/350 15 7.5 35.4 M 35
700/1400/2800 15 and 30/30 10 50 M 50
1400/2800 60 14.0 70.8 L 70
1400/2800 60 20.0 100 L 100
1400/2800 120 40.0 200 XL 200
Rotary actuators Opening angle 24° to 100° M 90°
14 EB 8384-3 EN
Attachment to the control valve – Mounting parts and accessories
Table 3 Attachment to NAMUR ribs or control valves with rod-type yokes (rod diameter Ø 35 mm or smaller)according to IEC 60534-6, see Fig. 5
Travel in mm Lever For actuators Order no.
7.5 S Type 3271-5 Actuator with 60/120 cm2 on Type 3510Valve, see Fig. 6 1400-7457
5 to 50 Without (lever M onbasic model)
Actuators from other manufacturers and Type 3271 with120 to 700 cm2 1400-7454
14 to 100 L Actuators f. other manufacturers and Type 3271 w. 1400 cm2 1400-7455
40 to 200 XL Actuators from other manufacturers and Type 3271 with1400/2800 cm2, 120 mm travel 1400-7456
30 or 60 L Type 3271 Actuator with 1400 cm2 (120 mm travel),2800 cm2 (30 or 60 mm travel) 1400-7466
Mounting brackets for Emerson and Masoneilan linear actuatorsIn addition, a mounting kit acc. to IEC 60534-6 is required depending on the travel. See row above. 1400-6771
Accessories
Connecting plate G ¼: 1400-7461 ¼ NPT : 1400-7462
or pressure gauge bracket (7) G ¼: 1400-7458 ¼ NPT: 1400-7459
Pressure gauge mounting kit (output/supply) St.st./Bs: 1400-6950 St.st./St.st.: 1400-6951
Table 1 Direct attachment to Type 3277-5 Actuator, see Fig. 3
Mounting parts For actuators with 120 cm2 effective diaphragm area 1400-7452
Accessoriesfor theactuator
Switchover plate (old) for Actuator Type 3277-5xxxxxx.00 (old) 1400-6819
Switchover plate new for Actuator Type 3277-5xxxxxx.01 (new) 1400-6822
Connecting plate for additional attachment of a solenoid valve G 1/8Connecting plate (old) for Actuator Type 3277-5xxxxxx.00 (old) 1/8 NPT
1400-68201400-6821
Connecting plate new for Actuator Type 3277-5xxxxxx.01 (new) 1400-6823
Note: Only new switchover and connecting plates can be used with new actuators (Index 01).Old and new plates are not interchangeable.
Accessoriesfor thepositioner
Connecting plate (6) G ¼: 1400-7461 ¼ NPT: 1400-7462
or pressure gauge bracket (7) G ¼: 1400-7458 ¼ NPT: 1400-7459
Pressure gauge mounting kit (8) (output/supply) St. st./Bs: 1400-6950 St. st./St. st.: 1400-6951
Table 2 Direct attachment to Type 3277 Actuator, see Fig. 4
Accessories
Mounting parts for actuators with 240, 350 and 700 cm2 1400-7453
Required piping with screw fittings for "Actuatorstem retracts" or when the top diaphragmchamber is filled with air
cm2 Steel Stainless steel240 1400-6444 1400-6445350 1400-6446 1400-6447700 1400-6448 1400-6449
Connection block with seals and screw G ¼: 1400-8811 ¼ NPT: 1400-8812
Pressure gauge mounting kit (output and supply) St.st./Bs: 1400-6950 St.st/St.st.: 1400-6951
EB 8384-3 EN 15
Attachment to the control valve – Mounting parts and accessories
Table 4 Attachment to rotary actuators (VDI/VDE 3845 for all sizes of fixing level 2) see Figs. 7 and 8
Mountingparts
With follower clampand coupling wheel
VDI/VDE 3845 for all sizes of fixing level 2for Type 3278 Actuator with 160/320 cm2
for Camflex II
1400-74481400-76141400-9120
Accessories
Connecting plate G ¼: 1400-7461 ¼ NPT: 1400-7462
or pressure gauge bracket (7) G ¼: 1400-7458 ¼ NPT: 1400-7459
Pressure gauge mounting kit (output/supply) St.st./Bs: 1400-6950 St.st./St.st: 1400-6951
Table 5 General accessories
Accessories
Pneumatic reversing amplifier for double-actingactuators
G ¼¼ NPT
1079-11181079-1119
Cable gland M20 x 1.5 Nickel-plated brass 1890-4875
Adapter M 20 x 1.5 to ½ NPT, aluminum 0310-2149
Retrofit kit for inductive limit switch 1x SJ 2-SN 1400-7460
Cover plate with list of parametersand operating instructions
German/English (standard)English/SpanishEnglish/French
1190-07611190-31001190-3142
2.1 Direct attachment
2.1.1 Type 3277-5 Actuator
Refer to Table 1 on page 14 for the requiredmounting parts as well as the accessorieswith their order numbers.Note the travel table on page 13!
Actuator with 120 cm2
Depending on the type of positioner attach-ment, the signal pressure is routed either leftor right of the yoke through a bore to theactuator diaphragm. Depending on thefail-safe action of the actuator "Actuatorstem extends" or "Actuator stem retracts"(valve closes or opens if the supply air fails),the switchover plate (9) must first be at-tached to the actuator yoke. Align theswitchover plate with the correspondingsymbol for left or right attachment accordingto the marking (view looking onto theswitchover plate).
1. Mount connecting plate (6) or pressuregauge bracket (7) with pressure gaugesonto the positioner, making sure bothseal rings (6.1) are seated properly.
2. Remove vent plug (4) on the back of thepositioner and close the signal pressureoutput "Output 38" on the connectingplate (6) or on the pressure gaugebracket (7) with the stopper (5) includedin the accessories.
3. Place follower clamp (3) on the actuatorstem, align and screw tight so that themounting screw is located in the grooveof the actuator stem.
4. Mount cover plate (10) with narrow sideof the cut-out opening (Fig. 3, on the
left) pointing towards the signal pressureconnection. Make sure that the bondedgasket (14) points towards the actuatoryoke.
5. 15 mm travel: Keep the follower pin (2)at lever M (1) on the back of thepositioner in the pin position 35 (deliv-ered state).7.5 mm travel: Remove the follower pin(2) from the pin position 35, reposition itin the bore for pin position 25 andscrew tight.
6. Insert formed seal (15) in the groove ofthe positioner casing.
7. Place positioner on the cover plate (10)in such a manner that the follower pin(2) rests on the top of the follower clamp(3). Adjust the lever (1) correspondinglyand open the positioner cover to holdthe positioner shaft in position at the capor the switch (Fig. 18).The lever (1) must rest on the followerclamp with spring force.Mount the positioner on the cover plate(10) using the two fixing screws. Duringthe installation make sure that the sealring (10.1) is inserted in the bore of theintermediate plate.
8. Mount cover (11) on the other side.Make sure that the vent plug pointsdownwards when the control valve is in-stalled to allow any condensed waterthat collects to drain off.
16 EB 8384-3 EN
Attachment to the control valve – Mounting parts and accessories
EB 8384-3 EN 17
Attachment to the control valve – Mounting parts and accessories
Fig. 3 · Direct attachment - Signal pressure connection for Type 3277-5 Actuator with 120 cm2
9 11
Supply 9 Output 38
56
4
7
61010.1
3
2
1
15
6.1
1.11.2
14
8
1 Lever1.1 Nut1.2 Disk spring2 Follower pin3 Follower clamp4 Vent plug5 Stopper6 Connecting plate6.1 Seal rings7 Pressure gauge bracket8 Press. gauge mounting kit9 Switchover plate
for actuator10 Cover plate10.1Seal ring11 Cover14 Gasket15 Formed seal
Important!Always use the connecting plate (6)included in the accessories to connectsupply and output.Never screw threaded parts directlyinto the housing.
Symbols
Actuator stemextends
Attachment left Attachment right
Actuator stemretracts
Switchover plate (9)
Signal pressureinput for right
attachmentMarking
Cut-out of coverplate
Signal pressureinput for leftattachment
2.1.2 Type 3277 Actuator
Refer to Table 2 on page 14 or the requiredmounting parts as well as the accessorieswith their order numbers.Note the travel table on page 13!
Actuators with 240 to 700 cm2
The positioner can be mounted either on theleft or on the right side of the yoke. The sig-nal pressure is routed to the actuator overthe connection block (12), for actuators withfail-safe action "Actuator stem extends" in-ternally through a bore in the valve yokeand for "Actuator stem retracts" through ex-ternal piping.
1. Place follower clamp (3) on the actuatorstem, align and screw tight so that themounting screw is located in the grooveof the actuator stem.
2. Mount cover plate (10) with narrow sideof the cut-out opening (Fig. 4, on theleft) pointing towards the signal pressureconnection. Make sure that the bondedgasket (14) points towards the actuatoryoke.
3. For actuators with 700 cm2, remove thefollower pin (2) at lever M (1) on theback of the positioner from pin position35, reposition it in the bore for pin posi-tion 50 and screw tight.For actuators 240 and 350 cm2 with15 mm travel, the follower pin (2) re-mains in pin position 35.
4. Insert formed seal (15) in the groove ofthe positioner casing.
5. Place positioner on the cover plate insuch a manner that the follower pin (2)
rests on the top of the follower clamp(3). Adjust the lever (1) correspondinglyand open the positioner cover to holdthe positioner shaft in position at the capor the switch (Fig. 18). The lever (1) mustrest on the follower clamp with springforce. Mount the positioner on the coverplate (10) using the two fixing screws.
6. Make sure that the tip of the gasket (16)projecting from the side of the connec-tion block (12) is positioned above theactuator symbol that corresponds withthe actuator with fail-safe action "Actua-tor stem extends" or "Actuator stem re-tracts." If necessary, remove the threefixing screws and the cover. Then repo-sition the gasket (16) turned by 180°.The previous version of the connectionblock (Fig. 4, bottom) requires the switchplate (13) to be turned such that the cor-responding actuator symbol points to themarking.
7. Place the connection block (12) with theassociated seal rings against thepositioner and the actuator yoke. Screwit tight using the fixing screw (12.1). Foractuators with fail-safe action "Actuatorstem retracts", additionally remove thestopper (12.2) and fit on the externalsignal pressure piping.
8. Mount cover (11) on the other side.Make sure that the vent plug pointsdownwards when the control valve is in-stalled to allow any condensed waterthat collects to drain off.
18 EB 8384-3 EN
Attachment to the control valve – Mounting parts and accessories
EB 8384-3 EN 19
Attachment to the control valve – Mounting parts and accessories
Fig. 4 · Direct attachment – Signal pressure connection for Type 3277 Actuator with 240, 350 and 700 cm2
2
10 1415
1 2 3 11
SUPPLY
13
16
B
1.11.2
1212.1
12
12.1
12.2
A
1216 12.2SUPPLY
Cut-out ofcover plate (10)
Actuator stemretracts extends
Stem retracts
Stem extends
Marking
Connection block (old)with switch plate (13)
Lever M
1 Lever1.1 Nut1.2 Disk spring2 Follower pin3 Follower clamp10 Cover plate11 Cover12 Connection block
12.1 Screw12.2 Stopper or connection for
external piping13 Switch plate14 Gasket15 Formed seal16 Gasket
2.2 Attachment according toIEC 60534-6
The positioner is attached to the controlvalve with a NAMUR bracket (10).
Refer to Table 3 on page 14 for the requiredmounting parts as well as the accessorieswith their order numbers.Note the travel table on page 13!
1. Screw the two bolts (14) to the bracket(9.1) of the stem connector (9), place thefollower plate (3) on top and use thescrews (14.1) to tighten.
Actuator size 2800 cm2:For a travel of 60 mm or smaller, screwthe longer follower plate (3.1) directly tothe stem connector (9). For a travel ex-ceeding 60 mm, mount the bracket (16)first and then the follower plate (3) to thebracket together with the bolts (14) andscrews (14.1).
2. Mount NAMUR bracket (10) to the con-trol valve as follows:For attachment to the NAMUR rib, usean M8 screw (11) and toothed lockwasher directly in the yoke bore.For attachment to valves with rod-typeyokes, use two U-bolts (15) around theyoke.Align the NAMUR bracket (10) in such away that the slot of the follower plate (3)is centrally aligned with the NAMURbracket at mid valve travel.
3. Mount connecting plate (6) or pressuregauge bracket (7) with pressure gauges
(8) on the positioner, making sure bothseal rings (6.1) are seated properly.
4. Select required lever size (1) M, L or XLand pin position according to the actua-tor size and valve travels listed in the ta-ble below.Should you require a pin position otherthan position 35 with the standard in-stalled lever M, or require a lever size Lor XL, proceed as follows:
5. Screw the follower pin (2) in the as-signed lever bore (pin position) as listedin the table. Only use the longer followerpin (2) included in the mounting kit.
6. Place lever (1) on the positioner shaftand screw tight using the disk spring(1.2) and nut (1.1).
Note!If you have mounted a new lever (1), youmust move it once all the way as far as itwill go in both directions.
7. Place positioner on the NAMUR bracketin such a manner that the follower pin(2) rests in the slot of the follower plate(3, 3.1). Adjust the lever (1) correspond-ingly.Screw the positioner to the NAMURbracket using both its fixing screws.
20 EB 8384-3 EN
Attachment to the control valve – Mounting parts and accessories
EB 8384-3 EN 21
Attachment to the control valve – Mounting parts and accessories
Fig. 5 · Attachment according to IEC 60534-6 (NAMUR)
10
11
6.1 6 7 8
1
1 14.1
3
3.1
16
15
14
11.21.12
9.19 Attachment to
NAMUR rib
Additional bracket foractuators with 2800 cm2
and travel ≥ 60 mm
Attachment to rod-type yokeRods with Ø max. 35 mm
Lever XL and L
1 Lever1.1 Nut1.2 Disk spring2 Follower pin3 Follower plate3.1 Follower plate6 Connecting plate6.1 Seal rings7 Pressure gauge bracket8 Pressure gauge
mounting kit9 Stem connector9.1 Bracket10 NAMUR bracket11 Screw14 Bolt14.1 Screw15 U-bolt16 Bracket
Important!Always use the connecting plate (6) included in the accessories to connectsupply and output. Never screw threaded parts directly into the housing.
2.3 Attachment to Type 3510Micro-flow Valve
The positioner is attached to the valve yokeusing a bracket.
Refer to Table 3 on page 14 for the requiredmounting parts as well as the accessorieswith their order numbers.Note the travel table on page 13!
1. Place clamp (3) on the valve stem con-nector, align at a right angle and screwtight.
2. Screw bracket (10) to the valve yoke us-ing two screws (11).
3. Mount connecting plate (6) or pressuregauge bracket (7) with pressure gaugesto the positioner, making sure both sealrings (6.1) are seated properly.
4. Unscrew the standard installed lever M(1) including follower pin (2) from thepositioner shaft.
5. Take lever S (1) and screw follower pin(2) in the bore for pin position 17.
6. Place lever S on the positioner shaft andscrew tight using the disk spring (1.2)and nut (1.1).Move lever once all the way as far as itwill go in both directions.
7. Place positioner on the bracket (10) insuch a manner that the follower pinslides into the groove of the clamp (3).Adjust the lever (1) correspondingly.Screw the positioner to the bracket (10)using both its hexagon screws.
22 EB 8384-3 EN
Attachment to the control valve – Mounting parts and accessories
EB 8384-3 EN 23
Attachment to the control valve – Mounting parts and accessories
Fig. 6 · Attachment to Type 3510 Micro-flow Valve
3
10
11
11
6
121.2 1.1
78
6.1
1 Lever1.1 Nut1.2 Disk spring2 Follower pin3 Clamp6 Connecting clamp6.1 Seal rings7 Pressure gauge bracket8 Pressure gauge
mounting kit10 Bracket11 Screw
Important!Always use the connecting plate (6)included in the accessories to connectsupply and output.Never screw threaded parts directlyinto the housing.
