series 3730 electropneumatic positioner · aluminum (standard) 0 stainless steel 1.4581 0 1 special...

Series 3730Electropneumatic PositionerType 3730-4

with PROFIBUS-PA communication

Mounting andOperating Instructions

EB 8384-4 EN (1300-1613)Firmware version 1.52Edition July 2012

Fig. 1 · Type 3730-4

2 EB 8384-4 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 serious inju-ry.

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 . . . . . . . . . . . . . . . . . . . . . . 8

2 Article code . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9

3 Design and principle of operation . . . . . . . . . . . . . . . . . . . 103.1 Additional equipment . . . . . . . . . . . . . . . . . . . . . . . . . 113.2 Communication . . . . . . . . . . . . . . . . . . . . . . . . . . . . 123.2.1 Configuration using TROVIS-VIEW software . . . . . . . . . . . . . . 123.3 Technical data. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13

4 Attachment to the control valve – Mounting parts and accessories . . . 164.1 Direct attachment . . . . . . . . . . . . . . . . . . . . . . . . . . . 184.1.1 Type 3277-5 Actuator . . . . . . . . . . . . . . . . . . . . . . . . . 184.1.2 Type 3277 Actuator . . . . . . . . . . . . . . . . . . . . . . . . . . 204.2 Attachment according to IEC 60534-6 (NAMUR) . . . . . . . . . . . . 224.3 Attachment to Type 3510 Micro-flow Valve. . . . . . . . . . . . . . . 244.4 Attachment to rotary actuators . . . . . . . . . . . . . . . . . . . . . 264.4.1 Heavy-duty version . . . . . . . . . . . . . . . . . . . . . . . . . . 284.5 Reversing amplifier for double-acting actuators . . . . . . . . . . . . . 304.5.1 Reversing amplifier (1079-1118 or 1079-1119) . . . . . . . . . . . . 304.6 Attaching an external position sensor. . . . . . . . . . . . . . . . . . 324.6.1 Mounting the position sensor with direct attachment. . . . . . . . . . . 324.6.2 Mounting the position sensor with attachment according to IEC 60534-6 344.6.3 Mounting the position sensor to Type 3510 Micro-flow Valve . . . . . . 354.6.4 Mounting the position sensor to rotary actuators . . . . . . . . . . . . 364.7 Attaching positioners with stainless steel housings . . . . . . . . . . . . 374.8 Air purging function for single-acting actuators . . . . . . . . . . . . . 374.9 Mounting parts and accessories . . . . . . . . . . . . . . . . . . . . 39

5 Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 425.1 Pneumatic connections . . . . . . . . . . . . . . . . . . . . . . . . . 425.1.1 Signal pressure gauges . . . . . . . . . . . . . . . . . . . . . . . . 425.1.2 Supply pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . 425.1.3 Signal pressure (output) . . . . . . . . . . . . . . . . . . . . . . . . 435.2 Electrical connections . . . . . . . . . . . . . . . . . . . . . . . . . 435.2.1 Establishing communication . . . . . . . . . . . . . . . . . . . . . . 46

6 Operator controls and readings . . . . . . . . . . . . . . . . . . . . 48

7 Start-up – Settings. . . . . . . . . . . . . . . . . . . . . . . . . . . 507.1 Defining the valve closed position . . . . . . . . . . . . . . . . . . . 507.2 Setting the volume restriction Q . . . . . . . . . . . . . . . . . . . . 517.3 Adapting the display. . . . . . . . . . . . . . . . . . . . . . . . . . 51

EB 8384-4 EN 3

Contents

7.4 Limiting the signal pressure. . . . . . . . . . . . . . . . . . . . . . . 527.5 Checking the operating range of the positioner . . . . . . . . . . . . . 527.6 Initialization . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 537.6.1 MAX – Initialization based on maximum range . . . . . . . . . . . . . 557.6.2 NOM – Initialization based on nominal range . . . . . . . . . . . . . 567.6.3 MAN – Initialization based on a manually selected range . . . . . . . . 577.6.4 SUb substitute calibration . . . . . . . . . . . . . . . . . . . . . . . 587.7 Zero calibration . . . . . . . . . . . . . . . . . . . . . . . . . . . . 617.8 Reset to default values . . . . . . . . . . . . . . . . . . . . . . . . . 627.9 Start-up via local interface (SSP) . . . . . . . . . . . . . . . . . . . . 627.10 Setting the bus address . . . . . . . . . . . . . . . . . . . . . . . . 63

8 Operation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 648.1 Enabling and selecting parameters . . . . . . . . . . . . . . . . . . 648.2 Operating modes . . . . . . . . . . . . . . . . . . . . . . . . . . . 658.2.1 Automatic and manual modes . . . . . . . . . . . . . . . . . . . . . 658.2.2 SAFE – Fail-safe position. . . . . . . . . . . . . . . . . . . . . . . . 668.3 Malfunction/maintenance alarm . . . . . . . . . . . . . . . . . . . . 668.3.1 Confirming error messages . . . . . . . . . . . . . . . . . . . . . . 67

9 Adjusting the limit switch . . . . . . . . . . . . . . . . . . . . . . . 689.1 Retrofitting an inductive limit switch. . . . . . . . . . . . . . . . . . . 70

10 Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71

11 Servicing explosion-protected devices . . . . . . . . . . . . . . . . . 71

12 Firmware update (serial interface) . . . . . . . . . . . . . . . . . . . 71

13 Maintenance, calibration and work on equipment . . . . . . . . . . . 72

14 Code list . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 73

15 Dimensions in mm. . . . . . . . . . . . . . . . . . . . . . . . . . . 9615.1 Fixing levels according to VDI/VDE 3845 (September 2010) . . . . . . 98

16 Valve characteristic selection . . . . . . . . . . . . . . . . . . . . . 99

Test certificates. . . . . . . . . . . . . . . . . . . . . . . . . . . . 101

4 EB 8384-4 EN

Contents

Revisions of the positioner firmware compared to the previous version – Control R

Control R 1.43 R 1.44

Internal revisions

R 1.45

Internal revisions

R 1.46

Internal revisions

R 1.52

Diagnosis All EXPERTplus diagnostic functions are available without havingto activate them in the positioner (see EB 8389 EN onEXPERTplus Valve Diagnostics).

Codes 48 extended The following subitems have been added to Code 48:h0: Activation/deactivation reference testh1: Reference test completed (YES/No)h3: Automatic reset of diagnosis after this timeh4: Remaining time until diagnosis timeSee section 14.

Revisions to the communication firmware are listed in the Configuration ManualKH 8384-4 EN.

EB 8384-4 EN 5

Revisions of the positioner firmware

Note:The functions of EXPERTplus valve diagnostics are described in the Mounting and OperatingInstructions EB 8389 EN

6 EB 8384-4 EN

Revisions of the positioner firmware

Note concerning these Mounting and Operating Instructions

These instructions EB 8384-4 EN describe the mounting, start up and on-site operation of theType 3730-4 Positioner.You can find additional information on the enclosed CD-ROM (CD 8384-4) or on the Internetat http://www.samson.de.

The CD-ROM (CD 8384-4) contains further information on the Type 3730-4 Positioner:

[Documentation]

– KH 8384-4 EN: Configuration Manual for Type 3730-4 ElectropneumaticPositioner, configuration and operation over PROFIBUS-PA

– T 8384-4 EN: Data Sheet for Type 3730-4 Electropneumatic Positioner– EB 8389 EN: Instructions for Series 373x Positioners; EXPERTplus Valve Diagnostics– T 8389 EN: Data Sheet for EXPERT/EXPERTplus Valve Diagnostics– T 6661 EN: Data Sheet for TROVIS-VIEW software

[Approvals]

– PTB/ATEX – CERTUSP/INMETRO– CSA – NEPSI– FM – GOST– IECEx – CCoE

[Declarations of Conformity]

[Integrations]

– Device Description data (GDD)– DTM/PACTware™– Siemens SIMATIC PDM

[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.

EB 8384-4 EN 7

Note concerning these Mounting and Operating Instructions

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 andexperienced personnel familiar with the product.According to these Mounting and Operating Instructions, trained personnel refers toindividuals 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 applicable 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 11.

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, the supply pressure must be restricted by means of a suitable supplypressure reducing station.

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

Do not operate the positioner with the back of the positioner/vent opening facingupwards.The vent opening must not be sealed when the positioner is installed on site.

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 included on the CD-ROM (CD 8384-4).

8 EB 8384-4 EN

Important safety instructions

Vent opening

2 Article code

Positioner Type 3730-4 x x x 0 x 0 x x 0 x 0 0 x 0 x x

With LCD and autotune, PROFIBUS-PA

Explosion protection

Without 0

ATEX: II 2G Ex ia IIC T6, II 2D Ex tb IIIC T 80°C IP 66 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 , II, Div.1, Groups A–G;Ex nA II T6; Ex nL IIC T6; Class I, II, Div.2, Groups A–G; Class II, Div.1, Groups E–D

3

ATEX: II 3G Ex nA II T6, II 3G Ex ic IIC T6, II 3D Ex ic IIIC T 80 °C IP 66 8

Additional equipment

Inductive limit switch WithoutSJ2-SNSJ2-S1N

012

Solenoid valve WithoutWith, 24 V DC

04

External position sensor WithoutWith 0

01 0 0

Binary input WithoutFloating contact 0

01

Diagnostics

EXPERTplus 4

Housing material

Aluminum (standard) 0

Stainless steel 1.4581 0 1

Special applications

None 0

Positioner compatible with paint 1

Vent connection with ¼-18 NPT thread, back of housing sealed 0 0 0 0 2

Special version

None 0 0 0

NEPSI: Ex ia IIC T6 1 0 0 9

NEPSI: Ex nA II T6; Ex nL IIC T6 8 0 1 0

IECEx: Ex ia IIC T6 1 0 1 2

GOST: 1Ex ia IIC T6 1 0 1 4

EB 8384-4 EN 9

Article code

3 Design and principle ofoperation

The electropneumatic positioner is attachedto pneumatic control valves. It is used to as-sign the valve stem position (controlled vari-able x) to the control signal (reference vari-able w). The input signal received from acontrol system is compared to the travel orrotational angle of the control valve, and apneumatic signal pressure (output variabley) is produced.

The positioner consists of a travel sensor sys-tem proportional to resistance, an analogi/p converter with a downstream boosterand the electronics unit with microcontroller.

When a deviation occurs, the actuator ispressurized or vented. If required, thechanges in the signal pressure can beslowed down by a connectable Q restriction.The signal pressure supplied to the actuatorcan be limited by software or on site to 1.4,2.4 or 3.7 bar.

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 case as well as to op-timize the air capacity booster. The i/pmodule (6) is supplied with a constant up-stream pressure by the pressure regulator(8) to make it independent of the supply airpressure.

10 EB 8384-4 EN

Design and principle of operation

Fig. 2 · Functional diagram

w

x

Q

%S

mm

GG

PD

SerialInterface

16

15 BE2

BE1

112

4

13

20

17 18

19

24V DC

5

3

12

6

7

8

10

1

14

9

xy

1 Control valve2 Travel sensor3 PD controller4 A/D converter5 Microcontroller6 i/p converter7 Air capacity booster8 Pressure regulator9 Flow regulator10 Volume restriction11* Inductive limit switch12* Solenoid valve13 IEC 61158-2

interface module14 Binary input, passive15* Binary input, active16 Display17* Solenoid valve control18* Galvanic isolation19 D/A converter20 Communication interface

* Optional

The positioner communicates and is pow-ered using IEC 61158-2 transmission tech-nology conforming to the PROFIBUS-PAspecification.

As a standard feature, the positioner comeswith a binary input for DC voltage signals tosignalize process information over thePROFIBUS-PA.

The extended EXPERTplus diagnostics are in-tegrated into the positioner. They provide in-formation on the positioner and generatesdiagnostic 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

Solenoid valve

If the operating voltage for the solenoidvalve (12) fails, the supply pressure for thei/p module is vented to the atmosphere. Thepositioner can no longer operate and thecontrol valve moves to the fail-safe positiondetermined by the actuator, independent ofthe reference variable.

NOTICEIn manual mode (MAN), the manual setpoint is also reset to 0 %. A different manualset point must be entered again (Code 1).

Inductive limit switch

The rotary shaft of the positioner carries anadjustable tag which actuates the installedproximity switch.

External position sensor

In this version, only the sensor is mounted tothe control valve. The positioner is locatedseparately from the valve.The connection of x and y signals to thevalve is established by cable and piping forair (only without inductive limit switch).

Binary contact

All positioners are fitted with a binary inputfor DC voltage signals over which processinformation can be issued over thePROFIBUS-PA network.Another optional binary input is an activeinput powered by the positioner to connect afloating contact. Its switching condition can

EB 8384-4 EN 11


also be issued over the PROFIBUS-PA net-work.

3.2 Communication

The positioner is completely controlled overthe digital signal transmission implementedcomplying with PROFIBUS-PA Profile B asper DIN EN 50170 and DIN 19245 Part 4.

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

Usually, the positioner settings are made ona computer which is connected to one ormore positioners linked over a segment cou-pler to the PROFIBUS segment of the com-puter..

The Configuration Manual KH 8384-4 ENcontains a description on how to configureand operate the positioner overPROFIBUS-PA.

3.2.1 Configuration usingTROVIS-VIEW software

The positioner can be configured usingTROVIS-VIEW Configuration and OperatorInterface software.The positioner is equipped with an addi-tional digital SERIAL INTERFACE to connectthe RS-232 or USB port of the computer tothe positioner over an adapter cable.The TROVIS-VIEW software enables the userto easily set parameters in the positionerand view process parameters online.

Note: The TROVIS-VIEW software is a com-mon operator interface for various smartSAMSON devices. The software togetherwith a device-specific module allow the con-figuration and parameterization of the de-vice.The device-specific module for Type 3730-4can be downloaded free of charge from theSAMSON website (Services > Software >TROVIS-VIEW).Additional information on TROVIS-VIEW(e.g. system requirements) can found on theSAMSON website and in the Data SheetT 6661 EN.

12 EB 8384-4 EN


3.3 Technical data

EB 8384-4 EN 13


Type 3730-4 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: 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-poweredField device acc. to FISCO (Fieldbus Intrinsically Safe Concept)

Communication

Fieldbus

Data transmission as in PROFIBUS-PA specification, acc. to IEC 61158 andIEC 61784

Certified DTM acc. to FDT Specification 1.2 for integration of the device into suitableFDT framework applications · Other integrations, e.g. EDD in SIMATIC PDM

Local Over SAMSON SSP interface and serial interface adapter

Software requirements SAMSON TROVIS-VIEW with database module 3730-4

Permissible operatingvoltage

9 to 32 V DC, power supply over bus lineThe limits in the test certificate additionally apply for explosion-protected devices

Max. operating current 15 mA

Add. current in case of fault 0 mA

Supply air

Supply pressure from 1.4 to 7 bar (20 to 105 psi),Air quality acc. to ISO 8573-1 Edition 2001: Max. particle size and density: Class 4Oil content: Class 3; Moisture and water: Class 3; Pressure dew point: At least 10 Kbeneath the lowest ambient temperature to be expected

Signal pressure (output) 0 bar up to supply pressure,limitable to 1.4/2.4/3.7 bar ±0.2 bar via software

Characteristic

Linear/equal percentage/reverse equal percentage · User-defined (over operatingsoftware and communication) · Butterfly valve linear/equal percentage · Rotary plugvalve linear/equal percentage · 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 approx. 110 ln/h

Air output capacityActuator 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

14 EB 8384-4 EN


Type 3730-4 Positioner (technical data in test certificates additionally apply for explosion-protected devices)

Permissible ambienttemperature

–20 to +80 °C for all versions–45 to +80 °C with metal cable gland–25 to +80 °C with inductive limit switch (SJ2-S1N) and metal cable glandThe limits in test certificate additionally apply for explosion-protected devices.

