mounting and operating instructions eb 8384-0 en (1300-1609) · series 3730 electropneumatic...

Series 3730Electropneumatic PositionerType 3730-0

Mounting andOperating Instructions

EB 8384-0 EN (1300-1609)Edition November 2010

Fig. 1 · Type 3730-0

2 EB 8384-0 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,information and tips

Definitions of the signal words used in these instructions

Contents Page1 Important safety instructions . . . . . . . . . . . . . . . . . . . . . . 42 Article code . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53 Design and principle of operation. . . . . . . . . . . . . . . . . . . . 63.1 Technical data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 74 Attachment to the control valve – Mounting parts and accessories . . . . 94.1 Direct attachment . . . . . . . . . . . . . . . . . . . . . . . . . . . 124.1.1 Type 3277-5 Actuator . . . . . . . . . . . . . . . . . . . . . . . . . 124.1.2 Type 3277 Actuator . . . . . . . . . . . . . . . . . . . . . . . . . . 144.2 Attachment according to IEC 60534-6 . . . . . . . . . . . . . . . . . 164.3 Reversing amplifier for double-acting actuators . . . . . . . . . . . . . 184.3.1 Reversing amplifier (1079-1118 or 1079-1119) . . . . . . . . . . . . 184.4 Attachment to Type 3510 Micro-flow Valve. . . . . . . . . . . . . . . 204.5 Attaching positioners with stainless steel housings . . . . . . . . . . . . 224.6 Air purging function for single-acting actuators . . . . . . . . . . . . . 225 Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 235.1 Pneumatic connections . . . . . . . . . . . . . . . . . . . . . . . . . 235.1.1 Signal pressure gauges . . . . . . . . . . . . . . . . . . . . . . . . 245.1.2 Supply pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . 245.2 Electrical connections . . . . . . . . . . . . . . . . . . . . . . . . . 256 Operation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 276.1 Operator controls . . . . . . . . . . . . . . . . . . . . . . . . . . . 277 Start-up and settings . . . . . . . . . . . . . . . . . . . . . . . . . 287.1 Default switch positions . . . . . . . . . . . . . . . . . . . . . . . . 287.2 Fail-safe position . . . . . . . . . . . . . . . . . . . . . . . . . . . 287.3 Volume restriction Q. . . . . . . . . . . . . . . . . . . . . . . . . . 287.4 Presetting the travel . . . . . . . . . . . . . . . . . . . . . . . . . . 297.5 Direction of action . . . . . . . . . . . . . . . . . . . . . . . . . . . 297.6 Limiting the signal pressure. . . . . . . . . . . . . . . . . . . . . . . 297.7 Reference variable. . . . . . . . . . . . . . . . . . . . . . . . . . . 297.8 Connecting the positioner . . . . . . . . . . . . . . . . . . . . . . . 307.9 Setting zero . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 307.10 Gain factor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 307.11 Adapting the travel . . . . . . . . . . . . . . . . . . . . . . . . . . 307.12 Activate the tight-closing function. . . . . . . . . . . . . . . . . . . . 308 Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 319 Servicing explosion-protected devices . . . . . . . . . . . . . . . . . 3110 Dimensions in mm. . . . . . . . . . . . . . . . . . . . . . . . . . . 32

3 EB 8384-0 EN

Contents

4 EB 8384-0 EN

1 Important safety instructions

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

� The positioner is to be mounted, started up or operated only by trained and experiencedpersonnel familiar with the product.According to these Mounting and Operating Instructions, trained personnel refers to indi-viduals who are able to judge the work they are assigned to and recognize possible dan-gers due to their specialized training, their knowledge and experience as well as theirknowledge of the applicable standards.

� Explosion-protected versions of this positioner may only be operated by personnel whohave undergone special training or instructions or who are authorized to work on explo-sion-protected devices in hazardous areas. Refer to section 9.

� 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 means ofthe appropriate measures.

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

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

� Proper shipping and appropriate storage are assumed.

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

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 available on request.

Safety instructions

2 Article code

EB 8384-0 EN 5

Article code

Article code Type 3730-0 x 0 0 0 0 0 0 0 0 x 0 0 x 0 x x

Explosion protection

Without 0

ATEX: II 2G EEx ia IIC T6, II 2D IP 65/66 T 80°C 1

FM/CSA:Class I, Zone 0 AEx ia IIC; Class I, II, III, Div.1, Groups A–G;Class I, Div. 2, Groups A–D; Class II, Div. 2, Groups F, G/Ex ia IIC T6; Class I, Zone 0; Class II, Groups E–G;Ex nA II T6; Class I, Zone 2; Class II, Division 2, Groups E–G

3

JIS: Ex ia IIC T6 7

ATEX: II 3G EEx nA II T6, II 3G EEx nL IIC T6, II 3D IP 54/65 T80°C 8

Housing material

Aluminum 0

Stainless steel 1.4581 1

Special applications

Without 0

Compatible with paint 1

Exhaust air with ¼ NPT connection, back of housing sealed 2

Special versions

Without 0 0

GOST: 1 Ex ia IIC T6 X, DIP A21 Ta80°C, IP 65; Ex nA II T6, Ex nL IIC T6, DIP A22 Ta80°C, IP 65 1 4

3 Design and principle ofoperation

The electropneumatic positioner is mountedto pneumatic control valves and is used toassign the valve position (controlled vari-able x) to the control signal (reference vari-able w). The DC control signal received froma control unit is compared to the travel ofthe control valve and issues a signal pres-sure (output variable y).A supply pressure between 1.4 to 6 bar isrequired. The electric input signal is a refer-ence variable between 4 to 20 mA.

