Samson foundation 3787 Mounting And Operating Instructions
FOUNDATION
TM
FIELDBUS Positioner
Type 3787
Fig. 1 ⋅Type 378 7
Mounting and
Operating Instructions
EB 8383-1 EN
Firmware R 1.4x/K 1.4x
Edition November 2004
Contents Page
1 Design and principle of operation
. . . . . . . . . . . . . . . . . . . . . . 8
1.1 Optional limit switches . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
1.2 Communication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
2 Attachment to the control valve
. . . . . . . . . . . . . . . . . . . . . . . 10
2.1 Direct attachment to Type 3277 Actuator . . . . . . . . . . . . . . . . . . . 10
2.2 Attachment acc. 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 . . . . . . . . . . . . . . . . . . . . . . . . 17
2.3.1 Mounting the lever with feeler roll . . . . . . . . . . . . . . . . . . . . . . . 18
2.3.2 Mounting the intermediate piece . . . . . . . . . . . . . . . . . . . . . . . 18
2.3.3 Aligning and mounting the cam disk . . . . . . . . . . . . . . . . . . . . . 20
2.3.4 Reversing amplifier for double-acting actuators . . . . . . . . . . . . . . . . 22
2.4 Fail-safe action of the actuator . . . . . . . . . . . . . . . . . . . . . . . . 22
3 Connections
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
3.1 Pneumatic connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
3.1.1 Pressure gauge . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
3.1.2 Supply air pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
3.2 Electrical connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
3.2.1 Establishing communication . . . . . . . . . . . . . . . . . . . . . . . . . 28
4Operation
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
4.1 LEDs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
4.2 Write protection and simulation switches . . . . . . . . . . . . . . . . . . . 30
4.3 Activate/deactivate forced venting function . . . . . . . . . . . . . . . . . . 30
4.4 Default setting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
4.4.1 Adjusting mechanical zero . . . . . . . . . . . . . . . . . . . . . . . . . . 30
4.4.2 Initialization . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
4.5 Operation via TROVIS-VIEW . . . . . . . . . . . . . . . . . . . . . . . . . 33
4.5.1 Initialization . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
4.5.2 Testing the control valve . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
4.6 Setting the inductive limit switches . . . . . . . . . . . . . . . . . . . . . . 34
Contents
2
EB 8383-1 EN
5 Maintenance
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
6 Servicing explosion-protected versions
. . . . . . . . . . . . . . . . . . . 35
7 Parameter description
. . . . . . . . . . . . . . . . . . . . . . . . . . . 36
7.1 General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
7.2 Device Description (DD) . . . . . . . . . . . . . . . . . . . . . . . . . . 36
7.3 Notes on the parameters . . . . . . . . . . . . . . . . . . . . . . . . . . 36
7.3.1 Legends assigned to the parameters . . . . . . . . . . . . . . . . . . . . . 37
7.3.2 Notes on parameter storage classes S, N and D . . . . . . . . . . . . . . . 37
7.4 Block structure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
7.4.1 Resource Block . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
7.4.2 Transducer Block . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46
7.4.3 Function Blocks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57
7.4.3.1 Analog Output Function Block . . . . . . . . . . . . . . . . . . . . . . . 57
Parameters of the Analog Output Function Block . . . . . . . . . . . . . . . 59
7.4.3.2 PID Function Block (PID controller) . . . . . . . . . . . . . . . . . . . . . . 65
Parameters of the PID Function Block . . . . . . . . . . . . . . . . . . . . 67
7.5 Other parameters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 78
7.5.1 Stale counter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 78
7.5.2 Link objects . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 78
7.5.3 LAS capabilities . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 78
8Diagnostic messages
. . . . . . . . . . . . . . . . . . . . . . . . . . . . 79
8.1 Messages of the XD_ERROR_EXT parameter (Transducer Block) . . . . . . . 79
8.2 Messages of the XD_ERROR parameter (Transducer Block) . . . . . . . . . . 80
8.3 Messages of the SELF_CALIB_STATUS parameter (Transducer Block) . . . . . 81
Dimensional drawing . . . . . . . . . . . . . . . . . . . . . . . . . . . 82
EC Type Examination Certificate . . . . . . . . . . . . . . . . . . . . . . 83
CSA/FM certification . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90
Contents
EB 8383-1 EN
3
Safety instructions
The device may only be assembled, started up, and operated by experienced
personnel familiar with this product.
In these mounting and operating instructions, the term "experienced personnel" refers to individuals who are able to evaluate the responsibilities assigned
to them as well as recognize potential hazards due to their specialized training, knowledge, and experience as well as their special knowledge of the relevant standards.
Explosion-protected versions of this device may only be operated by personnel who have undergone special training or instructions, or who are authorized to work on explosion-protected devices in hazardous areas.
Any hazards which could be caused by the process medium, the operating
pressure, the signal pressure and moving parts of the control valve, must be
prevented by means of appropriate measures.
Should inadmissible motions or forces be produced in the pneumatic actuator
as a result of the level associated with the supply air pressure, these must be
restricted by means of a suitable pressure reducing station.
Proper shipping and appropriate storage of the device are assumed.
