Mounting and Operating Instructions EB 8355-1 EN Positioners and...2 EB 8355-1 EN Safety instructions Safety instructions The positioner is to be mounted, started up or operated only

Pneumatic PositionerType 3766

Mounting andOperating Instructions

EB 8355-1 ENEdition November 2011

Fig. 1 · Type 3766 Pneumatic Positioner

2 EB 8355-1 EN

Safety instructions

Safety instructions

� The positioner is to be mounted, started up or operated only by trained andexperienced personnel familiar with the product.According to these Mounting and Operating Instructions, trained personnelrefers to individuals who are able to judge the work they are assigned toand recognize possible dangers due to their specialized training, theirknowledge and experience as well as their knowledge of the applicablestandards.

� Explosion-protected versions of this positioner may only be operated by per-sonnel who have undergone special training or instructions or who are aut-horized to work on explosion-protected devices in hazardous areas.

� 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, the supply pressure must be restricted by means of asuitable supply pressure 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 is available on request.

Note on modification:Positioners with model index 3766-x...x.03 and higher are equipped with ahinged cover without venting connection.The required exhaust air connection is now included in the mounting accesso-ries. If these positioners are mounted on older actuator models, make absolutelysure that there is a vent connection. If necessary, replace the mounting accesso-ries as well.

Contents Page

1 Design and principle of operation. . . . . . . . . . . . . . . . . . . . 41.1 Versions (article code). . . . . . . . . . . . . . . . . . . . . . . . . . 61.2 Technical data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8

2 Attachment to control valve . . . . . . . . . . . . . . . . . . . . . . 102.1 Direct attachment to Type 3277 Actuator . . . . . . . . . . . . . . . . 102.2 Attachment according to IEC 60534-6 . . . . . . . . . . . . . . . . . 152.2.1 Mounting sequence . . . . . . . . . . . . . . . . . . . . . . . . . . 162.2.2 Presetting the travel . . . . . . . . . . . . . . . . . . . . . . . . . . 162.3 Attachment to rotary actuators . . . . . . . . . . . . . . . . . . . . . 192.3.1 Mounting the cam follower lever . . . . . . . . . . . . . . . . . . . . 202.3.2 Mounting the intermediate piece . . . . . . . . . . . . . . . . . . . . 202.3.3 Default setting of the cam disk . . . . . . . . . . . . . . . . . . . . . 222.3.4 Reversing amplifier for double-acting actuators . . . . . . . . . . . . . 26

3 Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 283.1 Pneumatic connections . . . . . . . . . . . . . . . . . . . . . . . . . 283.1.1 Pressure gauge . . . . . . . . . . . . . . . . . . . . . . . . . . . . 283.1.2 Supply pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . 283.2 Electrical connections . . . . . . . . . . . . . . . . . . . . . . . . . 293.2.1 Switching amplifier . . . . . . . . . . . . . . . . . . . . . . . . . . 31

4 Operation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 324.1 Setting the positioner at the valve. . . . . . . . . . . . . . . . . . . . 324.1.1 Adjusting the proportional band Xp and air delivery Q . . . . . . . . . 334.1.2 Settings for actuator: "Actuator stem extends". . . . . . . . . . . . . . 334.1.3 Settings for actuator: "Actuator stem retracts" . . . . . . . . . . . . . . 344.2 Changing the operating direction . . . . . . . . . . . . . . . . . . . 354.3 Adjusting the limit switches. . . . . . . . . . . . . . . . . . . . . . . 364.4 Adjusting the position transmitter . . . . . . . . . . . . . . . . . . . . 38

5 Converting the positioner . . . . . . . . . . . . . . . . . . . . . . . 40

6 Service . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 426.1 Servicing explosion-protected devices . . . . . . . . . . . . . . . . . 426.2 Maintenance, calibration and work on equipment. . . . . . . . . . . . 42

7 Dimensions in mm. . . . . . . . . . . . . . . . . . . . . . . . . . . 43

Test certificates . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44

EB 8355-1 EN 3

Contents

1 Design and principle ofoperation

The positioners ensure a fixed assignmentbetween the valve stem position (controlledvariable x) and the pneumatic or electric in-put signal (reference variable w). They com-pare the input signal received from the con-trol unit with the travel of the control valveand, issue the corresponding output signalpressure pst (output variable).

The positioner consists of a lever for travelpick-up, a measuring diaphragm and thepneumatic control system with nozzle, dia-phragm lever (flapper plate) and booster.

The positioner is designed either for directattachment to SAMSON Type 3277 Actua-tors or for attachment according to NAMUR(IEC 60534-6-1) with an adapter housing.

The positioner can be additionally equippedwith either inductive limit switches and/or asolenoid valve or a position transmitter.

The positioner operates according to theforce-balance principle. The valve travel, i.e.the valve position, is transmitted to thepick-up lever (1) over the pin (1.1) and de-termines the force of the measuring spring(4). This force is compared to the positioningforce generated by the pressure pe at themeasuring diaphragm (5).

If either the control signal or the valve posi-tion changes, the diaphragm lever (3)moves, altering the distance to the nozzle(2.1 or 2.2), depending on the set operatingdirection of the positioner.

The air is supplied to the booster (10) andthe pressure regulator (9). The controlledsupply air flows through the Xp restriction

(8) and the nozzle (2.1, 2.2) to finallystream on the diaphragm lever (flapperplate). Any change in the reference variableor the valve stem position cause the pressureto change upstream or downstream of thebooster.

The air controlled by the booster (signalpressure pst) flows through the volume re-striction (11) to the pneumatic actuator,causing the plug stem to move to a positioncorresponding to the reference variable.

The adjustable Xp restriction (8) and volumerestriction Q (11) are used to optimize thepositioner control loop.

The pick-up lever (1) and the range spring(4) must be selected to match the rated valvetravel and the nominal span of the referencevariable.

Positioner with inductive limit switches

In this version, the rotary shaft of thepositioner carries two adjustable tags whichactuate the built-in proximity switches.

Positioner with solenoid valve

When the positioner is equipped with a so-lenoid valve, the valve can be moved to thefail-safe position regardless of thepositioner's output signal. If a control signalcorresponding to the binary signal '0' (off)is applied to the input, the signal pressurepst is shut off and the actuator is vented. Theactuator springs move the valve to itsfail-safe position. If a control signal corre-sponding to the binary signal '1' (on) is ap-plied to the input, the signal pressure pst issupplied to the actuator. The valve is inclosed-loop operation.

4 EB 8355-1 EN

Design and principle of operation

EB 8355-1 EN 5


4 3 7 8 9 11

6.1 6.2

Travel

1 Pick-up lever1.1 Pin1.2 Clamp2.1 Nozzle >>2.2 Nozzle <>3 Diaphragm lever4 Range spring5 Measuring

diaphragm

6.1 Span adjuster6.2 Zero adjuster7 Turnboard8 Xp restriction9 Pressure regulator10 Booster11 Volume restriction12 Solenoid valve

(optional)

7 8 9 10 11 12

6.1 4 6.2

2.13

2.2

5

1

1.1 1.2Pe

Supply9

V

PstQXp

ep

Fig. 2 · Functional diagram and inside view

Positioner with position transmitter

A positioner containing a position transmit-ter cannot be equipped with integrated limitswitches or an integrated solenoid valvesince the position transmitter requires mostof the space inside.

The position transmitter is used to establish acertain relationship between the valve posi-tion, i.e. the valve travel, and a controlleroutput signal of 4 to 20 mA.

1.1 Versions (article code)

The position transmitter setting ensures thatboth end positions "valve CLOSED" or"valve OPEN" as well as all intermediatepositions can be signalized. Since the valveposition is signalized independently of theinput signal to the positioner, the positiontransmitter is a suitable option for checkingthe current valve position.

