Mounting and Operating Instructions EB 8394 EN
Contents
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3. 6 3 V Supply air 1 4 to 7 bar 20 to 105 psi Max particle size and density Class 4 Oil content Class 3 Pressure dew point Class 3 or at least 10 K below the lowest ambient temperature to be expected 0 bar up to the capacity of the supply pressure Can be limited to approx 2 4 bar by software 3 characteristics for globe valves 9 characteristics for rotary valves lt 0 3 lt 0 1 for actuators with initialization time gt 0 5 s w x reversible lt 100 h with a supply pressure up to 6 bar and a signal pressure of 0 6 bar At Ap 6 bar 8 5 m 3 h At Ap 21 4 bar 1 4 m 3 h At Ap 6 bar 14 0 m h At Ap 21 4 bar 4 5 m 3 h 20 to 80 25 to 80 with metal cable gland The limits in the test certificate additionally apply for explosion protected versions lt 0 15 10 lt 0 5 up to 2000 Hz and 4 g according to IEC 770 None 20 0 09 20 C 0 15 Temperature Vibrations Supply air For faster actuators a volume restriction must be used Otherwise the initialization cannot be performed EB 8394 EN Design and principle of operation Electromagnetic Complying with EN 61000 6 2 EN 61000 6 3 and NAMUR Recommendation NE 21 compatibility Explosion protection 112 Ex ia TA Degree of protection Body Polyphthalamide PPA EB 8394 EN 11 Attachment to the control valve Mounting parts and accessories 4 Attachment
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5. The positioner moves the control valve to the CLOSED position and recalibrates the internal electric zero point When the zero calibration has been suc cessfully completed the positioner returns to closed loop operation display with status in dication EB 8394 EN Canceling zero calibration The zero calibration be canceled by touching ESC blinks on the display Touch to confirm Note This code must be confirmed by touch ing K Otherwise the code remains active The positioner returns to closed loop opera tion without performing a zero calibration A new zero calibration can be started direct ly afterwards EB 8394 EN Start up and settings 7 10 Manual mode The valve position can be moved as follows using the Manual mode function Enable configuration section 7 2 Touch V or A until Code P17 appears Touch six seconds long 6 5 4 3 2 1 is counted down on the display P17 blinks The manual set point w man is indicated on the display of an initialized positioner The lever position in degrees in relation to the longitudinal axis is indicated on the display of a positioner that has not been initialized Touch V or A to change the manual set point Initialized positioner The manual mode starts using the last set point of the automatic mode ensuring a bumpless changeover The bar elements on the display indicate the
6. projecting from the side of the connection block 12 is positioned above 18 Attachment to the control valve Mounting parts and accessories the actuator symbol that corresponds with the actuator with fail safe action Actuator stem extends or Actuator stem retracts If necessary remove the three mounting screws and the cover Then reposition the gasket 16 turned by 180 Place the connection block 12 with the associated seals against the positioner and the actuator yoke and fasten using the screw 12 1 For actuators with fail safe action Actua tor stem retracts additionally remove the stopper 12 2 and mount the external sig nal pressure pipe 7 Mount cover 11 on the other side Make sure that the vent plug is located at the bottom when the control valve is installed to allow any condensed water that collects to drain off see Fig 6 on page 16 EB 8394 EN Attachment to the control valve Mounting parts and accessories lever M Nut Disk spring Follower pin Follower clamp Cover Connection block Screw Stopper or connection for external piping Formed seal Gasket 10 15 1 2 3 F EC Fig 9 Direct attachment Signal pressure connection for Type 3277 Actuator with 240 to 700 cm EB 8394 EN 19 Attachment to the control valve Mounting parts and accessories 4 2 Attachment according to IEC 60534 6 NAMUR The positioner is attached to the control valve using a
7. system deviation between the manual and au tomatic set point while manually moving the valve in Code P17 Al Start up and settings The manual set point is adjusted in steps of 0 1 26 You can move the valve controlled with in its range Positioner that has not yet been initialized Touch V or longer to move the valve manually The valve is only moved in one direction un controlled The bar elements on the display in dicate the change in direction Touch K to deactivate the Manual mode func tion Note L The Manual mode function can only be exited as described or by interrupting the electrical supply cold start The positioner does not automatically exit this function and return to the display with status indication 42 7 11 Reset The is in closed loop operation after the initialization has been successful ly completed A reset causes an initialization to be undone and all parameters settings are reset to the de fault settings see code list in section 8 Enable configuration section 7 2 Touch or until Code P18 appears Touch six seconds long 6 5 4 3 2 1 is counted down on the display RST blinks After the positioner has been reset the display automatically returns to status indication In this display the angle is indicated in de grees relative to the longitudinal axis EB 8394 EN 7 12 Faults On occurrence o
8. 48 11 Dimensions In IN TT 49 11 1 Fixing levels according to VDI VDE 3845 September 2010 50 Firmware revisions 1 03 new Internal revisions To suppress common mode interference on the signal lines the D component of the positioner is switched off when the actuator is at a standstill 1 10 new Setting of the travel in Code PA in steps of 0 5 mm Monitoring of the end stops only during initialization and in man ual mode 4 EB 8394 EN Safety instructions 1 Safety instructions For your own safety follow these instructions concerning the mounting start up and opera tion of the positioner The device is to be assembled started up or operated only by trained and experienced per sonnel familiar with the product According to these mounting and operating instructions trained personnel is referred to as individuals who are able to judge the work they are as signed to and recognize possible dangers due to their specialized training their knowledge and experience as well as their knowledge of the applicable standards Explosion protected versions of this device are to be operated only by personnel who has undergone special training or instructions or who is authorized to work on explosion pro tected devices in hazardous areas Any hazards that could be caused in the valve by the process medium the signal pressure or by moving parts are to be prevented by means o
