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Series 3731Electropneumatic Ex d PositionerType 3731-5

with FOUNDATION™ fieldbus communication

Mounting andOperating Instructions

EB 8387-5 ENFirmware version R 1.45Edition April 2008

JIS

Fig. 1 · Type 3731-5

2 EB 8387-5 EN

DANGER!indicates a hazardous situation which, if notavoided, will result in death or serious injury.

WARNING!indicates a hazardous situation which, if notavoided, could result in death or seriousinjury.

NOTICEindicates a property damage message.

Note: Supplementary explanations, informa-tion and tips

Definitions of the signal words used in these instructions

Contents

1 Important safety instructions . . . . . . . . . . . . . . . . . . . . . . 6

2 Article code . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7

3 Design and principle of operation. . . . . . . . . . . . . . . . . . . . 83.1 Additional equipment . . . . . . . . . . . . . . . . . . . . . . . . . . 93.2 Communication . . . . . . . . . . . . . . . . . . . . . . . . . . . . 103.2.1 Configuration using TROVIS-VIEW software . . . . . . . . . . . . . . 103.2.2 Configuration using the NI-BUS™ Configurator . . . . . . . . . . . . . . . . . 10

3.3 Technical data. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11

4 Attachment to the control valve – Mounting parts and accessories . . . 134.1 Direct attachment . . . . . . . . . . . . . . . . . . . . . . . . . . . 154.1.1 Type 3277-5 Actuator . . . . . . . . . . . . . . . . . . . . . . . . . 154.1.2 Type 3277 Actuator . . . . . . . . . . . . . . . . . . . . . . . . . . 184.2 Attachment according to IEC 60534-6 (NAMUR) . . . . . . . . . . . . 204.3 Attachment to Type 3510 Micro-flow Valve. . . . . . . . . . . . . . . 224.4 Attachment to rotary actuators . . . . . . . . . . . . . . . . . . . . . 244.5 Reversing amplifier for double-acting actuators . . . . . . . . . . . . . 264.5.1 Reversing amplifier (1079-1118 or 1079-1119) . . . . . . . . . . . . 264.6 Required mounting parts and accessories . . . . . . . . . . . . . . . . 28

5 Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 315.1 Pneumatic connections . . . . . . . . . . . . . . . . . . . . . . . . . 315.1.1 Signal pressure gauges . . . . . . . . . . . . . . . . . . . . . . . . 325.1.2 Supply pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . 325.1.3 Signal pressure (output) . . . . . . . . . . . . . . . . . . . . . . . . 325.2 Electrical connections . . . . . . . . . . . . . . . . . . . . . . . . . 335.2.1 Establishing communication . . . . . . . . . . . . . . . . . . . . . . 37

6 Operator controls and readings . . . . . . . . . . . . . . . . . . . . 38

7 Start-up – Settings. . . . . . . . . . . . . . . . . . . . . . . . . . . 407.1 Adapting the display. . . . . . . . . . . . . . . . . . . . . . . . . . 407.2 Limiting the signal pressure. . . . . . . . . . . . . . . . . . . . . . . 407.3 Checking the operating range of the positioner . . . . . . . . . . . . . 417.4 Determining the fail-safe position. . . . . . . . . . . . . . . . . . . . 427.5 Positioner initialization. . . . . . . . . . . . . . . . . . . . . . . . . 437.5.1 Initialization based on MAX maximum range . . . . . . . . . . . . . 447.5.2 Initialization based on NOM nominal range . . . . . . . . . . . . . . 457.5.3 Initialization based on MAN manually selected range . . . . . . . . . 477.5.4 SUB substitute calibration . . . . . . . . . . . . . . . . . . . . . . . 48

EB 8387-5 EN 3

Contents

7.6 Zero calibration . . . . . . . . . . . . . . . . . . . . . . . . . . . . 527.7 Reset to default values . . . . . . . . . . . . . . . . . . . . . . . . 53

8 Operation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 548.1 Enabling and selecting parameters . . . . . . . . . . . . . . . . . . 548.2 Operating modes . . . . . . . . . . . . . . . . . . . . . . . . . . . 558.2.1 Automatic and manual operating modes . . . . . . . . . . . . . . . . 558.2.2 SAFE – Fail-safe position. . . . . . . . . . . . . . . . . . . . . . . . 568.3 Malfunction/maintenance alarm . . . . . . . . . . . . . . . . . . . . 568.3.1 Confirming error messages . . . . . . . . . . . . . . . . . . . . . . 57

9 Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58

10 Servicing explosion-protected devices . . . . . . . . . . . . . . . . . 58

11 Code list . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59

12 Dimensions in mm. . . . . . . . . . . . . . . . . . . . . . . . . . . 7812.1 Fixing levels according to VDI/VDE 3845 (September 2010) . . . . . . 80

13 Appendix . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8213.1 Selecting the valve characteristic . . . . . . . . . . . . . . . . . . . . 82

Test certificates . . . . . . . . . . . . . . . . . . . . . . . . . . . . 85

Index . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 88

4 EB 8387-5 EN

Contents

Note concerning these Mounting and Operating Instructions

These instructions EB 8387-5 EN describe the mounting, start up and on-site operation of theType 3731-5 Positioner.You can find additional information on the enclosed CD-ROM (CD 8387-5) or on the Internetat http://www.samson.de.

The CD-ROM (CD 8387-5) contains further information on the Type 3731-5 Positioner:

� [Documentation]

– KH 8387-5 EN: Configuration Manual for Type 3731-5 Electropneumatic Ex dPositioner, configuration and operation over FOUNDATION™ fieldbus andTROVIS-VIEW software

– T 8387-5 EN: Data Sheet for Type 3731-5 Electropneumatic Ex d Positioner– EB 8388-5 EN: Instructions for Type 373x-5 Electropneumatic Ex d Positioner with

EXPERT+ Valve Diagnostics including partial stroke test– T 8388 EN: Data Sheet for EXPERT/EXPERT+ Valve Diagnostics– T 6661 EN: Data Sheet for TROVIS-VIEW software

� [Approvals]

– PTB/ATEX – GOST– CSA – STCC– FM – JIS– IECEx – KOSHA– CERTUSP/IMMETRO

� [Declarations of Conformity]

� [Integrations]

– FOUNDATION™ fieldbus device description files– 375 Field Communicator– Emerson AMS™/DeltaV™– Yokogawa PRM - Device Viewer

� [TROVIS-VIEW (demo version)]

The HTML-based CD-ROM allows you to easily find any required information using a webbrowser.The PDF documents can be read using Acrobat Reader software.The entire range of information is available in both German and English.

EB 8387-5 EN 5

1 Important safety instructions

For your own safety, follow these instructions concerning the mounting, start up and opera-tion of the positioner:

� The positioner may only be mounted, started up or operated by trained and experi-enced personnel familiar with the product.According to these Mounting and Operating Instructions, trained personnel is referredto as individuals who are able to judge the work they are assigned to and recognizepossible dangers due to their specialized training, their knowledge and experience aswell as their knowledge of the relevant standards.

� Explosion-protected versions of this positioner may only be operated by personnelwho have undergone special training or instructions or who are authorized to workon explosion-protected devices in hazardous areas. Refer to section 10.

� Any hazards that could be caused by the process medium, the operating pressure, thesignal pressure or by moving parts of the control valve are to be prevented by meansof the appropriate measures.

� If inadmissible motions or forces are produced in the actuator as a result of the supplypressure level, it must be restricted by means of a suitable supply pressure reducingstation.

To avoid damage to any equipment, the following also applies:

� Do not operate the positioner with the back of the positioner/vent opening facing up-wards.

� Proper shipping and appropriate storage are assumed.

� Do not ground electric welding equipment near to the positioner.

6 EB 8387-5 EN

Important safety instructions

Vent opening

Note: The device with a CE marking fulfills the requirements of the Directives 94/9/EC(ATEX) and 89/336/EEC (EMC).The Declaration of Conformity is included on the enclosed CD-ROM (CD 8387-5).

2 Article code

Positioner Type 3731 - 5 x x x x x x 0 0 0 x 1 x 0 0 0

With LCD, autotune, FOUNDATION™ fieldbus

Explosion protection

ATEX: II 2 G Ex d IIC T6, T5, T4 Gb; II 2 G Ex d e IIC T6, T5, T4 Gb;II 2 D Ex tb IIIC T 80 °C Db IP 66

2 1

FM/CSA:Class I, Div.1+2, Groups B–D; Class II+III, Div.1+2, Groups E–G; Class I, Zone 1, IIB+H2/Class I, Div.1+2, Groups B–D T6…T4; Class II, Div.1+2, Groups E–G;Class III; Class I, Zone 1, Group IIB+H2, T6…T4

2 3

JIS: Ex d IIC T6 2 7

Options (additional equipment)

Without 0 0

Binary input 0 3

Forced venting 0 5

Diagnostics

EXPERT 1

EXPERT+/PST 2

Electrical connections

2x M20 x 1.5 1

2x ½ NPT 2

Explosion-protection certificates

As specified in Explosion protection 0

IECEx: Ex d IIC T6; II 2D IP 65 T 80° C 2 1 2

GOST: 1Ex d IIC T6/T4 2 1 3

Special applications

Without 0

Positioner compatible with paint (IP 41/NEMA 1) 1

Special version

Without 0 0 0

EB 8387-5 EN 7

Article code

3 Design and principle ofoperation

The electropneumatic Ex d positioner is at-tached to pneumatic control valves. It is usedto assign the valve stem position (controlledvariable x) to the control signal (referencevariable w). The input signal received froma control system is compared to the travel orrotational angle of the control valve, and asignal pressure (output variable y) is pro-duced for the pneumatic actuator.

The positioner basically consists of anelectrical travel sensor system (2), an analogi/p converter (6) with downstream air ca-pacity booster (7) and the electronic unitwith a microcontroller (5).

In case of a system deviation, the actuator iseither vented or filled with more air. The sig-nal pressure supplied to the actuator can belimited to 1.4 bar, 2.4 bar or 3.7 bar bysoftware or on site at the positioner.

8 EB 8387-5 EN

Design and principle of operation

Fig. 2 · Functional diagram

1 Control valve2 Travel sensor3 PD controller4 IEC 61158-2

interface module5 Microcontroller6 i/p converter7 Air capacity booster8 Pressure regulator9 Flow regulator

16 Display17 Forced venting control

(optional)19 D/A converter20 Serial interface (SSP)22 Rotary pushbutton23 Binary input

(optional)

FOUNDATION™

fieldbus

IEC 61158-2

A constant air stream to the atmosphere iscreated by the flow regulator (9) with afixed set point. The air stream is used topurge the inside of the housing as well as tooptimize the air capacity booster (7). Thei/p converter (6) is supplied with a constantupstream pressure by the pressure regulator(8) to make it independent of the supplypressure.

All parts are enclosed in an Ex d housing.The electrical cables are connected over aseparate terminal compartment which alsohas Ex d protection.

The standard EXPERT diagnostics are inte-grated into the positioner. It provides infor-mation on the positioner and generates di-agnostic and status messages, which allowfaults to be pinpointed quickly.

The positioner is suitable for the followingtypes of attachment using the correspondingaccessories:� Direct attachment to SAMSON

Type 3277 Actuator: Section 4.1� Attachment to actuators acc. to

IEC 60534-6 (NAMUR): Section 4.2� Attachment to Type 3510 Micro-flow

Valve: Section 4.3� Attachment to rotary actuators acc. to

VDI/VDE 3845: Section 4.4

3.1 Additional equipment

Binary input

The positioner has an optional binary input.

Connected at terminals A-B:The binary input for DC voltage signals al-lows process information to be exchangedover the FOUNDATION™ fieldbus network.

Connected at terminals B-C:This input connects a floating contact whichis powered by the positioner. The switchingstate of the binary input can be indicatedover the FOUNDATION™ fieldbus network.

Forced venting

The i/p converter stops working if the oper-ating voltage supply to the relevant terminalsis interrupted. The positioner can no longeroperate and the control valve moves to thefail-safe position determined by the actua-tor, independent of the reference variable.

Extended EXPERT+ valve diagnostics

Refer to Table 5 on page 30 for order num-bers.

EXPERT+ is an optional diagnostic firmwareintegrated in the positioner which allows thepredictive, status-oriented maintenance ofpneumatic control valves. It upgrades thestandard EXPERT diagnostics firmware in-corporated in the positioner. The upgradedversion provides extended functions to pin-point valve parameters that have worsened,allowing the user to plan predictive mainte-nance and service work before malfunctionscan affect the process, causing unscheduledplant shutdowns.The extended EXPERT+ diagnostics can beactivated later at the positioner by purchas-ing an activation code or using a USBdongle in conjunction with TROVIS-VIEWsoftware when EXPERT+ is not already acti-vated on delivery of the positioner.

EB 8387-5 EN 9


3.2 Communication

The positioner is completely controlled overthe digital signal transmission implementedaccording to FOUNDATION™ fieldbus spec-ification.

Data are transmitted as bit-synchronous cur-rent modulation at a rate of 31.25 kbit/sover twisted-pair cables conforming toIEC 61158-2.

3.2.1 Configuration usingTROVIS-VIEW software

Refer to Table 5 on page 30 for order num-bers.

The positioner can be configured using theTROVIS-VIEW configuration and operatorinterface.The positioner is equipped with an addi-tional digital SERIAL INTERFACE to allow acomputer to be connected over an adaptercable from the RS-232 or USB port of thecomputer to the positioner.The TROVIS-VIEW software enables the userto easily set parameters in the positionerand view process parameters online.

