Mounting and Operating Instructions EB 8355-2 EN · Mounting and Operating Instructions EB 8355-2 EN ... 3 Mounting on control valves ... travel and the nominal span of the reference

Mounting and Operating Instructions

EB 8355-2 EN Edition December 2016

Type 3767 Electropneumatic Positioner

Fig. 1: Type 3767

Definitionofsignalwords

DANGER!Hazardous situations which, if not avoided, will result in death or seri-ous injury

WARNING!Hazardous situations which, if not avoided, could result in death or seri-ous injury

NOTICEProperty damage message or mal-function

Note:Additional information

Tip:Recommended action

2 EB8355-2EN

Contents

EB8355-2EN 3

1 Generalsafetyinstructions.............................................................................52 Designandprincipleofoperation..................................................................62.1 Versions and article code ................................................................................92.2 Technical data .............................................................................................102.3 Additional equipment ...................................................................................112.4 Summary of explosion protection approvals ...................................................123 Mountingoncontrolvalves..........................................................................143.1 DirectattachmenttoType 3277Actuator .......................................................143.2 AttachmentaccordingtoIEC 60534-6 ...........................................................213.2.1 Mounting sequence ......................................................................................223.2.2 Initial adjustment of travel .............................................................................223.3 Attachment to rotary actuators ......................................................................253.3.1 Mounting the lever with feeler roll ..................................................................263.3.2 Mounting the intermediate piece ...................................................................263.3.3 Basic setting of the cam disk .........................................................................283.3.4 Reversingamplifierfordouble-actingactuators ..............................................324 Connections................................................................................................344.1 Pneumatic connections..................................................................................344.1.1 Pressure gauges ...........................................................................................344.1.2 Supply pressure ...........................................................................................344.2 Electrical connections ...................................................................................364.2.1 Switchingamplifier ......................................................................................375 Operation...................................................................................................385.1 Tuningthepositionermountedontothecontrolvalve .......................................385.1.1 AdjustingtheproportionalbandXpandairdeliveryQ ..................................395.1.2 Settingsforactuatorwith“actuatorstemextends”fail-safeaction .....................405.1.3 Settingsforactuatorwith“actuatorstemretracts”fail-safeaction .....................405.2 Changingtheoperatingdirection ..................................................................415.3 Adjustingthelimitcontacts ...........................................................................425.4 Adjustingthepositiontransmitter...................................................................44

4 EB8355-2EN

Contents

6 Convertingandretrofittingthepositioner.....................................................476.1 Convertingfromelectropneumatictopneumatic .............................................476.2 Installingthelimitcontacts ............................................................................486.3 Installingasolenoidvalve .............................................................................486.4 Removingthesolenoidvalve .........................................................................497 Servicingexplosion-protecteddevices..........................................................498 Dimensionsinmm.......................................................................................50

EB8355-2EN 5

Generalsafetyinstructions

1 GeneralsafetyinstructionsFor your own safety, follow these instructions concerning the mounting, start up and opera-tion of the device: − Thedeviceistobemounted,starteduporoperatedonlybytrainedandexperienced

personnel familiar with the product. According to these mounting and operating instruc-tions,trainedpersonnelreferstoindividualswhoareabletojudgetheworktheyareas-signedtoandrecognizepossibledangersduetotheirspecializedtraining,theirknowl-edgeandexperienceaswellastheirknowledgeoftheapplicablestandards.

− Anyhazardsthatcouldbecausedinthevalvebytheprocessmedium,thesignalpres-sureorbymovingpartsaretobepreventedbytakingappropriateprecautions.Ifinadmissiblemotionsorforcesareproducedinthepneumaticactuatorasaresultofthesupplypressurelevel,itmustberestrictedusingasuitablesupplypressurereducingstation.

− Explosion-protectedversionsofthisdevicearetobeoperatedonlybypersonnelwhohasundergonespecialtrainingorinstructionsorwhoisauthorizedtoworkonexplosion-pro-tecteddevicesinhazardousareas.Seesection7.

To avoid damage to any equipment, the following also applies: − Proper shipping and storage are assumed.

Note:Devices with a CE marking fulfill the requirements of the Directives 2014/34/EU and 2014/30/EU. The declaration of conformity is included at the end of these instructions.

6 EB8355-2EN

Designandprincipleofoperation

2 Designandprincipleofoper-ation

The positioner consists of an electropneumat-ic converter and a pneumatic unit equipped withaleverfortravelpick-up,ameasuringdiaphragm, and the pneumatic control system withnozzle,diaphragmlever(flapperplate),andbooster.The positioner is designed either for direct attachmenttoSAMSONType 3277Actuatorsor for attachment to actuators according to NAMUR(IEC 60534-6)usinganadapterhousing.Thepositionercanbeadditionallyequippedwith either inductive limit contacts and/or a solenoid valve or position transmitter.Thecontrolsignal,e.g.4to20 mA,issuedbythe controller is transmitted to the electropneu-maticconverter(13)whereitisconvertedintoa proportional pressure signal pe.The positioner operates according to the force-balanceprinciple.Thevalvetravel,i.e.thevalveposition,istransmittedtothepick-uplever(1)overthepin(1.1)anddeterminestheforceoftherangespring(4).Thisforceiscompared to the positioning force generat-edbythepressurepe at the measuring dia-phragm(5).If either the control signal or the valve posi-tionchanges,thediaphragmlever(3)moves,altering the distance to the nozzle (2.1 or 2.2),dependingontheadjusteddirectionofaction of the positioner.Thesupplyairissuppliedtothebooster(10)andthepressureregulator(9).

ThecontrolledsupplyairflowsthroughtheXp restriction(8)andthenozzle(2.1,2.2)andhitsthediaphragmlever(flapperplate).Anychangeinthereferencevariableorthevalve position causes the pressure to change upstreamordownstreamofthebooster.Theaircontrolledbythebooster(signalpres-sure pst)flowsthroughthevolumerestriction(11)tothepneumaticactuator,causingtheplug stem to move to a position correspond-ingtothereferencevariable.TheadjustableXprestriction(8)andvolumerestriction(11)areusedtooptimizetheposi-tioner control loop.Thepick-uplever(1)andtherangespring(4)mustbeselectedtomatchtheratedvalvetravel and the nominal span of the reference variable.

PositionerwithinductivelimitcontactsIn this version, the rotary shaft of the position-ercarriestwoadjustabletagswhichactuatethebuilt-inproximityswitches.

PositionerwithsolenoidvalveWhen the positioner is equipped with a so-lenoidvalve,thevalvecanbemovedtothefail-safeposition,regardlessoftheposition-er's output signal. If a control signal corre-spondingtothebinarysignal'0'(OFF)isap-plied to the input, the signal pressure pst is shut off and the actuator is vented. The actu-atorspringsmovethevalvetoitsfail-safepo-sition.

EB8355-2EN 7


1 Lever1.1 Pin1.2 Clamp2.1 Nozzle >>2.2 Nozzle <>3 Diaphragm lever4 Range spring5 Measuring

diaphragm6.1 Span adjuster

6.2 Zero adjuster7 Turnboard8 XP restriction9 Pressure regulator10 Booster11 Volume restriction12 Solenoid valve

(option)13 i/p converter

4

13 6.1 6.2

3 7 8 9 11

7 8 9 10 11 12

6.1 4 6.2

2.13

2.2

51

1.1

1.2

Pe

Supply 9

V

PstQXp

pi mA13

Travel

Fig. 2: Functional diagram and inside view

8 EB8355-2EN


When a control signal corresponding to the binarysignal'1'(ON)isappliedtothein-put, the signal pressure pst is applied to the actuator, allowing the valve to move accord-ingtotheinputsignalissuedbythecontrolequipment.

PositionerwithpositiontransmitterA positioner containing a position transmit-tercannotbeequippedwithintegratedlimitcontacts or an integrated solenoid valve since the position transmitter requires most of the space inside.The position transmitter is used to assign the valve position, i.e. the valve travel, to an out-putsignalof4to20 mA.Thetuningofthepositiontransmitterensuresthatbothendpositions "valve CLOSED" or "valve OPEN" aswellasallintermediatepositionscanbesignalized. Since the valve position is signal-ized independently of the input signal to the positioner, the position transmitter is a suit-ableoptionforcheckingtheactualvalvepo-sition.

