Samson 3785 series Mounting And Operating Instructions

PROFIBUS Positioner
Type 3785

PA device profile version 2.0

Mounting and
Operating Instructions

EB 8382-1 EN

Firmware version R 1.4x/K 1.6x
Edition July 2004

Fig. 1 · Type 3785 PROFIBUS Positioner

Contents Page

1 Design and principle of operation . . . . . . . . . . . . . . . . . . . 8

1.1 Optional accessories . . . . . . . . . . . . . . . . . . . . . . . . . . 8

1.2 Communication. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8

2 Attaching the positioner. . . . . . . . . . . . . . . . . . . . . . . . 10

2.1 Direct attachment to Type 3277 Actuator . . . . . . . . . . . . . . . . 10

2.2 Attachment according to IEC 60534-6 . . . . . . . . . . . . . . . . . 14

2.2.1 Mounting sequence . . . . . . . . . . . . . . . . . . . . . . . . . . 14

2.2.2 Presetting the valve travel . . . . . . . . . . . . . . . . . . . . . . . 16

2.3 Attachment to rotary actuators . . . . . . . . . . . . . . . . . . . . . 18

2.3.1 Mounting the cam follower roll lever . . . . . . . . . . . . . . . . . . 18

2.3.2 Mounting the intermediate piece . . . . . . . . . . . . . . . . . . . . 18

2.3.3 Aligning and mounting the cam disk . . . . . . . . . . . . . . . . . . 20

2.3.4 Reversing amplifiers for double-acting actuators . . . . . . . . . . . . 22

2.4 Fail-safe position of the actuator . . . . . . . . . . . . . . . . . . . . 22

3 Connections. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24

3.1 Pneumatic connections. . . . . . . . . . . . . . . . . . . . . . . . . 24

3.1.1 Pressure gauges. . . . . . . . . . . . . . . . . . . . . . . . . . . . 24

3.1.2 Supply air pressure . . . . . . . . . . . . . . . . . . . . . . . . . . 25

3.2 Electrical connections . . . . . . . . . . . . . . . . . . . . . . . . . 25

3.2.1 Forced venting . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27

3.2.2 Limit switches . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28

3.2.3 Establishing communication (bus address) . . . . . . . . . . . . . . . 28

3.2.4 Local interface (SSP) . . . . . . . . . . . . . . . . . . . . . . . . . . 28

4 Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30

4.1 LED controls. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30

4.2 Write protection. . . . . . . . . . . . . . . . . . . . . . . . . . . . 31

4.3 Activate/deactivate forced venting . . . . . . . . . . . . . . . . . . . 31

4.4 Default settings . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31

4.4.1 Adjusting mechanical zero. . . . . . . . . . . . . . . . . . . . . . . 32

4.4.2 Initialization. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32

4.5 Adjusting the inductive limit switches . . . . . . . . . . . . . . . . . . 34

5 Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35

6 Servicing explosion-protected devices . . . . . . . . . . . . . . . . . 35

2 EB 8382-1 EN

Contents

7 How to implement a Class 1 PROFIBUS Master . . . . . . . . . . . . 36

7.1 Device database files (GSD) . . . . . . . . . . . . . . . . . . . . . . 36

7.2 Data exchange . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36

7.3 Parameter description . . . . . . . . . . . . . . . . . . . . . . . . . 40

7.4 Coding of measured value status . . . . . . . . . . . . . . . . . . . . 42

7.5 Operating modes . . . . . . . . . . . . . . . . . . . . . . . . . . . 44

8 List of parameters. . . . . . . . . . . . . . . . . . . . . . . . . . . 47

9 Messages and diagnostics. . . . . . . . . . . . . . . . . . . . . . . 61

9.1 Diagnostic messages . . . . . . . . . . . . . . . . . . . . . . . . . 61

9.2 Extended diagnostic messages . . . . . . . . . . . . . . . . . . . . . 63

9.3 CHECKBACK messages . . . . . . . . . . . . . . . . . . . . . . . . 64

9.4 Messages during initialization . . . . . . . . . . . . . . . . . . . . . 66

Dimensional drawing . . . . . . . . . . . . . . . . . . . . . . . . . 69

Certificates . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70

EB 8382-1 EN 3

Contents

4

The device is to be assembled, started up or operated only by trained and ex­perienced personnel familiar with the product.
According to these mounting and operating instructions, trained personnel is
referred to as individuals who are able to judge the work they are assigned to
and recognize possible dangers due to their specialized training, their knowl­edge and experience as well as their knowledge of the applicable standards.

4

Explosion-protected versions of this device are to be operated only by person­nel who have undergone special training or instructions, or who are autho­rized to work on explosion-protected devices in hazardous areas.

4

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

4

Proper shipping and storage are assumed.

4

Note! Devices with a CE marking fulfil the requirements of the Directives
94/9/EC and 89/336/EEC. The declaration of conformity is available at
http://www.samson.de and on request.

!

Modifications of the firmware compared to the previous version

Old New
Control R 1.23 R 1.31

Firmware adaptation for a new hardware version
Hardware version device index .01

Control R 1.31 R 1.4

Actuator type When the actuator type is switched from "linear actuator" to "rotary actua-

tor", the following applies:
Initialization method . . . Based on maximum range

Transmission code . . . . 590

Nominal angle . . . . . 90°

End position for w < . . . 1 %
End position for w > . . . 99 %
Rot. angle range starts at 0°
Rot. angle range ends at 90°

When the actuator type is switched from "rotary actuator" to "linear actua­tor", the following applies:

Attachment . . . . . . . Integral . . . . . . . . . NAMUR

Initialization method . . . Based on nominal range . Based on nom. range

Mounting position: arrow Towards actuator . . . . Away from actuator

Transmission code . . . . D1 . . . . . . . . . . . –

Pin position . . . . . . . – . . . . . . . . . . . . A

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

End position for w < . . . 1 % . . . . . . . . . . . 1 %

End position for w > . . . 125 % . . . . . . . . . 125 %

Lower travel range value. 0 mm . . . . . . . . . . 0 mm

Upper travel range value 15 mm . . . . . . . . . 15 mm

Lever length . . . . . . . – . . . . . . . . . . . . 42 mm

Initialization method When the initialization method is switched from "maximum range" to "nomi-

nal range", the following applies:
End position for w < 1% End position for w > 125 %

When the initialization method is switched from "nominal range" to "maxi­mum range", the following applies:
End position for w < 1% End position for w > 99 %

Desired transit time
open/closed

The adjustment range of the desired transit time is now limited to 75 s.

Initialization During initialization, the minimum control pulses are determined for 20 % to

80 % of the manipulated variable range and saved in the EEPROM.

Proportional-action
coefficients
KP_Y1 and KP_Y2

The coefficients are adapted to the selected actuator type and the measured
transit times.

4 EB 8382-1 EN

Firmware modifications

Control R 1.41 R 1.42

Correction when zero calibration was triggered by communication.

Communication K 1.34 K 1.41

Firmware adaptation for new hardware version
Hardware version device index .01

Communication 1.41 K 1.51

Bit 7 of the CHECKBACK parameter indicates the current status of control
loop monitoring. In contrast to bit 13, bit 7 is automatically reset when control
loop monitoring detects no further errors. The function of bit 13 remains un­changed. Messages issued by bit 7 are only supported with firmware version
R 1.41 and higher.

The "warm start" message indicated by bit 11 of the DIAGNOSIS parameter
is automatically reset after 10 s.

In Local Override mode, bit 2 of the CHECKBACK parameter is activated.

Communication 1.51 K 1.60

A bad set point status no longer causes the positioner to move the valve to
fail-safe position in any case. Rather, the positioner's behavior is determined
by the FSAVE_TYPE parameter.

Using the serial interface, the positioner can be configured and operated with
SAMSON's TROVIS-VIEW Configuration and Operator Interface software.

EB 8382-1 EN 5

Firmware modifications

Positioner

Travel

Direct attachment Type 3277
Acc. to IEC 60534-6 (NAMUR)

Adjustable
5 mm to 30 mm
5 mm to 255 mm or 30° to 120° for rotary actuators

Bus connection Fieldbus interface according to IEC 61158-2

Field unit according to FISCO (Fieldbus Intrinsically Safe Concept)

Permissible operating voltage 9 to 32 V DC; the specifications in the EC type examination certifi-

cate additionally apply to explosion-protected devices.
Voltage supplied over bus cable

Static destruction limit 35 V

Max. operating current 10 mA

Current in case of fault 0 mA

Auxiliary energy Supply pressure of 1.4 to 6 bar (20 to 90 psi)

Air quality according to ISO 8573-1:2001, i.e. max. particle size
and density: Class 4; oil content: Class 3;
pressure dew point: Class 3 or at least 10 K above lowest ambient
temperature to be expected

Signal pressure (output) 0 bar up to supply air pressure

Adjustable characteristic Linear, equal percentage, reverse equal percentage, user-defined

Deviation from characteristic≤1 %

Dead band Adjustable from 0.1 to 10.0 %, default 0.5 % (based on rated

travel/angle)

Resolution < 0.05 % (internal measurement)

Desired transit time Up to 75 s, separately adjustable for exhaust and supply air

Direction of action Reversible, adjusted using software

Air consumption Independent of supply air < 90 l

n

/h

Air supply

Actuator pressurized for Δp = 6 bar: 9.3 mn³/h, for Δp = 1.4 bar: 3.5 mn³/h
Actuator vented for Δp = 6 bar: 15.5 m

n

³/h, for Δp = 1.4 bar: 5.8 mn³/h

Permissible ambient tempera­ture

–40 °C to 80 °C, the specifications in the EC type examination
certificate additionally apply to explosion-protected devices

Influences Temperature:≤0.15 %/10 K, auxiliary energy: none

Vibration: none up to 250 Hz and 4 g

Explosion protection II 2 G EEx ia IIC T6 acc. to ATEX, see EC type examination certificate

Degree of protection IP 65 using the included filter check valve

Electromagnetic compatibility Requirements acc. to EN 61000-6-2, EN 61000-6-3 and NE 21 met

Binary input Internal power supply 5 V DC,

R

i

= 100 kΩfor alarm function, e.g. connection of pressure switch

6 EB 8382-1 EN

Technical data

Forced venting

Input

K

V

coefficient

To be activated using switch inside the positioner
6 to 24 V DC, static destruction limit 45 V
R

i

approx. 6 kΩat 24 V DC (depending on voltage)
Switching point for "1" signal at≥3 V, switching point for "0" signal
only at 0 V

0.17

Communication Data transmission acc. to PROFIBUS-PA, Profile Class B, version 2.0

acc. to DIN EN 50170 and DIN 19245, Part 4 (version 3.0 also
available)

Local interface SAMSON SSP interface for configuration and start-up

Bus address Adjustable using software or microswitch, default upon delivery: 126

Accessories

Inductive limit switches Two Type SJ2SN proximity switches

For connection to switching amplifier according to EN 60947-5-6

Materials

Housing Die-cast aluminum, chromated and plastic-coated

External parts Stainless steel 1.4571 and 1.4301

Weight Approx. 1.3 kg

Positioner versions

Type 3785– XXXXX

3

X

Explosion
protection

Without
Ex II 2 G Ex ia IIC T6 acc. to ATEX
With Ex ia CSA/FM
Ex II 3 G Ex nA II T6 acc. to ATEX

0
1
3
8

Accessories Limit switches Without

2 inductive

0
22

Forced venting Without

With

0
12

PA device profile Version 2.0

Version 3.0

0
1

Pneumatic
connections

NPT ¼-18
ISO 228/1-G ¼

1
2

Electrical
connections

Cable gland M 20 x 1.5 with shielding,
nickel-plated brass
Quantity: 1
Quantity: 2

1
2

EB 8382-1 EN 7

Technical data

1 Design and principle of opera-

tion

The digital PROFIBUS-PA positioner is de­signed for attachment to pneumatic control
valves. It is used to assign the valve stem po­sition (controlled variable) to the control sig­nal (reference variable). It compares the digi­tal output signal to the travel of the control
valve and generates a corresponding pres­sure signal as the output variable. As a re­sult, the positioner requires auxiliary supply
air with a pressure of 1.4 to 6 bar. The nec­essary electrical power is supplied by the bus
of the PROFIBUS-PA segment based on
IEC 61158-2 standard transmission technol­ogy.

The positioner consists of an inductive,
contactless travel pick-off system and an
electrically controlled valve block comprising
two on/off valves and an electronic unit. This
unit contains two microcontrollers for pro­cessing the control algorithm and managing
PROFIBUS communication.
If 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 on/off valves, each of which
is assigned a downstream amplifier. One of
these valves controls the exhaust air, the
other the supply air.

The supply air valve (3) controls the connec­tion between the supply air (7, supply air
pressure 1.4 to 6 bar) and the actuator
(pressurizing). The exhaust air valve (4) con­trols the air exhausted from the actuator to
the atmosphere (venting). The on/off valves
can either have the switching states ("perma­nently open", "permanently closed" or gen-

erate single pulses of changing widths). The
two valves cause the plug stem to move to a
position corresponding to the reference vari­able. If there is no system deviation, both the
supply air valve and the exhaust air valve
are closed.

By default, the positioner is equipped with a
binary input for floating contacts, which ad­ditionally signals the switching state of a
further field device via PROFIBUS.
Activating the write protection switch, which
is located next to the bus address in the
hinged lid, prevents the positioner settings
from being overwritten by PROFIBUS com­munication.