The positioner is designed depending on thecorresponding accessories for direct attach-ment to Type 3277 Actuators or for attach-ment to actuators according to IEC 60534-6(NAMUR).

The positioner basically consists of a travelsensor system which is proportional to resis-tance, an analog i/p converter with down-stream air capacity booster, and analogcontroller electronics.

The position of the valve is transmitted aslinear travel motion via pick-up lever andtravel sensor (2) to an analog PD controller(3). The PD controller compares this actualposition to the 4 to 20 mA DC control signalreceived from a control unit. In case of asystem deviation, the operation of the i/pconverter (6) is changed so that the actuator(1) is filled or vented via the downstream aircapacity booster (7). This causes the valveplug to move to the position determined bythe reference variable.

The pneumatic air capacity booster (7) andthe pressure regulator (8) are provided withsupply air. An intermediate flow regulator

(9) with fixed settings is used to purge thepositioner and also guarantees trouble-freeoperation of the pneumatic booster.The output signal pressure supplied by thebooster can be limited over the DIP switchS5.

The volume restriction Q (10) and the switchS6 are used to optimize the positioner byadapting it to the actuator size and chang-ing the gain factor.

Tight-closing function:After activating the tight-closing function (re-fer to section 7.12), the pneumatic actuatoris completely filled with air or vented assoon as the reference variable falls below orexceeds the corresponding deactivatingpoint of 4.5 mA or 19.5 mA.

In the case of three-way valves, the functionallows the plug move to the end positionwith full actuator force.

6 EB 8384-0 EN

Design and principle of operation

3.1 Technical data

EB 8384-0 EN 7


2

3

6

7

8

10

1

9

4

w

x

Q y

x

Fig. 2 · Functional diagram

1 Control valve2 Travel sensor3 PD controller4 DIP switches6 i/p converter7 Air capacity booster8 Pressure regulator9 Flow regulator10 Volume restriction

Positioner (technical data in test certificates additionally apply for explosion-protected devices)

Nominal travel,adjustable

Direct attachment to Type 3277: 5.3 to 30 mm,Attachment acc. to IEC 60534-6: 5.3 to 200 mm

Travel range Adjustable within the rated travel, max. ratio 1:5

Reference variable wSignal range 4 to 20 mA, split-range range 4 to 12 mA/12 to 20 mA, selectable atDIP switches. 2-wire device, reverse polarity protection, static destruction limit100 mA.

Minimum current > 3.6 mA

8 EB 8384-0 EN


Positioner (technical data in test certificates additionally apply for explosion-protected devices)

Load impedance Version without explosion protection: � 6 V (corresponding to 300 � at 20 mA),explosion-protected version: � 6 V

Supply airSupply pressureAir quality acc. toISO 8573-1(edition 2001-02):

1.4 to 7 bar (20 to 105 psi)Max. particle size and density: Class 4Oil content: Class 3 · Pressure dew point: Class 3 or at least 10 K below the lowestambient temperature to be expected

Signal pressure (output) 0 bar up to supply pressure, can be limited to approx. 2.4 bar over DIP switch

Characteristic Linear; Deviation from terminal-based conformity � 1 %

Hysteresis � 1 %

Sensitivity � 0.1 %

Direction of action Selectable over DIP switch

Air consumption, st. state Independent of supply pressure approx. 120 ln/h

Air deliveryActuator pressurizedActuator vented

At �p = 6 bar: 8.5 mn3/h, at �p = 1.4 bar: 3.0 mn

3/h KVmax(20 °C) = 0.09at �p = 6 bar: 14.0 mn

3/h, at �p = 1.4 bar: 4.5 mn3/h KVmax(20 °C) = 0.15

Permissible ambienttemperature

–20 to +80 °C, with metal cable gland –45 to +80 °CThe limits in the test certificate 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

Electromagneticcompatibility

Complying with requirements specified in EN 61000-6-2, EN 61000-6-3,EN 61326-1 and NAMUR Recommendation NE 21

Explosion protection ATEX

FM

CSA

JISGOST

Type 3730-01: II 2 G EEx ia IIC T6, II 2D IP 65/66 T80°CType 3730-08: II 3 G EEx nA II T6, II 3G EEx nL IIC T6, II 3D IP 54/65 T80°CType 3730-03: Class I, Zone 0 AEx ia IIC; Class I, II, III, Div.1, Groups A–G;

Class I, Div. 2, Groups A–D; Class II, Div.2, Groups F, GType 3730-03: Ex ia IIC T6; Class I, Zone 0; Class II, Groups E–G;

Ex nA II T6; Class I, Zone 2; Class II, Division 2, Groups E–GType 3730-07: Ex ia IIC T6Type 3730-x00000000x00x014: 1 Ex ia IIC T6 X, DIP A21 Ta80°C, IP 65;

Ex nA II T6, Ex nL IIC T6, DIP A22 Ta80°C, IP 65

Use in safety-instrumented systemsacc. to IEC 61508

Suitable for use in safety instrumented systems up to SIL 2 (single device) and SIL 3(redundant configuration), safety shutdown at a reference variable 0 mA

Degree of protection IP 66

MaterialsDie-cast aluminum EN AC-Al Si12(Fe) (EN AC-44300) acc. to DIN EN 1706,chromated and plastic coatedExternal parts: Stainless steel 1.4571 and 1.4301

Weight Approx. 1 kg

4 Attachment to the controlvalve – Mounting parts andaccessories

The positioner can be attached either di-rectly to a SAMSON Type 3277 Actuator oraccording to IEC 60534-6 (NAMUR) to con-trol valves with cast yokes or rod-type yoke.