Lever S
2.4 Attachment to rotaryactuators
The positioner is mounted to the rotary actu-ator using two pairs of double brackets.
Refer to Table 4 on page 15 for the requiredmounting parts as well as the accessorieswith their order numbers.
Prior to the attachment of the positioner tothe SAMSON Type 3278 Rotary Actuator,you have to mount the associated adapter(5) to the free end of the rotary actuatorshaft.
Note!During the installation of the positioner asdescribed below, it is imperative that the ac-tuator's direction of rotation be observed.
1. Place follower clamp (3) on the slottedactuator shaft or the adapter (5).
2. Place coupling wheel (4) with flat sidefacing the actuator on the followerclamp (3). Refer to Fig. 8 to align slot sothat it matches the direction of rotationwhen the valve is in its closed position.
3. Screw coupling wheel and followerclamp tightly onto the actuator shaftusing screw (4.1) and disk spring (4.2).
4. Screw the bottom pair of brackets (10.1)with the bends pointing either to the in-side or to the outside (depending on theactuator size) to the actuator case. Posi-tion top pair of brackets (10) and screwtight.
5. Mount connecting plate (6) or pressuregauge bracket (7) with pressure gaugesto the positioner, making sure bothO-rings are seated properly.For double-acting, springless rotary ac-tuators, a reversing amplifier is requiredto attach the positioner to the actuator,see section 2.5.
6. Unscrew the standard follower pin (2)from the positioner's lever M (1). Use themetal follower pin (Ø5) included in themounting kit and screw tight into thebore for pin position 90°.
7. Place positioner on the top pair ofbrackets (10) and screw tight. Con-sidering the actuator's direction of rota-tion, adjust lever (1) so that it engages inthe slot of the coupling wheel (4) with itsfollower pin (see Fig. 8). It must be guar-anteed that the lever (1) is parallel to thelong side of the positioner when the ac-tuator is at half its angle of rotation.
8. Stick scale plate (4.3) on the couplingwheel so that the arrow tip indicates theclosed position, and it can be easilyread when the valve is installed.
24 EB 8384-3 EN
Attachment to the control valve – Mounting parts and accessories
Fig. 7 · Mounting the coupling wheel with Type 3278
1.21.1
1
2
4.1
4.2
53
Actuator flange
EB 8384-3 EN 25
Attachment to the control valve – Mounting parts and accessories
Fig. 8 · Attachment to rotary actuators
Slot
10
10.1
6(7, 8)
1.124.3
5
6.1
4
1.21
Control valve opens clockwise
Control valve opens counterclockwise
Slot
Important!Always use the connectingplate (6) included in theaccessories to connectsupply and output.Never screw threadedparts directly into thehousing.
Legends Figs. 7 and 81 Lever1.1 Nut1.2 Disk spring2 Follower pin3 Follower clamp (Fig. 7)4 Coupling wheel4.1 Screw4.2 Disk spring4.3 Scale plate4.3 Scale plate5 Actuator shaft
Adapter for Type 32786.1 Seal rings7 Pressure gauge bracket8 Pressure gauge
mounting kit10 Top pair of brackets10.1 Bottom pair of brackets
2.5 Reversing amplifier fordouble-acting actuators
For the use with double-acting actuators, thepositioner must be fitted with a reversingamplifier. The reversing amplifier is listed asan accessory in the Table 5 on page 15.
The output signal pressure of the positioneris supplied at the output A1 of the reversingamplifier. An opposing pressure, whichequals the required supply pressure whenadded to the pressure at A1, is applied atoutput A2.The rule A1 + A2 = Z applies.
Mounting
1. Mount the connecting plate (6) from theaccessories in Table 5 to the positioner.Make sure that both O-rings (6.1) areseated correctly.
2. Thread the special nuts (1.3) from theaccessories of the reversing amplifierinto the boreholes of the connectingplate.
3. Insert the gasket (1.2) into the recess ofthe reversing amplifier and push boththe hollowed special screws (1.1) intothe connecting boreholes A1 and Z.
4. Place the reversing amplifier onto theconnecting plate (6) and screw tight us-ing both the special screws (1.1).
5. Use a screwdriver (8 mm wide) to screwthe enclosed filters (1.6) into the con-necting boreholes A1 and Z.
Note!The sealing plug (1.5) in the Type 3730Positioner should not be unscrewed out ofthe reversing amplifier.The rubber seal (1.4) is not required andcan be removed when the sealing plug isused.
Signal pressure connections
A1: Output A1 leading to the signal pressureconnection at the actuator which opens thevalve when the pressure increases
A2: Output A2 leading to the signal pressureconnection at the actuator which closes thevalve when the pressure increases
Set slide switch on positioner toAIR TO OPEN.
26 EB 8384-3 EN
Attachment to the control valve – Mounting parts and accessories
EB 8384-3 EN 27
Attachment to the control valve – Mounting parts and accessories
Fig. 9 · Mounting a reversing amplifier
A1
1.5 1.6
1.3
6.266.1
1.2 1.1 1 1.6
Z
A2
1.4A1 A2
Z
A1
Output 38 Supply 9
Out
put 3
8Su
pply
9
1.3 1.21.1
1 Reversing amplifer1.1 Special screws1.2 Gasket1.3 Special nuts1.4 Rubber seal1.5 Sealing plug1.6 Filter
6 Connecting ring6.1 O-rings6.2 Screws
From the positioner
Control signals tothe actuator
2.6 Attaching an externalposition sensor
Refer to Table 6 on page 33 for a list of themounting parts as well as the accessories re-quired for mounting the position sensor.Accessories for the pneumatic connection tothe positioner housing can be found in Ta-ble 7.
In the positioner version with an externalposition sensor, the sensor placed in a sepa-rate housing is attached over a plate orbracket to the control valve. The travelpick-off corresponds to that of a standarddevice.The positioner unit can be mounted as re-quired to a wall or a pipe.
For the pneumatic connection either a con-necting plate (6) or a pressure gaugebracket (7) must be fixed to the housing, de-pending on the accessory chosen. Makesure the seal rings (6.1) are correctly in-serted (see Fig. 5, bottom right).
For the electric connection the connectinglead must be fitted with an M12x1 connec-tor plug at one end. The lead end withoutthe plug can be shortened, if required, andwired to the connector included (section 3.2on page 36). The electrical and pneumaticconnections between the sensor and thepositioner unit may be a maximum of 10meters.
Note! In addition, the instructions in section3.1 and 3.2 apply for the pneumatic andelectrical connection.Operation and setting are described in sec-tions 4 and 5.
2.6.1 Mounting the position sensorwith direct attachment
Type 3277-5 Actuator with 120 cm2
The signal pressure from the positioner isrouted over the signal pressure connectionof the connecting plate (9, Fig. 11 left) to theactuator diaphragm chamber. To proceed,first screw the connecting plate (9) includedin the accessories onto the actuator yoke.
Turn the connecting plate (9) so that thecorrect symbol for the fail-safe position"Actuator stem extends" or "Actuatorstem retracts" is aligned with the mark-ing (Fig. 11, below).
Make sure that the gasket for the con-necting plate (9) is correctly inserted.
The connecting plate has boreholes withNPT and G threads.Seal the threaded connection that is notused with the rubber seal and squareplug.
28 EB 8384-3 EN
Attachment to the control valve – Mounting parts and accessories
Fig. 10 · Positioner unit with sensor mounted on amicro-flow valve
Type 3277 Actuator with 240 to 700 cm2:
The signal pressure is routed to the connec-tion at the side of the actuator yoke for theversion "Actuator stem extends".For the fail-safe position "Actuator stem re-tracts" the connection on the top diaphragmcase is used. The connection at the side ofthe yoke must be fitted with a venting plug(accessories).
Mounting the position sensor
1. Place the lever (1) on the sensor inmid-position and hold it in place.Unthread the nut (1.1) and remove thelever together with the disk spring (1.2)from the sensor shaft.
2. Screw the position sensor (20) onto themounting plate (21).
3. Depending on the actuator size andrated travel of the valve, determine therequired lever and position of the fol-lower pin (2) from the travel table onpage 13.The positioner is delivered with lever Min pin position 35 on the sensor. If nec-essary, remove the follower pin (2) fromits pin position and move it to the bore-hole for the recommended pin positionand screw tight.
4. Place the lever (1) and disk spring (1.2)on the sensor shaft.
EB 8384-3 EN 29
Attachment to the control valve – Mounting parts and accessories
Fig. 11 · Mounting for Type 3277-5 Actuator (left) and Type 3277 Actuator (right)
2021
9
111.11.2
32
1
Signal pressure
Venting plug
Actuator stemextends retractsSymbol
Marking
Signal pressure
1 Lever1.1 Nut1.2 Disk spring2 Follower pin3 Follower clamp9 Connecting plate11 Cover20 Position sensor21 Mounting plate
Place the lever (1) in mid-position andhold it in place. Screw on the nut (1.1).
5. Place the follower clamp (3) on the actu-ator stem, align and fasten it, makingsure that the fastening screw rests in thegroove of the actuator stem.
6. Place the mounting plate (21) togetherwith the sensor onto the actuator yoke sothat the follower pin (2) rests on the topof the follower clamp (3). It must rest onit with spring force.Screw tight the mounting plate (21) ontothe actuator yoke using both fixingscrews.
7. Mount cover (11) on the other side.Make sure that the vent plug pointsdownwards when the control valve is in-stalled to allow any condensed waterthat collects to drain off.
2.6.2 Mounting the position sensorwith attachment according toIEC 60534-6
For the required mounting parts as well asthe accessories, refer to the order numberslisted in Tables 6 and 7 on page 33.
1. Place the lever (1) on the sensor inmid-position and hold it in place.Unthread the nut (1.1) and remove thelever together with the disk spring (1.2)from the sensor shaft.
2. Screw the position sensor (20) onto thebracket (21).
The standard attached lever M with the fol-lower pin (2) at position 35 is designed for120, 240 and 350 cm2 actuators with15 mm rated travel.
30 EB 8384-3 EN
Attachment to the control valve – Mounting parts and accessories
Fig. 12 · Mounting according to IEC 60534-6 (NAMUR)
20 21 1.1, 1.2 14.1 3 14 99.1
1 Lever1.1 Nut1.2 Disk spring2 Follower pin3 Follower plate9 Stem connector9.1 Bracket14 Bolt14.1 Screws20 Position sensor21 Bracket
For other actuator sizes or travels, select thelever and pin position from the travel tableon page 13. Lever L and XL are included inthe mounting kit.
3. Place the lever (1) and disk spring (1.2)on the sensor shaft.Place the lever (1) in mid-position andhold it in place. Screw on the nut (1.1).
4. Screw both bolts (14) to the bracket(9.1) of the stem connector (9). Attachthe follower plate (3) and fix with thescrews (14.1).
5. Place the bracket with the sensor at theNAMUR rib in such a manner that thefollower pin (2) rests in the slot of the fol-lower plate (3), then screw the bracketusing its fixing screws onto the valve.
2.6.3 Mounting the position sensorto Type 3510 Micro-flowValve
For the required mounting parts as well asthe accessories, refer to the order numberslisted in Tables 6 and 7 on page 33.
1. Place the lever (1) in mid-position andhold it in place. Unscrew the nut (1.1)and remove the standard attached leverM (1) together with the disk spring (1.2)from the sensor shaft.
2. Screw the position sensor (20) onto thebracket (21).
3. Select the lever S (1) from the accesso-ries and screw the follower pin (2) intothe hole for pin position 17.Place the lever (1) and disk spring (1.2)on the sensor shaft.
Place the lever (1) in mid-position andhold it in place. Screw on the nut (1.1).
4. Place the follower clamp (3) on the stemconnector, align it at a right angle andscrew tight.
5. Position the bracket (21) with the posi-tion sensor on the valve yoke and screwtight, making sure the follower pin (2)slides into the groove of the followerclamp (3).
EB 8384-3 EN 31
Attachment to the control valve – Mounting parts and accessories
Fig. 13 · Mounting a micro-flow valve
20 211.11.2
1
3
2
1 Lever1.1 Nut1.2 Disk spring2 Follower pin3 Follower clamp20 Position sensor21 Bracket
2.6.4 Mounting the position sensorto rotary actuators
For the required mounting parts as well asthe accessories, refer to the order numberslisted in Tables 6 and 7 on page 33.
1. Place the lever (1) in mid-position andhold it in place. Unscrew the nut (1.1)and remove the standard attached leverM (1) together with the disk spring (1.2)from the sensor shaft.
2. Screw the position sensor (20) onto thebracket (21).
3. Replace the follower pin (2) normally at-tached to the lever (1) with the metal fol-lower pin (∅ 5) from the accessories andscrew it into the hole for pin position90°.
4. Place the lever (1) and disk spring (1.2)on the sensor shaft.Place the lever (1) in mid-position andhold it in place. Screw on the nut (1.1).
Follow the instructions describing attachmentto the standard positioner in section 2.4Instead of the positioner, attach the positionsensor (20) with its mounting plate (21).
32 EB 8384-3 EN
Attachment to the control valve – Mounting parts and accessories
Fig. 14 · Positioner unit with sensor mounted on rotary actuators
2021
2 1 1.1, 1.2
1 Lever1.1 Nut1.2 Disk spring2 Follower pin20 Position sensor21 Mounting plate
EB 8384-3 EN 33
Attachment to the control valve – Mounting parts and accessories
Table 6 Mounting parts for position sensor Order no.
Direct attachment Mounting parts for actuators with 120 cm2 see Fig. 11 left 1400-7472
Accessories foractuator 120 cm2
Connecting plate (9, old) for Actuator Type3277-5xxxxxx.00
G 1/81/8 NPT
1400-68201400-6821
Connecting plate (new) for Actuator Type 3277-5xxxxxx.01 (new) 1400-6823
Note: Only new switchover and connecting plates can be used with new actuators(Index 01). Old and new plates are not interchangeable.
Direct attachment Mounting parts for actuators with 240, 350 and 700 cm2, see Fig. 11 right 1400-7471
NAMUR attachment Mounting parts for attachment to NAMUR rib w. lever L and XL, see Fig. 12 1400-7468
Attachment tomicro-flow valves Mounting parts for Type 3510 Micro-flow Valve, see Fig. 13 1400-7469
Attachment to rotaryactuators Mounting parts with follower clamp and coupling wheel, see Fig. 14 1400-7473
Table 7 Postioner accessories Order no.
Accessories
Connecting plate (6)G ¼¼ NPT
1400-74611400-7462
or pressure gauge bracket (7)G ¼¼ NPT
1400-74581400-7459
Pressure gauge mounting kit (8) (output and supply)St. steel/BrassSt.st./St. steel
1400-69501400-6951
3 Connections
3.1 Pneumatic connections
Caution!The threads in the positioner housing are notdesigned for direct air connection!
The screw glands must be screwed into theconnecting plate, the pressure gauge mount-ing block or the connection block from theaccessories. The air connections are option-ally designed as a bore with ¼ NPT or G ¼thread.The customary fittings for metal and copperpipes or plastic hoses can be used.
Note!The supply air must be dry and free from oiland dust. The maintenance instructions forupstream pressure reducing stations must beobserved.Blow through all air tubes and hoses thor-oughly prior to connecting them.
If the positioner is attached directly to theType 3277 Actuator, the connection of thepositioner's output pressure to the actuatoris fixed. For attachment according toIEC 60534-6 (NAMUR), the signal pressurecan be routed to either the top or bottom di-aphragm chamber of the actuator, depend-ing on the actuator's fail-safe action "Actua-tor stem extends" or "Actuator stem re-tracts".For rotary actuators, the manufacturer'sspecifications for connection apply.