EB8355-2EN 9


2.1 VersionsandarticlecodeElectropneumaticpositioner Type 3767- x x x 0 1 x x x x x x 0 0 0

Explosion protectionWithout 0 2

II2GEx iaIICT6accordingtoATEX 1CSA/FM intrinsically safe/non incendive 3

II3GExnAIIT6acc.toATEX 8Additional equipmentWithout 0Inductivelimitcontacts2xSJ2-SN 2(Analogpositiontransmitter4to20 mA)1) 6 0 03/2-waysolenoidvalveWithout 06 V DC 212 VDC 324 V DC 4Type of mountingStandard range spring 0 1Pneumatic connections¼-18 NPT 1ISO 221/1-G ¼ 2Electrical connectionsPlasticcableglandM20 x 1.5,blue 1 0PlasticcableglandM20 x 1.5,black 2 0CableglandM20 x 1.5,nickel-platedbrass 2 1Housing versionDie-castaluminum 1CrNiMo steel 2Referencevariable4 to 20 mA 10 to 20 mA 21to 5 mA 3Temperature rangeStandard 0Low-temperatureversion Tmin ≥–45 °C;optionallimitcontacts,solenoidvalve 2 1 2Special versionsWithout 0 0 0

1) AvailableuntilMarch2011

10 EB8355-2EN


2.2 TechnicaldataPositioner

Travelrange,adjustable Directattachment:7.5to30 mmAttachmentaccordingtoIEC 60534-6:7.5to120 mmor

Opening angles 30°to90°dependingonthecamdisk

Referencevariable

Signal range 0/4to20 mA 1to5mA

Span 8 to 20 mA 2 to 4 mA

Coil resistance Riat20 °C 200 Ω 880 Ω

Supply air 1.4to6 bar(20to90 psi)

Air quality acc. toISO 8573-1

Max. particle size and density: Class 4Oilcontent:Class3·Pressuredewpoint:Class3oratleast10 Kbelowthelowest

ambienttemperaturetobeexpected

Signal pressure pst(output) Canbelimitedbetweenapprox.2.5to6.0 bar(38to90 psi)

Characteristic Linearcharacteristic,deviationfromterminal-basedconformity≤1 %

Hysteresis ≤0.3 %

Sensitivity ≤0.1 %

Direction of action Reversible

ProportionalbandXp <1to2.5 %(proportional-actioncoefficientKp:>100to40)

Air consumptionAt1.4barsupplypressure:≤280 ln/h

At6barsupplypressure:≤280 ln/hWith lowest setting of pressure

regulator

Air output capacity Tofillactuatorwithair:3.0mn³/hToventactuator:4.5mn³/h

8.5mn³/h14.0 mn³/h

Permissibleambienttemperature

–20to80 °Cwithplasticcablegland–40to80 °Cwithmetalcablegland(specialversiondownto–45 °C)–20to70 °CwithpositiontransmitterSeetestcertificatesintheappendixforexplosion-protecteddevices

Influences Temperature: ≤0.3 %/10 KSupplyair:≤1 %between1.4and6 barVibration:Nonebetween10and150 Hzand4 g

Explosion protection SeetestcertificateintheappendixfortypeofprotectionEx iaIICT6

Degree of protection IP 54(IP 65andNEMA4Xpossiblebyfittingafiltercheckvalve.Seetableonaccessoriesonpage 19)

Electromagneticcompatibility ComplyingwithEN 61000-6-2,EN 61000-6-3andNAMURRecommendationNE 21

Compliance ·

Weight Approx.1 kg

EB8355-2EN 11


2.3 AdditionalequipmentInductivelimitcontacts

Two proximity switches SJ2-SN

Control circuit Values according to downstream transistor relay

Hysteresis at rated travel ≤1 %

Solenoidvalve

Input Binary DC voltage signal

Nominal signal 6 V DC 12 VDC 24 V DC

Signal'0'(noresponse) DCsignalat–25 °C ≤1.2 V ≤2.4 V ≤4.7 V

Signal'1'(response) DCsignalat80 °C ≥5.4 V ≥9.6 V ≥18 V

Maximumpermissiblesignal 28 V 25 V 32 V

Coil resistance Riat20 °C 2909 Ω 5832 Ω 11714 Ω

Air consumption in steady state In addition to that of the positioner: OFF ≤60 ln/h · ON ≤10 ln/h

Closing time for

Rated travel and signal pressure range(KVS=0.14)

Type 3277Actuator 120 cm² 240 cm² 350/355 cm² 700 cm²

0.2to1 bar

≤0.5s

≤1 s ≤1.5 s ≤4 s

0.4to2 bar ≤2 s ≤2.5 s ≤8 s

0.6to3 bar ≤1 s ≤1.5 s ≤5 s

Positiontransmitter1),2) – Outputcircuit,intrinsicallysafe

Output signal Two-wireconnection4to20 mA,reversibleoperatingdirection

Auxiliary power Minimumterminalvoltage:12 V DCmax.45 V DC Only with intrinsically safe circuit

Characteristic Linear characteristicDeviationfromcharacteristicaccordingtoterminalpointmethod:≤1 %

Hysteresis ≤0.6 %

Response ≤0.1 %

Influenceofpowersupply ≤1 %whenvoltagechangesoccurwithinthespecifiedlimits

High-frequencyinfluence ≤0.1 %,f=150 MHz,1 Wpoweroutputatadistanceof0.5 m

Loadinfluence ≤0.1 %

Permissibleambienttemperature –20to70 °C –20 to à See test certificate

Ambienttemperatureinfluence ≤0.4 %onlowermeasuringrangevalue,≤0.2 %onmeasuringspan

Ripple of output signal ≤0.3 %

1) Databasedonstandardspring(15 mmtravelwithType 3277Actuator)andgainof100.2) AvailableuntilMarch2011

12 EB8355-2EN


2.4 SummaryofexplosionprotectionapprovalsType Certification Typeofprotection

3767 STCC Number No.974 0ExiaIICT6X2ExsIIT6XValid until 2017-10-01

3767-1

No. RUCDE.08.006971ExiaIICT6/T5/T4GbXExtbIIICT80°CDbXDate 2014-12-15

Valid until 2019-12-14

Number 13-KB4BO-0037

ExiaIICT6/T5/T4Date 2013-01-31


No. PTB01ATEX2167

II2GExiaIICT6Date 2001-11-29EC type examination certificate

3767-3

®No. 1607848 Ex iaIICT6:ClassI,Zone0;

Class I, II, Div. 1, Groups A, B, C, D, E, F, D;Class I, II, Div. 2, Groups A, B, C, D, E, F, D;

Date 2005-09-16

No. 3020228 ClassI,Zone0AEx iaIICClass I, II, III, Div. 1, Groups A, B, C, D, E, F, GClassI,Div.2,GroupsA,B,C,D;ClassII,Div.2GroupsF,G;ClassIII;

Date 2005-02-28

3767-6 IECEx No. IECExTSA05.0004X ExiaI/IICT6IP65,ExnI/IICT6IP65Date 2005-05-24

3767-8

No. RUCDE.08.00697

2ExnAicIICT6/T5/T4GcXDate 2014-12-15


Number PTB01ATEX2170X

II3GExnAIIT6Date 2003-05-28Statement of conformity

EB8355-2EN 13


14 EB8355-2EN

Mountingoncontrolvalves

3 MountingoncontrolvalvesThepositionercanbemountedeitherdirectlytoSAMSONType 3277Actuatorortocon-trolvalveswithcastyokesorrod-typeyokesaccordingtoIEC 60534-6(NAMUR).Combinedwithanintermediatepiece,thepositionercanalsobemountedonrotaryactuators. The standard positioner is deliv-ered without accessories. Any additionally required accessories are listed together with theirordernumbersinthefollowingtables.Do not remove the protective cover on the backofthepositioneruntilyouactuallystartto attach the positioner.

MountingpositionandoperatingdirectionThe operating direction of the positioner also determines its mounting position on the actu-atorasillustratedinFig. 3,Fig. 4andFig. 6.Theturnboard(7inFig. 2)atthepositionermustbemountedcorrespondingly.For an increasing input signal (reference variable),thesignalpressurepst can either beincreasing(directaction>>)ordecreas-ing(reverseaction<>).Similarly,astheref-erencevariabledecreases,thesignalpres-surecaneitherdecrease(directaction>>)orincrease(reverseaction<>).Ontheturnboard(7),theoperatingdirectionisindicatedbysymbols(direct>>,reverse<>).Dependingonthepositionoftheturn-board,theadjustedoperatingdirectionandtheassociatedsymbolbecomevisible.If the required operating direction does not correspondtothevisiblesymbol,orifyouwant to change the operating direction, re-

movethefasteningscrewattheturnboard,turntheboardby180°andrefastentheturnboard.Makesurethethreerubbergas-kets inserted in the housing remain in posi-tion.

NOTICEWhen any subsequent changes are made, e.g. reversing the operating direction of the positioner control loop or changing the actuator fail-safe action from “actuator stem extends” to “actuator stem retracts” or vice versa, the positioner's mounting position must be changed accordingly.

3.1 DirectattachmenttoType 3277Actuator

Note:The required accessories are listed in Table 1 to Table 4 on page 18.