9. 6 1 Operating controls Touch V or A to select a parameter code PO to P20 Then touch to confirm the se lected code Down Operation locked Fail safe position active INVI INI um ENS Qm Parameter error code Fig 17 Capacitive keys and display EB 8394 EN Operation NOTICE Any parameter code settings that have been changed are first saved in a non volatile memory after the display has returned to the display with status in dication Go to Code PO by touching or or wait three minutes until the display returns automatically The amp icon on the display indicates that the changed parameter settings have not yet been saved in the non volatile memory Note After changing settings in P2 P8 and P9 parameter codes the posi must be re initialized Confirm Settings not yet saved in a non volatile memory mE ml ou Bar graph for system deviation Fault Manual mode Closed loop operation 33 Start up and settings Volume restriction Q The volume restriction serves to adapt the air output capacity to the size of the actuator Two fixed settings are possible refer to sec tion 7 3 Display esc _ Eo Ee wx E W AN AX T st NN Icons assigned to certain codes and functions are indicated on the display The bar elements indicate the system deviation that d
10. NAMUR bracket 10 Refer to Table 3 on page 27 for the re quired mounting parts and accessories Observe the travel table on page 13 1 Screw the two bolts 14 to the brack et 9 1 of the stem connector 9 place the follower plate 3 on top and use the screws 14 1 for fastening 2 Mount NAMUR bracket 10 using the M8 screw 11 and toothed lock washer di to the yoke hole Align the NAMUR bracket 10 so that its mounting holes are approximately in line with the mid dle of the travel scale indicator 15 the slot of the follower plate must be centrally aligned with the NAMUR bracket at mid valve travel 3 Mount connecting plate 6 or pressure gauge bracket 7 with pressure gauges 8 on the positioner making sure the two seals 6 1 are seated properly 4 Place positioner on the NAMUR bracket in such a manner that follower pin 2 rests in the slot of the follower plate 3 Adjust the lever 1 correspondingly Screw the positioner to the NAMUR brack et using both its mounting screws 20 EB 8394 EN Attachment to the control valve Mounting parts and accessories Lever Nut Disk spring Follower pin Follower plate Connecting plate Seal Pressure gauge bracket Pressure gauge Stem connector Bracket NAMUR bracket Screw Bolt Screws Travel indicator scale 2 1 1 2 3 6 6 7 Fig 10 Attachment according to IEC 60534 6 NAMUR EB 8394 E
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12. The screw fittings must be screwed into the connecting plate the pressure gauge mount ing block or the connection block from the ac cessories Their pneumatic connections are optionally designed as a bore with NPT 14 thread The customary fittings for met al and copper pipes or plastic hoses can be used Keep the length of the line as short as possible to avoid delays in control signal transmission The supply air must dry and free rom oil and dust The maintenance in structions for upstream pressure reduc ing stations must be observed Blow through all air pipes and hoses thoroughly prior to connecting them The signal pressure connection is fixed when the positioner is directly attached the Type 3277 Actuator For attachment according to IEC 60534 6 NAMUR the signal pressure can be routed to either the top or bottom diaphragm cham ber of the actuator depending on the actua EB 8394 EN Connections tor s fail safe action Actuator stem extends or Actuator stem retracts For rotary actuators the manufacturer s spec ifications for connection apply 5 1 1 To monitor the supply air supply and sig nal pressure output we recommend mount ing pressure gauges see accessories in sec tion 4 5 Signal pressure gauges 5 1 2 Supply pressure The required supply air pressure depends on the bench range and the actuator s operating direction fail safe action The
13. are described on the fol lowing pages Fig 8 3372 Actuator with Type 3725 Positioner direct attachment EB 8394 EN 17 Actuators with 240 to 700 effective ar eas The positioner can be mounted either on the left or right side of the yoke The signal pres sure is routed to the actuator over the con nection block 12 for actuators with fail safe action Actuator stem extends internally through a hole in the valve yoke and for Ac tuator stem retracts through an external pipe 1 Place follower clamp 3 actua tor stem align and screw tight so that the mounting screw is located in the groove of the actuator stem For actuators 240 and 350 cm with 15 mm travel keep the follower pin 2 in pin position 35 For actuators with 355 or 700 re move the follower pin 2 on lever M 1 on the back of the positioner from pin po sition 35 reposition it in the hole for pin position 50 and screw tight Insert formed seal 15 in the groove of the positioner housing Place positioner on the actuator in such a manner that the follower pin 2 rests on top of the follower clamp 3 While doing this press on the ribbed ar ea to lock the pick up lever in the top po sition see Fig 4 on page 14 The lever 1 must rest on the follower clamp with spring force Mount the positioner on the actuator using the two fixing screws Check to make sure that the tip of the gas ket 16
14. bracket E 1402 0238 Pressure gauge mounting kit up to max bar St steel brass 1400 6950 output supply St steel st steel 1400 6951 EB 8394 EN 27 Attachment to the control valve Mounting parts and accessories Table 4 Attachment to rotary actuators section 4 4 Order no Attachment acc to VDI VDE 3845 size AAT see dimension table on bae 50 1402 0243 Moni ark MM acc to VDI VDE 3845 size AA2 see dimension table on 1402 0244 Attachment to VETEC Type 5160 Actuator 1402 0294 SAMSON 3278 Rotary Actuator 160 cm level 2 1402 0235 Connecting plate NPT 1402 0236 1402 0237 Pressure gauge bracket Accessories 1402 0238 Pressure gauge mounting kit up to 6 bar St steel brass 1400 6750 output supply St steel st steel 1400 6951 Connecting plate for Type 3710 Reversing Amplifier 1402 0512 1 Refer to section 11 1 on page 50 for details Table 5 General accessories Order no 8808 1011 Plastic cable 8808 1012 gland M20x1 5 Nickel plated brass 1890 4875 Stainless steel 1 4305 8808 0160 Adapter Powder coated aluminum 0310 2149 M20x1 5 to 1400 7114 Brief instruc tions inside DE EN delivered state cover 0190 6173 0190 6174 28 EB 8394 EN 5 Connections 5 1 Pneumatic connections NOTICE The threaded connections in the po sitioner housing are not designed for the direct connection of pneumatic fit tings