3.1.1 Signal pressure gauges
To monitor the supply air (Supply) and sig-nal pressure (Output), we recommend thatpressure gauges be attached (see accesso-ries in Tables 1 to 5).
3.1.2 Supply pressure
The required supply air pressure dependson the bench range and the actuator's oper-ating direction (fail-safe action).The bench range is registered on the name-plate either as spring range or signal pres-sure range depending on the actuator. dieThe direction of action is marked FA or FE,or by a symbol.
Actuator stem extends FA (Air to openATO)
Fail-safe position "Valve Closed"(for globe and angle valves):
Required supply pressure = Upper benchrange value + 0.2 bar, minimum 1.4 bar.
Actuator stem retracts FE (Air to close ATC)
Fail-safe position "Valve Open"(for globe and angle valves):For tight-closing valves, the maximum signalpressure pstmax is roughly estimated as fol-lows:
pstmax = F +d p
A
2
4⋅ ⋅
⋅π ∆
34 EB 8384-3 EN
Connections
d = Seat diameter [cm]∆p = Differential pressure across the valve
[bar]A = Actuator diaphragm area [cm2]F = Upper bench range of the actuator
[bar]
If there are no specifications, calculate asfollows:
Required supply pressure =Upper bench range value + 1 bar
Note!The signal pressure at the output (Out-put 38) of the positioner can be limited to1.4, 2.4 or 3.7 bar over Code 16 or thepressure limit can be deactivated (MAX).
EB 8384-3 EN 35
Connections
3.2 Electrical connections
For electrical installation, you are re-quired to observe the relevantelectrotechnical regulations and theaccident prevention regulations thatapply in the country of use. In Ger-many, these are the VDE regulationsand the accident prevention regula-tions of the employers' liability insur-ance association.
The following standards apply for assemblyand installation in hazardous areas:EN 60079-14: 2003 (VDE 0165 Part 1/8.98) "Electrical apparatus for explosive gasatmospheres" and EN 50281-1-2: 1999(VDE 0165 Part 2/11.99) "Electrical appa-ratus for use in the presence of combustibledust".For the interconnection of intrinsically safeelectrical equipment, the permissible maxi-mum values specified in the EC type exami-nation certificate apply (Ui or U0; Ii or I0; Pior P0; Ci or C0, and Li or L0).
The following applies for equipment withtype of protection EEx nA (non-sparking ap-paratus) according to the standard EN50021 (1999): Connecting, interrupting, orswitching circuits while energized is only al-lowed during installation, maintenance orrepair work.The following applies for equipment con-nected to energy-limited circuits with type ofprotection EEx nL (energy-limited apparatus)according to the standard EN 50021(1999): This type of equipment may beswitched under normal operating conditions.
For the interconnection of equipment to en-ergy-limited circuits with type of protectionEEx nL IIC, the permissible maximum valuesspecified in the statement of conformity orthe addenda to the statement of conformityapply.Caution!The terminal assignment specified in the cer-tificate must be adhered to. Reversing theassignment of the electrical terminals maycause the explosion protection to become in-effective!Do not tamper with enameled screws insideor on the housing.
Note on the selection of cables and wires:To install intrinsically safe circuits, observesection 12 of the standard EN 60079-14:2003 (VDE 0165 Part 1). To run multi-corecables or lines with more than one intrinsi-cally safe circuit, section 12.2.2.7 of thisstandard applies.An additional cable gland can be installedwhen connecting the device over two sepa-rate cables. Cable entries left unused mustbe sealed with blanking plugs. Devices usedat ambient temperatures down to –20 °Cmust have metal cable entries.
The wires for the reference variable must beconnected to the terminals 11 and 12 lo-cated in the housing. Only use a currentsource!
Caution! The erroneous connection of a volt-age source of just around 7 V (or around2 V when connected to the wrong pole) candamage the positioner.
36 EB 8384-3 EN
Connections
In general, it is not necessary to connect thepositioner to a bonding conductor. Shouldthis be required, however, this conductorcan be connected inside the device.Depending on the version, the positioner isequipped with inductive limit switchesand/or a solenoid valve.The position transmitter is operated on atwo-wire circuit. The usual supply voltage is24 V DC. Considering the resistance of thesupply leads, the voltage at the positiontransmitter terminals can be between 12and 30 V DC.Refer to Fig. 15 or the label on the terminalstrip for terminal assignment.Note! The minimum permissible referencevariable should not fall below 3.8 mA foroperating the positioner.
Accessories:Plastic cable gland M20 x 1.5:Black Order no. 1400-6985Blue Order no. 1400-6986Nickel-plated brass Order no. 1890-4875
Adapter M20 x 1.5 to ½ NPTAluminum, powder-coated
Order no. 0310-2149
Connection for version with external posi-tion sensorThe terminal assignment is fixed by the con-nector of the connecting lead.
Shorten the connecting lead to the re-quired length and strip the insulation off.Route the strands to the following con-tacts of the free connector:
Contact Cable color1 Brown2 White3 Blue4 Black shielding5 Green/yellow
Connect the fixed M12x1 plug connectorto the position sensor and the mountedconnector to the positioner unit.
EB 8384-3 EN 37
Connections
Fig. 15 · Electric connections
G
+81 -82 +11 -12 +83 -84 +51 -52
A2A3 A1
+41 -42 +31 -32
ASwitching amplifieracc. to EN 60947-5-6
24 V DCsolenoid
valve
mAControl signal
A3Fault
indication
Limit switchesA2 A1
Software Softwareor inductive
2-wire transmittersupply unit for optionalposition transmitter only
Optional Optional
3.2.1 Switching amplifiers
For operation of the limit switches, switchingamplifiers must be connected in the outputcircuit. To ensure the operating reliability ofthe positioner, the amplifiers should complywith the limit values of the output circuitsconforming to EN 60947-5-6.If the positioner is to be installed in hazard-ous areas, the relevant regulations must beobserved.
3.2.2 Establishing communication
Communication between PC and positioner(via FSK modem or handheld communica-tor, if necessary, using an isolation ampli-fier) is based on the HART protocol.
Type Viator FSK modemRS 232 EExia Order no. 8812-0129RS 232 not ex Order no. 8812-0130PCMCIA not ex Order no. 8812-0131USB not ex Order no. 8812-0132
If the supply voltage of the controller or con-trol station becomes too low because it hasbeen reduced by the load in the circuit, anisolation amplifier is to be connected be-
38 EB 8384-3 EN
Connections
Fig. 16 · Connection with a FSK modem
3730-30
3730-31
Connection in non-hazardous area
Connection in hazardous area
Handheld communicatoror second FSK modem
Handheld communicatoror second FSK modem (explosion-protected)
Ex isolating amplifier
4 to 20 mA
Safe area
Hazardous area
Controller/control station
Controller/control station
tween controller and positioner (interfacingas for positioner connected in hazardous ar-eas, see Fig. 16).
If the positioner is used in hazardous areas,an explosion-protected isolation amplifier isto be used.
By means of the HART protocol, all controlroom and field devices connected in theloop are individually accessible throughtheir address via point-to-point or standardbus (Multidrop).
Point-to-point:
The bus address/polling address must al-ways be set to zero (0).
Standard bus (Multidrop):
In the standard bus (Multidrop) mode, thepositioner follows the analog current signal(reference variable) as for point-to-pointcommunication. This operating mode is, forexample, suitable for split-range operationof positioners (series connection). The busaddress/polling address has to be within arange of 1 to 15.
Note:
Communication errors may occur when theprocess controller/control station output isnot HART-compatible.
For adaptation, the Z box (order no.1170-2374) can be installed between out-put and communication interface.
At the Z box a voltage of 330 mV is re-leased (16.5 Ωat 20 mA).
Alternatively, a 250-Ω resistor can be con-nected in series and a 22-µF capacitor canbe connected in parallel to the analog out-put. Note that in this case, the controller out-put load will increase.
22 µF
250 Ω
EB 8384-3 EN 39
Connections
Fig. 17 · Adapting the output signal
Controller/control station
4 Operation
Note!A summary about operating and start upcan be found in section 8 on page 64. Aleaflet including the same summary is alsoenclosed with the positioner.
4.1 Operator controls anddisplay
Rotary pushbutton
The positioner is mainly operated with therotary pushbutton.
Turn the button to select and set codes,parameter and values. Press it to confirmthem.
Slide switch AIR TO OPEN or AIR TOCLOSE
This switch is used to adapt the positioner tothe operating direction of the actuator.
For actuator where the supply pressureopens the valve, fail-safe position: "springsclose valve": switch position AIR TO OPEN.
For actuator where the supply pressurecloses the valve, fail-safe position: "springsopen valve": switch position AIR TO CLOSE.
For positioners with an attached reversingamplifier for double-acting rotary actuators(section 2.5): switch position AIR TO OPEN.
The switch position is prompted prior to aninitialization. After an initialization has beencompleted, changing the switch positiondoes not have any effect on the operation ofthe positioner.
Volume restriction Q
The volume restriction is used to adapt theair delivery to the actuator size. Two fixedsettings are possible depending on how theair is routed at the actuator:
For actuators smaller than 240 cm2 witha loading pressure connection at the side(Type 3271-5), set restriction to MINSIDE.
For a connection at the back (Type3277-5), set restriction to MIN BACK.
For actuators 240 cm2 and larger, set toMAX SIDE for a side connection and toMAX BACK for a connection at the back.
Displays
Symbols appear on the LC display that areassigned to parameters, codes, and func-tions.The bar graph in the operating modes Man-ual and Automatic indicates the sys-tem deviation that depends on the sign (+/–)and the value. One bar graph element ap-pears per 1 % system deviation.
If the device has not yet been initialized (seesection 4.3.1), the lever position in degreesin relation to the longitudinal axis is indi-cated instead of the system deviation. Onebar graph element corresponds to approxi-mately a 5° angle of rotation.
If the fifth element blinks (value displayed> 30°), the permissible angle of rotation hasbeen exceeded. Lever and pin position mustbe checked.
40 EB 8384-3 EN
Operation
EB 8384-3 EN 41
Operation
Fig. 18 · Display and operator controls
AUtO Automatic modeCL ClockwiseCCL CounterclockwiseErr ErrorESC EscapeHI ix greater than 21.6 mALO ix smaller than 2.4 mALOW w too lowMAN Manual mode
MAX Maximum rangeNO Not availableNOM Nominal travelON ONOFF OFFRES ResetRUN StartSAFE Fail-safe positionSUb Substitute calibration
TunE Initialization in progressYES AvailableZP Zero calibration
Increasing/increasing Increasing/decreasing
Blinking Controlled operationBlinking Not initialized
Displays and their meaning
AIR TOO
PEN
CLO
SE
INIT
CA
UTIO
NVA
LVE
AC
TUATES
MIN
SIDE
MA
X BAC
K
MIN
BAC
KM
AX SID
E Q
%S
mm
%S
mm
SERIAL
INTERFA
CE
Failure/fault Manual operation Control operation Code
Configurationenabled
Limit value of totaltravel exceeded
Fail-safe positionactive
Bar graph forsystem deviationor lever position
Units
Limit switchAlarm 2
DesignationPositionParameter
Limit switchAlarm 1
Initialization key Cap or rotary switch Metal tag of proximity switch
SSP interface
Switch forfail-safe actionof the actuator
Volume restriction
Rotary pushbutton
4.2 Enabling and selectingparameters
The codes which are marked with an aster-isk (*) in section 12 on page 69 onwardsmust be enabled with Code 3 before the as-sociated parameters can be configured asdescribed below.
Code 3Configurationnot enabled
Configurationenabled
From the current display, turn the rotarypushbutton until Code 3 and OFF ap-pear on the display.Confirm Code 3 by pressing the but-ton, the code number blinks.
Turn button until ON appears.Confirm setting by pressing the but-ton.
Configuration is enabled and is indicated bysymbol appearing on the display.
Now you can adjust the codes, parametersand values for the control valve in any de-sired order by turning the button. Con-firm settings by pressing the button.
Note!To cancel a value that you have just enteredunder a code, turn the button until ESCappears on the display and press to con-firm.
Canceling the setting
Note! If no settings are entered within 120seconds, the enabled configuration functionbecomes invalid and the display resets toCode 0.
The code list on page 69 onwards in section12 shows all parameters that can be ad-justed, including their description and theirdefault settings.
Important!After attaching the positioner to the valve aswell as setting the fail-safe position and thevolume restriction, it is sufficient for standardoperation to press the initialization key inorder to ensure optimum positioner opera-tion (section 5.5 on page 47).For this purpose, the positioner must be op-erated with its default values. If necessary, areset must be carried out (section 5.8 onpage 56).
42 EB 8384-3 EN
Operation
4.3 Operating modes
4.3.1 Automatic and manualoperating modes
Prior to initialization:
If the positioner has not been initialized yet,the automatic operating AUtO cannot be se-lected.The valve can only be positioned manuallywith the positioner.
To proceed, turn button clockwise untilCode 1 appears, then confirm Code 1 bypressing the button.
If both the code number and the hand sym-bol are blinking, the valve can be manuallypositioned by turning the button.
After initialization:
After successful initialization in the MAX,NOM or MAN mode (section 5.5.1), thepositioner is in the automatic controloperation mode .
Standard
Switching to manual operating mode
Over Code 0, press the button, AUtOappears in the display, Code 0 blinks.
Turn button until MAN appears.
Press button to switchover to the manualoperating mode .
The switchover is smooth since the manualoperating mode starts up with the set pointlast used during automatic operating mode.The current position is displayed in %.
Adjusting the manual set point
Turn button until Code 1 appears.
Press button to confirm, Code 1 blinks.While Code 1 is blinking, you can move thevalve to the position required by turning thebutton. To proceed, turn the button untilenough the positioner has built up enoughpressure and the control valve starts to react.The positioner automatically returns to man-ual mode with Code 0 if the button is notactivated within two minutes.Switching from manual to automatic oper-ating mode works in the same manner.First, you must reset the positioner to Code 0and set it to automatic mode AUtO and con-firm.
EB 8384-3 EN 43
Operation
%
% %
4.3.2 SAFE – Fail-safe position
If you want to move the valve to fail-safe po-sition, proceed as follows:
Select Code 0, press the button, AUtO orMAN appears on the display, Code 0blinks.
Turn the button until SAFE appears.
Press the button to confirm this setting.
Operating mode SAFE has been selected,symbol S for the fail-safe position appears.
Caution!The valve moves to the fail-safe position.
Once the positioner is initialized, the currentvalve position is indicated on the digital dis-play in %.
If you want to return the valve from thefail-safe position to the operating modeAUtO or MAN, the button must bepressed while Code 0 is active.
When the code number blinks, turn thebutton to switch to the desired operatingmode.Press the button to confirm.
5 Start-up and settings
Note!A summary about start-up and operationcan be found in section 8 on page 64. Aleaflet including the same summary is alsoenclosed with the positioner.
Connect pneumatic supply air(Supply 9), making sure the pressure iscorrect as described in section 3.1.
Apply an electrical reference variable of4 to 20 mA (terminals 11 and 12).
The voltage supply >19 V DC for versionwith a solenoid valve must be connectedat terminals 81 (+) und 82 (–).
Warning!The signal pressure supplied maycause the actuator stem to move, beaware of risk of injury!
5.1 Determining the fail-safeposition
To adapt the positioner to the operating di-rection of the actuator, set slide switch toAIR TO OPEN or AIR TO CLOSE .
AIR TO OPEN = Signal pressure opens thevalve, for fail-safe position: actuator stemextends/valve closedAIR TO CLOSE = Signal pressure closes thevalve, for fail-safe position: actuator stemretracts/valve open.
The switch position is prompted prior to aninitialization. After an initialization has beencompleted, changing the switch position
44 EB 8384-3 EN
Start-up and settings
S
does not have any effect on the operation ofthe positioner.