Influences

Temperature 0.15 %/10 K

Supply air None

Vibration 0.25 % up to 2000 Hz and 4 g acc. to IEC 770

Electromagneticcompatibility

Complying with requirements of EN 61000-6-2, EN 61000-6-3, EN 61326-1 andNAMUR Recommendation NE 21

Explosionprotection

ATEX

FM

CSA

NEPSI

IECExGOST

Type 3730-41: II 2G Ex ia IIC T6, II 2D Ex tb IIIC T 80 °C IP 66Type 3730-48: II 3G Ex nA IIC T6, II 3G Ex ic IIC T6, II 3D Ex tc IIIC T 80 °C IP 66Type 3730-43: 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 3730-43: Ex ia IIC T6; Class I, II, Div.1, Groups A–G;

Ex nA II T6; Ex nL IIC T6; Class I, II, Div.2, Groups A–G; Class II, Div.1,Groups E–D

Type 3730-41xx0x0xx0x00x009: Ex ia IIC T6Type 3730-48xx0x0xx0x00x010: Ex nA II T6; Ex nL IIC T6Type 3730-41xx0x0xx0x00x012: Ex ia IIC T6Type 3730-41xx0x0xx1x00x014: 1Ex ia IIC T6

Electrical connection One M20 x 1.5 cable gland, for 6 to 12 mm clamping range · Second additionalthreaded M20 x 1.5 hole · Screw terminals for 0.2 to 2.5 mm² wire cross-section

Degree of protection IP 66/NEMA 4X

Implementation insafety-related systems incompliance withIEC 61508/SIL

Probability of failure on demand of safety functions PFD < 2.8 x 10–7 for a confidencelevel of 95 %.The safe failure fraction (SFF) according to Table A1 in IEC 61508-2 is greater orequal to 0.99.The valves are therefore suitable for implementation in safety-related systems with ahardware fault tolerance of 1 or 2 up to and including SIL 4.

Binary input BE1

Input 0 to 30 V DC reverse polarity protection, static destruction limit 40 V,current consumption 3.5 mA at 24 V, galvanically isolated

Signal Signal “1” at Ue > 5 V · Signal “0” at Ue < 3 V

Materials

Housing Die-cast aluminum EN AC-AlSi12(Fe) (EN AC-44300) acc. to DIN EN 1706;chromated and powder paint coated · Special version: stainless steel 1.4581

External parts Stainless steel 1.4571 and 1.4301

Cable gland Nickel-plated brass, M20x1.5

Weight Approx. 1 kg

EB 8384-4 EN 15


Options for Type 3730-4

Binary input BE2 for floating contact

Switching input R < 100 , contact loadability 100 mA, static destruction limit 20 V / 5.8 mA,galvanically isolated

Solenoid valve Approval acc. to IEC 61508/SIL

Input

24 V DC, reverse polarity protection, static destruction limit 40 V

Current consumption I =U 5.7 V3840

(corresponding to 4.8 mA at 24 V/114 mW)

Signal "0" no pick-up 15 V

Signal "1" safe pick-up >19 V

Service life >5 x 106 switching cycles

KV coefficient 0.15

Implementation insafety-related systems incompliance withIEC 61508/SIL

Same as positioner pneumatics

Inductive limit switch For connection to switching amplifier acc. to EN 60947-5-6

SJ2-SN proximity switch NAMUR NC contact

SJ2-S1N proximity switch NAMUR NO contact

External position sensor

Travel Same as positioner

Cable 10 m with M12x1 connector, designed for continuous flexing, flame retardant acc. toVDE 0472, resistant to oils, lubricants, coolants as well as other corrosive media

Perm. ambient temperature –60 to +105 °C

Vibration immunity Up to 10 g in the range between 10 and 2000 Hz

Degree of protection IP 67

4 Attachment to the controlvalve – Mounting parts andaccessories

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

connections.2. Mount the positioner on the control

valve3. Connect the supply air4. Connect the electrical power5. 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 39 to41) to mount the positioner. Observe thetype of attachment!

– Observe the assignment between leverand pin position (see travel tables onpage 17)!

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 17 show the maxi-mum adjustment range at the positioner. Thetravel that can be implemented at the valveis additionally restricted by the selectedfail-safe position and the required compres-sion of the actuator springs.

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

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

16 EB 8384-4 EN

Attachment to the control valve – Mounting parts and accessories

Fig. 3 · Lever M with pin position 35

EB 8384-4 EN 17


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 acces-sories (see Table 3 on page 40).

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 39 for the requiredmounting parts as well as the accessorieswith their order numbers.Note the travel table on page 17!

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 upon supply airfailure), the switchover plate (9) must first beattached 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 vent plug (4) on the back of thepositioner and close the signal pressureoutput "Output 38" on the connectingplate (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, left) point-

ing towards the signal pressure connec-tion. Make sure that the bonded gasket(14) points towards the actuator yoke.

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 (Fig. 20).The lever (1) must rest on the followerclamp 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 thecover 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.

18 EB 8384-4 EN


EB 8384-4 EN 19


9 11

Supply 9 Output 38

56

4

7

6

1010.1

3

2

1

15

6.1

1.11.2

14

8

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

Switchover plate (9) 1 Lever1.1 Nut1.2 Disk spring2 Follower pin3 Follower clamp4 Vent plug5 Stopper6 Connecting plate6.1 Seal rings7 Pressure gauge bracket8 Press. gauge mounting kit9 Switchover plate

for actuator10 Cover plate10.1 Seal ring11 Cover14 Gasket15 Formed seal

Signal pressureinput for right

attachment

Signal pressureinput for left

attachment Marking

Cut-out of coverplate

Lever M

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

Symbols

Actuator stemextends

Attachment left Attachment right

Actuator stemretracts

4.1.2 Type 3277 Actuator

Refer to Table 2 on page 39 or the requiredmounting parts as well as the accessorieswith their order numbers.Note the travel table on page 17!

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 (Fig. 20). The lever (1) mustrest on the follower clamp with springforce. Mount the positioner on the coverplate (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.


20 EB 8384-4 EN


EB 8384-4 EN 21


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

Actuator stemretracts extends

Actuator stem retracts

Actuator stem extends

Marking

Connection block (old)with switch plate (13)

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

external piping13 Switch plate14 Gasket15 Formed seal16 Gasket

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

Lever M

Cut-out ofcover plate (10)

4.2 Attachment according toIEC 60534-6 (NAMUR)


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(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) is cen-trally aligned with the NAMURbracket at mid valve 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 in the ta-ble on page 19.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.

22 EB 8384-4 EN


EB 8384-4 EN 23


10

11

1

1 14.1

3

3.1

16

15

14

11.21.12

9.1

9

6.1 6 7 8

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

Lever XL and L

Attachment toNAMUR rib

Additional bracket foractuators with 2800 cm2

and travel 60 mm

Attachment to rod-type yokeRod diameter 20 to 35 mm

1 Lever1.1 Nut1.2 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

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

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 yoke us-ing two screws (11).

3. Mount connecting plate (6) or pressuregauge bracket (7) with pressure gaugesto the positioner, making sure both sealrings (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.

24 EB 8384-4 EN


EB 8384-4 EN 25


3

10

11

11

6

121.2 1.1

78

6.1

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

1 Lever1.1 Nut1.2 Disk spring2 Follower pin3 Clamp6 Connecting clamp6.1 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 directly intothe housing.

Lever S

4.4 Attachment to rotaryactuators


The positioner is mounted to the rotary actu-ator using two pairs of double brackets.

Prior to attaching the positioner to theSAMSON Type 3278 Rotary Actuator,mount the associated adapter (5) to the freeend of the rotary actuator shaft.

Note: On attaching the positioner as de-scribed below, it is imperative that the actu-ator's direction of rotation is observed.

1. Place follower clamp (3) on the slottedactuator shaft or the adapter (5).

2. Place coupling wheel (4) with flat sidefacing the actuator on the followerclamp (3). Refer to Fig. 9 to align slot sothat it matches the direction of rotationwhen the valve is in its closed position.

3. Screw coupling wheel and followerclamp tightly onto the actuator shaft us-ing screw (4.1) and disk spring (4.2).

4. Screw the bottom pair of brackets (10.1)with the bends pointing either to the in-side or to the outside (depending on theactuator size) to the actuator case. Posi-tion top pair of brackets (10) and screwtight.

5. Mount connecting plate (6) or pressuregauge bracket (7) with pressure gaugesto the positioner, making sure both

O-rings are seated properly.For double-acting, springless rotary ac-tuators, a reversing amplifier is requiredto attach the positioner to the actuator,see section 4.5.

6. Unscrew the standard follower pin (2)from the positioner's lever M (1). Use themetal follower pin (Ø5) included in themounting kit and screw tight into thebore for pin position 90°.

7. Place positioner on the top pair ofbrackets (10) and screw tight. Con-sidering the actuator's direction of rota-tion, adjust lever (1) so that it engages inthe slot of the coupling wheel (4) with itsfollower pin ( Fig. 9). It must be guaran-teed that the lever (1) is parallel to thelong side of the positioner when the ac-tuator is at half its angle of rotation.

8. Stick scale plate (4.3) on the couplingwheel so that the arrow tip indicates theclosed position, and it can be easilyread when the valve is installed.

26 EB 8384-4 EN


1.2

1.11

2

4.1

4.2

53

Fig. 8 · Mounting the coupling wheel with Type 3278

Mounting flange

EB 8384-4 EN 27


10

10.1

6(7, 8)

1.124.3

5

6.1

4

1.21

130 mm

80 mm

Fig. 9 · Attachment to rotary actuators

Control valve opens clockwise

Slot

Note:Always use the connectingplate (6) included in theaccessories to connectsupply and output.Never screw threadedparts directly into thehousing.

Control valve opens counterclockwise

Slot

Legends Figs. 8 + 91 Lever1.1 Nut1.2 Disk spring2 Follower pin3 Follower clamp (Fig. 8)4 Coupling wheel4.1 Screw4.2 Disk spring4.3 Scale plate4.3 Scale plate5 Actuator shaft

Adapter for Type 32786.1 Seal rings7 Pressure gauge bracket8 Pressure gauge

mounting kit10 Top pair of brackets10.1 Bottom pair of brackets

4.4.1 Heavy-duty version

Refer to Table 4 on page 40 for the requiredmounting parts as well as the accessorieswith their order numbers.

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 the adapter(5) onto the free end of the shaft orplace adapter (5.1) onto the shaft of theVETEC R Actuator.Place adapter (3) onto Type 3278, VETECS160 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 valve isOPEN. Adhesive labels with explanatorysymbols are enclosed and can be stuckon 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), makingsure both seal rings (6.1) are seatedproperly.For double-acting, springless rotary ac-tuators, a reversing amplifier is requiredto attach the positioner to the actuator.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 signal pres-sure output of the positioner (or the out-put of the pressure gauge bracket orconnecting plate).

8. Place positioner on housing (10) andscrew it tight. Considering the actuator'sdirection of rotation, align lever (1) sothat it engages in the correct slot of thecoupling wheel with its follower pin (Fig.10).

28 EB 8384-4 EN


1

10

4

Fig. 10 · Direction of rotation

Counterclockwise

Clockwise

EB 8384-4 EN 29


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. 11 · Attachment to rotary actuators (heavy-duty version)

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

SAMSON Type 3278VETEC S160, VETEC R

Attachment acc. to VDE/VDI 3845 (2010)level 1, size AA1 to AA4, section 15.1

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

1. Mount the connecting plate (6) from theaccessories in Table 5 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 hollowed special screws (1.1) intothe connecting 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.

NOTICEDo not unscrew the sealing plug (1.5) out ofthe 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

Set slide switch on positioner toAIR TO OPEN.

6. After the initialization is completed, setCode 16 (Pressure limit) to No.

Pressure gauge attachment

The mounting sequence shown in Fig. 12 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.

30 EB 8384-4 EN


EB 8384-4 EN 31


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

Fig. 12 · 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

6 Connecting plate6.1 O-rings6.2 Screws

4.6 Attaching an externalposition sensor

Refer to Table 6 on page 41 for the mount-ing parts and accessories required.

In the positioner version with an external po-sition sensor, the sensor placed in a sepa-rate housing is attached over a plate orbracket to the control valve. The travelpick-off corresponds to that of a standarddevice.The positioner unit can be mounted as re-quired to a wall or a pipe.

For the pneumatic connection either a con-necting plate (6) or a pressure gaugebracket (7) must be fixed to the housing, de-pending on the accessory chosen. Makesure the seal rings (6.1) are correctly in-serted (see Fig. 6, bottom right).

For the electrical connection a 10 meterconnecting lead with M12x1 connectors isincluded in the scope of delivery.

Note:– In addition, the instructions in sections

5.1 and 5.2 apply for the pneumatic andelectrical connection.

Operation and setting are described insections 7 and 8.

– Since 2009, the back of the position sen-sor (20) is fitted with two pins acting asmechanical stops for the lever (1). If thisposition sensor is mounted using oldmounting parts, two correspondingØ8 mm holes must be drilled into themounting plate/bracket (21). A templateis available for this purpose. Refer to Ta-ble 6 on page 41.

4.6.1 Mounting the positionsensor with directattachment

Type 3277-5 Actuator with 120 cm²

The signal pressure from the positioner isrouted over the signal pressure connectionof the connecting plate (9, Fig. 14 left) to theactuator diaphragm chamber. To proceed,first screw the connecting plate (9) includedin the accessories onto the actuator yoke.

Turn the connecting plate (9) so that thecorrect symbol for the fail-safe position"Actuator stem extends" or "Actuatorstem retracts" is aligned with the marking(Fig. 14, below).

Make sure that the gasket for the con-necting plate (9) is correctly inserted.

The connecting plate has boreholes withNPT and G threads.Seal the threaded connection that is notused with the rubber seal and squareplug.

Type 3277 Actuator with 240 to 700 cm²:

The signal pressure is routed to the connec-tion at the side of the actuator yoke for the

32 EB 8384-4 EN


Fig. 13 · Positioner unit with sensor mounted on amicro-flow valve

version "Actuator stem extends".For the fail-safe position "Actuator stem re-tracts" the connection on the top diaphragmcase is used. The connection at the side ofthe yoke must be fitted with a venting plug(accessories).

Mounting the position sensor

1. Place the lever (1) on the sensor inmid-position and hold it in place.Unthread the nut (1.1) and remove thelever together with the disk spring (1.2)from the sensor shaft.

2. Screw the position sensor (20) onto themounting plate (21).

3. Depending on the actuator size andrated valve travel, determine the re-quired lever and position of the follower

pin (2) from the travel table on page 17.The positioner is delivered with lever Min pin position 35 on the sensor. If nec-essary, remove the follower pin (2) fromits pin position and move it to the bore-hole for the recommended pin positionand screw tight.

4. Place the lever (1) and disk spring (1.2)on the sensor shaft.Place the lever (1) in mid-position andhold it in place. Screw on the nut (1.1).

5. Place the follower clamp (3) on the actu-ator stem, align and fasten it, makingsure that the fastening screw rests in thegroove of the actuator stem.

6. Place the mounting plate (21) togetherwith the sensor onto the actuator yoke sothat the follower pin (2) rests on the top

EB 8384-4 EN 33


2021

9

11

1.11.2

3

2

1

Fig. 14 · Mounting for Type 3277-5 Actuator (left) and Type 3277 Actuator (right)

Signal pressure

Vent plug

Actuator stemextends retractsSymbol

Marking

Signal pressure

1 Lever1.1 Nut1.2 Disk spring2 Follower pin3 Follower clamp9 Connecting plate11 Cover20 Position sensor21 Mounting plate

of the follower clamp (3). It must rest onit with spring force.Screw tight the mounting plate (21) ontothe actuator yoke using both fixingscrews.


4.6.2 Mounting the positionsensor with attachmentaccording to IEC 60534-6

For the required mounting parts and the ac-cessories, refer to Table 6 on page 41.

1. Place the lever (1) on the sensor inmid-position and hold it in place.

Unthread the nut (1.1) and remove thelever together with the disk spring (1.2)from the sensor shaft.