The attachment of the positioner either on the left or right side of the actuator (always look-ing onto the signal pressure connection or switchoverplate)isdeterminedbythere-quired operating direction of the positioner, i.e. >> or <>.

EB8355-2EN 15


SUPPLY

Actuatorstemextends

Actuatorstemretracts

Internal signal pressure connection

Sideviewofconnectionblock

Signal pressure connection over piping

ConnectionblockTipofgasket(16)

Operating direction >> Left attachment

Operating direction <> Left attachment

With gasket (new) With switch plate (old)

Switchplate(13)

Gasket(16)

Cover

Switchover plate Signal pressure input

Signal pressure input for left attachment

Seal with filter

With right attachment

Marking

MarkingSymbol

Actuator stem extends

Actuator stem retracts

Operating direction <> Right attachment

Actuatorstemextends>> Operating direction <>Left attachment Right attachment

Actuatorstemretracts<> Operating direction >>

Left attachment Right attachment

Operating direction >> Right attachment

Fig. 3: Mounting position and connection of signal pressure for Type 3277 Actuator (top) and Type 3277-5 Actuator (120 cm²) (bottom)

16 EB8355-2EN


1. Fastentheclamp(1.2)totheactuatorstem, making sure that the fastening screw rests in the groove of the actuator stem.

2. Fastentheassociatedpick-upleverD1orD2(with355/700 cm²actuators)tothefeedbackleverofthepositioner.

3. Securetheintermediateplate(15)withthe gasket facing towards the actuator yoke.

4. Positionthepositionersuchthatthepick-upleverslidesinlineoverthepin(1.1)oftheclamp(1.2).Fastenthepositionertotheintermediateplate(15).

5. Mountcover(16).6. Check whether the correct range spring

hasbeeninstalledaslistedinTable 4.Range spring 1 is installed as standard. If necessary, replace it with range spring 2includedintheaccessoriesandfixitattheouterhook-inholes.

Actuatorswith240,350,355,and700 cm²diaphragmareas7. Makesurethatthetipofthegasket (16)

projecting from the side of the connec-tionblock(Fig. 3,middle)ispositionedtomatchtheactuatorsymbolfortheac-tuator'sfail-safeaction"actuatorstemextends" or "actuator stem retracts".If this is not the case, unscrew the three fastening screws and lift off the cover. Turnthegasket(16)by180°andre-in-sert it.Theoldconnectionblockversionrequirestheswitchplate(13)tobeturnedtoalign

theactuatorsymbolwiththearrowmark-ing.

8. Placetheconnectionblockwiththeasso-ciated gaskets against the positioner and the actuator yoke. Fasten it using the screw.Foractuatorswithfail-safeaction"actua-tor stem retracts", additionally mount the external signal pressure pipe.

Actuatorwith120 cm²diaphragmareaThe signal pressure is transmitted to the dia-phragmchamberovertheswitchoverplate(Fig. 3andFig. 4,bottom).7. Removescrewplugonthebackofthe

positioner(Fig. 5)andsealthesidesig-nal pressure output with the stopper in-cluded in the accessories.

8. Mount the positioner so that the hole in theintermediateplate(15)coverstheseal in the hole of the actuator yoke.

9. Align the switchover plate with the corre-spondingactuatorsymbol.Fastenittothe actuator yoke.

NOTICEIf a solenoid valve or a similar device is additionally mounted onto a 120 cm² actuator, do not remove the M3 screw plug at the back of posi-tioner. In this case, the signal pres-sure must be transmitted from the sig-nal pressure output to the actuator over an additional connecting plate (Table 2). The switchover plate is not used in this case.

EB8355-2EN 17


AirpurgingofthespringchamberIfthespringchamberoftheactuatoristobepurged with the exhaust air from the posi-tioner,usepiping(Table 3)toconnectthespringchamber(with"actuatorstemex-tends"version)totheconnectionblock.Todo so, remove the stopper from the connec-tionblock.Foranactuatorwithfail-safeac-tion "actuator stem retracts" and in

Type 3277-5Actuatorswithaneffectivedia-phragmareaof120 cm²,theexhaustairfrom the positioner is connected to the spring chamberoveraninternalhole.

NOTICEWhen the valve is installed, the side cover of the actuator must be mount-ed such that the vent plug points downward.

1.2

D2

D1

15Vent plug

Vent plug must point downward when the valve is installed

View onto the signal pressure connectionLeftattachment Rightattachment

Cover

Switchover plate

Intermediateplate(15)

Clamp(1.2)

Signalpressureborehole

240 cm²350 cm²355 cm²700 cm²

120 cm²

Type 3277

Type 3277-5

Fig. 4: Mounting the clamp

18 EB8355-2EN


Table 1: Lever (see Fig. 4) Mountingkit

Actuator size Lever with associated clamp and intermediate plate Order no.

120 cm² D1leverwithstopperforoutput(38)Standard version 1400-7116

Versioncompatiblewithpaint 1402-0944

240/350 cm² D1lever(33 mmlongwith17 mmclamp)

Standard version 1400-6370


355/700 cm² D2lever(44 mmlongwith13 mmclamp)

Standard version 1400-6371


Table 2: Switchover plates and connecting plates Order no.

Switchoverplate(for120 cm²actuator) Type3277-5xxxxxx.00Actuator(old) 1400-6819

New switchover plate Type3277-5xxxxxx.01Actuator(new)orhigher 1400-6822

Connecting plate for additional attachmentof, e.g. a solenoid valve

Type3277-5xxxxxx.00Actuator(old),G 1/8

Type3277-5xxxxxx.00Actuator(old),1/8 NPT1400-68201400-6821

New connecting plate Type3277-5xxxxxx.01Actuator(new)orhigherG 1/8 and 1/8 NPT 1400-6823

Note: Only new switchover and connecting plates can be used with new actuators (Index 01). Old and new plates are not interchangeable.

Requiredconnectionblockfor240,350,355,and700 cm²actuator(includinggasketsandfasteningscrew)

G ¼ 1400-8819

¼ NPT 1402-0901

Table 3: Pipe connection Material Actuatorsize[cm²] Order no.

Required pipe connection including screw fitting

For actuator with "actuator stem retracts" or with air purging of the top diaphragm cham-ber

Steel 240 1400-6444

Stainless steel 240 1400-6445

Steel 350 1400-6446

Stainless steel 350 1400-6447

Steel 355/700 1400-6448

Stainless steel 355/700 1400-6449

Table 4: Range spring Travel[mm] Actuatorsize[cm²] Order no.

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

1(9.5coils,installedasstandard) 10to15 120,240and350 1400-6442

2 15 355/700 1400-6443

1 30 355/700 1400-6442

EB8355-2EN 19


Accessories Order no.

Pressuregaugemountingblock(onlyfor120 cm²)G ¼ 1400-7458

¼ NPT 1400-7459

Pressure gauge mounting kit for supply pressure and signal pressure

Stainlesssteel/brass 1400-6950

Stainless steel/stainless steel 1400-6951

Filtercheckvalve,replacesventplugandincreasesthedegreeofprotectiontoIP 65

FiltercheckvalveinhousingwithG ¼thread

Polyamide, IP 65degreeofprotection 1790-7408

1.4301,IP 65degreeofprotection 1790-7253

Polyamide, NEMA 4 degree of protection 1790-9645

1.4301, NEMA 4 degree of protection 1790-9646

Assortment of spare parts including gaskets and diaphragms 1400-9895

20 EB8355-2EN


EB8355-2EN 21


Leftattachment Rightattachment

Mountingpositionontheplatelookingontothetravelpick-up(20),actuatorfacingupward(seealsoFig. 7)

Actuatorwith“actuatorstemextends”(FA)fail-safeaction

Direct operating direction >>

Reverse operating direction <>



20

Pneumatic connections Electrical connectionElectrical connection

Actuatorwith“actuatorstemretracts”(FE)fail-safeaction





Pneumatic connectionPneumatic connection Electrical connections

20

Fig. 6: Attachment to the left or right of the valve for NAMUR attachment (IEC 60534-6)

3.2 AttachmentaccordingtoIEC 60534-6

Required mounting parts are listed in Table 5.Theratedtravelofthevalvedetermines which lever and range spring (Table 6)arerequired.An adapter housing is used for attachment (Fig. 7).Thevalvetravelistransmittedbythelever(18)andtheshaft(25)tothebracket(28)oftheadapterhousingandthenpassedontothepin(27a)ontheleveroftheposi-tioner.Toensurethatthepin(27a)isproper-lylocatedinthebracket(28),fixthespringincludedintheaccessoriesatthebackofthepositionerhousingasillustratedinFig. 5.