Note:
Devices with the CE mark meet the requirements specified in the Directive
94/9/EC and the Directive 89/336/EEC.
The Declaration of Conformity can be viewed and downloaded from the
SAMSON website at www.samson.de.
Modifications of positioner firmware in comparison to previous versions
Previous New
Positioner R 1.41 R 1.42
Correction in the zero calibration activated over software
communication
4
EB 8383-1 EN
Firmware modifications
Communication
K1.00 K1.20
Version compatible with user interface software version number:
Fisher-Rosemount DeltaV in version 5.1 or higher
National Instruments Fieldbus Configurator in version 2.3 or
higher.
All host systems certified by the Fieldbus Foundation
Alteration to default values of the following parameters:
AO Function Block CHANNEL, PID Function Block GAIN,
PID Function Block RESET, PID Function Block BYPASS
Resource Block parameter extended:
BLOCK_ERROR, page 40
Transducer Block parameters changed/extended:
BLOCK_ERR, page 46.
Communication
K 1.00 K1.31
The output parameters of the function blocks can be
interconnected within a device and with blocks in other devices at
the same time. In the previous version, it was only possible to
either interconnect function blocks within a device or with blocks
in other devices.
An Output Failure in BLOCK_ERR of the AO Function Block
generates a Block Alarm.
The automatic resetting control loop monitor (previously not
automatic resetting) is evaluated for the control loop error
indication via LED or the message "Calibration Error". This means
this alarm or message is automatically reset as soon as the control
loop monitor cannot find an error anymore.
Communication
K 1.31 K1.40
The default value for RESET in the PID Block has been changed
from 0 to 3402823466 x 10
38
(maximum possible value). The
integral-action component of the PID is ineffective at this value as
well as at 0. On switching over the operating mode from MAN to
AUTO, a smooth switchover is achieved.
EB 8383-1 EN
5
Technical data
Positioner
Travel
Direct attachment to Type 3277
Attachment acc. to IEC 60534-6
Adjustable
5 to 30 mm
5 to 255 mm or 30 to 120° for rotary actuators
Bus connection Fieldbus interface as per IEC 61158-2, bus-powered
Physical Layer Class: 113 (not explosion-protected version) and 111 (Ex-version)
Field device according to FM 3610 entity and FISCO.
Per m issib le o perati ng v oltage 9 to 32 V DC; The speci f icatio ns i n the EC Type E xamina tion Certif i cate addit ionally
apply for explosion-protected devices. Power supply over bus cable
Max. operating current 13 mA
Additional current in case of fault 0 mA
Supply air Supply air from 1.4 to 6 bar (20 to 90 psi);
Air quality as per ISO 8573-1: Max. particle size and density: Class 4;
Oil co nt ents: C la ss 3; Pr es sure de w p oint: C la ss 3
Signal pressure (output) 0 bar up to the pressure of the supply air
Characteristic, adjustable
Deviation
Globe valve: linear, equal percentage, reverse equal percentage,
SAMSON butterfly valve: linear, equal percentage
VETEC plug rotary valve: linear, equal percentage
≤1 %
Dead band
(based on rated travel/angle
Adjustable from 0.1 to 10.0 % , default 0.5 %
Resolution (internal measurement) < 0.05 %
Tran sit time re quired For v al ve tra ns it time up to 75 s
Set point ramp for exhaust and supply air separately adjustable
Operating direction Reversible, setting by software
Air consumption Independent of supply air <90l
n
/h
Air s upply A ctuat or f illed: wh en Δp = 6 bar 9.3 m
n
3
/h, when Δp = 1.4 bar 3.5 m
n
3
/h
Actu at or vented : w hen Δp = 6 bar 15.5 m
n
3
/h, when Δp = 1.4 bar 5.8 m
n
3
/h
Permissible ambient temperature 40 to 80 °C
The specifi cation s in t h e EC Typ e Examin ation Certif icate addi tionally app ly f o r
explosion-protected devices
Effects Temperature: ≤0.15 %/10 K, supply air: none,
Vibrations: none up to 250 Hz and 4 g
Deg re e o f prote ct io n IP 65 us ing fil te r check va lve inc luded
Electromagnetic compatibility Requirements acc. to EN 61000-6-2, EN 61000-6-3 and
NAMUR Recommendations NE 21 are met
Bin ar y in pu t Inte rn al powe r s upply 5 V DC , R
i
= 100 kΩ for a la rm func ti on
Forced venting
(activated over an internal switch)
Input 6 to 24 V DC, R
i
approx. 6 kΩ at 24 V D C ( depend in g on volt age)
Switching point for "1" signal ≥ 3 V, switc hi ng poin t f or "0" sign al only at 0 V,
K
V
0.17
6
EB 8383-1 EN
Versions
Accessories
Inductive limit switches Two Type SJ 2 SN Proximity Switches for connection to a switching amplifier acc. to
EN 60947-5-6
Communication
Data transmission In accordance with FOUNDATION
TM
Fieldbus specification
Communication Profile Class: 31 PS, 32: Interoperability Test System (I TS) Revision 4.0
Materials
Case Die -c as t alumi num, chr om ized an d p lastic -c oated
External parts Stainless steel 1.4571 and 1.4301
Weigh t Appr ox 1. 3 kg
Versions of the positioner
Model
3787 -
XXX
0
X3X
Explosion protection Without
II 2 G EEx ia IIC T6/
II 2 D IP 65 T 80 °C acc. to ATEX
Ex ia FM/CSA
II 3 G EEx ia IIC T6/
II 3 D IP 54 T 80 °C acc. to ATEX
0
1
3
8
Accessories Limit switches Without
2 inductive
0
22
Forced venting Without (deactivated)
With (activated)
0
12
Pneumatic
connections
NPT 1/4- 18
ISO 228/1-G 1/4
1
2
Electric connections Cable gland M20 x 1.5
Nickel-plated brass
Quantity: 1
2
1
2
EB 8383-1 EN
7
1 Design and principle of operation
The digital positioner compares the reference variable, which is cyclically transmitted over the FOUNDATION
TM
Fieldbus,
with the travel or opening angle of the control valve. It then delivers a corresponding
signal pressure. It is suitable for attachment
to linear and rotary actuators.