5.2 Setting the volume restriction Q
For actuators smaller than 240 cm2 witha loading pressure connection at the side(Type 3271-5), set restriction to MINSIDE.
For a connection at the back(Type 3277-5), set restriction to MINBACK.
For actuators 240 cm2 and larger, set toMAX SIDE for a side connection and toMAX BACK for a connection at the back.
Note! The positioner must re-initialized if thevolume restriction setting is changed afterthe positioner has already been initialized.
Adapting the display
The data representation on the positionerdisplay can be turned by 180°.If the displayed data appear upside down,proceed as follows:
Reading direction for rightattachment of pneumaticconnections
Reading direction for leftattachment of pneumaticconnections
Turn the button until Code 2 appears,and press the button to confirm Code 2,Code 2 blinks.
Turn button until the display is ad-justed to the desired direction, then con-firm reading direction by pressing the
button.
5.3 Limiting the signal pressure
If the maximum actuator force may causedamage to the valve, the signal pressuremust be limited. Select Code 3 to enableconfiguration and then access Code 16 toset the pressure limit to 1.4, 2.4 or 3.7 bar.
The required signal pressure limit is only au-tomatically recognized on initializationwhen the fail-safe position AIR TO OPEN isset.
5.4 Checking the operatingrange of the positioner
To check the mechanical attachment and theproper functioning, the valve should bemoved through the operating range of thepositioner in the manual operating modewith the manual reference variable.
Code 0Selectmanual operationDefault MAN
Code 1Position valve using therotary pushbutton, thecurrent angle of rotation isindicated
1. Turn the button until Code 0 appears,then confirm Code 0 by pressing the
button.
EB 8384-3 EN 45
Start-up and settings
2. Turn the button until MAN appears inthe display, i.e. manual operating mode,confirm selected operating mode bypressing the button.
3. Turn the button until Code 1 appears,confirm Code 1 by pressing button.The hand symbol and Code 1 blink.
4. Position control valve by turning thebutton several times until pressure buildsup, and the control valve moves to its fi-nal positions so that the travel/angle ofrotation can be checked.The permissible range has been ex-ceeded when the displayed angle ishigher than 30°, and the outer right orleft bar graph element blinks.If this is the case, it is absolutely neces-sary to check lever and pin position asdescribed in section 2.
Note!If the selected pin position is smaller than in-tended for the respective travel range, thepositioner switches to the SAFE mode, thevalve moves to the fail-safe position (seesection 4.3.2 on page 44).
5. Initialize positioner as described in sec-tion 5.5.
46 EB 8384-3 EN
Start-up and settings
Simplified start-up!For most applications, the positioner with its default settings is ready for operation,provided it has been properly attached.After the fail-safe position and the volume restriction have been set, the positioner onlyneeds to be initialized by pressing the INIT key.
Caution!Prior to starting the initialization procedure, check the maximum permissible supplypressure of the control valve to prevent the valve from being damaged. On initialization,the positioner supplies the maximum available supply pressure. If necessary, restrict thesignal pressure by using a pressure reducing valve upstream of the control valve.Initialization is run in default mode MAX (section 5.5.1). During this process, thepositioner adapts itself optimally to the maximum travel/angle of rotation range.The only parameter that must be checked is the direction of action, i.e. whether the defaultsetting (Code 7 to = increasing/increasing) matches the application or whether itmust be changed.The initialization modes described in following serve to individually adapt and optimizethe positioner to the way it is attached to the valve.
5.5 Initialization
During initialization the positioner adapts it-self optimally to the friction conditions andthe signal pressure demand of the controlvalve.The type and extent of self-adaptation de-pends on the set initialization mode (seesection 5.5.1).MAX is the default setting for initializationbased on the maximum nominal range.
If configuration is enabled via Code 3,Code 6 can be used to change to other ini-tialization modes.
If the positioner has been initialized once al-ready, it will automatically go to the operat-ing mode used last after the electrical refer-ence variable is applied, Code 0 appearson the display.On initializing the positioner for the firsttime, the hand symbol appears on thedisplay.
Note!Every time you re-initialize the positioner, itshould be reset to its basic setting includingthe default values. Refer to section 5.8 onpage 56.
Start the initialization process by press-ing the INIT key with a suitable tool.
The time required for an initialization pro-cess depends on the transit time of the actu-ator and take several minutes.Positioners with EXPERT+ diagnostic func-tions start plotting the reference graphs after
the initialization process has been com-pleted. See note at the end of this section.
Warning!During the initialization, the controlvalve moves through its entiretravel/angle of rotation range.Therefore, do not start initializationwhile a process is running, but onlyduring start-up, when all shut-offvalves are closed.Note!The initialization procedure can beinterrupted while running by press-ing . StOP appears three secondslong and the positioner then movesto the fail-safe position.
Alternating displaysInitialization running
Bar graph displayindicating the progress ofthe initialization
Initialization successful,positioner in automaticoperating mode
After a successful initialization, thepositioner runs in control operation indi-cated by the control symbol.
EB 8384-3 EN 47
Start-up and settings
%
The control position in % predetermined bythe reference variable appears on the dis-play.
A malfunctioning leads to the process beinginterrupted. The initialization error appearson the display according to how it has beenclassified by the condensed status. See sec-tion 5.6 on page 55.
If the slide switch is set to AIR TO CLOSE,the positioner automatically switches to thedirection of action increasing/decreasing() on successful completion of initializa-tion. This results in the following assignmentbetween reference variable and valve posi-tion:
Fail-safeposition
Direction ofaction
ValveClosed at Open at
Actuator stemextends FA
AIR TO OPEN 4 mA 20 mA
Actuator stemretracts FE
AIR TO CLOSE 20 mA 4 mA
The tight-closing function is activated.Set Code 15 (final position w>) to 99 % forthree-way valves.Further settings relevant for the valve can beentered subsequently.
Note!Positioner with integrated EXPERT+ diagnos-tics automatically start to plot the referencegraphs (drive signal Y d1 and hysteresis d2)after initialization has been completed. TESTd1 and d2 appear on the display in an al-ternating sequence.An unsuccessful plotting of the referencegraphs are indicated on the display byCode 81 (see error code list).
After the initialization has been successfullycompleted, the positioner still works prop-erly, even though the reference graph plot-ting has not been completed successfully.The reference graphs are required for theextended diagnostic functions of EXPERT+.
5.5.1 Initialization modes
After enabling configuration with Code 3and accessing Code 6, you can choose oneof the initialization modes MAX, NOM,MAN or SUb to start initialization.ZP, the zero calibration is described in sec-tion 5.7 on page 56.
MAX – Initialization based on maximumrange
Initialization mode for simplified start-up forvalves with two clearly defined mechanicaltravel stops, e.g. three-way valves.
The positioner determines travel/angle ofrotation of the closing member from theCLOSED position to the opposite side andadopts this travel/angle of rotation as theoperating range from 0 to 100 %.
48 EB 8384-3 EN
Start-up and settings
Enable configuration:
Default OFF
Turn →Code 3, press ,
turn → ON, press .
After enabling:
Default MAX
Turn →Code 6, press ,
turn →MAX, press .
Press INIT key to start initialization!
The initialization procedure maytake several minutes, depending onthe actuator size, as the valve movesthrough its entire travel/angle of ro-tation range.
Positioners with EXPERT+ diagnostic func-tions automatically start plotting the refer-ence graphs after the initialization processhas been completed. See the note on page48.
Note!For MAX initialization, the positioner cannotindicate nominal travel/angle of rotation inmm/°, Code 5 remains disabled.
In addition, the lower (Code 8) and the up-per (Code 9) x-range value can only be dis-played and modified in %.During MAX initialization, an increased sys-tem deviation (undefined final position of theactuator) in the upper control range may oc-cur with some control valves due to thepneumatic actuator design.
If you want the display to indicate mm/°,proceed as follows after configuration hasbeen enabled:
Turn →Code 4, press ,
turn →Select pin position entered duringinstallation, press .
If you now switch to Code 5, the nominalrange appears in mm/°.The lower and upper x-range values forCode 8 and 9 are displayed in mm/° andcan be adapted accordingly.
NOM – Initialization based on nominalrange
Initialization mode for globe valves, espe-cially for valves with maximum ranges thatare clearly greater than the required nomi-nal range.For this initialization mode, the followingparameters must be entered: pin position(Code 4), nominal travel/angle (Code 5)and, if required, the direction of action(Code 7).
The calibrated sensor enables the effectivevalve travel to be preset very accurately.During the initialization procedure, thepositioner checks whether the control valvecan move through the indicated nominalrange (travel or angle) without collision.
EB 8384-3 EN 49
Start-up and settings
In case of a positive result, the indicatednominal range is adopted with the limits oflower x-range and upper x-range values asthe operating range.
Note!The maximum possible travel must alwaysbe greater than the nominal travel entered.If this is not the case, the initialization isinterrupted (error indication Code 52) be-cause the nominal travel is not achieved.
Enable configuration:
Default OFF
Turn →Code 3, press ,
turn →ON, press .
After enabling:
Default OFF
Turn → Code 4, press ,
turn →Select pin position entered duringinstallation, press .
Default 15
Turn →Code 5, press ,
turn →Enter nominal valve travel,
press .
Default MAX
Turn → Code 6, press ,
turn →NOM, press .
Press INIT key to start initialization!
The initialization procedure maytake several minutes, depending onthe actuator size, as the valve movesthrough its entire travel/angle of ro-tation range.
Positioners with EXPERT+ diagnostic func-tions automatically start plotting the refer-ence graphs after the initialization processhas been completed. See note on page 48.
MAN – Initialization based on a manuallyselected range
(with default upper x-range value by meansof manual adjustment).Initialization mode just as NOM, however,for starting up valves with unknown nominalrange.In this mode, the positioner expects the con-trol valve to be moved manually to the de-sired OPEN position prior to enabling theinitialization procedure.The upper range travel/angle of rotation
50 EB 8384-3 EN
Start-up and settings
mm
mm
value is adjusted using the rotarypushbutton. The positioner uses this OPENposition and the CLOSED position to calcu-late the differential travel/angle and acceptsit as the operating range with the lowerx-range value and upper x-range value be-ing the limits.
Enable configuration:
Default OFF
Turn →Code 3, press ,
turn →ON, press .
After enabling:
Turn →Code 4, press ,
turn →Select pin position entered duringinstallation, press .
Turn →Code 6 , press ,
turn →MAN, press .
Default MAX
Turn →Code 0, press ,
turn →MAN, press .
Default MAN
Turn →Code 1, press ,Code 1 blinks.
Turn until the valve reaches its OPEN po-sition, press .
Press INIT key to start initialization!
The initialization procedure maytake several minutes, depending onthe actuator size, as the valve movesthrough its entire travel/angle of ro-tation range.
Positioners with EXPERT+ diagnostic func-tions automatically start plotting the refer-ence graphs after the initialization processhas been completed. See note on page 48.
SUb
(substitute configuration, without initializa-tion)
This initialization mode is an emergencymode. The positioner parameters are esti-mated and not determined by an initializa-tion procedure, so that a high stationary ac-curacy cannot be expected.You should always select a different initial-ization mode if the plant allows it.
The initialization mode SUb is used to re-place a positioner while the process is in op-eration. For this purpose, the control valve isusually fixed mechanically in a certain posi-
EB 8384-3 EN 51
Start-up and settings
tion, or pneumatically by means of a pres-sure signal which is routed to the actuatorexternally. The blocking position ensuresthat the plant continues to operate with thisvalve position.
The spare positioner should not be initial-ized. If necessary, reset the spare positionerusing Code 36.
After the old positioner has been replacedwith a new one, the following parametersmust be entered: pin position (Code 4),nominal range (Code 5), direction of action(Code 7) and closing direction (Code 34).The default travel limit of 100 % (Code 11)must be disabled with OFF.In addition, the blocking position (Code 35)must be adjusted with the button so thatit matches the position of the previouslyblocked valve.
The parameters KP (Code 17), TV (Code 18)and the pressure limit (Code 16) should re-main set to their default values. If the config-uration data of the new positioner areknown, it is recommended to accept its KPand TV values.
After setting the AIR TO OPEN/CLOSEswitch for the fail-safe position, setting thevolume restriction and pressing the INIT key,the positioner calculates its configurationdata on the basis of the blocking positionand the closing direction as well as the otherentered data.The positioner switches to manual operation,subsequently the blocking position should becanceled as described on page 54.
Enable configuration:
Default OFF
Turn →Code 3, press ,
turn →ON, press .
After enabling:
Default OFF
Turn →Code 4, press ,
press →Select pin position entered dur-ing installation,press .
Default 15
Turn → Code 5, press ,
turn →Enter nominal travel/angle,
press .
Default MAX
Turn →Code 6, press ,
turn →SUb, press .
52 EB 8384-3 EN
Start-up and settings
mm
mm
Default
Turn →Code 7, press ,
turn →Retain direction of action orselect .
Press .
Default 100.0
Turn →Code 11, press ,
turn →Deactivate travel limit,
press .
Default OFF
Turn →Code 16,
Retain default value for pressure limit,change value only if necessary.
Default 7
Turn →Code 17
Retain default. Proceed as follows only ifknown:
Press ,
turn →Select KP,
press .
Default 2
Turn →Code 18,
Retain default TV, change only if known.
Default CCL
Turn →Code 34, press ,
turn →Select closing direction.
CCL = counterclockwise and CL = clockwise.
Direction of rotation which causes the valveto move to the CLOSED position (view ontothe rotary switch movement while positionercover is open).
Press .
Default 0.0
Turn →Code 35, press ,
turn →Enter blocking position, e.g.5 mm (read off at travel indicator scale ofthe blocked valve or measure with a ruler).
Press .
EB 8384-3 EN 53
Start-up and settings
mm
Set switch for fail-safe position AIR TOOPEN or AIR TO CLOSE as described insection 5.1 on page 44.
Set volume restriction as described insection 5.2 on page 45.
Press INIT key!
The positioner switches to manual operat-ing mode!
The adjusted blocking posi-tion is indicated
As initialization has not been carried outcompletely, the error code 76 (no emer-gency mode) and possibly also error code57 may appear on the display.These alarms do not influence thepositioner’s readiness for operation.
Canceling the blocking position
For the positioner to follow its referencevariable again, the blocking position mustbe canceled and the positioner must be setto automatic operation AUtO as follows:
Press →Code 1, press ,
turn in order to move the valve slightlypast the blocking position, then cancel me-chanical blocking.
Press .
Turn →Code 0, press ,Code 0 blinks.
Turn until AUtO appears on the display.
Press to confirm the operating mode.
The positioner switches to automatic oper-ating mode!
The current valve position is indicated in %.
Note!If the positioner shows a tendency to oscil-late in automatic operating mode, the pa-rameters KP and TV must be slightly cor-rected. Proceed as follows:Set TV to 4 (Code 18).If the positioner still oscillates, the gain KP(Code 17) must be decreased until thepositioner shows a stable behavior.
Zero point correction
Finally, if process operations allow it, thezero point must be adjusted according tosection 5.7 on page 56.
Caution!The positioner automatically moves to zeropoint.
54 EB 8384-3 EN
Start-up and settings
mm
5.6 Fault/failure
All status and fault alarms are assigned aclassified status in the positioner.
To provide a better overview, the classifiedalarms are summarized in a condensed sta-tus for the positioner (see section 6).
The condensed status appears on the dis-play with the following symbols:
Condensed status Display
Failure
Maintenance request/maintenance demand
Function check Text
No alarm
If the positioner has not been initialized, thefault symbol appears on the display asthe positioner cannot follows its referencevariable.Additionally, a signal is issued over the faultalarm contact when certain faults occur (seeerror code list).