Note: Instructions on how to install and ope-rate the TROVIS-VIEW software are inclu-ded in the Configuration ManualKH 8387-5 EN on the CD-ROM.

3.2.2 Configuration using theNI-BUS™ Configurator

The NI-FBUS™ Configurator from NationalInstruments can also be used to configurethe positioner. For this purpose, an interfacecard must be installed in a computer to con-nect it to the FOUNDATION™ fieldbus.

The integrated function blocks are linked us-ing the NI-FBUS™ Configurator.

10 EB 8387-5 EN


3.3 Technical data

EB 8387-5 EN 11


Type 3731-5 Ex d Positioner (technical data in test certificates additionally apply for explosion-protected devices)

Rated travel Adjustable Direct attachment to Type 3277: 3.6 to 30 mmAttachment acc. to IEC 60534-6 (NAMUR): 3.6 to 200 mmAttachment to rotary actuators (VDI/VDE 3845): 24° to 100°

Travel range Adjustable Adjustable within the initialized travel/angle of rotation;travel can be restricted to 1

5 at the maximum

Bus connection Fieldbus interface acc. to IEC 61158-2 bus-poweredPhysical Layer Class: 113 (without ex. protection) und 111 (with ex. protection)Field device acc. to FM 3610 Entity and FISCO

Communication

Local communication SAMSON SSP interface and serial interface adapter

Software requirements (SSP) TROVIS-VIEW with database module 3731-5 (order no. 6661-1065)

Fieldbus communication Data transmission as per FOUNDATION™ fieldbus specification,Communication Profile Class: 31 PS, 32 L;Interoperability tested according to Interoperability Test System (ITK) Revision 4.6

Permissible operatingvoltage

9 to 32 V DC · Powered over bus lineThe limits in the test certificate additionally apply.

Max. operating current 15 mA

Additional current in case of fault 0 mA

Supply air Pressure 1.4 to 6 bar (20 to 90 psi)

Air quality Compliance with ISO 8573-1: 2004Max. particle size and density: Class 4Oil content: Class 3Moisture and water: Class 3Pressure dew point: At least 10 K beneath the lowest ambient temperature to beexpected

Signal pressure (output) 0 bar up to supply pressure

Characteristic Linear/equal percentage/reverse equal percentageUser-defined (over operating software and communication)Butterfly valve/Rotary plug valve/Segmented ball valve: linear/equal percentageDeviation from terminal-based conformity � 1 %

Hysteresis � 0.3 %

Sensitivity � 0.1 %

Direction of action Reversible

Air consumption Independent from supply pressure 110 ln/h

Air output capacityto actuator

Pressurized At �p = 6 bar: 8.5 mn³/h · At �p = 1.4 bar: 30 mn³/h · KVmax(20° C) = 0.09

Vented At �p = 6 bar: 14.0 mn³/h · At �p = 1.4 bar: 4.5 mn³/h · KVmax(20° C) = 0.15

Permissible ambienttemperature

–40 to 80 °CThe limits in the test certificate additionally apply.

12 EB 8387-5 EN


Type 3731-5 Ex d Positioner (technical data in test certificates additionally apply for explosion-protected devices)

Influences Temperature: � 0.15/10 K · Supply air: NoneVibration: � 0.25 % up to 2000 Hz and 4 g acc. to IEC 770

EMC Complying with requirements of EN 61000-6-2, EN 61000-6-3, EN 61326-1 and NAMURRecommendation NE 21

Electrical connections 2 threaded connections with ½ NPT thread, optionally with M20 x 1.5Screw terminals for 2.5 mm² wire cross-section

Explosionprotection

ATEX Type 3730-521: II 2 G Ex d IIC T6, T5, T4 Gb; II 2 G Ex d e IIC T6, T5, T4 Gb;II 2 D Ex tb IIIC T 80 °C Db IP 66

FM Type 3730-523: XP/I/1/BCD/T4 Ta=80 °C, T5 Ta=70 °C, T6 Ta=60 °C; Type 4X/IP 66XP/I/1/IIB+H2/T4 Ta=80 °C, T5 Ta=70 °C, T6 Ta=60 °C; Type 4X/IP 66DIP/II, III/1/EFG/T4 Ta=80 °C, T5 Ta=70 °C, T6 Ta=60 °C, Type 4X/IP 66Class I, Division 1 and 2, Groups B, C, DClass II und III, Division 1 and 2, Groups E, F, GClass I, Zone 1, IIB+H2; Type 4X/IP66

CSA Type 3730-523: Class I, Division 1 and 2; Groups B, C, D, T6…T4Class II, Division 1 and 2, Groups E, F, G; Class IIIClass I, Zone 1, Group IIB+H2, T6…T4; Type 4X/IP 66

JIS Type 3730-527: Ex d IIC T6

IECEx Type 3731-521xxxx0002: Ex d IIC T6; II 2 D IP 65 T 80 °C

GOST Type 3731-521xxxx0003: 1Ex d IIC T6/T4

Degree of protection IP 66/NEMA 4 X

Materials Housing Die-cast aluminum EN AC-AlSi10Mg(Fe) (EN AC-44300) acc. to DIN EN 1706chromated and powder paint coated

Externalparts Stainless steel 1.4571 and 1.4301

Weight Approx. 2.5 kg

Additional equipment

Option: Binary input, galvanically isolated

Connection Terminals A-BVoltage input 0 to 30 V DC,reverse polarity protection

Terminals B-Cfor external floating contact

Input Current consumption: 3.5 mA at 24 VStatic destruction limit: 40 V

R < 100 �; contact loadability: 100 mAStatic destruction limit: 20 V/5.8 mA

Signal “1“ at Ue > 5 VSignal “0“ at Ue < 3 V

Option: Forced venting, galvanically isolated

Input 0 to 40 V DC/0 to 28 V AC, reverse polarity protection 45 V DC/32 V AC,input resistance � 7 k�

4 Attachment to the controlvalve – Mounting parts andaccessories

WARNING!Attach the positioner, keeping the followingsequence:1. Mount the positioner on the control valve2. Connect the supply air3. Connect the electrical power4. Perform the start-up settings

The positioner is suitable for the followingtypes of attachment:

� Direct attachment to SAMSONType 3277 Actuator

� Attachment to actuators according toIEC 60534-6 (NAMUR)

� Attachment to Type 3510 Micro-flowValve

� Attachment to rotary actuators

NOTICEAttach the positioner to the control valve,observing the following instructions to avoiddamaging the positioner.– Use only the mounting parts/accessories

listed in the Tables 1 to 5 (pages 28 and30) to mount the positioner. Observe thetype of attachment!

– The positioner is fitted with pneumaticconnections with ¼ NPT threads. If youneed G ¼ threads, attach the connectingplate (6) listed in the accessories.

– Observe the assignment between leverand pin position (see travel tables onpage 14).

– Fit a signal pressure restriction (Table 5on page 30) for actuators with di-aphragm areas less than 240 cm².

Lever and pin position

The positioner is adapted to the actuatorand to the rated travel by the lever on theback of the positioner and the pin insertedinto the lever.

The travel tables on page 14 show the maxi-mum adjustment range at the positioner. Thetravel that can be implemented at the valveis restricted by the pin position used and ad-ditionally by the selected fail-safe positionand the required compression of the actua-tor springs.

The positioner is standard equipped with thelever M (pin position 35).

Note: If the standard mounted lever M is re-placed, the newly mounted lever must bemoved once all the way as far as it will goin both directions to adapt it to the internalmeasuring lever.

EB 8387-5 EN 13

Attachment to the control valve – Mounting parts and accessories

Fig. 3 · Lever M with pin position 35 (delivered state)

14 EB 8387-5 EN


Travel tables

Note: The lever M is included in the scope of delivery.Levers S, L, XL for attachment according to IEC 60534-6 (NAMUR) are available as accesso-ries (see Table 3 on page 29).

Direct attachment to Type 3277-5 and Type 3277 Actuators

Actuator size Rated travel Adjustment range at positioner Requiredlever

Assignedpin position[cm²] [mm] Min. Travel Max.

120 7.5 5.0 to 25.0 M 25

120/240/350 15 7.0 to 35.0 M 35

355/700 30 10.0 to 50.0 M 50

Attachment according to IEC 60534-6 (NAMUR)

SAMSON valves/Type 3271 Actuator Other valves/actuatorsRequired

leverAssigned

pin positionActuator size Rated travel

[cm²] [mm] Min. Travel Max.

60 and 120 withType 3510 Valve 7.5 3.6 to 18.0 S 17

120 7.5 5.0 to 25.0 M 25

120/240/350 157.0 to 35.0 M 35

700 7.5

700 15 and 30 10.0 to 50.0 M 50

1000/1400/2800 30 14.0 to 70.0 L 70

1000/1400/2800 60 20.0 to 100.0 L 100

1400/2800 120 40.0 to 200.0 XL 200

Attachment to rotary actuators according to VDI/VDE 3845

Rotary actuators Requiredlever

Assignedpin positionMin. Opening angle Max.

24 to 100° M 90°

4.1 Direct attachment

4.1.1 Type 3277-5 Actuator

Refer to Table 1 on page 28 for requiredmounting parts and accessories.

Actuator with 120 cm²

NOTICEIf a solenoid valve or similar is additionallymounted to the control valve, observe thefollowing instructions which differ from theinstructions otherwise described:– The switchover plate (9) is omitted.– The signal pressure must be routed from

the signal pressure output over the con-necting plate (order no. 1400-6820) tothe actuator.

– Fit the screw-in restriction (order no.1400-6964) into the signal pressure out-put.

– Do not remove the screw plug (4) at theback of the positioner.

Depending on the type of positioner attach-ment, the signal pressure is routed either leftor right of the yoke through a bore to theactuator diaphragm.

1. Refer to Fig. 4 to select the symbol tomatch the required fail-safe positionand how the positioner is attached:Fail-safe position:“Actuator stem extends“ = Air-to-open“Actuator stem retracts“ = Air-to-closePositioner attachment: Left or right withview looking onto the switchover plate

2. Align the marking of the switchoverplate (9) to the corresponding symbol

and mount the plate on the actuatoryoke.

3. If applicable, mount pressure gaugebracket (7) with pressure gauges or, incase G ¼ threaded connections are re-quired, the connecting plate (6), mak-ing sure both seal rings (6.1) areseated properly.

4. Remove screw plug (4) on the back ofthe positioner and seal the signal pres-sure output "Output 38" on the con-necting plate (6) or on the pressuregauge bracket (7) with the stopper (5)included in the accessories.

5. Place follower clamp (3) on the actua-tor stem, align and screw tight so thatthe mounting screw is located in thegroove of the actuator stem.

6. Press brass restriction (order no.1400-6964) into the seal of the signalpressure input at the actuator yoke.

7. Mount cover plate (10) with the narrowside of the cut-out opening (Fig. 4, left)pointing towards the signal pressureconnection. Make sure that the bondedgasket (14) points towards the actuatoryoke.

8. 15 mm travel: Keep the follower pin(2) at lever M (1) on the back of thepositioner in the pin position 35 (deliv-ered state).7.5 mm travel: Remove the follower pin(2) from the pin position 35, repositionit in the hole for pin position 25 andscrew tight.

9. Insert formed seal (15) into the grooveof the positioner housing, pressing the

EB 8387-5 EN 15


four retaining rings over the housingscrews and both fittings into the hous-ing recesses.

10. Thread the bias spring (17) through thecrosspiece underneath the lever (1) andpush into the hole in the housing. Pushthe lever (1) until it engages into place.Place positioner on the cover plate (10)and fasten it using the three fixingscrews.Check to make sure that the followerpin (2) rest on top of the follower clamp(3). The lever (1) must rest on the fol-lower clamp with spring force.Make sure that the seal ring (10.1) isinserted in the borehole of the coverplate.

11. Mount cover (11) on the other side.Make sure that the vent plug (11.1)points downwards when the controlvalve is installed to allow any con-densed water that collects to drain off.

16 EB 8387-5 EN


EB 8387-5 EN 17


9 11

Supply 9 Output 38

56

4

17

7

6

1010.1

3

2

1

15

6.1

1.11.2

14

8

11.1

A

A-A

A

Fig. 4 · Direct attachment for Type 3277-5 Actuator with 120 cm²

Switchover plate (9)

Marking

1 Lever1.1 Nut1.2 Disk spring2 Follower pin3 Follower clamp4 Screw plug5 Stopper6 Connecting plate for G ¼6.1 Seal rings7 Pressure gauge bracket8 Press. gauge mounting kit9 Switchover plate

for actuator10 Cover plate10.1 Seal ring11 Cover11.1 Vent plug14 Gasket15 Formed seal17 Bias spring (only with

direct attachment)

Signal pressure inputfor right attachment

Symbols

Actuator stemextends

Left attachment Right attachment

Actuator stemretracts

Signal pressureinput for leftattachment

Signal pressure inputwith brass restriction

Cut-out ofcover plate

4.1.2 Type 3277 Actuator

Refer to Table 2 on page 28 for the requiredmounting parts and accessories.

Actuators with 240 to 700 cm²

Mount the positioner on the yoke as shownin Fig. 5. The signal pressure is routed to theactuator over the connection block (12), foractuators with fail-safe action "Actuatorstem extends" internally through a bore inthe valve yoke and for "Actuator stem re-tracts" through external piping.

1. Place follower clamp (3) on the actua-tor stem, align and screw tight so thatthe mounting screw is located in thegroove of the actuator stem.

2. Mount cover plate (10) with the narrowside of the cut-out opening (Fig. 5, left)pointing towards the signal pressureconnection. Make sure that the bondedgasket (14) points towards the actuatoryoke.

