Samson 3780 series Mounting And Operating Instructions

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Positioner with HART® communication Type 3780

Mounting and Operating Instructions

EB 8380-1 EN

Firmware R 2.22/K 2.23 Edition June 2004

Fig. 1 ⋅Type 378 0

Contents Page

1. Design and principle of operation

. . . . . . . . . . . . . . . . . . . . . . 10

1.1 Options . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10

1.2 Communication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11

2. Attachment to the control valve

. . . . . . . . . . . . . . . . . . . . . . . 13

2.1 Direct attachment to Type 3277 Actuator . . . . . . . . . . . . . . . . . . . 14

2.2 Attachment according to IEC 60534-6 . . . . . . . . . . . . . . . . . . . . 18

2.2.1 Mounting sequence . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18

2.2.2 Presetting the valve travel . . . . . . . . . . . . . . . . . . . . . . . . . . . 20

2.3 Attachment to rotary valves . . . . . . . . . . . . . . . . . . . . . . . . . . 22

2.3.1 Mounting the cam follower roll lever . . . . . . . . . . . . . . . . . . . . . 22

2.3.2 Mounting the intermediate piece . . . . . . . . . . . . . . . . . . . . . . . 22

2.3.3 Aligning and mounting the cam disk . . . . . . . . . . . . . . . . . . . . . 24

2.3.4 Reversing amplifiers for double-acting actuators . . . . . . . . . . . . . . . . 26

2.4 Fail-safe action of the actuator . . . . . . . . . . . . . . . . . . . . . . . . 26

3. Connections

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28

3.1 Pneumatic connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28

3.1.1 Pressure gauge . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28

3.1.2 Supply air pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29

3.2 Electrical connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29

3.2.1 Switching amplifiers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31

3.2.2 Establishing communication . . . . . . . . . . . . . . . . . . . . . . . . . 32

4. Operation

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34

4.1 Write protection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34

4.2 Activate/deactivate forced venting function . . . . . . . . . . . . . . . . . . 34

4.3 Default setting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35

4.3.1 Adjusting mechanical zero point . . . . . . . . . . . . . . . . . . . . . . . 35

4.3.2 Initialization . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35

4.4 Adjusting inductive limit switches . . . . . . . . . . . . . . . . . . . . . . . 37

5. Maintenance

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38

6. Servicing explosion-protected versions

. . . . . . . . . . . . . . . . . . . . 38

7. Summary of parameters

. . . . . . . . . . . . . . . . . . . . . . . . . . . 39

8. List of parameters

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42

9. Error messages and diagnostics

. . . . . . . . . . . . . . . . . . . . . . . 53

9.1 Information/alerts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54

9.2 Error messages . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56

Contents

EB 8380-1 EN

9.3 Error messages during initialization without abortion . . . . . . . . . . . . 59

9.4 Error messages during initialization with abortion . . . . . . . . . . . . . . 60

Dimensional diagram

. . . . . . . . . . . . . . . . . . . . . . . . . . . 62

Type examination certificates

. . . . . . . . . . . . . . . . . . . . . . . 63

Safety instructions



Assembly, commissioning and operation of the device may only be performed by trained and experienced personnel familiar with this product. According to these mounting and operating instructions, trained personnel is referred to persons who are able to judge the work they are assigned to and recognize possible dangers due to their specialized training, their knowledge and experience as well as their knowledge of the relevant standards.



Explosion-protected versions of this device may only be operated by personnel who have undergone special training or instructions or who are authorized to work on explosion-protected devices in hazardous areas. See section 6 for more details.



For devices in type of protection EEx nA, the following applies: live circuits may only be connected, interrupted, and switched for installation, maintenance or repair purposes.



Devices that have already been used outside of hazardous areas and are intended for use in hazardous areas in future shall comply with the safety demands placed on serviced devices. Prior to operation, they shall be tested according to paragraph 26 "Repairing explosion-protected devices" of EN 50014:2000 to meet the safety requirements specified in this standard.



Any hazards which could be caused by the process medium, the signal pressure and moving parts of the control valve are to be prevented by means of appropriate measures. If inadmissible motions or forces are produced in the actuator as a result of the level of the supply air pressure, this must be restricted by means of a suitable pressure reducing station.



Proper shipping and appropriate storage are assumed.

Note:

Devices with the CE mark meet the requirements specified in the Directive 94/9/EC and the Directive 89/336/EEC. The Declaration of Conformity is available on request.

EB 8380-1 EN

Modifications of positioner firmware

Modifications of positioner firmware in comparison to previous version

Former New

For more details on the listed parameters, please also refer to the list of parameters in section 8.

Positioner R 1.41 R 2.01

Parameters:

Operating direction Direction of action

The reference variable (w) is not assigned to the output signal pressure (y) anymore, but to the travel/angle of rotation (x). >> increasing/increasing, valve opens with increasing reference variable. <> increasing/decreasing, valve closes with increasing reference variable.

Minimum transit time filling/venting

Minimum transit time open/closed

The measured time is not referenced to filling/venting the actuator, but to the opening and closing the valve.

Required transit time filling/venting

Required transit time open/closed

The actuating time is not referenced to filling/venting the actuator, but to the opening and closing the valve.

Cycle time factor K_IS

Omitted

Initialization

For version

R2.02

or higher, an alarm message is generated for deviations larger than 10 % when the type of initialization is maximum range. It is for the user to decide if he wants to tolerate the deviation.

Tolerated overshoot

If overshoot and dead band are exceeded by the negative deviation value, the pulse is adapted.

Text field

Free space for storing information text in the field device.

EB 8380-1 EN

Modifications of positioner firmware

Former New Positioner 2.02 R 2.11

Parameters:

Minimum pulse filling/venting

The minimum pulses for filling and venting are determined for the travel ranges 0 to 20 %, 20 to 80 % and 80 to 100 %. The minimum pulses are no longer determined during initialization.

Proportional-action coefficient KP_Y1 and KP_Y2

These factors are adapted to the actuator type selected and to the transit times measured.

Gain factor KD

Initialization

"Air leakage of pneumatic system" is displayed as alarm message, but does not cause abortion of initialization anymore. Upon initialization in the "nominal range", the positioner assumes only 100 % travel (no overtravel). "Wrong selection of rated travel/angle of rotation or transmission" is displayed as alarm message, but does not cause abortion of initialization anymore.

Positioner 2.11 R 2.21 Type of actuator

Change over type of actuator from "linear actuator" to "rotary actuator"

Initialization type .................Based on maximum range

Transmission code................S90

Nominal angle.....................90°

End position when w <..........1 %

End position when w >..........99 %

Rot ation al an gle r ange star t ..0° Rot ation al an gle r ange end ... 90°

Change over type of actuator from "rotary actuator" to "linear actuator"

Attachment

.........................

Integral

...............................

Acc. to NAMUR

Initialization type .................Based on nominal range.......Based on nominal range

Mounting position................Arrow towards actuator........Arrow away from actuator

Transmission code................D1......................................

Pin position.......................... ........................................A

Rated travel .........................15 mm ................................15 mm

End position when w <..........1 %.....................................1 %

End position when w >..........125 %.................................125 %

Travel range start..................0 mm..................................0 mm

Travel range end ..................15 mm................................15 mm

Length of lever...................... ........................................42 mm

EB 8380-1 EN

Modifications of positioner firmware

End position when w </>

Changing the type of initialization from "maximum range" to "nominal range" causes: End position at < 1 % End position at > 125 %

Changing the type of initialization from "nominal range" to "maximum range" causes: End position at < 1 % End position at > 99 %

Extended valve diagnostics

Supports TROVIS-EXPERT in version 1.0 or higher

Required transit time open/closed

The adjustment range for the required transit times has been limited to 75 s. Safe functioning can only be guaranteed up to this limit value.

Initialization

During initialization, the minimum control pulses for the range 20 % to 80 % of the range of the manipulated variable are determined and saved in the EEPROM.

Proportional-action coefficient KP_Y1 and KP_Y2

These factors are adapted to the type of actuator chosen and the transit times measured.

Positioner 2.21

R 2.22

Correction in "manual" operating mode and direction of action Correction in zero calibration started via communication

Communication K 1.00 K 2.01

Characteristic type

Free space for entering information on the description of the user-defined characteristic saved in the device. Can be stored in the field device. For version K 2.02 or higher, when selecting [equal percentage] or [equal percentage reverse], the description text in parameter characteristic type of the device is automatically set to the selection made.

Communication K 2.02 K 2.11

Supports all functions of R 2.11

Type of initialization

For K 2.11 or higher, the default value is "maximum range"

End position when w >

For K 2.11 or higher, the default value is 99 %

EB 8380-1 EN

Positioner versions

Former New

Communication K 2.13 K 2.21

Supports all functions of R 2.21 as well as TROVIS-EXPERT in version 1.0 or higher

Communication K 2.21

K 2.22

Supports all functions of R 2.21 as well as TROVIS-VIEWin version 2.0 or higher

New for model index

3780-

x...x. 01 or higher:

Write protection switch

If this option is activated using the switch, the positioner settings cannot be written over by HART

communication. See section 4.1 for more details on the write protection switch.

Model index

3780-

x...x. 03 or higher are suitable for the extended valve diagnosis using

the TROVIS-EXPERT software.

Positioner versions

Model

3780 -

XXXXX

Explosion protection

Without Ex II 2 G EEx iA IIC T6 as per ATEX CSA/FM Ex II 3 G EEx nA II T6 as per ATEX

0 1 3 8

Additional accessories

Limit switches Without

2 inductive 2 software

0 2 3

Forced venting Without

With

0 1

Position transmitter Without

4...20 mA

0 1

Pneumatic connections

NPT 1/4-18 ISO 228/1-G 1/4

1 2

EB 8380-1 EN

Positioner

Rated travel, adjustable Direct attachm. 5 to 30mm

Attachment acc. to IEC 60534-6 (NAMUR), 5 to 255 mm or 30 to 120° C

Reference variable Two-wire connection, signal range 4 to 20 mA, span 4 to 16 mA

Min. cu rrent = 3 .6 mA , load ≤10.8 V (corresponding to 540 Ω at 20 mA), static destruction limit 500 mA

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

Sign al pres su re (out pu t) 0 ba r t o p ressu re of supp ly ai r

Characteristic, adjustable Linear, equal percentage, reverse equal percentage, user-programmable

Deviation from characteristic ≤1 %

Dea d ban d Adj ustable f rom 0. 1 to 10 %, d efault 0.5 %

Resolution

≤

0.05 %

Transit time to travel Up to 75 s, separately adjustable for exhaust and supply air

Moving direction Reversible, adjustment via software

Air consumption Independent of supply air <90l



Air delivery Actuator filled: for Δp = 6 bar 9.3 m





/h, for Δp = 1.4 bar 3.5 m





Actuator vented: for Δp = 6 bar 15.5 m





/h, for Δp = 1.4 bar 5.8 m





Perm. ambient temperature− 20 to 80 °C, with metal cable gland − 40 to 80 °C

Devices with position transmitter only − 20 to 80 °C For explosion-protected devices, see type examination certificate in appendix

Effects Temperature: ≤0.15 %/10 K, supply: none, vibrations: none up to 250 Hz and 4 g