To access the error codes, turn the buttonpast the Code 50.Err appears on the display with the respec-tive error code.For the cause of the fault and its remedy, re-fer to the codes listed in section 12 onpage 69 onwards.
Display indicating anerror code
After an error code has occurred, youshould first try to confirm it as follows:
Enable configuration:
Turn →Code 3 , press ,
turn →ON, press .
Turn until the error code number ap-pears, then press to confirm it.
Should the error occur again, read the rem-edy instructions in the error code list.
Occurrences such as when the total valvetravel is exceeded or when the temperatureleaves the permissible temperature range af-fect the condensed state and cause a faultalarm to be displayed depending on its clas-sification.
The optional EXPERT+ diagnostics generatesadditional diagnostic alarms which are in-cluded in the condensed status with theircorresponding status classification.When a diagnostic alarm is issued byEXPERT+, this is displayed by Code 79 (seeerror code list).
EB 8384-3 EN 55
Start-up and settings
S
5.7 Zero calibration
In case of discrepancies with the closing po-sition of the valve, e.g. with soft-sealedplugs, it may become necessary torecalibrate the zero point.
Enable configuration:
Default OFF
Turn →Code 3, press ,
turn →ON, press .
After enabling:
Default MAX
Turn → Code 6, press ,
turn →ZP, press .
Press INIT key!
Zero calibration is started, the positionermoves the control valve to the CLOSED posi-tion and readjusts the internal electrical zeropoint.
The valve briefly moves from the cur-rent travel/angle of rotation positionto the closed position.
5.8 Reset to default values
This function resets all parameters to the fac-tory default values (see code list in sec-tion 12).
Enable configuration:
Default OFF
Turn →Code 3, press ,
turn →ON, press .
After enabling:
Default OFF
Turn →Code 36, press ,
turn →RUN, press .
All parameters are reset and can be recon-figured.
56 EB 8384-3 EN
Start-up and settings
5.9 Start-up via local interface(SSP)
The positioner must be supplied with at least4 mA.The positioner can be connected directly tothe PC via the local serial interface and theserial interface adapter.
Use the TROVIS-VIEW software with 3730-3device module installed. Refer to section 13for more details.
For start-up and settings, proceed as de-scribed in section 5, 5.1 to 5.3 and thenproceed as described in section 13.
Note!Depending on the firmware installed in thepositioner, a certain minimum version of theTROVIS-VIEW device module is required forcommunication.If you have already installed the software,you can download updates atwww.samson.de (Support & Downloads -TROVIS VIEW Updates).
5.10 Start-up over HARTcommunication
The positioner must be supplied with at least4 mA current. The FSK modem must be con-nected in parallel to the current loop.
A DTM file (Device Type Manager) conform-ing to the Specification 1.2 is available forcommunication. This allows the device, forexample, to be run with the PACTware op-erator interface. All the positioner's parame-ters are then accessible over the DTM andthe operator interface.
For start-up and settings, proceed as de-scribed in section 5, 5.1 to 5.3. Refer to thecode list in section 12 as well as section 13for the parameters necessary for the opera-tor interface.
Note!The write access for HART communicationcan be disabled over Code 47. You canonly disable or enable this function locally atthe positioner.The write access is enabled by default. Theon-site operation including the INIT key canbe locked over HART communication. Theword "HART" then blinks on the displaywhen Code 3 is selected. This locking func-tion can only be disabled over HART com-munication. On-site operation is enabled bydefault.
EB 8384-3 EN 57
Start-up and settings
6 Status and diagnostic alarms
The Type 3730-3 Positioner contains an in-tegrated diagnostic approach to generateclassified status and diagnostic alarms.
There are two different on-board diagnosticsavailable: the standard integrated diagnos-tics (EXPERT) and the optional extendedEXPERT+ diagnostics.
6.1 Standard EXPERT diagnostics
The standard EXPERT diagnostics providesinformation about positioner states such asoperating hours counter, process monitor-ing, number of zero calibrations andinitializations, total valve travel, tempera-ture, initialization diagnostics, zero/controlloop errors, logging of the last 30 alarms,etc.
In addition, the standard EXPERT diagnosticsgenerates diagnostic and status alarmswhich allow faults to be pinpointed quicklywhen a fault occurs.
Alarms are classified in the following maingroups:
Status
Operation
Hardware
Initialization
Data memory
Temperature
6.2 Extended EXPERT+ diagnos-tics
In addition to the standard EXPERT diagnos-tic features, the optional EXPERT+ extendeddiagnostics provides the following onlineand offline test functions which enable sig-nificant statements on the condition of theentire control valve.
Online test functions (monitoring functions)
Data logger
Histogram
Cycle counter
Valve end position trend
Y = f (X) diagram (drive signal)
Hysteresis test
Offline test functions (manual functions)
Y = f (X) diagram over the entire valvetravel range
Hysteresis test over the entire valve travelrange
Static characteristic
Step response test
The diagnostic tests are completely inte-grated in the positioner. Further statusalarms are generated from the extensive in-formation gained in the diagnostic tests ofEXPERT+ which provide the user with infor-mation covering the whole control valve.The required reference curves are automati-cally plotted after initialization and saved inthe positioner if EXPERT+ is activated.The optional diagnostic functions providedby EXPERT+ can be selected when ordering
58 EB 8384-3 EN
Status and diagnostic alarms
the positioner. Additionally, it is possible toactivate EXPERT+ at a later point in time inan existing positioner.For this purpose, an activation code can beordered, specifying the serial number of thepositioner.
6.3 Classification of the statusalarms and the condensedstatus
The alarms are assigned a classification sta-tus in the positioner. The following states aredifferentiated between:
FailureThe positioner cannot perform its controltask due to a functional fault in the device orin one of its peripherals or an initializationhas not yet been successfully completed.
Maintenance demandThe positioner still performs its control task(with restrictions). A maintenance demandor above average wear has been deter-mined. The wear tolerance will soon be ex-hausted or is reducing at a faster rate thanexpected. Maintenance is necessary in themedium term.
Maintenance requirementThe positioner still performs its control task(with restrictions). A maintenance demandor above average wear has been deter-mined. The wear tolerance will soon be ex-hausted or is reducing at a faster rate thanexpected. Maintenance is necessary in theshort term.
Function checkTest or calibration procedures are beingperformed. The positioner is temporarily un-able to perform its control task until this pro-cedure is completed.
EB 8384-3 EN 59
Status and diagnostic alarms
Status alarm Engineering tool
Alarm inactive
Alarm activeClassified as “No alarm”
Alarm activeClassified as “Maintenance requirement”/
”Maintenance demand”
Alarm activeClassified as “Function check”
Alarm activeClassified as “Failure”
Classification process in the positionerAn alarm is assigned to one of followingclassified states in the table:
Condensed status
To provide a better overview, the state of thepositioner is summarized in a condensedstatus which is made up from a summary ofall classified positioner alarms.
If an event is classified as “No alarm”, thisevent does not have any affect on the con-densed status of the positioner.
The condensed status is displayed in the en-gineering tool as well as on the positionerdisplay as in the following table:
60 EB 8384-3 EN
Status and diagnostic alarms
Status alarm Engineering tool Positioner display
“Failure”
“Maintenance requirement”"Maintenance demand”
“Function check”Text
“No alarm”
Status modification
The classification of the status alarms can bechanged as required.They can be modified using TROVIS-VIEWsoftware over the local SSP interface.
In addition, the classification can be modi-fied over the parameters in DD or easily en-tered over the DTM.
Note!All additional alarms generated by EXPERT+
have the status “No alarm” by default.
Logging and displaying diagnosticfunctions/alarms
The last 30 alarms are logged in thepositioner. However, it is important to notethat the same alarm is only logged oncewhen it first occurs.The alarms and the condensed states ap-pear on the display as described in the codelist (section 12).In addition, the diagnostic parameters areissued over the communication interface ofthe positioner.
The diagnostic functions can easily be dis-played and configured using theTROVIS-VIEW software connected over thelocal interface (SSP) or over the DTM.
EB 8384-3 EN 61
Status and diagnostic alarms
7 Adjusting the limit switch
The positioner version with inductive limitswitch has one adjustable tag (1) mountedon the shaft which operates the proximityswitch (3).
For operation of the inductive limit switch,the corresponding switching amplifier (seesection 3.2.1) must be connected to the out-put.
If the tag (1) is inside the field of the switch,the switch assumes a high resistance. If thetag is outside of the field, the switch assumesa low resistance.
Normally, the limit switch is adjusted suchthat it will provide a signal in both end posi-tions of the valve. The switch, however, canalso be adjusted to indicate intermediatevalve positions.
The desired switching function, i.e. whetherthe output relay shall be picked up or re-leased when the tag has entered the field,has to be determined, if necessary, at theswitching amplifier.
Note!The inductive limit switch replaces the soft-ware limit switch A1 with terminal assign-ment +41/–42.Each switching position can optionally beset to indicate when the tag has entered thefield, or when it has left the field.The second software limit switch remains ef-fective, the function of the software limitswitch A1 is disabled.
Software adaptation
Code 38 (inductive alarm is set to YES).The inductive limit switch is connected to theterminals +41/–42.The device is set up accordingly when deliv-ered ex works SAMSON.
Setting the switching point:
Important!During adjustment or testing, the switchingpoint must always be approached frommid-position (50 %).
To ensure safe switching under any ambientconditions, the switching point should beadjusted to a value of approx. 5 % beforethe mechanical stop (OPEN – CLOSED).
For CLOSED position:
1. Initialize positioner.2. Use the MAN function to move the
positioner to 5 % (see LC display).3. Adjust the tag using the yellow adjust-
ment screw (2) until the tag enters orleaves the field and the switching ampli-fier responds. You can measure theswitching voltage as an indicator.
Contact function:Tag leaving the field > contact is made.Tag entering the field > contact is opened.
62 EB 8384-3 EN
Adjusting the limit switch
For OPEN position:
1. Initialize positioner.2. Use the MAN function to move the
positioner to 95 % (see LC display).3. Adjust the tag (1) using the yellow ad-
justment screw (2) until the tag enters orleaves the field of the proximity switch(3).You can measure the switching voltageas an indicator.
Contact function:
Tag leaving the field > Contact is made.Tag entering the field > Contact is opened.
EB 8384-3 EN 63
Adjusting the limit switch
Fig. 19 · Adjustment of the limit switch
Adjustment screw (2) Tag (1) Proximity switch (3)
8 Quick start-up guide
8.1 Mounting
Direct attachment
to SAMSON Type 3277 Actuator
Travel mm Actuator cm2 Pin position
7.5 120 25
15 120/240/350 35
15/30 700 50
Note!Standard delivery includes lever M readyassembled with the follower pin on 35 mmpin position for 15 mm travel!
To mount the positioner, lift the lever so thatthe follower pin rests on the follower clampof the actuator stem.
NAMUR attachment
Determine the maximum travel range ofthe control valve from the closed positionto as far it will go in the other direction.
Select the lever to match the maximumtravel range as well the next largest pinposition and screw onto the shaft of thepositioner.
Lever option/pin distance:see pin position table (Code 4) or coverplate on the positioner.
Screw the NAMUR bracket onto thevalve yoke so that it is aligned centrallyto the slot of the follower plate when thetravel position is at 50 %.
Secure the positioner to the NAMURbracket, making sure that the followerpin is in the slot of the follower plate.Make sure the lever can still move.
Attachment to rotary actuators
Lever M pin position 90° Put the valve into the closed position, de-
termine the opening direction. Place the follower plate on the slotted ac-
tuator shaft and fasten it to the couplingwheel. Attach the top pair of bracketsand the bottom pair of brackets to theactuator.
Place the positioner on the brackets andscrew tight, making sure that the leverwith its follower pin engages the slot ofthe coupling wheel, while taking into ac-count the opening direction.It is important to make sure that the le-ver's mid position corresponds to the midtravel of the valve (lever's mid position =the lever is parallel to the long side of thepositioner casing).
Pneumatic connections
Screw the threaded connections only intothe attached connection block, connect-ing plate or pressure gauge block fromthe accessories.
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Quick start-up guide
8.2 Start-up
Connect pneumatic supply air (1.4 to6 bar).
Apply an electrical reference variable (4 to20 mA).
Set the fail-safe position
Position the slide switch according tofail-safe position of the control valve:AIR TO OPEN or AIR TO CLOSE.
Adapt the volume restriction Q to the actu-ator size
Only set the restriction for actuators< 240 cm2 to:MIN SIDE for connection at the side orMIN BACK for connection at the back.
Note!After each change of the volume restrictionsetting, the positioner must be re-initialized.
Changing the reading direction of thedisplay
(if necessary)
Turn →Code 2, press ,
turn →Display ok, press .
Operation
Selecting the parameters or values
Each parameter has a code number whichis shown in the display. Use the button toselect.Turn the button to select parameters orvalues and then push to confirm.
Select and confirm ESC to prevent an en-tered value from being accepted.
Enabling parameters
Parameters that have a code marked withan asterisk (*) can only be changed whenthey are enabled beforehand using Code 3.
The configuration mode is shown in the dis-play with the symbol.
See the code list on page 69 onwards orcover plate of the positioner for a descrip-tion of the menu codes.
EB 8384-3 EN 65
Quick start-up guide
8.3 Initialization
Important!Perform a reset (Code 36) prior to each ini-tialization
Turn →Code 3, ↵
turn →ON, ↵
turn →Code 36, ↵
select RUN, ↵
Caution!During initialization, the valve runs throughits whole range of travel/angle of rotation.
8.3.1 Simplest method (MAX)
Mount and start up the positioner andpress the INIT key!READY!The positioner adapts itself automatically tothe maximum travel/angle of rotationrange of the control valve.
8.3.2 Precise method (NOM)
Positioner adapts itself precisely to the nomi-nal travel/rotational angle of the controlvalve!
Mount and start up the positioner, then pro-ceed as follows:
Turn →Code 3, ↵
turn →ON, ↵
turn →Code 4, ↵Select pin position, ↵
turn →Code 5, ↵
Enter nominal travel/range, ↵
turn →Code 6, ↵
select NOM, ↵
Press INIT key!
8.3.3 Manual method (MAN)
Initialization mode same as NOM, but forstart-up of control valves with unknownnominal ranges. The final position oftravel/angle of rotation (valve open) is en-tered manually.
Mount and start up the positioner, then pro-ceed as follows:
Turn →Code 0, ↵ ,
turn →select MAN, ↵
turn →Code 1, ↵ ,
turn →valve open position, ↵
turn →Code 3, ↵ ,
turn →ON, ↵
turn →Code 6, ↵ , select MAN, ↵
Press INIT key!
Note!After imposing the electrical reference vari-able, the positioner is in the last used oper-ating mode. Code 0 appears in the display.If the positioner has not yet been initialized,the fault symbol appears on the displayand the symbol blinks.
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Quick start-up guide
9 Retrofitting an inductive limitswitch
Required retrofit kit:Limit switch Order no. 1400-7460
1. Take off the rotary pushbutton (3) andcap (1), unthread the five fixing screws(2) and lift off the plastic cover (9).
2. Use a knife to cut an opening at themarked location (4).
3. Push the connector (11) with cablethrough the opening and secure theproximity switch (7) on the cover with adot of glue.
4. Remove the jumper at the socket ST1 ofthe top board and insert the cable con-nector (11).
5. Guide the cable in such a manner thatthe plastic cover can be placed backonto the positioner. Insert the fixingscrews (2) and screw tight. Attach theclamping plate (8) onto the proximityswitch.
6. Attach the rotary switch (5). Make surethe flattened side of the positioner shaftis turned so that the rotary switch (5) canbe attached with the metal tag next tothe proximity switch.