6 EB 8355-1 EN


Pneumatic positioner Type 3766- x x x 0 1 x x x x 1 x 0 x 0

Explosion protection

Without 0 2

II 2 G EEx ia IIC T6 acc. to ATEX 1

FM/CSA intrinsically safe/non incendive 3

Ex ia / Ex n I/IIC T6 IP 65 IECEx TSA Australia 6

II 3 G EEx nA II T6 acc. to ATEX 8

Additional equipment

Without 0

Limit switch, inductive 2x SJ2 SN 2

(Analog position transmitter 4 to 20 mA * 6 0 0)

3/2-way solenoid valve

Without 0

6 V DC 2

12 V DC 3

24 V DC 4

EB 8355-1 EN 7


Pneumatic positioner Type 3766- x x x 0 1 x x x x 1 x 0 x 0

Pneumatic connections

¼-18 NPT 1

ISO 228/1 - G ¼ 2

Electrical connections

Without (no additional equipment or solenoid valve) 0 0 0 0

Cable gland

M20 x 1.5, blue (plastic) 1 0 0

M20 x 1.5, black (plastic) 2 0 0

M20 x 1.5 (nickel-plated brass) 2 1 3

Housing version

Die-cast aluminum 0

Stainless steel (CrNiMo) 2

Temperature range

Standard 0

Low temperatureTmin � –50 °C; optional limit switches, solenoid valve 2 1 3

Special version

Without 0 0 0

GOST Ex approval 0Ex ia IIC T8 X 1 0 1 0

* Available until March 2011

Device functioning only as analog position transmitter: 3766-x60 000xxx00 000 0

1.2 Technical data

8 EB 8355-1 EN


Type 3766 Positioner

Travel range 7.5 to 30 mm Direct attachment to Type 3277 Actuator

7.5 to 120 mm Attachment acc. to IEC 60534-6 (NAMUR)

Opening angle 70°, 75° or 90° depending on the cam disk

Referencevariable w

Signal range 0.2 to 1 bar (3 to 15 psi)

Span 0.4 to 0.8 bar (6 to 12 psi)

Overloadable max. 2 bar (29 psi)

Supply air Auxiliary power 1.4 to 6 bar (20 to 90 psi)

Air quality acc. toISO 8573-1,edition 2001-02

Max. particle size and density: Class 4,Oil content: Class 3, pressure dew point: Class 3 or at least 10 Kbelow the lowest ambient temperature to be expected

Signal pressure pst (output) Can be limited between 0 to approx. 2.5 bar and 0 to 6 bar(0 to approx. 35 psi and 0 to 90 psi)

Characteristic Linear characteristicDeviation from terminal-based conformity: � 1 %

Hysteresis � 0.3 %

Sensitivity � 0.1 %

Operating direction Reversible

Proportional band Xp 0.5 to 2.5 % (proportional-action coefficient Kp: > 200 to 40)

Air consumption With 1.4 bar supply air With 6 bar supply air

� 230 In/h � 230 In/h 1)

Air delivery Actuator filled with air 3.0 mn³/h 8.5 mn³/h

Actuator vented 4.5 mn³/h 14.0 mn³/h

Permissibleambienttemperature 2)

Standard –20 to 80 °C: Optional limit switches/solenoid valve/positiontransmitter with plastic cable gland

–40 to 80 °C: Optional limit switches/solenoid valve withmetal cable gland

Low temperature version –50 to 80 °C: Optional limit switches/solenoid valve withmetal cable gland

The technical data of the test certificate also apply for explosion-pro-tected versions.

Influences Temperature: � 0.3 %/10 KSupply air: � 1 % between 1.4 and 6 barVibrations: None between 10 and 150 Hz and 4 g

EB 8355-1 EN 9


Electromagnetic compatibility Complying with requirements specified in EN 61000-6-2,EN 61000-6-3 and NAMUR Recommendation NE 21

Explosion protection Refer to article code or list of approvals in Data Sheet T 8355 EN

Degree of protection IP 54 (special version IP 65)

Weight Approx. 1 kg

Additional equipment

Limit switches

Two inductive proximity switches Type SJ 2-SN

Control circuit Ratings according to downstream transistor relay

Hysteresis at rated travel � 1 %

Solenoid valve

Input Binary direct current signal

Nominal signal 6 V DC 12 V DC 24 V DC

Signal 0 (no pick-up) 3) � 1.2 V � 2.4 V � 4.7 V

Signal 1 (safe pick-up) 4) � 5.4 V � 9.6 V � 18.0 V

Maximum permissible signal 28 V 25 V 32 V

Coil resistance Ri at 20 °C 2909 � 5832 � 11714 �

Air consumption in steady state In addition to that of the positioner:'Off' � 60 ln/h · 'On' � 10 ln/h 1)

Closing time forrated travel andsignal pressurerange (KVS 0.14)

Type 3277 Actuator 120 cm² 240 cm² 350 cm² 700 cm²

0.2 to 1 bar � 0.5 s � 0.8 s � 1.1 s � 4 s

0.4 to 2 bar � 0.5 s � 2 s � 2.5 s � 8 s

0.6 to 3 bar 6) � 1 s � 1.5 s � 5 s

Analog position transmitter

Output signal Two-wire circuit 4 to 20 mA

Auxiliary power Min. terminal voltage:12 V, max.: 45 V

The position transmitter must onlybe connected to a certifiedinstrinsically safe circuit 5)

1) With lowest setting of pressure regulator2) The limits of the EC-Type Examination Certificate additionally apply3) DC voltage at –25 °C4) DC voltage at +80 °C5) e.g. using a SAMSOMATIC Type 994-0103-KFD2-STC4-Ex1 Loop Isolator6) Actuator 120 cm² in all signal pressure ranges: � 0.5 s

2 Attachment to control valve

The positioner is attached either directly toSAMSON Type 3277 Actuator or to valveswith cast yokes or with rod-type yokes in ac-cordance with IEC 60534-6-1 (NAMUR).

When combined with an intermediate piece,the device can also be attached to rotary ac-tuators as a rotary positioner.

As the positioner is also available as a basicunit without accessory equipment, refer tothe tables on the following pages for boththe required mounting parts and their asso-ciated order numbers.

Do not remove the protective cover on theback of the positioner before actually start-ing to attach the positioner.

Mounting position and operating direction

The operating direction of the positioneralso determines its mounting position on theactuator as illustrated in Figs. 3, 4 and 6.

The turnboard (7 in Fig. 2) at the positionermust be mounted correspondingly.

For an increasing input signal (referencevariable), the signal pressure pst can eitherbe increasing (direct action >>) or decreas-ing (reverse action <>).

This also applies when the reference vari-able decreases: direct action >> causes thesignal pressure to decrease, reverse action<> causes the signal pressure to increase.

On the turnboard (7), the operating direc-tion is indicated by symbols (direct >>, re-verse <>).

Depending on the position of the turnboard,the adjusted operating direction and the as-sociated symbol become visible.

If the required operating direction does notcorrespond to the visible symbol, or if youwant to change the operating direction, re-move the fastening screw at the turnboard,turn the board by 180° and refasten theturnboard with the screw. Make sure thethree rubber gaskets inserted in the housingremain in position.

NOTICEWhen any subsequent changes are made,e.g. reversing the operating direction of thepositioner control loop or changing the actu-ator from “Actuator stem extends” to “Actu-ator stem retracts” or vice versa, thepositioner's mounting position must bechanged accordingly.

2.1 Direct attachment to Type3277 Actuator

Required accessories are listed in Tables 1to 4 on page 14.