15. following components see Fig 1 Anisotropic magnetoresistive AMR sen sor 2 Analog i p converter 6 with a down stream air capacity booster 7 Electronics unit with microcontroller 4 The travel or opening angle is measured by the pick up lever connected to a magnet and a non contact AMR sensor 2 installed in the positioner and the downstream electronics The motion of the pick up lever causes the di rection of the magnetic field to change This change is sensed by the AMR sensor The elec tronics unit determines the current valve posi tion or opening angle from this information The position of the valve is transmitted to the microcontroller 4 over its A D converter 3 The PD control algorithm in the microproces sor compares this actual position to the 4 to 20 mA control signal reference variable after it has been converted by the A D converter 3 In case of a system deviation the activa tion of the i p converter 6 is changed so that the actuator of the control valve 1 is pres surized or vented accordingly over the down stream booster 7 The supply air is supplied to the booster and the pressure regulator 8 The output signal pressure supplied by the booster can be limited to 2 4 bar by software The volume restriction Q 10 is used to opti mize the positioner by adapting it to the ac tuator size Tight closing function The pneumatic actuator is completely filled with ai
16. to the control valve Mounting parts and accessories NOTICE Attach the positioner keeping the fol lowing sequence 1 Mount the positioner on the control valve 2 Connect the supply air 3 Connect the electrical power 4 Perform the start up settings The positioner is suitable for the following types of attachment Direct attachment to SAMSON Type 3277 and Type 2780 2 Actuators Attachment according to IEC 60534 6 NAMUR Attachment to Type 3372 Actuator Se ries V2001 Valves Attachment to rotary actuators acc to VDI VDE 3845 Attach the positioner to the control valve only using the mounting parts and accessories as described in sec tion 4 5 Observe the type of attachment Observe the assignment between le ver and pin position Lever and pin position The positioner is adapted to the actuator and to the rated travel by the lever on the back of the positioner and the pin inserted into the le ver 12 The travel tables show the maximum adjust ment range at the positioner The travel that can be implemented at the valve is addition ally restricted by the selected fail safe posi tion and the required compression of the ac tuator springs The positioner is equipped with the lever M pin position 35 as standard Fig 2 lever M with pin position 35 Only remove the lever when it is posi tioned in the bottom mechanical stop Otherwi
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19. N 21 Attachment to the control valve Mounting parts and accessories 22 EB 8394 EN Attachment to the control valve Mounting parts and accessories 4 3 Attachment to Type 3372 Actuator V2001 The Type 3725 Positioner is already includ ed in the scope of delivery for Series V2001 Valves 3372 Actuator The attachment is briefly described below to allow conversion work to be performed Actuator with 120 350 stem extends The signal pressure is routed through the cor responding port in the support element to the actuator diaphragm Thread the screw plug on the positioner into the hole below park position see Fig 7 on page 16 Actuator with 120 350 cm2 stem retracts The signal pressure is routed through piping at the side of the support element to the actu ator diaphragm Attachment including solenoid valve The signal pressure is routed from the output port of the positioner to the solenoid valve and through a corresponding hole in the sup port element to the actuator diaphragm EB 8394 EN Type 3372 Actuator version 120 cm effective area Type 3372 Actuator version 350 cm effective area Fig 11 Mounting on Type 3372 Actuator 23 Attachment to the control valve Mounting parts and accessories 4 4 Attachment to rotary actu ators The positioner is mounted to the rotary actua tor using a mounting bracket Refer to Table 4 on page 28 for the re quired mountin
20. Series 3725 Electropneumatic Positioner Type 3725 Type 3725 Positioner Mounting and Operating Instructions EB 8394 EN C Ex Firmware version 1 10 Edition October 2012 Definition of the signal words used in these mounting and operating instructions DANGER NOTICE indicates a hazardous situation which indicates a property damage mes if not avoided will result in death or sage serious injury pM Note WARNING Supplementary explanations informa indicates a hazardous situation which tion and tips if not avoided could result in death or serious Injury 2 EB 8394 EN 3 1 4 1 4 1 1 4 1 2 4 2 4 3 4 4 4 4 1 4 5 5 1 5 1 1 5 1 2 5 2 6 1 7 1 7 2 7 3 7 4 7 5 7 6 Zu 7 8 9 7 10 Contents Safety dert ER 6 PRUNE 7 Design and principle of operation eee ecce e rece eee eren eene nenne 8 Technical C 10 Attachment to the control valve Mounting parts and accessories 12 Direct aliae 14 3277 5 and 2780 2 Actuators 14 POOR pesos 17 Attachment according to IEC 60534 6 20 Attachment to Type 3372 Actuator 2001 23 Atiachment
21. achment to the control valve Mounting parts and accessories 7 Mount cover 11 on the other side Make sure that the vent plug is located at the bottom when the control valve is installed to allow any condensed water that collects to drain off Fig 6 Vent plug Fig 6 Cover with venting when the valve is installed 16 Additional solenoid valve IF a solenoid valve is additionally mounted onto the actuator the signal pressure port at the back of the positioner must be sealed To do this unscrew the screw plug located in the middle hole screw plug in park position and screw it into the signal pressure port to seal it Screw plug 4 signal pressure port Park position Fastening screw Fig 7 Signal pressure port and park position lor screw plug In this case the signal pressure must be rout ed from the signal pressure output to the ac tuator over the connecting plate 6 or pres sure gauge bracket 7 The connecting plate accessories for the actuator replaces the swi tchover plate 9 Note The switchover plate or connecting plate are accessories for the actuator 120 cm listed in the table on page 27 EB 8394 EN Attachment to the control valve Mounting parts and accessories 4 1 2 Type 3277 Actuator Refer to section 4 5 for the required mounting parts and accessories Observe the travel table on page 13 Note The actuators with 240 to 700 cm ef lective areas