7. Important!On start-up of the positioner, set the op-tion "inductive alarm" under Code 38from NO to YES.
EB 8384-3 EN 67
Retrofitting an inductive limit switch
1 Cap2 Screws3 Rotary pushbutton4 Marking5 Rotary switch
6 Metal tag7 Proximity switch8 Clamping plate9 Plastic cover11 Connector Fig. 20 · Retrofitting an inductive limit switch
Socket ST1(11)
9 7
1
2
4
3
5
8
7
6
10 Maintenance
The positioner does not require any mainte-nance.
There are filters with a 100 µm mesh size inthe pneumatic connections for supply andoutput which can be removed and cleaned,if required.
The maintenance instructions of any up-stream supply air pressure reducing stationsmust be observed.
11 Servicing explosion-protecteddevices
If a part of the positioner on which the ex-plosion protection is based needs to be ser-viced, the positioner must not be put backinto operation until an expert has inspectedthe device according to explosion protectionrequirements, has issued a certificate statingthis or given the device a mark of confor-mity.
Inspection by an expert is not required if themanufacturer performs a routine check onthe device prior to putting it back into oper-ation. The passing of the routine check mustbe documented by attaching a mark of con-formity to the device.
Explosion-protected components may onlybe replaced by original, checked compo-nents from the manufacturer.
Devices that have already been used outsideof hazardous areas and are intended foruse in hazardous areas in future must com-ply with the safety demands placed on re-paired devices. Prior to operation, they mustbe tested according to the specifications sti-pulated for "Repairing explosion-protecteddevices".
68 EB 8384-3 EN
Maintenance
12 Code list
Codeno.
Parameter – Display, values[default setting] Description
Important! Codes with marked with an asterisk (*) must be enabled with Code 3 prior to configuration.
0 Operating mode[MAN]AUtOSAFEESC
AUtO = Automatic mode MAN = Manual modeSAFE = Fail-safe position ESC = EscapeSwitchover from automatic to manual mode is smooth.In fail-safe mode, the symbol S appears on the display.In MAN and AUtO mode, the system deviation is represented bythe bar graph elements.When the positioner is initialized, the numerical display indicatesthe valve position or the angle of rotation in %, otherwise the po-sition of the sensor in relation to the central axis is displayed indegrees °.
1 Manual w0 to 100 [0] %of the nominal range
Adjust the manual set point with the rotary pushbutton, thecurrent travel/angle is displayed in % when the positioner is ini-tialized, otherwise the sensor position in relation to the centralaxis is indicated in degrees °.
2 Reading directionNormal or upside downESC
The reading direction of the display is turned by 180°.
3 Enable configuration[OFF] ON ESC
Enables the option to modify data(automatically deactivated when the rotary pushbutton has not beenoperated for 120 s.)HART blinks on the display when the on-site operation is locked.Codes marked with an asterisk (*) can only be read and notoverwritten.Likewise, codes can only read over the SSP interface.
EB 8384-3 EN 69
Code list
4* Pin position[OFF]17, 25, 35, 50 mm70, 100, 200 mm,90° with rotary actuatorsESC
Note!If you select a pin position inCode 4 that is too small, thepositioner switches to SAFEmode for reasons of safety
For initialization using NOM or SUb, the follower pin must be in-serted into the correct pin position according to the valvetravel/angle of rotation.Pin position Standard Adjustment rangeCode 4 Code 5 Code 517 7.5 3.6 to 17.725 7.5 5.0 to 25.035 15.0 7.0 to 35.450 30.0 10.0 to 50.070 40.0 14.0 to 70.7100 60.0 20.0 to 100.0200 120.0 40.0 to 200.090° 90.0 24.0 to 110.0
5* Nominal range[15.0] mm or angle °ESC
For initialization using NOM or SUb, the nominal travel/angle ofrotation of the valve must be entered.The permissible adjustment range depends on the pin positionaccording to the table.After initialization has been successfully completed, the maximumnominal travel/angle reached on initialization is displayed.
6* Init mode[MAX]NOMMANSubZPESC
Select the initialization modeMAX: Maximum range of the control valve, the travel/angle of
the closure member from the CLOSED position to theopposite stop in the actuator.
NOM: Nominal range of the control valve, the travel/angle ofthe closure member measured from the CLOSED positionto the indicated OPEN position.
MAN: Manual adjustment: upper x-range valueSUb: No self-adjustment (emergency mode)ZP: Zero calibration
7* w/x[]
ESC
Direction of action of the reference variable w in relation to thetravel/angle of rotation x (increasing/increasing or in-creasing/decreasing)Automatic adaptation:AIR TO OPEN:On completing initialization, the direction of action remains in-creasing/increasing (), a globe valve opens as the mA signalincreases.AIR TO CLOSE:On completing initialization, the direction of action changes toincreasing/decreasing ( ), a globe valve closes as the mAsignal increases.
70 EB 8384-3 EN
Code list
8* Lower x-range value0.0 to 80.0 [0.0] % of thenominal range,Specified in mm or angle ° providedCode 4 is set
ESC
Lower range value for the travel/angle of rotation in the nominalor operating range.The operating range is the actual travel/angle of the controlvalve and is limited by the lower x-range value (Code 8) and theupper x-range value (Code 9).Usually, the operating range and the nominal range are iden-tical. The nominal range can be limited to the operating range bythe lower and upper x-range values.Value is displayed or must be entered.The characteristic is adapted. See also the example in Code 9!
9* Upper x-range value20.0 to 100.0 [100.0] %nominal range,Specified in mm or angle ° provided
Code 4 is set
ESC
Upper range value for the travel/angle of rotation in the nominalor operating range. Value is displayed or must be entered.The characteristic is adapted.Example: The operating range is modified, for example, to limitthe range of a control valve which has been sized too large. Forthis function, the entire resolution range of the reference variableis converted to the new limits. 0 % on the display corresponds tothe set lower limit and 100 % to the set upper limit.
10* Lower x-limit[OFF]0.0 to 49.9 % of theoperating rangeESC
Limitation of the travel/angle of rotation downwards to the en-tered value, the characteristic is not adapted.
The characteristic is not adapted to the reduced range. See alsoexample in Code 11.
11* Upper x-limit[100 %]50.0 to 120.0 [100] % ofthe operating rangeor OFFESC
Limitation of the travel/angle of rotation upwards to the enteredvalue, the characteristic is not adapted.Example: In some applications, it makes sense to limit the valvetravel, e.g. if a certain minimum medium flow is required or amaximum flow must not be reached.The lower limit must be adjusted with Code 10, and the upperlimit with Code 11. If a tight-closing function has been set up, ithas priority over the travel limitation!When set to OFF, the valve can be opened past the nominaltravel with a reference variable outside of the 4 to 20 mA range.
EB 8384-3 EN 71
Code list
12* w-start0.0 to 75.0 [0.0] % of thereference variable rangeESC
Lower range value of the applicable reference variable rangemust be smaller than the final value w-end, 0 % = 4 mAThe reference variable range is the difference between w-endand w-start, and must be ∆w ≥ 25 % = 4 mA.For an adjusted reference variable range of 0 to 100 % = 4 to20 mA, the control valve must move through its entire operatingrange from 0 to 100 % travel/angle of rotation.In split-range operation, the valves operate with smaller refer-ence variables. The control signal of the control unit to controltwo valves is divided such, for instance, that the valves movethrough their full travel/angle of rotation at only half the inputsignal (first valve set to 0 to 50 % = 4 to 12 mA and second valveset to 50 to 100 % =12 to 20 mA reference variable).
13* w-end25.0 to 100.0 [100.0] % ofthe reference variable rangeESC
Upper range value of the applicable reference variable range,must be greater than w-start.100 % = 20 mA
14* Final position w <0.0 to [1.0] %of the span adjusted viaCode 12/13OFFESC
If w approaches the percentage adjusted towards the final valuethat causes the valve to close, the actuator is immediately com-pletely vented (with AIR TO OPEN) or filled with air (with AIR TOCLOSE).This action always lead to maximum tight-closing of the valve.
Codes 14/15 have priority over Codes 8/9/10/11.
15* Final position w >[OFF]50.0 to 100.0 %of the span adjusted viaCode 12/13ESC
If w approaches the percentage adjusted towards the final valuethat causes the valve to open, the actuator is immediately com-pletely filled with air (with AIR TO OPEN) or vented (with AIR TOCLOSE).This action always lead to the valve being completely opened.Codes 14/15 have priority over Codes 8/9/10/11.Example: Set the final position w > to 99 % for three-way valves.
16* Pressure limit[OFF]1.4 2.4 3.7 barESC
The signal pressure can adopt the value of the applied supplypressure at the maximum [OFF] or it can be limited in stages of1.4, 2.4 or 3.7 bar. This pressure limitation is already effectiveduring the initialization.Note: After changing a pressure limit already set, the actuatormust be vented once (e.g. by selecting the fail-safe position overCode 0).
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Code list
17* KP step0 to 17 [7]ESC
Displaying or changing KP
Note on changing the KP and TV steps:During the initialization of the positioner, the KP and TV values areoptimized.Should the positioner show a tendency for impermissibly highpost-pulse oscillation due to additional interference, the KP andTV steps can be adapted after the initialization.For this, either the TV step can be increased in increments untilthe desired response behavior is reached or, when the maximumvalue of 4 is reached, the KP step can be decreased in incre-ments.
CAUTION! Changing the KP step influences the system deviation.This effect decreases as the KP step increases.
18* TV step[2]1 2 3 4 OFFESC
Displaying or changing TV,See note under KP stepA change of the TV step has no effect on the system deviation.
19* Tolerance band0.1 to 10.0 [5] % of theoperating rangeESC
Used for error monitoringDetermination of the tolerance band in relation to the operatingrange.Associated lag time [30] s is a reset criterion.If, during initialization, a transit time is determined which is6 times > 30 s, the 6fold transit time is accepted as lag time.
20* Characteristic0 to 9 [0]ESC
Select the characteristic:0: Linear 5: Rotary plug valve linear1: Equal percentage 6: Rotary plug valve eq. perc.2: Reverse equal percentage 7: Segmented ball valve linear3: Butterfly valve linear 8: Segmented ball valve eq. p.4: Butterfly valve eq. percentage 9: User-defined ** Definition over SAMSON TROVIS-VIEW software or HART communication
21* w-ramp Open0 to 240 s [0]ESC
The time required to pass through the operating range when thevalve opens.Limitation of the transit time (Code 21 and 22):For some applications it is recommendable to limit the transit timeof the actuator to prevent it from engaging too fast in the runningprocess.
EB 8384-3 EN 73
Code list
22* w-ramp Closed0 to 240 s [0]ESC
The time required to pass through the operating range when thevalve closes.
23* Total valve travel0 to 9999 [0]subsequently 10E3-99E7
RESESC
Totaled double valve travel.
Can be reset to 0 via RES.
24* LV total valve travel1000 to 9999 [100 000]subsequently 10E3-99E7ESC
Limit value of total valve travel. If the limit value is exceeded, thefault symbol and the wrench symbol appear.Exponential display for 10 000 travel cycles onwards.
25* Alarm mode0 to 3 [2]ESC
Switching mode of software limit switches alarm A1 and A2 inresponding state (when positioner has been initialized).
1) Explosion-protected version according to EN 60947-5-60: A1 ≥ 2.1 mA A2 ≤ 1.2 mA1: A1 ≤ 1.2 mA A2 ≤ 1.2 mA2: A1 ≥ 2.1 mA A2 ≥ 2.1 mA3: A1 ≤ 1.2 mA A2 ≥ 2.1 mA
2) Version without explosion protection0: A1 R = 348 Ω A2 Non-conducting1: A1 Non-conducting A2 Non-conducting2: A1 R = 348 Ω A2 R = 348 Ω3: A1 Non-conducting A2 R = 348 ΩWhen a positioner has not been initialized, the software limitswitches always register the signal as in the state of no response.If there is no mA signal at the terminals 11/12, the software limitswitches both switch to ≤ 1.2 mA signal (Ex) or non-conducting(without explosion protection).
26* Limit value A1OFF0.0 to 100.0 [2.0] % of theoperating rangeESC
Displaying or changing the software limit value A1 in relation tothe operating range.Setting has no effect when an inductive limit switch has been in-stalled.
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Code list
27* Limit value A2OFF0.0 to 100.0 [98.0] % of theoperating rangeESC
Displaying or changing the software limit value A2 in relation tothe operating range.
28* Alarm TestReading direction:Standard Turned[OFF] [OFF]RUN 1 1 RUNRUN 2 2 RUNRUN 3 3 RUNESC ESC
Testing the software limit switches alarm A1 and A2 in additionto the fault alarm contact A3.If the test is activated, the respective limit switches five times.RUN1/1 RUN: Software limit switch A1RUN2/2 RUN: Software limit switch A2RUN3/3 RUN: Fault alarm contact A3
29* Position transmitter x/ix 3)
[]
ESC
Operating direction of the position transmitter; indicates how thetravel/angle position is assigned to the output signal i, based onthe closed position.The operating range (see Code 8) of the valve is represented bythe 4 to 20 mA signal. Values exceeding or falling below thelimits 2.4 to 21.6 mA can be represented.When a positioner has not been connected (reference variableless than 3.6 mA), the signal is 0.9 mA and 3.8 mA in anuninitialized state.When YES is set in Code 32 , the position transmitter issues thevalue as per Code 30 during initialization or zero calibration.When NO is set in Code 32, 4 mA is issued during a runningself-adaptation.
30* Fault alarm ix 3)
[OFF] HI LOESC
Used to select whether faults causing the fault alarm contact toswitch should also be signaled by the position transmitter outputand how they should be signaledHI ix > 21.6 mA or LO ix < 2.4 mA
31* Position transmitter test 3)
–10.0 to 110.0 [x before thefunction is triggered] % ofthe operating rangeESC
Testing the position transmitter. Values can be entered in relationto the operating range.The current actual value is used in initialized positioners locallyas the start value (bumpless changeover to the test mode). Ontesting over software, the entered simulation value is issued asthe 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.
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Code list
32* Display special functionsNO [YES]ESC
Fault alarm via display and fault alarm contact for special func-tions, e.g. zero calibration, initialization and position transmittertest (Code 31).
33* Display total valve travelNO [YES]ESC
Fault alarm indicated on the display and over the fault alarmcontact when the limit value for the total valve travel is exceeded.
34* Closing directionCL [CCL]ESC
CL: Clockwise, CCL: CounterclockwiseTurning direction in which the valve is moved to the CLOSED po-sition (view onto the rotary switch motion when the positionercover is open).Needs only be entered in initialization mode SUb (Code 6).
35* Blocking position[0] mm/° /%ESC
Entering the blocking position.Distance up to the CLOSED position.Only necessary in initialization mode SUb.
36* Reset[OFF] RUNESC
Resets all parameters to default (factory setting).Note: After setting RUN, the positioner must be re-initialized.
37 Position transmitterYes No
Display only,indicates whether the position transmitter option is installed.
38* Inductive alarm[NO] YESESC
Indicates whether the inductive limit switch option is installed ornot.
39 System deviation e info–99.9 to 999.9 % ,
Display only,indicates the deviation from the set point position.
40 Transit time Open info0 to 240 s [0]
Display only,minimum opening time is determined during initialization
41 Transit time Closed info0 to 240 s [0]
Display only,minimum closing time is determined during initialization
42 Auto-w info0.0 to 100.0 % of the span4 to 20 mA
Display only,indicates the supplied automatic reference variable corre-sponding 4 to 20 mA.
43 Firmware infoXxxx
Display only,indicates the current firmware version of the positioner.
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Code list
44 y info[0] OP0 to 100 %MAX
Display only, blocked prior to initialization.After initialization: indicates the actuator pressure in %.0 to 100 % corresponds to the pressure range which adjusts thetravel/angle range from 0 to 100 %.If the actuator pressure is 0 bar, e.g. due to tight-closing onbottom or fail-safe action, 0 P appears on the display.If the actuator pressure is higher than the pressure required for X= 100 %, e.g. due to tight-closing on top, MAX appears on thedisplay.Value is determined during initialization.