The attachment of the positioner either onthe left or right side of the actuator (alwayslooking at the signal pressure connection orswitchover plate) is determined by the re-quired operating direction of the positioner,i.e. >> or <>.

1. Screw the clamp (1.2) to the actuatorstem. Make sure that the fastening screwis located in the groove of the actuatorstem.

10 EB 8355-1 EN

Attachment to control valve

EB 8355-1 EN 11


Fig. 3 · Mounting position and connections of Type 3277 (top) and Type 3277-5 120 cm2 (bottom) Actuators

Actuator stem extends

Actuator stem retracts

Internal signal pressureconnection

Connection block

Tip of gasket (16)

Op. direction >>Attachment left

Signal pressure connectionover piping

With gasket (new) With switch plate (old)

Side view ofconnection block

Cover plate

Actuator stem extends

Actuator stem retracts

Marking

Gasket (16)

Switch plate (13)

Switchover plate Signal pressure inputfor attachment

Symbol

Marking

Signal pressureinput for attach-ment left

Sealwith filter

Actuator stem extends>> Operating direction <>

Attachment left Attachment right

Actuator stem retracts<> Operating direction >>


Operatingdirection >>Attachment right

Op. direction <>Attachment left

Op. direction <>Attachment right

2. Screw the associated lever D1 or D2 (for700 cm² actuator) to the pick-up lever ofthe positioner.

3. Fasten the distance plate (15) with theseal pointing towards the actuator yoke.

4. Attach the positioner such that the leverD1 or D2 slides centrically over the pin(1.1) of the clamp (1.2). Screw thepositioner to the distance plate (15).

5. Mount the cover (16).6. Check whether the correct measuring

spring has been installed as listed in Ta-ble 4.Range spring 1 is installed as standard.If necessary, replace it with range spring2 included in the accessories and fix it atthe outer slot.

Actuators with 240, 350 and 700 cm² di-aphragm area

7. Make sure that the tip of the gasket (16)projecting from the side of the connec-tion block (Fig. 3, middle) is positionedto match the actuator symbol that corre-sponds to the actuator's fail-safe action"Actuator stem extends" or "Actuatorstem retracts."If necessary, remove the three fixingscrews and the cover. Reposition thegasket (16) turned by 180°.The old connection block version re-quires the switch plate (13) to be turnedsuch that the corresponding actuatorsymbol points to the marking.

8. Place the connection block with its sealson the positioner and the actuator yokeand screw tight using the fastening

screw.Actuators with "Actuator stem retracts"require the ready-made signal pressureline to be installed.

Actuators with 120 cm² diaphragm area

The signal pressure is transmitted to the dia-phragm chamber over the switchover plate(Figs. 3 and 4, bottom).

7. Remove the screw in the rear cover ofthe positioner (Fig. 5) and seal the sidesignal pressure output with the plug con-tained in the accessories kit.

8. Mount the positioner such that the borein the distance plate (15) mates with theseal in the bore of the actuator yoke.

9. Align the switchover plate with the corre-sponding symbol and fasten it to the ac-tuator yoke.

NOTICEWhen a solenoid valve or a similar device isattached to the 120 cm² actuator in additionto the positioner, do not remove the rear M3screw plug. In this case, the signal pressuremust be transmitted from the signal pressureoutput to the actuator over an additionalconnecting plate (Table 2). The switchoverplate (Figs. 3 and 4) is not used.

Filling the actuator with air

If the spring chamber of the actuator mustbe filled with the positioner's exhaust air,use piping (Table 3) to connect the springchamber (with version "Actuator stem ex-tends") to the connection block. To do so, re-move the plug from the connection block.

12 EB 8355-1 EN


For version "Actuator stem retracts" andType 3277-5 Actuators with an effective di-aphragm area of 120 cm², an internal borehole ensures that the spring chamber is filledwith air.

NOTICEWhen the valve is installed, the side cover ofthe actuator must be mounted such that thevent plug points downward.

EB 8355-1 EN 13


1.2

D2

D1

15

Fig. 4 · Mounting the clamp

Type 3277with 240, 350or 700 cm²

Type 3277-5with 120 cm²

Vent plug

Cover

Vent plug must pointdownward when valve isinstalled

Switchover plate

Distance plate (15)

Clamp (1.2)

Signal pressure bore

Attachment left Attachment rightLooking onto the signal pressure connection

14 EB 8355-1 EN


Table 1 Mounting kit

Required lever with associated clamp and distance plate Actuator size [cm²] Order no.

D1 with vent plug for output (38)Connecting thread

G ¼¼ NPT

1201400-67901400-6791

D1 (33 mm long with 17-mm-high clamp) 240 and 350 1400-6370

D2 (44 mm long with 13-mm-high clamp) 700 1400-6371

Table 2 Order no.

Swichover plate for actuators 120 cm² Actuator 3277-5xxxxxx.00 (old) 1400-6819

Swichover plate new Actuator 3277-5xxxxxx.01 or higher (new) 1400-6822

Connecting plate for additional attachment of,e.g. a solenoid valve

Actuator 3277-5xxxxxx.00 (old), G 18

Actuator 3277-5xxxxxx.00 (old), 18 NPT

1400-68201400-6821

Connecting plate new Actuator 3277-5xxxxxx.01 or higher (new) 1400-6823

Note! Only the new switchover and connecting plates can be used for new actuators (model index 01). Old and newplates cannot be interchanged.

Connection block required for actuators with 240, 350 and 700 cm2

diaphragm area (including seals and fastening screw)G ¼ 1400-8819

¼ NPT 1400-8812

Table 3 Material Actuator size [cm²] Order no.

Piping requiredincluding screw fitting

For actuator:“Actuator stem retracts“orwhen the top diaphragm case is filled with ex-haust air from the positioner

Steel240

1400-6444

Stainless steel 1400-6445

Steel350

1400-6446


Steel700

1400-6448


Table 4 · Range spring required Travel [mm] Actuator size [cm²] Order no.

2 (4.5 coils) 7.5 120, 240 1400-6443

1 (9.5 coils, installed as standard) 10 to 15 120, 240 and 350 1400-6442

2 15 700 1400-6443

1 30 700 1400-6442

Accessories Order no.

Pressure gauge build-on block (only for 120 cm2) G ¼ 1400-7458

¼ NPT 1400-7459

Pressure gauge kit for supply pressure and signal pressure Stainl. steel/Brass 1400-6950

Stainl. steel/St. steel 1400-6951

Filter check valve, replaces the vent plug and increases the degree of protection to IP 65 1790-7408

Assortment of spare parts including seals and diaphragms 1400-9895

2.2 Attachment according toIEC 60534-6

Note: Required mounting parts are listed inTable 5. The rated travel of the valve deter-mines which lever and range spring (Table 6)are required.

An adapter housing (Fig. 7) is required forNAMUR attachment. The valve travel istransmitted over the lever (18) and shaft(25) to the bracket (28) of the adapter hous-ing and then passed on to the pin (27a) lo-cated on the positioner lever.Fix the spring included in the accessories atthe back of the positioner housing as illus-trated in Fig. 5 to ensure that the pin (27a)is properly located in the bracket (28).

The positioner can be attached either to theleft or the right of the control valve (Figs. 6and 7). Turn the positioner at the adapterhousing by 180° to set or change the oper-ating direction of the positioner/controlvalve unit.