22. action Reset error code see section 7 12 Check positioner mounting and re initialize the positioner E9 Device error Device error Internal device error tum psone 1o SAMSON AG EB 8394 EN 47 Maintenance 9 Maintenance The positioner does not require any main tenance There are filters with a 100 pm mesh size in the pneumatic connections for supply and out put which can be removed and cleaned if re quired The maintenance instructions of any upstream supply air pressure reducing stations must be observed 10 Servicing explosion protect ed devices If a part of the device on which the explosion protection is based needs to be serviced the device must not be put back into operation until an approved notified body or a qual ified inspector has assessed it according to explosion protection requirements has issued an inspection certificate or given the device a mark of conformity Inspection by an approved notified body or a qualified inspector is not required if the man ufacturer performs a routine test on the de vice prior to putting it back into operation The passing of the routine test must be doc umented by attaching a mark of conformity to the device Replace explosion protected components on ly by original routine tested components pro vided by the manufacturer 48 D Note Devices that have already been used outside hazardous areas and are in tended for fu
23. ame pressure as the supply air at the maximum OFF or in the case that the maximum actua tor force can damage the valve the pressure is limited to approx 2 4 bar Lower tight closing function If w reaches up to 1 towards the final value that causes the valve to close the actuator is immediately completely vented with ATO air to open or filled with air with ATC air to close Upper tight closing function If w reaches up to 99 towards the final value that causes the valve to open the actuator is immediately completely filled with air with ATO air to open or vented with ATC air to close Indicates the internally adjusted set point adjusted set point in O to 100 according to the settings in and P7 Touch to display external set point applied set point in 0 to 100 according to the 4 20 mA signal Displays external set point in to 100 according to the 4 20 mA signal 45 Code list Start initialization The initialization process can be interrupted by touching X The control valve moves to its fail safe position After a power supply failure during initialization the positioner starts with the settings from the last initialization if they exist Start zero calibration The zero calibration process interrupted by touching The control valve returns to closed loop operation Note A zero calibration cannot be started when E1 error code ex ists After a power supply fa
24. been initialized 46 EB 8394 EN Code list action Check the volume restriction setting as described in section 7 3 Code P8 Re initialize the positioner setting Positioner hunts initialization error Volume restriction set incorrectly too much gain Transit time is too fast The transit times of the actuator determined during initialization are initialization error so short below 0 5 second that the optimal positioner tuning is not possible Recommended action Check the volume restriction setting as described in section 7 3 Re initialize the positioner Standstill detection is Supply pressure is too low or varies Mounting incorrect not possible initialization error Recommended action Check supply air and positioner mounting Re initialize the positioner Travel is not achieved Supply pressure is too low actuator leaks incorrect travel adjusted during initialization or pressure limit function activated initialization error Recommended action Check supply air positioner mounting and setting Re initialize the positioner Actuator does not No supply air mounting blocked move initialization error Recommended action Check supply air positioner mounting and mA input signal Re initialize the positioner Travel signal at lower Wrong pin position wrong lever wrong attachment direction when upper limit NAMUR attachment is used Recommended
25. bench range is registered on the nameplate either as spring range or signal pressure range depending on the actuator The direction of action is marked FA or FE or by a symbol Actuator stem extends FA air to open Fail safe position Valve Closed for globe and angle valves Required supply pressure Upper bench range value 0 2 bar minimum 1 4 bar 29 Connections Actuator stem retracts FE air to close Fail safe position Valve Open for globe and angle valves For tight closing valves the maximum signal pressure pst is roughly estimated as follows max bar 2 1 Pst d Seat diameter Ap Differential pressure across the valve bar A Actuator diaphragm area cm Upper bench range value bar If there are no specifications calculate as follows Required supply pressure Upper bench range value 1 bar rn Note The signal pressure at the output 38 of the positioner can be restricted to approx 2 4 bar by setting 9 param efer code ON 30 5 2 Electrical connections DANGER Risk of electric shock and or the for mation of an explosive atmosphere electrical installation observe the relevant electrotechnical regu lations and the accident prevention regulations that apply in the coun try of use The following regulation applies to mounting and installation in hazardous areas EN 60079 14 Explosive atmosphere
26. ce positioner on the actuator in such a manner that the follower pin 2 rests on top of the follower clamp 3 While do ing this press on the ribbed area shown in Fig 4 to lock the pick up lever in the top position The lever 1 must rest on the fol lower clamp with spring force Fig 4 Locking the pick up lever in position Mount the positioner on the actuator using the two fixing screws EB 8394 EN Attachment to the control valve Mounting parts and accessories 1 Lever 1 1 Nut 1 2 Disk spring Symbols Switchover plate 9 extends tt Actuator stem Left attachment v Right attachment 3 Actuator stem 5 retracts Signal pressure input for left attachment Signal pressure input for right Follower pin Follower clamp Screw plug Stopper Connecting plate Seal Pressure gauge bracket Pressure gauge mounting kit Switchover plate actuator Cover Formed seal attachment Vent plug SETZEN S SSS ap T Ce a ed ETE 9 Output 38 WX ur Note Always use the connecting plate 6 pressure gauge bracket 7 cluded in the accessories to connect 2 supply and output Never screw threaded parts directly into the housing Otherwise the filter will be damaged Fig 5 Direct attachment Signal pressure connection for Type 3277 5 Actuator with 120 cm EB 8394 EN 15 Att
27. counted down on the display Touch to reset the error The reset procedure can be canceled by touching when ESC appears 43 Code list 8 Code list Code Display values default setting Parameter codes Codes marked with indicate the positioner needs to be re initialized afterwards Status indication mode of the display showing basic information The reading indicates the valve position or the angle of rotation in when the positioner is initialized The position of the lever in relation to the mid axis is indicated in degrees when 3K is touched and the positioner has not yet been initialized PI Reading direction The reading direction of the display is turned by 180 ATO ATC ATO Pin position 17 25 35 50 90 Nominal range MAX Values with default setting 35 e g 7 5 8 92 10 6 12 6 15 0 17 8 21 2 mm Nominal range MAX 44 Parameter to adapt the positioner to how the control valve func tions ATO Air to open valve CLOSED in fail safe position Air to close valve OPEN in fail safe position The follower pin must be mounted in the proper position depend ing on the valve travel opening angle select according to the travel tables on page 13 Firmware 1 03 and lower The possible adjustment range can be selected in stages depending on the selected pin position 17 3 75 25 5 3 35 7 5 50 10 6 10 6 mm 15 0 mm 21 2 mm 30 0 mm For 90 MAX F
