Samson FOUNDATION 3730-5 Mounting And Operating Instructions

FOUNDATION
Type 3730-5

TM

FIELDBUS Positioner

Fig. 1 · Type 3730-5

Mounting and
Operating Instructions

EB 8384-5 EN

Firmware version K 1.1x/ R 1.4x
Edition August 2005

Contents

Contents Page

1 Design and principle of operation . . . . . . . . . . . . . . . . . . . 6

1.1 Additional equipment . . . . . . . . . . . . . . . . . . . . . . . . . 6

1.2 Communication . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7

1.3 Technical data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9

2 Attachment to the control valve – Mounting parts and accessories . . . 11

2.1 Direct attachment . . . . . . . . . . . . . . . . . . . . . . . . . . . 14

2.1.1 Type 3277-5 Actuator. . . . . . . . . . . . . . . . . . . . . . . . . 14

2.1.2 Type 3277 Actuator. . . . . . . . . . . . . . . . . . . . . . . . . . 16

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

2.3 Attachment to Type 3510 Micro-flow Valve. . . . . . . . . . . . . . . 20

2.4 Attachment to rotary actuators . . . . . . . . . . . . . . . . . . . . . 22

2.5 Reversing amplifier for double-acting actuators . . . . . . . . . . . . . 24

3 Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26

3.1 Pneumatic connections . . . . . . . . . . . . . . . . . . . . . . . . 26

3.1.1 Signal pressure gauges . . . . . . . . . . . . . . . . . . . . . . . . 26

3.1.2 Supply pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26

3.2 Electrical connections . . . . . . . . . . . . . . . . . . . . . . . . . 28

3.2.1 Establishing communication . . . . . . . . . . . . . . . . . . . . . . 30

4 Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32

4.1 Operator controls and display . . . . . . . . . . . . . . . . . . . . . 32

4.2 Enabling and selecting parameters . . . . . . . . . . . . . . . . . . 34

4.3 Operating modes . . . . . . . . . . . . . . . . . . . . . . . . . . . 35

4.3.1 Automatic and manual operating modes . . . . . . . . . . . . . . . . 35

4.3.2 SAFE – Fail-safe position . . . . . . . . . . . . . . . . . . . . . . . 36

5 Start-up and settings . . . . . . . . . . . . . . . . . . . . . . . . . 36

5.1 Determining the fail-safe position . . . . . . . . . . . . . . . . . . . 36

5.2 Setting the volume restriction Q . . . . . . . . . . . . . . . . . . . . . 37

5.3 Adapting the display . . . . . . . . . . . . . . . . . . . . . . . . . 37

5.4 Limiting the signal pressure . . . . . . . . . . . . . . . . . . . . . . 37

5.5 Checking the operating range of the positioner . . . . . . . . . . . . . 37

5.6 Initialization . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39

5.6.1 Initialization modes . . . . . . . . . . . . . . . . . . . . . . . . . . 40

5.7 Fault/failure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47

5.8 Zero calibration. . . . . . . . . . . . . . . . . . . . . . . . . . . . 48

5.9 Reset to default values . . . . . . . . . . . . . . . . . . . . . . . . 48

5.10 Start-up via local interface (SSP) . . . . . . . . . . . . . . . . . . . . 49

2 EB 8384-5 EN

Contents

6 Status and diagnostic alarms . . . . . . . . . . . . . . . . . . . . . 49

6.1 Standard EXPERT diagnostics . . . . . . . . . . . . . . . . . . . . . 49

6.2 Extended EXPERT

+

diagnostics . . . . . . . . . . . . . . . . . . . . . 50

6.3 Classification of the status alarms and the condensed status . . . . . . . 50

7 Adjusting the limit switch . . . . . . . . . . . . . . . . . . . . . . . 52

8 Quick start-up guide . . . . . . . . . . . . . . . . . . . . . . . . . 54

8.1 Mounting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54

8.2 Start-up. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55

8.3 Initialization . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56

8.3.1 Simplest method (

8.3.2 Precise method (

MAX

) . . . . . . . . . . . . . . . . . . . . . . . . 56

NOM

) . . . . . . . . . . . . . . . . . . . . . . . . 56

8.3.3 Manual method (MAN) . . . . . . . . . . . . . . . . . . . . . . . . 56

9 Retrofitting an inductive limit switch . . . . . . . . . . . . . . . . . . 57

10 Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58

11 Servicing explosion-protected devices . . . . . . . . . . . . . . . . . 58

12 Code list . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59

13 Parameter description . . . . . . . . . . . . . . . . . . . . . . . . 76

13.1 General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 76

13.2 Device description (DD) . . . . . . . . . . . . . . . . . . . . . . . . 76

13.3 Notes concerning the parameters . . . . . . . . . . . . . . . . . . . 76

13.3.1 Legend for the parameters . . . . . . . . . . . . . . . . . . . . . . . 77

TM

13.4 FOUNDATION

Fieldbus block model . . . . . . . . . . . . . . . . 77

13.5 Resource Block . . . . . . . . . . . . . . . . . . . . . . . . . . . . 78

13.5.1 Resource Block parameters . . . . . . . . . . . . . . . . . . . . . . 78

13.5.2 Analog Output Transducer Block . . . . . . . . . . . . . . . . . . . 88

13.5.3 Discrete Input Transducer Blocks . . . . . . . . . . . . . . . . . . . 115

13.5.4 Analog Output Function Block . . . . . . . . . . . . . . . . . . . . 115

13.5.5 Discrete Input Function Block DI1 . . . . . . . . . . . . . . . . . . . 125

13.5.6 Discrete Input Function Block DI2 . . . . . . . . . . . . . . . . . . . 130

13.5.7 Proportional Integral Derivative Function Block (PID process controller) . 131

13.6 Other parameters . . . . . . . . . . . . . . . . . . . . . . . . . . 147

13.6.1 Stale Counter . . . . . . . . . . . . . . . . . . . . . . . . . . . . 147

13.6.2 Link Objects . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 148

13.6.3 LAS Functionality . . . . . . . . . . . . . . . . . . . . . . . . . . 148

14 Resetting the device . . . . . . . . . . . . . . . . . . . . . . . . . 148

15 Dimensions in mm. . . . . . . . . . . . . . . . . . . . . . . . . . 149

Test certificates. . . . . . . . . . . . . . . . . . . . . . . . . . . . 150

EB 8384-5 EN 3

Safety instructions

General safety instructions

The positioner may only be assembled, started up or operated by trained

4

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 relevant
standards.
Explosion-protected versions of this positioner may only be operated by

