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
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