28. creasing gt gt ATO gt gt lt gt lt gt Increasing decreasing 7 6 Limiting the signal pressure IF the maximum actuator force may cause damage to the valve the signal pressure must be limited Set Code P9 to ON This limits the signal pressure to approx 2 4 bar Enable configuration at the positioner before activating the pressure limit function see sec tion 7 2 37 Start up and settings 7 7 Setting other parameters The following table lists all the parameter codes and their default settings If you want to change the default setting of a parameter proceed in the same manner as previously de scribed Note The selected parameter code remains active until you change the setting or exit the parameter code More details concerning the parameter codes can be found in section 8 Parameter codes Default setting Codes marked with indicate that the position er needs to be re initialized afterwards _ Reference 20 nA mw Gain SO Pressrelini 24 bor OFT 38 Parameter codes Default setting Codes marked with indicate that the position er needs to be re initialized afterwards Enable configuration EB 8394 EN 7 9 Initialization During initialization the positioner adapts it self optimally to the friction conditions and the signal pressure required by the control valve WARNING N During the initialization the control valve moves throu
29. e 3710 Reversing Amplifier 26 EB 8394 EN Attachment to the control valve Mounting parts and accessories 4 5 Required mounting parts and accessories Table 1 Direct attachment to Types 3277 5 and 3277 Actuators section 4 1 Order no Mounting parts Switchover plate for Type 3277 5xxxxxx 01 Actuator for actuator Connecting plate for additional attachment e g solenoid valve Connecting plate 6 G A NPT Accessories Pressure gauge bracket 7 V4 NPT 1402 0238 Pressure gauge mounting kit 8 up to max 6 bar St steel brass 1400 6950 output supply St steel st steel 1400 6951 Table 2 Direct attachment to Type 3277 Actuator section 4 1 2 Order no Mounting parts Mounting parts for actuators with 120 cm effective area or smaller 1402 0239 Attachment to actuators with 240 350 355 and 700 cm 1402 0240 1402 0241 Connection block with seals and screw PRI 125211249 ccessories Pressure gauge mounting kit up to max 6 bar St steel brass 1400 6950 output supply St steel st steel 1400 6951 Table 3 Attachment to NAMUR ribs according to IEC 60534 6 section 4 2 Travel mm Lever For actuators Order no 3 75 to 50 Without already Actuators from other manufacturers and 1402 0330 on positioner Type 3271 with 120 to 700 cm effective areas a 14 1402 0235 nnectin onnecting plate NPT 1402 0236 G 1 1402 0237 402 0237 Accessories Pressure gauge
30. epending on the type of positioner attach ment the signal pressure is routed either left or right of the yoke through a hole to the ac tuator diaphragm Depending on the fail safe action of the ac tuator Actuator stem extends or Actuator stem retracts valve closes or opens if the sup ply air fails the switchover plate 9 must first be attached to the actuator yoke Align the switchover plate with the corresponding sym bol for left or right attachment according to the marking view looking onto the switcho ver plate 1 Mount connecting plate 6 or pressure gauge bracket 7 with pressure gauges onto the positioner making sure both seal rings 6 1 are seated properly 2 Screw the screw plug 4 on the back of the positioner into the hole below it park position see Fig 7 and seal the signal pressure output on the connecting plate 6 or on the pressure gauge bracket 7 with the stopper 5 included in the ac cessories 3 Place follower clamp 3 on the actua tor stem align and screw tight so that the mounting screw is located in the groove of the actuator stem 15 mm travel Keep the follower pin 2 on lever M 1 on the back of the position er in the pin position 35 delivered state 7 5 mm travel Remove the follower pin 2 from the pin position 35 reposition it in the hole for pin position 25 and screw tight Insert formed seal 15 into the groove of the positioner housing Pla
31. epends on the sign and the value ES Er LO M M RS One bar element appears per 1 system de viation If the positioner has not yet been initialized the lever position in degrees in relation to the longitudinal axis is indicated One bar ele ment corresponds to approximately a 7 an gle of rotation If the fault indication icon I appears on the display touch or A until ERR appears on the display to view the EO to E15 error code s see code list in section 8 34 7 Start up and settings WARNING N Do not perform a while the process 15 On applying supply air and the elec tric control signal the control valve may move through its entire trav el range rotational angle range de pending on the setting start up running Connect the supply air Supply 9 Connect the 4 to 20 mA signal terminals 411 12 D Note After connecting the electrical signal power supply the positioner per forms a calibration of the capacitive keys which takes approx three sec onds During this time do not touch the key panel Otherwise the keys will not work properly Disconnect and recon the electrical signal to restart the calibration of keys LOW on the display indicates that the refer ence variable is lower than 3 6 mA The positioner is ready for operation with its default settings for most applications provid ed it has been mounted properly D Note The posit
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33. f a fault the fault indica tion icon 1 appears at the bottom of the dis play IF the fault indication icon appears after a pa rameter code setting has been changed this indicates that this setting does not match the values determined during initialization See Code E1 see code list in section 8 Touch or past Code or P20 the re spective error code EO to E15 together with ERR appear on the display Refer to the code list for the cause of the errors and the recommended action Example If for instance a travel has been entered in Code P4 nominal range which is larger than the maximum valve travel possible the initial ization process would be interrupted E2 er ror code because the rated travel would not have been reached E6 error code The valve moves to the fail safe position S indicated on the display n Display of fault P 0 indication S S C CIL CCCII CINES CINES EB 8394 EN Start up and settings The nominal range Code P4 must be changed and the positioner re initialized to remedy this problem Reset error codes The EO and E8 error codes can be reset as follows r v 6 zE A A Touch V or A until the error code appears Touch to confirm the error code ESC ap pears on the display Touch V until RST appears Touch six seconds long 6 5 4 3 2 1 is