EB 8355-1 EN 15


Fig. 5 · Installing the spring on the back of thehousing

Spring Plug screw

20

20


Mounting position on the plate looking onto the travel pick-up (20), actuator facing upward (see also Fig. 7)

Actuator with fail-safe action “Actuator stem extends” (FA)

Direct op. direction >> Reverse op. direction <> Direct op. direction >> Reverse op. direction <>

Actuator with fail-safe action “Actuator stem retracts” (FE)

Direct op. direction >> Reverse op. direction <> Direct op. direction >> Reverse op. direction <>

Fig. 6 · Attachment to the left or right of the valve when NAMUR attachment is used

Input

Input Output and supplyOutput and supply

InputOutput and supply

2.2.1 Mounting sequence

Choose the required mounting parts andrange spring from Table 4 or 5 and installthem as illustrated in Fig. 7.

Control valve with cast yoke

1. Screw the plate (20) to the stem connec-tor connecting the actuator and plugstems using countersunk screws.For 2100 and 2800 cm² actuators, usean additional mounting bracket (32).

2. Remove the rubber plug from inside theadapter housing. Fasten the housing tothe left or right side of the NAMUR rib(as shown in Fig. 6) using a hexagonscrew.

Control valve with rod-type yoke

1. Screw the plate (20) to the followerclamp of the plug stem.

2. Screw the studs (29) into the adapterhousing.

3. Place the housing with the mountingplate (30) on either the right or left side(Fig. 6) of the plug stem and fasten itwith the nuts (31). Make sure that the le-ver (18) to be mounted subsequently isin horizontal position when the valve isat mid-travel.

4. Screw the pin (19) into the center row ofholes in the plate (20) and lock it in aposition approximately above the correctlever marking (1 to 2) as in Table 6.

5. Attach the clip (21) to the lever (18). Ifthe actuator is attached with its air con-nection pointing to the front (Fig. 6), the

clip must be attached to the lever (18)with the open side pointing downward.

6. Plug the lever (18) together with theclamping plate (22) on the shaft (25).The clip must clasp the pin (19).

2.2.2 Presetting the travel

1. Move the valve to 50 % travel.2. Adjust the shaft (25) in the adapter

housing such that the black pointer (24)matches the cast mark on the adapterhousing.

3. Fasten the clamp (22) tightly in this posi-tion using the screw (23).

4. Screw in the pin (27a) at the positionerlever on the side of the insert nut and se-cure it with a hex nut (27b) on the oppo-site side. Observe the mounting positionA or B according to Table 6 and Fig. 7.

5. Place the positioner on the adapterhousing, observing the operating direc-tion. Make sure that the pin (27a) restsagainst the bracket (28) and screw ittight.

CAUTION!The pin must not slip out of the bracket onceit has been installed.

6. Hang the required range spring (Table6) between the diaphragm lever (3) andspan adjuster screw (6.1) using the outerslot.

7. Adjust positioner as described in section4.1.

16 EB 8355-1 EN


EB 8355-1 EN 17


21,51

24 25 22

32

31

20 19

19 21 2023 18

2930

2826

A B27b

27a

Fig. 7 · Attachment according to IEC 60534-6 (NAMUR)

Mounting position

18 Lever N1, N219 Pin20 Plate21 Clip22 Clamping plate23 Screw24 Pointer25 Shaft26 Lever of the positioner27a Pin27b Lock nut28 Bracket29 Studs30 Plate31 Nuts32 Mounting bracket

Attachment toNAMUR rib

Attachment torod-type yoke

18 EB 8355-1 EN


Table 5 Control valve Travel [mm] With lever Order no.

NAMUR mounting kit

Refer to Fig. 7concerning parts

Valve with cast yoke 7.5 to 60 N1 (125 mm) 1400-6787

22.5 to 120 N2 (212 mm) 1400-6789

Valve withrod-type yoke,rod diameter

[mm]

20 to 25 N1 1400-6436

20 to 25 N2 1400-6437

25 to 30 N1 1400-6438

25 to 30 N2 1400-6439

30 to 35 N1 1400-6440

30 to 35 N2 1400-6441

Attachment to Fisher and Masoneilan linear actuators(one each of both mounting kits is required per actuator)

1400-6771and

1400-6787

Additional range spring acc. to Table 6 Range spring 1 (9.5 coils, installed as standard)Range spring 2 (4.5 coils)

1400-64421400-6443


Pressure gauge build-on block G ¼ 1400-7458

¼ NPT 1400-7459

Pressure gauge kit Stainless steel/Brass 1400-6950

Stainless steel/Stainless steel 1400-6951



Table 6

Travel [mm]* 7.5 15 15 30 30 60 30 60 60 120

Pin on marking* 1 2 1 2 1 2 1 2 1 2

Distance pin/fulcrum of the lever 42 to 84 mm 84 to 168 mm

With lever N1 (125 mm long) N2 (212 mm long)

Pin (27a) on position A A B A B

Range spring required (see Table 5) 2 1 1 1 1

* Intermediate values must be interpolated

2.3 Attachment to rotaryactuators

The positioner can also be attached to rotaryactuators according to VDI/VDE 3845 whenthe mounting kits and accessories listed inTable 7 are used.

The rotary motion of these actuators is con-verted into a linear motion required by thepneumatic control unit of the positioner us-ing the cam disk of the actuator shaft and acam follower roll on the positioner lever.

EB 8355-1 EN 19


Table 7 · Complete mounting parts, including range spring 2, but excluding the cam disk Order no.

Attachment acc. to VDI/VDE 3845, level 1 1400-8815

SAMSON Type 3278 Actuator 160 cm² 1400-7103

VETEC Type S 320 cm² 1400-7104

VETEC Type R R 100 to R 250 1400-7117

Attachment to Masoneilan actuators Camflex I, DN 25 to 100 1400-7118

Camflex I, DN 125 to 250 1400-7119

Camflex II 1400-7120

Range spring required Order no.

Standard operation of reference variable, range spring 2 (4.5 coils) 1400-6443

Split-range operation, range spring 1 (9.5 coils, installed as standard) 1400-6442

Cam disk with accessories Order no.

Linear basic characteristic 3) (0050-0072), op. angle 0 to 70°, also for Type 3310 1400-6664

Equal percentage basic characteristic 3 (0050-0073), opening angle 0 to 90° 1400-6665

Linear 1) (0050-0080), op. angle 0 to 70°, for control butterfly valves 1400-6774

Equal percentage 2) (0050-0081), op. angle 0 to 70°, for control butterfly valves 1400-6775

Linear 1) (0050-0074, VETEC), opening angle 0 to 75° 1400-6666

Equal percentage 2) (0050-0075, VETEC), opening angle 0 to 75° 1400-6667

Linear 1) (0059-0007, Camflex) set to between 0 and 55° 1400-6637

Equal percentage 2) (0059-0008, Camflex) set to between 0 and 55° 1400-66381) Linearizes the flow characteristic 2) Creates an equal percentage flow characteristic 3) Based on opening angle


Pressure gauge build-on block G ¼ 1400-7458

¼ NPT 1400-7459

Pressure gauge kit St. steel/Brass 1400-6950

St. steel/St. steel 1400-6951



NOTICEUse the correct range spring (1 or 2)!Range spring 1 is installed as standard.

Double-acting springless rotary actuators re-quire the use of a reversing amplifier on theconnection side of the positioner housing(see section 2.3.4).

When using a reversing amplifier, the pres-sure regulator (9, Fig. 2) must be turnedclockwise as far as it will go (also see sec-tion 3.1.2).

When attaching the positioner to theSAMSON Type 3278 Rotary Actuator(Fig. 8, left), the actuator's inside and theunused reverse side of the diaphragm arefilled with the positioner's exhaust air. Addi-tional piping is not required. When attach-ing the positioner to actuators from othermanufacturers (Fig. 8, right), the reverseside of the diaphragm can be filled with airover a pipe connection installed between theactuator and the intermediate piece.

2.3.1 Mounting the cam followerlever

1. Place the lever with the cam follower roll(35) on the side of the feedback lever(37) opposite the insert nuts. Fasten withthe supplied screws (38) and washers.