2. Screw the position sensor (20) onto thebracket (21).

The standard attached lever M with the fol-lower pin (2) at position 35 is designed for120, 240 and 350 cm² actuators with15 mm rated travel.

For other actuator sizes or travels, select thelever and pin position from the travel tableon page 19. Lever L and XL are included inthe mounting kit.

3. Place the lever (1) and disk spring (1.2)on the sensor shaft. Place the lever (1) inmid-position and hold it in place. Screwon the nut (1.1).

4. Screw both bolts (14) to the bracket(9.1) of the stem connector (9). Attach

34 EB 8384-4 EN


20 21

2

1.1, 1.2 14.1 3 14 99.1

Fig. 15 · Mounting according to IEC 60534-6 (NAMUR)

1 Lever1.1 Nut1.2 Disk spring2 Follower pin3 Follower plate9 Stem connector9.1 Bracket14 Bolt14.1 Screws20 Position sensor21 Bracket

the follower plate (3) and fix with thescrews (14.1).

5. Place the bracket with the sensor at theNAMUR rib in such a manner that thefollower pin (2) rests in the slot of the fol-lower plate (3), then screw the bracketusing its fixing screws onto the valve.

4.6.3 Mounting the positionsensor to Type 3510Micro-flow Valve


1. Place the lever (1) in mid-position andhold it in place. Unscrew the nut (1.1)and remove the standard attached leverM (1) together with the disk spring (1.2)from the sensor shaft.

2. Screw the position sensor (20) onto thebracket (21).

3. Select the lever S (1) from the accesso-ries and screw the follower pin (2) intothe hole for pin position 17.Place the lever (1) and disk spring (1.2)on the sensor shaft.Place the lever (1) in mid-position andhold it in place. Screw on the nut (1.1).

4. Place the follower clamp (3) on the stemconnector, align it at a right angle andscrew tight.

5. Position the bracket (21) with the positi-on sensor on the valve yoke and screwtight, making sure the follower pin (2)slides into the groove of the followerclamp (3).

EB 8384-4 EN 35


20 211.11.2

1

3

2

Fig. 16 · Mounting on a micro-flow valve

1 Lever1.1 Nut1.2 Disk spring2 Follower pin3 Follower clamp20 Position sensor21 Bracket

4.6.4 Mounting the positionsensor to rotary actuators


1. Place the lever (1) in mid-position andhold it in place. Unscrew the nut (1.1)and remove the standard attached leverM (1) together with the disk spring (1.2)from the sensor shaft.

2. Screw the position sensor (20) onto themounting plate (21).

3. Replace the follower pin (2) normally at-tached to the lever (1) with the metal fol-lower pin (Ø 5) from the accessoriesand screw it into the hole for pin position90°.

4. Place the lever (1) and disk spring (1.2)on the sensor shaft.Place the lever (1) in mid-position andhold it in place. Screw on the nut (1.1).

Follow the instructions describing attachmentto the standard positioner in section 4.4Instead of the positioner, attach the positionsensor (20) with its mounting plate (21).

36 EB 8384-4 EN


2021

2 1 1.1, 1.2

Fig. 17 · Positioner unit with sensor mounted on rotary actuators

1 Lever1.1 Nut1.2 Disk spring2 Follower pin20 Position sensor21 Mounting plate

4.7 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 apressure gauge bracket made of stainlesssteel are available (order numbers listed be-low). The Type 3710 Pneumatic ReversingAmplifier is also 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 5 (pages 39 and 41) 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.

Attachment to rotary actuatorsAll mounting kits from Table 4 can be usedexcept for the heavy-duty version. Con-necting plate in stainless steel.

4.8 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 cm2

FA: Remove the stopper 12.2 (Fig. 5 onpage 21) 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,follow the instructions for attachmentdescribed below in “Attachment acc. toIEC 60534-6 (NAMUR rib orattachment to rod-type yokes) and torotary actuators”.

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

Attachment acc. to IEC 60534-6 (NAMURrib or attachment to rod-type yokes) and torotary actuatorsThe positioner requires an additional portfor the exhaust air that can be connected

EB 8384-4 EN 37


over piping. An adapter available as an ac-cessory is used for this purpose:

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.

38 EB 8384-4 EN


4.9 Mounting parts and accessories

EB 8384-4 EN 39


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

Mounting parts Mounting parts for actuators 120 cm² or smaller 1400-7452

Accessories fortheactuator

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 forthepositioner

Connecting plate (6)G ¼ 1400-7461

¼ NPT 1400-7462

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. steel/brass 1400-6950

St. steel/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 Actuator (Fig. 5) Order no.

Mounting parts Attachment to actuators with 240, 350, 355, 700 cm2 1400-7453

Accessories

Required piping with screw fittings– 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 cm2/700 cm2

Steel 1400-6448


Connection block with seals and screwG ¼ 1400-8819

¼ NPT 1400-8820

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

St. steel/brass 1400-6950

St. steel/st. steel 1400-6951

40 EB 8384-4 EN


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 with 60/120 cm² on Type 3510 Valve (Fig. 7) 1400-74575 to 50 M 1) Actuators from other manufacturers and Type 3271 with 120 to 700 cm² 1400-745414 to 100 L Actuators from other manufacturers and Type 3271, versions 1000 and

1400-60 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 with 30/60 mm travel 1400-7466Mounting bracket for Emerson and Masoneilan linear actuatorsIn addition, a mounting kit acc. to IEC 60534-6 is required depending on thetravel. See row above.

1400-6771

Valtek Type 25/50 1400-9554

Accessories


¼ NPT 1400-7462


¼ NPT 1400-7459

Pressure gauge mounting kit up to max. 6 bar (output/supply)St. steel/brass 1400-6950St. steel/st. st. 1400-6951

1) Lever M is mounted on basic device (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), refer to section 15.1 for details

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

1400-74481400-92441400-9542

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

Attachment for SAMSON Type 3278 with 160/320 cm², CrNiMo steel bracket 1400-7614

Attachment for SAMSON Type 3278 with 160 cm² and for VETEC Type S160, Type Rand Type M, 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


¼ NPT 1400-7462


¼ 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

41 EB 8384-4 EN


Table 5 · General accessories

Accessories

Pneumatic reversing amplifier for double-acting actuators Type 3710

Cable gland M20 x 1.5, nickel-plated brass 1890-4875

EMC cable gland M20 x 1.5 8808-0143

Adapter M20 x 1.5 to ½ NPT, aluminum 0310-2149

Retrofit kit for inductive limit switch 1x SJ 2-SN 1400-7460

Llist of parameters and operating instructions inside cover German/English (std) 1990-5328

TROVIS-VIEW with device module, see section

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

Isolated USB interface adapter (SAMSON SSP interface - USB port on computer)including TROVIS-VIEW CD-ROM 1400-9740

Table 6 · Attachment of external position sensor Order no.

Template for mounting position sensor on older mounting parts. See note on page 32. 1060-0784

Direct attachment

Mounting parts for actuators with 120 cm² see Fig. 14 left 1400-7472

Connecting plate (9, old) for ActuatorType 3277-5xxxxxx.00

G 18 1400-6820

18 NPT 1400-6821

Connecting plate (new) for Actuator Type 3277-5xxxxxx.01 (new) 1) 1400-6823Mounting parts for actuators with 240, 350, 355 and 700 cm², see Fig. 14 right 1400-7471

NAMUR attachmt. Mounting parts for attachment to NAMUR rib w. lever L and XL, see Fig. 15 1400-7468Micro-flow valve Mounting parts for Type 3510 Micro-flow Valve, see Fig. 16 1400-7469

Attachment torotary actuators

VDI/VDE 3845 (September 2010), refer to section 15.1 for detailsActuator surface corresponds to level 1

Size AA1 to AA4 with follower clamp and coupling wheel, versionwith CrNiMo steel bracket, see Fig. 17Size AA1 to AA4, heavy-duty versionSize AA5, heavy-duty version (e.g. Air Torque 10 000)

1400-74731400-93841400-9992

Bracket surface corresponds to level 2, heavy-duty version 1400-9974SAMSON Type 3278 with 160 cm² (also for VETEC Type S160 and Type R),heavy-duty version 1400-9385

SAMSON Type 3278 with 320 cm² and for VETEC Type S320, heavy-dutyversion

1400-5891and

1400-9974

Accessories forpositioner

Connecting plate (6)G ¼ 1400-7461¼ NPT 1400-7462

Pressure gauge bracket (7)G ¼ 1400-7458¼ NPT 1400-7459

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

St. steel/brass 1400-6950St. steel/st. steel 1400-6951

Bracket to mount the positioner on a wallNote: The other fastening parts are to be provided at the site of installation aswall foundations vary from site to site.

0309-0111

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

5 Connections


connections.2. 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 screw glands must be screwed intothe connecting plate, the pressure gaugemounting block or the connection blockfrom the accessories.The air connections are optionally de-signed as a bore with ¼ NPT or G ¼thread.The customary fittings for metal and cop-per pipes or plastic hoses can be used.

– The supply air must be dry and free fromoil and dust.The maintenance instructions for upstre-am pressure reducing stations must be

observed.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.

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 air pressure depends onthe bench range and the actuator's operat-ing 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. Thedirection of action is marked FA or FE, or bya 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.

42 EB 8384-4 EN

Connections

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]

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.

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.

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

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

– Do not loosen enameled screws in or onthe housing.

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

EB 8384-4 EN 43

Connections

Selecting cables and wires:

To install and select cables and wires as wellas to run several intrinsically safe circuits inone multi-core cable, observe the installationregulations valid in the country of use. Thediameter 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 EEx nA II (non-sparking equipment)Ex nL (energy-limited equipment), 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) may be switchedunder normal operating conditions.

The maximum permissible values specifiedin the national explosion protection certifi-cates also apply when interconnecting theequipment with energy-limited circuits intype of protection Ex nL IIC.

Cable entries

The cable entry with M20 x 1.5 cable gland,6 to 12 mm clamping range.There is a second M20 x 1.5 threaded borein the housing that can be used for addi-tional connection, when required.The screw terminals are designed for wirecross-sections of 0.2 to 2.5 mm². Tighten byat least 0.5 Nm.

Note: The power supply for the positionercan be supplied either over the connectionto the fieldbus segment or over a DC voltagesource (9 to 32 V) connected to the bus ter-minals in the positioner.You are required to observe the relevantregulations for use in hazardous areas.

Bus line

Route the two-wire bus line to the screw ter-minals marked "IEC 1158-2", whereby nopolarity has to be observed.

Refer to the PROFIBUS-PA User + InstallationGuide (PNO document 2.092) for more in-formation.

NOTICETo connect the limit switch, binary inputs,and forced venting, an additional cablegland that needs to be fitted in place of theexisting blanking plug is necessary.Open cable glands are not permissible asthe degree of protection IP 66 only applieswhen the positioner housing is sealed.

44 EB 8384-4 EN

Connections

Limit switch

For operation of the limit switches, switchingamplifiers have to be connected in the out-put circuit. Their function is to control thelimit values of the control circuit according toEN 60947-5-6, thus ensuring operationalreliability of the positioner. If the positioneris installed in hazardous areas, the relevantregulations must be observed.

Binary input BE1

An active contact can be operated at binaryinput 1. The positioner can report the switch-ing state over the bus protocol.

Binary input BE2

A passive, floating contact can be operatedat binary input 2.The positioner can report the switching stateover the bus protocol.

Solenoid valve (forced venting function)

For positioners fitted with the optional sole-noid valve for the forced venting function, avoltage of 24 V DC must be connected tothe relevant terminals +81 and –82.

NOTICEIf there is no voltage connected for the sole-noid valve at terminals +81 and –82 orwhen the voltage signal is interrupted, thepositioner vents the actuator and does notrespond to the reference variable.Observe the switching thresholds specifiedin the technical data.

EB 8384-4 EN 45

Connections

uOption

+81 -82 IEC 1158-2 +87 -88 +85 -86 +41 -42 A B

24 V DC BE1 BE2

G

Fig. 18 · Electrical connections

Binary contactsBus line

Inductive limitswitch (optional)

Switch. amplifierEN 60947-5-6

In preparation

Solenoid valveForced venting

(optional)

(optional)

5.2.1 Establishing communication

The communication structure between thecontroller, logic solvers (PLC) or automationsystem, or between a PC or work stationand the positioner(s) is implemented by asegment coupler (see Fig. 19) conforming toPROFIBUS directives.Explosion-protected versions ofPROFIBUS-PA segment couplers must beused in hazardous areas.A maximum of 32 positioners may be oper-ated in parallel over a segment coupler inone PROFIBUS-PA segment. In hazardousareas, the number of positioners that can beconnected is reduced.

Each positioner connected in the segmentmust be assigned a unique bus address be-tween 0 and 125 (refer to section 7.10).

46 EB 8384-4 EN

Connections

EB 8384-4 EN 47

Connections

PROFIBUS-DP(E) RS 485

3730-40 3730-40 3730-40 3730-40

PROFIBUS-PA IEC 61158-2

PROFIBUS-DP RS 485

3730-41 3730-41 3730-41 3730-41

PROFIBUS-PA IEC 61158-2

PROFIBUS-DP(E) RS 485

PROFIBUS-DP RS 485

Fig. 19 · Connection according to PROFIBUS, for safe areas (top) and hazardous areas (bottom)

Display and operating elementsController/PLC/Control system

Bus termination

Segment coupler

Bustermination

Display and operating elements

Bus termination

Expl.-protected segment coupler

Controller/PLC/Control system

Bustermination

Hazardousarea

6 Operator controls andreadings

Rotary pushbuttonThe rotary pushbutton is located underneaththe front protective cover.The positioner is operated on site using therotary pushbutton:

Turn to select codes and values.Press to confirm setting.

Slide switch AIR TO OPEN or AIR TO CLOSE AIR TO OPEN applies when the increas-

ing signal pressure opens the valve AIR TO CLOSE applies when the increas-

ing signal pressure closes the valve

The signal pressure is the air pressure at theoutput of the positioner which is transferredto the actuator.For positioners with an attached reversingamplifier for double-acting rotary actuators(section 4.5): switch position AIR TO OPEN.

Volume restriction Q

The volume restriction is used to adapt theair delivery to the actuator size. Two fixedsettings are possible depending on how theair is routed at the actuator:

For actuators smaller than 240 cm² witha loading pressure connection at the side(Type 3271-5), set restriction to MINSIDE.

For a connection at the back (Type3277-5), set restriction to MIN BACK.

For actuators 240 cm² and larger, set toMAX SIDE for a side connection and toMAX BACK for a connection at the back.

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

Operating modes:Manual mode (section 8.2.1) blinking:not initializedAutomatic mode (section 8.2.1) blinking:emergency mode (see page 86)

SAFE (section 8.2.2) blinking: valvemoved to fail-safe position by SET_FAIL_SAFE_POS parameter or due toinvalid set point (see KH 8384-4 EN)and : AO Transducer Block is

in MAN mode Bar elements:

In manual and automatic modes,the bars indicate the system deviationthat depends on the sign (+/–) and thevalue. One bar element appears per 1 %system deviation.If the device has not yet been initialized,the icon blinks on the display and thelever position in degrees in relation tothe 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 alarms: Maintenance alarm: Maintenance required/demanded

These icons indicate that an error has oc-curred. A classified status can be as-signed to each error. Classifications in-clude “No message”, “Maintenance re-quired”, “Maintenance demanded” and“Maintenance alarm“ (see section 8.3).

48 EB 8384-4 EN

Operator controls and readings

S

Configuration enabledThis indicates that the codes marked withan asterisk (*) in the code list (section 14)

are enabled for configuration (see sec-tion 8.1).