Positioner with forced venting function:

The positioner is controlled by 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 in the ac­tuator move the valve to its fail-safe position.
The forced venting function is included in all
positioners and can be activated/deactivated
as required over a switch. Refer to sec­tion 4.3 for details.

1.1 Optional accessories

As a supplement to the standard positioner
version, the positioner can be equipped with
limit switches. Two proximity switches can be
used to indicate the valve's end positions in
safety-related circuits.

1.2 Communication

The positioner is completely controlled by
digital signal transmission according to the
PROFIBUS-PA Profile Class B based on

8 EB 8382-1 EN

Design and principle of operation

DIN EN 50170 and DIN 19245, Part 4.
Data is transmitted as bit-synchronous cur­rent modulation at a transmission rate of

31.25 kbit/s over twisted-pair cables ac­cording to IEC 61158-2. Positioners are gen­erally set up using a PC. One or more
positioners are connected to the PC's
PROFIBUS segment via segment coupler.
After mechanically resetting the positioner to
zero, it can be automatically started up using
an initialization routine. During initialization,
zero is automatically adjusted and the preset
span is checked.

The positioner is delivered with a standard
configuration for a control valve with a rated
travel of 15 mm designed for integral
positioner attachment.

Customized configuration to adapt the
positioner to other actuators can only be car­ried out using communication.

Configuration

The positioner is configured and operated on
the PC over the SSP interface (13) using
TROVIS-VIEW. Alternatively, it can be con­figured and operated via a segment coupler,
e.g. using the COMMUWIN II user interface
(by Endress + Hauser) or the SIMATIC PDM
user interface (by SIEMENS).
During configuration, parameters such as
control characteristic, direction of action,
travel limitation, travel range, transit time
and alarms, can be entered.

EB 8382-1 EN 9

Design and principle of operation

11

10

1

12

e

p

3

4

2

5

9

7

6

1

G

μC

61158-2
IEC

e

p

G

μC

PROFIBUS-PA

8

Serial Interface

13

Fig. 2 · Functional diagram

Binary input

Forced venting

Supply

air

Exhaust
air

1 Inductive travel pick-off
2 Microcontroller
3 On/off valve for supply air
4 On/off valve for exhaust air
5 Microcontroller
6 Switch for bus address and

write protection
7 Binary input
8 Forced venting
9 IEC 61158-2 interface module
10 Actuator stem
11 Lever
12 Clamp
13 SSP interface

2 Attaching the positioner

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 positioner can also be attached as a ro­tary positioner to rotary actuators.

Since the standard positioner unit is deliv­ered without accessories, refer to the corre­sponding tables for required mounting parts
and their order numbers.

Note!

For fast control valves with small travels
(transit time < 0.6 s), replace the filter in the
signal pressure output with a screw-in restric­tion, if necessary, to improve the control
properties. See also sections 2.1, 2.2 and

2.3.

Important!

The positioner does not have its own vent
plug so that the air is exhausted to the atmo­sphere through vent plugs located on the ac­cessories (see also Figs. 3, 5 and 6).
A filter check valve for the exhaust air is in­cluded with each positioner (underneath the
transparent cover on the back of the
positioner).
Replace the standard vent plug included in
the accessories with this filter check valve.
This is necessary to achieve degree of protec­tion IP 65 by preventing dirt and moisture
from entering the device.

2.1 Direct attachment to
Type 3277 Actuator

For selection of the required mounting parts,
refer to Tables 1, 2 and 3 on page 13.

When looking at the signal pressure connec­tion or the switchover plate (120 cm² actua­tor) from the top, the positioner must be at­tached to the left side of the actuator.
The arrow on the black housing cover
(Fig. 11) points 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 actuator, i.e.
with the arrow pointing away from the dia­phragm chamber.

1. Screw clamp (1.2) to the actuator stem,

ensuring that the fastening screw is lo­cated in the groove of the actuator stem.

2. Screw associated lever D1 or D2 (for

700 cm² actuator) to the transmission le­ver of the positioner.

3. Fasten distance plate (15) with the seal

pointing towards the actuator yoke.

4. Place positioner on the plate so that the

pick-off lever D1 or D2 slides centrically
over the pin of the clamp (1.2). Screw
positioner to the distance plate (15).

5. Mount cover (16).

10 EB 8382-1 EN

Attaching the positioner

EB 8382-1 EN 11

Attaching the positioner

SUPPLY

1817 19

1.2
D2

D1

17

16

15

1.2

16

17

15

Fig. 3 · Attachment and signal pressure connection for Types 3277 (top) and 3277-5 with 120 cm² (bottom)

1.2 Clamp
D1 Lever
D2 Lever
15 Distance plate
16 Cover
17 Seal
18 Cover plate
19 Switch plate

Actuator stem

extends

Actuator stem

retracts

Switchover plate Signal pressure input

Marking

Signal pressure input with
brass restriction, if required

Signal pressure bore Switchover plate

Vent

Connection block

Side view of connection block

with seal (new) with switch plate (old)

Actuator stem extends Actuator stem retracts

Internal signal pressure
connection

Signal pressure
connection over piping

Symbol "Actuator
stem extends"

Marking

Symbol "Actuator
stem retracts"

240, 350 and 700 cm² actuators

6. Check whether the tongue of the
seal (17) is properly aligned at the side
of the connection block with the actuator
symbol "Actuator stem extends" or "Actu­ator stem retracts" to match the actuator
version used. If it does not match, remove
the three fastening screws and the cover
plate (18), turn the seal (17) by 180° and
reinsert it.
When the old connection block is used,
turn the switch plate (19) to align the ar­row with the actuator symbol.

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 position "Ac­tuator stem retracts", additionally mount
the prefabricated signal pressure line.

120 cm² actuator

For Type 3277-5 Actuators with 120 cm²,
the signal pressure is transmitted to the dia­phragm chamber over the switchover plate
(see Fig. 3, bottom).
For a rated travel of 7.5 mm, a brass restric­tion (see Accessories table on page 13) must
be pressed into the seal located in the signal
pressure input on the actuator yoke.
With 15 mm rated travel, this is only re­quired if the supply pressure exceeds 4 bar

6. Remove screw at the back of the
positioner and close the signal pressure
output (output 38) at the side with the as­sociated plug included in the accessories
kit.

7. Mount positioner so that the bore in the
distance plate (15) is aligned with the
seal located in the bore of the actuator
yoke.

8. Align switchover plate with the corre­sponding symbol for attachment on the
left. Screw the plate to the actuator yoke.

Important!

If, in addition to the positioner, a solenoid
valve or a similar device is attached to the
120 cm² actuator, the rear M3 screw must
not be removed. In this case, the signal pres­sure has to be fed from the signal pressure
output to the actuator over the required con­necting plate (see Table 2). The switchover
plate is no longer required.

Note!

For faster control valves with a transit time
< 0.6 s, replace the filter in the signal pres­sure output (output 38) with a screw-in
restriction (see Accessories table), if neces­sary.

Filling the spring chamber with air

If the Type 3277 Actuator's spring chamber
must be pressurized with the air exhausted
from the positioner, the spring chamber (ver­sion "Actuator stem extends") can be con­nected to the connection block using a tube
(Table 3). To do so, remove the plug on the
connection block.

With the Type 3277-5, version "Actuator
stem retracts", the spring chamber is con­stantly pressurized with the air exhausted
from the positioner through an internal bore.

12 EB 8382-1 EN

Attaching the positioner

Table 1

Required lever with associated clamp and distance plate

Actuator size

cm²

Mounting kit

Order no.

D1 (33 mm in length with clamp, 17 mm in height) 120 (G ¼)

120 (¼ NPT)

1400-6790
1400-6791

D1 (33 mm in length with clamp, 17 mm in height) 240 and 350 1400-6370

D2 (44 mm in length with clamp, 13 mm in height) 700 1400-6371
Table 2 Order no.
Switchover plate for 120 cm² actuator Actuator 3277-5xxxxxx.00 (old) 1400-6819
Switchover plate new Actuators with index .01 or higher (new) 1400-6822

Connecting plate for additional attachment
of, e.g. a solenoid valve

3277-5xxxxxxxx.00 G

1

8

(old)

1

8

NPT

1400-6820
1400-6821

Connecting plate new Actuators with index .01 or higher (new) 1400-6823
Note! Only new switchover plates and connecting plates can be used with the new actuators (modifica-

tion index .01). Old and new plates are not interchangeable.

Connection block required for actuator sizes 250, 350 and
700 cm² (including seals and fastening screw)

G ¼

¼ NPT

1400-8811
1400-8812

Table 3 Actuator size cm² Material Order no.

Required tubes including fittings 240 Steel 1400-6444

240 Stainless steel 1400-6445

For version
"Actuator stem retracts"
or
when pressurizing the upper diaphragm
chamber

350 Steel 1400-6446

350 Stainless steel 1400-6447

700 Steel 1400-6448

700 Stainless steel 1400-6449

Accessories Order no.

Pressure gauge mounting kit for supply air and signal pressure St. steel/brass

St. steel/St. steel

1400-6957
1400-6958

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

Filter check valve, replaces vent plug and increases degree of protection to IP 65
(one included with every positioner delivered)

1790-7408

EB 8382-1 EN 13

Attaching the positioner

2.2 Attachment according to
IEC 60534-6

For selection of the required mounting
parts, refer to Tables 4 and 5 on page 17.

For positioner attachment according to
NAMUR as shown in Fig. 4, an adapter
housing is required. The valve travel is trans­mitted over the lever (18) and shaft (25) to
the bracket (28) of the adapter housing and
then to the pin (27) located on 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.
The positioner must be attached to the
adapter housing so that the arrow on the
black housing cover points away from the di­aphragm actuator towards the valve.
Exception: control valves in which the plug
closes the seat area when the actuator stem
retracts. In this case, the arrow must point to­wards the diaphragm actuator.

If the adapter housing cannot be mounted
between the actuator and the valve (e.g.
non-SAMSON actuators), make sure the ar­row on the housing cover points towards the
control valve.

Note!

For faster control valves with a transit time
< 0.6 s, replace the filter in the signal pres­sure output (output 38) with a screw-in re­striction (see Accessories table), if necessary.

2.2.1Mounting sequence

Important!

Before mounting the parts, apply a signal
pressure to the actuator so that the valve is
set to 50 % of its travel. It is only in this posi­tion that the lever (18) and bracket (28) can
be aligned exactly.

Control valve with cast yoke

1. Use countersunk screws to attach the
plate (20) to the coupling that connects
the plug and actuator stem. For 2100
and 2800 cm² actuators, use additional
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 housing with the plate (30) on ei­ther the right or left side of the valve rod
and screw the housing tight using
nuts (31). Align the height of the housing
so that the lever (18) to be mounted sub­sequently is horizontal.

4. Move clamp (21) to surround the
pin (19). Screw pin in the center row of
bores in the plate (20) and lock it so that
it will be located above the correct lever
marking (1 to 2) for the assigned travel
(see Table 5).
Intermediate values must be interpolated.

14 EB 8382-1 EN

Attaching the positioner

EB 8382-1 EN 15

Attaching the positioner

2

1,5

1

2826

AB

24 25 22

32

31

20 19

19 21 2023 18

27b

27a

29
30

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

Mounting position

Attachment to
NAMUR rib

Attachment to rods

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

5. Measure distance between the center of
the shaft (25) and the center of the
pin (19). This value must later be entered
when configuring the positioner.

2.2.2Presetting the valve travel

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

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

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

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

5. Screw positioner to the adapter housing.

6. Relieve actuator of the signal pressure.

16 EB 8382-1 EN

Attaching the positioner

Table 4 Attachment IEC 60534-6

Control valve Travel [mm] With lever Order no.

NAMUR mounting kit

Parts, see 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,

rod diame

-

ter [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

Attachment to linear Fisher and Masoneilan actuators
(one each of both mounting kits is needed per actuator)

1400-6771

and

1400-6787

Accessories Order no.

Pressure gauge mounting block G ¼

¼ NPT

1400-7106
1400-7107

Pressure gauge mounting kit (output and supply)
Order with every pressure gauge kit: 2 restrictions (1790-6121)

St. st./Brass
St. st./St. st.

1402-0938
1402-0939

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

Filter check valve, replaces vent plug and increases degree of protection to IP 65
(one included with every positioner delivered)

1790-7408

Table 5 Attachment acc. to IEC 60534-6

Travel in mm*

7.5 15 15 30 30 60 30 60 60 120

Pin on marking* 1 1 2 1 2 1 2 1 2

Corresp. distance pin to lever fulcrum 42 42 84 42 84 84 168 84 168

With lever N1 (125 mm long) N2 (212 mm long)

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

* Deviating travel values (intermediate values) are to be interpolated accordingly

EB 8382-1 EN 1

7

Attaching the positioner

2.3 Attachment to rotary actuators

For selection of the required mounting
parts, refer to Table 6 on page 21.