The Type 3787 Positioner communicates as
per FOUNDATION
TM
Fieldbus specification
with field devices, programmable logic controllers and process management systems.
An integrated PID Function Block allows the
control of required process variables directly in the field.
The travel of the control valve is picked up
by the inductive displacement sensor (1)
and supplied to the microcontroller (2) via a
converter.
The microcontroller compares the travel
with the reference variable and controls the
two pneumatic 2/2-way on-off valves (3, 4)
when a system deviation occurs. The on-off
valves fill (3) or vent (4) the pneumatic actuator via corresponding amplifiers corresponding to the system deviation.
Two LEDs on the inside of the cover indicate
the operating status of the positioner.
The positioner is equipped with a standard
binary input over which any process information can be signaled via the FOUNDATION
TM
Fieldbus.
The write protection switch (6) located on
the inside of the cover prevents stored configuration data from being overwritten.
Forced venting:
The positioner is controlled over a 6 to 24 V
signal which causes the corresponding signal pressure to be applied to the actuator. If
the voltage signal drops, the signal pressure
is shut off and the actuator is vented. The
control valve moves to its fail-safe position
regardless of the output variable issued by
the microcontroller.
1.1 Optional limit switches
Limit switches can be retrofitted to the standard positioner.
Two proximity switches can be used for failsafe circuits to indicate the valves end positions.
1.2 Communication
The positioner is completely controlled via
digital signal transmission according to the
FOUNDATION
TM
Fieldbus specification
based on the E EN 50170/A1 draft. Data
is transmitted as bit synchronous current
modulation at a transmission rate of
31.25 kbit/s over twisted pairs according
to IEC 61158-2.
Configuration with TROVIS-VIEW
The positioner can be configured using the
SAMSON Configuration and Operator Interface, TROVIS-VIEW.
To configure the positioner, connect its additional
SERIAL INTERFACE
to the RS-232 interface of a PC using an adapter cable.
After adapting the positioner to the process
requirements, TROVIS-VIEW enables the
process to be controlled online.
8
EB 8383-1 EN
Design and principle of operation
Configuration with NI-FBUSTM Configurator
The positioner can also be configured using
the NI-FBUS
TM
Configurator from National
Instruments.
An interface card installed in a PC is required to connect it to FOUNDATION
TM
Fieldbus.
The NI-FBUS
TM
Configurator can be used to
configure the whole FOUNDATION
TM
Fieldbus network.
Fig. 2 ⋅Functional diagram
e
p
3
4
2
9
7
8
6
1
G
μC
&
IEC 61158-2
e
p
G
Fieldbus
Foundation
8
TROVIS
VIEW
11
10
1
12
u
13
Forced
venting
Binary
input
Supply
air
Exhaust
air
Serial Interface
1 Inductive displacement sensor
2 Microcontroller
3 On-off valve for supply air
4 On-off valve for exhaust air
5 Microcontroller
6 Switches for write protection and
simulation mode
7 Binary input
8 Forced venting
9 IEC 61158-2 interface module
10 Actuator stem
11 Lever
12 Clamp
13 Configuration interface
EB 8383-1 EN
9
Design and principle of operation
2 Attachment to the control valve
The positioner can be attached either directly to a SAMSON Type 3277 Actuator
or to control valves with cast yokes or rodtype yokes according to IEC 60534-6
(NAMUR).
In connection with an intermediate piece,
the positioner can also be attached to rotary actuators.
Since the standard positioner is delivered
without accessories, please refer to the
tables for required mounting parts and their
order numbers.
Note!
For fast control valves with small travel volumes (transit time < 0.6 sec.), replace the filter in the signal pressure output with a
screw-in throttle, 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 venting plug, instead vented air has to escape
through venting plugs located on the mounting parts (see Figs. 3, 5 and 7).
A filter check valve for the vented air is included in every positioner delivery (under
the transparent protective cap on the back
of the positioner). Replace the standard venting plug included in the accessories with
this filter check valve. This is the only way to
achieve the degree of protection IP 65 by
preventing dirt and moisture from entering
the device.