Spring Screw plug

Fig. 5:Installing the spring on the back of the housing

Thepositionercanbemountedeitherontheleftorrightsideofthecontrolvalve(Fig. 6andFig. 7).Turnthepositionerattheadapt-erhousingby180°todetermineorchangethe operating direction of the positioner/control valve unit.

22 EB8355-2EN


3.2.1 Mountingsequence Î Mounting parts and range spring: see Table 4/Table 5.InstallationinFig. 7.

Valvewithcastyoke1. Screwtheplate(20)tothestemconnec-

tor of the actuator and plug stems using the countersunk screws.Usetheadditionalbracket(32)for2100and2800 cm²actuatorswith120 mmtravel.

2. Removetherubberstopperfromtheadapter housing and fasten the adapter housing either on the left or right of the NAMURribusingthehexagonheadscrewasshowninFig. 6.

Valvewithrod-typeyoke1. Screwtheplate(20)tothefollower

clamp of the plug stem.2. Screwthestuds(29)intotheadapter

housing.3. Place the adapter housing with the plate

(30)ontoeithertheleftorrightvalverodandscrewtightusingthenut(31).Makesure that the adapter housing is at the correctheighttomountthelever(18)sothat it is in a horizontal position when thevalveisatmid-travel.

4. Screwthepin(19)intothemiddlerowofholesontheplate(20)andlockitintoposition over the correct lever marking (1 or2)asindicatedinTable 6.

5. Clamptheclip(21)ontothelever(18).Theclipmustbeclampedontothelever(18)withtheopensidefacingdown-

ward when the positioner is attached with the air connection at the front.

6. Attachthelever(18)includingclampingplate(22)totheshaft(25),makingsurethattheclipclaspsthepin(19).

3.2.2 Initialadjustmentoftravel

1. Movethevalveto50 %travel.2. Movetheshaft(25)intheadapterhous-

ingsothattheblackpointer(24)match-es the cast marking on the adapter hous-ing.

3. Fastentheclampingplate(22)inthispo-sitionusingthescrew(23).

4. Screwthepin(27a)intothepositionerlever on the side where the press nut is located. Lock it in position with the hex nutontheotherside,observingthemounting position A or B according to Table 6andFig. 7.

5. Place the positioner on the adapter hous-ing, taking into account the mounting di-rection. Fasten it, making sure that the pin(27a)restsagainstthebracket(28).Thepinmustnotslipoutofthebracketonce installed.

6. Check whether the correct range spring hasbeeninstalledaslistedinTable 6.Range spring 1 is installed as standard. If necessary, replace it with range spring 2includedintheaccessoriesandfixitattheouterhook-inholes.

7. Performpositionersettingasdescribedinsection 5.1.

EB8355-2EN 23


21,51

24 25 22

32

31

20 19

19 21 2023 18

2930

2826

A B27b

27a

Mountingposition

AttachmenttoNAMURrib

Attachmenttorods

18 Lever N1, N219 Pin20 Plate21 Clip22 Clamping plate23 Screw24 Pointer25 Shaft26 Lever of positioner27a Coupling pin27b Lock nut28 Bracket29 Studs30 Plate31 Nuts32 Mountingbracket

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

24 EB8355-2EN


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

NAMUR mounting kit, seeFig. 7forparts.

Valve with cast yoke7.5to60 N1(125 mm) 1400-6787

22.5to120 N2(212 mm) 1400-6789

Rod diameter [mm]ofrod-type yoke

20to25 N1 1400-6436

20to25 N2 1400-6437

25to30 N1 1400-6438

25to30 N2 1400-6439

30to35 N1 1400-6440

30to35 N2 1400-6441

Attachment to Fisher and Masoneilan linear actuators (oneofeachmountingkitsisrequiredperactuator)

1400-6771 and

1400-6787

Additional range spring acc. to Table 6

Rangespring1(9.5coils,installedasstandard)Rangespring2(4.5coils)

1400-64421400-6443

Accessories Order no.

PressuregaugemountingblockG ¼ 1400-7458

¼ NPT 1400-7459

Pressure gauge kitStainlesssteel/brass 1400-6950

Stainless steel/stainless steel 1400-6951

Filtercheckvalve,replacesventplugandincreasesthedegreeofprotectiontoIP 65

FiltercheckvalveinhousingwithG ¼thread

Polyamide,IP 65degreeofprotection 1790-7408

1.4301,IP 65degreeofprotection 1790-7253

Polyamide, NEMA 4 degree of protection 1790-9645

1.4301, NEMA 4 degree of protection 1790-9646

Assortment of spare parts including gaskets and diaphragms 1400-9895

Table 6:Mounting position

Travel[mm]1) 7.5 15 15 30 30 60 30 60 60 120

Pin at marking 1) 1 2 1 2 1 2 1 2 1 2

Distancebetweenpinandleverful-crum 42to84 mm 84to168 mm

With lever N1(125 mmlong) N2(212 mmlong)

Pin(27a)atposition A A B A B

Requiredrangespring(seeTable 5) 2 1 1 1 1

1) Calculate intermediate values

EB8355-2EN 25


3.3 Attachmenttorotaryactuators

Thepositionercanalsobemountedonro-taryactuatorsaccordingtoVDI/VDE 3845(September2010)usingthemountingpartslistedinTable 7.

Table 7: Complete mounting parts, including range spring 2, but not including the cam disk Order no.

Actuatoracc.toVDI/VDE 3845(September2010),level2 1400-8815

SAMSONType 3278ActuatorVETEC Type S

160 cm² 1400-7103

320 cm² 1400-7104

VETEC Type R R 110toR 250 1400-7117

Attachment Masoneilan

CamflexI,DN 25to100 1400-7118

CamflexI,DN 125to250 1400-7119

CamflexII 1400-7120

Requiredrangespring Order no.

Standardoperationofreferencevariable,rangespring2(4.5coils) 1400-6443

Split-rangeoperation,rangespring1(9.5coils,installedasstandard) 1400-6442

Camdiskwithaccessories Order no.

~,linearbasiccharacteristic3)~,equalpercentagebasiccharacteristic3)~, linear 1)~, equal percentage 2)~, linear 1)~, equal percentage 2)~, linear 1)~, equal percentage 2)

(0050-0072),0to90°openingangle,alsoforType 3310(0050-0073),0to90°openingangle(0050-0080),0to70°openingangle,forcontrolbutterflyvalves(0050-0081),0to70°openingangle,forcontrolbutterflyvalves(0050-0074,VETEC),0to75°openingangle(0050-0075,VETEC),0to75°openingangle(0059-0007,Camflex)tobesetbetween0and55°(0059-0008,Camflex)tobesetbetween0and55°

1400-6664

1400-66651400-6774

1400-6775

1400-66661400-66671400-66371400-6638

Accessories

Seelistonpage 24

1) Linearizestheflowcharacteristic2) Createsanequalpercentageflowcharacteristic3) Based on opening angle

26 EB8355-2EN


The rotary motion of these actuators is con-vertedintoalinearmotionrequiredbythepneumatic control unit of the positioner using the cam disk of the actuator shaft and a feel-er roll on the positioner lever.

NOTICECheck whether the correct range spring has been installed as listed in Table 7. Range spring 1 is installed as standard. If necessary, replace it with range spring 2 included in the accessories and fix it at the outer hook-in holes.

Double-actingspringlessrotaryactuatorsre-quire the use of a reversingamplifier on the connection side of the positioner housing (seesection 3.3.4).Whenusingareversingamplifier,thepres-sureregulator(9,Fig. 2)mustbeturnedclockwise as far as it will go (also see sec-tion 4.1.2).When attaching the positioner to the SAMSONType 3278RotaryActuator(Fig. 8,left),theinsideoftheactuatorandthe unused reverse side of the diaphragm are purged with the positioner's exhaust air. Additional piping is not required.When attaching the positioner to actuators fromothermanufacturers(Fig. 8,right),thereversesideofthediaphragmcanbepurged with air over a pipe connection in-stalledbetweentheactuatorandintermedi-ate piece.

3.3.1 Mountingtheleverwithfeelerroll

1. Placetheleverwithfeelerroll(35)onthesideofthelever(37)oppositetowherethe press nuts are located and secure it usingthesuppliedscrews(38)andwashers.

NOTICETo ensure a close physical contact be-tween the lever with feeler roll and the cam disk, attach the spring contained in the accessories kit (order no. 1400-6660) to the back of the positioner housing (see Fig. 5).

3.3.2 Mountingtheinterme-diatepiece

SAMSONType 3278Actuator1. Fastentheadapter(36)tothefreeshaft

end of the rotary actuator.2. Fastentheintermediatepiece(34)tothe

actuator housing using two screws. Align the intermediate piece so that the air con-nections of the positioner point toward the diaphragm case side.