3. Actuators with 355/700 cm²: Removethe follower pin (2) at lever M (1) onthe back of the positioner from pin po-sition 35, reposition it in the hole forpin position 50 and screw tight.Actuators 240 and 350 cm² with15 mm travel: The follower pin (2) re-mains in pin position 35 (deliveredstate).

4. Insert formed seal (15) into the grooveof the positioner housing, pressing thefour retaining rings over the housingscrews and both fittings into the hous-ing recesses.

5. Thread the bias spring (17) through thecrosspiece underneath the lever (1) andpush into the hole in the housing. Pushthe lever (1) until it engages into place.Place positioner on the cover plate (10)and fasten it using three fixing screws.Check whether the follower pin (2) restson top of the follower clamp (3).The lever (1) must rest on the followerclamp with spring force.

6. Make sure that the tip of the gasket(16) projecting from the side of theconnection block (12) is positionedabove the actuator symbol that corre-sponds with the actuator with fail-safeaction "Actuator stem extends" or "Ac-tuator stem retracts." If necessary, re-move the three fixing screws and thecover plate. Then reposition the gasket(16) turned by 180°. The previous ver-sion of the connection block (Fig. 5,bottom) requires the switch plate (13) tobe turned such that the correspondingactuator symbol points to the marking.

7. Place the connection block (12) with theassociated seal rings against thepositioner and the actuator yoke. Screwit tight using the fixing screw (12.1).For actuators with fail-safe action "Ac-tuator stem retracts", additionally re-move the stopper (12.2) and attach theexternal signal pressure line.

8. Mount cover (11) on the other side.Make sure that the vent plug (11.1)points to the back when the controlvalve is installed to allow any con-densed water that collects to drain off.

18 EB 8387-5 EN


EB 8387-5 EN 19


2

17

10 1415

1 2 3 11

SUPPLY

13

B

1.11.2

12

12.1

12

12.2

12.11216

1616

12.2SUPPLY

Ansicht B

Ansicht A

Ansicht C

SUPPLY

G

G 3/8

11.1

A

C

Fig. 5 · Direct attachment – Signal pressure connection for Type 3277 Actuator with 240, 350 and 700 cm2

View A

1 Lever1.1 Nut1.2 Disk spring2 Follower pin3 Follower clamp10 Cover plate G ¼11 Cover11.1 Vent plug

Connection block (old)with switch plate (13)

12 Connection block12.1 Screw12.2 Stopper or connection for

external piping13 Switch plate14 Gasket15 Formed seal16 Gasket17 Bias spring

(only for direct attachment)

Cut-out ofcover plate (10)

Stem retracts

Stem extends

Marking

View A

View C

View B

Actuator stemretracts extends

4.2 Attachment according toIEC 60534-6 (NAMUR)


The positioner is attached to the controlvalve using a NAMUR bracket (10).

1. Actuator sizes 120 to 700 cm²:Screw the two bolts (14) to the bracket(9.1) of the stem connector (9), placethe follower plate (3) on top and usethe screws (14.1) to tighten.Actuator size 2800 cm² and 1400 cm²(120 mm travel):– For a travel of 60 mm or smaller,

screw the longer follower plate (3.1)directly to the stem connector (9).

– For a travel exceeding 60 mm,mount the bracket (16) first and thenthe follower plate (3) to the brackettogether with the bolts (14) andscrews (14.1).

2. Mount NAMUR bracket (10) to the con-trol valve as follows:– For attachment to the NAMUR rib,

use an M8 screw (11), washer andtoothed lock washer directly in theyoke bore.

– For attachment to valves withrod-type yokes, use two U-bolts (15)around the yoke. Align the NAMURbracket (10) in such a way that theslot of the follower plate (3/3.1) iscentrally aligned with the NAMURbracket at mid valve travel.

3. If applicable, mount pressure gaugebracket (7) with pressure gauges or, in

case G ¼ threaded connections are re-quired, the connecting plate (6), mak-ing sure both seal rings (6.1) areseated properly.

4. Fit screw-in restriction (order no.1400-6964) into the signal pressureoutput for actuators with diaphragm ar-eas smaller than 240 cm².

5. Select required lever (1) size M, L or XLand pin position according to the actu-ator size and valve travels listed in thetable on page 14.Lever M with pin position 25 or 50:5.1 Remove follower pin (2) from pin

position 35 and screw it into therequired hole

Lever L or XL:5.1 Unscrew the standard lever M from

the shaft of the positioner.5.2 Screw the long follower pin (2) in-

cluded in the mounting kit in thepin position of the required lever(1) assigned in the table.

5.3 Place lever (1) on the positionershaft and screw tight using the diskspring (1.2) and nut (1.1).

5.4 Move the lever once all the way asfar as it will go in both directions.

6. Place positioner on the NAMURbracket in such a manner that the fol-lower pin (2) rests in the slot of the fol-lower plate (3/3.1). Adjust the lever (1)correspondingly. Screw the positionerto the NAMUR bracket using three fix-ing screws.

20 EB 8387-5 EN


EB 8387-5 EN 21


Lever XL and L

10

11

1

114.1

3

3.116

15

14

11.21.12

9.1

9

6

7

8

6.1

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

1 Lever1.1 Nut1.2 Disk spring3 Follower plate3.1 Follower plate6 Connecting plate

(only for G ¼)6.1 Seal rings

7 Pressure gauge bracket8 Pressure gauge

mounting kit9 Stem connector9.1 Bracket10 NAMUR bracket11 Screw14 Bolt14.1 Screw15 U-bolt16 Bracket

Additional bracket foractuators with 2800 cm²and travel � 60 mm

Fit screw-in restriction into output(38) for actuators smaller than240 cm²

Attachment toNAMUR rib

Attachment to rod-type yokeRods with 20 to 35 mm Ø

4.3 Attachment to Type 3510Micro-flow Valve


The positioner is attached to the valve yokeusing a bracket.

1. Place clamp (3) on the valve stem con-nector, align at a right angle and screwtight.

2. Screw bracket (10) to the valve yokeusing two screws (11).

3. If applicable, mount pressure gaugebracket (7) with pressure gauges or, incase G ¼ threaded connections are re-quired, the connecting plate (6), mak-ing sure both seal rings (6.1) areseated properly.

4. Fit screw-in restriction (order no.1400-6964) into the signal pressureoutput of the positioner (or output of thepressure gauge bracket or connectingplate).

5. Unscrew the standard installed lever M(1) including follower pin (2) from thepositioner shaft.

6. Remove follower pin (2) from lever Mand screw it into the hole for pin posi-tion 17 of lever S.

7. Place lever S on the positioner shaftand screw tight using the disk spring(1.2) and nut (1.1).

8. Move the lever once all the way as faras it will go in both directions.

9. Place positioner on the bracket (10) insuch a manner that the follower pinslides into the groove of the clamp (3).

Adjust the lever (1) correspondingly.Screw the positioner to the bracket (10)using three fixing screws.

22 EB 8387-5 EN


EB 8387-5 EN 23


6211.2

1.1

78

6.1

3

10

11

11

Fig. 7 · Attachment to Type 3510 Micro-flow Valve

Lever S

1 Lever1.1 Nut1.2 Disk spring2 Follower pin3 Clamp6 Connecting plate

(only for G ¼)6.1 Seal rings7 Pressure gauge bracket8 Pressure gauge

mounting kit10 Bracket11 Screw

Fit screw-in restriction intooutput (38)

4.4 Attachment to rotaryactuators


Both mounting kits contain all the necessarymounting parts. First select correct actuatorsize. Prepare actuator, and mount requiredadapter supplied by the actuator manufac-turer, if necessary.

1. Mount the housing (10) onto the rotaryactuator. In case of VDI/VDE attach-ment, place spacers (11) underneath, ifnecessary.

2. For SAMSON Type 3278 and VETECS160 Rotary Actuator, screw theadapter (5) onto the free end of theshaft or place adapter (5.1) onto theshaft of the VETEC R Actuator.Place adapter (3) onto Type 3278,VETEC S160 and VETEC R Actuator. ForVDI/VDE version, this step depends onthe actuator size.

3. Stick adhesive label (4.3) onto the cou-pling wheel in such a manner that theyellow part of the sticker is visible in thewindow of the housing when the valveis OPEN. Adhesive labels with explana-tory symbols are enclosed and can bestuck on the housing, if required.

4. Screw tight coupling wheel (4) onto theslotted actuator shaft or adapter (3) us-ing screw (4.1) and disk spring (4.2).

5. Undo the standard follower pin (2) onthe lever M (1) of the positioner. Attachthe follower pin (Ø 5) included in themounting kit to pin position 90°.

6. If applicable, mount pressure gaugebracket (7) with pressure gauges or, incase G ¼ threaded connections are re-quired, the connecting plate (6), mak-ing sure both seal rings (6.1) areseated properly.For double-acting, springless rotary ac-tuators, a reversing amplifier is re-quired to attach the positioner to theactuator. Refer to section 4.5.

7. For actuators with a volume of less than300 cm³, fit the screw-in restriction (or-der no.1400-6964) into the signalpressure output of the positioner (or theoutput of the pressure gauge bracket orconnecting plate).

8. Place positioner on the housing (10)and screw it tight. Considering the ac-tuator's direction of rotation, align lever(1) so that it engages in the correct slotof the coupling wheel with its followerpin (Fig. 8).

24 EB 8387-5 EN


1

10

4

Fig. 8 · Direction of rotation

Clockwise

Counterclockwise

EB 8387-5 EN 25


SAMSON Type 3278VETEC S160, VETEC R

Attachment acc. to VDI/VDE 3845(Sept. 2010) level 1, size AA1 to AA4(see section 12.1)

66.178

11.11.2

2

4.1

3

10.1

10

11

5

4.344.2

4.1

3

5.1

5

10.1

10

4.344.2

Fig. 9 · Attachment to rotary actuators

1 Lever1.1 Nut1.2 Disk spring2 Follower pin3 Adapter4 Coupling

wheel4.1 Screw4.2 Disk spring4.3 Adhesive label5 Actuator shaft

or adapter5.1 Adapter

6 Connecting plate (only for G ¼)6.1 Seal rings7 Pressure gauge bracket8 Pressure gauge mounting kit10 Adapter housing10.1 Screws11 Spacers

Fit screw-in restriction into signal pressure outputfor actuators with < 300 cm³ volume

4.5 Reversing amplifier fordouble-acting actuators

For the use with double-acting actuators, thepositioner must be fitted with a reversingamplifier, e.g. the SAMSON Type 3710 Re-versing Amplifier (see Mounting and Oper-ating Instructions EB 8392 EN).

If a different reversing amplifier (item no.1079-1118 or 1079-1119) is used, followthe mounting instructions described in sec-tion 4.5.1.

4.5.1 Reversing amplifier(1079-1118 or 1079-1119)

The output signal pressure of the positioneris supplied at the output A1 of the reversingamplifier. An opposing pressure, whichequals the required supply pressure whenadded to the pressure at A1, is applied atoutput A2.The rule A1 + A2 = Z applies.

Mounting

NOTICEDo not unscrew sealing plug (1.5) out of thereversing amplifier.

1. Thread the special nuts (1.3) from theaccessories of the reversing amplifierinto the boreholes of the positioner.Remove the rubber seal (1.4).

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

3. Position the reversing amplifier (1) andscrew tight using both the specialscrews (1.1).

4. Use a screwdriver (8 mm wide) toscrew the enclosed filters (1.6) into theconnecting boreholes A1 and Z.

Signal pressure connections

A1: Output A1 leading to the signal pressureconnection at the actuator which opens thevalve when the pressure increases

A2: Output A2 leading to the signal pressureconnection at the actuator which closes thevalve when the pressure increases

NOTICEOn start up of double-acting actuators, thefollowing settings as described in sectionmust be made:– Pressure limit (Code 16) = OFF– Fail-safe position (Code 0) = AIR TO

OPEN (AtO)

Pressure gauge attachment

The mounting sequence shown in Fig. 10 re-mains unchanged. Screw a pressure gaugebracket onto the connections A1 and Z.

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

Pressure gauges for supply air Z and outputA1 as listed in Tables 1 to 4.

26 EB 8387-5 EN


EB 8387-5 EN 27


A1

1.5 1.6

1.3 1.2 1.1 1 1.6

Z

A2

1.4

A1 A2

Z

A1

Output 38 Supply 9

Out

put 3

8Su

pply

9

1.3 1.21.1

Fig. 10 · Mounting a reversing amplifier (1079-1118 or 1079-1119)

From the positioner

Control signals tothe actuator

1 Reversing amplifier1.1 Special screws1.2 Gasket1.3 Special nuts1.4 Rubber seal1.5 Sealing plug1.6 Filter

4.6 Required mounting parts and accessories

28 EB 8387-5 EN


Table 1 · Direct attachment to Type 3277-5 (Fig. 4) Order no.

Mounting parts For actuators with 120 cm² effective diaphragm area 1400-7452

Accessories forthe actuator

Switchover plate (old) for Actuator Type 3277-5xxxxxx.00 (old) 1400-6819

Switchover plate new for Actuator Type 3277-5xxxxxx.01 (new) 1) 1400-6822

Connecting plate new for Actuator Type 3277-5xxxxxx.01 (new) 1), G ¼ and ¼ NPT 1400-6823

Connecting plate old for Actuator Type 3277-5xxxxxx.00 (old): G ¼ 1400-6820

Connecting plate old for Actuator Type 3277-5xxxxxx.00 (old): ¼ NPT 1400-6821

Accessories forthe positioner

Connecting plate (6) G ¼ 1400-7461

Pressure gauge bracket (7)G ¼ 1400-7458

¼ NPT 1400-7459

Pressure gauge mounting kit (8) up to max. 6 bar (output/supply)St. st./Brass 1400-6950

St. st./St. st. 1400-69511) Only new switchover and connecting plates can be used with new actuators (Index 01).