34. f the appropriate measures If inadmissible motions or forces are produced in the pneumatic actuator as a result of the supply pressure level it must be restricted using a suitable supply pressure reducing station Proper shipping and storage are assumed To avoid damage to any equipment the following also applies not operate the positioner with the back of the positioner vent opening facing upwards The vent opening must not be sealed when the positioner is installed on site Note D Positioners with a CE marking fulfill the requirements of the Directives 2004 108 EC and 2006 95 EC The Declaration of Conformity is available on request 6 8394 Article code 2 Article code Positioner Type 3725 x 00000000 0009 9 9565 With LCD and autotune 4 20 mA reference variable Explosion protection amp 112 Ex ia acc to ATEX Other certification is pending EB 8394 EN 7 Design and principle of operation 3 Design and principle of oper ation The electropneumatic positioner is mount ed on pneumatic control valves and is used to assign the valve position controlled vari able x to the control signal reference vari able w The positioner compares the electric control signal of a control system to the travel or opening angle of the control valve and is sues a signal pressure output variable y for the pneumatic actuator The positioner mainly consists of the
35. for a clamping range of 6 to 12 mm The cage clamp terminals hold wire cross sec tions of 0 2 to 1 5 mm and additionally have test connections for 1 mm probe tips EB 8394 EN Connections Notch on plastic part Fig 15 Cage clamp terminal NOTICE Applying excessive force to the cage clamp terminals may damage them The test connections are also used to unlock the cage clamp terminals place a slotted screwdriver on the notch of the plastic part of the test connection Fig 15 and press down while inserting or removing the wire The wires for the reference variable must be connected to the terminals 11 and 12 locat ed in the housing NOTICE The static destruction limit of the posi is at 33 V Do not allow input signal to fall below the lowest permissible value of 3 8 mA for posi Honer operation 31 Connections Accessories Plastic cable gland M20 x 1 5 Black Order no 8808 1011 Blue Order no 8808 1012 Nickel plated brass Order no 1890 4875 Stainless steel 1 4305 Order no 8808 0160 Adapter M20x1 5 to NPT Powder coated aluminum Order no 0310 2149 Stainless steel Order no 1400 7114 mA control signal Fig 16 Electrical connections 32 EB 8394 EN 6 Operation Three capacitive keys and a LCD are used to operate the positioner see below To adapt the air capacity the volume restric tion must be adjusted section 7 3
36. g 13 It must be guaranteed that the lever 1 is parallel to the long side of the positioner when the actuator is at half its angle of rotation 8 Stick the scale label on the coupling wheel 4 so that the arrow tip indicates the closed position and it can be easily read when the valve is installed Fig 12 Direction of rotation EB 8394 EN Attachment to the control valve Mounting parts and accessories Lever Connecting plate Nut 1 Seal Disk spring Pressure gauge Follower pin bracket Follower clamp Pressure gauge Coupling wheel mounting kit Screw Mounting bracket Disk spring 1 Screws Actuator shaft Attachment to VETEC Type 5160 Actuator or Attachment according to VDI VDE 3845 SAMSON Type 3278 Rotary Actuator level 1 160 cm Fig 13 Attachment to rotary actuators EB 8394 EN 25 Attachment to the control valve Mounting parts and accessories 4 4 1 Mounting the Type 3710 Reversing Amplifier When a Type 3710 Reversing Amplifier is used a connecting plate must be installed between the positioner and reversing amplifier The reversing amplifier is fastened to the positioner to gether with the connecting plate using screws Fig 14 Refer to the Mounting and Operating Instructions of the Type 3710 Reversing Amplifier gt 8392 EN Type 3710 Reversing Amplifier Fig 14 Mounting the Typ
37. g parts and accessories Before attaching the positioner onto the SAMSON Type 3278 Rotary Actuator 160 or VETEC Type 5160 Actuator first mount the adapter 13 to the free end of the shaft end using four screws 11 12 On attaching the positioner as de scribed below it is imperative that the actuator s direction of rotation is ob served 1 Place follower clamp 3 on the slotted ac tuator shaft or adapter 13 2 Place coupling wheel 4 with flat side facing the actuator on the follower clamp 3 Refer to Fig 12 to align slot so that it matches the direction of rotation when the valve is in its closed position 3 Fasten the coupling wheel 4 and follow er clamp 3 tightly onto the actuator shaft using screw 4 1 and disk spring 4 2 4 Mount connecting plate 6 or pressure gauge bracket 7 with pressure gauges 8 on the positioner making sure the two seals are seated properly 5 Fasten the mounting bracket 10 to the actuator using four screws 10 1 24 6 Unscrew the standard follower pin 2 from the positioner s lever M 1 Use the metal follower pin 5 mm included in the mounting kit and screw tight into the hole for pin position 90 7 Place positioner on the mounting brack et 10 and screw tight Taking the actua tor s direction of rotation into account ad just lever 1 so that it engages in the slot of the coupling wheel 4 with its follower pin Fi
38. gh its entire travel range angle of rotation Therefore do not start initialization while a process is running but on ly during start up when all shut off valves are closed The type and extent of self adaptation de pends on the preset parameters MAX is the default setting for the nominal range Code P4 During the initialization process the position er determines the travel range angle of rota tion of the valve from the CLOSED position to the other end position Alternatively a different travel can be selected in Code P4 see code list in section 8 Note W The travel set in Code PA is only lim ited during initialization However it might be exceeded in closed loop con trol when the control signal is higher than 20 mA Start initialization by activating Code 15 as follows EB 8394 EN Start up and settings Touch V or A to select Code 15 Touch six seconds long 6 5 4 3 2 1 is counted down on the display Initialization starts INIT blinks on the display Note The time required for the initialization procedure depends on the actuator transit time and can take a few minutes gt lt gt cm _ 2 1 Initialization successfully completed positioner runs in closed loop operation After a successful initialization the position er runs in closed loop operation indicated by closed loop operation icon and con trol posi