The positioner can also be attached to rotary
actuators in accordance with VDI/VDE 3845
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 fol­lower roll of the positioner lever to a linear
motion required by the positioner's inductive
travel pick-off system.
Each cam disk is suitable for two curves: for
angles of rotation from 0° to 90° (for all an­gles smaller than 90°) and for 0° to 120°
(for all angles of 90° and larger).
For double-acting, springless rotary actua­tors, it is necessary to connect a reversing
amplifier to the connection side of the
positioner (see section 2.3.4).
If the positioner is attached to a SAMSON
Type 3278 Rotary Actuator, the positioner's
exhaust air is routed to the inside of the actu­ator and the chamber behind the dia­phragm. No additional tubing is required.
If the positioner is attached to non-SAMSON
actuators (NAMUR), the air is applied to the
chamber behind the diaphragm through a
tube assembly and a tee, connected between
the actuator and the exhaust connection of
the intermediate piece.

Note!

For faster control valves with a transit time
< 0.6 s, replace the filter in the signal pres­sure output (output 38) with a screw-in re­striction (see Accessories table), if necessary.

2.3.1Mounting the cam follower
roll lever

1. Place lever with the attached roll (35) on

the transmission lever (37) and secure it
with the enclosed screws (38) and wash­ers.

2.3.2Mounting the intermediate
piece

SAMSON Type 3278 Actuator

1. Screw adapter (36) to the free end of the

rotary actuator shaft using two screws.

2. Place the positioner's intermediate

piece (34) on the actuator housing and
secure it using two screws. Align interme­diate piece so that the air connections of
the positioner face towards the dia­phragm case side.

Non-SAMSON actuators

1. Position complete intermediate piece (34,

42, 44 and 45) on the bracket (fixing
level 1, VDI/VDE 3845) delivered with
the actuator and fasten it with screws.

2. Align cam disk (40) and scale according

to section 2.3.3 and fasten them with
screws.

With springless actuators, the reversing am­plifier (45) must be screwed to the side of the
positioner housing. Refer to section 2.3.4 for
details.

18 EB 8382-1 EN

Attaching the positioner

EB 8382-1 EN 19

Attaching the positioner

33

3835

39

39
40

34

36

40

34

44

45

42

43

37

Fig. 5 · Attachment to rotary actuators

Attachment to

SAMSON Type 3278 Actuator

Attachment acc. to
VDI/VDE 3845

Vent plug or
filter check valve

33 Positioner
34 Intermediate piece
35 Lever with 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

2.3.3Aligning and mounting 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 (clockwise,
counterclockwise).
With double-acting, springless rotary actua­tors, the direction of rotation depends on
both the actuator and the valve model used.

Close the valve before making any adjust-

ments.

The positioner's direction of action, i.e.
whether the valve opens or closes when the
reference variable increases, has to be soft­ware-adjusted using communication (in­creasing/increasing or increasing/decreas­ing).

1. Position cam disk with scale on the

adapter (36) or the coupling (34) 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.

Important!

With the valve closed, the starting point
(bore hole) of the respective curve 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 plate are aligned.
The starting point for the closing position
must not be below 0° position!

In actuators with fail-safe position "Control
valve open" (OPEN), pressurize the actuator
with the max. signal pressure before aligning
the cam disk.
In springless actuators, connect the supply
air.

2. On aligning the cam disk, the dou­ble-sided scale disk must be clipped on
so that the value on the scale corre­sponds to the control valve's direction of
rotation. Tightly secure the cam disk with
the fastening screws now.

Securing the aligned cam disk

If you want to additionally secure the cam
disk to prevent it from being turned, proceed
as follows:
Four bore holes are located centrically
around the center bore on the cam disk. Se­lect a suitable hole to secure the cam disk.
Through this hole, drill a hole in the
adapter (36) or coupling (44) and insert a
2 mm dowel pin.

3. Attach 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 Allen wrench or
screwdriver from the front into the bore
located below the oblong hole on the
cover plate and push the positioner lever
to the required position.

4. Screw positioner to the intermediate
piece.

20 EB 8382-1 EN

Attaching the positioner

Table 6 Rotary actuators (complete mounting parts, but without cam disk)

Attachment acc. to

VDI/VDE 3845,

level 1

SAMSON Type 3278 Actuator Attachment to Masoneilan actuators

160 cm²

actuator

320 cm²

actuator

Camflex I

DN 25 to 100

Camflex I

DN 125 to 250

Camflex II

Order no.

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

Piping kit, 8 x 1 stainless steel

G: 1400-6670 G: 1400-6672

NPT: 1400-6669 NPT: 1400-6671

Accessories Order no.
Reversing amplifier for springless double-acting 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) esp. for VETEC, adjustable by software from 0° to 75° 1400-6960
Cam disk (0050-0090) esp. for Camflex, adjustable by software from 0° to 50° 1400-6961
Pressure gauge mounting block G ¼: 1400-7106 ¼ NPT: 1400-7107
Pressure gauge set Stainl. steel/Br:

1400-6957

St. steel/st. steel:

1400-6958

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

Filter check valve, replaces vent plug and increases degree of
protection to IP 65 (one included with every positioner delivered)

1790-7408

EB 8382-1 EN 21

Attaching the positioner

Fig. 6 · Aligning the cam disk

Cam follower roll

Starting point

Bore holes to secure
the cam disk

Insert clip and press
tongues outward.

View onto actuator shaft from positioner

Control valve opens counterclockwise Control valve opens clockwise

2.3.4Reversing amplifiers 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 Table 6 on page 21.

The signal pressure of the positioner is sup­plied at output A1 of the reversing amplifier.
An opposing pressure, which equals the re­quired supply pressure when added to the
pressure at A

1

, is applied at output A2. The

rule A

1

+ A2= Z applies.

Mounting

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

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

2. Remove sealing plug (1.5) from the re-

versing amplifier. The rubber seal (1.4)
must remain installed.

3. Insert gasket (1.2) into recess of the re-

versing amplifier and push both hollow
special screws (1.1) into the connection
bores A1 and Z.

4. Place reversing amplifier onto the

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

5. Replace vent plug in the reversing ampli-

fier with the included filter check valve.

Signal pressure connections
A

1

: Connect output A1to the signal pressure

connection at the actuator that opens the
valve when the pressure increases.

A

2

: Connect output A2to the signal pressure

connection at the actuator that closes the
valve when the pressure increases.

4

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

2.4 Fail-safe position of the actua­tor

Important!

If the fail-safe position of the actuator is
changed subsequently by modifying the actu­ator springs from "Actuator stem extends" to
"Actuator stem retracts", readjust mechanical
zero and re-initialize the positioner.

22 EB 8382-1 EN

Attaching the positioner

EB 8382-1 EN 23

Attaching the positioner

1.3 1.2 1.1 1

Output 38 Supply 9

A

1

1.5 1.6

Z

A

2

1.4

A

1

A

2

Output 38 Supply 9

1.3 1.21.1

1.6

Z

A

1

Fig. 7 · Mounting a reversing amplifier

From the positioner

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

3 Connections

3.1 Pneumatic connections

The air connections are either ¼ NPT or G ¼
tapped holes. Common fittings for metal and
copper tubes or plastic hoses can be used.

Important!

The supply air must be dry and free of oil
and dust. The maintenance instructions for
upstream pressure reducing stations must be
observed. Carefully purge all air tubes and
hoses before connecting them.

If the positioner is attached directly to the
Type 3277 Actuator, the connection of the
signal 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 action (either "Ac­tuator stem retracts" or "stem extends").

Exhaust air: The exhaust air connection of
the positioner is located on the mounting kit.
For direct attachment, a vent plug is located
on the plastic cover of the actuator. For
NAMUR attachment, the vent plug can be
found at the adapter housing. For attachment
to rotary actuators, it is either located either
on the intermediate piece or the reversing
amplifier.
To guarantee degree of protection IP 65, the
vent plug must be replaced with the filter
check valve included with the positioner.
Refer to section 2 on page 10 (Important!)
for details.

3.1.1Pressure gauges

To monitor positioner operation, it is recom­mended to connect pressure gauges for the
supply air and signal pressure. The required
gauges are listed as accessories in Tables 3,
4 or 6.

24 EB 8382-1 EN

Connections

2...3mm

Fig. 8 · Mounting pressure gauges

Nut Restriction with filter

Order no. 1790-6121

3.1.2Supply air pressure

The required supply air pressure depends on
the bench range and the operating direction
(fail-safe action) of the actuator. The bench
range is indicated on the nameplate as a
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:

The required supply air pressure for
tight-closing valves is estimated on the basis
of the maximum signal pressure p

st max

:

p

st max

= F +

d² p p

4A

⋅⋅⋅Δ

[bar]

d = Seat diameter [cm]
Δp = Differential pressure across the valve [bar]
A = Actuator area [cm²]
F = Upper bench range value of actuator [bar]

If there are no specifications, calculate as
follows:

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

3.2 Electrical connections

For electrical installation, you are re­quired to observe the relevant
electrotechnical regulations and the
accident prevention regulations that
apply in the country of use. In Ger­many, these are the VDE regulations
and the accident prevention regula­tions of the employers’ liability insur­ance.
The following regulations apply for
installation in hazardous areas:
EN 60079-14:2003; VDE 0165
Part 1:1998 ”Electrical apparatus for
explosive gas atmospheres”, and
EN 50281-1-2: VDE 0165
Part 2:1999 ”Electrical apparatus for
use in the presence of combustible
dust”.
For intrinsically safe electrical equip­ment approved in accordance with
Directive 79/196/EEC, the data
specified in the certificate of confor­mity apply for the connection of in­trinsically safe circuits. For intrinsi­cally safe electrical equipment ap­proved in accordance with Directive
94/9/EC, the data specified in the
EC type examination certificate apply
for the connection of intrinsically safe
circuits.
Caution! The terminal assignment
specified in the certificate must be
observed! Switching the assignment
of the electrical terminals may cause
the explosion protection to become
ineffective! Do not loosen enameled
screws in or on the housing.

EB 8382-1 EN 25

Connections

!

Note on the selection of cables and wires

To run several intrinsically safe circuits in one
multi-core cable, observe section 12 of
EN 60079-14; VDE 0165:1998.
Note especially that, for commonly used in­sulating materials such as polyethylene, the
radial thickness of the conductor insulation
must be at least 0.2 mm. The diameter of a
single wire of a flexible conductor must not
be smaller than 0.1 mm.
The conductor ends must be protected
against unlaying, e.g. by using wire-end fer­rules. When two separate cables are used
for connection, an additional cable gland
can be installed.
Cable entries left unused must be sealed with
plugs.
Positioners used in ambient temperatures
down to –40 °C must be fitted with metal ca­ble entries.

For terminal assignment, refer to Fig. 9 or to
the designations on the cover plate inside the
lid.

Cable entries

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 mm² (tightening
torque at least 0.5 Nm).

Bus line

The shielded PROFIBUS connecting cable
must be routed over the EMC-proof brass ca­ble gland (standard) of the positioner to the
terminals. The shield, which is placed over
the clamping insert, is connected over a
large area to the gland and housing.

1. To connect the bus line, remove coupling

nut and clamping insert from the
positioner. Also remove the dust cap.

2. Slide coupling nut and clamping insert

over the connecting cable.

3. Strip insulation off the end of the bus line

to the required connecting length. Cut off
the wire shield up to a length of approx.
13 mm. If necessary, cut off any filling
cable cores as well.

4. Disentangle the braided shield and pull it

over the clamping insert.

5. Press clamping insert into connecting

screw gland. Tighten coupling nut until
the connecting cable is clamped tightly.

6. Route two-wire bus line to the screw ter-

minals marked "IEC 1158-2"; when do­ing so, no polarity has to be observed.

In exceptional cases, if the plant does not
permit such a connection, feed the cable
shield through the cable gland and connect it
to be capacitive over terminal "S". However,
make sure that no conducting connection oc­curs from the shield to the cable gland or
housing.

26 EB 8382-1 EN

Connections

Refer to PROFIBUS-PA User and Installation
Guideline (PROFIBUS User Organization
document 2.091) for further information.

At the binary input, a passive floating con­tact can be used. The positioner signals the
circuit's state using the bus protocol.

Important!

The connection of limit switches, binary input
and forced venting function requires an ad­ditional cable gland that must replace the
cap fitted on the housing.
Accessories: M20 x 1.5 cable gland,
nickel-plated brass, order no. 8808-0143

3.2.1Forced venting

For positioners with forced venting function,
a voltage of 6 to 24 V DC must be applied to
the associated terminals.

The forced venting function can be activated
or deactivated over an internal switch. See
section 4.3 for details.

Note!

If there is no voltage connected or when the
voltage signal is interrupted, the positioner
vents the actuator and does not respond to
the reference variable.

EB 8382-1 EN 27

Connections

Fig. 9 · Electrical connections (terminal assignment according to DIN 45140)

GW2 GW1

PE

S

NC

-52

+51

-42

+41 -86

+85

-82 +81

IEC 1158-2

PROFIBUS-PA

6...24 VDC

Brass cable gland Shielding Clamping insert Coupling nut

Switching amplifier

acc. to EN 60947-5-6

Bus line

Limit switches Binary input Forced venting

3.2.2Limit switches

Switching amplifiers have to be connected in
the output circuit to operate limit switches. To
ensure operational safety of the positioner,
these switching amplifiers must comply with
the limits of the control circuit according to
NAMUR. Observe the relevant regulations if
the positioner is installed in hazardous ar­eas.