Old and new plates are not interchangeable.

Table 2 · Direct attachment to Type 3277 (Fig. 5)

Mounting parts For actuators with 240, 350, 355 and 700 cm² 1400-7453

Accessories

Required piping with screw fitting– for "Actuator stem retracts"– when the top diaphragm chamber is filled with

air

240 cm²Steel 1400-6444

Stainless steel 1400-6445

350 cm²Steel 1400-6446


355/700 cm²Steel 1400-6448


Connection block with seals and screwG ¼ 1400-8819

¼ NPT 1400-8820


St. st./St. st. 1400-6951

EB 8387-5 EN 29


Table 3 · Attachment to NAMUR ribs or control valves with rod-type yokes(20 to 35 mm rod diameter) according to IEC 60534-6 (Figs. 6 and 7)

Travel in mm Lever For actuators Order no.

7.5 S Type 3271-5 Actuator w. 60/120 cm² on Type 3510 Valve (Fig. 7) 1400-7457

5 to 50 M 1) Actuators from other manufacturers and Type 3271with 120 to 700 cm² 1400-7454

14 to 100 L Actuators from other manufacturers and Type 3271, versions 1000 and1400-60

1400-7455

40 to 200 XL Actuators from other manufacturers and Type 3271, versions 1400-120 and2800 cm² with 120 mm travel 1400-7456

30 or 60 L

Type 3271, versions 1400-120 and 2800 cm² (30 or 60 mm travel) 1400-7466

Mounting bracket for Emerson and Masoneilan linear actuators; a mountingkit acc. to IEC 60534-6 is necessary depending on the travel (see above) 1400-6771

Valtek Type 25/50 1400-9554

Accessories

Connecting plate G ¼ 1400-7461

Pressure gauge bracket (7)G ¼ 1400-7458

¼ NPT 1400-7459


St. st./St. st. 1400-69511) Lever M is attached to basic positioner (included in the scope of delivery)

Table 4 · Attachment to rotary actuators (Figs. 8 and 9) Order no.

Mountingparts

Attachment acc. to VDI/VDE 3845 (September 2010), see section 12.1 for details

Actuator surface corresponds to level 1Size AA1 to AA4, heavy-duty versionHeavy-duty version (e.g. Air Torque 10 000)

1400-92441400-9542

Bracket surface corresponds to level 2, heavy-duty version 1400-9526

Attachment for SAMSON Type 3278 with 160 cm² and for VETEC Type S160, R andM, heavy-duty version

1400-9245

Attachment for SAMSON Type 3278 with 320 cm² and for VETEC Type S320,heavy-duty version

1400-5891and

1400-9526

Attachment to Camflex II 1400-9120

Accessories

Connecting plate (6)G 1400-7461

NPT 1400-7462

Pressure gauge bracket (7)G 1400-7458

NPT 1400-7459

Pressure gauge mounting kit up to max. 6 bar (output/supply)St. steel/brass 1400-6950

St. steel/st. steel 1400-6951

30 EB 8387-5 EN


Table 5 · General accessories Order no.

Accessories

Reversing amplifier for double-acting actuators Type 3710

Signal pressure restrictions (screw-in and brass restrictions) 1400-6964

Activation code for EXPERT+ for Type 3731-5 Positioner 1400-9318

USB dongle for EXPERT+ (specify the number of activations)Only can be used in combination with TROVIS-VIEW 6661-1065 1400-9555

TROVIS-VIEW with database module 3731-5 6661-1065

Serial interface adapter (SAMSON SSP interface – RS-232 port of computer) 1400-7700

Isolated USB interface adapter (SAMSON SSP interface – USB port on computer)including TROVIS-VIEW CD-ROM

1400-9740

5 Connections

WARNING!Mount the positioner, keeping the followingsequence:1. Mount the positioner on the control valve2. Connect the supply air3. Connect the electrical power4. Perform the start-up settings

The connection of the electrical auxilarypower may cause the actuator stem to move,depending on the operating mode.Do not touch the actuator stem or obstruct itto avoid risk of injury to hands or fingers.

5.1 Pneumatic connections

DANGER!Danger from the formation of an explosiveatmosphere!The operator of the apparatus must ensurethat the working medium cannot form an ex-plosive atmosphere, i.e. only such gasesmay be used which are free from substanceswhose presence in the medium might lead tothe formation of an explosive atmosphere(e.g. do not use flammable gases, oxygen oroxygen-enriched gases).

Follow the instructions below to avoid dam-aging the positioner.– The supply pressure at the input must

not exceed 6 bar.– The screw fittings with ¼ NPT thread can

be screwed directly into the positioner.In case G ¼ threaded connections arerequired, the fittings must be screwedinto the connecting plate (6) or pressuregauge mounting block or connectionblock available from the accessories.Customary screw-in fittings for metal andcopper pipes or plastic hoses can beused.

– The supply air must be dry and free fromoil and dust.The maintenance instructions for upstre-am pressure reducing stations must beobserved.Blow through all air pipes and hoses tho-roughly prior to connecting them.

If the positioner is attached directly to theType 3277 Actuator, the connection of thepositioner's output pressure to the actuator isfixed. For attachment according toIEC 60534-6 (NAMUR), the signal pressurecan be routed to either the top or bottom di-aphragm chamber of the actuator, depend-ing on the actuator's fail-safe action "Actua-tor stem extends" or "Actuator stem re-tracts".For rotary actuators, the manufacturer'sspecifications for connection apply.

EB 8387-5 EN 31

Connections

5.1.1 Signal pressure gauges

To monitor the supply air (Supply) and sig-nal pressure (Output), we recommend thatpressure gauges be attached (see accesso-ries in Tables 1 to 5).

5.1.2 Supply pressure

The required supply pressure (of supply air)depends on the bench range and the actua-tor's operating direction (fail-safe action).The bench range is registered on the name-plate either as spring range or signal pres-sure range depending on the actuator.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 benchrange value + 0.2 bar, minimum 1.4 bar.

Actuator stem retracts FE (AIR TO CLOSE)

Fail-safe position "Valve Open"(for globe and angle valves):For tight-closing valves, the maximum signalpressure pstmax is roughly estimated as fol-lows:

pstmax = F + d pA

2

4� �

�

� � [bar]

d = Seat diameter [cm]�p = Differential pressure across the valve

[bar]A = Actuator diaphragm area [cm²]F = Upper bench range of the actuator

[bar]

If there are no specifications, calculate asfollows:

Required supply pressure =Upper bench range value + 1 bar

5.1.3 Signal pressure (output)

The signal pressure at the output (Out-put 38) of the positioner can be limited to1.4, 2.4 or 3.7 bar in Code 16.

The limitation is not activated [OFF] by de-fault.

32 EB 8387-5 EN

Connections

5.2 Electrical connections

EB 8387-5 EN 33

Connections

DANGER!Risk of electric shock and/or the formation of an explosive atmosphere!

� For electrical installation, you are required to observe the relevantelectrotechnical regulations and the accident prevention regulations that ap-ply in the country of use. In Germany, these are the VDE regulations and theaccident prevention regulations of the employers' liability insurance associa-tion.

� The following standards apply for assembly and installation in hazardousareas EN 60079-14: 2003 (VDE 0165 Part 1/1.98) "Electrical apparatus forexplosive gas atmospheres" and EN 50281-1-2: 1999 (VDE 0165Part 2/11.99) "Electrical apparatus for use in the presence of combustibledust".

� Install the connecting line rigidly and ensure it is protected adequately frombeing damaged.

� In case the temperature exceeds 70 °C at the cable entries, use appropriatetemperature-resistant connecting lines.Integrate the positioner into the equipotential bonding system on site.

Connection to conform with the type of protection EEx d

� The Type 3731 Positioner must be connected over the appropriate cableglands or conduit systems which meet the requirements of EN 60079-1:2004 “Electrical apparatus for explosive gas atmospheres” - Part 1:Flameproof enclosures "d" Clauses 13.1 and 13.2 and for which a specialtest certificate exists.

� Do not use simple types of cable glands or blanking plugs.� Seal any openings that are not used as specified in Clause 11.9 of

EN 60079-1.� For installation in type of protection Ex d, observe in particular Clauses 9.4

and 10 of EN 60079-14: 2003.

Connection to conform with the type of protection EEx e

� Clause 11 of EN 60079-14: 2003 applies.� On connecting cables to electrical apparatus with the type of protection “In-

creased safety” according to EN 60079-7: 2004 “Electrical apparatus forexplosive gas atmospheres” - Part 7: Increased safety “e”, entries must beused which are suitable for the type cable being used.

34 EB 8387-5 EN

Connections

Table 6 · Accessories Order no.

Cable gland M20 x 1.5; EEx e, black plastic 8808-0178

Blanking plugs; EEx de; stainless steel(approvals: CENELEC, CSA, GOST, IECEx)

M20 x 1.5 8323-1203

½ NPT 8323-1204

Cable entry for unarmored cables; EEx e, EEx d, EEx tD A21(approvals: CENELEC, IECEx)

M20 x 1.5 8808-0200

½ NPT 8808-2010

� The cable entries and blanking plugs must conform to the type of protection“Ex e” and a special test certificate must be issued for them. They must con-tain a suitable sealing element to achieve the required degree of protection(at least IP 54) of the positioner.

� Devices used at ambient temperatures below –20 °C must have metal cableentries

� In cases where more than one cable core is connected to the same terminal,make sure that each cable core is clamped adequately. Two cables withvarying cross-sections may only be connected to one terminal after being se-cured with a common crimp sleeve beforehand if it is not explicitly allowedin the documentation related to the electrical apparatus.

Cable entry

The threaded connections for the terminalcompartment are designed with ½ NPT orM20x1.5 threads.

The electrical connections are screw termi-nals for wire cross-sections of 0.2 to2.5 mm² using a tightening torque of at least0.5 Nm.

Note: The positioner is powered either overthe connection to the fieldbus segment orover a DC voltage source (9 to 32 V) con-nected to the bus terminals in the positioner.You are required to observe the relevantregulations for use in hazardous areas!

EB 8387-5 EN 35

Connections

Power supply unit

Ex-fieldbus barrier/isolator

Hazardous area

Power conditioner

Control system

3731-52 3731-52 3731-52 3731-52

IEC 61158-2

IEC 61158-2

Bus termination

FOUNDATIONTM fieldbus

FOUNDATIONTM fieldbus

Fig. 11 · Connection according to FOUNDATIONTM

fieldbus for hazardous areas

Fig. 12 · Location of the terminals(lid unscrewed)

Electrical auxiliary power supplied over thebus line

� Route the two-wire bus line to the screwterminals marked “Signal”. Polarity doesnot have to be observed.Refer to Fig. 13 or the nameplate for theterminal assignment.After connecting the electrical auxiliarypower, tEStinG runs across the display ofthe positioner.

Note: Just one binary input is available (either version 1 or version 2).

Version 1 of binary input (terminals A–B)

An active contact can be operated at version1 of the binary input. The positioner signalthe switching state over the bus protocol.

Version 2 of binary input (terminals B–C)

A floating passive contact can be operatedat version 2 of the binary input. Thepositioner receives the switching state overthe bus protocol.

36 EB 8387-5 EN

Connections

Fig. 13 · Electrical connections

Forced venting

Version 1 Version 2or

Binary input

5.2.1 Establishing communication

Communication between the controller orautomation system, or between a computeror work station and the positioner(s) is im-plemented to conform with EN 61158-2.

Note: Refer to the Configuration ManualKH 8387-5 EN for more information.

EB 8387-5 EN 37

Connections

6 Operator controls andreadings

Rotary pushbutton

The operator controls are located under-neath the front protective cover.

The positioner is operated on site using therotary pushbutton:

Turn to select codes and values.

Press to confirm setting.

Serial interface

The serial interface connection is located un-derneath the display lid: Unscrew and re-move retaining screw and then unscrew dis-play lid.

NOTICEThe explosion protection is ineffective assoon as the display lid is opened!

To use the TROVIS-VIEW software, connectthe positioner over an adapter to theRS-232 or USB port of the computer.

Display

Icons appear on the display that are as-signed to parameters, codes and functions.

Operating modes:– Manual operating mode (see sec-

tion 8.2.1)– Automatic operating mode (see section

8.2.1)– SAFE (see section 8.2.2)

� Bar elementsIn manual and automatic operat-ing modes, the bars indicate the systemdeviation that depends on the sign (+/–)and the value.One bar element appears per 1 % sys-tem deviation.If the device has not yet been initialized,the icon appears on the display andthe lever position in degrees in relationto the longitudinal axis is indicated. Onebar element corresponds to approxi-mately a 5° angle of rotation.If the fifth bar element blinks (reading> 30°), the permissible angle of rotationhas been exceeded. Lever and pin posi-tion must be checked.

� Status messages:Maintenance alarmMaintenance required/Maintenance

demandedThese icons indicate that an error has oc-curred.A classified status can be assigned toeach error. Classifications include “Nomessage”, “Maintenance required”,“Maintenance demanded” or “Mainte-nance alarm“ (see section 8.3).

� Configuration enabled:This indicates that the codes marked withan asterisk (*) in the code list (section 11)are enabled for configuration (see sec-tion 8.1).