Explosion protection EEx ia IIC T6, see type examination certificate

Degree of protection IP 65 by using the filter check valve included

Electromagnetic compatibility

Requirements stipulated in EN 61000-6-2, EN 61000-6-3 as well as NAMUR Recommendation 21 have been met

Electrical connections 1 cable gland M20x1.5, black plastic;

other threaded hole M20x1.5 available

Fault alarm output For connection to switching amplifier acc. to EN 60947-4-6, static destruction limit 16 V

Forced venting (model index .03 or higher)

Activated/deactivated by a switch inside case Input: 6...24 V DC, R



appr ox . 6 kΩ, at 24 V D C ( de pendin g o n volta ge ), swit ch ing poi nt

for "1" signal at ≥ 3 V, si gnal "0 " o nl y at 0 V, K



val ue 0.17; st at ic dest ru ction l im it 45 V

Technical data

EB 8380-1 EN

Communication

Hardware requirements SAMSONs TROVIS-VIEW Operator Interface (see Data Sheet T 6661 EN) or handheld

communicator, e.g. Type 275 by Rosemount Integration of other operator interfaces, e.g. DTM, are available

Data transmission HART

Fiel d C om munica ti on Prot oc ol

Impedance in HART

frequency range: receive: 350 to 450 Ω; send: approx. 115

Accessory equipment

Inductive limit switches Two Type SJ 2 SN Prox. Switches for connection to switching amplifier acc. to EN 60947-5-6

Software limit switches Two configurable limit values for connection to switching amplifier acc. to EN 60947-5-6

Switching hysteresis 1%, static destruction limit 16 V

Analog position transmitter

Two-wire transmitter, output 4 to 20 mA Sup pl y: termin al vo ltage 12 to 35 V D C, stat ic de struct io n limit 40 V Direction of action reversible, characteristic linear, operating range: 10 % to + 114 % DC current signal ripple content: 0.6 % at 28 Hz/IEC 381 T1 Resolution ≤0.05 % HF influence <2 % with f= 50 to 80 Mhz Infl ue nce au x. su pply: n on e; temp er ature i nf luence : s ame as p os itione r

Materials

(num be rs acc or di ng to DIN )

Case Di e- cast al um inum, c hr om ed and pl astic- co at ed

External parts: stainless steel 1.4571 and 1.4301

Weight Approx. 1.3 kg

Versions

EB 8380-1 EN

1. Design and principle of operation

The positioner essentially consists of an inductive, non-contact travel measuring system and an electrically controlled valve block comprising two 2/2-way on-off valves and an electronic unit. This unit contains two microcontrollers for processing the control algorithm and managing the communication. Whenever a deviation between the actual valve travel (actual value) and the reference variable (set point) occurs, the microcontroller produces binary pulse-pause modulated signals to control the two 2/2-way on-off valves, each of which is assigned an amplifier. One of these valves controls the exhaust air, and the other one controls the supply air. The supply air valve (3) switches the supply air (7, supply air pressure 1.4 to 6 bar) to the actuator (filling). The exhaust air valve (4) controls the air exhausted from the actuator to the atmosphere (venting). These onoff valves can either have the switching states - permanently open, permanently closed - or generate single pulses of changing widths. With the two valves being controlled, the plug stem moves to a position corresponding to the reference variable. If there is no system deviation, both the supply air and the exhaust air valve are closed.

As a standard feature, the positioner is equipped with a fault alarm output (binary output according to EN 60947-5-6) used to signalize a fault to the control room.

Activating the write protection switch located in the hinged cover prevents the positioner settings from being overwritten by the HART

protocol.

Forced venting function

The positioner is controlled via a 6 to 24 V signal, causing the signal pressure to be applied to the actuator. If this voltage signal decreases, the signal pressure is shut off and the actuator is vented. The springs contained in the actuator move the valve to its fail-safe position. The forced venting function is installed in all positioners from model index .03 or higher. The function can be activated or deactivated by a switch. See section 4.2 (page

34) for more details.

1.1 Options

As a supplement to the standard positioner version, there are several additional options to extend the positioner functions.

Limit switches

To signalize the valves end positions in failsafe circuits, either two software limit switches or two proximity switches can be used.

Position transmitter

The position transmitter is an intrinsically safe 2-wire transmitter controlled by the microcontroller of the positioner. It serves to assign the valve position with the 4 to 20 mA output signal. The position transmitter signalizes both end positions, "valve closed" or "valve fully open", as well as all intermediate positions. Since the valve positions are signalized to the positioner independently of the input signal (minimum current must be observed), the position transmitter is a suitable option for checking the current valve position.

EB 8380-1 EN

Design and principle of operation

1.2 Communication

For communication, the positioner is equipped with an interface for the HART

protocol (Highway Addressable Remote Transducer). Data transmission is accomplished by superimposing an FSK signal (FSK = Frequency Shift Keying) over the existing 4 to 20 mA signal lines for the reference variable.

You can configure and operate the positioner either via HART

-compatible, handheld communicator or via PC, using an FSK modem and an RS-232 interface.

After mechanically resetting the positioner to zero, it can be automatically started up via initialization procedure. During this initialization procedure, zero is automatically adjusted, and the preset span is checked.

Fig. 2 ⋅Functional diagram

11 10

μC

FSK

μC

1 Inductive displacement sensor 2 Microcontroller 3 2/2 way valve for supply air 4 2/2 way valve for exhaust air 5 Microcontroller 6 Pressure regulator 7 Supply air 1.4 to 6 bar 8 Reference variable 4 to 20 mA

with superimposed FSK signal 10 Actuator stem 11 Lever 12 Clamp

EB 8380-1 EN

Design and principle of operation

The positioner is supplied with a standard configuration applying to a valve with 15 mm rated travel, which is designed for integrated positioner attachment.

An individual configuration needed to adapt the positioner to deviating actuators can only be carried out by means of a communicator or a PC with a connected FSK modem, using the HART

protocol.

You can enter the following parameters: control characteristic, direction of action, limitation of travel, travel range, transit time to travel and fault messages.

Operating software



TROVIS-VIEW for devices with firmware K 2.11 or higher, Data Sheet T 6661 EN



IBIS (DOS-based, no longer runs on Windows 2000/ME/XP/NT), see EB 8380-2 EN for more details



DMT 1.2 and PACTware



Integration e.g. Fisher AMS, Siemens PDM, etc.

Handheld communicator DD-based handheld communicators, e.g. Fisher-Rosemount HART

Communica-

tor.

EB 8380-1 EN

Design and principle of operation

2. Attachment to the control valve

The positioner can be attached either directly to a SAMSON Type 3277 Actuator, or according to Namur (IEC 60534-6), to control valves with cast yokes or rod-type yokes.

In combination with an intermediate piece, the device can also be attached as rotary positioner to rotary actuators.

Since the standard positioner unit is delivered without accessories, the required mounting parts and their order numbers have to be derived from the tables.

Note!

For quick-acting control valves with a small travel volume (transit time < 0.6 s), it might be necessary to replace the filter installed in the output pressure bore with a screw-in throttle to obtain good control properties. For further information, refer to sections

2.1, 2.2 and 2.3.

Caution!

The positioner does not have a venting plug. Instead the air is exhausted via venting plugs on the mounting parts (see also Fig. 3, 5 and 7). A filter check valve for the exhaust air is supplied with every positioner (located underneath a transparent cover at the back of the positioner). Use this filter check valve in place of the standard venting plug included in the accessories. The IP 65 degree of protection to prevent dirt and moisture entering the device is only achieved when this filter check valve is used.

EB 8380-1 EN

Attachment to the control valve

2.1 Direct attachment to Type 3277 Actuator

For the selection of the required mounting parts, refer to Tables 1, 2 and 3 (page 17).

When looking at the signal pressure connection or the switchover plate (Fig. 3) from the top, the positioner must be attached to the left side of the actuator. The

arrow

on the

black case cover (Fig. 12) should then point

towards

the

diaphragm chamber.

Exception:

Control valves in which the plug closes the seat area when the actuator stem retracts. In this case, the positioner has to be attached to the right side of the yoke, i.e. with the arrow pointing away from the diaphragm chamber).

1. First screw the clamp (1.2) to the actua-

tor stem. Make sure the fastening screw is located in the groove of the actuator stem.

2. Screw the associated lever D1 or D2 to

the transmission lever of the positioner.

3. Fasten distance plate (15) with seal to-

wards the actuator yoke.

4. Place positioner on the plate (15) so

that the lever D1 or D2 will slide centrically over the pin of the clamp (1.2). Then screw on to distance plate (15).

5. Attach cover (16).

Note!

For quick-acting control valves (transit time < 0.6 s), it is necessary to replace the filter installed in the output pressure bore (Output

38) with a screw-in throttle (accessories specified in Table 3).

Actuator with 240, 350 and 700 cm

6. Check whether the tongue of the seal (17) is aligned on the side of the connection block such that the actuator symbols for "Actuator stem extends" or "Actuator stem retracts" match the actuator design. Otherwise, remove the three fixing screws, remove the cover plate (18) and reinsert the seal (17) turned by 180°. When using an

old

connection block, turn the switch plate (19) such that the corresponding actuator symbol is aligned with the arrow.

7. Place connection block with the associated sealing rings against the positioner and the actuator yoke and screw it tight, using the fastening screw. For actuators with fail-safe action "actuator stem retracts", additionally install the ready-made signal pressure pipe between the connection block and the actuator.

Actuator with 120 cm

With Type 3277-5 Actuator with 120 cm

the signal pressure is transmitted via the switchover plate to the diaphragm chamber.

For a rated travel of 7.5 mm, a brass throttle has to be pressed into the seal located in the signal pressure input on the actuator yoke. With 15 mm rated travel, this is only required when the supply air pressure is higher than 4 bar.

6. Remove the vent plug on the back of the positioner and close the side-located signal pressure output (38) with the plug from the accessory kit.

EB 8380-1 EN

Attachment to the control valve

Actuator stem

retracts

Ventin g

"Actuator stem retracts" symbol

With switch plate (formerly)

With seal

(new)

SUPPLY

1817 19

1.2 D2

1.2

Actuator stem retracts

Internal signal pressure connection

Signal pressure connection via piping

1.2 Clamp D 1 Lever D2 Lever 15 Distance plate 16 Cover 17 Seal 18 Cover plate 19 Switch plate

Signal pressure hole

Side view of connection block

Connection block

Mark

"Actuator stem extends" symbol

Switchover plate

Signal pressure input

Signal pressure input, if necessary with brass throttle

Actuator stem extends

Actuator stem

extends

Fig. 3 ⋅Attachment and signal pressure connection for Type 3277 (top) and Type 3277-5 with 120 cm (below)

EB 8380-1 EN

Attachment to the control valve

7. Mount the positioner so that the hole in the distance plate (15) matches the seal located in the hole of the actuator yoke.

8. Align the switchover plate with the corresponding symbol for left attachment according to the marking and screw tight onto the actuator yoke.

Important!

If, with the 120 cm

actuator in addition to the positioner, a solenoid valve or a similar device is attached to the actuator, do not remove the rear M3 screw. In this case, the signal pressure has to be fed from the signal pressure output to the actuator via the required connecting plate (see Table 2). The switchover plate is not used.