For attachment to the various actuators, cor-responding mounting parts and accessoriesare required. These are listed with their or-der numbers in Tables 1 to 4.

On attaching the positioner, it is importantto observe the assignment between leverand pin position according to the travelslisted in the travel tables.

The travel that can be achieved at the valveis restricted by the pin position used and ad-ditionally by the selected fail-safe action andthe actuator spring compression required.

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

Note:If the standard mounted lever M (pin posi-tion 35) is replaced, the newly mounted le-ver must be moved once all the way as faras it will go in both directions to adapt it tothe internal measuring lever.

EB 8384-0 EN 9

Attachment to the control valve – Mounting parts and accessories

Fig. 3 · Lever M with pin position 35

10 EB 8384-0 EN


Travel table for direct attachment to Type 3277 Actuator

Type3277-5

and3277

Actuators

Actuator sizecm²

Rated travelmm

Adjustment range at positionerMin. Travel Max.

Requiredlever

Assignedpin position

120 7.5 5.0 25.0 M 25

120/240/350 15 7.0 35.0 M 35

355/700 30 10.0 50.0 M 50

Travel table for attachment according to IEC 60534-6 (NAMUR)

SAMSON valves Other valves/actuators Requiredlever

Assignedpin position

Type 3271Actuator

cm² Rated travel mm Min. Travel Max.

60 and 120 withType 3510 Valve 7.5 3.6 18.0 S 17

120 7.5 5.0 25.0 M 25

120/240/350 157.0 35.0 M 35

700 7.5

700 15 and 30 10.0 50.0 M 50

1000/1400/2800 30 14.0 70.0 L 70

1000/1400/2800 60 20.0 100.0 L 100

1400/2800 120 40.0 200.0 XL 200

Table 1 Direct attachment to Type 3277-5 Actuator Order no.

Mounting parts For actuators with 120 cm² effective diaphragm area, see Fig. 4 1400-7452

Accessoriesfor theactuator

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

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

Connecting plate 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

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

Accessoriesfor thepositioner

Connecting plate (6) G ¼: 1400-7461 ¼ NPT: 1400-7462

or pressure gauge bracket (7) G ¼: 1400-7458 ¼ NPT: 1400-7459

Pressure gauge mounting kit (8)up to max. 6 bar (output and supply)

Stainless steel/Brass:1400-6950

Stainless steel/St. steel:1400-6951

EB 8384-0 EN 11


Table 3 Attachment to NAMUR ribs or control valves with rod-type yokes (20 to 35 mm rod diameter)according to IEC 60534-6, see Fig. 6

Travel in mm Lever For actuators Order no.

7.5 S Type 3271-5 Actuator with 60/120 cm² on Type 3510Valve, see Fig. 8 1400-7457

5 to 50 Without (lever M onbasic model)

Actuators from other manufacturers and Type 3271 with120 to 700 cm² 1400-7454

14 to 100 L Actuators from other manufacturers and Type 3271, versions1000 and 1400-60 1400-7455

40 to 200 XL Actuators from other manufacturers and Type 3271, versions1400-120 and 2800 cm² with 120 mm travel 1400-7456

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

Mounting brackets for Emerson and Masoneilan linear actuatorsIn addition, a mounting kit acc. to IEC 60534-6 is required depending on the travel. See row above. 1400-6771

Accessories

Connecting plate G ¼: 1400-7461 ¼ NPT: 1400-7462

or pressure gauge bracket (7) G ¼: 1400-7458 ¼ NPT: 1400-7459

Pressure gauge mounting kitup to max. 6 bar (output/supply)

St. steel/Brass: 1400-6950St. steel/St. steel: 1400-6951

Table 2 Direct attachment to Type 3277 Actuator

Accessories

Mounting parts for actuators with 240, 350, 355 and 700 cm², see Fig. 5 1400-7453

Required piping with screw fittings for "Actuatorstem retracts" or when the top diaphragmchamber is filled with air

cm² Steel Stainl. steel240 1400-6444 1400-6445350 1400-6446 1400-6447355/700 1400-6448 1400-6449

Connection block with seals and screw G ¼: 1400-8819 ¼ NPT: 1400-8820

Pressure gauge mounting kitup to max. 6 bar (output and supply)

Stainless steel/Brass:1400-6950

Stainl. steel/St. steel:1400-6951

Table 4 General accessories

Accessories

Pneumatic reversing amplifier for double-acting actuators Type 3710

Cable gland M20 x 1.5 Nickel-plated brass 1890-4875

Adapter M 20 x 1.5 to ½ NPT, aluminum 0310-2149

Cover plate with list of parametersand operating instructions

German/English (standard)English/SpanishEnglish/French

1990-35281990-57691990-5768

4.1 Direct attachment

4.1.1 Type 3277-5 Actuator

Refer to Table 1 on page 10 for the requiredmounting parts and the accessories withtheir order numbers as well as to the traveltable on page 10!