39. ilure during zero calibration the positioner starts with the settings from the last zero calibration Manual mode Touch A to enter the set point Parameters are reset to their default setting The positioner can only return to closed loop operation after it has been re initialized Enable configuration Enable configuration to change parameter settings LOCK OPEN This function is automatically canceled when none of the keys are touched within three minutes Read firmware Installed firmware version is displayed Touch to display the last four digits of the serial number Error codes Zero error Only with tight closing function PIO w lt set to ON operational error The zero point has shifted by more than 5 compared to initial ization The error may arise when the mounting position linkage of the positioner moves or when the valve seat trim is worn espe cially with soft seated plugs Recommended action Check valve and positioner attachment If OK perform a zero calibration over Code P16 see section 7 9 or reset the error code see section 7 12 Displayed and INIT Parameter code settings were changed after the initialization values are not identi cal operational error Recommended action Reset parameters or perform initialization Positioner has not been initialized Recommended action Set parameters and initialize the positioner over Code P15 Also not available when the positioner has not
40. ioner needs to be initialized again after the position of the volume restriction has been changed The po sitioner also needs to be initialized again after the setting for the fail safe position has been changed EB 8394 EN Reading after connecting the electrical sig nal The 4 fault indication icon and und 5 fail safe position appear on the display when the po sitioner has not yet been initialized The read ing indicates the lever positioner in degrees relative to the longitudinal axis Reading when the posi has not yet been initialized Code appears on the display after con necting the electrical signal to an initial ized positioner 7 1 Adapting the display direc The data representation the positioner dis play can be turned by 180 IF the displayed data appear upside down proceed as follows Touch V or A until Code appears Touch to confirm the selected code P1 blinks Leo MEM Reading direction for right attachment of pneumatic connections Touch or until until the display is set in the desired direction Touch to confirm display direction EB 8394 EN Start up and settings 7 2 Enabling configuration Note Before changing parameter settings configuration must be enabled first by selecting Code P19 Enabling configuration with Code 19 If no settings are entered within three minute
41. irmware 1 10 and higher Maximum range only if P3 90 Maximum possible travel The possible adjustment range can be selected in steps of 0 5 mm depending on the selected pin position 17 3 9 25 5 0 35 7 0 50 10 0 11 0 mm alternatively MAX 16 0 mm alternatively MAX 22 0 mm alternatively MAX 32 0 mm alternatively MAX For 90 MAX Maximum range only if P3 90 Maximum possible travel EB 8394 EN Reference variable 4 to 20 mA SRLO SRHI Pressure limit ON OFF End position w ON OFF End position w ON OFF Info w EB 8394 EN Initialized Not initialized Code list Characteristic selection O 1 2 for globe valves to 8 with rotary actuators 90 Linear Equal percentage Reverse equal percentage SAMSON butterfly valve linear SAMSON butterfly valve equal percentage VETEC rotary plug valve linear VETEC rotary plug valve equal percentage Segmented ball valve linear Segmented ball valve equal percentage COON CO 09 For split range operation SRLO low range 4 to 11 9 mA SRHI high range 12 1 to 20 mA Direction of action of the reference variable w to the travel rota tional angle x increasing increasing or increasing decreasing On initializing the positioner the gain is set to the selected value If the positioner hunts the K value can be reduced The positioner must be then re initialized afterwards The signal pressure can take on the s
42. it time 1 5 do not require the air flow rate to be restricted Setting to MAX Intermediate settings are not permitted NOTICE The positioner needs to be initialized again after the position of the restric tion has been changed EB 8394 EN 7 4 Entering the opening direc tion direction of action AIR TO OPEN ATO applies to a valve opening as the signal pressure increases AIR TO CLOSE ATC applies to a valve closing as the signal pressure increases The signal pressure is the pneumatic pressure at the output of the positioner applied to the actuator Enable configuration section 7 2 Default ATO Touch V or A until Code P2 appears Touch to confirm selected code P2 blinks Touch V or A until the required fail safe po sition appears Touch to confirm setting Note The changed opening direction di rection of action first becomes effec tive after the positioner has been re initialized 7 5 Entering the direction of ac tion The direction of action P7 is set to increas ing increasing by default EB 8394 EN Start up and settings For checking purposes After successfully completing initialization the positioner display should read when the valve is closed and 100 when the valve is open If necessary the direction of action can be changed either before or after initialization The following correlation applies gt gt Increasing in
43. r or vented as soon as the reference variable falls below 1 or exceeds 99 see end positions set and P11 parame ter codes Air to open ATO P10 ON P11 OFF Air to close ATC P10 OFF P11 ON EB 8394 EN Design and principle of operation 880 OF Control valve 7 Air capacity booster AMR sensor 8 Pressure regulator A D converter 9 Fixed restriction Microcontroller 10 Volume restriction D A converter 11 Display i p converter Fig 1 Functional diagram EB 8394 EN 9 Design and principle of operation 3 1 Positioner Travel adjustable Reference variable w Power consumption start up Power consumption operation Load impedance Supply air Air quality acc to ISO 8573 1 Signal pressure output Characteristic Hysteresis Sensitivity Transit time Direction of action Air consumption Air output capacity Actuator filled with air Actuator vented Permissible ambient temperature Influences 1 successfully 10 Technical data 3 75 to 30 mm 6 12 15 mm 15 30 mm 3 75 to 50 mm 24 to 100 Direct attachment to Type 3277 Direct attachment to Type 2780 2 Attachment to Type 3372 Actuator Attachment according to IEC 60534 6 NAMUR Attachment to rotary actuators 4 to 20 mA signal range Two wire device with reverse polarity protection Split range operation 4 to 11 9 mA and 12 1 to 20 mA Static destruction limit 33 V 3 8 mA 3 6 mA