EB 8384-4 EN 49

Operator controls and readings

Fig. 20 · Display and operator controls

Readings in display

AUtO Automatic modeCL ClockwiseCCL CounterclockwiseErr ErrorESC EscapeLOW w too smallMAN Manual mode

MAX Maximum rangeNo Not available/

not activeNOM Nominal travelRES ResetRUN StartSAFE Fail-safe position

Sub Substitute calibrationTunE Initialization in progressYES Available/activeZP Zero calibrationtEStinG Test function active

Increasing/increasing Increasing/decreasing

%mm

AIR TOO

PEN

CLO

SE

INIT

CA

UTIO

NVA

LVEA

CTU

ATES

MIN

SIDE

MA

X BAC

K

MIN

BAC

KM

AX SID

E Q

%S

mm

%S

mm

SERIAL

INTERFA

CE

%mm

Maintenance alarm/fault Manual mode Closed-loop operation Code

DesignationPositionParameter

Binary contact 1

Bar graph forsystem deviationor lever position

Units

Binary contact 2

Configurationenabled

Maintenance requiredMaintenance demanded

Fail-safe positionactive

Initialization key Cap or rotary switch Metal tag of proximity switch

SSP interface

Switch forAIR TO OPEN/AIR TO CLOSE

Volume restriction

Rotary pushbutton

7 Start-up – Settings


connections.2. Mount the positioner on the control valve3. Connect the supply air4. Connect the electrical power5. Perform the start-up settings

Reading on display after connecting theelectrical auxiliary power:

tEStinG runs across the display and thenthe fault alarm icon appears and blinkson the display when the positioner hasnot yet been initialized. The reading in-dicates the lever position in degrees inrelation to the longitudinal axis.

Reading when thepositioner has not yet beeninitialized

If 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 7.6).

Note: The positioner performs a test in thestart-up phase while following its automa-tion task at the same time. During thestart-up phase, operation on site is unre-stricted, yet write access is limited.

7.1 Defining the valve closedposition

To adapt the positioner to the operating di-rection of the actuator, set slide switch to AIRTO OPEN or AIR TO CLOSE .

AIR TO OPEN = Signal pressure opensthe valve, for fail-safe position: actuatorstem extends/fail close

AIR TO CLOSE = Signal pressure closesthe valve, for fail-safe position: actuatorstem retracts/fail open.

NOTICEThe AIR TO OPEN (AtO) setting always ap-plies to double-acting actuators.

For checking purposes:After successfully completing initialization,the positioner display should read 0 % whenthe valve is closed and 100 % when thevalve is open. If this is not the case, changethe slide switch position and re-initialize thepositioner.

50 EB 8384-4 EN

Start-up – Settings

Note: The switch position is prompted priorto an initialization. After an initialization hasbeen completed, changing the switch posi-tion does not have any effect on the opera-tion of the positioner.The positioner only needs to be initializedagain after the fail-safe action of the actua-tor has been changed.

7.2 Setting the volume restrictionQ

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 ap-plies for actuators from other manufac-turers.

Overview · Position of volume restriction Q*

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.

NOTICEThe positioner needs to be initialized againafter the position of the restriction has beenchanged.

7.3 Adapting the display

The data representation on the positionerdisplay can be turned by 180° to adapt it tohow the positioner is mounted.

Reading direction for rightattachment of pneumaticconnections

Reading direction for leftattachment of pneumaticconnections

If the displayed data appear upside down,proceed as follows:

EB 8384-4 EN 51


MAX BACKMIN SIDE

MIN BACKMAX SIDE

Q

Fig. 21 · Volume restriction QMAX BACK/MIN SIDE setting

Turn Code 2

Press Code 2 blinks.

Turn Required direction

Press to confirm reading direction.

7.4 Limiting the signal pressure

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

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: No

Turn Code 3, display: No


Turn YES

Press display

Limiting the signal pressure:

Pressure limitDefault: No

Turn Code 16


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

Press to confirm the pressure limit set-ting.

7.5 Checking the operatingrange of the positioner

To check the mechanical attachment and theproper functioning, the valve should bemoved through the operating range of thepositioner in the manual operating modewith the manual reference variable.

Selecting manual operating mode:

Operating modeDefault MAN

Turn Code 0


Turn MAN

Press . The positioner changes to themanual operating mode.

Checking the operating range:

Manual reference variablew (current angle of rotationis indicated)

Turn Code 1

Press Code 1 and blink.

52 EB 8384-4 EN


Turn until the pressure in the positionerbuilds up, and the control valve moves to itsfinal positions so that the travel/angle of ro-tation can be checked.The angle of rotation on the back of thepositioner is indicated. A horizontal lever(mid position) is equal to 0°.

To ensure the positioner is working prop-erly, the outer bar elements may not blinkwhile the valve is moving through the oper-ating range.Exit Code 1 by pressing the rotarypushbutton ( ).

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.

7.6 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.

NOTICEAfter the positioner has been mounted on toanother actuator or its mounting locationhas been changed and prior tore-initializing the positioner, the positionerneeds to be reset to its basic setting (defaultvalues). Refer to section 7.8.

During initialization the positioner adapts it-self optimally to the friction conditions andthe signal pressure demand of the controlvalve. The type and extent of self-adaptationdepends on the set initialization mode:

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 7.6.1)

EB 8384-4 EN 53


NOM nominal rangeInitialization mode for all globe valves(see section 7.6.2)

MAN manually selected rangeInitialization mode for globe valves withan unknown nominal range (see section7.6.3)

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 7.6.4)

Note: For normal operation, simply start ini-tialization by pressing the INIT key aftermounting the positioner on the valve anddefining the valve closed position and set-ting the volume restriction. The positioneronly needs to work with its default settings. Ifnecessary, perform a reset (see section 7.8).

Alternating displaysInitialization runningSymbol depending on ini-tialization mode selected

Bar graph displayindicating the progress ofthe initialization

Initialization successful,positioner in automaticoperating mode

The time required for an initialization pro-cess depends on the transit time of the actu-ator and take several minutes. After a suc-cessful initialization, the positioner runs inclosed-loop operation indicated by .A malfunctioning leads to the process beingcanceled. The initialization error appears onthe display according to how it has beenclassified by the condensed state. See sec-tion 8.3.

Note: When Code 48 - h0 = YES, the diag-nostics automatically start to plot the refer-ence graphs (drive signal steady-state d1and hysteresis d2) after initialization hasbeen completed.tESt d1 or tESt d2 appear on the display inan alternating sequence.An error during the plotting of the referencegraphs is indicated on the display overCode 48 - h1 and Code 81.The positioner still works properly, eventhough the reference graph plotting has notbeen completed successfully.

Valve closed position AIR TO CLOSE

If the slide switch is set to AIR TO CLOSE,the positioner automatically switches to thedirection of action increasing/decreasing() on successful completion of initializa-tion.This results in the following assignment be-tween reference variable and valve position:

Valve closedposition

Direction ofaction

Reference variableValve

Closed at Open at

AIR TO OPEN 0 % 100 %

AIR TO CLOSE 100 % 0 %

54 EB 8384-4 EN


%

The tight-closing function is activated.

NOTICESet Code 15 (final position w>) to 99 % forthree-way valves.

Canceling an initalization process

The initialization procedure can be canceledwhile running by pressing the rotarypushbutton ( ). StOP appears three sec-onds long and the positioner then changesto the fail-safe position (SAFE).

Exit the fail-safe position again over Code 0(see section 8.2.2).

7.6.1 MAX – Initialization basedon maximum 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:


Default No


Press Code 3 blinks

Turn YES

Press , display

Select the initialization mode:

Initialization modeDefault MAX

Turn Code 6

Press

Turn MAX

Press to confirm the MAX as the initial-ization mode.

Start initialization:

Press INIT key to start initialization!

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).

EB 8384-4 EN 55


Enter the pin position:

Pin positionDefault No

Turn Code 4

Press , Code 4 blinks

Turn Pin position on lever (see rele-vant section on attachment)

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

7.6.2 NOM – Initialization basedon nominal 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 oftravel/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 alarm Code 52) becausethe nominal travel is not achieved.



Default No



Turn YES

Press , display

Enter the pin position and nominal range:


Nominal range(locked with Code 4 = No)

Turn Code 4



Press .

Turn Code 5


56 EB 8384-4 EN


mm

mm

mm

Turn Nominal travel/angle

Press .



Turn Code 6


Turn NOM

Press to confirm the NOM as the initial-ization mode.



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

7.6.3 MAN – Initialization basedon a manually selectedrange

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 amonotonically 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).



Default No



Turn YES

Press , display

Enter the pin position:


Turn Code 4



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

EB 8384-4 EN 57


mm



Turn Code 6


Turn MAN

Press to confirm the MAN as the initial-ization mode.

Enter OPEN position:

Manual reference variable(the current angle of rota-tion is displayed)

Turn Code 0


Turn MAN

Press

Turn Code 1


Turn until the valve reaches its OPEN po-sition.

Press to confirm the OPEN position.



7.6.4 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. You should always select a differ-ent initialization mode if the plant allows it.

The SUb initialization mode is used to re-place a positioner while the process is run-ning. For this purpose, the control valve isusually fixed mechanically in a certain posi-tion, 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 7.8.



58 EB 8384-4 EN


Default No



Turn YES

Press , display

Enter the pin position and nominal range:

Default No

Nominal range(locked with Code 4 = No)

Turn Code 4



Press .

Turn Code 5


Turn Nominal travel/angle

Press .



Turn Code 6


Turn SUb

Press to confirm the SUb as the initializa-tion mode.

Enter the direction of action:

Default

Turn Code 7


Turn Direction of action ( or )

Press .

Deactivate travel limit:

Default 100.0

Turn Code 11


Turn No

Press .

EB 8384-4 EN 59


mm

mm

Change pressure limit and control parame-ters:

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

Pressure limitDefault No

KPDefault 7

TVDefault 2

Turn Code 16/17/18

Press , Code 16/17/18 blinks

Turn to set the control parameter se-lected.

Press to confirm the setting.

Enter closing direction and blocking posi-tion:

Closing directionDirection of rotation caus-ing the valve to move to theCLOSED position (viewonto positioner display)Default: CCL (counterclock-wise)

Blocking positionDefault: 0

Turn Code 34


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 to confirm the setting.

Set the valve closed position:

Set switch for valve closed positionAIR TO OPEN or AIR TO CLOSE as de-scribed in section 7.1 on page 50.

Set volume restriction as described insection 7.2 on page 51.

60 EB 8384-4 EN


mm


Press INIT key!The positioner switches to MAN mode.The blocking position is indicated.

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 alarms do not influence thepositioner’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 as follows:

Turn Code 1

Press , Code 1 and blink

Turn in order to move the valve slightlypast the blocking position.

Press to cancel mechanical blocking.

Turn Code 0

Press , Code 0 blinks.

Turn AUtO

Press . The positioner switches to auto-matic operating mode. The current valve po-sition is indicated in %.

Note: If the positioner shows a tendency tooscillate in automatic operating mode, theparameters KP and TV must be slightly cor-rected. Proceed as follows:– Set TV to 4 (Code 18).– If the positioner still oscillates, the gain

KP (Code 17) must be decreased until thepositioner shows a stable behavior.

Zero point calibration

Finally, if process operations allow it, thezero point must be adjusted according tosection 7.7.

7.7 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 positioner must be connected tothe supply air to perform the zero calibra-tion.


Turn Code 3


Turn ON

Press , display

EB 8384-4 EN 61


Perform zero calibration:


Turn Code 6


Turn ZP

Press .

Press INIT key!Zero calibration starts.The positioner movesthe valve to the CLOSED position and read-justs the internal electrical zero point.

7.8 Reset to default values

This function resets all parameters to the fac-tory default values (see code list in sec-tion 14).


Turn Code 3, display No


Turn ON

Press , display

Reset start-up parameters:

ResetDefault No

Turn Code 36, display ••–••–


Turn Std

Press . All start-up parameters and the di-agnosis are reset to their default values.

Note:– Code 36 - diAG allows just the diagnosis

data (EXPERTplus) to be reset. Refer toEB 8389 EN on EXPERTplus valve diag-nostics.

– Reset the control and identification pa-rameters as well as the bus address withthe FACTORY_RESET parameter (refer toConfiguration Manual KH 8384-4 EN).

7.9 Start-up via local interface(SSP)

The positioner can either be commissioned,configured, and operated on site, using theFieldbus configuration or operating system,or TROVIS-VIEW operator interface con-nected over the serial interface in thepositioner.

Use the TROVIS-VIEW software with 3730-4device module installed.

To connect the positioner directly to the PCvia the local serial interface, an adapter (or-der no. 1400-7700) is required.

The positioner can be supplied with powerby connecting it to a fieldbus segment orover a DC voltage source (9 to 32 V) con-nected to the bus terminals in the positioner.The simultaneous operation ofTROVIS-VIEW and the fieldbus system ispossible without any restrictions when con-nected to a PROFIBUS-PA segment.

62 EB 8384-4 EN


7.10 Setting the bus address

A maximum of 32 positioners in a safe(non-hazardous) area can be operated overa segment coupler in one PROFIBUS-PA seg-ment.

Each positioner connected in the segmentmust be assigned a unique bus address be-tween 0 and 125.

Default 126


Press , Code 3 blinks.Change the setting of Code 3.

Turn YES

Press , display:The configuration is enabled.

Turn Code 46, press ,

turn required address,

press 10 seconds The address isadopted straightaway, provided that cyclicdata exchange is not taking place.During the cyclic data exchange, the newlyset address for the positioner is saved andadopted after the cyclic data exchange isfinished.The newly assigned address is indicated un-der Code 46 in alternating sequence withthe current address. The new address ismarked with “n“ (new) and the currentlyused address with “o“ (old).

Note: The bus address can only be imple-mented by the PROFIBUS commandSET_ADRESS when the bus address is set tothe default setting [126]. Refer to Configura-tion Manual KH 8384-4 EN.

EB 8384-4 EN 63


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

The codes which are marked with an aster-isk (*) in section 14 on page 73 onwardsmust be enabled with Code 3 before the as-sociated parameters can be configured asdescribed below.

Code 3Configurationnot enabled

Configurationenabled


Press , Code 3 blinks.Change the setting of Code 3.

Turn YES

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 changes toCode 0.

Cancel the setting:

Canceling the setting

To cancel a value before it is confirmed (bypressing ) proceed as follows:

Turn ESC

Press . The entered value is not adopted.

64 EB 8384-4 EN

Operation

8.2 Operating modes

8.2.1 Automatic and manualmodes

After initialization has been completed suc-cessfully, the positioner is in automaticmode (AUTO).

Automatic mode

Switch to manual operating mode(MAN)

Turn Code 0

Press , display: AUtO,Code 0 blinks.

Turn MAN

Press to switchover to manual mode.The switchover is smooth since the manualmode starts up with the set point last usedduring automatic mode. The current positionis displayed in %.

Adjust the manual reference variable

Turn Code 1


Turn until sufficient pressure has beenbuilt up in the positioner and the controlvalve moves to the required position.

Note: The positioner automatically returns tomanual mode with Code 0 if no settings

are made within 120 seconds.

Switch to automatic operating mode

Turn Code 0


Turn AUtO

Press . The positioner changes to au-tomatic operating mode.

EB 8384-4 EN 65

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 7.1), proceed as follows:

Turn Code 0

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

Turn SAFE

Press , display: S.The valve moves to the fail-safe position.Once the positioner is initialized, the currentvalve position is indicated on the digital dis-play in %.

Exit the fail-safe position

Turn Code 0


Turn and select the required operatingmode AUtO or MAN.

Press . The positioner switches to the op-erating mode selected.

8.3 Malfunction/maintenancealarm

All status and fault alarms are assigned to aclassified status in the positioner. The defaultsettings of the status classification are listedin the code list.

Note: The status classification can bechanged in TROVIS-VIEW and over thePROFIBUS-PA parameters.Refer to the Configuration ManualKH 8384-4 EN on the supplied CD-ROM(CD 8384-4) for more details.

To provide a better overview, the classifiedalarms are summarized in a condensedstate. The following status alarms are avail-able:

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. Maintenanceis necessary 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

66 EB 8384-4 EN

Operation

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

Process-related faults/outside of specifi-cationsThe positioner is being operated outsidethe specified conditions of use.