Actuator with 120 cm²

Depending on the type of positioner attach-ment, the signal pressure is routed either leftor right of the yoke through a bore to theactuator diaphragm. Depending on thefail-safe action of the actuator "Actuatorstem extends" or "Actuator stem retracts"(valve closes or opens if the supply air fails),the switchover plate (9) must first be at-tached to the actuator yoke. Align theswitchover plate with the correspondingsymbol for left or right attachment accordingto the marking (view looking onto theswitchover plate).

1. Mount connecting plate (6) or pressuregauge bracket (7) with pressure gaugesonto the positioner, making sure bothseal rings (6.1) are seated properly.

2. Remove screw plug (4) on the back ofthe positioner and close the signal pres-sure output "Output 38" on the connect-ing plate (6) or on the pressure gaugebracket (7) with the stopper (5) includedin the accessories.

3. Place follower clamp (3) on the actuatorstem, align and screw tight so that themounting screw is located in the grooveof the actuator stem.

4. Mount cover plate (10) with narrow sideof the cut-out opening (Fig. 4, on the left)

pointing towards the signal pressureconnection. Make sure that the bondedgasket (14) points towards the actuatoryoke.

5. 15 mm travel: Keep the follower pin (2)at lever M (1) on the back of thepositioner in the pin position 35 (deliv-ered state).7.5 mm travel: Remove the follower pin(2) from the pin position 35, reposition itin the bore for pin position 25 andscrew tight.

6. Insert formed seal (15) in the groove ofthe positioner casing.

7. Place positioner on the cover plate (10)in such a manner that the follower pin(2) rests on the top of the follower clamp(3). Adjust the lever (1) correspondinglyand open the positioner cover to holdthe positioner shaft in position at the capor the switch. The lever (1) must rest onthe follower clamp with spring force.Mount the positioner on the cover plate(10) using the two fixing screws. Duringthe installation make sure that the sealring (10.1) is inserted in the bore of theintermediate plate.

8. Mount cover (11) on the other side.Make sure that the vent plug pointsdownwards when the control valve is in-stalled to allow any condensed waterthat collects to drain off.

12 EB 8384-0 EN


EB 8384-0 EN 13


9 11

Supply 9 Output 38

56

4

7

6

1010.1

3

2

1

15

6.1

1.11.2

14

8

Note:Always use the connecting plate (6)included in the accessories to connectsupply and output.Never screw threaded parts directlyinto the housing.

Switchover plate (9)

MarkingSignal pressureinput for rightattachment

Signal pressureinput for leftattachment

1 Lever1.1 Nut1.2 Disk spring2 Follower pin3 Follower clamp4 Screw plug5 Stopper6 Connecting plate6.1 Seal rings7 Pressure gauge bracket8 Press. gauge mounting kit9 Switchover plate f. actuator10 Cover plate10.1 Seal ring11 Cover14 Gasket15 Formed seal

Cut-out of coverplate

Symbols

Actuator stemextends

Left attachment Right attachment

Actuator stemretracts

Fig. 4 · Direct attachment – Signal pressure connection for Type 3277-5 Actuator with 120 cm2

Lever M

4.1.2 Type 3277 Actuator


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 actuatorstem, align and screw tight so that themounting screw is located in the grooveof the actuator stem.

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

3. For actuators with 355/700 cm², re-move the follower pin (2) at lever M (1)on the back of the positioner from pinposition 35, reposition it in the bore forpin position 50 and screw tight.For actuators 240 and 350 cm2 with15 mm travel, the follower pin (2) re-mains in pin position 35.

4. Insert formed seal (15) in the groove ofthe positioner casing.

5. Place positioner on the cover plate insuch a manner that the follower pin (2)rests on the top of the follower clamp

(3). Adjust the lever (1) correspondinglyand open the positioner cover to holdthe positioner shaft in position at the capor the switch. The lever (1) must rest onthe follower clamp with spring force.Mount the positioner on the cover plate(10) using the two fixing screws.

6. Make sure that the tip of the gasket (16)projecting from the side of the connec-tion block (12) is positioned above theactuator symbol that corresponds withthe actuator with fail-safe action "Actua-tor stem extends" or "Actuator stem re-tracts." If necessary, remove the threefixing screws and the cover. Then reposi-tion the gasket (16) turned by 180°. Theprevious version of the connection block(Fig. 5, bottom) requires the switch plate(13) to be turned such that the corre-sponding actuator symbol points to themarking.

7. Place the connection block (12) with theassociated seal rings against thepositioner and the actuator yoke. Screwit tight using the fixing screw (12.1). Foractuators with fail-safe action "Actuatorstem retracts", additionally remove thestopper (12.2) and fit on the externalsignal pressure piping.

8. Mount cover (11) on the other side.Make sure that the vent plug pointsdownwards when the control valve is in-stalled to allow any condensed waterthat collects to drain off.