4

personnel who have undergone special training or instructions or who are
authorized to work on explosion-protected devices in hazardous areas.
Refer to section 11 on Servicing explosion-protected versions.
Any hazards that could be caused by the process medium, the operating

4

pressure, the signal pressure or by moving parts of the control valve are to
be prevented by means of the appropriate measures.
If inadmissible motions or forces are produced in the actuator as a result of

4

the supply pressure level, it must be restricted by means of a suitable supply
pressure reducing station.
Do not operate the positioner with the back of it/exhaust air opening facing
upwards. Never seal the exhaust air opening when the positioner is
mounted on site.
Proper shipping and appropriate storage are assumed.

4

4 EB 8384-5 EN

Note! The device with a CE marking fulfils the requirements of the Directives
94/9/EC (ATEX) and 89/336/EEC (EMC).
The declaration of conformity is available on request.

Article code

Article code Type 3730-5 XXX000XX0X00X0XX

Explosion protection

Without

II 2 G EEx ia IIC T6/II 2 D IP 65 T 80 °C

0

1
acc. to ATEX
CSA/FM applied for

II 3 G EEx nA/nL II T6/II 3 D IP 65 T 80°C

3

8
acc. to ATEX

Additional equipment

Inductive
limit switch

Solenoid
valve SIL 4

Binary input 1
Binary input 2

Without
With Type SJ 2-SN

Without
24 V DC

Standard
Add. floating contact

Diagnostics EXPERT

EXPERT

+

Housing material Aluminum

Stainless steel 1.4581

Positioner for
special
applications

Without

Free of substances that
impair painted surfaces

Exhaust air with pneum.
connection ¼ NPT

(extended)

0
1

0
4

0
1

00 0

1
2

0
1

0

1

2

Special versions Without 0 0 0

EB 8384-5 EN 5

Design and principle of operation

1 Design and principle of

operation

The digital positioner receives the reference
variable (reference variable w) transmitted
cyclically over FOUNDATION
and compares it to the travel or rotational
angle of the control valve (controlled vari­able x). The positioner issues a pneumatic
signal pressure (output variable y) to correct
the valve position.

The Type 3730-5 Positioner communicates
with field devices, logic solvers, and process
control system over FOUNDATION
Fieldbus protocol.
An integrated PID function block permits the
required process variable to be controlled
directly in the field.

The positioner is designed depending on the
corresponding accessories for direct attach­ment to SAMSON Type 3277 Actuators or
for attachment to actuators according to
IEC 60534-6 (NAMUR).

TM

Fieldbus

TM

Simultaneously, an A/D converter (4) trans­mits the position of the valve to the
microcontroller (5). The PD compares this
actual position to the FOUNDATION

TM

Fieldbus reference variable transmitted cycli­cally by the control equipment.
In case of a system deviation, the operation
of the i/p converter (6) is changed so that
the actuator (1) is filled or vented via the
downstream air capacity booster (7). This
causes the closure member of the control
valve to move to the position determined by
the reference variable.

The pneumatic air capacity booster (7) and
the pressure regulator (8) are provided with
supply air. An intermediate flow regulator
(9) with fixed settings is used to purge the
positioner and also guarantees trouble-free
operation of the pneumatic booster. The out­put signal pressure supplied by the booster
can be limited over the software.
The volume restriction Q (10) is used to opti­mize the positioner.

Additionally, a coupling wheel included in
the accessories is required to transfer the ro­tary motion for rotary actuators according to
VDI/VDE 3845.
Springless rotary actuators require a revers­ing amplifier to allow the positioner to oper­ate in either direction.

The positioner basically consists of a travel
sensor system that functions proportional to
the resistance, an analog i/p module with
downstream booster as well as the electronic
unit with a microcontroller.
The position of the valve is transmitted as an
angle of rotation to the travel sensor (2) and
to an analog PD controller (3).

6 EB 8384-5 EN

1.1 Additional equipment

Version with solenoid valve

If the operating voltage for the solenoid
valve (12) fails, the supply pressure for the
i/p module is vented to the atmosphere. The
positioner can no longer operate and the
control valve moves to the fail-safe position
determined by the actuator, independent of
the reference variable.

Design and principle of operation

Version with inductive limit switch

The rotary shaft of the positioner carries an
adjustable tag which actuates the installed
proximity switch.

Version with binary contact

All positioners are fitted with a binary input
for DC voltage signals over which process
information over FOUNDATION

TM

Fieldbus
can be issued.
Another optional binary input is an active
input powered by the positioner to connect
a floating contact. Its switching condition
can also be issued over FOUNDATION

TM

Fieldbus.

FOUNDATION
Fieldbus

TM

1.2 Communication

The positioner is completely controlled over
the digital signal transmission implemented
by FOUNDATION
as per the draft E EN 50170/A1.
Data transmission is implemented as bit-syn­chronous current modulation at a rate of

31.25 kbit/s over twisted-pair cables con­forming to EN 61158-2.