3. Alignthecamdisk(40)andscale(39)asdescribedinsection3.3.3andfasten.

ActuatorsaccordingtoVDI/VDE3845(09/2010)(fixinglevel2)1. Placetheassembledintermediatepiece

(34,44,45and42)ontothemountingbracketincludedinthescopeofactuatordelivery and fasten.

2. Alignthecamdisk(40)andscale(39)asdescribedinsection2.3.3andfasten.

EB8355-2EN 27


33

3835

39

39

40

34

36

40

34

44

45

42

43

37

AttachmentaccordingtoVDI/VDE 3845

(09/2010)

AttachmenttoSAMSONType3278

33 Positioner34 Intermediate piece35 Lever with feeler roll36 Adapter37 Transmission lever38 Screws39 Scale40 Cam disk41 Actuator shaft42 Washer43 Mountingbracket44 Coupling

Ventplugorfiltercheck valve

Fig. 8: Attachment to rotary actuators

28 EB8355-2EN


3.3.3 Basicsettingofthecamdisk

Thevalvemodeluseddeterminesthebasicsetting of the cam disk.

NOTICECam disks tailored to the special characteristic of a valve cause the valve to open in a non-linear or non-equal percentage way.The visible difference between the set point (4 to 20 mA) and the actual position (opening angle) does not constitute a system deviation of the positioner.

Fig. 9andFig. 10showlinearcamdisks.Fig. 9illustratesacontrolvalveassemblywitharotaryactuatorwithspring-returnmechanism that opens counterclockwise. The arrangement of the springs in the actuator determinesthefail-safepositionofthevalve.Fig. 10showshowtoadjustthecamdiskwhenadouble-actingspringlessrotaryactu-ator is used. The direction of rotation (either counterclockwiseorclockwise)dependsonthe actuator and valve model used. The cam diskmustbesetwhenthevalveisclosed.Usetheturnboard(7)toadjusttheoperatingdirection of the positioner, i.e. whether the valve opens or closes when the reference variableincreases(direct>>orreverse<>).

Each cam disk carries two cam sections whosestartingpointsareindicatedbysmallholes. Depending on the operating direction oftherotaryactuator(air-to-openorair-to-close),thestartingpointofthecam,eithermarked N(standardcharacteristic)orI (re-versecharacteristic),mustpointtowardsthelever with feeler roll. When the starting point islocatedonthebackofthecamdisk,turnover the cam disk.

NOTICEThe starting point (hole) of the select-ed cam must be aligned so that the fulcrum of the cam disk and 0° posi-tion on the scale as well as the arrow on the window are in line with each other.

When aligning the cam disk, clip the dou-ble-sidedscalediskonthecamdisk,whilemaking sure that the value on the scale matches the valve's direction of rotation.

NOTICEMake sure the 0° position of the scale always corresponds to CLOSED posi-tion.Therefore, for fail-open actuators and for springless actuators, the maxi-mum supply pressure needs to be ap-plied to the actuator before aligning the cam disk.

EB8355-2EN 29


Single-actingrotaryactuatorwithspring-returnmechanismLinearcamdisk(equalpercentagecamdiskisrepresentedbyabrokenanddottedline)ControlvalveopenscounterclockwiseForvalvesthatopenclockwise,thecamdiskmustbeturnedoversothatleverwithfeelerrollmovesoverthesamedisksegmentsasshownintheimagesbelow,butwiththecamdiskturningclockwise.

Fail-safeposition:Fail-closevalve

Directoperatingdirection>> Reverseoperatingdirection<>Reference variable

Signal pressure Valve Characteristic Reference

variableSignal

pressure Valve Characteristic

increases increases opens N decreases increases opens I

90˚60˚

30˚ 0˚

90˚60˚

30˚ 0˚

Feeler rollStarting point N

Starting point I

Hole to secure the cam disk

Insertclipandpresstheflapsoutwards

Fail-safeposition:Fail-openvalve

Directoperatingdirection>> Reverseoperatingdirection<>Reference variable

Signal pressure Valve Characteristic Reference

variableSignal

pressure Valve Characteristic

decreases decreases opens I increases decreases opens N

90˚60˚

30˚ 0˚

90˚60˚

30˚ 0˚

Feeler roll

Starting point NStarting point I

Alignment at max. signal pressure

Fig. 9: Cam disk settings for single-acting actuators

30 EB8355-2EN


Double-acting,springlessrotaryactuatorwithreversingamplifierLinearcamdisk(equalpercentagecamdiskisrepresentedbyabrokenanddottedline)

View from the positioner onto the actuator shaftControlvalveopenscounterclockwise–Basedonaclosedvalve

Directoperatingdirection>> Reverseoperatingdirection<>Reference variable Signal pressure Valve Charac-

teristic

increases A1 increases, A2 decreases opens N

Reference variable Signal pressure Valve Charac-

teristic

decreases A1 increases, A2 decreases opens I

90˚60˚

30˚ 0˚

90˚60˚

30˚ 0˚


Starting point I

Hole to secure the cam disk

Insertclipandpresstheflapsoutwards

View from the positioner onto the actuator shaftControlvalveopenscounterclockwise – Based on a closed valve

Directoperatingdirection>> Reverseoperatingdirection<>Reference variable Signal pressure Valve Charac-

teristic

increases A1 increases, A2 decreases opens N

Reference variable Signal pressure Valve Charac-

teristic

decreases A1 increases, A2 decreases opens I

0˚

90˚

60˚

30˚0˚

90˚

60˚

30˚


Starting point I

Fig. 10:Cam disk settings for double-acting actuators

EB8355-2EN 31


SecuringthealignedcamdiskTo prevent the cam disk from turning, drill a holeintotheadapter(36)orcoupling(44)toallowa2 mmdowelpintobeinserted.Select one of the four holes located around the center hole of the cam disk to secure the cam disk in position.

32 EB8355-2EN


3.3.4 Reversingamplifierfordouble-actingactuators

Fortheusewithdouble-actingactuators,thepositionermustbefittedwithareversingam-plifier,e.g.theSAMSONType 3710Revers-ingAmplifier(seeMountingandOperatingInstructions uEB 8392).The signal pressure of the positioner is sup-plied at the output A1 of the reversing ampli-fier.Anopposingpressure,whichequalstherequired supply pressure Z when added to the pressure at A1, is applied at output A2. The rule A1 + A2 = Z applies.Ifadifferentreversingamplifier(itemno.1079-1118or1079-1119)isused,followthemountinginstructionsdescribedbelow:

Mounting

NOTICEWhen using a reversing amplifier, the pressure regulator (9) must be turned as far as it will go in the clockwise di-rection.Remove the sealing plug (1.5) before mounting the reversing amplifier. The rubber seal (1.4) must remain in-stalled.

1. Screwthespecialnuts(1.3)fromtheac-cessoriesofthereversingamplifierintothe threaded connections of the position-er.

2. Insertthegasket(1.2)intotherecessofthereversingamplifierandslideboththehollowedspecialscrews(1.1)intotheconnectingboreholesA1 and Z.

3. Placethereversingamplifierontothepo-sitioner and screw tight using the two specialscrews(1.1).

4. Useascrewdriver(8mmwide)toscrewtheenclosedfilters(1.6)intotheconnec-tionboreholesA1 and Z.

SignalpressureconnectionsA1: Connect output A1 to the signal pressure connection on the actuator that causes the valve to open when the pressure rises.A2: Connect output A2 to the signal pressure connection on the actuator that causes the valve to close when the pressure rises.

PressuregaugeattachmentThemountingsequenceshowninFig. 11re-mains unchanged. Screw a pressure gauge bracketontotheconnectionsA1 and Z.Pressuregaugebracket: − G ¼1400-7106 − ¼NPT1400-7107

Pressure gauges for supply air Z and output A1aslistedinTable 4andTable 5.

http://www.samson.de/pdf_en/e83920en.pdf

EB8355-2EN 33


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

From the positioner

Control signals to the actuator

1 Reversingamplifier1.1 Special screws1.2 Gasket1.3 Special nuts1.4 Rubberseal1.5 Sealing plug1.6 Filter

Fig. 11:Mounting a reversing amplifier

34 EB8355-2EN

Connections

4 Connections

4.1 PneumaticconnectionsThe pneumatic connections are optionally designedasaborewith¼NPTorG¼thread.Customaryfittingsformetalorcop-pertubingorplastichosescanbeused.

NOTICEThe supply air must be dry and free from oil and dust. The maintenance instructions for upstream pressure reducing stations must be observed.Blow through all air pipes and hoses thoroughly before connecting them.

If the positioner is attached directly to the Type 3277Actuator,theconnectionofthepositioner's output pressure to the actuator is fixed.ForattachmentaccordingtoIEC 60534-6(NAMUR),thesignalpressurecanberoutedtoeitherthetoporbottomdiaphragmchamberoftheactuator,dependingontheactuator'sfail-safeaction"actuator stem extends" or "actuator stem retracts".