38 EB 8387-5 EN

Operator controls and readings

S

and together:AO Transducer Block is inMAN operating mode

blinks Emergency mode,see Code 62

blinks Not initializedblinks Valve in mechanical

fail-safe position

Protective cover Rotary pushbutton LC display Serial interface

Fail-safe positionactive

Code

Bar elements forsystem deviationor lever positionUnits

Condensed state:Maintenance alarm

DesignationPosition

Parameter

Binary input

Condensed state:Maintenance required

Maintenance demanded

Configurationenabled

Manual operation Closed-loop operation

Retainingscrew

EB 8387-5 EN 39

Operator controls and readings

S

RES ResetRUN StartSAFE Fail-safe positionSUb Substitute calibrationTunE Initialization in progressYES ExistsZP Zero calibrationtEStinG Self-testtESt Test function active

�� Increasing/increasing�� Increasing/decreasing

AUtO Automatic modeCL ClockwiseCCL CounterclockwiseErr ErrorESC EscapeMAN Manual settingMAX Maximum rangeNO Not availableNOM Nominal travelON OnOFF Off

Readings and their meanings

Fig. 14 · Readings and operator controls

7 Start-up – Settings

WARNING!Attach the positioner, keeping the followingsequence:1. Mount the positioner on the control valve2. Connect the supply air3. Connect the electrical power4. Perform the start-up settings

Reading on display after connecting theelectrical auxiliary power:

� tEStinG runs across the display and thenthe fault alarm icon appears andblinks on the display when the positionerhas not yet been initialized. The readingindicates the lever position in degrees inrelation to the longitudinal axis.

Reading when thepositioner has not yetbeen initialized

� Code 0 appears on the display when apositioner has been initialized. Thepositioner is in the last active operatingmode.

WARNING!The actuator stem moves while the start-upsettings are being performed.Do not touch the actuator stem or obstruct itto avoid risk of injury to hands or fingers.

NOTICEPerform the start-up settings in the same se-quence as listed (section 7.1 to section 7.5).

7.1 Adapting the display

The reading on the display can be turned by180° to adapt it to how the positioner is at-tached.

Reading direction for rightattachment of pneumaticconnections

Reading direction for leftattachment of pneumaticconnections

If the display appears upside down, proceedas follows:

Turn � Code 2

Press , Code 2 blinks.

Turn � Desired reading direction.

Press to confirm the reading direction.

7.2 Limiting the signal pressure

If the maximum actuator force may causedamage to the valve, the signal pressuremust be limited.

40 EB 8387-5 EN

Start-up – Settings

NOTICEDo not activate the pressure limit function inactuators with fail-safe action AIR TO OPEN(AtO), e.g. double-acting actuators (OFF =default).

Enable configuration at the positioner beforeactivating the pressure limit function:

Note: If no settings are entered within120 seconds, the enabled configurationfunction becomes invalid.

Configuration enabledDefault: OFF

Turn � Code 3, display: OFF


Turn � ON

Press , display:

Pressure limit function:

Pressure limitDefault: OFF

Turn � Code 16


Turn until the required pressure limit(1.4/2.4/3.7 bar) appears.

Press to confirm the pressure limit.

7.3 Checking the operatingrange of the positioner

To check the mechanical attachment, thevalve should be moved through the operat-ing range of the positioner in the manualoperating mode using the manual referencevariable w.

Select manual operating mode:

ModeDefault: MAN

Turn � Code 0


Turn � MAN

Press to change the positioner tomanual mode.

Checking the operating range:

Manual reference variable(the current opening angleappears)

Turn � Code 1

Press , Code 1 and blink.

Turn until the pressure builds up in thepositioner, and the control valve moves to itsend positions to check the travel range/an-gle of rotation.

EB 8387-5 EN 41


The angle of the lever on the back of thepositioner is indicated on the display.A horizontal lever (mid-position) is equal to0°.

To ensure the positioner is working prop-erly, the outer bar elements may not blinkwhile the valve is moving through the oper-ating range.The manual operating mode can be exitedby pressing the rotary pushbutton ( ).

The permissible range has been exceededwhen the displayed angle is greater than30°, and the outer right or left bar elementblinks.The positioner changes to the fail-safe posi-tion SAFE.After canceling the fail-safe position SAFE(see section 8.2.2) it is absolutely necessaryto check the lever and pin position as de-scribed in section 4.

WARNING!To avoid personal injury or property dam-age caused by the supply air or electricalauxiliary power, disconnect the supply airand electrical auxiliary power (bus line) be-fore exchanging the lever or changing thepin position.

7.4 Determining the fail-safeposition

To adapt the positioner to the operating di-rection of the actuator, the fail-safe positionof the positioner must be determined:

� AIR TO OPEN (AtO)Signal pressure opens the valve.Fail-safe position: Valve CLOSED

� AIR TO CLOSE (AtC)Signal pressure closes the valve.Fail-safe position: Valve OPEN

NOTICEDouble-acting actuators must always be setto AIR TO OPEN (AtO).

Note: The fail-safe position setting remainsset even when the positioner is started upagain after the power supply has been dis-connected.

Initialization

Fail-safe positionAIR TO OPEN

Fail-safe positionAIR TO CLOSE

42 EB 8387-5 EN


Turn � Code 0

Press , display: MANCode 0 blinks.

Turn � Init

Press .

Turn until the required fail-safe positionappears on the display.

Press to confirm the fail-safe position.

Turn � ESC

Press to exit or:

Start initialization as described in sec-tion 7.5.

For checking purposes: After the positionerhas been initialized successfully, the valveclosed position is indicated on the positionerdisplay as 0 %, whereas the valve open po-sition is indicated by 100 %. If this is not thecase, the closing direction has to be adaptedcorrespondingly and the positioner needs tobe re-initialized.

7.5 Positioner initialization

WARNING!During initialization, the control valve movesthrough its entire travel/angle of rotationrange. Therefore, do not start the initializa-tion procedure while a process is running,but only during start-up when all shut-offvalves are closed.

Before starting initialization, check the maxi-mum permissible signal pressure of the con-

trol valve. During initialization, thepositioner issues an output signal pressureup to the maximum supply pressure sup-plied. If necessary, limit the signal pressureby connecting an upstream pressure reduc-ing valve.

NOTICEIf the positioner is mounted onto another ac-tuator or its mounting position is changed,reset the positioner to its default settings be-fore re-initializing it. Refer to section 7.7.

During initialization the positioner adapts it-self optimally to the friction conditions andthe signal pressure requirements of the con-trol valve.The type and extent of self-adaptation de-pends on the initialization mode selected:� MAX maximum range (standard range)

Initialization mode for simple start-up ofvalves with two clearly defined mechani-cal end positions, e.g. three-way valves(see section 7.5.1)

� NOM nominal rangeInitialization mode for all globe valves(see section 7.5.2)

� MAN manually selected rangeInitialization mode for globe valves withan unknown nominal range (see section7.5.3)

� SUB substitute calibration (emergencymode)This mode allows a positioner to be re-placed while the plant is running, withthe least amount of disruption to theplant (see section 7.5.4)

EB 8387-5 EN 43


Note: The initialization procedure can be in-terrupted while running by pressing the rota-ry pushbutton ( ). StOP appears three se-conds long and the positioner then moves tothe fail-safe position.The fail-safe position can be canceled againover Code 0.

Alternating displays:Initialization running

Initialization progressindicated(MAX, NOM, MAN or SUBappears, depending on theinitialization mode selected)

Initialization successfulPositioner in automaticoperating mode

The time required for an initializationprocess depends on the stroking speed ofthe actuator and may take several minutes.

After a successful initialization, thepositioner runs in automatic mode indicatedby the closed-loop operation icon.

A malfunctioning leads to the process beinginterrupted. The initialization error appearson the display according to how it has beenclassified by the condensed state. See sec-tion 8.3 on page 56).

Note: Positioner with extended EXPERT+ di-agnostics automatically start to plot the refe-rence graphs (drive signal y d1 and hystere-sis d2) after initialization has been comple-ted. TEST d1 and d2 appear on the displayin alternating sequence.An unsuccessful plotting of the referencegraphs is indicated on the display by Code81.The positioner still works properly, eventhough the reference graph plotting has notbeen completed successfully.

7.5.1 Initialization based on MAXmaximum range

The positioner determines travel/angle ofrotation of the closing member from theCLOSED position to the opposite side andadopts this travel/angle of rotation as theoperating range from 0 to 100 %.

Enable configuration:





Turn � ON

44 EB 8387-5 EN


Press , display:

Select initialization mode:

Init modeDefault: MAX

Turn � Code 6

Press

Turn � MAX

Press to confirm the MAX initializationmode.

Start initialization:

Initialization

Fail-safe position setting

Progress indicated untilinitialization starts

Turn � Code 0


Turn � Init

Press . The setting of the fail-safe positionAtO or AtC appears.

Keep pressed down for 6 seconds.Initialization starts after the progress indica-tion has stopped.

The nominal travel/angle of rotation is indi-cated in % after initialization. Code 5 (nomi-nal range) remains locked. The parametersfor travel/angle range start (Code 8) andtravel/angle range end (Code 9) can alsoonly be displayed and modified in %.

For a reading in mm/°, enter the pin posi-tion (Code 4).

Enter pin position:

Pin positionDefault: OFF

Turn � Code 4


Turn � Pin position on lever (see sec-tions on attachment)

Press . The reading of the nominal rangeappears in mm/°.

7.5.2 Initialization based on NOMnominal range

The calibrated sensor allows the effectivevalve travel to be set very accurately. Duringthe initialization process, the positionerchecks whether the control valve can movethrough the indicated nominal range (travelor angle) without collision.If this is the case, the indicated nominalrange is adopted with the limits of

EB 8387-5 EN 45


travel/angle range start (Code 8) andtravel/angle range end (Code 9) as the op-erating range.

Note: The maximum possible travel must al-ways be greater than the nominal travel en-tered. If this is not the case, initialization isinterrupted (error message Code 52) becau-se the nominal travel is not achieved.






Turn � ON

Press , display:

Enter pin position and nominal travel:


Nominal range(with Code 4 = OFF locked)

Turn � Code 4


Turn � Pin position on lever (see sec-tions on attachment)

Press .

Turn � Code 5


Turn � Nominal valve travel

Press .


Initialization modeDefault: MAX

Turn � Code 6


Turn � NOM

Press to confirm the NOM initializationmode.

46 EB 8387-5 EN



Initialization



Turn � Code 0


Turn � Init



Note: After initialization, check the directionof action and, if necessary, change it(Code 7).

7.5.3 Initialization based on MANmanually selected range

Before starting initialization, move the con-trol valve manually to the OPEN position byturning in small steps. The valve mustmove to the required valve position with a

monotonically increasing signal pressure.The positioner calculates the differentialtravel/angle using the OPEN and CLOSEDpositions and adopts it as the operatingrange with limits of travel/angle range start(Code 8) and travel/angle range end(Code 9).

Enter OPEN position:

Manual reference variable(the current angle of rotationis displayed)

Turn � Code 0


Turn � MAN

Press .

Turn � Code 1


Turn until the OPEN position of the valveis reached.

Press to confirm the OPEN position.



EB 8387-5 EN 47





Turn � ON

Press , display:

Enter pin position:


Turn � Code 4


Turn � Pin position on lever (see sec-tions on attachment).

Press .



Turn � Code 6


Turn � MAN

Press to confirm the MAN initializationmode.


Initialization



Turn � Code 0


Turn � Init



7.5.4 SUB substitute calibration

A complete initialization procedure takesseveral minutes and requires the valve tomove through its entire travel range severaltimes. This initialization mode, however, isan emergency mode, in which the controlparameters are estimated and not deter-mined by an initialization procedure. As aresult, a high level of accuracy cannot beexpected.

48 EB 8387-5 EN


You should always select a different initial-You should always select a different initial-ization mode if the plant allows it.

The SUB initialization mode is used to re-place a positioner while the process isrunning. For this purpose, the control valveis usually fixed mechanically in a certain po-sition, or pneumatically by means of a pres-sure signal which is routed to the actuatorexternally. The blocking position ensuresthat the plant continues to operate with thisvalve position.

By entering the blocking position (Code 35),closing direction (Code 34), pin position(Code 4), nominal range (Code 5) and di-rection of action (Code 7), the positionercan calculate the positioner configuration.

NOTICEPerform a reset before re-initializing thepositioner if the substitute positioner has al-ready been initialized. Refer to section .






Turn � ON

Press , display:

Enter pin position and nominal travel:


Nominal range(with Code 4 = OFF locked)

Turn � Code 4


Turn � Pin position on lever (see sec-tions on attachment).

Press .

Turn � Code 5


Turn � Nominal travel of the valve

Press .



Turn � Code 6

Press .

Turn � SUB

EB 8387-5 EN 49


Press to confirm the SUB initializationmode.

Enter direction of action:

Direction of actionDefault: ��

Turn � Code 7


Turn � Direction of action (��/��)

Press .

Deactivate travel limit:

Travel limitDefault: 100.0

Turn � Code 11


Turn � OFF

Press .

Change pressure limit and control parame-ters:

Note: Do not change the pressure limit(Code 16). Only change the control para-meters KP (Code 17) and TV (Code 18) if thesettings of the replaced positioner areknown.

Pressure limitDefault: OFF

KP stageDefault: 7

TV stageDefault: 2

Turn � Code 16/17/18

Press , Code16/17/18 blinks.

Turn and set the selected control param-eter.

Press to confirm setting.

Enter closing direction and blocking posi-tion:

Closing positionDirection of rotation causingthe valve to move to theCLOSED position (view ontopositioner display)Default: CCL(counterclockwise)

Blocking positionDefault: 0

Turn � Code 34


50 EB 8387-5 EN


Turn � Closing direction (CCL counter-clockwise/CL clockwise)

Press .