Configuration using TROVIS-VIEW software

The positioner can be configured using
TROVIS-VIEW Configuration and Operator
Interface software.
The positioner is equipped with an addi­tional digital SERIAL INTERFACE to allow a

TM

Fieldbus specification

1 Control valve
2 Travel sensor
3 PD controller
4 A/D converter
5 Microcontroller
6 i/p converter
7 Air capacity booster
8 Pressure regulator
9 Flow regulator
10 Volume restriction
11* Inductive limit switch
12* Solenoid valve
13* EN 61158-2

interface module
14 Binary input, passive
15* Binary input, active
16 Display
17* Solenoid valve control
18* Galvanic isolation
19 D/A converter
20 Communication interface

Fig. 2 · Functional diagram

* Optional

EB 8384-5 EN 7

Design and principle of operation

computer to be connected over an adapter
cable from the RS-232 interface of the com­puter to the positioner.
The TROVIS-VIEW software enables the user
to easily set parameters in the positioner
and view process parameters online.

Configuration using the NI-FBUS

TM

Configurator

The NI-FBUS

TM

Configurator from National
Instruments can also be used to configure
the positioner. For this purpose, an interface
card must be installed in a computer to con­nect it to the FOUNDATION
The planning of whole FOUNDATION

TM

Fieldbus.

TM

Fieldbus network can be performed using
the NI-FBUS

TM

Configurator.

8 EB 8384-5 EN

1.3 Technical data

Positioner

Design and principle of operation

Nominal travel,
adjustable

Direct attachment to Type 3277: 3.6 to 30 mm, attachment acc. to IEC 60534-6:

3.6 to 200 mm or 24° to 100° opening angle for rotary actuators

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

Feldbus interface acc. to EN 61158-2 bus-powered

Bus connection

Physical Layer Class: 113 (without explosion protection) und 111 (with ex. protection)
Field device acc. to FM 3610 Entity and FISCO.

Perm. operating voltage 9 to 32 V DC, power supply over bus line

Maximum operating cur­rent

Additional current
in case of failure

15 mA

0 mA

Supply pressure from 1.4 to 6 bar (20 to 90 psi),

Supply air

Air quality acc. to ISO 8573-1 Edition 2001: Max. particle size and density: Class 4
Oil content: Class 3, pressure dew point: Class 3 or at least 10 K beneath the lowest
ambient temperature to be expected

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

Characteristic,
user-defined adjustable
over operating software

Linear/equal percentage/reverse equal percentage/butterfly valve linear/
butterfly valve eq. percentage/rotary plug valve linear/rotary plug valve eq. percenta­ge/segmented ball valve linear/segmented ball valve eq.percentage
Deviation from terminal-based conformity≤1 %

Hysteresis

Sensitivity

0.3 %

≤

0.1 %

≤

Direction of action Reversible

Air consumption, steady
state

Air delivery

Actuator pressurized
Actuator vented

Permissible ambient
temperature

Influences

Independent from supply pressure approx. 110 l

3

At∆p = 6 bar:≥8.5 m
at∆p = 6 bar:≤14.0 m

/h, at∆p = 1.4 bar: 3.0 m

n

3

/h, at∆p = 1.4 bar: 4.5 m

n

–40 to +80 °C, with metal cable gland
The limits specified in the EC Type Examination Certificate additionally apply for
explosion-protected devices.

Temperature:≤0.15 %/10 K Supply air: None
Vibration:≤0.25 % up to 2000 Hz and 4 g acc. to IEC 770

/h

n

3

/h K

n

3

/h K

n

Vmax (20 °C)

Vmax (20 °C)

= 0.09

= 0.15

Electromagn. compatability Complying with EN 61000-6-2, EN 61000-6-3 and NAMUR Recommendation NE 21

Explosion protection

II 2 G EEx ia IIC T6 / II 2 D IP 65 T 80 °C
II 3 G EEx nA/nL II T6 / II 3 D IP 65 T 80 °C

Degree of protection IP 65

EB 8384-5 EN 9

Design and principle of operation

Binary contact 1

Input

5 to 30 V DC reverse polarity protection, static destruction limit 40 V / 5.8 mA,
current consumption 3.5 mA at 24 V, galvanically isolated

Signal Signal “0” at Ue > 5 V Signal “1” at Ue < 3 V
Binary contact 2 for floating contact

Switching input

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

Solenoid valve SIL 4 approval acc. to IEC 61508

Input 24 V DC, max. 40 V, reverse polarity protection, static destruction limit 40 V;

Signal Signal "0" no pick-up≤15 V Signal "1" safe pick-up >19 V

5

Service life >2 x 10

Probability of failure on demand of safety functions PFD < 2.8 x 10

Implementation in safety­relevant systems in compli­ance with IEC 61508

level of 95 %.
The safe failure fraction (SFF) according to Table A1 in IEC 61508-2 is greater or
equal to 0.99.
The valves are therefore suitable for implementation in safety-related systems with a

switching cycles

-7

for a confidence

hardware fault tolerance of 1 or 2 up to and including SIL 4.

Inductive limit switch

Type SJ 2SN Proximity
Switch

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

Communication

(Local)

Software requirements
(SSP)

Over SAMSON SSP interface and serial interface adapter
SAMSON TROVIS-VIEW with database module 3730-5

Data transmission as per FOUNDATION

(Bus communication)

Profile Class: 31 PS, 32; Interoperability
tested according Interoperability Test System (ITK) Revision 4.6.