ExhaustairModelswithindex3767-x...x.03 and higher are equipped with a hinged cover without its own exhaust air hole. The exhaust air con-nections for these models are included in the accessories.The vent plug is located on the plastic cover of the actuator for direct attachment, where-as for NAMUR attachment, it is located on the adapter housing. The vent plug is located

on the intermediate piece or reversing ampli-fierforattachmenttorotaryactuators.

NOTICEIf you intend to replace older models with index 3767-x...x.02 or lower, the mounting parts may need to be replaced as well.

4.1.1 PressuregaugesTo precisely tune the positioner, we recom-mend installing pressure gauges for the sup-ply air and signal pressure.The required parts are listed as accessories inTable 4,Table 5andTable 7.

4.1.2 SupplypressureThe required supply air pressure depends on thebenchrangeandtheactuator'soperat-ingdirection(fail-safeaction).Thebenchrangeiswrittenonthenameplateeither as the spring range or signal pressure range. The operating direction is marked FAor FE,orbyasymbol.Actuatorstemextends(FA):Fail-close(forglobeandanglevalves)Required supply pressure = Upperbenchrangevalue+0.2 bar, atleast1.4 bar.

EB8355-2EN 35

Connections

Actuatorstemretracts(FE):Fail-open(forglobeandanglevalves)Fortight-closingvalves,themaximumsignalpressure pstmax is roughly estimated as fol-lows:

pstmax = F + d²·π·∆p [bar]4 · A

d = Seatdiameter[cm]∆p = Differential pressure across the

valve[bar]A = Actuatorarea[cm²]F = Upperbenchrangevalueofthe

actuator[bar]

Iftherearenospecifications,calculateasfollows:Required supply pressure =Upperbenchrangevalue+1 bar

PressureregulatorAftertiltingthecoverplateback,thepres-sureregulator(9)canbecontinuouslyad-justed. When the adjuster is turned counter-clockwise as far as it will go, signal pres-suresforspringrangesupto2.5 bararecontrolled. When the adjuster is turned clockwise all the way, signal pressures for springrangesupto6.0 bararecontrolled.If the signal pressure must not exceed a cer-tainvalue,thislimitcanbeadjustedusingapressuregauge(accessories).

36 EB8355-2EN

Connections

4.2 Electricalconnections

DANGER!For electrical installation, observe the relevant electrotechnical regulations and the accident prevention regula-tions that apply in the country of use. In Germany, these are the VDE regu-lations and the accident prevention regulations of the employers’ liability insurance.The following regulations apply to in-stallation in hazardous areas: EN 60079-14: 2008 (VDE 0165, Part 1) Explosive Atmospheres – Elec-trical Installations Design, Selection and Erection.Adhere to the terminal assignment. Switching the assignment of the elec-trical terminals may cause the explo-sion protection to become ineffective. Do not loosen enameled screws in or on the housing. The maximum per-missible values specified in the EC-type examination certificates apply when interconnecting intrinsically safe electrical equipment (Ui or U0, li or I0, Pi or P0, Ci or C0 and Li or L0).

SelectingcablesandwiresObserveclause 12of EN 60079-14:2008 (VDE 0165,Part 1)forinstallationofthein-trinsically safe circuits.Clause 12.2.2.7applieswhenrunningmulti-corecablesandwireswithmorethanoneintrinsically safe circuit.

The radial thickness of the insulation of a conductor for common insulating materials (e.g.polyethylene)mustnotbesmallerthan0.2 mm.The diameter of an individual wire in a fine-strandedconductormustnotbesmallerthan0.1 mm.Protecttheconductorendsagainstsplicing,e.g.byusingwire-endfer-rules.Whentwoseparatecablesareusedforcon-nection,anadditionalcableglandcanbeinstalled.Sealcableentriesleftunusedwithplugs.Fitequipmentusedinambienttemperaturesbelow–20 °Cwithmetalcableentries.

Zone2/Zone22In equipment operated according to type of protectionEx nAII(non-sparkingequipment)accordingtoEN 60079-15:2003,circuitsmaybeconnected,interruptedorswitchedwhile energized only during installation, maintenance or repair.Equipmentconnectedtoenergy-limitedcir-cuitswithtypeofprotectionEx nLaccordingtoEN 60079-15:2003maybeswitchedun-der normal operating conditions.Themaximumpermissiblevaluesspecifiedinthestatementofconformityanditsad-dendaapplywheninterconnectingtheequipmentwithenergy-limitedcircuitsintypeofprotectionEx nL IIC.

EB8355-2EN 37

Connections

Thewiresforthereferencevariablemustbeconnected to the terminals 11 and 12 locat-ed in the housing.In general, it is not necessary to connect the positionertoabondingconductor.Shouldthisberequired,however,thisconductorcanbeconnectedinsidethedeviceoroutsideonthe device.Depending on the version, the positioner is equipped with inductive limit contacts and/or a solenoid valve.Versions with position transmitter do not per-mit the connection of additional equipment.The position transmitter is operated on a two-wirecircuit.Theusualsupplyvoltageis24 V DC.Taking the resistance of the supply leads into account, the voltage at the position transmit-terterminalscanbebetween12and45 V DC.RefertoFig. 12ortothelabelonthetermi-nalblock.

Accessories:Deviceindex3767-x...x.03 and lowerCableglandPG13.5Black plastic Orderno.1400-6781Blue plastic Orderno.1400-6782Nickel-platedbrass Orderno.1400-6979AdapterPG13.5to½NPT:Metal to metal Orderno.1400-7109Paintedblue Orderno.1400-7110Deviceindex3767-x...x.04 and higherCableglandM20 x 1.5Black plastic Orderno.1400-6985Blue plastic Orderno.1400-6986Nickel-platedbrass Orderno.1890-4875AdapterM20 x 1.5to½ NPT:Powder-coatedaluminum

Orderno.0310-2149

4.2.1 SwitchingamplifierThe operation of the inductive limit contacts requiresswitchingamplifiersinaccordancewithEN 60947-5-6tobeconnectedintheoutputcircuit.Observetherelevantregula-tions for installation in hazardous areas.

+41 –42 +51 –52 +81 –82 +31 –32

GEi

+ –

+ –

(B)A

(A)B

A

+11 –12 +11 –12

Ei/Ei/ AA

mA control signal

mA control signal6to24 V DC

solenoid valveTransmitter supply voltage

for position transmitter only

Rear Version with position transmitter

Switchingamplifieracc.toEN 60947-5-6

Fig. 12:Electrical connections

38 EB8355-2EN

Operation

5 Operation

5.1 Tuningthepositionermountedontothecontrolvalve

StartingpointandreferencevariableWhen adjusting the positioner directly at the controlvalve,thetravel(openingangle)mustbeadaptedtothereferencevariable.Withareferencevariable,forexample,4to20 mA,thevalvemustmovethroughitsen-tiretravelrangefrom0to100 %(Fig. 13,left).For positioners for rotary actuator, an open-ingangle,forexample,0to70°mustbeas-signedtothereferencevariable.ThestartingpointisbasedontheCLOSEDposition of the valve.Depending on the actuator version ("actua-torstemextends"or"actuatorstemretracts")and the operating direction of the positioner (>>or<>),thisstartingpointcanbeeitherthelowerorupperrangevalue(4or20 mA)ofthereferencevariable.Thereferencevariablerangeandthustheupper range value determine the travel of the valve.Insplit-rangeoperation(Fig. 13,right),thecontrol valves work with smaller reference variableranges.Thecontrolleroutputsignalis used to control two control valves, dividing it such that the valves move through their en-tire travel range at half the input signal rangeeach(e.g.firstvalvesetto4to

12 mA,secondvalvesetto12to20 mA).Toavoidoverlapping,allowforadeadbandof±0.5 mAasshowninFig. 13.The startingpoint(zero)isadjustedatthezero adjuster (6.2); the span, i.e. the upper range value, is adjusted at the span adjuster (6.1).Duringtheadjustment,connectasuitableammeter to the signal input and apply air to the supply air input.

NOTICEWhen the positioner is controlled by a computer whose signal is limited, e.g. between 4 to 20 mA, set the po-sitioner to the range from 4.5 to 20 mA.This is the only way to ensure that the actuator is completely vented and the valve completely closed when the controller issues a 4 mA signal.For operating direction <>, set the range to 4 to 19.5 mA.