Turn � Code 35


Turn � Blocking position, e.g. 5 mm(read off at travel indicator scale of theblocked valve or measure with a ruler)

Press .


Initialization



Blocking position

Turn � Code 0


Turn � Init


Keep pressed down for 6 seconds.Initialization starts after the progress indica-tion has stopped.The operating mode changes to MAN.The blocking position appears.

Note: As initialization has not been carriedout completely, the error code 76 (no emer-gency mode) and possibly also error code57 (control loop) may appear on the dis-play.These messages do not influence the positio-ner’s readiness for operation.

Cancel the blocking position and change toautomatic operating mode:

For the positioner to follow its referencevariable again, the blocking position mustbe canceled and the positioner must be setto automatic operating mode.

Turn � Code 1

Press , Code 1 and blink.

Turn until the pressure in the positionerbuilds up and the valve moves slightly pastthe blocking position.

Press to cancel the blocking position.

Turn � Code 0


Turn � AUtO

EB 8387-5 EN 51


Press . The positioner changes to the au-tomatic operating mode. The current valveposition is indicated in % on the display.

Note: If the positioner shows a tendency tohunt in automatic operating mode, the pa-rameters KP and TV must be slightly cor-rected. Proceed as follows:– Set TV (Code 18) to 4.– Reduce KP (Code 17) until the positioner

shows a stable behavior.

Zero point correction

Finally, if process operations allow it, thezero point must be calibrated as describedin section 7.6.

7.6 Zero calibration

In case of discrepancies with the closing po-sition of the valve, e.g. with soft-sealedplugs, it may become necessary torecalibrate the zero point.

NOTICEThe valve briefly moves from the currenttravel/angle of rotation position to theclosed position.

Note: The supply air must be connected topeform a zero calibration.




Turn � ON

Press , display:

Perform zero calibration:


Turn � Code 6


Turn � ZP

Press .

Turn � Code 0

Press .Display: MAN, Code 0 blinks.

Turn � Init


Keep pressed down for 6 seconds.Zero calibration is started, the positionermoves the control valve to the CLOSED posi-tion and recalibrates the internal electricalzero point.

52 EB 8387-5 EN


7.7 Reset to default values

This function resets all parameters to the fac-tory default values (see code list insection 11).




Turn � ON

Press , display:

Reset start-up parameters:

ResetDefault: OFF



Turn � RUN

Press . All start-up parameters are resetto their default values.

EB 8387-5 EN 53


8 Operation

WARNING!The actuator stem moves while the positioneris being operated.Do not touch the actuator stem or obstruct itto avoid risk of injury to hands or fingers.

8.1 Enabling and selectingparameters

All codes with their meanings and defaultsettings are listed in the code list in sec-tion 11 on page 59 onwards.The codes which are marked with an aster-isk (*) must be enabled with Code 3 beforethe associated parameters can be config-ured as described below.

Code 3Configurationnot enabled

Configurationenabled


Press , Code 3 blinksChange the setting of Code 3.

Turn � ON

Press , display:The configuration is enabled.

You can now configure codes one after theother:

Turn and select the required code.

Press to access the selected code. Thecode number starts to blink.

Turn and select the setting.

Press to confirm the selected setting.

Note: If no settings are entered within 120seconds, the enabled configuration functionbecomes invalid and the display resets toCode 0.

Canceling the setting

Canceling the setting

To cancel a value before it is confirmed (ro-tary pushbutton ) without the value youhave just selected being adopted:

Turn � ESCPress to confirm the cancelation.The entry is completed without the value youhave just selected being adopted.

54 EB 8387-5 EN

Operation

8.2 Operating modes

8.2.1 Automatic and manualoperating modes

After initialization has been completed suc-cessfully for the first time, the positioner isautomatically in automatic operatingmode.

automatic operatingmode

Switching to manual operating mode

Turn � Code 0

Press , display: AUtO,Code 0 blinks.

Turn � MAN

Press to switchover to manual operat-ing mode.The switchover is smooth since the manualoperating mode starts up with the set pointlast used during automatic operating mode.The current position is displayed in %.

Adjust the manual reference variable

Turn � Code 1


Turn until the positioner has built upenough pressure and the control valvemoves to the required position.

Note: If no settings are entered withinapprox. two minutes, the positioner auto-matically returns to Code 0, but remains in

manual operating mode.

Switching to automatic operatingmode:

Turn � Code 0


Turn � AUtO

Press to switchover to the automaticoperating mode.

EB 8387-5 EN 55

Operation

8.2.2 SAFE – Fail-safe position

If you want to move the valve to fail-safe po-sition determined during start-up (see sec-tion 7.4), proceed as follows:

Turn � Code 0

Press , display: current operating mode(AUtO or MAN), Code 0 blinks.

Turn � SAFE

Press , display: SThe valve moves to the fail-safe position.If the positioner is initialized, the currentvalve position is indicated on the display in%.

Exit the fail-safe position

Turn � Code 0


Turn and select the required operatingmode AUtO or MAN.

Press .The positioner switches to the operatingmode selected.

8.3 Malfunction/maintenancealarm

All status messages and fault alarms are as-signed to a classified status in the positioner.The default settings of the status classifica-tion are listed in the code list.

Note: The classification of the statusmessages can be changed in TROVIS-VIEWand over the parameters in the DD file.Refer to the Configuration ManualKH 8387-5 EN on the supplied CD-ROM(CD 8387-5) for more information.

To provide a better overview, the classifiedalarms are summarized in a condensedstate. The following status messages areavailable:

� Maintenance alarmThe positioner cannot perform its controltask due to a functional fault in the de-vice or in one of its peripherals or an ini-tialization has not yet been successfullycompleted.

� Maintenance requiredThe positioner still performs its controltask (with restrictions). A maintenancerequirement or above average wear hasbeen determined. The wear tolerance willsoon be exhausted or is reducing at afaster rate than expected. Maintenance isnecessary in the medium term.

� Maintenance demandedThe positioner still performs its controltask (with restrictions). A maintenancedemand or above average wear hasbeen determined. The wear tolerance willsoon be exhausted or is reducing at a

56 EB 8387-5 EN

Operation

faster rate than expected. Maintenanceis necessary in the short term.

� Function checkTest or calibration procedures are beingperformed. The positioner is temporarilyunable to perform its control task untilthis procedure is completed

Note: If an event is assigned to the “Nomessage” status, this event does not haveany effect on the condensed state.

The condensed state is represented by thefollowing icons:

Condensed state Positionerdisplay

Maintenance alarm

Maintenance required/Maintenance demanded

Function check tESting, TunE ortESt

If the positioner has not been initialized, themaintenance alarm icon ( ) appears onthe display as the positioner cannot followits reference variable.

If fault alarms exist, the possible source oferror is displayed in Code 49 onwards. Inthis case, Err appears on the display.

The cause and recommended action arelisted in the code list (section 11).

Error: Pin position

Note: The optional EXPERT+ valve diagnos-tics generate further diagnostic messageswhich are included in the condensed stateaccording on how they have been classified.A diagnostic alarm generated by the ex-tended EXPERT+ diagnostics is issued byCode 79.

8.3.1 Confirming error messages



Configuration enabledStandard: OFF



Turn � ON

Press , display:

Confirming alarm:

Turn � Error code that is to be con-firmed.

Press to confirm the errror message.

EB 8387-5 EN 57

Operation

9 Maintenance

The positioner does not require any mainte-nance.There are filters with a 100 m mesh size inthe pneumatic connections for supply andoutput which can be removed and cleaned,if required.The maintenance instructions of any up-stream supply air pressure reducing stationsmust be observed.

10 Servicing explosion-protecteddevices

If a part of the positioner on which the ex-plosion protection is based needs to be ser-viced, the positioner must not be put backinto operation until an expert has inspectedthe device according to explosion protectionrequirements, has issued a certificate statingthis or given the device a mark of confor-mity.Inspection by an expert is not required if themanufacturer performs a routine test on thedevice prior to putting it back into opera-tion. The passing of the routine test must bedocumented by attaching a mark of confor-mity to the device.

58 EB 8387-5 EN

Maintenance

11 Code list

Codeno.

Parameter – Display, values[default setting] Description

Note: Codes with marked with an asterisk (*) must be enabled with Code 3 prior to configuration.

0 Operating mode[MAN]AUtO · SAFEESC

AUtO Automatic modeMAN Manual modeSAFE Fail-safe positionESC EscapeIn MAN and AUtO mode, the system deviation is represented bybar elements on the display.If the positioner has been initialized, the numerical reading indi-cates the valve position or the angle of rotation in %, otherwisethe position of the lever in relation to the central axis is displayedin degrees °.Switchover from automatic to manual mode is smooth.In fail-safe position, the S icon appears on the display.

InitAtO · AtC

Init Start initializationDetermine fail-safe position:

AtO: AIR TO OPEN (valve CLOSED in fail-safe position) orAtC: AIR TO CLOSE (valve OPEN in fail-safe position)

1 Manual reference variablew0 to 100 [0] %of the nominal range

Setting the manual reference variable wThe current travel/angle is displayed in % when the positionerhas been initialized, otherwise the position of the lever in relationto the central axis is indicated in degrees °.Can only be selected when Code 0 = MAN.

2 Reading direction[Normal] or upside downESC

The reading direction of the display is turned by 180°.

3 Enable configuration[OFF]ONESC

Enables the option to modify data (automatically deactivated whenthe rotary pushbutton has not been operated for 120 s.)FF blinks on the display when the on-site operation is locked overthe FF network.Codes marked with an asterisk (*) can only be read and notoverwritten.Codes can also only be read over the SSP interface.

EB 8387-5 EN 59

Code list

Codeno.



4* Pin position[OFF]17, 25, 35, 50, 70, 100,200 mm90° with rotary actuatorsESC

Note! If you select a pinposition in Code 4 that is toosmall, the positioner switchesto the fail-safe position(SAFE mode) for reasons ofsafety.

The follower pin must be inserted into the correct pin position ac-cording to the valve travel/angle of rotation.The pin position must be entered for initialization using NOM orSUb.

Pin position Standard Adjustment rangeCode 4 Code 5 Code 517 7.5 3.6 to 17.725 7.5 5.0 to 25.035 15.0 7.0 to 35.450 30.0 10.0 to 50.070 40.0 14.0 to 70.7100 60.0 20.0 to 100.0200 120.0 40.0 to 200.090° 90.0 24.0 to 100.0

5* Nominal rangemm or angle °ESC

For initialization using NOM or SUb, the nominal travel/angle ofrotation of the valve must be entered.The permissible adjustment range depends on the pin positionaccording to the table for Code 4.Code 5 is generally locked until Code 4 is set to OFF, i.e. after apin position has been entered, Code 5 can be configured.After initialization has been successfully completed, the max-imum nominal travel/angle reached on initialization is dis-played.

6* Initialization mode[MAX]NOM · MAN · SUb · ZPESC

Select the initialization modeMAX: Maximum range of the control valve, the travel/angle of

the closure member from the CLOSED position to the op-posite stop in the actuator.

NOM: Nominal range of the control valve, the travel/angle ofthe closure member measured from the CLOSED positionto the indicated OPEN position.

MAN: Manually selected rangeSUb: Substitute calibration (emergency mode)ZP: Zero calibration

60 EB 8387-5 EN

Code list

Codeno.



7* Direction of action[��]��

ESC

Direction of action of the reference variable w in relation to thetravel/angle of rotation x (increasing/increasing or in-creasing/decreasing).Automatic adaptation:AIR TO OPEN: After initialization, the direction of action remains

increasing/increasing (��), a globe valve opens as thereference variable increases.

AIR TO CLOSE: After initialization, the direction of actionchanges to increasing/decreasing (��), a globe valvecloses as the reference variable increases.

8* Travel/angle range start(lower x-range value)0.0 to 80.0 [0.0] % of thenominal rangeSpecified in mm or angle ° providedCode 4 is set

ESC

Starting value for the travel/angle of rotation in the nominal oroperating range.The operating range is the actual travel/angle of the controlvalve and is limited by the travel/angle range start (Code 8) andthe travel/angle range end (Code 9).Usually, the operating range and the nominal range are iden-tical. The nominal range can be limited to the operating rangeby the travel/angle range start and end. Value is displayed ormust be entered.The characteristic is adapted.See also the example in Code 9.

9* Travel/angle range end(upper x-range value)20.0 to 100.0 [100.0] % ofthe nominal rangeSpecified in mm or angle ° providedCode 4 is set

ESC

End value for the travel/angle of rotation in the nominal or oper-ating range. Value is displayed or must be entered.The characteristic is adapted.Example: The operating range is modified, for example, to limitthe range of a control valve which has been sized too large. Forthis function, the entire resolution range of the reference variableis converted to the new limits. 0 % on the display corresponds tothe adjusted lower limit and 100 % to the adjusted upper limit.

10* Travel/angle lower limit(lower x-limit)[OFF]0.0 to 49.9 % of theoperating rangeESC

Limitation of the travel/angle of rotation downwards to the en-tered value.The characteristic is not adapted.See also example in Code 11.

EB 8387-5 EN 61

Code list

Codeno.



11* Travel/angle upper limit(upper x-limit)50.0 to 120.0 [100] % ofthe operating rangeOFF · ESC

Limitation of the travel/angle of rotation upwards to the enteredvalue.When set to OFF, the valve can be opened past the nominaltravel with a reference variable outside of the 0 to 100 % range.The characteristic is not adapted.Example: In some applications, it is better to limit the valvetravel, e.g. if a certain minimum medium flow is required or amaximum flow must not be reached.The lower limit must be adjusted with Code 10, and the upperlimit with Code 11.If a tight-closing function has been set up, it has priority over thetravel limitation.