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 appears on the displaywith the following icons:

Condensed state Positionerdisplay

Maintenance alarm

Function check Text

Maintenance required/Maintenance demanded

Process-related faults/outside of specifications –

No message –

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 14).

ExampleError caused by pinposition

Fault alarm output

The “Maintenance alarm” as the condensedstate causes the optional fault alarm outputto be switched.

The “Function check” condensed statecan also switch the fault alarm contact inCode 32.

The “Maintenance required/demanded”condensed state can also switch the faultalarm contact in Code 33.

8.3.1 Confirming error messages





Turn YES

Press , display:

Confirm error messages:

Turn Error code which you want toconfirm.

Press to confirm the error message.

EB 8384-4 EN 67

Operation

S

9 Adjusting the limit switch

The positioner version with an inductive limitswitch has one adjustable tag (1) mountedon the shaft which operates the proximityswitch (3).

For operation of the inductive limit switch,the corresponding switching amplifier (seesection 5.2.1) must be connected to the out-put.

If the tag (1) is inside the field of the switch,the switch assumes a high resistance. If thetag is outside of the field, the switch assumesa low resistance.

Normally, the limit switch is adjusted suchthat it will provide a signal in both end posi-tions of the valve. The switch, however, canalso be adjusted to indicate intermediatevalve positions.

The desired switching function, i.e. whetherthe output relay shall be picked up or re-leased when the tag has entered the field,has to be determined, if necessary, at theswitching amplifier.

Setting the switching point:

NOTICEDuring adjustment or testing, the switchingpoint must always be approached frommid-position (50 %).

To ensure safe switching under any ambientconditions, the switching point should be ad-justed to a value of approx. 5 % before themechanical stop (OPEN – CLOSED).

68 EB 8384-4 EN

Adjusting the limit switch

Fig. 22 · Adjustment of the limit switch

Adjustment screw (2) Tag (1) Proximity switch (3)

For CLOSED position:

1. Initialize positioner.2. Use the MAN function to move the

positioner to 5 % (see LC display).3. Adjust the tag using the yellow adjust-

ment screw (2) until the tag enters orleaves the field and the switching ampli-fier responds. You can measure theswitching voltage as an indicator.

Contact function:Tag leaving the field > contact is made.Tag entering the field > contact is opened.

For OPEN position:

1. Initialize positioner.2. Use the MAN function to move the

positioner to 95 % (see LC display).3. Adjust the tag (1) using the yellow ad-

justment screw (2) until the tag enters orleaves the field of the proximity switch(3).You can measure the switching voltageas an indicator.

Contact function:

Tag leaving the field > Contact is made.Tag entering the field > Contact is opened.

EB 8384-4 EN 69


9.1 Retrofitting an inductive limitswitch

Required retrofit kit:Limit switch Order no. 1400-7460

Note! For explosion-protected devices, therequirements in section 11 need to be kept.

1. Take off the rotary pushbutton (3) andcap (1), unthread the five fixing screws(2) and lift off the plastic cover (9) to-gether with the display, taking care notto damage the ribbon cable (betweenPCB and display).

2. Use a knife to cut an opening at themarked location (4).

3. Push the connector (11) with cablethrough the opening and secure theproximity switch (7) on the cover with adot of glue.

4. Remove the jumper (8801-2267) at thesocket X7 of the top board and insert thecable connector (11).

5. Guide the cable in such a manner thatthe plastic cover can be placed backonto the positioner. Insert the fixingscrews (2) and screw tight. Attach theclamping plate (8) onto the proximityswitch.

6. Attach the rotary switch (5). Make surethe flattened side of the positioner shaftis turned so that the rotary switch (5) canbe attached with the metal tag next tothe proximity switch.

7. Note: On start-up of the positioner, setthe option inductive alarm under Code38 from No to YES.

70 EB 8384-4 EN


1

2

4

3

1 Cap2 Screws3 Rotary pushbutton4 Marking5 Rotary switch

6 Metal tag7 Proximity

switch8 Clamping plate9 Plastic cover11 Connector

Socket X7 (11)

9 7

5

8

7

6

Fig. 23 · Retrofitting an inductive limit switch

10 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.

11 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.

Read section 13 for maintenance, calibra-tion and adjustment work inside and outsidehazardous areas.

12 Firmware update (serialinterface)

Firmware updates on positioners currently inoperation can be performed as follows:

When updates are performed by a serviceemployee appointed by SAMSON, the up-date is confirmed on the positioner by thetest mark assigned by SAMSON’s QualityAssurance.

In all other cases, only persons from theplant operator with written approval mayperform updates. This person must confirmthe update on the positioner.

Laptops and PCs connected to the powersupply must use an additional safety barrier.

This does not apply to laptops in battery op-eration. In this case, it is assumed that a bat-tery-powered laptop runs briefly for soft-ware programming or for testing purposes.

EB 8384-4 EN 71

Maintenance

a) Updates outside the hazardous area:

Remove the positioners from the plantand update them outside the hazardousarea.

b.) Updates on site:

Updates on site are only permitted afterthe plant operator has presented a sig-ned hot work permit.

After updating has been completed, add thecurrent firmware to the nameplate; this canbe done using labels.

13 Maintenance, calibration andwork on equipment

The interconnection with intrinsically safecircuits to check or calibrate the apparatusmust only be performed with intrinsicallysafe current/voltage calibrators and mea-suring instruments to rule out any damageto components relevant for explosion pro-tection.

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

72 EB 8384-4 EN

Maintenance, calibration and work on equipment

14 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] Manual modeAUtO Automatic modeSAFE Fail-safe positionESC Escape

Switchover from automatic to manual mode is smooth.In fail-safe mode, the symbol S appears on the display.In MAN and AUtO mode, the system deviation is represented bythe bar graph elements.When the positioner is initialized, the numerical display indicatesthe valve position or the angle of rotation in %, otherwise the po-sition of the lever in relation to the central axis is displayed in de-grees °.

1 Manual w0 to 100 [0] %of the nominal range

Adjust the manual set point with the rotary pushbutton, thecurrent travel/angle is displayed in % when the positioner is ini-tialized, otherwise the position of the lever in relation to the cen-tral axis is indicated in degrees °.Note: Can only be selected when Code 0 = MAN

2 Reading direction, ESC

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

3 Enable configuration[No], YES, ESC

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.Codes marked with an asterisk (*) can only be read and notoverwritten.Likewise, codes can only read over the SSP interface.

4* Pin position17, 25, 35, 50, 70, 100,200 mm90° with rotary actuators[No], ESC

Note: If you select a pinposition in Code 4 that is toosmall, the positioner switchesto 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.For initialization using NOM or SUb, this pin position must beentered.

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

EB 8384-4 EN 73

Code list

12341234

Codeno.



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 No, i.e. after apin position has been entered, Code 5 can be configured.After initialization has been successfully completed, the maxi-mum nominal travel/angle reached on initialization is displayed.

6* Init mode[MAX]NOMMANSUbZPESC

Select the initialization modeMAX: Travel/angle of the closure member from the CLOSED

position to the opposite stop in the actuator.NOM: Travel/angle of the closure member measured from the

CLOSED position to the indicated OPEN position.MAN: Manually selected rangeSUb: Substitute calibration (without initialization)

7* w/x[] increasing/increasing increasing/decreasingESC

Direction of action of the reference variable w in relation to thetravel/angle of rotation xAutomatic adaptation:AIR TO OPEN:On completing initialization, the direction of action remains in-creasing/increasing (), a globe valve opens as the mA signalincreases.AIR TO CLOSE:On completing initialization, the direction of action changes toincreasing/decreasing (), a globe valve closes as the mA sig-nal increases.

8* Travel/angle range start(lower x-range value)0.0 to 80.0 [0.0] % of thenominal rangeESC

Note: Specified in mm orangle ° provided Code 4 isset

Lower range value for the travel/angle of rotation in the nominalor operating range.The operating range is the actual travel/angle of the controlvalve and is limited by the lower x-range value (Code 8) and theupper x-range value (Code 9).Usually, the operating range and the nominal range are identi-cal. The nominal range can be limited to the operating range bythe lower and upper x-range values.Value is displayed or must be entered.

The characteristic is adapted. See also the example in Code 9!

74 EB 8384-4 EN

Code list

Codeno.



9* Travel/angle range end(upper x-range value)20.0 to 100.0 [100.0] % ofthe nominal rangeESC

Note: Specified in mm orangle ° provided Code 4 isset

Upper range value for the travel/angle of rotation in the nominalor operating 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)0.0 to 49.9 % of theoperating range[No], ESC

Limitation of the travel/angle of rotation downwards to the en-tered value, the characteristic is not adapted.

The characteristic is not adapted to the reduced range. See alsoexample in Code 11.

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

Limitation of the travel/angle of rotation upwards to the enteredvalue, 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!When set to No, the valve can be opened past the nominal travelwith a reference variable outside of the 0 to 100 % range.

14* Reference variable rangestart (w-start)0.0 to 49.9 [1.0] %of the span adjusted viaCode 12/13No, ESC

If w approaches the percentage adjusted at the final value 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.

EB 8384-4 EN 75

Code list

Codeno.



15* Reference variable rangeend (w-end)50.0 to 100.0 %of the span adjusted viaCode 12/13[No], ESC

If w approaches the percentage adjusted at the final value 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.Codes 14/15 have priority over Codes 8/9/10/11.Codes 21/22 have priority over Codes 14/15.Example: Set the final position w > to 99 % for three-way valves.

16* Pressure limit1.4 2.4 3.7 bar[No], ESC

The signal pressure to the actuator can be limited in stages.After changing a pressure limit already set, the actuator must bevented once (e.g. by selecting the fail-safe position (SAFE) overCode 0).NOTICEDo not activate the pressure limit for double-acting actuators withvalve closed position AIR TO OPEN (AtO).

17* Proportional-actioncoefficient KP (step)0 to 17 [7]ESC

Displaying or changing KP

Note on changing the KP and TV steps:During the initialization of the positioner, the KP and TV values areoptimized.Should the positioner show a tendency for impermissibly highpost-pulse oscillation due to additional interference, the KP andTV steps can be adapted after the initialization.For this, either the TV step can be increased in increments untilthe desired response behavior is reached or, when the maximumvalue of 4 is reached, the KP step can be decreased in incre-ments.

NOTICEChanging the KP step influences the system deviation.

18* Rate time TV (step)1 [2] 3 4No, ESC

Displaying or changing TV,see note under KP stepA change of the TV step has no effect on the system deviation.

76 EB 8384-4 EN

Code list

Codeno.



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 transit time is determined during initialization which issix times > 30 s, the six-fold transit time is accepted as the lagtime.

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 16).

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 recommendable to limit the transit timeof the actuator to prevent it from engaging too fast in the runningprocess.Code 21 has priority over Code 15.NOTICEThe function is not activated when the fail-safe function or sole-noid valve is triggered nor upon failure of the auxiliary power.

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

The time required to pass through the operating range when thevalve closes.Code 22 has priority over Code 14.NOTICEThe function is not activated when the fail-safe function or sole-noid valve is triggered nor upon failure of the auxiliary power.

EB 8384-4 EN 77

Code list

Codeno.



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 by RES.Note: The total valve travel is saved in a non-volatile memoryafter every 1000 double travel.

24* LV 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 faultsymbol and the wrench symbol corresponding with the collectivestatus appear.

34* Closing directionCL Clockwise[CCL] CounterclockwiseESC

Turning direction in which the valve is moved to the CLOSED po-sition (view onto the rotary switch motion when the positionercover is open).Needs only be entered in initialization mode SUb (Code 6).

35* Blocking position[0] mm/° /%ESC

Entering the blocking position.Distance up to the CLOSED position.Only necessary in initialization mode SUb.

36* Reset[No], Std, diAG, ESC

Std: Resets all parameters to default (factory setting) as wellas the diagnosis data. After a reset, the positioner mustbe re-initialized.

diAG: Resets diagnosis data only. Plotted reference graphs andlogs remain unaffected. The positioner does not need tobe re-initialized.

38* Inductive alarm[No], YES, ESC

Indicates whether the inductive limit switch option is installed ornot.

39 System deviation e info–99.9 to 999.9 %

Read only,indicates the deviation from the position required.

40 Transit time Open info0 to 240 s [0]

Read only,minimum opening time determined during initialization.

41 Transit time Closed info0 to 240 s [0]

Read only,minimum closing time determined during initialization.

78 EB 8384-4 EN

Code list

Codeno.



42 Auto-w/manual-w info0.0 to 100.0 % of the span

Read only,Auto mode: indicates the supplied automatic reference variableMan mode: indicates the supplied manual reference variable

43 Firmware info control Read only,indicates the positioner type and current firmware version inalternating sequence.

44 y info[0] to 100 %0P, MAX, – – –

Read only.Indicates the control signal y in % based on the travel range de-termined on initializationMAX: The positioner builds up its maximum output pressure, seedescription in Code 14 and 15.0P: The positioner vents completely, see description in Code 14and 15.– – –: The positioner is not initialized.

45 Solenoid valve infoYES, HIGH/LOW, No

Read only,indicates whether a solenoid valve is installed or not.If a voltage supply is connected at the terminals of the installedsolenoid valve, YES and HIGH appear on the display in alternat-ing sequence. If a voltage supply is not connected (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

Select bus address

47* Write protection PAYES, [No], ESC

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

48* Diagnostic parameters d

d0 Current temperature–55.0 to 125.0

Operating temperature [°C] inside the positioner

d1 Minimum temperature[20]

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

d2 Maximum temperature[20]

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

EB 8384-4 EN 79

Code list

Codeno.



48* d3 Number of zerocalibrations

The number of zero calibrations since the last initialization.

d4 Number of initializations The number of initializations that have been performed.

d5 Zero point limit0.0 to 100.0 % [5 %]

Limit for the zero point monitoring.

d6 Condensed status Condensed status, made up from the individual states.0 OK: Okay1 C: Maintenance required2 CR: Maintenance demanded3 B: Maintenance alarm7 I: Function check

d7 Start reference run[No], YES, ESC

Triggering of a reference run for the functions: Drive signal ysteady-state and drive signal y hysteresis.The reference run can only be activated in manual operatingmode as the valve moves through its entire travel 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 Only for firmware version 1.51 or lower:Enter the activation code for EXPERT+.After the activation procedure has been successfully completed,YES appears under d8.The EXPERTplus diagnostics are always activated for firmware1.52 or higher

Diagnostic parameters h

h0 Initialization withreference test[No] · YES · ESC

The reference graphs for Drive signal y steady-state (d1) anddrive signal y hysteresis (d2) (Tests) are plotted during the refer-ence test.

h1 Reference test result[No] · YES

Display onlyNo A reference test has not been performed.YESThe reference graphs for Drive signal y steady-state (d1) and

drive signal y hysteresis (d2) (Tests) have been plotted suc-cessfully.

h2 – Unassigned

80 EB 8384-4 EN

Code list

Codeno.



48* h3 Auto reset diAG0 to 365 days;[0 days]

After an adjustable time period, the diagnosis data are reset au-tomatically according to the settings in Code 36 - diAG.Example: A start-up behavior of the plant which is untypical forthe process is not to be included in the total diagnosis.

h4 Rest time for auto resetdiAG

Display onlyRemaining time until the diagnosis data are reset automaticallyaccording to the settings in Code 48 - h3

PA parameters PA-P

F0 Firmware Rev.Communication

F1 Binary input1 1 Active 0 Inactive

F2 Binary input2 1 Active 0 Inactive

F3 Counter device start-ups

F4 Counter resetcommunication

F5 Counter reset control

F6 Counter reset busconnection

F7 Slave status 0 Undefined 2 wait_cfg1 wait_prm 3 data_exchg

AO Function Block A

A0 Target Mode Required operating mode 1)

A1 Actual Mode Actual operating mode 1)

A2 SP Value Displays the setpoint (reference variable)

A3 SP Status and its status

A4 Readback Value Displays the current position

A5 Readback Status and its status

1) See page 83

EB 8384-4 EN 81

Code list

Codeno.