14 EB 8384-0 EN


EB 8384-0 EN 15


2

10 1415

1 2 3 11 11.1

SUPPLY

13

B

C

1.11.2

12

12.1

12

12.2

12.11216

16 16

12.2SUPPLY

Ansicht A

Ansicht B

Ansicht C

SUPPLY

G

G 3/8

A

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

View A

View C

View B

1 Lever1.1 Nut1.2 Disk spring2 Follower pin3 Follower clamp10 Cover plate11 Cover11.1 Vent plug

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

external piping13 Switch plate14 Gasket15 Formed seal16 Gasket

Lever M

Cut-out ofcover plate (10)

Actuator stemretracts extends

Actuator stem retracts

Actuator stem extends

Marking

Connection block (old)with switch plate (13)

4.2 Attachment according toIEC 60534-6

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


1. Screw the two bolts (14) to the bracket(9.1) of the stem connector (9), place thefollower plate (3) on top and use thescrews (14.1) to tighten.

Actuator size 2800 cm² and 1400 cm² with120 mm travel:For a travel of 60 mm or smaller, screw thelonger follower plate (3.1) directly to thestem connector (9). For a travel exceeding60 mm, mount the bracket (16) first andthen the follower plate (3) to the bracket to-gether with the bolts (14) and screws (14.1).

2. Mount NAMUR bracket (10) to the con-trol valve as follows:For attachment to the NAMUR rib, usean M8 screw (11) and toothed lockwasher directly in the yoke bore.For attachment to valves with rod-typeyokes, use two U-bolts (15) around theyoke.Align the NAMUR bracket (10) accord-ing to the embossed scale so that the slotof the follower plate (3) is centrallyaligned with the NAMUR bracket at midvalve travel.

3. Mount connecting plate (6) or pressuregauge bracket (7) with pressure gauges

(8) on the positioner, making sure bothseal rings (6.1) are seated properly.

4. Select required lever size (1) M, L or XLand pin position according to the actua-tor size and valve travels listed at thebottom of the table.Should you require a pin position otherthan position 35 with the standard in-stalled lever M, or require a lever size Lor XL, proceed as follows:

5. Screw the follower pin (2) in the as-signed lever bore (pin position) as listedin the table. Only use the longer followerpin (2) included in the mounting kit.

6. Place lever (1) on the positioner shaftand screw tight using the disk spring(1.2) and nut (1.1).

Note: If you have mounted a new lever (1),you must move it once all the way as far asit will go in both directions.

7. Place positioner on the NAMUR bracketin such a manner that the follower pin(2) rests in the slot of the follower plate(3, 3.1). Adjust the lever (1) correspond-ingly.Screw the positioner to the NAMURbracket using both its fixing screws.

16 EB 8384-0 EN


EB 8384-0 EN 17


10

11

1

1 14.1

3

3.1

16

15

14

11.21.12

9.1

9

6.1 6 7 8

Attachment toNAMUR rib

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

1 Lever1.1 Nut

1.2 Disk spring2 Follower pin3 Follower plate3.1 Follower plate6 Connecting plate6.1 Seal rings7 Pressure gauge bracket8 Pressure gauge

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

Lever XL and L

Note:Always use the connecting plate (6) included in the accessories to connectsupply and output. Never screw threaded parts directly into the housing.

Additional bracket foractuators with 2800 cm2

and travel � 60 mm

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

4.3 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 4.3.1.

4.3.1 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

1. Mount the connecting plate (6) from theaccessories in Table 4 to the positioner.Make sure that both O-rings (6.1) areseated correctly.

2. Thread the special nuts (1.3) from theaccessories of the reversing amplifierinto the boreholes of the connectingplate.

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

4. Place the reversing amplifier onto theconnecting plate (6) and screw tight us-ing both the special screws (1.1).

5. Use a screwdriver (8 mm wide) to screwthe enclosed filters (1.6) into the con-necting boreholes A1 and Z.

NOTICEThe sealing plug (1.5) should not be un-screwed out of the reversing amplifier.The rubber seal (1.4) is not required andcan be removed when the sealing plug isused.

Signal pressure connections

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

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

� Position the DIP switch S1 according tothe symbol AIR TO OPEN as describedin section 7.2.

Pressure gauge attachment

The mounting sequence shown in Fig. 7 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 3.

18 EB 8384-0 EN


EB 8384-0 EN 19


A1

1.5 1.6

1.3

6.266.1

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

From the positioner

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

Control signals tothe actuator

6 Connecting plate6.1 O-rings6.2 Screws

Fig. 7 · Mounting a reversing amplifier (1079-1118 or 1079-1119)

4.4 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 yoke us-ing two screws (11).

3. Mount connecting plate (6) or pressuregauge bracket (7) with pressure gaugesto the positioner, making sure bothO-rings (6.1) are seated properly.

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

5. Take lever S (1) and screw follower pin(2) in the bore for pin position 17.

6. Place lever S on the positioner shaft andscrew tight using the disk spring (1.2)and nut (1.1).Move lever once all the way as far as itwill go in both directions.

7. Place positioner on the bracket (10) insuch a manner that the follower pinslides into the groove of the clamp (3).Adjust the lever (1) correspondingly.Screw the positioner to the bracket (10)using both its screws.