2.1 Direct attachment to Type
3277 Actuator
The necessary accessories are listed in the
Tables 1, 2 and 3 on page 13
.
When looking at the signal pressure connection or the switchover plate (actuator 120
cm
2
), the positioner must be attached to the
left side of the actuator.
The
arrow
on the black cover of the case
(Fig. 11) should point
towards the dia-
phragm 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
and the arrow points away from the diaphragm chamber.
1. Screw the clamp (1.2) to the actuator
stem, ensuring that the fastening screw
is located in the groove of the actuator
stem.
2. Screw the assigned pick-up lever D1 or
D2 to the transmission lever of the positioner.
3. Fasten the distance plate (15) with seal
pointing towards the actuator yoke.
4. Place the positioner on the plate so that
the lever D1 or D2 slides centrally over
the pin of the clamp (1.2). Then screw
tight to the distance plate (15).
5. Mount cover (16).
Actuators with 240, 350 and 700 cm
2
6. Check whether the tongue of the seal
(17) is properly aligned at the side of
the connection block (Fig. 3, center)
10
EB 8383-1 EN
Attachment to the control valve
Actuator stem retracts
Side view of connection block
with seal
(ne w
) with switch plate (old)
Fig. 3 ⋅Attachment and signal pressure connection for Type 3277 Actuators (top) and 3277-5 with 120 cm (bottom)
SUPPLY
1817 19
1.2
D2
D1
17
16
15
1.2
16
17
15
Actuator stem retracts
Internal signal pressure
connection
Signal pressure tube
1.2 Clamp
D1 Lever
D2 Lever
15 Distance plate
16 Cover
17 Seal
18 Cover plate
19 Switch plate
Signal pressure bore
Connection block
Marking
Marking
Symbol "actuator
stem extends"
"Actuator stem
retracts"
Switchover
plate
Switchover plate
Signal pressure input
Signal pressure
input with brass
throttle, if required
Actuator stem extends
Ventin g
Actuator stem extends
EB 8383-1 EN
11
Attachment to the control valve
with the actuator symbol "actuator stem
extends" or "actuator stem retracts" to
match the actuator version used.
If not, 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 actuator symbol with the arrow.
7. Place the connection block with its seal
rings on the positioner and actuator
yoke and screw it tight using the fastening screw.
For actuators with "actuator stem retracts", additionally attach the readymade signal pressure line.
Actuator with 120 cm
2
For the Type 3277-5 Actuator with 120 cm
2
effective diaphragm area, the signal pressure is transmitted to the diaphragm chamber via the switchover plate (Fig. 3 bottom).
For a rated travel of 7.5 mm, a brass
throttle (see Accessories table on page 13)
must be pressed into the seal located in the
signal pressure input on the actuator yoke.
For a rated travel of 15 mm, this is only required when the supply pressure exceeds
4 bar.
6. Remove the screw plug on the rear of
the positioner case and seal the signal
pressure output (Output 38) with the
plug from the accessories.
7. Mount the 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 the switchover plate with the
corresponding symbol for left attachment and 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 cm
2
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 via the required
connecting plate (see Table 2). The switchover plate is no longer required.
Note!
For faster control valves with a transit time
less than 0.6 seconds, replace the filter in
the signal pressure output (output 38) with a
screw-in throttle (see Accessories table), if
necessary.
Filling the diaphragm chamber with air
If the Type 3277 Actuators diaphragm
chamber must be filled with air exhausted
from the positioner, the diaphragm chamber (for version with "actuator stem extends") can be connected to the connection
block using a tube (see Table 3). To do
this, first remove the screw plug from the
connection block.
For the Type 3277-5 Actuator with "actuator stem retracts", the air exhausted from
the positioner is constantly supplied to the
diaphragm chamber through an internal
bore.
12
EB 8383-1 EN
Attachment to the control valve
1402-0938 1402-0939
1)
Order with every pressure gauge kit: 2 restrictions (1790-6121)
1)
2.2 Attachment acc. to IEC 60534-6
The positioner is attached according to
NAMUR as shown in Fig. 4 using an adapter housing. The valve travel is transmitted
via the lever (18) and the shaft (25) to the
bracket (28) in the adapter housing and
then to the coupling pin (27) located on the
lever of the positioner.
To attach the positioner, you will require the
mounting parts listed in Table 4. Which
lever should be used depends on the rated
valve travel.
The positioner must be attached to the
adapter housing with the
arrow
on the
black case cover pointing
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 valve (e.g. because the actuator is from another manufacturer), the
arrow
on the case cover must
point towards the valve!
Note!
For faster control valves with a transit time
less than 0.6 seconds, replace the filter in
the signal pressure output (output 38) with a
screw-in throttle (see Accessories table).
2.2.1 Mounting sequence
Refer to Tables 4 and 5 on page 16 for required mounting parts.
Note!
Prior to mounting the parts, apply signal
pressure to the actuator so that the valve is
set to 50 % of its travel. This is the only way
to make sure that the lever (18) and bracket
(28) are exactly aligned.