Materials

Die-cast aluminum GD AlSi12 acc. to DIN 1725 (3.2582), chromated and plastic-

Housing:

External parts:

coated, special version CrNiMo (1.4581);

Stainless steel 1.4571 and 1.4301.
Cable gland M20x1.5, black polyamide

Weight Approx. 1.0 kg

TM

Fieldbus specification Communication

10 EB 8384-5 EN

Attachment to the control valve – Mounting parts and accessories

2 Attachment to the control

valve – Mounting parts and
accessories

The positioner can be attached either di­rectly to a SAMSON Type 3277 Actuator or
according to IEC 60534-6 (NAMUR) to con­trol valves with cast yokes or rod-type yokes
as well as to rotary actuators according to
VDI/VDE 3845.

For attachment to the various actuators, cor­responding mounting parts and accessories
are required. These are listed with their or­der numbers in Tables 1 to 5.

On attaching the positioner, it is important
to observe the assignment between lever
and pin position according to the travels
listed in the travel tables.

Travel table for direct attachment to Type 3277 Actuator

Type

3277-5

and

3277

Actuators

Actuator size

2

cm

120 7.5 5.0 25 M 25

120/240/350 15 7.5 35.4 M 35

700 30 10.0 50.0 M 50

Rated travelmmAdjustment range at positioner

Min. Travel Max.

The tables show the maximum adjustment
range at the positioner. The travel that can
be implemented at the valve is restricted by
the pin position used and additionally by the
actuator spring compression required.
The positioner is standard equipped with the
lever M (pin position 35).

Note!

If the standard mounted lever M (pin posi­tion 35) is replaced, the newly mounted le­ver must be moved once all the way as far
as it will go in both directions to adapt it to
the internal measuring lever.

Required

lever

Assigned

pin position

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

SAMSON valves Other valves/actuators Required

2

cm

60 and 120 with
Type 3510 Valve

Type 3271

Actuator

Rotary actuators

120 7.5 5.0 25.0 M 25

120/240/350 15 7.0 35.4 M 35

700/1400/2800 15 and 30/30 10.0 50.0 M 50

1400/2800 60 14.0 70.7 L 70

1400/2800 60 20.0 100 L 100

1400/2800 120 40.0 200 XL 200

Rated travel mm Min. Travel Max.

7.5 3.6 17.7 S 17

Angle of rotation 24 to 100° M 90°

lever

Assigned

pin position

EB 8384-5 EN 11

Attachment to the control valve – Mounting parts and accessories

Table 1 Direct attachment to Type 3277-5 Actuator, see Fig. 3 Order no.

Mounting parts For actuators with 120 cm

Switchover plate (old) for Actuator Type 3277-5xxxxxx.00 (old) 1400-6819
Switchover plate new for Actuator Type 3277-5xxxxxx.01 (new) 1400-6822

2

effective diaphragm area 1400-7452

Accessories
for the
actuator

Connecting plate for additional attachment of a solenoid valve G 1/8
Connecting plate (old) for Actuator Type 3277-5xxxxxx.00 (old) 1/8 NPT

Connecting plate new for Actuator Type 3277-5xxxxxx.01 (new) 1400-6823

1400-6820
1400-6821

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

Accessories
for the
positioner

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

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

Pressure gauge mounting kit (8) (output/supply) St. st./Bs: 1400-6950 St. st./St. st.: 1400-6951

Table 2 Direct attachment to Type 3277 Actuator, see Fig. 4

Accessories

Mounting parts for actuators with 240, 350 and 700 cm

2

Required piping with screw fittings for "Actuator
stem retracts" or when the top diaphragm
chamber is filled with air

cm
240 1400-6444 1400-6445
350 1400-6446 1400-6447
700 1400-6448 1400-6449

2

Steel Stainless steel

1400-7453

Connection block with seals and screw G ¼: 1400-8811 ¼ NPT: 1400-8812

Pressure gauge mounting kit (output and supply) St.st./Bs: 1400-6950 St.st/St.st.: 1400-6951

Table 3

Attachment to NAMUR ribs or control valves with rod-type yokes (rod diameter Ø 35 mm or smaller)
according to IEC 60534-6, see Fig. 5

Travel in mm Lever For actuators Order no.

2

7.5 S

5 to 50

Without (lever M on
basic model)

Type 3271-5 Actuator with 60/120 cm
Valve, see Fig. 6

Actuators from other manufacturers and Type 3271 with
120 to 700 cm

2

14 to 100 L Actuators f. other manufacturers and Type 3271 w. 1400 cm

40 to 200 XL

30 or 60 L

Actuators from other manufacturers and Type 3271 with

2

1400/2800 cm

, 120 mm travel

Type 3271 Actuator with 1400 cm
Type 3271 Actuator with 2800 cm

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

on Type 3510

2

(120 cm travel),

2

(30 or 60 mm travel)

1400-7457

1400-7454

2

1400-7455

1400-7456

1400-7466

1400-6771

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

Accessories

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

Pressure gauge mounting kit (output/supply) St.st./Bs: 1400-6950 St.st./St.st.: 1400-6951

12 EB 8384-5 EN

Attachment to the control valve – Mounting parts and accessories

Table 4 Attachment to rotary actuators (VDI/VDE 3845 for all sizes of fixing level 2) see Figs. 7 and 8

Mounting
parts

With follower clamp
and coupling wheel

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

Accessories

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

Pressure gauge mounting kit (output/supply) St.st./Bs: 1400-6950 St.st./St.st: 1400-6951

Table 5 General accessories

Pneumatic reversing amplifier for double-acting
actuators

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

Accessories

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

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

Cover plate with list of parameters
and operating instructions

VDI/VDE 3845 for all sizes of fixing level 2
for Type 3278 Actuator with 160/320 cm
for Camflex II

G ¼
¼ NPT

English (standard) 1190-5328

2

1400-7614
1400-9120

1079-1118
1079-1119

1400-7448

EB 8384-5 EN 13

Attachment to the control valve – Mounting parts and accessories

2.1 Direct attachment

2.1.1 Type 3277-5 Actuator

Refer to Table 1 on page 12 for the required
mounting parts as well as the accessories
with their order numbers.
Note the travel table on page 11!