48* A6 Out Value Displays the manipulated variable (output value)

A7 Out Status and its status

A8 Unassigned

A9 Simulate Positioner simulation1 Enabled 0 Disabled

Transducer Blocks A0, DI1, DI2 t

t0 Target Mode AO Trd Required operating mode 1)

t1 Actual Mode AO Trd Actual operating mode 1)

t2 Final_Position_Value.Value

Displays the current valve position in relation to the operatingposition

t3 Final_Position_Value.State

and its status

t4 AO Feedback Value Displays the current valve position [OUT_SCALE]

t5 AO Feedback State and its status

t6 AO Final_Value.Value Displays the output value [FVR]

t7 AO Final_Value.State and its status

t8 AO Final_Position_Value.Value

Displays the current valve position [FVR]

t9 AO Final_Position_Value.State

and its status

Resource Block S

S0 Resource Target Mode Required operating mode 1)

S1 Resource Actual Mode Actual operating mode 1)

DI1Function Block I

I0 Target Mode DI1 Required operating mode 1)

I1 Actual Mode DI1 Actual operating mode 1)

1) See page 83

82 EB 8384-4 EN

Code list

Codeno.



48* I2 DI1 Trd PV_D.Value Displays the discrete input variable

I3 DI1 Trd PV_D.State and its status

I4 DI1 Fb Target Mode Required operating mode FB

I5 DI1 Fb Actual Mode Actual operating mode FB

I6 DI1 Fb OUT_D.Value Displays the discrete output variable

I8 DI1 FSAFE_VAL_D Default value when the sensor reports an error

I9 Simulate Simulation

D2 Function Block L

L0 Target Mode DI2 Required operating mode 1)

L1 Actual Mode DI2 Actual operating mode 1)

L2 DI2 Trd PV_D.Value Displays the discrete input variable

L3 DI2 Trd PV_D.State and its status

L4 DI2 Fb Target Mode Required operating mode FB

L5 DI2 Fb Actual Mode Actual operating mode FB

L6 DI2 Fb OUT_D.Value Displays the discrete output variable

L7 DI2 Fb OUT_D.State and its status

L8 DI2 FSAFE_VAL_D Default value when the sensor reports an error

L9 Simulate Simulation1) Display of actual/required operating mode

Operating mode Displayed value (display)Auto 8MAN 16External cascade RCAS 2O/S 128

EB 8384-4 EN 83

Code list

Codeno.



49* Partial stroke test (PST)

A Partial stroke test (PST)

A0 Start Partial Stroke Test[No] · YES · ESC

Operating mode and PST testing mode must be set to MAN.

A1 Time until the next auto-matic PST test takesplace

Remaining time [d_h] until the next partial stroke test is per-formed. Only applies to PST Auto mode.Read only

A2 Desired PST testingmodeAuto · [Man] · ESC

Activates (PST Auto) or deactivates (PST Man) the scheduled au-tomatic partial stroke test.

A3 Auto test time Time [h] between for partial stroke tests (PST)

A4 Status classificationPST status[C] · OK · CR · b · SESC

C Maintenance requiredOK No messageCR Maintenance demandedb Maintenance alarmS Out of specification

A5 Min. recommended scantime

Scan time [s] required to plot the complete step response test in agraph.Read only

A6 – Unassigned

A7 y-monitoring referencevalue

The valve moves to the valve position Step start (Code 49 - d2)and Step end (Code 49 - d3) with certain control pulses. The dif-ference between these control pulses creates the delta y value[1/s].The y-monitoring reference value applies to the adjusted stepvalues (Code 49 - d2 and Code 49 - d3) and for the selectedramp times (Code 49 - d5 and Code 49 - d6). The y-monitoringreference value must be determined again if any of the abovementioned values change.Read only

84 EB 8384-4 EN

Code list

Codeno.



49* A8 Activation delta y-moni-toring[No] · YES · ESC

Activates/deactivates delta y-monitoring

A9 delta y-monitoring value0 to 100 %; [10 %]

The percentage [%] of the entire range of the control pulse be-tween 1 and 10000 1/s (Example: 10 % = 10000 1/s)The partial stroke test is canceled if the change in control signal(delta y) varies from the y-monitoring reference value by thisamount.

d Step parameters for the partial stroke test (PST)

d1 – Unassigned

d2 Step start0.0 to 100.0 %;[95.0 %]

Start value to perform the step response test

d3 Step end0.0 to 100.0 %;[90.0 %]

End value to perform the step response test

d4 Activation of the rampfunction[No] · YES

Activates/deactivates the ramp function.

d5 Ramp time (rising)0 to 9999 s; [15 s]

Ramp time for 0 to 100 % travel (rising) of the ramp function.Do not enter a ramp time which is lower than the value automati-cally given during initialization.

d6 Ramp time (falling)0 to 9999 s; [15 s]

Ramp time for 0 to 100 % travel (falling) of the ramp function.Do not enter a ramp time which is lower than the value automati-cally given during initialization.

d7 Settling time before teststart1.0 to 240.0 s; [10.0 s]

Waiting time before the test starts to allow the valve to safelyreach the step start value.

d8 Delay time after step1.0 to 240.0 s; [2.0 s]

Time after the first step until the second step starts.

d9 Scan time0.2 to 250.0 s; [0.2 s]

Scan time of the step response test

EB 8384-4 EN 85

Code list

Codeno.



49* E Cancelation conditions of the partial stroke test (PST)

E0 Activation x control[No] · YES

Activates/deactivates x control.

E1 x control value–10.0 to 110.0 % oftotal travel; [0.0 %]

The test is automatically canceled as soon as the valve positionfalls below this value.

E2 – Unassigned

E3 – Unassigned

E4 – Unassigned

E5 Activation toleranceband control[No] · YES

Activates/deactivate tolerance band control.

E6 PST Tolerance band0.1 to 100.0 %;[5.0 %]

The test is automatically canceled as soon as the Step end (Code49 - d3) exceeds this value.

E7 Max. test duration30 to 25000 s; [30 s]

Maximum time within which a test can be completed before thetest is canceled automatically.

F Partial stroke test (PST) information · Read only

F0 No test available No test exists or the test has been canceled manually.

F1 Test OK

F2 x cancelation The test was canceled by the x cancelation function.

F3 y cancelation The test was canceled by the y cancelation function.

F4 Tolerance band ex-ceeded

The test was canceled. The x-values exceeded the toleranceband.

F5 Max. test time exceeded The test was not completed within the maximum test time andwas automatically canceled.

F6 Test man. canceled The test has been manually canceled by the user.

86 EB 8384-4 EN

Code list

Codeno.



49* F7 Measured data storageout of memory

The maximum capacity of the memory for measured data hasbeen reached. After 100 measured data per measured variablehave been recorded, the logging stops. However, the test is con-tinued.

F8 Int. solenoid valve The test was canceled by the activation of the solenoid valve.

F9 Supply pressure/friction An insufficient supply pressure or excessive friction occurredduring the test.

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).

EB 8384-4 EN 87

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 during

initialization under NOM (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.

88 EB 8384-4 EN

Code list


53 Initialization time exceeded(Init time >)

The initialization routine lasts too long.• 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 - solenoidvalve

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 7.2,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.

EB 8384-4 EN 89

Code list

Operational errors


57 Control loop Control loop error, the control valve does not react within the tol-erable 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 7.7 on page 61).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 positioner changes to the fail-safe position (SAFE).

Status classification Maintenance alarm (cannot be classified)

Recommended action Reset over Code 36.Re-initialize the positioner.

90 EB 8384-4 EN

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 operation icon and 4 dashes instead of the positionindication.

Note on the closed-loop operation: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.

Status classification [Maintenance demanded]

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.

EB 8384-4 EN 91

Code list

Error appendix


65 Hardware A hardware error has occurred, the positioner changes 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.



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.

92 EB 8384-4 EN

Code list

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.


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

70 Calibration parameter 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.

73 Internal device error 1 Internal device error



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


Recommended action Confirm error and perform reset.

EB 8384-4 EN 93

Code list


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 changes to the fail-safe position (SAFE) when ameasuring error occurs. During the initialization, the positionerchecks whether the actuator has such a function or not.


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

77 Program loading error 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



94 EB 8384-4 EN

Code list

Diagnosis errors


79 Diagnostic alarms Alarms are generated by the extended EXPERTplus diagnostics

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 graphs An error occurred during plotting the reference graphs for drivesignal y steady-state or drive signal y hysteresis.• Reference test was interrupted• Reference line for drive signal y steady-state or drive signal y

hysteresis was not adopted.


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

EB 8384-4 EN 95

Code list

15 Dimensions in mm

96 EB 8384-4 EN

Dimensions in mm

40

34

210

2814

80164 Output (38) Supply (9)

86

70

15

46

34 70

7028

Schild

58

58

Fig. 24a · NAMUR and direct attachment

Direct attachment

Attachment acc. to IEC 60534-6 Externalposition sensor

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

Pressuregaugebracket

or connection plate

M20 x 1.5

EB 8384-4 EN 97

Dimensions in mm

5686

13080

166

3086

Ø 101

80

52 Output Y1

Output Y2

Supply (9)Output Y1

Output Y2

Fig. 24b · Attachment to rotary actuators VDI/VDE 3845 (Sept. 2010), fixing level 1, size AA1 to AA4

A1 Z

A2

Output A1

Output A2

Supply (9)

50 80

58

130

495979

7650

150

Heavy-duty version

Reversingamplifier (optional)*

Light version

Reversingamplifier (optional)*

* Reversing amplifier

– Type 3710 (see drawing of heavy-duty version for dimensions)

– 1079-1118/1079-1119, no longer available(see drawing of light version for dimensions)

Connectingplate G ¼or ¼ NPT

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

98 EB 8384-4 EN

Dimensions in mm

A

M6

C

B

25

Mmin

Ød

ØD 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

Level 2 (bracket surface)

Level 1 (actuator surface)

Actuator

16 Valve characteristic selection

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)

EB 8384-4 EN 99

Valve characteristic selection

0

50

100

0 50 100

Travel/ angle of rotation [%]

Reference variable [%]

0

50

100

0 50 100



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: 8)

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



EB 8384-4 EN 101

102 EB 8384-4 EN

EB 8384-4 EN 103

104 EB 8384-4 EN

EB 8384-4 EN 105

106 EB 8384-4 EN

EB 8384-4 EN 107

108 EB 8384-4 EN

EB 8384-4 EN 109

110 EB 8384-4 EN

EB 8384-4 EN 111

112 EB 8384-4 EN

EB 8384-4 EN 113

114 EB 8384-4 EN

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ual o

r gr

eate

r th

an th

e vo

ltag

e

(V0C

) th

e cu

rren

t (IS

C)

and

the

pow

er (

P0)

leve

ls w

hich

can

be

deliv

ered

by

the

asso

ciat

ed a

ppar

atus

, con

side

ring

fau

lts

and

appl

icab

le f

acto

rs. I

n ad

ditio

n, th

e m

axim

um u

npro

tect

ed c

apac

itan

ce (

Ci)

and

indu

ctan

ce (

Li)

of e

ach

appa

ratu

s (o

ther

than

the

term

inat

ion)

con

nect

ed to

the

fiel

dbus

mus

t be

less

than

or

equa

l to

5 nF

and

10

µH

res

pect

ivel

y.

In e

ach

segm

ent o

nly

one

acti

ve d

evic

e, n

orm

ally

the

asso

ciat

ed a

ppar

atus

, is

allo

wed

to p

rovi

de th

e ne

cess

ary

ener

gy f

or th

e

fiel

dbus

sys

tem

The

all

owed

vol

tage

(V

0C)

of th

e as

soci

ated

app

arat

us is

lim

ited

to th

e ra

nge

of

14V

DC

. to

24V

DC

. All

oth

er e

quip

men

t con

nect

ed to

the

bus

cabl

e ha

s to

be

pass

ive,

mea

ning

that

they

are

not

all

owed

to

prov

ide

ener

gy to

the

syst

em, e

xcep

t to

a le

akag

e cu

rren

t of

50m

A f

or e

ach

conn

ecte

d de

vice

. Sep

arat

ely

pow

ered

equ

ipm

ent

need

s a

galv

anic

isol

atio

n to

ass

ure

that

the

intr

insi

call

y sa

fe f

ield

bus

circ

uit r

emai

ns p

assi

ve.

The

cab

le u

sed

to in

terc

onne

ct th

e de

vice

s ne

ed to

hav

e th

e pa

ram

eter

s in

the

follo

win

g ra

nge:

L

oop

resi

stan

ce R

‘:

15 ..

. 150

Ohm

/km

In

duct

ance

per

uni

t len

gth

L‘:

0,

4 ...

1

m

H/k

m

C

apac

itan

ce p

er u

nit l

engt

h C

‘:

80 ..

. 200

n

F/k

m

C‘

= C

‘ li

ne/l

ine

+ 0

,5 C

‘ li

ne/s

cree

n, if

bot

h lin

es a

re f

loat

ing

or, C

‘ =

C‘

line

/lin

e +

C’l

ine/

scre

en, i

f th

e sc

reen

is

conn

ecte

d to

one

line

L

engt

h of

spu

r ca

ble:

30

m

L

engt

h of

trun

k ca

ble:

1

km

At e

ach

end

of th

e tr

unk

cabl

e an

app

rove

d in

fall

ible

line

term

inat

ion

wit

h th

e fo

llow

ing

para

met

ers

is s

uita

ble:

R

= 9

0 ...

100

Ohm

C

= 0

...

2,2

µF

One

of

the

allo

wed

term

inat

ions

mig

ht a

lrea

dy b

e in

tegr

ated

in th

e as

soci

ated

app

arat

us.

The

num

ber

of p

assi

ve d

evic

es c

onne

cted

to th

e bu

s se

gmen

t is

not l

imit

ed d

ue to

I.S

. rea

sons

. If

the

abov

e ru

les

are

resp

ecte

d,

the

indu

ctan

ce a

nd c

apac

itan

ce o

f th

e ca

ble

wil

l not

impa

ir th

e in

trin

sic

safe

ty o

f th

e in

stal

lati

on.

Not

es:

1.

App

rove

d as

soci

ated

app

arat

us m

ust b

e in

stal

led

in a

ccor

danc

e w

ith

man

ufac

ture

r in

stru

ctio

ns

2.

App

rove

d as

soci

ated

app

arat

us m

ust m

eet t

he f

ollo

win

g re

quir

emen

ts:

V

oc

Vm

ax, I

sc≤

Im

ax, P

o

Pm

ax

3.

The

max

imum

non

-haz

ardo

us a

rea

volt

age

mus

t not

exc

eed

250

V.

4.

The

inst

alla

tion

mus

t be

in a

ccor

danc

e w

ith

the

Can

adia

n E

lect

rica

l cod

e P

art 1

.

5.

Eac

h se

t of

wir

es m

ust b

e pr

ovid

ed w

ith

grou

nded

shi

eld.

The

shi

eld

mus

t ext

end

as c

lose

to th

e te

rmin

al(s

) as

pos

sibl

e an

d it

mus

t be

grou

nded

shi

eld

at I

. S. B

arri

er g

roun

d.

6.

Cau

tion

: Use

onl

y su

pply

wir

es s

uita

ble

for

5 °C

abo

ve s

urro

undi

ng.

7.

War

ning

: Sub

stitu

tion

of c

ompo

nent

s m

ay im

pair

intr

insi

c sa

fety

. PE

= I

. S. G

roun

d

8.

The

pol

arit

y fo

r co

nnec

ting

11

and

12 is

of

no im

port

ance

due

to a

n in

tern

al r

ecti

fier

.

9.

FIS

CO

con

cept

app

lies

to f

ield

bus

/ cir

cuit

onl

y.

10.