Note!

For quick-acting control valves (transit time < 0.6 s), it is necessary to replace the filter installed in the output pressure bore (Output

38) with a screw-in throttle (accessories specified in Table 3).

Filling the spring chamber with air

If the spring chamber of the Type 3277 Actuator must be filled with the air exhausted from the positioner, the spring chamber (version "Actuator stem extends") can be connected to the connection block by means of a tube (see Table 3). To proceed, remove the venting plug in the connection block.

In Type 3277-5 when "Actuator stem retracts" the exhausted air from the positioner is constantly applied to the spring chamber through an internal hole.

EB 8380-1 EN

Attachment to the control valve

Order with every pressure gauge kit: 2 restrictions (1790-6121)

1402-0938 1402-0939

2.2 Attachment according to IEC 60534-6

For the selection of the required mounting parts, refer to Tables 4 and 5 (page 21).

The positioner is attached according to NAMUR using an adapter housing as shown in Fig. 4. The valve travel is transmitted via the lever (18) and the shaft (25) to the bracket (28) of the adapter housing and then to the pin (27a) located at the positioner lever. To attach the positioner, the mounting parts listed in Table 4 are required. Which lever is to be used depends on the rated valve travel. Once the positioner is attached, however, the

arrow

on the black case cover has to

point downwards

away

from the

dia-

phragm actuator

. (

Exception

: Control valves in which the plug closes the seat area when the actuator stem retracts. In this case, the arrow has to point

towards

the dia-

phragm actuator).

Note!

For quick-acting control valves (transit time < 0.6 s), it is necessary to replace the filter installed in the output pressure bore (Output

38) with a screw-in throttle (accessories specified in Table 4).

2.2.1 Mounting sequence

NOTE

Before you mount the parts, load the actuator with air pressure so that the valve is set to 50 % of its travel. This will ensure the exact alignment of the lever (18) and the bracket (28).

Control valve with cast yoke

1. Use countersunk screws to screw the plate (20) to the coupling which connects the plug and actuator stem. With 2100 and 2800 cm

actuators, use ad-

ditional mounting bracket (32).

2. Remove rubber plug from the adapter housing and fasten the housing to the NAMUR rib, using the hexagon head screw.

Control valve with rod-type yoke

1. Screw plate (20) to the follower clamp of the plug stem.

2. Screw studs (29) into the adapter housing.

3. Place the housing with the plate (30) on either the right or left side of the valve rod and screw the housing tight by using nuts (31). While doing so, make sure that lever (18) to be mounted subsequently is horizontal (when the valve is at midtravel).

4. Screw the pin in a hole in the center row of holes in the plate (20) and lock it such that it will be located above the correct lever marking (1 to 2) for the assigned travel, see Table 5. Intermediate values must be calculated. Beforehand,

EB 8380-1 EN

Attachment to the control valve

1,5

2826

24 25 22

20 19

19 21 2023 18

27b

27a

29 30

Mounting position

Fig. 4 ⋅Attachment according to IEC 60534-6 (NAMUR)

18 Lever N1, N2 19 Pin 20 Plate 21 Clamp 22 Clamping plate 23 Screw 24 Pointer 25 Shaft 26 Lever of positioner 27a Coupling pin 27b Lock nut 28 Bracket 29 Studs 30 Plate 31 Nuts 32 Mounting bracket

Attachment to NAMUR rib

Attachment to rod-type yoke

EB 8380-1 EN

Attachment to the control valve

move the clamp (21) to surround the pin.

5. Measure the distance between the center of the shaft (25) and the center of the pin (19). You will be prompted for this value subsequently during the configuration of the positioner.

2.2.2 Presetting the valve travel

1. Adjust the shaft (25) in the adapter housing so that the black pointer (24) is aligned with the casted marking on the adapter housing.

2. Screw tight clamping plate (22) in this position, using a screw (23).

3. Screw in the pin (27) at the positioner lever (26) and secure it with a hex nut on the opposite side. Note the mounting position A or B respectively according to Table 5 and Fig. 5.

4. Put the positioner to the adapter housing such that the pin (27) will lie properly within the arms of the bracket (28). To do so, insert a 2.5 mm Allen key or a screwdriver from the front into the hole located below the oblong hole on the cover plate, and push the positioner lever in the required position.

5. Screw the positioner to the adapter housing.

6. Relieve the actuator from the signal pressure.

EB 8380-1 EN

Attachment to the control valve

Ta bl e 4

Attachment acc. to IEC 60534-6 Control valve Travel in mm With lever Order no.

NAMUR mounting kit

Parts illustrated in Fig.4

Valve with cast yoke

7.5 to 60 N1 (125 mm) 1400-6787

30 to 120 N2 (212 mm) 1400-6789

Valve with

rod-type yoke

with

rod diameter

in mm

20 to 25 N1 1400-6436

20 to 25 N2 1400-6437

25 to 30 N1 1400-6438

25 to 30 N2 1400-6439

30 to 35 N1 1400-6440

30 to 35 N2 1400-6441

Attac hm ent to F is he r and M as on eilan l inear a ct uators (o ne each of bo th mo unting ki ts is needed per one actuator)

1400-6771

and

1400-6787

Accessories

Order no.

Pre ss ure gau ge mo unting bl ock G 1/4

1/4 N PT

1400-7458 1400-7459

Pre ss ure gau ge set St. s t. /Brass

St. st./St. st.

1400-6957 1400-6958

Signal pressure throttles (screw-in type and brass throttle) 1400-6964

Filter check valve, replaces venting plug and increases the degree of protection to IP 65 (one in cluded wi th the d el ivere d p os itione r)

1790-7408

Table 5

Attachment according to IEC 60534-6

Travel in mm *) 7.51515303060306060120

Pin on marking *) 1 12121212

Corresp. distance pin/lever fulcrum 42 428442848416884168

With lever N1 (125 mm in length) N2 (212 mm in length)

Transmission pin (27) on position A A B A B

*) Deviating travel values (intermediate values) must be calculated accordingly.

EB 8380-1 EN

Attachment to the control valve

2.3 Attachment to rotary actuators

For the selection of the required mounting parts, refer to Table 6 (page 25).

The positioner can also be attached to rotary actuators in accordance with VDI/VDE 3845 by using the mounting parts and accessories listed in Table 6. In this arrangement, the actuators rotary motion is converted via the cam disk on the actuator shaft and the feeler roll of the positioner lever to a linear motion required by the positioners inductive displacement sensor system.

Each cam disk is suitable for two characteristics, i.e. for the ranges of angle of rotation from 0 to 90° (recommended for angles below 90°) and 0 to 120° (recommended for 90° and greater).

For double-acting, springless rotary actuators, it is necessary that a reversing amplifier be attached to the positioner on the side of the connection. (See section 2.3.4.)

If the positioner is attached to a SAMSON Type 3278 Rotary Actuator, the air exhausted from the positioner is admitted to the inside of the actuator and the chamber behind the diaphragm. No additional piping is required. If the positioner is attached to actuators of other manufacturers (NAMUR) the air is applied to the chamber behind the diaphragm through a tube assembly and a tee, connected between actuator and intermediate piece.

Note!

For quick-acting control valves (transit time < 0.6 s), it is necessary to replace the filter installed in the output pressure bore (Output

38) with a screw-in throttle (accessories spe-

cified in Table 6).

2.3.1 Mounting the cam follower

roll lever

1. Place lever with the attached roll (35) on the side of the transmission lever (37) and secure it with the enclosed screws (38) and washers.

2.3.2 Mounting the intermediate

piece

SAMSON Type 3278 Actuator:

1. Screw adapter (36) to the free end of the rotary actuator shaft with two screws.

2. Place the intermediate piece (34) on the actuator case and fasten with two screws. Align intermediate piece of the positioner so that the air connections of the positioner will face towards the diaphragm case side.

Actuators according to VDI/VDE 3845

1. Place the complete intermediate piece (34, 44, 45 and 42) onto the mounting bracket included in the delivery (fixing level 1 VDI/VDE 3845) and screw tight.

2. Align the cam disk (40) and scale (39) as described in section 2.3.3 and fasten tight.

With springless actuators, the reversing amplifier must be screwed to the side of the positioner case. See section 2.3.4 for more details.

EB 8380-1 EN

Attachment to the control valve

Fig. 5 ⋅Attachment to rotary actuators

3835

39 40

42 43

Attachment to SAMSON Type 3278

Attachment acc. to VDI/VDE 3845

Vent plug or filter check valve

33 Positioner 34 Intermediate piece 35 Lever w. cam follower roll 36 Adapter 37 Transmission lever 38 Screws 39 Scale 40 Cam disk 41 Actuator shaft 42 Plate 43 Bracket 44 Coupling 45 Seal

EB 8380-1 EN

Attachment to the control valve

2.3.3 Aligning and mounting of the cam disk

In rotary actuators with spring-return mechanism, the built-in actuator springs determine the fail-safe position and the direction of rotation of the control valve (either counterclockwise or clockwise). With double acting, springless rotary actuators, the direction of rotation depends on both the actuator and the valve model used. Any adjustments are only permitted when the valve has been closed. The direction of action of the positioner, i.e. whether the valve shall either open or close when the reference variable increases, has to be software-adjusted via the communication (increasing/increasing or increasing/decreasing direction of action).

1. Position the cam disk with the scale on the adapter (36) or the coupling (44) and fasten the screw loosely at first.

The cam disk carries two cam sections. The starting point of each section is marked by a small bore.

Note!

With the valve closed, the starting point (bore hole) of the respective characteristic is to be aligned so that the center of rotation of the cam disk, the 0° position on the scale, and the arrow mark on the disk are aligned. The starting point when the valve is closed should not under any circumstances be below the 0° position!

With actuators with fail-safe position "Valve OPEN", the maximum signal pressure must be applied to the actuator before aligning the cam disk. With springless actuators, the supply air must be connected.

2. In aligning the cam disk, clip on the double-sided scaled disk in such a way that the valve on the scale will correspond to the direction of rotation of the control valve. Only then, secure the cam disk with the fastening screws.

Securing the aligned cam disk

If the cam disk should be additionally secured to prevent it from being turned, proceed as follows:

Choose one of the four bore holes located centrically around the center bore on the cam disk which is suitable to secure the cam disk. Drill a hole in the adapter (36) or coupling (44) through the selected hole so that a 2 mm dowel pin can be inserted in this hole.

3. Attach the positioner to the intermediate piece (34) so that the lever (35) contacts the cam disk with its cam follower roll. To do so, insert a 2.5 mm hexagon socket key or a screw driver from the front into the bore hole which can be seen below an oblong hole on the cover plate and bring the positioner lever in the required position.

4. Screw the positioner onto the intermediate piece.

EB 8380-1 EN

Attachment to the control valve

Fig. 6 ⋅Aligning the cam disk

Ta b le 6

Rotary actuators (Complete mounting parts, but without cam disks)

SAMSON Type 3278 Actuator Attachmt. acc. to VDI/VDE 3845 Attachment to Masoneilan actuator

Actuator

160 cm



Actuator

320 cm2

Camflex I

DN 25 ...100

Camflex I

DN 125...250

Camflex II

Order no.