NOTICETo ensure a close physical contact betweenthe cam follower roll and the cam disk, fixthe spring contained in the accessories kit

(order no. 1400-6660) at the back of thepositioner housing (see Fig. 5).

2.3.2 Mounting the intermediatepiece

SAMSON Type 3278 Actuator

1. Screw the adapter (36) to the free end ofthe actuator shaft.

2. Attach the intermediate piece (34) to theactuator housing using two screws.Align the intermediate piece to ensurethat the air connections of the positionerpoint towards the diaphragm housing.

3. Align the cam disk (40) and scale (39)as described in section 2.3.3 and fastenwith screws.

Actuators according to VDI/VDE 3845

(fixing level 1)

1. Place the complete intermediate piece(34, 44, 45 and 42) onto the mountingbracket that came with the actuator andfasten with screws.

2. Align the cam disk (40) and scale (39)as described in section 2.3.3 and fastenwith screws.

20 EB 8355-1 EN


EB 8355-1 EN 21


33

3835

39

39

40

34

36

40

34

44

45

42

43

37

Fig. 8 · Attachment to rotary actuators

Attachment to SAMSONType 3278

Attachment acc. toVDI/VDE 3845

Vent plug orfilter check valve

33 Positioner34 Intermediate piece35 Lever with cam follower roll36 Adapter37 Feedback lever38 Screws39 Scale40 Cam disk41 Actuator shaft42 Plate43 Mounting bracket44 Coupling45 Seal

2.3.3 Default setting of the camdisk

The valve model used determines the defaultsetting of the cam disk.

NOTICECam disks tailored to the special character-istic of a valve cause the valve to open in anon-linear or non-equal percentage way.The visible difference between the set point(4 to 20 mA) and the actual value (openingangle) does not constitute a system deviationof the positioner.

Figs. 9 and 10 show linear cam disks.

Fig. 9 illustrates a control valve assemblywith a spring-loaded rotary actuator thatopens counterclockwise. The arrangement ofthe springs in the actuator determines thefail-safe position of the valve.

Fig. 10 shows how to adjust the cam diskwhen a double-acting springless rotary actu-ator is used. The direction of rotation, eithercounterclockwise or clockwise, depends onthe actuator and valve model used. The camdisk must be set when the valve is closed.

Use the turnboard (7) to adjust the operatingdirection of the positioner, i.e. whether thevalve opens or closes when the referencevariable increases (direct >> or reverse <>).

Each cam disk carries two cam sectionswhose starting points are indicated by smallbores. Depending on the operating directionof the rotary actuator – signal pressureopens or closes the valve – the starting pointof the cam, either marked N (standard char-acteristic) or I (reverse characteristic), must

point towards the cam follower roll. Whenthe starting point is located on the back ofthe cam disk, turn over the cam disk.

NOTICEThe starting point (bore) of the selected camsection must be aligned with the fulcrum ofthe cam disk, the 0° position of the scale,and the arrow symbol on the inspectionglass.

When aligning the cam disk, the double-sided scale disk must be clipped on the camdisk such that the value on the scale corre-sponds to the control valve's direction of ro-tation.

NOTICEMake sure the 0° position of the scale al-ways corresponds to CLOSED position.For actuators with fail-safe position "ValveOPEN" and for springless actuators, it istherefore necessary to apply the maximumsupply pressure to the actuator before align-ing the cam disk.

22 EB 8355-1 EN


EB 8355-1 EN 23


90˚60˚

30˚ 0˚

90˚60˚

30˚ 0˚

90˚60˚

30˚ 0˚

90˚60˚

30˚ 0˚

Cam follower rollStarting point I

Starting point N

Position at max. signal pressure

Starting point IStarting point NHoles to securethe cam disk

Insert clip and presstongue outwards

Cam follower roll

Single-acting spring-loaded rotary actuatorLinear cam disk (equal percentage cam disk is represented by a broken and dotted line)Valve opens counterclockwiseFor valves that open clockwise, the cam disk must be turned over so that the cam follower roll movesover the same disk segments as shown in the figures below, but with the cam disk turning clockwise.

Fail-safe position: Valve CLOSED without supply air

Direct operating direction >> Reversible operating direction <>

Referencevariable

Signalpressure

Valve Charact-eristic

Referencevariable

Signalpressure


increases increases opens N decreases increases opens I

Fail-safe position: Valve OPEN without supply air


Referencevariable

Signalpressure


Referencevariable

Signalpressure


decreases decreases opens I increases decreases opens N

Fig. 9 · Setting the cam disk for single-acting rotary actuators

24 EB 8355-1 EN


90˚60˚

30˚ 0˚

90˚60˚

30˚ 0˚

Cam follower rollStarting point N

Starting point I

Insert clip and press tongue out-wards

0˚

90˚

60˚

30˚0˚

90˚

60˚

30˚

Starting point ICam follower rollStarting point N

Double-acting springless rotary actuator with reversing amplifierLinear cam disk (equal percentage cam disk is represented by a broken and dotted line)

View from the positioner onto the actuator shaftValve opens counterclockwise – Starting position: valve CLOSED


Referencevariable

Signalpressure


Referencevariable

Signalpressure


increases A1 increases,A2 decreases

opens N decreases A1 increases,A2 decreases

opens I

View from the positioner onto the actuator shaftValve opens clockwise – Starting position: valve CLOSED


Referencevariable

Signalpressure


Referencevariable

Signalpressure


increases A1 increases,A2 decreases

opens N decreases A1 increases,A2 decreases

opens I

Fig. 10 · Setting the cam disk for double-acting actuators

Holes to securethe cam disk

Securing the aligned cam disk

To additionally prevent the cam disk frombeing turned, drill a hole into the adapter(36) or the coupling (44) and install a 2 mmdowel pin.

Four bore holes are located centricallyaround the center hole on the cam disk. Se-lect a suitable hole to install the pin.

EB 8355-1 EN 25


2.3.4 Reversing amplifier fordouble-acting actuators

For the use with double-acting actuators, thepositioner must be fitted with a reversingamplifier.

Type 3710

Refer to the Mounting and Operating In-structions EB 8392 EN for the mounting ofthe SAMSON Type 3710 Reversing Ampli-fier.

1079-1118 or 1079-1119

If a different reversing amplifier (item no.1079-1118 or 1079-1119) is used, followthe mounting instructions described below:

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.

On using the reversing amplifier, make surethat the adjuster of the pressure regulator (9in Fig. 2) is turned as far as it will go in theclockwise direction. Refer also to section3.1.2.

Mounting

Note: Remove the sealing plug (1.5) beforeinstalling the reversing amplifier. The rubberseal (1.4) must remain installed.

1. Thread the special nuts (1.3) from theaccessories of the reversing amplifierinto the threaded holes of the positioner.

2. Insert the gasket (1.2) into the recess ofthe reversing amplifier and push boththe special hollow screws (1.1) into theconnecting boreholes A1 and Z.

3. Place the reversing amplifier onto thepositioner and screw tight using both thespecial screws (1.1).

Signal pressure connections

A1: Connect output A1 to the signal pressureconnection on the actuator that opens thevalve when the pressure increases.

A2: Connect output A2 to the signal pressureconnection on the actuator that closes thevalve when the pressure increases.

Pressure gauge attachment

The mounting sequence shown in Fig. 11 re-mains unchanged. Screw a pressure gaugebracket onto the connections A1 and Z.

Pressure gauge G ¼ 1400-7106bracket: ¼ NPT 1400-7107

Pressure gauges for supply air Z and outputA1 as listed in Tables 4, 5 and 7.