EB8355-2EN 39

Operation

100%

0%4 20 mA124 20 mA

100%

0%

< > < < < > < <

Referencevariable Input signal

Deadband

OpenOpen

TravelTravel

ClosedClosed Valve 2 Valve 1

Fig. 13:Normal or split-range operation

5.1.1 AdjustingtheproportionalbandXpandairdeliveryQ

1. Closethevolumerestriction(11)asfaras the required positioning speed permits.Checkthepositioningspeedbypushingthediaphragmlever(3)asfaritwillgo.

2. Adjustthereferencevariableattheinputtoapprox.50 %ofitsrange.

3. Turnthezeroadjuster(6.2)untilthevalvehasreachedapprox.mid-travel.

4. Usetheadjuster(8)tosettheproportion-albandXp to a value half way (half turn).

5. Check the valve's tendency to hunt and thepositioningspeedbybrieflytappingthediaphragmlever(3).TheXpvalueistobeadjustedtobeassmallaspossible,withoutconsiderableovershooting occurring.

NOTICEAlways adjust the Xp restriction be-fore setting the starting point.Changing it later will cause the zero point to be shifted.

40 EB8355-2EN

Operation

5.1.2 Settingsforactuatorwith“actuatorstemex-tends”fail-safeaction

Startingpoint(e.g.4 mA)1. Set the input signal at the ammeter to

4.5 mA2. Turnthezeroadjuster(6.2)untilthe

valve just starts to move from its initial position.

3. Reducetheinputsignalto0 mAandslowly increase it again. Check whether the valve starts to move at exactly 4.5 mA.Correctanydeviationatthezeroadjuster(6.2).

Upperrangevalue(span)e.g.20mA1. Oncethestartingpointhasbeenset,

increasetheinputsignalto20 mAattheammeter.

Atexactly20 mA,theplugstemmuststandstill,havingmovedthrough100 %travel(watchthetravelindicatoratthevalve).If the upper range value is incorrect, turn the spanadjuster(travel).Fourturnscorrespondtoatravelchangeof10 %instandardoper-ation.Insplit-rangeoperation,thisvalueisreducedbyhalf.Turn the adjuster clockwise to reduce the travel and counterclockwise to increase it.2. Afterthecorrectionhasbeencompleted,

reduce the input signal and slowly increase it again.Check the starting point and the upper range value. Repeat the correction pro-cedureuntilbothvaluesarecorrect.

NOTICEWhen setting the zero adjuster (6.2), check whether the actuator is relieved of pressure.When the input signal is 4 mA and the operating direction >>, or the in-put signal is 20 mA and the operat-ing direction <>, the pressure gauge must indicate 0 bar.Correct zero accordingly.

5.1.3Settingsforactuatorwith“actuatorstemretracts”fail-safeactionNOTICEWhen using an actuator with fail-safe action "actuator stem retracts", the diaphragm chamber must be pressurized with a signal pressure that is high enough to tightly close the valve against the upstream pres-sure in the plant. This applies to an upper range value of the reference variable (20 mA) with operating di-rection >> as well as a lower range value of the reference variable (4 mA) with operating direction <>.

The requiredsignalpressure is either indi-catedonthepositionerlabelortherequiredsupplypressurecanberoughlycalculatedasdescribedinsection4.1.2.

Startingpoint(e.g.20 mA)1. Set the input signal at the ammeter to

20 mA

EB8355-2EN 41

Operation

2. Turnthezeroadjuster(6.2)untilthevalve just starts to move from its initial position.

3. Increase the input signal and slowly re-duceitagainto20 mA.Checkwhetherthe valve starts to move at exactly 20 mA.

4. Correct any deviation at the zero adjust-er(6.2).Turningtheadjustercounter-clockwise causes the valve to move from itsendpositionearlier;turningclockwisecauses the valve to move from its end po-sition later.

Upperrangevalue(span)e.g.4mA1. Oncethestartingpointhasbeenset,in-

creasetheinputsignalto4 mAattheammeter.Atexactly4 mA,theplugstemmust stand still, having moved through 100 %travel(watchthetravelindicatoratthevalve).

2. If the upper range value is incorrect, turn thespanadjuster(travel).Fourturnscor-respondtoatravelchangeof10 %instandardoperation.Insplit-rangeopera-tion,thisvalueisreducedbyhalf.Turn the adjuster clockwise to reduce the travel and counterclockwise to increase it.

3. Afterthecorrectionhasbeencompleted,settheinputsignalto20 mAagain.

4. Turnthezeroadjuster(6.2)againuntilthe pressure gauge indicates the re-quiredsignalpressure (see section 4.1.2).

NOTICEAfter mounting and tuning the posi-tioner, make sure that the vent plug of the housing cover faces downward when the valve is installed.

5.2 Changingtheoperatingdi-rection

If the operating direction of directly attached positioners(Fig. 3)istobechangedaftertheyhavebeeninstalled,turntheturnboard(7)andchangethepositionoftheconnec-tionblock,positionerandclamp(1.2).ForattachmentaccordingtoIEC 60534-6(NAMUR),turntheturnboard(7)andthepositionerontheadapterhousing(Fig. 6).In positioners for rotary actuators, reassign thecamdiskasshowninFig. 9andFig. 10.Fordetailsonchangingtheturnboard(7)re-fer to section 3.

42 EB8355-2EN

Operation

5.3AdjustingthelimitcontactsThe positioner version with inductive limit contactshastwoadjustabletagsmountedona rotary shaft which operate the associated proximityswitches(50).The operation of the inductive limit contact requiresswitchingamplifierstobeconnectedintheoutputcircuit.Refertosection 4.2.1.Whenthetag(51)islocatedintheinductivefieldoftheswitch,theswitchassumesahighresistance.Whenitmovesoutsidethefield,the switch assumes a low resistance.The limit contacts are usually adjusted to is-sueasignalforbothendpositions.Theswitchingpointscanalsobeadjustedtoin-dicate intermediate positions.TheswitchesAandBmustbeassignedtothe end positions of the control valve (valve OPENorCLOSED)dependingontheoper-ating direction and the mounting position ac-cordingtoTable 8andTable 9.

Theterminals41/42and51/52canoption-allybeassignedtotheswitchesAandBbyturningtheassociatedlabelontheterminalblock(alsoseeFig. 12).

NOTICEThe tags of the limit contacts cannot be turned by 360°. As a result, it is important to observe the correct as-signment of switches A and B to the valve positions (valve CLOSED and valve OPEN), especially when the limit contacts are to be connected in safety circuits.

The required switching function, i.e. whether theoutputrelayistobepickeduporre-leasedwhenthetagentersthefield,mustbedeterminedattheswitchingamplifier.

Fig. 14:Limit contacts

EB8355-2EN 43

Operation

AdjustingtheswitchingpointMove the valve to the switching point and adjustthetagbyturningtheadjustmentscrew(53)sothattheswitchingpointisreachedandindicatedbytheLEDontheswitchingamplifier.Toguaranteetheswitchingunderallambientconditions, adjust the switching point ap-prox.2 %beforethemechanicalstop(OPEN/CLOSED).

NOTICEAfter tuning the positioner, make sure that the vent plug of the housing cov-er faces downward when the valve is installed.

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

Left attachment Right attachment

Switch

Valve position Tag outside inductive field

Tag inside inductive field

Tag outside inductive field

Tag inside inductive field

Closed B A A B

Open A B B A

Table 9: Right or left attachment according to NAMUR (Fig. 6) and attachment to rotary actuators (Fig. 8)

Directionofaction

Valveposition

Actuatorstemextends(FA) Actuatorstemretracts(FE)

SwitchTag

SwitchTag

Outside inductive field Insideinductivefield Outside inductive

fieldInsideinductivefield

>> CLOSED OPEN

B A

A B

A B

B A

<> CLOSED OPEN

A B

B A

B A

A B

44 EB8355-2EN

Operation

5.4 Adjustingthepositiontransmitter

NOTICEThe starting point (zero) and upper range value (span) must be set before adjusting the position transmitter.

Dependingonthepositionofthemulti-pinconnector(symbolonconnector:>>or<>),thefeedbacksignalcanbesettoeitherarangeof4to20 mAor20to4 mAfor0to100 %travel.

Fig. 15:Position transmitter

ZeropointUse the switches 1 and 2 to roughly set the zero point and the ZERO potentiometer for fine-tuning.Theadjustedvalueisalwaysbasedona4 mAsignal.

SpanUse the switches 3 and 4 to roughly set the span, i.e. the upper range value, and the SPANpotentiometerforfine-tuning.Thead-justedvalueisalwaysbasedona20 mAsignal.

Example:Move the valve to the open position while observingthepositiontransmittersignal.If the signal does not move in the desired di-rection,changethepositionofthemulti-pinconnector.Adjustthezeropoint(4 mA)andspan(20 mA)forthevalvepositionsaccordingtoTable 10.