3.2.3Establishing communication
(bus address)

Communication between positioner, pro­grammable logic controller or automation
system, i.e. between PC or workstation and
the positioner(s), is established using a seg­ment coupler (see Fig. 10) in accordance
with the PROFIBUS guidelines.
If the positioner is used in hazardous areas,
exlosion-protected PROFIBUS-PA segment
couplers must be used.
A maximum of 32 positioners can be oper­ated in parallel on a segment coupler in one
PROFIBUS-PA segment. In hazardous areas,
fewer positioners can be connected.
Each positioner in a segment must be as­signed a unique bus address between 0
and 125. Seven microswitches located on the
inside of the positioner's hinged lid serve to
enter the bus address either directly by
switch numbers 1, 2, 4 etc. or by adding up
several switch positions. The positioner is de­livered with the default address set to 126.
Make absolutely sure that the switches are
adjusted all the way to either 1 or 0, not set
to an intermediate position.

Note!

Start the positioner up again for a new bus
address to be adopted.

3.2.4Local interface (SSP)

The local interface is located on the inside of
the positioner's hinged lid. It is connected to
a PC over the serial interface adapter (order
no. 1400-7700). The positioner can be
started up using the interface and
SAMSON's TROVIS-VIEW software.

It is no longer necessary to connect the de­vice to a PROFIBUS DP/PA segment. Only
the power supply needs to be connected over
the bus terminals of the positioner (any DC
voltage supply unit between 9 and 32 V).

The TROVIS-VIEW software and the device
module 3785 in version 2.02 are required.

The positioner can also be accessed over the
SSP interface when it is connected to a bus
segment.

Cyclic and acyclic data exchange are not af­fected. The value written last is always valid
for the device parameters.

28 EB 8382-1 EN

Connections

EB 8382-1 EN 29

Connections

PROFIBUS-DP(E) RS 485

3785

3785

3785

3785

PROFIBUS-PA IEC 61158-2

PROFIBUS-DP RS 485

3785-1

3785-1

3785-1

3785-1

PROFIBUS-PA IEC 61158-2

PROFIBUS-DP(E) RS 485

PROFIBUS-DP RS 485

Fig. 10 · PROFIBUS connection

Controller/PLC/control system
(Class 1 Master)

Display and control component
(Class 2 Master)

Segment coupler

Termination

Termination

Fig. 10.1 · Connection of Type 3785 Positioners

Fig. 10.2 · Connection of Type 3785-1 Positioners in hazardous areas

Controller/PLC/control system
(

Class 1 Master)

Display and control component
(

Class 2 Master)

Termination

Ex-proof segment coupler

Termination

Non-haz­ardous
area

Hazard­ous area

4 Operation

Warning!

Before putting the positioner into op­eration, carefully move the control
valve to its end position by covering
the hole (manually) on the cover plate
(Fig. 11). Check whether the lever
mechanism functions properly.
If the maximum angle of rotation is
exceeded by selecting the wrong le­ver mechanism or sizing the lever
mechanism incorrectly, the positioner
may be destroyed.

4.1 LED controls

Two LEDs located inside the cover serve to
monitor the positioner, indicating the
positioner's status during start-up, operation
and in the event of defects.

The colors indicate the following:
Red Start-up or error, no control

operation possible

Green No error recognized, control

operation or fail-safe position
(e.g. if not initialized)

Red + Green Error recognized, control

operation possible

For details, refer to the table below.

30 EB 8382-1 EN

Operation

!

Description LED

Positioner start-up Red ON

No errors
Positioner connected to bus, cold start performed, initial­ization required
When initializing or adjusting zero
Positioner initialized, no valid set point
Positioner initialized, valid set point, control operation

Green, generally
Green blinks slowly

Green blinks quickly
Green blinks 3 times quickly + long pause
Green ON

Errors during control operation
Zero point error
Control loop error

Red and green
Red and green blink slowly
Red and green blink quickly

Errors causing the first initialization to be canceled
(positioner does not start standard operation)
Zero point error
Error in mechanics/pneumatics section
Control loop error

Red, generally

Red blinks slowly
Red ON
Red blinks quickly

Errors causing the positioner to stop control operation
Positioner recognized an internal error Red blinks 3 times quickly + long pause

4.2 Write protection

A microswitch marked "write protection" is
located to the right of the seven bus address
selector switches inside the hinged cover.
When it is activated (position ON), the
positioner settings are write-protected so that
they cannot be overwritten by the PROFIBUS
communication protocol. If you want to
change the settings via communication, set
the switch to position OFF.

4.3 Activate/deactivate forced
venting

For model index .03 and higher:

1. Remove four screws from the cover inside

the hinged lid and remove the cover.

2. Remove screw in the middle of the

printed circuit board and turn the PCB to
one side.

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

4.4 Default settings

All parameters are set to their default values.
Refer to section 8 for descriptions of the pa­rameters.

Caution!

Manual operation and activated end
position function can cause the actua­tor to be pressurized with the maxi­mum supply pressure. If this causes
inadmissible forces, restrict the supply
pressure using a suitable pressure re­ducing station.

EB 8382-1 EN 31

Operation

GW1

GW2

3785

PE

IEC 1158-2

S

NC -52

+51

-42

+41

-86

+85

-82

+81

LED 1

LED 2

1

2

4

8

16

32

64

Write protection

Caution!

Valve

actuates

Init/Zero

Bus address

10

0N0FF

0

Fig. 11 · Inside view of the cover plate

Arrow for
mounting position Pointer Manual operation Bus address Write protection switch

Zero point lever Metal tags Adjustment screws LEDs Key for initialization

for limit switches or zero adjustment

!

4.4.1Adjusting mechanical zero

Important!

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

4

Firmly push the zero point lever, which is
located on 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.

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

4.4.2Initialization

After the electric reference variable and the
supply air have been connected to the
positioner, the initialization process can be
started. During initialization, the positioner is
optimally adapted to the friction conditions
and signal pressure demands of the control
valve.

Warning!

The initialization process takes sev­eral minutes. During that time, the
valve changes its position. Therefore,
never initialize the positioner during
a running process; only perform ini­tialization 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
bench.

4

Enter data for valve and actuator in the
Start-up section of the operating software.

4

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

4

Start initialization.

A successful initialization is indicated in the
operating software and over the LEDs (see
section 4.1).

4

Carry out the configuration suitable for
the valve type.

The following settings are recommended:

4

Fail-safe position "Actuator stem ex­tends":

Direction of action: increasing/increasing
(>>), a globe valve opens with increasing
reference variable
End position at a reference variable be­low 1 % (tight closing)
End position at a reference variable
above 125 % (function deactivated).

4

Fail-safe position "Actuator stem re­tracts":

Direction of action: increasing/decreas­ing (<>), a globe valve closes with in­creasing reference variable
End position at a reference variable
below –2.5 % (function deactivated)
End position at a reference variable
above 99 % (tight closing).

32 EB 8382-1 EN

Operation

!

4

Set delay time to at least 30 s.

4

Enter tag identification.

4

If necessary, configure the positioner
further, e.g. special characteristics for ro­tary valves.

If no communication can be established on
the valve, the positioner can also be initial­ized directly on the device itself.

4

Connect positioners that are not mounted
on a valve to a power supply and initial­ize the positioner as described in section

4.4.2.
If communication cannot be established,
the default settings must be used.

4

Mount positioner and adjust mechanical
zero as described in section 4.4.1.

4

Start initialization by pressing the
Init/Zero key on the positioner's hinged
lid using a suitable tool.

Initialization is completed when the
positioner moves to the position predeter­mined by the reference variable.

Note!

Once the positioner has been initialized suc­cessfully for the first time, pressing the
Init/Zero key only starts a zero calibration.

After a successful initialization, the positioner
can be re-initialized when communication is
established.

A completed initialization routine can be
canceled using communication with the "Re­set to default values" command. After that,
the Init/Zero key can be pressed again to
start a complete initialization.

Electric zero calibration

If mechanical zero has shifted during the
valve's operation, an electric zero calibration
can be carried out. To do so, press the
Init/Zero key located on the inside of the
lid (Fig. 11).

Caution!

The control valve moves to its end po­sition.

4

Firmly push the zero point lever, which is
located on 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.

4

Press key again to start electric calibra­tion.

After the key has been pressed for the sec­ond time, it is locked for approximately one
minute.
Electric calibration is completed when the
positioner moves to the position predeter­mined by the reference variable.

EB 8382-1 EN 33

Operation

!

4.5 Adjusting the inductive limit
switches

The positioner version with inductive limit
switches has two adjustable metal tags that
are mounted on the shaft of the positioner le­ver and operate the associated proximity
switches.
Connect appropriate switching amplifiers to
the output circuit to operate the inductive
limit switches (see section 3.2.2).

If the tag is inside the inductive field of the
proximity switch, the switch assumes a high
resistance. If the tag is outside 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 signal in­termediate valve positions.

The desired switching function, i.e. whether
the output relay is to be pulled in or dropped
out when the tag has entered the field, has to
be determined at the switching amplifier, if
required.

Adjusting the switching point

The limit switches are marked GW1 and
GW2 on the inside of the housing cover. Yel­low tags and the associated adjustment
screws (Fig. 11) are located below these
markings.

Each switching position can optionally be
signaled when the tag has entered or left the
field.

4

Move the valve to the switching position
and adjust the tag of the desired 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 transistor relay.

When doing so, one edge of the yellow tag
is aligned with the white, horizontal line on
the housing cover. This indicates the side
from which the tag enters the inductive field
of the proximity switch.

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

34 EB 8382-1 EN

Operation

5 Maintenance

The positioner is maintenance free.
Pneumatic connection 9/Supply contains a
filter with a mesh size of 100 µm. Remove
and clean the filter, if required.

Observe the maintenance instructions for up­stream pressure reducing stations for supply
air, if applicable.

6 Servicing explosion-protected

devices

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

Inspection by an expert is not required if the
manufacturer performs a routine test on the
device prior to putting it back into operation.
The passing of the routine test must be docu­mented by attaching a mark of conformity to
the device.

EB 8382-1 EN 35

Maintenance

7 How to implement a Class 1 PROFIBUS Master

7.1 Device database files (GSD)

The device data are provided as a text file (SAMS3785.GSD). It is available from
SAMSON AG under order no. 1400-7417 on a 3½" 1.44 MB floppy disk or on the Internet
at http://www.samson.de or http: //www.profibus.com.
The device database file permit the standardized implementation of the SAMSON
Type 3785 PROFIBUS Positioner as a PROFIBUS slave unit in the programming and configu­ration environment of a Class 1 master (example: SIEMENS Simatic Step 7, HWConfig).
Using the device database file, the Class 1 master is informed about the basic possibilities of
cyclic data exchange with the slave unit – in this case, the Type 3785 Positioner.

7.2 Data exchange

According to the PROFIBUS PA device profile for electropneumatic actuators, a total of seven
cyclic parameter combinations is available for the exchange of data. One of the combina­tions is to be selected in the programming and configuration environment of the Class 1
master.
The terms "Output" and "Input" refer to the control system/Class 1 master.

Variant 1: Module = SP; 0xA4

Output value (Output)

Byte 0 1234

Octet 1

Sign,

exponent

Octet 2

Exponent,

fraction

Octet 3

Fraction

Octet 4

Fraction

Octet 5

SP, value

(floating point, IEEE)

Status

Variant 2: Module = RCAS_OUT, RCAS_IN; 0xB4

Input value (Input)

Byte 0 1234

Octet 1

Sign,

exponent

Octet 2

Exponent,

fraction

Octet 3

Fraction

Octet 4

Fraction

Octet 5

RCAS_OUT, value

(floating point, IEEE)

Status

36 EB 8382-1 EN

How to implement a Class 1 PROFIBUS Master

Output value (Output)

Byte 0 1234

Octet 1

Sign,

exponent

Octet 2

Exponent,

fraction

Octet 3

Fraction

Octet 4

Fraction

Octet 5

RCAS_IN, value

(floating point, IEEE)

Status

Variant 3: Module = READBACK + POS_D, SP; 0x96, 0xA4

Input value (Input)

Byte 0 123456

Octet 1

Sign,

exponent

Octet 2

Exponent,

fraction

Octet 3

Fraction

Octet 4

Fraction

Octet 5 Octet 1 Octet 2

READBACK, value

(floating point, IEEE)

Status POS_D

value

POS_D

status

Output value (Output)

Byte 0 1234

Octet 1

Sign,

exponent

Octet 2

Exponent,

fraction

Octet 3

Fraction

Octet 4

Fraction

Octet 5

SP, value

(floating point, IEEE)

Status

Variant 4: Module = CHECKBACK, SP; 0x92, 0xA4

Input value (Input)

Byte 0 1 2

Octet 1 Octet 2 Octet 3

CHECK_
BACK[0]

CHECK_

BACK[1]

CHECK_
BACK[2]

EB 8382-1 EN 37

How to implement a Class 1 PROFIBUS Master

Output value (Output)

Byte 0 1234

Octet 1

Sign,

exponent

Octet 2

Exponent,

fraction

Octet 3

Fraction

Octet 4

Fraction

Octet 5

SP, value

(floating point, IEEE)

Status

Variant 5: Module = READBACK + POS_D + CHECKBACK, SP; 0x99, 0xA4

Input value (Input)

Byte 0 123456789

Octet 1

Sign, ex-

ponent

Octet 2

Exponent,

fraction

Octet 3

Fraction

Octet 4

Fraction

Octet 5 Octet 1 Octet 2 Octet 1 Octet 2 Octet 3

READBACK, value

(floating point, IEEE)