26 EB 8355-1 EN


EB 8355-1 EN 27


1.3 1.2 1.1 1

Out

put 3

8Su

pply

9

A1

1.5 1.6

Z

A2

1.4A1 A2

Output 38 Supply 9

1.3 1.21.1

1.6

Z

A1

Fig. 11 · Mounting a reversing amplifier

From the positioner

1 Reversing amplifier1.1 Special screws1.2 Gasket1.3 Special nuts1.4 Rubber seal1.5 Sealing plug

Control signals tothe actuator

3 Connections

3.1 Pneumatic connections

The pneumatic connections are designed astapped holes with ¼ NPT or G ¼ thread.The conventional male connections for metaland copper pipes (or plastic hoses) can beused.

NOTICEThe supply air must be dry and free of anyoil and dust.Always observe the maintenance instructionsapplicable to the connected pressure reduc-ing stations. Blow out air lines thoroughlybefore connecting them.

When attaching the Type 3277 Actuator di-rectly, the signal pressure connection isfixed. When using NAMUR attachment, thesignal pressure line is connected to either theupper or lower diaphragm chamber of theactuator depending on the actuator'sfail-safe action, i.e. "Actuator stem retracts"or "Actuator stem extends".

Exhaust air

Positioners with model index 3766-x...x.03or higher are equipped with a hinged coverwithout a vent connection. The required ex-haust air connection for these models arenow included in the mounting accessories.

For direct positioner attachment, the ventplug is located on the plastic cover of the ac-tuator; for NAMUR attachment, it is locatedon the adapter housing, and for attachmentto rotary actuators the vent plug can be

found on the intermediate piece or the re-versing amplifier.

Note: When using older models with index3766-x...x. 02 or lower, mounting parts willhave to be replaced as well.

3.1.1 Pressure gauge

To monitor the positioner, we recommend toinstall pressure gauges for the supply airand the signal pressure.

The required parts are listed as accessoriesin Tables 4, 5 or 7.

3.1.2 Supply pressure

The required supply pressure is determinedby the bench range and the operating direc-tion (fail-safe action) of the actuator.

The bench range is written on the nameplateas spring range or signal pressure rangedepending on the type of actuator. FA (actu-ator stem extends) or FE (actuator stem re-tracts) or a symbol indicates the operatingdirection.

Actuator stem extends (FA):Fail-safe position "Valve CLOSED"(for globe and angle valves)

Required supply pressure =Upper bench range value + 0.2 bar,minimum 1.4 bar.

28 EB 8355-1 EN

Connections

Actuator stem retracts (FE):Fail-safe position "Valve OPEN"(for globe and angle valves)

The required supply pressure for atight-closing valve is roughly estimated fromthe maximum signal pressure pstmax:

pstmax = F + d pA

² � �

�

� �

4[bar]

d = Seat diameter [cm]�p = Differential pressure at the valve [bar]A = Actuator diaphragm area [cm²]F = Upper range value of the actuator

In the absence of such specifications, pro-ceed as follows:

Required supply pressure =Upper bench range value + 1 bar

Pressure regulator

After tilting the cover plate back, the pres-sure regulator (9) can be continuously ad-justed. When the adjuster is turned counter-clockwise as far as it will go, signal pres-sures for spring ranges up to 2.5 bar arecontrolled. When the adjuster is turnedclockwise all the way, signal pressures forspring ranges up to 6.0 bar are controlled.

If the signal pressure must not exceed a cer-tain value, this limit can be adjusted using apressure gauge (accessories).

3.2 Electrical connections

DANGER!Risk of electric shock and/or theformation of an explosive atmo-sphere!

– For electrical installation, observe the rel-evant electrotechnical regulations andthe accident prevention regulations thatapply in the country of use.

– The following regulations apply tomounting and installation in hazardousareas: EN 60079-14: 2008 Explosiveatmospheres – Part 14: Electrical instal-lations design, selection and erection (orVDE 0165 Part 1).

NOTICE– Adhere to the terminal assignment!– Switching the assignment of the electrical

terminals may cause the explosion pro-tection to become ineffective!

– Do not loosen enameled screws in or onthe housing.

– The maximum permissible values speci-fied in the national EC type examinationcertificates apply when interconnectingintrinsically safe electrical equipment (Uior Uo; Ii or Io; Pi or Po; Ci or Co, and Li orLo).

Depending on the version use, the positioneris equipped with inductive limit switchesand/or a solenoid valve.

Versions with position transmitter do notpermit the connection of this additionalequipment.

EB 8355-1 EN 29

Connections

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 12 and45 V DC.

For terminal assignment, refer to Fig. 12 orthe label on the terminal strip.

Selecting cables and wires:Observe Clause 12 of EN 60079-14: 2008(VDE 0165 Part 1) when installing intrinsi-cally safe circuits. The Subclause 12.2.2.7applies when running multi-core cables con-taining more than one intrinsically safe cir-cuit.In particular, the radial thickness of the con-ductor insulation for common insulation ma-terials, such as polyethylene, must have aminimum radial thickness of 0.2 mm.The diameter of an individual wire in afine-stranded conductor must not be smallerthan 0.1 mm. Protect the conductor endsagainst splicing, e.g. by using wire-end fer-rules.When two separate cables are used for con-

nection, an additional cable gland can beinstalled.Seal cable entries left unused with plugs.Devices used at ambient temperatures be-low –20 °C must be fitted with metal cableglands.

Equipment for use in zone 2/zone 22

In equipment operated with type of protec-tion Ex nA II (non-sparking equipment) ac-cording to EN 60097-15: 2003, circuitsmay be connected, interrupted or switchedwhile energized only during installation,maintenance or repair.

Equipment connected to energy-limited cir-cuits with type of protection Ex nL (en-ergy-limited equipment) according toEN 60097-15: 2003 may be switched un-der normal operating conditions.

The maximum permissible values specifiedin the Statement of Conformity or its ad-denda apply when interconnecting theequipment with energy-limited circuits intype of protection Ex nL IIC.

30 EB 8355-1 EN

Connections

+41 –42 +51 –52 +81 –82 +31 –32

GEi

+ –

+ –

(B)A

(A)B

A

+11 –12 +11 –12

Ei/Ei/ AA

Fig. 12 · Electrical connections

Switching amplifieracc. to EN 60947-5-6

Voltage supply for transmitter,only for position transmitter

On the rear Version with position transmitter

6 to 24 V DCsolenoid valve

Accessories

Cable gland M20 x 1.5Black plastic Order no. 1400-6985Blue plastic Order no. 1400-6986Nickel-plated brass Order no. 1890-4875Adapter M20 x 1.5 to NPT:Aluminum, powder-coated 0310-2149

3.2.1 Switching amplifier

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 NAMUR.If the positioner is to be installed in hazar-dous areas, the relevant regulations must beobserved.

EB 8355-1 EN 31

Connections

4 Operation

4.1 Setting the positioner at thevalve

Starting point and reference variable

When adjusting the positioner directly at thecontrol valve, the travel (opening angle)must be adapted to the reference variable.

With a reference variable, for example, 4 to20 mA, the valve must pass through its en-tire travel range from 0 to 100 % (Fig. 13,left).

For rotary positioners, an opening angle, forexample, 0 to 70° must be assigned to thereference variable.

The starting point refers to CLOSED positionof the valve.

Depending on the actuator version (Actuatorstem extends or Actuator stem retracts) andthe operating direction of the positioner (>>or <>), this starting point can be representedby either the lower or upper range value(0.2 or 1 bar) of the reference variable.

The reference variable range and thus theupper range value determine the travel ofthe valve.