Actuator with 120 cm

Depending on the type of positioner attach­ment, the signal pressure is routed either left
or right of the yoke through a bore to the
actuator diaphragm. Depending on the
fail-safe action of the actuator "Actuator
stem extends" or "Actuator stem retracts"
(valve closes or opens if the supply air fails),
the switchover plate (9) must first be at­tached to the actuator yoke. Align the
switchover plate with the corresponding
symbol for left or right attachment according
to the marking (view looking onto the
switchover plate).

1. Mount connecting plate (6) or pressure

gauge bracket (7) with pressure gauges
onto the positioner, making sure both
seal rings (6.1) are seated properly.

2. Remove vent plug (4) on the back of the

positioner and close the signal pressure
output "Output 38" on the connecting
plate (6) or on the pressure gauge
bracket (7) with the stopper (5) included
in the accessories.

3. Place follower clamp (3) on the actuator

stem, align and screw tight so that the
mounting screw is located in the groove
of the actuator stem.

4. Mount cover plate (10) with narrow side

of the cut-out opening (Fig. 3, left) point-

2

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

5. 15 mm travel: Keep the follower pin (2)
at lever M (1) on the back of the
positioner in the pin position 35 (deliv­ered state).

7.5 mm travel: Remove the follower pin
(2) from the pin position 35, reposition it
in the bore for pin position 25 and
screw tight.

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

7. Place positioner on the cover plate (10)
in such a manner that the follower pin
(2) rests on the top of the follower clamp
(3). Adjust the lever (1) correspondingly
and open the positioner cover to hold
the positioner shaft in position at the cap
or the switch (Fig. 12).
The lever (1) must rest on the follower
clamp with spring force.
Mount the positioner on the cover plate
(10) using the two fixing screws. During
the installation make sure that the seal
ring (10.1) is inserted in the bore of the
cover plate.

8. Mount cover (11) on the other side.
Make sure that the vent plug points
downwards when the control valve is in­stalled to allow any condensed water
that collects to drain off.

14 EB 8384-5 EN

Symbols

Actuator stem

extends

Attachment left Attachment right

Actuator stem

retracts

Signal pressure

input for left

attachment

Attachment to the control valve – Mounting parts and accessories

1 Lever

Switchover plate (9)

Marking

15

Signal pressure

input for right

attachment

1.1 Nut

1.2 Disk spring
2 Follower pin
3 Follower clamp
4 Vent plug
5 Stopper
6 Connecting plate

6.1 Seal rings
7 Pressure gauge bracket
8 Press. gauge mounting kit
9 Switchover plate

for actuator

10 Cover plate

10.1Seal ring
11 Cover
14 Gasket

14

15 Formed seal

Supply 9

Lever M

Output 38

1

2

3

1.1

1.2

Cut-out of cover

plate

4

6.1

6

5

10.1
10

6

Important!

Always use the connecting plate (6)
included in the accessories to connect
supply and output.

7

Never screw threaded parts directly
into the housing.

8

9 11

Fig. 3 · Direct attachment - Signal pressure connection for Type 3277-5 Actuator with 120 cm

2

EB 8384-5 EN 15

Attachment to the control valve – Mounting parts and accessories

2.1.2 Type 3277 Actuator

Refer to Table 2 on page 12 or the required
mounting parts as well as the accessories
with their order numbers.
Note the travel table on page 11!

Actuators with 240 to 700 cm

The positioner can be mounted either on the
left or on the right side of the yoke. The sig­nal pressure is routed to the actuator over
the connection block (12), for actuators with
fail-safe action "Actuator stem extends" in­ternally through a bore in the valve yoke
and for "Actuator stem retracts" through ex­ternal piping.

1. Place follower clamp (3) on the actuator
stem, align and screw tight so that the
mounting screw is located in the groove
of the actuator stem.

2. Mount cover plate (10) with narrow side
of the cut-out opening (Fig. 4, on the
left) pointing towards the signal pressure
connection. Make sure that the bonded
gasket (14) points towards the actuator
yoke.

3. For actuators with 700 cm
follower pin (2) at lever M (1) on the
back of the positioner from pin position
35, reposition it in the bore for pin posi­tion 50 and screw tight.
For actuators 240 and 350 cm
15 mm travel, the follower pin (2) re­mains in pin position 35.

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

5. Place positioner on the cover plate in
such a manner that the follower pin (2)

2

2

, remove the

2

with

rests on the top of the follower clamp
(3). Adjust the lever (1) correspondingly
and open the positioner cover to hold
the positioner shaft in position at the cap
or the switch (Fig. 12). The lever (1) must
rest on the follower clamp with spring
force. Mount the positioner on the cover
plate (10) using the two fixing screws.

6. Make sure that the tip of the gasket (16)
projecting from the side of the connec­tion block (12) is positioned above the
actuator symbol that corresponds with
the actuator with fail-safe action "Actua­tor stem extends" or "Actuator stem re­tracts." If necessary, remove the three
fixing screws and the cover. Then repo­sition the gasket (16) turned by 180°.
The previous version of the connection
block (Fig. 4, bottom) requires the switch
plate (13) to be turned such that the cor­responding actuator symbol points to the
marking.

7. Place the connection block (12) with the
associated seal rings against the
positioner and the actuator yoke. Screw
it tight using the fixing screw (12.1). For
actuators with fail-safe action "Actuator
stem retracts", additionally remove the
stopper (12.2) and fit on the external
signal pressure piping.