Control valve with cast yoke
1. Use countersunk screws to fix the plate
(20) to the coupling which connects the
plug stem and actuator stem. With actuators 2100 and 2800 cm
2
, use addi-
tional mounting bracket (32).
2. Remove rubber plug from the adapter
housing and fasten the housing to the
NAMUR rib with hexagon head screw.
Control valve with rod-type yoke
1. Screw plate (20) to the follower clamp
of the plug stem.
2. Screw the studs (29) into the adapter
housing.
3. Place the housing with the plate (30) on
either the right or left side of the valve
stem and fasten tight using the nuts
(31). On doing so, make sure the housing is aligned at a height which will
still allow the lever (18) to be attached
horizontally.
4. Screw the pin (19) into the center row
of holes in the plate (20) and lock into
place so that it is located approximately
above the correct lever marking (1 to 2)
14
EB 8383-1 EN
Attachment to the control valve
Fig. 4 ⋅Attachment according to IEC 60534-6 (NAMUR)
2
1,5
1
2826
AB
24 25 22
32
31
20 19
19 21 2023 18
27b
27a
29
30
Attachment to
NAMUR rib
Mounting position
Attachment to rod
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
EB 8383-1 EN
15
Attachment to the control valve
for the assigned travel, see Table 5.
Intermediate values must be calculated.
Move the clamp (21) beforehand to
clasp the pin.
5. Measure the distance from the middle
of the shaft (25) to the middle of the pin
(19). This value must be entered later
when the positioner is being configured.
2.2.2 Presetting the valve travel
1. Adjust the shaft (25) in the adapter
housing so that the black pointer (24) is
aligned with the casted marking on the
adapter housing.
2. Screw the clamping plate (22) tight in
this position using the screw (23).
3. Screw the coupling pin (27) into the positioner lever (26) on the side with the
Table 4
Attach. acc. to IEC 60534-6 Control valve Travel in mm With lever Order no.
NAMUR mounting kit
See Fig. 4 for parts
Valve w it h cast yoke
7.5 to 60 N1 (125 mm) 1400-6787
30 to 120 N2 (212 mm) 1400-6789
Valve with
rod-type
yoke with
rod diameter
in mm
20 to 25 N1 1400-6436
20 to 25 N2 1400-6437
25 to 30 N1 1400-6438
25 to 30 N2 1400-6439
30 to 35 N1 1400-6440
30 to 35 N2 1400-6441
Attachment to Fisher and Masoneilan linear actuators
(one ea ch of bo th mo un ting ki ts is need ed per one ac tuator )
1400-6771
and
1400-6787
Accessories
Press. gauge mounting block G 1/4: 1400-7458 1/4 NPT: 1400-7459
Pressure gauge set St. st./brass: 1400-6957 St. st./St. st.: 1400-6958
Signal pressure throttles (screw-in type and brass throttle) 1400-6964
Filter check valve, replaces vent plug and increases the degree of protection
to IP 65 (one included with the delivered positioner)
1790-7408
Table 5
Attachment according to IEC 60534-6
Travel mm *) 7.51515303060306060120
Pin on mark *) 1 12121212
Corresp. distance: pin/lever pivot 42 42 84 42 84 84 168 84 168
With lever N1 (125 mm in length) N2 (212 mm in length)
Tran sm is sion pi n ( 27 ) a t posit io n A A B A B
*) Deviating travels (intermediate values) must be calculated accordingly
16
EB 8383-1 EN
Attachment to the control valve
insert nuts and secure the pin on the
other side with a hex nut. Observe the
mounting position A or B explained in
Table 5 and Fig. 4.
4. Place the positioner onto the adapter
housing, making sure the coupling pin
(27) is positioned within the arms of the
bracket (28).
To do so, insert a 2.5 mm Allen key or
a screwdriver from the front into the
bore located below the oblong hole on
the cover plate, and push the positioner
lever into the required position.
5. Screw positioner to the adapter housing.
6. Relieve signal pressure from the actuator.
2.3 Attachment to rotary actuators
The positioner can also be attached to rotary actuators in accordance with VDI/VDE
3845 by using the mounting parts and accessories listed in Table 6. In this arrangement, the actuators rotary motion is converted via the cam disk of the actuator stem
and the feeler roll of the positioner lever
into a linear motion which is required for
the inductive displacement sensor.
Each cam disk has two curves for the
ranges of rotational angle from 0 to 90°
(recommended for all angles of rotation
smaller than 90°) and 0 to 120° (recommended for all angles of rotation larger
than 90°).
Ta bl e 6
Rotary actuators (Complete mounting parts, but without cam disks)
Attachment acc. to
VDI/VDE 3845, level
1
SAMS ON Type Actu at or Atta ch me nt to Mas on eilan ac tu ator
Actuator
160 cm
2
Actuator
320 cm
2
Camflex I
DN 25 ...100
Camflex I
DN 125...250
Camflex II
Order no.
1400-8815 1400-7103 1400-7104 1400-7118 1400-7119 1400-7120
Pip ing k it 8 x 1 stainle ss st eel
G: 1400-6670 NPT: 1400-6672
G: 1400-6669 NPT: 1400-6671
Accessories
Order no.