In split-range operation (Fig. 13, bottom),the control valves operate on smaller refer-ence variables. The controller output signalis used to control two control valves, divid-ing it such that the valves pass through theirentire travel range at half the input signalrange each (e.g. first valve set to 0.2 to0.6 bar, second valve set to 0.6 to 1 bar).To avoid overlapping, allow for a deadband of �0.05 bar as shown in Fig. 13.

The starting point (zero) is adjusted at thezero adjuster screw (6.2); the span, i.e. theupper range value, is adjusted at the spanadjuster screw (6.1).

When adjusting, connect a suitable pressureadjuster to the signal input and apply supplypressure to the supply air input.

32 EB 8355-1 EN

Operation

100%

0%

0.2 1 bar0.6

0.2 1 bar

100%

0%

< > < <

< > < <

Fig. 13 · Normal and split-range operation

Open

Travel

Closed

Open

Travel

Closed

Valve 2 Valve 1

Dead band

Reference variableInput signal

4.1.1 Adjusting the proportionalband Xp and air delivery Q

1. Close the volume restriction Q (11) asfar as the required positioning speedpermits.To check, push the diaphragm lever (3)as far it will go.

2. Adjust the reference variable at the inputto approx. 50 % of its range.

3. Turn the zero adjuster (6.2) until thevalve has reached approx. mid-travel.

4. Use the adjuster (8) to set the propor-tional band Xp to a medium value (½turn).

5. Check the valve's tendency to hunt andthe positioning speed by briefly tappingthe diaphragm lever (3).The Xp value is to be adjusted to be assmall as possible, without considerableovershooting occurring.

Note: Always adjust the Xp restriction be-fore setting the starting point.Later modifications shift the zero point!

4.1.2 Settings for actuator:"Actuator stem extends"

NOTICETo ensure that the valve can be closed withfull force, fully vent the diaphragm chamberwhen the reference variable reaches itslower (operating direction <<) and upper(operating direction <>) value.As a result, adjust the input signal to aslightly increased starting point of 0.23 barfor direct operating direction <<; for reverseoperating direction <>, adjust the input sig-nal to a slightly reduced starting point of0.97 bar.

Starting point (e.g. 0.23 bar)

1. Use the pressure adjuster to set the inputsignal to 0.2 bar.

2. Turn the zero adjuster (6.2) until thevalve just starts to move from its initialposition.

3. Shut off the input signal and slowly in-crease it again. Check whether the valvestarts to move at exactly 0.23 bar.Correct any deviation at the zero ad-juster (6.2).

Upper range value (e.g. 1 bar)

1. Once the starting point has been set, in-crease the input signal to 1 bar using thepressure adjuster.

At exactly 1 bar, the plug stem must standstill, having passed through 100 % travel(watch the travel indicator at the valve).

EB 8355-1 EN 33

Operation

If the upper range value is incorrect, turn thespan adjuster (travel). Four turns correspondto a travel change of 10 % in standard oper-ation. In split-range operation, this value isreduced by half.

Turn the adjuster clockwise to reduce thetravel and counterclockwise to increase it.

2. After correction has been completed,shut off the input signal and slowly in-crease it again. Check the starting pointand the upper range value. Repeat thecorrection procedure until both valuesare correct.

4.1.3 Settings for actuator:"Actuator stem retracts"

NOTICEWhen using an actuator with fail-safe ac-tion"Actuator stem retracts", the diaphragmchamber must be pressurized with a signalpressure that suffices to tightly close thevalve even when an upstream pressure isapplied in the plant. This applies to an up-per range value of the reference variable(1 bar) and operating direction >> as wellas a lower range value of the reference vari-able (0.2 bar) and operating direction <>.

The required signal pressure is either indi-cated on the positioner label or can beroughly calculated as described in section3.1.2.

Starting point (e.g. 1 bar)

1. Use the pressure adjuster to set the inputsignal to 1 bar.

2. Turn the zero adjuster (6.2) until thevalve just starts to move from its initialposition.

3. Increase the input signal and slowly re-duce it to 1 bar again. Check whetherthe valve start to move at exactly 1 bar.

4. Correct any deviation on the zeroadjuster (6.2). Turning the adjustercounterclockwise causes the valve tomove from its end position earlier; turn-ing clockwise causes the valve to movefrom its end position later.

Upper range value (e.g. 0.2 bar)

1. Once the starting point has been set, ad-just the control signal to 0.2 bar usingthe pressure adjuster. At exactly 0.2 bar,the plug stem must stand still, havingpassed through 100 % travel (watch thetravel indicator at the valve).

2. If the upper range value is incorrect, turnthe span adjuster (travel). Four turns cor-respond to a travel change of 10 % instandard operation. In split-range oper-ation, this value is reduced by half.Turn the adjuster clockwise to reduce thetravel and counterclockwise to increaseit.

3. After correction has been completed, re-set the control signal to 1 bar.

4. Turn the zero adjuster (6.2) again untilthe pressure gauge indicates the re-quired signal pressure (see sec-tion 3.1.2).

34 EB 8355-1 EN

Operation

If no pressure gauge is available, set thestarting point to 0.97 bar instead.

NOTICEAfter attaching and calibrating thepositioner, make sure that the vent plug onthe housing cover points downward whenthe valve is installed in the plant.

4.2 Changing the operatingdirection

If you want to change the operating direc-tion of directly attached positioners (Fig. 3)after they have been installed, turn theturnboard (7) and change the position of theconnection block, of the positioner, and ofthe clamp (1.2).

For attachment according to IEC 60534-6(NAMUR), turn the turnboard (7) and thepositioner on the adapter housing (Fig. 6).

For positioners for rotary actuators, reassignthe cam disk as shown in Figs. 9 and 10.

For details on changing the turnboard (7),refer to section 2.

EB 8355-1 EN 35

Operation

4.3 Adjusting the limit switches

The positioner version with inductive limitswitches has two adjustable tags mountedon a rotary axis which operate the associ-ated proximity switches (50).

To operate the inductive limit switches, con-nect the corresponding switching amplifiersin the output circuit (see section 3.2.1).

When the tag (51) is inside the inductivefield of the switch, the switch assumes a highresistance. When the tag is outside the field,the switch assumes a low resistance.

The limit switches are usually adjusted to is-sue a signal for both end positions. Never-theless, they can also be set to signalize in-termediate positions.

The switches A and B must be assigned tothe end positions of the control valve (valveOPEN or CLOSED) depending on the oper-ating direction and the mounting positionaccording to Tables 8 and 9.

The terminals 41/42 and 51/52 can op-tionally be assigned to the switches A and Bby turning the associated nameplate on theterminal block (also see Fig. 12).

Note: As the tags of the limit switches can-not be turned by 360°, make sure that theswitches A and B are correctly assigned tothe end positions "valve OPEN" and "valveCLOSED", especially when the limit switchesare to be used for fail-safe circuits.

The desired switching function, i.e. whetherthe output relay must be picked up or re-leased when the tag has entered the field,must be determined by means of jumpers foreither working current or closed circuit cur-rent at the switching amplifier.

36 EB 8355-1 EN

Operation

Fig. 14 · Limit switches

Setting the switching point

Move the valve to the switching position andadjust the tag by turning the adjustmentscrew (53) so that the switching point isreached and indicated by the LED on theswitching amplifier.

To ensure safe switching under any condi-tion, the switching point is to be adjusted tostop approx. 2 % before the mechanicalstop (OPEN – CLOSED) is reached.