8. Mount cover (11) on the other side.
Make sure that the vent plug points
downwards when the control valve is in­stalled to allow any condensed water
that collects to drain off.

16 EB 8384-5 EN

Attachment to the control valve – Mounting parts and accessories

1 Lever

1.1 Nut

1.2 Disk spring
2 Follower pin
3 Follower clamp
10 Cover plate
11 Cover
12 Connection block

Lever M

Cut-out of
cover plate (10)

12.1 Screw

12.2 Stopper or connection for
external piping

13 Switch plate
14 Gasket
15 Formed seal
16 Gasket

Actuator stem

retracts extends

Fig. 4 · Direct attachment – Signal pressure connection for Type 3277 Actuator with 240, 350 and 700 cm

Connection block (old)
with switch plate (13)

Stem retracts

Stem extends

Marking

2

EB 8384-5 EN 17

Attachment to the control valve – Mounting parts and accessories

2.2 Attachment according to
IEC 60534-6

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

Refer to Table 3 on page 12 for the required
mounting parts as well as the accessories
with their order numbers.
Note the travel table on page 11!

1. Screw the two bolts (14) to the bracket

(9.1) of the stem connector (9), place the
follower plate (3) on top and use the
screws (14.1) to tighten.

Actuator size 2800 cm

2

and 1400 cm

(120 mm travel):
For a travel of 60 mm or smaller, screw the

longer follower plate (3.1) directly to the
stem connector (9). For a travel exceeding
60 mm, mount the bracket (16) first and
then the follower plate (3) to the bracket to­gether with the bolts (14) and screws (14.1).

2

4. Select required lever size (1) M, L or XL

and pin position according to the actua­tor size and valve travels listed in the ta­ble on page 11.
Should you require a pin position other
than position 35 with the standard in­stalled lever M, or require a lever size L
or XL, proceed as follows:

5. Screw the follower pin (2) in the as­signed lever bore (pin position) as listed
in the table. Only use the longer follower
pin (2) included in the mounting kit.

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

Note!

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

2. Mount NAMUR bracket (10) to the con­trol valve as follows:
For attachment to the NAMUR rib, use
an M8 screw (11), washer, and toothed
lock washer directly in the yoke bore.
For attachment to valves with rod-type
yokes, use two U-bolts (15) around the
yoke.
Align the NAMUR bracket (10) in such a
way that the slot of the follower plate (3)
is centrally aligned with the NAMUR
bracket at mid valve travel.

3. Mount connecting plate (6) or pressure
gauge bracket (7) with pressure gauges
(8) on the positioner, making sure both
seal rings (6.1) are seated properly.

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

18 EB 8384-5 EN

Attachment to the control valve – Mounting parts and accessories

Attachment to rod-type yoke
Rods with Ø max. 35 mm

10

9

9.1

1 Lever

1.1 Nut

1.2 Disk spring
2 Follower pin
3 Follower plate

3.1 Follower plate
6 Connecting plate

6.1 Seal rings
7 Pressure gauge bracket
8 Pressure gauge

mounting kit

9 Stem connector

9.1 Bracket
10 NAMUR bracket
11 Screw
14 Bolt

14.1 Screw
15 U-bolt
16 Bracket

Lever XL and L

Important!

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

Additional bracket for
actuators with 2800 cm
and travel≥60 mm

16

2

11

Attachment to
NAMUR rib

1

1

2

1.1

1.2
1

15

3.1

14

3

14.1

6.1 6 7 8

Fig. 5 · Attachmet according to IEC 60534-6 (NAMUR)

EB 8384-5 EN 19

Attachment to the control valve – Mounting parts and accessories

2.3 Attachment to Type 3510
Micro-flow Valve

The positioner is attached to the valve yoke
using a bracket.

Refer to Table 3 on page 12 for the required
mounting parts as well as the accessories
with their order numbers.
Note the travel table on page 11!

1. Place clamp (3) on the valve stem con-

nector, align at a right angle and screw
tight.

2. Screw bracket (10) to the valve yoke us-

ing two screws (11).

3. Mount connecting plate (6) or pressure

gauge bracket (7) with pressure gauges
to the positioner, making sure both seal
rings (6.1) are seated properly..

4. Unscrew the standard installed lever M

(1) including follower pin (2) from the
positioner shaft.

5. Take lever S (1) and screw follower pin

(2) in the bore for pin position 17.

6. Place lever S on the positioner shaft and

screw tight using the disk spring (1.2)
and nut (1.1).
Move lever once all the way as far as it
will go in both directions.

7. Place positioner on the bracket (10) in

such a manner that the follower pin
slides into the groove of the clamp (3).
Adjust the lever (1) correspondingly.
Screw the positioner to the bracket (10)
using both its hexagon screws.

20 EB 8384-5 EN

1 Lever

1.1 Nut

1.2 Disk spring
2 Follower pin
3 Clamp
6 Connecting clamp

6.1 Seal rings
7 Pressure gauge bracket
8 Pressure gauge

mounting kit
10 Bracket
11 Screw

Attachment to the control valve – Mounting parts and accessories

Important!

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

Lever S

Fig. 6 · Attachment to Type 3510 Micro-flow Valve

EB 8384-5 EN 21

Attachment to the control valve – Mounting parts and accessories

2.4 Attachment to rotary
actuators

The positioner is mounted to the rotary actu­ator using two pairs of double brackets.

Refer to Table 4 on page 13 for the required
mounting parts as well as the accessories
with their order numbers.

Prior to the attachment of the positioner to
the SAMSON Type 3278 Rotary Actuator,
you have to mount the associated adapter
(5) to the free end of the rotary actuator
shaft.

Note!

During the installation of the positioner as
described below, it is imperative that the ac­tuator's direction of rotation be observed.