Status POS_D

value

POS_D

status

CHECK_
BACK[0]

CHECK_
BACK[1]

CHECK_

BACK[2]

Output value (Output)

Byte 0 1234

Octet 1

Sign,

exponent

Octet 2

Exponent,

fraction

Octet 3

Fraction

Octet 4

Fraction

Octet 5

SP, value

(floating point, IEEE)

Status

Variant 6: Module = RCAS_OUT + CHECKBACK, RCAS_IN; 0x97, 0xA4

Input value (Input)

Byte 0 1234567

Octet 1

Sign,

exponent

Octet 2

Exponent,

fraction

Octet 3

Fraction

Octet 4

Fraction

Octet 5 Octet 1 Octet 2 Octet 1

RCAS_OUT, value

(floating point, IEEE)

Status CHECK_

BACK[0]

CHECK_

BACK[1]

CHECK_
BACK[2]

38 EB 8382-1 EN

How to implement a Class 1 PROFIBUS Master

Output value (Output)

Byte 0 1234

Octet 1

Sign,

exponent

Octet 2

Exponent,

fraction

Octet 3

Fraction

Octet 4

Fraction

Octet 5

RCAS_IN, value

(floating point, IEEE)

Status

Variant 7:

Module = READBACK + RCAS_OUT + POS_D + CHECKBACK, SP + RCAS_IN; 0x9E, 0xA9

Input value (Input)

Byte 0 123456789

Octet 1

Sign,

exponent

Octet 2

Exponent,

fraction

Octet 3

Fraction

Octet 4

Fraction

Octet 5 Octet 1

Sign,

exponent

Octet 2

Exponent,

fraction

Octet 3

Fraction

Octet 4

Fraction

Octet 5

READBACK, value

(floating point, IEEE)

Status RCAS_OUT, value

(floating point, IEEE)

Status

Byte 10 11 12 13 14

Octet 1 Octet 2 Octet 1 Octet 2 Octet 3

POS_D

value

POS_D

status

CHECK_
BACK[0]

CHECK_
BACK[1]

CHECK_
BACK[2]

Output value (Output)

Byte 0 123456789

Octet 1

Sign,

exponent

Octet 2

Exponent,

fraction

Octet 3

Fraction

Octet 4

Fraction

Octet 5 Octet 1

Sign,

exponent

Octet 2

Exponent,

fraction

Octet 3

Fraction

Octet 4

Fraction

Octet 5

SP, value

(floating point, IEEE)

Status RCAS_IN, value

(floating point, IEEE)

Status

EB 8382-1 EN 39

How to implement a Class 1 PROFIBUS Master

7.3 Parameter description

SP – Set point with status: Reference variable w in "Auto" operating mode

The reference variable w of the positioner is preset by SP in automatic mode (AUTO).
SP consists of a floating point value (4 bytes) and the associated status (1 byte). Value and
status must be transferred together (data consistency = 5 bytes). If the status of the reference
variable is "bad" (value < 64 dec.), the positioner remains in the fail-safe position deter­mined by the actuator.

RCAS_IN/RCAS_OUT: Reference variable w in RCAS operating mode

The reference variable w of the positioner is preset in REMOTE CASCADE (RCAS) operating
mode by RCAS_IN/RCAS_OUT. RCAS_IN/RCAS_OUT both consist of one floating point
value (4 bytes) and the associated status (1 byte).
Value and status must be transferred together (data consistency = 5 bytes). If the status of the
reference variable is "bad" (value < 64 dec.), the positioner remains in the fail-safe position
determined by the actuator.

Note! RCAS operating mode is implemented in version K1.60 and higher.
READBACK – Current position with status: Controlled variable x

Position feedback is provided by the READBACK parameter and consists of a floating point
value (4 bytes) and the associated status (1 byte).

POS_D – Discrete valve position feedback with status: End position indication

The final valve position is indicated by the POS_D parameter and consists of one message
value (1 byte) and the associated status (1 byte). The message value is encoded as follows:

0 = not initialized, 1 = closed (x < 0.5 %), 2 = open (x > 99.5 %), 3 = intermediate position

CHECK_BACK – Device status: Detailed device information, bit-wise encoded

Bit no. Name Description Byte

0 CB_FAIL_SAFE Fail-safe position (mode = Out of Service)

0

1 CB_REQ_LOC_OP Request for local operation

2 CB_LOCAL_OP Device in local mode

3 CB_OVERRIDE Emergency operation / forced venting active

4, 5, 6 Not used

7 CB_TRAV_TIME Status of travel monitoring (reset automatically) 0

8, 9 Not used

1

10 CB_UPDATE_EVT Indicates change to static device data

40 EB 8382-1 EN

How to implement a Class 1 PROFIBUS Master

11 CB_SIMULATE

Simulation mode, i.e. value are not derived from the
process

1

12 CB_DISTURBANCE Error, refer to DIAGNOSIS parameter for cause

13 CB_CONTR_ERR

Error in internal positioner control loop (to be con­firmed by Class 2 master), indicated by LED, reset au­tomatically when control loop monitoring no longer
detects any errors

14 CB_CONTR_INACT Positioner inactive (mode = Out of Service)

15 CB_SELFTEST Positioner in self-test mode (mode = Out of Service)

16 CB_TOT_VALVE_TRAV Limit for total valve travel exceeded

2

17 to 23 Not used

Diagnostic messages of the positioner (slave diagnostic information)

In addition to the standard diagnostic messages, the positioner can provide further messages
as "Ext_Diag_Data". These are bit-wise encoded as well and correspond to the
PROFIBUS PA profile DIAGNOSIS parameter.

Bit no. Name Description

0 DIA_HW_ELETR Hardware error, electronics

1 DIA_HW_MECH Hardware error, mechanics

4 DIA_MEM_CHKSUM Checksum error, memory

5 DIA_MEASUREMENT Measurement error

6 DIA_NOT_INIT Positioner not initialized (no auto-initialization performed)

7 DIA_INIT_ERR Auto-initialization error

8 DIA_ZERO_ERR Zero point error (end position)

10 DIA_CONF_INVAL Invalid configuration

11

DIA_WARMSTART Restart (warm start) completed, refer to Profile A for definition of

warm start

12

DIA_COLDSTART New start (cold start) completed, refer to Profile A for definition of

cold start

13 DIA_MAINTENANCE Maintenance required

14 DIA_CHARACT Invalid characteristic

31 EXTENSION_AVAILABLE Further information available

EB 8382-1 EN 41

How to implement a Class 1 PROFIBUS Master

7.4 Coding of measured value status

Measured value status

The following status codes are used by the Type 3785 Positioner:

Bad Value is valid

Substatus Condition Decimal value

Configuration error Error in device configuration, value cannot be

determined

4

Device failure Device error: memory, electronics 12

Sensor failure Error in travel measurement, limit bits indicate

which measured value limits were exceeded*

16/17/18/19

No communication
(last usable value)

Internal communication error,
device operates with last usable value

20

No communication
(no usable value)

Internal communication error,
no usable error available

24

Out of service Transducer block in Out of Service mode

(e.g. device not initialized)

28

* Limit bits:
The two lowest bits of the measuring value status indicate that the limits for the measuring
value have been exceeded.

Bit 0 = Low limited – lower limit value not reached
Bit 1 = High limited – upper limit value exceeded
Bit 0 and 1 = Constant (high and low limited) – value is blocked

Uncertain Value is valid, but not derived from the process

Substatus Condition Value

Non-specific Initialization or zero calibration running 64

Initial value Initial value during device start-up (temporary) 76

42 EB 8382-1 EN

How to implement a Class 1 PROFIBUS Master

Good (non-cascade) Value is valid

Substatus Condition Value

OK Everything OK, no other status available 128

Maintenance required Transit time monitoring active, zero point error ac-

tive or total valve travel exceeded

164

Set point status

Good (non-cascade)

Substatus Condition Value

OK Everything OK 128 (80)

Good_INITIATE_FAIL_SAFE Positioner's defined fail-safe action activated 160 (AO)

Good (cascade)

Substatus Condition Value

Good_CAS_Init_Acknowledge Status required for transition to RCAS mode 196 (C4)

EB 8382-1 EN 43

How to implement a Class 1 PROFIBUS Master

7.5 Operating modes

Possible operating modes

The following operating modes are defined in the AO (Analog Output) profile:

4

Automatic (Auto)

4

Manual (Man)

4

Remote Cascade (RCas)

4

Local Override (LO)

4

Out of Service (OS)

The Type 3785 Positioner supports the following operating modes:

Up to firmware version K 1.20: OS, AUTO

Firmware version K 1.30 and higher: OS, LO, MAN, AUTO

Automatic (Auto) mode

In this operating mode, the positioner follows the set point that is cyclically or acyclically pre­set by the SP (w) parameter according to the scale and unit preset by PV_SCALE (reference
variable range).

Local Override (LO) or Manual (Man) mode

In these operating modes, the positioner follows the acyclic set point preset by the OUT pa­rameter (correction value) according to the scale and unit (mm or degrees) entered as
OUT_SCALE (travel/angle of rotation range). With the characteristic deactivated, this value
corresponds to the actual valve position in mm or degrees.
The INCREASE_CLOSE parameter (direction of action), however, is not processed. Neither
are the communication monitoring parameters (FSAFE_TIME, _TYPE, _VALUE) processed.

Remote cascade (Rcas) mode

In this operating mode, the positioner follows the set point cyclically preset by the RCAS_IN
(w_rcas) parameter according to the scale and unit preset by PV_SCALE (reference variable
range).

Out of Service (OS) mode

In this operating mode, the valve is automatically moved to its fail-safe position.

44 EB 8382-1 EN

How to implement a Class 1 PROFIBUS Master

EB 8382-1 EN 45

w_man

Configuration block diagram

Start

End

Reference

variable

range

Direction

of action

Correction

value

Speed

limit

Travel

limit

Travel

adapt.

> end

pos.

at

< end

pos.

at

End position function

Supply

valve

Exhaust

valve

Fail-safe position

Control

characteristic

Fail-safe action

"Stem extends"

"Stem

retracts"

Travel

range

relation

Travel

convers.

Filter

Forced venting,

optional

Hardware or system

software failure

Initialization

parameter

Transit time

Upper, lower

Travel range

Rated travel

Travel

Start-up (warm start)

The response of the positioner to a warm start is determined by the FSAFE_TYPE parameter
(fail-safe action).

If FSAFE_TYPE is set to "control to fail-safe value", the positioner switches to automatic oper­ating mode and adjusts to the value determined by the FSAFE_VALUE parameter.

If FSAFE_TYPE is set to "control to last set point" or "fail-safe position determined by spring
action", the device remains in fail-safe position. As soon as a valid set point SP is transmitted
to the positioner, the operating mode changes to automatic.

If the status of the transmitted set point is "bad" or the positioner has not been successfully in­itialized, it remains in fail-safe position (Out of Service) up to firmware version K1.51. With
version K1.6 and higher, the behavior for a bad set point status is determined by the
FSAFE_TYPE parameter.

Monitoring parameters FSAFE_TIME, FSAFE_TYPE, FSAFE _VALUE

The action determined by the FSAFE_TYPE (fail-safe action) parameter is triggered by the fol­lowing events:

4

Start-up of the positioner (warm start)

4

Elapsing of DP-Watchdog through interruption of the cyclic communication with a
Class 1 master (not applicable when communication is terminated properly).

4

Elapsing of FSAFE_TIME in Automatic or Remote Cascade operating modes, when the
status of the reference variable valid in this operating mode (SP or RCAS_IN) is set to
"initiate fail-safe"

4

Receipt of a DP-Global Control service for which the clear bit is set (not yet applicable for
version K1.30)

By setting the status of the reference variable used in the valid operating mode to "bad", the
actuator always moves to the fail-safe position determined by the spring action (for firmware
versions K1.30 to K1.51). In version K1.6 and higher, the behavior for a bad set point status
is determined by the FSAFE_TYPE parameter.

46 EB 8382-1 EN

How to implement a Class 1 PROFIBUS Master

8 List of parameters

Below is an overview of parameters ordered by their fields of application.
The list of parameters following the overview is in alphabetical order and describes all
positioner parameters that can be displayed or modified using PROFIBUS communication,
e.g. on a PC.
Manufacturer-specific parameters of the SAMSON Type 3785 PROFIBUS-PA Positioner are
marked with (M).