Table 10: Position transmitter

Valve movement Observedfeedbacksignal Direction of signal Set zero/span to

OPEN á

CLOSED

Signal increases á

OK 20 mA ValveOPEN4 mA ValveCLOSED

NotOK à Change connector's

position

4 mA ValveOPEN20 mA ValveCLOSED

Signal drops â

OK 4 mA ValveOPEN20 mA ValveCLOSED

NotOK à Change connector's

position

20 mA ValveOPEN4 mA ValveCLOSED

EB8355-2EN 45

Operation

Zeropointadjustment1. Use the input signal of the positioner to

move the valve to closed position (valve CLOSED,travel0 %).

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

3. Correct smaller deviations at the ZERO potentiometer until the meter shows ex-actly4 mA.Forlargerdeviationsthatcannotbecor-rected using the potentiometer (adjust-mentrangeofapprox.20turns),settheswitches 1 and 2 to indicate an mA val-ue which is within the adjustment range of the ZERO potentiometer.

4. Setthezeropointtoexactly4 mAusingthe ZERO potentiometer.

Adjustingthespan1. Use the input signal of the positioner to

move the valve to closed position (valve CLOSED,travel100 %).

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

3. Correct smaller deviations at the SPAN potentiometer until the meter shows ex-actly20 mA.Ifdeviationsaretoohigh,set the switches 3 and 4 to indicate an mA signal which is within the adjustment range of the SPAN potentiometer.

4. Turn the SPAN potentiometer until the ammetershowsexactly20 mA.Since the zero point and span have a mutualinfluenceoneachother,repeatthecorrectionprocedureatbothpotenti-ometersuntilbothvaluesarecorrect.

46 EB8355-2EN

Operation

Note:The following applies to positioners with adapter housing for NAMUR attachment:When the positioner and the position transmitter signal have different operating di-rections (<< and <>), it may be impossible to adjust the zero point of the transmitter signal due to the additional deflection caused by the bracket (28) of the adapter housing.In this case, readjust the black pointer (section 3.2.2 on page 16) so that the sensor of the position transmitter reaches the control range.Unscrew the clamp. For “actuator stem extends” (FA), shift the pointer upward to-wards the actuator; for "actuator stem retracts" (FE), shift the pointer downward to-wards the valve. For valves with rod-type yoke, slightly shift the positioner on the rod in the downward (FE) or upward (FA) direction.

NOTICEEvery time you make a change as described above, the zero point and span of the po-sitioner must be readjusted before adjusting the position transmitter.After tuning the positioner, make sure that the vent plug of the housing cover faces downward when the valve is installed.

EB8355-2EN 47

Convertingandretrofittingthepositioner

6 Convertingandretrofittingthepositioner

NOTICERead instructions in section 7 for ex-plosion-protected versions!

6.1 Convertingfromelectro-pneumatictopneumatic

Theelectropneumaticpositionercanbecon-vertedintoaType 3766PneumaticPosition-er with the following conversion kit:Required conversion kit:M20x1.5,orderno.:1400-75751. Remove the holder with the terminal

block.Disconnectthecabletothei/pmodule.

2. Unscrew the fastening screws and re-movethei/pmodule(6)includingtheseals(7,8).

3. Placetheconnectingplate(3)withthesealonthehousingboresandscrewtight.Therestrictionmustbeseatedinthesealabovetherightinnerbore.

4. Replacethecablegland(5)withthepneumaticscrewfitting(1).

5. Connectthesiliconehose(2)andinserttheguardplate(4)intothehousing.

6. Remounttheholderwithterminalblock.7. Change type designation (model num-

ber)onthenameplatetoType 3766Pneumatic Positioner.

Note:For details on Type 3766 Positioners, refer to Mounting and Operating In-structions u EB 8355-1.

1 2 3 4

5 6 7 8

Fig. 16:Converting the positioner

http://www.samson.de/pdf_en/e83551en.pdf

48 EB8355-2EN

Convertingandretrofittingthepositioner

6.2 Installingthelimitcontacts

Accessories: Limit switch retrofit kit depend-ing on model index 3767-xxxxxxxxxx.04Order no. 1400-8810 for index .06 or higherOrder no. 1400-7573 for index .04/.05Order no. 1400-6389 for index .03

1. Unscrewthebracketwithplate(1).2. Removethescrews (2)andreplacethe

entiresetpointcalibrator (3)withacali-bratorincludinglimitcontacts.MakesuretheO-ringisinsertedintothehousing.

3. Attachtheterminalblockforthelimitsig-nals41/42and51/52intheterminalbase.

4. Guidetheconnectingcabletothetermi-nals and fasten.(brown=+,blue=–)

5. Refastenthebracketwithplate(1)andsticktheadhesivelabelforthelimitswitches on the housing cover.

6. Screwadditionalcableglandontothehousing.

6.3 Installingasolenoidvalve

Accessories: Solenoid valve retrofit kitOrder no. 1400-7712 for index .05 or lowerOrder no. 1400-8808 for index .06

1. Pushtheplate(5)tooneside.2. Unscrewthefourscrews(7).Liftoffthe

blackcoverwiththerubbergasketandinsertthesolenoidvalve(6).Therubbergasket with the restriction is located in the rear of the solenoid valve.

3. Unscrewtheplate(1).

1 2 23

4

5

6789

10

Fig. 17:Installing the limit switches and solenoid valve

EB8355-2EN 49

Servicingexplosion-protecteddevices

4. Attachtheterminalblock(10)fortheso-lenoidvalveintheterminalbase.

5. Insertthepanel (9)attherearofthepo-sitioner and attach it to the set point cali-bratorusingtwoscrews.

6. Guidetheconnectingcabledownbehindthe mounted panel of the set point cali-bratorandupagaintoterminals81/82and fasten.(brown=+,blue=–)

7. Screwonthebracketwithplate(1).8. Screwadditionalcableglandontothe

housing.

6.4 Removingthesolenoidvalve

Accessories: Retrofit kit containing cover for solenoid valve opening: order no. 1400-6949

1. Unscrewbracketwithplate(1).Removetheconnectingcableofthesolenoidvalve from terminals 81/82.

2. Unscrewthetwoscrews(7)thatarenotsealed with paint and remove the sole-noidvalvewithitsconnectingcable.

3. Placetherubbergasketonthespigotofthe cover and screw it into the housing.

4. Screwonthebracketwithplate(1).

7 Servicingexplosion-protecteddevices

If a part of the device on which the explosion protectionisbasedneedstobeserviced,thedevicemustnotbeputbackintooperationuntilaqualifiedinspectorhasassesseditac-cording to explosion protection require-ments,hasissuedaninspectioncertificateorgiven the device a mark of conformity.Inspectionbyaqualifiedinspectorisnotre-quired if the manufacturer performs a rou-tinetestonthedevicebeforeputtingitbackinto operation. Document the passing of the routinetestbyattachingamarkofconformi-ty to the device.Inspectionbyaqualifiedinspectorisnotre-quired if the manufacturer performs a rou-tinetestonthedevicebeforeputtingitbackinto operation. Document the passing of the routinetestbyattachingamarkofconformi-tytothedevice.Replaceexplosion-protectedcomponentsonlywithoriginal,routine-testedcomponentsbythemanufacturer.Devicesthathavealreadybeenusedout-sidehazardousareasandareintendedforfutureuseinsidehazardousareasmustcomplywiththesafetyrequirementsplacedonserviceddevices.Beforebeingoperatedinsidehazardousareas,testthedevicesac-cordingtothespecificationsforservicingexplosion-protecteddevices.ObserveEN 60079-17duringservicing.

50 EB8355-2EN

Dimensionsinmm

8 Dimensionsinmm

44

19.5

3539

164

4676 50

36N

1=11

3 N

2=20

0

5856

68

28

1429

150

16419.5

37

6818

5

76

Ø110

82

5666

50

M20 x 1.5

28.5

28.5

Output 1 (A1)

Output 2 (A2) Supply (Z)

50

Output (38)

Supply (9)

Pneumatic connectionsG ¼or¼ NPT

Reversingamplifier(optional)

Attachment with intermediate piece for rotary actuators

AttachmentIEC 60534-6(NAMUR)withadapterhousing

Fulcrum of actuator shaft

Pneumatic connection reversingamplifier

52 EB8355-2EN

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EB8355-2EN 55

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EB8355-2EN 67

SAMSON AG · MESS- UND REGELTECHNIKWeismüllerstraße 3 · 60314 Frankfurt am Main, GermanyPhone: +49 69 4009-0 · Fax: +49 69 [email protected] · www.samson.de EB 8355-2 EN 20

17-06-29·English

Documents

Mounting and Operating Instructions EB 8355-2 EN · Mounting and Operating Instructions EB 8355-2 EN ... 3 Mounting on control valves ... travel and the nominal span of the reference