1. Place follower clamp (3) on the slotted

actuator shaft or the adapter (5).

2. Place coupling wheel (4) with flat side

facing the actuator on the follower
clamp (3). Refer to Fig. 8 to align slot so
that it matches the direction of rotation
when the valve is in its closed position.

3. Screw coupling wheel and follower

clamp tightly onto the actuator shaft us­ing screw (4.1) and disk spring (4.2).

4. Screw the bottom pair of brackets (10.1)

with the bends pointing either to the in­side or to the outside (depending on the
actuator size) to the actuator case. Posi­tion top pair of brackets (10) and screw
tight.

5. Mount connecting plate (6) or pressure

gauge bracket (7) with pressure gauges

to the positioner, making sure both
O-rings are seated properly.
For double-acting, springless rotary ac­tuators, a reversing amplifier is required
to attach the positioner to the actuator,
see section 2.5.

6. Unscrew the standard follower pin (2)

from the positioner's lever M (1). Use the
metal follower pin (Ø5) included in the
mounting kit and screw tight into the
bore for pin position 90°.

7. Place positioner on the top pair of
brackets (10) and screw tight. Con­sidering the actuator's direction of rota­tion, adjust lever (1) so that it engages in
the slot of the coupling wheel (4) with its
follower pin (see Fig. 8). It must be guar­anteed that the lever (1) is parallel to the
long side of the positioner when the ac­tuator is at half its angle of rotation.

8. Stick scale plate (4.3) on the coupling
wheel so that the arrow tip indicates the
closed position, and it can be easily
read when the valve is installed.

Actuator flange

Fig. 7 · Mounting the coupling wheel with Type 3278

22 EB 8384-5 EN

Important!

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

Attachment to the control valve – Mounting parts and accessories

Control valve opens counterclockwise

Slot

Legends Figs. 7 and 8
1 Lever

1.1 Nut

1.2 Disk spring
2 Follower pin
3 Follower clamp (Fig. 7)
4 Coupling wheel

4.1 Screw

4.2 Disk spring

4.3 Scale plate

4.3 Scale plate
5 Actuator shaft

Adapter for Type 3278

6.1 Seal rings
7 Pressure gauge bracket
8 Pressure gauge

mounting kit

10 Top pair of brackets

10.1 Bottom pair of brackets

Fig. 8 · Attachment to rotary actuators

Control valve opens clockwise

Slot

EB 8384-5 EN 23

Attachment to the control valve – Mounting parts and accessories

2.5 Reversing amplifier for
double-acting actuators

For the use with double-acting actuators, the
positioner must be fitted with a reversing
amplifier. The reversing amplifier is listed as
an accessory in the Table 5 on page 13.

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

.

2

+ A2= Z applies.

1

Mounting

1. Mount the connecting plate (6) from the

accessories in Table 5 to the positioner.
Make sure that both O-rings (6.1) are
seated correctly.

2. Thread the special nuts (1.3) from the

accessories of the reversing amplifier
into the boreholes of the connecting
plate.

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

the reversing amplifier and push both
the hollowed special screws (1.1) into
the connecting boreholes A

4. Place the reversing amplifier onto the

connecting plate (6) and screw tight us­ing both the special screws (1.1).

5. Use a screwdriver (8 mm wide) to screw

the enclosed filters (1.6) into the con­necting boreholes A

of the reversing

1

, is applied at

1

and Z.

1

and Z.

1

Note!

The sealing plug (1.5) in the Type 3730
Positioner should not be unscrewed out of
the reversing amplifier.
The rubber seal (1.4) is not required and
can be removed when the sealing plug is
used.

Signal pressure connections
A

: Output A1leading to the signal pressure

1

connection at the actuator which opens the
valve when the pressure increases

A

: Output A2leading to the signal pressure

2

connection at the actuator which closes the
valve when the pressure increases

Set slide switch on positioner to

AIR TO OPEN.

24 EB 8384-5 EN

From the positioner

Attachment to the control valve – Mounting parts and accessories

Control signals to

the actuator

1 Reversing amplifer

1.1 Special screws

1.2 Gasket

1.3 Special nuts

1.4 Rubber seal

1.5 Sealing plug

1.6 Filter

6 Connecting plate

6.1 O-rings

6.2 Screws

Fig. 9 · Mounting a reversing amplifier

EB 8384-5 EN 25

Connections

3 Connections

3.1 Pneumatic connections

Caution!

The threads in the positioner housing are not
designed for direct air connection!

The screw glands must be screwed into the
connecting plate, the pressure gauge mount­ing block or the connection block from the
accessories. The air connections are option­ally designed as a bore with ¼ NPT or G ¼
thread.
The customary fittings for metal and copper
pipes or plastic hoses can be used.

Note!

The supply air must be dry and free from oil
and dust. The maintenance instructions for
upstream pressure reducing stations must be
observed.
Blow through all air tubes and hoses thor­oughly prior to connecting them.

3.1.1 Signal pressure gauges

To monitor the supply air (Supply) and sig­nal pressure (Output), we recommend that
pressure gauges be attached (see accesso­ries in Tables 1 to 5).

3.1.2 Supply pressure

The required supply air pressure depends
on the bench range and the actuator's oper­ating direction (fail-safe action).
The bench range is registered on the name­plate either as spring range or signal pres­sure range depending on the actuator. die
The direction of action is marked FA or FE,
or by a symbol.

Actuator stem extends FA (Air to open
ATO)

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

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

Actuator stem retracts FE (Air to close ATC)

If the positioner is attached directly to the
Type 3277 Actuator, the connection of the
positioner's output pressure to the actuator
is fixed. For attachment according to
IEC 60534-6 (NAMUR), the signal pressure
can be routed to either the top or bottom di­aphragm chamber of the actuator, depend­ing on the actuator's fail-safe action "Actua­tor stem extends" or "Actuator stem re­tracts".
For rotary actuators, the manufacturer's
specifications for connection apply.