Ent

ity

para

met

ers

appl

y to

cir

cuit

2, 3

and

4 a

nd f

urth

er r

equi

red

to m

eet t

he f

ollo

win

g co

ndit

ions

:

C

o

Ci +

Cca

ble;

Lo

L

i + L

cabl

e

EB 8384-4 EN 115

Add

endu

m P

age

4

Rev

isio

ns C

ontr

ol N

o. 1

: Mar

ch.2

006

A

dden

dum

to E

B 8

384-

5 E

N

Tab

le 2

: C

SA –

cer

tifi

ed b

arri

er p

aram

eter

s of

cir

cuit

4

Supp

ly b

arri

er

Eva

luat

ion

barr

ier

Bar

rier

V

0C

Rm

in

V0C

R

min

circ

uit 3

≤

28V

≥

245Ω

≤28

V

Dio

de

circ

uit 4

≤

30V

≥

300Ω

≤30

V

Dio

de

The

cor

rela

tion

bet

wee

n te

mpe

ratu

re c

lass

ific

atio

n an

d pe

rmis

sibl

e am

bien

t te

mpe

ratu

re r

ange

s is

sho

wn

in t

he ta

ble

3 be

low

:

Tab

le 3

:

Tem

pera

ture

cla

ss

Per

mis

sble

am

bien

t te

mpe

ratu

re r

ange

T6

T5

T4

+60°

C

-40°

C ≤

Ta≤

+70°

C

+80°

C

Tab

le 4

: E

nerg

y-L

imit

ed (N

on-

Ince

ndiv

e) P

aram

eter

s

Fou

ndat

ion

Fie

ldbu

sor

Pro

fibu

s P

A

(Non

ince

ndiv

e E

quip

men

t)

Lim

it-

swit

ches

(i

nduc

tive

)

For

ced

vent

ing

func

tion

Bin

ary-

In

put

1

Ter

min

al11

/ 12

(IE

C 1

148-

2)

41 /

42

81 /

82

87 /

88

Gro

ups

A, B

and

IIC

C

, D a

nd I

IB

#/#

#/#

#/#

Uio

r Vm

ax

[VD

C]

20V

24

V

30V

32

V

20V

24

V

30V

32

V

20V

28

V

30V

32

V

28V

30

V

32V

Iior

Imax

[mA

]46

4 26

1 15

2 13

0 1,

117

A

650

379

324

25m

A

52m

A

115m

A

100m

A

90m

A

115m

A

100m

A

90m

A

Pio

rP

max

[W]

2,32

1,

56

1,14

1,

14

5,88

3,

89

3,85

2,

77

64m

W16

9mW

##

##

Ci

2nF

30

5,

3 0

Li

10µ

H

100

0 0

Maximum values for serial-interface and binary input 2 see table 1

Add

endu

m P

age

3

Rev

isio

ns C

ontr

ol N

o. 1

: Mar

ch.2

006

A

dden

dum

to E

B 8

384-

5 E

N

Tab

le 1

: In

trin

sic

Safe

ty P

aram

eter

s

Fie

ldbu

s B

inar

y- in

put

Seri

al-I

nter

face

Fou

ndat

ion

Pro

fibu

s

Lim

it-

swit

ches

in

duct

ive

For

ced

vent

ing-

fu

ncti

on

1 2

Act

ive

Pas

sive

Cir

cuit

No.

1

1 2

3 4

5 6

6

Ter

min

al

No.

11 /

12

(IE

C 1

148-

2)

11 /

12

(IE

C 1

148-

2)

41 /

42

81 /

82

87 /

87

85 /

86

plug

Gro

ups

IIC

II

B

IIC

II

B

#/#

#/#

#/#

#/#

#/#

#/#

Vm

ax[

V ]

24

17

,5

16

28

30

28

30

###

###

16

U0

orV

0C

####

####

####

####

####

####

####

####

####

####

####

##

5,88

V8,

61V

###

Imax

[ m

A ]

360

380

380

25

52

115

100

115

100

###

###

25

I0or

ISC

####

####

####

####

####

####

####

####

####

####

####

##

1mA

55

mA

##

#

Pm

ax[

W ]

1,04

2,

58

5,32

64

mW

169m

W##

##

7,

2 m

W25

0 m

W64

m

W

Ci

[ nF

]2

60

5,3

0 ##

# ##

# 0

C0

or C

a ##

####

####

####

####

####

####

####

####

####

####

####

2µ

F

0,61

µF

##

#

Li

[ µ

H ]

10

100

0 0

###

###

0

L0

or L

a ##

####

####

####

####

####

####

####

####

####

####

####

10

mH

9m

H

###

Bin

ary-

inpu

t 1:

F

or c

onne

ctio

n of

an

activ

e si

gnal

cir

cuit

Bin

ary-

inpu

t 2:

Fo

r co

nnec

tion

of

an p

assi

ve c

onta

ct c

ircu

it di

rect

ly o

n th

e co

ntro

l val

ve, e

.g.

pass

ive

pres

sure

sw

itch

for

leak

age

mon

itor

ing

Not

es:

1.

Ent

ity p

aram

eter

s m

ust m

eet t

he f

ollo

win

g re

quir

emen

ts:

V

0C≤

Vm

ax ,

ISC≤

Im

ax, P

0≤

Pm

ax

C

0 or

Ca≥

Ci +

Cca

ble

and

L0

or L

a≥

Li +

Lca

ble

2.

Inst

all i

n ac

cord

ance

with

the

Can

adia

n E

lect

rica

l Cod

e Pa

rt I

3.

Cab

le e

ntry

M 2

0 x1

,5 o

r m

etal

con

duit

acc.

to d

wg.

No.

105

0-05

40

* C

ircu

it 3

can

be c

onne

cted

to a

CSA

Cer

tifie

d ze

ner

barr

ier

that

is r

ated

as

follo

ws:

-

Supp

ly c

hann

el (

conn

ect t

o T

erm

inal

81)

: V

oc ≤

28V

max

. and

Rm

in ≥

245

-

Ret

urn

chan

nel (

conn

ect t

o T

erm

inal

82)

: ≤

28V

max

wit

h di

odes

Ret

urn

(zer

o cu

rren

t)

** C

ircu

it 4

can

be c

onne

cted

to a

CSA

Cer

tifie

d ze

ner

barr

ier

that

is r

ated

as

follo

ws:

-

Supp

ly c

hann

el (

conn

ect t

o T

erm

inal

87)

: Voc

≤ 3

0V a

nd R

min

≥ 3

00

- R

etur

n ch

anne

l (co

nnec

t to

Ter

min

al 8

8): V

oc ≤

30V

max

with

dio

des

Ret

urn

(zer

o cu

rren

t)

116 EB 8384-4 EN

Add

endu

m P

age

6

Rev

isio

ns C

ontr

ol N

o. 1

: Mar

ch.2

006

A

dden

dum

to E

B 8

384-

5 E

N

Inst

alla

tion

dra

win

g C

ontr

ol R

elay

KH

A5-

OT

I/E

x2, K

HA

6-O

TI/

Ex1

or

K

HA

6-O

TI/

Ex2

wit

h M

odel

SJ-

b-N

Pro

xim

ity

Sens

ors

Syst

em p

aram

eter

s

Con

trol

Rel

ay

Ter

min

al N

o.

Gro

ups

L

[ m

H ]

C

[

µF

]

V0C

[ V

]

ISC

[ m

A ]

V

max

[ V

]

Rm

in[ Ω

]

A +

B

192

2,66

C +

E

671

7,9

1-3;

2-3

4-

6; 5

-6

D, F

, G

1000

21

,3

10,5

13

10

,5

811

HA

ZA

RD

OU

S

LO

CA

TIO

N

SAF

E

LO

CA

TIO

N

to in

trin

sica

lly

safe

out

put

Model 3730-43

or 3730-53

41+

42-

Ext

erna

l po

siti

on s

enso

r

term

inal

No.

Pro

xim

ity

sens

or

soft

war

e lim

it s

wit

ch

intr

insi

cally

out

put

to s

enso

r or

con

tact

chan

nel 2

intr

insi

cally

out

put

to s

enso

r or

con

tact

chan

nel 1

to o

ne c

omm

on

line

poss

ible

1+

12

+

2+

11

+

3-

10

-

Swit

ch-I

sola

tors

T

ype

KH

A5

– O

TI/

Ex2

o

r K

HA

6 -

OT

I/E

x.

4+

9+

5+

8+

6-

7-

87+

88-

Mod

el d

esig

nati

on c

ode

Typ

e K

Hab

– c

Exd

e

a= S

uppl

y V

olta

ge t

ype

A o

r D

a=

AC

, d=D

C

b= S

uppl

y L

evel

2=

24V

DC

±15%

; 5=

120V

AC

+10

%-1

5%;

6=23

0V A

C+1

0%-1

5%;

c= O

utpu

t ty

pe R

TA

/; R

W1/

; SS

1/; S

S2/;

RS1

/;

SR

/; S

T-o

r SO

T

d= N

umbe

r of

cha

nnel

s 1

or 2

e=

Pow

er r

ail d

esig

nati

on, P

, 2S.

P o

r G

S.P

(i

nclu

des

Mod

el K

HD

2-E

B-P

B P

ower

Fee

d M

odul

e) o

r B

lank

The

tota

l ser

ies

indu

ctan

ce a

nd s

hunt

cap

acit

ance

of

shie

ld w

irin

g sh

all

be r

estr

icte

d to

the

follo

win

g m

axim

um v

alue

s

Div

isio

n 2

wir

ing

met

hod

shal

l be

in a

ccor

danc

e to

the

C

anad

ian

Ele

ctri

cal C

ode

Par

t 1.

max

imum

cap

acit

ance

of

each

indu

ctiv

e se

nsor

30n

F

max

imum

indu

ctan

ce o

f ea

ch in

duct

ive

sens

or 1

00µ

H

Add

endu

m P

age

5

Rev

isio

ns C

ontr

ol N

o. 1

: Mar

ch.2

006

A

dden

dum

to E

B 8

384-

5 E

N

CSA

cer

tifi

ed fo

r ha

zard

ous

loca

tion

s:

Ex

nA I

I T

6 / E

x nL

IIC

T6

Cla

ss I

, Div

. 2;

Gro

ups

A, B

, C, D

; C

lass

II,

Div

. 2 G

roup

s E

, F +

G;

Cla

ss I

II

Typ

e 4

Enc

losu

re

G

RO

UN

D

Div

isio

n 2

wir

ing

met

hod

mus

t be

in a

ccor

danc

e to

th

e C

anad

ian

Ele

ctri

cal C

ode

Par

t 1


11+

12-

41+

42-

85+

86-

Fie

ldbu

s

circ

uit 1

Lim

it s

wit

ch c

ircu

it 2

81+

F

orce

d ve

ntin

g fu

ncti

on

82-

c

ircu

it 3

Ter

min

al N

o.

CSA

-cer

tifi

ed

term

inat

ion

wit

h R

= 9

0 . .

.100Ω

, C

= 0

. . .

2,2µ

F

CSA

-cer

tifi

edap

para

tus

suit

able

fo

r F

IEL

DB

US

CSA

-cer

tifi

edap

para

tus

suit

able

fo

r F

IEL

DB

US

CSA

-cer

tifi

ed a

ssoc

iate

d ap

para

tus

suit

able

fo

r P

rofi

bus

PA

or

FO

UN

DA

TIO

N F

F

FIE

LD

BU

S

Bin

ary

cont

act 2

ci

rcui

t 5

Isol

atin

g am

plif

ier

1 or

2

chan

nels

Haz

ardo

us

Loc

atio

n

Safe

Loc

atio

n

87+

Bin

ary

cont

act 1

88-

cir

cuit

4

.

Ext

erna

l pos

itio

n se

nsor

(o

ptio

nally

)

Seri

al in

terf

ace,

C

SA c

erti

fied

UNSPECIFIED APPARATUS e.g. transmitter relay

EB 8384-4 EN 117

Add

endu

m P

age

8

Rev

isio

ns C

ontr

ol N

o. 1

: Mar

ch.2

006

A

dden

dum

to E

B 8

384-

5 E

N

Intr

insi

cally

saf

e if

inst

alle

d as

spe

cifi

ed in

man

ufac

ture

r’s

inst

alla

tion

man

ual.

FM

- ap

prov

ed fo

r ha

zard

ous

loca

tion

s

Cla

ss I

, Zon

e 0

AE

x ia

IIC

T6:

C

lass

I, I

I, I

II D

iv. 1

, Gro

ups

A, B

, C, D

, E, F

+ G

. F

ield

enc

losu

re N

EM

A 4

X


11+

12-

41+

42-

85+

86-

Fie

ldbu

s

circ

uit 1

Lim

it s

wit

ch c

ircu

it 2

81+

F

orce

d ve

ntin

g fu

ncti

on

82-

c

ircu

it 3

Ter

min

al N

o.

I.S.

Gro

und

FM

-app

rove

d te

rmin

atio

n w

ith

R =

90

. . .1

00Ω

, C

= 0

. . .

2,2µ

F

FM

-app

rove

d in

trin

sica

lly s

afe

appa

ratu

s su

itab

le

for

FIE

LD

BU

S

FM

-app

rove

d in

trin

sica

lly s

afe

appa

ratu

s su

itab

le

for

FIE

LD

BU

S

FM

-app

rove

d as

soci

ated

ap

para

tus

suit

able

fo

r P

rofi

bus

PA

or

FO

UN

DA

TIO

N F

F

FIE

LD

BU

S

Bin

ary

cont

act 2

ci

rcui

t 5

supp

ly b

arri

er

eval

uati

on b

arri

er

FM

-app

rove

dba

rrie

r

Isol

atin

g am

plif

ier

1 or

2

Cha

nnel

s F

M-a

ppro

ved

Haz

ardo

us

Loc

atio

n

Safe

Loc

atio

n

The

inst

alla

tion

mus

t be

in a

ccor

danc

e w

ith

the

Nat

iona

l Ele

ctri

cal

Cod

e A

NSI

/NF

PA

70

and

AN

SI/I

SA R

P 1

2.06

.01

87+

Bin

ary

cont

act 1

88-

cir

cuit

4

eval

uati

on b

arri

er

supp

ly b

arri

er

.

Ext

erna

l pos

itio

n se

nsor

(o

ptio

nally

)

Seri

al in

terf

ace,

for

con

nect

ion

to F

M a

ppro

ved

intr

insi

cally

sa

fe c

ircu

it

Add

endu

m P

age

7

Rev

isio

ns C

ontr

ol N

o. 1

: Mar

ch.2

006

A

dden

dum

to E

B 8

384-

5 E

N

Inst

alla

tion

Man

ual f

or a

ppar

atus

app

rove

d by

FM

for

use

in h

azar

dous

loca

tion

s.

Com

mun

icat

ion

is o

ptio

nally

eit

her

acco

rdin

g to

the

FO

UN

DA

TIO

NT

MFi

eldb

us S

peci

fica

tion

orac

cord

ing

to P

RO

FIB

US

PA

in c

ompl

ianc

e F

ISC

O-C

once

pt

The

FIS

CO

Con

cept

all

ows

inte

rcon

nect

ion

of in

trin

sica

lly

safe

app

arat

us to

ass

ocia

ted

appa

ratu

s no

t spe

cifi

call

y ex

amin

ed in

such

com

bina

tion

. The

cri

teri

a fo

r in

terc

onne

ctio

n is

that

the

volt

age

(Vm

ax/U

i) th

e cu

rren

t (Im

ax/I

i) an

d th

e po

wer

(P

i) w

hich

intr

insi

call

y sa

fe a

ppar

atus

can

rec

eive

and

rem

ain

intr

insi

call

y sa

fe, c

onsi

deri

ng f

ault

s, m

ust b

e eq

ual o

r gr

eate

r th

an th

e vo

ltag

e

(V0C

/U0)

the

curr

ent (

ISC

/I0)

and

the

pow

er (

P0)

leve

ls w

hich

can

be

deli

vere

d by

the

asso

ciat

ed a

ppar

atus

, con

side

ring

fau

lts

and

appl

icab

le f

acto

rs. I

n ad

ditio

n, th

e m

axim

um u

npro

tect

ed c

apac

itan

ce (

Ci)

and

indu

ctan

ce (

Li)

of e

ach

appa

ratu

s (o

ther

than

the

term

inat

ion)

con

nect

ed to

the

fiel

dbus

mus

t be

less

than

or

equa

l to

5 nF

and

10

µH

res

pect

ivel

y.