20 EB 8384-0 EN


EB 8384-0 EN 21


3

10

11

11

6

121.2 1.1

78

6.1

Lever S

1 Lever1.1 Nut1.2 Disk spring2 Follower pin3 Clamp6 Connecting plate6.1 Seal rings7 Pressure gauge bracket8 Pressure gauge

mounting kit10 Bracket11 Screw

Note:Always use the connecting plate (6)included in the accessories to connectsupply and output.Never screw threaded parts directlyinto the housing.

Fig. 8 · Attachment to Type 3510 Micro-flow Valve

4.5 Attaching positioners withstainless steel housings

Positioners with stainless steel housings re-quire mounting parts that are completelymade of stainless steel or free of aluminum.

Note:The pneumatic connecting plate and pres-sure gauge bracket are available in stainlesssteel (order numbers listed below). TheType 3710 Pneumatic Reversing Amplifier isalso available in stainless steel.

Connecting plate(stainless steel):

G ¼¼ NPT

1400-74761400-7477

Pressure gaugebracket (st. steel):

Only in¼ NPT 1400-7108

The Tables 1 to 4 (pages 10 and 11) applyfor attaching positioners with stainless steelhousings with the following restrictions:

Direct attachmentAll mounting kits from Tables 1 and 2 canbe used. The connection block is not re-quired. The stainless steel version of thepneumatic connecting plate routes the air in-ternally to the actuator.

Attachment according to IEC 60534-6(NAMUR rib or attachment to rod-typeyokes)All mounting kits from Table 3 can be used.Connecting plate in stainless steel.

4.6 Air purging function forsingle-acting actuators

The exhaust air from the positioner is di-verted to the actuator spring chamber toprovide corrosion protection inside the actu-ator. The following must be observed:

Direct attachment to Type 3277-5 (stem ex-tends FA/stem retracts FE)The air purging function is automaticallyprovided.

Direct attachment to Type 3277, 240 to700 cm²FA: Remove the stopper 12.2 (Fig. 5 on

page 15) at the connection block andmake a pneumatic connection to thespring chamber on the vented side.

NOTICEThe method described does not apply toold connection blocks in powder-paint-coated aluminum. In this case, followthe instructions for attachment describedbelow in “Attachment acc. to IEC60534-6 (NAMUR rib or attachment torod-type yokes) and to rotary actua-tors”.

FE: The air purging function is automati-cally provided.

Attachment acc. to IEC 60534-6 (NAMURrib or attachment to rod-type yokes)The positioner requires an additional portfor the exhaust air that can be connectedover piping. An adapter available as an ac-cessory is used for this purpose:

22 EB 8384-0 EN


Threaded bushing(M20 x 1.5):

G ¼¼ NPT

0310-26190310-2550

NOTICEThe adapter uses one of the M20 x 1.5 con-nections in the housing which means justone cable gland can be installed.

Should other valve accessories be usedwhich vent the actuator (e.g. solenoid valve,volume booster, quick exhaust valve), thisexhaust air must also be included in thepurging function. The connection over theadapter at the positioner must be protectedwith a check valve (e.g. check valve G ¼,order no. 8502-0597) mounted in the pip-ing. Otherwise the pressure in the positionerhousing would rise above the ambient pres-sure and damage the positioner when theexhausting components respond suddenly.

5 Connections

WARNING!Mount the positioner, keeping the followingsequence:1. Remove the protective film from the

pneumatic connections2. Mount the positioner on the control valve3. Connect the supply air4. Connect the electrical power5. Perform the start-up settings

The connection of the electrical auxiliarypower 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

NOTICEFollow the instructions below to avoid dam-aging the positioner:– The threaded connections in the

positioner housing are not designed di-rect air connection!

– The supply air must be dry and free fromoil and dust.The maintenance instructions for up-stream pressure reducing stations mustbe observed.Blow through all air pipes and hosesthoroughly prior to connecting them.

The screw glands must be screwed into theconnecting plate, the pressure gauge mount-ing block or the connection block from theaccessories. The air connections are option-

EB 8384-0 EN 23

Connections

ally designed as a bore with ¼ NPT or G ¼thread.The customary fittings for metal and copperpipes or plastic hoses can be used.

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".

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 4).

5.1.2 Supply pressure

The required supply air pressure depends onthe bench range and the actuator's operat-ing direction (fail-safe action). The benchrange is registered on the nameplate eitheras spring range or signal pressure range.The direction of action is marked FA or FE,or by a symbol.

Actuator stem extends FA (Air to openATO)

Fail-safe position "Valve CLOSED"(for globe and angle valves):

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

Actuator stem retracts FE (Air to close ATC)

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

pstmax = F + d 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

Note:The signal pressure at the output (Out-put 38) of the positioner can be limited toapprox. 2.4 bar by setting the DIP switchS5.

24 EB 8384-0 EN

Connections

5.2 Electrical connections

DANGER!Risk of electric shock and/orthe formation of an explosiveatmosphere!

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

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

NOTICE– Adhere to the terminal assignment!

Switching the assignment of the electricalterminals may cause the explosion pro-tection to become ineffective!

– Do not loosen enameled screws in or onthe housing.