Parameter overview
Device identification

Tag identification . . . . . . . . . . . . . . . . . . TAG_DESC

Firmware version, communication/control . . . . . . SW_REVISION

Hardware version, electronics/mechanics . . . . . . . HW_REVISION

Manufacturer, positioner . . . . . . . . . . . . . . . DEVICE_MAN_ID

Manufacturer, valve . . . . . . . . . . . . . . . . . VALVE_MAN

Manufacturer, actuator. . . . . . . . . . . . . . . . ACTUATOR_MAN

Type number, positioner . . . . . . . . . . . . . . . DEVICE_ID

Serial number, positioner. . . . . . . . . . . . . . . DEVICE_SER_NUM

Serial number of corresponding actuator . . . . . . . ACTUATOR_SER_NUM

Serial number of corresponding valve. . . . . . . . . VALVE_SER_NUM

Type of protection . . . . . . . . . . . . . . . . . . DEVICE_CERTIFICATION

Description . . . . . . . . . . . . . . . . . . . . . DESCRIPTOR

Message . . . . . . . . . . . . . . . . . . . . . . DEVICE_MESSAGE

Date of installation . . . . . . . . . . . . . . . . . . DEVICE_INSTALL_DATE

Identification, forced venting . . . . . . . . . . . . . IDENT_FORCED_VENTING (M)

Binary input . . . . . . . . . . . . . . . . . . . . . IDENT_BINARY_INPUT (M)

Identification, limit switches. . . . . . . . . . . . . . IDENT_LIMIT_SWITCHES (M)

Product number, positioner . . . . . . . . . . . . . . DEVICE_PRODUCT_NUM (M)

Text fields . . . . . . . . . . . . . . . . . . . . . . TEXT_INPUT_1…TEXT_INPUT_3 (M)

Date of last maintenance . . . . . . . . . . . . . . . VALVE_MAINT_DATE

Date of last calibration . . . . . . . . . . . . . . . . DEVICE_CALIB_DATE

Date of last configuration. . . . . . . . . . . . . . . DEVICE_CONFIG_DATE

EB 8382-1 EN 47

List of parameters

Start-up

Security locking . . . . . . . . . . . . . . . . . . . SECURITY_LOCKING

Cold start . . . . . . . . . . . . . . . . . . . . . . FACTORY_RESET

Warm start . . . . . . . . . . . . . . . . . . . . . DEVICE_RESET_CMD

Actuator type . . . . . . . . . . . . . . . . . . . . ACTUATOR_TYPE

Valve type. . . . . . . . . . . . . . . . . . . . . . VALVE_TYPE

Fail-safe position. . . . . . . . . . . . . . . . . . . ACTUATOR_ACTION

Attachment . . . . . . . . . . . . . . . . . . . . . ATTACHMENT (M)

Actuator version . . . . . . . . . . . . . . . . . . . ACTUATOR_VERSION (M)

Mounting position . . . . . . . . . . . . . . . . . . MOUNTING_POSITION (M)

Transit time, minimum OPEN . . . . . . . . . . . . . ACT_STROKE_TIME_INC

Transit time, minimum CLOSED. . . . . . . . . . . . ACT_STROKE_TIME_DEC

Calibration, command . . . . . . . . . . . . . . . . SELF_CALIB_CMD

Calibration, status . . . . . . . . . . . . . . . . . . SLF_CALIB_STATUS

Transmission, code. . . . . . . . . . . . . . . . . . TRANSM_CODE (M)

Transmission, length . . . . . . . . . . . . . . . . . TRANSM_LENGTH (M)

Transmission, pin position . . . . . . . . . . . . . . TRANSM_PIN_POS (M)

Initialization method . . . . . . . . . . . . . . . . . INIT_METHOD (M)

Device settings
Configuration

Write protection . . . . . . . . . . . . . . . . . . . WRITE_PROTECTION_SWITCH (M)

Reference variable range. . . . . . . . . . . . . . . PV_SCALE

Fail-safe value, reference variable . . . . . . . . . . FSAFE_VALUE

Fail-safe action . . . . . . . . . . . . . . . . . . . FSAFE_TYPE

Fail-safe time . . . . . . . . . . . . . . . . . . . . FSAFE_TIME

Travel/angle of rotation range . . . . . . . . . . . . OUT_SCALE

Direction of action . . . . . . . . . . . . . . . . . . INCREASE_CLOSE

Local operation enabled . . . . . . . . . . . . . . . LOCAL _OP_ENA

Rated travel/nominal angle . . . . . . . . . . . . . RATED_TRAVEL

Travel/angle limit, lower . . . . . . . . . . . . . . . TRAVEL_LIMIT_LOW

Travel/angle limit, upper. . . . . . . . . . . . . . . TRAVEL_LIMIT_UP

Transit time, desired CLOSED. . . . . . . . . . . . . TRAVEL_RATE_DEC

Transit time, desired OPEN. . . . . . . . . . . . . . TRAVEL_RATE_INC

48 EB 8382-1 EN

List of parameters

End pos. when reference variable is below limit value . SETP_CUTOFF_DEC
End pos. when reference variable is above limit value . SETP_CUTOFF_INC

Selection of characteristic . . . . . . . . . . . . . . CHARACT

Type of characteristic . . . . . . . . . . . . . . . . CHARACT_TYPE

Control parameters

Proportional-action coefficient KP_Y1 . . . . . . . . . SERVO_GAIN

Derivative-action coefficient KD. . . . . . . . . . . . SERVO_RATE

Deadband Xtot . . . . . . . . . . . . . . . . . . . DEADBAND

Proportional-action coefficient KP_Y2 . . . . . . . . . KP_Y2

Tolerated overshoot . . . . . . . . . . . . . . . . . TOL_OVERSHOOT (M)

Operation

Operating mode, desired/current . . . . . . . . . . MODE_BLK/TARGET_MODE

Controlled variable x. . . . . . . . . . . . . . . . . READBACK

Reference variable w. . . . . . . . . . . . . . . . . SP

Reference variable w_rcas . . . . . . . . . . . . . . RCAS_IN/RCAS_OUT

Valve position feedback, discrete . . . . . . . . . . . POS_D

Set point deviation e . . . . . . . . . . . . . . . . . SETP_DEVIATION

Correction value . . . . . . . . . . . . . . . . . . . OUT

Transducer state . . . . . . . . . . . . . . . . . . . TRANSDUCER_STATE (M)

Diagnostics

Diagnostics . . . . . . . . . . . . . . . . . . . . . DIAGNOSIS

Diagnostics extension . . . . . . . . . . . . . . . . DIAGNOSIS_EXTENSION

Simulation. . . . . . . . . . . . . . . . . . . . . . SIMULATE

Device status. . . . . . . . . . . . . . . . . . . . . CHECK_BACK

Total valve travel, absolute . . . . . . . . . . . . . . TOTAL_VALVE_TRAVEL

Total valve travel, limit . . . . . . . . . . . . . . . . TOT_VALVE_TRAV_LIM

Delay time. . . . . . . . . . . . . . . . . . . . . . DELAY_TIME (M)

Tolerance band . . . . . . . . . . . . . . . . . . . TOLERANCE_BAND (M)

Calibration, alarm message . . . . . . . . . . . . . SELF_CALIB_WARNING (M)

Binary input, status. . . . . . . . . . . . . . . . . . BINARY_INPUT (M)

Travel/angle of rotation, max. permissible . . . . . . MAX_HUB (M)

EB 8382-1 EN 49

List of parameters

Actuator type

ACTUATOR_TYPE
States:

Default:

Identifies the actuator design
Read-only parameter, determined by actuator
0 = Electropneumatic 1 = Electric

2 = Electrohydraulic 3 = Other
0

Actuator version

ACTUATOR_VERSION (M)
States:

Default:

Specifies the actuator version with/without spring return mechanism

0 = Single-acting with spring return mechanism
1 = Double-acting without spring return mechanism

0

Attachment

ATTACHMENT (M)

States:

Default:

Defines positioner attachment to control valves with linear actuators.
For rotary actuators, only attachment according to VDI/VDE 3845
(NAMUR) is possible. For details, refer to sections 2.1 and 2.2.

0 = Integral – attachment with SAMSON Type 3277 Linear Actuator
1 = NAMUR – attachment acc. to IEC 60534-6 (NAMUR)

0

Binary input

IDENT_BINARY_INPUT (M)
States:

Default:

Describes whether and how the binary switch option is evaluated

0 = Not evaluated 1 = Actively open
2 = Actively closed

0

Binary input, status

BINARY_INPUT (M)
States:

Default:

Indicates state of the binary switch

0 = Deactivated 1 = Activated
254 = Not evaluated

0

Calibration, alarm message

SELF_CALIB_WARNING (M)
States:

Default:

Indicates additional alarm messages of started calibration procedure

0 = Not determined
13 = Improper selection of rated travel or transmission
15 = Air leakage of pneumatic system (during initialization)
254 = Successful
255 = No valid data in application

0

Calibration, command

SELF_CALIB_CMD
States:

Starts manufacturer-specific procedures in the field device

0 = No test, standard control operation
1 = Zero calibration
2 = Initialization
7 = Reset total valve travel
10 = Reset control loop error
255 = Cancel current action

50 EB 8382-1 EN

List of parameters

Calibration, status

SELF_CALIB_STATUS
States:

Indicates manufacturer-specific status of calibration procedure started
with SELF_CALIB_CMD

0 = Not determined
2 = Canceled
4 = Error in mechanics/pneumatics
11 = Timeout
17 = Initialization status: determining mechanical stops
19 = Initialization status: determining minimum transit times
20 = Initialization canceled by activating forced venting
30 = Zero point error
254 = Successful

Characteristic selection

CHARACT
States:

Default:

Selects characteristic to assign the reference variable to the valve
travel/angle range

0 = Linear
1 = Equal percentage
2 = Reverse equal percentage
3 = User-defined (will be supported in future firmware version)
4 = SAMSON butterfly valves: linear
5 = SAMSON butterfly valves: equal percentage
6 = VETEC rotary plug valves: linear
7 = VETEC rotary plug valves: equal percentage

0

Characteristic type

CHARACT_TYPE

Text field to describe the adjusted characteristic
Length: 32 characters

Cold start

FACTORY_RESET
States:

Default:

Resets the positioner to its default values

0 = No action
1 = Resets application to default values. All positioner data are reset
to their default values. Positioner moves to fail-safe position and must
be re-initialized. Only device identification parameters are retained.
2 = Resets device identification parameters to their default values.
Application parameters are retained.

0

Controlled variable x

READBACK

Indicates current valve position with status
Controlled variable x in % of travel/angle of rotation range

Correction value

OUT

Calculated by the function block from the set point in [mm] or [de­gree]. Value can be preset in Local Override mode

Date of installation

DEVICE_INSTALL_DATE

Indicates when the field device was installed

Date of last calibration

DEVICE_CALIB_DATE

Indicates when the field device was last calibrated

Date of last configuration

DEVICE_CONFIG_DATE

Indicates when the field device was last configured

EB 8382-1 EN 51

List of parameters

Date of last maintenance

VALVE_MAINT_DATE

Indicates when the last maintenance was performed on the field
device

Dead band Xtot

DEAD_BAND
Default:

Indicates dead band of the control characteristic between 0.1 and

10.0 % of the rated travel/nominal angle

0.5 %

Delay time

DELAY_TIME (M)

Range:

Default:

Specifies reset criterion for active control loop monitoring. If the en­tered delay time is exceeded and the system deviation is outside the
limits of the entered tolerance band, a control loop error is issued.

0 to 240 s
Determined during initialization from min. transit time; can be

adapted
10 s

Derivative-action coefficient KD

SERVO_RATE

Range:
Default:

Specifies gain factor of derivative element. We recommend incre­menting the value in steps of 0.02. Incrementing the value causes an
increased deceleration before the reference variable is reached.

0.0 to 1.00

0.12

Description

DESCRIPTOR

Text field to describe the application, saved in field device
Length: 32 characters

Device status

CHECK_BACK
Message type:

States:

Provides detailed, bitwise-encoded device information, which permits
several simultaneous messages; see also section 9

A: Dynamic messages, automatically reset when read
R: Static messages, retained as long as event exists in the field device

0 = No message
1 = Device status message active

Diagnostic extension

DIAGNOSIS_EXTENSION

Message type:

States:

Provides additional, detailed manufacturer-specific device informa­tion; bitwise-encoded, which allows for several simultaneous mes­sages; see also section 9

A: Dynamic messages, automatically reset when read
R: Static messages, remain active while error persists in field unit

0: No message
1: Diagnostic message active

Diagnostics

DIAGNOSIS
Message type:

States:

Provides detailed, bitwise-encoded device information, which permits
several simultaneous messages; see also section 9

A: Dynamic messages, automatically reset when read
R: Static messages, remain active while error persists in field unit

0 = No message
1 = Diagnostic message active

52 EB 8382-1 EN

List of parameters

Direction of action

INCREASE_CLOSE (M)
States:

Default:

Determines the assignment of reference variable to travel/angle

0 = Increasing/increasing, valve opens when reference variable

increases (for rotary plug valves, the actuator stem retracts)

1 = Increasing/decreasing, valve closes when reference variable

increases (for rotary plug valves, the actuator stem extends)

0

End position when reference
variable is above limit value

SETP_CUTOFF_INC

Default:

If the reference variable exceeds the entered limit, the valve moves to­wards its end position that corresponds to 100 % of the reference
variable; hysteresis: 1 %
Function is deactivated when the value is 125 %

1 %
Caution! Since the actuator is fully pressurized or vented when this

function is active, the valve moves to its absolute end positions. Re­strictions specified by the "travel range" or "travel limit" functions do
not apply. Deactivate the function if excessive positioning forces are
created by fully pressurizing or venting the actuator.

End position when reference
variable is below limit value

SETP_CUTOFF_DEC

Default:

If the reference variable exceeds the entered limit, the valve moves to­wards its end position that corresponds to 0 % of the reference vari­able; hysteresis: 1 %
Function is deactivated when the value is –2.5 %

99 %
Caution! Since the actuator is fully pressurized or vented when this

function is active, the valve moves to its absolute end positions.
Restrictions specified by the "travel range" or "travel limit" functions
do not apply. Deactivate the function if excessive positioning forces
are created by fully pressurizing or venting the actuator.