26 EB 8384-5 EN

Fail-safe position "Valve Open"
(for globe and angle valves):
For tight-closing valves, the maximum signal
pressure pst

is roughly estimated as fol-

max

lows:

2

dp

⋅⋅

pst

max

= F +

π∆

4

⋅

[bar]

A

d = Seat diameter [cm]

p = Differential pressure across the valve

∆

[bar]

A = Actuator diaphragm area [cm

2

]

F = Upper bench range of the actuator

[bar]

If there are no specifications, calculate as
follows:

Required supply pressure =
Upper bench range value + 1 bar

Note!

The signal pressure at the output (Out­put 38) of the positioner can be limited to

1.4, 2.4 or 3.7 bar over Code 16 or the
pressure limit can be deactivated (MAX).

Connections

EB 8384-5 EN 27

Connections

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 insur-

ance association.
The following standards apply for assembly
and installation in hazardous areas:
EN 60079-14: 2003 (VDE 0165 Part 1/

8.98) "Electrical apparatus for explosive gas
atmospheres" and EN 50281-1-2: 1999
(VDE 0165 Part 2/11.99) "Electrical appa­ratus for use in the presence of combustible
dust".

For the interconnection of intrinsically safe
electrical equipment, the permissible maxi­mum values specified in the EC type exami­nation certificate apply (U
or P0; Cior C0, and Lior L0).

The following applies for equipment with
type of protection EEx nA (non-sparking ap­paratus) according to the standard EN
50021 (1999): Connecting, interrupting, or
switching circuits while energized is only al­lowed during installation, maintenance or
repair work.

The following applies for equipment con­nected to energy-limited circuits with type of
protection EEx nL (energy-limited apparatus)
according to the standard EN 50021
(1999): This type of equipment may be
switched under normal operating conditions.

or U0; Iior I0; P

i

i

For the interconnection of equipment to en­ergy-limited circuits with type of protection
EEx nL IIC, the permissible maximum values
specified in the statement of conformity or
the addenda to the statement of conformity
apply.

Caution!

The terminal assignment specified in the cer­tificate must be adhered to. Reversing the
assignment of the electrical terminals may
cause the explosion protection to become in­effective!
Do not tamper with enameled screws inside
or on the housing.

Note on the selection of cables and wires:

To install intrinsically safe circuits, observe
section 12 of the standard EN 60079-14:
2003 (VDE 0165 Part 1). To run multi-core
cables or lines with more than one intrinsi­cally safe circuit, section 12.2.2.7 of this
standard applies.
An additional cable gland can be installed
when connecting the device over two sepa­rate cables. Cable entries left unused must
be sealed with blanking plugs. Devices used
at ambient temperatures down to –20 °C
must have metal cable entries.

Cable entry

Cable entries with M20x1.5 cable gland,
clamping area 6 to 16 mm.
There is a second M20x1.5 entry in the
housing which can be used to install an
additional connection, if required.
The screw terminals are designed for 0.2 to

2.5 mm wire cross sections and for a
tightening torque of 0.5 Nm.

28 EB 8384-5 EN

Connections

Bus line

The shielded fieldbus connecting cable is to
be routed over the electromagnetic-compati­ble brass cable gland (standard) in 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, loosen the gland
nut and the clamping insert from the
positioner and remove the dust cap.

2. Slide the gland nut and clamping insert
over the connecting cable.

3. Strip the insulation off the end of the bus
line to the required connecting length
and cut the wire shield off up to a length

Brass cable gland Shielding Clamping insert Gland nut

of approx. 13 mm. If necessary, cut off
any cable core filling as well.

4. Disentangle the braided shield and pull
it over the clamping insert.

5. Press the clamping insert into the con­necting screw gland and screw tight the
gland nut until the connecting cable is
clamped tightly.

6. Route the two-wire bus line to the screw
terminals marked "EN 61158-2",
whereby no polarity has to be observed.

Solenoid valve
Forced venting

Fig. 10 · Electrical connections

Bus line

Binary contacts

In preparation

Switch. amplifier

EN 60947-5-6

Limit switch

EB 8384-5 EN 29

Connections

Note!

To connect the limit switch, binary inputs,
and forced venting, an additional cable
gland that needs to be fitted in place of the
existing blanking plug is necessary.
Open cable glands are not permissible as
the degree of protection IP 65 only applies
when the positioner housing is sealed.

Limit switch

For operation of the limit switches, switching
amplifiers have to be connected in the out­put circuit. Their function is to control the
limit values of the control circuit according
to EN 60947-5-6, thus ensuring operational
reliability of the positioner. If the positioner
is installed in hazardous areas, the relevant
regulations must be observed.

Note!

If there is no voltage connected for the sole­noid valve at terminals +81 and –82 or
when the voltage signal is interrupted, the
positioner vents the actuator and does not
respond to the reference variable.
Observe the switching thresholds specified
in the technical data.

3.2.1 Establishing communication

The communication structure between the
controller, logic solvers (PLC) or automation
system, or between a PC or work station
and the positioner(s) is implemented to con­form with EN 61158-2.

Binary input 1

An active contact can be operated at binary
input 1. The positioner can report the
switching state over the bus protocol.

Binary input 2

A passive, floating contact can be operated
at binary input 2.
The positioner can report the switching state
over the bus protocol.

Solenoid valve (forced venting function)

For positioners fitted with the optional sole­noid valve for the forced venting function, a
voltage of 24 V DC must be connected to
the relevant terminals +81 and –82.

30 EB 8384-5 EN