14* Setpoint cutoff decrease(final position w <)0.0 to 49.9 [1.0] %OFF · ESC

If reference variable w reaches the percentage adjusted thatcauses the valve to close, the actuator is immediately completelyvented (with AIR TO OPEN) or filled with air (with AIR TOCLOSE). This action always lead to maximum tight-closing of thevalve.Codes 14/15 have priority over Codes 8/9/10/11.Codes 21/22 have priority over Codes 14/15.

15* Setpoint cutoff increase(final position w >)[OFF]50.0 to 100.0 %ESC

If reference variable w reaches the percentage adjusted thatcauses the valve to open, the actuator is immediately completelyfilled with air (with AIR TO OPEN) or vented (with AIR TOCLOSE). This action always lead to the valve being completelyopened.A signal pressure limit is possible over Code 16.Codes 14/15 have priority over Codes 8/9/10/11.Codes 21/22 have priority over Codes 14/15.Example: Set the cutoff to 99 % for three-way valves.

16* Pressure limit[OFF]P 1.4 2.4 3.7ESC

The pressure limit determined during initialization is displayed inbar. The pressure limit can be changed for fail-safe position AIRTO OPEN (AtO).After changing a pressure limit already set, the actuator must bevented once (e.g. by selecting the fail-safe position over Code 0).NOTICEDo not activate the pressure limit for actuators with fail-safe posi-tion AIR TO OPEN (AtO), e.g. double-acting actuators.

62 EB 8387-5 EN

Code list

Codeno.



17* Proportional-action coeffi-cient KP (step)0 to 17 [7]ESC

Displaying or changing the KP and TV steps:During initialization, the KP and TV values are optimized. Shouldthe positioner show a tendency for impermissibly high post-pulseoscillation due to additional interference, the KP and TV steps canbe adapted after initialization. For this, either the TV step can beincreased in increments until the desired response behavior isreached or, when the maximum value of 4 is reached, the KPstep can be decreased in increments.Note: Changing the KP step influences the system deviation.

18* Rate time TV (step)[2]1 3 4 OFFESC

Changing TV, see Code 17.Note: Changing the TV step has no effect on the system devia-tion.

19* Tolerance band0.1 to 10.0 [5] % of theoperating rangeESC

Used for error monitoringDetermination of the tolerance band in relation to the operatingrange.Associated lag time [30] s is a reset criterion.If a lag time is determined during initialization which is six times> 30 s, the six-fold lag time is accepted as the lag time.

20* Characteristic0 to 9 [0]ESC

Select the characteristic:0 Linear1 Equal percentage2 Reverse equal percentage3 SAMSON butterfly valve linear4 SAMSON butterfly valve equal percentage5 VETEC rotary plug valve linear6 VETEC rotary plug valve equal percentage7 Segmented ball valve linear8 Segmented ball valve equal percentage9 User-defined (defined over operating software)Note: The various characteristics are listed in the Appendix

(section 13.1).

EB 8387-5 EN 63

Code list

Codeno.



21* Required transit time OPEN(w ramp open)0 to 240 s [0]ESC

The time required to pass through the operating range when thevalve opens.Limitation of the transit time (Code 21 and 22):For some applications it is better to limit the actuating speed ofthe actuator to prevent it from engaging too fast in the runningprocess.Code 21 has priority over Code 15.

22* Required transit timeCLOSED (w ramp closed)0 to 240 s [0]ESC

The time required to pass through the operating range when thevalve closes.Code 22 has priority over Code 14.

23* Total valve travel0 to 99 · 107 [0]Exponential reading from 9999 travelcycles onwards

RES · ESC

Totaled double valve travel.Can be reset to 0 via RES.Note: The number of travel cycles (in steps of 1000) is saved in anon-volatile memory.

24* Limit of total valve travel1000 to 99 · 107

[1 000 000]Exponential reading from 9999 travelcycles onwards

ESC

Limit value of total valve travel. If the limit is exceeded, the faultalarm and the wrench icons appear on the display.

34* Closing direction[CCL] CounterclockwiseCL ClockwiseESC

Turning direction of the lever in which the valve is moved to theCLOSED position (view onto the display of the positioner).Needs only be entered in SUb initialization mode.

35* Blocking position[0] mm/° /%ESC

Distance up to the CLOSED position (0 % position).Only needs to be entered in SUb initialization mode.

36* Reset[OFF]RUN · ESC

Resets all parameters to default settings.Note: After setting RUN, the positioner must be re-initialized.

64 EB 8387-5 EN

Code list

Codeno.



39 System deviation e–99.9 to 999.9 %

Deviation from the target position (e = w – x)Display only

40 Minimum transit time OPEN0 to 240 s [0]

Time [s] needed by the system (positioner, actuator and valve) tomove through the nominal travel/angle to open the valve (100 %position).Display only

41 Minimum transit timeCLOSED0 to 240 s [0]

Time [s] needed by the system (positioner, actuator and valve) tomove through the nominal travel/angle to close the valve (0 %position).Display only

42 Auto-w/manual-w0.0 to 100.0 % of the span

Supplied manual and automatic reference variableDisplay only

43 Firmware version controlXxxx

Positioner type and current firmware version (in alternating se-quence)Display only

44 y info0 to 100 %, [0 %]

Control signal y [%] based on the travel range determined on ini-tialization · Display onlyMAX: The positioner builds up its maximum output pressure,

see description in Code 14 and 15.0 P: The positioner vents completely, see description in

Code 14 and 15.– – –: The positioner has not been initialized.

45 Forced venting statusYES · HIGH/LOW · NO

Indicates whether the option is installed or not · Display onlyNO No forced venting installedYES Forced venting installedIf a voltage supply is connected at the terminals of the forcedventing option, YES and HIGH appear on the display in alter-nating sequence. If a voltage supply is not applied (actuatorvented, fail-safe position indicated on the display by the S icon),YES and LOW appear on the display in alternating sequence.

46* Bus addressESC

Display only

EB 8387-5 EN 65

Code list

Codeno.



47* Status of write protectionswitch[NO]YES · ESC

When the write protection function is activated, device data canonly be read, but not overwritten over FF communication.

48* Diagnostics

Diagnostic parameters d

d0 Temperature–55 to 125 °C

Current operating temperature [°C] inside the positioner(accuracy 3 %)Display only

d1 Minimum temperature[20]

The lowest temperature below 20 °C that has ever occurred.Display only

d2 Maximum temperature[20]

The highest temperature above 20 °C that has ever occurred.Display only

d3 Number of zerocalibrations[0]

The number of zero calibrations since the last initialization.Display only

d4 Number ofinitializations[0]

The number of initializations that have been performed since thelast reset.Display only

d5 Zero point limit[5 %]0.0 to 100.0 % of thenominal range

User-defined zero point monitoringUsed for error monitoring of the zero point shift.

d6 Condensed state Condensed state, made up from the individual states · DisplayonlyOK OkayC Maintenance requiredCR Maintenance demandedB Maintenance alarmI Function check

66 EB 8387-5 EN

Code list

Codeno.



48* d7 Start reference test[OFF]ON · ESC

Starting of a reference test (for the EXPERT+ functions: Drivesignal y steady-state (d1) and drive signal y hysteresis (d2).The reference test can only be activated in manual operatingmode as the valve moves through its entire working range.If EXPERT+ is activated at later point in time, the reference graphsmust be plotted in order to activate the diagnostic functions.

d8 EXPERT+ activation Enter the activation code for EXPERT+.After the activation procedure has been successfully completed,YES appears under d8.

FF parameters

F0 Firmware Rev.Communication

Display only

F1 Binary input Display only1 Active · 2 Inactive

F3 Simulate PV Activation of simulation mode

Positioner (AO)

A0 Target Mode Target operating mode

A1 Actual Mode Actual operating mode · Display only

A2 CAS_IN Value Analog reference variable adopted from an upstream functionblock (value) · Display only

A3 CAS_IN Status Analog reference variable adopted from an upstream functionblock (status) · Display only

A4 SP Value Reference variable w (value) · Display only

A5 SP Status Reference variable w (status) · Display only

A6 OUT Value Manipulated variable (value) · Display only

A7 OUT Status Manipulated variable (status) · Display only

A8 BLOCK ERR Active block error · Display only

EB 8387-5 EN 67

Code list

Codeno.



48* Process controller (PID)

P0 Target Mode Target operating mode

P1 Actual Mode Actual operating mode · Display only

P2 CAS_IN Value Analog reference variable adopted from an upstream functionblock (value) · Display only

P3 CAS_IN Status Analog reference variable adopted from an upstream functionblock (status) · Display only

P4 SP Value Reference variable w (value) · Display only

P5 SP Status Reference variable w (status) · Display only

P6 OUT Value Manipulated variable (value) · Display only

P7 OUT Status Manipulated variable (status) · Display only

P8 BLOCK ERR Active block error · Display only

Positioner (AO TRD), binary input (DI1 TRD, DI2 TRD)

t0 Target Mode (AO TRD) Target operating mode

t1 Actual Mode (AO TRD) Actual operating mode · Display only

t2 Transducer State State of the Transducer Block · Display only

t3 BLOCK ERR AO TRD Active block error · Display only

t4 Target Mode (DI1 TRD) Target operating mode

t5 Actual Mode (DI1 TRD) Actual operating mode · Display only

t6 BLOCK ERR DI1 TRD Active block error · Display only

t7 Target Mode (DI2 TRD) Target operating mode

t8 Actual Mode (DI2 TRD) Actual operating mode · Display only

t9 BLOCK ERR DI2 Active block error · Display only

68 EB 8387-5 EN

Code list

Codeno.



48* Operating unit (RES)

S0 Target Mode (RES) Target operating mode

S1 Actual Mode (RES) Actual operating mode · Display only

S2 BLOCK ERR (RES) Active block error · Display only

Binary input (DI1)

I0 Target Mode (DI1) Target operating mode

I1 Actual Mode (DI1) Actual operating mode · Display only

I2 Field_Val_D Value Discrete process variable field hardware (value) · Display only

I3 Field_Val_D Status Discrete process variable field hardware (status) · Display only

I4 OUT_D Value Discrete output variable (value) · Display only

I5 OUT_D Status Discrete output variable (status) · Display only

I6 BLOCK ERR Active block error · Display only

Binary input DI2

L0 Target Mode (DI2) Target operating mode

L1 Actual Mode (DI2) Actual operating mode · Display only

L2 Field_Val_D Value Discrete process variable field hardware (value) · Display only

L3 Field_Val_D Status Discrete process variable field hardware (status) · Display only

L4 OUT_D Value Discrete output variable (value) · Display only

L5 OUT_D Status Discrete output variable (status) · Display only

L6 BLOCK ERR Active block error · Display only

D2 Function Block L

L0 Target Mode DI2 Required operating mode

L1 Actual Mode DI2 Actual operating mode

L2 Field_Val_D Value Displays the discrete input variable

EB 8387-5 EN 69

Code list

Codeno.



48* L3 Field_Val_D Status and its status

L4 OUT_D Value Displays the discrete output variable

L5 OUT_D Status and its status

L6 BLOCK ERR Displays the current block error

49* PST Description of partial stroke test function (refer to EB 8388-5 EN)

Note: The error codes listed in following appear in the display corresponding to their statusclassification set over the condensed state (Maintenance required/Maintenance demanded:

, Maintenance alarm: ). If “No message” is assigned to the error code as the statusclassification, the error is not included in the condensed state.

A status classification is assigned to every error code in the default setting. The status classifi-cation of error codes can also be changed as required using an operating software (e.g.TROVIS-VIEW). Refer to the Configuration Manual KH 8387-5 EN.

70 EB 8387-5 EN

Code list

Initialization errors

Error codes – Recommended action Condensed state alarm active, when prompted, Err appears.When fault alarms exist, they are displayed here.

50 x > range The value supplied by the measuring signal is either too high ortoo low, the measuring sensor is close to its mechanical limit.• Pin positioned incorrectly.• Bracket slipped in case of NAMUR attachment or positioner is

not central.• Follower plate incorrectly attached.

Status classification [Maintenance required]

Recommended action Check attachment and pin position, set operating mode fromSAFE to MAN and re-initialize the positioner.

51 �x < range The measuring span of the sensor is too low.• Pin positioned incorrectly.• Wrong lever.A rotational angle smaller than 16° at the positioner shaft createsjust an alarm. An angle below 9° leads to the initialization beingcanceled.


Recommended action Check attachment and re-initialize the positioner.

52 Attachment • Positioner attachment incorrect.• Nominal travel/angle (Code 5) could not be achieved on

initialization under NOM or SUb (no tolerance downwardspermissible).

• Mechanical or pneumatic fault, e.g. wrong lever selected orsupply pressure too low to move to the required position.


Recommended action Check attachment and supply pressure. Re-initialize thepositioner.Under certain circumstances, it may be possible to check themaximum travel/angle by entering the actual pin position andthen performing an initialization under MAX.After initialization has been completed, the Code 5 indicates themaximum achieved travel or angle.

EB 8387-5 EN 71

Code list


53 Initialization time exceeded(Init time >)

The initialization routine lasts too long. The positioner returns toits previous operating mode.• No pressure on the supply line or there is a leak.• Supply air failure during initialization.


Recommended action Check attachment and supply pressure.Re-initialize the positioner.

54 Initialization/forced venting 1) A solenoid valve is installed (Code 45 = YES) and wasnot or not properly connected so that an actuator pressurecould not be built up. The alarm is generated when youattempt to initialize the positioner.