In e

ach

segm

ent o

nly

one

acti

ve d

evic

e, n

orm

ally

the

asso

ciat

ed a

ppar

atus

, is

allo

wed

to p

rovi

de th

e ne

cess

ary

ener

gy f

or th

e

fiel

dbus

sys

tem

The

all

owed

vol

tage

(V

0C /U

o) o

f th

e as

soci

ated

app

arat

us is

lim

ited

to th

e ra

nge

of 1

4V D

C. t

o 24

V D

C. A

ll

othe

r eq

uipm

ent c

onne

cted

to th

e bu

s ca

ble

has

to b

e pa

ssiv

e, m

eani

ng th

at th

ey a

re n

ot a

llow

ed to

pro

vide

ene

rgy

to th

e sy

stem

,

exce

pt to

a le

akag

e cu

rren

t of

50m

A f

or e

ach

conn

ecte

d de

vice

. Sep

arat

ely

pow

ered

equ

ipm

ent n

eeds

a g

alva

nic

isol

atio

n to

assu

re th

at th

e in

trin

sica

lly

safe

fie

ldbu

s ci

rcui

t rem

ains

pas

sive

.

The

cab

le u

sed

to in

terc

onne

ct th

e de

vice

s ne

ed to

hav

e th

e pa

ram

eter

s in

the

follo

win

g ra

nge:

L

oop

resi

stan

ce R

‘:

15 ..

. 150

Ohm

/km

In

duct

ance

per

uni

t len

gth

L‘:

0,

4 ...

1

m

H/k

m

C

apac

itan

ce p

er u

nit l

engt

h C

‘:

80 ..

. 200

n

F/k

m

C‘

= C

‘ li

ne/l

ine

+ 0

,5 C

‘ li

ne/s

cree

n, if

bot

h lin

es a

re f

loat

ing

or, C

‘ =

C‘

line

/lin

e +

C’l

ine/

scre

en, i

f th

e sc

reen

is

conn

ecte

d to

one

line

L

engt

h of

spu

r ca

ble:

30

m

L

engt

h of

trun

k ca

ble:

1

km

At e

ach

end

of th

e tr

unk

cabl

e an

app

rove

d in

fall

ible

line

term

inat

ion

wit

h th

e fo

llow

ing

para

met

ers

is s

uita

ble:

R

= 9

0 ...

100

Ohm

C

= 0

...

2,2

µF

One

of

the

allo

wed

term

inat

ions

mig

ht a

lrea

dy b

e in

tegr

ated

in th

e as

soci

ated

app

arat

us.

The

num

ber

of p

assi

ve d

evic

es c

onne

cted

to th

e bu

s se

gmen

t is

not l

imit

ed d

ue to

I.S

. rea

sons

. If

the

abov

e ru

les

are

resp

ecte

d,

the

indu

ctan

ce a

nd c

apac

itan

ce o

f th

e ca

ble

wil

l not

impa

ir th

e in

trin

sic

safe

ty o

f th

e in

stal

lati

on.

Not

es:

1.

App

rove

d as

soci

ated

app

arat

us m

ust b

e in

stal

led

in a

ccor

danc

e w

ith

man

ufac

ture

r in

stru

ctio

ns

2.

App

rove

d as

soci

ated

app

arat

us m

ust m

eet t

he f

ollo

win

g re

quir

emen

ts:

U

o or

Voc

U

i or

Vm

ax, I

o or

Isc≤

Ii o

r Im

ax, P

o

Pi o

r P

max

3.

The

max

imum

non

-haz

ardo

us a

rea

volt

age

mus

t not

exc

eed

250

V.

4.

The

inst

alla

tion

mus

t be

in a

ccor

danc

e w

ith

the

Nat

iona

l Ele

ctri

cal C

ode

AN

SI/

NF

PA

70

and

A

NS

I/IS

A R

P 1

2.06

.01

5.

Eac

h se

t of

wir

es m

ust b

e pr

ovid

ed w

ith

grou

nded

shi

eld.

The

shi

eld

mus

t ext

end

as c

lose

to th

e te

rmin

al(s

) as

pos

sibl

e an

d it

mus

t be

grou

nded

shi

eld

at I

. S. B

arri

er g

roun

d.

6.

Cau

tion

: Use

onl

y su

pply

wir

es s

uita

ble

for

5 °C

abo

ve s

urro

undi

ng.

7.

War

ning

: Sub

stitu

tion

of c

ompo

nent

s m

ay im

pair

intr

insi

c sa

fety

. PE

= I

. S. G

roun

d

8.

The

pol

arit

y fo

r co

nnec

ting

11

and

12 is

of

no im

port

ance

due

to a

n in

tern

al r

ecti

fier

.

9.

FIS

CO

con

cept

app

lies

to f

ield

bus

/ cir

cuit

onl

y.

10.

Ent

ity

para

met

ers

appl

y to

cir

cuit

2, 3

and

4 a

nd f

urth

er r

equi

red

to m

eet t

he f

ollo

win

g co

ndit

ions

:

C

o

Ci +

Cca

ble;

Lo

L

i + L

cabl

e

118 EB 8384-4 EN

Add

endu

m P

age

9

Rev

isio

ns C

ontr

ol N

o. 1

: Mar

ch.2

006

A

dden

dum

to E

B 8

384-

5 E

N

Tab

le 1

: M

axim

um v

alue

s

Fie

ldbu

s B

inar

y- in

put

Seri

al-I

nter

face

Fou

ndat

ion

Pro

fibu

s

Lim

it-

swit

ches

in

duct

ive

For

ced

vent

ing-

fu

ncti

on

1 2

acti

ve

pass

ive

Cir

cuit

No.

1 1

2 3

4 5

6 6

Ter

min

al

No.

11

/ 12

11

/ 12

41

/ 42

81

/ 82

87

/ 88

85

/ 86

pl

ug

Gro

ups

A, B

II

C

C, D

II

B

A, B

, C, D

II

C /

IIB

#/

# #/

# #/

# #/

# #/

# #/

#

Uio

r V

max

[ V

]

24

17,5

16

28

30

V

0C

5,88

V

0C

8,61

V

max

16

Iior

Im

ax

[ m

A ]

360

380

380

25

115

100

ISC 1

ISC

55

Imax

25

Pio

r P

max

[ W

]1,

04

2,58

5,

32

64

mW

##

##

7,2

mW

250

mW

64

mW

Ci[

nF ]

5 60

5,

3 0

2µF

0,

61µ

F

0

Li[

µH

]10

10

0 0

0 10

mH

9m

H

0

Bin

ary-

inpu

t 1:

F

or c

onne

ctio

n of

an

activ

e si

gnal

cir

cuit

Bin

ary-

inpu

t 2:

Fo

r co

nnec

tion

of

an p

assi

ve c

onta

ct c

ircu

it di

rect

ly o

n th

e co

ntro

l val

ve, e

.g.

pass

ive

pres

sure

sw

itch

for

leak

age

mon

itor

ing

Not

es:

1.

Ent

ity p

aram

eter

s m

ust m

eet t

he f

ollo

win

g re

quir

emen

ts:

U

0≤

Ui o

r V

max

, I0≤

Ii o

r Im

ax, P

0≤

Pio

r P

max

C

0 or

Ca≥

Ci +

Cca

ble

and

L0

or L

a≥

Li +

Lca

ble

2.

The

inst

alla

tion

mus

t be

in a

ccor

danc

e w

ith th

e N

atio

nal E

lect

rica

l Cod

e

A

NS

I/N

FPA

70

and

AN

SI/I

SA R

P 12

.06.

01

3.

Cab

le e

ntry

M 2

0 x1

,5 o

r m

etal

con

duit

acc.

to d

wg.

No.

105

0-05

40

Add

endu

m P

age

10

Rev

isio

ns C

ontr

ol N

o. 1

: Mar

ch.2

006

A

dden

dum

to E

B 8

384-

5 E

N

Tab

le 2

: FM

– a

ppro

ved

barr

ier

para

met

ers

of c

ircu

it 4

Supp

ly b

arri

er

Eva

luat

ion

barr

ier

Bar

rier

V

0C

Rm

in

I0C

P

max

V

0C

Rm

in

circ

uit 3

≤

28V

≥

245Ω

≤11

5mA

##

≤

28V

D

iode

circ

uit 4

≤

30V

≥

300Ω

≤10

0mA

##

≤

30V

D

iode

The

cor

rela

tion

bet

wee

n te

mpe

ratu

re c

lass

ific

atio

n an

d pe

rmis

sibl

e am

bien

t te

mpe

ratu

re r

ange

s is

sho

wn

in t

he ta

ble

3 be

low

:

Tab

le 3

:

Tem

pera

ture

cla

ss

Per

mis

sble

am

bien

t te

mpe

ratu

re r

ange

T6

T5

T4

+60°

C

-40°

C ≤

Ta≤

+70°

C

+80°

C

Tab

le 4

:

Fou

ndat

ion

Fie

ldbu

sor

Pro

fibu

s P

A

(Non

ince

ndiv

e Fi

eld

wir

ing)

Lim

it-

swit

ches

(i

nduc

tive

)

For

ced

vent

ing

func

tion

Bin

ary-

In

put

1

Ter

min

al11

/ 12

41

/ 42

81

/ 82

87

/ 88

Gro

ups

A, B

and

IIC

C

, D a

nd I

IB

#/#

#/#

#/#

Uio

rVm

ax

[VD

C]

20V

24

V

30V

32

V

20V

24

V

30V

32

V

20V

30

V

30V

Iior

Im

ax

[mA

]46

4 26

1 15

2 13

0 1,

117

A

650

379

324

25m

A

100m

A

100m

A

Pio

r P

max

[W]

2,32

1,

56

1,14

1,

14

5,88

3,

89

3,85

2,

77

64m

W

##

##

Ci

5nF

60

5,

3 0

Li

10µ

H

100

0 0

Maximum values for serial-interface and binary input 2 see table 1

EB 8384-4 EN 119

Add

endu

m P

age

11

Rev

isio

ns C

ontr

ol N

o. 1

: Mar

ch.2

006

A

dden

dum

to E

B 8

384-

5 E

N

FM

app

rove

d fo

r ha

zard

ous

loca

tion

s:

Ex

nA I

I T

6; E

x nL

IIC

T6

Zon

e 2.

C

lass

I, I

I, D

iv. 2

Gro

ups

A, B

, C, D

, E+F

.

Fie

ld e

nclo

sure

NE

MA

4X


11+

12-

41+

42-

85+

86-

Fie

ldbu

s

circ

uit 1

Lim

it s

wit

ch c

ircu

it 2

81+

F

orce

d ve

ntin

g fu

ncti

on

82-

c

ircu

it 3

Ter

min

al N

o.

FM

-app

rove

d te

rmin

atio

n w

ith

R =

90

. . .1

00Ω

, C

= 0

. . .

2,2µ

F

FM

-app

rove

d ap

para

tus

suit

able

fo

r F

IEL

DB

US

FM

-app

rove

d ap

para

tus

suit

able

fo

r F

IEL

DB

US

FM

-app

rove

d as

soci

ated

ap

para

tus

suit

able

fo

r P

rofi

bus

PA

or

FO

UN

DA

TIO

N F

F

FIE

LD

BU

S

Bin

ary

cont

act 2

ci

rcui

t 5

Isol

atin

g am

plif

ier

1 or

2

chan

nels

Haz

ardo

us

Loc

atio

n

Safe

Loc

atio

n

87+

Bin

ary

cont

act 1

88-

cir

cuit

4

.

Ext

erna

l pos

itio

n se

nsor

(o

ptio

nally

)

Seri

al in

terf

ace,

F

M-a

ppro

ved

UNSPECIFIED APPARATUS e.g. transmitter relay

GR

OU

ND

The

inst

alla

tion

mus

t be

in a

ccor

danc

e w

ith

the

Nat

iona

l Ele

ctri

cal

Cod

e A

NSI

/NF

PA

70

and

AN

SI/I

SA R

P 1

2.06

.01

Add

endu

m P

age

12

Rev

isio

ns C

ontr

ol N

o. 1

: Mar

ch.2

006

A

dden

dum

to E

B 8

384-

5 E

N

Inst

alla

tion

dra

win

g C

ontr

ol R

elay

KH

A5-

OT

I/E

x2, K

HA

6-O

TI/

Ex1

or

K

HA

6-O

TI/

Ex2

wit

h M

odel

SJ-

b-N

Pro

xim

ity

Sens

or

Syst

em p

aram

eter

s

Con

trol

Rel

ay

Ter

min

al N

o.

Gro

ups

L

[ m

H ]

C

[

µF

]

V0C

[ V

]

ISC

[ m

A ]

V

max

[ V

]

Rm

in[ Ω

]

A +

B

192

2,66

C +

E

671

7,9

1-3;

2-3

4-

6; 5

-6

D, F

, G

1000

21

,3

10,5

13

10,5

81

1

HA

ZA

RD

OU

S

LO

CA

TIO

N

SAF

E

LO

CA

TIO

N

Ex

nA I

I T

6; E

x nL

IIC

T6

Zon

e 2.

C

lass

I, I

I, D

iv. 2

Gro

ups

A, B

, C, D

,E

+F.

to in

trin

sica

lly

safe

out

put

Model 3730-43

or 3730-53

41+

42-

Ext

erna

l pos

itio

n se

nsor

(o

ptio

nally

)

term

inal

No.

Pro

xim

ity

sens

or

soft

war

e lim

it s

wit

ch

intr

insi

cally

out

put

to s

enso

r or

con

tact

chan

nel 2

intr

insi

cally

out

put

to s

enso

r or

con

tact

chan

nel 1

to o

ne c

omm

on

line

poss

ible

1+

12

+

2+

11

+

3-

10

-

Swit

ch-I

sola

tors

T

ype

KH

A5

– O

TI/

Ex2

o

r K

HA

6 -

OT

I/E

x1

4+

9+

5+

8+

6-

7-

87+

88-

Mod

el d

esig

nati

on c

ode

Typ

e K

Hab

– c

Exd

e

a= S

uppl

y V

olta

ge t

ype

A o

r D

a=

AC

, d=D

C

b= S

uppl

y L

evel

2=

24V

DC

±15%

; 5=

120V

AC

+10

%-1

5%;

6=23

0V A

C+1

0%-1

5%;

c= O

utpu

t ty

pe R

TA

/; R

W1/

; SS

1/; S

S2/;

RS1

/;

SR

/; S

T-o

r SO

T

d= N

umbe

r of

cha

nnel

s 1

or 2

e=

Pow

er r

ail d

esig

nati

on, P

, 2S.

P o

r G

S.P

(i

nclu

des

Mod

el K

HD

2-E

B-P

B P

ower

Fee

d M

odul

e) o

r B

lank

Eac

h pa

ir o

f I.

S. w

ires

mus

t be

pro

tect

ed b

y a

shie

ld t

hat

is g

roun

ded

at t

he I

.S. G

roun

d. T

he s

hiel

d m

ust

be e

xten

d as

clo

se

to t

he t

erm

inal

s as

pos

sibl

e in

stal

lati

on s

hall

be in

acc

orda

nce

wit

h th

e N

atio

nal

Ele

ctri

cal C

ode

AN

SI/N

FP

A 7

0 an

d A

NSI

/ISA

RP

12.

06.0

1.

The

tot

al s

erie

s in

duct

ance

and

shu

nt c

apac

itan

ce o

f sh

ield

wir

ing

shal

l be

rest

rict

ed t

o th

e fo

llow

ing

max

imum

val

ues

max

imum

cap

acit

ance

of

each

indu

ctiv

e se

nsor

30n

F

max

imum

indu

ctan

ce o

f ea

ch in

duct

ive

sens

or 1

00µ

H

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 8384-4 EN S/

Z20

12-08

series 3730 electropneumatic positioner · aluminum (standard) 0 stainless steel 1.4581 0 1 special...

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