1400-7103 1400-7104 1400-8815 1400-7118 1400-7119 1400-7120

Pip in g kit 8 x 1 st ai nl. st ee l

G 1400-6670 1400-6672

NPT 1400-6669 1400-6671

Accessories

Order no.

Reversing amplifier for double-acting, springless actuators G: 1079-1118 NPT: 1079-1119

Cam disk (0050-0089) with accessories, angle of rotation 0 to 90° and 0 to 120° 1400-6959

Cam disk (0050-0089) especially for VETEC, adjustable to 0 to 75° via software 1400-6960

Cam disk (0050-0090) especially for Camflex, adjustable to 0 to 50° via software 1400-6961

Pressure gauge mounting block G 1/4: 1400-7458 1/4 NPT: 1400-7459

Pressure gauge set St. st./Br.: 1400-6957 St. st./St. st.: 1400-6958

Signal pressure throttles (screw-in type and brass throttle) 1400-6964

Filt er check v alve, r ep laces v enting pl ug and i nc rease s t he degre e o f p ro tectio n t o I P 6 5 (one included with the delivered positioner)

1790-7408

Cam follower roll

Starting point

Holes to secure cam disk

Insert clip and then press

tongues outwards!

Control valve opens

counterclockwise

View onto actuator shaft from positioner

Control valve opens

clockwise

EB 8380-1 EN

Attachment to the control valve

2.3.4 Reversing amplifier for double-acting actuators

For the use with double-acting actuators, the positioner must be fitted with a reversing amplifier. The reversing amplifier is listed as an accessory in the Table 6 on page 25.

The output signal pressure of the positioner is supplied at the output A

of the reversing amplifier. An opposing pressure, which equals the required supply pressure when added to the pressure at A

is applied at

output A

. The rule A1 + A2 = Z applies.

Mounting

Note!

Prior to attaching the reversing amplifier, remove the sealing plug (1.5). The rubber seal (1.4) must remain installed.

1. Screw the special nuts (1.3) from the ac-

cessories of the reversing amplifier into the threaded connections of the positioner.

2. Insert the gasket (1.2) into the recess of

the reversing amplifier and push both the hollowed special screws (1.1) into the connecting boreholes A1 and Z.

3. Place the reversing amplifier onto the

positioner and screw tight using both the special screws (1.1).

4. Screw the enclosed filter (1.6) into the

connecting boreholes A1 and Z using a screwdriver (8 mm wide).

Signal pressure connections

: Output A1 leading to the signal pressure connection at the actuator which opens the valve when the pressure increases

: Output A2 leading to the signal pressure connection at the actuator which closes the valve when the pressure increases



Enter the actuator as "Double-acting without spring-return mechanism" in the user interface under Start-up → Actuator type.

2.4 Fail-safe action of the actuator

Note!

If the fail-safe action of the actuator is changed subsequently by modifying the actuator springs from "Actuator stem extends" to "Actuator stem retracts", the mechanical zero must be readjusted and the positioner must be re-initialized.

EB 8380-1 EN

Reversing amplifier for double-acting actuators

1.3 1.2 1.1 1

Output 38 Supply 9

1.5 1.6

1.4

Output 38 Supply 9

1.3 1.21.1

1.6

Fig. 7 ⋅Mounting a reversing amplifier

Control signals

to the actuator

1 Reversing amplifier

1.1 Special screws

1.2 Gasket

1.3 Special nuts

1.4 Rubber seal

1.5 Plug

1.6 Filter

From the positioner

EB 8380-1 EN

Reversing amplifier for double-acting actuators

3. Connections

3.1 Pneumatic connections

The air connections are either 1/4 NPT or G 1/4 tapped holes. The customary fittings for metal and copper tubes or plastic hoses can be used.

Note!

The supply air has to be dry and free from oil and dust. The maintenance instructions for upstream pressure reducing stations must be observed. Carefully blow through all air tubes and hoses before connecting them.

If the positioner is attached directly to the Type 3277 Actuator, the connection of the positioners output pressure to the actuator is fixed. For Namur attachment, the signal pressure can be applied to either the upper or lower diaphragm chamber of the actuator, depending on the actuators fail-safe position.

Exhaust air:

The exhaust air connection of the positioner is located in the mounting kit. If the positioner is attached directly, a vent plug is located in the plastic cover of the actuator. For Namur attachment, it is in the adapter housing and for attachment to rotary actuators, it will either be located in the intermediate piece or in the reversing amplifier.

3.1.1 Pressure gauge

To monitor the positioner operation, we recommend connecting a pressure gauge for supply air and signal pressure. These parts are listed as accessories in Table 3, 4 or 6.

Nut Throttle with filter (1790-6121)

Fig. 8 ⋅Attaching the pressure gauge

2...3mm

EB 8380-1 EN

Connections

3.1.2 Supply air pressure

The required supply air pressure depends on the bench range and the actuators failsafe action. The bench range is registered on the nameplate either as spring range or signal pressure range.

Actuator stem extends:

required supply air pressure = upper bench range value + 0.2 bar at least 1.4 bar.

Actuator stem retracts:

for tight-closing valves, the signal pressure p

st max

is roughly estimated as follows:

pst

max

= F +

⋅ π ⋅ Δp

4 ⋅ A

[bar]

d = Seat diameter [cm]

p = Differential pressure p



 p [bar]

A = Actuator area [cm



]

F = Upper bench range value of the actuator [bar]

If there are no specifications, calculate as follows:

required supply air pressure = upper bench range value + 1 bar

3.2 Electrical connections

As far as the electrical installation of the device is concerned, the relevant national regulations governing the installation of electrical equipment and the national accident prevention regulations of the country of destination must be adhered to. In Germany, these are the VDE regulations and accident prevention regulations of the employers liability insurance. For installation in hazardous areas, the following standards apply: EN 60079-14: 1997; VDE 0165 Part 1/8.98 "Electrical apparatus for explosive gas areas" and EN 50281-12: VDE 0165 Part 2/11.99 "Electrical apparatus for use in the presence of combustible dust". For intrinsically safe electrical apparatus that are certified according to the Directive 79/196/EEC, the data specified in the certificate of conformity apply for connection of intrinsically safe circuits. For intrinsically safe electrical apparatus that are certified according to the Directive 94/9/EC, the data specified in the EC type examination certificate apply for connection of intrinsically safe circuits.

Note:

It is absolutely necessary to keep to the terminal plan specified in the certificate. Reversal of the electrical connections may cause the explosion protection to be ineffective!

EB 8380-1 EN

Connections

Note on the selection of cables and wires:

To run several intrinsically safe circuits in a multi-core cable, read paragraph 12 of EN 60039-14; VDE 0165/8.98. For generally used insulating materials, for example polyethylene, the radial thickness of the conductor insulation has to be at least

0.2 mm. The diameter of a single wire in a flexible conductor shall not be smaller than

0.1 mm. The conductor ends are to be protected against unlaying, e.g. by using wire end ferrules. If the positioner is connected via two separate cables, an additional cable gland can be mounted. Wire entries left unused must be sealed with caps.

Cable entries

The cable entry with M20x1.5 cable gland, 7 to 12 mm clamping range.

There is a second M20x1.5 cable gland in the housing that can be used for additional connection, if required.

The screw terminals are designed for wire cross-sections of 0.2 to 2.5 mm

. Tighten by

at least 0.5 Nm. The wires for the reference variable are to

be connected to the terminals 11 and 12 located in the case as shown in Fig. 9. Make sure to connect the appropriate poles. The voltage applied must not exceed 15 V.

Caution!

If the poles are connected incorrectly, just 1.4 V is sufficient to reach the static destruction limit of 500 mA.

The + and  socket contacts allow a communication to be connected locally.

Supply voltage for position transmitter

Control signal i

Limit switches

Fault alarm

Forced

venting

Communication

6 to 24 V DC

Fig. 9 ⋅Electrical connections

GW2 GW1

PE –12+11 –52+51 –42+41 –82+810 –32+31–84+83

–

+–

Switching amplifier

acc. to EN 60947-5-6

EB 8380-1 EN

Connections

In general, it is not necessary to connect the positioner to a bonding conductor (0). Should there be the need, however, this conductor can be connected either to the inside or outside of the case. For plants in hazardous areas, see paragraph 5.3.3 of VDE standard 0165.

Depending on the supplied version, the positioner is equipped with either inductive limit switches, software limit switches and/or forced venting function. All electric circuits are electrically isolated.

In versions with position transmitter, the built-in transmitter is operated in a two-wire circuit. With regard to the resistance of the supply lead, the voltage at the position transmitter terminals must not be lower than 12 V and not higher than 35 V DC. Terminal assignment is shown in Fig. 9 and is indicated on the cover plate inside the case cover.

Accessories:

Model index 3780-x...x. 0

Cable gland PG 13.5: Black Order no. 1400-6781 Blue Order no. 1400-6782

Adapter PG 13.5 on 1/2" NPT: Metallic Order no. 1400-7109 Blue finish Order no. 1400-7110

Model index 3780-x...x. 02 or higher Cable gland M20 x 1.5:

Black plastic Order no. 1400-6985 Blue plastic Order no. 1400-6986

Adapter M20 x 1.5 on1/2" NPT: Aluminum powder-coated

Order no. 0310-2149

3.2.1 Switching amplifiers

For operation of the limit switches and the fault alarm output, switching amplifiers complying to EN 60947-5-6 have to be connected in the output circuit. If the positioner is to be installed in hazardous areas, the relevant regulations are to be observed.

EB 8380-1 EN

Connections

3.2.2 Establishing communication

Communication between PC and positioner via FSK modem or communicator, if necessary, using an isolating amplifier is based on the HART

protocol.

Viator FSK modem RS-232 EEx ia  Order no. 8812-0129 RS-232 not Ex  Order no. 8812-0130 PC MCIA  Order no. 8812-0131 USB not Ex  Order no. 8812-0132

If the supply voltage of the controller or control station becomes too low because it has been reduced by the load in the circuit, an isolating amplifier is to be connected between controller and positioner (interfacing same as for positioner connected in hazard-

ous areas, see Fig. 10). If the positioner is used in hazardous areas, an explosion-protected isolating amplifier is to be used. Connection of an FSK bus always requires interfacing of isolating amplifiers. By means of the HART

protocol, all control room and field devices connected in the loop are accessible through their address via point-to-point or standard bus (multidrop).

Point-to-point:

The bus address/polling address must always be set to zero (0).

Standard bus (multidrop):

In the standard bus (multidrop) mode, the positioner follows the analog current signal (reference variable) as for point-to-point

Communicator or 2nd FSK modem (explosion-protected design)

FSK modem

Non-haz. area Hazardous area

3780

3780–1

PC RS 232

Controller/ control station

Controller/control station

Communicator or 2nd FSK modem

4 to 20 mA

FSK modem

Ex isolating amplifier

Connection in hazardous areas

Connection in non-hazardous areas

Fig. 10 ⋅Connection with FSK modem

EB 8380-1 EN

Connections

communication. This operating mode is, for example, suitable for split-range operation (series connection) of positioners. The bus address/polling address has to be within a range of 1 to 15.

Connect the FSK modem to the interface of the PC. If several interfaces are available, the selected interface may have to be configured over the user interface.