Reversing amplifier for double-acting actuators without springs 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) specially for VETEC, adjustable per software from 0 to 75° 1400-6960
Cam disk (0050-0090) specially for Camflex, adjustable per software from 0 to 50° 1400-6961
Pressure gauge mounting block G 1/4: 1400-7458; 1/4 NPT: 1400-7459
Pressure gauge set St. steel/Brass:
1400-6957
St. steel/St. steel:
1400-6958
Signal pressure throttles (screw-in type and brass throttle) 1400-6964
Filter check valve, replaces vent plug and increases the degree of protection to IP 65 (o ne inc lu ded wit h t he deliv er ed posi ti on er)
1790-7408
EB 8383-1 EN
17
Attachment to the control valve
For double-acting, springless rotary actuators, a reversing amplifier must be attached
to the positioner housing on the side where
it is connected to the actuator (see section
2.3.4).
If the positioner is attached to a SAMSON
Type 3278 Rotary Actuator, the air exhausted from the positioner is admitted to
the inside of the actuator without any additional tubing.
If the positioner is attached to actuators
from other manufacturers (NAMUR), the air
is applied to the diaphragm chamber
through a tube with a tee connecting the actuator and the exhaust connection of the intermediate piece.
Note!
For faster control valves with a transit time
less than 0.6 seconds, replace the filter in
the signal pressure output (output 38) with a
screw-in throttle (see Accessories Table 6).
2.3.1 Mounting the lever with
feeler roll
1. Place lever with attached feeler roll
(35) on the transmission lever (37) and
secure it with the supplied screws (38)
and washers.
2.3.2 Mounting the intermediate
piece
SAMSON Type 3278 Actuator:
1. Screw adapter (36) to the free end of
the rotary actuator shaft, using two
screws.
2. Position intermediate piece (34) on the
actuator housing and secure it with two
screws. Align the intermediate piece so
that the air connections of the positioner face the side of the diaphragm
case.
Actuators according to VDI/VDE 3845
1. Place the whole intermediate piece (34,
42, 44 and 45) onto the bracket included in the delivery scope of the actuator (fixing level 1 VDI/VDE 3845) and
secure with screws.
2. Align the cam disk (40) and scale (39)
as described in section 2.3.3 and screw
tight.
With springless actuators, the reversing amplifier must be screwed to the side of the positioner case. See section 2.3.4.
18
EB 8383-1 EN
Attachment to the control valve
Vent p lu g o r
filter check valve
Fig. 5 ⋅Attachment to rotary actuators
33
3835
39
39
40
34
36
40
34
44
45
42
43
37
Attachment to
SAMSON Type 3278
Attachment acc. to
VDI/VDE 3845
33 Positioner
34 Intermediate piece
35 L ev er with ca m f ollowe r r oll
36 Adapter
37 Transmission lever
38 Screws
39 Scale
40 Cam disk
41 Actuator shaft
42 Plate
43 Bracket
44 Coupling
45 Seal
EB 8383-1 EN
19
Attachment to the control valve
2.3.3 Aligning and mounting the
cam disk
In rotary actuators with spring-return mechanism, the actuator springs determine the
fail-safe position and the direction of rotation of the control valve.
With double-acting, springless rotary actuators, the direction of rotation depends on
both the actuator and valve version used.
The initial position is always based on a
closed valve!
Whether the control valve should open or
close when the reference variable increases
must be set in the software (direction of action increasing/increasing or increasing/decreasing).
1. Place the cam disk with scale on the
adapter (36) or coupling (34), and
fasten the screws loosely at first.
The cam disk has two cam sections. The
starting point of each section is marked by
a small hole.
Note!
When the valve is closed, the starting point
(hole) of the disk must be aligned so that the
pivot of the cam disk, the 0° position of the
scale and the arrow mark on the viewing
window are in one line.
The starting point for the closed valve position should never be below the 0° position!
In actuators with fail-safe position "valve
OPEN", the maximum signal pressure must
be applied to the actuator prior to aligning
the cam disk.
In springless actuators, the supply air must
be connected.
2. On aligning the cam disk, clip on the
double-sided scale disk so that the scale
matches the direction of rotation of the
control valve. Only then secure the cam
disk with the fastening screws.
Securing the aligned cam disk
If you want to additionally secure the cam
disk to prevent it from being turned, proceed as follows:
There are four holes arranged around the
center hole on the cam disk. Select a suitable hole from the four holes to secure the
cam disk.
Drill a hole in the adapter (36) or coupling
(44) through the hole chosen and insert a
2 mm dowel pin.
3. Attach the positioner to the intermediate
piece (34) so that the lever (35) touches
the cam disk with its feeler roll.
To do so, insert a 2.5 mm Allen key or
screwdriver from the front into the bore
hole located below an oblong hole in
the cover plate and bring the positioner
lever in the required position.
4. Screw positioner to the intermediate
piece.