45 Solenoid valve infoYesNo
Display only,indicates whether a solenoid valve is installed.If a voltage supply is connected at the terminals of the installedsolenoid valve, YES and HIGH appear on the display in alter-nating sequence. If a voltage supply is not connected (actuatorvented, fail-safe position indicated on the display by the Ssymbol), YES and LOW appear on the display in alternating se-quence.
46* Polling address0 to 63 [0]ESC
Select bus address
47* Write protection HARTYES [NO]ESC
When the write protection function is activated, device data canonly be read, but not overwritten over HART communication.
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Code list
48 Diagnostics
d Diagnostic parameters
d0 Current temperature–55 to 125
Operating temperature [°C] inside the positioner
d1 Minimum temperature[20]
The lowest temperature below 20 °C that has ever occurred.
d2 Maximum temperature[20]
The highest temperature above 20 °C that has ever occurred.
d3 Number of zerocalibrations
The number of zero calibrations since the last initialization.
d4 Number of initializations The number of initializations that have been performed.
d5 Zero point limit[5 %]0.0 to 100.0 %
Limit for the zero point monitoring.
d6 Condensed status Condensed status, made up from the individual states.OK: Okay, C: Maintenance requirement, CR: Maintenance de-mand, B: Failure, I: Function check.
d7 Start reference run[OFF]ONESC 1
Triggering of a reference run for the functions: Drive signal Y sta-tionary and drive signal Y hysteresis.The reference run can only be activated in manual operation asthe valve moves through its entire travel range.If EXPERT+ is activated at later point in time, the reference graphsmust be plotted in order to activate the diagnostic functions.
d8 EXPERT+ activation Enter the activation code for EXPERT+.After the activation procedure has been successfully completed,YES appears under d8.
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Code list
Error codes – Remedy Condensed status alarm active, when prompted, Err appears.
Initialization error(indicated on the display by the condensed status with the corresponding classification)
50 x < range The value supplied by the measuring signal is either too high ortoo low, the measuring sensor is close to its mechanical limit.• Pin positioned incorrectly.• Bracket slipped in case of NAMUR attachment or positioner is
not central.• Follower plate incorrectly attached.
Remedy Check attachment and pin position, set operating mode fromSAFE to MAN and re-initialize the positioner.
51 x > range The measuring span of the sensor is too low.• Pin positioned incorrectly.• Wrong lever.A rotational angle smaller than 11° at the positioner shaft createsjust an alarm. An angle below 6° leads to the initialization beingcanceled.
Remedy Check attachment and re-initialize the positioner.
52 Attachment • Positioner attachment incorrect.• Nominal travel/angle (Code 5) could not be achieved on
initialization under NOM or SUB (no tolerance downwardspermissible)
• Mechanical or pneumatic error, e.g. wrong lever selected orsupply pressure too low to move to the required position orpneumatic fault
Remedy Check attachment and supply pressure. Re-initialize thepositioner.Under certain circumstances, it may be possible to check themaximum travel/angle by entering the actual pin position andthen performing an initialization under MAX.After initialization has been completed, the Code 5 indicates themaximum achieved travel or angle.
53 Init time > The initialization routine lasts too long. The positioner returns toits previous operating mode.• No pressure on the supply line or there is a leak.• Supply air failure during initialization.
Remedy Check attachment and supply pressure.Re-initialize the positioner.
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Code list
54 Init – Solenoid valve 1) A solenoid valve is installed (Code 45 = YES) and wasnot or not properly connected so that an actuator pressurecould not be built up. The message appears when youattempt to initialize the positioner.
2) If you attempt to initialize the device from the fail-safeposition (SAFE).
Remedy Re. 1) Check connection and supply voltage of the solenoidvalve.
Re. 2) Set the MAN operating mode over Code 0. Then initializethe positioner.
55 Transit time < The actuator transit times determined during the initialization areso short that the positioner cannot adapt itself optimally.
Remedy Check the volume restriction setting as described in section 5.2,re-initialize the positioner.
56 Pin pos. Initialization was canceled because you are required to enter thepin position for the selected initialization modes NOM and SUb.
Remedy Enter pin position over Code 4 and nominal travel/angle overCode 5. Re-initialize the positioner.
Operational error(indicated on the display by the condensed status with the corresponding classification)
57 Control loop
Additional alarm at the faultalarm contact!
Control loop error, the control valve does not react within the tol-erable times of the controlled variable (tolerance band alarmCode 19).• Actuator mechanically blocked.• Attachment of the positioner subsequently postponed.• Supply pressure not sufficient.
Remedy Check attachment.
58 Zero point Zero point incorrect. Error may arise when the mounting posi-tion/linkage of the positioner moves or when the valve seat trimis worn, especially with soft-sealed plugs.
Remedy Check valve and mounting of the positioner. If OK, perform azero calibration over Code 6 (see section 5.7 on page 56).
59 Autocorrection Should an error occur in the data range of the positioner, theself-monitoring function recognizes it and automatically correctsit.
Remedy Automatic
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Code list
60 Fatal error
Additional alarm at the faultalarm contact!
An error was detected in the data relevant for safety, autocorrec-tion is not possible. This may be due to EMC disturbances.The control valve moves to its fail-safe position.
Remedy Reset over Code 36.Re-initialize the positioner.
Hardware error (indicated on the display by the condensed status with the corresponding classification)
62 x signal
Additional alarm at the faultalarm contact!
Determination of the measured value for the actuator has failed.Conductive plastic element is defective.The positioner continues to run in emergency mode, but shouldbe replaced as soon as possible.The emergency mode on the display is indicated by a blinkingcontrol symbol and 4 dashes instead of the position indication.
Note on the control:If the measuring system has failed, the positioner is still in a reli-able state. The positioner switches to emergency mode where theposition cannot be accurately controlled anymore. However, thepositioner continues operation according to its reference variablesignal so that the process remains in a safe state.
Remedy Return the positioner to SAMSON AG for repair.
63 w too small The reference variable is much smaller than 4 mA (0 %); occurs ifthe power source that drives the positioner does not comply withthe standard.This state is indicated on the positioner display by a blinkingLOW.
Remedy Check reference variable.If necessary, limit the current source downwards so that no valuesbelow 4 mA can be issued.
64 i/p converter (y) The circuit of the i/p converter has been interrupted.
Remedy Cannot be remedied.Return the positioner to SAMSON AG for repair.
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Code list
Error appendix
65 Hardware
Additional alarm at the faultalarm contact!
A hardware error has occurred, the positioner moves to thefail-safe position SAFE.
Remedy Confirm error and return to the automatic operating mode, orperform a reset and re-initialize the device. If this is not suc-cessful, return device to SAMSON AG for repair.
66 Data memoryAdditional alarm at the faultalarm contact!
The writing of data to the data memory does not work anymore,e.g. when the written data deviate from the read data.Valve moves to the fail-safe position.
Remedy Return the positioner to SAMSON AG for repair.
67 Test calculationAdditional alarm at the faultalarm contact!
The hardware positioner is monitored by means of a test calcula-tion.
Remedy Confirm error. If this is not possible, return the positioner toSAMSON AG for repair.
Data error
68 Control parameterAdditional alarm at the faultalarm contact!
Control parameter error, e.g. due to EMC disturbances.
Remedy Confirm error, perform reset and re-initialize the positioner.
69 Poti parameterAdditional alarm at the faultalarm contact!
Parameter error of the digital potentiometer.
Remedy Confirm error, perform reset and re-initialize the positioner.
70 CalibrationAdditional alarm at the faultalarm contact!
Error in the production calibration data, e.g. due to EMC distur-bances. Subsequently, the device runs on default values
Remedy Return the positioner to SAMSON AG for repair.
71 General parameters Parameter errors that are not critical for the control.
Remedy Confirm error.Check and, if necessary, reset required parameters.
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72 Start-up parameters Start-up parameter errors
Remedy Confirm error, perform reset and re-initialize the positioner.
73 Internal device error 1 Internal device error
Remedy Return the positioner to SAMSON AG for repair.
74 HART parameters Error in the HART parameters that are not critical for the controlfunction.
Remedy Confirm error.Check and, if necessary, reset required parameters.
75 Info parameters Error in the info parameters that are not critical for the controlfunction.
Remedy Confirm error.Check and, if necessary, reset required parameters.
76 No emergency mode The travel measuring system of the positioner has a self-moni-toring function (see Code 62).A controlled emergency mode is not available on certain actua-tors, such as double-acting actuators. For this reason, thepositioner moves to the fail-safe position when a measuring erroroccurs. During the initialization, the positioner checks whetherthe actuator has such a function or not.
Remedy Merely information, confirm, if necessary.No further action necessary.
77 Program loading errorAdditional alarm at the faultalarm contact!
When the device starts operation for the first time after the inputsignal has been applied, it carries out a self-test (tEStinG runsacross the display).If the device loads a program that does not correspond to that ofthe positioner, the valve moves to the fail-safe position. It is notpossible to make the valve leave this fail-safe position again byoperating the positioner.
Remedy Interrupt current and restart positioner. Otherwise, return thepositioner to SAMSON AG for repair.
78 Options parameter Errors in options parameters, e.g. due to EMC disturbances.
79 Diagnostic alarms Alarms are generated in the EXPERT+ extended diagnostics ifEXPERT+ has been successfully activated in Code 48.
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Code list
80 Diagnostic parameters Error which is not critical for control.
Remedy Confirm error.Check and, if necessary, start new reference run.
81 Reference graphs Error on plotting the reference graphs of drive signal Y stationaryor drive signal Y hysteresis.• Reference run was interrupted• Reference line Y stationary or Y hysteresis was not adopted.
84 EB 8384-3 EN
Code list
13 Setting with TROVIS-VIEW software – Parameter list
13.1 General
A CD-ROM containing the program for installing the TROVIS-VIEW Configuration and Op-erator Interface is provided by SAMSON.
Insert the installation CD-ROM to start the installation program. Once inserted, the CD-ROMusually starts the installation program automatically depending on the configuration of theoperating system.If the program does not start automatically, double-click setup.exe in the root directory of theCD-ROM in order to install TROVIS-VIEW.Follow the on-screen prompts and instructions of the installation program.
The system requirements are specified in the readme.txt file in the root directory of theCD-ROM.
The TROVIS-VIEW Operator Interface can be used for different SAMSON devices. Note thatthe installation program also offers you the option of installing a demo module. To use thesoftware without restrictions, the software needs to be activated as described below:
After installation, a dialog box will appear, prompting you to enter the CD key, which youwill find on the cover of the original CD-ROM. Once you have entered the correct CD keyand initiated the activation process, a request code will be automatically generated. The Ac-tivation dialog box will come up displaying the generated request code and an Internet linkto SAMSON’s activation server where a unique activation code will then be generated anddisplayed. Enter this activation code into TROVIS-VIEW’s Activation dialog box. The soft-ware is now ready for use without any restrictions in the purchased scope.
To enable communication with the PC, connect the serial interface to the serial interface(5-pole female socket) of the positioner using a SAMSON connecting cable with serial inter-face adapter (order no. 1400-7700).
The positioner settings configured in TROVIS-VIEW can be directly transferred over theSAMSON connecting cable to the positioner on site. This online connection enables you toread any entered settings as well as providing a diagnostic function.
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Setting with TROVIS-VIEW software – Parameter list
13.2 Starting TROVIS-VIEW and performing basic settings
Settings may be entered into the TROVIS-VIEW operator interface when either the positioneris connected or not connected. When the positioner is connected, the data uploaded fromthe positioner can be overwritten.
When the positioner is not connected, the default settings appear on the operator interfacedisplay or, alternatively, a stored TROVIS-VIEW file (*.tro) can be loaded and written over inthe File menu by selecting Open.
Connection to the positioner is established by clicking the symbols on top right on the buttonbar:
Upload data from the positioner and displayed in the operator interface
Download data onto the positioner from the operator interface
The positioner is in online mode, indicated by the TROVIS-VIEW 3 logo on the topright in the blue bar
The positioner is in offline mode.
You can also activate the listed functions in the Device menu.
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Setting with TROVIS-VIEW software – Parameter list
1. Start TROVIS-VIEW
Make required settings in View menu by activating or deactivating functions.
When the Trend Viewer is activated, all operating data are uploaded cyclically from thepositioner in online mode and shown in the form of graphs.Right-click on the graph to edit the graph format or to copy the logged data to a file.
2. Select required language in Options menu.The selected language can be changed at any time except in online mode.
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Setting with TROVIS-VIEW software – Parameter list
3. Select Communication fromthe Options menu and choose.communication settings.
4. Click on Port settings and select port as well as serversetting.
5. Select Convert in the File menu to select thefirmware version of the positioner.It must match the version specified in the bar atthe top.
6. Enter more details about the plant,if necessary, in Customer Data in theEdit menu.
7. Select Load Factory Defaults in Edit menu to upload default settings to the operator inter-face.
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Setting with TROVIS-VIEW software – Parameter list
13.3 Setting the parameters
Click on one of the folders listed in the left column to open a window listing the settings of thecorresponding parameters. Place the mouse arrow on the parameter name to open a tool tipproviding information about that particular parameter.
Double-click on a parameter to open a window to enable the parameter to be modified.
Right-click on the parameter to open a drop-down menu pro-viding further editing options.
The parameters in all the folders are listed in the following parameter list.
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Setting with TROVIS-VIEW software – Parameter list
13.4 Parameter list
Parameter Values Defaultsetting
DescriptionRefer to section 11 for the description of thecodes
Identification – Operation unit
TAG Max. 32 charac-ters
Tag identification of operation unit
Long TAG
Bus address 0 Code 46
Description Freely available text fields
Message
Text field 1 to 5
Positioner serialnumber
Serial number of the positioner
Positioner productnumber
3730-3 xxx Manufacturer model number of the positioner
Firmware version x.xx Current firmware version of device, Code 43
Diagnosis level EXPERT
Final assemblynumber
0...16777215 0 Any number assignable to clearly identify theentire field device
Date (day) 1...31 1Date that can be entered. Stored in thepositioner
Date (month) January
Date (year) 1900...2155 2003
Certification Indicates whether the positioner can be used inhazardous area
Number of pream-bles
5 Number of required synchronization bytes
Required number ofpreambles
5...20 5
HART revision 5 Designates the version of the HART specifica-tion which is supported by the positioner
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Setting with TROVIS-VIEW software – Parameter list
Identification – Positioner
Device type 3730-3 Indicates exact model designation
Identification – Positioner – Actuator
Type identificationactuator
Manufacturer ID number of the actuator that thepositioner is mounted upon
Actuator type Single-actingDouble-acting
Single-acting Actuator with or without spring return mecha-nism
Attachment Integral/NAMUR
Integral Defines the attachment of the positioner on thecontrol valve
Booster Not present/present
Not present Pneumatic volume booster
Actuator size 60...5600 240 cm2 Effective diaphragm or piston area of the actu-ator
Signal pressurelower value
0.0...6 0.2 bar Initial value of the actuator bench range
Signal pressureupper value
0.0...6 1.0 bar Final value of the actuator bench range
Supply pressure 0.0...6 6.0 bar Supply pressure of compressed air network
Identification – Positioner – Valve
Type identificationvalve
Manufacturer ID number of the valve that thepositioner is mounted upon
Direction of flow Flow-to-open(FTO)/Flow-to-close(FTC)
Flow-to-open(FTO)
Indicates in which direction the process mediumflows to the valve plug.