Fail-safe action

FSAFE_TYPE
States:

Default:

Defines response when communication failure or device start-up is
detected

0 = Control to fail-safe value
1 = Control to/save last valid set point
2 = Move to fail-safe position determined by spring action

1

Fail-safe position

ACTUATOR_ACTION

States:

Indicates actuator's fail-safe position upon air/power supply failure
or device start-up; read-only value; automatically detected during ini­tialization

0 = Not initialized
1 = Opening in direction of 100 % position
2 = Closing in direction of 0 % position
3 = None/saving (position is retained)

Fail-safe time

FSAFE_TIME
Range:
Default:

When DP-Watchdog detects a communication failure, fail-safe action
is triggered after the fail-safe time has elapsed.

0 to 3600 s
10 s

EB 8382-1 EN 53

List of parameters

Fail-safe value, reference var.

FSAFE_VALUE
Default:

Functions as replacement value for set point (reference variable w or
w_cas) when communication failure was detected

0

Firmware version

SW_REVISION

Firmware version, communication/control

Hardware version

HW_REVISION

Hardware version, electronics/mechanics

Identification, forced venting

IDENT_FORCED_VENTING (M)
States:

Indicates whether the optional forced venting function is installed
Read-only parameter, automatically set by the device

0 = Not installed
1 = Installed

Identification, limit switches

IDENT_LIMIT_SWITCHES (M)
States:

Default:

Indicates whether optional inductive limit switch function is installed;
not detected automatically

0 = Not installed
1 = Installed

0

Initialization method

INIT_METHOD (M)

States:

Default:

Specifies Initialization method based on nominal or maximum range.
For initialization in nominal range, only the manipulated variable
range entered under rated travel/nominal angle is considered (e.g.
globe valve with mechanical stop on one side).
For initialization in maximum range, the max. possible manipulated
variable range is used (e.g. three-way valve with mechanical stops
on both sides).

0 = Initialization based on maximum range
1 = Initialization based on nominal range

0

Local operation enabled

LOCAL_OP_ENA
States:

Default:

Unlocks local operation (zero/initialization button). Local operation
is enabled when communication fails for longer than 30 s.

0 = Disabled
1 = Enabled

1

Manufacturer, actuator

ACTUATOR_MAN

Clearly identifies the manufacturer of the actuator
Length: 16 characters

Manufacturer, positioner

DEVICE_MAN_ID

Clearly identifies the manufacturer of the field device
Read-only parameter

Manufacturer, valve

VALVE_MAN

Clearly identifies the manufacturer of the valve
Length: 16 characters

Message

DEVICE_MESSAGE

Text field to enter any desired text, saved in the field device
Length: 32 characters

54 EB 8382-1 EN

List of parameters

Mounting position

MOUNTING_POSITION (M)
(linear actuator)

States:

Default:

An arrow on the positioner's cover plate indicates how to attach the
positioner to the actuator.
For direct attachment, the arrow must point towards the actuator.
For NAMUR attachment, the arrow must point away from the actuator.

0 = Arrow points away from actuator
1 = Arrow points towards actuator

1

Operating mode, current
Operating mode, desired

MODE_BLK / TARGET_MODE

Positioner operating modes for firmware versions:
K 1.20 and earlier: OS, AUTO
K 1.30 and higher: OS; LO, MAN, AUTO

Operating modes of the positioner:
Automatic (AUTO): In AUTO mode, the positioner follows the set

point defined by the SP (w) parameter, which is preset cyclically or
acyclically, according to the scale and unit determined by PV_SCALE
(reference variable range).

Manual (MAN): In MAN mode, the positioner also follows the set
point defined by the SP (w) parameter, which is preset cyclically or
acyclically, according to the scale and unit determined by PV_SCALE
(reference variable range). The INCREASE_CLOSE (direction of ac­tion) parameter, however, is not processed; neither are the communi­cation monitoring parameters (FSAFE_TIME, _TYPE, _VALUE).

Local Override (LO): In LO mode, the positioner follows the set point
defined by the OUT parameter (correction value), which is refreshed
acyclically, according to the scale and unit (mm or degree) preset by
OUT_SCALE (travel/angle of rotation range). With the characteristic
deactivated, this value corresponds to the actual valve position in mm
or degrees. The INCREASE_CLOSE parameter (direction of action),
however, is not processed; neither are the communication monitoring
parameters (FSAFE_TIME, _TYPE, _VALUE).

Out of Service (OS): In this mode, the valve is automatically moved to
fail-safe position.

Remote Cascade (RCas): In RCas mode, the positioner follows the set
point defined by the RCAS_IN (w_rcas) parameter, which is re­freshed cyclically, according to the scale and unit preset by
PV_SCALE (reference variable range).

Operating mode during start-up (warm start)

The positioner's response to a warm start is determined by the
FSAFE_TYPE parameter (fail-safe action).
If FSAFE_TYPE is set to "control to fail-safe value", the positioner
switches to automatic operating mode and controls to the value pre­set by FSAFE_VALUE.
If FSAFE_TYPE is set to "control to last set point" or "fail-safe position
determined by spring action", the positioner remains in fail-safe posi­tion. The positioner switches to automatic operating mode as soon as
a valid set point SP is transmitted to the device.

If the status of the transmitted set point is "bad" or if the positioner
has not been successfully initialized, the positioner remains in
fail-safe position (Out of Service).

EB 8382-1 EN 55

List of parameters

Operating mode, current
Operating mode, desired

MODE_BLK / TARGET_MODE
(continued)

The action determined by the FSAFE_TYPE parameter (fail-safe ac­tion) is triggered by the following events:
– Start-up of the positioner (warm start)
– Elapsing of DP watchdog by interrupting the cyclic communica-

tion with a Class 1 master (not applicable when communication
is properly terminated)

– Elapsing of FSAFE_TIME (fail-safe time) in automatic or remote

cascade operating mode when the status of the reference vari­able valid in this operating mode, SP or RCAS_IN, is set to "Initi­ate fail-safe"

– Receipt of a DP "Global Control" service for which the CLEAR bit

is set (not in K 1.30)

By setting the reference variables tatus, which is used in the current
operating mode, to "bad", the actuator always moves to the fail-safe
position determined by the spring action (version K 1.30 and
higher).

Product number, positioner

DEVICE_PRODUCT_NUM (M)

Indicates the manufacturer's product number of the positioner

Proportional-action coefficient
KP_Y1

SERVO_GAIN

Proportional-action coefficient for supply air:
When writing, the value is written to KP_Y1 (supply air) and KP_Y2
(exhaust air).

Proportional-action coefficient
KP_Y2

Range:
Default:

Proportional-action coefficient for exhaust air:
When writing, the value is written to KP_Y2 (exhaust air). KP_Y1 (sup­ply air) remains unchanged.

Between 0.01 to 10.0, we recommend incrementing the value in steps
of 0.1. When increasing the value, the set point is reached faster.

0.01 to 10.0

1.2

Note!

The proportional-action coefficients KP_Y1 and KP_Y2 are deter­mined when the positioner is initialized for the first time. The initial­ization values listed in the table on page 57 may have to be adapted
to the changed operating conditions to achieve optimum control be­havior.

Rated travel/nominal angle

RATED_TRAVEL
Default:

Specifies rated travel [mm] or nominal angle [degree] of the valve
Nominal operating range 5 to 255 mm or 0.0° to 120.0°

15 mm

Reference variable range

PV_SCALE
Default:

Specifies scale and unit of reference variable w/w_cas (SP or
RCAS_IN)

0 to 100 %

Reference variable w

SP

Specifies the set point with status. Reference variable in AUTO /
MANUAL mode. See also "Reference variable range"

Reference variable w_rcas

RCAS_IN / RCAS_OUT

Specifies the set point with status. Reference variable in RCAS mode
See also Reference variable range

56 EB 8382-1 EN

List of parameters

Security locking

SECURITY_LOCKING
Default:

Memory position for a password to be used by the host, serves to
check access rights (format: 16 bit unsigned integer)

0x2457

Serial no., actuator

ACTUATOR_SER_NUM

Indicates serial number of the actuator associated with the positioner
Length: 16 characters

Serial no., positioner

DEVICE_SER_NUM

Indicates positioner's serial number. Clearly identifies the field unit
together with the manufacturer ID and type number.

Serial no., valve

VALVE_SER_NUM

Indicates serial number of the valve associated with the positioner
Length: 16 characters

Set point deviation e

SETP_DEVIATION

Indicates the system deviation in percent

Simulation

SIMULATE

Allows operators to specify a simulation value for the current
READBACK position including status

Tag identification

TAG_DESC

Indicates tag number of the positioner
Length: 32 characters

Text fields

TEXT_INPUT_1 to
TEXT_INPUT_3 (M)

Text fields to enter any desired text
Length: 32 characters

EB 8382-1 EN 57

List of parameters

Type of
actuator

Rated travel/

nom. angle

Transit time

KD

KP_Y1
Supply

KP_Y2

Exhaust

Min Fail-safe action OPEN CLOSED

Rotary

actuator

–

– > 0.7 s > 0.7 s

0.12

0.5 0.5

Closing > 0.7 s < 0.7 s 0.5 0.1

Closing < 0.7 s > 0.7 s 0.1 0.5

– < 0.7 s < 0.7 s 0.1 0.1

Opening > 0.7 s < 0.7 s 0.1 0.5

Opening < 0.7 s > 0.7 s 0.5 0.1

Linear

actuator

≥

60 mm

< 10 s – 0.5 0.5

≥

10 s – 3.0 4.0

< 60 mm

< 10 s

– > 0.7 s > 0.7 s 0.5 1.2

Stem extends > 0.7 s < 0.7 s 0.5 0.8

Stem extends < 0.7 s > 0.7 s 0.3 1.2

– < 0.7 s < 0.7 s 0.3 0.8

Stem retracts > 0.7 s < 0.7 s 0.3 1.2

Stem retracts < 0.7 s > 0.7 s 0.5 0.8

≥

10 s – 3.0 4.0

Tolerance band

TOLERANCE_BAND (M)
Range:
Default:

Reset criterion for active control loop monitoring. Enter permissible de­viation for control loop monitoring. See also DELAY_TIME parameter.

0.1 to 10.0 %
5 %

Tolerated overshoot

TOL_OVERSHOOT (M)

Adjustment range:
Default:

If the set point deviation e exceeds the tolerated overshoot, pulse adaptation re­duces the minimal pulses in operating direction that caused the overshooting.
If the set point deviation e exceeds the dead band Xtot, but stays within the toler­ated overshooting range, pulse adaptation reduces the minimal pulses in both
moving directions after two complete amplitudes with the overshooting range.

0.01 to 10.00 % of rated travel/opening angle

0.5 %

Total valve travel, absolute

TOTAL_VALVE_TRAVEL

Specifies absolute total valve travel, i.e. sum of nominal duty cycles
(e.g. valve travels from fully open to fully closed position and back)
Maximum value: 16,500,000

Total valve travel, limit

TOT_VALVE_TRAV_LIM
Default:

Specifies limit for the total valve travel.
Range: 0 to 16,500,000

1,000,000

Transducer state

TRANSDUCER_STATE (M)
States:

Indicates current state of control

0 = See current operating mode 1 = Forced venting active
2 = Lower travel limit active 3 = Upper travel limit active
4 = End position at < active 5 = End position at > active

Transit time, desired CLOSED

TRAVEL_RATE_DEC
Range:

Default:

Specifies the adjustable min. time in seconds that the valve needs to
move through the manipulated variable range towards 0 % position.

0 to 75 s
0 s

Transit time, desired OPEN

TRAVEL_RATE_INC

Default:

Specifies the adjustable minimum time in seconds that the valve
needs to move through the manipulated variable range towards
100 % position. Range: 0 to 75 s

0 s

Transit time, minimum CLOSED

ACT_STROKE_TIME_DEC

The minimum transit time to CLOSE the valve (towards 0 % position)
specifies the actual time in seconds that the system (positioner, actua­tor, valve) needs to move through the rated travel/angle and close
the valve. This parameter is measured during start-up.

Read-only value

Transit time, minimum OPEN

ACT_STROKE_TIME_INC

The minimum transit time to OPEN the valve (towards 100 % posi­tion) specifies the actual time in seconds that the system (positioner,
actuator, valve) needs to move through the rated travel/angle and
open the valve. This parameter is measured during start-up.

Read-only value

58 EB 8382-1 EN

List of parameters

Transmission code

TRANSM_CODE (M)
States:

States:

Default:

For linear actuators with integrally attached positioner: determine
geometrical dimensions of the travel pick-off with integral attachment

1 = D1, lever length 64 mm 2 = D2, lever length 106 mm

For rotary actuators:

Max. opening angle of selected segment of the installed cam disk
3 = S90, 90° segment 4 = S120, 120° segment

1

Transmission length

TRANSM_LENGTH (M)

Range:
Default:

Only for linear actuators with positioner attached acc. to NAMUR

Lever length, distance between travel pick-off and fulcrum of pick-off
lever

0.0 to 1023.0 mm

42.0 mm

Transmission pin position

TRANSM_PIN_POS (M)
States:
Default:

Only for linear actuators with positioner attached acc. to NAMUR

Position of pin on positioner lever, see marking on positioner lever
0 = A 1 = B
0

Travel/angle limit, lower

TRAVEL_LIMIT_LOW
Default:

Allows you to enter the lower limit of the valve travel/angle
Range: –20.0 to 99.9 %. The characteristic is not adapted.