20
EB 8383-1 EN
Attachment to the control valve
Fig. 6 ⋅Aligning the cam disk
Control valve opens
counterclockwise
Control valve opens
clockwise
Feeler roll
Starting point
Holes to secure the cam disk
View onto the actuator shaft from the positioner
Insert clip and then
press tongues outwards
EB 8383-1 EN
21
Attachment to the control valve
2.3.4 Reversing amplifier for
double-acting actuators
For the use with double-acting actuators,
the positioner must be fitted with a reversing amplifier.
The reversing amplifier is listed as an accessory in the Table 6 on page 17.
The output signal pressure of the positioner
is supplied at the output A
1
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 A
2
. The rule A1 + A2 = Z applies.
Mounting
Note!
Prior to mounting the reversing amplifier,
remove the sealing plug (1.5). The rubber
seal (1.4) must be remain attached.
1. Thread the special nuts (1.3) from the
accessories of the reversing amplifier
into the threaded ports of the positioner.
2. Insert the gasket (1.2) into the recess of
the reversing amplifier and push both
the hollowed special screws (1.1) into
the connecting ports A1 and Z.
3. Place the reversing amplifier onto the
positioner and screw tight using both
the special screws (1.1).
4. Screw the supplied filter (1.6) using a
screwdriver (8 mm wide) into the connecting bore holes A1 and Z.
Signal pressure connections
A
1
: Output A1 leading to the signal pressure connection at the actuator which opens
the valve when the pressure increases
A
2
: Output A2 leading to the signal pressure connection at the actuator which closes
the valve when the pressure increases
Enter the actuator as "Double-acting
without spring-return mechanism" in the
user interface software under Start-up
→
Type of actuator.
2.4 Fail-safe action of the actuator
Note!
If the fail-safe action of the actuator is
changed subsequently by converting the actuator springs from "actuator stem extends"
to "actuator stem retracts", the mechanical
zero must be recalibrated and the positioner reinitialized.
22
EB 8383-1 EN
Reversing amplifier for double-acting actuators
Fig. 7 ⋅Mounting a reversing amplifier
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
From the positioner
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
EB 8383-1 EN
23
Reversing amplifier for double-acting actuators
3 Connections
3.1 Pneumatic connections
The air connections are either 1/4 NPT or
G 1/4 tapped holes. Customary fittings for
metal and copper pipes or plastic tubes can
be used.
Note!
The supply air must be dry and free from oil
and dust. Observe the maintenance instructions for upstream pressure reducing stations. Carefully purge all tubes before connecting them.
If the positoner is attached directly to Type
3277 Actuator, the connection for the signal pressure is fixed. For NAMUR attachment, the signal pressure can be applied to
either the top or bottom diaphragm chamber depending on the fail-safe position "actuator stem extends or retracts".
Exhaust air: The exhaust air connection of
the positioner is included in the mounting
parts. For direct attachment of the positioner, there is a vent plug on the plastic
cover of the actuator. For NAMUR attachment, this plug is on the adapter housing
and for attachment to rotary valves, it is on
the intermediate piece or reversing amplifier.
3.1.1 Pressure gauge
We recommend mounting pressure gauges
for supply air and signal pressure to monitor the positioner. The parts are listed as accessories in Tables 3, 4 and 6.
Fig. 8 ⋅Mounting the pressure gauge
2...3mm
Nut Throttle with filter
Order no. 0250-1090 1790-6121
24
EB 8383-1 EN
Connections
3.1.2 Supply air pressure
The required supply air pressure depends
on the bench range and the operating direction (fail-safe position) of the actuator.
The bench range is mentioned on the nameplate as spring range or signal pressure
range.
Actuator stem extends:
Required supply air pressure =
Upper bench range value + 0.2 bar,
min. 1.4 bar.
Actuator stem retracts:
The required supply air pressure for tightclosing valves is calculated from the maximum signal pressure pst
max
pst
max
= F +
d
2
⋅ π ⋅ Δp
4 ⋅ A
[bar]
d = Seat diameter [cm]
Δ
p = Differential pressure across the valve [bar]
A = Actuator area [cm
2
]
F = Upper bench range value of the actuator [bar]
If there are no specifications, calculate as
follows:
Required supply air pressure = Upper
bench range value + 1 bar
3.2 Electrical connections
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 association.
The following standards apply for installation in hazardous areas:
EN 60079-14: 2003 (VDE 0165
Part 1)
"Electrical apparatus for ex-
plosive gas atmospheres"
and
EN 50281-1-2: 1999 (VDE 0165
Part 2)
"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
i
or U0; Ii or I0; Pi or
P
0
; Ci or C0, and Li or L0).
For EEx nA equipment (non-sparking apparatus), the standard
EN 50021: 1999 specifies that connecting, interrupting, or switching
circuits while energized is only
allowed during installation, maintenance or repair work.
For EEx nL equipment (energylimited apparatus), the standard
EN 50021: 1999 allows this type of
equipment to be switched under normal operating conditions.
EB 8383-1 EN
25
Connections
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 40 °C must have
metal cable entries.
The terminal assignment can be found in
Fig. 9 as well as on the labels on the cover
plate of the positioner case.
Cable entries
The cable entry with M20x1.5 cable gland,
7 to 12 mm clamping range.
There is a second M20x1.5 cable gland in
the housing that can be used for additional
connection, if required.