Packing Adjustable/Self-adjusting/Bellows seal
Self-adjusting
Sealing of the plug stem to the atmosphere
Seating surface(leakage class)
Metal sealing/Lapped-in metal/Soft sealing/Nickel sealing
Metal sealing Type of sealing between seat and plug
Pressure balancing Without/With (PTFE)/With (graphite)
Without Plug with pressure balancing to compensate forforces
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Setting with TROVIS-VIEW software – Parameter list
Flow characteristic Linear 30:1/Eq. perc. 30:1/Linear 50:1/Eq. perc. 50:1/Other
Linear 50:1 Valve characteristic: Flow to valve travel
Valve dimensionsstandard
DIN/ANSI DIN Valve dimensions according to DIN or ANSI
Nominal size DN 8...2100 50 Nominal size in mm (DIN) or inch (ANSI)
Kvs coefficient 0.0001...20000.0000
1.0000 Kv Valve flow coefficient
Kvs unit Kv/cv Kv Flow coefficient, metric unit (Kvs) or US Amer-ican units (cv)
Seat diameter of thevalve
2.0...500.0 6.0 mm Diameter of valve seat bore
Identification – Positioner – Additional components
Solenoid valveNotinstalled
Code 45
Position transmitter Code 37
Inductive limitswitch
Installed/Not installed
Code 38
Operation unit
HART write protec-tion
Not writeprotected
Code 47
Start with defaultsettings
Code 36
Positioner – Operating mode
Current operatingmode
Indicated the current operating mode used bythe device
Target operatingmode
Automatic/Manual/Fail-safeposition
Automatic Code 0
Positioner – Process data
Reference variable w
Displays currentprocess variables
Code 42
Controlled variable x Current position
System deviation e Deviation from target position (e=w–x)
Manipulated vari-able
Indicates the actuator pressure after the initial-ization has been completed
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Setting with TROVIS-VIEW software – Parameter list
Status
Condensed state Summarized state of the positioner.The condensed status is made up from the var-ious states.The condensed status can take on the followingstates:
No alarm
Maintenance requirement
Maintenance demand
Failure
Function check
The condensed states “Maintenance require-ment” and “Maintenance demand” are also in-dicated on the positioner display by .The condensed status “Failure” causes thefault alarm symbol to appear on the display.
Fault exists(fault alarm contact)
Display and alarm
Status of the fault alarm contact
Status of limit switchA1
Status of the switching output for limit switch A1
x falls below A1 Indicates whether the controlled variable x hasfallen below the limit for A1
Status of limit switchA2
Status of the switching output for limit switch A2
x exceeds A2 Indicates whether the controlled variable x hasexceeded the limit for A2
Operational status Indicates the current operational status of theinternal control
Temperature Current temperature in the positioner
EB 8384-3 EN 93
Setting with TROVIS-VIEW software – Parameter list
Positioner – Reference variable
Direction of action Increasing/increasing >>Incr./decr. <>
Increasing/increasing >>
Code 7
Lower referencerange value
0.0...75.0 % 0.0 % Code 12
Upper referencerange value
25.0...100.0 % 100.0 % Code 13
Enable final posi-tion smaller than w
On/Off On Code 14
Final position whenw is smaller
0.0...49.9 % 1.0 % Code 14
Enable final posi-tion greater than w
On/Off Off Code 15
Final position whenw is greater
50.0...100.0 % 100.0 % Code 15
Required transittime OPEN
0...240 s 0 s Code 21
Required transittime CLOSED
0...240 s 0 s Code 22
Positioner – Working range
Initial value oftravel range/angleof rotation range
0.0...12.0 mm 0.0 % Code 8
Final value of travelrange/angle ofrotation range
3.0...15.0 mm 100.0 % Code 9
Enable travel/angleof rotation lowerlimit
On/Off Off Code 10
Travel/angle ofrotation lower limit
0.0...49.9 % 0.0 % Code 10
Enable travel/angleof rotation upperlimit
On/Off On Code 11
Travel/angle ofrotation upper limit
50.0...120.0 % 100.0 % Code 11
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Setting with TROVIS-VIEW software – Parameter list
Positioner – Characteristic
Characteristic selec-tion
LinearEqual percentageEq. perc. reverse
SAMSONbutterfly valves
lineareq. perc.
VETEC rotaryplug valves
lineareq. perc.
Segmented ballvalves
lineareq. perc.
User defined
Linear Code 20
Graphs of the user-defined characteristics,loading and saving characteristics.See example on the next page.
Characteristic type Free text for describing the user-defined char-acteristic
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Setting with TROVIS-VIEW software – Parameter list
Example for user-defined characteristic
• Select User defined characteristic in Characteristic selection parameter.• Double-click on Edit, open or save characteristic to open a window where the characteristic can be
edited.Click on Characteristic button on the bottom right to open and save a characteristic.
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Setting with TROVIS-VIEW software – Parameter list
Parameter Values Default Description
Positioner – Performance characteristics
Required propor-tional-action coeffi-cient KP (step)
0...17 7 Code 17
Proportional-actioncoefficient KP (step)
Code 17
Required deriva-tive-action time TV(step)
Off/1/2/3/4 2 Code 18
Derivative-actiontime TV (step)
Code 18
Positioner – Fail-safe action
Fail-safe position Closing Fail-safe action of the actuator upon air/auxil-iary power failure or device start-up.Determined during initialization by the positionof the slide switch (see section 5.1).In double-acting actuators, the fail-safe positionrelates only to the failure of the auxiliary powersupply. There is no defined position when thesupply air fails.
Positioner – Error control
Tolerance band 0.1...10.0 % 5.0 % Code 19
Delay time 0...9999 s 30 s Reset criterion for running control loop moni-toring.A control loop error is issued when the delaytime is exceeded and the system deviation is notwithin the tolerance band.
Total valve travel 1 Code 23
Limit of the totalvalve travel
1000...990 000 000
1 000 000 Code 24
Alarm mode A1 Conducting/highA2 Non-conduc./low
A1 Non-conduc./lowA2 Non-conduc./low
A1 Conducting/highA2 Conduc./high
A1 Non-conduc./lowA2 Conducting/high
A1Con-ducting/highA2Conducting/high
Code 25
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Setting with TROVIS-VIEW software – Parameter list
Enable limit valueA1
On/Off On Code 26
Limit value A1 0.0...100.0 % 2.0 % Code 26
Enable limit valueA2
On/Off On Code 27
Limit value A2 0.0...100.0 % 98.0 % Code 27
Fault alarmspecial functions
Yes/No Yes Code 32
Fault alarmtotal valve travel
Yes/No Yes Code 32
Zero point limit 0.0...100.0 % 5.0 % Limit for zero point monitoring
Positioner – Error control – Classification report
Condensed status error alarms
Note!Each fault alarm has a status assigned to it.The possible states are placed in order starting with the lowest priority:
Maintenance demand Lowest
Maintenance requirement
Failure
Function check Highest priority
No alarm Alarm is not added to the condensed status
The fault alarm present in the device with the highest priority determines which condensed status is dis-played.The condensed states “Maintenance requirement” and “Maintenance demand” are also indicated onthe positioner display by .The condensed status “Failure” causes the fault alarm symbol to appear on the display.
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Setting with TROVIS-VIEW software – Parameter list
x > range
Determines the individual statusfor each alarm
with symbol
an alarm is not added tothe condensed status
Symbol
for maintenance requirementand
maintenance demand
Symbol
for failure
or symbol
for function check
Code 50
Delta x < range Code 51
Attachment Code 52
Initialization timeexceeded
Code 53
Initialization/solenoid valve
Code 54
Transit time notachieved
Code 55
Pin position Code 56
Control loop Code 57
Zero point Code 58
Autocorrection Code 59
x signal Code 62
w too small Code 63
Control parameter Code 68
Poti parameter Code 69
Calibration param-eter
Code 70
General parameters Code 71
Internaldevice error 1
Code 73
HART parameter Code 74
Parameter info Code 75
No emergencymode
Code 76
Options parameter Code 78
Total valve travelexceeded
Determines the condensed status when a faultoccurs
Temperature< –40 °C
Temperature fell below –40 °C duringoperation
Temperature> 80 °C
Temperature exceeded +80 °C duringoperation
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Setting with TROVIS-VIEW software – Parameter list
Positioner – Start-up
Reading direction Pneumaticconnectionright/left
Pneumaticconnectionright
Code 2
Pin position Off17/25/35/50/70/100/200 mm90°
Off Code 4
Initialization mode Nominal rangeMaximum rangeManual adjust-mentSubstitution
Maximumrange
Code 6
Pressure limit Off /2.4/3.7/1.4 bar
Off Code 16
Determined nom-inal range
Code 5
Minimum transittime OPEN
Code 40
Minimum transittime CLOSED
Code 41
Fail-safe action Fail-safe action of the actuator upon air/auxil-iary power failure or device start-up.Determined during initialization by the positionof the slide switch (see section 5.1).In double-acting actuators, the fail-safe positionrelates only to the failure of the auxiliary powersupply. There is no defined position when thesupply air fails.
Positioner – Start-up – Initialization
Initialization mode Nominal rangeMaximum rangeManual adjust-mentSubstitution
Maximumrange
Code 6
Device initialized Status of device initialization
Initialization Starting of initialization procedure.The initialization mode parameter must be firstset to the required initialization procedure.
100 EB 8384-3 EN
Setting with TROVIS-VIEW software – Parameter list
Initialization status Status of the running initialization procedure
Initialization can-celed
Running initialization procedure has been can-celed. The control valve moves to its fail-safeposition.
Target operatingmode
AutomaticManualSAFE
Automatic Code 0
Current operatingmode
Indicates current operating mode of positioner
Initialization error
x > range
Alarm
Code 50
Delta x < range Code 51
Attachment Code 52
Initialization timeexceeded
Code 53
Initialization/sole-noid valve
Code 54
Transit time too short Code 55
Pin position Code 56
No emergencymode
Code 76
Positioner – Start-up – Substitution
Initialized in Submode
Indicates whether the substitute configuration(sub mode) has been performed
Closing direction Counter-clockwise
Code 34
Blocking position 0.0 % Code 35
Positioner – Maintenance
Start zero calibration
Zero calibration Starts zero calibration
Initialization status Status of running initialization procedure
Initialization can-celed
Running initialization procedure has been can-celed. The valve moves to fail-safe position.
Target operatingmode
AutomaticManualSAFE
Automatic Code 0
Current operatingmode
Indicates current operating mode of positioner
EB 8384-3 EN 101
Setting with TROVIS-VIEW software – Parameter list
Positioner – Simulation
Alarm test A1 Code 28
Alarm test A2 Code 28
Alarm test A3(alarm fault output)
Code 28
Diagnosis
Diagnosis levelsetting
Expert
Current operatingmode
Automatic Indicates current operating mode of positioner
Diagnosis – Status alarms
Status
Condensed status Alarm symbol Summarized condensed status.Made up from various states.
Operating hourscounter
Display or status
Time elapsed since first initialization
Device in closedloop
Time elapsed in closed loop since first initializa-tion
Device switched onsince lastinitialization
Time elapsed since last initialization
Device in closedloop since lastinitialization
Time elapsed in closed loop since last initializa-tion
Error occurred(fault alarm output)
Status of fault alarm output
Solenoid valvestatus
Status of optional solenoid valve
Fail-safe position Fail-safe action of actuator upon airsupply/auxiliary power failure or devicestart-up.Determined during initialization.
Device initialized Status of device initialization
Start performedwith default settings
Indicates whether a start has been performedwith default settings.
Local operation ac-tive
Local operation is active
Configurationchanged
Status of device status bit configurationchanged.
102 EB 8384-3 EN
Setting with TROVIS-VIEW software – Parameter list
Number of zerocalibrations
Number of zero calibrations performed sincelast initialization
Number ofinitializations
Number of initializations performed
Zero point limit Limit for zero point monitoring
Operation
Control loop
Alarm
Code 57
Zero point Code 58
Autocorrection Code 59
Fatal error Code 60
w too small Code 63
Total valve travelexceeded
Status of total valve travel limit
Temperatureexceeded
Status alarm resulting from diagnosis analysis
Hardware
x-signal
Alarm
Code 62
i/p converter Code 64
Hardware Code 65
Data memory Code 66
Control calculation Code 67
Program load error Code 77
Initialization
x range
Alarm
Code 50
Delta x < range Code 51
Attachment Code 52
Initialization timeexceeded
Code 53
Initialization/solenoid valve
Code 54
Transit time tooshort
Code 55
Pin position Code 56
No emergencymode
Code 76
EB 8384-3 EN 103
Setting with TROVIS-VIEW software – Parameter list
Data memory
Control parameter
Alarm
Code 68
Poti parameter Code 69
Calibrationparameter
Code 70
General parameters Code 71
Internal deviceerror 1
Code 73
HART parameter Code 74
Info parameter Code 75
Option parameter Code 78
Diagnosticparameters
Code 80
Temperature
Min. temperature
Display
Lowest temperature recorded in the positioner
Max. temperature Highest temperature recorded in the positioner
Min. temperature(time)
Operating hours counter logging when thelowest temperature was recorded in thepositioner
Max. temperature(time)
Operating hours counter logging when thehighest temperature was recorded in thepositioner
Diagnosis – Status messages – Data logger
Alarms(1) to (30)
Alarm
Recorded alarms issued by the positioner
Operating hours counter logging of each alarmOperating hourssince first initializa-tion
Diagnosis – Status alarms – Reset
Reset absolute totaltravel
Resetting correspondingalarms
Reset counter for absolute total valve travelback to 0
Resetdefault values flag
Set back default values flag to 0
Reset configurationchanged
Reset device status bitconfiguration changed.
104 EB 8384-3 EN
Setting with TROVIS-VIEW software – Parameter list
Reset initialization error
Resetx > range
Resetting correspondingalarms
Code 50
ResetDelta x < range
Code 51
Reset attachment Code 52
Resetinitializationexceeded
Code 53
Resetinitialization/solenoid valve
Code 54
Resettransit time tooshort
Code 55
Reset pin position Code 56
Reset operational error
Reset zero point Resetting correspondingalarms
Code 58
Reset autocorrection Code 59
Reset hardware error
Reset hardware
Resetting correspondingalarms
Code 65
Reset controlcalculation
Code 67
Reset data error
Reset controlparameter
Resetting correspondingalarms
Code 68
Reset poti param-eter
Code 69
Resetgeneral parameters
Code 71
HART parameter Code 74
Reset options pa-rameter
Code 78
Reset diagnosticparameters
Code 80
EB 8384-3 EN 105
Setting with TROVIS-VIEW software – Parameter list
Reset statistical information
Reset data logger Measured data in the data logger buffermemory are deleted
106 EB 8384-3 EN
Setting with TROVIS-VIEW software – Parameter list
A1 Z
A2
40
34
210
28
1480
164 Output (38) Supply (9)
86
70
15
46
3470
7028
Schild
Output A1
Output A2
Supply (9)
50 80
58
58
58
130
495979
76
50
14 Dimensions in mm
EB 8384-3 EN 107
Dimensions in mm
Direct attachment
Attachment acc. to IEC 60534-6Pressure gaugebracket
Attachment to rotary actuatorsVDI/VDE 3845
for all sizes of fixing level 2
or connecting plate
Reversing amplifier(option)
Lever mmS = 17M = 50L = 100XL = 200
ConnectingplateG ¼ or¼ NPT
External position sensor
M20 x 1.5
108 EB 8384-3 EN
EB 8384-3 EN 109
110 EB 8384-3 EN
EB 8384-3 EN 111
112 EB 8384-3 EN
EB 8384-3 EN 113
114 EB 8384-3 EN
EB 8384-3 EN 115
116 EB 8384-3 EN
EB 8384-3 EN 117
118 EB 8384-3 EN
EB 8384-3 EN 119
SAMSON AG · MESS- UND REGELTECHNIKWeismüllerstraße 3 · 60314 Frankfurt am Main · GermanyPhone: + 49 69 4009-0 · Fax: +49 69 4009-1507Internet: http://www.samson.de EB 8384-3 EN S/
Z20
05-0
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