Note: Communication faults

may occur when the process controller/control station output is not HART

compatible. For adaptation, the Z box, order no. 1170-2370, can be installed between output and communication interface. At the Z box a voltage of approx. 330 mV is released (

16.5 Ω at 20 mA). Alternatively, a 250-Ω resistor can be connected in series and a 22-μF capacitor can be connected in parallel to the analog output. Note that in this case, the controller output load will increase.

22 μF

250 Ω

Controller/ control station

Fig. 11 ⋅Adapting the output signal

EB 8380-1 EN

Connections

4. Operation

Caution!

Before taking the positioner into operation, carefully move the control valve to its end position by covering the hole (manual adjustment) on the cover plate (Fig. 12). Check whether the lever mechanism functions properly. If the wrong lever is used or the lever mechanism does not function properly, the valve will exceed the maximum permissible angle of rotation, which can destroy the positioner.

4.1 Write protection

A sliding switch is located inside the hinged cover.

When it is activated (position 1), the positioner settings are write-protected so that they cannot be overwritten by the HART

protocol. If you want to change the settings via communication, set the switch to 0 position.

4.2 Activate/deactivate forced venting function

Model index .03 or higher

1. Remove cover inside the positioners lid by unscrewing the four screws.

2. Loosen the screw in the center of the board and swivel out the board.

3. Set switch to desired position 1 ENABLED > Function activated 2 DISABLED > Function deactivated.

Arrow for

mounting position

Manual adjustment

Zero point lever

Pointer

Adjustment screws GW (option)

Metal tags

Key for initialization or zero calibration

Write protection switch

GW1

GW2

Initialisierung / Nullabgleich

Iintialization / Zero adjustm.

Initialistation / Tarage zéro

Inicialización / Puesta acero

Vorsicht !

Caution !

Attention !

Atención

Ventil wird verstellt

Valve actuates

Vanne en mouvement

La válvula actua

Schreibgeschützt

Write protected

Protégé en écriure

Fig. 12 ⋅Inside view of cover plate

EB 8380-1 EN

Operation

4.3 Default setting

All parameters are set to default values. See section 8 for a description of parameters.

Note!

Manual operation and activated final position functions can cause the actuator to be filled with the maximum supply pressure. Should this lead to impermissible forces occurring, the supply pressure must be restricted by a reducing station.

4.3.1 Adjusting mechanical zero point

Note!

Zero must be adjusted with the valve completely closed (for three-way valves with the actuator stem extended).



Firmly push the zero point lever, which is located in the cover plate of the positioner, once in the direction indicated by the arrow, as far as it will go. The yellow pointer will then be on the white marking line.

For control valves with the starting position OPEN, e.g. an actuator employing fail-safe action "actuator stem retracts", it is first necessary to supply the positioner with auxiliary air. If the manual operation function is activated then, the signal pressure builds up and the valve moves to the closed position. Subsequently, the zero point lever can be operated.

4.3.2 Initialization

After the electric reference variable and the auxiliary supply pressure have been connected to the positioner, the initialization process can be started. In this process, the positioner adapts itself optimally to the mechanical conditions (friction) and signal pressure requirements of the control valve.

See list of parameters on page 48 for required changes of the proportional-action coefficient KP_Y1 and KP_Y2.

Caution!

The initialization process takes several minutes. During that time the valve leaves its position. Therefore, never initialize the positioner during a running process, but only during the start-up cycle when the shut-off valves in the plant are closed, or when the control valve with the positioner has been removed from the plant and is used on a test stand.



Enter data on valve and actuator under "Start-up" in the operating software.



Set "Type of initialization" to "Rated range", select "Maximum range" only for three-way valves.



Start initialization.



When the initialization process is completed, perform configuration suitable for the type of valve.

The following setting is recommended:

EB 8380-1 EN

Operation



Fail-safe position "Actuator stem extends"

(FA): Direction of action: increasing/increasing (>>), the globe valve opens with increasing reference variable Final position at a reference variable less than 1% (tight closing), Final position at a reference variable larger than 125 % (function deactivated).



Fail-safe position "Actuator stem retracts"

(FE): Direction of action: increasing/decreasing (<>), the globe valve closes with increasing reference variable Final position at a reference variable less than −2.5% (function deactivated), Final position at a reference variable larger than 99 % (tight closing).



Set delay time to 30 s at the minimum.



Enter tag identification.



If necessary, other configuration, e.g. special characteristics for rotary valves.

If there is

no communication

set up on the valve, initialization directly at the valve is also possible.



Connect positioners that are not mounted on a valve to a power supply and initialize the positioner as described in section 4.3.2. If communication is not possible, the default setting must be used.



Mount positioner and set the mechanical zero point as described in section

4.3.1.



Start initialization by pressing the

Init/Zero

key on the positioner hinged

cover using a suitable tool.

The initialization is completed when the positioner takes on the position predetermined by the reference variable.

Note!

After the positioner has been initialized successfully for the first time, pressing the

Init/Zero

key subsequently only starts a

zero calibration.

A new initialization routine can only be started after this when communication is connected.

A completed initialization can be cancelled via the communication with the command "Reset to default values". After this, the Init/Zero key can be pressed to start a complete initialization.

Electric zero calibration

If, during the valves operation, the mechanical zero has shifted, an electric zero calibration can be carried out. To do this, press the Init/Zero key located on the inside of the cover (Fig. 12).

Caution!

The control valve moves to its final position.



Firmly press the zero lever, located on the cover plate of the positioner, in the direction indicated by the arrow as far as it will go once. The yellow pointer will then be aligned with the white line.



Press the key again to start the electric calibration.

After the key is pressed twice, it is locked for approximately one minute!

EB 8380-1 EN

Operation

The electric calibration has been completed when the positioner takes on the position predetermined by the reference variable.

4.4 Adjusting inductive limit switches

The positioner version with inductive limit switches has two adjustable tags that are mounted on the shaft of the positioner lever and operate the associated proximity switches.

For operation of the inductive limit switches, the corresponding switching amplifiers have to be connected to the output (see section

3.2.1). If the tag is in the inductive field of the switch, the switch assumes a high resistance. If the tag is out of the field, the switch assumes a low resistance.

Normally, the limit switches are adjusted such that they will provide a signal in both end positions of the valve. These switches, however, can also be adjusted to signalize intermediate valve positions.

The desired switching function, i.e. whether the output relay shall be picked up or released when the tag has entered the field, has to be selected, if necessary, at the switching amplifier.

Adjusting the switching point:

The limit switches are marked GW1 and GW2 on the inside of the case cover. Yellow tags and the associated adjustment screws (Fig. 12) are located below these markings. Each switching position can optionally be signalized when the tag has entered the field, or when it has left the field.



Move the valve to the switching position and adjust the tag of the required limit switch GW1 or GW2 by turning the related adjustment screw until the switching point is reached. This is indicated by the LED at the switching amplifier.

In so doing, one edge of the yellow tag will be in alignment with the white, horizontal line on the case cover. This indicates the side from which the tag enters the inductive field of the proximity switch.

To ensure safe switching under any ambient conditions, the switching point should be adjusted to a value of approx. 5% before the mechanical stop (OPEN - CLOSED).

EB 8380-1 EN

Operation

5. Maintenance

The positioner is maintenance-free. The pneumatic connection 9/Supply features a filter with 100 μm mesh size. If required, the filter can be unscrewed and cleaned.

The maintenance instructions for any upstream air pressure reducing stations for supply air must be observed.

6. Servicing explosion-protected versions

In the event that a positioners part on which the explosion protection is based must be serviced, the positioner must not be put back into operation again until an expert has inspected the device according to explosion protection requirements, has issued a certificate stating this, or given the device a mark of conformity.

Inspection by an expert does not have to be carried out, if the manufacturer performs a routine check test on the device prior to taking it into operation again, and the success of the routine check test is documented by attaching a mark of conformity to the device.

Explosion-protected components may only be replaced by original checked components from the manufacturer.

EB 8380-1 EN

Maintenance

7. Summary of parameters

The list of parameters describes - in alphabetical order - all parameters of the Type 3780 Positioner that can be transferred via HART

communication and displayed or modified on a

PC, a handheld communicator, or a similar device.

Device identification

 MSR no./bus identification  Manufacturer  Type number controller Product number controller  Serial number controller  Hardware version electronics/mechanics  Firmware version communication/control HART

universal revision, field device revision  Number of required preambles  Bus address/polling address  Message/loop tag identification/numbers  Description/plant identification Date Type of protection  Identification of the options forced venting, contacts, position transmitter  Ident. number actuator  Ident. number valve  Text field, not allocated

Start-up

 Actuator type  Attachment Model  Mounting position  Rated travel/nominal angle Transmission code/length/pin position  Initialization related to nominal range /maximum range  Fail-safe position

EB 8380-1 EN

Summary of parameters

 Minimum control pulses  Minimum transit time on/off  Initialization cycle

Device settings

Configuration

 Reference variable range  Final position with reference variable below preset value  Final position with reference variable above preset value  Travel range/angle of rotation  Limitation of travel range / angle of rotation  Moving direction  Selection of characteristic  User-defined characteristic with 11 co-ordinates  Required transit time on/off  Limit values for software limit switches GW1/GW2  GW1/GW2 on when the respective limit value is exceeded/not attained  Operating direction position transmitter  Write protection

Parameters

 Dead band Xtot  Proportional-action coefficient KP_Y1/KP_Y2  Derivative-action coefficient KD  Tolerated overshoot

Operation

Operating mode  Reference variable w_analog  Reference variable w_manual  Reference variable w  Controlled variable x  Error e  State fault message

EB 8380-1 EN

Summary of parameters

 State software limit switches GW1/GW2 Forced venting function

Diagnostics

 Device status (control loop monitoring, zero point monitoring, etc.)  Total valve travel  Limit value total valve travel  Error monitoring tolerance band/lag time  Fault message in case of communication fault Fault message with controller in special function  Fault message if limit value for total valve travel is exceeded  Test of fault indication output  Test of position transmitter  Test of software limit switches GW1/GW2  Zero adjustment

EB 8380-1 EN

Summary of parameters

8. List of parameters

Actuator id number

Range:

Manufacturers identification (id) number of the actuator and the positioner. 0 to 999 999

Actuator type

----

States: Default (coldstart value):

Linear actuator/rotary actuator Linear actuator

Angle range End

Uppe r l imit of th e e ff ec tive wo rk ing ran ge (o penin g a ngle). Fo r a non-li near ch ar acteri st ic, the characteristic is adapted to the reduced angle. If in it ializa ti on is ba se d o n "maxi mu m r ange" , t he angle r ange is al ways re lated t o t he entered nominal angle. The working range may not be selected 1/4 less than the nominal angle. Maximum value = nominal angle.

Range: Default (coldstart) value:

0.0 degrees to 120.0 degrees

90.0 degrees

Angle range Start

Lowe r l imit of th e e ff ec tive wo rk ing ran ge (o penin g a ngle). Fo r a non-li near ch ar acteri st ic, the characteristic is adapted to the reduced angle. If in it ializa ti on is ba se d o n "maxi mu m r ange" , t he angle r ange is al ways re lated t o t he entered nominal angle. The working range may not be selected 1/4 less than the nominal angle.