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

Selecting cables and wires:

Observe Clause 12 of EN 60079-14: 2008when installing intrinsically safe circuits. TheSubclause 12.2.2.7 applies when runningmulti-core cables containing more than oneintrinsically safe circuit.

In particular, the radial thickness of the con-ductor insulation for common insulation ma-terials, such as polyethylene, must have aminimum radial thickness of 0.2 mm.

The diameter of an individual wire in afine-stranded conductor must not be smallerthan 0.1 mm. Protect the conductor endsagainst splicing, e.g. by using wire-end fer-rules.

When two separate cables are used for con-nection, an additional cable gland can beinstalled.Seal cable entries left unused with plugs.

Devices used at ambient temperatures be-low –20 °C must be fitted with metal cableglands.

Equipment for use in zone 2/zone 22

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

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

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

EB 8384-0 EN 25

Connections

Cable entries

The cable entry with M20x1.5 cable gland,6 to 12 mm clamping area.There is a second M20x1.5 threaded hole inthe housing that can be used for additionalconnection, when required.

The screw terminals are designed for wirecross-sections of 0.2 to 2.5 mm². Tighten byat least 0.5 Nm.

The wires for the reference variable must beconnected to the terminals 11 and 12 lo-cated in the housing.

In general, it is not necessary to connect thepositioner to a bonding conductor. Shouldthis be required, however, this conductorcan be connected inside the device.

NOTICEThe minimum permissible reference variableshould not fall below 3.8 mA for operatingthe positioner.

Accessories:Plastic cable gland M20x1.5:– Black Order no. 8808-1011– Blue Order no. 8808-1012– Ni-plated brass Order no. 1890-4875– Stainless steel 1.4305

Order no. 8808-0160

Adapter M20 x 1.5 to ½ NPT:– Aluminum, powder-coated

Order no. 0310-2149– Stainless steel Order no. 1400-7114

26 EB 8384-0 EN

Connections

Fig. 9 · Electrical connection

Inputcontrol signal

Actuator symbols for pneumatic connections on the right

DIP switches

Zero adjuster

Volume restriction

Span adjuster Actuator symbols for pneumatic connections on the left

Fig. 10 · Operator controls

6 Operation

6.1 Operator controls

DIP switches S1 to S10

The positioner is mainly operated via the DIPswitches, which allow you to set the most im-portant functions.

ZERO and SPAN adjusters

The ZERO and SPAN potentiometers areused to adjust the starting point (zero) andthe upper range value (span) of the refer-ence variable.

Volume restriction Q

The volume restriction is used to adapt theair supply to the actuator size. Dependingon the air passage at the actuator, two fixedsettings are available.

EB 8384-0 EN 27

Operation

DIP switches and their functions S5 Limit output signal pressure to 2.4 bar

S1 Fail-safe action of the actuator S6 Change gain factor

S2/S3 Rated travel of the control valve S7/S8 Set range of reference variable

S4 Direction of action w/x S9/S10 Activate tight-closing function

7 Start-up and settings

7.1 Default switch positions

After the positioner has been mounted onthe valve, all switches S1 to S10 must be setto OFF.

7.2 Fail-safe position

The switch position of switch S1 depends onthe fail-safe position of the valve:

� AIR TO OPEN · Upon air supply failure,the valve is completely closed by theactuator. As the signal pressure in-creases at the output of the positioner(OUTPUT 38), the valve opens.

� AIR TO CLOSE · Upon air supply failure,the valve is completely opened by the ac-tuator. As the signal pressure increasesat the output of the positioner, the valvecloses.

To determine the switch position, read theassociated switch position S1 = ON or OFFfrom the cover plate at the actuator symbols.

The symbols are read properly when thesymbol shows the actuator on top of thevalve; symbols upside down do not apply.

AIR TO OPEN: Pneumatic connections pointto the right S1 = ON. Pneumatic connectionspoint to the left S1 = OFF.

AIR TO CLOSE: Pneumatic connections pointto the right S1 = OFF. Pneumatic connec-tions point to the left S1 = ON.

AIR TO OPEN always applies for dou-ble-acting actuators. Proceed as describedin section 4.3 to connect the reversingamplifier.

7.3 Volume restriction Q

The volume restriction Q is used to adapt theair delivery to the size of the actuator:

� Actuators with a transit time < 1 s, e.g.linear actuators with an effective areasmaller than 240 cm², require a re-stricted air flow rate (MIN).

� Actuators with a transit time � 1 s do notrequire the air flow rate to be restricted(MAX).

The position of volume restriction Q also de-pends on how the signal pressure is routedat the actuator in SAMSON actuators:

� The “SIDE“ position applies for actuatorswith a loading pressure connection at theside, e.g. Type 3271-5.

� The “BACK“ position applies for actua-tors with a loading pressure connectionat the back, e.g. in Type 3277-5.

The “SIDE”restriction position always appliesfor non-SAMSON actuators.

Overview · Position of the volume restriction*

Signalpressure

Transittime

< 1 s � 1 s

Connection at the side MIN SIDE MAX SIDE

Connection at the back MIN BACK MAX BACK

* Intermediate positions are not permitted.

28 EB 8384-0 EN

Start-up and settings

MAX BACKMIN SIDE

MIN BACKMAX SIDE

Q

Fig. 11 · Volume restriction QMAX BACK/MIN SIDE setting

7.4 Presetting the travel

At switches S2 and S3, select the travel thatcomes closest to the rated valve travel, tak-ing into account the pin position. If neces-sary, perform a final adaptation as de-scribed in section 7.11.