EB 8355-1 EN 37

Operation

Table 8 Direct attachment to Type 3277 Actuator (Fig. 3)

Left attachment Right attachment

Switch

Valve position Tag OUT Tag IN Tag OUT Tag IN

CLOSED B A A B

OPEN A B B A

Table 9 NAMUR attachment on right or left (Fig. 6) and attachment to rotary actuators (Fig. 8)

Actuator stem extends (FA) Actuator stem retracts (FE)

Operatingdirection

Valveposition

SwitchTag

Operatingdirection

Valveposition

SwitchTag

OUT IN OUT IN

>> CLOSEDOPEN

BA

AB

>> CLOSEDOPEN

AB

BA

<> CLOSEDOPEN

AB

BA

<> CLOSEDOPEN

BA

AB

4.4 Adjusting the positiontransmitter

Note: The starting point (zero) and upperrange value (span) must be set before cali-brating the position transmitter.

Depending on the position of the 4-pin plug(symbol on plug: >> or <>), the feedbacksignal can be set to either a range of 4 to20 mA or 20 to 4 mA for 0 to 100 % travel.

Zero point (ZERO)

Use the switches 1 and 2 to preset the zeropoint and the ZERO potentiometer forfine-tuning. The adjusted value always refersto 4 mA.

Span (SPAN)

Use the switches 3 and 4 to preset the span,i.e. the upper range value, and the SPANpotentiometer for fine-tuning. The adjustedvalue always refers to 20 mA.

Example:Move the valve to open position while ob-serving the position transmitter signal.

If the signal does not move in the desired di-rection, switch over the multi-pin plug.

Adjust the zero point (4 mA) and span(20 mA) for the valve positions according toTable 10.

38 EB 8355-1 EN

Operation

Table 10 Position transmitter

Valve movement Transmitter signal Direction of signal Set zero/span to

OPEN

CLOSED

Current increases

OK 20 mA4 mA

Valve OPENValve CLOSED

Not OKChange plug

4 mA20 mA


Current drops

OK 4 mA20 mA


Not OKChange plug

20 mA4 mA


ZEROSPAN

12

34

SPAN

ZERO

Fig. 15 · Position transmitter

Adjusting the zero point

1. Use the input signal of the positioner tomove the valve to closed position (valveCLOSED – travel 0 %).

2. The ammeter must now indicate approx.4 mA.

3. Correct smaller deviations on the ZEROpotentiometer until the meter shows ex-actly 4 mA.If deviations are too high and cannot becorrected using the potentiometer (ad-justment range of approx. 20 turns), setthe switches 1 and 2 to indicate an mAvalue which is within the adjustmentrange of the ZERO potentiometer.

4. Set the zero point to exactly 4 mA usingthe ZERO potentiometer.

Adjusting the span

1. Use the input signal of the positioner tomove the valve to open position (valveOPEN – travel 100 %).

2. The ammeter must now indicate approx.20 mA.

3. Correct smaller deviations on the SPANpotentiometer until the meter shows ex-actly 20 mA.If deviations are too high, set theswitches 3 and 4 to indicate an mAvalue which is within the adjustmentrange of the SPAN potentiometer.

4. Turn the SPAN potentiometer until themeter shows exactly 20 mA.Since zero and span have a mutual in-fluence on each other, repeat the correc-

tion procedure at both potentiometersuntil both values are correct.

Note on adjusting the position transmitterfor positioners with NAMUR adapter hous-ingWhen the positioner and the position trans-mitter signal have different operating direc-tions (<< and <>), the zero point of thetransmitter signal could be unadjustable dueto the additional deflection caused by thebracket (28 in Fig. 7) of the adapter hous-ing.If so, readjust the black pointer (section2.2.2 on page 16) so that the sensor of theposition transmitter reaches the controlrange.Unscrew the clamp. For “Actuator stem ex-tends” (FA), shift the pointer upward to-wards the actuator; for "Actuator stem re-tracts" (FE), shift the pointer downward to-wards the valve. For valves with rod-typeyoke, slightly shift the positioner on the rodin downward (FE) or upward (FA) direction.

Note: Every time you make a change as de-scribed above, the zero point and span ofthe positioner must be readjusted before cal-ibrating the position transmitter.

EB 8355-1 EN 39

Operation

5 Converting the positioner

The pneumatic positioner (3766-x...x.04and higher) can be converted to form aType 3767 Electropneumatic Positioner.

Note: Conversion of explosion-protectedversions only on request.

Apart from the Type 6112 i/p Module (seeTable 11), the associated conversion kit in-cluding screw gland, fastening screw,clamps and cables must be ordered.

1. Remove the support with the terminalcase (if existing).

2. Unscrew the connecting plate (3) and re-move the silicone hose (2). Remove theguard plate (4) and pneumatic screwgland (1).

3. Connect the connecting cable to the ter-minal base and the i/p module (6). Leadthe blue cable to the minus side and thered cable to the plus side. Fasten the ca-bles with terminal screws.

4. Check that the sealing hoses (7, 8) areproperly inserted on the bottom sectionof the i/p module. When the module isinstalled (broken line in Fig. 16), thesealing hose including restriction and fil-

ter must be located on the right abovethe inner of the two bore holes (supply).

5. Fasten the i/p module and terminal baseusing two screws each.

6. Close the housing on the side using thecable gland (5) or a plug with sealingring.

7. Change model index on the nameplateto Type 3767 i/p Positioner.

40 EB 8355-1 EN

Converting the positioner

Table 11

Required input signal(reference variable)

Required i/p module(order no.)

Required conversion kit(order no.)

4 … 20 mA0 … 20 mA1 … 5 mA

6112-0411106112-0421106112-043110

1400-7574

1 2 3 4

5 6 7 8

Fig. 16 · Converting the positioner

Note: For details on Type 3767 Positioners,refer to Mounting and Operating Instruc-tions EB 8355-2 EN.

EB 8355-1 EN 41

Converting the positioner

6 Service

6.1 Servicing explosion-protecteddevices

If a part of the device on which the explo-sion protection is based needs to be ser-viced, the device must not be put back intooperation until a qualified inspector has as-sessed it according to explosion protectionrequirements, has issued an inspection cer-tificate or given the device a mark of confor-mity.

Inspection by a qualified inspector is not re-quired if the manufacturer performs a rou-tine test on the device prior to putting it backinto operation. The passing of the routinetest must be documented by attaching amark of conformity to the device. Replaceexplosion-protected components only byoriginal, routine-tested components from themanufacturer.

Devices that have already been operatedoutside hazardous areas and are intendedfor future use inside hazardous areas mustcomply with the safety requirements placedon serviced devices. Before being used in-side hazardous areas, test the devices ac-cording to the specifications for servicingexplosion-protected devices.

6.2 Maintenance, calibration andwork on equipment

The interconnection with intrinsically safecircuits to check or calibrate the apparatusmust only be performed with intrinsicallysafe current/voltage calibrators and mea-suring instruments to rule out any damage to

components relevant for explosion protec-tion.

The maximum values for intrinsically safecircuits specified in the approvals must bekept.

42 EB 8355-1 EN

Service

7 Dimensions in mm

EB 8355-1 EN 43

Dimensions in mm

44

19.5

3539

164

4676 50

36N

1=11

3 N

2=20

0

5856

68

28

1429

150

16419.5

37

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5

76

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82

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50

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28.5

28.5

Output 1 (A1)

Output 2 (A2) Supply (Z)

50

Output (38)

Supply (9)Input signal

Pneumatic connectionsG ¼ or ¼ NPT

Attachment with intermediatepiece for rotary actuators

Attachment IEC 60534-6(NAMUR) with adapter housing

Pneum. connectionof reversing amplifierFulcrum of

actuator shaft

Reversing amplifier(optional)

44 EB 8355-1 EN

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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 8355-1 EN 20

11-1

1

Documents

Mounting and Operating Instructions EB 8355-1 EN Positioners and...2 EB 8355-1 EN Safety instructions Safety instructions The positioner is to be mounted, started up or operated only