Range: Default (coldstart) value:

0.0 degrees to 120.0 degrees

0.0 degrees

Attachment

Defi nes the po si tioner at ta chment to th e contr ol va lve wi th a linea r a ct uator. For a r ot ar ymoti o n actuat or, only att achme nt accord ing to VDI / VDE 3845 (NAMUR ) is possible.

States:

Default (coldstart) value:

Integral - Type of attachment in combination with a SAMSON Type 3277 Linear Actuator. NAMUR - Type of attachment according to IEC 60534-6 (NAMUR). Integral

Bus address

Address used by the control station to identify a field device. Changeable by the user: 0 for point-to-point, 1 to 15 for multidrop communication.

Range: Default (coldstart) value:

0 to 15 0 Non-IBIS devices → poll ing add re ss

Bus identification

Text for instrument identification in connection with the field device installation. The text may b e f reely as si gned. We re co mm end to cl ea rly ide nt ify the fi eld dev ic e. For f ie ld bus installation, a bus identification has to be assigned. Length: 8 characters Non-IBIS devices → MSR no.

EB 8380-1 EN

List of parameters

Characteristic

Creation of assignments between the reference variable and valve travel/angle range. When th e equal percen ta ge char ac terist ic is sele ct ed, thi s c harac te ristic is co pied in th e user-defined characteristic, overwriting the previously entered user-defined characteristic. The control loop is interrupted (for approx. 3 seconds) while the characteristic is internally transmitted.

States:

Default (coldstart) value:

User defined - characteristic in accordance with enterable coordinates x[n], y[n], preset to butterfly valve equal percentage Linear  linear characteristic Equal percent.  equal percentage characteristic Equal percent. reverse  equal percentage reverse characteristic Linear

Characteristic co-ordinates x [0] /y [0 ] to x [10] /y [10]

Characteristic co-ordinates for user-defined assignment between reference variable and travel/angle range. x[n] = reference size in % of the reference size range. y[n] = t ravel/ an gle in % o f t ra vel/an gle ran ge . The control loop is interrupted until the characteristic transmission is completed (max. 15 s).

Range: Default (coldstart) :

0.0 % to 100 % For characteristic points: butterfly valve equal percentage.

Date

A date entered according to the European date format [DD.MM.YYYY] can be stored in the field device. The date can be entered as required.

Dead band Xtot

Maximum tolerated deviation between set point value and actual value specified as a percentage of the travel range. A small dead band means a high degree of control accuracy. The smallest possible dead band is determined by the quality of the control valve; high friction and a small actuator volume can otherwise lead to unstable operation.

Range: Default (coldstart) value:

0.0 1 % to 0.00 % o f the nomin al tr avel/nominal angle

0.5 %

Description

Tex t s to red in t he field d ev ice. L en gt h: 16 ch ar acters . For IBIS → plant identification

Direction of action

Dete rm ines th e a ssignm en t o f refe re nc e vari ab le to the tr avel/ an gle of ro ta ti on.

States: >>, Increasing reference variable opens the valve (for three-way valves: Actuator stem

retracts)

<>, Increasing reference variable closes the valve (for three-way valves: Actuator stem extends)

Default (coldstart) value: >>

End position when w: above limit value

If the reference value exceeds the entered limit, the valve moves in the pre-determined end position, corresponding to 100 % of the reference variable. Hysteresis 1 %. When the value is 125 %, the function is deactivated.

Range: Default (coldstart) value:

0 % to 125.0 % 99 %

EB 8380-1 EN

List of parameters

Caution:

Sin ce th e actua to r w ill au to ma ti cally be fi lled ( lo ad ed with ai r) or ven ted (exhausted) when this function is executed, the control valve moves to its absolute end position. Constraints specified in the function "travel range" or "travel limit" are inapplicable here. This function must be deactivated if unacceptably high positioning forces might result from the complete filling/venting action.

End position when w: below limit value

If the reference variable falls below the entered limit, the valve moves in the pre-determined end position, corresponding to 0 % of the reference variable. Hysteresis 1 %. When th e valu e i s  2.5 %, t he fu nction is deacti va ted.

Range: Default (coldstart) value:

2.5 % to 100.0 % 1 %

Caution:

Sin ce th e actua to r w ill au to ma ti cally be fi lled ( lo ad ed with ai r) or ven ted (exhausted) when this function is executed, the control valve moves in its absolute end position. Constraints specified in the function "travel range" or "travel limit" are inapplicable here. This function must be deactivated if unacceptably high positioning forces might result from the complete filling/venting action.

Error e

Control system deviation in %

Error monitoring of delay time

Reset criterion for active control loop monitoring. A control loop fault is reported when an entered delay time is exceeded and the deviation (error) does not lie within the entered tole ra nce ban d. The de lay tim e i s d etermi ne d from t he mi nimum t ra nsit ti me du ring th e initialization process when the detected value exceeds the preset value.

Range: Default (coldstart) value:

0 s to 240 s 10 s

Error monitoring of tolerance band

Reset criterion for active control loop monitoring. Entry of the specified maximum permissible control system deviation (error). See also delay time.

Range: Default (coldstart) value:

0.1 % to10.0 % of nominal travel/nominal angle 5 %

Error variable x

Error variable in % related to travel/angle range.

Ex-proof type

States: Not installed/Installed

Fail-safe action

Fail-safe action of the actuator in the event of air/power failure. This is determined automatically during the initialization process.

States:

Default (coldstart) value:

Unknown ............................if not yet initialized

Actuator stem retracts...........linear actuator

Actuator stem extends ..........linear actuator

Opening .............................rotary actuator

Closing ...............................rotary actuator

None..................................double acting

Unknown

Fault alarm: Communication failure

Fault of the positioner communication hardware

EB 8380-1 EN

List of parameters

States: Default (coldstart) value:

No/Yes Ye s

Fault alarm: Special function

Faul t m essage fo r c ontrol le r in sp ec ia l func ti on (z ero cal ib ratio n, in itiali za tion, t es t functions).

States: Default (coldstart) value:

No/Yes Ye s

Fault alarm: Total valve travel exceeded

Faul t a larm wh en ever th e limit va lu e for th e t ot al valv e t ravel i s e xceed ed .

States: Default (coldstart) value:

No/Yes Ye s

Field device revision

Revision status of the field device-specific description that the field device conforms to.

Firmware version Communication/Control

Revi sion st at us of the com mu ni cation an d contro l s oftwar e i mp lemen te d i n the fi el d devi ce .

Forced venting

States:

Indicates whether the optional forced venting function has been installed. Not installed/Installed

Hardware version electronics/ mechanics

Revision number of the electronics/mechanics implemented in the field device.

Inductive limit switches

For devices without software limit switches you can enter whether inductive contacts were installed (no automatic identification).

States: Default (coldstart) value:

Not installed/Installed Not installed

Initialization (special function)

Automatic start-up. Prerequisite: Mechanical zero point adjustment must have been carried out once. Valid initialization data must have been entered.

Initialization alarm

Message concerning initialization.

States: Unknown

Ok Air leakage of pneumatic system Wr ong selec tion o f rat ed travel or transm ission

KD derivative-action coefficient

Derivative-action coeff. of the differential element. When optimizing the value, increments of 0.02 are recommended. Higher increments cause an increased "deceleration" before rea ch ing the re ferenc e v ariab le .

Range: Default (coldstart) value:

0.0 to 1.00

0.12

Limit switches

Indicates which type of limit switch is installed.

States: Not installed

Inductive  inductive limit switches attached to the internal travel pick-up. Soft wa re  Der iv ed by so ft wa re from th e s ignal o f t he displa cement pi ck-up.

Limit switch Software GW1

Limit value alarm referring to travel/angle range, determined by the software from the signal of the travel (displacement) pick-up. (Switching hysteresis 1%).

EB 8380-1 EN

List of parameters

Range: Default (coldstart) value:

0.0 % to 120 %

2.0 %

Limit switch Software GW2

Limit value alarm referring to travel/angle range, determined by the software from the signal of the travel (displacement) pick-up. (Switching hysteresis 1%).

Range: Default (coldstart) value:

0.0 % to 120 % 98 %

Limit switch Sof tw are GW1 se t w he n

Defines the contact circuit state as ≤1 or ≥3 mA

States: Default (coldstart) value:

≥

3 mA values under range for travel/angle, values over range for travel/angle

values under range

Limit switch Sof tw are GW2 se t w he n

Defines the contact circuit state as ≤1 or ≥ 3 mA

States: Default (coldstart) value:

≥

3 mA values under range for travel/angle, values over range for travel/angle

values over range

Limit value for total valve travel

An alarm message is issued as soon as the limit for the total valve travel is exceeded.

Range: Default (coldstart) value:

0 to 16 500 000 1 000 000

Loop/tag number

Loop /t ag number - t ext that is associ at ed with th e f ield de vice in st allati on . T his tex t c an be used by the user in any way. Each field device is recommended to be assigned a unique loop/tag number. Length: 32 characters For non-IBIS devices →message

Manufacturer

Manufacturers id code - Clearly identifies the manufacturer of the field device.

Message

Unassigned text stored in the field device. Length: 32 characters. For IBIS devices → loop /t ag number.

Minimum control pulses

Sho rte st pu lse su pp lied to th e s upply a ir or exh au st air v al ve. The pu lses f or th e trave l ranges 0 to 20 %, 20 to 80 % and 80 to 100 % are determined separately!

States: None..................................no pulses determined yet

Exhaust air .........................pulse for exhaust air determined

Supply air ...........................pulse for supply air determined

Valid...................................pulse for exhaust and supply air determined

Minimum transit time (filling/venting)

The minimum transit time, in seconds, for filling or venting air from the actuator during initialization is measured separately for supply and vented air. The transit time is defined as the tim e req uired by t he sy stem c omprisin g position er, actuator, and v alve to pa ss th rough the rated travel /nominal angle.

EB 8380-1 EN

List of parameters

Mounting position (linear actuator)

An ar ro w is loc at ed on the c ov er plat e o f t he positi on er, wh ic h is use d f or alig nm ent on t he actuator. This arrow must either point toward the actuator (direct attachment) or away from the actuator (N AMUR at tach ment ). Exception : C ontro l valves for whic h the seat is solely clos ed by a ret ra cting a ct uator st em . In thi s c as e, the ar ro w must p oi nt either aw ay from th e actuator (direct attachment) or toward the actuator (NAMUR attachment). For rotary-type (part-turn) actuators, this parameter is omitted.

States: Default (coldstart) value:

Arrow pointing toward the actuator / Arrow pointing away from the actuator. Integral attachment: Arrow pointing toward the actuator. NAMUR attachment: Arrow pointing away from the actuator.

MSR no.

Text for instrument identification in connection with the installation of the field device. This text can be used by the user in any way. Each field device is recommended to be assigned a unique MSR no. Length: 8 characters. For IBIS devices → bus id entific at ion.

Nominal angle

Nominal working range of the valve.

Range: Default (coldstart) value:

0.0 degrees to 360.0 degrees

60.0 degrees

Nominal travel

Nominal working range of the valve.