The screw terminals are designed for wire
cross-sections of 0.2 to 2.5 mm
2
. Tighten
by at least 0.5 Nm.
Bus line
The shielding of the Fieldbus connecting
cable is connected to the equipotential
bonding system on the process control system side. At the positioner side, the shielded
cable must be routed over the EMI-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.
To connect the bus line, loosen the coupling nut and the clamping insert from the
positioner and remove the dust cap.
Slide the coupling nut and clamping insert over the connecting cable.
Insulate the end of the bus line to the required connecting length and cut the
wire shield off up to a length of approx.
13 mm. If necessary, cut off any cable
core filling as well.
Disentangle the braided shield and pull
it over the clamping insert.
Press the clamping insert into the connecting screw gland and screw tight the
coupling nut until the connecting cable is
clamped tight.
Route the two-wire bus line to the screw
terminals marked "IEC 1158-2",
whereby no polarity has to be observed.
In exceptional cases, when the plant may
not allow such a connection, feed the cable
shield through the cable gland and connect
it to be capacitive over the terminal "S".
However, make sure that a conducting connection cannot occur from the shield to the
cable gland or housing.
If the shielding is not placed on both sides,
we recommend installing an additional sup-
26
EB 8383-1 EN
Connections
pressor kit (order no. 1400-9324). Separate installation instructions are included.
Note!
The connection of limit switches, binary
input and forced venting function requires
an additional cable gland that must replace
the cap fitted on the housing.
Accessories:
Cable gland M20 x 1.5, nickel-
plated brass, order no. 8808-0143
Limit switches
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 NAMUR, thus ensuring operational reliability of the positioner.
If the positioner is installed in hazardous
areas, the relevant regulations must be observed.
Binary input
A passive floating contact can be used at
the binary input. The positioner signals the
status over the bus protocol.
Fig. 9 ⋅Bus line connection and terminal assignment (terminal markings according to DIN 45140)
Brass screw fitting Shield Clamping insert Coupling nut
GW2 GW1
PE
S
NC
-52
+51
-42
+41 -86
+85
-82 +81
IEC 1158-2
FOUNDATION
TM
Fieldbus
Bus cable
Switching amplifier
acc. to EN 60 947-5-6
6 to 24 VDC
Limit switches Binary input Forced venting
EB 8383-1 EN
27
Connections
Forced venting
For the positioners with forced venting function, a voltage between 6 and 24 V DC
must be connected to the terminals 81 and
82.
Note!
If there is no voltage connected or the voltage drops, the positioner vents the actuator
and does not respond to the reference variable.
28
EB 8383-1 EN
Connections
3.2.1 Establishing communication
Communication between positioner, programmable logic controller or automation
system or between PC and workstation and
positioner(s) is established in accordance
with IEC 61158-2.
If positioners are used in hazardous areas,
ex-barriers must be used.
A maximum of 32 control valves can be
operated in one segment. The number of positioners that can be connected is reduced
when they are used in hazardous areas.
Fig. 10 ⋅ FOUNDATIONTM Fieldbus connection, for non-hazardous areas (top) and for hazardous areas (bottom)
3787
3787
3787
3787
FOUNDATION
TM
Fieldbus IEC 61158-2
FOUNDATION
TM
Fieldbus IEC 61158-2
3787-1
3787-1
3787-1
3787-1
FOUNDATION
TM
Fieldbus IEC 61158-2
FOUNDATION
TM
Fieldbus
IEC 61158-2
Process
management
system
Process
management
system
Te rm in at i o n
Ex-fieldbus barriers
Termination
Hazardous area
Supply unit
Non-hazardous area
Supply unit
Termination
EB 8383-1 EN
29
Connections
4Operation
Warning!
Before you take the control valve
into operation, carefully move the
control valve to its end position by
covering the hole (manual operation) on the cover plate (Fig. 11).
On doing so, check whether the
lever mechanism works properly.
If the maximum angle of rotation is
exceeded because the wrong lever
mechanism has been selected or incorrectly sized, the positioner may
be ruined.
4.1 LEDs
There are two LEDs located inside the cover
used to monitor the positioner during startup, operation and to indicate possible faults.
General meaning of LEDs:
Red
Device start-up or error,
no control operation possible
Green
No error detected, control operation
or fail-safe position
(e.g. if not initialized)
Red and green
Error detected,
control operation possible
See table below for detailed description.
Description LED
Device start-up:
Red on
No error detected:
Device connected to bus, cold start completed,
initialization required
Initialization or zero calibration running
Device is initialized, no valid set point
Device is initialized, valid set point, control operation
Green, generally
Green blinks slowly
Green blinks quickly
Green blinks 3x quickly + long interval
Green on
Error in the control loop:
Zero point error
Control loop fault
Red and green
Red and green blink slowly
Red and green blink quickly
Error leading to first initialization being cancelled
(Device does not go to standard operation)
Zero point error
Mechanics/pneumatics failure
Control loop fault
Red, generally
Red blinks slowly
Red on
Red blinks quickly
Device errors causing the control operation to be
left
Device has detected an internal fault Red blinks 3x quickly + long interval
30
EB 8383-1 EN
Operation
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