2) If you attempt to initialize the device from the fail-safeposition (SAFE).


Recommended action Re. 1) Check connection and supply voltage of the forced ventingCode 45 HIGH/LOW

Re. 2) Set the MAN operating mode over Code 0. Then initializethe positioner.

55 Transit time too short(transit time <)

The actuator positioning rates determined during the initializati-on are so short that the positioner cannot adapt itself optimally.


Recommended action Check the volume restriction setting as described in section 4,re-initialize the positioner.

56 Pin position Initialization was canceled because you are required to enter thepin position for the selected initialization modes NOM and SUb.


Recommended action Enter pin position over Code 4 and nominal travel/angle overCode 5. Re-initialize the positioner.

72 EB 8387-5 EN

Code list

Operational errors


57 Control loop Control loop error, the control valve does not react within the to-lerable times of the controlled variable (tolerance band alarmCode 19).• Actuator mechanically blocked.• Attachment of the positioner subsequently shifted.• Supply pressure not sufficient.


Recommended action Check attachment.

58 Zero point Zero point incorrect.Error may arise when the mounting position/linkage of the posi-tioner moves or when the valve seat trim is worn, especially withsoft-sealed plugs.


Recommended action Check valve and mounting of the positioner. If OK, perform azero calibration over Code 6 (see section 7.6 on page 52).If the lever position on the back of the positioner has beenchanged (e.g. while exchanging the lever), move the lever as faras it will go in both directions to adapt it to the internal mea-suring lever.

59 Autocorrection Should an error occur in the data range of the positioner, theself-monitoring function recognizes it and automatically correctsit.

Status classification [No message]

Recommended action Automatic

60 Fatal error An error was detected in the data relevant for safety,autocorrection is not possible. This may be due to EMCdisturbances.The control valve moves to its fail-safe position.

Status classification Maintenance alarm (cannot be classified)

Recommended action Reset over Code 36.Re-initialize the positioner (see sections 7.7 and 7.5).

EB 8387-5 EN 73

Code list

Hardware errors


62 x signal Determination of the measured data for the actuator has failed.Conductive plastic element is defective.The positioner continues to run in emergency mode, but shouldbe replaced as soon as possible.The emergency mode on the display is indicated by a blinkingclosed-loop control icon and 4 dashes instead of the position in-dication.

Note on the control:If the measuring system has failed, the positioner is still in a reli-able state. The positioner switches to emergency mode where theposition cannot be accurately controlled anymore. However, thepositioner continues operation according to its reference variablesignal so that the process remains in a safe state.


Recommended action Return the positioner to SAMSON AG for repair.

64 i/p converter The circuit of the i/p converter has been interrupted.


Recommended action Cannot be remedied.Return the positioner to SAMSON AG for repair.

65 Hardware A hardware error has occurred, the positioner moves to thefail-safe position SAFE.


Recommended action Confirm error and return to the automatic operating mode, orperform a reset and re-initialize the device. If this is not success-ful, return device to SAMSON AG for repair.

66 Data memory The writing of data to the data memory does not work anymore,e.g. when the written data deviate from the read data.Valve moves to the fail-safe position.



74 EB 8387-5 EN

Code list


67 Test calculation The hardware controller is monitored by means of a testcalculation.


Recommended action Confirm error. If this is not possible, return the positioner toSAMSON AG for repair.

Data errors


68 Control parameter Control parameter error


Recommended action Confirm error, perform reset and re-initialize the positioner.

69 Poti parameter Parameter error of the digital potentiometer.



70 Calibration Error in the production calibration data. Subsequently, the deviceruns on default values.



71 General parameters Parameter errors that are not critical for the control.


Recommended action Confirm error.Check and, if necessary, reset required parameters.

72 Start-up parameters Start-up parameter error



EB 8387-5 EN 75

Code list


73 Internal device error 1 Internal device error



74 FF parameters Parameter errors that are not critical for the control.


Recommended action Confirm error and perform reset.

75 Info parameters Info parameter errors that are not critical for the control.


Recommended action Confirm error.Check and, if necessary, reset required parameters.

76 No emergency mode The travel measuring system of the positioner has aself-monitoring function (see Code 62).An emergency mode (open-loop control) is not available forcertain actuators, such as double-acting actuators. In this case,the positioner moves to the fail-safe position when a measuringerror occurs. During the initialization, the positioner checkswhether the actuator has such a function or not.

Status classification [No message]

Recommended action Merely information, confirm, if necessary.No further action necessary.

77 Program loading errorAdditional alarm at the faultalarm contact

When the positioner starts operation for the first time after the in-put signal has been applied, it carries out a self-test (tEStinG runsacross the display).If the positioner loads the wrong program, the valve moves to thefail-safe position. It is not possible to make the valve leave thisfail-safe position again.


Recommended action Interrupt current and restart positioner.Otherwise, return the positioner to SAMSON AG for repair.

78 Options parameter Errors in options parameters



76 EB 8387-5 EN

Code list

Diagnosis errors


79 Extended diagnostics Error messages are generated in the extended EXPERT+ diagnos-tics if EXPERT+ has been successfully activated in Code 48.

Status classification Maintenance required (cannot be classified)

80 Diagnostic parameters Errors that are not critical for control.

Status classification Maintenance required (cannot be classified)

81 Reference test canceled The reference graphs were not plotted or an error occurredduring plotting the reference graphs for drive signal ysteady-state or drive signal y hysteresis.• Reference test was interrupted• Reference line y steady-state or y hysteresis was not adopted.Error messages are saved in EEPROM. They cannot be reset.


Recommended action Check and, if necessary, perform a new reference test

EB 8387-5 EN 77

Code list

12 Dimensions in mm

78 EB 8387-5 EN

Dimensions in mm

70

15

46

34

1412

2

95

34

53 28NPT ½, ¼

58

58236

Output Supply

Fig. 15a · Attachment according to IEC 60534-6 and direct attachment

Attachment acc. toIEC 60534-6 �

Directattachment �

Pressuregaugebracket

or connecting plate(G ¼ only)

Electrical connections:2 x female thread½ NPT orM20 x 1.5

Lever in mm

S = 17M = 50L = 100

¼ NPT

EB 8387-5 EN 79

Dimensions in mm

80

52 Output Y1

Output Y2

Supply (9)Output Y1

Output Y2

5686

13080

166

3086

Ø 101

Fig. 15b · Attachment to rotary actuators VDI/VDE 3845 (Sept. 2010), level 1, size AA1 to AA4

Type 3710ReversingAmplifier(option)

A1 Z

A2

5686

13080

166

3086

Ø 101

76

50

Output A2

Output A1Supply (9)

Reversing amplifier1079-1118 or1079-1119(option)

12.1 Fixing levels according to VDI/VDE 3845 (September 2010)

80 EB 8387-5 EN

Dimensions in mm

A

M6

C

B

25

Mmin

Ød

ØD

Level 2 (bracket surface)

Level 1 (actuator surface)

Actuator

Dimensions in mm

Size A B C �d Mmin �D*

AA0 50 25 15 5.5 for M5 66 50

AA1 80 30 20 5.5 for M5 96 50

AA2 80 30 30 5.5 for M5 96 50

AA3 130 30 30 5.5 for M5 146 50

AA4 130 30 50 5.5 for M5 146 50

AA5 200 50 80 6.5 for M6 220 50

* Flange type F05 according to DIN EN ISO 5211

EB 8387-5 EN 81

13 Appendix

13.1 Selecting the valve characteristic

The characteristics that can be selected in Code 20 are shown in following in graph form.

Note: A characteristic can only be defined (user-defined characteristic) using a workstation/operating software (e.g. TROVIS-VIEW).

Linear (select characteristic: 0)

Equal percentage (select characteristic: 1) Rev. equal percentage (select characteristic: 2)

82 EB 8387-5 EN

Appendix

0

50

100

0 50 100

Travel/ angle of rotation [%]

Reference variable [%]0

50

100

0 50 100


Reference variable [%]

0

50

100

0 50 100



SAMSON butterfly valve linear(select characteristic: 3)

SAMSON butterfly valve equal percentage(select characteristic: 4)

VETEC rotary plug valve linear(select characteristic: 5)

VETEC rotary plug valve equal percentage(select characteristic: 6)

Segmented valve ball linear(select characteristic: 7)

Segmented ball valve equal percentage(select characteristic: 7)

0

50

100

0 50 100



0

50

100

0 50 100



0

50

100

0 50 100



0

50

100

0 50 100



0

50

100

0 50 100



0

50

100

0 50 100



84 EB 8387-5 EN

EB 8387-5 EN 85

86 EB 8387-5 EN

EB 8387-5 EN 87

Index

A

Accessories . . . . . . . . . . . . . . . . . . 28 - 29Additional equipment

binary input. . . . . . . . . . . . . . . . . . . . 9electrical connection . . . . . . 36technical data . . . . . . . . . 12

extended EXPERT+ valve diagnostics . . 9forced venting . . . . . . . . . . . . . . . . . . 9

electrical connection . . . . . . 36technical data . . . . . . . . . 12

Article code . . . . . . . . . . . . . . . . . . . . . . 7Attachment

acc. to IEC 60534-6 (NAMUR) . . . . . 20direct attachment

to Type 3277 Actuator . . . . . 18to Type 3277-5 Actuator . . . . 15

reversing amplifier . . . . . . . . . . . . . . 26to rotary actuators . . . . . . . . . . . . . . 24to Type 3510 Micro-flow Valve. . . . . 22

B

Bar elements . . . . . . . . . . . . . . . . . . . . . 38Blocking position

canceling . . . . . . . . . . . . . . . . . . . . 51Bus line. . . . . . . . . . . . . . . . . . . . . . . . . 36

C

Cable entry . . . . . . . . . . . . . . . . . . . . . . 35Characteristic

selecting . . . . . . . . . . . . . . . . . . 63, 82Code list . . . . . . . . . . . . . . . . . . . . 59 - 77Communication . . . . . . . . . . . . . . . 10 - 11Configuration

using NI-BUS Configurator . . . . . . . . 10using TROVIS-VIEW. . . . . . . . . . . . . 10

Connectionselectrical . . . . . . . . . . . . . . . . . . . . . 33pneumatic . . . . . . . . . . . . . . . . . . . . 31

D

Default values . . . . . . . . . . . . . . . . . . . . 53Design, positioner . . . . . . . . . . . . . . . . . . 8Display . . . . . . . . . . . . . . . . . . . . . 38 - 39

turned by 180° . . . . . . . . . . . . . . . . 40

E

Electrical connections. . . . . . . . . . . . . . . 33Enable configuration . . . . . . . . . . . . 38, 54Error messages

confirming. . . . . . . . . . . . . . . . . . . . 57data errors . . . . . . . . . . . . . . . . . . . 75diagnosis errors. . . . . . . . . . . . . . . . 77initialization errors. . . . . . . . . . . . . . 71operational errors . . . . . . . . . . . . . . 73

Explosion protection . . . . . . . . . . . . . . . 12

F

Fail-safe position . . . . . . . . . . . . . . . . . . 56determining. . . . . . . . . . . . . . . . . . . 42

I

InitializationMAN manually selected range . . 43, 47MAX maximum range. . . . . . . . 43 - 44NOM nominal range . . . . . . . . . 43, 45SUB substitute calibration . . . . . . 43, 48

M

Maintenance. . . . . . . . . . . . . . . . . . . . . 58Malfunction. . . . . . . . . . . . . . . . . . . . . . 56Mounting parts . . . . . . . . . . . . . . . 28 - 29

88 EB 8387-5 EN

Index

O

Operating modes . . . . . . . . . . . . . . 38, 55Operating range

checking . . . . . . . . . . . . . . . . . . . . . 41MAN manually selected range . . 43, 47MAX maximum range. . . . . . . . 43 - 44NOM nominal range . . . . . . . . . 43, 45

Operation . . . . . . . . . . . . . . . . . . . 54 - 57Operator controls . . . . . . . . . . . . . . . . . 39

P

Pneumatic connections. . . . . . . . . . . . . . 31Principle of operation, positioner . . . . . . . 8

R

Reset . . . . . . . . . . . . . . . . . . . . . . . . . . 53Reversing amplifier . . . . . . . . . . . . . . . . 26Rotary pushbutton . . . . . . . . . . . . . . . . . 38

S

Serial interface . . . . . . . . . . . . . . . . . . . 38Signal pressure . . . . . . . . . . . . . . . . . . . 32

limiting . . . . . . . . . . . . . . . . . . . . . . 40Start-up . . . . . . . . . . . . . . . . . . . . . 40, 53Status messages . . . . . . . . . . . . . . . . . . 38

Function check. . . . . . . . . . . . . . . . . 57Maintenance alarm . . . . . . . . . . . . . 56Maintenance demanded. . . . . . . . . . 56Maintenance required . . . . . . . . . . . 56

Substitute calibration . . . . . . . . . . . . 43, 48Supply pressure. . . . . . . . . . . . . . . . . . . 32

T

Technical data. . . . . . . . . . . . . . . . . . . . 11Travel tables . . . . . . . . . . . . . . . . . . . . . 14

V

Valve characteristic, selecting. . . . . . . . . 82

Z

Zero calibration . . . . . . . . . . . . . . . . . . 52

EB 8387-5 EN 89

Index

SAMSON AG · MESS- UND REGELTECHNIKWeismüllerstraße 3 · 60314 Frankfurt am Main · GermanyPhone: +49 69 4009-0 · Fax: +49 69 4009-1507Internet: http://www.samson.de EB 8387-5 EN 20

12-0

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