Range: Default (coldstart) value:

0.0 mm to 255.0 mm

15.0 mm

Number of (request) preambles

Number of preambles required from the control station requested by the field device.

Operating direction of position transmitter

Determines the operating direction of the optional position transmitter.

States:

Default (coldstart) value:

>>, Increasing controlled variable causes increasing output signal. <>, Increasing controlled variable causes decreasing output signal . >>

Operating mode

Dete rm ines wh et her the re feren ce variab le is sp ec if ied vi a t he analo g c ur rent si gn al (aut om at ic) or v ia th e digit al commun ic at ion (ma nu al). Th e m an ual/a ut om at ic tran sf er is smooth.

States:

Default (coldstart) value: Default (warmstart) value:

Automatic - The reference variable is specified via the analog current signal. Manual - The reference variable is specified via the digital communication by entering w_manual. Fail-safe - The valve moves in the fa il-saf e p os ition. Fail-safe position Automatic

Plant identification

Tex t s to red in t he field d ev ice. L en gt h: 16 ch ar acters For non-IBIS devices → des cr iption

Polling address

Address used by the control station to identify a field device. Changeable by the user: 0 for point-to-point, 1 to 15 for multidrop communication.

EB 8380-1 EN

List of parameters

Range: Default (coldstart) value:

0 to 15 0 For IBIS devices

→

bus address

Positioner type number

Type number of the positioner

Position transmitter

Indicates whether the option position transmitter is installed.

States: Not installed/Installed

Product number

Manu fa cturer s pr oduct n um be r of the po si tioner. Len gt h: 16 cha racter s.

Proportional-action coefficient KP_Y1/ KP_Y2

Proportional-action coefficient KP_Y1 for supply air, KP_Y2 for exhaust air. We recommend to adjust the value in increments of 0.1. If the value is increased, the set point will be attained faster.

Range: Default (coldstart) value:

0.01 to 10.0

1.2

Note:

Pro po rti on al-ac ti on co ef fi cients KP _Y 1/ KP_Y2 ar e deter mi ned whe n t he posi ti on er is initialized for the first time. The initialization values listed in the table below may possibly have to be adapted to the changed operating conditions, in order to attain the best control response.

Type o f

actuator

Nom.

travel/angle

Transit time KD KP_Y1

Filling

KP_Y2

Ventin g

Min. Effect of spring Open Close

Rotary

actuator



 > 0.7 s > 0.7 s 0.12 0.5 0.5

Closes > 0.7 s < 0.7 s 0.12 0.5 0.1

Closes < 0.7 s > 0.7 s 0.12 0.1 0.5

 < 0.7 s < 0.7 s 0.12 0.1 0.1

Opens > 0.7 s < 0.7 s 0.12 0.1 0.5

Opens < 0.7 s > 0.7 s 0.12 0.5 0.1

Linear

actuator

≥

60 m m

< 10 s  0.12 0.5 0.5

≥

10 s  0.12 3.0 4.0

< 60 mm

< 10 s

 > 0.7 s > 0.7 s 0.12 0.5 1.2

Extends > 0.7 s < 0.7 s 0.12 0.5 0.8

Extends < 0.7 s > 0.7 s 0.12 0.3 1.2

 < 0.7 s < 0.7 s 0.12 0.3 0.8

Retracts > 0.7 s < 0.7 s 0.12 0.3 1.2

Retracts < 0.7 s > 0.7 s 0.12 0.5 0.8

≥

10 s  0.12 3.0 4.0

EB 8380-1 EN

List of parameters

Pulse adaptation

Adaptation of the minimum pulses in order to optimize the control algorithm for the system comprising positioner, actuator and valve. In normal control mode the parameter should be set to "Automatic". Disable this parameter when tuning the control parameters. For R 1.20 and upwards, the pulse adaptation is internally set to "Automatic".

States:

Default (coldstart) value:

Disabled Automatic Automatic

Reference variable end

End of the valid input range (corresponding to 100 % w). The minimum span is 4.0 mA.

Range: Default (coldstart) value:

4.00 mA to 20.00 mA

20.00 mA

Reference variable start

Start of the valid input variable (corresponding to 0 % w). The minimum span is 4.0 mA.

Range: Default (coldstart) value:

4.00 mA to 20.00 mA

4.00 mA

Reference variable w

Reference variable in % with consideration of reference variable start and reference variable end.

Reference variable w_analog

Current input signal in mA, used as reference variable in "Automatic" mode.

Reference variable w_manual

Reference variable in mA, adjustable in "Manual" mode via communication.

Range: 3.8 mA to 22 mA

Required transit time (filling/venting)

The transit time is defined as the time required by the system comprising positioner, actuator and valve to pass through the complete rated travel/nominal range. The actual transit time is ex te nded to th e enter ed value. If the req ui red tra ns it time is less th an the min im um transi t time determined during initialization, the minimum transit time shall apply. Separately adjustable for filling and venting.

Range: Default (coldstart) value:

0 s to 75 s 0 s

Scanning rate

Tim e b etween th e start o f t wo re qu ests t o t he po sition er (o nly for IB IS ).

Range: 1 to 3600 s

Serial no.

Uniquely identifies the field device combined with the manufacturer name and the device type number.

State of fault alarm

Switching state of fault alarm output.

States: Off, ≥3 mA

On, ≤1 mA

State of forced venting

If in st alled , t he absen ce of th e inpu t s ig nal for ce s the co nt ro l valve to mo ve in th e appropriate fail-safe position.

States: Forced venting off with control signal >3 V

Forc ed ventin g o n ( i.e. a ct ua to r vent ed ) w ith cont ro l signa l <3 V

EB 8380-1 EN

List of parameters

State of software limit switch GW1/ GW2

Stat e o f t he soft wa re limit sw it ch GW1 or GW 2.

States: Off, ≤1 mA

On, ≥3 mA

Test of fault alarm (special function)

Func ti onal te st of th e fault al arm outp ut by acti va ti ng it th re e times .

Tes t of pos it ion tra ns mitte r (special function)

Tes t o f t he opti on al positi on tr ansmit te r by spe ci fying v al ues in % ( on ly when th e s oftwar e limit switch option is installed).

Test of software limit switch GW1

(special function)

Test of software limit switch GW1 by activating it three times (only when this option is installed).

Te s t o f s of tw a r e l i mi t switch GW2

(special function)

Test of software limit switch GW2 by activating it three times (only when this option is installed).

Te x t f i el d

Unassigned information text to be stored in the field device 4 lines with 32 characters each

To l era te d overshoot

If the error signal e exceeds the overshoot, the pulse adaptation reduces the minimum pulses in the moving direction that has caused the overshoot. If the error signal e exceeds the dead band xtot, but remains within the overshoot range, the puls e adapt at io n only r ed uces th e m inimum pu lses in bo th moving di rectio ns after t wo comp le te osci ll ations wi th in the o ve rshoot ra ng e.

Range: Default (coldstart) value:

0.01 % to 10.00 % of the nominal travel/nominal angle

0.5 %

Total valve travel

Sum of nominal duty cycles. Maximum value: 16 500 000. The value is indicated in double in up-and-down travels, i.e. corresponds to the travel rate determined during initialization multiplied by 2.

Transmission code

(for linear actuator with integral positioner attachment)

Determination of the geometrical code for the travel pick-up when the positioner is integrally attached.

States: Default (coldstart) value:

D1 for actuators 120, 240 and 350 cm2 / D2 for actuator 700 cm2 D1

Transmission code for rotary actuator

Maximum opening (rotational) angle of the selected cam segment.

States: S90, 90 degree segment / S120, 120 degree segment

Transmission code (length) for linear actuator acc. to NAMUR

Lever length, distance between the travel pick-up and pivot of the pick-up lever.

Range: Default (coldstart) value:

0.0 mm to 1023.0 mm

42.0 mm

EB 8380-1 EN

List of parameters

Transmission pin position

Pin position of the positioner lever. See marking on the positioner lever. Onl y f or at tachme nt to linea r a ct uator a cc . t o N AM UR .

States: Default (coldstart) value:

A/B A

Travel/angle limit lower

Lowe r l imitat io n o f valve tr avel/ an gle to th e e ntere d v al ue. The ch aract er istic i s n ot ad apted .

Range: Default (coldstart) value:

20.0 % to 99.9 % of the travel/angle range

0.0 %

Travel/angle limit upper

Upper limitation of valve travel/angle to the entered value. The characteristic is not adapted.

Range: Default (coldstart) value:

0.0 % to 120.0 % of the travel/angle range

100.0 %

Travel range end

Upper limitation of the effective working range (travel). For a non-linear characteristic, the characteristic is adapted to the reduced valve travel. Maximum value = rated travel. If th e " ma ximum ra nge" ha s b een ini ti alize d, th e trave l range is always re lated to th e entered nominal travel. The working range may not be selected 1/4 less than the nominal angle.

Range: Default (coldstart) value:

0.0 mm to 255.9 mm

15.0 mm

Travel range start

Lower limitation of the effective working range (travel). For a non-linear characteristic, the characteristic is adapted to the reduced travel. If th e " ma ximum ra nge" ha s b een ini ti alize d, th e trave l range is always re lated to th e entered nominal travel. The working range may not be selected 1/4 less than the nominal angle.

Range: Default (coldstart) value:

0.0 mm to 255.9 mm

0.0 mm

Type of initialization

Type of initialization related to the nominal or maximum range. For initialization in the nominal range, only the range of the manipulated variable is considered (e.g. globe valve with mechanical stop at one side). When the maximum range is initialized, the maximum range is passed (e.g. three-way valve with mechanical stop at both sides).

States: Default (coldstart) value:

Nominal range / maximum range Maximum range

Type of characteristic

Unassigned text describing the user-defined characteristic Length: 32 characters

Universal revision

Revi sion nu mb er of the un iversa l devic e d escrip ti on that th e f ield de vice con fo rm s to.

Valve id number

Manu fa cturer id entifi ca tion of t he valve d eliver ed with th e p ositio ne r.

Versio n

Actuator with/without spring return.

States: Default (coldstart) value:

Sin gl e acting wi th spri ng retu rn / d ouble a ct ing wit ho ut spring re turn. Single acting.

EB 8380-1 EN

List of parameters

Write protection

When this option is activated, the device data can only be read, but they cannot be over wri tt en. The on ly way to a ct iv ate the wr ite pro te ct io n is us in g t he swi tc h i nstall ed on the device.

States: Activated/deactivated

Zero calibration

(special function)

Zero co rrecti on wi th vali d m echani cal zer o p oi nt.