0.0 %

Travel/angle limit, upper

TRAVEL_LIMIT_UP
Default:

Allows you to enter the upper limit of the valve travel/angle
Range: 0.0 to 120.0 %. The characteristic is not adapted.

100.0 %

Travel/angle of rotation range

OUT_SCALE

Range:
Default:

Specifies the adjusted upper and lower values of the actual operating
range in mm or degrees. For non-linear characteristics, the charac­teristic is adapted to the reduced travel.

If the positioner is initialized based on the maximum range, the travel/angle
range is always relative to the entered rated travel/angle. The operating range
must not be smaller than ¼ of the rated travel/angle.

0.0 to 255.9 mm / 0.0° to 120.0°
Lower limit: 0 Upper limit: 15 mm/90°

Travel/angle of rotation, max.
permissible

MAX_HUB (M)

Specifies the maximum permissible travel/opening angle determined
during initialization in percent of the rated travel/opening angle

Note! If initialization was successful with regard to the nominal
range, the maximum permissible travel/angle is not determined.

Type number, positioner

DEVICE_ID

Specifies the type number of the field unit

Type of protection

DEVICE_CERTIFICATION

Specifies the field unit's type of protection

Valve position feedback, discrete

POS_D
States:

Indicates the discrete valve position feedback with status

0 = Not initialized 1 = Closed (x < 0.5 %)
2 = Open (x > 99.5 %) 3 = Intermediate

EB 8382-1 EN 59

List of parameters

Valve type

VALVE_TYPE
States:

Default:

Specifies the valve design

0 = Control valve with linear motion of the connecting element
1 = Control valve with rotary or part-turn motion of the element

0

Warm start

DEVICE_RESET_CMD
States:
Default:

Resets the field device (warm start)

0 = No action 1 = Reset the device
0

Write protection

WRITE_PROTECT_SWITCH (M)

States:

Indicates state of the write-protection switch in the positioner
When write protection is activated, device data can only be read, but
not overwritten. Write protection can only be activated on the switch
in the positioner.

0 = Write enabled 1 = Write protected

60 EB 8382-1 EN

List of parameters

9 Messages and diagnostics

The Type 3785 PROFIBUS-PA Positioner provides the best opportunities for diagnostics dur­ing the initialization phase. The positioner automatically conducts detailed tests to check the
mounting position and valve response as well as to evaluate them based on the entered or
preset parameters.
When running routine tests or when unclear diagnostic/error messages occur during opera­tion, we recommend to re-initialize the positioner to better assess the control system.

9.1 Diagnostic messages

Hardware error in electronics

This message is issued when the cyclic check detects a defect in the electronics module.
Requires repair.

Hardware error in mechanics

This message is issued when the cyclic check detects a defect in the mechanics module.
Requires repair.

Error in data memory

This message is issued when the cyclic check detects that a storage cell was changed without
verification. The static message remains active while the error persists in the field unit.

Measurement error

This message indicates that the internal analog/digital converter does not work properly within
its time frame or the measured values are outside the physical measuring range limits of the
analog/digital converter. Repair is required if resetting the positioner fails after performing a
warm start. The static message remains active while the error persists in the field unit.

Device not initialized (no auto-initialization performed)

This message indicates that the device has not been initialized yet or a cold start was per­formed. The message is automatically reset when initialization has been competed successfully.

Auto-initialization error

This message indicates that initialization could not be completed successfully. Detailed error
messages will be issued (see section 9.4). The message is automatically reset when initializa­tion has been competed successfully.

EB 8382-1 EN 61

Messages and diagnostics

Zero point error (end position)

This message indicates any change that exceeds the value determined during initialization or
zero adjustment by more than ±5 %. Possible sources of error:
– Worn-out valve seat or plug
– Foreign particles between seat and plug

The message is automatically reset when zero adjustment has been competed successfully.

Incorrect configuration

This message indicates that incorrect values have been entered. When receiving an incorrect
value, the positioner indicates that the received value is outside the permissible range. The
previous value remains valid. The message is reset by confirmation.

Restart (warm start) completed

This message indicates that the positioner was reset by performing a warm start. The reset is
triggered by a restart after an electrical power failure or by the DEVICE_RESET_CMD = 1
command. The message is automatically reset when it is read.

New start (cold start) completed

This message indicates that the positioner was reset by performing a cold start and that it is
started up again with the default control values. The reset is triggered by the
FACTORY_RESET = 2 command. The positioner needs to be re-initialized.
The message is automatically reset when it is read.

Maintenance required

This message indicates that the current total valve travel value exceeds the entered or preset
limit. If the limit is adjusted slightly below the value determined for a reference valve, the
positioner automatically signals that the valve needs to be serviced so that a possible failure
is prevented. The message is reset by the SELF_CALIB_CMD = 7 command (reset total valve
travel).

Invalid characteristic

This message indicates that:
– An error occurred while the characteristic was transmitted to the positioner, or
– The input values for a user-defined characteristic were not entered in ascending order, or
– The gradient of a user-defined characteristic exceeds 16.

If an Invalid characteristic error occurs, the positioner automatically switches from a user-de­fined characteristic to a linear characteristic after receiving the values.
The message is automatically reset when a correct characteristic has been received.

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Messages and diagnostics

Further information available

This message indicates that extended diagnostic messages have been generated.

9.2 Extended diagnostic messages

Binary input active

This message indicates that the condition for activating the binary input has been fulfilled.

Invalid start values for min. pulses in range 1

This message indicates that the pulse search for the 0 to 20 % range of the rated travel/an­gle by adapting the pulse-pause ration has not been completed yet.
The message is automatically reset after supply and exhaust air pulses have successfully been
adapted.

Invalid start values for min. pulses in range 2

This message indicates that the pulse search for the 20 to 80 % range of the rated travel/an­gle by adapting the pulse-pause ration has not been completed yet.
The message is automatically reset after supply and exhaust air pulses have successfully been
adapted.

Invalid start values for min. pulses in range 3

This message indicates that the pulse search for the 80 to 100 % range of the rated
travel/angle by adapting the pulse-pause ration has not been completed yet.
The message is automatically reset after supply and exhaust air pulses have successfully been
adapted.

Error in optional forced venting function

This message indicates that either the optional module is not screwed on tightly or that the
coding jumper is not set when the optional forced venting function is missing.

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Messages and diagnostics

9.3 CHECKBACK messages

Fail-safe position (mode = Out of Service)

This message indicates that fail-safe position was triggered by the positioner. This can be
caused by selecting Out of Service mode, by activating the optional forced venting function
or by a communication failure. The positioner switches to Out of Service mode.

Request for Local Operation mode

This message indicates that local operation was requested, but not enabled
(LOCAL_OP_ENA = 0). The message is automatically reset when it is read.

Positioner in Local Operation mode
Forced venting active

This message indicates that forced venting was triggered, i.e. the signal at terminals +81
and –82 is smaller than 3 V. The valve is moved to fail-safe position regardless of the control
loop. The message is automatically reset when a 6 to 24 V DC signal is applied to terminals
+81 and –82.

Static data changed

This message indicates that positioner data have been changed, which allows operators to
detect (unintentional/unauthorized) changes of the originally adjusted values.
The message is automatically reset when it is read.

Simulation mode (values not derived from the process)

This message indicates that the positioner is in simulation mode. In this case, the controlled
variable x is preset.

Error (refer to section on diagnostic messages for possible causes)

This message indicates that the positioner is defective. Diagnostic messages indicate specific
causes.

64

Messages and diagnostics

Control loop error

This message indicates that the positioner fails to control within the adjusted tolerance band
for error monitoring within the specified delay time.

Possible sources of error:
– Oscillation caused by the actuator working too fast (small travel volume)

Remedy: reduce supply pressure (see section 3.1.2) or install signal pressure restriction.
– Supply air failure/insufficient supply air
– Clogged filter
– Oiled-up solenoid valves
– Ruptured actuator diaphragm
– Broken actuator springs
– Considerable increase in friction on the control valve
– Blocked control valve

The message is indicated by bit 7 and bit 13 of the Checkback parameter (see table on
pages 38/39). The state of bit 7 is automatically reset; bit 13 is reset by the
SELF_CALIB_CMD = 10 command (reset Control Loop Error).

Positioner inactive (mode = Out of Service)

This messages indicates that the positioner is in Out of Service mode.

Positioner in self-test mode (mode = Out of Service)

This message indicates that the positioner is going through the initialization process or elec­tric zero calibration.

Limit for total valve travel exceeded

This message indicates that the current total valve travel value exceeds the entered/preset
limit. If the limit is adjusted slightly below the value determined for a reference valve, the
positioner automatically signals that the valve needs to be serviced so that a possible failure
is prevented.
The message is reset by the SELF_CALIB_CMD = 7 command (reset total valve travel).

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Messages and diagnostics

9.4 Messages during initialization

Not defined

This message indicates that the positioner has not yet been initialized or that a cold start was
performed.
The message is reset by confirmation.

Canceled

This message indicates that the initialization routine was aborted by the user.
The message is reset by confirmation.
If the positioner had already been initialized successfully and no cold start has been trig­gered, the positioner returns to control operation.

Error in mechanics/pneumatics section

This message indicates that the initialization routine detects no or a constant change of the
value measured for the controlled variable travel/angle. Initialization is canceled.

Possible sources of error:
– Insufficient/unstable supply pressure
– Insufficient air capacity
– Improper mechanical attachment
– Pick-off lever improperly mounted
– With NAMUR attachment: lever incorrectly secured to the shaft of the adapter housing
– Connecting cable between logic unit and PCB for travel pick-off removed

Timeout

This message indicates that the valve could not be moved to its end position within max.
240 seconds. Initialization is canceled.

Possible sources of error:
– Large difference between static and sliding friction on the control valve (oscillation) triggers

separate message
– Unstable supply pressure
– Insufficient air capacity

66 EB 8382-1 EN

Messages and diagnostics

Incorrect selection of rated travel or transmission

This message indicates that the maximum travel determined, which is issued in percent of the
rated travel/angle, is smaller than the selected rated travel/angle.
Warning! Initialization is not canceled.

Possible sources of error:
– Improper mechanical attachment
– Improper transmission entered
– With NAMUR attachment: wrong pin position selected
– Valve blocked
– Insufficient supply pressure. Adjust the supply pressure to be at least 0.4 bar above the

upper spring range value (see section 3.1.2).

Leakage in pneumatic system

When initially determining the minimum control pulse, the actuator must stall for a few sec­onds. This period of time is used to leak-test the pneumatic system. If the control valve moves
from its rest position by more than 9.3 % within seven seconds, the associated message is
generated. Additionally, an initialization warning is issued.
Warning! initialization is not canceled.

Possible sources of error:
– Leakage in actuator
– Leakage in signal pressure connection

Initialization state: determining mechanical stops

When determining the mechanical stops, the initialization routine detects the spring action
and zero point by completely pressurizing and venting the actuator. In addition, the routine
checks whether the positioner can move through 100 % of its rated travel/angle.

Initialization state: determining the minimum transit times

When determining the transit time, the time required by the valve to move through its rated
travel/angle from 0 % to 100 % and back is measured.

Initialization canceled by activating the forced venting function

Initialization is canceled if the optional forced venting function is activated. When the op­tional forced venting function is included, make sure a voltage between 6 and 24 V DC is
applied to terminals +81 and –82.

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Messages and diagnostics

Zero point error

This message indicates that the zero point determined is outside the permissible tolerance of
max. ±5 % around the absolute internal value for measurement. Initialization is canceled.
To remove the error, adjust mechanical zero (see section 4.4.1). After that, make sure that
the yellow position pin of the travel pick-off is roughly aligned with the white line marking
zero on the cover plate.

Proportional band excessively restricted

This message indicates that even the smallest permissible pulses cause excessive changes in
travel. Initialization is canceled.

Possible sources of error:
– Excessive supply pressure
– Missing signal pressure restriction for small-volume actuators
– Error in mechanics section, particularly with NAMUR attachment (acc. to IEC 60534-6)
– Bypass not opened far enough with booster valve mounted on large-volume actuator

Successful

This message indicates that initialization was completed without any errors.

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Messages and diagnostics

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Dimensional drawing

39

35

14

198

78.5

40

86

30.5

164

150

27

14

28

56 58

N1=113

N2=200

39

50

78.5

45

50

82

150

164

27

75

56

50

86

46

28.5

28.5

Output 1 (A1)

Output 2 (A2)

Supply (Z)

Output (38)

Supply (9)

M20 x1.5

G ¼ or ¼ NPT
pneumatic connections

Direct attachment

Reversing amplifier

(optional)

Attachment using intermediate
piece for rotary actuators Fulcrum of

actuator shaft

IEC 60534-6 attachm.with adapter housing

Pneumatic connection, reversing amplifier

(old PG 13.5)

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SAMSON AG · MESS- UND REGELTECHNIK
Weismüllerstraße 3 · 60314 Frankfurt am Main · Germany
Phone: [phone] · Fax: [phone]
Internet: http://www.samson.de

EB 8382-1 EN

S/Z 2017-07 · (version 3785-xxx0...)