44. s Part 14 Electrical installations design selec tion and erection Avoid electrostatic charging of the plastic housing when mounting and servicing the positioner in hazard ous areas Do not loosen enameled screws in or on the housing The maximum permissible values U I P L and specified in the EC type examination certificate ap ply when interconnecting intrinsical ly safe electrical equipment Only a current source must be used for the electrical supply Do not use a volt age source EB 8394 EN Selecting cables and wires Observe EN 60079 14 and particularly Clause 12 in it when installing intrinsically safe circuits The Subclause 12 2 2 7 applies when running multi core cables containing more than one intrinsically safe circuit The minimum radial thickness of the conduc tor insulation must be suitable for the conduc tor diameter and type of insulation It must be at least 0 2 mm The diameter of an individual wire in a fine stranded conductor must not be smaller than 0 1 mm Protect the conductor ends against splicing e g by using wire end ferrules Equipment for use in zone 2 In equipment operated with type of protection Ex nA non sparking equipment according to EN 60097 15 circuits may be connected interrupted or switched while energized on ly during installation maintenance or repair Cable entry The M20 x 1 5 cable gland is designed
45. s the enabled configuration function becomes invalid Touch V or until Code 19 appears ga Touch to confirm the selected code P19 blinks Touch until OPEN appears on the display Touch to unlock operation During start up the actuator stem moves Do not touch the actuator stem or ob struct it to avoid risk of injury to hands or fingers The permissible range has been exceeded when the displayed angle is more than 30 The positioner goes to the fail safe position SAFE Make sure that the lever and pin position match the details as described in section 4 35 Start up and settings Note D The positioner has a function to moni the working range If the lever moves too close to the me chanical stops risk of mechanical damage the positioner vents the ac tuator and the valve moves to its fail safe position 5 displayed together with E8 error code In this case check the positioner at tachment Reset the displayed error code by selecting RST see section 7 11 36 7 3 Adjusting the volume re striction Fig 18 Volume restriction Q MAX MIN setting The volume restriction Q serves to adapt the air output capacity to the size of the actuator Actuators with a transit time lt 1 s e g linear actuators with an effective area smaller than 240 cm require a restrict ed air flow rate Setting to MIN Actuators with trans
46. se the internal stops may be damaged Removing the lever 1 Hold the lever place Undo the nut us ing a wrench width across flats SW 10 2 Remove the lever from the shaft Top stop Fig 3 Mechanical stops for lever EB 8394 EN Attachment to the control valve Mounting parts and accessories Travel tables Note The lever M is included in the scope of delivery Direct attachment to Type 3277 5 and Type 3277 Actuators Actuator size Rated travel n range at a Assigned NE CUN Travel lever pin position ME zu 160 NENNEN NE Direct attachment to Type 2780 2 Actuator cm mm lever pin position sm 160 m Lm 79 0 as Attachment according to IEC 60534 6 NAMUR SAMSON Type 3271 Actuator Travel of other valves mm Required Assigned lever pin position Rated travel mm zs 3s no 7 wo 7s se 250 M 3 120 240 350 omo 75 i gt 70 15 30 Attachment to rotary actuators acc to VDI VDE 3845 Rotary actuators Required Assigned lever pin ae Size cm 27 4 10 EB 8394 EN 13 Attachment to the control valve Mounting parts and accessories 4 1 Direct attachment 4 1 1 3277 5 and Type 2780 2 Actuators Refer to Table 1 on page 27 for the re quired mounting parts and accessories Observe the travel table on page 13 Actuator with 120 cm D
47. tion in predetermined by the refer ence variable on the display Configuration is locked A malfunction leads to the process being in terrupted and the positioner moving to the fail safe position The fault indication icon ap pears on the display Refer to section 7 12 IL Initialization canceled 39 Start up and settings Canceling initialization The initialization can be canceled by touch ing ESC blinks on the display Touch to confirm Note This code must be confirmed by touch ing Otherwise the code remains active Case 1 A positioner that has not yet been ini tialized goes to the fail safe position after the initialization process has been canceled Case 2 The initialized positioner goes to AU TO mode after re initialization process has been canceled The settings of the previous initialization are used A new initialization can be started directly af terwards 40 7 9 Zero calibration In case of inconsistencies in the closing posi tion of the valve e g with soft seated plugs it might be necessary to recalibrate zero En able configuration as described in section 7 2 Start the zero calibration by activating Code 16 as follows PIBO Touch or until Code 16 appears Touch six seconds long 6 5 4 3 2 1 is counted down on the display Zero calibration starts the display blinks
48. to rotary 24 Mounting Type 3710 Reversing 26 Required mounting parts and accessories 27 COMMECTIONS M 29 Pneumatic connections 29 Signal pressure Gauges eub apnd Patti ne 29 SUB VISITES 29 RS 30 A 33 Operaling COM ONS NIME 33 Siari up and EEE E EE EnA een 34 Adapting the display 35 10 919 tonssliampebusdaastins 35 Adjusting the volume restriction 36 Entering the opening direction direction of action 97 Entering the direcion of ses dae odes uu MM SOIN ele Ep 37 Limiting the signal pressure Srt gutter x Eau 37 Setting other 38 99 io 15146 1 0 40 Mana ee RT 41 8394 3 7 11 42 7 12 jj 43 8 Cade MSE T P I 44 9 48 10 Servicing explosion protected devices ssscsssscssscessscsssesscccssessssssessesees
49. ture use inside hazardous areas must comply with the safety re quirements placed on serviced devic es Before being operated inside haz ardous areas test the devices accord ing to the specifications for servicing explosion protected devices EB 8394 EN Dimensions in mm 11 Dimensions in mm Fig 19 Dimensional drawings for Type 3375 Positioner EB 8394 EN 49 Dimensions in mm 11 1 Fixing levels according to VDI VDE 3845 September 2010 25 KHEN sse 96 EN 50 type F05 acc to DIN EN ISO 5211 50 EB 8394 EN ieys 1X9 LEWES eu Jo aged Meisuesapung euosiuuse u smexisAua Aq 1a qne JO spena uongaeye pappa aq seyeoruso eu pies eq you eys eroe pue aunjeutirs NOW uoneuruexe ad 3 pp LLALLACACO LEC EEULLLOTIILIZIZCLLELIEILRr CATPI CETIIIILELTLUS CLC RL LGUCLIECESIGCEOUEXR1t 0 1 272 199us eudinba eq eus Jeqe v unuiuiu e OSU eui psa uoneuuojur penbeJ pnpu peus jenuew Dunejedo pue 291 asn ajes 10 suonipuco jeroeds 41 6501 11 Xd did poda ps3 pue 10541555557 91 7 3928 0 vu 1 85 n senjeA ejes
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