EB 8380-1 EN

List of parameters

9. Error messages and diagnostics

9.1 Information/alerts

9.1.1 Device settings changed 54

9.1.2 Insufficient power supply 54

9.1.3 Warmstart completed 54

9.1.4 Coldstart completed 54

9.1.5 Choose "MANUAL" mode 54

9.1.6 Parameter not supported 55

9.1.7 Limit value of total valve travel exceeded 55

9.1.8 Zero adjustment aborted 55

9.1.9 Initialization aborted 55

9.1.10 Not initialized 55

9.2 Error messages

9.2.1 Communication fault 56

9.2.2 Control loop error 56

9.2.3 Zero point erroneous 56

9.2.4 Zero calibration erroneous, mechanical readjustment necessary 57

9.2.5 Measuring mode erroneous 57

9.2.6 Reference variable w out of range 57

9.2.7 Controlled variable x out of range 57

9.2.8 Parameter out of range 57

9.2.9 Erroneous characteristic 58

9.2.10 Erroneous characteristic monotony 58

9.2.11 Erroneous characteristic inclination 58

9.2.12 Time out 58

9.2.13 Application data invalid 58

9.2.14 Control data memory erroneous 58

9.2.15 Checksum error control data memory 58

9.2.16 Communication data memory erroneous 59

9.2.17 Checksum error communication data memory 59

9.2.18 Checksum error device information 59

9.3 Error messages during initialization without abortion

9.3.1 Wrong selection of rated travel or transmission 59

9.3.2 Air leakage of pneumatic system 60

9.4 Error messages during initialization with abortion

9.4.1 Forced venting check 60

9.4.2 Determining the mechanical end stops 60

9.4.3 Messages during determination of transit time 61

9.4.4 Messages during determination of minimum pulses 61

EB 8380-1 EN

Error messages and diagnostics

During the initialization cycle, the Type 3780 HART® Positioner offers the best possibilities for diagnosis. In the automatic mode, detailed tests are carried out in order to check the attachment situation and the positioners reaction while taking the preset or entered data into account. When routine tests are carried out or in case of unclear error messages during operation the system should be initialized so that the positioner system can be optimally assessed. The IBIS user software differentiates between information/alerts which are displayed on the screen in yellow, and errors which are displayed in red.

9.1 Information/alerts

9.1.1 Device setup modified

Is always set if the device data were modified, thus checking (unintentional/unauthorized) modifications of the originally preset values. The error message is reset via

[Device data → Specialist → Device data

→

Reset "Device setup modified"]

9.1.2 Insufficient power supply

The parameter is set when the power supply exceeds ≤3.6 mA. It is automatically reset when the current exceeds 3.6 mA again.

9.1.3 Warmstart completed

This message is displayed when the power supply was ≤3.2 mA informing about a possible power supply failure. The device is automatically reset after the message has been acknowledged.

9.1.4 Coldstart completed

This message is displayed if the device was reset via

[Device data

→

Specialist

→

Device → Reset]

and restarted with the standard control values. The device must be re-initialized. Information, such as loop/tag number, bus identification or plant identification remain intact. The device is automatically reset after acknowledgement.

9.1.5 Choose mode "Manual"

This message is issued when the "Manual" reference variable is modified, but the device is not set for "Manual" operating mode. This error can not occur under IBIS. The device is automatically reset after correction.

EB 8380-1 EN

Error messages and diagnostics

9.1.6 Parameter not supported

After downloading to the positioner, the positioner intelligence replies that this parameter is unknown. This message can occur with older firmware versions. The device is automatically reset after acknowledgement.

9.1.7 Limit value of total valve travel exceeded

The current value which is stored after 1024 double strokes and protected against power failure lies above the limit value entered or preset via

[Device data

→

Specialist

→

Extension → Configuration].

When this limit value is preset slightly below the value determined for a broken-down reference valve, the positioner automatically signals that the valve needs to be maintained so that possible failure is prevented.

Reset via [

Diagnostics

→

Device status]

9.1.8 Zero adjustment aborted

Zero adjustment was aborted by the user. Automatic reset after acknowledgement. The previous zero point is maintained if zero adjustment has already been carried out successfully.

Initialization status

9.1.9 Initialization aborted

Initialization was aborted by the user. If the device has been successfully initialized and no coldstart was triggered, the control operation is restarted.

9.1.10 Not initialized

The device has not been initialized, or a coldstart was carried out. The device is automatically reset after initialization has been successfully completed.

EB 8380-1 EN

Error messages and diagnostics

9.2 Error messages

9.2.1 Communication fault

This message is displayed when the HART

communication is interrupted. Possible sources of error:  Auxiliary power too low or power failure  FSK modem not properly connected  Communication (for example COM1) configured incorrectly

[Options → Con-

figure communication]

 Attempt to set up communication via menu item

[Set up communication

→

Single unit]

while the system is in bus mode

The device is reset after the error has been eliminated.

9.2.2 Control loop error

This message is displayed when the positioner fails to control the adjusted range of tolerance for error messages within the preset delay time. The criteria are adjusted via

[Device

data

→

Specialist → Extension → Configuration]

. Possible sources of error:  Oscillation caused by actuator being operated too fast (small travel volume).

Remedy: Reduce the supply air pressure as described in section 3.1.2 and install a sig-

nal pressure throttle (see chap. 2)  Supply air failure/supply air insufficient Filter clogged  Solenoid valves oiled-up  Actuator diaphragm torn  Actuator springs broken  Considerable increase of friction at the control valve  Control valve blocked Reset via

[Diagnostics

→

Device status]

9.2.3 Zero point erroneous

The zero point monitoring signals any changes exceeding the value determined during the initialization or zero adjustment by ±5 % .

Possible sources of error:  Worn-out valve plug/seat

EB 8380-1 EN

Error messages and diagnostics

 Impurities between valve plug/seat The device is reset after the zero adjustment has been carried out effectively.

9.2.4 Zero calibration erroneous, mechanical readjustment necessary

The value determined during electric zero calibration exceeds the permissible tolerance of

5 % by the internal absolute value for the detection of measured values. The device is reset after electric zero calibration has been successfully completed and after mechanical zero point adjustment.

9.2.5 Measuring mode erroneous

The internal A/D converter does not function properly within its specified time frame, or the measured values are not within the physical measuring range limits. In case reset is not successful after a warmstart, repair work is required.

9.2.6 Reference var. w out of range

The internal A/D conversion results in values which are not within the permissible measuring range.

Possible sources of error:  Reference variable exceeded (power supply) >22.5 mA This message is automatically reset when the power supply decreases below 22.5 mA.

9.2.7 Controlled var. x out of range

The internal A/D conversion results in values which are not within the permissible measuring range.

Possible sources of error:  Improper mechanical attachment  Incorrect transmission value entered  For attachment according to NAMUR: incorrect pin position entered  Overtravel larger than rated travel This message is automatically reset after the error has been eliminated.

9.2.8 Parameter out of range

Message indicating that incorrect values have been entered. After downloading data to the positioner, it responds with the message that the downloaded value is not within the permissible range. The previous value is retained. Acknowledge this message to reset.

EB 8380-1 EN

Error messages and diagnostics

Characteristic fault

In case a characteristic fault (sections 9.2.9 to 9.2.11) occurs, the characteristic is automatically switched from user-defined to linear after downloading data to the positioner.

9.2.9 Erroneous characteristic

This message is generated when errors are recognized during transmission of the characteristic. It is automatically reset after a correct characteristic has been transmitted.

9.2.10 Erroneous characteristic monotony

This message is generated when you did not enter the input values in ascending order for a user-defined characteristic. It is automatically reset after a correct characteristic has been transmitted.

9.2.11 Erroneous characteristic inclination

This message is generated when you enter too high an inclination value (>16). It is automatically reset after a correct characteristic has been transmitted.

9.2.12 Timeout

This message is generated when a specified time frame is exceeded during certain tests. Acknowledge this message to reset.

9.2.13 Application data invalid

This message is generated in case an internal communication fault or a HART

communication fault occurs. It is reset after the error has been eliminated.

9.2.14 Control data memory erroneous

A memory block in the EEPROM area cannot be written. Repair required.

9.2.15 Checksum error control data memory

This message is generated when the cyclic check determines that a memory block in the control parameter section has been modified without verification. The user can reset this message by rewriting one memory block minimum after checking all values.

EB 8380-1 EN

Error messages and diagnostics

9.2.16 Communication data memory erroneous

A memory block in the RAM/EEPROM area cannot be written. Repair required.

9.2.17 Checksum error communication data memory

This message is generated when, during cyclic check, a memory block in the communication parameter area has been modified without verification. It is automatically reset when the communication parameters are reset to the default values.

9.2.18 Checksum error device information

This message is generated when, during the cyclic check, a memory block in the device information area has been modified without verification. The user can reset this message by rewriting one memory block minimum after checking all values.

9.3 Error messages during initialization without abortion

Error message without abortion of the initialization procedure. Error message with abortion of the initialization procedure. After the error has been eliminated, initialization must be restarted.

9.3.1 Wrong selection of rated travel or transmission

The maximum determined travel which is read out as %-value of the rated travel/angle is smaller than the selected rated travel/angle. This message is only generated in initialization mode "related to nominal range".

Possible sources of error:  Incorrect mechanical attachment  Incorrect transmission entered  For NAMUR attachment: wrong pin position entered Valve is blocked Supply pressure too low. The supply pressure must be higher than the spring range and

stable. It should be minimum 0.4 bar above the upper spring range value (refer also to section 3.1.2)

EB 8380-1 EN

Error messages and diagnostics

9.3.2 Air leakage of pneumatic system

The actuator stalls for a few seconds when the duty cycle is being determined. This time is used by initialization to check the pneumatic system for leaks. If the control valve moves more than 9.3 % from this resting position within 7 seconds, initialization is aborted with this error message.

Possible sources of error:  Actuator not tight  Signal pressure connection not tight 

9.4 Error messages during initialization with abortion

9.4.1 Forced venting check:

Initialization cannot be started if the implemented option forced venting is activated

If the implemented option forced venting is activated, the initialization procedure is aborted. For implemented option forced venting it is required that between 6 and 24 V DC be applied to terminal +81 and 82.

9.4.2 Determining the mechanical end stops

The initialization routine recognizes the spring action and zero during determination of the mechanical end stops by completely venting and exhausting the actuator. In addition, the routine checks whether the positioner can pass 100 % rated travel/angle.

9.4.2.1 Defective mechanics/pneumatic section when determining the mechanical end stops

The initialization routine recognizes a constant change or no change of the value measured for travel/angle.

Possible sources of error:  Supply pressure too low/not stable  Air capacity too low  Improper mechanical attachment  Lever not properly hung  For NAMUR attachment: lever not correctly secured to the shaft of the adapter housing  Connecting cable between logic and displacement sensor board disengaged

EB 8380-1 EN

Error messages and diagnostics

9.4.2.2 Zero calibration error

The determined zero point does not lie within the acceptable tolerance limit of max. ±5 % by the internal absolute value for the detection of measured values. To eliminate this error, mechanical zero must be adjusted. The yellow pointer of the displacement sensor must then be approximately in alignment with the marking on the cover plate.

9.4.3 Messages during determination of transit time

Transit time determination measures the time required by the valve to pass through the rated travel/angle from 0 % to100 %.

9.4.3.1 Control loop error

If the system cannot travel through the entire rated travel/angle, the supply air pressure is usually too low.

9.4.4 Messages during determination of minimum pulses

9.4.4.1 Proportional band restricted too much

Even the smallest permissible pulses still cause too large changes in travel. Initialization is aborted.

Possible sources of error:  Supply pressure too high  Missing signal pressure throttle for actuators with small volumes  Fault in the mechanics, particularly with attachment according to IEC 60534-6

(NAMUR)

 In case a booster valve has been mounted with large volume actuators, the bypass

should be opened further.

EB 8380-1 EN

Error messages and diagnostics