Pinposi-tion

Travel when span adjuster is set to 0

S2 S3OFF OFF

S2 S3ON OFF

S2 S3OFF ON

S2 S3ON ON

17 5.3 7.5 10.6

25 5.3 7.5 10.6 15

35 7.5 10.6 15 21.2

50 10.6 15 21.2 30

70 15 21.2 30 42.4

100 21.2 30 42.4 60

200 42.4 60 84.8 120

7.5 Direction of action

At switch S4, set the direction of action w/x.

� > > The valve travel x increases as thereference variable w increases.

� < > The valve travel decreases when thereference variable increases.

Fail-safe action AIR TO OPEN>>

S4ON

<> OFF

Fail-safe action AIR TO CLOSE>>

S4OFF

<> ON

7.6 Limiting the signal pressure

Set switch S5 to ON to limit the output signalpressure to 2.4 bar if required by the actua-tor.

7.7 Reference variable

Use switches S7 and S8 to determine the in-put signal, i.e. the range of the referencevariable.

Switches S7OFF

S8OFF

S7ON

S8OFF

S7OFF

S8ON

Input mA 4...11.9 12.1...20 4...20

In split-range operation (Fig. 12, below), thecontrol valves work with smaller referencevariable ranges. The signal to control twocontrol valves is divided such that bothvalves move through their full travel range at50 % of the input signal (e.g. first valve setto 4 to 11.9 mA and second valve adjustedto 12.1 to 20 mA).To avoid overlapping, a dead band of± 0.1 mA is to be observed.

EB 8384-0 EN 29


100%

0%

4 20 mA12

4 20 mA

100%

0%

< > < <

< > < <

Fig. 12 · Standard and split-range operation

OPEN

Travel

CLOSED

OPEN

Travel

CLOSED

Reference variableInput signal

Dead band

7.8 Connecting the positioner

Apply the supply air to the pneumatic con-nection (Supply 9). Make sure to use the ap-propriate pressure as specified in section5.1.2.

Apply the electric reference variable (amme-ter at terminals 11 and 12).

WARNING!Upon connection of the electric referencevariable, the signal pressure may cause theplug stem to move, risk of injury!

7.9 Setting zero

Note: Before setting zero, settings usingswitches S1 to S5 as well as switches S7 andS8 must be made first. Refer to sections 7.1to 7.8.

� Set SPAN adjuster to 0.� Adjust the input signal according to the

table below using an ammeter.� Turn ZERO adjuster until the plug stem

just starts to move from its initial position.

Direction ofaction

Referencevariable

[mA]

Input signal forzero [mA]

>> 4 to 20 4

>> 4 to 12 4

>> 12 to 20 12

<> 4 to 20 20

<> 4 to 12 12

<> 12 to 20 20

7.10 Gain factor

� Move the valve in small steps. If the valvetends to hunt, set switch S6 to ON to re-duce the gain of the control loop.

7.11 Adapting the travel

In case the rated travel of the control valvedoes not correspond with the selected travelaccording to the table in section 7.4:

� Adjust the upper range value of the inputsignal (e.g. 4, 12 or 20 mA) using theammeter.

� Turn the SPAN adjuster until the plugstem moves as far as it will go to the endposition.

7.12 Activate the tight-closingfunction

Having adjusted zero and span, thetight-closing function (description on page 6)must be activated at switches S9 and S10 toensure a tight valve shut-off.

AIR TO OPENS9ON

S10OFF

AIR TO CLOSES9

OFFS10ON

Three-way valveS9ON

S10ON

30 EB 8384-0 EN


8 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.

9 Servicing explosion-protecteddevices

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

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

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

EB 8384-0 EN 31

Maintenance

10 Dimensions in mm

32 EB 8384-0 EN

Dimensions in mm

Type 3710 Reversing Amplifier(option)

40

5858

58

34

210

28

1480

164

86

70

15

46

34

76

50

Supply (Z)

Output (A2)

Supply (9)Output (38)

Output (A1)

A1 Z

A2

Direct attachment

Attachment acc. to IEC 60534-5 (NAMUR)

Pressuregauge bracket

Lever mmS = 17M = 50L = 100XL = 200

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

M20 x 1.5

or connecting plate

EB 8384-0 EN 33

Dimensions in mm

80

52 Output Y1

Output Y2

Supply (9)Output Y1

Output Y2

58

Type 3710 Reversing Amplifier(optional)

34 EB 8384-0 EN

EB 8384-0 EN 35

36 EB 8384-0 EN

EB 8384-0 EN 37

38 EB 8384-0 EN

EB 8384-0 EN 39

40 EB 8384-0 EN

EB 8384-0 EN 41

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EB 8384-0 EN 43

SAMSON AG · MESS- UND REGELTECHNIKWeismüllerstraße 3 · 60314 Frankfurt am Main · GermanyPhone: +49 69 4009-0 · Fax: +49 69 4009-1507Internet: http://www.samson.de EB 8384-0 EN S/

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mounting and operating instructions eb 8384-0 en (1300-1609) · series 3730 electropneumatic...

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